Edition:November 2011 VOLUME 1

Printing: October 2011 INTRODUCTION 01

Pulication NO:FTSM-201110 PREPARATION 02
Printed in China SERVICE SPECIFICATIONS 03
DIAGNOSTICS 04
VEHICLE MAINTENNANCE 05
VOLUME 2
ENGINE CONTROL SYSTEM 11A
FUEL 12A
EMISSION CONTROL 13A
INTAKE AIR 14A
ENGINE MECHANICAL 15A
EXHAUST 16A
COOLING 17A
LUBRICATION 18A
IGNITION 19A
STARTING AND CHARGING 20A
FUEL 12B
INTAKE AIR 14B
ENGINE MECHANICAL 15B
EXHAUST 16B
COOLING 17B
STARTING AND CHARGING 20B
FRONT SUSPENSION 31
REAR SUSPENSION 32
TIRE AND WHEEL 33
AXLE AND PROPELLER SHAFT 34
BRAKE 35
PARKING BRAKE 36
TRANSMISSION(R5M21) 41A
TRANSMISSION(JC538) 41B
CLUTCH 42
VOLUME 3
STEERING COLUMN 51
POWER STEERING 52
HEATER AND AIR CONDITIONING 61
SUPPLEMENTAL RESTRAINT SYSTEM 62
SEAT BELT 63
LIGHTING 64
WIPER AND WASHER 65
AUDIO SYSTEM 66
WIRING 71
COMMUNICATION SYSTEM 81
WINDSHIELD 82
INSTRUMENT PANEL 83
© 2011 Beiqi Foton Motor Co., Ltd SEAT 84
DOOR LOCKS 85
All right reserved. No part of this service
manual may be reproduced or stored in a ENGINE HOOD AND DOORS 87
retrieval system, or transmitted in any form, or EXTERIOR AND INTERIOR TRIM 88
by any means, electronic, mechanical, photo- VEHICLE CONTROL SYSTEM 91
copying, recording or otherwise, without the
proir written permission of Foton. INDEX
INTRODUCTION 01

HOW TO USE..................................................01-1
OVERVIEW ................................................01-1
IDENTIFICATION............................................01-5
VEHICLE IDENTIFICATION NUMBER
(VIN)............................................................01-5
SERIAL NUMBER (SN)..............................01-6
GENERAL SERVICE GUIDELINE..................01-7
OPERATION PRECAUTION.......................01-7
VEHICLE LIFTING & SUPPORTING
POSITIONS...............................................01-15
HOW TO TROUBLESHOOT..........................01-16
OVERVIEW ..............................................01-16
ELECTRIC TEST PROCEDURE..............01-24
01
 INTRODUCTION - HOW TO USE 01-1

HOW TO USE
01
OVERVIEW
1. Overview
(a) This manual offers general information on repair services. Following this instrument will help to ensure
service quality and efficiency.
(b) In general, repair service consists of three components as follows:
• Diagnostics

• Replacement (removal & installation), disassembly and assembly, and (on-vehicle) inspection
and adjustment
(c) This manual focuses on "Diagnostics" (refer to "Chapter 4. Diagnostics") and "Replacement (removal &
installation, Disassembly & Assembly and (On-vehicle) Inspection and Adjustment", while excluding
"Final Check".
(d) This manual doesn't involve the following important operations in practical services:
• Jack or lift operation

• Cleaning of removed parts if needed

• Visual inspection

2. Index
(a) There is a glossary index at the end of this manual, for your reference.
3. Preparation
(a) Chapter 2 "Preparation" of this manual lists the specialized and recommended tools, equipments and
supplies required by repair services, which shall be used exactly following proper processes.
4. Repair Process
(a) Depending on chapters, part diagrams are presented for system description.
(b) In exploded view, the part diagram clearly states the assembling relationship between the parts, followed
by a table of part names.
 01-2 INTRODUCTION - HOW TO USE

Example:
01
 INTRODUCTION - HOW TO USE 01-3

(c) If the installation process is simply the opposite to the removal, only the key points are illustrated.
(d) The repair process presented in this manual only focuses are important steps, completed by illustrated 01
operation targets and actions. The process description states the detailed operations, standards and
precautions.
(e) Some similar models may share the same illustration in this manual. In such case, the content may be
slightly different from the actual model.
(f) The process is presented as follows:
• The process illustration describes "what and where to do".

• The process heading explains "what to do".

• The process description states "how to do" and offers "Repair Standard", "Repair Warning" and
other information.
Example:

5. Repair Standard
(a) In this manual, repair standards are in bold fonts, so that you don't need to look it up while stopping your
work at hand. The related information is also listed in Chapter 3 "Repair Standard" for quick reference.
6. "Danger", "Warning" & "Attention"
 01-4 INTRODUCTION - HOW TO USE

Danger In bold, it explains the potential personal injuries on you or others.

01 In bold, it represents potential damage to the part under service or the
Warning
equipment in use.
Attention In bold, it provides further information on repair service.

7. Unit: international measurement unit.

(a) All units used in this manual are international measurement units (SI units).
Example:
Torque: 30 N.m
 INTRODUCTION - IDENTIFICATION 01-5

IDENTIFICATION
01
VEHICLE IDENTIFICATION NUMBER (VIN)
1. Vehicle Identification Number (VIN)
(a) As illustrated, vehicle identification number (VIN) is pressed on VIN label and VIN plate.
• VIN label - at the front right part of the dashboard, it is visible via the front windscreen.

• VIN plate - it can be seen when the engine hood is open.

 01-6 INTRODUCTION - IDENTIFICATION

SERIAL NUMBER (SN)

01
1. The serial number of the rear drive axle.
(a) The serial number of the rear drive axle is stamped on the
axle tube.

2. Transmission Shaft SN
(a) Transmission shaft SN is printed on the transmission shaft
tube.
 INTRODUCTION - GENERAL SERVICE GUIDELINE 01-7

GENERAL SERVICE GUIDELINE

01
OPERATION PRECAUTION
1. Basic Precaution
(a) Service Precaution

• Wear clean working uniform.

1 Clothes • Wear protective hamlet and shoes.

2 Vehicle Protection • Before service, prepare the front grill pad, wing pad, seat cover and carpet.
• Be careful of the others when working with other coworkers.
• When servicing when the engine is on, keep the workspace well ventilated.
• Wear necessary protective equipments when working on hot, rotating,
3 Safe Operation moving or vibrating parts, to avoid burn or injury.
• When lifting the vehicle, work on the specified supporting points and ensure
it is securely supported.
• When lifting the vehicle, use safe and qualified equipments.
 01-8 INTRODUCTION - GENERAL SERVICE GUIDELINE

Preparation of Tools & • Before service, prepare the tool shelf, dedicated tools, measuring devices,
4 vehicle supplies, cloth and spare parts.
01 Measuring Devices
•Perform complete analysis and diagnostics on the defect and take effective
solutions.
• Before removing a part, check its general situation for distortion or damage.
Removal, Installation,
5
Disassembly & Assembly • If the part is complicated, note down the steps or make necessary marks to
avoid functional failure.
• Clean the removed parts if needed and install them after overall inspection.

• Place the removed parts in order and prevent them from confusion or con-
tamination.
6 Removed Parts • Once removed, replace O-ring, self-locking screw and other disposable parts
according to this manual.
• Keep the removed parts for customer reference.

(b) Lifting & Supporting Vehicle

• When lifting and supporting the vehicle, be careful to work on the right positions. (Refer to "Chapter
1. Introduction - service guideline, vehicle lifting and supporting positions")
(c) Glued Parts
• Glued parts refer to the bolts, nuts and other parts applied with sealant before delivery.

• If it is necessary to release, refasten or move a glued part by any means, reapply the specified
sealant.
• To reuse a glued part, clean and remove the original sealant, blow it dry with compressed air and
apply the specified sealant onto the bolt, nut or thread.
DANGER

Check the torque subject to the lower limit of the torque requirement.

• When using sealant, in some cases, it is necessary to wait for a while until the sealant becomes
hard.
(d) Gasket
• Add a gasket on the lining if necessary, to avoid leakage.

(e) Bolt, Nut & Screw

• Tighten them exactly following the specified torque with torque wrench.

(f) Fuse
• When replacing fuse, ensure the rated current of the new fuse is qualified. Don't use any fuse
incompliant with the rated current.
 INTRODUCTION - GENERAL SERVICE GUIDELINE 01-9

Illustration Symbol Part Name Abbrevation

01
Fuse F

Fuse Link F/L

(g) Clip
• See the table blow for the installation and removal of clips regularly used for vehicle parts.
CAUTION

If a clip is damaged during service, replace a new one.

Shape (Example) Removal & Installation

 01-10 INTRODUCTION - GENERAL SERVICE GUIDELINE

Shape (Example) Removal & Installation

01

(h) Removal & Installation of Vacuum Hose

• When removing and installing vacuum hose, grab
the end of the hose, instead of the middle.

• When disconnecting a vacuum hose connector, label

it to faciliate the identification upon connection.
• After removal and installation, check carefully whether
the vacuum hose is correctly connected.
• When using vacuum pressure gauge, if the connector
is too large, don't directly connect it to a vacuum hose.
Use a specialized adapater instead. If the vacuum hose
is expanded, leakage may occur.

(i) Use a Torque Wrench with Extended Handle

• When using a torque wrench with special service
tool or extended handle, if the torque displayed by
the wrench reaches the rated figure, it means the
actual torque is excessive.
• In this manual, only the torque values that require
special notes are described. When using a torque
wrench with special service tool or extended
handle, calculate the proper torque based on the
equation below.
 INTRODUCTION - GENERAL SERVICE GUIDELINE 01-11
• Equation: T＇=T×L2/（L1＋L2）
T＇ Torque reading (N•m) 01

T Actual torque (N•m)

Length of specialized tool
L1
or extended handle (mm)
Length of torque handle
L2
(mm)

2. Service Precaution on Model with Supplemental Restraint System

DANGER

Some vehicles are equipped with Supplemental Restraint System (SRS), i.e., driver airbag. Failure to
carry out service operations in the correct sequence may cause the SRS to unexpectedly deploy during
servicing, or even lead to critical accident. Furthermore, an operational mistake may also prevent the
SRS from normal operations. Before servicing (including removal, installation, inspection or replacement
of any part), be sure to read through the following items carefully and perform the correct procedures
described in the service manual.

(a) General Precaution

• Since it is difficult to identify the failure of the SRS, Diagnostic Trouble Code (DTC) is an essential
source of information during troubleshooting. Thus, when troubleshooting the SRS, always
remember to check the DTCs before disconnecting the battery.
• Operation can only be started 90 seconds after the ignition switch is turned to the “LOCK”
position and the negative (-) cable and the positive (+) cable are disconnected from the battery.
(The SRS is equipped with backup power supply. Therefore, if any operation is taken within 90
seconds after disconnecting the battery negative (-) cable and positive (+) cable, the SRS may
deploy suddenly.)
• When the negative (-) cable is disconnected from the battery, the memory of the clock and the
radio system will be reset. So before repairing, record all necessary data. At the end of repairing,
reset the radio system and the clock. Never use any backup power supply from another vehicle,
which may reset the memory of the systems. The backup power supply will power up the SRS,
which may unexpectedly deploy the airbag during servicing.
• Even after a minor impact that the SRS does not deploy, it is always important to check the horn
button assembly and airbag ECU. (Refer to “Chapter 62. Supplemental restraint system - horn
button assembly, replacement”, “Chapter 62. Supplemental restraint system - airbag ECU,
replacement”)
• Never use any SRS part from another vehicle. If replacement is required, be sure to use new
spare parts.
• Do not disassemble the horn button assembly.

• If the horn button assembly has been dropped, or there are cracks, dents or other faults on the
housing, replace it with a new one.
• Do not expose the horn button assembly to heat or flame.

• Use a multimeter with high resistance to troubleshoot the SRS electrical circuits.

• During servicing, be sure to follow the instructions on the labels attached to the SRS components.

• After repairing the SRS, remember to check the airbag indicator lamp. (Refer to “Chapter 04.
Diagnosis - airbag system, pre-check”, “Chapter 04: Diagnosis - airbag system, airbag indicator
lamp always on”, “Chapter 04. Diagnosis - airbag system, airbag indicator lamp always off”)
 01-12 INTRODUCTION - GENERAL SERVICE GUIDELINE

(b) Clock Spring

01 • Ensure the clock spring is centrally aligned and the
steering wheel is correctly installed on the steering
column. Otherwise it may lead to loose harness
connector or other defect. (Refer to "Chapter 51.
Steering system - steering wheel assembly,
overhaul", "Chapter 62. Supplemental restraint
system - clock spring, replacement")

(c) Horn Button Assembly (with Air Bag)

• When storing the horn button assembly, ensure it
faces up and don't place anything on the horn
button.
• Don't measure the resistance of the air bag trigger
unit, or the air bag may suddenly explode and
cause danger.
• Don't apply any grease or cleaner onto the horn
button.
• Store the horn button assembly in a place with the
ambient temperature lower than 93 ℃, moderate
humidity and free of electromagnetic intervention.
• Before welding, disconnect the air bag ECU
connector.
• Before disposing the prior horn button assembly,
explode the air bag with specialized tools in a safe
location free of electromagnetic intervention. (Refer
to “Chapter 62. Supplemental restraint system -
horn button assembly, disposal”)

3. Electric Control
(a) Connect & Disconnect Negative Battery Cable
• Before any electric service, disconnect the negative
battery cable to prevent any incident due to short
circuit.
• When disconnecting and connecting the battery
cable, turn off the ignition and lighting switch and
complete unscrew the cable retaining nuts, without
bending or movement.
• Once the negative battery cable is disconnected,
the clock and radio records will be reset. So before
repairing, record all necessary data.
 INTRODUCTION - GENERAL SERVICE GUIDELINE 01-13

(b) Work on Electric Components

• Unless particularly necessary, don't open the 01
control module housing (it may be damaged due
to static if the IC pins are touched by accident).
• When disconnecting the harness connector, pull
the connector instead of the harness.
• Be careful not to drop any electric component, such
as sensor or relay. If it is dropped on the hard
ground, replace it instead of reusing it.
• When cleaning the engine with steam, prevent the
electric components, air filter and other parts in
relation to emission control from steam.
• Don't install or remove the thermostat switch or
temperature sensor with impact wrench.
• When checking the conduction of the harness
connector, carefully insert the probe to prevent the
pins from distortion or damage.
• Once an electric component is replaced, check its
function and ensure it's functioning.

4. Removal & Installation of Fuel Control System Parts

(a) Site Precaution
• Work in a place with good ventilation, free of any equipment or object that may create flame,
including welding, grinder, electric drill, motor or oven.
• Don't work in or near a gas station, because the vaporized fuel may be alll over the place.

(b) Removal & Installation of Fuel System Parts

• Prepare a fire extinguisher before service.

• To prevent static, ground the vehicle and fuel tank and maintain the workshop ground dry, to
prevent slipping.
• Don't use motor, working lamp or similar electric unit, to avoid spark or high temperature.

• Don't use an iron hammer to prevent spark.

• Dispose the cloth containing fuel in a nonignitable container.

5. Removal & Installation of Engine Intake System Parts

CAUTION

Any metal fragment in the intake air pipe will seriously damage the engine.

(a) When removing or installing the intake air system parts, close the opening caused by the removed part
with clean cloth or tape.
(b) When installing the intake system parts, ensure there is no metal fragment.
 01-14 INTRODUCTION - GENERAL SERVICE GUIDELINE

6. Service on Hose Clip

01 (a) Before removing the hose, check the depth of the
connector and the position of the clip, to ensure correct
reinstallation.
(b) If any distortion or dent in the hose, replace it.
(c) If the hose is reusable, place the spring clip on the original
mark.
(d) For spring clip, after installation, adjust its position by
pushing towards the arrow direction.

7. Catalyst Converter
CAUTION

If plenty of fuel flows into the catalyst converter without combustion, the catalyst converter will be
overheated, which may cause fire. In order to prevent such accident, follow the precautions below during
service.

(a) Use only unleaded gasoline (for gasoline model).

(b) Don't idle the engine for more than 20 minutes.
(c) Avoid unnecessary sparking test.
• Don't do any sparking test unless necessary. If it is necessary, complete it as soon as possible.

• Don't press the accelerator when doing sparking test.

(d) Don't perform an engine stress test on an ongoing basis. Complete it as soon as possible.
(e) Don't run the engine when the fuel tank is nearly empty, or it may cause extra burden to the catalyst
converter when the engine is out of service.
 INTRODUCTION - GENERAL SERVICE GUIDELINE 01-15

VEHICLE LIFTING & SUPPORTING POSITIONS

01
1. When lifting, pay attention to the vehicle condition.
(a) Principle: Lift the vehicle without load. This operation isn't allowed for loaded vehicle.
(b) When removing the engine, transmission or heavier part, the gravity center of the vehicle may change.
Place some balance blocks to avoid rollover, or support it with a jack at the specified position.
2. Precaution on Jack & Lift Use
(a) Work safety according to this manual.
(b) Don't lift the tires with a bar, or it may damage the wheel and tire.
(c) Park the vehicle on flat ground and engage the park brake.
(d) Engage the shift to the reverse gear position.
(e) With stop block, hold the wheel diagonal to the position to lift.
(f) Lift the vehicle with a jack with rubber pad or a lift.
DANGER

Lift the vehicle at the specified lifting positions.

 01-16 INTRODUCTION - HOW TO TROUBLESHOOT

HOW TO TROUBLESHOOT
01
OVERVIEW
There are a number of circuits in the model. In general, the troubleshooting of complicated circuit
defects requires rich knowledge and skills of the service professinals. However, most of the defects
can be identified by checking the circuit one by one. As long as with sufficient understanding and
fundamental electric knowledge, the service professional will be able to accurately troubleshoot
and fix the system.
Based on the above principles, this manual offers accurate and effective solutions to service
professionals.
Please refer to details below on troubleshooting process.
System Reference
Anti-lock Brake System (ABS) Chapter 4. Diagnostics - ABS
Air Bag System Chapter 4. Diagnostics - air bag system
Reverse Sensor System Chapter 04. Diagnosis - reverse sensor system
Electric Window Control System Chapter 4. Diagnostics - electric window control system
Electric Rearview Mirror Chapter 4. Diagnostics - electric rearview mirror
Electric Door Lock Control System Chapter 4. Diagnostics - electric door lock control system
Engine Control System Chapter 4. Diagnostics - gasoline engine control system
Wiper & Washer Chapter 4. Diagnostics - wiper & washer
Chapter 4. Diagnostics - rear windscreen defrosting
Rear Windscreen Defrosting System
system
Horn Chapter 4. Diagnostics - horn
Heating & Air-conditioning Chapter 4. Diagnostics - heating & air-conditioning
Radio System Chapter 4. Diagnostics - radio system
Lighting System Chapter 4. Diagnostics - lighting system
Instrument Panel Chapter 4. Diagnostics - instrument panel
Combined Display Chapter 4. Diagnostics - combined display
Body Controller Chapter 4. Diagnostics - body controller
Tire Pressure Monitoring System Chapter 4. Diagnostics - tire pressure monitoring system
Transfer Case Chapter 4. Diagnostics - transfer case
Front Axle Clutch Chapter 4. Diagnostics - front axle clutch

About Analyzer
1. Before using the analyzer, carefully review the user's manual.
2. Connect the analyzer to the dashboard diagnostics harness connector and switch on the ignition.
If there is no communication between the analyzer and the control module, it means either the
vehicle or the analyzer is defective.
(a) If the analyzer works properly when connected another vehicle, check the dashboard diagnostics harness
or the control module power supply.
 INTRODUCTION - HOW TO TROUBLESHOOT 01-17

(b) If no communication when the analyzer is connected to another vehicle, it means the analyzer might be
defective. Follow the self-diagnostics procedure in the user's manual. 01
How to Troubleshoot

CAUTION
• In this part, we focus on the fundamental processes.
• Please troubleshoot subject to the detailed processes listed below.
• This manual explains the most effective troubleshooting process for each circuit. (Refer to
"Chapter 4. Diagnostics".)
• Before any service, review the troubleshooting process of the related circuits.

1. Defective Vehicle Delivered

2. The customer describes the defect.
(a) Inquire the customer about the situation and circumstance when the defect occurred.
3. Identify symptom and check DTC (with data flow).
(a) Measure the battery voltage.
Voltage: 11~14V (engine off)
(b) Visually check for broken or short circuit in the harness, connector and fuse.
(c) Start the engine and warm it up to normal working temperature.
(d) Identify the symptom and conditions and check DTC.
If any DTC?
Yes > Go to Step 4.
No > Go to Step 5.
4. Check DTC list.
(a) Check DTC obtained in Step 3, review DTC list and define the system or part inspection process by
defective position.
Go to Step 6.
5. Review defects.
(a) Check the exact symptom obtained in Step 3, review the defect list and define the system or part inspection
process by potential positions.
6. Check the Circuit & Part
(a) Check the system circuit or part identified in Steps 4 & 5, as the potential cause of the defect.
(b) Confirm the defective circuit or part.
7. Repair
(a) Adjust, repair or replace the defective circuit or part.
8. Verification
(a) After repair, confirm the defect is eliminated.
(b) If the defect doesn't reoccur, it is also important to simulate the vehicle condition and circumstance at
the first occurrence for verification.
9. Done
The customer describes the defect.
 01-18 INTRODUCTION - HOW TO TROUBLESHOOT

CAUTION
01
• During troubleshooting, don't be judgmental. Accurately analyze the situation and identify the
symptom.
• It is important to inquire the customer about the situation and circumstance when the defect
occurred.
• Some seemingly experiences of defect or repair may also help the troubleshooting. Therefore,
collecting as much information related to symptom as possible will faciliate the process.
• To accurately identify the symptom, pay close attention to the following 5 items in the customer's
description on the defect.

What? Model No., system name

When? Date, time, frequency
Where? Road condition
Under what situation? Conditions of operation, driving, weather
How? Symptom

Identify symptom and check DTC (with data flow).

CAUTION

The analyzer system has a numbere of functions.

(1) The first function is Diagnostics Troubleshooting Code (DTC) check. The defect signal of the control
model circuit is stored in the RAM by code. The service professional may review prior DTC during the
operation.

(2) Another function is the input check. Check whether the signals from different switches are properly
sent to the control module.

These functions help to quickly narrow down the scope and improve the efficiency.

System De- Signal Check

System DTC Data Flow Diagnostics
scription (Sensor)
Anti-lock Brake
— O O O O
System (ABS)
Engine Control
O O O O O
System
Body Control
O O O O O
System
Supplemental
Restraint System — — — — O
(SRS)
Reverse Sensor
— — — — O
System
Electric Window
— — — — O
Control System
Electric Rearview
— — — — O
Mirror
 INTRODUCTION - HOW TO TROUBLESHOOT 01-19

System De- Signal Check

System DTC Data Flow Diagnostics
scription (Sensor) 01
Electric Door
Lock Control — — — — O
System
Wiper & Washer — — — — O
Rear Windscreen
Defrosting Sys- — — — — O
tem
Horn — — — — O
Heating & Air-
— — — — O
conditioning
Radio System — — — — O
Lighting System — — — — O
Instrument Panel — — — — O
Combined Dis-
— — — — O
play
Tire Pressure
Monitoring Sys- — — — — O
tem
Transfer Case — — — — O
Front Axle Clutch — — — — O

(1) During DTC check, it is critical to identify whethe the defect remains or it occurred once and
now comes back to normal. In addition, when identifying the symptom, check whether the defect
displayed by DTC and the actual symptom is directly related. Therefore, perform DTC check both
before and after identifying the symptom, in order to understand the current vehicle condition.
Otherwise, it may lead to unnecessary diagnostics and troubleshooting on normal system, which
increases the difficulty of troubleshooting or causes unrelated operations. Thus, it is essential to
perform DTC check as required.
(2) THe process to use DTC check for troubleshooting, as illustrated below. The process
demonostrates how to efficiencly use DTC check. Finally, it also illustrates how to troubleshoot
with DTC and defect list.
1. DTC Check
2. Record the displayed DTC and then erase it.
CAUTION

If DTC appears in the first check, it means there was defect in the circuit harness or connector. Check
the related harness or connector. (Refer to "Chapter 1. Introduction - how to troubleshoot, electric test
procedure")

3. Identify the Symptom

Does the symptom remain?
Yes > Go to Step 4.
 01-20 INTRODUCTION - HOW TO TROUBLESHOOT

No > Go to Step 5.
01 4. Simultaneous Symptom Test (Refer to "Chapter 1. Introduction - how to troubleshoot, how to
troubleshot")
5. DTC Check Again
If any DTC?
Yes > Troubleshoot the defect displayed by DTC.
No > System in normal condition.
6. Identify the Symptom
Does the symptom exist?
Yes > Go to Step 7.
No > System in normal condition.
7. Troubleshoot by Defect List
The exact defect exceeds the scope of the diagnostics system (the prior DTC refers to
former defect or is not the key point).
8. Done
Simultaneous Symptom Test

CAUTION
• For troubleshooting, the most difficult situation is no symptom at all. In such case, it is important
to thoroughly analyze the defect described by the customer and simulate the vehicle and
circumstance upon the defect. Regardless of experience and skill, if a service professional fails
to verify the symptom during troubleshooting, he may ignore some important messages and
make the wrong guess, which leads to ineffectiveness.
• For example, the defects occurred at cool state or due to bumpy road in driving can never be
identified when the engine is hot or the vehicle is parked. Since vibration, heat and water leakage
(humidity) are frequent causes of defects, which are hard to reduplicate, simultaneous symptom
test is introduced, which effectively simulates the circumstance for diagnostics when the vehicle
is parked.
• Key points of simultaneous symptom test: (1) First of all, confirm the symptom and identify the
position or part of the defect. To do this, before the simulation, connect the analyzer first and
narrow down the troubleshooting scope depending on the symptom. (2) Perform the simulation
symptom test, determine whether the tested circuit is broken or working, and also verify the
symptom. Refere to the system defect lists and narrow down the scope of possible causes.
INTRODUCTION - HOW TO TROUBLESHOOT 01-21

1. Swinging - for defects potentially caused by vibration.

(a) Part and sensor. 01
• Slightly swing the potentially defective sensor with
your finger and notice the defect.
CAUTION

If too much force is imposed, it may break the relay circuit.

(b) Connector.
• Slightly swing the connector vertically and
horizontally.
(c) Harness.
• Slightly swing the harness vertically and
horizontally. Carefully check the connection
between the harness and the connector.

2. Heating - for any defect caused by partial heat.

(a) Heat the potentially defective part with a hair dryer or
equivalent and notice the defect.
CAUTION
• Don't allow the temperature exceeding 60 ℃, or it may
damage the part.
• Don't directly heat the parts inside the control module.

3. Raining - for any defect potentially caused by rain or

high humidity.
(a) Spray water onto the vehicle and notice the defect.
CAUTION
• Don't directly spray water onto the engine hood. Spray
water onto the radiator, which will indirectly change
the engine temperature and humidity.
• Don't spray water directly onto the electic components.

CAUTION

If any leakage, the fluid may contaminate the control module.

Pay attention to it during the raining test.
 01-22 INTRODUCTION - HOW TO TROUBLESHOOT

4. High electric load - for any defect potentially caused

01 by high electric load.
(a) Switch on all consumers, including A/C, headlight and rear
windscreen heating and notice the defect.

DTC List
Take the DTC list of the engine control system as an example, as shown in the table below.
The table shows DTCs and corresponding test procedures. Troubleshooting by the table will
substantially improve your efficiency and accuracy.

Defects
 INTRODUCTION - HOW TO TROUBLESHOOT 01-23

Defects deliver the possible causes (such as circuit or part) of each defect as follows. When the
analyzer displays that the system is working properly, yet the defect remains, troubleshoot by the 01
defect list. The number in the table refers to the sequence of circuit or part check.
If the vehicle diagnostics system cannot find the defect, while the symptom actually exists, it means
the defect exceeds the scope of the system.
 01-24 INTRODUCTION - HOW TO TROUBLESHOOT

ELECTRIC TEST PROCEDURE

01
How to read and use the Electric Test section in this manual as the table below.

1. Basic Check
(a) Resistance Measuring Conditions on Electric Components
• All resistance measurements are under the ambient temperature of 20℃ unless otherwise
indicated.
• A running vehicle increases the temperature, under which the measured resistance may exceed
the specified range. Therefore, perform the resistance measurement after the engine cools down.
INTRODUCTION - HOW TO TROUBLESHOOT 01-25

(b) Precaution on Connector Operation

• When removing a connector with buckle, slightly 01
press the connector along the interface, gently
press the clip and open the buckle.
• When removing the connector, hold it without
stretching the harness.
• When connecting the connector, check for
distortion, damage or missing pin in the connector.
• When connecting the connector with buckle, ensure
you hear the click, which means it is firmly secured.
• When checking the connector with multimeter, use
mini probe at the back of the connector (one side
of the harness).
CAUTION
• Since no back check is available to waterproof
connector, check it after connecting a supplementary
harness.
• When moving the probe, be careful not to damage the
connector pin. Key Points on Connector Check

(c) Key Points on Connector Check

When connecting the connector, check:
• Hold the connector. Check the inserting and locking
situations (connected).
When disconnecting the connector, check:
• Gently pull the harness and check for missing or
bent pin or broken central harness.
• Visually check for rust, metal fragment, water and
bent or rusty pin, impurities or distortion in the
connector.

Check the contact pressure at the pin:

• Prepare a male connector and insert it into the female
connector, to check the connection and sliding
resistance.
CAUTION

Use gold-plated male connector to check gold-plated female

connector.
 01-26 INTRODUCTION - HOW TO TROUBLESHOOT

(d) Service at Connector Pin

01 • If any dirt or oil, clean the contact point with air gun
or cloth. Don't polish with sand paper, or it may
damage the plated layer.
• If the contact pressure is abnormal, replace the
female connector. In such case, if the male
connector is gold plated, use a female gold-plated
connector. And if the male connector is silver
plated, use a female connector in the same
material.

(e) Service Precaution on Harness

• Before removing the harness, check the positions
of the harness and the band, to faciliate
reinstallation.
• Don't excessively twist, pull or hang the harness.

• Keep the harness away from hot, rotating, moving,

vibrating or sharp (such as panel edge or screw
point) parts.
• When installing the parts, don't clamp or catch the
harness.
• Don't cut or break the harness insulation. In case
of breakage, replace the harness or wrap the
broken part with insulation tape.

2. Check for Broken Circuit

(a) See the circuit diagram as illustrated at the left. Perform
conduction test and voltage test in Step 2 and 3
respectively, to identify the position of broken circuit.

(b) Conduction Test

• Disconnect the connectors A and C and measure
the resistance in between.
Resistance: < 2Ω

CAUTION

Slightly swing the harness horizontally and vertically, and

measure the resistance.

Take this circuit for an example.

If the resistance between Pin 1 of
Connectors A and C: ≥ 1 M
And the resistance between Pin 2 of
Connectors A and C: < 2 M
INTRODUCTION - HOW TO TROUBLESHOOT 01-27

It means the circuit is broken between Pin 1

of Connectors A and C. 01

• Disconnect Connector B and measure the resistance

between the connectors.
Take this circuit for an example.
And the resistance between Pin 1 of Connectors
A and B1: < 2
And the resistance between Pin 1 of Connectors
B2 and C: ≥ 1 M
It means the circuit is broken between Pin 1 of
Connectors B2 and C.

(c) Voltage Test

• When the circuit is energized, check for broken
circuit by means of voltage test.
• Take the circuit as an example. All the connectors
are connected. Measure the voltage between Pin
1 of Connector A, Pin 1 of Connector B, Pin 1 of
Connector C at the 5V output of the control module
and the grounding in sequence.
If the following results are achieved:
Voltage between Pin 1 of Connector A and
grounding: 5V
Voltage between Pin 1 of Connector B and
grounding: 5V
Voltage between Pin 1 of Connector C and
grounding: 0 V
It means the circuit is broken between Pin 1
of Connectors B and C.

3. Check for Short Circuit

(a) As illustrated at the left, there is short circuit between the
harness and the grounding. Perform conduction test
between it and the grounding in Step 2, to identify the short
position.
 01-28 INTRODUCTION - HOW TO TROUBLESHOOT

(b) Conduction Test

01 • Disconnect Connectors A and B and measure the
resistance between Pins 1 & 2 of Connector A and
the grounding.
Resistance: ≥ 1 MΩ

CAUTION

Slightly swing the harness horizontally and vertically, and

measure the resistance.

Take this circuit for an example.

If the resistance between Pin 1 of Connector
A and grounding: ＜ 2
And the resistance between Pin 2 of
Connector A and grounding: ≥ 1 M
It means the circuit is broken between Pin 1
of Connectors A and C.

• Disconnect Connector B and measure the resistance

between Pin 1 of Connectors A and B2 and the
grounding.
Take this circuit for an example.
And the resistance between Pin 1 of Connector A
and grounding: ≥ 1 M
And the resistance between Pin 1 of Connector B2
and grounding: ＜ 2
It means there is short circuit between Pin 1 of
Connectors B2 and C.
 PREPARATION
SEAT BELT...............................................02-1 PREPARATION...................................02-19 02
PREPARATION.....................................02-1 CLUTCH..................................................02-20
TRANSMISSION.......................................02-2 PREPARATION...................................02-20
PREPARATION.....................................02-2 DOOR LOCK..........................................02-21
VEHICLE CONTROL SYSTEM................02-4 PREPARATION...................................02-21
PREPARATION.....................................02-4 HEATING & AIR-CONDITIONING..........02-22
WHEEL & TIRE.........................................02-5 PREPARATION...................................02-22
PREPARATION.....................................02-5 EMISSION CONTROL............................02-24
DOOR & ENGINE HOOD.........................02-6 PREPARATION...................................02-24
PREPARATION.....................................02-6 EXHAUST...............................................02-25
WINDSCREEN, WINDOW & BACKVIEW PREPARATION...................................02-25
MIRROR....................................................02-7 START & CHARGE.................................02-26
PREPARATION.....................................02-7 PREPARATION...................................02-26
POWER STEERING..................................02-9 FRONT SUSPENSION...........................02-28
PREPARATION.....................................02-9 PREPARATION...................................02-28
ENGINE MECHANICAL SYSTEM..........02-10 AXLE & TRANSMISSION SHAFT..........02-29
PREPARATION...................................02-10 PREPARATION...................................02-29
ENGINE CONTROL SYSTEM................02-12 FUEL.......................................................02-32
PREPARATION...................................02-12 PREPARATION...................................02-32
SUPPLEMENTAL RESTRAINT LUBRICATION........................................02-33
SYSTEM..................................................02-13 PREPARATION...................................02-33
PREPARATION...................................02-13 DASHBOARD & INSTRUMENTS...........02-34
WIPER & WASHER.................................02-14 PREPARATION...................................02-34
PREPARATION...................................02-14 DIAGNOSTICS........................................02-35
BRAKE....................................................02-15 PREPARATION...................................02-35
PREPARATION...................................02-15 PARK BRAKE.........................................02-37
REAR SUSPENSION..............................02-17 PREPARATION...................................02-37
PREPARATION...................................02-17 STEERING SYSTEM..............................02-38
INTAKE...................................................02-18 PREPARATION...................................02-38
PREPARATION...................................02-18 SEATING.................................................02-39
COOLING................................................02-19 PREPARATION...................................02-39
02
 PREPARATION - SEAT BELT 02-1

SEAT BELT
PREPARATION
Recommended Tools 02

Digital Multimeter Electrical Buckle Assembly

Torque Wrench
 02-2 PREPARATION - TRANSMISSION

TRANSMISSION
PREPARATION
02 Recommended Tools

Synchronizer
Feeler Gauge
Intermediate Shaft Spacer

Needle Nose Pliers Return Spring

Cooper Rod Reverse idler shaft

Hammer Reverse idler shaft

Dial Indicator

Micrometer
 PREPARATION - TRANSMISSION 02-3

Circlip Pliers 02

Shifting Fork
Vernier Calipers
Synchronizer

Puller Bearing

Torque Wrench

Equipments
V Bench
Table Vice

Supplies
Item Usage Specification
GL-5 75W/90
Transmission Oil 2.0L GL-5 80W/90
GL-5 85W/90
Lubricant Mitsubishi No.0101011
Sealant Mitsubishi No.997740
Adhesive 3M No.4170
 02-4 PREPARATION - VEHICLE CONTROL SYSTEM

VEHICLE CONTROL SYSTEM

PREPARATION
02 Recommended Tools

KT600 Integrated Diagnostic Unit

Digital Multimeter

Torque Wrench
 PREPARATION - WHEEL & TIRE 02-5

WHEEL & TIRE

PREPARATION
Recommended Tools 02

Tire Pressure Gauge Wheel & Tire

Torque Wrench

Equipments
Dynamic Balancer
Tire Changer
Tire Inflator

Supplies
Item Usage Specification
Balance Block
 02-6 PREPARATION - DOOR & ENGINE HOOD

DOOR & ENGINE HOOD

PREPARATION
02 Recommended Tools

Grease Gun Door

Torque Wrench

Supplies
Item Usage Specification
Grease
 PREPARATION - WINDSCREEN, WINDOW & BACKVIEW MIRROR 02-7

WINDSCREEN, WINDOW & BACKVIEW MIRROR

PREPARATION
Recommended Tools 02

Windscreen
Plastic Spatula
Rear Windscreen

Windscreen
Glass Sucker
Rear Windscreen

Windscreen
Utility Knife
Rear Windscreen

Windscreen
Silicon Gun
Rear Windscreen

Windscreen
Rubber Hammer
Rear Windscreen

Supplies
Item Usage Specification
Protective Strap
Wooden Block
Plastic Sheet
Fine Wire
Nylon String
 02-8 PREPARATION - WINDSCREEN, WINDOW & BACKVIEW MIRROR

Item Usage Specification

Tape

02 Primer Reactive Polyester Primer in Black

Glass Sealant Polyurethane Sealant in Black

 PREPARATION - POWER STEERING 02-9

POWER STEERING
PREPARATION
Recommended Tools 02

Tape Measure Driving Wandering

Torque Wrench

Supplies
Item Usage Specification
Steering Fluid 0.4.0L ATF-III
Steering Lubricant QL-5 80W/90
Sealant for Hydraulic Return Pipe
 02-10 PREPARATION - ENGINE MECHANICAL SYSTEM

ENGINE MECHANICAL SYSTEM

PREPARATION
02 Special Tools

Cylinder Head Bolt Remover Cylinder Head Bolt

To remove valve and related com-

Valve Spring Compressor ponents

Recommended Tools

Dial Indicator Crankshaft

Micrometer Piston

Circlip Pliers Piston Pin

Hydraulic Jack Vernier Calipers Engine

 PREPARATION - ENGINE MECHANICAL SYSTEM 02-11

Vernier Calipers Camshaft 02

Feeler Gauge Crankshaft

Needle Nose Pliers Water Pipe Clip

Torque Wrench

Supplies
Item Usage Specification
Sealant Foton-authorized Sealant
Coolant 10.0L Foton-authorized Coolant
SAE 0W-30
Engine Oil 4.0.0L SAE 5W-30
SAE 5W-40
 02-12 PREPARATION - ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM

PREPARATION
02 Recommended Tools

Fuel Injection System

Ignition System
KT600 Integrated Diagnostic Unit
sensor
Actuator

sensor
Digital Multimeter Actuator
ECM

sensor
Test Cable Set Actuator
ECM

Torque Wrench

Equipments
Oscillograph Read the wave form of sensor
Fuel pressure gauge Check the fuel pressure.

Supplies
Item Usage Specification
Threaded Seal 3M NO.4171 or equivalent
 PREPARATION - SUPPLEMENTAL RESTRAINT SYSTEM 02-13

SUPPLEMENTAL RESTRAINT SYSTEM

PREPARATION
Recommended Tools 02

Hexagon Wrench Horn Button Assembly

Torque Wrench
 02-14 PREPARATION - WIPER & WASHER

WIPER & WASHER

PREPARATION
02 Recommended Tools

Digital Multimeter

Torque Wrench

Equipments
Oscillograph
 PREPARATION - BRAKE 02-15

BRAKE
PREPARATION
Recommended Tools 02

Micrometer Brake Disc

Dial Indicator Brake Disc

Rear Brake Drum

Vernier Calipers
Rear Brake Shoe

Tape Measure Brake Lining

Front Rim
Grease Gun
Rear Rim

Front Rim
Rear Rim
Puller Front Rim Oil Seal
Rear Rim Oil Seal
Half Axle
 02-16 PREPARATION - BRAKE

02 Torque Wrench Thermostat

Supplies
Item Usage Specification
Braking Fluid 1.0L 7104-1(D0T4)
 PREPARATION - REAR SUSPENSION 02-17

REAR SUSPENSION
PREPARATION
Recommended Tools 02

Torque wrench (20–120N.m)

Equipments
Wheel Alignment
Tire Changer
Wheel Dynamic Balancer

Supplies
Item Usage Specification
Grease
 02-18 PREPARATION - INTAKE

INTAKE
PREPARATION
02 Recommended Tools

Needle Nose Pliers

Gas Leakage Sensor

High Pressure Air Gun

 PREPARATION - COOLING 02-19

COOLING
PREPARATION
Recommended Tools 02

Radiator Cover Tester Water Tank

High Pressure Air Gun Water Tank

Thermometer Thermostat

Equipments
Steam Cleaner

Supplies
Item Usage Specification
Sealant Foton-authorized Sealant
Coolant (Gas engine) 6.5L Foton-authorized Coolant
Coolant (Diesel engine) 8–9L Foton-authorized Coolant
 02-20 PREPARATION - CLUTCH

CLUTCH
PREPARATION
02 Recommended Tools

Dial Indicator Lining

Vernier Calipers Lining

Circlip Pliers Clutch Pump

Torque Wrench -

Equipments
Table Vice

Supplies
Item Usage Specification
Braking Fluid 1L DOT3
Grease Mitsubishi No.0101011
 PREPARATION - DOOR LOCK 02-21

DOOR LOCK
PREPARATION
Recommended Tools 02

Circlip Pliers Lock Cylinder

Supplies
Item Usage Specification
Grease
 02-22 PREPARATION - HEATING & AIR-CONDITIONING

HEATING & AIR-CONDITIONING

PREPARATION
02 Recommended Tools

Rubber Tube for Refrigerant Topping Add refrigerant.

Gas Leakage Sensor Check refrigerant leakage

Heating & Air-conditioning Control

Digital Multimeter System

Belt Tension Gauge Check compressor belt tension

Refrigerant Topping & Recycling Unit Fill and collect the refrigerant
(No Vacuum Pump is Needed with
Repair compressor assembly
This Unit)

Fill up the Refrigerant

Vacuum Pump
Repair compressor assembly

Equipments
Steam Cleaner Clean A/C pipeline
 PREPARATION - HEATING & AIR-CONDITIONING 02-23

Supplies
Item Usage Specification
Refrigerant 700 ± 50g R134a 02
 02-24 PREPARATION - EMISSION CONTROL

EMISSION CONTROL
PREPARATION
02 Recommended Tools

Carbon Canister
Canister Solenoid Valve
High Pressure Air Gun
Positive Crankcase Ventilation
Valve
 PREPARATION - EXHAUST 02-25

EXHAUST
PREPARATION
Recommended Tools 02

Feeler Gauge Exhaust Manifold

Torque Wrench

Supplies
Item Usage Specification
Foton-authorized Exhaust Pipe
Exhaust Pipe Sealant
Sealant
 02-26 PREPARATION - START & CHARGE

START & CHARGE

PREPARATION
02 Recommended Tools

Digital Multimeter Alternator

Alternator
Dial Indicator
Starter

Vernier Calipers Starter

Puller Starter

Electric Iron Alternator

Circlip Pliers Starter

 PREPARATION - START & CHARGE 02-27

Torque Wrench 02

Equipments
Battery Recharger

Supplies
Item Usage Specification
Grease
 02-28 PREPARATION - FRONT SUSPENSION

FRONT SUSPENSION
PREPARATION
02 Recommended Tools

Torque Wrench

Equipments
Wheel Alignment
Tire Changer
Wheel Dynamic Balancer

Supplies
Item Usage Specification
Add (1.8±0.1)g to the sliding part of
Lithium base grease
the column connecting rod
 PREPARATION - AXLE & TRANSMISSION SHAFT 02-29

AXLE & TRANSMISSION SHAFT

PREPARATION
Recommended Tools 02

Tire Pressure Gauge Tire

Transmission Shaft Spline

Feeler Gauge
Half Axle Gear

Transmission Shaft Cardin Joint

Intermediate Bearing
Front Wheel Trim
Hammer Rear Wheel Trim
Rear Wheel Bearing
Cardin Joint
Differential Planetary Gear Shaft

Transmission Shaft Cardin Joint

Intermediate Bearing
Front Wheel Trim
Cooper Rod Rear Wheel Trim
Rear Wheel Bearing
Cardin Joint
Differential Planetary Gear Shaft

Transmission Shaft Cardin Joint

Micrometer Cross Shaft

Transmission Shaft Cardin Joint

Front Wheel Bearing
Rear Wheel Bearing
Dial Indicator
Drive Gear
Passive Wheel
Half Axle Gear
 02-30 PREPARATION - AXLE & TRANSMISSION SHAFT

Planetary Gear
Drive Gear Flange

02
Transmission Shaft Cardin Joint
Circlip Pliers Rear Wheel Bearing
Main Reducer Output Flange

Puller Transmission Shaft Yoke

Front Wheel Bearing

Grease Gun Rear Wheel Bearing
Cardin Joint

Front Wheel Turning Force

Spring Balance
Rear Wheel Turning Force

Split Pin
Intermediate Bearing Oil Seal
Needle Nose Pliers Main Reducer Output Flange Oil
Seal
Drive Gear Oil Seal

Tape Measure Rear Axle Windage

 PREPARATION - AXLE & TRANSMISSION SHAFT 02-31

Main Reducer Oil Filler Plug

Hexagon Wrench 02
Main Reducer Oil Drain Plug

Hydraulic Jack Main Reducer Assembly

Half Axle Gear Thrust Washer

Planetary Gear Thrust Washer
Vernier Calipers
Differential Bearing Spacer
Drive Gear Spacer

Torque Wrench Drive Gear Starting Torque

Equipments
V Bench
Transmission Shaft Dynamic Balancer
Table Vice
Benchpress

Supplies
Item Usage Specification
Front Main Reducer Gear Oil 1.2L GL-5 85W/90
Rear Main Reducer Gear Oil (1.27±0.03)L GL-5 85W/90
Rear Main Reducer Gear Oil Additive Approx. 0.06L Houghton Sturaco 7098
Loctite 5699 surface sealant or
Sealant Proper amount
equivalent
 02-32 PREPARATION - FUEL

FUEL
PREPARATION
02 Recommended Tools

Needle Nose Pliers Fuel Pressure Regulator

Pressure Jack Fuel Tank Assembly

Filter Wrench Fuel Filter Assembly

Equipments
Fuel Nozzle Leakage Detector
 PREPARATION - LUBRICATION 02-33

LUBRICATION
PREPARATION
Recommended Tools 02

Feeler Gauge Engine Oil Pump

Hammer Oil Pan

Torque Wrench

Supplies
Item Usage Specification
Sealant Foton-authorized Sealant
SAE 0W-30
Engine Oil 4L SAE 5W-30
SAE 5W-40
 02-34 PREPARATION - DASHBOARD & INSTRUMENTS

DASHBOARD & INSTRUMENTS

PREPARATION
02 Recommended Tools

KT600 Integrated Diagnostic Unit Instrument Panel

Hexagon Wrench Horn Button Assembly

 PREPARATION - DIAGNOSTICS 02-35

DIAGNOSTICS
PREPARATION
Recommended Tools 02

KT600 Inte- Engine Control System

grated Diag- Anti-lock Brake System (ABS)
nostic Unit Supplemental Restraint System (SRS)

Engine Control System

Anti-lock Brake System (ABS)
Supplemental Restraint System (SRS)
Electric Window Control System
Electric Rearview Mirror
Electric Door Lock Control System
Digital Multi- Wiper & Washer
meter
Rear Windscreen Defrosting System
Heating & Air-conditioning
Information System
Audio System
Lighting System
Instrument Panel

Engine Control System

Anti-lock Brake System (ABS)
Supplemental Restraint System (SRS)
Electric Window Control System
Electric Rearview Mirror
Electric Door Lock Control System
Test Cable Wiper & Washer
Set
Rear Windscreen Defrosting System
Heating & Air-conditioning
Information System
Audio System
Lighting System
Instrument Panel

To r q u e
Wrench
 02-36 PREPARATION - DIAGNOSTICS

Equipments
Oscillograph
02
Supplies
Item Usage Specification
Thread Sealant 3M NO.4171 or equivalent
 PREPARATION - PARK BRAKE 02-37

PARK BRAKE
PREPARATION
Recommended Tools 02

Rear Brake Drum

Vernier Calipers
Rear Brake Shoe

Front Park Brake Cable

Needle Nose Pliers Left Rear Park Brake Cable
Right Rear Park Brake Cable

Equipments
Table Vice

Supplies
Item Usage Specification
Braking Fluid 1L 7104–1(D0T4)
 02-38 PREPARATION - STEERING SYSTEM

STEERING SYSTEM
PREPARATION
02 Recommended Tools

Tape Measure Driving Wandering

Hexagon Wrench Horn Button Assembly

Steering Wheel Force (Engine

Spring Balance Switch)

Dial Indicator

Torque Wrench

Equipments
V Bench
 PREPARATION - SEATING 02-39

SEATING
PREPARATION
Recommended Tools 02

Driver's/Front Passenger Backrest

Hexagon Wrench Driver's/Front Passenger Seat Base
Assembly

Needle Nose Pliers Driver's/Front Passenger Backrest

Torque Wrench
 02-40 PREPARATION - SEATING

02
 SERVICE SPECIFICATIONS
SEAT BELT...............................................03-1 REQUIRED TORQUE.........................03-27
REQUIRED TORQUE...........................03-1 COOLING................................................03-28
TRANSMISSION.......................................03-2 SERVICE DATA...................................03-28 03
SERVICE DATA.....................................03-2 REQUIRED TORQUE.........................03-29
REQUIRED TORQUE...........................03-3 CLUTCH..................................................03-30
WHEEL & TIRE.........................................03-4 SERVICE DATA...................................03-30
SERVICE DATA.....................................03-4 REQUIRED TORQUE.........................03-31
REQUIRED TORQUE...........................03-5 INTERIOR & EXTERIOR TRIMS............03-32
DOOR & ENGINE HOOD.........................03-6 REQUIRED TORQUE.........................03-32
SERVICE DATA.....................................03-6 EMISSION CONTROL............................03-33
REQUIRED TORQUE...........................03-7 REQUIRED TORQUE.........................03-33
IGNITION..................................................03-8 EXHAUST...............................................03-34
SERVICE DATA.....................................03-8 SERVICE DATA...................................03-34
REQUIRED TORQUE...........................03-9 REQUIRED TORQUE.........................03-35
POWER STEERING................................03-10 START & CHARGE.................................03-36
SERVICE DATA...................................03-10 SERVICE DATA...................................03-36
REQUIRED TORQUE.........................03-11 REQUIRED TORQUE.........................03-37
ENGINE MECHANICAL SYSTEM..........03-12 FRONT SUSPENSION...........................03-38
SERVICE DATA...................................03-12 SERVICE DATA...................................03-38
REQUIRED TORQUE.........................03-15 REQUIRED TORQUE.........................03-39
ENGINE CONTROL SYSTEM................03-16 AXLE & TRANSMISSION SHAFT..........03-40
SERVICE DATA...................................03-16 SERVICE DATA...................................03-40
REQUIRED TORQUE.........................03-17 REQUIRED TORQUE.........................03-42
SUPPLEMENTAL RESTRAINT FUEL.......................................................03-43
SYSTEM..................................................03-18 SERVICE DATA...................................03-43
SERVICE DATA...................................03-18 REQUIRED TORQUE.........................03-44
REQUIRED TORQUE.........................03-19 LUBRICATION........................................03-45
BRAKE....................................................03-20 SERVICE DATA...................................03-45
SERVICE DATA...................................03-20 REQUIRED TORQUE.........................03-46
REQUIRED TORQUE.........................03-21 PARK BRAKE.........................................03-47
REAR SUSPENSION..............................03-22 REQUIRED TORQUE.........................03-47
SERVICE DATA...................................03-22 STEERING SYSTEM..............................03-48
REQUIRED TORQUE.........................03-23 SERVICE DATA...................................03-48
INTAKE...................................................03-24 REQUIRED TORQUE.........................03-49
SERVICE DATA...................................03-24 SEATING.................................................03-50
REQUIRED TORQUE.........................03-25 REQUIRED TORQUE.........................03-50
AIR-CONDITIONING SYSTEM...............03-26 WIPER & WASHER.................................03-51
SERVICE DATA...................................03-26 SERVICE DATA...................................03-51
03
 SERVICE SPECIFICATIONS - SEAT BELT 03-1

SEAT BELT
REQUIRED TORQUE
Fastener N•m
Driver's/front passenger seat belt retractor * body 45 ~ 55
03
Upper rivet point on driver's/front passenger seat belt *
45 ~ 55
height adjustor
Lower rivet point on driver's/front passenger seat belt *
45 ~ 55
body
Driver's/front passenger seat height adjustor * body 45 ~ 55
 03-2 SERVICE SPECIFICATIONS - TRANSMISSION

TRANSMISSION
SERVICE DATA
Transmission Model (JC538)
Transmission Constant mesh, five speed
03
1st gear transmission ratio 4.016
2nd gear transmission ratio 2.318
3rd gear transmission ratio 1.401
4th gear transmission ratio 1.000
5th gear transmission ratio 0.723
Reverse gear transmission ratio 3.549
V. Axial clearance between reverse
0.15~0.30mm
synchronizer ring & gear
Axial clearance between 5th gear
0.15~0.25mm
synchronizer ring & gear
Axial clearance between 3rd gear
0.15~0.25mm
synchronizer ring & gear
Axial clearance between 2nd gear
0.10~0.29mm
synchronizer ring & gear
Axial clearance between 1st gear
0.15~0.25mm
synchronizer ring & gear
 SERVICE SPECIFICATIONS - TRANSMISSION 03-3

REQUIRED TORQUE
Transmission Model (JC538)
Fastener N•m
Oil Drain Plug 30~35
03
Connection between the transmission and the engine 30~35
Connection between the transmission and the body
41~51
bracket
Switch, reverse lamp 30~35
Bolts of the reverse idler shaft fitting 38~49
positioning bolts of the gear shift fork 38~49
Front housing retaining bolts 30~35
Clutch housing retaining bolts 30~42
 03-4 SERVICE SPECIFICATIONS - WHEEL & TIRE

WHEEL & TIRE

SERVICE DATA
Tire Model 265/70R16 112T or 265/65R17 112T
Front 220±10Kpa
03
Tire Pressure Rear 240±10Kpa
Spare 260±10Kpa
 SERVICE SPECIFICATIONS - WHEEL & TIRE 03-5

REQUIRED TORQUE
Fastener N•m
2WD: 111~131 (aluminum rim)
Tire Nut
4WD: 95~115 (aluminum rim)
03
 03-6 SERVICE SPECIFICATIONS - DOOR & ENGINE HOOD

DOOR & ENGINE HOOD

SERVICE DATA
Engine Hood

Clearance 3.5 +/-1.0 mm

03
Evenness 0.5+ 0.5 /-0.5 mm
Front Door

Clearance 4.5+/-1.5 mm
Evenness -3.5+1.0/-1.0 mm
Rear Door

Clearance 4.5+/-1.5 mm
Evenness -3.5+1.0/-1.0mm
 SERVICE SPECIFICATIONS - DOOR & ENGINE HOOD 03-7

REQUIRED TORQUE
Fastener N•m
Door Hinge Bolt 34 +/- 5

03
 03-8 SERVICE SPECIFICATIONS - IGNITION

IGNITION
SERVICE DATA
Spark plug Sparkling Clearance 0.7~0.8mm

03
 SERVICE SPECIFICATIONS - IGNITION 03-9

REQUIRED TORQUE
Fastener N•m
Spark Plug 25
Ignition Coil 10
03
 03-10 SERVICE SPECIFICATIONS - POWER STEERING

POWER STEERING
SERVICE DATA
Steering Oil ATF-Ⅲ
Steering oil temperature
03
Oil level increase ≤ 5 mm
Engine idling, valve open and steer-
Steering oil pressure
ing wheel at extreme position
 SERVICE SPECIFICATIONS - POWER STEERING 03-11

REQUIRED TORQUE
Fastener N•m
Front retaining bolt of steering oil pump
Rear retaining bolt of steering oil pump
Retaining bolt of steering oil pump belt pulley 03

Steering gear retaining bolt

Retaining bolt of steering transmission shaft
Retaining nut of steering gear ball joint
Retaining bolt of front axle base plate
 03-12 SERVICE SPECIFICATIONS - ENGINE MECHANICAL SYSTEM

ENGINE MECHANICAL SYSTEM

SERVICE DATA
Gasoline engine (4G69)
Engine Assembly
03
Inline 4-cylinder 4-stroke water-cool-
Form ing SOHC 16-valve multi-point se-
quential injection
Number of Cylinders 4
Combustion Chamber Roof-shaped combustion chamber
Displacement 2.374L
Cylinder Diameter 87mm
Travel 100mm
Maximum torque (rotational speed)
200/2500~3000
[N.m(r/min)]
Rated power (rotational speed)
100/5250
[KW(r/min)]
Compression Ratio 10
Lubrication System Pressure feed, and full flow filter
Oil Pump Form Gear type
Water Pump Form Centrifugal impeller type
Generator pulley

Tensioner Arm Protrusion Standard 12mm

Tensioner Arm Press (98~196N) Standard ≤1mm
Camshaft

Intake Standard 37.20mm

Limit 36.70mm
Cam Height
Exhaust Standard 36.83mm
Limit 36.33mm
Cylinder Head

Cylinder Head Height Standard 19.9.0～120.1mm

Standard 0.03mm
Lower Surface Flatness
Limit 0.2mm
Surface Grinding Limit Limit 0.2mm
Standard 97.4mm
Bolt Length
Limit ≤99.4mm
Valve

Edge Thickness Intake Standard 1.0mm

 SERVICE SPECIFICATIONS - ENGINE MECHANICAL SYSTEM 03-13

Limit 0.5mm
Exhaust Standard 1.2mm
Limit 0.7mm
Valve Rod Diameter Standard 6.0mm
Intake Standard 0.02.0～0.05mm 03
Radial Clearance between Valve Rod
Limit 0.10mm
& Guide
Exhaust Standard 0.03.0～0.07mm
Limit 0.15mm
Caster Standard 45°~45.5°
Intake Standard 112.30mm
Limit 111.80mm
Valve Height
Exhaust Standard 114.11mm
Limit 113.61mm
Valve Spring

Standard 51.0mm
Free Height
Limit 50.0mm
Working Pre-tension/Working Height
Standard 27.2/44.2
(kg/mm)
Standard ≤2°
Verticality
Limit ≤4°
Valve Duct

Belt Width in Contact Standard 0.9~1.3mm

Inner Diameter Standard 6.0mm
Outer Diameter Standard 11.0mm
Pressed Height Standard 14mm
Standard 49.3mm
Valve Rod Protrusion
Limit 49.8mm
Driving Gear Standard 0.08~0.14mm
Engine Oil Pump Side Clearance
Driven Gear Limit 0.06~0.12
Piston Clearance Standard 0.02~0.04mm
Piston Ring

Piston Pin Outer Diameter Standard 22.0mm

Press Force (kg) 755~1750

Axial Clearance at Larger End of Standard 0.10.0～0.25mm

Connecting Rod Limit 0.4mm

Side Clearance between Piston Ring Standard 0.02.0～0.06mm

& Piston Ring Groove Limit 0.1mm
 03-14 SERVICE SPECIFICATIONS - ENGINE MECHANICAL SYSTEM

Crankshaft

Standard 0.02~0.05mm
Crankshaft Pin Windage
Limit 0.1mm
Standard 0.05～0.18mm
03 Axial Clearance
Limit 0.25mm
Main Shaft Journal Standard 57mm
Connecting Rod Journal Standard 45mm
Standard 0.02~0.04mm
Axial Clearance of Main Shaft
Limit 0.1mm
Cylinder Block

Standard 0.05mm
Upper Surface Flatness
Limit 0.1mm
Surface Grinding Limit Limit 0.2mm
Full Height Standard 284 ± 0.1mm
Inner Diameter of Cylinder Hole Standard 87mm
Cylindricity Standard 0.01mm
 SERVICE SPECIFICATIONS - ENGINE MECHANICAL SYSTEM 03-15

REQUIRED TORQUE
Gasoline engine (4G69)
Fastener N•m
Timing Belt
03
Retaining bolt of timing gear belt front lower cap 11
Retaining bolt of crankshaft shock absorber belt pulley 120
Retaining nut of water pump belt pulley 14
Retaining bolt of timing gear belt front middle cap 11
Retaining bolt of timing gear belt front upper cap 10
Retaining bolt of balance shaft gear belt pulley 42 ～ 48
Retaining bolt of balance shaft gear belt tensioner 48
Toothed Oil Pump Belt Pulley 55
Retaining bolt of tensioner arm 22
Retaining bolt of automatic tensioner 24
Toothed camshaft belt pulley bolt 90
Retaining bolt of timing belt tensioner B 48
Rock arm, rock arm shaft, hydraulic tappet & camshaft

Retaining bolt of rock arm shaft 31

Retaining bolt of tight rock arm cap 4
Stop cap screw 19
Retaining bolt of cylinder head 78
Cylinder Head Bolt 20
Oil Drain Plug 45
Crankshaft, cylinder block & flywheel)

Retaining bolt of crankshaft main bearing cap 25

Retaining bolt of flywheel 135
Oil Strainer 19
Retaining bolts of oil pump front cover 24

Diesel Engine
Fastener N•m
Retaining bolt of right suspension assembly 95~ 100
Retaining bolt of left suspension assembly 95~ 100
Steering oil pump pipe 35 ~ 40
A/C compressor pipe 21 ~ 25
Starter retaining nut 68 ~ 72
Alternator retaining nut 20 ~ 24
 03-16 SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM

SERVICE DATA
Gasoline Engine
0℃ 5.1~6.5Ω
03
20 ℃ 2.1~2.7Ω
ECT Sensor Resistance
40 ℃ 0.9~1.3Ω
80 ℃ 0.26~0.36Ω
Engine idling RPM Standard 750±50rpm
Idling stepping motor coil resistance Standard 28~33Ω(20°C)
Throttle valve position sensor resis-
Standard 3.5~6.5Ω(20°C)
tance
0℃ 5.3~6.7Ω
20 ℃ 2.3~3.0Ω
Intake temperature sensor resistance
40 ℃ 1.0~1.5Ω
80 ℃ 0.30~0.42Ω
Knocking sensor resistance Standard >1MΩ
CKP sensor resistance Standard 560Ω±10%(20°C)
Front oxygen sensor resistance Pin 3 & 4 2.5~4.5Ω(20°C)
Rear oxygen sensor resistance Pin 3 & 4 2.5~4.5Ω(20°C)
Canister solenoid valve resistance Standard 19~22Ω(20°C)
 SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM 03-17

REQUIRED TORQUE
Gasoline Engine
Fastener N•m
Engine control module (ECM) * body 15
03
ECT sensor * engine cylinder block 30
Idling stepping motor * throttle valve 4
Throttle valve position sensor * throttle valve 4
Intake manifold absolute pressure sensor/intake temper-
24
ature sensor * intake manifold
Knocking sensor * cylinder block 24
CKP sensor * transmission flywheel housing 24
Front oxygen sensor * exhaust pipe 45
Rear oxygen sensor * exhaust pipe 45
Canister solenoid valve * engine bracket 9
Speed sensor * transmission 20
 03-18 SERVICE SPECIFICATIONS - SUPPLEMENTAL RESTRAINT SYSTEM

SUPPLEMENTAL RESTRAINT SYSTEM

SERVICE DATA
Air Bag System

Working temperature - 35 ～ 85 ℃
03
Working voltage 12 ± 3 V
 SERVICE SPECIFICATIONS - SUPPLEMENTAL RESTRAINT SYSTEM 03-19

REQUIRED TORQUE
Fastener N•m
Horn button assembly (with air bag) * steering wheel 6±1
Air bag ECU retaining nut 9±1
03
 03-20 SERVICE SPECIFICATIONS - BRAKE

BRAKE
SERVICE DATA
Brake Pedal

Brake pedal height Standard 192mm

03
Free travel of brake pedal Standard 10mm
Remaining travel of brake pedal Standard 25mm
Front brake

Standard 12mm
Brake lining thickness
Limit 2mm
Standard 22mm
Brake disc thickness
Limit 21mm
Standard 0.1mm
Brake disc swing
Limit 0.15mm
Rear brake

Standard 7.5mm
Brake shoe thickness
Limit 2.5mm
Shoe drum clearance
Inner diameter of brake drum Standard 295mm
 SERVICE SPECIFICATIONS - BRAKE 03-21

REQUIRED TORQUE
Fastener N•m
Master clutch cylinder pipe connector bolt 19 ~ 21
Retaining nut connecting brake pedal assembly and
20±2
dashboard beam 03
Retaining nut connecting brake pedal assembly and
20±2
master brake cylinder
Locking nut of brake lamp switch 18±2
Master Brake Cylinder Retaining Nut 15±3
Retaining nut of vacuum booster 20±2
Master brake cylinder oil pipe connector nut 22 ~ 24
Retaining bolt of front brake calipers 90 ~ 120
Rear wheel brake cylinder retaining bolt 19 ~ 21
Rear wheel brake cylinder oil pipe connector nut 19 ~ 21
Discharge plug 12±2
19 ~ 21(M10X1)
Brake fluid pipe connected to ABS executor
22 ~ 24(M12X1)
ABS executor bracket and body 20±2
ABS executor and bracket 8±2
Retaining nut of front wheel speed sensor 8±2
Retaining nut of rear wheel speed sensor 8±2
 03-22 SERVICE SPECIFICATIONS - REAR SUSPENSION

REAR SUSPENSION
SERVICE DATA
Dimension parameter
Rear wheel wheelbase 1,580mm
03
Length of the rear suspension plate spring 1,300mm
 SERVICE SPECIFICATIONS - REAR SUSPENSION 03-23

REQUIRED TORQUE
Fastener N•m
Upper mounting bolt of rear shock absorber 95～115
Lower mounting bolt of rear shock absorber 95～115
03
Rear Leaf Spring 140～160
Exterior hanger plate 140～160
 03-24 SERVICE SPECIFICATIONS - INTAKE

INTAKE
SERVICE DATA
0℃ 5.3–6.7kΩ
20℃ 2.0–3.0kΩ
03 Intake temperature sensor resistance
40℃ 1.0-1.5.0kΩ
80℃ 0.30-0.42.0kΩ
 SERVICE SPECIFICATIONS - INTAKE 03-25

REQUIRED TORQUE
Fastener N•m
Air filter assembly retaining bolt 20

03
 03-26 SERVICE SPECIFICATIONS - AIR-CONDITIONING SYSTEM

AIR-CONDITIONING SYSTEM
SERVICE DATA
Refrigerant filling volume

Compressor has 150ml self-con-

03 When replacing compressor tained coolant and it is unnecessary
to add some.
When replacing evaporator 50ml
When replacing fluid reservoir 30ml
Replace A/C pipe 40-50ml
 SERVICE SPECIFICATIONS - AIR-CONDITIONING SYSTEM 03-27

REQUIRED TORQUE
Fastener N•m
【Φ9 aluminum pipe, M16 * 1.5 threaded connector】 12~15

【Φ12 aluminum pipe, M22 * 1.5 threaded connector】 20~26

03
【Φ126 aluminum pipe, M24 * 1.5 threaded connector】 30~35
Central pipe of the heating water pipe 8~9
Connection between the A/C pipe and the compressor 21~25
Connection between the pipe and the condenser 8~9
Connection between the A/C pipe and the expansion
8~9
valve
Connecting bolts of the compressor and the compressor
40~45
bracket
Upper condenser fitting bolts. 20~24
 03-28 SERVICE SPECIFICATIONS - COOLING

COOLING
SERVICE DATA
Gas Engine
Engine coolant filling volume 6.5.0L
03
Thermostat trigger temperature

Diesel engine
Engine coolant filling volume 8–9L
Thermostat trigger temperature
 SERVICE SPECIFICATIONS - COOLING 03-29

REQUIRED TORQUE
Fastener N•m
Radiator Assembly 46
Electronic Fan Assembly 23
Coolant Reservoir Assembly 23 03
 03-30 SERVICE SPECIFICATIONS - CLUTCH

CLUTCH
SERVICE DATA
Clutch pedal

Clutch pedal height Standard 170mm

03
Free travel of clutch pedal Standard 10~15mm
Clutch

Height gap of clutch diaphragm

Limit 0.5mm
spring
Clutch lining thickness Limit 0.3mm
 SERVICE SPECIFICATIONS - CLUTCH 03-31

REQUIRED TORQUE
Fastener N•m
Clutch pedal retaining nut 15~26N•m
Master clutch cylinder retaining nut 21~25N•m
Master clutch cylinder oil pipe connector nut 21~25N•m 03

Retaining nut of clutch booster assembly 21~25N•m

 03-32 SERVICE SPECIFICATIONS - INTERIOR & EXTERIOR TRIMS

INTERIOR & EXTERIOR TRIMS

REQUIRED TORQUE
Fastener N•m
Driver's/front passenger seat belt retractor * body 45 ~ 55
03
Upper rivet point on driver's/front passenger seat belt *
45 ~ 55
height adjustor
Lower rivet point on driver's/front passenger seat belt *
45 ~ 55
body
Driver's/front passenger seat height adjustor * body 45 ~ 55
Driver's/front passenger seat base assembly * body 45 ~ 55
 SERVICE SPECIFICATIONS - EMISSION CONTROL 03-33

EMISSION CONTROL
REQUIRED TORQUE
Fastener N•m
Retaining bolt of canister solenoid valve 9
03
 03-34 SERVICE SPECIFICATIONS - EXHAUST

EXHAUST
SERVICE DATA
Oxygen sensor resistance 2.5~4.5Ω(20°C)

03
 SERVICE SPECIFICATIONS - EXHAUST 03-35

REQUIRED TORQUE
Fastener N•m
Catalyst converter assembly 75~92
Connecting bolt between catalyst converter and bracket 22~27
Front exhaust pipe assembly & catalyst converter assem- 03
45~55
bly
Front exhaust pipe assembly & muffler assembly 45~55
Muffler assembly & rear exhaust pipe assembly 45~55
 03-36 SERVICE SPECIFICATIONS - START & CHARGE

START & CHARGE

SERVICE DATA
Alternator
Rated voltage
03
Rated current
Rated RPM
Power
Starter
Voltage
Output
Rotation direction
Battery rated voltage
 SERVICE SPECIFICATIONS - START & CHARGE 03-37

REQUIRED TORQUE
Fastener N•m
Alternator * alternator bracket
Alternator adjusting bolt
Alternator terminal nut 03

Retaining bolt of engine belt pulley

Starter Housing Retaining Bolt
Retaining bolt of electromagnetic switch
Electromagnetic switch * magnetic coil
Startup motor * power supply connection
Startup motor * transmission housing
Battery tray bracket * body
Battery tray bracket * battery tray
Battery bracket
Battery terminal
 03-38 SERVICE SPECIFICATIONS - FRONT SUSPENSION

FRONT SUSPENSION
SERVICE DATA
Front Wheel Alignment
Front Hub C-D/A+B:(2.2 ± 1) mm/(0.05±0.05)′
03
Camber 25′±30′
Kingpin caster 2.5°±30′
Kingpin inclination angle 12°05′±30′
 SERVICE SPECIFICATIONS - FRONT SUSPENSION 03-39

REQUIRED TORQUE
Fastener N•m
Upper mounting bolt of front shock absorber 80～100
Lower mounting bolt of front shock absorber 110～130
03
Retaining bolt of lower swing arm ball joint bracket 120～150
Retaining nut connecting upper swing arm shaft and
120～140
frame
Retaining nut of upper swing arm ball joint 85～145
Connecting bolt nut of lower swing arm and frame 150～190
Retaining nut of lower swing arm ball joint 130～190
Bolt connecting stabilizer bracket and frame 50～70
Retaining bolt of engine base plate 20 ~ 25
Nut connecting stabilizer connection and stabilizer 90～110
Nut connecting stabilizer connection and steering
90～110
knuckle
 03-40 SERVICE SPECIFICATIONS - AXLE & TRANSMISSION SHAFT

AXLE & TRANSMISSION SHAFT

SERVICE DATA
Front Axle Assembly

Driving/Driven Gear Type Standard Hypoid

03
Speed Ratio (Qty of Teeth) Standard 3.91(43/11)
Driving/Driven Gear Gap (mm) Standard 0.11～0.16
Driven Gear Swing (mm) Max. 0.05
Differential Gear Type Standard Straight Bevel
Differential Gear Speed Ratio (Qty of
Half Axle Teech/Qty of Planetary Standard 14/10
Teeth)
Standard 0～0.076
Differential Gear Gap (mm)
Limit 0.2
Driving Gear Front Bearing (Ext. Dia.
Standard 79.4*36.5*29.4
* Int. Dia. * Width)
Driving Gear Rear Bearing (Ext. Dia.
Standard 68.3*30.2*22.2
* Int. Dia. * Width)
Differential Gear Bearing (Ext. Dia. *
Standard 80*45.2*19.8
Int. Dia. * Width)
Inner Axle Bearing (Ext. Dia. * Int.
Standard 62*35*14
Dia. * Width)
Electric Clutch Working Voltage Standard 12V
Standard >80N
Electric Clutch Radial Force
Limit 120N(max)
Ventilation Tube Size (Ext. Dia. * Wall
Standard Φ7*2*180
Thickness * Length)
Driving Pionion Torque (N•m) Standard 0.97～1.32
Driving gear flange assembly end
runout
Model Hyboid gear oil
Main Reducer Gear Oil
Usage 1.2L
Rear Axle Assembly

Driving/Driven Gear Type Standard Hypoid

Driving/Driven Gear Clearance Standard 0.127.0～0.203 mm
Half axle assembly end clearance
Standard 0.05~0.125mm
(one side)
Main gear reduction ratio Standard 3.91(43/11)
Wheelbase Standard 1,580mm
Carrier Plate Distance Standard 1114 ± 2mm
Rear Axle Noise Standard Below 77dB
 SERVICE SPECIFICATIONS - AXLE & TRANSMISSION SHAFT 03-41

Qty of Teeth Standard 44

Distance t Standard ≥4.1
Single tooth error tp Standard ≤±4%
Accumulated error Tp Standard ≤±4%
03
Gear top distance ratio A/t Standard 0.4～0.5
Gear top circle diameter dk Standard ＞60mm
Tooth width b Standard ＞5mm
Tooth height h Standard ＞2.5mm
Filler plug torque Standard 27～41 N·m
Model GL-5 85W/90
Rear Reducer Gear Oil (1.27±0.03)L Add 0.06L Houghton
Usage
Sturaco 7098 under LSD condition
 03-42 SERVICE SPECIFICATIONS - AXLE & TRANSMISSION SHAFT

REQUIRED TORQUE
Fastener N•m
Gear oil filler bolt of the rear differential 27~41
Retaining nuts of the rear half axle 50~60
03 Nut of leaf spring fastening plate 140~160
Lower mounting bolt of rear shock absorber 95~115
Brake Fluid Pipe 21~25
Bolt connecting transmission shaft cardin joint and main reducer pinion flange
65~79
assembly
Connecting nuts of the pipe bracket and rear main reducer 38~45
Retaining bolts of the driven gear of rear differential 129~142
Retaining bolt of differential bearing cap 95~122
Rear cover retaining bolt 38~45
Bolt connecting transmission shaft cardin joint and transfer case flange as-
65~79
sembly
Gear oil filler bolt of the front main reducer 41~51
Connecting nuts of the front main reducer right fitting and the front main re-
78~98
ducer
Connecting nuts of the front main reducer left fitting and the front main reduc-
78~98
er
Connecting nuts of the front main reducer fitting and the body 113~138
Bolts of the transfer case ventilation pipe 9~11
Retaining bolts of the front differential driven disc 78~88
Front differential bearing cap bolt 54~64
Front differential rear cover bolts 15~22
Front axle tube bolts 78~98
Rear main reducer oil filler plug 27~41
Rear main reducer oil drain plug 38~45
Front main reducer oil drain plug 59~69
Front main reducer oil filler plug 41~51
Nut connecting upper swing arm ball stud and steering knuckle 85~145
Nut connecting lower swing arm ball stud and steering knuckle 130~190
Connecting nuts of the column connecting rod and steering knuckle 50~70
Connecting bolts of the intermediate bearing bracket and body 58~70
Nut connecting front half axle (right) and intermediate shaft 63~77
Retaining bolts of the lower swing arm fitting 120~150
 SERVICE SPECIFICATIONS - FUEL 03-43

FUEL
SERVICE DATA
Gas Engine
Fuel tank volume 76L
03
Fuel standard Euro IV emission standard
Fuel pump control working voltage 12V
Voltage value of the fuel level sensor Maximum 13.5 ± 0.1V
Minimum 8 ± 0.1V
Voltage value of the fuel level sensor Maximum level 38±1.5Ω
Minimum level 283±6Ω

Diesel engine
Fuel tank volume 76L
Fuel standard Euro IV emission standard
Voltage value of the fuel level sensor Maximum 13.5 ± 0.1V
Minimum 8 ± 0.1V
Voltage value of the fuel level sensor Maximum level 38±1.5Ω
Minimum level 283±6Ω
 03-44 SERVICE SPECIFICATIONS - FUEL

REQUIRED TORQUE
Fastener N•m
Retaining bolt of fuel tank door 15 ~ 20
Torque of the fuel tank retaining bolt 41 ~ 51
03 Torque of the retaining screws of the accelerator pedal
9 ~ 11
assembly
Torque of the retaining screws of the oil level sensor 75
 SERVICE SPECIFICATIONS - LUBRICATION 03-45

LUBRICATION
SERVICE DATA
Gasoline engine (4G69)
Driving Gear Standard 0.08.0～0.14mm
Gear side clearance 03
Driven Gear Standard 0.06.0～0.12mm
 03-46 SERVICE SPECIFICATIONS - LUBRICATION

REQUIRED TORQUE
Gasoline engine (4G69)
Fastener N•m
Engine oil drain plug 45
03
Oil Filter 14N.m or 3/4 circle
Oil pan retaining bolt 7
Retaining bolt of oil pump cover 16
Engine Oil Pressure Switch 10
 SERVICE SPECIFICATIONS - PARK BRAKE 03-47

PARK BRAKE
REQUIRED TORQUE
Fastener N•m
Park brake lever retaining bolt 20±2
03
Baffle retaining bolt 20±2
Retaining bolt of park brake cable 8±2
 03-48 SERVICE SPECIFICATIONS - STEERING SYSTEM

STEERING SYSTEM
SERVICE DATA
Driving

Turning radius Min.

03
Left
Deviation (30 m, 40Km/h)
Right
Steering Wheel

Free travel
Upward/downward adjustment travel
Steering force Engine off
 SERVICE SPECIFICATIONS - STEERING SYSTEM 03-49

REQUIRED TORQUE
Fastener N•m
Steering wheel retaining nut
Retaining bolt of horn button assembly
Bolt connecting upper part of steering column assembly 03
and steering column beam welded assembly
Bolt connecting lower part of steering column assembly
and steering column beam welded assembly
Bolt connecting steering column assembly and steering
transmission shaft
Steering transmission shaft and steering column assem-
bly
Retaining bolt of steering transmission shaft housing
Retaining nut of transfer case controller
Fuse box retaining bolt
Antitheft controller retaining nut
Reverse sensor controller retaining nut
 03-50 SERVICE SPECIFICATIONS - SEATING

SEATING
REQUIRED TORQUE
Fastener N•m
Driver's/front passenger seat base assembly * body 45～55
03
Rear seat * body 21～25
 SERVICE SPECIFICATIONS - WIPER & WASHER 03-51

WIPER & WASHER

SERVICE DATA
Wiper motor

Low
Wiper motor RPM 03
High
 03-52 SERVICE SPECIFICATIONS - WIPER & WASHER

03
 DIAGNOSTICS
ANTI-LOCK BRAKING SYSTEM (ABS) INTERMITTENT FAILURE .................04-40
..................................................................04-1 BASIC INSPECTION .........................04-43
PRECAUTIONS....................................04-1 CONFIGURATION DIAGRAM OF ECM-SIDE
COMPONENTS DRAWING .................04-2 TERMINALS........................................04-44
THE CONNECTOR OF THE ABS CONTROL DIAGNOSIS SYSTEM........................04-47 04
MODULE. .............................................04-4 READING AND CLEARANCE OF THE
DIAGNOSTIC TROUBLE CODE DIAGNOSTIC TROUBLE CODE
(DTC)LIST.............................................04-6 (DTC)..................................................04-48
DEFECT PHENOMENON FORM ........04-8 CAPTURED DATA...............................04-50
PRE-INSPECTION................................04-9 LIST OF FAILURE PHENOMENON
C0031– LEFT FRONT WHEEL SPEED PROTECTIONS..................................04-51
SENSOR FAILURE: THE SCOPE, LIST OF DATA STREAMS, MOTION
PERFORMANCE, CONTINUITY TEST...................................................04-53
C0032–LEFT FRONT WHEEL SPEED DTC LIST............................................04-57
SENSOR CIRCUIT FAILURE: OPEN DEFECT DIAGNOSTICS CODE (DTC) TEST
CIRCUIT OR SHORT CIRCUIT (ENGINE CONTROL SYSTEM)
C0034–RIGHT FRONT WHEEL SPEED P0107–INTAKE PRESSURE SENSOR
SENSOR FAILURE: THE SCOPE, CIRCUIT IS SUBJECTED TO LOW
PERFORMANCE, CONTINUITY VOLTAGE P0108–INTAKE PRESSURE
C0035–RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT IS SUBJECTED TO
SENSOR FAILURE: OPEN CIRCUIT OR HIGH VOLTAGE .................................04-62
SHORT CIRCUIT ...............................04-10 P0112 - LOW VOLTAGE OF INTAKE
C0038– LEFT REAR WHEEL SPEED TEMPERATURE SENSOR CIRCUIT P0113
SENSOR CIRCUIT FAILURE: OPEN - HIGH VOLTAGE OF INTAKE
TEMPERATURE SENSOR CIRCUIT
CIRCUIT OR SHORT CIRCUIT C0037–
............................................................04-67
LEFT REAR WHEEL SPEED SENSOR
P0117-LOW VOLTAGE OF COOLANT
FAILURE: THE SCOPE, PERFORMANCE,
TEMPERATURE SENSOR CIRCUIT
CONTINUITY C003B– RIGHT REAR P0118-HIGH VOLTAGE OF COOLANT
WHEEL SPEED SENSOR CIRCUIT TEMPERATURE SENSOR CIRCUIT
FAILURE: OPEN CIRCUIT OR SHORT ............................................................04-72
CIRCUIT C003A–RIGHT REAR WHEEL P0122-LOW VOLTAGE OF THROTTLE
SPEED SENSOR FAILURE: THE SCOPE, POSITION SENSOR P0123-HIGH VOLTAGE
PERFORMANCE, CONTINUITY .......04-16 OF THROTTLE POSITION SENSOR
C1095－VALVE RELAY FAILURE.......04-22 ............................................................04-77
C0020–RETURN PUMP FAILURE....04-26 P0131-TO-GROUND SHORT-CIRCUIT OF
ABS INDICATING LAMP IS ALWAYS ON. FRONT OXYGEN SENSOR
ABS INDICATING LAMP IS NOT BRIGHT P0132-TO-POWER-SUPPLY
............................................................04-30 SHORT-CIRCUIT OF FRONT OXYGEN
ENGINE CONTROL SYSTEM................04-33 SENSOR P0134-OPEN CIRCUIT OF FRONT
PRECAUTION.....................................04-33 OXYGEN SENSOR ............................04-80
COMPONENTS .................................04-36 P0325-KNOCKING SYSTEM FAILURE
HOW TO CONDUCT FAILURE P0327-KNOCK SENSOR FAILURE ....04-86
ANALYSIS...........................................04-37
 P0336 - CRANKSHAFT POSITION SENSOR LOW RESISTANCE, PASSENGERS’ AIR
CIRCUIT INTERFERING SIGNAL......04-90 BAG IGNITER ..................................04-168
P0480-FAN 1 FAILURE P0481-FAN 2 B1354 GROUND, PASSENGERS’ AIR
FAILURE ............................................04-95 BAG IGNITER ..................................04-170
P0201-NOZZLE A CIRCUIT B 1355-PASSENGERS’ AIR BAG IGNITER
FAILURE...........................................04-101 CONNECTION BATTERY ................04-173
P0443-CARBON POT CONTROL VALVE B1361-HIGH RESISTANCE OF THE
04 FAILURE...........................................04-105
PRELOADING IGNITER, DRIVER’S SEAT
DEFECTS ........................................04-109
BELT B1362-LOW RESISTANCE OF
ENGINE PHENOMENA DIAGNOSIS
TEST.................................................04-110 PRELOADING IGNITER, DRIVER’S SEAT
KT600 DIAGNOSTIC APPARATUS IS BELT .................................................04-175
UNABLE TO COMMUNICATE WITH GROUND OF THE PRELOADING IGNITER,
ECM..................................................04-113 DRIVER’S SEAT BELT ..................04-178
THE STARTER ROTATES, BUT THE B1364-PRELOADING IGNITER
ENGINE IS UNABLE TO START.......04-115 CONNECTION BATTERY, DRIVER’S
THE COLD CAR IS DIFFICULT TO START SEAT BELT .......................................04-182
AND VEHICLE BODY QUIVERS......04-119 B 1367-HIGH RESISTANCE OF THE
UNSTABLE IDLING SPEED ............04-123 PRELOADING IGNITER, PASSENGER’S
IDLING SPEED TOO HIGH..............04-128 SEAT BELT B 1368-LOW RESISTANCE OF
THE ENGINE CAN STALL WHEN IT IS THE PRELOADING IGNITER,
COLD................................................04-131 PASSENGERS’ SEAT BELT ..........04-185
THE ENGINE CAN STALL WHEN B1369 PRELOADING IGNITER GROUND,
STARTING........................................04-135 PASSENGERS’ SEAT BELT ..........04-188
SLOW, MALADJUSTED ACCELERATION B1370-PRELOADING IGNITER
RESPONSE......................................04-139 CONNECTION BATTERY, PASSENGERS'
POOR ACCELERATION AND SEAT BELT........................................04-192
PERFORMANCE..............................04-143 TRANSFER GEAR ..............................04-195
SRS SYSTEM.......................................04-147 DEFECT PHENOMENON FORM ....04-195
PRECAUTION...................................04-147 U0101 SIGNAL FAILURE, GEAR U0402
COMPONENTS DRAWING .............04-148 SIGNAL FAILURE, GEAR ................04-197
SRS CONTROL MODULE SPEEDOMETER DEFECTS ............04-199
CONNECTOR...................................04-149 U0100 SIGNAL FAILURE, CLUTCH PEDAL
DIAGNOSTIC DTC CODE LIST ......04-151 POSITION U0401 SIGNAL FAILURE,
DEFECT PHENOMENON FORM ....04-153 CLUTCH PEDAL POSITION ............04-204
B 1102 OVER-LOW THE POWER SUPPLY U0001 CAN BUS DISCONNECTION .04-206
VOLTAGE .........................................04-154 P0560 SYSTEMATIC VOLTAGE EXCEEDS
B1346 HIGH RESISTANCE, DRIVER’S NORMAL WORK SCOPE ................04-208
AIR BAG IGNITER B 1347LOW P1728 SYNCHRONIZATION COIL
RESISTANCE, DRIVER’S AIR BAG DEFECTS P1729 SYNCHRONIZATION
IGNITER ...........................................04-158 COIL DEFECTS P1730
B1348 GROUND, DRIVER’S AIR BAG SYNCHRONIZATION COIL DEFECTS
IGNITION .........................................04-161 ..........................................................04-211
B1349 CONNECTION BATTERY, P1734 SIGNAL FAILURE FEEDBACK,
DRIVER’S AIR BAG IGNITER ......04-165 FRONT AXLE CLUTCH ...................04-213
B1352HIGH RESISTANCE , P1738 DEFECTS, MODE SELECT SWITCH
PASSENGERS’ AIR BAG IGNITER B1352 ..........................................................04-215
 P1780 MOTOR DEFECTS, GEAR SHIFT WINDOW IS STUCK AT ON LOCATION
P1781 MOTOR DEFECTS, GEAR SHIFT ..........................................................04-266
P1782 MOTOR DEFECTS, GEAR SHIFT B1362 LOW CURRENT OF CONTROL
..........................................................04-218 CIRCUIT, LEFT BACK WINDOW RISE
REVERSE RADAR SYSTEM................04-220 B1363 B1366THE RELAY OF CONTROL
PRECAUTION...................................04-220 CIRCUIT FOR LEFT REAR WINDOW RISE
COMPONENTS DRAWING .............04-221 IS STUCK AT THE “NO” LOCATION
SYSTEM SPECIFICATION...............04-222 ..........................................................04-274 04
DEFECT PHENOMENON FORM ....04-224 B1368 B1371LOW CURRENT OF CONTROL
REVERSE RADAR SYSTEM DOESN’T CIRCUIT, RIGHT BACK WINDOW RISE
WORK AT ALL .................................04-225 B1369 B1372CONTROL CIRCUIT RELAY
REVERSE RADAR SYSTEM SELF-CHECK OF RIGHT REAR WINDOW IS STUCK AT
ABNORMAL .....................................04-230 ON LOCATION .................................04-282
BEFORE ENTERING REVERSE GEAR, REAR WINDSCREEN DEFROST
REVERSE RADAR APPEAR WORKING SYSTEM................................................04-290
PHENOMENON ...............................04-233 SYSTEM SPECIFICATION...............04-290
ENTER REVERSE GEAR, AND THE COMPONENTS DRAWING .............04-291
OBSTACLE IS WITHIN THE DISTANCE OF BASIC INSPECTION .......................04-292
EFFECTIVE SENSE。 THE REVERSE DEFECT PHENOMENON FORM ....04-293
RADAR SYSTEM DOESN’T WORK REAR WINDSCREEN DEFROSTER
..........................................................04-235 DOESN’T WORK. ..........................04-294
ENTER REVERSE GEAR, NO OBSTACLES B 1391 DEFROST CONTROL CIRCUIT
BEHIND THE VEHICLES WHILE THE --OPEN CIRCUIT B1392DEFROST
REVERSE RADAR SYSTEM IS ABNORMAL CONTROL CIRCUIT --HIGH CURRENT
..........................................................04-238 ..........................................................04-303
THE OBSTACLE IS WITHIN THE DISTANCE POWER REARVIEW MIRROR. ...........04-310
OF EFFECTIVE SENSE, AND THE BUZZER COMPONENTS DRAWING .............04-310
DOESN’T WORK OR IS ABNORMAL STITCH DESCRIPTION, POWER
..........................................................04-240 REARVIEW MIRROR SWITCH .......04-311
POWER WINDOW.................................04-243 BASIC INSPECTION .......................04-312
PRECAUTION...................................04-243 DEFECT PHENOMENON FORM ....04-313
COMPONENTS DRAWING .............04-244 UPPER AND LOWER ADJUSTMENT OF
BASIC INSPECTION .......................04-245 POWER REARVIEW MIRROR DOESN’T
DEFECT PHENOMENON FORM ....04-247 WORK ..............................................04-314
ALL THE POWER WINDOW STOP LEFT/RIGHT ADJUSTMENT OF POWER
WORKING.........................................04-249 REARVIEW MIRROR DOESN’T WORK
B1350 B1353 LOW CURRENT OF ..........................................................04-317
CONTROL CIRCUIT, LEFT FRONT POWER REARVIEW MIRROR ON BOTH
WINDOW RISE B1351 B1354 CONTROL SIDES DON’T WORK AT ALL. ......04-320
CIRCUIT RELAY OF LEFT FRONT POWER REARVIEW MIRROR ON ONE
WINDOW IS STUCK AT ON LOCATION SIDE DON’T WORK AT ALL. .........04-324
..........................................................04-260 HEATING POWER REARVIEW MIRROR
B1356 B1359 LOW CURRENT OF DOESN'T WORK .............................04-327
CONTROL CIRCUIT, LEFT FRONT POWER DOOR LOCK CONTROL SYSTEM
WINDOW RISE B1357 B1360 CONTROL ..............................................................04-336
CIRCUIT RELAY OF LEFT FRONT PRECAUTION...................................04-336
COMPONENTS DRAWING .............04-337
 BASIC INSPECTION .......................04-338 TERMINAL, ACOUSTICS UNIT .......04-437
DEFECT PHENOMENON FORM ....04-339 BASIC INSPECTION .......................04-439
CENTRAL CONTROL LOCK DOESN’T DEFECT PHENOMENON FORM ....04-440
WORK...............................................04-340 ACOUSTICS UNIT DOES NOT
ONLY THE CENTRAL CONTROL LOCK OF WORK...............................................04-442
ONE DOOR DOESN’T WORK ......04-351 SPEAKERS MAKE NO SOUND IN ANY
WIPER & WASHER...............................04-355 MODE ..............................................04-447
04 PRECAUTION...................................04-355 SPEAKERS MAKE POOR-QUALITY SOUND
COMPONENTS DRAWING .............04-356 IN ANY MODE..................................04-451
BASIC INSPECTION .......................04-357 SPEAKERS MAKE WEAK SOUND IN ANY
DEFECT PHENOMENON FORM ....04-358 MODE...............................................04-453
FRONT WIPER DOESN'T WORK.....04-360 SPEAKERS MAKE POOR-QUALITY SOUND
B1376 HIGH-SPEED CONTROL CIRCUIT ONLY WHEN PLAYING BACK
OF FRONT WIPER IS OPEN-CIRCUITED CD/DVD.............................................04-457
B1377 HIGH-SPEED CONTROL CIRCUIT NO RADIO STATIONS CAN BE RECEIVED
OF FRONT WIPER IS SUBJECTED TO OR THE RECEIVING EFFECT IS POOR
HIGH CURRENT ..............................04-364 ..........................................................04-458
B1374 LOW SPEED CONTROL CIRCUIT CD/DVD CANNOT BE INSERTED/PLAYED
OF FRONT WIPER IS SUBJECTED TO BACK, OR CD/DVD IS EJECTED
HIGH CURRENT B1373 LOW SPEED IMMEDIATELY ONCE IT IS
CONTROL CIRCUIT OF FRONT WIPER IS INSERTED........................................04-460
OPEN-CIRCUITED ..........................04-372 CD/DVD TUNE SKIPPING................04-462
FRONT WIPER DOESN'T WORK WHEN IT HORN....................................................04-463
IS SET TO ITS INTERMITTENT GEAR COMPONENTS DRAWING .............04-463
..........................................................04-379 DEFECT PHENOMENON FORM ....04-464
FRONT WASHER DOESN'T WORK..04-384 B1385 OPEN CIRCUIT OF HORN
AIR CONDITIONING SYSTEM.............04-389 CONTROL CIRCUIT B1386 HIGH CURRENT
PRECAUTION...................................04-389 OF HORN CONTROL CIRCUIT ......04-465
BASIC INSPECTION .......................04-390 LIGHTING SYSTEM.............................04-473
COMPONENTS DRAWING .............04-391 PRECAUTION...................................04-473
DEFECT PHENOMENON FORM ....04-393 COMPONENTS DRAWING .............04-474
NO FUNCTION OF THE AIR BASIC INSPECTION .......................04-476
CONDITIONING SYSTEM WORKS..04-395 DEFECT PHENOMENON FORM ....04-477
BLOWER DOES NOT WORK...........04-400 B1346 OPEN CIRCUIT OF DRIVING LIGHT
AIR OUTPUT CONTROL: AIR EXHAUST IS CONTROL CIRCUIT B1347 HIGH CURRENT
INADEQUATE...................................04-407 OF DRIVING LIGHT CONTROL CIRCUIT
REFRIGERATING SYSTEM: FAILURE TO ..........................................................04-483
REFRIGERATE (GASOLINE) ..........04-412 B1344OPEN CIRCUIT OF PASSING LAMP
REFRIGERATING SYSTEM: FAILURE TO CONTROL CIRCUIT B1345HIGH CURRENT
REFRIGERATE (DIESEL OIL) .........04-419 OF PASSING LAMP CONTROL CIRCUIT
FAILURE OF SERVO MOTOR OF MODE ..........................................................04-491
AIR DOOR........................................04-427 B1045OPEN CIRCUIT OF FRONT FOG
FAILURE OF TEMPERATURE LAMP CONTROL CIRCUIT B1046HIGH
REGULATION SERVO MOTOR .......04-430 CURRENT OF FRONT FOG LAMP
AUDIO SYSTEM...................................04-433 CONTROL CIRCUIT ........................04-499
PRECAUTION...................................04-433 B1048OPEN CIRCUIT OF REAR FOG LAMP
COMPONENTS DRAWING .............04-436 CONTROL CIRCUI B1049LOW CURRENT
OF REAR FOG LAMP CONTROL CIRCUIT
 B1050 HIGH CURRENT OF REAR FOG COMPONENTS DRAWING .............04-623
LAMP CONTROL CIRCUIT .............04-508 COMBINED DISPLAY
B1001 LOW CURRENT OF LEFT TURN DESCRIPTION..................................04-624
LIGHT CONTROL CIRCUIT PIN DESCRIPTION FOR THE COMBINED
B1002TO-GROUND SHORT-CIRCUIT OF DISPLAY...........................................04-625
LEFT TURN LIGHT CONTROL CIRCUIT BASIC INSPECTION .......................04-626
..........................................................04-516 DEFECT PHENOMENON FORM ....04-627
B1004 LOW CURRENT OF RIGHT TURN THE COMBINED DISPLAY DOESN’T 04
LIGHT CONTROL CIRCUIT WORK AT ALL..................................04-628
B1005TO-GROUND SHORT-CIRCUIT OF VEHICLE CONTROL SYSTEM............04-632
RIGHT TURN LIGHT CONTROL CIRCUIT PRECAUTION...................................04-632
..........................................................04-525 COMPONENTS DRAWING .............04-633
B1063LOW CURRENT OF PARKING LIGHT VEHICLE BODY CONTROLLER
CONTROL CIRCUIT B1064TO-GROUND DESCRIPTION..................................04-634
SHORT-CIRCUIT OF PARKING LIGHT DEFINITION FOR THE VEHICLE BODY
CONTROL CIRCUIT ........................04-534 CONTROLLER PIN...........................04-636
BRAKES LAMPS ON 2 SIDES FAIL TO GO DEFECT PHENOMENON FORM ....04-641
ON.....................................................04-544 B353C THE POWER SUPPLY IS GREATER
TOP BRAKES LAMPS FAIL TO GO THAN 16V WITHIN BCM B353D THE
ON.....................................................04-550 POWER SUPPLY IS SMALLER THAN 9V
REVERSE LAMPS ON 2 SIDES FAIL TO WITHIN BCM ...................................04-642
GO ON..............................................04-556 B1402 BATTERY ENERGY-SAVING
POSITION LIGHTS/LICENSE PLATE LAMP OUTPUTS CIRCUIT LOW-VOLTAGE B1403
FAIL TO GO ON................................04-562 BATTERY ENERGY-SAVING OUTPUTS
STEP LAMPS FAIL TO GO ON.........04-571 CIRCUIT HIGH-VOLTAGE ...............04-645
ASSEMBLY INSTRUMENT..................04-578 TYRE PRESSURE MONITORING
PRECAUTION...................................04-578 SYSTEM................................................04-648
COMPONENTS DRAWING .............04-579 PRECAUTION...................................04-648
INSTRUMENT DESCRIPTION.........04-580 COMPONENTS DRAWING .............04-649
INSTRUMENT TERMINAL................04-583 SYSTEM SPECIFICATION...............04-650
BASIC INSPECTION .......................04-585 TPMS SETTING METHOD ..............04-653
DEFECT PHENOMENON FORM ....04-586 DEFECT PHENOMENON FORM ....04-656
THE ENTIRE COMBINATION INSTRUMENT TYRE PRESSURE MONITORING
DOES NOT WORK............................04-588 CONTROLLER DOESN’T WORK ..04-657
WATER TEMPERATURE ALARM LAMP TYRE PRESSURE IS NOT MEASURED
FAILS TO GO ON/NORMALLY ON....04-592 CORRECTLY. ...................................04-661
VACUUM ALARM INDICATOR LAMP FAILS FRONT AXLE CLUTCH .......................04-663
TO GO ON/NORMALLY ON..............04-598 PRECAUTION...................................04-663
SPEEDOMETER DEFECTS ............04-602 COMPONENTS DRAWING .............04-664
SEAT BELT INDICATING LAMP IS NOT SYSTEM SPECIFICATION...............04-665
ON/ALWAYS ON...............................04-607 DEFECT PHENOMENON FORM ....04-667
FUEL GAGE FAULTS........................04-613 FRONT AXLE CLUTCH CAN'T WORK
BRAKE FAULT ALARM LAMP FAILS TO GO NORMALLY.......................................04-668
ON/NORMALLY ON..........................04-617 THE FRONT AXLE CLUTCH INDICATING
COMBINED DISPLAY...........................04-622 LAMP DOESN’T WORK. ...............04-673
PRECAUTION...................................04-622
04
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-1

ANTI-LOCK BRAKING SYSTEM (ABS)

PRECAUTIONS
1. Disconnect the power supply.
(a) Before dismounting or installing any electric apparatus, or when tool or equipment is susceptible to touch
exposed electric pins, be sure to disconnect the negative-pole cable of battery firstly to prevent persons
or vehicle from being damaged.
(b) If there is special illustration, ignition switch must be closed. 04

CAUTION
If the vehicle is equipped with central console lock, don't leave the key inside the vehicle before
disconnecting the negative battery cable, or it may automatically lock up.
2. Dismantle assembly instrument or disconnect battery negative (-) may cause daily mileage and
the clock to be reset.
CAUTION
The overall speedometer cannot be reset to zero.
3. Disconnection the battery negative (-) may cause audio system lose the stored settings.
CAUTION
When reconnecting the negative cable of the battery, the sound system should be reset.
4. Position definition, ignition switch.
Ignition switch (location) Position definition, ignition switch
LOCK Ignition Switch: OFF.
ACC Ignition Switch ACC
ON Ignition Switch: ON.
START （ST） Start the engine.

5. Troubleshoot precautions of ABS antilock brake system.

(a) When the contact of the stitch or component mounting meet defects, dismantling and remounting the
suspected defect components may make the system recover normal completely or temporarily.
(b) To determine the failure location, it is required to check the condition of the vehicle when a failure occurs.
For example, conduct checks as per the diagnosis failure code (DTC) output, and record the conditions
before each connector is disconnected or any part is dismounted and remounted.
(c) Unless otherwise specified in the checking steps, ABS control unit, sensor and actuator must be dismantled
and installed at the time when the ignition switch is closed.
(d) If reassemble ABS control unit, sensor and actuator that have been dismantled and installed, do remember
to check whether the system is normal or not after assembling. (Observe relevant display of assembly
instrument and use special detector to inspect diagnostic defect code (DTC). ）
(e) Do not use multimeter to measure the stitch of ABS control unit.
 04-2 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

COMPONENTS DRAWING

04

1 ABS Control Module 4 Left Rear Wheel Speed Sensor

2 Left Front Wheel Speed Sensor 5 Right Rear Wheel Speed Sensor
3 Right Front Wheel Speed Sensor
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-3

04

6 Travel Braking Switch 8 Combination Instrument

7 Indoor fuse box
 04-4 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

THE CONNECTOR OF THE ABS CONTROL MODULE.

04

Number Definition Colour Number Definition Colour

Left rear wheel
1 Power supply Red 20 speed sensor white
signal input
Left front wheel
2 - - 21 speed sensor Orange - red
signal output
3 - - 22 - -
4 - - 23 - -
Acceleration sen-
5 Green - yellow 24 - -
sor signal
Right front wheel
6 speed sensor Orange - blue 25 Power supply Red
signal input
7 - - 26 CAN-H Red-white
8 - - 27 - -
Ground of accel-
9 - - 28 Brow-yellow
eration sensor
10 - - 29 - -
braking signal in-
11 - - 30 Grey - white
put
Right rear wheel
12 - - 31 speed sensor Green - white
signal input
13 ground Black 32 Ig power supply Orange - red
left rear wheel
14 CAN-L Blue-yellow 33 speed sensor White - red
signal output
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-5

Number Definition Colour Number Definition Colour

Left front wheel
Acceleration sen-
15 Purple -yellow 34 speed sensor Red-blue
sor power supply
signal input
16 - - 35 - -
17 - - 36 - -
Right front wheel 04
18 speed sensor Yellow 37 - -
signal output
Right rear wheel
19 speed sensor Blue-red 38 ground Black
signal output
 04-6 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

DIAGNOSTIC TROUBLE CODE (DTC)LIST

CAUTION
When checking DTC in the checking module, if certain DTC displayed, then the circuit of the code listed
in the following list should be checked.The detailed description of each DTC can refer to corresponding
pages.
DTC code Diagnostic items (DTC definition) Trouble location
04 Voltage trouble of supplying power • Battery
C1900 of the low voltage- The voltage is too • Charging system
high
Voltage trouble of supplying power • Battery
C1901 of the low voltage- The voltage is in- • Charging system
sufficient
• Left front wheel speed sensor
• Left front wheel speed sensor
C0032 –Left front wheel speed sen-
C0032 sor circuit failure: open circuit or short circuit
circuit • Left front wheel speed sensor
signal wheel
• Left front wheel speed sensor
• Left front wheel speed sensor
Left front wheel speed sensor failure: circuit
C0031
The scope, performance, continuity • Left front wheel speed sensor
signal wheel
•
right front wheel speed sensor
•
Right front wheel speed sensor
Right front wheel speed sensor circuit circuit
C0035
failure: open circuit or short circuit • right front wheel speed sensor
signal wheel
•
right front wheel speed sensor
•
Right front wheel speed sensor
right front wheel speed sensor failure: circuit
C0034
The scope, performance, continuity •
right front wheel speed sensor
signal wheel
• Left rear wheel speed sensor
•Left rear wheel speed sensor cir-
Left rear wheel speed sensor circuit cuit
C0038
failure: open circuit or short circuit • Left rear wheel speed sensor
signal wheel
•
Left rear wheel speed sensor
•
Left rear wheel speed sensor cir-
Left rear wheel speed sensor failure: cuit
C0037
The scope, performance, continuity •
Left rear wheel speed sensor
signal wheel
• right rear wheel speed sensor
Right rear wheel speed sensor circuit •
C003B Right rear wheel speed sensor
failure: open circuit or short circuit
circuit
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-7

DTC code Diagnostic items (DTC definition) Trouble location

• Right rear wheel speed sensor
signal wheel
• right rear wheel speed sensor
• Right rear wheel speed sensor
Right rear wheel speed sensor fail-
C003A ure: The scope, performance, conti- circuit
nuity • Right rear wheel speed sensor
04
signal wheel
• ABS control units
C1099 Wheel speed sensor frequency error • ABS system circuit

Hardware failure of electronic control • ABS control units

C1000
unit
• ABS control units
C1001 Hardware failure of CAN line • ABS system circuit
• ABS control units
U1000 Bus off failure of CAN line • ABS system circuit
• fuse
C1095 Valve relay failure • ABS system circuit
• Left front liquid intake valve
C0010 Left front liquid intake valve failure • ABS control units
• Left front liquid output valve
C0011 Left front liquid output valve failure • ABS control units
• Right front liquid intake valve
C0014 Right front liquid intake valve failure • ABS control units
• Right front liquid output valve
C0015 Right front liquid output valve failure • ABS control units
• Left rear liquid intake valve
C0018 Left rear liquid intake valve failure • ABS control units
• Left rear liquid output valve
C0019 Left rear liquid output valve failure • ABS control units
• Right rear liquid intake valve
C001C Right rear liquid intake valve failure • ABS control units
• Right rear liquid output valve
C001D C001D • ABS control units
• fuse
C0020 Return pump failure (motor) • ABS system circuit
• fuse
General trouble of valve(overheat
C0072 •
protection) ABS system circuit
 04-8 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

DEFECT PHENOMENON FORM

CAUTION
• If defects code fails to appear when checking DTC, and the components of the system don’t
work normally, check the circuit in line with the defect phenomenon listed in the following form.
• While replacing ABS control module, sensor and actuator, the ignition switch shall be turned to
OFF position, and the negative cable of battery shall be disconnected.
04 • Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.

Defect phenomenon Trouble location Reference

1.Confirm that DTC outputs normal Chapter 35.Travel Braking – master
code of system braking pump, overhaul
2. Braking pipeline leakage, damage, Chapter 35. Travel Braking - front
ABS system doesn’t work
distortion etc. disc braking, overhaul
Chapter 35. Travel Braking - rear disc
3. ABS control module assembly
braking, overhaul
1.Confirm that DTC outputs normal Chapter 35.Travel Braking – master
code of system braking pump, overhaul
2. Braking pipeline leakage, damage, Chapter 35. Travel Braking - front
ABS system can’t work efficiently
distortion etc. disc braking, overhaul
Chapter 35. Travel Braking - rear disc
3. ABS control module assembly
braking, overhaul
Chapter 04 Diagnosis - ABS, ABS
1. ABS indicating lamp circuit
indicating lamp is always on
ABS indicating lamp is always on.
Chapter 04 Diagnosis - ABS, ABS
2. ABS control module assembly
indicating lamp is always on
Chapter 04 Diagnosis - ABS, ABS
1. ABS indicating lamp circuit
indicating lamp is always on
ABS indicating lamp is not bright.
Chapter 04 Diagnosis - ABS, ABS
2. ABS control module assembly
indicating lamp is always on
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-9

PRE-INSPECTION
1. Self-diagnosis system
(a) Open the ignition switch to ON position, check the ABS
indicating lamp on the combination instrument.
Standard: ABS indicating lamp will go out
automatically 3-4 seconds after the ignition switch is
turn on. 04

If ABS indicating lamp is ( ), it shows that there are

circuit troubles in the system, maintenance shall
be carried out after reading the diagnostic trouble
code(DTC) by using the diagnostic apparatus.
CAUTION
After the ignition switch is turned to ON position, the ABS
control module will inspect the electric apparatus and
components in the system.

2. Reading and clearance of the trouble code (DTC)

(a) Use diagnostic apparatus to read diagnostic trouble code
(DTC)
• Connect the diagnostic apparatus and DLC- data
chain socket connector(diagnostic box).
• Click to enter " Beiqi Futian - pika - ABS - read the
trouble code ", the diagnostic apparatus will display
diagnostic trouble code in the ABS control module.
(b) Clearing diagnostic trouble code
• Click to enter " Clear trouble code "
Clear the diagnostic trouble code in the ABS
control module through operating diagnostic
apparatus.
 04-10 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

C0031– LEFT FRONT WHEEL SPEED SENSOR FAILURE: THE

SCOPE, PERFORMANCE, CONTINUITY
C0032–LEFT FRONT WHEEL SPEED SENSOR CIRCUIT FAILURE:
OPEN CIRCUIT OR SHORT CIRCUIT
C0034–RIGHT FRONT WHEEL SPEED SENSOR FAILURE: THE
04
SCOPE, PERFORMANCE, CONTINUITY
C0035–RIGHT FRONT WHEEL SPEED SENSOR FAILURE: OPEN
CIRCUIT OR SHORT CIRCUIT
Speed sensor detects wheel speed and transmits speed
signal to the ABS module. ABS system uses these signals
to control each actuator.
When the signal wheel rotates, its wire will intersect with
the magnetic line of force of the magnet in the speed
sensor, therefore, an alternate current voltage (AC) is
produced. Because the voltage frequency of the AC
voltage is proportional to the rotational speed of signal
wheel, the speed of the wheel can be detected.

Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• If the vehicle speed is not lower
than 20km/h, no signal will be in-
put to the ABS module within 15 •
Right front, left front wheel speed
C0301 seconds.
sensor
• When the ignition switch is
C0302 • Right front, left front wheel speed
changed from OFF position to ON
C0304 sensor circuit
position, the wheel speed sensor
• Right front, left front sensor signal
C0305 signal will be interrupted momen-
tarily. wheel
• Wheel speed sensor circuit is
open
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-11

Circuit Diagram

04

Diagnostic step

1. Read DTC and data on the diagnostic apparatus

(a) Choose mode for reading dataflow in diagnostic apparatus.
(b) Check whether the speed showing on the speed meter on the instrument is consistent to that of the
diagnostic apparatus when the vehicle is running.
CAUTION
It is a normal scope if the difference of vehicle speed value of instrument and the diagnostic apparatus
is within ± 10%,.

Check whether the result is normal?

Yes > If the values are identical, go to step 5.
No > If the values are different, go to step 2.

2. Check the front wheel speed sensor

(a) Ignition switch: Switch to OFF Disconnect both the positive and negative poles of the battery terminal
and dismantle the battery.
 04-12 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

(b) Disconnect the connector A002 of right front wheel speed

sensor and the connector A014 of left front wheel speed
sensor.

04

(c) Measure the voltage value between the pins of right front
and left front wheel speed sensor.
Standard electrical resistance (check whether there
existent an open circuit)
Connection of the multime- Standard value
ter
A002（1）-A002（2）
0.9-1.8K
A014（1）-A014（2）

(d) Measure the voltage between the pin of the connector of

wheel speed sensor and ground.
Standard resistance (check whether there is short
circuit)
Connection of the multime- Standard value
ter
A002 (1) - ground
A002 (2) - ground
≥ 1 MΩ
A014 (1) - ground
A014 (2) - ground

Check whether the result is normal?

Yes> go to step 3
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-13

If no > maintain or replace the wheel speed sensor..

3. Check the left front wheel speed sensor output signal

(a) Check output voltage of the right front, left front wheel
speed sensor while rotating.
Standard voltage
Connection of the multime- Standard value 04
ter
A002（1）-A002（2）
120 mV
A014（1）-A014（2）

CAUTION
The multimeter should be set in millivolt grade while
operating. Check output voltage of the left front wheel speed
sensor while rotating at a speed of 2 rounds per second.

Check whether the result is normal?

Yes> go to step 4
No> go to step 5

4. Check harness and connector

(a) disconnect the connector A006 of the ABS module.
 04-14 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

(b) Measure the resistance of the connectors of the harness

as per the values given in the table below
Standard electrical resistance (check whether there
existent an open circuit)
Connection of the multime-
Standard value
ter

04 A006（6）-A002（1）
A006（18）-A002（2）
＜2
A006（34）-A014（1）
A006（21）-A014（2）

(c) Measure whether there is short circuit between harness

pins
Standard voltage
Connection of the multime- Standard value
ter
A006（6）- ground
A006（18）- ground
≥ 1 MΩ
A006（34）- ground
A006（21）- ground

Check whether the result is normal?

Yes >Maintain or change the ABS control module.
No > Maintain or replace the harness and connectors

5. Check right front, left front wheel speed sensor installation

(a) Check right front, left front wheel speed sensor installation
CAUTION
The installation bolt shall be fastened appropriately, and the position of installation of sensor should
be leveled.

Check whether the result is normal?

Yes> go to step 6
No > maintain or replace the wheel speed sensor..

6. Check right front, left front wheel speed sensor signal terminal
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-15

(a) Check right front, left front wheel speed sensor signal
terminal
CAUTION
The sensor signal terminal shall be free of scratch or
absorbing broken metal scraps.

04

Check whether the result is normal?

Yes> go to step 7
No > Clean corresponding wheel speed sensor signal terminal.

7. Check the sensor signal gear

(a) Check the teeth of signal gear.
CAUTION
• The signal gear shall be free of scratch, absorbing the
broken metal scarps or external material.
• If there are outside materials, the output voltage shall
be checked after taking them out.

Check whether the result is normal?

Yes >Maintain or change the ABS control module.
No > Clean corresponding speed sensor signal gear.
 04-16 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

C0038– LEFT REAR WHEEL SPEED SENSOR CIRCUIT FAILURE:

OPEN CIRCUIT OR SHORT CIRCUIT
C0037– LEFT REAR WHEEL SPEED SENSOR FAILURE:THE SCOPE,
PERFORMANCE, CONTINUITY
C003B– RIGHT REAR WHEEL SPEED SENSOR CIRCUIT FAILURE:
04
OPEN CIRCUIT OR SHORT CIRCUIT
C003A–RIGHT REAR WHEEL SPEED SENSOR FAILURE: THE
SCOPE, PERFORMANCE, CONTINUITY
Speed sensor detects wheel speed and transmits speed
signal to the ABS module. ABS system uses these signals
to control each actuator.
When the signal wheel rotates, its wire will intersect with
the magnetic line of force of the magnet in the speed
sensor, therefore, an alternate current voltage (AC) is
produced. Because the voltage frequency of the AC
voltage is proportional to the rotational speed of signal
wheel, the speed of the wheel can be detected.

Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• If the vehicle speed is not lower
than 20km/h, no signal will be in-
put to the ABS module within 15 •
Right rear, left rear wheel speed
C003A seconds.
sensor
• When the ignition switch is
C003B • Right rear, left rear wheel speed
changed from OFF position to ON
C0037 sensor circuit
position, the wheel speed sensor
• Right rear, left rear sensor signal
C0038 signal will be interrupted momen-
tarily. wheel
• Wheel speed sensor circuit is
open
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-17

Circuit Diagram

04

Diagnostic step

1. Read DTC and data on the diagnostic apparatus

(a) Choose mode for reading dataflow in diagnostic apparatus.
(b) Check whether the speed showing on the speed meter on the instrument is consistent to that of the
diagnostic apparatus when the vehicle is running.
CAUTION
It is a normal scope if the difference of vehicle speed value of instrument and the diagnostic apparatus
is within ± 10%,.

Check whether the result is normal?

Yes > If the values are identical, go to step 5.
No > If the values are different, go to step 2.

2. Check the left rear wheel speed sensor

(a) Ignition switch: Switch to OFF Disconnect both the positive and negative poles of the battery terminal
and dismantle the battery.
 04-18 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

(b) Disconnect the socket connector B003 of right rear wheel

speed sensor and the socket connector B002 of left rear
wheel speed sensor.

04

(c) Measure the voltage value between the pins of right and
left rear wheel speed sensors.
Standard electrical resistance (check whether there
existent an open circuit)
Connection of the multime- Standard value
ter
B003（1）-B003（2）
0.9 - 1.8 K
B002（1）-B002（2）

(d) Measure the voltage between the pin of the connector of

wheel speed sensor and ground.
Standard resistance (check whether there is short
circuit)
Connection of the multime- Standard value
ter
B003（1） - ground
B003（2） - ground
≥ 1 MΩ
B002（1）- ground
B002（2）- ground

Check whether the result is normal?

Yes> go to step 3
If no > Replace or change the wheel speed sensor..

3. Check the left rear wheel speed sensor output signal

 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-19

(a) Check output voltage of the right rear, left rear wheel speed
sensors while rotating.
Standard voltage
Connection of the multime-
Standard value
ter
B003（1）-B003（2）
120 mV
B002（1）-B002（2） 04

CAUTION
The multimeter should be set in millivolt grade while
operating. Check output voltage of the left rear wheel speed
sensor while rotating at a speed of 2 rounds per second.

Check whether the result is normal?

Yes> go to step 4
No> go to step 5

4. Check harness and connector

(a) disconnect the connector A006 of the ABS module.

(b) Measure the resistance of the connectors of the harness

as per the values given in the table below
Standard electrical resistance (check whether there
existent an open circuit)
Connection of the multime-
Standard value
ter
A006（31）-B003（1）
A006（19）-B003（2）
＜2
A006（20）-B002（1）
A006（33）-B002（2）
 04-20 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

(c) Measure whether there is short circuit in the resistance

between harness pins
Standard voltage
Connection of the multime-
Standard value
ter
A006（31）- ground
04 A006（19）- ground
≥ 1 MΩ
A006（20）- ground
A006（33）- ground

Check whether the result is normal?

Yes >Maintain or change the ABS control module.
No > Maintain or replace the harness and connectors

5. Check right rear, left rear wheel speed sensor installation

(a) Check right rear, left rear wheel speed sensor installation
CAUTION
The installation bolt shall be fastened appropriately, and the position of installation of sensor should
be leveled.

Check whether the result is normal?

Yes> go to step 6
No > maintain or replace the wheel speed sensor..

6. Check right rear, left rear wheel speed sensor signal terminal
(a) Check right rear, left rear wheel speed sensor signal
terminal
CAUTION
The sensor signal terminal shall be free of scratch or
absorbing broken metal scraps.

Check whether the result is normal?

Yes> go to step 7
No > Clean corresponding wheel speed sensor signal terminal.

7. Check the sensor signal gear

 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-21

(a) Check the teeth of signal gear.

CAUTION
• The signal gear shall be free of scratch, absorbing the
broken metal scarps or external material.
• If there are outside materials, the output voltage shall
be checked after taking them out.

04

Check whether the result is normal?

Yes >Maintain or change the ABS control module.
No > Clean corresponding speed sensor signal gear.
 04-22 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

C1095－VALVE RELAY FAILURE

Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• The power supply of electromag- •
ABS electromagnetic valve power
C1095 netic valve is at low electric poten-
supply circuit
tial state
04

Circuit Diagram
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-23

Diagnostic step

1. Check the relay and fuse (fuse box inside the vehicle)
(a) Check the fuse F17 in the in-vehicle fuse box.
Standard voltage
Connection of the multime-
Standard value
ter 04
Fuse F17-ground
Battery voltage
Fuse F17-ground

Check whether the result is normal?

Yes> go to step 2
No > The voltages of both ends of the fuse are different, go to step 3.

2. Check the connector of the ABS control module.

(a) disconnect the connector A006 of the ABS module.
 04-24 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

(b) Measure the voltage between the pin 25 and pin 38 of the
connector A006 of ABS control module.
Standard voltage
Connection of the multime-
Standard value
ter
A006（25）-A006（38） Battery voltage
04

Check whether the result is normal?

Yes >Maintain or change the ABS control module.
No> go to step 3

3. Check harness and connector

(a) Pull out the fuse F17 and measure the resistance value
between the output end of fuse and the pin 25 of the
connector A006 of ABS control module.
Standard resistance (check for any open circuit)
Connection of the multime-
Standard value
ter
A006（25）-F17 ＜2
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-25

(b) Measure the voltage between the pin 25 of the connector

A006 of ABS control module and ground.
Standard resistance (check whether there is short
circuit)
Connection of the multime-
Standard value
ter
A006（25）- ground ≥ 1 MΩ 04

Check whether the result is normal?

Yes > Replace fuse F17（25A）.
No > Maintain or replace the harness and connectors
 04-26 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

C0020–RETURN PUMP FAILURE

Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• ABS pump motor circuit
• The abnormal operation of pump •
C0020 ABS control module (pump mo-
motor under self-check state.
tor)
04

Circuit Diagram
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-27

Diagnostic step

1. Check the relay and fuse (vehicle-body fuse box)

(a) Check the fuse F15 inside the vehicle-body fuse box.
Standard voltage
Connection of the multime-
Standard value
ter 04
Fuse F15-ground
Battery voltage
Fuse F15-ground

Check whether the result is normal?

Yes> go to step 2
No > The voltages of both ends of the fuse are different, go to step 3.

2. Check the connector of the ABS control module.

(a) disconnect the connector A006 of the ABS module.
 04-28 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

(b) Measure the voltage between the pin 1 and pin 13 of the
connector A006 of ABS control module.
Standard voltage
Connection of the multime-
Standard value
ter
A006（1）-A006（13） Battery voltage
04

Check whether the result is normal?

Yes >Maintain or change the ABS control module.
No> go to step 3

3. Check the harness（indoor fuse box-ABS control module)

(a) Pull out the fuse F15 and measure the resistance value
between the output end of fuse and the pin 1 of the
connector A006 of ABS control module.
Standard electrical resistance (check whether there
existent an open circuit)
Connection of the multime-
Standard value
ter
A006（1）-F15 ＜2
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-29

(b) Measure the resistance value between the pin 1 of the

connector A006 of ABS control module and ground.
Standard resistance (check whether there is short
circuit)
Connection of the multime-
Standard value
ter
A006（1）- ground ≥ 1 MΩ 04

Check whether the result is normal?

Yes > Change the fuse F15 （40A）inside the vehicle-body fuse box.
No > Maintain or replace the harness and connectors
 04-30 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

ABS INDICATING LAMP IS ALWAYS ON.

ABS INDICATING LAMP IS NOT BRIGHT
Circuit Diagram

04
 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS) 04-31

Diagnostic step

1. Check the power supply of combination instrument

(a) disconnect the connector A006 of the ABS module.

04

(b) Turn on the ignition switch and measure the voltage

between the pin32 and pin 38 of the connector C006 of
ABS control module.
Standard voltage
Connection of the multime-
Standard value
ter
A006（32）-A006（38） Battery voltage

Check whether the result is normal?

Yes> go to step 2
No > Maintain or replace the harness or the connectors

2. Check the harness

 04-32 DIAGNOSTICS - ANTI-LOCK BRAKING SYSTEM (ABS)

(a) Turn off the ignition switch and disconnect the connector
C 13 of the combination instrument.
(b) Measure the voltage between the no.17 pin of connector
C013 of the combination instrument and the no.26 pin of
the connector A006 of ABS control module.
Standard voltage
Connection of the multime-
Standard value
04 ter
C013（17）-A006（26） ＜2

(c) Measure the voltage between the no.1pin of connector

C013 of the combination instrument and the no.14 pin of
the connector A006 of ABS control module.
Standard voltage
Connection of the multime-
Standard value
ter
C013（1）-A006（14） ＜2

Check whether the result is normal?

Yes > Maintain or replace the combination instrument.
No > Maintain or replace the harness and connectors
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-33

ENGINE CONTROL SYSTEM

PRECAUTION
1. Disconnect the Power Supply
• When disassembling or installing any electric unit, or touching the exposed electrical terminal
with tools or devices, disconnect the negative battery cable firstly, and connect the negative
battery cable at last so as to avoid personal injury or damage to the vehicle.
• Turn off the ignition if not otherwise specified. 04

DANGER
Before connecting or disconnecting the negative battery cable, do turn off the ignition switch and lighting
switch (if not, the semiconductor element may be damaged)
WARNING
If the vehicle is equipped with central console lock, don't leave the key inside the vehicle before
disconnecting the negative battery cable, or it may automatically lock up.
2. The daily odometer and clock of combination instrument may be zero-cleared once the combination
instrument is dismounted or the negative pole of battery is disconnected.
DANGER
The overall speedometer cannot be reset to zero.
3. Disconnect negative cable of the battery can make the sound system lose the stored settings.
WARNING
When reconnecting the negative cable of the battery, the sound system should be reset.
4. Ignition switch representation
Ignition switch (location) Ignition switch representation
LOCK Ignition Switch: OFF.
ACC Ignition Switch ACC
ON Ignition Switch: ON.
START Start the engine.

5. Precautions for failure shooting of the engine control system

(a) It is strictly forbidden to disconnect the battery from the circuit when engine runs at high speed, so as to
avoid transient overvoltage that may damage the ECM and sensors.
(b) To carry out electric welding on the vehicle body, the ECM power supply shall be disconnected firstly.
Special attention shall be paid to that when repairing an element of the vehicle body which is close to
the ECM or sensors.
(c) When terminal contact or mounted parts occur failure, the system might be returned to its normal state
absolutely or temporarily when a questionable part is dismounted and remounted.
(d) Unless otherwise specified in test process, test ECM and sensors with high-resistance digital multimeter
instead of pointer multimeter.
(e) Do not use a test lamp to test any electric apparatus connected to ECM.
(f) The positive and negative poles of battery must not be connected incorrectly, and the negative pole must
be earthed (ground).
(g) ECM and sensors must be protected from moisture. It is not allowed to damage the sealing gland of
ECM or sensors, and it is especially not allowed to rinse ECM and sensor with water.
 04-34 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(h) Countermeasures against damages to the computer by human-body static electricity: To test the ECM
or replace a chip, the operator must earth his body (earth) by attaching one end of agrounding ground
metal tape to his wrist and the other end to the vehicle body, so as to prevent the human-body static
electricity from damage the computer.
(i) To determine the failure location, it is required to check the condition of the vehicle when a failure occurs.
For example, conduct checks as per the diagnostic trouble code (DTC) output, and record the conditions
before each connector is disconnected or any part is dismounted and remounted.
(j) Do dismount and remount the ECM, actuators and all independent sensors after the ignition switch are
04 turned off, unless otherwise specified in the inspection procedures.
(k) If a dismounted and reassembled ECM, actuator or sensor is remounted, the system shall be checked
for normal conditions when assembling is finished. Use special diagnostic instrument to check DTC
(l) Use a digital multimeter to check the ECM terminals of engine
• Connect a fine probe to the probe of digital multimeter.

• Connect the fine probe to the inside of each terminal (from the inside harness) of ECM, and
measure the magnitude of voltage of the terminals with reference to the check list.

WARNING
• When the ignition switch is set to ON and the connectors are disconnected during diagnosis,
other system may store the DTC. When the job is finished, verify the failure codes of all systems.
Delete any DTC if available. To connect or disconnect the connector, set the ignition switch to
its “LOCK” (OFF) position.
• Do not insert the testing probe into the harness for testing, so as not to deteriorate the
water-repellent property and lead to corrosion. Use special tools such as testing harness, harness
connector or inspection connectors.
• To check ordinary (non waterproof) connectors when the harness connectors are connected,
insert the probe from the harness; if the connector is too small for insertion of the testing probe
(for example the ECM connector), do not conduct insertion barely.
• To conduct checks when the connector is not connected (check male terminals):
• Caution: The used testing probe must not lead to short circuit of connector terminals so as not
to damage the interior circuits of ECM.
• When the connector is disconnected, the system to be checked or other systems may store the
trouble code.
• To conduct checks when the harness connector is not connected (check female terminals):
• Use special tools designed for harness checks. Forced probe insertion may lead to poor contact.

• When the connector is disconnected, relevant system to be checked or other systems may store
the trouble code.
• Short-circuit caused by incorrect terminal insertion may damage the harness, sensor ECM or
other elements. Be careful!
• It is unnecessary to conduct checks as per the sequence listed in the check list.
• If the results of voltage are different from the standard value, check relevant sensors, actuators
and harness, and repair or replace them when necessary.
• When repair or replacement is finished, use a voltmeter to check the values over again, and verify
whether or not the failure is eliminated.

(m) Use a multimeter to check the resistance and conduction between the ECM terminals
• Ignition Switch: OFF.

• Remove the connectors of ECM harness.

 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-35

• As per the check list, measure and check the resistance and conduction between the terminals
of harness-side connectors of ECM.

WARNING
• Use special-purpose check lines instead of ordinary test bars to measure the resistance and
conduction between the terminals, so as not to affect the contact pressure of terminals.
• It is unnecessary to conduct checks as per the sequence listed in the check list.
• To check the resistance and conduction between the terminals, incorrect terminal insertion or 04
incorrect short-circuit groundinggrounding (ground) of connector terminals may possibly damage
the vehicle-body harness, sensors, ECM or multimeter, be careful!
• If the tested results are different from the standard value, check relevant sensors, actuators and
harness, and repair or replace them when necessary.
• When repair or replacement is finished, check the values over again, and verify whether or not
the failure is eliminated.

(n) Grounding (ground) checks

• Remove the grounding bolt or screw.

• Check all mating surfaces for blemish, soil and rust etc.

• Clean them as necessary so as to ensure good contact.

• Remount the bolts or screws securely.

• Check for any "additional" accessories that may interfere with the grounding circuit.

• If multiple conductors are press-bonded to 1 grounding hole, check it for correct press bond.
Verify that all circuits are cleaned, secured and earthed properly. If multiple strands of electric
wires are fitted to 1 grounding hole, verify that there is no grounding (earth) wire with too long
insulating sheath.
• To replace the ECM, conduct adequate diagnosis of other causes since ECM is an expensive
product with high reliability and cannot be damaged in most cases.

WARNING
• Grounding connection is extremely important for normal operation of the electric and electronic
circuits. The grounding connection is usually exposed to moisture, soil and other corrosive
chemicals. Additional resistance may be generated in the eroded (rusted) places. The said
additional resistance may change the working properties of the circuits.
• The electronic control circuits are extremely sensitive to the correctness of grounding, and loose
or corroded grounding may have a strong impact on the electronic control circuits. Poor grounding
or corrosion may easily affect the circuits. The earthed place may be covered by a layer of thin
rust even though it appeared clean.
 04-36 DIAGNOSTICS - ENGINE CONTROL SYSTEM

COMPONENTS

04

1 Nozzle B 11 Engine Control Unit

2 Nozzle D 12 Nozzle B
3 Nozzle A 13 Oil Pressure Warning Switch
4 Power Steering Switch 14 CKP Sensor
5 Ignition Coil 15 Wheel Speed Sensor
6 Generator 16 Absolute pressure / temperature
7 Canister Solenoid Valve sensor, intake manifold
8 Sensor Unit, Water Temperature 17 Stepping Motor
9 Knock Sensor 18 TPS
10 Compressor 19 Starter
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-37

HOW TO CONDUCT FAILURE ANALYSIS

CAUTION
Use a diagnostic apparatus to diagnose a vehicle
1. Send a vehicle to a maintenance depot.
Yes > Go to the next step.
2. Collect and analyze the failure phenomena described by the customer.
04
Yes > Go to the next step.
3. Connect the diagnostic apparatus to DLC.
Yes > Go to the next step.
4. Check the DTC and still data.
Yes > Go to the next step.
5. Clear the DTC and still data.
Yes > Go to the next step.
6. Conduct visual check.
Yes > Go to the next step.
7. Verify the failure phenomena.
Results (if the engine fails to start up, conduct the following “check for DTC” and basic
inspection)
Result Go to
The failure does not occur The next step
The failure occurs Step 9
8. Simulation Symptom Test
Result Go to
The failure does not occur Step 11
The failure occurs The next step
9. Check for DTC.
Results
Result Go to
Failure code occurs The next step
No failure codes occur Step 11
10 . Refer to the DTC list.
Yes > Go to Step 13.
11 . Conduct basic inspection.
Results
Result Go to
The faulty component cannot be identified The next step
The faulty component can be identified Step 16
12 . Refer to the list of failure phenomena
 04-38 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Results
Result Go to
The faulty component cannot be identified The next step
The faulty component can be identified Step 15
13 . Check the power supply circuit of ECM.
Yes > Go to the next step.
04
14 . Check the circuit.
Results
Result Go to
The faulty component cannot be identified The next step
The faulty component can be identified Step 17
15 . Check for the intermittent failure.
Yes > Go to Step 17.
16 . Check the components
Yes > Go to the next step.
17 . Verify the failure.
Yes > Go to the next step.
18 . Adjust or repair
Yes > Go to the next step.
19 . Conduct a confirmation test.
Yes> Complete

Main points for inspection and maintenance if fuse is blown out

The failure code may be stored since the fuse is blown out.

Remove the blown-out fuse, and measure the resistance between the load side of the blown-out
fuse and the ground. Turn off all switches connected to the circuit where the said fuse stays. If the
resistance measured at this moment approximates to 0, a short-circuit must occur in some places
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-39

of the switches or loads. If the resistance is not 0, no short circuit exist at this moment; however,
transient short circuit may cause fuse burn-out.
Major factors leading to short circuits are listed as follows:
• Harness is nipped up by the vehicle body
• Sheath of the harness is damaged due to wear or heat
• Water enters into the connecters or circuits
• 04
Human errors (mal-operation short circuit etc.)
1 Battery
2 Fuse
3 Load switch
4 Fuse burn-out
5 Short circuit occurring position
 04-40 DIAGNOSTICS - ENGINE CONTROL SYSTEM

INTERMITTENT FAILURE
If an intermittent failure exists, diagnosis may be conducted as per the following steps:
WARNING

In many cases, intermittent failure may be eliminated by itself (the functions of a part or circuit return
to normal when no intervention is implemented). The phenomenon complained by the customer might
not reoccur when DTC is tested. In addition, the most common causes of intermittent failures usually
04
lie in the poor electric connectors. Therefore, the state in which the failure occurred is not very clear.
So, the circuit check, which is part of the standard diagnosis steps, may fail to find out the specific
failure zones.

In such a case, we have to inquire the customer for the condition when the failure happened, inquire
the vehicle owner for the driving details, weather condition, occurrence frequency and failure phenomena,
carry out analysis, simulate the identical or similar condition and environment in which the failure
happened, and then verify whether or not the failure phenomena were caused by vibration, temperature
or other factors.

No matter how the serviceman is experienced and skillful, some important factors will certainly be
ignored in process of repair if failure is analyzed without verification, and incorrect guesses may urge
the personnel to take a wrong path, or even the repair cannot be carried out.

The following checks may be conducted to find out such failures.

1. Vibration method.
When vibration is considered as the major cause of the failure, the connectors and
subassemblies may be checked so as to verify whether or not the failure phenomena occur.
Failure simulation may be performed as per the following procedures:
(a) Connector: Shake the connectors gently in vertical and
horizontal directions, and check whether or not the harness
connectors connected to corresponding parts get loose.
Check the terminals for soil, rust, corrosion, and bend.
Check for any loose contact caused by elongation of
terminals.

(b) Harness: Shake the harness gently in vertical and

horizontal directions, and check thoroughly connections
of the vibrated connectors and the harness inside the
engine/ driver's cabin instruments for disconnected
harness.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-41

(c) Relay: parts and sensors: Pat the sensors, relays, or parts
which are considered as the source of failure, and check
them for malfunction. However, do not beat the relays
violently for fear of open circuit of the relays.

04

2. Heating method.
If a questionable zone is considered as the source of failure, use a hairdryer or similar device
to heat the most probable components that may cause the failure, and check whether or
not the failure occurs.

WARNING
The heating up temperature shall not exceed 60℃ (the heating temperature of components shall allow
free touch). Do not heat up the electronic control modules.
3. Water spray method.
If the failure is considered to occur in rainy days or moist weather, spray water onto the
vehicle and check for any failure.

WARNING
• Do not spray water onto the engine directly. Water shall be sprayed onto the front side of the
radiator so as to change the temperature and humidity indirectly.
• Do not spray water directly onto the electronic elements.
• Do be careful to conduct water spraying on vehicle in which water leak exists, since the water
leak may possibly damage the ECM.

4. Overall electric apparatus power-on method.

If the failure was possibly caused by too high electric load, power on all electric loads
including the central heating blower, headlights and rear window defroster, and check
whether or not the failure occur.
During the simulation test of failure phenomena, not only the phenomena shall be identified,
but also the faulty location or faulty parts shall be found out. For this reason, the range of
circuits (in which the failure might occur) shall be reduced as per the failure phenomena
before the test is conducted and the tester is connected in advance. Then phenomenon
simulation test may be conducted so as to determine whether or not the tested circuits are
normal.
In case of failures that are hard to be handled, the list of troubleshooting and diagnosis
codes may be utilized to conduct failure analysis/diagnosis so as to reduce the range of
failure and find out the failure location quickly. The said method is considered as fairly
practical and effective.
5. Diagnostic apparatus data-stream freezing method.
 04-42 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Use the data stream capturing function of diagnostic apparatus. Simulate the failure
conditions as per the frozen failure data recorded by the diagnostic apparatus when people
read the data stream displayed by the diagnostic apparatus.
6. Oscilloscope method.
Oscilloscope may be used to capture the waveforms such that the intermittent failures may
be found out quickly.
04 7. Other methods.
Part replacement method. To replace ECM or other control modules, conduct adequate
diagnosis of other external causes since ECM is an expensive product with high reliability.

WARNING
To conduct part-replacement check of a control unit that might be damaged, the said control unit shall
be mounted onto a failure-free vehicle and subjected to tests.The new control unit must not be mounted
onto a faulty vehicle and subjected to relevant tests so as not to damage the control unit.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-43

BASIC INSPECTION
If the failure cannot be identified through DTC check, failureshooting analysis shall be conducted
for all circuits that might cause the failure. In most cases, the faulty position may be quickly found
out by conducting the basic inspections of engine shown in the following process chart. Therefore,
it is extremely necessary to adopt such a test method to eliminate the engine failures.
1. Check battery voltage
WARNING 04

The check shall be conducted when the engine is shut down or the ignition switch is set to its OFF
position.
Results
Result Go to
11V or higher The next step
Lower than 11V Recharge or change the battery
2. Check whether or not the engine can be started up.
Check whether the result is normal?
Yes > Go to the next step.
No > Go to the list of failure phenomena
3. Check the air filter.
Is the result normal (whether or not containing dust, soil or oil)?
Yes > Go to the next step.
No > Replace or clean the filter.
4. Check the idle speed.
Check whether the result is normal?
Yes > Go to the next step.
No > Go to the list of failure phenomena
5. Check the fuel pressure.
Check whether the result is normal?
Yes > Go to the next step.
No > Exclude the failure of fuel pressure; go to the next step.
6. Check the ignition.
Check whether the result is normal?
Yes > Go to the next step.
No > Exclude the ignition system.
 04-44 DIAGNOSTICS - ENGINE CONTROL SYSTEM

CONFIGURATION DIAGRAM OF ECM-SIDE TERMINALS

04

Terminal no. Terminal definition Color Inspection Condition Normal state

1 Ignition Coil B Blue
2 Earthing Black
3 Earthing Black
4 Ignition coil A Green
5
6 Nozzle A (1-cylinder) Blue - white
7 Nozzle B (4-cylinder) Blue - pink
8 Nozzle D (3-cylinder) Blue - purple
9 Fuel pump relay control Purple
10 A/C grant signal Yellow - green
11 Crankshaft position signal (low) Pink
12
13
14
15
16
17 High-speed electronic fan control Purple - yellow
18
19
20 Idle-speed control valve A (high) Green - brown
21 Idle-speed control valve A (low) Green - yellow
22
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-45

Terminal no. Terminal definition Color Inspection Condition Normal state

23 Heater of rear oxygen sensor Blue - black
24 Heater of front oxygen sensor Blue - red
25 Nozzle C (2-cylinder) Blue - orange
26 Medium voltage switch signal Brown - red
27 TPS Purple - green
04
28
29
30 Crankshaft position signal (high) Orange
31
32
33
34
35
36
37 Knock Sensor Orange - purple
38 CAN L Red - white
39 CAN H Blue - yellow
40
41 Idle-speed control valve B (high) Yellow - pink
42 Idle-speed control valve B (low) Brown - yellow
43
44 Main relay control Pink
45
46
47 Front oxygen sensor signal White
48 Rear oxygen sensor signal White - black
Sensor unit, water temperature
49 White - red
V5–
50
51
52 Sensor Unit, Water Temperature White - black
53
54 Intake pressure sensor Blue - yellow
55
56
57 Clutch switch
58 Knock sensor V5– Black - white
 04-46 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Terminal no. Terminal definition Color Inspection Condition Normal state

59 Acceleration sensor signal Brown - green
60 Power steering switch input Black - yellow
61
62
63
04
64 Canister Solenoid Valve White - yellow
65 Low-speed fan control Yellow - purple
66 Intake pressure sensor V5 Sky blue
67 Electric power supply 12V Red - yellow
68 IG power supply Light green
69
70 Throttle position sensor V5 Brown
71 Intake Temperature Sensor Blue - white
72
73 Oxygen sensor (ground) White - pink
74 Throttle position sensor V5– Yellow - black
75 K line Gray - pink
76 Intake temperature sensor V5– Brown - red
77
78
79 A/C request signal Orange - purple
80
81
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-47

DIAGNOSIS SYSTEM
1. Failures of engine electric control system may be divided into 2 types:
(a) One type is to light up the MIL lamp (OBD failure indicating lamp), indicating the emission control failure
and limp mode of the system. Once the MIL lamp of instrument goes on, immediate treatment shall be
performed as per relevant national laws and regulations. Otherwise the system may limit the fuel injection
and speed of the engine so that the normal use of vehicle may be affected.
(b) The other type may have the SVS failure indicating lamp lit up, which indicates that the electric control
system develops a fault that shall be repaired in time. 04
(c) For the both types of failures, failure diagnostic apparatus or special equipment designed for corresponding
functions shall be used to conduct corresponding checks.
2. Light-up of SVS lamp and MIL lamp are under the control of ECM. Detailed light-up of SVS and
MIL lamps before and after startup is described below:
• When the system is failure free and the ignition switch is set to its ON position, the MIL lamp and
the SVS lamp will go on (system self-check); neither the SVS lamp nor MIL lamp goes on after
startup and engine stall.
• When the system is faulty and the ignition switch is set to its ON position, the MIL lamp and the
SVS lamp will constantly go on (system self-check); After startup, if the SVS lamp is defined as
- ON mode in the failure categories, the SVS lamp may constantly go on when the SVS lamp
-ON conditions are satisfied.If the MIL lamp is defined as - ON mode in the failure categories, the
MIL lamp will constantly go on when the MIL lamp- ON conditions are satisfied. When the ignition
switch is set to it OFF position after engine stall, the both lamps go out when the AFTERRUN
process (90s at most) expires.
3. To diagnose and exclude an engine failure that might relate to the electric-control fuel injection
system, it is required to judge whether or not the failure relates to the electric-control fuel injection
system firstly. If the engine is faulty while the failure indicating lamp does not go on, the failure
may not relate to the electric control system in most cases.
(a) Relevant failure code record and data stored in the ECM, which are related to the sensors and actuators,
may be read by diagnostic apparatus KT600. In addition, actuator may be compulsorily driven by the
diagnostic apparatus under specific conditions.
(b) DLC- data interlink connector.
Terminal no. Name
4 Earthing
5 Earthing
6 CAN_H
7 Diagnostic communication K
14 CAN_L
15 LIN
16 Battery power supply
 04-48 DIAGNOSTICS - ENGINE CONTROL SYSTEM

READING AND CLEARANCE OF THE DIAGNOSTIC TROUBLE CODE

(DTC)
CAUTION
Failures are detected by the engine control system and stored in the engine control module (ECM), and
the system failures may be current or historic ones.
1. Current failures: It refers to the failures currently existing in ECM, for example: open circuit of
04 engine coolant temperature sensor.The current failures must be repaired; otherwise, they cannot
be cleared from the memory.
2. Historic failures: They may be stored in 2 modes:
• The failures had been repaired, the actual failures do not exist, however the memorized data are
not cleared from ECM.
• Failures had occurred but do not exist presently, however, they might reoccur. For example: poor
contact of harness. Since the stored failures are not the present failures, they require no repair
before they are cleared from the memory, or they may be handled as per the elimination of
intermittent failures.

CAUTION
• If the battery voltage is too low and the testing codes of ECM cannot be output normally, the
battery voltage must be detected before the check, and the voltage shall not be lower than 11V.
• When the battery or ECM connector is disconnected, the failure codes stored in ECM may be
cleared.
• Before the KT600 intelligent diagnostic apparatus is connected or disconnected, the ignition
switch must be set to its OFF (LOCK) position.

CAUTION
Use a special-purpose test tool to read the engine failure codes: KT600 comprehensive intelligent
diagnostic apparatus.
Use a diagnostic apparatus to perform DTC reading procedures.
1. Check and ensure the following conditions:
• Throttle is completely closed.

• Air conditioner switch is set to its OFF position.

• Transmission is set to its neutral gear.

2. Switch off the ignition.

3. Connect the analyzer to the diagnostics connector (16-pin) at the lower left of the dashboard.
4. Switch on the ignition and the analyzer - use the latest software version.
5. Select menu items:【Beiqi Foton】-【pick-up】-【Tunland】-【engine】-【4G69 gas-engine】-
【Delphi system】-【MT22.1.1】-【read the current code】.
6. Check, record and delete the DTC and data stream (in case DTC cannot be deleted, implement
diagnostic steps as per “the check list of failure codes”, and repair the failure).
7. Start the engine until it reaches normal working temperature.
8. Run the engine till MIL goes on in one of the following conditions:
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-49

• Simulated preset conditions of DTC.

• Simulated failure conditions described by customer.

• Simulated still data status read by diagnostic apparatus.

9. Use a diagnostic apparatus to read the DTC recorded by ECM.

10 . If DTC records are available while data or functions are normal, refer to the Diagnostic help –
Elimination methods for intermittent failures; If DTC records are available while data or functions
are abnormal, implement diagnostic steps as per “check list of failure codes” and repair the 04
failure.
CAUTION
• Use a diagnostic apparatus to read and capture the data. Once DTC is stored, ECM may record
the information about the vehicle and driving conditions as still data. To eliminate the failures,
the data capturing function may help determining whether or not the vehicle is running or stopped
when the failure occurred, whether or not the engine is warm, whether or not the air-fuel ratio is
too low or too high, and other data.
• Preset conditions of DTC include, but not limited to the following:
(a) Engine speed.
(b) Vehicle speed.
(c) Engine coolant temperature sensor.
(d) Intake-manifold absolute pressure / temperature sensor.
(e) Atmospheric pressure sensor.
(f) Intake temperature sensor.
(g) Throttle position.
(h) Canister discharge.
(i) Fuel adjustment
(j) Air conditioner (A/C) switch.

Failure code clearing methods

1. Switch off the ignition.
2. Connect the analyzer to the diagnostics connector (16-pin) at the lower left of the dashboard.
3. Switch on the ignition and the analyzer - use the latest software version.
4. Select menu items:【Beiqi Foton】-【pick-up】-【Tunland】-【engine】-【4G69 gas-engine】-
【Delphi system】-【MT22.1.1】-【clear trouble code】.
 04-50 DIAGNOSTICS - ENGINE CONTROL SYSTEM

CAPTURED DATA
WARNING
• DTC - Once DTC is stored, ECM may record the information about the vehicle and driving
conditions as still data. To eliminate the failures, the still data may help determining whether or
not the vehicle is running or stopped when the failure occurred, whether or not the air-fuel ratio
is too low or too high, and whether or not other data are recorded.
• If a failure cannot recur even if DTC is detected, the still data have shall be verified. ECM may
04
record the engine conditions at intervals as still data. Diagnostic apparatus may be used to read
a certain groups of still data, since KT600 diagnostic apparatus is provided with powerful help
functions designed for random data stream. In the engine system 4G69, select the data stream
reading function menu to access the data stream test result display interface, click ? the “Help”
button, and the following window pops up:
• Driving record playback.

• Calculator.

• Data area reference.

• Data capturing.

• Data comparing

• Relevant data stream setup.

• Data/waveform display.

• Traveling recorder menu.

• These data may be used to simulate the vehicle conditions when the failure occurred. They may
help determine the source of failure, and judge whether the failure falls within transient failures.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-51

LIST OF FAILURE PHENOMENON PROTECTIONS

When the self-diagnosis function of engine control system detects that the main sensor fails to
work, the vehicle may be controlled by a preset control logic loop once a DTC is set up, such that
the vehicle may run safely. In addition, the following phenomena may occur when the sensor or
actuator fails to work:

Sequence number Trouble items Control contents during failure 04

• Failure signal lamp goes on
• Idle speed gets unstable
1 Injector • Engine gets powerless
• Engine startup gets hard
• Acceleration performance gets poor

• Failure signal lamp goes on

2 Relay • System fails to work
• Engine cannot be started up

• Failure signal lamp goes on

• Noises are heard when fuel pump works
3 Fuel pump • Acceleration performance gets poor
• Engine cannot be started up

• Failure signal lamp goes on

• Oil injection into corresponding cylinder is stopped
• Target idle speed is raised
• Idle speed gets unstable
4 Ignition Coil • Engine gets powerless
• Fuel economy gets poor
• Emission exceeds standard
• Ignition gets weak
• Failure signal lamp goes on
• System postpones the closed ring working time
• Fuel economy gets poor
5 Oxygen sensor • Emission exceeds standard
• Acceleration gets slow
• Driving force gets weak
• Failure signal lamp goes on
• Canister solenoid valve is turned off
Canister Solenoid • System turns off the self-learning of basis fuel control closed ring
6
Valve • System turns off the self-learning of idle speed air control
• Idle speed gets unstable or higher

• Failure signal lamp goes on

• Safe ignition advance angle is adopted
7 Knock Sensor • Engine knocking occurs
• Engine is overheated
• Emission exceeds standard
 04-52 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Sequence number Trouble items Control contents during failure

• Fuel economy gets poor
• Drive
• Interior destructive force of engine gets weak/poor

• Failure signal lamp goes on

• Driving restriction measures might be taken
04 Wheel Speed
8 • Instrument does not display vehicle speed
Sensor
• Fuel economy gets poor

• Failure signal lamp goes on

Intake Tempera-
9 •
ture Sensor Intake temperature is equal to the coolant temperature
• Failure signal lamp goes on
• Engine cannot be started up
• Speed is restricted after the engine is started up
• Maximum engine speed is not higher than approximately 4000RPM
10 CKP Sensor • Emission exceeds standard
• No ignition signals are sent to ECM
• tachometer fails to work
• Noisy engine
• Failure signal lamp goes on
• At idle speed, the opening of throttle position sensor may be set
to 0%. At other speeds, the opening of throttle position sensor may
11 TPS vary as per the speed.
• Fuel injection-quantity cannot be increased when acceleration, so
the acceleration performance gets poor.
• Failure signal lamp goes on
• Intake temperature is adopted when the engine is started up, and
the value is fixed when time increase progressively to a certain
one.
• Engine startup gets hard in cold-vehicle state
Absolute pressure
• Engine startup gets hard in warm-vehicle state
/ temperature sen-
12 •
sor, intake mani- Driving force gets weak
fold • If engine coolant temperature sensor circuit and power supply is
short-circuited, the engine may work at the default values
• Cooling fan continuously works at high speed
• The high temperature warning lamp flickers when high temperature
is displayed in the instruments
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-53

LIST OF DATA STREAMS, MOTION TEST

1. List of data stream
CAUTION
• The data list displayed on the diagnostic apparatus may be read, and the data values of parts
including switches, sensors and actuators nay be checked without removing any parts. Data list
reading is conducted as the first step for troubleshooting such that the diagnosis time may be
reduced. 04
• Data under normal conditions are given in the table below (for reference only). Never judge
whether or not a part gets faulty only as per these reference values.

Steps to read data list:

(a) Start up the engine, and allow it to run till it reaches its normal working temperature.
(b) Switch off the ignition.
(c) Connect the analyzer to the diagnostics connector (16-pin) at the lower left of the dashboard.
(d) Switch on the ignition and the analyzer - use the latest software version.
(e) Select the following menu items:【Beiqi Foton】-【pick-up】-【Tunland】-【engine】-【4G69
gas-engine】-【Delphi system】-【MT22.1.1】-【read the data stream】.
(f) Refer to the following table and check the data. The following table gives the values of tested items under
different conditions within the “data stream reading” item observed by using KT600 diagnostic
apparatus.
• If no specific idle speed status is indicated, the transmission shift lever of transmission shall be
set to its neutral position, and the air conditioner switch and all accessory switches shall be set
to their OFF positions.
• Fuel injector drive time indicates the period of time when the crankshaft speed is lower than
2500RPM and the supply voltage is 11V.
• For new vehicles (driving mileage is less than 500km), the drive time of fuel injector may be longer
than standard time by 10%.
• For new vehicles (driving mileage is less than 500km), the step length of step motor may be 3
step length longer than standard step length.

Analyzer Item Checked items (range) Normal Condition

• Engine: warming-up When reducing the en-
status gine speed from ≤200mV
• Air-fuel ratio: getting 4000RPM
lower when decelera-
tion; getting higher Sudden acceleration 600-1,000mV
when acceleration
Oxygen sensor • Engine: warming-up Engine idling ≤400mV
status
• Use a oxygen sensor
signal to check the air-
fuel ration, and use At 2500RPM 600-1,000mV
ECU to check the con-
trolled conditions
• Engine coolant tempera- Engine idling
Intake Manifold Pressure ture: 80–95℃ At 2500RPM
Sensor • Lighting and all acces-
sories: OFF
 04-54 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Analyzer Item Checked items (range) Normal Condition

• Transmission: neutral When engine is accelerat-
gear ed

Intake temperature: -20℃ -20℃

Intake temperature: 0℃ 0℃
• Ignition: ON
Intake Temperature Sen-
04 • Or engine: ON Intake temperature: 20℃ 20℃
sor
Intake temperature: 40℃ 40℃
Intake temperature: 80℃ 80℃
Idling Position 300~1000m
Proportional increase
Throttle valve opens
TPS Ignition: ON with the throttle valve
gradually
open angle
Fully open 4500~5500mV
Power supply voltage Ignition: ON System voltage
Engine: stopped OFF
Ignition switch Ignition: ON
Engine: Start the engine. ON
Intake temperature: -20℃ -20℃
Intake temperature: 0℃ 0℃
Ignition switch: On or en-
ECT Sensor Intake temperature: 20℃ 20℃
gine running
Intake temperature: 40℃ 40℃
Intake temperature: 80℃ 80℃
Engine: idle speed (com- A/C switch: OFF OFF
Air conditioner (A/C) pressor works when A\C
switch switch is set to ON posi- A/C switch: ON ON
tion)
Cooling temperature: 0℃ 60 ～ 90 ms
Cooling temperature:
30 ～ 5 ms
Injector Engine: rotating 20℃
Cooling temperature:
6.7 ～ 10.1 ms
80℃
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-55

Analyzer Item Checked items (range) Normal Condition

• Engine coolant tempera- Engine: idle speed 2.2 ～ 3.4 ms
ture: 80–95℃
2500RPM 1.9 ～ 3.1 ms
• Lighting and all acces-
Injector
sories: OFF
• Transmission: neutral Engine idles at high
Increased
speed suddenly
gear
04
• Engine: warming-up Engine idling 2 ～ 18 BTDC
status
Ignition coil and transis- • Timing lamp: used (us-
tor ing the timing lamp is to 2500RPM 27 ～ 47 BTDC
test the actual ignition
time)
• Engine coolant tempera- A/C switch: OFF 2-25 steps
ture: 80–95℃
• Lighting and all acces-
sories: OFF
Idle Stepping Motor • Gearbox: Neutral A/C switch: OFF→ON
• Engine: idle speed
• When A/C is on, A/C
compressor shall work

Unactivated (compressor
A/C switch: OFF
Engine: post-warming- clutch does not work)
A/C relay
up/idle speed Activated (compressor
A/C switch: ON
clutch works)
Compare the engine
• Engine: running speed values that are
• read respectively from identical
Tachometer: connected
the tachometer and
KT600
Coolant temperature: -
1275 ～ 1475 RPM
20℃
CKP Sensor Coolant temperature: 0℃ 1225 ～ 425 RPM
Coolant temperature:
1100 ～ 1300 RPM
Engine: idle speed 20℃
Coolant temperature:
950 ～ 1150 RPM
40℃
Coolant temperature:
750 ～ 850 RPM
80℃
2. Motion test.
WARNING
Motion test may implement tests and other special operation learning for relays and actuators, and no
parts have to be removed. Use a diagnostic apparatus to conduct motion test. Data list reading is
conducted as the first step for troubleshooting such that the diagnosis time may be reduced.
Data list may be displayed when motion test is conducted.
 04-56 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Connect the diagnostic apparatus to the trouble diagnostic connector (16-pin) located in the lower left
side of the instrument panel.
(b) Switch on the ignition and the analyzer - use the latest software version.
(c) Select the following menu items:【Beiqi Foton】-【pick-up】-【Tunland】-【engine】-【4G69
gas-engine】-【Delphi system】-【MT22.1.1】-【motion test】.
(d) Conduct motion test with reference to the following table. The table below gives the “motion test”
items by using KT600 trouble diagnostic apparatus.
04 (e) If any exception is detected when engine is checked by "motion test" functions, the harness or elements
shall be repaired.
(f) When repair is finished, use KT600 diagnostic apparatus to conduct verification once again to confirm
that the problem points had been solved.
(g) Clear the trouble code.
(h) Remove the KT600 diagnostic apparatus.
(i) Restart up the engine and conduct test, and confirm that the trouble is already eliminated.
Displayed by diagnostic Tested parts Control range Diagnostic comments
apparatus
Trouble indicator lamp Trouble indicator lamp ON/OFF -
Canister solenoid valve
Carbon Canister ON/OFF -
control
Fuel pump relay Fuel pump relay ON/OFF -
Low-speed fan Control the low-speed fan ON/OFF -
Control the high-speed
High-speed fan ON/OFF -
fan
Air conditioner relay A/C trip relay ON/OFF -
Idle-speed air control Control the number of
- -
motor (stepping) steps of step motor
Idle-speed air control Control the speed of step
- -
motor (speed) motor
Idle-speed air control Control the resetting of
- -
motor (reset) step motor
Control the ignition ad-
Ignition Advance Angle - -
vance angle
Gear speed learning 58X learning - -
Control the cylinder fuel
Injector (A/B/C/D) ON/OFF -
cutoff
BLM learning - - -
BLM resetting - - -
Fuel open loop control Control the open loop - -
Idle-speed catalyzer Idle-speed catalyzer
- -
monitoring monitoring
Oxygen sensor response Oxygen sensor response - -
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-57

DTC LIST
CAUTION
When checking DTC in the checking model, if certain DTC is displayed, then the circuit of the code listed
in the following list should be checked.The detailed description of each DTC can refer to corresponding
pages.

Failure code Diagnostic Trouble location 04

items (DTC definition)
•Intake Manifold Pressure Sensor
•The pressure sensor connector of intake manifold is subject-
Rationality failure of intake
P0106 pressure / throttle position sig- ed to poor contact, and the sensor harness is open-circuited
nals or short-circuited
• ECM

•
Intake Manifold Pressure Sensor
•
The pressure sensor connector of intake manifold is subject-
The Intake pressure sensor cir-
P0107 cuit is subjected to low voltage ed to poor contact, and the sensor harness is open-circuited
or disconnection. or short-circuited
• ECM

• Intake Manifold Pressure Sensor

• The pressure sensor connector of intake manifold is subject-
The Intake pressure sensor cir- ed to poor contact, and the sensor harness is open-circuited
P0108
cuit is subjected to high voltage.
or short-circuited
• ECM

•
Intake Temperature Sensor
Low voltage of intake tempera- •
The intake temperature sensor connector is subjected to
P0112 poor contact, and the sensor harness is short-circuited
ture sensor
• ECM

•
Intake Temperature Sensor
•
The intake temperature sensor connector is subjected to
High voltage of intake tempera- poor contact, and the sensor harness is open-circuited or
P0113
ture sensor
short-circuited
• ECM

•
Engine coolant temperature sensor
•
The engine coolant temperature sensor connector is sub-
Low voltage of coolant temper- jected to poor contact, and the sensor harness is open-cir-
P0117
ature sensor circuit
cuited or short-circuited
• ECM

•
Engine coolant temperature sensor
•
The engine coolant temperature sensor connector is sub-
High voltage of coolant temper- jected to poor contact, and the sensor harness is open-cir-
P0118
ature sensor circuit
cuited or short-circuited
• ECM

Low voltage of throttle position •

P0122 Failure or maladjustment of throttle position sensor
sensor
 04-58 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Failure code Diagnostic Trouble location

items (DTC definition)
• The throttle position sensor connector is subjected to poor
contact, and the sensor harness is open-circuited or short-
circuited
• ECM

04 • Failure or maladjustment of throttle position sensor

• The throttle position sensor connector is subjected to poor
High voltage of throttle position contact, and the sensor harness is open-circuited or short-
P0123
sensor
circuited
• ECM

• Front Oxygen Sensor

• The front oxygen sensor connector is subjected to poor
To-ground short-circuit of front contact, and the sensor harness is open-circuited or short-
P0131
oxygen sensor
circuited
• ECM

• Front Oxygen Sensor

• The front oxygen sensor connector is subjected to poor
To-power-supply short-circuit of contact, and the sensor harness is open-circuited or short-
P0132
front oxygen sensor
circuited
• ECM

• Front Oxygen Sensor

• The front oxygen sensor connector is subjected to poor
Slow-response failures of front contact, and the sensor harness is open-circuited or short-
P0133
oxygen sensor
circuited
• ECM

• Front Oxygen Sensor

Inadequate activity or open cir-• The front oxygen sensor connector is subjected to poor
P0134 contact, and the sensor harness is open-circuited
cuit of front oxygen sensor
• ECM

• Heater of front oxygen sensor

Heating failure of front oxygen • The front oxygen sensor connector is subjected to poor
P0135 contact, and the sensor harness is open-circuited
sensor
• ECM

• Rear Oxygen Sensor

• The rear oxygen sensor connector is subjected to poor
To-ground short-circuit of rear contact, and the sensor harness is open-circuited or short-
P0137
oxygen sensor
circuited
• ECM

• Rear Oxygen Sensor

• The rear oxygen sensor connector is subjected to poor
To-power-supply short-circuit of contact, and the sensor harness is open-circuited or short-
P0138
rear oxygen sensor
circuited
• ECM
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-59

Failure code Diagnostic Trouble location

items (DTC definition)
• Rear Oxygen Sensor
• The rear oxygen sensor connector is subjected to poor
Inadequate activity or open cir- contact, and the sensor harness is open-circuited or short-
P0140
cuit of rear oxygen sensor
circuited
• ECM 04
•Heater of rear oxygen sensor
•The rear oxygen sensor connector is subjected to poor
Heating failure of rear oxygen contact, and the sensor harness is open-circuited or short-
P0141
sensor
circuited
• ECM

• Intake Air System

• Fuel injector blocked
• Manifold pressure sensor
• ECT sensor
• Pressure of the fuel system
• Gas leak of exhaust system
• The oxygen sensor harness is subjected to open circuit or
P0171 Fuel system is too thin short circuit
• Oxygen sensor
• Heater of oxygen sensor
• Relay and harness
• Air hose connection
• Vent valve and hose
• ECM
• Fuel injector leaking or blocked
• Manifold pressure sensor
• Sensor Unit, Water Temperature
• Ignition System
• Fuel pressure
• Gas leak of exhaust system
P0172 Fuel system is too thick • The oxygen sensor harness is subjected to open circuit or
short circuit
• Oxygen sensor
• Sensor heater
• Relay and harness
• ECM
• Injector A
P0201 Nozzle A circuit failure • Injector harness
• ECM

• Injector B
P0202 Nozzle B circuit failure • Injector harness
• ECM
 04-60 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Failure code Diagnostic Trouble location

items (DTC definition)
• Injector C
P0203 Nozzle C circuit failure • Injector harness
• ECM

• Injector D
04
P0204 Nozzle D circuit failure • Injector harness
• ECM

• Relay
P0230 Fuel pump relay failure • Fuel pump relay harness
• ECM

• The engine control system harness is subjected to open

circuit or short circuit
• Connector connection
• Vacuum hose connection
• Ignition System
• Injector
• Fuel pressure
• Manifold pressure sensor
P0300 Accident fire • ECT sensor
• Compression pressure
• Valve clearance
• Valve mechanism timing
• Vent valve and hose
• Air hose connection
• Intake Air System
• ECM
• Knocking sensor harness
P0325 Knocking control system failure • Knock Sensor
• ECM

• The crankshaft position sensor connector is subjected to

Crankshaft position sensor cir- poor contact, and the sensor harness is open-circuited or
P0336 short-circuited
cuit interfering signal
• ECM

• CKP Sensor
No signals from crankshaft posi-• The circuit connector is subjected to poor contact, and the
P0335 sensor harness is open-circuited or short-circuited
tion sensor
• ECM

•
The carbon canister control valve harness is subjected to
Carbon canister control valve open circuit or short circuit
P0443 • Carbon canister control valve
failure
• ECM

P0480 Fan 1 failure • Fan 1

 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-61

Failure code Diagnostic Trouble location

items (DTC definition)
• Fan 1 harness
• ECM
• Fan 2
P0481 Fan 2 failure • Fan 2 harness 04
• ECM

• Trouble indicator lamp

P0650 Failure indicating lamp failure • Failure indicating lamp harness
• ECM

• Main relay
P0685 Main relay output failure • Main relay harness
• ECM

• After replacing ECU or crank gear ring, or adjusting the rel-

ative position of the gear ring and the 58X sensor
• The crankshaft position sensor connector is subjected to
P1336 Need gear speed learning poor contact, and the sensor harness is open-circuited or
short-circuited
• ECM
 04-62 DIAGNOSTICS - ENGINE CONTROL SYSTEM

DEFECT DIAGNOSTICS CODE (DTC) TEST (ENGINE CONTROL

SYSTEM)
P0107–INTAKE PRESSURE SENSOR CIRCUIT IS SUBJECTED TO
LOW VOLTAGE
P0108–INTAKE PRESSURE SENSOR CIRCUIT IS SUBJECTED TO
04 HIGH VOLTAGE
Description
The system adopts speed-density-air metering method
to detect the air quantity entering into the engine in order
to control the fuel-injection pulse width and precisely
control the engine power output.

Circuit Diagram
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-63

DTC DTC definition DTC inspection conditions Trouble location

• MAP sensor
• Poor contact of the sensor connector
• The sensor signal circuit is subjected to open
•
circuit or high resistance
Ignition: ON •
•
To-ground short circuit of sensor signal circuit
Low voltage of in- No TPS defect • 04
•
5V reference voltage circuit is disconnected
P0107 take pressure sensor ECM detects that the MAP •
circuit Sensor ground wire is disconnected
input signal is lower than the
• sensor 5V reference voltage circuit and
preset minimum value
ground wire of the sensor is reversely connect-
ed (the defect may lead to damage of the
sensor)
• .ECM
• MAP sensor
•
Engine: running • .Sensor signal circuit and 12V power supply
The Intake pressure • No TPS defect
sensor circuit is sub- • are short-circuited
P0108 ECM detects that the MAP •
jected to high volt- The 5V reference voltage circuit and 12V
input signal is higher than
age. power supply of the sensor are short-circuited
the preset maximum value •
ECM

CAUTION
• To implement the following steps, ensure that ECM is grounded properly.
• Before conducting electric diagnosis, do refer to the reference circuit diagram and the element
information.
• Before conducting measurement, check the pins of connectors for rupture, looseness and rust,
and ensure that the pins are contacted properly.
• Engine fails to run when ignition switch is set to ON, and the manifold pressure is equivalent to
the atmospheric pressure. In addition, the sensor signal outputs high voltage.

Diagnostic step

1. Read DTC and data on the diagnostic apparatus

(a) Start the engine until it reaches normal working temperature.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Read the data from intake manifold pressure (MAP) sensor displayed on the diagnostic apparatus.
Displayed DTC and temperature Go to Status
values
• P0107
• Open circuit or to-ground short
Pressure is lower than or equal The next step
circuit
to 5 kPa
• P0107
• The next step To-circuit short circuit
Pressure is higher than 117kPa
• P0107 or P0108
• Diagnosis help Intermittent failure
Pressure is normal
 04-64 DIAGNOSTICS - ENGINE CONTROL SYSTEM

2. Check the reference voltage of MAP sensor

(a) Switch off the ignition.
(b) Disconnect the connector E009 of MAP sensor.
(c) Turn the ignition switch to “ON”.
(d) Measure the voltage between pin B of connector E009 of
MAP sensor and ground.
04 Standard voltage
Multimeter Connection Specified Condition
E009 (B) - ground 5.0 ± 0.25 V

Are the results normal?

Yes > go to next step.
No > Maintain or replace the connector or harness. If the harness is normal, replace the ECM.

3. Check the sensor ground .

(a) Switch off the ignition.
(b) Disconnect the connector E009 of MAP sensor.
(c) Measure the resistance between pin C of connector E009
of MAP sensor and ground.
Resistance: < 2Ω

Are the results normal?

Yes > go to next step.
No > Maintain or replace the connector or harness. If the harness is normal, replace the ECM.

4. Check the signal wire of MAP

 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-65

(a) Switch off the ignition.

(b) Disconnect the connector E009 of MAP sensor.
(c) Disconnect the connector E006 of ECM.
(d) Turn the ignition switch to “ON”.
(e) Measure the voltage between pin A of connector E009 of
MAP sensor and ground.
Voltage: 0 V
04

Are the results normal?

Yes > go to next step.
No > Maintain or replace the connector or harness.

5. Check the signal wire of MAP

(a) Switch off the ignition.
(b) Disconnect the connector E009 of MAP sensor.
(c) Disconnect the connector E006 of ECM.
(d) Measure the resistance between pin A of connector E009
of MAP sensor and ground.
Resistance: ≥ 1 MΩ

Are the results normal?

Yes > go to next step.
No > Maintain or replace the connector or harness.

6. Check the MAP signal

 04-66 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Connect the connector E009 of MAP sensor.

(b) Start the engine. Set the digital universal meter to its DC
voltage position, connect its black pin to ground, and
connect the read pin to pins A or B of MAP sensor
connector.
(c) In idling mode, the red pin B shall have a reference voltage
of 5V, and pin A shall have a voltage of approximately
1.3V.
04 (d) In no-load mode, open the throttle gradually, and the
voltage of pin A shall be minor. Open the throttle quickly,
the voltage of pin A may reach approximately 4V
momentarily, and then drop to about 1.5V.
Multimeter Connection Specified Condition
E009 (B) - ground • Idle speed: 5.0±0.25V
• Idle speed: 1.3V
• No-load when throttle is
E009 (A) - ground opened gradually: 1.3V
• Opened quickly: 4V, and
then returning to 1.5V

Are the results normal?

Yes > go to next step.
No > Maintain or replace the sensor harness, connector or MAP sensor.

7. Replace the ECM

(a) Replace the ECM.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream. Verify that no DTC exists and the data are normal.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-67

P0112 - LOW VOLTAGE OF INTAKE TEMPERATURE SENSOR

CIRCUIT
P0113 - HIGH VOLTAGE OF INTAKE TEMPERATURE SENSOR
CIRCUIT
Description Intake temperature sensor is a resister of negative
temperature coefficient type. Its resistance is drops when 04
intake temperature rises. When resistance rises, the output
voltage of intake temperature sensor rises; when resistance
drops, the output voltage of intake temperature sensor drops.

Circuit Diagram
 04-68 DIAGNOSTICS - ENGINE CONTROL SYSTEM

DTC DTC definition DTC inspection condi- Trouble location

tions
• Ignition: ON
• In 120 seconds after the
ignition switch is set to • MAT sensor
its ON position or after • The 5V reference volt-
Low voltage of intake tem- the engine is started up age circuit and ground
P0112 • Sensor output voltage of MAT sensor are
04 perature sensor circuit
may be lower than 0.2V short-circuited
(equivalent to intake • ECM
temperature at125℃ or
higher) for 4 seconds
• MAT sensor
•Ignition: ON • Poor contact of the MAT
• In 60 seconds after the
sensor connector
ignition switch is set to • The sensor circuit is
its ON position or after
subjected to open circuit
High voltage of intake tem- the engine is started up
P0113 • Sensor output voltage
or high resistance
perature sensor circuit • The 5V reference volt-
may be lower than 4.6V
age circuit and 12V
(equivalent to intake
power supply are short-
temperature at -45℃ or
circuited
higher) for 4 seconds • ECM

CAUTION
• To implement the following steps, ensure that ECM is grounded properly.
• Before conducting electric diagnosis, do refer to the reference circuit diagram and the element
information.
• Before conducting measurement, check the pins of connectors for rupture, looseness and rust,
and ensure that the pins are contacted properly.

Diagnostic step

1. Read DTC and data on the diagnostic apparatus

(a) Start the engine until it reaches normal working temperature.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Read the data from intake temperature (MAT) sensor displayed on the diagnostic apparatus
Displayed DTC and temperature Go to Status
values
• P0113
• The next step Open circuit or to-voltage short circuit
Lower than -40℃
• P0112
• Step 5 To-ground short circuit
>140 ℃
• P0112 or P0113
• Diagnosis help Intermittent failure
Temperature is normal
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-69

2. Read the data on the diagnostic apparatus

(a) Switch off the ignition.
(b) Disconnect the connector of MAT sensor.
(c) Connect pins C and D of connector E009 of MAT sensor.
(d) Turn the ignition switch to “ON”.
(e) Read the MAT value displayed on the diagnostic
apparatus. 04
Temperature: about 140 ℃

Check whether the result is normal?

Yes > Verify that the sensor is connected properly. If the connection is normal, replace the MAT sensor.
No > Go to the next step.

3. Check the reference voltage of MAT sensor

(a) Disconnect the connecting conductor connector E009 of
MAT sensor.
(b) Measure the voltage between pin D of connector E009 of
MAT sensor and ground
Voltage: 4.5 ~ 5.0V

Check whether the result is normal?

Yes > go to next step.
No > Maintain or replace the connector or harness. If the harness is normal, replace ECM.

4. Check the MAT sensor ground.

 04-70 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Disconnect the connecting conductor connector E009 of

MAT sensor.
(b) Measure the resistance between pin C of connector E009
of MAT sensor and ground.
Resistance: < 2Ω

04

Check whether the result is normal?

Yes > Go to Step 7.
No > Maintain or replace the connector or harness.

5. Read the data on the diagnostic apparatus

(a) Switch off the ignition.
(b) Disconnect the connector of MAT sensor.
(c) Turn the ignition switch to “ON”.
(d) Read the MAT value displayed on the diagnostic apparatus.
Temperature: about -40 ℃

Check whether the result is normal?

Yes > Verify that the sensor is connected properly. If the connection is normal, replace the MAT sensor.
No > Go to the next step.

6. Check harness and connector

(a) Switch off the ignition.
(b) Measure the resistance of MAT sensor harness.
Multimeter Connection Specified Condition
E009(C)–E009(D)
≥ 1 MΩ
E009 (C) - ground

Check whether the result is normal?

 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-71

Yes > go to next step.

No > Maintain or replace the connector or harness.

7. Replace the ECM

(a) Replace the ECM.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Verify that no DTC exists and the data are normal. 04
 04-72 DIAGNOSTICS - ENGINE CONTROL SYSTEM

P0117-LOW VOLTAGE OF COOLANT TEMPERATURE SENSOR

CIRCUIT
P0118-HIGH VOLTAGE OF COOLANT TEMPERATURE SENSOR
CIRCUIT
Description Engine coolant temperature sensor is a resister
04 of negative temperature coefficient type. It is characterized
by reduction of resistance when engine coolant temperature
rises. When resistance rises, the output voltage of engine
coolant temperature sensor rises; when resistance drops,
the output voltage of engine coolant temperature sensor
drops.

Circuit DiagramCircuit Diagram

 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-73

DTC DTC definition DTC inspection condi- Trouble location

tions
• Ignition: ON
• In 60 seconds after the
ignition switch is set to •
ECT sensor
its ON position or after •
The ECT sensor circuit
Low voltage of coolant the engine is started up
P0117 • ECT sensor output volt-
is subjected to to-
temperature sensor circuit 04
ground short circuit
age may be higher than •
ECM
0.1V (equivalent to ECT
of 145℃ or lower) for 4
seconds
• Ignition: ON
• In 60 seconds after the • ECT sensor
ignition switch is set to • Poor contact of the ECT
its ON position or after sensor connector
High voltage of coolant the engine is started up • The ECT sensor circuit
P0118 • ECT sensor output volt-
temperature sensor circuit is subjected to open cir-
age may be higher than cuit, or the 12V power
4.6V (equivalent to ECT supply is short-circuited
of 145℃ or lower) for 4 • ECM
seconds

CAUTION
• To implement the following steps, ensure that ECM is grounded properly.
• Before conducting electric diagnosis, do refer to the reference circuit diagram and the element
information.
• Before conducting measurement, check the pins of connectors for rupture, looseness and rust,
and ensure that the pins are contacted properly.
• Once either DTCP0117 or P0118 is detected, ECM enters into its failure protection mode. In the
said failure protection mode, ECM tacitly approves the ECT values, and the cooling fan works at
high speed when the ignition switch is set to its ON position. The failure protection mode will
remain till the ECM detects acceptable conditions.

Diagnostic step

1. Read DTC and data on the diagnostic apparatus

(a) Start the engine until it reaches normal working temperature.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Read the data from coolant temperature (ECT) sensor displayed on the diagnostic apparatus
Displayed DTC and temperature Go to Status
values
• P0118 Open circuit or to-power-supply short
• The next step
Approximately - 40°C circuit
• P0117
• Step 5 To-ground short circuit
Approximately 140°C or higher
 04-74 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Displayed DTC and temperature Go to Status

values
• P0117 or P0118
• Diagnosis help Intermittent failure
Between 80°C and 100°C

2. Read the data on the diagnostic apparatus

04
(a) Switch off the ignition.
(b) Disconnect the ETC sensor connector.
(c) Connect pins A and B of connector E016 of MAT sensor.
(d) Turn the ignition switch to “ON”.
(e) Read the coolant temperature value displayed on the
diagnostic apparatus
Temperature: about 140 ℃

Check whether the result is normal?

Yes > Verify that the sensor is connected properly. If the connection is normal, replace the ECT sensor.
No > Go to the next step.

3. Check the reference voltage of ECT sensor

(a) Disconnect the connection wires of pins A and B of
connector E016 of ECT sensor.
(b) Measure the voltage between pin A of connector E016 of
ECT sensor and ground.
Voltage: 4.5 ~ 5.0V

Check whether the result is normal?

Yes > go to next step.
No > Replace the harness of ECT sensor. If the harness is normal, replace ECM.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-75

4. Check the ECT sensor ground.

(a) Disconnect the connection wires of pins A and B of
connector E016 of ECT sensor.
(b) Measure the voltage between pin B of connector E016 of
ECT sensor and ground.
Resistance: < 2Ω
04

Check whether the result is normal?

Yes > Go to Step 7.
No > Maintain or replace the connector or harness.

5. Read the data on the diagnostic apparatus

(a) Switch off the ignition.
(b) Disconnect the ETC sensor connector.
(c) Turn the ignition switch to “ON”.
(d) Read the coolant temperature value displayed on the diagnostic apparatus
Temperature: approximately - 40°C

Check whether the result is normal?

Yes > Verify that the sensor is connected properly. If the connection is normal, replace the ECT sensor.
No > Go to the next step.

6. Check harness and connector

 04-76 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Switch off the ignition.

(b) Measure the resistance of ECT sensor harness.
Multimeter Connection Specified Condition
E016(A)-E016(B)
≥ 1 MΩ
E016 (A) - Ground

04

Check whether the result is normal?

Yes > go to next step.
No > Maintain or replace the connector or harness.

7. Replace the ECM

(a) Replace the ECM.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Verify that no DTC exists and the data are normal.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-77

P0122-LOW VOLTAGE OF THROTTLE POSITION SENSOR

P0123-HIGH VOLTAGE OF THROTTLE POSITION SENSOR
Description
ECM provides 5V reference voltage and ground for the throttle position sensor (TPS). TPS sends
a feedback voltage signal of throttle opening to the ECM. The voltage signal is changed from signal
0.5V (when closed) to approximately 4.5V (when fully opened).
04
Circuit Diagram

DTC DTC definition DTC inspection conditions Trouble location

•Ignition: ON • TPS or maladjustment
•In 60 seconds after the ignition switch is •
TPS connector is subjected to
Low voltage of set to its ON position or after the engine
poor contact, and the sensor
P0122 throttle position is started up
harness is open-circuited or to-
sensor • In the engine idle speed position, the
ground short-circuited
sensor output voltage remains lower than •
ECM
0.35V for 4 seconds
•Ignition: ON • TPS
•In 60 seconds after the ignition switch is •
TPS connector is subjected to
High voltage of set to its ON position or after the engine
poor contact, and the sensor
P0123 throttle position is started up
harness is open-circuited or to-
sensor • In the engine idle speed position, the
power-supply short-circuited
sensor output voltage remains higher than •
ECM
4.8V for 4 seconds
 04-78 DIAGNOSTICS - ENGINE CONTROL SYSTEM

CAUTION
• To implement the following steps, ensure that ECM is grounded properly.
• Before conducting electric diagnosis, do refer to the reference circuit diagram and the element
information.
• Before conducting measurement, check the pins of connectors for rupture, looseness and rust,
and ensure that the pins are contacted properly.
• If the connection is good, check the sensor signal voltage when moving the connector and
04
harness, and the voltage displayed on the diagnostic apparatus may vary if any trouble occurs.

Diagnostic step

1. Read DTC and data on the diagnostic apparatus

(a) Start the engine until it reaches normal working temperature.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Depress the accelerator pedal gradually till the throttle is fully opened
(e) Read the data of throttle signal displayed on the diagnostic apparatus
Voltage varies consecutively between 0.35V and 4.8V.

Check whether the result is normal?

Yes > Intermittent trouble exists; refer to the diagnostic help.
No > If change of voltage occurs discontinuously, replace TPS. If the voltage is constant, go to the next
step.

2. Check the reference voltage of throttle position sensor.

(a) Switch off the ignition.
(b) Disconnect the connector E012 of TPS.
(c) Turn the ignition switch to “ON”.
(d) Measure the voltage of pin A of connector E012 of TPS.
Standard voltage
Multimeter Connection Specified Condition
E012 (A) - ground 4.5.0～5.0 V

Check whether the result is normal?

Yes > go to next step.
No > Maintenance or replace harness. If the harness is normal, replace the ECM.

3. Check the earth wire of throttle position sensor

 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-79

(a) Switch off the ignition.

(b) Disconnect the connector E012 of TPS.
(c) Measure the resistance between pin B of connector E012
of TPS sensor and ground.
Resistance: < 2Ω

04

Check whether the result is normal?

Yes > go to next step.
No > Maintenance or replace harness. If the harness is normal, replace the ECM.

4. Check the signal wire of throttle position sensor

(a) Connect the pins A and C of connector E012 of TPS.
(b) Use a diagnostic apparatus to perform sensor data stream
reading procedures.
Voltage: 4 V

Check whether the result is normal?

Yes > go to next step.
No > Maintenance or replace harness. If the harness is normal, replace the ECM.

5. Replace the ECM

(a) Replace the ECM.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Verify that no DTC exists and the data are normal.
 04-80 DIAGNOSTICS - ENGINE CONTROL SYSTEM

P0131-TO-GROUND SHORT-CIRCUIT OF FRONT OXYGEN SENSOR

P0132-TO-POWER-SUPPLY SHORT-CIRCUIT OF FRONT OXYGEN
SENSOR
P0134-OPEN CIRCUIT OF FRONT OXYGEN SENSOR
Description
04 ECM provides a voltage of approximately 450mV to
between pins 47 and 73 of ECM. The voltage of oxygen
sensor may vary from approximately 1V to approximately
0.1V as the exhaust changes from thick to thin. When the
temperature is below 350℃, the oxygen sensor fails to
work normally. An open-circuited oxygen sensor and
low-temperature oxygen sensor may make the system to
enter into its "open loop" status.

Circuit Diagram
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-81

DTC DTC definition DTC inspection conditions Trouble location

•
Engine control system at closed ring
•
Engine speed is lower than 6000RPM • Front Oxygen Sensor
To-ground short-cir- •
The voltage of front oxygen sensor is • To-ground short-circuit of front
P0131 cuit of front oxygen oxygen sensor harness
lower than 0.03V for at least 25 seconds
sensor
• DTC P0107, P0108, P0117, P0118, • ECM
P0122, P0123 and P0335 does not exist 04

• The voltage of front oxygen sensor is • Front Oxygen Sensor

To - p o w e r - s u p p l y higher than 2.5V for at least 25 seconds • To-power-supply short-circuit
P0132 short-circuit of front • DTC P0107, P0108, P0117, P0118, of front oxygen sensor harness
oxygen sensor
P0122, P0123 and P0335 does not exist • ECM
•
Front Oxygen Sensor
•
The feedback voltage of front oxygen • The front oxygen sensor con-
Open circuit of front sensor ranges from 1.3 to 2.5V nector is subjected to poor
P0134 • contact, and the sensor har-
oxygen sensor DTC P0107, P0108, P0117, P0118,
P0122, P0123 and P0335 does not exist ness is open-circuited
• ECM

CAUTION
• To implement the following steps, ensure that ECM is grounded properly.
• Before conducting electric diagnosis, do refer to the reference circuit diagram and the element
information.
• Before conducting measurement, check the pins of connectors for rupture, looseness and rust,
and ensure that the pins are contacted properly.
• If the connection is good, check the sensor signal voltage when moving the connector and
harness, and the voltage displayed on the diagnostic apparatus may vary if any trouble occurs.

Diagnosis help
• Normal change in closed-loop voltage of oxygen sensor displayed in diagnostic apparatus ranges
from 0.1V to 1.0V.
• Check the oxygen sensor harness. The oxygen may be mounted incorrectly such that it may
touch the exhaust tube.
• Check for intermittency ground between ECM and sensor harness.
• Conduct a balance test of fuel injector, so as to make certain whether or not the thin gas mixture
is caused by fuel injector blocking.
• Vacuum leak of crankcase causes the thin status.
• Leakage of exhaust manifold gasket causes external air to enter into the exhaust tube through
the sensor.
Diagnostic step

1. Read the DTC on the diagnostic apparatus

(a) Start the engine until it reaches normal working temperature.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Use a diagnostic apparatus to perform sensor data stream reading procedures.
(d) Engine idling running
(e) Read the data of oxygen sensor signal displayed on the diagnostic apparatus.
 04-82 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Result
Displayed DTC and voltage val-
Go to Status
ues
• P0131 （＜ 0.03 V） Go to step 6 To-ground short circuit
• P0132 （＞ 2.5 V） Go to step 7 To-power-supply short circuit
04 • P0134（1.3 V ～ 2.5 V ） The next step Open circuit

2. Check the signal circuit of oxygen sensor (check for open circuit)
(a) Switch off the ignition.
(b) Disconnect the connector E008 of oxygen sensor.
(c) Turn the ignition switch to “ON”.
(d) Measure the voltage between pins A and B of connector
E008 of oxygen sensor.
Voltage: 0.45 V

Check whether the result is normal?

Yes > Replace the oxygen sensor.
No > Go to the next step.

3. Check the signal voltage of oxygen sensor

(a) Switch off the ignition.
(b) Connect the pin A of connector E008 of oxygen sensor to
ground.
(c) Turn the ignition switch to “ON”.
(d) Measure the voltage between pin B of connector E008 of
oxygen sensor and ground.
Voltage: 0.45 V

Check whether the result is normal?

 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-83

Yes > Go to Step 5.

No > Go to the next step.

4. Check the signal circuit of oxygen sensor (check for open circuit between sensor pin B and ECM
pin 47)
(a) Switch off the ignition.
(b) Disconnect the connector E006 of ECM.
(c) Measure the resistance between pin A of connector E008 04
of oxygen sensor and pin 47 of ECM connector E006.
Resistance: < 2Ω

Check whether the result is normal?

Yes > go to next step.
No > Replace or maintain the signal harness of oxygen sensor.

5. Check the signal circuit of oxygen sensor (check for open circuit between sensor pin A and ECM
pin 73)
(a) Disconnect the E008 pin A from the ground.
(b) Measure the resistance between pin A of connector E008
of oxygen sensor and pin 73 of ECM connector E006.
Resistance: < 2Ω

Check whether the result is normal?

Yes > go to next step.
No > Replace or maintain the signal harness of oxygen sensor.

6. Check the signal circuit of oxygen sensor (check for to-ground short circuit)
 04-84 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Measure the resistance between pin B of connector E008

of oxygen sensor and ground.
Resistance: ≥ 1 MΩ

04

Check whether the result is normal?

Yes > go to next step.
No > Replace or maintain the signal harness of oxygen sensor.

7. Check the signal circuit of oxygen sensor (check for to-power-supply short circuit between sensor
pin B and ECM pin 47)
(a) Turn the ignition switch to “ON”.
(b) Measure the voltage between pin B of connector E008 of
oxygen sensor and ground.
Voltage: 0 V

Check whether the result is normal?

Yes > go to next step.
No > Replace or maintain the signal harness of oxygen sensor.

8. Check the signal circuit of oxygen sensor (check for to-power-supply short circuit between sensor
pin A and ECM pin 73)
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-85

(a) Turn the ignition switch to “ON”.

(b) Measure the voltage between pin A of connector E008 of
oxygen sensor and ground.
Voltage: 0 V

04

Check whether the result is normal?

Yes > go to next step.
No > Replace or maintain the signal harness of oxygen sensor.

9. Replace the ECM

(a) Replace the ECM.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Verify that no DTC exists and the data are normal.
 04-86 DIAGNOSTICS - ENGINE CONTROL SYSTEM

P0325-KNOCKING SYSTEM FAILURE

P0327-KNOCK SENSOR FAILURE
Description
Knocking sensor (KS) is used to detect the engine
vibrations. ECM is allowed to postpone the ignition angle
04 based on the received knocking signals. KS generates
an alternative current (AC) signal

Circuit Diagram
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-87

DTC DTC definition DTC inspection conditions Trouble location

KS •
•
ECT is higher than 80℃ • Poor contact of the KS connec-

Knocking system • Engine speed is higher than 2,500RPM tor

P0325 • ECM detects that the KS input signal • KS harness is short-circuited or
failure
voltage is lower than 0.2V open-circuited
• ECM 04
• KS
• ECT is higher than 80℃ • Poor contact of the KS connec-
Knock sensor fail- • Engine speed is higher than 2,500RPM tor
P0327
ure • ECM detects that the KS input signal
• KS harness is short-circuited
exceeds the preset range • ECM

CAUTION
• To implement the following steps, ensure that ECM is grounded properly.
• Before conducting electric diagnosis, do refer to the reference circuit diagram and the element
information.
• Before conducting measurement, check the pins of connectors for rupture, looseness and rust,
and ensure that the pins are contacted properly.
• If the connection is good, check the sensor signal voltage when moving the connector and
harness, and the voltage displayed on the diagnostic apparatus may vary if any trouble occurs.

Diagnostic step

1. Check the resistance of KS knocking sensor

(a) Switch off the ignition.
(b) Disconnect the KS connector E004.
(c) Measure the resistance of KS pins.
Standard voltage
Multimeter Connection Specified Condition
E004（A）-E004（B）
E004（A）- casing ≥ 1 MΩ
E004（B）- casing

Check whether the result is normal?

Yes > go to next step.
No > Replace KS.

2. Check the KS harness (check for open circuit between KS and ECM)
 04-88 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Switch off the ignition.

(b) Disconnect the connector E006 of ECM.
(c) Measure the resistance of pins of KS connector E004.
Standard voltage
Multimeter Connection Specified Condition
E004（A）-E006(37)
＜2
04 E004（B）-E006(58)

Check whether the result is normal?

Yes > go to next step.
No > Replace KS.

3. Check the KS harness (check for short circuit between KS and ECM)
(a) Measure the resistance between pins of KS connector
E004 and the ground.
Standard voltage
Multimeter Connection Specified Condition
E004 (A) - ground
≥ 1 MΩ
E004 (B) - ground

Check whether the result is normal?

Yes > go to next step.
No > Replace KS.

4. Check the KS harness (check for to-power-supply short circuit between KS and ECM)
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-89

(a) Turn the ignition switch to “ON”.

(b) Measure the voltage between pins of KS connector E004
and the ground.
Standard voltage
Multimeter Connection Specified Condition
E004 (A) - ground
0V
E004 (B) - ground 04

Check whether the result is normal?

Yes > go to next step.
No > Replace KS.

5. Check the signals from KS knocking sensor

(a) Switch off the ignition.
(b) Disconnect the KS connector, and connect it to an
oscilloscope.
(c) Turn the ignition switch to its ON position, and allow the
engine to idle.
(d) There shall be pulse shape output.

Check whether the result is normal?

Yes > go to next step.
No > Replace KS.

6. Replace the ECM

(a) Replace the ECM.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Verify that no DTC exists and the data are normal.
 04-90 DIAGNOSTICS - ENGINE CONTROL SYSTEM

P0336 - CRANKSHAFT POSITION SENSOR CIRCUIT INTERFERING

SIGNAL
Description
The crankshaft position (CKP) sensor produces 58 X reference signals. ECM uses 58 X reference
signal to calculate engine rotational speed CKP. ECM continuously monitor the number of pulse
on the in 58 X reference line bunch and compare it with the signal number of manifold pressure
04
(MAP) it received. If ECM receives incorrect pulse number on the 58 X reference line bunch, it will
set up DTCP0336.
Circuit Diagram

DTC DTC definition DTC inspection condi- Trouble location

tions
•CKP sensor
•Poor contact of the con-
• Ignition: ON nector of CKP sensor
Crankshaft position sensor • •
P0336 ECM receives incorrect The harness of CKP
circuit interfering signal
signal or no signal sensor has short circuit
or open circuit
• ECM
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-91

CAUTION
• To implement the following steps, ensure that ECM is grounded properly.
• Before conducting electric diagnosis, do refer to the reference circuit diagram and the element
information.
• Before conducting measurement, check the pins of connectors for rupture, looseness and rust,
and ensure that the pins are contacted properly.
• If the connection is good, check the sensor signal voltage when moving the connector and
04
harness, and the voltage displayed on the diagnostic apparatus may vary if any trouble occurs.

Diagnostic step

1. Read DTC and CKP signal on the diagnostic apparatus

(a) Start the engine until it reaches normal working temperature.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Use a diagnostic apparatus to perform sensor data stream reading procedures.
(d) Engine idling running
(e) Use a diagnostic apparatus to perform reading the wave form of CKP sensor.
Check whether the result is normal?
Yes > Intermittent trouble exists; refer to the diagnostic help.
No > Go to the next step.

2. Use a wave meter to check CKP signal

(a) Use a wave meter to check the wave form of CKP sensor
signal

Check whether the result is normal?

Yes > Go to Step 5.
No > Go to the next step.

3. Check the resistance of CKP sensor

 04-92 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Disconnect the connector E021 of CKP sensor.

(b) Switch off the ignition.
(c) Measure the resistance between the pin A and pin B of
the CKP sensor E021.
Resistance: 560 ohms ± 10% (25 ± 5 ℃)

04

Check whether the result is normal?

Yes > go to next step.
No > Replace CK sensor.

4. Replace and check the CKP sensor

(a) Use a CKP sensor which has been known as normal to
replaced onboard CKP sensor.
(b) Use a wave meter to check the wave form of CKP sensor
signal

Check whether the result is normal?

Yes > go to next step.
No > Go to Step 7.

5. Check the harness of CKP sensor (check whether it is of short circuit or open circuit)
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-93

(a) Switch off the ignition.

(b) Disconnect the connector E023 of ECM.
(c) Measure the resistance between the connectors E021 and
E006 of the CKP sensor.
Measure the resistance between the connectors
E021 and E006 of the CKP sensor.
Multimeter Connection Specified Condition
04
E021（A）-E006(30)
＜2
E021（B）-E006(11)

(d) Measure the resistance between the connector E021 and

ground.
Standard resistance (Check whether it is of short
circuit to ground)
Multimeter Connection Specified Condition
E021 (A) - ground
≥ 1 MΩ
E021 (B) - ground

Check whether the result is normal?

Yes > go to next step.
No > Maintain or replace the harness between CKP sensor and ECM

6. Check the harness of CKP sensor (check whether it is of short circuit)

 04-94 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Turn the ignition switch to “ON”.

(b) Measure the voltage between the connector E021 and
ground.
Standard resistance (Check whether it is of short
circuit to power supply)
Multimeter Connection Specified Condition
04 E021 (A) - ground
0V
E021 (B) - ground

Check whether the result is normal?

Yes > go to next step.
No > Maintain or replace the harness between CKP sensor and ECM

7. Check the signal panel of CKP sensor

(a) Switch off the ignition.
(b) Check whether there are scraps, greasy dirt, foreign
objects on the 58X sensor signal tooth, whether the signal
panel becomes loose.
(c) Check the clearance for installing CKP sensor
Clearance: 0.3 ～ 1.5 mm

Check whether the result is normal?

Yes > go to next step.
No > Remove any foreign object, wash the 58X sensor signal tooth, if damaged, replace the 58X sensor
signal panel.

8. Replace the ECM

(a) Replace the ECM.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Verify that no DTC exists and the data are normal.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-95

P0480-FAN 1 FAILURE
P0481-FAN 2 FAILURE
Description
Cooling fan is used for cooling the engine system and dispelling heat of condenser after air
conditioner is turned on. The fan control is under the effect of signal which is sent to ECM by ECT
sensor. If coolant is of high temperature (exceed ECM preset value), the fan operates at a high
04
speed. If coolant is of high temperature (exceed ECM preset value), the fan operates at a high
speed. The fan is started at a low speed when turning on the air conditioner.
Circuit Diagram
 04-96 DIAGNOSTICS - ENGINE CONTROL SYSTEM

DTC DTC definition DTC inspection Trouble location

conditions
•Main fan relay R5
• Main fan A012 is operating •Poor contact in the connectors of con-
• ECM detects that the trouble in the trol harness of main fan A012
P0480 Fan 1 failure
driving harness of relay R5 lasts for • The driving harness R5 is of short cir-
04 more than 3 seconds cuit or open circuit
• ECM

•Auxiliary fan relay R4

• Auxiliary fan A013 is operating •Poor contact in the connectors of con-
• ECM detects that the trouble in the trol harness of auxiliary fan A013
P0481 Fan 2 failure •
driving harness of relay R4 lasts for The driving harness R4 is of short cir-
more than 3 seconds cuit or open circuit
• ECM

CAUTION
• To implement the following steps, ensure that ECM is grounded properly.
• Before conducting electric diagnosis, do refer to the reference circuit diagram and the element
information.
• Before conducting measurement, check the pins of connectors for rupture, looseness and rust,
and ensure that the pins are contacted properly.
• If the connection is good, check the sensor signal voltage when moving the connector and
harness, and the voltage displayed on the diagnostic apparatus may vary if any trouble occurs.

Diagnostic step

1. Use a diagnostic apparatus to test action (operate the fan)

(a) Connect the diagnostic apparatus to DLC.
(b) Start the engine until it reaches normal working temperature.
(c) Use a diagnostic apparatus to perform procedure for reading fan dataflow.
Standard: value change
Diagnostic apparatus operation Specified Condition
• Main fan A012 is operating
Low-speed fan: ON • Auxiliary fan A013 is not operating
• Main fan A012 is not operating
Low-speed fan: OFF • Auxiliary fan A013 is not operating
• Main fan A012 is operating
High-speed fan: ON • Auxiliary fan A013 is operating
• Main fan A012 is not operating
High-speed fan: OFF • Auxiliary fan A013 is not operating

Check whether the result is normal?

Yes > Intermittent trouble exists; refer to the diagnostic help.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-97

No > If the low-speed fan is abnormal, go to next step. No > If the high-speed fan is abnormal, go to step
7.

2. Check fuse
(a) Switch off the ignition.
(b) Disconnect fuse F12 (30A).
(c) Check fuse
04

Check whether the result is normal?

Yes > go to next step.
No > Replace fuse F12 （30A）. Go to step 5, check whether the harness is short circuit to ground.

3. Check relay R5
(a) Pull out low-speed main fan relay R5 from the fan
slow-blow fuse box in the engine compartment.
(b) Measure the resistance between the pins.
Standard voltage
Multimeter Connection Specified Condition
Greater than or equal to 1M ,
R5(30)–R5(87)
or <2

Check whether the result is normal?

Yes > go to next step.
No > Replace the relay R5.

4. Check the harness (between R5 and E006)

 04-98 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Dismantle the connector E006 of ECM.

(b) Measure the resistance between the pins as per the table
below
Standard voltage
Multimeter Connection Specified Condition
R5（86）-E006（65） ＜2
04

Check whether the result is normal?

Yes > go to next step.
No > Maintenance or replace harness.

5. Check the harness (between R5 and ground)

(a) Measure the resistance between the pins as per the table
below
Standard voltage
Multimeter Connection Specified Condition
R5 (86) - Ground ≥ 1 MΩ

Check whether the result is normal?

Yes > go to next step.
No > Maintenance or replace harness.

6. Check the harness (between R5 and ground)

 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-99

(a) Turn the ignition switch to “ON”.

(b) Measure the voltage between the pins as per the table
below.
Standard voltage
Multimeter Connection Specified Condition
R5 (86) - Ground 0V
04

Check whether the result is normal?

Yes > Go to Step 10.
No > Maintenance or replace harness.

7. Check fuse
(a) Switch off the ignition.
(b) Disconnect fuse F16 (40A).
(c) Check fuse

Check whether the result is normal?

Yes > go to next step.
No > Replace fuse F16 （30A）. Go to step 9.

8. Check relays R16 and R4

(a) Pull out fan relay R16 and R4 from the fan slow-blow fuse
box in the engine compartment.
(b) Measure the resistance between the pins.
Standard voltage
Multimeter Connection Specified Condition
Greater than or equal to 1M ,
R16(30)–R16(87)
or <2
Greater than or equal to 1M ,
R4(30)–R4(87)
or <2

Check whether the result is normal?

Yes > go to next step.
 04-100 DIAGNOSTICS - ENGINE CONTROL SYSTEM

No > Replace the relays R16 and R4.

9. Use a diagnostic apparatus to test action

(a) Use a diagnostic apparatus to perform procedure for
reading fan dataflow.
(b) Measure the voltage between the pins.
Standard: value change
04
Diagnostic apparatus opera- Specified Condition
tion
High-speed fan: ON Battery voltage
High-speed fan: OFF 0V

Check whether the result is normal?

Yes > go to next step.
No > Maintenance or replace harness.

10 . Replace the ECM

(a) Replace the ECM.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Verify that no DTC exists and the data are normal.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-101

P0201-NOZZLE A CIRCUIT FAILURE

Description
Injector itself is an electromagnetic valve; when it is energized, suction force is produced, the
needle valve is sucked up, injecting hole is opened, and the fuel passes the needle valve head
and spray out at a high speed.
Circuit Diagram
04
 04-102 DIAGNOSTICS - ENGINE CONTROL SYSTEM

DTC DTC definition DTC inspection conditions Trouble location

• Time of engine operation > 0.5 seconds • Injector A
P0201 Injector A circuit failure • Oil pump works normally • Injector harness
• Duration >5 seconds • ECM

CAUTION
04
• To implement the following steps, ensure that ECM is grounded properly.
• Before conducting electric diagnosis, do refer to the reference circuit diagram and the element
information.
• Before conducting measurement, check the pins of connectors for rupture, looseness and rust,
and ensure that the pins are contacted properly.
• If the connection is good, check the sensor signal voltage when moving the connector and
harness, and the voltage displayed on the diagnostic apparatus may vary if any trouble occurs.

Diagnostic step

1. Check the resistance of injector A

(a) Switch off the ignition.
(b) Disconnect the connector E015 of the injector A.
(c) Measure the resistance between the pin A and pin B of
injector A.

Check whether the result is normal?

Yes > go to next step.
No > Replace the injector A.

2. Check the resistance of harness between injector A and ECM

 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-103

(a) Switch off the ignition.

(b) Disconnect the connector E006 of ECM.
(c) Measure the resistance of the pins of connector E015 of
injector A.
Standard voltage
Multimeter Connection Specified Condition
E015（A）-E006(6) ＜2 04

Check whether the result is normal?

Yes > go to next step.
No > Replace the harness of injector A.

3. Check whether the harness of injector A is of short circuit to power supply

(a) Turn the ignition switch to “ON”.
(b) Measure the voltage between of the pin A of connector
E015 of injector A to ground.
Standard voltage
Multimeter Connection Specified Condition
E015（A) - ground 0V

Check whether the result is normal?

Yes > go to next step.
No > Replace the harness of injector A.

4. Check the power supply cable voltage of injector A

 04-104 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Turn the ignition switch to “ON”.

(b) Measure the voltage between of the pin B of connector
E015 of injector A to ground.
Standard voltage
Multimeter Connection Specified Condition
E015（B) - ground Battery voltage
04

Check whether the result is normal?

Yes > go to next step.
No > Replace the harness of injector A.

5. Replace the ECM

(a) Replace the ECM.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Verify that no DTC exists and the data are normal.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-105

P0443-CARBON POT CONTROL VALVE FAILURE

Description
The carbon pot electromagnetic valve is opened after receiving ECM signal, which de-absorb the
carbon pot through absorbing air from the air inlet of the carbon pot under the effect of the manifold
vacuum degree.
Circuit Diagram
04
 04-106 DIAGNOSTICS - ENGINE CONTROL SYSTEM

DTC DTC definition DTC inspection conditions Trouble location

• The carbon canister control valve
•Time of engine operation > 0.5
harness is subjected to open circuit
Carbon canister con- seconds
P0443 or short circuit
trol valve failure • 11V < system voltage > 16V
• Carbon canister control valve
• Duration >5 seconds
• ECM
04
CAUTION
• To implement the following steps, ensure that ECM is grounded properly.
• Before conducting electric diagnosis, do refer to the reference circuit diagram and the element
information.
• Before conducting measurement, check the pins of connectors for rupture, looseness and rust,
and ensure that the pins are contacted properly.
• If the connection is good, check the sensor signal voltage when moving the connector and
harness, and the voltage displayed on the diagnostic apparatus may vary if any trouble occurs.

Diagnostic step

1. Check the resistance of carbon pot control valve

(a) Switch off the ignition.
(b) Disconnect the connector E018 of the carbon pot control
valve.
(c) Measure the resistance between the pin A and pin B of
the carbon pot control valve.

Check whether the result is normal?

Yes > go to next step.
No > Replace the carbon pot control valve.

2. Check the resistance of harness between the carbon pot control valve and ECM
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-107

(a) Switch off the ignition.

(b) Disconnect the connector E006 of ECM.
(c) Measure the resistance between of the pins of connector
E018 of the carbon pot control valve.
Standard voltage
Multimeter Connection Specified Condition
E018（A）-E006(64) ＜2 04

Check whether the result is normal?

Yes > go to next step.
No > Replace the harness of the carbon pot control valve.

3. Check whether the harness of the carbon pot control valve is of short circuit to power supply
(a) Turn the ignition switch to “ON”.
(b) Measure the voltage between of the pin A of connector
E018 of carbon pot control valve to ground.
Standard voltage
Multimeter Connection Specified Condition
E018 (A) - ground 0V

Check whether the result is normal?

Yes > go to next step.
No > Replace the harness of the carbon pot control valve.

4. Check the power supply cable voltage of carbon pot control valve
 04-108 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Turn the ignition switch to “ON”.

(b) Measure the voltage between of the pin B of connector
E018 of carbon pot control valve to ground.
Standard voltage
Multimeter Connection Specified Condition
E018（B) - ground Battery voltage
04

Check whether the result is normal?

Yes > go to next step.
No > Replace the harness of the carbon pot control valve.

5. Replace the ECM

(a) Replace the ECM.
(b) Use a diagnostic apparatus to perform DTC verification procedures.
(c) Implement the steps to read sensor data stream.
(d) Verify that no DTC exists and the data are normal.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-109

DEFECTS
If the fault has not been confirmed in DTC (diagnostic trouble code), and is unable to confirm the
reason to cause the fault in basic checking, the fault shall be eliminated according to the procedure
in the table below, then enter the relevant troubleshooting pages to eliminate the fault.
Gasoline engine control system fault phenomena
Defect Checking procedure
04
It is unable to use the diag-
KT600 diagnostic apparatus is unable to communicate with
nostic apparatus to commu- 1
ECM
nicate with KT600
The starter rotates, but the engine is unable to start 2
Starting
The cold car is difficult to start and vehicle body quivers 3
Unstable idling speed (fluctuating) 4
Idling stability (idling is bad) The idling speed is too high (the rotational speed of engine
5
is not within specified value)
The engine can stall when it is cold (during idling) 6
Idling stability (engine stalls)
The engine can stall when starting 7
Slow, maladjusted acceleration response 8
When driving
Poor acceleration and performance 9

Engine control system fault phenomena description

Item Defect
When the starter drives the engine to rotate, there is no combus-
It is unable to start
Starting tion phenomena in the cylinder, the engine is unable to start
Difficult starting The starter rotates very long before it is able to start
Idling stabili- Idle speed gets unstable The rotational speed of engine is unable to remain stable
ty (idling is
bad) Idling speed too high The engine does not operate under the normal idling speed

The engine can stall when it is The engine is apt to stall when it is just started and coolant is at
Idling stabili- cold (during idling) a low temperature
ty (engine
stalls) The engine stalls as soon as the accelerator pedal is stepped
The engine can stall when starting
on
If the vehicle needs to accelerate, the engine rotational speed
Slow, maladjusted acceleration fails to rise immediately, or acceleration responses slowly, or
response rotational speed drops temporarily when stepping on the accel-
When driv- erator pedal.
ing
Acceleration efficiency can't reach suitable acceleration according
Poor acceleration and perfor-
to the throttle position (even though accelerating course is very
mance
smooth), or the max vehicle speed can’t be reached
 04-110 DIAGNOSTICS - ENGINE CONTROL SYSTEM

ENGINE PHENOMENA DIAGNOSIS TEST

WARNING
Some phenomena diagnostic procedures require visual and exterior inspection. Every time such visual
and exterior inspection shall be carried out firstly. Such inspections can solve one problem and need
not further test, and can save precious time.
1. After receiving a vehicle, shall ask the owner the following problems:
04 (a) The earliest time that fault appeared.
(b) The engine temperature when the fault occur.
(c) Mileage the vehicle travelled.
(d) Road and habit which the car owner often drives.
(e) The maintenance situation of the car.
(f) The maintenance history of the car.
(g) Has the car been installed additional apparatus? The trouble can be judged tentatively from the
above-mentioned understanding, so as to shorten the time for inspection.
2. Before perform steps of fault diagnostic precedure according to engine phenomena, initial
inspection shall be performed first.
(a) Confirm that engine fault indicator lamp can work normally. If abnormal, eliminate trouble of the indicator
lamp at first.
(b) Confirm that no engine trouble codes (DTC) are stored in the engine module (ECM). If they exist, refer
to corresponding DTC list to eliminate them. Read the trouble codes(both present and historical trouble
codes shall be recorded) - clear trouble codes – run (the condition which the trouble occur shall re-appear
this time) - read trouble codes again. Read the trouble code list in the servicing manual, refer to the
reason, influence and elimination method of the trouble. Intermittent trouble codes can't be ignored.
(c) Use a diagnostic apparatus to check the idling data of heat engine of the electronic control system and
confirm that they are within normal scope.
(d) Confirm that the trouble is present, and the reason for causing the trouble exist.
(e) When maintaining the vehicle, maintaining record, the engine cylinder compression pressure, the engine
machinery timing, and fuel state shall be confirmed.
3. External visual inspection
(a) Check the connecting condition of ECM ground (earth).
(b) Check whether the connecting pipe of engine vacuum system splits, distorts and is connected correctly;
whether it is flattened or damaged.
(c) Whether the engine oil dipstick, engine oil filling cover are installed correctly.
(d) Check whether ground of the engine (earth) is clean and is fastened firmly.
(e) Check whether the connecting surface of engine gas inlet manifold leak, and whether the sealing surface
between the air throttle and gas inlet manifold is in good condition.
(f) Check whether the high-voltage wire for ignition is ruptured, aging, and arranged correctly; whether there
is carbon mark. Whether it is in good contact and is fastened firmly.
(g) Check whether there is any leakage in the engine fuel system.
(h) Check whether the engine fuel is deteriorated and contains water.
(i) Check whether the socket connectors of engine sensor and actuators are connected correctly and is
fastened firmly.
4. The accumulated carbon belt which formed on the back of air throttle may directly lead to a series
of problems such as bad idling, unstable idling of engine, sometimes explosion sound in the gas
inlet manifold, and difficult cold car starting etc..
(a) Carbon accumulates in the air throttle and combustion chamber.
Due to the characteristic of electronic fuel injection engine, the cylinder always injects fuel
first and then ignites. Ignition is interrupted at the moment that the engine is stalled, but the
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-111

gasoline which is injected in the last circulation can’t be reclaimed and can only attach on
air inlet valve and the wall of the combustion chamber. Gasoline is very easy to volatilize,
but the wax and colloid matter in the gasoline stays, which can accumulate to be thicker
and thicker after a long time, and is hardened to form an accumulated carbon while being
heated repeatedly.
If the engine burns the engine oil, or impurity which the fuel of low quality contains is too
much, then it is more serious that the valve accumulates carbons and the forming speed is 04
faster.
Because the structure of the accumulated carbon is similar to the sponge, a part of the fuel
of each time sprayed into the cylinder is absorbed after the accumulated carbon is formed,
making the mixing gas thinner which enter into the cylinder, which may lead to such abnormal
phenomena as bad engine operation, difficult starting, unstable idling, bad acceleration,
emergency refuel backfire, and cheering such anomalies as the flash back, exhaust exceed
standard, exhaust gas exceeding the standard, increased fuel consumption etc.. Serious
situation can cause that the air inlet valve can’t be closed tightly, individual cylinder cannot
work completely due to no pressure or even that the air inlet valve is adhered and can’t
restore. The air inlet valve and piston will produce the movement interference at this moment,
and damage the engine finally.
(b) Carbon accumulates on the air intake pipe.
Because each piston of the whole engine does not work simultaneously, when the engine
goes out, the air inlet valve of some cylinders can't be totally closed, some unburned fuel
is continuously to vaporize and be oxidized, some softer black carbon will be produced in
the air intake pipe, especially in the rear part of the air throttle.
On one hand, these accumulated carbon can make tube wall of intake pipe coarser, where
the air intake will produce volution, influencing air intake efficiency and the quality of mixing
gas.
On the other hand, these accumulated carbon will also block idling path, making idling
control unit catching or beyond their adjustment range, such case will cause low idling speed
and idling quiver.
5. Methods to judge accumulated carbon in the cylinder:
(a) Use an inner sight glass to observe the inside condition of the cylinder.
(b) Use a diagnostic apparatus to read the change of the feedback voltage of oxygen sensor, so as to detect
indirectly the existence of accumulated carbon.
Once the air inlet valve accumulates carbon, the fluctuation of feedback voltage of oxygen
sensor will get largely, for example change from original 0.3-0.7V to 0.1-0.9V. Moreover,
the central value of voltage will become large, and varying frequency will slow down at the
same time.
(c) Disassembly method:
 04-112 DIAGNOSTICS - ENGINE CONTROL SYSTEM

CAUTION
If there is too much accumulated carbon in the engine cylinder, cylinder pressure will get higher. But
vehicles which have more accumulated carbon often have longer travel mileage, cylinder pressure will
drop due to abrasion. So it is not feasible to judge accumulated carbon in the cylinder through cylinder
pressure.
6. To the danger of the accumulated carbon, the following several points should be paid attention
to:
04 (a) Refill high-quality gasoline.
(b) Not to run at idling for a long time.
(c) Run at high speed as possible, try hard to improve the rotational speed of shift gears of the manually
shifting vehicles.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-113

KT600 DIAGNOSTIC APPARATUS IS UNABLE TO COMMUNICATE

WITH ECM
Symptom Diagnostic Logic Possible Cause
• The power supply is not supplied • The power supply loop of ECM is
to ECM bad
KT600 diagnostic apparatus is unable • ECM failure • Circuit between ECM and KT600
to communicate with ECM • Circuit connection between ECM diagnostic apparatus is open cir- 04
and KT600 diagnostic apparatus cuit
is bad • ECM

Trouble phenomena diagnostic procedure

1. Check the data of the engine.
(a) Switch off the ignition.
(b) Connect the analyzer to the diagnostics connector (16-pin) at the lower left of the dashboard.
(c) Switch on the ignition and the analyzer - use the latest software version.
(d) Read the data of the engine on the diagnostic apparatus
Can the diagnostic apparatus enter ECM module to read the dataflow?
Yes > Intermittent trouble exists; refer to the diagnostic help.
No > Go to the next step.

2. Check other data of the module

(a) Read the data of SRS and ABS on the diagnostic apparatus
(b) Read the data on the diagnostic apparatus
Can the diagnostic apparatus enter the SRS and ABS module to read the dataflow?
Yes > Go to Step 4.
No > Go to the next step.

3. Check the diagnostic communication line K of ECM

(a) Switch off the ignition.
(b) Disconnect the socket connector of ECM.
(c) Use a multimeter to measure the conduction between the terminal 7 of the diagnostic box C005 and the
terminal 75 of ECM.
Resistance: < 2Ω
(d) Use a multimeter to measure the conduction between the terminal 7 of the diagnostic box C005 and
ground.
Resistance: ≥ 1 MΩ
(e) Turn the ignition switch to ON position, use a multimeter to measure the voltage between the terminal 7
of the diagnostic box C005.
Voltage: 0V

Are the results normal?

Yes > go to next step.
No > maintain the diagnostic communication line K of ECM
 04-114 DIAGNOSTICS - ENGINE CONTROL SYSTEM

4. Check the power supply of ECM and ground

(a) Check power supply of ECM.
(b) Check the ground of EC.
Are the results normal?
Yes > go to next step.

04 No > Maintain the power supply of ECM or ground

5. Replace the ECM

(a) Replace the ECM. (Refer to "Chapter 11. Engine Control System - engine control module")
(b) Read the data of the engine on the diagnostic apparatus Confirm that KT600 diagnostic apparatus is
able to communicate with ECM
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-115

THE STARTER ROTATES, BUT THE ENGINE IS UNABLE TO START

Symptom Status Diagnostic Logic Possible Cause
There is leakage in the air
intake system; fuel pres-
• The rotational speed of sure is too low; air cleaner
the crankshaft is normal is clogged; water tempera-
• Battery is fully ture sensor is faulty; air
recharged flowmeter is faulty; idling 04
• Faulty spark plug
The starter can drive the • The warning lamp of the control valve or additional
• There is no fuel in the air valve are faulty; The in-
engine to rotate at normal
engine is normal
speed, there are obvious combustion chamber jector for cold starting
• When the starter drives
signs of ignition, but the • Incorrect cylinder pres- can’t work; the injector
engine can't start the engine to rotate, leaks; incorrect electronic
sure
there is no combustion spark timing; the connec-
phenomena in the cylin- tion circuit of the start
der, the engine is un- switch to the computer is of
able to start short circuit; The compres-
sion pressure in the cylin-
der is too low.

Trouble phenomena diagnostic procedure

1. Check engine fault indicator lamp and DTC

(a) Use a diagnostic apparatus to perform procedure for reading DTC.
Is there DTC?
Yes > refer to DTC list, carry out DTC trouble diagnostic procedure.
No > Go to the next step.

2. Check the secondary ignition system

(a) Pull out the fuel of the fuel spray nozzle.
(b) Pull out the high-voltage line, unplug the spark plug.
(c) Connect spark plug to the high voltage line, and contact the negative pole of the spark plug with the
cylinder body.
(d) Check engine to test secondary ignition system
Correct result: When the engine rotates, strong blue and white spark can be seen on each spark
plug.

Check whether the result is normal?

Yes > Go to Step 4.
No > Go to the next step.

3. Check the secondary ignition system

(a) Check the resistance value of high-voltage coil, and clean the terminals of connector.
Resistance: ≥ 4 k
(b) Check whether the spark plug accumulates carbons, carbon mark, whether the ceramic insulating part
is cracked and leaks electricity; whether the interval is normal; whether the positive and negative poles
are burned corrupt; and clean the spark plug.
 04-116 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Check whether the result is normal?

Yes > go to next step.
No > Clean, replace faulty components

4. Check the sensor of crankshaft position

(a) Use a diagnostic apparatus to read the sensor dataflow of the engine crankshaft position (CKP) shown
in the diagnostic apparatus, which shall reach the stipulated value while starting.
04
Check whether the result is normal?
Yes > go to next step.
No > Check whether the sensor is installed correctly (refer to the engine control system - disassembly
and assembly of sensor), maintain or replace the harness, connectors or damaged components.

5. Check the air throttle:

(a) Press the accelerator pedal gently and start the engine. Check whether the engine can start.
Check whether it can start.
Yes > Check the air throttle and idling path, eliminate accumulated carbon. Unplug the connector of the
step motor, measure to check whether the voltage between the terminals is 12 V; when the temperature
is at 20 ℃, the normal scope of resistance value shall be 28-33 ohms. Check whether the step motor is
clogged, maintain or replace it if necessary.
No > Go to the next step.

6. Check the absolute pressure/temperature sensor of the engine coolant temperature sensor and
intake manifold
(a) Check whether the absolute pressure/temperature sensor of intake manifold is installed correctly.
(b) Remove the absolute pressure/temperature sensor of intake manifold.
(c) Check whether the sensing hole is clogged and the resistance value between every wiring ends comply
with the standard.
(d) Check whether the temperature sensor is dirty.
(e) Ignition switch: ON, read the sensor dataflow of coolant temperature and intake manifold absolute
pressure (MAP)\ temperature of engine which show in the diagnostic apparatus.
Are the results normal?
Yes > go to next step.
No > Clean, replace faulty components Go to step 11.

7. Check the power circuit of fuel system

(a) Ignition Switch: ON.
(b) Check whether relay of the fuel pump and fuel pump can work.
Check whether the result is normal?
Yes > go to next step.
No > Maintain or replace the harness of the fuel pump.

8. Check the pressure of the fuel system

(a) Check the pressure of the fuel system Refer to "Chapter 12A. Fuel system- precaution")
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-117

Are the results normal?

Yes > Go to Step 10.
No > Maintain or replace the components or circuit of the fuel system, if fuel pressure is lower than 400
kPa, and go to next step.

9. Check the fuel supply of the fuel system

(a) Check for leakage in the fuel intake pipe. 04
(b) Check whether the gasoline cleaner is clogged.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

10 . Check the injector

(a) Pull out the connector of the injector.
(b) Pull out the fuel delivery pipe and injector together.
(c) Directly apply battery 12V voltage to the injector.
(d) Each injector shall inject standard volume of fuel, and it shall be pulverized evenly.

CAUTION
While checking the spraying state of the injector, if spraying looks like a " column " instead of a “cone”,
or the injectors of the four cylinders inject different volumes of fuel (difference greater than 5ml), injectors
shall be replaced. Check whether there is colloidal material in the injector nozzle, if yes, it shall be soaked
in detergent and sprayed, otherwise it will lead to insufficient injected fuel quantity or poor acceleration,
etc.
DANGER
When testing the fuel system:
• Put a mark " caution: Flammable " in the working area.
• Jobs shall be carried out in well-ventilated area, and a carbon dioxide fire extinguisher shall be
equipped.
• Smoking shall be strictly forbidden while carrying out work which is relevant to the fuel system.
The working area shall be far away from flame and spark.
• Put the discharged fuel in explosion-proof containers.

Check whether the result is normal?

Yes > go to next step.
No > Clean injector Recheck the working state of the fuel injector If the injector still works abnormally,
change it.

11 . Check the pressure of the cylinders

(a) Carry out compression pressure test for the cylinders.
The pressure of each cylinder: 1270 kPa
The limit value of each cylinder: 880 kPa
The difference of limit value of cylinders: Can't exceed 25%

Check whether the result is normal?

 04-118 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Yes > Go to Step 13.

No > Go to the next step.

12 . Check engine for automatic timing

(a) Check whether the mark of engine timing gear is aligned, damaged, whether the belt becomes loose or
jump tooth.
Check whether the result is normal?
04
Yes > go to next step.
No > Carry out timing belt aligning operation or change the timing belt.

13 . Check the machine of the engine.

(a) Use an inner sight glass to observe the inside condition of the cylinder.
(b) Observe the change of feedback voltage.
(c) Disintegrate the engine and maintain the interior trouble.
Clean accumulated carbon or dismantle and check the engine cylinder cover. Check the
air throttle, air intake manifold for accumulated carbon. For instance: cylinder is not sealed
tightly due to too big clearance between the piston-ring and cylinder body, the cylinder
cushion leaks, the valve conduit becomes loose, the valve is not be closed tightly, the valve
accumulates carbon.

Check whether the result is normal?

Yes > go to next step.
No > Maintain the interior trouble of the engine.

14 . Check the starting signal of the starting switch to the computer

(a) Check whether there is signal of starting switch which is sent to the computer when starting at the position
of harness pin.
Check whether the result is normal?
Yes > go to next step.
No > Maintain or replace faulty components

15 . Replace the ECM

(a) Replace the ECM. (Refer to "Chapter 11. Engine Control System - engine control module")
(b) Check the engine dataflow, and confirm that no more such engine phenomena, and the system is normal.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-119

THE COLD CAR IS DIFFICULT TO START AND VEHICLE BODY

QUIVERS
Symptom Status Diagnostic Logic Possible Cause
There is leakage in the air
intake system; fuel pres-
sure is too low; air cleaner
• Mixing ratio isn’t right
is clogged; water tempera- 04
• The rotational speed of • Carbon accumulates in ture sensor is faulty; air
the crankshaft is normal the air throttle and air flowmeter is faulty; idling
• The warning lamp of the intake path. control valve or additional
The cold car is difficult to engine is normal • Faulty coolant tempera- air valve are faulty; The
start and vehicle body • When the cold car ture sensor injector for cold starting
quivers starter drives the engine • Absolute pressure / can’t work; the injector
to rotate, it needs many temperature sensor, in- leaks; incorrect electronic
times of starting before take manifold spark timing; the connec-
it runs. • Idle Stepping Motor tion circuit of the start
• Fuel switch to the computer is
of short circuit; The com-
pression pressure in the
cylinder is too low.

Trouble phenomena diagnostic procedure

1. Check engine fault indicator lamp and DTC

(a) Use a diagnostic apparatus to perform procedure for reading DTC.
Is there DTC?
Yes > refer to DTC list, carry out DTC trouble diagnostic procedure.
No > Go to the next step.

2. Check battery
(a) While starting the engine, check the voltage of the battery.
Battery voltage: ≥ 9.6 V

Check whether the result is normal?

Yes > go to next step.
No > Recharge or replace the battery.

3. Check the starter

(a) Check whether the starter or the starter circuit is faulty.
Check whether the result is normal?
Yes > go to next step.
No > Eliminate problems, confirm that no more such phenomena.

4. Check the sensor of crankshaft position

(a) Use a diagnostic apparatus to read the sensor dataflow of the engine crankshaft position (CKP) shown
in the diagnostic apparatus, which shall reach the stipulated value while starting.
 04-120 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Check whether the result is normal?

Yes > go to next step.
No > Check whether the sensor is installed correctly (refer to the engine control system - disassembly
and assembly of sensor), maintain or replace the harness, connectors or damaged components.

5. Check the absolute pressure/temperature sensor of the engine coolant temperature sensor and
intake manifold
04
(a) Check whether the absolute pressure/temperature sensor of intake manifold is installed correctly.
(b) Remove the absolute pressure/temperature sensor of intake manifold.
(c) Check whether the sensing hole is clogged and the resistance value between every wiring ends comply
with the standard.
(d) Check whether the temperature sensor is dirty.
(e) Ignition switch: ON, read the sensor dataflow of coolant temperature and intake manifold absolute
pressure (MAP)\ temperature of engine which show in the diagnostic apparatus.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

6. Check intake system

(a) Check vacuum degree of intake pipe while idling.
(b) Check each fitting, gasket, vacuum hose of the intake pipe, and waste gas circulatory system, fuel
evaporation system.
(c) Check whether the filtering core of the air cleaner is clogged.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

7. Check the air throttle:

(a) Press the accelerator pedal gently and start the engine. Check whether the engine can start.
Check whether it can start.
Yes > Check the air throttle and idling path, eliminate accumulated carbon. Unplug the connector of the
step motor, measure to check whether the voltage between the terminals is 12 V; when the temperature
is at 20 ℃, the normal scope of resistance value shall be 28-33 ohms. Check whether the step motor is
clogged, maintain or replace it if necessary.
No > Go to the next step.

8. Check the step motor

(a) When ignition switch is on, the step motor can be checked for expansion.
(b) When ignition switch is off, the step motor can be checked for action; the air throttle opening position
shall be the biggest if it is normal.
Check whether the result is normal?
Yes > go to next step.
No > Maintain or replace the connectors, harness or the step motor.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-121

9. Check the pressure of the fuel system

(a) Check the pressure of the fuel system Refer to "Chapter 12A. Fuel system- precaution")
Check whether the result is normal?
Yes > Go to Step 11.
No > Maintain or replace the components or circuit of the fuel system, if fuel pressure is lower than 400
kPa, and go to next step. 04

10 . Check the fuel supply of the fuel system

(a) Check for leakage in the fuel intake pipe.
(b) Check whether the gasoline cleaner is clogged.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

11 . Check the injector

(a) Pull out the connector of the injector.
(b) Pull out the fuel delivery pipe and injector together.
(c) Directly apply battery 12V voltage to the injector.
(d) Each injector shall inject standard volume of fuel, and it shall be pulverized evenly.

CAUTION
While checking the spraying state of the injector, if spraying looks like a " column " instead of a “cone”,
or the injectors of the four cylinders inject different volumes of fuel (difference greater than 5ml), injectors
shall be replaced. Check whether there is colloidal material in the injector nozzle, if yes, it shall be soaked
in detergent and sprayed, otherwise it will lead to insufficient injected fuel quantity or poor acceleration,
etc.
DANGER
When testing the fuel system:
• Put a mark " caution: Flammable " in the working area.
• Jobs shall be carried out in well-ventilated area, and a carbon dioxide fire extinguisher shall be
equipped.
• Smoking shall be strictly forbidden while carrying out work which is relevant to the fuel system.
The working area shall be far away from flame and spark.
• Put the discharged fuel in explosion-proof containers.

Check whether the result is normal?

Yes > go to next step.
No > Clean injector Recheck the working state of the fuel injector If the injector still works abnormally,
change it.

12 . Check the pressure of the cylinders

(a) Carry out compression pressure test for the cylinders.
The pressure of each cylinder: 1270 kPa
The limit value of each cylinder: 880 kPa
 04-122 DIAGNOSTICS - ENGINE CONTROL SYSTEM

The difference of limit value of cylinders: Can't exceed 25%

Check whether the result is normal?

Yes > Go to Step 14.
No > Go to the next step.

04 13 . Check engine for automatic timing

(a) Check whether the mark of engine timing gear is aligned, damaged, whether the belt becomes loose or
jump tooth.
Check whether the result is normal?
Yes > go to next step.
No > Carry out timing belt aligning operation or change the timing belt.

14 . Check the machine of the engine.

(a) Use an inner sight glass to observe the inside condition of the cylinder.
(b) Observe the change of feedback voltage.
(c) Disintegrate the engine and maintain the interior trouble.
Clean accumulated carbon or dismantle and check the engine cylinder cover. Check the
air throttle, air intake manifold for accumulated carbon. For instance: cylinder is not sealed
tightly due to too big clearance between the piston-ring and cylinder body, the cylinder
cushion leaks, the valve conduit becomes loose, the valve is not be closed tightly, the valve
accumulates carbon.

Check whether the result is normal?

Yes > go to next step.
No > Maintain the interior trouble of the engine.

15 . Replace the ECM

(a) Replace the ECM. (Refer to "Chapter 11. Engine Control System - engine control module")
(b) Check the engine dataflow, and confirm that no more such engine phenomena, and the system is normal.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-123

UNSTABLE IDLING SPEED

Symptom Status Diagnostic Logic Possible Cause
• Ignition System
• Air-fuel ratio
• Ignition System
• Faulty step motor
• Air-fuel ratio
The rotational speed of en- • Compression pressure
Unstable idling speed gine is unable to remain • Faulty step motor
too low
stable • Compression pressure 04
• Reverse installation of
too low
front and rear oxygen
sensors

CAUTION
When the engine runs at idling, if individual cylinder can’t work due to maladjusted, mixed air and
agent ratio, air intake system leakage or faulty ignition system, it will lead to the faults such as no idling,
too high idling speed, unstable idling and bad high idling etc..
Trouble phenomena diagnostic procedure

1. Check engine fault indicator lamp and DTC

Is there DTC?
Yes > refer to DTC list, carry out DTC trouble diagnostic procedure.
No > Go to the next step.

2. Carry out visual and exterior inspection

(a) Observe the situation of the engine operation and the intensity of quivering.
(b) Meanwhile, observe the swing range of the engine speedometer indicator, check the rotational speed is
out of the specified range of idling speed.
(c) Observe it is a normal quivering or a loaded idling one. ( Opening air conditioner, light, changing gear,
operating steering wheel, etc.)
(d) Check whether the external components of the engine are of abnormal state; Whether the vacuum tube
has come off or damaged; Whether the wire connector has come off.
(e) Check whether there are oil leakage, water leakage, gas leakage, leakage of electricity.
(f) Check whether there are abnormal phenomena such as sound which shows bad combustion, black
smoke, smell of fresh gasoline, etc..
Check whether the result is normal?
Yes > go to next step.
No > Eliminate external problems, confirm that no more such phenomena.

3. Check the air throttle body and step motor

(a) Check whether there are greasy dirt, charcoal on the air throttle and the air throttle is clogged; whether
there are dirt and charcoal on the air intake path nearby; whether there is charcoal on the step motor.
(b) Start the engine in idling.
(c) Use a diagnostic apparatus to carry out step motor test.
(d) When the diagnostic apparatus control the step motor to rotate telescopically, the speed of the engine
can fluctuate synchronously. ( You can feel it by touching the step motor with hand)
(e) Unplug the connector of the step motor, measure whether there is 12 V voltage between the connector
ends.
 04-124 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(f) When ignition switch is on, the step motor can be checked for expansion.
(g) When ignition switch is off, the step motor can be checked for action.
Check whether the result is normal?
Yes > go to next step.
No > Wash, maintain or replace the harness, connectors or the step motor.
04
4. Check engine ignition system
(a) Make the engine run at idling, stall cylinders one by one, observe whether the engine speed change.
(b) When each cylinder stalls, the rotational speed of engine should drop evidently or quiver simultaneously.
Check whether the result is normal?
Yes > Go to Step 11.
No > Go to the next step.

5. Check the secondary ignition system

(a) Check the resistance value of high-voltage coil, and clean the terminals of connector.
Resistance: ≥ 4 k
(b) Check whether the spark plug accumulates carbons, carbon mark, whether the ceramic insulating part
is cracked and leaks electricity; whether the interval is normal; whether the positive and negative poles
are burned corrupt; and clean the spark plug.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

6. Check the injector

(a) Pull out the connector of the injector.
(b) Pull out the fuel delivery pipe and injector together.
(c) Directly apply battery 12V voltage to the injector.
(d) Each injector shall inject standard volume of fuel, and it shall be pulverized evenly.
CAUTION
While checking the spraying state of the injector, if spraying looks like a " column " instead of a “cone”,
or the injectors of the four cylinders inject different volumes of fuel (difference greater than 5ml), injectors
shall be replaced. Check whether there is colloidal material in the injector nozzle, if yes, it shall be soaked
in detergent and sprayed, otherwise it will lead to insufficient injected fuel quantity or poor acceleration,
etc.
DANGER
When testing the fuel system:
• Put a mark " caution: Flammable " in the working area.
• Jobs shall be carried out in well-ventilated area, and a carbon dioxide fire extinguisher shall be
equipped.
• Smoking shall be strictly forbidden while carrying out work which is relevant to the fuel system.
The working area shall be far away from flame and spark.
• Put the discharged fuel in explosion-proof containers.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-125

Check whether the result is normal?

Yes > go to next step.
No > Clean injector Recheck the working state of the fuel injector If the injector still works abnormally,
change it.

7. Check the pressure of the fuel system

(a) Check the pressure of the fuel system Refer to "Chapter 12A. Fuel system- precaution") 04
Check whether the result is normal?
Yes > Go to step 9.
No > Maintain or replace the components or circuit of the fuel system, if fuel pressure is lower than 400
kPa, and go to next step.

8. Check the fuel supply of the fuel system

(a) Check for leakage in the fuel intake pipe.
(b) Check whether the gasoline cleaner is clogged.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

9. Check the air intake and exhaust system

(a) Check whether there is leakage in the engine air intake system
(b) Check whether there are coming off, fracture, distortion, aged sealing on the intake pipe.
(c) Grip the vacuum booster hose, or stop it after pulling out, observe whether there is change in idling.
(d) Check whether there is gas leakage sound of " whistling " in the air intake pipe when the engine is
operating.
(e) Check whether there is leakage in the hose of crankshaft box forced ventilation valve (PCV), then check
whether PCV is opened too large.
(f) Check whether there is leakage in the vacuum tube of the evaporation emission control system.
(g) Check whether the vacuum hose of the fuel pressure regulator is damaged, come off or cracked.
(h) Check whether the three-way catalytic converter is blocked.
(i) Check whether the sealing of the air throttle leak.
(j) Check whether the intake manifold gasket leaks.
Check whether the result is normal?
Yes > go to next step.
No > Maintain or replace faulty components

10 . Check the absolute pressure/temperature sensor of the engine coolant temperature sensor and
intake manifold
(a) Check whether the absolute pressure/temperature sensor of intake manifold is installed correctly.
(b) Remove the absolute pressure/temperature sensor of intake manifold.
(c) Check whether the sensing hole is clogged and the resistance value between every wiring ends comply
with the standard.
(d) Check whether the temperature sensor is dirty.
(e) Ignition switch: ON, read the sensor dataflow of coolant temperature and intake manifold absolute
pressure (MAP)\ temperature of engine which show in the diagnostic apparatus.
 04-126 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Check whether the result is normal?

Yes > go to next step.
No > Clean, replace faulty components

11 . Check the oxygen sensor,

(a) Check whether front and rear oxygen sensors are installed properly.
(b) Make the engine run at idling, check the dataflow of the diagnostic apparatus, observe whether oxygen
04
sensor work normally after the cooling liquid reach normal temperature to activate closed loop control.
Normal data of oxygen sensor: Fluctuate normally between 0-1 V.There are 8 times of the alternate
changes of maximum and minimum values within 10 seconds.

Check whether the result is normal?

Yes > go to next step.
No > Maintain or replace faulty components

12 . Check the pressure of the cylinders

(a) Carry out compression pressure test for the cylinders.
The pressure of each cylinder: 1270 kPa
The limit value of each cylinder: 880 kPa
The difference of limit value of cylinders: Can't exceed 25%

Check whether the result is normal?

Yes > Go to Step 14.
No > Go to the next step.

13 . Check engine for automatic timing

(a) Check whether the mark of engine timing gear is aligned, damaged, whether the belt becomes loose or
jump tooth.
Check whether the result is normal?
Yes > go to next step.
No > Carry out timing belt aligning operation or change the timing belt.

14 . Check the machine of the engine.

(a) Use an inner sight glass to observe the inside condition of the cylinder.
(b) Observe the change of feedback voltage.
(c) Disintegrate the engine and maintain the interior trouble.
Clean accumulated carbon or dismantle and check the engine cylinder cover. Check the
air throttle, air intake manifold for accumulated carbon. For instance: cylinder is not sealed
tightly due to too big clearance between the piston-ring and cylinder body, the cylinder
cushion leaks, the valve conduit becomes loose, the valve is not be closed tightly, the valve
accumulates carbon.

Check whether the result is normal?

Yes > go to next step.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-127

No > Maintain the interior trouble of the engine.

15 . Replace the ECM

(a) Replace the ECM. (Refer to "Chapter 11. Engine Control System - engine control module")
(b) Check the engine dataflow, and confirm that no more such engine phenomena, and the system is normal.

04
 04-128 DIAGNOSTICS - ENGINE CONTROL SYSTEM

IDLING SPEED TOO HIGH

Symptom Status Diagnostic Logic Possible Cause
• Faulty idling stepping
motor
The idling speed is too high • Vacuum leakage
The reason may be that
(the rotational speed of The engine’s rotational • Too tight throttle valve
there is too much air inflow
idling is not within specified speed is too high
during idling cable
04 value) • Faulty air throttle body
• ECM

CAUTION
When the engine runs at idling, if individual cylinder can’t work due to maladjusted, mixed air and
agent ratio, air intake system leakage or faulty ignition system, it will lead to the faults such as no idling,
too high idling speed, unstable idling and bad high idling etc..
Trouble phenomena diagnostic procedure

1. Check engine fault indicator lamp and DTC

(a) Use a diagnostic apparatus to perform procedure for reading DTC.
Is there DTC?
Yes > refer to DTC list, carry out DTC trouble diagnostic procedure.
No > Go to the next step.

2. Carry out visual and exterior inspection

(a) Carry out visual and exterior inspection
Check whether the result is normal?
Yes > go to next step.
No > Eliminate external problems, confirm that no more such phenomena.

3. Check intake system

(a) Check whether there is leakage in the engine air intake system
(b) Check whether there is gas leakage sound of " whistling " in the air intake pipe when the engine is
operating.
(c) Check whether there is coming off, fracture, distortion, aged sealing on the intake pipe.
Check whether there is coming off, fracture and distortion; Are the results normal?
Yes > go to next step.
No > Maintain, replace or reinstall.

4. Check relevant components

(a) Check whether the vacuum hose of the carbon pot control valve is connected reliably or is damaged.
(b) Check whether the vacuum regulating hose of the fuel pressure regulator is installed reliably or is damaged.
(c) Check whether the vacuum hose of the crankshaft box which is used for forced ventilation is installed
reliably or is damaged.
(d) Check whether the vacuum tube of the braking system is installed reliably or is damaged.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-129

Check whether the result is normal?

Yes > go to next step.
No > Adjust or replace

5. Check the air throttle body and step motor

(a) Check whether the throttle valve cable is too tight.
(b) Check whether there are greasy dirt, charcoal on the air throttle and the air throttle is clogged; whether
04
there are dirt and charcoal on the air intake path nearby; whether there is charcoal on the step motor.
(c) Start the engine in idling.
(d) Use a diagnostic apparatus to carry out step motor test.
(e) When the diagnostic apparatus control the step motor to rotate telescopically, the speed of the engine
can fluctuate synchronously. ( You can feel it by touching the step motor with hand)
(f) Unplug the connector of the step motor, measure whether there is 12 V voltage between the connector
ends.
(g) When ignition switch is on, the step motor can be checked for expansion.
(h) When ignition switch is off, the step motor can be checked for action.
Check whether the result is normal?
Yes > go to next step.
No > Wash, maintain or replace the harness, connectors or the step motor.

6. Check the absolute pressure/temperature sensor of the engine coolant temperature sensor and
intake manifold
(a) Check whether the absolute pressure/temperature sensor of intake manifold is installed correctly.
(b) Remove the absolute pressure/temperature sensor of intake manifold.
(c) Check whether the sensing hole is clogged and the resistance value between every wiring ends comply
with the standard.
(d) Check whether the temperature sensor is dirty.
(e) Ignition switch: ON, read the sensor dataflow of coolant temperature and intake manifold absolute
pressure (MAP)\ temperature of engine which show in the diagnostic apparatus.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

7. Check the pressure of the fuel system

(a) Check the pressure of the fuel system Refer to "Chapter 12A. Fuel system- precaution")
Check whether the result is normal?
Yes > go to next step.
No > Maintain or replace the components or circuit of the fuel system.

8. Check the injector

(a) Pull out the connector of the injector.
(b) Pull out the fuel delivery pipe and injector together.
(c) Directly apply battery 12V voltage to the injector.
(d) Each injector shall inject standard volume of fuel, and it shall be pulverized evenly.
 04-130 DIAGNOSTICS - ENGINE CONTROL SYSTEM

CAUTION
While checking the spraying state of the injector, if spraying looks like a " column " instead of a “cone”,
or the injectors of the four cylinders inject different volumes of fuel (difference greater than 5ml), injectors
shall be replaced. Check whether there is colloidal material in the injector nozzle, if yes, it shall be soaked
in detergent and sprayed, otherwise it will lead to insufficient injected fuel quantity or poor acceleration,
etc.
04 DANGER
When testing the fuel system:
• Put a mark " caution: Flammable " in the working area.
• Jobs shall be carried out in well-ventilated area, and a carbon dioxide fire extinguisher shall be
equipped.
• Smoking shall be strictly forbidden while carrying out work which is relevant to the fuel system.
The working area shall be far away from flame and spark.
• Put the discharged fuel in explosion-proof containers.

Check whether the result is normal?

Yes > go to next step.
No > Clean injector Recheck the working state of the fuel injector If the injector still works abnormally,
change it.

9. Replace the ECM

(a) Replace the ECM. (Refer to "Chapter 11. Engine Control System - engine control module")
(b) Check the engine dataflow, and confirm that no more such engine phenomena, and the system is normal.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-131

THE ENGINE CAN STALL WHEN IT IS COLD

Symptom Status Diagnostic Logic Possible Cause
• Faulty ignition system
• Idling air–fuel ratio
•
Ignition System control system failure
•
Air-fuel ratio • Faulty air intake system
The rotational speed of en-
The engine can stall when •
gine is unable to remain Faulty step motor • Compression pressure 04
it is cold
stable • Compression pressure too low
too low • Faulty discharge control
system
• ECM

Trouble phenomena diagnostic procedure

1. Check engine fault indicator lamp and DTC

(a) Use a diagnostic apparatus to perform procedure for reading DTC.
Is there DTC?
Yes > refer to DTC list, carry out DTC trouble diagnostic procedure.
No > Go to the next step.

2. Carry out visual and exterior inspection

(a) Observe the situation of the engine operation and the intensity of quivering.
(b) Observe the swing range of the engine speedometer indicator and the rotational speed while stalling at
the same time.
(c) Observe it is normal idling stalling or loaded idling stalling(opening air-conditioner, lights, gear position,
turning turn wheel etc.)
(d) Check whether the external components of the engine are of abnormal state; Whether the vacuum tube
has come off or damaged; Whether the wire connector has come off.
Check whether the result is normal?
Yes > go to next step.
No > Eliminate abnormal problems, confirm that no more such phenomena.

3. Check the air throttle body and step motor

(a) Check whether there are greasy dirt, charcoal on the air throttle and the air throttle is clogged; whether
there are dirt and charcoal on the air intake path nearby; whether there is charcoal on the step motor.
(b) Start the engine in idling.
(c) Use a diagnostic apparatus to carry out step motor test.
(d) When the diagnostic apparatus control the step motor to rotate telescopically, the speed of the engine
can fluctuate synchronously. ( You can feel it by touching the step motor with hand)
(e) Unplug the connector of the step motor, measure whether there is 12 V voltage between the connector
ends.
(f) When ignition switch is on, the step motor can be checked for expansion.
(g) When ignition switch is off, the step motor can be checked for action.
Check whether the result is normal?
Yes > go to next step.
 04-132 DIAGNOSTICS - ENGINE CONTROL SYSTEM

No > Wash, maintain or replace the harness, connectors or the step motor.

4. Check the coolant temperature sensor

(a) Check whether the resistance value between every wiring end of cooling liquid temperature sensors
comply with the standard.
(b) Check whether the cooling liquid temperature sensor is polluted.
(c) Ignition switch: ON, read the dataflow of the cooling liquid temperature sensor of the diagnostic apparatus.
04 Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

5. Check the air intake temperature sensor

(a) Check whether the resistance value between every wiring end of air intake temperature sensors comply
with the standard.
(b) Check whether the air intake temperature sensor is polluted.
(c) Ignition switch: ON, read the dataflow of the air intake temperature sensor of the diagnostic apparatus.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

6. Check the injector

(a) Pull out the connector of the injector.
(b) Pull out the fuel delivery pipe and injector together.
(c) Directly apply battery 12V voltage to the injector.
(d) Each injector shall inject standard volume of fuel, and it shall be pulverized evenly.

CAUTION
While checking the spraying state of the injector, if spraying looks like a " column " instead of a “cone”,
or the injectors of the four cylinders inject different volumes of fuel (difference greater than 5ml), injectors
shall be replaced. Check whether there is colloidal material in the injector nozzle, if yes, it shall be soaked
in detergent and sprayed, otherwise it will lead to insufficient injected fuel quantity or poor acceleration,
etc.
DANGER
When testing the fuel system:
• Put a mark " caution: Flammable " in the working area.
• Jobs shall be carried out in well-ventilated area, and a carbon dioxide fire extinguisher shall be
equipped.
• Smoking shall be strictly forbidden while carrying out work which is relevant to the fuel system.
The working area shall be far away from flame and spark.
• Put the discharged fuel in explosion-proof containers.

Check whether the result is normal?

Yes > go to next step.
No > Clean injector Recheck the working state of the fuel injector If the injector still works abnormally,
change it.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-133

7. Check the pressure of the fuel system

(a) Check the pressure of the fuel system Refer to "Chapter 12A. Fuel system- precaution")
Check whether the result is normal?
Yes > Go to Step 9.
No > Maintain or replace the components or circuit of the fuel system, if fuel pressure is lower than 400
kPa, and go to next step. 04

8. Check the fuel supply of the fuel system

(a) Check for leakage in the fuel intake pipe.
(b) Check whether the gasoline cleaner is clogged.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

9. Check the pressure of the cylinders

(a) Carry out compression pressure test for the cylinders.
The pressure of each cylinder: 1270 kPa
The limit value of each cylinder: 880 kPa
The difference of limit value of cylinders: Can't exceed 25%

Check whether the result is normal?

Yes > Go to Step 11.
No > Go to the next step.

10 . Check engine for automatic timing

(a) Check whether the mark of engine timing gear is aligned, damaged, whether the belt becomes loose or
jump tooth.
Check whether the result is normal?
Yes > go to next step.
No > Carry out timing belt aligning operation or change the timing belt.

11 . Check the machine of the engine.

(a) Use an inner sight glass to observe the inside condition of the cylinder.
(b) Observe the change of feedback voltage.
(c) Disintegrate the engine and maintain the interior trouble.
Clean accumulated carbon or dismantle and check the engine cylinder cover. Check the
air throttle, air intake manifold for accumulated carbon. For instance: cylinder is not sealed
tightly due to too big clearance between the piston-ring and cylinder body, the cylinder
cushion leaks, the valve conduit becomes loose, the valve is not be closed tightly, the valve
accumulates carbon.

Check whether the result is normal?

 04-134 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Yes > go to next step.

No > Maintain the interior trouble of the engine.

12 . Replace the ECM

(a) Replace the ECM. (Refer to "Chapter 11. Engine Control System - engine control module")
(b) Check the engine dataflow, and confirm that no more such engine phenomena, and the system is normal.

04
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-135

THE ENGINE CAN STALL WHEN STARTING

Symptom Status Diagnostic Logic
Insufficient temporary power for
starting
• Faulty idling stepping motor
• Faulty air throttle
Engine stalls during starting if the
The engine can stall when starting • Faulty oil injector
accelerator pedal is stepped 04
• Faulty ignition system
• Poor load signal
• ECM

CAUTION
If the engine quivers when starting in idling mode, the rotational speed drops, it is apt to stall.The reason
for the fault shall be found from idling control.
Trouble phenomena diagnostic procedure

1. Check engine fault indicator lamp and DTC

(a) Use a diagnostic apparatus to perform procedure for reading DTC.
Is there DTC?
Yes > refer to DTC list, carry out DTC trouble diagnostic procedure.
No > Go to the next step.

2. Carry out visual and exterior inspection

(a) Observe the situation of the engine operation and the intensity of quivering.
(b) Observe the swing range of the engine speedometer indicator and the rotational speed while stalling at
the same time.
(c) Observe it is normal idling stalling or loaded idling stalling(opening air-conditioner, lights, gear position,
turning turn wheel etc.)
(d) Check whether the external components of the engine are of abnormal state; Whether the vacuum tube
has come off or damaged; Whether the wire connector has come off.
Check whether the result is normal?
Yes > go to next step.
No > Eliminate abnormal problems, confirm that no more such phenomena.

3. Check the air throttle body and step motor

(a) Check whether there are greasy dirt, charcoal on the air throttle and the air throttle is clogged; whether
there are dirt and charcoal on the air intake path nearby; whether there is charcoal on the step motor.
(b) Start the engine in idling.
(c) Use a diagnostic apparatus to carry out step motor test.
(d) When the diagnostic apparatus control the step motor to rotate telescopically, the speed of the engine
can fluctuate synchronously. ( You can feel it by touching the step motor with hand)
(e) Unplug the connector of the step motor, measure whether there is 12 V voltage between the connector
ends.
(f) When ignition switch is on, the step motor can be checked for expansion.
(g) When ignition switch is off, the step motor can be checked for action.
 04-136 DIAGNOSTICS - ENGINE CONTROL SYSTEM

Check whether the result is normal?

Yes > go to next step.
No > Wash, maintain or replace the harness, connectors or the step motor.

4. Check the air throttle position

(a) Use a diagnostic apparatus to check whether the air throttle is normal.
(b) Check whether the air throttle position change is normal after stepping on the accelerator pedal.
04
Check whether the result is normal?
Yes > go to next step.
No > adjust the air throttle position

5. Check the secondary ignition system

(a) Pull out the fuel of the fuel spray nozzle.
(b) Pull out the high-voltage line, unplug the spark plug.
(c) Connect spark plug to the high voltage line, and contact the negative pole of the spark plug with the
cylinder body.
(d) Check engine to test secondary ignition system
Correct result: When the engine rotates, strong blue and white spark can be seen on each spark
plug.

Check whether the result is normal?

Yes > Go to Step 7.
No > Go to the next step.

6. Check the secondary ignition system

(a) Check the resistance value of high-voltage coil, and clean the terminals of connector.
Resistance: ≥ 4 k
(b) Check whether the spark plug accumulates carbons, carbon mark, whether the ceramic insulating part
is cracked and leaks electricity; whether the interval is normal; whether the positive and negative poles
are burned corrupt; and clean the spark plug.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

7. Check the injector

(a) Pull out the connector of the injector.
(b) Pull out the fuel delivery pipe and injector together.
(c) Directly apply battery 12V voltage to the injector.
(d) Each injector shall inject standard volume of fuel, and it shall be pulverized evenly.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-137

CAUTION
While checking the spraying state of the injector, if spraying looks like a " column " instead of a “cone”,
or the injectors of the four cylinders inject different volumes of fuel (difference greater than 5ml), injectors
shall be replaced. Check whether there is colloidal material in the injector nozzle, if yes, it shall be soaked
in detergent and sprayed, otherwise it will lead to insufficient injected fuel quantity or poor acceleration,
etc.
DANGER
04
When testing the fuel system:
• Put a mark " caution: Flammable " in the working area.
• Jobs shall be carried out in well-ventilated area, and a carbon dioxide fire extinguisher shall be
equipped.
• Smoking shall be strictly forbidden while carrying out work which is relevant to the fuel system.
The working area shall be far away from flame and spark.
• Put the discharged fuel in explosion-proof containers.

Check whether the result is normal?

Yes > go to next step.
No > Clean injector Recheck the working state of the fuel injector If the injector still works abnormally,
change it.

8. Check the pressure of the fuel system

(a) Check the pressure of the fuel system Refer to "Chapter 12A. Fuel system- precaution")
Check whether the result is normal?
Yes > Go to Step 10.
No > Maintain or replace the components or circuit of the fuel system, if fuel pressure is lower than 400
kPa, and go to next step.

9. Check the fuel supply of the fuel system

(a) Check for leakage in the fuel intake pipe.
(b) Check whether the gasoline cleaner is clogged.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

10 . Check the pressure of the cylinders

(a) Carry out compression pressure test for the cylinders.
The pressure of each cylinder: 1270 kPa
The limit value of each cylinder: 880 kPa
The difference of limit value of cylinders: Can't exceed 25%

Check whether the result is normal?

Yes > Go to Step 12.
No > Go to the next step.
 04-138 DIAGNOSTICS - ENGINE CONTROL SYSTEM

11 . Check engine for automatic timing

(a) Check whether the mark of engine timing gear is aligned, damaged, whether the belt becomes loose or
jump tooth.
Check whether the result is normal?
Yes > go to next step.
No > Carry out timing belt aligning operation or change the timing belt.
04

12 . Check the machine of the engine.

(a) Use an inner sight glass to observe the inside condition of the cylinder.
(b) Observe the change of feedback voltage.
(c) Disintegrate the engine and maintain the interior trouble.
Clean accumulated carbon or dismantle and check the engine cylinder cover. Check the
air throttle, air intake manifold for accumulated carbon. For instance: cylinder is not sealed
tightly due to too big clearance between the piston-ring and cylinder body, the cylinder
cushion leaks, the valve conduit becomes loose, the valve is not be closed tightly, the valve
accumulates carbon.

Check whether the result is normal?

Yes > go to next step.
No > Maintain the interior trouble of the engine.

13 . Replace the ECM

(a) Replace the ECM. (Refer to "Chapter 11. Engine Control System - engine control module")
(b) Check the engine dataflow, and confirm that no more such engine phenomena, and the system is normal.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-139

SLOW, MALADJUSTED ACCELERATION RESPONSE

Symptom Status Diagnostic Logic Possible Cause
• Air-fuel ratio control
The engine rotational
speed fails to rise immedi- system failure
• Fuel supply system fail-
ately, or acceleration re-
Slow, maladjusted acceler- Bad air-fuel ratio or com- ure
sponses slowly, or rotation-
ation response pression pressure • Compression pressure
al speed drops temporarily
04
when stepping on the accel- too low
erator pedal • ECM

Trouble phenomena diagnostic procedure

1. Check engine fault indicator lamp and DTC

(a) Use a diagnostic apparatus to perform procedure for reading DTC.
Is there DTC?
Yes > refer to DTC list, carry out DTC trouble diagnostic procedure.
No > Go to the next step.

2. Check intake system

(a) Check each fitting, gasket, vacuum hose of the intake pipe, and waste gas circulatory system, fuel
evaporation system.
(b) Check whether the filtering core of the air cleaner is clogged.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

3. Check engine idling

(a) Check whether the engine idling is normal.
Check whether the result is normal?
Yes > go to next step.
No > refer to the engine phenomenon diagnosis table – eliminate idle speed trouble, confirm that no
more such phenomena.

4. Check the absolute pressure/temperature sensor of the engine coolant temperature sensor and
intake manifold
(a) Check whether the absolute pressure/temperature sensor of intake manifold is installed correctly.
(b) Remove the absolute pressure/temperature sensor of intake manifold.
(c) Check whether the sensing hole is clogged and the resistance value between every wiring ends comply
with the standard.
(d) Check whether the temperature sensor is dirty.
(e) Ignition switch: ON, read the sensor dataflow of coolant temperature and intake manifold absolute
pressure (MAP)\ temperature of engine which show in the diagnostic apparatus.
Check whether the result is normal?
Yes > go to next step.
 04-140 DIAGNOSTICS - ENGINE CONTROL SYSTEM

No > Clean, replace faulty components

5. Check the air throttle position

(a) Use a diagnostic apparatus to check whether the air throttle is normal.
(b) Check whether the air throttle position change is normal after stepping on the accelerator pedal.
Check whether the result is normal?

04 Yes > go to next step.

No > Maintain or replace faulty components

6. Check the injector

(a) Pull out the connector of the injector.
(b) Pull out the fuel delivery pipe and injector together.
(c) Directly apply battery 12V voltage to the injector.
(d) Each injector shall inject standard volume of fuel, and it shall be pulverized evenly.

CAUTION
While checking the spraying state of the injector, if spraying looks like a " column " instead of a “cone”,
or the injectors of the four cylinders inject different volumes of fuel (difference greater than 5ml), injectors
shall be replaced. Check whether there is colloidal material in the injector nozzle, if yes, it shall be soaked
in detergent and sprayed, otherwise it will lead to insufficient injected fuel quantity or poor acceleration,
etc.
DANGER
While checking the spraying state of the injector, if spraying looks like a " column " instead of a “cone”,
or the injectors of the four cylinders inject different volumes of fuel (difference greater than 5ml), injectors
shall be replaced. Check whether there is colloidal material in the injector nozzle, if yes, it shall be soaked
in detergent and sprayed, otherwise it will lead to insufficient injected fuel quantity or poor acceleration,
etc.
• Put a mark " caution: Flammable " in the working area.
• Jobs shall be carried out in well-ventilated area, and a carbon dioxide fire extinguisher shall be
equipped.
• Smoking shall be strictly forbidden while carrying out work which is relevant to the fuel system.
The working area shall be far away from flame and spark.
• Put the discharged fuel in explosion-proof containers.

Check whether the result is normal?

Yes > go to next step.
No > Clean injector Recheck the working state of the fuel injector If the injector still works abnormally,
change it.

7. Check the pressure of the fuel system

(a) Check the pressure of the fuel system Refer to "Chapter 12A. Fuel system- precaution")
Check whether the result is normal?
Yes > Go to Step 9.
No > Maintain or replace the components or circuit of the fuel system, if fuel pressure is lower than 400
kPa, and go to next step.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-141

8. Check the fuel supply of the fuel system

(a) Check for leakage in the fuel intake pipe.
(b) Check whether the gasoline cleaner is clogged.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components 04

9. Check exhaust system

(a) Check exhaust system and three-way catalytic converter.
(b) Use the exhaust back pressure gauge to check whether the tailpipe is clogged.

10 . Check the pressure of the cylinders

(a) Carry out compression pressure test for the cylinders.
The pressure of each cylinder: 1270 kPa
The limit value of each cylinder: 880 kPa
The difference of limit value of cylinders: Can't exceed 25%

Check whether the result is normal?

Yes > Go to Step 12.
No > Go to the next step.

11 . Check engine for automatic timing

(a) Check whether the mark of engine timing gear is aligned, damaged, whether the belt becomes loose or
jump tooth.
Check whether the result is normal?
Yes > go to next step.
No > Carry out timing belt aligning operation or change the timing belt.

12 . Check the machine of the engine.

(a) Use an inner sight glass to observe the inside condition of the cylinder.
(b) Observe the change of feedback voltage.
(c) Disintegrate the engine and maintain the interior trouble.
Clean accumulated carbon or dismantle and check the engine cylinder cover. Check the
air throttle, air intake manifold for accumulated carbon. For instance: cylinder is not sealed
tightly due to too big clearance between the piston-ring and cylinder body, the cylinder
cushion leaks, the valve conduit becomes loose, the valve is not be closed tightly, the valve
accumulates carbon.

Check whether the result is normal?

Yes > go to next step.
No > Maintain the interior trouble of the engine.

13 . Replace the ECM

 04-142 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(a) Replace the ECM. (Refer to "Chapter 11. Engine Control System - engine control module")
(b) Check the engine dataflow, and confirm that no more such engine phenomena, and the system is normal.

04
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-143

POOR ACCELERATION AND PERFORMANCE

Symptom Status Diagnostic Logic Possible Cause
Acceleration efficiency can't • Faulty ignition system
reach suitable acceleration •
according to the throttle
Air-fuel ratio control
position (even though accel- system failure
• Fuel supply system fail-
erating course is very
The ignition system may be ure
Poor acceleration and per- smooth), or the max vehicle 04
poor in air-fuel ration or •
formance speed can’t be reached, Compression pressure
compression pressure
the engine misfire, backfire, too low
while accelerating, or the • Exhaust System is
vehicle stops suddenly, clogged
there are fluctuations in the • ECM
speed

Trouble phenomena diagnostic procedure

1. Check engine fault indicator lamp and DTC

(a) Use a diagnostic apparatus to perform procedure for reading DTC.
Is there DTC?
Yes > refer to DTC list, carry out DTC trouble diagnostic procedure.
No > Go to the next step.

2. Carry out visual and exterior inspection

(a) Perform external visual inspection.
(b) Check whether the manual brake is loose.
(c) Check the clutch for slippage.
(d) Check whether the positioning of the four wheels is proper.
(e) Check whether the tire model is right and air pressure is normal.
(f) Check whether the braking system is normal, eliminate braking drag, ensure that the braking branch
pump can restore its position, eliminate ABS trouble.
Check whether the result is normal?
Yes > go to next step.
No > Eliminate external problems, confirm that no more such phenomena.

3. Check the air throttle position

(a) Use a diagnostic apparatus to check whether the air throttle is normal.
(b) Check whether the air throttle position change is normal after stepping on the accelerator pedal.
Check whether the result is normal?
Yes > go to next step.
No > Maintain or replace faulty components

4. Check the absolute pressure/temperature sensor of the engine coolant temperature sensor and
intake manifold
(a) Check whether the absolute pressure/temperature sensor of intake manifold is installed correctly.
(b) Remove the absolute pressure/temperature sensor of intake manifold.
 04-144 DIAGNOSTICS - ENGINE CONTROL SYSTEM

(c) Check whether the sensing hole is clogged and the resistance value between every wiring ends comply
with the standard.
(d) Check whether the temperature sensor is dirty.
(e) Ignition switch: ON, read the sensor dataflow of coolant temperature and intake manifold absolute
pressure (MAP)\ temperature of engine which show in the diagnostic apparatus.
Check whether the result is normal?
04 Yes > go to next step.
No > Clean, replace faulty components

5. Check the pressure of the fuel system

(a) Check the pressure of the fuel system Refer to "Chapter 12A. Fuel system- precaution")
Check whether the result is normal?
Yes > Go to Step 9.
No > Maintain or replace the components or circuit of the fuel system, if fuel pressure is lower than 400
kPa, and go to next step.

6. Check the fuel supply of the fuel system

(a) Check for leakage in the fuel intake pipe.
(b) Check whether the gasoline cleaner is clogged.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

7. Check the injector

(a) Pull out the connector of the injector.
(b) Pull out the fuel delivery pipe and injector together.
(c) Directly apply battery 12V voltage to the injector.
(d) Each injector shall inject standard volume of fuel, and it shall be pulverized evenly.

CAUTION
While checking the spraying state of the injector, if spraying looks like a " column " instead of a “cone”,
or the injectors of the four cylinders inject different volumes of fuel (difference greater than 5ml), injectors
shall be replaced. Check whether there is colloidal material in the injector nozzle, if yes, it shall be soaked
in detergent and sprayed, otherwise it will lead to insufficient injected fuel quantity or poor acceleration,
etc.
 DIAGNOSTICS - ENGINE CONTROL SYSTEM 04-145

DANGER
While checking the spraying state of the injector, if spraying looks like a " column " instead of a “cone”,
or the injectors of the four cylinders inject different volumes of fuel (difference greater than 5ml), injectors
shall be replaced. Check whether there is colloidal material in the injector nozzle, if yes, it shall be soaked
in detergent and sprayed, otherwise it will lead to insufficient injected fuel quantity or poor acceleration,
etc.
• Put a mark " caution: Flammable " in the working area.
• Jobs shall be carried out in well-ventilated area, and a carbon dioxide fire extinguisher shall be 04
equipped.
• Smoking shall be strictly forbidden while carrying out work which is relevant to the fuel system.
The working area shall be far away from flame and spark.
• Put the discharged fuel in explosion-proof containers.

Check whether the result is normal?

Yes > go to next step.
No > Clean injector Recheck the working state of the fuel injector If the injector still works abnormally,
change it.

8. Check the secondary ignition system

(a) Pull out the fuel of the fuel spray nozzle.
(b) Pull out the high-voltage line, unplug the spark plug.
(c) Connect spark plug to the high voltage line, and contact the negative pole of the spark plug with the
cylinder body.
(d) Check engine to test secondary ignition system
Correct result: When the engine rotates, strong blue and white spark can be seen on each spark
plug.

Check whether the result is normal?

Yes > Go to Step 10.
No > Go to the next step.

9. Check the secondary ignition system

(a) Check the resistance value of high-voltage coil, and clean the terminals of connector.
Resistance: ≥ 4 k
(b) Check whether the spark plug accumulates carbons, carbon mark, whether the ceramic insulating part
is cracked and leaks electricity; whether the interval is normal; whether the positive and negative poles
are burned corrupt; and clean the spark plug.
Check whether the result is normal?
Yes > go to next step.
No > Clean, replace faulty components

10 . Check the pressure of the cylinders

(a) Carry out compression pressure test for the cylinders.
The pressure of each cylinder: 1270 kPa
The limit value of each cylinder: 880 kPa
 04-146 DIAGNOSTICS - ENGINE CONTROL SYSTEM

The difference of limit value of cylinders: Can't exceed 25%

Check whether the result is normal?

Yes > Go to Step 12.
No > Go to the next step.

04 11 . Check engine for automatic timing

(a) Check whether the mark of engine timing gear is aligned, damaged, whether the belt becomes loose or
jump tooth.
Check whether the result is normal?
Yes > go to next step.
No > Carry out timing belt aligning operation or change the timing belt.

12 . Check the machine of the engine.

(a) Use an inner sight glass to observe the inside condition of the cylinder.
(b) Observe the change of feedback voltage.
(c) Disintegrate the engine and maintain the interior trouble.
Clean accumulated carbon or dismantle and check the engine cylinder cover. Check the
air throttle, air intake manifold for accumulated carbon. For instance: cylinder is not sealed
tightly due to too big clearance between the piston-ring and cylinder body, the cylinder
cushion leaks, the valve conduit becomes loose, the valve is not be closed tightly, the valve
accumulates carbon.

Check whether the result is normal?

Yes > go to next step.
No > Maintain the interior trouble of the engine.

13 . Replace the ECM

(a) Replace the ECM. (Refer to "Chapter 11. Engine Control System - engine control module")
(b) Check the engine dataflow, and confirm that no more such engine phenomena, and the system is normal.
 DIAGNOSTICS - SRS SYSTEM 04-147

SRS SYSTEM
PRECAUTION
DANGER

This model equipped with SRS system. Failure to carry out service operations in the correct sequence
may cause the SRS to unexpectedly deploy during servicing, or even lead to critical accident. Furthermore,
an operational mistake may also prevent the SRS from normal operations. Operation can only be started
04
90 seconds after the ignition switch is turned to the “LOCK” position and the negative (-) cable and
the positive (+) cable are disconnected from the battery. (The SRS is equipped with backup power supply.
Therefore, if any operation is taken within 90 seconds after disconnecting the battery negative (-) cable
and positive (+) cable, the SRS may deploy suddenly.) Do not expose the horn button assembly to heat
or open fire.

CAUTION

Since it is difficult to identify the failure of the SRS, Diagnostic Trouble Code (DTC) is an essential source
of information during troubleshooting. Thus, when troubleshooting the SRS, be sure to remember to
check the DTCs before disconnecting the battery. Even after a minor impact that the SRS assembly does
not deploy, it is always important to check the horn button assembly and airbag ECU. In case impact
may be caused on SRS control module when conducting maintenance, do remember to disconnect SRS
control module ECM first. Never use any SRS part removed from another vehicle. If replacement is
required, be sure to use new spare parts. Do not disassemble the horn button assembly. If the horn
button assembly has been dropped, or there are cracks, dents or other faults on the housing, replace
it with a new one. Use a multimeter with high resistance to troubleshoot the SRS electrical circuits.
During servicing, be sure to follow the instructions on the labels attached to the SRS components. After
repairing the SRS, remember to check the airbag indicator lamp. When the negative (-) cable is
disconnected from the battery, the memory of the clock and the radio system will be reset. So before
repairing, record all necessary data. At the end of repairing, reset the radio system and the clock. Never
use any backup power supply from another vehicle, which may reset the memory of the systems. The
backup power supply will power up the SRS, which may unexpectedly deploy the airbag during servicing.
 04-148 DIAGNOSTICS - SRS SYSTEM

COMPONENTS DRAWING

04

1 Automobile body fuse box 4 Clock Spring

2 Passenger SRS assembly 5 Airbag Control Module
3 Horn button assembly 6 Assembly instrument
 DIAGNOSTICS - SRS SYSTEM 04-149

SRS CONTROL MODULE CONNECTOR

04

Number Definition Colour Number Definition Colour

1 - - 26 - -
2 - - 27 - -
3 - - 28 - -
4 - - 29 - -
lock catch switch
5 Switch Power Yellow-white 30 input, driver seat Black-Red
belt
6 ground Black 31 - -
7 - - 32 - -
8 - - 33 CAN L Blue-yellow
9 - - 34 CAN H Red-white
Main air bag+,
10 brown 35 - -
operator's seat
Main air bag+,
11 Brown-red 36 - -
operator's seat
lock catch switch
12 - - 37 input, driver seat Yellow-black
belt
Preloading, driv-
13 Brow-yellow 38 - -
er’s seat belt
Preloading, driv-
14 Brown-green 39 - -
er’s seat belt
15 - - 40 - -
Preloading, assis-
16 tant driver’s Green-black 41 - -
seat belt
Preloading, assis-
17 tant driver’s Green-red 42 - -
seat belt
Main air bag+,
18 assistant driver's green 43 - -
seat
 04-150 DIAGNOSTICS - SRS SYSTEM

Number Definition Colour Number Definition Colour

Main air bag+,
19 assistant driver's Yellow 44 - -
seat
20 - - 45 - -
21 - - 46 - -
04 22 - - 47 - -
23 - - 48 - -
24 - - 49 - -
25 - - 50 - -
 DIAGNOSTICS - SRS SYSTEM 04-151

DIAGNOSTIC DTC CODE LIST

CAUTION

When checking DTC in the checking module, if certain DTC displayed, then the circuit of the code listed
in the following list should be checked.The detailed description of each DTC can refer to corresponding
pages.

DTC code Diagnostic items (DTC definition) Trouble location 04

• Battery
B1101 Over-high power supply voltage • Charging system
• Systematic power supply

• fuse
B1102 Over-low power supply voltage • Systematic power supply
• SRS Control Module

• SRS circuit, driver

High resistance , driver’s Air bag • Driver’s SRS Assembly
B1346
igniter • SRS Control Module

• SRS circuit, driver

Low resistance , driver’s Air bag • Driver’s SRS Assembly
B1347
igniter • SRS Control Module

• SRS circuit, driver

• Driver’s SRS Assembly
B1348 Ground, driver’s Air bag igniter
• SRS Control Module

• SRS circuit, driver

• Driver’s SRS Assembly
B1349 Battery, driver’s Air bag igniter
• SRS Control Module

• SRS system circuit, assistant

driver
High resistance, assistant driver’s • Assistant driver’s SRS Assem-
B1352
Air bag igniter
bly
• SRS Control Module

• SRS system circuit, assistant

driver
Low resistance, assistant driver’s • Assistant driver’s SRS Assem-
B1353
Air bag igniter
bly
• SRS Control Module

• SRS system circuit, assistant

driver
Ground, assistant driver’s air bag • Assistant driver’s SRS Assem-
B1354
igniter
bly
• SRS Control Module

Battery, assistant driver’s air bag • SRS system circuit, assistant

B1355
igniter driver
 04-152 DIAGNOSTICS - SRS SYSTEM

DTC code Diagnostic items (DTC definition) Trouble location

• Assistant driver’s SRS Assem-
bly
• SRS Control Module

•Preloading circuit, driver’s seat

belt
High resistance of the preloading ig- •
04 B1361 Preloading circuit, driver’s seat
niter, driver’s seat belt
belt
• SRS Control Module

• Preloading circuit, driver’s seat

belt
Low resistance of the preloading ig- • Preloading circuit, driver’s seat
B1362
niter, driver’s seat belt
belt
• SRS Control Module

• Preloading circuit, driver’s seat

belt
Ground of the preloading igniter, • Preloading circuit, driver’s seat
B1363
driver’s seat belt
belt
• SRS Control Module

• Preloading circuit, driver’s seat

belt
Battery of the preloading igniter, • Preloading circuit, driver’s seat
B1364
driver’s seat belt
belt
• SRS Control Module

•Preloading circuit, assistant driv-

er’s seat belt
High resistance of the preloading ig- •
B1367 Preloading assembly, assistant
niter, assistant driver’s seat belt
driver’s seat belt
• SRS Control Module

• Preloading circuit, assistant driv-

er’s seat belt
Preloading igniter ground, assistant • Preloading assembly, assistant
B1368
driver’s seat belt
driver’s seat belt
• SRS Control Module

• Preloading circuit, assistant driv-

er’s seat belt
Preloading igniter battery, driver’s • Preloading assembly, assistant
B1369
seat belt
driver’s seat belt
• SRS Control Module

• Preloading circuit, assistant driv-

er’s seat belt
Preloading igniter battery, driver’s • Preloading assembly, assistant
B1370
seat belt
driver’s seat belt
• SRS Control Module
 DIAGNOSTICS - SRS SYSTEM 04-153

DEFECT PHENOMENON FORM

CAUTION

If defects code fails to appear when checking DTC, and the components of the system don’t work
normally, check the circuit in line with the defect phenomenon listed in the following form.

When replacing SRS control module, assembly instrument and so on, turn the ignition switch to “OFF”,
and disconnect negative(-) cable of the battery. Check the table below to find the cause of the problem. 04
The numbers rank the possibility of the causes. Check each part in order and replace the part if necessary.

Defect phenomenon Trouble location Reference

Chapter4, Diagnosis of SRS system
1. Indicator light circuit, SRS and the indicator light of SRS is con-
stantly on.
SRS indictor light is constantly on.
Chapter4, Diagnosis of SRS system
2. SRS Control Module and the indicator light of SRS is con-
stantly on.
Chapter4, Diagnosis of SRS system
1. Indicator light circuit, SRS
and the indicator light of SRS is off.
SRS indictor light is off.
Chapter4, Diagnosis of SRS system
2. SRS Control Module
and the indicator light of SRS is off.
 04-154 DIAGNOSTICS - SRS SYSTEM

B 1102 OVER-LOW THE POWER SUPPLY VOLTAGE

Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• If the speed of the vehicle is 3 • fuse
kilometer/hour, the voltage of ig- •
B1102 Systematic power supply
nition switch is 10V or lower than
• SRS Control Module
04 10 seconds or longer time.

Circuit diagram
 DIAGNOSTICS - SRS SYSTEM 04-155

Diagnostic steps

1. Check harness (SRS control module-lock spring)

(a) Confirm the ignition switch is closed, and disconnect the negative pole of the battery for more than 90
seconds.

(b) Disconnect the connector of lock spring C009.

04

(c) Disconnect SRS control module connector C016.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C016 (6) ground ＜2Ω

Check whether the result is normal?

 04-156 DIAGNOSTICS - SRS SYSTEM

Yes> go to step 2
No > Maintenance or replace harness.

2. Check fuse and relay (vehicle body fuse box)

(a) Confirm the ignition switch is closed, and disconnect the negative pole of the battery for more than 90
seconds.

04 (b) When ignition switch is on, check fuse F24 of the fuse box
on the vehicle body.
Standard voltage
Multimeter connection Standard value
F24-ground
Battery voltage
F24-ground

Check whether the result is normal?

Yes> go to step 3
No> replace fuse

3. Check the harness (fuse box of vehicle body-SRS control module)

 DIAGNOSTICS - SRS SYSTEM 04-157

(a) When ignition switch is off, pull out fuse F24 of the fuse
box and check the resistance value between the connector
C016 for the fuse box and SRS control module.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C016（5）-F24 ＜2Ω 04

(b) Check the resistance between SRS control module

connector C016 and the ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C016 (5) ground ≥ 1 MΩ

Check whether the result is normal?

Yes> Replace SRS Control Module
No> replace harness
 04-158 DIAGNOSTICS - SRS SYSTEM

B1346 HIGH RESISTANCE, DRIVER’S AIR BAG IGNITER

B 1347LOW RESISTANCE, DRIVER’S AIR BAG IGNITER
Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• Short circuit of SRS harness • SRS circuit, driver
04 • Open circuit of SRS harness
B1346 • Driver’s SRS Assembly
• SRS defects, driver
B1347 • Clock Spring
• Defects, clock spring
• SRS Control Module
• SRS Control Module defects

Circuit diagram
 DIAGNOSTICS - SRS SYSTEM 04-159

Diagnostic steps

1. Check clock spring

(a) Confirm the ignition switch is closed, and disconnect the negative pole of the battery for more than 90
seconds.

(b) Dismantle horn button assembly and disconnect the

driver's SRS assembly connector.
(c) Disconnect the connector of clock spring C010. 04

(d) Check the resistance between clock spring socket C010

and driver’s SRS assembly connector.
Standard voltage
Multimeter connection Standard value
C010 (1) Driver’s SRS assem-
bly connector (1)
＜2Ω
C010 (2) Driver’s SRS assem-
bly connector (2)

Check whether the result is normal?

Yes> go to step 2
No> Replace the clock spring

2. Check the harness (SRS control module-clock spring)

 04-160 DIAGNOSTICS - SRS SYSTEM

(a) Disconnect SRS control module connector C016.

04

(b) Measure the resistance between SRS control module

connector C016 and clock spring Connector C010.
Standard voltage
Multimeter connection Standard value
C016(10) - C010(1)
＜2Ω
C016(11) - C010(2)

Check whether the result is normal?

Yes> Replace Driver’s SRS assembly, and use diagnostic unit to remove diagnostic defect code; if the
defect code is not removed, replace SRS control module.
No > Maintenance or replace harness.
 DIAGNOSTICS - SRS SYSTEM 04-161

B1348 GROUND, DRIVER’S AIR BAG IGNITION

Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• Ground short circuit of SRS har- • SRS circuit, driver
ness •
• SRS defects, driver Driver’s SRS Assembly
B1348 • Clock Spring
• Defects, clock spring 04
• SRS Control Module
• SRS Control Module defects

Circuit diagram
 04-162 DIAGNOSTICS - SRS SYSTEM

Diagnostic steps

1. Check clock spring

(a) Confirm the ignition switch is closed, and disconnect the negative pole of the battery for more than 90
seconds.

(b) Dismantle horn button assembly and disconnect the

driver's SRS assembly connector.
04 (c) Disconnect the connector of clock spring C010.

(d) Check the resistance between clock spring socket C010

and driver’s SRS assembly connector.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C010 (1) Driver’s SRS assem-
bly connector (1)
＜2Ω
C010 (2) Driver’s SRS assem-
bly connector (2)
 DIAGNOSTICS - SRS SYSTEM 04-163

(e) Check the resistance between clock spring socket C010

and driver’s SRS assembly connector.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C010 (1) ground
≥ 1 MΩ
C010 (2) ground 04

Check whether the result is normal?

Yes> go to step 2
No> Replace the clock spring

2. Check the harness (SRS control module-clock spring)

(a) Disconnect SRS control module connector C016.
 04-164 DIAGNOSTICS - SRS SYSTEM

(b) Measure the resistance between SRS control module

connector C016 and clock spring Connector C010.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
C016(10) - C010(1)
＜2Ω
04 C016(11) - C010(2)

Check whether the result is normal?

Yes> Replace Driver’s SRS assembly, and use diagnostic unit to remove diagnostic defect code; if the
defect code is not removed, replace SRS control module.
No> replace harness
 DIAGNOSTICS - SRS SYSTEM 04-165

B1349 CONNECTION BATTERY, DRIVER’S AIR BAG IGNITER

Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• Battery short circuit of SRS har- • SRS circuit, driver
ness •
• SRS defects, driver Driver’s SRS Assembly
B1349 • Clock Spring
• Defects, clock spring 04
• SRS Control Module
• SRS Control Module defects

Circuit diagram
 04-166 DIAGNOSTICS - SRS SYSTEM

Diagnostic steps

1. Check harness (SRS control module-lock spring)

(a) Turn off the ignition switch, and disconnect the negative pole of the battery for more than 90 seconds.

(b) Dismantle horn button assembly and disconnect the

driver's SRS assembly connector.

04

(c) Disconnect SRS control module connector C016.

(d) Disconnect the connector of clock spring C010.
(e) Connect the negative pole of the battery and turn on
ignition switch to “ON”.

(f) Disconnect the connector of clock spring C010.

Standard voltage
Multimeter connection Standard value
C010 (1) ground
0V
C010 (2) ground

Check whether the result is normal?

Yes> go to step 2
 DIAGNOSTICS - SRS SYSTEM 04-167

No> replace harness

2. Check clock spring

(a) Turn off ignition switch and connect Clock spring connector C010.

(b) Turn on ignition switch to “ON”, and check driver’s

SRS connector.
Standard voltage
04
Multimeter connection Standard value
Driver’s SRS connector (1)
ground
0V
Driver’s SRS connector (2)
ground

Check whether the result is normal?

Yes> Replace SRS Control Module
No> Replace the clock spring
 04-168 DIAGNOSTICS - SRS SYSTEM

B1352HIGH RESISTANCE , PASSENGERS’ AIR BAG IGNITER

B1352 LOW RESISTANCE, PASSENGERS’ AIR BAG IGNITER
Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• Short circuit of SRS harness • Passenger SRS circuit
04 B1352 • Open circuit of SRS harness • Passenger SRS assembly
B1353 • Passenger SRS defect
• SRS Control Module
• SRS Control Module defects

Circuit diagram
 DIAGNOSTICS - SRS SYSTEM 04-169

Diagnostic steps

1. Check the harness (Passengers’ air bag assembly-SRS control module)

(a) Confirm the ignition switch is closed, and disconnect the negative pole of the battery for more than 90
seconds.
(b) Dismantle horn button assembly and disconnect the driver's SRS assembly connector.
(c) Disconnect Passengers’ air bag assembly connector C030.
04
(d) Disconnect SRS control module connector C016.

(e) Measure the resistance between SRS control module

connector C016 and Passengers’ air bag connector
C030.
Standard voltage
Multimeter connection Standard value
C016(18) - C010(1)
＜2Ω
C016(19) - C010(2)

Check whether the result is normal?

Yes> Replace passengers’ SRS assembly, and use diagnostic unit to remove diagnostic defect code;
if the defect code is not removed, replace SRS control module.
No > Maintenance or replace harness.
 04-170 DIAGNOSTICS - SRS SYSTEM

B1354 GROUND, PASSENGERS’ AIR BAG IGNITER

Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• Ground short circuit of SRS har- • Passenger SRS circuit
ness
B1354 • Passenger SRS assembly
• Passenger SRS defect
04 • SRS Control Module
• SRS Control Module defects

Circuit diagram
 DIAGNOSTICS - SRS SYSTEM 04-171

Diagnostic steps

1. Check passengers’ air bag assembly (passengers’ air bag assembly-ground)

(a) Confirm the ignition switch is closed, and disconnect the negative pole of the battery for more than 90
seconds.
(b) Disconnect Passengers’ air bag assembly connector C030.

(c) Disconnect SRS control module connector C016.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C016 (1) ground
≥ 1 MΩ
C016 (2) ground

Check whether the result is normal?

Yes> go to step 2
No> Replace passengers’ air bag assembly.

2. Check the harness (Passengers’ air bag assembly-SRS control module)

(a) Disconnect Passengers’ air bag assembly connector C030.
 04-172 DIAGNOSTICS - SRS SYSTEM

(b) Disconnect SRS control module connector C016.

04

(c) Measure the resistance between SRS control module

connector C016 and Passengers’ air bag connector
C030.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C016(18) - C010(1)
＜2Ω
C016(19) - C010(2)

Check whether the result is normal?

Yes> Replace passengers’ air bag assembly, and use diagnostic unit to remove diagnostic defect
code; if the defect code is not removed, replace SRS control module.
No> replace harness
 DIAGNOSTICS - SRS SYSTEM 04-173

B 1355-PASSENGERS’ AIR BAG IGNITER CONNECTION BATTERY

Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• Battery short circuit of SRS har- • Passenger SRS circuit
ness
B1355 • Passenger SRS assembly
• Passenger SRS defect
• SRS Control Module 04
• SRS Control Module defects

Circuit diagram
 04-174 DIAGNOSTICS - SRS SYSTEM

Diagnostic steps

1. Check passengers’ SRS (SRS control module-passengers’ SRS)

(a) Turn off the ignition switch, and disconnect the negative pole of the battery for more than 90 seconds.
(b) Disconnect Passengers’ air bag assembly connector C030.

(c) Disconnect SRS control module connector C016.

(d) Connect the negative pole of the battery and turn on
04
ignition switch to “ON”.

(e) Check passengers’ air bag assembly connector C030.

Standard voltage
Multimeter connection Standard value
C016 (1) ground
0V
C016 (1) ground

Check whether the result is normal?

Yes> Replace SRS Control Module
No> Replace passengers’ air bag assembly.
 DIAGNOSTICS - SRS SYSTEM 04-175

B1361-HIGH RESISTANCE OF THE PRELOADING IGNITER,

DRIVER’S SEAT BELT
B1362-LOW RESISTANCE OF PRELOADING IGNITER, DRIVER’S
SEAT BELT
Diagnostic Logic
04
DTC code DTC inspection conditions Trouble location
• Short circuit of seat belt, preload-
ing harness • Preloading circuit, driver’s seat
• Open circuit of seat belt , belt
B1361 preloading harness • Preloading circuit, driver’s seat
B1362 • Preloading defects, driver’s seat belt
belt • Preloading control module de-
• Preloading control module de- fects, seat belt
fects, seat belt

Circuit diagram
 04-176 DIAGNOSTICS - SRS SYSTEM

Diagnostic steps

1. Check the harness (Preloading assembly, driver’s seat belt—SRS control module)
(a) Confirm the ignition switch is closed, and disconnect the negative pole of the battery for more than 90
seconds.

(b) Disconnect preloading assembly connector D002, driver’s

seat belt.
04

(c) Disconnect SRS control module connector C016.

(d) Measure the resistance between SRS control module

connector C016 and Passengers’ air bag connector
D002.
Standard voltage
Multimeter connection Standard value
C016(13) - C010(1)
＜2Ω
C016(14) - C010(2)

Check whether the result is normal?

 DIAGNOSTICS - SRS SYSTEM 04-177

Yes> Replace Driver’s seat belt preloading assembly, and use diagnostic unit to remove diagnostic
defect code; if the defect code is not removed, replace SRS control module.
No > Maintenance or replace harness.

04
 04-178 DIAGNOSTICS - SRS SYSTEM

GROUND OF THE PRELOADING IGNITER, DRIVER’S SEAT BELT

Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• The preloading harness is short •
Preloading circuit, driver’s seat
circuit to the ground, driver’s
belt
seat belt
04 • Preloading circuit, driver’s seat
• Preloading defects, driver’s seat
B1363
belt
belt
• Preloading control module, driv-
• Preloading control module de-
er’s seat belt
fects, driver’s seat belt

Circuit diagram
 DIAGNOSTICS - SRS SYSTEM 04-179

Diagnostic steps

1. Check the preloading assembly (preloading assembly –ground, driver’s seat belt), driver's seat
belt.
(a) Confirm the ignition switch is closed, and disconnect the negative pole of the battery for more than 90
seconds.

(b) Disconnect preloading assembly connector D002, driver’s

seat belt. 04

(c) Disconnect SRS control module connector C016.

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
D002(1) ground
≥ 1 MΩ
D002(2) ground
 04-180 DIAGNOSTICS - SRS SYSTEM

Check whether the result is normal?

Yes> go to step 2
No ? Replace preloading assembly, driver’s seat

2. Check the harness (Preloading assembly, driver’s seat belt—SRS control module)
(a) Disconnect preloading assembly connector D002, driver’s
04 seat belt.

(b) Disconnect SRS control module connector C016.

(c) Measure the resistance between SRS control module

connector C016 and driver’s seat belt preloading
assembly connector D002.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C016(13) - C010(1)
＜2Ω
C016(14) - C010(2)

Check whether the result is normal?

 DIAGNOSTICS - SRS SYSTEM 04-181

Yes > Replace preloading assembly- driver’s seat belt, and use diagnostic unit to remove diagnostic
defect code; if the defect code is not removed, replace SRS control module.
No> replace harness

04
 04-182 DIAGNOSTICS - SRS SYSTEM

B1364-PRELOADING IGNITER CONNECTION BATTERY, DRIVER’S

SEAT BELT
Diagnostic code
DTC code DTC inspection conditions Trouble location
• The preloading harness is short •
Preloading circuit, driver’s seat
04 circuit to the ground, driver’s
belt
seat belt
• Preloading circuit, driver’s seat
• Preloading defects, driver’s seat
B1364
belt
belt
• Preloading control module, driv-
• Preloading control module de-
er’s seat belt
fects, driver’s seat belt

Circuit diagram
 DIAGNOSTICS - SRS SYSTEM 04-183

Diagnostic steps

1. Check preloading assembly, driver’s seat belt (SRS control module-preloading assembly,
driver’s seat belt)
(a) Turn off the ignition switch, and disconnect the negative pole of the battery for more than 90 seconds.

(b) Disconnect preloading assembly connector D002, driver’s

seat belt.
04

(c) Disconnect SRS control module connector C016.

(d) Connect the negative pole of the battery and turn on
ignition switch to “ON”.

(e) Check preloading assembly connector D002, driver’s

seat belt.
Standard voltage
Multimeter connection Standard value
D002(1) ground
0V
D002(2) ground

Check whether the result is normal?

 04-184 DIAGNOSTICS - SRS SYSTEM

Yes> Replace SRS Control Module

No> Preloading assembly, driver’s seat belt

04
 DIAGNOSTICS - SRS SYSTEM 04-185

B 1367-HIGH RESISTANCE OF THE PRELOADING IGNITER,

PASSENGER’S SEAT BELT
B 1368-LOW RESISTANCE OF THE PRELOADING IGNITER,
PASSENGERS’ SEAT BELT
Diagnostic Logic
04
DTC code DTC inspection conditions Trouble location
• Short circuit of seat belt, preload-
ing harness • Preloading circuit, driver’s seat
• Open circuit of seat belt , belt
B1367 preloading harness • Preloading circuit, driver’s seat
B1368 • Preloading defects, driver’s seat belt
belt • Preloading control module de-
• Preloading control module de- fects, seat belt
fects, seat belt

Circuit diagram
 04-186 DIAGNOSTICS - SRS SYSTEM

Diagnostic steps

1. Check the harness (Preloading assembly, passengers’ seat belt—SRS control module)
(a) Confirm the ignition switch is closed, and disconnect the negative pole of the battery for more than 90
seconds.

(b) Disconnect preloading assembly connector D009,

passengers’ seat belt.
04

(c) Disconnect SRS control module connector C016.

(d) Measure the resistance between SRS control module

connector C016 and Passengers’ air bag connector
D009.
Standard voltage
Multimeter connection Standard value
C016(16) - C009(1)
＜2Ω
C016(17) - C009(2)

Check whether the result is normal?

 DIAGNOSTICS - SRS SYSTEM 04-187

Yes> Replace passenger’s seat belt preloading assembly, and use diagnostic unit to remove diagnostic
defect code; if the defect code is not removed, replace SRS control module.
No > Maintenance or replace harness.

04
 04-188 DIAGNOSTICS - SRS SYSTEM

B1369 PRELOADING IGNITER GROUND, PASSENGERS’ SEAT

BELT
Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• The preloading harness is short •
circuit to the ground, passen- Preloading circuit, passengers’
04 seat belt
gers’ seat belt
• Preloading assembly, passen-
• Preloading defects, passengers’
B1369
gers’ seat belt
seat belt
• Preloading control module , pas-
• Preloading control module de-
sengers’ seat belt
fects, passengers’ seat belt

Circuit diagram
 DIAGNOSTICS - SRS SYSTEM 04-189

Diagnostic steps

1. Check the preloading assembly (preloading assembly –ground, passengers’ seat belt),
passengers’ seat belt.
(a) Confirm the ignition switch is closed, and disconnect the negative pole of the battery for more than 90
seconds.

(b) Disconnect preloading assembly connector D009,

04
passengers’ seat belt.

(c) Disconnect SRS control module connector C016.

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C009 (1) ground
≥ 1 MΩ
C009 (2) ground
 04-190 DIAGNOSTICS - SRS SYSTEM

Check whether the result is normal?

Yes> go to step 2
No> Replace preloading assembly, passengers’ seat belt

2. Check the harness (Preloading assembly, passengers’ seat belt—SRS control module)
(a) Disconnect preloading assembly connector D009,
04 passengers’ seat belt.

(b) Disconnect SRS control module connector C016.

(c) Measure the resistance between SRS control module

connector C016 and Passengers’ preloading assembly
connector D009.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C016(16) - C009(1)
＜2Ω
C016(17) - C009(2)

Check whether the result is normal?

 DIAGNOSTICS - SRS SYSTEM 04-191

Yes> Replace passenger’s seat belt preloading assembly, and use diagnostic unit to remove diagnostic
defect code; if the defect code is not removed, replace SRS control module.
No> replace harness

04
 04-192 DIAGNOSTICS - SRS SYSTEM

B1370-PRELOADING IGNITER CONNECTION BATTERY,

PASSENGERS' SEAT BELT
Diagnostic Logic
DTC code DTC inspection conditions Trouble location
• The preloading harness is short •
circuit to the ground, passen- Preloading circuit, passengers’
04 seat belt
gers’ seat belt
• Preloading assembly, passen-
• Preloading defects, passengers’
B1370
gers’ seat belt
seat belt
• Preloading control module , pas-
• Preloading control module de-
sengers’ seat belt
fects, passengers’ seat belt

Circuit diagram
 DIAGNOSTICS - SRS SYSTEM 04-193

Diagnostic steps

1. Check preloading assembly, passengers’seat belt (SRS control module-preloading assembly,

passengers’seat belt)
(a) Turn off the ignition switch, and disconnect the negative pole of the battery for more than 90 seconds.

(b) Disconnect preloading assembly connector D009,

passengers’ seat belt.
04

(c) Disconnect SRS control module connector C016.

(d) Connect the negative pole of the battery and turn on
ignition switch to “ON”.

(e) Check preloading assembly connector D009, passengers’

seat belt.
Standard voltage
Multimeter connection Standard value
C009 (1) ground
0V
C009 (2) ground

Check whether the result is normal?

 04-194 DIAGNOSTICS - SRS SYSTEM

Yes> Replace SRS Control Module

No> Replace preloading assembly, passengers’ seat belt

04
 DIAGNOSTICS - TRANSFER GEAR 04-195

TRANSFER GEAR
DEFECT PHENOMENON FORM
When checking DTC in the checking module, if certain DTC displayed, then the circuit of the code
listed in the following list should be checked. The detailed description of each DTC can refer to
corresponding pages.
DTC code Diagnostic items (DTC definition) Trouble location 04
• Ground harness, gear shift motor
• Signal output harness, gear shift
motor
U0101 Signal failure, Gears • Gear shift motor
• Raider module, electric timeshar-
ing
• Ground harness, gear shift motor
• Signal output harness, gear shift
motor
U0402 Signal failure, Gears • Gear shift motor
• Raider module, electric timeshar-
ing
• Fuse, vehicle body
• Vehicle speed sensor harness,
U0155 Signal failure, vehicle speed • Vehicle speed sensor,
• Assembly instrument

• Fuse, vehicle body

• Vehicle speed sensor harness,
U0423 Signal failure, vehicle speed • Vehicle speed sensor,
• Assembly instrument

• Clutch switch
U0100 signal failure, clutch pedal • Clutch switch harness
U0100
position • Control module, engine

• Clutch switch
U0100 signal failure, clutch pedal • Clutch switch harness
U0401
position • Control module, engine

• Raider module, electric timeshar-

U0001 CAN bus disconnection ing
• CAN harness

• Battery
Systematic voltage exceeds normal • fuse
P0560
work scope • BCM control unit

• Electromagnetic clutch coil

• Electromagnetic clutch coil wire
P1728 Synchronization coil defects • Raider module, electric timeshar-
ing
 04-196 DIAGNOSTICS - TRANSFER GEAR

DTC code Diagnostic items (DTC definition) Trouble location

• Electromagnetic clutch coil
• Electromagnetic clutch coil wire
P1729 Synchronization coil defects • Raider module, electric timeshar-
ing
• Electromagnetic clutch coil
• Electromagnetic clutch coil wire
04 P1730 Synchronization coil defects • Raider module, electric timeshar-
ing
• Control module wire, front axle
clutch
Signal failure feedback, front axle • Control module, front axle clutch
P1734
clutch • Raider module, electric timeshar-
ing
• Fuse, vehicle body
• Switch wire
P1738 Switch defects, model choice • Central control switch block
• Raider module, electric timeshar-
ing
• Gear shift motor assembly
• Motor harness
P1780 ,Motor failure, gear shift • Raider module, electric timeshar-
ing
• Gear shift motor assembly
• Motor harness
P1781 ,Motor failure, gear shift • Raider module, electric timeshar-
ing
• Gear shift motor assembly
• Motor harness
P1782 ,Motor failure, gear shift • Raider module, electric timeshar-
ing
 DIAGNOSTICS - TRANSFER GEAR 04-197

U0101 SIGNAL FAILURE, GEAR

U0402 SIGNAL FAILURE, GEAR
Circuit diagram

04
 04-198 DIAGNOSTICS - TRANSFER GEAR

Diagnostic steps

1. Measure the electrical resistance based on the value in the following form.
(a) Switchover the ignition switch to “OFF”.
Standard electrical resistance (check whether there
existent an open circuit)
04 Multimeter connection Standard value
C040(17)-K001(A) ＜2Ω
C040(18)-K001(A) ＜2Ω
C040(5)-K001(A) ＜2Ω
C040(19)-K001(A) ＜2Ω
C040(20)-K001(A) ＜2Ω

Check whether the result is normal?

Yes> go to step 2
No> replace connection harness

2. Check whether the output signal is normal.

(a) Start the vehicle
(b) Switchover transfer gear switch to different gears .
(c) Check whether there is voltage output.
Check whether the result is normal?
Yes> Replacement motor assembly.
NO> Replace control unit.
 DIAGNOSTICS - TRANSFER GEAR 04-199

SPEEDOMETER DEFECTS
Circuit diagram

04
 04-200 DIAGNOSTICS - TRANSFER GEAR

Diagnostic steps

1. Check operating voltage of the sensor , speedometer

(a) Ignition Switch: OFF.

(b) Disconnect speedometer E001 connector

(c) Ignition Switch: ON.

04

(d) Use multimeter to measure speedometer sensor E001

connector No.1 stitch and No.2 stitch respectively, and the
voltage between No.1 stitch and ground connection.
Standard voltage
Multimeter connection Standard value
E001 (1) - E001 (2)
Battery voltage
E001 (1) ground

Check whether the result is normal?

Yes> go to step 3
No> If both have no voltage, go to step2. If there is voltage between No.1 stitch and ground connection,
repair the open circuit between No.2 stitch of the speed sensor E001 connector and No.7 stitch of
assembly instrument C013 connector .

2. Check supply circuit, speed sensor

 DIAGNOSTICS - TRANSFER GEAR 04-201

(a) Check whether fuse F26 (7.5A) of the body is fusing or

not.

04

(b) Use multimeter to measure the voltage between fuse F26

of the body and ground .
Standard voltage
Multimeter connection Standard value
F26-ground Battery voltage

Check whether the result is normal?

Yes> go to step 3
No> Repair the circuit between fuse box of vehicle body: F26 (7.5A) and No.1 stitch of vehicle speed
sensor E001 connector.

3. Check speedometer sensor

(a) Ignition Switch: OFF.
 04-202 DIAGNOSTICS - TRANSFER GEAR

(b) Dismantle vehicle speed sensor.

(c) Rotate the spindle of vehicle speed sensor.

04

(d) Use multimeter to measure the resistance between No.2

stitch speed sensor E001 connector and No.3 stitch.
Pulse signal: each rotation should have 8 pulse
resistance signal

Check whether the result is normal?

Yes> go to step 4
No> Replace speedometer sensor

4. Check sensor signal circuit, speedometer

(a) Disconnect assembly instrument C013 connector
 DIAGNOSTICS - TRANSFER GEAR 04-203

(b) Use multimeter to measure the resistance between No.3

stitch of speed sensor E001 connector and ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
E001 (3) ground ≥ 1 MΩ

04

(c) Use multimeter to measure the resistance between No.3

stitch speed sensor E001 connector and No.8 stitch of
C013 connector. Standard electrical resistance (check
whether there existent an open circuit)
Multimeter connection Standard value
E001 (3) - C013 (8) ≤2Ω

Check whether the result is normal?

Yes> replace combination instrument assembly.
No > Repair signal circuit between No.3 stitch of speed sensor E001 connector and No.8 stitch of
combination instrument C013 connector
 04-204 DIAGNOSTICS - TRANSFER GEAR

U0100 SIGNAL FAILURE, CLUTCH PEDAL POSITION

U0401 SIGNAL FAILURE, CLUTCH PEDAL POSITION
Circuit diagram

04
 DIAGNOSTICS - TRANSFER GEAR 04-205

Diagnostic steps

1. Check clutch switch

(a) Pedal and loosen clutch pedal.
(b) Disconnect the connector, clutch switch.
(c) Check the resistance, clutch switch
Multimeter connection Standard value
04
Pedal: C001(1)-COO1(2) ＜2Ω
Loosen: C001(1)-COO1(2) >1KΩ

2. Measure the electrical resistance based on the value in the following form.
(a) Switchover the ignition switch to “OFF”.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
E006 (40) - COO1 (2) ＜2Ω
COO1 (1) ground ＜2Ω

Check whether the result is normal?

Yes> replace engine control unit
No> replace connection harness
 04-206 DIAGNOSTICS - TRANSFER GEAR

U0001 CAN BUS DISCONNECTION

Circuit diagram

04
 DIAGNOSTICS - TRANSFER GEAR 04-207

Diagnostic steps

1. Check the harness

(a) Turn on the ignition switch.
(b) Rotate gear switch, and switchover 2 drive and 4 drive.
(c) Check whether 4 drive of electric timesharing module(8,9) has voltage output.
Check whether the result is normal?
04
Yes> replace CAN wire.
No> Replace 4-drive module, electric timesharing.
 04-208 DIAGNOSTICS - TRANSFER GEAR

P0560 SYSTEMATIC VOLTAGE EXCEEDS NORMAL WORK SCOPE

Circuit diagram

04
 DIAGNOSTICS - TRANSFER GEAR 04-209

Diagnostic steps

1. Check fuse
(a) Ignition Switch: ON.
(b) Check whether the fuse of the interior fuse box: F8 (20A), F26 (7.5A) is fusing or not.
Check whether the result is normal?
Yes> go to step 2
04
No> replace fuse

2. Check power supply circuit of 4-drive module ofelectric timesharing

(a) Ignition Switch: ON.
(b) Disconnect 4-drive module C040 connector of electric
timesharing.
(c) Use multimeter to measure 4-drive module C040 of electric
timesharing.
Voltage between connectors No.13 and 23 ground
connection.
Multimeter connection Standard value
C040 (13) ground
Battery voltage
C040 (23) ground

Check whether the result is normal?

Yes> go to step 3
No> If No.13 stitch of C040 connector of 4-drive electric timesharing has no battery voltage, repair the
open circuit from fuse F8 (20A) to No.13 stitch of C040 connector of the 4-drive module of electric
timesharing. If No.23 stitch of C040 connector of 4-drive electric timesharing has no battery voltage,
repair the open circuit from fuse F26 (7.5A) to No.23 stitch of C040 connector of the 4-drive module of
electric timesharing.

3. Check power supply ground connection of 4-drive module electric timesharing

 04-210 DIAGNOSTICS - TRANSFER GEAR

(a) Ignition Switch: OFF.

(b) Use multimeter to measure the resistance between No.13
and 23 stitch of C040 connector of 4-drive module of
electric timesharing, and the ground respectively.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
04
C040 (12) ground
≤2Ω
C040 (25) ground

Check whether the result is normal?

Yes> replace combination instrument assembly.
No> repair the circuit between No. 12 and 25 Stitches of C040 connector of 4-drive module of electric
timesharing, and the ground.
 DIAGNOSTICS - TRANSFER GEAR 04-211

P1728 SYNCHRONIZATION COIL DEFECTS

P1729 SYNCHRONIZATION COIL DEFECTS
P1730 SYNCHRONIZATION COIL DEFECTS
Circuit diagram

04
 04-212 DIAGNOSTICS - TRANSFER GEAR

Diagnostic steps

1. Check synchronization coil

(a) Disconnect coil connector of electromagnetic clutch.
(b) Check the resistance of electromagnetic clutch coil.

04

Check whether the result is normal?

Yes> go to step 2
No> Replace clutch coil of the battery.

2. Measure the electrical resistance based on the value in the following form.
Standard electrical resistance (check whether there existent an open circuit)
Multimeter connection Standard value
C040(11)-electromagnetic clutch coil (1) ＜2Ω

Check whether the result is normal?

Yes> replace 4-drive module, electric timesharing.
No> replace connection harness
 DIAGNOSTICS - TRANSFER GEAR 04-213

P1734 SIGNAL FAILURE FEEDBACK, FRONT AXLE CLUTCH

Circuit diagram

04
 04-214 DIAGNOSTICS - TRANSFER GEAR

Diagnostic steps

1. Check connection harness

(a) Switchover the ignition switch to “OFF”.
(b) Measure the electrical resistance based on the value in
the following form.
Standard electrical resistance (check whether there
04
existent an open circuit)
Multimeter connection Standard value
C040(3)-C038(9)
＜2Ω
C040(6)-C038(8)

Check whether the result is normal?

Yes> go to step 2
No> replace connection harness

2. Check whether there is signal output.

(a) Turn on the ignition switch.
(b) Pedal clutch pedal.
(c) Swithover 2-drive and 4-drive
(d) Check whether the output signal is normal.
Check whether the result is normal?
Yes> 4-drive module, electric timesharing
No> replace control module , front axle clutch
 DIAGNOSTICS - TRANSFER GEAR 04-215

P1738 DEFECTS, MODE SELECT SWITCH

Circuit diagram

04
 04-216 DIAGNOSTICS - TRANSFER GEAR

Diagnostic steps

1. Check fuse
(a) Ignition Switch: ON.
(b) Check whether the fuse of fuse box: F11(60A), F36(10A) is fusing or not.
Check whether the result is normal?
Yes> go to step 2
04
No> replace fuse

2. Check C039 power supply circuit, mode select switch.

(a) Ignition Switch: ON.
(b) Disconnect C039 connector, mode select switch.
(c) Use multimeter to measure the voltage between No.9 stitch
of C039 connector of mode select switch and the ground
connection.
Multimeter connection Standard value
C039 (9) ground Battery voltage

Check whether the result is normal?

Yes> go to step 3
No> if there is no battery voltage at No.9 stitch of C039 connector of mode select switch, repair the open
circuit between Fuse F36 (10A) and No.6 stitch of C039 connector of the mode select switch.

3. Check power supply ground connection of 4-drive module electric timesharing

(a) Ignition Switch: OFF.
(b) Use multimeter to measure the voltage between No.8 stitch
of C039 connector of mode select switch and the ground
connection.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C039 (8) ground ≤2Ω
 DIAGNOSTICS - TRANSFER GEAR 04-217

Check whether the result is normal?

Yes> go to step 4
No> Repair the circuit between No.8 stitch of C039 connector of mode select switch and ground
connection.

4. Check control circuit.

(a) Ignition Switch: ON. 04
(b) Use multimeter to measure the resistance between No.1
and 2 stitches of C039 connector of mode select switch
and the connectors 4 and 16 of 4-drive module C040of
electric timesharing.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C040(4)- C039(1)
≤2Ω
C040(16)- C039(2)

Check whether the result is normal?

Yes> replace mode select switch.
No>repair the circuit between No.1 and 2 stitches of C039 connector of mode select switch and connectors
4 and 16 of 4-drive module C040 of electric timesharing.
 04-218 DIAGNOSTICS - TRANSFER GEAR

P1780 MOTOR DEFECTS, GEAR SHIFT

P1781 MOTOR DEFECTS, GEAR SHIFT
P1782 MOTOR DEFECTS, GEAR SHIFT
Circuit diagram

04
 DIAGNOSTICS - TRANSFER GEAR 04-219

Diagnostic steps

1. Check motor
(a) Disconnect the connector.
(b) Check whether the resistance of motor is normal or not.
Check whether the result is normal?
Yes> go to step 2
04
No> Replace motor assembly.

2. Check whether the wire is normal of not.

(a) Switchover the ignition switch to “OFF”.
(b) Measure the electrical resistance based on the value in
the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C040(1)-K001(G) ＜2Ω
C040(2)-K001(B) ＜2Ω

Check whether the result is normal?

Yes> Replace 4-drive module, electric timesharing
No> replace connection harness
 04-220 DIAGNOSTICS - REVERSE RADAR SYSTEM

REVERSE RADAR SYSTEM

PRECAUTION
1. Check causes for the abnormal test functions of the reverse radar system:
(a) The probe of reverse radar is covered by mud or snow and other impurities (the test functions will recover
after cleaning the sensor).
(b) The reverse radar sensor is freezed (the test functions will return to normal after the temperature of the
04 sensor rises).
(c) The reverse radar probe is covered.
2. The test scope is affected by the following conditions:
(a) The reverse radar probe is covered by the mud or snow and other impurities.
(b) The vehicle is located at the extremely hot or cold areas.
3. The reverse radar probe may encounter test errors, for example:
(a) The vehicle will travel on rugged roads, unpaved roads or in the tall glasses.
(b) The horn sound, engine sound of motorcycle, the sound of air brake of large vehicles or the ultrasonic
wave of the sonar of another vehicle transmitted from nearby.
(c) In case of heavy rain, or the reverse radar probe exposed to water.
(d) The vehicle slants substantially.
(e) The vehicle is equipped with additional purchased protection rod or wireless core antenna.
(f) The reverse radar probe is covered by the mud or snow and other impurities.
(g) The vehicle is moving toward the edge of the object.
4. The reverse radar probe can not test some objects:
(a) Such as line, rope and other thin objects.
(b) Such as cotton, snow and other material that can absorb ultrasonic
(c) Objects whose edges are sharp
(d) Short and small objects
5. Other precautions:
(a) The reverse radar probe cannot check the objects directly under the beam.
(b) The reverse radar probe cannot check obstacles too close to it.
(c) The reverse radar probe cannot check the obstacles if it drops or is fiercely shocked.
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-221

COMPONENTS DRAWING

04

1 Reverse Radar Probe 3 Fixed bolt, reverse radar controller

2 Reverse Radar Controller
 04-222 DIAGNOSTICS - REVERSE RADAR SYSTEM

SYSTEM SPECIFICATION
1. Summary
After the objects are emitted by ultrasonic wave, a set of reflected wave will return to reverse
radar probe, and radar controller uses the interval time between emission wave and reflected
wave to measure the distance, so as to remind the driver that there are obstacles at the
rear.
04 2. Components functions
Components Function
• Check the distance between the vehicle and the
Reverse Radar Probe obstacles.
• According to the distance of the obstacles, buzz to
Intermittent buzzer inform the driver.
• Judge the rough distance between the vehicles and
Reverse Radar Controller the obstacles based on the signals from ultrasonic
sensor.

Switch, reverse lamp • Send the reverse signal to reverse radar probe.
3. Self-check functions of reverse radar probe
(a) Turn the ignition switch to “ON”.
(b) Transfer to reverse gear and reverse radar probe self checks.
• If the function of reverse radar probe is normal, then the buzzer will buzz once and the buzzing
time is 0.5 seconds.
• If the function of one of the reverse radar probes are abnormal, then the buzzer will buzz two
times and the buzzing time is 0.5 seconds with interval of 0.5 seconds.
• If the function of two of the reverse radar probes are abnormal, then the buzzer will buzz three
times and the buzzing time is 0.5 seconds with interval of 0.5 seconds.
4. The check scope and the segmentation of reverse radar probe
(a) The check scope and the segmentation of reverse radar probe on both sides

5. The distance of the obstacles, the response frequency of the buzzer and buzz methods
Sequence number Obstacle distance Buzz methods of the Buzz methods of the
buzzer buzzer
A 90 - 150 cm Long intermittent sound 1 Hz
B 60 - 90 cm Short intermittent sound 2 Hz
C 40 - 60 cm Rapid intermittent sound 4 Hz
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-223

Sequence number Obstacle distance Buzz methods of the Buzz methods of the
buzzer buzzer
D Within 40± 5 cm Long buzz Long buzz
6. Reverse Radar Controller Stitch

04

Stitch number Connection rod Description Stitch number Connection rod Description
color color
1 - - 9 - -
Left side sensor
2 Grey 10 - -
signal
3 - - 11 - -
4 - - 12 - -
5 - - 13 - -
6 - - 14 - -
Right side sen-
7 - - 15 Green-black
sor signal
Reverse signal
8 Yellow 16 Black ground
input
 04-224 DIAGNOSTICS - REVERSE RADAR SYSTEM

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Defect phenomenon Suspect Area Reference
1. Fuse -

04 Chapter 41 transmission-gear box

2. Reverse switch
Reverse radar system doesn’t work assembly, replacement
at all 3. Harness -
Chapter 8. Information system - re-
4. Reverse Radar Controller
verse radar controller, replacement
Chapter 81 Information system - re-
Reverse Radar Sensor
Reverse radar system self-check ab- verse radar probe, replacement
normal Chapter 8. Information system - re-
2. Reverse Radar Controller
verse radar controller, replacement
Chapter 41 transmission-gear box
1. Reverse switch
assembly, replacement
Before entering reverse gear, reverse Chapter 81 Information system - re-
Reverse Radar Probe
radar appear working phenomenon verse radar probe, replacement
Chapter 8. Information system - re-
3. Reverse Radar Controller
verse radar controller, replacement
1. Fuse -
Enter reverse gear, and the obstacle 2. Harness -
is within the distance of effective
sense, and the reverse radar Chapter 81 Information system - re-
3.Reverse Radar Sensor
doesn’t work (reverse switch, nor- verse radar probe, replacement
mal) Chapter 8. Information system - re-
4. Reverse Radar Controller
verse radar controller, replacement
1. Harness -
Chapter 41 transmission-gear box
2. Reverse switch
Enter reverse gear, no obstacles be- assembly, replacement
hind the vehicles and the reverse Chapter 81 Information system - re-
radar system is abnormal 3.Reverse Radar Sensor
verse radar probe, replacement
Chapter 8. Information system - re-
4. Reverse Radar Controller
verse radar controller, replacement
1. Harness -
The obstacle is within the distance of Chapter 81 Information system - re-
2.Reverse Radar Sensor
effective sense, and the buzzer verse radar probe, replacement
doesn’t work or is abnormal
Chapter 8. Information system - re-
3. Reverse Radar Controller
verse radar controller, replacement
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-225

REVERSE RADAR SYSTEM DOESN’T WORK AT ALL

Circuit diagram

04
 04-226 DIAGNOSTICS - REVERSE RADAR SYSTEM

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.
(b) Turn on interior fuse box (C037).
(c) Pull out reverse radar fuse: F31 (7.5A).
CAUTION
04
Dismantle of the fuse needs special fuse detacher, don’t pull it out with hands directly in order to avoid
damages.

(d) Check interior fuse box (C037) fuse: F31 (7.5A).

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check reverse switch

(a) Ignition Switch: OFF.
(b) Disconnect reverse switch connector E002.

(c) Use multimeter to measure reverse switch.

Standard voltage
Conditions Multimeter connec- Specified value
tion stitch
Place in reverse
1-2 ＜2Ω
gear
Retreat from reserve
1-2 ≥1 MΩ
gear
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-227

Check whether the result is normal?

Yes> go to step 3
No> replace reverse switch

3. Check the harness and connector (ignition switch-fuse)

(a) Ignition Switch: OFF.

(b) Measure the electrical resistance based on the value in 04

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F31 (7.5A) Ignition switch ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the harness and connector (fuse- reverse switch)

(a) Ignition Switch: OFF.
(b) Disconnect reverse switch connector E002.
 04-228 DIAGNOSTICS - REVERSE RADAR SYSTEM

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F31(7.5 A） - E002 （1） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check harness and connector (reverse switch-reverse radar controller)

(a) Ignition Switch: OFF.
(b) Disconnect reverse switch connector E002.
(c) Disconnect connector C015, reverse radar controller

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
E002 (2) - C015 (8) ＜2Ω

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-229

6. Check harness and connector (reverse radar controller-ground)

(a) Ignition Switch: OFF.
(b) Disconnect connector C015, reverse radar controller

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit) 04

Multimeter connection Standard value

C015 (16) ground ≥1MΩ

Check whether the result is normal?

Yes> go to step 7
No > Maintenance or replace harness.

7. Check whether the result is normal?

(a) 1) Ignition Switch: OFF.
(b) Disconnect connector C015, reverse radar controller

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
is short circuit)
Multimeter connection Standard value
C015 (8) ground ≥1MΩ

Check whether the result is normal?

Yes>Replacement (Reverse Radar Controller)
No > Maintenance or replace harness.
 04-230 DIAGNOSTICS - REVERSE RADAR SYSTEM

REVERSE RADAR SYSTEM SELF-CHECK ABNORMAL

Circuit diagram

04
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-231

Diagnostic steps

1. Check reverse radar probe

(a) Ignition Switch: OFF.
(b) Disconnect connector B006, left reverse radar probe
(c) Disconnect connector B009, right reverse radar probe
(d) Replacement of new reverse radar probe. (Refer to Chapter 81. Information system - reverse radar,
replacement of reverse radar probe) 04
CAUTION
Replacement of new reverse radar probe shall be of the same size and model of the old reverse radar
probe
(e) Ignition Switch: ON.
(f) Place in reverse gear
Whether self-checking of the reverse radar is normal or not?
Yes> Replace reverse radar probe.
No> go to step 2

2. Check harness and connector (reverse radar probe-ground)

(a) Ignition Switch: OFF.
(b) Disconnect connector B006, left reverse radar probe
(c) Disconnect connector B009, right reverse radar probe

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C016 (2) ground
≥1MΩ
C016 (2) ground

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connector (reverse radar controller-reverse radar probe)

(a) Ignition Switch: OFF.
(b) Disconnect connector B006, left reverse radar probe
(c) Disconnect connector B009, right reverse radar probe
(d) Disconnect connector C015, reverse radar controller
 04-232 DIAGNOSTICS - REVERSE RADAR SYSTEM

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C015（2） - B006（1）
＜2Ω
04 C015（15） - B009 （1）

Check whether the result is normal or not?

Yes>Replacement (Reverse Radar Controller)
No > Maintenance or replace harness.
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-233

BEFORE ENTERING REVERSE GEAR, REVERSE RADAR APPEAR

WORKING PHENOMENON
Circuit diagram

04
 04-234 DIAGNOSTICS - REVERSE RADAR SYSTEM

Diagnostic steps

1. Check reverse lamp switch

(a) Ignition Switch: OFF.
(b) Disconnect reverse lamp switch connector E002.

(c) Check reverse switch

04 Standard voltage （short circuit or not）

Conditions Multimeter connec- Specified value
tion stitch
Place in reverse
1-2 ＜2Ω
gear
Retreat from reserve
1-2 ≥1MΩ
gear

Check whether the result is normal?

Yes> go to step 2
No> replace reverse switch

2. Check reverse radar controller

(a) Ignition Switch: OFF.
(b) Disconnect connector C015, reverse radar controller
(c) Replacement new reverse radar controller. (Refer to Chapter 81. Information system - reverse radar,
replacement of reverse radar controller)
CAUTION
Replacement of reverse radar controller needs to select the controller of the same size and model.

Check whether the result is normal or not?

Yes>Replacement (Reverse Radar Controller)
No> Remove defect 29 by other means.
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-235

ENTER REVERSE GEAR, AND THE OBSTACLE IS WITHIN THE

DISTANCE OF EFFECTIVE SENSE。THE REVERSE RADAR SYSTEM
DOESN’T WORK
Circuit diagram

04
 04-236 DIAGNOSTICS - REVERSE RADAR SYSTEM

Diagnostic steps

1. Check reverse radar probe

(a) Ignition Switch: OFF.
(b) Disconnect connector D001, left reverse radar probe
(c) Replacement of new reverse radar probe. (Refer to Chapter 81. Information system - reverse radar,
replacement of reverse radar probe)
04 CAUTION
Replacement of reverse radar probe needs to select the probe of the same size and model.
(d) Ignition Switch: ON.
(e) Place in reverse gear
Whether reverse radar is normal or not?
Yes> Replace reverse radar probe.
No> go to step 2

2. Check harness and connector (reverse radar probe-ground)

(a) Ignition Switch: OFF.
(b) Disconnect connector B006, left reverse radar probe
(c) Disconnect connector B009, right reverse radar probe

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C016 (2) ground
＜2Ω
C016 (2) ground

Check whether the result is normal or not?

Yes> go to step 3
No > Maintenance or replace harness.

4. Check harness and connector (reverse radar controller-reverse radar probe)

(a) Ignition Switch: OFF.
(b) Disconnect connector B006, left reverse radar probe
(c) Disconnect connector B009, right reverse radar probe
(d) Disconnect connector C015, reverse radar controller
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-237

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C015（2） - B006（1）
＜2Ω
C015（15） - B009 （1） 04

Check whether the result is normal or not?

Yes>Replacement (Reverse Radar Controller)
No > Maintenance or replace harness.
 04-238 DIAGNOSTICS - REVERSE RADAR SYSTEM

ENTER REVERSE GEAR, NO OBSTACLES BEHIND THE VEHICLES

WHILE THE REVERSE RADAR SYSTEM IS ABNORMAL
Circuit diagram

04
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-239

Diagnostic steps

1. Check the work environment of reverse radar probe

(a) Check whether the surface of the reverse radar probe is covered by the mud or snow and other impurities.
(b) Check whether reverse radar probe is freezed.
Whether the above reasons exist?
Yes> Clean the foreign body on the surface of reverse radar probe or let reverse radar probe work under 04
normal temperature.
No> go to step 2

2. Check reverse radar probe

(a) Ignition Switch: OFF.
(b) Disconnect connector D001, left reverse radar probe
(c) Disconnect connector B004, right reverse radar probe
(d) Replacement of new reverse radar probe. (Refer to Chapter 81. Information system - reverse radar,
replacement of reverse radar probe)
CAUTION
Replacement of the reverse radar probe needs to select the probe of same size and model.
(e) Ignition Switch: ON.
(f) Place in reverse gear
Whether reverse radar is normal or not?
Yes> Replace reverse radar probe.
No> go to step 3

3. Check reverse radar controller

(a) Ignition Switch: OFF.
(b) Disconnect connector C015, reverse radar controller
(c) Replacement new reverse radar controller. (Refer to Chapter 81. Information system - reverse radar,
replacement of reverse radar controller)
CAUTION
Replacement of reverse radar controller needs to select the controller of the same size and model.

Check whether the result is normal or not?

Yes>Replacement (Reverse Radar Controller)
No> Remove the defects by other means.
 04-240 DIAGNOSTICS - REVERSE RADAR SYSTEM

THE OBSTACLE IS WITHIN THE DISTANCE OF EFFECTIVE SENSE,

AND THE BUZZER DOESN’T WORK OR IS ABNORMAL
Circuit diagram

04
 DIAGNOSTICS - REVERSE RADAR SYSTEM 04-241

Diagnostic steps

1. Check harness and connector (reverse radar probe-ground)

(a) Ignition Switch: OFF.
(b) Disconnect connector B006, left reverse radar probe
(c) Disconnect connector B009, right reverse radar probe

(d) Measure the electrical resistance based on the value in

the following form. 04

Standard electrical resistance (check whether there

existent an open circuit)
Multimeter connection Standard value
C016 (2) ground
≥1MΩ
C016 (2) ground

Check whether the result is normal?

Yes> go to step 2
No > Maintenance or replace harness.

3. Check harness and connector (reverse radar controller-reverse radar probe)

(a) Ignition Switch: OFF.
(b) Disconnect connector B006, left reverse radar probe
(c) Disconnect connector B009, right reverse radar probe
(d) Disconnect connector C015, reverse radar controller

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C015（2） - B006（1）
＜2Ω
C015（15） - B009 （1）

Check whether the result is normal or not?

 04-242 DIAGNOSTICS - REVERSE RADAR SYSTEM

Yes> go to step 3
No > Maintenance or replace harness.

5. Check reverse radar probe

(a) Ignition Switch: OFF.
(b) Disconnect connector B006, left reverse radar probe
(c) Disconnect connector B009, right reverse radar probe
04 (d) Replace new reverse radar probe. (Refer to Chapter 81. Information system - reverse radar, replacement
of reverse radar probe)
(e) Ignition Switch: ON.
(f) Place in reverse gear
Whether reverse radar is normal or not?
Yes> Replace reverse radar probe.
No> Replacement (Reverse Radar Controller)
 DIAGNOSTICS - POWER WINDOW 04-243

POWER WINDOW
PRECAUTION
1. Ignition switch representation
Ignition switch (location) Ignition switch representation
LOCK Ignition Switch: OFF.
ACC Ignition Switch ACC
04
ON Ignition Switch: ON.
START Start the engine.
2. Disconnect power supply
(a) When disconnecting or installing any electric equipments, or when the tools and equipments are easy
to contact exposed electric terminal, the negative（-）cable of the battery must be disconnected firstly
so as to prevent people or vehicles from being damaged.
CAUTION

Before disconnecting negative cable of the battery, remember to take away the car keys for fear that the
car is locked.

(b) If there is special illustration, ignition switch must be closed.

3. Disconnect negative(-) cable of the battery which can reset the daily speedometer, clock of the
combination instrument to zero.
CAUTION

The overall speedometer cannot be reset to zero.

4. Disconnect negative cable of the battery can make the sound system lose the stored settings.
CAUTION

When reconnecting the negative cable of the battery, the sound system should be reset. (refer to
“instruction for use of the sound system (in English)”)
 04-244 DIAGNOSTICS - POWER WINDOW

COMPONENTS DRAWING

04

1 Body Controller 6 Lifter assembly, left front door

2 Control switch assembly, driver’s 7 Lifter assembly, left rear door
door 8 Power window switch, left rear door
3 Lifter assembly, right front door 9 Power window switch, assistant
4 Power switch, right rear door driver’s door
5 Lifter assembly, right rear door
 DIAGNOSTICS - POWER WINDOW 04-245

BASIC INSPECTION
Steps Inspection contents Measures
Yes No> go to step 2
Check Battery voltage
1 • Battery voltage shall not be lower than 12V. Charge or replace the battery. Refer to
Check whether the result is normal? No? “Chapter 20A, start and charge--bat-
tery”
04
Check the glass lifter of left front door Yes No> go to step 3
• Ignition Switch: ON.
• Use overall control switch of the door to
2
operate the up and down of the lifter at left No? Go to defect phenomenon form
front door at gear1.
Check whether the result is normal?

Check the automobile lowering functions for left Yes No> go to step 4
front door glass
• Ignition Switch: ON.
3
• Ignition Switch: ON. No? Go to defect phenomenon form
Check whether the result is normal?

Check glass lifter of left front door Yes No> go to step 5

• Use overall control switch of the door to
operate the up and down of the glass lifter
4 at left front door at gear 1.
Use overall control switch of the door to oper- No? Go to defect phenomenon form
ate the up and down of the glass lifter at left
front door at gear 1.

Check glass lifter of left front door Yes No> go to step 6

• Use overall control switch of the door to
5 operate the up and down of the glass lifter
at left front door at gear1. No? Go to defect phenomenon form
Check whether the result is normal?

Check function of automobile window close Yes No> go to step 7

• Ignition Switch: OFF.
• Close all the doors of the vehicle.
6 • Lock the door, and the power window will
close automatically in the order of left to No? Go to defect phenomenon form
right after 2 seconds.
Check whether the result is normal?

Check the lock switch of the window Replace overall switch of the door. (Refer
• Press down the lock switch on the overall to "Chapter 88. Interior & exterior trims -
Yes
control switch of the door. door interior panel, replacement(power
window)")
7 • Use overall control switch of the door to
operate the up and down of the glass lifter
at left front door at gear1. No? No> go to step 8
Check glass lifter of left front door is work or not.
 04-246 DIAGNOSTICS - POWER WINDOW

Steps Inspection contents Measures

Check the lock switch of the window Yes Go to defect phenomenon form
• Press down the lock switch on the overall
control switch of the door.
• Use overall control switch of the door to Replace control switch of the right front
8 door. (Refer to "Chapter 88. Interior &
operate the up and down of the glass lifter No?
at left front door at gear1. exterior trims - door interior panel, replace-
04 ment(power window)")
Check glass lifter of left front door is work or
not.
 DIAGNOSTICS - POWER WINDOW 04-247

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Defect phenomenon Possible Cause Reference
Chapter 82. Windscreen/window
1. Power supply, ground circuit glass /rearview mirror – power win-
dow, replacement 04
B1356 low current of control circuit,
Chapter 82. Windscreen/window
right front window rise B1357 The
2.Replace overall switch of the door. glass /rearview mirror – power win-
relay of control circuit for right front
dow, replacement
window rise is stuck at the “NO”
location B1359 low current of the Chapter 82. Windscreen/window
3.Replace overall switch of the right
control circuit for the right front win- glass /rearview mirror – power win-
front door.
dow lower B 1360 relay of the control dow, replacement
circuit for right front window lower is
Chapter 82. Windscreen/window
stuck at the “ON” location.
4.Check glass lifter of right front door glass /rearview mirror – power win-
dow, replacement
5. Harness circuit —
Chapter 82. Windscreen/window
1. Power supply, ground circuit glass /rearview mirror – power win-
dow, replacement
B1368 low current of control circuit,
right front window rise B1369 The Chapter 82. Windscreen/window
relay of control circuit for right back 2.Replace overall switch of the door. glass /rearview mirror – power win-
window rise is stuck at the “NO” dow, replacement
location B1371 low current of the
Chapter 82. Windscreen/window
control circuit for right back window 3.Replace control switch of the win-
glass /rearview mirror – power win-
lower B 1372 relay of the control cir- dow at right rear door.
dow, replacement
cuit for the lowering of right back
window is stuck at the “ON” loca- Chapter 82. Windscreen/window
tion. 4.Glass lifter of right rear door glass /rearview mirror – power win-
dow, replacement
5. Harness circuit —
Chapter 82. Windscreen/window
1. Power supply, ground circuit glass /rearview mirror – power win-
dow, replacement
Chapter 82. Windscreen/window
2.Replace overall switch of the door. glass /rearview mirror – power win-
dow, replacement
All the power window stop working Chapter 82. Windscreen/window
3. Central control lock controller glass /rearview mirror – power win-
dow, replacement
Chapter 82. Windscreen/window
4.Check glass lifter of left and right
glass /rearview mirror – power win-
front door
dow, replacement
5. Harness circuit —
 04-248 DIAGNOSTICS - POWER WINDOW

Defect phenomenon Possible Cause Reference

Chapter 82. Windscreen/window
1. Power supply, ground circuit glass /rearview mirror – power win-
dow, replacement
B1350 low current of control circuit,
Chapter 82. Windscreen/window
left front window rise B1351 The relay
2.Replace overall switch of the door. glass /rearview mirror – power win-
of control circuit for left front window
dow, replacement
04 rise is stuck at the “NO” location
B1353 low current of the control cir- Chapter 82. Windscreen/window
3.Replace overall switch of the left
cuit for left front window lower B 1354 glass /rearview mirror – power win-
front door.
relay of the control circuit for the l left dow, replacement
front window lower is stuck at the
Chapter 82. Windscreen/window
“ON” location.
4.Glass lifter of left front door glass /rearview mirror – power win-
dow, replacement
5. Harness circuit —
Chapter 82. Windscreen/window
1. Power supply, ground circuit glass /rearview mirror – power win-
dow, replacement
B1362 low current of control circuit,
Chapter 82. Windscreen/window
left back window rise B1363 The re-
2.Replace overall switch of the door. glass /rearview mirror – power win-
lay of control circuit for left rear win-
dow, replacement
dow rise is stuck at the “NO” loca-
tion B1365 low current of the control Chapter 82. Windscreen/window
3. Window control switch, left rear
circuit for left back window lower B glass /rearview mirror – power win-
door
1354 relay of the control circuit for dow, replacement
the left rear window lower is stuck at
Chapter 82. Windscreen/window
the “ON” Location.
4.Glass lifter of left rear door glass /rearview mirror – power win-
dow, replacement
5. Harness circuit —
 DIAGNOSTICS - POWER WINDOW 04-249

ALL THE POWER WINDOW STOP WORKING

Circuit diagram

04
 04-250 DIAGNOSTICS - POWER WINDOW

04
DIAGNOSTICS - POWER WINDOW 04-251

04
 04-252 DIAGNOSTICS - POWER WINDOW

Diagnostic steps

1. Check power supply fuse of power window

(a) Ignition Switch: OFF.

(b) Check fuse of fuse box, engine room: F13 (30A), F14 (30A)

04

Check whether the fuse is good or not?

Yes> go to step 2
No> replace fuse

2. Check fuse: the control circuit from F13 (30A) to body

(a) Use multimeter to measure the resistance between No.B7
stitch of connector C033 of the body and the ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C033 (B7) ground ≥ 1 MΩ

Check whether the fuse is good or not?

Yes> Replace fuse: F13 (30A).
No> go to step 3

3. Check fuse: the control circuit from F13 (30A) to body

 DIAGNOSTICS - POWER WINDOW 04-253

(a) Disconnect connector C033, body controller.

04

(b) Use multimeter to measure the resistance between No.B7

stitch of connector C033 of the body and the ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C033 (B7) ground ≥ 1 MΩ

Check whether the result is normal?

Yes> replace body controller
No> replace fuse: F13 (30A), repair to-ground short circuit between fuse F13(30A) and No.B8 stitch of
connector C033 of body controller

4. Check power supply circuit of body controller

(a) Use multimeter to measure the resistance between No.B78
stitch of connector C033 of body controller and the ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C033 (B8) ground ≥ 1 MΩ

Check whether the result is normal?

 04-254 DIAGNOSTICS - POWER WINDOW

Yes> go to step 5
No> replace fuse: F14 (30A), repair to-ground short circuit between fuse F14 (30A) and pin B8 of connector
C033 of body controller

5. Check power supply circuit of body controller

(a) Disconnect connector C033, body controller.
04

(b) Use multimeter to measure the voltage between stitches

B7 and B8 of connector C033 of body controller and
ground.
Standard voltage
Multimeter connection Standard value
C033 (B7) ground Battery voltage
C033 (B8) ground Battery voltage

Check whether the result is normal?

Yes> go to step 6
No> Repair the open circuit between fuse F13 (30A), F14 (30A) and the stitches B7, B8 of connector C033
of the body controller.

6. Check ground circuit of body controller

(a) Disconnect connector C033, body controller.
 DIAGNOSTICS - POWER WINDOW 04-255

(b) Use multimeter to measure the resistance between stitches

B11, B12 of connector C033 of the body controller and
ground.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C033 (B11) ground ＜2Ω 04
C033 (B12) ground ＜2Ω

Check whether the result is normal?

Yes> go to step 7
No> Repair the open circuit between stitches B11, B12 of connector C033 of the body controller and
ground

7. Check assembly circuit of power lifter

(a) Ignition Switch: OFF.

(b) Disconnect motor connector J002, left front power window

(c) Disconnect motor connector I004, left rear power window
(d) Disconnect motor connector G001, right front power
window
(e) Disconnect motor connector H004, left rear power window
 04-256 DIAGNOSTICS - POWER WINDOW

(f) Use multimeter to measure the resistance between stitches

A7, A8, A9, A10, A11, A12 of connector C033 of body
controller and the ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value

04 C032 (A7) ground ＜2Ω

C032(A8) ground ＜2Ω
C032 (A9) ground ＜2Ω
C032 (A10) ground ＜2Ω
C032 (A12) ground ＜2Ω
C032 (A11) ground ＜2Ω

(g) Use multimeter to measure the resistance between stitches

B9 and B10 of connector C033 of body controller and the
ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C033 (B9) ground ＜2Ω
C033 (B10) ground ＜2Ω

Check whether the result is normal?

Yes> go to step 8
No> Repair the to-ground circuit from body controller to the power window motor.

8. Check assembly circuit of power lifter

(a) Disconnect the connector of power window motor.
(b) Connect the positive (+) of the battery and stitch Tl of the
connector of power lifter assembly, and connect negative
(-) of the battery and stitch T2 of the connector of power
lifter assembly. Power lifter assembly should move up.
(c) Connect the positive (+) of the battery and stitch Tl of the
connector of power lifter assembly, and connect negative
(-) of the battery and stitch T2 of the connector of power
lifter assembly. Power lifter assembly should move down.
 DIAGNOSTICS - POWER WINDOW 04-257

Check whether the result is normal?

Yes> go to step 9
No> replace power lifter assembly.

9. Check short circuit of power supply switch of power window switch, driver’s door
(a) Disconnect connector C033, body controller.
04

(b) Disconnect connector J004, power window switch ,

driver’s door.

(c) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
J004 (6) - C035(D13) ＜2Ω
J004 (8) - C035(D12) ＜2Ω
J004 (15) - C035(D10) ＜2Ω
J004 (16) - C035(D11) ＜2Ω

Check whether the result is normal?

 04-258 DIAGNOSTICS - POWER WINDOW

Yes> go to step 10
No > Maintenance or replace harness.

10 . Check ground circuit, power window, switch driver’s door

(a) Ignition Switch: OFF.

(b) Disconnect connector J004 of power window switch,

04 driver’s door.

(c) Use multimeter to measure the resistance between stitch

11 of connector J004 of the power window switch of
driver’s door and the ground.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C040 (11) ground ≤2Ω

Check whether the result is normal?

Yes> go to step 11
No> Repair the open circuit between stitch 11of connector J004 of power window switch, driver’s door
and ground.

11 . Check power window switch, driver’s door

 DIAGNOSTICS - POWER WINDOW 04-259

(a) Disconnect connector J004 of power window switch,

driver’s door.

04

(b) Use a multmeter to measure power window switch,

driver’s door.
Multimeter connec-
Conditions Standard value
tion
Left front power win-
J004 (6) - J004 (11) About1.2 kΩ
dow rise
Left front power win-
J004 (6) - J004 (11) ≤2Ω
dow lower
Left front power win-
J004 (8) - J004 (11) About1.2 kΩ
dow rise
Right front power
J004 (8) - J004 (11) ≤2Ω
window lower
Left rear power win-
J004 (15) - J004 (11) About1.2 kΩ
dow rise
Left rear power win-
J004 (15) - J004 (11) ≤2Ω
dow lower
Left rear power win-
J004 (16) - J004 (11) About1.2 kΩ
dow rise
Right rear power
J004 (16) - J004 (11) ≤2Ω
window lower

Check whether the result is normal?

Yes> replace body controller
No> Replace power window switch, driver’s door.
 04-260 DIAGNOSTICS - POWER WINDOW

B1350 B1353 LOW CURRENT OF CONTROL CIRCUIT, LEFT FRONT

WINDOW RISE
B1351 B1354 CONTROL CIRCUIT RELAY OF LEFT FRONT WINDOW
IS STUCK AT ON LOCATION
Circuit diagram
04
 DIAGNOSTICS - POWER WINDOW 04-261

Diagnostic steps

1. Check fuse
(a) Ignition Switch: ON.

(b) Check fuse inside fuse box, engine compartment : F13

(30A).

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the harness and connector (fuse-BCM control unit)

(a) Disconnect battery negative cable.

(b) Disconnect connector C033 , BCM control unit.

 04-262 DIAGNOSTICS - POWER WINDOW

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F13（30A） - C033（B7） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connector (power window switch, driver’s door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Pull out power window switch J004, driver’s door

(c) Disconnect connector C035, BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-263

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection stitch Specified value
J004（6） - C035（D13） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check harness and connector (power window switch, driver’s door-ground)

(a) Ignition Switch: OFF.

(b) Pull out Power window switch connector J004, driver’s

door

(c) Disconnect connector C035, BCM control unit.

 04-264 DIAGNOSTICS - POWER WINDOW

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
J040 (11) ground ＜2Ω
04

Check whether the result is normal?

Yes> Replace power window switch, driver’s door.
No > Maintenance or replace harness.

5. Check harness and connector (power window motor, driver’s door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Pull out power window motor J002, driver’s door

(c) Disconnect connector C032, BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-265

(d) Measure the electrical resistance based on the value in

the following form.
Multimeter connection Standard value
J002（T2） - C032（A12）
＜2Ω
J002（T1） - C032（A11）

04

Check whether the result is normal?

Yes> Replace power window motor, driver’s door.
No > Maintenance or replace harness.
 04-266 DIAGNOSTICS - POWER WINDOW

B1356 B1359 LOW CURRENT OF CONTROL CIRCUIT, LEFT FRONT

WINDOW RISE
B1357 B1360 CONTROL CIRCUIT RELAY OF LEFT FRONT WINDOW
IS STUCK AT ON LOCATION
Circuit diagram
04
 DIAGNOSTICS - POWER WINDOW 04-267

Diagnostic steps

1. Check fuse
(a) Ignition Switch: ON.

(b) Check fuse inside fuse box, engine compartment : F13

(30 A).

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the harness and connector (fuse-BCM control unit)

(a) Disconnect battery negative cable.

(b) Disconnect connector C033 , BCM control unit.

 04-268 DIAGNOSTICS - POWER WINDOW

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F13(30A)-C033（B7） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connector (power window switch, driver’s door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Pull out power window switch J004, driver’s door

(c) Disconnect connector C035, BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-269

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection stitch Specified value
J004(8)-C035（D12） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check harness and connector (power window switch, driver’s door-ground)

(a) Ignition Switch: OFF.

(b) Pull out power window switch J004, driver’s door

(c) Disconnect connector C035, BCM control unit.

 04-270 DIAGNOSTICS - POWER WINDOW

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
J040 (11) ground ＜2Ω
04

Check whether the result is normal?

Yes> Replace power window switch, driver’s door.
No > Maintenance or replace harness.

5. Check harness and connector (power window switch, assistant driver’s door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Pull out power window switch G003, assistant driver’s

door

(c) Disconnect connector C035, BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-271

(d) Measure the electrical resistance based on the value in

the following form.
Multimeter connection Standard value
G003(3)-C035（D9） ＜2Ω

04

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check harness and connector (, power window switch, assistant driver’s door-ground)
(a) Ignition Switch: OFF.

(b) Pull out power window switch G003, assistant driver’s

door

(c) Disconnect connector C035, BCM control unit.

 04-272 DIAGNOSTICS - POWER WINDOW

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
G003 (1) ground ＜2Ω
04

Check whether the result is normal?

Yes> Replace power window switch, assistant driver’s door.
No > Maintenance or replace harness.

7. Check harness and connector (power window motor, assistant driver’s door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Pull out power window motor G001, assistant driver’s

door

(c) Disconnect connector C032, BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-273

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
G001(T1)-C032（A10）
＜2Ω
G001(T2)-C032（A9） 04

Check whether the result is normal?

Yes> Replace power window motor, assistant driver’s door.
No > Maintenance or replace harness.
 04-274 DIAGNOSTICS - POWER WINDOW

B1362 LOW CURRENT OF CONTROL CIRCUIT, LEFT BACK WINDOW

RISE
B1363 B1366THE RELAY OF CONTROL CIRCUIT FOR LEFT REAR
WINDOW RISE IS STUCK AT THE “NO” LOCATION
Circuit diagram
04
 DIAGNOSTICS - POWER WINDOW 04-275

Diagnostic steps

1. Check fuse
(a) Ignition Switch: ON.

(b) Check fuse inside fuse box, engine compartment : F14

(30A).

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the harness and connector (fuse-BCM control unit)

(a) Disconnect battery negative cable.

(b) Disconnect connector C033 , BCM control unit.

 04-276 DIAGNOSTICS - POWER WINDOW

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F14（30A） - C033（B8） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connector (power window switch, driver’s door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Pull out power window switch J004, driver’s door

(c) Disconnect connector C035, BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-277

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection stitch Specified value
J004（8）- C035（D12） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check harness and connector (power window switch, driver’s door-ground)

(a) Ignition Switch: OFF.

(b) Pull out Power window switch connector J004, driver’s

door

(c) Disconnect connector C035, BCM control unit.

 04-278 DIAGNOSTICS - POWER WINDOW

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
J040 (11) ground ＜2Ω
04

Check whether the result is normal?

Yes> Replace power window switch, driver’s door.
No > Maintenance or replace harness.

5. Check harness and connector (power window switch, left rear door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Pull out power window switch I001, left rear door

(c) Disconnect connector C035, BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-279

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
I001（3）- C035（D7） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check harness and connector (power window switch, left rear door-ground)
(a) Ignition Switch: OFF.

(b) Pull out power window switch I001, left rear door
 04-280 DIAGNOSTICS - POWER WINDOW

(c) Measure the electrical resistance based on the value in

the following form.

04

Check whether the result is normal?

Yes> Replace power window switch, left rear door.
No > Maintenance or replace harness.

7. Check harness and connector (power window motor, left rear door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Press down power window motor I004, left rear door

(c) Disconnect connector C032, BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-281

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
I004（T1） - C032（A7）
＜2Ω
I004（T2） - C032（A8） 04

Check whether the result is normal?

Yes> Replace power window motor, left rear door.
No > Maintenance or replace harness.
 04-282 DIAGNOSTICS - POWER WINDOW

B1368 B1371LOW CURRENT OF CONTROL CIRCUIT, RIGHT BACK

WINDOW RISE
B1369 B1372CONTROL CIRCUIT RELAY OF RIGHT REAR WINDOW
IS STUCK AT ON LOCATION
Circuit diagram
04
 DIAGNOSTICS - POWER WINDOW 04-283

Diagnostic steps

1. Check fuse
(a) Ignition Switch: ON.

(b) Check fuse inside fuse box, engine compartment : F14

(30 A).

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the harness and connector (fuse-BCM control unit)

(a) Disconnect battery negative cable.

(b) Disconnect connector C033 , BCM control unit.

 04-284 DIAGNOSTICS - POWER WINDOW

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F14(30A)-C033（B8） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connector (power window switch, driver’s door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Pull out power window switch J004, driver’s door

(c) Disconnect connector C035, BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-285

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection stitch Specified value
J004(8)-C035（D12） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check harness and connector (power window switch, driver’s door-ground)

(a) Ignition Switch: OFF.

(b) Pull out power window switch J004, driver’s door

(c) Disconnect connector C035, BCM control unit.

 04-286 DIAGNOSTICS - POWER WINDOW

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
Power window switch (11), driv-
＜2Ω
04 er’s door, ground

Check whether the result is normal?

Yes> Replace power window switch, driver’s door.
No > Maintenance or replace harness.

5. Check harness and connector (power window switch, right rear door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Press down power window switch H001, right rear door.

(c) Disconnect connector C035, BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-287

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
H001(3)-C035（D8） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check harness and connector (power window switch, right rear door-ground)
(a) Ignition Switch: OFF.

(b) Press down power window switch H001, right rear door.

(c) Disconnect connector C035, BCM control unit.

 04-288 DIAGNOSTICS - POWER WINDOW

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
H001(1) ground ＜2Ω
04

Check whether the result is normal?

Yes> Replace power window switch, right rear door.
No > Maintenance or replace harness.

7. Check harness and connector (power window motor, right rear door-BCM control unit)
(a) Ignition Switch: OFF.

(b) Press down power window motor H004, right rear door

(c) Disconnect connector C033 , BCM control unit.

 DIAGNOSTICS - POWER WINDOW 04-289

8. Measure the electrical resistance based on the value

in the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
H004(T1)-C033（B9）
＜2Ω 04
H004(T2)-C033（B10）

Check whether the result is normal?

Yes> Replace power window motor, right rear door.
No > Maintenance or replace harness.
 04-290 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM

REAR WINDSCREEN DEFROST SYSTEM

SYSTEM SPECIFICATION
1. Summary
The thin heating wire of rear windscreen defrost system is installed inside the rear window,
which can defrost the surface of window fast. The rear defrost switch controls the defrost
work of the rear windscreen defroster, when pressing down the rear defrost switch, rear
04
windscreen defroster begin the work.
2. Components functions
Components Brief introduction
Receive the start request signal from rear defroster,
Defrost relay and connect to the circuit of rear windscreen de-
froster, to power up the rear windscreen defroster.
Receive power supply from defrost relay, heat the
Rear windscreen defroster heating wire of defogger, and defrost the rear wind-
screen.
 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM 04-291

COMPONENTS DRAWING

04

1 Right rearview mirror heating wire 3 Rear windscreen defrost heating wire
2 Left rearview mirror heating wire
 04-292 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM

BASIC INSPECTION
Inspection Measures
Steps
step
Check Battery voltage Yes No> go to step 2
• Battery voltage shall not be lower
1 than 12V. Charge or replace the battery. (Refer to "Chapter
No?
04 Check whether the result is nor- 20. Start & charge - battery, overhaul")
mal?

Check the Ignition Switch Yes No> go to step 3

•Check whether the ignition switch
2 is working properly. Maintain or replacement of ignition switch. Chapter
No? 91. Vehicle control system - ignition switch assem-
Check whether the result is nor-
bly, removal & installation")
mal?

Check fuse Yes No> go to step 4

• Check whether the fuse is good
3 or not?
No? to Defect Phenomenon Form
Check whether the result is nor-
mal?

Check rear defrost switch Replace rear defrost switch (Refer to "Chapter 83.
•Check whether the deforst switch Yes Dashboard/instruments - instrument panel, replace-
is working properly. ment")
4
Check whether the result is nor-
No? No> go to step 5
mal?

Check rear windscreen defroster Replace rear windscreen defroster (Refer to

• Check whether the defroster is Yes "Chapter 82. Windscreen/window glass/rearview
working properly. mirror -windscreen, replacement")
5
Check whether the result is nor-
No? to Defect Phenomenon Form
mal?
 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM 04-293

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Defect phenomenon Suspect Area Reference
1. Fuse -
2. Relay - 04
Rear windscreen defroster doesn’t Chapter 83. Dashboard/instruments
3.Rear defrost switch
work. - instrument panel, replacement
Chapter 82. Windscreen/window
4.Rear windscreen defroster glass /rearview mirror – power win-
dow, replacement
1. Fuse -
2. Relay -

Defrost control open circuit defrost Chapter 83. Dashboard/instruments

3.Rear defrost switch
control circuit high current - instrument panel, replacement
Chapter 82. Windscreen/window
4.Rear windscreen defroster glass /rearview mirror – power win-
dow, replacement
 04-294 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM

REAR WINDSCREEN DEFROSTER DOESN’T WORK.

Circuit diagram

04
DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM 04-295

04
 04-296 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM

Diagnostic steps

1. Check fuse
(a) Disconnect battery negative cable.

(b) Check fuse : F11 (60A).inside fuse box, engine

compartment
(c) Check fuses: F:33(5A), F39 (15A) inside fuse box of the
04 body.

Check whether the result is normal?

Yes> go to step 4
No> replace fuse

2. Check harness and connector (defrost relay--ground)

(a) Ignition Switch: ON.
(b) Pull out rear windscreen defrost relay R1 inside fuse box of body.

(c) Measure the voltage based on the value in the following

form.
Standard voltage
Multimeter connection Multimeter connection
R1(87) ground Battery voltage

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connector (start and cut-off relay--ground)

 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM 04-297

(a) Ignition Switch: ON.

(b) Pull out start and cut-off relay R4 inside fuse box of body.

(c) Measure the voltage based on the value in the following

form.
Standard voltage
Multimeter connection Multimeter connection
04
R4(3) ground Battery voltage

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the relay

(a) Disconnect battery negative cable.
(b) Pull out rear windscreen defrost relay R1 inside fuse box of body.

(c) Check rear windscreen defrost relay R1

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 85 - 86 Breakover
Apply power supply
voltage to position
30 - 87 ＜2Ω
between stitch 85
and 86,
(d) Pull out start and cut-off relay R4 inside fuse box of body.
 04-298 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM

(e) Check start and cut-off relay R4

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 1-2 Breakover
Apply power supply
04 voltage to position
3-4 Cut-off
between stitch 1 and
2,

Check whether the result is normal?

Yes> go to step 5
No>Replace relay

5. Check harness and connector (rear defrost relay—body controller)

(a) Disconnect battery negative cable.
(b) Pull out rear windscreen defrost relay R1 inside fuse box of body.

(c) Disconnect connector D012 of rear windscreen defroster.

 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM 04-299

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
D012 (1） - R1(30) ＜2Ω
04

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check harness and connector (rear windscreen defroster--ground)

(a) Ignition Switch: ON.

(b) Disconnect connector D004 of rear windscreen defroster.

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
D004 (1) ground ＜2Ω
 04-300 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM

Check whether the result is normal?

Yes> go to step 7
No > Maintenance or replace harness.

7. Check harness and connector (defrost switch--ground)

(a) Ignition Switch: ON.
04 (b) Disconnect connector C021 of air-conditioner controller.

(c) Measure the voltage based on the value in the following

form.
Automatic air conditioner
Standard voltage
Multimeter connection Standard value
C021(A13) ground Battery voltage

Manual air conditioner

Standard voltage
Multimeter connection Standard value
C021(A3) ground Battery voltage

Check whether the result is normal?

Yes> go to step 8
No> replace body controller

8. Check harness and connector (defrost switch—body controller)

(a) Disconnect battery negative cable.
 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM 04-301

(b) Disconnect connector C021 of air-conditioner controller.

04

(c) Disconnect connector C036, body controller

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C021 (A13） - C036(E29) ＜2Ω

Check whether the result is normal?

Yes> go to step 9
No > Maintenance or replace harness.

9. Check harness and connector (rear defrost relay—body controller)

(a) Disconnect battery negative cable.
(b) Pull out rear windscreen defrost relay R1 inside fuse box of body.
 04-302 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM

(c) Disconnect connector C036, body controller

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C036 (E21） - R1(85) ＜2Ω

Check whether the result is normal?

Yes> replace body controller
No > Maintenance or replace harness.
 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM 04-303

B 1391 DEFROST CONTROL CIRCUIT --OPEN CIRCUIT

B1392DEFROST CONTROL CIRCUIT --HIGH CURRENT
Circuit diagram

04
 04-304 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM

04
 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM 04-305

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F39 (15 A) in the indoor fuse box.

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check rear windscreen defrost relay

(a) Ignition Switch: OFF.
(b) Pull out rear windscreen defrost relay

(c) Check rear windscreen defrost relay R1

Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 85-86 Breakover
Apply power supply
voltage to position
87-30 ＜2Ω
between stitches 85
and 86,

Check whether the result is normal?

Yes> go to step 3
No> replace rear windscreen defrost relay

3. Check rearview mirror heating relay

(a) Ignition Switch: OFF.
(b) Pull out rearview mirror heating relay R2.
 04-306 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM

(c) Check rearview mirror heating relay R2

Standard voltage
Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 1-2 Breakover
Apply power supply
04 voltage to position
3-5 ＜2Ω
between stitches 1
and 2,

Check whether the result is normal?

Yes> go to step 4
No> replace rear windscreen heating relay

4. Check harness and connector (rearview mirror heating relay—rear windscreen defrost relay)
(a) Ignition Switch: OFF.
(b) Pull out rearview mirror heating relay R2.
(c) Pull out rear windscreen defrost relay

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
R2(1)-R1(86) ＜2Ω

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check harness and connector (rearview mirror heating relay—BCM control unit)
(a) Ignition Switch: OFF.
(b) Pull out rearview mirror heating relay R2.
 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM 04-307

(c) Disconnect connector C035, BCM control unit.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
R2（2）- C035（D22） ＜2Ω

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check harness and connector (rear windscreen defrost relay—BCM control unit)
(a) Ignition Switch: OFF.
(b) Pull out rear windscreen defrost relay

(c) Disconnect connector C035, BCM control unit.

 04-308 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
R1（85） - C035（D21） ＜2Ω
04

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.

7. Check harness and connector (rear windscreen defrost relay—rear windscreen defrost)
(a) Ignition Switch: OFF.
(b) Pull out rear windscreen defrost relay
(c) Disconnect connector D004 of rear windscreen defroster.

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
R1（30）-D004（1） ＜2Ω

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check harness and connector (rear windscreen defrost--ground)

(a) Ignition Switch: OFF.
(b) Pull out rear windscreen defrost relay
(c) Disconnect connector D004 of rear windscreen defroster.
 DIAGNOSTICS - REAR WINDSCREEN DEFROST SYSTEM 04-309

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
D004 (1) ground ＜2Ω
04

Check whether the result is normal?

Yes> replace rear windscreen defrost.
No > Maintenance or replace harness.
 04-310 DIAGNOSTICS - POWER REARVIEW MIRROR.

POWER REARVIEW MIRROR.

COMPONENTS DRAWING

04

1 Right rearview mirror assembly 3 Left rearview mirror assembly

2 Switch assembly, power rearview
mirror
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-311

STITCH DESCRIPTION, POWER REARVIEW MIRROR SWITCH

04

Stitch number Connection rod color Description

1 Red Power supply
2 Black ground
3 Red-orange Connect to left/right rearview mirror
4 - -
5 Blue-red Connect to left/right adjustment motor of left rearview mirror
6 Red-grey Connect to upper/lower adjustment motor of left rearview mirror
Connect to upper/lower adjustment motor of right rearview
7 Black-Red
mirror
8 Red-blue Connect to left/right adjustment motor of right rearview mirror
 04-312 DIAGNOSTICS - POWER REARVIEW MIRROR.

BASIC INSPECTION
Steps Inspection contents Measures
Check Battery voltage Yes No> go to step 2
• Battery voltage shall not
1 be lower than 12V. Charge or replace the bat-
Check whether the result No? tery. Refer to “Chapter 20,
is normal? start and charge- battery”
04
Check switch adjustment to Defect Phenomenon
Yes
situation, power rearview Form
mirror
• Ignition Switch: ON. Replace switch of power
• Adjust visible angle of rearview mirror. (Refer to
2 left and right power "Chapter 82. Wind-
rearview mirror respec- No? screen/window
tively. glass/rearview mirror –
power rearview mirror
Check whether the result
switch, replacement")
is normal?
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-313

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Defect phenomenon Suspect Area Suspect Area
1. Fuse -
Power rearview mirror on both sides Chapter 85 Lock-- front door lock,
2. Switch, power rearview mirror. 04
don’t work at all. replacement
3. Harness -
Chapter 85 Lock-- front door lock,
1. Switch, power rearview mirror.
replacement
Power rearview mirror on one side Chapter 82. Windscreen/window
don’t work at all. 2. Power rearview mirror. glass/rearview mirror - rearview mir-
ror, replacement
3. Harness -
Chapter 85 Lock-- front door lock,
1. Switch, power rearview mirror.
replacement
, Upper and lower adjustment of
Chapter 85 Lock-- front door lock,
power rearview mirror doesn’t work 2. Rearview mirror motor
replacement
3. Harness -
Chapter 85 Lock-- front door lock,
1. Switch, power rearview mirror.
replacement
, Left/right adjustment of power Chapter 82. Windscreen/window
rearview mirror doesn’t work 2. Rearview mirror motor glass/rearview mirror - rearview mir-
ror, replacement
3. Harness -
Chapter 85 Lock-- front door lock,
1. Switch, power rearview mirror.
replacement
Heating power rearview mirror Chapter 82. Windscreen/window
2. Heating wires of power rearview
doesn't work glass/rearview mirror - rearview mir-
mirror
ror, replacement
3. Harness -
 04-314 DIAGNOSTICS - POWER REARVIEW MIRROR.

UPPER AND LOWER ADJUSTMENT OF POWER REARVIEW MIRROR

DOESN’T WORK
Circuit diagram

04
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-315

Diagnostic steps

1. Check the switch of power rearview mirror

(a) Ignition Switch: OFF.

(b) Disconnect switch connector C003 of power rearview

mirror

04

(c) Use multimeter to check the switch of power rearview

mirror.
Standard resistance:
Multimeter
Specified val-
Function Operation connection
ue
stitch
1-6
Upper
Left rearview 2-3
＜2Ω
mirror 1-3
Lower
2-6

Check whether the result is normal?

Yes> go to next step.
No> Replace switch assembly of power rearview mirror.

2. Check harness and connector (power rearview mirror switch-left rearview mirror)
(a) Ignition Switch: OFF.

(b) Disconnect left power rearview mirror connector J003.

 04-316 DIAGNOSTICS - POWER REARVIEW MIRROR.

(c) Disconnect switch connector C003 of power rearview

mirror

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C003 (6) - J003 (4)
＜2Ω
C003 (3) - J003 (5)

Check whether the result is normal?

Yes> replace left rearview mirror assembly.
No > Maintenance or replace harness.
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-317

LEFT/RIGHT ADJUSTMENT OF POWER REARVIEW MIRROR

DOESN’T WORK
Circuit diagram

04
 04-318 DIAGNOSTICS - POWER REARVIEW MIRROR.

Diagnostic steps

1. Check the switch of power rearview mirror

(a) Ignition Switch: OFF.

(b) Disconnect switch connector C003 of power rearview

mirror

04

(c) Use multimeter to check the switch of power rearview

mirror.
Standard resistance:
Multimeter
Specified val-
Function Operation connection
ue
stitch
1-5
Left
Left rearview 2-3
＜2Ω
mirror 2-5
Right
1-3

Check whether the result is normal?

Yes> go to next step.
No> Replace switch assembly of power rearview mirror.

2. Check harness and connector (power rearview mirror switch-left rearview mirror)
(a) Ignition Switch: OFF.

(b) Disconnect left power rearview mirror connector J003.

 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-319

(c) Disconnect switch connector C003 of power rearview

mirror

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C003 (5) - J003 (6)
＜2Ω
C003 (3) - J003 (5)

Check whether the result is normal?

Yes> replace power rearview mirror assembly.
No > Maintenance or replace harness.
 04-320 DIAGNOSTICS - POWER REARVIEW MIRROR.

POWER REARVIEW MIRROR ON BOTH SIDES DON’T WORK AT

ALL.
Circuit diagram

04
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-321

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check fuse : F22 (7.5A). inside fuse box(C037) of the body

04

Check whether the result is normal?

Yes> go to step 3
No> go to next step.

2. Check harness and connector (power rearview mirror switch-ground)

(a) Ignition Switch: OFF.

(b) Disconnect switch connector C003 of power rearview

mirror
 04-322 DIAGNOSTICS - POWER REARVIEW MIRROR.

(c) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C003 (1) ground ≥1 ΜΩ
04

Check whether the result is normal?

Yes> Replace fuse
No > Maintenance or replace harness.

3. Check harness and connector (power rearview mirror switch-left rearview mirror)
(a) Ignition Switch: OFF.

(b) Disconnect switch connector C003 of power rearview

mirror

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C003 (2) ground ＜2Ω

Check whether the result is normal?

Yes> go to next step.
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-323

No > Maintenance or replace harness.

4. Check harness and connector (power rearview mirror switch-fuse, power rearview mirror)
(a) Ignition Switch: OFF.

(b) Disconnect switch connector C003 of power rearview

mirror

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F22（7.5A） - C003 (1） ＜2Ω

Check whether the result is normal?

Yes>Replace switch, power rearview mirror.
No > Maintenance or replace harness.
 04-324 DIAGNOSTICS - POWER REARVIEW MIRROR.

POWER REARVIEW MIRROR ON ONE SIDE DON’T WORK AT ALL.

Circuit diagram

04
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-325

Diagnostic steps

1. Check the switch of power rearview mirror

(a) Ignition Switch: OFF.

(b) Disconnect switch connector C003 of power rearview

mirror

04

(c) Use multimeter to check the switch of power rearview

mirror.
Multimeter
Specified val-
Function Operation connection
ue
stitch
1-5
Left
2-3
2-5
Right
Left rearview 1-3
＜2Ω
mirror 1-6
Upper
2-3
2-6
Lower
1-3

Check whether the result is normal?

Yes> go to next step.
No> Replace switch assembly of power rearview mirror.

2. Check harness and connector (power rearview mirror switch-left rearview mirror)
(a) Ignition Switch: OFF.

(b) Disconnect left power rearview mirror connector J003.

 04-326 DIAGNOSTICS - POWER REARVIEW MIRROR.

(c) Disconnect switch connector C003 of power rearview

mirror

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C003 (6) - J003 (4)
C003 (3） - J003 (5) ＜2Ω
C003 (5) - J003 (6)

Check whether the result is normal?

Yes> replace power rearview mirror assembly.
No > Maintenance or replace harness.
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-327

HEATING POWER REARVIEW MIRROR DOESN'T WORK

Circuit diagram

04
 04-328 DIAGNOSTICS - POWER REARVIEW MIRROR.

04
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-329

Diagnostic steps

1. Check fuse
(a) Disconnect battery negative cable.

(b) Check fuse : F11 (60A).inside fuse box, engine

compartment
(c) Check fuse: F40 (10A). inside fuse box of the body
04

Check whether the result is normal?

Yes> go to step 4
No> replace fuse

2. Check harness and connector (rearview mirror heating relay-ground)

(a) Ignition Switch: ON.
(b) Pull out rearview mirror heating relay R2 inside fuse box of the body.

(c) Measure the voltage based on the value in the following

form.
Standard voltage
Multimeter connection Multimeter connection
R2(3) ground Battery voltage

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connector (start and cut-off relay--ground)

 04-330 DIAGNOSTICS - POWER REARVIEW MIRROR.

(a) Ignition Switch: ON.

(b) Pull out start and cut-off relay R4 inside fuse box of body.

(c) Measure the voltage based on the value in the following

form.
Standard voltage
Multimeter connection Multimeter connection
04
R4(3) ground Battery voltage

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the relay

(a) Disconnect battery negative cable.
(b) Pull out rearview mirror heating relay R2 inside fuse box of the body.

(c) Check rearview mirror heating relay R2

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 1-2 Breakover
Apply power supply
voltage to position
3-5 ＜2Ω
between stitch 1 and
2,
(d) Pull out start and cut-off relay R4 inside fuse box of body.
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-331

(e) Check start and cut-off relay R4

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 1-2 Breakover
Apply power supply
voltage to position 04
3-4 Cut-off
between stitch 1 and
2,

Check whether the result is normal?

Yes> go to step 5
No>Replace relay

5. Check harness and connector (rearview mirror heating relay—body controller)

(a) Disconnect battery negative cable.
(b) Pull out rearview mirror heating relay R2 inside fuse box of the body.

(c) Disconnect left power rearview mirror connector J003.

(d) Disconnect right power rearview mirror connector G002.

(e) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
J003 (1） - R2(5) ＜2Ω
D012 (1） - R2(5) ＜2Ω
 04-332 DIAGNOSTICS - POWER REARVIEW MIRROR.

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check harness and connector (rearview mirror--ground)

(a) Ignition Switch: ON.
04 (b) Disconnect left power rearview mirror connector J003.
(c) Disconnect right power rearview mirror connector G002.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
G002 (2) ground ＜2Ω
J003 (2) ground ＜2Ω

Check whether the result is normal?

Yes> go to step 7
No > Maintenance or replace harness.

7. Check harness and connector (rearview mirror heating switch--ground)

(a) Ignition Switch: ON.
(b) Disconnect the connector C019, rearview mirror heating switch
 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-333

(c) Measure the electrical resistance based on the value in

the following form.
4-drive vehicle type
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C019 (8) ground ＜2Ω 04

2-drive vehicle type

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C019 (2) ground ＜2Ω

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check harness and connector (rearview mirror heating switch—body controller)

(a) Disconnect battery negative cable.
(b) Disconnect the connector C019, rearview mirror heating switch

(c) Disconnect connector C036, body controller

 04-334 DIAGNOSTICS - POWER REARVIEW MIRROR.

(d) Measure the electrical resistance based on the value in

the following form.
4-drive vehicle type
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
04 C019 (3） - C036(E21) ＜2Ω

2-drive vehicle type

Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C019 (1） - C036(E21) ＜2Ω

Check whether the result is normal?

Yes> go to step 9
No > Maintenance or replace harness.

9. Check rearview heating switch

(a) Ignition Switch: ON.
(b) Disconnect the connector C019, rearview mirror heating switch

(c) Measure the electrical resistance based on the value in

the following form.
4-drive vehicle type
Standard resistance (check whether there is short
circuit)
Multimeter connec-
Conditions Standard value
tion
Turn on the rearview
C019 (3） - C019(8) ＜2Ω
mirror heating switch

2-drive vehicle type

Standard resistance (check whether there is short
circuit)
Multimeter connec-
Conditions Standard value
tion
Turn on the rearview
C019 (1） - C019(2) ＜2Ω
mirror heating switch

Check whether the result is normal?

 DIAGNOSTICS - POWER REARVIEW MIRROR. 04-335

Yes> go to step 10
No> replace rearview mirror heating switch.

10 . Check harness and connector (rearview mirror heating relay—body controller)

(a) Disconnect battery negative cable.
(b) Pull out rearview mirror heating relay R2 inside fuse box of the body.

(c) Disconnect connector C036, body controller 04

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C036 (E22） - R2(2) ＜2Ω

Check whether the result is normal?

Yes> replace body controller
No > Maintenance or replace harness.
 04-336 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM

POWER DOOR LOCK CONTROL SYSTEM

PRECAUTION
1. Ignition switch representation
Ignition switch (location) Ignition switch representation
LOCK Ignition Switch: OFF.

04 ACC Ignition Switch ACC

ON Ignition Switch: ON.
START Start the engine.
 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 04-337

COMPONENTS DRAWING

04

1 Body Controller 5 Left front lock assy

2 Control switch assembly, driver’s 6 Left rear lock assy
door 7 Remote control
3 Right front lock assy
4 Right rear lock assy
 04-338 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM

BASIC INSPECTION
Inspection Measures
Steps
contents
Yes No> go to step 2
Check Battery voltage
1 • Battery voltage shall not be lower than 12V. Charge or replace the battery. Refer
No? to “Chapter 20A, start and charge-
Check whether the result is normal?
04 battery”
Check basic functions Yes No> go to step 3
• Use lock master control switch to control the lock
and unlock of all doors
• Use key to lock the door on the side of the driver,
2
all the doors should be locked. No? Go to defect phenomenon form
• Use key to lock the door on the side of the driver,
all the doors should be locked.
Check whether the result is normal?
Check lock-prevention function of the keys Yes Go to defect phenomenon form
• Insert the key of the door into the ignition switch.
• When the driver's door is open, press down
driving lever beside the driver to lock the door,
and all the doors should be locked and then un-
3
locked. No? Replace body controller
• When the driver's door is open, press down
master control switch of the door and all the
doors should be locked and then unlocked.
Check whether the result is normal?
 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 04-339

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Defect phenomenon Possible Cause Reference
Chapter 4 Diagnosis-power door lock
1. Power supply, ground circuit control system, central control lock
doesn’t work 04

Chapter 4 Diagnosis-power door lock

2.Dead lock, Left front door (left front
control system, central control lock
door switch)
doesn’t work
Central control lock doesn’t work
Chapter 4 Diagnosis-power door lock
3. Body Controller control system, central control lock
doesn’t work
Chapter 4 Diagnosis-power door lock
4. Harness circuit control system, central control lock
doesn’t work
Chapter 4 Diagnosis-power door lock
1. Central control lock controller control system, only the central lock
Only the central control lock of one of one door doesn’t work
door doesn’t work Chapter 4 Diagnosis-power door lock
2. Harness circuit control system, only the central lock
of one door doesn’t work
 04-340 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM

CENTRAL CONTROL LOCK DOESN’T WORK

Circuit diagram

04
DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 04-341

04
 04-342 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check fuse of fuse box, engine compartment: F2 (20A),

F13(30A)
(c) Check fuse of fuse box, engine compartment: F1 (15A)
04

Check whether the fuse is good or not?

Yes> go to step 2
No> replace fuse

2. Check fuse: the control circuit from F13 (30 A) to body

(a) Use multimeter to measure the voltage between stich 7 of
connector C033 of the body controller and the ground .
Standard voltage
Multimeter connection Standard value
C033 (B7) ground Battery voltage

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connector (power window switch, left front door-ground)
 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 04-343

(a) Disconnect connector J004 of power window switch, left

front door.

04

(b) Use multimeter to measure the resistance between stitch

11 of connector J004 of power window switch of left front
door and the ground.
Standard electrical resistance (check whether there existent
an open circuit)
Multimeter connection Standard value
C040 (11) ground ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check circuit of body controller

(a) Disconnect connector C033, body controller.
 04-344 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM

(b) Use multimeter to measure the resistance between stitch

D6 of connector C035 of body controller and the ground.
Standard resistance (check whether there is short circuit)
Multimeter connection Standard value
C035 (D6) ground ≥ 1 MΩ

04

Check whether the result is normal?

Yes> go to step 5
No> replace body controller

5. Check harness and connector (body controller-power window switch, left front door )
(a) Disconnect connector J004 of power window switch, left
front door.

(b) Disconnect connector C033, body controller.

 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 04-345

(c) Use multimeter to measure the resistance between stitch

2 of connector J004 of power window switch of right front
door and stitch D6 of connector C035 of body controller.
Standard resistance (check whether there is short circuit)
Multimeter connection Standard value
J004 (2) - C035 (D6) ＜2Ω

04

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check power window switch, left front door (central door lock switch)
(a) Dismantle power window switch, left front door.
 04-346 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM

(b) Use multimeter to measure the resistance between stitch

11of connector J004 of power window switch of left front
door and stitch11 .
Standard voltage
Conditions Multimeter connection Standard value
central door lock-
J004 (2) - J004 (11)
closed ＜2Ω
04 central door -opened J004 (2) - J004 (11)

Check whether the result is normal?

Yes> go to step 7
No> Replace power window switch, left front door.

7. Check harness and connector (lock assy- left front door-ground)

(a) Disconnect connector J007, lock assy, left front door.
 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 04-347

(b) Use multimeter to measure the resistance between stitch

13of connector J007 of lock assy of left front door and the
ground.
Standard electrical resistance (check whether there existent
an open circuit)
Multimeter connection Standard value
J007(13) ground ＜2Ω
04

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check circuit of body controller

(a) Disconnect body controller C036 connector.

(b) Use multimeter to measure the resistance between.

stitches E27, E28of connector C036 of the body controller
and the ground.
Standard resistance (check whether there is short circuit)
Multimeter connection Standard value
C036 (E27) ground
≥ 1 MΩ
C036 (E28) ground

Check whether the result is normal?

Yes> go to step 9
 04-348 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM

No> replace body controller

9. Check harness and connector (body controller-power window switch, left front door )
(a) Disconnect connector J007, lock assy, left front door.

04

(b) Disconnect body controller C036 connector.

(c) Use multimeter to measure the resistance between stitches

19 and 20 of connector J007of lock assy for the left front
door and stitchesE27,28 of connector C036 of body
controller.
Standard resistance (check whether there is short circuit)
Multimeter connection Standard value
J007 (19) - C036 (E28)
＜2Ω
J007 (20) - C036 (E27)

Check whether the result is normal?

Yes> go to step 10
No > Maintenance or replace harness.

10 . Check lock assy, left front door

 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 04-349

(a) Disconnect connector J007, lock assy, left front door.

04

(b) Use multimeter to measure the resistance between

stitches19 and 20 of connector J007 of lock assy for the
left front door and stitch13.
Standard voltage
Conditions Multimeter connection Standard value
The switch of lock-
J007 (19) - J007 (13)
up clutch, closed
＜2Ω
The switch of lock-
J007 (20) - J007 (13)
up clutch, opened

Check whether the result is normal?

Yes> go to step 11
No> Replace lock assy, left front door.

11 . Check signal output circuit, body controller

(a) Disconnect connector G006 of door lock motor of right
front door. (Left driving type)
(b) Disconnect connector G006 of door lock motor of left front
door. (Right driving type)
(c) Disconnect connector I005of door lock motor of left rear
door.
(d) Disconnect connector H005 of door lock motor of right rear
door.
 04-350 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM

(e) Use multimeter to measure the resistance between stitches

B1, B2 of connector C033 of body controller and stitches
6 and 5.
Standard resistance (check whether there is short circuit)
Multimeter connection Standard value
C033(B1)-G006(6)or H005(6)or
I005(6)
04 ≤2Ω
C033(B2)-G006(5)or H005(5)or
I005(5)

Check whether the result is normal?

Yes> go to step 12
No > Maintenance or replace harness.

12 . Check signal output circuit, body controller

(a) Close all the doors of the vehicle.
(b) Use power switch of left front door to lock and unlock
repsectively, meanwhile use multimeter to measure the
voltage between stitchB1 of connector C033 of body
controller and stitch 2 The voltage should appear twice.
Standard voltage
Multimeter connection Standard value
Battery voltage（Lasts about
C033 (B1) - C033 (B2)
0.3 ～ 1.1 s）

Check whether the result is normal?

Yes> Maintain or replace harness.
No> replace body controller
 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 04-351

ONLY THE CENTRAL CONTROL LOCK OF ONE DOOR DOESN’T

WORK
Circuit diagram

04
 04-352 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM

04
 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 04-353

Diagnostic steps
• This diagnostic step follows right front door, and the diagnosis of other door is the same as the
right front door.

1. Check motor control circuit, right front door lock

(a) Disconnect connector G006 of door lock motor of right
front door.
04

(b) Use master control switch to lock the door, meanwhile use
multimeter to measure the voltage between stitch5 of
connector G006 of right front lock motor and the ground.
Standard voltage
Multimeter connection Standard value
Battery voltage
G006 (5) ground
(Lasts about 0.3 ～ 1.1 s)

Check whether the result is normal?

Yes> go to step 3
No> Repair the open circuit between stitch 5 of connector G006 of the lock motor, right front door and
stitch B2 of connector C033 of the body controller.

2. Check motor control circuit, right front door lock

 04-354 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM

(a) Use master control switch to unlock the door, meanwhile

use multimeter to measure the voltage between Stitch 6
of connector G006 of the right front lock motor and the
ground
Standard voltage
Multimeter connection Standard value
Battery voltage
04 G006 (6) ground
(Lasts about 0.3 ～ 1.1 s)

Check whether the result is normal?

Yes> replace lock motor, right front door
No> Repair the open circuit between stitch 6 of connector G006 of the lock motor, right front door and
stitch B3 of connector C033 of the body controller.
 DIAGNOSTICS - WIPER & WASHER 04-355

WIPER & WASHER

PRECAUTION
1. Ignition switch representation
Ignition switch (location) Ignition switch representation
LOCK Ignition Switch: OFF.
ACC Ignition Switch ACC 04
ON Ignition Switch: ON.
START Start the engine.
2. Switch off the power.
(a) Before dismounting or installing any electric apparatus, or when tool or equipment is susceptible to touch
exposed electric pins, be sure to disconnect the negative-pole cable of battery firstly to prevent persons
or vehicle from being damaged.
(b) If there is special illustration, ignition switch must be closed.
 04-356 DIAGNOSTICS - WIPER & WASHER

COMPONENTS DRAWING

04

1 Wiper assembly 5 Motor assembly, wiper

2 Nozzle (with wash tube) 6 Connecting rod assembly, wiper
3 Motor, washer 7 Bolt
4 Reservoir, wiper
 DIAGNOSTICS - WIPER & WASHER 04-357

BASIC INSPECTION
Inspection Measures
Steps
contents
Check Battery voltage Yes No> go to step 2
• Battery voltage shall not be lower than
1 Charge or replace the battery. see
12V. No? “Chapter 20 Startup and charging –
Check whether the result is normal? battery, replacement” 04

check the high-speed gear of wiper. Yes No> go to step 3

• Use combination switch to turn on the
2 high-speed gear of wiper. No? to Defect Phenomenon Form
Check whether the result is normal?

check the low-speed gear of wiper. Yes No> go to step 4

• Ignition Switch: ON.
3 • Use combination switch to turn on the
low-speed gear of wiper. No? to Defect Phenomenon Form
Check whether the result is normal?

check the intermittence gear of wiper. Yes Check the wiper motor.
•Use combination switch to turn on the in-
4 termittence gear of wiper. No? to Defect Phenomenon Form
Check whether the result is normal?
 04-358 DIAGNOSTICS - WIPER & WASHER

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Defect phenomenon Suspect Area Reference
1. Fuse (damaged) -

04 Chapter 65 Wiper and washer - inspection of

2. Wiper switch (damaged)
Front wiper does not wiper and washer
work Chapter 65 Wiper and washer - inspection of
3. Wiper motor (damaged)
wiper and washer
4. Harness (broken circuit or short circuit) -
High-speed control cir- Chapter 65 Wiper and washer - inspection of
1. Wiper switch (damaged)
cuit of front wiper is wiper and washer
open-circuited\ High-
Chapter 65 Wiper and washer - inspection of
speed control circuit of 2. Wiper motor (damaged)
wiper and washer
front wiper is subjected
to high current 3. Harness (broken circuit or short circuit) -
Low-speed control cir- Chapter 65 Wiper and washer - inspection of
1. Wiper switch (damaged)
cuit of front wiper is wiper and washer
open-circuited\ Low-
Chapter 65 Wiper and washer - inspection of
speed control circuit of 2. Wiper motor (damaged)
wiper and washer
front wiper is subjected
to high current 3. Harness (broken circuit or short circuit) -
Chapter 65 Wiper and washer - inspection of
1. Wiper switch (damaged)
wiper and washer
2. Intermittent activator of wiper (dam- Chapter 65 Wiper and washer - inspection of
Wiper does not work aged) wiper and washer
Chapter 65 Wiper and washer - inspection of
3. Wiper motor (damaged)
wiper and washer
4. Harness (broken circuit or short circuit) -
Chapter 65 Wiper and washer – replacement
1. Wiper arm (installed incorrectly )
Wiper arm cannot re- of wiper assembly
turn or is positioned in-
Chapter 65 Wiper and washer - inspection of
correctly (wiper switch 2. Wiper motor (damaged)
wiper and washer
is turned off)
3. Harness (broken circuit or short circuit) -
1. Worm (getting rusty or lack of lubrica- Chapter 65 Wiper and washer – replacement
tion) of connecting rod assembly of wiper
abnormal sound given Chapter 65 Wiper and washer – replacement
2. Connecting rod (wear or deformed)
by wiper of connecting rod assembly of wiper
Chapter 65 Wiper and washer – replacement
3. Wiper blade (rubber aging or chapping)
of wiper blade assembly
 DIAGNOSTICS - WIPER & WASHER 04-359

Defect phenomenon Suspect Area Reference

1. Windshield glass (oily stain or car wax) -
2. Washing liquid (poor quality) -
3. Wiper blade (incorrect type) -
Chapter 65 Wiper and washer – replacement
Wiping effect is poor 4. Wiper blade (rubber aging or chapping)
of wiper blade assembly
04
Chapter 65 Wiper and washer – replacement
5. Wiper arms (deformed or damaged)
of wiper assembly
Chapter 65 Wiper and washer – replacement
6. Wiper arms (deteriorated spring)
of wiper assembly
Chapter 65 Wiper and washer - inspection of
1. Washer switch (damaged)
wiper and washer
Washer doesn't work Chapter 65 Wiper and washer - inspection of
2. Washer pump assembly (damaged)
wiper and washer
3. Harness (broken circuit or short circuit) -
1. Washer fluid (inadequate) -
2. Washer fluid (frozen) -
3. Washer fluid hose (damaged or
No washer fluid injec- -
blocked)
tion or weak injection
4. Nozzle (blocked) Chapter 65. Wiper & washer - nozzle, check")
Chapter 65 Wiper and washer - inspection of
5. Washer pump assembly (damaged)
wiper and washer
Incorrect nozzle cover- Chapter 65 Wiper and washer - inspection of
1. Nozzle (adjustment required)
age wiper and washer
 04-360 DIAGNOSTICS - WIPER & WASHER

FRONT WIPER DOESN'T WORK

Circuit diagram

04
 DIAGNOSTICS - WIPER & WASHER 04-361

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse inside engine compartment: F8 (25A)

04

Check whether the result is normal?

Yes> go to step 3
No> replace fuse

2. Check the harness and connectors (front wiper assembly - ground)

(a) Ignition Switch: OFF.

(b) Disconnect the connector A007 of front wiper assembly.

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A 007 (4) - ground ＜2Ω
 04-362 DIAGNOSTICS - WIPER & WASHER

Check whether the result is normal?

Yes> go to next step.
No > Maintain or replace the harness

3. Check the harness and connectors (wiper and washer switch - ground)
(a) Ignition Switch: OFF.
04 (b) Disconnect the connector C012 of combination switch
(wiper).

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C012 (3) - ground ＜2Ω

Check whether the result is normal?

Yes> go to next step.
No > Maintenance or replace harness.

4. Check the front washer motor.

(a) Ignition Switch: OFF.
 DIAGNOSTICS - WIPER & WASHER 04-363

(b) Disconnect the connector A007 of front wiper assembly.

04

(c) Check the low gear function of front washer motor.

Conditions Connecting pin Specified value
Apply a battery volt- Battery (+)- 5
Low-speed running
age to between the
Battery (-)- 4 of front wiper motor
pins 1 and 5

(d) Check the high gear function of front wiper motor.

Conditions Connecting pin Specified value

Apply a battery voltage to between Battery (+)- 3 High-speed running of front wiper
the pins 3 and 4 Battery (-)- 4 motor

Check whether the result is normal?

Yes> go to next step.
No > Replace the motor assembly of front wiper.
 04-364 DIAGNOSTICS - WIPER & WASHER

B1376 HIGH-SPEED CONTROL CIRCUIT OF FRONT WIPER IS

OPEN-CIRCUITED
B1377 HIGH-SPEED CONTROL CIRCUIT OF FRONT WIPER IS
SUBJECTED TO HIGH CURRENT
Circuit diagram
04
 DIAGNOSTICS - WIPER & WASHER 04-365

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check fuse: F8 (25A) inside interior fuse box fuse.

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. check the high speed relay of front wiper.

(a) Ignition Switch: OFF.
(b) Pull out the high speed relay R11 of front wiper.

(c) Measure the electrical resistance based on the value in

the following form.
Standard voltage
Multimeter connec-
Conditions Standard value
tion
Normal situation 1–2 Breakover
Apply power supply
voltage to position
3–5 ＜2Ω
between stitch 1 and
2,

Check whether the result is normal?

Yes> go to step 3
No > Replace the high speed relay of front wiper.

3. check the low speed relay of front wiper.

(a) Ignition Switch: OFF.
(b) Pull out the low speed relay R10 of front wiper.
 04-366 DIAGNOSTICS - WIPER & WASHER

(c) Measure the electrical resistance based on the value in

the following form.
Standard voltage
Multimeter connec-
Conditions Standard value
tion
Normal situation 1–2 Breakover
04 Normal situation 3–4 ＜2Ω
Apply power supply
voltage to position
3–5 ＜2Ω
between stitch 1 and
2,

Check whether the result is normal?

Yes> go to step 4
No > Replace the low speed relay of front wiper.

4. Check the harness and connectors (high speed relay of front wiper - BCM control unit)
(a) Ignition Switch: OFF.
(b) Pull out the high speed relay R11 of front wiper.

(c) Disconnect connector C035, BCM control unit.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection stitch Specified value
R11（2）-C035（D24） ＜2Ω

Check whether the result is normal?

Yes> go to step 5
 DIAGNOSTICS - WIPER & WASHER 04-367

No > Maintenance or replace harness.

5. Check the harness and connectors (low speed relay of front wiper - BCM control unit)
(a) Ignition Switch: OFF.
(b) Pull out the low speed relay R10 of front wiper.

(c) Disconnect connector C035, BCM control unit.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection stitch Specified value
R10（1）-C035 （D23） ＜2Ω

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the combination switch (wiper).

(a) Ignition Switch: OFF.
 04-368 DIAGNOSTICS - WIPER & WASHER

(b) Disconnect the connector C012 of combination switch

(wiper).

04

(c) Check the combination switch (wiper).

Standard voltage
Multimeter connec-
Conditions Specified value
tion stitch
Switch off the wiper
1-3 ≥ 1 MΩ
switch
Turn on the low-
speed gear of wiper 1-3 ＜2Ω
switch

Check whether the result is normal?

Yes> go to step 7
No > Replace the combination switch.

7. Check the harness and connectors (combination switch - ground)

(a) Ignition Switch: OFF.

(b) Disconnect the connector C012 of combination switch

(wiper).
 DIAGNOSTICS - WIPER & WASHER 04-369

(c) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
C012 (3) - ground ＜2Ω
04

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check the harness and connectors (combination switch - BCM control unit)
(a) Ignition Switch: OFF.

(b) Disconnect the connector C012 of combination switch

(wiper).

(c) Disconnect connector C035, BCM control unit.

 04-370 DIAGNOSTICS - WIPER & WASHER

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
C012(1)-C035(D3) ＜2Ω
04

Check whether the result is normal?

Yes> go to step 9
No > Maintenance or replace harness.

9. Check the harness and connectors (high speed relay of front wiper – front wiper motor)
(a) Ignition Switch: OFF.
(b) Pull out the high speed relay R11 of front wiper.

(c) Disconnect the connector A007 of front wiper motor.

 DIAGNOSTICS - WIPER & WASHER 04-371

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
R11（5）-A007（3） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 10
No > Maintenance or replace harness.

10 . Check the harness and connectors (front wiper motor- ground)

(a) Ignition Switch: OFF.
(b) Pull out the high speed relay R11 of front wiper.

(c) Disconnect the connector A007 of front wiper motor.

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
A007 (4) - ground ＜2Ω

Check whether the result is normal?

No > Replace the front wiper motor.
No > Maintenance or replace harness.
 04-372 DIAGNOSTICS - WIPER & WASHER

B1374 LOW SPEED CONTROL CIRCUIT OF FRONT WIPER IS

SUBJECTED TO HIGH CURRENT
B1373 LOW SPEED CONTROL CIRCUIT OF FRONT WIPER IS
OPEN-CIRCUITED
Circuit diagram
04
 DIAGNOSTICS - WIPER & WASHER 04-373

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check fuse: F8 (25A) inside interior fuse box fuse.

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the low speed relay of front wiper.

(a) Ignition Switch: OFF.
(b) Pull out the low speed relay R10 of front wiper.

(c) Measure the electrical resistance based on the value in

the following form.
Standard voltage
Multimeter connec-
Conditions Standard value
tion
Normal situation 1–2 Breakover
Apply power supply
voltage to position
3–5 ＜2Ω
between stitch 1 and
2,

Check whether the result is normal?

Yes> go to step 3
No > Replace the low speed relay of front wiper.

3. Check the harness and connectors (low speed relay of front wiper - BCM control unit)
(a) Ignition Switch: OFF.
(b) Pull out the low speed relay R10 of front wiper.
 04-374 DIAGNOSTICS - WIPER & WASHER

(c) Disconnect connector C035, BCM control unit.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection stitch Specified value
R10（2）-C035 （D23） ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the combination switch (wiper).

(a) Ignition Switch: OFF.

(b) Disconnect the connector C012 of combination switch

(wiper).
 DIAGNOSTICS - WIPER & WASHER 04-375

(c) Check the combination switch (wiper).

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Switch off the wiper
2-3 ≥ 1 MΩ
switch
Turn on the low- 04
speed gear of wiper 2-3 ＜2Ω
switch

Check whether the result is normal?

Yes> go to step 5
No > Replace the combination switch.

5. Check the harness and connectors (power window switch of assistant driver’s door - BCM
control unit)
(a) Ignition Switch: OFF.

(b) Disconnect the connector C012 of combination switch

(wiper).
 04-376 DIAGNOSTICS - WIPER & WASHER

(c) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
C012 (3) - ground ＜2Ω
04

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the harness and connectors (combination switch - BCM control unit)
(a) Ignition Switch: OFF.

(b) Disconnect the connector C012 of combination switch

(wiper).

(c) Disconnect connector C035, BCM control unit.

 DIAGNOSTICS - WIPER & WASHER 04-377

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
C012（2）-C035（D2） ＜2Ω
04

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.

7. Check the harness and connectors (low speed relay of front wiper – front washer motor)
(a) Ignition Switch: OFF.
(b) Pull out the low speed relay R10 of front wiper.

(c) Disconnect the connector A007 of front wiper motor.

 04-378 DIAGNOSTICS - WIPER & WASHER

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
R10（5）-A007（5） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check the harness and connectors (front wiper motor- ground)

(a) Ignition Switch: OFF.
(b) Pull out the low speed relay R10 of front wiper.

(c) Disconnect the connector A007 of front wiper motor情况

与F04_10_8相同 .

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is an open
circuit)
Multimeter connection Standard value
A007 (4) - ground ＜2Ω

Check whether the result is normal?

No > Replace the front wiper motor.
No > Maintenance or replace harness.
 DIAGNOSTICS - WIPER & WASHER 04-379

FRONT WIPER DOESN'T WORK WHEN IT IS SET TO ITS

INTERMITTENT GEAR
Circuit diagram

04
 04-380 DIAGNOSTICS - WIPER & WASHER

Diagnostic steps

1. Check the low gear function of front washer motor.

(a) Ignition switch: ACC.
(b) Set the wiper and washer switch to the low-speed gear, and check the lower-speed running of front wiper
motor.
Check whether the result is normal?
04
Yes> go to step 3
No> go to step 2

2. Check the front washer motor.

(a) Ignition Switch: OFF.
(b) Disconnect the connector A007 of front wiper.

(c) Check the function of intermittent gear of front wiper motor

Conditions Connecting pin Specified value
Apply a battery volt- Battery (+)- 5
Low-speed running
age to between the
Battery (-)- 4 of front wiper motor
pins 5 and 4

Check whether the result is normal?

Yes> go to step 3
No > Replace the motor assembly of front wiper.

3. Check the harness and connectors (vehicle body controller -ground)

(a) Ignition Switch: ON.
 DIAGNOSTICS - WIPER & WASHER 04-381

(b) Use a multimeter to measure the voltage between pin E24

of connector C036 of vehicle body controller and ground.
Standard voltage
Multimeter connection Standard value
C036 (E24) - Ground Battery voltage

04

Check whether the result is normal?

Yes> go to step 4
No> go to step 5

4. Check the harness and connectors (vehicle body controller - front wiper assembly)
(a) Ignition Switch: OFF.

(b) Disconnect connector C036, body controller

(c) Disconnect the connector A007 of front wiper.

 04-382 DIAGNOSTICS - WIPER & WASHER

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A007 (2）-C036（E24） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the harness and connectors (vehicle body controller -ground)

(a) Ignition Switch: ON.

(b) Use a multimeter to measure the voltage between pin D4

of connector C035 of vehicle body controller and ground.
Standard voltage
Multimeter connection Standard value
C035 (D4) - ground Battery voltage

Check whether the result is normal?

Yes> go to step 6
No> replace body controller

6. Check the harness and connectors (vehicle body controller - combination switch (wiper)).
(a) Ignition Switch: OFF.
 DIAGNOSTICS - WIPER & WASHER 04-383

(b) Disconnect the connector C035 of the vehicle body

controller.

04

(c) Disconnect the connector C012 of combination switch

(wiper).

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C012 (4）-C035（D4） ＜2Ω

Check whether the result is normal?

Yes > Replace the combination switch.
No > Maintenance or replace harness.
 04-384 DIAGNOSTICS - WIPER & WASHER

FRONT WASHER DOESN'T WORK

Circuit diagram

04
 DIAGNOSTICS - WIPER & WASHER 04-385

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F32 (10A) in the vehicle-borne fuse box.

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the harness and connectors (fuse - combination switch (wiper)).

(a) Ignition Switch: OFF.

(b) Disconnect the connector C012 of combination switch

(wiper).
 04-386 DIAGNOSTICS - WIPER & WASHER

(c) Measure the voltage based on the value in the following

form.
Standard voltage
Multimeter connection Standard value
C012 (7) - ground Battery voltage

04

Check whether the result is normal?

Yes> go to step 3
Maintain or replace the harness

3. Check the harness and connectors (front washer motor - combination switch (wiper)).
(a) Ignition Switch: OFF.

(b) Disconnect the connector C012 of combination switch

(wiper).

(c) Disconnect the connector A015 of front washer motor.

 DIAGNOSTICS - WIPER & WASHER 04-387

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A015 (2)–C012（6) ＜2Ω
04

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the harness and connectors (front washer motor - ground)

(a) Ignition Switch: OFF.

(b) Disconnect the connector A015 of front washer motor.

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A015 1 (1) - Ground ＜2Ω

Check whether the result is normal?

Yes> go to step 5
 04-388 DIAGNOSTICS - WIPER & WASHER

No > Maintenance or replace harness.

5. Check the front washer motor.

(a) Connect the battery positive terminal (+) to pin 2 of front
washer motor connector.
(b) Connect the battery negative terminal (-) to pin 1 of front
washer motor connector.
04

Check whether there is fluid coming out of the front washer motoroutlet.
Yes > Replace the combination switch (wiper).
No > Replace the front washer motor.
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-389

AIR CONDITIONING SYSTEM

PRECAUTION
1. Do not handle refrigerant inside enclosed space or nearby open fire.
2. Protective glasses must be worn.
3. Be careful not to have eyes or skin exposed to liquid refrigerant.
If eyes or skin are exposed to liquid refrigerant:
(a) Rinse them with cold water with plenty of water. 04
(b) Apply clean vaseline onto the skin.
(c) Seek medical advice immediately or reach a hospital for professional treatment.
4. Do not heat up a container or have it exposed to open fire.
5. Do not allow a container to drop off or to be subjected to impact.
6. Do not allow the compressor to work if there is not enough refrigerant inside the refrigeration
system.
Lack of refrigerant inside the air conditioning system may cause inadequate lubrication and
damage to compressor.
7. Do not open the high pressure manifold valve when the compressor works.
(a) Open and close the low pressure valve only.
If the high-pressure valve is opened, the refrigerant may back flow and lead to fracture of
the charging cylinder.
8. Do not add too much refrigerant into the system.
(a) Too much refrigerant might cause the problems such as poor refrigeration performance, poor fuel
economy, and engine superheating etc.
9. Do not run the compressor when refrigerant is not available.
10 . Ignition switch representation
Ignition switch (location) Ignition switch representation
LOCK Ignition Switch: OFF.
ACC Ignition Switch ACC
ON Ignition Switch: ON.
START Start the engine.
 04-390 DIAGNOSTICS - AIR CONDITIONING SYSTEM

BASIC INSPECTION
Steps Inspection contents Measures
Check for refrigerant. Yes No> go to step 2
• Screw off the protective cap of maintenance
1 valve of air condition refrigeration system,
and push the valve core. No? Add refrigerant.

04 Check whether the result is normal?

Check the air condition switch. Yes No> go to step 3
• Turn on the air conditioner
2 • Check in a visual manner whether the air
conditioner operating indicator lamp goes on. No? to Defect Phenomenon Form
Check whether the result is normal?
Check the magnetic clutch. Yes No> go to step 4
• Check the magnetic clutch for normal engage-
3
ment. No? to Defect Phenomenon Form
Check whether the result is normal?
Check the drive belt. Yes No> go to step 5
4 • Check the drive belt for slippage.
No? to Defect Phenomenon Form
Check whether the result is normal?
Check the compressor. Yes No> go to step 6
• Check whether any abnormal sound may be
5
heard during operation of the compressor. No? to Defect Phenomenon Form
Check whether the result is normal?
Check the condenser. Yes No> go to step 7
• Check whether there is any rubbish lying
6 between the condenser and radiator. Remove the rubbish or replace the
• Check the condenser fan for normal work. No?
condenser fan
Check the condenser for normal work.
Check the pipeline and circuits. Yes Go to defect phenomenon form
• check the pipelines and circuits for any bends
7
or twists that might cause jamming. No? Lay again the pipeline and circuits
Check whether the result is normal?
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-391

COMPONENTS DRAWING

04
 04-392 DIAGNOSTICS - AIR CONDITIONING SYSTEM

1 Unit air heater 8 Evaporator shell (lower)

2 Core, unit air heater 9 Motor, circulating air door
3 Water pipe guard board, unit air 10 Blower
heater 11 Governing resistor
4 filter element baffle-plate, air 12 Expansion valve
conditioner 13 Motor, cold/warm air door
5 Filter element, air conditioner 14 Motor, mode air door
04 6 Evaporator shell (upper)
7 Evaporator
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-393

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Defect phenomenon Suspect Area Reference
1. Fuse -
2. Relay - 04
No function of the air Chapter 61. Heating & A/C - evaporator, replace-
3. Air condition magnifier
conditioning system ment
works
Chapter 61. Heating & A/C - A/C compressor, re-
4. A/C compressor
placement
5. Harness -
1. Fuse -
2. Relay -
3. Blower switch Chapter 61. Heating & A/C - blower, replacement
Air output control: 4. Governing resistor of blower Chapter 61. Heating & A/C - blower, replacement
Blower does not work
5. Blower motor Chapter 61. Heating & A/C - blower, replacement
Chapter 61. Heating & A/C - control mechanism,
6. Air conditioner controller
replacement
7. Harness -
1. Blower switch Chapter 61. Heating & A/C - blower, replacement
2. Governing resistor of blower Chapter 61. Heating & A/C - blower, replacement
3. Blower motor Chapter 61. Heating & A/C - blower, replacement
Air output control: Air Chapter 61. Heating & A/C - control mechanism,
exhaust is inadequate 4. Air conditioner controller
replacement
Chapter 61. Heating & A/C - instrument board air
5. Front air outlet
passage, replacement
6. Harness -
 04-394 DIAGNOSTICS - AIR CONDITIONING SYSTEM

Defect phenomenon Suspect Area Reference

1. Fuse -
2. Relay -
Chapter 61. Heating & A/C - A/C compressor,
3. A/C compressor
overhaul
Chapter 61. Heating & A/C - control mechanism,
4. Air conditioner controller
04 Refrigerating system: replacement
Failure to refrigerate Chapter 61. Heating & A/C - evaporator, replace-
5. Air condition magnifier
ment
6. Refrigerant -
Chapter 61. Heating & A/C - A/C pipeline, replace-
7. Air condition pipeline
ment
8. Harness -
1. Fuse -
Failure of servo motor Chapter 61. Heating & A/C - A/C air door motor,
2. Motor, air-conditioner air door
of mode air door replacement
3. Harness -
1. Fuse -
Failure of temperature Chapter 61. Heating & A/C - unit air heater, replace-
2.Temperature regulation servo motor
regulation servo motor ment
3. Harness -
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-395

NO FUNCTION OF THE AIR CONDITIONING SYSTEM WORKS

Circuit diagram

04
 04-396 DIAGNOSTICS - AIR CONDITIONING SYSTEM

Diagnostic steps

1. Check fuse
(a) Disconnect battery negative cable.

(b) Check the fuse inside the fuse box of engine compartment:
• F2（60A）
04 (c) Check the fuse inside the vehicle-body fuse box:
• F7（7.5A）
• F33（5A）

2. Check harness and connectors (vehicle-body fuse F7- air conditioner controller)
(a) Disconnect battery negative cable.

(b) Disconnect connector C021 of air-conditioner controller.

 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-397

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F7（7.5A）—C021（A1） ＜2
04

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connectors (vehicle-body fuse F33- air conditioner controller)
(a) Disconnect battery negative cable.

(b) Disconnect connector C021 of air-conditioner controller.

 04-398 DIAGNOSTICS - AIR CONDITIONING SYSTEM

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F33（5A）—C021（A1） ＜2
04

Check whether the result is normal?

Yes> go to step 10
No > Maintenance or replace harness.

4. Check the harness and connectors (air conditioner controller -ground)

(a) Disconnect battery negative cable.

(b) Disconnect connector C021 of air-conditioner controller.

 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-399

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C021 (A14) - ground
＜2
C021 (A16) - ground 04

Check whether the result is normal?

Yes > Replace the air conditioner controller, and verify again whether the failure exists.
No > Maintenance or replace harness.
 04-400 DIAGNOSTICS - AIR CONDITIONING SYSTEM

BLOWER DOES NOT WORK

Circuit diagram

04
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-401

Diagnostic steps

1. Check fuse
(a) Disconnect battery negative cable.

(b) Check the fuse inside the fuse box of engine compartment:
• F11（60A）
(c) Check the fuse inside the vehicle-body fuse box: 04
• F33（5A）
• F44（30）

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the starter relay

(a) Disconnect battery negative cable.
(b) Unplug the relay R4 of starter.

(c) Check the relay R4 of no-load starter.

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 1-2 Breakover
Apply power supply
voltage to position
3-4 ＜2
between stitch 3 and
4,

Check whether the result is normal?

Yes> go to step 3
No > Replace the starter relay, and verify again whether the failure exists.

3. Check the blower relay

 04-402 DIAGNOSTICS - AIR CONDITIONING SYSTEM

(a) Disconnect battery negative cable.

(b) Unplug the blower relay R3.

(c) Check the blower relay R3.

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
04
Normal situation 85–86 Breakover
Apply power supply
voltage to position
30–87 ＜2
between stitch 85
and 86,

Check whether the result is normal?

Yes> go to step 4
No > Replace the blower relay, and verify again whether the failure exists.

4. Check the harness and connectors (blower relay – blower motor)

(a) Disconnect battery negative cable.

(b) Disconnect the connector C025 of blower.

(c) Unplug the blower relay R3.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R3（30）—C025（1） ＜2
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-403

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the harness and connectors (blower motor – blower switch)

(a) Disconnect battery negative cable.

(b) Disconnect the connector C018 of blower switch. 04

(c) Disconnect the connector C025 of front blower.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C025（2）—C018（1） ＜2

Check whether the result is normal?

Yes> go to step 6
 04-404 DIAGNOSTICS - AIR CONDITIONING SYSTEM

No > Maintenance or replace harness.

6. Check the blower motor

(a) Connect the battery positive terminal (+) to pin 2 of blower
motor connectors.
(b) Connect the battery negative terminal (-) to pin 1 of blower
motor connectors.
04

Check whether the result is normal?

Yes> go to step 7
No > Replace the blower motor, and verify again whether the failure exists.

7. Check the harness and connectors (blower switch - ground)

(a) Disconnect battery negative cable.

(b) Disconnect the connector C018 of blower switch.

 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-405

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C018 (3) - ground ＜2
04

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

8. Check the harness and connectors (blower switch - air conditioner controller)
(a) Disconnect battery negative cable.

(b) Disconnect the connector C018 of blower switch.

(c) Disconnect the connector C021 of front air conditioner

controller.
 04-406 DIAGNOSTICS - AIR CONDITIONING SYSTEM

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C018（2）—C021（A5）
＜2
04 C018（2）—R3（85）

Check whether the result is normal?

Yes > Replace the blower switch, and verify again whether the failure exists.
No > Maintenance or replace harness.
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-407

AIR OUTPUT CONTROL: AIR EXHAUST IS INADEQUATE

Circuit diagram

04
 04-408 DIAGNOSTICS - AIR CONDITIONING SYSTEM

Diagnostic steps

1. Check the governing resistor of blower

(a) Disconnect battery negative cable.
(b) Replace the governing resistor of blower.
Check whether the result is normal?
Yes> go to step 2
04
No > Replace the blower governing resistor, and verify again whether the failure exists.

2. Check the harness and connectors (blower motor – blower governing resistor)
(a) Disconnect battery negative cable.

(b) Disconnect the connector C024 of blower governing

resistor.

(c) Disconnect the connector C025 of blower motor.

 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-409

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C025（2）—C024（4） ＜2
04

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check the harness and connectors (blower switch - ground)

(a) Disconnect battery negative cable.

(b) Disconnect the connector C018 of blower switch.

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C018 (3) - ground ＜2
 04-410 DIAGNOSTICS - AIR CONDITIONING SYSTEM

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the harness and connectors (blower governing resistor – blower switch)
(a) Disconnect battery negative cable.
04 (b) Disconnect the connector C018 of blower switch.

(c) Disconnect the connector C024 of blower governing

resistor.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C024（1）—C018（6）
C024（2）—C018（5） ＜2
C024（3）—C018（4）

Check whether the result is normal?

Yes> go to step 5
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-411

No > Maintenance or replace harness.

5. Check the harness and connectors (blower switch - air conditioner controller)
(a) Disconnect battery negative cable.

(b) Disconnect the connector C018 of blower switch.

04

(c) Disconnect the connector C021 of front air conditioner

controller.
(d) Measure the electrical resistance based on the value in
the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C018（2）—C021（A5） ＜2

Check whether the result is normal?

Yes > Replace the blower switch, and verify again whether the failure exists.
No > Maintenance or replace harness.
 04-412 DIAGNOSTICS - AIR CONDITIONING SYSTEM

REFRIGERATING SYSTEM: FAILURE TO REFRIGERATE (GASOLINE)

Circuit diagram

04
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-413

Diagnostic steps

1. Check fuse
(a) Disconnect battery negative cable.

(b) Check the fuse inside the fuse box of engine compartment:
• F20（7.5A）
(c) Check the fuse inside the vehicle-body fuse box: 04
• F25（7.5A）

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the relay of air conditioner compressor

(a) Disconnect battery negative cable.
(b) Unplug the relay R14 of air conditioner compressor

(c) Check the relay of air conditioner compressor

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 1-2 Breakover
Apply power supply
voltage to position
3-5 ＜2
between stitch 3 and
5,

Check whether the result is normal?

Yes> go to step 3
No > Replace the relay of air conditioner compressor, and verify again whether the failure exists.

3. Check the harness and connectors (relay of air conditioner compressor - ground)
 04-414 DIAGNOSTICS - AIR CONDITIONING SYSTEM

(a) Disconnect battery negative cable.

(b) Unplug the relay of air conditioner compressor
(c) Connect battery negative cable.
(d) Start the engine.
(e) Turn on the A/C switch.

(f) Measure the voltage based on the value in the following

04 form.
Standard voltage
Multimeter connection Standard value
R14 (2) - ground
Battery voltage
R14 (3) - ground

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the harness and connectors (air conditioner controller -air-condition pressure switch)
(a) Disconnect battery negative cable.

(b) Disconnect the connector C021 of air conditioner controller.

 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-415

(c) Disconnect the connector A001 of air-condition pressure

switch.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C021（A8）—A001（1） ＜2

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the harness and connectors (air-condition pressure switch - ground)

(a) Disconnect battery negative cable.

(b) Disconnect the connector C021 of air conditioner controller.

 04-416 DIAGNOSTICS - AIR CONDITIONING SYSTEM

(c) Disconnect the connector A001 of air-condition pressure

switch.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A001 (2) - ground ＜2

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the harness and connectors (air conditioner controller - engine control unit)
(a) Disconnect battery negative cable.

(b) Disconnect the connector A001 of air-condition pressure

switch.
(c) Unplug the electronic control unit E006 of engine.
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-417

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A001（3）—E006（26）
＜2
A001（4）—E006（50） 04

Check whether the result is normal?

Yes > Replace the air-condition pressure switch, and verify again whether the failure exists.
No > Maintenance or replace harness.

7. Check the harness and connectors (relay of air conditioner compressor - magnetic clutch)
(a) Unplug the relay R14 of air conditioner compressor
(b) Unplug the connector E017 of magnetic clutch.

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R14（5）- E017 ＜2

Check whether the result is normal?

Yes > Replace the magnetic clutch, and verify again whether the failure exists.
No > Maintenance or replace harness.

8. Check the harness and connectors (replay of air conditioner compressor - engine control unit)
(a) Disconnect battery negative cable.
(b) Unplug the relay R14 of air conditioner compressor
(c) Unplug the electronic control unit E006 of engine.
 04-418 DIAGNOSTICS - AIR CONDITIONING SYSTEM

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R14（1）—E006（10） ＜2
04

Check whether the result is normal?

Yes > Replace the engine control unit, and verify again whether the failure exists.
No > Maintenance or replace harness.
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-419

REFRIGERATING SYSTEM: FAILURE TO REFRIGERATE (DIESEL

OIL)
Circuit diagram

04
 04-420 DIAGNOSTICS - AIR CONDITIONING SYSTEM

Diagnostic steps

1. Check fuse
(a) Disconnect battery negative cable.

(b) Check the fuse inside the fuse box of engine compartment:
• F20（7.5A）
04 (c) Check the fuse inside the vehicle-body fuse box:
• F33（5A）

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the starter relay

(a) Disconnect battery negative cable.
(b) Unplug the relay R4 of starter.

(c) Check the relay, starter.

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 1-2 Breakover
Apply power supply
voltage to position
3-5 ＜2
between stitch 3 and
5,

Check whether the result is normal?

Yes> go to step 3
No > Replace the starter relay, and verify again whether the failure exists.

3. Check the harness and connectors (starter relay - ground)

 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-421

(a) Disconnect battery negative cable.

(b) Unplug the relay R4 of starter.
(c) Connect battery negative cable.
(d) Start the engine.
(e) Turn on the A/C switch.

(f) Measure the voltage based on the value in the following

form. 04
Standard voltage
Multimeter connection Standard value
R14 (2) - ground
Battery voltage
R14 (3) - ground

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the relay of air conditioner compressor

(a) Disconnect battery negative cable.
(b) Unplug the relay R14 of air conditioner compressor

(c) Check the relay of air conditioner compressor

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 1-2 Breakover
Apply power supply
voltage to position
3-5 ＜2
between stitch 3 and
5,

Check whether the result is normal?

Yes> go to step 5
No > Replace the relay of air conditioner compressor, and verify again whether the failure exists.
 04-422 DIAGNOSTICS - AIR CONDITIONING SYSTEM

5. Check the harness and connectors (relay of air conditioner compressor - ground)
(a) Disconnect battery negative cable.
(b) Unplug the relay R14 of air conditioner compressor
(c) Connect battery negative cable.
(d) Start the engine.
(e) Turn on the A/C switch.

04 (f) Measure the voltage based on the value in the following

form.
Standard voltage
Multimeter connection Standard value
R14 (2) - Ground
Battery voltage
R14 (3) - Ground

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the harness and connectors (air conditioner controller -air-condition pressure switch)
(a) Disconnect battery negative cable.

(b) Disconnect the connector C021 of air conditioner controller.

 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-423

(c) Disconnect the connector A001 of air-condition pressure

switch.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C021（A8）—A001（1） ＜2

Check whether the result is normal?

Yes> go to step 7
No > Maintenance or replace harness.

7. Check the harness and connectors (air-conditioner pressure switch - engine control unit)
(a) Disconnect battery negative cable.

(b) Disconnect the connector A001 of air-condition pressure

switch.
(c) Unplug the control unit E006 of engine.
 04-424 DIAGNOSTICS - AIR CONDITIONING SYSTEM

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A001（2）—E006（29） ＜2
04

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check the harness and connectors (air conditioner controller - engine control unit)
(a) Disconnect battery negative cable.

(b) Disconnect the connector A001 of air-condition pressure

switch.
(c) Unplug the electronic control unit E006 of engine.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A001（3）—E006（11）
＜2
A001（4）—E006（27）
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-425

Check whether the result is normal?

Yes > Replace the air-condition pressure switch, and verify again whether the failure exists.
No > Maintenance or replace harness.

9. Check the harness and connectors (relay of air conditioner compressor - magnetic clutch)
(a) Unplug the relay R14 of air conditioner compressor
(b) Unplug the connector E017 of magnetic clutch.
04
(c) Measure the electrical resistance based on the value in
the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R14（5）- E017 ＜2

Check whether the result is normal?

Yes > Replace the magnetic clutch, and verify again whether the failure exists.
No > Maintenance or replace harness.

10 . Check the harness and connectors (replay of air conditioner compressor - engine control unit)
(a) Disconnect battery negative cable.
(b) Unplug the relay R14 of air conditioner compressor
(c) Unplug the electronic control unit E006 of engine.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R14（1）—E006（48） ＜2

Check whether the result is normal?

 04-426 DIAGNOSTICS - AIR CONDITIONING SYSTEM

Yes > Replace the engine control unit, and verify again whether the failure exists.
No > Maintenance or replace harness.

04
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-427

FAILURE OF SERVO MOTOR OF MODE AIR DOOR

Circuit diagram

04

Diagnostic steps

1. Check fuse
(a) Disconnect battery negative cable.

(b) Check the fuse inside the vehicle-body fuse box:

• F7（7.5A）
• F9（5A）
• F33（5A）

Check whether the result is normal?

 04-428 DIAGNOSTICS - AIR CONDITIONING SYSTEM

Yes> go to step 2
No> replace fuse

2. Check the harness and connectors (air condition controller - mode air door servo motor)
(a) Disconnect battery negative cable.

(b) Disconnect the controller connector C022 of air conditioner.

04

(c) Disconnect the connector C014 of mode air door servo

motor.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C022（B2）—C014（1）
C022（B12）—C014（2）
C022（B1）—C014（3） ＜2
C022（B7）—C014（5）
C022（B8）—C014（6）
 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-429

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check the mode air door servo motor.

(a) Connect the battery positive terminal (+) to pin 3 of
connector of mode air door servo motor. 04
(b) Connect the battery negative terminal (-) to pin 1 of
connector of mode air door servo motor.

Check whether the result is normal?

Yes > Replace the air conditioner controller.
No > Replace the mode air door servo motor, and verify again whether the failure exists.
 04-430 DIAGNOSTICS - AIR CONDITIONING SYSTEM

FAILURE OF TEMPERATURE REGULATION SERVO MOTOR

Circuit diagram

04

Diagnostic steps

1. Check fuse
(a) Disconnect battery negative cable.

(b) Check the fuse inside the vehicle-body fuse box:

• F7（7.5A）
• F9（5A）
• F33（5A）

Check whether the result is normal?

 DIAGNOSTICS - AIR CONDITIONING SYSTEM 04-431

Yes> go to step 2
No> replace fuse

2. Check the harness and connectors (air condition controller - temperature regulation servo motor)
(a) Disconnect battery negative cable.

(b) Disconnect the controller connector C022 of air conditioner.

04

(c) Disconnect the temperature regulation servo motor C031.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C022（B2）—C031（1）
C022（B11）—C031（2）
C022（B1）—C031（3） ＜2
C022（B5）—C031（5）
C022（B6）—C031（6）
 04-432 DIAGNOSTICS - AIR CONDITIONING SYSTEM

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check the temperature regulation servo motor

(a) Connect the battery positive terminal (+) to pin 3 of
04 connector of temperature regulation servo motor.
(b) Connect the battery negative terminal (-) to pin 1 of
connector of temperature regulation servo motor.

Check whether the result is normal?

Yes > Replace the air conditioner controller.
No > Replace the temperature regulation servo motor, and verify again whether the failure exists.
 DIAGNOSTICS - AUDIO SYSTEM 04-433

AUDIO SYSTEM
PRECAUTION
1. It is strictly forbidden to modify the audio system or add other audio apparatus into the system.
2. The audio system uses the following radio bands.
Radiowave AM FM
Modulation meth-
Amplitude modulation Frequency modulation 04
ods
Wave bands: AM1 AM2 FM1 FM2
Frequency range 522 ～ 1620 KHz 87.5 ～ 108 MHz
3. Precautions for CD/DVD player
CAUTION

Do not look at laser head straight since the CD/DVD player uses invisible laser beams. Operate the player
according to the instruction strictly

(a) The CD/DVD player uses its laser head to read the digital signals recorded on the CDs/DVDs. It playbacks
music and other objects by converting digital signals into analog signals.
(b) The CD/DVD player uses 8cm and 12cm CD.
(c) CD player can only playback the CDs marked with the logo.

(d) DVD player can only playback the CDs marked with the
following logos.

(e) Precautions for usage of CDs

• The CD/DVD player is designed as a single-disc player. Never put multiple CDs into the player;
otherwise the player may be damaged.
 04-434 DIAGNOSTICS - AUDIO SYSTEM

• The CD/DVD player uses 12±0.03mm CDs.

• Some CDs/DVDs cannot be played back due to the special property or CDs or damages, filth or
aging of CDs after long-term storage inside the vehicle.
• The CDs shall be protected from filth/contamination. Be careful not to damage the CDs or have
finger marks left over on them.
• Hold the outer edge and center hole of a CD, with its labeled side facing upward.

• If a CD is kept outside the slot for a long period after the CD ejection button is pushed, the CD
04 may be subjected to deformation and cannot be used again.
• If there is any traces of tapes, labels or any similar labels are left over on a CD, the CD cannot
be ejected or may cause failure of the player.
• Keep the CDs from direct sunshine (CDs cannot be used if they are exposed to direct sunshine).
）
• Do not use any CDs/DVDs of grotesque in shape or appearance; otherwise the CD/DVD player
may fail to work.
• Do not use any CDs with transparent or partially transparent burnt sections because such CDs
cannot be inserted, ejected or played back normally.
(f) The following CDs may not be used, and the acoustics unit may be damaged if they are used.
 DIAGNOSTICS - AUDIO SYSTEM 04-435

(g) Cleaning
• If the CDs surfaces get dirty, wipe them from
interior to exterior in radial direction with dry soft
cloth (such as wiping cloth for plastic lens and
spectacles).

CAUTION
• Do not use camera lens cleanser since it may cause 04
the failure of laser head of the CD/DVD player.

• The CD surface may be damaged if wiping it with

hands or coarse cloth.
• CDs may be damaged by substances such as CD
atomizing agents, antistatic agents, alcohol, benzene
and thinning agents or cloth dipped with chemicals,
such that they may not be used again.

4. Switch off the power.

(a) When disconnecting or installing any electric equipments, or when the tools and equipments are easy
to contact exposed electric terminal, the negative（-）cable of the battery must be disconnected firstly
so as to prevent people or vehicles from being damaged.
(b) If there is special illustration, ignition switch must be closed.
 04-436 DIAGNOSTICS - AUDIO SYSTEM

COMPONENTS DRAWING

04

1 CD player assembly 4 Rear speaker LH

2 Antenna 5 Front speaker RH
3 Front speaker LH 6 Rear speaker RH
 DIAGNOSTICS - AUDIO SYSTEM 04-437

TERMINAL, ACOUSTICS UNIT

04

Terminal Connection rod color Description

no.
1 - -
2 Purple - white Speaker+, front left door
3 Green-black Speaker -, front left door
4 Black - pink Speaker +, rear left door
5 Grey Speaker -, rear left door
C029
6 Black Ground, circuit control switch
7 Red ACC power
8 - -
9 Blue Backlight lighting +
10 - -
 04-438 DIAGNOSTICS - AUDIO SYSTEM

Terminal Connection rod color Description

no.
11 brown Speaker+, front right door
12 Light green Speaker -, front right door
13 Orange: Speaker+, rear right door
14 Pink Speaker -, rear right door
04
15 Red-white Ground, circuit control switch
16 - -
17 - -
18 - -
19 Black-Red Constant power supply
20 Black ground
 DIAGNOSTICS - AUDIO SYSTEM 04-439

BASIC INSPECTION
Steps Inspection Measures
contents
Yes No> go to step 2
Check Battery voltage
1 Battery voltage shall not be lower than 12V. Replace the battery. Refer to
Check whether the result is normal? No? “Chapter 20A, start and charge-
-battery” 04
Check the antenna Yes No> go to step 3
• Check the antenna for foreign matter covering.
2 • Check the antenna for bending or deformation.
No? Repair or replace the antenna
Check whether the result is normal?

Check the acoustics unit Yes No> go to step 4

• Push the acoustics power switch, and check the liq-
3 uid crystal display for normal displaying. No? Go to defect phenomenon form
Check whether the result is normal?

Check the acoustics unit Yes No> go to step 5

• Set the volume to over 10VOL, and check the
4 speakers for sound. No? Go to defect phenomenon form
Check whether the result is normal?

Check the radiowave Yes Go to defect phenomenon form

• There is a big difference in the coverage of AM and
FM broadcast; sometimes AM broadcast may be
received clearly while FM stereo broadcast cannot
be received. The coverage of FM stereo broadcast
is the minimum one and is susceptible to the interfer-
ence of electromagnetic waves.
• Phasing adjustment interference may be generated
when a vehicle receives 2 radio-signals from 1 signal
radiation tower, one of which is received directly from
the signal radiation tower, and the other is reflected
by the ionosphere.
• Check whether or not there are high buildings or
5 mountains around the vehicle; if any, they may ob- Move the vehicle to a place with
No?
struct part of the signals coming from the signal radi- better signals available
ation tower to the vehicle.
• Check whether or not there are any large-scale
transformer substations and electric transmission
stations around the vehicle. The strong electromag-
netic wave emitted by them may lead to failure to
receive the broadcast signals.
• Due to the building materials, some buildings may
reflect broadcast signals such that 2 signals may be
received, and the desired signals are therefore inter-
fered.
Check whether the result is normal?
 04-440 DIAGNOSTICS - AUDIO SYSTEM

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Defect phenomenon Possible Cause Reference
Chapter 04 Audio system - acoustics
1. Power supply, ground circuit
unit does not work
04 Acoustics unit does not work
Chapter 04 Audio system - acoustics
2. Acoustics unit itself
unit does not work
Chapter 04 Audio system - Speakers
1. In mute mode
make no sound in any mode
Chapter 04 Audio system - Speakers
2. Speaker circuit
Speakers make no sound in any make no sound in any mode
mode Chapter 04 Audio system - Speakers
3. Speakers
make no sound in any mode
Chapter 04 Audio system - Speakers
4. Acoustics unit itself
make no sound in any mode
Chapter 04 Audio system - Speakers
1. Acoustics unit is set up improperly
make poor-quality sound in any mode
Speakers make poor-quality sound Chapter 04 Audio system - Speakers
2. Speaker circuit
in any mode make poor-quality sound in any mode
Chapter 04 Audio system - Speakers
3. Speakers
make poor-quality sound in any mode
Chapter 04 Audio system - Speakers
1. Acoustics unit is set up improperly
make weak sound in any mode
Chapter 04 Audio system - Speakers
2. Speaker circuit
Speakers make weak sound in any make weak sound in any mode
mode Chapter 04 Audio system - Speakers
3. Speakers
make weak sound in any mode
Chapter 04 Audio system - Speakers
4. Acoustics unit itself
make weak sound in any mode
Chapter 04 Audio system - Speakers
1. Acoustic fidelity of the media
make poor-quality sound only when
source file is poor
Speakers make poor-quality sound playing back CD/DVD
only when playing back CD/DVD Chapter 04 Audio system - Speakers
2. Acoustics unit itself make poor-quality sound only when
playing back CD/DVD
Chapter 04 Audio system - No radio
1. The interference of peripheral
stations can be received or the receiv-
electromagnetic waves is too strong
ing effect is poor
Chapter 04 Audio system - No radio
No radio stations can be received or
2. Antenna stations can be received or the receiv-
the receiving effect is poor
ing effect is poor
Chapter 04 Audio system - No radio
3. Acoustics unit itself stations can be received or the receiv-
ing effect is poor
 DIAGNOSTICS - AUDIO SYSTEM 04-441

Defect phenomenon Possible Cause Reference

Chapter 04 Audio system - CD/DVD
cannot be inserted/played back, or
1. CD cannot be recognized
CD/DVD is ejected immediately once
CD/DVD cannot be inserted/played it is inserted
back, or CD/DVD is ejected immedi-
ately once it is inserted Chapter 04 Audio system - CD/DVD
cannot be inserted/played back, or
2. Acoustics unit itself
CD/DVD is ejected immediately once 04
it is inserted
Chapter 66 Audio system - CD/DVD
1. Unknown CD is used
player assembly, replacement
CD/DVD cannot be ejected
Chapter 66 Audio system - CD/DVD
2. Acoustics unit itself
player assembly, replacement
1. Acoustic fidelity of the CD source Chapter 04 Audio system - CD/DVD
file is poor tune skipping
CD/DVD tune skipping
Chapter 04 Audio system - CD/DVD
2. Acoustics unit itself
tune skipping
Chapter 66 Audio system - CD/DVD
The display of CD/DVD player cannot 1. CDs
player assembly, replacement
display anything, while the acoustics
system works normally Chapter 66 Audio system - CD/DVD
2. Acoustics unit itself
player assembly, replacement
Chapter 66 Audio system - CD/DVD
1. CDs
player assembly, replacement
The display of CD/DVD player is ca-
pable of normal displaying, while the Chapter 66 Audio system - CD/DVD
2. Acoustics unit is set up improperly
speakers make no sound (in CD/DVD player assembly, replacement
playback mode only)
Chapter 66 Audio system - CD/DVD
3. Acoustics unit itself
player assembly, replacement
 04-442 DIAGNOSTICS - AUDIO SYSTEM

ACOUSTICS UNIT DOES NOT WORK

Circuit diagram

04

Diagnostic steps

1. Check the fuse of power supply to the audio system

(a) Ignition Switch: OFF.

(b) Check the fuse inside the vehicle-body fuse box:

• F22(7.5)

• F3(15A)

Check whether the fuse is good or not?

 DIAGNOSTICS - AUDIO SYSTEM 04-443

Yes> go to step 4
No > If fuse only: F22 (7.5A) is blown out, go to step 2. If fuse only: F3 (15A) is blown out, go to step 3.

2. Check the fuse of acoustics unit

(a) Disconnect the connectors of acoustics unit.
CAUTION
04
Be careful not to drop the acoustics unit.

(b) Use a multimeter to measure the resistance between pin

7 of connector C029 of acoustics unit and the ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C029(7) - ground ≥ 1 MΩ

Check whether the result is normal?

Yes > Replace the CD/DVD acoustics unit
No > Replace fuse: F22 (7.5A), and repair the to-earth short-circuit of circuit from fuse F22 (7.5A) to pin
7 of connector C029 of acoustics unit.

3. Check the fuse of acoustics unit

 04-444 DIAGNOSTICS - AUDIO SYSTEM

(a) Disconnect the connectors of acoustics unit.

CAUTION

Be careful not to drop the acoustics unit.

04

(b) Use a multimeter to measure the resistance between pin

19 of connector C029 of acoustics unit and the ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C029(19) - ground ≥ 1 MΩ

Check whether the result is normal?

Yes > Replace the CD/DVD acoustics unit
No > Replace fuse: F3 (15A), and repair the to-earth short-circuit of circuit from fuse F3 (15A) to pin 19
of connector C029 of acoustics unit.

4. Check the power supply and ground circuit of the audio system
(a) Ignition Switch: OFF.
 DIAGNOSTICS - AUDIO SYSTEM 04-445

(b) Disconnect the connectors of acoustics unit.

CAUTION

Be careful not to drop the acoustics unit.

(c) Ignition Switch: ON.

04

(d) Use a multimeter to measure the voltage between pin 7

and pin 20, and the voltage between pin 7 of connector
C029 of acoustics unit and the ground.
Standard voltage
Multimeter connection Standard value
C029(7) - C029(20) Battery voltage
C029(7) - ground Battery voltage

Check whether the result is normal?

Yes> go to step 5
No > If battery voltage is unavailable in both cases, repair the open circuit between F22 (7.5A) to pin 7
of connector C029 of acoustics unit. If battery voltage is not available only between pin 7 and pin 20 of
connector C029 of acoustics unit, repair the open circuit between pin 20 of connector C029 of acoustics
unit and the ground.

5. Check the power circuit of audio system

 04-446 DIAGNOSTICS - AUDIO SYSTEM

(a) Use a multimeter to measure the voltage between pin 19

of connector C029 of acoustics unit and the ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C029(19) - ground Battery voltage
04

Check whether the result is normal?

Yes > Replace the CD/DVD acoustics unit
No > Repair the open circuit between pin 19 of connector C029 of acoustics unit and the fuse F3 (15A).
 DIAGNOSTICS - AUDIO SYSTEM 04-447

SPEAKERS MAKE NO SOUND IN ANY MODE

Circuit diagram

04

Diagnostic steps

1. Check the setup of the acoustics unit

(a) Ignition switch: ON
(b) Push the power switch (PWR key) of acoustics unit.
(c) In start-up mode, push PWR key to access the mute function.
(d) Set the volume of acoustics unit to over 10VOL.
Check the speakers for sound making?
Yes > Acoustics unit is set up improperly.
No> go to step 1

2. Check the speakers

(a) Ignition Switch: OFF.
(b) Dismount all speakers see “Chapter 66 Audio system - speaker assembly,replacement”)
(c) Check the speakers for damaged cones.
 04-448 DIAGNOSTICS - AUDIO SYSTEM

(d) Use a multimeter to measure the resistance between pin

1 and pin 2 of the front speaker.
Standard voltage
Multimeter connection Standard value
Standard value 4Ω

04

(e) Use a multimeter to measure the resistance between pin

1 and pin 2 of the rear speaker.
Standard voltage
Multimeter connection Standard value
1-2 4Ω

Check whether the result is normal?

Yes> go to step 2
No > Replace the speakers.

3. Check the signal circuits of speakers

 DIAGNOSTICS - AUDIO SYSTEM 04-449

(a) Disconnect the connectors of acoustics unit.

04

(b) Use a multimeter to measure the resistance between the

pins of connector C029 of acoustics unit respectively.
Standard voltage
Multimeter connection Standard value
C029(2) - C029(3) ≥ 1 MΩ
C029(4) - C029(5) ≥ 1 MΩ
C029(11) - C029(12) ≥ 1 MΩ
C029(13) - C029(14) ≥ 1 MΩ

Check whether the result is normal?

Yes> go to step 3
No > Repair the short circuit between connector C029 of acoustics unit and the speakers.

4. Check the signal circuits of speakers for short circuit

 04-450 DIAGNOSTICS - AUDIO SYSTEM

(a) Use a multimeter to measure the resistance between pin

2 and pins 5, 11 and 14 of connector C029 of acoustics
unit and the ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value

04 C029(2) - ground ≥ 1 MΩ
C029(3) - ground ≥ 1 MΩ
C029(4) - ground ≥ 1 MΩ
C029(5) - ground ≥ 1 MΩ
C029(11) - ground ≥ 1 MΩ
C029(12) - ground ≥ 1 MΩ
C029(13) - ground ≥ 1 MΩ
C029(14) - ground ≥ 1 MΩ

Check whether the result is normal?

Yes> go to step 4
No >Repair the to-ground short circuit of signal circuits of speakers.

5. Check the signal circuits of speakers for short circuit

(a) Ignition Switch: ON.
(b) (b) Use a multimeter to measure the voltage between pin
2 and pins 5, 11 and 14 of connector C029 of acoustics
unit and the ground.
Standard voltage
Multimeter connection Standard value
C029(2) - ground 0V
C029(3) - ground 0V
C029(4) - ground 0V
C029(5) - ground 0V
C029(11) - ground 0V
C029(12) - ground 0V
C029(13) - ground 0V
C029(14) - ground 0V

Check whether the result is normal?

Yes > Replace the CD/DVD acoustics unit
No >Repair the to-power-supply short circuit of signal circuits of speakers.
 DIAGNOSTICS - AUDIO SYSTEM 04-451

SPEAKERS MAKE POOR-QUALITY SOUND IN ANY MODE

Diagnostic steps

1. Check the setup of the acoustics unit

(a) Ignition Switch: ON.
(b) Push the power switch of acoustics unit.
(c) Set the volume of acoustics unit to over 10VOL.
04
(d) Set the “FAD” and “BAL” to their initial settings.
(e) Push and hold “VOL” for at least 2 seconds to turn on the loudness function.
Check the speakers for normal tone quality?
Yes > CD/DVD acoustics unit is set up improperly.
No> go to step 2

2. Check the speakers

(a) Ignition Switch: OFF.
(b) Dismount the speakers. see “Chapter 66 Audio system - speaker assembly,replacement”)
(c) Check the speakers for attached foreign matters.
(d) Check the cones of speakers for excessive accumulated dust.
(e) Check the speakers for damaged cones.

(f) Use a multimeter to measure the resistance between pin

1 and pin 2 of the front speaker.
Standard voltage
Multimeter connection Standard value
1-2 4Ω
 04-452 DIAGNOSTICS - AUDIO SYSTEM

(g) Use a multimeter to measure the resistance between pin

1 and pin 2 of the rear speaker.
Standard voltage
Multimeter connection Standard value
1-2 4Ω

04

Check the speakers for normal tone quality?

Yes> go to step 3
No > Remove the foreign matters and dust, or replace the speakers.

3. Make comparison with similar vehicle models

(a) Set the acoustics unit “FAD” and “BAL” to one level.
(b) Make comparison with similar vehicle models
Check whether or not the tone quality of speakers is identical?
Yes > complete
No > Replace the CD/DVD acoustics unit
 DIAGNOSTICS - AUDIO SYSTEM 04-453

SPEAKERS MAKE WEAK SOUND IN ANY MODE

Circuit diagram

04

Diagnostic steps

1. Check the setup of the acoustics unit

(a) Ignition Switch: ON.
(b) Push the power switch of acoustics unit.
(c) Set the volume of acoustics unit to over 10VOL.
(d) Set “BAL” to 0.
Check the speakers for normal volume?
Yes > CD/DVD acoustics unit is set up improperly.
No> go to step 2

2. Check the speakers

(a) Ignition Switch: OFF.
(b) Dismount the speakers. see “Chapter 66 Audio system - speaker assembly,replacement”)
(c) Check the speakers for damaged cones.
 04-454 DIAGNOSTICS - AUDIO SYSTEM

(d) Use a multimeter to measure the resistance between pin

1 and pin 2 of the front speaker.
Standard voltage
Multimeter connection Standard value
1-2 4Ω

04

(e) Use a multimeter to measure the resistance between pin

1 and pin 2 of the rear speaker.
Standard voltage
Multimeter connection Standard value
1-2 4Ω

Check whether the result is normal?

Yes> go to step 3
No > Replace the speakers.

3. Check the circuits of speakers

DIAGNOSTICS - AUDIO SYSTEM 04-455

(a) Disconnect the connectors of acoustics unit.

04

(b) Use a multimeter to measure the resistance between pins

2 and 3 of connector C029 of acoustics unit and pins 1
and 2 of connector J005 of speaker of front left door.
Standard electrical resistance (check whether there existent
an open circuit)
Multimeter connection Standard value
C029(2)-J005(1) ≤2Ω
C029(3)-J005(2) ≤2Ω

(c) Use a multimeter to measure the resistance between pins

11 and 12 of connector C029 of acoustics unit and pins 1
and 2 of connector G004 of speaker of front right door.
Standard electrical resistance (check whether there existent
an open circuit)
Multimeter connection Standard value
C029(11)-G004(1) ≤2Ω
C029(12)-G004(2) ≤2Ω
 04-456 DIAGNOSTICS - AUDIO SYSTEM

(d) Use a multimeter to measure respectively the resistance

between pins 4 and 5 of connector C029 of acoustics unit
and pins 1 and 2 of connector J002 of speaker of rear left
door.
Standard electrical resistance (check whether there existent
an open circuit)
Multimeter connection Standard value
04 C029(4)-I002(1) ≤2Ω
C029(5)-I002(2) ≤2Ω

(e) Use a multimeter to measure respectively the resistance

between pins 13 and 14 of connector C029 of acoustics
unit and pins 1 and 2 of connector H002 of speaker of rear
right door.
Standard electrical resistance (check whether there existent
an open circuit)
Multimeter connection Standard value
C029(13)-H002(1) ≤2Ω
C029(14)-H002(2) ≤2Ω

Check whether the result is normal?

Yes> go to step 4
No > Repair the open circuit between connector C029 of acoustics unit and the speakers.

4. Make comparison with similar vehicle models

(a) Set the acoustics unit “FAD” and “BAL” to one level.
(b) Make comparison with similar vehicle models
Check whether or not the volume of speakers is identical?
Yes > complete
No > Replace the CD/DVD acoustics unit
 DIAGNOSTICS - AUDIO SYSTEM 04-457

SPEAKERS MAKE POOR-QUALITY SOUND ONLY WHEN PLAYING

BACK CD/DVD
Diagnostic steps
1. Check the CD/DVD media source files
(a) Change for a CD/DVD source file known as legal copy, and play it back.
Check the speakers for normal tone quality?
04
Yes > Please use genuine CDs/DVDs.
No> go to step 2
2. Check the setup of the acoustics unit
(a) Ignition Switch: ON.
(b) Push the power switch of acoustics unit.
(c) Set the volume of acoustics unit to over 10VOL.
(d) Set the “FAD” and “BAL” to their initial settings.
(e) Push and hold “VOL” for at least 2 seconds to turn on the loudness function.
(f) In CD/DVD mode, push the “CD/DVD” key successively, and select the tone field modes “FLAT”,
“JAZZ”, “POP”, “CLASSIC”, “ROCK” and“VOCAL” as per the type of music played back.
Check the speakers for normal tone quality?
Yes > CD/DVD acoustics unit is set up improperly.
No > Replace the CD/DVD acoustics unit
 04-458 DIAGNOSTICS - AUDIO SYSTEM

NO RADIO STATIONS CAN BE RECEIVED OR THE RECEIVING

EFFECT IS POOR
Diagnostic steps

1. Check the setup of the acoustics unit

(a) Ignition Switch: ON.
04 (b) Push the power switch “PWR” of acoustics unit.
(c) Set the volume of acoustics unit to over 10VOL.
(d) Push repeatedly “BAND” to select frequency channel “FM1”.
(e) Allow the acoustics unit to conduct automatic station searching.
Does the automatic station searching function of acoustics unit work normally?
Yes > Replace the acoustics unit.
No> go to step 2

2. Check the antenna of the acoustics unit

(a) Check the antenna for bending or deformation.
(b) Check the antenna for foreign matter covering.
Check whether the result is normal?
Yes> go to step 3
No > Replace the antenna.

3. Check the acoustics unit

(a) Ignition Switch: OFF.

(b) Remove the antenna connector of the acoustics unit.

 DIAGNOSTICS - AUDIO SYSTEM 04-459

(c) Ignition Switch: ON.

(d) Push the power switch of acoustics unit.
(e) Set the volume of acoustics unit to over 10VOL.
(f) Push repeatedly “BAND” to select frequency channel
“FM1”.
(g) Put a screwdriver, fine conductor or other metal object
onto the antenna socket of acoustics unit, and check and
verify that broadcast may be received. 04

Check whether or not the acoustics unit can receive broadcast?

Yes> go to step 4
No > Replace the acoustics unit.

4. Check the antenna cable

(a) Ignition Switch: OFF.
(b) Disconnect the antenna cable connector.
Check the both ends of antenna cable for continuity.
Yes > Replace the antenna.
no > clean and tighten the connectors between antenna cable and antenna, and the connectors between
antenna cable and acoustics unit. If the problem remains the same, replace the antenna cable.
 04-460 DIAGNOSTICS - AUDIO SYSTEM

CD/DVD CANNOT BE INSERTED/PLAYED BACK, OR CD/DVD IS

EJECTED IMMEDIATELY ONCE IT IS INSERTED
Diagnostic steps

1. Check whether or not a proper CD/DVD is inserted

(a) Ensure that the CD/DVD is an audio CD/DVD free of deformation, defect, filth, scribes or failure.
04 CAUTION
• Semitransparent or unique-shaped CDs/DVDs cannot be played back.
• CDs/DVDs attached with sticky paper labels shall not be played back.
• Commercial audio or audio-visual CDs/DVDs may be played back.
• For details about CDs/DVDs that may be played back, see “operating instruction manual for the
acoustics system”.

Check whether the result is normal?

Yes> go to step 2
No > Replace and use proper CDs/DVDs.

2. Check whether or not the CDs/DVDs are inserted properly

(a) Check whether or not the CDs/DVDs are inserted upside down.
Check whether the result is normal?
Yes> go to step 3
No > Please insert CDs/DVDs correctly (see “operating instruction manual for acoustics system”)

3. Check the CDs/DVDs

(a) Check whether or not the CDs/DVDs are too dirty.

(b) If yes, wipe and clean the CDs from interior to exterior in
radial direction with soft cloth, as shown in the figure.
CAUTION

Do not use ordinary CD cleanser or anti-static protective

material.

(c) Insert a CD/DVD

Check the acoustics unit for normal playback?

Yes > Please use clean CDs/DVDs.
No> go to step 4
 DIAGNOSTICS - AUDIO SYSTEM 04-461

4. Check the CD/DVD media source files

(a) Change for a CD/DVD source file known as legal copy, and play it back.
Check the acoustics unit for normal playback?
Yes > Please use genuine CDs/DVDs.
No> go to step 5

04
5. Check the acoustics unit
(a) Check the core for foreign matters.
(b) Check the core for existing CD.
(c) Check whether or not the core is already set to CD-inserted status; in such a case, push and hold the
ejection key to reset the core.
Check whether the result is normal?
Yes > Replace the CD/DVD acoustics unit
no > remove the existing CD, and reset the core. If there is any foreign matter, sent the player to
appointed service points for maintenance.
 04-462 DIAGNOSTICS - AUDIO SYSTEM

CD/DVD TUNE SKIPPING

Diagnostic steps

CAUTION

CD/DVD tune skipping may take place sometimes when the vehicle is running on uneven pavement.

04 1. Check the CDs/DVDs

(a) Ensure that the CD/DVD is free of deformation, filth and scribes.

(b) If yes, wipe and clean the CDs from interior to exterior in
radial direction with soft cloth, as shown in the figure.
CAUTION

Do not use ordinary CD cleanser or anti-static protective

material.

(c) Insert a CD/DVD

Check whether the result is normal?

Yes> go to step 2
No > Replace the vehicle-door master-control switch.

2. Check the CD/DVD media source files

(a) Change for a CD/DVD source file known as legal copy, and play it back.
Check the acoustics unit for normal playback?
Yes > Please use genuine CDs/DVDs.
No> go to step 3

3. Check the acoustics unit

(a) Check the acoustics unit for correct installation.
(b) Check whether or not the fixed bolts of acoustics unit are properly tightened.
(c) Check whether or not the operating site of acoustics unit is kept away from dust.
Check whether the result is normal?
Yes > Replace the CD/DVD acoustics unit
no > Reinstall the acoustics unit and keep it away from dust.
 DIAGNOSTICS - HORN 04-463

HORN
COMPONENTS DRAWING

04

1 Horn button 4 Althorn

2 Fuse box, engine compartment 5 Bass horn
3 Hexagonal bolt
 04-464 DIAGNOSTICS - HORN

DEFECT PHENOMENON FORM

When checking DTC in the checking module, if certain DTC displayed, then the circuit of the code
listed in the following list should be checked. The detailed description of each DTC can refer to
corresponding pages.
DTC code Diagnostic items (DTC definition) Trouble location
• fuse
04
• Horn relay
B1385 Open circuit of horn control circuit • Horn switch
• Control circuit

• fuse
• Horn relay
B1386 High current of horn control circuit • Horn switch
• Control module, engine
• Control circuit
 DIAGNOSTICS - HORN 04-465

B1385 OPEN CIRCUIT OF HORN CONTROL CIRCUIT

B1386 HIGH CURRENT OF HORN CONTROL CIRCUIT
Circuit diagram

04
 04-466 DIAGNOSTICS - HORN

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check fuse inside fuse box, engine compartment : F19

(15A).

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the horn relay

(a) Ignition Switch: OFF.
(b) Unplug the horn relay R13.

(c) Measure the electrical resistance based on the value in

the following form.
Standard voltage
Multimeter connec-
Conditions Specified value
tion stitch
Normal situation 1-2 Breakover
Apply power supply
voltage to position
3-5 ＜2Ω
between stitch 1 and
2,

Check whether the result is normal?

Yes> go to step 3
No > Replace the horn relay.

3. Check the harness and connectors (horn relay - BCM control unit)
 DIAGNOSTICS - HORN 04-467

(a) Ignition Switch: OFF.

(b) Unplug the horn relay R13.

(c) Disconnect connector C035, BCM control unit.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R13（2）-C035（D18） ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the harness and connector (BCM control unit - clock spring)
(a) Ignition Switch: OFF.

(b) Disconnect connector C035, BCM control unit.

 04-468 DIAGNOSTICS - HORN

(c) Disconnect the connector of lock spring C009.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there existent
an open circuit)
Multimeter connection Standard value
C035（D5）-C009（3） ＜2Ω

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.

5. Check the harness and connector (clock spring – horn switch)

(a) Ignition Switch: OFF.
 DIAGNOSTICS - HORN 04-469

(b) Disconnect the connector of lock spring C009.

(c) Disconnect the horn switch connector.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C009 (3) - horn switch ＜2Ω

Check whether the result is normal?

Yes > Replace the clock spring.
No > Maintenance or replace harness.

6. Check the harness and connectors (horn switch - ground)

(a) Ignition Switch: OFF.

(b) Disconnect the connector of lock spring C009.

(c) Disconnect the horn switch.
 04-470 DIAGNOSTICS - HORN

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
Horn switch - ground ＜2Ω
04

Check whether the result is normal?

Yes > Replace the horn switch.
No > Maintenance or replace harness.

7. Check the harness and connectors (horn relay - horn)

(a) Ignition Switch: OFF.
(b) Unplug the horn relay R13.

(c) Disconnect the connector A018 of bass horn.

(d) Disconnect the connector A017 of althorn.
 DIAGNOSTICS - HORN 04-471

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R13（5）-A018（1）
＜2Ω
R13（5）-A017（1） 04

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check the harness and connectors (horn - ground)

(a) Ignition Switch: OFF.
(b) Unplug the horn relay R13.

(c) Disconnect the connector A018 of bass horn.

(d) Disconnect the connector A017 of althorn.
 04-472 DIAGNOSTICS - HORN

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A018 (2) - ground
＜2Ω
04 A017 (2) - ground

Check whether the result is normal?

Yes > Replace the horn.
No > Maintenance or replace harness.
 DIAGNOSTICS - LIGHTING SYSTEM 04-473

LIGHTING SYSTEM
PRECAUTION
1. Precautions for usage of battery during inspection
(a) To use the battery for inspection, do not allow the tester probes of positive pole and negative pole to
abut against each other so as not to cause a short circuit.
2. Precautions for replacement of the headlight bulbs
(a) Any contamination of engine oil will reduce the lifecycle of the halogen bulbs. 04
(b) Since the interior of the halogen bulb is highly pressurized, handle it with great care. If the bulb is dropped,
it may explode and cause personal injury.
(c) Do not directly touch the bulb by hand.
(d) Always use a bulb of the same wattage for replacement.
(e) Once the bulb is installed, fix the bulb cover with care,Otherwise moisture may enter the combination
lamp. and make it cloudy or steamy.
3. Ignition switch representation
Ignition switch (location) Ignition switch representation
LOCK Ignition Switch: OFF.
ACC Ignition Switch ACC
ON Ignition Switch: ON.
START Start the engine.
 04-474 DIAGNOSTICS - LIGHTING SYSTEM

COMPONENTS DRAWING

04
 DIAGNOSTICS - LIGHTING SYSTEM 04-475

1 Front interior lamp assembly 8 Rear combination lamp assembly RH

2 Right turning signal assembly 9 Rear license plate lamp assembly
3 Front combination lamp assembly RH 10 Front fog lamp assembly LH
4 Front fog lamp assembly RH 11 Front combination lamp assembly LH
5 Rear combination lamp assembly LH 12 Left turning signal assembly
6 Top braking lamp 13 Rear interior lamp assembly
7 Rear fog lamp LH/RH 14 Step lamp
04
 04-476 DIAGNOSTICS - LIGHTING SYSTEM

BASIC INSPECTION
Steps Inspection contents Measures
Check Battery voltage Yes No> go to step 2
• Battery voltage shall not be lower than
1 12V. Charge or replace the battery. See
No?
"Chapter 20. Battery - Battery")
Check whether the result is normal?
04
Check the passing lamps. Yes No> go to step 3
• Ignition Switch: ON.
2 • Use the combination switch to turn on the
passing lamps. No? Go to defect phenomenon form
Check whether the result is normal?

Check the driving lights. Yes No> go to step 4

• Use the combination switch to turn on the
3 driving lights. No? Go to defect phenomenon form
Check whether the result is normal?

Check the cut-in lamps. Yes No> go to step 5

• Use the combination switch to turn on the
4 cut-in lamps. No? Go to defect phenomenon form
Check whether the result is normal?

Check the turn lights. Yes No> go to step 6

• Use the combination switch to turn on the
5 turn lights. No? Go to defect phenomenon form
Check whether the result is normal?

Check the hazard warning lamps. Yes No> go to step 7

• Use the hazard warning switch to turn on
6 the hazard warning lamps. No? Go to defect phenomenon form
Check whether the result is normal?

Check the room lamp. Yes Check the harness

• Use the room lamp switch to turn on the
7 room lights. No? Go to defect phenomenon form
Check whether the result is normal?
 DIAGNOSTICS - LIGHTING SYSTEM 04-477

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
1. Headlights
Defect phenomenon Suspect Area Reference
Chapter 64 Lighting – bulb of
1. Bulb front combination lamp assembly 04
Passing lamp on 1 side fails to go
on LH, replacement
2. Harness -
Chapter 64 Lighting – bulb of
1. Bulb front combination lamp assembly
LH, replacement

Passing lamps on 2 sides fail to 2. Relay -

go on 3. Harness -
Chapter 51 Steering gear - combi-
4. Combination switch nation switch assembly, replace-
ment
Chapter 64 Lighting – bulb of
Driving light on 1 side fails to go 1. Bulb front combination lamp assembly
on LH, replacement
2. Harness -
1. Relay -
Chapter 51 Steering gear - combi-
Driving lights on 2 sides fail to go
2. Combination switch nation switch assembly, replace-
on
ment
3. Harness -
Chapter 51 Steering gear - combi-
1. Combination switch nation switch assembly, replace-
ment
Driving light and passing lamp on
Chapter 64 Lighting – bulb of
1 side fail to go on
2. Bulb front combination lamp assembly
LH, replacement
3. Harness -
1. Relay -
Chapter 51 Steering gear - combi-
Driving light and passing lamp on
2. Combination switch nation switch assembly, replace-
2 sides fail to go on
ment
3. Harness -
2. Fog lamp
Defect phenomenon Suspect Area Reference
Front fog lamp on 1 side fails to Chapter 64 Lighting – bulb of
1. Bulb
go on front fog lamp LH, replacement
 04-478 DIAGNOSTICS - LIGHTING SYSTEM

Defect phenomenon Suspect Area Reference

Chapter 51 Steering gear - combi-
2. Combination switch nation switch assembly, replace-
ment
3. Harness -
1. Fuse -
04 2. Relay -
Front fog lamps on 2 sides fail to Chapter 51 Steering gear - combi-
go on 3. Combination switch nation switch assembly, replace-
ment
4. Harness -
Chapter 51 Steering gear - combi-
1. Combination switch nation switch assembly, replace-
ment
Front fog lamp is constantly on
2. Front fog lamp relay -
3. Harness -
Chapter 64 Lighting – bulb of rear
1. Bulb combination lamp assembly LH,
replacement
Rear fog lamp on 1 side fails to go
Chapter 51 Steering gear - combi-
on
2. Combination switch nation switch assembly, replace-
ment
3. Harness -
Chapter 64 Lighting – bulb of rear
1. Bulb combination lamp assembly LH,
replacement
Rear fog lamps on 2 sides fail to Chapter 64 Lighting - the rear fog
go on 2. Rear fog lamp switch
lamp switch，transmission,
3. 3-in-1 controller -
4. Harness -
Chapter 64 Lighting - the rear fog
1. Rear fog lamp switch
lamp switch，transmission,
Rear fog lamp is constantly on
2. 3-in-1 controller -
3. Harness -
3. Turn lights and hazard warning lamps
Defect phenomenon Suspect Area Reference
1. Fuse -
Chapter 83. Dashboard/instru-
Hazard warning lights fail to go on 2. Hazard warning switch ments - instrument panel, replace-
(turn lights work normally) ment
3. 3-in-1 controller -
4. Harness -
 DIAGNOSTICS - LIGHTING SYSTEM 04-479

Defect phenomenon Suspect Area Reference

1. Fuse -
Chapter 51 Steering gear - combi-
Turn lights fail to go on (hazard 2. Combination switch nation switch assembly, replace-
warning lamps work normally) ment
3. 3-in-1 controller -
4. Harness - 04
1. 3-in-1 controller -
Chapter 51 Steering gear - combi-
Turn lights and hazard warning
2. Combination switch nation switch assembly, replace-
lamps fail to go on
ment
3. Harness -
Chapter 51 Steering gear - combi-
1. Combination switch nation switch assembly, replace-
ment
Turn light on 1 side fails to go on
2. 3-in-1 controller -
3. Harness -
1. 3-in-1 controller -
Chapter 83. Dashboard/instru-
2. Hazard warning switch ments - instrument panel, replace-
Hazard warning lamps are con- ment
stantly on Chapter 51 Steering gear - combi-
3. Combination switch nation switch assembly, replace-
ment
4. Harness -
4. Brake lamps
Defect phenomenon Suspect Area Reference
1. Fuse -
Brakes lamps on 2 sides fail to go Chapter 35 Driving braking - brake
2. Brake lamp switch
on pedal, replacement
3. Harness -
Chapter 64 Lighting – bulb of rear
Brakes lamp on 1 side fails to go 1. Bulb combination lamp assembly LH,
on replacement
2. Harness -
Chapter 88 Interior & exterior trims
1. Bulb
Top brakes lamps fail to go on - spoiler assembly, replacement
2. Harness -
5. Reverse lamps
Defect phenomenon Suspect Area Reference
Chapter 64 Lighting – bulb of rear
Reverse lamp on 1 side fails to go
1. Bulb combination lamp assembly LH,
on
replacement
 04-480 DIAGNOSTICS - LIGHTING SYSTEM

Defect phenomenon Suspect Area Reference

2. Harness -
1. Fuse -
Chapter 41 Transmission - primary
2. Reverse lamp switch shaft and reverse gear, replace-
Reverse lamps on 2 sides fail to ment
04 go on Chapter 64 Lighting – bulb of rear
3. Bulb combination lamp assembly LH,
replacement
4. Harness -
6. Interior lamp
Defect phenomenon Suspect Area Reference
Chapter 64 Lighting –front read-
1. Bulb
ing/map lamp, replacement
Reading/map lamp fails to go on Chapter 64 Lighting –front read-
2. Front indoor roof lamp switch
ing/map lamp, replacement
3. Harness -
Chapter 64 Lighting –rear roof
1. Bulb
lamp assembly, replacement
Rear roof lamp fails to go on Chapter 64 Lighting –rear roof
2. Rear roof lamp switch
lamp assembly, replacement
3. Harness -
Chapter 64 Lighting –step lamp
1. Door control switch
assembly, replacement
Sliding-door step lamp fails to go
on Chapter 64 Lighting –step lamp
2. Bulb
assembly, replacement
3. Harness -
1. Bulb -
1. Baggage compartment lamp Chapter 64 Lighting –step lamp
2. Door control switch
fails to go on. assembly, replacement
3. Harness -
7. Interior background lamp lighting
Defect phenomenon Suspect Area Reference
Chapter 83 Dashboard/instruments
Backlight in combination instru- 1. Light emitting diode (LED) - combination instrument, replace-
ment fails to go on ment
2. Harness -
Chapter 83 Dashboard/instruments
Backlight in electronic clock fails 1. Electronic clock assembly - combination instrument, replace-
to go on ment
2. Harness -
 DIAGNOSTICS - LIGHTING SYSTEM 04-481

Defect phenomenon Suspect Area Reference

Chapter 83 Dashboard/instruments
Backlight in hazard switch fails to 1. Hazard warning switch assembly - combination instrument, replace-
go on ment
2. Harness -
Chapter 83 Dashboard/instruments
Backlight in 12V power outlet 1. Power outlet socket - combination instrument, replace-
ment 04
socket fails to go on
2. Harness -
Chapter 83 Dashboard/instruments
Backlight in cigarette lighter fails 1. Cigarette lighter assembly - combination instrument, replace-
to go on ment
2. Harness -
Chapter 83 Dashboard/instruments
Backlight in front air conditioner 1. Front air conditioner controller - combination instrument, replace-
controller fails to go on ment
2. Harness
Chapter 83 Dashboard/instruments
Backlight in radio recorder player 1. Radio recorder player assembly - combination instrument, replace-
fails to go on ment
2. Harness
Chapter 83 Dashboard/instruments
Backlight in rear fog lamp switch 1. Rear fog lamp switch assembly - combination instrument, replace-
fails to go on ment
2. Harness -
Chapter 83 Dashboard/instruments
1. Rear-view mirror defrosting
Backlight in rear-view mirror de- - combination instrument, replace-
switch
frosting switch fails to go on ment
2. Harness -
Chapter 83 Dashboard/instruments
Backlight in combined display ails 1 Combined display assembly - combination instrument, replace-
to go on ment
2. Harness -
Chapter 83 Dashboard/instruments
1. Rear window defrost switch as-
Backlight in rear window defrost - combination instrument, replace-
sembly
switch fails to go on ment
2. Harness -
Chapter 83 Dashboard/instruments
1. Rear heater switch (front con-
Backlight in rear heater switch - combination instrument, replace-
trol) assembly
(front control) fails to go on ment
2. Harness -
Chapter 83 Dashboard/instruments
Backlight in rear heater switch 1. Rear heater switch (rear control) - combination instrument, replace-
(rear control) fails to go on ment
2. Harness -
 04-482 DIAGNOSTICS - LIGHTING SYSTEM

Defect phenomenon Suspect Area Reference

Chapter 83 Dashboard/instruments
Backlight in rear heater controller 1. Rear heater controller - combination instrument, replace-
fails to go on ment
2. Harness -
Chapter 83 Dashboard/instruments
Backlight in rear A/C switch (front 1. Rear A/C switch (front control) - combination instrument, replace-
04 ment
control) fails to go on
2. Harness -
8. Side-marker lamps, back lamps and license plate lamp
Defect phenomenon Suspect Area Reference
Chapter 64 Lighting –front combi-
Front side-marker lamp fails to go 1. Bulb
nation lamp LH, replacement
on
2. Harness -
Chapter 64 Lighting –rear combi-
1. Bulb
Rear back lamps fail to go on nation lamp LH, replacement
2. Harness -
1. Fuse -
2. Small light relay -

License plate lamp fails to go on Chapter 51 Steering gear - combi-

3. Combination switch nation switch assembly, replace-
ment
4. Harness -
1. Fuse -
2. Relay -
No side-marker lamps, back lamps Chapter 51 Steering gear - combi-
and license plate lamp go on 3. Combination switch nation switch assembly, replace-
ment
4. Harness -
 DIAGNOSTICS - LIGHTING SYSTEM 04-483

B1346 OPEN CIRCUIT OF DRIVING LIGHT CONTROL CIRCUIT

B1347 HIGH CURRENT OF DRIVING LIGHT CONTROL CIRCUIT
Circuit diagram

04
 04-484 DIAGNOSTICS - LIGHTING SYSTEM

Diagnostic steps

1. Check the bulbs of driving lights.

(a) Ignition Switch: OFF.

(b) Check whether or not the bulbs of front fog lamps are
damaged.

04

Check whether the result is normal?

Yes> go to step 2
No > Replace the bulbs of driving lights.

2. Check the relays of driving lights

(a) Ignition Switch: OFF.
(b) Unplug the relays R6 of driving lights

(c) Check the relays R6 of driving lights.

Standard voltage
Connecting pins
Conditions Specified value
of multimeter
Normal situation 1–2 Breakover
Apply power supply
voltage to position
3–5 ＜2Ω
between stitches 1
and 2,

Check whether the result is normal?

Yes> go to step 3
No > Replace the driving light relay.

3. Check the harness and connectors (driving light relay – supply voltage)
 DIAGNOSTICS - LIGHTING SYSTEM 04-485

(a) Ignition Switch: OFF.

(b) Unplug the relays R6 of driving lights

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
04
Multimeter connection Standard value
R6 (1) - Ground 9-16V (battery voltage)
R6 (3) - Ground 9-16V (battery voltage)

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F27 (15A) inside the fuse box of engine
compartment.

Check whether the result is normal?

Yes> go to step 5
No> replace fuse

5. Check the harness and connectors (driving light relay – driving light)
(a) Ignition Switch: OFF.
(b) Unplug the relays R6 of driving lights
 04-486 DIAGNOSTICS - LIGHTING SYSTEM

(c) Disconnect the connector A011 of left front driving light.

(d) Disconnect the connector A003 of right front driving light.

04

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R2（5）-A011（2）
＜2Ω
R2（5）-A003（2）

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the harness and connectors (driving light - ground)

(a) Ignition Switch: OFF.
(b) Unplug the relays R6 of driving lights

(c) Disconnect the connector A011 of left front driving light.

(d) Disconnect the connector A003 of right front driving light.
 DIAGNOSTICS - LIGHTING SYSTEM 04-487

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A011 (5) - ground
＜2Ω
A003 (5) - ground 04

Check whether the result is normal?

Yes> go to step 7
No > Maintenance or replace harness.

7. Check the harness and connectors (driving light relay - BCM control unit)
(a) Ignition Switch: OFF.
(b) Unplug the relays R6 of driving lights

(c) Disconnect connector C035, BCM control unit.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R6(1)-C035（D14） ＜2Ω

Check whether the result is normal?

 04-488 DIAGNOSTICS - LIGHTING SYSTEM

Yes> go to step 8
No > Maintenance or replace harness.

8. Check the combination switch (lamplight switchover)

(a) Ignition Switch: OFF.

(b) Disconnect the connector C008 of combination switch

04 (lamplight switchover).

(c) Check the combination switch (lamplight switchover)

Standard voltage
Connecting pins
Conditions Specified value
of multimeter
Turn off the driving
19-20 ≥ 1 MΩ
light switch
Turn on the driving
19-20 ＜2Ω
light switch

Check whether the result is normal?

Yes> go to step 9
No > Replace the combination switch.

9. Check the harness and connectors (combination switch - ground)

(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-489

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C008 (19) - ground ＜2Ω

Check whether the result is normal?

Yes> go to step 10
No > Maintenance or replace harness.

10 . Check the wiring harness and connectors (BCM controlling unit - combination switch)
(a) Ignition Switch: OFF.
 04-490 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Disconnect the connector C036 of BCM control unit.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C036（E7）-C040（20） ＜2Ω

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.
 DIAGNOSTICS - LIGHTING SYSTEM 04-491

B1344OPEN CIRCUIT OF PASSING LAMP CONTROL CIRCUIT

B1345HIGH CURRENT OF PASSING LAMP CONTROL CIRCUIT
Circuit diagram

04
 04-492 DIAGNOSTICS - LIGHTING SYSTEM

Diagnostic steps

1. Check the low beam bulbs.

(a) Ignition Switch: OFF.

(b) Check whether or not the low beam bulbs are damaged.

04

Check whether the result is normal?

Yes> go to step 2
No > Replace the low beam bulbs.

2. Check the relays of passing lamps

(a) Ignition Switch: OFF.
(b) Unplug the relay R2 of passing lamps.

(c) Check the front fog lamp relay R2.

Standard voltage
Connecting pins
Conditions Specified value
of multimeter
Normal situation 1–2 Breakover
Apply power supply
voltage to position
3–5 ＜2Ω
between stitches 1
and 2,

Check whether the result is normal?

Yes> go to step 3
No > Replace the relays of passing lamps.

3. Check the harness and connectors (passing lamp relay – supply voltage)
 DIAGNOSTICS - LIGHTING SYSTEM 04-493

(a) Ignition Switch: ON.

(b) Unplug the relay R2 of passing lamps.

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
04
Multimeter connection Standard value
R2 (1) - Ground 9-16V (battery voltage)
R2 (3) - Ground 9-16V (battery voltage)

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse inside the fuse box of engine compartment:
• F21（10A）
• F22（10A）

Check whether the result is normal?

Yes> go to step 5
No> replace fuse

5. Check the harness and connectors (passing lamp relay – passing lamps)
(a) Ignition Switch: OFF.
(b) Unplug the relay R2 of passing lamps.
 04-494 DIAGNOSTICS - LIGHTING SYSTEM

(c) Disconnect the connector A011 of left front passing lamp.

(d) Disconnect the connector A003 of right front passing lamp.

04

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R2（5）-A011（1）
＜2Ω
R2（5）-A003（1）

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the harness and connectors (passing lamp - ground)

(a) Ignition Switch: OFF.
(b) Unplug the relay R2 of passing lamps.

(c) Disconnect the connector A011 of left front passing lamp.

(d) Disconnect the connector A003 of right front passing lamp.
 DIAGNOSTICS - LIGHTING SYSTEM 04-495

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A011 (5) - ground
＜2Ω
A003 (5) - ground 04

Check whether the result is normal?

Yes> go to step 7
No > Maintenance or replace harness.

7. Check the harness and connectors (passing lamp relay - BCM control unit)
(a) Ignition Switch: OFF.
(b) Unplug the fog lamp relay R2.

(c) Disconnect connector C035, BCM control unit.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R2(2)-C035（D15） ＜2Ω

Check whether the result is normal?

 04-496 DIAGNOSTICS - LIGHTING SYSTEM

Yes> go to step 8
No > Maintenance or replace harness.

8. Check the combination switch (lamplight switchover)

(a) Ignition Switch: OFF.

(b) Disconnect the connector C008 of combination switch

04 (lamplight switchover).

(c) Check the combination switch (lamplight switchover)

Standard voltage
Connecting pins
Conditions Specified value
of multimeter
Turn off the passing
11-13 ≥ 1 MΩ
lamp switch
Turn on the passing
11-13 ＜2Ω
lamp switch

Check whether the result is normal?

Yes> go to step 9
No > Replace the combination switch.

9. Check the harness and connectors (combination switch - ground)

(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-497

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C008 (13) - ground ＜2Ω

Check whether the result is normal?

Yes> go to step 10
No > Maintenance or replace harness.

10 . Check the wiring harness and connectors (BCM controlling unit - combination switch)
(a) Ignition Switch: OFF.
 04-498 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Disconnect the connector C036 of BCM control unit.

(d) Measure the resistance as per the values given in the table
below
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C036(E6)-C008(11) ＜2Ω

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.
 DIAGNOSTICS - LIGHTING SYSTEM 04-499

B1045OPEN CIRCUIT OF FRONT FOG LAMP CONTROL CIRCUIT

B1046HIGH CURRENT OF FRONT FOG LAMP CONTROL CIRCUIT
Circuit diagram

04
 04-500 DIAGNOSTICS - LIGHTING SYSTEM

Diagnostic steps

1. Check the front fog lamp bulb.

(a) Ignition Switch: OFF.

(b) Check whether or not the bulbs of front fog lamps are
damaged.

04

Check whether the result is normal?

Yes> go to step 2
No > Replace the front fog lamp bulb.

2. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F18 (15A) inside the fuse box of engine
compartment.

Check whether the result is normal?

Yes> go to step 3
No> replace fuse

3. Check the front fog lamp relay.

(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-501

(b) Unplug the front fog lamp relay R7.

(c) Check the front fog lamp relay R7.

Standard voltage
Connecting pins
Conditions Specified value
of multimeter
Normal situation 1–2 Breakover 04
Apply power supply
voltage to position
3–5 ＜2Ω
between stitches 1
and 2,

Check whether the result is normal?

Yes> go to step 4
No > Replace the front fog lamp relay.

4. Check the harness and connectors (front fog lamp relay – front fog lamp)
(a) Ignition Switch: OFF.
(b) Unplug the front fog lamp relay R7.

(c) Disconnect the left front fog lamp connector A016.

(d) Disconnect the right front fog lamp connector A005.
 04-502 DIAGNOSTICS - LIGHTING SYSTEM

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R7（5）-A016（1）
＜2Ω
04 R7（5）-A005（1）

Check whether the result is normal?

Yes> go to step 5
No > Maintain or replace the harness

5. Check the harness and connectors (front fog lamp - ground)

(a) Ignition Switch: OFF.
(b) Unplug the front fog lamp relay R7.

(c) Disconnect the left front fog lamp connector A016.

(d) Disconnect the right front fog lamp connector A005.
 DIAGNOSTICS - LIGHTING SYSTEM 04-503

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A016 (2) - ground
＜2Ω
A005 (2) - ground 04

Check whether the result is normal?

Yes> go to step 6
No > Maintain or replace the harness

6. Check the harness and connectors (fog lamp relay - BCM control unit)
(a) Ignition Switch: OFF.
(b) Unplug the fog lamp relay R7.

(c) Disconnect connector C035, BCM control unit.

 04-504 DIAGNOSTICS - LIGHTING SYSTEM

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
R7（2）- C035（D16） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 7
No > Maintain or replace the harness

7. Check the combination switch (lamplight switchover)

(a) Ignition Switch: OFF.

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).
 DIAGNOSTICS - LIGHTING SYSTEM 04-505

(c) Check the combination switch (lamplight switchover)

Standard voltage
Connecting pins
Conditions Specified value
of multimeter
Turn off the fog lamp
7-8 ≥ 1 MΩ
switch
Turn on the fog lamp 04
7-8 ＜2Ω
switch

Check whether the result is normal?

Yes> go to step 8
No > Replace the combination switch.

8. Check the harness and connectors (combination switch - ground)

(a) Ignition Switch: OFF.

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).
 04-506 DIAGNOSTICS - LIGHTING SYSTEM

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C008 (7) - ground ＜2Ω
04

Check whether the result is normal?

Yes> go to step 9
No > Maintenance or replace harness.

9. Check the wiring harness and connectors (BCM controlling unit - combination switch)
(a) Ignition Switch: OFF.

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

(c) Disconnect the connector C036 of BCM control unit.

 DIAGNOSTICS - LIGHTING SYSTEM 04-507

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C036（E9）-C008（8） ＜2Ω
04

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.
 04-508 DIAGNOSTICS - LIGHTING SYSTEM

B1048OPEN CIRCUIT OF REAR FOG LAMP CONTROL CIRCUI

B1049LOW CURRENT OF REAR FOG LAMP CONTROL CIRCUIT
B1050 HIGH CURRENT OF REAR FOG LAMP CONTROL CIRCUIT
Circuit diagram

04

Diagnostic steps
 DIAGNOSTICS - LIGHTING SYSTEM 04-509

1. Check the rear fog lamp bulb.

(a) Ignition Switch: OFF.

(b) Check whether or not the bulbs of rear fog lamps are
damaged.

04

Check whether the result is normal?

Yes> go to step 2
No > Replace the rear fog lamp bulbs.

2. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F1 (15A) in the indoor fuse box.

Check whether the result is normal?

Yes> go to step 3
No> replace fuse

3. Check the harness and connector (fuse-BCM control unit)

(a) Disconnect battery negative cable.
 04-510 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect connector C033 , BCM control unit.

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F1(15A)-C033（B6） ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the harness and connector (BCM control unit - rear fog lamp)
(a) Ignition Switch: OFF.

(b) Disconnect the connector C034 of BCM control unit.

 DIAGNOSTICS - LIGHTING SYSTEM 04-511

(c) Disconnect the left rear fog lamp connector B011.

(d) Disconnect the right rear fog lamp connector B004.

04

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C034(C8) - B011(1)
＜2Ω
C034(C8) - B004(1)

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the harness and connectors (rear fog lamp - ground)

(a) Ignition Switch: OFF.

(b) Disconnect the left rear fog lamp connector B011.

(c) Disconnect the right rear fog lamp connector B004.
 04-512 DIAGNOSTICS - LIGHTING SYSTEM

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
B011 (2) - ground
＜2Ω
04 B004 (2) - ground

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the rear fog lamp switch

(a) Ignition Switch: OFF.

(b) Disconnect the rear fog lamp switch connector C017.

 DIAGNOSTICS - LIGHTING SYSTEM 04-513

(c) Check the rear fog lamp switch

Standard electrical resistance (check whether there
existent an open circuit)
Connecting pins
Conditions Specified value
of multimeter
Turn off the front fog
1-2 ≥ 1 MΩ
lamp switch 04
Turn on the rear fog
1-2 ＜2Ω
lamp switch

Check whether the result is normal?

Yes> go to step 7
No > Replace the rear fog lamp switch.

7. Check the harness and connectors (rear fog lamp switch - ground)
(a) Ignition Switch: OFF.

(b) Disconnect the rear fog lamp switch connector C017.

 04-514 DIAGNOSTICS - LIGHTING SYSTEM

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C017 (2) - ground ＜2Ω
04

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check the harness and connectors (rear fog lamp switch - BCM control unit)
(a) Ignition Switch: OFF.

(b) Disconnect the rear fog lamp switch connector C017.

(c) Disconnect the connector C036 of BCM control unit.

 DIAGNOSTICS - LIGHTING SYSTEM 04-515

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
2- drive: C017(1)-C036（E10）
＜2Ω
4- drive: C017(6)-C036（E10） 04

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.
 04-516 DIAGNOSTICS - LIGHTING SYSTEM

B1001 LOW CURRENT OF LEFT TURN LIGHT CONTROL CIRCUIT

B1002TO-GROUND SHORT-CIRCUIT OF LEFT TURN LIGHT CONTROL
CIRCUIT
Circuit diagram

04
 DIAGNOSTICS - LIGHTING SYSTEM 04-517

Diagnostic steps

1. Check the left turn light bulb

(a) Ignition Switch: OFF.

(b) Check whether or not the bulb of left turn light is damaged.

04

Check whether the result is normal?

Yes> go to step 2
No > Replace the bulb of left turn light.

2. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F5 (10A) in the indoor fuse box.

Check whether the result is normal?

Yes> go to step 3
No> replace fuse

3. Check the harness and connector (fuse-BCM control unit)

(a) Disconnect battery negative cable.
 04-518 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the connector C034 of BCM control unit.

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F5（10A）- C034（C6） ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the harness and connector (BCM control unit – left turn light)
(a) Ignition Switch: OFF.

(b) Disconnect the connector C034 of BCM control unit.

DIAGNOSTICS - LIGHTING SYSTEM 04-519

(c) Disconnect the left front turn light connector A010.

04

(d) Disconnect the left rear turn light connector B010.

(e) Disconnect the left rear-view mirror connector J003.

 04-520 DIAGNOSTICS - LIGHTING SYSTEM

(f) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C034（C2）- A010（3）
04 C034（C2）- B010（5） ＜2Ω
C034（C2）- J003（3）

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the harness and connectors (left turn light - ground)

(a) Ignition Switch: OFF.

(b) Disconnect the connector C034 of BCM control unit.

(c) Disconnect the left front turn light connector A010.

 DIAGNOSTICS - LIGHTING SYSTEM 04-521

(d) Disconnect the left rear turn light connector B010.

04

(e) Disconnect the left rear-view mirror connector J003.

(f) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A010 (2) - ground
B010 (1) - Ground ＜2Ω
J003 (2) - ground

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the combination switch (lamplight switchover)

(a) Ignition Switch: OFF.
 04-522 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Check the combination switch (lamplight switchover)

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Turn off the left turn
17-19 ≥ 1 MΩ
switch
Turn on the left turn
17-19 ＜2Ω
switch

Check whether the result is normal?

Yes> go to step 7
No > Replace the combination switch.

7. Check the harness and connectors (combination switch - ground)

(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-523

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C008 (19) - ground ＜2Ω

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check the wiring harness and connectors (BCM controlling unit - combination switch)
(a) Ignition Switch: OFF.
 04-524 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Disconnect the connector C036 of BCM control unit.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C036（E11） - C008（17） ＜2Ω

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.
 DIAGNOSTICS - LIGHTING SYSTEM 04-525

B1004 LOW CURRENT OF RIGHT TURN LIGHT CONTROL CIRCUIT

B1005TO-GROUND SHORT-CIRCUIT OF RIGHT TURN LIGHT
CONTROL CIRCUIT
Circuit diagram

04
 04-526 DIAGNOSTICS - LIGHTING SYSTEM

Diagnostic steps

1. Check the right turn light bulb

(a) Ignition Switch: OFF.

(b) Check whether or not the bulb of right turn light is

damaged.

04

Check whether the result is normal?

Yes> go to step 2
No > Replace the bulb of right turn light.

2. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F5 (10A) in the indoor fuse box.

Check whether the result is normal?

Yes> go to step 3
No> replace fuse

3. Check the harness and connector (fuse-BCM control unit)

(a) Disconnect battery negative cable.
 DIAGNOSTICS - LIGHTING SYSTEM 04-527

(b) Disconnect the connector C034 of BCM control unit.

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F5(10A) - C034（C6） ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the harness and connector (BCM control unit – right turn light)
(a) Ignition Switch: OFF.

(b) Disconnect the connector C034 of BCM control unit.

 04-528 DIAGNOSTICS - LIGHTING SYSTEM

(c) Disconnect the right front turn light connector A004.

04

(d) Disconnect the right rear turn light connector B005.

(e) Disconnect the left rear-view mirror connector G002.

 DIAGNOSTICS - LIGHTING SYSTEM 04-529

(f) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C034（C1）- A004（3）
C034（C1）- B005（5） ＜2Ω 04

C034（C1）- G002（3）

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the harness and connectors (right turn light - ground)

(a) Ignition Switch: OFF.

(b) Disconnect the connector C034 of BCM control unit.

(c) Disconnect the right front turn light connector A004.

 04-530 DIAGNOSTICS - LIGHTING SYSTEM

(d) Disconnect the right rear turn light connector B005.

04

(e) Disconnect the left rear-view mirror connector G002.

(f) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A004 (2) - ground
B005 (1) - Ground ＜2Ω
G002 (2) - ground

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the combination switch (lamplight switchover)

(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-531

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Check the combination switch (lamplight switchover)

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Turn off the right turn
18-19 ≥ 1 MΩ
switch
Turn on the right turn
18-19 ＜2Ω
switch

Check whether the result is normal?

Yes> go to step 7
No > Replace the combination switch.

7. Check the harness and connectors (combination switch - ground)

(a) Ignition Switch: OFF.
 04-532 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C008 (19) - ground ＜2Ω

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check the wiring harness and connectors (BCM controlling unit - combination switch)
(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-533

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Disconnect the connector C036 of BCM control unit.

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C036（E12） - C008（18） ＜2Ω

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.
 04-534 DIAGNOSTICS - LIGHTING SYSTEM

B1063LOW CURRENT OF PARKING LIGHT CONTROL CIRCUIT

B1064TO-GROUND SHORT-CIRCUIT OF PARKING LIGHT CONTROL
CIRCUIT
Circuit diagram

04
 DIAGNOSTICS - LIGHTING SYSTEM 04-535

Diagnostic steps

1. Check the parking light bulbs.

(a) Ignition Switch: OFF.

(b) Check whether or not the bulbs of parking lights are

damaged.

04

Check whether the result is normal?

Yes> go to step 2
No > Replace the parking light bulbs.

2. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F6 (7.5A) in the indoor fuse box.

Check whether the result is normal?

Yes> go to step 3
No> replace fuse

3. Check the harness and connector (fuse-BCM control unit)

(a) Disconnect battery negative cable.
 04-536 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the connector C034 of BCM control unit.

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F6(7.5A) - C034（C5） ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the combination switch (lamplight switchover)

(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-537

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Check the combination switch (lamplight switchover)

Standard resistance:
Multimeter connec-
Conditions Specified value
tion stitch
Turn off the parking
13-14 ≥ 1 MΩ
light switch
Turn on the parking
13-14 ＜2Ω
light switch

Check whether the result is normal?

Yes> go to step 5
No > Replace the combination switch.

5. Check the harness and connectors (combination switch - ground)

(a) Ignition Switch: OFF.
 04-538 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C008 (13) - ground ＜2Ω

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the wiring harness and connectors (BCM controlling unit - combination switch)
(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-539

(b) Disconnect the connector C008 of combination switch

(lamplight switchover).

04

(c) Disconnect the connector C036 of BCM control unit.

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (Check for any open circuit)
Multimeter connection Standard value
C036（E5） - C008（14） ＜2Ω

Check whether the result is normal?

Yes> go to step 7
No > Maintenance or replace harness.
 04-540 DIAGNOSTICS - LIGHTING SYSTEM

7. Check the harness and connector (BCM control unit – front parking light)
(a) Ignition Switch: OFF.

(b) Disconnect the connector C034 of BCM control unit.

04

(c) Disconnect the connector A011 of left front parking light.

(d) Disconnect the connector A011 of right front parking light.

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C034（C3） - A011（4）
＜2Ω
C034（C2） - A003（4）

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.
 DIAGNOSTICS - LIGHTING SYSTEM 04-541

8. Check the harness and connectors (front parking light - ground)

(a) Ignition Switch: OFF.

(b) Disconnect the connector C034 of BCM control unit.

04

(c) Disconnect the connector A011 of left front parking light.

(d) Disconnect the connector A011 of right front parking light.

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
A011 (5) - ground
＜2Ω
A003 (5) - ground

Check whether the result is normal?

Yes> go to step 9
No > Maintenance or replace harness.

9. Check the harness and connector (BCM control unit – rear parking light)
(a) Ignition Switch: OFF.
 04-542 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the connector C034 of BCM control unit.

04

(c) Disconnect the connector A011 of left front parking light.

(d) Disconnect the connector A011 of right front parking light.

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C034（C3）- B010（6）
＜2Ω
C034（C2）- B005（6）

Check whether the result is normal?

Yes> go to step 10
No > Maintenance or replace harness.

10 . Check the harness and connectors (rear parking light - ground)

(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-543

(b) Disconnect the connector C034 of BCM control unit.

04

(c) Disconnect the left rear parking light connector B010.

(d) Disconnect the right rear parking light connector B005.

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
B010 (1) - Ground
＜2Ω
B005 (1) - Ground

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.
 04-544 DIAGNOSTICS - LIGHTING SYSTEM

BRAKES LAMPS ON 2 SIDES FAIL TO GO ON

Circuit diagram

04
 DIAGNOSTICS - LIGHTING SYSTEM 04-545

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F2 (60A) inside the fuse box (A020) of
engine compartment.
(c) Check the fuse F4 (7.5 A) in the indoor fuse box (A037).
04

Check whether the result is normal?

Yes> go to step 3
No > Go to the next step.

2. Check the harness and connectors (brake lamp switch - ground)

(a) Disconnect battery negative cable.
(b) Unplug the fuse F4 (7.5 A) in the indoor fuse box (A037).

(c) Disconnect the driving braking switch connector C004.

 04-546 DIAGNOSTICS - LIGHTING SYSTEM

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Ground of multimeter Standard value
C004 (1) - Ground ≥1 ΜΩ
04

Check whether the result is normal?

Yes> Replace fuse
No > Maintenance or replace harness.

3. Check the brake lamp switch

(a) Disconnect battery negative cable.

(b) Remove the brake lamp switch.

(c) Check the brake lamp switch.
Standard voltage
Multimeter connec-
Conditions Specified value
tion stitch
Turn off the brake
1-2 ≥ 1 MΩ
lamp switch
Turn on the brake
1-2 ＜2Ω
lamp switch

Check whether the result is normal?

Yes> go to step 4
No > Replace the brake lamp switch.

4. Check the harness and connectors (fuse – driving braking switch)

(a) Disconnect battery negative cable.
 DIAGNOSTICS - LIGHTING SYSTEM 04-547

(b) Disconnect the driving braking switch connector C004.

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F4（7.5 A） - C004（1） ＜2Ω

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the harness and connectors (driving brake lamp switch - brake lamp)
(a) Disconnect battery negative cable.
 04-548 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the brake lamp switch connector.

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C004（2） - B005（3）
＜2Ω
C004（2） - B010（3）

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the harness and connectors (brake lamp - ground)

(a) Disconnect battery negative cable.

(b) Disconnect the brake lamp switch connector.

 DIAGNOSTICS - LIGHTING SYSTEM 04-549

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
B005 (1) - Ground
＜2Ω
B010 (1) - Ground 04

Check whether the result is normal?

Yes > Replace the bulb.
No > Maintenance or replace harness.
 04-550 DIAGNOSTICS - LIGHTING SYSTEM

TOP BRAKES LAMPS FAIL TO GO ON

Circuit diagram

04
 DIAGNOSTICS - LIGHTING SYSTEM 04-551

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F2 (60A) inside the fuse box (A020) of
engine compartment.
(c) Check the fuse F4 (7.5 A) in the indoor fuse box (A037).
04

Check whether the result is normal?

Yes> go to step 3
No > Go to the next step.

2. Check the harness and connectors (brake lamp switch - ground)

(a) Disconnect battery negative cable.
(b) Unplug the fuse F4 (7.5 A) in the indoor fuse box (A037).

(c) Disconnect the driving braking switch connector C004.

 04-552 DIAGNOSTICS - LIGHTING SYSTEM

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Ground of multimeter Standard value
C004 (1) - Ground ≥1 ΜΩ
04

Check whether the result is normal?

Yes> Replace fuse
No > Maintenance or replace harness.

3. Check the brake lamp switch

(a) Disconnect battery negative cable.

(b) Remove the brake lamp switch.

(c) Check the brake lamp switch.
Standard voltage
Multimeter connec-
Conditions Specified value
tion stitch
Turn off the brake
1-2 ≥ 1 MΩ
lamp switch
Turn on the brake
1-2 ＜2Ω
lamp switch

Check whether the result is normal?

Yes> go to step 4
No > Replace the brake lamp switch.

4. Check the harness and connectors (fuse – driving braking switch)

(a) Disconnect battery negative cable.
 DIAGNOSTICS - LIGHTING SYSTEM 04-553

(b) Disconnect the driving braking switch connector C004.

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F4（7.5 A） - C004（1） ＜2Ω

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the harness and connectors (top brake lamp - ground)

(a) Disconnect battery negative cable.

(b) Disconnect the top brake lamp connector F003.

 04-554 DIAGNOSTICS - LIGHTING SYSTEM

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F003 (2) - ground ＜2Ω
04

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the harness and connectors (driving brake lamp switch – top brake lamp)
(a) Disconnect battery negative cable.

(b) Disconnect the driving braking switch connector C004.

(c) Disconnect the top brake lamp connector F003.

 DIAGNOSTICS - LIGHTING SYSTEM 04-555

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C004（2） - F003（1） ＜2Ω
04

Check whether the result is normal?

Yes > Replace the bulb.
No > Maintenance or replace harness.
 04-556 DIAGNOSTICS - LIGHTING SYSTEM

REVERSE LAMPS ON 2 SIDES FAIL TO GO ON

Circuit diagram

04
 DIAGNOSTICS - LIGHTING SYSTEM 04-557

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F31 (7.5A) in the vehicle body fuse box
(C301).

04

Check whether the result is normal?

Yes> go to step 3
No> go to step 2

2. Check the harness and connectors (reverse lamp switch - ground)

(a) Ignition Switch: OFF.

(b) Disconnect reverse lamp switch connector E002.

 04-558 DIAGNOSTICS - LIGHTING SYSTEM

(c) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
B002 (1) - Ground ≥1 ΜΩ
04

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check reverse lamp switch

(a) Ignition Switch: OFF.
(b) Remove the reverse lamp switch (see "Chapter 31 Transmission - transmission, replacement").

(c) Check the reverse lamp switch.

Standard voltage
Multimeter connec-
Conditions Specified value
tion stitch
Turn off the reverse
1-2 ≥ 1 MΩ
lamp switch
Turn on the reverse
1-2 ＜2Ω
lamp switch

Check whether the result is normal?

Yes> go to step 4
No > Replace the reverse lamp switch.

4. Check the harness and connectors (reverse lamp fuse – reverse lamp switch)
(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-559

(b) Disconnect reverse lamp switch connector E002.

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
F31（7.5 A） - E002（1） ＜2Ω

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the harness and connectors (reverse lamp switch - rear combination lamp)
(a) Ignition Switch: OFF.
 04-560 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect reverse lamp switch connector E002.

04

(c) Disconnect the left rear combination lamp switch connector

B010.
(d) Disconnect the right rear combination lamp switch
connector B005.

(e) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
E002（2） - B010（4）
＜2Ω
E002（2） - B005（4）

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the harness and connectors (rear combination lamp - ground)

(a) Ignition Switch: OFF.
 DIAGNOSTICS - LIGHTING SYSTEM 04-561

(b) Disconnect the left rear combination lamp switch connector

B010.
(c) Disconnect the right rear combination lamp switch
connector B005.

04

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
B010 (1) - Ground
＜2Ω
B005 (1) - Ground

Check whether the result is normal?

Yes > Replace the bulb.
No > Maintenance or replace harness.
 04-562 DIAGNOSTICS - LIGHTING SYSTEM

POSITION LIGHTS/LICENSE PLATE LAMP FAIL TO GO ON

Circuit diagram

04
 DIAGNOSTICS - LIGHTING SYSTEM 04-563

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F2 (60A) inside the fuse box (A020) of
engine compartment.
(c) Check the fuse F6 (7.5 A) in the indoor fuse box (A037).
04

Check whether the result is normal?

Yes> go to step 3
No > Go to the next step.

2. Check the harness and connectors (vehicle body controller -ground)

(a) Disconnect battery negative cable.
(b) Unplug the fuse F6 (7.5 A) in the indoor fuse box (A037).

(c) Disconnect the connector C034 of the vehicle body

controller.
 04-564 DIAGNOSTICS - LIGHTING SYSTEM

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Ground of multimeter Standard value
C034 (C5) - ground ≥1 ΜΩ
04

Check whether the result is normal?

Yes> Replace fuse
No > Maintenance or replace harness.

3. Check the harness and connectors (vehicle body controller - combination switch (turn)).
(a) Disconnect battery negative cable.

(b) Disconnect connector C036, body controller

(c) Disconnect the connector C008 of combination switch

(turn).
 DIAGNOSTICS - LIGHTING SYSTEM 04-565

(d) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C036（E5） - C008（14） ＜2Ω
04

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the harness and connectors (combination switch (turn) - ground)

(a) Disconnect battery negative cable.

(b) Disconnect the connector C008 of combination switch

(turn).
 04-566 DIAGNOSTICS - LIGHTING SYSTEM

(c) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Ground of multimeter Standard value
C008 (13) - ground ＜2Ω
04

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the combination switch (turn)

(a) Disconnect battery negative cable.

(b) Disconnect the connector C008 of combination switch

(turn).
 DIAGNOSTICS - LIGHTING SYSTEM 04-567

(c) Check the combination switch (turn)

Standard voltage
Multimeter connec-
Conditions Specified value
tion stitch
Open the combina-
tion switch and posi- 14 - 13 ＜2Ω
tion light cover
04

Check whether the result is normal?

Yes> go to step 6
No > Replace the combination switch (turn).

6. Check the harness and connectors (vehicle body controller - license plate lamp/position light
ground)
(a) Disconnect battery negative cable.

(b) Disconnect connector C036, body controller

(c) Disconnect the license plate lamp connectors B007 and

B008.
 04-568 DIAGNOSTICS - LIGHTING SYSTEM

(d) Disconnect the left rear combination lamp connector B010.

(e) Disconnect the right rear combination lamp connector
B005.

04

(f) Disconnect the left front combination lamp connector A011.

(g) Disconnect the right front combination lamp connector
A003.

(h) Measure the electrical resistance based on the value in

the following form.
Measure the resistance as per the values given in the
table below
Multimeter connection Standard value
CO34(C3) - B007（1） ＜2Ω
CO34(C3) - B008（1） ＜2Ω
CO34(C3) - B006（6） ＜2Ω
CO34(C3) - B010（6） ＜2Ω
CO34(C3) - A003（4） ＜2Ω
CO34(C3) - A011（4） ＜2Ω

Check whether the result is normal?

Yes> go to step 7
No > Maintenance or replace harness.

7. Check the harness and connectors (license plate lamp / position light - ground)
(a) Disconnect battery negative cable.
DIAGNOSTICS - LIGHTING SYSTEM 04-569

(b) Disconnect the license plate lamp connectors B007 and

B008.

04

(c) Disconnect the left rear combination lamp connector B010.

(d) Disconnect the right rear combination lamp connector
B005.

(e) Disconnect the left front combination lamp connector A011.

(f) Disconnect the right front combination lamp connector
A003.
 04-570 DIAGNOSTICS - LIGHTING SYSTEM

(g) Measure the electrical resistance based on the value in

the following form.
Measure the resistance as per the values given in the
table below
Multimeter connection Standard value
B007 (2) - ground ＜2Ω
04 B008 (2) - ground ＜2Ω
C016 (1) ground ＜2Ω
B010 (1) - Ground ＜2Ω
A003 (5) - ground ＜2Ω
A011 (5) - ground ＜2Ω

Check whether the result is normal?

Yes> replace body controller
No > Maintenance or replace harness.
 DIAGNOSTICS - LIGHTING SYSTEM 04-571

STEP LAMPS FAIL TO GO ON

Circuit diagram

04
 04-572 DIAGNOSTICS - LIGHTING SYSTEM

04
 DIAGNOSTICS - LIGHTING SYSTEM 04-573

Diagnostic steps

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F36 (10 A) in the indoor fuse box (A037).

04

Check whether the result is normal?

Yes> go to step 3
No > Go to the next step.

2. Check the harness and connectors (vehicle body controller -ground)

(a) Disconnect battery negative cable.
(b) Unplug the fuse F36 (10 A) in the indoor fuse box (A037).

(c) Disconnect the connector C034 of vehicle body controller.

 04-574 DIAGNOSTICS - LIGHTING SYSTEM

(d) Measure the electrical resistance based on the value in

the following form.
Standard resistance (check whether there is short
circuit)
Ground of multimeter Standard value
C034 (C10) - ground ≥1 ΜΩ
04

Check whether the result is normal?

Yes> Replace fuse
No > Maintenance or replace harness.

3. Check the step lamps.

(a) Disconnect battery negative cable.

(b) Disconnect the left step lamp connector J006.

(c) Replace the step lamp assembly.

Check whether the step lamp is working properly.

Yes > Replace the step lamp.
No> go to step 2

4. Check the harness and connectors (vehicle body controller - step lamps)
(a) Disconnect battery negative cable.
 DIAGNOSTICS - LIGHTING SYSTEM 04-575

(b) Disconnect the connector C034 of vehicle body controller.

04

(c) Disconnect the left front step lamp connector J006.

(d) Disconnect the right front step lamp connector G005.
(e) Disconnect the left rear step lamp connector I003.
(f) Disconnect the right rear step lamp connector H003.

(g) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C034（C12） - J006（2）
C034（C12） - G005（2）
＜2Ω
C034（C12） - I003（2）
C034（C12） - H003（2）

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check the harness and connector (step lamps – door control switch)
(a) Disconnect battery negative cable.
 04-576 DIAGNOSTICS - LIGHTING SYSTEM

(b) Disconnect the left front step lamp connector J006.

(c) Disconnect the right front step lamp connector G005.
(d) Disconnect the left rear step lamp connector I003.
(e) Disconnect the right rear step lamp connector H003.

04

(f) Disconnect the left front door switch connector D001.

(g) Disconnect the right front door switch connector D010.
(h) Disconnect the left rear door switch connector D011.
(i) Disconnect the right rear door switch connector D003.

(j) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
J006（1） - D001（1）
I003（1） - D003（1）
＜2Ω
G005（1） - D010（1）
H003（1） - D011（1）

Check whether the result is normal?

Yes > Replace the door switch and go to step 5.
No > Maintenance or replace harness.
 DIAGNOSTICS - LIGHTING SYSTEM 04-577

6. Check the door control switch

(a) Disconnect the door control switch connector.

04

(b) Check the door control switch

Standard voltage
Multimeter connec-
Conditions Specified value
tion stitch
Door closed 1 - Ground ＜2Ω
Door opened 1 - Ground Cut-off

Check whether the result is normal?

Yes> replace body controller
No > Replace the door control switch.
 04-578 DIAGNOSTICS - ASSEMBLY INSTRUMENT

ASSEMBLY INSTRUMENT
PRECAUTION
1. Disconnect power supply
(a) When disassembling or installing any electric unit, or touching the exposed electrical terminal with tools
or devices, disconnect the negative battery cable firstly, to prevent vehicle damage or personal injury.
(b) During the operation, turn off the ignition if not otherwise specified.
04 (c) When the ignition is switched on, if the power supply stops in the combination instrument, all indicators
will stay where they are at the moment of outage. When the power supply is restored, turn off the ignition.
The combination instrument will be energized and perform a self test firstly, before the indicators show
the current measurement.
2. Ignition switch representation
Ignition switch (location) Ignition switch representation
LOCK Ignition Switch: OFF.
ACC Ignition Switch ACC
ON Ignition Switch: ON.
START Start the engine.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-579

COMPONENTS DRAWING

04

1 Assembly instrument 3 Speedometer sensor

2 Fuel sensor 4 Oil pressure alarm switch (4G69 gas
engine)
 04-580 DIAGNOSTICS - ASSEMBLY INSTRUMENT

INSTRUMENT DESCRIPTION

04

Instrument gauge
Sequence number Item Description
It may indicate the current vehicle speed as per the pulse signals
16 Speedometer
received from the vehicle speed sensor.
It may indicate the engine speed as per the signals received
2 Tachometer
from ECM.

Warning / indicator lamp

Sequence number Item Description
The air bag module may light the air bag alarm indicator lamp
22 SRS alarm lamp
when the air bag develops a fault.
It may light the oil pressure indicator lamp as per the signals
3 Oil pressure indicator lamp
received from the oil pressure alarm switch.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-581

Sequence number Item Description

When ABS system develops a fault, the ABS control unit may
14 ABS fault indicating lamp
light the ABS fault indicating lamp.
ECM may light the engine fault indicating lamp when the en-
5 Engine fault indicating lamp
gine electric control system develops a fault.
The left turning signal and hazard warning indicator lamp may
Left turning signal and haz-
8 be lit when the turn light switch or hazard warning switch are
ard warning indicator lamp 04
turned on.
Right turning signal and The left turning signal and hazard warning indicator lamp may
11 hazard warning indicator be lit when the turn light switch or hazard warning switch are
lamp turned on.
When engine ECM detects a common fault of the system and
SVS alarm lamp (gasoline
1 the diagnosis switch is set to the off position, the lamp may
vehicle)
be lit and kept constantly on before the fault is eliminated.
20 Reset button It may be used to set and rest the liquid crystal display signals.
The rear fog lamp indicator lamp may be lit as per the signals
13 Rear fog lamp indicator lamp received from 3-in-1 controller when the rear fog lamp switch
is turned on.
The seat belt indicator lamp may be lit as per the signal re-
21 Seat belt indicator lamp
ceived from the seat belt non-fastening alarm switch.
The parking brake indicator lamp may be lit when the parking
brake switch is turned on or when the level of brake fluid is
15 Brake fault alarm lamp
lower than the minimum scale marks and the brake fault low
alarm switch is set to its on position.
Vacuity alarm indicator lamp The vacuity alarm indicator lamp may be lit when the vacuum
17
(diesel vehicle) power take off switch is turned on.
The door non-closing alarm lamp may be lit when the door
10 Door non-closing alarm lamp
non-closing alarm switch is turned on.
When the water deposit inside fuel water separator in the
Water deposit indicator lamp diesel oil filter element reaches a certain amount, the water
18
(diesel vehicle) deposit switch is set to its on position, and the water deposit
is lit.
When the engine temperature is lower than the preset temper-
Preheating indicator lamp ature, the engine control unit may issue a command to preheat
23
(diesel vehicle) the engine intake system and light the preheating indicator
lamp simultaneously.
When the level of fuel inside the fuel tank is lower than the
19 Fuel alarm lamp setting dial, the fuel alarm switch is set to its on position, and
the fuel alarm lamp is lit.
When charging system develops a fault, the alternator indicator
6 Alternator indicator lamp
may be lit.
The high beam indicator lamp may be lit as per the signals
7 High-beam indicator lamp received from high beam relay when the driving lights are
turned on.
The front fog lamp indicator lamp may be lit as per the signals
Front fog lamp indicator
12 received from front fog lamp relay when the front fog lamp
lamp
switch is turned on.
 04-582 DIAGNOSTICS - ASSEMBLY INSTRUMENT

Sequence number Item Description

When water temperature is ≥ 102 ℃ (diesel engine) or ≥
Water temperature alarm 110 ℃ (gas-engine), or coolant temperature sensor develops
4 a fault or water level alarm switch is closed or develops a fault,
lamp
the combination instrument may light the water temperature
alarm lamp.

04 LCD
Sequence number Item Description
Contents displayed: transient fuel consumption graduation apparatus,
endurance mileage, average fuel consumption, total mileage, subtotal
9 Display screen
mileage, maintenance prompt, tire pressure, tire temperature, door status,
character alarm prompt, fuel gauge, and water thermometer.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-583

INSTRUMENT TERMINAL

04

Terminal no. Connection rod color Description

1 Blue-yellow CAN L
2
3 Black Battery ground
Vehicle speed output (re-
4
served)
5 Pink - black Battery +
C013
6
7 Black - blue Sensor earth
8 Blue - black Vehicle speed signal
9
10
11 Brown - white Oil pressure alarm switch
 04-584 DIAGNOSTICS - ASSEMBLY INSTRUMENT

Terminal no. Connection rod color Description

12
Front-axle engaging/disen-
13 Green-black
gaging operating switch
Brake liquid level alarm
14 Grey
switch
04 15
Digital signal input reserved
16
2
17 Red-white CAN H
18
Ignition switch (ON posi-
19 Pink
tion)
20 Yellow Vacuum alarm switch
21
22 Red-blue Fuel level signal
23 Black-Red Alternator D+ terminal
24
25 Black-Red Driver seat belt switch
26 Yellow-black Passenger seat belt switch
27 K line diagnosis
28
Digital signal input reserved
29
1
30
31 White - black Parking brake switch
32 Orange -violet Vehicle-body anti-theft
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-585

BASIC INSPECTION
CAUTION

Before basic inspection, the engine must reach its operating temperature.Trial driving must be conducted
by 2 persons or more.

Steps Inspection Measures

contents 04
Yes No> go to step 2
Check the battery
1 • Battery voltage shall not be lower than 12V. Charge or replace the battery. Re-
No? fer to “Chapter 20A, start and
Check whether the result is normal?
charge- battery”
Check the speedometer Yes No> go to step 3
• Connect a diagnosis instrument, and select ve-
hicle speed.
• Observe the readings indicated by the
speedometer when the vehicle speed is 20~100
Km/h, 120Km/h, and 140Km/h.
• The errors shall be +5, +6, and +7Km/h respec-
tively.
2 • The index hand shall be free of pulsation when
uniform speed or uniform acceleration is select- No? to Defect Phenomenon Form
ed.
CAUTION

Either tire wear, over-inflation or under infla-

tion may lead to errors.

Check whether the result is normal?

Check the oil pressure indicator lamp Yes No> go to step 4

• Ignition Switch: ON.
• Oil pressure indicator lamp shall be lit
3
• When the engine is started up, oil pressure indi- No? to Defect Phenomenon Form
cator lamp shall go out.
Check whether the result is normal?

Check the fuel gauge Yes Completed

• Ignition switch: ON (ACC).
4 • fuel gage shall display the current fuel level.
No? to Defect Phenomenon Form
Check whether the result is normal?
 04-586 DIAGNOSTICS - ASSEMBLY INSTRUMENT

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Entire system
Defect phenomenon Suspect Area Reference

04 Chapter 04 Diagnosis - combination

1. Power supply, ground wire instrument, entire combination instru-
The entire combination instrument ment does not work
does not work Chapter 04 Diagnosis - combination
2. Combination instrument itself instrument, entire combination instru-
ment does not work

Instrument gauge
Defect phenomenon Suspect Area Reference
Chapter 4. Diagnosis - combination
1. Vehicle speed sensor
instrument, speedometer fault
Chapter 4. Diagnosis - combination
Speedometer defects 2. Speedometer circuit
instrument, speedometer fault
Chapter 4. Diagnosis - combination
3. Speedometer itself
instrument, speedometer fault
Chapter 04 Diagnosis - combination
1. Fuel sensor
instrument, fuel gauge fault
Chapter 04 Diagnosis - combination
Fuel gage faults 2. Fuel gauge circuit
instrument, fuel gauge fault
Chapter 04 Diagnosis - combination
3. Fuel gage itself
instrument, fuel gauge fault

Warning lamp
Defect phenomenon Suspect Area Reference
Chapter 04 Diagnosis - combination
1. Brake fault alarm switch instrument, brake fault alarm lamp
fails to go on/normally on
Chapter 04 Diagnosis - combination
Brake fault alarm lamp fails to go
2. Brake fault alarm lamp circuit instrument, brake fault alarm lamp
on/normally on
fails to go on/normally on
Chapter 04 Diagnosis - combination
3. Combination instrument assembly instrument, brake fault alarm lamp
fails to go on/normally on
Chapter 04 Diagnosis - combination
1. Coolant temperature sensor instrument, water temperature alarm
Water temperature alarm lamp fails lamp fails to go on/normally on
to go on/normally on Chapter 04 Diagnosis - combination
2. Water level alarm switch instrument, water temperature alarm
lamp fails to go on/normally on
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-587

Defect phenomenon Suspect Area Reference

Chapter 04 Diagnosis - combination
3. Water temperature alarm lamp
instrument, water temperature alarm
circuit
lamp fails to go on/normally on
Chapter 04 Diagnosis - combination
4. Combination instrument assembly instrument, water temperature alarm
lamp fails to go on/normally on
04
Indicating lamp
Defect phenomenon Suspect Area Reference
Chapter 04 Diagnosis - combination
1. Oil pressure switch instrument, oil pressure indicator
lamp fails to go on/normally on
Chapter 04 Diagnosis - combination
Oil pressure indicator lamp fails to go
2. Oil pressure indicating lamp circuit instrument, oil pressure indicator
on/normally on
lamp fails to go on/normally on
Chapter 04 Diagnosis - combination
3. Combination instrument assembly instrument, oil pressure indicator
lamp fails to go on/normally on
Chapter 04 Diagnosis - combination
1. Fuse instrument, vacuum alarm indicator
lamp fails to go on/normally on
Chapter 04 Diagnosis - combination
Vacuum alarm indicator lamp fails to
2. Vacuity alarm instrument, vacuum alarm indicator
go on/normally on
lamp fails to go on/normally on
Chapter 04 Diagnosis - combination
3. Combination instrument assembly instrument, vacuum alarm indicator
lamp fails to go on/normally on

LCD
Defect phenomenon Suspect Area Reference
Chapter 83 Dashboard/instruments
No mileage display or blurry display 1. LCD - combination instrument, replace-
ment
 04-588 DIAGNOSTICS - ASSEMBLY INSTRUMENT

THE ENTIRE COMBINATION INSTRUMENT DOES NOT WORK

Circuit diagram

04
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-589

Diagnostic steps

1. Check fuse
(a) Ignition Switch: ON.

(b) Check whether the fuse of the interior fuse box: F7 (7.5A),
F30 (7.5A) is fusing or not.

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the power circuit of combination instrument

(a) Disconnect assembly instrument C013 connector
(b) Ignition Switch: ON.
 04-590 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(c) Use a multimeter to measure the voltage between pins 5

and 19 of connector C013 of the combination instrument
C013 and the ground.
Standard voltage
Multimeter connection Standard value
C013 (5) -ground
Battery voltage
04 C013 (19) -ground

Check whether the result is normal?

Yes> go to step 3
No > If battery voltage is unavailable in pin 5 of connector C013 of combination instrument, repair the
open circuit of the circuit between F7 (7.5A) and pin 5 of connector C013 of the combination instrument.
If battery voltage is unavailable in pin 19 of connector C013 of combination instrument, repair the open
circuit of the circuit between F30 (7.5A) and pin 19 of connector C013 of the combination instrument.

3. Check the ground circuit of combination instrument

(a) Ignition Switch: OFF.

(b) Use a multimeter to measure the resistance between pins

3 of connector C013 of the combination instrument and
the ground.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C013 (3) -ground ≤2Ω

Check whether the result is normal?

Yes> replace combination instrument assembly.
No > Repair the circuit between pin 3 of connector C013 of combination instrument and the ground.

4. Check the power-supply short circuit of combination instrument

(a) Ignition Switch: OFF.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-591

(b) Disconnect the connector C013 of combination instrument.

04

(c) Use a multimeter to measure the resistance between pin

19 of connector C013 of combination instrument and the
ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C013 (19) -ground ≥ 1 MΩ

(d) Use a multimeter to measure the resistance between pins

5 of connector C013 of the combination instrument and
the ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
C013 (5) -ground ≥ 1 MΩ

Check whether the result is normal?

Yes> replace combination instrument assembly.
No > Repair the to-ground short circuit of the circuit between fuse F30 (7.5A) and pin 19 of connector
C013 of combination instrument; Repair the to-ground short circuit of the circuit between fuse F7 (7.5A)
and pin 5 of connector C013 of combination instrument
 04-592 DIAGNOSTICS - ASSEMBLY INSTRUMENT

WATER TEMPERATURE ALARM LAMP FAILS TO GO ON/NORMALLY

ON
Circuit diagram

04

Diagnostic steps
• When water temperature is too low or resistance of engine coolant temperature sensor is ≥ 5KΩ,
the water temperature alarm lamp fails to go on.
• When engine coolant temperature sensor does not work or Engine Coolant Temperature Sensor
is open-circuited, the water temperature alarm lamp fails to go on.
• When coolant level is lower than the standard lowest graduation, the water temperature alarm
lamp will be constantly on.
• When water temperature is too high (water temperature is ≥ 102 ℃ (diesel engine) or ≥ 110 ℃
(gas engine)), water temperature alarm lamp will flicker.
• When the Engine Coolant Temperature Sensor is short-circuited, the water temperature alarm
lamp will flicker.
• When ignition switch is set to ON, water temperature alarm lamp will go on for about 3 seconds
and then normally on.
• Verify that the coolant level is within the standard graduation.
• Verify that the water temperature of engine is normal.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-593
• Ignition Switch: ON.

1. Check the coolant temperature sensor

(a) Ignition Switch: OFF.
(b) Dismount the coolant temperature sensor.
CAUTION

Engine coolant temperature sensor shall be dismounted in cold vehicle status (or water temperature ≤
04
40℃).

(c) Use a multimeter to measure the resistance of engine

coolant temperature sensor at different water temperature,
and its reference value shall conform to the items listed in
the table below.
Tempera-
50 85 110 115
ture (℃)
Resistance
226 ± 35 64 ± 8 28 26.4 ± 2
（Ω）

Check whether the result is normal?

Yes> go to step 2
No > Replace the coolant temperature sensor

2. Check the signal circuit of engine coolant temperature sensor.

(a) Ignition Switch: OFF.

(b) Disconnect the connector E016 of engine coolant

temperature sensor. (gasoline vehicle)
(c) Disconnect the connector E016 of engine coolant
temperature sensor. (diesel vehicle)
(d) Ignition Switch: ON.
 04-594 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(e) Use a multimeter to measure the voltage between pin A

of connector of engine coolant temperature sensor and
ground.
Standard voltage
Multimeter connection Standard value
E016 (A) - Ground 5V

04

Check whether the result is normal?

Yes> go to step 4
No> go to step 3

3. Check the signal power supply of engine coolant temperature sensor.

(a) Use a multimeter to measure the voltage between pin 49
of connector E006 of engine control module and the
ground.
Standard voltage
Multimeter connection Standard value
E006 (49) -ground 5V

Check whether the result is normal?

Yes >Repair the opened signal circuit between pin 49 of connector E006 of engine control module and
pin B of connector E016 of engine coolant temperature sensor.
No > Replace the engine control module.

4. Check the ground circuit of engine coolant temperature sensor.

(a) Ignition Switch: OFF. a
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-595

(b) Disconnect the connector E016 of engine coolant

temperature sensor. (gasoline vehicle)
(c) Disconnect the connector E016 of engine coolant
temperature sensor. (diesel vehicle)
(d) Ignition Switch: ON.

04

(e) Use a multimeter to measure the resistance between pin

B of connector E016 of engine coolant temperature sensor
and pin 52 of connector E006 of engine control module.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
E016(B) - E006(52） ≤2Ω

Check whether the result is normal?

Yes> go to step 5
No>Repair the open circuit between pin 52 of connector E006 of combination instrument and pin A of
connector E016 of engine coolant temperature sensor.

5. Check the ground of engine coolant temperature sensor.

 04-596 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(a) Use a multimeter to measure the resistance between pin

52 of connector E006 of engine control module and the
ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value

04 E006 (52) -ground ≤2Ω

Check whether the result is normal?

Yes> go to step 6
No > Replace the engine control module.

6. Check the CAN bus circuit

(a) Ignition Switch: ON.

(b) Disconnect the connector C013 of combination instrument.

(c) Use a multimeter to measure the voltage between pins 17

and 1 of connector C013 of combination instrument and
the ground.
Standard voltage
Multimeter connection Standard value
C013 (17) -ground 12 V
C013 (1) -ground 1V

Check whether the result is normal?

 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-597

Yes > Replace the combination instrument.

No> go to step 7

7. Check the output control circuit of engine control module

(a) Ignition Switch: ON.
(b) Disconnect the connector E006 of engine control module.

(c) Use a multimeter to measure the voltage between pins 38 04

and 39 of connector E006 of engine control module and
the ground.
Standard voltage
Multimeter connection Standard value
E006 (38) -ground 1V
E006 (39) -ground 12 V

Check whether the result is normal?

Yes >Repair the opened circuit between pins 1 and 17 of connector C013 of combination instrument
and the pins 38 and 39 of connector E001 of engine coolant temperature sensor.
No > Replace the engine control module.
 04-598 DIAGNOSTICS - ASSEMBLY INSTRUMENT

VACUUM ALARM INDICATOR LAMP FAILS TO GO ON/NORMALLY

ON
Circuit diagram

04
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-599

Diagnostic steps

1. Check whether the signal circuit of vacuum alarm indicating lamp is short circuit
(a) Ignition Switch: OFF.

(b) Disconnect the connector A008of the vacuum alarm.

(c) Ignition Switch: ON.

04

Check whether the vacuum alarm indicating lamp is off.

Yes > Change the vacuum alarm.
No> go to step 2

2. Check whether the signal circuit of vacuum alarm indicating lamp is short circuit
(a) Ignition Switch: OFF.

(b) Disconnect the connector C013 of combination instrument.

 04-600 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(c) Use a multimeter to measure the resistance between pin

1 of connector A008 of vacuum alarm and ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
A 008 (1) - Grounding ≥ 1 MΩ
04

Check whether the result is normal?

Yes> replace combination instrument assembly.
No > Repair the to-ground short circuit of signal circuit between the pin 1 of connector C013 of the
vacuum alarm and the pin 20 of connector C013 of the combination instrument.

3. Check whether the signal circuit of vacuum alarm indicating lamp is of open circuit
(a) Ignition Switch: OFF.

(b) Disconnect the connector A008 of the vacuum alarm.

(c) Ignition Switch: ON.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-601

(d) Use the multimeter to measure the voltage betweenpin 1

of connector A008 of vacuum alarm and ground .
Standard voltage
Multimeter connection Standard value
A 008 (1) - Grounding Battery voltage

04

Check whether the result is normal?

Yes > Change the vacuum alarm.
No> go to step 4

4. Check whether the signal circuit of vacuum alarm indicating lamp is of open circuit
(a) Use a multimeter to measure the voltage between pin 20
of connector C013 of combination instrument and the
ground.
Standard voltage
Multimeter connection Standard value
C013 (20) -ground Battery voltage

Check whether the result is normal?

If Yes> Repair the open circuit of signal circuit between the pin 1 of connector A008 of the vacuum alarm
and the pin 20 of connector C013 of the combination instrument.
No> Replace the combination instrument assembly.
 04-602 DIAGNOSTICS - ASSEMBLY INSTRUMENT

SPEEDOMETER DEFECTS
Circuit Diagram

04
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-603

Diagnostic step

1. Check operating voltage of the sensor , speedometer

(a) Ignition Switch: OFF.

(b) Disconnect speedometer E001 connector

(c) Ignition Switch: ON.

04

(d) Use multimeter to measure speedometer sensor E001

connector No.1 stitch and No.2 stitch respectively, and the
voltage between No.1 stitch and ground connection.
Standard voltage
Multimeter connection Standard value
E001 (1) - E001 (2)
Battery voltage
E001 (1) ground

Check whether the result is normal?

Yes> go to step 3
No> If both have no voltage, go to step2. If there is voltage between No.1 stitch and ground connection,
repair the open circuit between No.2 stitch of the speed sensor E001 connector and No.7 stitch of
assembly instrument C013 connector .

2. Check supply circuit, speed sensor

 04-604 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(a) Check whether fuse F26 (7.5A) of the body is fusing or

not.

04

(b) Use multimeter to measure the voltage between fuse F26

of the body and ground .
Standard voltage
Multimeter connection Standard value
F26-ground Battery voltage

Check whether the result is normal?

Yes> go to step 3
No> Repair the circuit between fuse box of vehicle body: F26 (7.5A) and No.1 stitch of vehicle speed
sensor E001 connector.

3. Check speedometer sensor

(a) Ignition Switch: OFF.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-605

(b) Dismantle vehicle speed sensor.

(c) Rotate the spindle of vehicle speed sensor.

04

(d) Use multimeter to measure the resistance between No.2

stitch speed sensor E001 connector and No.3 stitch.
Pulse signal: each rotation should have 8 pulse
resistance signal

Check whether the result is normal?

Yes> go to step 4
No> Replace speedometer sensor

4. Check sensor signal circuit, speedometer

(a) Disconnect assembly instrument C013 connector
 04-606 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(b) Use multimeter to measure the resistance between No.3

stitch of speed sensor E001 connector and ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
E001 (3) ground ≥ 1 MΩ
04

(c) Use multimeter to measure the resistance between No.3

stitch speed sensor E001 connector and No.8 stitch of
C013 connector.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
E001 (3) - C013 (8) ≤2Ω

Check whether the result is normal?

Yes> replace combination instrument assembly.
No > Repair signal circuit between No.3 stitch of speed sensor E001 connector and No.8 stitch of
combination instrument C013 connector
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-607

SEAT BELT INDICATING LAMP IS NOT ON/ALWAYS ON

Circuit Diagram

04

Diagnostic step
• Ignition Switch: ON.
• Seat belt indicating lamp on the side of driver shall be on
• Insert the seat belt into the buckle and seat belt indicating lamp on the side of driver shall go out.
Check the seat belt indicating lamp on the side of driver, if it is always on or off, then go to the step 1.
Check the seat belt indicating lamp on the side of passenger, if it is always on or off, then go to the step
5.

1. Check whether the signal circuit of seat belt indicating lamp is of short circuit
(a) Ignition Switch: OFF.
 04-608 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(b) Disconnect the connector of the seat belt alarm switch

D006 on the side of driver.
(c) Ignition Switch: ON.

04

Check whether the seat belt indicating lamp on the side of driver is off
Yes> Replace the seat belt alarm switch on the side of driver.
No> go to step 2

2. Check whether the signal circuit of seat belt indicating lamp is of short circuit
(a) Ignition Switch: OFF.

(b) Disconnect the connector C013 of combination instrument.

(c) Use a multimeter to measure the resistance between the

pin 1 of the connector of the seat belt alarm switch D006
on the side of driver and ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
D006 (1) - Grounding ≥ 1 MΩ

Check whether the result is normal?

Yes> replace combination instrument assembly.
No > Repair the ground short circuit of signal circuit between the pin 1 of the seat belt alarm switch
D006 and the no.26 pin of connector of the combination instrument C013.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-609

3. Check whether the signal and ground circuit of seat belt indicating lamp on the side of driver are
of short circuit
(a) Ignition Switch: OFF.

(b) Disconnect the connector of the seat belt alarm switch

D006 on the side of driver.
(c) Ignition Switch: ON.
04

(d) Use a multimeter to measure the voltage between the pin

1 of the connector of the seat belt alarm switch D013 on
the side of passenger and ground; the pin 1 and pin 2.
Standard voltage
Multimeter connection Standard value
D006 (1) - D006 (2) Battery voltage
D006 (1) - Grounding Battery voltage

Check whether the result is normal?

Yes> Replace the seat belt alarm switch on the side of driver.
No > If there is no voltage of a storage battery, go to step 4. If battery voltage is not available only between
pin 1 and pin 2 of connector of seat belt alarm switch D006 on the side of driver, repair the open circuit
between pin 2 of seat belt alarm switch D006 on the side of driver and the ground F1.

4. Check whether the signal circuit of seat belt indicating lamp on the side of driver is of short circuit
 04-610 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(a) Use a multimeter to measure the voltage between pin 25

of connector of the combination instrument C013 and the
ground.
Standard voltage
Multimeter connection Standard value
C013 (25) -ground Battery voltage

04

Check whether the result is normal?

Yes> Repair the open circuit of signal circuit between the pin 1 of the seat belt alarm switch D006 and
the no.25 pin of connector of the combination instrument C013. 。
No> Replace the combination instrument assembly.

5. Check whether the signal circuit of seat belt indicating lamp on the side of driver is of short circuit
(a) Ignition Switch: OFF.

(b) Disconnect the connector of the seat belt alarm switch

D013 on the side of driver.
(c) Ignition Switch: ON.

Check whether the seat belt indicating lamp on the side of passenger is off
Yes> Replace the seat belt alarm switch on the side of passenger.
No> go to step 2

6. Check whether the signal circuit of seat belt indicating lamp on the side of driver is of short circuit
(a) Ignition Switch: OFF.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-611

(b) Disconnect the connector C013 of combination instrument.

04

(c) Use a multimeter to measure the resistance between the

pin 1 of the connector of the seat belt alarm switch D013
on the side of passenger and ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
D013 (1) - Grounding ≥ 1 MΩ

Check whether the result is normal?

Yes> replace combination instrument assembly.
No > Repair the ground short circuit of signal circuit between the pin 1 of the seat belt alarm switch
D006 and the no.26 pin of connector of the combination instrument C013.

7. Check whether the signal and ground circuit of seat belt indicating lamp on the side of passenger
are of open circuit
(a) Ignition Switch: OFF.

(b) Disconnect the connector of the seat belt alarm switch

D013 on the side of driver.
(c) Ignition Switch: ON.
 04-612 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(d) Use a multimeter to measure the voltage between the pin

1 of the connector of the seat belt alarm switch D013 on
the side of passenger and ground; the pin 1 and pin 2。
Standard voltage
Multimeter connection Standard value
D013 (1) - D013 (2) Battery voltage
04 D013 (1) - Grounding Battery voltage

Check whether the result is normal?

Yes> Replace the seat belt alarm switch on the side of passenger.
No > If there is no voltage of a storage battery, go to step 4. If battery voltage is not available only between
pin 1 and pin 2 of connector of seat belt alarm switch D013 on the side of passenger, repair the open
circuit between pin 2 of seat belt alarm switch D013 on the side of passenger and the ground F1.

8. Check whether the signal circuit of seat belt indicating lamp on the side of passenger is of open
circuit
(a) Use a multimeter to measure the voltage between pin 26
of connector of the combination instrument C013 and the
ground.
Standard voltage
Multimeter connection Standard value
C013 (26) -ground Battery voltage

Check whether the result is normal?

Yes> Repair the open circuit of signal circuit between the pin 1 of the seat belt alarm switch D013 on
the side of passenger and the no.26 pin of connector of the combination instrument C013.
No> Replace the combination instrument assembly.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-613

FUEL GAGE FAULTS

Circuit Diagram

04

Diagnostic step
• Ignition switch: ON, confirm whether there is enough fuel in the fuel tank (greater than 1/4 fuel
liquid level).
• When the fuel level of the fuel tank is lower than 27± 2.5 mm or fuel sensor resistance value is
greater than 189 ± 4 Ω, fuel alarm indicating lamp will be on.
• When the fuel level of the fuel tank is greater than 27± 2.5 mm or fuel sensor resistance value is
lower than 189 ± 4 Ω, fuel alarm indicating lamp will be off.

1. Check the fuel sensor

(a) Ignition Switch: OFF.
 04-614 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(b) Disconnect the connector of the fuel sensor B001.

04

(c) Use a multimeter to measure the resistance between pin

1 and pin 2 of the connector of the fuel sensor B001.
(d) Dismantle the fuel sensor, imitate the states of different
positions under the fuel liquid surface according to the
form below.
Floater Alarm
Emp-
posi- posi- 1/4 1/2 3/4 Full
ty:
tion tion
Resis-
62 ± 38 ±
tance 283 ± 6 189 ± 4 137 ± 4 89 ± 3
2.5 1.5
（Ω）

Check whether the result is normal?

Yes> go to step 2
If no > Replace the fuel sensor..

2. Check whether the signal circuits of the fuel sensor is of open circuit
(a) Ignition Switch: ON.

(b) Use a multimeter to measure the voltage between pin 2

of the connector of the fuel sensor B001 and ground.
Standard voltage
Multimeter connection Standard value
B001 (2) - grounding 5V
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-615

Check whether the result is normal?

Yes> go to step 4
If no > Go to step 3.

3. Check whether the signal circuits of the fuel sensor is of open circuit
(a) Use a multimeter to measure the voltage between pin 22
of connector of the combination instrument C013 and the 04
ground.
Standard voltage
Multimeter connection Standard value
C013 (22) -ground 5V

Check whether the result is normal?

If yes >Repair the circuit open circuit between pin 22 of connector of the combination instrument C013and
the pin 2 of connector of the fuel sensor B001.
No> go to step 5

4. Check whether the signal circuits of the fuel sensor is of short circuit
(a) Ignition Switch: OFF.

(b) Disconnect the connector of the combination instrument

C045.
 04-616 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(c) Use a multimeter to measure the resistance between pin

7 of connector of the combination instrument C013 and
the ground.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value

04 C013 (7) -ground ≤2Ω

Check whether the result is normal?

Yes> replace combination instrument assembly.
If no> Repair the open circuit of ground circuit between the pin 1 of the fuel sensor B001and the pin 7
of the connector of the combination instrument C013.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-617

BRAKE FAULT ALARM LAMP FAILS TO GO ON/NORMALLY ON

Circuit Diagram

04

Diagnostic step
• Check whether the brake (or clutch) liquid is too low, and specialized brake (or clutch) liquid shall
be added if it is too low.
• Fix the four wheels with wedges.
• Ignition Switch: ON.
• Release and pull onboard brake separately.
Check whether the brake alarm lamp is not on /always on

1. Check the manual braking switch circuit.

(a) Ignition Switch: OFF.
(b) Release onboard brake
 04-618 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(c) Disconnect the braking switch connector D007.

(d) Ignition Switch: ON.

04

Check whether the brake failure alarm lamp is off

Yes > Replace the manual braking switch.
No> go to step 2

2. Check whether the brake failure alarm lamp signal circuit

(a) Use a multimeter to measure the voltage between the pin
1 of manual braking switch and ground.
Standard voltage
Multimeter connection Standard value
D 007 (1) - Grounding Battery voltage

Check whether the result is normal?

Yes > Replace the manual braking switch.
No> go to step 3

3. Check the manual braking switch circuit.

(a) Disconnect the connector C013 of combination instrument.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-619

(b) Use a multimeter to measure the resistance between pin

31of connector of the combined instrument C013 and the
pin 1 of connector D007 of manual braking switch.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C013 (31) - D007 (1) ≤2Ω 04

Check whether the result is normal?

Yes> replace combination instrument assembly.
No >Repair the circuit open circuit between pin 31of connector of combination instrument C013and the
pin 1 of connector of manual braking switch D007.

4. Check the brake liquid level alarm switch circuit

(a) Ignition Switch: OFF.

(b) Disconnect the connector of brake liquid level alarm switch

A009.
(c) Ignition Switch: ON.

Check whether the brake failure alarm lamp is off

No > Replace the brake liquid level alarm switch.
No> go to step 5

CAUTION

Brake liquid level alarm switch should not be replaced separately, instead, the oil storage cup assembly
is required to be replaced.

5. Check the brake liquid level alarm switch signal circuit

 04-620 DIAGNOSTICS - ASSEMBLY INSTRUMENT

(a) Use a multimeter to measure the voltage between the pin

1 of the brake liquid level alarm switch and ground.
Standard voltage
Multimeter connection Standard value
A009 (1) - grounding Battery voltage

04

Check whether the result is normal?

Yes> go to step 6
No> go to step 7

6. Check whether the brake liquid level alarm switch circuit is of short circuit
(a) Use a multimeter to measure the resistance between
thepin 2 of the brake liquid level alarm switch A009 and
ground.
Standard resistance (check whether there is short
circuit)
Multimeter connection Standard value
A009 (2) - grounding ≤2Ω

Check whether the result is normal?

No > Replace the brake liquid level alarm switch.
No> go to step 7

7. Check the brake liquid level alarm switch circuit

(a) Disconnect the connector C013 of combination instrument.
 DIAGNOSTICS - ASSEMBLY INSTRUMENT 04-621

(b) Use a multimeter to measure the resistance between no.

14 pin of connector of the combination instrument C013and
the pin 1 of connector of the brake liquid level alarm switch
A009.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
04
C013 (14) - A009 (1) ≤2Ω

Check whether the result is normal?

Yes> replace combination instrument assembly.
No >Repair the circuit open circuit between pin 31of connector of connector of combination instrument
C013and the pin 1 of connector of brake liquid alarm switch D007.
 04-622 DIAGNOSTICS - COMBINED DISPLAY

COMBINED DISPLAY
PRECAUTION
1. Ignition switch representation
Ignition switch (location) Ignition switch representation
LOCK Ignition Switch: OFF.

04 ACC Ignition Switch ACC

ON Ignition Switch: ON.
START Start the engine.

2. Disconnect power supply

(a) Before dismounting or installing any electric apparatus, or when tool or equipment is susceptible to touch
exposed electric pins, be sure to disconnect the negative-pole cable of battery firstly to prevent persons
or vehicle from being damaged.
(b) If there is special illustration, ignition switch must be closed.
 DIAGNOSTICS - COMBINED DISPLAY 04-623

COMPONENTS DRAWING

04

1 Combined Display
 04-624 DIAGNOSTICS - COMBINED DISPLAY

COMBINED DISPLAY DESCRIPTION

04

1 Time display
 DIAGNOSTICS - COMBINED DISPLAY 04-625

PIN DESCRIPTION FOR THE COMBINED DISPLAY

04

Stitch number Connection rod color Description

B1 White - red Battery power supply
B2 - -
B3 Purple - pink LIN
B4 Blue Backlight lighting
B5 Black ground
B6 - -
 04-626 DIAGNOSTICS - COMBINED DISPLAY

BASIC INSPECTION
Steps Inspection contents Measures
Check Battery voltage Yes Go to step 2
• Battery voltage shall not be lower than
1 12V. No? Charge or replace the battery.
Check whether the result is normal?
04
Check the function of combined display Yes Go to defect phenomenon form
• Ignition switch: ACC. The background
2 light, time display, compass display are
on. No? Replace the combined display
Check whether the result is normal?
 DIAGNOSTICS - COMBINED DISPLAY 04-627

DEFECT PHENOMENON FORM

Check the table below to find the cause of the problem. The numbers rank the possibility of the
causes. Check each part in this order and replace the part if necessary.
Defect phenomenon Suspect Area Reference
1. Fuse -
The combined display doesn’t work Chapter 81. Information system - 04
2. Combined Display
at all combined display, replacement
3. Circuit -
 04-628 DIAGNOSTICS - COMBINED DISPLAY

THE COMBINED DISPLAY DOESN’T WORK AT ALL

Circuit Diagram

04
 DIAGNOSTICS - COMBINED DISPLAY 04-629

Diagnostic step

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F36 (10 A) in the vehicle body fuse box
(C037).

04

Check whether the result is normal?

Yes> go to step 3
No> go to step 2

2. Check the harness and connector (combined display -grounding)

(a) Ignition Switch: OFF.

(b) Disconnect the connector C027 of the combined display.

(c) Measure the electrical resistance based on the value in

the following form.
Standard resistance (Check for any short circuit)
Multimeter connection Standard value
C027 (B1) - grounding ≥1 ΜΩ
 04-630 DIAGNOSTICS - COMBINED DISPLAY

Check whether the result is normal?

Yes> Replace fuse
No > Maintenance or replace harness.

3. Check the harness and connectors (combined display fuse - combined display)
(a) Ignition Switch: OFF.
04 (b) Disconnect the connector C027 of the combined display.

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there existent
an open circuit)
Multimeter connection Standard value
F36 (10 A） - C027（B1） ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check the harness and connector (combined display -grounding)

(a) Ignition Switch: OFF.
 DIAGNOSTICS - COMBINED DISPLAY 04-631

(b) Disconnect the connector C027 of the combined display.

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there existent
an open circuit)
Multimeter connection Standard value
C027 (B5) - grounding ＜2Ω

Check whether the result is normal?

Yes >Replace the combined display.
No > Maintenance or replace harness.
 04-632 DIAGNOSTICS - VEHICLE CONTROL SYSTEM

VEHICLE CONTROL SYSTEM

PRECAUTION
1. Disconnect power supply
(a) When disassembling or installing any electric unit, or touching the exposed electrical terminal with tools
or devices, disconnect the negative battery cable firstly, to prevent vehicle damage or personal injury.
(b) During the operation, turn off the ignition if not otherwise specified.
04 2. Ignition switch representation
Ignition switch (location) Ignition switch representation
LOCK Ignition Switch: OFF.
ACC Ignition Switch ACC
ON Ignition Switch: ON.
START Start the engine.
 DIAGNOSTICS - VEHICLE CONTROL SYSTEM 04-633

COMPONENTS DRAWING

04

1 Ignition Key 4 Ignition switch assembly

2 Ignition switch backlight 5 Body Controller
3 Ignition Switch Key
 04-634 DIAGNOSTICS - VEHICLE CONTROL SYSTEM

VEHICLE BODY CONTROLLER DESCRIPTION

The electronic vehicle body control system of this style, in which a centralized type vehicle body controller
(BCM) is adopt and car lights, door locks, wipers, car windows of the whole vehicle are intelligently
controlled by a control module, is mainly used for vehicle body electric appliances control. At the same
time, it has also functions such as electric appliance intelligent fault diagnosis, intelligent energy-saving
and bus communication etc.
04
The function and function description are as follows:
Function Description
Over-voltage mode
Power supply management 2.Under-voltage mode
3. Low energy consumption mode
Activate the matching function of the remote controller
Remote controller matching
through the printing and writing system
1.Early warning
2. Setting up defences
Vehicle anti-theft alarm
3. Relieving defences in two stages
4. Secondary anti-theft
1.Central controlled locking
2. Central controlled unlocking (including automatic un-
locking function through colliding )
Door lock Control
3. Automatic locking
4.Door lock shall be used firstly
5.Mechanical unlocking / locking
1.Roll up/down car window manually
Car window control 2.Close window through remote control
3.Anti-pinching window
1.prompt that small light has not been turned off
Prompts and alarms. 2. Prompt that door has not been closed
3.Prompt that the key has not been pulled out
BCM will get back to under the mode before power failure
Function of memory of anti-theft (power failure)
if after power supply is restored
1.Switch control for internal and external lights(small
light,headlight low beam, high beam, high beam flashing,
turn light, step lamp, front and rear foglight, backup door
light, daytime travel light)
2. automatic on / off (reading lamp, ignition lock lighting)
Car lights control
3.Lights which is followed for going home
4.lights for seeking car
5.Turn light fault detection
6.Hazard warning lamp function
 DIAGNOSTICS - VEHICLE CONTROL SYSTEM 04-635

Function Description
1.Run at a high speed
1.Run at a low speed
Wiper water -sprayer 3.Removing the mist
4.Intermittent running
5.Washing / wiping
04
Rear-view mirror defrosting
Defrosting
2.Rear windscreen defrosting
Diagnosis Diagnosing through CAN bus
Car window anti-pinching module is controlled through
LIN communication
LIN line to form communication with the central display
 04-636 DIAGNOSTICS - VEHICLE CONTROL SYSTEM

DEFINITION FOR THE VEHICLE BODY CONTROLLER PIN

04

Connector A
Terminal no. Connection rod color Description
A1 Purple Ceiling lamp
The front axle clutch out-
A2
puts signal
A3 —

C032 A4 —
A5 —
A6 —
A7 Red Left rear window drops
A8 Blue Left rear window rises
 DIAGNOSTICS - VEHICLE CONTROL SYSTEM 04-637

Terminal no. Connection rod color Description

assistant driver’s car win-
A9 Grey - red
dow drops
assistant driver’s car win-
A10 Grey
dow rises
A11 brown Driver’s car window drops
A12 brown Driver‘s car window rises 04

Connector B
Terminal no. Connection rod color Description
B1 brown Door locks
B2 Blue Door unlocks
B3 Blue - black Driver’s door unlocks
B4 —
B5 —
Rear foglight power sup-
B6 Red-blue
ply+ driver’s door unlock
C033 The front window power
B7 white
supply + central control
Rear car window power
B8 Purple
supply
B9 Orange: Right rear car window rises
Right rear car window
B10 White - red
drops
B11 Black ground
B12 Black ground

Connector C
Terminal no. Connection rod color Description
C1 Right turnlight.
C2 green Left turnlight.
C3 Blue Small lamp
C4 —
C5 White - black Lamp power supply 2
C034
C6 Black-Red Lamp power supply 1
C7 Rear wiper
C8 Red-white Rear foglight
C9 —
C10 White - red Battery power-saving input
 04-638 DIAGNOSTICS - VEHICLE CONTROL SYSTEM

Terminal no. Connection rod color Description

C11 —
Battery power-saving out-
C12 Red-yellow
put

Connector D
04 Terminal no. Connection rod color Description
D1 Black - green External antenna
Front wiper switch(low-
D2 Purple - white
speed)
Front wiper switch(high-
D3 Purple - green
speed)
Front wiper switch(intermit-
D4 Purple -yellow
tent)
D5 Horn switch
( Driver's door) unlock/un-
D6 Yellow-black
lock switch
D7 White - brown Left rear car window switch
Right rear car window
D8 White - orange
switch
Passenger seat car window
D9 White - red
switch
(Driver’s door)left rear car
D10 White - black
window switch
(Driver’s door)right rear
C035 D11 Blue-yellow
car window switch
(Driver’s door)passenger
D12 Orange - black
seat car window switch
(Driver’s door) passenger
D13 White - green seat side car window
switch
D14 Orange: High beam
D15 Purple -red aLow beam
D16 White - violet Front foglight（DRL)
D17 Safety indicating lamp
D18 Red Althorn/bass Horn
D19 Red-white CAN H
D20 Blue-yellow CAN L
Rear windscreen defrosting
D21 Brown - white
unit.
D22 Grey -purple Rear-view mirror defrosting
D23 green Front wiper (low-speed)
 DIAGNOSTICS - VEHICLE CONTROL SYSTEM 04-639

Terminal no. Connection rod color Description

D24 Yellow - red Front wiper (high-speed)
Signal for closing remote
D25
control skylight
Request switch for electri-
D26
cal air conditioner.
Medium-voltage switch for 04
D27
electrical air conditioner.
D28 Auto-dimmer switch
D29
D30
D31 LIN
D32 Purple - pink LIN

Connector E
Terminal no. Connection rod color Description
E1 Red ACC
E2 KEY IN
E3 Orange - red IGN
E4 Rear wiper switch
E5 Black - white Small lamp switch
E6 Light green Low beam switch
E7 Blue-red High beam switch
E8 green Flash on/off switch
E9 Blue Front foglight switch
E10 Blue - white Rear foglight switch
E11 Red-blue Left turn light switch
C036 E12 Green-red Right turn light switch
Hazard warning lamp
E13 Grey
switch
Passenger car window
E14 White -pink
prohibition
E15 Yellow - green Left front car door switch
E16 Purple Right front car door switch
E17 Blue Left rear car door switch
E18 Yellow-black Right rear car door switch
E19 Engine bonnet ajar input
E20 Trunk door opens
Rear-view mirror defrosting
E21
unit switch.
 04-640 DIAGNOSTICS - VEHICLE CONTROL SYSTEM

Terminal no. Connection rod color Description

E22 Reverse switch
Rear wiper stop position
E23
switch
Front wiper stop position
E24 brown
switch
04 E25 Rear washer switch
E26 Green - white Front washer switch
(Mechanical key) door un-
E27 Orange:
locking switch
(Mechanical key) door
E28 Blue - black
locking switch
E29 Yellow - red Rear defrosting unit switch.
Mechanical key anti-unlock-
E30 Yellow - red
ing switch
E31 Snowfield mode switch
E32 Motion mode switch
 DIAGNOSTICS - VEHICLE CONTROL SYSTEM 04-641

DEFECT PHENOMENON FORM

When checking DTC in the checking module, if certain DTC displayed, then the circuit of the code
listed in the following list should be checked. The detailed description of each DTC can refer to
corresponding pages.
DTC code Diagnostic items (DTC definition) Trouble location
• Battery
04
• Charging system
The power supply is greater than 16V
B353C • Systematic power supply
within BCM
• Body Controller

• Battery
• Charging system
The power supply is smaller than 9V
B353D • Systematic power supply
within BCM
• Body Controller

• Battery
• Charging system
Battery energy-saving outputs circuit
B1402 • Systematic power supply
low-voltage
• Body Controller

• Battery
• Charging system
Battery energy-saving outputs circuit
B1403 • Systematic power supply
high-voltage
• Body Controller
 04-642 DIAGNOSTICS - VEHICLE CONTROL SYSTEM

B353C THE POWER SUPPLY IS GREATER THAN 16V WITHIN BCM

B353D THE POWER SUPPLY IS SMALLER THAN 9V WITHIN BCM
Circuit Diagram

04

Diagnostic step

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse in the indoor fuse box.

• F22(7.5A)

• F26(7.5A)
 DIAGNOSTICS - VEHICLE CONTROL SYSTEM 04-643

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the harness and connector (fuse-BCM control unit)

(a) Disconnect battery negative cable.

(b) Disconnect the connector C036 of BCM control unit. 04

(c) Measure the electrical resistance based on the value in

the following form.
Multimeter connection Standard value
F22(7.5A)-C036（E1）
＜2Ω
F26(7.5A)-C036（E3）

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check the harness and connectors (BCM controlling unit -grounding)

(a) Ignition Switch: OFF.
 04-644 DIAGNOSTICS - VEHICLE CONTROL SYSTEM

(b) Disconnect the connector C036 of BCM control unit.

04

(c) Measure the electrical resistance based on the value in

the following form.
Multimeter connection Standard value
C033（B11) - grounding
＜2Ω
C033（B12) - grounding

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.
 DIAGNOSTICS - VEHICLE CONTROL SYSTEM 04-645

B1402 BATTERY ENERGY-SAVING OUTPUTS CIRCUIT

LOW-VOLTAGE
B1403 BATTERY ENERGY-SAVING OUTPUTS CIRCUIT
HIGH-VOLTAGE
Circuit Diagram
04
 04-646 DIAGNOSTICS - VEHICLE CONTROL SYSTEM

Diagnostic step

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check fuse inside fuse box, engine compartment : F11

(60A).
(c) Check the fuse F36（10A) in the indoor fuse box.
04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the harness and connectors (fuse - fuse).

(a) Disconnect battery negative cable.

(b) Measure the resistance as per the values given in the table
below
Multimeter connection Standard value
F2(60A)-F36(10A) ＜2Ω

Check whether the result is normal?

 DIAGNOSTICS - VEHICLE CONTROL SYSTEM 04-647

Yes> go to step 3
No > Maintenance or replace harness.

3. Check the harness and connector (fuse-BCM control unit)

(a) Disconnect battery negative cable.

(b) Disconnect the connector C034 of BCM control unit.

04

(c) Measure the electrical resistance based on the value in

the following form.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection stitch Specified value
F36(10A) - C034（C10） ＜2Ω

Check whether the result is normal?

Yes> Replace BCM control unit.
No > Maintenance or replace harness.
 04-648 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM

TYRE PRESSURE MONITORING SYSTEM

PRECAUTION
1. Install the tyre pressure monitoring sensor into the inflating valve installing position of spoke
and check whether it has matched the surface of installation.
2. Tyre pressure monitoring module shall be placed correctly, the module main body shall be vertical
to the wheel central face, so as to avoid interfering with it while installing the outer tube afterwards.
04 3. While installing the tyre pressure monitoring module and tyre, rude operation is forbidden, so as
to avoid damaging the module.
4. While assembling the tyre, tyre installation apparatus needs to be far away from the inflating
valve to avoid damaging tyre pressure monitoring module.
5. While installing the tyre pressure monitoring module and inflating valve , pulling in force shall
be (250-600)N, and pulling off force shall be greater than 750N.
6. When installing the tyre pressure monitoring module and inflating valve , attention shall be paid
to that the rubber seat is installed vertical to the inflating valve , so as to avoid damaging the
rubber.
7. The installation of tyre pressure monitoring module involves the tyre, which will affect the security
of complete vehicle. Therefore, the installation must be operated by professional personnel to
guarantee that no damage to the tyre and no leaking etc. Finally, tyre dynamic balancing must
be carried out.
8. The inflating valve needs to be installed while aligning the white or yellow dot of the tyre side.
9. Carry out dynamic balancing of the tyre, it is required that: residual unbalance for steel wheel
assembly to be less than or equal to 11g; while residual unbalance for aluminium wheel assembly
to be less than or equal to 5g.
 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM 04-649

COMPONENTS DRAWING

04

1 Fixing screw for tyre pressure 3 Inflating valve

monitoring controller 4 Tyre pressure monitoring module
2 Tyre pressure monitoring controller
 04-650 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM

SYSTEM SPECIFICATION
1. Technical specifications:
Item parameters.
Standard voltage DC12V
Operating voltage DC9~16V
Operating temperature -30℃～80℃
04
Storage temperature range —40℃～85℃
Working frequency range 422.92MHz ±100KHz
Low frequency controlling distance ≤15cm
Working current（IGN ON） 22mA ±3mA
Static average current (IGN ON) ≤3mA
High frequency receiving sensitivity Greater than or equal to - 95dBm
Modulating mode of high-frequency signals FSK

2. Pin definition

Pin position Function property Voltage

1 BAT Input: 12V
2 (LF1) (reserve) /
3 (LF2) (reserve) /
4 / / /
5 IGN Input: 12V
 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM 04-651

Pin position Function property Voltage

6 / / /
7 / / /
8 CANL Input/output /
9 CANH Input/output /
10 / / /
04
11 / / /
12 / / /
13 (LF2) (reserve) /
14 (LF2) (reserve) /
15 / / /
16 GND Input: OV

3. Function diagram

4. System specification
(a) This system includes one receiving module and 4 tyre pressure monitoring modules.
(b) Tyre pressure monitoring module: Mounted in the vehicle tyre to monitor and control the pressure
temperature information of the tyre in real time, and send the corresponding data of this information
through radio frequency signal.
 04-652 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM

(c) Receiving module: Mounted in the vehicle to receive tyre pressure message which is sent by the tyre
pressure monitoring module in real time; Through corresponding data processing, when the tyre present
low pressure, high pressure, high temperature, fast gas leakage or the sensor does not have signal,
corresponding alarm signal will be sent out in time.
(d) Moreover, the system has the function to arouse form a state of dormancy.
5. Functional Description
Function Description
04 When IGN is ON, push down the setter for about 6s
at a distance of about 10cm from the host computer,
themain machine main machine will enter studying
Studying condition mode, studying setter will touch off SENSOR one by
one to make it send out corresponding ID; The main
machine will withdraw from studying mode after
studying.
When IGN is ON, the main machine enters working
state, receives the tyre pressure message and carries
Working state
out corresponding data processing, outputs informa-
tion such as tyre pressure, temperature through CAN.
When IGN is OFF, the main machine enters the
power-saving mode.
 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM 04-653

TPMS SETTING METHOD

CAUTION

Tyre pressure receiving module will enter studying mode in case of any following situations: Tyre
pressure receiving module has not been set 1 min after it has entered studying mode. Use setter to
touch off the tyre pressure receiving module 5s later after it enters studying mode. While withdrawing
from the studying mode in the both situations, please reset tyre pressure monitoring module again from
the first step. 04

1. Entering into the studying state.

(a) Use a hand-hold setter, with the front end(LED indicating
lamp end) aiming at the tyre pressure receiving module
under the left seat, press any key for about 6s at a distance
of about 10cm.

(b) Graphic patterns appear on the instrument LCD of the

vehicle, showing that it has entered studying state, now
loosen the button. Now the four wheels are at twinkling
state.
 04-654 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM

2. Position setting
(a) Use a hand-hold setter, aim at the air valve nozzle of the
tyre pressure monitoring module which need to be set,
with a distance smaller than 50cm. Corresponding relation
of buttons: LED indicating lamp end is the advancing
direction of the car, four buttons correspond to four wheel
positions separately, FL: Corresponds to the left front
wheel; RL: Corresponds to the left rear wheel; FR:
04 Corresponds to the right-front wheel; RR: Corresponds to
the right rear wheel.

(b) Set the tyre pressure monitoring module at left-front

position, press down FL button for about 3s, if the wheel
corresponding to a wheel location stops flickering, setting
succeeds.

(c) Alike, set the tyre pressure monitoring module at left-rear

position, press down RL button for about 3s, if the wheel
corresponding to a wheel location stop flickering, setting
succeeds.
DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM 04-655

(d) Set the tyre pressure monitoring module at right-front

position, press down FR button for about 3s, if the wheel
corresponding to a wheel location stops flickering, setting
succeeds.

04

(e) Set the tyre pressure monitoring module at right-rear

position, press down RR button for about 3s, if the wheel
corresponding to a wheel location stops flickering, setting
succeeds.
 04-656 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM

DEFECT PHENOMENON FORM

Defect phenomenon Suspect Area Reference
1. Fuse -
2.Harness and connector -
Tyre pressure monitoring controller
doesn’t work Chapter 33 tyre and wheel - receiving
3. Tyre pressure monitoring con-
module of the tyre pressure monitor-
troller.
04 ing system, replacement
Chapter 33 tyre and wheel - receiving
1. Tyre pressure monitoring con-
module of the tyre pressure monitor-
troller.
ing system, replacement
Tyre pressure is not measured cor-
Chapter 33. Tyre & wheel - front
rectly.
wheel & tyre, replacement
2.Tyre pressure monitor.
Chapter 33. Tyre & wheel - rear
wheel & tyre, replacement
 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM 04-657

TYRE PRESSURE MONITORING CONTROLLER DOESN’T WORK

Circuit Diagram

04
 04-658 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM

Diagnostic step

1. Check fuse
(a) Ignition Switch: OFF.
(b) Open the fuse box (A020) of the engine compartment and take out the fuse: F2(60 A).
(c) Open the indoor fuse box (C037), take out the fuses: F4（7.5 A）and F30（7.5 A）.

CAUTION
04
Dismantle of the fuse needs special fuse detacher, don’t pull it out with hands directly in order to avoid
damages.

(d) Check fuse F2 (60 A) of the engine compartment (A020),

and indoor fuse box (C037) fuse: F4 (7.5 A), F30 (7.5 A).

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check harness and connector (storage battery -Tyre pressure monitoring controller)
(a) Ignition Switch: OFF.
(b) Disconnect the connectorD005 of the tyre pressure monitoring controller.

(c) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
Battery (+) -D005（1 ＜2Ω
 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM 04-659

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check the harness and connector (tyre pressure monitoring controller -grounding)
(a) Ignition Switch: OFF.
(b) Disconnect the connectorD005 of the tyre pressure monitoring controller.
04
(c) Use a multimeter to measure resistance value.
Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
D005（16）- grounding ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check harness and connector (ignition switch -tyre pressure monitoring controller)
(a) Ignition Switch: OFF.
(b) Disconnect the connectorD005 of the tyre pressure monitoring controller.
 04-660 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM

(c) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
D005（5） - ignition switch. ＜2Ω

04

Check whether the result is normal?

Yes>Tyre pressure monitoring controller.
No > Maintenance or replace harness.
 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM 04-661

TYRE PRESSURE IS NOT MEASURED CORRECTLY.

Circuit Diagram

04
 04-662 DIAGNOSTICS - TYRE PRESSURE MONITORING SYSTEM

Diagnostic step

1. Preset tyre pressure monitoring module

(a) Adjust the tyre pressure to the standard value.
(b) reset tyre pressure monitoring module See " Chapter 4 Diagnosis - tyre pressure monitoring system
diagnosis, TPMS setting method)
Have the function returned to normal?
04
Yes> Complete
No> go to step 2

2. Check the tyre pressure monitoring controller.

(a) Ignition Switch: OFF.
(b) Disconnect the connectorD005 of the tyre pressure monitoring controller.
(c) Replace the tyre pressure monitoring controller.
Have the function returned to normal?
Yes>Replace the tyre pressure monitoring controller.
No> go to step 3

3. Check the tyre pressure monitor.

(a) Ignition Switch: OFF.
(b) Remove the tyre.
(c) Replace the tyre pressure monitor.
Have the function returned to normal?
Yes>Replace the tyre pressure monitor.
No> Remove the defects by other means.
 DIAGNOSTICS - FRONT AXLE CLUTCH 04-663

FRONT AXLE CLUTCH

PRECAUTION
1. If vehicle goes greater than 80km/h, the front axle clutch controller will refuse to execute switch
instruction of the four wheel driving system.
2. If dynamic assembly is damaged, it is recommended that the whole assembly to be replaced, it
is unsuitable to be opened and repaired.
3. Maintenance shall be carried out according to the standardized steps. 04
4. Connection in the circuit is forbidden.
 04-664 DIAGNOSTICS - FRONT AXLE CLUTCH

COMPONENTS DRAWING

04

1 Motor component of the front axle 2 The front axle clutch controller
clutch
 DIAGNOSTICS - FRONT AXLE CLUTCH 04-665

SYSTEM SPECIFICATION
1. PRINCIPLE OF OPERATION
(a) 2H →4H: The four-wheel driving system offers combined instruction to the front axle clutch controller,
after receiving it, the front axle clutch will send corresponding instruction to the front axle clutch actuator
assembly. The actuator assembly motor drives internal gears to rotate, at last, clutch shifter drives the
clutch gear to match the main shaft. Feedback signal indicating that execution is finished to the four
wheel driving system, at the same time switch the signal to the signal the instrument, the instrument
indicating lamp shall be always on at this moment. If the first execution can’t be finished, the front axle 04
clutch controller will execute for the second time automatically; If the second time still can’t be finished,
the controller will feedback the information to the instrument, at this time, the instrument indicating lamp
glimmers, and front axle clutch will stop.
(b) 4H →2H: The four-wheel driving system offers disconnection instruction to the front axle clutch controller,
after receiving it, the front axle clutch controller will send corresponding order to the front axle clutch
actuator assembly. The actuator assembly motor drives internal gears to rotate, at last, clutch shifter
drives the clutch gear to disconnect with the main shaft. Feedback signal indicating that execution is
finished to the four wheel driving system, at the same time switch the signal to the signal the instrument,
the instrument indicating lamp shall be always off at this moment. If the first execution can’t be finished,
the front axle clutch controller will execute for the second time automatically; If the second time still can’t
be finished, the controller will feedback the information to the instrument, at this time, the instrument
indicating lamp glimmers, and front axle clutch will stop.
(c) If vehicle goes greater than 80km/h, the front axle clutch controller will refuse to execute switch instruction
of the four wheel driving system.
2. The front axle clutch controller pin

Stitch number Pin definition Description

Connect to the ON line of ignition lock of car, and a 15A fuse
1 Power supply 12V(ON)
shall be installed on the line.
 04-666 DIAGNOSTICS - FRONT AXLE CLUTCH

Stitch number Pin definition Description

Connect to the cable of the clutch motor, this cable will output
2 Motor output (positive rotation) 12V voltage when it is in 4WD →2WD and it grounds at ordinary
times.
Connect to the cable of the clutch motor, this cable will output
3 Motor output (reverse rotation) 12V voltage when it is in 2WD →4WD and it grounds at ordinary
times.
04
Connect to the negative pole of LED light, and low level will be
4 LED light output
output the, the instrument indicating lamp is on.
Inspect the state of the clutch
5 Connect to the third pin of the clutch power assembly.
controller
Inspect the state of the clutch
6 Connect to the fifth pin of the clutch power assembly.
controller
Inspect the state of the clutch
7 Connect to the sixth pin of the clutch power assembly.
controller
When the four wheel driving system ECU sends a low level signal,
it shows that the front axle is required to combine; if it is not a
8 Gear switch signal input;
low level , it shows that the front axle is required to be disconnect-
ed.
Feedback signal which is sent to the four wheel driving system
ECU. When the signal is a low level, it means that the front axle
clutch has already been combined, the four wheel driving system
can work normally, the instrument indicating lamp is on; When it
9 State output signal is not a low level, it means that the front axle clutch is disconnect-
ed, indicating lamp is off; If the clutch is out of order, then the
controller will directly send the unusual signal to the instrument
to warn by glimmering. ( The indicating lamp is controlled through
the fourth pin)
When the speed is greater than or equal to 80km/h, BCM will offer
Vehicle speed limitation sig- a low level (0V 2V) continuously, the controller will forbid the front
10
nals (80km/h) axle clutch to work at this moment. Signals are cleared at ordinary
times.
11 Empty: -
12 Empty: -
13 Cathode power supply. -
 DIAGNOSTICS - FRONT AXLE CLUTCH 04-667

DEFECT PHENOMENON FORM

Defect phenomenon Suspect Area Reference
1. Fuse —
The front axle clutch indicating lamp
2.Harness or connector —
doesn’t work.
3. indicating lamp is damaged —
1. Fuse — 04
2.Harness or connector —
Chapter 34 The axle and transmis-
3 The front axle clutch actuator is of
Front axle clutch can't work normally sion shaft – front axle clutch assem-
fault
bly, replacment
Chapter 34 The axle and transmis-
4.The front axle clutch controller
sion shaft – front axle clutch control
module
module, replacement
 04-668 DIAGNOSTICS - FRONT AXLE CLUTCH

FRONT AXLE CLUTCH CAN'T WORK NORMALLY

Circuit Diagram

04
 DIAGNOSTICS - FRONT AXLE CLUTCH 04-669

Diagnostic step

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F35(20 A) in the indoor fuse box (C037).

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check harness and connectors (front axle clutch controller -grounding)

(a) Ignition Switch: ON.
(b) Disconnect the connector C038 of the front axle clutch controller.

(c) Use a multimeter to measure resistance value.

Standard voltage
Multimeter connection Standard value
C038 (13) - grounding Battery voltage

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connectors (front axle clutch controller -grounding)

 04-670 DIAGNOSTICS - FRONT AXLE CLUTCH

(a) Ignition Switch: OFF.

(b) Disconnect the connector C038 of the front axle clutch controller.

(c) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)

04 Multimeter connection Standard value

C038 (13) - grounding ＜2Ω

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

4. Check harness and connectors (front axle clutch controller - front axle clutch actuator)
(a) Ignition Switch: OFF.
(b) Disconnect the connector C038 of the front axle clutch controller.
(c) Disconnect theconnector K007 of the front axle clutch actuator.

(d) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C038 (2） - K007(1）
C038 (3） - K007(2）
C038 (5） - K007(3） ＜2Ω
C038 (6） - K007(5）
C038 (7） - K007(6）

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check harness and connectors (front axle clutch actuator -grounding)

(a) Ignition Switch: OFF.
 DIAGNOSTICS - FRONT AXLE CLUTCH 04-671

(b) Disconnect theconnector K007 of the front axle clutch actuator.

(c) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
K 007 (4) - grounding ＜2Ω 04

Check whether the result is normal?

Yes> go to step 6
No > Maintenance or replace harness.

6. Check the front axle clutch actuator.

(a) Ignition Switch: OFF.
(b) Disconnect theconnector K007 of the front axle clutch actuator.
(c) Replace the front axle clutch actuator.
Has the fault been eliminated?
YES>replace the front axle clutch actuator.
No> go to step 7

7. Check harness and connectors (front axle clutch controller - electrical clutch release system,
vehicle speed control module, combination instrument)
(a) Ignition Switch: OFF.
(b) Disconnect the connector C038 of the front axle clutch controller.
 04-672 DIAGNOSTICS - FRONT AXLE CLUTCH

(c) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C038 (8, 9) – electrical separa-
tor system
04 C038 (10) – vehicle speed
＜2Ω
control module
C038 (10) - combination instru-
ment

Check whether the result is normal?

Yes> go to step 8
No > Maintenance or replace harness.

8. Check the front axle clutch controller.

(a) Ignition Switch: OFF.
(b) Disconnect the connector C038 of the front axle clutch controller.
(c) Replace new front axle clutch controller.
Has the fault been eliminated?
YES>replace the front axle clutch controller.
No> Remove the defects by other means.
 DIAGNOSTICS - FRONT AXLE CLUTCH 04-673

THE FRONT AXLE CLUTCH INDICATING LAMP DOESN’T WORK.

Circuit Diagram

04
 04-674 DIAGNOSTICS - FRONT AXLE CLUTCH

Diagnostic step

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F30(7.5 A) in the indoor fuse box (C037).

04

Check whether the result is normal?

Yes> go to step 2
No> replace fuse

2. Check the harness and connectors (combination instrument - ground)

(a) Ignition Switch: ON.
(b) Disconnect the connector of the combination instrumentC013。

(c) Use a universal meter to measure voltage

Standard voltage
Multimeter connection Standard value
C013 (19) ground Battery voltage

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check the harness and connectors (combination instrument - ground)

 DIAGNOSTICS - FRONT AXLE CLUTCH 04-675

(a) Ignition Switch: OFF.

(b) Disconnect the connector of the combination instrumentC013。

(c) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value 04
C013 (3) ground ＜2Ω

Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

4. Check the harness and connectors(Control module, front axle clutch -electric sub-actuator four
wheel driving module)
(a) Ignition Switch: OFF.
(b) Disconnect the front axle clutch controller module
(c) Disconnect the electric sub-actuator four wheel driving module C040

(d) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C038（9） - C040（3）
＜2Ω
C038（8） - C040（6）

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.
 04-676 DIAGNOSTICS - FRONT AXLE CLUTCH

5. Check wiring bunch and socket connector(combined instrument-Electric sub-actuator four wheel
driving module)
(a) Ignition Switch: OFF.
(b) Disconnect assembly instrument C013
(c) Disconnect the electric sub-actuator four wheel driving module C040

(d) Use a multimeter to measure resistance value.

04 Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C013（1） - C040（9）
＜2Ω
C013（17） - C040（8）

Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

6. Check indicator lamp

(a) Remove the indicator lamp
(b) Replace the indicator lamp
Check whether the result is normal?
Yes >Replace the indicator lamp
No> Remove the defects by other means.
VEHICLE MAITENANCE
SERVICE SCHEDULE....................................05-1
PRECAUTION.............................................05-1
REGULAR SERVICE ITEMS &
INTERVALS.................................................05-3
SERVICE SCHEDULE AT EXTREME
CONDITIONS..............................................05-6
CHECK............................................................05-8 05
CHECK ELECTRICAL SYSTEM.................05-8
CHECK BATTERY.......................................05-9
CHECK AIR BAG......................................05-10
CHECK SEAT BELT..................................05-11
CHECK PARK BRAKE & BRAKE PEDAL..05-13
CHECK DOOR STOPPER, LOCK &
HINGE.......................................................05-14
CHECK WINDSCREEN DRAIN HOLE.....05-16
CHECK ENGINE COMPARTMENT
COMPONENTS........................................05-17
CHECK TOOTHED TIMING BELT............05-18
CHECK ACCESSORY BELT.....................05-20
CHECK STEERING BALL JOINT & DUST
SHIELD.....................................................05-21
CHECK & TIGHTEN CHASSIS BOLTS AT
SPECIFIED TORQUE...............................05-22
CHECK HEADLIGHT................................05-23
CHECK WIPER/WASHER........................05-24
CHECK VEHICLE BOTTOM.....................05-26
CHECK SUSPENSION COMPONENTS...05-27
CHECK SUSPENSION BALL JOINT & DUST
SHIELD.....................................................05-28
CHECK POWER STEERING TANK
LEVEL.......................................................05-29
CHECK BRAKING SYSTEM.....................05-30
CHECK BRAKE DISC, BRAKE DRUM &
LINING......................................................05-31
CHECK TIRE.............................................05-32
CHECK EXHAUST SYSTEM....................05-33
CHECK COOLANT TANK LEVEL.............05-34
CHECK ENGINE OIL LEVEL (4G69)........05-35
CHECK ENGINE OIL LEVEL (4161P)......05-36
REPLACEMENT...........................................05-38
REPLACE AIR FILTER ELEMENT
(4G69).......................................................05-38
REPLACE AIR FILTER ELEMENT
(4161P).....................................................05-40
 REPLACE AIR-CONDITIONING FILTER
ELEMENT.................................................05-42
REPLACE ENGINE OIL & OIL FILTER
(4G69).......................................................05-44
REPLACE ENGINE OIL & OIL FILTER (4161P)
(REPLACEMENT).....................................05-50
REPLACE SPARK PLUG (4G69)..............05-56
REPLACE FUEL FILTER ASSEMBLY
(4G69).......................................................05-57
05 REPLACE FUEL FILTER ELEMENT
(4161P).....................................................05-59
REPLACE COOLANT...............................05-63
REPLACE BRAKING FLUID.....................05-66
REPLACE MANUAL GEARBOX LUBRICANT
(JC538).....................................................05-69
REPLACE MANUAL GEARBOX LUBRICANT
(R5M21)....................................................05-71
REPLACE REAR MAIN REDUCER GEAR
OIL............................................................05-73
REPLACE FRONT MAIN REDUCER GEAR OIL
(4WD)........................................................05-75
REPLACE DIFFERENTIAL OIL (4WD).....05-77
 VEHICLE MAITENANCE - SERVICE SCHEDULE 05-1

SERVICE SCHEDULE
PRECAUTION
Service Precaution
1. Safety
(a) Preparation Before Service
• If necessary, the staff shall wear safety shoes, gloves and goggles.

• Ensure the site is well ventilated and clean, and the tools and instruments are well organized.
Provide fire extinguishers if needed. 05
• Check the safety status of the instruments and equipments, such as lifting jack.

• Check the driving and operating condition of the vehicle, to ensure smooth service.

(b) Precaution During Service

• Before the vehicle is driven into the lifting frame, ensure sufficient clearance between the frame
and the bottom and sides of the vehicle, in order to prevent scratch.
• Before lifting the vehicle, ensure the weight of the vehicle doesn't exceed the rated load of the
lifter.
• When lifting the vehicle, choose the right lifting points.

• During lifting, do not start the engine or engage in the gear when the driving wheels are grounded,
so as to prevent potential hazards to the staff and the vehicle.
• During servicing, the staff shall strictly adhere to all safety and operawtion rules, so as to prevent
potentional hazards to the staff and the vehicle.
• When replacing parts and consumables, use the products authorized by Foton, to ensure the
safety and performance of the vehicle.
(c) Precaution After Service
• A trial drive is necessary after servicing, in particular focusing on the inspection of braking sytem
and safety restraint system.
• The vehicle can only be handed over to the customer after the fault records in the fault memory
are cleared.
2. Schedule
(a) The interval of service and maintenance depends on mileage or time interval, whichever is earlier, as
shown in the schedule.
(b) The interval to the next service shall equal to that from the last service.
(c) Refer to the service schedule for the specific service intervals of different parts.
(d) Some parts are the focuses of service. Replace any aging or damaged hose immediately. Please note
that rubber hose ages over times, which will lead to inflation, scratch or crack.
(e) After a 4WD model drives through sand, soil or pond, pleasse check the following parts and service or
repair them if needed.
• Brake lining and brake drum.

• Brake pad and brake disc.

• Brake pipe and rubber hose.

• Transmission, transfer case and differential oil or fluid.

• Air filter element.

Service Conditions
1. In daily driving circumstance, follow the regular service schedule of the vehicle.
 05-2 VEHICLE MAITENANCE - SERVICE SCHEDULE

2. If the vehicle is mainly driven in one or more special conditions as follows, some parts need
service more frequently (refer to "Extreme Conditions").
(a) Road:
• Uneven, muddy or snow melting road.

• Dusty road.

• Salina road.

(b) Driving:
• Towing another vehicle or using camping rack or roof rack.
05
• Short distance no more than 8KM repeatedly at 0℃ or below.
• Long distance at idling or low speed, such as petrol car, taxi or door-to-door delivery truck.

• More than 2 hours at extremely high speed (80% of the maximum speed).

Note: Any information involving the code "4G69" refers to gasoline engine and "4161P" refers to
diesel engine.
 VEHICLE MAITENANCE - SERVICE SCHEDULE 05-3

REGULAR SERVICE ITEMS & INTERVALS

Regular Inspection & Service Checklist of 4G69 Gasoline Engine Parts
Distance and interval (in month) are indicated for each item, whichever is earlier.
I. Check, adjustment or replacement; R: Replacement, removal or lubrication; L: Lubricant; blank:
N/A.
Service Interval (The Earlier of Mileage Reading or Months)
Months — 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48
Item
05
Mileage Reading *
1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
1,000 KM
Interior Check of Engine Chamber
Check for crack, fragment or wear
I I I I I I I I
in belt and adjust its tension
Engine toothed timing belt R R R R R R R R
Check crankshaft ventilation con-
trol system (including crankshaft I I I I
ventilation element in air filter)
Spark Plug R R R R
Check for radiator hose damage
I I I I
and connection
Check engien coolant level I I I I I I I I
Engien coolant R R
Others
Normal con-
First 5,000KM and later every 5,000KM or every three months
dition
Replace oil
Extreme
Same mileage
condition
Normal con-
First 5,000KM and later every 5,000KM or every three months
Replacement oil fil- dition
ter Extreme
Same mileage
condition
Normal con-
First 5,000KM and later every 5,000KM or every three months
Replacement gaso- dition
line filter Extreme
Same mileage
condition
Air filter element I I I R I I I R I I I R I I I R
Check engine idling I I I I I I I I
Check crankshaft ventilation hose I I I I I I I I

Regular Inspection & Service Checklist of E2.8 Diesel Engine Parts

Distance and interval (in month) are indicated for each item, whichever is earlier.
 05-4 VEHICLE MAITENANCE - SERVICE SCHEDULE

I. Check, adjustment or replacement; R: Replacement, removal or lubrication; L: Lubricant; blank:

N/A.
Service Interval (The Earlier of Mileage Reading or Months)
Months — 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48
Item
Mileage Reading
1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
* 1,000 KM
Interior Check of Engine Chamber
Check for crack, fragment
05
or wear in belt and adjust I I I I I I I I I I I I I I I I
its tension
Check for radiator and
A/C hose damage and I I I I I I I I
connection
Check engien coolant lev-
I I I I I I I I
el
Engien coolant R R
Others
Normal
R First 10,000KM and later every 20,000KM or every 12 months
condition
Replace oil
Extreme
R First 10,000KM and later every 10,000KM or every 6 months
condition
Normal
R First 10,000KM and later every 20,000KM or every 12 months
Replacement condition
oil filter Extreme
R First 10,000KM and later every 10,000KM or every 6 months
condition
Normal
R First 10,000KM and later every 20,000KM or every 12 months
Replacement condition
diesel filter Extreme
R First 10,000KM and later every 10,000KM or every 6 months
condition
Normal
R First 10,000KM and later every 20,000KM or every 12 months
Replace air condition
filter element Extreme
R First 10,000KM and later every 10,000KM or every 6 months
condition
Check engine idling I I I I I I I I
Timing belt R R R R R R R R

Regular Check & Service Checklist of Chassis & Electric Parts

Distance and interval (in month) are indicated for each item, whichever is earlier.
I. Check, adjustment or replacement; R: Replacement, removal or lubrication; L: Lubricant; blank:
N/A.
Service Interval (The Earlier of Mileage Reading or Months)
Item
Months — 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48
 VEHICLE MAITENANCE - SERVICE SCHEDULE 05-5

Mileage Reading * 1,000 KM 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Chassis Parts
Brake pedal, clutch pedal & hand brake I I I I I I I I
Brake lining & brake drum I I I I I I I I
Brake tube & brake hose I I I I I I I I
Brake fluid (including clutch oil) I I I I I I I R I I I I I I I R
Power steering oil I I I I I I I I I I I I I I I I
Manual transmission oil I I I R I I I R 05
Transfer case oil I I I I
Main reducer & differential oil I I R I R
Steering wheel, steering rod & steering
I I I I I I I I
gear
Ball joint & dust shield I I I I I I I I I I I I I I I I
Front & rear suspension systems I I I I
Front wheel alignment I I I I
Tire & pressure I I I I I I I I
Transmission shaft connecting parts I I I I I I I I
Transmission shaft sliding fork R R R R R R R R
Cnstant driving half axle dust shield I I I I I I I I
Wheel bearing & ball pin grease I R I R I R I R
Emission pipe & muffler I I I I I I I I
Electric System
Lighting & horn I I I I I I I I I I I I I I I I
A/C system & refrigerant I I I I I I I I
SRS air bag Initial inspection 12 months after licensing and later every 24 months
Battery I I I I I I I I
Wheel Nut Tighten it to rated torque, check every 5,000 or 10,000KM
 05-6 VEHICLE MAITENANCE - SERVICE SCHEDULE

SERVICE SCHEDULE AT EXTREME CONDITIONS

According to the driving conditions listed below, implement services to the items with extra service
frequency (refer to Regular Service Schedule for unlisted items).
A-1: Uneven, muddy or snow melting road
□ Check brake lining and brake drum Every 5,000KM or 3 months

□ Check brake pad and brake disc Every 5,000KM or 3 months

First 5,000KM and later every 5,000KM or every
□ Check brake pipe and hose
05 three months
□ Check steering wheel, steering rod and gearbox oil Every 5,000KM or 3 months

□ Replace wheel bearing grease Every 5,000KM or 3 months

□ Grease transmission shaft (apply grease within 24 hours

after immersed in water, regardless of service interval; check Every 10,000KM or 6 months
and tighten bolts)）
□ Check transmission shaft and constant driving half axle
Every 10,000KM or 6 months
rubber pad
□ Check front & rear suspension systems Every 10,000KM or 6 months

□ Tighten bolts and nuts connecting chassis and body Every 10,000KM or 6 months
A-2: Dusty road
□ Check air filter element Every 5,000KM or 3 months
First 5,000KM and later every 5,000KM or every
□ Replacement engine oil and oil filter
three months
□ Check brake lining and brake drum Every 5,000KM or 3 months

□ Check brake pad and brake disc Every 5,000KM or 3 months

□ Grease transmission shaft (apply grease within 24 hours

after immersed in water, regardless of service interval; check Every 5,000KM or 3 months
and tighten bolts)）
□ Check transmission shaft and constant driving half axle
Every 5,000KM or 3 months
rubber pad
A-3: Salina road
□ Grease transmission shaft (apply grease within 24 hours
after immersed in water, regardless of service interval; check Every 5,000KM or 3 months
and tighten bolts)）
□ Check transmission shaft and constant driving half axle
Every 5,000KM or 3 months
rubber pad
B-1: Towing another vehicle or using camping rack or roof rack
First 5,000KM and later every 5,000KM or every
□ Replacement engine oil and oil filter
three months
□ Check brake lining and brake drum Every 5,000KM or 6 months

□ Check brake pad and brake disc Every 5,000KM or 3 months

□ Replace differential gear oil Every 20,000KM or 12 months

 VEHICLE MAITENANCE - SERVICE SCHEDULE 05-7

□ Check or replace manual transmission oil Check every 5,000KM and replace every 20,000KM

□ Grease transmission shaft (apply grease within 24 hours

after immersed in water, regardless of service interval; check Every 5,000KM or 3 months
and tighten bolts)）
□ Check front & rear suspension systems Every 10,000KM or 6 months

□ Tighten bolts and nuts connecting chassis and body Every 10,000KM or 6 months

B-2: Short distance no more than 8KM repeatedly at 0℃ or below

First 5,000KM and later every 5,000KM or every 05
□ Replacement engine oil and oil filter
three months
B-3: Long distance at idling or low speed, such as petrol car, taxi or door-to-door delivery truck
□ Check brake lining and brake drum Every 5,000KM or 3 months

□ Check brake pad and brake disc Every 5,000KM or 3 months

First 5,000KM and later every 5,000KM or every
□ Replacement engine oil and oil filter
three months
B-4: More than 2 hours at extremely high speed (80% of the maximum speed)
□ Replace differential gear oil Every 20,000KM or 12 months

□ Check or replace manual transmission oil Check every 5,000KM and replace every 20,000KM
 05-8 VEHICLE MAITENANCE - CHECK

CHECK
CHECK ELECTRICAL SYSTEM
• Check the performance and operation of front combined lamp, fog lamp, turning signal, alarming
flash, rear combined lamp, rear fog lamp, reverse lamp and park lamp.
• Check the operation of interior lighting.
• Check the operation of buzz indicator, control unit, central channel, all switches on the dashboard
and horn.
• Check the operation of electric windows, side mirrors and central lock.
• Check the reception and interference resistance of the radio and speakers.
05
 VEHICLE MAITENANCE - CHECK 05-9

CHECK BATTERY
CAUTION
• Keeping the battery cable clean and secured will help to ensure its performance and service life.
• When securing the batter cable, make sure it is at the right position, or it will affect the use of the
consumers and the service life of the battery.

1. Open the battery cable cover.

05

2. Check the battery:

(a) Check if there is any corrosion or breakage on the battery
housing and cable, and replace them if needed.
(b) Swing the batter cable and ensure it is secured.
(c) If the positive battery cable is not secured, disconnect the
negative cable, fix the positive cable and then reinstall and
secure the negative cable nut.

3. Check the color of the battery power indicator.

(a) Blue means it is in good condition.
(b) White means the power is low and needs recharging.
(c) Red means the electrolyte is inadequate and the battery
needs replacement.
 05-10 VEHICLE MAITENANCE - CHECK

CHECK AIR BAG

CAUTION
• It is important to inform the user that no adhesive or attachment is allowed on the cover of the
air bag, in order to prevent any damage or barrier to the air bag and ensure its normal functioning.
• The cover of the air bag can only be cleaned with dry or slightly wet cloth.

Check Driver's Air Bag

1. The driver's air bag is located in the center of the
05 steering wheel. Visually inspect the completeness of
the plastic cover.

Check Front Passenger's Air Bag

1. The front passenger's air bag is located above the
glove compartment.Visually inspect the completeness
of the plastic cover.
 VEHICLE MAITENANCE - CHECK 05-11

CHECK SEAT BELT

CAUTION
• During inspection, completely pull the seat belt from the automatic winder.
• Check the cleanness of the seat belt and wash it in mild soap solution if needed.

1. Check for the following damages in the seat belt and replace it if necessary:
(a) Broken, torn or scratched

05

(b) Torn fabric at the edge.

(c) Cigerrette or other burnt mark.

(d) Distortion in one side or wave-like edge.

2. Check seat belt lock

 05-12 VEHICLE MAITENANCE - CHECK

(a) Quickly and forcefully pull down the seat belt, check its
locking performance and replace it if needed.

05

3. Check guide buckle & lock tongue

(a) Check for distortion, disconnection and crack on the cover
of guide buckle and replace it if needed.

(b) Check for distortion and crack on the lock tongue and
replace it if needed.
(c) Insert the lock tongue into the guide buckle and check
whether it is firmly secured. Make 5 or more tests and
replace if if any of the tests fails.
 VEHICLE MAITENANCE - CHECK 05-13

CHECK PARK BRAKE & BRAKE PEDAL

1. Check Park Brake & Brake Pedal
2. Check whether the park brake works smoothly,
whehter the pulling strength required by the handle
is correct and whether the cable is damaged. Overhaul
it if needed.

05

3. Check whether the brake pedal is loose and whehter

the free travel is correct. Overhaul it if needed.
Free travel: 10mm

4. Take a trial drive and check the functioning of the park brake and brake pedal. Overhaul it again
if needed.
 05-14 VEHICLE MAITENANCE - CHECK

CHECK DOOR STOPPER, LOCK & HINGE

1. Check door stopper
(a) Check the functioning of the door stopper and apply grease
to the joint if less smooth.

05

2. Check door lock, safety button and child safety lock

(a) Lock up the door and check the functioning of the safety
button.
(b) Press down the safety button and close the door. The
safety button will bounce up to prevent door from being
locked by accident.

(c) Switch the child safety lock from OFF to ON, when the
door can only be opened from outside.

3. Check lock element

 VEHICLE MAITENANCE - CHECK 05-15

(a) Insert the key into the door lock.

(b) The lock element must rotate smoothly when turning the
key clockwise and counterclockwise.

05
4. Check engine hood cover and rear plate assembly hinge
(a) Repeatedly open and close the engine hood cover, check
whether the hinge moves smoothly and apply grease if
needed.

(b) Repeatedly open and close the rear plate assembly hinge,
check whether the hinge moves smoothly and apply grease
if needed.
 05-16 VEHICLE MAITENANCE - CHECK

CHECK WINDSCREEN DRAIN HOLE

1. Open the engine hood.
2. Check whether there is any impurity and blockage in
the drain whole and clean it if needed.

05

3. Restore the engine hood.

 VEHICLE MAITENANCE - CHECK 05-17

CHECK ENGINE COMPARTMENT COMPONENTS

CAUTION
• Fix any fault in a timely manner.
• Refill the fluid loss and fix leakage promptly.

1. Open the engine hood.

2. Check for leakage, damage and aging sign in the following pipes, hoses and joints. Ensure the
proper clearance between the piping and the body and adjust or replace it if needed.
(a) Fuel system 05
(b) Piping of air-conditioning and cooling systems
(c) Braking unit and piping
 05-18 VEHICLE MAITENANCE - CHECK

CHECK TOOTHED TIMING BELT

1. Switch off the ignition.
2. Remove the retaining bolts on the front upper cover
of the toothed timing belt and then the cover.

05

3. Check for any of the following conditions and replace it if needed:

CAUTION
• Water or grease on the toothed belt will quickly reduce its service life. If there is serious oil mark
on the belt, replace it with a new one instead of washing.
• If there is oil mark on the toothed belt, check for oil and fluid leakage in the engine.

(a) Aged and shiny rubber on the back, showing no nail

scratch.

(b) Cracked or peeled canvas.

(c) Cracked rubber on the back.
(d) Cracked belt tooth at the bottom.
(e) Cracked belt tooth at the bottom.
(f) Cracked belt tooth on the side.
VEHICLE MAITENANCE - CHECK 05-19

(f) Unusual tear wear on the side of the belt.

05
(g) Unusual tear wear of the belt.
(h) Missing tooth.

4. Install the front upper cover of the timing belt and

tighten the retaining bolts.
Torque: 18～26N.m
 05-20 VEHICLE MAITENANCE - CHECK

CHECK ACCESSORY BELT

1. Switch off the ignition.
2. Open the engine hood.
3. Check for breakage and aging sign on the accessory
belt and replace it if needed.

05

CAUTION
• Water or grease on the belt will quickly reduce its service life. If there is serious oil mark on the
belt, replace it with a new one instead of washing.
• If there is oil mark on the belt, check for oil and fluid leakage in the engine.

4. Restore the engine hood.

 VEHICLE MAITENANCE - CHECK 05-21

CHECK STEERING BALL JOINT & DUST SHIELD

1. Lift up the vehicle.
2. Swing the tie rod and make sure there is no gap.
3. Check whether the retaining nut on the ball joint is
secured.

05

4. Check for damage in dust shield and ball rubber, and

replace them if needed.
 05-22 VEHICLE MAITENANCE - CHECK

CHECK & TIGHTEN CHASSIS BOLTS AT SPECIFIED TORQUE

CAUTION
• When looking up at the chassis, be careful of dust, sand and soil, which may fall into your eyes.
• Wear safety hamlet, gloves and other protective equipments when tightening the chassis bolts.

1. Switch off all electrical units and ignition.

2. Lift up the vehicle.
3. Check all retaining bolts on the chassis and the tightness and rust of the nuts.
05 4. Retighten all retaining bolts and nuts at specified torque.
 VEHICLE MAITENANCE - CHECK 05-23

CHECK HEADLIGHT
1. Prepare for checking the headlight:
(a) Place the vehicle on a level ground.
(b) A driver is in the vehicle (or replaced by a weight of 73 KG), and the fuel tank is more than half full.
(c) The tire pressure is normal.
(d) The interior structure of the headlight is normal.
2. Check the headlight:
(a) Check for damage in the headlight assembly and replace if needed.
(b) Test the headlight functions and replace any burnt bulb. Make sure whether the adjustment function is 05
normal.
(c) Check for steam or other impurity inside the headlight.
(d) If any deviation in the range of the headlight, make proper adjustment. (Refer to "Chapter 64. Lighting -
front combination lamp assembly LH, adjustment")
 05-24 VEHICLE MAITENANCE - CHECK

CHECK WIPER/WASHER
1. Check the limit position of the windscreen wiper:
CAUTION
• When checking, the wiper blade shall be static. Adjust it if needed.
• Wiper arm torque: 18～21N•m.

(a) Driver side

• The distance between the wiper blade and the
05
lower edge of the windscreen is 30mm.
• If necessary, move the wiper arm for adjustment.

(b) Front passenger side

• The distance between the wiper blade and the
lower edge of the windscreen is 45mm.
• If necessary, move the wiper arm for adjustment.

(a) Move the wiper arm to the service position, press the
locking button of the wiper blade and remove the blade
downward.
(b) Install the blade and switch the locking button to the locking
position.
(c) Switch on the ignition and briefly operate the wiper arm,
so that the windscreen wiper are repositioned at the end
position.

3. Check windscreen cleaner:

 VEHICLE MAITENANCE - CHECK 05-25

(a) The level of the windscreen cleaner shall be 10cm below

the opening. Top it up if below that level.
CAUTION
Please check the windscreen cleaner on a regular basis, for
it is a consumable.

05

4. Check the windscreen spray:

(a) The normal spray coverage is as illustrated.

(b) If any deviation, adjust the nozzle.

 05-26 VEHICLE MAITENANCE - CHECK

CHECK VEHICLE BOTTOM

1. Lift up the vehicle.
2. Check for leakage in the fuel and brake fluid pipes.
3. Inspect the bottom protection and check for damage on the wheel cover and fringe beam.
4. Visually check for any aging sign in the installation lug of the exhaust pipe and whether it is
secured.

05
 VEHICLE MAITENANCE - CHECK 05-27

CHECK SUSPENSION COMPONENTS

1. Lift up the vehicle.
2. Check for aging sign and breakage in all connection bush.
3. Tighten all connection bolts and nuts at specified torque.
4. Check for distortion and crack at all connections.
5. Check for leakage in the shock absorber and damage in the dust shield.

05
 05-28 VEHICLE MAITENANCE - CHECK

CHECK SUSPENSION BALL JOINT & DUST SHIELD

1. Check for damage in the dust shield of the upper arm
ball and replace it if needed.

05

2. Check for damage in the dust shield of the bottom arm

ball and replace it if needed.
 VEHICLE MAITENANCE - CHECK 05-29

CHECK POWER STEERING TANK LEVEL

1. Place the vehicle on a level ground.
2. Switch off the ignition.
3. Turn the front wheels straight forward.
4. Open the engine hood.
5. Screw out the filler cap of the power steering tank.

05

6. Check the level, which should be between the

maximum level and the minimum level. If not, drain it
or top it up.
Steering fluid model : ATF-III

7. Tighten the filler cap of the power steering tank.

8. Restore the engine hood.

 05-30 VEHICLE MAITENANCE - CHECK

CHECK BRAKING SYSTEM

CAUTION
• Only use the braking fluid authorized by Foton.
• Do not mix the braking fluid with other liquid, or it may damage the braking system and affect
the driving.
• Determine whether topping is necessary depending on the tear and wear of the brake lining.

1. Open the engine hood.

05 2. Check braking fluid tank level:
(a) When the brake lining is extremely worn, the level should be close to the minimum level.
(b) When the brake lining is hardly worn, the level should be close to the maximum level.
3. Check for damage and leakage in the following parts:
(a) Brake pump
(b) Servo brake
(c) Brake calipers
(d) Brake pipe
4. Check whether the gap between the brake hose and the body is correct, whether there is any
scratch on the brake hose and whether the connection and fitting of the brake pipe are secured.
 VEHICLE MAITENANCE - CHECK 05-31

CHECK BRAKE DISC, BRAKE DRUM & LINING

CAUTION
If the brake disc, brake drum or brake lining is worn to its extreme, it is necessary to inform the customer
and suggest replacement.
1. Check front brake disc & brake lining
(a) Remove the front wheel. (Refer to "Chapter 33. Wheel & tire - front wheel & tire, replacement")

(b) Meausre the thickness of the brake lining (without back

plate) and brake disc.
05
• Standard thickness of brake lining (without back
plate): 12mm, extreme thickness: 2mm.
• Standard thickness of brake disc: 22mm, extreme
thickness:21mm.

(c) Install the front wheel. (Refer to "Chapter 33. Wheel & tire - front wheel & tire, replacement")
2. Check rear brake drum & brake lining
(a) Remove the rear wheel.

(b) Measure the thickness of the brake lining (without back

plate) and brake drum.
• Standard thickness of brake lining (without back
plate): 7.5mm, extreme thickness: 2.5mm.
• Standard thickness of brake drum: Φ295mm,
extreme thickness: Φ296mm.

(c) Install the rear wheel. (Refer to "Chapter 33. Wheel & tire - rear wheel & tire, replacement")
 05-32 VEHICLE MAITENANCE - CHECK

CHECK TIRE
CAUTION
When it is found that the tire is worn to its extreme or so damaged that it affects driving safety, it is
necessary to inform the customer and suggest replacement.
1. Check for damage and impurity on the rolling surface and side wall of the tire as well as hole, cut
and piercing on the wall.
2. Check whether the rolling surface is seriously worn in one side, and if yes, perform wheel
alignment.
05 3. Check the tread depthn (including spare tire) and
ensure the depth is greater than that of the wear
indicator and the side wear indicator hasn't been fully
worn.
Max. tread depth: 1.6mm

4. Check and adjust the tire pressure (including spare tire):

Front tire Rear tire Spare tire
P245/70 R16 220kPa 240kPa 260kPa
P265/70 R16 220kPa 240kPa 260kPa
P265/65 R17 220kPa 240kPa 260kPa
 VEHICLE MAITENANCE - CHECK 05-33

CHECK EXHAUST SYSTEM

CAUTION
When working on the exhaust system, be careful of possible burn.
1. Lift up the vehicle.
2. Check for damage in the front and rear exhaust pipes, silencer and catalyst converter housing.
3. Check for leakage in the connections between the parts in the exhaust system.
4. Check for aging sign or breakage in the hanging block

05
 05-34 VEHICLE MAITENANCE - CHECK

CHECK COOLANT TANK LEVEL

CAUTION
• When working on the cooling system, be careful of possible burns caused by hot water and
steam.
• Only use the coolant authorized by Foton.

1. Switch off the ignition.

2. Wait until the engine cools down.
05 3. Open the engine hood.
4. Check the coolant level, which should be near Line
(when the engine is cooled down).

5. Restore the engine hood.

 VEHICLE MAITENANCE - CHECK 05-35

CHECK ENGINE OIL LEVEL (4G69)

1. Place the vehicle on a level ground.
2. Heat up the engine to its normal working temperature.
3. Switch off the ignition.
4. Wait for around 3 minutes.
5. Open the engine hood.
6. Slowly pull out the oil gauge.

05

7. Check the engine oil level, which should be within the

range of the gauge scale.

8. Check the quality of the engine oil. If it is too dirty or thin, fix the fault and then replace the oil.
9. Restore the oil gauge.

10 . Restore the engine hood.

 05-36 VEHICLE MAITENANCE - CHECK

CHECK ENGINE OIL LEVEL (4161P)

1. Place the vehicle on a level ground.
2. Heat up the engine to its normal working temperature.
3. Switch off the ignition.
4. Wait for around 3 minutes.
5. Open the engine hood.
6. Remove the upper engine hood.

05

7. Slowly pull out the oil gauge.

8. Check the engine oil level, which should be within the

range of the gauge scale.

9. Check the quality of the engine oil. If it is too dirty or thin, fix the fault and then replace the oil.
 VEHICLE MAITENANCE - CHECK 05-37

10 . Restore the oil gauge.

05

11 . Install the upper engine hood.

12 . Restore the engine hood.

 05-38 VEHICLE MAITENANCE - REPLACEMENT

REPLACEMENT
REPLACE AIR FILTER ELEMENT (4G69)
1. Switch off the ignition.
2. Open the engine hood.
3. Unscrew the screw. Slightly lift up the outlet in the
upper housing of the air filter, while pulling it towards
the engine. Pull it out of the dowel pin hole in the lower
housing, in order to separate the upper and lower
05 housings.

4. Remove the air filter element.

CAUTION
How to clean the element: Blow compressed air from the
outlet of the element to the inlet, with the pressure of the
compressed air below 0.07MPa. If any damage, replace it with
a new and qualified element.

5. Clean the impurities inside the air filter.

6. Mount the air filter element.
 VEHICLE MAITENANCE - REPLACEMENT 05-39

7. Insert the dowel pin in the upper housing of the air

filter to the hotel in the lower housing, in an inclined
way. Press the outlet of the upper housing downward
and align three screw holes in both housings. Install
and tighten the retaining screws.

05

8. Restore the engine hood.

 05-40 VEHICLE MAITENANCE - REPLACEMENT

REPLACE AIR FILTER ELEMENT (4161P)

1. Switch off the ignition.
2. Open the engine hood.
3. Unscrew the screw. Slightly lift up the outlet in the
upper housing of the air filter, while pulling it towards
the engine. Pull it out of the dowel pin hole in the lower
housing, in order to separate the upper and lower
housings.

05

4. Remove the air filter element.

CAUTION
How to clean the element: Blow compressed air from the
outlet of the element to the inlet, with the pressure of the
compressed air below 0.07MPa. If any damage, replace it with
a new and qualified element.

5. Clean the impurities inside the air filter.

6. Mount the air filter element.

7. Insert the dowel pin in the upper housing of the air

filter to the hotel in the lower housing, in an inclined
way. Press the outlet of the upper housing downward
and align three screw holes in both housings. Install
and tighten the retaining screws.
 VEHICLE MAITENANCE - REPLACEMENT 05-41

8. Restore the engine hood.

05
 05-42 VEHICLE MAITENANCE - REPLACEMENT

REPLACE AIR-CONDITIONING FILTER ELEMENT

1. Switch off all electrical units and ignition.
2. Open the glove compartment.

05

3. Press the clip and remove the cover used to replace

the air-conditioning filter element.

4. Remove the filter element.

5. Mount a new air-conditioning filter element.
CAUTION
During installation, make sure the arrow on the filter element
pointing downward.
VEHICLE MAITENANCE - REPLACEMENT 05-43

6. Mount the cover used to replace the filter element and

then the clip.

05

7. Close the glove compartment.

 05-44 VEHICLE MAITENANCE - REPLACEMENT

REPLACE ENGINE OIL & OIL FILTER (4G69)

1. Place the vehicle on a level ground.
2. Heat up the engine to its normal working temperature.
3. Switch off the ignition.
4. Wait for around 3 minutes.
5. Clean the engine oil filler cap with cloth and unscrew
it.

05

6. Lift up the vehicle.

7. Remove the lower engine baffle:
(a) Unscrew the retaining bolts of the small baffles on both
sides and remove the baffles.

(b) Unscrew the retaining bolts of the front baffle and remove
the baffle.
VEHICLE MAITENANCE - REPLACEMENT 05-45

(c) Remove the retaining bolts of the rear baffle and then the
baffle.

05
8. Remove the oil drain plug and drain the engine oil.
CAUTION
• When draining, be careful of possible burns caused
by hot engine oil.
• The drained engine oil shall be properly collected and
treated as regulated.

9. Once completely drained, replace a new drain plug

gasket, tighten the drain plug and clean the dirt.
Torque: 45N.m

10 . Use the tools to remove the oil filter and replace a new
one.
 05-46 VEHICLE MAITENANCE - REPLACEMENT

11 . Clean the interface between the oil filter holder and

the filter.

05

12 . Apply a small amount of engine oil on the O-ring of

the new oil filter.

13 . Mount the oil filter onto the holder by hand, until the
O-ring of the filter touch the holder, and then tighten
the filter with tools.
Torque: 14N.m or 3/4 circle

14 . Lower the vehicle.

15 . Unscrew the engine oil filler cap.
 VEHICLE MAITENANCE - REPLACEMENT 05-47

16 . Fill up the engine oil.

Engine oil: 10W/30 or 15W/40 engine oil at Grade SL or above (5W/30 engine oil for Northeast
China in winter)
Filling volume: 4L

CAUTION
Only use the engine oil authorized by Foton.

17 . Tighten the engine oil filler cap.

05

18 . Start the engine and run it at idling for a few minutes.

19 . Switch off the ignition.
20 . Wait for a few minutes.
21 . Pull out the oil gauge.

22 . Check the engine oil level. If it is above the maximum

level, drain the oil to the normal range. If it is below
the minimum level, top it up to the normal range.
 05-48 VEHICLE MAITENANCE - REPLACEMENT

23 . Restore the oil gauge.

05

24 . Lift up the vehicle.

25 . Check for leakage at the oil drain hole and the connection of the oil filter.
26 . Remove the upper engine baffle:
(a) Install the rear baffle and tighten the retaining bolts.
Torque: 23±2N.M

(b) Install the front baffle and tighten the retaining nuts.
Torque: 23±2N.M
 VEHICLE MAITENANCE - REPLACEMENT 05-49

(c) Install the small baffles on both sides and tighten the
retaining bolts.
Torque: 23±2N.M

05

27 . Lower the vehicle.

 05-50 VEHICLE MAITENANCE - REPLACEMENT

REPLACE ENGINE OIL & OIL FILTER (4161P) (REPLACEMENT)

1. Place the vehicle on a level ground.
2. Heat up the engine to its normal working temperature.
3. Switch off the ignition.
4. Wait for around 3 minutes.
5. Remove the upper engine hood.

05

6. Clean the engine oil filler cap with cloth and unscrew
it.

7. Lift up the vehicle.

8. Remove the lower engine baffle:
(a) Unscrew the retaining bolts of the small baffles on both
sides and remove the baffles.
VEHICLE MAITENANCE - REPLACEMENT 05-51

(b) Unscrew the retaining bolts of the front baffle and remove
the baffle.

05

(c) Remove the retaining bolts of the rear baffle and then the
baffle.

9. Use the tools to remove the oil drain plug and drain
the engine oil.
CAUTION
• When draining, be careful of possible burns caused
by hot engine oil.
• The drained engine oil shall be properly collected and
treated as regulated.

10 . Once completely drained, replace a new drain plug

gasket, tighten the drain plug and clean the dirt.
Torque: 24±4N•m
 05-52 VEHICLE MAITENANCE - REPLACEMENT

11 . Use the tools to remove the oil filter and replace a new
one.

05

12 . Clean the interface between the oil filter holder and the filter.
13 . Apply a small amount of engine oil on the O-ring of
the new oil filter.

14 . Mount the oil filter onto the holder by hand and then
tighten the filter with tools.
Torque: 38N.m

15 . Lower the vehicle.

 VEHICLE MAITENANCE - REPLACEMENT 05-53

16 . Unscrew the engine oil filler cap.

05

17 . Fill up the engine oil.

Engine oil: CH-4 or above
Filling volume: 4.5～5L

CAUTION
Only use the engine oil authorized by Foton.

18 . Tighten the engine oil filler cap.

19 . Start the engine and run it at idling for a few minutes.

20 . Switch off the ignition.
21 . Wait for a few minutes.
22 . Pull out the oil gauge.
 05-54 VEHICLE MAITENANCE - REPLACEMENT

23 . Check the engine oil level. If it is above the maximum

level, drain the oil to the normal range. If it is below
the minimum level, top it up to the normal range.

05
24 . Restore the oil gauge.

25 . Install the upper engine hood.

26 . Lift up the vehicle.

27 . Check for leakage at the oil drain hole and the connection of the oil filter.
28 . Remove the upper engine baffle:
(a) Install the rear baffle and tighten the retaining bolts.
Torque: 23±2N•m
 VEHICLE MAITENANCE - REPLACEMENT 05-55

(b) Install the front baffle and tighten the retaining nuts.
Torque: 23±2N•m

05

(c) Install the small baffles on both sides and tighten the
retaining bolts.
Torque: 23±2N•m

29 . Lower the vehicle.

 05-56 VEHICLE MAITENANCE - REPLACEMENT

REPLACE SPARK PLUG (4G69)

1. Switch off the ignition.
2. Disconnect battery negative cable. (Refer to "Chapter 20. Start & charge - battery, replacement")
3. Pull out the spark plug cable.

05

4. Remove the spark plug with tools.

5. Replace a new spark plug and tighten it onto the cylinder head.
Torque:25N.m

6. Install the spark plug cable to the rock arm cap.

7. Connect battery negative cable. (Refer to "Chapter 20. Start & charge - battery, replacement")
 VEHICLE MAITENANCE - REPLACEMENT 05-57

REPLACE FUEL FILTER ASSEMBLY (4G69)

CAUTION
Before replacing the fuel filter, ensure fire extinguishers are properly equipped at the site.
1. Discharge the pressure in the fuel system. (Refer to "Chapter 12A. Fuel - fuel system, precaution")
2. Lift up the vehicle.
3. Press the locking block and remove the fuel filter
connector.
CAUTION
05
Before removing the connector, place a specified vessel right
beneath it, which will prevent the fuel from contaminating
the site.

4. Unscrew the clip bolt and remove the hose.

5. Unscrew the retaining bolts of the fuel filter and

remove the filter assembly.
 05-58 VEHICLE MAITENANCE - REPLACEMENT

6. Install a new fuel filter assembly and tighten the

retaining bolts.

05

7. Install the hose and tighten the clip bolts.

8. Mount the fuel filter connector until you hear the click.

9. Lower the vehicle.

 VEHICLE MAITENANCE - REPLACEMENT 05-59

REPLACE FUEL FILTER ELEMENT (4161P)

CAUTION
Before replacing the fuel filter, ensure fire extinguishers are properly equipped at the site.
1. Switch off the ignition.
2. Disconnect battery negative cable. (Refer to "Chapter 20. Start & charge - battery, replacement")
3. Remove the diesel filter & heater connector.

05

4. Drain the fuel inside the fuel filter:

(a) Press the locking pin while removing the fuel pipe.

(b) Press the locking pin while removing the fuel pipe. Collect
the drained fuel with a specified vessel.
 05-60 VEHICLE MAITENANCE - REPLACEMENT

5. Remove the diesel filter & heater connector.

05

6. Remove the fuel filter element and replace it with a

new one.

7. Replace a new O-ring and apply some engine oil on

the surface.

8. Install the cap and tighten it by turning 3 and a half

circles clockwise.
 VEHICLE MAITENANCE - REPLACEMENT 05-61

9. Restore the fuel pipe until you hear the click.

05

10 . Restore the fuel pipe until you hear the click.

11 . Restore the diesel filter & heater connector until you

hear the click.

12 . Discharge the air inside inside the fuel filter:

(a) Unscrew the discharge screw.
 05-62 VEHICLE MAITENANCE - REPLACEMENT

(b) Press the cover and pump the fuel manually, until fuel
spills front he discharge screw.

05

(c) Tighten the discharge screw.

13 . Connect battery negative cable. (Refer to "Chapter 20. Start & charge - battery, replacement")
 VEHICLE MAITENANCE - REPLACEMENT 05-63

REPLACE COOLANT
1. Switch off the ignition.
2. Wait until the engine cools down.
3. Slowly open the coolant filler cap.
DANGER
Do not open the coolant filler cap before the engine cools
down to the ambient temperature. Otherwise the hot coolant
or steam may lead to personal injury.
05

4. Lift up the vehicle.

5. Remove the lower engine baffle:
(a) Unscrew the retaining bolts of the small baffles on both
sides and remove the baffles.

(b) Unscrew the retaining bolts of the front baffle and remove
the baffle.
 05-64 VEHICLE MAITENANCE - REPLACEMENT

6. Slowly unscrew the coolant drainage plug and drain

the coolant.
CAUTION
Collect the coolant in a specified container. If not recycled,
it shall be disposed properly.

05

7. Once the coolant is drained up, tighten the plug.

8. Remove the upper engine baffle:

(a) Install the front baffle and tighten the retaining nuts.
Torque: 23±2N.M
 VEHICLE MAITENANCE - REPLACEMENT 05-65

(b) Install the small baffles on both sides and tighten the
retaining bolts.
Torque: 23±2N.M

05

9. Lower the vehicle.

10 . Top up the engine coolant to the specified level.
Filling volume(4G69): 6～7L
Filling volume(4161P): 8～9L

CAUTION
Only use the engine coolant authorized by Foton.

11 . Tighten the coolant filler cap.

CAUTION
Remember to turn the free point on the inlet cap to that
between the two free points on the inlet.

12 . Start the engine and accelerate to 2,500 RPM, until the electronic fan runs quickly. Check whether
the coolant in the coolant reservoir reaches the specified level. If not, continue to top it up to the
said level.
 05-66 VEHICLE MAITENANCE - REPLACEMENT

REPLACE BRAKING FLUID

CAUTION
• Only use the braking fluid authorized by Foton.
• Do not mix the braking fluids of different brands and types, or it may affect the braking
performance.
• If your skin is in contact with braking fluid, rinse it with water immediately.
• The drained braking fluid should be collected and treated as regulated.

05 1. Switch off the ignition.

2. Open the engine hood.
3. Drain the braking fluid:
(a) Connect the discharge screw and the collection vessel
with a clear plastic hose.

(b) Unscrew the filler cap of the braking fluid tank.

(c) Drain the fluid and top it up depending on the level.

Brake fluid model: 7104-1
 VEHICLE MAITENANCE - REPLACEMENT 05-67
• A mechanic shall press the brake pedal by full force
for 7-9 times and hold it in position.

05

• The other mechanic unscrews the braking fluid

discharge screw, until the pressed brake pedal moves
downward. Immediately tighten the discharge screw.

(d) Repeat Step 3, until fresh braking fluid flows out of the discharge screw. Tighten the discharge screw.
(e) Clean the dirt on the discharge screw.
4. Drain the braking fluid as illustrated in Step 1, subject
to the sequence shown in the figures.
 05-68 VEHICLE MAITENANCE - REPLACEMENT

5. After the drainage, top the braking fluid inside the tank
up to the standard range.

05

6. Tighten the filler cap of the braking fluid tank.

7. Restore the engine hood.

 VEHICLE MAITENANCE - REPLACEMENT 05-69

REPLACE MANUAL GEARBOX LUBRICANT (JC538)

1. Switch off the ignition.
2. Lift up the vehicle.
3. Unscrew the gearbox filler bolt.

05

4. Unscrew the gearbox drain bolt and drain the lubricant.

CAUTION
The drained lubricant shall be properly collected and treated
as regulated.

5. Once completely drained, tighten the drain bolt.

Torque: 65 ~ 78N.M
 05-70 VEHICLE MAITENANCE - REPLACEMENT

6. Top the gearbox lubricant from the filler until it

overflows from the hole.
Gearbox lubricant model: GL-4, 75W/90
Filling volume: 1.6L

CAUTION
Only use the gearbox lubricant authorized by Foton.

05

7. Tighten the filler bolt and clean the dirt.

Torque: 65 ~ 78N.M

8. Check for leakage at the bolt.

9. Lower the vehicle.
 VEHICLE MAITENANCE - REPLACEMENT 05-71

REPLACE MANUAL GEARBOX LUBRICANT (R5M21)

1. Switch off the ignition.
2. Lift up the vehicle.
3. Unscrew the gearbox filler bolt.

05

4. Unscrew the gearbox drain bolt and drain the lubricant.

CAUTION
The drained lubricant shall be properly collected and treated
as regulated.

5. Once completely drained, tighten the drain bolt.

Torque: __ N.m
 05-72 VEHICLE MAITENANCE - REPLACEMENT

6. Use tools to top the gearbox lubricant up at the filler,

until it overflows from the hole.
Gearbox lubricant model: __ Filling volume: __L

CAUTION
Only use the gearbox lubricant authorized by Foton.

05

7. Tighten the filler bolt and clean the dirt.

Torque: __ N.m

8. Check for leakage at the bolt.

9. Lower the vehicle.
 VEHICLE MAITENANCE - REPLACEMENT 05-73

REPLACE REAR MAIN REDUCER GEAR OIL

1. Switch off the ignition.
2. Lift up the vehicle.
3. Unscrew the rear main reducer filler plug.

05

4. Unscrew the rear main reducer drain plug and drain

the gear oil.
CAUTION
The drained gear oil shall be properly collected and treated
as regulated.

5. Once completely drained, tighten the drain bolt.

Torque: 38 ~ 45N.M
 05-74 VEHICLE MAITENANCE - REPLACEMENT

6. Use tools to add rear main reducer gear oil at the filler,
and additive as well for LSD.
Additive model: Houghton Sturaco 7098
Filling volume: Approx. 0.06L
Gear oil model: GL-5 85W/90
Filling volume: (1.27±0.03)L

CAUTION
05 Only use the rear main reducer gear oil authorized by Foton.

7. Tighten the filler plug and clean the dirt.

Torque: 27 ~ 41N.M

8. Check for leakage at the bolt.

9. Lower the vehicle.
 VEHICLE MAITENANCE - REPLACEMENT 05-75

REPLACE FRONT MAIN REDUCER GEAR OIL (4WD)

1. Switch off the ignition.
2. Lift up the vehicle.
3. Unscrew the front main reducer filler plug.

05

4. Unscrew the front main reducer drain plug and drain

the gear oil.
CAUTION
The drained gear oil shall be properly collected and treated
as regulated.

5. After completely drained, replace the drain bolt gasket

and tighten the drain bolt.
Torque: 59 ~ 69N.M
 05-76 VEHICLE MAITENANCE - REPLACEMENT

6. Use tools to front main reducer gear oil at the filler.

Gear oil model: GL-5 85W/90
Filling volume: 1.2L

CAUTION
Only use the front main reducer gear oil authorized by Foton.

05

7. Replace the filler bolt gasket, tighten the filler bolt and
clean the dirt.
Torque: 41 ~ 51N.M

8. Check for leakage at the bolt.

9. Lower the vehicle.
 VEHICLE MAITENANCE - REPLACEMENT 05-77

REPLACE DIFFERENTIAL OIL (4WD)

1. Switch off the ignition.
2. Lift up the vehicle.
3. Unscrew the differential filler plug.

05

4. Unscrew the differential drain plug and drain the

differential oil.
CAUTION
The drained differential oil shall be properly collected and
treated as regulated.

5. After completely drained, tighten the differential drain

plug.
Torque: 19 ~ 30N.M
 05-78 VEHICLE MAITENANCE - REPLACEMENT

6. Use tools to top the differential oil up at the filler, until

it overflows the hole.
Differential oil model: SPEC40–00–244–001
Filling volume: 1.33～1.52L

CAUTION
Only use the differential oil authorized by Foton.

05

7. Tighten the filler plug and clean the dirt.

Torque: 19 ~ 30N.M

8. Check for leakage at the bolt.

9. Lower the vehicle.
 Index
(Sorted by Alphabet)

B1344 Open circuit of passing lamp control

, lefe/right adjustment of power rearview mirror
circuit (lighting system).......................04 - 491
doesn’t work (power rearview B1346 high resistance(SRS system), Driver's
mirror).................................................04 - 317 air bag igniter......................................04 - 158
, Upper and lower adjustment of power rearview B1346 Open circuit of driving light control circuit
mirror doesn’t work..........................04 - 314 (lighting system).................................04 - 483
B1348 Ground (SRS system), Driver's air bag
A igniter..................................................04 - 161
Abnormal self-checking of reverse radar system B1349 connection battery (SRS system),
(reverse radar system).......................04 - 230 driver's air bag igniter.........................04 - 165
ABS indicating lamp is always on B1350 low current of control circuit, left front
(ABS)....................................................04 - 30 window rise (power window)..............04 - 260
Acoustics unit does not work (acoustics B1352 high resistance (SRS system),
system)...............................................04 - 442 Passengers’ air bag igniter..............04 - 168
Air conditioning system......................04 - 389 B1354 ground (SRS system), Driver's air bag
Air output control:Air exhaust is inadequate (air igniter..................................................04 - 170
conditioning system)..........................04 - 407 B1355 igniter connection battery (SRS system),
Air-conditioning System.......................03 - 26 passengers’ air bag igniter..............04 - 173
All the power windows stop working (power B1356 low current of control circuit, right front
window)..............................................04 - 249 window rise (power window)..............04 - 266
Anti-lock Braking System (ABS).............04 - 1 B1361-High resistance of the preloading igniter,
Assembly instrument..........................04 - 578 driver’s seat belt..............................04 - 175
Audio system......................................04 - 433 B1363-High resistance of the preloading igniter,
Axle & Transmission Shaft..........0203 - 29, 40 driver’s seat belt(SRS system)........04 - 178
B1364-connection battery of preloading igniter,
B driver’s seat belt (SRS system).......04 - 182
B 1102 over-low power supply voltage (SRS B1367-High resistance of the preloading igniter
system)...............................................04 - 154 (SRS system), passengers’ seat
B 1391 defrost control circuit --open circuit belt.....................................................04 - 185
(defects).............................................04 - 303 B1368 low current of control circuit, right rear
B1001 Low current of left turn light control window rise (power window)......04 - 274, 282
circuit (lighting system).......................04 - 516 B1369- preloading igniter ground,
B1004 Low current of right turn light control passengers’ seat belt (SRS
circuit (lighting system).......................04 - 525 system)...............................................04 - 188
B1045 Open circuit of front fog lamp control B1370-connection battery of preloading igniter,
circuit (lighting system).......................04 - 499 passengers' seat belt (SRS system)...04 - 192
B1048 Open circuit of rear fog lamp control B1374 Low speed control circuit of front wiper
circuit (lighting system).......................04 - 508 is subjected to high current (wiper and
B1063 Low current of parking light control washer)..............................................04 - 372
circuit (lighting system).......................04 - 534
A-1-
B1376 High speed control circuit of front wiper Caution (tyre pressure monitoring
is open-circuited (wiper and washer)..04 - 364 system)...............................................04 - 648
B1385 Open circuit of horn control circuit CD/DVD cannot be inserted/played back, or
(horn).................................................04 - 465 CD/DVD is ejected immediately once it is
B1402 battery energy-saving outputs circuit inserted (audio system)......................04 - 460
low-voltage(fault)................................04 - 645 CD/DVD tune skipping (audio
Basic inspection (air conditioning system)...............................................04 - 462
system)...............................................04 - 390 Central control lock doesn't work (power door
Basic inspection (audio system).........04 - 439 lock control system)...........................04 - 340
Basic inspection (combination Check.....................................................05 - 8
instrument).........................................04 - 585 Check & Tighten Chassis Bolts at Specified
Basic inspection (combined display)...04 - 626 Torque (Check).....................................05 - 22
Basic inspection (engine control Check Accessory Belt (Check).............05 - 20
system).................................................04 - 43 Check Air Bag (Check).........................05 - 10
Basic inspection (lighting system)......04 - 476 Check Battery (Check)...........................05 - 9
Basic inspection (power door lock control Check Brake Disc, Brake Drum & Lining
system)...............................................04 - 338 (Check).................................................05 - 31
Basic inspection (power rearview Check Braking System (Check)...........05 - 30
mirror).................................................04 - 312 Check Coolant Tank Level (Check)......05 - 34
Basic inspection (power window).......04 - 245 Check Door Stopper, Lock & Hinge
Basic inspection (rear windscreen defrost (Check).................................................05 - 14
system)...............................................04 - 292 Check Electrical System (Check)...........05 - 8
Basic inspection (wiper and washer)...04 - 357 Check Engine Compartment Components
Before entering reverse gear, reverse radar (Check).................................................05 - 17
appear work phenomenon （reverse radar Check Engine Oil Level (4161P)
system）............................................04 - 233 (Check).................................................05 - 36
Blower does not work (air conditioning Check Engine Oil Level (4G69)
system)...............................................04 - 400 (Check).................................................05 - 35
Brake..........................................0203 - 15, 20 Check Exhaust System (Check)...........05 - 33
Brake failure alarm lamp is not on/always on Check Headlight (Check).....................05 - 23
(combination instrument)....................04 - 617 Check Park Brake & Brake Pedal
Brakes lamps on 2 sides fail to go on (lighting (Check).................................................05 - 13
system)...............................................04 - 544 Check Power Steering Tank Level
(Check).................................................05 - 29
C Check Seat Belt (Check)......................05 - 11
Check Steering Ball Joint & Dust Shield
C0020－return pump failure (ABS Anti-lock (Check).................................................05 - 21
Braking System)...................................04 - 26 Check Suspension Ball Joint & Dust Shield
C0031– Left front wheel speed sensor (Check).................................................05 - 28
failure:The scope, performance, continuity(ABS Check Suspension Components
Anti-lock Braking System)....................04 - 10 (Check).................................................05 - 27
C0038– Left rear wheel speed sensor circuit Check Tire (Check)..............................05 - 32
failure:open circuit or short circuit(ABS Anti-lock Check Toothed Timing Belt (Check).....05 - 18
Braking System)...................................04 - 16 Check Vehicle Bottom (Check).............05 - 26
C1095－Valve relay failure (ABS Anti-lock Check Windscreen Drain Hole
Braking System)...................................04 - 22 (Check).................................................05 - 16
Captured data (engine control system).04 - 50 Check Wiper/Washer (Check)..............05 - 24
Clutch.........................................0203 - 20, 30
A-2-
Combined Display..............................04 - 622 Defect phenomena form (vehicle control
Combined display description (combined system)...............................................04 - 641
display)...............................................04 - 624 Defect phenomena from (front axle clutch
Component drawing (air conditioning diagnosis)...........................................04 - 667
system)...............................................04 - 391 Defect phenomena table (ABS)..............04 - 8
Component Drawing (Audio System)..04 - 436 Defect Phenomenon Form (air conditioning
Component Drawing (combination system)...............................................04 - 393
instrument).........................................04 - 579 Defect Phenomenon Form (audio
Component drawing (engine control system)...............................................04 - 440
system).................................................04 - 36 Defect Phenomenon Form (combination
Component Drawing (horn)................04 - 463 instrument).........................................04 - 586
Component Drawing (lighting Defect Phenomenon Form (horn)......04 - 464
system)...............................................04 - 474 Defect Phenomenon Form (lighting
Component drawing (power door lock control system)...............................................04 - 477
system)...............................................04 - 337 Defect Phenomenon Form (Power door lock
Component drawing (power rearview control system)...................................04 - 339
mirror).................................................04 - 310 Defect Phenomenon Form (power rearview
Component drawing (Power window)..04 - 244 mirror).................................................04 - 313
Component drawing (rear windscreen defrost Defect Phenomenon Form (power
system)...............................................04 - 291 window)..............................................04 - 247
Component drawing (SRS system)....04 - 148 Defect Phenomenon Form (rear windscreen
Component drawing (tyre pressure monitoring defrost system)...................................04 - 293
system)...............................................04 - 649 Defect phenomenon form (SRS
Component drawing (wiper and system)...............................................04 - 153
washer)..............................................04 - 356 Defect phenomenon form (transfer
Components drawing (ABS)...................04 - 2 gear)...................................................04 - 195
Components drawing (front axle clutch Defect Phenomenon Form (wiper and
diagnosis)...........................................04 - 664 washer)..............................................04 - 358
Components drawing (Reverse Radar Defects Phenomenon Form (Reverse Radar
system)...............................................04 - 221 system)...............................................04 - 224
Components drawing (vehicle control Definition for the vehicle body controller
system)...............................................04 - 633 pin......................................................04 - 636
Components drawing(combined Diagnosis system (engine control
display)...............................................04 - 623 system).................................................04 - 47
Configuration diagram of ECM-side terminals Diagnostic DTC code list (SRS
(engine control system)........................04 - 44 system)...............................................04 - 151
Connector of ABS control module(ABS).04 - 4 Diagnostic failure code list (engine control
Cooling.......................................0203 - 19, 28 system).................................................04 - 57
Diagnostic trouble code (DTC) list
D (ABS)......................................................04 - 6
Diagnostics...........................................02 - 35
Dashboard & Instruments....................02 - 34
Door & Engine Hood......................0203 - 6, 6
Defect diagnostics code (DTC) test (engine
Door Lock.............................................02 - 21
control system).....................................04 - 62
Defect phenomena form (combined
E
display)...............................................04 - 627
Defect phenomena form (tyre monitoring Electric Test Procedure (How to
system)...............................................04 - 656 Troubleshoot).......................................01 - 24

A-3-
Emission Control........................0203 - 24, 33 How to Use.............................................01 - 1
Engine Control System....020304 - 12, 16, 33
Engine Mechanical System........0203 - 10, 12 I
Engine phenomena diagnosis test (engine
Identification...........................................01 - 5
control system)...................................04 - 110
Idling speed too high (the engine control
Enter reverse gear, and the obstacle is within
system)...............................................04 - 128
the distance of effective sense and the reverse
Ignition....................................................03 - 8
radar doesn’t work (reverse radar Instrument description (combination
system)...............................................04 - 235 instrument).........................................04 - 580
Enter reverse gear, no obstacles behind the Instrument terminal (combination
vehicles while the reverse radar system is instrument).........................................04 - 583
abnormal (reverse radar system).......04 - 238 Intake.........................................0203 - 18, 24
Exhaust......................................0203 - 25, 34 Interior & Exterior Trims........................03 - 32
Intermittent failure (engine control
F system).................................................04 - 40
Failure of servo motor of mode air door (air
conditioning system)..........................04 - 427 K
Failure of temperature regulation servo motor KT600 diagnostic apparatus is unable to
(air conditioning system)....................04 - 430 communicate with ECM (engine control
Fault phenomena table (engine control system)...............................................04 - 113
system)...............................................04 - 109
Front axle clutch.................................04 - 663 L
Front axle clutch can't work normally (front axle
clutch diagnosis)................................04 - 668 Lighting system..................................04 - 473
Front Suspension.......................0203 - 28, 38 List of data streams, motion test (engine control
Front washer does not work (wiper & system).................................................04 - 53
washer)..............................................04 - 384 List of failure phenomenon protections (engine
Front wiper does not work (wiper & control system).....................................04 - 51
washer)..............................................04 - 360 Lubrication..................................0203 - 33, 45
Front wiper does not work when it is set to its
intermittent gear (wiper & washer).....04 - 379 N
Fuel............................................0203 - 32, 43 No function of the air conditioning system works
Fuel gauge fault(combination (air conditioning system)....................04 - 395
instrument).........................................04 - 613 No radio stations can be received or the
receiving effect is poor (audio
G system)...............................................04 - 458
General Service Guideline.....................01 - 7
O
H Only the central control lock of one door
Heating & Air-conditioning....................02 - 22 doesn’t work (Power door lock control
Heating power rearview mirror doesn’t work system)...............................................04 - 351
(power rearview mirror)......................04 - 327 Operation Precaution (General Service
Horn...................................................04 - 463 Guideline)...............................................01 - 7
How to conduct failure analysis (engine control Overview (How to Troubleshoot)..........01 - 16
system).................................................04 - 37 Overview (How to Use)..........................01 - 1
How to Troubleshoot.............................01 - 16

A-4-
 P Precaution (combination instrument)..04 - 578
Precaution (combined display)...........04 - 622
P0112 - Low voltage of intake temperature
Precaution (engine control system)......04 - 33
sensor circuit (engine control system)...04 - 67
Precaution (power window)................04 - 243
P0117 - Low voltage of coolant temperature
Precaution (Service Schedule)..............05 - 1
sensor circuit (engine control system)...04 - 72
Precaution(front axle clutch
P0122- Low voltage of throttle position sensor
diagnosis)...........................................04 - 663
(engine control system)........................04 - 77
Precaution(Reverse radar system).....04 - 220
P0131- To-ground short-circuit of front oxygen
Precaution(SRS system)....................04 - 147
sensor (engine control system)............04 - 80
Precautions (air conditioning system).04 - 389
P0201-Nozzle A circuit failure (engine control
Precautions (Anti-lock Braking System (ABS)
system)...............................................04 - 101
)..............................................................04 - 1
P0325- Knocking system failure (engine control
Precautions (audio system)................04 - 433
system).................................................04 - 86
Precautions (lighting system).............04 - 473
P0336 - crankshaft position sensor circuit
Precautions (power door lock control
interfering signal(engine control
system)...............................................04 - 336
system).................................................04 - 90
Precautions (Wiper & Washer)...........04 - 355
P0443-Carbon pot control valve failure (engine
control system)...................................04 - 105 Precautions（The SRS is equipped）
P0480-Fan 1 failure (engine control ...........................................................04 - 632
system).................................................04 - 95 Preparation (Axle & Transmission
P0560 Systematic voltage exceeds normal Shaft)....................................................02 - 29
Preparation (Clutch).............................02 - 20
work scope （transfer gear）.............04 - 208
Preparation (Cooling)...........................02 - 19
P1728 Synchronization coil defects （transfer Preparation (Dashboard &
gear）................................................04 - 211 Instruments).........................................02 - 34
P1734 Signal failure feedback,（transfer Preparation (Diagnostics).....................02 - 35
gear）, front axle clutch.....................04 - 213 Preparation (Door & Engine Hood)........02 - 6
P1738 defects, mode select Switch （transfer Preparation (Door Lock).......................02 - 21
gear）................................................04 - 215 Preparation (Emission Control)............02 - 24
P1780 Motor defects, gear shift (transfer Preparation (Engine Control System)...02 - 12
gear)...................................................04 - 218 Preparation (Engine Mechanical
Park Brake..................................0203 - 37, 47 System)................................................02 - 10
Pin description for the combined display Preparation (Exhaust)..........................02 - 25
(combined display).............................04 - 625 Preparation (Front Suspension)...........02 - 28
Poor acceleration and performance (Engine Preparation (Fuel)................................02 - 32
Control System).................................04 - 143 Preparation (Heating &
Position lights/license plate lamp fail to go on Air-conditioning)...................................02 - 22
(lighting system).................................04 - 562 Preparation (Intake).............................02 - 18
Power door lock control system..........04 - 336 Preparation (Lubrication)......................02 - 33
Power rearview mirror........................04 - 310 Preparation (Park Brake)......................02 - 37
Power rearview mirrors on both sides don’t Preparation (Power Steering).................02 - 9
work (power rearview mirror).............04 - 320 Preparation (Rear Suspension)............02 - 17
Preparation (Seat Belt)...........................02 - 1
Power rearview mirrors on one side doesn’t
Preparation (Seating)...........................02 - 39
work (power rearview mirror).............04 - 324
Preparation (Steering System).............02 - 38
Power Steering.............................0203 - 9, 10
Preparation (Supplemental Restraint
Power window....................................04 - 243
System)................................................02 - 13
Pre-inspection(ABS)...............................04 - 9

A-5-
Preparation (Transmission)....................02 - 2 Required Torque (Air-conditioning
Preparation (Vehicle Control System)....02 - 4 System)................................................03 - 27
Preparation (Wheel & Tire).....................02 - 5 Required Torque (Axle & Transmission
Preparation (Windscreen, Window & Backview Shaft)....................................................03 - 42
Mirror).....................................................02 - 7 Required Torque (Brake)......................03 - 21
Preparation (Wiper & Washer).............02 - 14 Required Torque (Clutch).....................03 - 31
Required Torque (Cooling)...................03 - 29
R Required Torque (Door & Engine
Hood).....................................................03 - 7
Reading and clearance of the diagnostic trouble
Required Torque (Emission Control)....03 - 33
code (DTC) (engine control system)....04 - 48
Required Torque (Engine Control
Rear Suspension........................0203 - 17, 22
System)................................................03 - 17
Rear windscreen defrost system........04 - 290
Required Torque (Engine Mechanical
Rear windscreen defrost system doesn’t work System)................................................03 - 15
(rear windscreen defrost system).......04 - 294 Required Torque (Exhaust)..................03 - 35
Refrigerating system:Failure to refrigerate (air Required Torque (Front Suspension)....03 - 39
conditioning system)..................04 - 412, 419 Required Torque (Fuel)........................03 - 44
Regular Service Items & Intervals (Service Required Torque (Ignition)......................03 - 9
Schedule)...............................................05 - 3 Required Torque (Intake)......................03 - 25
Replace Air Filter Element (4161P) Required Torque (Interior & Exterior
(Replacement)......................................05 - 40 Trims)...................................................03 - 32
Replace Air Filter Element (4G69) Required Torque (Lubrication)..............03 - 46
(Replacement)......................................05 - 38 Required Torque (Park Brake)..............03 - 47
Replace Air-conditioning Filter Element Required Torque (Power Steering).......03 - 11
(Replacement)......................................05 - 42 Required Torque (Rear Suspension)....03 - 23
Replace Braking Fluid (Replacement)..05 - 66 Required Torque (Seat Belt)...................03 - 1
Replace Coolant (Replacement)..........05 - 63 Required Torque (Seating)...................03 - 50
Replace Differential Oil (4WD) Required Torque (Start & Charge).......03 - 37
(Replacement)......................................05 - 77 Required Torque (Steering System).....03 - 49
Replace Engine Oil & Oil Filter (4161P) Required Torque (Supplemental Restraint
(Replacement)......................................05 - 50 System)................................................03 - 19
Replace Engine Oil & Oil Filter (4G69) Required Torque (Transmission)............03 - 3
(Replacement)......................................05 - 44 Required Torque (Wheel & Tire).............03 - 5
Replace Front Main Reducer Gear Oil (4WD) Reverse lamps on 2 sides fail to go on (lighting
(Replacement)......................................05 - 75 system)...............................................04 - 556
Replace Fuel Filter Assembly (4G69) Reverse radar system........................04 - 220
(Replacement)......................................05 - 57
Reverse radar system doesn’t work at all
Replace Fuel Filter Element (4161P)
(reverse radar system).......................04 - 225
(Replacement)......................................05 - 59
Replace Manual Gearbox Lubricant (JC538)
S
(Replacement)......................................05 - 69
Replace Manual Gearbox Lubricant (R5M21) Seat Belt.........................................0203 - 1, 1
(Replacement)......................................05 - 71 Seat belt indicating lamp is not on/always on
Replace Rear Main Reducer Gear Oil (combination instrument)....................04 - 607
(Replacement)......................................05 - 73 Seating.......................................0203 - 39, 50
Replace Spark Plug (4G69) Serial Number (SN) (Identification)........01 - 6
(Replacement)......................................05 - 56 Service Data (Air-conditioning
Replacement........................................05 - 38 System)................................................03 - 26

A-6-
Service Data (Axle & Transmission Stitch description, power rearview mirror switch
Shaft)....................................................03 - 40 (power rearview mirror)......................04 - 311
Service Data (Brake)............................03 - 20 Supplemental Restraint System..0203 - 13, 18
Service Data (Clutch)...........................03 - 30 System description (defrost system, rear
Service Data (Cooling).........................03 - 28 windscreen ).......................................04 - 290
Service Data (Door & Engine Hood)......03 - 6 System description (front axle clutch
Service Data (Engine Control System).03 - 16 diagnosis)...........................................04 - 665
Service Data (Engine Mechanical System description (tyre pressure monitoring
System)................................................03 - 12 system)...............................................04 - 650
Service Data (Exhaust)........................03 - 34 System specification(reverse radar
Service Data (Front Suspension).........03 - 38 system)...............................................04 - 222
Service Data (Fuel)..............................03 - 43
Service Data (Ignition)...........................03 - 8 T
Service Data (Intake)...........................03 - 24
Terminal, acoustics unit (audio
Service Data (Lubrication)...................03 - 45
system)...............................................04 - 437
Service Data (Power Steering).............03 - 10
The cold car is difficult to start and vehicle body
Service Data (Rear Suspension).........03 - 22
quivers (the engine control system)....04 - 119
Service Data (Start & Charge).............03 - 36
Service Data (Steering System)...........03 - 48 The combined display doesn’t work at all
Service Data (Supplemental Restraint (combined display).............................04 - 628
System)................................................03 - 18 The engine can stall if starts from cold car idling
Service Data (Transmission)..................03 - 2 (engine control system)......................04 - 131
Service Data (Wheel & Tire)..................03 - 4 The engine can stall while starting(engine
Service Data (Wiper & Washer)...........03 - 51 control system)...................................04 - 135
Service Schedule...................................05 - 1 The entire combination instrument does not
Service Schedule at Extreme Conditions work (combination instrument)...........04 - 588
(Service Schedule).................................05 - 6 The front axle clutch indicating lamp doesn’t
Slow, maladjusted acceleration response work.（front axle clutch diagnosis）...04 - 673
(Engine Control System)....................04 - 139 The obstacle is within the distance of effective
Speakers make no sound in any mode (audio sense, the buzzer doesn’t work or is abnormal
system)...............................................04 - 447 （reverse radar system）..................04 - 240
Speakers make poor-quality sound in any mode The power supply is greater than 16V within
(audio system)....................................04 - 451 B353C BCM (fault).............................04 - 642
Speakers make poor-quality sound only when The starter rotates, but the engine is unable to
playing back CD/DVD (audio start (the engine control system)........04 - 115
system)...............................................04 - 457 Top brake lamps fail to go on (lighting
Speakers make weak sound in any mode system)...............................................04 - 550
(audio system)....................................04 - 453 TPMS setting method (tyre pressure monitoring
Speedometer defects (assembly system)...............................................04 - 653
instrument).................................04 - 199, 602 Transfer gear......................................04 - 195
SRS control module connector (SRS Transmission..................................0203 - 2, 2
system)...............................................04 - 149 Tyre pressure is measured inaccurately (the
SRS system.......................................04 - 147 monitoring system of tyre pressure)....04 - 661
Start & Charge...........................0203 - 26, 36 Tyre pressure monitoring controller doesn’t
Steering System.........................0203 - 38, 48 work (the tyre pressure monitoring
Step lamps fail to go on (lighting system)...............................................04 - 657
system)...............................................04 - 571 Tyre pressure monitoring system.......04 - 648

A-7-
 U Vehicle body controller description(vehicle
control system)...................................04 - 634
U0001 CAN bus disconnection （transfer Vehicle Control System..............0204 - 4, 632
gear）................................................04 - 206 Vehicle Identification Number (VIN)
U0100 signal failure, clutch pedal position (Identification).........................................01 - 5
（transfer gear）................................04 - 204 Vehicle Lifting & Supporting Positions (Service
U0101 Gear signal failure, (transfer Guideline).............................................01 - 15
gear)...................................................04 - 197
Unstable idling speed (fluctuating) (engine W
control system)...................................04 - 123
Water temperature alarm lamp fails to go
V on/normally on (combination
instrument).........................................04 - 592
vacuum alarm indicator lamp fails to go Wheel & Tire...................................0203 - 5, 4
on/normally on (combination Windscreen, Window & Backview
instrument).........................................04 - 598 Mirror......................................................02 - 7
Wiper & Washer.............020304 - 14, 51, 355

A-8-