D90 Service Workbook

D90 Service
Workbook
orkbook
D90
2017 Year
Contents
Overview ......................................................................................................... 1-1
Overview .............................................................................................................................. 1-1
Battery Disconnection ........................................................................................................................................ 1-1
Electric Coolant Fan........................................................................................................................................... 1-1
Moving Parts and Hot Surfaces ......................................................................................................................... 1-1
Radiator Cap Removal....................................................................................................................................... 1-1
Fuel Pressure Relief .......................................................................................................................................... 1-1
Vehicle Lifting..................................................................................................................................................... 1-1
Window Removal ............................................................................................................................................... 1-1
Drive Belt Repair................................................................................................................................................ 1-1
Fasteners ........................................................................................................................................................... 1-1
General ........................................................................................................... 2-1

General ............................................................................................................................... 2-1
Specification....................................................................................................................................................... 2-1
Front/Rear Ventilated Disc Brake ...................................................................................................................... 2-1
Technical Parameters ........................................................................................................................................ 2-2
Lifting and Towing.............................................................................................................................................. 2-6
Roadside Assistance ......................................................................................................................................... 2-7
Maintenance and Lubrication............................................................................................................................. 2-9
Fuel, Lubricant and Operating Fluid ................................................................................................................ 2-10
Service and Maintenance................................................................................................... 2-11
Engine Mechanical System ............................................................................. 3-1

Specification ........................................................................................................................ 3-1
Service and Maintenance ................................................................................................... 3-8
Layout ................................................................................................................................. 3-9

Engine Assembly ............................................................................................................................................... 3-9
Cylinder Head and Intake and Exhaust System .............................................................................................. 3-10
Engine Block and Cylinder Power.................................................................................................................... 3-11
Timing System ................................................................................................................................................. 3-13
Repair Guidance ............................................................................................................... 3-19

Engine Hood Replacement .............................................................................................................................. 3-19
V-belt Replacement ......................................................................................................................................... 3-19
Automatic Tensioner Replacement.................................................................................................................. 3-20
Replacement of Steering Pump Bracket.......................................................................................................... 3-20
Replacement of Mechanical Vacuum Pump (if equipped) ............................................................................... 3-21
Replacement of Oil Control Valve.................................................................................................................... 3-21
Replacement of CVVT Cover........................................................................................................................... 3-22
Replacement of Thermostat Housing .............................................................................................................. 3-22
Contents
Replacement of Intake and Exhaust Phase Modulator .................................................................................... 3-23
Replacement of Oil-Gas Separator .................................................................................................................. 3-24
Cylinder Head Check (after removing cylinder head)....................................................................................... 3-24
Crankshaft Check (after removing the engine)................................................................................................. 3-28
Connecting Rod Bearing Shell Check .............................................................................................................. 3-31
Piston Check .................................................................................................................................................... 3-33
Replacement of Rear Crankshaft Oil Seal ....................................................................................................... 3-35
Replacement of Front Crankshaft Oil Seal....................................................................................................... 3-36
Flywheel Replacement ..................................................................................................................................... 3-37
Valves Replacement ........................................................................................................................................ 3-38
Valve Tappet Replacement .............................................................................................................................. 3-41
Replacement of Camshaft (Intake or Exhaust) ................................................................................................ 3-42
Replacement of Intake Manifold Liner.............................................................................................................. 3-45
Replacement of Exhaust Manifold Liner........................................................................................................... 3-46
Replacement of Oil Pump ................................................................................................................................ 3-47
Replacement of Engine Oil and Oil Filter ......................................................................................................... 3-49
Engine Oil Pressure Check .............................................................................................................................. 3-50
Replacement of Oil Pump Suction Pipe ........................................................................................................... 3-50
Oil Pan Replacement ....................................................................................................................................... 3-51
Replacement of Timing Chain Cover ............................................................................................................... 3-52
Crankshaft Pulley Replacement ....................................................................................................................... 3-53
Cylinder Gasket Replacement.......................................................................................................................... 3-54
Turbocharger Replacement.............................................................................................................................. 3-55
Replacement of Turbocharger Coolant Outlet Pipe ......................................................................................... 3-57
Replacement of Turbocharger Coolant Inlet Pipe ............................................................................................ 3-58
Replacement of Turbocharger Oil Return Pipe ................................................................................................ 3-59
Replacement of Turbocharger Oil Inlet Pipe .................................................................................................... 3-60
Replacement of Oil Filter Module ..................................................................................................................... 3-61
Camshaft Cover Replacement ......................................................................................................................... 3-62
Replacement of Engine Timing Chain.............................................................................................................. 3-64
Engine Ladder Replacement............................................................................................................................ 3-66
Replacement of Engine Assembly ................................................................................................................... 3-68
Description and Operation ................................................................................................. 3-70

Overview .......................................................................................................................................................... 3-70
Cylinder Head Components ............................................................................................................................. 3-70
Cylinder Block Components ............................................................................................................................. 3-70
Oil Pan Components ........................................................................................................................................ 3-71
Lower Crankcase Body .................................................................................................................................... 3-71
Engine Accessories.......................................................................................................................................... 3-71
Positive Crankcase Ventilation......................................................................................................................... 3-71
High Pressure Common Rail and Direct Injection System ............................................................................... 3-71
Turbocharger.................................................................................................................................................... 3-71
Operation ........................................................................................................................... 3-72
Lubricating Oil Circuit ......................................................................................................... 3-72

Contents
Engine Cooling System ................................................................................... 4-1
Specification ........................................................................................................................ 4-1
Torque................................................................................................................................................................ 4-1
Technical Parameters ........................................................................................................................................ 4-2
Cooling System Layout ...................................................................................................................................... 4-5
Repair Guidance ................................................................................................................. 4-7

Thermostat Replacement................................................................................................................................... 4-7
Replacement of Water Pump............................................................................................................................. 4-7
Coolant Drain ..................................................................................................................................................... 4-8
Coolant Refill...................................................................................................................................................... 4-8
Radiator Replacement ....................................................................................................................................... 4-8
Replacement of Radiator Water Inlet and Outlet Pipes ..................................................................................... 4-9
Replacement of Intercooler Assembly ............................................................................................................. 4-10
Replacement of Intercooler Intake and Exhaust Hoses................................................................................... 4-11
Replacement of Expansion Tank Assembly .................................................................................................... 4-12
Replacement of Engine Exhaust Pipe Assembly............................................................................................. 4-13
Replacement of Hose between Engine and Expansion Tank.......................................................................... 4-14
Replacement of Cooling Fan Assembly........................................................................................................... 4-15
Description and Operation ................................................................................................ 4-15

Overview .......................................................................................................................................................... 4-15
Small Circulation .............................................................................................................................................. 4-15
Large Circulation.............................................................................................................................................. 4-15
Thermostat....................................................................................................................................................... 4-15
Water Pump ..................................................................................................................................................... 4-15
Auxiliary Water Pump ...................................................................................................................................... 4-15
Engine Electrical System................................................................................. 5-1

Specification ....................................................................................................................... 5-1
Layout ................................................................................................................................. 5-2
Diagnostic Information and Procedures ............................................................................. 5-3
Repair Guidance ................................................................................................................. 5-4

Alternator Replacement ..................................................................................................................................... 5-4
Starter Replacement .......................................................................................................................................... 5-5
Description and Operation .................................................................................................. 5-6

Overview ............................................................................................................................................................ 5-6
Starter Motor ...................................................................................................................................................... 5-6
Alternator ........................................................................................................................................................... 5-6
Battery................................................................................................................................................................ 5-6
Battery Usage and Maintenance ......................................................................................... 5-7

Contents
Safe Operation ................................................................................................................................................... 5-7
Battery Maintenance Requirements: .................................................................................................................. 5-8
Battery Recharging:.......................................................................................................................................... 5-10
Operation.......................................................................................................................................................... 5-11
Battery Failure Judgment ................................................................................................................................. 5-13
Causes for General Battery Failures ................................................................................................................ 5-14
Engine Control System ................................................................................... 6-1

Specification ........................................................................................................................ 6-1
Technical Parameters ....................................................................................................................................... 6-1
Technical Parameters 2 ..................................................................................................................................... 6-3
Engine Controller Layout.................................................................................................................................... 6-8
Right Side of the Engine..................................................................................................................................... 6-9
Upper Part of the Engine.................................................................................................................................. 6-10
Left Side of the Engine ..................................................................................................................................... 6-11
Repair Guidance ................................................................................................................ 6-13

Engine Controller Replacement ....................................................................................................................... 6-13
Replacement of Turbocharger Solenoid Valve Vacuum Pipe .......................................................................... 6-14
Replacement of Turbocharger Solenoid Control Valve .................................................................................... 6-15
Ignition Coil Replacement ................................................................................................................................ 6-15
Spark Plug Replacement.................................................................................................................................. 6-16
Replacement of Engine Coolant Temperature Sensor..................................................................................... 6-16
Replacement of Intake Camshaft Position Sensor........................................................................................... 6-17
Replacement of Exhaust Camshaft Position Sensor........................................................................................ 6-17
Replacement of Oil Pressure Switch................................................................................................................ 6-18
Replacement of High-pressure Fuel Pump ...................................................................................................... 6-19
Replacement of Fuel Rail Pressure Sensor ..................................................................................................... 6-20
Replacement of Crankshaft Position Sensor.................................................................................................... 6-21
Replacement of Intake Air Temperature/Manifold Absolute Pressure Sensor ................................................. 6-22
Knock Sensor Replacement............................................................................................................................. 6-22
Fuel Rail Replacement ..................................................................................................................................... 6-23
Injector Replacement ....................................................................................................................................... 6-24
Activated Canister Solenoid ............................................................................................................................. 6-25
Replacement of Electronic Throttle .................................................................................................................. 6-25
Engine Harness Installation.............................................................................................................................. 6-26
Replacement of Accelerator Pedal Assembly .................................................................................................. 6-28
Special Tool ...................................................................................................................... 6-28

Engine Control System Control Diagram ......................................................................................................... 6-29
Engine Fuel System ........................................................................................ 7-1

Contents
Specification ....................................................................................................................... 7-1
Layout ................................................................................................................................. 7-2
Repair Guidance ................................................................................................................. 7-5

Replacement of Fuel Tank Assembly ................................................................................................................ 7-5
Replacement of Fuel Filter................................................................................................................................. 7-6
Replacement of Canister Assembly................................................................................................................... 7-7
Replacement of Fuel Tank Filler Pipe................................................................................................................ 7-8
Fuel System Pressure Test................................................................................................................................ 7-9
Fuel Pump Replacement ................................................................................................................................. 7-10
Replacement of Fuel Pump Level Sensor Float .............................................................................................. 7-10

Fuel Pump........................................................................................................................................................ 7-12
Evaporative Emission System ......................................................................................................................... 7-12
Engine Intake/Exhaust System ....................................................................... 8-1

Specification ....................................................................................................................... 8-1
Intake System Layout ........................................................................................................................................ 8-2
Exhaust System Layout ..................................................................................................................................... 8-3
Repair Guidance ................................................................................................................. 8-4

Replacement of Air Flow Meter.......................................................................................................................... 8-4
Replacement of Air Filter Assembly................................................................................................................... 8-5
Replacement of Air Filter Outlet Pipe Assembly ................................................................................................ 8-5
Replacement of Front Catalytic Converter Assembly ........................................................................................ 8-6
Removal/Installation of Exhaust Pipe Front Segment Assembly Bracket.......................................................... 8-7
Replacement of Rear Catalytic Converter Assembly ......................................................................................... 8-8
Replacement of Front Muffler Assembly............................................................................................................ 8-9
Replacement of Rear Muffler Assembly ............................................................................................................ 8-9

Catalytic Converter .......................................................................................................................................... 8-10
Intake System .................................................................................................................................................. 8-10
Exhaust System ............................................................................................................................................... 8-11
6MT Manual Transmission .............................................................................. 9-1

Specification ........................................................................................................................ 9-1
Service Standard .............................................................................................................................................. 9-1
Snap Ring and Gasket for Adjustment............................................................................................................... 9-1
Tightening Torque ............................................................................................................................................. 9-3
Lubricating Oil ................................................................................................................................................... 9-4
Contents
Layout .................................................................................................................................. 9-5
Repair Guidance .................................................................................................................. 9-6

Replacement of Manual Transmission ............................................................................................................... 9-6
Transmission Assembly Replacement ............................................................................................................. 9-37
Shift Cable Replacement.................................................................................................................................. 9-39
Replacement of Shift Lever Handle.................................................................................................................. 9-43
Special Tool ....................................................................................................................... 9-45

Overview .......................................................................................................................................................... 9-49
6AT................................................................................................................ 10-1
Technical Parameters ......................................................................................................... 10-1
Torque .............................................................................................................................................................. 10-1
Layout ................................................................................................................................. 10-3
Service ................................................................................................................................ 10-9
Repair Guidance ............................................................................................................... 10-10

Replacement of 6AT Shift Cable .................................................................................................................... 10-10
P Gear Unlock ................................................................................................................................................ 10-12
Removal/Installation of Shift Lever Handle .................................................................................................... 10-13
Removal/Installation of Transmission Assembly ............................................................................................ 10-15
Transmission Drain and Oil Pan Removal ..................................................................................................... 10-17
Oil Pan Installation ......................................................................................................................................... 10-19
Removal/Installation of Transmission Fluid Filler Rubber Plug ...................................................................... 10-19
Transmission Fluid Level Adjustment............................................................................................................. 10-20
Transmission Fluid Level Check .................................................................................................................... 10-21
Hydraulic Torque Converter Removal ............................................................................................................ 10-23
Hydraulic Torque Converter Installation ......................................................................................................... 10-24
Oil Filter Edge Seal Removal ......................................................................................................................... 10-25
Oil Filter Bushing Seal Installation.................................................................................................................. 10-26
Electric Component Removal......................................................................................................................... 10-28
Precautions for Electro Static Discharge (ESD) ............................................................................................. 10-31
Electric Component Installation...................................................................................................................... 10-31
Gear Selector and Seal Removal................................................................................................................... 10-34
Gear Selector Shaft and Seal Installation ...................................................................................................... 10-35
Removal/Installation of AWD Output Shaft O-ring Seal ................................................................................. 10-36
Shift Connector Adjustment............................................................................................................................ 10-37
Transmission Adjustment ............................................................................................................................... 10-39
Removal/Installation of Automatic Transmission Assembly ........................................................................... 10-42
Special Tool ...................................................................................................................... 10-45

Contents
SAGW 6MT Transmission............................................................................. 11-1
Overview ............................................................................................................................ 11-1
Overview and Characteristic of Transmission Assembly ................................................................................. 11-1
Transmission Assembly Specifications............................................................................................................ 11-5
Transmission Assembly Structure Detail ......................................................................... 11-11

Transmission Assembly Exploded View ........................................................................................................ 11-11
Power Flow Chart .......................................................................................................................................... 11-17
Expanded Product Identification .................................................................................................................... 11-24
Repair Guidance .............................................................................................................. 11-28

Transmission Removal/Installation ................................................................................................................ 11-28
Transmission Assembly Replacement........................................................................................................... 11-49
Removal/Installation of Shift Cable ................................................................................................................ 11-51
Replacement of Shift Lever Handle ............................................................................................................... 11-56
Special Tool ..................................................................................................................... 11-57
Description and Operation ............................................................................................... 11-60

Overview ........................................................................................................................................................ 11-60
Clutch ............................................................................................................ 12-1

Specification....................................................................................................................... 12-1
Layout ................................................................................................................................ 12-2
Repair Guidance ................................................................................................................ 12-5

Replacement of Clutch Cover/Clutch Disc....................................................................................................... 12-5
Replacement of Clutch Main Pump ................................................................................................................. 12-5
Replacement of Clutch Pedal .......................................................................................................................... 12-6
Replacement of Clutch Pedal Position Sensor ................................................................................................ 12-7
Replacement of Clutch CSC Bleeder Connector ............................................................................................. 12-8
Air Exhaust of Hydraulic Clutch ....................................................................................................................... 12-9

Clutch Hydraulic System................................................................................................................................ 12-10
Clutch Mechanical System............................................................................................................................. 12-10
Driven Plate ................................................................................................................................................... 12-10
Clutch Cover Assembly.................................................................................................................................. 12-10
Steering System ............................................................................................ 13-1

Specification....................................................................................................................... 13-1
Specification .................................................................................................................................................... 13-1
Contents
Torque ............................................................................................................................................................. 13-1
Layout ................................................................................................................................. 13-2

Power Steering System Layout (LHD) ............................................................................................................. 13-2
Power Steering System Layout (RHD)............................................................................................................. 13-3
Electric Steering Gear Assembly Exploded View (LHD) .................................................................................. 13-4
Electric Steering Gear Assembly Exploded View (RHD).................................................................................. 13-5
Repair Guidance ................................................................................................................. 13-6

Replacement of Steering Wheel....................................................................................................................... 13-6
Replacement of Steering Column Assembly.................................................................................................... 13-6
Replacement of Steering Intermediate Shaft ................................................................................................... 13-7
Replacement of Electric Steering Gear Assembly and Steering Intermediate Shaft Extension....................... 13-8
Replacement of Steering Gear Outer Rod ..................................................................................................... 13-10
Replacement of Steering Gear Dust Shield ................................................................................................... 13-11
Special Tool ...................................................................................................................... 13-12

EPS System Control Diagram ........................................................................................................................ 13-13
Electric Steering Gear .................................................................................................................................... 13-14
Front Suspension .......................................................................................... 14-1

Specification........................................................................................................................ 14-1
Torque ............................................................................................................................................................. 14-1
Layout ................................................................................................................................. 14-2

Front Suspension Layout ................................................................................................................................. 14-2
Front Upper/Lower Swing Arm Exploded View ................................................................................................ 14-3
Front Horizontal Stabilizer Bar Exploded View................................................................................................. 14-4
Front Shock Absorber Strut and Spring Assembly Exploded View .................................................................. 14-5
Front Steering Knuckle Exploded View (4WD)................................................................................................. 14-6
Front Steering Knuckle Exploded View (2WD)................................................................................................. 14-7
Repair Guidance ................................................................................................................. 14-8

Four-wheel Alignment ...................................................................................................................................... 14-8
Front Wheel Alignment..................................................................................................................................... 14-8
Replacement of Front Suspension Upper Swing Arm Assembly ..................................................................... 14-9
Replacement of Front Lower Swing Arm Assembly ......................................................................................... 14-9
Lower Swing Arm Bumper Block.................................................................................................................... 14-11
Replacement of Front Lower Swing Arm Bushing.......................................................................................... 14-11
Replacement of Front Horizontal Stabilizer Bar ............................................................................................. 14-12
Replacement of Front Shock Absorber Assembly.......................................................................................... 14-13
Replacement of Front Shock Absorber Assembly Component ...................................................................... 14-13
Replacement of Front Steering Knuckle......................................................................................................... 14-14
Special Tool ...................................................................................................................... 14-16

Contents
Rear Suspension........................................................................................... 15-1

Specification....................................................................................................................... 15-1
Torque ............................................................................................................................................................. 15-1
Layout ................................................................................................................................ 15-2

Rear Suspension Layout.................................................................................................................................. 15-2
Rear Suspension Exploded View..................................................................................................................... 15-3
Repair Guidance ................................................................................................................ 15-5

Replacement of Rear Shock Absorber ............................................................................................................ 15-5
Replacement of Rear Suspension Upper Control Arm .................................................................................... 15-5
Replacement of Rear Suspension Lower Control Arm .................................................................................... 15-6
Replacement of Rear Coil Spring .................................................................................................................... 15-7
Replacement of Rear Horizontal Stabilizer Bar and Stabilizer Bar Link .......................................................... 15-8
Replacement of Lateral Push Rod ................................................................................................................... 15-8
Replacement of Rear Suspension Buffer Block............................................................................................... 15-9
Tires and Wheels .......................................................................................... 16-1

Specification....................................................................................................................... 16-1
Torque ............................................................................................................................................................. 16-1
Tire Parameters ............................................................................................................................................... 16-1
Layout ................................................................................................................................ 16-2

Tire Exploded View (Aluminum Wheel) ........................................................................................................... 16-2
Spare Tire Device Layout ................................................................................................................................ 16-3
Repair Guidance ................................................................................................................ 16-4

Wheels Replacement....................................................................................................................................... 16-4
Replacement of Spare Tire Device .................................................................................................................. 16-5
Brake System ................................................................................................ 17-1

Specification....................................................................................................................... 17-1
Technical Parameters ...................................................................................................................................... 17-1
Torque ............................................................................................................................................................. 17-3
Layout ................................................................................................................................ 17-4

Brake System Layout....................................................................................................................................... 17-4
ABS/ESP Exploded View................................................................................................................................. 17-5
Vacuum Booster Assembly Exploded View ..................................................................................................... 17-6
Contents
Parking Brake Exploded View .......................................................................................................................... 17-7
Exploded View of Front and Rear Brake Calipers............................................................................................ 17-8
EPB Exploded View ......................................................................................................................................... 17-9
Repair Guidance ............................................................................................................... 17-10

Brake Disc Check........................................................................................................................................... 17-10
Brake System Drain ....................................................................................................................................... 17-11
Adjustment of Parking Brake Handle Assembly............................................................................................. 17-12
Replacement of Front and Rear Brake Linings (Mechanical Parking Brake) ................................................. 17-14
Replacement of Brake Caliper Guide Pin Components ................................................................................. 17-15
Replacement of Front and Rear Brake Calipers Assembly............................................................................ 17-15
Replacement of Front Brake Disc .................................................................................................................. 17-16
Replacement of Rear Brake Disc ................................................................................................................... 17-16
Replacement of Rear Parking Brake Shoe .................................................................................................... 17-17
Replacement of Brake Master Cylinder and Brake Fluid Reservoir ............................................................... 17-18
Replacement of Vacuum Booster Assembly .................................................................................................. 17-19
Replacement of Vacuum Pipe Assembly ....................................................................................................... 17-20
Replacement of ABS/ESP Regulator ............................................................................................................. 17-20
Replacement of Brake Pedal Assembly ......................................................................................................... 17-22
Replacement of Brake Pedal Position Sensor ............................................................................................... 17-23
Yaw Sensor .................................................................................................................................................... 17-23
Replacement of Brake Pipeline ...................................................................................................................... 17-24
Replacement of Parking Brake Cable ............................................................................................................ 17-24
Replacement of Parking Brake Handle .......................................................................................................... 17-25
EPB Control Unit ............................................................................................................................................ 17-26
Manual Release of EPB ................................................................................................................................. 17-26
Replacement of EPB Brake Pad .................................................................................................................... 17-27
Replacement of Motor Components............................................................................................................... 17-29
Replacement of Brake Caliper Housing Assembly......................................................................................... 17-30
Replacement of Caliper Bracket Assembly .................................................................................................... 17-31

Parking Brake System Control Diagram......................................................................................................... 17-32
ABS/ESP System Control Diagram................................................................................................................ 17-33
Wheel Speed Sensor ..................................................................................................................................... 17-34
Stroke Position Sensor................................................................................................................................... 17-34
Yaw Speed Sensor......................................................................................................................................... 17-34
Steering Angle Sensor ................................................................................................................................... 17-34
EBD System ................................................................................................................................................... 17-34
TCS System ................................................................................................................................................... 17-34
ESP System ................................................................................................................................................... 17-34
EBA System ................................................................................................................................................... 17-34
RMI System.................................................................................................................................................... 17-34
HAS System ................................................................................................................................................... 17-35
Auto Hold........................................................................................................................................................ 17-35
ATS System ................................................................................................................................................... 17-35
HDC System................................................................................................................................................... 17-35
Contents
Electrical Park Brake (EPB) System ............................................................................................................. 17-35
Starting Aid Function...................................................................................................................................... 17-36
ECD Function................................................................................................................................................. 17-36
Transfer Case (Part-time).............................................................................. 18-1

Specification....................................................................................................................... 18-1
Torque ............................................................................................................................................................. 18-1
Layout ................................................................................................................................ 18-2

Transfer Case Layout ...................................................................................................................................... 18-2
Transfer Case Exploded View ......................................................................................................................... 18-3
Troubleshooting ................................................................................................................. 18-5

General Inspection Process............................................................................................................................. 18-5
Specific Inspection Process ............................................................................................................................. 18-5
Gear/Sprocket Tooth Check ............................................................................................................................ 18-5
Spline Tooth Check.......................................................................................................................................... 18-6
4-3 Service/Replacement................................................................................................................................. 18-6
Gear/Sprocket Tooth Service........................................................................................................................... 18-6
Table 4-1 Inspection ........................................................................................................................................ 18-7
Repair Guidance .............................................................................................................. 18-10

Replacement of Transfer Case Assembly ..................................................................................................... 18-10
TCCU Replacement....................................................................................................................................... 18-12
Transfer Case Removal ................................................................................................................................. 18-13
Removal of Transfer Case Electric Shift Component .................................................................................... 18-13
Rear Housing Removal.................................................................................................................................. 18-14
4WD Shift Component Removal .................................................................................................................... 18-15
Chain Drive System Removal ........................................................................................................................ 18-15
Rear Output Shaft/Pump Subassembly Removal.......................................................................................... 18-16
Deceleration Shift Component Removal........................................................................................................ 18-16
Front Output Shaft Subassembly Removal.................................................................................................... 18-17
Shift Cam Mechanism Removal..................................................................................................................... 18-17
Removal of Front Housing/Input Shaft/Planet Mechanism Subassembly...................................................... 18-18
Transfer Case Installation .............................................................................................................................. 18-19
Installation of Front Transfer Case Housing Subassembly............................................................................ 18-19
Installation of Front Housing/Input Shaft Subassembly/Planet Mechanism................................................... 18-21
Front Output Shaft Installation ....................................................................................................................... 18-22
Electric Shift Cam Installation ........................................................................................................................ 18-23
Deceleration Shift Component Installation..................................................................................................... 18-24
Output Shaft/Pump Subassembly Installation................................................................................................ 18-24
Chain Drive System Installation ..................................................................................................................... 18-25
Installation of 4WD Shift Component/Shift Lock Mechanism......................................................................... 18-25
Installation of Rear Transfer Case Housing Subassembly ............................................................................ 18-26
Installation of Transfer Case Housing Subassembly ..................................................................................... 18-27
Shift Motor Subassembly Installation............................................................................................................. 18-28
Contents
Rear Flange Component Installation & Lubricant Refill.................................................................................. 18-29
Installation of Transfer Case Transitional Housing (with AT) ......................................................................... 18-30
Special Tool ...................................................................................................................... 18-31

Internal Structure of Transfer Case ................................................................................................................ 18-32
Function Description of Transfer Case........................................................................................................... 18-33
Transfer Case Power Flow............................................................................................................................. 18-33
2H Power Flow Chart ..................................................................................................................................... 18-34
4H Power Flow Chart ..................................................................................................................................... 18-36
4L Power Flow Chart...................................................................................................................................... 18-38
Transfer Case (Real-time/All-terrain) ............................................................ 19-1

Specification........................................................................................................................ 19-1
Torque ............................................................................................................................................................. 19-1
Layout ................................................................................................................................. 19-2

Transfer Case Layout....................................................................................................................................... 19-2
Transfer Case Exploded View.......................................................................................................................... 19-3
Repair Guidance ................................................................................................................. 19-4

Replacement of Transfer Case Assembly........................................................................................................ 19-4
TCCU Replacement ......................................................................................................................................... 19-6
Refill & Drain of Transfer Case Lubricant......................................................................................................... 19-6
Removal/Installation of Transfer Case Transitional Housing ........................................................................... 19-6
Removal/Installation of Transfer Case Front Flange and Oil Seal ................................................................... 19-7
Removal/Installation of Transfer Case Rear Flange and Oil Seal.................................................................... 19-7
Removal/Installation of Transfer Case Motor Components.............................................................................. 19-8

Internal Structure of Transfer Case .................................................................................................................. 19-9
Function Description of TOD Transfer Case .................................................................................................. 19-10
Propeller Shaft .............................................................................................. 20-1

Specification........................................................................................................................ 20-1
Torque ............................................................................................................................................................. 20-1
Layout ................................................................................................................................. 20-2

Propeller Shaft System (4WD) Layout ............................................................................................................. 20-2
Propeller Shaft System (2WD) Layout ............................................................................................................. 20-3
Exploded View of Front Drive Shaft Assembly................................................................................................. 20-4
Exploded View of Propeller Shaft Assembly .................................................................................................... 20-5
Contents
Repair Guidance ................................................................................................................ 20-6
Replacement of Front Drive Shaft Assembly (4WD)........................................................................................ 20-6
Replacement of Constant-velocity Universal Joint and its Dust Shield............................................................ 20-7
Replacement of Tripod Universal Joint and its Dust Shield ............................................................................. 20-8
Replacement of Propeller Shaft ....................................................................................................................... 20-9
Replacement of Cross Shaft .......................................................................................................................... 20-10
Replacement of Intermediate Support of Propeller Shaft .............................................................................. 20-11
Front Axle and Rear Axle .............................................................................. 21-1

Specification....................................................................................................................... 21-1
Torque ............................................................................................................................................................. 21-1
Layout ................................................................................................................................ 21-2

Exploded View of Front Axle............................................................................................................................ 21-2
Exploded View of Rear Axle ............................................................................................................................ 21-4
Repair Guidance ................................................................................................................ 21-6

Replacement of Front Axle Assembly.............................................................................................................. 21-6
Replacement of Rear Axle Assembly .............................................................................................................. 21-7
Refill & Drain of Front Axle Lubricant............................................................................................................... 21-8
Replacement of Front Axle Drive Gear Male Flange and Drive Gear Oil Seal ................................................ 21-8
Replacement of Front Axle Rim Oil Seal and Needle Bearing....................................................................... 21-10
Replacement of Front Axle Output Shaft ....................................................................................................... 21-11
Replacement of Front Axle Bracket ............................................................................................................... 21-11
Replacement of Front Axle Final Drive Assembly.......................................................................................... 21-12
Refill & Drain of Rear Axle Lubricant ............................................................................................................. 21-20
Replacement of Drive Gear Male Flange and Oil Seal .................................................................................. 21-20
Replacement of Drive Gear ........................................................................................................................... 21-22
Replacement of Differential Assembly ........................................................................................................... 21-25
Half Shaft Assembly....................................................................................................................................... 21-31
Rear Axle EDL Control Unit ........................................................................................................................... 21-33
Special Tool ..................................................................................................................... 21-34

Front Axle and Rear Axle............................................................................................................................... 21-36
Electronic Differential Lock (EDL) .................................................................................................................. 21-37
Exteriors ........................................................................................................ 22-1

Technical Parameters ........................................................................................................ 22-1
Torque.............................................................................................................................................................. 22-1
Layout ................................................................................................................................ 22-2

Contents
Repair Guidance ................................................................................................................. 22-4
Replacement of Front Windscreen Cover Plate Assembly .............................................................................. 22-4
Replacement of Radiator Grille Assembly........................................................................................................ 22-5
Replacement of License Plate Trim Panel ....................................................................................................... 22-6
Replacement of Exterior Rearview Mirror ........................................................................................................ 22-6
Replacement of Exterior Rearview Mirror Glass .............................................................................................. 22-7
Replacement of Interior Rearview Mirror.......................................................................................................... 22-7
Driver Compartment Interiors and Switches ................................................. 23-1

Torque .............................................................................................................................................................. 23-1
Layout ................................................................................................................................. 23-2
Repair Guidance ................................................................................................................. 23-5

Replacement of Front Door Interior Trim Panel Assembly............................................................................... 23-5
Replacement of Rear Door Interior Trim Panel ................................................................................................ 23-6
Replacement of Front/Rear Door Waterproof Membrane ................................................................................ 23-6
Replacement of Tailgate Trim Panel Assembly ............................................................................................... 23-7
Replacement of Treadboard Cover .................................................................................................................. 23-7
Replacement of Driver Compartment Roof Interior Assembly ......................................................................... 23-8
Replacement of A-pillar Upper Trim Panel....................................................................................................... 23-8
Replacement of A-pillar Lower Trim Panel....................................................................................................... 23-8
Replacement of B-pillar Upper Trim Panel....................................................................................................... 23-9
Replacement of C-pillar Upper Trim Panel..................................................................................................... 23-10
Replacement of Sun Visor Assembly ............................................................................................................. 23-10
Replacement of Rear Body Side Trim Panel Assembly ................................................................................. 23-11
Replacement of Rear Body Side Armrest ...................................................................................................... 23-11
Replacement of Roof Handles in Front Passenger Area and Passenger Compartment ............................... 23-11
Replacement of Footrest Assembly ............................................................................................................... 23-11
Replacement of Instrument Panel Body......................................................................................................... 23-12
Replacement of Instrument Panel Lower Body Assembly ............................................................................. 23-13
Replacement of Instrument Panel Beam........................................................................................................ 23-13
Replacement of Auxiliary Fascia Console Assembly ..................................................................................... 23-14
Replacement of Outer Cover Plate Assembly of Auxiliary Fascia Console Guard Plate ............................... 23-15
Replacement of CNSL Front Storage Box ..................................................................................................... 23-15
Replacement of Instrument Panel Side End Cover Assembly ....................................................................... 23-16
Replacement of Driver Side Instrument Panel Lower Guard Plate Assembly................................................ 23-16
Replacement of Driver Side Footrest Assembly............................................................................................. 23-17
Replacement of Upper and Lower Steering Column Shrouds ....................................................................... 23-17
Replacement of Instrument Panel Wood Grain Trim Panel Assembly (Cladding Trim Panel Assembly) ...... 23-18
Replacement of Front Passenger Side Footrest Assembly............................................................................ 23-18
Replacement of Glove Box Assembly ............................................................................................................ 23-19
Replacement of Instrument Cluster Shroud Assembly................................................................................... 23-19
Replacement of Driver Side Atmosphere Lamp ............................................................................................. 23-20
Contents
Replacement of Front Passenger Side Atmosphere Lamp............................................................................ 23-20
Replacement of Combination Switch Assembly ............................................................................................ 23-21
Replacement of Rearview Mirror Adjustment and Dimmer Switch Assembly................................................ 23-21
Replacement of Hazard Warning Lamp Switch ............................................................................................. 23-22
Replacement of Driver Side Window Regulator Switch Assembly ................................................................ 23-22
Replacement of Auxiliary Fascia Console Switch Set ................................................................................... 23-22
Seats ............................................................................................................. 24-1

Torque.............................................................................................................................................................. 24-1
Layout ................................................................................................................................ 24-2
Repair Guidance ................................................................................................................ 24-3

Replacement of Driver Seat and Front Passenger Seat.................................................................................. 24-3
Replacement of Rear Seats............................................................................................................................. 24-4

Front Seat Assembly........................................................................................................................................ 24-4
Seat Belt........................................................................................................ 25-1

Torque.............................................................................................................................................................. 25-1
Repair Guidance ................................................................................................................ 25-2

Precautions for handling expanded pretightening seat belt or lap belt pretensioner ....................................... 25-2
Precautions for handling unexpanded pretightening seat belt or lap belt pretensioner ................................... 25-2
Replacement of Driver/Front Passenger Seat Belt (Without Lap Belt Pretensioner)....................................... 25-2
Replacement of Driver/Front Passenger Seat Belt (With Lap Belt Pretensioner) ............................................ 25-3
Replacement of Height Regulator.................................................................................................................... 25-5
Replacement of Lap Belt Pretensioner (If Any)................................................................................................ 25-5
Replacement of Rear Seat Belt ....................................................................................................................... 25-6
Replacement of Front/Rear Seat Belt Buckle .................................................................................................. 25-6
Seat Belt Check/Test ....................................................................................................................................... 25-6
Special Tool ....................................................................................................................... 25-7

Front Seat Belt Pretensioner............................................................................................................................ 25-8
Seat Belt .......................................................................................................................................................... 25-8
Front Seat Belt ................................................................................................................................................. 25-8
Seat Belt Alarm Indicator ................................................................................................................................. 25-8
Rear Body ..................................................................................................... 26-1

Contents
Torque .............................................................................................................................................................. 26-1
Layout ................................................................................................................................. 26-2
Repair Guidance ................................................................................................................. 26-3

Tailgate Replacement ...................................................................................................................................... 26-3
Replacement of Tailgate Gas Stay Bar ............................................................................................................ 26-4
Power Liftgate ............................................................................................... 27-1

Torque .............................................................................................................................................................. 27-1
Layout ................................................................................................................................. 27-2
Repair Guidance ................................................................................................................. 27-3

Power Liftgate Replacement ............................................................................................................................ 27-3
Replacement of Power Liftgate Electric Stay Bar............................................................................................. 27-4
Replacement of Power Liftgate Balance Bar.................................................................................................... 27-5
Replacement of Power Liftgate Anti-pinch Molding.......................................................................................... 27-6
Replacement of Power Tailgate Control Box Assembly................................................................................... 27-7

Introduction of Power Liftgate Parts Function .................................................................................................. 27-8
Operation Principles of System ........................................................................................................................ 27-8
Procedures for Aftersales Self-learning (Repeat Self-learning) ....................................................................... 27-9
Factors for Retriggering Self-learning .............................................................................................................. 27-9
Front Body..................................................................................................... 28-1

Torque .............................................................................................................................................................. 28-1
Layout ................................................................................................................................. 28-2
Repair Guidance ................................................................................................................. 28-4

Engine Hood Replacement .............................................................................................................................. 28-4
Replacement of Engine Hood Hinge ................................................................................................................ 28-5
Replacement of Gas Stay Bar.......................................................................................................................... 28-5
Fender Replacement........................................................................................................................................ 28-6
Entertainment System................................................................................... 29-1

Torque .............................................................................................................................................................. 29-1
Contents
Layout ................................................................................................................................ 29-2
Repair Guidance ................................................................................................................ 29-4

Replacement of MP5 display ........................................................................................................................... 29-4
Replacement of Radio+MP5+Mirrorlink ........................................................................................................... 29-4
Replacement of Radio+MP3 ............................................................................................................................ 29-5

Entertainment and Navigation System Control Diagram ................................................................................. 29-6
Entertainment Mainframe................................................................................................................................. 29-7
Audio Control Buttons on Steering Wheel ....................................................................................................... 29-7
Display ............................................................................................................................................................. 29-7
Full Range Speaker ......................................................................................................................................... 29-7
Tweeter ............................................................................................................................................................ 29-7
Antenna............................................................................................................................................................ 29-7
Operation ......................................................................................................................................................... 29-7
Frame ............................................................................................................ 30-1

Torque.............................................................................................................................................................. 30-1
Layout ................................................................................................................................ 30-2
Repair Guidance ................................................................................................................ 30-3

Mount Installation............................................................................................................................................. 30-3
Stationary Windows ...................................................................................... 31-1

Layout ................................................................................................................................ 31-1
Repair Guidance ................................................................................................................ 31-2
Replacement of Front Door Window Glass...................................................................................................... 31-2
Replacement of Rear Door Window Glass ...................................................................................................... 31-2
Replacement of Rear Side Window Glass....................................................................................................... 31-3
Replacement of Front Door Quarter Window................................................................................................... 31-4
Replacement of Front Windscreen .................................................................................................................. 31-4
Replacement of Rear Windscreen ................................................................................................................... 31-6
Doors............................................................................................................. 32-1
Torque.............................................................................................................................................................. 32-1
Layout ................................................................................................................................ 32-2
Repair Guidance ................................................................................................................ 32-3

Contents
Replacement of Front Door/Hinge.................................................................................................................... 32-3
Replacement of Rear Door/Hinge .................................................................................................................... 32-4
Front Door Adjustment ..................................................................................................................................... 32-5
Front Door Hinge Adjustment........................................................................................................................... 32-5
Replacement of Front Door Lock Assembly..................................................................................................... 32-6
Replacement of Front Door Lock Catch Assembly .......................................................................................... 32-7
Rear Door Adjustment...................................................................................................................................... 32-8
Rear Door Hinge Adjustment ........................................................................................................................... 32-8
Replacement of Rear Door Lock Assembly ..................................................................................................... 32-9
Replacement of Rear Door Lock Catch Assembly ......................................................................................... 32-10
Replacement of Engine Hood Lock Assembly ............................................................................................... 32-11
Replacement of Front/Rear Door Outer Handle............................................................................................. 32-11
Replacement of Front/Rear Door Inner Handle.............................................................................................. 32-12
Replacement of Front Door Window Regulator Assembly ............................................................................. 32-13
Replacement of Rear Door Window Regulator Assembly.............................................................................. 32-14
Replacement of Fuel Filler Flap Assembly..................................................................................................... 32-15

Description and Operation.............................................................................................................................. 32-15
Overview ........................................................................................................................................................ 32-15
Roof (Sunroof)............................................................................................... 33-1

Layout ................................................................................................................................. 33-1
Repair Guidance ................................................................................................................. 33-3

Replacement of Panoramic Sunroof Assembly................................................................................................ 33-3
Replacement of Front Sunroof Glass Assembly (Panoramic Sunroof) ............................................................ 33-3
Replacement of Rear Sunroof Glass Assembly (Panoramic Sunroof)............................................................. 33-4
Replacement of Front Sunroof Motor (Panoramic Sunroof)............................................................................. 33-4
Replacement of Front Sunroof Sunshade Assembly (Panoramic Sunroof) ..................................................... 33-5
Replacement of Wind Guide Assembly (Panoramic Sunroof).......................................................................... 33-6
Replacement of Front Sunroof Assembly (Common Sunroof) ......................................................................... 33-6
Replacement of Front Sunroof Glass Assembly (Common Sunroof)............................................................... 33-7
Replacement of Front Sunroof Motor (Common Sunroof) ............................................................................... 33-7

System Control Diagram .................................................................................................................................. 33-8
Sunroof Assembly ............................................................................................................................................ 33-9
Sunroof Switch ................................................................................................................................................. 33-9
Sunroof Glass................................................................................................................................................... 33-9
Sunroof Sunshade............................................................................................................................................ 33-9
Input and Output of the Motor and Drive Unit................................................................................................... 33-9
Sunroof Switch Operation ................................................................................................................................ 33-9
Mechanical Key Operation ............................................................................................................................... 33-9
Anti-pinch Function........................................................................................................................................... 33-9
Initialization of Sunroof Assembly .................................................................................................................. 33-10
Contents
Supplemental Inflatable Restraint (SIR) ........................................................ 34-1
Torque.............................................................................................................................................................. 34-1
SRS-ECU Parameters ..................................................................................................................................... 34-1
Frontal/Side Impact Sensor Parameters.......................................................................................................... 34-1
Layout ................................................................................................................................ 34-2
Repair Guidance ................................................................................................................ 34-5

Replacement of Steering Wheel (Driver) Airbag Assembly ............................................................................. 34-5
Replacement of Instrument Panel (Front Passenger) Airbag Assembly.......................................................... 34-6
Replacement of Curtain Airbag Assembly ....................................................................................................... 34-7
Replacement of Curtain Airbag Bracket........................................................................................................... 34-8
Replacement of Airbag Control Module ........................................................................................................... 34-8
Replacement of Airbag Frontal Impact Sensor ................................................................................................ 34-9
Replacement of Airbag Side Impact Sensor .................................................................................................... 34-9
Body Control System .................................................................................... 35-1

Torque.............................................................................................................................................................. 35-1
Body Controller Parameters............................................................................................................................. 35-1
Gateway Parameters ....................................................................................................................................... 35-1
Layout ................................................................................................................................ 35-2
Repair Guidance ................................................................................................................ 35-5

Replacement of Body Control Module ............................................................................................................. 35-5
Gateway Replacement..................................................................................................................................... 35-5
Replacement of Driver Assist System Controller ............................................................................................. 35-6
Replacement of Rain/Solar Sensor.................................................................................................................. 35-6

Function Description ........................................................................................................................................ 35-8
Description ....................................................................................................................................................... 35-8
Operation ......................................................................................................................................................... 35-9
Load Management ......................................................................................................................................... 35-11
PEPS and Immobilizer System (with key start) ............................................. 36-1

PEPS-ECU Parameters ................................................................................................................................... 36-1
RKE Parameters .............................................................................................................................................. 36-1
Door Handle Antenna Parameters................................................................................................................... 36-2
Parameters of Low-Frequency Antenna Inside the Vehicle............................................................................. 36-2
Tailgate Antenna Parameters .......................................................................................................................... 36-2
Contents
Layout ................................................................................................................................. 36-3
Repair Guidance ................................................................................................................. 36-4

Replacement of Low-Frequency Antenna (Instrument Panel) Inside the Vehicle ............................................ 36-4
Replacement of Low-Frequency Antenna (Auxiliary Fascia Console) Inside the Vehicle................................ 36-4
Replacement of Ceiling Low-Frequency Antenna ............................................................................................ 36-5
Replacement of Front Door Handle Antenna ................................................................................................... 36-5
Replacement of Tailgate Antenna .................................................................................................................... 36-5
Replacement of Tailgate Induction Open Sensor............................................................................................. 36-6
Replacement of PEPS Controller ECU ............................................................................................................ 36-6
Replacement of Start-Stop Switch ................................................................................................................... 36-7
Replacement of Clock Spring Assembly and Clock Spring Returning Ring..................................................... 36-7
Replacement of Immobilizer Base Station ....................................................................................................... 36-8
Replacement of Remote Control Receiving Module ........................................................................................ 36-8

PEPS System Control Diagram........................................................................................................................ 36-9
Immobilizer System Control Diagram............................................................................................................. 36-10
Overview ........................................................................................................................................................ 36-11
Mounting Location .......................................................................................................................................... 36-11
Operation of Passive Entry and Passive Start (PEPS) .................................................................................. 36-11
Identifier/Smart Key........................................................................................................................................ 36-11
Normal Locking/Unlocking Operation............................................................................................................. 36-11
Function of Smart Key in PEPS ..................................................................................................................... 36-11
Effect of Smart Key on Vehicle Access .......................................................................................................... 36-11
Effect of Smart Key on Vehicle Start .............................................................................................................. 36-11
Exterior Door Handle Antenna/Switch (HSU)................................................................................................. 36-12
LF Antenna..................................................................................................................................................... 36-12
Internal LF Antenna........................................................................................................................................ 36-12
LF Antenna of Rear Bumper Upholstery ........................................................................................................ 36-12
Start-Stop Button (SSB) ................................................................................................................................. 36-13
PEPS ECU ..................................................................................................................................................... 36-13
Retained Accessory Power (RAP) ................................................................ 37-1

Torque .............................................................................................................................................................. 37-1
DC Stabilizer Parameters................................................................................................................................. 37-1
On-board Inverter Parameters ......................................................................................................................... 37-1
Layout ................................................................................................................................. 37-2
Repair Guidance ................................................................................................................. 37-4

Replacement of On-board Inverter Assembly .................................................................................................. 37-4
Replacement of DC Stabilizer Assembly.......................................................................................................... 37-5
Replacement of Cigar Lighter........................................................................................................................... 37-5
Replacement of Power Outlet .......................................................................................................................... 37-6
Contents
DC Stabilizer .................................................................................................................................................... 37-6
On-board Inverter............................................................................................................................................. 37-6
Parking Assist System................................................................................... 38-1

Parking Distance Control, Radar Sensor and Camera .................................................................................... 38-1
Layout ................................................................................................................................ 38-2
Repair Guidance ................................................................................................................ 38-5

Replacement of Parking Distance Control ....................................................................................................... 38-5
Replacement of Front Bumper Radar Sensor and its Bracket......................................................................... 38-5
Replacement of Rear Bumper Radar Sensor and its Bracket ......................................................................... 38-6
Replacement of Front Camera......................................................................................................................... 38-6
Replacement of Rear Camera ......................................................................................................................... 38-7

Description ....................................................................................................................................................... 38-8
Operation ......................................................................................................................................................... 38-9
Tire Pressure Monitoring ............................................................................... 39-1

Torque.............................................................................................................................................................. 39-1
Controller Performance Index .......................................................................................................................... 39-1
Layout ................................................................................................................................ 39-2

Repair Guidance ................................................................................................................ 39-3
Replacement of Tire Pressure Monitoring Control Module .............................................................................. 39-3
Replacement of Tire Pressure Sensor............................................................................................................. 39-3
Instructions for Handheld TPMS Match Tool ..................................................................... 39-4

1. Introduction of Handheld TPMS Match Tool ................................................................................................ 39-4
Overview .......................................................................................................................................................... 39-4
Package ........................................................................................................................................................... 39-4
Appearance...................................................................................................................................................... 39-4
Schematic Diagram.......................................................................................................................................... 39-4
Keyboard.......................................................................................................................................................... 39-4
2 Battery and Charging of Handheld TPMS Match Tool
........................................................................................................................................................................ 39-5
3 Radio Frequency Parameters of Handheld TPMS Match Tool..................................................................... 39-5
4 Configuration File of Handheld TPMS Natch Tool ........................................................................................ 39-5
5 Handheld TPMS Match Tool: Match mode ................................................................................................... 39-6

Contents
Lighting System............................................................................................. 40-1
Bulb Specification............................................................................................................................................. 40-1
Layout ................................................................................................................................. 40-2
Repair Guidance ................................................................................................................. 40-3

Replacement of Front Combination Headlamp ................................................................................................ 40-3
Replacement of Front Fog Lamp...................................................................................................................... 40-3
Replacement of Front Roof Interior Reading Lamp Assembly ......................................................................... 40-4
Replacement of Rear Roof Interior Reading Lamp Assembly.......................................................................... 40-5
Replacement of Rear Combination Headlamp A ............................................................................................. 40-6
Replacement of Rear Combination Headlamp B ............................................................................................. 40-6
Replacement of Rear Roof Interior Reading Lamp Assembly.......................................................................... 40-7
Replacement of Rear Height Sensor and Bracket ........................................................................................... 40-7
Replacement of Rear Combination Lamp ........................................................................................................ 40-8
Replacement of License Lamp......................................................................................................................... 40-9
Replacement of Reflex Reflector.................................................................................................................... 40-10
Replacement of High Mounted Stop Lamp .................................................................................................... 40-10
Air Conditioning............................................................................................. 41-1

Parameters....................................................................................................................................................... 41-1
Torque .............................................................................................................................................................. 41-1
Technical Requirements of A/C:....................................................................................................................... 41-2
Technical Parameters of A/C Components ...................................................................................................... 41-3
Troubleshooting Information and Procedure....................................................................... 41-5

Layout ................................................................................................................................. 41-7
Repair Guidance ................................................................................................................. 41-8

Coolant Drain and Refill ................................................................................................................................... 41-8
Replacement of A/C Compressor Assembly .................................................................................................... 41-9
Refill of Refrigerant Oil ................................................................................................................................... 41-10
Replacement of Compressor Intake/Exhaust Pipe Assembly ........................................................................ 41-11
Condenser Replacement................................................................................................................................ 41-12
Replacement of Front A/C Assembly ............................................................................................................. 41-13
Replacement of Front Floor Air Duct.............................................................................................................. 41-14
Replacement of Front Heater Water Inlet Pipe Assembly.............................................................................. 41-14
Replacement of Rear Floor Air Duct .............................................................................................................. 41-15
Replacement of Rear A/C Assembly.............................................................................................................. 41-16
Replacement of Front A/C Control Panel ....................................................................................................... 41-18
Replacement of Rear A/C Control Panel........................................................................................................ 41-18
Replacement of Transmission Oil Cooler Pipe Assembly .............................................................................. 41-19
Replacement of Transmission Oil Cooler Water Inlet/Outlet Pipe Assembly ................................................. 41-19
Contents
Replacement of Front A/C Intake/Outlet Pipe Assembly ............................................................................... 41-20
Replacement of Rear A/C Intake/Outlet Pipe Assembly................................................................................ 41-21
Replacement of Air Pressure/Temperature Sensor ....................................................................................... 41-22
Replacement of Rear A/C Air Duct ................................................................................................................ 41-23

Overview ........................................................................................................................................................ 41-24
Operating Principle ........................................................................................................................................ 41-24
HVAC Schematic Diagram............................................................................................................................. 41-24
Introduction of Parts Function ........................................................................................................................ 41-26
Wiper/Washer System................................................................................... 42-1

Torque.............................................................................................................................................................. 42-1
Layout ................................................................................................................................ 42-2
Repair Guidance ................................................................................................................ 42-4

Replacement of Front Wiper Blade.................................................................................................................. 42-4
Replacement of Wiper Arm Assembly ............................................................................................................. 42-4
Replacement of Wiper Linkage Assembly (with Motor) ................................................................................... 42-4
Replacement of Wiper Motor Assembly........................................................................................................... 42-5
Replacement of Washer Reservoir Body Assembly ........................................................................................ 42-5
Replacement of Washer Reservoir Cover Assembly ....................................................................................... 42-6
Replacement of Front Windscreen Washer Pump........................................................................................... 42-6
Replacement of Front Washer Fluid Hose and Nozzle .................................................................................... 42-7
Replacement of Rear Wiper Blade .................................................................................................................. 42-7
Replacement of Rear Wiper Arm Assembly .................................................................................................... 42-7
Replacement of Rear Wiper Motor Assembly.................................................................................................. 42-8
Horn .............................................................................................................. 43-1

Torque.............................................................................................................................................................. 43-1
Horn Parameters.............................................................................................................................................. 43-1
Layout ................................................................................................................................ 43-2

Layout .............................................................................................................................................................. 43-2
Repair Guidance ................................................................................................................ 43-3

Horn Replacement ........................................................................................................................................... 43-3
Bumper.......................................................................................................... 44-1
Contents
Torque .............................................................................................................................................................. 44-1
Layout ................................................................................................................................. 44-2
Repair Guidance ................................................................................................................. 44-3

Impact Check ................................................................................................................................................... 44-3
Replacement of Front Bumper ......................................................................................................................... 44-3
Replacement of Front Bumper Bracket ............................................................................................................ 44-5
Replacement of Rear Bumper.......................................................................................................................... 44-6
Replacement of Rear Bumper Bracket............................................................................................................. 44-7
Replacement of Rear Bumper Beam Assembly............................................................................................... 44-9
On-board Communication System ................................................................ 45-1

Torque .............................................................................................................................................................. 45-1
TBOX Technical Parameters............................................................................................................................ 45-1
GNSS Technical Parameters ........................................................................................................................... 45-2
4G Antenna and BD/GPS Antenna Technical Parameters .............................................................................. 45-3
Layout ................................................................................................................................. 45-4
Repair Guidance ................................................................................................................. 45-5

Replacement of BD/GPS Output Antenna ....................................................................................................... 45-5
Replacement of On-board Communication Module ......................................................................................... 45-5
Replacement of 4G Antenna Assembly ........................................................................................................... 45-6
Overview
Overview
Overview
Battery Disconnection jack standard to support the other end. This can avoid
vehicle damage, serious personal injury and even death.
Before servicing any electrical components, ensure the
ignition key is in "OFF" or "LOCK" position and all Window Removal
electrical loads are turned "OFF", unless otherwise stated
To avoid injury, wear certified goggles and gloves when
in the operating procedure. If the exposed live terminals
machining any type of glass.
can be accessed easily by any tool or device, be sure to
disconnect the negative battery cable. Violation of these
safety instructions could cause personal injury and/or
Drive Belt Repair
damage to the vehicle or its components.
Do not repair the drive belt. Repairing of the drive belt
could cause belt texture breakage. Failure to observe this
instruction may cause the damage to drive belt.
Electric Coolant Fan
The fan under the engine hood may start and cause
injury even when the engine is not running. Be careful to
Fasteners
keep your hands, clothes and tool away from the fan.
Use the correct fastener in the correct location. Fastener
replacement must have correct part number. Fasteners
requiring thread locker, lubricating oil, corrosion inhibitor
Moving Parts and Hot Surfaces
or sealant and fasteners requiring the replacement shall
To avoid injury, do not come into contact with moving
be specified in the service procedures. Unless otherwise
parts and hot surfaces while the engine is running.
stated, do not apply paint, lubricating oil or corrosion
inhibitor to the fasteners or the junction surface. These
coating will affect the torque and connection force of the
Radiator Cap Removal fastener and cause damages to fastener. Follow correct
To avoid scalding, do not remove the radiator cap or tightening sequence and torque for fastener installation.
auxiliary water tank cap while the engine is hot. Power Steering Fluid
Otherwise the boiling high-pressure fluid and steam will Use proper power steering fluid when refilling or
be flown out of the cooling system. completely replacing the fluid. Use of improper fluid could
cause damage to hoses or seals and fluid leakage.
Fuel Pressure Relief

Before servicing any components of the fuel system, be
sure to relieve pressure in the system to avoid fire hazard
and injury. Servicing fuel pipe or joint can cause spilling of
a small amount of fuel. To prevent personal injury, cover
the adjuster and fuel pipe joints with cotton towels before
disconnection so as to absorb leaked fuel. After
disconnecting the fuel pipe, place the towels in a proper
container.
Vehicle Lifting
Before removing any main component from one end of
the vehicle, or using a hook to support the vehicle, use a
1-1
Overview
1-2
General
General
General
Specification system on the single car. The brake system employs the
9th generation BOSCH ESP system. It is the only one in
D90 is the first large-scale C2B intelligent customized
the same-level models that uses the latest
model introduced by SAIC MOTOR, which is positioned
ESP+TCS+EBD system of BOSCH, and it also provides
as network intelligent customized SUV. As an elaborate
the RMI and EBA functions; it monitors the driving state
design of the world-famous Torino company, D90 model
in real time, applies brake force to one or more wheels
achieves a perfect balance between the dynamic
when necessary, and keeps the vehicle in normal drive
appearance and the ride space; the new generation of
ways; by controlling the engine speed and output torque,
SAIC MOTOR engines with cutting-edge technology and
it adjusts the drive force and brake force of each wheel to
high efficiency of this model are equipped with
correct oversteer and understeer. This ensures that the
turbochargers and intercoolers which are longitudinally
vehicle can keep the driver away from danger and greatly
arranged on the frame, power is transmitted by the
improve driving safety under straight line, sharp turn or
transmission propeller shaft so as to provide rear wheel
emergency conditions.
drive; the engine introduces relevant program to control
the in-cylinder direct injection system, which improves the Front/Rear Ventilated Disc Brake
combustion efficiency and takes low fuel consumption
Disc brake system is applied on both front and rear
and low emission into consideration, the emission meets
wheels. And front and rear wheels both use the
the European stage V standard. The level of the power,
ventilated disc brake with good heat dissipation
noise and fuel consumption can match the latest
performance and brake performance. Meanwhile, good
international standard. Integrated with the excellent
brake performance can be realized by improving the
performance of 20L4E engine, the maximum
rigidity of the brake pedal, employing brake linings of high
horsepower of it can reach 224Ps, with the maximum
friction coefficient and developing new tire with strong
torque of 360N.m. 6-speed manual transmission and 6-
adhesion, etc. When supplying strong brake force, the
speed automatic transmission of D90 SUV are matched.
front/rear ventilated disc brake greatly enhances the heat
In addition, D90 applies the chassis of high comfort
dissipation effect of the brake and effectively prevents
accurately calibrated by the Lotus Cars, European body
decay of the brake force on mountain road and under
structure design and the latest generation of BOSCH
frequent brake conditions. D90 model is equipped with 3-
ESP security system. And D90 model can provide 3
zone automatic temperature control (ATC) system, which
types of seats layout: 5-seat, 6-seat and 7-seat. More
can independently control the temperature of each zone.
flexible seats layout can be selected during car ordering,
The seat of each row is provided with the special A/C
so as to meet the actual requirements of different users.
outlet. The A/C outlet of the rear row applies the
Owing to the large size of D90 model, sufficient space
concealed design, the layout of the outlet reflects the
can still be provided even when 3-row seats layout is
humane design.
selected. And various interiors are available in the vehicle
for different demands. This model is also equipped with
abundant advanced, humane and comfortable
configurations such as luxury power sunroof, PEPS,
start/stop button (SSB) system, automatic wiper,
multifunctional steering wheel, AFS, HID automatic
halogen headlamp, center console 12.3-inch touch
screen, LCD instrument panel, rear seats air conditioner
and 220V power interface, etc. D90 model carries
integral bridge suspension with double-wishbone at the
front and 5-link suspension at the rear. And it acts as a
pioneer to provide real-time 4WD and part-time 4WD
2-1
General
Technical Parameters
Main Technical Parameters of Complete Vehicle
Model SH6501FAG5 SH6501FAG5-A SH6501GAG5 SH6501GAG5-A
Drive type 4X2, front-engine RWD 4X4, front-engine 4WD
Overall dimension L (A), 5005

mm
Overall dimension W (B), 1932

mm
Overall dimension H (C), 1875

mm
Wheel base D, mm 2950
Front overhang E/rear 935/1120

overhang F, mm
Front wheel track G, mm 1600
Rear wheel track H, mm 1620
Minimum turning circle 12

diameter, m
Fuel tank capacity, L 75
Note: The technical parameters are only provided as a basis for vehicle model selection, please refer to
the Vehicle Certification for actual specifications.
2-2
General
Key Engine Parameters
Engine model NLE 2.0T
Engine model In-line 4-cylinder, water-cooling, turbocharged inter-cooling

and in-cylinder GDI (gasoline direct injection) engine
Displacement, L 1.995
Number of cylinder 4
Cylinder diameter, mm 88
Stroke, mm 82
Volume compression ratio 10:1
Rated power, KW 165
Speed at rated power, rpm 5300
Maximum net power, KW 160
Maximum torque, Nm 360
Speed at max. torque, rpm 2500~3500
Speed at max. torque, rpm 750 ± 30

Fuel type & grade 92# and above gasoline of national stage V standard and
above
Key Transmission Parameters
Type 6MT SAGW 6MT DYMOS 6AT Punch
1st gear 4.340 4.371 4.065
2nd gear 2.264 2.270 2.371

3rd gear 1.504 1.443 1.551
4th gear 1.152 1.000 1.157
5th gear 1.000 0.817 0.853
6th gear 0.720 0.679 0.674
Reverse gear 3.870 4.253 3.2
Transmitted torque (N.m) 350 350 350
Operations Direct Direct Remote cable
2-3
General
Wheel Alignment Parameters
Items Four-wheel Alignment Parameter (Unilateral Four-wheel Alignment Parameter (Bilateral

Nominal Value and Tolerance) Sum/Difference)
Front wheel camber 0 ± 0.5° Difference between left and right ≤ 0.5°
Front wheel kingpin 3.6 ± 0.8° Difference between left and right ≤ 0.5°
caster
Front wheel toe-in angle 0 ± 0.15° Total front toe-in ≤ 0.15°

Rear wheel toe-in angle 0°± 0.25° -
Rear wheel camber 0°± 0.25° -
Rear shaft thrust angle 0°± 0.25° -
Wheel and Tire Parameters
Items Parameters
Wheel dimension 7.5Jx18 7.5Jx19 7Jx17 8.5Jx21
Tire dimension 255/60R18 255/55R19 255/65R17 265/45R21
Tire pressure Front 220kPa/2.2bar/ 220kPa/2.2bar/ 220kPa/2.2bar/ 230kPa/2.3bar/

(cold) wheels 32psi 32psi 32psi 33psi
Rear 220kPa/2.2bar/ 270kPa/2.7bar/ 270kPa/2.7bar/ 280kPa/2.8bar/

wheels 32psi 39psi 39psi 41psi
Small spare tire dimension 245/65R17 245/65R17 245/65R17 245/65R17
Small spare tire pressure 290kPa/2.9bar/ 290kPa/2.9bar/ 290kPa/2.9bar/ 290kPa/2.9bar/

(cold) 42psi 42psi 42psi 42psi
Full size spare tire dimension 255/60R18 255/55R19 255/65R17 265/45R21
Full size spare tire pressure 270kPa/2.7bar/ 270kPa/2.7bar/ 270kPa/2.7bar/ 280kPa/2.8bar/

(cold) 39psi 39psi 39psi 41psi
Body Color
White Blanc white
Gray Lava gray
Blue Jewelry blue
Golden Amber gold
Champaign gold
Silver Aurora silver
Red Zircon red
Green Olive green
Black Obsidian black
2-4
General
Vehicle Identification Number

Vehicle Identification Number (VIN) - Location
VIN
VIN
VIN
GS010002
Example of VIN: LSFA431J0HAXXXXXX
Vehicle Identification
Digit Code Description
1~3 LSF Automaker identification number
4 A Vehicle brand
MAXUS
5 4 Vehicle length (chassis length)
L<5.0m
6 3 Driver compartment type
Without integrated driver compartment
7 1 Power source layout
Front engine
8 J Power source feature
J： 150<= P < 250

9 O Check digit
10 H Model year
H = 2017
11 A Assembly plant
A = manufacturer
12~17 XXXXXX (6 digits) Production serial number
2-5
General
Lifting and Towing

Front/Rear Jacking Point of the Vehicle
Lifting
Lifting Description The jack of the vehicle is only applied to replace wheels
in emergency. Do not use it for other purposes.
Before lifting the vehicle, note the followings:
·The vehicle shall be parked on a level and firm ground.
·Apply the parking brake.
·Select P or N gear.
Do not put the jack or axle bracket under the following

components:
·Body structural parts
·Bumper
·Fuel pipe GS010003
·Brake pipe
If using the jack to replace wheels, ensure that the jack is
·Front suspension arm placed on a solid level ground and under the supporting
·Steering connecting mechanism point near the wheel to be removed. Note: the round
head of the jack must be in the corresponding slot on the
·Rear suspension arm baseplate.
·Fuel tank Warning: Do not operate under a vehicle

supported by a jack only. The vehicle must be
·Engine oil pan
supported on a safe device.
·Transmission housing
·Rear towing eye

Hydraulic Jack
Note: Lift and support the front of vehicle under
The hydraulic jack to be used must have a bearing
the front jacking point and/or the supporting
bracket on the front part of front subframe. capacity of at least 1,500kg.
Warning: Operations can be carried out under the

vehicle only when the vehicle is safely and
reliably supported.
Warning: Please use a block to lock the wheel
when using the jack. Lift and support the vehicle.
Front wheel jacking point: on the plane under the

longitudinal beam (between the 4th beam and the 2nd
mount).
Rear wheel jacking point: on the rear axle housing

(90mm from the rear leaf spring), and the concave side of
the jack shall be aligned with the curved surface of the
rear axle housing sleeve. The jack of the vehicle is only
2-6
General
applied to replace wheels in emergency, do not use it for Roadside Assistance

any other purpose. Instructions for Roadside Assistance
Caution: Lift or support the vehicle on the It is recommended that a rescue trailer or a two-wheel
specified location only, or damage to the body or rescue vehicle shall be used. In emergency, use a towing
chassis component may occur. vehicle with front towing point.
Warning: Operations can be carried out under the Front Towing Eye
vehicle only when the vehicle is safely and
reliably supported.
Warning: Please use a block to lock the wheel
when using the jack.
Warning: Column Lifter
GS010005
In the front of the vehicle, non-removable towing eye can

be used for rescue operation. Front towing eye is welded
at the right bottom of anti-collision beam.
Caution: The mass that the front towing eye can

bear is 1/2GVW (total mass), do not exceed this
GS010004
value.
Place the mat at appropriate jacking point for lifting Rear Towing Eye
operation.
Front jacking point: between the 4th beam and the 2nd
mount.
Rear jacking point: on the plane before the leaf spring

bracket.
GS010006
In the rear of the vehicle, removable towing eye can be

used for rescue operation. The towing eye is usually kept
in the toolbox and should be put back after use. When
installing the towing eye, the towing eye cover at the right
side of the rear bumper shall be removed first, then screw
the towing eye into the mounting position of the rear
bumper assembly (bumper beam). The rear towing eye
can only be used to tow light vehicles. The rear towing
2-7
General
point of the vehicle equipped with manual transmission AWD Vehicles

can be used for rear towing.
Caution: The mass that the rear towing eye can

bear is 1/2 GVW (total mass), do not exceed this
value.
GS010007
For AWD vehicles, the vehicle shall be towed with all

wheels off the ground, this operation involves use of the
wheel lift, wheel trolley or flat-bed trailer.
2-8
General
Maintenance and Lubrication

Liquid Capacity
The following capacity values are merely approximate

value of liquids to be refilled into the corresponding
system.
Items Grade Capacity
Engine lubricating oil (NLE 2.0T), L ACEA C3 5W-30 5.6

Engine coolant, L JFL-3(-35 ℃ ) 11.5
6-speed manual transmission oil Fuchs MTF SAE 75W-85
(SAGW), L 2.5( ± 0.1)
6-speed manual transmission oil Fuchs MTF SAE 75W-85

(DYMOS), L 2.5
Automatic transmission oil, L petro-Canada DEXRON VI 10.2

Brake fluid, L Laike 901-4 DOT 4 0.66
Washer fluid, L General low-freezing detergent 2.3 (front)
2.3 (rear)
Air conditioning refrigerant, g R134a 900 ± 30 (dual-zone A/C
system)
620 ± 30 (single-zone A/C
system)
Front axle lubricant, L Total/Tampo GL-5 80W-90 0.9
Rear axle lubricant, L Total/Tampo GL-5 80W-90 1.74
Transfer case lubricant (real-time Mobil LT
4WD, ATS 4WD system), L 1.5
Transfer case lubricant (part-time ATF-DEXRON III

4WD), L 1.5
2-9
General
Fuel, Lubricant and Operating Fluid
Antifreeze specification Non-methanol product: ethylene glycol product

Use antifreeze certified by SAIC MAXUS only
Solution concentration 50% antifreeze, 50% water
Capacity 11.5 L
Sealant/Thread Locking Agent
Loctite 680 or 11264 Bowl plug
Loctite 510 Turbocharger oil return pipe transition connector
Molykote 111 O-ring (rear crankshaft bearing, rear bearing seat)
Polymer 400 Cylinder liner O-ring
Loctite 567 or Tonsan 1567F Coolant temperature sensor
Screw plug
Loctite 271 or Tonsan 1262 Engine support stud
Teflon grease Vacuum pump check valve
Oil pressure warning switch
Molycote P-1500 grease Fuel injector
Loctite 5900 Rear crankshaft bearing seat
Gear chamber casing
2-10
General
Service and Maintenance
S Items Regular maintenance Refill capacity Grade Recommended

N. brands
1 Engine oil 5,000km for first 5L ACEA 5W-30

maintenance and every
7,500km for subsequent
maintenances
2 Replace oil 5,000km for first

filter maintenance and every
7,500km for subsequent
maintenances (also
replace the oil filter cover
seal ring)
3 Replace air Replace every 20,000km

filter element
4 Replace fuel Replace every 40,000km

filter
5 Replace 6MT (SAGW): 10,000km 2.5L( ± 0.1L) GL4 75W-85 Fuchs MTF SAE
transmission for first maintenance and 75W-85, Castrol
fluid every 80,000km for BOT581, Shell
subsequent MTF GJ and SK
maintenances MTF 75W-85
201005
6 6MT (DYMOS): 2.5L GL4 75W-85 Fuchs MTF SAE

60,000km or 4 years for 75W-85, Castrol
first maintenance, BOT581, Shell
120,000km for MTF GJ and SK
subsequent maintenance MTF 75W-85
201005
7 6AT6AT- LDV countries: 10.2L petro-Canada DEXRON VI

Replace every
160,000km (replace oil
filter)
6AT- non-LDV countries:

Replace every
100,000km (replace oil
filter)
8 Replace Replace every 2 years or 11.5L JFL-3 (-35 ℃ )

engine every 60,000km
coolant
9 V-belt Replace every 3 years or

every 80,000km
10 Timing 80,000km/4 years

tensioner
pulley
11 Brake fluid 2 years/60,000km 0.66L DOT4
12 Transfer case Every 80,000km 1.5L Mobil LT

lubricant
2-11
General
S Items Regular maintenance Refill capacity Grade Recommended

N. brands
13 Front axle 3,000-5,000km for first 0.9L GL-5 80W-90 (Shanghai

lubricant maintenance and every 3 Tempo/Total)
years or 80,000km for
subsequent
maintenances
14 Rear axle 3,000-5,000km for first 1.74L GL-5 80W-90 (Shanghai

lubricant maintenance and every 3 Tempo/Total)
years or 80,000km for
subsequent
maintenances
2-12
Engine Mechanical System
Specification
Torque
Fastener Tightening Torque
Items Torque (N.m)
Bolt - automatic tensioner 35 ± 3N.m

Bolt - steering pump bracket 25 ± 3N.m
Bolt - mechanical vacuum pump 8-12N.m
Bolt - oil control valve 5-7N.m
Bolt - oil control valve cap 9-11N.m
Bolt - thermostat housing 8-12N.m
Nut - thermostat housing 9-11N.m
Coolant temperature sensor 15-17N.m
Bolt - thermostat housing 22-28N.m
Bolt - phase modulator 40N.m+120°

Bolt - oil-gas separator 9-11N.m
Cylinder head check
Bolt - piston cooling nozzle 25N.m
Bolt - signal wheel 14-16N.m
Bolt - crankshaft holder (special tool) 9-11N.m
Bolt - connecting rod 25N.m+90°

Bolt - rear crankshaft oil seal 9-11N.m
Bolt - flywheel 30N.m+60°

Bolt - auxiliary water pump bracket 9-11N.m
Bolt - camshaft cover to cylinder head 9-11N.m
Bolt - intake camshaft observation hole 5-7N.m
Nut - intake manifold 23-27N.m
Stud - intake manifold to cylinder head 9-11N.m
Bolt - intake manifold bracket 23-26N.m
Nut - exhaust manifold 25 ± 2N.m

Stud - exhaust manifold to cylinder head 13-17N.m
Stud - exhaust manifold to turbocharger 8-12N.m
Bolt - exhaust manifold heat shield 22-25N.m
Bolt - oil pump 23-27N.m
Bolt - oil pump sprocket 63-67N.m
Oil drain plug 20-25N.m
3-1
Bolt - oil suction pipe 9-11N.m
Bolt - oil pan 8-12N.m
Bolt - air compressor 23 ± 2N.m

Bolt - timing chain cover M12 80-90N.m
Bolt - idler pulley A 32-38N.m
Bolt - idler pulley C 45-55N.m
Bolt - timing chain cover to oil pan 9-11N.m
Bolt - water pump pulley 9-11N.m
Bolt - crankshaft pulley 85N.m+90°

Bolt - cylinder head to cylinder block 45N.m +90°+90°
Bolt - water pump inlet pipe 9-11N.m
Nut - turbocharger to exhaust manifold 28-32N.m
Bolt - Turbocharger heat shield 22-25N.m
Stud - turbocharger to exhaust manifold 15 ± 2N.m

Nut - turbocharger water outlet pipe 35-40N.m
Hallow bolt - turbocharger coolant inlet pipe 35-40N.m
Bolt - turbocharger coolant inlet pipe clamp 9-11N.m
Bolt - turbocharger oil return pipe to turbocharger 9-11N.m
Bolt - turbocharger oil return pipe clamp 7-10N.m
Bolt - turbocharger oil inlet pipe to turbocharger oil return pipe 7-10N.m
clamp
Hallow bolt - turbocharger oil inlet pipe 18-22N.m
Bolt - turbocharger oil inlet pipe 18-22N.m
Bolt - oil filter module 22-28N.m
Bolt - oil pump chain tensioner 23-27N.m
Bolt - timing chain guide rail 23-27N.m
Bolt - timing chain upper guide rail 9-11N.m
Bolt - timing chain tensioner 9-11N.m
Bolt - bearing ladder to bearing 35N.m +90°+45°

Bolt - bearing ladder to cylinder block 23-27N.m
Nut -front engine mount to front engine mount bracket 110 ± 10N.m
Bolt -front engine mount bracket to engine 60 ± 5N.m
Bolt -front engine mount to subframe 60 ± 5N.m
Bolt - engine lower guard plate (M8) 16 ± 2N.m
3-2
Bolt - engine lower guard plate (M10) 70 ± 10N.m
3-3
Model 20L4E gasoline engine, with 16 valves, dual overhead

camshaft, variable cam timing
Cylinder arrangement 4-cylinder, longitudinally set, in-line
Cylinder bore diameter 88 mm
Stroke 82 mm
Displacement 1995 ml
Ignition sequence 1-3-4-2
Compression ratio 10:1
Direction of rotation Clockwise, viewed from engine front end
Rated power 165KW / 5300rpm
Max. torque 360N.m / 2500~3500rpm
Idle speed 750 ± 50 rpm

Max. engine speed 6500 rpm
Weight (excluding engine oil, A/C, clutch assembly) 144kg (2.0T 6MT)/129.8kg (2.0T 6AT)
Crankshaft
Crankshaft axial clearance 0.094-0.277mm
Cylinder block/bearing ladder grade dimension

Grade A 56.000 / 56.006mm
Grade B 56.006 / 56.012mm
Grade C 56.012 / 56.019mm
Main journal tolerance 52 0/-0.019

Grade 0 Group 1 51.988 under - 51.981 min
Grade 1 Group 2 51.994 under - 51.988 min
Crankshaft connecting rod journal diameter Group 3 52.000 max - 51.994 min
Roundness 0.004
Main bearing shell
Quantity of main bearing shell 5 pieces on top and bottom respectively
Model The upper shell of the main bearing shell is provided with oil
hole and oil passage
Thrust washer Semi-washers are fitted on the left and right thrust washers of
the 4th main bearing seat, which fit the thrust surface.
Thrust washer thickness 2.413-2.463mm
Cylinder block and piston
Cylinder block material Aluminum alloy

Cylinder liner type Precast cylinder liner
Cylinder liner diameter 88-88.01mm
Connecting rod
Model of connecting rod Fractured connecting rod, C70S6
Distance between central connecting rods 150.5
3-4

Type of piston pin Full floating type
Mounted connecting rod Clearance
Piston pin length 57mm (-0.3-0)
Connecting rod bearing shell
Clearance 0.023-0.073mm
Piston
Model Aluminum alloy piston
Piston diameter 87.965mm
Tolerance in piston pin bore Φ 23 (+0.005, +0.013)

Max. ovality 0.5 +/-0.03
0.7 +/-0.03
Piston ring
Model 2 compression rings, 1 oil ring
Top compression ring Steel strip ring, ring height: 1.2 ( – 0.03, – 0.01)
Secondary compression ring Cast iron ring, ring height: 1.2 ( – 0.03, – 0.01)
Oil ring Two-piece oil ring, ring height: 2.0 ( – 0.03, – 0.01)
Tolerance between piston ring and ring groove:
Top compression ring 0.04~0.08
Secondary compression ring 0.03~0.07
Oil ring 0.02~0.06
Piston ring assembly gap in bore (from which it measured): Measured by standard ring gauge ( Φ 88)
Top compression ring 0.20~0.35
Secondary compression ring 0.40~0.60
Oil ring 0.20~0.40
Width of piston ring:

Top compression ring 3.1 ± 0.10
Secondary compression ring 3.6 ± 0.10
Oil ring 2.75 ± 0.15
Cylinder head
Material Aluminum alloy
25*25 local flatness 0.0075mm
Cylinder head height: 137 ± 0.05mm

Flatness 0.08mm
Camshaft
Model Dual overhead assembled camshaft
Bearing 6th gear bearing
Drive Timing chain drive
Camshaft axial clearance 0.07-0.22mm
3-5

Bearing clearance 1st gear bearing clearance 0.02-0.065mm, 2-6th gear

bearing clearance 0.02-0.061mm
Hydraulic tappets
Model Hydraulic tappet, directly driven by camshaft
Hydraulic tappet outer diameter Φ 11.994 ± 0.006mm

Valve timing Timing information for initial assembly is as follows:
Intake valve:
ON 20°CA ATDC
OFF 80°CA ABDC
Max. lift 40°CA BBDC
Exhaust valve:
ON 64°CA BBDC
OFF 4°CA BTDC
Max. lift 56°CA ABDC
Valve stem diameter:
Intake valve 5.475+/_0.0075mm
Exhaust valve 5.455+/_0.0075mm
Gap between valve stem and valve guide:

Intake valve 0.012mm
Exhaust valve 0.032mm
Valve stem fit height:

New intake valve 112+/_0.1mm
New exhaust valve 114.79+/_0.1mm
Valve head diameter:

Intake valve 34.2+/_0.1mm
Exhaust valve 28.3+/_0.1mm
Valve - valve seat ring width:

Intake valve 1.65 ± 0.15mm
Exhaust valve 1.75 ± 0.15mm
Intake valve length 112 ± 0.1mm
Exhaust valve length 113.79 ± 0.1mm
Valve stem diameter (intake valve) Φ 5.475 ± 0.0075mm
Valve stem diameter (exhaust valve) Φ 5.455 ± 0.0075mm
Valve surface angle - intake valve and exhaust valve 45°15′± 15′
Valve spring:
Free length 52.3 mm
Mounting length 40.2 mm
Assembly load 250N
Intake valve open load 250N
Exhaust valve open load 250N
Lubrication
Oil pump model External gear pump
3-6

Free length of pressure relief valve spring 45 mm
Oil filter Full flow oil filter
Spark plug
Supplier: NGK
Clearance: 0.7-0.8mm
Ignition coil manufacturer UAES
Primary resistance 0.453 Ω ± 12%

Secondary resistance 9.64K Ω ± 12%
3-7
Service and Maintenance
Items Maintenance Requirements
Replace engine oil 5,000km for first maintenance and every 7,500km for subsequent maintenances
Replace oil filter 5,000km for first maintenance and every 7,500km for subsequent maintenances (also
replace the oil filter cover seal ring)
Replace air filter element Replace every 20,000km
Replace fuel filter Replace every 40,000km
V-belt Maintenance Replace every 3 years or every 80,000km
Replace engine coolant Replace every 2 years or every 60,000km
Replace transmission fluid (6MT- 10,000km for first maintenance and every 80 000km for subsequent maintenances
SAGW)
Replace transmission fluid (6MT- 60,000km or 4 years for first maintenance and 120,000km for subsequent
DYMOS) maintenances
Replace transmission fluid (6AT - Replace every 100 000km (replace oil filter)
non-LDV countries)
Replace transmission fluid (6AT - Replace every 160 000km (replace oil filter)
LDV countries)
Replace brake fluid
Rear axle lubricant
Spark plug Replace every 20,000km
3-8
Layout
Engine Assembly
GS030009
1 Engine assembly
3-9
Cylinder Head and Intake and Exhaust System
16
3
14 13
15
6 5
4 9
1
25 10 11
26
2
22
24 21
23 20
19 8
7
18 17
12
GS030010
1 Cylinder head assembly 15 Oil control valve seat gasket

2 Cylinder head liner 16 Oil control valve
3 Intake manifold 17 Exhaust valve
4 Intake manifold liner 18 Intake valve
5 Intake manifold liner 19 Valve stem oil seal
6 Throttle liner 20 Valve spring
7 Exhaust manifold 21 Valve spring cap
8 Exhaust manifold liner 22 Valve lock clamp
9 Turbocharger 23 Engine rocker arm
10 Turbocharger liner 24 Valve tappet
11 Turbocharger oil inlet pipe 25 Intake camshaft
12 Turbocharger oil return pipe 26 Exhaust camshaft
13 Oil separator
14 Oil control valve seat
3-10
Engine Block and Cylinder Power
3
5
5
23 26
24
6
4 2
25
27
22
13 15
10
11 28
12
14
9 7
20
8
9 19 21
1817
16
GS030011
1 Cylinder block assembly 9 Connecting rod bearing shell

2 Crankshaft 10 Piston
3 Crankshaft main bearing shell (upper) 11 Piston pin
4 Crankshaft main bearing shell (lower) 12 Piston pin retaining ring
5 Crankshaft thrust plate 13 Piston ring
6 Crankshaft signal wheel 14 Piston cooling nozzle
7 Connecting rod 15 Dipstick
8 Connecting rod bolt 16 Oil pan
3-11
17 Oil pan drain plug gasket 23 Oil filter cover

18 Oil pan drain plug 24 Oil filter element
19 Oil pump 25 Oil filter cover seal ring
20 Oil pump connector 26 Input shaft supporting bearing (if equipped)
21 Oil pump suction pipe 27 Rear crankshaft oil seal
22 Oil filter seal ring 28 Bearing ladder
3-12
Timing System
10
8
4
11
6
12
9
12
14
7
5
13
15
2
3
1
GS030012
1 Crankshaft torsional vibration shock absorber 14 Oil pump chain

2 Front crankshaft oil seal 15 Oil pump chain tensioner
3 Timing chain cover
4 Oil filler cap
5 Timing chain tensioner
6 Timing chain guide rail
8 Intake modulator
9 Exhaust modulator
11 Timing chain
12 Crankshaft sprocket
13 Oil pump sprocket
3-13
Diagnostic Information and Procedures
Failure Possible Causes Measures
Hard Engine Start or Start Failure Starting circuit loose or corroded Clean and tighten circuit connectors
Starter motor and electric appliance Check/replace defective parts

system failure
Intake system blocked Check whether the intake system

pipeline is unobstructed
Insufficient fuel in the fuel tank Fill the tank with appropriate amount of
fuel
Air mixed in the fuel system Exhaust the air
Incorrect specification of fuel or engine Use the fuel or engine oil specified in
oil this manual. Fill a temporary fuel tank
with high-quality fuel and verify its
quality by driving
Sudden Engine Flameout Fuel contamination Replace the original fuel with clean and
qualified fuel
Air mixed in the fuel system Fuel system bleeds
High-pressure fuel pipe leaks Check leakage, and tighten/replace

relevant parts if necessary
Fuel pipeline or filter blocked Check the pipeline and filter element,
replace the fuel filter if necessary
Incorrect injection or valve timing Check DTCs. Check the timing system
and retime when necessary
Fuel delivery pump fails Repair or replace the fuel delivery

pump
3-14
Engine Underpower Vehicle overloaded Reduce vehicle load to the allowable

range
Fuel supply system blocked Check the fuel supply resistance. Clean
the coarse filter and screen and replace
the fuel filter if necessary
High-pressure fuel pipe or joint leaks Check leakage. Tighten/replace the

joint or high-pressure fuel pipe if
necessary
Air mixed in the fuel system Fuel system bleeds and check the fuel
inlet pipe for leakage
Intake or exhaust system blocked Check the resistance for intake or

exhaust system and the air filter.
Replace if necessary
Incorrect injection or valve timing Check DTCs
Turbocharger damaged Check the boost pressure. Replace the

turbocharger if the pressure is low
Injection hole of fuel injector blocked, Check, clean or replace the fuel injector
leading to a poor atomizing effect
Excessively high ambient temperature In high-altitude areas or at excessively

or operating in high-altitude areas high ambient temperature, the engine
power will decrease. Reduce load
properly during use
Check whether the engine MIL goes on Check DTCs
High oil level Check the engine oil level, and adjust it
to specified range
High Fuel Consumption Fuel leaks Check the pipeline sealing of fuel
system. Tighten the pipeline if it is
loose.
Poor fuel quality Use recommended fuel
Resistance for the intake system Check the filter element of air filter, and
increases replace if necessary
Check whether the MIL goes on Check DTCs
Engine Overheating Coolant insufficient Check coolant for leakage. Add coolant
to fully exhaust the air
Engine overload Reduce engine load for operation
Water pump failure Overhaul the water pump
Air or gas mixed in the cooling system Check the coolant pipeline for leakage
and looseness
Water temperature sensor or Check the sensor and thermometer

thermometer damaged
Thermostat failure Replace the thermostat
3-15
High Oil Pressure Pressure gauge failing to work Check the function of pressure gauge
High engine oil viscosity due to Check the oil and replace with qualified
incorrect specification oil if necessary
Bypass valve stuck near OFF position Check/replace the bypass valve
Low Oil Pressure Low oil level Adjust the oil level
Low engine oil viscosity due to incorrect Check the oil and replace with qualified
specification oil if necessary
Engine oil pipeline joint loose or oil duct Check engine oil for leakage
bulkhead coming off
Oil diluted by water Find out the reason for dilution, and
replace the oil
Oil pressure regulating valve failure Check/replace the pressure regulating

valve
Oil pressure gauge failure Check the oil pressure gauge
Engine shaft and bearing shell parts Replace the worn shaft or bearing shell
worn
Exhaust Pipe Smokes Engine overload Use low deceleration gear
Air mixed in the fuel system Exhaust the air and check the oil
suction part for leakage
Intake system blocked Check the intake system for blockage
Turbocharger failure Replace the turbocharger
Fuel injector failure Check DTCs/replace parts
Check whether the engine MIL goes on Check DTCs
Low Engine Coolant Temperature Radiator shutter stuck at the maximum Check the shutter, and replace if
opening necessary
Temperature sensor failure Check/verify the sensor
Thermometer failure Verify the thermometer, and replace if

necessary
Thermostat damaged Replace the thermostat
Loud Engine Noise The drive belt makes noise Check the drive belt system
Intake and exhaust leakage Check/repair the leakage
The turbocharger makes noise Check whether there is friction between

the impeller and housing
Engine oil low level Check/refill oil
Drive gear makes noise Check/replace defective parts
3-16
Severe Engine Vibration Engine frame loose or damaged Check/replace the engine frame
Fan damaged or accessory failure Check/replace defective parts
Crankshaft torsional vibration absorber Check/replace defective parts

failure
Drive system components worn and Check/replace the components

unbalanced according to the specification given by
the manufacturer
Moving parts loose or damaged Check/replace defective parts
Alternator Does Not Work or Battery connector loose or corroded Clean/tighten the battery connector
Undercharges
Engine belt slips Check/replace the belt and tension
pulley
Instrument or indicator lamp failure Check/replace the instrument or

indicator lamp
Engine wire loose or damaged Repair the wire
Alternator failure Replace the alternator
Engine Running Unsteadily at Idle Air mixed in the fuel system Exhaust the air from the fuel system,
Speed, Hunting and check the oil suction part for
leakage
Oil Contamination Engine oil is mixed with coolant due to Check/replace defective parts
engine internal parts leakage
Too much oil deposits Check the replacement interval of

engine oil and its filter
Engine oil is mixed with fuel, and Check whether long idle running time of
engine runs in the undercooling engine causes engine running below
condition normal temperature
Fuel System Leakage Air mixed in the fuel system Bleed the fuel system, and check the
fuel suction pipe for leakage
Engine Knock Poor fuel quality Fill a temporary fuel tank with high-
quality fuel and verify its quality by
driving
Engine overload Prove whether the engine exceeds the

designed load with a low gear
Incorrect timing Check/adjust the timing
Fuel injector failure Remove the fuel injector. Check and

repair it
Fuel or Engine Oil Leaks from Exhaust Intake pipe blocked Check/replace the component of air
Pipe filter element
Fuel injector needle valve stuck Find out and replace the failed fuel
injector
Turbocharger oil return pipe blocked Check/dredge the oil pipeline
Turbocharger seal ring leaks oil Check/replace the turbocharger
Engine keeps running at idle speed for Change the operating habit
a long time
3-17
Crankcase Leaks Too Much Air Breather pipe of crankcase ventilation Check whether the ventilation device
device blocked and breather pipe are blocked
Turbocharger seal leaks air Check the turbocharger sealing device
Valve guide of cylinder head Check/replace defective parts

excessively worn
Piston ring damaged or worn Check the piston ring and cylinder liner
Vacuum connecting pipe leaks Check the vacuum connecting pipe for
leakage, exclude leakage sources
Vacuum Regulator Failure Loud noise Check/replace defective parts
No pressure Check/replace the vacuum pipeline
Failing to operate Check whether it is powered on. Check/

replace defective parts if necessary
Diagnosis of Excessive Belt Wear The belt squeaks Belt slips or worn or stretched. Check/
replace the belt and tension pulley
Squeal or harsh noise Check the belt surface for foreign

objects
Continuous hiss or rattle Check the tension pulley and accessory

for failure
3-18
V-belt Replacement
Repair Guidance
Removal
Engine Hood Replacement 1 Release the automatic tensioner and locate.
Removal
1 Remove the engine hood.
GS030015
2 Remove the V-belt.
GS030013 Installation
Installation
1 Install clockwise from the position indicated by the
1 Install 4 supporting legs of engine hood assembly arrow.
to the engine assembly. Apply sealant on 3 ball
studs (5-6 gears). Sealant brand: Loctite 545 Caution: The belt must be seized in the correct
sealant. Tightening torque: 10 ± 1N.m. pulley groove. Otherwise it may be cut off by the
pulley while running.
GS030014
3-19
Automatic Tensioner Replacement Replacement of Steering Pump Bracket

Removal Removal
1 Remove 2 bolts from the automatic tensioner.
GS030018
GS030016 1 Remove the power steering pump.
2 Remove the automatic tensioner. 2 Remove 3 fastening bolts from the power steering
pump bracket.
3 Remove the steering pump bracket.
Installation
1 Installation is the reverse of removal.
Installation
2 Tightening torque of steering pump bracket bolt:
25 ± 3N.m.
GS030017
2 Tightening torque of automatic tensioner bolt: 35±
3N.m.
3 After installing V-belt, pull out the self-carrying
limiting pin of automatic tensioner.
3-20
Replacement of Mechanical Vacuum Pump (if Replacement of Oil Control Valve

equipped) Removal:
Removal:
1 Remove the engine hood (refer to Replacement of
1 Remove the engine hood (refer to Replacement of Engine Hood).
Engine Hood). 2 Disconnect the oil control valve connector.
2 Disconnect the vacuum pipe from the vacuum
pump.
3 Remove 3 bolts mounting the vacuum pump to the
cylinder head, remove the mechanical vacuum
pump, and discard the sealing gasket.
GS030020
3 Remove 1 bolt securing the oil control valve to the

housing and remove the oil control valve.
GS030019
Installation:
1 Install a new sealing gasket, and apply a small
amount of engine oil.
2 Adjust the connector of the mechanical vacuum
pump to a horizontal position, insert it into the
camshaft groove, install 3 bolts, tighten them to
16-18N.m, and check the torque.
3 Install the vacuum pump pipeline.
4 Install the engine hood (refer to Replacement of
Engine Hood). GS030021
Installation:
1 Secure the oil control valve to the housing, install 1
bolt respectively, tighten to 5-7N.m, and check the
torque.
2 Connect the oil control valve connector.
Engine Hood).
3-21
Replacement of CVVT Cover Replacement of Thermostat Housing

Removal: Removal:
1 Remove the oil control valve (refer to 1 Disconnect harness connector 1 of the coolant
Replacement of Oil Control Valve). temperature sensor.
2 Remove 9 bolts securing the oil control valve 2 Drain the engine coolant.
cover to the camshaft cover and remove the oil 3 Remove the coolant temperature sensor (refer to
control valve cover. Replacement of Engine Coolant Temperature
Sensor).
4 Release all clamps to disconnect the coolant pipe.
5 Remove 2 bolts and 2 nuts securing the
thermostat housing to the engine block, remove
the thermostat housing and discard the sealing
gasket.
GS030022
Installation:
1 Clean the junction between the oil control valve
cover and the camshaft cover.
2 Install the gasket and ensure it is aligned with all
holes. GS030001
3 Secure the oil control valve cover to the camshaft
cover, install 9 bolts, tighten to 9-11N.m, and Installation:
check the torque. 1 If the studs in the cylinder block are damaged,
4 Install the oil control valve (refer to Replacement install 2 new studs to the cylinder block with the
of Oil Control Valve). short thread end into cylinder block, tighten the
torque to 3-5N.m and check the torque.
2 Install a new gasket, secure the thermostat
housing to the engine block, install and pre-tighten
2 nuts.
3 Install 2 bolts securing the thermostat housing to
cylinder block, tighten 2 bolts and 2 nuts to 9-
11N.m from left to right and from top to bottom,
and check the torque.
4 Install the thermostat (refer to Thermostat
Replacement).
5 Install the coolant temperature sensor (refer to
Replacement of Coolant Temperature Sensor).
6 Connect the coolant temperature sensor
connector.
7 Refill the coolant.
3-22
Replacement of Intake and Exhaust Phase 2 Install the intake phase modulator to the front end
Modulator of intake camshaft, and pre-tighten the phase
Removal: modulator bolts.
1 Drain the engine oil (refer to Replacement of
Engine Oil and Oil Filter).
2 Remove the timing chain cover (refer to
Replacement of Timing Chain Cover).
3 Remove the timing chain (refer to Replacement of
Engine Timing Chain).
4 Remove the phase modulator bolts, identify the air
intake and exhaust phase modulators and then
remove.
Installation:
1 Install the camshaft timing tooling kit C00044505,
locate the rear end tool to ensure the TOP in the GS030025
front of camshaft faces up, then install the front
tools and tighten with proper bolts. 3 Install the exhaust phase modulator to the front
end of exhaust camshaft, and pre-tighten the
phase modulator bolts.
C00044505
GS030023
GS030026
4 Install the timing chain (refer to Replacement of

5 Tighten the phase modulator bolts to 40N.m+120
°and check the torque.
6 Install the timing chain cover (refer to
7 Install the crankshaft pulley, check whether the
notch of it is aligned with the timing mark on the
timing chain cover; if not, reinstall the timing chain.
8 Refill the engine oil (refer to Replacement of
GS030024 Engine Oil and Oil Filter).
3-23
Replacement of Oil-Gas Separator Cylinder Head Check (after removing cylinder

Removal: head)
Removal:
2 Release the clamp, and disconnect 3 breather 1 Remove 5 nuts securing the intake manifold to the
pipes from the oil-gas separator. cylinder head, and then remove the intake
manifold.
3 Remove 8 bolts fixing the oil-gas separator to the
camshaft cover to release the oil-gas separator.
3 4
2 5 1
GS030029
GS030027 2 Remove 4 bolts securing the exhaust manifold

heat shield to the exhaust manifold to take down
Installation:
the heat shield.
1 Clean the mounting junction of the oil-gas
separator.
2 Connect the breather pipe on the oil-gas separator
and secure with clamps.
3 Secure the oil-gas separator to the camshaft
cover, install 8 bolts, tighten to 9-11N.m, and
check the torque.
2 3 7
6
GS030030
5 8 3 Remove and discard 8 nuts securing the exhaust

1 manifold to the engine, remove the exhaust
4
manifold and discard the gaskets.
GS030028
3-24
2 8 6 4
5 3 7 1
GS030031 GS030033
4 Remove 2 bolts securing the auxiliary water pump 10 If the end float exceeds 0.07-0.22mm, replace with
bracket to the cylinder head, and remove the a new camshaft and check it again. If the end float
auxiliary water pump and bracket. still exceeds the tolerance, replace the cylinder
5 Clear the dirt in the spark plug gap, and remove head and camshaft cover assembly.
the spark plug from the cylinder head. 11 Remove 39 bolts (35 and 27 are studs) securing
6 According to the camshaft thrust surface, put the the camshaft cover to the cylinder head in the
camshaft into the camshaft bearing seat on the sequence as shown, and remove the camshaft
cylinder head. cover.
7 Apply engine oil to the camshaft journal evenly.

8 Secure the camshaft cover to the cylinder head, 39 37
12 4 5 36 13 35
install 39 bolts (35 and 27 are studs), tighten them 20 38
to 9-11N.m in the sequence as shown, and check
the torque. 19 11 3 6 14 31
34 33 32
18 10 30 2 29 7 28 15 27
39 37 26
12 4 5 36 13 35 9 1 8 16 21
20 38 17 25 24 23 22
19 11 3 6 14 31 GS030034
34 33 32
12 Identify the position of each camshaft carefully,
18 10 30 2 29 7 28 15 27 and remove the camshaft from the camshaft seat.
26
9 1 8 16 21
17 25 24 23 22
GS030032
9 Check the end float of the camshaft with a dial

gauge (refer to "Specifications").
GS030035
3-25
13 With a viscous magnet, remove 16 roller rocker 21 Measure the matching clearance between each
arms and hydraulic tappet from the cylinder head, journal and the cylinder head.
and keep them in the mounting sequence.
mm
0.25
0.38
0.51
0.16
GS030038
GS030036
22 If the clearance exceeds the tolerance 0.04-
14 Measure the outer diameter of each tappet. The 0.075mm, install new camshafts and repeat the
measurement shall be carried out at the half of the check. If the clearance still exceeds the tolerance,
tappet's length. replace with new cylinder head and camshaft
cover assembly.
a. Tappet's outer diameter = 11.994 ± 0.006mm.
23 Remove the valve (refer to Replacement of Valve).
15 Ensure that the oil holes in each tappet are clean.
24 Clean the mating face of the cylinder head. Check
16 Clean the surfaces of the camshafts and cylinder the cylinder head for damage. Pay special
head bearing. attention to the gasket surface of the cylinder
17 Inspect the camshaft and replace if it is scratched, head.
pitted or excessively worn. 25 Check the surface of the cylinder head for scratch.
18 Secure the camshafts to the cylinder head, and 26 And check the flatness of cylinder head with the
place a plastic gauge on each journal. method as shown, do the operation in a cross way.
19 Then install the camshaft cover and 39 bolts (35 If the flatness is not within the specified value
and 27 are studs), tighten them to 9-11N.m in the (0.08mm), replace the cylinder head.
sequence as shown, but do not rotate the
camshaft.
39 37
12 4 5 36 13 35
20 38
19 11 3 6 14 31
34 33 32
18 10 30 2 29 7 28 15 27
26
9 1 8 16 21
17 25 24 23 22
GS030037
20 Loosen the bolts slowly and remove the camshaft

cover.
3-26
7 1 3 5
7 3 35
62 42 2
6 4 2 8
GS030039
GS030040
27 Check the height of the cylinder head, if it is out of
the specified range (137 ± 0.05mm), replace the 6 Secure the exhaust manifold heat shield to the
cylinder head.
exhaust manifold, install 4 bolts, tighten them to
28 Remove the carbon buildup from the valve duct, 22~25N.m, and check the torque.
valve, valve seat and combustion surface.
7 Install the hydraulic tappet into the corresponding
Remove all loose particles of the carbon buildup.
mounting bore on the cylinder head, and lubricate
it with clean engine oil.
Installation:
1 Clean the sealing area of the cylinder head and
camshaft bracket. Treat the sealing surface with
foam remover and plastic scraper, but never use
any metal scraper. Clean the mating surface of the
intake/exhaust manifolds.
2 Blow the oil passage and coolant passage dry.
Ensure clean oil will be supplied to the camshaft
cover.
Note: Use the clean solvent recommended by SAIC
to remove the residual sealant.
3 Install the valves. (refer to Replacement of GS030041
Valves).
8 Ensure the roller rocker arm holder is secure, align
4 Secure the auxiliary water pump bracket to the
the ball groove of the roller rocker arm with the
cylinder head, install 2 bolts, tighten them to
plunger ball head of the hydraulic tappet, and
9~11N.m, and check the torque. Clean the
gently press the ball head into the ball groove.
junction surface of the components.
5 Install new gaskets to the exhaust manifold,
secure the exhaust manifold on the engine, install
8 gaskets and new nuts with high temperature
antiwelding agent, tighten them to 25±2N.m in the
sequence as shown and check the torque.
3-27
Crankshaft Check (after removing the engine)

Removal:
1 Remove the ladder (refer to Replacement of
Engine Ladder).
2 Remove the connecting rod bearing shell (refer to
Connecting Rod Bearing Shell Check).
3 Remove the crankshaft.
4 Remove the upper main bearing and thrust
washer from the cylinder block.
GS030042
9 Adjust the clearance of each spark plug to 0.9 ±

0.1mm.
10 Install the spark plug and tighten to 19-21N.m.
GS030043
5 Remove 3 bolts securing the signal gear to the

crankshaft, and remove the signal gear.
GS030044
3-28
6 Remove 4 bolts securing 4 piston cooling nozzles 8 Check the corresponding grade identification on
to the cylinder block. the cylinder block and ladder.
GS030047
GS030045 9 Select the correct main bearing according to the

group number of the cylinder block/ladder and
Installation crankshaft, see the chart below. The colors on the
edge of bearing shells which indicate the thickness
1 Clean the crankshaft, cylinder block, signal gear, of bearing shells are as follows:
ladder and mating face of the main bearing, and
ensure there is no foreign material. a. Blue = Thick
2 Clean the oil duct, water channel and ensure there b. Yellow = Medium
is no foreign material.
3 Secure 4 piston cooling nozzles to the cylinder c. Red = Thin
block and locate, install 4 bolts, tighten them to 20
± 2N.m (never allow the torque to exceed 25N.m)
4 Check the crankshaft and signal gear for damage.
5 Secure the signal gear to the crankshaft, align it
with the locating pin, install 3 bolts, tighten to 10-
12N.m and check the torque.
6 Check the grade identification of the crankshaft
main journal from the crankshaft.
GS030046
7 Check the diameter of the main journal.
3-29
MAIN BEARING SHELL SELECTION CHART

.
CRANKSHAFT MAIN JOURNAL 1 2 3

GRADE / SIZES
51.981 - 51.988 51.988 - 51.994 51.994 - 52.000
BEARING SHELLS TO Upper Lower Upper Lower Upper Shell Lower Shell
BE INSTALLED Shell Shell Shell Shell
BLOCK / A 56.000 / RED BLUE RED YELLOW RED RED

LADDER 56.006
GRADE /
SIZE CLEARANCES 0.028 - 0.054 0.028 - 0.052 0.028 - 0.052
(CLEARANCE
B 56.006 / YELLOW BLUE YELLOW YELLOW YELLOW RED
S INCLUDING
56.012
BEARING
SWELL） CLEARANCES 0.028 - 0.053 0.028 - 0.052 0.028 - 0.052
C 56.012 / BLUE BLUE BLUE YELLOW BLUE RED

56.019
CLEARANCES 0.028 - 0.054 0.028 - 0.054 0.28 - 0.054
10 Press the upper main bearing into the bore of the 15 Measure the crankshaft end float. (Requirement:
cylinder block bearing seat. Align the bearing with 0.094 - 0.277mm).
the groove of the bearing seat bore, and ensure 16 Install the connecting rod bearing shell (refer to
the oil orifice is not covered. Connecting Rod Bearing Shell Check).
17 Remove the special tool secured at bearing 1 and
5 (crankshaft holder).
18 Install the lower bearing to the bore of the ladder
bearing seat.
19 Install the ladder (refer to Replacement of Engine
Ladder).
GS030048
11 Clean and install the new thrust washer to both

sides of the cylinder block main bearing 3. Make
the oil passage outward.
12 Apply oil to the crankshaft main journal and inner
surface of the upper main bearing shell, and put
the crankshaft assembly (installed with signal
gear) into the engine block.
13 Secure to bearing 1 and 5 with crankshaft holder
C00044504 and tighten to 9-11N.m.
14 Rotate the crankshaft to locate cylinder 1 and 4 at
the top dead center.
3-30
Connecting Rod Bearing Shell Check

Removal:
1 Remove the ladder (refer to Replacement of
Engine Ladder).
2 Secure to bearing 1 and 5 with crankshaft holder
C00044504 and tighten to 9-11N.m.
GS030050
3 Install the two halves of the connecting rod

bearing shell with the installation and centering
tool C00044511 to the connecting rod and the
corresponding big end shell cover.
GS030049
3 Rotate the crankshaft to allow each connecting rod

bolt to be easily removed.
4 Remove the connecting rod bolts and connecting
rod big end shell cap. Number it according to the
corresponding cylinder number.
5 Remove the half shell from the shell cap of the
connecting rod big end.
6 Disconnect the connecting rod from the
crankshaft, and remove the other half of the shell
from the connecting rod. GS030051
Installation:
4 Apply lubricating oil to the connecting rod bearing
1 Clean the crankshaft journal, connecting rod, shell surface.
connecting rod big end shell cap and bearing 5 Position the connecting rod to crankshaft.
shell, and ensure there is no foreign material.
6 The raised letter "ZY" and "A/B/C..." on the shell
2 To replace the connecting rod with a new one, cover shall face the front of the engine and be
select correct piston connecting rod assembly installed to the connecting rod.
through reading the quality group no. on the
connecting rod. Caution: The cylinder protrusion on the connecting
rod and the arrow on the piston shall both face the
front of the engine.
The number identifications of all connecting rods shall be
on the same side.
3-31
Caution:
GS030052 GS030054
11 Install the ladder (refer to Replacement of Engine

Ladder).
GS030053
7 Install and tighten the connecting rod bolts to

25N.m+90° and check the torque.
8 Tighten the connecting rod bolts in sequence as
follows: 1. For the same connecting rod, tighten 2
bolts at the same time; 2. For different connecting
rods, tighten #2 and #3 first and then #1 and #4.
Piston position: The piston is at the lower dead
center.
9 Rotate the crankshaft and ensure free rotation of
the crankshaft connecting rod.
10 Remove the crankshaft holder C00044504
secured at bearing 1 and 5.
3-32
Piston Check
Removal:
1 Remove the cylinder head (refer to Replacement
of Cylinder Head).
2 Remove the connecting rod bearing shell (refer to
Connecting Rod Bearing Shell Check).
3 Push the piston to the top of the cylinder bore.
Caution: Remove the carbon deposit on the top of
cylinder bore first to avoid scratching the piston
ring and piston.
4 The connecting rod shall not contact the inner wall
GS030056
of cylinder bore. Push the piston assembly out of
cylinder bore carefully.
8 Measure inner diameter of the connecting rod
Caution: Carefully align each piston and small end, if it exceeds the specified specification
appropriate cylinder liner. Φ 23 (+0.014, +0.021), replace it.
5 Install the connecting rod big end cap into the 9 Measure the size of piston pin, if it exceeds the
connecting rod, and lightly tighten the connecting specified specification Φ 23 (0.005-0), replace it.
rod bolt. 10 Measure the size of piston pin hole, if it exceeds
6 Remove and discard the used piston ring with an the specified specification Φ 23 (+0.008, +0.013),
expander (tool). replace it.
11 Measure inner diameter of the cylinder bore, if it
exceeds the specified specification Φ 88-
88.01mm, replace the cylinder block ladder
assembly.
Installation:
1 Check the pistons for deformation and crack.
2 Clean the piston ring groove and purge the oil
passage.
3 Install the piston pin circlip on one side into the pin
hole circlip slot.
4 Place the connecting rod small end to the inner
side of the piston pin boss, after applying
GS030055
lubricating oil, install the piston pin into the piston
pin hole and connecting rod small end hole, and
7 Remove the circlips from both ends of piston pin,
install the piston pin circlip on the other side into
and push the piston pin out from the pin hole and
the pin hole circlip slot.
connecting rod small end hole.
Caution: The arrow on the connecting rod is on the
same side with that on the piston.
5 Measure the outer circle diameter of piston at right
angles to piston pin and at 10mm from the bottom
of ladder. It shall not exceed 87.965+/-0.009mm.
3-33
B
C
GS030057 GS030059
6 Make the "TOP" or identification mark face the top 9 Install the piston ring clamping tool C00017024 to
surface of piston. Install the piston ring with an the piston. Make the front mark on the piston
expander in the order: oil ring, secondary faces the front of the engine, and install the piston
compression ring and top compression ring. into the cylinder liner.
7 Ensure piston rings are free to rotate, the gap A
and B of the two air rings shall form an angle of
120° and be away from the piston thrust side.
13I RING
120°
GAP
6AP
120° 2nd RING
GS030060
3rd RIHG
Caution: Make sure the opening position of piston

GAP
GS030058 ring is the same as shown in the figure, and the

arrow on the piston top points to the engine front
8 Check the clearance between new piston ring and end.
ring groove by referring to the parameters.
10 Push the piston into the cylinder liner until it is
Replace and reinstall the piston if it does not meet aligned with the upper surface of the cylinder liner,
the specification. take away the piston ring clamping tool
C00017024.
3-34
Replacement of Rear Crankshaft Oil Seal

Removal:
1 Remove the transmission (refer to Transmission
Replacement).
2 Remove the flywheel or torque converter drive
C00017024 plate.
3 Remove 6 bolts securing the rear crankshaft oil
seal onto the engine, then remove and discard the
rear crankshaft oil seal.
Installation:
1 Clean the working surface of the cylinder block
GS030061 and crankshaft. Keep these surfaces clean, dry,
and free from sealant.
Caution: Before installing the connecting rod big
end bearing shell and connecting rod big end cap, Note: Use the clean solvent recommended by SAIC
do not push the piston below the upper surface of to remove the residual sealant.
the cylinder liner. 2 Apply engine oil on the new oil seal lip for
lubrication purpose.
11 Check the close clearance of the piston ring by
referring to the parameters. Replace and reinstall 3 Apply sealant to the bracket of rear crankshaft oil
the piston and piston ring if it does not meet the seal.
specification.
GS030063
GS030062
4 Install the rear oil seal cover to the rear end of
12 Install the connecting rod bearing shell (refer to crankshaft with installer C00044509, fit it closely
Connecting Rod Bearing Shell Check). with the engine block, install 6 bolts, tighten to 9-
11N.m and check the torque.
13 Install the cylinder head (refer to Replacement of
Cylinder Head).
3-35
Replacement of Front Crankshaft Oil Seal

Removal:
C
E 1 Remove the V-belt (refer to Replacement of V-
belt).
2 Remove the crankshaft pulley (refer to
Replacement of Crankshaft Pulley).
A
B 3 Remove the front crankshaft oil seal with a slotted
screwdriver or equivalent.
F
D
GS030064
5 Install the flywheel or the torque converter drive

plate.
6 Install the transmission (refer to Transmission
Replacement).
GS030065
Installation:
1 Clean the crankshaft operating surface and the
chain cover oil seal groove to ensure there is no
foreign material.
2 Apply engine oil on the new oil seal lip for
lubrication purpose.
3 Install the front crankshaft oil seal to the
corresponding hole in the lower front cover (as
illustrated), and press the oil seal in place with
front crankshaft oil seal installer C00044510.
GS030066
3-36
Flywheel Replacement
Removal
1 Remove the transmission (refer to Transmission
Replacement).
2 Secure the flywheel lock pin C00044503 to the
flywheel to limit the flywheel.
GS030068
7 Install the clutch (refer to Clutch Replacement).

TEN00122 8 Install the transmission (refer to Transmission
Replacement).
GS030067
3 Remove the clutch (refer to Clutch Replacement).
GS030075
4 Unscrew the flywheel fastening bolts to remove

the flywheel.
Installation:
1 Clean the bolt hole on the crankshaft.
2 Clean the mating face of flywheel and crankshaft
and ensure there is no foreign material.
3 Install the flywheel to the crankshaft.
4 Install new bolts, but do not tighten them.
5 Install the flywheel lock pin C00044503.
6 Tighten the flywheel bolts to 30N.m in diagonal
sequence, then further tighten 60°.
Caution: Flywheel bolts can be used once.
3-37
Valves Replacement
Removal:
1 Remove the cylinder head.
2 With a viscous magnet, remove 16 roller rocker
arms and hydraulic tappet from the cylinder head,
and keep them in the mounting sequence.
GS030071
5 Remove 4 bolts securing the exhaust manifold

the heat shield.
GS030069
3 Remove 5 nuts securing the intake manifold to the

cylinder head, remove the intake manifold and
discard the gasket.
3 4
2 5 1
GS030072
6 Unscrew 2 bolts from the small heat shield at rear

end of exhaust manifold, and remove the heat
shield.
7 Remove 8 nuts securing the exhaust manifold to
the engine,and discard the nuts and washers;
GS030070
remove the exhaust manifold, take out and discard
4 Remove 3 bolts securing the EPAS idler support to the gaskets.
cylinder head, and remove the EPAS idler support. 8 Remove the studs from the cylinder head and
discard.
9 Unscrew 2 bolts securing the auxiliary water pump
bracket to the cylinder head, and remove the
auxiliary water pump and bracket.
10 Clear the dirt in the spark plug gap, and remove
the spark plug from the cylinder head.
3-38
GS030073 GS030077
11 Remove the lock clamp and release the valve

spring with compression valve spring.
GS030074
12 Remove the valve spring, valve spring cover and

valve.
GS030076
13 Remove all valves following steps 9-10, and

arrange the valve, spring, valve spring seat in
sequence.
14 Remove 16 valve oil seals with the caliper.
3-39
Installation: 8 Lubricate the valve and valve stem oil seal.

1 Remove the carbon deposit from the valve guide, 9 Install 16 new valve stem oil seals to the valve
valve, valve seat and combustion surface, and guide pipe.
remove all loose particles of the carbon deposit. 10 Install the valves. Install the spring and spring
2 Check the diameter of the existing valve stem. cap, and secure to the valve and compression
spring.
A B
GS030078
GS030079
3 Replace with new valves if necessary, if the valve
guides need to be replaced, replace with new 11 Install the locking clamps. Release the valve
cylinder head and camshaft cover assembly. spring.
4 Check the conditions of the valve seat and valve 12 Repeat steps 10-11, install the remaining valves.
before another use. 13 Secure the auxiliary water pump bracket to the
5 Measure the valve surface angle and valve seat cylinder head, install 2 bolts, tighten them to
and check if it meets the following standards: 9~11N.m, and check the torque. Clean the
junction surface of the components.
Valve seat:
14 Install the new stud securing cylinder head to
Angle = 45° cylinder manifold, and tighten the torque to 15 ±
2N.m.
Width A:
Intake -1.2mm secure the exhaust manifold on the engine, install
8 gaskets and new nuts, tighten them to 25±2N.m
Exhaust -1.6mm in the sequence as shown and check the torque.
Valve surface angle B:
Intake = 45°
7 1 3 5
Exhaust = 45°
7 3 35
6 Check the valve spring:

Free length = 50.0mm
62 42 2
Mounting length = 37.0mm
6 4 2 8
Load: valve closed = 250 ± 12.5N
Load: valve opened = 450 ± 18N GS030080

7 Make sure that the tappet, valve, valve spring,
spring cover and locking clamp are clean.
3-40
16 Secure the exhaust manifold heat shield to the Valve Tappet Replacement
exhaust manifold, install 4 bolts, tighten them to Removal:
22~28N.m, and check the torque.
1 Remove the camshaft (refer to Replacement of
17 Secure EPAS idler support to the cylinder head,
Camshaft (Intake or Exhaust)).
install 3 bolts, tighten to 23-27N.m and check the
torque. 2 Remove the roller rocker arm, and put it aside.
18 Clean the mating surface of the intake manifold
and the cylinder head and ensure there is no
foreign material.
19 Install new gaskets.
20 Secure the intake manifold to the cylinder head,
install 5 nuts, tighten them to 23~27N.m in the
sequence as shown, and check the torque.
3 4
2 5 1
GS030082
3 Remove the hydraulic tappet.
GS030081
21 Install the hydraulic tappet into the corresponding

mounting bore on the cylinder head, and lubricate
gently press the ball head into the ball groove. GS030083
23 Install the cylinder head (refer to Replacement of
Installation:
Cylinder Head).
24 Install the spark plug (refer to Replacement of 1 Install the hydraulic tappet into the corresponding
Spark Plug). mounting bore on the cylinder head, and lubricate
gently press the ball head into the ball groove.
3-41
3 Ensure the coaxiality of the roller rocker arm and Replacement of Camshaft (Intake or Exhaust)
the valve stem tip, and lubricate the rocker arm Removal:
roller with clean engine oil.
1 Remove the front engine cover (refer to
2 Remove the timing chain (refer to Replacement of
3 Remove the phase modulator (refer to
Replacement of Phase Modulator (Intake and
Exhaust)).
4 Remove the camshaft cover (refer to Replacement
of Camshaft Cover).
5 Identify the position of each camshaft carefully,
and remove the camshaft from the camshaft seat.
GS030084
4 Install the camshaft (refer to Replacement of
Camshaft (Intake or Exhaust)).
GS030085
Installation:
1 Rotate the crankshaft and allow the crankshaft to
be located at 90° CA before the acting TDC of
cylinder 1, and secure the crankshaft with flywheel
lock pin C00044503 (MT) and flywheel lock tool
C00044516 (AT).
2 Clean the camshaft.
3 Clean the mating face of the cylinder head and
camshaft cover.
4 Clean the bolt hole and pin of the camshaft cover.
5 Blow the oil gallery dry and lubricate the camshaft
bearing seat.
6 Put the camshaft into the camshaft bearing seat of
the cylinder head.
7 Apply engine oil to the camshaft journal evenly.
8 Apply sealant to the camshaft cover (as
illustrated).
3-42
C00044505
GS030086 GS030088
9 Secure the camshaft cover to the cylinder head,

install 39 bolts (35 and 27 are studs), tighten them
to 9-11N.m in the sequence as shown, and check
the torque.
39 37
12 4 5 36 13 35
20 38
19 11 3 6 14 31
34 33 32
18 10 30 2 29 7 28 15 27
GS030089
26
9 1 8 16 21 12 Remove the phase modulator bolts.
17 25 24 23 22
13 Install the intake/exhaust phase modulator (refer
GS030087 to Replacement of Phase Modulator (Intake and
Exhaust)).
10 Tighten the phase modulator bolts at front end of 14 Install the timing chain (refer to Replacement of
the camshaft. Engine Timing Chain).
11 Tighten the phase modulator bolts, rotate the 15 Install the front cover (refer to Replacement of
camshaft, then clamp the cam timing tool into the Timing Chain Cover).
rear end tail groove of intake/exhaust camshaft;
16 Check the camshaft timing.
make sure the TOP mark in the front of camshaft
faces up, then clamp the locating tool of camshaft 17 Remove all special tools.
front end and tighten with proper bolts. 18 Apply sealant to the observation hole cover of the
intake camshaft according to the method shown.
3-43
28 Secure the low-pressure fuel intake pipe to the

high-pressure fuel pump, slightly tighten it first,
then tighten to 20-22N.m and check the torque.
29 Install the full load vacuum pipe to the
turbocharger intake pipe.
30 Install the oil-gas separator. (refer to Replacement
of Oil-Gas Separator).
Engine Hood).
GS030090
19 Secure the observation hole cover of the intake

camshaft to the camshaft cover, install 3 bolts,
tighten them to 5-7N.m, and check the torque.
20 Install the turbocharger control solenoid valve.
21 Install the mechanical vacuum pump (AT) (refer to
Replacement of Mechanical Vacuum Pump).
22 If the mechanical vacuum pump is not installed,
install the cover plate instead. Apply sealant as
illustrated, install it to the cylinder head and tighten
to 5-7N.m.
DS030091
23 Install CVVT cover (refer to Replacement of CVVT

Cover).
24 Install the intake/exhaust camshaft position sensor
(refer to Replacement of Camshaft Position
Sensor).
25 Install the ignition module (refer to Replacement of
Spark Plug and Replacement of Ignition Coil).
26 Install the fuel rail (refer to Replacement of Fuel
Rail)
27 Install the high-pressure fuel pump (refer to
Replacement of High-pressure Fuel Pump).
3-44
Replacement of Intake Manifold Liner 7 Remove 5 nuts securing the intake manifold to the
Removal: cylinder head, remove the intake manifold and
discard the gasket.
1 Remove the oil-gas separator 1 (refer to
Replacement of Oil-Gas Separator).
2 Remove the canister solenoid (2) (refer to
Replacement of Activated Canister Solenoid). 3 4
2 5 1
3 Disconnect the connector (3) from intake air
temperature/manifold absolute pressure (TMAP)
sensor, and remove the harness.
1 GS030094
Installation:
1 Clean the mating surface of the intake manifold
and cylinder head and ensure there is no foreign
2
3 material.
2 Secure the intake manifold to the cylinder head,
install 5 nuts, tighten them to 23~27N.m in the
GS030092 sequence as shown, and check the torque.
4 Release the clamp and remove the breather pipe

from the intake manifold.
3 4
2 5 1
GS030095
3 Secure the intake manifold bracket to the intake

GS030093 manifold, install 1 bolt, tighten to 22-28N.m, and
check the torque.
5 Disconnect the connector of the throttle body.
4 Connect the connector of the throttle body.
6 Remove 1 bolt securing the intake manifold
5 Connect vacuum hoses to the intake manifold, and
bracket to the intake manifold.
secure them with clamps.
6 Reset the harness, and the connector of intake
temperature/manifold absolute pressure (TMAP)
sensor.
7 Install the activated canister solenoid (refer to
Replacement of Activated Canister Solenoid).
3-45
8 Install the oil-gas separator (refer to Replacement Replacement of Exhaust Manifold Liner
of Oil-Gas Separator). Removal:
1 Drain the cooling system.
2 Remove the turbocharger (refer to Turbocharger
Replacement).
3 Remove 4 bolts securing the exhaust manifold
the heat shield. Remove the heat shield bolts from
rear end exhaust manifold, and remove the heat
shield.
GS030096
4 Remove 8 nuts securing the exhaust manifold to

the engine, and discard the nuts and washers;
remove the exhaust manifold.
5 Remove the stud securing the exhaust manifold to
the cylinder block and discard.
Installation:
1 Clean the junction surface of the components.
2 Install the fastening stud to the cylinder head,
tighten to 15 ± 2N.m and check the torque.
secure the exhaust manifold on the engine, install
8 gaskets and new nuts, tighten them to 25±2N.m
in the sequence as shown and check the torque.
3-46
Replacement of Oil Pump

Removal:
7 1 3 5
7 3 35
2 Remove the oil pan (refer to Oil Pan
Replacement).
3 Remove the oil suction pipe (refer to Replacement
62 42 2 of Oil Pump Suction Pipe).
6 4 2 8 4 Lock the oil pump sprocket with the lock tool
C00044507, and remove 1 bolt securing the oil
pump sprocket to the oil pump.
GS030097
4 Secure the exhaust manifold heat shield to the

exhaust manifold, install 4 bolts, tighten them to
22~28N.m, and check the torque. Secure the rear
end exhaust manifold heat shield to the exhaust C00044507
manifold, install 2 bolts, tighten them to 22~28N.m,
5 Install the turbocharger (refer to Turbocharger
Replacement).
6 Refill the cooling system.
GS030098
5 Remove the sprocket.
GS030099
3-47
6 Remove 4 bolts securing the oil pump to the sprocket, tighten to 68-72N.m, and check the
ladder, remove the oil pump, and remove the pipe torque.
connector (oil pump to ladder). 6 Install the oil suction pipe (refer to Replacement of
Oil Pump Suction Pipe).
7 Install the oil pan (refer to Oil Pan Replacement).
GS030100
Installation:
1 Clean the oil pump, pipe connector (oil pump to
the ladder) and ladder junction surface, and
ensure there is no foreign material.
2 Apply a small amount of oil to the pipe connector
(oil pump to ladder), and install it to the oil inlet of
the ladder.
3 Secure the oil pump to the ladder, install 4 bolts,
tighten them to 23-27N.m and check the torque.
1 4
GS030101
4 Pull the top part of oil pump chain tensioner to the

right, install the oil pump sprocket (the surface with
timing mark faces outward) to the oil pump chain,
rotate the oil pump manually to make the D hole in
the center align with the D shaft of the oil pump,
and then release the oil pump chain mechanical
tensioner. Check if the chain is pressed on the
guide plate surface (not bulged side edge) of the
tensioner after completing the installation.
5 Lock the oil pump sprocket with the lock tool
C00044507, install the bolts of the oil pump
3-48
Replacement of Engine Oil and Oil Filter 3 Install the oil filter and oil filter cover with the
Removal: suitable wrench, tighten the oil filter cover until it is
fully seated and the torque is not larger than 20-
1 Remove the engine oil filler cap. 25N.m.
2 Raise the vehicle on a lifting machine, and remove Caution: Tightening the oil filter cover excessively
the lower guard plate from engine condenser. may damage it and cause oil leaks.
3 Put the oil pan under the drain plug of the engine
Note: Do not use the open-end wrench at the
oil pan, remove the drain plug and discard the seal
hexagon head on the top of the oil filter cover.
washer.
Warning: The engine oil may be very hot, therefore, 4 Refill the engine oil.
special care shall be taken when releasing engine 5 Install the oil filler cap.
oil. 6 Start and run the engine until the oil pressure
Warning: Avoid excessive skin contact with used warning lamp goes out.
oil. It may contain poisonous contaminant, which 7 Stop the engine, and check the engine oil level.
may cause skin cancer or other severe skin 8 Check for any signs of leakage.
inflammations.
4 Drain the engine oil.
5 Secure the oil drain plug and new sealing washer
of oil pan to the oil pan, tighten to 20-25N.m and
check the torque.
6 Lower the vehicle.
7 Remove the oil filter cover 1 and discard O-ring.
1 2
GS030102
Caution: Do not use the open-end wrench at the

hexagon head on the top of the oil filter cover.
8 Remove the oil filter (2) from the cover and discard
it.
9 Clean the oil filter housing in the engine cylinder
block.
Installation:
1 Install a new oil filter (2) to the oil filter cover (1).
2 Replace with a new oil filter cover O-ring, and
lubricate with engine oil.
3-49
Engine Oil Pressure Check Replacement of Oil Pump Suction Pipe

Check for: Removal:
1 Remove the oil pressure switch (refer to 1 Drain the engine oil (refer to Replacement of
Replacement of Oil Pressure Switch). Engine Oil and Oil Filter).
2 Remove the seal ring from the oil pressure switch, 2 Remove the oil pan (refer to Oil Pan
and install it to the connector of oil pressure Replacement).
gauge. 3 Remove 2 bolts securing the oil pump suction pipe
3 Install and tighten the connector of oil pressure to the oil pump, and remove the oil suction pipe.
gauge to the original oil pressure switch position.
4 Connect the oil pressure gauge and tighten the
connector.
5 Check the engine oil, and refill as needed.
6 Start and run the engine until the normal operating
temperature is reached.
7 Note the readings indicated on the oil pressure
gauge is 1.5~2.0bar when the engine runs at 1000
rev/min (oil temperature 100°).
8 Turn off the engine.
9 Unscrew the pressure gauge connector, remove
the gauge and remove the connector.
GS030002
10 Wipe off the spilled oil.
11 Install the oil pressure switch (refer to Installation:
Replacement of Oil Pressure Switch). 1 Clean the oil suction pipe and oil inlet of the oil
pump, and ensure there is no foreign material.
2 Secure the oil suction pipe to the oil pump, install 2
bolts, tighten to 9-11N.m, and check the torque.
3-50
Oil Pan Replacement

Removal:
1 Remove the front axle and steering gear (refer to 18 16 14 12 10 8 6
Replacement of Front Axle and Steering Gear).
22 1
2 Remove the bolts securing the oil pan to the
transmission. 21
2
3 Unscrew the bolt securing the air conditioning 3
20
compressor to the oil pan (refer to Replacement of
Air Conditioning Compressor). 19 4
4 Remove 22 bolts securing the oil pan to the engine 11 9 7 5

17 15 13
ladder. Pay attention to the locations of 2 longest
bolts. GS030104
Installation:
6 Install 1 bolt securing the air conditioning
1 Clean the junction surface of the oil pan and the
compressor to the oil pan, tighten to 23 ± 2N.m,
engine ladder and ensure there is no foreign and check the torque (refer to Replacement of Air
material. Conditioning Compressor)
2 Install oil pan locating tool C00044508 on the 7 Install the bolts securing the oil pan to the
ladder.
transmission, tighten to 62.5 ± 2N.m (6AT)/80 ±
3 Apply the sealant with width of 3mm to the surface 5N.m (6MT), and check the torque.
of the oil pan as indicated by the route. 8 Install the front axle and steering gear (refer to
Caution: Confirm that the sealant is continuous Replacement of Front Axle and Steering Gear).
and smooth and the assembly shall be completed 9 Lower the vehicle.
within 5 minutes after applying.
GS030103
4 Install the oil pan to the ladder, install 20 bolts and

tighten them to 5N.m.
5 Remove the special tool (locating tool for oil pan).
Install 2 remaining bolts. Tighten all bolts to 8-
12N.m in the sequence as shown, and check the
torque.
3-51
Replacement of Timing Chain Cover

Removal:
2 Remove the V-belt (refer to V-belt Replacement). 2
1
3 Remove the steering pump (refer to Steering
Pump Replacement).
4 Remove 3 bolts securing the water pump pulley to
the oil filter module, and remove the water pump
pulley. 4
3
5 Remove idler pulley C.
6 Remove the crankshaft pulley (refer to GS030106
Replacement of Crankshaft Pulley).
Installation:
7 Remove 4 bolts connecting the oil pan to the front
cover. 1 Clean the junction surface of the engine block, oil
pan and front cover and ensure there is no foreign
8 Remove 23 M6 bolts, 2 M8 bolts, 3 M12 bolts and
material.
idler pulley A securing the front cover to the engine
in the order of 7-29, 5-6, 4 and 1-3. 2 Apply the sealant with the width of 2.5mm to the
surface of front cover as indicated by the route.
Caution: Confirm that the sealant is continuous
15 21 25 22 16
and smooth and the assembly shall be completed
9 1 10 within 5 minutes after applying.
5 6
7 8
2 3
11 12
13
4 14
17
19 18
23 20
24
26 27
28 29
GS030105
9 Tap them from the back according to the position

and order as shown to remove the chain cover.
GS030107
3 Apply the sealant to the junction surface of the oil

pan.
4 Align 2 locating pin holes of the front cover with 2
locating pins and assemble them to the junction
surface of the engine block ladder and cylinder
head assembly.
5 Install 23 M6 bolts, 2 M8 bolts, 3 M12 bolts and
idler pulley A.
6 Tighten 3 M12 bolts to 80-90N.m in the sequence
of 1-3, and check the torque.
7 Tighten idler pulley A to 32~38N.m in the
sequence of 4, and check the torque.
3-52
8 Tighten 2 M8 bolts to 23~27N.m in the sequence Crankshaft Pulley Replacement

of 5-6, and check the torque. Removal:
9 Tighten 23 M6 bolts to 9-11N.m in the sequence of
1 Remove the V-belt (refer to V-belt Replacement).
7-29, and check the torque.
2 Secure the crankshaft with flywheel lock tool
10 Install 4 bolts connecting the oil pan and the front
C00044503.
cover, tighten them to 9-11N.m, and check the
torque.
11 Secure the water pump pulley on the water pump
oil filter module, install 3 bolts, tighten them to
9~11N.m, and check the torque.
12 Install the steering pump (refer to Steering Pump
Replacement).
13 Install the crankshaft pulley (refer to Crankshaft
Pulley Replacement).
TEN00122
14 Install idler pulley C, tighten the torque to
45~55N.m and check the torque.
15 Install the V-belt (refer to V-belt Replacement).
16 Refill the engine oil (refer to Replacement of GS030108
3 Remove the fastening bolts from crankshaft pulley,
and discard the bolts.
4 Remove the crankshaft pulley.
Caution: When removing the pulley, do not damage
the front crankshaft oil seal lip.
Installation:
1 Pay attention to the mounting position of locating
key on the crankshaft. Align the crankshaft pulley
groove with locating key and install the pulley in
place.
2 Install the new bolts, tighten to 85N.m+90°, and
check the torque.
3 Remove the special tool.
3-53
Cylinder Gasket Replacement 7 Install new cylinder gasket to the cylinder block
Removal: and note the "UP" mark.
8 Install the cylinder head to the cylinder block and
carefully align it with the locating pins.
9 Carefully install the cylinder head bolts, do not
2 Drain the coolant.
apply much force to plug it or drop it into the bolt
3 Remove the timing chain cover (refer to holes, tighten the bolt by hand.
10 Tighten the cylinder head bolts to 45N.m +90°
4 Remove the intake and exhaust phase modulator +90 progressively in the sequence as shown and
(refer to Replacement of Phase Modulator (Intake check the torque.
and Exhaust)).
5 Remove the intake/exhaust camshaft (refer to
Camshaft Replacement).
10 6 2 3 7
6 Disconnect the connector of the electronic throttle.
7 Remove 1 bolt securing the intake manifold
bracket to the intake manifold.
8 Remove 10 bolts securing the cylinder head to the
cylinder block, and remove the cylinder head.
9 Remove the cylinder head gasket from the
cylinder block and discard it. 9 5 1 4 8
GS030110
11 Secure the intake manifold bracket to the intake

manifold, install 1 bolt, tighten to 23-26N.m, and
check the torque.
12 Connect the electronic throttle connector.
13 Install the intake/exhaust camshaft (refer to
Camshaft Replacement).
14 Install the intake/exhaust phase modulator (refer
to Replacement of Phase Modulator (Intake and
Exhaust)).
GS030109
Installation: Replacement of Timing Chain Cover).
1 Clean the mating surface of the cylinder head and 16 Refill the coolant.
cylinder block, and ensure there is no foreign 17 Refill the engine oil (refer to Replacement of
material. Engine Oil and Oil Filter).
2 Clean the passages of the engine oil and the
coolant.
3 Clean the cylinder head bolts and wipe them,
check the thread for any sign of damage.
4 Apply a thin oil film on the threads and the
underside of the bolt head.
5 Check the surface of the cylinder head for scratch.
6 Check the height of cylinder head, if it exceeds the
specified value, replace it.
3-54
Turbocharger Replacement
Removal:
2 Drain the engine coolant.
3 Remove the exhaust pipe front section.
2
4 Remove 3 bolts securing the turbocharger heat
shield to the turbocharger, and remove the
turbocharger heat shield.
GS030112
11 Remove and discard the hallow bolt securing the

turbocharger coolant inlet pipe to the turbocharger,
remove and discard the copper gaskets.
GS030111
5 Remove 2 bolts securing the turbocharger bracket

to the cylinder block and turbocharger, and
remove the bracket.
6 Disconnect the connector of the turbocharger.
7 Loosen the clamp, disconnect the air filter outlet
hose from the turbocharger, seal the opening and GS030113
ensure no foreign material dropped into the
12 Remove the bolts securing the turbocharger
turbocharger.
coolant inlet pipe clamp to the heat shield, and
8 Loosen the clamp, disconnect the intercooler take away turbocharger inlet pipe.
intake hose from the turbocharger, seal the
opening and ensure no foreign material dropped
into the turbocharger.
9 Disconnect the pressure control hose from the
turbocharger and exhaust gas port, seal the
opening and ensure no foreign material dropped
into the turbocharger.
10 Loosen the clamp and disconnect the
turbocharger coolant drain pipe from the
turbocharger.
GS030114
3-55

turbocharger oil inlet pipe to the turbocharger,
GS030117
1 17 Remove and discard 4 nuts securing the

turbocharger to the exhaust manifold, remove the
GS030115
turbocharger, take away and discard the gasket.
14 Remove 1 bolt (1) securing the turbocharger oil
inlet pipe to the turbocharger oil return pipe clamp,
and remove the turbocharger oil inlet pipe.
return pipe clamp to the exhaust manifold.
GS030118
16 Remove 2 bolts securing the turbocharger oil

return pipe to the turbocharger, and remove the
turbocharger oil return pipe.
3-56
Installation: Replacement of Turbocharger Coolant Outlet

Pipe
1 Secure the turbocharger oil return pipe to the
turbocharger, use new gaskets to oil return pipe, Removal:
install 2 bolts, tighten to 9-11N.m, and check the 1 Drain the engine coolant.
torque.
2 Remove the turbocharger heat shield.
2 Replace with a new gasket, locate the
turbocharger to the exhaust manifold, install 4 new
nuts, tighten to 28-32N.m, and check the torque.
3 Secure the turbocharger oil return pipe bracket to
the exhaust manifold, install 1 bolt, tighten to 22-
28N.m, and check the torque.
Caution: The oil return pipe bracket shares the bolt
with turbocharger heat shield.
4 Use new gaskets and tighten the turbocharger

water return pipe assembly to the turbocharger
water outlet to the torque of 35-40N.m.
5 Replace with a new gasket, secure the
turbocharger oil inlet pipe to the turbocharger, GS030119
install 1 new hollow bolt, tighten to 18-22N.m , and
check the torque. 3 Release clamp 1 and disconnect the engine
exhaust pipe from turbocharger water outlet pipe.
6 Secure the turbocharger oil inlet pipe to the lower
bracket of turbocharger oil return pipe, install 1
bolt, tighten to 9-11N.m, and check the torque.
turbocharger coolant inlet pipe to the turbocharger,
install 1 new hollow bolt, tighten to 35-40N.m, and
check the torque.
Caution: The water inlet pipe bracket must be secured
on the engine before tightening. 2
8 Secure the turbocharger coolant inlet pipe bracket

to the engine, install 1 bolt, tighten to 8-12N.m,
and check the torque. 1
9 Connect the turbocharger connector. GS030120
10 Secure the turbocharger bracket to the cylinder 4 Remove the nut (2) securing the turbocharger
block and turbocharger, install 2 bolts and pre- water outlet pipe connector to the turbocharger
tighten to 2N.m, then install the bolt securing the and discard the gasket, then remove the water
bracket to turbocharger to 45-50N.m, and the bolt outlet connector.
securing the bracket to cylinder block to 50-
60N.m, and check the torque. Installation:
11 Secure the turbocharger heat shield to the 1 Replace with a new gasket, secure the
turbocharger, install 3 bolts, tighten to 22-28Nm, turbocharger water outlet pipe connector to the
and check the torque. turbocharger, tighten the nut to 35-40N.m, and
check the torque.
12 Refill the engine oil.
2 Connect the turbocharger water outlet pipeline.
Engine Oil and Oil Filter
3 Install the turbocharger heat shield, tighten the
fastening bolts to 22-28N.m and check the torque.
3-57
Replacement of Turbocharger Coolant Inlet

Pipe
Removal:
2 Remove the turbocharger heat shield.
GS030123
5 Release the clamp, and disconnect the

turbocharger water inlet pipe from the auxiliary
water pump.
6 Remove the turbocharger water inlet pipe.
GS030121 Installation:
1 Connect the turbocharger water inlet pipe to the
3 Remove 1 bolt securing the turbocharger water
auxiliary water pump, and secure with clamps.
inlet pipe clamp to the heat shield, then remove
the heat shield. 2 Secure the turbocharger water inlet pipe to the
turbocharger, install 1 hollow bolt and 2 new
copper gaskets, tighten to 35-40N.m, and check
the torque.
3 Secure the turbocharger water inlet pipe clamp to
the heat shield, install 1 bolt, tighten to 9-11N.m,
4 Install the turbocharger heat shield, install 3 bolts,
tighten to 22-28N.m, and check the torque.
GS030122
4 Remove 1 hallow bolt securing the turbocharger

water inlet pipe to the turbocharger, and discard
the copper gaskets.
3-58
Replacement of Turbocharger Oil Return Pipe

Removal:
GS030125
Installation:
turbocharger, install 2 bolts, tighten to 9-11N.m,
cylinder block, install 2 bolts, tighten to 9-11N.m,
GS030124 and check the torque.
3 Secure the turbocharger oil return pipe clamp to
3 Remove 1 bolt securing the turbocharger oil return
the exhaust manifold, install 1 bolt, tighten to 22-
pipe clamp to the exhaust manifold.
4 Remove 1 bolt securing the turbocharger oil inlet
4 Secure the turbocharger oil inlet pipe to the upper
pipe to the turbocharger oil return pipe clamp, and
clamp of the turbocharger oil return pipe, install 1
remove the turbocharger oil inlet pipe.
5 Secure the turbocharger heat shield to the
return pipe to the cylinder block, and then
disconnect the pipe from cylinder block.
return pipe to the turbocharger, and remove the
turbocharger oil return pipe.
3-59
Replacement of Turbocharger Oil Inlet Pipe

Removal:
2 Remove the alternator (refer to Alternator
Replacement).
8 Remove the turbocharger oil inlet pipe.

Installation:
turbocharger oil inlet pipe to the cylinder block,
install 1 new hollow bolt, tighten to 18-22N.m, and
check the torque.
2 Secure the turbocharger oil inlet pipe to the
cylinder block, install 1 bolt, tighten to 18-22N.m,
GS030126 and check the torque.
3 Secure the turbocharger oil inlet pipe to the upper
clamp of the turbocharger oil return pipe, install 1
remove and discard 2 copper gaskets.
install 1 new hollow bolt, tighten to 18-22N.m , and
check the torque.
5 Secure the turbocharger heat shield to the
2
6 Install the alternator (refer to Alternator
Replacement).
1
GS030127
5 Remove the bolt (1) securing the turbocharger oil

inlet pipe to the turbocharger oil return pipe clamp,
and remove the turbocharger oil inlet pipe.
inlet pipe to the cylinder block.
7 Remove and discard the hallow bolt (3) securing
the turbocharger oil inlet pipe to the cylinder block,
3-60
Replacement of Oil Filter Module 6 Remove 4 bolts securing the oil filter module to the
Removal: cylinder block, remove the oil filter module and
discard the gasket.
3 Remove the V-belt (refer to V-belt Replacement).
4 Remove 2 bolts securing the water pump inlet pipe
to the cylinder block and oil filter module,
disconnect the water pump inlet pipe from the oil
filter module and discard the seal ring.
GS030131
Installation:
1 Clean the mating surface between the cylinder
block and the oil filter module, ensure it is clean
and smooth.
2 Install a new sealing gasket, tighten 4 bolts
securing the oil filter module to the cylinder block
GS030129 to 23-27N.m, and check the torque.
5 Disconnect the connector of the engine oil 3 Connect the oil pressure switch connector.
pressure switch. 4 Install a new O-ring to the water pump inlet pipe,
apply sealant to it, and install the water pump inlet
pipe to the oil filter module.
5 Secure the water pump inlet pipe to the cylinder
block, install 2 bolts, tighten to 8-12N.m, and
check the torque.
1 2
GS030130
3-61
Camshaft Cover Replacement sequence as shown, and remove the camshaft

Removal: cover.
1 Remove the engine hood (refer to Engine Hood

Replacement). 39 37
12 4 5 36 13 35
2 Remove the top harness from the engine. 20 38
3 Remove the oil-gas separator (refer to
Replacement of Oil-Gas Separator). 19 11 3 6 14 31
34 33 32
4 Remove the high-pressure fuel pump (refer to
Replacement of High-pressure Fuel Pump). 18 10 30 2 29 7 28 15 27
5 Remove the fuel rail (refer to Fuel Rail
Replacement) 26
9 1 8 16 21
17 25 24 23 22
6 Remove the ignition module (refer to Spark Plug
Replacement and Ignition Coil Replacement). GS030133
7 Remove the intake/exhaust camshaft position
14 Remove 2 bolts securing the upper guide rail to
sensor (refer to Replacement of Camshaft
the camshaft head, and remove the upper guide
Position Sensor).
rail.
8 Remove CVVT cover (refer to CVVT Cover
Replacement).
9 Remove the mechanical vacuum pump (refer to
10 Remove the turbocharger control solenoid valve
(refer to Replacement of Turbocharger Control
Solenoid Valve).
11 Remove 3 bolts securing the observation hole
cover of the intake camshaft to the camshaft
cover, and remove the observation hole cover of
the intake camshaft.
GS030134
Installation:
1 Secure the upper guide rail to the camshaft cover,
install 2 bolts, tighten to 9-11N.m, and check the
torque.
2 Clean the junction surface of the front cover,
camshaft cover and cylinder head and ensure
there is no foreign material.
3 Apply sealant to the junction surface of front cover.
GS030132 4 Apply engine oil to the camshaft journal evenly.

13 Remove 39 bolts (35 and 27 are studs) securing
the camshaft cover to the cylinder head in the
3-62
5 Apply sealant to the camshaft cover (as

illustrated).
GS030137
GS030135 9 Secure the observation hole cover of the intake

6 Secure the camshaft cover to the cylinder head, camshaft to the camshaft cover, install 3 bolts,
install 39 bolts (35 and 27 are studs), tighten them tighten them to 5-7N.m, and check the torque.
to 9-11N.m in the sequence as shown, and check 10 Install the exhaust camshaft observation hole
the torque. cover (refer to Exhaust Camshaft Observation
Hole Cover).
11 Install the turbocharger control solenoid valve
(refer to Replacement of Turbocharger Control
39 37
12 4 5 36 13 35 Solenoid Valve).
20 38 12 Install the mechanical vacuum pump (refer to
19 11 3 6 14 31
34 33 32 13 Install CVVT cover (refer to Replacement of CVVT
Cover).
18 10 30 2 29 7 28 15 27
14 Install the intake/exhaust camshaft position sensor
26 (refer to Replacement of Camshaft Position
9 1 8 16 21 Sensor).
17 25 24 23 22
15 Install the ignition module (refer to Ignition Coil
GS030136 Replacement and Spark Plug Replacement).
16 Install the fuel rail (refer to Replacement of Fuel
Rail)
17 Install the high-pressure fuel pump (refer to
8 Apply sealant to the observation hole cover of the
Replacement of High-pressure Fuel Pump).
18 Install the oil-gas separator (refer to Replacement
of Oil-Gas Separator).
19 Install the top harness on the engine.
20 Install the engine hood (refer to Engine Hood
Replacement).
3-63
Replacement of Engine Timing Chain

Removal:
3 Remove CVVT cover (refer to CVVT Cover
Replacement).
4 Remove the mechanical vacuum pump.
5 Remove 3 bolts securing the observation hole
C00044505
cover of the intake camshaft to the camshaft
cover, and remove the observation hole cover of GS030141
the intake camshaft.
6 Install the timing location special tool C00044505
by rotating the crankshaft, locate the rear end tool
first to ensure the TOP mark in the front of
camshaft faces up, then install the front tools (MT).
Rotate the crankshaft and secure the crankshaft
with tool C00051509, in this case, the notch of
crankshaft pulley is aligned with the imprint on
timing cover housing (AT).
MT
GS030142
7 Secure the crankshaft with flywheel lock tool

C00044503.
TEN00122 8 Remove 2 bolts securing the timing chain
tensioner to the cylinder block, and remove the
timing chain tensioner.
GS030139
AT
GS030143
9 Remove 2 bolts securing the upper guide rail to

GS030140 the cylinder head, and remove the upper guide
rail.
3-64
15 Remove the oil pump chain tensioner.

16 Remove the bolt (2) of the oil pump chain
tensioner.
1
GS030144 1
10 Remove the tensioner rail and chain guide rail

from the chain guide rail bolt.
17 Remove the oil pump chain.

18 Remove the crankshaft sprocket.
Installation:
1 Install the drive crankshaft sprocket to the
crankshaft.
2 Install the oil pump chain.
3 Secure the bolt (2) of the oil pump chain tensioner
to the ladder, tighten to 20-24N.m, and check the
torque.
4 Install the oil pump chain tensioner.
GS030145 5 Pull the oil pump chain tensioner, secure the bolt
(1) of the oil pump chain tensioner to the ladder,
11 Remove the timing chain. tighten to 20-24N.m, and check the torque.
12 Remove 3 chain guide rail bolts from the cylinder 6 Install 3 bolts of the chain guide rail to the cylinder
head/block. block/head, tighten to 20-24N.m, and check the
torque.
13 Remove the crankshaft timing sprocket.
7 Install the timing chain.
14 Remove the bolt (1) of the oil pump chain
tensioner. 8 Install the tensioner rail and chain guide rail to the
chain guide rail bolt and push it to the end.
9 Secure the upper guide rail to the cylinder head,
install 2 bolts, tighten to 9-11N.m, and check the
torque.
10 Secure the timing chain tensioner to the cylinder
block, install 2 bolts, tighten to 9-11N.m, and check
the torque.
11 Pull out the pin from the timing chain tensioner.
1 12 Install the timing chain cover (refer to

1 Replacement of Timing Chain Cover).
13 Install the crankshaft shock absorber, observe if its
notch is aligned with the mark on the timing chain
cover, if it is not aligned, remove the crankshaft
3-65
pulley and timing chain cover; and reinstall the Engine Ladder Replacement
chain after alignment. Removal:
14 Remove the crankshaft locking tool and intake/
exhaust cam position check tool.
15 Apply sealant to the observation hole cover of the
2 Remove the timing chain (refer to Timing Chain
Replacement).
3 Remove the oil pan (refer to Oil Pan
Replacement).
4 Remove the oil suction pipe (refer to Replacement
of Oil Pump Suction Pipe).
5 Remove the rear crankshaft oil seal (refer to
Replacement of Rear Crankshaft Oil Seal).
6 Remove 16 bolts securing the ladder to the
cylinder block in the sequence as shown.
15 9 13 16 12 8 14
GS030148
16 Secure the observation hole cover of the intake

camshaft to the camshaft cover, install 3 bolts,
tighten them to 5-7N.m, and check the torque. 1 2
17 Install the mechanical vacuum pump (refer to

18 Install CVVT cover (refer to Replacement of CVVT
6 10 4 5 11 7 3
Cover).
19 Refill the engine oil (refer to Replacement of GS030149
7 Remove the oil pump and pipe connector (oil
pump to ladder).
8 Remove 10 bearing bolts in the sequence as
shown.
1 5 9 8 4
2 6 10 7 3
GS030150
9 Remove the ladder, and remove the oil return pipe

from the ladder.
3-66
GS030151 GS030153
Installation: 6 Align the locating pin and secure the ladder to the
cylinder block.
1 Clean the junction surface between the cylinder
block and the ladder, and ensure there is no 7 Install the bearing bolts, tighten to 35N.m +90°
foreign material. +45 ° in the sequence of 10-1, and check the
torque.
2 Clean water and oil ducts, and ensure there are no
foreign material.
3 Apply fresh engine oil to the crankshaft main
journal.
1 5 9 8 4
2 6 10 7 3
GS030154
8 Apply a small amount of oil to the pipe connector

(oil pump to ladder), and install it to the oil inlet of
GS030152 the ladder.
9 Secure the oil pump to the ladder, install 4 bolts
4 Manually press the oil return pipe into the ladder,
and pre-tighten manually.
when the exposed section is appr. 10mm, tap it
with a rubber hammer until the end of the pipe 10 Install 14 remaining bolts securing the ladder to
touches the bottom. the cylinder block, tighten them to 23-27N.m in the
sequence as shown, and check the torque.
5 Apply sealant evenly to the junction surface
between the ladder and the cylinder block, see the
figure.
3-67
Replacement of Engine Assembly

Removal
15 9 13 16 12 8 14 1 Open the engine hood. Disconnect and remove
the battery (refer to Battery Replacement).
2 Remove the engine hood, disconnect the power
steering pump pipeline, and collect steering fluid
1 2 with a container.
3 Drain the coolant in the radiator, and collect the
coolant with a container (refer to Coolant
Replacement).
6 10 4 5 11 7 3
GS030155
Caution: After application of the sealant, tighten to

the specified torque within 15 minutes.
11 Install the rear crankshaft oil seal (refer to
Replacement of Rear Crankshaft Oil Seal).
12 Install the oil suction pipe (refer to Replacement of
Oil Pump Suction Pipe).
14 Install the timing chain (refer to Timing Chain
Replacement).
GS030156
15 Install the front cover (refer to Replacement of
Timing Chain Cover). 4 Remove the intake grille.
5 Remove the intercooler (refer to Intercooler
Replacement).
6 Remove the cooling module assembly from the
complete vehicle (refer to Replacement of Cooling
Module).
7 Disconnect the connector of transmission cable.
Remove the center console (refer to Removal of
Center Console) first, and then remove the gear
shift lever (refer to Removal of Gear Shift Lever).
8 Remove the catalytic converter assembly (refer to
Replacement of Catalytic Converter Assembly).
3-68
GS030157 GS030159
9 Disconnect pipes and harnesses connected to the

engine.
10 Lift the complete vehicle to a certain height with a
lifter, and disconnect the transmission rear mount.
11 Lower the lifter to a certain height, and support the
transmission assembly with an universal carrier.
GS030160
13 Lift out the engine assembly from the engine

compartment with a proper lifting arm.
GS030158
12 Unscrew the nuts securing engine mount and

transmission to the engine. Place a proper
wooden or plastic block between the engine rear
end and dash panel to prevent the engine from
damaging the dash panel.
GS030161
Installation
3-69
A phase modulator is installed to the drive ends of the

Description and Operation
intake and exhaust camshafts and fixed by bolts. The main
Overview parts of phase modulator is made by powder metallurgy
The NLE engine features in-line 4-cylinder, 16-valve, methods. The outer housing driven by timing chain is
DOHC, timing chain drive and direct injection system. connected with inner rotor through five blades fixed at
camshaft end in a hydraulic way. When the engine is not
It is mainly composed of cylinder block, cylinder head, running, a pin with elastic load locks both halves of the
crankshaft, connecting rod and camshaft. The cylinder phase modulator; when the engine operates, they are
head is made of cast aluminum material and connected loosened in a hydraulic way to ensure stable starting.
with the cast aluminum cylinder block through multi-layer
cylinder gaskets by using 10 high-strength bolts, providing Two oil control valves are installed on the camshaft cover
high overall strength and reliable structure. control valve housing and fixed with an O-ring and a bolt.
The control valve is a four-way proportioning valve,
Cylinder Head Components including an oil inlet, an oil return port and two oil ducts
The cylinder head adopts 4 valves per cylinder structure connected with the working chamber.
with a spark plug mounted at the center of the combustion
Cylinder Block Components
chamber. Due to adoption of overhead valve structure,
powerful whirlpool will be formed in the combustion Adopting the cast aluminum material AlSi9Cu3, the
chamber to make the mixed gas evenly distributed, which cylinder block and ladder are formed by high pressure
is good for transmission of flame to improve combustion casting. They are characterized by light weight and high
condition, so as to enhance the power performance, fuel strength. The precast cylinder liner is used on cylinder
economy and emission performance of the engine. block to prevent the cylinder liner from deformation and
improve the heat transfer. Y-shaped water passages are
The camshaft drives the roller rocker, one end of the roller processed between two adjacent cylinders to ensure heat
rocker is supported by a hydraulic tappet, and the other dissipation effect of the cylinder block. Iron cast inserts are
end is supported by a valve stem end. The valve is driven used for ladder bearing seat to satisfy the strength
by swing arm torque. The valve clearance can be requirements of high performance engine.
automatically compensated by the hydraulic tappet. The
valve stem oil seal is press-fitted on the cylinder head oil The aluminum alloy thermal expansion piston is provided
seal seat and can be used as the valve spring seat to with a full floating piston pin fit to the clearance of the small
support the valve spring. end of connecting rod, and both ends of the piston pin are
fixed and limited by circlips. Each piston is provided with
The exhaust valve is of a carbon deposit removal type, and two compression rings and one oil ring.
the valve stem with the side machined can clean the
carbon deposit at the end of the valve guide and in the The forging steel connecting rod has the structure of the H-
combustion chamber so as to prevent valve seizing. section. The big end of connecting rod moves on the
bearing shell of crankshaft journal. The connecting rod
The metal cylinder gasket is of a multi-layer structure, the adopts forging and cracking process.
cylinder opening adopts a pressing ring structure, which
enhances sealing at cylinder opening; local rubber coat The crankshaft has four balance weights and is supported
technology is adopted to ensure the sealing performance. by five bearing shells. The end float is controlled by the
thrust washer on the top of the central main bearing shell.
There are four oil ducts at front bearing of the camshaft, The radial clearance of the bearing shell is optional, which
one oil inlet duct, one oil return duct and two operating oil is controlled by the bearing shells of two different grades.
ducts. Oil enters the oil control solenoid valve via the oil The oil groove offered in the upper half part of the main
ducts. The tail end of intake camshaft is equipped with a bearing shell supplies oil to the connecting rod big end
camshaft signal wheel to provide signals for camshaft bearing shell through the oil hole in the crankshaft.
position sensor. A stern notch is formed in the camshaft for
controlling camshaft timing phase during assembly.
3-70
Oil Pan Components High Pressure Common Rail and Direct

The oil pan assembly consists of the oil pan machining Injection System
parts, drain plug bolt gasket and drain plug bolt. The Comparing with PFI engine, the gasoline direct injection
aluminum oil pan is designed in a shape suitable for engine avoids introducing moisture to the wall of the intake
collecting the oil around the oil suction pipe. The oil suction port, this allows accurate calculation of the fuel, reduction
pipe of oil pump module installed on the engine block - of the HC emission level during cold start and improvement
ladder assembly is inserted in the bottom of oil pan and of the engine transient response speed.
draws oil during engine running to lubricate the crankshaft,
GDI (Gasoline In-Cylinder Direct Injection) fuel injection
connecting rod and camshaft, etc. The junction surface of
system mainly includes: high-pressure fuel pump, high-
the oil pan and ladder is sealed with sealant and fixed by
pressure fuel pipe, fuel rail, rail pressure sensor and fuel
bolts.
injector.
Lower Crankcase Body The high-pressure oil pump driven by the overhead cam
The lower crankcase assembly consists of lower pumps high-pressure fuel into the fuel rail through the fuel
crankcase and oil pump. The aluminum lower crankcase is pipe, the injector injects fuel in the rail into the cylinder at a
designed into a shape that is suitable for accumulating oil certain pulse width, and the rail pressure sensor returns a
around the strainer, the oil pump is assembled to the signal of pressure in the rail to the ECU which controls the
bottom of the crankcase, and the oil passes through the oil pressure in the fuel rail through the high-pressure fuel
strainer with screen and then the oil filter after pressurized pump. NLE fuel injection system pressure is up to 15MPa.
through the oil pump. Clean oil free from impurities is ECU controls the fuel-injection amount by controlling the
distributed to the main bearing and cylinder head via the rail pressure and fuel injection pulse width to meet the
main oil duct of the engine block to lubricate the crankshaft, requirements of different conditions for injection amount.
connecting rod and camshaft, etc. The junction surface of
the lower crankcase and engine block is sealed with Turbocharger
sealant and fixed by bolts. The high temperature and high pressure gas exhausted
from the engine exhaust manifold contains a certain
Engine Accessories energy. For naturally aspirated engines, this energy is
The accessories system is a drive system driven by often wasted during emission. The turbocharger can
crankshaft shock absorber: to drive the water pump, convert waste gas into energy to enhance the engine
alternator and A/C compressor via a single 6-ribbed belt power (about 30%) and cylinder scavenging to effectively
and to tension the belt by the tensioner. reduce NOx emissions. The turbine wheel and compressor
impeller realize rigid connection through the turbocharger
Positive Crankcase Ventilation
shaft, and this is called the turbocharger rotor. The
The ventilation system, with the help of intake system
turbocharger rotor is fixed in the turbocharger through the
vacuum level, redirects the exhaust gas escaped to the
floating bearing (A small friction resistance moment can be
crankcase back into the cylinder for combustion, so as to
guaranteed when the rotor rotates at high speed.). When
reduce the air pollution.
the engine operates, the exhausted gas impacts on the
Oil-gas separation will be made for the oil and gas via an oil turbocharger impeller at a certain angle at a high speed, so
separator installed on the camshaft cover, and the that the turbocharger rotor rotates at a high speed. The
separated engine oil will flow back to the crankcase. high-speed rotation of the compressor impeller raises the
pressure in the engine intake manifold, and pressurization
is thus achieved during this process. So air will be exposed
to greater pressure in the intake process, so that more,
denser air enters the cylinder. This helps to improve fuel
combustion and engine performance. Water cooling and
oil cooing are used due to high temperature of the gasoline
engine tubocharger.
3-71
Operation
Lubricating Oil Circuit
GS030162
The lubrication system is a full-flow filtration, forced oil so you just need to replace the filter element when doing
supply system. Oil is drawn from the oil pan through the oil maintenance. The oil filter is provided with a bypass valve,
suction pipe by the oil pump, and the oil suction pipe is when the filter element is blocked, it will open and ensure
equipped with a screen which can prevent impurities from free flow of the oil, but the element shall be replaced as
entering the oil pump. The oil pump with a pressure relief soon as possible under this situation. The oil then enters
valve is driven by the crankshaft via a chain. When the oil into the main oil duct fitted with the piston cooling nozzle
pressure reaches a certain value, the pressure relief valve which is used for cooling the piston and lubricating the
will open, the excess oil returns to the inlet side of oil pump, connecting rod small end and piston pin. The oil lubricates
and this helps maintain the oil pressure within a certain the main bearing shell through the cross oil duct, and the
operating pressure range and ensure the normal operation cross oil duct of the crankshaft delivers the oil from the
of engine. Oil flows out from the oil pump outlet, then main bearing shell to the connecting rod big end bearing
enters into the oil filter module through the ladder and the shell. The cylinder head has three side oil ducts
oil duct of engine block. The oil filter module is directly connecting with the main oil duct of the engine block. One
installed on the engine block, which contains the oil cooler of them is used to provide pressure for the VCT. The oil
and oil filter. The oil cooler cools the oil before delivering it flows into two horizontal oil ducts of the standard length
into the oil filter, this oil filter is an environment-friendly filter,
3-72
through the rest two side oil ducts and is supplied to each
hydraulic tappet and camshaft journal.
A mechanical vacuum pump (if equipped) is installed at the

rear end of one cross oil duct.
The turbocharger lubricating oil pipe of the turbocharged

engine is connected with the main oil duct of engine. Oil
flows back to the engine cavity (if equipped) through the oil
return pipe after flowing through the turbocharger.
3-73
Special Tool
SN. Tool Number/ Illustration
Description
SN. Tool Number/ Illustration

Description
C00044505
5 Camshaft timing
tooling kit
C00044501
1
Engine lug kit
C00044505
C00044501
C00044507
6 Oil pump sprocket
C00044502 lock
2 Fuel injector
remover
C00044507
C00044502
C00044508
7 Oil pan locating
C00044503 tool
3
Flywheel lock pin
C00044508
C00044503
C00044509
8 Rear crankshaft oil
C00044504 seal installer
4
Crankshaft holder
C00044509
C00044504
3-74
SN. Tool Number/ Illustration SN. Tool Number/ Illustration

Description Description
C00044510 C00044517
9 Front crankshaft oil 13 Shaft 1 supporting
seal installer bearing remover
C00044510 C00044517
C00044511
Connecting rod C00051510
10 bearing shell 14 Flywheel locking
installation and tool
centering tool
C00044511 C00044518
C00046379 C00051509
11 Belt tensioner 15 Crankshaft location
thrust wrench timing tool (AT)
C00046379 C00051509
C00044515 C00089859
12 Shaft 1 supporting 16 Fuel sensor cover
bearing installer remover
C00044515 C00089859
3-75
3-76
Engine Cooling System
Specification
Torque
Application Torque (N.m)
Screw - thermostat outlet pipe 9-11N.m
Screw - water pump pulley 9-11N.m
Bolt - water pump assembly 9-11N.m
Nut - expansion tank assembly to body dash panel 9±1

Bolt - expansion tank assembly to body dash panel 9±1
Bolt - engine cooling fan assembly to radiator 5±1
Bolt - condenser assembly to radiator assembly 5±1
Bolt - intercooler assembly to body 22 ± 2
Clamp - connecting intercooler intake hose and engine turbocharger outlet 5 ± 0.5
Clamp - connecting intercooler intake hose and intercooler assembly 5 ± 0.5
Clamp - connecting intercooler exhaust pipe assembly and engine throttle 5 ± 0.5
inlet
Clamp - connecting intercooler exhaust pipe assembly and intercooler 5 ± 0.5

assembly
Clamp - connecting radiator water inlet pipe, engine assembly and engine 5 ± 0.5
cooling module assembly
Clamp - connecting radiator water outlet pipe, engine assembly and 5 ± 0.5
engine cooling module assembly
Bolt - front assembly bracket of transmission oil cooler pipe to engine 11 ± 1

cooling module assembly
Bolt - rear assembly pressing plate of transmission oil cooler pipe to 23 ± 3

transmission assembly
Bolt - rear assembly bracket of transmission oil cooler pipe to engine 23 ± 3

assembly
Bolt - rear assembly bracket of transmission oil cooler pipe to engine 11 ± 1

assembly
Nut - front/rear assembly of transmission oil cooler pipe 28 ± 2
4-1
Cooling fan model PWM pulse fan
Cooling fan ON/OFF
·ON 92 ℃ (high load)/102 ℃ (low load)
·OFF 89 ℃ (high load)/99 ℃ (low load)

Cooling fan ON/OFF - after engine shutdown
ON/Duration: 1. Entry time: 91 ℃≤ water temperature T ＜ 96 ℃ , the fan

30% operates. Exit time: difference calculation is made
between 120s and 240s (transient water temperature at
engine shutdown), if the cooling fan causes the water
temperature to be ＜ 88 ℃ during subsequent operation, the
fan is off (even it is not the time for exiting).
2. Entry time: 96 ℃≤ water temperature T, the fan 60%
operates. Exit time: 240s (transient water temperature at
engine shutdown), if the cooling fan causes the water
temperature to be ＜ 96 ℃ during subsequent operation, the
fan 30% operates, when the water temperature is ＜ 88 ℃ ,
the fan is off (even it is not the time for exiting).
Thermostat operating temperature
Initial ON 90 ℃ (high load)/102 ℃ (low load)

Fully open 115 ℃
Fully open lift ≥ 8mm
Pressure relief valve of the expansion tank cap
High pressure ON 140Kpa
Low pressure ON -10Kpa
Coolant pump (model) Electronic clutch water pump
Drive ratio of coolant pump 1.26
4-2
Layout
2
7
3
6
5
GS03206
1 Thermostat pipe 5 Water pump inlet pipe assembly

2 Water pump pulley 6 Oil filter module
3 Thermostat housing assembly 7 Engine water pump
4 Water pump inlet pipe
4-3
2
4
DS570010
1 Turbocharger
2 Turbocharger water inlet pipe assembly
3 Electronic auxiliary water pump outlet pipe
assembly
4 Engine auxiliary water pump
5 Turbocharger water outlet pipe assembly
4-4
Cooling System Layout
4
3
DS570010
1 Expansion tank assembly

2 Engine exhaust pipe assembly
3 Transmission oil cooler pipe assembly
4 Engine cooling module assembly
5 Intercooler assembly
4-5
Overheated Engine Coolant insufficient Refill coolant
Radiator pressure cover failure Replace
Engine overload Reduce engine load for operation
Too much dust on the radiator Wash
Cooling fan shroud damaged or Repair or replace

separated from the fan
Fan drive belt damaged or loose Repair or replace
Water pump failure Replace
Air or gas mixed in the cooling system For partial leakage, add sealant or
sealing parts to block the leaking
position; for severe leakage, replace
the cylinder block
Coolant temperature sensor or Replace

thermometer damaged
Thermostat failure Replace
Low Engine Coolant Temperature Too much cold air flowing through the Replace the fan clutch
radiator
Radiator shutter stuck at the maximum Replace

opening
Temperature sensor failure Replace
Thermometer failure Replace
Thermostat damaged Replace
4-6
Repair Guidance Replacement of Water Pump

Removal
Thermostat Replacement
Removal
2 Remove the V-belt.
3 Remove the bolt (1) of the water pump pulley, and
2 Disconnect the connector of the coolant remove the pulley.
temperature sensor.
3 Remove 3 bolts fixing the water outlet pipe to the
thermostat housing.
2
1
1
DS570010
4 Remove the bolt (2) of the water pump, and

GS030003 remove the water pump assembly.
Installation
4 Remove the thermostat assembly.
Installation
2 Tightening torque: to be determined
1 Replace the thermostat, and ensure the seal ring
of the thermostat is properly installed. Water pump pulley bolts: 9-11N.m.
2 Installation is the reverse of removal. Water pump assembly bolts: 9-11N.m.

3 Tighten to the specified torque, refill coolant:
3 Refill coolant.
Thermostat outlet pipe bolts: 9-11N.m.
4 Connect the connector of the coolant temperature

sensor.
4-7
Coolant Drain Radiator Replacement
1 Open the engine hood. Removal
2 Open the expansion tank cover. 1 Drain the coolant first (refer to Coolant Drain).
3 Put a container under the radiator to collect water. 2 Disconnect the radiator from the condenser (refer
to Replacement of Condenser).
4 Release the radiator drain valve.
3 Unscrew the bolts fixing the upper radiator bracket
5 Tighten the radiator drain valve after draining. onto both girders.
4 Pull out the rubber gasket under the radiator from

the radiator lower mounting bracket.
Coolant Refill
5 Disconnect the radiator from the radiator water
1 Refill coolant to the expansion tank. inlet/outlet pipe respectively.
2 Observe the level mark on the expansion tank and 6 Remove the connector of the electric fan.
maintain the coolant within the reasonable level.
7 Remove the radiator.
3 Start the engine for 1min, then observe the level
on the expansion tank. If the coolant is below the 8 Remove the electric fan.
MIN. mark, keep refilling until the coolant achieves
the reasonable level (between the MAX and MIN).
GS350014
Installation
1 Install the electric fan to the radiator.
2 Install the radiator to the bracket, and fix the
condenser to the radiator, install 2 bolts and
tighten them.
3 Connect the radiator water inlet/outlet pipe.
4 Connect the connector of the electric fan.
5 Refill coolant (refer to Coolant Refill).
4-8

Replacement of Radiator Water Inlet and
Outlet Pipes
Removal
1 Drain the coolant (refer to Coolant Drain).
2 Respectively separate the radiator water inlet pipe
(1) and outlet pipe (2) from the radiator.
GS350015

and outlet pipe from the engine. Remove the
radiator water inlet and outlet pipes.
GS350016
Installation
and outlet pipe from the engine. Remove the
radiator water inlet and outlet pipes.
2 Connect the radiator water inlet pipe (1) and outlet
pipe (2) to the radiator.
4-9
5 Pull out the rubber gasket under the intercooler

Replacement of Intercooler Assembly
assembly from the body mounting hole.
Removal
1 Lift the vehicle.
2 Remove the lower spoiler of the engine.
3 Disconnect the intercooler assembly from the

intercooler intake hose (1) and intercooler exhaust
pipe assembly (2).
GS350019
2
6 Remove the intercooler assembly.
1 Installation
1 Install the intercooler assembly.
GS350017
2 Pull out the rubber gasket under the intercooler
4 Unscrew the bolts fastening the intercooler assembly from the body mounting hole.
assembly to body.
3 Tighten the bolts fastening the intercooler
assembly to the body. Tighten the bolts fastening
the intercooler assembly to the body to the torque
of 22 ± 2N.m
4 Install the intercooler assembly to the intercooler
intake hose (1) and intercooler exhaust pipe
assembly (2) respectively.
5 Install the lower spoiler of the engine.
GS350018
4-10
3 Unscrew the bolts fixing the intercooler exhaust

Replacement of Intercooler Intake and
hose to the engine.
Exhaust Hoses
Removal
1 Disconnect the intercooler intake hose (1) and
intercooler exhaust pipe assembly (2) from the
intercooler assembly respectively.
2
GS350021
4 Disconnect the intercooler intake hose and

1 intercooler exhaust pipe assembly from the
engine. Remove the intercooler intake hose and
intercooler exhaust pipe assembly.
GS350017
2 Unscrew the bolts fixing the intercooler intake

hose to the subframe. Installation
1 Install the intercooler intake hose and intercooler
exhaust pipe assembly to the engine. Install the
intercooler intake hose and intercooler exhaust
pipe assembly.
2 Tighten the bolts fixing the intercooler exhaust
hose to the engine.
3 Tighten the bolts fixing the intercooler intake hose

to the subframe.
4 Install the intercooler intake hose (1) and

intercooler exhaust pipe assembly (2) to the
intercooler assembly.
GS350020
4-11
3 Separate the expansion tank assembly from the

Replacement of Expansion Tank Assembly
hose between engine and expansion tank.
Removal
1 Unscrew the bolts fastening the expansion tank
assembly to the body.
GS350024
4 Remove the expansion tank assembly.

GS350022
2 Separate the expansion tank assembly from the Installation

engine exhaust pipe assembly.
1 Install the expansion tank assembly.
2 Install the expansion tank assembly to the hose
between the engine and the expansion tank.
3 Install the expansion tank assembly and engine

exhaust pipe assembly.
4 Tighten the bolts fastening the expansion tank

assembly to the body.
5 Refill coolant.
GS350023
4-12
3 Separate the engine exhaust pipe assembly from

Replacement of Engine Exhaust Pipe
the engine. Remove the engine exhaust pipe
Assembly assembly.
Removal
1 Remove the clamp fixing the engine exhaust pipe
assembly to the expansion tank assembly, and
remove the engine exhaust pipe assembly.
GS350027
Installation
GS350025
1 Connect the engine exhaust pipe assembly to the
2 Remove the clamp fixing the engine exhaust pipe engine. Remove the engine exhaust pipe
assembly to the engine cooling fan assembly, and assembly.
remove the engine exhaust pipe assembly. 2 Install the clamp fixing the engine exhaust pipe
assembly to the engine cooling fan assembly, and
install the engine exhaust pipe assembly.
3 Install the clamp fixing the engine exhaust pipe

assembly to the expansion tank assembly, and
install the engine exhaust pipe assembly.
DS030026
4-13
2 Tighten the bolts fixing the hose bracket between

Replacement of Hose between Engine and
engine and expansion tank to the body.
Expansion Tank
3 Install the clamp fixing the hose between engine
Removal
and expansion tank to expansion tank assembly,
1 Drain the coolant. and install the hose between engine and
2 Remove the clamp fixing the hose between engine expansion tank.
and expansion tank to expansion tank assembly, 4 Refill coolant.
and pull out the hose between engine and
expansion tank.
GS350028
3 Unscrew the bolts fixing the hose bracket between

engine and expansion tank to the body.
GS350029
4 Separate the hose between engine and expansion

tank from the engine. Remove the hose between
engine and expansion tank.
Installation
1 Connect the hose between engine and expansion
tank to the engine. Install the hose between
engine and expansion tank.
4-14
Replacement of Cooling Fan Assembly Description and Operation

Removal
Overview
1 Disconnect the negative/positive battery cable.
The main task of the cooling system is to ensure engine
2 Unscrew the bolts fixing the cooling fan assembly operation at an optimum temperature, when the engine is
to the radiator. cold, the system is slowly getting cold or it warms up the
engine without any cooling.
The cooling system applies a pressurized water forced

circulation cooling system which consists of the cooling
water jacket, radiator, expansion tank, water pump,
auxiliary water pump, thermostat, thermostat housing,
cooling fan, water pipe (including turbocharger cooler
water pipe), drive belt, etc.
Coolant heated in the water jacket is delivered to the

radiator by the water pump, and when passing through the
radiator, it is cooled by the cooling fan and the airflow from
GS350030 driving. The cooled coolant is then sent back to the engine
by the water pump. The above circulation allows the
3 Pull out the cooling fan assembly from the radiator engine to work at an appropriate temperature.
slot.
The cooling system also provides heat for the vehicle.
4 Pull out the harness connector from the cooling
fan assembly. Small Circulation
5 Remove the cooling fan assembly. When starting off the vehicle, the coolant cannot reach the
temperature for enabling the thermostat, and it will not
warm the engine quickly by the radiator.
Installation
Large Circulation
1 Install the cooling fan assembly.
When the engine reaches a certain temperature, the
2 Install the harness connector of the cooling fan
assembly. thermostat is enabled, the coolant flows into the radiator so
that it can maintain an appropriate temperature.
3 Install the cooling fan assembly into the radiator
slot. Thermostat
4 Tighten the bolts fixing the cooling fan assembly to Change of the coolant circulation path is made based on
the radiator. the coolant temperature. Maintain an appropriate coolant
5 Connect the battery positive/negative. temperature.
Water Pump
The water pump driven by the drive belt helps the engine
coolant to circulate.
Auxiliary Water Pump

The auxiliary water pump driven by power helps the
turbocharger coolant to circulate.
4-15
4-16
Engine Electrical System
Specification
Bolt - alternator 47.5 ± 2.5

Nut - battery harness alternator positive 12.5 ± 2.5
Bolt - starter 50 ± 5
Nut - battery harness starter positive 12.5 ± 2.5
Nut - starter terminal 5±1
Bolt/screw - battery lock block 22 ± 2
Bolt/screw - battery tray 22 ± 2
Bolt - battery fixed support 20 ± 2
5-1
Layout
2
DS050000
1 Starter assembly 2 Motor assembly
5-2
Hard Engine Start or Start Failure Starting circuit loose or corroded Clean and tighten circuit connectors
The preheater is operated improperly Take correct preheating steps

(when necessary)
Intake system blocked Check whether the intake system

pipeline is unobstructed
Insufficient fuel in the fuel tank Fill the tank with appropriate amount of
fuel
Starter motor and electric appliance Consult an authorized repairer for

system failure DTC query
Air mixed in the fuel system Exhaust the air
Starter motor does not operate Battery undercharged Charge or

normally replace the battery
Alternator Does Not Work or Battery connector loose or corroded Clean/tighten the battery connector
Undercharges
Engine belt slips Check/replace the belt and tension
pulley
Instrument or indicator lamp failure Check/replace the instrument or

indicator lamp
Engine wire loose or damaged Repair the wire
Alternator failure Replace the alternator
5-3
Repair Guidance
Alternator Replacement
Removal
1 Disconnect the battery negative. A
C
2 Remove the drive belt (refer to V-belt
Replacement).
3 Remove 3 bolts securing the EPAS idler support to
cylinder head, and remove the EPAS idler support.
DS050002
GS030205
4 Remove the battery harness alternator positive nut

(1) and disconnect the harness connector (2). B
DS050003
2 Tightening torque:
3 3
Bolts securing alternator to engine: 47.5 ± 2.5 N.m.
2 Tightening sequence: A-B-C.
1 Battery harness alternator positive nut: 12.5 ± 2.5 N.m.
3 Secure the EPAS idler support to the cylinder

head, install 3 bolts, tighten to 23-27N.m and
check the torque.
4
DS050001
5 Remove 2 mounting bolts (3) from the upper part

of the alternator.
6 Lift the car, and remove 1 mounting bolt (4) from
the lower part of the alternator.
7 Remove the alternator.
Installation
5-4
Starter Replacement
Removal
1 Disconnect the battery negative.
3
1
DS050004
DS050005
2 Remove the battery harness starter positive nut

(1).
3 Remove the tightening nut (2) of starter terminal
and 2 mounting bolts (3) of the starter.
4 Remove the starter.
Installation
Bolts securing starter to engine: 50 ± 5 N.m.
Starter terminal nut: 5 ± 1 N.m
Battery harness starter positive nut: 12.5 ± 2.5 N.m
5-5
Caution: Battery may produce explosive gases. Battery

contains corrosive acid. Battery supplies the electrical
Overview current high enough to cause burns. Therefore, in order to
The starting system of the vehicle includes a 12V starter reduce the risk of injury, be sure to follow the rules below
motor which drives the engine to start combustion process when operating near the battery:
and convert electrical energy to mechanical energy. The Be sure to wear protective glasses and try to avoid the
electric power system of the vehicle must be able to battery from tilting.
provide sufficient energy to ensure the starter motor can
rotate the crankshaft. Do not place the battery near open fire or sparks.
The charging system consists of the battery, alternator and Protect skin and eyes from contacting battery electrolyte. If
related electrical elements. skin or eyes contact the electrolyte, flush immediately and
take medical measures.
The alternator obtains mechanical energy from the
crankshaft during engine running and transforms it into Follow each step of the jump start procedure in order.
electric energy for operation of electrical elements and
Treat both the booster and the discharged battery with care
battery charging. A charging indicator is installed on the
when using a jumper cable.
instrument cluster. It will be illuminated when the alternator
has no output voltage or when the voltage is lower than the
battery voltage.
Starter Motor
The starter motor is located at the right rear side of the
engine, it is fixed with 2 bolts. The mechanical energy of
the pinion drives the flywheel, the transmission ratio of
them enlarges the torque so as to provide sufficient torque.
Alternator
The alternator at the left front of the engine is secured on
the support with 3 bolts. The drive pulley is connected to
the tail end of the rotor, which is driven by the drive belt of
the crankshaft. The belt tension is maintained by the
frictional restriction tension pulley. The instrument cluster is
used together with a charging indicator, this indicator will
illuminate when the output of the alternator is zero or low.
Battery
Battery provides electric energy to start the vehicle and
adjusts the imbalance between alternator output and load.
When the engine does not work or runs at a low speed, the
battery supplies power for electric appliances; when the
power of electric appliances is higher than the alternator
output power, the battery and alternator will supply power
in parallel; when the power of electric appliances is lower
than the alternator output power, the alternator will supply
power for the battery and electric appliances.
5-6
Preventative measures: Charge in a well-ventilated place.

Battery Usage and Maintenance
Smoking is prohibited to prevent sparks and open fire.
Safe Operation Sequence for connecting battery harness: Connect the
Electric energy positive cable and then the negative; Sequence for
When the positive and negative terminals of a battery is disconnecting battery harness: Disconnect the negative
short-circuited by a metal conductor (such as a metal tool, cable and then the positive.
metal wire or metal part) accidentally, that is, the battery is
Protective measures: Wear protective glasses and acid-
short-circuited externally, an electric arc will be produced,
proof clothes.
leading to terminal melting and splash of melted lead alloy.
In severe cases, a lot of heat will be produced, leading to Emergency measures: When a large amount of sulfuric
combustion. acid splashes due to the battery burst, the operator shall
flush the positions with splashed sulfuric acid with water
Preventative measures: When assembling the battery with
immediately; immediately send the operator ablated by
a metal tool or troubleshoot a battery with a metal wire,
sulfuric acid to hospital for treatment when necessary.
avoid the direct shortcircuit between the battery positive
and negative terminals.
Protective measures: Wear protective glasses and gloves.
Emergency measures: In case of a fire, immediately

disconnect the external short-circuit metal conductor with
an adjustable wrench or another tool from the battery. Do
not contact with hands. Then extinguish the fire with
extinguishing material.
Sulfuric acid
If the battery housing is broken due to drop or overcharge
of the battery, sulfuric acid may flow or splash from the
broken position.
Preventative measures: Handle with care; keep upright;

recharge the battery as per specified procedures.
Protective measures: Wear protective glasses and acid-

proof clothes.
Emergency measures: When skin contacts sulfuric acid,

immediately flush skin surface with plenty of water and
take off the contaminated clothes; when eyes contact
sulfuric acid, immediately keep flushing eyes with clean
water for at least 10min; when sulfuric acid splashes into
the oral cavity accidentally, drink plenty of water or milk
immediately. See a doctor for treatment if necessary.
Exhaust gases
During charging and discharging, a battery will exhaust the
mixture of oxygen and hydrogen from its exhaust vent. If
the concentration of hydrogen in the environment exceeds
4%, an explosion would occur when the gas mixture
contacts open fire, sparks or excessive heat.
5-7
Battery Maintenance Requirements: It is also prohibited to install a battery with leakage to a

Battery warehousing management vehicle.
Check incoming goods for damage. Battery case surface
Do not knock or twist battery terminals during installation.
or the juncture between it and positive or negative pole
shall be free of acid liquid overflow, cracks, bumps or dirts. Battery circuit connection during assembly
Sequence for connecting battery circuit: Connect the
Check the status indicator (electric eye) of the battery.
positive cable and then the negative.
Battery power indicator:
Sequence for disconnecting battery circuit: Disconnect the
Green: The battery has enough power to start the
negative cable and then the positive.
vehicle normally.
Assembling process
Black: Low battery. The battery shall be recharged.
When assembling a battery, ensure all electrical
White: The battery is scrapped and shall be replaced. accessories are turned off.
The length of forklift's fork handle had better be consistent In different assembling areas, try to close doors, engine
with the width of pallet, so as to prevent the battery hood and trunk lid to prevent unnecessary electric energy
damage. loss.
Batteries shall be placed on a flat bracket in a centralized Ensure all on-board electrical systems are turned off during
way. Batteries can be stacked if isolation plates made of a break, lunch or shift turnover or after work.
paper or foam are provided (maximum stacking layers: 4);
Check and assess vehicles for current leakage
stacking is not allowed when there is no isolation plate.
periodically.
Obey the "first in, first out" principle.
When the vehicle is off-line, check and ensure its battery
DO NOT store batteries in a hot place. It is preferably to electric eye displays green. In case of undercharge,
store batteries in a ventilated dry room at 5 ～ 40 ℃ . immediately recharge the battery.
Battery installation Repair area

When carrying the battery, do not tilt it to an angle over 40 Develop the habit of saving battery power (except for
°; vehicle adjustment or maintenance, ensure air-
conditioning, lamps, radio and ignition system are turned
After installing to a complete vehicle, the battery shall not off and doors and trunk lid are closed).
tilt by more than 3° relative to the horizontal level.
Ensure all electrical systems are turned off during a break
It is prohibited to invert or laterally place a battery. or lunch or after work.
Check the electric eye and confirm it is green before
During "overhaul", disconnect the battery circuit.
installation.
After repair, check and ensure the battery electric eye
Check whether there are screws or nuts in the pallet for
displays green.
transporting the battery, if any,clean them to prevent the
battery from suffering secondary damage. In case of low battery (the battery electric eye displays
black), analyze and judge the causes for the battery failure,
It is prohibited to install a battery with a black electric eye and recharge the battery in accordance with recharging
into a vehicle (at the time of warehousing inspection, if a procedures.
battery's electric eye is black but the production batch or
date of the battery is recent (within 3 months), this battery Battery maintenance of inventory vehicle
may be defective). For the vehicle storing for 7 days above, disconnect its
negative battery cable.
5-8
Check the status of battery electric eye once every three During vehicle sales, check and ensure the battery electric
months; eye displays green. It is prohibited to directly deliver a
vehicle powered by another vehicle's battery to the
The green electric eye indicates that the battery is normal;
customer.
The black electric eye indicates low battery and it must be
recharged.
For vehicles with battery cable connected, check the

electric eye monthly. Recharge the battery with a black
electric eye.
For vehicles warehoused for one year above, if its battery

has never been recharged as per the aforesaid
requirements, the battery must be replaced and scrapped.
Battery maintenance requirements for agents and

dealers
Remove the negative battery cables from inventory
vehicles and exhibition vehicles which have been parked
for 7 days above.
The battery shall be installed firmly; battery case surface or

the juncture between it and positive or negative pole shall
be free of acid liquid overflow, cracks, bumps or dirts.
Check the status indicator (electric eye) of the battery.

Battery power indicator:
Green: The battery has enough power to start the vehicle

normally.
Black: Low battery. The battery shall be recharged.
White: The battery is scrapped and shall be replaced.
Check the status of battery electric eye once every three

months;
The green electric eye indicates that the battery is normal;
The black electric eye indicates low battery and it must be

recharged.
Batteries of warehousing vehicles must be recharged

every 6 months.
For vehicles with battery cable connected, check the

electric eye monthly. Recharge the battery with a black
electric eye.
The battery of a vehicle warehoused for one year above

(i.e. the battery has never been recharged) must be
replaced and scrapped.
5-9
Battery Recharging: Battery recharging:

Battery recharging
Ensure the battery terminal is clean and the charging circuit
When the vehicle is not started, prolonged use of on-board
is properly connected.
electrical appliances and other abnormal uses, electric
leakage and long-time vehicle lay-off, or vehicle alternator Connect the positive pole of the charger to the battery
charging fault may cause charging failure, low battery and positive; so does for the negative pole. Do not charge a
black electric eye, even failure of vehicle start. The battery battery through a series circuit (24V).
needs to be recharged by external power supply.
It is recommended to charge a battery with the power
Battery appearance check before recharging: supply with a constant voltage: 14.4V ± 0.2V (the
maximum limit is 16.0V. If the voltage exceeds this limit,
A battery with a cracked case or acid leakage shall not be
the fluid in battery will be electrolyzed largely, leading to
recharged. Check the causes and replace the battery.
level decline, white electric eye and battery scrap) and 1/10
A battery with broken terminals shall not be recharged. of current limiting rated capacity until the charging current
Check the causes and replace the battery. ≤ 0.5A and the electric eye turns green.
A battery with a white electric eye shall not be recharged. If charging with constant voltage cannot be realized,
Replace the battery directly. conduct constant-current charging as per the following
rules:
Before recharging, clean battery terminals and remove the
oxide coating on the surface. 1 Select the charging current which is 1/8 ～ 1/10 of
the rated capacity. At the end of charging, the
Precautions for charging: voltage shall reach but not exceed 16V (if final
voltage is less than 16V, the electric eye may still
Wear safety goggles.
be black after charging in some cases, but it will
Charge in a well ventilated environment with room not affect the use). When the charger cannot limit
the charging voltage within 16V, the voltage of
temperature.
charging battery terminals must be manually
No smoking and source of flame during charging. monitored hourly. Otherwise the battery will lose
electrolyte due to overvoltage charging, thereby
For wiring after charging, connect the positive cable first; causing service life reduction even battery failure.
for disconnection before charging, disconnect the negative 2 Relations between recharging time and battery
cable first. voltage (for reference)
Battery 12.55- 12.45- 12.35- 12.20- 12.05- 11.95- 11.80- 11.65- 11.50- 11.30- Below
Voltage 12.45V 12.35V 12.20V 12.05V 11.95V 11.80V 11.65V 11.50V 11.30V 11.00V 11.00V
Rechargin 2h 3h 4h 5h 6h 7h 8h 9h 10h 12h 14h
g Time
3 After recharging, check the color of battery electric bubbles. If it still white after shaking (showing the
eye. If the electric eye displays green, it is shown electrolyte has lost), replace the battery.
that the battery has been charged fully. If the For the battery with voltage lower than 11.0V, it may not be
electric eye displays black, check whether the
charged at the beginning of recharging. In case of low
charging wire has been connected firmly, whether
the connectors are clean and whether the battery, the proportion of sulfuric acid in the battery has
charging voltage reaches 16V. Keep the battery been close to that of pure water, thus the internal
stand still for 24h. Then measure its voltage, and resistance of the battery is very high. At this time, decrease
continue recharging by reference to the relations charging current or replace the charger with a new one
between recharging time and battery voltage. with higher power or charge the battery with another
4 If the electric eye displays white, there may be battery in parallel. As the battery is being charged, the
bubbles in it. Slightly shake the battery to remove
5-10
sulfuric acid inside the battery will increase, and the The output signal of the HAB 60 – S current sensor used
charging current will return to normal gradually. by the vehicle is the standard PWM signal of 125Hz, and
the linearity is 0.2%. If the interference inside the vehicle is
During charging, if acid is sprayed from the battery gas
much stronger, PWM signal can control this interference.
vent, immediately stop charging and conduct
troubleshooting. This series product applies the ultrasonic seal welding, so it
is waterproof and dustproof, which ensures the safe use of
During charging, when the battery temperature is higher
the engine compartment.
than 45 ℃ , stop charging, and continue with half of
charging current after the battery temperature drops to Operation
room temperature. Starter Motor
When the ignition key is in "ON" position, the engine
During recharging, check the state of electric eye hourly. If
locking device in the instrument cluster will compare the
the electric eye displays green, it is shown that the battery
code stored in the ignition key and that stored in the locking
has been charged fully, and stop charging.
device. If these codes are matched, the signal will be sent
The voltage of a battery charged just now may be higher by BCM and ECM to the starter motor relay in the engine
than 13V, which is void power. Keep the battery still for compartment fuse box. The starter motor relay supplies
several days or discharge it for several times, its void power to the starter motor solenoid. The solenoid winding
power will disappear. is powered on, allowing the pinion to engage with the
flywheel gear ring. The engaging lever will drive the pinion
It is recommended to apply grease to the terminals to
to engage with the flywheel gear ring. If the gear wheel is
prevent electric corrosion after recharging the battery and
engaged incompletely, the flexible connection will enable
passing the tests.
the solenoid to close the contact of the motor and battery
Battery Replacement power supply connection. Thus, the high current may flow
When removing a battery, make sure the alarm has been to the motor enabling the gear engagement. The pinion
disabled and the ignition switch is off. Always disconnect rotates through the one-way clutch, turning the flywheel/
the negative terminal first, then the positive terminal. starter gear ring on the drive disc. Once the engine is
started, the speed of the pinion will exceed the speed of the
When reinstalling the battery, always connect the positive
starter motor. If the ignition key is kept in the IGN position,
terminal first, then the negative terminal.
the one-way clutch will decrease its protection to the motor.
For battery replacement, refer to "Battery - Removal/ When the ignition key is released, the power to the
Installation" section. solenoid will be cut off, the switch contact is open, the
spring force will withdraw the pinion from the flywheel gear
When charging/discharging the battery with external
ring.
device or during jump start, take care not to connect the
external cable directly to the battery negative, but connect it When starting the engine, to allow the starter motor get the
maximum current, some electric load will be cut off when
to a good ground point on the body.
the ignition key is moved to the IGN position. The power
Current Sensor supply of the headlamp, heated rear window (HRW),
Models with the start/stop function are equipped with the heating, ventilation and air conditioning (HVAC) and blower
battery current sensor which is widely used for measuring motor will be switched off. When the engine start is
DC, AC and pulse current. The sensor applies open-loop complete, these loads are to be reactivated respectively so
hall effect technique, current can be measured just by as to the restrict the battery current drawing.
connecting the sensor to the negative battery cable, this
After the following delays, the electric loads will be
simplifies the procedures for installation and maintenance.
switched on again:
The sensor output is the pulse width modulation (PWM)
output signal proportional to the primary current, which is ·After HVAC blower is stopped for 1s
powered by the single 5V voltage.
5-11
·After HRW is stopped for 1.5s
If the starting time exceeds 15s, the power supply of the

starter motor will be cut off, all electric loads will be
powered on again immediately.
Alternator uses the self-excited system, where many

diodes supply part of the current generated by the
alternator for the rotors. Alternator can not supply the initial
current required for start-up of the charging procedure.
Initial current is supplied by the battery power supply
through ignition switch to activate the exciting winding to
start up the charging procedure. When the ignition switch is
turned on, the charging warning lamp can also be used to
supply the battery voltage. Use the ground of the alternator
to flash the warning lamp and supply initial current to the
alternator.
When starting the engine, the rotor is rotating in the stator,

generating the 3-phase alternating current (AC). The
generated alternating current is not suitable for the vehicle
electrical system use, which must be rectified by the
semiconductor diodes of the rectifier. The diodes only allow
the single direction current, so as to guarantee the output
current is rectified. The diodes in the rectifier also prevents
the current from flowing from the battery to alternator when
the output voltage of alternator is
lower than the battery voltage.
The regulator has a power transistor, which is grounded at

the ground side of the magnetic field, acting as a quick
switch of the magnetic field switch. Thus, it regulates the
voltage output according to the internal induced voltage, to
protect against the overcharge and the damage to the
vehicle electrical components caused by it. The output is
restricted to approximately 14.2V, and it is protected by the
over-voltage protection diodes. This voltage value allows
the alternator to change the output voltage according to the
charging condition of the battery, and charge the battery
when the battery is low, for example, operating the starter
motor, and decreasing the charging rate to zero when the
battery is fully charged, so as to avoid the overcharge.
5-12
Battery Failure Judgment

Visual Check
Check Items Causes Measures Remarks

Damag 1. Battery case damage Replace with a new
e 2. Improper installation one
Burning 1. Looseness or poor contact of terminal Replace with a new

Battery wire connectors one
2. External shortcircuit
Burst 1. Internal shortcircuit Replace with a new
case one
2. Electrolyte level low, producing sparks
inside the battery
3. Gas vent blockage
Deform 1. Overcharge Replace with a new
ation 2. Charge with an excessive current one
3. Gas vent blockage

Acid leakage 1. The plastic case is damaged due to Replace with a new
impact one
2. The battery is inverted or tilts excessively
3. Poor thermal sealing
Terminal erosion 1. External shortcircuit Repair or replace with
2. Poor contact a new one
3. Poor welding
Voltage Check
1 Visual check of electric eye state
The battery is equipped with a built-in densimeter. And there is a color display point in the top of densimeter. In case of a
battery failure or vehicle start problem due to unknown reason, visually check the state of electric eye, then you can know the
current state of charge and measures to be taken. (Note: The electric eye can only display the state of unit cell. Thus it is
necessary to make a comprehensive judgment in combination with open-circuit voltage, etc. in some cases.)
Color Green Black Bright color (white)

State of Charge More than 65% Lower than 65% Electrolyte level low
Measures Use normally Recharge the battery Replace the battery
2 Check of battery open-circuit voltage
Check Items Causes Measures Remarks

Voltage 12.5V above, the electric Normal Use normally
eye displays green
Between 12.4 and 11V, the Undercharge Recharge the battery
electric eye displays black
Around 10.5V or below 1. Overdischarge (the electric eye Recharge the battery
displays black)
2. Shortcircuit (the electric eye displays Replace with a new
green in most cases) one
3. Break circuit (the electric eye displays Replace with a new
green in most cases) one
5-13
Causes for General Battery Failures
Type Symptoms Causes Measures Remarks

Underc 1. Charging voltage is lower 1. The set value of vehicle voltage 1. Adjust the vehicle's
harge. than 12V regulator is too low electrical
2. The vehicle is hard to 2. Electrical load of the vehicle is more configuration
start and lamps are dim than the charging amount 2. Adjust the charging
3. The result of the tester is 3. Driving at idle speed or at night voltage to the range of
in the yellow or red area 4. Electrical overload 14V~14.5V (the
charging voltage for
5. The vehicle is started for multiple times
two batteries in series
and drives for a short distance or drives
shall be between
at idle speed
28V~29.0V)
6. Engine drive belt loose or circuit fault
3. Battery recharging
7. Battery terminal connectors or
harnesses are corroded
Overch 1. Battery case deforms 1. The set value of vehicle voltage 1. Adjust the charging
arge 2. Acid mist overflows from regulator is high voltage (refer to the
the case surface 2. Recharging time is long aforesaid
3. Lead powder on the plate 3. Charging voltage exceeds 16V during requirements)
is easy to fall off recharging 2. Replace the battery
4. The battery electric eye with a new one
displays white
Overdis 1. The voltage is lower than 1. Vehicle charging circuit fault 1. Adjust electric
charge 11.0V 2. Vehicle shortcircuit appliances
2. The battery electric eye 3. Electrical load is not turned off when 2. Recharge the
displays black the vehicle is not used battery
3. The surface of battery 4. Vehicle is parked with the negative 3. Replace the battery
internal plate turns white battery cable connected for a long time in severe cases
Shortcir 1. The voltage is around 1. Internal manufacture fault of the Replace the battery
cuit 10.5V and the battery battery with a new one
electric eye displays green 2. Plate growth shortcircuit caused by
2. Self-discharge capacity is excessive use, overcharge or high
great temperature during use
Break 1. Voltage is unstable Internal manufacture fault of the battery Replace the battery
circuit 2. Voltage is 0V during with a new one
discharging
3. The battery cannot be
recharged or electrolyte
rises during recharging
Revers 1. Voltage value is negative Positive and negative poles are Replace the battery
e 2. The colors of positive and connected incorrectly during discharging with a new one
chargin negative plates are opposite
g
Battery Battery slot bursts with acid The flammable oxygen-hydrogen mixed Replace the battery
bursts splashed gas inside the battery is ignited due to with a new one
sparks or excessive heat
1. Poor welding or shortcircuit inside the
battery causes sparks
2. Electrolyte level is low, producing
sparks inside the battery
3. The battery is overcharged
4. Gas vent is blocked
5-14
Engine Control System
Specification
Application Torque Value (N.m)
Bolt - ECU 9 ± 1, M6 × 20
Bolt - ECU bracket to body 18 ± 2, M8X16
Bolt - turbocharger solenoid control valve 2.5 ± 0.5
Bolt - ignition coil 7-10
Spark plug 15-20
Coolant temperature sensor 14-18
Bolt - intake camshaft position sensor 8-12
Bolt - exhaust camshaft position sensor 8-12
Oil pressure switch 14-18
Bolt - high-pressure fuel pump 9-11
Nut - low-pressure fuel pipe 18-22
Nut - High-pressure fuel pipe 28 (-2+6)N.m
Fuel rail pressure sensor 32.5 ± 2.5N.m

Bolt - crankshaft position sensor 8-12
Bolt - intake air temperature/manifold absolute pressure 7-10

sensor
Bolt - knock sensor 15-25
Bolt - fuel rail 23-27
Bolt - canister solenoid support 9-11
Bolt - electronic throttle 8-12
Nut - accelerator pedal assembly to dash panel 9±1
Spark plug
NGK NGK
Clearance: 0.7-0.8mm
Ignition coil manufacturer UAES
Primary resistance 0.453 Ω ± 12%

Secondary resistance 9.64K Ω ± 12%
Fuel injection system
Model Fuel returnless system, controlled by ECM; in-cylinder

direct injection system; ECU controls the spray form and
fuel-injection quantity by controlling the rail pressure and
fuel injection pulse width to meet the requirements of
different conditions for injection
Operating pressure of high-pressure fuel rail System pressure: 15MPa; operating pressure: 5-15MPa
6-1
Spark plug
Nozzle: 4*EV6
Static flow rate of nozzle 923.5 ± 5% g/min

Fuel rail material 06Cr19Ni10
Main filter 5 μ m, between the low pressure system and high

pressure system
Relief valve opening pressure 19.5 ± 1.4MPa

Max. allowable pressure of fuel pump during pumping 22Mpa
Operating temperature range -40 ～ 130°C

Max. allowable pressure for high-pressure fuel pipe 29Mpa
High-pressure fuel pipe ID, OD 6mm, 8mm
Rail pressure fluctuation less than 6 bar
Operating pressure range of fuel injector 5-15 MPa
Max. allowable peak pressure 20.9MPa
Crankshaft sensor model/manufacturer UAES
Camshaft sensor model/manufacturer UAES
Electronic throttle manufacturer UAES

Total rail resistance 1.25K Ω +-30%
Coolant temperature sensor manufacturer/model UAES
TMAP sensor manufacturer United Automotive Electronic Systems Co.,Ltd

Supply voltage 5V
6-2
Technical Parameters 2
Component Name Connector Status Technical Parameters (static)
Air flow sensor 2#: 5 ± 0.5V

3#: ground
1 2 3 4
Intake air temperature/ 1#: ground

pressure sensor 2#: temperature
signal output
3#: 10.8~16V
4#: pressure signal
output
1 2 3 4
Crankshaft position 1#: 4.75~16V

sensor 2#: signal output
3#: ground
3 2 1
Camshaft position 1#: ground

sensor - exhaust 2#: signal output
3#: 4.75~16V
3 2 1
Camshaft position 1#: ground

sensor - intake 2#: signal output
3#: 4.75~16V
3 2 1
6-3
Coolant temperature 1#: 5V -40 ℃ : 73.4K Ω -77.5K Ω

sensor -20 ℃ : 21.3K Ω -22.3K Ω
0 ℃ : 7.2K Ω -7.4K Ω
20 ℃ : 2.8K Ω -2.9K Ω
40 ℃ : 1182.7 Ω -1215.3 Ω
60 ℃ : 553.9 Ω -566.3 Ω
1 2 75 ℃ : 329.9 Ω -336.9K Ω
90 ℃ : 203.9 Ω -208.9 Ω
120 ℃ : 86.3 Ω -88.9 Ω
140 ℃ : 51.9 Ω -53.7 Ω
Common-rail pressure 1#: 5V
sensor 2#: signal output
3#: ground
3 2 1
Fuel control valve 1#: 9~18V 1#-2#: 0.8 Ω
1 2
Fuel injector 1#: 4~65V 1#-2#: 1.6 Ω
2 1
Electronic throttle 1# and 4#: 5V 3# 5#: 22 Ω

vacuum regulator 6#: ground
2#: 6~16V
1 2 3
6 5 4
6-4
Canister solenoid 1#: 9~16V 1#-2#: 24 Ω

2#: signal output
1 2
Knock sensor 1#: 5V 1#-2#: 5M Ω
2 1
Engine oil pressure 1#: 0~12V 1#: 0.5 Ω

sensor
1 2
VVT 1#: 10.8~16V 1#-2#: 7~9 Ω

2#: signal output
2 1
Inlet relief valve 1#: 8~16V 1#-2#: 12.8 Ω

2#: ground
2 1
6-5
Switch type water 1#: 9~16V 1#-2#: 10.5 Ω

pump
1 2
Electronic thermostat 1#: 8~16V 1#-2#: 9.5 ± 1 Ω
1 2
Accelerator pedal 1#: 5 ± 0.2V

2#: signal output
(0.275~2.2V) 电压（N）
3#: ground
4.1±0.15
4#: ground 信号１
1 2 3 4 5 6 5#: signal output 2.05±0.15
0.75±0.1
(0.65~4.25V) 0.375±0.1
信号２
6#: 5 ± 0.2V 0 50±5 mm 行程
Electronic auxiliary 1#: 9~16V

water pump
2 1
Vacuum control valve 1#: 10.8~16V 1#2#: 23 ± 1.2 Ω
2 1
6-6
Ignition coil 1#: 6~16V Primary coil: 0.45 Ω (1 ±

2#: signal output 12%)
3#: N/A Secondary coil: 9.64K Ω (1
4#: ground ± 12%)
1 2 3 4
Clutch position sensor A#:5V A#B#: 3 ± 0.6K Ω

B#: signal output
C#: ground
Pin A Pin C
Pin B
6-7
Layout
Engine Controller Layout
GS030004
1 Engine controller 2 Engine controller support assembly
6-8
Right Side of the Engine
1 2 3
DS570010
1 Crankshaft position sensor

2 Knock sensor
3 Oil pressure switch
4 Electronic throttle
6-9
Upper Part of the Engine
8
3
2
4 1
DS570010
1 Ignition coil
2 Exhaust camshaft position sensor
3 Intake camshaft position sensor
4 High-pressure fuel pump
5 Intake air temperature/manifold absolute pressure

sensor
6 Activated canister solenoid
7 Fuel rail pressure sensor
8 Engine harness
6-10
Left Side of the Engine
1
DS570010
1 Coolant temperature sensor

2 Turbocharger solenoid control valve
6-11
DS570010
1. Accelerator pedal assembly
6-12
Repair Guidance
Engine Controller Replacement

Removal
1 Open the engine hood.
2 Release the engine controller connector.
GS030204
Installation
1 Installation is the reverse of removal. Pay attention
to the following precautions:
- Tightening torque of engine controller bolts: 9 ± 1N.m
- Tightening torque of the bolts securing engine controller

GS030202
bracket to body: 9 ± 1N.m
3 Release the fixing point of expansion tank, move
the expansion tank aside and secure with the
makeup pipe not disassembled (refer to Removal
of Expansion Tank） .
4 Remove the expansion tank bracket (refer to
Removal of Expansion Tank).
GS030203
5 Remove the engine controller and its bracket

(refer to Removal of Expansion Tank).
6-13
Replacement of Turbocharger Solenoid Valve

Vacuum Pipe
Removal
Engine Hood).
2 Remove each vacuum pipe. reinforcing rib
Installation color mark
1 Connect the turbocharger solenoid control valve

with the air compressor outlet, with one end
plugged in the turbocharger solenoid control valve
port, and the other end plugged in the compressor
outlet port. GS030215
GS030207
2 Connect one end of vacuum pipe (2) C00029279

connecting turbocharger solenoid control valve
and bypass valve actuator to turbocharger
solenoid control valve port, and the other end with
bypass valve actuator port.
3 Connect one end of vacuum pipe (3) C00029280
connecting turbocharger solenoid valve with the
air compressor inlet to the turbocharger solenoid
control valve port, and the other end with the
compressor inlet port.
Caution: When installing the vacuum pipe joint, the
color mark should be aligned with solenoid valve
reinforcing rib.
6-14
Replacement of Turbocharger Solenoid Ignition Coil Replacement

Control Valve Removal:
Removal
1 Disconnect the battery negative. Engine Hood).
2 Remove the engine hood (refer to Replacement of 2 Disconnect the ignition coil connector (1).
Engine Hood).
3 Disconnect the solenoid valve harness from
vacuum pipe.
2 1
DS060011
3 Remove 2 bolts (2) securing the ignition coil to the

engine.
GS030207
4 Hold the rubber sleeve end of the ignition coil, and
4 Remove 2 bolts of solenoid valve. pull out the ignition coil from the spark plug (if it is
5 Remove the solenoid valve. difficult to pull out, you can rotate the ignition coil
leftward and rightward to loosen it).
Installation
5 Repeat steps 3 to 5 to remove other ignition coils.
Installation:
1 Install the ignition coils to the spark plug, install 2
Turbocharger solenoid control valve bolts: 2.5-3.5N.m. retaining bolts, tighten to 10N.m, and check the
torque.
Caution: When installing the vacuum pipe joint, the
Caution: Make sure the spark plug is inserted in
color mark should be aligned with solenoid valve
the ignition coil.
reinforcing rib.
2 Connect the ignition coil connector.
3 Repeat steps 1 to 2 to install other ignition coils.
reinforcing rib
color mark
GS030215
6-15
Spark Plug Replacement Replacement of Engine Coolant Temperature

Removal: Sensor
Removal:
1 Remove the ignition coil (refer to Ignition Coil
Replacement). 1 Disconnect the connector of the coolant
2 Clean the area around the spark plug. Remove the temperature sensor.
dust around the spark plug with high pressure gas. 2 Place a proper container to collect the spilled
3 Remove 4 spark plugs with the spark plug socket. coolant.
3 Remove the engine coolant temperature sensor
and discard the seal ring.
DS060012
Installation: GS030005
1 Install new spark plug, tighten to 20N.m, and Installation:

check the torque.
1 Clean the thread of the coolant temperature
2 Install the ignition coil (refer to Ignition Coil
sensor.
Replacement).
2 Install new sealing washer to the coolant
temperature sensor.
3 Install the engine coolant temperature sensor,
tighten to 15-17N.m, and check the torque.
4 Connect the connector of the engine coolant
temperature sensor.
5 Check the engine coolant level, refill when
necessary.
6-16
Replacement of Intake Camshaft Position Replacement of Exhaust Camshaft Position

Sensor Sensor
Removal: Removal:
1 Remove the engine hood (refer to Replacement of 1 Remove the engine hood (refer to Replacement of
Engine Hood). Engine Hood).
2 Disconnect connector 1 from the intake camshaft 2 Disconnect connector 1 from the exhaust
position sensor. camshaft position sensor.
DS060003 DS060004
3 Remove 1 bolt (2) securing the intake camshaft 3 Remove 1 bolt (2) securing the exhaust camshaft
position sensor (CMP) to the cylinder block, and position sensor to the cylinder block, and remove
remove the intake camshaft position sensor. the exhaust camshaft position sensor.
Installation: Installation:
1 Clean the junction surface of the intake camshaft 1 Clean the junction surface of the exhaust camshaft
position sensor and cylinder block. position sensor and cylinder block.
2 Secure the intake camshaft position sensor to the 2 Secure the exhaust camshaft position sensor to
cylinder block, install 1 bolt, tighten to 8-12N.m, the cylinder block, install 1 bolt, tighten to 8-
and check the torque. 12N.m, and check the torque.
3 Connect the connectors of intake camshaft 3 Connect the connectors of exhaust camshaft
position sensor. position sensor.
6-17
Replacement of Oil Pressure Switch 4 Connect the oil pressure switch connector.
Removal: 5 Remove the oil sink.
1 Disconnect the connector of the oil pressure 6 Check the engine oil level, refill when necessary.
switch.
DS060007
2 Place the oil sink under the switch to collect the

spilled oil.
3 Remove the oil pressure switch, and discard the
gasket.
4 Take out the oil pressure switch strainer.
DS060014
Warning: The engine oil may be very hot, therefore,

special care shall be taken when releasing engine
oil.
Installation:
1 Clean the thread of the oil pressure switch.
2 Install the oil pressure switch strainer in the oil
pressure switch mounting hole, with the steel wire
end outward.
3 Install new sealing washer to the oil pressure
switch and tighten the switch to 14-18N.m.
6-18
Replacement of High-pressure Fuel Pump

Removal:
4
3
1
5
2
DS060006
DS060005 9 Remove the fuel pump roller strut.
1 Place cloths with strong absorptivity around the

high-pressure fuel pump to collect the spilled fuel.
Warning: Fuel steam is highly flammable, and it
may be explosive and toxic in narrow space. Fire
extinguishers must be provided nearby when
operating or draining the fuel, which can be foam,
carbon dioxide, gas or power extinguisher.
Warning: Fuel leakage is inevitable during such
operations. Ensure necessary measures have been
taken to avoid the fire and explosion.
2 Keep the engine stationary and cool down, loosen
the high-pressure fuel pipe nut (3) one or two DS060015
circles at high-pressure fuel pump end first,
release the fuel pressure and then fully release the Installation:
nut to remove it. 1 Align the locating pin of roller strut with the locating
3 Take away the cloth from the high-pressure fuel pin slot in fuel pump mounting hole of camshaft
pump and put it into a permissible container. cover and then put it down slowly.
Caution: Do not drip fuel onto the paint. 2 Make sure the drive cam of high-pressure fuel
pump is located at the bottom dead center.
4 Remove the high-pressure fuel pipe nut (4) from
the fuel rail and remove the high-pressure fuel 3 Apply engine oil to the cam, fuel pump base hole
pipe. and strut evenly.
Caution: Plug the connector disconnected to 4 Press high-pressure fuel pump into the mounting
prevent contaminants. As a disposable part, high- hole with the pressure no more that 1KN, install 2
bolts, tighten them to 9-11N.m and check the
pressure fuel pipe shall also be replaced.
torque.
5 Disconnect connector 1 of the high-pressure fuel
pump.
6 Remove the low-pressure fuel pipe nut (5) from
the high-pressure fuel pump.
7 Disconnect the fuel pipe (2).
8 Remove 2 bolts securing the high-pressure fuel
pump to the camshaft cover, and remove the high-
pressure fuel pump.
6-19
Replacement of Fuel Rail Pressure Sensor

Removal:
1 Remove the shield of the high-pressure fuel pump.
DS060016 operations. Ensure necessary measures have been
5 Connect the low-pressure fuel pipe to the high-
pressure fuel pump, tighten the nut to 18-22N.m 3 Keep the engine stationary and cool down, loosen
and check the torque. the high-pressure fuel pipe nut (3) one or two
6 Connect the connector of the high-pressure fuel circles at high-pressure fuel pump end first,
pump. release the fuel pressure and then fully release the
nut to remove it.
7 Install the high-pressure fuel pipe, tighten the nut
at fuel rail end to specified torque of 28 (-2+6)N.m
first, then tighten the nut at fuel pump end to 28 (-
2+6)N.m, and then tighten them once more in the 2
same sequence and check the torque.
1
Caution: Bundle the high-pressure fuel pump
harness branch reversely.
DS060017
4 Take away the cloth from the high-pressure fuel

pump and put it into a permissible container.
Caution: Do not drip fuel onto the paint. As a
disposable part, high-pressure fuel pipe shall also
be replaced.
DS060048
5 Disconnect the connector of the fuel rail pressure
sensor.
6 Remove the fuel rail pressure sensor.
6-20
Replacement of Crankshaft Position Sensor

Removal:
1 Disconnect the connector of the crankshaft
position sensor.
2 Remove 1 bolt securing the crankshaft position
sensor to the cylinder block, and remove the
crankshaft position sensor.
DS060018
Installation:
1 Install the fuel rail pressure sensor to the fuel rail,
2
tighten to 32.5 ± 2.5N.m and check the torque.
2 Connect the connector of the fuel rail pressure 1
sensor.
at fuel rail end to specified torque of 28 (-2+6)N.m DS060019
Installation:
2+6)N.m, and then tighten them once more in the
same sequence and check the torque. 1 Clean the junction surface of the crankshaft
4 Install the shield of the high-pressure fuel pump. position sensor and cylinder block.
Crankshaft position sensor tightening bolts: 8-12N.m.
6-21
Replacement of Intake Air Temperature/ Knock Sensor Replacement

Manifold Absolute Pressure Sensor Removal:
Removal:
1 Disconnect the knock sensor connector 1.
1 Disconnect TMAP sensor connector 1. Warning: As the exhaust system components may
have a very high temperature, DO NOT operate it
until the system is completed cooled down to
avoid burns and other personal injuries.
2
DS060020
1
2 Unscrew 2 screws (2) securing TMAP sensor to
the intake manifold and remove the sensor.
DS060021
Installation:
1 Clean the junction surface of TMAP sensor and 2 Remove 1 bolt (2) securing the knock sensor to
the intake manifold. the cylinder block, and take away the sensor.
2 Installation is the reverse of removal. Installation:
3 Tightening torque: 1 Clean the mating face of the knock sensor and the
cylinder block.
TMAP sensor tightening bolts: 1.2-1.8N.m.
Knock sensor tightening bolts: 15-25N.m.
6-22
Fuel Rail Replacement

Removal:
taken to avoid the fire and explosion. DS060023
2 Keep the engine stationary and cool down, loosen 7 Remove 7 bolts securing the fuel rail to camshaft
the high-pressure fuel pipe nut (3) one or two cover in the sequence shown.
circles at high-pressure fuel pump end first,
release the fuel pressure and then fully release the
nut to remove it.
2 6 5 1
4 7 3
DS060024
8 Remove the fuel rail assembly.

DS060022
Installation:
3 Take away the cloth from the high-pressure fuel 1 Install the fuel rail, ensure the injector will not
pump and put it into a permissible container. contact the camshaft cover, then install 7 bolts and
Caution: Do not drip fuel onto the paint. pre-tighten.
2 Tighten the bolts to 23-27N.m in the sequence
4 Remove the high-pressure fuel pipe nut (2) from
shown and check the torque.
the fuel rail and remove the high-pressure fuel
pipe.
Caution: Plug the connector disconnected to
prevent contaminants.
5 Disconnect the connectors from the injector nozzle
and high-pressure sensor, and also disconnect the
connector from oil control valve if necessary.
Caution: Plug the connector disconnected to
prevent contaminants.
6 Remove the engine harness clip from the fuel rail
bolt.
6-23
Injector Replacement
Removal:
6 1 Remove the fuel rail assembly (refer to Fuel Rail

2 3 7 Replacement)
2 Release the spring clamp securing the fuel injector
to the fuel rail, and remove the fuel injector.
3 If the fuel injector is not removed with fuel rail, then
remove it with the remover C00044502.
4 1 5
DS060026
3 Install the engine harness clip to the fuel rail bolt.

4 Connect the connectors of the injector nozzle,
high-pressure sensor and oil control valve.
at fuel rail end to specified torque of 28 (-2+6)N.m
2+6)N.m, and then tighten them once more in the
same sequence and check the torque.
DS060042
4 Remove and discard the fuel injector seal rings.

5 Install the end cap to the end of each fuel injector.
Installation:
1 Remove the end cap from each fuel injector.
2 Clean the groove of the fuel injector and fuel rail.
3 Lubricate new seal rings with oil, and install them
to each fuel injector.
4 Install the fuel injector to the fuel rail.
5 Secure the fuel injector to the fuel rail with spring
clamps.
6 Install the fuel rail assembly (refer to Replacement
of Fuel Rail)
6-24
Activated Canister Solenoid Replacement of Electronic Throttle

Removal: Removal:
1 Disconnect the connector of the activated canister 1 Disconnect the electronic throttle from the intake
solenoid. pipe.
2 Disconnect the electronic throttle connector.
3 Unscrew the bolts securing the electronic throttle,
and remove the electronic throttle and discard the
gaskets.
Installation:
1 Install new gaskets, and install the electronic
throttle to intake manifold assembly, install the
bolts and pre-tighten.
DS060034
2 Loosen the clamps, and disconnect 2 pipes

connecting to the activated canister solenoid.
3 Remove the activated canister solenoid from the
bracket.
4 Remove 1 bolt securing the bracket of the
activated canister solenoid to the intake manifold
and remove the bracket.
DS060043
2 Tighten the bolts to 8-12N.m and check the torque.

3 Connect the electronic throttle harness connector.
DS060035
Installation:
Canister solenoid bracket retaining bolts: 9-11N.m.
6-25
Engine Harness Installation

Installation
6
1 Secure the harness grounding terminal with

harness bracket simultaneously, the grounding
4
terminal shall be between the bracket and cylinder Installation state
of harness
head. terminal
2
3
6
5
1
4
Installation state
of harness
terminal GS030006
2
Note:
3
(1) Harness bracket
5
1 (2) Fuel rail retaining bolt
GS030006 (3) Ignition coil
Note: (4) Intake phase sensor
(1) Harness bracket (5) Exhaust phase sensor
(2) Fuel rail retaining bolt (6) Fuel injector
(3) Ignition coil 8 Install the harness sheet metal clamps to the fuel
rail edge and ensure it is installed in place.
(4) Intake phase sensor 9 Install the harness C-clamp to full load breathing
tube, the direction of clamp clip shall be as
(5) Exhaust phase sensor
indicated by the arrow.
(6) Fuel injector
2 Secure 3 stud staple bolts of engine harness to the

4
stud of fuel rail.
3
5
3 Plug 4 connectors of ignition coil into correct 6
position. 7
4 Plug 4 connectors of fuel injector into correct 2 1

position. 10
5 Install the connectors at the intake phase sensor

harness end to the sensor port. 8
9 12
6 Install the connectors at the exhaust phase sensor
harness end to the sensor port, the wire at
connector rear part is attached with white GS030007 11
adhesive tapes.
7 Install the clips (see A in enlarger drawing) on Note:
harness to oval mounting hole of harness bracket.
(1) Rail pressure sensor
(2) Full load breather pipe
6-26
(3) Canister solenoid 24 Install the connector of coolant temperature

sensor to the sensor, and install the sheet metal
(4) Intake VCT valve clamp to rear oxygen sensor bracket.
(5) Stud - exhaust VCT valve 25 Install the harness clip to the threaded hole in
cylinder head, and insert it to the bottom.
(6) Exhaust VCT valve 26 Install the harness clip to water pipe assembly.
(7) Exhaust gas control valve 27 Install the oil pressure switch connector to the
sensor interface, take care not to drag the wire
(8) Alternator (bundled reversely) at the tail of connector.
28 Install the knock sensor connector, throttle body
(9) Air compressor
connector and crankshaft sensor to sensor
(10) Turbocharger control valve interface.
29 Install the starter motor terminal to the starter
(11) Electronic thermostat motor stud. (Torque: 8-10N.m).
(12) Coolant temperature sensor 30 Install the TMAP connector to the sensor interface,
and install 2 sheet metal clamps on the branch.
10 Install the connector of rail pressure sensor to the
31 Connect INLINE connector with the body harness,
sensor interface.
and make sure the connector lock catch is
11 Install the connector of intake VCT valve to the installed in place.
valve interface, take care not to drag the wire
(bundled reversely) at the tail of connector.
12 Install the canister solenoid connector to the
sensor interface. 2
13 Install the round stud staple bolts of harness to
stud of exhaust VCT valve. 1
14 Install the connector of exhaust VCT valve to VCT
control valve interface.
15 Install the connector of exhause gas control valve 3
to control valve interface.
16 Install the harness staple bolts to alternator
mounting hole, and insert it in place.
17 Install the air compressor connector to GS030008
compressor interface.
Note:
18 Install the harness C-clamp to PAS pump tube,
with the opening of C-clamp outward. (1) Body INLINE connector
19 Install the connector of turbocharger control valve
to control valve interface. (2) Bracket
20 Install the high-pressure fuel pump connector to (3) ECU

the pump body interface, take care not to drag the
wire (bundled reversely) at the tail of connector. 32 Install the harness clip to the bracket hole.
21 Install the harness sheet metal clamp to auxiliary 33 Connect ECU connector with ECU, and make sure
water pump bracket, and install the connector to the connector lock catch is installed in place.
control valve interface.
22 Install the harness clamp to water pump inlet pipe.
23 Plug the connector of rear oxygen sensor in the
sensor interface, and then install to rear oxygen
sensor bracket.
6-27
Replacement of Accelerator Pedal Assembly

Special Tool
Removal
1 Unscrew 3 nuts (2) securing the accelerator pedal Tool Tool Name Illustration
assembly 1 to dash panel (3). Number
2 Disconnect the connector between accelerator C00044502 Fuel injector
pedal harness and engine compartment harness. remover
3 Remove the accelerator pedal assembly.
2
C00044502
DS060009
Installation
- Tighten the nuts securing accelerator pedal assembly to

dash panel to 9 ± 1N.m
6-28

Engine Control System Control Diagram
Lgnition Switch Injector

⛯⚡ᔶީ ௭⋯౪
Variable Camshaft Timing Valve

Crankshaft position Sensor
ਥ਎࠮䖤䖪↙ᰬ䰶
ᴨ䖪փ㖤Ֆ᝕ಞ
Canister Purge Valve

Fuel Pump ⛣㖆᧝࡬䰶
⟹⋯⌫
Fuel Pump
Oxygen Sensor ⟹⋯⌫
≝Ֆ᝕ಞ
A/C Compressor Relay

グ䈹ু㕟ᵰ㔝⭫ಞ
Coolant temperature Sensor
߭প⏨⑟ᓜՖ᝕ಞ
Cooling Fan Ralay
߭প伄᡽㔝⭫ಞ
Boost Pressure temperature Sensor
໔ুু࣑⑟ᓜՖ᝕ಞ
Throttle Body
⭫ᆆ㢸≊䰞
Acceleration Pedal module
ࣖ䙕䑅ᶵ⁗ඍ
Oxygen Sensor
≝Ֆ᝕ಞ
Throttle Position Sensor

㢸≊䰞փ㖤Ֆ᝕ಞ ECM
GW Diagnostic Interface
ਇࣞᵰ PT 㖇ީ VD 䈀ᯣ᧛ਙ
Camshaft Position Sensor
࠮䖤䖪փ㖤Ֆ᝕ಞ
᧝࡬⁗ඍ
Main Relay
ѱ㔝⭫ಞ
Brake Light Switch
࡯䖜⚥ᔶީ
Ignition Coil
⛯⚡㓵ാ
Oil Pressure Switch
ᵰ⋯ু࣑ᔶީ
Quanlity Flow Control Valve
⟹⋯⌫⍷䠅᧝࡬䰶
Knock Sensor
⠼䴽Ֆ᝕ಞ
Wastegate Control
໔ু᧝࡬䰶
Hot Film Air Mass Meter

グ≊⍷䠅䇗 Switchable Water Pump
⿱ਾಞ≪⌫
Fuel Rail Pressure Sensor

⋯䖞ু࣑Ֆ᝕ಞ Dump Valve
䘑≊⋺⍷䰶
Manifold Pressure Sensor

Eletrical Thermostat
R䘑≊ু࣑Ֆ᝕ಞ
⭫ᆆ㢸⑟ಞ
AC Pressure Sensor Starter

ACু࣑Ֆ᝕ಞ 䎭ࣞᵰ
⺢㓵䈀ᯣCAN ࣑ࣞ儎䙕CAN㓵
GS030213
6-29
TCM
GW IPK
਎䙕ಞ PT PT 㖇ީ INFO 㓺ਾԠ㺞
᧝࡬⁗ඍ
ECM
ਇࣞᵰ
᧝࡬⁗ඍ
ESP BCM
GW
⭫ᆆど䖜䓡᧝
PT PT 㖇ީ BO
ᇐ㌱㔕 ࡬⁗ඍ
࣑ࣞ儎䙕CAN㓵 ၧ҆儎䙕CAN㓵䖜䓡儎䙕CAN㓵
GS030214
6-30
throttling condition and avoid air change loss. In addition,

Engine control system is composed of engine control
this also helps to avoid thermal loss of the combustion
module, various kinds of sensors, harness assembly and
chamber wall and improve the thermodynamic efficiency.
actuators.
·High-load range
A series of sensors constantly provide information for
engine control module, so that the ECM can control the When the engine load and quantity of fuel injection rise, the
injection timing. delaminated gas mixture gets increasingly rich, this can
deteriorate the emission, especially the black smoke.
If it is replaced with a brand new engine controller
Therefore, when the engine works at a high load, the gas
assembly, engine data writing shall be conducted for
mixture in the cylinder shall be evenly distributed. The fuel
engine controller by using SAIC MAXUS diagnostic
injects into the cylinder during the intake stroke so that the
software, after that relevant operations such as DTC
fuel and air can mix evenly.
reading and anti-theft function matching must be carried
out. To precisely control the air inflow, the engine management
system is provided with the boost pressure sensor, intake
Engine Air Supply Control System
air pressure sensor and air flow meter, ECM will obtain air
The engine air supply control system mainly includes: inflow information from such sensors. After the air inflow
information is obtained, on one hand, ECM can control the
·Electronic throttle body turbocharging system through the intake bleeder valve and
·Accelerator pedal module boost control valve; on the other hand, ECM can control
the air intake and exhaust valves based on the signal from
·Boost pressure sensor the intake/exhaust camshaft position sensor for optimal
·Camshaft position sensor control on the air inflow.
·Variable camshaft timing valve Electronic Throttle
·Air flow meter The electronic throttle is composed of throttle, throttle

actuator (DC motor) and throttle position sensor, etc. ECM
·Boost pressure control solenoid valve makes commands to actuate the DC motor to influence the
opening of throttle through drive mechanism. The two
·Intake air pressure sensor
potentiometers function as position sensors which are
·Intake bleeder valve fitted in reverse phase. When the position of the throttle
The gasoline direct injection system requires a complicated changes, the two resistances vary linearly, one increases
engine management system to fully satisfy the high fuel and the other decreases. When a +5V voltage is added,
economy and high output power. In terms of gas mixture the position of the sensor will be transformed into a voltage
formation, the two basic operating modes are somewhat output which varies with the resistance. These two
different: potentiometers along with two potentiometers on the

accelerator pedal module used for monitoring the stroke of
·Low-load range the accelerator pedal form part of the whole electronic
throttle control system monitoring function, which can
In this range, the engine works in a highly delaminated and
provide the redundancy protection expected by the system
thin gas mixture so as to achieve the minimum possible
control.
fuel consumption. Injection is postponed until the ignition
timing so as to obtain a desired two layers of gas mixture in Throttle Position Sensor
the combustion chamber: The first layer of combustible
The throttle position sensor is used for providing ECM with
mixture is concentrated at the spark plug, and the outer
throttle angle information. Based on such information,
second layer is an isolation layer formed by air and residual
ECM can obtain engine load information and working
exhaust gas. So the engine can run under a larger non-
condition information (such as start-up, idle speed,
6-31
motoring, part load, full load, acceleration and camshaft phase information, namely, identify the
deceleration). Actually, the throttle sensor is an angle compression top dead center and exhaust top dead center
potentiometer characterized by linear output. The of the 1st cylinder. The camshaft position sensor is
potentiometer rotor arm and throttle are installed coaxially. composed of a hall sensor and a rotor made of steel plate.
When the throttle rotates, the potentiometer rotor arm will The hall sensor is fixed, and the rotor with a 36° arc boss
be driven to slide into a certain position and the is installed on the camshaft. The magnetic field inside the
potentiometer output a voltage signal proportional to the hall sensor will change when the boss passes it, which
throttle position. leads to change of the output signal voltage. In this way,
two top dead centers are identified.
Accelerator Pedal Module
Failure
The two potentiometers in the accelerator pedal module
act as sensors, their resistance varies with the position of CMP sensor or magnetic ring may have failures or provide
the electronic accelerator pedal, and ECM can response incorrect signals due to the following conditions:
precisely to the movement of the accelerator pedal, so it
·CMP sensor gap fails to comply with the specifications
can also monitor the motion of the accelerator pedal.
Because both potentiometers are installed in the same ·CMP sensor is contaminated by metallic debris
phase, when the position of the accelerator pedal changes,
their resistances will increase or decrease linearly. When a ·CMP sensor hall-effect semiconductor is damaged
+5V voltage is added, the pedal position will be ·CMP sensor magnetic field too weak
transformed into a voltage output which varies with the
resistance. These two potentiometers and two ·CMP sensor harness break-circuited
potentiometers on the electronic throttle used for ·CMP sensor harness short-circuited
monitoring the position of the throttle form part of the
monitoring function of the whole electronic throttle control ·CMP sensor harness high resistance
system, which can provide the redundancy protection
·Magnetic ring contaminated by metallic debris
expected by the system control.
·Poor magnetic ring precision due to mechanical damage
Temperature and Manifold Absolute Pressure (TMAP)
·Exhaust camshaft timing incorrect
The temperature and manifold absolute pressure is
installed on the pipe between the air compressor and the ·Intake camshaft timing incorrect
throttle. The pressure is measured by a piezoelectric type Variable Camshaft Timing Valve
sensor which can perform direct pressure measurement
through sensing elements. It may provide the "Load The engine control module outputs pulse width modulation
Signal" to the controller according to the measured (PWM) signal to drive the solenoid. Change in duty ratio
boosted intake manifold pressure; the controller provides a may adjust the opening of the solenoid. At low engine
5V voltage and feeds back a 0 - 5V voltage to the controller speed, the system can reduce fuel consumption and
depending on the boost pressure. The part for measuring improve the engine performance during emission process,
the intake temperature is an NTC sensor. When the especially torque characteristics. ECM receives signals
temperature rises, the resistance decreases. It also feeds from CKP sensor and CMP sensor. With these signals,
back a 0 - 5V voltage to the controller depending on the ECM will determine the valve timing by consulting the
intake air temperature. control chart. Then ECM operates the oil control valve
installed on the side of cylinder head. These solenoids
Camshaft Position (CMP) Sensor adjust the valve timing by controlling the oil to flow into the
The camshaft position sensor is applied to cooperate with phase modulator and changing the position of the phase
the rotational speed sensor in the circumstances without modulator relative to the camshaft.
the electricity distributor, so as to provide ECM with the
6-32
Manifold Absolute Pressure Sensor (MAP)

Hot Film Meter (HFM)
The manifold absolute pressure/temperature sensor is
HFM works according to the hot film principle. HFM
installed on the intake pipe. The pressure is measured by a
combines with NTC thermistor in the current voltage
piezoelectric type sensor which can perform direct
divider circuit. The internal resistance value of the
pressure measurement through sensing elements. It may
thermistor decreases with the increase of the intake air
provide the "Load Signal" to the controller according to the
temperature. NTC thermistor current forms a voltage
measured MAP. The controller provides a 5V voltage and
divider circuit, the variation of the reference voltage which
feeds back a 0 - 5V voltage to the controller depending on
controls the voltage divider circuit is transformed into a
the intake pressure.
more stable frequency signal in HFM and outputs to ECM,
and ECM calculates the air flow and corrects the quantity Intake Bleeder Valve
of fuel injection by this frequency signal.
The intake bleeder valve is mainly used to recirculate the
If HFM failure occurs, ECM will perform backup strategy. If pressurized air in the compressor in the turbocharging
HFM signal failure occurs, the following phenomena may system to the air intake pipe, so that the boost pressure
occur: rapidly decreases during engine surge and gear shift. ECM
sends ON/OFF command to allow the solenoid in the
·Hard starting
intake bleeder valve to operate. When the solenoid is
·Stop after engine startup open, compressed air can be circulated to the air intake
pipe side.
·Emission control does not work
Engine Ignition Control System
·Idle speed control does not work
The engine ignition control system includes:
·Engine performance degrades
If NTC thermistor failure occurs, one of the following ·Ignition coil 1 - 4

symptoms can be observed: ·Crankshaft position (CKP) sensor
·Black smoke caused by excessive oil supply ·Knock sensor
·Idle speed control does not work Ignition Coil
Boost Pressure Control Solenoid Valve The ignition coil converts the battery low voltage DC to high
voltage and uses the spark by spark plug discharge to
The boost pressure control solenoid valve receives the
ignite the gas mixture in the cylinder. Each ignition coil
duty ratio information sent by ECM to adjust the boost
contains a pair of coil windings around the laminated iron
pressure of the turbocharger. The greater the duty ratio is,
core, it also includes a primary resistance and secondary
the higher the boost pressure will be. When the engine
resistance. There are four ignition coils installed on the
works at medium load or small load, the boost pressure
camshaft cover. They are installed to each cylinder, and
solenoid valve controls the diaphragm type bypass valve to
connected with the harness through connectors. A spark
lead the exhaust gas from the exhaust pipe into the bypass
plug is provided under each coil.
pipeline, and the boost pressure is extremely small at the
moment; when the engine accelerates or works at high Failure
load and high speed, the boost pressure solenoid valve
The ignition coil may have failures under the following
controls the diaphragm type bypass valve to reduce the
conditions:
bypass opening of the exhaust pipe, then the exhaust gas
flows into the turbocharger and the boost pressure rises at ·Primary winding break-circuited
this stage.
·Primary winding short-circuited
·Resistance of primary winding out of tolerance
6-33
·Secondary winding break-circuited Check the operation of the fuel pump in the engine starting
process; if the fuel pump supplies fuel when the ignition is
·Secondary winding short-circuited
on but not operating, it indicates that ECM does not receive
·Secondary winding short to primary winding CKP sensor signal.
·Resistance of secondary winding out of tolerance Knock Sensor
·Coil top insulation mechanically damaged The knock sensor is used to provide electronic controller
ECM with engine knock information to carry out knock
Crankshaft Position (CKP) Sensor
control.
CKP sensor provides the engine speed information and
The knock sensor is a vibration acceleration sensor. It is
crankshaft top dead center information. It is a hall-effect
installed on the engine block. The sensitive element of the
sensor and used in conjunction with the pulse wheel. The
sensor is a piezoelectric crystal. The vibration of the engine
pulse wheel is a tooth plate, with 58 small teeth spaced at
block is transferred to the piezoelectric crystal through the
an interval of 6° on the magnetic ring and with 2 teeth mass block in the sensor. The vibration of the mass block
absent. The pulse wheel is fitted on the crankshaft, which
can produce pressure which helps the piezoelectric crystal
rotates with the crankshaft. When the tooth tips pass by
to generate voltage on both pole surfaces and transform
sensor ends, the pulse wheel made of steel magnetic
the vibration signal into voltage signal output.
materials cuts the magnetic force line of the permanent
magnets in the sensor and produces induced voltage in the Failure
coil, which will be output as the speed signal.
The knock sensor may have failures or provide incorrect
Failure signals under the following conditions:
CKP sensor or magnetic ring may have failures or provide ·Sensor break-circuited
incorrect signals due to the following conditions:
·Sensor short to ground
·CKP sensor gap fails to comply with the specifications
·Sensor circuit intermittently breaks
·CKP sensor is contaminated by dust
·Incorrect knock sensor installation
·CKP sensor hall-effect semiconductor is damaged
In case of knock sensor signal error, the following
·CKP sensor magnetic field too weak symptoms may occur:
·CKP sensor harness break-circuited ·DTC is stored
·CKP sensor harness short-circuited ·ECM cannot detect engine combustion knock
·CKP sensor harness high resistance ·ECM restores default settings
·Magnetic ring is contaminated by dust
·Poor magnetic ring precision due to erosion or Engine Fuel Supply Control System
mechanical damage
The engine fuel supply control system mainly includes:
·CKP sensor signal is distorted due to out-of-round
·Upstream oxygen sensor
flywheel or drive disk
·Downstream oxygen sensor
·CKP sensor signal is changed due to crank radial
movement ·Fuel injectors 1 - 4
In order to check whether ECM can receive signal from ·Canister valve
CKP sensor, following operations may be conducted:
6-34
·Low-pressure fuel pump relay a non-linearity measurement method for excessive air
coefficient.
·Fuel control valve
Failure
·Fuel rail pressure sensor
It may have failures or provide incorrect signals under the
The engine fuel supply control system is applied to control
following conditions:
the fuel supply of the engine under different working
conditions. ·Impact damage/mechanical impact
MED-Motronic injection system stores the fuel to the fuel ·External harness break-circuited
rail according to the specific pressure, and the fuel is
·External harness short to vehicle power or ground
injected into the combustion chamber by the
electromagnetically controlled injector. And thus it can ·Contaminated by carbon or silicon deposits
provide the following functions:
·Air mixes in exhaust system
·Free selection of injection starting point
Rear Oxygen Sensor
·Variable system pressure
The downstream oxygen sensor is a heated oxygen
Front Oxygen Sensor sensor which measures the oxygen content in the engine
exhaust and determines if the oil and air are burnt
The upstream oxygen sensor is a wide-range oxygen
completely. The electronic controller implements the
sensor which can determine the oxygen concentration of
closed-loop control aiming at excessive air coefficient λ =
the exhaust within a wide range. The data provided by the
1 according to the information to ensure that three-way
sensor shows the air/fuel ratio in the engine combustion
catalytic converters have a high conversion efficiency in
chamber. It can produce correct and continuous signal in
such three kinds of pollutants as HC, CO and NOx in the
the range from thick gas mixture to thin gas mixture.
exhaust.
The wide-range oxygen sensor is a flat-plate type double-
Its sensing element is a ceramic tube, the outside connects
unit current limiting sensor, which has a zirconia measuring
the exhaust and the inside connects the atmosphere.
unit. This unit is a combination of the Nernest concentration
When the temperature of sensing ceramic tube reaches
sensor and oxygen "pump battery" sensor (which is used
350 ℃ , it will have the property of solid electrolyte. With this
for transferring the oxyanion). Oxygen sensor must be
property, the concentration difference of oxygen can be
heated to 350 ℃ before it produces effective signals. It has
converted into potential difference which forms electric
an integrated heater to reach the required temperature
signal outputs. If the gas mixture is rich, the concentration
quickly. Since the oxygen atom can be transfered with the
difference of oxygen inside and outside the ceramic tube is
current according to the polarity, ECM controls the pump
high, the potential difference is high, a large amount of
voltage of the pump battery to pump in or pump out
oxygen ions move from inside to outside and the output
appropriate amount of oxygen to the concentration sensor
voltage is high (approximate to 900mV); if the gas mixture
so as to maintain the air/fuel ratio measured by
is thin, the concentration difference of oxygen inside and
concentration sensor to be 1. When there is excessive air
outside the ceramic tube is low, the potential difference is
in the exhaust (thin), the oxygen is pumped out and the
low, only a few of oxygen ions move from inside to outside
forward pump current is formed. The more oxygen content,
and the output voltage is low (approximate to 100mV).
the bigger the pump current; when the residual oxygen
content in the exhaust is low (rich), the pump battery Failure
pumps the oxygen in, and the pump current is reversal at
It may have failures or provide incorrect signals under the
this time. Oxygen sensor transfers a current signal,
showing the change of oxygen concentration, to ECM, and
the pump current is proportional to the oxygen ·Contaminated by leaded fuel
concentration in the exhaust, therefore, the pump current is
6-35
·Contaminated by carbon or silicon deposits Low-pressure Fuel Pump
·Impact damage/mechanical impact The electric fuel pump transfers the fuel from the fuel tank
to the engine and provides sufficient fuel pressure and rich
·External harness break-circuited
fuel.
·External harness short to 12V power supply
It is a DC motor driven vane pump, which is located in the
·External harness short to ground fuel tank and immersed in fuel. It utilizes fuel for heat
dissipation and lubrication. The battery supplies power to
·External harness high resistance the electric fuel pump via fuel pump relay, which allows the
·Heating device break-circuited electric fuel pump circuit to be switched on only when the
relay is energized, starts and the engine operates. When
·Heating device short-circuited the engine stops due to accident, the fuel pump will stop
·ECM fails to provide ground access for heating device automatically.
·Harness shielding not connected to the ground Direct Fuel Injection System
Canister Control Valve The direct fuel injection system is composed of the high-
pressure fuel pump, fuel pipe (fuel pump to fuel rail), fuel
The canister control valve is applied to control the rail assembly (including fuel rail, fuel rail pressure sensor,
regeneration air flow of the fuel evaporation control system. fuel injector) and low-pressure fuel pipe (in front of the high-
The canister in the fuel evaporation control system absorbs pressure pump). The system operating pressure is 15MPa.
fuel vapor from the fuel tank till it cannot absorb any more.
ECM controls the canister control valve to open and allows High-pressure Fuel Pump
fresh air and saturated fuel steam in the canister to form
The function of the high-pressure fuel pump is to increase
regeneration air flow, then send it to engine air inlet pipe.
the pressure of the low-pressure fuel to 15MPa, minimize
The electronic controller changes the duty cycle of the the pressure fluctuation in the fuel rail and prevent it from
pulse signal transmitted to the canister control valve coil mixing with the oil. The working process goes like this:
and controls the regeneration air flow based on different when the fuel pump plunger goes down, the fuel pump is in
working conditions of the engine. Moreover, the flow is also the fuel suction stroke, and the low-pressure fuel enters
influenced by the pressure difference on both ends. into the cavity of the fuel pump plunger; the plunger starts
to goes up after reaching the BDC, and the pressurized
Failure fuel is delivered to the high-pressure fuel rail.
The canister control valve may have failures under the Fuel Control Valve
ECM can control high-pressure fuel flow by controlling the
·Electromagnetic winding break-circuited opening or closing of the fuel control valve. For the front
half of the rising part of the high-pressure fuel pump
·Electromagnetic winding short-circuited
plunger, the fuel control valve is open, and the fuel cannot
·External harness short to 12V power supply generate pressure, so part of the fuel returns to the low-
pressure oil circuit by the fuel control valve. After the
·External harness short to ground
solenoid valve is energized, the fuel control valve starts
·External harness high resistance being closed, and completely closed after a period, and
then the plunger cavity is completely closed; the plunger
·ECM does not provide PWM signal
continues to ascend, when the pressure in the plunger
·Mechanical problems occur in the valve cavity continues to rise and exceeds the rail pressure, the
high pressure fuel is pumped into the fuel rail.
6-36
Fuel Rail Pressure Sensor Failure
The fuel rail pressure sensor is used to measure the ECT sensor may have failures or provide incorrect signals
pressure in the fuel rail. It measures the pressure based on due to the following conditions:
the piezoelectric crystal resistance value, and sends a
·Insufficient system coolant due to leakage
voltage signal to ECM.
Fuel injector
·External harness short to ground
According to the ECM commands, the injector injects fuel
within the specified time, supplies the engine with fuel and ·External harness short to 5V power supply
atomizes it. ECM energizes the injector coil to form
magnetic force. When the magnetic force is strong enough ·External harness high resistance
to overcome the resultant force of the return spring ·ECM fails to provide ground access
pressure, needle valve gravity and friction, the needle
valve begins to rise, and the fuel injection process starts. ·ECT thermistor damaged
When the fuel injection pulse ends, the pressure of return Clutch Water Pump (switch type water pump)
spring makes the needle valve close again.
The clutch water pump takes the structure of a clutch,
Failure when starting a cold engine, ECM controls the clutch
solenoid coil, the water pump pulley rotates, and the water
The fuel injector may have failures under the following
pump impeller does not turn, and the engine coolant does
conditions:
not circulate, this shortens the engine warm-up time and
·Nozzle contaminated by dust or wax (flow reduced) reduces CO2 emission and fuel consumption. Vehicles
with a turbocharger also contain an auxiliary electric water
·Nozzle offset (injection positioned incorrectly)
pump relay which can pump the cooling water into the
·Fuel filter blockage turbocharger and lower its temperature in some cases after
the engine stops.
·Winding break-circuited
Electronic Thermostat
·Winding short to ground
The electronic thermostat adjusts engine coolant
·Winding short to 12V power supply
temperature, ensures the coolant temperature can rise
·Winding resistance out of tolerance rapidly and prevents hot engine. When the engine works at
a low/medium load, increase of the engine coolant
temperature can decrease oil viscosity, mechanical friction
·External harness short to ground loss of the piston and heat transfer loss and optimize
combustion; when the engine works at a high load/speed,
·External harness short to 12V power supply decrease of the engine temperature can cool the engine
Coolant Temperature Sensor rapidly.
The coolant temperature sensor is used to provide the ECM gives PWM command to make the electronic
engine with coolant temperature information. Whereby, the thermostat work, when the paraffin and wax package in the
controller can correct the fuel injection and ignition. It is a heater core expand, the paraffin applies pressure to the
negative temperature coefficient (NTC) thermistor, its push rod. The upper side and housing of the push rod are
resistance value is reduced as the temperature rises, but fixed, so the push rod pushes the whole core to move
not a linear relationship. The thermistor is installed in a down reversely, and the interference fit between the
copper heat-conducting sleeve. copper cap and the main valve drives the main valve to
open. The opening of the electronic thermostat is
proportional to the duty cycle of the PWM signal.
6-37
4 3
5 2
6 1
GS030208
1 Wax package
2 Push rod
3 Copper cap
4 Main valve
5 Spring
6 Bracket
6-38
Engine Fuel System
Engine Fuel System
Specification
Bolt - fuel tank strap to body 40 ± 3

Bolt - front engine mount bracket to engine (x5) 60 ± 5
Bolt - engine mount to frame 60 ± 5
Nut - front engine mount to front engine mount bracket 110 ± 10
Bolt - front engine mount bracket to engine (x1) 110 ± 10
Bolt - rear mount bracket to transmission 60 ± 5
Bolt - rear engine mount to transfer case 60 ± 5
Bolt - rear mount bracket to transmission 60 ± 5
Nut - rear mount pad assembly to rear mount bracket 60 ± 5
Bolt - fuel filler pipe 9±1
Bolt - fuel tank strap to body 40 ± 3
Bolt - canister assembly 5 ± 0.5
Filter screw 2.5 ± 0.5
Nut - rear mount pad assembly and cross member 60 ± 5
Fuel filter ground nut 9±1
7-1
Engine Fuel System
Layout
Fuel Tank Exploded View
1
4
5
2 10
6
7 11 9
8
12
13
14
3
16
15
GS030185
1 Fuel tank assembly 9 Filter assembly

2 Fuel filler pipe assembly 10 Filter to fuel tank return pipe
3 Canister 11 Fuel tank to filter supply pipe
4 Loop - fuel pump assembly 12 Canister to engine desorption pipe
5 Fuel pump assembly seal ring 13 Fuel tank to canister evaporator pipe
6 Fuel pump assembly 14 Canister to engine desorption pipe Ⅰ
7 Fuel pump level sensor unit 15 Front fuel tank strap
8 Fuel pump level sensor float 16 Rear fuel tank strap
7-2
Engine Fuel System
Powertrain Exploded View
5 5
7
7 6
6
1 2
3 4
9 11 11
8
13
12
12
13
10 8 8
10 10
4WD 2WD(6MT) 2WD(6AT)
GS030186
1 Left front engine mount bracket 8 Rear engine mount

2 Right front engine mount bracket 9 Bolt - rear engine mount to transfer case
3 Left front engine mount 10 Nut - rear mount pad assembly to cross member
4 Right front engine mount 11 Nut - rear mount pad assembly to rear mount
bracket
5 Nut - front engine mount to front engine mount
bracket 12 Bolt - rear mount bracket to transmission
6 Bolt - engine mount to frame 13 Rear engine mount bracket
7 Bolt - front engine mount bracket to engine
7-3
Engine Fuel System
Symptom Check & Measures
Fuel level sensor failure Check the slide resistor disc for contamination, corrosion and
poor contact; replace the fuel sensor component.
Deformed, disabled and damaged fuel float swing arm due to

transportation and installation; replace the fuel sensor
component.
Loud fuel pump noise Check for strainer blockage; wash the strainer.
Check the fuel pump for wear, expired service life; replace
the fuel pump.
Fuel pump assembly failure Check the fuel pump for loose power cord, poor contact;
check for power continuity with a multimeter.
Check the carbon brush commutator for excessive wear,

failure; replace fuel pump assembly.
Broken negative/positive pump wire; change the negative/

positive pump wire.
Fuel pump pressure relief Check if the clamp at the connection of the fuel pump pipe is
loose or if there is any gap which causes ingress of fuel into
the fuel tank, check if the pipe connection is secure.
Fuel leak due to damaged pipe of fuel pump assembly;

replace the rubber pipe or bellows.
7-4
Engine Fuel System
Replacement of Fuel Tank Assembly

Repair Guidance
Removal
Note: Place a piece of highly absorptive cloth
1 Press the button of the fuel filler cap on driver side
around the joint of the high-pressure fuel pump
to open it. Place the vehicle on the lifting platform
low-pressure fuel pipe and underfloor fuel pipe to and lift it to a certain height.
collect the spilled fuel. Disconnect the negative
2 Remove the fuel filler cap, and release 3 bolts of
battery cable, before installing/removing any fuel
the fuel filler pipe.
system, please disconnect the connector of the
fuel pipe for 5s, then release fuel pressure and
carry out repair work.
Warning: Fuel vapor is highly flammable, and it is
explosive and toxic in narrow space. Fire
GS030187
3 Remove the front/rear strap (2)/(3), then lower the

fuel tank a little bit to access the clamp (fuel filler
pipe - fuel tank, fuel filler/exhaust pipe - fuel tank,
fuel filler pipe - canister).
4
2
3
GS030188
4 Remove the clamps (fuel filler pipe - fuel tank, fuel

filler/exhaust pipe - fuel tank, fuel filler pipe -
canister).
Recommendation: Cover the joint of the fuel filler pipe
and fuel tank with a warm towel for 3-4min before
removal.
7-5
Engine Fuel System
Replacement of Fuel Filter

1 Lift the vehicle to a proper height.
2 Release the ground nut.
3 Release fuel bolts.
4 Release fuel pipe connector.
GS030189
GS030191
Installation
- Tightening torque of fuel filter bolt: 2.5 ± 0.5N.m

GS030190 - Tightening torque of ground nut: 9 ± 1N.m
5 Disconnect the harness of the fuel pump.

Installation
1 Connect the harness of the fuel pump.
2 Install the front and rear straps of the fuel tank on
the specified position of the fuel tank, and secure
them to the body with bolts and nuts (torque: 40 ±
3N.m).
3 Connect the clamp of the connector between fuel
filler pipe and fuel tank pipe.
4 Lower the vehicle to the ground.
7-6
Engine Fuel System
Replacement of Canister Assembly Installation

Removal 1 Installation is the reverse of removal. Pay attention
1 Lift the vehicle to a proper height. to the following precautions:
- Tightening torque of canister assembly bolts: 5 ± 0.5N.m
GS030192
2 Use a proper tool to remove 2 bolts (1) of the

canister assembly under the vehicle.
GS030193
3 Disconnect the pipes between the canister

assembly and fuel filler pipe/fuel tank.
GS030194
7-7
Engine Fuel System
Replacement of Fuel Tank Filler Pipe Recommendation: Cover the joint of the fuel filler pipe
Removal and fuel tank with a warm towel for 3-4min before
removal.
1 Press the button of the fuel filler cap on driver side
to open it. Place the vehicle on the lifting platform
and lift it to a certain height.
2 Remove the fuel filler cap, and release 3 bolts of
the fuel filler pipe.
GS030190
5 Open wheel arch, remove the bolts at the

connection of the filler pipe and body.
GS030187
3 Remove the front/rear strap (2)/(3), then lower the

fuel tank a little bit to access the clamp (fuel filler
pipe - fuel tank, fuel filler/exhaust pipe - fuel tank,
fuel filler pipe - canister).
4
2
3
GS030209
Installation
1 1 Connect the harness of the fuel pump.
2 Install the front and rear straps of the fuel tank on
the specified position of the fuel tank, and secure
them to the body with bolts and nuts (torque: 40 ±
3N.m).
GS030188 3 Connect the clamp of the connector between fuel
filler pipe and fuel tank pipe.
4 Remove the clamps (fuel filler pipe - fuel tank, fuel
4 Tighten the bolts of the fuel filler pipe to 9 ± 1N.m.
filler/exhaust pipe - fuel tank, fuel filler pipe -
canister). 5 Lower the vehicle to the ground.
7-8
Engine Fuel System
Fuel System Pressure Test Caution: 1bar=100kpa=0.1Mbar

Inspection 4 Disconnect the tool from the high-pressure fuel
1 Disconnect the high-pressure fuel pump low- pump low-pressure fuel pipe, place a measuring
pressure fuel pipe from fuel supply pipe. cup under the pipe, start the engine to enable the
fuel pump, observe the fuel in the measuring cup
within 1 min, if the reading is between 1.9 and
2.4L, the fuel system is in normal state.
5 Disconnect the high-pressure fuel pump low-
pressure fuel pipe and fuel supply pipe from
C00089859.
6 Drain the remaining fuel in the tool to the
container.
7 Connect the high-pressure fuel pump low-
pressure fuel pipe and fuel supply pipe.
GS030210
2 Connect the connector of the high-pressure fuel

pump low-pressure fuel pipe and fuel supply pipe
to the quick connector of C00089859.
Caution: The connector of the high-pressure fuel
pump low-pressure fuel pipe is slightly smaller
than the quick connector of C00089859, wind
appropriate tape around the connector of the high-
pressure fuel pump low-pressure fuel pipe to allow
it to fit closely with the quick connector of
C00089859.
GS030211
3 Start the engine to allow the fuel pump to work,

observe the readings on the fuel pressure gauge
within 1 min, if the readings are in the range of 5.4-
5.5bar, the fuel system is in normal state.
Caution: If the travel of the fuel pressure gauge is
less than 5bar, replace it.
7-9
Engine Fuel System
Fuel Pump Replacement Replacement of Fuel Pump Level Sensor Float

Removal Removal
1 Remove the fuel tank assembly (refer to 1 Remove the fuel tank assembly (refer to
Replacement of Fuel Tank Assembly). Replacement of Fuel Tank Assembly).
2 Disconnect the fuel supply pipe between fuel tank 2 Disconnect the fuel supply pipe between fuel tank
and filter and the fuel return pipe between filter and filter and the fuel return pipe between filter
and fuel tank from the fuel pump. and fuel tank from the fuel pump.
GS030195 GS030195
3 Loosen the loop coil securing fuel pump with tool 3 Loosen the loop coil securing fuel pump with tool
C00045017, and remove the fuel pump. C00045017, and remove the fuel pump.
GS030212
GS030196
4 Remove the fuel pump assembly.
4 Hold the float pole with one hand, insert the flat-
bladed screwdriver in the gap between sensor
frame and float pole with the other hand,then pick
Installation out the float pole.
1 Installation is the reverse of removal, and note the
torque of the fuel pump loop coil (80 ± 5N.m).
7-10
Engine Fuel System
2 Press the float pole into slot by left and right

thumbs, try to avoid other part of the pole under
pressure to prevent it from deformation.
GS030197
5 Check whether the slot of sensor frame is broken,

if yes, replace the level sensor.
GS030200
3 The standard state of the pressed float pole is as

illustrated. Check whether the slot of sensor frame
is broken again, if yes, replace the level sensor.
GS030198
Installation
1 Insert the float pole to the slot A and slot B of the
sensor frame. GS030201
4 Rotate the float pole with hand in the full range of

stroke to confirm that the pole can rotate normally
B
and encounter no obvious resistance during the
rotation.
GS030199
7-11
Engine Fuel System
Evaporative Emission System

EVAP system prevents the fuel evaporative emission into
Fuel Pump the air. The system contains a canister filled with activated
Operation principle of the fuel pump: when enabling the carbon particles, when the vehicle is unused, it can absorb
permanent magnet motor, it drives the pump to rotate and hydrocarbon vapors. The canister is near the left rear
sucks fuel through the fuel inlet, the fuel from the electric wheel. The pipeline connects to the fuel tank (air space
fuel pump comes out from the fuel outlet before entering above the fuel) and the canister. The capacity of canister
the fuel system. pipe is limited, therefore, when the engine is running, it is
required to suck the fuel vapor into the cylinder for
The fuel pump is at the bottom of the fuel tank, the bottom purification. A pipe connects to the canister and the intake
of the fuel tank has the oil pool caused by local subsidence. manifold via the canister control valve. For ventilation,
When the fuel pump is working, it sucks fuel from the oil connect a pipe to the canister.
pool, the fuel outlet connects with the exterior fuel supply
pipe through delivery pipe and fuel tank cover.
Identification of a faulty electric fuel pump:
1 The noise of a damaged fuel pump is much louder,

you can identify a damaged fuel pump by its noise.
2 Test the armature winding resistance of the fuel
pump (generally around 10 ～ 20 Ω ), if the
resistance is high or low, the armature winding of
the electric fuel pump has a short circuit, the brush
contact is poor or the winding has a break circuit.
3 Check the fuel output of the electric fuel pump:
remove the fuel outlet pipe of the electric fuel
pump, apply voltage (above 11.5V) to the terminal
of the electric fuel pump, use a measuring cup to
collect the fuel from the fuel outlet, the pump fuel
shall be no less than 0.6L within 30s, or the pump
safety valve is faulty.
The electric fuel pump is unrepairable, a damaged one

shall be replaced.
When installing/removing the electric fuel pump,

disconnect the main power.
The owners often ask how mangy kilometers or years the

fuel pump can be used, the fuel pump actually has no
specified service life or maintenance mileage, because the
service life of the fuel pump depends on many factors such
as fuel quality, refill habit, fault condition, etc. The owner
shall pay attention to the following precautions:
1 Fuel with excessive impurities may shorten the

service life of the fuel pump, so please refill high
quality fuel. However, fuel with a higher ROZ does
not necessarily mean it is the fuel of high quality!
2 Check and maintain the fuel filter (gasoline) on a
regular basis, and wash the fuel circuit regularly.
7-12
Engine Intake/Exhaust System
Specification
Self-tapping screw - air flow sensor to air filter assembly 2.5 ± 0.5
Nut - intake pipe of air filter to body 5±1
Bolt - air filter assembly 9±1
Bolt - air filter outlet pipe bracket 40 ± 3
Oxygen sensor (front/rear) 50 ± 5
Nut - turbocharger and exhaust pipe 45 ± 5
Bolt - exhaust pipe front segment assembly bracket to engine 22 ± 2
assembly (M8*20)

assembly (M10*35)

assembly bracket
Clamp - catalytic converter assembly 9±1

Bolt - Exhaust system heat shield 9±1
Nut - catalytic converter assembly 45 ± 5
Nut - muffler assembly 45 ± 5
Bolt - front exhaust pipe bracket 45 ± 5Nm
8-1
Layout
Intake System Layout
GS030163
1 Air filter intake pipe assembly 3 Air flow sensor

2 Air filter assembly 4 Air filter outlet pipe assembly
8-2
Exhaust System Layout
4 3
GS030164
1 Front catalytic converter assembly 4 Exhaust muffler assembly

2 Rear catalytic converter assembly 5 Oxygen sensor
3 Exhaust muffler assembly 6 Oxygen sensor
8-3
Replacement of Air Filter Intake Passage

Repair Guidance
Assembly
Replacement of Air Flow Meter Removal
Removal 1 Take down the fender.
1 Unscrew 2 screws (1) from the air flow meter.
2 Remove the air flow meter from the air filter (2).
GS030166
2 Unscrew the nuts securing the air filter intake

GS030165 passage assembly.
Installation
- Tighten the screws securing air flow meter to air filter

assembly to the torque of 2.5 ± 0.5N.m.
GS030167
Installation
- Torque of the nuts securing the air filter intake pipe to the
body: 5 ± 1N.m
8-4
Replacement of Air Filter Assembly Replacement of Air Filter Outlet Pipe

Removal Assembly
Removal
1 Remove the air filter intake pipe (Refer to Removal
of Air Filter Intake Pipe). 1 Remove 2 clamps connecting to the air filter outlet
2 Loosen the clamp of air filter outlet pipe. pipe assembly (1) and air filter (2) and engine
assembly respectively, disconnect the breather
pipe (4) from the engine assembly and separate
the air filter outlet pipe assembly from the air flow
meter and engine assembly respectively.
GS030168
3 Separate the air filter and air flow meter (Refer to

Replacement of Air Flow Meter).
GS030169
4 Remove 3 bolts securing the air filter to the body.
Installation 2 Remove the air filter outlet pipe assembly from the
bracket (4).
- Tighten the bolts securing the air filter to body to the

torque of 9 ± 1N.m
GS030170
Installation
- Torque of the clamps of the air filter outlet pipe assembly:

3 ± 0.5N.m
- Torque of the bolts of the air filter outlet pipe bracket: 40±
3N.m
8-5
Replacement of Front Catalytic Converter 4 Unscrew 3 nuts (1) fixing the front catalytic
Assembly converter assembly (3) to the engine turbocharger,
Removal and discard gaskets (2).
1 Remove the turbocharger heat shield (refer to

Removal of Turbocharger Heat Shield).
GS030174
5 Release the clamps fixing the front catalytic

GS030171 converter assembly and rear catalytic converter
assembly, and discard the gasket 1.
2 Remove the front oxygen sensor.
GS030175
GS030172
6 Take down the catalytic converter assembly form
3 Unscrew 2 bolts (4) fixing the front catalytic the rubber hook of exhaust pipe.
converter assembly (3) to the engine bracket.
GS030176
GS030173
8-6
Installation Removal/Installation of Exhaust Pipe Front

Segment Assembly Bracket
to the following precautions: Removal
- Tighten the nuts fixing the catalytic converter assembly to 1 Remove the catalytic converter assembly from the
engine (refer to Removal/Installation of Catalytic
the engine turbocharger to 45 ± 5N.m
Converter Assembly).
- Tighten the bolts fixing the front catalytic converter 2 Remove 2 bolts fixing the exhaust pipe front
assembly to the engine bracket to 45 ± 5N.m segment assembly bracket to engine assembly.
- Tighten the clamps of the catalytic converter to 9 ± 1N.m
GS030177
Installation
- Tighten the bolts securing the exhaust pipe front segment
assembly bracket to engine assembly to 22 ± 2N.m（bolt
1） and 45 ± 5N.m （bolt 2）
8-7
Replacement of Rear Catalytic Converter

Assembly
Removal
1 Release the clamps fixing the front catalytic
converter assembly and rear catalytic converter
assembly, and discard gaskets.
GS030180
4 Take down the rear catalytic converter assembly

form the rubber hook.
Installation
GS030178
- Tighten the clamps of the catalytic converter to 9 ± 1N.m
2 Remove the rear oxygen sensor from the rear
catalytic converter assembly. - Tighten the nuts of the muffler assembly to 45 ± 5N.m
- Tighten the rear oxygen sensor to 50 ± 5N.m
GS030179
3 Release 2 nuts connecting the rear catalytic

converter assembly to the front muffler assembly,
and discard gaskets.
8-8
Replacement of Front Muffler Assembly Replacement of Rear Muffler Assembly

Removal Removal
1 Release the clamps fixing the front catalytic 1 Release the clamps fixing the front catalytic
converter assembly and rear catalytic converter converter assembly and rear catalytic converter
assembly, and discard gaskets. assembly, and discard gaskets.
GS030181 GS030183
2 Release 2 nuts connecting the rear catalytic 2 Release 2 nuts connecting the rear catalytic
converter assembly to the front muffler assembly, converter assembly to the front muffler assembly,
and discard gaskets. and discard gaskets.
GS030182 GS030184
3 Release 2 bolts connecting rear muffler and front 3 Release 2 bolts connecting rear muffler and front
muffler, and discard gaskets. muffler, and discard gaskets.
4 Take down the front muffler assembly form the 4 Take down the rear muffler assembly form the
rubber hook. rubber hook.
Installation Installation
1 Installation is the reverse of removal. Pay attention 1 Installation is the reverse of removal. Pay attention
to the following precautions: to the following precautions:
- Tighten the clamps of the catalytic converter to 9 ± 1N.m - Tighten the clamps of the catalytic converter to 9 ± 1N.m
- Tighten the nuts of the muffler assembly to 45 ± 5N.m - Tighten the nuts of the muffler assembly to 45 ± 5N.m
8-9
Description and Operation Catalyst converter may have the following problems during
operation:
Catalytic Converter
The catalyst converter is equipped with a catalytic "partition Problems Possible Causes
brick", which can significantly reduce the emissions of Click sounds can Improper handling
diesel engine. be heard during "Partition brick" fractured
use "Partition brick" melted
It is obvious why installing a catalyst converter is important. Entry of foreign object/
The toxic gas emitted from the exhaust system of diesel turbocharger failure
engine shall not be released into the atmosphere until its Power "Partition brick" blocked
toxicity is reduced and converted. As shown above, the consumption
catalyst converts nitrogen oxides (NOX), carbon monoxide Noise "Partition brick" fractured
(CO1) and hydrocarbons (HC) into less harmful nitrogen
High emission No conversion
(N2), carbon dioxide (CO2) and water (H2O). If the catalyst
converter fails, the vehicle will not pass any emission
There are many factors that possibly cause catalyst failure
inspection, including MOT (annual inspection).
in operation, such as:
The catalyst converter is not widely known due to its
expensive price. Its "partition brick" is mainly designed into ·Long-time misfire of engine
a ceramic honeycomb structure with platinum, palladium ·Incorrect air-fuel ratio
and other valuable metal catalytic materials coated on the
surface. It is more likely to be damaged due to misuse ·Fuel additive
compared with muffler (equipped with baffle to reduce ·Improper fuel, such as biodiesel, gasoline, etc.
exhaust noise). Catalyst converter may get failure for many
reasons ranging from improper operation to incorrect air- ·Carbon deposit -·high oil consumption - intake airflow
fuel ratio. blocked - excessive fuel supply
Due to its special design and material, the catalyst Note: The catalyst acts efficiently only at high
temperature, therefore, it will be installed close to
converter is easy to be damaged if not properly handled.
the engine to get high temperature from the heat
Please handle with care to avoid collision; dropping or
radiated by the engine.
collision will cause damage to or dislocation of the "partition
brick". Intake System
Parts and components assembly which can guide the air
or mixed gas into the engine cylinder is regarded as engine
N2 CO2 intake system.
H 2O
It consists of air flow sensor, air filter, turbocharger and
various breather pipes. Passing through the air filter, air
goes into the turbocharger via pipeline to become high-
temperature and high-pressure gas which is pressed into
the intercooler and then goes into the intake pipe via the
breather pipe. The air filter is composed of upper and
NO x
lower sealing parts, filter element, bottom and side intake
CO
HC dust shields to supply clean air for the engine.
DS080016
·Air filter: It is the device to clean particles in air. It consists
of filter element and casing. Main requirements of the air
8-10
filter refer to high filtration efficiency, low flow resistance

and continuous use for a long time without maintenance.
Exhaust System
Parts and components assembly which can guide the
combusted exhaust gas from the cylinder is regarded as
the engine exhaust system.
It consists of a series of steel parts (catalytic converter

assembly and exhaust muffler assembly). The catalyst
converter is mainly designed into a ceramic honeycomb
structure with platinum, palladium and other precious metal
catalytic materials coated on the surface. The function of it
is to convert nitrogen oxides (NOX), carbon monoxide
(CO1) and hydrocarbons (HC) into less harmful nitrogen
(N2), carbon dioxide (CO2) and water (H2O). The catalyst
acts efficiently only at high temperature, therefore, it will be
installed close to the engine to get high temperature from
the heat radiated by the engine. The exhaust muffler is
equipped with baffle and sound absorber inside, on one
hand, to decrease the power of exhaust gas by causing
friction with glass fiber, steel fiber and other damping
materials; on the other hand, to effectively reduce the
exhaust vibration and exhaust noise after several
reflections, collisions and expansions inside pipelines in
different shapes and the resonant cavity. Exhaust gas
emitted from the catalytic converter and exhaust muffler
goes into the atmosphere via the exhaust tail pipe.
·Muffler: The muffler is a device which prevents sound

transmission but allows air circulation and also an import
measure to eliminate air dynamic noise.
·Catalytic converter: It is the most important outer purifier

installed into the exhaust system. It can convert CO, HC
and NOX and other noxious gas emitted from vehicle
exhaust into harmless carbon dioxide (CO2), water (H2O)
and nitrogen (N2) through oxidation and reduction reaction.
8-11
8-12
6MT Manual Transmission
Specification
Service Standard
Items Standard Value (mm)
Main shaft bearing clearance (snap ring) 0 ~ 0.06L
Main shaft bearing clearance (gasket) 0 ~ 0.05L
Main shaft clearance (snap ring) 0 ~ 0.06L
Intermediate shaft roller bearing clearance (snap ring) 0 ~ 0.15L
Snap Ring and Gasket for Adjustment
Items Thickness (mm)
Gasket (for main shaft bearing clearance) 0.81
0.84
0.87
0.90
0.93
0.96
0.99
1.02
1.05
1.08
1.11
1.14
1.17
1.20
Snap ring (for main shaft bearing clearance) 1.49
1.52
1.55
1.58
1.61
1.64
1.67
1.70
1.73
1.76
9-1
Snap ring (for intermediate shaft roller bearing clearance) 1.39
1.46
1.53
1.60
Snap ring (for main shaft clearance) 1.47
1.50
1.53
1.56
1.59
1.62
1.65
1.68
1.71
1.74
9-2
Tightening Torque
Rear oil deflector bolt 7.8 ~ 9.8
Rear bearing seat bolt 19.6 ~ 26.5
Main shaft gear lock nut (4WD) 245.2~ 264.8
Flange lock nut (2WD) 156.9 ~ 186.3
Intermediate shaft R gear lock nut 156.9 ~ 186.3
5th&6th gear shift assembly bolt 14.7 ~ 21.6
Gear selection lever assembly bolt 19.6~ 26.5
Control component assembly bolt 26.5 ~ 33.4
Front transmission housing bolt 42.2 ~ 53.9
Front bearing seat bolt 19.6 ~ 24.5
Oil drain bolt 58.8 ~ 78.5
Oil filling bolt 58.8 ~ 78.5
Guide bolt 14.7 ~ 21.6
CSC assembly bolt 9.8 ~ 11.8
Reverse shift fork hinge bolt 53.9 ~ 67.7
Reverse indicator switch 39.2 ~ 58.8
Flange clip bolt (4WD) 19.6 ~ 26.5
Nut - transmission shift lever to body 20 ± 2

Bolt - transmission to engine 80 ± 5
Bolt - cable bracket assembly to transmission 20 ± 2
Nut - shift cable to body 9±1
Warning:
Always follow the specified torque. Violation of the specified torque will lead to breakage or looseness due to high/
low torque. Any of the above situations
can cause serious personal injury or death to the

occupants.
9-3
Lubricating Oil
Items Designated lubricant Volume
Transmission gear oil MTF SAE 75W-85 2.5 L
Transmission input shaft spline CASMOLY L9508 0.2g
Front bearing seat oil seal Lithium grease As required
Front transmission housing oil seal Lithium grease 0.2g
Control lever oil seal Lithium grease
9-4
Layout
Shift Cable Layout
GS040172
9-5
Repair Guidance 3 Remove 2 bolts and then disassemble the gear

selection lever (A).
Replacement of Manual Transmission
Removal
1 Disassemble the oil drain plug (A).
GS040154
A
Caution: Do not reuse the bolt.
GS040002 4 Remove the pin (B) and (C) and then disassemble
the gear shift lever (A).
Caution: Do not reuse the gasket.
2 Disassemble the guide bolt (A).
A
A B
C
GS040004
Caution: Pins can be removed immediately.

GS040003
Caution: Do not reuse the guide bolt.
9-6
5 Remove 3 bolts with a rubber hammer and then 8 Destroy the 2 locking points (C), remove the lock
disassemble the control components. nut (C) from the main shaft assembly, and remove
the flange (A) and O-ring (B).
B
C
GS040005
GS040008
6 Disassemble the locking busing (A).
Caution: Do not reuse the O-ring (B).
GS040006
7 Remove the oil seal (A) and linear ball bearing (B)
in sequence.
B
A
GS040007
9-7
9 Disassemble the starter (B) and 3 bolts to remove Caution: Do not reuse the oil seal.
the C.S.C (A).
12 Remove the snap ring (A) with a special plier from
the main shaft.
GS040009
GS040012
10 Release 8 bolts to remove the front bearing seat
component (A).
13 Disassemble the reverse indicator switch (A).
GS040010
GS040013
11 Remove the washer (A) and oil seal (B) from the
Caution: Do not reuse the reverse indicator switch.
front bearing seat components.
GS040011
9-8
14 Remove 2 hinge bolts (A) from the front

transmission housing.
GS040016
A Caution: Do not reuse the oil seal (A).

GS040014
Caution: Do not reuse the hinge bolt.
15 Remove 12 fastening bolts from rear transmission

housing.
16 Remove the rear transmission housing (A) with a
rubber hammer.
GS040015
17 Remove the main shaft oil seal (A) from the rear
9-9
18 Remove the magnet (A) and reverse idler gasket Caution: Take care not to drop and damage the main
(B). drive shaft component.
21 Remove the spring pin (A), reverse gear control

lever (B) and reverse gear handle (C) in
sequence.
A B
GS040017 C
A
19 Remove the reverse gear shaft shift fork (A).
GS040020
Caution: When removing the spring pin (A), gears

cannot be impacted by the spring pin (A)
22 Release 2 bolts to remove the shift assembly (A)

of the 5th/6th gears.
B
A
GS040018
Caution: Do not reuse the shift fork gasket (B). A
20 Disassemble the transmission housing (A) with a

rubber hammer.
GS040021
A 23 Remove the spring pin (A), reverse gear control

lever (B) and reverse gear handle (C) in
sequence.
GS040019
9-10
26 Remove the reverse gear needle bearing (A).

27 Remove the reverse idler (B).
A
C
A
B
GS040022
Caution: When removing the spring pin (A), gears GS040025

cannot be impacted by the spring pin (A) 28 Pull out the main shaft 6th gear (B) and reverse
gear sleeve (C) with the puller (A).
24 Destroy the 2 locking points (B), and remove the
lock nut (A) from the intermediate shaft.
C
GS040026
29 Remove the main shaft gasket (A).
GS040023
25 Use the puller (A) to pull the reverse gear (B), and
pull out the ball bearing (F), reverse gear
synchronizer hub sleeve (E), synchronizer ring (C)
and reverse gear (D). A
F
E
C
D A
GS040027
GS040024
9-11
30 Remove the reverse gear (A) of the intermediate 33 Remove the shift fork (B) and synchronizer gear
shaft. sleeve (A) of the 5th/6th gears.
GS040028 GS040031
31 Remove the 6th gear (A) of the intermediate shaft. 34 Remove 3 synchronizer sliders (A).
A
A
GS040029 GS040032
32 Remove the synchronizer ring (B) and the 6th gear 35 With the puller (A), pull out the main shaft 5th gear
needle bearing (A) of the intermediate shaft. (B), and remove the 6th gear sleeve (C) of the
intermediate shaft, hub (D) of the 5th/6th gears,
outer synchronizer ring (E)/synchronizer cone (F)/
inner synchronizer ring (G) of the 5th gear and 5th
A gear.
B
C
D
E
F
G
B
GS040030
A
GS040033
9-12
36 Remove the 6th gear needle bearing (A) of the 39 Remove the snap ring (C) between the
intermediate shaft. intermediate shaft (A) and the middle panel (B)
with a plier.
C A
GS040034
37 Remove 8 bolts with a box spanner to remove the GS040037
bearing seat (A). 40 Release 2 bolts to remove the oil deflector (A).
GS040035 GS040038
Caution: Do not reuse the bolt. 41 Disconnect the main shaft (A), intermediate shaft
(B) and middle panel (C) with a rubber hammer.
38 Remove the snap ring (C) between the
intermediate shaft (A) and the middle panel (B)
with a plier. C
A A
C
B
GS040039
GS040036
9-13
42 Remove 1st&2nd and 3rd&4th gear assemblies 45 Remove the snap ring (A) of the front ball bearing.
from the main shaft assembly
.
A
A
GS040043
GS040040 46 Remove the ball bearing (A) with the pressing
43 Disconnect the main drive shaft component (A) machine.
and main shaft component (B).
A
GS040044
GS040041 47 Remove the synchronizer ring (A) from the main
44 Remove the needle bearing (B) from the drive shaft assembly.
gear (A).
GS040045
GS040042
9-14
48 Remove the snap ring (A) of the hub sleeve 51 Remove the needle bearing (A).
assembly of the 3rd/4th gears.
GS040049
GS040046 52 Press the 2nd gear with the pressing machine,
49 Remove the synchronizer gear sleeve (A) of the then remove the 5th gear, ball bearing, 1st gear,
3rd/4th gears. needle bearing, 1st gear synchronizer assembly,
1st gear sleeve, synchronizer hub sleeve
assembly of the 1st/2nd gears, 2nd gear
A synchronizer assembly and 2nd gear.
GS040047
50 Press the 3rd gear (C) with the pressing machine,
and remove the synchronizer ring assembly (B) of
the 3rd/4th gears and 3rd gear (C) in sequence. GS040050
53 Remove the 5th gear (A).
GS040048
GS040051
9-15
54 Remove the ball bearing (A). 57 Remove the needle bearing (A).
GS040052 GS040055
58 Remove the synchronizer ring assembly (A) of the
1st gear.
55 Remove the 1st gear sleeve (A).
GS040056
GS040053
59 Remove the synchronizer gear sleeve (A) of the
56 Remove the 1st gear (A). 1st/2nd gears.
GS040054 GS040057
9-16
60 Remove 3 spring synchronizer sliders (A). 63 Remove the 2nd gear (A).
GS040058 GS040061
61 Remove the hub (A) of the 1st/2nd gears. 64 Remove the needle bearing (A).
A
A
GS040059 GS040062
62 Remove the synchronizer ring assembly (A) of the 65 Remove the snap ring (A) of the front roller
2nd gear. bearing from the intermediate shaft assembly.
GS040060 GS040063
9-17
66 Remove the front roller bearing (A) with the Installation

pressing machine.
1 Install the bushing (A) on the transmission housing
with C00089874.
Caution: Install opposite bushing assembly
components.
A
Warning: The bushing components after installation
should be without any deformation.
GS040064
67 With the gear puller (A), remove the roller bearing
(C), bearing shim and sleeve (B) of the 5th gear.
GS040067
A 2 Install the air vent hole cap on the transmission.
B
C A
GS040065
68 Remove the inner ring (A) of the roller bearing with
C00044499.
GS040068
3 Install the bushing (A) on the transmission
housing.
A 4 Install the needle bearing (B) on the transmission
housing.
Warning: The bushing component (A) installed with
C00089874 and the bearing (B) installed with
C00089872 should be without any deformation.
GS040066
9-18
7 Install the locating pin on the middle panel with

tooling.
GS040069
5 Install the bushing (A) on the middle panel with
C00089874. GS040071
6 Install the locating pin (B) on the middle panel. 8 Install the needle bearing (A) on the main shaft.
Warning:
The bushing components after installation should be

without any deformation.
The locating pin after installation should be without

any deformation.
GS040072
9 Install the 2nd gear (A).
GS040070
A
GS040073
9-19
10 Install the synchronizer ring (A) of the 2nd gear.
A C
D
GS040076
GS040074 12 Install the synchronizer hub (A) of the 1st/2nd

gears.
11 Install the synchronizer hub (A) of the 1st/2nd
gears. Warning: Install the synchronizer gear sleeve (B) with
the gear upward.
Warning:
When assembling the hub assembly, the side with 3

oil grooves (E) shall face up.
GS040077
13 Install 3 sliders (A).
GS040075
Carefully align the groove between the synchronizer
ring (B) and the hub (C). After the press operation, A
check the rotation state of the synchronizer gear ring
assembly (D).
GS040078
9-20
14 Place C00089875 on the sleeve (A) of the 1st 17 Install the 1st gear (A).
gear, and press the sleeve (A) of the 1st gear with
a pressing machine or hammer.
A A
GS040082
18 Place C00089875 on the ball bearing (A), and
GS040079 press the ball bearing (A) with a pressing machine
15 Install the needle bearing (A). or hammer.
A
A
GS040080 GS040083
16 Install the synchronizer ring assembly (A) of the 19 Invert the main shaft, and install the needle
1st gear. bearing (A) of the 3rd gear.
GS040081 GS040084
9-21
20 Install the 3rd gear (A).
E
A
GS040087
GS040085
21 Install the synchronizer ring assembly (A) of the Carefully align the groove of the synchronizer ring (D)
3rd gear. and hub (C). After the press operation, check the
rotation state of the synchronizer ring.
B
A
A
C
D
GS040086
GS040088
22 Place C00089875 (B) on the synchronizer hub (A) 23 Install the synchronizer gear sleeve (A) of the 3rd/
of the 3rd/4th gears, and press the synchronizer 4th gears.
hub (A) of the 3rd/4th gears with a pressing
Warning: Install the synchronizer gear sleeve (B) with
machine or hammer.
this surface upward.
Warning:
When assembling the hub, the surface with 3 oil

grooves (E) shall be up.
A B
GS040089
9-22
24 Install the synchronizer slider (A) of the 3rd/4th 26 Install the synchronizer ring (A).
gears on 3 positions.
GS040092
GS040090
27 Install the needle bearing (A).
25 Install the synchronizer assembly snap ring (A) of
the 3rd/4th gears [gap: 0 ~ 0.06L] A
Warning: Confirm that the snap ring is new.
GS040093
position the ball bearing (A) on the gear assembly
(B), then press it with the pressing machine or
GS040091
hammer.
Snap ring 1.47
1.50
1.53
A
1.56
1.59 B
1.62
1.65
GS040094
1.68 29 Install the snap ring (A) of the front ball bearing
1.71 [gap (mm): 0 ~ 0.06L].
1.74 Warning: Confirm that the snap ring is new.
9-23
GS040095 GS040097
32 Position the rear ball bearing (A) and rear bearing
shim, and press the sleeve of the 5th gear in place
with a pressing machine or hammer.
Snap ring 1.49
1.52
1.55
1.58 B
1.61 A
1.64
1.67
1.70
1.73 GS040098
1.76 33 Place C00089875 on the front ball bearing (A),
and press the front ball bearing (A) with a pressing
machine or hammer.
30 Assemble the main shaft components (A) and
main shaft assembly (B).
GS040099
B 34 Install the snap ring (A) of the front ball bearing
GS040096
[gap (mm): 0 ~ 0.15L].
31 Place C00089875 on the inner ring (A) of the ball
bearing, and press the inner ring (A) of the ball Warning: Confirm that the snap ring is new.
bearing into the intermediate shaft with a pressing
machine or hammer.
9-24
GS040100 GS040102
37 Install 1st&2nd and 3rd&4th gear assemblies on
the main shaft assembly.
Snap ring 1.39
1.46
A
1.53
1.60
B
35 Position the main shaft (A) on main shaft and

intermediate shaft assembly C00044497.
GS040103
38 Install the middle panel, middle panel hole (A) and
shift fork rail (B) with C00044497.
GS040101
36 Assemble the intermediate shaft (A) into an
B
assembly of main shaft/intermediate shaft with A
C00044497.
GS040104
39 Assemble the snap ring (C) between the main
shaft (A) and the middle panel (B) with a plier.
9-25
C A
B B
GS040105
40 Install the snap ring (C) between the intermediate
GS040108
shaft (A) and the middle panel (B).
43 Place C00089875 (B) on the 5th gear (A) of the
main shaft, and press the 5th gear (A) of the main
shaft with the pressing machine or hammer.
Warning: Install the 5th gear of the main shaft with the
A direction point (C) upward.
C
B
B
C
GS040106 A
41 Install the synchronizer protective plate between
the 4th gear synchronizer ring (A) of the main shaft
and the main drive gear (B) with C00044498.
Warning: Ensure the synchronizer protective plate is
properly installed, because the 4th gear may be GS040109
damaged during press operation. 44 Place C00089875 (B) on the 5th gear sleeve (A) of
the intermediate shaft, and press the 5th gear
sleeve (A) with the pressing machine or hammer.
A
B
A
B
GS040107
42 Install 8 bolts (B) with a hexagon wrench to secure GS040110
the bearing seat (A) [tightening torque: 19.6 ~
26.5 N.m]
9-26
GS040111 GS040114
46 Install the 5th gear (A) of the intermediate shaft. Carefully align the groove of the synchronizer ring (D)
and hub (C). After the press operation, check the
rotation state of the synchronizer ring.
A
C
D
GS040112
47 Install the synchronizer ring assembly (A) of the
5th gear.
GS040115
49 Install the shift fork (B) and synchronizer gear
sleeve (A) of the 5th/6th gears.
Warning: Install the synchronizer gear sleeve (C) with
A this surface upward.
C
A
GS040113 B
48 Place C00089875 (B) on the synchronize hub (A)

of the 5th/6th gears, and press the synchronize
hub (A) of the 5th/6th gears with a pressing
machine or hammer.
Warning: GS040116
Assemble the hub with 3 oil grooves (D) upward. 50 Place C00089875 (B) on the 6th gear sleeve (A) of
the intermediate shaft, and press the 6th gear
9-27
sleeve of the intermediate shaft with a pressing 53 Install the 6th gear (A) of the intermediate shaft.
machine or hammer.
Warning: When installing the gear sleeve (A), align the
6th gear sleeve (A-1) with the hole of the main shaft
A
(C).
GS040120
A-1 54 Install the main shaft gasket (A).
Warning: The raised part (B) shall be down.
C
GS040117
51 Install the 6th gear synchronizer ring (A) of the
intermediate shaft.
B
A
A
GS040121
55 Place C00089875 (B) on the 6th gear (A) of the
main shaft, and press the 6th gear (A) of the main
shaft with a pressing machine or hammer.
GS040118
Warning: Install the 6th gear of the main shaft with the
direction point (C) upward or the inner big chamfer (D)
downward.
B
C
A
A
GS040119 D
GS040122
9-28
56 Place C00089875 (B) on the reverse gear sleeve 59 Install the synchronizer ring (A) of the reverse
(A), and press the reverse gear sleeve (A) with a gear.
pressing machine or hammer.
A
B
GS040126
GS040123
60 Install the synchronizer hub (A) and synchronizer
57 Install the needle bearing (A) of the reverse gear. gear sleeve (B) of the reverse gear.
61 Install 3 sliders (C) and snap ring (D).
D
A
B
GS040124
58 Install the reverse gear (A) of the main shaft. GS040127
62 Install the synchronizer hub sleeve assembly (A)
of the reverse gear.
Warning: The inner synchronizer ring (B) shall match
A with the inner side of the hub (C).
B
A
C
GS040125
GS040128
9-29
63 Install the reverse gear (A) of the intermediate 66 Remove the synchronizer protective jacket
shaft. between the 4th gear synchronizer ring (A) of the
main shaft and the main drive shaft (B).
A
B
GS040129
GS040132
press the ball bearing (A) with a pressing machine 67 Install the reverse gear rail (B), reverse gear lug
or hammer. (C) and spring pin (A) in sequence.
Caution: Install the spring pin with hammer or chisel
Warning: Location of spring pins (A, B): the axial

clearance between the spring pin and the fork rail (C)
A
shall be within ± 15°.
±15° B
GS040130
65 Install the lock nut (A) of the intermediate shaft,
and lock 2 points at (B). [Tightening torque: 16.0 ~ C
19.0 kgf.m A
156.9 ~ 186.3 N.m]
GS040133
68 Install the reverse gear rail (B), reverse gear lug
(C) and spring pin (A) in sequence.
GS040131
9-30
Warning: Location of spring pins (A, B): the axial

Warning: Location of spring pins (A, B): the axial shall be within ± 15°.
shall be within ± 15°.
±15° A
C
A GS040136
71 Install the shift assembly of the 5th/6th gear with
GS040134 the mounting bolt (2EA). [Tightening torque: 14.7 ~
21.6 N.m]
69 Install 2 bolts to secure the oil deflector (A).
[Tightening torque: 7.8 ~ 9.8 N.m]
GS040137
GS040135 72 Apply sealant (A) onto the sealing surface of the
70 Install the locating pin of the shift fork (A) and (B)
of the 3rd/4th gears and 1st/2nd gears. Caution: The section with sealant applied is
0.8~1.0mm, and the sealant shall be continuous
[standard sealant: LOCTITE 5060]
9-31
GS040138 GS040141
76 Apply sealant (A) onto the sealing surface of the
73 Install the gear assembly (A) to the front
Caution: The section with sealant applied is
0.8~1.0mm, and the sealant shall be continuous
[standard sealant: LOCTITE 5060]
GS040139
74 Install the fork (A) of the reverse shaft.
Caution: Do not reuse the 2 fork gaskets (B). GS040142
77 Install 4WD and 2WD rear housing oil seal with
C00089878-1/C00089878-2 respectively.
Caution: If the inner lip of the oil seal assembled has
no grease, apply lithium grease of 0.2g to the inner lip
of oil seal. Do not reuse the oil seal.
B
A
GS040140 A
75 Install the magnet (A) and reverse idler gasket (B).
GS040143
9-32
78 Assemble the rear transmission housing assembly Caution: Do not reuse the reverse indicator.
(A). [Tightening torque: 39.2 ~ 58.8 N.m]
79 Tighten 12 bolts to the specified torque: 42.2 ~
53.9 N.m.
GS040146
GS040144 82 Install the snap ring (A) on the main shaft

assembly.
80 Install 2 hinge bolts (A) on the two sides of each
front housing.
Caution: Do not reuse the hinge bolt. [Tightening
torque: 53.9 ~ 67.6 N.m]
GS040147
83 Install the shim (A) and oil seal (B) on the front
bearing seat with tool C00089873.
A
GS040145
81 Install the reverse indicator switch (A).
A
GS040148
84 Temporarily assemble the front bearing seat (A).
Caution: Do not reuse the bolt. [Tightening torque:
19.6 ~ 24.5 N.m]
9-33
Snap ring 0.81

A
0.84
0.87
0.90
0.93
0.96
0.99
GS040149
1.02
85 Position the dial gauge (A) on the main shaft and
1.05
adjust to 0.
86 Pull the main shaft (B) forward to measure the 1.08
axial clearance. 1.11
1.14
1.17
1.20
B
88 If the axial clearance meets the specified value,

apply sealant (A) to the left of the front bearing
seat assembly.
Caution:
A
The mating surface with sealant shall be clean
GS040150 The section with sealant applied is 0.8~1.0mm, and the
87 If the axial clearance does not meet the standard sealant shall be continuous [standard sealant:
value (0 - 0.06L), select a suitable gasket LOCTITE 5060]
according to the table below before re-
measurement.
GS040151
89 Install 8 bolts to secure front bearing retainer (A).
9-34
91 Install the dust shield (A) on the flange with

C00089877.
GS040152 A
90 Install the bushing (B) and 3 bolts to secure the

C.S.C. (A). [Tightening torque: 9.8 ~ 11.8 N.m] GS040155
92 Install the removable flange (A) and O-ring (B).
93 Install the lock nut (C) on the main shaft assembly,
B and lock the two parts on point (D). [Tightening
torque: 156.8 ~ 186.2N.m]
B
A
C
GS040153
GS040156
94 Install the linear ball bearing (B) and oil seal (A)
with C00089879/C00089870-2 respectively.
Caution: If the inner lip of oil seal is not applied with
lubricating oil, 0.2g lithium grease shall be taken and
applied on the inner lip during installation. Do not
reuse the oil seal.
9-35
Warning:
Location of the spring pin (B)：The angle of their gaps

is 90 ± 15° to the control axis (D)
Their gaps are opposite to each other.

B A
D
B B,C
A
A
B
C
GS040157
95 Install the locking busing (A).
GS040160
98 Install the guide bolt (A). [Tightening torque: 14.7~

21.6 N.m]
GS040158 A
96 Install the control components (3ea) with mounting

bolts by a rubber hammer. [Tightening torque:
26.5~ 33.4 N.m]
GS040161
99 Install the drain plug (A). [Tightening torque: 58.8

~ 78.5 N.m]
Caution: Do not reuse the gasket (B).
GS040159
97 Install the spring pin (B) and (C) first and then
install the gear shift lever (A).
9-36
Transmission Assembly Replacement

Removal
1 Apply the hand brake, hold it in N gear and place
the ignition switch in OFF position.
2 Disconnect the negative battery cable.
3 Lift the vehicle from the lifting machine. Remove
the catalytic converter assembly (refer to Removal
of Catalytic Converter Assembly).
4 Release the drain plug to drain the transmission
A fluid, and keep the fluid in a proper container.
5 Detach the shift lever panel with a small flat-blade
GS040162 screwdriver along the edge of control panel.
100 Install the filler plug (A) by refilling gear oil.

Caution: Do not reuse the gasket (B).
GS040164
6 Remove the center console (refer to Removal/
Installation of Center Console)
A 7 Remove the transmission shift cable (refer to
Removal/Installation of Shift Cable).
GS040163
8 Disconnect the CSC bleeder connector. Remove
with the connector upward, so that brake fluid leak
can be avoided.
GS040166
9 Drain the brake fluid to a proper container.
9-37
10 Disconnect the reverse lamp harness, and remove 13 Remove 4 bolts securing the propeller shaft to the
the cable from the housing harness clip. transmission, disconnect the propeller shaft, and
move the propeller shaft properly so that it will not
interfere with the operation.
GS040167
11 Unscrew 2 bolts of the intermediate support
assembly of the propeller shaft to remove the GS040170
intermediate support assembly. 14 Support the bottom of the transmission with a
suitable bracket.
15 Remove 4 bolts connecting the rear mount bracket
to the transmission.
GS040168
12 Remove 4 bolts securing the propeller shaft to the
rear axle.
GS040171
Caution: If a 4WD transmission is used, release the
bolt of the rear mount bracket on the transfer case.
16 Remove 4 bolts connecting the transmission

mount beam and the body, and remove the
transmission mount beam.
17 Remove 11 bolts securing the transmission to the
engine.
18 Release the transmission from 2 locating pins, and
carefully put the bracket down to remove the
transmission assembly.
GS040169
Installation
9-38
- Slightly lubricate the input shaft spline. Shift Cable Replacement
- Before installing the bolt, never hang the transmission on Caution: Lift the vehicle with the lifting machine,
the input shaft. remove the lower guard plate of the transmission, and
maintain the shift lever in N gear.
- After installing the propeller shaft, refill 2.5L specified oil
through the oil filler plug aperture. Remove the oil level plug Removal
to drain the excess oil. Reinstall the plug. 1 Pull out the gasket in cable connector at
transmission end and the cotter pin.
- Connect the transmission gear cable, and check if all
gears are correct.
- The transmission mount uses self-locking nuts that allow

for one time use only, so new nut shall be used after any
removal, otherwise its tightening performance cannot be
guaranteed.
GS040173
screwdriver along the edge of control panel.
GS040174
9-39
3 Remove the transmission shift lever handle (refer 6 Remove the shift cable from the shift mechanism.
to Removal of Transmission Shift Lever Handle).
GS040175 GS040178
4 Remove the instrument panel central lower trim 7 Remove the transmission shift cable.
panel assembly (refer to Removal of Central
Lower Trim Panel Assembly).
GS040179
GS040176
5 Remove the shift cable and the sealing gasket at
car body assembly.
GS040177
9-40
Installation 3 Connect the cable connector at the shifter end,

1 Make sure the shifter assembly is in Neutral and engage the cable connector into the shifter.
position, and install the shift cable into the shift
mechanism.
Caution: The brand new shifter assembly is provided
with a N gear locating pin before delivery to make sure
the shifter is locked in N position.
GS040182
GS040180
2 The gear selection/shift swing arm of the
transmission assembly allows it to be in neutral
position (purple and orange areas in the figure).
GS040195
4 Install the shift cable to body, and it shall face
forward.
GS040181
GS040183
5 Connect the cable connector at transmission end
and install the gasket and cotter pin.
9-41
b. Press lock 1 along the arrow direction to make its end

face flush with the connector end face.
GS040184
6 Install the shift cable to transmission shift cable
support.
GS040187
c. Lift lock 2 along the arrow direction, once a "click" sound

is heard, the installation is completed.
GS040185
Caution: The shift cable skin of DYMOS transmission is
black.
7 Adjust to lock the gear selection connector

mechanism. GS040188
a. When lock 1 and 2 are confirmed unlocked (as indicated
8 Pull out the locating pin of shifter N gear.
in the figure), the cable connector can be moved freely
in axial direction.
GS040189
GS040186
9 Install the hollow plate assembly (refer to
Installation of Hollow Plate).
9-42
10 Install the gear shift control panel to the hollow Replacement of Shift Lever Handle
plate. Removal
screwdriver along the edge of control panel.
GS040190
11 Lower the lifting machine. GS040191

Check of the cable adjustments: depress the clutch pedal, 2 Slide the lock ring of shift lever handle upwards to
and place the control lever to 1st/2nd position to shift the top, then pull out the shift lever handle with
between 1st gear and 2nd gear, then check if the shift force.
operation is smooth and if the gear is correct. Similarly,
check the R gear, 5th/6th gear and 3rd/4th gear according
to above method. Smooth gear operation and correct gear
during above check indicates that the cable is adjusted in
place, otherwise it shall be re-adjusted.
GS040192
9-43
Installation
1 Install the shift lever handle into the shift lever,
then slide down the lock catch.
GS040193
2 Press the shift lever panel into the center console
panel.
GS040194
9-44
Special Tool
SN. Tool Number Tool Name Illustration Remark
Remove the
1 C00044496 Oil seal installer transmission from the
vehicle before use
Support tool for

installing the main
2 C00044497
shaft and
intermediate shaft
C00044497
Synchronizer
3 C00044498
protective plate
C00044498
4 C00044499 Shaft sleeve remover
C00044499
9-45
5 C00089876 Tool
C00089876
6 C00089875 Gear installer
C00089875
7 C00089873 Front oil seal installer
C00089873
8 C00089870-2 Shift oil seal installer
C00089870-2
9 C00089874 Bushing installer
C00089874
9-46
Needle bearing
10 C00089879
installer
C00089879
11 C00087972 Bearing installer
C00089872
Applicable for 4WD

Rear housing oil seal transmission, and
12 C00089878-1
installer can be used on
complete vehicle
C00089878-1
Applicable for 2WD

Rear housing oil seal transmission, and
13 C00089878-2 can be used on
installer
complete vehicle
C00089878-2
14 C00089862 Push rod
C00089862
9-47
15 C00089877 Dust shield installer
9-48
block to drive the operation of 1st/2nd gear synchronizer so

as to achieve the gear selection/shift function of the 1st
Overview gear. The operations of other drive gears are the same as
This vehicle is equipped with a 6-speed manual that of the 1st gear. When the shift lever is moved to
transmission. The shift lever is located at the center reverse gear position, the reverse gear wheel is engaged
console of the passenger compartment, it provides the with the reverse idler gear to change the rotation direction
driver with 7 choices for variable speed position, namely, of the output shaft.
1st gear, 2nd gear, 3rd gear, 4th gear, 5th gear, 6th gear Differential
and reverse gear. The gears of all positions are engaged Differential with traditional design secures the driven gear
by the synchronizer. The drive shaft is installed in the of final drive to differential housing with bolts, differential
differential assembly at the rear of the transmission, and it housing supports the planetary shaft, planetary gear and
is used to transmit the driving force to the wheel. The sun gear. The differential assembly is supported by
transmission housing is made of cast aluminum, and is bearings in the transmission housing.
connected to the engine block with bolts. The transmission
input shaft and output shaft are supported by bearings. The The differential allows the wheels to rotate at different
transmission clutch case is equipped with an oil filler plug, speeds when the output torques are the same. The pinion
and there is an oil drain plug at the lower rear side of the integrated with the output shaft is engaged with the final
transmission main housing, both of them are sealed with drive driven gear of the differential assembly. When the
an aluminum washer. The transmission is filled with output shaft rotates, and the wheels swivel straight forward,
lubricating oil so as to lubricate the internal components in the torque will be applied to the whole assembly, and the
a splashing manner. planetary gear does not rotate. The torque is transmitted to
the wheels through drive shaft. When the vehicle takes a
Gear Shift and Gear Selection turn, the inner wheels will pass a shorter distance at a
Gear selection is realized by manipulating the shift lever lower speed. Thus it drives the planetary gear to rotate,
installed at the center console of the passenger and the outer sun gear offers a higher speed for outer
compartment. Both cables have one end connected to the wheels.
bottom of the shift lever, and the other end connected to
the gear selection rocker arm and gear shift rocker arm Transmission Components
installed outside the transmission through the connector Drivetrain changes the speed and direction of rotation
ring assembly. In the transmission housing, the fork shaft is through the engagement between different gears of the
connected with the fork, turn an appropriate synchronizer input shaft and output shaft, thereby generating 7 drive
to shift to the drive gear or the reverse gear. gears of different speed ratio and 1 reverse gear. The gear
wheels of all other gears are constantly engaged. If the 1st
When the shift lever is moved to the 1st gear position, the gear is selected, the synchronizer gear ring is pressed by
shift lever will control the gear selection/shift rocker arm the synchronizer gear bushing so as to contact with the
through the cable. The gear selection rocker arm rotates conical ring of the corresponding gear selected. In this way,
and moves the gear selection/shift shaft through the torque the speeds of both synchronizer hub and gear are
of the cable, and the gear selection/shift taper head on the synchronized. Ensure that the taper head on the gear
gear selection/shift shaft moves along with it and locates at selection/shift sleeve can select the gear accurately and
the groove of the 1st/2nd shift fork, at this time, the gear the gears are remained in the correct work position. After
selection/shift taper head shall be completely separated being transmitted from the engine to the transmission input
from the groove of 3rd/4th taper head. One end of the shaft through the clutch, the torque is transmitted to the
interlock pin will lock 1st/2nd gear. Then the gear shift output shaft pinion and final drive driven gear and then to
rocker arm rotates the gear selection/shift shaft through the the drive shaft through the selected gear. The operation of
torque of the cable, and the gear selection/shift sleeve the 2nd, 3rd, 4th, 5th, 6th and reverse gears is the same
rotates along with the gear selection/shift shaft, one side of with that of the 1st gear. When the reverse gear is selected,
the gear selection/shift taper head turns 1st/2nd gear taper the reverse gear tooth is engaged with the output shaft
9-49
reverse gear tooth and reverse idler gear, hence, the

rotation direction of the driven shaft is changed and the
reverse gear is achieved.
9-50
6AT
6AT
Model 6L50
Hydraulic torque converter 240mm (with lock-up clutch control)
Engine input power 235 kw
Max. input torque of diesel engine 550 N.m
Max. load of transmission 650 N.m
Speed ratio Gear 1. 4.065 Gear 2. 2.371 Gear 3. 1.551

Gear 4. 1.157 Gear 5. 0.853 Gear 6. 0.674
Mode Default, sport, cruise, manual
Lubricant petro-Canada DEXRON VI
Weight 90Kg (wet weight)
Torque

Nut - transmission rocker arm 33 ± 3
Nut - transmission shift lever assembly 20 ± 2
Nut - shift cable to body 9±1
Bolt - engine to transmission 65 ± 5
Bolt - flexible plate to hydraulic torque converter 55 ± 5
Bolt - flexible plate to engine 20+60°
Bolt - oil cooler bracket 9±1
10-1
6AT
2WD 4WD
GS080001
10-2
6AT
Layout
Layout
GS080002
10-3
6AT
Layout
1
1
2
10
12
13
4
3
11
8
6
5
GS080003
1 RWD AT/4WD AT 7 Transmission oil pan gasket

2 Hydraulic torque converter assembly 8 Transmission fluid filter component
3 Electric component 9 Transmission oil pan component
4 O-ring component 10 Seal plug for transmission oil filter
5 Drain plug component for transmission fluid 11 Transmission tightening bolt
renew 12 Shift control component
6 Transmission oil pan tightening bolt 13 Transmission O-ring
Caution: Electric component = hydraulic valve

assembly + 2 gaskets + control & support gasket
+ electric plug sleeve + speed sensor + internal
mode switch + bolt
10-4
6AT
Transmission/Electric Component Diagnosis
Transmission/Electric
Component Diagnosis
Description on testing and repair Description on testing and repair
Clear DTCs and conduct

the road test for 30km
NO
Return to the vehicle DTC reoccurs?
YES
Refer to Testing
Recommendations
GS080004
10-5
6AT
Oil Leak
Oil leak
NO Is the transmission
Check for other faulty parts
fluid leaking
YES
Clear the possible leaking area with a piece of rag
Run normally for 15-20min to recover the oil temperature

Note: Do not run at high speed,
otherwise the leaking location cannot be determined
due to oil dispersion
Park at a clean place and shut down the engine
Seek for leaking locations
NO
Is the leakage can be repaired Contact us
by aftersales parts?
YES
Repair
GS080005
Caution: Do not use active detergent like brake cleaner, etc to remove the leaking fluid, this may damage
the rubber mat, gasket and shaft bushing.
10-6
6AT
Location of 2WD Seals
6
2
12
1 3
7 13
11
10
14
8
4A
4B
5 9
GS080006
1 Electric plug sleeve 8 Output shaft seal
2 Hole for pressure test 9 Oil pan gasket
3 Junction between main transmission body and front 10 Seal for torque converter installation
housing
11 Oil level plug of oil pan
4A Transmission to oil cooler
12 External control of ASM park pawl
4B Oil cooler to transmission
13 Park pawl guide shaft
5 Shift shaft seal
14 Adjuster extension
6 Breather pipe
7 Seal plug for lubricant filler hole
10-7
6AT
Location of 4WD Seals
6
14 2
12
1 3
7 13
11
10
4A
4B
5 9
GS080007
1 Electric plug sleeve 8 Output shaft seal
2 Hole for pressure test 9 Oil pan gasket
3 Junction between main transmission body and front 10 Seal for torque converter installation
housing
11 Oil level plug of oil pan
4A Transmission to oil cooler
12 External control of ASM park pawl
4B Oil cooler to transmission
13 Park pawl guide shaft
5 Shift shaft seal
14 Transfer case seal
6 Breather pipe
7 Seal plug for lubricant filler hole
10-8
6AT
Service Frequency of Maintenance

·100,000Km is recommended.
Suggestions for Towing:
Make sure the drive wheels are towed at a speed lower Characteristics of Transmission Fluid:
than 50Km/h, and the towing distance is below 50Km.
Make sure the vehicle is in N gear.
Items Specification
Type petro-Canada DEXRON VI
Total capacity ~ 10.2 L
Oil pan removal 6.5-7L
Wet weight of ~ 90 kg
transmission
GS080008
The label of the transmission is on the main transmission

body, the specific information is as follows.
Transmission label
GS080009
10-9
6AT
4 Detach the shift lever panel with a small flat-

Repair Guidance
blade screwdriver along the edge of control
Replacement of 6AT Shift Cable panel.
Caution: Lift the vehicle with the lifting machine,

remove the lower guard plate of the automatic
transmission, and maintain the shift lever in N gear.
Removal
1 Remove the shift cable.
GS080012
5 Remove the transmission shift lever handle

(refer to Removal of Transmission Shift Lever
Handle).
GS080010
2 Confirm that the shift lever and transmission

gear selector are in the N gear. Confirm that the
position of the gear selector is unchanged during
the tightening process.
3 Push out the adjuster of the shift cable laterally.
GS080013
6 Remove the instrument panel central lower trim

GS080011
Caution: Push out the adjuster of the shift cable to

adjust the length of the cable.
GS080014
10-10
6AT
7 Remove the shift cable from the shift shaft. For this process, the shift mechanism shall
mechanism. be in the N gear.
GS080015 GS080017
Installation 3 Install the shift cable and body.

1 Insert tool C00045013 into the shift arm to
secure the shift arm, for this operation, the
transmission is in the N gear.
GS080018
C00045013 Caution: The arrow of the shift cable is facing

forward.
GS080016
4 Install the shift cable into the shift cable bracket.
2 Clamp the shift cable into the slot of the shift
Push up with great effort, and a "snap" indicates
mechanism, rotate 90° to clamp the shift cable correct installation.
and connect the cable connector with the pin
GS080019
10-11
6AT
5 Adjust the latch of the shift cable to align it with

P Gear Unlock
the shaft pin axis of the rocker arm, install the
latch into the rocker arm shaft, and push the In case of flat battery or transmission computer failure,
latch, then the shift cable locks, remove the shift the vehicle cannot recognize the brake pedal signal, thus
cable installer. the P gear shall be unlocked manually. Push the car to
the safe location.
LHD models:
Use an appropriate tool to open the shift lever panel,

press and hold "P Gear Unlock Button" on the shift
mechanism with mechanical key or one hand,
meanwhile hold the shift lever handle and press the Lock
button on the handle to pull the shift lever rearward from
P gear to N gear. Replace all opened parts, and engage
into P gear after parking the car.
GS080020
6 Confirm that the shift lever corresponds to the

instrument indication displayed on the vehicle.
7 Lower the lifting machine.
GS080021
GS080022
10-12
6AT
RHD models: Removal/Installation of Shift Lever Handle

Pry off the cap on the shift lever panel (as illustrated), Removal
insert the mechanical key in, press and hold "P Gear 1 Detach the shift lever panel with a small flat-
Unlock Button" under the cap, meanwhile hold the shift blade screwdriver along the edge of control
lever handle and press the Lock button on the handle to panel.
pull the shift lever rearward from P gear to N gear.
Replace all removed parts, and engage into P gear after
parking the car.
GS080024
2 Remove the wiring harness from the shift lever

panel.
GS080023
GS080025
10-13
6AT
3 Slide the lock ring of shift lever handle upwards Installation

to the top, then pull out the shift lever handle with
force.
GS080026
GS080027
2 Insert the wiring harness into the shift lever

panel.
3 Press the shift lever panel into the center
console panel.
10-14
6AT

Removal/Installation of Transmission
assembly of the propeller shaft to remove the
Assembly intermediate support assembly.
Removal
2 Lift the vehicle on the lifting machine. Remove
the catalytic converter assembly (refer to
Removal of Catalytic Converter Assembly).
3 Release the drain plug, remove the transmission
oil pan, drain the transmission fluid and collect
the fluid in a proper container.
4 Disconnect the cable of the shift lever from the
transmission (refer to Replacement of
Transmission Cable).
5 Disconnect the connector of the transmission
harness assembly, and remove the cable. GS080030
8 Remove 4 bolts securing the propeller shaft to

the rear axle.
GS080028
6 Unscrew the bolts connecting the rear end

assembly of the transmission oil cooler pipe and GS080031
transmission, and separate the rear end
assembly of the transmission oil cooler pipe.
the transmission, disconnect the propeller shaft,
and move the propeller shaft properly so that it
will not interfere with the operation.
GS080029
GS080032
10-15
6AT
10 Support the bottom of the transmission with a 13 Remove the starter from the engine.
suitable bracket (no direct contact).
Caution: The oil pan shall not be under direct stress.
11 Remove 2 bolts connecting the rear mount

bracket to the transmission.
GS080035
14 Rotate the flange of the transmission output

shaft clockwise, remove the bolts fastening the
flexible plate to the automatic transmission
GS080033 hydraulic torque converter at the starter
mounting port, and remove 3 bolts securing the
Caution: It is a 4WD transmission as shown below, flexible plate with torque converter.
release the bolt of the rear mount bracket on the
transfer case.
GS080036
15 Remove 10 bolts securing the transmission to

GS080034 the engine.

GS080037
10-16
6AT
16 Release the transmission from 2 locating pins,

Transmission Drain and Oil Pan Removal
and ensure the torque converter is still
connected to the transmission. 1 Properly park on the lifting machine.
17 Carefully put the bracket down to remove the · Maintain the shift lever in P gear.
Caution: When removing the automatic transmission ·Place the ignition switch in OFF position.
assembly, do not drop the hydraulic torque 2 Lift the vehicle, and ensure there is an
converter. Place a proper wooden or plastic block appropriate space for removing the transmission
between the engine rear end and dash panel to oil pan.
prevent the engine from damaging the dash panel. 3 If the transmission is equipped with the guard
plate, remove and keep the bolts and gaskets.
Caution: It is strictly prohibited to remove: 1. Start/
4 Place a container under the transmission for fluid
Stop solenoid valve components; 2. Hydraulic
collection.
cylinder components
Caution: The ATF may burst out when the drain
plug is released, please ensure a container is
placed under the oil pan.
GS080039
Installation
ES050005
1 Installation is the reverse of removal. Pay
attention to the following precautions:
5 Wait the temperature of the transmission fluid to
- Clean the junction of the engine and transmission. reach the ambient temperature.
6 Slowly release and remove the drain plug of the
- Lubricate the torque converter jack.
transmission.
- After installing the propeller shaft, refill the specified oil
through the oil filler plug aperture. Remove the oil level
plug to drain the excess oil. Reinstall the plug.
- The transmission mount uses self-locking nuts that

allow for one time use only, so new nut shall be used after
any removal, otherwise its tightening performance cannot
be guaranteed.
ES050006
10-17
6AT
7 If the O-ring (gasket) is deformed, and the drain 10 Remove the oil pan and its gasket.
plug is used, replace the drain plug.
ES050010
ES050007
Caution:
8 Remove the drain plug to drain the transmission · Check the surface of the oil pan gasket for obvious
fluid until the fluid changes from line to drop. deformation or fracture.
9 Release 17 bolts of the oil pan with a normal
hexagon wrench (M10). · Seal of the oil pan gasket is achieved by deformation
under compression, it can be reused.
· Check the two protrusions on the gasket, locate the

gasket and oil pan. If the oil pan gasket is damaged, do
not reuse.
ES050008
ES050011
11 Check the oil pan gasket for fracture, bubble due

to overheating and delamination of the rubber
and underlayer metal, etc.
12 If any of above situations, even leakage occurs,
use new parts for reinstallation.
ES050009
10-18
6AT
Oil Pan Installation Removal/Installation of Transmission Fluid

Filler Rubber Plug
1 The sealing surface of the oil pan shall be clean
and free from any metal debris, etc. 1 Lift the vehicle to facilitate the operation.
2 Install the oil pan and gasket with two positioning 2 Before removal, clear the surrounding (J) of the
devices. fluid filler pipe.
顶塞J1
胶塞J2
润滑油填充口J
ES050012 ES050014
3 When removing the magnetic absorptive piece, 3 Place the screwdriver under the top plug (J1).
metal debris may occur.
4 Pry off the top plug (Figure 1).
4 Install the above parts properly, then tighten 17
5 Clamp the rubber plug (J2) with a plier.
bolts to a torque of
6 Pull out the rubber plug (Figure 2).
5 8-10 N.m in the sequence below.
5 4 1 9 17
7
13 14
11 12
16 15
8 6 2 3 10
ES050015
ES050013
7 Discard the filler plug (J) removed, and do not

6 For transmission fluid refill, please refer to
reuse it.
procedures for transmission fluid refill.
Caution: When the top plug (J1) is lifted, the
diameter of the rubber plug (J2) diminishes, so it
is easy to remove the whole rubber plug.
8 Insert a new filler plug into the main transmission
body.
10-19
6AT
9 Install the top plug (J1).

Transmission Fluid Level Adjustment
Caution: Lift the vehicle and remove the guard
plate.
1 For removal of the fluid filler plug, refer to the

document Removal/Installation of Fluid Filler
Plug.
J
ES050016
ES050017
2 Eliminate fluid residue in all pipes with a

compressed air tool. Use a machine to connect
the fluid filler hole.
ES050018
Caution: Use the following parameters to give an

approximate estimation of the fluid volume to be
refilled.
- Oil pan removal, 6.5-7L
- Hydraulic torque converter removal, 1L
- Transmission cooler oil line, 0.4L
3 Refill fluid until it overflows the filler port.
10-20
6AT
Caution: Use petro-Canada DEXRON VI

Transmission Fluid Level Check
transmission fluid only, use of other fluids may
cause damage to the transmission. 1 Read the transmission fluid temperature (TFT)
4 Remove fluid refill tool. with the testing tool.
5 For installation and refill of the filler pipe, refer to 2 Start and idle the engine.
the document Removal/Installation of 3 Fully depress the brake pedal, shift gears and
Transmission Fluid Pipe. stay in each gear for more than 3s, finally return
6 Lower the vehicle. to P gear.
7 For fluid level check, refer to Transmission Fluid

Level Check.
2 3 100 120 140

80 160
60 180
1 4 40 200
20 220
0 240
0 5
P
R
N
D
SD
M1...M4
ES050020
4 Idle the engine for at least 1mim.

Caution: If the vehicle is provided with the
manual mode, no need to upshift to M5 and M6
gears, because the clutch of these two gears is
identical with that of the M2 and M3 gears.
5 Lift the vehicle with a lifting machine, maintain
the P gear and idle the engine.
6 Place a container under the transmission for oil
collection, and slowly release the drain plug (F).
Caution: During fluid level check, the engine shall
be in a stable idling. If the engine does not work,
when refilling according to the above methods,
the fluid volume is below the normal value, this
can lead to premature wear or failure of the parts.
Caution: For fluid check and refill, the TFT shall
be 30°-50°.
10-21
6AT
7 Remove and replace the drain plug (F). Caution:

Check the color of the fluid.
The fluid shall be red or dark brown.
If the fluid appears to be dull black or black, and has a

pungent burning odor, it indicates the fluid is
contaminated or becomes invalid due to overheating.
ES050023
8 Observe the following instructions:

· When the temperature rises, the transmission fluid
starts to come out, the fluid changes from stable liquid
flow to drops.
· The TFT is increasingly high, observe its state at a

temperature of 30°-50°.
· If the TFT is above 50°, but the fluid is still not drops,
fluid failure may occur, refill transmission fluid and repeat
the above steps.
·The identification standard is as follows:
Upper limit: when the fluid becomes drops at 30°C (+/- 2

°C);
Normal volume: when the fluid becomes drops at 40°C

(+/- 2°C);
Lower limit: when the fluid becomes drops at 50°C (+/- 2

°C).
9 Replace with a new drain plug and tighten it to a

torque of 25N.m.
10 Check the surrounding of the drain plug, and
check for fluid leak. For other locations required
a check for possible leaks, refer to the document
Oil Leak Location.
11 Install the lower guard plate of the transmission.
12 Lower the lifting machine and vehicle.
10-22
6AT
4 Pull out and remove the hydraulic torque

Hydraulic Torque Converter Removal
converter (B).
1 Drain transmission fluid. Please refer to
Transmission Fluid Drain and Oil Pan Removal.
2 Remove the transmission from the vehicle.
B
ES050026
2
Caution: When removing the hydraulic torque
converter, the transmission fluid will come out.
ES050024
Be sure to prepare an oil pan under the
Caution: Keep the transmission level to avoid transmission.
release of the hydraulic torque converter. 5 Remove the O-ring (D) of the input shaft with a
screwdriver and discard it.
3 Secure the transmission on the turning support.
6 Replace with a new O-ring (D) and soak it with
transmission fluid.
ES050025
ES050027
10-23
6AT
7 Install it into the input shaft.

Hydraulic Torque Converter Installation
Caution: Please make sure that the O-ring (D) is
not damaged and locates in the ring groove.
ES050028
D
ES050029
1 Push the hydraulic torque converter along the

input shaft, turn it manually until it completely
enters into the housing.
ES050030
2 Axial installation is made.
10-24
6AT
3 Check the distance between the surface of the Oil Filter Edge Seal Removal
transmission housing and the hydraulic torque
converter with a gauge or check if the hydraulic 1 Drain transmission fluid, refer to Oil Drain and Oil
torque converter is properly installed with the Pan Removal.
retaining plate for transportation (if the hydraulic 2 Manually remove and discard the oil filter.
torque converter is properly installed, it will not Directly pull out the oil filter, do not bend or twist
interfere with the retaining plate when rotating). the pipe of the filter.
ES050030 ES050032
Caution: The distance (a) shall be at least 13mm.

3 If the edge of the entire bushing is higher than
the pump, the seal is invalid.
Note: A good bushing shall be smooth and fit
with the oil circuit.
Unacceptable:
a
ES050031
ES050033
10-25
6AT
Acceptable: Oil Filter Bushing Seal Installation

Caution: Ensure the bushing is properly installed,
please refer to Oil Filter and Bushing Removal.
1 If the pump seal is correct and intact, please

directly refer to section 6 of the document.
2 Before using a new bushing, ensure the edge of
the mounting hole is free from any rubber debris
that affects the sealing.
3 Bushing with transmission fluid is allowed.
4 Install the bushing with seal installer C00089880.
ES050156
·Remove the sealing bushing with a screwdriver or plier.
·Replace the sealing bushing, and do not reuse it.
·Install a new bushing (refer to procedures for bushing

installation).
ES050035
10-26
6AT
5 Uniformly press the bushing. 7 Ensure the filter is correctly installed, then the
position of the filter can press the bushing and
guarantee the seal function.
C00089880
ES050036
ES050039
ES050037
6 When installing the filter component (H), ensure ES050040

it is perpendicular with the pump.
ES050038
10-27
6AT
5 Remove the sleeve (2) of the electric connector.

Electric Component Removal
1 Drain transmission fluid, refer to Oil Drain and Oil

Pan Removal.
2 Remove the oil filter, refer to Oil Filter and Seal
Removal.
2
ES050043
Caution: Pull out the sleeve of the connector

axially, do not turn/twist it.
6 Remove 6 bolts in the sequence shown only.
ES050041
Bolts – 6 – M5 × 73 – 10N.m
Caution: The seal position of the bushing is very
crucial, it shall be smooth, fit and free of
deformation.
3 Remove the harness connector, rotate the 3 2 6
handle, and disconnect the connector plug with
the guide of the guide groove.
4 1 5
ES050044
7 Remove the electric control module.
ES050042
Caution: Do not touch the connector pin.

4 Unlock the slide lock 1 of the sleeve of the
electric connector.
ES050045
10-28
6AT
Special Notice: Do not touch the connector pin 9 Lock the anti-release lock (1).
and welding component on the circuit board.
Edge seal O-ring
SCALE : FULL
ES050048
ES050046
Caution: If the sleeve is improperly installed, the
Caution: anti-release lock cannot lock.
Check the sealing surface: 10 Remove the seal component (3) from the valve
components.
· O-ring (X2)
11 Remove the seal component (4) from the valve
· Edge seal (X1) components.
8 Reinstall the sleeve (2).
4
ES050049
ES050047 Caution: Discard the seal component, and do not

reuse it.
Caution: For sleeve installation, a position notch
for correct installation is provided, please align
and insert it into the notch.
10-29
6AT
12 Remove the seal component (5) from the main

transmission body.
5
ES050050
Caution: Discard the seal component, and do not

reuse it.
Important Notice: To remove or replace the gear
selector shaft, the electric component must be
removed first.
10-30
6AT
Precautions for Electro Static Discharge Electric Component Installation

(ESD) Special Notice: For electro static discharge,
The electric component is quite susceptible to the static please refer to Precautions for Electro Static
(including TCU, sensor, etc), and the static warning sign Discharge (ESD).
will be provided during the service.
1 Check the oil inlet of the electric component.
E - Electro
S - Static
D - Discharge
When the operator touches any electric component, the

static will discharge directly;
When replacing any electric component, pay particular

attention to the electro static discharge (ESD). Failure to
follow the general security specifications may cause
damage to other electric components of the car.
To avoid electric component damage due to static, ES050051

please follow the following instructions:
2 Check the oil outlet of the oil pump.
For replacement, do not open the original package in
advance, remove the part from the original package only
when installation can be done immediately. Do not
directly touch the pin of the electric component, touch the
outer package of the electric component only. If the
electric component must be taken out, put it back to the
original package as fast as possible (take out fast and put
back fast).
Necessary protective articles for the operator: antistatic

shoes, gloves.
ES050052
TEHCM
ES050137
10-31
6AT
3 Check the middle oil passage hole. 7 Remove the connector sleeve (1), refer to
Electric Component Removal.
ES050053
ES050056
Caution: The hole shall be clean, smooth and free
from residues. 8 Use the two holes of the main transmission body
to ensure correct installation of the control valve
4 Install a new seal component (3).
components.
ES050057
ES050054
ES050058
Caution: When installing a new electric
component, do not forget to remove the spring of
ES050055 the shift mechanism from the former component,
10-32
6AT
and an H10 wrench shall be used, the torque is 14 Clear the TCU cache, input the VIN of the TCU
12N.m. with the scan tool.
9 Install bolts 1-6 in the sequence shown, ensure 15 Clear the DTCs due to rewriting or replacement.
the control valve component is on the 16 Perform a road test and execute a self-learning
transmission, 6 bolts – M5 × 73 – torque: for the transmission.
10N.m.
Caution: Do not touch the connector pin.
3 2 6
4 1 5
ES050059
Caution: Remember to tighten the bolts in the

sequence shown.
10 Reinstall the sleeve 1 of the electric connector,
axially insert the sleeve to connect the
connector, do not rotate the sleeve and ensure it
is properly installed. For correct installation, the
distance between the outer surface of the sleeve
and the surface of the transmission shall be 14-
16mm. If the sleeve is properly installed, the
slide lock (2) can lock.
14 - 16 mm
2
ES050060
11 Reinstall the oil filter and oil pan, refer to Oil Filter
and Oil Pan Installation.
12 Connect the vehicle harness, please refer to
Electric Component Removal.
13 Rewrite the transmission data.
10-33
6AT
9 Remove the spring pin (L1) of the shift lever

Gear Selector and Seal Removal
shaft, discard the spring pin removed, and do not
1 Lift the vehicle and drain transmission fluid, refer reuse it.
to Oil Drain and Oil Pan Removal. Caution: The two spring pins have a different
2 Remove the oil filter, refer to Oil Filter and Seal size, Remove L2 first, then L1.
Removal. 10 Remove the shift shaft (L3) as illustrated, do not
3 Remove the electric control valve, refer to reuse the shift shaft with any wear or
Electric Component Removal. deformation.
4 Remove the gear selector lever from the gear
selector shaft of the transmission.
L1
L2
L3
ES050067
ES050061
5 Install C000898821 into the gear selector shaft,

and turn it to the end, then rotate the bolt to
remove the seal ring with a tool.
C00089882(1)
ES050062
6 Discard the gasket, and do not reuse it.

7 Remove the gear selector lever from the gear
selector shaft of the transmission.
8 Remove the spring pin (L2) of the shift lever
shaft, discard the spring pin removed, and do not
reuse it.
10-34
6AT
4 Install the spring pin (L1) of the shift shaft with a

Gear Selector Shaft and Seal Installation
hammer.
1 Select an appropriate new seal ring, and ensure
the shaft hole and the mounting surface of the
seal ring are free from any residue.
2 Install a new seal ring (L4) with C00089882 (2),
and ensure it is completely pressed in with a
uniform force.
L1
C00089882(2)
ES050070
L4
5 Align the pin hole of the stop shaft with that of the
shift shaft, and install a new spring pin (L2) with a
hammer.
ES050068
3 Install a new shift shaft (L3) and stop lever. L2
L3
ES050071
Caution: The two sides of the spring pin shall

have a same length.
ES050069
L1 L2
ES050072
10-35
6AT
5 Install it on the output shaft.

Removal/Installation of AWD Output Shaft O-
ring Seal
1 Drain transmission fluid, refer to Oil Drain and Oil

Pan Removal.
2 Remove the transmission, refer to Transmission
Removal.
3 Pry and remove the O-ring (M) with a
screwdriver.
ES050075
M
ES050073
Caution: Discard the ring, and do not reuse it.

4 Apply transmission fluid to the new ring.
ES050074
10-36
6AT
4 Insert tool C00045013 into the shift arm to

Shift Connector Adjustment
secure the shift arm, for this operation, the
Caution: Lift the vehicle with the lifting machine, transmission is in the N gear.
remove the lower guard plate of the automatic
transmission, and maintain the shift lever in N
gear.
1 Remove the shift cable.
C00045013
ES050139
5 Clamp the shift cable into the slot of the shift

mechanism, rotate 90° to clamp the shift cable
and connect the cable connector with the pin
ES050076 shaft. For this process, the shift mechanism shall
be in the N gear.
2 Confirm that the shift lever and transmission
gear selector are in the N gear.
Confirm that the position of the gear selector is
unchanged during the tightening process.
3 Push out the adjuster of the shift cable laterally.
ES050140
ES050138
Caution: Push out the adjuster of the shift cable

to adjust the length of the cable.
10-37
6AT
6 Install the shift cable and body. latch, then the shift cable locks, remove the shift
cable installer.
ES050141
ES050143
Caution: The arrow of the shift cable is facing
9 Confirm that the shift lever corresponds to the
forward.
instrument indication displayed on the vehicle.
7 Install the shift cable into the shift cable bracket.
10 Lower the lifting machine.
Push up with great effort, and a "snap" indicates
correct installation.
ES050142
8 Adjust the latch of the shift cable to align it with

the shaft pin axis of the rocker arm, install the
latch into the rocker arm shaft, and push the
10-38
6AT
and improve comfort, avoiding more customer

Transmission Adjustment
complaints about gearshift quality.
Description
After transmission rewriting, mechanical part or electric The scan tool can be used to monitor the state of the
component replacement, a self-learning is required for transmission (positions of the throttle and accelerator
the transmission (actually control valve). pedal, TFT, gear engagement,etc) during self-learning.
The electric component will keep learning the The self-learning shall be carried out after the TFT is
accumulative operation of the transmission and above 25 ℃ .
optimizing the gearshift quality, power output and fuel
Caution: Each process shall be performed
economy. repeatedly to ensure there are enough input value
If the data is rewritten or the electric component and for calculation of the basic effective value during
self-learning. Therefore, each procedure of the
transmission are replaced, the self-learning value will be
operation is very important, including the
removed. The user can feel change of the gearshift
process of gear shift and gear maintenance.
quality
before the transmission acquires enough self-learning

values.
The following procedures for transmission adaptive

control is a guide document for shortening the duration of
self-learning and reducing difficulty in operation, in the
period after program update or part replacement,
customers' questions about change of the gearshift
quality shall be solved as soon as possible through
constant learning of the working conditions for different
gears in different driving environments.
Caution: The safety shall be guaranteed for self-

learning, the operation shall comply with
applicable laws and regulations and shall be
done in the site that will not affect the traffic.
Procedures for transmission adaptive control:

Frequent upshift, coast, downshift and slowdown are
more favorable to the quick self-learning of the
transmission than constant driving at a single mode.
During driving before the self-learning, if frequent

downshift for some gears occurs, especially when more
than one gear downshifts at a time, a jerk will appear, this
will substantially reduce drive comfort.
The procedures listed below are basic driving principles

which can be used to optimize the gearshift performance
10-39
6AT
Gearshift during steady slow-speed driving: will drop slowly until the vehicle downshifts to the 1st
N-R: depress the brake for at least 5 times. gear, then slightly depress the brake pedal to stop.
N-DS: depress the brake for at least 5 times (do not stop The adaptive operation of the future upshift and downshift
in D gear). shall follow the same way: when the accelerator pedal is
released, the vehicle speed drops slowly until the vehicle
N-D: depress the brake for at least 5 times.
slows down, then slightly depress the brake to stop the
D-R and R-D follow the sequence: release the brake for vehicle, this helps to accumulate data during self-
at least 5 times (shift every two seconds during slow- learning.
speed shift).
Upshift in warm-up state and downshift by

coasting (throttle off or accelerator pedal
released).
Maintain the accelerator pedal (appr. 30%-50%), ensure
upshift (1-6). After the vehicle upshifts to the 6th gear
(with the accelerator pedal released), the vehicle speed
will drop slowly until the vehicle downshifts to the 1st
gear, then slightly depress the brake pedal to stop.
Steady gearshift during warm-up process/after

warm-up process:
N-R: depress the brake pedal.
N-DS: depress the brake (do not stop in D gear).
N-D: depress the brake, N-D gear, release the brake, do

not depress the accelerator pedal.
D-R and R-D follow the sequence: release the brake

(shift every two seconds during slow-speed shift).
Upshift during warm-up process:

1-6 gear:
Maintain the accelerator pedal (appr. 30%-50%), ensure

steady upshift (1-2, 2-3, 3-4, 4-5, 5-6).
Downshift by coasting (with the accelerator pedal

released):
After the vehicle upshifts to the 6th gear (approximately),
with the accelerator pedal released, the vehicle speed
10-40
6AT
Downshift controlled by accelerator pedal: finally), and depress the brake pedal only in the final low
Use the following gearshift methods to depress the speed stage.
accelerator pedal gradually and perform the self-learning
Important Notice:
for downshift.
Before replacing the transmission, hydraulic torque
Two different ways of gear operation: converter or electric component, contact
1. At medium speed, depress the throttle pedal with and authorize the PPT.
moderate acceleration;
2. At low speed, quickly depress the accelerator pedal.
At medium speed, moderately depress the accelerator

pedal:
Perform 6-5, 5-4, 4-3, 3-2 and 2-1 gearshift (shift when
engine speed reaches 2000-4000rpm)
At low speed, quickly depress the accelerator pedal:
Perform 6-5, 5-4, 4-3, 3-2 and 2-1 gearshift (shift when
engine speed reaches 2000-4000rpm)
Low-speed gearshift at normal oil temperature:

Same with warm-up process (see above)
Upshift at normal oil temperature:
1-6 gear:
Perform 1-2, 2-3, 3-4, 4-5 and 5-6 gearshift, slightly

depress the accelerator pedal to upshift (10-20%).
1-6 gear:
Perform 1-2, 2-3 and 3-4 gearshift, moderately depress

the accelerator pedal to upshift (30-40%).
1-5 gear:
Perform 1-2, 2-3 and 3-4 gearshift, moderately depress

the accelerator pedal to upshift (50-60%).
1-4 gear:
Perform 1-2, 2-3 and 3-4 gearshift, quickly depress the

accelerator pedal to upshift (100%).
Note: Downshift by coasting.

6-1 gear:
Whenever an upshift cycle is finished, perform a steady

downshift (the vehicle decelerates slowly and stops
10-41
6AT

Removal/Installation of Automatic
assembly of the propeller shaft to remove the
Transmission Assembly intermediate support assembly.
Removal
2 Lift the vehicle on the lifting machine. Remove
3 Release the drain plug, remove the transmission
oil pan, drain the transmission fluid and collect
the fluid in a proper container.
4 Disconnect the cable of the shift lever from the
transmission (refer to Replacement of
Transmission Cable).
5 Disconnect the connector of the transmission
harness assembly, and remove the cable. ES050148

the rear axle.
ES050146
6 Unscrew the bolts connecting the rear end

assembly of the transmission oil cooler pipe and ES050149
transmission, and separate the rear end
assembly of the transmission oil cooler pipe. 9 Remove 4 bolts securing the propeller shaft to
the transmission, disconnect the propeller shaft,
ES050147
10-42
6AT
and move the propeller shaft properly so that it remove 6 bolts securing the flexible plate and
will not interfere with the operation. torque converter.
ES050150 ES050152
10 Support the bottom of the transmission with a 14 Remove 10 bolts securing the transmission to
suitable bracket (no direct contact). the engine.
Caution: The oil pan shall not be under direct
stress.
ES050153

and ensure the torque converter is still
connected to the transmission.
ES050151
16 Carefully put the bracket down to remove the
Caution: If a 4WD transmission is used, release transmission assembly.
the bolt of the rear mount bracket on the transfer
case.
13 Rotate the flange of the transmission output
shaft clockwise, remove the flywheel housing
baffle from the engine, and align the flexible plate
with the bolt of the automatic transmission, then
10-43
6AT
Caution: When removing the automatic

transmission assembly, do not drop the hydraulic
torque converter.
Installation:
- Clean the junction of the engine and transmission.
- Lubricate the torque converter jack.
- After installing the propeller shaft, refill the specified oil

through the oil filler plug aperture. Remove the oil level
plug to drain the excess oil. Reinstall the plug.

allow for one time use only, so new nut shall be used after
any removal, otherwise its tightening performance cannot
be guaranteed.
10-44
6AT
Special Tool
1 C00089880 Oil seal installer
C00089880
Use for removal.
C00089882
Shift shaft oil seal
2 C00089882
installer/remover
Use for installation.
C00089882
3 C00045013 Neutral gear lock pin
C00045013
10-45
6AT
10-46
SAGW 6MT Transmission
Assembly
Overview
Overview and Characteristic of Transmission
SC36M(B)6C transmission includes 6 drive gears and 1 reverse gear. The drive gear and reverse gear are normally
engaged gears with synchronizers, the transmission housing is an aluminum alloy die casting, which can match 2WD
(SC36M6C) and 4WD (SC36MB6C) models, and the operation mode is soft shaft indirect operation.
SC36MB6C Transmission Outline View
2 1
GS050001
1 Bolt 2 Wire clip
11-1
SC36M6C Transmission Outline View
GS050002
Power transfer is realized by a series of normally engaged spiral gears which are installed on the 1st shaft, 2nd shaft,
intermediate shaft and reverse gear shaft. The free gear on the 2nd shaft, intermediate shaft and reverse gear shaft is
supported by the needle bearing, the 1st shaft and 2nd shaft on the transmission housing are supported by the bearing,
and the intermediate shaft on the transmission housing is supported by the cylindrical bearing.
The synchromesh operation of the transmission is achieved by the synchronizer; the synchronizer of the 5th/6th/R gears
is equipped with the single synchronizing ring, the synchronizer of the 3rd/4th gear is equipped with the double-cone
synchronizing ring and that of the 1st/2nd gear is equipped with the tri-cone synchronizing ring. Gear selection/shift of the
transmission is done by 4 shift fork shafts and 1 main shift fork shaft:
·The main shift fork shaft realizes gear selection and gear shift by selecting and toggling the other 3 shift fork shafts.
·The other 3 shift fork shafts toggle the shift fork to engage the gear by the fork head on the shaft.
·Gear selection/shift control outside the transmission is realized by the gear shift tower control mechanism.
11-2
SC36M(B)6C Transmission Structure Diagram
4
5
6
GS050003
3 Locating pin 6 Bolt M8X40
4 Output shaft 7 Rear housing
5 Lock nut
11-3
SC36M6C Transmission Outline View
2
3
4
5
GS050004
1 Flange 4 Dust shield

2 Flange lock bolt 5 Bolt M8X32
3 Output shaft 6 Rear housing
11-4
Transmission Assembly Specifications

Transmission Technical Parameters
Schematic Items Technical parameters
Model SC36MB6C SC36M6C
Drive type 4WD 2WD
Input torque/center distance 350N.m/82mm
Weight 59Kg 57.5Kg
Gear 6 drive gears
R 1 3 5
1 reverse gear
2 4 6
Shift mode Mechanical/manual, indirect operation
Gear Normally engaged spiral gear
Drive ratio 1st gear 4.340
2nd gear 2.264
3rd gear 1.504
4th gear 1.152
5th gear 1
6th gear 0.72
R gear 3.870
11-5
Gear axial clearance
1st gear 0.1 ～ 0.36 mm

2nd gear 0.1 ～ 0.31 mm
3rd gear 0.105 ～ 0.365 mm
4th gear 0.15 ～ 0.32 mm
6th gear 0.15 ～ 0.32 mm
R gear 0.1 ～ 0.32 mm
Reverse gear idler 0.1 ～ 0.3 mm
Thickness of input shaft bearing circlip 1.96 ～ 2.11mm (accumulate at an
increment of 0.05mm)
Thickness of 1st/2nd gear hub circlip 1.93 ～ 2.08mm (accumulate at an



11-6
Plane sealant grade Tonsan 1598
Transmission fluid 2.5 ± 0.1L
11-7
Thread Tightening Torque
SN. Part Thread specification Use Torque (N.m)
1 Hexagon bolt M6X25 M6 Secure CSC 10 ± 3

2 Bolt M8X40 M8 Clutch housing and 25 ± 1.5
bearing box
Bearing box and rear
housing
3 Oil level hole bolt M16X1.5 Plug oil filling port 40 ± 3

4 Bolt M8X45 M8 Secure intermediate plate 25 ± 3
5 Drain plug M18X1.5 Plug drain hole 45 ± 3
6 Bolt M8X32 M8 Secure shaft 1, shaft 2 25 ± 1.5
and intermediate shaft
bearing
7 R gear shaft bolt M8 Secure R gear shaft 25 ± 1.5

8 Interlocking plate bolt M8X1 Secure interlocking plate 25 ± 1.5
9 Flange lock bolt (2WD) M24X1.5 Secure flange 200 ± 10
10 Lock bolt M20X1.5 Secure intermediate shaft 180 ± 10
bearing
11 Shift fork pin shaft M16X1.5 Support shift fork 40 ± 3

12 Hexagon socket set M12X1 Secure gear selection/shift 35 ± 5
screws with cone point knob seat
13 Reverse lamp switch M14X1.5 Transmit reverse signal 27 ± 1.5

assembly
14 Lock nut (4WD) M38X1.5 Axial locking 280 ～ 360

15 Bolt M8X15 M8 Retain wire clip 20 ± 1.5
16 Bolt M6X18 M6 Secure oil groove 8±1
17 Bolt M8X22 M8 Secure gear selection/shift 25 ± 1.5
supporting plate, gear
selection shaft seat
assembly
18 Bolt M8X30 M8 Secure control cover 25 ± 1.5

assembly
19 Nut - transmission shift lever to body 20 ± 2

20 Bolt - transmission to engine 80 ± 5
21 Bolt - cable bracket assembly to transmission 20 ± 2
22 Nut - shift cable to body 9±1
11-8
List of Disposable Parts
SN. Part Name Quantity/unit
1 Flat washer φ 6 3
2 Pressed outer ring HK162313 2
3 Aluminum washer 16 1
4 Oil seal Φ 35X52X6.8 1
6 Shaft 1 bearing circlip Φ 33 1
11 Gear selection/shift shaft oil seal 1
12 Bearing 4
13 Oil seal Φ 52X68X8 1
14 5th/6th gear synchronizer circlip Φ 29.2 1
20 1st/2nd gear synchronizer circlip Φ 47.7 1
24 3rd/4th gear synchronizer circlip Φ 42.5 1
30 Control cover plug 1
31 Snap pin Φ 6X25 4
32 Gear selection block 1
33 Locating pin of shift fork shaft 3
11-9
SN. Part Name Quantity/unit
34 Hexagon socket set screws with cone point 1
35 Locating pin of R gear shift fork shaft 1
36 Interlocking plate bolt 2
37 Hollow pin 6
11-10
Transmission Assembly Structure Detail

Transmission Assembly Exploded View
Peripheral Transmission Accessory Diagram
9
5
6
8 12
7 10 11
13 14
2
1
3 4
27
15
28
17 18
20
25 20 16
26
24
21 19 13
4
22 7
23
GS050005
11-11
Gear Selection/Shift Mechanism and Housing
34
34 37 41
42
31
33 35
31
32
29
30 40 51 44 49
46
63 39 39
45
62 47 36
48
13 38 43 52 50
59
61
34
32
55
58
60 31
57
31 54 53
56
34
GS050006
11-12
Gear Drive Mechanism
76 77 78 77 81 84 86 87
75 79 80 82 83 85
65 67 70 71 70 72 74
64 66 68 69 73
90 91 92 93 96 97 96 98
89 94 95 99 100
88
101 104
102 103
GS050007
11-13
SN. Name Quantity
1 Flange lock bolt 1
2 Flange 1
3 Dust shield 1
4 Bolt M8X32 10
5 Reverse lamp switch assembly 1
6 Locating pin of shift fork shaft 3
7 Bolt M8X40 26
8 Locating pin of R gear shift fork shaft 1
9 Bolt M8x30 6
10 Control cover assembly 1
12 Oil level hole bolt 1
13 Hollow pin 6
14 Ventilation pipe assembly 1
15 CSC oil pipe sleeve 1
16 CSC assembly 1
17 Flat washer φ 6 3
18 Hexagon bolt M6X25 3
19 Gear selection block 1
20 Bolt M8X22 4
21 Gear selection shaft seat assembly 1
23 Drain plug 1
24 R gear shaft bolt 1
25 Gear selection/shift supporting plate 1
26 Bolt M8X15 1
27 Shifter locating pin 1
28 Shift fork pin shaft 6
29 Clutch housing 1
30 Bearing box 1
31 Shift fork leg 8
32 5th/6th/R gear shift fork component 2
33 5th/6th gear shaft fork head 1
34 Snap pin Φ 6X25 7
35 5th/6th gear shift fork shaft 1
11-14
SN. Name Quantity
36 Shift fork shaft bushing 6
37 3rd/4th gear shift fork shaft 1
38 Bearing Φ 50X78X17.5 1
39 Bearing 4
41 3rd/4th gear shaft fork head 1
42 3rd/4th gear shift fork component 1
43 Intermediate plate 1
44 Locating pin bushing of intermediate plate 2
45 Interlocking plate 1
46 Bolt M8X45 3
47 Interlocking plate bolt 2
49 Rear housing 1
51 Interlocking plate gasket 2
52 Bolt M6X18 1
53 Fork head of R gear shaft 1
54 R gear shift fork shaft 1
55 Oil groove 1
56 1st/2nd gear shift fork shaft 1
57 Gear selection/shift shaft component 1
58 1st/2nd gear shift fork 1
59 Locating pin 2
60 Gear selection/shift fork head seat component 1
61 Hexagon socket set screws with cone point 1
62 Magnetic steel 1
65 Bearing Φ 35X85X23 1
66 Shaft 1 1
67 5th gear engaging tooth 1
70 5th/6th gear ring 2
11-15
SN. Name Quantity
71 5th/6th gear synchronizer assembly 1
72 6th driven gear component 1
73 Needle bearing Φ 33X38X36 1
74 Shaft 2 1
76 2nd driven gear component 1
77 1st/2nd gear synchronizer ring component 2
78 1st/2nd gear synchronizer assembly 1
81 1st driven gear (precision forging) 1
82 Bushing 1
83 Needle bearing Φ 53X58X42.8 1
84 Reverse driven gear (precision forging) 1
85 Reverse gear synchronizer ring 1
86 Reverse gear synchronizer assembly 1
88 Lock bolt 1
90 Oil sump 1
91 Normally engaged gear of intermediate shaft 1
92 6th drive gear 1
93 3rd drive gear component 1
96 3rd/4th gear synchronizer ring component 2
97 3rd/4th gear synchronizer assembly 1
98 4th drive gear component 1
100 Intermediate shaft 1
101 Reverse gear shaft bracket 1
102 Reverse gear shaft 1
104 Reverse gear idler 1
11-16
Power Flow Chart

1st Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
GS050010
1 Input shaft 8 Normally engaged gear

2 5th/6th gear synchronizer assembly 9 6th gear
3 3rd gear 10 3rd/4th gear synchronizer assembly
4 4th gear 11 2nd gear
5 1st/2nd gear synchronizer assembly 12 R gear
6 1st gear 13 Output shaft
7 Reverse gear synchronizer assembly
11-17
2nd Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
GS050011

11-18
3rd Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
GS050012

11-19
4th Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
GS050013

11-20
5th Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
GS050014

11-21
6th Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
GS050015

11-22
Reverse Gear
1 2 3 4 5 6 7
12
8 9 10 11 13
GS050017

11-23
Expanded Product Identification

SC36M6B & SC36MB6B Identification Table
SN. Part Name Schematic Quan Comparing with SC36M6B

tity
1 Wire clip 1 Add-on special part
2 Bolt M8X15 1 Add-on special part, torque: 25 ± 3N.m
3 Bushing 1 Add-on special part
4 Lock nut 1 Add-on special part, torque: 280-

360N.m, replace flange lock bolt, cancel
flange and flange dust shield
11-24
SN. Part Name Schematic Quan Comparing with SC36M6B

tity
5 Locating pin 2 Add-on special part
6 Rear housing 1 Special part, replace SC36M6B rear

housing
7 Bolt M8X40 4 Torque: 25 ± 3N.m, replace 4 bolts

(M8*32) used by SC36M6B
8 Shaft 2 1 Special part, replace SC36M6C shaft 2
11-25
Installation Location Diagram
8 3 4 7 5
6 1 2
GS050018
11-26
Shift Cable Layout
GS050019
11-27
3 Remove 4 bolts (M8X32).

Repair Guidance
Transmission Removal/Installation
Removal
1 Remove the drain plug and gasket, and drain the
transmission fluid.
GS050022
4 Remove 3 hexagon bolts (M6X25) and flat

washer, and remove the CSC assembly and
CSC oil pipe sleeve.
GS050020
2 Remove the flange lock bolt, and remove the

flange assembly.
GS050023
GS050021
GS050024
11-28
6 Remove 6 bolts (M8X30), and remove the 9 Remove 2 bolts (M8X22) and 1 bolt (M8X15) and
control cover assembly. take out the gear selection/shift supporting plate.
GS050025 GS050028
Caution: The plane sealant on the connecting

10 Remove 6 shift fork pin shafts.
surface shall be thoroughly cleaned.
7 Remove 2 bolts (M8X22), and remove the gear

selection seat assembly.
GS050029
11 Remove the shifter locating pin.

GS050026
8 Remove the reverse lamp switch assembly.
GS050030
GS050027
11-29
12 Remove the locating pins of Reverse gear fork. 15 Remove 13 bolts (M8X40), and remove the rear
housing assembly.
GS050031
GS050034
13 Remove the breather plug.
Caution: The plane sealant on the connecting
surface shall be thoroughly cleaned.
16 Remove the magnetic steel.
GS050032
14 Remove 2 locating pins.
GS050035
17 Remove the Reverse gear shift fork component,

shift fork leg and Reverse gear shift fork shaft
component.
GS050033
GS050036
11-30
18 Remove the hexagon socket set screws with 21 Remove 1st driven gear, bushing, needle
cone point, and remove the gear selection/shift bearing Φ 53X58X42.8, reverse driven gear,
fork head seat component and gear selection/ reverse gear synchronizer ring, reverse gear
shift shaft component. synchronizer assembly and bearing Φ
40X90X23 with a puller.
GS050037
GS050040
19 Remove the bolts (M6X18) and oil groove.
Caution: Reverse gear synchronizer slider is easy to
drop.
22 Remove the needle bearing Φ 48X54X40.
GS050038
20 Remove the snap pin Φ 6X25, and remove 1st/

2nd gear shift fork, shift fork leg and 1st/2nd gear
shift fork shaft. GS050041
GS050039
11-31
23 Remove 1st/2nd gear circlip. 26 Unscrew 2 interlocking plate bolts, and remove
the interlocking plate and 2 gaskets.
GS050042
GS050045
24 Remove the 1st/2nd gear synchronizer ring
component, 1st/2nd synchronizer assembly and 27 Remove 3 bolts (M8X45).
2nd driven gear component.
GS050046
GS050043
28 Remove the intermediate plate component,
Caution: Reverse gear synchronizer slider is easy to bearing Φ 57X77X17 and bearing Φ 50X78X17.
drop.
GS050047
29 Remove shaft 2 component (A), shaft 1

GS050044 component (B), intermediate shaft components
(C), 3rd/4th gear shift fork shaft component (D),
11-32
3rd/4th gear shift fork component (E), 5th/6th 32 Remove shaft 1 bearing circlip and bearing Φ
gear shift fork shaft component (F) and 5th/6th 35X85X23.
gear shift fork component (G).
G C
E
GS050051
GS050048
33 Remove the oil sump.
GS050052
GS050049
34 Remove the lock bolt.
31 Remove the clutch housing.
GS050053
GS050050
11-33
35 Remove the bearing Φ 35X72X18.2 and the 38 Remove the needle bearing Φ 42X47X34.
normally engaged gear of the intermediate shaft.
GS050057
GS050054
39 Remove 3rd/4th gear synchronizer circlip.
36 Remove 6th drive gear.
GS050058
GS050055
40 Remove 4th drive gear component, 3rd/4th gear
37 Remove 3rd drive gear component. synchronizer ring components and 3rd/4th gear
synchronizer assembly.
GS050056
GS050059
11-34
41 Remove the needle bearing Φ 45X50X37. 44 Remove 6th driven gear component (A), 5th/6th
gear ring (B) and 5th/6th gear synchronizer
assembly (C).
B
A
GS050060
42 Remove the bearing Φ 23X38X20. GS050063
GS050061
43 Remove 5th/6th gear synchronizer circlip. GS050064
46 Remove 3 locating pins of the shift fork shaft.
GS050062
GS050065
11-35
Check before Assembly 6 Check the gear surface of the gear set for wear.
1 Clean all components disassembled with 7 Check the gear set for excessive wear, crack
solvents, and dry them with compressed air. and damage.
Check the component for crack, wear and 8 Check the status of each synchronizer assembly:
damage.
1) Hub and gear sleeve engagement.
1) Clutch housing, bearing box, rear housing and control
assembly. 2) Wear of the inner conical surface of the synchronizer
ring.
2) 5th gear engaging gear.
2 Check the support location of the shaft and

bearing on the clutch housing, bearing box and
rear housing for wear, and replace it when
necessary.
3 Check the surface condition of the following
components:
1) Input shaft.
2) Output shaft and each gear.
3) Intermediate shaft.
4 Reverse gear idler shaft and reverse gear idler GS050066

Caution: Replace components with excessive wear,
9 Measure the gap between the synchronizer ring
do not rub parts treated by precision machining.
and the transmission gear.
5 Check the following components for wear: 1) 1st/2nd gear synchronizer ring: 1.1 ～ 1.7mm
1) Control assembly.
2) 3rd/4th gear synchronizer ring: 1.1 ～ 1.7mm
2) Gear shift fork and shift fork bushing.
3) 5th/6th gear synchronizer ring: 1 ～ 1.4mm
3) Shift fork components of the 1st/2nd gear, 3rd/4th
4) R gear synchronizer ring: 1 ～ 1.4mm
gear, 5th/6th/R gear.
4) Gear synchronizer assembly.
5) Interlocking plate.
Check the following components for excessive wear:
1) Bearing Φ 35X85X23 (ball bearing).
2) Bearing Φ 57X77X17 (cylindrical bearing).
3) Needle bearing of the output shaft gears.
4) Bearing Φ 40X90X23 (ball bearing).
5) Bearing Φ 27X44X23 (cylindrical bearing). GS050068
6) Bearing Φ 35X72X18.2 (ball bearing). Caution: If the gap is small, replace with a new
synchronizer ring, otherwise damage may occur,
7) Needle bearing of the intermediate shaft gears.
which will lead to missing gear or damaged gear.
8) Reverse gear idler needle bearing.
11-36
10 Check the engaging gear for each gear and the Installation
gear tooth of the synchronizer gear sleeve for
1 Install the bearing Φ 35X85X23 into shaft 1 with
wear.
C00051495.
11 Check the engagement state of the synchronizer
gear sleeve and the engaging gear for each
gear.
GS050069
2 Install the shaft 1 bearing circlip.

GS050067
GS050070
3 Install the needle bearing Φ 45X50X37 in the

intermediate shaft.
GS050071
11-37
4 Install 4th drive gear component and 3rd/4th 6 Install 3rd/4th gear synchronizer ring component.
gear synchronizer ring component with
C00089865.
GS050074
GS050072 Caution: The outer conical ring clamp leg of the

synchronizer ring is aligned with the synchronizer
Caution: hub groove
·The inner ring of the synchronizer ring has no any 7 Install 3rd/4th gear synchronizer circlip.
conical surface
·The middle ring clamp leg of the synchronizer ring

is fixed into the groove of 4th gear engaging gear
5 Install 3rd/4th gear synchronizer assembly.
GS050075
GS050073
Caution:
· The outer conical ring clamp leg of the

synchronizer ring is aligned with the synchronizer
hub groove
·The high boss of the synchronizer hub faces up
11-38
8 Install the needle bearing Φ 42X47X34 (A) and 10 Install the normally engaged gear of the
3rd drive gear component (B). intermediate shaft.
GS050076 GS050078
Caution: The middle ring clamp leg of the Caution: The high boss of the normally engaged
synchronizer ring is aligned with the groove of the gear faces down.
3rd gear engaging gear
11 Install the bearing Φ 35X72X18.2 with
9 Install 6th drive gear with C00051496. C00051496.
GS050077 GS050079
Caution: The high boss of the 6th gear faces up. 12 Install the lock bolt.
GS050080
11-39
13 Install the needle bearing Φ 33X38X36 into shaft 16 Install 5th/6th gear synchronizer circlip (A).
2.
GS050084
GS050081
17 Install 2 hollow pins into the bearing box and
14 Install 6th driven gear component and 5th/6th assemble together with the clutch case.
gear ring.
GS050085
GS050082
18 Install 13 bolts (M8X40).
15 Install 5th/6th gear synchronizer assembly.
GS050086
GS050083
19 Assemble shaft 1 component, 5th gear engaging
Caution: The synchronizer ring clamp leg is aligned gear, 5th/6th gear ring, bearing ( Φ 23X Φ 38X20)
with the synchronizer hub groove
11-40
and shaft 2 component in sequence and install to shift fork shaft component (D) in sequence to the
the assembling base. assembling base with C00089868.
B
A
GS050087 GS050089
20 Assemble shaft 1, 2 and intermediate shaft, and Caution: The fork head leg shall be clamped into
install the shafting component to the assembling gear sleeve groove.
base and install the oil sump.
22 Assemble the bearing box component with the
shafting.
GS050088
21 Install 3rd/4th gear shift fork component (A), 3rd/ GS050090

4th gear shift fork shaft component (B), 5th/6th
gear shift fork component (C) and 5th/6th gear Caution: Each thread hole of the bearing press plate
is aligned with the through-hole of the bearing box.
11-41
23 Install 4 shift fork pin shafts. 26 Install 2 locating pins of the shift fork shaft.
GS050091 GS050094
24 Install 6 bolts (M8X32). 27 Install the bearing Φ 57X77X17, bearing Φ

50X78X17 and intermediate plate component
with C00089866.
GS050092
25 Install the CSC assembly (A) and CSC oil pipe GS050095
sleeve (B); and install 3 hexagon bolts (M6X25)
(C) and flat washer (D). 28 Install 3 bolts (M8X45).
GS050093 GS050096
11-42
29 Install the interlocking plate gasket, interlocking 31 Install the needle bearing Φ 48X54X40.1 (A),
plate and 2 press plate bolts in sequence. 2nd driven gear component (B) and 1st/2nd gear
synchronizer ring component (C) in sequence.
GS050097
GS050099
30 Install the oil groove and hexagon bolt M6 × 18.
Caution： The middle ring clamp leg of the
synchronizer ring is fixed into the groove of the
engaging gear
32 Install 1st/2nd gear synchronizer assembly with

C00089865.
GS050098
GS050100
Caution:
·The outer ring clamp leg of the synchronizer ring is

aligned with the synchronizer hub groove
·The high step of the synchronizer hub faces down
11-43
33 Install the synchronizer ring components of 1st/ 36 Install the sleeve.

2nd gear.
GS050104
GS050101
37 Install the needle bearing Φ 53X58X42.8 and
Caution: The outer ring clamp leg of the reverse gear synchronizer ring. Install the
synchronizer ring is aligned with the synchronizer reverse driven gear component with C00089865.
hub groove
34 Install the 1st/2nd gear synchronizer circlip.
GS050105
GS050102
35 Install the needle bearing Φ 48X54X40.1 and 1st

driven gear component.
GS050103
11-44
38 Install the reverse gear synchronizer assembly. Then the gear selection/shift shaft shall locate in
the shaft slot of the 3rd/4th gear shift fork.
GS050106
ES040103
Caution:
Caution: When installing the gear selection/shift
·The outer ring clamp leg of the synchronizer ring is
shaft, remove the locating pin of the gear
aligned with the synchronizer hub groove
selector/N gear from the rear housing assembly,
·The high step of the synchronizer hub faces up and do not reuse the locating pin.
41 For the shaft at the mating face between the
39 Install the bearing Φ 40X90X23 (A).
intermediate shaft and the rear housing, the big
end faces the input shaft, and the small end
faces the rear housing, apply grease and install it
into the rear housing.
ሿཤㄟ
GS050107
40 Install the gear selection/shift shaft. Press the
3rd/4th gear shift fork shaft into the 3rd gear.
ES040132
11-45
42 The boss of the reverse gear idler shall face the 44 Install the gear selection/shift shaft assembly (A),
input shaft. gear selection/shift fork base (B) and hexagon
socket set screws with cone point (C).
ES040133
GS050109
43 Install the shift fork and shift fork shaft of 1st/2nd
gear, and install the snap pin ( Φ 6X25). 45 Install the reverse gear shift fork and reverse
gear shift fork shaft.
GS050108
GS050110
Caution: Clamp the shift fork leg into the
synchronizer gear sleeve groove of the 1st/2nd gear Caution: Clamp the shift fork leg into the
synchronizer gear sleeve groove of the reverse gear
46 Install the magnetic steel.
GS050111
11-46
47 Screw into the flange of the bearing ( φ 40 × 90 50 Install 13 bolts (M8X40).

× 23) with C00017013, then assemble the rear
housing component.
GS050115
GS050112 51 Install 4 bolts (M8X32).
48 Install 2 shift fork pin shafts.
GS050116
GS050113 52 Install the locating pins of shift fork shaft and that
of reverse gear shift fork shaft.
49 Install 2 locating pins of the housing.
GS050117
GS050114
11-47
53 Install the shifter locating pin. 56 Install the gear selection/shift supporting plate, 1
bolt (M8X15) and 2 bolts (M8X22).
GS050118
GS050121
54 Install 2 hallow pins, gear selection shaft seat
assembly and 2 bolts (M8X22). 57 Install the reverse lamp switch assembly.
GS050119 GS050122
55 Install 2 hallow pins (A), control cover assembly 58 Install the flange component and flange lock bolt.
(B) and 6 bolts (M8X30) (C).
GS050123
GS050120
11-48
59 Install aluminum washer 18 and the drain plug.

Transmission Assembly Replacement
Removal
1 Apply the hand brake, hold it in N gear and place
the ignition switch in OFF position.
3 Lift the vehicle from the lifting machine. Remove
4 Release the drain plug to drain the transmission
fluid, and collect the fluid in a proper container.
GS050124 panel.
60 Install aluminum washer 16 (A) and oil lever hole

bolt (B).
GS040164
6 Remove the center console (refer to Removal/

GS050125 Installation of Center Console)
7 Remove the transmission shift cable (refer to
Removal/Installation of Shift Cable).
8 Disconnect the CSC bleed connector. Remove
with the connector upward, so that brake fluid
leak can be avoided.
GS040166
11-49
9 Drain the brake fluid to a proper container. 13 Remove 4 bolts securing the propeller shaft to
10 Disconnect the reverse lamp harness, and the transmission, disconnect the propeller shaft,
remove the cable from the housing harness clip. and move the propeller shaft properly so that it
will not interfere with the operation.
GS040167
GS040170
assembly of the propeller shaft to remove the 14 Support the bottom of the transmission with a
intermediate support assembly. suitable bracket.
GS040168

GS040171
the rear axle.
Caution: If a 4WD transmission is used, release the
bolt of the rear mount bracket on the transfer case.

17 Remove 11 bolts securing the transmission to
the engine.
and carefully put the bracket down to remove the
GS040169
11-50
Installation
Removal/Installation of Shift Cable
Caution: Lift the vehicle with the lifting machine,
remove the lower guard plate of the transmission,
- Slightly lubricate the input shaft spline. and maintain the shift lever in N gear.
- Before installing the bolt, never hang the transmission Removal
on the input shaft.
1 Pull out the gasket in cable connector at
- After installing the propeller shaft, refill the specified oil transmission end and the cotter pin.
of 2.5 ± 0.1L through the oil filler plug aperture. Remove
the oil level plug to drain the excess oil. Reinstall the plug.
- Connect the transmission gear cable, and check if all

gearshift operations are correct.

allow for one time use only, so new nut shall be used
after any removal, otherwise its tightening performance
cannot be guaranteed.
GS050126

panel.
GS050127
11-51
3 Remove the transmission shift lever handle 6 Remove the shift cable from the shift
(refer to Removal of Transmission Shift Lever mechanism.
Handle).
GS050131
GS050128
7
4 Remove the instrument panel central lower trim
GS050132
GS050129
5 Remove the shift cable and the sealing gasket at

body assembling position.
GS050130
11-52
Installation 2 The gear selection/shift rocker arm of the

transmission assembly allows it to be in neutral
1 Make sure the shifter assembly is in Neutral
position.
position, and install the shift cable into the shift
mechanism.
Caution: The brand new shifter assembly is provided
with a N gear locating pin before delivery to make
sure the shifter is locked in N position
GS050135
3 Connect the cable connector at the shifter end,

and engage the cable connector into the shifter.
GS050133
GS050136
4 Install the shift cable to body, and it shall face

GS050134 forward.
GS050137
11-53
5 Connect the cable connector at transmission end 7 Adjust to lock the gear selection connector
and install the gasket and cotter pin. mechanism.
a. When lock 1 and 2 are confirmed unlocked, the cable
connector can be moved freely in axial direction.
GS050138
GS050141
GS050139
6 Install the shift cable to transmission shift cable
support.
GS050140
11-54
10 Install the gear shift control panel to the hollow

b. Press lock 1 along the arrow direction to make its end
plate.
face flush with the connector end face.
GS050145
GS050142 11 Lower the lifting machine.
c. Lift lock 2 along the arrow direction, once a "click" Check of the cable adjustments: depress the clutch
sound is heard, the installation is completed. pedal, and place the control lever to 1st/2nd position to
shift between 1st gear and 2nd gear, then check if the
shift operation is smooth and if the gear is correct.
Similarly, check the R gear, 5th/6th gear and 3rd/4th gear
according to above method. Smooth gear operation and
correct gear during above check indicates that the cable
is adjusted in place, otherwise it shall be re-adjusted.
GS050143
8 Pull out the locating pin of shifter N gear.
GS050144
9 Install the hollow plate assembly (refer to Hollow
Plate Installation).
11-55
Installation
Replacement of Shift Lever Handle
Removal
panel.
GS040193
2 Press the shift lever panel into the center

GS040191 console panel.
2 Slide the lock ring of shift lever handle upwards

to the top, then pull out the shift lever handle with
force.
GS040194
GS040192
11-56
Special Tool
SN. Drawing Number Description Illustration Remark
1 C00051495 Shaft 1 bearing tooling Assemble bearing

Φ 35X85X23,
assemble bushing
reverse gear synchronizer
assembly
C00051495
2 C00051496 Cone bearing outer circle Assemble 5th/6th gear
installer synchronizer assembly, 6th
drive gear,
normally engaged gear of
the intermediate shaft,
bearing
Φ 35X72X18.2
C00051496
3 C00089866 Bearing installer Assemble bearing
Φ 27X44X23;
Assemble bearing
Φ 57X77X17;
bearing
Φ 50X78X17
C00089866
4 C00089865 Synchronizer socket tool Assemble 3rd/4th gear
synchronizer assembly,
1st/2nd gear synchronizer
assembly,
bushing and reverse gear
synchronizer assembly
C00089865
11-57
5 C00089869 Input shaft oil seal tool
C00089869
6 C00086867-1 Oil seal installer
C00086867-1
7 C00089870-1 Shift shaft oil seal tool
C00089870-1
8 C00089868 Assembly tooling Assemble the shafting, shift
fork, shift fork shaft, and
finally install the bearing
box and clutch housing
assembly
C00089868
9 C00017013 Camshaft bearing guide pin Install the guide rod into the
thread hole of the bearing
press plate, which will
function as a guide unit
when the rear housing
closes
C00017013
11-58
10 C00089871 Limit bushing installer Assemble limit bushing
C00089871
11 C00089944 Lock nut remover/installer Install input shaft lock
shafting to prevent it from
turning
C00089944
12 C00051493 Elastic pin installer
C00051493
13 C00089862 Push rod
C00089862
11-59
taper head turns 1st/2nd gear block to drive the operation

of 1st/2nd gear synchronizer so as to achieve the gear
Overview selection/shift function of the 1st gear. The operations of
This vehicle is equipped with a 6-speed manual other drive gears are the same as that of the 1st gear.
transmission. The shift lever is located at the center When the shift lever is moved to reverse gear position,
console of the passenger compartment. It provides the the reverse gear wheel is engaged with the reverse idler
driver with 7 choices for variable speed position, namely, gear to change the rotation direction of the output shaft.
1st gear, 2nd gear, 3rd gear, 4th gear, 5th gear, 6th gear
Differential
and reverse gear. The gears of all positions are engaged
Differential with traditional design secures the driven gear
by the synchronizer. The drive shaft, installed in the
of final drive to differential housing with bolts, differential
differential assembly at the rear of transmission,
housing supports the planetary shaft, planetary gear and
transmits the driving force to the wheel. The transmission
sun gear. The differential assembly is supported by
housing is made of cast aluminum, and is connected to
bearings in the transmission housing.
the engine block with bolts. The transmission input shaft
and output shaft are supported by bearings. The The differential allows the wheels to rotate at different
transmission clutch case is equipped with an oil filler plug, speeds when the output torques are the same. The
and there is an oil drain plug at the lower rear side of the pinion integrated with the output shaft is engaged with the
main transmission housing, both of them are sealed with final drive driven gear of the differential assembly. When
aluminum washer. The transmission is filled with the output shaft rotates, and the wheels swivel straight
lubricating oil so as to lubricate the internal components forward, the torque will be applied to the whole assembly,
in a splashing manner. and the planetary gear does not rotate. The torque is
transmitted to the wheels through drive shaft. When the
Gear Shift and Gear Selection
vehicle takes a turn, the inner wheels will pass a shorter
Gear selection is realized by manipulating the shift lever
distance at a lower speed. Thus it drives the planetary
installed at the center console of the passenger
gear to rotate, and the outer sun gear offers a higher
compartment. Both cables have one end connected to
speed for outer wheels.
the bottom of the shift lever, and the other end connected
to the gear selection rocker arm and gear shift rocker arm Transmission Components
installed outside the transmission through the connector Drivetrain changes the speed and direction of rotation
ring assembly. In the transmission housing, the fork shaft through the engagement between different gears of the
is connected with the fork, turn an appropriate input shaft and output shaft, thereby generating 7 drive
synchronizer to shift to the drive gear or the reverse gear. gears of different speed ratio and 1 reverse gear. The
gear wheels of all other gears are constantly engaged. If
When the shift lever is moved to the 1st gear position, the
the 1st gear is selected, the synchronizer gear ring is
shift lever will control the gear selection/shift rocker arm
pressed by the synchronizer gear bushing so as to
through the cable. The gear selection rocker arm rotates
contact with the conical ring of the corresponding gear
and moves the gear selection/shift shaft through the
selected. In this way, the speeds of both synchronizer
torque of the cable, and the gear selection/shift taper
hub and gear are synchronized. Ensure that the taper
head on the gear selection/shift shaft moves along with it
head on the gear selection/shift socket can select the
and locates at the groove of the 1st/2nd shift fork, at this
gear accurately and the gears are remained in the correct
time, the gear selection/shift taper head shall be
work position. After being transmitted from the engine to
completely separated from the groove of 3rd/4th taper
the transmission input shaft through the clutch, the torque
head. One end of the interlock pin will lock 1st/2nd gear.
is transmitted to the output shaft pinion and final drive
Then the gear shift rocker arm rotates the gear selection/
driven gear and then to the drive shaft through the
shift shaft through the torque of the cable, and the gear
selected gear. The operation of the 2nd, 3rd, 4th, 5th, 6th
selection/shift socket rotates along with the gear
and reverse gears is the same with that of the 1st gear.
selection/shift shaft, one side of the gear selection/shift
When the reverse gear is selected, the reverse gear
11-60
tooth is engaged with the output shaft reverse gear tooth

and reverse idler gear, hence, the rotation direction of the
driven shaft is changed and the reverse gear is achieved.
Reverse Lamp Switch

The reverse lamp plunger switch is installed on the rear
11-61
11-62
Clutch
Clutch
Specification
Bolt - clutch pedal 25 ± 3

Nut - clutch pedal 25 ± 3
Bolt - clutch disc Tighten the torque to 9 ± 1N.m diagonally in sequence,
then re-tighten to 35 ± 3N.m diagonally.
Hose/tube assembly connectors 16 ± 2
Nut - clutch oil pipe 9±1
12-1
Clutch
Layout
5
6
DS110005
1 Transmission assembly 4 Clutch hose/tube subassembly

2 Clutch cover 5 Clutch master cylinder assembly
3 Clutch disc 6 Clutch pedal assembly
12-2
Clutch
When the clutch pedal is fully Linkage mechanism is loosened Repair or replace the loosened linkage
depressed, the shift lever cannot shift mechanism when necessary
to/out of R gear freely
Clutch disc is damaged Replace damaged clutch disc
Shift fork shaft is installed improperly Remove the shift fork shaft and re-
install it properly Apply a small amount
of wheel bearing grease on the shift
fork end at the release bearing
Clutch disc hub is stuck in the input Repair or replace the clutch disc hub
shaft spline
Clutch disc warps or bends Replace warped or bent clutch disc
Clutch slips Driver operates the car improperly Correct the driver's operation when
necessary
Clutch disc is immersed with oil Eliminate the failure at oil leakage
point and install new clutch disc
Friction surface of clutch disc is worn Replace worn clutch disc with a new
or torn one
Clutch cover or flywheel warps Replace warped clutch cover or

flywheel
Diaphragm spring is weak Replace the diaphragm spring
Clutch disc is not in place Start the engine 30-40 times Do not
overheat the engine
Clutch disc is overheated Cool down the clutch disc
Clutch jitters Friction surface is burned or worn Eliminate the failure at oil leakage
caused by oil on it point and install new clutch disc
Input shaft spline is worn Replace worn input shaft
Clutch cover or flywheel warps Replace warped clutch cover or

flywheel
Burned or smeared resin appears on Grind away the burned or smeared

clutch cover or flywheel resin on surface Replace any burned
parts or parts with hot cracks
Clutch clicks Contraction spring is weak Eliminate the failure of oil leakage
source and replace clutch disc
Oil exists in bumper block of clutch Eliminate the failure of oil leakage
disc source and replace clutch disc
Shock absorption spring of clutch disc Replace clutch disc

is damaged
12-3
Clutch
Clutch makes noises during Driver operates the car incorrectly Correct the driver's operation when
engagement necessary
Check if the release lever is installed Remove and reinstall the release lever
improperly properly
The return spring of connecting rod Replace the weak return spring of
degrades connecting rod
Pedal stays on the floor without Connecting rod is stuck Lubricate and move the clamped
recovery connecting rod
Clutch cover spring is weak Replace clutch cover
12-4
Clutch
Replacement of Clutch Main Pump

Repair Guidance
Removal
Replacement of Clutch Cover/Clutch Disc
Removal 1 Disconnect the negative battery cable. (Refer to
Battery section for precautions)
1 Remove the engine (refer to Engine Assembly
Replacement).
2 Support clutch disc with a proper tool, then
screw out fastening bolts successively.
3 Remove the clutch cover and clutch disc.
GS070002
2 Drain the brake fluid reservoir.

Caution: Caution: If brake fluid splashes on the
painting surface, flush the affected area with cold
GS070001 water immediately.
Installation 3 Disconnect the spring clamp, remove the oil

supply hose from clutch main pump and cover
1 Install the clutch cover and clutch disc, and align two ends tightly to prevent dust.
clutch disc with proper tool.
4 Disconnect the clutch high-pressure tube from
2 Tighten fastening bolts successively. Tighten the main pump.
torque to 9 ± 1N.m diagonally in sequence, then
5 Unscrew 2 nuts to take off the pin shaft - main
re-tighten to 35 ± 3N.m diagonally.
pump push rod and pedal swing arm (2), lock pin
Caution: Check the thickness of clutch disc. - main pump push rod and pedal swing arm (3),
Replace the disc when it exceeds or approaches then remove the clutch main pump from the dash
the wearing limit. Clutch cover must be replaced panel.
when it is fallen off accidentally. Clutch disc and
clutch cover must be replaced at the same time.
GS070003
Installation
12-5
Clutch
Tightening torque of main pump mounting bolt: 22 - Replacement of Clutch Pedal

28N.m Removal
1 Remove the clutch main pump (refer to
Replacement of Clutch Main Pump).
2 Remove fastening bolts and nuts from the clutch
pedal.
GS070004
2 Exhaust the air(Refer to Air Exhaust of Hydraulic

Clutch).
3 Refill the brake fluid to the level marked with
GS070005
MAX in the reservoir and connect the negative
battery cable.
3 Remove fastening bolts from the clutch pedal.
4 Remove the clutch pedal.
Caution: After clutch switch or pedal is replaced,
it is required to perform initial "learning":
1 Completely depress the clutch pedal;

2 Pull the push rod of clutch switch to the highest
point;
3 Release the clutch pedal, and the pedal will
press the clutch switch to proper operating gear;
The clutch switch will not work properly until initial
"learning" is completed.
Installation
Tightening torque of clutch pedal mounting bolts: 22 -
28N.m
12-6
Clutch
Replacement of Clutch Pedal Position 3 Tighten the screws to 1.5 ± 0.5N.m.

Sensor
Removal
1 Remove the harness of clutch pedal position
sensor.
GS070006
2 Remove fastening bolts of clutch pedal position

sensor.
3 Remove the clutch pedal position sensor.
Caution: After the switch of clutch pedal position
sensor or clutch pedal is replaced, it is required
to perform initial "learning":
The clutch switch will not work properly until initial
"learning" is completed.
Installation
1 Put the cylindrical bracket rod on the clutch
pedal in the middle of U-shaped structure of the
sensor (A in the figure below).
GS070007
2 Align the locating pin on the sensor with the

locating hole in the clutch pedal bracket (B in the
figure above).
12-7
Clutch
Technical Parameters Replacement of Clutch CSC Bleeder

Connector
Removal
Component Clutch pedal sensor
Name 1 Disconnect the negative battery cable. (Refer to
Battery section for precautions)
Connector Status
2 Drain the brake fluid reservoir.
3 Disconnect the clutch high-pressure tube from
main pump.
4 Disconnect CSC bleed connector from
Pin A Pin C transmission.
Pin B
DS110009
Technical A#:5V
Parameters C#: grounding
(static)
A#B#：3 ± 0.6K Ω

It monitors the position of clutch pedal, converts the
position into voltage signal and sends to the control
module.
GS070008
Learning method for clutch pedal sensor: install
diagnostic software CVDS of the latest version
1.7.3.40964 and above.
After data has been refreshed, enter into EMS Special

Function- Clutch Pedal Self-learning to perform the
learning of clutch pedal sensor:
Caution: This function only applies to 6MT

vehicles equipped with clutch pedal position
sensor. When replacing with a new EMS or clutch
pedal or clutch pedal position sensor, it is aways
necessary to utilize Special Function- Clutch
Pedal Self-learning in the diagnostic software to
GS070009
learn position information of clutch pedal
position sensor in EMS. Before learning, user can
enter into data flow, and view Data Flow - Self-
learning Status of Clutch Pedal Position.
12-8
Clutch
5 Remove the nuts securing the clutch pipeline Air Exhaust of Hydraulic Clutch
support to the dash panel.
1 Exhaust air entering into the hydraulic system
when pipelines are disconnected for repair.
During air exhaust, the brake fluid in clutch fluid
reservoir must be kept in MIN or a slightly higher
level.
GS070010
6 Take out the hose/tube assembly from each

clamp.
Installation DS110003
attention to the following precautions: 2 Connect ethylene plastic hose to the air exhaust
plug of the clutch sub-pump. Insert the other end
- Clutch fuel pipe bracket nuts 9 ± 1N.m of ethylene plastic hose into a glass container
half filled with brake fluid.
2 Exhaust the air. Refer to Air Exhaust of Hydraulic
Clutch. 3 Slowly depress the clutch pedal.
3 Refill the brake fluid to the level marked with 4 While depressing the clutch pedal, rotate the
MAX in the reservoir and connect the negative knob at the upper part of bleed connector by
battery cable. hand until the fluid flows out, tighten the knob
and release the clutch pedal.
5 Repeat Step 3 and 4 until no bubble exists in the
fluid.
6 Refill the brake fluid to the level marked with
MAX in the reservoir. Caution: Brake fluid may
damage electrical connector and painting
surface. Use cotton cloth, proper container and
fender cover to prevent brake fluid from
contacting these areas.
Caution: It is prohibited to refill the fluid drained
from the system back into fluid reservoir of
clutch main pump. Because:
1 Air may mix in the fluid

2 The fluid may be contaminated
3 The fluid may contain too much water
12-9
Clutch
pull rings on the outer ring of the pressure plate, which is

then connected to the housing through a spring. The
The hydraulic clutch separating system is composed of spring is composed of three quenched and tempered
two main parts, one master cylinder and one release steel sheets. When the clutch pedal is depressed, it will
bearing. pull the pressure plate away from the driven plate. The
clutch housing is punched by steal plate.
Clutch Hydraulic System
The clutch master cylinder is directly installed on the The diaphragm spring is a cast ring with many release
pedal box in the passenger compartment, and its piston fingers in its inner ring. There are round support rings
push rod is secured to the clutch pedal box by master installed on the housing so that the diaphragm spring can
cylinder fastening clips. rotate between them. The diaphragm spring is not
directly connected to the pressure plate. When the
The clutch pipeline is connected to the master cylinder
release bearing applies stress on the release finger of the
with a rotary connector, and this kind of connector is
diaphragm spring, the diaphragm spring will rotate
useful for installation and adjustment. The other end of
around the support ring to leave the pressure plate. And
the pipeline is connected to the release bearing with
meanwhile, the spring of the pressure plate connected to
quick connector. The pipeline is of a flexible type for easy
the housing will also be away from the driven plate.
installation and also can buffer the replacement and
vibration generated by the engine.
The cylinder connecting piece installed on the manual

transmission housing, and the release bearing coaxial
with the transmission input shaft form a release
mechanism, the clutch pipeline from the cylinder
connecting piece is connected to the pipeline of the
master cylinder through the quick connector.
Clutch Mechanical System

The vehicle with manual transmission is equipped with
double mass flywheel. The clutch cover assembly is
installed on the flywheel with three locating pins and is
secured with six bolts.
Driven Plate
The driven plate is installed between the flywheel and the
pressure plate. Its feature is that the spline hub engages
the spline on the transmission input shaft. The friction
plate is composed of two discs, which are riveted on
each side of the driven plate body. The rivets are installed
in the notches in the friction plate as well as that at the
other side to protect the pressure plate and flywheel from
damage.
Clutch Cover Assembly

The clutch cover assembly is composed of the
diaphragm spring, pressure plate and cover. The
pressure plate is made of cast iron and has a smooth
plane machined to connect the driven plate. There are 3
12-10
Steering System
Steering System
Specification
Specification
Type Electric Power Assisted Steering
Steering column type 2-way/4-way adjustment shrinkable energy-absorbing

steering column
Steering wheel turns - from a dead center at one side to 3.4

another dead center at the other side
Total transmission ratio 18.2
Minimum turning circle diameter 12m
Electric steering gear type Rack-assist type EPS
Torque
Nut/bolt - steering column bracket to body 22 ± 2

Bolt - intermediate shaft to extension shaft 30 ± 3
Bolt - steering column to intermediate shaft 22 ± 2
Bolt - steering intermediate shaft extension to steering gear 22 ± 2
Nut - dust shield of steering intermediate shaft to body dash 9±1
panel
Nut - steering gear outer rod to steering knuckle 90 ± 5

Locking nut of steering gear 53~72
Nut - steering gear outer rod to steering knuckle 90 ± 5

Bolt - frame to steering gear 100 ± 10
Bolt/nut - frame to steering gear 180 ± 10
Nut - steering wheel assembly 35 ± 3
13-1
Steering System
Layout
Power Steering System Layout (LHD)
GS060001
1 Steering column 4 Electric steering gear assembly

2 Steering intermediate shaft 5 Steering wheel
3 Steering intermediate shaft extension
13-2
Steering System
Power Steering System Layout (RHD)
GS060002
1 Steering column 4 Electric steering gear assembly

2 Steering intermediate shaft 5 Steering wheel
3 Steering intermediate shaft extension
13-3
Steering System
Electric Steering Gear Assembly Exploded View (LHD)
8
8
7
7
6
6
7
7
5 1
9
5
2
4
3
2
3
4
GS060004
1 Steering gear body 6 Nut - steering gear to frame

2 Dust shield assembly 7 Gasket - steering gear to frame
3 Lock nut 8 Bolt - steering gear to frame
4 Outer rod 9 Nut - steering gear outer rod to steering knuckle
5 Bolt - steering gear to frame
13-4
Steering System
Electric Steering Gear Assembly Exploded View (RHD)
7
8
6
7 7
6
7
10
1
5
4
3 5
2
10
2
3
4
GS060003
1 Steering gear body 6 Nut - steering gear to frame

2 Dust shield assembly 7 Gasket - steering gear to frame
3 Lock nut 8 Bolt - steering gear to frame
4 Outer rod 9 Nut - steering gear outer rod to steering knuckle
5 Bolt - steering gear to frame
13-5
Steering System
Repair Guidance Replacement of Steering Column Assembly
Replacement of Steering Wheel Removal
Removal 1 Remove the steering wheel. Refer to Removal/

Installation of Steering Wheel for details.
1 Disconnect the battery (negative first).
2 Remove the upper and lower steering column
2 Remove the driver airbag module assembly shroud. Refer to Replacement of Upper and
(refer to Removal of Steering Wheel (Driver) Lower Steering Column Shroud for details.
Airbag Assembly).
3 Secure the clock spring with adhesive tape or
3 Disconnect the electrical connector of steering equivalent, remove the clock spring and steering
wheel switch. angle sensor. Refer to Replacement of Clock
4 Screw out the nuts of steering wheel assembly Spring for details.
and remove the steering wheel assembly. 4 Remove the combination switch. Refer to
5 Remove the steering wheel assembly. Replacement of Combination Switch for details.
5 Remove the ignition switch. Refer to
Replacement of Ignition Switch for details.
Installation
6 Unscrew the top clamping bolt connecting the
1 Installation is the reverse of removal. steering column and the steering intermediate
shaft.
Caution: When installing the steering wheel,
ensure the steering column is matched with the 7 Unscrew and remove the nuts and bolts securing
rectangular key slot of the steering wheel. the steering column bracket to the body.
6
GS060005
GS210002
Installation
Where:
- The tightening torque of the bolt/nut - steering column

bracket to body is 22 ± 2N.m.
- The tightening torque of the bolt - steering column to

intermediate shaft is 22 ± 2N.m.
13-6
Steering System
Replacement of Steering Intermediate Shaft

Removal
1 Remove the bolt connecting the steering column
and the steering intermediate shaft. (Tightening
torque: 22 ± 2N.m)
2 Remove the bolt connecting the steering
intermediate shaft and the steering extension
shaft from one side of the wheel. (Tightening
torque: 30 ± 3N.m)
3 Remove the nut connecting the dust shield of
steering intermediate shaft and body dash panel.
(Tightening torque: 9 ± 1N.m) GS060019
GS060006
Installation
Caution: The error-proofing connection shall be
made between steering column and steering
intermediate shaft as well as steering
intermediate shaft and electric steering gear via
Double-D. The installation direction shall be
noticed and violent installation is not allowed.
13-7
Steering System
For 4WD (LHD), the gap between steering gear and front
Replacement of Electric Steering Gear
axle housing is small. It is quite difficult to remove the
Assembly and Steering Intermediate Shaft
Extension steering gear with the front axle still installed, in this case,
operate according to the following methods:
Removal
1 Remove the two front wheels. a. Move the steering gear rightward first and then
downward in the direction as indicated by the arrow to
2 Remove the bolt connecting the steering
intermediate shaft to the steering extension shaft allow the steering gear not to contact the protruding
from the side of wheel. part of the axle housing.
GS060007 GS060009
3 Lift the vehicle from the lifting platform. b. Move the entire steering gear leftward in the direction
4 Remove the nut connecting the steering gear tie as indicated by the arrow, till the right tie rod of
rod and the steering knuckle. Use ball head steering gear passes through the lower swing arm
puller C00017036 if necessary. corner.
5 Remove the longitudinal thrust beam (if any).
GS060010
GS060008
6 Pull out the connector from the steering motor.

7 Remove the bolts, nuts and gaskets securing the
steering gear to the frame.
8 Take out the steering gear and the intermediate
shaft extension assembly.
13-8
Steering System
c. Move the steering gear to the bottom right to take it out. 4 Install the bolt and tighten to 100 ± 10N.m.
5 Tighten the bolt/nut mentioned in Step 3 to 180±
10N.m.
6 Install the nut connecting the steering gear tie
rod and the steering knuckle, and tighten to 90 ±
5N.m.
7 Install the bolt securing the steering intermediate
shaft to the steering intermediate shaft extension
from the wheel side, and then tighten to 30 ±
10N.m.
8 Install the two front wheels. Refer to Wheels
Installation for details.
GS060011
9 Remove the steering gear and steering 10 Align four wheels.
intermediate shaft extension (remove the
steering gear first before removing the steering
intermediate shaft extension).
Installation
1 Install the bolt connecting the steering gear and L
the steering intermediate shaft extension and
tighten to 22 ± 2N.m.
Caution: The error-proofing connection shall be
made between steering column and steering
intermediate shaft as well as steering
intermediate shaft and electric steering gear via
Double-D. The installation direction shall be
GS060013
noticed and violent installation is not allowed.
2 Pass the steering intermediate shaft extension
through the hole in the frame, and align the
steering gear to corresponding mounting hole.
GS060014
GS060012
3 Pass the bolt through the steering gear and the

frame, then install the gasket and nut, but do not
tighten.
13-9
Steering System
Installation
Replacement of Steering Gear Outer Rod
1 Tighten the steering tie rod to the position
Removal
marked on the inner rod thread, with the steering
1 Lift the vehicle from the lifting platform. tie rod ball joint upward. Never tighten the
2 Remove the wheels. Refer to Wheels locking nut of tie rod.
Replacement for details. 2 Connect the steering tie rod ball joint to the
3 Remove the nut securing the tie rod ball head steering knuckle, install new nut and tighten to
with the steering knuckle, detach the ball head 90 ± 5N.m.
with the tool C00017036. 3 Install the wheels.
4 Align four wheels.
5 Tighten the locking nut to 53-72N.m.
C00017036
GS060015
4 Release the locking nut of the steering tie rod.

5 Mark the relative position of the outer rod on the
inner rod thread, and screw off the steering tie
rod from power steering gear.
GS060016
13-10
Steering System
Replacement of Steering Gear Dust Shield

Removal
1 Remove the steering gear outer rod. Refer to
Replacement of Outer Rod for details.
2 Loosen 2 clamps of the steering gear sleeve and
discard them.
GS060017
3 Take off the steering gear sleeve.
Installation
1 Clean the junction surface of the dust shield on
the steering gear.
2 Apply silicone oil around the junction surface of
the dust shield and the steering gear.
3 Install the dust shield and rotate it manually 3
turns and above.
4 Install a new clamp and tighten it.
5 Install the steering gear outer rod. Refer to Outer
Rod Installation for details.
6 Align four wheels.
13-11
Steering System
Special Tool
Tool Number and Illustration

Description
C00017036
Ball head puller
C00017036
13-12
Steering System

EPS System Control Diagram
Steering Sensor EPS Motor

ᢣ⸟Ֆ᝕ಞ EPS⭫ᵰ
TCM
਎䙕㇧
ESP PT ᧝࡬⁗ඍ
ࣞᘷどᇐ᧝࡬㌱㔕 CH
EPS
GW
⭫ᆆ࣑ࣟ䖢ੇ CH
㖇ީ ECM
ਇࣞᵰ
PT ᧝࡬⁗ඍ
EPB
⭫ᆆ傱䖜࡬ࣞ CH
IPK
INFO 㓺ਾԠ㺞
BCM
DiagnoStic
BO 䖜䓡᧝࡬⁗ඍ
䈀ᯣ VD
⺢㓵 ࣑ࣞ儎䙕CAN㓵 ᓋⴎ儎䙕CAN㓵䖜䓡儎䙕CAN㓵

䈀ᯣCAN ၧ҆儎䙕CAN㓵
GS060020
13-13
Steering System
The steering system is designed to change and keep the driving direction of the vehicle. Electric power steering is a
specialized system for helping the driver with steering so as to reduce fatigue strength of the driver. EPS system is
composed of steering wheel, steering column, steering intermediate shaft and electric steering gear, etc.
Electric Steering Gear

D90 adopts rack-assist type electric steering gear, with the schematic diagram shown as below. When the driver
operates the steering wheel for steering, on the one hand, the force from input shaft (1) will directly transfer to the rack (3)
through gear and rack engagement (4); on the other hand, the steering angle sensor (under the combination switch),
torque sensor (2) and wheel speed sensor (on the brake angle) detects the steering and torque of steering wheel as well
as the car speed, and transmits the voltage signal to ECU (5), ECU then gives commands to the motor (5) according to
that signal to make the motor (5) output the power torque with specified magnitude and direction, the power then will be
driven to rack (3) by the pulley (7) and ball screw (8) system, thereby generating assisted power. If no steering operation
needed, ECU will not give commands to the motor, and the motor does not work.
9 8
3
5 6 7
GS060018
1 Input shaft 6 Bias wheel

2 Torque sensor 7 Belt or pulley
3 Drive rack 8 Ball nut component
4 Gear and rack engagement 9 Bearing
5 Motor assembly
13-14
Front Suspension
Front Suspension
Specification
Torque
Bolt - upper swing arm ball head assembly to upper swing 35 ± 3

arm welding assembly
Bolt - lower swing arm ball head assembly to lower swing 125 ± 10
arm welding assembly
Bolt/nut - front suspension lower swing arm assembly to 240 ± 10

frame
Bolt/nut - front suspension upper swing arm assembly to 140 ± 20

frame
Bolt/nut - front shock absorber strut to lower swing arm 180 ± 10

welding assembly
Nut - front suspension lower swing arm ball head assembly 150 ± 10
to steering knuckle
Nut - front suspension upper swing arm ball head assembly 100 ± 10
to steering knuckle
Nut - brake hose to upper swing arm 16 ± 2

Nut - front stabilizer bar link to lower swing arm 65 ± 5
Nut - front stabilizer bar to stabilizer bar link 50 ± 5
Nut - steering gear tie rod to steering knuckle 90 ± 5
Nut - front hub 350 ± 15
Nut - top of front shock absorber to frame 65 ± 5
Nut - steering gear tie rod to steering knuckle 90 ± 5
Nut - top of front shock absorber to frame 65 ± 5
Nut - front shock absorber locking nut 70 ± 5
Bumper block - frame 95 ± 9
Bolt - stabilizer bar clamping bracket to frame 35 ± 3Nm
14-1
Front Suspension
Layout
Front Suspension Layout
2
8 9 4 7
ES060000
1 Front suspension upper swing arm assembly 6 Bumper block

2 Front suspension lower swing arm assembly 7 Brake angle assembly
3 Front suspension stabilizer bar 8 Steering gear
4 Front suspension stabilizer bar link 9 Propeller shaft (4WD)
5 Front shock absorber strut and spring assembly
14-2
Front Suspension
Front Upper/Lower Swing Arm Exploded View
1
6
2
4 6 5
ES060001
1 Front suspension upper swing arm assembly 4 Front suspension lower swing arm ball head
assembly
2 Front suspension upper swing arm ball head
assembly 5 Front suspension lower swing arm bushing
3 Front suspension lower swing arm assembly 6 Front suspension upper swing arm bushing
14-3
Front Suspension
Front Horizontal Stabilizer Bar Exploded View
4
1
2
3
ES060002
1 Front suspension stabilizer bar 3 Front suspension stabilizer bar clamping bracket
2 Front suspension stabilizer bar link 4 Stabilizer bar bushing
14-4
Front Suspension
Front Shock Absorber Strut and Spring Assembly Exploded View
1
2
11 4
6
7
8
10
9
ES060003
1 Lock nut 6 Lower vibration isolator

2 Upper gasket 7 Lower gasket
3 Upper vibration isolator 8 Lower washer
4 Front shock absorber upper spring seat 9 Front shock absorber strut dust shield
5 Rubber gasket of front shock absorber upper 10 Front shock absorber strut subassembly
spring seat 11 Coil spring
14-5
Front Suspension
Front Steering Knuckle Exploded View (4WD)
3
1 2
ES060004
1 Brake disc 5 Brake disc mudguard

2 Front hub 6 Brake angle
3 Collar 7 Brake caliper
4 Front hub bearing
14-6
Front Suspension
Front Steering Knuckle Exploded View (2WD)
5
4 8
3
1 2
ES060005
1 Brake disc 6 ABS gear ring

2 Front hub 7 Mudguard
3 Collar 8 Brake angle
4 Front hub bearing 9 Brake caliper
5 Spindle
14-7
Front Suspension
Repair Guidance
Four-wheel Alignment Front Wheel Alignment
Check
1 Unscrew 4 lower swing arm nuts as well as left
1 Ensure that the correct vehicle data has been and right steering gear adjusting nuts.
entered into the equipment.
2 Check if the steering tie rod ball joint, front lower
swing arm ball joint and wheel bearing are worn
or run properly. Replace or repair if necessary.
3 Check the tire pressure.
4 Lift the vehicle from the lifting platform. Ensure
that vehicle weight is on the support. Ensure that
the size of the mounting clamp for wheels has
been calibrated correctly and secured safely to
the vehicle.
5 Ensure that the camera device is secured and
aligned properly.
6 Conduct the wheels alignment according to ES060007
instruction of equipment manufacturer.
7 Ensure that the steering wheel is in middle 2 Adjust the angle of lower swing arm adjusting
position. bolt and the length of steering gear tie rod to
make four-wheel alignment parameters fall in the
Four-wheel Alignment Parameters target range (adjust according to indication of
four-wheel aligner system).
Items Four-wheel Four-wheel
Alignment Alignment
Parameter Parameter
(Unilateral (Bilateral Sum/
Nominal Value Difference)
and Tolerance)
Front wheel 0 ± 0.5° Difference

camber between left and
right ≤ 0.5°
Front wheel 3.6 ± 0.8° Difference
kingpin caster between left and
right ≤ 0.5°
Front wheel 0 ± 0.15° Total front toe-in
toe-in angle ≤ 0.15°
ES060006
Rear wheel toe- ± 0.25° -
in angle
3 Tighten the lower swing arm nut to 240 ± 20N.m;
Rear wheel ± 0.5° - and tighten the steering locking nut to
camber 53~72N.m.
Rear shaft 0 ± 0.25° - 4 After adjustment, turn the steering wheel leftward
thrust angle and rightward to a fully locked position and
check whether wheels interfere suspension
components.
14-8
Front Suspension
Replacement of Front Suspension Upper Replacement of Front Lower Swing Arm

Swing Arm Assembly Assembly
Removal
1 Lift the vehicle.
2 Remove the wheels. Refer to Wheels Removal
for details.
3 Detach the wheel speed sensor and brake hose
installed on the upper swing arm.
4 Remove the nuts connecting front suspension
upper swing arm to brake angle. Use ball head
puller C00017036 if necessary.
6
5 Detach the left/right bolts and nuts connecting
front upper swing arm to frame.
8 9 3 4
6 Remove front suspension upper swing arm 5
ES060008
assembly.
Removal
7 To replace the ball head assembly, unscrew the
bolt connecting ball head to upper swing arm 1 Lift the vehicle.
(tightening torque: 35 ± 3N.m), take out the bolt, 2 Remove the wheels. Refer to Wheels Removal
then control arm ball head can be removed.
for details.
Installation
3 Unscrew the lower nuts of stabilizer bar link.
1 Secure the upper swing arm to the frame. 4 Unscrew the nut fastening the steering gear tie
2 Tighten the left/right bolts and nuts on the frame rod to the steering angle. If necessary, use the
to 140 ± 10N.m. ball head puller C00017036.
3 Tighten the nut connecting upper swing arm to 5 Remove the nut connecting lower swing arm and
brake angle to 100 ± 10N.m. brake angle. Use ball head puller C00017036 if
necessary.
4 Install the wheel speed sensor and brake hose
connected to the upper swing arm. Tighten the Steps 6-7 are only for 4WD models.
nut connecting brake hose to upper swing arm to
16 ± 3N.m. 6 Remove the nuts at propeller shaft wheel end,
refer to Removal of Propeller Shaft Assembly for
5 Install wheels. Refer to Removal/Installation of
details. Use a jack to support the steering angle.
Wheels for details.
7 Remove the upper swing arm assembly. Refer to
6 For models with AFS system, the height sensor
Removal of Upper swing Arm Assembly for
shall be learned via a scan tool.
details.
8 Remove the left/right bolts and nuts connecting
lower swing arm to frame.
9 Remove the nut at the bottom of shock absorber,
and use a jack to support front lower swing arm
(to the height where lower swing arm can be
removed).
Caution: Avoid damages to wheel speed harness
and brake pipeline. It is required to support the
swing arm and steering angle to avoid injury from
falling objects.
10 Remove the lower swing arm.
11 To replace the ball head assembly, unscrew the
bolt connecting ball head to lower swing arm
14-9
Front Suspension
(tightening torque: 125 ± 10N.m), take out the When installing the hub nut, note that:
bolt, then the control arm ball head can be
removed. · The mating surface with a "JPS" mark of the locking
washer shall face the mounting surface of nut.
Installation ·Pre-tightening torque: 100 ± 10N.m.

2WD:
·Rotate the hub for 10 circles back and force. Install the
1 Install the bolt and nut connecting shock hub bearing in place and tighten to: 350 ± 15N.m.
absorber assembly to lower swing arm
assembly, but do not tighten them. (Tightening · Vertically knock down the lock nut of front hub into the
torque: 180 ± 10N.m) groove of drive shaft or spindle to prevent the nut from
loosening.
2 Install the nut connecting lower swing arm
assembly to steering knuckle, but do not tighten
it. (Tightening torque: 150 ± 10N.m)
3 Tighten left/right bolts and nuts connecting lower
swing arm assembly to frame to 240 ± 20N.m.
4 Tighten the lower nut of stabilizer bar link to 65 ±
5N.m.
5 Tighten the nut connecting the steering gear tie
rod to the steering angle to 90 ± 5N.m.
6 Tighten the bolts/nuts mentioned in Step 1 and 2.
7 Install the wheels.
8 Check four-wheel alignment parameters.
4WD: ES060018
1 Install left/right bolts and nuts connecting upper 6 Install the nut connecting upper swing arm
swing arm assembly to frame and tighten to 140 assembly to steering knuckle and tighten to 100
± 10N.m. ± 10N.m.
2 Install left/right bolts and nuts connecting lower 7 Tighten successively the nuts mentioned in Step
swing arm assembly to frame and tighten to 240 4 to 5.
± 20N.m.
8 Tighten the lower nut of stabilizer bar link to 65 ±
3 Install the bolt and nut connecting shock 5N.m.
absorber assembly to lower swing arm assembly
9 Tighten the nut connecting the steering gear tie
and tighten to 180 ± 10N.m.
rod to the steering angle to 90 ± 5N.m.
4 Install the nut connecting lower swing arm
assembly to steering knuckle, but do not tighten
it. (Tightening torque: 150 ± 10N.m) 11 For models with AFS system, the height sensor
shall be learned via a scan tool.
5 Install a new drive shaft nut, but do not tighten
(tightening torque: 350 ± 15N.m). Refer to 12 Check four-wheel alignment parameters.
Installation of Drive Shaft for details. When
installing the steering knuckle, rotate it outside to
a certain angle to allow the half shaft to insert
into steering knuckle hole.
14-10
Front Suspension
Lower Swing Arm Bumper Block Replacement of Front Lower Swing Arm
Install the bumper block to front frame. The lower swing Bushing
arm bumper block of high chassis is shown below. The Removal
special tool for removal and installation of bumper block 1 Use special tool C00089916 to press out the
is C00089915. The tightening torque of bumper block is lower swing arm bushing. It must be pressed out
95 ± 9N.m. vertically to prevent sleeve deformation.
ES060028
ES060009
Installation
1 Check the sleeve for deformation. If any, replace
the lower swing arm assembly; press vertically
the bushing into sleeve, with the press-in force
controlled within 12 ～ 40KN. If beyond the range,
replace the lower swing arm assembly.
14-11
Front Suspension
Replacement of Front Horizontal Stabilizer Incorrect Picture

Bar
Removal
1 Detach the lower fastening nut of the stabilizer
bar link.
2 Unscrew the nut securing the stabilizer bar to the
stabilizer bar link.
3 Unscrew the stabilizer bar bracket bolt, remove
the stabilizer bar, stabilizer bar clamping bracket
and stabilizer bar bushing.
ES060032
Installation
1 Install the stabilizer bar, stabilizer bar clamping 2 Tighten the nut connecting stabilizer bar to
bracket and stabilizer bar bushing. stabilizer bar link to 50 ± 5N.m.
· Do not put the bracket on two lugs at the lower of 3 Tighten the bolt connecting stabilizer bar
bushing. The two lugs shall be placed outside the clamping bracket to frame to 35 ± 3N.m.
bracket. 4 Tighten the nut connecting stabilizer bar link to
lower swing arm to 65 ± 5N.m.
ES060011
· The white mark on horizontal stabilizer bar shall be

flush with the bushing.
Correct Picture
ES060012
14-12
Front Suspension
Replacement of Front Shock Absorber Replacement of Front Shock Absorber

Assembly Assembly Component
Removal Removal
1 Remove the wheels. Refer to Removal/ 1 Remove the front shock absorber assembly.
Installation of Wheels for details. Refer to Removal of Front Shock Absorber
2 Unscrew the nut fastening the steering gear tie Assembly for details.
rod to brake angle. Use ball head puller 2 Secure the spring compressor C00017035-1 and
C00017036 if necessary. C00017035-2 to front shock absorber spring.
3 Remove the front upper swing arm assembly.
Refer to Removal of Upper Swing Arm Assembly
for details. Jack the front lower swing arm with a
jack.
4 Remove the drive shaft nut, detach the drive
shaft and steering angle (for 4WD model).
5 Remove the bolt securing the upper part of
shock absorber to frame.
6 Remove the bolt securing shock absorber to
lower swing arm.
7 Remove the front shock absorber assembly.
Installation
ES060013
1 Install the nut connecting front shock absorber
assembly to frame, but do not tighten it. 3 Unscrew the nut on the top of front shock
(Tightening torque: 65 ± 5N.m) absorber and discard it.
2 Install the bolt connecting front shock absorber
assembly to lower swing arm and tighten to 180
±10N.m. Then tighten the nut mentioned in Step 3
1.
3 Tilt the steering knuckle outside to a certain
angle to allow the half shaft to insert into the 5
4
steering angle hole. Install the drive shaft nut
(tightening torque: 350 ± 15N.m). Refer to
Installation of Drive Shaft for details.
4 Install the upper swing arm assembly. Refer to 6
Removal/Installation of Upper Swing Arm
Assembly for details.
5 Install the nut connecting the steering gear tie ES060014
rod to the brake angle and tighten to 90 ± 5N.m.
6 Install the wheels. Warning: Make sure the spring compressor has
compressed the spring and removed the bearing
7 Check four-wheel alignment.
pressure from shock absorber before removing
self-locking nut on the top of front shock
absorber strut.
Caution: Ensure that the black coating on the
spring is not damaged.
4 Remove the upper gasket, upper vibration
isolator, front shock absorber upper spring seat,
front shock absorber upper spring seat rubber
14-13
Front Suspension
gasket, lower vibration isolator, lower gasket and Replacement of Front Steering Knuckle
lower washer. Removal
5 Remove the coil spring of front shock absorber.
1 Remove the brake caliper and brake disc. Refer
6 Remove the dust shield and lower washer of to Replacement of Front Brake Disc and Brake
front shock absorber. Caliper Assembly for details.
7 Release the pressure of coil spring, loosen 2 Disconnect the brake angle from upper swing
adapter from spring compressor and remove the arm/lower swing arm, the propeller shaft from
coil spring. brake angle and the wheel speed sensor, then
remove the brake angle assembly.
3 Press out the spindle (for 2WD model).
Installation
1 Check the front shock absorber strut, upper/
lower vibration isolators, washers, front shock
absorber upper spring seat and front shock
absorber dust shield for signs of crack, aging
and damage.
3
2 Clean the front shock absorber strut and 6
1 4 5
washers.
3 Successively install washer, dust shield, washer,
lower gasket and lower vibration isolator to front
shock absorber assembly.
4 Install the coil spring of front shock absorber to
front shock absorber strut. ES060016
5 Locate the spring compressor to the front shock
absorber, use spring compressor C00017035-1 4 Press out the hub.
and C00017035-2 to compress the spring.
5 Take out the circlip.
6 Ensure correct relative installation position,
6 Press out the front hub bearing.
install the upper vibration isolator of front shock
absorber, rubber gasket of upper spring seat and
upper spring seat of front shock absorber to front
shock absorber shaft.
7 Install the upper washer of front shock absorber
and new nuts and tighten to 70 ± 5N.m.
8 Release the elasticity of spring, loosen the
adapter of spring compressor and take off the
spring compressor.
9 Clean the junction between front shock
absorber/spring assembly and the body.
10 Install the front shock absorber assembly.
ES060017
Caution: When pressing out the bearing, take

care to avoid producing burr on the inner cavity
hole surface of steering knuckle.
14-14
Front Suspension
Installation
1 Check and confirm there is no damages and
impact traces on components, and no damages
and impurities on machined component surface.
2 Press the hub bearing into steering knuckle.
Make sure the outer ring of bearing contacts
closely with inner hole shaft shoulder of steering
knuckle. Press-in force shall not exceed 60KN.
3 Put the circlip into the slot of steering knuckle
inner hole with a caliper, and take care not to
damage the bearing seal ring.
4 By aligning to front hub bearing inner ring end
face, press the front hub into front hub inner ring
to make front hub shaft shoulder contact closely
with the end face of front hub bearing inner ring.
5 Press in the spindle. (2WD model)
6 Successively connect the brake angle to lower
swing arm, propeller shaft to brake angle, brake
angle to upper swing arm and wheel speed
sensor. Refer to Installation of Lower Swing Arm,
Upper Swing Arm and Propeller Shaft.
14-15
Front Suspension
Special Tool

Description
C00017036
Ball head puller
C00017036
C00017035-1
MacPherson spring
damper removal and
installation tool 1
C00017035-1
C00017035-2
MacPherson spring
damper removal and
installation tool 2
C00017035-2
C00089915
Lower swing arm
bumper block removal
and installation tool
C00089915
C00089916
Lower arm bushing
remover
C00089916
14-16
Front Suspension
Four-wheel Alignment
D90 front suspension is an independent double Toe-in
wishbone type suspension, consisting of front upper
swing arm assembly (guiding mechanism), front lower
swing arm assembly (guiding mechanism), coil spring
A
(elastic element), shock absorber assembly and stabilizer
bar. When front wheels are turning, the upper and lower
cross arms can absorb cross force borne by tires
simultaneously, which, with high rigidity, leads to slight
sidesway during turning, large contact area between tire
and ground, excellent grip performance and little uneven B
wear of tire. Additionally, the double wishbone type
suspension has more adjustable parameters during four-
wheel alignment for adjusting the wheel camber, wheel ES060033
kingpin caster and toe-in.
Seeing from the center of the tire, toe-in means the two
Upper and lower swing arm assembly: the cross force is front wheels face inwards, while toe-out means they
absorbed simultaneously by two swing arms, while the faces outwards. Toe-in makes the front wheels rotate in
shock absorber only bears the body weight. The 2 swing parallel. When the car is driving forward, toe-in can
arms (upper and lower) can locate various parameters of reduce the resultant repulsion force. Incorrect toe-in may
front wheels accurately. When front wheels are turning, cause tire wear and excessive fuel consumption. In case
the two swing arms can absorb the cross force borne by of the wear of steering and suspension components
tires simultaneously, plus the large lateral rigidity of two arising from excessive travel, it is necessary to
swing arms, the tires just make slight sidesway during compensate with the adjustment of toe-in. The
turning. adjustment of toe-in shall be carried out at final stage.
Coil spring: Coil spring is a buffer element. When the Front Wheel Camber
impulsive force of road surface against the wheels is
transmitted to coil spring, the coil spring will deform to
absorb the kinetic energy of wheels, and then converts to
the energy of position (potential energy), thereby
mitigating the ground impact to the vehicle body.
Shock absorber: It is a kind of device which reduces the

vibration by changing the disturbance force from the
vibration source or the transmission characteristics of the
system.
Positive (+) Zero camber Negative (-)
Stabilizer bar: When the vehicle body tilts, the camber camber
suspensions on both sides deform and cannot keep GS060034

balance; the stabilizer bar will function as a lever in this
Watching the wheel from the front and the back, tires are
case to try to keep the deformation of springs on the left
not installed vertically but slightly slantways,representing
and right sides consistent, therefore reducing the
as splayed which has been called as negative (-)
inclination and vibration of the vehicle body and
camber, while splay towards the reverse direction shall
improving the driving stability.
be called as positive (+)camber. While the vehicle is
moving, generally, positive (+) camber is required to
offset the force generating negative (-) camber (the curve
14-17
Front Suspension
of the road, weight load of the passengers, forces on the

road or some dynamic balance factors). Meanwhile, the
purpose of camber is to achieve the camber angle to be
"0°" while the car is in motion. Generally, the excessive
wear of tire edge is arising from the incorrect camber of
the front wheel. The excessive positive (+) camber will
lead to the wear of tire outer ring, while the excessive
negative (-) camber lead to the wear of tire inner ring.
Same as the kingpin caster,the front wheel camber can
be detected with angle and can also be adjusted.
Kingpin Caster
Positive (+) Zero caster Negative (-)

caster caster
GS060035
Watching the wheels edgewise, the steering kingpin (the

pivot for the rotation of wheel) falls backward shall be
deemed as positive (+) caster; while falls forward shall be
deemed as negative (-) caster. When driving at high
speed, the caster shall improve the safety (linearity) of
the vehicle but not lead to the tire wear. The reduction of
spring intensity and excessive loads shall have an
influence on the caster. In case the deviation of caster is
quite large, it may lead to the heavy steering of the
steering wheel. The excessive positive (+) caster may
lead to the bumpy front wheel and heavy steering wheel.
The caster can be detected with angle and can also be
adjusted.
14-18
Rear Suspension
Rear Suspension
Specification
Torque
Bolt - lateral push rod to axle 210 ± 20

Bolt - lateral push rod to body 210 ± 20
Nut - lateral push rod to body 210 ± 20
Nut - ball pins at both ends of rear stabilizer bar link 120 ± 10
Bolt - stabilizer bar clamp to rear axle 35 ± 3
Bolt - rear bumper block to frame 45 ± 5
Nut - rear shock absorber to frame 180 ± 10
Bolt - rear shock absorber to body 180 ± 10
Bolt - rear shock absorber to drive axle 180 ± 10
Bolt - rear shock absorber to drive axle 210 ± 20
Bolt - upper trailing arm to frame 210 ± 20
Bolt - lower trailing arm to axle 210 ± 20
Bolt - lower trailing arm to frame 210 ± 20
Nut - locking the front mounting bolt of upper trailing arm 210 ± 20
Nut - locking the rear mounting bolt of upper trailing arm 210 ± 20
Nut - locking the rear mounting bolt of lower trailing arm 210 ± 20
Nut - locking the front mounting bolt of lower trailing arm 210 ± 20
15-1
Rear Suspension
Layout
Rear Suspension Layout
7 8 5
4
3
1
GS090001
1 Rear axle 5 Rear suspension upper swing arm

2 Rear shock absorber 6 Rear suspension lower swing arm
3 Horizontal stabilizer bar 7 Rear coil spring
4 Lateral push rod 8 Rear suspension buffer block
15-2
Rear Suspension
Rear Suspension Exploded View
22
21
10
23 15
1 16
7
9
17
20
29
11 24
26
30
25 12
13 4
27 18
14 28
2 5
3
19
GS090002
1 Lateral push rod 13 Upper trailing arm bushing

2 Rear stabilizer bar bushing 14 Lower trailing arm bushing
3 Rear stabilizer bar clamp 15 Bolt - lateral push rod to axle
4 Rear stabilizer bar link assembly 16 Bolt - lateral push rod to body
5 Rear stabilizer bar assembly 17 Nut - lateral push rod to body
6 Rear suspension spring upper vibration insulator 18 Nut - ball pins at both ends of rear stabilizer bar
link
7 Rear suspension spring lower vibration insulator
19 Bolt - stabilizer bar clamp to rear axle
8 Rear coil spring
20 Bolt - rear bumper block to frame
9 Rear suspension buffer block
21 Nut - rear shock absorber to frame
10 Rear suspension shock absorber
22 Bolt - rear shock absorber to body
11 Rear suspension upper control arm assembly
23 Bolt - rear shock absorber to drive axle
12 Rear suspension lower control arm assembly
15-3
Rear Suspension
24 Bolt - upper trailing arm to axle 28 Nut - locking the front mounting bolt of lower
25 Bolt - upper trailing arm to body trailing arm
26 Bolt - lower trailing arm to axle 29 Nut - locking the rear mounting bolt of upper
trailing arm
27 Bolt - lower trailing arm to body
30 Nut - locking the rear mounting bolt of lower
trailing arm
15-4
Rear Suspension
Repair Guidance
Replacement of Rear Shock Absorber Replacement of Rear Suspension Upper
Removal Control Arm
Removal
1 Lift the vehicle to a certain height, and remove
the wheels (Refer to Wheels Replacement). 1 Lift the vehicle to a certain height, and remove
2 Unscrew and remove 2 bolts connecting rear the wheels (Refer to Wheels Replacement).
shock absorber to frame and rear axle. 2 Remove the bolts securing the upper trailing arm
to rear axle and frame, then remove the upper
trailing arm assembly.
GS090003
3 Remove the rear shock absorber assembly. GS090004

4 Check the shock absorber. Hold one end of the
shock absorber, check whether there is 3 To replace the upper swing arm bushing, press it
resistance when the shock absorber extends and out first with special tool.
compresses quickly. If not, the shock absorber Installation
has deteriorated and needs to be replaced.
1 Clean the junction of the swing arm and bushing,
press the bushing into the swing arm, refer to the
figure below for the pressing depth (check if the
Installation sleeve is deformed, if yes, replace the control
1 Install the bolts, gaskets and nuts connecting the arm assembly; the minimum press force to the
rear shock absorber to the frame and rear axle bushing shall be greater than 10KN; if the
and tighten them to 180 ± 10N.m. bushing fits loosely with the sleeve, replace the
control arm assembly).
2 Install wheels. Refer to Wheels Replacement for
details.
16±0.5
16±0.5
GS090005
15-5
Rear Suspension
2 Locate the upper swing arm to the frame and Replacement of Rear Suspension Lower
axle as illustrated below. Control Arm
Removal
1 Lift the vehicle to a certain height.
2 Remove the bolts securing the lower control arm
to rear axle and frame, then remove the lower
control arm assembly.
GS090006
3 Tighten the bolts/nuts securing the upper swing

arm to the frame and axle to 210 ± 20N.m.

details. GS090007
5 Lower down the vehicle from the lifting platform
to the ground. 3 To replace the lower control arm bushing, press
it out first with special tool.
Installation
1 Clean the junction of the swing arm and bushing,
press the bushing into the swing arm (check if
the sleeve is deformed, if yes, replace the control
arm assembly; the minimum press force to the
bushing shall be greater than 10KN; if the
bushing fits loosely with the sleeve, replace the
control arm assembly).
2 Locate the lower control arm to the frame and
axle as illustrated below, and pay attention to the
installation direction.
GS090008
15-6
Rear Suspension
3 Tighten the bolts/nuts securing the lower control Replacement of Rear Coil Spring
arm to the frame and axle to 210 ± 20N.m. Removal
to the ground.
the wheels (Refer to Wheels Replacement).
2 Hold up the rear axle housing with the bracket
(use the bracket that can be moved up and
down).
3 Remove the bolts/nuts securing the lower control
arm to rear axle (1), the upper control arm to rear
axle (2), shock absorber to rear axle (3), lateral
push rod to rear axle (4), horizontal stabilizer bar
link to frame (5) and propeller shaft to rear axle
flange (6).
2 5
4
1
3
GS090009
4 Detach the pipeline and circuit secured on the

rear axle housing and record the installing
location to facilitate re-installation.
5 Move down the bracket to lower down the whole
rear axle until sufficient space is provided for
removing the coil spring.
6 Remove the coil spring and upper and lower
vibration isolator.
Installation
1 Install the lower vibration isolator 1, coil spring 2
and upper vibration isolator 3 in sequence to the
rear axle.
15-7
Rear Suspension
GS090010 GS090011
2 Move up the bracket to lift up the whole rear axle

until the upper vibration isolator is well fit into
corresponding hole in the frame. Installation
3 Install the bolts/nuts securing the lower control 1 Install the stabilizer bar, stabilizer bar clamping
arm to rear axle (210±20N.m), the upper control bracket and stabilizer bar bushing. The white
arm to rear axle (210 ± 20N.m), shock absorber mark on horizontal stabilizer bar shall be flush
to rear axle (180 ± 10N.m), lateral push rod to with the bushing.
rear axle (210 ± 20N.m), horizontal stabilizer bar
link to frame (120 ± 10N.m) and propeller shaft
to rear axle flange (75 ± 5N.m).
4 Move out the bracket.
details.
to the ground.
Replacement of Rear Horizontal Stabilizer

Bar and Stabilizer Bar Link
GS090012
Removal 2 Tighten the nuts securing the stabilizer bar to
1 Remove the nut securing the stabilizer bar link to stabilizer bar link to 120 ± 10N.m.
the frame. 3 Tighten the bolts securing the stabilizer bar
2 Unscrew the nut securing the stabilizer bar to the clamping bracket to frame to 35 ± 3N.m.
stabilizer bar link, and remove the stabilizer bar 4 Tighten the nuts securing the stabilizer bar link to
link. lower frame to 120 ± 10N.m.
3 Unscrew the clamp bolts from the stabilizer bar, 5 Lower down the vehicle from the lifting platform
remove the stabilizer bar, stabilizer bar clamp to the ground.
and stabilizer bar bushing.
Replacement of Lateral Push Rod

Removal
1 Place the vehicle on the lifting platform and lift it
to a certain height.
15-8
Rear Suspension
2 Remove the bolts/nuts connecting the lateral

push rod to rear axle support (tightening torque:
210 ± 20N.m).
3 Remove the nuts connecting the lateral push rod
to frame (tightening torque: 210 ± 20N.m).
Installation
Replacement of Rear Suspension Buffer

Block
Removal
2 Remove the bolts mounting the buffer block to
frame and tighten to 210 ± 20N.m.
Installation
15-9
Rear Suspension

Suspension is a device combining all transmission forces
between the frame and wheels. It is designed to transmit
the force acted on between the wheel and frame, buffer
the impact force transmitted to the frame or body by
uneven road surface and decay the resultant vibration,
thereby guaranteeing the smooth driving of the vehicle.
5-link rear suspension can significantly mitigate the
forward and backward forces from the road surface, so
as to improve the smoothness and comfort during
acceleration and brake. By using the coil springs for
extension through hanging or compression, the lateral
offset of wheels will be slight, thus greatly reducing the
possibility of unequal distance between the rear axle
wheels on both sides and the longitudinal axis of the car,
and maintaining the straight driving. The rear shock
absorber is bilaterally symmetrical. The upper point is
connected to the body with 1 bolt; and the bottom point is
connected to the rear axle with 1 bolt and 1 nut.
15-10
Tires and Wheels
Tires and Wheels
Specification
Torque
Nut - wheel to hub 125 ± 13

Bolt - spare tire device to frame 22 ± 2
Tire Parameters
Items Parameter
Wheel dimension 7 .5Jx18 7 .5Jx19 7Jx17 8 .5Jx21
Tire dimension 8 .5Jx21 255/55R19 255/65R17 265/45R21
Tire Front 220 kPa/2.2bar/32psi 220 kPa/2.2bar/32psi 220 kPa/2.2bar/32psi 230 kPa/2.3bar/33psi
pressure wheels
(cold)
Rear 270 kPa/2.7bar/39psi 270 kPa/2.7bar/39psi 270 kPa/2.7bar/39psi 280 kPa/2.8bar/41psi
wheels
Small spare tire 245/65R17 245/65R17 245/65R17 245/65R17

dimension
Full size spare tire 255/60R18 255/55R19 255/65R17 265/45R21

dimension
Small spare tire 290kPa/2.9bar/42psi 290kPa/2.9bar/42psi 290kPa/2.9bar/42psi 290kPa/2.9bar/42psi

pressure
(cold)
Full size spare tire 270 kPa/2.7bar/39psi 270 kPa/2.7bar/39psi 270 kPa/2.7bar/39psi 280 kPa/2.8bar/41psi
pressure
(cold)
16-1
Tires and Wheels
Layout
Tire Exploded View (Aluminum Wheel)
5
3
GS100001
1 Tire 4 Valve
2 Rim 5 Wheel nut
3 Wheel trim cover 6 Wheel balancer
16-2
Tires and Wheels
Spare Tire Device Layout
GS100002
1 Spare tire 3 Spare tire bracket damping mat

2 Spare tire device
16-3
Tires and Wheels
Repair Guidance
Wheels Replacement
Warning: DO NOT lubricate the rim and tire with
10°Max
lubricating oil containing silicone oil. Clean the
tire bead before removal of tire. Lubricate the 1
2
area completely using 50% lubricating oil and
50% water before installation.
Warning: Use a tire changer to remove tires and
avoid using manual tools or tire lever alone to
replace tires, otherwise wheel disk or rim may be
damaged.
Removal
1 Place the vehicle on the lifting platform and lift it ES060029
2 Remove the wheel trim cover with a screwdriver. ·During the installation of alloy wheels, the tire with mark
1 of φ 10 red dot shall be installed on the same side with
3 Remove 6 wheel bolts with a socket wrench.
the steel wheel with mark 2 of φ 10 red dot (if marked) at
4 Remove the wheel.
0 angle. The tire assembly is required to be within 10
Caution: Avoid placing the hub panel towards the degrees after installation.
ground to prevent scratches.
5 Take down the wheel balance block and record
the location and mass of each balance block for
re-installation. (if applicable) 10°Max
6 Loosen the valve cap and release the air. 1

2
Remove the tire and pull out the wheel valve or
tire pressure monitoring sensor.
Installation
Caution: Brush away the deposited corrosion on
the mounting surfaces of wheel, brake drum and
brake disc with scraping tool or steel wire before
installation of wheels. During the installation,
improper mating of metal mounting surface and ES060030
metal will cause the looseness of wheel bolts.
The wheel may thus fall off in driving, resulting in 3 Inflate the tire until the wheel disk is in place.
vehicle out of control and even personal injury. Ensure the locating ring outside the tire bead is
around the wheel rim flange on both sides. This
1 Install the wheel valve assembly and ensure it is
method can ensure the correct position of tire
fully matched and sealed with the rim.
bead.
2 Install the tire with the tire changer and align the
4 Check the air tightness of the valve with soap
tire to the matching marks on the wheel.
water or reinstall it.
·During the installation of steel wheels, the tire with mark
Caution: DO NOT damage the tire when installing
1 of φ 10 red dot shall be installed on the same side with accessories, especially the tire bead.
the steel wheel with mark 2 of φ 8 white dot (if marked) at
5 After each wheel is assembled, carry out the
0 angle. The tire assembly is required to be within 10
balance test to the tire with a tire dynamic
degrees after installation.
balancer.
16-4
Tires and Wheels
6 Pay attention to the followings when installing Replacement of Spare Tire Device
the balance block: Removal
1) After installation of the steel wheel assembly, the
1 Loosen the spare tire device and take off the
allowable unilateral residual unbalance is 10 grams or wheel.
less. The maximum weight of the balance block is 60
2 Remove the bolt securing the spare tire device to
grams on the outer side and no more than 120 grams the frame. (Tightening torque: 22 ± 2N.m)
on both sides.
3 Remove the guide sleeve of spare tire device.
2) After installation of the alloy wheel assembly, the Installation
allowable unilateral residual unbalance is 8 grams or 1 Installation is the reverse of removal.
less. The maximum weight of the balance block is 80
grams unilaterally and no more than 160 grams on
both sides.
7 After the wheel dynamic balance test, determine

the mass of the balance block and install it on the
wheel.
8 Install the wheel trim cover.
9 Install the wheel and tighten the wheel nuts in
sequence with the socket wrench to the torque:
125 ± 13N.m.
Warning: The penetrating oil on the vertical
surface between the wheel, the brake disc and
brake drum will cause wheel looseness in driving,
thereby resulting in injury accidents due to
vehicle out of control. DO NOT heat to loosen the
wheel fastened tightly, which will shorten the
service life of the wheel, wheel bolt, hub and
bearing assembly. The wheel nuts must be
tightened to the correct torque in proper
sequence to prevent distortion of the wheel,
brake disc and brake drum.
16-5
Tires and Wheels
16-6
Brake System
Brake System
Specification
Model D90
·Front Disc brake
·Rear Disc brake
Brake caliper piston diameter:
·Front 2 × 45mm
·Rear 1 × 43mm
Brake disc diameter:
·Front 330mm
·Rear 324mm
Minimum thickness of front brake disc
·New (nominal dimension) 30mm
·Service limit 28mm
Minimum thickness of rear brake disc/maximum bore diameter
·New (nominal dimension) 18mm 210mm
Service limit 16mm 211mm
Minimum thickness of brake pad material
·Front brake lining (with a self-adhesive gasket) 8 mm (friction lining material is 2mm left only)
·Rear brake shoe (with a self-adhesive gasket) 8 mm (friction lining material is 2mm left only)
·Rear parking brake shoe (with a self-adhesive gasket) The friction lining material is 2mm left only
Parking brake: Manual type mechanical/electronic parking brake
Electronic stability program ABS/ESP
Brake pipeline type X-shape pipeline layout
Brake master cylinder Series-type dual-chamber independent master cylinder
Vacuum booster Dual-diaphragm vacuum booster
17-1
Brake System
Model High chassis
·Front Disc brake
·Rear Disc brake
Brake caliper piston diameter:
·Front 2 × 45mm
·Rear 1 × 43mm
Brake disc diameter:
·Front 300mm
·Rear 324mm
Minimum thickness of front brake disc
·New (nominal dimension) 27mm
Service limit 25mm
Minimum thickness of rear brake disc/maximum bore diameter
·New (nominal dimension) 18mm 210mm
Service limit 16mm 211mm
Minimum thickness of brake pad material
·Front brake lining (with a self-adhesive gasket) 8 mm (friction lining material is 2mm left only)
·Rear brake lining (with a self-adhesive gasket) 8 mm (friction lining material is 2mm left only)
·Rear brake shoe (with a self-adhesive gasket) The friction lining material is 2mm left only
Parking brake: Manually operating mechanical-type, the cable transfers

power on the rear disc middle-drum parking brake
Antilock brake system Standard ABS
Electronic stability program Optional ESP
Brake pipeline type X-shape pipeline layout
Brake master cylinder Series-type dual-chamber independent master cylinder
Vacuum booster Dual-diaphragm vacuum booster
17-2
Brake System
Torque
Sunk screw - brake disc to hub 8±2

Brake drain screw 9~13
Front brake caliper hinge pin bolt 30~35
Rear brake caliper hinge pin bolt 50~60
Bolt - front brake caliper to brake angle 200 ± 20

Bolt - rear brake caliper to brake angle 130 ± 10
Bolt - brake hose to brake caliper 35 ± 3
Brake tube to rear drum brake wheel cylinder 15 ± 2
Nut - brake master cylinder assembly to vacuum booster 18~20
Nut - vacuum booster to engine compartment 20 ± 2

Bolt - ABS/ESP regulator bracket to body 22 ± 2
Nut - brake pedal to engine compartment 20 ± 2
Brake tube to brake master cylinder 15 ± 2
Brake pipeline to ABS/ESP regulator 15 ± 2
Bolt - cable to rear leaf spring 22 ± 2
Bolt - cable to frame 10 ± 1
Bolt - cable to body 20 ± 2
Bolt - parking brake handle to body 22 ± 2
17-3
Brake System
Layout
Brake System Layout
12
11
10 6
5
2
9
1
8
3
7
4
GS110001
1 Vacuum booster assembly 7 Front brake tube

2 Brake pedal assembly 8 Front brake hose
3 ABS/ESP 9 Rear brake tube (front segment)
4 Front brake angle assembly 10 Rear brake tube (middle segment)
5 Rear brake assembly 11 Rear brake tube (rear segment)
6 Steering angle sensor 12 Rear brake hose
17-4
Brake System
ABS/ESP Exploded View
6
5
4
3
GS110002
1 Connecting master cylinder rear cavity to ABS/ 4 Connecting right front brake tube
ESP brake tube 5 Connecting left rear brake tube (front segment)
2 Connecting master cylinder front cavity to ABS/ 6 Connecting right rear brake tube (front segment)
ESP brake tube
7 ABS/ESP damping pad
3 Connecting left front brake tube
8 ABS/ESP regulator bracket
17-5
Brake System
Vacuum Booster Assembly Exploded View
5
4 4 4 9
3
2
1
GS110003
1 Thermal isolation baffle mounting components 5 Vacuum booster to the brake master cylinder
assembly O-ring
2 Vacuum booster master cylinder thermal
isolation baffle 6 Brake fluid reservoir cover
3 Vacuum booster 7 Filter
4 Vacuum booster pad 8 Master cylinder and fluid reservoir
9 Nut - master cylinder to vacuum booster
17-6
Brake System
Parking Brake Exploded View
3 8
1
2
4 9
7 5
ES110002
1 Parking baseplate 6 Parking push board

2 Brake shoe 7 Brake pressure spring
3 Upper return spring 8 Shoe limiting pin and spring
4 Lower return spring 9 Observation hole plug
5 Clearance adjusting mechanism
17-7
Brake System
Exploded View of Front and Rear Brake Calipers
3
5 7
2
3
4 7
6
GS110004
1 Brake block assembly 6 Buffer rubber sleeve

2 Brake block circilp 7 Guide pin dust shield
3 Hinge pin bolt 8 Bleeder screw
4 Guide pin 9 Bleeder screw cap
5 Locating pin
17-8
Brake System
EPB Exploded View
7
4
6
GS110005
1 Motor repair kit 6 Rear brake caliper bleeder screw

2 Bolt - motor to caliper bracket 7 Bleeder bolt cap
3 O-ring 8 Friction plate repair kit
4 Guide pin repair kit 9 Caliper bracket assembly
5 Brake caliper shell assembly
17-9
Brake System
Repair Guidance
Brake Disc Check
Removal
to a certain height. Then remove wheels (refer to
Wheels Replacement).
2 Remove the bolt securing the caliper to the
steering knuckle. Remove the brake caliper
assembly and hold it with a bracket.
Caution: Do not hang the brake caliper on the
hose.
ES110007
3 Clear slight rust spots, scratches and grooves on
the operating surface of brake disc with an
abrasive paper. In case of severe wear signs,
scratches or cracks on the operating surface, 7 Zero set the dial indicator and rotate wheels for a
conduct turning to the brake disc or replace it circle. Then measure the brake disc runout,
with a new one. which shall not exceed 0.02mm, and the
thickness variation of brake disk shall not exceed
4 Measure the brake disc thickness of more than 4
0.006mm. If the runout exceeds the limit, the
testing points on the circumference of contact
brake pedal will vibrate and shake during
center between the brake disc and friction lining
braking.
with an outer-diameter dial indicator. The
minimum thickness of brake disc shall not be 8 If the brake disc runout exceeds the limit:
lower than the value specified in Technical 1) Remove the sunk screw securing the brake disc onto
Parameters, and the thickness change on the
the hub, and then remove the brake disc.
same-radius circumference shall not exceed
0.006mm. If exceeds, the brake disc must be 2) Keep the brake disc to hub flange clean.
replaced.
5 Measure the brake disc inner diameter of more 3) Install the front brake disc onto the front hub. Then
than 4 testing points on the circumference of install the sunk screw and tighten it to 8 ± 2N.m.
contact center between the brake disc and drum
4) Check the brake disc runout according to the aforesaid
friction lining with an outer-diameter dial
indicator. The maximum bore diameter of brake steps.
disc shall not exceed the value specified in
5) If the runout still exceeds the limit, replace the front
Technical Parameters. If exceeds, the brake disc
must be replaced. brake disc.
Caution: Brake discs must be replaced in pairs, 9 Install the brake caliper onto the brake angle.
unless the mileage does not reach 1,500km after Then install the sunk screw and tighten it to 8 ±
this brake disc is replaced. 2N.m.
6 Secure the dial indicator onto the steering 10 Install the wheels.
knuckle as illustrated below. Secure the dial 11 Depress the brake pedal for several times to
indicator measuring head onto the position adjust the brake block.
10mm away from the brake disc edge. 12 Lower the vehicle.
17-10
Brake System
Brake System Drain · Repeat the aforesaid steps to exhaust air from the
The following steps show the drain method of the overall brake tube joint 2.
system. When the main or auxiliary line becomes an 5 Remove the bleeder screw cap from the rear
independent line, operate the line which shall be drained. right brake caliper (for LHD model), and install
Only when the brake tube is disconnected from the brake the hose onto the exhaust screw. Insert the free
hose and there is little oil loss, the hydraulic system can end of hose into the container filled with new
be drained partially. brake fluid.
Warning: Protect eyes and skin from contacting

the brake fluid.
Caution: DO NOT reuse the brake fluid drained
from the brake system.
Drain:
1 Refill the brake fluid reservoir to the MAX level.

Caution: Ensure new brake fluid level is between
the MIN and MAX mark during the whole
drainage.
2 Lift the vehicle from the lifting platform.
ES110009
3 Start the engine. Do not conduct air clearance
operation with the engine shut down, which may 6 Apply braking onto the brake pedal for several
damage the vacuum booster. times, and then apply stable pressure onto it.
4 Exhaust the brake master cylinder assembly. 7 Loosen the bleeder screw to separate the brake
fluid from air. Leave the brake pedal to return
without any external force.
2 8 Depress the brake pedal to the maximum stroke
steadily, and leave it to return without any
external force. Repeat this operations for several
times until the brake fluid containing no bubble
1
flows into the container. Then securing the brake
pedal to the maximum stroke position, tighten
the drain screw to 9-13N.m, and loosen the
brake pedal.
9 Remove the hose from the drain screw, and
install the bleeder screw cap.
ES110008 10 Repeat the drain procedures for the rest 3 brake
calipers according to the sequence below:
·Connect the brake tube. For LHD model: rear right, rear left, front right and front
left
·Depress the brake pedal slowly and hold.
For RHD model: rear left, rear right, front left and front
·Loosen the brake tube joint 1.
right
· Re-tighten the brake tube joint, and leave the brake
Warning: The incorrect drain sequence may
pedal to return slowly.
severely weaken the braking efficiency.
· Repeat the aforesaid steps until there is no air 11 Shut down the engine.
exhausted when the brake tube joint 1 is loosened. 12 Lower the vehicle.
17-11
Brake System
13 Refill the brake fluid reservoir to the MAX mark Adjustment of Parking Brake Handle
line. Assembly
14 Apply braking and check for leakage. Before adjusting the parking brake cable, adjust the
15 Test the vehicle on road. When the braking parking brake clearance adjusting mechanism first.
works, check whether the free stroke of brake
pedal is within 10mm. If the brake pedal is weak, 1 Clamp wheels and release the parking brake
do not drive the vehicle. Confirm whether the handle (push it to the bottom).
unacceptable brake pedal foot feeling and stroke 2 Lift the vehicle from the lifting platform until
is not caused by the dislocation of brake friction wheels leave the ground.
lining or other mechanical faults. Then repeat the
3 Then apply a force within 200N to pull up the
brake system exhaust process. Besides, if the
parking brake handle by 6~7 teeth generally, and
aforesaid exhaust process does not achieve the
the rear wheels will be locked. After the brake
ideal effect due to the severe brake fluid loss,
handle is completely released, rear wheels can
drain the ABS/ESP regulator. This operation is
rotate freely. Otherwise it is required to adjust the
conducted through the scan tool. Refer to
clearance between the parking brake shoe and
Instructions for SAIC Commercial Vehicle Scan
brake drum and then adjust the length of parking
Tool for details.
brake cable.
4 The brake cable lever assembly can be seen
after the rear cover plate of auxiliary fascia
console is removed.
ES110010
5 Loosen the adjusting nut on the brake cable

lever. The exposing length of screw shall not be
less than 15mm.
17-12
Brake System
14 Turn off the ignition key.

15 Install the rear cover plate of auxiliary fascia
console.
16 Install rear wheels.
15
ES110011
Caution: The vehicle must be supported on a safe

device.
6 Remove rear wheels.
7 Adjustment of the clearance between brake
shoes of rear wheels:
1) Keep rotating the parking brake clearance adjusting
ratchet with a flat screwdriver or equivalent to expand
the brake shoe outwards until the rear brake disc is
slightly hindered when rotating. (The clearance
adjusting mechanism will be pushed outwards for
0.125mm after adjustment by every tooth)
2) Loosen the clearance adjusting ratchet for 5~7 teeth.
3) Ensure the rear brake disc can rotate freely without

obstruction.
8 Move the parking brake handle back and forth for

5 times to set the rear brake shoes and hand
brake cable.
9 Tighten the adjusting nut on the brake cable
lever. It is required that rear wheels are locked
after the parking brake handle is pulled for 6~7
teeth with a force within 200N.
10 Move the parking brake handle up and down
completely.
11 Loosen the parking brake handle and ensure the
rear brake disc can rotate without obstruction.
12 Rotate the ignition key to ON position.
13 Pull up the parking brake handle for 6~7 teeth.
Then the parking brake indicator lamp will go on
and both rear brake discs will be locked; loosen
the parking brake handle. Then the parking
brake indicator lamp will go out and rear brake
discs can rotate freely. Re-adjust if the
adjustment result is nonconforming.
17-13
Brake System
Replacement of Front and Rear Brake Installation

Linings (Mechanical Parking Brake)
1 Clean the brake caliper housing and front brake
Removal caliper bracket.
The front and rear disc-type brakes are equipped with a 2 Check the brake caliper and seals for damage.
wear indicator respectively as illustrated. When the
3 Secure the brake lining onto the bracket with a
brakes make noise due to the wear is lower than the circlip, and close the caliper body. Tighten the
specification, the friction lining shall be replaced. The guide pin bolts: tighten the front brake caliper to
thickness of friction lining shall not be lower than the 31~38N.m; tighten the rear brake caliper to
value specified in Technical Parameters. 50~60N.m.
4 Depress the brake pedal for several times to
install the brake pad.
5 Prompt: The stroke of brake pedal may be longer
than usual for the first time of braking.
6 Install wheels. Refer to Wheels Replacement.
7 Lower the vehicle to ground.
ES110012
Warning: The brake linings of front wheels or rear

wheels must be replaced meanwhile, otherwise
the braking efficiency will be weakened.

Warning: The vehicle must be supported on a
safe device.
2 Remove wheels.
3 Loosen the guide pin, rotate the caliper body to a
certain angle, and remove the circlip and brake
lining from the bracket.
ES110013
17-14
Brake System
Replacement of Brake Caliper Guide Pin Replacement of Front and Rear Brake
Components Calipers Assembly
Removal Removal
1 Remove the front and rear brake caliper 1 Lift the vehicle from the lifting platform.
assembly.
Warning: Do not operate under a vehicle
2 Remove the guide pin bolt. The bolt is applied supported by a jack only. The vehicle must be
with anti-looseness glue, therefore a new one is supported on a safe device.
recommended.
2 Remove the wheels. Refer to Wheels Removal
Installation
for details.
1 Installation is the reverse of removal. 3 Place a container under the vehicle to collect
spilled oil.
4 Loosen the bolt securing the brake hose to brake
cylinder.
Caution: Before disconnecting or removing the
brake pipeline, ensure the middle area and
connecting joints around the junction surface are
clean. Block the opened junction to prevent
contaminant from entering.
5 Loosen the bolt securing the brake caliper to the
brake angle, and remove the brake caliper.
GS110006
Installation
Caution: Apply sufficient grease on the pin and 1 Secure the brake calipers onto the brake angles.
bracket sealing trench and the sliding part of pin Tighten the front brake caliper to 200 ± 20N.m;
(the area indicated by dotted line). tighten the rear brake caliper (integrated with
EPB) to 100 ± 10N.m; and tighten the rear brake
caliper (without EPB) to 130 ± 10N.m.
2 Tighten the bolt connecting the brake hose to
brake caliper to 35 ± 3N.m.
3 Drain the brake system. Refer to Brake System
Drain for details.
17-15
Brake System
Replacement of Front Brake Disc Replacement of Rear Brake Disc

Removal Removal
1 Ensure the parking brake is completely 1 (Hand brake) Ensure the brake is completely
loosened. released. (EPB) Allow EPB to enter
2 Place the vehicle on the lifting platform and lift it "maintenance mode" via the scan tool. In special
to a certain height. cases, such as the vehicle powers off/fails to
enter the "maintenance mode", or the scan tool
Warning: Do not operate under a vehicle is not available, EPB can be released manually,
supported by a jack only. The vehicle must be refer to Manual Release of EPB.
supported on a safe device.
3 Remove the wheels. Refer to Wheels to a certain height.
Replacement for details.
Warning: Do not operate under a vehicle
4 Remove the bolt securing the steering knuckle to supported by a jack only. The vehicle must be
the front brake caliper. supported on a safe device.
Caution: Do not hang the brake caliper on the 3 Remove the wheels. Refer to Wheels
brake hose. Replacement for details.
5 Remove the sunk screw securing the brake disc 4 Remove the bolt securing the steering knuckle to
to the front hub. the rear brake caliper.
Caution: Do not hang the brake caliper on the
brake hose.
5 Remove the sunk screw securing the brake disc
to the rear hub.
ES110016
6 Remove the front brake disc assembly.

Installation
1 Ensure the junction surface between the front ES110018
brake disc and front hub is clean.
2 Install the brake disc to the hub. Then install the 6 Remove the rear brake disc assembly.
sunk screw and tighten it to 9 ± 2N.m.
3 Check the brake disc runout. Refer to Brake Disc
Check for details.
4 Install the brake disc. Refer to Replacement of
Brake Caliper Assembly for details.
17-16
Brake System
Installation Replacement of Rear Parking Brake Shoe

1 Ensure the junction surface between the rear Removal
brake disc and rear hub is clean. 1 Remove the rear brake disc. Refer to
2 Install the brake disc to the hub. Then install the Replacement of Brake Disc for details.
sunk screw and tighten it to 9 ± 2N.m. 2 Check the parking brake shoe. Replace it in any
3 Check the brake disc runout. Refer to Brake Disc of the following cases:
Check for details. 1) The thickness of parking brake lining friction lining
4 Install the brake disc. Refer to Replacement of material is less than 2mm.
Brake Caliper Assembly for details.
5 Install the wheels. 2) The brake friction lining fractures.
6 Check the parking brake. Adjust the parking 3) The brake friction lining is contaminated by engine oil
brake if necessary. Refer to Adjustment of or other fluids.
Parking Brake Handle Assembly for details.
3 Loosen the brake shoe limiting pin and spring,
and loosen the rear brake shoe assembly from
the rear brake disc guard plate.
ES110019
4 Remove the brake shoe components. Pay

attention to their mounting positions.
17-17
Brake System
Installation Replacement of Brake Master Cylinder and

Brake Fluid Reservoir
1 Clean the rear brake disc guard plate and brake
disc, and check whether the brake drum is worn Removal
uniformly. 1 Place a piece of cloth under the brake fluid
2 Check the state of spring in the parking brake, reservoir to absorb the spilled oil.
and replace it if necessary. 2 Pull out the level sensor connector.
3 Assemble rear brake shoe components. 3 Disconnect the brake tube connected to the
master cylinder and the pipeline connected to
the clutch master cylinder.
ES110021
3
4 Secure brake shoe components onto the brake ES110023

disc guard plate with limiting pin and spring.
5 Secure the brake cable onto the brake shoe. Caution: Before disconnection, ensure the middle
6 Install the brake disc. area and connecting joints around the junction
7 Adjust the parking brake. are clean. Block the opened junction to prevent
4 Remove 2 nuts and washers securing the master
cylinder to the vacuum booster, and scrap the
nuts. Then remove the brake master cylinder
and brake fluid reservoir assembly.
Installation
1 Install an O-ring to the master cylinder.
2 Install the brake master cylinder and brake fluid
reservoir assembly onto the vacuum booster,
and secure them with new nuts. Tightening
torque: 18-22N.m.
3 Clean the brake tube joint.
4 Connect the brake tube and clutch tube onto the
brake master cylinder, and tighten them to 15 ±
2N.m.
5 Install the level sensor.
6 Refill the specified brake fluid to the specified
level range.
7 Exhaust the brake system. Refer to Brake
System Exhaust for details.
17-18
Brake System
Replacement of Vacuum Booster Assembly Installation

Removal 1 Install the brake master cylinder and brake fluid
1 Remove the windshield cover plate and reservoir assembly onto the vacuum booster
windshield gutter channel. Refer to Baffle with new nuts. Refer to Replacement of Brake
Replacement for details. Master Cylinder and Brake Fluid Reservoir
2 Pull out the vacuum tube from the booster.
2 Clean the junction surface between the vacuum
3 Pull out the level sensor connector.
booster and body, and install the new vacuum
4 Disconnect the brake tube from the brake master booster pad onto the vacuum booster.
cylinder.
3 Locate the vacuum booster and brake pedal onto
Caution: Before disconnection, ensure the middle the engine compartment, and install 4 nuts.
area and connecting joints around the junction Tighten the nuts to 20 ± 2N.m.
are clean. Block the opened junction to prevent 4 Connect the vacuum booster push rod to the
contaminant from entering. brake pedal with hinge pin, cotter pin and
washer. Refer to Replacement of Brake Pedal
5 Remove the hinge pin and cotter pin securing
the vacuum resistance push rod to the brake
pedal. 5 Clean the brake tube joint.
6 Remove 4 nuts securing the booster and brake 6 Connect the brake tube and clutch tube onto the
pedal to the engine compartment. brake master cylinder, and tighten them to 15 ±
2N.m.
7 Pull out and scrap the booster pad.
7 Connect the level sensor connector.
8 Remove 2 nuts and washers securing the master
cylinder to the vacuum booster, and scrap the 8 Connect the vacuum tube to the vacuum
nuts. Then separate the vacuum booster from booster.
the master cylinder. 9 Refill the specified brake fluid to the specified
level range.
System Exhaust for details.
7
8
ES110044
17-19
Brake System
Replacement of Vacuum Pipe Assembly Replacement of ABS/ESP Regulator

The mounting points of vacuum pipe are shown in the Removal
figure below, all the mounting points can be plugged in 1 Place the ignition switch in OFF position and
and pulled out directly. disconnect the negative battery cable.
2 Place a piece of cloth under the ABS/ESP
regulator to absorb the spilled oil.
Caution: The brake fluid may damage the paint
surface. If it spills by accident, wipe it rapidly and
clean these areas.
3 Disconnect the ABS/ESP regulator harness.
4 Depress the brake pedal and support it with a
pedal bracket to avoid brake fluid from flowing
out after the brake pipeline is removed.
5 Mark the position of ABS/ESP regulator oil outlet
for assembling. Then disconnect 6 brake tubes
connected with the regulator.
GS110007
Caution: The vacuum pressure sensor is

integrated in the vacuum pipe, and it cannot be
replaced as an individual part.
ES110029
Caution: Before disconnection, ensure the middle

area and connecting joints around the junction
are clean. Block the opened junction to prevent
6 Remove the bolt securing the regulator bracket
to the body, and remove the regulator bracket
and regulator.
17-20
Brake System
Installation
1 Install the ABS/ESP regulator onto the bracket
with nuts, and tighten to 8 ± 2N.m.
2 Clamp the shock pad into the bracket mounting
hole.
3 Clamp the regulator onto the shock pad.
4 Secure the regulator and bracket assembly to
the body with bolts, and tighten the bolts to 22 ±
2N.m.
5 Clean up the brake connector.
6 According to the marks made during removal,
ES110030 connect 6 tubes to correct pipe orifices
respectively. Tighten brake tube joints to 15 ±
7 Loosen the nut connecting the bracket to the 2N.m.
regulator, and remove ABS/ESP regulator from
7 Connect the regulator harness.
the bracket.
8 Loosen the pedal bracket. Refill brake fluid to
Max position.
9 Drain the ABS/ESP regulator. The regulator
replaced during after-sales service is filled with
oil, generally there is no need to drain the
regulator. The drain operation can be conducted
through the scan tool. Refer to Instructions for
SAIC Commercial Vehicle Scan Tool for details.
10 Drain the brake system. Refer to Brake System
Drain for details.
11 Connect the scan tool to clear the DTC.
ES110031
8 Remove the shock pad clamped on the regulator

bracket.
ES110032
17-21
Brake System
Replacement of Brake Pedal Assembly Installation

Removal 1 Secure the brake pedal to the vacuum booster
1 Disconnect the negative battery. with 4 nuts. Secure the brake pedal to engine
compartment with 1 bolt. Then tighten them to 20
2 Unplug the brake pedal position sensor harness.
± 2N.m.
3 Remove the hinge pin, washer and cotter pin
2 Secure the vacuum booster push rod onto the
securing the vacuum booster push rod to the
brake pedal with hinge pin, washer and cotter
brake pedal.
pin, and apply some lubricating grease (all-
4 Remove 4 nuts securing the brake pedal to the purpose MR2 lithium grease) onto the surfaces
booster and 1 bolt securing the brake pedal to of hinge pin, vacuum booster push rod U-fork
the engine compartment. hole and pedal hole. Do not install the hinge pin
reversely.
For LHD models:
ES110033
ES110034
5 Remove the brake pedal assembly.
For RHD models:
ES110045
3 Install the brake pedal position sensor, and

connect the harness. Refer to Replacement of
Brake Pedal Position Sensor for details.
4 Connect the battery negative.
5 Start the vehicle and depress the brake pedal for
8-20mm. Then the brake lamp shall go on. If not,
conduct self-learning to the pedal stroke sensor
again.
17-22
Brake System
Replacement of Brake Pedal Position Sensor Yaw Sensor

Removal Yaw sensor is under the front passenger's seat. There
1 Pull out the sensor connector, and remove are access holes provided on the carpet for diagnosis
screws. Then the sensor can be removed. and replacement of yaw sensor.
ES110035 GS110029
Installation
2 After installation, conduct self-learning to the
clutch stroke sensor via a scan tool.
Caution: Depress the brake pedal for 8-20mm.
Then the brake lamp shall illuminate. If not,
conduct self-learning to the pedal stroke sensor
again.
17-23
Brake System
Replacement of Brake Pipeline Replacement of Parking Brake Cable

Removal
1 The tightening torque for the nuts/bolts securing
the brake pipeline to brake master cylinder, 1 Place the vehicle on the lifting platform and lift it
securing the brake pipeline to ABS/ESP to a certain height.
regulator and between brake pipelines is 15 ± Warning: The vehicle must be supported on a
2N.m.
safe device.
2 The tightening torque for the nuts/bolts securing
2 Remove the bolt connecting the cable to the
the brake hose to the front/rear brake caliper is
body.
35 ± 3N.m; the tightening torque for the nuts/
bolts securing the front brake hose bracket is 16 3 Remove the rear cover plate of auxiliary fascia
± 2N.m. console, and disconnect the cable from the
balancer.
ES110049
ES110036
4 Remove the bolt connecting the cable to the

frame.
5 Remove the bolt connecting the cable support to
rear suspension lower control arm.
6 Remove wheels, disconnect the cable from the
rear brake, and remove the cable.
ES110038
17-24
Brake System
Installation Replacement of Parking Brake Handle

1 Connect the cable to the rear brake. Removal
2 Connect the cable to the frame beams and 1 Remove the auxiliary fascia console assembly.
girders with bolts, and tighten to 9 ± 1N.m. Refer to Removal of Auxiliary Fascia Console
3 Bolt - cable support to rear suspension lower Assembly for details.
control arm: 22 ± 2N.m. 2 Remove the parking brake balancer.
4 Nut - parking brake cable to brake angle: 9 ± 3 Remove the bolt securing the parking brake
1N.m. handle to body, and remove the parking brake
5 Connect the cable to the balancer. Install the rear handle.
cover plate of auxiliary fascia console. 4 Remove the parking brake switch.
6 Adjust the parking brake handle, and install the
wheels.
Installation
1 Installation is the reverse of removal. Adjust the
parking brake handle after installation. Refer to
Adjustment of Parking Brake Handle Assembly
for details.
Tighten the bolt securing the parking brake handle to
body to 22 ± 2N.m.
GS110026
17-25
Brake System
EPB Control Unit Manual Release of EPB

EPB control unit is under the rear part of front 1 Power on the vehicle, operate the EPB switch to
passenger's seat. Lift the carpet under the seat before release EPB caliper.
control unit diagnosis and replacement. 2 Disconnect two EPB connectors on the left and
right side, then power off the vehicle.
3 Release and remove EPB actuator bolts.
GS110008
GS110009
4 Remove the actuator (note for dust), rotate the

spindle spline clockwise with a tool, as shown in
the figure.
GS110010
17-26
Brake System
5 Install the actuator, and tighten the bolts to Replacement of EPB Brake Pad
10~13N.m.
1 Allow EPB to enter "Pad changing" in
"maintenance mode" via the scan tool. Then the
motor drives the spindle to make the pressure
nut return to its initial position. In special cases,
such as the vehicle powers off/fails to enter the
"maintenance mode", or the scan tool is not
available, EPB can be released manually, refer
to Manual Release of EPB.
GS110011
GS110012
2 Remove 1 guide bar bolt away from EPB motor.
GS110013
17-27
Brake System
3 Turn over the housing assembly. 7 Install the housing assembly to its original
position, and tighten the guide bar bolts to
31~38N.m.
GS110014
4 Push back the piston with a tool.

GS110017
8 Plug EPB connectors, then power on the vehicle.
9 Clear ESC DTCs with a scan tool.
10 Operate EPB switch to conduct the clamping and
release action once.
GS110015
5 Remove the friction lining.
GS110016
6 Replace with a new friction lining, and the circlip

is also recommended to be replaced together.
17-28
Brake System
Replacement of Motor Components 5 Remove the seal ring and check for damage,
Removal replace it as necessary.
1 Allow EPB to enter "maintenance mode" via the

scan tool. In special cases, such as the vehicle
powers off/fails to enter the "maintenance
mode", or the scan tool is not available, EPB can
be released manually, refer to Manual Release
of EPB.
2 Disconnect the harness connector.
3 Release the tightening bolts of motor (tightening
torque: 10-13N.m).
GS110020
Caution: Thoroughly clean the surface. Entry of

impurities may cause EPB failure.
7 Operate EPB switch to conduct the clamping and
Installation
GS110018 1 Installation is the reverse of removal.
4 Remove the motor as indicated by the arrow.
GS110019
17-29
Brake System
Replacement of Brake Caliper Housing Installation

Assembly
1 Install a new seal ring to the new brake caliper
Removal housing assembly, and secure the housing
1 Allow EPB to enter "maintenance mode" via the assembly to the caliper bracket with a new guide
scan tool. In special cases, such as the vehicle pin bolt and tighten to 31-38N.m.
of EPB.
2 Disconnect the brake pipe and plug it to prevent
the brake fluid flowing out and contaminating the
vehicle.
3 Remove the motor, refer to Replacement of
Motor Components.
GS110023
Caution: The after-sales brake caliper housing

assembly is filled with brake fluid. When
connecting the brake pipe, remove the plug for
connecting the brake pipe on the housing first.
2 The remaining installation procedure is the
reverse of removal.
GS110021 System Exhaust for details.
4 Unscrew the guide pin bolts and discard, then 5 Operate EPB switch to conduct the clamping and
remove the brake caliper housing assembly as
indicated by the arrow.
GS110022
17-30
Brake System
Replacement of Caliper Bracket Assembly 2 Clear the ESC DTCs with a scan tool after
Removal installation. Then operate EPB switch to
complete the clamping and release action once.
1 Allow EPB to enter "maintenance mode" via the
scan tool. In special cases, such as the vehicle
of EPB.
2 Remove the brake caliper housing assembly,
refer to Replacement of Brake Caliper Housing
Assembly.
3 Remove the friction lining and the circlip.
GS110024
4 Remove the bolt securing the caliper bracket to

brake angle, and take down the caliper bracket
assembly (Tighten the bolt securing the caliper
to brake angle to 100 ± 10N.m).
GS110025
Installation
17-31
Brake System

Parking Brake System Control Diagram
SCS
BCM
ࣞᘷどᇐ
CH BO 䖜䓡᧝࡬⁗ඍ
᧝࡬㌱㔕
DiagnoStic IPK
䈀ᯣ VD INFO 㓺ਾԠ㺞
EPB
GW
⭫ᆆ傱䖜࡬ࣞ CH
㖇ީ
EPB Switch ECM

⭫ᆆ傱䖜 ਇࣞᵰ
࡬ࣞ㌱㔕 PT ᧝࡬⁗ඍ
TCM
EPB motor
਎䙕ಞ
EPB ⭫ᵰ PT ᧝࡬⁗ඍ

ၧ҆儎䙕CAN㓵䈀ᯣCAN㓵
GS110027
17-32
Brake System
ABS/ESP System Control Diagram
Wheel Speed
BCM
Sensor
BO 䖜䓡᧝࡬⁗ඍ
䖤䙕Ֆ᝕ಞ
GW
CH 㖇ީ
SDM IPK
ᆿ‫≊ޞ‬ഀ 㓺ਾԠ㺞
᧝࡬⁗ඍ PT INFO
ECM
TCCM
ਇࣞᵰ
PT ABS/ESP PT ഑傧᧝࡬⁗ඍ
᧝࡬⁗ඍ
EPB
SAS CH ⭫ᆆ傱䖜࡬ࣞ
䖢䀈Ֆ᝕ಞ CH
TCM DiagnoStic
਎䙕ಞ 䈀ᯣ
PT CH
᧝࡬⁗ඍ

ၧ҆儎䙕CAN㓵
GS110028
17-33
Brake System
Wheel Speed Sensor microstructure capacity acceleration sensor. When the

The wheel speed sensors are active sensors (i.e. they sensor chip rotates around its vertical axis in yaw rate Ω ,
receive the power supply from the ABS regulator), and the Coriolis acceleration which is perpendicular to the
they transmit the wheel speed signal to the ABS oscillating direction on the crystal surface is recorded.
regulator. The sensors are mounted in each front wheel The accelerations are proportional to the product by the
hub and each rear wheel hub, and are extremely close to yaw rate and the current maintained constant oscillating
the inner sealing device of each relevant wheel bearing. speed.
Rotating together with the wheels, the sealing device
Steering Angle Sensor
includes a magnetic element with 48 pairs of magnetic
It mainly feeds back the driver's steering information to
poles, when the wheels rotate, the magnetic poles in the
ESP control module. It is located over the combination
sealing device generates voltage fluctuation in the ABS
switch below the steering wheel.
sensor, the voltage fluctuation is converted into square
wave signal and output to the ABS regulator. The signal ESP has the functions of ABS, EBD, TCS, VDC, EBA,
frequency is proportional to wheel speed. In practice, RMI, HAS, AUTO HOLD, ATS and HDC.
each ABS sensor has a connecting wire located in the
engine compartment or the chassis, which connects
EBD System
each sensor to the whole vehicle harness. EBD system automatically detects the gripping force
between wheels and ground, distributes the optimum
A Hall-effect sensor is used as the wheel speed sensor brake force to 4 wheels, so as to improve brake efficiency
and installed on the brake angle. and driving stability.
Stroke Position Sensor TCS System
It transmits signals to ABS module and ECM during TCS system automatically controls the driving force
braking; it is installed on the brake pedal. during takeoff and acceleration to prevent wheel slip and
The brake pedal position sensor is installed on the brake keep the driving stability.
pedal bracket, which is used to detect the driver's action ESP System
on the brake pedal. The brake pedal position sensor
ESP system is an advanced computer system, which
provides an analog voltage signal for the BCM and ECM,
can help you to control the vehicle driving direction in bad
which will increase when the brake pedal is depressed.
driving conditions. When the computer detects the
Yaw Speed Sensor deviation between the expected driving route and the
The yaw speed sensor is used for measuring the lateral actual driving direction, ESP system will apply braking
acceleration sensor of the vehicle and the vehicle's pressure onto one or several brakes of the vehicle
rotating motion around its mass center axis. It is installed selectively to keep the vehicle driving in the direction
on the floor in front of the central armrest. commanded.
It measures the vehicle rotary motion around the vertical EBA System
axis and the slippage of vehicle and sends corresponding In case of an emergency, the force applied by a driver on
data to SCS ECU. ECU compares the signals received the brake pedal is usually insufficient. EBA system can
from the yaw rate sensor and steering angle sensor, recognize this rapid action with insufficient force on the
judges the forthcoming situation and then takes brake pedal and automatically establishes a brake
corresponding control. The yaw sensor adopts the whole pressure close to the locking level to shorten the braking
micro-structure method to process two relative thick distance greatly.
oscillating components (quality film) from the crystal, the
RMI System
two components take antiphase oscillation at a resonant
RMI system can recognize the vehicle rollover trend as
frequency determined by quality and the coupling spring.
soon as possible by monitoring the turning angle and
Each oscillating component has a miniaturized formal
lateral acceleration of steering wheel, and apply braking
17-34
Brake System
to a single wheel or multiple wheels to furthest prevent ATS System

rollover. In different driving modes, ESP will adapts with different
road conditions by controlling the different torque request
HAS System
from engine and the brake force.
When the car drives uphill, HAS system can prevent it
from sliding backwards after the driver releases the brake HDC System
pedal. The driver has 1.5s at most to move his foot from When driving on a long downhill surface with large slope
the brake pedal to the accelerator pedal for hill takeoff. (4°-26°), if the speed falls in the range of 8-35km/h, the
car will automatically run at a low speed, with no need for
Auto Hold
the driver to depress brake pedal and accelerator pedal,
When the engine is working, and where regular or long-
so as to make sure the car can drive downhill steadily.
time stop is required (for example, waiting for traffic lights,
Meanwhile, the driver can also adjust the speed with the
stopping on a hill or driving in the stop and go traffic), the
brake pedal and accelerator pedal.
auto hold function can help the driver to stabilize the
vehicle. If the speed is less than 8km/h or in the range of 35-
60km/h, HDC does not work, but it keeps in Standby
After the vehicle stops, the driver does not need to
mode.
depress the brake pedal, the auto hold function can lock
the vehicle automatically. If the speed exceeds 60km/h, HDC function will
automatically exit; press the HDC switch again to enable.
When the driver depresses the accelerator pedal to start
the vehicle, the auto hold function releases the brake Electrical Park Brake (EPB) System
immediately and the vehicle moves according the The EPB system is comprised of EPB switch, EPB
inclination of the road. module and 2 EPB motors. The EPB switch is installed
on the auxiliary fascia console to facilitate the driver's
ESP and EPB work together to help you park your car in
operation. Under the condition of power shortage, the
any stationary conditions, with no need for always
electrical parking brake can not be engaged or released.
depressing the brake pedal.
The EPB module is under the right seat, which is
connected with the body harness by a harness
connector. The EPB motor, installed on the rear brake
caliper housing, directly drives the piston to apply the
brake force to the rear wheels.
Powering on EPB
When the vehicle is stationary or the ignition switch is off,

EPB can be applied at any time. When leaving the
vehicle or parking, the parking brake must be applied.
· Pull the EPB switch upward until the indicator in the

EPB switch illuminates.
· If the indicators in EPB switch and in the instrument

cluster illuminates, it indicates that the parking brake has
been applied.
If the indicator P in the instrument cluster illuminates, it

indicates an EPB fault. Please contact an authorized
local after-sales service center for service as soon as
possible.
17-35
Brake System
Manually disabling EPB Starting Aid Function

The EPB automatically judges the intention of the driver,
·Switch on the ignition
and release the parking brake automatically. For hill
· Press the EPB switch, depress the brake pedal or start, the EPB can judge engine torque output and
slightly depress the accelerator pedal when the engine is prevent slip.
running
When you fasten the seat belt, place the ignition switch in
· If the indicators in the switch and in the instrument "ON" position, engage a gear and slightly depress the
cluster extinguishes, it indicates that the parking brake accelerator pedal to start the vehicle, the EPB will close
has been disabled. automatically. For manual transmission, the clutch must
be depressed completely before starting off for system
recognition and release of the parking brake.
ECD Function
In case of any emergency during driving, such as the
vehicle can not be stopped by stepping on the pedal,
decelerate by pulling up and holding the EPB switch.
· Pull the EPB switch up and hold to realize emergency

brake. Continuous acoustic alarm will sound
simultaneously during emergency brake.
· Release the EPB switch or depress the accelerator

pedal to cancel the brake process.
· During dynamic deceleration of the EPB, the EPB can

prevent the rear wheel from being locked by the clamp
force of the EPB actuator (i.e. anti-lock function).
While the parking brake is required, press the EPB

button, the signal will be fed back to ECU; then ECU will
controls the motor and planetary deceleration gear
mechanism to apply the brake on left/right rear brake
calipers.
The two normally-used auto control functions of EPB

system includes: 1. Apply the brake on the left/right rear
brake calipers after engine flameout through the
combined control of motor by vehicle CAN and EPB
ECU. 2. Drive away from the hill. When the car is driving
away from the hill, EPB ECU will control the left/right rear
brake caliper to release it automatically. Then the car will
drive away automatically.
17-36
Transfer Case (Part-time)
Specification
Torque
Nut - front flange (62) 203 ～ 241

Nut - rear flange (62) 305 ～ 332
Oil filler plug, drain plug (5) 19 ～ 30
Motor bracket bolt (66) 8 ～ 11
Motor subassembly screw (71) 8 ～ 11
Clutch coil nut (64) 8 ～ 11
Housing connecting bolt (59) 27 ～ 40
Air nozzle (43) 4～7
Bolt - transitional housing to transfer case 27 ～ 35
Bolt - transfer case to 6AT transmission 65 ± 5
Bolt - propeller shaft to transfer case 100 ± 10
Nut - transfer case controller to body 9±1
Bolt - transfer case to rear engine mount 60 ± 5
18-1
Layout
Transfer Case Layout
1
2
ES080000
1 Transmission 3 Propeller shaft

2 Transfer case
18-2
Transfer Case Exploded View
66 56
78
54
79 62 53
61
60 76
77 44 43
75 1
7 4
65
2
3
8
45 9
46 5
49 6 11
42 12
47 38
41 13
48 40
37 10
39
36 14
8 15
35
34 16
51
17
52
33
50 18
32
73 19
57 20
72 73 31
66 64 58 30
74 59
70 68 55 24
67 29 23 21
69 71 7
28
63
61 25
60 27 22
62
26
ES080001
1 Transfer case assembly 7 Transfer case front output shaft oil seal
2 Front transfer case housing 8 Transfer case front output shaft bearing
3 Locating pin - transfer case housing 9 Clamp - transfer case input shaft
4 Transfer case input shaft oil seal 10 Transfer case input shaft
5 Transfer case input shaft gear ring 11 Clamp - transfer case input shaft bearing
6 Clip - transfer case washer 12 Transfer case input shaft bearing
13 Gasket - transfer case sun gear thrust
18-3
14 Transfer case input shaft internal bearing 45 Front transfer case housing magnet
15 Clip - transfer case sun gear 46 Transfer case front output shaft
16 Transfer case sun gear thrust plate 47 Transfer case front output shaft driven sprocket
17 Thrust plate sun gear at transfer case input end 48 Transfer case front output shaft spacer bush
18 Planet carrier component at transfer case input 49 Transfer case sprocket chain
end 50 Rear transfer case housing
19 Clip - transfer case sun gear 51 Clip - rear transfer case housing
20 Deceleration shift gear sleeve of transfer case 52 Rear transfer case housing bearing
planet mechanism
53 Front transfer case housing transitional housing
21 Transfer case rear output shaft
54 Screw - transfer case transitional housing
22 Transfer case rear output shaft oil pump
55 Rear transfer case housing bushing
component
56 Clip - transfer case transitional housing
23 Clamp - transfer case rear output shaft (elastic)
57 Rear transfer case housing oil seal
24 Transfer case rear output shaft oil pipe
58 Clip - rear transfer case housing
25 Transfer case rear output shaft oil filter
component 59 Bolt - rear transfer case housing
26 Rear transfer case housing solenoid coil 60 Transfer case rear output shaft oil seal
component 61 Washer - transfer case input end
27 Clutch coil housing assembly of transfer case 62 Nut - transfer case front output shaft
rear output shaft
63 Transfer case rear output shaft plate
28 Clip - transfer case shift gear sleeve
64 Nut - rear transfer case housing
29 Transfer case shift gear sleeve armature
65 Bolt - transfer
30 Transfer case shift gear sleeve return spring
66 Bolt - transfer
31 Transfer case shift gear sleeve/hub
67 Clip - rear transfer case housing
32 Transfer case shift gear sleeve return spring
68 Clip - transfer case motor
33 Transfer case shift gear hub/sleeve
69 Clip - transfer case motor connector
34 Transfer case rear output shaft drive sprocket
70 Clip - transfer case solenoid coil connector
35 Transfer case shift shaft return spring
71 Bolt - transfer motor
36 Front transfer case housing shift shaft
72 Rear transfer case housing shift motor
37 Transfer case shift shaft 4WD shift fork subassembly
38 Transfer case shift shaft deceleration shift fork 73 Rear transfer case housing oil plug
subassembly
74 Transfer case motor bracket
39 Transfer case shift shaft/cam
75 Transfer case rear dust shield
40 Transfer case shift shaft torsional spring
76 Transfer case assembly
41 Transfer case shift shaft bushing
77 Transfer case control module
42 Transfer case shift shaft
78 Transfer case breather pipe
43 Front transfer case housing air nozzle
79 Nut - transfer case controller
44 Transfer case front output shaft plate
18-4
Troubleshooting
General Inspection Process Specific Inspection Process
Carry out visual inspection for all parts (excluding parts to Follow the instructions specified in table 4-1 to check the
be renewed, such as oil pump pipe, O-ring and oil seal, parts listed in the table. The part number shown in table
etc) to see if the parts are damaged or excessively and 4-1 is identical with the part indicated in the Transfer
unevenly worn, and discard the damaged or worn parts Case Assembly Exploded View in Chapter 8.
that will affect the performance. Items to be inspected are
as follows:
Gear/Sprocket Tooth Check
Burr: raised sharp edge on some part of the material.
When specified by table 4-1, check the gear or sprocket
Debris: broken or grated piece or particle. tooth according to the following methods:
Crack: surface crack line that represents the material will Caution: Do not mix the tool mark resulted from
partially or completely separate. machining with the extrusion mark. Figure 4-1
shows the typical machining mark.
Excessive wear: severe or obvious wear that goes
beyond the range of application. 1 Check the form of the engagement/contact area
of the gear or sprocket tooth. Figure 4-2 provides
Shrinkage: material slip due to local stress. the forms of common engagement/contact area.
Parts with the contact area shown by the
Adhesion: loose soft metal material particles adhere to
ACCEPT column are acceptable, if other
the hard metal surface.
requirements are met, continue to use the part.
Furrow: local crack or groove, normally refers to the Parts with the contact area shown by the
REJECT column are unacceptable, discard the
transfer of the material instead of loss of the material.
part and do not repair it.
Pitting: break of the metal surface due to contact
pressure. Change of color due to heat from metal friction
is visible.
Step type wear: a visible or perceptible step between the

Typical machining mark on
adjacent contact surface and non-contact surface, which the gear face is acceptable,
Typical gear shaving mark while the rough surface or
is caused by excessive wear. irregular mark will be
rejected
Uneven wear: locally and unevenly distributed wear,

including hole, bright spot, non-uniform polish and other
visible signs.
Typical gear grinding mark
Figure 4-1: Typical Gear Face Machining Mark

ES080002
18-5
Description Accept Reject Repair Reject

Ideal engagement Two sides of contact
contact area
Middle part of
face tooth top spalling contact area spalling
Contact area locating

at one side Two sides of tooth
Middle part of contact
top spalling
face tooth top spallin
Contact area locating
at the other side
One side of non-contact
face tooth top spalling
Contact area close to
the tooth top
Contact area close to Middle part of one

the tooth root side of contact
face tooth spalling
Figure 4-2: Gear Face Contact Area Figure 4-3: Gear Face Defect
ES080003 ES080004
2 Check the gear/sprocket tooth for peeling. Tooth 1 Service the patch peeling with a suitable manual
peeling or groove form is shown in figure 4-3. As high-speed grinding tool.
shown by the REPAIR column, parts with patch
2 When grinding the base metal, try not to remove
peeling can be repaired and reused (see section
more metal.
4-3). As shown by the REJECT column, parts
with severe peeling or broken tooth cannot be 3 All sharp corners or flashes shall be the smooth
repaired, the part shall be discarded and no outline after service. The sharp corner or flash
repair is allowed. may peel off again or becomes cracks. Remove
the burr with a suitable grinding stone, and
remove the raised material carefully without
damaging the base. Replace the unrepairable
Spline Tooth Check
parts (for example, bearing, etc), If there is any
Check for broken or peeling spline tooth. Patch peeling doubt whether the part can be reused, replace it.
and gear tooth peeling can be repaired in the same way,
and such parts can be reused (see figure 4-2 and 4-3). If
any broken spline tooth is found, the part shall be
discarded and no repair is allowed. The contact form of
the spline tooth is different form that of the gear, however,
splines showing step slip shall be discarded and no
repair is allowed.
4-3 Service/Replacement
Replace the parts rejected by the inspection, unless the
parts are serviced according to the procedures specified
in the figure below or other parts only needing minor
repair can be further used.
Gear/Sprocket Tooth Service

The service shall be limited to the patch peeling shown in
figure 4-3.
18-6
Table 4-1 Inspection
Parts (items) Inspection Accept/Reject
All parts (including all springs) Inspect for crack. Reject all parts with cracks.
Inspect for twist. Reject parts with curve, twist and
Inspect for corrosion. unsatisfactory runout.
Reject all parts with pitting or
corrosion.
All threaded parts Inspect the thread for damage or other Reject parts not suitable for tapping or
damages. clamping.
Flange (44), (63) Inspect splines according to section 4- Handle as per section 4-2.
2.
Motor assembly (72), electric clutch Perform a function inspection on the Replace the parts as required.
parts vehicle with reference to the Service
Manual of the vehicle.
Ball bearing (8, 12, 52, 53) Perform a visual inspection for the Reject damaged bearing.
bearing ball and raceway to see if
there is any peeling, adhesion, pitting Reject damaged and loose bearing or
or other damages. inspect if the axial clearance exceeds
Confirm that the bearing is lubricated, 0.23mm.
hold the inner ring of the bearing and
turn the outer ring of the bearing
slowly. Determine if it can work freely
or if it is corroded. The bearing shall
turn smoothly and shall be no any play
and wandering.
Needle bearing (14) Perform a visual inspection for the Reject damaged bearing.
bearing needle and raceway to see if
there is any peeling, adhesion, pitting
or other damages.
Transfer case front housing (2)/rear Inspect the mating face for burrs or Remove the burr according to section
housing (50) other damages that may affect fit and 4-3, or replace the damaged parts.
seal.
Transfer case front housing (2) Inspect the bore of bearing (8). If any pitting or damage is observed,
reject the part.
Transfer case rear housing (50) Inspect the bore of bearings (52 and If any pitting or damage is observed,
53). reject the part.
Clutch coil housing (27) and shift gear Inspect splines according to section 4- Handle as per section 4-2.
hub (31) 2.
Shift gear sleeve (33) Inspect the shift fork groove for If any step slip or damage is observed,
damage or wear. reject the part.
Inspect splines according to section 4- Handle as per section 4-2.
2.
Shift shaft (36) Inspect for deformation. If any curve is found, reject the part.
Inspect the outer circle for any burr or Handle as per section 4-3, or reject the
other damages. damaged shaft.
Inspect the outer circle for wear. If any step slip or damage is observed,
reject the part.
18-7
Shift fork (37) Inspect the location where the shift If any step slip or damage is observed,
fork, shift cam and gear sleeve fit for reject the part.
wear or damage.
Shift fork subassembly (38) Inspect the shift fork veneer fitting with If step wear or damage occurs, reject
the gear sleeve for wear or damage. the veneer.
Inspect if the roller can rotate freely or
if it is damaged. If the roller cannot rotate freely or if it is
damaged, use a new pin - roller
subassembly.
Drive sprocket (34) and driven Inspect the sprocket tooth according to Sprocket Tooth Check in section 4-2
sprocket （47） section 4-2. Spline Check in section 4-2
Inspect the sprocket spline according
to section 4-2.
Drive sprocket (34) Inspect the inner diameter fitting with If any pitting or damage is observed,
the output shaft. reject the part.
Drive chain (49) Inspect for step slip, loose part or Reject worn or damaged drive chain.
damaged pin/connector.
Strainer (25) Inspect the strainer for cleanness, Clean it when necessary, and reject if
small hole or damage. it is damaged.
Oil pump component (22) Check the inner diameter of the pump If the pump housing is damaged or
housing for pitting or step slip. severely worn, reject it.
Output shaft (21) Inspect splines according to section 4- Spline Check in section 4-2
2. If any pitting or damage is observed,
Inspect the surface fitting with the reject the part.
bearing. If any curve occurs or the runout is
Inspect for twist. unsatisfactory, reject the part.
Deceleration shift gear sleeve (20) Inspect the sprocket spline according Spline Check in section 4-2
to section 4-2. If any step slip or damage is observed,
Inspect the location fitting with the shift reject the part.
fork for wear or damage.
Front output shaft (46) Inspect the surface fitting with the If any pitting or damage is observed,
bearing. reject the part.
Inspect splines according to section 4- Spline Check in section 4-2
2.
Input shaft (10) Inspect splines according to section 4- Spline Check in section 4-2
2. If any curve occurs or the runout is
Inspect for twist. unsatisfactory, reject the part.
Thrust gasket (13) and thrust plate Check for pitting. If any pitting or damage is observed,
(16) reject the part.
Sun gear (17) Inspect the gear tooth according to Gear Tooth Check in section 4-2
section 4-2. Spline Check in section 4-2
Inspect splines according to section 4-
2.
Planet carrier component (18) Inspect the gear tooth according to Gear Tooth Check in section 4-2
section 4-2. If any step slip or pitting is observed,
Inspect if the shaft pin of the planet reject the part.
gear is worn or loose and if the thrust
washer is worn.
18-8
Shift cam (39) Inspect for pitting or step slip. If any step slip or pitting is observed,
reject the part.
Shift shaft (42) Inspect for pitting or step slip. If any step slip or pitting is observed,
Inspect for twist. reject the part.
If the part is curved, reject it.
Big gear ring (5) Inspect the gear tooth according to Gear Tooth Check in section 4-2
section 4-2.
18-9
Repair Guidance
Replacement of Transfer Case Assembly 11 Remove the bolts connecting the transfer case
Removal and the transmission, and remove the transfer
case.
1 Position the vehicle on a suitable lifting machine.
12 Simply move the transfer case backward until
Caution: The transfer case bracket or jack shall the transfer case input shaft is completely
support the transfer case independently, and disconnected from the transmission spline.
shall be able to lift up/lower down and move the 13 Carefully lower the lifting machine of the transfer
transfer case horizontally. case and remove the transfer case.
2 When moving the transmission shift lever to P or
N position, the transfer case will switch to 2H
mode and the engine is shut down.
3 Disconnect the battery negative after the ignition
switch is off for 1min.
4 Lift the vehicle.
5 Remove all electrical harnesses related to the
transfer case.
6 Remove the hose from the vent valve of the
transfer case.
7 Disconnect the front/rear propeller shaft from the
flange of the transfer case.
8 Disconnect the rear propeller shaft from the rear
9 Support the transfer case with the jack.
Warning: Ensure the transfer case is completely
under the support of the lifting machine before
removing the bolt connecting the transfer case
and transmission. Do not hang the transfer case
directly on the transmission through the spline
shaft, this may cause damage to the parts of the
transfer case.
10 Remove the bolts connecting the transfer case
and rear mount.
ES080005
18-10
Installation
1 Apply appropriate specified grease to the spline
of the transmission input shaft with a thin sleeve
containing grease.
2 Raise the lifting bracket of the transfer case, and
ensure the transfer case and transmission are
aligned with one axis.
Warning: Before connecting the spline, ensure
the transfer case is aligned with the transmission.
Do not force the spline of the transfer case into
the transmission, otherwise, the transfer case
may damage. When necessary, turn the rear
output flange of the transfer case to align it with
the spline.
3 Move the transfer case forward slowly, assemble
the spline of the transmission output shaft,
locating pin and stud of the rear transmission
housing until the front transfer case housing and
rear transmission housing fit closely.
4 Ensure the front transfer case housing is aligned
with the mounting hole of the rear transmission
housing, then align the lower mounting hole of
the transfer case with the mounting hole of the
rear mount. Install the bolt/nut, and tighten the
bolt/nut in the diagonal sequence, the torque is
as follows:
·Transfer case connected with Punch 6AT transmission:
the torque of 6 bolts is 65 ± 5N.m.
·Transfer case connected with rear mount: the torque of

2 bolts is 60 ± 5N.m.
5 Connect the front/rear propeller shaft and front/

rear output flange of the transfer case, and
tighten the bolts to 100 ± 10N.m.
6 Connect the air nozzle and breather hose.
7 Connect all electrical harnesses related to the
transfer case.
8 Lower the vehicle and connect the battery
negative.
18-11
TCCU Replacement
Removal
Note: The transfer case control unit (TCCU) is
under the rear part of front passenger's seat. Lift
the carpet under the seat before control unit
diagnosis and replacement.
GS120002
1 Lift the carpet under the front passenger's seat,

refer to Removal/Installation of Carpet.
2 Remove the nuts securing the transfer case to
body (nut tightening torque: 9 ± 1N.m).
3 Disconnect the connector of the TCCU to
remove the TCCU.
Installation
18-12
Transfer Case Removal Removal of Transfer Case Electric Shift

Note: If the service is only for the damaged part Component
on the transfer case, as long as the damaged part
is taken out, stop disassembling the transfer
case. Remove the part from the transfer case as a 71
67
subassembly or assembly, no need to
disassemble it, unless it contains any damaged
part. 68 69 70
1 Position the transfer case on the workbench,

with the rear housing up. 72 66
ES080010
1 Remove the flange bolt (66), 3 bolts (71) and 2 J-

clips (67).
2 Remove the shift motor subassembly (72).
3 The harness clip (68), connector harness clip
(69) and connector (70) are removed for
5D 5L replacement only.
ES080008
ES080009
2 Prepare a clean container for oil collection,

release the drain plug 5D (73) from the rear
housing (50), invert the transfer case and drain
the lubricant in the transfer case.
3 Then turn over the transfer case, place a block
under the front housing to keep the transfer case
level, and release the oil filler plug 5L (73).
4 Secure the flange (63) with an anti-torsion bar,
release the nut (62), remove the washer (61),
and remove the flange (63) and oil seal (60).
18-13
Rear Housing Removal
83
50
52 82
51 59
58 59
26
56
55
64 83
57
35 53
36 83
21
45
2
ES080011
1 Remove 17 bolts (59), nameplate (82) and 2 6 Remove the oil seal (56) from the rear transfer
harness clips (58). The nameplate contains case housing (50).
information for replacement, so please keep it 7 Remove the magnet (45) from the front transfer
properly. Keep the harness clip properly, case housing (2).
remember the location of the harness clip (58)
8 Remove the return spring (35) from the shift
for subsequent installation.
shaft (36).
2 Slightly pry the housing, and release the sealant
9 Remove the sealant on the mating face of the
on the mating face, then directly lift the rear
front (2)/rear (50) housing of the transfer case,
transfer case housing subassembly (83).
take care not to damage the mating face of the
3 Remove the oil seal (57), 3 flange nuts (64) and two housings or drop the material removed into
clutch solenoid coil (26). the transfer case.
4 Remove the snap ring (51), and remove the
bearing (52) and shaft bush (55) from the rear
housing (50).
5 Remove the bearing (53) from the rear transfer
case housing (50).
18-14
4WD Shift Component Removal Chain Drive System Removal

Remove the following parts from the remaining transfer Remove the following parts from the remaining transfer
case housing subassembly. case housing subassembly.
34
21
27 21
48
28
47
29
30
84 46
31 36
32
37
33 49
ES080012 ES080013
1 Remove the clutch coil housing (27) from the 1 Remove the spacer bush (48) from the front
rear output shaft (21). output shaft (46).
2 Remove the 4WD shift gear sleeve subassembly 2 Remove the drive sprocket (34), driven sprocket
(84) and 4WD shift fork (37) from the rear output (47) and chain (49) from the two output shafts
shaft (21) and shift shaft (36), separate each (21 and 46).
subassembly and remove the shift shaft (36).
3 Disassemble the 4WD shift gear sleeve
subassembly (84), remove the snap ring (28)
first, then remove the armature (29), return
spring (30), shift gear hub (31), conical return
spring (32) and shift gear sleeve (33) in
sequence.
18-15
Rear Output Shaft/Pump Subassembly Deceleration Shift Component Removal

Removal Remove the following parts from the remaining transfer
Remove the following parts from the remaining transfer case housing subassembly.
case housing subassembly.
20
22
85
23 83
24
21 25
38
ES080015
ES080014
1 Remove the deceleration shift gear sleeve (20)

1 Remove the rear output shaft and pump and deceleration shift fork subassembly (38)
subassembly (85). from the housing.
2 Remove the oil pump component (22) and rear
output shaft (21) from the rear output shaft and
pump subassembly (85).
3 Remove the elastic clamp (23), oil pipe (24) and
oil filter component (25) from the oil pump
component (22).
18-16
Front Output Shaft Subassembly Removal Shift Cam Mechanism Removal

Remove the following parts from the remaining transfer Remove the following parts from the remaining transfer
case housing subassembly. case housing assembly.
42 41 40 39
62 61 60 44 2 46
ES080016 ES080017
1 Secure the front output flange (44) with the anti- 1 Remove the electric shift cam mechanism (39-
torsion bar, release the nut (62), and remove the 42) from the front transfer case housing as an
washer (61), front output flange and O-ring (60). assembly.
2 Remove the front output shaft (46). 2 Use a vise with soft mouth to clamp the end of
the shift shaft (42), knock it with a screwdriver to
disconnect and remove the shift cam (39),
torsional spring (40) and bushing (41).
18-17
Removal of Front Housing/Input Shaft/Planet

Mechanism Subassembly
86
6
5
9
2
43
8
3 19
7 18
17
16
86 15
14
10 88
13
12
11
87 89
ES080018
Remove the following parts from the remaining transfer 5 Remove the planet mechanism subassembly
case housing subassembly. (89) of the input shaft, stretch the snap ring (19)
with a plier, and remove the planet gear
1 The air nozzle (43) is removed from the front subassembly (88) from the input shaft
housing subassembly (86) for replacement only. subassembly (87).
2 Remove the snap ring (6) and take out the big 6 The input shaft subassembly (87) is removed for
gear ring (5). replacement only. Remove the snap ring (11)
from the input shaft (10), press and remove the
3 Hold one end of the input shaft (10) on the bearing (12), and then remove the thrust gasket
workbench, stretch the long end of the snap ring (13) and needle bearing (14).
(9), and slightly press the front end of the input
shaft (10) to remove the planet mechanism 7 Remove the snap ring (15) from the planet
subassembly (89) of the input shaft as an carrier gear subassembly (88), remove the thrust
assembly, then remove the split ring (9) from the plate (16) and sun gear (17), and detach the
front transfer case housing (2). planet carrier component (18).
4 Remove the oil seal (4), (7) from the front 8 Do not attempt to disassemble the planet carrier
transfer case housing (2), and pull out the component (18).
bearing (8). The 2 locating pins (3) are removed
for replacement only.
18-18
Transfer Case Installation Installation of Front Transfer Case Housing

Precautions before Installation Subassembly
Cleaning Installation of the front transfer case housing
subassembly is as follows:
Caution: Check the magnet for metal debris prior
to cleaning. Occurrence of big, granular or
irregular particle indicates fracture or similar
damage; occurrence of small and powder debris 6
5
indicates non-uniform or excessive wear. In case 9
2
of metal debris, carefully check the rotating part
and the corresponding part for damage and wear.
86
General Cleaning Process
Clean the part in cleaner, remove lubricant residue and

precipitate. Remove the precipitate in the oil hole with a 4 8
brush. For parts that cannot be cleaned with a brush,
3
take care not to scratch the metal mating face etc. during 7
cleaning. ES080019
Blow the parts cleaned dry.

1 Position the front transfer case housing (2) on a
Dry the parts with low-pressure compressed air (max. 20 suitable press machine, the mating face is up
psi), do not wipe with a cloth, for this may leave lint on the and parallel with the working face of the press
machine.
parts. When drying the bearing, hold it with hands to
prevent it from rotating. 2 Press the bearing (8) into the front transfer case
housing (2) with tool C00089925.
Lubrication during Installation 3 Turn over the housing, position the new oil seal
All internal parts without grease shall be lubricated with using the specification shown and press it into
the specified lubricant (grease) before installation, this the housing. Install the oil seal (4) with tool
can facilitate installation and helps to provide initial C00089920 and oil seal (7) with tool C00089921.
lubrication for the operation. 4 If 2 locating pins (3) are removed, install new
locating pin (3) of the specification shown into
1 Prior to installation, damage to the O-ring or oil the housing.
seal without grease may occur.
2 Ensure the bearing or bushing is sufficiently
lubricated before installation, operation of the
non-lubricated bearing or bushing even for a 6 9 5 8 10.0 3
short period of time will cause damage.
3 Before installation, lubricate the lip of the oil seal
and the corresponding parts.
2.0
4
1.0
ES080020
5 Install the snap ring (9) into the snap ring slot on
the housing (2).
18-19
6 Place the big gear ring (5) into the groove in the
housing (2), and install the snap ring (6).
Caution: Execute this process after installing the
planet mechanism subassembly (89) of the input
shaft into the front housing, input shaft
subassembly and planet mechanism assembly.
18-20
Installation of Front Housing/Input Shaft

Subassembly/Planet Mechanism
86
19
9 18
2 17
16
15
14
10 88
13
12
11
87 89
43
ES080021
Install the following parts on the workbench. 2 Install the thrust gasket (13) into the input shaft,
install the bearing (12) with tool C00089927, and
1 If the input shaft subassembly (87) is install the snap ring (11) into the slot of the input
disassembled, position the needle bearing (14) shaft, then complete installation of the input shaft
as illustrated and press into the input shaft using subassembly (87).
the specification shown.
3 Place the planet carrier component (18) on the
workbench, the end with the snap ring slot shall
be up.
12
4 Install the sun gear (17), the section with the
protruding end shall be up. Turn the planet
11 carrier component until the planet gear
completely engages with the sun gear.
14 5 Align the protruding tooth, and install the thrust
plate (16) into the planet carrier component (18).
6 Install the snap ring (15) to complete installation
of the whole planet gear subassembly (88).
7 Lift the planet gear subassembly (88), install the
10
13 input shaft subassembly (87), stretch the snap
ES080022
ring (19) with a plier and install it into the snap
ring slot of the input shaft to complete installation
18-21
of the planet mechanism subassembly (89) of Front Output Shaft Installation

the input shaft.
Install the front output shaft component.
8 With the mating face of the front housing
subassembly (86) up, position the front mating
face of the transfer case housing (2) on two
blocks so that a gap can be maintained between
the input shaft (10) installed on the front housing
and the workbench. Stretch the long end of the
snap ring (9) on the front transfer case housing
(2), lift the planet mechanism subassembly (89)
of the input shaft to have the spline end of the
input shaft (10) down, until the snap ring (9)
enters into the snap ring slot on the outer ring of
the bearing (12).
9 Install the air nozzle (43) to a torque of 4～7N.m.
62 61 60 44 2 46
ES080023
1 Place the front output shaft (46) into the front

transfer case housing (2), and install the flange
(44), seal ring (60), washer (61) and nut (62).
2 Insert the anti-torsion bar into the mounting hole
of the front flange to secure the flange, and
tighten the nut (62) to a torque of 203 ～ 241N.m.
18-22
Electric Shift Cam Installation

Installation of the electric shift cam subassembly is as
follows:
39
40
41 40
41 42
ES080026
42
4 Try to push the torsional spring (40) and bushing
(41) back.
ES080024
40
1 Insert the bushing (41) into the inner diameter of
the torsional spring (40), and pass it through the
free end of the shift shaft (42).
2 Slide the torsional spring (40) and bushing (41) 41
on the shift shaft (42) to the drive tongue, and
place the first finger of the torsional spring on the
left of the drive tongue (viewed from the free end
of the shift shaft).
42
ES080027
40 5 Install the electric shift cam (39) into the shift

shaft (42), the cam end with drive tongue enters
first. Place the cam drive tongue under the drive
41
tongue of the shift shaft (between the two fingers
42 of the torsional spring), and keep it inward as
much as possible.
6 Install the shift fork to the housing, and then
install the shift cam subassembly (39-42) into the
front housing subassembly of the transfer case
ES080025
(refer to Shift Lock Component Installation).
3 Turn the second finger of the torsional spring on

the shift shaft (42) to the right of the drive tongue.
18-23
Deceleration Shift Component Installation Output Shaft/Pump Subassembly Installation

The installation process is as follows. Caution: By immersing the strainer of the oil
pump into the lubricant, and rotating the output
shaft counterclockwise (viewed from the rear of
the output shaft), you can observe if the oil pump
delivers oil and determine if the oil pump can
20
work properly. The parts assembled can be
88
installed into the transfer case housing as a
18 subassembly.
Ensure the oil pump, etc to be installed is sufficiently
lubricated and the lubricant can be pumped out of the
taper hole on the front cover of the oil pump. Installation
of the oil pump is as follows.
38
ES080028
22
1 The deceleration shift fork subassembly (38) and
85
deceleration gear sleeve (20) are in the housing,
and the deceleration shift gear sleeve is in the 21
planet gear subassembly installed (88).
20 23
24
25
85
ES080029
1 Install the oil filter into the oil pipe (24), place the
elastic clamp (23) on the end of the oil pipe (24),
install the oil pipe to the oil nozzle of the oil pump
component (22) and tighten the elastic clamp
(23).
2 Locate the fitting part of the rear output shaft (21)
and oil pump component (22), and slide it to the
rear output shaft (21) through the shaft hole of
the oil pump component (22).
3 Vertically position the output shaft into the
deceleration shift gear sleeve (20).
18-24
Chain Drive System Installation Installation of 4WD Shift Component/Shift

The installation process is as follows: Lock Mechanism
The installation process is as follows:
34
21
48 21
47 27
28
46
29
30
84
31 36
49 32
37
ES080030 33
ES080031
1 After the front housing subassembly of the
transfer case is installed on the workbench,
1 Install the conical return spring (32) and shift
position the drive sprocket (34) on the rear end
of the rear output shaft (21) and the driven gear hub (31) into the shift gear sleeve (33), then
sprocket (47) on the rear end of the front output install the return spring (30) and armature (29),
and secure with a snap ring (28) to complete
shaft (46).
installation of the 4WD shift gear sleeve
2 Position the sprockets (34 and 47) horizontally, subassembly (84).
install the chain (49) with the blue link of the
chain facing up. 2 Pass the shift shaft (36) through the deceleration
shift fork subassembly installed, and install it into
3 Grasp the two sprockets and attach the chain the blind hole of the front housing of the transfer
closely to the sprocket, parallel it with the case.
transfer case, and install the chain and sprockets
3 Install the 4WD shift fork (37) on the 4WD shift
(34 and 47) through the two output shafts (21
and 46), and slightly turn the driven sprocket (47) gear sleeve subassembly (84), and slide the
to ensure it engages with the spline of the front whole subassembly through the shift shaft (36)
and rear output shaft (21).
output shaft (46).
4 Install the spacer bush (48) on the front output 4 Install the electric shift cam component and
shaft (46). clutch coil housing assembly (27) installed in
section 5-5, the process is as follows:
1) Position the shift cam component as illustrated.
38
42
40
39
36 37
ES080032
18-25
2) Hold the shift shaft (36) down, and gently lift the shift Installation of Rear Transfer Case Housing
Subassembly
forks (37 and 38). Turn the shift cam component in
place, so that the roller of the deceleration shift fork Installation of rear transfer case housing subassembly is
subassembly (38) can enter into the groove of the as follows.
shift cam and the protrusion of the 4WD shift fork (37)
locates at the tail end of the shift cam. Then, lower the
component, allow it to come into the front housing of
the transfer case, and allow the shift shaft (42) to 83 55 56
engage with the pin hole in the transfer case housing. 57
64
50
52
3) Install the clutch coil housing assembly (27) on the rear 51
output shaft (21), and ensure its spline engages with 26
the spline of the rear output shaft (21).
51 83
ES080033
1 Position the rear transfer case housing (50) on a

suitable press machine, the mating face is up
and parallel with the working face of the press
machine.
2 Press the ball bearings (52, 53) into the rear
transfer case housing (50), and install the snap
ring (51). Install two bearings with tool
C00089926.
3 Turn over the housing, install the shaft bushing
(55) into the rear transfer case housing (50).
4 Position the new oil seals (56, 57) using the
specification shown and press it into the housing.
Install the oil seal (56) with tool C00089921 and
oil seal (57) with tool C00089924.
56
55
57 54
54
50
53 52 51
ES080034
5 Installation of the transfer case solenoid coil

component is as follows:
18-26
Confirm that 4 O-rings are on the specified location of the Installation of Transfer Case Housing
solenoid coil component (26) (on one coil harness, three Subassembly
studs). Install the solenoid coil component (26) into the Install the rear housing subassembly installed above on
rear housing (50), the harness and stud extend from the the front housing subassembly, the process is as follows.
rear housing, and take care not to damage the electrical
harness. Install 3 nuts (64) and tighten to the torque of 8
～ 11N.m. 59
82
59
58
88
35
36
50
45
83
ES080035
1 Install the return spring (35) on the shift shaft

(36) of the transfer case.
2 Install the magnet (45) on the corresponding slot
of the front transfer case housing (2).
3 Apply Loctite adhesive 598 with a diameter of
1.6mm to the mating face of the front transfer
case housing, the adhesive shall go round the
thread hole and be continuous.
Warning: During the following procedures, do not
clamp the rear housing into the front transfer
case housing with excessive force. When all
requirements for alignment are met, it takes no
efforts to install the rear housing into the front
housing. If installation is impossible, remove the
rear housing subassembly and check for
alignment.
4 Install the rear housing subassembly (83) on the
front transfer case housing (2), the following
conditions for alignment shall be met:
18-27
Shift Motor Subassembly Installation

Installation of the electric shift transfer case is as follows.
35
42 36 21
40
3 50 68 69
70
71
60
72 61
ES080036
1) Align the locating pin (3) on the housing with the pin
hole on the rear transfer case housing (50). ES080038
2) The rear output shaft (21), front output shaft (46) and
the bearing in the hole of the rear transfer case
1.6mm to the mating face of the motor
housing (50) shall be aligned. subassembly (72) and rear transfer case
housing (50), the adhesive shall go round the
3) The blind hole of the rear housing and shift shaft (36)
thread hole and be continuous.
shall be aligned, ensure the return spring (35) will not
2 Position the shift motor subassembly (72), and
tilt.
align the triangular groove of the motor with the
4) Align the shift shaft (42) with the shift shaft mounting shift shaft (42). Move the shift motor
subassembly, assemble it into the shift shaft and
hole on the rear transfer case housing.
allow it to fit tightly with the rear transfer case
5 Position the nameplate, and tighten 17 bolts (59) housing (50). Then, rotate the motor until it
to 27 ～ 40N.m. locates properly and is aligned with the mounting
hole.
42
72
ES080039
18-28
3 Install 2 J-clips (67) properly, and install 3 bolts Rear Flange Component Installation &
(71) to the torque of 8 ～ 11N.m. Lubricant Refill
The installation process is as follows.
72
50
62
60 61
63
73
73
67 67 67 82
ES080037
ES080040
4 Tighten the flange bolt (66) at the end of motor
harness clip to the torque of 8 ～ 11N.m.
1 Position the transfer case horizontally, refill 1.5±
0.05L of Dexron III lubricant as per the location
of oil filler plug shown in the figure.
5D 5L
ES080008
2 Install 2 oil filler plugs (73) to the rear housing

(50) to the torque of 19 ～ 30N.m.
3 Install the flange (63), oil seal (60) and gasket
(61) in sequence. Tighten the nut (62) to the
torque of 305 ～ 332N.m.
18-29
Installation of Transfer Case Transitional

Housing (with AT)
When installing the transitional housing (77), keep the
edge clean. The outer elongation of the locating pin is
10.0 ± 0.4mm, the torque of the screw is 27-35Nm,
please tighten the screw symmetrically and uniformly.
77
ES080041
18-30
Special Tool Tool Number and Illustration

Description

Description C00089927
Bearing (input shaft)
press tool
C00089920 C00089927
Oil seal input shaft
press tool
C00089920
C00089921
Oil seal (front/rear
output shaft) press
tool
C00089921
C00089924
Oil seal (motor)
press tool
C00089924
C00089925
Bearing (front output
shaft) press tool
C00089925
C00089926
Bearing (rear output
shaft) press tool
C00089926
18-31

Internal Structure of Transfer Case
ES080042
1 Planet gear set 6 Shift motor

2 Oil pump 7 Output shaft - front propeller shaft
3 Electromagnetic clutch 8 4H-4L shift fork (deceleration shift fork)
4 Output shaft - rear propeller shaft 9 Input shaft
5 2H-4H shift fork (lock shift fork)
18-32
Function Description of Transfer Case

This transfer case is an electric dual range part-time 4WD one. Deceleration is achieved by a planet gear mechanism,
and power transmission to the front drive wheel is realized by a silent chain of high precision. Lubrication of the planet
gear pair and rear output component of the transfer case is performed by oil bath and oil pump. The transfer case is
provided with 3 ranges, when 2WD HIGH is selected, only two rear wheels are driven; when 4WD HIGH is selected, 4
wheels are driven, the transmission connects the transfer case directly; and when 4WD LOW is selected, the speed ratio
will be 2.48. The gearshift operation of the transfer case is achieved by a shift cam driven by a shift servo motor. In
addition, shift to 2H/4H can be easily realized by the switch on the instrument panel, and parking is required for shifting to
4L. When the speed control system of the transfer case fails, the warning lamp will alert the driver.
Transfer Case Power Flow
Rear Shaft
Input Shaft
2H
Front Shaft
ES080043
18-33
2H Power Flow Chart
Transmission
Front output shaft

of transfer case Transfer case
Rear output shaft

Front axle of transfer case
Rear axle
ES080044
18-34
Input Rear Shaft

Shaft
4H
Front Shaft
ES080045
18-35
4H Power Flow Chart
TCCU
Half shaft clutch
Electromagnetic
Shift motor
clutch
Transmission
2H-4H fork
Front output shaft

Rear output shaft

Rear axle
ES080046
18-36
Rear Shaft
Input Shaft
4L
Front Shaft
ES080047
18-37
4L Power Flow Chart
TCCU
Half shaft clutch
Electromagnetic
Shift motor
clutch
Transmission
2H-4H fork
4H-4L fork
Front output shaft

Rear output shaft

Rear axle
ES080048
18-38
Transfer Case (Real-time/All-terrain)
Specification
Torque
Nut - front flange 203~241
Nut - rear flange 305~332
Oil filler/drain plug 19~30
Bolt - transitional housing to transfer case 27~35
Bolt - motor support to rear housing 27~35
Bolt - motor component to rear housing 8~11
Bolt - transfer case (real-time 4WD) to transmission 22 ± 2

Bolt - transfer case (part-time 4WD/ATS) to transmission 65 ± 5
Nut - transfer case controller to body 5±1
Bolt - transfer case to rear engine mount 60 ± 5
19-1
Layout
Transfer Case Layout
1
2
ES080000
1 Transmission 3 Propeller shaft

2 Transfer case
19-2
Transfer Case Exploded View
4
8
5
6
15 14
11
13
9 12
11
10
3
8
2
1 6 7
5
4
GS120010
1 Bolt 9 Bolt
2 Bracket 10 Aluminum plate
3 Adapter housing 11 Plug
4 Nut 12 Motor components
5 Washer 13 Blank aluminum plate
6 Sealing ring 14 Clip
7 Front flange 15 Rear flange
8 Dust shield
19-3
Repair Guidance
Replacement of Transfer Case Assembly 11 Remove the bolts connecting the transfer case
Removal and the transmission, and remove the transfer
case.
1 Position the vehicle on a suitable lifting machine.
12 Simply move the transfer case backward until
Caution: The transfer case bracket or jack shall the transfer case input shaft is completely
support the transfer case independently, and disconnected from the transmission spline.
shall be able to lift up/lower down and move the 13 Carefully lower the lifting machine of the transfer
transfer case horizontally. case and remove the transfer case.
2 When moving the transmission shift lever to P or
N position, the transfer case will switch to 2H
mode and the engine is shut down.
3 Disconnect the battery negative after the ignition
switch is off for 1min.
4 Lift the vehicle.
5 Remove all electrical harnesses related to the
transfer case.
6 Remove the hose from the vent valve of the
transfer case.
7 Disconnect the front/rear propeller shaft from the
8 Disconnect the rear propeller shaft from the rear
9 Support the transfer case with the jack.
Warning: Ensure the transfer case is completely
under the support of the lifting machine before
removing the bolt connecting the transfer case
and transmission. Do not hang the transfer case
directly on the transmission through the spline
shaft, this may cause damage to the parts of the
transfer case.
10 Remove the bolts connecting the transfer case
and rear mount.
ES080005
19-4
Installation
1 Apply appropriate specified grease to the spline
of the transmission input shaft with a thin sleeve
containing grease.
2 Raise the lifting bracket of the transfer case, and
ensure the transfer case and transmission are
aligned with one axis.
Warning: Before connecting the spline, ensure
the transfer case is aligned with the transmission.
Do not force the spline of the transfer case into
the transmission, otherwise, the transfer case
may damage. When necessary, turn the rear
output flange of the transfer case to align it with
the spline.
3 Move the transfer case forward slowly, assemble
the spline of the transmission output shaft,
locating pin and stud of the rear transmission
housing until the front transfer case housing and
rear transmission housing fit closely.
4 Ensure the front transfer case housing is aligned
with the mounting hole of the rear transmission
housing, then align the lower mounting hole of
the transfer case with the mounting hole of the
rear mount. Install the bolt/nut, and tighten the
bolt/nut in the diagonal sequence, the torque is
as follows:
·Real-time 4WD: The torque of 11 bolts is 22 ± 2N.m.
·Part-time 4WD/ATS: The torque of 6 bolts is 65±5N.m.
·Transfer case connected with rear mount: the torque of

2 bolts is 60 ± 5N.m.
5 Connect the front/rear propeller shaft and front/

rear output flange of the transfer case, and
tighten the bolts to 110 ± 10N.m.
6 Connect the air nozzle and breather hose.
7 Connect all electrical harnesses related to the
transfer case.
8 Lower the vehicle and connect the battery
negative.
19-5
TCCU Replacement Refill & Drain of Transfer Case Lubricant

Removal
Note: The transfer case control unit (TCCU) is
under the rear part of front passenger's seat. Lift
the carpet under the seat before control unit
diagnosis and replacement.
1 2
GS120004
Drain
The oil drain plug is located in the upper position of the
figure,the tightening torque for the oil drain plug is 19-
30N.m.
GS120002
Refill
1 Lift the carpet under the front passenger's seat,
The oil filler plug is located in the upper position of the
refer to Removal/Installation of Carpet.
figure, refill specified lubricating oil Mobil LT until the level
2 Remove the nuts securing the transfer case to
is flush with the filler port basically. Tightening torque for
body (nut tightening torque: 9 ± 1N.m).
the oil filler plug: 19-30N.m.
3 Disconnect the connector of the TCCU to
remove the TCCU.
Removal/Installation of Transfer Case

Installation Transitional Housing
Removal
1 Remove the transfer case assembly, refer to
Removal/Installation of Transfer Case.
2 Remove the bolts securing the transfer case
transitional housing to the front transfer case
housing.
Installation
1 When installing the transitional housing, keep
the edge clean. The outer elongation of the
locating pin is 10.0 ± 0.4mm, the torque of all 11
screws is 27-35N.m, please tighten the screw
symmetrically and uniformly.
2 Install the transfer case assembly, refer to
Removal/Installation of Transfer Case.
19-6
Removal/Installation of Transfer Case Front Removal/Installation of Transfer Case Rear

Flange and Oil Seal Flange and Oil Seal
1
2
3
4
4
2 3
1
GS120005 GS120006
Removal Removal
1 Remove the bolts connecting the propeller shaft 1 Remove the bolts connecting the propeller shaft
to the transfer case front flange. to the transfer case front flange.
2 Remove the transfer case front flange nuts, and 2 Remove the transfer case front flange nuts, and
take out the gasket 1, seal ring 2, front flange 3 take out the gasket 1, seal ring 2, rear flange 3
and dust shield 4 in sequence. and dust shield 4 in sequence.
Installation Installation
1 Press-fit the oil seal with the special tool. 1 Press-fit the oil seal with the special tool.
2 Install the front flange, seal ring, gasket and nuts 2 Install the rear flange, seal ring, gasket and nuts
in sequence, tighten the nuts to 203-241N.m. in sequence, tighten the nuts to 305-332N.m.
3 Connect the propeller shaft to the transfer case, 3 Connect the propeller shaft to the transfer case,
tighten the bolts to 110 ± 10N.m. tighten the bolts to 110 ± 10N.m.
19-7
Removal/Installation of Transfer Case Motor

Components
Removal
1 Remove the bolts connecting the motor to rear
transfer case housing, unplug relevant
connectors to remove the motor.
Installation
1.6mm to the mating face of the motor assembly
(72) and rear transfer case housing, the
GS120008
adhesive shall go round the thread hole and be
continuous.
5 Connect relevant harness connectors.
2 Position the shift motor assembly (72), and align
the triangular groove of the motor with the shift
shaft (42). Move the shift motor subassembly,
assemble it into the shift shaft and allow it to fit
tightly with rear transfer case housing. Then,
rotate the motor until it locates properly and is
aligned with the mounting hole.
42
72
GS120007
3 Install 3 bolts securing the motor to the rear

housing, and tighten the bolts to 8-11N.m.
4 Install the bolts securing the motor support to the
rear housing, and tighten the bolts to 27-35N.m.
19-8

Internal Structure of Transfer Case
1 2 3
Rear Shaft
Input Shaft
8
5
Front Shaft
GS120009
1 Planet gear set 5 2H-4H shift fork (lock shift fork)

2 Oil pump 6 Shift motor
3 Electromagnetic clutch 7 Output shaft - front propeller shaft
4 Output shaft - rear propeller shaft 8 Input shaft
19-9
Function Description of TOD Transfer Case

This transfer case is an electric part-time 4WD one. Deceleration is achieved by a planet gear mechanism, and power
transmission to the front drive wheel is realized by a silent chain of high precision. Lubrication of the planet gear pair and
rear output component of the transfer case is performed by oil bath and oil pump. TOD transfer case is provided with 4
ranges, when 2H is selected, only two rear wheels are driven; when AUTO is selected, TOD can analyze and calculate
the signals (such as engine speed signal and wheel speed signal) collected by the sensors equipped on the vehicle, and
transfer the torque with controllable magnitude in appropriate time to the front axle, thereby controlling the 4WD status in
an intelligent manner; when 4H is selected, the distribution proportion of front and rear axle torques can be varied, but
comparing to AUTO mode, the torque distributed to the front axle is larger; When 4L is selected, the distribution
proportion of front and rear axle torques can be varied, but the torque will be enlarged by 2.48 times. The shift operations
from 2H to 4H/AUTO is achieved by the electromagnetic clutch coil through pushing the clutch to engage/disengage. To
increase or decrease the clutch coil current, multiple clutch plates will be pressed or separated to control the magnitude of
torque output to the front axle; the operation in 4L mode is achieved by a shift servo motor through driving a gear shift
cam. In addition, shift to 2H, 4H and AUTO modes can be easily realized by the switch on the instrument panel, and
parking is required for shifting to 4L mode. When the transfer case fails, the warning lamp will alert the driver.
19-10
Propeller Shaft
Propeller Shaft
Specification
Torque

Nut - front stabilizer bar link to lower swing arm 65 ± 5
Nut - front stabilizer bar to stabilizer bar link 65 ± 5
Nut/bolt - propeller shaft to transmission 75 ± 5
Nut/bolt - propeller shaft to rear axle 75 ± 5
Bolt - intermediate support of propeller shaft to frame 55 ± 5
Bolt/nut - propeller shaft to front axle 75 ± 5
Bolt - intermediate support to propeller shaft 35~50
20-1
Propeller Shaft
Layout
Propeller Shaft System (4WD) Layout
4
2
3
ES100000
1 Front drive shaft 4 Transfer case

2 Front axle 5 Rear axle
3 Propeller shaft
20-2
Propeller Shaft
Propeller Shaft System (2WD) Layout
ES100001
1 Transmission 3 Rear axle

2 Propeller shaft
20-3
Propeller Shaft
Exploded View of Front Drive Shaft Assembly
1
3
5
4
ES100002
1 Constant-velocity universal joint assembly 7 Clamp (small)

2 Snap ring 8 Dust shield of tripod universal joint
3 Clamp (large) 9 Clamp (large)
4 Dust shield of constant-velocity universal joint 10 Circlip
5 Clamp (small) 11 Tripod universal joint assembly
6 Intermediate solid shaft 12 Connecting ring
20-4
Propeller Shaft
Exploded View of Propeller Shaft Assembly
ES100003
1 Cross shaft assembly 3 Propeller shaft

2 Intermediate support assembly
20-5
Propeller Shaft
Repair Guidance
Replacement of Front Drive Shaft Assembly
(4WD)
Removal
2
6 8
5 ES100005
9 After removing the front drive shaft, block the

front axle connecting port with a plug to prevent
3 dust.
1 4
ES100004
Installation
1 Lift the vehicle from the lifting platform.
Caution: During shipping and installation/
2 Remove the upper swing arm assembly. Refer to
removal of the propeller shaft, ensure the swing
Removal of Upper Swing Arm Assembly for
angle of movable joint (the end close to the front
details.
axle) does not exceed 26°and the swing angle of
3 Unscrew the nut fastening the stabilizer bar link
fixed joint (the end close to the wheel) does not
to the lower swing arm.
exceed 50°.
4 Unscrew the nut fastening the steering gear tie
rod to the steering angle. If necessary, use the 1 Replace the drive shaft with a new one, and
ball head puller C00017036 and support the clean its mounting position inside the front wheel
steering angle with a jack. hub and its junction with the front axle.
Caution: Do not damage the dust shield. 2 Locate the drive shaft on the front axle housing
and push it into place.
5 Remove and discard the locking nut and washer
of drive shaft hub. Caution: When installing the front drive shaft
assembly, pay attention to not damaging the
6 Rotate the steering angle outward to a certain
angle to remove the outside constant-velocity sealing parts inside front axle housing.
universal joint from the knuckle. 3 Install the drive shaft into the knuckle with new
Caution: Do not damage the dust shield. washer and nut.
7 Place a proper drain pan under the front axle When installing the hub nut, follow the instructions below:
housing.
·The mating surface with a "JPS" mark of the locking
8 To avoid damage to the front axle oil seal, washer shall face the mounting surface of nut.
horizontally pull out the inside tripod universal
joint connecting the drive shaft to the front axle. ·Pre-tightening torque: 100 ± 10N.m.
During removal, pry it up as shown in the figure.
If it is difficult to remove, rotate the shaft for 1/3 ·Rotate the hub for 10 circles back and force. Install the
circle (1/3 circle more if necessary). hub bearing in place and tighten to: 350 ± 15N.m.
Caution: Do not damage the front axle oil seal.
·Vertically knock down the locking nut of front hub into
the groove of drive shaft or spindle to prevent the nut
from loosening.
20-6
Propeller Shaft
Replacement of Constant-velocity Universal

Joint and its Dust Shield
Removal
1 Remove the drive shaft assembly. Refer to
Replacement of Drive Shaft for details.
2 Install the drive shaft clip to the vise.
3 Loosen and discard both clamps of the dust
shield.
4 Align the constant-velocity universal joint with the
intermediate solid shaft. Then slightly knock the
constant-velocity universal joint with a copper
ES100006 hammer to separate it. Remove the constant-
velocity universal joint and its dust shield.
4 Install the lower nut of stabilizer bar link and the
nut fastening the steering gear tie rod to the
knuckle, and tighten them to 65 ± 5N.m and 90
± 5N.m respectively.
5 Install the upper swing arm assembly. Refer to
Installation of Upper Swing Arm Assembly for
details.
ES100007
5 Remove the snap ring from the drive shaft and

discard.
ES100008
20-7
Propeller Shaft
Installation Replacement of Tripod Universal Joint and

its Dust Shield
1 Secure the dust shield to the intermediate solid
shaft with a clamp (small), and install its ends to Removal
the outside of two grooves. 1 Remove the drive shaft. Refer to Replacement of
Drive Shaft for details.
2 Install the drive shaft clip to the vise.
3 Loosen and discard both clamps of the dust
shield.
4 Remove the intermediate solid shaft of drive
shaft.
5 Remove the circlip at the end of intermediate
solid shaft with a nipper plier and discard it.
ES100009
2 Install a new snap ring to the intermediate solid

shaft.
3 Fill the constant-velocity universal joint with the
lubricating grease provided, and apply the
residual grease on the inner side of dust shield of
constant-velocity universal joint.
4 Press the intermediate solid shaft into the
constant-velocity universal joint completely. ES100010
5 Clean the juncture between the dust shield and

constant-velocity universal joint, and secure the 6 Remove the tripod joint and dust shield from the
intermediate shaft.
dust shield clamp (large).
6 Ensure the constant-velocity universal joint will
not interfere the dust shield when rotating freely
Installation
from each direction.
7 Install the drive shaft. Refer to Installation of 1 Clean the intermediate solid shaft, tripod shaft
Drive Shaft for details. and sleeve.
2 Install the dust shield to the intermediate solid
shaft with a new clamp (small) and install its
ends to the outside of two grooves.
3 Locate the tripod joint to the intermediate solid
shaft.
4 Install new circlip onto the end of intermediate
solid shaft.
5 Fill the tripod universal joint with the lubricating
grease provided, and apply the residual grease
on the inner side of dust shield of constant-
velocity universal joint.
6 Press the intermediate solid shaft into the tripod
universal joint completely.
20-8
Propeller Shaft
7 Clean the juncture between the dust shield and Replacement of Propeller Shaft
tripod universal joint, and secure the dust shield Removal
clamp (large).
8 Ensure the tripod universal joint will not interfere
the dust shield when rotating freely from each
direction. 2 Remove the bolt connecting the propeller shaft
to the rear axle flange.
9 Install the drive shaft. Refer to Installation of
Drive Shaft for details. 3 Remove the bolt fastening the intermediate
support to the body.
4 Remove the bolt connecting the propeller shaft
to the transmission. (2WD model)
to the transfer case. (4WD model)
to the front axle flange. (4WD model)
7 Remove the propeller shaft.
Installation
Key torques for installation are shown as follows. Please
tighten torques symmetrically and evenly during
installation:
- For the nut/bolt fastening the propeller shaft to the

transmission, tighten to 75 ± 5N.m. (2WD)
- For the nut/bolt fastening the propeller shaft to the rear

axle, tighten to 75 ± 5N.m. (2WD/4WD)
- For the bolt fastening the intermediate support of

propeller shaft to the frame, tighten to 55 ± 5N.m. (2WD/
4WD)
- For the nut/bolt fastening the propeller shaft to the front

axle, tighten to 75 ± 5N.m. (4WD)
- For the bolt fastening the propeller shaft to the transfer

case, tighten to 110 ± 10N.m. (4WD)
20-9
Propeller Shaft
Replacement of Cross Shaft 4 Knock the universal joint fork with the punch.
Removal Push out the bearing bowl through the opposite
Caution: Do not secure the propeller shaft with a force of the universal joint.
bench vice directly, as indentation or local cracks
may lead to propeller shaft failure during vehicle
usage.
1 Mark the matching position line at the position on

the universal joint for replacing the cross shaft.
ES100013
5 Remove the bearing bowl. Repeat step 4 to

remove the other 3 bearing bowls, and then
remove the cross shaft.
ES100011
Installation
2 Knock the circlip with a hammer and a punch to
1 Prepare the cross shaft repair package. Check
loosen it.
whether the roller pins in the bearing bowl are
3 Remove 4 circlips with a nipper plier. arranged neatly without any shortage. Check
and ensure the inner wall of universal joint fork
earhole is smooth and clean.
2 Place the bearing bowl outside one end of the
universal joint fork earhole. Then place the cross
shaft near the earhole and insert its one end into
the bearing bowl.
ES100012
ES100014
20-10
Propeller Shaft
3 Knock the bearing bowl from outside of earhole Replacement of Intermediate Support of
to the depth where the retainer groove is just Propeller Shaft
exposed with a hammer and a punch, and install Removal
the circlip with a nipper plier. Caution: Do not secure the propeller shaft with a
Caution: bench vice directly, as indentation or local cracks
may lead to propeller shaft failure during vehicle
1) After installation, check and confirm the circlip is in the
usage.
retainer groove and has rebounded in place.
2) In case of a great resistance during push-in of bearing

bowl, stop pushing immediately, and check the
matching between the cross shaft and bearing bowl 1
and the interference between the cross shaft and the
1
universal joint fork. 2
3
4
ES100016
1 Mark the mounting positions of the propeller

shaft and steering yoke.
2 Pry up the locking gasket with a flat-blade
screwdriver.
ES100015 3 Lock the propeller shaft with a long thrust rod,
and loosen the bolt of intermediate support with
a wrench.
4 Overturn the universal joint fork for 180°, and
repeat the aforesaid steps to install the bearing
bowl and circilp on the other side. The cross
shaft must be swung during push-in, so as to
prevent the clamping stagnation between the
cross shaft and bearing bowl.
5 Place the cross shaft journals at the rest two
ends near the universal joint fork earhole on the
other end. Repeat the aforesaid steps to install
the bearing bowls and circlips at two other sides.
Pay attention to the marked position on the
universal joint fork during installation to ensure
the alignment.
6 After installation, swing the universal joint
ES100018
towards four directions to check whether it
swings flexibly. If the swing torque is excessively
great or it is stuck, hammer the outside of the 4 Remove the U-shape gasket and pull out the
universal joint fork earhole clamping the bearing steering yoke and intermediate support.
bowl with a rubber hammer.
20-11
Propeller Shaft
Installation 6 Flatten the turnup of locking gasket with a flat-

blade awl.
1 After installing the intermediate support, install
the locking gasket and bolt into the spline sleeve,
and then install the spline sleeve into the
steering yoke shaft hole.
Caution: The right angle of the sheet shall face
the intermediate support.
ES100021
ES100019
2 Align with the mark of the mounting position of

steering yoke and propeller shaft.
3 Pry up the locking gasket with a flat-blade
screwdriver, meanwhile insert a new U-shape
gasket.
ES100020
4 Lock the propeller shaft with a long thrust rod,

secure the bolt of intermediate support with a
wrench and tighten to 35-50N.m.
5 Turn the locking gasket outwards with a nipper
awl.
20-12
Propeller Shaft

The front drive shaft connects the front axle to the wheel
and transmits the torque. The inner tripod universal joint
(movable joint 2) can move along the shaft direction to
realize both steering and driving; the outer joint adopts
the rzeppa constant-velocity universal joint (fixed joint 1)
structure.
1 2
ES100022
The intermediate propeller shaft is composed of one or

two integrated tubes. Cross universal joints are used
between propeller shafts as well as propeller shaft and
male flange for connection. Secure the long propeller
shaft with an intermediate shaft onto the frame.
20-13
Propeller Shaft
20-14
Front Axle and Rear Axle
Specification
Torque
Front axle bolt - the third beam to frame 70 ± 5

Bolt/nut - front axle to frame assembly 180 ± 10
Bolt/nut - front axle to the third beam 180 ± 10
Bolt/nut - front axle male flange to propeller shaft 75 ± 5
Front axle oil filler plug/drain plug 30~40
Bolt - front axle half shaft clutch to axle housing 44~50
Bolt - front axle driven gear to differential 110~130
Bolt - front axle differential bearing cap to front axle housing 56~70
Bolt - bracket cover to front axle housing 25~35
Bolt - front axle bracket to front axle housing 125~135
Front axle drive gear lock nut 200~800
Bolt - lateral push rod to rear axle 210 ± 20

Nut - ball pins at both ends of rear stabilizer bar link 120 ± 10
Bolt - rear shock absorber to rear axle 180 ± 10
Bolt - upper trailing arm to rear axle 210 ± 20
Bolt - lower trailing arm to rear axle 210 ± 20
Bolt/nut - propeller shaft to rear axle flange 75 ± 5
Rear axle oil drain plug 20~34
Rear axle oil filler plug 20~34
Nut - half shaft assembly to axle housing 110~130
Bolt - rear axle driven gear to differential 180~230
Bolt - rear axle differential bearing cap to rear axle housing 90~100
Bolt - bracket cover to rear axle housing 38~45
Rear axle drive gear lock nut 298~678
Rear axle breather plug 9~13
21-1
Layout
Exploded View of Front Axle
6
7
8
11
17 19
20
12 9 12
6 10 15
16
24
7
23
2 3 18
14
1
13
5
4 7 29
22 21
20
19
27
28
26
10
9
25
11
GS130011
1 Drive gear lock nut 6 Bolt - drive axle to frame assembly

2 Male flange assembly 7 Gasket - drive axle to frame assembly
3 Drive gear oil seal 8 Front axle bracket
4 Drive gear outer bearing 9 Front axle output oil seal
5 Bearing spacer bush 10 Front axle output bearing
21-2
11 Bolt - front axle bracket 21 Differential assembly

12 Front axle oil filler/drain plug 22 Driven gear mounting bolt
13 Washer - bracket cover 23 Rear axle bracket cover
14 Drive gear inner bearing 24 Bracket cover bolt
15 Drive gear adjusting gasket 25 Front axle bracket
16 Breather pipe joint 26 Front axle output shaft assembly
17 Breather plug 27 Clip - transfer case washer
18 Drive/driven gear set 28 Front axle
19 Differential bearing adjusting gasket 29 Nut - drive axle to frame assembly
20 Differential bearing
21-3
Exploded View of Rear Axle
29
1
2
19
3
4
5 20
6 18
21
8
22
17
16 24 25 14
12
9
13 10
10 13
11
23
15
GS130012
1 Drive gear lock nut 8 Drive gear adjusting gasket

2 Drive gear lock gasket 9 Drive/driven gear set
3 Male flange assembly 10 Differential bearing
4 Drive gear oil seal 11 Driven gear mounting bolt
5 Drive gear outer bearing 12 Differential assembly
6 Bearing spacer bush 13 Differential bearing adjusting gasket
7 Drive gear inner bearing 14 O-ring
21-4
15 Oil filler plug assembly 21 Rear brake disc

16 Oil drain plug 22 Breather plug
17 Nut - rear brake to rear axle 23 Cap
18 Half shaft 24 Half shaft oil seal
19 Wheel bolt 25 Half shaft guide ring
20 Bolt/screw - rear brake disc
21-5
6 Connect the propeller shaft to the front axle

Repair Guidance
flange, and tighten the bolt to 75 ± 5N.m.
Replacement of Front Axle Assembly
7 Install the drive shaft. Refer to Installation of
Removal Drive Shaft for details.
2 Remove the front drive shaft assembly. Refer to
Replacement of Front Drive Shaft Assembly for
details.
3 Loosen the bolt securing the propeller shaft to
the front axle flange.
4 Remove the third beam bracket.
6 6
4
ES150001
5 Jack up the front axle.

Warning: Ensure the front axle is completely
jacked up.
6 Remove the bolt securing the front axle to the
frame.
7 Lower the jack and take down the front axle.
Installation
1 Lift the front axle and ensure the mounting holes
on both ends of the front axle are aligned with
the frame mounting holes on the same axis.
2 Install the gasket and bolt, and tighten the bolt to
180 ± 10N.m.
3 Install the third beam bracket. Do not tighten the
bolt temporarily.
4 Install the front axle intermediate bolt and
gasket, and tighten the bolt to 180 ± 10N.m.
5 Tighten the bolt mentioned in Step 3 to 70 ±
5N.m.
21-6
Replacement of Rear Axle Assembly

Removal
1 Lift the vehicle to a certain height, and remove 3
the wheels (Refer to Wheels Replacement).
2 Hold up the rear axle housing with the bracket 2
(use the bracket that can be moved up and
down). 1
3 (Hand brake) Remove the parking brake cable.
Refer to the Removal/Installation of Parking
Brake Cable for details.
4 Remove the bolts/nuts securing the lower control
arm to rear axle (1), the upper control arm to rear GS130002
axle (2), shock absorber to rear axle (3), lateral
push rod to rear axle (4), horizontal stabilizer bar 2 Move down the rear axle under the rear
link to frame (5) and propeller shaft to rear axle suspension and place it in proper position, then
flange (6). move up the bracket to lift up the whole rear axle
until the upper vibration isolator is well fit into
corresponding hole in the frame.
5 1
3 Install the bolts/nuts securing the lower control
arm to rear axle (210±20N.m), the upper control
arm to rear axle (210 ± 20N.m), shock absorber
to rear axle (180 ± 10N.m), lateral push rod to
rear axle (210 ± 20N.m), horizontal stabilizer bar
link to frame (120 ± 10N.m) and propeller shaft
6 to rear axle flange (75 ± 5N.m).
4 Move out the bracket.
4
5 (Hand brake) Install the parking brake cable.
3 2 Refer to the Removal/Installation of Parking
GS130001 Brake Cable for details.
6 Secure relevant pipes and harness to rear axle.
5 Detach the pipeline and harness secured on the 7 Install wheels. Refer to Wheels Replacement for
rear axle housing and record the mounting details.
location to facilitate re-installation.
6 Move the bracket downwards to remove the rear to the ground.
axle and coil spring.
Installation
1 Install the lower vibration isolator 1, coil spring 2
and upper vibration isolator 3 in sequence to the
rear axle.
21-7
Refill & Drain of Front Axle Lubricant Replacement of Front Axle Drive Gear Male
Drain Flange and Drive Gear Oil Seal
The oil drain plug 1 is located at the bottom of final drive Removal
housing. Tightening torque for the oil drain plug: 1 Place the vehicle on the lifting platform and lift it
30~40N.m. to a certain height.
2 Disconnect the propeller shaft from the front axle
Refill
flange, and place the propeller shaft aside.
The oil filler plug 2 is in the middle of rear oil cap. Refill the
3 Drain the oil.
specified lubricant GL-5 80W-90 until the level is flush
with the filler port basically. Tightening torque for the oil 4 Remove the lock nut and washer of drive gear
shaft flange with the special tool C00045930,
filler plug: 30~40N.m.
and discard them.
C00045930
2
ES150008 ES150009
5 Remove the drive gear shaft flange with a dual-

foot puller.
ES150010
6 Pry out the oil seal with a flat-blade screwdriver

and discard it.
21-8
Installation
1 Check and clean the burrs and contamination of
drive gear seal cavity, and clean the sealant on
the spline.
2 Press-fit the drive gear oil seal with the special
tool C00089941, but pay attention to not
contaminating the oil seal lip.
ES150013
5 Install the new drive gear gasket and nut. During

assembly, rotate the drive gear flange forwards
and backwards while tightening the nut to
200N.m.
6 Check the starting torque of drive gear with the
torque wrench.
ES150011
The starting torque shall be between 1.7 and 3.4N.m
3 Apply Loctite 565 pipe thread sealant from the (remove the front drive shaft. Refer to the Removal/
center of flange inner spline towards 360 ° Installation of Drive Shaft). It shall be measured for
circular direction. multiple times to obtain an accurate value.
If the starting torque is less than the target range value,

the drive gear nut must be tightened with the torque
increased by 5N.m until the starting torque reaches the
target value, but the tightening torque for the nut shall not
exceed 800N.m.
If the starting torque is more than the target range value,

replace the elastic spacer bush with a new one.
7 Connect the propeller shaft to the front axle

flange, and tighten the bolts to 75 ± 5N.m.
8 Refill oil.
ES150012 9 Lower the vehicle to the ground.
4 Install the flange onto the drive gear and press it

to the bottom.
21-9
Replacement of Front Axle Rim Oil Seal and

Needle Bearing
Removal
the rear wheels. Refer to Removal/Installation of
Wheels for details.
2 Drain the oil.
3 Remove the drive shaft assembly. Refer to
Replacement of Drive Shaft for details.
4 Pry out the oil seal with a flat-blade screwdriver
and discard it.
5 Remove the half shaft bearing. ES150015
3 Refill oil.
Installation 4 Install rear wheels and lower the vehicle.
1 Check and clean the mounting surface, and
press-fit the half shaft bearing with the special
tool C00089945 (apply some 40012020 multi-
function lithium grease onto the front axle needle
bearing for installation).
ES150014
2 Check and clean the oil seal hole. Then press-fit

the drive gear oil seal with the special tool
C00089937 (the lip is pre-applied with lithium
grease), but do not contaminate the oil seal lip.
21-10
Replacement of Front Axle Output Shaft Replacement of Front Axle Bracket

Remove the left and right drive shaft assemblies first Remove the front axle assembly first. For the bolts
(refer to Removal/Installation of Drive Shaft Assembly for securing the left and right bracket assemblies to the front
details). There are elastic circlips on both ends of a half axle housing, the tightening torque is 125~135N.m.
shaft. Push the front axle output shaft out with the special
tool C00089928.
C00089928
ES150022
ES150021
21-11
Replacement of Front Axle Final Drive

Assembly
Removal
1 Remove the front axle assembly. Refer to
Replacement of Front Axle Assembly.
2 Remove the drive gear male flange and oil seal.
Refer to Replacement of Drive Gear Male Flange
and Oil Seal for details.
3 Remove the front axle output half shaft. Refer to
Replacement of Front Axle Output Half Shaft for
details.
4 Remove the rear oil filler cap and washer. ES150024
6 Remove the differential bearing cap. Pay

attention to the pairing mark on the bearing cap.
If there is no mark or the mark is unclear, make a
mark again.
7 Remove the differential bearing adjusting
gaskets, and mark the left and right gaskets.
8 Remove the differential assembly.
ES150023
5 Check the overall final drive assembly to provide

reference for subsequent gasket assembly and
facilitate the subsequent troubleshooting
analysis.
Apply red lead powder onto 4~5 gears in three positions
120° apart on the driven gear.
Rotate the driven gear for 2~3 circles forwards and

backwards to mesh the drive gear with the driven gear
and form spots. Then make a record.
21-12
9 Remove bearings from both ends of differential 13 Move the drive gear inner bearing cone out with
with a puller. a puller.
ES150025 ES150027
Caution: If you plan to reuse the driven and drive

Drive/Driven Gears Disassembly
gears, take them out carefully to protect the drive
10 Clamp the differential assembly into the caliper, gear from damage.
and cover the driven gear on the caliper with a
14 Remove the drive gear adjusting gasket. Then
cloth.
measure and record the thickness of adjusting
11 Release the driven gear bolts in turn, and knock gasket.
the driven gear edge slightly with a copper rod or
15 Remove the inner bearing outer ring and outer
wooden hammer to separate the driven gear
bearing outer ring of the drive gear.
from the differential housing.
Installation
1 Install the outer bearing outer ring of drive gear
with the special tool C00089940.
ES150026
Caution: If you plan to reuse the driven and drive

gears, take them out carefully to protect the
driven gear from damage.
ES150028
12 Knock the drive gear out of the final drive
housing with a rubber hammer, and take out the
elastic spacer bush.
21-13
2 Install the inner bearing outer ring of drive gear

with the special tool C00089943.
Gear face contacting Cause Adjustment
condition s method:
A - gear face
contact area
adjustment
B - backlash
adjustment
Lean to tooth top The The drive gear

drive
adjusting gasket is
gear is
too far thicker than the
from drive gear gasket
the
removed
driven
ES150029 gear
3 Select the drive gear adjusting gasket. ES150031
The thicknesses of gaskets include:

Lean to tooth root The The drive gear
drive
0.79mm/0.84mm/0.86mm/0.91mm/0.94mm/0.99mm adjusting gasket is
gear is
too thinner than the
Standard even engaging mark close drive gear gasket
to the
removed
driven
gear
ES150032
>50%齿高
Lean to small end The The drive gear

1~2
driven
adjusting gasket is
gear is
too thinner than the
close drive gear gasket
3~5
to the
>50%齿长 removed
drive
gear
ES150030
ES150033
In Step 4 of differential assembly removal, select the
Lean to big end The The drive gear
thickness of new gasket according to this engaging mark driven
adjusting gasket is
when checking the overall final drive assembly. In Step gear is
too far thicker than the
14 of differential assembly disassembly, the thickness of
from drive gear gasket
original adjusting gasket has been measured. the
removed
drive
gear
ES150034
The specific adjustment amount of gasket thickness shall

be judged according to spots and experience.
21-14
4 Press-fit the drive gear inner bearing cone to the Drive/Driven Gears Assembly
drive gear with the special tool C00089935. Do
not leave out the drive gear adjusting gasket. 10 Clear burrs and sundries on the mating face
between the driven gear and differential housing.
Align the screw hole of driven gear with that of
differential housing. Then tighten bolts diagonally
in turn to 110~130N.m.
ES150035
Caution: The drive and driven gears must be

replaced in pair.
ES150037
5 Pass the elastic spacer bush into the drive gear
shaft. Caution: The drive and driven gears must be
6 Install the drive gear into the reducer housing. replaced in pair.
7 Press the drive gear outer bearing cone into the 11 Press the differential bearing cone with special
drive gear shaft to the bottom. tools C00089938 and C00089939.
Caution: Press it carefully to protect the drive
gear from damage.
8 Press the drive gear oil seal with the special tool
C00089934 to the bottom.
ES150038
ES150036
9 Install the drive gear male flange and oil seal.

Refer to Replacement of Drive Gear Male Flange
and Oil Seal for details.
21-15
12 Install the differential assembly and left and right 14 Measure the backlash with a dial indicator.
adjusting gaskets into the final drive housing Measure 4 points above uniformly. The required
(The thickness of left and right gaskets removed value shall be 0.127~0.203mm.
is okay by default. Adjust the thickness later).
ES150041
ES150039
Adjustment Method for Backlash
13 Install the bearing cap. Pay attention to pairing Increase or reduce the thickness specification of
the bearing cap with the bearing. Then tighten
differential adjusting gasket to obtain the correct
the bolt of bearing cap to 56-70N.m.
backlash. The adjustment method is as illustrated below.
The thicknesses of gaskets include:
Later when the backlash shall be adjusted due to spot
6.25mm/6.35mm/6.40mm/6.45mm/6.55mm adjustment, in order to keep the pre-tightening degree of
originally adjusted differential bearing, the thickness
increased on one end shall be equal to the thickness
decreased on the other end.
When the clearance is large
Increase the gasket Decrease the gasket
ES150040 Increase the gasket Decrease the gasket
When the clearance is small

ES150042
21-16
15 Apply red lead powder onto 4~5 gears in three Adjustment Method for Driven Gear Spots
positions 120 ° apart on the driven gear. Rotate
the driven gear for 2~3 circles forwards and
backwards to mesh the drive gear with the driven
gear and form spots. Gear face contacting Cause Adjustment
condition s method:
A - gear face
contact area
adjustment
B - backlash
＞ 50% tooth depth

adjustment
Lean to tooth top The 1. The drive gear

1~2 drive
gets close to the
gear is
too far driven gear
from (increase the drive
3~5 the
gear bearing
>50% tooth length driven
gear gasket)
ES150043 2. The driven gear

ES150031
leaves the drive
Correct meshing spots gear to obtain
correct backlash
(increase or
d e c r e a s e
differential bearing
gasket)
ES150044
21-17
Gear face contacting Cause Adjustment Gear face contacting Cause Adjustment
condition s method: condition s method:
A - gear face A - gear face
contact area contact area
adjustment adjustment
B - backlash B - backlash
adjustment adjustment
Lean to tooth root The 1. The drive gear Lean to small end The 1. The driven gear
drive driven
gets close to the leaves the drive
gear is gear is
too driven gear too gear to obtain
close (decrease the close correct backlash
to the to the
drive gear bearing (increase or
driven drive
gear gasket) gear d e c r e a s e
2. The driven gear
ES150032 ES150033 gasket)
leaves the drive
gear to obtain 2. The drive gear
correct backlash gets close to the
(increase or driven gear
d e c r e a s e (decrease the
differential bearing drive gear bearing
gasket) gasket)
ES150045 ES150046
21-18
conforming. If so, it is proven that the adjustment

Gear face contacting Cause Adjustment
condition s method: succeeded; if not, adjust the backlash to the specified
A - gear face range. Then measure the final drive starting torque. If it is
contact area
conforming, the adjustment succeeded; if it is
adjustment
B - backlash nonconforming, continue adjusting according to the
adjustment torque. Keep this cycle until the starting torque and
backlash are conforming.
Lean to big end The 1. The driven gear
driven
leaves the drive 20 Install the front axle output half shaft. Refer to
gear is
too far gear to obtain Replacement of Front Axle Output Half Shaft for
from correct backlash details.
the
(increase or 21 After aligning the seal washer and rear oil filler
drive
gear d e c r e a s e cap with the screw hole correspondingly, tighten
differential bearing the bolts to 25~35N.m.
ES150034 gasket)
2. The drive gear

gets close to the
driven gear
(increase the drive
gear bearing
gasket)
ES150048
ES150047
22 Refill oil.
16 Adjust the backlash. Refer to the above

Backlash Adjustment for details.
17 Adjust the driven gear spots. Refer to the above
Adjustment of Driven Gear Spots for details.
18 Adjust the backlash and spots until they are
conforming.
19 Check the starting torque (which shall be no
more than 3.7N.m) of final drive with the torque
wrench.
The starting torque shall be measured for multiple times
to obtain an accurate value.
Firstly, ensure the drive gear starting torque is within the

specified range.
If the final drive starting torque is high, it is proven that the

differential bearing pre-tightening force is great. Reduce
the gaskets on both sides by the same thickness
meanwhile and reduce the differential bearing pre-
tightening force. Then check whether the backlash is
21-19
Refill & Drain of Rear Axle Lubricant Replacement of Drive Gear Male Flange and
Drain Oil Seal
The oil drain plug is located at the bottom of axle housing. 1 Place the vehicle on the lifting platform and lift it
Apply Loctite 572 sealant on the oil drain plug, and to a certain height.
tighten the oil drain plug to 20~34N.m. 2 Mark the position of propeller shaft flange
relative to the drive gear male flange,
Refill
The oil filler plug is in the middle of axle housing. Refill the 3 remove the propeller shaft from drive gear shaft
flange and put it aside;
specified lubricant GL-5 80W-90 (lubricant from
Shanghai Tampo/Total) until the level is flush with the 4 Remove the lock nut and washer of drive gear
shaft flange with the special tool C00045930,
filler port basically. Apply Loctite 572 sealant on the oil
and discard them.
filler plug, and tighten the oil filler plug to 20~34N.m.
C00045930
DS170028
ES150049
5 Remove the drive gear shaft flange with a dual-
foot puller from the spline of drive gear.
DS170029
6 Remove the oil seal with a tool.

Installation
1 Check and clean the burrs and contamination of
drive gear seal cavity.
2 A 2mm gap shall be left when installing the oil
seal, fix the oil seal with special tool C00089950
and a punch.
21-20
Caution: Install the gaskets to new drive gear

lock nut
GS130006
3 Install the drive gear flange to the spline of drive

gear. DS170033
6 Check the rolling torque of drive gear with a

leverage torque wrench and make sure the
rolling torque is between 4.03 and 6.56N.m; if
the rolling torque is below the specified range,
then the torque of drive gear nut must be
increased to the target value with an increment
of 5N.m; but the torque of nuts shall be in the
range of 298~678N.m and cannot exceed
678N.m.
Caution: DO NOT rotate back the nut already
tightened in order to reduce the torque. Once
exceeding the specified torque, re-install with a
DS170031 new gasket.
4 Install the drive gear flange to the spline of drive

gear with special tool C00045930 till no gap in
axial direction.
C00045930
DS170034
7 Align the mark on propeller shaft flange with that

on the drive gear flange, and install the drive
DS170032 shaft to the drive gear flange.
5 Install the gaskets and tighten the drive gear nuts
to 298N.m.
21-21
Replacement of Drive Gear

1 Remove the differential assembly (refer to
Replacement of Differential Assembly).
2 Remove the drive gear male flange and oil seal
(refer to Replacement of Drive Gear Male Flange
and Oil Seal).
3 Remove the outer drive gear bearing and
bearing spacer bush;
4 Tap out the outer ring from outer bearing with
special tool C00046375;
DS170037
8 note the etching number on the gear.

Installation
1 Install the outer ring of outer bearing to the rear
axle housing with the special tool C00089948.
2 Install the outer ring of inner bearing to the rear
axle housing with the special tool C00089952.
3 There is 1 etching (+) mark, 1 (-) mark or (0)
made on the bottom of each drive gear to help
predict the optimal running position for each
DS170036 peculiar gear device.
5 Tap out the outer ring from inner bearing with 4 Install the adjusting gaskets on the drive gear
special tool C00046378; shaft, the number of adjusting gaskets shall be
based on etching number in the new and old
drive gears.
5 The etching figure in the drive gear shaft is -
1; the drive gear and driven gear are
supplied in pair, both with 678 mark on it.
-1
678
DS170035
6 Remove the inner bearing of drive gear with a

678
puller.
Caution: Once the bearing is removed, replace
with a new one. DS170043
7 Remove the adjusting gasket from inner bearing 6 To use a new gear device, confirm the number
of drive gear, on the drive gear is consistent with that on the
driven gear before installation.
21-22
7 When replacing the drive gear, refer to the drive gear gaskets. The thicknesses of gaskets
etching markings on the head of drive gear, and include 1.37, 1.45, 1.50 and 1.55 for selection.
check the table below to determine whether to
increase or decrease the new and old drive gear
gaskets, so as to obtain correct thickness of
OLD PINION NEW PINION MARKING

MARKING
-2 -1 0 +1 +2
+2 +.10 +.08 +.05 0.02 0
+1 +.08 +.05 +.02 0 -.02
0 +.05 +0.2 0 -.02 -.05
-1 +.02 0 -.02 -.05 -.08
-2 0 -.02 -.05 -.08 -.10
21-23
8 Install the big end of bearing spacer bush into

the bracket and pass through the outer ring of
outer drive gear bearing.
DS170046
13 Install the inner drive gear bearing cone with the
special tool C00089951,
DS170044
9 Install the outer drive gear bearing cone into the

outer ring of outer drive gear bearing.
C00089951
10 Install the oil baffle gasket of drive gear to the
outer bearing.
GS130007
14 the drive gear will pass through the outer bearing

ring, oil baffle gasket and outer drive gear
bearing.
15 Install the drive gear male flange and oil seal (refer to
Replacement of Drive Gear Male Flange and Oil Seal).
DS170045 16 Check the rolling torque of drive gear with a
leverage torque wrench and make sure the
11 Install the drive gear oil seal. rolling torque is between 3.57 and 5.56N.m; if
12 Install the selected gaskets on and against the the rolling torque is below the specified range,
gear. then the torque of drive gear must be increased
to the target value with an increment of 5N.m;
but the torque of nuts shall be in the range of
298~678N.m and cannot exceed 678N.m.
Caution: DO NOT rotate back the nut already
tightened in order to reduce the torque. Once
exceeding the specified torque, re-install with a
new gasket.
21-24
Replacement of Differential Assembly

to a certain height. Then remove wheels (refer to
Wheels Replacement).
2 Mark the position of propeller shaft flange
relative to the drive gear shaft flange, and
remove the propeller shaft from the flange of rear
axle drive gear.
3 Remove the lateral push rod from the axle
housing.
4 Remove the bolts securing the bracket cover.
DS170100
17 Install the differential assembly (refer to Caution: DO NOT bend the convex edge of
Replacement of Differential Assembly). bracket cover and damage the mounting face of
it.
DS170048
5 Remove 4 bolts tightening the bearing cap.
Carefully mark the locations on the differential
bearing cap and bracket. During the process of
reinstalling the bearing cap, the direction must
be in consistent with that before removal.
DS170049
6 Remove the differential assembly with 2 pry

bars.
21-25
Caution: If you plan to reuse the driven and drive 11 Remove the bearings on both sides of differential
gears, take them out carefully to protect the with a puller.
driven gear from damage. Installation
1 To install a new driven gear, remove the drive
gear first (refer to Replacement of Drive Gear).
2 To make sure the flange surface of differential
assembly is free of fracture and burr, install the
through bolt of driven gear and pass it through
differential assembly to the driven gear, then
tighten the bolts to 180~230N.m in an alternate
and even manner.
DS170051
7 Place the differential assembly with driven gears

in the caliper with a protected jaw, and cover the
driven gear on the caliper with the rag used in
the workshop.
DS170056
3 Determine the thickness of differential gasket,

which includes 2.82, 3.20, 3.43 and 3.76 for
selection.
4 Press into the differential bearing with the special
tool C00089946.
DS170052
8 Release the bolts from driven gear, and knock

out the driven gear from the differential assembly
with a rubber hammer.
Caution: In any cases, once the bolt of driven
gear is removed, it must be replaced with a new
one for reinstallation.
9 Remove the differential bearing adjusting gasket.
10 Remove the rolling bearing race from the GS130008
differential housing.
5 Install the differential gear bearing outer ring to
the differential bearing cone.
6 Install the differential assembly in the bracket,
and tap it into the bracket with a rubber hammer.
21-26
7 Install the differential bearing cap, and place it

into correct position (torque: 90~100N.m).
GS130009
10 To increase the backlash, add gaskets to gasket

DS170061
group B of the opposite differential, and remove
the gaskets with equal number from gasket
8 Check the front-load torques of the drive gear
group A of the flange end differential; to reduce
and differential. The full-load torque is measured
the backlash, add gaskets to gasket group A of
as (0.46~1.0N.m)+drive gear starting torque
the flange end differential, and remove the
(refer to step 16 in Installation of Drive Gear for
gaskets with equal number from gasket group B
specific value); if the full-load torque is lower
of the opposite differential.
than (0.46N.m+drive gear starting torque (refer
to step 16 in Installation of Drive Gear for specific
value), replace with thicker gaskets on both
sides of differential bearing; if the full-load torque
exceeds (1.0N.m+drive gear starting torque
(refer to step 16 in Installation of Drive Gear for
specific value)), replace with thinner gasket on
both sides of differential bearing.
A B
DS170058
11 Apply red lead oil on the front and back sides of
2~3 gears in three positions 120° apart on the
driven gear, so as to allow the gear to form
engaging gear imprint.
DS170062
9 Measure the backlash of hyperboloid gear

between driven gear and drive gear on 3
different locations with a dial indicator, the
reference value of hyperboloid backlash is
0.076~0.152mm.
21-27
DS170064
12 The correct engaging is as illustrated, it shall be

engaged at the small end in the middle of tooth
depth, and accounts for more than 60% of the
tooth width; the contacting imprint in the direction
of tooth depth shall be no less than 60%.
DS170115
13 Adjust the backlash and imprint till both of them

are satisfied with the requirements.
21-28
Adjustment methods for engaging imprint and gap:

Contact area on driven gear surface
Moving direction of
Adjustment method:
gears
Driving 倒车
forward
When the engaging imprint is in the big end of

driven cone gear: move the driven gear closer to
the drive gear, if the tooth space is small, move the
drive gear outwards
When the engaging imprint is in the small end of

driven cone gear: move the driven gear from the
drive gear, if the tooth space is large, move the
drive gear outwards to get closer
When the engaging imprint is in the top of driven

gear: move the drive gear closer to the driven gear,
if the tooth space is small, move away the driven
gear
When the engaging imprint is in the root segment

of driven gear: move the drive gear from the driven
gear, if the tooth space is large, move away the
driven gear
21-29
14 Clean the sealant and contaminant on the

bracket cover flange face, and wash oil residues
with mineral ethyl alcohol until the flange is
completely dry, then clean the assembly surface
of bracket with the same method. Install the seal
ring.
DS170067
DS170065
15 Install the bracket cover with bolts, and

diagonally tighten them to 38~45N.m.
1
10
3
8
5
6
7
4 9
2
DS170066
16 Apply Loctite 572 sealant on the oil drain plug,

and tighten to 20~34N.m.
17 Install the half shaft (refer to Removal/Installation
of Half Shaft).
18 Refill 2L rear axle lubricant 80W-90.
19 Apply Loctite 572 sealant on the oil filler plug,
and tighten the oil filler plug to 20~34N.m.
21-30
Half Shaft Assembly

Removal
to a certain height. Then remove 2 wheels from
the rear axle (refer to Wheels Replacement).
2 Remove the brake components (refer to
Replacement of Rear Axle).
3 Drain the gear oil from rear axle assembly and
collect with a proper container.
4 Remove 4 nuts from the rear axle shaft tube
flange.
DS170070
7 When the half shaft assembly is pulled out from
the axle housing for a short distance, remove the
half shaft assembly out rapidly. DO NOT allow it
to contact the inner oil seal, thereby avoiding the
replacement of oil seal.
DS170068
5 Grab the half shaft flange with hand, pull the half
shaft assembly from the axle housing for a short
distance; if it is difficult to remove the half shaft
with hand, remove it with a special tool.
DS170071
DS170069
DS170072
6 If the half shaft assembly cannot be removed
with hand or it is with great difficulties to do so,
you can use the adjustable sliding hammer, and
secure the hammer to wheel end flange with
nuts.
21-31
Installation with inner oil seal to protect the oil seal from
damage.
1 Confirm whether the half shaft assembly to be
assembled (left or right half shaft) is properly 6 Insert the half shaft till it is flush with the shaft
installed on both sides of the rear axle. You can tube flange, screw the flange nuts manually to
confirm the left or right half shaft based on the the bolts and tighten 4 flange nuts to
mark on the back side of brake (steal seal "L" or 110~130N.m.
"R"). 7 Reinstall the brake components and etc. (refer to
2 To replace the O-ring of half shaft assembly, Replacement of Rear Axle Assembly).
clean the half shaft shoulder position of O-ring. 8 Remove the oil plug and refill 1.25L rear axle
lubricant.
9 Reinstall the oil filler plug and tighten it to
20~34N.m.
10 Install wheels (refer to Wheels Replacement).
DS170073
3 Before installing a half shaft assembly, check the

aperture area of shaft tube flange, and clear any
debris with a clean cloth if necessary. If the oil
seal leaks, replace the shaft tube inner oil seal
and then install a new oil seal with special tool
C00089923.
DS170074
4 Push the half shaft assembly into the rear axle

housing, locate 4 bolts through 4 shaft tube
flange holes, and confirm that the brake bracket
of half shaft assembly is installed to proper
location.
5 When pushing the half shaft assembly to the
shaft tube, prevent the half shaft from contacting
21-32
Rear Axle EDL Control Unit

EDL control unit is located in the left rear side wall trim
panel. To replace the control unit, remove the rear side
wall trim panel.
GS130010
21-33
Special Tool Tool Number and Illustration

Description

Description C00089941
Front axle drive gear
oil seal installer
C00089928 C00089941
Front axle output
shaft remover
C00089928 C00089942
Installer for the
inner bearing inner
ring of front axle
drive gear
C00089937 C00089942
Front axle half shaft
oil seal installer
C00089937 C00089943
Installer for the
inner bearing outer
ring of front axle
drive gear
C00089938
C00089943
Front axle
installer
C00089938
C00089945
Front axle half shaft
bearing installer
C00089939
C00089945
Front axle
mounting block
C00089939 C00089946
Rear axle
installer
C00089940
Installer for the C00089946
outer bearing outer
ring of front axle
drive gear
C00089940 C00089948
Installer for the
outer bearing outer
ring of rear axle
drive gear
C00089948
21-34

Description
C00089950
Rear axle drive gear
oil seal installer
C00089950
C00089951
Installer for the
inner bearing inner
ring of rear axle
drive gear
C00089951
C00089952
Installer for the
inner bearing outer
ring of rear axle
drive gear
C00089952
C00089923
Rear axle oil seal
(rear output shaft)
press tool
C00089923
C00045930
Common wrench
C00045930
21-35

The front axle is composed of the reducer assembly, differential assembly, front axle housing assembly, etc.
The rear axle is composed of the final drive assembly, differential assembly, differential lock assembly (optional), rear
axle housing assembly, left & right half shaft assemblies, brake drum (disc), etc.
The drive axle distributes the power input by the universal drive device of which torque is increased and power transfer
direction is changed by the reducer to the left and right driving wheels, so as to propel the vehicle to drive. It allows the left
and right driving wheels to rotate at different speeds.
The final drive increases the torque input, lowers the speed and transfers the power to the differential after changing its
transfer direction.
The differential transfers the power from the final drive to the left and right half shafts and allows the two half shafts to
rotate at different speeds when necessary to satisfy the differential need of both driving wheels.
21-36
Electronic Differential Lock (EDL)

The toothed ELD equipped on this model as shown in the figure below can achieve complete locking. The side gear can
be locked on the differential housing via an electromagnetic drive cam ring.
3
5 1
5 3
4
2
GS130005
1 Solenoid valve 4 Plunger

2 Spring 5 Half shaft gear
3 Cam ring
21-37
21-38
Exteriors
Exteriors
Torque
Application Torque value (N.m)
Bolt - front windscreen cover plate assembly 9±1

Screw - front grille assembly 9±1
Nut - license plate trim panel to tailgate 9±1
Screw - license plate trim panel to tailgate 9±1
Bolt - exterior rearview mirror 9±1
Bolt - interior rearview mirror 5 ± 0.5
22-1
Exteriors
Layout
Layout
GS330001
1 Radiator grille assembly 3 Front windscreen cover plate trim cover

2 Front windscreen cover plate assembly 4 License plate trim panel
22-2
Exteriors
Layout
GS330002
1 Exterior rearview mirrors 2 Interior rearview mirrors
22-3
Exteriors
Repair Guidance Installation

Replacement of Front Windscreen Cover attention to the following precautions:
Plate Assembly
- Tighten the bolts of front windscreen cover plate
Removal
assembly to 9 ± 1N.m.
1 Remove the wiper arm (refer to Replacement of
Wiper Arm).
2 Remove the front windscreen cover plate trim
covers on both sides (1).
GS330003
3 Remove the bolts (2) securing the front

windscreen plate assembly to the windscreen
gutter channel and remove the snap fasteners
(3).
2
3
GS330004
4 Remove the front windscreen cover plate

assembly from front windscreen weatherstrip.
22-4
Exteriors
5 Install the snap fasteners connecting the front

Replacement of Radiator Grille Assembly
grille cover plate assembly to the front grille
Removal assembly and upper radiator beam.
1 Remove the snap fasteners connecting the front
grille cover plate assembly to the front grille
assembly and upper radiator beam.
2 Remove the front grille cover plate assembly.
GS330005
3 Respectively remove the screws (2) securing the

radiator grille assembly (1) to headlamp
assembly (1 on either side).
4 Remove the ambient temperature sensor.
5 Remove the radiator grille assembly (1).
GS330006
Installation
1 Install the radiator grille assembly.
2 Install the ambient temperature sensor.
3 Respectively tighten the screws (1 on either

side) securing the radiator grille assembly (1) to
headlamp assembly to 9 ± 1N.m.
4 Install the front grille cover plate assembly.
22-5
Exteriors
Replacement of License Plate Trim Panel Replacement of Exterior Rearview Mirror

Removal Removal
1 Remove the tailgate trim panel (refer to 1 Remove the door trim panel first.
Replacement of Tailgate Trim Panel). 2 Remove 3 mounting bolts.
2 Remove 2 screws (2) and 2 nuts (3) securing the
license plate trim panel to tailgate.
2
3
2
1 GS330008
GS330007 3 Disconnect the rearview mirror harness and

body harness (also remove the camera harness
3 Disconnect the harness connector of the tailgate. if any) (2).
4 Remove the license lamp assembly (refer to 4 Pull out the block (3).
Replacement of License Lamp Assembly).
5 Remove the reversing camera (refer to
Replacement of Reversing Camera).
6 Remove the license plate trim panel.
Installation
- Tighten the screws and nuts securing the license plate
3 2
trim panel to tailgate to 9 ± 1N.m
GS330009
5 Remove the exterior rearview mirror.
Installation
- Tightening torque of exterior rearview mirror bolts: 9 ±
1N.m
22-6
Exteriors
Replacement of Exterior Rearview Mirror Replacement of Interior Rearview Mirror

Glass Removal
Removal
1 Remove the mounting bolts from interior
1 Adjust the glass as illustrated. rearview mirror.
2 Push out the interior rearview mirror assembly
from bottom to top.
GS330010
1
2 Jack up the clamping bracket with a screwdriver, GS330012

then remove the glass from rearview mirror
assembly.
Installation
- Tightening torque of interior rearview mirror bolts: 5 ±
0.5N.m
GS330011
3 Disconnect the heating glass wire (if equipped).
Installation
22-7
Exteriors
22-8
Driver Compartment Interiors and Switches
Torque
Bolt - instrument panel beam to body 20 ± 2

Bolt - instrument panel beam connecting plate 22 ± 2
Bolt - instrument panel beam to beam fixed bracket 20 ± 2
Bolt - instrument panel beam bracket to body 20 ± 2
Screw - A-pillar handle 5±1
Screw/bolt - sun visor 5±1
Screw - B-pillar handle 5±1
23-1
Layout
Layout
4
3
5
2
6
1
16
17 14
8 13 15
9
10 11 12
GS220001
1 D-pillar upper trim panel 10 B-pillar handle assembly

2 C-pillar upper trim panel 11 Rear door treadboard cover
3 B-pillar upper trim panel 12 Front door interior trim panel assembly
4 A-pillar upper trim panel 13 B-pillar lower trim panel
5 Driver compartment roof interior assembly 14 Rear door interior trim panel assembly
6 A-pillar handle assembly 15 Tailgate trim panel assembly
7 A-pillar lower trim panel 16 Rear body side trim panel assembly
8 Floor cover assembly 17 Footrest assembly
9 Front door treadboard cover
23-2
Layout
13
1
2
12 2
5 4
10 6
7 3
11
GS220002
1 Cladding trim panel assembly (instrument panel 7 Outer cover plate assembly of auxiliary fascia
wood grain trim panel assembly) console guard plate
2 Instrument panel end cover assembly 8 CNSL front storage box
3 Driver side footrest assembly 9 Glove box assembly
4 Driver side lower guard plate assembly 10 Armrest assembly of auxiliary fascia console
5 Upper and lower steering column shrouds 11 Rear panel assembly of auxiliary fascia console
assembly
12 Instrument panel lower body assembly
6 Forward extending plate of auxiliary fascia
13 Instrument cluster shroud assembly
console
23-3
Layout
7 4
3
6
GS220003
1 Rearview mirror adjustment and dimmer switch 6 Auxiliary fascia console switch set (seat heating/
assembly venting switch, drive transfer switch, EPB switch,
Auto parking switch, HDC switch, ESP OFF
2 Driver window regulator switch assembly
switch, engine start-stop OFF switch, EDL
3 Fuel tank switch assembly control switch)
4 Combination switch assembly 7 Hazard warning lamp switch
5 Start-stop switch
23-4
5 Release outer pull rod assembly of front door

Repair Guidance
outer handle.
Replacement of Front Door Interior Trim
Panel Assembly
Installation
Removal
2 Remove the fastening screws from front door
interior trim panel.
GS220004
3 Disconnect the electrical connector.
4 Remove the front door interior trim panel

assembly.
GS220005
Caution: 6 reeds between interior trim panel and

door frame shall be lifted up.
23-5
Replacement of Rear Door Interior Trim Replacement of Front/Rear Door Waterproof

Panel Membrane
Removal Removal
1 Disconnect the battery (negative first). 1 Remove the front/rear door interior trim panel
2 Remove the fastening screws from front door assembly (refer to Replacement of Front/Rear
interior trim panel. Door Interior Trim Panel Assembly).
2 Remove the front/rear door inner handle (refer to
Replacement of Front/Rear Door Handle).
3 Remove the front/rear door waterproof

membrane.
Installation
1 Installation is the reverse of removal. Note:
When attaching the waterproof membrane, it
shall be closely and smoothly fit with side door
sheet metal.
GS220006
4 Remove the rear door interior trim panel

assembly.
GS220007
Caution: 5 reeds between interior trim panel and

door frame shall be lifted up.
5 Release outer pull rod assembly of rear door
outer handle.
Installation
23-6
3 Remove the tailgate trim panel (2), the engaging

Replacement of Tailgate Trim Panel
locations are as illustrated.
Assembly
Removal
1 Remove the tailgate interior trim panel (1), the
engaging locations are as illustrated.
GS220010
4 Finally, remove the remaining tailgate trim

panels.
GS220008
2 Remove 2 fastening screws. Installation

Replacement of Treadboard Cover

Removal
1 Pry up the treadboard cover along the board
edge with a flat-blade screwdriver or another
tool.
Installation
GS220009
23-7
Replacement of Driver Compartment Roof Replacement of A-pillar Upper Trim Panel

Interior Assembly Removal
Removal
1 Remove the A-pillar handle (refer to
1 Remove A, B, C and D-pillar upper trim panels Replacement of Pillar Handle).
(refer to Replacement of A, B, C and D-pillar 2 Remove the A-pillar upper trim panel (clips and
Upper Trim Panels). engaging locations are as illustrated).
2 Remove the sun visor retaining bracket and sun
visor assembly.
3 Remove the roof handles from front passenger

area and passenger compartment.
4 Remove the roof reading, sunroof and tailgate

switch assembly.
5 Remove the A/C air vents.
6 Remove the driver compartment roof interior

assembly along the edge.
GS220012
Installation
Replacement of A-pillar Lower Trim Panel

Removal
GS220011 1 Remove the instrument panel end cover
assembly (Refer to Replacement of Instrument
Panel End Cover Assembly).
Installation 2 Remove the front door treadboard cover (refer to

Replacement of Treadboard Cover).
3 Remove the footrest assembly (refer to
Replacement of Footrest Assembly).
4 Pry up the A-pillar lower trim panel slowly along

the edge.
Installation
23-8
6 Remove the B-pillar upper trim panel (engaging

Replacement of B-pillar Upper Trim Panel
locations are as illustrated).
Removal
1 Remove the front/rear door treadboard cover
(refer to Replacement of Treadboard Cover).
2 Remove the B-pillar lower trim panel (engaging
GS220015
Installation
GS220013
3 Remove the B-pillar upper trim panel plug and

bolts.
GS220014
4 Remove the B-pillar handle assembly (refer to

Replacement of Pillar Handle)
5 Remove seat belt anchor points (refer to

Replacement of Seat Belt).
23-9
Replacement of C-pillar Upper Trim Panel Replacement of Sun Visor Assembly

Removal Removal
1 Remove the rear body side trim panel assembly 1 Disconnect the battery (negative cable first).
(refer to Replacement of Rear Body Side Trim 2 Remove the sun visor retaining bracket.
Panel Assembly).
2 Unscrew fastening screws.
GS220017
GS220016 3 Remove 2 screws from the sun visor.
3 Remove the C-pillar upper trim panel.
Installation
GS220018
5 Remove the sun visor assembly.
Installation
23-10
Replacement of Rear Body Side Trim Panel Replacement of Roof Handles in Front
Assembly Passenger Area and Passenger
Removal Compartment
Removal
1 Remove the treadboard cover (rear door
treadboard cover, tailgate treaboard cover) (refer 1 Pry the handle plug.
to Replacement of Treadboard Cover).
2 Remove the rear body side armrest (refer to
Replacement of Rear Body Side Armrest).
3 Pry up D-pillar upper trim panel slowly from the

rear body side trim panel assembly.
4 Remove the rear body side trim panel (engaging

GS220020
2 Remove handle retaining screws.
3 Remove the pillar handle.
Installation
Replacement of Footrest Assembly

Installation
Removal
1 Pry the footrest assembly along the edge.
Replacement of Rear Body Side Armrest

Installation
Removal
1 Pry up rear body side armrest slowly from the
rear body side trim panel assembly.
Installation
23-11
12 Remove the instrument panel body assembly.

Replacement of Instrument Panel Body
Removal
1 Disconnect the battery (negative first). Installation
2 Remove the auxiliary fascia console assembly 1 Installation is the reverse of removal. Pay
(refer to Replacement of Auxiliary Fascia attention to the following precautions: The
Console Assembly). sealing strap shall be fit in place.
3 Remove left and right end cover assemblies
(refer to Replacement of Left and Right End
Cover Assemblies).
4 Remove the driver side instrument panel lower

guard plate assembly (refer to Replacement of
Driver Side Instrument Panel Lower Guard Plate
Assembly).
5 Remove the steering wheel (refer to

Replacement of Steering Wheel).
6 Remove the instrument cluster and shroud

assembly (refer to Replacement of Instrument
Cluster and Shroud Assembly).
7 Remove the glove box assembly (refer to

Replacement of Glove Box Assembly).
8 Remove the A/C control panel (refer to

Replacement of A/C Control Panel).
9 Remove the entertainment system (refer to

Replacement of Entertainment System Display
and Mainframe).
10 Disconnect corresponding electrical harness

connector.
11 Unscrew the screws as shown in the figure.
GS220021
23-12
Replacement of Instrument Panel Lower Replacement of Instrument Panel Beam

Body Assembly Removal
Removal
1 Remove the instrument panel body (refer to
1 Remove the auxiliary fascia console assembly Replacement of Instrument Panel Body).
(refer to Replacement of Auxiliary Fascia 2 Remove the steering column assembly (refer to
Console Assembly). Replacement of Steering Column Assembly).
2 Remove the glove box assembly (refer to
3 Remove 2 bolts connecting the auxiliary fascia
Replacement of Glove Box Assembly). console to instrument panel beam (refer to
3 Remove the driver side instrument panel lower Replacement of Auxiliary Fascia Console
guard plate assembly (refer to Replacement of Assembly).
Driver Side Instrument Panel Lower Guard Plate 4 Unscrew 4 bolts connecting the instrument panel
Assembly).
beam to the beam bracket (2 on either side).
4 Remove the instrument panel wood grain trim
panel assembly (cladding trim panel
assembly)(refer to Replacement of Instrument
Panel Wood Grain Trim Panel Assembly
(Cladding Trim Panel Assembly)).
5 Remove the instrument cluster shroud assembly

(refer to Replacement of Instrument Cluster
Shroud Assembly).
6 Remove the start-stop switch (refer to

Replacement of Start-stop Switch).
7 Remove the screws connecting the instrument

panel lower body assembly to the instrument
panel assembly. GS220022
5 Unscrew 6 bolts connecting the instrument panel

beam to the body.
Installation
GS220023
6 Remove the fastening nuts from the fuse box.
23-13
7 Unscrew the bolts securing the brake pedal to

Replacement of Auxiliary Fascia Console
instrument panel beam.
Assembly
Removal
1 Remove the rear panel assembly of the auxiliary
fascia console (refer to Replacement of Rear
Panel Assembly of the Auxiliary Fascia
Console).
2 Remove the auxiliary fascia console plug, and
unscrew two bolts.
GS220024
8 Remove the instrument panel beam assembly.
Installation
- Torque of bolts connecting the instrument panel beam GS220025
to the body: 20 ± 2N.m. 3 Remove left/right front extension plates of the
- Torque of bolts connecting the instrument panel beam auxiliary fascia console (remove the driver side
footrest assembly first).
to the beam bracket: 20 ± 2N.m.
4 Unscrew 2 screws (as shown in the figure below)
connecting the instrument panel beam.
GS220026
5 Remove the outer cover plate assembly of

auxiliary fascia console guard plate on both
sides (refer to Replacement of Outer Cover Plate
Assembly of Auxiliary Fascia Console Guard
Plate).
23-14
6 Remove 2 screws connecting the auxiliary fascia

Replacement of Outer Cover Plate Assembly
console assembly to instrument panel.
of Auxiliary Fascia Console Guard Plate
Removal
1 Slowly knock open the outer cover plate
assembly of auxiliary fascia console guard plate,
engaging locations are as illustrated.
GS220027
7 Remove the auxiliary fascia console assembly.
Installation GS220028
Installation
Replacement of CNSL Front Storage Box

Removal
1 Remove the auxiliary fascia console assembly
(refer to Replacement of Auxiliary Fascia
Console Assembly).
2 Remove 7 screws connecting CNSL front
storage box to auxiliary fascia console.
Installation
23-15
Replacement of Instrument Panel Side End Replacement of Driver Side Instrument Panel
Cover Assembly Lower Guard Plate Assembly
Removal Removal
1 Disassemble the left and right end cover 1 Disconnect the battery (negative first).
assemblies (pay attention to the engaging 2 Remove the instrument panel wood grain trim
locations). panel assembly (cladding trim panel
assembly)(refer to Instrument Panel Wood Grain
Trim Panel Assembly (Cladding Trim Panel
Assembly)).
3 Disconnect the atmosphere lamp connectors (if

any).
4 Remove the driver side footrest assembly (refer

to Replacement of Driver Side Footrest
Assembly).
5 Remove the driver side instrument panel end

cover assembly.
6 Remove 4 bolts securing the driver side

GS220029 instrument panel lower guard plate assembly.
2 Remove the left and right end cover assemblies.
Installation
GS220030
7 Remove the engine hood cable handle.

guard plate assembly.
Installation
Installation is the reverse of removal.
23-16
Replacement of Driver Side Footrest Replacement of Upper and Lower Steering

Assembly Column Shrouds
Removal Removal
1 Remove 2 screws connecting the footrest to 1 Place the steering wheel adjusting handle to the
lower guard plate. bottom.
2 Remove the steering wheel assembly (Refer to
Replacement of Steering Wheel Assembly).
3 Pry off the upper steering column shroud with a

flat-blade screwdriver.
4 Remove 2 screws connecting the lower steering

column shroud to the combination switch base.
GS220031
2 Remove the driver side footrest assembly.
Installation
GS220032
5 Remove the screws from the bottom of lower

steering column shroud.
GS220033
6 Remove the lower steering column shroud.
Installation
23-17
Replacement of Instrument Panel Wood Replacement of Front Passenger Side

Grain Trim Panel Assembly (Cladding Trim Footrest Assembly
Panel Assembly) Removal
Removal
1 Release the bayonet connecting the front
1 Remove left and right end cover assemblies passenger side footrest assembly with the glove
(refer to Replacement of Left and Right End box assembly.
Cover Assemblies).
2 Remove the screws connecting the instrument
panel wood grain trim panel assembly (cladding
trim panel assembly) to the instrument panel.

panel assembly (cladding trim panel assembly).
Installation
GS220034
2 Remove the front passenger side footrest

assembly.
Installation
23-18
Replacement of Glove Box Assembly Replacement of Instrument Cluster Shroud

Removal Assembly
Removal
1 Remove the front passenger side footrest
assembly (refer to Front Passenger Side 1 Remove the instrument panel wood grain trim
Footrest Assembly). panel assembly (cladding trim panel
2 Remove 6 screws connecting the glove box assembly)(refer to Replacement of Instrument
assembly with the instrument panel. Panel Wood Grain Trim Panel Assembly
2 Remove the upper steering column shrouds
(refer to Replacement of Upper and Lower
Steering Column Shrouds).
3 Unscrew 4 screws connecting the instrument

cluster shroud.
GS220035
3 Remove the glove box assembly.
Installation
1 Installation is the reverse of removal. GS220036
4 Remove the instrument cluster shroud assembly.
Installation
23-19
4 Remove the atmosphere lamp.

Replacement of Driver Side Atmosphere
Lamp
Removal Installation
GS220037

(refer to Replacement of Instrument Cluster
Shroud Assembly).
3 Disconnect the atmosphere lamp connectors.
4 Remove the atmosphere lamp from driver side

lower guard plate assembly.
Installation
Replacement of Front Passenger Side

Atmosphere Lamp
Removal
3 Disconnect the atmosphere lamp connectors.
23-20
Replacement of Combination Switch Replacement of Rearview Mirror Adjustment

Assembly and Dimmer Switch Assembly
Removal Removal
1 Remove the steering wheel assembly (Refer to 1 Disconnect the battery (negative first).
Replacement of Steering Wheel Assembly).
2 Remove the upper and lower steering column guard plate assembly (refer to Driver Side
shrouds (refer to Replacement of Upper and Instrument Panel Lower Guard Plate Assembly).
Lower Steering Column Shrouds).
3 Disconnect the connectors from rearview mirror
3 Remove the clock spring assembly and clock adjustment and dimmer switch.
spring returning ring (refer to Replacement of
4 Remove the rearview mirror adjustment and
Clock Spring Assembly and Clock Spring
dimmer switch assembly.
Returning Ring).
4 Remove 3 bolts connecting the combination

switch to the steering column.
GS220039
GS220038
Installation
5 Remove the combination switch base and 1 Installation is the reverse of removal.
combination switch assembly.
Installation
23-21
Replacement of Hazard Warning Lamp Replacement of Driver Side Window

Switch Regulator Switch Assembly
Removal Removal
1 Disconnect the battery (negative first). 1 Disconnect the battery (negative first).
2 Remove the instrument panel wood grain trim 2 Remove the driver side front door interior trim
panel assembly (cladding trim panel panel assembly (refer to Replacement of Front
assembly)(refer to Replacement of Instrument Door Interior Trim Panel Assembly).
3 Disconnect the driver door regulator switch
connector.
3 Disconnect the hazard warning lamp switch
4 Remove the driver side window regulator switch
connector.
assembly.
4 Remove the hazard warning lamp switch.
Installation
Installation

Switch Set
GS220040 Removal
Console Assembly).
Installation
2 Remove the auxiliary fascia console switch set.
Installation
23-22
Seats
Seats
Torque
Bolt - seat to body 58 ± 5

Bolt - seat cushion assembly to seat back assembly 45 ± 3
24-1
Seats
Layout
Layout
2+3 2+3+2 2+3+3
2+2 2+2+2 2+2+3
GS140001
Driver seat Manual 6-way/power 8-way
Front passenger seat Manual 4-way/power 4-way
2nd row seats Fixed/sliding seats
3rd row seats Foldable seat back
24-2
Seats
5 Install 4 plastic seat leg caps into each clamp

Repair Guidance
one by one and clamp the caps into the sheet
Replacement of Driver Seat and Front metal slot.
Passenger Seat
Removal
1 Disconnect the battery negative and wait for 1
minute. (For power seat).
2 Remove 4 leg caps.
GS140002
3 Remove 4 fastening bolts from the seat leg

bracket.
4 Disconnect the harness connector of seat belt
switch. For vehicles with power seats,
disconnect the seat harness connector.
5 Remove the seat. Pay attention to the locator at
the front mounting point of the seat.
Caution: The seat with an airbag is marked with
"AIRBAG" on the lower side of the seat shoulder,
where shall be protected from overpressure
during installation.
Installation
1 Firstly insert the seat locator into the locating
hole in the underbody.
2 Then pre-tighten 4 bolts on the leg brackets to
pre-install the seat on the floor.
3 Adjust the slide rail to the rearmost position,
tighten 2 bolts at the front, then adjust the slide
rail to the frontmost position, and tighten the
bolts at the rear end. The tightening torque of the
bolts is 58 ± 5N.m.
4 Connect the seat harness connector.
24-3
Seats
Replacement of Rear Seats Description and Operation

Rear seats includes individual seat, double seats and Front Seat Assembly
triple seats.
The configuration of the front seat assembly may vary
Removal according to vehicle configuration and seat exterior, for
example, 4-way manual seat (forward/backward
1 Remove the seat leg trim cover.
adjustment, seat back inclination adjustment); 6-way
manual (forward/backward adjustment, seat back
inclination adjustment, seat height and optional lumbar
support adjustment); 8-way power seat (forward/
backward adjustment, seat back inclination adjustment,
seat height and optional lumbar support adjustment);
fabric of high quality, PU or leather, optional side airbag,
optional heating function.
GS140003
2 Unscrew the bolts securing the seat to the body,

and remove the seat.
Installation
1 Installation is the reverse of removal. Tighten the
bolts securing the seat to the body to 58±5N.m.
24-4
Seat Belt
Seat Belt
Torque
Bolt - seat belt upper anchor point 50 ± 5

Bolt - seat belt lower anchor point 50 ± 5
Bolt - seat belt retractor upper anchor point 9±1
Bolt - seat belt retractor lower anchor point 50 ± 5
Bolt - height regulator to body 50 ± 5
Nut - seat belt buckle to front seat 48 ± 3
Bolt - seat belt buckle to 2nd row seats 50 ± 5
Bolt - seat belt buckle to 3rd row seats 47 ± 7
25-1
Seat Belt
Repair Guidance Replacement of Driver/Front Passenger Seat

Belt (Without Lap Belt Pretensioner)
Precautions for handling expanded
pretightening seat belt or lap belt Removal
pretensioner Warning: For seat belt retractors with
pretensioner, do not start work until the battery
The expanded pretightening seat belt or lap belt
(or any possible auxiliary power supply of the
pretensioner may carry some sodium hydroxide which is
vehicle) is disconnected and the capacitor of the
the by-product of the expansion action, in case of skin or SRS control module is discharged for at least
eye contact, irritation may occur. 10min.
When handling the expanded pretightening seat belt or 1 Disconnect the battery. Note: Disconnect the
lap belt pretensioner, please wear protective gloves and negative first.
goggles. Please wash your hands with soap after the
operation.
Precautions for handling unexpanded 4/5

pretightening seat belt or lap belt
pretensioner
When handling the unexpanded pretightening seat belt 3
or lap belt pretensioner, ensure the back of the gas
generator faces the body.
When handling the pretightening seat belt or lap belt 2

pretensioner, never hold its connector or harness with ES170002
your hands,
2 Remove the seat belt lower anchor point.
and never place any article on the unexpanded
3 Remove the B-pillar lower trim panel.
pretightening seat belt.
4 Remove the cap of the height regulator.
5 Remove the seat belt upper anchor point.
6 Disconnect the pretensioner harness (if
equipped).
7 Unscrew the retractor bolt, and remove the seat
belt.
25-2
Seat Belt
Installation
Replacement of Driver/Front Passenger Seat
1 Installation is the reverse of removal. Pay Belt (With Lap Belt Pretensioner)
Removal
- Ensure the assembly is properly located in the mounting Warning: For seat belt retractors with
slot provided. pretensioner, do not start work until the battery
(or any possible auxiliary power supply of the
- Before re-installing the trim panel, ensure the seat belt is
vehicle) is disconnected and the capacitor of the
properly positioned on the trim panel.
SRS control module is discharged for at least
- Reconnect the battery, the positive (+) first. 10min.
- Check the operation of the SRS warning lamp.
- The torque of the seat belt upper/lower anchor point is

50 ± 5N.m.
3/4
- The torque of the retractor upper anchor point is 9 ±
1N.m, and that of the lower anchor point is 50 ± 5N.m.
2 6
ES170005
1 Disconnect the battery.

Caution: Disconnect the negative first.
2 Remove the B-pillar lower trim panel.
3 Remove the cap of the height regulator.
ES170003 4 Remove the seat belt upper anchor point.
5 Disconnect the pretensioner harness (if
equipped).
25-3
Seat Belt
6 Disconnect the locking tab from the lap belt 5N.m.

pretensioner. Use the following methods:
- The torque of the retractor upper anchor point is 9 ±
1) Insert tool C00089919 into the 2 lap belt pretensioner
1N.m, and that of the lower anchor point is 50 ± 5N.m.
holes shown in the figure below.
ES170010
2) Insert a sharp object into the hole on the opposite side

of the lap belt pretensioner to remove the locking tab.
ES170011
Installation
- Ensure the assembly is properly located in the mounting
slot provided.
- Before re-installing the trim panel, ensure the seat belt is

properly positioned on the trim panel.
- Reconnect the battery, the positive (+) first.
- Check the operation of the SRS warning lamp.
- The torque of the seat belt upper anchor point is 50 ±
25-4
Seat Belt
Replacement of Height Regulator Replacement of Lap Belt Pretensioner (If

Removal Any)
Removal
1 Remove the B-pillar upper trim panel, refer to
Replacement of B-pillar Upper Trim Panel. 1 Disconnect the locking tab from the lap belt
2 Remove the seat belt upper anchor point. pretensioner. For specific procedures, please
refer to Replacement of Driver/Front Passenger
3 Remove the bolt of the height regulator.
Seat Belt (With Lap Belt Pretensioner).
4 Remove the height regulator.
2 Remove the anchor point of the lap belt
pretensioner.
Installation
1 Installation is the reverse of removal. Tightening
torque of the bolts securing the height regulator
to body: 50 ± 5N.m; tightening torque of the seat
belt upper anchor point: 50 ± 5N.m.
ES170006
Installation
1 Installation is the reverse of removal. The torque
of the lap belt pretensioner bolt is 50 ± 5N.m.
25-5
Seat Belt
Replacement of Rear Seat Belt Replacement of Front/Rear Seat Belt Buckle

Removal Removal
1 Remove the seat belt lower anchor point. 1 Disconnect the wiring harness of the seat belt
2 Remove the C-pillar lower trim panel. buckle (if any).
2 Unscrew the seat belt buckle bolt/nut.
3 Remove the seat belt buckle.
Installation
torque of the nut securing front seat belt buckle
to seat: 48 ± 3N.m; tightening torque of the bolt
securing 2nd row seat belt buckle to seat: 50 ±
5N.m; tightening torque of the bolt securing 3rd
row seat belt buckle to seat: 47 ± 7N.m.
GS150001
Seat Belt Check/Test
In case of impact, perform the following checks/tests for
Installation the seat belt unused in the impact, if any damage is
found, install new seat belt parts.
torque: seat belt upper anchor point 1 and lower 1 Check the appearance for obvious mechanical
anchor point 2 (50 ± 5N.m); retractor upper damage, if any, replace the parts. Check if all
anchor point 3 (9±1N.m) and lower anchor point bolts and screws of the seat belt are secure. The
4 (50 ± 5N.m). buckle shall be easily locked and unlocked.
Insert the locking plate into the buckle, and push
the belt hard. The buckle shall not be loose. Pull
out all shoulder straps, and ensure the strap is
not twisted or torn.
2 The seat belt pretensioner is controlled as a part
of the SRS. When turning the ignition switch to
START position, the SRS warning lamp will
illuminate for 4s. If the self-test of the system is
OK, the SRS warning lamp will be off. If any
failure occurs (airbag or seat belt pretensioner),
the SRS warning lamp will illuminate the SRS
warning lamp on the instrument panel.
3 Test seat belt retaining performance: keep the
vehicle stationary, park on the level road, and
tightly hold the seat belt and pull it out swiftly, the
retractor shall retract within appr. 0.05m, while
the damaged belt will be pulled beyond this
range, in this case, the seat belt assembly must
be replaced. Warning: All seat belts (including
the retractor, buckle and other hardwares) used
in the impact shall be replaced with a new seat
belt assembly. Never attempt to service or
lubricate the retractor/buckle mechanism or
25-6
Seat Belt
modify the seat belt. After replacement, if the

Special Tool
seat belt cannot properly retract to the retractor,
check if the trim panel is properly installed or if it
rubs the seat belt. If any friction appears, release
the bolts and correct the retractor to keep the Tool Number and Illustration
seat belt in the center and then tighten the bolts. Description
C00089919
Unlocking device for
dual pretightening
seat belt
C00089919
25-7
Seat Belt
Description and Operation Front Seat Belt
Front Seat Belt Pretensioner The inertial retractor of the front seat belt is installed on
the body, in the cavity at the bottom of B-pillar lower trim
In case of collision, the front seat belt pretensioner is
panel. Pull the belt webbing from the retractor, and
tightened to ensure that the occupants are securely kept
secure it to the mounting point at the bottom of B-pillar
in their seats. The seat belt pretensioner unit is fixed by
with the manual height adjustment device on the upper
bolts to the seat belt inertial retractor assembly in the B-
part of B-pillar.
pillar. The connector of the seat belt pretensioner is a 2-
pin connector which is connected with the body harness. Seat Belt Height Regulator Assembly
In case of collision, the seat belt pretensioner is controlled The seat belt height regulator is fixed above the B-pillar
by the signal from the SRS ECU. The inertial retractors of by bolts. The belt webbing is fixed to the seat belt height
the two pretensioners are positioned and work in the regulator assembly by D rings, and the seat belt can be
same way. Each pretensioner unit is provided with an fixed in the optimal position under different conditions
initiator and a propulsion generator which act on the rotor through the up-and-down sliding of the seat belt height
of the seat belt retractor. regulator assembly. The seat belt buckle assembly is
installed to the interior trim panel bracket of the seat
Warning: The pretensioner device cannot be reset after it
cushion.
works. Therefore the activated pretensioner must be
replaced. Seat Belt Alarm Indicator
Seat Belt The front seat belt buckle is integrated with the seat belt
unfastened warning switch, which is connected to the
The seat belt provides the most basic protection for all
instrument cluster through SRS ECU. If the occupant
occupants. The restraint system also provides further
does not fasten the seat belt when the vehicle is in
protection for the front occupants through the airbag
motion, the seat belt alarm will be triggered. The warning
module and the pretensioner seat belts. The front seats
message comprises an acoustic alarm and an
are provided with appropriate inertial retractors and hip-
illuminating warning lamp on the instrument panel. Some
shoulder belts. Emergency locking retractors (ELR) are
vehicle specifications specify that: to prevent
used for the vehicle.
unnecessary warning when there is no passenger on the
The inertial retractor is provided with an additional lock seat, a pressure sensor shall be installed within the foam
mechanism which includes a webbing sensor and an of the passenger seat. If the seat is occupied, but the
inclination acceleration sensor. If the webbing is suddenly pressure sensor is not activated, then the seat belt
pulled, the webbing sensor will immediately start the lock warning will not be triggered even if the occupant does
mechanism. If the vehicle suddenly slows down or tilts at not fasten the seat belt.
a large angle, the automotive sensor will start the lock
mechanism.
The retractor will lock in case of impact, so the front seat

belt retractor are equipped with load limiters. If the load
limit has exceeded the critical level, the load limiter
loosens the seat belt webbing and reduces the load
acting on the occupants.
25-8
Rear Body
Rear Body
Torque
Nut - tailgate assembly (with hinge) to body 32 ± 3
26-1
Rear Body
Layout
Tailgate Layout
GS180001
26-2
Rear Body
Repair Guidance
Tailgate Replacement 10 Remove the tailgate from the vehicle.
Removal
Installation
2 Open and support the tailgate.
3 Remove the tailgate interior trim panel (refer to attention to the following precautions:
Replacement of Tailgate Interior Trim Panel).
- Tighten the tailgate hinge bolts to the torque of 32 ±
4 Disconnect the harness connector of tailgate.
3N.m
5 Remove the rear wiper motor (refer to
Replacement of Rear Wiper Motor).
6 Remove the rear wiper arm (refer to
Replacement of Rear Wiper Arm).
7 Remove the rear washer nozzle (refer to
Replacement of Rear Washer Nozzle).
8 Remove the gas stay bar assembly from the
tailgate. To remove or install the tailgate gas stay
bar, additional support must be used to avoid
any possible vehicle damage.
GS180002
9 Remove the bolts from the tailgate hinge.
GS180013
26-3
Rear Body
bar, additional support must be used to avoid

Replacement of Tailgate Gas Stay Bar
any possible vehicle damage.
Removal
Installation
2 Pry up the spring piece from the bottom of
tailgate gas stay bar with a small flat-bladed tool. 1 Installation is the reverse of removal.
3 Remove the bottom part of tailgate gas stay bar
from gas spring lower ball pin.
GS180014
4 Pry up the spring piece from the top of tailgate

gas stay bar with a small flat-bladed tool.
5 Remove the top part of tailgate gas stay bar from
gas spring upper mounting bracket.
GS180015
6 Remove the gas stay bar assembly from the

tailgate. To remove or install the tailgate gas stay
26-4
Power Liftgate
Power Liftgate
Torque
Bolt - tailgate hinge 32 ± 3
27-1
Power Liftgate
Layout
Power Liftgate Layout
GS180003
1 Power liftgate electric stay bar 4 Power liftgate right anti-pinch molding
2 Power liftgate balance bar 5 Power liftgate control box assembly
3 Power liftgate left anti-pinch molding
27-2
Power Liftgate
Repair Guidance
Power Liftgate Replacement 9 Remove the bolts from the tailgate hinge.
Removal
3 Remove the tailgate interior trim panel (refer to
4 Remove the harness connector from the drive
mechanism assembly of the power tailgate.
5 Remove the rear wiper motor (refer to
Replacement of Rear Wiper Motor).
6 Remove the rear wiper arm (refer to
Replacement of Rear Wiper Arm).
GS180012
7 Remove the rear washer nozzle (refer to
Replacement of Rear Washer Nozzle).
10 Remove the tailgate from the vehicle.
8 Remove the electric stay bar and balance bar of
the power liftgate from the tailgate. When
installing/removing the electric stay bar and
Installation
balance bar of the power liftgate, the right
balance bar shall be removed first, then the left 1 Installation is the reverse of removal. Pay
stay bar. Additional support must be used to attention to the following precautions:
avoid any possible vehicle damage.
- Tighten the tailgate hinge bolt to the torque of 32±3N.m
When installing the tailgate stay bar, install the left electric
stay bar before the right balance bar is installed. Direction
of the ball head when installing the balance bar: ball head
with a large sleeve diameter is connected to the ball head
at the body side, and that with a small sleeve diameter is
connected to the ball head at the door side.
GS180004
27-3
Power Liftgate
8 Remove the electric stay bar of the power

Replacement of Power Liftgate Electric Stay
liftgate.
Bar
Removal
1 Open and support the tailgate. Installation
2 Remove the right rear interior trim panel (refer to 1 Installation is the reverse of removal. Pay
Replacement of Rear Interior Trim Panel). attention to the following precautions:
3 Remove the harness connector from the drive - Tighten the gas spring bracket screws/bolts to the
mechanism assembly of the power tailgate. torque of 9 ± 1N.m.
4 Pry up the spring piece from the top of the
tailgate electric stay bar with a small flat-bladed
tool.
5 Remove the top part of the tailgate electric stay

bar from the gas spring upper mounting bracket.
GS180005
6 Pry up the spring piece from the bottom of the

tailgate electric stay bar with a small flat-bladed
tool.
7 Remove the bottom of the tailgate electric stay

bar from the gas spring lower mounting bracket.
GS180006
27-4
Power Liftgate
6 Remove the balance bar of the power liftgate.

Replacement of Power Liftgate Balance Bar
Removal
1 Open and support the tailgate. Installation
2 Pry up the spring piece from the top of the 1 Installation is the reverse of removal. Pay
tailgate balance bar with a small flat-bladed tool. attention to the following precautions:
3 Remove the top part of the tailgate balance bar - Tighten the gas spring bracket screws/bolts to the
from the gas spring upper mounting bracket. torque of 9 ± 1N.m.
GS180007
4 Pry up the spring piece from the bottom of the

tailgate balance bar with a small flat-bladed tool.
5 Remove the bottom of the tailgate balance bar

from the gas spring lower mounting bracket.
GS180008
27-5
Power Liftgate
Installation
Replacement of Power Liftgate Anti-pinch
Molding 1 Installation is the reverse of removal, and please
note that the anti-pinch molding harness shall be
Removal
located at the slot.
2 Remove the tailgate interior trim panel (refer to
3 Remove the harness connector of the power

tailgate anti-pinch molding.
4 Remove the electric stay bar and balance bar of

the power tailgate (refer to Replacement of
Power Tailgate Electric Stay Bar and Balance
Bar).
5 Release the nut.
GS180016
GS180009
6 Remove the anti-pinch molding of the power

liftgate.
27-6
Power Liftgate
Replacement of Power Tailgate Control Box

Assembly
Removal
1 Remove the right rear interior trim panel (refer to
Replacement of Rear Interior Trim Panel).
2 Remove the harness connector from the power
tailgate control box.
3 Remove the bolts of the power tailgate control

box.
GS180010
4 Remove the control box assembly.
Installation
- Tighten the bolts of the power tailgate control box
assembly to the torque of 3.5 ± 0.5N.m.
27-7
Power Liftgate
Description and Operation Operation Principles of System
Introduction of Power Liftgate Parts Function When the drive system of the power tailgate receives a
command from the user (such as open command), the
Tailgate Stay Bar
control unit sends the signal to the tailgate lock first, the
The tailgate stay bar ensures opening and closing of the
tailgate lock then performs the action after receiving the
tailgate by providing a driving force during opening and
signal, then the tailgate stay bar provides a driving force
closing operations.
to open the tailgate, the stay bar motor will be released
Electronic Control Unit (ECU) when the tailgate achieves the height set; When a close
The electronic control unit is a control logic made command is received, the control unit first transmits the
according to the function matrix of the tailgate, use this signal to the stay bar motor of the tailgate, the tailgate
logic to set the tailgate opening/closing, reversal due to closes due to reversal of the motor, and the lock starts to
obstacles and response to unexpected situations, etc. close when the tailgate lock is in the FULL LOCK
position.
Anti-pinch Molding
At the moment when the tailgate is about to close, if your When the tailgate touches any obstacle or anti-pinch
hand is pinched between the tailgate and the side wall, molding in motion, it will reverse.
the anti-pinch molding will be triggered, and the tailgate
will reverse to avoid hand injury.
Full open position
Buzzer Strategy
Obstacle
During opening and closing of the tailgate, when any
anti-pinch
obstacle or abnormal operation occurs, an acoustic alarm Auto open Following-up logic
will be issued to alert the user to avoid impact by the actuator after closing
tailgate. Auto close
actuator
Semi-lock
Lock catch Full-lock
engagement
GS180011
27-8
Power Liftgate
Procedures for Aftersales Self-learning Factors for Retriggering Self-learning

(Repeat Self-learning)
1 ECU has been replaced or the ECU connector
1 Manually turn the power tailgate to the FULL has been removed.
LOCK position from the current position, wait the 2 The electric stay bar has been replaced or the
self-locking lock to close and the tailgate to come connector of the electric stay bar has been
into the FULL LOCK position. removed.
Caution: The tailgate shall be located at the FULL
LOCK position, if the tailgate is partially locked,
then the lock system will not close.
2 The offline equipment established by the TGC
communication is in EOL mode.
3 Enter 27 01/27 02 by the security certificate of

level 1.
4 Trigger self-learning command, enter 31 01 AB

A1.
5 Reply message 71 01 AB A1 will be received

about 6s after the self-learning is completed.
6 Check self-learning result, enter 31 03 AB A1. If

80 is received, then the self-learning is
successful; if other negative responses are
received, then perform a troubleshooting with
reference to the negative response section, and
repeat step 1-6 for self-learning.
7 When pressing the open/close button of the

tailgate, the tailgate will be closed by power.
8 Clear system DTC, enter 14 FF FF FF and

complete the self-learning.
27-9
Power Liftgate
27-10
Front Body
Front Body
Torque
Bolt - engine hood hinge 22 ± 2

Bolt - fender 9±1
28-1
Front Body
Layout
Engine Hood Layout
1 4
GS170001
1 Engine hood weld assembly 4 Engine hood gas stay bar

2 Engine hood hinge assembly 5 Engine hood gas stay bar
3 Engine hood hinge assembly
28-2
Front Body
Fender Layout
GS170002
1 Fender 2 Fender
28-3
Front Body
Installation
Repair Guidance
Engine Hood Replacement attention to the following precautions:
Removal - Tighten the hinge bolt of the engine hood to 22 ± 2N.m.
2 Pull the release handle of the engine hood.
GS170003
3 Toggle the lock lever and raise the engine hood,

then support the engine hood after removing the
gas spring.
4 Install the protective cover on the fender to avoid
paint damage during engine hood removal/
installation.
5 Mark the position of the engine hood hinge
relative to the engine hood to re-install the
engine hood.
6 Remove the bolt of the engine hood hinge.
GS170004
28-4
Front Body
Replacement of Engine Hood Hinge Replacement of Gas Stay Bar

Removal Removal
1 Disconnect the negative battery cable. 1 Disconnect the negative battery cable.
2 Pull the release handle of the engine hood. 2 Pull the release handle of the engine hood.
3 Toggle the lock lever and raise the engine hood, 3 Toggle the lock lever to open and support the
then support the engine hood after removing the engine hood.
gas spring. 4 Disconnect the clamp connecting engine hood
4 Mark the position of the engine hood hinge gas stay bar and gas spring ball head.
relative to the engine hood to re-install the
engine hood.
5 Remove the bolts securing the engine hinges to
the engine hood.
6 Remove the bolts securing the engine hinges to
the fender beam.
GS170005
5 Remove the engine hood stay bar.

Special Notice: When removing the body panel,
tape the panel corner and adjacent surface to
avoid paint damage. The inner surface of some
GS170009 metal panels is applied with anticorrosive agent
to avoid rusting. When repairing the panel with
7 Remove the engine hinge. the anticorrosive agent damaged or installing a
new panel, you must apply the anticorosive agent
to avoid corrosion damage. When removing the
Installation engine hood from the vehicle, DO NOT place it
1 Installation is the reverse of removal. Pay vertically with the rear corner downward.
attention to the following precautions: Otherwise, the paint and panel will be damaged.
- Tighten the hinge bolt of the engine hood to 22 ± 2N.m. Caution: When preparing the supporting device
during engine hood installation or removal,
additional support must be used to avoid any
possible vehicle damage and personal injury.
Engine hood stay bar consists of the gas stay bar
and gas spring ball head. It is designed to
provide reliable support after opening the engine
hood, thereby facilitating the fluid refilling and
service operations,
Installation
28-5
Front Body
7 Remove all bolts securing the fender to the body.

Fender Replacement
Removal
1 Toggle the lock lever and raise the engine hood.
3 Remove the headlamp assembly.
4 Remove the front bumper.
5 Remove the front wheelhouse liner and fender
flare trim panel.
GS170008
8 Remove the fender.
Installation
GS170006 - Tighten the bolts of the fender to 9 ± 1N.m.
6 Remove the ventilation grille trim panel.
GS170007
28-6
Entertainment System
Torque
Nut - DVD mainframe 9±1
29-1
Layout
Layout
GS330001
1 Radio+MP5+Mirrorlink 2 MP5 display
29-2
Layout
GS330002
1 Radio+MP3
29-3
Repair Guidance
Replacement of MP5 display
Replacement of Radio+MP5+Mirrorlink
Removal
Removal
2 Remove the auxiliary fascia console (refer to
Assembly).
Panel Assembly).
3 Remove 4 bolts securing the
Radio+MP5+Mirrorlink to the instrument panel
(refer to Replacement of Instrument Panel
body.
Assembly).
4 Remove 6 bolts securing the MP5 display to the
instrument panel body.
GS330004

GS330003
5 Remove the Radio+MP5+Mirrorlink assembly.
6 Remove the MP5 display assembly.
Installation
Installation
29-4
Replacement of Radio+MP3
Removal
Panel Assembly).
(refer to Replacement of Instrument Panel
Assembly).
4 Remove 6 bolts fixing the Radio+MP3 to the
instrument panel body.
GS330005
6 Remove the Radio+MP3 assembly.
Installation
29-5

Entertainment and Navigation System Control Diagram
GPS Antenna Tweeter

GPSཟ㓵儎丩ᢢ༦ಞ
Radio Antenna MIC

᭬丩ᵰཟ㓵哜‫ށ‬伄
USB Socket T-Box Cellular

USBᨈᓝ INFO 䙐䇥⁗ඍ 㖇㔒ཟ㓵
Infortainment Panel GPS Antenna

ၧ҆᧝࡬䶘ᶵ LIN GPS ཟ㓵
Front View Camera FICM

‫ޞ‬Ქᖧ‫ࢃ܅‬㿼᩺‫܅‬ཪ VD
ၧ҆ѱᵰ
GW ESP
INFO 㖇ީ ⭫ᆆどᇐ᧝࡬㌱㔕
Rear View Camera

‫ޞ‬Ქᖧ‫੄܅‬㿼᩺‫܅‬ཪ
Steering Wheel Switch

ᯯੇⴎၧ҆ᔶީ
Left View Camera

‫ޞ‬Ქᖧ‫܅‬ᐜ‫ם‬᩺‫܅‬ཪ
Rear View Camera

੄㿼᩺‫܅‬ཪ
Right View Camera

‫ޞ‬Ქᖧ‫܅‬਩‫ם‬᩺‫܅‬ཪ
INFO
IPK
Microphone 㓺ਾԠ㺞
哜‫ށ‬伄
USB
⺢㓵 ၧ҆儎䙕&$1㓵 LIN㓵䈀ᯣCAN

GS0330006
29-6
tweeters on the rear door is fixed to the rear door inner

Entertainment Mainframe
handle assembly by clips.
According to vehicle configuration and optional assembly,
there are three types of entertainment mainframe Antenna
available for installation: The antenna of the entertainment system may vary
depending on the configuration of the vehicle.
1 The entertainment mainframe with low
configuration supports the radio, USB, Bluetooth The entertainment mainframe with low configuration is
phone function, etc. provided with the rear window printed antenna.
2 The navigation mainframe with medium
configuration is provided with a 10.3-inch display, The navigation mainframe with medium configuration is
which supports the navigation, radio, USB, provided with BD/GPS output antenna without network.
Bluetooth phone, video function, etc.
The navigation mainframe with high configuration is
3 The navigation mainframe with high provided with BD/GPS output antenna and 4G network
configuration supports the radio, USB, Bluetooth
antenna.
phone, video, navigation, 4G network function,
etc. Operation
Audio Control Buttons on Steering Wheel The entertainment system is operable only when the
The audio device can be controlled by the remote remote key is inserted or the ignition switch is ON.
switches mounted on the steering wheel. These function
For details of the operation of the entertainment system,
buttons allow the most common functions in the ICE
please refer to "User Manual" and "Navigation Manual".
system to be used in a much more convenient manner.
Display
The display shows the audio information and relevant
information.
Full Range Speaker

The full range speaker is inside the four doors. Secure
the speaker on the door panel with 3 screws.
Tweeter
Two tweeters are on the left/right A-pillar, and the other
two are on the two rear doors. The tweeters on the A-
pillar are fixed to the A-pillar trim panel by clips, and the
29-7
29-8
Frame
Frame
Torque
1
5
7 6
8
GS160001
No. Part Name Tightening Torque (N.m)
1 Nut - frame baffle to mount bracket 65 ± 10

2 Nut - 3rd beam 70 ± 10
3 Bolt - frame baffle to mount bracket 65 ± 10
4 Bolt - 3rd beam 70 ± 10
5 Bolt - 4th beam reinforcing beam 110 ± 10
6 Bolt - longitudinal thrust beam 45 ± 5
30-1
Frame
Layout
Frame Mount Layout
GS160002
1 1st mount on the body 3 3rd mount on the body

2 2nd mount on the body 4 4th mount on the body
30-2
Frame
2nd/3rd Row Mounts Installation

Repair Guidance
Mount Installation
Removal
1 Lift the vehicle.
2 Remove mounting bolts from 4th row mount.
3 Slightly raise the body, and remove the mount.
Installation
1 Align the body with frame mounting holes.
2 Pre-tighten and install the 2nd mount on the left
of body, then the 3rd mount on the left, and then
the remaining mounts. GS160004
3 Lower down the body, and then tighten the

mount bolts/nuts in sequence. 1 Place the upper rubber cushion of the mount to
the mount bracket.
2 Secure the mount to the mount bracket with nuts,
1st Mount Installation and tighten to 120 ± 10N.m.
3 Get the gasket and bolt, pass the bolt through
the body hole from top to bottom.
4 Install the mount nuts, and tighten to 190 ±
10N.m.
GS160003
1 Place the upper rubber cushion of the 1st mount

and mount sleeve to the 1st mount bracket.
2 Install the lower rubber cushion of the 1st mount
to the position as shown in the figure.
3 Pass the bolt through the body hole from top to
bottom.
4 Install the mount nuts, and tighten to 70 ± 5N.m.
30-3
Frame
4th Row Mount Installation
GS160005
1 Place the upper rubber cushion of the 4th mount

to the mount bracket.
2 Secure the mount to the mount bracket with nuts,
and tighten to 120 ± 10N.m.
3 Get the gasket and bolt, pass the bolt through
from top to bottom.
4 Install the mount nuts, and tighten to 190 ±
10N.m.
30-4
Stationary Windows
Stationary Windows
Layout
Layout
4 5
2
1
GS190001
1 Front windscreen 4 Rear door window glass

2 Front door quarter window 5 Rear side window glass
3 Front door window glass 6 Rear windscreen
31-1
Stationary Windows
Repair Guidance Replacement of Rear Door Window Glass
Replacement of Front Door Window Glass Removal
Removal 1 Remove the interior trim panel and waterproof

membrane of the door.
1 Remove the interior trim panel and waterproof
2 Lower down the glass to the position as shown
membrane of the door.
below till the nuts connecting the glass and
2 Lower down the glass to the position as shown regulator are exposed, then loosen the nuts.
below till the nuts connecting the glass and
regulator are exposed, then loosen the nuts.
ES210002
GS190002
3 Pull the glass upward and outward from the door.
3 Pull the glass upward and outward from the door.

Installation
Installation 1 Installation is the reverse of removal.
31-2
Stationary Windows
Caution: The surface coated with primer must be

Replacement of Rear Side Window Glass
dry and free from dust, grease and other
Removal contaminants that may affect adhesion. Shake up
1 Cut the adhesive around the rear side window the primer to prevent it from precipitation each
glass with the cutting tool. time it is not in use for a long period.
2 Remove 3 glass clips. Warning: Do not apply primer onto the body and
glass with any remaining polyurethane adhesive,
otherwise it may result in poor adhesion of the
newly coated polyurethane adhesive.
3 Apply a layer of 8mm wide polyurethane
adhesive evenly, continuously and vertically
around the rear side window glass with standard
pneumatic or manual glue gun by reference to
the glue track.
4 Align the locating pin of rear side window glass

with the body hole.
5 Press hard the rear side window glass in place.
GS190003 Caution: For moisture-curable polyurethane

adhesive, solidify it at 21 °C (70 °F) or higher
3 Push the glass out slowly from the inside out. temperature and the relative humidity no less
than 30% for at least 6 hours. It takes at least 24
hours for the polyurethane adhesive to be fully
Installation solidified. For chemical-curable polyurethane
1 Wipe the inner surface of glass with clean cloth adhesive, solidify it for at least 1 hour. DO NOT
or bleached fiber (roll paper) immersed with a physically disturb the repair area until the
proper amount of specified glass cleaner, and minimum solidification time has elapsed.
clean the body paint with organic solvent inactive 6 Conduct a rain test, that is, shower the window
to the surface (such as acetone), then dry it for at glass softly with warm water to check the rear
least 5 minutes. side window glass for any sign of leakage.
Caution: The used cloth or bleached fiber (roll
7 If any leakage is found, apply more polyurethane
paper) must be replaced. Use the cleaner directly adhesive around the leakage point. If it still
and never dilute it with water. leaks, remove the rear side window glass and
Warning: To avoid any adverse reaction between repeat the whole procedure.
cleaner and primer or polyurethane adhesive,
prevent the cleaner from contacting with newly
painted primer or polyurethane adhesive. Do not
use the cleaner to remove excess primer or
polyurethane adhesive; the surface to be cleaned
must be complete dry before applying primer or
polyurethane adhesive.
2 Fully shake the glass primer and paint primer.
Dip a small amount of mixture with a clean brush
or gauze and evenly wipe the surface of the
glass and side wall sheet metal edge which have
been cleaned by cleaner. One-time instead of
repeated painting is required with drying time of
approximately 5-15 minutes.
31-3
Stationary Windows
Replacement of Front Door Quarter Window Replacement of Front Windscreen

Removal Removal
1 Remove the front door trim panel. 1 Remove the interior rearview mirror, refer to the
2 Remove the inner/outer watercut, glasses and Replacement of Interior Rearview Mirror.
glass grooves from the front door. 2 Disconnect the harness connectors from rain
sensor and lane departure warning system (if
3 Remove 3 screws (1,2 and 3) as shown in the
equipped).
figure.
3 Remove the wiper arm. Refer to Replacement of
Wiper Arm.

1 assembly and front windscreen cover plate trim
cover. Refer to Replacement of Front
Windscreen Cover Plate Assembly.
5 Cut the adhesive around the front windscreen

2
with tool.
GS190004
4 Remove the quarter window from the edge of

interior/exterior door panel.
Installation
1 Tighten the front door quarter window to front
door window frame assembly with screw 1.
GS190005
2 Tighten the front door quarter window to front
door interior panel with screw 2 first and then 6 Remove the front windscreen with a sucker
screw 3. aided by assistant.
Installation
1 Wipe the inner surface of glass with clean cloth
or bleached fiber (roll paper) immersed with a
proper amount of specified glass cleaner, and
clean the body paint with organic solvent inactive
to the surface (such as acetone), then dry it for at
least 5 minutes.
Caution: The used cloth or bleached fiber (roll
paper) must be replaced. Use the cleaner directly
and never dilute it with water.
Warning: To avoid any adverse reaction between
cleaner and primer or polyurethane adhesive,
prevent the cleaner from contacting with newly
painted primer or polyurethane adhesive. Do not
31-4
Stationary Windows
use the cleaner to remove excess primer or 9 Install the front windscreen cover plate assembly
polyurethane adhesive; the surface to be cleaned and front windscreen cover plate trim cover.
must be complete dry before applying primer or
10 Install the wiper arm.
11 Connect the rain sensor harness connector (if
equipped).
glass and top cover edge which have been
cleaned by cleaner. One-time instead of

contaminants that may affect adhesion. Shake up
the primer to prevent it from precipitation each
time it is not in use for a long period.
Warning: Do not apply primer onto the body and
glass with any remaining polyurethane adhesive, GS190006
adhesive evenly, continuously and vertically
around the front windscreen with standard
pneumatic or manual glue gun by reference to
the glue track.
4 Align the upper locating pin of the front

windscreen with the body hole.
5 Press the front windscreen in place.
6 Attach tapes around the front windscreen to

keep it in the correct installation position until the GS190007
polyurethane adhesive is solidified.
Caution: For moisture-curable polyurethane

temperature and the relative humidity no less
than 30% for at least 6 hours. It takes at least 24
hours for the polyurethane adhesive to be fully
solidified. For chemical-curable polyurethane
adhesive, solidify it for at least 1 hour. DO NOT
physically disturb the repair area until the
minimum solidification time has elapsed.
7 Conduct a rain test, that is, shower the front
windscreen softly with warm water to check the
windscreen for any signs of leakage.
8 If any leakage is found, apply more polyurethane

adhesive around the leakage point. If it still
leaks, remove the front windscreen and repeat
the whole procedure.
31-5
Stationary Windows

Replacement of Rear Windscreen
Removal
1 Remove the harness connector from the heater adhesive evenly, continuously and vertically
wire joint (if equipped). around the rear windscreen with standard
2 Remove the wiper arm. Refer to Replacement of pneumatic or manual glue gun by reference to
Wiper Arm. the glue track.
3 Cut the adhesive around the front windscreen 4 Align the upper locating pin of the rear
with tool. windscreen with the body hole.
4 Remove the rear windscreen with a sucker aided 5 Press hard the rear windscreen in place.
by assistants. 6 Attach tapes around the rear windscreen to keep
5 Remove the quarter window from the edge of it in the correct installation position until the
interior/exterior door panel. polyurethane adhesive is solidified.
Caution: For moisture-curable polyurethane

Installation temperature and the relative humidity no less
1 Wipe the inner surface of glass with clean cloth than 30% for at least 6 hours. It takes at least 24
or bleached fiber (roll paper) immersed with a hours for the polyurethane adhesive to be fully
proper amount of specified glass cleaner, and solidified. For chemical-curable polyurethane
clean the body paint with organic solvent inactive adhesive, solidify it for at least 1 hour. DO NOT
to the surface (such as acetone), then dry it for at physically disturb the repair area until the
least 5 minutes. minimum solidification time has elapsed.
Caution: The used cloth or bleached fiber (roll 7 Conduct a rain test, that is, shower the rear
paper) must be replaced. Use the cleaner directly windscreen softly with warm water to check the
and never dilute it with water. rear windscreen for any signs of leakage.
Warning: To avoid any adverse reaction between 8 If any leakage is found, apply more polyurethane
cleaner and primer or polyurethane adhesive, adhesive around the leakage point. If it still
prevent the cleaner from contacting with newly leaks, remove the rear windscreen and repeat
painted primer or polyurethane adhesive. Do not the whole procedure.
use the cleaner to remove excess primer or
9 Install the wiper arm.
polyurethane adhesive; the surface to be cleaned
must be complete dry before applying primer or 10 Connect the heater wire harness (if equipped).
glass and top cover edge which have been
cleaned by cleaner. One-time instead of

contaminants that may affect adhesion. Shake up
the primer to prevent it from precipitation each
time it is not in use for a long period.
Warning: Do not apply primer onto the body and
glass with any remaining polyurethane adhesive,
31-6
Doors
Doors
Torque
Bolt - front door hinge 26 ± 3

Bolt - front door check 22 ± 2
Bolt - rear door hinge 26 ± 3
Bolt - rear door check 22 ± 2
32-1
Doors
Layout
Front/Rear Door Layout
2
1
GS200001
1 Front door 2 Rear door
32-2
Doors
Repair Guidance
Replacement of Front Door/Hinge 13 Remove the front door.
Removal
1 Open the front door and support it.
Installation
2 Remove the front door interior trim panel.
3 Remove the front door waterproof membrane. attention to the following precautions:
4 Remove the front door glass and regulator. - Tighten the hinge bolt of the front door to the torque of
5 Remove the front door lock and link. 26 ± 3N.m;
6 Remove the loudspeaker assembly. - Tighten the hinge bolt of the front door check to the
torque of 22 ± 2N.m.
7 Remove the exterior rearview mirror.
8 Remove the front door inner/outer handle.
10 Disconnect the front door harness from the front

door.
11 Remove the front door check.
GS200002
12 Remove the front door upper/lower hinge.
GS200003
32-3
Doors
12 Remove the rear door.

Replacement of Rear Door/Hinge
Removal
1 Open the rear door and support it. Installation
2 Remove the rear door interior trim panel. 1 Installation is the reverse of removal. Pay
3 Remove the rear door waterproof membrane.
- Tighten the hinge bolt of the rear door to the torque of
4 Remove the rear door glass and regulator.
26 ± 3N.m;
5 Remove the rear door lock and link.
- Tighten the hinge bolt of the rear door check to the
6 Remove the loudspeaker assembly.
7 Remove the rear door inner/outer handle.
9 Disconnect the rear door harness from the rear

door.
10 Remove the rear door check.
GS200004
11 Remove the rear door upper/lower hinge.
GS200005
32-4
Doors
Front Door Adjustment Front Door Hinge Adjustment

Front door lock catch is a latch with two screws. Adjust Removal
the lock catch upward/downward or inward/outward is 1 Open the front door.
necessary in many cases:
2 Put the wood block on the jack, and put the jack
1 Frame damage caused by collision. under the door to support the front door.
2 Install a new door weatherstrip. 3 Unscrew 2 bolts securing the upper and lower
door hinges on the front door.
3 The customer complaints that the wind noise is
loud. 4 Use a jack to support the vehicle and adjust the
front door.
4 There is difficulty in opening or closing the door.
5 Pre-tighten the hinge bolts.
Adjust the lock catch upward/downward or inward/
outward according to the following procedures: 6 Take away the jack, close the door to check if the
adjustment is proper.
1 The door must be positioned correctly. 7 When the desired adjustment is achieved,
2 Open the front door. tighten the bolts fixing the hinge to the door to
specified torque (TBD) and check the torque.
3 Loosen 2 lock catch screws. Adjust the lock
catch to align with the door pin, then pre-tighten
the screws.
4 Close the door, and check if the rear of the door

is flush with the sheet metals of the body side
panel and if the door can open and close
normally.
5 After the adjustment, open the door, tighten the

bolts fixing the lock catch to the body to 22 ±
6 Close the door.
32-5
Doors
5 Disconnect the front door lock assembly from the

Replacement of Front Door Lock Assembly
front door lock cylinder lever.
Removal
1 Disconnect the battery negative. Ensure that the
front door glass rises to the highest position.
2 Remove the front door trim panel.
3 Remove the bolts fixing the front door lock

assembly to the sheet metal.
GS200008

front door outer handle link.
GS200006

front door inner unlock cable assembly.
GS200009
7 Remove the door harness connector of the front

door lock assembly, and remove the front door
lock assembly.
1 Install the door harness connector of the front
door lock assembly.
2 Connect the front door lock assembly with the
front door outer handle link.

front door lock cylinder lever.

front door inner unlock cable assembly.
32-6
Doors
5 Secure the front door lock assembly to the sheet

Replacement of Front Door Lock Catch
metal, install 3 bolts, tighten them to 22 ± 2N.m,
Assembly
Removal
6 Install the waterproof membrane.
1 Remove the bolts securing the front door lock
7 Install the front door trim panel.
catch assembly to the sheet metal.
8 Connect the negative battery cable.
9 Check if the outer and inner handles of the front

door can work properly.
GS200010
2 Remove the front door lock catch assembly.
Installation
1 Install the front door lock catch assembly.
2 Tighten the bolts securing the front door lock
catch assembly to the sheet metal. Tightening
torque: 22 ± 2N.m.
32-7
Doors
Rear Door Adjustment Rear Door Hinge Adjustment

Rear door lock catch is a latch with two screws. Adjust Removal
the lock catch upward/downward or inward/outward is 1 Open the rear door.
necessary in many cases:
2 Put the wood block on the jack, and put the jack
1 Frame damage caused by collision. under the door to support the rear door.
2 Install a new door weatherstrip. 3 Loosen 3 bolts securing the upper/lower door
hinges of the rear door to the rear door.
3 The customer complaints that the wind noise is
loud. 4 Correct the rear door with the jack.
4 There is difficulty in opening or closing the door. 5 Pre-tighten the hinge bolts.
Adjust the lock catch upward/downward or inward/ 6 Take away the jack, close the door to check if the
outward according to the following procedures: adjustment is proper.
7 When the desired adjustment is achieved,

1 The door must be positioned correctly. tighten the bolts fixing the hinge to the door to 22
2 Open the rear door. ± 2N.m and check the torque.
3 Loosen 3 lock catch screws. Adjust the lock
catch to align with the door pin, then pre-tighten
the screws.
4 Close the door, and check if the rear of the door

is flush with the sheet metals of the body side
panel and if the door can open and close
normally.
5 After the adjustment, open the door, tighten the

bolts fixing the lock catch to the body to 22 ±
6 Close the door.
32-8
Doors
5 Disconnect the rear door lock assembly from the

Replacement of Rear Door Lock Assembly
rear door lock cylinder lever.
Removal
1 Disconnect the battery negative. Ensure that the
rear door glass rises to the highest position.
2 Remove the rear door trim panel.
3 Remove the bolts fixing the rear door lock

GS200013

rear door outer handle link.
GS200011

rear door inner unlock cable assembly.
GS200014
7 Remove the door harness connector of the rear

door lock assembly, and remove the rear door
lock assembly.
1 Install the door harness connector of the rear
door lock assembly.
2 Connect the rear door lock assembly with the
rear door outer handle link.

rear door lock cylinder lever.

rear door inner unlock cable assembly.
32-9
Doors
5 Secure the rear door lock assembly to the sheet

Replacement of Rear Door Lock Catch
metal, install 3 bolts, tighten them to 22 ± 2N.m,
Assembly
Removal
6 Install the waterproof membrane.
1 Remove the bolts fixing the rear door lock catch
7 Install the rear door trim panel.
8 Connect the negative battery cable.
9 Check if the outer and inner handles of the rear

doors can work properly.
GS200010
2 Remove the rear door lock catch assembly.
Installation
1 Tighten the rear door lock catch assembly and
unscrew the bolts securing the rear door lock
catch assembly to the sheet metal; tightening
torque: 22 ± 2N.m.
32-10
Doors
Replacement of Engine Hood Lock Assembly Replacement of Front/Rear Door Outer

Removal Handle
Removal
1 Mark the lock location on the upper radiator
beam bracket so that proper location can be 1 Remove the front/rear door interior trim panel
found for installation. (refer to Removal/Installation of Front/Rear Door
2 Remove the bolts securing the engine hood lock Interior Trim Panel).
body to the upper radiator beam. 2 Remove the front/rear door waterproof
membrane.
3 Disconnect the harness connector of the engine
hood lock. 3 Remove the link of the front door lock cylinder
and that of the front/rear door outer handle.
4 Disconnect the engine hood lock assembly from
the engine hood unlock cable and harness 4 Remove the front door lock cylinder from the
connector. bracket screw of the front door outer handle.
(refer to Removal/Installation of Front Door Lock
5 Remove the engine hood lock assembly.
Cylinder).
5 Remove the front/rear door outer handle from

Installation the bracket screw of the front/rear door outer
handle.
1 1Connect the lock end of the engine hood
release cable assembly and the lock assembly 6 Move the outer handle toward the rear of vehicle
firmly, i.e. install the spherical end of the cable body, then pull the rear end of the handle
core wire into the hook slot of the engine hood outwards to separate it from the driver door outer
lock, put the core wire into the long slot of the handle liner and remove.
engine hood lock case, and align the circular
groove of the main cable pipe connector with the
mounting slot of the lock case, then press it hard
until it clicks.
2 Connect the harness connector of engine hood
lock body.
3 Locate the engine hood lock body assembly to

the upper radiator beam bracket, aligning it with
the location marked at the time of removal.
4 Connect the engine hood lock assembly with the

engine hood unlock cable and harness
connector respectively.
GS200015
5 Install the bolts securing the lock assembly to the
bracket of upper radiator beam, and do not 7 Remove the front/rear door outer handle.
tighten the bolt to the specified torque at this
step. Installation
6 Close the engine hood, observe the relative 1 Insert the front of driver door outer handle into
location of lock and lock catch, and adjust the the front door mounting hole, and move the outer
lock location until the lock catch drops into tab handle towards the rear vehicle. Install the front/
smoothly. rear door outer handles and their covers.
7 After adjustment, tighten the bolts to the 2 Install the front/rear door outer handle.
specified torque of 9 ± 1N.m, and check the 3 Install the rear gasket of outer handle. Caution:
torque. Make sure all gaskets are properly installed to
door outer handle.
32-11
Doors
4 Install the door lock cylinder (refer to Removal/

Replacement of Front/Rear Door Inner
Installation of Front Door Lock Cylinder).
Handle
5 Install the front door lock cylinder removed from
Removal
the bracket screw of the front door outer handle.
1 Remove the front/rear door interior trim panel
6 Install the link of the front door lock cylinder and
(refer to Removal/Installation of Front/Rear Door
that of the front/rear door outer handle.
Interior Trim Panel).
7 Install the front/rear door waterproof membrane. 2 Remove the base of the front/rear door inner
8 Install the front/rear door interior trim panel (refer handle.
to Removal/Installation of Front/Rear Door
Interior Trim Panel).
9 Close the door and check if the outer handle can

work properly.
GS200016
3 Remove the front/rear door inner handle from its

base.
Installation
1 Install the front/rear door inner handle.
2 Install the base of the front/rear door inner
handle.
3 Install the base of the front/rear door inner

handle.
32-12
Doors
6 Remove the bolts securing front door window

Replacement of Front Door Window
regulator assembly to the front door sheet metal.
Regulator Assembly
Removal
2 Remove the front door interior trim panel (refer to
Removal/Installation of Front Door Interior Trim
Panel).
Caution: Before removing the door trim panel,

please lift up the glass to a certain height to align
the 2 tightening bolts on the glass with the
mounting holes on the door.
GS200018
7 Carefully remove the window regulator from the

door cavity.
Installation
1 Install the window regulator into the front door
cavity, install the bolts securing the window
regulator to the door sheet metal, tighten the
bolts to specified torque (TBD) from top to
GS200017 bottom/left to right, and check the torque.
2 Connect the connector of the window regulator
3 Remove the front door waterproof membrane
motor.
(refer to Removal/Installation of Front Door
Waterproof Membrane). 3 Install the front door glass assembly (refer to
Removal/Installation of Front Door Window
4 Remove the front door window glass (refer to
Glass).
Removal/Installation of Front Door Window
Glass). 4 Install the front door waterproof membrane.
5 Disconnect the connector from the window 5 Install the front door interior trim panel (refer to
regulator motor. Removal/Installation of Front Door Interior Trim
Panel).
7 Check if the window regulator can work properly,

and check if the window with "One-touch Up"
function can operate normally.
Note: In case of a power failure, the "One-touch

Up" function may be disabled. Raise the glass to
the top, then press and hold the switch for
approximately 5 seconds to complete the self-
learning of window regulator, the "One-touch Up"
function will be resumed.
32-13
Doors
6 Remove the bolts securing rear door window

Replacement of Rear Door Window
regulator assembly to the rear door sheet metal.
Regulator Assembly
Removal
2 Remove the rear door interior trim panel (refer to
Removal/Installation of Rear Door Interior Trim
Panel).
Caution: After removing the door trim panel,

please lift up the glass to a certain height to align
the 2 tightening bolts on the glass with the
mounting holes on the door.
GS200018
7 Carefully remove the window regulator from the

door cavity.
Installation
1 Install the window regulator into the rear door
cavity, install the bolts securing the window
regulator to the door sheet metal, tighten the
bolts to specified torque (TBD) from top to
GS200017 bottom/left to right, and check the torque.
2 Connect the connector of the window regulator
3 Remove the rear door waterproof membrane
motor.
(refer to Removal/Installation of Rear Door
Waterproof membrane). 3 Install the rear door window glass (refer to
Removal/Installation of Rear Door Window
4 Remove the rear door window glass (refer to
Glass).
Removal/Installation of Rear Door Window
Glass). 4 Install the rear door waterproof membrane.
5 Disconnect the connector from the window 5 Install the rear door interior trim panel (refer to
regulator motor. Removal/Installation of Rear Door Interior Trim
Panel).
7 Check if the window regulator can work properly,

and check if the window with "One-touch Up"
function can operate normally.
Note: In case of a power failure, the "One-touch

Up" function may be disabled. Raise the glass to
the top, then press and hold the switch for
approximately 5 seconds to complete the self-
learning of window regulator, the "One-touch Up"
function will be resumed.
32-14
Doors
Replacement of Fuel Filler Flap Assembly Description and Operation

Removal Description and Operation
1 When it is powered on, push the button of the The power window system consists of the following
fuel filler flap to open it, and release the filler cap components:
connecting wire from the fuel filler flap.
2 Fully open the fuel filler flap with hands. ·Driver window switch
3 Remove 4 rivets from the fuel filler flap. ·Front passenger window switch
·Rear left window switch
·Rear right window switch
·Window motor in each door
·BCM
Overview
BCM controls the operations of window regulator system:
·Manually ascend/descend the individual window glass.
·Automatically (one-button control) ascend/descend the

GS200019
window glass by using the intelligent window motor.
4 Remove the fuel filler flap.
·Automatically (one-button control) descend the window
glass by using the window regulator system with heat
protection (for individual front/rear window glass only).
Installation
1 Locate the fuel filler flap to the vehicle body, take ·Manually ascend/descend all windows simultaneously.
care to adjust the gap around the fuel filler flap to
·Automatically (one-button control) ascend/descend all
avoid the interference with side panel. Install 4
windows simultaneously.
rivets to and align with corresponding holes for
tightening purpose. The window regulator system transmits information via
LIN and low current switch. The LSDs or intelligent motor
allows BCM to control the relay:
·BCM receives the hard wire input signal of the window

switch, remote key radio frequency signal and the
UNLOCK/LOCK signal of the mechanical key from the
32-15
Doors
DDSP via LIN. By this way, it controls the relay via the
LSD (standard motor).
·BCM sends the request signal to the intelligent motor

via LIN and hard wire of the local switch and controls the
internal relay.
For power window systems with standard regulator

motor, BCM receives the UP/DOWN signal directly. The
motor uses the LSD integrated circuit to control the relay.
For power window systems with intelligent regulator

motor, BCM sends operation signal via LIN or hard wire
of the local switch.
When you lock/unlock the driver door, or the remote key

gives radio frequency signal or when any impact occurs,
the window can be opened/closed simultaneously.
32-16
Roof (Sunroof)
Roof (Sunroof)
Layout
Panoramic Sunroof Layout
4 8
GS190008
1 Front sunroof glass assembly 5 Wind guide assembly

2 Rear sunroof glass assembly 6 Sunroof drain pipe assembly
3 Sunroof weatherstrip 7 Front sunroof motor
4 Front sunroof frame assembly 8 Front sunroof sunshade assembly
33-1
Roof (Sunroof)
Common Sunroof Layout
4
5
GS190009
1 Front sunroof glass assembly 5 Front sunroof motor

2 Front sunroof weatherstrip 6 Front sunroof frame assembly
3 Sunroof sun visor assembly 7 Sunroof drain pipe assembly
4 Sunroof wind shield assembly
33-2
Roof (Sunroof)
Repair Guidance Replacement of Front Sunroof Glass

Assembly (Panoramic Sunroof)
Replacement of Panoramic Sunroof
Assembly Removal
Removal 1 Open the sunroof sunshade.

2 Open the sunroof by sliding slightly.
2 Remove the driver compartment ceiling interior 3 Remove the sunroof flex molding.
assembly (refer to Replacement of Driver 4 Remove the screws securing the front sunroof
Compartment Ceiling Interior Assembly). glass to the bracket (6 screws on both sides in
3 Disconnect the harness from sunroof motor. total).
4 Separate the sunroof drain pipe from sunroof

drain valve.
5 Remove 18 bolts securing the sunroof assembly

to the vehicle body.
GS190011
5 Remove the front sunroof glass assembly, and

do not move manually the brackets on both sides
for installing the glass panel.
GS190010
6 Remove the sunroof assembly slowly. Installation

Installation
33-3
Roof (Sunroof)
Replacement of Rear Sunroof Glass Replacement of Front Sunroof Motor

Assembly (Panoramic Sunroof) (Panoramic Sunroof)
Removal Removal
1 Remove the front sunroof glass assembly (refer 1 Disconnect the battery (negative first).
to Replacement of Front Sunroof Glass 2 Remove the front ceiling interior reading lamp
Assembly). assembly (refer to Replacement of Front Ceiling
2 Remove the bolts securing the rear sunroof Interior Reading Lamp Assembly).
glass to the sunroof frame.
3 Disconnect the electrical connector from the
motor.
4 Remove 3 bolts connecting the sunroof motor.
GS190013
3 Remove the rear sunroof glass assembly slowly.

GS190014
Installation 5 Remove the front sunroof motor.
Installation
33-4
Roof (Sunroof)
6 Remove the sunshade cover.

Replacement of Front Sunroof Sunshade
Assembly (Panoramic Sunroof)
Removal
1 Remove the driver compartment ceiling interior
assembly (refer to Replacement of Driver
Compartment Ceiling Interior Assembly).
2 Remove the front sunroof glass assembly (refer
to Replacement of Front Sunroof Glass
Assembly).
3 Remove the rear sunroof glass assembly (refer

to Replacement of Rear Sunroof Glass
Assembly).
4 Remove 2 screws fixing the sunroof weatherstrip GS190017

on the sunroof.
7 Slide the front sunroof sunshade backwards to
remove.
Installation
- The sunroof sunshade limit block must be tightened
after installation.
GS190015
5 Release the clips and remove the sunroof

sunshade limit block.
GS190016
33-5
Roof (Sunroof)
Replacement of Wind Guide Assembly Replacement of Front Sunroof Assembly

(Panoramic Sunroof) (Common Sunroof)
Removal Removal
1 Open the sunroof by sliding. 1 Disconnect the battery (negative first).
2 Remove the bolts connecting the wind guide 2 Remove the driver compartment ceiling interior
assembly. assembly (refer to Replacement of Driver
3 Disconnect the harness from sunroof motor.
4 Separate the sunroof drain pipe from sunroof

drain valve.
5 Remove 10 nuts securing the front sunroof

assembly.
GS190018
3 Loosen the clips retaining the wind guide

assembly, and slowly take down the wind guide
assembly.
Installation
GS190019
6 Take down the front sunroof assembly slowly.
Installation
- Tightening torque of the front sunroof assembly
fastening nuts: 9 ± 1N.m.
33-6
Roof (Sunroof)
Replacement of Front Sunroof Glass Replacement of Front Sunroof Motor

Assembly (Common Sunroof) (Common Sunroof)
Removal Removal
1 Disconnect the battery (negative first). 1 Disconnect the battery (negative first).
2 Remove the driver compartment ceiling interior 2 Remove the front ceiling interior reading lamp
assembly (refer to Replacement of Driver assembly (refer to Replacement of Front Ceiling
Compartment Ceiling Interior Assembly). Interior Reading Lamp Assembly).
3 Separate the sunroof drain pipe from sunroof 3 Disconnect the harness from sunroof motor.
drain valve.
4 Remove 2 fastening bolts from sunroof motor.
4 Remove the sunroof sun visor assembly.
5 Remove 4 bolts connecting the front sunroof

glass.
GS190021
5 Remove the front sunroof motor.
GS190020
6 Remove the sunroof glass. Installation

Installation
33-7
Roof (Sunroof)
System Control Diagram
Sunroof Motor Sun Shade Motor

ཟネ⭫ᵰ 䚤䱩ᶵ⭫ᵰ
BCM
䖜䓡᧝࡬⁗ඍ
Sunroof ECU
LIN ཟネ᧝࡬ঋ‫ݹ‬
Sunroof Switch
ཟネᔶީ
⺢㓵 LIN㓵
GS190022
33-8
Roof (Sunroof)
motor to drive the sunroof glass panel to move in the

The sunroof system has one-button slide opening/closing
required direction.
function. All operations on the sunroof system are
completed by the knob switch. Sunroof Sunshade
Sunroof Assembly It is activated when the system is running, press the
control switch of the sunroof sunshade to open or close
The sunroof assembly consists of a front sunroof glass
the sunshade.
panel, a rear glass panel, a sunshade, a frame assembly
between the roof and the interior roof panel, a deflector Input and Output of the Motor and Drive Unit
(on the frame assembly), 4 drain gutters, a sunroof motor
The sunroof glass ECU and its motor are powered by
and a sunshade motor.
fuse 13. The system ground wire can be connected for
The frame assembly is composed of the front frame, the operation of ECU, motor and switch. The switch
guide rails on both sides and a drain gutter on the beam. ground signal and two control signals of the sunroof are
input by the switch.
The sunroof deflector is designed with a knife-edge
shape, which includes the formed leaf spring installed on The sunroof sunshade ECU and its motor are powered
the front of the guide rail. by fuse 17. The system ground wire can be connected
for the operation of ECU, motor and switch. The switch
The sunroof glass is made of safety glass. The front and
ground signal and two control signals of the sunroof
rear sunroof glass panels are fixed on the sunroof
sunshade are input by the switch.
assembly with 6 screws.
Sunroof Switch Operation
The sunroof sunshade is in the slot in the inner edge of
The sunroof control unit drives the sunroof motor to open,
the front frame side rail, the scroll of sunshade is at the
tilt or close by sliding according to the input command
rear end of the frame. The operation of sunroof sunshade
from the sunroof switch, and drives the sunshade motor
is controlled by a motor.
to open or close by sliding.
The sunroof assembly is provided with a drainage control
system. Water can be introduced into the drain pipe Mechanical Key Operation
through the drain gutter, and then enters into each wheel When the driver door is locked with the mechanical key
house via the drain pipe. and the locking operation maintains for more than 2
seconds, the lock signal will be transmitted to the sunroof
Sunroof Switch control unit by BCM via LIN bus to drive the sunroof
The sunroof switch controls the lifting and slide of the motor to close, and all windows will be closed
sunroof glass assembly and the operation of the simultaneously.
sunshade.
Anti-pinch Function
Sunroof Glass When being closed by automatically sliding, the sunroof
The rotation of the switch controls the contacts inside the glass and sunshade will stop movement and
switch and transfers the signal output to the motor and
drive unit of the sunroof assembly. The sunroof electronic
control unit (ECU) analyzes signals and powers the
33-9
Roof (Sunroof)
automatically open after encountering an obstacle to

facilitate the obstacle removal. In case of low battery,
the anti-pinch function is ineffective.
Initialization of Sunroof Assembly

Sunroof operation will be influenced by power failure
when sunroof glass and sunshade is in motion, and it is
necessary to initialize after power on.
Window Initialization:
Close the sunroof, pull down the sunroof switch and hold
it for approximate 10 seconds, and the sunroof will
automatically open by sliding for a distance during which
the switch shall keep being pulled down and then close
automatically
Sunshade Initialization:
Close the sunshade, press the close button of sunshade

and hold for 10 seconds, and the sunshade will
automatically open by sliding for a distance during which
the switch shall keep being pulled down and then close
automatically
33-10
Supplemental Inflatable Restraint (SIR)
Torque
Bolt - curtain airbag 9±1

Bolt - passenger airbag 9±1
Nut - airbag ECU 9±1
Bolt/screw - airbag frontal impact sensor 9±1
Bolt/screw - airbag side impact sensor 9±1
SRS-ECU Parameters
Items Parameters
Voltage range DC 9V ～ DC 16V

Operating temperature -40 ℃～ +85 ℃
Storage temperature -40 ℃～ +85 ℃
Frontal/Side Impact Sensor Parameters
Items Parameters

34-1
Layout
Layout
1
2 1
3
GS230001
1 Curtain airbag assembly 3 Instrument panel (front passenger) airbag

assembly
2 Steering wheel (driver) airbag assembly
34-2
Layout
GS230006
1 Airbag control module
34-3
Impact Sensor Layout
GS230007
1 Airbag frontal impact sensor 2 Airbag side impact sensor
34-4
Repair Guidance
Replacement of Steering Wheel (Driver) Caution: The airbag electrical connector has a
Airbag Assembly safety buckle to secure it in place. Loosen the
safety buckle before removing the connector.
Warning: DO NOT remove the airbag until the
battery (or any possible auxiliary power supply of 4 Store the airbag in place according to storage
the vehicle) is disconnected and the capacitor of requirements.
10min.
Installation
Removal
2 Make sure the wheels are kept straight, pry off
- Re-tighten the safety buckle when installing the
the circlips on both sides and at the lower side
with a screwdriver (the diameter shall not exceed electrical connector.
5mm).
-·Reconnect the battery (positive (+) first).
- Ensure correct wiring.
- Check the operation of SRS warning lamp after

installation. (Check if SRS warning lamp works properly
after power-on.)
GS230002
GS230011
3 Lift the airbag module assembly from the

steering wheel carefully and disconnect the
airbag electrical connector.
34-5
7 Store the airbag in place according to storage

Replacement of Instrument Panel (Front
requirements.
Passenger) Airbag Assembly
battery (or any possible auxiliary power supply of Installation
the vehicle) is disconnected and the capacitor of
10min.
- Tighten the airbag bolts to the torque of 9 ± 1N.m.
Removal
1 Disconnect the battery (negative first). -·Reconnect the battery (positive (+) first).
2 Remove the glove box (refer to Replacement of - Ensure correct wiring.

Glove Box Assembly).
- Check the operation of SRS warning lamp after
3 Remove the instrument panel assembly (Refer to
installation. (Check if SRS warning lamp works properly
Replacement of Instrument Panel Assembly).
after power-on.)
4 Disconnect the lighting switch and electrical
connector.
5 Unscrew 2 bolts securing the airbag to the
instrument panel cross member assembly.
GS230003
6 Lift the airbag from instrument panel carefully,

loosen the electrical connector safety buckle and
disconnect the harness connector.
34-6
5 Store the left (right) curtain airbag assembly in

Replacement of Curtain Airbag Assembly
place according to storage requirements.
battery (or any possible auxiliary power supply of
the vehicle) is disconnected and the capacitor of Installation
10min.
Removal - Tighten the airbag bolts to the torque of 8-10N.m.
-·Reconnect the battery (positive (+) first).
2 Remove the A-pillar upper trim panel and driver
compartment ceiling trims (refer to Replacement - Ensure correct wiring.
of Pillar Trim Panel and Driver Compartment
Ceiling Trims). - Check the operation of SRS warning lamp after
3 Disconnect the curtain airbag electrical installation. (Check if SRS warning lamp works properly
connector carefully. after power-on.)
4 Unscrew the bolts securing the curtain airbag to
body.
GS230004
34-7
Replacement of Curtain Airbag Bracket Replacement of Airbag Control Module

Removal Removal
1 Remove the curtain airbag assembly (refer to 1 Disconnect the negative battery cable.
Replacement of Curtain Airbag Assembly). 2 Remove the auxiliary fascia console assembly
2 Unscrew the bolts securing the curtain airbag (refer to Replacement of Auxiliary Fascia
bracket to body. Console Assembly).
4 Remove 3 nuts securing airbag ECU to the
reinforcing plate of front floor central channel.
GS230005
3 Remove the curtain airbag bracket.

GS230008
Installation
5 Remove the airbag control module assembly.
- Tighten the curtain airbag bracket bolts to 9 ± 1N.m. Installation
34-8
Replacement of Airbag Frontal Impact Replacement of Airbag Side Impact Sensor

Sensor Removal
Removal
1 Disconnect the negative battery cable. 2 Remove the B-pillar lower trim panel (refer to
2 Remove the front bumper assembly (refer to Replacement of B-pillar Lower Trim Panel).
Replacement of Front Bumper Assembly). 3 Disconnect the electrical connector.
3 Disconnect the electrical connector. 4 Remove 1 bolt securing the airbag side impact
4 Remove 1 bolt securing the airbag frontal impact sensor to B-pillar.
sensor to the lower radiator beam.
GS230010
GS230009
5 Remove the airbag side impact sensor
5 Remove the airbag frontal impact sensor assembly.
assembly.
Installation
Installation
34-9
34-10
Body Control System
Body Control System
Torque
Bolt - body controller 9 ± 1.5

Nut - body controller 9 ± 1.5
Body Controller Parameters
Items Requirements Remarks
Operating voltage range DC9V~DC16V With the wires connected, all functions works
properly
Operating temperature range -40~+80 ℃
Storage temperature range -40~+80 ℃
Static current Below 3mA
Reverse pressure resistant 16V
Maximum operating humidity 95%
High pressure resistant +28V
Insulation pressure resistant Above 500M Ω , DC500V high Applicable to components with insulation
resistance gauge requirements such as power OFF switch
(between each terminal and applied with moisture-proofing coating
housing case)
Gateway Parameters
Items Requirements
Rated operating voltage 13.5 ± 0.5V

Normal operating voltage range 9~16V
CAN operating voltage range 6~28V
LIN operating voltage range 6~18V
Static current ≤ [email protected]

Operating current ≤ 200mA (reserved function is not enabled, and CAN
communication load rate less than 30%).
Operating temperature -40 ℃ ~+85 ℃
35-1
Body Control System
Layout
Layout
GS260001
1 Body control module
35-2
Body Control System
Layout
GS260002
1 Gateway
35-3
Body Control System
Layout
1
2
ES280002
1 Rain/solar sensor 2 Driver assist controller
35-4
Body Control System
Repair Guidance
Replacement of Body Control Module
Gateway Replacement
Removal
Removal
2 Remove the left A-pillar lower trim panel.
2 Remove the seat assembly (refer to
3 Disconnect the harness connector. Replacement of Driver and Front Passenger
4 Remove 4 nuts fixing the BCM to the bracket. Seats).
3 Lift the carpet assembly.
5 Remove 3 nuts securing the gateway to the floor.
GS260003
5 Remove the BCM assembly.

6 Remove 3 bolts fixing the BCM bracket to the GS260005
dash panel.
6 Remove the gateway assembly.
Installation
GS260004
7 Remove the BCM bracket.
Installation
35-5
Body Control System
Replacement of Driver Assist System Replacement of Rain/Solar Sensor

Controller Removal
Removal
1 Disconnect the negative battery cable. 2 Remove the cover of the rain/solar sensor.
2 Remove the cover of the rain/solar sensor. 3 Disconnect the electrical connector.
4 Remove the driver assist system controller from
rain/solar sensor base.
GS260007
4 Remove the rain/solar sensor assembly.

GS260006
Caution: Please immediately paste 2 holes on the

camera bracket and camera with the sticker to
avoid the entrance of impurities and moisture
when removing the forward camera.
Installation
GS260008
Installation
35-6
Body Control System
IPK
BO 㓺ਾԠ㺞
LDW SWITCH
䖜䚉‫⿱څ‬人䆜ᔶީ
TCU
PT ਎䙕ಞ᧝࡬ঋ‫ݹ‬
ESP
⭫ᆆどᇐ᧝࡬㌱㔕 CH
DAS GW BCM
傴催䖻ࣟ㌱㔕 CH 㖇ީ NIFO 䖜䓡᧝࡬⁗ඍ
SAS
䖢ੇ䀈Ֆ᝕ಞ CH
ECM
PT ਇࣞᵰ᧝࡬⁗ඍ
ABS/ESP
䖢ੇ䀈Ֆ᝕ಞ CH
FICM
BO ၧ҆‫ؗ‬ᚥ᧝࡬⁗ඍ
⺢㓵 ࣑ࣞ儎䙕CAN㓵䖜䓡儎䙕CAN㓵 ၧ҆儎䙕CAN㓵

ᓋⴎ儎䙕CAN㓵
GS260009
35-7
Body Control System
When the driver has no intention of departing from the Description

original lane (does not enable the direction indicator
Mounting Location:
lamp), the lane departure warning system (LDWS) can
send an alarm by sound and light before the departure to BCM is on the left front panel of the A-pillar.
alert the driver to correct the direction. It prevents
BCM consists of the low power microprocessor,
entrance into other lanes and even the collision with other
electrically erasable programmable read-only memory
vehicles, thus dramatically reducing collisions due to
(EEPROM), CAN and LIN transceiver and power supply.
departure.
It contains discrete input/output terminals which controls
Function Description most of the body functions. It interacts with other primary
electrical systems via HS CAN bus and with other
1 When the power mode is switched to KL15, the secondary electrical systems via LIN bus. The power
LDWS activates the alarm function
mode master control module (PMM) of the BCM provides
automatically. The user can disable the alarm
function manually, then the yellow warning lamp power for most of the vehicle electric components.
on the instrument will alert the user that the
BCM communicates directly with the following
function is disabled.
components via body HS CAN bus:
2 When the vehicle speed reaches 60km/h, the
LDWS enables the alarm function, then if the ·PLG (power liftgate control module)
vehicle departs from the lane and goes across
the lane line, the system gives an alarm by ·HVAC
sound and light; when it speeds down to 50km/h,
the LDWS stops the alarm function. ·PEPS control module
3 The LDWS can accurately detect and identify the ·GATEWAY

following lane lines:
·DSM (driver seat memory module)
a. Solid line and dash line;
·TMPS (tire pressure monitoring system)
b. Single solid line and double solid line;
And BCM communicates directly with the following
c. White and yellow lines; components via LIN bus:
4 The LDWS can accurately detect and identify ·SR (sunroof)

lane line on roads with a turning radius greater
than 250m and straight roads. ·SS (sunshade)
·IMMO (low frequency immobilizer coil)
·RLS (rain sensor)
·PWM (power window regulator motor)
35-8
Body Control System
transportation mode may have restrictions on some

Operation
functions of the electric component, as follows:
When the ignition switch is turned on, BCM will wake up
the security system, lighting system and diagnostic ·The rear fog lamp does not work when the engine is off.
system. When the ignition switch is in the "AUX" position,
·The front fog lamp (if equipped) does not work when the
the BCM allows the washer/wiper and power window
engine is off.
system to operate. When the ignition switch is in the
"IGN" position, the fuel system starts to work, and BCM ·The high beam headlamp does not work when the
communicates with other ECUs via CAN and LIN bus. engine is off.
Load Management ·The low beam headlamp does not work when the
BCM can manage the load of some electric appliances engine is off.
by configuration and ensure low battery power
·The reverse lamp does not work when the engine is off.
consumption during storage and transportation or idle
time. ·The parking lamp does not work when the engine is off.
Production Mode ·The direction indicator lamp does not work when the
The mode configured for BCM during vehicle assembly. engine is off.
Transportation Mode ·The daytime running lamp (if equipped) does not work
After vehicle assembly, program the BCM so that the when the engine is off.
transportation mode can be used during transportation.
·The auto lighting control (if equipped) does not work
This can avoid severely low battery when delivering the
when the engine is off
vehicle to the local Authorized Repairer. The
·"Follow Me Home" and "Vehicle Locating" functions
cannot be used.
·When the engine is off, the hazard warning lamp

backlight does not work, but the function of this lamp is
not affected.
·When the engine is off, the window can be ascended,

but cannot be descended.
With the aftermarket scan tool, the local Authorized

Repairer can change the configuration of the vehicle load
management from transportation mode to normal mode.
35-9
Body Control System
Normal Mode
The normal mode is the default setting, in this mode, the
vehicle can function properly.
Sleep Status
With the ignition switch OFF, and the CAN and LIN buses
disabled, if the battery is still connected, BCM will stay in
sleep mode and be prepared for receiving the signal from
CAN and LIN buses.
Wake-up Status
In sleep mode, when one of the following operations is
done, BCM will be waked up.
·Activation signal of hazard warning lamp switch is

received.
·Activation signal of direction indicator lamp switch is

received.
·LOCK signal of internal lock is received.
·UNLOCK signal of internal lock is received.
·Activation signal of driver door switch is received.
·Activation signal of passenger door switch is received.
·Activation signal of engine hood switch is received.
·Activation signal of tailgate switch is received.
·Activation signal of tailgate release switch is received.
·Activation signal of driver door lock switch is received.
·Activation signal of driver door unlock switch is received.
·The ignition switch is in the 1st position.
·The ignition switch is in the 2nd position.
·Signal of depressing brake pedal
·SSB data (PEPS)
·Activation signal of internal lamp switch
·Wake-up signal from LIN bus
·Wake-up signal from CAN bus
·Wake-up signal from local hard wire
·Valid radio frequency signal
35-10
Body Control System
Load Management
At the moment when the engine is started, to ensure the
starter motor can obtain the maximum current required,
the power of some electric loads shall be disconnected.
For example, disconnect the heated rear window (HRW)
and DISABLE switch of the intelligent Stop/Start fuel-
saving system, and power off the front fog lamp (if
equipped), high beam headlamp, reverse lamp, horn,
internal lighting, etc.
Diagnosis
BCM monitors all the information input and output, if

faults are detected, the corresponding DTCs will be
stored in fault records. BCM can detect the short and
open circuits as well as wrong CAN and LIN bus signals.
When the fault is detected, BCM will close the
corresponding functions. When the fault is eliminated, the
corresponding function will be activated when the
function is requested next time.
BCM can exchange information with the aftermarket

scan tool through the DLC. DLC is located in the driver
side instrument closure panel (on driver's leg) and is
made according to ISO Standards. There is a special
diagnostic bus between the gateway and the TBOX. The
diagnostic bus allows to read the diagnostic information
with the scan tool and program some functions.
35-11
Body Control System
35-12
PEPS and Immobilizer System (with key start)
PEPS-ECU Parameters
Items Parameters Remarks
Normal operating voltage 9V~16V
Normal operating voltage (start-related 9V~16V

functions)
Static current <3mA

Storage temperature -40 ℃ ~+85 ℃
Frequency of controller receiving 433.87MHz
center
Modulation mode ASK
Receiving sensitivity <-80dBm
RKE Parameters

Normal operating voltage range 2.35V~3.5V
Static current <6uA
Frequency of low-frequency receiving 125kHz

center
Frequency of radio frequency 433.87MHz

transmission center
Pressure 11 ± 2N
Stroke 0.4~0.8mm
Waterproof/dustproof grade IP5K7
36-1
Door Handle Antenna Parameters

Operating voltage 0~46V
Operating current 0~1020mAp
Resonant frequency 125KHZ ± 5%

Impedance <30 Ω
Parameters of Low-Frequency Antenna

Inside the Vehicle

Operating voltage 9v~16v
Operating frequency 125KHZ
Modulation mode ASK
Inductance 491uH
Capacitance 3.3nF
Tailgate Antenna Parameters

Static current Below 1mA
Case material PBT GF15
Dustproof and waterproof grade IP5K3
Operating current 200mA~1A
36-2
Layout
Layout
GS240001
1 Ceiling LF antenna 6 Low-frequency antenna inside the vehicle

2 Remote control receiving module 7 Front door handle antenna
3 Tailgate antenna 8 PEPS controller ECU
4 Tailgate induction open sensor 9 Start-stop switch
5 IMMO base station
36-3
Repair Guidance Replacement of Low-Frequency Antenna

(Auxiliary Fascia Console) Inside the Vehicle
Replacement of Low-Frequency Antenna
(Instrument Panel) Inside the Vehicle Removal
Removal 1 Disconnect the battery (negative first).

2 Remove the front A/C control panel assembly Console Assembly).
(refer to Replacement of Front A/C Control Panel
Assembly). 3 Disconnect the antenna connector.
3 Disconnect the antenna connector. 4 Screw out 2 fastening screws, and remove the
low-frequency antenna (auxiliary fascia console)
4 Screw out 2 fastening screws, and remove the inside the vehicle.
low-frequency antenna (instrument panel) inside
the vehicle.
GS240003
GS240002
Installation
Installation 1 Installation is the reverse of removal.
36-4
Replacement of Ceiling Low-Frequency Replacement of Tailgate Antenna

Antenna Removal
Removal
1 Disconnect the battery (negative first). 2 Raise the vehicle on a lifting machine.
2 Remove the driver compartment ceiling interior
3 Remove the tailgate antenna connector from
assembly (refer to Replacement of Driver
rear bumper assembly.
4 Disconnect the tailgate antenna connector.
3 Disconnect the antenna connector.
5 Remove the tailgate antenna from rear bumper.
4 Remove 2 connecting screws from ceiling low-
frequency antenna.
GS240005
GS240004
5 Remove the ceiling low-frequency antenna. Installation

Installation
Replacement of Front Door Handle Antenna

Removal
2 Remove the outer pull rod assembly of front door
outer handle (refer to Replacement of Front Door
Outer Handle).
3 Remove the front door handle antenna from the

handle assembly.
Installation
36-5
Replacement of Tailgate Induction Open Replacement of PEPS Controller ECU

Sensor Removal
Removal
1 Disconnect the battery (negative first). 2 Remove the glove box assembly (refer to
2 Raise the vehicle on a lifting machine. Replacement of Glove Box Assembly).
3 Remove the tailgate antenna connector from 3 Disconnect the connector of PEPS controller.
4 Screw out the fastening nut, and remove the
4 Disconnect the tailgate antenna connector. PEPS controller ECU.
5 Remove the tailgate antenna from rear bumper.
GS240007
GS240006
Installation
Installation 1 Installation is the reverse of removal. Pay

- After replacing PEPS controller ECU, the controller
configuration shall be completed with diagnostic software
according to actual vehicle configuration.
- The tightening torque is 9 ± 1N.m.
36-6
Replacement of Start-Stop Switch Replacement of Clock Spring Assembly and

Removal Clock Spring Returning Ring
Removal
2 Remove the driver side instrument panel lower 1 Remove the steering wheel assembly (Refer to
guard plate assembly (refer to Driver Side Replacement of Steering Wheel Assembly).
Instrument Panel Lower Guard Plate Assembly). 2 Remove the upper and lower steering column
shrouds (refer to Replacement of Upper and
3 Disconnect the start-stop switch connector.
Lower Steering Column Shrouds).
4 Remove the start-stop switch.
3 Remove the clock spring assembly and the clock
spring returning ring.
Installation
- The clock spring is retained with a pin, which shall not
be pulled out before installing the steering wheel,
otherwise the clock spring will rotate freely and deviate
from the center position.
- When installing the steering wheel, pull out the pin to

GS240008
confirm whether the clock spring is at the center position
(if a yellow mark is visible on the clock spring surface
window, it means the spring is centered). If yes, fix the
Installation
steering wheel.
- If not, adjust the spring to the center position, and then
install the steering wheel.
- Removal/installation of the clock spring may cause the

position change to the steering angle sensor, please
carry out zero calibration for the steering angle sensor
with an aftermarket scan tool after the installation (if not
calibrated, ESP warning indicator may keep ON).
36-7
Replacement of Immobilizer Base Station Replacement of Remote Control Receiving

Removal Module
Removal
(refer to Replacement of Auxiliary Fascia 1 Disconnect the battery (negative first).
Console Assembly).
2 Remove the rear side body trim panel (left), and
2 Remove 3 screws securing the immobilizer base disconnect the cable of remote control receiving
station to the cup holder. module.
3 Remove the remote control receiving module.
GS240009
GS240010
Installation
1 Installation is the reverse of removal. Installation
1 Installation is the reverse of removal. Note that
sealant shall be applied before installation.
36-8

PEPS System Control Diagram
IMMO
Trunk Switch LIN 䱨ⴍ㓵ാ
㺂ᶄ㇧ᔶީ
GW ECM
BO 㖇ީ PT ਇࣞᵰ᧝࡬⁗ඍ
BCM
BO 车身控制模块
Door Lock
ESCL 䖜䰞䬷
⭫ᆆ䖢ੇ㇗ḧ䬷 LIN
Facia LF Antenna
IPK PEPS
ք仇ཟ㓵ࢃ
㓺ਾԠ㺞 BO ᰖ䫛ॏ䘑
‫ૂޛ‬䎭ࣞ
Console
LF Antenna
ք仇ཟ㓵ѣ
Smart Key
Ჰ㜳䫛ॏ
Start Stop Button
ж䭤䎭ࣞ᤿䫤 Body LF Antenna
ք仇ཟ㓵䖜京
Bumper
LF Antenna
ք仇ཟ㓵੄ؓ䲟ᶖ
Touch PAD Switch

᝕ᓊᔶ੥ᔶީ HSC
䖜䰞ཌᣀᢁ
ཟ㓵਀ᔶީ
⺢㓵 LIN㓵 ࣑ࣞ儎䙕CAN㓵䖜䓡儎䙕CAN㓵 ሺ仇‫ؗ‬ਭ
GS240011
36-9
Immobilizer System Control Diagram
Remote Key Ignition Switch

䚛᧝䫛ॏ ⛯⚡ᔶީ
ECM BCM IMMO

ਇࣞᵰਙ᧝࡬⁗ඍ PT 䖜䓡᧝࡬⁗ඍ LIN ք仇䱨ⴍ㓵ാ
GW
㖇ީ BO
IPK
㓺ਾԠ㺞 INFO
⺢㓵 ࣑ࣞ儎䙕CAN㓵䖜䓡儎䙕CAN㓵 ሺ仇‫ؗ‬ਭ LIN㓵
GS240012
36-10
smart key can receive LF signal and communicate with

Overview
the BCM to lock/unlock the vehicle.
For vehicles with PEPS, the traditional key is replaced by
the smart key, the operation of PEPS is achieved by LF/ Normal Locking/Unlocking Operation
RF (wireless) communication between the smart key and The smart key detects the 125kHz LF electromagnetic
the vehicle. field signal from the LF antenna and exterior door handle
antenna/switch (HSU). The smart key sends an RF
·Passive entry: No action is required for the smart key.
signal within the 433MHz ISM band and gives a
You just need to take the smart key with you, and you can
response when it appears in the coverage area of the LF
enter into your vehicle by simply pressing the button on
antenna.
the door handle and pulling the handle.
Function of Smart Key in PEPS
·Passive start: Without inserting/pulling out the key, you
just need to put the smart key in the vehicle and press the The PEPS shall have smart keys.
start/stop button (SSB) to start/stop the vehicle.
Effect of Smart Key on Vehicle Access
The PEPS includes: PEPS ECU, smart key, interior LF ·PEPS mode (passive entry): The smart key receives the
antenna, exterior door handle antenna/switch (HSU) and LF signal and sends the RF signal to complete the
rear bumper upholstery LF antenna. authentication and matching in the LF coverage area.
Mounting Location Remote key entry mode: When pressing the button on
·PEPS ECU: under the instrument panel (front the key, the authentication code transmitted by the RF
passenger side). signal will be used as the LOCK/UNLOCK request for the
doors or tailgate.
·Exterior door handle antenna/switch (HSU): installed
inside the front door exterior handle. ·Exhaustion mode of the smart key lithium battery: The
smart key is provided with a mechanical key matching
·3 LF antennas in the vehicle: respectively installed on A/ the vehicle lock, use the mechanical key to lock/unlock
C box assembly, the centerline at the lower part of the vehicle.
auxiliary fascia console and ceiling.
Effect of Smart Key on Vehicle Start
·Rear bumper upholstery LF antenna: on the centerline
of the rear bumper upholstery bracket. ·PEPS mode (passive start): The smart key receives the
LF signal and sends the RF signal to complete the
Operation of Passive Entry and Passive Start authentication and matching.
(PEPS)
·Low battery mode of the smart key: The smart key shall
In the vicinity of the closed door and in the driver
be close to the spare coil. Then, use the BCM to perform
compartment, the PEPS can monitor and identify the
the authentication of the smart key in the transponder
smart key.
mode.
Function of CAN Bus in PEPS
In order to inform the operator to replace the battery in
The PEPS communicates with other ECUs via CAN bus. time, the smart key applies the RF signal transmitted to
the IPK by BCM, and the general message display will
Identifier/Smart Key show "Low Key Battery, Please Replace!".
The smart key is a hand-held electronic device which is
Once the button on the smart key is pressed, this
powered by the lithium battery. Each vehicle is provided
operation will be regarded as the default RF request
with 2 matching smart keys. Once the match is finished,
signal of the remote key entry. When the button is
the smart key can perform LF/RF communication in the pressed for more than 20s, the smart key will stop
PEPS. As long as the lithium battery provides power, the
36-11
transmitting the RF signal until the button is released and LF Antenna

pressed again. The independent LF transmitter consists of 3 internal LF
The management system of smart key/identifier permits antennas and 1 rear bumper upholstery antenna. To
to handle 4 identifiers at one time. ensure the smart key can receive the signal in the
coverage area, the transmitter generates the LF
When leaving the factory, 2 matching smart keys are magnetic field signal of the 125kHz band.
provided generally, and the smart key can be added or
deleted during the subsequent aftersales diagnosis. Function of LF Antenna in PEPS
Smart key addition and deletion are the tasks of BCM, The LF antenna transmits LF signal in the PEPS and
and BCM will inform the PEPS ECU that a new key is communicates with the smart key.
added or an old key is deleted.
Internal LF Antenna
Exterior Door Handle Antenna/Switch (HSU)
The internal LF antenna, which is necessary for the
Exterior door handle antenna/switch (HSU) is an PEPS system, sends the LF signal to the smart key
assembly of the LF antenna and switch. It connects to which sends the authentication information to BCM via
PEPS ECU, the PEPS ECU generates current for the LF the LF signal. After the legal authentication is passed, the
antenna engine will be allowed to start.
to form the magnetic field. The PEPS ECU reads the The internal LF antenna can also be used to search the
status of the switch, i.e. detects the action of the operator. smart key in the driver compartment and determine if the
The PEPS ECU and HSU are connected by stranded vehicle can be locked, this prevents the operator from
wires. leaving the smart key in the vehicle when locking the
Function of Exterior Door Handle Antenna/Switch (HSU) vehicle. Although the vehicle cannot be locked when it is
in PEPS detected that the smart key is in the driver compartment,
it is necessary to alert the operator that the current
The LF antenna is used to generate an LF security system is vulnerable. As a matter of fact, the
electromagnetic induction area near the door so that the internal LF antenna is designed to search the valid smart
operator can lock/unlock the door switch. Only when a key in the vehicle. Therefore, the radiation area of the
matching smart key is detected in the LF antenna antenna shall cover the entire area inside the vehicle. If
coverage area, and the LOCK/UNLOCK request the valid smart key can receive the signal from the
received matches the status of the door lock, can the lock internal LF antenna and give a response, it indicates that
and unlock operation be performed. the smart key is in the driver compartment.
After the operator finishes the operation of the HSU, the LF Antenna of Rear Bumper Upholstery
PEPS ECU will generate and transmit current to the HSU
In the passive entry system, the antenna of the rear
LF antenna to generate the electromagnetic field signal.
bumper upholstery is used to separately open the
The operator's smart key
tailgate. However, it cannot be used for the passive start.
can detect/receive the electromagnetic field signal and The function of the rear bumper upholstery antenna is to
give a response to BCM via the RF signal, and the PEPS send the LF signal to the smart key near the tailgate, and
validates the legality of the key and unlocks the door then the smart key returns signal to BCM. So, the
eventually, this ensures access of the legal user. radiation range of the antenna shall be a small area near
the trunk. After necessary authentication is completed,
HSU coverage area:
open the tailgate. When the key is outside the vehicle, the
HSU coverage area: appr. 1.5m around the center of the
door handle surface.
36-12
radiation area of the bumper upholstery antenna is 1m When the engine is running, within a certain vehicle
above the ground, and the radius is within 1.0m. speed, press the SSB to stop the engine.
If the smart key in the vehicle makes a response to the PEPS ECU
antenna of the rear bumper upholstery (i.e. LF signal PEPS ECU contains the system software controlling the
from the internal antenna and that from the antenna of operation of the PEPS. The PCB circuit board of PEPS
rear bumper upholstery detects a smart key ECU contains the interface circuit of all PEPS
simultaneously), then the smart key cannot open the components and the interface used to communicate with
tailgate or unlock the vehicle. In this case, other vehicle controllers.
if the valid smart key gives a response to the signal from

the antenna of the rear bumper upholstery, it indicates
that the smart key is near the tailgate. Once the tailgate
switch is pressed and the operation is authorized,
BCM releases the tailgate switch.
Start-Stop Button (SSB)

The start-stop button (SSB) is on the instrument panel of
the driver compartment, which is used for requesting the
engine to start and stop. When the engine does not start,
different power modes (ACC, IGN) can be selected. The
SSB is integrated with the backlight control, it provides
the operator with the power mode and indicates whether
the conditions for starting the engine are met by changing
the internal yellow and green LED lamps.
The SSB has two identical parts. The first part connects
to the BCM, and the second part connects to the PEPS
ECU. The PEPS ECU will monitor the second part, BCM
receives the power status CAN information from the
PEPS ECU and determines whether to handle it. Unless
an error occurs, these two parts work together.
Function of SSB in PEPS
The SSB is used to start/stop the engine or shift the

vehicle status to "ACC" and "IG" and indicate the power
status of the vehicle. The SSB is used for the passive
start system, and it does not work for the passive entry
system.
The authorized operator should complete the following

start requests:
Automatic transmission: When the transmission shift

lever is in "P" gear or "N" gear, depress the brake pedal,
and press start-stop button (SSB) to start the engine.
36-13
36-14
Retained Accessory Power (RAP)
Torque
Nut - DC stabilizer assembly 9 ± 1.5
DC Stabilizer Parameters
Operating humidity 25% ～ 80%

Dustproof grade IP5K
Operating temperature -40 ～ +85 ℃ Outside ambient temperature for controller operation
Storage temperature -40 ～ +90 ℃ Outside ambient temperature for static storage of power-
off controller
The normal operating voltage of the logic power of DCDC controller is 6 ～ 16V, the nominal operating voltage is 14V, the
static current is less than 0.1mA.
On-board Inverter Parameters
Operating voltage 10.5 ～ 15.5V

Operating temperature -40 ～ -75 ℃
Storage temperature -40 ～ -85 ℃
Static current ≤ 0.1mA
Reverse pressure resistant Reverse polarity protection Fractured external fuse due to reverse
Transfer efficiency ＞ 90%typ

Waveform distortion rate ＜ 10%
Unload current ≤ 500mA
37-1
Layout
Layout
GS270001
1 DC stabilizer assembly 2 On-board inverter assembly
37-2
Layout
GS270002
1 Cigar lighter assembly 2 Power outlet
37-3
Repair Guidance
Replacement of On-board Inverter Assembly 6 Remove 3 nuts securing the on-board inverter to
the front floor.
Removal
2 Remove the rear panel assembly of the auxiliary
fascia console.
GS270005
8 Remove the on-board inverter assembly.

GS270003
3 Pry off the on-board inverter outlet.

Installation
GS270004
4 Remove the seat assembly (refer to

Replacement of Seat Assembly).
37-4
Replacement of DC Stabilizer Assembly Replacement of Cigar Lighter

Removal Removal
2 Remove the seat assembly (refer to 2 Remove the front storage box.
Replacement of Seat Assembly).
4 Remove 2 nuts securing the DC stabilizer to the
front floor.
GS270007

4 Remove the cigar lighter assembly.
GS270006
5 Remove the DC stabilizer assembly. Installation

Installation
37-5
Replacement of Power Outlet Description and Operation

Removal DC Stabilizer
1 Disconnect the negative battery cable. The DC stabilizer stabilizes the supply voltage for vehicle
2 Pry off the power outlet. start and operation of the electrical devices on the
3 Disconnect the electrical connector. vehicle.
The electrical devices are powered by the vehicle power,

such as the audio system, radio, air conditioning system,
etc, driving may affect the vehicle circuits and cause
unstable voltage, so if you do not add a stabilizer, the
unstable voltage will affect the electrical devices, for
example, the volume of the audio system will goes up
and down, the air conditioning will give cool air at one
moment and give no air at the next moment, etc.
Use of the stabilizer allows you to maintain normal

operation of the electrical devices on the vehicle,
besides, it also stabilizes the circuit for starting the vehicle
GS270008
and achieves stable and effective ignition.
4 Remove the power outlet assembly. On-board Inverter

The 220V on-board inverter is on the floor control seat
between the driver and the front passenger. It provides a
Installation convenience interface primarily for the laptop, portable
1 Installation is the reverse of removal. printer and small electrical appliance for daily office work,
etc.
Its output power is 150W. When the ignition switch is in

"ACC" position, the on-board inverter works. When using
it, please note the power status indicator beside the outlet
and follow the indication of the indicator.
1 Green light: normal operation.

2 Light off: the battery voltage is low, please
remove the electrical device and wait the battery
voltage to resume.
3 Red light flashes: the battery voltage is high,

please wait the battery voltage to resume; the
220V supply is hot, please remove the electrical
device powered by the supply, and wait the
green light to illuminate; 220V supply output
overloads, please remove the electrical device
powered by the supply, normal operation can be
resumed by restarting the engine; outside circuit
is short, please remove the electrical device,
normal operation can be resumed by restarting
the engine.
37-6
Parking Assist System
Parking Distance Control, Radar Sensor and
Camera
Items Parameters
Voltage range DC9V ～ DC16V

38-1
Layout
Layout
GS280001
1 Parking distance control
38-2
Layout
1
2
GS280002
1 Front camera 3 Front bumper radar sensor bracket

2 Front bumper radar sensor 4 Side camera
38-3
Layout
3
1
GS280003
1 Rear bumper radar sensor bracket 3 Rear camera

2 Rear bumper radar sensor
38-4
Repair Guidance
Replacement of Parking Distance Control
Replacement of Front Bumper Radar Sensor
Removal and its Bracket
1 Disconnect the negative battery cable. Removal
2 Remove the seat assembly (refer to Seat 1 Disconnect the negative battery cable.
Assembly Replacement).
2 Remove the front bumper assembly (refer to
3 Lift the right front carpet. Replacement of Front Bumper Assembly).
4 Disconnect the harness connector. 3 Disconnect the harness connector.
5 Remove 2 nuts securing the parking distance
control to the front floor.
GS280005
GS280004 4 Loosen the clip fixing the sensor to the sensor

bracket.
6 Remove the parking distance control assembly. 5 Remove the front bumper radar sensor and its
bracket.
Installation
GS280006
Installation
38-5
Replacement of Rear Bumper Radar Sensor Replacement of Front Camera

and its Bracket Removal
Removal
1 Disconnect the negative battery cable. 2 Remove the front grille assembly.
2 Remove the rear bumper assembly.
GS280009
GS280007
4 Loosen the clip fixing the sensor to the sensor 4 Remove the front camera assembly.
bracket.
5 Remove the rear bumper radar sensor and its
bracket.
GS280010
GS280008
Installation
Installation
38-6
Replacement of Rear Camera

Removal
2 Remove the license plate trim panel assembly
(refer to Replacement of License Plate Trim
Panel).
GS280011

4 Remove the rear camera assembly.
GS280012
Installation
38-7
will send an acoustic alarm. The system is able to detect

hard solid objects and objects like wire fence.
Parking distance control (PDC) system is a safety assist
device for parking or reversing the car. It consists of rear If the rear camera is provided, the image of the vehicle
camera, ultrasonic sensor, radar sensor and parking rear area will be displayed on the navigation display.
distance control. During reversing, the front display can
If a 360° panoramic imaging system is installed, the
show the real-time video of the rear camera so that the image around the vehicle will be provided on the
safe parking can be realized. navigation screen.
Description Ultrasonic Sensor (if equipped)

Rear Obstacle Detection (if equipped)
The ultrasonic sensors are fixed on the front/rear bumper.
During reversing, if the vehicle has to go through All the sensors share the same structure, with the color
obstructions on the road, the PDC system will send a matching the vehicle.
warning to the driver. The system consists of four
The detection range of the 4 sensors on the rear bumper
ultrasonic sensors installed on the rear bumper, PDC
is the area 1500mm away from the rear bumper.
ECU and instrument cluster, entertainment mainframe
and the speaker controlled by the entertainment The detection range of the 4 sensors on the front bumper
mainframe. is the area 1500mm away from the front bumper.
When the vehicle is in reverse gear, PDC ECU uses PDC Switch (if equipped)
ultrasonic sensors to monitor the area around the rear
The PDC switch is a soft switch on the entertainment
bumper, if the monitor detects an object within the area,
screen, the PDC cannot be disabled when the vehicle is
the acoustic alarm in the instrument cluster or the
in "R" gear. When the vehicle is in the "N" gear or "D"
speaker controlled by the entertainment mainframe will
gear, press the PDC switch on the display interface to
send an acoustic alarm. The system is able to detect
manually enable/disable the front/rear PDC, this switch is
hard solid objects and objects like wire fence.
used to detect the obstacle around the vehicle.
Front Obstacle Detection (if equipped)
Parking Distance Control Module (PDC ECU)
The feature of the front obstacle detection: when
PDC ECU is behind the trim panel of the left luggage
reversing or driving away, if the vehicle has to go through
compartment. It is connected with the sensor by
obstructions on the road, the PDC system will send a
harnesses, when the system is activated, PDC ECU
warning to the driver. The system consists of four
outputs signal to the sensor and acoustic device and
ultrasonic sensors installed on the front bumper, PDC
receives the distance information from the sensor.
ECU and instrument cluster, entertainment mainframe
and the speaker controlled by the entertainment Acoustic Alarm
mainframe. When the vehicle is in reverse gear, PDC
The acoustic alarm in the instrument cluster and the
ECU uses ultrasonic sensors to monitor the area around
speaker controlled by the entertainment mainframe can
the front bumper, if the monitor detects an object within
send an audible alarm to inform the driver of the system
the area, the acoustic alarm in the instrument cluster or
status and presence of obstacles in the monitoring area.
the speaker controlled by the entertainment mainframe
Rear Camera (if equipped)
The rear camera is between the two license plate lamps

under the tailgate, it can provide the driver with real-time
38-8
image around the rear of the vehicle and facilitate the

Operation
reverse operation.
When the ignition switch is in the "II" position and the
360° Panoramic Imaging System (if equipped) reverse gear is selected, the system runs. When the
reverse gear is selected, ECU will activate the system
The 360° panoramic imaging system includes 4
after 1s delay.
cameras which provide the driver with the view around
the moving vehicle and enable the driver to control the After ECU receives the information that the R gear is
vehicle in a more reliable and more secure manner. selected, it starts the ultrasonic sensor and inputs signal
to the speaker, then the speaker will give an acoustic
1. Front camera: under the vehicle logo.
alarm, this indicates that the system is activated. Then,
2. Side camera: under the left/right exterior rearview ECU receives distance reading from the ultrasonic
mirrors. sensor and determines whether there is any object in the
detection zone. If no objects within the detection range, it
3. Rear camera: between the two license plate lamps.
will not issue an audible alarm; if there are objects
detected, ECU outputs signal to the speaker to produce a
repetitive audible alarm.
From the detection range margin, about 1500mm away

from the vehicle tail part, 1500mm away from the vehicle
front part, the frequency of the alarm increases with the
decrease of the distance between the detected object
and the vehicle, until the distance from the vehicle
reaches about 300mm and the audible alarm becomes
consecutive alarm.
If the vehicle is installed with a draw bar, ECU will detect

the towing eye/draft ball from the input information of the
sensor, and in order to compensate the towing eye/draft
ball, delay the system activation to prevent invalid alarm
when shifting between D gear and P gear.
38-9
38-10
Tire Pressure Monitoring
Torque
Screw/bolt - tire pressure monitoring 9 ± 1.5
Controller Performance Index
Items Requirements
Operating current ≤ 100mA

Static current ＜ 1mA
Receiving center frequency 433.92MHz
Receiving sensitivity ≤ -95dBm

Communication with instrument CAN
Operating temperature -40 ～ +85 ℃

Storage temperature -40 ～ +90 ℃
39-1
Layout
Layout
GS290001
1 Tire pressure monitoring control module
39-2
Repair Guidance Replacement of Tire Pressure Sensor
Replacement of Tire Pressure Monitoring Removal

Control Module 1 Remove the wheel assembly (refer to
Removal Replacement of Wheel Assembly).
2 Remove the tire.
3 Remove the tire pressure sensor assembly.
2 Remove the rear body side interior trim panel
assembly (refer to Replacement of Rear Body
Side Interior Trim Panel Assembly).
4 Remove 2 bolts fixing the tire pressure
monitoring control module to the rear body side
interior panel assembly.
GS290003
Installation
GS290002
5 Remove the tire pressure monitoring control

module assembly.
Installation
39-3
Instructions for Handheld TPMS Match Keyboard

Tool
1 Keyboard schematic
1. Introduction of Handheld TPMS Match Tool
Overview
The handheld TPMS match tool is used for the factory 读左前轮信息
Read LF Tire
读右前轮信息
Read RF Tire
中文
English
match and fault diagnosis of the TPMS tire pressure 读左后轮信息

Read LR Tire
读右后轮信息
Read RR Tire
匹配
Match
monitoring sensor and tire pressure controller, which

ensures normal operation of the TPMS.
OK
Package
1 2 3
1 1 handheld TPMS match tool
4 5 6
2 1 SD card
7 8 9
3 1 OBDII adapter ESC 0 DEL
DS380006
4 1 battery charger
Appearance 2 Keyboard function
Button Function
Read LF tire Enable the function to read LF tire
information information by quick start in match
mode
Read LR tire Enable the function to read LR tire
mode
Read RF tire Enable the function to read RF tire
mode
Read RR tire Enable the function to read RR tire
DS380004 mode
Chinese/English Switch language
Schematic Diagram Match Enable the function by quick start in
match mode
Direction button Move it to select cursor/page down/up
3.转接线接口
OK Confirm
8.电源开关 4.充电电源接口
Numeric key Shortcut key used to enable functions
corresponding to current menus
1.液晶屏
Numeric keyboard used to set
password or input service command
ESC Exit/cancel
OK
DEL Delete the match function by quick start
2.键盘 in match mode/delete content in the
1 2 3
4 5 6 current input box during password

7 8 9
ESC 0 DEL setting or service command input

5.SD卡接口 6.USB接口
DS380005
39-4
2 Battery and Charging of Handheld TPMS

Match Tool
Rated capacity Nominal capacity 1600mAh Standard discharge 0.2A after standard
Min. capacity 1560mAh charging.
Normal voltage 7.5V Operating voltage

Charging voltage DC12 ± 0.06V
Standard charging Continuous current: 0.5A Charging duration: appr. 4h.
Continuous voltage: 8.4V
Cut-off current: 0.01A
Operating temperature range Charging: 0 ～ 45 ℃
Discharge: -20 ～ 60 ℃
3 Radio Frequency Parameters of Handheld

TPMS Match Tool
1 LF communication parameter
LF transmission 125kHz ± 5kHz

frequency
Baud rate 3.9kbps ± 0.05kbps
Field intensity The sensor is located in the tire based on the actual effect of the communication, the
communication distance is 0.2m-0.5m
Modulation ASK
Encoding Manchester encoding
2 HF communication parameter
HF transmission 433.92MHz ± 200kHz

frequency
Baud rate 9.6kbps
Field intensity Based on the actual effect of the communication, communication at high frequency is greater
than 5m
Modulation ASK
Encoding Manchester encoding
4 Configuration File of Handheld TPMS Natch

Tool
The configuration information of the equipment can be
changed quickly by simply updating the configuration file
in the SD card.
39-5
8 After the process, use the data line to connect

5 Handheld TPMS Match Tool: Match mode
the adapter interface of the OBD and TPMS
1 Place the ignition switch in ON position; match tool (see the figure):
2 Turn on the power switch of the TPMS match

tool;
3 When a saved model configuration is displayed,
press OK button;
4 The following model selection interface occurs:
3/3 选择车型
>SV91-255/55R19
DS380009
>SV91-255/60R18 9 Press OK button to match the data with the
>SV91-255/65R17 control module;
>SV91-265/45R21 10 If it is OK, the interface will prompt Match

Successful;
11 Press ESC to exit, remove the data line and turn
GS290004 off the power switch of the TPMS match tool.
Caution: If the match fails, then turn off the
SV91-255/55R19: 19″ tire switch of the TPMS match tool, and repeat the
match according to the above steps.
SV91-255/60R18: 18″ tire
SV91-255/65R17: 17″ tire
SV91-265/45R21: 21″ tire
5 Model selection is based on the configuration of

the current model;
6 As shown in the figure, select [read LF sensor],
align the TPMS match tool with the LF tire valve,
press OK button to read data;
DS380008
7 Follow the interface prompt to read the tire
pressure parameter in sequence;
39-6

The tire pressure monitoring system uses the tire sensor
to monitor the pressure and/or temperature inside the tire
and sends the pressure and temperature data from the
sensor to the receiver in a form of radio frequency, the
receiver data processed transmit the relevant information
to the display (instrument cluster) by the CAN network,
the LCD will display the information and provide acoustic
and icon warnings, etc when abnormal tire pressure or
temperature occurs
39-7
39-8
Lighting System
Lighting System
Bulb Specification
Bulb Specification
Headlamp low/high beam HIR2
Front turning signal lamps PY21W
Front fog lamps H11
Rear turning signal lamps (I type) PY21W
Reverse lamps (I type) W21W
Brake lamp/rear position lamp (I type) P12/5W
Rear turning signal lamps (II type) WY21W
Reverse lamps (II type) W21W
License plate lamp W5W
Front roof reading lamp W5W
Rear roof reading lamp W5W
40-1
Lighting System
Layout
Layout
4
3
1
2
GS300001
1 Front combination headlamp 5 Rear combination headlamp A

2 Front fog lamp 6 Rear combination headlamp B
3 Front roof interior reading lamp assembly 7 Rear roof interior reading lamp assembly
4 Rear roof interior reading lamp assembly
40-2
Lighting System
Repair Guidance
Replacement of Front Combination
Replacement of Front Fog Lamp
Headlamp
Removal
Removal
2 Remove the front bumper assembly.
2 Remove the front bumper assembly.
3 Remove 4 fastening bolts of the front fog lamp.
3 Remove 4 fastening bolts of the front
combination headlamp.
GS300004
GS300002
4 Disconnect the harness connector. 5 Remove the front fog lamp assembly.
5 Remove the front combination headlamp 6 Remove the inoperative bulb.
assembly.
6 Remove the inoperative bulb.
GS300005
GS300003
Installation
Installation
40-3
Lighting System
6 Remove the inoperative bulb and microphone.

Replacement of Front Roof Interior Reading
Lamp Assembly
Removal
2 Pry off the lampshade.
GS300008
Installation
3 Remove 2 fastening screws of the front reading

lamp.
4 Pry off the front reading lamp assembly.
GS300007
5 Disconnect the harness connector and remove

the front reading lamp assembly.
40-4
Lighting System

Replacement of Rear Roof Interior Reading
Lamp Assembly
Removal
2 Pry off the lampshade.
GS300011
Installation
3 Remove 2 fastening screws of the rear reading

lamp.
GS300010
5 Remove the rear reading lamp assembly.
40-5
Lighting System
Replacement of Rear Combination Headlamp Replacement of Rear Combination Headlamp

A B
Removal Removal
2 Remove 2 fastening bolts of the rear 2 Remove the tailgate interior trim panel (refer to
combination headlamp A. Replacement of Tailgate Interior Trim Panel).
3 Remove 3 fastening nuts of the rear combination

headlamp B.
GS300012
3 Remove the rear combination headlamp A

GS300015
assembly and disconnect the harness connector.
4 Remove the inoperative bulb. 4 Remove the rear combination headlamp B

assembly and disconnect the harness connector.
Installation
GS300013
Installation
40-6
Lighting System
Replacement of Rear Roof Interior Reading Replacement of Rear Height Sensor and
Lamp Assembly Bracket
Removal Removal
2 Pry off the rear roof reading lamp assembly. 2 Disconnect the electrical connector.
3 Remove 2 bolts fixing the rear height sensor and

bracket to the right side member welding
assembly.
GS300014
3 Disconnect the harness connector and remove

the reading lamp assembly. ES220020
Installation
ES220022
40-7
Lighting System
4 Remove 2 nuts fixing the rear height sensor and

Replacement of Rear Combination Lamp
bracket to the rear axle assembly.
Removal
2 Remove 2 bolts fixing the rear combination lamp
to the rear panel mounting plate.
ES220021
5 Remove the rear height sensor and bracket

assembly.
ES220007
4 Remove the rear combination lamp assembly.
5 Remove the inoperative bulbs of position lamp

and brake lamp (1), bulb of turning signal lamp
(2), bulb of reverse lamp (3) and bulb of rear fog
lamp (4).
1
ES220023
2
Installation 3
ES220024
Installation
40-8
Lighting System
5 Remove the inoperative bulb of license lamp.

Replacement of License Lamp
Removal
ES220025
ES220008
Installation
ES220009
2 Pry off the license lamp through the access hole.
4 Remove the license lamp assembly.
40-9
Lighting System
Replacement of Reflex Reflector Replacement of High Mounted Stop Lamp

Removal Removal
2 Remove 2 fastening nuts and 2 washers of the 2 Remove the interior trim panel assembly.
reflex reflector.
3 Press the buckle of high mounted stop lamp with
a flat blade screwdriver through the access hole,
and eject out the high mounted stop lamp.
ES220010
3 Remove the reflex reflector assembly.

ES220011

Installation
5 Remove the high mounted stop lamp assembly.
ES220012
Installation
40-10
Air Conditioning
Air Conditioning
Parameters
Compressor model 7PV18
Compressor displacement 8~175cm3/r
Speed
·Minimum speed 700r/min
·Maximum speed 8000r/min
Lubricating oil PAG
Refill amount 120ml
Evaporator temperature sensor
·Compressor ON ≥3℃
·Compressor OFF ≤1℃

Pressure protection
·High pressure protection opening ≥ 3.14 Mpa, the switch disconnects

pressure
·Low pressure protection opening ≤ 0.196Mpa, the switch disconnects

pressure
Rated voltage 12V
Consumed electric power ≤ 45W

Refrigerant R134a
Refrigerant filling amount Dual-zone A/C 900 ± 30g, single-zone A/C 620 ± 30g
Torque
Bolt - front A/C assembly to IP frame 9±1

Nut - front A/C assembly to IP frame 9±1
Bolt - A/C compressor assembly to engine assembly 22 ± 2
Bolt - A/C pipe to condenser 9±1
Bolt - compressor exhaust pipe 22 ± 2
Nut - cooling pipe pressing plate 9±1
Bolt - compressor intake pipe 22 ± 2
Bolt - upper radiator bracket 9±1
Bolt - intercooler intake pipe to subframe 9±1
41-1
Air Conditioning
Bolt - cooling fan radiator 5±1

Bolt - A/C pipe to front expansion valve pipeline 9±1
Nut - A/C pipe assembly to vehicle body 9±1
Bolt - A/C pipe assembly to vehicle body 9±1
Bolt - transmission oil cooler pipe assembly to transmission 22 ± 2
Bolt - transmission oil cooler water inlet pipe assembly to 9±1
middle third beam
Bolt - rear A/C air duct to vehicle body 5±1

Bolt - tightening front A/C intake/outlet pipe assembly to 9±1
right front wheelhouse panel of body
Nut - compressor intake pipe assembly and condenser 9±1

outlet pipe assembly
Bolt - A/C pipe to front expansion valve pipeline 9±1

Nut - A/C pipe assembly to vehicle body 9±1
Bolt - A/C pipe assembly to vehicle body 9±1
Bolt - air pressure/temperature sensor 3 ± 0.5
Technical Requirements of A/C: 11 Noise: less than 43dB(A)
1 Operating voltage range: DC 9V ~ 18V 12 Consistency of angle on the drawing and angle
with load in fact shall be met.
2 Operating temperature range: -40 ℃ ~ +85 ℃
13 Electromagnetic compatibility (EMC) shall meet
3 Rated voltage: DC 12V with ES 96200-00
4 Rated current: ≤ 150 mA 14 Flame retardance: apply to specifications of
5 Rated load: 4 kgf-cm flame retardant UL94-HB and above
6 Specifications of resistor: 15 Resistance of servo motor armature is 26.47 Ω

|20 ℃
1） Rated voltage: DC 12V
2） Rated power: 0.25W (at 40°)
3） Operating voltage range: DC 5V ± 0.5V
4） Resistance value range: 5K ± 10%
5） Damping properties meet with JIS C 6444
7 Speed:
1） Rated speed: 3.6 ± 0.6 rpm
2） No-load speed: 4.1 ± 0.9 rpm
8 Stall torque: 1.76 N.m(18 Kgf.cm)/at DC 12V
9 Locked-rotor current: ≤ 400 mA

10 Torque when stopping (power off): 2 Kgf-cm
41-2
Air Conditioning
2 Mode damper motor (DC motor)

Technical Parameters of A/C Components
1 Internal/external circulation motor (DC motor)
3 4 5 6 7
3 4 5 6 7
GS350001
GS350001
PIN FUNCTION
1 -
PIN FUNCTION
2 -
1 -
3 VENT
2 -
4 DEF
3 FRE
5 SENSOR REF(+5V)
4 REC
6 ACTUATOR F/B
5 SENSOR REF (+5V)
7 GND
6 ACTUATOR F/B
7 GND
VENT DEF
7 GND (12V)
CCW
FRE REC 6 F/B
(0V)
7 GND (12V) 5 +5V
CCW
6 F/B 4 DEF DEF VENT
(0V)
5 +5V (0V)
M 3 VENT CW
4 REC REC FRE (12V)
(0V)
M 3 FRE CW
(12V)
GS350003
GS350002
41-3
Air Conditioning
3 Left blend damper motor 4 Right blend damper motor
3 4 5 6 7 3 4 5 6 7
GS350001 GS350001
PIN FUNCTION PIN FUNCTION
1 - 1 -
2 - 2 -
3 MAX BOT 3 MAX COOL
4 MAX COOL 4 MAX HOT
5 SENSOR REF(+5V) 5 SENSOR REF(+5V)
6 ACTUATOR F/B 6 ACTUATOR F/B
7 GND 7 GND
HOT COOL COOL HOT

7 GND (12V) 7 GND (12V)
CCW CCW
6 F/B 6 F/B
(0V) (0V)
5 +5V 5 +5V
4 COOL COOL HOT 4 HOT HOT COOL
(0V) (0V)
M 3 HOT CW M 3 COOL CW
(12V) (12V)
GS350003 GS350005
41-4
Air Conditioning
Troubleshooting Information and

Procedure
System Failure
Poor refrigeration effect Lack of refrigerant Exclude leakage points, and refill the
refrigerant
Excessive refrigerant Release a proper amount of refrigerant
Check the evaporator core for dirts Clean/clear dirts
Condenser contaminated or blocked Clear dirts
There is frost on the compressor air return Re-fix the thermal bulb
connecting pipe joint
Compressor starts and Check high pressure Release a proper amount of refrigerant
stops frequently
There is frost on the Receiver-drier blocked Replace

dryer connecting outlet
There is frost on the Expansion valve blocked Replace

expansion valve inlet
side
Electric Appliance Failure
A/C does not work A/C fuse failure Replace
Compressor does not A/C switch failure Replace

work
Compressor power line failure Repair
Pressure switch failure Re-plug or replace
Electromagnetic clutch failure Replace the compressor
The blower does not Fuse failure Replace

work
Control panel blower speed switch failure Replace
Blower wiring failure Repair
Blower failure Replace
Evaporator freezes Defroster switch is on Replace the defroster switch
Poor contact of defroster switch Repair
Fuse failure Replace
The condenser fan Pressure switch failure Re-plug or replace

does not work
Condenser fan power line failure Repair
Condenser fan failure Replace
Control panel failure Replace
Mechanical Failure
Belt slackness Belt vibrates severely Adjust the belt tension
41-5
Air Conditioning
Clutch slip The clutch slips due to friction surface Clean the clutch surface
contamination Replace the compressor
The clutch makes friction noise after
engagement
The compressor makes The compressor makes metal friction sound Replace the compressor
abnormal sound inside
The compressor gets The compressor does not work Replace the compressor
stuck
Poor Heating Effect
No warm air or poor Low water temperature Notify the engine manufacturer or vehicle
heating effect manufacturer
Lack of coolant Refill coolant
Coolant circulates inadequately Clean or replace
41-6
Air Conditioning
Layout
A/C System Layout
4
2 3
GS350006
1 Front A/C assembly 3 Rear A/C assembly

2 A/C pipeline 4 A/C compressor
41-7
Air Conditioning
Refill
Repair Guidance
1 Confirm the system is vacuum without leakage,
Coolant Drain and Refill connect the intermediate pipe connecting the
Emission manifold gauge to the vacuum pump to the joint
of refrigerant tank.
1 Connect 3 pipes to the manifold gauge as
required. 2 Place the refrigerant tank on an electronic scale,
open the refrigerant tank valve, and loosen the
2 Respectively connect the red high-pressure pipe intermediate pipe on the manifold gauge to
and blue low-pressure pipe to the flush valve of release air in the pipe. Do not tighten the joint
A/C system. until refrigerant flows out from the joint.
3 Prepare a measuring cup, place a yellow 3 Check and record the weight reading on the
intermediate connecting pipe in it, and cover it electronic scale, and turn on the high-pressure
with a clean cloth to prevent the refrigerant oil switch on the manifold gauge. Then refrigerant
from spraying out. flows into HVAC system. Observe the weight
4 Slowly turn the blue and red knobs on the reading on the electronic scale at any time.
manifold gauge, and then coolant and refrigerant 4 When the refilling amount reaches the specified
oil will flow out slowly. weight, turn off the manifold gauge switch and
5 After the coolant in the system is drained subsequently close the refrigerant tank valve.
completely, tighten the high-low pressure knob 5 Remove the manifold gauge, and refilling is
on the gauge, and remove the pipe. finished.
6 Suck the refrigerant oil drained out into the Note: High pressure: 3.14MPa
system in virtue of the vacuum in the system and
the manifold gauge after vacuuming the system. Low pressure: 0.196MPa
Medium pressure: 1.77MPa
Low pressure High pressure

gauge gauge LOW pressure
pipe (blue) Placement
Vacuum pumping starts
Vacuum pumping stops
20 for 5 Pressure gauge

Air tightness check
Refrigerant charge
minutes minutes indicating normal
Connecting pipe
(yellow) End
High pressure -750

pipe (red) mmhg
Gauge seat
Check the Pressure

connection rises back
ES310001
ES310002
41-8
Air Conditioning
7 Disconnect the A/C compressor assembly from

Replacement of A/C Compressor Assembly
engine harness connector.
Removal
1 Recycle the A/C system refrigerant.
3 Release the V-belt.
4 Remove the turbocharger intake pipe.
5 Remove the compressor intake pipe 1.
1 2 GS030219
GS030217
6 Remove the compressor exhaust pipe.
GS030220
8 Unscrew 3 bolts fixing the A/C compressor

assembly to the engine assembly.
GS030218
GS030221
9 Remove the A/C compressor assembly.
41-9
Air Conditioning
Installation
Refill of Refrigerant Oil
Removal
1 Place the liquid filling machine flat onto the
- Tighten the bolts fixing the A/C compressor assembly to
working table or the oil drum.
the engine assembly to the torque of 23 ± 2N.m
- Tighten the bolts of the compressor intake pipe to the

torque of 9 ± 1N.m
- Tighten the bolts of the compressor exhaust pipe to the

- Tighten the A/C pipeline to the engine oil pan to the

torque of 9 ± 1N.m
GS350008
2 Open the plug cap of the hole marked with IN on

the reservoir, and refill the refrigerant oil (type:
PAG) with specific filling capacity shown in the
table below. After refilling, cover the plug cap and
press it tightly. The refilling process should be
completed within 1 minute.
3 Check the reservoir body for oil contamination. If

any, wipe it clean.
GS350009
41-10
Air Conditioning
Replacement of Compressor Intake/Exhaust

SN. Items Refill Capacity (ml) Pipe Assembly
1 Replace the 30 Removal
condenser
1 Drain first and then recycle the refrigerant.
2 Replace the 30
auxiliary 2 Unscrew the nuts (2) fixing the compressor
condenser intake pipe to the right front wheelhouse panel of
body.
3 Replace the 15
drier
4 Replace the 50
evaporator
5 Replace the 20
single pipeline
6 Replace the A/C If the residual oil poured

compressor out form the compressor is
less than 30 ml, refrigerant
oil with the amount of 50 ml
should be compensated.
If the amount is greater
than 30 ml, the same
amount of refrigerant oil
should be compensated. GS350010
7 Recycle the Dual-zone A/C 50 ml;
refrigerant Single-zone A/C 20ml. 3 Unscrew 2 bolts (3) and 1 bolt (4) fixing the
compressor intake pipe (1) to the engine
assembly.
GS350011
4 Release the nuts securing the condenser outlet

pipe assembly to the refrigerant coupling pipe
assembly. Disconnect the connector between
the pressure switch on condenser outlet pipe
assembly and the engine compartment harness.
5 Unscrew 1 bolt (3) fixing the compressor exhaust

pipe assembly (1) to the A/C compressor
assembly.
6 Unscrew 1 bolt securing the condenser outlet

pipe assembly to the cooling system.
41-11
Air Conditioning
7 Unscrew 1 bolt (2) securing the compressor

Condenser Replacement
exhaust pipe assembly (1) to the condenser.
Removal
1 Drain first and then recycle the refrigerant.
2 Remove the upper front bumper beam.
3 Remove the bolts connecting the condenser and

the radiator.
4 Remove the condenser.
GS350012
8 Remove the compressor intake pipe assembly,

compressor exhaust pipe assembly and
condenser outlet pipe assembly respectively.
Installation
GS350013
-Tighten the nuts securing the compressor intake pipe (1) Installation
to the right front wheelhouse panel of body to: 9 ± 1N.m
1 Install the condenser.
-Tighten the bolts securing the compressor exhaust pipe 2 Tighten relevant bolts.
(1) to the compressor assembly to: 22 ± 2N.m
3 Install the front bumper and beam (Refer to
-Tighten the bolts securing the compressor exhaust pipe Installation of Front Bumper).
(1) to the condenser to: 9 ± 1N.m 4 Refill the refrigerant.
41-12
Air Conditioning
9 Remove the front A/C assembly (1).

Replacement of Front A/C Assembly
Removal
1 Recycle the A/C system refrigerant. Installation
2 Remove the bolts securing the A/C hard pipe 1 Install the front A/C assembly.
assembly to the expansion valve, and disconnect
2 Connect the connector of front A/C assembly
the connection. and instrument harness.
3 Remove 2 clamps securing heater core water
3 Tighten 4 nuts fixing the front A/C assembly to IP
inlet/outlet pipe to the core and disconnect the
frame to the torque of 9 ± 1N.m.
connection.
4 Tighten 1 bolt fixing the front A/C assembly to IP
4 Remove the instrument panel assembly.
frame. Tightening torque: 9 ± 1N.m.
5 Remove bolts and nuts fixing the A/C assembly 5 Install bolts and nuts fixing the A/C assembly to
to the dash panel. the dash panel.
6 Install the instrument panel assembly.
7 Install 2 clamps securing the heater core water

inlet/outlet pipe to the core and connect them.
8 Install the bolts securing the A/C hard pipe

assembly to the expansion valve, and connect
them.
9 Refill the A/C system refrigerant.
GS350031
6 Unscrew 1 bolt fixing the front A/C assembly (1)

to IP frame.
7 Unscrew 4 nuts fixing the front A/C assembly (1)

to IP frame.
GS350032
8 Disconnect the connector of front A/C assembly

(1)and instrument harness.
41-13
Air Conditioning
Replacement of Front Floor Air Duct Replacement of Front Heater Water Inlet Pipe
Removal Assembly
Removal
1 Remove the seats, carpet and CNSL.
2 Unscrew 8 nuts (2) fixing the front floor air duct 1 Remove the clamps fixing the front heater water
(1) to the front floor. inlet pipe assembly to the rear heater water inlet/
outlet pipe assembly. (If equipped with the rear
heater).
GS350033
3 Disconnect the front end of air duct from the joint GS350035
of front A/C air vents.
2 Unscrew the bolts fixing the front heater water
4 Remove the front floor air duct. inlet pipe assembly to the transmission
assembly.
GS350034
GS350036
Installation
1 Install the front floor air duct.
2 Connect the front end of air duct and front A/C
air vents.
3 Unscrew 8 nuts (2) fixing the front floor air duct

(1) to the front floor. Tightening torque: 5±1N.m.
4 Install the seats, carpet and CNSL.
41-14
Air Conditioning
3 Remove the clamps fixing the front heater water

Replacement of Rear Floor Air Duct
inlet pipe assembly to the front A/C assembly.
Removal
1 Remove the seats (refer to Removal/Installation
of Seats).
2 Remove the carpet (refer to Removal/Installation
of Carpet).
3 Remove the interior trim panel (refer to Removal/

Installation of Interior Trim Panel).
4 Remove the bolts - rear A/C air duct to body (2)

tightening the rear floor air duct to body.
GS350037
4 Remove the clamps fixing the front heater water

inlet pipe assembly to the engine.
GS350039
GS350038
5 Remove the front heater water inlet pipe

assembly.
Installation
1 Install the front heater water inlet pipe assembly.
GS350040
2 Install the clamps fixing the front heater water
inlet pipe assembly to the engine. 5 Remove the rear floor air duct.
3 Install the clamps fixing the front heater water
inlet pipe assembly to the front A/C assembly.
Installation
4 Install the bolts fixing the front heater water inlet
pipe assembly to the transmission assembly. 1 Install the rear floor air duct.
5 Install the clamps fixing the front heater water 2 Tighten the bolts - rear A/C air duct to body (2)
inlet pipe assembly to the rear heater water inlet/ tightening the rear floor air duct to body.
outlet pipe assembly (if equipped with the rear Tightening torque: 5 ± 1N.m.
heater).
41-15
Air Conditioning
3 Install the interior trim panel (refer to Removal/

Replacement of Rear A/C Assembly
Installation of Interior Trim Panel).
Removal
4 Install the carpet (refer to Removal/Installation of
Carpet). 1 Remove the rear body side trim panel (refer to
Replacement of Rear Body Side Trim Panel).
5 Install the seats ( refer to Removal/Installation of
Seats). 2 Unscrew 1 bolt (9) fixing the rear A/C air duct
assembly F (8) to rear body side interior sheet
metal. Disconnect the rear A/C air duct assembly
(8) from the rear A/C assembly (1).
3 Unscrew 2 bolts (7) fixing the rear A/C intake/

outlet pipe assembly (4) to the rear body floor.
4 Unscrew 1 bolt (5) fixing the rear A/C intake/

outlet pipe assembly (4) to the expansion valve
of rear A/C assembly (1). Take down 1 thermal
insulation rubber of A/C pipe (6) from the joint of
rear A/C intake/outlet pipe assembly (4) and rear
A/C assembly (1). Disconnect the rear A/C
intake/outlet pipe assembly (4) from the rear A/C
assembly (1).
5 Disconnect the rear A/C drain pipe assembly (2)

from the rear A/C assembly (1).
6 Unscrew 5 bolts (3) fixing the rear A/C assembly

(1) to the left rear side wall.
7 Take out the lower pipeline of rear A/C assembly

(1) from the underbody (S1), install it to the
indicated location, and disconnect 3 harnesses
(T1-T3) of rear A/C assembly (1) from the left
floor harness connector.
41-16
Air Conditioning
8 Remove the rear A/C assembly (1). 10 Take 3 bolts/screws - rear A/C assembly to body
(2) and tighten the rear A/C assembly to body.
Installation
-Tighten the bolts fixing the rear A/C air duct assembly F
to rear body side interior sheet metal to the torque of 5 ±
1N.m.
-Tighten the bolts fixing the rear A/C intake/outlet pipe

assembly to the rear body floor to the torque of 9 ± 1N.m
GS350041
-Tighten the bolts fixing the rear A/C intake/outlet pipe
assembly to the expansion vale of rear A/C assembly to
the torque of 9 ± 1N.m
-Tighten the bolts fixing the rear A/C assembly to the left
rear side wall to the torque of 9 ± 1N.m
GS350042
9 Take 1 nut - rear A/C reinforcing bracket to body

(3) and tighten the rear A/C assembly to body.
41-17
Air Conditioning
Replacement of Front A/C Control Panel Replacement of Rear A/C Control Panel
Removal Removal
1 Remove the air duct trim panel first. 1 Remove the auxiliary fascia console rear panel
2 Unscrew 2 screws fixing the front A/C control
Console Rear Panel) first.
panel to the instrument panel body assembly.
2 Remove the rear A/C control panel from the
3 Disconnect the harness connector from front A/C
auxiliary fascia console assembly.
control panel.
3 Disconnect the rear A/C control panel from the
4 Remove the front A/C control panel.
ceiling harness connector.
4 Remove the rear A/C control panel.
GS350043
GS350044
Installation
1 Install the front A/C control panel.
Installation
2 Connect the harness connector of front A/C
1 Install the rear A/C control panel.
control panel.
2 Install the rear A/C control panel and the ceiling
3 Tighten 2 screws fixing the front A/C control
harness connector.
panel to the instrument panel body assembly.
3 Install the rear A/C control panel from the
4 Install the air duct trim panel.
auxiliary fascia console assembly.
5 Conduct the matching after installation, refer to
4 Install the auxiliary fascia console rear panel
Scan Tool Matching for details.
Console Rear Panel).
5 Conduct the matching after installation, refer to

Scan Tool Matching for details.
41-18
Air Conditioning
Replacement of Transmission Oil Cooler Replacement of Transmission Oil Cooler

Pipe Assembly Water Inlet/Outlet Pipe Assembly
Removal Removal
1 Disconnect the water inlet/outlet pipe first. 1 Remove 2 bolts (2) fixing the transmission oil
cooler water inlet pipe assembly (1) to the middle
2 Unscrew the bolts fixing the transmission oil
third beam assembly.
cooler pipe assembly to the transmission.
GS350047
GS350045
2 Release the clamps inserting pipe orifices on
3 Unscrew the bolts fixing the engine assembly to
both sides of transmission oil cooler water inlet
the transmission.
pipe assembly into the transmission oil cooler
assembly and heater water pipeline assembly.
Release the clamps inserting pipe orifices on
both sides of transmission oil cooler water outlet
2
pipe assembly into the transmission oil cooler
assembly and heater water pipeline assembly.
1
GS350046
4 Remove the transmission oil cooler pipe

assembly.
Installation
GS350048
1 Install the transmission oil cooler pipe assembly.
2 Install the bolts fixing the engine assembly to the
transmission.
3 Remove the bolts fixing the transmission oil

cooler pipe to the transmission, tightening
torque: 22 ± 2N.m.
4 Connect the water inlet/outlet pipe.
41-19
Air Conditioning
3 Remove the transmission oil cooler water inlet

Replacement of Front A/C Intake/Outlet Pipe
pipe.
Assembly
Removal
Installation 1 Remove the bolts securing the front A/C intake/
1 Installation is the reverse of removal. Pay outlet pipe assembly to the right front
attention to the following precautions: wheelhouse panel of body.
-Tighten the bolts securing the transmission oil cooler 2 Remove the nuts inserting the front A/C intake/
outlet pipe assembly into the compressor intake
water inlet pipe assembly to the middle third beam to
pipe assembly and condenser outlet pipe
the torque of 9 ± 1N.m assembly.
3 Remove the bolts securing the front A/C intake/

outlet pipe assembly to the body dash panel.
GS350049
4 Remove the bolts securing the front A/C intake/

outlet pipe assembly to the front A/C assembly.
GS350050
Installation
1 Install the bolts securing the front A/C intake/
outlet pipe assembly to the front A/C assembly.
41-20
Air Conditioning

Replacement of Rear A/C Intake/Outlet Pipe
outlet pipe assembly to the body dash panel.
Assembly
3 Install the nuts inserting the front A/C intake/
Removal
outlet pipe assembly into the compressor intake
pipe assembly and condenser outlet pipe 1 Remove the bolts connecting the rear A/C
assembly. intake/outlet pipe assembly (3) to the pipe orifice
of rear A/C assembly.
outlet pipe assembly to the right front 2 Unscrew the nuts fixing the rear A/C intake/outlet
wheelhouse panel of body. pipe assembly (3) to the body.
3 Unscrew the nuts connecting the rear A/C intake/

outlet pipe assembly (3) to the pipe orifice of rear
A/C intake/outlet pipe assembly (2).
GS350051
4 Unscrew the nuts fixing the rear A/C intake/outlet

pipe assembly (2) to the body.
5 Unscrew the nuts (4) connecting the rear A/C

intake/outlet pipe assembly (2) to the pipe orifice
of rear A/C intake/outlet pipe assembly (1).
GS350052
41-21
Air Conditioning
Replacement of Air Pressure/Temperature

Sensor
Removal
1 Remove the intercooler assembly, refer to
Removal/Installation of Intercoller.
2 Remove the bolts fixing the air pressure/
temperature sensor to the intercooler assembly.
3 Remove the air pressure/temperature sensor.
GS350053
6 Unscrew the nuts fixing the rear A/C intake/outlet
pipe assembly (1) to the body, unplug the pipe
orifices of the rear A/C intake/outlet pipe
assembly (1) and the front A/C intake/outlet pipe
assembly.
GS350055
Installation
GS350054
7 Remove the rear A/C intake/outlet pipe

assembly.
Installation
41-22
Air Conditioning
Replacement of Rear A/C Air Duct

Removal
1 Remove the ceiling (refer to Ceiling
Replacement).
2 Remove the rear A/C air duct assembly F (refer
to Replacement of Rear A/C Assembly).
3 Remove the rear A/C air duct assembly A, rear

A/C air duct assembly B, rear A/C air duct
assembly C and rear A/C air duct assembly D
from the ceiling successively.
GS350056
GS350057
Installation
Clean the contact surfaces between each rear A/C air
duct assembly and the ceiling, and spray moderate
amount of hot melt adhesive onto the ceiling.
41-23
Air Conditioning

Overview
The heating, ventilation and air-conditioning (HVAC) system can create a comfortable environment with fresh air and
moderate temperature for driver and passengers in the vehicle. The automobile HVAC system shall have greater
refrigerating capacity, warm air capacity and ventilation volume to adapt to the great temperature disparity in different
areas. The HVAC system equipped for this vehicle can realize rapid refrigeration to satisfy the user's demand.
HVAC system is mainly composed of the compressor, condenser, expansion valve, evaporator, pipeline assembly, etc.
Operating Principle
The HVAC system absorbs heat from air through refrigerant circulation to lower the air temperature and eliminate water
vapor in the air, so as to maintain the cooling and moisture. Meanwhile, the HVAC system also can clear the frost and fog
on the windscreens and side windows by introducing cool and hot air.
HVAC Schematic Diagram
Gas
High temperature and
high pressure Low temperature and
low pressure
High-temperature Compre
high-pressure gas ssor Expansion Gas
valve
Compre
Liquid ssing Evapora
Condenser Conden tion
sation To absorb
heat
Release of heat
Expan Expansion
sion valve
Liquids(high pressure)
ES310070
1 After starting the vehicle, driven by the engine, the compressor starts operating to impel refrigerant to
circulate in the sealed HVAC system. Then the compressor compresses the gaseous refrigerant into high-
temperature and high-pressure refrigerant gas and exhausts the gas.
2 After flowing into the condenser via pipeline, the high-temperature and high-pressure refrigerant gas will
radiate and cool down in the condenser, and then become medium-temperature and high-pressure liquid
refrigerant and flow out. (Condensation refers to the process of cooling steam to a temperature no more
41-24
Air Conditioning
than its saturation temperature to convert the steam to liquid. It is an exothermic process because the
conversion from gas to liquid must be realized through heat release).
3 Then the medium-temperature and high-pressure liquid refrigerant flows into the receiver-drier via pipeline.
After drying and filtration, it flows into the expansion valve.
4 The medium-temperature and high-pressure liquid refrigerant will rapidly change into the low-temperature/
pressure fog-state refrigerant after it is throttled by the expansion valve.
5 Then the low-temperature/pressure fog-state refrigerant immediately enters the evaporator and absorbs
heat from the air flowing through the evaporator, so as to lower the air temperature and generate cool air,
realizing cooling effect. Then the refrigerant will evaporate to the low-temperature/pressure gaseous
refrigerant due to heat absorption. (In refrigeration technology, evaporation refers to the process where a
liquid converts from liquid to gas in the boiling state. It is an endothermic process because the conversion
from liquid to gas must be realized by absorbing heat from the external).
6 Then the low-temperature/pressure gaseous refrigerant is sucked by the compressor again via pipeline for
compression and enters the next circulation. As long as the compressor keeps operating, the refrigerant will
circulate in the HVAC system to realize refrigeration; if the compressor stops operating, the refrigerant will
stop circulating accordingly and not produce refrigeration effect.
41-25
Air Conditioning
Introduction of Parts Function

Compressor: It compresses the low-temperature and low-pressure gas from the evaporator to the high-temperature and
high-pressure gas. It is located between the evaporator and condenser and driven by the engine.
Condenser: It converts the gaseous refrigerant to liquid refrigerant. It is located between the compressor and receiver-
drier.
Expansion valve: It is the throttling device which isolates the system high-pressure side and low-pressure side. After the
high-pressure liquid refrigerant is throttled, the refrigerant will convert into the low-pressure and low-temperature fog
mixture of gas and liquid, which has the capacity to absorb heat. It measures the volume of liquid refrigerant entering the
evaporator by detecting the temperature of evaporator outlet and adjusts the inlet clearance to adapt to condition change.
It automatically adjusts the refrigerant flow according to the size of thermal load, so as to ensure the evaporator operates
safely and efficiently.
Evaporator: It absorbs heat from exterior air to heat and evaporate the refrigerant from the expansion valve to the low-
temperature and low-pressure gas. At this time, the air around the evaporator exterior cools down, and then the blower
blows out the cool air. Then the gas is sent to the compressor again to carry on refrigerating through circulation.
41-26
Wiper/Washer System
Wiper/Washer System
Torque
Nut - wiper arm assembly 45 ± 2

Bolt - wiper motor assembly 9±1
Bolt - front washer reservoir assembly 9±1
Nut - rear wiper arm assembly 20 ± 2
Bolt - rear wiper motor assembly 9±1
Bolt - front washer reservoir cover assembly 9±1
42-1
Wiper/Washer System
Layout
Front Wiper and Washer Layout
2 4
1 1
6
2 4
3
4
5
7
8
10
GS250001
1 Front wiper blade 6 Wiper motor assembly

2 Wiper arm assembly 7 Washer reservoir cover assembly
3 Front washer nozzle assembly 8 Bolt - front washer reservoir cover assembly
4 Bolt - wiper motor assembly 9 Washer reservoir body assembly
5 Front washer fluid hose assembly 10 Front windscreen washer pump
42-2
Wiper/Washer System
Rear Wiper and Washer Layout
2 4
5 5
6
GS250002
1 Rear wiper blade 4 Nut - rear wiper arm assembly

2 Rear wiper arm assembly 5 Bolt - rear wiper motor assembly
3 Rear wiper arm cover 6 Rear wiper motor assembly
42-3
Wiper/Washer System
Repair Guidance Replacement of Wiper Linkage Assembly

(with Motor)
Replacement of Front Wiper Blade
Removal
Removal
1 Place the wiper control switch to "OFF" position.
1 Rotate the wiper blade on the wiper arm.
2 Slide the wiper blade downward along the wiper
arm while pressing the retaining clip to remove it. 3 Remove the wiper arm assembly (refer to
Replacement of Wiper Arm Assembly).
assembly (refer to Replacement of Front
Windscreen Cover Plate Assembly).
5 Disconnect the harness from the wiper motor.
6 Remove the bolts from the linkage mechanism
(as indicated by the arrow).
GS250003
Installation
1 Slide the wiper blade into the arm till the
retaining clip is engaged to install the wiper
blade.
2 Locate the wiper blade to the windscreen.
GS250004
Installation
Replacement of Wiper Arm Assembly
Removal 1 Place the wiper motor assembly into the
windscreen gutter channel.
1 Remove the front wiper blade (refer to 2 Tighten the bolts connecting the linkage
Replacement of Front Wiper Blade). mechanism assembly and the front wall to 9 ±
2 Remove the wiper arm cover. 1N.m.
3 Unscrew the nuts securing the wiper arm to the 3 Adjust the linkage position to allow three joints of
spindle of linkage mechanism. the drive rod on the same line.
4 Remove the wiper arm assembly. 4 Tighten the nuts of wiper arm assembly to 45 ±
2N.m.
5 Connect the harness of wiper motor.
Installation 6 Connect the battery (positive first).
1 Installation is the reverse of removal. Pay 7 Briefly operate the wiper switch to check whether
attention to the following precautions: the wiper mechanism is in "OFF" position.
- Tighten the nuts of wiper arm assembly to 20 ± 2N.m. 8 Pour water on the windscreen to check the
operability of the wiper.
42-4
Wiper/Washer System
Replacement of Wiper Motor Assembly Replacement of Washer Reservoir Body

Removal Assembly
Removal
1 Remove the wiper linkage assembly (with
motor), refer to Replacement of Wiper Linkage 1 Disconnect the battery (negative first).
Assembly (with Motor).
2 Disconnect the electrical connector of the front
2 Unscrew the bolts and nuts connecting the motor windscreen washer pump.
to linkage mechanism, and remove the wiper
motor assembly. 3 Disconnect the hose from the front windscreen
washer pump.
4 Remove the washer reservoir cover assembly

(refer to Replacement of Washer Reservoir
Cover Assembly).
5 Remove the wheelhouse liner.
6 Remove all connecting bolts and nuts from the

washer reservoir body assembly.
GS250005
Installation
1 Installation is the reverse of removal. Observe
the following precaution:
-·Reconnect the battery (positive first).
GS250006
7 Remove the washer reservoir body assembly.
Installation
42-5
Wiper/Washer System
Replacement of Washer Reservoir Cover Replacement of Front Windscreen Washer

Assembly Pump
Removal Removal
1 Remove the bolts and washers, and carefully 1 Disconnect the battery (negative first).
pull out the washer reservoir cover assembly. 2 Disconnect the electrical connector of the front
windscreen washer pump.
3 Disconnect the hose from the front windscreen
washer pump.
4 Remove the washer pump from the washer
reservoir assembly.
GS250007
Installation
GS250008
5 Remove the washer pump from the washer

reservoir assembly.
Installation
42-6
Wiper/Washer System
Replacement of Front Washer Fluid Hose and Replacement of Rear Wiper Arm Assembly
Nozzle Removal
Removal
1 Remove the rear wiper blade (refer to
1 Remove the front windscreen cover plate Replacement of Rear Wiper Blade).
assembly (refer to Replacement of Front 2 Remove the rear wiper arm cover.
Windscreen Cover Plate Assembly).
3 Unscrew the nuts securing the wiper arm to the
2 Open and support the engine hood. motor.
3 Disconnect the hose from the washer water
pump end.
4 Disconnect the front washer fluid hose assembly

from the nozzle.
5 Remove the washer nozzle.
Installation
Replacement of Rear Wiper Blade GS250009

Removal
4 Remove the rear wiper arm assembly.
1 Rotate the blade on the wiper arm.
2 Slide the wiper blade downward along the wiper
Installation
arm while pressing the retaining clip to remove it.
Installation - Tighten the nuts of rear wiper arm assembly to 20 ±
1 Slide the wiper blade into the arm till the 2N.m.
retaining clip is engaged to install the wiper
blade.
2 Locate the wiper blade to the rear windscreen.
42-7
Wiper/Washer System
Replacement of Rear Wiper Motor Assembly Description and Operation

Removal Wiper system is a functional system designed to keep a
clear view for the driver and passengers, which shall
1 Place the wiper control switch to "OFF" position.
work normally when the vehicle is parking or driving or at
the highest speed. The front wipers are required to wipe
3 Remove the rear wiper arm assembly (refer to in a clockwise manner. And the wiper system shall
Replacement of Rear Wiper Arm Assembly).
possess the function of pedestrian protection.
4 Remove the tailgate trim panel assembly (refer
to Replacement of Tailgate Trim Panel Wiper motor assembly includes (but is not limited to): 1
Assembly). wiper motor, 1 pair of drive linkage, left and right wiper
5 Unscrew 3 fastening bolts and remove the shaft lock ring (1 for each) and structures related to body
washer. installation. IP54 wiper motor and above is equipped with
thermal protection device to prevent the performance
reduction in case of motor stalling.
The wiper shaft lock ring can not only reduce the
vibration, but also introduce the water flow at the end of
wiper arm to the windscreen gutter channel, thereby
discharging out of the vehicle.
Wiper Arm Assembly
The wipe arm shall be serviceable during all wiping

processes. It is connected on the propeller shaft with the
nuts (each with a cap). The wiper arm shall be in an error
GS250010 proofing design to ensure correct installation. And it must
be able to endure an excess of torque of the nut.
6 Remove the rear wiper motor assembly.
Wiper Blade
Installation After-sales repair shall be achievable for the wiper blade

1 Installation is the reverse of removal. Observe without using special tool. Under no circumstance can
the following precaution: the blade vibrate. And it should be with the function of
rotation prevention, so that the end of the blade will not
knock the glass during repair. Traditional wiper blades
are recommended for SV71 front wipers.
The wiper blade at the driver side shall be in the length of

600mm, at the front passenger side shall be 500mm and
355mm for the rear wiper blades.
42-8
Wiper/Washer System
Requirements for Wiping Mode
a Requirement for the minimum clearance between wiper blade top and intake grille/A-pillar (see Table 1)
Table 1
Intake grille/windscreen weatherstrip (original position) Windscreen weatherstrip (wiping

position)
Driver side 2 degrees 2 degrees
Passenger side 2 degrees 2 degrees
b When the wiper blade at the passenger side is adopting the wiping mode at the driver side, the clearance between it
and the eye ellipse shall be no less than 100mm;
c The tolerance (as follows) of the wiper mechanism in the output shaft direction should be regards as the critical
dimension:
F/A C/C
Driver side: + 1° + 1°
Passenger side: + 1° + 1°
d The tolerance (critical dimension) within 1mm is allowed for the mounting point of front wiper mechanism;
e The positional tolerance (critical dimension) at the front wiper mechanism shaft spline shall be no more than 2mm;
f The torsion angle of front wiper is the critical dimension, with the tolerance within 2°; while the pressure at the wiper
arm top shall also be the critical dimension, with the tolerance within 8%.
Wipe blade quality
In the whole life span, the wipe blade can provide smooth wiping and the wiping quality shall be at least grade 5 (see
Table 2);
42-9
Wiper/Washer System
Table 2: Wiping Quality
Volts 13.5 10.5
Glass dry wet dry wet

Condition
Arm Force Blade Condition Motor Speed low high low high low high low high
Nominal New > 10 > 10 > 10 > 10 > 10 > 10 > 10 > 10
Perm. set >7 >7 >7 >7 >7 >7 >7 >7
End of Useful Life >5 >5 >5 >5 >5 >5 >5 >5
Min New > 10 > 10 > 10 > 10 > 10 > 10 > 10 > 10
Perm. set >7 >7 >7 >7 >7 >7 >7 >7
Max New > 10 > 10 > 10 > 10 > 10 > 10 > 10 > 10
Perm. set >7 >7 >7 >7 >7 >7 7 >7
04 A number of continuous
stripes
10 A very thin and
discontinuous stripe
03 A layer of thin film that

cannot be wiped
09 A very thin and
discontinuous stripe
02 Some areas cannot be
wiped
08 A very thin and continuous

stripe
01 Shake during the wiping
07 3 very thin and continuous

stripes, but cannot be
shown in the center of the
area being wiped
06 4 continuous stripes (with In any cases, wiper blade cannot be contacted with
the width not more than
surrounding parts to avoid damage.
1mm), and only 1 thin and
discontinuous stripe can be
shown in the center of the
area being wiped
05 6 thin and continuous

stripes (with the width not
more than 1mm), and only
1 very thin and continuous
stripe can be shown in the
center of the area being
wiped
42-10
Horn
Horn
Torque
Bolt - horn 9±1
Horn Parameters
Items Specified parameters
Rated voltage 12V
Max. current Up to 6A
Fundamental frequency of bass 400 ± 25Hz

Fundamental frequency of treble 500Hz ± 25Hz
Horn sound level 05-118dB;13.0V>=105dB(A),13.8V <=118dB(A)
Life span 100,000 times, 1s on and 4s off
Normal operating temperature -40 ℃ -+85 ℃
43-1
Horn
Layout
Layout
2
1
GS310001
1 Tweeter assembly 2 Woofer assembly
43-2
Horn
Repair Guidance
Horn Replacement
Removal
2 Remove the front grille assembly.
GS310002
4 Remove 1 retaining bolt from the horn.
GS310003
5 Remove the horn assembly.
Installation
43-3
Horn
43-4
Bumper
Bumper
Torque
Bolt/screw - front bumper lower baffle 9±1

Bolt/screw - front bumper 9±1
Bolt - bumper bracket assembly 9±1
Bolt - rear bumper beam assembly 9±1
44-1
Bumper
Layout
Layout
GS340001
1 Front bumper 2 Rear bumper
44-2
Bumper
Repair Guidance Replacement of Front Bumper
Impact Check Removal
If the impact causes the bumper to deviate from its 1 Disconnect the negative battery cable.
normal position, replace the following components: 2 Disconnect the harness of the front fog lamp.
3 Disconnect the headlamp washer pump and
Bumper skin
washer hose.
Bumper energy absorption component 4 Remove the fender flare assembly (1) on both
sides.
Bumper beam
GS340002
5 Release 8 bolts of the bottom deflector to

remove bottom deflector.
GS340003
44-3
Bumper
6 Remove the front bumper lower baffle. 9 Remove the bolts securing the front bumper
assembly to the front bumper upper beam
assembly.
1
GS340004
7 Remove some clips of the front wheelhouse GS340010

liner, and disconnect the front bumper from the
fender upper bracket.
Installation
- Tighten the screws of the bumper bracket assembly to 9
± 1N.m
GS340005
8 Remove the bolts securing the front bumper

assembly to the bumper bracket.
GS340006
44-4
Bumper
7 Remove the bumper bracket assembly (1).

Replacement of Front Bumper Bracket
Removal
1 Remove the front bumper (refer to Removal/
Installation of Bumper).
2 Remove the screws fixing the bumper bracket
assembly (1) to the lower radiator beam.
3 Remove the bumper bracket assembly.
2
GS340009
Installation
2 1 Installation is the reverse of removal. Pay
1 attention to the following precautions:
GS340008 - Tighten the screws of the bumper bracket assembly to 9

± 1N.m
assembly (1) to the vertical beam of the
headlamp frame.
5 Remove the bumper bracket assembly (1).
GS340009

assembly to the lower radiator beam and front
bumper upper beam.
44-5
Bumper
Replacement of Rear Bumper

Removal
2 Disconnect the harness connector of the rear fog
lamp.
3 Disconnect the connector of the reverse radar
sensor.
4 Remove the rear body side fender flare
assembly (1) (1 on either side) from body side
exterior panel.
GS340013
6 Remove 4 bolts of the bumper bracket from the
GS340011
5 Remove the snap fastener installing the rear

wheelhouse liner (3) to the corresponding GS340014
location on the body, and remove the rear
wheelhouse liner and rear wheelhouse trim 7 Remove the mounting hole plug, remove the bolt
panel. from the rear bumper assembly to body, and
remove the plastic nut of the rear bumper
assembly (3) connecting the tail lamp mounting
panel of the D-pillar exterior panel and the rear
beam lower panel assembly.
GS340012
GS340015
44-6
Bumper
8 Pry the rear bumper assembly at the LR/RR side

Replacement of Rear Bumper Bracket
with a screwdriver.
Removal
1 Remove the rear bumper.
2 Remove the screws fixing the rear bumper
bracket to the body.
3 Take the bolts/screws (2 on either side) of the
rear bumper assembly (2), and fix the rear
mounting bracket (1) of the rear bumper to the
tail lamp mounting panel of the D-pillar exterior
panel, as shown in the figure. Torque D: 2.5 ±
0.5N.m, S: 2.5 ± 0.5N.m.
4 Take the rear mounting bracket (1) of the rear
bumper (1 on either side), and install it to the
GS340016 indicated location on the tail lamp mounting
panel of the D-pillar exterior panel, as shown in
the figure; remove the plastic nuts (2 on either
side) of the rear bumper assembly (3), and
Installation clamp it into the indicated location on the tail
1 Installation is the reverse of removal. Pay lamp mounting panel of the D-pillar exterior
attention to the following precautions: panel, as shown in the figure.
- Tighten the screws of the rear bumper to 9 ± 1N.m.
- Tighten the screws securing the rear bumper to the rear

body side panel to 2.5 ± 0.5N.m.
- Tighten the bolts securing the left/right rear bumper to

the body to 9 ± 1N.m
GS340017
5 Take the bolts/screws (4 on either side) of the

rear bumper assembly (2), and fix the front
mounting bracket (1) of the rear bumper to the
body side exterior panel, as shown in the figure.
Torque D: 2.5 ± 0.5N.m, S: 2.5 ± 0.5N.m.
6 Take the front mounting bracket (1) of the rear
bumper (1 on either side), and install it to the
indicated location on the body side exterior
panel,as shown in the figure.
7 Take the plastic nuts (4 on either side) of the rear
bumper assembly (3), and clamp it into the
44-7
Bumper
indicated location on the body side exterior

panel, as shown in the figure.
GS340018
Installation
- Tighten the screws securing the rear bumper bracket to
the body to 2.5 ± 0.5N.m.
44-8
Bumper
Replacement of Rear Bumper Beam

Assembly
Removal
1 Remove the rear bumper assembly.
2 Remove the bolts mounting the rear bumper
beam assembly to the body.
3 Take the bolts (2 on either side) of the rear
bumper beam assembly (2), and secure the rear
bumper beam assembly (1) to the indicated
location on the rear panel, as shown in the
figure. Torque D: 9 ± 1N.m; S: 9 ± 1N.m.
4 Take the rear bumper beam assembly (1), 1 on
either side, and install it to the indicated location,
as shown in the figure.
GS340019
Installation
- Tighten the bolts fixing the rear bumper beam assembly
to the body to 9 ± 1N.m
44-9
Bumper
44-10
On-board Communication System
Torque
Screw - BD/GPS output antenna 2.5 ± 0.5

Bolt - 4G antenna assembly 9±1
Bolt - on-board communication module 9±1
TBOX Technical Parameters
Power Supply
Supply voltage 9~16V
Power consumption Full function ON state ＜ 15W (1.25A)

Standby state ＜ 36mW (3mA)
Power off state ＜ 360uW (30uA)
Operating Environment
Temperature Operation functions: -40~+85 ℃ ; Entertainment functions: -20~+70 ℃

Moisture ＜ 95%RH (with no condensation)
WLAN
Frequency band range 2.4GHz (optional: 5GHz)
Maximum transmit power 11b 16dBm
11g 15.5dBm
11n 15dBm
Receiving sensitivity 11b -88dBm
11g -74dBm
11n -90dBm
45-1
GNSS Technical Parameters
GPS frequency band 1575.42MHz
GLONASS frequency band 1602MHz
Big Dipper frequency band 1561.098MHz
Channel 25 star-tracking channels

32 star-capturing channels
RF input impedance 50ohms
Precision Location ＜ 10m (RMS)
＜ 5m (WAAS)
＜ 2.5m (DGPS)
Velocity 0.1m/s
Time 1us
Sensitivity Capture -142dBm
Track -160dBm
Starting time Hot start ＜ 3s

(in open environment)
Warm start ＜ 38s
Cold start ＜ 42s
Antenna Fakra connector, externally connected with 3.3V active antenna
45-2
4G Antenna and BD/GPS Antenna Technical

Parameters
Description Parameters
Electric 4G antenna GPS/BD antenna

parameters
Main antenna Sub antenna
Frequency 698-960MHz 1710-2690MHz 698-960MHz 1710-2690MHz GPS: 1575.42 ± 1.023MHz

range BD: 1561 ± 2.046MHz
Power gain >=1dBi >=2dBi >=1dBi >=2dBi 26 ± 3dB
Voltage <=3.5 <=3.5 <=3.5 <=3.0 <=2.0
standing-
wave ratio
(SWR)
Impedance 50 Ω 50 Ω 50 Ω
Polarity Linearity Linearity Right-hand circular polarization
Isolation >=10dB@698-960MHz, >=20dB@1710-2690MHz -

degree
DC 100K Ω 100K Ω -
resistance
Supply - - 5 ± 0.5V
voltage
Current - - 15~35mA
(typical)
Mechanical parameters
Connector FAKRA (D-CODE) FAKRA (D-CODE) FAKRA (C-CODE)
Mechanical >=50 times of plug in/pull out >=50 times of plug in/pull out >=50 times of plug in/pull out
operations
Antenna RG174 RG174 RG174

shield
materials
Operating -40 ～ +85°C -40 ～ +85°C -40 ～ +85°C

temperature
45-3
Layout
Layout
3
2
1
GS320001
1 BD/GPS output antenna 3 4G antenna assembly

2 On-board communication module
45-4
Repair Guidance Replacement of On-board Communication

Module
Replacement of BD/GPS Output Antenna
Removal
Removal
2 Remove the instrument panel body assembly
2 Remove the instrument panel body assembly (refer to Replacement of Instrument Panel Body
(refer to Replacement of Instrument Panel Body Assembly).
Assembly).
3 Remove 2 screws securing the BD/GPS output
antenna to the instrument panel beam. 4 Remove 2 nuts securing the on-board
communication module to the instrument panel
beam.
GS320002
GS320004
4 Remove the strip securing the BD/GPS output
antenna.
5 Remove the on-board communication module
5 Disconnect the harness connector of the assembly.
communication module.
6 Remove the BD/GPS output antenna.
GS320005
GS320003
Installation
Installation
45-5
Replacement of 4G Antenna Assembly

Removal
2 Remove the instrument panel body assembly
(refer to Replacement of Instrument Panel Body
Assembly).
3 Remove 2 bolts securing 4G antenna assembly
to the instrument panel beam.
GS320006
4 Disconnect the harness connector of the

communication module.
5 Remove 4G antenna assembly.
GS320007
Installation
45-6
System Overview 1-1
1.1 Electrical protection
Summary
The following guidelines are aimed to guarantee the safety of operators, and to prevent the electric
component and electronic parts installed in the vehicle from damage.
Equipment
Before performing the vehicle testing procedure, make sure the relevant testing instruments operate
normally, and the harnesses and connectors are connected well.
Warning: Before any operation of the ignition system, make sure the high-voltage terminal, adapter and
diagnostic equipment used for testing are insulated or isolated absolutely, so as to prevent personal
accident and minimum the possibility of electric shock.
Polarity
Reverse connection of the battery poles is prohibited. When connecting to testing equipment, make sure
the poles are correctly connected.
Battery disconnection
Before disconnecting the battery, turn off all the electric equipment. When the battery is discon-
nected, some data, such as the time of the clock, may be lost. 90
Warning: To prevent the electric equipment from damage, always disconnect the battery when repairing
the electric systems in the vehicle. The Ground terminal must be disconnected first when disconnecting
the battery,
and connected last when connecting the battery. Always make sure the battery harness is connected cor-
rectly and routed properly, keeping away any potential danger.
Battery charging
When charging for the battery outside the car, ensure good ventilation above the battery. When the bat-
tery is charged or discharged for about 15 minutes, it will release hydrogen. The gas is flammable.
Always ensure good ventilation in the charging area of the battery, and prevent naked flame and spark
from producing.
Connectors and harnesses
Before disconnecting and connecting testing instrument, make sure the electronic parts and connectors
are dry and oil-free. It’s prohibited to remove or install the connectors forcibly with tool or by
pulling the harness. When replacing parts, keep your oily hands from touching the electronic connect-
ing area, and make sure the connectors are dry and oil-free. Make sure the connector clasps fully
meshes.
SAIC-SV91 09/2017
System Overview 1-2
1.2 Harness color information
Harness color codes Harness color (Eng- Harness color (Chinese)

lish)
BK Black Black
BN Brown Brown
BU Blue Blue
GY Gray Grey
GN Green Green
NAT Nature Natural color
OG Orange Orange
PK Pink Pink
PU Purple Purple
RD Red Red
TN Tan Brown
WH White White
YE Yellow Yellow
D-BU Dark Blue Dark Blue
L-BU Little Blue Little Blue
90 D-GN Dark Green Dark Green
L-GN Little Green Light Green
YE/BK Yellow/Black Yellow/Black
BARE Bare Shielded bare wire
Note: The combination of two colors is a mix-color code, the former letter of which represents the
essential color, and the latter letter represents the secondary color. (For example: YE/WH represents
the mix-color wire with the essential color of yellow and the secondary color of white.)
SAIC-SV91 09/2017
System Overview 1-3
1.3 Harness name codes
BD Engine bay harness Engine bay harness

BT Battery harness Battery harness
BTN Battery negative harness Battery negative harness
GB Transmission harness Transmission harness
IP Instrument panel harness Instrument panel harness
ROOF Roof harness Roof harness
CH Chassis harness Chassis harness
RLD Left rear door Left rear door harness
RRD Right rear door Right rear door harness
PR Parking radar harness Parking radar harness
ENG_GND Engine ground harness Engine ground harness
CN Console harness Steering column harness
DRD Left front door Left front door harness
PAD Right front door Right front door harness
TLD Tail door Tail door harness
90
SAIC-SV91 09/2017
System Overview 1-4
1.4 Configuration codes
LHD LHD
RHD RHD
LWB Long shaft
SWB Short shaft
HGC HGC
LGC LGC
4WD 4WD
SCB Single row
EXCB Single and a half row
DCB Double row
EDCB Extended double row
ALL Standard configuration
MT Manual transmission
6MT 6MT SAGW 6MT SAGW
6MT 6MT DYMOS 6MT DYMOS
AT 6AT PUNCH 6AT PUNCH
RCSW Cruise control
90 EFAC Electric control front axle semi-axle clutch
ELC Electronic lock control + one-button start + MT
ABS Anti-lock braking system + electronic brake

force distribution
Electronic stability program + electronic brake
ESP
assist (HAS RMI HDC)
TPMS Tire pressure detection system
SPHM Exterior power heating mirror
SPHCM Exterior power heating & close-up mirror
PGAM Anti-glare interior mirror
CIGAR Cigarette lighter
Driver’s & passenger’s power seats 6-direction
PST
+ manual 2-direction (lumbar support)
FSHF Driver’s & passenger’s seats heating (cush-

ions)
SRSH Airbag ECU high configuration
SRSL Airbag ECU low configuration
DAB Driver’s side airbag
PAB Passenger’s side airbag
LDW Lane departure warning system
BSD Blind zone monitoring system
FRSAB Driver’s side & passenger’s side airbags
CAB With back and forth through air curtain
SAIC-SV91 09/2017
System Overview 1-5
D2PSB Driver’s side adjustable dual-stage pre-tighten

seat belt
D1PSB Driver’s side adjustable pre-tighten seat belt
DSBR “Only driver’s side seat belt not buckled up”

warning
FSBR “Only front row seat belts not buckled up”

warning
SBR “All seat belts not buckled up” warning
P2PSB Passenger’s side adjustable dual-stage pre-

tighten seat belt
P1PSB Passenger’s side adjustable pre-tighten seat

belt
BL Backlight adjustment
HALP Halogen head lamps
XELP LED head lamps + lens
AFS Adaptive head lamp system + ESP
RFOG Rear fog lamps
FFOG Front fog lamps
DRLP With DRL
FRLP Front reading light (with spectacle case)
CHMSL High-mounted brake lamp
ALLP Head lamp automatic light-up + rainfall sunlight 90

sensor
RLP Rear tail lamps (without light guide)
TULP Turning auxiliary lamps
RRDEFROST Rear window electric heating and defrosting
PZLP Passenger zone lighting
RCAM Rear camera
PEPS Passive entry passive start system
-PEPS None passive entry passive start system
IMMO Immobilizer system
PDC Parking radar (parking distance control)
RLS Rainfall sunlight sensor
ANTIPIN One-shot lift & fall (anti-pinch)
1SHOT One-shot fall
RREGL Rear row power window lift & fall
INV 220V convenient power supply
12V DC 12V power supply
MSAC Manual front A/C
AT A/C Auto front A/C
RADIO RADIO
BLTH Bluetooth
12-inch touch screen (Radio MP5 CarLife auto A/
12-SCREEN
C display buletooth + AUX + USB)
AR Voice recognition
SAIC-SV91 09/2017
System Overview 1-6
T-BOX Telematics
0 SPEAKER No speaker
2 SPEAKER 2 speakers
PTANT Built-in printed antenna
TRAILER Trailer
GTWY Gateway
-GTWY Non gateway
PABSW Passenger’s side airbag switch
HeatingOnly Heating only (“HeatingOnly” is only for South

Africa Standard Version)
-HeatingOnly Non heating only
MFSW Multifunction steering wheel
-MFSW Non multifunction steering wheel
GCC Saudi
-GCC Non Saudi
600W 600 watts fan
800W 800 watts fan
EPS Electric power steering
90 ESSS Start-stop function
SAIC-SV91 09/2017
System Overview 1-7
1.5 How to use the electrical circuit diagrams
Power supply mode description
B+ Positive battery
ACC Ignition switch unlocks
1G1 Ignition switch 1
1G2 Ignition switch 2
ST Ignition switch starts
90
Wire properties
IP 5391AD PU FLRB 0.35 AT
The description of the wire property locates above the wire in the circuit diagram.
“IP” represents instrument panel harness;
“5391AD” represents wire code.
“PU” represents wire color, see “Harness color information” for related information.
“0.35” represents wire sectional area, in unit of square millimeter.
“AT” represents 6AT Punch.
SAIC-SV91 09/2017
System Overview 1-8
Connector
63
IP 249C WH FLRB 0.5

,3B%
Relay
Body Control Module

(&0
For example: IP01_B represents connector IP01_B, pin 48.

90
Represents a female connector.
Represents a male connector.
Grounding point
G_EBR3
The grounding point is indicated with a double circle, marked with the grounding point number, as shown
in the figure G_EBR3.
SAIC-SV91 09/2017
System Overview 1-9
Twisted-pair
Twisted pair
Twisted-pair
The twisted pair is as shown in the circuit diagram.
Shielded wire
90
Shielded Wire
The shielded wire is as shown in the circuit diagram.
SAIC-SV91 09/2017
System Overview 1-10
90
SAIC-SV91 09/2017
Fuse Boxes 2-11
2.1 Engine bay (pre-fuse) fuse box
90
D9013-0208b
2.1.1 Fuse information sheet
Fuse Specifications Function

1 175A Front Fuse Box
2 - Starter
3 100A Electronic Power Steering
4 175A Front Fuse Box 2
5 175A Generator
SAIC-SV91 09/2017
Fuse Boxes 2-12
2.2 Engine bay fuse box
U-JF10 40A JCASE U-FS1 10A MINI U-PR2 PWR MINI U-PR1 PWR MINI U-R1 MINI
./3:5
KL30 PWR
ऽ呂䷽ᱩ
REAR BLOWER
MINI
⩤ၿⅣ∤㐖⩤஗
U-FS2 25A
WATER PUMP RLY
ऽ⿆ߏ☜ऽ㻵䪋㵻ᱽ࣑▞
䶳⪈ 䶳⪈
RRDEFROST/MIRROR/TRUNK LP
RESERVED RESERVED
U-JF9 40A JCASE

U-FS3 30A MINI
,(&⩤⎿
‫ݼ‬呂䷽ᱩ
IEC PWR 5
FRT BLOWER
U-FS4 25A MINI

⛲⇨∤
U-JF8 40A JCASE FUEL PUMP
MICRO MINI MINI
MICRO
U-R9 U-FS17 U-R2
䶳⪈
$%6(63B⩤ᱩ U-FS5 25A MINI RESERVED
LOW BEAM RLY

⾩䄲ࢺ㑘ᱩ㐖⩤஗
䔀‫▞ٸ‬㐖⩤஗
ABS/ESP_MOT $%6(63B䬯
A/C COMPRESSOR
ABS/ESP_VALVE
MINI
䶳⪈
U-FS18 15A
RESERVED
‫⅖ݼ‬яᙎ஗
U-FS6 15A MINI FRT LAMBDA SEN
JCASE
U-R14
U-JF7 40A ऀߗᱩᣖ‫ݥ‬ὐಆ
ECM
U-FS19 5A MINI
Ⱓ≰⽢ࢺ஗ U-R10 MICRO ऽ⅖яᙎ஗
DCDC 2
UFS7 30A MINI RR LAMBDA SEN
‫ݼ‬䰗‫ݝ‬
ऽ䰭▞㐖⩤஗
MICRO
FRT WIPER
REAR FOG RELAY
U-FS20 15A MINI
JCASE MINI
◨▚㏮ష
U-JF6 40A U-R3
U-FS8 15A MINI IGN COIL
HIGH BEAM RLY

䔋‫▞ٸ‬㐖⩤஗
⩤ၿⅣ∤
,(&⩤⎿ WATER PUMP
IEC PWR 9
U-FS21 15A MINI
U-R11 MICRO ͪ㐖⩤஗⩤⎿ શज
MINI
U-R15
U-FS9 15A MAIN RLY HORN
⾩䄲ࢺ㑘ᱩ㧳⩤↏яᙎ஗
A/C COMPRESSOR/IBS Ѽ㒝▞㐖⩤஗
U-JF5 60A JCASE POSITION LP RLY
U-FS22 20A MINI
શज
U-FS10 30A MINI HORN
$&&⩤⎿
MICRO
,(&⩤⎿
ACC PWR
IEC PWR 3
U-FS23 10A MINI
ጕӖᬔ㵻▞㐖⩤஗
䊦ߗᱩࣼ亷
U-FS11 25A MINI U-R12 MICRO STARTER FB
DTL_L RLY
90 U-JF4 30A JCASE 䰭▞Ѽ㒝▞ᬔ㵻▞

FOG/POS/DRLP
U-R4 MINI
ጕ‫ݼ‬䰭▞㐖⩤஗ U-FS24 10A MINI
FOG_FL RLY
U-R16
ऽ䰭▞Ѽ㒝▞ᬔ㵻▞
,*⩤⎿
IG PWR
U-FS12 25A MINI RFOG/POS/DRLP
䊦ߗᱩ㐖⩤஗
,(&⩤⎿
STARTER RLY
IEC PWR 8
U-FS25 10A MINI
ऽ㻵䪋ះएᅭ䬗⇨ムⰅ
BCM_REAR FOLD/PLCM/FUEL FLAP
U-JF3 30A JCASE U-FS13 25A MINI
MICRO
MICRO
䔀‫▞ٸ‬
U-R13
LO BEAM
䊦ߗᱩ U-FS26 25A MINI
ढӖᬔ㵻▞㐖⩤஗
ढ‫ݼ‬䰭▞㐖⩤஗
STARTER ͜ᣖ䨰
DTL_R RLY
FOG_FR RLY
U-FS14 20A MINI BCM_CDL/P UNLOCK MOT
䔋‫▞ٸ‬
HI BEAM U-R5 MINI
U-FS27 10A MINI
JCASE
U-R17
U-JF2 50A ‫ڴ‬亟▞‫ڦ‬

U-FS15 30A MINI BCM_INT LP
,(&⩤⎿
⩤ၿ侪䒕
⛲⇨∤㐖⩤஗
IEC PWR 2
EPB
U-FS28 15A MINI FUEL PUMP RLY
ጕӖ䔋‫▞ٸ‬
U-FS16 30A MINI HI BEAM_L
,(&⩤⎿
U-JF1 30A JCASE IEC PWR 4
U-FS29 15A MINI
ढӖ䔋‫▞ٸ‬
ͪ㐖⩤஗ HI BEAM _R
MAIN RLY
MINI
JCASE
JCASE
U-FS34 15A
U-FS30 15A MINI
≆⋓ऽ䰗‫ݝ‬
BCM_RR/WIPER/WASH ጕӖ䔀‫▞ٸ‬
U-R6 MINI
LO BEAM_L
,(&⩤⎿
,(&⩤⎿
IEC PWR 6
IEC PWR 1
U-JF12 60A
U-JF11 60A
MINI
䰗‫⎿⩤ݝ‬㐖⩤஗
U-FS31 15A
U-FS33 25A MINI ढӖ䔀‫▞ٸ‬
WIPER PWR RLY
ๅ▞
BCM_EXT LP
LO BEAM_R
U-FS32 10A MINI

๖▞䄲㞱
ADJ MOT
MID1 100A MIDI
‫䷽ࢣۦ‬᝶
COOLING FAN(850W/600W)
U-R8 MINI U-R7 MINI
ͪ㐖⩤஗ 䰗‫ݝ‬䄲䕎㐖⩤஗
MAIN RLY WIPER SPEED RLY
UEC D9013-0209b
SAIC-SV91 09/2017
Fuse Boxes 2-13

MID1 100A Cooling fan
U_FS1 10A KL30 PWR
U_FS2 25A Rear Window Heating / Rear View Mirror / Trunk

Light
U_FS3 30A IEC Power Supply 5
U_FS4 25A Fuel Pump
U_FS5 25A ABS / ESP_Valve
U_FS6 15A Engine Control Module
U_FS7 30A Front Wiper
U_FS8 15A Electric Water Pump
U_FS9 15A A/C Compressor / Battery Sensor
U_FS11 25A Fog Lamp / Sidelight / DRL
U_FS13 25A Low Beam
U_FS14 20A High Beam
U_FS15 30A IEC Power Supply 2 90
U_FS17 - Reserved
U_FS18 15A Front Oxygen Sensor
U_FS19 5A Rear Oxygen Sensor
U_FS20 15A Ignition coil
U_FS21 15A Main Relay Power Supply
U_FS22 20A Horn
U_FS23 10A Starter Feedback
U_FS24 10A Rear Fog Lamp / Sidelight / DRL
U_FS25 10A Rear View Mirror Close-up / Tail Door / Fuel

Tank Cap
U_FS26 25A Central Control Lock
U_FS27 10A Interior Light
U_FS28 15A Left High Beam
U_FS29 15A Right High Beam
U_FS30 15A Left Low Beam
U_FS31 15A Right Low Beam
U_FS32 10A Head Lamp Adjustment
U_FS33 25A Exterior Lamp
U_FS34 15A Washer / Rear Wiper
U_JF1 30A Relay - Main
SAIC-SV91 09/2017
Fuse Boxes 2-14

U_JF2 50A Electronic Parking
U_JF3 30A Starter
U_JF4 30A IG Power Supply
U_JF5 60A ACC Power Supply
U_JF6 40A IEC Power Supply
U_JF7 40A DC Stabilizer 2
U_JF8 40A ABS / ESP_Motor
U_JF9 40A Front Blower
U_JF10 40A Rear Blower
U_JF11 60A IEC Power Supply 1
U_JF12 60A IEC Power Supply 6
2.2.2 Relay information sheet
Relay Function
90 U_R1 Electronic Water Pump Relay
U_R2 Reserved
U_R3 Horn
U_R4 Starter Relay
U_R5 Fuel Pump Relay
U_R6 Wiper Power Supply Relay
U_R7 Wiper Governor Relay
U_R8 Main Relay
U_R9 A/C Compressor Relay
U_R10 Rear Fog Lamp Relay
U_R11 Sidelight Relay
U_R12 Front Left Fog Lamp Relay
U_R13 Front Right Fog Lamp Relay
U_R14 Low Beam Relay
U_R15 High Beam Relay
U_R16 Left DRL Relay
U_R17 Right DRL Relay
U_PR1 Reserved
U_PR2 Reserved
SAIC-SV91 09/2017
Fuse Boxes 2-15
2.3 Engine bay fuse box 2

MINI
MINI
MINI
MINI
RESERVED
,*⩤⎿
,*⩤⎿
IG PWR3
IG PWR1
ACC 1
$&&
䶳⪈
U2-FS15 10A
U2-FS13 10A
U2-FS11 30A
U2-FS17
MINI
MINI
MINI
MINI
RESERVED
,*⩤⎿
,*⩤⎿
IG PWR4
IG PWR2
$&&
ACC 2
䶳⪈
U2-FS16 10A
U2-FS14 10A
U2-FS12 10A
U2-FS18
U2-R1 MINI U2-JF1 JCASE

U2-FS1 20A MINI
䔵इ஗
INVERTER 䶳⪈
$&&㐖⩤஗ RESERVED 90
ACC RELAY
U2-FS2 10A MINI
㒀‫ڢ‬
GATEWAY
U2-JF2 JCASE
U2-FS3 10A MINI 䶳⪈
ጝ䕎䨰ᣖ‫ݥ‬஗
RESERVED
EDL ECU
U2-FS4 30A MINI

RESERVED
ጕऽ⩤ߗ䒕⿆
PWR WIN_RL
U2-JF3 JCASE
䶳⪈
䶳⪈
U2-FS5 10A MINI RESERVED
㗽ࢺᷯ≺
TPMS
MICRO U2-R2
U2-FS6 15A MINI U2-JF4 25A JCASE

‫ݼ‬ᣁᏖḴߏ☜
FRT SEAT HEATER
⩤ߗͭࡶ䬗ᣖ‫ݥ‬஗
3/&0
U2-FS7 15A MINI
REAR BLOWER ऽᣁᏖḴߏ☜
REAR SEAT HEATER
ऽ呂䷽ᱩ
U2-JF5 JCASE
U2-FS8 30A MINI
7&&8⩤⎿
䶳⪈
MICRO U2-R3 TCCU PWR1
RESERVED
U2-FS9 30A MINI

7&&8⩤⎿
TCCU PWR2 U2-JF6 JCASE
IG RELAY
U2-FS10 30A MINI 䶳⪈
ढऽ⩤ߗ䒕⿆ RESERVED
,*㐖⩤஗
PWR WIN_RR
MICRO U2-R4 UEC_2 D9013-0210b
SAIC-SV91 09/2017
Fuse Boxes 2-16

U2_FS1 20A Converter
U2_FS2 10A Gateway
U2_FS3 10A Differential Lock Control Module
U2_FS4 30A Rear Left Power Window
U2_FS5 10A Tire Pressure Detection
U2_FS6 15A Front Seat Heating
U2_FS7 15A Rear Seat Heating
U2_FS8 30A TCCU Power Supply 1
U2_FS9 30A TCCU Power Supply 2
U2_FS10 30A Rear Right Power Window
U2_FS11 30A ACC 1
U2_FS12 10A ACC 2
U2_FS13 10A IG Power Supply 1
90 U2_FS17 - Reserved
U2_FS18 - Reserved
U2_JF1 - Reserved
U2_JF2 - Reserved
U2_JF3 - Reserved
U2_JF4 25A Power Lifting Door Control Module
U2_JF5 - Reserved
U2_JF6 - Reserved
Relay Function
U2-R1 ACC Relay
U2-R2 Reserved
U2-R3 Rear Blower
U2-R4 IG Relay
SAIC-SV91 09/2017
I-JF1 JCASE
MINI I-FS34 10A I-FS21 10A MINI I-FS13 10A MINI I-FS1 15A MINI
ऽ㻵䪋ߏ☜ ㏳षЙ㶗䒕㖃㒀ᄧᅾ ,*3:5
䶳⪈
CLUSTER T- BOX/12- SCREEN IG PWR 2
MICRO
MIRROR HEATER RESERVED
MINI I-FS33 10A I-FS22 15A MINI I-FS14 10A/15A MINI I-FS2 10A MINI
䶳⪈ 㜙ߗइ䕎ム ◨▚ᐯ‫ ڢ‬3(36__667* ,*3:5
TCU IGN SW/(PEPS| | SSTG) IG PWR 1
䶳⪈
RESERVED
RESERVED
LOGO LP RLY
⚖౟▞㐖⩤஗
I-JF2 40A JCASE
MINI I-FS32 I-FS23 25A MINI I-FS15 10A MINI I-FS3 10A MINI
⩤ߗᏖḴ
䶳⪈ འͿ㈪㐎ᩥ䴢ᱩ ‫ݼ‬呂䷽ᱩࣼ亷 Ⴘ‫⅃ڗ‬௹ᣖ‫ٲࢄݥ‬
PWR SEAT
MP5/RADIO FRT BLOWER_FB IG PWR 2(ACU)
RESERVED
I-R6
I-R7
MINI I-FS31 I-FS24 10A MINI I-FS16 10A MINI I-FS4 15A MINI
䶳⪈ 䃹᫜ऒ ऽ呂䷽ᱩࣼ亷 3(36
2.4 Instrument panel fuse box
OBD RR BLOWER_FB PEPS

RESERVED
I-JF3 30A JCASE
‫ڗ‬ᮞ๘⿆
I-FS25 10A MINI I-FS17 10A MINI I-FS5 10A MINI
MINI I-FS30 30A
SUNROOF ⾩䄲ᣖ‫ݥ‬䲑ᲮጕӖ͜ᣖᐯ‫ڢ‬ $&& ,*3:5
‫ޞ‬侭⣪⦲ࡶ䭼⩤ᱩ
A/C PANEL/LUMBAR ACC 2 IG PWR 3
PWR WIN_PD
I-FS26 MINI I-FS18 10A MINI I-FS6 10A MINI
MINI I-FS29 25A
MICRO
MICRO
䶳⪈ $&& ,*3:5
ͪ侭⣪⦲ࡶ䭼⩤ᱩ
RESERVED ACC 3 IG PWR 4
PWR WIN_DD
I-FS19 15A MINI I-FS7 7.5A MINI
MINI I-FS28
$&& 䒕䖂վ⻪䒴ߘ
TRUNK LP
䶳⪈
ACC 1 LDW
㵻ᱽ࣑▞㐖⩤஗
RESERVED
ऽ㻵䪋঻ऽ⿆ߏ☜㐖⩤஗
I-R3 MICRO
REAR WIN/MIRROR HEATING RLY

I-FS20 30A MINI I-FS8 25A MINI
MINI I-FS27
ߎ⢶ᩭ๖஗ ‫ݼ‬๘⿆䖝䭢ፇ
䶳⪈ AMP FRT SUNROOF/SUN SHADE
,*⩤㐖⩤஗
I-R4
I-R5
RESERVED
IG RELAY
I-FS9 25A MINI

‫ޞ‬侭⩤ߗᏖḴ
PWR SEAT_PAS
I-R2
I-FS10 25A MINI

ͪ侭⩤ߗᏖḴ
I-R1
PWR SEAT_DRV
I-FS11 15A MINI

ACC RLY
IEC_A
$&&㐖⩤஗
$&&
ACC 4
‫ݼ‬呂䷽ᱩ㐖⩤஗
FRT BLOWER RELAY
SAIC-SV91
Fuse Boxes
I-FS12 MINI
䶳⪈
RESERVED
MINI
MICRO
IEC
D9013-0211b
09/2017
2-17
90
Fuse Boxes 2-18

I-FS1 15A IG PWR 2
I-FS2 10A IG PWR 1
I-FS3 10A Airbag Control Unit
I-FS4 15A PEPS
I-FS5 10A IG PWR 3
I-FS6 10A IG PWR 4
I-FS7 7.5A Lane Departure Aid
I-FS8 25A Front Sunroof / Sunshade
I-FS9 25A Passenger’s Side Power Seat
I-FS10 25A Driver’s Side Power Seat
I-FS11 15A ACC 4
I-FS12 - Reserved
I-FS13 10A Telematics /12-inch Display Screen
I-FS14 10A/15A Ignition Switch (PEPSIISSTG)
I-FS15 10A Front Blower Feedback
I-FS16 10A Rear Blower Feedback
90 I-FS17 10A ACC 2
I-FS18 10A ACC 3
I-FS19 15A ACC 1
I-FS20 30A Power Amplifier
I-FS21 10A Instrument Cluster
I-FS22 15A AMT
I-FS23 25A Entertainment System / Radio
I-FS24 10A Diagnosis Interface
I-FS25 10A A/C Control Panel / Left Central Control Switch
I-FS26 - Reserved
I-FS27 - Reserved
I-FS28 - Reserved
I-FS29 25A Driver’s Side Power Window Lifter
I-FS30 30A Passenger’s Side Power Window Lifter
I-FS31 - Reserved
I-FS32 - Reserved
I-FS33 - Reserved
I-FS34 10A Rear View Mirror Heating
I-JF1 - Reserved
I-JF2 40A Power seat
I-JF3 30A Panoramic sunroof
SAIC-SV91 09/2017
Fuse Boxes 2-19
Relay Function
I-R1 Front Blower Relay
I-R2 ACC Relay
I-R3 IG Relay
I-R4 Trunk Light Relay
I-R5 Rear View Mirror & Rear Window Heating Relay
I-R6 Reserved
I-R7 Under Mirror Relay
90
SAIC-SV91 09/2017
Fuse Boxes 2-20
90
SAIC-SV91 09/2017
Grounding point distribution and positions 3-3
3.1 Schematic diagrams of the grounding points distribution and positions
G_EN2 G_EBR1
G_BTN
G_EN1
G_EBL2_1
G_EBL2_2 G_EBR2
G_EBL2_3
G_EBL2_4
G_EBR3
G_EBL3
G_IPB1_1
G_IPA1_1 G_IPB1_2
G_IPA1_2
G_IPA1_3
G_IPA2_0 G_IPB2_0
G_IPA2_1 G_IPB2_1
G_IPA2_3 G_IPB2_2
G_IPM1_0 G_IPM3_1
G_IPM1_1 G_IPM3_2
G_IPM1_2
G_IPM1_3
G_IPM1_4
G_FLR2_1
90
G_FLR2_2
G_IPM2_0
G_IPM2_1
G_IPM2_2
G_IPM2_3
G_FLL2_1
G_FLL2_2
G_FLL2_3
G_FLL2_4 G_FLR1_1
G_FLL1_1 G_FLR1_2
G_FLL1_2 G_FLR1_3
G_FLL1_3
G_FLL1_4
G_FLCL_1 G_FLCR_1
G_FLCL_2 G_FLCR_2
G_FLCL_3 G_FLCR_3
G_FLCL_4
G_FLCR_4
G_FLDL2
G_FLDL1_1 G_FLDR1_1
G_FLDL1_2 G_FLDR1_2
G_FLDL1_3 G_FLDR1_3
G_FLDR2_1
G_FLDR2_2
G_FLDR2_3
D9013-0200b
SAIC-SV91 09/2017
Grounding point distribution and positions 3-4
90
SAIC-SV91 09/2017
Harness distribution and the definitions of electric component pins 4-23
4.1 Engine bay harness
EB08 EB14 EB40
EB2EN
EB04
EB06
EB15
90
EB02_K
EB35_1
EB36_1 EB35_2
EB36_2
EB51
EB52
EB33
EB34
EB54
EB12 EB2BT EB18 EB11 EB56 EB32 EB48 EB49 EB55 EB31 EB21 EB17 EB29 EB53
EB13 EB22
D9013-0201b
SAIC-SV91 09/2017
4.1.1 The definitions of the engine bay harness pins
20 L-BU A/C Pressure

Switch (High)
21 D-GN A/C Pressure

Switch (Middle)
WITH COVER 13663586
22 L-GN P/N Signal
23 - -
91
81
80
94
93
92
90
89
88
87
86
85
84
83
82
79
78
77
76
75
74
73
6
5
51
71
61
68
67
66
65
64
53
52
72
70
69
63
62
60
59
58
57
56
55
54
24 - -
3
4
29
41
31
30
50
49
48
47
46
45
44
43
42
40
39
38
37
36
35
34
33
32
1
2 25 - -
11
10
21
19
18
17
16
15
14
13
12
20
28
27
26
25
24
23
22
7
9
8
26 D-BU Fan Dissipation

26 WH Fan Dissipation
27 WH/BK Hydraulic Accu -

mulator
28 OG Fuel Pump Relay
Engine Control Module EB02_k
29 GY/WH Rear Oxygen Sen -
sor
30 RD/WH Supply
Pin Color Function Rema 31 YE Starting Con -
number rk trol+
1 BK Ground 32 - -
2 BK Ground 33 TN/WH Rear Oxygen Sen -
90 sor
3
WH/D- Power Supply -
GN Main Relay 34 - -
4 BK Ground Electronic
WH/D- Power Supply - 35 BN Throttle Pedal
5
GN Main Relay Ground 1
6
WH/D- Power Supply - Fuel Pump Sig -
36 PU
GN Main Relay nal+
7 - - Boost Pressure &
8 - - 37 OG/BK Temperature
Sensor
9 PU/WH Starting Con -
trol- 38 - -
10 - - 39 - -
Electronic 40 YE Airflow signal
11 PU Throttle Pedal 41 - -
Ground 2 Electronic
42 D-BU/WH
12 D-GN Cruise Control- Water Pump Relay
Brake Vacuum 43 - -
13 OG
Sensor 44 TN B.D.CAN1L
14 BK/WH Sensor- 45 RD/WH B.D.CAN1H
15 BN/WH Cruise Control+ 46 - -
16 - - 47 - -
17 - - Starting Feed -
48 PU
18 PU/WH Airflow Signal back
19 - - 49 GY S/S OFF Signal
50 - -
SAIC-SV91 09/2017
51 - - Electronic
52 - - 81 BN Throttle Pedal
53 - - Power Supply 2
54 - - Electronic
82 WH/BK Throttle Pedal
55 - -
Power Supply 1
56 - -
Electronic
Airflow Sensor
57 GY/BK 83 D-BU Throttle Pedal
Ground
Signal Output 1
58 PU Cruise Control-
84 - -
Airflow Sensor
59 GY 85 YE/BK ACC Awake
Supply
85 YE/BK Remote Awake
60 GY Clutch Travel
Sensor+ 86 - -
Electronic 87 RD/BK IG Power Supply
61 L-BU Throttle Pedal 88 - -
Signal Output 2 89 - -
62 PU Rear Oxygen Sen - 90 - -
sor
91 - -
Boost Pressure &
92 - -
63 WH Temperature
Sensor 93 - -
64 L-GN Cruise Control+ 94 PU S/S OFF LED
90
65 PU Charging Indi -
cator
66 - -
67 - -
68 - -
69 BN Main Relay Con -

trol
70 - -
71 - -
72 PU/WH A/C Compressor

Relay
73 GY/WH Oxygen Sensor

Heating
74 - -
75 - -
76 TN/WH Oxygen Sensor

Signal
77 PU/WH Oxygen Sensor

Signal
78 PU/WH Oxygen Sensor

Signal
79 WH Oxygen Sensor
Signal
80 - -
SAIC-SV91 09/2017
19 BK Rear Wiper
Ground
20 GY Door Lock Motor-
21 BK Fuel Tank Ground
22 BK Ground
2 4 6 8 10 12 14 16 18 20 22
1 3 5 7 9 11 13 15 17 19 21
2 4 6 8 10 12 14 16 18
Body Control Module EB57_C
1 3 5 7 9 11 13 15 17
Pin Color Function Rema

number rk
KL30 Interior
1 RD/BK
Light
KL30 Front
2 RD/BK
Washer Pump Body Control Module EB57_E
90 KL30 Turning
3 RD/BK
Signal Light
4 OG Washer Pump+ Pin Color Function Rema
5 PU/WH Back Lighting number rk
KL30 Rear 1 PK Backlight
6 RD/BK
Washer Pump P-gear Sole -
2 TN
7 BK Signal Ground noid Valve
Washer Pump P-gear Release
8 BK 3 BK
Ground Motor Ground
9 BK Signal Ground 4 BK Rear View Mirror
10 D-GN Washer Pump- Close-up Ground
11 WH Filler Cap Motor
5 - -
Driver’s Side
6 PK Close-up-
12 L-GN
Door Lock Motor- KL30
13 WH Rear wiper 7 RD/BK P-gear Release
13 WH Rear wiper Motor
14 RD/BK KL30 CDL KL30
8 RD/BK Rear View Mirror
14 RD/BK KL30 CDL
Close-up
KL30 Fuel Tank
15 RD/BK 9 L-GN/WH Trunk Light
Cap
16 TN Tail Door Motor
10 YE Close-up+
17 RD/BK KL30 Rear Wiper

11 - -
12 - -
18 TN Door Lock Motor+
13 - -
14 - -
SAIC-SV91 09/2017
15 - - 15 - -
16 - - Right Front
17 - -
16 GY/WH Wheel Speed Sen -
sor
18 - -
17 GY/BK Right Rear Wheel
Speed Signal
18 L-GN Left Rear Wheel

Speed Sensor
19 GY/WH Left Front Wheel

Speed Sensor
20 GY/BK CAN_L
21 - -
ESP Turned Off
26 27 28 29 30 31 32 33 34 35 36 37
25
14 15 16 17 18 19 20 21 22 23 24
38
22 D-BU
1 2 3 4 5 6 7 8 9 10 11 1 2 13
ESP Turn-Off
23 L-BU/BK
LED
24 - -
25 PU Valve Power Sup -

ply
26 D-BU CAN1P
27 - -
Anti-lock Braking System / 28 GY/BK Supply
Electronic Stability Control Unit EB04 29 PU Right rear wheel

speed sensor 90
30 - -
31 GY/BK Left Rear Wheel

Pin Color Function Rema Speed Signal
number rk 32 - -
1 D-GN Pump Power 33 L-GN/BK CAN_H
Source
Hill Decent Con -
2 - - 34 WH
trol LED
ESP Turn-Off
3 BN 35 - -
LED
36 - -
Right Front
4 D-GN Wheel Speed Sen - 37 - -
sor 38 BK Ground
5 - -
6 - -
7 - -
8 L-BU Left Front Wheel

Speed Sensor
9 PK Hill Decent Con -

trol
10 YE/BK VSO
11 - -
12 TN ESP Turned Off
13 BK Ground
14 L-GN CAN1M
SAIC-SV91 09/2017
22 - -
12V Power Sup -
23 RD/BK
ply

number rk
26 25 24 23 22 21 20 19 18 17 16 15 14
24 - -
13 12 11 10 9 8 7 6 5 4 3
2 1 25 BK Ground
12V Power Sup -
26 YE/BK
ply
Transfer Case Control Unit FL01

number rk 10 1
1 OG Motor H-L
20 11
2 TN Motor L-H
3 - -
2WD/4WD
90
4 D-GN Change-over
Switch
5 YE/BK Motor Decoder
Gateway FL02_A
6 - -
7 - -
8 RD/WH CAN_H
9 TN CAN_L Pin Color Function Rema
number rk
10 - -
1 BN/WH DIAG_CAN_H
11 PK/BK Solenoid Clutch
2 D-BU CAN_H
Coil
12 BK Ground 3 D-GN CAN_H
12V Power Sup - 4 RD/WH CAN_H
13 YE/BN
ply 5 BN/WH CAN_H
14 OG Motor H-L 6 - -
15 TN Motor L-H 7 - -
H/L Mode 8 - -
D-GN/
16 Change-over 9 BN LIN1
WH
Switch 10 - -
17 BN/WH Motor Decoder 11 WH/BK DIAG_CAN_L
18 D-BU/WH Motor Decoder 12 L-GN CAN_L
19 OG/WH Motor Decoder
13 L-BU CAN_L
20 YE/BK Critical Moment
14 TN CAN_L
Recovery
21 - - 15 BN CAN_L
SAIC-SV91 09/2017
16 - -
17 - -
18 RD/BK KL15
19 RD/WH KL30
20 BK/WH Ground
D6
D5
D4
D3
D8
D7
D1
D2
C12 B12
C11 B11
C10 B10
C7
C9
C8
C6
C5
C3
C4
C1
C2
B6
B5
B3
B4
B2
B9
B7
B8
B1
A6
A5
A4
A3
A7
A2
A1
A8
6 5 4 3 2 1
Driver’s Side Power Seat FL03
12 11 10 9 8 7
number rk
A1 - -
Gateway FL02_B A2 YE/BK NTC+
90
A3 PK Driver’s Side
Seat Heat+
A4 OG Electronic fan
number rk A5 - -
1 - - Driver’s Side
A6 L-GN
2 - - Seat Heat-
3 - - A7 YE NTC-
4 - - A8 RD/BK KL15
5 - - Right Side Seat
B1 PU/WH
X/Y Axis
6 BK/WH Ground
7 - -
B2 YE Ground
8 - - Right Side Seat
B3 GY
Y Axis
9 - -
X Axis Adjust -
10 - - B4 WH
ment
11 RD/BK Supply
Y Axis Adjust -
12 RD/WH KL30 B5 WH
ment
B6 - -
B7 - -
B8 - -
B9 - -
B10 - -
B11 - -
B12 - -
SAIC-SV91 09/2017
D-GN/ Left Rear View

C1
WH Mirror Horizon -
tal Adjustment Pin Color Function Rema
number rk
C2 WH Adjustment
Motor Ground 1 TN Right Front
Grouped Lamp
Left Rear View
Mirror Vertical Right Front
C3 D-BU/WH 2 OG Grouped Lamp
Adjustment
Motor Motor1+
Right Seat Ver - 3 L-GN B_D_CANL
C4 GY/BK
tical Front Body
4 BN/WH
C5 WH Horizontal- Height Signal
C6 OG/BK Vertical+ Left head
5 L-BU/BK grouped lamp
C7 YE Supply
assembly
C8 GY Left Aisle Sen -
Rear Body Height
sor Vertical 6 PU
Signal
C9 D-GN Left Aisle Sen -
7 BK/WH Ground
sor Horizontal
8 BARE Shielded wire
C10 BN Right Seat Hori -
zontal 9 RD/BK KL15
Right Seat Ver - Left Front
C11 L-BU/BK
tical 10 BN Grouped Lamp
Motor 1+
C12 L-GN Ground
90 D1 - - Left Front
11 L-BU Grouped Lamp
D2 RD/BK KL15
Motor 1-
D3 L-GN KL30
12 GY Rear Body Height
D4 L-BU CAN_L Power Supply
D5 D-GN CAN_H Left Front
D6 BK MSM GND 13 GY Grouped Lamp
Motor 2-
D7 - -
14 RD/WH KL30
D8 BK FAN & MSM
Front Body
15 GY/WH Height Power
Supply
16 D-BU B_D_CANH
Right head
17 L-GN/BK grouped lamp
assembly
Right Front
1 2 3 4 5 6 7 8 9 10 11 12 13 18 PK Grouped Lamp
Motor 1-
14 15 16 17 18 19 20 21 22 23 24 25 26
19 PU/WH Front Body

Height Circuit
Right Front
20 TN Grouped Lamp
Motor2+
21 BARE Shielded wire
Adaptive Head Lamp Control Unit FL27
SAIC-SV91 09/2017
Right Front 16 - -
22 YE Grouped Lamp 17 RD/WH KL30
Motor 2-
18 BK/WH Ground
23 WH Left Front
Grouped Lamp
19 - -
Rear Body Height

20 - -
24 BN
Signal 21 - -
Left Front 22 RD/BK KL15
25 D-GN Grouped Lamp 23 - -
Motor 2+
24 - -
26 - -
1 2 5 6
1 2 3 4 5 6 7 8 9 10 11 12 3 4
13 14 15 16 17 18 19 20 21 22 23 24 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
90
Stabilizing DC Module FL31_A

Tire Pressure Monitoring Control Unit FL30

Pin Color Function Rema number rk
number rk
1 L-GN Output
1 D-GN CAN_H
2 D-BU Output
2 L-BU CAN_L
3 RD/WH KL30
3 - - 4 - -
4 - - 5 BN Output
5 - - 6 RD Output
6 BK/WH Ground 7 - -
7 - - 8 - -
8 - - 9 - -
9 - - 10 RD/BK KL15
10 - - 11 - -
11 - - 12 - -
12 - - 13 - -
13 - - 14 - -
14 - - 15 - -
15 - -
SAIC-SV91 09/2017
16 - - 17 - -
17 - - 18 - -
18 - - 19 - -
19 - - 20 - -
20 - - 21 - -
22 TN CAN_L 22 - -
23 RD/WH CAN_H 23 - -
24 - - 24 - -
25 - -
26 YE Starting Relay
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
15 14 13 12 11 10 9
30 29 28 27 22 20 19 18 17 16
90
Stabilizing DC Module FL31_B
Electronic Parking Brake Control Module FL34

number rk
1 YE/BN Supply
2 YE/BN Supply number rk
3 BK Ground 12 RD Right Brake
4 BK Ground Motor+
5 OG/RD Supply Right Brake
13 RD/WH Motor Power Sup -
6 OG/RD Supply ply
7 - - Left Brake
14 WH
8 - - Motor+
9 - - 15 RD/WH Left Brake Motor
10 RD/BK KL15 Power Supply
11 - - 27 D-BU Right Brake
Motor-
12 - -
28 BK Ground
13 - -
29 GY Left Brake
14 - - Motor-
15 - - 30 BK Ground
16 - - 9 D-GN Switch 1
SAIC-SV91 09/2017
10 PK Switch 2 13 - -
11 - - 14 - -
16 D-BU CAN_H 15 BN CAN_L
17 L-GN CAN_L 16 BN/WH CAN_H
18 L-GN/BK Switch 3
19 L-GN Switch 4
20 - -
22 RD/BK KL15
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
Rear A/C Control Panel FL38_1
90
Power Amplifier FL44_A
number rk
1 L-GN/WH Mode+
Pin Color Function Rema 2 L-GN/BK Mode-
number rk 3 - -
1 D-GN Rear Left 4 RD/BK Supply
Speaker Input+
5 RD/WH Supply
2 GY Rear Left
Speaker Input- 6 - -
Rear Right 7 D-GN LIN
3 GY
4 L-GN Rear Right 9 OG/WH Mode Feedback
Speaker Input+
10 PK Temperature
5 - - Feedback
6 - - 11 - -
7 - - 12 - -
8 RD/YE Supply 13 GY Temperature+
9 L-BU Front Right 14 OG Temperature-
Speaker Input+ 15 BK/WH Ground
Front Right
10 GY 16 D-BU/WH Sensor Ground
Speaker Input-
17 BK/WH Ground
11 GY/BK Front Left
Front Left 19 - -
12 OG/BK
Speaker Input+ 20 - -
SAIC-SV91 09/2017
21 BN Sensor 5V 21 BN Sensor 5V
22 WH Blower Control 22 WH Blower Control
23 TN Blower Feedback 23 TN Blower Feedback
24 L-BU Blower FB- 24 L-BU Blower FB-
1 2 3 4 5 6 7 8 9 10 11 12
11 12 13 14 15 16 17 18 19 20
13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10
Rear A/C Control Panel FL38_2 Differential Lock Control Module FL59_A
90
Pin Color Function Rema Pin Color Function Rema

number rk number rk
1 L-GN/WH Mode+ Differential
2 L-GN/BK Mode-
1 GY Lock Solenoid
Valve
3 - -
Differential
4 RD/BK Supply 2 GY Lock Solenoid
5 RD/WH Supply Valve
6 - - 3 - -
7 D-GN LIN 4 - -
8 - - 5 - -
9 OG/WH Mode Feedback 6 - -
10 PK Temperature 7 - -
Feedback 8 BK Ground
11 - - 9 - -
12 - - 10 BK Ground
13 GY Temperature+ 11 - -
14 OG Temperature- 12 - -
15 BK/WH Sensor Ground Differential
13 L-BU
16 D-BU/WH Sensor Ground Turned On Signal
18 - - 15 D-BU CAN_H
19 - - 16 L-GN CAN_L
20 - - 17 - -
SAIC-SV91 09/2017
18 - -
19 GY/BK Supply
20 RD/WH Supply
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 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Power Tail Door Control Unit FL62_A

Differential Lock Control Module FL59_B number rk
1 L-BU/WH Left Aisle Sig -
nal 1
2 - - 90
3 D-GN CAN_H
number rk
4 L-BU CAN_L
1 GY/BK Supply
Differential Lock 5 PK/BK Tail Door Sens -
2 GY/WH ing Switch Ground
Solenoid Valve
3 GY/BK Supply
6 - -
Differential Lock
7 - -
4 GY/WH
Solenoid Valve 8 D-GN Operating Signal
5 - - 9 PK/BK Tail Door Look
6 - - Ajar Signal
7 - -
10 - -
8 - -
11 WH/BK Release Signal
9 - - Tail Door Right
12 PU/WH Sensing Switch
10 - - Signal
11 - - 13 RD/BK KL30
12 - - 14 D-GN Aisle Ground
13 - - 15 - -
14 - - 16 L-GN Tail Door Latch
15 - - 17 L-GN/BK Mode Signal
16 - - Aisle Power Sup -
18 TN/BK
ply
19
D-GN/ Trunk Close But -
WH ton
20 - -
21 YE Tail Door Lock

Stop Signal
SAIC-SV91 09/2017
22 PU Left Aisle Sig -

nal 2
23 BK Ground
Tail Door Left
24 PU/WH Sensing Switch
Signal
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 27 28 29 30 31 32
2 4 6 8 10 12 14
13
Blind Zone Monitoring Control Unit FL71
1 3 5 7 9 11

number rk
1 PK Sensor Power
Supply
Power Tail Door Control Unit FL62_B Sensor Signal
2 PU/WH Front Left Mid -
dle
90 Sensor Signal
Pin Color Function Rema 3 D-GN
number rk Left Front
1 - - Sensor Signal
4 WH Front Left Back -
2 WH Tail Door Motor+
side
3 - -
5 PK Sensor Power
4 BN/WH Tail Door Motor- Supply
5 BK Ground Sensor Power
5 PK
6 - - Supply
7 - - Sensor Signal
6 D-GN
8 - - Rear Left Middle
9 D-BU/WH Tail Door Lock 7 WH Sensor Signal

Motor Rear Left
10 - - 7 WH Sensor Signal
11 BN Tail Door Latch Rear Left
12 RD/WH KL30 Sensor Signal
8 D-BU Rear Left Back -
13 L-BU Tail Door Latch
side
14 - -
Sensor Signal
8 D-BU Rear Left Back -
side
9 D-BU CAN_H
10 - -
11 YE Left Rear View

Mirror
21 BN Sensor Ground
SAIC-SV91 09/2017
4.2 Instrument panel harness
IP31_C IP31_A IP31_B IP22 IP2RF_2

IP35 IP2RF_1 IP02_B IP21 IP41 IP44 IP02_A IP27 IP38
IP39
IP47 IP10
IP11
IP12
IP29 IP2BD_3
IP2DRD_1 IP07 IP03 IP04 IP28 90
IP2DRD_2 IP2BD_1
IP50_A
IP50_B IP01_A
IP50_C IP01_B
IP50_D IP01_D
IP2PAD
CN09 IP05 IP61 IP2BD_2
IP2BD_5 CN08 CN08 CN07 CN01 IP2BD_6 2P62 IP08_A IP55_A IP2BD_4
CN02 IP2CN_1 IP2CN_1 IP63 IP08_B IP55_B
IP2BD_7
CN03IP58 IP08_C IP55_D
CN05 IP55_E
CN06 IP56_A
IP56_B
D9013-0203b
SAIC-SV91 09/2017
4.2.1 The definitions of the instrument panel harness pins
20 - -
21 GY Rear Wiper
Switch
22 GY/BK ECO/SPORT
1 13
14 26 number rk
27 39
23 YE Lighting Main
40 52
Switch
24 PK Front Washer
25 BN Lighting Switch
Ground
26 - -
27 D-GN Roof Light
Body Control Module IP01_A
28 YE Front Right Fog
Lamp Relay
29 BN/OG Wiper Switch

Pin Color Function Rema Ground
number rk Roof Light
30 PU
1 - - Turned Off
Ignition Switch 31 D-BU/BK Door Unlocking
2 PK
90 Ground Switch
Dual Brake 32 YE High Beam
3 YE Flasher
Sensor Signal
4 BK/WH Signal Ground 33 L-GN Front Wiper High
Speed
5 L-BU Gearshift Sig -
nal Right Turning
34 D-BU/WH Signal Light
6 GY/BK Dimmer Switch Switch
7 BN KL15 35 - -
7 BN KL15 36 - -
8 RD/BK KL16 Rear Fog lamp
37 L-BU
Hazard Warning Switch
9 WH
Lamp Switch 38 PU High Beam
10 GY/BK Roof Light Auto 39 - -
11 GY Anti-theft Trunk Light
Lockup Signal 40 L-GN/WH
(Lower)
12 - - 41 L-BU CAN_L
13 D-BU Rear Washer 42 D-GN CAN_H
14 - - 43 - -
15 WH Position Lamp 44 - -
Relay
45 D-BU/YE Wiper Switch
16 L-BU Front Wiper Low Ground
Speed
46 WH/BK 5V
17 - -
47 D-BU/YE Door Locking
18 - - Switch
19 - - 48 - -
SAIC-SV91 09/2017
49 D-GN Cruise Control+ Front Wiper

Roof Light
17 GY Motor Power Sup -
50 PK/BK ply
Switch
Ignition Switch
18 L-BU/BK High Beam Relay
51 D-BU/BN
Backlight 19 OG/BK Tail Door Not
12 1
Ignition Switch Close
51 24L-BU 13
Backlight 20 - -
36 25
52 48 - - 37 21 YE Front Wiper
Reset
22 GY ECO/SPORT Mode
Switch
23 BN Brake Lamp
24 L-BU Left Turning

Body Control Module IP01_B Signal Light
25 YE High-mounted
Brake Lamp
26 - -
number rk 27 BN/OG Passenger’s
Side Door Ajar
1 L-BU/BK Rear Left Door
Not Close 28 WH/BK Under Mirror
Light Relay
2 L-GN/BK Rear Right Door
Not Close
29 D-BU Right DRL
Locking/unlock -
30 - -
3 PK/BK 90
ing Switch 31 TN Wiper Governing
Passenger’s 32 - -
4 L-BU
Side Door Lock Rear Wiper Reset
33 YE
Engine Hood Switch
5 PU
Switch 34 D-GN LIN
5 GY/BK Engine Hood Right Turning
Switch 35 D-BU
Signal Light
6 YE ACC Relay Reversing Sig -
36 OG/BK
Left Turning nal
7 L-BU/WH Signal Light 37 BK Accident Signal
Switch 37 OG Accident Signal
8 BK/WH Signal Ground
38 YE One-Button
9 - - Start Switch
39 GY/BK
11 L-BU Brake Lamp Door Ajar
12 YE Roof Light 40 PK/WH Fuel Tank Cap
13 D-BU KL15 Switch
13 D-BU KL15
41 GY Low Beam Relay
42 TN Horn Relay
14 YE Rear Fog Lamp
Relay Rear View Mirror
43 WH & Rear Window
D-GN/ Front Left Fog
15 Heating Relay
WH Lamp Relay
Front Fog Lamp
16 PU Left DRL 44 OG
Switch
SAIC-SV91 09/2017
45 L-GN Reverse Gear Dual Brake Sen -

Switch 18 OG sor
46 D-BU LIN Ground
47 YE/BK ACC Awake 19 - -
48 WH IG Relay 20 - -
21 - -
22 - -
23 - -
24 - -
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
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Body Control Module IP01_D

90

number rk Instrument Cluster IP02_A
1 - -
2 GY/BK Dual Brake Sen -

sor
3 PK Rear View Mirror number rk
Governor Switch 1 RD/BK KL15
4 - - 2 RD/WH Supply
5 - - 3 BK/WH Ground
6 - -
4 PU Brake Fluid
7 - - Level Signal
8 - - Handle brake
5 YE/BK
9 - - signal
10 - - 6 - -
12 - - 8 BN/WH CAN_H
13 - - 9 BN CAN_L
14 - - 10 OG Cruise Switch 1
15 - - 11 PK Cruise Switch 2
16 - - Anti-theft
17 - -
12 GY Lockup Indica -
tor +
13 BK/WH Ground
SAIC-SV91 09/2017
14 - - 4 - -
15 - - 5 YE Rear Left Seat
16 - - Belt
17 - -
6 L-BU Ground
7 YE Side-collision
19 - - Signal-
21 - - 8 PK/BK Side-collision
22 - - Signal+
23 - - Passenger’s
9 D-GN Side Side-col -
24 - - lision Signal+
25 - - Passenger’s
26 - - 10 GY Side Side-col -
27 - - lision Signal-
28 - - 11 TN CAN_L
29 - - 12 RD/WH CAN_H
30 - - 13 YE Driver Seat Belt
31 - - 14 - -
16 - -
Passenger’s 90
17 OG Side Seat Belt
Pre-tighten-
Passenger’s
18 L-GN Side Seat Belt
Pre-tighten+
Driver’s Side
1 2 3 4 5 6 7 8 9 10 11 12
19 BN/OG Seat Belt Pre-
13 14 15 16 17 18 19 20 21 22 23 24 tighten 1+
Driver’s Side
20 OG/BK Seat Belt Pre-
tighten 1-
21 PK/BK Passenger’s
Side Airbag-
22 RD/OG Passenger’s
Side Airbag+
Airbag Control Unit IP08_A Driver’s Side
23 TN
Airbag+
24 BN Driver’s Side
Airbag-
number rk
1 RD/YE KL15
2 BK Accident Signal
Output
Passenger’s
3 OG Side Seat Belt &
Airbag
SAIC-SV91 09/2017
Driver’s Side
12 D-GN Head-on Colli -
sion Signal+
13 BN/WH Rear Right Seat

Belt Pre-tighten-
14 PU Rear Right Seat

12 1 Belt Pre-tighten+
24 13 Rear Left Seat
15 BN
36 25 Belt Pre-tighten+
48 37 Rear Left Seat
16 YE/BK
Belt Pre-tighten-
17 L-GN Passenger’s Side

Airbag-
18 BN/OG Passenger’s Side

Airbag+
Airbag Control Unit IP08_B Airbag+
20 YE/BK Driver’s Side

Airbag-
Pin Color Function Rem 21 WH/BK Passenger’s Side
numbe ark Air Curtain-
r Passenger’s Side
22 YE/BK
1 - - Air Curtain+
90 2 - - 23 PU/WH Driver’s Side
Air Curtain+
3 PK/WH Rear Middle Seat
Belt 24 PK Driver’s Side
Air Curtain-
4 PU Rear Right Seat
Belt
Passenger’s Side
5 OG Seat Belt Pre-
tighten-
Passenger’s Side
6 L-GN Seat Belt Pre-
tighten+
1
16
Driver’s Side
7 BN/OG Seat Belt Pre-
tighten 2+ 17
32
Driver’s Side
8 OG/BK Seat Belt Pre-
tighten 2-
Passenger’s Side
9 WH/BK Head-on Colli -
sion Signal+
Passenger’s Side
10 PU/WH Head-on Colli - Airbag Control Unit IP08_C
sion Signal-
Driver’s Side
11 WH/BK Head-on Colli -
sion Signal-
SAIC-SV91 09/2017
31 RD/WH CAN_L
32 TN CAN_H
number rk
1 OG Accident Signal
Output
2 TN Driver’s Side
Airbag+
Airbag-
4 PK/BK Passenger’s
1 2 11 12 13
Side Airbag- 3 4 5 6 7 8 9 10
Passenger’s 14 15 24 25 26
16 17 18 19 20 21 22 23
5 RD/OG
Side Airbag+
6 - -
7 - -
8 - -
9 - -
10 - -
PEPS Control Unit IP09_A
11 - -
12 - -
13 - -
Passenger’s Pin Color Function Rema
14 OG number rk 90
Side Seat Belt
1 RD/WH KL30
15 - -
16 RD/YE KL15 2 RD KL30
17 L-BU Ground 3 OG/BK P-SE Output
18 - - 4 D-BU Driver’s Side
Door Switch
19 - -
5 GY/BK Trunk Light
20 - -
Switch
21 - - 6 YE Steering Aangle
22 - - 7 - -
23 - - 8 - -
Passenger’s 9 - -
24 D-GN Side Side-col -
lision Signal+ 10 - -
Passenger’s 11 - -
25 GY Side Side-col - 12 D-GN Immobilizer LIN
lision Signal-
13 - -
Driver’s Side
14 BK Ground
26 YE Side-collision
Signal- 15 BK Ground
Driver’s Side 16 YE/BK ABS/ESP
27 PK/BK Side-collision Passenger’s
Signal+ 17 GY
Side Door Switch
28 - - 18 - -
29 - - 19 GY FR Receiver
30 YE Driver Seat Belt 20 - -
SAIC-SV91 09/2017
21 - - One-Button
22 - -
13 BK/GY Start Switch
Ground
23 - -
Immobilizer Pin Color Function Rema
24 D-BU number rk
Power Supply
Immobilizer 14 - -
25 L-GN
Ground 15 L-BU CAN_L
26 - - 16 - -
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 4 3 2 1
90
PEPS Control Unit IP09_B
Steering Wheel Angle Sensor IP14

number rk Pin Color Function Rema
number rk
One-Button
1 BK/WH Supply
1 BN/BK Start Switch
2 GY/BK Supply
Backlight
3 D-BU CAN_H
2 - -
4 L-GN CAN_L
3 - -
4 BN ACC
5 D-BU Running / Opera -

tion
6 - -
7 D-GN CAN_H
8 - -
9 PU Wireless Charg -
ing Module
One-Button
10 D-BU/BK Start Switch
Backligh
11 D-GN/BK One-Button
Start Switch
12 - -
SAIC-SV91 09/2017
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
9 10 11 12 13 14 15 16 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Diagnosis Interface IP28 Front A/C Control Panel IP38

number rk number rk
1 - - 1 RD/BK KL15
2 - - 2 RD/WH KL30
3 - - 3 - -
90
5 BK/WH Signal Ground 5 D-GN LIN
6 BN/WH CAN_H 6 L-BU CAN_L
7 - - 7 D-GN CAN_H
8 - - 8 - -
9 - - 9 GY/BK Blower Control
10 - - 10 YE Blower+
11 - - 11 OG Blower FB-
12 - - 12 - -
13 - - 13 D-BU/YE Sensor 5V+
14 WH/BK CAN_L 14 L-GN/WH Sensor 5V-
15 - - 15 PK/D-GN Sensor Ground_
16 RD/L-GN Supply 16 WH Sensor Ground+
17 RD/WH Motor +
18 WH/BK Motor-
19 L-BU/WH Sunlight Sen -

sor+
20
WH/D- Sunlight Sen -
GN sor-
21 BK/WH Ground
22 D-GN/YE Sensor Ground
23 - -
SAIC-SV91 09/2017
24 - -
25 PK/WH Sun sensor
26 WH/D-BU Sun sensor number rk
Temperature Rear Right
27 L-GN/BK 1 WH
Signal -RR Speaker+
Temperature 1 L-GN Rear Right
28 BN
Signal -RR Speaker+
Temperature 2 OG/BK Rear Right
29 TN/WH Speaker+
Signal-FR
Temperature 3 L-BU Front Right
30 YE Speaker+
Signal-FR
Temperature 4 BN Rear Left
31 TN Speaker+
Signal-FL
Rear Left
Temperature 4 D-GN
32 YE/BK Speaker+
Signal-FL
5 OG Rear Right
33
D-GN/ Ambient Temper - Speaker-
WH ature Sensor
5 GY Rear Right
34 GY Evaporator Tem - Speaker-
perature
6 GY/BK Rear Right
35 D-BU Pressure Sensor Speaker-
36 PK Motor Front Right
7 GY
37 L-GN Mode Damper Speaker-
90
38 L-BU Temperature Rear Left
8 YE
Damper Actuator Speaker-
39 D-BU/GY Sunlight Sensor Rear Left
8 GY
Power Supply Speaker-
40 PU Sensor 5V
1 2 3 4
5 6 7 8
Entertainment System Host IP55_B

Entertainment System Host IP55_A
SAIC-SV91 09/2017

number rk
9 - -
10 - -
7 8 9 10 11 12
11 YE Key
12 - - 1 2 3 4 5 6
13 - -
14 - -
15 RD/WH Supply
16 BK/WH Ground
Entertainment System Host IP55_E

number rk
1 - -
6 5 4 3 2 1 2 D-BU/YE Mic+
12 11 10 9 8 7
3 - -
4 BN/WH Ground
90
5 GY Rear View Camera
5 GY Rear View Camera
6 YE Telematics
Audio Output+
7 D-GN Key
Entertainment System Host IP55_D 8 BARE Mic-
9 - -
10 BN LIN
11 BARE Shield
number rk 11 BARE Shield
1 - - 12 D-GN Telematics
Audio Output-
2 - -
3 WH Switch in Common
4 L-GN Switch 1+
5 BARE Audio-
6 BN/WH CAN_H
7 - -
8 - -
9 - -
10 L-BU Switch 2+
11 YE Audio+
12 BN CAN_L
SAIC-SV91 09/2017
7 5 3 1 7 5 3 1
8 6 4 2 8 6 4 2
Radio IP56_A Radio IP56_B

number rk number rk
1 BARE Mic- 1 WH Rear Right
Reversing Sig - Speaker+
2 OG/BK
nal 2 OG Rear Right
3 PK/BK Mic+ Speaker-
90 4 RD/YE ACC 3 L-GN Front Right
Speaker+
5 - -
4 PU Front Right
6 PU/WH Back Lighting Speaker-
7 RD/WH Supply Front Left
5 TN
8 BK/WH Ground Speaker+
6 GY Front Left
Speaker-
7 BN Rear Left
Speaker+
8 YE Rear Left
Speaker-
SAIC-SV91 09/2017
28 D-GN Audio Output-

29 - -
30 - -
31 - -
32 - -
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 33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 WH/BK HS CAN_L
Telematics Control Unit IP60 40 BK/WH Ground

number rk
1 - -
2 - -
3 - -
4 3 2 1
4 - -
12 11 10 9 8 7 6 5 90
5 BARE Audio-
6 YE Mic+
7 - -
8 YE Audio Output+
9 - -
10 - - Entertainment System Host IP63
11 - -
12 - -
13 - - Pin Color Function Rema
14 - - number rk
15 - - 1 OG/BK Camera Power
Supply
16 - -
2 BK Camera Ground
17 - -
3 - -
18 - -
4 - -
19 BN/WH HS CAN_H
5 GY Signal+
20 RD/WH KL30
6 BARE Shield
21 - -
7 GY Signal+
22 - -
8 BARE Shield
23 - -
9 GY Shield
24 - -
10 BARE Signal+
25 YE Audio+
11 - -
26 BARE Mic-
12 - -
27 - -
SAIC-SV91 09/2017
4.3 Parking radar harness
90
PR09
PR07
PR2FL
PR05
PR06
PR08
PR10
D9013-0205b
SAIC-SV91 09/2017
4.3.1 The definitions of the parking radar harness pins
10 10
3 3
15 11 15 11
8 4 8 4
12 1 12 1
16 5 16 5
13 9 13 9
6 2 6 2
14 14
7 7
AMT Control Unit GB02-1 AMT Control Unit GB02_2

number rk number rk
1 RD Supply 1 RD Supply
2 BK/WH Ground 2 BK/WH Ground
90
3 L-GN P/N Signal 3 L-GN P/N Signal
4 RD Supply 4 RD Supply
5 BK/WH Ground 5 BK/WH Ground
6 - - 6 - -
7 - - 7 - -
8 - - 8 - -
9 YE/BK ACC 9 YE/BK ACC
10 TN/BK CAN_H 10 TN/BK CAN_H
11 TN CAN_L 11 TN CAN_L
12 RD/BK Operation / 12 RD/BK Operation /

Crankshaft Crankshaft
13 - - 13 - -
14 - - 14 - -
15 - - 15 - -
16 - - 16 - -
SAIC-SV91 09/2017
4.4 Body harness
BD2IP_1
EB57_C
FL31_A FL03 EB57_E
BD2DRD
FL31_B FL07
FL02_A
FL02_B BD2IP_5 BD2IP_3
BD2IP_7
FL55
FL23 FL60
FL77 FL11
FL75 FL53 FL09
FL59_B FL06 FL2CH FL51 FL21
FL44_A
FL44_B FL57 FL15
FL44_C FL25 FL13
FL62_A FL30 FL59_A FL67
FL62_B
FL28
FL2TLD_1
FL43 FL65
FL19
FL32
90
BD2IP_2
BD2IP_4
FL34
FL56
FL2GB FL27
FL2RRD FL14 FL71
FL04 FL16
FL41 FL22 FL10
FL01
FL35 FL24
FL40 FL39_1 FL38 FL08
FL48 FL39_2 FL97 FL12
FL2PR FL38_1
FL38_2 FL68
FL73 FL69
FL05
FL63 FL58_1 FL76
FL33 FL64 FL58_2 FL52
FL2TLD_2 FL74 FL26_1 FL78
FL45_1
FL26_2
FL66 FL50_A FL45_2
FL20_1 FL50_B
FL20_2 FL61 FL50_C
D9013-0204b
SAIC-SV91 09/2017
4.5 Roof harness
RF05_1 RF01 RF13 RF2IP_1 RF03 RF20 RF07 RF10 RF08_1

RF05_2 RF14 RF09 RF22 RF08_2
RF04 RF05_3 RF12
RF21_1
RF21_2
RF17_2
RF21_3
RF17_3
RF19_1
RF15_1 RF19_2
RF15_2
RF15_3
90
RF2IP_2
RF02
RF06_1
RF06_2
RF06_3
RF18_2
RF18_3
RF19_3
D9013-0212b
SAIC-SV91 09/2017
4.5.1 The definitions of the body and the roof harness pins
12 11 10 9 8 7
6 5 4 3 2 1
Lane Departure Aid Control Unit RF10

number rk
90 1 D-BU CAN_H
2 - -
3 RD/WH Ground
4 - -
5 YE O_S_OUT1
6 RD/BK KL30
7 L-GN CAN_L
8 - -
9 L-BU I_S_IN1
10 - -
11 - -
12 RD/WH KL15
SAIC-SV91 09/2017
4.6 Door harness
PD03_A
PD03_B
DD03_A PD13 PD03_C PD02 PD06
DD04_A PAD2IP
DD03_B
DD04_B DD01 DD08 DD07 DD12 DD13 DD03_C DD02 DD10 DRD2IP
RLD2FL
RL01
RL06
RL05
RL04
RL03
RL02
TLD21
TLD2FL_1
TLD03 90
TLD11
PD12
PD05
PD01
PD04_A
PD04_B
RRD2FL
RR06
RR01
RR05
RR03
RR02
TLD01
TLD12
TLD07 TLD10 TLD14 TLD17
TLD20 TLD18 TLD08 TLD02 TLD04 TLD2FL_2
D9013-0206b
SAIC-SV91 09/2017
90
SAIC-SV91 09/2017
Electrical circuit diagrams 5-57
5.1 Starting system
Battery
BTN01
- +
175 A
Pre-fuse Box Instrument Panel Fuse Box 10/15A
I-FS14
P-MG2 PFB IEC Ignition
Switch
UEC /(PEPS
STA-2 STA UEC SSTG)
2 1 2 26 34
BT01_2 BT01_1 IP07
IP 140A RD/WH FLRB 0.35 -PEPS

BTN 150 BK FL2G 25.0 -ESSS
BT 1F RD FL2G 25.0 -ESSS
BT 1B RD FL2G 25.0 ESSS
BT 1C RD FL2G 25.0 ESSS
a
BT04-1 Engine Bay Fuse Box UEC
30 85
30 A U-R4 10 A 30 A
U-JF3 Starting U-FS23 U-FS15
Starter Relay 87 86
Starter IEC
Feedback Power
Supply 6 90
3 133 137 135 134 35 54 27
EB01
IP 2540ERD/L-GN FLRB 2.5 RADIO

BD 102 RD/BK FLRB 3.0
BD 6 PU FLRB 3.0
BD 447 YE FLRB 0.5
BD 6B PU FLRB 3.0
BD 2540 RD/L-GN FLRB 2.5
SP0102
BD2IP_1
12
IP2BD_1
BD 6A PU FLRB 3.0
BD 1035 PU/WH FLRB 0.5
BD 6BD PU FLRB 0.5
SP0105
BD 447B YE FLRB 0.5
EB2BT
20
BT2EB
BT 6C PU FLRB 3.0
BT02_1 BT03 EB02_K

9 31 48
Power
Starting Control
Starting Control
Starting Feedback
Supply
BT02_2 Engine
Starting
Starter Control
Module
ECM
G_BTN
D9013-0002b
SAIC-SV91 09/2017
Ignition Switch
Control Turned Off/ Key Key

Power Power Running/ Running/ Key Identification Identification
Supply Supply ACC Operation Operation Identification Switch Switch
2 6 3 5 1 4 2 1
IP19_A IP19_B
IP 140A RD/WH FLRB 0.35 -PEPS
IP 1073 WH/BK FLRB 0.35-PEPS
IP 4 BN FLRB 0.35-PEPS
IP 1020B PK FLRB 0.35-PEPS
IP 3 D-BU FLRB 0.35 -PEPS
IP 80 L-GN FLRB 0.35-PEPS
IP 1020 PK FLRB 0.35-PEPS

a
90
SP0103
IP 1020A PK FLRB 0.35-PEPS
IP01_A IP01_B
46 7 2 13
5V ACC Ignition KL15
Switch
Ground
Body Control Module BCM

D9013-0026b
SAIC-SV91 09/2017
5.2 Charging system
Battery
BTN01
- +
ESSS
Battery Sensor EB06 Pre-fuse Box PFB

Charge 1
BTN02 175 A
RT BATTLIN -
P-MG3
Power Supply 2 ALT
ALT-2 ALT
2 3
BT01_2 BT01_1
BTN 150A BK FL2G 25.0 ESSS
BD 42 RD/BK FLRB 1.0 ESSS
BD 5428B PU FLRB 0.5 ESSS
BT 1E RD FL2G 25.0 -ESSS
BT 1A RD FL2G 25.0 ESSS

SP0225
BT05_2 BT05_1
BD 1240A RD/WH FLRB 1.0 ESSS
Power Power
Supply Supply
Generator
Charging Indicator 90
1
EN01
11 EN2EB
EB2EN
BD 5428 PU FLRB 0.5 ESSS
SP0101
ENN 2450 BK FL2G 25.0 ENGN
ENN 2450 BK FL2G 25.0 ENGN
EB01 EB02_K
65 65
Indicator
Charging
U-R9 30 85
AC
Compressor
87 86
Relay
Engine Bay Fuse Box Engine Control Module

G_BTN G_EN01 G_EN02 UEC ECM
D9013-0001b
SAIC-SV91 09/2017
5.3 Power distribution
Pre-fuse Box PFB

+
175 A P-MG4
175 A
Battery
P-MG3 EPS
P-MG2 100 A
ALT UEC
ALT-2 ALT UEC
2 3 2 2 EPS_1
BT01_2 BT01_1 UEC_1
BTN01
-
BT 142A RD/BK FLRB 10.0 -ESSS
BT 142L RD/BK FLRB 10.0 ESSS&&LHD

BT 1E RD FL2G 25.0 -ESSS
BT 1A RD FL2G 25.0 ESSS

BT05_2 BT05_1 BT04-1 Engine Bay Fuse Box UEC

2 BT07_A
Power Supply Power Supply Power Supply
30 A U-R4 30 85
10 A
U-JF3 Starting U-FS23
90 Starter Relay 87 86 Starter
Feedback
3 133 137 135 134 35 54

Alternator EB01
EPB ECU
BD 6 PU FLRB 3.0
BD 447 YE FLRB 0.5
BD 6B PU FLRB 3.0
SP0102
BD 6A PU FLRB 3.0
BD 6BD PU FLRB 0.5
SP0105
BD 447B YE FLRB 0.5
EB2BT
20
BT2EB
BT 6C PU FLRB 3.0
BT03 EB02_K
9 31 48
Starting Control -
Starting Control +
Starting Feedback
Engine
Control
Module
ECM
G_BTN Starter
D9013-0148b
SAIC-SV91 09/2017
Engine Bay Fuse Box UEC

KL30
25 A 25 A 15 A 30A
U-FS4 U-FS8 U-FS9 U-FS7
Fuel Electronic AC Compressor / Front
Pump Water Pump Battery Sensor Wiper
16 20 21 19
EB01
BD 1240B RD/WH FLRB 1.0 -ESSS

BD 1040A RD/WH FLRB 1.5
BD 1040C RD/WH FLRB 1.0
BD 1440 BN FLRB 2.0

SP0223
BD 1440B BN FLRB 2.0
BD 1440C BN FLRB 2.0

EB01 138 118 65 144 147 149
U-R1 KL30
30 85 Electronic 30 85 30 85 15 A 86 87 87A 86 87 87A
U-R5 U-R9 U-FS6 U-R7
Water
Fuel AC Engine U-R6 Wiper 90
Pump
Pump 87 86 87 86 Compressor 87 86
Control
85 30
Wiper Power 85 30 Governor
Relay
Relay Relay Module Supply Relay Relay
18 143 148
Engine Bay Fuse Box UEC EB01
BD 40 RD/WH FLRB 0.75
BD 1440AA BN FLRB 2.0
EB02_K 30
Power
Supply
Engine Control Module ECM

D9013-0149b
SAIC-SV91 09/2017

KL30
25A 10A
U-FS11 U-FS24
Fog U-R11
Fog Lamp/
Lamp / Sidelight
Sidelight / 87
Sidelight / 86
Relay
DRL DRL
EB01 23 36 53 77 75
BD 1640D RD/WH FLRB 0.5

BD 1540E RD/YE FLRB 2.0

BD 1540 RD/YE FLRB 2.0
SP0221
SP0222
BD 1540A RD/YE FLRB 2.0 FFOG
BD 1540B RD/YE FLRB 2.0 FFOG
BD 1540C RD/YE FLRB 2.0 FFOG

BD 1540D RD/YE FLRB 2.0 FFOG
BD 1640G RD/WH FLRB 0.5 DRLP

BD 1640F RD/WH FLRB 0.5 DRLP
BD 1640E RD/WH FLRB 0.5 DRLP
BD 1640H RD/WH FLRB 0.5 DRLP
BD 1640B RD/WH FLRB 0.5

90
EB01 82 80 87 85 102 100 107 105 72 70
U-R12 U-R13 30
85
85 30
Front 85 30
Front U-R16 U-R10
Left Right Left U-R17 Rear
87 Fog 87 Fog 86 87 DRL 86 87 Right 86 87 Fog
86 86
Lamp Relay Lamp Relay Relay DRL Relay Lamp Relay
EB01 84 81 89 86 71
Engine Bay
BD 122 OG FLRB 0.5
BD 5062 BN FLRB 2.0 FFOG
BD 5061 PK FLRB 2.0 FFOG
Fuse Box
UEC
FL2PR
12 PR2FL
PR 122D OG FLRB 0.5
2 EB33 2 EB34 2 PR03
Front Left Front Right 21W

Rear Fog
Fog Lamp Fog Lamp Lamp
D9013-0150b
SAIC-SV91 09/2017
KL30
25A
20A
U-FS13
U-FS14
Low Beam
High Beam
EB01 26 25
BD 1940 PK FLRB 2.0

SP0220 SP0218
BD 1940A PK FLRB 2.0

BD 1940B PK FLRB 2.0
90
EB01 97 95 92 90
10A
85 30 30
U-R15 15A 15A 85
U-R14 15A 15A U-FS32
High U-FS28 U-FS2 Low U-FS3 U-FS31 Head
86 87 Beam Left Right 86 87 Beam Left Right Lamp
Relay High Beam High Beam Relay Low Beam Low Beam Adjustment
EB01 99 96 41 40 49 48 91 44 43 42 47 46 45
BD 312B TN/WH FLRB 0.75 HALP
Engine Bay
BD 711A D-GN/WH FLRB 0.75 HALP
BD 1940AD PK FLRB 2.0 HALP
BD 712B YE FLRB 0.75 HALP
BD 189 D-GN FLRB 0.5 HALP

BD 311B L-GN/BK FLRB 0.75 HALP
BD 1940AA PK FLRB 2.0
BD 1940AC PK FLRB 2.0
BD 1940AB PK FLRB 2.0

BD 1940 PK FLRB 2.0
Fuse Box
UEC
SP0218
SP0216
BD 189A D-GN FLRB 0.5 HALP
BD 189B D-GN FLRB 0.5 HALP
SP0602
EB35_1 2 2 EB36_1 EB35_1 2 10 2 10 EB36_1

High Beam
High Beam
Low Beam
Low Beam
Motor Motor
Front Left Front Right Front Left Front Right Grouped Lamp
Grouped Lamp Grouped Lamp Grouped Lamp D9013-0151b
SAIC-SV91 09/2017
Engine Bay Fuse Box UEC Canister Exhaust Gas Intake Venting Electronic thermostat
Purge Valve Bypass Relief Valve Valve Control Valve
KL30
30 A
U-JF1 + -
Main Relay
- + - + - +
1 1 1 2
EB01 1
SP0105
EN2EB EB2EN
17
BD 5291A PK/BK FLRB 0.75

90
EB01 Engine Bay Fuse Box UEC

155 153
15 A
85 30
15 A 5A U-FS21 15 A
U-R8 U-FS19
U-FS18 Main U-FS20
Main Front Rear Relay
87 Relay Oxygen Ignition
86
Oxygen Power
Sensor Sensor Supply Coil
EB01 154 157 32 33 31 30 59 58 56 57

BD 5290 WH/D-GN FLRB 2.5
BD 3123E BN/WH FLRB 0.75 6MT-DYMOS||6MT-SAGW

BD 5290E WH/D-GN FLRB 2.5
BD 5290D WH/D-GN FLRB 2.5
BD 5290C WH/D-GN FLRB 2.5
BD 3112 GY FLRB 1.0
BD 5291 PK/BK FLRB 0.75

BD 5290F WH/D-GN FLRB 2.5
BD 5291E PK/BK FLRB 0.75 6MT-DYMOS||6MT-SAGW
EN2EB
12 EB2EN SP0306
SP0302 EN2EB
SP0215 1 EB2EN
BD 5290A WH/D-GN FLRB 2.5
BD 5290AC WH/D-GN FLRB 2.5
BD 5290AB WH/D-GN FLRB 2.5
BD 5290AA WH/D-GN FLRB 2.5
FL2CH
E CH2FL
CH 3123 BN/WH FLRB 0.75
4 3 CH08 1 4 EB12
EB02_K Heat Heat + + +
3 5 6
Power Power Power
Supply - Supply - Supply -
Main Main Main
Relay Relay Relay
Front Oxygen Sensor Rear Oxygen Sensor Injector AC Pressure Switch

D9013-0152b
SAIC-SV91 09/2017

KL30
100 A 30 A
U-MID U-JF2 40 A 25 A U-FS16
Cooling Fan EPB U-JF8 U-FS5 IEC
（850W)/ 50 A ABS/ESP ABS/ESP Power
(600W) _Motor _Valve Supply 4
6 EB01_B EB01 2 8 17 28
BD 173D-GN FLRB 4.0 ABS

BD 856 PU FLRB 1.5 ABS
BD 240 RD/WH FLRB 4.0 EPB
BD 532 RD FLRB 10.0 850W
BD 409 RD FLRB 10.0 600W
SP0241
SP2301

BD 240C RD/WH FLRB 4.0 EPB
BD 240D RD/WH FLRB 4.0 EPB
90
EB01
61 63
Engine Bay 25 A 15 A
Fuse Box U-FS33 U-FS34
Washer /
UEC Exterior
Light Rear Wiper
62 64
EB01
SP0208
BD 1542C RD/BK FLRB 0.75
BD 1542A RD/BK FLRB 0.75
BD 1542B RD/BK FLRB 0.75
EB22 EB21 FL34 EB04 EB57_C

1 1 13 15 1 25 3 17 2 6
+ + Right Brake Left Brake Pump Valve KL30 KL30 KL30 KL30
Motor Motor Power Power Turning Rear Front Rear
Power Power Supply Supply Signal Wiper Washer Washer
Supply Supply Light Pump Pump
Radiator Fan Radiator Fan Electronic Parking Anti-lock BrakingSystem / Body Control Module
（850W）（600W） Braking Electronic Electronic Stability Program BCM D9013-0153b
Control Unit EPB ECU ABS/ESP
SAIC-SV91 09/2017
D9013-0154b
Panel Fuse
Light -
Under
Instrument
Mirror
Right
PAD2IP
PD03_A
IP2PAD
Box
IEC
IP 1802DC PK FLRB 0.5 SPHCM PAD 1802DCA PK FLRB 0.5 SPMH
40
9
Light Relay
Under
Mirror
I-R7
IP07
110 IP07
SP0250
DRD2IP_2 IP2DRD_2
IP 1802H RD/BK FLRB 0.5 SPHCM IP 1802DA PK FLRB 0.5 SPHCM IP 1802DB PK FLRB 0.5 SPHCM
87
30
109
35
IP 1802F RD/BK FLRB 0.5 SPHCM
104
106
85
86
DRD 1802DBA PK FLRB 0.5 SPMH
RF08_2
PD03_A
Under Mirror
Light - Left
Supply
RF 842BE RD/BK FLRB 0.5 RLS&&-LDW

Power
Rainfall Sensor
BD2IP_2
IP2BD_2
9
12 IP2BD_2
BD2IP_2
SP0248
RF08_1
Supply
RF 842BD RD/BK FLRB 0.5 RLS&&-LDW IP 1802B RD/BK FLRB 0.5 IP 1802C RD/BK FLRB 0.5
Power
16
1
SP1205
Door Control Unit

Engine Bay
Right Make-up
Fuse Box
Mirror Light
RF02
Power Tail
UEC
BD 1802D RD/BK FLRB 0.5

BD 1642B RD/BK FLRB 0.5 ATTG
KL30
Ground
FL62_A 13
Power RF 1802BB RD/BK FLRB 0.5
1
Supply
Interior Light
Left Make-up
U-FS27
10 A
EB57_C
Mirror Light
RF01
5-66
Ground BD 3240D RD/WH FLRB 2.5 BD 1802 RD/BK FLRB 0.5 BD 1802A RD/BK FLRB 0.5
Fuel Tank Rear View Interior

Power RF 1820BC RD/BK FLRB 0.5
KL30
Cap Mirror Close-up Light

50
39
1
1
Supply
SP0256
Close-up/Tail Door/
Rear View Mirror
EB57_E
Fuel Tank Cap
KL30
U-FS25
10 A
BD 1642A RD/BK FLRB 0.5 SPHCM
SP0209
Electrical circuit diagrams
Body Control Module

KL30
BD 3240B RD/WH FLRB 2.5 BD 1642 RD/BK FLRB 0.5 BD 1642C RD/BK FLRB 0.5
52
15
37
BCM
09/2017
BD 1742C RD/BK FLRB 1.5 6MT-DYMOS||6MT-SAGW
Central Lock
KL30
CDL
14
U-FS26
25 A
EB57_C
BD 1742A RD/BK FLRB 1.5 AT
Supply 3
U-FS10
Power
30 A
IEC
P Release
Motor
KL30
BD 3240 RD/WH FLRB 2.5 BD 1742 RD/BK FLRB 1.5 AT BD 1742B RD/BK FLRB 1.5 AT
38
22
51
EB57_E 7
SAIC-SV91
SP0233
SP0207
EB01
EB01
EB01
KL30
90
KL30
30 A
U-JF4
IG
Power
Supply
4
EB01
SP0257
BD2IP_1
2 IP2BD_1
IP 340A RD/WH FLRB 2.5
90
Instrument Panel Fuse Box
IEC
1 2 IP07
85 30
I-R3 10 A 10 A 10 A 15 A
IG 10 A I-FS1
I-FS5 I-FS3 I-FS2
Relay I-FS6 IG PWR2
87 86
Airbag Airbag IG
IG PWR4
Control Unit Control Unit PWR1
60 68 1 2 3 5 6 18 17 15 14 13 IP07
IP 340AFRD/D-GN FLRB 2.5
IP 642 RD/BK FLRB 0.5
IP 842 RD/BK FLRB 0.5 LDW||PGAM||SWHIP

IP 340AG RD/D-GN FLRB 2.5
IP 442B RD/YE FLRB 0.5 SRSL

IP 340AE RD/D-GN FLRB 2.5 LDW||PGAM
IP 3440A RD/BK FLRB 3.0 -ESSS

IP 340AA RD/D-GN FLRB 2.5
IP 842E RD/WH FLRB 0.75 SWH
SP0210
IP 1442A RD/BK FLRB 0.5
SP0240 SP0213
SP0259
IP 842B RD/BK FLRB 0.5 PGAM
CN 642GC RD/BK FLRB 0.5 ESP

RF 842DA RD/BK FLRB 0.5 LDW
RF 842BB RD/BK FLRB 0.5 PGAM

CN 642GD RD/BK FLRB 0.5 ESP
IP 842D RD/BK FLRB 0.5 LDW
CN06 CN09 RF10 RF07 IP08_C IP01_B IP50_D

6 7 6 1 16 8 1
KL15 IG Body HEAT+
Clock
RF2IP_1 IP2RF_1
RF2IP_1 IP2RF_1
Relay
Control
Module HEAT- Spring
19 10 BCM
Central Control EPB Switch Lane Departure Automatic Airbag Control Unit
Switch Block - Right Aid Control Unit Anti-glare
Rear View Mirror
SRS D9013-0155b
SAIC-SV91 09/2017
KL30
60 A Engine Bay Rear Left Rear Left
U-JF5
ACC
Fuse Box Power Window Power Window
Power UEC Switch Switch
电源电源
Supply
3 RF04 3 RF04
EB01 5
RLD 202DCA RD/BK FLRB 0.5
RRD 202DDA RD/BK FLRB 0.5

BD 342 RD FLRB 5.0
BD 342E RD FLRB 5.0 IP 342H RD FLRB 5.0

SP0258 4 a
BD 342C RD FLRB 5.0
BD2IP_3 IP2BD_3
SP0205
RLD2FL
BD 342D RD FLRB 5.0
RRD2FL
BD 342CA RD FLRB 5.0
FL2RLD 8
8 FL2RRD
90
EB58 Engine Bay Fuse Box 2 UEC2

32 36
KL30
85 30
U2-R1 30 A 10 A 20 A
86 30
U2-R3
ACC U2-FS11 U2-FS12 U2-FS1 Rear
86 87
Relay ACC1 ACC2 Converter 85 87
Blower
Relay
35 33 39 37 38 40 7 24
EB58
BD 202GB RD/BK FLRB 0.5
BD 202DD RD/BK FLRB 0.5

BD 202BB RD/BK FLRB 0.5 MDAC||ADAC
BD 242A RD/BK FLRB 3.0 12V DC
BD 1264 D-GN FLRB 2.5 12V DC
SP0253
SP0263
BD 202GC RD/BK FLRB 0.5 USB1||USB2
SP1902
BD 1264A D-GN FLRB 2.5 12V DC&&HPB
BD 1264B D-GN FLRB 2.5 12V DC
SP1902
BD 1140 RD/WH FLRB 1.5 INV
BD 202UA RD/BK FLRB 0.35USB2
BD 202UB RD/BK FLRB 0.35USB1
BD 202N D-GN FLRB 1.5 INV
BD 202GA RD/BK FLRB 0.5
FL39_1 2 2 FL39_2 FL40 2 FL48 FL47 FL60 3 2 FL02_B

1 1 11
ACC ACC ACC Power Power Power
Supply Supply Supply
12V Power Supply 12V Power Supply USB - USB - Middle Converter Gateway
Socket - Middle Socket - Rear Left Rear Right D9013-0156b
SAIC-SV91 09/2017
90
5-69
09/2017
D9013-0157b
SAIC-SV91
BD2IP_3
IP2BD_3
6 CN03
FL45_2
I-FS19
ACC1
Supply Socket -
Wireless Charging Module

15 A
CN 202ED RD/BK FLRB 0.35 CHARG
Cigar Lighter 12V Power
Rear Right
ACC
ACC
IP 1263 OG FLRB 0.75 12V DC BD 1263BB OG FLRB 0.75 12V DC&&(MDAC||ADAC)

39
2
4
I-FS11
ACC4
15 A
SP1906
IP05
23
Power Supply
Ground
ACC
CN 202EF RD/BK FLRB 0.35 CHARG
1
1
I-FS17
SP0239
ACC2
10 A
IP 202AA RD/BK FLRB 0.5 IP 202EB RD/BK FLRB 0.35CHARG CN 202EC RD/BK FLRB 0.35 CHARG
37
CN2IP_2 13
IP 202CC RD/YE FLRB 0.5 AMP
I-FS18
ACC3
10 A
IP2CN_2
IP 202CA RD/YE FLRB 0.5 RADIO
38
36 BD2IP_3 LHD
IP 202C RD FLRB 3.0 RADIO||AMP
30
FL44_A
IP2BD_3
Power Amplifier
IP 202A RD FLRB 3.0
Power Supply
29
BD 202CCA RD/YE FLRB 0.5 AMP
ACC
8
11
B2
Instrument Panel Fuse Box IEC
BD2IP_4
IP2BD_4
31
IP56_A
SP0237
Relay
ACC
I-R2
RHD
Radio
IP 202 RD FLRB 3.0 IP 202CB RD/YE FLRB 0.5 RADIO
87
30
ACC
42
4
85
Antenna Amplifier
86
IP58
45
IP 342B RD/BK FLRB 3.0 IP 202CD RD/YE FLRB 0.5 RADIO
43
1
SP0247
SP0230
41
IP 342H RD FLRB 5.0

IP07
a
Engine Bay Fuse Box 2 UEC-2
KL30 KL30
30 A 30 A 10 A
Engine Bay U2-FS3
25 A U2-FS8 U2-FS9
U-FS2 Fuse Box TCCU TCCU
Differential
Lock
Gateway UEC Power Power Control
Supply 1 Supply 2 Module
14 14 15
EB01 EB58 9
BD 2840 RD/WH FLRB 0.5 EDL

BD 440D YE/BN FLRB 2.0 4WD
BD 440C YE/BK FLRB 2.0 4WD

BD2IP_1
3 IP2BD_1
SP0231
IP 2340C RD/WH FLRB 1.5
IP 2340B RD/WH FLRB 1.5
Power Supply
90
Instrument
Panel Fuse Box
IP07 IEC FL01 FL59_A
96 100 26 13 20
Rear Window Heat
I-R5 Power Power Power Differential

85 30
Rear View 10 A Transfer Case Supply Supply Supply
Lock
Mirror & I-FS34
Rear Control Unit Control
86 87 Rear View
Window Heat
Mirror Heat
TCCU Module
Relay
+
94 99 82 90 IP07
TLD04 1
IP 293 PU FLRB 1.5
IP 293B PU FLRB 1.5 SPHM
IP 502B RD/WH FLRB 0.5 SPHM

IP 502 RD/WH FLRB 0.5 SPHM
TLD 293AB PU FLRB 1.5
SP0206
IP 502A RD/WH FLRB 0.5 SPHM
IP2DRD_2 IP2PAD
36 46 PAD2IP
DRD2IP_2
PAD 502BL RD/WH FLRB 0.5 SPML
PAD 502BA RD/WH FLRB 0.5 SPMH

DRD 502AA RD/WH FLRB 0.5 SPMH
DRD 502AL RD/WH FLRB 0.5 SPML
12 TLD2FL_1
FL2TLD_1
BD 293AA PU FLRB 1.5
SP0238
IP 293A PU FLRB 1.5
PD03_A
DD03_C DD03_A PD03_C
38 IP2BD_2 1 7 11 1 7 11
BD2IP_2
Driver's Side
Rear View
Mirror
D9013-0158b
SAIC-SV91 09/2017
90
5-71
09/2017
27 IP2BD_1
BD2IP_1
D9013-0159b
Drive Mode Central Control Air Cleaner
FL79
IP 640K RD/WH FLRB 1.0 APM BD 640KA RD/WH FLRB 1.0 APM
KL30
SAIC-SV91
CN05
Light Module
Converting SwitchBlock -
Atmosphere
IP43
IP 640H RD/WH FLRB 0.5 MMHT||PST-LUB-HT CN 3540EP RD/WH FLRB 0.5 MMHT||PST-LUB-HT
KL30
Left
IP 640J RD/WH FLRB 0.5 CALP
CN2IP_2 12
3
KL30
2
IP2CN_2
CN01
IP38
Control Panel
Switch
IP 640A RD/WH FLRB 0.5 IP 640W RD/WH FLRB 0.5 4WD CN 640WA RD/WH FLRB 0.5 4WD
Front AC
KL30
KL30
CN2IP_1 45
1
2
IP2CN_1
Light Relay
Trunk
I-R4
AC Control Panel /
Control Switch
Left Central
IP 2340D RD/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW IP 6630A L-GN/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW
87
30
I-FS25
98
97
10 A
IP2BD_3
BD2IP_3
IP 640 RD/WH FLRB 0.5 IP 2340E RD/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW
85
86
1 FL41
93
91
56
Trunk Light
SP0201
BD 6630B L-GN/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW
IP07
IP07
45
Instrument
Fuse Box
Panel
IEC
I-FS24
IP28
OBD
10 A
IP 840CRD/L-GN FLRB 0.5
Supply
Power
OBD
16
55
Relay
U-R3
Horn
EB01
IP 3040CA YE/BK FLRB 2.0
SP0211
EB32
49
Horn - Left Horn - Right

13 IP2BD_1
BD2IP_1
BD 1329AA D-GN FLRB 1.0 BD 1329AC D-GN FLRB 1.0
30
87
SP0235
132
1
IP 3040CB YE/BK FLRB 2.0 IP 3040C YE/BK FLRB 2.0
50
EB31
IP07
BD 1329AB D-GN FLRB 1.0
129
85
86
1
IEC PWR8
U-FS12
SP0244
25 A
BD 1329B D-GN FLRB 1.0
130
BD 3040 YE/BK FLRB 2.0 BD 3040A YE/BK FLRB 2.0
24
BD 1329A D-GN FLRB 1.0
128
KL30
EB01
U-PS22
SP0232
Horn
20A
EB01
BD 3040B YE/BK FLRB 2.0 BD 1329 D-GN FLRB 1.0
34
55
Front AC Control Panel Engine Bay Fuse Box UEC

KL30
60 A 40 A
40 A U-JF11 U-JF10
U-JF9 IEC Rear
Front Power
Blower Blower
Blower Supply 1
Feedback
10 9 11 10
IP38 EB01
BD 2440 OG FLRB 5.0

BD 2240 D-GN FLRB 3.0
BD2IP_1 BD2IP_3
IP2BD_1 1 29 IP2BD_3
IP 2440A OG FLRB 5.0
BD 1592 BN/WH FLRB 3.0 MDAC||ADAC
BD 2140 RD/WH FLRB 3.0 MDAC||ADAC

SP0229 BD2IP_1
4
IP 65BA YE FLRB 0.5
IP 2240A D-GN FLRB 3.0
IP2BD_1
BD 1592B NA/WH FLRB 3.0 MDAC||ADAC
90 ＲｅａｒＡＣ
IP07 35 61 70 78 77 28 24 22 EB58
10 A 30 A Instrument
I-R1 10 A
I-FS15
85 30
I-FS30 25 A
85 30
U2-R3 Engine Bay
Front
Front I-FS16Rear Panel Rear
Blower
Passenger's I-FS29Driver's Blower Fuse Box 2
Blower 87 Side Power Side Power Feedback
Fuse Box 86 87
Blower
UEC_2
86
Relay
Feedback Window Motor Window Motor IEC Relay
27 71 72 86 85 36 26 23
IP07 EB58
IP 2440BA D-GN FLRB 2.0
IP 2440CA RD FLRB 2.0
BD 1592 BN/WH FLRB 3.0 MDAC||ADAC

IP 1592BA TN FLRB 0.5 MDAC||ADAC
IP 65B PU FLRB 3.0
IP 65 PU FLRB 3.0
IP2PAD 14 14 IP2DRD_1
BD 1592BANB/WH FLRB 3.0 MDAC||ADAC
PAD2IP DRD2IP_1
DRD 2440BC D-GN FLRB 2.0
PAD 4040DA RD FLRB 2.0
SP2103
BD2IP_6
7 SP2105
IP 65A PU FLRB 3.0
IP2BD_6
BD 1592BC TN FLRB 0.5 (MDAC||ADAC)&&EPB
BD 1592BB TN FLRB 0.5 MDAC&&HPB
PD06 DD08 FL38_2 FL38_1 FL50_B

IP31_B 1 5 4 23 1
23
KL30 Blower Blower
Blower +
Blower -
Blower + KL30
Feedback Feedback
Front AC Passenger's Driver's Rear AC Control Panel Rear AC

Side Power Side Power D9013-0160b
Window Motor Window Motor
SAIC-SV91 09/2017
KL30
40 A 40 A
U-JF7 U-JF6
DC IEC PWR9
Stabilizer 2
6
EB01 7
BD 3440F RD/BK FLRB 3.0 -ESSS

BD 3440K RD/WH FLRB 3.0 ESSS
BD 3640 RD/WH FLRB 3.0 ESSS
BD2IP_1
IP2BD_1 11
SP0234
SP6402
SP6403
IP 3440C RD/BK FLRB 3.0 -ESSS

IP 3440B RD/BK FLRB 3.0 -ESSS
IP 3440E RD/BK FLRB 3.0 -ESSS&&AMP
IP 3440D RD/BK FLRB 3.0 -ESSS
BD 3640KB YE/BN FLRB 2.0 ESSS
BD 3640KC YE/BN FLRB 2.0 ESSS
BD 3440KC OG/RD FLRB 2.0 ESSS
BD 3440KB OG/RD FLRB 2.0 ESSS
90
IP07
1 2 6 5 FL31_B 48 32 46 47
Power Power Power Power
25 A 30 A
Supply Supply Supply Supply
I-FS23 10 A 15 A Instrument Panel
I-FS20
Entertainment Power I-FS21 I-FS22 Fuse Box
Instrument AMT
System / Radio Amplifier IEC
Cluster
54 40 52 53
Stabilizer DC Module IP07
IP 3440EA RD/WH FLRB 2.5 AMP
IP 3440BA RD/WH FLRB 0.5
IP 402 RD FLRB 0.75 AT
DCDC
IP 3440DA RD/WH FLRB 2.5 RADIO
IP 3440DB RD/WH FLRB 2.5 12-SCRN
SP0704
GB 402B RD FLRB 0.75 AT&&4WD
GB 402C RD FLRB 0.75 AT&&4WD
GB 402D RD FLRB 0.75 AT&&4WD
19 IP2BD_1
BD2IP_1
A7 IP2BD_4
BD 402A RD FLRB 0.75 AT
BD2IP_4
BD 3440EB RD/WH FLRB 2.5 AMP
GB2FL
17
FL2GB
IP55_B IP56_A FL44_B

15 7 4 2 IP02_A 4 1 GB02_1
Supply Supply Supply Supply 电源电源
Entertainment Radio Power Instrument Transmission Control Module

System Host Amplifier Cluster D9013-0161b
SAIC-SV91 09/2017
D9013-0162b
副驾
电动
座椅
IP2BD_2
21 BD2SI_2
FL04
NTCBD 3540CDA RD FLRB 2.0 PST-LUB
Supply
Power
1
Driver's Side Driver's Side

Power Seat Power Seat
FL11
BD 3540CG L-GN FLRB 2.0 8PST-4LUB
Supply
Power
1
SP2505
BD 3540CW L-GN FLRB 2.0 8PST-4LUB||MMHT BD 3540CC L-GN FLRB 2.0 MMHT
Supply
Power
D3
19
FL03
Passenger's Driver's
I-FS10
Power
Seat
Side
25 A
IP 3540CA L-GN FLRB 2.0 8PST-4LUB||MMHT IP 3540CN RD/GY FLRB 3.0 8PST-4LUB||MMHT
10
22
Panoramic Panoramic Power

I-FS9
Seat
Side
25 A
IP 3540CD RD FLRB 2.0 PST-LUB IP 3540CM RD/GY FLRB 3.0 PST-LUB
21
SP0265
Sunroof
I-JF2
30 A
IP 3540C RD FLRB 5.0 IP 3540CE RD/GY FLRB 3.0
66
63
BD2IP_3
IP2BD_3
RF2IP_1
IP2RF_1
Sunroof
RF14
I-JF3
30 A
Panoramic
Sunroof
IP 3540A RD FLRB 5.0 8PST-4LUB||MMHT||PST-LUB||PSR IP 3540D RD FLRB 5.0 PSRF IP 540 D-BU FLRB 2.0 PSRF RF 540A D-BU FLRB 2.0 PSRF
Supply
Power
67
30
64
3
1
SP0246
Panel Fuse
Instrument
5-74
Box
IEC
Departure Aid
Supply 6
15 RF2IP_1
IP2RF_1
U-JF12
Power
I-FS7
Aid Control Unit

Lane Departure
Lane
RF10
7.5 A
60 A
IEC
BD 3540 RD FLRB 5.0 8PST-4LUB||MMHT||PST-LUB||PSR IP 3840 RD/WH FLRB 0.5 LDW

IP 3140B RD FLRB 2.5 LDW RF 540A D-BU FLRB 2.0 PSRF
KL15
12
19
12
7
Supply 5
BD2IP_1
IP2BD_1
U-FS3
Power
30 A
SP2004
IG
Front Sunroof /
BD 3140 RD FLRB 2.5 LDW||PSRF||FSRF IP 3140A RD FLRB 2.5 LDW||PSRF||FSRF RF 3940A RD/WH FLRB 1.5 FSRF
Sunshade
15
09/2017
I-FS8
25 A
SP0245
RF 3940C RD/WH FLRB 1.5 FSRF||PSRF
EB01
KL30
Sunroof
IP 3140C RD FLRB 2.5 PSRF||FSRF IP 3940 RD/WH FLRB 1.5 FSRF||PSRF
Supply
Power
20
6
1
8
RF13
IP2RF_2
RF2IP_2
IP07
IP07
SAIC-SV91
90
KL30
10 A
25 A 10 A 30 A 30 A 15 A 15 A
U2-FS5
U2-JF4 U2-FS2 U2-FS4 U2-FS10 U2-FS6 U2-FS6
Tire
Power Tail Gateway Rear Left Rear Right Front Front
Pressure
Door Control Unit Power Window Power Window Seat Heat Seat Heat
Monitoring
4 8 10 16 11 12 13
EB58
BD 2440DA L-GN FLRB 2.0
BD 3540FA RD/WH FLRB 0.75 RSHT

BD 2440EA OG/BK FLRB 2.0
BD 3540EA RD/WH FLRB 0.75 PST-LUB-HT||MMHT

BD 740 RD/WH FLRB 1.5 ATTG
BD 840A RD/WH FLRB 0.5 TPMS

SP1849
SP2502 SP2502
BD 3540FC RD/WH FLRB 0.75 RSHT

BD 3540EE RD/WH FLRB 0.75 PST-LUB-HT||MMHT
BD 3540FD RD/WH FLRB 0.75 RSHT

BD 3540ED RD/WH FLRB 0.75 PST-LUB-HT||MMHT
90
FL02_B FL02_A RL04 RR04

FL04 FL30
1 12 19 5 5 17
Power KL30 KL30 KL30 KL30 KL30
Supply
Power Tail Gateway Rear Left Rear Right Tire Pressure

Door Control Power Window Power Monitoring &
Unit Switch Window Switch Control Unit
FL04 FL06
10 11 1 2
Supply Supply Supply Supply
Passenger's Side Power Seat

Power Seat D9013-0163b
SAIC-SV91 09/2017
Engine Bay Engine Engine

Fuse Box Control Module Transmission Control Module Transmission ABS/ESP Steering Wheel Yaw Velocity Differential
UEC ECM Control Module ECM Lever Angle Sensor Sensor Control Module
KL30 30 A
U-JF4
IG
Power IG IG
Power Power 12V Power Power Power Power
Supply Supply Supply (KL15) Supply Supply Supply Supply
4 87 12 12 5 6 28 EB04 2 4 FL35 19 FL59_A

EB02_K GB02_2 GB02_1 BT07_B IP59 IP14
EB01
IP 642E RD/BK FLRB 0.5 AT
BD 1687B GY/BK FLRB 0.5 ESP

GB 642DD RD/BK FLRB 0.5 AT&&2WD

IP 1687D GY/BK FLRB 0.5 EPS
GB 642DB RD/BK FLRB 0.5 AT&&4WD
BD 1687A GY/BK FLRB 0.5 ABS

BT 1442CBL RD/BK FLRB 0.5 LHD
SP0257
GB2FL BT2EB
BD 340E RD/WH FLRB 2.5
18 FL2GB 1 33 IP2BD_1 B12 IP2BD_4

EB2BT
BD2IP_1 BD2IP_4
BD 642FA RD/BK FLRB 0.5 AT
BD 1687C GY/BK FLRB 0.5

BD 642BC RD/BK FLRB 0.5 AT
SP0261
BD 642F RD/BK FLRB 0.5
BD 1687 GY/BK FLRB 0.5

90 SP0261
EB58 17 44
19 42
10 A 10 A 10 A
U2-FS13 U2-FS14 10 A U2-FS15
85 30
U2-R4 U2-FS16
IG IG IG IG
IG
87 86 Relay Power Power Power Power
Supply 1 Supply 2 Supply 4 Supply 3
18 21 41 43 45 47 48 46 EB58
BD 340EA RD/WH FLRB 2.5
BD 340EB RD/WH FLRB 2.5
BD 340ED RD/WH FLRB 2.5
BD 340EE RD/WH FLRB 2.5
BD 642BS RD/BK FLRB 0.5
BD 642BA RD/BK FLRB 0.5
BD 642RD BU/BK FLRB 0.5 (MDAC||ADAC)&&EPB

BD 3540EF RD/WH FLRB 0.5 PST-LUB||MMHT
SP0262 SP0249
BD 642BB RD/BK FLRB 0.5 MDAC&&HPB
SP0264
BD 642BL RD/BK FLRB 0.5 MMHT
BD 642BH RD/BK FLRB 0.5 MMHT
BD 642BE RD/BK FLRB 0.5 AFS

BD 642BG RD/BK FLRB 0.5 ESSS
BD 642BF RD/BK FLRB 0.5 PDC4

FL31_A FL02_A FL04 FL03 FL27 FL71 FL38_1 FL38_2

10 18 2 D2 A8 9 16 4 4
KL15 KL15 Power KL15 KL15 Power Power Power Power
Supply Supply Supply Supply Supply
Stabilizer DC Gateway Passenger's Driver's Side Adaptive Head Blind Zone Monitoring Rear AC Control Panel
Module DCDC Side Power Seat Power Seat Light Control Unit & Control Unit D9013-0164b
SAIC-SV91 09/2017
5.4 Engine management system
Battery
BTN01
- +
BT04-1 Engine Bay Fuse Box UEC
Pre-fuse 30 A U-R4 30 85
10 A
175 A
U-JF3 Starting U-FS23
Box PFB P-MG2
Starter Relay Starter
87 86
UEC
Feedback
UEC
2 3 133 137 135 134 35 54
BT01_1 EB01
BD 6 PU FLRB 3.0
BD 447 YE FLRB 0.5
BD 6B PU FLRB 3.0
BD 6BD PU FLRB 0.5

BD 6A PU FLRB 3.0 SP0102
SP0105 90
EB2BT
20
BT2EB BD 447B YE FLRB 0.5
BD 6A PU FLRB 3.0
EB02_K
BT03 9 31 48
Starting Control-
Starting Control+
Starting Feedback
Starting
Engine Control
Starter Module ECM
Ground Ground Ground

1 2 4
EB02_K
BD 51B BK FLRB 2.5
BD 51A BK FLRB 2.5
BD 51C BK FLRB 2.5
SP0303
BD 51 BK FLRB 2.5
G_BTN G_EBR3
D9013-0003b
SAIC-SV91 09/2017
a
D9013-0004b
GB07_1
FL2GB
GB2FL
GB 5666 WH/BK FLRB 0.75AT&&4WD
BD 5290C WH/D-GN FLRB 2.5
BD 3123A BN/WH FLRB 0.75AT

20
Hydraulic Accumulator
BD 3121B TN/WH FLRB 0.5 GB 3123BA BN/WH FLRB 0.75AT&&4WD
1
1
BD 3123D BN/WH FLRB 0.75AT GB 5666A WH/BK FLRB 0.75AT&&2WD
2
SP0307
GB 3123BC BN/WH FLRB 0.75AT&&2WD
1
BD 3123A BN/WH FLRB 0.75AT
GB07_2
U-FS19
Oxygen
Sensor
Rear
5A
BD 3123E BN/WH FLRB 0.75 6MT-DYMOS||6MT-SAGW

58
EB02_K
SP0215
FL2CH
CH2FL
CH08
BD 5290D WH/D-GN FLRB 2.5
Accumulator
Hydraulic
27
31
CH 3123 BN/WH FLRB 0.75
3
E
5-78
Main Relay
Control
85
86
154
69
Rear Oxygen Sensor

BD 3121B TN/WH FLRB 0.5 CH 3121 TN/WH FLRB 0.5
33
4
BD 5290A WH/D-GN FLRB 2.5

87
157
30
Relay BD 3120B PU FLRB 0.5 CH 3120 PU FLRB 0.5

U-R8
G
Main
62
2
Power Supply -
Main Relay
BD 2040A RD/WH FLRB 2.5 BD 5290AC WH/D-GN FLRB 2.5
153
09/2017
SP0105
BD 3122B GY/WH FLRB 0.75 CH 3122 YE FLRB 1.5
H
29
1
Power Supply -
Main Relay
BD 2040B RD/WH FLRB 2.5 BD 5290AB WH/D-GN FLRB 2.5
EB02_K
155
5
SP0302
U-JF1
Relay
Main
30 A
Module ECM
Power Supply -
Main Relay
SAIC-SV91
Control
Engine
BD 2040 RD/WH FLRB 2.5 BD 5290AA WH/D-GN FLRB 2.5
3
EB01
90
15 A
15 A 15 A U-FS18
U-FS21 U-FS20 Front
Main Relay Ignition Oxygen
Power Supply Coil Sensor
30 32 33 56 57 59
EB01
EB2EN
EN2EB
BD 5290C WH/D-GN FLRB 2.5 BD 3112 GY FLRB 1.0
a 12 d
b 1 e
BD 5290F WH/D-GN FLRB 2.5 BD 5291D PK/BK FLRB 0.75

c f
BD 5291A PK/BK FLRB 0.75 SP0306 BD 5291F PK/BK FLRB 0.75
g
BD 5291G PK/BK FLRB 0.75
h
EB2EN Engine Control Module ECM

17 EN2EB 90
Electronic
AC Pressure AC Pressure Canister Exhaust Gas thermostat
Switch (High) Switch (Middle) Purge Valve Bypass Relief Valve Intake Venting Valve Control Valve
21 35 18 21 60
EB02_K 20 EB02_A
SP2635
BD 5291E PK/BK FLRB 0.75 6MT-DYMOS||6MT-SAGW
BD 451C BK/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW
BD 603 D-GN FLRB 0.75 6MT-DYMOS||6MT-SAGW
BD 451 BK/WH FLRB 1.0
0.75
0.75
0.75
0.5
4 3 2 1 EB12 2 1 1 2 1 2 2 1
- + + - + - + -
Middle
Pressure
Low Pressure
High Pressure
AC Pressure Switch Canister Exhaust Gas Intake Venting Electronic thermostat

G_EBL2_4 Purge Valve Bypass Relief Valve Valve Control Valve
D9013-0005b
SAIC-SV91 09/2017
Clutch Water Variable Valve Timing Variable Valve Timing

Front Oxygen Sensor Pump Valve (Intake) Valve (Exhaust)
Heat +
Heat -
Signal
Signal
Signal -
Signal +
- + - + + -
4 3 1 5 2 6 2 1 2 1 1 2
d
EB2EN
e EN2EB 4 2 5 3 8
BD 5291D PK/BK FLRB 0.75

f f
BD 5291F PK/BK FLRB 0.75
g g
BD 3113 GY/WH FLRB 0.75
BD 3111 TN/WH FLRB 0.75
h h
BD 5279 WH FLRB 0.75
0.75
0.75
0.75
EB02_K EB02_A
73 79 78 76 77 15 50 05
90 Oxygen Oxygen Oxygen Oxygen Oxygen Clutch Water Variable Valve Variable Valve
Sensor Sensor Sensor Sensor Sensor Pump - Timing Valve Timing Valve
Heat Signal Signal Signal Signal (Intake) (Exhaust)
Injector 1
Injector 2
Injector 3
Injector 4
16 02 17 01
EB02_A Engine Control Module ECM
1.0
1.0
1.0
1.0
2 1 1 2 1 2 2 1
- + + - + - + -
Injector 1 Injector 2 Injector 3 Injector 4

D9013-0006b
SAIC-SV91 09/2017
30 85 30 85
U-R5 25 A
25 A U-R1
U-FS8
U-FS4 Fuel Electronic
Electronic
Fuel Pump Pump 87 86
Water Pump
Water 87 86
Relay Pump Relay
16 140 138 157 154 20 120 118 119 122

EB01
BD 5291D PK/BK FLRB 0.75
BD 458 OG FLRB 0.5
BD 7421 D-BU/WH FLRB 0.5
BD 6554 L-GN/BK FLRB 1.0

f
g EB2EN
7
EN2EB
h h
FL2CH
A CH2FL
CH 120B GY FLRB 1.5
90
CH07 EB02_K
1 28 42 1
Power Electronic
Fuel
Supply
Pump Water
Fuel Pump
Pump
Relay
Relay Electronic
Water Pump
Ground
2 2
CH07 Engine Control Module ECM
CH 1550CB BK FLRB 1.5
FL2CH EN2EB
B 14
CH2FL EB2EN
BD 1550CA BK FLRB 1.5
BD 650A BK FLRB 1.0
G_FLCL_3 G_EBR2
D9013-0007b
SAIC-SV91 09/2017
Engine Bay Fuse Box UEC Engine Bay Fuse Box 2 UEC_2
30 85
30 85 15 A 10 A
U-FS9 U-FS6 30 A U2-R4
15 A AC U-R9 U-JF4 IG U2-FS13
AC Engine
Compressor Control IG Power IG Power
Compressor 87 86 Supply Relay 87 86
/ Battery Module Supply 1
Sensor Relay
21 67 65 66 69 18 4 19 17 18 21 41 119
EB01 EB58



BD 451D BK/WH FLRB 0.5
BD 249D WH FLRB 0.35
BD 642F RD/BK FLRB 0.5


SP0257 SP0264
SP0261
h

SP2635
BD 5728C YE/BK FLRB 0.5 6MT-DYMOS||6MT-SAGW

BD 5728A YE/BK FLRB 0.5 AT
72 30 87 85 EB02_K
90 AC Power IG ACC
Compressor Supply Power ACC
Relay Supply Awake
P/N Charge
Signal Indicator
22 65 EB02_K SP0301
BD 5728 YE/BK FLRB 0.5 AT
BD 275B L-GN FLRB 0.5 AT
FL2GB SP0101
11
GB2FL
GB 275 L-GN FLRB 0.5 AT&&4WD
GB 275C L-GN FLRB 0.5 AT&&2WD
EB2EN BD2IP_3
9
6 EN2EB IP2BD_3
BD 5728 YE/BK FLRB 0.5 AT
EB2EN
11 EN2EB
1 GB02_1 3 2 GB02_2 1 EN01 48 47 IP01_B

P/N P/N Charge IG ACC
Signal Signal Indicator Body Control Relay Awake
Module
BCM
G_EBL2_4 AC Compressor Transmission Alternator

Control Unit TCU D9013-0008b
SAIC-SV91 09/2017
Airflow Sensor Electron Accelerator Pedal
Signal Signal Power Signal Power

Output Signal 5V- 5V+ Ground Output 2 Supply Ground Output 1 Supply
1 4 3 2 3 2 1 4 5 6
EB14 IP45
BD 492 YE FLRB 0.5
BD 7387 GY FLRB 0.5
IP 1272A PU FLRB 0.5
1162A L-BU FLRB 0.5
IP 1174A BN FLRB 0.5
IP 1271A BN FLRB 0.5
IP 1161A D-BU FLRB 0.5
IP 1164A WH/BK FLRB 0.5

IP2BD_1 24 25 26 27 28 29
BD2IP_1 BD 1272 PU FLRB 0.5
BD 1162 L-BU FLRB 0.5
BD 1174 BN FLRB 0.5
BD 1271 BN FLRB 0.5
BD 1161 D-BU FLRB 0.5
BD 1164 WH/BK FLRB 0.5

EB02_K 18 40 57 59 11 61 81 35 83 82
Airflow Airflow Airflow Airflow Electron Electron Electron Electron Electron Electron 90
Signal Signal Sensor Sensor Accelerator Accelerator Accelerator Accelerator Accelerator Accelerator
Ground Power Pedal Ground 2 Pedal Signal Pedal Power Pedal Ground 1 Pedal Signal Pedal Power
Supply Output 2 Supply 2 Output 1 Supply 1
Fan Phase Sensor Phase Sensor Phase Sensor

(Intake) Power (Intake) (Intake)
Radiation Supply Signal Ground
26 EB02_K Engine Control Module ECM 27 08 53

EB02_A
0.75
0.75
0.75
BD 2364 D-BU FLRB 0.75 600W
BD 2368 WH FLRB 0.75 850W
EB22 EB21
4 4 3 1 2
+ Power Signal Ground -
Supply Output
Radiator Fan（850W） Radiator Fan（600W） Intake Phase Sensor

D9013-0009b
SAIC-SV91 09/2017
Fuel Rail Pressure Sensor Intake Pressure Sensor Electronic Throttle Valve
Signal Signal
+ + -
- Output
1 3 3 4 1 1 2 4 6 3 5
2
0.75
0.5
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
EB02_A 13 40 29 39 24 12 41 44 19 20
90 Pressure
Sensor
Fuel Rail
Pressure
Pressure
Sensor Power
Intake
Pressure
Electronic
Throttle
Electronic
Throttle
Electronic
Throttle
Electronic
Throttle
Electronic
Throttle
Electronic
Throttle
Ground Signal Supply Signal Valve Valve Valve Valve Valve Valve
Phase
Water Water Fuel Fuel Revolution Revolution Revolution Oil Phase Sensor Phase Sensor Sensor
Temperature Temperature Control Control Speed Sensor Speed Speed Sensor Knocking Knocking Pressure (Exhaust) (Exhaust) (Exhaust)
Sensor Sensor Valve + Valve - Power Supply Signal Ground Sensor Sensor Switch Power Supply Signal Ground
14 57 04 03 07 23 22 25 10 55 07 22 54
EB02_A
0.75
0.75
0.75
0.75
0.75
0.75
0.5
0.5
0.75
0.5
0.5
0.75
0.5
1 2 1 2 1 2 3 1 2 1 3 1 2
Power Signal Ground + - Power Signal Ground
Supply Output Supply Output
Water Temperature Fuel Control Revolution Speed Sensor Knocking Sensor Oil Pressure Exhaust Phase Sensor
Sensor Valve Switch D9013-0010b
SAIC-SV91 09/2017
Body Control Module
Lighting
Cruise Switch
Control + Ground
49 25
IP01_A
IP 1349 BN FLRB 0.35

BD 84 D-BU FLRB 0.5 CRSW
BD2IP_1
39 40 IP2BD_1
SP0308 SP0601
BD 6281C BN/WH FLRB 0.5
BD 83 D-GN FLRB 0.5 CRSW
P 83A D-GN FLRB 0.5 CRSW
IP 84A D-BU FLRB 0.5 CRSW
IP 83C D-GN FLRB 0.5 ADCR

EB02_K 15 12 7 8 4 5 IP50_B
Cruise Cruise
90
Control + Control -
Spiral
Spring
Injector 1+ Injector 1- Injector 2+ Injector 2- Injector 3+ Injector 3- Injector 4+ Injector 4-
31 33 47 49 46 34 32 48 7 8 4 5
SW04
EB02_A
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
1 2 1 2 1 2 1 2 5 6
+ - + - + - + - Cruise Cruise
Control + Control -
Injector 1 Injector 2 Injector 3 Injector 4 Cruise Control Switch

D9013-0011b
SAIC-SV91 09/2017
Boost Pressure Temperature Sensor Brake Vacuum Sensor
Signal - Signal 5V - Signal +
B A D C 2 1 3
EB11 EB41
BD 5391D PU FLRB 0.35 ESSS

BD 5266 OG/BK FLRB 0.5
BD 5073C BK/WH FLRB 0.35
BD 1533 WH FLRB 0.5
IP 84A D-BU FLRB 0.5 CRSW
BD 5073D BK/WH FLRB 0.35 ESSS
SP0305 BD 5391A PU FLRB 0.35
BD 5073A BK/WH FLRB 0.35

SP0304

BD 6041 L-GN FLRB 0.35
BD 5391 PU FLRB 0.5
BD2IP_1
35 34 32 IP2BD_1
IP 5391AD PU FLRB 0.35 AT
IP 6041A L-GN FLRB 0.35
IP 5073AD BK/WH FLRB 0.35 AT

IP 5391AA PU FLRB 0.35 AT
IP 5073AA BK/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW

EB02_K
IP 5073AB BK/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW

IP 5391AB PU FLRB 0.35 6MT-DYMOS||6MT-SAGW
37 63 14 64 58 13
90 Boost Pressure Boost Pressure Sensor - Brake Sensor + Brake
Temperature Temperature Vacuum Vacuum
Sensor Signal Sensor Signal Sensor Sensor
- +
Clutch 6 4 5 IP44
Travel Sensor Signal -
+
EB02_K 60 Engine Control Module ECM Dual Brake Sensor

BD 48 GY FLRB 0.5 6MT-DYMOS||6MT-SAGW
- Signal +
1 3 2
IP44
IP 5391AC PU FLRB 0.5 6MT-DYMOS||6MT-SAGW
SP0313 SP0314
IP 5073AC BK/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW
IP 5689B GY/BK FLRB 0.35 6MT-DYMOS||6MT-SAGW
IP 48A GY FLRB 0.5 6MT-DYMOS||6MT-SAGW
BD2IP_1
IP2BD_1 6 IP 1349D BN FLRB 0.35 6MT-DYMOS||6MT-SAGW
j
IP 1349GA OG FLRB 0.35 AT
IP 5066A YE FLRB 0.35
IP 5689A GY/BK FLRB 0.35 AT
IP01_D IP01_A IP01_D IP01_B

2 3 1 IP44 18 3 2 5
Dual Brake Dual Brake Dual Brake Dual Brake
+ Signal -
Sensor Sensor Sensor Sensor /
Ground Signal Engine Hood
Switch
Clutch Travel Sensor Body Control Module BCM

D9013-0012b
SAIC-SV91 09/2017
Engine Hood Switch
Ground BCM ECM
A C B
EB48
BD 109 PK FLRB 0.35AT
BD 5531 PU FLRB 0.35 AT
BD 1349J BN FLRB 0.35 ESSS
BD2IP_1 EB2EN
IP2BD_1 31 30 9 EN2EB
IP 1349C BN FLRB 0.5 ESP
IP 5531A PU FLRB 0.35 AT
Body Control Module BCM 37 EB02_A

Engine
Hood
Switch Engine Control 90
S/S OFF Signal

S/S OFF LED
Module ECM
ECO/SPORT
Lighting
Switch
Ground
25 22 94 49 EB02_K
IP01_A
IP 1349 BN FLRB 0.35
IP 5066A YE FLRB 0.35
BD 5067B PU FLRB 0.5 ESSS
BD 5086B GY FLRB 0.5 ESSS
BD2IP_4
IP2BD_4 A2 A3
IP 5067A PU FLRB 0.5 ESSS

SP0611 IP 1349C BN FLRB 0.5 ESP
IP 5085A GY FLRB 0.5 ESSS
j IP2CN_1
CN2IP_1 40 41 27 39
k
CN 5054A GY FLRB 0.5
CN 1349CA BN FLRB 0.5

CN06 16 15 3 5
ECO/SPORT
ECO/SPORT
S/S OFF Signal

S/S OFF LED
Central Control Switch Block - Right

D9013-0013b
SAIC-SV91 09/2017
5.5 Occupant information display system
Battery
BTN01
- +
Body Control Handbrake
BT04_1
Module BCM Switch
30 A 40 A
Pre-fuse Box 175 A U-JF6 Immobilizer
U-JF4
PFB P-MG2 Power IEG Signal
UEC Supply Power
UEC Supply 9
2 4 6 11 1
BT01_1 EB01 IP01_A FL70
IP 728 GY FLRB 0.5
BD 1131 YE/BK FLRB 0.5 HPB

BD 340D RD/WH FLRB 2.5 SP0257 BD2IP_7

22
IP2BD_7
BD2IP_1
IP2BD_1 2 11
SP0257
90

IP07 58 69 46 14
85 30
I-R3 10 A 10 A
IG I-FS21 I-FS2
86 87
Relay Instrument IG
Cluster PWR1
IP 2451CD BK/WH FLRB 0.5
IP07 60 68 52 2
IP 340AARD/D-GN FLRB 2.5

IP 249 WH FLRB 0.35
SP0210
IP 1131A YE/BK FLRB 0.5 HPB
SP0904
IP 249C WH FLRB 0.5
SP0240 IP 3440A RD/BK FLRB 3.0 -ESSS
IP 2451AC BK/WH FLRB 0.5
IP 2451AB BK/WH FLRB 0.5
IP 2451AA BK/WH FLRB 0.5
SP2626
BD 51 BK FLRB 2.5
48 IP01_B IP02_A
3 7 13 2 1 12 5
IG Body Ground Ground Ground KL30 KL15 Immobilizer Handbrake
Relay Indicator+ Signal
Control
Module
BCM
G_BTN G_EBR3 Instrument Cluster
D9013-0014b
SAIC-SV91 09/2017
Cruise Control Brake Fluid

Switch Level
Cruise 1 Cruise 2 Signal Ground
3 4 SW01 A B EB28
BD 209 PU FLRB 0.5
BD 451B BK/WH FLRB 0.5
BD2IP_1
9
IP2BD_1
IP 209A PU FLRB 0.5
9 10 SW04
90
Spiral
Spring
9 10
IP50_B
IP 1544 OG FLRB 0.5
IP 1545 PK FLRB 0.5
SP2635
IP02_A 10 11 4
Cruise Cruise Brake Fluid
Switch 1 Switch 2 Level Signal
Instrument Cluster G_EBL2_4

D9013-0015b
SAIC-SV91 09/2017
5.6 Front A/C and heating system
Engine Bay Fuse Box UEC Front AC Control Panel

KL30
30 A 60 A 25 A
U-JF4 U-JF5 40 A U-FS12
IGIG ACC U-JF9 IEC
Power Power Front Power
Supply Supply Blower Supply 8 Blower+ KL15 KL30
10 1 2
4 5 9 24 IP38
EB01
BD 342 RD FLRB 5.0
BD 3040 YE/BK FLRB 2.0 BD 3040A YE/BK FLRB 2.0
SP0244
BD 342E RD FLRB 5.0

BD2IP_3 BD2IP_1 BD2IP_1
SP0258
4 IP2BD_3 IP2BD_1 1 13 IP2BD_1
IP 342H RD FLRB 5.0
IP 3040C YE/BK FLRB 2.0

SP0257 BD2IP_1 SP0239

IP2BD_1 2 SP0230 IP 2240A D-GN FLRB 3.0 SP0235 SP0202
IP 65BA YE FLRB 0.5

IP 202AA RD/BK FLRB 0.5

IP 202BA RD/BK FLRB 0.5
IP 3040CB YE/BK FLRB 2.0

IP 342B RD/BK FLRB 3.0
90
IP07 69 37 61 70 35 50 18
58 43 41
Instrument 10 A 10 A
Panel 85 30
I-R3
85 30
I-R2
85 30 I-R1 I-FS15 I-FS25 10 A
10 A AC Control
IG Front I-FS6
Fuse Box ACC I-FS17
Blower
Front Panel/Left
86 87
Relay 86 87
Relay ACC2 86 87
Blower Central IG
IEC Relay Control PWR4
Feedback Switch
42 29 27 6
IP07 60 68 45 71 72 56

IP 5199D YE FLRB 0.35
IP 202 RD FLRB 3.0

IP 65B PU FLRB 3.0

IP 65 PU FLRB 3.0
IP 640 RD/WH FLRB 0.5

IP 202A RD FLRB 3.0
IP 2451CA BK/WH FLRB 0.5

IP 249 WH FLRB 0.35
SP0904 SP0901 SP0201

SP0237 SP2103
IP 5199C YE FLRB 0.35
IP 249C WH FLRB 0.5
SP0240
IP 65A PU FLRB 3.0
SP2626 IP 374 PU/WH FLRB 3.0

a
IP 2451SB BK/WH FLRB 0.75
IP01_B
IP31_B 2
48 6 1
IG ACC
Blower +
Blower -
Relay Relay
G_IPA2_1 Body Control Module BCM Front AC D9013-0077b
SAIC-SV91 09/2017
Front AC Control Panel
Temperature Sunlight
Blower Blower Damper Sensor Sensor Sensor Sunlight Sunlight Mode Sensor Sensor Motor Motor
FB- Control Actuator 5V+ 5V- Power Supply Sensor + Sensor - Damper Ground+ Ground- Motor R/F + R/F-
11 9 38 13 14 39 19 20 37 16 15 36 17 18
IP38
IP 754 GY/BK FLRB 0.5
IP 1236 WH/D-GN FLRB 0.5 ADAC

IP 761 OG FLRB 0.5
IP 1614 WH/BK FLRB 0.5

IP 1646 D-BU/GY FLRB 0.5 ADAC
IP 1316 L-BU/WH FLRB 0.5 ADAC
IP 1838 PK FLRB 0.5

IP 1199 D-BU/YE FLRB 0.5
IP 119 WH FLRB 0.5
IP 2273 PK/D-GN FLRB 0.5

IP 733 L-BU FLRB 0.5
IP 2275 L-GN FLRB 0.5

IP 2210 L-GN/WH FLRB 0.5
90
IP 374 PU/WH FLRB 3.0
a
IP31_C
IP31_A
D R G S 6 5 4 3 2 1 9 8 7 12 11 10
+ - + - + -
Sunlight Sunlight Sunlight
Sensor Sensor + Sensor -
Power
Supply
Blower Speed Governor Module
Temperature Mode Damper Actuator Damper Actuator
Damper Actuator
G_IPM1_1 Front AC D9013-0078b
SAIC-SV91 09/2017
D9013-0079b
b
Rear AC
Control
Panel
FL38_1
BD 6134B D-GN FLRB 0.5 MDAC&&HPB
BD2IP_2
26 IP2BD_2
SP2106
LIN
7
SP2104
IP 6134 D-GN FLRB 0.5 MDAC||ADAC IP 6134AA D-GN FLRB 0.5 MDAC||ADAC BD 6134A D-GN FLRB 0.5 MDAC||ADAC BD 6134BA D-GN FLRB 0.5 (MDAC||ADAC)&&EPB
LIN
LIN
7
5
FL38_2
G_IPM2_1
IP 751HA BK/WH FLRB 0.5 IP 751D BK/WH FLRB 0.5 IP 751S BK/WH FLRB 0.75 IP 751W BK/WH FLRB 1.0
Ground
21
SP2615
SP2643
SP2634
IP 279 PK/WH FLRB 0.5 ADAC
Sunlight
Sensor
19
IP17
NTC
IP 278 WH/D-BU FLRB 0.5 ADAC IP 6101DL-GN/YE FLRB 0.5 ADAC
Sunlight
Supply
Sensor
Power
39
6
IP17
Sunlight
Sensor
IP 6101DM-GN/YE FLRB 0.5
NTC
BD 6101MDA-GN/YE FLRB 0.5
Temperature
IP 636 D-GN/WH FLRB 0.5 BD 636A D-GN/WH FLRB 0.5

Ambient
IP 6101K D-GN FLRB 0.5 ADAC

Sensor
22
2
1
IP2BD_2 24
33
IP 6101DH-GN/YE FLRB 0.5 ADAC

EB29
BD2IP_2
IP2BD_2
EB29
BD2IP_2
Temperature
Ambient
Sensor
5-92
Pressure
IP 204 D-BU FLRB 0.5 AT BD 204A D-BU FLRB 0.5 AT

Sensor
Virtual output
35
B3
EB13
GND
NTC
5V+
IP 130B PU FLRB 0.5 AT BD 130BA PU FLRB 0.5 AT BD 6101BDA-GN/YE FLRB 0.5 AT IP 6101DB-GN/YE FLRB 0.5 AT
IP2BD_4 B1
IP2BD_4 B2
1
EB13
BD2IP_4
BD2IP_4
Pressure
Sensor
AC
SP2101
IP 130A PU FLRB 0.5
09/2017
IP 130 PU FLRB 0.5
Sensor
Sensor
40
14
5V
5V
Front AC
Actuator Ground
IP 6101A D-GN/YE FLRB 0.5
Damper Sensor
IP 6101D-GN/YE FLRB 0.5
Damper Ground
Temperature Sensor
15
22
SP2102
Temperature
Actuator
SAIC-SV91
38
6
IP31_A
IP38
90
Temperature Temperature Temperature Temperature Temperature Temperature

Signal Signal Signal Signal Signal Signal
-FL -FL -FR -FR -RR -RR
32 31 30 29 28 27
IP38
IP 520 TN/WH FLRB 0.5 ADAC
IP 404 BN FLRB 0.5 ADAC
IP 405 L-GN/BK FLRB 0.5 ADAC

IP 516 YE/BK FLRB 0.5 ADAC
IP 518 TN FLRB 0.5 ADAC
IP 517 YE FLRB 0.5 ADAC
IP2RF_2 8
RF2IP_2 IP2BD_4 4
BD2IP_4
RF 404C BN FLRB 0.5 ADAC&&PSRF

RF 404B BN FLRB 0.5 ADAC&&FSRF
RF 404A BN FLRB 0.5 ADAC&&NSRF
BD 405A L-GN/BK FLRB 0.5 ADAC

RF21_1 RF21_2 RF21_3
IP35 1 IP36 1 IP39 1 IP40 1 1 1 1 FL66 1 90
5V+ 5V+ 5V+ 5V+ 5V+ 5V+ Temperature 5V+
Temperature Temperature Temperature Temperature Temperature Sensor
Sensor Left NTC Sensor Left NTC Sensor Right NTC Sensor Right NTC Sensor Right NTC NTC NTC Right NTC
Front Top Front Bottom Front Top Front Bottom Rear Top Rear
GND GND GND GND GND GND Bottom GND
IP35 3 IP36 3 IP39 3 IP40 3 3 3 3 FL66 3

RF21_1 RF21_2 RF21_3
BD 6102HDA-GN/YE FLRB 0.5 ADAC

RF 6101GC D-GN/YE FLRB 0.5 ADAC&&PSRF
RF 6101GB D-GN/YE FLRB 0.5 ADAC&&FSRF
IP 520 TN/WH FLRB 0.5 ADAC
RF 6101GA D-GN/YE FLRB 0.5 ADAC&&NSRF

IP 516 YE/BK FLRB 0.5 ADAC
IP 518 TN FLRB 0.5 ADAC
IP 517 YE FLRB 0.5 ADAC
BD2IP_4
IP2BD_4 B11
RF2IP_2
IP2RF_2 7
IP 6101K D-GN FLRB 0.5 ADAC IP 6101DG-GN/YE FLRB 0.5 ADAC

b
SP2109

c
D9013-0080b
SAIC-SV91 09/2017
5.7 Rear A/C and heating system

KL30
25 A
30 A 15 A U-FS2
U-FS21 15 A 10 A Rear Window
U-JF1 85 30 U-R8 Main U-FS9 85 30 U-R9 U-FS1 Heat /
Main Main Relay AC Rear View
AC Compressor KL30
Relay Power Mirror /
Relay 86 87
Supply Compressor 86 87
Relay PWR Trunk Light
1 153 155 154 157 33 56 21 65 67 69 66 13 14
EB01


BD 640E RD/WH FLRB 0.5 AFS||ESSS||MDAC||(ADAC&&EPB)


BD 5069 BN FLRB 0.5
BD2IP_1
SP0217 SP0215 5 IP2BD_1

SP0306
SP0260
BD 640BA RD/WH FLRB 0.5 (MDAC||ADAC)&&EPB
BD 640B RD/WH FLRB 0.5 MDAC&&HPB
SP0231
SP2601
90
TLD 1750TD BK FLRB 2.0

TLD 1750TR BK FLRB 1.5
FL38_1 FL38_2
5 5 IP07
96 100
TLD03
1 14 TLD2FL_1
FL2TLD_1
Rear Window Heat
- BD 1750TP BK FLRB 2.0

Power Supply Power Supply
Instrument 85 30 I-R5
Rear View
Panel Fuse Mirror &
Box 86 87
Rear Window
EB2EN
IEC Heat Relay +
6
EN2EB Rear AC Control Panel IP07 94 99
TLD04 1
SP2629
IP 293 PU FLRB 1.5
IP 193 WH FLRB 0.35
TLD 293AB PU FLRB 1.5
SP0238
IP 293A PU FLRB 1.5
TLD2FL_1 12
BD 1750 BK FLRB 3.0
FL2TLD_1
BD 293AA PU FLRB 1.5
EB02_K IP01_B
1 38 IP2BD_2
69 72 43 BD2IP_2
Main Relay AC Engine AC Body Rear View
Compressor Mirror
Relay Control Compressor Control & Rear
Module Module Window

Heat Relay
BCM G_FLDL1_1
ECM
D9013-0081b
SAIC-SV91 09/2017
90
5-95
09/2017
D9013-0082b
a
FL38_1
Rear Blower
Feedback
BD 1592BB TN FLRB 0.5 MDAC&&HPB
Supply Feedback Feedback
I-FS16
BD2IP_6
7 IP2BD_6
Power Blower Blower
23
10 A
IP07
IP07
SAIC-SV91
BD 1592BC TN FLRB 0.5 (MDAC||ADAC)&&EPB IP 1592BA TN FLRB 0.5 MDAC||ADAC BD 1592 BN/WH FLRB 3.0 MDAC||ADAC
28
36
23
Rear AC Control Panel
Panel Fuse
Engine Bay
Instrument
Fuse Box 2
UEC_2
BD 642RD BU/BK FLRB 0.5 (MDAC||ADAC)&&EPB
Box
IEC
4
FL38_2
SP0249
IP2BD_2
BD 642BB RD/BK FLRB 0.5 MDAC&&HPB
Supply
Power
U2-FS15
Supply 4
4
Power
4
10 A
IG
BD2IP_2
FL38_1
BD 1592B NA/WH FLRB 3.0 MDAC||ADAC

45
46
U2-R4
Relay
IG
SP0257
Supply
Power
U-JF4
SP0264
30 A
IG
BD 340 RD/WH FLRB 2.5 BD 340E RD/WH FLRB 2.5 BD 340EA RD/WH FLRB 2.5

87
30
18
17
4
BD 451D BK/WH FLRB 0.5 BD 249D WH FLRB 0.35
85
86
21
19
IP2BD_1 4
Blower -
BD2IP_1
Rear AC
Blower
U2-R3
Relay
Rear
U-JF10
Blower
Rear
40 A
BD 2140 RD/WH FLRB 3.0 MDAC||ADAC BD 1592 BN/WH FLRB 3.0 MDAC||ADAC BD 1592BANB/WH FLRB 3.0 MDAC||ADAC
87
30
23
22
1
10
Blower +
SP2105
FL50_B
G_EBL2_4
BD 202BB RD/BK FLRB 0.5 MDAC||ADAC BD 2451CB BK/WH FLRB 0.5 MDAC||ADAC BD 451 BK/WH FLRB 1.0
85
86
26
24
SP0253
SP2635
U2-FS12
ACC2
10 A

BD 202GB RD/BK FLRB 0.5 BD 242B RD/BK FLRB 3.0 IP 249B WH FLRB 0.35 IP 249C WH FLRB 0.5
Relay
48
40
39
IG
SP0904
U2-R1
Relay
ACC
SP0263
BD 342CA RD FLRB 5.0 BD 242 RD/BK FLRB 3.0
87
30
36
33
Supply
Power
U-JF5
ACC
60 A
BD 342 RD FLRB 5.0 BD 342C RD FLRB 5.0 BD 342D RD FLRB 5.0 BD 5199B YE FLRB 0.35 IP 5199D YE FLRB 0.35 IP 5199C YE FLRB 0.35
Relay
85
86
ACC
32
EB58 35
5
6
IP2BD_1 3
SP0205
SP0258
SP0901
EB01
IP01_B
KL30
BD2IP_1
EB58
D9013-0083b
G_FLDR2_1
BD 1851HA BK/WH FLRB 0.5 MDAC&&HPB
GND
15
FL50_A
BD 5730 L-GN/BK FLRB 0.5 MDAC&&HPB
-
Mode
4
-
Mode Damper Actuator

BD 5729 L-GN/WH FLRB 0.5 MDAC&&HPB
Mode
+
5
1
+
Feedback
BD 2215 OG/WH FLRB 0.5 MDAC&&HPB

Temperature Temperature Temperature Mode
6
9
BD 2775 OG FLRB 0.5 MDAC&&HPB
Temperature Damper Actuator

14
1
-
Rear AC
BD 2614 GY FLRB 0.5 MDAC&&HPB

13
2
+
+
BD 7523 PK FLRB 0.5 MDAC&&HPB
Feedback
10
Ground
Sensor
BD 6556 D-BU/WH FLRB 0.5 MDAC&&HPB
Ground
Sensor
16
9
5-96
Sensor
BD 6555 BN FLRB 0.5 MDAC&&HPB
Sensor
5V
21
5V
8
BD 1850H BK FLRB 3.0 MDAC||ADAC
Blower Speed Governor Module

Control BD 2613 WH FLRB 0.5 MDAC&&HPB

Blower
22
G
BD 5433 L-BU FLRB 0.5 MDAC&&HPB
Blower
FB-
24
09/2017
R
FL38_1
BD 5434 D-BU FLRB 3.0 MDAC||ADAC
D
FL50_C
G_FLDR1_3
SAIC-SV91
a
90
90
5-97
09/2017
D9013-0084b
SAIC-SV91
G_FLDR2_1
BD 1851HD BK/WH FLRB 0.5 (MDAC||ADAC)&&EPB
Ground
Sensor
15
FL50_A
BD 5730A L-GN/BK FLRB 0.5 (MDAC||ADAC)&&EPB
Mode
-
-
4
2
Mode Damper Actuator

BD 5729A L-GN/WH FLRB 0.5 (MDAC||ADAC)&&EPB
Mode
+
5
1
+
Feedback
BD 2215A OG/WH FLRB 0.5 (MDAC||ADAC)&&EPB

Temperature Temperature Temperature Mode
6
9
BD 2775A OG FLRB 0.5 (MDAC||ADAC)&&EPB
Temperature Damper Actuator

-
14
1
-
Rear AC
BD 2614A GY FLRB 0.5 (MDAC||ADAC)&&EPB

13
+
2
+
BD 7523A PK FLRB 0.5 (MDAC||ADAC)&&EPB
Feedback
10
Ground
Sensor
BD 6556A D-BU/WH FLRB 0.5 (MDAC||ADAC)&&EPB
Ground
Sensor
16
Sensor
BD 6555A BN FLRB 0.5 (MDAC||ADAC)&&EPB
Sensor
5V
21
5V
8
BD 2613A WH FLRB 0.5 (MDAC||ADAC)&&EPB
Control
Blower
22
Governor Module
G
Blower Speed
Blower BD 5433A L-BU FLRB 0.5 (MDAC||ADAC)&&EPB
FB-
24
R
FL50_C
FL38_2
Engine Bay Fuse Box Instrument Panel Fuse Box Front AC

UEC IEC Control Panel
KL30
25 A 10 A
U-FS12 I-FS25
IEC Power AC Control Panel /
Supply 8 Left Central LIN
Control Switch
24 50 56 5
EB01 IP07 IP38
IP 6134 D-GN FLRB 0.5 MDAC||ADAC

BD 3040 YE/BK FLRB 2.0

SP0244
SP0201
BD 3040A YE/BK FLRB 2.0
SP2106
IP 640K RD/WH FLRB 1.0 APM
IP 6134AA D-GN FLRB 0.5 MDAC||ADAC

BD2IP_1
13 IP2BD_1
27 IP2BD_1
BD2IP_1
BD 640KA RD/WH FLRB 1.0 APM
90
26 IP2BD_2
BD2IP_2
BD 6134A D-GN FLRB 0.5 MDAC||ADAC
SP0235
SP2104
BD 6134F D-GN FLRB 1.0 APM
SP2636
BD 1451S BK/WH FLRB 1.0
BD 1451H BK FLRB 1.0 APM
FL79 1 3 2
KL30 LIN Ground
Air Cleaner G_FLR2_1

D9013-0085b
SAIC-SV91 09/2017
5.8 Occupant entertainment system
Engine Bay Fuse Box UEC Micropnhone

KL30
60 A
U-JP5 40 A
ACC U-JF6
Power IEC PWR9
Supply + -
5 6 EB01 2 1 RF09
RF SHIELD3004BARE DRAN0.5
BD 342 RD FLRB 5.0
BD 342E RD FLRB 5.0

SP0258
RF 7044 YE FLRB 0.5

BD2IP_3
4 IP2BD_3 BD2IP_1
11 IP2BD_1
IP 342H RD FLRB 5.0
SP0234
RF SHIELD3004 BARE DRAN0.5

SP0230
90
15 16 RF2IP_2
IP2RF_2
IP SHIELD7044CBARE DRAN0.5 RADIO
43 41 48 IP07
85 30 25 A
I-R2 10 A
I-FS23
ACC I-FS18
Entertainment
86 87
Relay ACC3
System / Radio
45 42 30 38 54 IP07
IP 202CA RD/YE FLRB 0.5 RADIO
IP 202 RD FLRB 3.0
IP 7044C PK/BK FLRB 0.5 RADIO

IP 3440DA RD/WH FLRB 2.5 RADIO
IP SHIELD7044CBARE DRAN0.5 RADIO

IP 202CD RD/YE FLRB 0.5 RADIO
IP 202CB RD/YE FLRB 0.5 RADIO
SP0901
SP1237 SP0247
6 IP01_13 1 IP58 4 7 3 1 IP56_A

ACC Body ACC Power Supply Mic + Mic -
Relay Control Antenna Radio
Module Amplifier
BCM D9013-0049b
SAIC-SV91 09/2017
IP2BD_7
BD2IP_7
FL2RRD
RRD2FL
D9013-0050b
IP56_B
Rear Right Door Speaker

BD 115C OG FLRB 0.5 6-SPK
Rear Right
RRD 115D OG FLRB 0.5 6-SPK

Speaker -
IP 115R OG FLRB 0.5 RADIO BD 115W OG FLRB 0.5 -AMP RRD 115E OG FLRB 0.5 6-SPK
14
2
1
7
SP1417
SP1415
IP 46R WH FLRB 0.5 RADIO BD 46W WH FLRB 0.5 -AMP BD 46C WH FLRB 0.5 6-SPK RRD 46D WH FLRB 0.5 6-SPK RRD 46E WH FLRB 0.5 6-SPK
Rear Right
Speaker +
13
RLD2FL 6
1
RR01 2
SP1416
SP1414
FL2RLD
Speaker -
BD 116C YE FLRB 0.5 6-SPK

Rear Left
IP 116R YE FLRB 0.5 RADIO BD 116W YE FLRB 0.5 -AMP RLD 116D YE FLRB 0.5 6-SPK RLD 116E YE FLRB 0.5 6-SPK
Door Speaker
8
1
3
Rear Left
SP1413
SP1411
IP 199R BN FLRB 0.5 RADIO BD 199W BN FLRB 0.5 -AMP BD 199C BN FLRB 0.5 6-SPK
Speaker +
RLD 199D BN FLRB 0.5 6-SPK RLD 199E BN FLRB 0.5 6-SPK
Rear Left
6
7
RL01 2
SP1412
SP1410
Pressure Speaker
IP 1852 L-GN FLRB 0.5 6-SPK
Right High
1
IP 1952 PU FLRB 0.5 6-SPK
2
Radio
IP22
IP2PAD
16 PAD2IP
Front Right
Speaker -
IP 117R PU FLRB 0.5 RADIO IP 117D PU FLRB 0.5 6-SPK PAD 117E PU FLRB 0.5 6-SPK
Door Speaker
4
Front Right
SP1409
5-100
Front Right
Speaker +
IP 200R L-GN FLRB 0.5 RADIO IP 200D L-GN FLRB 0.5 6-SPK PAD 200E L-GN FLRB 0.5 6-SPK
17
3
2
SP1408
PD02
Pressure Speaker
IP 1856 TN FLRB 0.5 6-SPK
1
Left High
IP 1956 GY FLRB 0.5 6-SPK
2
IP2DRD_2
34 DRD2IP_2
09/2017
IP21
Speaker -
Front Left
IP 118R GY FLRB 0.5 RADIO IP 118D GY FLRB 0.5 6-SPK DRD 118E GY FLRB 0.5 6-SPK
Door Speaker
6
Front Left
SP1407
SP1406
SAIC-SV91
Speaker +
Front Left
IP 201R TN FLRB 0.5 RADIO IP 201D TN FLRB 0.5 6-SPK DRD 201E TN FLRB 0.5 6-SPK
33
5
2
DD02
90
Engine Bay Fuse Box

Woofer
KL30
30 A 40 A
U-FS15 U-JF6
IEC PWR2 IEC PWR9 L+ L- R+ R-
1 2 3 4 FL43
27 6 EB01
SP0234

SP0242

IP 2540A RD/L-GN FLRB 2.5 12-SCRN||TBOX
IP 2540C RD/L-GN FLRB 2.5 12-SCRN||TBOX
IP 3440E RD/BK FLRB 3.0 -ESSS&&AMP
BD 1750M BK FLRB 2.5 AMP

BD 346 D-BU/WH FLRB 0.5 AMP
BD 1794 L-GN/BK FLRB 0.5 AMP
BD 315 L-BU/BK FLRB 0.5 AMP
BD 1795 D-GN FLRB 0.5 AMP

BD2IP_1 BD2IP_1
12 IP2BD_1 IP2BD_1 11
FL44_B
25 32 48 IP07 4 3 2 1 5 8
Power Supply Woofer Bass Bass Bass Ground
10 A 25 A
30 A I-FS23
2 2 2
Instrument I-FS13 - + -
Telematics/
I-FS20 Entertainment 90
Panel Fuse 12-inch
Power System/
Box Amplifier Radio
Display Screen
IEC 33 40 54 IP07
Power Amplifier
IP 2540CA RD/WH FLRB 0.5 12-SCRN||TBOX
BD2IP_4
A7 IP2BD_4
G_IPM1_2
SP0243
IP 2540CC RD/WH FLRB 0.5 TBOX

IP 751RB BK/WH FLRB 0.5 12-SCRN
IP 2540CB RD/WH FLRB 0.5 12-SCRN
IP 621 YE FLRB 0.5 12-SCRN
IP 620 BN/WH FLRB 0.5 12-SCRN

IP 2355 BN FLRB 0.5 12-SCRN
IP 1755 D-GN FLRB 0.5 12-SCRN
IP55_E IP55_B
IP57 6 5 7 1 2 3 6 5 4 4 5 6 7 10 4 11 15
Ground Power Key Ground LIN Key DRAIN Data + Data - Output - Output + DRAIN Key LIN Ground Key Power
Supply FOR FOR Supply
FCD FCD
G_IPM1_2
12-inch Display Screen Entertainment System Host D9013-0051b
SAIC-SV91 09/2017
D9013-0052b
RF SHIELD3004 BARE DRAN0.5
16
1
IP SHIELD7044ABARE DRAN0.5 12-SCRN
Mic -
8
IP 7044A D-BU/YE FLRB 0.5 12-SCRN
RF 7044 YE FLRB 0.5
Mic +
Microphone
15
2
2
IP60
Telematics
IP 2386 D-GN FLRB 0.5 TBOX
Output -
Audio
12
IP SHIELD7043BARE DRAN0.5TBOX
Output -
RF SHIELD7043 BARE DRAN0.5TBOX
Audio
28
12
Mic -
26
-
Telematics
IP 2385 YE FLRB 0.5 TBOX
Output +
Audio
Output +
Audio
6
RF 7043 YE FLRB 0.5 TBOX IP 7043A YE FLRB 0.5 TBOX
8
+
11
IP55_E
Mic +
6
4
IP SHIELD7043CBARE DRAN0.5TBOX
Audio -
Audio -
RF2IP_2
RF09
IP2RF_2
5
IP 7043C YE FLRB 0.5 TBOX
Audio +
Audio +
25
11
IP55_D
Ground
USB
B3
Ground
Data -
USB
B4
IP28
Diagnose Interface OBD
Data -
SP1840
SP1842
IP 6436CA WH/BK FLRB 0.5 IP 6436B WH/BK FLRB 0.35 IP 6436BA WH/BK FLRB 0.35 TBOX
Data +
CAN_L
USB
HS CAN_L
39
B2
14
Data +
Power Supply
5-102
IP 6437CA BN/WH FLRB 0.5 IP 6437B BN/WH FLRB 0.35 IP 6437BA BN/WH FLRB 0.35 TBOX
USB
B1
HS CAN_H
19
Supply
Power
CAN_H
6
SP1839
SP1841
IP60
G_IPB2_2
IP 2351T BK/WH FLRB 0.5 TBOX
Ground
40
KL30
20
09/2017
IP 2540CC RD/WH FLRB 0.5 TBOX
Telematics Control Unit
T-BOX
SAIC-SV91
a
90
90
5-103
09/2017
D9013-0053b
IP55_B
G_IPM1_3
IP 751RC BK/WH FLRB 2.5 12-SCRN
Ground
16
SAIC-SV91
IP63
Right View Panoramic Camera

IP SHIELD6798DBARE DRAN0.35 BSV IP SHIELD6798DBARE DRAN0.35 BSV PADSHIELD6798DABARE DRAN0.35BSV PADSHIELD6798DABARE DRAN0.35BSV
Signal + Shield
Signal + Shield
10
32
2
IP 6798D GY FLRB 0.35 BSV PAD 6798DA GY FLRB 0.35 BSV
31
9
1
MC1435
MC1434
MC1435
MC1434
PAD 6202DA BK FLRB 0.35 BSV
Ground
IP 6202D BK FLRB 0.35 BSV
33
3
Entertainment System Host
IP 6201D OG/BK FLRB 0.35 BSV PAD 6201DA OG/BK FLRB 0.35 BSV
Supply
Power
34
4
PD13
IP2PAD
PAD2IP
SP1402
Left View Panoramic Camera

IP SHIELD6798CBARE DRAN0.35 BSV IP SHIELD6798CBARE DRAN0.35 BSV DRDSHIELD6798CABARE DRAN0.35BSV DRDSHIELD6798CABARE DRAN0.35BSV
Signal + Shield
Signal + Shield
46
2
8
IP 6798C GY FLRB 0.35 BSV DRD 6798CA GY FLRB 0.35 BSV
45
7
1
MC1433
MC1433
MC1432
MC1432
IP 6202 BK FLRB 0.35 BSV IP 6202C BK FLRB 0.35 BSV DRD 6202CA BK FLRB 0.35 BSV
Ground
Camera
Ground
44
3
2
SP1402
Power Supply
IP 6201 OG/BK FLRB 0.35 BSV IP 6201C OG/BK FLRB 0.35 BSV DRD 6201CA OG/BK FLRB 0.35 BSV
Supply
Power
Camera
IP2DRD_2 43
4
1
SP1401
DRD2IP_2
DD13
SP1402
Front View Panoramic Camera

BDSHIELD6798AABARE DRAN0.35BSV
Signal + Shield
IP SHIELD6798ABARE DRAN0.35 BSV IP SHIELD6798ABARE DRAN0.35 BSV BD SHIELD6798AB BN FLRB 0.35 BSV
Signal + Shield
33
2
6
IP 6798A GY FLRB 0.35 BSV BD 6798AA GY FLRB 0.35 BSV
31
5
1
MC1431
MC1431
MC1430
MC1430
IP 6202A BK FLRB 0.35 BSV BD 6202AA BK FLRB 0.35 BSV
Ground
26
3
IP 6201A OG/BK FLRB 0.35 BSV BD 6201AA OG/BK FLRB 0.35 BSV
Supply
Power
24
4
BD2IP_3
IP2BD_3
EB49
D9013-0054b
BD2IP_4
C8 IP2BD_4
IPSHIELD6793BF BARE DRAN0.35BSV
SP1425
BD 6793BG YE FLRB 0.5 BSV&&(MDAC||ADAC) IP6793BF GY FLRB 0.35 BSV
C7
MC1487
MC1487
MC1429
MC1487
BD 6793BH GY FLRB 0.5 (RCAM||BSV)&&(MDAC||ADAC) BD 6793BC GY FLRB 0.35 RCAM&&(MDAC||ADAC)
MC1427
MC1490
MC1490
SP1424
TLD20
11 IP55_E

IP2BD_2
BD2IP_2
SP1423
TLD SHIELD6793BB BARE DRAN 0.35RCA BDSHIELD6793BABARE DRAN0.35 RCAM&&MSAC IP SHIELD6793B BARE DRAN0.35RCAM
Shield
Shield
14
2
SP1422
TLD 6793BB GY FLRB 0.35 RCAM||BSV
Camera
BD 6793BD GY FLRB 0.5 (RCAM||BSV)&&MSAC BD 6793BA GY FLRB 0.35 RCAM&&MSAC IP 6793B GY FLRB 0.35 RCAM
Signal
13
Rear
View
1
5
MC1426
MC1426
MC1426
MC1426
MC1425
MC1425
Rear View Panoramic Camera
36 IP01_B
Gear Signal
IP 5219F OG/BK FLRB 0.5
SP0613
Reverse
IP 5219CB OG/BK FLRB 0.5
Module
Control
Body
BCM
Power Supply
TLD 6201BB OG/BK FLRB 0.35 RCAM||BSV BD 6201BC OG/BK FLRB 0.35 (RCAM||BSV)&&MSAC BD 5219B OG/BK FLRB 0.5 RCAM&&MSAC BD 5219 OG/BK FLRB 0.5
9
4
8
SP1421
SP0612
BD 5219BA OG/BK FLRB 0.5 RCAM&&(MDAC||ADAC)
BD2IP_2
IP2BD_2
BD 6201BE OG/BK FLRB 0.35 (RCAM||BSV)&&(MDAC||ADAC) BD 6201BD OG/BK FLRB 0.5 BSV&&(MDAC||ADAC)
SP1427
G_FLDR2_2
5-104
BD 6202BC BK FLRB 0.35 (RCAM||BSV)&&MSAC

Ground
TLD 6202BB BK FLRB 0.35 RCAM||BSV BD 1851C BK FLRB 0.35 RCAM&&MSAC
TLD2FL_2 8
3
SP1420
FL2TLD_2
BD 6201BA OG FLRB 0.5 BSV&&MSAC IP 6201B OG/BK FLRB 0.35 BSV
C10
BD 6202BA BN/OG FLRB 0.5 BSV&&MSAC IP 6202B BK FLRB 0.35 BSV
C9
09/2017
BD2IP_4
IP2BD_4
BD 6202BE BK FLRB 0.35 (RCAM||BSV)&&(MDAC||ADAC) BD 6202BD BK FLRB 0.5 BSV&&(MDAC||ADAC)
SP1426
G_FLDR2_3
BD 1851D BK FLRB 0.35 RCAM&&(MDAC||ADAC)
SAIC-SV91
b
90
90
5-105
09/2017
IP SHIELD117BARE DRAN0.512-SCRN
IP55_A
D9013-0055b
6
Rear Right
Speaker -
IP 11G7Y/BK FLRB 0.5 12-SCRN BD 117GAY/BK FLRB 0.5 AMP

11
6
BD 117W PU FLRB 0.5 -AMP

SAIC-SV91
IP 200 OG/BK FLRB 0.5 12-SCRN BD 200A OG/BK FLRB 0.5 AMP
Rear Right
Speaker +
IP2BD_7 10
2
FL44_A
BD 200W L-GN FLRB 0.5 -AMP

BD2IP_7
Pressure Speaker
IP 1852 L-GN FLRB 0.5 6-SPK
Front Left
Speaker
1
Input +
12
Left High
IP 1952 PU FLRB 0.5 6-SPK
Front Left
Speaker
Input -
12 FL44_B 11
2
IP2DRD_2
34 DRD2IP_2
SP1418
BD2IP_7
IP22
19 IP2BD_7
BD 117B PU FLRB 0.5 AMP IP 117C PU FLRB 0.5 12-SCRN IP 118D GY FLRB 0.5 6-SPK DRD 118E GY FLRB 0.5 6-SPK
Front Left
Speaker
Output -
Door Speaker
SP1409
Front Left
BD 200B L-GN FLRB0.5 AMP IP 200C L-GN FLRB 0.5 12-SCRN IP 201D TN FLRB 0.5 6-SPK DRD 201E TN FLRB 0.5 6-SPK
Front Left
Output +
Speaker
18
16 PAD2IP 33
11
DD02 2
SP1408
IP2PAD
Power Amplifier
Front Right
Speaker BD 118B GY FLRB 0.5 AMP IP 118C GY FLRB 0.5 12-SCRN IP 117D PU FLRB 0.5 6-SPK PAD 117E PU FLRB 0.5 6-SPK
Output -
16
Door Speaker
1
2
Front Right
SP1407
Front Right
BD 201B TN FLRB 0.5 AMP IP 201C TN FLRB 0.5 12-SCRN IP 200D L-GN FLRB 0.5 6-SPK
Output +
PAD 200E L-GN FLRB 0.5 6-SPK
Speaker
15
17
1
PD02 2
SP1406
FL44_A
Front Right Front Right
IP 1856 TN FLRB 0.5 6-SPK
Speaker
Pressure Speaker
Input +
Right High
Speaker
Input -
IP 1956 GY FLRB 0.5 6-SPK
10
2
IP21
SP1418
IP SHIELD118BARE DRAN0.5 12-SCRN
5
Front Right
Speaker -
IP 118 GY FLRB 0.5 12-SCRN BD 118A GY FLRB 0.5 AMP
1
BD 118W GY FLRB 0.5 -AMP
Front Right
Speaker +
IP 201 L-BU FLRB 0.5 12-SCRN BD 201A L-BU FLRB 0.5 AMP
2
3
BD2IP_7
IP2BD_7
BD 201W TN FLRB 0.5 -AMP
FL26_1
D9013-0056b
IP55_A
IP SHIELD115F BARE DRAN0.5AMP&&12-SCRN

9
BD 1955A OG FLRB 0.5 12-SPK&&MSAC
1
IP 115 OG FLRB 0.5 -AMP&&12-SCRN BD 115A GY FLRB 0.5 AMP
Rear Right
Speaker -
14
5
IP 115F GY FLRB 0.5 AMP&&12-SCRN BD 115W OG FLRB 0.5 -AMP

BD 1855A WH FLRB 0.5 12-SPK&&MSAC
Rear Right Speaker

IP 46 WH FLRB 0.5 -AMP&&12-SCRN BD 46W WH FLRB 0.5 -AMP
2
Rear Right
Speaker +
IP2BD_7 13
BD 1955 OG FLRB 0.5 12-SPK&&(MDAC||ADAC)

1
BD2IP_7
BD 46A L-GN FLRB 0.5 AMP
1
IP 46F L-GN FLRB 0.5 AMP&&12-SCRN
FL26_2
Rear Right
Speaker
Input +
BD 1855 WH FLRB 0.5 12-SPK&&(MDAC||ADAC)

4
Pressure Speaker
Rear Right
RRD 1854 WH FLRB 0.5 8-SPK
Rear Right High

Speaker
Input -
1
FL44_B FL44_A 3
SP1418 RRD 1954 OG FLRB 0.5 8-SPK
RRD2FL
FL2RRD
SP1417
2
RR06
BD 115B OG FLRB 0.5 AMP BD 115C OG FLRB 0.5 6-SPK RRD 115D OG FLRB 0.5 6-SPK RRD 115E OG FLRB 0.5 6-SPK
Rear Right
Speaker
Door Speaker
Output -
1
7
Rear Right
SP1415
9
Rear Right RRD 46D WH FLRB 0.5 6-SPK
Power Amplifier
BD 46B WH FLRB 0.5 AMP BD 46C WH FLRB 0.5 6-SPK
Output +
RRD 46E WH FLRB 0.5 6-SPK
Speaker
10
2
SP1414
SP1416
RR01
BD 116C YE FLRB 0.5 6-SPK
Rear Left
BD 116B YE FLRB 0.5 AMP
Speaker
Output -
RLD 116D YE FLRB 0.5 6-SPK RLD 116E YE FLRB 0.5 6-SPK
Door Speaker
1
4
SP1411
Rear Left
SP1413
5-106
Rear Left
BD 199B BN FLRB 0.5 AMP RLD 199D BN FLRB 0.5 6-SPK
Output +
BD 199C BN FLRB 0.5 6-SPK
Speaker
RLD 199E BN FLRB 0.5 6-SPK
2
FL2RLD 6
SP1410
RL01
SP1412
RLD2FL
1 FL44_A
Rear Left Rear Left
Speaker Speaker
Input +
Pressure Speaker
RLD 1858 BN FLRB 0.5 8-SPK
Rear Left High

1
Input -
BD2IP_7
8 IP2BD_7
RLD 1958 YE FLRB 0.5 8-SPK
SP1418
09/2017
2
RL06
BDSHIELD116ABARE DRAN0.5AMP
Speaker -
Rear Left
IP 116 YE FLRB 0.5 -AMP&&12-SCRN BD 116A GY FLRB 0.5 AMP
8
BD 1959 YE FLRB 0.5 12-SPK
1
IP 116F GY FLRB 0.5 AMP&&12-SCRN BD 116W YE FLRB 0.5 -AMP
Rear Left
Speaker
SAIC-SV91
Speaker +
Rear Left
IP 199 BN FLRB 0.5 -AMP&&12-SCRN BD 199A D-GN FLRB 0.5 AMP
BD 1859 BN FLRB 0.5 12-SPK
4
4
2
IP 199F D-GN FLRB 0.5 AMP&&12-SCRN BD 199W BN FLRB 0.5 -AMP
FL25
90
Engine Bay Fuse Box UEC Cruise Control Switch Entertainment System Host
60 A
U-JF5
ACC Switch 1 Switch 2 Switch in
Power - + + + Common
Supply
4 10 3
EB01 5 SW01 2 1
BD 342E RD FLRB 5.0
IP55_D
IP 1765 WH FLRB 0.5 12-SCRN

BD 342 RD FLRB 5.0
IP 1763 L-GN FLRB 0.5 12-SCRN
IP 1764 L-BU FLRB 0.5 12-SCRN

BD2IP_3
28 IP2BD_3
SP0258
IP 342H RD FLRB 5.0
IP 1382AF PU/WH FLRB 0.5

IP 2451D BK/WH FLRB 0.5
Steering Wheel Switch IP50_B
1 2 3 12 11
Clock
Switch 2
Switch 1
SP0230
Spring
- +
2 1 5 4 3 3 12 11
SW02 SW04 1 2
90
SP1206 IP 1382A PU/WH FLRB 0.5
IP07 43 41 Steering Wheel Switch IEC Power Amplifier SP1207
P 1382EA PU/WH FLRB 0.5P
85 30
I-R2 10 A Instrument Instrument
ACC I-FS18 Panel Panel
Relay Center Center
86 87
ACC3 Power Speaker Speaker
Supply CAN_H CAN_L Input + Input -
30 38 8 16 15 7 8 FL44_B
45 42 FL44_A
IP07 SP2610
BD 1860 YE FLRB 0.5 AMP
BD 1960 L-BU FLRB 0.5 AMP

BD 5169AA BN/WH FLRB 0.35 AMP
BD 5170AA BN FLRB 0.35 AMP

IP 202CC RD/YE FLRB 0.5 AMP

IP 202 RD FLRB 3.0
IP 2451SA BK/WH FLRB 0.75

IP2BD_3 57
BD2IP_3
BD 1382E PU/WH FLRB 0.5
BD2IP_7
20 21 IP2BD_7
IP 1860A YE FLRB 0.5 12-SPK
IP 1960A L-BU FLRB 0.5 12-SPK
BD2IP_3 SP1835 SP1836

IP2BD_3 36
BD 5169 BN/WH FLRB 0.35
BD 5170 BN FLRB 0.35
SP0901
SP0237

SP1217
IP15
IP01_B EB57_C FL02_A
6 5 5 13 2 1
ACC Back
Relay Lighting Body CAN_H CAN_L
Control
Module
BCM Gateway Instrument Panel G_IPB2_1
Center Speaker D9013-0057b
SAIC-SV91 09/2017
5.9 Interior lighting
发动机舱保险丝盒 UEC 仪表板下保险丝盒 IEC

KL30
85 30
25 A 10 A I-R4
U-FS12 I-FS25 行李箱灯
IEC PWR8 空调控制面板/ 86 87
继电器
左侧中控开关
24 EB01 IP07 50 56 98 93 91 97
IP 2340D RD/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW
IP 2340E RD/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW
IP 6630 L-GN/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW
IP 6630A L-GN/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW

SP0244 SP0235
IP2BD_3
45
BD2IP_3
BD 6630B L-GN/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW

90 13 IP2BD_1
BD2IP_1
SP0201
IP 640J RD/WH FLRB 0.5 CALP
BD 6630H L-GN/WH FLRB 0.5 AT
IP43 2 IP01_A 40 9 EB57T_E 1 FL41

KL30 行李行李
箱灯箱灯行李
氛围灯 (低) (高)
模块箱照
明灯
车身控制器 BCM 2 FL41

SP2613
BD 2051 BK FLRB 0.75
G_FLDL_2 D9013-0045b
SAIC-SV91 09/2017
迎宾灯踏板灯-左前迎宾灯踏板灯-左前
a
+ - + -
FL55 1 2 1 2 FL56
BD 149AA D-GN FLRB 0.5 COLP
BD 149AB D-GN FLRB 0.5 COLP

BD 148AA YE FLRB 0.5 COLP
BD 148AB YE FLRB 0.5 COLP

BD 149A D-GN FLRB 0.5 COLP SP1215
IP2RF_1
56 RF21P_1
IP 149 D-GN FLRB 0.5 COLP
90
IP 7555Y D-GN FLRB 0.5
SP1213
SP1219 IP 148BB YE FLRB 0.5 COLP BD 148BC YE FLRB 0.5 COLP SP1216
9
IP 148 YE FLRB 0.5 COLP
IP 148BA YE FLRB 0.5 COLP
IP2BD_1
BD2IP_1
SP1214 IP 7556Y YE FLRB 0.5
9
BD 148BD YE FLRB 0.5 COLP SP1220
IP 7555 D-GN FLRB 0.5
IP 7556 YE FLRB 0.5
BD 149AC D-GN FLRB 0.5 COLP
BD 148AC YE FLRB 0.5 COLP
BD 149AD D-GN FLRB 0.5 COLP
BD 148AD YE FLRB 0.5 COLP
IP01_A 27 12 IP01_B 1 2 FL67 1 2 FL68

+ - + -
顶灯顶灯
车身控制器BCM 迎宾灯踏板灯-左后迎宾灯踏板灯-右后 D9013-0041b
SAIC-SV91 09/2017
m
n
o
p
q
d
e
g
c
D9013-0042b
f
RF19_1
h
k
i
j
RF19_1
中部阅读灯
RF 7556E YE FLRB 0.5 NSRF RF 1382BG PU/WH FLRB 0.5 NSRF
3
2
RF 7555E D-GN FLRB 0.5 NSRF
1
4
RF19_2
RF19_2
4
RF 7555EA D-GN FLRB 0.5 FSRF
1
SP1202
RF 7556EA YE FLRB 0.5 FSRF RF 1382BU PU/WH FLRB 0.5 FSRF
2
RF 7556EB YE FLRB 0.5 PSRF RF 1382BW PU/WH FLRB 0.5 PSRF
2
3
SP1208
RF 7555EB D-GN FLRB 0.5 PSRF
4
RF19_3
RF19_3
RF 2350RW BK FLRB 0.5 PSRF
RF 2350RG BK FLRB 0.5 NSRF

RF 2350RU BK FLRB 0.5 FSRF
前阅读灯
RF2IP_2
IP2RF_2
RF03
门控
RF 7555B D-GN FLRB 0.5
13
SP1203
RF 2351RH BK/WH FLRB 1.5
IP 2351RS BK/WH FLRB 1.5

阅读
RF 7556B YE FLRB 0.5
2
RF21P_1
5-110
IP2RF_1
30 IP01_A
RF 7555A D-GN FLRB 0.5
RF 7556A YE FLRB 0.5
OFF
G_IPB1_1
IP 328 PU FLRB 0.5 RF 328A PU FLRB 0.5
SP2608
顶灯关
三档开关
RF03
SP2646
AUTO
RF2IP_1
IIP 1598 GY/BK FLRB 0.5 RF 1598A GY/BK FLRB 0.5 RF 2350RF BK FLRB 0.5 RF 2350RA BK FLRB 0.75
顶灯自动
10
1
车身控制器 BCM
9
2 IP 1597 PK/BK FLRB 0.5 RF 1597A PK/BK FLRB 0.5 RF 1382BF PU/WH FLRB 0.5
ON
顶灯开
IP2RF_1
6
3
09/2017
IP 7555Y D-GN FLRB 0.5
EB57_C
IP 7556Y YE FLRB 0.5
BD2IP_3
IP2BD_3
IP2RF_1
RF2IP_1
SP1217
SP1206
BD 1382 PU/WH FLRB 0.5 BD 1382E PU/WH FLRB 0.5 IP 1382EA PU/WH FLRB 0.5 IP 1382B PU/WH FLRB 0.5 RF 1382BA PU/WH FLRB 0.5
SAIC-SV91
背光照明
57
5
5
a
90
90
5-111
09/2017
中部阅读灯
RF04
RF04
D9013-0043b
RF 7555F D-GN FLRB 0.5 NSRF RF 2350RM BK FLRB 0.5 NSRF
4
1
SAIC-SV91
RF 7556F YE FLRB 0.5 NSRF
3
RF 1382BM PU/WH FLRB 0.5 NSRF

2
左后阅读灯
RF17_2
2 RF17_2
RF 1382BL PU/WH FLRB 0.5 FSRF
RF 7555C D-GN FLRB 0.5 FSRF
1
RF 7556C YE FLRB 0.5 FSRF RF 2350RL BK FLRB 0.5 FSRF

3
4
RF 7556CA YE FLRB 0.5 PSRF RF 1382BR PU/WH FLRB 0.5 PSRF
2
3
RF 7555CA D-GN FLRB 0.5 PSRF
RF2IP_2
IP2RF_2
RF 2350RR BK FLRB 0.5 PSRF
4
RF17_3
RF17_3
13
RF 2351RH BK/WH FLRB 1.5
IP 2351RS BK/WH FLRB 1.5
G_IPB1_1
右后阅读灯
RF18_2
RF18_2
SP2646
RF 2350RH BK FLRB 0.5 FSRF RF 2350RH BK FLRB 0.5 FSRF
4
RF 7555D D-GN FLRB 0.5 FSRF
SP2608
1
RF 7556D YE FLRB 0.5 FSRF RF 1382BH PU/WH FLRB 0.5 FSRF
2
RF 7556DA YE FLRB 0.5 PSRF RF 1382BT PU/WH FLRB 0.5 PSRF
2
3
RF 7555DA D-GN FLRB 0.5 PSRF
1
RF 2350RT BK FLRB 0.5 PSRF
RF18_3 4
RF18_3
m
d
e
n
o
p
q
k
c
i
j
l
RRD2FL
19 FL2RRD
FL2RRD
RRD2FL
D9013-0044b
RR05
RR05
SP2628
G_FLOR_1
BD 7557FC PK FLRB 0.5 ABLP RRD 7557FE PK FLRB 0.5 ABLP 1650DB BK FLRB 0.5 ABLP RRD 1650DA BK FLRB 2.0 BD 1650DP BK FLRB 2.0 MDAC||ADAC
+
-
2
1
2
右后门照地灯
RLD2FL
FL2RLD
FL2RLD
RLD2FL
SP2627
RL05
RL05
G_FLCL_3
BD 7557FB PK FLRB 0.5 ABLP RLD 7557FD PK FLRB 0.5 ABLP 1550DB BK FLRB 0.5 ABLP RLD 1550DA BK FLRB 2.0 BD 1550DP BK FLRB 2.0
+
19
2
1
2
SP1201
左后门照地灯
右前门照地灯
IP2PAD
PAD2IP
PD12
PD12
SP2604
PAD 7557EA PK FLRB 0.5 ABLP PAD 2350DC BK FLRB 0.5 ABLP PAD 2350DA BK FLRB 2.0
-
39
2
IP 2350D BK FLRB 2.0
IP2PAD 31
PAD2IP
氛围灯仪-表右
G_IPB1_1
IP 7557E PK FLRB 0.5 ABLP
IP30
IP30
IP 7557C PK FLRB 0.5 ABLP IP 2250AC BK FLRB 0.5 ABLP
-
1
2
BD 7557F PK FLRB 0.5 ABLP
氛围灯仪-表左
BD2IP_3
IP2BD_3
5-112
SP1204
SP2621
IP29
IP29
G_IPA1_3
IP 7557H PK FLRB 0.5 ABLP IP 7557B PK FLRB 0.5 ABLP IP 2250AB BK FLRB 0.5 ABLP IP 2250A BK FLRB 0.5 ABLP
-
2
1
6
SP2630
BD 7557G PK FLRB 0.5 ABLP
G_IPA3_3
IP 7557D PK FLRB 0.5 ABLP
IP 2251 BK/WH FLRB 1.5
09/2017
37 DRD2IP_2
IP2DRD_2
车身控制器 BCM
驾驶员门照地灯
IP2DRD_2
DRD2IP_2
IP 2251DS BK/WH FLRB 1.0
EB57_E
DD12
DD12
SP2606
SP1218
SAIC-SV91
DRD 7557DA PK FLRB 0.5 ABLP DRD 2250DC BK/WH FLRB 0.5 ABLP DRD 2251DA BK/WH FLRB 1.0
背光灯
-
1
40
2
1
BD 7557 PK FLRB 0.5 ABLP
90
90
5-113
09/2017
副驶
门照
地灯
s
28 IP2PAD
PAD2IP
r
D9013-0165b
IP 7559F YE FLRB 0.5 CALP PAD 7559FA YE FLRB 0.5 CALPP
PAD2IP
26 IP2PAD
LIN
3
BD2IP_1
G_IPB1_1
SAIC-SV91
IP 7558F PK FLRB 0.5 CALP PAD 7557EA PK FLRB 0.5 CALP PAD 2350DC BK FLRB 0.5 CALP PAD 2350DA BK FLRB 2.0 IP 2350D BK FLRB 2.0
接地
电源
39
PD14 4
SP2604
PD14
26
DRD2IP_2
37 IP2DRD_2
8
38 IP2DRD_2
DRD2IP_2
IP2BD_1
驾驶
员门
照地
SP2630
灯
G_IPB2_3
IP 7559E YE FLRB 0.5 CALP DRD 7559EA YE FLRB 0.5 CALP IP 2251DS BK/WH FLRB 1.0 IP 2251 BK/WH FLRB 1.0
IP 7559G YE FLRB 0.5 CALP
IP 7558G PK FLRB 0.5 CALP
LIN
3
IP 7558E PK FLRB 0.5 CALP DRD 7557DA PK FLRB 0.5 CALP DRD 2250DC BK/WH FLRB 0.5 CALP DRD 2251DA BK/WH FLRB 1.0
接地
电源
40
DD14 4
SP2606
DD14
SP1224
氛
围
灯
右
2
-
IP 7559 YE FLRB 0.5 CALP IP 7559D YE FLRB 0.5 CALP
LIN
LIN
3
9
IP 7558D PK FLRB 0.5 CALP IP 2250AD BK FLRB 0.5 CALP
接地
电源
4
1
IP37
IP37
氛
围
灯
右
1
-
IP 7559C YE FLRB 0.5 CALP
LIN
3
IP 7558C PK FLRB 0.5 CALP IP 2250AC BK FLRB 0.5 CALP
接地
电源
4
1
IP34
IP34
氛
围
灯
左
2
-
氛围灯模块
IP 7559B YE FLRB 0.5 CALP
LIN
3
IP 7558B PK FLRB 0.5 CALP IP 2250AE BK FLRB 0.5 CALP
接地
电源
4
1
IP33
IP33
氛
围
灯
左
1
-
IP 7559A YE FLRB 0.5 CALP
LIN
3
G_IPA1_3
氛围灯
IP 7558 PK FLRB 0.5 CALP IP 7558A PK FLRB 0.5 CALP IP 2250AB BK FLRB 0.5 CALP IP 2250A BK FLRB 0.5 ABLP
电源
接地
电源
6
SP2621
SP1221
IP43
IP32
IP32
D9013-0040b
RF2IP_2
IP2RF_2
G_IPB1_1
RF 2351RH BK/WH FLRB 1.5 IP 2351RS BK/WH FLRB 1.5
13
右侧化妆镜灯
SP2608
RF02
RF02
SP2646
接地
电源
RF 2350RA BK FLRB 0.75 RF 2350RD BK FLRB 0.5 RF 1802BB RD/BK FLRB 0.5
1
IEC RWR2
U-FS15
SP0256
30 A
左侧化妆镜灯
RF01
RF01
50
接地
电源
SP1205
RF 2350RC BK FLRB 0.5 RF 1820BC RD/BK FLRB 0.5
1
发动机舱保险丝盒 UEC
BD 3240D RD/WH FLRB 2.5 BD 1802D RD/BK FLRB 0.5

16
BD2IP_2
IP2BD_2
IP2RF_1
RF2IP_1
SP0248
IEC PWR3
U-FS10
20 A
SP0233
IP 1802C RD/BK FLRB 0.5 IP 1802B RD/BK FLRB 0.5 RF 1802BA RD/BK FLRB 0.5
12
16
EB01 22
右后
门照
地灯
FL2RRD
RRD2FL
KL30
BD 7559GC YE FLRB 0.5 CALP RRD 7559GCA YE FLRB 0.5 CALP
RRD2FL
19 FL2RRD
LIN
3
9
G_FLCR_2
5-114
BD 7558GC PK FLRB 0.5 CALP RRD 7557FE PK FLRB 0.5 CALP RRD 1650DB BK FLRB 0.5 CALP RRD 1650DA BK FLRB 2.0 BD 1650DM BK FLRB 2.0 MSAC
接地
电源
RR07 4
1
2
SP2628
RR07
FL2RLD
RLD2FL
左后
门照
地灯
BD 7559GA YE FLRB 0.5 CALP BD 7559GB YE FLRB 0.5 CALP RLD 7559GBA YE FLRB 0.5 CALP
RLD2FL
19 FL2RLD
LIN
3
9
SP1222 SP1223
G_FLCL_1
BD 7558GA PK FLRB 0.5 CALP BD 7558GB PK FLRB 0.5 CALP RLD 7557FD PK FLRB 0.5 CALP RLD 1550DB BK FLRB 0.5 CALP RLD 1550DA BK FLRB 2.0 BD 1550DP BK FLRB 2.0
接地
电源
4
1
2
09/2017
SP2627
RL07
RL07
SAIC-SV91
s
r
90
5.10 Exterior lamp system

KL30
85 30
20A U-R15 15A 15A
U-FS14 High U-FS28 U-FS29
High Beam 86 87 Beam Left High Right High
Relay Beam Beam
EB01 26 95 97 99 96 41 40 49 48
BD 712B YE FLRB 0.75 HALP

BD 1940 PK FLRB 2.0

BD 1969AL-BU/BK FLRB 0.35

SP0220 SP0218
a
BD2IP_1
LHD 6 b
IP2BD_1
BD2IP_2 c
55 IP2BD_2 RHD
SP0603
d
BD 7538A L-BU FLRB 0.75 DRLP&&HALP

IP 1969ABL-BU/BK FLRB 0.35
IP 1969L-BU/BK FLRB 0.35
BD 711A D-GN/WH FLRB 0.75 HALP e
BD 189A D-GN FLRB 0.5 HALP

BD 868B GY FLRB 0.5 HALP
BD 868A GY FLRB 0.5 HALP
BD 868A GY FLRB 0.5 HALP

90
Left Switch Block EB35_1 2 1 5 11 10

High Beam Low Beam Delay Anti-glare
Signal
Front Left
Motor Grouped
High Beam Low Beam Lamp BD2IP_2
RHD 36 IP2BD_2
6 12 5 7 1 IP03 4 12
EB35_1
BD 450LH BK FLRB 0.75 HALP
BD 450LA BK FLRB 0.5 HALP
BD2IP_1
IP2BD_1 29 LHD
IP 868 GY FLRB 0.5 HALP
IP 868 GY FLRB 0.5 HALP
SP0611
SP2610
SP2633
BD 450L BK FLRB 1.0
Left Right
Rudder Rudder
IP01_A 38 IP01_B 18 IP12

32 23 25 16
High High Lighting Lighting High Beam Automatic Output
Beam Beam Main Switch Relay
Flasher Switch Ground
Anti-glare
Interior Rear
View Mirror
G_IPA2_1 Body Control Module BCM G_EBL2_4
D9013-0125b
SAIC-SV91 09/2017
Front Right
D9013-0126b
Grouped
c
Lamp
f
Head Lamp
Regulator
U-FS32
SP0602
10A
Motor
BD 189 D-GN FLRB 0.5 HALP BD 189B D-GN FLRB 0.5 HALP BD 550LA BK FLRB 0.5 HALP
45
10
12
Anti-glare
Signal
BD 868C GY FLRB 0.5 HALP
11
High Beam Low Beam Delay
Low Beam
BD 7539A D-BU FLRB 0.75 DRLP&&HALP
Right Low
U-FS31
5
Beam
15A
BD 311B L-GN/BK FLRB 0.75 HALP

46
High Beam
1
G_EBR1
Left Low
U-FS30
BD 312B TN/WH FLRB 0.75 HALP BD 550LG BK FLRB 0.75 HALP BD 550L BK FLRB 1.0
Beam
15A
SP2637
EB36_1
EB36_1
47

42

43
BD 1940AD PK FLRB 2.0 HALP

44
RHD
U-R14
Beam
Relay
SP0216
Low
BD2IP_2
54 IP2BD_2
Module
Control
5-116
BCM
Body
87
30
91
BD 691A GY FLRB 0.35 IP 691 GY FLRB 0.35

IP 691AB GY FLRB 0.35
Low Beam
BD 691A GY FLRB 0.35
85
86
Relay
94
41
7
BD2IP_1
IP2BD_1
IP01_B
BD 7538A L-BU FLRB 0.75 DRLP&&HALP
92
LHD
09/2017
90
Low Beam
SP0218
U-FS13
25A
BD 1940 PK FLRB 2.0
EB01 25
SAIC-SV91
KL30
c
a
90
90
5-117
09/2017
D9013-0127b
h
g

36
Fog Lamp/
Sidelight /
U-FS24
Rear Fog
DRL
10A
Lamp
SAIC-SV91
PR2FL
FL2PR
FL2PR
12 PR2FL
53
PR03
PR03
21W
G_FLCL_1
BD 122 OG FLRB 0.5 PR 122D OG FLRB 0.5 PR 1550CDA BK FLRB 0.5 BD 1550C BK FLRB 0.5
87
30
71
13
2
1
BD 1977A YE FLRB 0.35
85
86
74

U-R10
Relay
Lamp
Rear
Fog

72

70

102
RHD
BD2IP_2
50 IP2BD_2
100
SP0221

107
14 IP01_B
IP 1977 YE FLRB 0.35
Lamp Relay
Rear Fog
BD 1640G RD/WH FLRB 0.5 DRLP IP 1977AB YE FLRB 0.35
105
IP2BD_1 20
BD2IP_1
DRL Relay
U-R17
RHD
Right
BD2IP_2
52 IP2BD_2
LHD
BD 7539A D-BU FLRB 0.75 DRLP&&HALP

87
106
BD 545A D-BU FLRB 0.35 DRLP IP 545 D-BU FLRB 0.35
Right DRL
BD 545A D-BU FLRB 0.35 DRLP BD 544A PU FLRB 0.35 DRLP
86
109
29
IP2BD_1 16
RHD
BD2IP_1
Left DRL
U-R16
Relay
BD2IP_2
53 IP2BD_2
87 BD 7538A L-BU FLRB 0.75 DRLP&&HALP
LHD
101
BD 544A PU FLRB 0.35 DRLP IP 544 PU FLRB 0.35
Left DRL
BD 544A PU FLRB 0.35 DRLP IP 544AB PU FLRB 0.35
86
104
16
IP2BD_1 17
BD2IP_1
EB01
LHD
c
f

KL30 U-R13
25A U-R12
85 30 85 30 Front
U-FS11 Front Right
Fog Lamp / Left
Fog Fog
Sidelight / 86 87
Lamp 86 87 Lamp
DRL Relay Relay
EB01 23 85 87 80 82 84 81 89 86



BD 1769A YE FLRB 0.35 FFOG

BD 1317A D-GN/WH FLRB 0.35 FFOG

g
SP0222
h h
i i
90
Left Switch Block
BD2IP_1 BD2IP_1 EB33 EB34

2 2
IP2BD_1 18
LHD
IP2BD_1 19
LHD
Fog Light Switch
BD2IP_2 BD2IP_4 Front Left
51 IP2BD_2 RHD A8 IP2BD_4 RHD Front Right
Fog Lamp Fog Lamp
Front Rear
IP 1769 YE FLRB 0.35FFOG

IP 1317AB D-GN/WH FLRB 0.35 FFOG
IP 1317 D-GN/WH FLRB 0.35 FFOG
6 8 9 1 EB33 1
IP03 EB34
IP 192 OG FLRB 0.35 FFOG
BD 550LD BK FLRB 0.75 FFOG

SP2610
SP2637
SP2633
BD 550L BK FLRB 1.0
BD 450L BK FLRB 1.0
IP01_A
IP01_B IP01_A 28
37 44 15
Rear
Fog
Front
Fog
Front Left
Fog Lamp Relay
Front Right
Fog Lamp Relay
Body Control
Lamp Lamp Module
Switch Switch
BCM
G_IPA2_1 G_EBL2_4 G_EBR1
D9013-0128b
SAIC-SV91 09/2017
Rear Left Rear Right Rear Left

U-R11 Grouped Sidelight Sidelight Grouped Sidelight
License Light
Sidelight Light Light
87
86
Relay (Tail Door) (Tail Door)
6 4 6 4 1 2
EB01 77 75 79 76 TLD01 TLD02 TLD07
TLD 9EB BN FLRB 0.5
TLD 9EC BN FLRB 0.5

TLD 9EA BN FLRB 0.5
TLD 1750TF BK FLRB 0.5
TLD 1850LF BK FLRB 0.5
TLD1750TE BK FLRB 0.5

BD 1080A WH FLRB 0.35
BD 9 BN FLRB 0.5
TLD 9E BN FLRB 0.5

SP0609 TLD 9ED BN FLRB 0.5
j
SP0602 TLD 1850LD BK FLRB 0.5

k
TLD2FL_1 18 SP2601 TLD 1750TD BK FLRB 2.0
h FL2TLD_1
BD 9DC BN FLRB 0.5
i
BD 9C BN FLRB 0.5
SP0606
BD 9DB BN FLRB 0.5 MDAC||ADAC

SP0601 TLD2FL_1 TLD2FL_2
BD 9AB BN FLRB 0.5 HALP
BD 9BA BN FLRB 0.5 HALP
BD 9DA BN FLRB 0.5
14 3
FL2TLD_1 FL2TLD_2
BD 1750TP BK FLRB 2.0

90
BD2IP_2
8 RHD
IP2BD_2
6 EB35_1 6 EB36_1 6 FL19 6 FL20_2

BD2IP_3 Front Left Front Right Rear Left Rear Right
Sidelight
Sidelight
Sidelight
Sidelight
IP2BD_3 35
LHD
Grouped Grouped Grouped Grouped
Light Light Light Light
BD 1850LA BK FLRB 0.5 MDAC||ADAC

4 EB35_1 4 EB36_1 4 4
FL19 FL20_2
IP 1080 WH FLRB 0.35
BD 550LG BK FLRB 0.75 HALP
BD 1750LA BK FLRB 0.5
SP2611
SP2641
BD 1750P BK FLRB 3.0
BD 1850A BK FLRB 1.0 MDAC||ADAC
SP2641
SP2633 SP2637
BD 450L BK FLRB 1.0
BD 550L BK FLRB 1.0
SP2629
BD 1750 BK FLRB 3.0
IP01_A 15
Sidelight
Body
Relay Control
Module
BCM
G_EBL2_4 G_EBR1 G_FLDL1_1 G_FLDR1_2 G_FLDR1_2
D9013-0129b
SAIC-SV91 09/2017
D9013-0130b
G_EBL2_4 G_FLDL1_1
BD 1750P BK FLRB 3.0 BD 1750 BK FLRB 3.0
SP2611
SP2629
BD 450L BK FLRB 1.0
Grouped Light
Rear Left
SP2633
DRD2IP_2
37 IP2DRD_2
SP2630
G_IPA2_3
IP 2251DS BK/WH FLRB 1.0 IP 2251 BK/WH FLRB 1.5
BD 1750LB BK FLRB 0.5
11 DD03_A
Turn Signal Light
SP2606
BD 14C L-BU FLRB 0.5 DRD 2251DA BK/WH FLRB 1.0 DRD 2250DB BK/WH FLRB 0.5 SPMH
View Mirror
Turn Signal Light
Left Rear
3
FL19
IP 14D L-BU FLRB 0.5 DRD 14BA L-BU FLRB 0.5 SPMH
DRD2IP_2 42
3
IP2DRD_2
LHD
BD 450LB BK FLRB 0.75 HALP
Turn Signal Light
BD2IP_3
41 IP2BD_3
IP01_B
Signal Light
Left Turn
BD 14LA-B BU FLRB0.5 HALP BD 14BC L-BU FLRB 0.5 BD 1540E RD/YE FLRB 2.0 IP 14 L-BU FLRB 0.5
24
EB35_1 7
SP0604
SP0613
Grouped Light

IP 14B L-BU FLRB 0.5 BD 1540E RD/YE FLRB 2.0
Front Left
IP2BD_2 13
BD2IP_2
IP01_A
LHD
5-120
5 IP27
Light Switch
IP 27 WH FLRB 0.5
Warning
Hazard
9
Hazard Warning
IP 1382AA PU/WH FLRB 0.5 IP 1382A PU/WH FLRB 0.5 IP 1382EA PU/WH FLRB 0.5 BD 1382E PU/WH FLRB 0.5 BD 1382 PU/WH FLRB 0.5
Light Switch
Lighting
Back
57
3
5
SP1207
SP1206
SP1217
EB57_C
BD2IP_3
IP2BD_3
IP 751A BK/WH FLRB 0.5
SP2643
SP2615
SP0634
1
G_IPM1_1
IP 751B BK/WH FLRB 0.5 IP 751D BK/WH FLRB 0.5 IP 751S BK/WH FLRB 0.75 IP 751W BK/WH FLRB 1.0
09/2017
TLD08 4
TLD1850LE BK FLRB 0.5
License Light
Rear Right
2
Sidelight
SAIC-SV91
TLD 9ED BN FLRB 0.5
k
j
90
Turn Signal Light

Front Right Turn Signal Light
Rear Right
Grouped Light Grouped Light
3 1
EB36_1 7 8
FL20_2
BD 1850LB BK FLRB 0.5 MDAC||ADAC

BD 15C D-BU FLRB 0.5 MDAC||ADAC
BD 15AB D-BU FLRB 0.5 HALP
SP0614
BD 15DA D-BU FLRB 0.5
BD2IP_2 BD2IP_3
46 IP2BD_3 RHD
IP2BD_2 40
LHD
IP 15D D-BU FLRB 0.5
90
SP0605
IP 15B D-BU FLRB 0.5
Left Grouped Switch

IP 15 D-BU FLRB 0.5
Turn Signal Light Switch
Right Left
PAD 2350DA BK FLRB 2.0
6 2 11 IP03 IP2PAD 41
PAD2IP
IP 1415 D-BU/WH FLRB 0.35
IP 1414 L-BU/WH FLRB 0.35
PAD2IP
26 IP2PAD
SP2604
SP2610
PAD 2350DB BK FLRB 0.5 SPMH
PAD 15BA D-BU FLRB 0.5 SPMH
SP2637
SP2641
BD 550L BK FLRB 1.0
IP01_A
34 7 35 IP01_B 3 11 PD03_A
Right Left Turn Right Turn
Turn Signal Signal Light
Signal Light
Light Turn Signal Light
Switch Switch
G_IPA2_1 Body Control Module BCM Right Rear G_IPB1_1 G_EBR1 G_FLDR1_2
View Mirror D9013-0131b
SAIC-SV91 09/2017
Rear Right
Grouped
D9013-0132b
Light
G_FLDR1_2
BD 1850LA BK FLRB 0.5 MDAC||ADAC BD 1850A BK FLRB 1.0 MDAC||ADAC
4
BD2IP_2
10 IP2BD_2
SP2641
Brake Light
RHD
BD 20B L-BU FLRB 0.5 IP 20BA L-BU FLRB 0.5

5
FL20_2
BD 20C L-BU FLRB 0.5 MDAC||ADAC IP 20CA L-BU FLRB 0.5

IP2BD_2 38
BD2IP_2
SP2629
G_FLDL1_1
LHD

TLD 1750TD BK FLRB 2.0 BD 1750TP BK FLRB 2.0
SP2611
14
TLD2FL_1
FL2TLD_1
4
BD2IP_2
10 IP2BD_2
IP01_B
Brake Light
RHD
Brake Light
BD 20B L-BU FLRB 0.5 IP 20BA L-BU FLRB 0.5 IP 20 L-BU FLRB 0.5
11
5

SP0608
Front Right
BD 20BA L-BU FLRB 0.5

Grouped
FL19
IP 20B L-BU FLRB 0.5

Light
IP2BD_3 7
BD2IP_3
19 TLD2FL_1 LHD
LHD
FL2TLD_1
BD2IP_3
IP2BD_3
SP0610
LHD
Brake Light
5-122
TLD 20F BN FLRB 0.5 TLD 20E BN FLRB 0.5 BD 20H BN FLRB 0.5 IP 20HA BN FLRB 0.5
23
6
9
Brake Light
SP0610
BD 20H BN FLRB 0.5 IP 20HA BN FLRB 0.5
11
4
BD2IP_2
IP2BD_2
TLD01
(Tail Door)
Rear Left
Grouped
Light
RHD
09/2017
TLD 20G BN FLRB 0.5
FL2TLD_2
TLD2FL_2
6
Brake Light
SP2602
G_FLDR1_2
TLD 1850LF BK FLRB 0.5 TLD 1850LD BK FLRB 0.5 BD 1850LA BK FLRB 0.5 MDAC||ADAC BD 1850A BK FLRB 1.0 MDAC||ADAC
SP2641
SAIC-SV91
TLD02
Rear Right
(Tail Door)
Grouped
Light
90
5.11 The adaptive lamps in the exterior lamp system

KL30
85 30
20A U-R15 15A 15A
U-FS14 High U-FS28 U-FS29
High Beam 86 87 Beam Left High Right High
Relay Beam Beam
EB01 26 95 97 99 96 41 40 49 48
BD 712A YE FLRB 0.75 LED

BD 1940 PK FLRB 2.0


SP0220 SP0218
a
BD2IP_1
LHD 6 b
IP2BD_1
BD2IP_2 c
55 IP2BD_2 RHD
BD 7538 L-BU FLRB 0.75 DRLP&&LED

IP 1969ABL-BU/BK FLRB 0.35
IP 1969L-BU/BK FLRB 0.35
BD 711 D-GN/WH FLRB 0.75 LED
90
Left Switch Block

3 2 1 5 EB35_2
Delay High Beam Low Beam Delay
Motor1 Motor2
Front Left
Grouped lamp
High Beam Low Beam
6 12 5 7 1 IP03 4 12 10 11 14 13
EB35_2
BD SHIELD9A BK FLRB 0.5 AFS
BD 450LC BK FLRB 0.75 LED
BD 7129B BN FLRB 0.5 AFS
BD 7130B L-BU FLRB 0.5 AFS
BD 7131B D-GN FLRB 0.5 AFS
BD 711 D-GN/WH FLRB 0.75 LED

BD 5752A L-BU/BK FLRB 0.5 LED
SP0611
SP2610
SP2633 SP0615
BD 450L BK FLRB 1.0
IP01_A 38 IP01_B FL27 FL27 8

32 23 25 18 5 10 11 25 13
High High Lighting Lighting High Delay Check Shield Motor Motor Motor Motor
Beam Beam Main Switch Beam 1A+ 1A- 1B+ 1B-
Flasher Switch Ground Relay
G_IPA2_1 Body Control Module BCM Adaptive Front Head G_EBL2_4 Adaptive Front Head Lamp Control Unit
Lamp Control Unit D9013-0139b
SAIC-SV91 09/2017

KL30
85 30
15A 15A
25A U-R14
U-FS30 U-FS31
U-FS13 Low Beam
86 87 Left Low Right Low
Low Beam Relay
Beam Beam
EB01 25 90 92 94 91 43 42 47 46
BD 311A L-GN/BK FLRB 0.75 LED

BD 1940 PK FLRB 2.0

SP0218 SP0216
b
BD 7538 L-BU FLRB 0.75 DRLP&&LED
c c
BD 7539 D-BU FLRB 0.75 DRLP&&LED

BD 312A TN/WH FLRB 0.75 LED
d
BD2IP_1
LHD 7
IP2BD_1
BD2IP_2
90 54 IP2BD_2 RHD
IP 691AB GY FLRB 0.35
IP 691 GY FLRB 0.35
EB36_2 3 2 1 5
High Beam Low Beam Delay
Front Right Motor1 Motor2
Grouped
Light High Beam Low Beam
4 12 10 11 14 13
EB36_2
BD 550LC BK FLRB 0.75
BD SHIELD11A BK FLRB 0.5 AFS
BD 7133B OG FLRB 0.5 AFS
BD 7134B PK FLRB 0.5 AFS
BD 7135B TN FLRB 0.5 AFS
BD 7136B YE FLRB 0.5 AFS

BD 5752A L-BU/BK FLRB 0.5 LED
SP2637
SP0616
BD 550L BK FLRB 1.0
IP01_B FL27 FL27 21 2 18 20 22

41 17
Body Delay Check
Low Beam Shield Motor Motor Motor Motor
Relay Control 2A+ 2A- 2B+ 2B-
Module
BCM G_EBR1
Adaptive Front Head Adaptive Front Head Lamp Control Unit
Lamp Control Unit D9013-0140b
SAIC-SV91 09/2017
90
5-125
09/2017
e
D9013-0141b
f

36
Fog Lamp/
Sidelight /
U-FS24
Rear Fog
DRL
10A
Lamp
SAIC-SV91
PR2FL
FL2PR
FL2PR
12 PR2FL
53
PR03
PR03
21W
G_FLCL_1
BD 122 OG FLRB 0.5 PR 122D OG FLRB 0.5 PR 1550CDA BK FLRB 0.5 BD 1550C BK FLRB 0.5
87
30
71
13
2
1
85
86
74

U-R10
Relay
Lamp
Rear
Fog

72

70

102
RHD
BD2IP_2
50 IP2BD_2
100
SP0221

107
14 IP01_B
IP 1977 YE FLRB 0.35
Lamp Relay
Rear Fog
BD 1640G RD/WH FLRB 0.5 DRLP IP 1977AB YE FLRB 0.35
105
IP2BD_1 20
BD2IP_1
Right DRL
U-R17
RHD
Relay
BD2IP_2
52 IP2BD_2

LHD
BD 7539 D-BU FLRB 0.75 DRLP&&LED
87
106
BD 545A D-BU FLRB 0.35 DRLP IP 545 D-BU FLRB 0.35
Right DRL
BD 545A D-BU FLRB 0.35 DRLP BD 544A PU FLRB 0.35 DRLP
86
109
29
IP2BD_1 16
RHD
BD2IP_1
U-R16
Relay
DRL
Left
BD2IP_2
53 IP2BD_2
87 BD 7538 L-BU FLRB 0.75 DRLP&&LED
LHD
101
BD 544A PU FLRB 0.35 DRLP IP 544 PU FLRB 0.35
Left DRL
BD 544A PU FLRB 0.35 DRLP IP 544AB PU FLRB 0.35
86
104
16
IP2BD_1 17
BD2IP_1
EB01
LHD
d
c

KL30 U-R13
25A
85 30
U-R12 85 30 Front
U-FS11 Right
Fog Lamp / Front Left
Fog
Sidelight / 86 87 Fog Lamp 86 87 Lamp
DRL Relay Relay
EB01 23 85 87 80 82 84 81 89 86





e
SP0222
f f
j j
90
Left Switch Block
BD2IP_1 BD2IP_1 EB33 EB34

2 2
IP2BD_1 18
LHD
IP2BD_1 19
LHD
Fog Lamp Switch
BD2IP_2 BD2IP_4 Front Left
51 IP2BD_2 RHD A8 IP2BD_4 RHD Front Right
Fog Lamp Fog Lamp
Front Rear

IP 1317AB D-GN/WH FLRB 0.35 FFOG
IP 1317 D-GN/WH FLRB 0.35 FFOG
6 8 9 1 EB33 1
IP03 EB34
IP 192 OG FLRB 0.35 FFOG

SP2610
SP2637
SP2633
BD 550L BK FLRB 1.0
BD 450L BK FLRB 1.0
IP01_A
IP01_B IP01_A 28
37 44 15
Rear Fog Front Fog
Lamp Lamp
Front Left
Fog Lamp
Front Right
Fog Lamp
Body Control
Switch Switch Relay Relay Module
BCM
G_IPA2_1 G_EBL2_4 G_EBR1
D9013-0142b
SAIC-SV91 09/2017
Engine Bay Fuse Box UEC Rear Left Grouped Rear Right Grouped
Light (Tail Door) Light (Tail Door) Rear Left License Light
Sidelight Sidelight Sidelight

U-R11
Sidelight
87
86
Relay
6 4 6 4 1 2
EB01 77 75 79 76 TLD01 TLD02 TLD07
TLD 9EB BN FLRB 0.5
TLD 9EC BN FLRB 0.5

TLD 9EA BN FLRB 0.5
TLD1750TE BK FLRB 0.5

BD 9 BN FLRB 0.5
TLD 9E BN FLRB 0.5

SP0609 TLD 9ED BN FLRB 0.5
h
SP0602 TLD 1850LD BK FLRB 0.5

i
TLD2FL_1 18 SP2601 TLD 1750TD BK FLRB 2.0
f FL2TLD_1
BD 9DC BN FLRB 0.5
j
BD 9C BN FLRB 0.5
SP0606
BD 9DD BN FLRB 0.5 MSAC

SP0601 TLD2FL_1 TLD2FL_2
BD 9AB BN FLRB 0.5 HALP
BD 9BA BN FLRB 0.5 HALP
BD 9DA BN FLRB 0.5
14 3
FL2TLD_1 FL2TLD_2

90
BD2IP_2
8 RHD
IP2BD_2
6 EB35_1 6 EB36_1 6 FL19 6 FL20_1

BD2IP_3 Front Left Front Right Rear Left Rear Right
Sidelight
Sidelight
Sidelight
Sidelight
IP2BD_3 35
LHD
Grouped Grouped Grouped Grouped
Light Light Light Light

4 EB35_1 4 EB36_1 4 4
FL19 FL20_1
BD 1850LK BK FLRB 0.5 MSAC
SP2611
SP2641
SP2632
BD 1850 BK FLRB 1.0 MSAC
SP2633 SP2637
BD 450L BK FLRB 1.0
BD 550L BK FLRB 1.0
SP2629
BD 1750 BK FLRB 3.0
IP01_A 15
Body
Sidelight
Relay Control
Module
BCM
G_EBL2_4 G_EBR1 G_FLDL1_1 G_FLDR1_1 G_FLDR1_2
D9013-0143b
SAIC-SV91 09/2017
Rear Left Group Light
D9013-0144b
G_EBL2_4 G_FLDL1_1
BD 1750LB BK FLRB 0.5 BD 1750P BK FLRB 3.0 BD 1750 BK FLRB 3.0
1
Turn Signal Light
SP2611
SP2629
BD 14C L-BU FLRB 0.5 BD 450L BK FLRB 1.0
3
SP2633
FL19
DRD2IP_2
37 IP2DRD_2
SP2630
Front Left Grouped Light
G_IPA2_3
8
Turn Signal Light
DD03_C
SP2606
BD 14A L-BU FLRB 0.5 LED
7
DRD 2251DA BK/WH FLRB 1.0 DRD 2250BDKF/WH FLRB 0.5 SPML
View Mirror
Turn Signal Light
Left Rear
2
BD 6568A WH FLRB 0.5 LED
IP 14D L-BU FLRB 0.5
9
DRD 14BB D-BU FLRB 0.5 SPML
DRD2IP_2 42
7
EB35_2
Rudder
Left
IP2DRD_2
BD2IP_3
41 IP2BD_3
IP01_B
Left Turn
Check
Signal Light
BD 14BC L-BU FLRB 0.5 BD 1540E RD/YE FLRB 2.0 IP 14 L-BU FLRB 0.5
23
Left Turn
24
SP0604
SP0613

FL27
Adaptive Front
IP 14B L-BU FLRB 0.5 BD 1540E RD/YE FLRB 2.0

Control Unit
Head Lamp
IP2BD_2 13
BD2IP_2
IP01_A
Rudder
5-128
5 IP27
Left
Light Switch
IP 27 WH FLRB 0.5
Warning
Hazard
9
Hazard Warning
IP 1382AA PU/WH FLRB 0.5 IP 1382A PU/WH FLRB 0.5 IP 1382EA PU/WH FLRB 0.5 BD 1382E PU/WH FLRB 0.5 BD 1382 PU/WH FLRB 0.5
Light Switch
Lighting
Back
57
3
5
SP1207
SP1206
SP1217
EB57_C
BD2IP_3
IP2BD_3
SP2643
SP2615
SP0634
1
G_IPM1_1
IP 751B BK/WH FLRB 0.5 IP 751D BK/WH FLRB 0.5 IP 751S BK/WH FLRB 0.75 IP 751W BK/WH FLRB 1.0
09/2017
TLD08 4
TLD1850LE BK FLRB 0.5
License Light
Rear Right
2
Sidelight
SAIC-SV91
TLD 9ED BN FLRB 0.5
90
Front Right Grouped Light Rear Right Grouped Light
Adaptive Front
Head Lamp Turn Signal Light Turn Signal Light
Control Unit Right Turn

Check
FL27 1 9 7 8 3 1
EB36_2 FL20_1
BD 1850LH BK FLRB 0.5 MSAC

BD 15E D-BU FLRB 0.5 MSAC
BD 550LC BK FLRB 0.75 HALP
BD 7545A TN FLRB 0.5 LED
BD 15A D-BU FLRB 0.5 LED
SP0614
BD2IP_2 BD2IP_3
46 IP2BD_3 RHD
IP2BD_2 40
LHD
90
Left Switch Block SP0605

IP 15B D-BU FLRB 0.5
IP 15 D-BU FLRB 0.5
Turn Signal Light Switch
Right Left
6 2 11 IP03 IP2PAD 41
PAD2IP
IP 1415 D-BU/WH FLRB 0.35
IP 1414 L-BU/WH FLRB 0.35
PAD2IP
26 IP2PAD
SP2604
SP2610
PAD 2350DF BK FLRB 0.5 SPML
PAD 15BB L-BU FLRB 0.5 SPML
SP2637
SP2632
BD 1850 BK FLRB 1.0 MSAC
BD 550L BK FLRB 1.0
IP01_A
34 7 35 IP01_B 7 2 PD03_C
Right Turn Left Turn Right Turn
Signal Signal Signal Light
Light Light Turn Signal Light
Switch Switch
G_IPA2_1 Body Control Module BCM Right Rear G_IPB1_1 G_EBR1 G_FLDR1_1
View Mirror D9013-0145b
SAIC-SV91 09/2017
D9013-0146b
Rear Right Grouped Light
G_FLDR1_2
BD 1850LA BK FLRB 0.5 MDAC||ADAC BD 1850A BK FLRB 1.0 MDAC||ADAC
4
BD2IP_2
10 IP2BD_2
SP2641
Brake Light
RHD
BD 20B L-BU FLRB 0.5 IP 20BA L-BU FLRB 0.5

5
FL20_2
BD 20C L-BU FLRB 0.5 MDAC||ADAC IP 20CA L-BU FLRB 0.5

IP2BD_2 38
BD2IP_2
SP2629
G_FLDL1_1
LHD

Front Right Grouped Light
TLD 1750TD BK FLRB 2.0 BD 1750TP BK FLRB 2.0

SP2611
14
TLD2FL_1
FL2TLD_1
4
BD2IP_2
10 IP2BD_2
IP01_B
Brake Light
RHD
Brake Light
BD 20B L-BU FLRB 0.5 IP 20BA L-BU FLRB 0.5 IP 20 L-BU FLRB 0.5

11
5
SP0608
BD 20BA L-BU FLRB 0.5
FL19
IP 20B L-BU FLRB 0.5
IP2BD_3 7
BD2IP_3
19 TLD2FL_1 LHD
LHD
FL2TLD_1
BD2IP_3
IP2BD_3
SP0610
LHD
Brake Light
Rear Left Grouped
5-130
Light (Tail Door)
TLD 20F BN FLRB 0.5 TLD 20E BN FLRB 0.5 BD 20H BN FLRB 0.5 IP 20HA BN FLRB 0.5
23
6
9
Brake Light
SP0610
BD 20H BN FLRB 0.5 IP 20HA BN FLRB 0.5
11
4
BD2IP_2
IP2BD_2
TLD01
RHD
Rear Right Grouped
09/2017
Light (Tail Door)
TLD 20G BN FLRB 0.5
FL2TLD_2
TLD2FL_2
6
Brake Light
SP2602
G_FLDR1_2
TLD 1850LF BK FLRB 0.5 TLD 1850LD BK FLRB 0.5 BD 1850LA BK FLRB 0.5 MDAC||ADAC BD 1850A BK FLRB 1.0 MDAC||ADAC
SAIC-SV91
SP2641
TLD02
90
KL30
85 30
10 A 30 A U2-R4 10 A
U-FS1 U-JF4 IG U2-FS15
KL30 IG Power Relay 86 87 IG Power
PWR Supply Supply 3
13 4 17 19 21 18 45 46 EB58
EB01



BD 640E RD/WH FLRB 0.5 AFS||ESSS||MDAC||(ADAC&&EPB)
SP0264 SP0249
SP0257
BD 642BE RD/BK FLRB 0.5 AFS

SP2635
BD2IP_1
4
IP2BD_1
BD 640C RD/WH FLRB 0.5 AFS
SP0257
Adaptive Front Head
FL27 14 9 Lamp Control Unit 90
KL30 KL15
Rear Body Front Body
Height Rear Body Rear Body Height Front Body Front Body
Power Height Height Power Height Height
IP 249B WH FLRB 0.35
Supply Signal Ground Supply Signal Ground
12 24 6 15 4 19
BD 7524A GY/WH FLRB 0.35AFS
BD 7525A BN/WH FLRB 0.35AFS

BD 2165A GY FLRB 0.35 AFS
BD 7526A PU/WH FLRB 0.35AFS

BD 2184A BN FLRB 0.35 AFS
BD 2185A PU FLRB 0.35 AFS
SP0904 EB2BT
3 4 5
BT2EB
BT 7524 GY/WH FLRB 0.35 AFS
BT 7525 BN/WH FLRB 0.35 AFS
BT 7526 PU/WH FLRB 0.35 AFS

IP 249C WH FLRB 0.5
48 IP01_B 2 3 6 FL69 2 3 6 BT10

GND
GND
IG Power Signal Power Signal

Relay Supply Supply
G_EBL2_4 Body Control Rear Body Front Body

Module BCM Height Sensor Height Sensor D9013-0147b
SAIC-SV91 09/2017
5.12 Anti-lock brake system

a
Engine Bay Fuse Box Engine Bay Fuse Box 2 UEC_2
UEC

85 30
40 A 25 A 30 A 10 A
U2-R4
U-JF8 U-FS5 U-JF4 U2-FS14
ABS/ESP ABS/ESP IGPower
IG
86 87 Power
_Motor _Valve Supply Relay
Supply 2
8 17 4 EB01 EB58 17 19 21 18 43 44

BD 340EC RD/WH FLRB 2.5


BD 173D-GN FLRB 4.0 ABS
BD 340 RD/WH FLRB 2.5 BD 340E RD/WH FLRB 2.5

SP0257
SP0264
b
SP0203
BD 1687A GY/BK FLRB 0.5 ABS
BD2IP_1
BD 1687C GY/BK FLRB 0.5

4
IP2BD_1

SP2635
Anti-lock Braking System /

Electronic Stability Program
ABS/ESP
90
EB04
1 25 28
B12 BD2IP_4
Supply
Pump Power
Supply
Valve Power
Power Supply
IP2BD_4
IP 249 WH FLRB 0.35
c
Front Left Front Left Front Right Front Right SP0904
Wheel Speed Wheel Speed Wheel Speed Wheel Speed
Ground Ground Sensor Sensor Sensor Sensor
13 38 19 8 16 4
EB04
BD 7065 GY/WH FLRB 0.5 ABS
BD 872 D-GN FLRB 0.5 ABS

BD 350A BK FLRB 4.0 ABS
BD 350B BK FLRB 1.5 ABS
SP2634
IP 751S BK/WH FLRB 0.75

IP 249C WH FLRB 0.5
EB2BT SP2615
17 16
BT2EB
BT 7065A GY/WH FLRB 0.5 ABS
BD 7064 GY/WH FLRB 0.5 ABS
BT 872A D-GN FLRB 0.5 ABS
IP 1687D GY/BK FLRB 0.5 EPS

BD 830 L-BU FLRB 0.5 ABS
IP 751E BK/WH FLRB 0.5 EPS
SP2643
IP 751W BK/WH FLRB 1.0
2 1 EB15 2 1 BT08 48 IP01_B 2 1 IP14

Ground
Supply
Power
Signal
Supply
Power
Signal
Supply
Power
Body
Relay
Control
Module
G_EBL3 BCM
G_EBL2_4 G_IPM1_1
Front Left Wheel Front Right Wheel Steering Wheel
Speed Sensor Speed Sensor Angle Sensor D9013-0021b
SAIC-SV91 09/2017
90
5-133
09/2017
e
d
D9013-0022b
Module
Control
CN 751CE BK/WH FLRB 0.5
Body
BCM
2
CN2IP_1
IP2BD_3
IP2CN_1
BD2IP_3
-
EB57_C
Lamp
Tail
CN 1382CA PU/WH FLRB 0.5 IP 1382EA PU/WH FLRB 0.5 BD 1382 PU/WH FLRB 0.5
Lighting
CN 1382CC PU/WH FLRB 0.5 IP 1382C PU/WH FLRB 0.5 ESP BD 1382E PU/WH FLRB 0.5
+
Back
SAIC-SV91
Central Control Switch Block - Right
5
1
43
43
SP1217
SP1210
SP1206
Descent
Control
Signal
Hill
CN 2031 PK FLRB 0.5 ESP IP 2031A PK FLRB 0.5 ESP BD 2031B PK FLRB 0.5 ESP
Hill Descent
10
Control
9
32
27
FL74
Rear Left Wheel Rear Right Wheel

Speed Signal
Rear Right
Speed Sensor
LED
BD 7128 GY/BK FLRB 0.5 ABS
Wheel
17
Hill Descent
1
CN 1961 WH FLRB 0.5 ESP IP 1961A WH FLRB 0.5 ESP BD 1961B WH FLRB 0.5 ESP
Control
LED
Signal
34
9
30
23
Turned
Power
Speed Signal Speed Sensor

Signal
Rear Right
ESP
Supply
Wheel
Off
Turned Off
29
2
CN 848 TN FLRB 0.5 ESP IP 848A TN FLRB 0.5 ESP BD 848B TN FLRB 0.5 ESP
ESP
31
12
25
8
FL73
LED
Speed Sensor
BD 7127 GY/BK FLRB 0.5 ABS
Rear Left
Wheel
Turned Off
31
CN 583 L-BU/BK FLRB 0.5 ESP
1
IP 583A L-BU/BK FLRB 0.5 ESP BD 583B L-BU/BK FLRB 0.5 ESP
ESP
LED
23
Signal
29
15
7
SP0259
IP2BD_3
BD2IP_3
Power
EB04
CN2IP_1
IP2CN_1
Speed Sensor
BD 866 L-GN FLRB 0.5 ABS Supply
Rear Left
Wheel
18
2
CN 642GC RD/BK FLRB 0.5 ESP
6
FL35
CN06
BD 6435 GY/BK FLRB 0.35 ESP
CAN_L
CAN_L
2
20
Yaw Velocity sensor

Instrument Panel
IP 642 RD/BK FLRB 0.5 BD 6432 L-GN/BK FLRB 0.35 ESP
CAN_H
CAN_H
3
18
33
Fuse Box
IG PWR4
EB04
I-FS6
10 A
IEC
ABS/ESP
IP 340AFRD/D-GN FLRB 2.5 BD 1687B GY/BK FLRB 0.5 ESP Power
4
Supply
Relay
I-R3
IG
IP 340A RD/WH FLRB 2.5 IP 340AARD/D-GN FLRB 2.5 BD 1151E BK/WH FLRB 0.5 ESP
87
30
Ground
1
2
68
69
SP0240
G_FLR2_1
BD2IP_1
IP2BD_1

IP 249 WH FLRB 0.35
85
86
60
58
SP2636
SP2626
IP07
IP07
G_EBR3
IP 2451CD BK/WH FLRB 0.5 BD 51 BK FLRB 2.5

c
a
d
Electronic Park Switch
Electronic Electronic
Park Park
LED Signal Signal
+ Output - Input
7 10 8 9 CN09
CN 6108 D-BU FLRB 0.5 ESP

CN 6107 BN FLRB 0.5 ESP
CN 751CD BK/WH FLRB 0.35ESP
CN 751CE BK/WH FLRB 0.5 33 34 CN2IP_1

e IP2CN_1
IP 6107A BN FLRB 0.5 ESP
SP2614
IP 6108A D-BU FLRB 0.5 ESP
CN 751CA BK/WH FLRB 0.5
90 32 34 IP2BD_3
BD2IP_3
BD 6108B D-BU FLRB 0.5 ESP
BD 6107B BN FLRB 0.5 ESP
44 CN2IP_1
IP2CN_1
IP 751C BK/WH FLRB 0.5 ESP
EB04
3 22
ESP ESP
Turn Off Turn Off
LED
SP2643

ABS/ESP
G_IPM2_1 D9013-0023b
SAIC-SV91 09/2017
5.13 Differential lock control system
KL30 KL30
30 A 85 30
10 A
U-JF4 U2-R4 10 A U2-FS3
IG IG U2-FS14 Differential
Power Relay 86 87 IG Power Lock Control
Supply Supply 2 Module
4 EB01 17 19 21 18 43 44 9 EB58

BD 340EC RD/WH FLRB 2.5


SP0264
SP0257 BD 1687F GY/BK FLRB 0.5 EDL SP0203

SP0502
SP0503
BD 1687E GY/BK FLRB 0.5 EDL
BD 2840 RD/WH FLRB 0.5 EDL

BD 1687FB GY/BK FLRB 0.5 EDL
BD 1687FA GY/BK FLRB 0.5 EDL
BD 1230B GY/WH FLRB 0.5 EDL
BD 1230C GY/WH FLRB 0.5 EDL

BD2IP_1
4
IP2BD_1
SP2635
FL59_B
90
1 3 19 20 FL59_A FL59_B 4 2
Power Power Power Power Differential Differential
Supply Supply Supply Supply Lock Lock
Solenoid Solenoid
Differential Lock Control Module
Differential Differential Differential
SP0904 Turned On Lock Lock
Ground Ground Signal Solenoid Solenoid
FL59_A 8 10 13 1 2
BD 1230 GY/WH FLRB 0.5 EDL

BD 680A L-BU FLRB 0.5 EDL
BD 1231C GY FLRB 0.5 EDL
BD 1231B GY FLRB 0.5 EDL
BD 1231 GY FLRB 0.5 EDL

BD 1750VA BK FLRB 0.5 EDL
BD 1750VB BK FLRB 0.5 EDL
BD2IP_4 FLA2FLB
IP 249C WH FLRB 0.5
C5 IP2BD_4 SP0501 19 13
SP2611 FLB2FLA
CN 680B L-BU FLRB 0.5 EDL
BD 1230A GY/WH FLRB 0.5 EDL

IP 680 L-BU FLRB 0.5 EDL
BD 1231A GY FLRB 0.5 EDL

SP2629
BD 1750 BK FLRB 3.0
23
IP2CN_2
CN2IP_2
CN06
48 IP01_B 12 2 1 FL61
Body Differential
IG
Relay Control Signal
Module
BCM
Central Control Differential
G_EBL2_4 G_FLDL1_1 Switch Block - Right Lock Solenoid
D9013-0089b
SAIC-SV91 09/2017
D9013-0024b
a
BD 642F RD/BK FLRB 0.5 BD 642FA RD/BK FLRB 0.5 AT

42
SP0261
U2-FS13
Supply 1
Power
10 A
IG

41
Engine Bay Fuse Box 2 UEC_2
SP0264
Module
Control
Body
BCM
87
30
18
BD2IP_1
IP2BD_1
48 IP01_B
SP0904
BD 249D WH FLRB 0.35 IP 249B WH FLRB 0.35 IP 249C WH FLRB 0.5
Relay
85
86
21
IG
4
SP2635
U2-R4
Relay
G_EBL2_4
IG
BD 451D BK/WH FLRB 0.5 BD 451 BK/WH FLRB 1.0

19
GB02_1
17
Operation /
Crankshaft
GB 642DB RD/BK FLRB 0.5 AT&&4WD
12
GB02_2
SP0257
EB01
Supply
Power
U-JF4
Operation /
Crankshaft
30 A
BD 642BC RD/BK FLRB 0.5 AT GB 642DD RD/BK FLRB 0.5 AT&&2WD

IG
FL2GB 18
12
Transmission Control Module

5-136
GB2FL
4
BD2IP_1
11 IP2BD_1
5.14 Transmission control system
Supply 9
GB 402CA RD FLRB 0.75 AT&&2WD
Suppley
Power
Power
U-JF6
40 A
IEG
1
BD 3440F RD/BK FLRB 3.0-ESSS IP 3440A RD/BK FLRB 3.0 -ESSS
6
GB 402BA RD FLRB 0.75 AT&&2WD
GB 402DA RD FLRB 0.75 AT&&2WD

KL30
Suppley
Power
4
SP0706
SP0234
IP 3440C RD/BK FLRB 3.0 -ESSS GB 402D RD FLRB 0.75 AT&&4WD
Suppley
Power
09/2017
47
1
I-FS22
AMT
15 A
Suppley
IP 402 RD FLRB 0.75 AT BD 402A RD FLRB 0.75 AT GB 402B RD FLRB 0.75 AT&&4WD GB 402C RD FLRB 0.75 AT&&4WD
Power
FL2GB 17
19
53
GB02_1 4
SP0704
GB2FL
IP2BD_1
BD2IP_1
SAIC-SV91
Panel Fuse
IP07
Instrument
Box
IEC
90
90
5-137
09/2017
IP 1382A PU/WH FLRB 0.5
D9013-0025b
BD 1382E PU/WH FLRB 0.5 IP 1382EA PU/WH FLRB 0.5
IP2BD_3 57
IP01_C
SP1207
BD2IP_3
Control Unit
SP1217
SP1207
PEPS
PEPS
10 IP59

Lighting
Back
Back Lighting
5
SAIC-SV91
IP 1382AB PU/WH FLRB 0.5 AT
7 IP59
IP09_A
IP 553 L-BU FLRB 0.5 AT
Gearshift
Gearshift
Output
Signal
Sinal
5
P-SE Input
IP 233 OG/BK FLRB 0.5 AT && PEPS
Output
SP0703
P-SE
3
3
Switch Ground
SP2643
IP 6009 BN/OG FLRB 0.5 IP 6009C BN/OG FLRB 0.5 AT
SP2634
Ground
Wiper
29
BCM
2
G_IPM1_1
IP01_A
IP 751SA BK/WH FLRB 0.5 AT IP 751S BK/WH FLRB 0.75 IP 751W BK/WH FLRB 1.0
Ground
4
P Solenoid
P Solenoid
IP 6009 BN/OG FLRB 0.5 IP 7553 TN FLRB 0.5 AT

Valve
Valve
IP2BD_1 18
1
2
9 GB02_2
EB57_E
IP 751SB BK/WH FLRB 0.5 AT

BD2IP_1
Ground
11
(KL15) GB 5728BC YE/BK FLRB 0.5 AT&&2WD
12V
ACC
6
GB02_1
SP0301
IP 5728D YE/BK FLRB 0.5 BD 5728 YE/BK FLRB 0.5 AT BD 5728B YE/BK FLRB 0.5 AT GB 5728BB YE/BK FLRB 0.5 AT&&4WD
Awake
ACC
ACC
47
9
9
FL2GB 4
GB2FL
IP2BD_3
BD2IP_3
IP01_B
P/N Signal
Engine Control Unit ECU
GB 275 L-GN FLRB 0.5 AT&&4WD
3
GB02_2
P/N Signal
BD 275B L-GN FLRB 0.5 AT GB 275C L-GN FLRB 0.5 AT&&2WD
Signal
P/N
22
Transmission Control Unit TCU

FL2GB 5
3
IP 642E RD/BK FLRB 0.5 AT
GB2FL
EB02_K
GB 1451GB BK/WH FLRB 0.75 AT&&2WD
Ground
2
BD2IP_1
33 IP2BD_1
GB 1451G BK/WH FLRB 0.75 AT&&2WD GB 1451GA BK/WH FLRB 0.75 AT&&2WD
Ground
5
SP0707
GB 1451BC BK/WH FLRB 0.75 AT&&4WD
Ground
2
BD 642FA RD/BK FLRB 0.5 AT
Ground
GB 1451BA BK/WH FLRB 0.75 AT&&4WD GB 1451BB BK/WH FLRB 0.75 AT&&4WD
FL2GB 19
GB02_1 5
SP0705
GB2FL
G_FLR2_1
BD 1451B BK/WH FLRB 0.75 AT
a
D9013-0027b
G_F2R2_1
SP2636
GB 1451EC BK FLRB 0.5 6MT-DYMOS&&2WD

FL2GB
19 GB2LF
45 IP01_B
Gear Switch
BD 1451E BK FLRB 0.5 6MT-DYMOS||6MT-SAGW GB 1451EA BK FLRB 0.5 6MT-DYMOS&&4WD

Reverse
GB 1451EB BK FLRB 0.5 6MT-SAGW&&4WD

GB 1451ED BK FLRB 0.5 6MT-SAGW&&2WD
IP 5007 L-GN FLRB 0.5 6MT-DYMOS||6MT-SAGW
Reverse
Switch
Gear
6MT
GB04_1
GB04_1
GB 5007AD L-GN FLRB 0.5 6MT-SAGW&&2WD GB 5007AB L-GN FLRB 0.5 6MT-SAGW&&4WD
5-138
1
GB04_2
GB04_2
GB 5007AB L-GN FLRB 0.5 6MT-SAGW&&4WD GB 5007AD L-GN FLRB 0.5 6MT-SAGW&&2WD
1
IP2BD_2
BD2IP_2
GB2F2
FL2GB
GB03_1
GB03_1
09/2017
49 BD 5007A L-GN FLRB 0.5 6MT-DYMOS||6MT-SAGW GB 5007AA L-GN FLRB 0.5 6MT-DYMOS&&4WD GB 5007AA L-GN FLRB 0.5 6MT-DYMOS&&4WD
1
4
GB03_2
GB03_2
GB 5007AC L-GN FLRB 0.5 6MT-DYMOS&&2WD GB 5007AC L-GN FLRB 0.5 6MT-DYMOS&&2WD
SAIC-SV91
Reverse
Switch
Gear
6MT
90
Engine Bay Fuse Box UEC Engine Bay Fuse Box UEC
KL30 KL30
30 A
U-R4 85 30
10 A 10 A 10 A
U-JF4
IG Starting U-FS15 U-FS8 U-FS9
Power Relay 86 87 Power Power Power
UEC Supply Supply 3 Supply 1 Supply 2
4 EB01 EB58 17 19 21 18 45 46 14 15
BD 440C YE/BK FLRB 2.0 4WD
BD 440D YE/BN FLRB 2.0 4WD


B02IP_1
SP0257 4 IP2BD_1
SP0264
SP2635
23 26 13 FL01
12V 12V 12V

Power Supply Power Supply Power Supply
90
Transfer Case Control Unit TCCU

SP0904
IP 249C WH FLRB 0.5
48 IP01_B
IG
Relay
G_EBL2_4 Body Control Module

BCM D9013-0028b
SAIC-SV91 09/2017
Central Control
Switch Block - Right Engine Bay Fuse Box UEC Instrument Panel Fuse Box IEC
10 A
25 A I-FS25
U-FS12 AC Control Panel /
IEC Right Central IP2CN_1
Economical / Economical / Power Supply 8 Control Switch 45 CN2IP_1 IP2CN_1 28
Sport Sport UEC BD2IP_1
50 56 CN2IP_1
9 48 24 EB01 IP2BD_1 3 EB58
CN06
IP 640W RD/WH FLRB 0.5 4WD
CN 640WA RD/WH FLRB 0.5 4WD
IP 6132A BN FLRB 0.5 4WD

CN 6132B BN FLRB 0.5 4WD


SP0305 SP0316 SP0244 SP0201

SP0235
CN 5054C GY FLRB 0.5 PT4WD
CN 1349CC BN FLRB 0.5 PT4WD
CN 751CB BK/WH FLRB 0.35 4WD

CN 751CJ BK/WH FLRB 0.5 PT4WD
CN 751CK BK FLRB 0.5 PT4WD
SP2614
2 1 CN01
Ground KL30
Drive Mode
Converting Switch
ILL+ LIN1
4CN 1382CF PU/WH FLRB 0.35 4WD 3 CN01
90 44 IP2CN_1 IP2BD_3 46
CN2IP_1 BD2IP_3
2 7 3 6 CN02 IP2BD_3
Economical / Economical / Ground Ground
57
BD2IP_3
Sport Sport
BD 6132 BN FLRB 0.5 4WD

IP 1382EA PU/WH FLRB 0.5
Drive Mode Converting Switch 2
2H 4L ILL+
4 5 1 CN02
CN 1562 D-GN FLRB 0.5 PT4WD
CN 1559 D-GN/WH FLRB 0.5 PT4WD
SP1210
CN 1382CA PU/WH FLRB 0.5
CN 1382CG PU/WH FLRB 0.5 PT4WD

SP1206 SP1217
B9 B10 IP2BD_4 SP2643

BD2IP_4
BD 1562B D-GN FLRB 0.5 PT4WD
BD 1559B D-GN/WH FLRB 0.5 PT4WD
IP2CN_1
28 45
CN2IP_1
IP 1562A D-GN FLRB 0.5 PT4WD
IP 1559A D-GN/WH FLRB 0.5 PT4WD
IP2CN_1
43
CN2IP_1
IP 1382C PU/WH FLRB 0.5 ESP
EB57_C FL02_A
4 16 FL01 5 9
2WD / 4WD H/L Mode Back LIN1
Converting Converting Lighting
Switch Switch
Transfer Case Body Control Gateway

Control Unit TCCU G_IPW2_1
Module BCM D9013-0029b
SAIC-SV91 09/2017
90
5-141
09/2017
GB 5501M PK/BK FLRB 1.0 4WD&&(6MT-DYMOS||6MT-SAGW)
D9013-0030b
Clutch Coil Drive
Electromagnetic
B
Tranfer Case
FL01
GB06_2
Electromagnetic
BD 5501C PK/BK FLRB 1.0 4WD
Clutch Coil
GB 5501 PK/BK FLRB 1.0 4WD&&AT
FL2GB 12
G
11
SAIC-SV91
GB06_1
GB 1557 D-BU/WH FLRB 0.5 4WD&&AT
GB2FL
17
11 FL2GB
GB2FL
Motor Decoder
GB 1557M D-BU/WH FLRB 0.5 4WD&&(6MT-DYMOS||6MT-SAGW BD 1557C D-BU/WH FLRB 0.5 4WDZ
18
E
GB 1558M YE/BK FLRB 0.5 4WD&&(6MT-DYMOS||6MT-SAGW)

D
Motor Decoder
GB 1558 YE/BK FLRB 0.5 4WD&&AT BD 1558C YE/BK FLRB 0.5 4WD
D
10
5
Decoder
GB 1556 OG/WH FLRB 0.5 4WD&&AT

C
Motor Decoder
GB 1556M OG/WH FLRB 0.5 4WD&&(6MT-DYMOS||6MT-SAGW BD 1556C OG/WH FLRB 0.5 4WD
C
19
Transfer Case Control Unit TCCU

GB 1555M BN/WH FLRB 0.5 4WD&&(6MT-DYMOS||6MT-SAGW)
A
Recovery
Transfer Case Gearshift Motor
Motor Decoder
GB 1555 BN/WH FLRB 0.5 4WD&&AT BD 1553C OG FLRB 1.0 4WD
A
17
8
Recovery
GB 7478 YE/BK FLRB 0.5 4WD&&AT

F
Critical-moment
Motor
H-L
Recovery
20
7
F
Motor
Motor
L-H
GB 1552M TN FLRB 1.0 4WD&&(6MT-DYMOS||6MT-SAGW)
B
BD 1552E TN FLRB 1.0 4WD
Motor
Motor
L-H
H-L
15
GB 1553M OG FLRB 1.0 4WD&&(6MT-DYMOS||6MT-SAGW)
SP0702
G
BD 1552C TN FLRB 1.0 4WD BD 1552D TN FLRB 1.0 4WD
Motor
L-H
2
Motor
L-H
GB 1552 TN FLRB 1.0 4WD&&AT
16
B
BD 1553E OG FLRB 1.0 4WD
Motor
H-L
14
SP0701
Motor
H-L
GB 1553 OG FLRB 1.0 4WD&&AT BD 1553C OG FLRB 1.0 4WD BD 1553D OG FLRB 1.0 4WD
Motor
1
G
H-L
15
D9013-0058b
G_IPN_1
Backlight-
CN 751CC BK/WH FLRB 0.5 EPB CN 751CA BK/WH FLRB 0.5 IP 751C BK/WH FLRB 0.5 ESP IP 751W BK/WH FLRB 1.0
CN2IP_1 44
3
SP2614
SP2643
57 BD2IP_3
IP2BD_3
IP2CN_1
Backlight+
Lighting
CN 1382CB PU/WH FLRB 0.5 EPB CN 1382CA PU/WH FLRB 0.5 IP 1382C PU/WH FLRB 0.5 ESP IP 1382EA PU/WH FLRB 0.5 BD 1382E PU/WH FLRB 0.5 BD 1382 PU/WH FLRB 0.5
Back
CN2IP_1 43
5
2
SP2505
SP1206
SP1217
EB57_C
IP2CN_1
Body Control
ModuleBCM
Fuse Box UEC
BT07_A
Electronic Power Steering

P-MG4
EPS_1
Engine Bay
100 A
Control Unit EPB ECU

EPS
BT 142L RD/BK FLRB 10.0 ESSS&&LHD
Power Supply
5.15 Electronic parking brake and electronic power steering system
BT 142A RD/BK FLRB 10.0 -ESSS
2
2
Electronic Park Switch
KL30
G_BT1
BT 1050L BK FLRB 10.0 ESSS&&LHD
BT07_A
BT07-B
EB2BT
BT2EB
U2-FS13
IG Power
Supply 1
SP0261
10 A
Power Supply
Fuse Box 2 UEC
G_BT1
Ground
BT 1050A BK FLRB 10.0 -ESSS
BD 1442C RD/BK FLRB 0.5 BT 1442CBL RD/BK FLRB 0.5 LHD
1
Engine Bay
42
5
1
U2-FS15
FL34
Supply 3
SP0249
Power
10 A
22 FL34
IG
G_F LR1_3 G_FLR1_1

BD 642BA RD/BK FLRB 0.5 BD 642BM RD/BK FLRB 0.5 EPB BD 1450AA BK FLRB 3.0 EPB
KL15
Ground
46
28
Electronic park brake control EPB ECU
Signal 1 Signal 2 Signal 3 Signal 4
CN 1088 L-GN FLRB 0.5 EPB IP 1088A L-GN FLRB 0.5 EPB BD 1088B L-GN FLRB 0.5 EPB BD 1450AB BK FLRB 3.0 EPB
Ground
Switch 4
30
38
19
4
5
5-142
FL64
CN 1087 L-GN/BK FLRB 0.5 EPB IP 1087A L-GN/BK FLRB 0.5 EPB BD 1087B L-GN/BK FLRB 0.5 EPB
Switch 3
18
37
Right Brake
4
Motor+
BD 1610 RD FLRB 3.0 EPB MOT_R+
12
Wheel Brake
2
Front Right
Switch 2
CN 1086 PK FLRB 0.5 EPB IP 1086A PK FLRB 0.5 EPB BD 1086B PK FLRB 0.5 EPB
36
10
2
6
BD 1611 D-BU FLRB 3.0 EPB
Right Brake
Motor-
27
1
CN 1079 D-GN FLRB 0.5 EPB IP 1079A D-GN FLRB 0.5 EPB BD 1079B D-GN FLRB 0.5 EPB MOT_R
Switch 1
CN2IP_1 35
IP2BD_6 1
1
9
BD2IP_6
IP2CN_1
FLB2F2LA
CN09
09/2017
FLA2FLB
FL63
Motor Power
BD 240D RD/WH FLRB 4.0 EPB
Left Brake
Left Brake
Motor+
Supply
MOT_R+
15
BD 1612B WH FLRB 3.0 EPB BD 1612 WH FLRB 3.0 EPB
Wheel Brake
14
11
2
EB01
SP2301
Front Left
U-JF2
50 A
EPB
SAIC-SV91
BD 240 RD/WH FLRB 4.0 EPB BD 240C RD/WH FLRB 4.0 EPB
Motor Power
Right Brake
Left Brake
Supply
Motor-
13
2
BD 1613B GY FLRB 3.0 EPB BD 1613 GY FLRB 3.0 EPB
29
20
1
KL30
MOT_R
90
5.16 Occupant protection system
Battery
BTN01
- +
BT04_1 Airbag Control Unit SRS
30 A
Pre-fuse Box 175 A U-JF4
PFB P-MG2 IG
UEC Power Driver's Side Passenger's
KL15 Ground
UEC Supply Seat Belt Side Seat Belt
2 4 16 30 17 14
BT01_1 EB01 IP08_C
IP 234A YE FLRB 0.5 SRSL
IP 1751LB L-BU FLRB 0.5 SRSL

SP1502
SP0257
IP2BD_3
IP 1361EB L-BU FLRB 0.5 SRSL&&FSBR
IP 1362J OG FLRB 0.5 SRSL&&FSBR

55 BD2IP_3
IP 1361LA L-BU FLRB 0.5 SRSL

BD2IP_1
IP2BD_1 2
90
BD 234 YE FLRB 0.5
16 IP2BD_5
BD2IP_5
IP07 69 IEC
58
85 30
IP2BD_6
I-R3 10 A 26 IP2BD_6 24
BD2IP_6 BD2IP_6
IG I-FS3
BD 1361A L-BU FLRB 0.5
86 87
Relay Airbag
Control Unit
3 15
IP07 60 68
IP 249 WH FLRB 0.35
IIP 442B RD/YE FLRB 0.5 SRSL
SP1501
BD 1361F L-BU FLRB 0.5
BD 1361E L-BU FLRB 0.5 FSBR
BD 1362A OG FLRB 0.5 FSBR

IP 1751L BK/WH FLRB 0.5 SRSL
SP0904
IP 249C WH FLRB 0.5
BD 1363 D-BU FLRB 0.5 FSBR
SP2626
SP0240
BD 51 BK FLRB 2.5
IP01_B FL12 FL08

48 FL07 1 2 1 2 2 1
IG + -
Relay Body Control
Module BCM
G_BTN G_EBR3 G_IPM3_2 Driver's Side Passenger's Side Passenger's Side

Seat Belt Seat OccupancySensor Seat Belt
D9013-0064b
SAIC-SV91 09/2017
Airbag Control Unit SRS
Driver's Side Driver's Side Passenger's Side Passenger's Side Accident

Passenger's Passenger's Driver's Side Driver's Side Side-collision Side-collision Side-collision Side-collision Signal
Side Airbag + Side Airbag - Airbag + Airbag - Signal + Signal - Signal + Signal - Output CAN_L CAN_H
5 4 2 3 27 26 24 25 1 31 32
IP08_C
IP 1409J D-GN FLRB 0.5 SRSL

IP 5045J PK/BK FLRB 0.5 SRSL
IP 5600J GY FLRB 0.5 SRSL
IP 2500CA RD/WH FLRB 0.35 SRSL

IP 354J YE FLRB 0.5 SRSL
IP 2501CA TN FLRB 0.35 SRSL

IP 3021J TN FLRB 0.5 SRSL && DAB
IP 3020J BN FLRB 0.5 SRSL && DAB
SP1803
SP1804
51 52 53 54 IP2BD_3
BD2IP_3
IP 2501CB TN FLRB 0.35 SRSH

90
IP50_A
3 4
Clock
BD 354A YE FLRB 0.5
10 1 IP2BD_5
Spring BD2IP_5
BD 2501A TN FLRB 0.35
3 4
SW04
IP 3025J RD/OG FLRB 0.5 SRSL && PAB
IP 3024J PK/BK FLRB 0.5 SRSL && PAB
IP 1000B OG FLRB 0.5 SRSL
SP1802
SP1801
BD 2501 TN FLRB 0.35
IP24 EB17 EB18 FL02_A

1 2 1 2 1 2 1 2 37 IP01_B 14 4
+ - + - - Accident
Signal - Signal CAN_L CAN_H
Signal
Passenger's Driver's Driver's Side Passenger's Side Body Control Gateway

Side Airbag Side Airbag Side-collision Sensor Side-collision Sensor Module BCM D9013-0065b
SAIC-SV91 09/2017
Battery
BTN01
- +
BT04_1 Airbag Control Unit SRS
30 A
Pre-fuse Box 175 A U-JF4
PFB P-MG2 IG
UEC Power Driver's Side Rear Left Rear Center Rear Right
KL15 Seat Belt Ground Seat Belt Seat Belt Seat Belt
UEC Supply
2 4 1 13 6 5 3 4
BT01_1 EB01 IP08_A IP08_B
IP 5161 YE FLRB 0.5 SRSH&&SBR

IP 1361 L-BU FLRB 0.5 SRSH
IP 234B YE FLRB 0.5 SRSH
IP 5163 PK/WH FLRB 0.5 SRSH&&SBR
IP 5162 PU FLRB 0.5 SRSH&&SBR


SP1503

BD 340D RD/WH FLRB 2.5 SP0257 a
IP2BD_3
BD2IP_1 55 BD2IP_3
IP2BD_1 2
IP2BD_5
BD2IP_5 16 15 14 5
BD 5161A YE FLRB 0.5 SBR
BD 5162A PU FLRB 0.5 SBR

BD 5163A PK/WH FLRB 0.5 SBR
90
BD 234 YE FLRB 0.5
BD 1361A L-BU FLRB 0.5

IP07 69
58 FL51 FL53 FL52
1 1 1
85 30
I-R3 10 A
IG I-FS3 Rear Rear Rear
86 87
Relay Airbag Left Center Right
Control Unit Seat Seat Seat
Belt Belt Belt

3 15
IP07 60 68
2 2 2
IP 442A RD/YE FLRB 0.5 SRSH
IP 249 WH FLRB 0.35
FL51 FL53 FL52

BD 1361D L-BU FLRB 0.5 SBR
BD 1361B L-BU FLRB 0.5 SBR

BD 1361C L-BU FLRB 0.5 SBR
SP0904
SP2626
IP 249C WH FLRB 0.5
BD 51 BK FLRB 2.5
SP0240 SP1501
48 IP01_B
FL07 1 2
IG
Relay Body Control
Module
BCM
G_BTN G_EBR3 Driver's Side Seat Belt D9013-0066b
SAIC-SV91 09/2017
Airbag Control Unit SRS
Passenger's Driver's Side Driver's Side Passenger's Passenger's Driver's Side Driver's Side Passenger's Side Passenger's Side
Side Seat Driver's Driver's Head-on Head-on Side Head-on Side Head-on Side-collision Side-collision Side-collision Side-collision
Belt Airbag Side Airbag + Side Airbag - Collision Signal + Collision Signal - Collision Signal + Collision Signal - Signal + Signal - Signal + Signal -
3 23 24 12 11 9 10 8 7 9 10
IP08_A IP08_B IP08_A
IP 1362 OG FLRB 0.5 SRSH&&FSBR
IP 2132 WH/BK FLRB 0.5 SRSH

IP 2134 D-GN FLRB 0.5 SRSH
IP 1409 D-GN FLRB 0.5 SRSH

IP 5045 PK/BK FLRB 0.5 SRSH
IP 6628 PU/WH FLRB 0.5 SRSH
IP 6629 WH/BK FLRB 0.5 SRSH
IP 5600 GY FLRB 0.5 SRSH

IP 354 YE FLRB 0.5 SRSH
IP 3021 TN FLRB 0.5 SRSH && DAB
IP 3020 BN FLRB 0.5 SRSH && DAB
IP2BD_6 IP2BD_5
24 BD2IP_6 6 17 BD2IP_5 22 23 IP2BD_6 51 53 54 IP2BD_3
52
BD2IP_6 BD2IP_3
IP 1361EA L-BU FLRB 0.5 SRSH&&FSBR
BD 1362A OG FLRB 0.5 FSBR
90
FL08
1 IP50_A
3 4
BD 2132A WH/BK FLRB 0.5 SRSH
BD 2134A D-GN FLRB 0.5 SRSH

BD 6628A PU/WH FLRB 0.5 SRSH
Clock
BD 6629A WH/BK FLRB 0.5 SRSH

BD 354A YE FLRB 0.5
Passenger's
Side Spring
Seat Belt
3 4
2 SW04
FL08
BD 1363 D-BU FLRB 0.5 FSBR
IP2BD_6
26 BD2IP_6
BD 1361E L-BU FLRB 0.5 FSBR
FL21 FL22 EB17 EB18

FL12 1 2 1 2 1 2 1 2 1 2 1 2
+ - Signal - Signal - Signal - Signal -
Passenger's Side Seat Passenger's Side Head-on Driver's Side Passenger's Side
Driver's Side Airbag Driver's Side Side-collision Sensor
Occupancy Sensor Head-on Collision Sensor Collision Sensor Side-collision Sensor D9013-0067b
SAIC-SV91 09/2017
Driver's Side Seat Belt Driver's Side Seat Belt Driver's Side Seat Belt
Passenger's Side Air Curtain Pretensioner 2 (Dual-stage) Pretensioner 1 (Dual-stage) Pretensioner 1 (Single-stage)
+ - + - + - + - + - + -
1 2 1 2 1 2 RF06_3 1 2 1 2 1 2 FL09
RF06_1 RF06_2 FL15 FL13
BD 2119D OG/BK FLRB 0.5 D1PSB

BD 2118A BN/OG FLRB 0.5 D2PSB
BD 2119A OG/BK FLRB 0.5 D2PSB

BD 2118C BN/OG FLRB 0.5 D2PSB
BD 2119C OG/BK FLRB 0.5 D2PSB
BD 2118D BN/OG FLRB 0.5 D1PSB

RF 5021A YE/BK FLRB 0.5 CAB&&NSRF
RF 5022A WH/BK FLRB 0.5 CAB&&NSRF
RF 5021B YE/BK FLRB 0.5 CAB&&FSRF
RF 5022B WH/BK FLRB 0.5 CAB&&FSRF
RF 5021C YE/BK FLRB 0.5 CAB&&PSRF
RF 5022C WH/BK FLRB 0.5 CAB&&PSRF
BD2IP_5
IP2BD_5 2 11 2 12
IP 2118 BN/OG FLRB 0.5 D2PSB||D1PSB
IP 2119 OG/BK FLRB 0.5 D2PSB||D1PSB

IP 2118B BN/OG FLRB 0.5 D2PSB
IP 2119B OG/BK FLRB 0.5 D2PSB

13 14 RF2IP_1
IP2RF_1
IP 5022 WH/BK FLRB 0.5 CAB
IP 5021 YE/BK FLRB 0.5 CAB
IP08_B 21 IP08_A
22 7 8 19 20 90
Passenger's Side Passenger's Side Driver's Side Seat Driver's Side Seat Driver's Side Driver's Side
Air Curtain + Air Curtain - Belt Pretensioner 2+ Belt Pretensioner 2- Seat Belt Seat Belt
Pretensioner 1+ Pretensioner 1-
Passenger's Passenger's Driver's Side Driver's Side Passenger's Passenger's Driver's Side Driver's Side
Side Airbag + Side Airbag - Airbag + Airbag - Side Airbag + Side Airbag - Air Curtain + Air Curtain -
22 21 19 20 18 17 23 24
IP08_A IP08_B Airbag Control Unit SRS
IP 5020 PK FLRB 0.5 CAB
IP 5019 PU/WH FLRB 0.5 CAB
IP 2135 BN/OG FLRB 0.5 FRSAB
IP 2137 BN FLRB 0.5 FRSAB
IP 2136 L-GN FLRB 0.5 FRSAB

IP 2138 YE/BK FLRB 0.5 FRSAB
IP2RF_1
11 12 RF2IP_1
IP 3025 RD/OG FLRB 0.5 SRSH && PAB
IP 3024 PK/BK FLRB 0.5 SRSH && PAB
4 13 IP2BD_5 14 15 IP2BD_6
BD2IP_5 BD2IP_6
RF 5019B PU/WH FLRB 0.5 CAB&&FSRF
RF 5019A PU/WH FLRB 0.5 CAB&&NSRF
RF 5019C PU/WH FLRB 0.5 CAB&&PSRF

RF 5020B PK FLRB 0.5 CAB&&FSRF
BD 2135A BN/OG FLRB 0.5 FRSAB
BD 2137A BN FLRB 0.5 FRSAB
RF 5020A PK FLRB 0.5 CAB&&NSRF
RF 5020C PK FLRB 0.5 CAB&&PSRF

BD 2136A L-GN FLRB 0.5 FRSAB
BD 2138A YE/BK FLRB 0.5 FRSAB
IP24 FL23 FL24 RF05_1 RF05_2

1 2 1 2 1 2 1 2 1 2 1 2 RF05_3
+ - + - + - + - + - + -
Passenger's Driver's Passenger's Driver's Side Air Curtain

Side Airbag Side Airbag Side Airbag D9013-0068b
SAIC-SV91 09/2017
Passenger's Side Seat Belt Passenger's Side Seat Belt Passenger's Side Seat Belt
Pretensioner 2 - (Dual-stage) Pretensioner 1 - (Dual-stage) Pretensioner 1 - (Single-stage)
+ - + - + -
1 2 1 2 1 2 FL10
FL16 FL14
BD 2117D OG FLRB 0.5 P1PSB

BD 2116A L-GN FLRB 0.5 P2PSB
BD 2117A OG FLRB 0.5 P2PSB

BD 2116C L-GN FLRB 0.5 P2PSB
BD 2117C OG FLRB 0.5 P2PSB
BD 2116D L-GN FLRB 0.5 P1PSB

SP1803
BD2IP_6
IP2BD_6 16 17 18 19 IP 2501B TN FLRB 0.35
SP1804
IP 2116 L-GN FLRB 0.5 P2PSB||P1PSB
IP 2500CB RD/WH FLRB 0.35 SRSH

IP 2117 OG FLRB 0.5 P2PSB||P1PSB
IP 2501CB TN FLRB 0.35 SRSH

IP 2116B L-GN FLRB 0.5 P2PSB
IP 2117B OG FLRB 0.5 P2PSB
10 1 IP2BD_5
BD2IP_5
BD 2501A TN FLRB 0.35

P08_B IP08_A
90 6 5 18 17 12 11
Passenger's Passenger's Passenger's Passenger's CAN_H CAN_L
Side Seat Belt Side Seat Belt Side Seat Belt Side Seat Belt Airbag
Pretensioner + Pretensioner - Pretensioner + Pretensioner -
Rear Left Rear Right Rear Right Accident
Control Unit
Seat Belt Seat Belt Seat Belt Signal SRS
Pretensioner - Pretensioner + Pretensioner - Output Ground
15 16 14 13 2 15
IP08_B IP08_A
IP 5157 PU FLRB 0.5 RPSB
IP 5155 BN FLRB 0.5 RPSB
IP 5158 BN/WH FLRB 0.5 RPSB

IP 5156 YE/BK FLRB 0.5 RPSB
SP1802
SP1801
21 IP2BD_6
BD 2501 TN FLRB 0.35
20
BD2IP_6
7 18 IP2BD_5
BD 5158A BN/WH FLRB 0.5 RPSB&&(MDAC||ADAC)
BD2IP_5
BD 5155A BN FLRB 0.5 RPSB
BD 5156A YE/BK FLRB 0.5 RPSB
BD 5157A PU FLRB 0.5 RPSB&&(MDAC||ADAC)
BD 5157C PU FLRB 0.5 RPSB&&MSAC
BD 5158C BN/WH FLRB 0.5 RPSB&&MSAC
IP 1000A BK FLRB 0.5 SRSH
IP 1751H BK/WH FLRB 0.5 SRSH
FL57 FL58_2 FL02_A

FL58_1
1 2 1 2 1 2 37 IP01_B 14 4
+ - + - + - Accident CAN_L CAN_H
Signal
Rear Left Seat Belt Rear Right Seat Belt Body Control G_IPM3_1 Gateway
Pretensioner - (Single-stage) Pretensioner - (Single-stage) Module BCM D9013-0069b
SAIC-SV91 09/2017
KL30 KL30
30 A 85 30 10 A 10 A
U-JF4 U2-R4 U2-FS16 U2-FS5
IG IG IG Tire
Power Relay 86 87
Power Pressure
Supply Supply 4 Monitoring
4 17 19 21 18 47 48 11 EB58
EB01


BD 840A RD/WH FLRB 0.5 TPMS

SP0264
SP0257
SP2635
SP0262
BD 842A RD/BK FLRB 0.5 TPMS
BD2IP_1
4
IP2BD_1
90
FL30
22 17
KL15 KL30
Tire Pressure
Monitoring
Control Unit
Ground Ground CAN_H CAN_L
6 18 1 2
FL30
BD 2051A BK/WH FLRB 0.5 TPMS
BD 2051B BK/WH FLRB 0.5 TPMS
BD 7493AA D-GN FLRB 0.35 TPMS
BD 7494AA L-BU FLRB 0.35 TPMS
SP0904
IP 249C WH FLRB 0.5
SP1823 SP1824
BD 7494 L-BU FLRB 0.35
SP2613
FL02_A
48 IP01_B 3 13
IG
Relay
Body Control CAN_H CAN_L
Module
BCM
G_EBL2_4 G_FLDL2 Gateway
D9013-0070b
SAIC-SV91 09/2017
D9013-0031b
G_EBL2_2
BD 478 D - GN FLRB 2.0 Ground BD 250WA BK FLRB 2.0
H
152
1
5
Reset
BD 477 D - BU FLRB 2.0 BD 196 YE FLRB 0.75
151
3
2
L
EB08
EB08
Governor Relay
Motor
Wiper
Front
Wiper
U-R7
87A
Multifunction
30
148
IP2BD_2
BD2IP_2
87
IP01_B
Switch -
Wiper
Wiper Adjustment
BD 92 TN FLRB 0.35 IP 92A TN FLRB 0.35 Reset IP 196A YE FLRB 0.75
86
85
21
37
150
57
31
Front Wiper
IP04
Rear Wiper
BD 250WB BK FLRB 2.0 IP 391 GY FLRB 0.35 Switch
146
Switch
4
21
SP0703
Rear Wiper
Ground IP 6009 BN/OG FLRB 0.5 IP 6009B BN/OG FLRB 0.5 Ground
29
5
BD 1440AA BN FLRB 2.0 Wiper Switch
87A
30
143
Front Wiper Motor Power Supply

87
4
Ground IP 6985 D - BU/YE FLRB 0.5
10
3
45
Wiper Switch
BD 95 GY FLRB 0.35 IP 95A GY FLRB 0.35
2
86
85
145
17
56
5-150
IP 1715 L-GN FLRB 0.5

High Speed
1
Supply Relay
33
7
Front Wiper Signal 1
Power
Wiper
U-R6
BD2IP_2
IP2BD_2
IP01_B
Low Speed
16
Front Wiper Signal 2
9
BD 1440B BN FLRB 2.0
5.17 Wiper and washer system
144
Front
IP 94 PK FLRB 0.5
Washer
Front Washer
24
6
BD 1440A BN FLRB 2.0
147
Rear
IP 7593 D - BU FLRB 0.35
SP0223
Rear Washer Washer
13
3
BD 1440C BN FLRB 2.0
09/2017
IP01_A
149
Control Module
IP 2451E BK/WH FLRB 0.5 Ground
1
U-FS7
Wiper
Front
30A
SP2610
BCM
Body
BD 1440 BN FLRB 2.0
19
IP 2451F BK/WH FLRB 0.5 Ground
SAIC-SV91
EB01
KL30
G_IPA2_1
90
90
5-151
09/2017
RF08_2
RF2IP_2
13 IP2RF_2
D9013-0032b
SP2605
SP2646
G_IPB1_1
RF 2351RR BK FLRB 0.5 RLS&&LDW
Ground
RF 2351RR BK FLRB 0.5 RLS&&LDW RF 2351RH BK/WH FLRB 1.5 IP 2351RS BK/WH FLRB 1.5
3
RF08_1
SAIC-SV91
Ground
RF 2351RC BK FLRB 0.5 RLS&&-LDW
SP2641
G_FCOR_2
3
BD 1850A BK FLRB 1.0 MDAC||ADAC BD 1850A BK FLRB 1.0 MDAC||ADAC

Rainfall Sensor
RF 6133AC D-BU FLRB 0.35 RLS&&-LDW

2
LIN
TLD2FL_2
FL2ILD_2
RF2IP_1
IP2RF_1
RF08_2
SP2632
G_FCOR_1
RF 6133AE D-BU FLRB 0.35 RLS&&LDW RF 6133AE D-BU FLRB 0.35 RLS&&LDW BD 1850LC BK FLRB 0.5 MSAC BD 1850A BK FLRB 1.0 MDAC||ADAC
LIN
3
2
3 TLD14
SP2602
SP0902
TLD 1850LD BK FLRB 0.5 TLD 1850WBA BK FLRB 0.5

Supply
RF 842BE RD/BK FLRB 0.5 RLS&&-LDW

Power
BD2IP_2
IP2BD_2
BD2IP_2
IP2BD_2
RF08_1
BD 5456C YE FLRB 0.5 MDAC||ADAC

Supply
Power
RF 842BD RD/BK FLRB 0.5 RLS&&-LDW BD 1802A RD/BK FLRB 0.5 IP 5456AB YE FLRB 0.5 BD 5456A YE FLRB 0.5 MSAC TLD 5456B YE FLRB 0.5
Rear Wiper Motor

48
16
1
2
SP1205
BD 5456A YE FLRB 0.5 MSAC
IP 5456AB YE FLRB 0.5 BD 5456C YE FLRB 0.5 MDAC||ADAC
SP0903
10
Interior Light
12 BD2IP_2
IP2BD_2
U-FS27
EB01
SP0256
BD2IP_3
IP2BD_3
10 A

Engine Bay Fuse Box LEC
BD 1802 RD/BK FLRB 0.5 BD 393C WH FLRB 0.5 MDAC||ADAC
IP 6133 D-BU FLRB 0.35

50
Rear Wiper
Reset Switch
Rear Wiper
BD 393A WH FLRB 0.5 MSAC TLD 393B WH FLRB 0.5
1
33
13
4
IP 1802C RD/BK FLRB 0.5
TLD2FL_2
FL2ILD_2
39
EB07
Washer Pump-
46
LIN
Washer Pump
10
ICE PWR3
2
U-FS10
BCM IP01_B
30 A
SP0233
Body Control
Washer Pump+
Module
22
BD 228 OG FLRB 1.0
SP0248
1
KL30
EB57_C
EB57_C
BD2IP_3
57 IP2BD_3
DRD2IP_2
37 IP2DRD_2
D9013-0086b
SP1217
SP2630
Passagener's
SP2606
G_IPA2_1 G_IPB2_3
BD 1382 PU/WH FLRB 0.5 BD 1382E PU/WH FLRB 0.5
Window
Lighting
Switch
Power
Back
DRD 2251DA BK/WH FLRB 1.0

Side

5
PD06
PD06
IP 1382EA PU/WH FLRB 0.5 DRD 2251DK BK/WH FLRB 0.5

Module
Control
Body
BCM
SP2603
IP 1382P PU/WH FLRB 0.5 PAD 1382PB PU/WH FLRB 0.5 PAD 2351DG BK/WH FLRB 0.5
PAD2IP
IP2PAD
10
PAD2IP 24
11
SP1206
Ground
SP2617
IP2PAD
PAD 6859BA YE/BK FLRB 0.5 PAD 2351DA BK/WH FLRB 0.5 IP 2351DS BK/WH FLRB 0.5
27
9
SP2607
Auto
Ground
G_IPB1_2
Downword Auto
DRD 167 TN FLRB 0.35 IP 167A TN FLRB 0.35 PAD 167B TN FLRB 0.35 PAD 2351DF BK FLRB 2.0 PAD 2350DA BK FLRB 2.0 IP 2350D BK FLRB 2.0
21
17
28
19
1
Downword
SP2604
MCU
DRD 2765 PU FLRB 0.35 IP 2765A PU FLRB 0.35 PAD 2765B PU FLRB 0.35 IP 2765A PU FLRB 0.35
16
16
25
13
4
6
Upword
Upword
Downword
DRD 166 YE FLRB 0.35 IP 166A YE FLRB 0.35 PAD 166B YE FLRB 0.35 IP 166A YE FLRB 0.35
18
23
IP2DRD_1 15
PD05 5
Driver's Side Power Window Switch
DRD2IP_1
Upword
KL30
Front Right Power

PAD 4040DA RD FLRB 2.0 KL30 PAD 202DBA RD/YE FLRB 0.5
Window Motor
14
3
5
Window
Driver's
Power
Lifter
DRD2IP_2
Side
28 IP2DRD_2
Auto
LIN
DRD 6133BA D-BU FLRB 0.35 IP 6133B D-BU FLRB 0.35
Downword Auto
6
DRD 7628 D-GN/VT FLRB 0.35
SP0903
17
Downword
MCU
Ground
5-152
G_IPB1_2
DRD 165A BN FLRB 0.35 DRD 2250DD BK FLRB 2.0 IP 2250D BK FLRB 2.0
15
DRD2IP_1 26
3
1
Upword
Upword
IP2DRD_1
Supply
Power
DRD 164A D-BU FLRB 0.35 DRD 2440BC D-GN FLRB 2.0
DD07 14
DD08 5
DD08 4
DRD2IP_1
5.18 Window control system
Passagener's Driver's Side Panel Fuse

I-FS29 Instrument
Box IEC
14
IP2DRD_1
BD2IP_3
29 IP2BD_3
09/2017
Supply 1
Window
U-JF11
Power
Power
Module
Control
IP 6133 D-BU FLRB 0.35
Window Motor Motor
25 A
60 A
IEC
Body
BCM
IP07
IP07
46 IP01_B
BD 2440 OG FLRB 5.0 IP 2440A OG FLRB 5.0 IP 2440B RD/WH FLRB 3.0 IP 2440BA D-GN FLRB 2.0
EB01 11
85
77
SP0229
Side Power
KL30
I-FS30
30 A
SAIC-SV91
LIN
IP 2440C RD/WH FLRB 3.0 IP 2440CA RD FLRB 2.0
78
86
90
90
5-153
09/2017
Window
Switch
Power
b
Rear
c
Left
D9013-0087b
RL04
RL04
BD 1550DP BK FLRB 2.0
1
IP 6859C YE/BK FLRB 0.35 BD 6859CA YE/BK FLRB 0.35 RLD 6859CB YE/BK FLRB 0.35
G_FLCL_1
RLD2FL
FL2RLD
14
Downword
14
9
RLD 1550DA BK FLRB 2.0
Ground
SAIC-SV91
Downword Auto
DRD 169 PU FLRB 0.35 IP 169A PU FLRB 0.35 BD 169B PU FLRB 0.35 RLD 169C PU FLRB 0.35 RLD 1550DC BK FLRB 2.0
21
13
13
1
1
7
SP2627
1 RL03
Auto
Downword
Rear Left Power

MCU
Window Motor
DRD 5048 D-GN/BK FLRB 0.35 IP 5048A D-GN/BK FLRB 0.35 BD 5048B D-GN/BK FLRB 0.35 RLD 5048C D-GN/BK FLRB 0.35 RLD 669 BN FLRB 2.0
Downword
19
12
10
8
4
6
Upword
Upword
DRD 168 D-GN FLRB 0.35 IP 168A D-GN FLRB 0.35 BD 168B D-GN FLRB 0.35 RLD 168C D-GN FLRB 0.35 RLD 668 D-BU FLRB 2.0 Upword
IP2BD_3 11
IP2DRD_1 18
2
8
2
4
DD07 3
DRD2IP_1
BD2IP_3
Upword
202DCA RD/BK FLRB 0.5
KL30
3
RLD 4042CB L-GN FLRB 2.0
Rear Left
11
U2-FS4
5
Window
Power
SP2622
30 A
SP1209
BD 2440DA L-GN FLRB 2.0 BD 1382FD PU/WH FLRB 0.5 RLD 1382FDA PU/WH FLRB 0.5 RLD 1551DC BK/WH FLRB 0.5
15
11
10
10
KL30
BD 202GB RD/BK FLRB 0.5 BD 202GB RD/BK FLRB 0.5

40
FL2RLD 8
SP0253
U2-FS12
ACC2
RLD2FL
10 A
RLD 1551DA BK/WH FLRB 0.5

G_FLCL_2
BD 1551DS BK/WH FLRB 0.5 BD 1551 BK/WH FLRB 0.5
39
SP0263
FL2RLD 1
U2-R1
Relay
ACC
SP2618
RLD2FL
EB57_C
SP1217
Engine Bay Fuse Box 2 UEC2

87
30
33
BD 1382FA PU/WH FLRB 0.5 BD 1382 PU/WH FLRB 0.5
Lighting
Back
5
BD 5199B YE FLRB 0.35
85
86
35
IP2BD_1 4

BD2IP_1
BD 342D RD FLRB 5.0 IP 202AA RD/BK FLRB 0.5 IP 202AA RD/BK FLRB 0.5
37
32
SP0239
PAD2IP IP2PAD
I-FS17
ACC2
10 A
IEC
SP0240
15
BD 342CA RD FLRB 5.0 IP 202A RD FLRB 3.0
29
PAD 202DBA RD/YE FLRB 0.5

36
SP0237
Relay
ACC
I-R2
EB58
BD 342C RD FLRB 5.0

BD 342E RD FLRB 5.0 IP 342A RD/BK FLRB 3.0 IP 202 RD FLRB 3.0
87
30
42
41
IP01_B
Supply
Power
U-JF5
ACC
60 A
BD 342 RD FLRB 5.0 IP 342H RD FLRB 5.0 IP 342B RD/BK FLRB 3.0 IP 5199D YE FLRB 0.35 IP 5199C YE FLRB 0.35
Relay
85
86
ACC
45
43
IP2BD_3 28
6
EB01 5
SP0901
SP0258
KL30
SP0230
BD2IP_3
IP07
IP07
a
D9013-0088b
DRD2IP_2
IP2DRD_2
DRD 2251DG BK/WH FLRB 0.5
19
SP2606
SP2630
SP2603
Body Control Module BCM G_IPA2_3

DRD 2251DF BK/WH FLRB 0.5 DRD 2251DK BK/WH FLRB 0.5 DRD 2251DA BK/WH FLRB 1.0 IP 2251DS BK/WH FLRB 1.0 IP 2251 BK/WH FLRB 1.5
37
7
SP1211
DRD 1382DC PU/WH FLRB 0.5 DRD 1382DA PU/WH FLRB 0.5 IP 1382D PU/WH FLRB 0.5 IP 1382EA PU/WH FLRB 0.5 BD 1382E PU/WH FLRB 0.5 BD 1382 PU/WH FLRB 0.5
Lighting
Back
57
IP2DRD_2 41
6
5
SP1206
DRD2IP_2
SP1217
30 IP2DRD_2
EB57_C
DRD2IP_2
IP2BD_3
BD2IP_3
Unlocking
Door
Unlocking
DRD 7177 D-BU/BK FLRB 0.5 IP 7177A D-BU/BK FLRB 0.5
Switch
Door
31
13
Locking
Door
Locking
Switch
DRD 7176 D-BU/YE FLRB 0.5 IP 7176A D-BU/YE FLRB 0.5
Door
24
47
29
IP01_A
RRD2FL
Rear Right
19 FL2RRD
Window
IP 6859D YE/BK FLRB 0.35
Switch
Power
SP2001
12 IP2BD_2
FL2RRD
BD2IP_2
RRD2FL
G_FLCR_2
RR04
RR04
IP 6859A YE/BK FLRB 0.35 BD 1650DM BK FLRB 2.0 MSAC
Window
Lockup
Switch
Power Window
DRD 6859 YE/BK FLRB 0.35 BD 6859DA YE/BK FLRB 0.35 RRD 6859DB YE/BK FLRB 0.35
14
Rear Right
25
9
RRD 1650DA BK FLRB 2.0
4
Downword
Motor
Ground
Downword Auto
DRD 171 GY FLRB 0.35 IP 171A GY FLRB 0.35 BD 171B GY FLRB 0.35 RRD 171C GY FLRB 0.35 RRD 1650DC BK FLRB 2.0
24
13
11
12
1
7
SP2628
Auto Downword
MCU
DRD 5049 L-GN/BK FLRB 0.35 IP 5049A L-GN/BK FLRB 0.35 BD 5049B L-GN/BK FLRB 0.35 RRD 5049C L-GN/BK FLRB 0.35 RRD 671 BN FLRB 2.0 Downword
23
10
10
5
4
6
1
Upword
5-154
Upword
DRD 170 L-GN FLRB 0.35 IP 170A L-GN FLRB 0.35 BD 170B L-GN FLRB 0.35 RRD 170C L-GN FLRB 0.35 RRD 670 D-BU FLRB 2.0 Upword
DD07 10
IP2DRD_1 22
2
8
4
2
9
RR03
DRD2IP_1
Upword
RRD 202DDA RD/BK FLRB 0.5
KL30
3
RRD 4042DB OG/BK FLRB 2.0
Rear Right
U2-FS10
11
Window
5
Power
SP2623
30 A
BD 2440EA OG/BK FLRB 2.0 BD 1382FD PU/WH FLRB 0.5 RRD 1382FEA PU/WH FLRB 0.5 RRD 1651DC BK/WH FLRB 0.5
15
11
16
10
KL30
09/2017
BD 202DD RD/BK FLRB 0.5
FL2RRD 8
RRD2FL
RRD 1651DA BK/WH FLRB 0.5
G_FLCR_1
BD 1651DS BK/WH FLRB 0.5 MDAC||ADAC
SAIC-SV91
FL2RRD 1
RRD2FL
d
c
b
90
90
5-155
09/2017
b
a
G_IPB1_1
D9013-0112b
RF 2351RA BK/WH FLRB 1.0 RLS||ATTG RF 2351RH BK/WH FLRB 1.5 IP 2351RS BK/WH FLRB 1.5
IP2RF_2 13
Sunroof
(U/D)
Switch
SP2646
RF2IP_2
EB57_C
RF22
RF 110B OG FLRB 0.35 FSRF

SP1217
Tilt Downward
SAIC-SV91
RF13
Ground
4
BD 1382 PU/WH FLRB 0.5 RF 2351RG RD/WH FLRB 0.35 FSRF
Lighting
Back
2
5
RF 5027 L-BU FLRB 0.35 FSRF

SP2605
4
3
Tilt Upward
RF 1382BC PU/WH FLRB 0.5 PSRF
Sunroof
Tilt
Body Control
Module BCM
LED+
BD 1382E PU/WH FLRB 0.5 RF 1382BE PU/WH FLRB 0.35 FSRF

1
BD2IP_3 57
5
RF22
IP2BD_3
Sunroof Sunroof
Close
Close RF 110A OG FLRB 0.35 FSRF RF 110 OG FLRB 0.35 FSRF
10
Ground
SP2002
RF 3940B RD/WH FLRB 1.5 PSRF
RF 2351RF RD/WH FLRB 0.35 FSRF
Open
2
RF 100 BN FLRB 0.35 FSRF
5
3
Open
LED+
IP 1382B PU/WH FLRB 0.5 RF 1382BA PU/WH FLRB 0.5 RF 1382BD PU/WH FLRB 0.35 FSRF
RF20 1
Sunroof
5
Power Supply
5
SP1206
SP1208
Sunroof/ （O/C）
RF2IP_1
Sunroof
IP2RF_1
Switch
RF20
RF 3940A RD/WH FLRB 1.5 FSRF
6
SP2004
Sunshade
RF 3940C RD/WH FLRB 1.5 FSRF||PSRF
I-FS8
Front
25 A
IP 3140C RD FLRB 2.5 PSRF||FSRF IP 3940 RD/WH FLRB 1.5 FSRF||PSRF
20
8
1
SP0245
IP2RF_2
RF2IP_2
IP 3140A RD FLRB 2.5 LDW||PSRF||FSRF
RF 202RD RD/BK FLRB 0.35FSRF
RAP
RF 202RC RD/BK FLRB 0.35 FSRF RF 202RB RD/BK FLRB 0.5 FSRF
3
SP2003
RF 202RA RD/BK FLRB 0.5 FSRF
IP 202AA RD/BK FLRB 0.5 IP 202R RD/BK FLRB 0.5 FSRF
37
BD2IP_1
4
10 IP2BD_1
IEC
SP0239
I-FS17
Supply 5
ACC2
10 A
U-FS3
Power
IP2RF_2
RF2IP_2
IEC
30 A
15 BD 3140 RD FLRB 2.5 LDW||PSRF||FSRF IP 202A RD FLRB 3.0
29
Body Control
Module BCM
SP0237
Relay
ACC
I-R2
BD 342E RD FLRB 5.0 IP 342A RD/BK FLRB 3.0 IP 202 RD FLRB 3.0
87
30
42
41
IP01_B
Supply
Power
U-JF5
ACC
60 A
BD 342 RD FLRB 5.0 IP 342H RD FLRB 5.0 IP 5199D YE FLRB 0.35 IP 5199C YE FLRB 0.35
Relay
85
86
ACC
45
43
IP2BD_3 28
6
EB01 5
SP0901
SP0258
KL30
SP0230
BD2IP_3
IP07
IP07
D9013-0113b
RF2IP_1
IP2RF_1
46 IP01_B
IP 6133 D-BU FLRB 0.35 IP 6133A D-BU FLRB 0.5 PSRF||RLS RF 6133AA D-BU FLRB 0.5 PSRF||RLS RF 6133AB D-BU FLRB 0.35 PSRF
LIN
5
LIN
SP0903
SP0902
Body Control
Module BCM
BD2IP_3
IP2BD_3
Power Supply
Panoramic
RF2IP_1
IP2RF_1
Sunroof
IP07
I-JF3
30 A
67 IP07
Sunroof
IP 3540A RD FLRB 5.0 8PST-4LUB||MMHT||PST-LUB||PSR IP 3540D RD FLRB 5.0 PSRF IP 540 D-BU FLRB 2.0 PSRF RF 540A D-BU FLRB 2.0 PSRF
64
30
3
1
Panoramic Sunroof
SP0246
Supply 6
U-JF12
Power
Panel Fuse
Instrument
60 A
IEC
Box IEC
BD 3540 RD FLRB 5.0 8PST-4LUB||MMHT||PST-LUB||PSR
EB01 12
ILL+
KL30
RF 1382BC PU/WH FLRB 0.5 PSRF
Power Supply
Sunshade
RF 3940B RD/WH FLRB 1.5 PSRF
2
Ground
RF 2350RZ BK FLRB 2.0 PSRF
4
5-156
RF14
20 RF2IP_1
IP2RF_1
G_IPA1_2
RF 2350RX BK FLRB 2.0 PSRF||FSRF IP 2350R BK FLRB 2.0 PSRF||FSRF
SP2645
RF13
RF 2351RE BK FLRB 1.0 FSRF
09/2017
7
Speed
Signal
Sunroof
SP0504
Ground
ABS/ESP BD 1827 YE/BK FLRB 0.5 ABS&&(PEPS||FSRF) IP 1827A YE/BK FLRB 0.5 ABS&&(PEPS||FSRF) IP 1827C YE/BK FLRB 0.5 ABS&&FSRF RF 1827CA YE/BK FLRB 0.5 FSRF
VSO
IP2BD_2 15
EB04 10
14
2
BD2IP_2
IP2RF_2
RF2IP_2
SAIC-SV91
a
b
90
5.19 Rear view mirrors (LHD)
KL30
30 A 60 A
U-JF4 U-JF5
IG Power ACC
Supply Power
Supply
4 5
EB01
BD 342 RD FLRB 5.0

SP0257
BD 342E RD FLRB 5.0
SP0258 BD2IP_3
4 IP2BD_3
IP 342H RD FLRB 5.0

BD2IP_1
IP2BD_1 2
a
SP0230
90
IP07 69
58 43 41
85 30 Instrument
I-R3 10 A 85 30
I-R2 10 A
IG I-FS6 ACC
Panel Fuse
I-FS17
86 87
Relay IG 86 87
Relay ACC2
Box IEC
PWR4
6 42 29
IP07 60 68 18 45 37
IP 202 RD FLRB 3.0

IP 202A RD FLRB 3.0

IP 249 WH FLRB 0.35
SP0904 SP0202
SP0237
IP 642H RD/BK FLRB 0.5 SPM&&HALP
SP0240 SP2610
IP 249C WH FLRB 0.5
SP2626 SP0239
IP 2451A BK/WH FLRB 0.5 SPM
IP 202W RD/BK FLRB 0.5 SPM

SP0901
IP01_B 48 6 IP12 10 8 11
IG
Relay
ACC
Relay
Body Control KL15 Power Supply Ground
Module BCM
G_IPB2_1
G_IPA2_1 Rear View Mirror Governor Switch
D9013-0120b
SAIC-SV91 09/2017
b
D9013-0121b
G_IPA2_3
DRD 2251DA BK/WH FLRB 1.0 IP 2251DS BK/WH FLRB 1.0 IP 2251 BK/WH FLRB 1.5
IP2DAD_2 37
Driver's
DD03_A
DD03_A
SP2630
Mirror
Rear
View
Side
DRD2IP_2
DRD2BD
BD2DRD
SP2606
DRD 2250DB BK/WH FLRB 0.5 SPMH

11
DRD 6802 YE FLRB 0.5 SPMH BD 190A YE FLRB 0.5 SPHCM

+
2
5
IP2DRD_2
36 DRD2IP_2
DRD 6803 PK FLRB 0.5 SPMH BD 191A PK FLRB 0.5 SPHCM

-
10
1
SP0206
IP 502A RD/WH FLRB 0.5 SPHM DRD 502AL RD/WH FLRB 0.5 SPML
1
PAD2IP
26 IP2PAD
DD03_C
SP2604
G_IPA1_1
PAD 2350DB BK FLRB 0.5 SPMH PAD 2350DA BK FLRB 2.0 IP 2350D BK FLRB 2.0
PD03_A
PD03_A
IP2BD_1
BD2IP_1
PAD2IP
IP2PAD
EB57_E
SP1302
11
BD 191AB PK FLRB 0.5 SPHCM
Automatic Anti-glare Rear View Mirror Body Control Module BCM

Reverse Closing-up + Closing-up -
PAD 6805 PK FLRB 0.5 SPMH IP 191B PK FLRB 0.5 SPHCM BD 191 PK FLRB 0.5 SPHCM
-
40
30
6
1
SP1301
7
IP2PAD
PAD2IP
PAD 6804 YE FLRB 0.5 SPMH IP 190B YE FLRB 0.5 SPHCM BD 190 YE FLRB 0.5 SPHCM BD 190AB YE FLRB 0.5 SPHCM
39
29
10
2
46
SP2613
PD03_C 1
Gear Signal
Passenger's Side
Rear View Mirror
IP 5219A OG/BK FLRB 0.5 PGAM IP 5219F OG/BK FLRB 0.5
36
RF2IP_1 8
IP01_B
5-158
IP2RF_1
RF 5219AA OG/BK FLRB 0.5 PGAM Signal
3
IP2RF_1
RF2IP_1
IG PWR3
I-FS5
SP0213
IP07
10 A
+
IP 842 RD/BK FLRB 0.5 LDW||PGAM RF 842BB RD/BK FLRB 0.5 PGAM
17
10
09/2017
RF 2350RB BK FLRB 0.5 PGAM
-
2
SP2608
RF07
5
RF2IP_2
IP2RF_2
SAIC-SV91
SP2646
G_IPB1_1
RF 2350RA BK FLRB 0.75 RF 2350RH BK FLRB 0.5 FSRF IP 2351RS BK/WH FLRB 1.5
13
a
90
KL30 25 A
U-FS26
Engine Bay
25 A 30 A
Central Fuse Box
U-FS2 U-FS10
Gateway IEC PWR3 Control UEC
Lock
14 22 38 51 EB01

b
SP0233 SP0256 BD2IP_2

BD2IP_1 12
3 IP2BD_1 BD2IP_2
IP 1802C RD/BK FLRB 0.5

SP0248
SP0231
IP 1802H RD/BK FLRB 0.5 SPHCM

90
96 100 90 106 110 IP07
85 30
I-R5 10 A
85 30
I-R7 Instrument
Rear View I-FS34 Under
Mirror & Mirror
Panel Fuse
Rear View
Box IEC
86 87 86 87
Rear Window Mirror Heat Light Relay
Heat Relay
94 99 82 104 109 IP07
IP 293 PU FLRB 1.5

IP 193 WH FLRB 0.35
IP 6767 WH/BK FLRB 0.35 SPHCM
IP 1802DA PK FLRB 0.5 SPHCM
IP2PAD PAD2IP
IP 1802DC PK FLRB 0.5 SPHCM
PAD 1802DCA PK FLRB 0.5 SPMH
40
SP0250
IP 1802DB PK FLRB 0.5 SPHCM
SP0238
48 28 9 PD03_A 9 PD03_A
Rear View Mirror Under Mirror
& Rear Window Light
Heat Relay
35
IP2DRD_2 DRD2IP_2
Body Control Module BCM Under Mirror Light - Left Under Mirror Light - Right
D9013-0122b
SAIC-SV91 09/2017
Driver's Side Rear View Mirror Body Control Module BCM
Horizontal Vertical Horizontal Vertical Rear View

Regulating Regulating Regulating Regulating left Aisle Mirror
Horizontal Vertical Power Regulating
Ground Ground Regulating Regulating Supply Ground Backlight Switch
4 5 6 16 13 15 5 8 6 12 5 3
DD03_C DD03_A EB57_C IP01_D
DRD 7391AB WH FLRB 0.5 SPML
DRD 82L L-BU FLRB 0.5 SPML
DRD 89L L-GN FLRB 0.5 SPML
IP 1963 PK FLRB 0.5 SPHCM

DRD 82A L-BU FLRB 0.5 SPMH
DRD 89A L-GN FLRB 0.5 SPMH
DRD 7391AA WH FLRB 0.5 SPMH
DRD 784B D-GN FLRB 0.5 SPMH
DRD 786B GY FLRB 0.5 SPMH
DRD 788BA YE FLRB 0.5 SPMH

SP1217
DRD2BD

1 2 3 4 BD2DRD
27 31 39 DRD2IP_2
IP2DRD_2
PAD 6805 PK FLRB 0.5 SPMH
BD 675B L-GN FLRB 0.5 RMM

IP 7391D WH FLRB 0.5 SPM
IP 82C L-BU FLRB 0.5 SPM
IP 89C L-GN FLRB 0.5 SPM
IP 6159A D-GN/WH FLRB 0.5 RMM
BD2IP_3 57
IP 7196A WH FLRB 0.5 RMM
BD2IP_3 IP2BD_3
IP2BD_3
c
IP 6160A D-BU/WH FLRB 0.5 RMM
49 48 47
90 SP1304 SP1305
BD 6160 D-BU/WH FLRB 0.5 RMM
BD 7196 WH FLRB 0.5 RMM
BD 6159 D-GN/WH FLRB 0.5 RMM
d
BD 784 D-GN FLRB 0.5 RMM
BD 786 GY FLRB 0.5 RMM
PAD 6805 PK FLRB 0.5 SPMH
BD 788B YE FLRB 0.5 RMM
SP1306

SP1307
SP1308
IIP 82B L-BU FLRB 0.5 SPM&&-RMM
IP 89B L-GN FLRB 0.5 SPM&&-RMM
IP 7391A WH FLRB 0.5 SPM&&-RMM
C3 C2 C1 C9 C8 C7 C12 FL03
LeftRear Regulating left Rear Left Aisle Left Power Ground
View Mirror Motor View Sensor Aisle Supply
Vertical Ground Mirror Horizontal Sensor
Driver's Side Regulating Horizontal Vertical SP1206
motor Regulating
Power Seat
X-axis Y-axis
Ground Regulating Regulating
B2 B4 B5 FL03
IP2BD_5 BD2IP_5
SP1313 IP 88 YE FLRB 0.5 SPM&&RMM BD 88A YE FLRB 0.5 RMM
9
SP1312 IP 81 WH FLRB 0.5 SPM&&RMM BD 81A WH FLRB 0.5 RMM
8
SP1303 SP1207
IP 7391C WH FLRB 0.5 RMM BD 7391CA WH FLRB 0.5 RMM
50
IP2BD_3 BD2IP_3 IP 7391B WH FLRB 0.5 SPM&&-RMM
IP 82 L-BU FLRB 0.5 SPM
IP 89 L-GN FLRB 0.5 SPM
IP 7391 WH FLRB 0.5 SPM
e
IP 1382AC PU/WH FLRB 0.5 SPM
IP12
7 3 6 IP12 1 5
Folding
Backlight+
Left Left Left & Right

X-axis X/Y-axis X/Y-axis
Rear View Mirror / Regulating Switch

D9013-0123b
SAIC-SV91 09/2017
90
5-161
09/2017
PD03_C
D9013-0124b
PAD2IP
IP2PAD
SP1309
Regulating
SP1314
Horizontal
PAD 1498L BN/WH FLRB 0.5 SPML
Rear View Mirror Regulating Switch

IP 1498C BN/WH FLRB 0.5 SPM IP 1498B BN/WH FLRB 0.5 SPM&&-RMM IP 1498 BN/WH FLRB 0.5 SPM
X-axis
Right
44
4
4
SP1315
SP1310
SAIC-SV91
Ground
X/Y-axis
PAD 881L OG/WH FLRB 0.5 SPML IP 881C OG/WH FLRB 0.5 SPM IP 881B OG/WH FLRB 0.5 SPM&&-RMM IP 881 OG/WH FLRB 0.5 SPM
Right
45
5
2
Regulating
SP1311
Vertical
PAD 7391BB WH FLRB 0.5 SPML IP 7391E WH FLRB 0.5 SPM IP 7391B WH FLRB 0.5 SPM&&-RMM
43
6
IP 889 PU/WH FLRB 0.5 SPM&&RMM
IP 90 GY FLRB 0.5 SPM&&RMM

16 PD03_A
IP 6162A OG/BK FLRB 0.5 RMM

IP 6161A GY/BK FLRB 0.5 RMM
Backlight-
Regulating
Horizontal
9
IP 2451H BK/WH FLRB 0.5 SPM
PAD 1498A BN/WH FLRB 0.5 SPMH
IP12
Ground
BD2IP_5 IP2BD_5
PAD 881A OG/WH FLRB 0.5 SPMH
13
Regulating
Vertical
19
20
G_IPB2_1
PAD 7391BA WH FLRB 0.5 SPMH IP 2451SB BK/WH FLRB 0.75
15
SP2626
Passenger's Side Rear View Mirror
BD 889A PU/WH FLRB 0.5 RMM

Driver's Side
Power Seat
BD 90A GY FLRB 0.5 RMM

FL03
FL03
BD 6162 OG/BK FLRB 0.5 RMM
Vertical+
C5 C6
5
Right Seat Right Seat

X/Y-axis
B1
Horizontal-
B3
BD 6161 GY/BK FLRB 0.5 RMM
Y-axis
Vertical
PAD2IP
37 IP2PAD
Right
Seat
C4
3
Regulating Regulating
PAD 785B L-BU/BK FLRB 0.5 SPMH IP 785A L-BU/BK FLRB 0.5 RMM BD 785 L-BU/BK FLRB 0.5 RMM
Vertical
Vertical
Right
C11
Seat
5
7
Horizontal
PAD 787B BN FLRB 0.5 SPMH IP 787A BN FLRB 0.5 RMM BD 787 BN FLRB 0.5 RMM
Right Seat
Horizontal
38
C10
8
6
PAD 675CA L-GN FLRB 0.5 SPMH IP 675C L-GN FLRB 0.5 RMM BD 675 L-GN FLRB 0B.D5 6R7M5MA
Ground
12
36
2
PAD 788CA YE FLRB 0.5 SPMH
Supply
IP 788C YE FLRB 0.5 RMM BD 788A YE FLRB 0.5 RMM
Power
35
6
IP2BD_2 1
BD2IP_2
e
5.20 Rear view mirrors (RHD)
KL30
60 A
30 A
U-JF5
U-JF4
ACC
IG Power
Power
Supply
Supply
4 5
EB01
BD 342 RD FLRB 5.0

SP0257
BD 342E RD FLRB 5.0
SP0258 BD2IP_3
4 IP2BD_3
BD2IP_1 IP 342H RD FLRB 5.0

IP2BD_1 2
a
SP0230
90
IP07 69
58 43 41
85 30 Instrument
I-R3 10 A 85 30
I-R2 10 A
IG I-FS6 ACC
Panel Fuse
I-FS17
86 87
Relay IG 86 87
Relay ACC2
Box IEC
PWR4
6 42 29
IP07 60 68 18 45 37
IP 202 RD FLRB 3.0

IP 202A RD FLRB 3.0

IP 249 WH FLRB 0.35
SP0904 SP0202
SP0237
IP 642H RD/BK FLRB 0.5 SPM&&HALP
SP0240 SP2610
IP 249C WH FLRB 0.5
SP2626 SP0239
IP 202W RD/BK FLRB 0.5 SPM

SP0901
IP01_B 48 6 IP12 10 8 11
IG ACC Power Supply
Relay Relay Body Control KL15 Ground
Module BCM
G_IPB2_1
G_IPA2_1 Rear View Mirror Regulating Switch
D9013-0133b
SAIC-SV91 09/2017
90
5-163
09/2017
b
D9013-0134b
G_IPA2_3
IP2DAD_2 37
Driver's
DD03_A
DD03_A
Mirror
SP2630
View
Side
Rear
DRD2IP_2
DRD2BD
BD2DRD
SP2606
SAIC-SV91
11
DRD 6802 YE FLRB 0.5 SPMH BD 190A YE FLRB 0.5 SPHCM

+
2
5
IP2DRD_2
36 DRD2IP_2
DRD 6803 PK FLRB 0.5 SPMH BD 191A PK FLRB 0.5 SPHCM

-
10
1
SP0206
IP 502A RD/WH FLRB 0.5 SPHM DRD 502AL RD/WH FLRB 0.5 SPML
1
PAD2IP
26 IP2PAD
DD03_C
SP2604
G_IPA1_1
PAD 2350DB BK FLRB 0.5 SPMH PAD 2350DA BK FLRB 2.0 IP 2350D BK FLRB 2.0
PD03_A
PD03_A
IP2BD_1
BD2IP_1
PAD2IP
IP2PAD
EB57_E
SP1302

11
PAD 6805 PK FLRB 0.5 SPMH IP 191B PK FLRB 0.5 SPHCM BD 191 PK FLRB 0.5 SPHCM BD 191AB PK FLRB 0.5 SPHCM
-
Closing-up-
38
30
6
1
SP1301
7
IP2PAD
PAD2IP
PAD 6804 YE FLRB 0.5 SPMH IP 190B YE FLRB 0.5 SPHCM BD 190 YE FLRB 0.5 SPHCM BD 190AB YE FLRB 0.5 SPHCM
+
37
Closing-up+
29
10
2
46
SP2613
PD03_C 1
Gear Signal
Reverse
Passenger's Side
Rear View Mirror
IP 5219A OG/BK FLRB 0.5 PGAM IP 5219F OG/BK FLRB 0.5
36
RF2IP_1 8
IP01_B
IP2RF_1
Automatic Anti-glare Rear View Mirror

RF 5219AA OG/BK FLRB 0.5 PGAM Signal
3
IP2RF_1
RF2IP_1
IG PWR3
I-FS5
SP0213
IP07
10 A
+
IP 842 RD/BK FLRB 0.5 LDW||PGAM RF 842BB RD/BK FLRB 0.5 PGAM
17
10
1
-
2
SP2608
RF07
5
RF2IP_2
IP2RF_2
SP2646
G_IPB1_1
RF 2350RA BK FLRB 0.75 RF 2350RH BK FLRB 0.5 FSRF IP 2351RS BK/WH FLRB 1.5
13
a
KL30
Engine Panel
25 A 30 A 25 A
U-FS26 Fuse Box
U-FS2 U-FS10
Gateway IEC PWR3 Central UEC
Control Lock
14 22 38 51 EB01

b
SP0233 SP0256 BD2IP_2

BD2IP_1 12
3 IP2BD_1 IP 1802C RD/BK FLRB 0.5
BD2IP_2
SP0248
SP0231
IP 1802H RD/BK FLRB 0.5 SPHCM

90
96 100 90 106 110 IP07
85 30 I-R5 85 30
Instrument
10 A I-R7
Rear View I-FS34 Under Mirror
Panel
Mirror & Rear View Fuse Box
86 87 86 87 Light Relay
Rear Window Mirror Heat
Heat Relay IEC
94 99 82 104 109 IP07
IP 293 PU FLRB 1.5

IP 193 WH FLRB 0.35
IP 6767 WH/BK FLRB 0.35 SPHCM
IP 1802DA PK FLRB 0.5 SPHCM
IP2PAD PAD2IP
IP 1802DC PK FLRB 0.5 SPHCM
PAD 1802DCA PK FLRB 0.5 SPMH
40
SP0250
IP 1802DB PK FLRB 0.5 SPHCM
SP0238
48 28 9 PD03_A 9 PD03_A
Rear View Mirror Under Mirror
& Rear Window Light
Heat Relay
35
IP2DRD_2 DRD2IP_2
Body Control Module BCM Under Mirror Light - Left Under Mirror Light - Right
D9013-0135b
SAIC-SV91 09/2017
Driver's Side Rear View Mirror Body Control Module BCM
Horizontal Vertical Horizontal Vertical Rear View

Regulating Regulating Regulating Regulating Left Aisle
Mirror
Horizontal Vertical Power
Ground Ground Regulating
Regulating Regulating Supply Ground
Backlight Switch
4 5 6 PD03_C 16 13 15 5 8 6 12 PD03_A 5 3
EB57_C IP01_D
DRD 7391AB WH FLRB 0.5 SPML
DRD 82L L-BU FLRB 0.5 SPML
DRD 89L L-GN FLRB 0.5 SPML
DRD 82A L-BU FLRB 0.5 SPMH
DRD 89A L-GN FLRB 0.5 SPMH
DRD 7391AA WH FLRB 0.5 SPMH
DRD 784B D-GN FLRB 0.5 SPMH
DRD 786B GY FLRB 0.5 SPMH
DRD 788BA YE FLRB 0.5 SPMH
IP 1963 PK FLRB 0.5 SPHCM

SP1217
PAD2IP
37 38 35 36

IP2PAD
PAD2IP
IP 784A D-GN FLRB 0.5 RMM
IP 786A GY FLRB 0.5 RMM
IP 788B YE FLRB 0.5 RMM
IP 675B L-GN FLRB 0.5 RMM

44 45 43
IP2PAD
IP 7391D WH FLRB 0.5 SPM
IP 82C L-BU FLRB 0.5 SPM
IP 89C L-GN FLRB 0.5 SPM
IP 6159A D-GN/WH FLRB 0.5 RMM
BD2IP_3 57
BD2IP_6 IP2BD_6
IP2BD_3
IP 6160A D-BU/WH FLRB 0.5 RMM
22 21 20 23 24 25 26
BD 675A L-GN FLRB 0.5 RMM 90
BD 6160 D-BU/WH FLRB 0.5 RMM
BD 6159 D-GN/WH FLRB 0.5 RMM
BD 784 D-GN FLRB 0.5 RMM
BD 786 GY FLRB 0.5 RMM
c
SP1305
SP1306 BD 788A YE FLRB 0.5 RMM
d
SP1304

SP1307 BD 788 YE FLRB 0.5 RMM
SP1308 BD 675 L-GN FLRB 0.5 RMM

IIP 82B L-BU FLRB 0.5 SPM&&-RMM
IP 89B L-GN FLRB 0.5 SPM&&-RMM
IP 7391A WH FLRB 0.5 SPM&&-RMM
C3 C2 C1 C9 C8 C7 C12 FL03
Left Rear Regulating Left Rear Left Aisle Left Aisle Power Ground
View Mirror Motor View Mirror Sensor Sensor Supply
Vertical Ground Horizontal Horizontal Vertical
Regulating Regulating
Driver's Side Motor SP1206
Power Seat
X-axis Y-axis
Ground Regulating Regulating
B2 B4 B5 FL03
SP1313 IP 88 YE FLRB 0.5 SPM&&RMM BD 88A YE FLRB 0.5 RMM
52
SP1312 IP 81 WH FLRB 0.5 SPM&&RMM BD 81A WH FLRB 0.5 RMM
51
SP1303 IP 7391C WH FLRB 0.5 RMM BD 7391CA WH FLRB 0.5 RMM
50
SP1207
IP 82 L-BU FLRB 0.5 SPM
IP 89 L-GN FLRB 0.5 SPM
IP 7391 WH FLRB 0.5 SPM
IP2BD_3 BD2IP_3
IP 7391B WH FLRB 0.5 SPM&&-RMM
e
IP 1382AC PU/WH FLRB 0.5 SPM
7 3 6 IP12 IP12 1 5
Left Left Left & Right
Backlight+
Folding
X-axis X/Y-axis X/Y-axis
Rear View Mirror / Regulating Switch

D9013-0136b
SAIC-SV91 09/2017
Passenger Side's Rear View Mirror
Vertical Horizontal Vertical Horizontal

Regulating Regulating Regulating Regulating
Sower Horizontal Vertical
supply Ground Regulating Regulating Ground Ground
6 12 8 5 15 13 16 DD03_A 6 5 4 DD03_C
PAD 788CA YE FLRB 0.5 SPMH
PAD 675CA L-GN FLRB 0.5 SPMH
PAD 787B BN FLRB 0.5 SPMH
PAD 785B L-BU/BK FLRB 0.5 SPMH
PAD 7391BA WH FLRB 0.5 SPMH
PAD 881A OG/WH FLRB 0.5 SPMH
PAD 1498A BN/WH FLRB 0.5 SPMH
PAD 7391BB WH FLRB 0.5 SPML
PAD 881L OG/WH FLRB 0.5 SPML
PAD 1498L BN/WH FLRB 0.5 SPML

DRD2BD
3 4 2 1 BD2DRD
IP 788C YE FLRB 0.5 RMM
IP 675C L-GN FLRB 0.5 RMM
DRD2IP_2
39 31 27 IP2DRD_2
IP 7391E WH FLRB 0.5 SPM
IP 881C OG/WH FLRB 0.5 SPM
IP 1498C BN/WH FLRB 0.5 SPM

49 48 47 IP2BD_3
90 BD2IP_3
BD 787 BN FLRB 0.5 RMM
BD 785 L-BU/BK FLRB 0.5 RMM
BD 6161 GY/BK FLRB 0.5 RMM
BD 6162 OG/BK FLRB 0.5 RMM
c IP 6161A GY/BK FLRB 0.5 RMM

SP1309
d IP 7197A WH FLRB 0.5 RMM
SP1310
IP 6162A OG/BK FLRB 0.5 RMM
SP1311
IP 7391B WH FLRB 0.5 SPM&&-RMM
IP 881B OG/WH FLRB 0.5 SPM&&-RMM
IP 1498B BN/WH FLRB 0.5 SPM&&-RMM

C10 C11 C4 C5 C6 FL03
Right Seat Right Seat Right Seat
Horizontal-
Vertical+
Horizontal Vertical Vertical

Driver's Side
Right Seat Right Seat
Power Seat
Y-axis X/Y-axis
B3 B1 FL03
BD 889A PU/WH FLRB 0.5 RMM IP 889 PU/WH FLRB 0.5 SPM&&RMM
53 SP1315
BD 90A GY FLRB 0.5 RMM IP 90 GY FLRB 0.5 SPM&&RMM
54 SP1314
BD2IP_3 IP2BD_3
IP 881 OG/WH FLRB 0.5 SPM
IP 1498 BN/WH FLRB 0.5 SPM
SP2626 IP 2451H BK/WH FLRB 0.5 SPM

IP12 9 2 4
Backlight- Right Right
X/Y-axis X-axis
G_IPB2_1 Rear View Mirror Regulating Switch

D9013-0137b
SAIC-SV91 09/2017
5.21 Parking aid system
Engine Bay Fuse Box

Engine Bay Fuse Box 2 UEC_2 Blind Zone Monitor And Control Unit
UEC
KL30
85 30
30 A U2-R4 10 A
U-JF4 IG U2-FS15
IG Power 87 IG Power APA
Relay 86
Power CTRL Right Rear
Supply Supply 3 Supply Ground SW View Mirror
4 17 19 21 18 45 46 EB58 16 27 13
EB01 32 FL71


BD 5247 GY FLRB 0.5 BSD||APA

BD 2373B GY FLRB 0.5 APA

BD 1451F BK/WH FLRB 0.5 PDC4
BD 642BF RD/BK FLRB 0.5 PDC4
SP0264 SP0249 BD2IP_4
SP0257
SP2635 IP2BD_4 B5 B8
IP 5248A GY FLRB 0.5 BSD||APA

IP 2373A GY FLRB 0.5 APA
SP2636
BD2IP_1
4
IP2BD_1
90
IP2CN_2
CN2IP_2 22
42 IP2PAD
CN 2373 GY FLRB 0.5 APA

PAD2IP
PAD 5248B GY FLRB 0.5 SPMH

10 PD03_A
BSD LED+
Right Rear
SP0904 View Mirror
-
4 PD03_A
IP 249C WH FLRB 0.5
PAD 2350DE BK FLRB 0.5 SPMH
PAD2IP
26 IP2PAD

48 IP01_B 11 CN06 SP2604

IG
Relay
Body APA IN
Control
Module
G_EBL2_4 BCM G_FLR2_1 Central Control G_IPA1_1
Switch Block - Right D9013-0071b
SAIC-SV91 09/2017
D9013-0072b
BD2IP_2
IP2BD_2
FL02_A
SP1847
BD 6105 D-BU FLRB 0.35 BD 6105AB D-BU FLRB 0.35 IP 6105A D-BU FLRB 0.35
CAN_H
Gateway
3
SP1848
FL71
BD 6106 L-GN FLRB 0.35 BD 6106AB L-GN FLRB 0.35 IP 6106A L-GN FLRB 0.35
CAN_L
12
4
BD2IP_6
IP2BD_6
SP1814
SP1816
SP1812
SP1810
BD 6106FA L-GN FLRB 0.35 PDC4 BD 6106E L-GN FLRB 0.35 BD 6106D L-GN FLRB 0.5 IP 6106C L-GN FLRB 0.5 IP 6106B L-GN FLRB 0.35
CAN_L
25
6
SP1813
SP1815
SP1811
SP1809
Blind Zone Monitor And Control Unit
BD 6105FA D-BU FLRB 0.35 PDC4 BD 6105E D-BU FLRB 0.35 BD 6105D D-BU FLRB 0.5 IP 6105C D-BU FLRB 0.5 IP 6105B D-BU FLRB 0.35
CAN_H
5
9
Module
Control
Body
BCM
36 IP01_B
SP0612
SP0613
BD 5219DA OG/BK FLRB 0.5 PDC4||PDC6 BD 5219 OG/BK FLRB 0.5 IP 5219CB OG/BK FLRB 0.5
Reversing
Reversing
IP 5219F OG/BK FLRB 0.5
Signal
Signal
29
8
5-168
BD2IP_2
IP2BD_2
DRD2IP_2
37 IP2DRD_2
G_IPB2_3
View Mirror
Left Rear
SP2630
DRD2BD
DD03_A
DD03_A
6 BD2DRD
2251DA BK/WH FLRB 1.0
SP2606
View Mirror
Left Rear
BSD LED+
BD 5248 YE FLRB 0.5 BSD||APA DRD 5247B YE FLRB 0.5 SPMHH DRD 2250DE BK/WH FLRB 0.5 SPMH
-
11
10
09/2017
SAIC-SV91
90
90
5-169
09/2017
FL71
D9013-0073b
SP1602
BD 5214A BN FLRB 0.5 PDC6
Ground
Sensor
17
Blind Spot Monitor - Front Left Middle

EB51
SAIC-SV91
BD 5214G BN FLRB 0.5 BSD
EB51
GND
3
Front Left Middle
Output
Signal
Sensor Signal
BD 5215 PU/WH FLRB 0.5 BSD

2
Supply
Power
1 BD 6581G PK FLRB 0.5 BSD

Blind Spot Monitor - Front Left
EB53
BD 5214F BN FLRB 0.5 PDC6
EB53
GND
3
Output
Signal
Sensor Signal
BD 5213D D-GN FLRB 0.5 PDC6

Front Left
Supply
Power
BD 6581F PK FLRB 0.5 PDC6
1
Blind Spot Monitor - Front Left Backside
EB55
BD 5214E BN FLRB 0.5 APA
EB55
GND
Front Left Backside
3
Sensor Signal
Output
Signal
BD 5216 WH FLRB 0.5 APA
4
Supply
Power
BD 6581E PK FLRB 0.5 APA
1
Blind Spot Monitor - Front Right Backside
EB56
BD 5214D BN FLRB 0.5 APA
EB56
GND
Front Right Backside
3
Output
Signal
Sensor Signal
BD 5218 YE FLRB 0.5 APA

20
Supply
Power
BD 6581D PK FLRB 0.5 APA
EB54 1
Blind Spot Monitor - Front Right
BD 5214C BN FLRB 0.5 PDC6
EB54
GND
3
Output
Signal
Sensor Signal
BD 5213C OG FLRB 0.5 PDC6

Front Right
19
Supply
Power
BD 6781C PK FLRB 0.5 PDC6
EB52 1
Blind Spot Monitor - Front Right Middle
BD 5214B BN FLRB 0.5 BSD
EB52
GND
Front Right Middle
3
Sensor Signal
Output
Signal
BD 5217 GY FLRB 0.5 BSD
18
Supply
Power
BD 6581B PK FLRB 0.5 BSD
SP1601
BD 6581A PK FLRB 0.5 PDC6
Sensor
Supply
Power
1
PR2FL
FLD2FLC
FLC2FLD
FL2PR
D9013-0074b
FL71
SP1604
PR 5976B BN FLRB 0.5 PDC4
Ground
Sensor
BD 5976AB BN FLRB 0.5 PDC4&&HPB BD 5976A BN FLRB 0.5 PDC4&&HPB

21
25
Blind Zone Monitor - Rear Right Middle
PR05
BD 5976 BN FLRB 0.5 PDC4&&EPB
PR05
GND PR 5976H BN FLRB 0.5 APA
FLB2FLA
FLA2FLB
3
Rear Left Middle
Output
Signal
Sensor Signal
PR 5972F D-GN FLRB 0.5 APA

8
6
Supply
Power
BD 5972L D-GN FLRB 0.5 APA BD 5972D D-GN FLRB 0.5 APA
PR 5974H PK FLRB 0.5 APA
15
FLD2FLC
FLC2FLD
1
Blind Zone Monitor - Rear Right
PR07
BD 5973KA WH FLRB 0.5 PDC4&&HPB BD 5973K WH FLRB 0.5 PDC4&&HPB
PR07
GND PR 5976G BN FLRB 0.5 PDC4
24
3
Output
Signal
Sensor Signal
BD 5973D WH FLRB 0.5 PDC4&&EPB PR 5973F WH FLRB 0.5 PDC4

Rear Left
7
7
Supply
Power
PR 5974G PK FLRB 0.5 PDC4
FLD2FLC
FLC2FLD
1
Blind Zone Monitor - Rear Right Backside
PR09
BD 5977AB D-BU FLRB 0.5 PDC4&&HPB BD 5077A D-BU FLRB 0.5 PDC4&&HPB
23
PR09
GND PR 5976F BN FLRB 0.5 PDC4
Rear Left Backside
3
Output
Sensor Signal
Signal
BD 5977 D-BU FLRB 0.5 PDC4&&EPB PR 5977B D-BU FLRB 0.5 PDC4
6
8
Supply
Power
PR 5974F PK FLRB 0.5 PDC4
FLD2FLC
FLC2FLD
1
PR10
BD 5975AB YE FLRB 0.5 PDC4&&HPB BD 5975A YE FLRB 0.5 PDC4&&HPB
Blind Zone Monitor -Rear Left Backside
22
PR10
GND PR 5976E BN FLRB 0.5 PDC4
Rear Right Backside
3
Output
Signal
Sensor Signal
BD 5975 YE FLRB 0.5 PDC4&&EPB PR 5975B YE FLRB 0.5 PDC4

24
2
4
Supply
Power
5-170
PR 5974E PK FLRB 0.5 PDC4
FLD2FLC
FLC2FLD
PR08 1
BD 5973AB OG FLRB 0.5 PDC4&&HPB
Blind Zone Monitor - Rear Left
BD 5973A OG FLRB 0.5 PDC4&&HPB
21
PR08
GND PR 5976D BN FLRB 0.5 PDC4
3
Output
Signal
Sensor Signal
PR 5973B OG FLRB 0.5 PDC4

Rear Right
BD 5973 OG FLRB 0.5 PDC4&&EPB
23
2
3
Supply
Power
PR 5974D PK FLRB 0.5 PDC4
PR06 1
12 FLB2FLA
FLA2FLB
09/2017
Blind Zone Monitor - Rear Left Middle
BD 5217 GY FLRB 0.5 BSD BD 5972 GY FLRB 0.5 APA PR 5976C BN FLRB 0.5 APA
PR06
GND
Rear Right Middle
3
Sensor Signal
Output
Signal
PR 5972B GY FLRB 0.5 APA
15 FLD2FLC
FLC2FLD
22
2
2
Supply
Power
PR 5974C PK FLRB 0.5 APA
SAIC-SV91
1
BD 5974AB PK FLRB 0.5 PDC4&&HPB BD 5974A PK FLRB 0.5 PDC4&&HPB
SP1603
BD 5974 PK FLRB 0.5 PDC4&&EPB PR 5974B PK FLRB 0.5 PDC4
Sensor
Supply
Power
1
5
90
5.22 Body control system

KL30
30 A 30 A
30 A 10 A 15 A 25 A
U-FS10 25 A U-FS25 10 A U-FS16
U-JF4 Rear View U-FS34 U-FS33
IEC U-FS26 U-FS27 IEC
IG Power Mirror Close-up / Washer /
Exterior
Power Central Lock Tail Door /Fuel Interior Light Power Rear
Supply Light
Supply 3 Tank Cap Supply 4 Wiper
4 22 39 37 38 51 52 50 28 61 63 64 62
EB01




BD 1742 RD/BK FLRB 1.5 AT
BD 1742C RD/BK FLRB 1.5 6MT-DYMOS||6MT-SAGW

SP0257 SP0256
SP0209
SP0233 SP0241

BD 1642A RD/BK FLRB 0.5 SPHCM

SP0207
BD 1742A RD/BK FLRB 1.5 AT
BD 1742B RD/BK FLRB 1.5 AT
SP0208
BD2IP_1


IP2BD_1 2
90
Instrument Panel
Fuse Box EB57_E EB57_C
EB57_C
58 69 IP07 IEC EB57_E 7 15 8 1 EB57_C 6
14 2 17 3
KL30 KL30 KL30 KL30 KL30 KL30 KL30 KL30 KL30
85 30
Body P-gear CDL Fuel Tank Rear View Interior Rear
Washer
Front Rear Turn
I-R3 10 A Release Cap Mirror Light Washer Wiper Signal
IG I-FS2
Control Motor Close-up Pump Pump Light
86 87
Relay IG Module Fuel
Tank
Rear View
Mirror P-gear Washer Rear
PWR 1 BCM IG
Relay
Signal
Ground
Cap
Ground
Close-up Release
Ground Motor Ground
Signal
Ground
Signal
Ground
Pump
Ground
Wiper
Ground
60 68 2 14 IP07 8 48 21 4 3 7 9 8 19 EB57_C
IP01_B EB57_C EB57_E EB57_C

BD 2450BF BK FLRB 0.75

IP 249 WH FLRB 0.35
IP 249C WH FLRB 0.5

IP 340AC RD/D-GN FLRB 2.5
BD 2450BD BK FLRB 0.75

BD 2450BE BK FLRB 0.5 SPHCM
BD 2450BG BK FLRB 0.75 AT
BD 2450BB BK FLRB 2.5
BD 2450BC BK FLRB 2.5

BD 2450BH BK FLRB 0.5
SP0210
SP0240 SP2640
SP0904
SP2609
SP2626
BD 2450BK BK FLRB 3.0
BD 2450BP BK FLRB 1.0
BD 51 BK FLRB 2.5
G_EBR3 G_FLR1_4 G_FLR2_3

D9013-0114b
SAIC-SV91 09/2017
IP01_A
D9013-0115b
Ground
IP 2451BA BK/WH FLRB 0.5

Signal
G_IPB2_1
Ground
Signal
IP 2451BB BK/WH FLRB 0.5 IP 2451SA BK/WH FLRB 0.75

8
SP2610
IP01_B
G_FLR1_3
BD 2450BA BK FLRB 2.5
Ground
22
EB57_C
Power Window Lifter

DD08
Driver's Side
IP 6133B D-BU FLRB 0.35 DRD 6133BA D-BU FLRB 0.35
LIN
IP2DRD_2 28
6
5-172
DRD2IP_2
RF08_2
RF 6133AE D-BU FLRB 0.35 RLS&&LDW
Rainfall Sensor
LIN
2
2 RF08_1
LIN
09/2017
RF2IP_1
IP2RF_1
RF14
Panoramic
Sunroof
IP 6133 D-BU FLRB 0.35 IP 6133A D-BU FLRB 0.5 PSRF||RLS RF 6133AA D-BU FLRB 0.5 PSRF||RLS RF 6133AB D-BU FLRB 0.35 PSRF
LIN
LIN
46
5
SP0902
SP0903
SAIC-SV91
IP01_B
90
90
5-173
09/2017
IP2BD_4
BD2IP_4
D9013-0037b
SP2618
G_FLCL_2
IP 140F RD/WH FLRB 0.75 PEPS BD 140FA RD/WH FLRB 0.75 PEPS||SSTG BD 1551 BK/WH FLRB 0.5
12
SAIC-SV91
FL2PR
FR2FL
PR11
Steering Column Lock Sensor

PEPS Control Unit PEPS
BD 1551C BK/WH FLRB 0.5 SSTG PR 1551CBA BK/WH FLRB 0.5 SSTG
Ground
16
3
21 IP2BD_3
BD2IP_3
Steering Angle
IP 1398C YE FLRB
0.5 SSTG&&PEPS BD 1398B YE FLRB 0.5 SSTG PR 1398 YE FLRB 0.5 SSTG
Output
15
6
4
SP0255
BD 140D RD/WH FLRB 0.75 SSTG PR 140DC RD/WH FLRB 0.75 SSTG
Supply
Power
14
1
FL28
IP09_A
Ignition
10/15 A
I-FS14
Switch
IP07
BD 140E RD/WH FLRB 0.75 PEPS

1
FLA2FLB
IP 140 RD/WH FLRB 0.75 PEPS IP 140B RD/WH FLRB 0.75 PEPS
FLB2FLA
BD2IP_4
C4 IP2BD_4
KL30
39
1
SP0204
PEPS Control
FR Receiver
IP 344A GY FLRB0.5 PEPS BD 344AB GY FLRB 0.5 PEPS&&EPB BD 344 GY FLRB 0.5 PEPS&&EPB
I-FS4
15 A
Unit
RF
19
RF Receiver
18
2
5.23 Passive entry passive start system
IP 140C RD FLRB 0.75 PEPS
KL30
IP09_A
16
FLC2FLD
2
18 FLD2FLC
IP 2540F RD/L-GN FLRB 2.5 PEPS&&(12-SCRN||TBOX) BD 344CB GY FLRB 0.5 PEPS&&HPB BD 344C GY FLRB 0.5 PEPS&&HPB
4
BD 1151P RD/WH FLRB 0.75 PEPS
Ground
IP 2540D RD/L-GN FLRB 2.5 12-SCRN||TBOX
3
26
SP0242
SP2624
IP 2540E RD/L-GN FLRB 2.5 RADIO
G_FLL2
IP09_A
1151 BK/WH FLRB 1.0
Engine Bay Fuse
BD2IP_1
IP2BD_1
IEC RWR2
IP 2351PB BK FLRB 0.75 PEPS
U-FS15
Ground
27 EB01
30 A
Box UEC
15
SP2617
12
G_IPA2_1
IP 2351PA BK FLRB 0.75 PEPS IP 2351 BK/WH FLRB 1.5
Ground
KL30
14
D9013-0166b
RF 6645C BN/WH FLRB 0.5 PEPS&&NSRF
+
2
Control
PEPS
PEPS
Unit
IP2CN_2
CN2IP_2
RF 6652C WH FLRB 0.5 PEPS&&NSRF
-
IP09_A
1
RF15_3
IP 483 L-GN FLRB 0.5 PEPS
Theftproof Base Station
CN 483A L-GN FLRB 0.5 PEPS

Ground
25
3
21
Ground
Antenna - Roof
Radio - Roof
IP 6645 BN/WH FLRB 0.5 PEPS RF 6645B BN/WH FLRB 0.5 PEPS&&PSRF
+
2
6
2
LIN
CN 220A D-GN FLRB 0.5 PEPS IP 220 D-GN FLRB 0.5 PEPS
LIN
2
12
16
Radio - Roof
IP 6652 WH FLRB 0.5 PEPS RF 6652B WH FLRB 0.5 PEPS&&PSRF
Supply
Power
-
Power Supply
12
1
CN 229A D-BU FLRB 0.5 PEPS IP 229 D-BU FLRB 0.5 PEPS
RF15_2
15
1
24
IP09_C
RF2IP_2
IP2RF_2
CN07
RF 6645A BN/WH FLRB 0.5 PEPS&&FSRF
+
2
IP09_B
RF 6652A WH FLRB 0.5 PEPS&&FSRF
IP20
-
1
Start Switch
One-button One-button
RF15_1
IP 3558 D-GN/BK FLRB 0.35PEPS
4
4
+
IP09_B
Switch Ground
IP 3559 BK/GY FLRB 0.35PEPS
-
Start
13
5
BD 1166AA D-BU FLRB 0.5 PEPS
RUN
SSB_
LED1
5
IP 5719 D-BU/BK FLRB 0.35PEPS
SSB_
LED1
10
2
One-button Start Switch
5-174
SSB_
LED2
IP 5720 BN/BK FLRB 0.35PEPS BD 218AA PU FLRB 0.5 PEPS
SSB_
LED2
ACC
4
1
3
IP01_A
Start Switch
IP 5723 YE FLRB 0.35 PEPS
One-button
38
6
Module BCM
Body Control
IP01_B
ACC
7
Lighting
IP 6817 D-BU/BN FLRB 0.5 PEPS
Back
IP01_B
51
1
09/2017
Ground
Switch
IP 1349H BN FLRB 0.35 PEPS IP 1349 BN FLRB 0.35
Light
RUN
25
4
7
SP2634
IP01_A
SP2634
SP2643
G_IPM1_1
IP 751G BK/WH FLRB 0.35PEPS IP 751S BK/WH FLRB 0.75 IP 751W BK/WH FLRB 1.0
SAIC-SV91
8
90
90
5-175
09/2017
D9013-0038b
IP09_A
Gear Lever
IP59
P-gear Signal
IP 233 OG/BK FLRB 0.5 AT && PEPS
Signal
P-gear
SAIC-SV91
3
3
Antenna - Front
CN 5713A PK/WH FLRB 0.5 PEPS
Radio -
IP 5713 PK/WH FLRB 0.5 PEPS
Front
10
18
4
Radio -
CN 5709A PK FLRB 0.5 PEPS IP 5709 PK FLRB 0.5 PEPS
Front
26
17
4
CN08
IP2CN_2
CN2IP_2
Antenna - Middle
IP 5712 OG/BK FLRB 0.5 PEPS
Radio -
Middle
-
8
2
IP 5708 OG FLRB 0.5 PEPS
Radio -
Middle
+
2
1
PEPS Control Unit

FLC2FLD
FLD2FLC
IP10
BD 5714AA YE/BK FLRB 0.5 PEPS&&HPB BD 5714DA YE/BK FLRB 0.5 PEPS&&HPB
17
BD 5710AA YE FLRB 0.5 PEPS&&HPB BD 5710DA YE FLRB 0.5 PEPS&&HPB
16
Antenna - Rear
PR 5714C YE/BK FLRB 0.5 PEPS BD 5714A YE/BK FLRB 0.5 PEPS&&EPB BD 5714D YE/BK FLRB 0.5 PEPS&&EPB IP 5714 YE/BK FLRB 0.5 PEPS
Radio -
Rear
-
C3
11
18
17
1
Radio -
Rear
PR 5710C YE FLRB 0.5 PEPS BD 5710A YE FLRB 0.5 PEPS&&EPB BD 5710D YE FLRB 0.5 PEPS&&EPB IP 5710 YE FLRB 0.5 PEPS
C2
17
16
5
2
BD2IP_4
IP2BD_4
FLA2FLB
FLB2FLA
PR2FL
FL2PR
PR15
IP09-B
SP2617
D9013-0039b
G_IPA2-1
27
FL28
SP2607
PAD 2351DA BK/WH FLRB 0.5 PAD 2351DE BK/WH FLRB 0.5 PEPS
2
IP09-C
Driver's Side Door Handle

Passenger's
Side Door
Antenna
IP 5711 L-GN/BK FLRB 0.5 PEPS PAD 5711A L-GN/BK FLRB 0.5 PEPS
Handle
-
9
22
4
Passenger's
IP 5707 L-GN FLRB 0.5 PEPS PAD 5707A L-GN FLRB 0.5 PEPS
Side Door
Antenna
+
Handle
21
3
3
IP09-A
PEPS Control Unit
Passenger's Side
Door Switch
IP 1167 GY FLRB 0.5 PEPS PAD 1167A GY FLRB 0.5 PEPS

17
23
1
PAD2IP
IP2PAD
BD2DRD
DRD2BD
IP2BD-4
BD2IP-4
DD01
Door Switch
Driver's Side
IP 1166 D-BU FLRB 0.5 PEPS BD 1166AA D-BU FLRB 0.5 PEPS DRD 1166A D-BU FLRB 0.5 PEPS
D5
14
Driver's Side Door Handle

5-176
Driver's Side
Door Handle
BD 218AA PU FLRB 0.5 PEPS DRD 218A PU FLRB 0.5 PEPS

Antenna
IP 218 PU FLRB 0.5 PEPS
+
D3
8
1
3
Driver's Side
Door Handle
Antenna
IP 219 BN FLRB 0.5 PEPS BD 219AA BN FLRB 0.5 PEPS DRD 219A BN FLRB 0.5 PEPS
-
D4
7
09/2017
DRD 2251DA BK/WH FLRB 1.0 DRD 2251DE BK/WH FLRB 0.5 PEPS
IP09-C
2
SP2606
G_IPB2-3
SAIC-SV91
37
SP2630
DRD2IP_2
IP2DRD_2
90
90
5-177
09/2017
Horn - Right
D9013-0033b
EB32
EB32
BD 1329AC D-GN FLRB 1.0 BD 550HB BK FLRB 1.0

1
2
SAIC-SV91
Horn - Left
EB31
SP0211
EB31
SP2638
G_EBR1
Relay
Horn
U-R3
BD 1329AB D-GN FLRB 1.0 BD 550HA BK FLRB 1.0 BD 550H BK FLRB 1.5
1
2
BD 1329AA D-GN FLRB 1.0
30
87
132
SP2616
SP2630
G_IPB2_3
BD2IP_3
5 IP2BD_3
IP 2251H BK/WH FLRB 0.5 IP 2251S BK/WH FLRB 0.75 IP 2251 BK/WH FLRB 1.5
BD 28 TN FLRB 0.35 IP 28BA TN FLRB 0.35
129
Horn
85
86
Horn Switch
1
1
1
IP 28B TN FLRB 0.5
Horn
2
+
2
2
SP0212
IP50_A
IP01_B
Spring
Clock
130
IP 28A TN FLRB 0.35
Relay
Horn
42
BD 1329A D-GN FLRB 1.0 SP0232
128
U-PS22
Horn
20A
Engine Bay Fuse Box

55

IP07
5.24 Theft security system (LHD)
PWR1
I-FS2
10 A
IG
IEC
IP 1442 RD/BK FLRB 0.5 IP 1442D RD/BK FLRB 0.5 -PEPS
14
SP0210
SP0244
BD 3040B YE/BK FLRB 2.0
34
Supply 8
U-FS12
2
Power
25 A
IEC
SP0240
Relay
I-R3
IG
IP07
24
IP 340A RD/WH FLRB 2.5 IP 340AA RD/D-GN FLRB 2.5
68
30
86
2
Power Supply
BD2IP_1
IP2BD_1
SP0904
U-JF4
SP0257
30 A
IG
IP 249 WH FLRB 0.35 IP 249C WH FLRB 0.5
Relay
87
85
60
IG
48
1
BD 340 RD/WH FLRB 2.5 BD 340D RD/WH FLRB 2.5
SP2626
4
G_GBR3
KL30
EB01
D9013-0034b
EB57_C
FL32
FL32
G_IPB2_3
Filler Cap
BD 93A WH FLRB 0.5 BD 1550CC BK FLRB 0.5

Motor
11
1
2
Engine Hood
Control
Switch
Engine
Module
ECM
Actuator
Filler
EB02_A
Cap
EN2EB
EB2EN
EB48
IP01_A
EB48
Engine Hood
IP 1349F BN FLRB 0.35 ESSS BD 109 PK FLRB 0.35AT
Lighting
IP 1349 BN FLRB 0.35 BD 1349J BN FLRB 0.35 ESSS

Ground
Switch
Switch
B
31
A
25
2
9
Ground
ECM
SP0611
Engine Hood
BCM
IP 5531A PU FLRB 0.35 AT BD 5531 PU FLRB 0.35 AT
Switch
+
C
5
IP2BD_1 30
IP2DRD_2
DRD2IP_2
IP01_B
BD2IP_1
G_IPB2_3
37
SP2630
SP2606
DD10
DRD 2251DK BK/WH FLRB 0.5 DRD 2251DD BK/WH FLRB 0.5
1
Ground
SP2603
Fuel Tank Cap Switch

IP2DRD_2
DRD2IP_2
DRD 2251DH BK/WH FLRB 0.5
-
IP01_B
3
Fuel Tank Cap
IP 1447A PK/WH FLRB 0.5 DRD 1447 PK/WH FLRB 0.5

Switch
+
32
40
4
LED+
DRD 1382DB PU/WH FLRB 0.5
5-178
2
DRD 1382DA PU/WH FLRB 0.5
BD2IP_3
IPIBD_3
EB57_C
SP1211
Back Lighting
BD 1382 PU/WH FLRB 0.5 BD 1382E PU/WH FLRB 0.5 IP 1382EA PU/WH FLRB 0.5 IP 1382D PU/WH FLRB 0.5
57
IP2DRD_2 29
5
SP1217
SP1206
DRD2IP_2
Anti-theft
Module
Control
09/2017
IP01_A
IP16
IP16
G_IPA2_1
Ignition Switch
Back Light
IP 7561 L-BU FLRB 0.5 -PEPS IP 2451BC BK/WH FLRB 0.5 -PEPS IP 2451SA BK/WH FLRB 0.75
Contorl
Power Supply Ground

LED
51
2
4
SP2610
SAIC-SV91
IP 7560 D-GN FLRB 0.5 -PEPS IP 1442D RD/BK FLRB 0.5 -PEPS
34
LIN
LIN
1
3
IP01_B
a
90
Driver's Side Door Lock / Unlock Driver's Side Door Door Lock Motor + Passenger's Side Passenger's Side
Ajar Switch Lock Motor Door Lock Motor - Door Ajar Door Lock
IP01_B 39 3 12 18 EB57_C EB57_C 20 27 4 IP01_B

IP 745A GY/BK FLRB 0.5
IP 780A PK/BK FLRB 0.5
BD 295HB L-GN FLRB 1.0
BD 294 TN FLRB 1.0
BD 295 GY FLRB 1.0

BD 294CA TN FLRB 1.0
b
BD 294DA TN FLRB 1.0
SP1001 c
BD 294BB TN FLRB 1.0
BD 294A TN FLRB 1.0
BD 295CA GY FLRB 1.0

SP1002 d
BD 295DA GY FLRB 1.0
e
BD 295BB GY FLRB 1.0

BD2IP_1
IP 746A BN/OG FLRB 0.5
IP 244A L-BU FLRB 0.5 PEPS

31 30 IP2BD_1
BD2IP_2
16 17
IP2BD_2
IP 295H L-GN FLRB 1.0
IP 294AB TN FLRB 1.0
90
IP 294B TN FLRB 1.0
IP 295B GY FLRB 1.0
DRD2IP_2 PAD2IP
IP2DRD_1 12 13 20 11 37 IP2DAD_2 11 20 12 13 27 IP2PAD
IP2PAD
DRD2IP_1 PAD2IP

PAD 294BA TN FLRB 1.0
PAD 295BA GY FLRB 1.0
PAD 746 BN/OG FLRB 0.5
PAD 244 BN FLRB 0.5 PEPS

DRD 745 GY/BK FLRB 0.5
DRD 780 PK/BK FLRB 0.5
DRD 295HA L-GN FLRB 1.0
DRD 294AA TN FLRB 1.0
DD04-A DD04-B DD04-A

D B B A PD04_A D C B A PD04_B
+ - - + + - - +
Door Door Door Door
Ajar Lock Ajar Lock
Switch Switch SP2606 SP2630 Switch Switch
SP2617
C F A B
DD04-A DD04-B Driver's Side Passenger's Side Door Lock PD04_A PD04_B
Door Lock
PAD 2351DC BK/WH FLRB 0.5 PEPS

PAD 2351DA BK/WH FLRB 0.5
DRD 2251DK BK/WH FLRB 0.5
PAD 2351DB BK/WH FLRB 0.5

DRD 2251DB BK/WH FLRB 0.5
DRD 2251DC BK/WH FLRB 0.5
G_IPB2_1
SP2603 G_IPA2_3
SP2607 D9013-0035b
SAIC-SV91 09/2017
G_FLDL1_1
D9013-0036b
BD 1750TP BK FLRB 2.0 BD 1750 BK FLRB 3.0
SP2629
14
16 EB57_C
Door
Lock
Tail
SP2404
SP2601
Tail Door
TLD 5790A D-BU/WH FLRB 0.75

Motor
BD 294EA TN FLRB 1.0 MNTG BD 5790B D-BU/WH FLRB 0.75 TLD 1750TB BK FLRB 0.75
-
16
2
SP2403
Not Close
Ajar Switch
Tail Door
IP 744AB OG/BK FLRB 0.5 BD 744A OG/BK FLRB 0.5 MNTG BD 1303B PK/BK FLRB 0.5 TLD 1303A PK/BK FLRB 0.5 TLD 2051TB BK FLRB 0.5
3
15
19
SP2612
TLD10
TLD10
IP2BD_3
BD2IP_3
TLD 2051TS BK FLRB 0.5
TLD2FL-1 13
FL2TLD-1
SP2613
G_FLDL2
BD 2051T BK FLRB 0.5 BD 2051 BK FLRB 0.75
IP2BD_2
BD2IP_2
FL2RRD
RRD2FL
RLD2FL
FL2RLD
SP2622
RR02
Rear Right Door
Not Close
IP 748B L-GN/BK FLRB 0.5 BD 748A L-GN/BK FLRB 0.5 RRD 748 L-GN/BK FLRB 0.5 Ajar Switch RRD 1551DB BK/WH FLRB 0.5 RRD 1551DA BK/WH FLRB 0.5
37
C
2
1
3
Rear Right Door Lock

+
BD 294DA TN FLRB 1.0 RRD 294DB TN FLRB 1.0 BD 1551DS BK/WH FLRB 0.5
12
SP2618
5-180
G_FLCL_2
BD 295DA GY FLRB 1.0 RRD 295DB GY FLRB 1.0 BD 1551 BK/WH FLRB 0.5
-
B
5
RR02
IP2BD_3
BD2IP_3
FL2RLD
RLD2FL
SP2623
RL02
RL02
Rear Left Door
Not Close
IP 747B L-BU/BK FLRB 0.5
BD 747A L-BU/BK FLRB 0.5 RLD 747 L-BU/BK FLRB 0.5 Ajar Switch RRD 1651DB BK/WH FLRB 0.5 RRD 1651DA BK/WH FLRB 0.5
B
1
3
6
09/2017
IP01_B
Rear Left Door Lock

+
RRD2FL
FL2RRD
RLD 294CB TN FLRB 1.0
D
5
G_FLCR_1
BD 1651DS BK/WH FLRB 0.5 MDACIIADAC
1
BD 295CA GY FLRB 1.0 RLD 295CB GY FLRB 1.0
SAIC-SV91
C
12
d
b
e
c
90
90
5-181
09/2017
Horn - Right
D9013-0116b
EB32
EB32
BD 1329AC D-GN FLRB 1.0 BD 550HB BK FLRB 1.0

1
2
SAIC-SV91
Horn - Left
EB31
SP0211
EB31
SP2638
G_EBR1
Relay
U-R3
Horn
BD 1329AB D-GN FLRB 1.0 BD 550HA BK FLRB 1.0 BD 550H BK FLRB 1.5
1
2
BD 1329AA D-GN FLRB 1.0
30
87
132
SP2616
SP2630
G_IPB2_3
BD2IP_3
5 IP2BD_3
IP 2251H BK/WH FLRB 0.5 IP 2251S BK/WH FLRB 0.75 IP 2251 BK/WH FLRB 1.5
BD 28 TN FLRB 0.35 IP 28BA TN FLRB 0.35
129
Horn
85
86
Horn Switch
1
1
1
IP 28B TN FLRB 0.5
Horn
2
+
2
2
SP0212
IP50_A
IP01_B
Spring
Clock
130
Relay
IP 28A TN FLRB 0.35
Horn
42
BD 1329A D-GN FLRB 1.0 SP0232
128
U-PS22
Horn
20A

55

IP07
5.25 Theft security system (RHD)
PWR1
I-FS2
10 A
IG
IEC
IP 1442 RD/BK FLRB 0.5 IP 1442D RD/BK FLRB 0.5 -PEPS
14
SP0210
SP0244
BD 3040B YE/BK FLRB 2.0
34
Supply 8
U-FS12
2
Power
25 A
IEC
SP0240
Relay
I-R3
IG
IP07
24
IP 340A RD/WH FLRB 2.5 IP 340AA RD/D-GN FLRB 2.5
68
30
86
2
Power Supply
BD2IP_1
IP2BD_1
SP0904
U-JF4
30 A
SP0257
IG
Relay
87
85
60
IG
48
1
BD 340 RD/WH FLRB 2.5 BD 340D RD/WH FLRB 2.5
SP2626
4
G_GBR3
KL30
EB01
D9013-0117b
EB57_C
FL32
FL32
G_IPB2_3
Filler Cap
BD 93A WH FLRB 0.5 BD 1550CC BK FLRB 0.5

Motor
11
1
2
Module
Control
Engine
ECM
Actuator
Engine
Switch
Hood
Filler
EB02_A
Cap
EN2EB
EB2EN
EB48
IP01_A
EB48
Engine Hood
IP 1349 BN FLRB 0.35 IP 1349F BN FLRB 0.35 ESSS BD 1349J BN FLRB 0.35 ESSS BD 109 PK FLRB 0.35AT
Lighting
Ground
Switch
Switch
B
15
A
25
2
9
Ground
ECM
SP0611
Engine Hood
BCM
IP 5531A PU FLRB 0.35 AT BD 5531 PU FLRB 0.35 AT
Switch
+
C
5
IP2BD_1 14
IP2DRD_2
DRD2IP_2
IP01_B
BD2IP_1
G_IPB2_3
37
SP2630
SP2606
DD10
DRD 2251DK BK/WH FLRB 0.5 DRD 2251DD BK/WH FLRB 0.5
1
Ground
SP2603
Fuel Tank Cap Switch

IP2DRD_2
DRD2IP_2
-
IP01_B
3
Fuel Tank Cap
IP 1447A PK/WH FLRB 0.5 DRD 1447 PK/WH FLRB 0.5

Switch
+
32
40
4
LED+
DRD 1382DB PU/WH FLRB 0.5
5-182
2
DRD 1382DA PU/WH FLRB 0.5
BD2IP_3
IPIBD_3
EB57_C
SP1211
BD 1382 PU/WH FLRB 0.5 BD 1382E PU/WH FLRB 0.5 IP 1382EA PU/WH FLRB 0.5 IP 1382D PU/WH FLRB 0.5
Lighting
Back
57
IP2DRD_2 29
5
SP1217
SP1206
DRD2IP_2
Anti-theft
Module
Control
09/2017
IP01_A
IP16
IP16
Ignition Switch
G_IPA2_1
Back Light
IP 7561 L-BU FLRB 0.5 -PEPS IP 2451BC BK/WH FLRB 0.5 -PEPS IP 2451SA BK/WH FLRB 0.75
Contorl
Power Supply Ground

LED
51
2
4
SP2610
SAIC-SV91
IP 7560 D-GN FLRB 0.5 -PEPS IP 1442D RD/BK FLRB 0.5 -PEPS
34
LIN
LIN
1
3
IP01_B
a
90
Driver's Side Lock / Unlock Driver's Side Door Door Lock Motor + Passenger's Side Passenger's Side
Door Ajar Switch Lock Motor - Door Lock Motor - Door Ajar Door Lock
IP01_B 39 3 12 18 EB57_C EB57_C 20 27 4 IP01_B

IP 745A GY/BK FLRB 0.5
IP 780A PK/BK FLRB 0.5
BD 295HB L-GN FLRB 1.0
BD 294 TN FLRB 1.0
BD 295 GY FLRB 1.0

b
BD 294DA TN FLRB 1.0
SP1001 c
BD 294BB TN FLRB 1.0
BD 294A TN FLRB 1.0
BD 295CA GY FLRB 1.0

SP1002 d
BD 295DA GY FLRB 1.0
e
BD 295BB GY FLRB 1.0

BD2IP_1
IP 746A BN/OG FLRB 0.5
IP 244A L-BU FLRB 0.5 PEPS

31 30 IP2BD_1
BD2IP_2
16 17
IP2BD_2
IP 295H L-GN FLRB 1.0
IP 294AB TN FLRB 1.0
90
IP 294B TN FLRB 1.0
IP 295B GY FLRB 1.0
DRD2IP_2 PAD2IP
IP2DRD_1 12 13 20 11 37 IP2DAD_2 11 20 12 13 27 IP2PAD
IP2PAD
DRD2IP_1 PAD2IP

PAD 294BA TN FLRB 1.0
PAD 295BA GY FLRB 1.0
PAD 746 BN/OG FLRB 0.5
PAD 244 BN FLRB 0.5 PEPS

DRD 745 GY/BK FLRB 0.5
DRD 780 PK/BK FLRB 0.5
DRD 295HA L-GN FLRB 1.0
DRD 294AA TN FLRB 1.0
DD04-A DD04-B DD04-A

D B B A PD04_A D C B A PD04_B
+ - - + + - - +
Door Door Door Door
Ajar Lock Ajar Lock
Switch Switch SP2606 SP2630 Switch Switch
SP2617
C F Driver's Side Passenger's Side A B
DD04-A DD04-B PD04_A PD04_B
Door Lock Door Lock
PAD 2351DC BK/WH FLRB 0.5 PEPS

PAD 2351DA BK/WH FLRB 0.5
DRD 2251DK BK/WH FLRB 0.5

G_IPB2_1
SP2603 G_IPA2_3
SP2607 D9013-0118b
SAIC-SV91 09/2017
G_FLDL1_1
D9013-0119b
BD 1750TP BK FLRB 2.0 BD 1750 BK FLRB 3.0
SP2629
14
16 EB57_C
Door
Lock
Tail
SP2404
SP2601
Tail Door
BD 5790B D-BU/WH FLRB 0.75 TLD 5790A D-BU/WH FLRB 0.75 TLD 1750TB BK FLRB 0.75
Motor
BD 294EA TN FLRB 1.0 MNTG
-
16
2
SP2403
Ajar Switch
Not Close
Tail Door
IP 744AB OG/BK FLRB 0.5 BD 744A OG/BK FLRB 0.5 MNTG BD 1303B PK/BK FLRB 0.5 TLD 1303A PK/BK FLRB 0.5 TLD 2051TB BK FLRB 0.5
3
15
19
SP2612
TLD10
TLD10
IP2BD_3
BD2IP_3
TLD2FL-1 13
FL2TLD-1
SP2613
G_FLDL2
BD 2051T BK FLRB 0.5 BD 2051 BK FLRB 0.75
IP2BD_2
BD2IP_2
FL2RRD
RRD2FL
RLD2FL
FL2RLD
SP2622
RR02
Rear Right Door
Not Close
BD 748A L-GN/BK FLRB 0.5 RRD 748 L-GN/BK FLRB 0.5 Ajar Switch RRD 1551DB BK/WH FLRB 0.5 RRD 1551DA BK/WH FLRB 0.5
IP 748B L-GN/BK FLRB 0.5
37
C
2
1
3
Rear Right Door Lock

+
BD 294DA TN FLRB 1.0 RRD 294DB TN FLRB 1.0 BD 1551DS BK/WH FLRB 0.5
12
SP2618
5-184
G_FLCL_2
BD 295DA GY FLRB 1.0 RRD 295DB GY FLRB 1.0 BD 1551 BK/WH FLRB 0.5
-
B
5
RR02
IP2BD_3
BD2IP_3
FL2RLD
RLD2FL
SP2623
RL02
RL02
Rear Left Door
Not Close
IP 747B L-BU/BK FLRB 0.5
BD 747A L-BU/BK FLRB 0.5 RLD 747 L-BU/BK FLRB 0.5 Ajar Switch RRD 1651DB BK/WH FLRB 0.5 RRD 1651DA BK/WH FLRB 0.5
B
1
3
6
09/2017
IP01_B
Rear Left Door Lock

+
RRD2FL
FL2RRD
RLD 294CB TN FLRB 1.0
D
5
G_FLCR_1
BD 1651DS BK/WH FLRB 0.5 MDACIIADAC
1
BD 295CA GY FLRB 1.0 RLD 295CB GY FLRB 1.0
SAIC-SV91
C
12
d
b
e
c
90
5.26 Auxiliary equipment
Battery
BTN01
- +
BT04_1 Engine Bay Fuse Box UEC
30 A 40 A 40 A
Pre-fuse Box 175 A U-JF6 30 A U-R4 30 86
U-FS1 U-JF7 U-JF3 Starting

PFB P-MG2
Main
IEG
UEC DC Power Starter Relay 87 85
Relay Stabilizer 2 Supply 9
UEC
2 1 7 6 3 133 137 135 134
BT01_1 EB01
BD 3440F RD/BK FLRB 3.0-ESSS
BD 6 PU FLRB 3.0
BD 447 YE FLRB 0.5

BD 3640 RD/WH FLRB 3.0 ESSS
BD 3440K RD/WH FLRB 3.0 ESSS

SP0105
SP0260 11 a
SP6402
BD2IP_1
IP2BD_1
SP6403
BD447A YE FLRB 0.5 ESSS

BD 3440KB OG/RD FLRB 2.0 ESSS
BD 3440KC OG/RD FLRB 2.0 ESSS

BD 3640KB YE/BN FLRB 2.0 ESSS
BD 3640KC YE/BN FLRB 2.0 ESSS

BD 640D RD/WH FLRB 0.5 ESSS
90
FL31_A 3 1 2 5 6 26 FL31_B
KL30 Power Supply Power Supply Power Supply Power Supply Starting
Relay
Ground Ground Ground
FL31_A 21 3 4 FL31_B Stabilizing DC Module SP0102

DCDC
BD 1150DA BK FLRB 2.0 ESSS
BD 1150DB BK FLRB 2.0 ESSS
BD 6A PU FLRB 3.0

BD 640G RD/WH FLRB 0.5
EB2BT
SP2624 20
BT2EB
BD 1151CA BK/WH FLRB 0.5
BD 1151CB BK/WH FLRB 0.5
SP1904
BD 6A PU FLRB 3.0
BD 1150D BK FLRB 3.0 ESSS
5 4 16 FL18 BT03 9 EB02_K

Ground Ground KL30 Starting Starting Engine
Control
Control
Starter Module
ECM
G_BTN G_FLL2_1 OBD2 G_FLL1_4
D9013-0016b
SAIC-SV91 09/2017
b

85 30
U2-R4 10 A
30 A IG U2-FS16
U-JF4 87 IG Power
IG Power Relay 86
Supply Supply 4
4 17 19 21 18 47 48



BD 340 RD/WH FLRB 2.5 BD 340E RD/WH FLRB 2.5
SP0257
SP0234
IP2BD_3 BD2IP_3 LHD
IP2BD_4 BD2IP_4 RHD
A6 40
A3 38
SP0264
A4 37
SP2635
A5 39
BD 3740C BN FLRB 2.0 ESSS
BD 3740B D-BU FLRB 2.0 ESSS&&AT
BD 3740A L-GN FLRB 2.0 ESSS
BD 3740D RD FLRB 2.0 ESSS&&AMP

IP 3440C RD/BK FLRB 3.0 -ESSS
SP0262
IP 3440E RD/BK FLRB 3.0 -ESSS
IP 3740BA D-BU FLRB 2.0 ESSS&&AT
IP 3740CA BN FLRB 2.0 ESSS

IP 3740DA RD FLRB 2.0 ESSS&&AMP
a
IP 3740AA L-GN FLRB 2.0 ESSS
BD 642BG RD/BK FLRB 0.5 ESSS

右舵左舵
BD2IP_1
4
IP2BD_1
90
FL31_A
IP07 5 2 1 6
32 46 47 48
Output Output Output Output

Instrument 30 A 10 A 15 A
Panel I-FS20 I-FS21 I-FS22 25 A
I-FS23
Stabilizing DC
Power Instrument AMT
Fuse Box Amplifier Cluster Entertainment Module DCDC
System / Radio
IEC KL15
40 52 53 54 IP07 FL31_A 10
IP 402 RD FLRB 0.75 AT
SP0704 IP 249 WH FLRB 0.35

c
GB 402B RD FLRB 0.75 AT&&4WD

GB 402C RD FLRB 0.75 AT&&4WD
GB 402D RD FLRB 0.75 AT&&4WD
SP0904
IP 249C WH FLRB 0.5
19 IP2BD_1
BD2IP_1
BD 402A RD FLRB 0.75 AT
IP2BD_4 A7
BD2IP_4
GB2FL
17
FL2GB
FL44_C 4 2 IP02_A 4 1 GB02_1 15 IP55_B 48 IP01_B

Power Power Power Power Power IG Body
Supply Supply Supply Supply Supply Relay
Control
Module
BCM
Power Instrument Transmission Entertainment G_EBL2_4
Amplifier Cluster Control Module System / Radio D9013-0017b
SAIC-SV91 09/2017

b
BD2IP_1
IP2BD_1 2

25 A
U-FS12
IEC
Power
Supply 8
IP 3040CA YE/BK FLRB 2.0

24
Instrument Panel

Fuse Box IEC
IP07 69 49
58
85 30
I-R3 15 A 10 A
IG I-FS1 I-FS24
86 87
Relay IG PWR2 OBD SP0235
SP0244

1 13 55
IP07 60 68

IP 249 WH FLRB 0.35
IP 842E RD/WH FLRB 0.75 SWH
IP 840CRD/L-GN FLRB 0.5
BD2IP_1
IP2BD_1 13
SP0240
90
IP50_D IP28
SP2626 1 16
HEAT+ Power
BD 51 BK FLRB 2.5
Supply
Clock
Spring OBD
Signal
HEAT- Ground Ground
IP50_D 2 4 5 IP28
IP 2251E BK/WH FLRB 1.0 SWH
c
IP 2251S BK/WH FLRB 0.75
SP2616
SP2630
G_EBR3 G_IPA2_3
D9013-0018b
SAIC-SV91 09/2017
60 A
Engine Bay 85 30
U2-R1 30 A 10 A 20 A
U-JF5 Fuse Box ACC U2-FS11 U2-FS12 U2-FS1
ACC Relay ACC1 ACC2 Inverter
UEC
86 87
Power
Supply
36 32 35 33 39 37 38 40 7
EB01 5 EB58
BD 342 RD FLRB 5.0
BD 342CA RD FLRB 5.0
BD 342D RD FLRB 5.0
BD 5199B YE FLRB 0.35
BD 1264 D-GN FLRB 2.5 12V DC
BD 1140 RD/WH FLRB 1.5 INV

BD 342C RD FLRB 5.0
SP0258 SP0205 SP0263

BD 342E RD FLRB 5.0 IP 342H RD FLRB 5.0
4 d
BD2IP_1
IP2BD_1 4 BD2IP_3 IP2BD_3
SP0253
e
SP1902
BD 202GC RD/BK FLRB 0.5 USB1||USB2

BD 1264B D-GN FLRB 2.5 12V DC
SP1902

BD 202UB RD/BK FLRB 0.35USB1
BD 202N D-GN FLRB 1.5 INV

SP0901
90
FL39_1 2 2 FL39_2 FL40 2 FL48 1 FL47 1 FL60 3 2

ACC ACC ACC Power Power 12VConnector
Supply Supply
12V Power 12V Power USB- USB-
Inverter
Power Supply
Input
Output
Socket-Center Socket-Rear Rear Center GND
Gled Rled N L
Left Right
220V
AC Socket
220V AC
LED
Ground Ground Ground Ground Ground
1 1 1 2 2 1
FL39_1 FL39_2 FL40 FL48 FL47 FL60
BD 1150VA BK FLRB 1.5 INV
BD 1750V BK FLRB 0.75 12V DC
BD 1150VC BK FLRB 0.35 USB2

BD 1150VB BK FLRB 0.75 12V DC&&HPB
BD 1150VD BK FLRB 0.75 12V DC&&EPB

SP2642 SP2611
BD 1150VE BK FLRB 1.0 12V DC||USB2
6 IP01_B
ACC
BD 1750 BK FLRB 3.0
Relay
Body Control
SP2629
Module BCM
G_FLL1_2 G_FLDL1_1 G_FLL1_1

D9013-0019b
SAIC-SV91 09/2017
85 30
I-R2 10 A 15 A 15 A
ACC I-FS17 I-FS11 I-FS19
86 87
Relay ACC2 ACC4 ACC1
41 43 45 42 31 11 29 37 23 39
IP07
IP 202A RD FLRB 3.0

IP 202 RD FLRB 3.0
IP 1263 OG FLRB 0.75 12V DC

SP0237
IP 342H RD FLRB 5.0

d IP 202EB RD/BK FLRB 0.35CHARG SP0239
SP0230
IP2CN_2 IP2BD_3
13 4
CN2IP_2 BD2IP_3
BD 1263BB OG FLRB 0.75 12V DC&&(MDAC||ADAC)

CN 202EC RD/BK FLRB 0.35 CHARG
e
CN 202EF RD/BK FLRB 0.35 CHARG
CN 202ED RD/BK FLRB 0.35 CHARG
90
SP1906
1 6 CN03 IP05 1 FL45_2 2 2 FL45_1

Power ACC ACC
ACC ACC
Wireless Cigar
Supply
12V Power
Charging Lighter Socket-
PEPS
Control
Module Rear Right
Ground Module Ground Ground Ground
2 5 CN03 IP05 2 FL45_2 1 1 FL45_1
BD 1850VA BK FLRB 0.75 12V DC&&(MDAC||ADAC)
CN 5721A PU FLRB 0.35 PEPS&&CHARG
CN 751RD BK FLRB 0.35 CHARG
IP 850LB OG FLRB 0.75
SP2641
25 24 CN2IP_2
IP2CN_2
IP 751RE BK FLRB 0.35 CHARG
IP 5721 PU FLRB 0.35 PEPS&&CHARG
9 IP09_B
Wireless
Charging PEPS
Module
Control
Module
G_IPM1_2 G_FLDR1_2
D9013-0020b
SAIC-SV91 09/2017
D9013-0075b
SP1847
BD 6105AB D-BU FLRB 0.35 BD 6105 D-BU FLRB 0.35

CAN_H
2
3
Gateway
SP1848
RF2IP_2
IP2RF_2
BD 6106AB L-GN FLRB 0.35
CAN_L
BD 6106 L-GN FLRB 0.35
SP2646
FL02_A 12
4
G_IPB1_1
IP2BD_2
BD2IP_2
2
RF 2351RA BK/WH FLRB 1.0 RLS||ATTG
17 RF2IP_1
IP2RF_1
RF 2351W RD/WH FLRB 0.5 LDW
Ground
SP1810
Lane Departure Aid
3
Control Unit LDW
SP2605
IP 6106A L-GN FLRB 0.35 IP 6106BA L-GN FLRB 0.5 LDW RF 6106BB L-GN FLRB 0.5 LDW
CAN_L
7
SP1809
RF 842DA RD/BK FLRB 0.5 LDW
KL30
19
6
IP 6105A D-BU FLRB 0.35 IP 6105BA D-BU FLRB 0.5 LDW RF 6105BB D-BU FLRB 0.5 LDW
CAN_H
18
RF10 1
RF 3840A RD/WH FLRB 0.5 LDW
KL15
RF10 12
RF2IP_1 15
BD2IP_1
IP2BD_1
IG Power
Supply 5
U-FS3
IP2RF_1
30 A
IP 842D RD/BK FLRB 0.5 LDW

BD 3140 RD FLRB 2.5 LDW||PSRF||FSRF IP 3140A RD FLRB 2.5 LDW||PSRF||FSRF
15
Departure
IG Power
BT04_1
SP0245
Supply
I-FS7
U-JF4
Lane
7.5 A
Aid
30 A
SP0257
BD 340 RD/WH FLRB 2.5 IP 3140B RD FLRB 2.5 LDW IP 3840 RD/WH FLRB 0.5 LDW
19
4
Control Unit
EB01
SP0213
Airbag
I-FS5
Instrument Panel
5.27 Advanced driver assistance system
10 A
Fuse Box IEC
IP 842 RD/BK FLRB 0.5 LDW||PGAM||SWHIP
5-190
17
BT01_1
P-MG2
5
175 A
UEC
Relay
I-R3
IG
UEC
Module
SP0240
Control
BCM
Body
2
IP 340A RD/WH FLRB 2.5 IP 340AARD/D-GN FLRB 2.5
87
30
68
69
IP2BD_1 2
IP01_B
+
SP0904
BD2IP_1
Pre-fuse Box
09/2017
Relay
85
86
Battery
IG
PFB
IP07 60
48
58
SP2626
IP07
G_BTN G_EBR3
SAIC-SV91
-
BTN01
90
Central Control Switch Bolck - Right
Lane Lane
Departure Departure
Switch Switch
Signal LED
13 14 CN06
IP 8011A L-BU FLRB 0.5 LDW
IP 8012A YE FLRB 0.5 LDW

CN2IP_2 19 20
IP2CN_2
IP 8011A L-BU FLRB 0.5 LDW
IP 8012A YE FLRB 0.5 LDW
90
IP2RF_2 9 10
RF2IP_2
RF 8011C L-BU FLRB 0.5 LDW
RF 8012C YE FLRB 0.5 LDW
RF10 9 5
I_S_IN1 O_S_OUT1
Lane Departure Aid Control Unit

LDW
D9013-0076b
SAIC-SV91 09/2017
D9013-0061b
a
FL05
FL06
Heat + Heat -
BD 2295 BN FLRB 0.75 RSHT

加热+ 加热-
10
Power Seat (4PIN)
1
BD 642BNB RD/BK FLRB 0.5 8PST-4LUB
BD 2294 GY FLRB 0.75 RSHT BD 6134E D-GN FLRB 0.5 RSHT
LIN
8
5
4
b
BD 2079B YE/BK FLRB 0.5 RSHT BD 1750S BK FLRB 1.5 RSHT
NTC+
Ground
NTC+
4
7
3
FL06
BD 2080B YE FLRB 0.5 RSHT
NTC-
NTC-
9
2
IP 6134EA D-GN FLRB 0.35 RSHT||RS11

U2-FS16
Supply 4
Power
EB58
SP2507
10 A
IG
HSM IGN
BD 642BK RD/BK FLRB 0.5 RSHT||RS11 BD 642BR RD/BK FLRB 0.5 RSHT
48
6
SP0262
Power Seat (10PIN)

Seat Heat
U2-FS7
SP2505
Rear
15 A
Supply 1
BD2IP_7 IP2BD_7
Power
BD 3540FA RD/WH FLRB 0.75 RSHT||RS11 BD 3540FC RD/WH FLRB 0.75 RSHT
13
7
Supply 2
BD 3540FD RD/WH FLRB 0.75 RSHT
KL30
Power
2
FL75
Supply 2 Supply 1
BD 3540FE RD/WH FLRB 0.75 RS11
Heat + Heat - LMF_IGN Power Power

1
BD 6134EB D-GN FLRB 0.5 RS11 BD 6134EC D-GN FLRB 0.5 RSHT||RS11
LIN
6
BD 3540FF RD/WH FLRB 0.75 RS11
SP2110
2
BD 1750SA BK FLRB 1.5 RS11
Ground
BD 642BQ RD/BK FLRB 0.5 RS11
20
4
5-192
12
Power Seat
Rear Left
19
NTC- NTC+
13
BD 2080BA YE/BK FLRB 0.5 RS11
18
FL75
FL76
G_FLCL_4
LMF_IGN Heat + Heat - NTC+ NTC-
09/2017
BD 1750SC BK FLRB 0.5 RS11 BD 1750SB BK FLRB 1.5 RSHT||RS11
18
Ground
20
5.28 Power seats
BD 2079BA YE FLRB 0.5 RS11
SP2647
13
Power Seat
Rear Right
BD 2295A BN FLRB 0.75 RS11
19
BD 2294A GY FLRB 0.75 RS11
SAIC-SV91
12
BD 642BP RD/BK FLRB 0.5 RS11
4
FL76
90
Engine Bay Fuse Box UEC Instrument Panel Fuse Box IEC
KL30 10 A
25 A I-FS25
U-FS12 AC Control Panel /
IEC PWR8 Left Central
Control Switch
24 IP07 50 56
EB01

IP2CN_2
12 CN2IP_2 BD 642BNB RD/BK FLRB 0.5 8PST-4LUB
a a
CN 3540EP RD/WH FLRB 0.5 MMHT||PST-LUB-HT

SP0235
SP0244 SP0201
IP 640H RD/WH FLRB 0.5 MMHT||PST-LUB-HT
IP2BD_1 13
BD2IP_1 4 CN05 Central Control Switch Block - Left
Power Supply
Back Lighting
LIN Ground Ground
8 10 5 CN05 90
CN 6134C D-GN FLRB 0.35 MMHT||PST-LUB-HT
CN 751CH BK/WH FLRB 0.5

MMHT||PST-LUB-HT
CN 751CG BK/WH FLRB 0.5

MMHT||PST-LUB-HT
SP2614
CN2IP_2 11 SP2643
IP2CN_2
IP 6134AB D-GN FLRB 0.5 MMHT||PST-LUB-HT
CN2IP_1
44 IP2CN_1
SP2106
IP 6134 D-GN FLRB 0.5 MDAC||ADAC
IP 6134EA D-GN FLRB 0.35 RSHT||RS11

c
5
LIN
b
Front AC Control Panel G_IPM1_1
D9013-0167b
SAIC-SV91 09/2017

25 A 25 A
I-FS10 I-FS9
Driver's Side Passenger's
Power Seat Side Power Seat
ID07 22 21
IP 3540CA L-GN FLRB 2.0 8PST-4LUB||MMHT
IP 3540CD RD FLRB 2.0 PST-LUB

a
19 IP2BD_3
BD2IP_3
BD 3540CW L-GN FLRB 2.0 8PST-4LUB||MMHT
90
SP2505
BD 3540CG L-GN FLRB 2.0 8PST-4LUB
BD 3540CC L-GN FLRB 2.0 MMHT
21 IP2BD_2
BD2IP_2
NTCBD 3540CDA RD FLRB 2.0 PST-LUB
FL11 2 1 D3 FL03
Power Power KL30(20A)
Driver's Side Supply Supply Driver's Side
Power Seat Power Seat
Ground Ground Ground Ground
3 4 FL11 D6 D8 FL03
BD 1150SD BK FLRB 0.5 8PST-4LUB
BD 1150SC BK FLRB 1.5 8PST-4LUB
BD 1150SA BK FLRB 1.5 MMHT
BD 1150SB BK FLRB 0.5 MMHT

c c
FL04
1
Power
Supply
G_IPM1_1 Passenger's Side

Power Seat D9013-0062b
SAIC-SV91 09/2017
90
5-195
09/2017
D9013-0063b
SAIC-SV91
FL04
FL04
Front Seat Heat
BD 3540ED RD/WH FLRB 0.75 PST-LUB-HT||MMHT
Ground
Power
Supply
BD 1450SA BK FLRB 2.0 PST-LUB
U2-FS6
10
8
15 A
SP2502
SP2039
Engine Bay Fuse Box 2 UEC_2
BD 3540EA RD/WH FLRB 0.75 PST-LUB-HT||MMHT BD 3540ED RD/WH FLRB 0.75 PST-LUB-HT||MMHT
Power
Supply
12
11
BD 1450SB BK FLRB 1.5 PST-LUB||MMHT
Ground
16
BD 1450S BK FLRB 3.0 PST-LUB||MMHT
U2-FS16
Supply 4
Power
10 A
IG
SP0262
G_FLR11_2
BD 3540EF RD/WH FLRB 0.5 PST-LUB||MMHT
Power
Supply
48
2
ID07
FL03
BD 6134D D-GN FLRB 0.5 MMHT||PST-LUB-HT
13
LIN
NTC+ Power Seat
FL03
Driver's
BD 5919 OG FLRB 0.5 MMHT BD 5919A OG FLRB 0.5 MMHT
Power
Seat
Side
A4
21
Passenger's Side Power Seat

BD 2079 YE/BK FLRB 0.5 MMHT BD 2079A YE/BK FLRB 0.5 MMHT
A2
Driver's Driver's Driver's
Power Power Power

Seat
Side
22
3
BD 642BH RD/BK FLRB 0.5 MMHT
KL15
D2
BD 6134A D-GN FLRB 0.5 MDAC||ADAC
BD 2080 YE FLRB 0.5 MMHT BD 2080A YE FLRB 0.5 MMHT
Seat
Side
23
Heat - NTC-
IP2BD_2 BD2IP_2
6
A3 A7
BD 642BL RD/BK FLRB 0.5 MMHT
KL15
BD 2077 PK FLRB 0.75 MMHT BD 2077A PK FLRB 0.75 MMHT
A8
Heat
Seat
Side
24
12
26
BD 2078 L-GN FLRB 0.75 MMHT BD 2078A L-GN FLRB 0.75 MMHT
Heat +
Driver's
A6
Power
FLB2FLA 25
15
Heat
Seat
Side

FLA2FLB
Driver's Side
Power Seat
c
D9013-0059b
RF2IP_2
IP2RF_2
RF12
SP2617
SP2605
SP2646
G_EBR3
RF 2351RB BK FLRB 0.35 ATTG RF 2351RA BK/WH FLRB 1.0 RLS||ATTG RF 2351RH BK/WH FLRB 1.5 IP 2351RS BK/WH FLRB 1.5 IP 2351 BK/WH FLRB 1.5
13
1
GND
Tail Door Switch (Roof)
53 IP2BD_2
BD2IP_2
1 RF2IP_2
FL62_B
IP2RF_2
CLOSE
OPEN/
Operation
RF 6112 D-GN FLRB 0.35 ATTG IP 6112A D-GN FLRB 0.5 ATTG BD 6112B D-GN FLRB 0.35 ATTG
Signal
Tail Door
Tail Door
4
BD 5790 BN FLRB 0.75 ATTG
Latch
Latch
11
2
RF 6116 L-GN/BK FLRB 0.35 ATTG IP 6116A L-GN/BK FLRB 0.5 ATTG BD 6116B L-GN/BK FLRB 0.35 ATTG
Signal
Mode
54
17
1
2
LVL
Tail Door
Power Liftgate Control Unit
Latch
RF2IP_2
IP2RF_2
Tail Door
BD 5791 L-BU FLRB 0.75 ATTG
Latch
13
3
SP1208
Tail Door latch

TAIL+ RF 1382BB PU/WH FLRB 0.35 ATTG RF 1382BB PU/WH FLRB 0.35 ATTG RF 1382BB PU/WH FLRB 0.35 ATTG
3
Tail Door
Tail Door
BD 1382FF PU/WH FLRB 0.5 ATTG&&(MDAC||ADAC) BD 5792 L-GN FLRB 0.5 ATTG
TLD18
Latch
Latch
16
FL2TLD_2
4
TLD2FL_2
SP1209
SP1217
Release
Release
BD 1221 WH/BK FLRB 0.5 ATTG
Signal
Signal
11
TAIL+ TLD 1382FBA PU/WH FLRB 0.5 ATTG TLD 1382FBA PU/WH FLRB 0.5 ATTG
Tail Door Closing Switch
6
Trunk Closing Button
1
3
FL62_A
Ground
OFF SW SIG TLD 5800B D-GN/WH FLRB 0.5 ATTG BD 5800 D-GN/WH FLRB 0.5 ATTG
19
TLD2FL_1 22
5
4
FL62_A
FL33
FL2TLD_1
BD 2051TC BK FLRB 0.5 ATTG

Module
Control
Back Lighting
Body
5
5-196
EB57_C
TLD 2051TD BK FLRB 0.5 ATTG
LED
Economic /Sport
G_FLDL2
5
Module
PEPS Control Control
IP 6113B GY/BK FLRB 0.5 -PEPS
5.29 Power tail door System
Body
22
FL2TLD_2
BD 6113AA GY/BK FLRB 0.5 MDAC||ADAC
TLD2FL_2
TLD11
IP01_A
BD2IP_2
IP2BD_2
Tail Door Touch Switch
Unit PEPS
Trunk Light
09/2017
OFFSIG TLD 6113 GY/BK FLRB 0.5 BD 6113A GY/BK FLRB 0.5 MSAC IP 6113C GY/BK FLRB 0.5 PEPS
Switch
55
5
1
TLD2FL_1
FL2TLD_1
IP09_A
GND
G_EBR3
SAIC-SV91
TLD 2051TE BK FLRB 0.5 TLD 2051TS BK FLRB 0.5 BD 2051T BK FLRB 0.5 BD 2051 BK FLRB 0.75
13
2
SP2612
SP2613
90
Engine Bay Tail Door Tail Door

Fuse Box Sensing Sensing Switch
Tail Door Lock
UEC Switch Rightside Leftside
U-FS25
10 A
Sensor Sensor Sensor Sensor Stop Micro
Output Output Output Output Ground Switch Switch Motor- Motor+
52 1 2 1 2 4 5 3 1 2
EB58
TLD17 TLD12 TLD10
TLD 5801D PU/WH FLRB 0.5 ATTG
TLD 5802D PK/BK FLRB 0.5 ATTG
TLD 5802C PK/BK FLRB 0.5 ATTG
TLD 5801C PU/WH FLRB 0.5 ATTG
TLD 2051TB BK FLRB 0.5
TLD 1892A YE FLRB 0.5 ATTG
TLD 1303A PK/BK FLRB 0.5
TLD 5790A D-BU/WH FLRB 0.75

SP2612
SP2601

SP2401 21 15 16 TLD2FL_1
FL2TLD_1
BD 1892 YE FLRB 0.5 ATTG
BD 1303B PK/BK FLRB 0.5
BD 5790B D-BU/WH FLRB 0.75

TLD 5802B PK/BK FLRB 0.5 ATTG
SP2401
TLD2FL_1 13 14 TLD2FL_1
FL2TLD_1 FL2TLD_1
BD 2051T BK FLRB 0.5

SP2403 SP2404 90
BD 1303 PK/BK FLRB 0.5 ATTG
BD 5796 D-BU/WH FLRB 0.75 ATTG

TLD2FL_1 25 24 23
FL2TLD_1 SP2613 SP2629
BD 1642B RD/BK FLRB 0.5 ATTG
BD 5801B PU/WH FLRB 0.5 ATTG
BD 5802 PK/BK FLRB 0.5 ATTG
BD 5801A PU/WH FLRB 0.5 ATTG
BD 2051TA BK FLRB 0.5 ATTG
BD 1750 BK FLRB 3.0

SP2611
G_FLR2_1 G_FLR2_1 FL62_B
13 12 5 24 23 21 9 FL62_A 9 5
Sensor Tail Door Right Tail Door Tail Door Left Ground Tail Door Tail Door lock Tail Door Ground
Output Sensing Switch Signal Sensing Switch Sensing lock Stop Micro Open Lock Motor
Ground Switch Signal Signal Signal
Tail Door Tail Door Left Aisle Left Aisle Aisle Aisle Power
Power Supply Motor + Motor - Signal 2 Signal 1 Ground Supply
Power Tail Door Control Unit 12 FL62_B FL62_B 4 2 22 1 14 18 FL62_A

BD 5805 L-BU/WH FLRB 0.5 ATTG
BD 5799 BN/WH FLRB 0.75 ATTG
BD 740 RD/WH FLRB 1.5 ATTG
BD 5798 WH FLRB 0.75 ATTG
BD 5806 PU FLRB 0.5 ATTG
BD 5804 D-GN FLRB 0.5 ATTG
BD 5803 TN/BK FLRB 0.5 ATTG
Engine Bay Fuse

Box 2 UEC-2
U2-JF4
25 A
FL65
4 EB58 2 9 10 3 1 8
Tail Tail Left Left Aisle Aisle
Door Door Aisle Aisle Ground Power
Motor + Motor - Signal 2 Signal 1 Supply
Tail Door Motor D9013-0060b
SAIC-SV91 09/2017
5.30 On-board diagnostic system
Drive Converting Entertainment

Engine Bay Fuse Box 2 UEC_2 Instrument Cluster
Switch System Host
KL30 10 A
10 A 10 A U2-FS16
U2-FS12 U2-FS2 IG
ACC2 Gateway Power
CAN_H CAN_L CAN_H CAN_L
Supply 4
LIN
40 8 48 6 12 8 9
3
EB58 CN01 IP55_D IP02_A
IP 5169CA BN/WH FLRB 0.35 12-SCRN
IP 5170CA BN FLRB 0.35 12-SCRN
IP 5169C BN/WH FLRB 0.35
IP 5170C BN FLRB 0.35

SP0253 SP0262
CN 6132B BN FLRB 0.5 4WD

SP1837
SP1838
IP 5170B BN FLRB 0.35

IP 5169B BN/WH FLRB 0.35
BD 202GA RD/BK FLRB 0.5
CN2IP_1 28 IP2BD_3
IP2CN_1 1 2
90 BD2IP_3
IP 6132A BN FLRB 0.5 4WD
BD 5169A BN/WH FLRB 0.35
BD 5170A BN FLRB 0.35
SP1849
SP1835
SP1836
BD 5170AA BN FLRB 0.35 AMP
IP2BD_3
BD 5169AA BN/WH FLRB 0.35 AMP

46
BD 5169 BN/WH FLRB 0.35
BD 5170 BN FLRB 0.35
BD2IP_3
BD 6132 BN FLRB 0.5 4WD
FL02_B FL02_A FL44_A
11 12 19 18 9 5 15 15 16
Power Supply KL30 KL30 KL15 LIN1 CAN_H CAN_L CAN_L CAN_H
Ground Ground
6 20
Gateway Power Amplifier
FL02_B FL02_A
BD 1151GB BK/WH FLRB 0.5
BD 1151GA BK/WH FLRB 0.5
SP2624 G_FLL2_1 D9013-0108b
SAIC-SV91 09/2017
90
5-199
09/2017
PEPS Control Unit
IP 7494FA L-BU FLRB 0.35 IP 7494G L-BU FLRB 0.35
D9013-0109b
CAN_L
IP 7493EA D-GN FLRB 0.35 PEPS
CAN_H
CAN_L
Resistance
B
6
7
Terminal
CAN_H
IP 7494EA L-BU FLRB 0.35 PEPS IP 7493FA D-GN FLRB 0.35 IP 7493G D-GN FLRB 0.35
CAN_L
SAIC-SV91
CAN_H
15
A
7
IP09_B
IP38
IP41
SP1833
SP1831
SP1829
Body Control Module

IP 7493E D-GN FLRB 0.35 IP 7493F D-GN FLRB 0.35 IP 7493GA D-GN FLRB 0.35
CAN_H
42
SP1830
IP 7494E L-BU FLRB 0.35 IP 7494F L-BU FLRB 0.35 IP 7494GA L-BU FLRB 0.35
CAN_L
41
SP1834
SP1832
IP01_A
Power Tail Door Control Unit
Driver's Side Power Seat

BD 7493CA D-GN FLRB 0.35 MMHT BD 7493BA D-GN FLRB 0.35 ATTG
CAN_H
CAN_H
D5
3
BD 7493AA D-GN FLRB 0.35 TPMS
CAN_H
Control Unit
1
BD 7494CA L-BU FLRB 0.35 MMHT BD 7494BA L-BU FLRB 0.35 ATTG
CAN_L
CAN_L
D4
4
BD 7494AA L-BU FLRB 0.35 TPMS
FL62_A
FL03
CAN_L
2
BD2IP_2
FL30
IP2BD_2
SP1826
SP1828
SP1824
IP 7494D L-BU FLRB 0.35 BD 7494C L-BU FLRB 0.35 BD 7494B L-BU FLRB 0.35 BD 7494A L-BU FLRB 0.35 BD 7494 L-BU FLRB 0.35
BD_CAN_H BD_CAN_L
47
13
SP1825
SP1827
SP1823
IP 7493D D-GN FLRB 0.35 BD 7493C D-GN FLRB 0.35 BD 7493B D-GN FLRB 0.35 BD 7493A D-GN FLRB 0.35 BD 7493 D-GN FLRB 0.35
46
3
Telematics Control Unit
IP 6436C WH/BK FLRB 0.35
HSCAN_H1
IP 6437BA BN/WH FLRB 0.35 TBOX
CAN_L
Resistance
19
B
Terminal
Gateway
HSCAN_L1
IP 6437C BN/WH FLRB 0.35 IP 6436BA WH/BK FLRB 0.35 TBOX
CAN_H
39
A
IP42
IP60
SP1842
SP1840
DIAG_CAN_H DIAG_CAN_L
IP 6436CA WH/BK FLRB 0.5 IP 6436B WH/BK FLRB 0.35 IP 6436A WH/BK FLRB 0.35
CAN_L
BD 6436 WH/BK FLRB 0.35
14
52
11
Diagnose
Interface
IP 6437CA BN/WH FLRB 0.5 IP 6437B BN/WH FLRB 0.35 IP 6437A BN/WH FLRB 0.35 BD 6437 BN/WH FLRB 0.35
CAN_H
51
6
1
IP2BD_2
BD2IP_2
SP1841
SP1839
FL02_A
IP28
Blind Zone Monitroing
D9013-0110b
BT 6106HBL L-GN FLRB 0.35 LHD
EPS Control Unit

BD 6105FA D-BU FLRB 0.35 PDC4 BD 6106HA L-GN FLRB 0.35 BD 6106K L-GN FLRB 0.35
CAN_L
CAN_H
CAN1L
Control Unit
Resistance
8
9
B
4
Terminal
BD 6106FA L-GN FLRB 0.35 PDC4 BT 6105HBL D-BU FLRB 0.35 LHD
CAN_H
BD 6105K D-BU FLRB 0.35
CAN1H
CAN_L
BD 6105HA D-BU FLRB 0.35

25
A
3
FL71
BT07_B
FL34
EB40
BT2EB
EB2BT
EPB Control Module
BD 6106GA L-GN FLRB 0.35 EPB

CAN_L
Control Unit
17
ABS / ESP
BD 6105GA D-BU FLRB 0.35 EPB
CAN_H
16
SP1821
SP1819
SP1815
SP1817
BD 6105G D-BU FLRB 0.35 BD 6105H D-BU FLRB 0.35 BD 6105KA D-BU FLRB 0.35
BD 6105F D-BU FLRB 0.35
CANIP
26
SP1816
BD 6106G L-GN FLRB 0.35
CAN1M
BD 6106F L-GN FLRB 0.35 BD 6106H L-GN FLRB 0.35 BD 6106KA L-GN FLRB 0.35
14
SP1822
SP1820
SP1818
EB04
BD 6106E L-GN FLRB 0.35
BD 6105E D-BU FLRB 0.35
RF2IP_1
Differential Lock Control Module

Lane Departure Aid Control Unit
IP2RF_1
Lamp Control Unit
B_D_CANH
BD 6105EA D-BU FLRB 0.35 AFS IP 6105BA D-BU FLRB 0.5 LDW RF 6105BB D-BU FLRB 0.5 LDWL BD 6105AD D-BU FLRB 0.35 EDL
B.D.CAN1H
Adaptive Head
CAN_H
5-200
16
18
15
1
SP1813
B_D_CANL
BD 6106EA L-GN FLRB 0.35 AFS RF 6106BB L-GN FLRB 0.5 LDW
B.D.CAN1L
IP 6106BA L-GN FLRB 0.5 LDW BD 6106AD L-GN FLRB 0.35 EDL
CAN_L
Steering Wheel Angle Sensor
17
16
3
7
SP1814
IP14
FL27
FL59_A
RF10
IP 6105CA D-BU FLRB 0.35 EPS
CAN_H
3
BD2IP_6
IP2BD_6
09/2017
IP 6106CA L-GN FLRB 0.35 EPS
BD2IP_3
FL02_A
IP2BD_3
CAN_L
4
SP1848
SP1810
SP1812
CH_CAN_H CH_CAN_L
BD 6106D L-GN FLRB 0.5 IP 6106C L-GN FLRB 0.5 IP 6106B L-GN FLRB 0.35 IP 6106A L-GN FLRB 0.35 BD 6106AB L-GN FLRB 0.35 BD 6106 L-GN FLRB 0.35
12
4
6
Gateway
SP1809
SP1847
SP1811
SAIC-SV91
BD 6105D D-BU FLRB 0.5 IP 6105C D-BU FLRB 0.5 IP 6105B D-BU FLRB 0.35 IP 6105A D-BU FLRB 0.35 BD 6105AB D-BU FLRB 0.35 BD 6105 D-BU FLRB 0.35
2
5
3
90
90
5-201
09/2017
D9013-0111b
BD 2500F RD/WH FLRB 0.35
B.D.CAN1H
Engine Control
45
Module
BD 2501F TN FLRB 0.35

B.D.CAN1L
SAIC-SV91
44
EB02_K
SP1807
BD 2500FA RD/WH FLRB 0.35 4WD

Transfer Case
CAN_H
Control Unit
8
SP1808
BD 2501FA TN FLRB 0.35 4WD

CAN_L
9
FL01
Stabilizing DC Module
GB02_2
BD 2501E TN FLRB 0.35
GB 2500EC RD/WH FLRB 0.35 AT&&2WD IP 2500CA RD/WH FLRB 0.35 SRSL
CAN_H
CAN_H
10
31
Airbag Control Unit

AMT Control Unit
GB 2501EC TN FLRB 0.35 AT&&2WD IP 2501CA TN FLRB 0.35 SRSL
CAN_L
CAN_L
32
11
BD 2500AA RD/WH FLRB 0.35 ESSS
CAN_H
IP08_C
23
FL2GB
BD 2500EA RD/WH FLRB 0.35 AT GB2FL GB 2500EB RD/WH FLRB 0.35 AT&&4WD IP 2500CB RD/WH FLRB 0.35 SRSH
CAN_H
BD 2501AA TN FLRB 0.35 ESSS
CAN_H
CAN_L
10
12
13
22
FL31_A
BD 2501EA TN FLRB 0.35 AT GB 2501EB TN FLRB 0.35 AT&&4WD IP 2501CB TN FLRB 0.35 SRSH
CAN_L
CAN_L
14
11
11
IP08_A
Gateway
GB02_1
BD2IP_2
IP2BD_2
SP1804
BD2IP_5
IP2BD_5
FL02_A
SP1806
SP1802
PT_CAN_L
BD 2501D TN FLRB 0.35 IP 2501C TN FLRB 0.35 IP 2501B TN FLRB 0.35 BD 2501A TN FLRB 0.35 BD 2501 TN FLRB 0.35
14
45
10
SP1803
SP1805
SP1801
PT_CAN_H
BD 2500D RD/WH FLRB 0.35 IP 2500C RD/WH FLRB 0.35 IP 2500B RD/WH FLRB 0.35 BD 2500A RD/WH FLRB 0.35 BD 2500 RD/WH FLRB 0.35
44
4
5.31 Cooling fan
15 A 100 A
30 A 30 85
U-FS21 U-MID
U-JF1 U-R8 Main
Main Cooling Fan
Main Relay
Relay
87 86
Power （850W)/
Relay (600W)
Supply
1 155 153 157 154 33 56 6 EB01_B
EB01


BD 532 RD FLRB 10.0 850W
BD 409 RD FLRB 10.0 600W

SP0105 SP0215 SP0306
ＥｎｇｉｎｅＣｏｎｔｒｏｌＭｏｄｕｌｅ ECM EB02_K

69
90 Main Relay Control
Water Water
Temperature Temperature
Sensor Sensor Fan Dissipation
14 57 26 EB02_K
EB02_A
BD 409 RD FLRB 10.0 600W
BD 2364 D-BU FLRB 0.75 600W
BD 250A BK FLRB 10.0 600W
BD 2368 WH FLRB 0.75 850W

BD 5291B PK/BK FLRB 0.75
BD 250B BK FLRB 10.0 850W

0.75
0.75
1 2 1 4 2 EB21 3 1 4 2 EB22
+ - + -
Water Temperature Radiator Fan（600W） G_EBL2_1 Radiator Fan（850W） G_EBL2_3

Sensor D9013-0138b
SAIC-SV91 09/2017
5.32 Grounding distribution
Electric Power Anti-lock Braking System /

Steering Control Cooling Fan Cooling Fan ElectronicStability Program
Unit （600W） Engine Bay Fuse Box Front Wiper Motor （850W） Control Unit
U-R4 U-R6
1 2 137 146 4 2 13 38
BT07_A EB21 EB01 EB08 EB22 EB04
BT1050L BK FLRB 10.0 ESSS&&LHD
BT 1050A BK FLRB 10.0 -ESSS
BD 250A BK FLRB 10.0 600W
BD 6 PU FLRB 3.0
BD 250WB BK FLRB 2.0
BD 250WA BK FLRB 2.0
BD 250B BK FLRB 10.0 850W
BD 350A BK FLRB 4.0 ABS
BD 350B BK FLRB 1.5 ABS

SP0102
BD 6Y PU FLRB 3.0
90
SPD1
Diode
SPD2
BD 6X BK FLRB 3.0
G_BT1 G_EBL2_1 G_EBL2_2 G_EBL2_3 G_EBL3 D9013-0090b
SAIC-SV91 09/2017
Cigar Lighter
D9013-0091b
G_IPM2_2
IP 850LB OG FLRB 0.75
2
IP31_C IP05
level Sensor Front AC
G_IPM2_1
IP 850H BK FLRB 3.0
S
EB28
AC Pressure Brake Fluid
BD 451B BK/WH FLRB 0.5

B
EB12
Switch
BD 451C BK/WH FLRB 0.5 6MT-DYMOS||6MT-SAGW

2
EB58

Engine Bay Fuse Box 2
U2-R4
19
SP2635
BD 2451CB BK/WH FLRB 0.5 MDAC||ADAC BD 451 BK/WH FLRB 1.0
26
U2-R3
G_EBL2_4
5-204
EB35_2
Front Left Grouped Head Lamp
BD 450LC BK FLRB 0.75 LED BD 450L BK FLRB 1.0

4
SP2633
EB35_1
12
09/2017
8
SAIC-SV91
Fog Lamp
EB33
Front Left
90
90
5-205
09/2017
Engine Control Module
D9013-0092b
BD 51C BK FLRB 2.5
4
BD 51B BK FLRB 2.5

SP0303
G_EBR3
SAIC-SV91
BD 51A BK FLRB 2.5 BD 51 BK FLRB 2.5
1
EB02_K
EN2EB
EB2EN
UNKNOWN Water Pump
BD 650A BK FLRB 1.0
14
2
G_EBR2
BD 650B BK FLRB 0.5
13
EB32
Right Horn
BD 550HB BK FLRB 1.0

2
SP2638
EB31
Left Horn
BD 550HA BK FLRB 1.0

BD 550H BK FLRB 1.5
2
G_EBR1
EB36_2
Front Right Grouped Head Lamp
BD 550LC BK FLRB 0.75 LED BD 550L BK FLRB 1.0

4
EB36_1
SP2637
12
8
4
EB34
Front Right
Fog Lamp
1
Rear Left
Rear Left Rear Left Steering Door Power
door Under Door Power Rear Fog Filler Cap Column Window Rear Left Fuel Power Rear Left Rear Right
Mirror Light Window Switch Lamp Actuator Lock Sensor Switch Door Lock Pump Seat Power Seat Power Seat
1 1 1 1 3 10 B 2 4 20 20
RL07 RL04 PR03 FL32 PR11 RL04 RL02 CH07 FL06 FL75 FL76
RLD 1550DB BK FLRB 0.5 CALP
RLD 1550DC BK FLRB 2.0
PR 1550CDA BK FLRB 0.5
BD 1550CC BK FLRB 0.5
PR 1551CBA BK/WH FLRB 0.5 SSTG
RLD 1551DC BK/WH FLRB 0.5
RLD 1551DB BK/WH FLRB 0.5
CH 1550CB BK FLRB 1.5
BD 1750S BK FLRB 1.5 RSHT
BD 1750SA BK FLRB 1.5 RS11
BD 1750SC BK FLRB 0.5 RS11

SP2627 SP2622
RLD 1551DA BK/WH FLRB 0.5
90
RLD 1550DA BK FLRB 2.0
RLD2FL
16 PR2FL FL2RLD 1 SP2647
FL2PR
BD 1551C BK/WH FLRB 0.5 SSTG
BD 1551DS BK/WH FLRB 0.5
CH2FL
B
FL2CH
RLD2FL PR2FL
FL2RLD 19 13
FL2PR
BD 1550DP BK FLRB 2.0
BD 1550C BK FLRB 0.5
SP2618
BD 1550CA BK FLRB 1.5
G_FLCL_1 G_FLCL_2 G_FLCL_3 G_FLCL_4 D9013-0093b
SAIC-SV91 09/2017
90
5-207
09/2017
Driver's Side
D9013-0094b
Seat Belt
BD 1361A L-BU FLRB 0.5 IP 1361LA L-BU FLRB 0.5 SRSL

16
2
SP1501
FL07
BD2IP_6 BD2IP_5
IP2BD_6 IP2BD_5
SAIC-SV91
FL12
Passenger's
Occupancy
G_IPM3_2
IP 1751L BK/WH FLRB 0.5 SRSL
Sensor
BD 1361E L-BU FLRB 0.5 FSBR IP 1361EB L-BU FLRB 0.5 SRSL&&FSBR
Seat
26
2
SP1502
IP08_C
Control
Airbag
IP 1751LB L-BU FLRB 0.5 SRSL

Unit
17
IP08_A
G_IPM3_1
IP 1751H BK/WH FLRB 0.5 SRSH
Control
Airbag
Unit
15
SP1418
G_FLDL1_2 G_FLDL1_3
BD 1750F BK FLRB 0.75 AMP
FL44_C
Amplifier
Power
BD 1750M BK FLRB 2.5 AMP

8
RR07
Window Door Under
Switch Mirror Light
Door Power Rear Right
RRD 1650DB BK FLRB 0.5 CALP

1
SP2628
RR04
Rear Right
G_FLCR_2
RRD 1650DC BK FLRB 2.0 RRD 1650DA BK FLRB 2.0 BD 1650DM BK FLRB 2.0 MSAC
19
1
BD 1650DP BK FLRB 2.0 MDAC||ADAC
RR02
Rear Right
Door Lock
RRD 1651DB BK/WH FLRB 0.5 RRD 1651DA BK/WH FLRB 0.5 BD 1651DM BK/WH FLRB 0.5 MSAC
1
c
SP2623
FL2RRD
RRD2FL
G_FLCR_1
RR04
BD 1651DS BK/WH FLRB 0.5 MDAC||ADAC
Door Power
Rear Right
Window
Switch
RRD 1651DC BK/WH FLRB 0.5
10
Power USB - 12V Power Rear Rear Left Rear Left

Liftgate Rear Socket - Differential Rear Left Window License Grouped Liftgate
Control Unit Right Rear Left Lock Control Module Grouped Lamp Heat Plate Light Lamp Door lock
5 2 1 8 10 1 4 1 2 4 2
TLD10
FL62_B FL48 FL40 FL59_A FL19 TLD03 TLD07 TLD01
BD 1750V BK FLRB 0.75 12V DC
BD 1750VA BK FLRB 0.5 EDL
BD 1750VB BK FLRB 0.5 EDL
BD 1750LB BK FLRB 0.5
TLD 1750TR BK FLRB 1.5
TLD 1750TE BK FLRB 0.5

90
SP2611 SP2601
TLD2FL_1
14
FL2TLD_1
SP2629
BD 1750 BK FLRB 3.0
G_FLDL1_1 D9013-0095b
SAIC-SV91 09/2017
90
5-209
09/2017
D9013-0096b
Rear AC
G_FLDR1_3
S
FL20_2 FL50_C
SAIC-SV91
Grouped Lamp
Front Right
BD 1850LB BK FLRB 0.5 MDAC||ADAC

1
FL45_2
12V power
G_FLDR1_2
Right rear
Socket -

BD 1850VA BK FLRB 0.75 12V DC&&(MDAC||ADAC)
1
SP2641
TLD14
Rear Wiper
Motor
TLD 1850WBA BK FLRB 0.5

3
TLD02
Rear Right
Grouped
Lamp

4
License High Mounted
TLD21
Plate Light Brake Lamp
TLD 1850LG BK FLRB 0.5

1
FL2TLD_2
TLD2FL_2
BD 1850LL BK FLRB 0.5 MDAC||ADAC
SP2602
TLD08
Rear Right
G_FLDR1_1
TLD 1850LD BK FLRB 0.5 BD 1850LC BK FLRB 0.5 MSAC BD 1850 BK FLRB 1.0 MSAC
TLD 1850LE BK FLRB 0.5
2
SP2632
FL20_1
Grouped Lamp
Front Right BD 1850LK BK FLRB 0.5 MSAC
4
BD 1850LH BK FLRB 0.5 MSAC
1
D9013-0097b
FL04
BD 1450SB BK FLRB 1.5 PST-LUB||MMHT

Side Power Seat
16
Passenger's
SP2639
G_FLR1_2
BD 1450SA BK FLRB 2.0 PST-LUB BD 1450S BK FLRB 3.0 PST-LUB||MMHT
8
Camera System Host control Module
FL34
Panoramic Entertainment Park Brake
G_FLR1_1
Electronic
BD 1450AA BK FLRB 3.0 EPB

28
IP63
IP 6202 BK FLRB 0.35 BSV

2
PAD2IP
IP2PAD
PD13
Passenger's
PAD 6202DA BK FLRB 0.35 BSV IP 6202D BK FLRB 0.35 BSV

Side
33
3
DRD2IP_2
IP2DRD_2
DD13
Driver's Side
Panoramic
Camera
DRD 6202CA BK FLRB 0.35 BSV

44 IP 6202C BK FLRB 0.35 BSV
3
BD2IP_3
BD2IP_4
IP2BD_3
IP2BD_4
SP1426
EB49
G_FLDR2_3
Panoramic
Fore Sight
Camera
5-210
BD 6202AA BK FLRB 0.35 BSV IP 6202A BK FLRB 0.35 BSV IP 6202B BK FLRB 0.35 BSV BD 6202BD BK FLRB 0.5 BSV&&(MDAC||ADAC) BD 1851D BK FLRB 0.35 RCAM&&(MDAC||ADAC)
C9
26
3
SP1402
BD 6202BA BN/OG FLRB 0.5 BSV&&MSAC
FL2TLD_2
TLD2FL_2
TLD20
G_FLDR2_2
Panoramic
Rear View
Camera
TLD 6202BB BK FLRB 0.35 RCAM||BSV BD 6202BC BK FLRB 0.35 (RCAM||BSV)&&MSAC BD 1851C BK FLRB 0.35 RCAM&&MSAC
3
SP1420
09/2017
FL38_2
G_FLDR2_1
BD 1851HD BK/WH FLRB 0.5 (MDAC||ADAC)&&EPB
Control Panel
17
Rear AC
FL38_1
SAIC-SV91
BD 1851HA BK/WH FLRB 0.5 MDAC&&HPB
17
90
90
5-211
09/2017
GB04_2
D9013-0098b
GB 1451ED BK FLRB 0.5 6MT-SAGW&&2WD
1
SAIC-SV91
GB 1451EB BK FLRB 0.5 6MT-SAGW&&4WD
1 GB03_2 1
GB04_1
BD 1451E BK FLRB 0.5 6MT-DYMOS||6MT-SAGW

Reverse
Switch
19
Gear
6MT
GB 1451EC BK FLRB 0.5 6MT-DYMOS&&2WD

GB 1451EA BK FLRB 0.5 6MT-DYMOS&&4WD
GB02_2
GB03_1 1
GB 1451GA BK/WH FLRB 0.75 AT&&2WD

Reverse
Switch
Gear
5
6MT
GB 1451GB BK/WH FLRB 0.75 AT&&2WD GB 1451G BK/WH FLRB 0.75 AT&&2WD
AMT Control Unit
SP0707
GB02_1
GB 1451BB BK/WH FLRB 0.75 AT&&4WD
GB2FL
FL2GB
5
SP2636
G_FLR2_1
GB 1451BC BK/WH FLRB 0.75 AT&&4WD GB 1451BA BK/WH FLRB 0.75 AT&&4WD BD 1451B BK/WH FLRB 0.75 AT BD 1451S BK/WH FLRB 1.0
19
2
SP0705
FL35
Velocity
Sensor
BD 1151E BK/WH FLRB 0.5 ESP

Yaw
1
FL27
Adaptive
Monitoring Control
BD 1451A BK/WH FLRB 0.5 AFS

Blind Zone Lamp
Head
Cleaner Control Unit Unit
7
FL71
BD 1451F BK/WH FLRB 0.5 PDC4
32
FL79
BD 1451H BK FLRB 1.0 APM
Air
2
FL34
G_FLR1_3
Module
Control
BD 1450AB BK FLRB 3.0 EPB
EPB
30
D9013-0099b
BD 1150DB BK FLRB 2.0 ESSS
4
DC Module
Stabilizing
FL31_B
SP1904
G_FLL1_4
BD 1150DA BK FLRB 2.0 ESSS BD 1150D BK FLRB 3.0 ESSS
3
FL11
BD 1150SC BK FLRB 1.5 8PST-4LUB

Driver's Side
Power Seat
BD 1150SD BK FLRB 0.5 8PST-4LUB

3
G_FLL1_3
FL03
BD 1150SB BK FLRB 0.5 MMHT

Driver's Side
D8
Power Seat
BD 1150SA BK FLRB 1.5 MMHT

D6
FL39_2
5-212
BD 1150VD BK FLRB 0.75 12V DC&&EPB

Socket - Middle
12V Power
1
FL39_1
BD 1150VB BK FLRB 0.75 12V DC&&HPB
1
SP2642
USB - Middle
FL47
09/2017
G_FLL1_2
BD 1150VC BK FLRB 0.35 USB2 BD 1150VE BK FLRB 1.0 12V DC||USB2
SAIC-SV91
FL60
G_FLL1_1
Inverter
BD 1150VA BK FLRB 1.5 INV
220V
90
90
5-213
09/2017
Panoramic Power Window
Driver's Side
D9013-0100b
DRD 2250DD BK FLRB 2.0 IP 2350D BK FLRB 2.0
G_IPA1_2
Lifter
26
1
DRD2IP_1
DD08
IP2DRD_1
SAIC-SV91
RF14
RF 2350RZ BK FLRB 2.0 PSRF

Sunroof Sunroof
SP2645
RF13
IP 2350R BK FLRB 2.0 PSRF||FSRF
G_IPA1_1
RF 2351RE BK FLRB 1.0 FSRF RF 2350RX BK FLRB 2.0 PSRF||FSRF
20
2
RF2IP_1
IP2RF_1
FL62_A
Door Control
Power Tail

Unit
23
FL41

Trunk
Light
2
TLD10
Tail Door

Lock
4
TLD11
Tail Door
Switch
TLD 2051TE BK FLRB 0.5

Touch
FL2TLD_1
TLD2FL_1
SP2613
SP2612
TLD18
Tail Door
G_FLDL2
Closing
Switch
TLD 2051TD BK FLRB 0.5 ATTG TLD 2051TS BK FLRB 0.5 BD 2051T BK FLRB 0.5 BD 2051 BK FLRB 0.75
13
5
FL33
Tail Door
Latch
BD 2051TC BK FLRB 0.5 ATTG

5
FL30
BD 2051B BK/WH FLRB 0.5 TPMS BD 1850LK BK FLRB 0.5 MSAC
Tire Pressure
Control Unit
18
Monitoring
BD 2051A BK/WH FLRB 0.5 TPMS BD 1850LH BK FLRB 0.5 MSAC
6
D9013-0101b
BD 2450BE BK FLRB 0.5 SPHCM
4
EB57_E
BD 2450BG BK FLRB 0.75 AT

3
EB57_C
SP2609
G_FLL2_4
BD 2450BH BK FLRB 0.5 BD 2450BP BK FLRB 1.0
21
BD 2450BF BK FLRB 0.75

19
BD 2450BD BK FLRB 0.75

8
EB57_C
G_FLL2_3
BD 2450BA BK FLRB 2.5
22
BD 2450BC BK FLRB 2.5

9
SP2640
BD 2450BB BK FLRB 2.5 BD 2450BK BK FLRB 3.0
G_FLL2_2
5-214
7
FL02_B
BD 1151GB BK/WH FLRB 0.5
6
Gateway
FL02_A
BD 1151GA BK/WH FLRB 0.5
20
09/2017
SP2624
FL28
DC Module Receiver
G_FLL2_1
BD 1151P RD/WH FLRB 0.75 PEPS BD 1151 BK/WH FLRB 1.0
RF
3
FL31_A
SAIC-SV91
Stabilizing
21
90
90
5-215
09/2017
D9013-0102b
IP 2451AC BK/WH FLRB 0.5
13
Multifunction Switch - Wiper

7
SAIC-SV91
3
IP02_A
IP 2451CA BK/WH FLRB 0.5

71

58
IP07
SP2626
Anti-theft Module
IP 2451H BK/WH FLRB 0.5 SPM

9
IP12
IP 2451BC BK/WH FLRB 0.5 -PEPS

2
IP16
G_IPA2_1
Spring
Clock
11
IP50_B
IP 2451BB BK/WH FLRB 0.5

Body Control
Module BCM
SP2610
IP01_B

IP 2451BA BK/WH FLRB 0.5
4
IP01_A
Switch - Wiper
IP 2451F BK/WH FLRB 0.5

Multifunction
8
IP 2451E BK/WH FLRB 0.5
IP04
Switch
Block IP 2451C BK/WH FLRB 0.5
Left
IP03
Rear View
Governor
Switch
Mirror
11
IP12
D9013-0103b
IP28

Diagnostic
5
Interface
DD04_B

4

Driver's Side
SP2616
IP50_A
Door Lock
Clock Spring Clock Spring
IP 2251H BK/WH FLRB 0.5 IP 2251S BK/WH FLRB 0.75

2
B
DD04_A
IP50_D
DRD 2251DG BK/WH FLRB 0.5
Power Window
Driver's Side
IP 2251E BK/WH FLRB 1.0 SWH

Fuel Tank Cap Switch Lifter Switch
19
DRD 2251DF BK/WH FLRB 0.5 2

7
DD07
DRD2IP_2
IP2DRD_2
SP2606
3
G_IPB2_3 (RHD)
G_IPA2_3 (LHD)
DRD 2251DD BK/WH FLRB 0.5 DRD 2251DK BK/WH FLRB 0.5 DRD 2251DA BK/WH FLRB 1.0 IP 2251DS BK/WH FLRB 1.0 IP 2251 BK/WH FLRB 1.5
37
1
DD10
SP2630
SP2603
DD03_A

5-216
11
Rearview mirror
of driver side
DRD 2250DE BK/WH FLRB 0.5 SPMH

4
DD03_C
DRD 2250DF BK/WH FLRB 0.5 SPML
2
Driver's Driver's Side
Mirror Lamp
Side Door Door Under
DD14
09/2017
DRD 2250DC BK/WH FLRB 0.5 CALP
1
DD01
SAIC-SV91
Handle
DRD 2251DE BK/WH FLRB 0.5 PEPS
90
Passenger's
Passenger's Side Power Front Right Passenger's Wireless
Side Rear Window Lifter Door Under Side Rear 12-inch Display Charging Entertainment
View Mirror Switch Mirror Lamp View Mirror Screen Module System Host Radio
2 1 1 4 11 6 2 16 8
PD03_C PD06 PD14 PD03_A IP57 CN03 IP55_B IP56_A
PAD 2350DF BK FLRB 0.5 SPML
PAD 2351DF BK FLRB 2.0
PAD 2350DC BK FLRB 0.5 CALP
PAD 2350DE BK FLRB 0.5 SPMH
PAD 2350DB BK FLRB 0.5 SPMH
IP 751RB BK/WH FLRB 0.5 12-SCRN
CN 751RD BK FLRB 0.35 CHARG
IP 751RC BK/WH FLRB 2.5 12-SCRN
IP 751RA BK/WH FLRB 0.5 RADIO

SP2604
90
PAD2IP
26 CN2IP_2
IP2PAD 25
IP2CN_2
IP 750Z BK FLRB 4.0
IP 751RE BK FLRB 0.35 CHARG
G_IPB1_1 G_IPM1_0 G_IPA2_0 G_IPM1_2 G_IPM1_3 G_IPM1_4

D9013-0104b
SAIC-SV91 09/2017
D9013-0105b
Departure Liftgate Sunroof
Aid Control Switch Switch
RF 2351RF RD/WH FLRB 0.35

(RF) (O/C)
RF 2351RR BK FLRB 0.5 RLS&&LDW

2
Switch Sunlight
Sunroof Rainfall
3
Sensor
RF20
RF 2351RC BK FLRB 0.5 RLS&&-LDW RF22 RF08_1 RF08_2

RF12
RF 2351RB BK FLRB 0.35 ATTG
3
1
RF 2351RG RD/WH FLRB 0.35 FSRF
(U/D)
RF17_2 RF17_3 RF18_2 RF18_3 RF19_1 RF19_2 RF19_3 RF10
2
RF 2351W RD/WH FLRB 0.5 LDW RF 2351RA BK/WH FLRB 1.0 RLS||ATTG
Lane
Unit
Light Module
PEPS Control Atmosphere
SP2605
IP 2351PC BK FLRB 0.75 CALP
13
RF 2350RW BK FLRB 0.5 PSRF
4
Middle Reading
IP43
RF 2350RU BK FLRB 0.5 FSRF
Light
IP 2351PB BK FLRB 0.75 PEPS

4
15
Unit
RF 2350RG BK FLRB 0.5 NSRF
4
IP 2351PA BK FLRB 0.75 PEPS
14
IP09_A
RF 2350RT BK FLRB 0.5 PSRF
Rear Right
SP2617
4
Reading
SP2646
Light

RF 2350RH BK FLRB 0.5 FSRF
13
4
Mirror Reading Light
RF2IP_2
RF 2350RR BK FLRB 0.5 PSRF
IP2RF_2
Rear Left
Passenger's Side Power SP2608

RF 2350RL BK FLRB 0.5 FSRF RF 2350RA BK FLRB 0.75
5-218
4
RF07
Window Lifter Switch

Middle Anti-dazzling
Mirror Mirror Reading Reading Rear View
Automatic
PAD 2351DG BK/WH FLRB 0.5
10
2
RF04
PAD 6859BA YE/BK FLRB 0.5
RF 2350RM BK FLRB 0.5 NSRF
9
Light
PD06
RF03
RF 2350RF BK FLRB 0.5 PAD 2351DC BK/WH FLRB 0.5 PEPS PAD 2351DA BK/WH FLRB 0.5 IP 2351DS BK/WH FLRB 0.5
Passenger's
09/2017
Makeup Makeup Front
Light
Side Door
27
C
Locking
1
PD04_B
PAD2IP
SP2607
IP2PAD
RF02
RF 2350RD BK FLRB 0.5
C
Right
Light
PD04_A
2
SAIC-SV91
Passenger's
RF01
Side Door
G_IPB2_1
Handle
Switch
RF 2350RC BK FLRB 0.5 PAD 2351DE BK/WH FLRB 0.5 PEPS IP 2351 BK/WH FLRB 1.5
Light
Left
2
2
PD01
90
90
5-219
09/2017
D9013-0106b
Switch Block - Left
Central Control
CN 751CH BK/WH FLRB 0.5 MMHT||PST-LUB-HT

10
CN05
CN 751CG BK/WH FLRB 0.5 MMHT||PST-LUB-HT
SAIC-SV91
5
CN09
CN 751CD BK/WH FLRB 0.35ESP

EPS Switch
10
CN 751CC BK/WH FLRB 0.5 EPB

3
CN02
CN 751CJ BK/WH FLRB 0.5 PT4WD

Converting
Switch 2
6
Drive
CN 751CK BK FLRB 0.5 PT4WD

3
CN06
Switch Block - Right
Central
Control
Switch
CN 751CE BK/WH FLRB 0.5
CN2IP_1
IP2CN_1
2
SP2614
CN01
Converting
G_IPM1_1
CN 751CB BK/WH FLRB 0.354WD CN 751CA BK/WH FLRB 0.5 IP 751C BK/WH FLRB 0.5 ESP IP 751W BK/WH FLRB 1.0
Drive
44
2
SP2643
IP59
IP27
IP 751SB BK/WH FLRB 0.5 AT
Gear Lever
11
IP 751B BK/WH FLRB 0.5
Light Switch
Warning
4
Hazard
IP 751SA BK/WH FLRB 0.5 AT

4
1
SP2615
SP2634
IP14
Control Wheel Angle
Front AC Steering

Sensor
IP 751E BK/WH FLRB 0.5 EPS IP 751S BK/WH FLRB 0.75
1
IP38
Start switch
One-button
IP20
IP 751HA BK/WH FLRB 0.5
Panel
21
IP 751G BK/WH FLRB 0.35PEPS
8
Atmosphere Atmosphere Atmosphere Atmosphere Transfer Case Telematics

Light - Left 1 Light - Left 2 Light - Right 1 Light - Right 2 Control Unit Control Unit
1 1 1 1 12 25 40
IP32 IP33 IP34 IP37 FL01 IP60
IP 2250AB BK FLRB 0.5 CALP
IP 2250AE BK FLRB 0.5 CALP
IP 2250AC BK FLRB 0.5 CALP
IP 2250AD BK FLRB 0.5 CALP
BD 1451D BK FLRB 2.0 4WD
BD 1451C BK FLRB 2.0 4WD
IP 2351T BK/WH FLRB 0.5 TBOX

90
SP2621
IP 850Z BK FLRB 4.0
G_IPA1_3 G_FLR2_2 G_IPM2_0 G_IPB2_0 G_IPB2_2

D9013-0107b
SAIC-SV91 09/2017

D90 Service Workbook

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D90 Service

General ........................................................................................................... 2-1

Service and Maintenance................................................................................................... 2-11

Engine Mechanical System ............................................................................. 3-1

Layout ................................................................................................................................. 3-9

Repair Guidance ............................................................................................................... 3-19

Description and Operation ................................................................................................. 3-70

Operation ........................................................................................................................... 3-72

Lubricating Oil Circuit ......................................................................................................... 3-72

Repair Guidance ................................................................................................................. 4-7

Description and Operation ................................................................................................ 4-15

Engine Electrical System................................................................................. 5-1

Layout ................................................................................................................................. 5-2

Diagnostic Information and Procedures ............................................................................. 5-3

Repair Guidance ................................................................................................................. 5-4

Description and Operation .................................................................................................. 5-6

Battery Usage and Maintenance ......................................................................................... 5-7

Engine Control System ................................................................................... 6-1

Repair Guidance ................................................................................................................ 6-13

Special Tool ...................................................................................................................... 6-28

Description and Operation ................................................................................................. 6-29

Engine Fuel System ........................................................................................ 7-1

Layout ................................................................................................................................. 7-2

Diagnostic Information and Procedures ............................................................................. 7-4

Repair Guidance ................................................................................................................. 7-5

Description and Operation ................................................................................................ 7-12

Engine Intake/Exhaust System ....................................................................... 8-1

Repair Guidance ................................................................................................................. 8-4

Description and Operation ................................................................................................ 8-10

6MT Manual Transmission .............................................................................. 9-1

Repair Guidance .................................................................................................................. 9-6

Special Tool ....................................................................................................................... 9-45

Description and Operation ................................................................................................. 9-49

Layout ................................................................................................................................. 10-3

Service ................................................................................................................................ 10-9

Repair Guidance ............................................................................................................... 10-10

Special Tool ...................................................................................................................... 10-45

Transmission Assembly Structure Detail ......................................................................... 11-11

Repair Guidance .............................................................................................................. 11-28

Special Tool ..................................................................................................................... 11-57

Description and Operation ............................................................................................... 11-60

Clutch ............................................................................................................ 12-1

Layout ................................................................................................................................ 12-2

Diagnostic Information and Procedures ............................................................................. 12-3

Repair Guidance ................................................................................................................ 12-5

Description and Operation ............................................................................................... 12-10

Steering System ............................................................................................ 13-1

Layout ................................................................................................................................. 13-2

Repair Guidance ................................................................................................................. 13-6

Special Tool ...................................................................................................................... 13-12

Description and Operation ................................................................................................ 13-13

Front Suspension .......................................................................................... 14-1

Layout ................................................................................................................................. 14-2

Repair Guidance ................................................................................................................. 14-8

Special Tool ...................................................................................................................... 14-16

Rear Suspension........................................................................................... 15-1

Layout ................................................................................................................................ 15-2

Repair Guidance ................................................................................................................ 15-5

Description and Operation ............................................................................................... 15-10