3.1.4-20 Cooling System 3.1.

4-20

Test Conditions Details/Results/Actions

5. Inspect radiator fan relay IR03 power supply circuit
A. Remove the radiator fan relay.
B. Turn the ignition switch to "ON", and execute
"Actuators" test - "Fan" with a diagnostic tool.
P40
C. At the same time, measure the voltage between
terminals 57, 58 of radiator fan relay IR03 and
reliable grounding with a multimeter.
Standard voltage: 11 ~ 14 V
IR03

58 Is the voltage value normal?

57

Yes
Go to step 6.
No
Inspect and repair the open circuit fault between
terminal 58 of radiator fan relay IR03 and terminal 6
of instrument panel fuse box.
Inspect and repair the open circuit fault between
terminal 57 of radiator fan relay IR03 and terminal
69 of main relay IR05.

M3104035

6. Inspect radiator fan relay IR03

A. Remove the radiator fan relay.
B. Replace with a normal one of same type.
Is the system normal?
Yes
Replace the radiator fan relay.
No
Go to step 7.

M201 2014.01
3.1.4-21 Cooling System 3.1.4-21

Test Conditions Details/Results/Actions

7. Inspect radiator fan relay control circuit
A. Turn the ignition switch to "ON", and execute
E18 "Actuators" test - "Fan" with a diagnostic tool.
B. At the same time, measure the voltage between
terminal 52 of engine control module wiring harness
1 2 9 22
connector E18 and reliable grounding with a
3 4 23 36 multimeter.
5 6 37 50 Standard voltage: 11 ~ 14 V
7 8 51 52 64 Is the voltage value normal?
Yes
Go to step 8.
No
Inspect and repair the open circuit fault between
terminal 52 of engine control module wiring harness
connector E18 and terminal 85 of radiator fan relay
IR03.
M3104036

8. Inspect radiator fan power supply circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the radiator fan wiring harness
connector P10.
C. Remove the radiator fan relay IR03.
2 1 D. Measure the resistance between terminal 1 of
radiator fan wiring harness connector P10 and
terminal 59 of radiator fan relay IR03.
P10 Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 9.
No
Inspect and repair the open circuit fault between
terminal 1 of radiator fan wiring harness connector
P10 and terminal 59 of radiator fan relay IR03.
IR03

59

P40
M3104037

M201 2014.01
3.1.4-22 Cooling System 3.1.4-22

Test Conditions Details/Results/Actions

9. Inspect radiator fan grounding circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the radiator fan wiring harness
connector P10.
P10
C. Measure the resistance between terminal 2 of
radiator fan wiring harness connector P10 and
reliable grounding.
2 1 Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the radiator fan.
M3104038
No
Inspect and repair the open circuit fault between
terminal 2 of radiator fan wiring harness connector
P10 and reliable grounding.

M201 2014.01
3.1.4-23 Cooling System 3.1.4-23

Diagnosis Procedure for Radiator Fan Constantly Running

Radiator fan constantly

running

General inspection
(Inspect the related wiring
harness connector for damage,
poor contact, aging and
loosen.)

Is the fault Yes

confirmed

No

Perform radiator fan active test

Is the fault Yes

confirmed

No

Inspect fuse

Is the fault Yes

confirmed

No

Inspect fuse IF03 power supply

Inspect radiator fan relay IR03
power supply circuit
Inspect radiator fan relay IR03
Inspect radiator fan relay control Is the fault Yes
circuit confirmed
Inspect radiator fan power supply
circuit
No

Inspect radiator fan grounding

circuit

End

M201 2014.01
3.1.4-24 Cooling System 3.1.4-24

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the each related wiring harness connector
for damage, poor contact, aging and looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the fault point.

2. Perform radiator fan active test

A. Connect diagnostic tool.
B. Turn the ignition switch to "ON", and execute
"Actuators" test - "Fan" with a diagnostic tool.
Does the fan rotate?
Yes
Inspect the coolant temperature sensor.
Refer to: DTCs P0116, P0117, P0118
(3.1.12 Electronic control
System - M7, DTC Diagnosis and
Testing).
No
Go to step 3.

3. Inspect fuse
A. Inspect the radiator fan fuse IF03.
Fuse rated capacity: 30 A
Is the fuse normal?
Yes
Go to step 4.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
3.1.4-25 Cooling System 3.1.4-25

Test Conditions Details/Results/Actions

4. Inspect fuse IF03 power supply
• Measure the voltage between terminal 5 of
instrument panel fuse box P40 fuse IF03 and
reliable grounding.
P40
Standard voltage: 11 ~ 14 V
5
IF03
6
Is the voltage value normal?
Yes
Go to step 5.
No
Inspect and repair the open circuit fault between
terminal 5 of instrument panel fuse box P40 and
battery.

M3104034

M201 2014.01
3.1.4-26 Cooling System 3.1.4-26

Test Conditions Details/Results/Actions

5. Inspect radiator fan relay IR03 power supply circuit
A. Remove the radiator fan relay.
B. Turn the ignition switch to "ON", and execute
"Actuators" test - "Fan" with a diagnostic tool.
P40
C. At the same time, measure the voltage between
terminals 57, 58 of radiator fan relay IR03 and
reliable grounding with a multimeter.
Standard voltage: 11 ~ 14 V
IR03

58 Is the voltage value normal?

57

Yes
Go to step 6.
No
Inspect and repair the open circuit fault between
terminal 58 of radiator fan relay IR03 and terminal 6
of instrument panel fuse box.
Inspect and repair the open circuit fault between
terminal 57 of radiator fan relay IR03 and terminal
69 of main relay IR05.

M3104035

6. Inspect radiator fan relay IR03

A. Remove the radiator fan relay.
B. Replace with a normal one of same type.
Is the system normal?
Yes
Replace the radiator fan relay.
No
Go to step 7.

M201 2014.01
3.1.4-27 Cooling System 3.1.4-27

Test Conditions Details/Results/Actions

7. Inspect radiator fan relay control circuit
A. Turn the ignition switch to "ON", and execute
E18 "Actuators" test - "Fan" with a diagnostic tool.
B. At the same time, measure the voltage between
terminal 52 of engine control module wiring harness
1 2 9 22
connector E18 and reliable grounding with a
3 4 23 36 multimeter.
5 6 37 50 Standard voltage: 11 ~ 14 V
7 8 51 52 64 Is the voltage value normal?
Yes
Go to step 8.
No
Inspect and repair the open circuit fault between
terminal 52 of engine control module wiring harness
connector E18 and terminal 85 of radiator fan relay
IR03.
M3104036

8. Inspect radiator fan power supply circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the radiator fan wiring harness
connector P10.
C. Remove the radiator fan relay IR03.
2 1 D. Measure the resistance between terminal 1 of
radiator fan wiring harness connector P10 and
terminal 59 of radiator fan relay IR03.
P10
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 9.
No
Inspect and repair the open circuit fault between
terminal 1 of radiator fan wiring harness connector
P10 and terminal 59 of radiator fan relay IR03.
IR03

59

P40
M3104037

M201 2014.01
3.1.4-28 Cooling System 3.1.4-28

Test Conditions Details/Results/Actions

9. Inspect radiator fan grounding circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the radiator fan wiring harness
connector P10.
P10
C. Measure the resistance between terminal 2 of
radiator fan wiring harness connector P10 and
reliable grounding.
2 1 Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the radiator fan.
M3104038
No
Inspect and repair the open circuit fault between
terminal 2 of radiator fan wiring harness connector
P10 and reliable grounding.

M201 2014.01
3.1.4-29 Cooling System 3.1.4-29

Removal and Installation

Radiator Fan
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the front bumper upper grille.

Refer to: Front Bumper (5.1.7 Bumper,
Removal and Installation).
3. Disconnect the radiator fan wiring harness
connector.

M3104005

4. Remove 2 retaining bolts from the radiator

fan.
Torque: 10 Nm

M3104006

5. Remove the front wind guiding cover.

Refer to: Front Wind Guiding Cover (5.1.10
Exterior Trim, Removal and
Installation).

M201 2014.01
3.1.4-30 Cooling System 3.1.4-30

6. Loosen 2 clamps, and disconnect the radiator

lower water pipe.

M3104007

7. Remove the radiator fan.

Installation
1. Installation is in the reverse order of removal.
CAUTION: Be aware that the clip at the
lower part of radiator fan must be seized in
the holder at the lower part of radiator
when installing the radiator fan.

CAUTION: Start engine to inspect cooling

system for any leaks.

M201 2014.01
3.1.4-31 Cooling System 3.1.4-31

Radiator
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the front wind guiding cover.

Refer to: Front Wind Guiding Cover (5.1.10
Exterior Trim, Removal and
Installation).
3. Loosen the radiator drain plug to drain the
cooling system.
WARNING: To avoid the danger of being
scalded, do not drain the cooling system
when engine and radiator still hot. The
boiling liquid and steam may spurt out
under the pressure since the reservoir cap
opens earlier.

M3104009

4. Remove the radiator fan.

Refer to: Radiator Fan (3.1.4 Cooling
System, Removal and
Installation).

5. Disconnect the condenser fan wiring harness

connector.

M3104010

M201 2014.01
3.1.4-32 Cooling System 3.1.4-32

6. Loosen the clamp, and separate the radiator

upper water pipe from the radiator.

M3104011

7. Remove 2 retaining bolts from the condenser

fan.
Torque: 10 Nm

×2

M3104012

8. Lift the vehicle, and remove the condenser

fan from below of vehicle.
9. Remove 2 connecting screws between
condenser and radiator.

×2

M3104013

M201 2014.01
3.1.4-33 Cooling System 3.1.4-33

10. Remove 2 retaining bolts from the radiator

upper bracket.
Torque: 9 Nm

×2

M3104014

11. Remove 4 retaining bolts from the radiator

bracket assembly.
Torque: 20 Nm
CAUTION: Secure the condenser to the
body before removing the radiator bracket ×4
assembly to prevent damaging the A/C
pipe.

12. Remove the radiator.

M3104015

Installation
1. Installation is in the reverse order of removal.
CAUTION: Be aware that the clip at the
lower part of radiator must be seized in the
holder of radiator bracket assembly when
installing the radiator.

CAUTION: Start engine to inspect cooling

system for any leaks.

M201 2014.01
3.1.4-34 Cooling System 3.1.4-34

Thermostat
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Loosen the radiator drain plug to drain the

cooling system.
Refer to: Coolant Draining and Filling
(3.1.4 Cooling System, General
Inspection).
3. Disconnect the connection between No.2
water outlet pipe and thermostat cap.
4. Loosen the hoop, and disconnect the
connection between the top radiator hose and
thermostat cap.

M3105022

5. Remove 2 retaining bolts from the thermostat.

Torque: 23 ± 2 Nm

×2

M3105020

6. Remove the thermostat.

M3105021

M201 2014.01
3.1.4-35 Cooling System 3.1.4-35
Installation
1. Installation is in the reverse order of removal.
CAUTION: The thermostat paraffin
inductor faces towards the engine side.

CAUTION: Falling out of thermostat seal

ring is not allowed.

CAUTION: Fully turn the thermostat cap.

CAUTION: Start engine to inspect cooling

system for any leaks.

M201 2014.01
3.1.4-36 Cooling System 3.1.4-36

Water Pump
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Lift the vehicle.

Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).

3. Remove the front wind guiding cover.

Refer to: Front Wind Guiding Cover (5.1.10
Exterior Trim, Removal and
Installation).

4. Loosen the radiator drain plug to drain the

cooling system.
Refer to: Coolant Draining and Filling
(3.1.4 Cooling System, General
Inspection).
5. Remove the compressor belt. (Vehicle with
A/C)
1 Loosen 2 compressor connecting bolts.
Torque: 25 ~ 30 Nm
×2

M3104023

2 Loosen the compressor adjusting bracket

bolts (1) and (2) in order.
Torque for bolt (1) : 25 ± 1 Nm

M3104024

M201 2014.01
3.1.4-37 Cooling System 3.1.4-37

3 Turn the water pump pulley toward the

engine side until the compressor belt can be
removed.

M3104025

6. Remove the elastic belt. (Vehicle without A/C)

1 Turn the water pump pulley toward the
engine side until the compressor belt can be
removed.

M3104025

7. Remove the water pump.

1 Use a screwdriver to position the water
pump pulley, and use a ratchet wrench to
remove the retaining bolts from the water ×4
pump pulley in order.
Torque: 10 ± 1 Nm

M3104026

2 Remove 2 retaining bolts from the bolster

plate of compressor tension bracket. ×2
(Vehicle with A/C)
Torque: 23 ± 2 Nm

M3104027

M201 2014.01
3.1.4-38 Cooling System 3.1.4-38

3 Move the compressor adjusting bracket

away. (Vehicle with A/C)
4 Remove 3 retaining bolts and 2 nuts from
the water pump, and remove the water pump.
Torque: 20 ± 5 Nm

×2
×3

M3104028

5 Clean the joint surface of engine cylinder

block and water pump.

Inspection
Inspect the water pump for damage; inspect if the
water pump is stuck by turning it. Replace the
water pump if any defect is found.

Installation
Install the water pump assembly and the bolster
plate of compressor tension bracket. Apply
sealant when installing the water pump, and
make sure that the smear surface is clean without
oil contamination and scratches before
application. The apply area is shown in the figure,
1
and install the water pump assembly within 5
minutes after application.
Sealant type: Tonsan 1596Fa
CAUTION: Inspect the drive belt tension. M3104029

Refer to: Drive Belt Tension Inspection

(3.1.4 Cooling System, General
inspection).

CAUTION: After installing the water pump,

do not add coolant within 20 minutes to
avoid the sealant to enter the water pump
turbine.

M201 2014.01
3.1.4-39 Cooling System 3.1.4-39

Floor Water Pipe

Removal
1. Remove the front wind guiding cover.
Refer to: Front Wind Guiding Cover (5.1.10
Exterior Trim, Removal and
Installation).
2. Loosen the radiator drain plug to drain the
cooling system.
WARNING: To avoid the danger of being
scalded, do not drain the cooling system
when engine and radiator still hot. The
boiling liquid and steam may spurt out
under the pressure since the reservoir cap
opens earlier.

M3104009

3. Remove the rear wind guiding cover.

Refer to: Rear Wind Guiding Cover (5.1.10
Exterior Trim, Removal and
Installation).
4. Loosen the clamp, and disconnect the
connecting hose (1) between floor water pipe
rear end and engine inlet hose.
5. Loosen the clamp, and disconnect the
1
connecting hose (2) of floor water pipe rear 4 5
end to A/C heater core.
6. Loosen the clamp, and disconnect the
connecting hose (3) between floor water pipe 2
rear end and engine outlet hose. 3
7. Disconnect the connecting hose (4) between M3104030
floor water pipe rear end and water reservoir.
8. Loosen the hoop, and disconnect the
connecting hose (5) between floor water pipe
rear end and intake manifold.

M201 2014.01
3.1.4-40 Cooling System 3.1.4-40

9. Loosen the clamp, and disconnect the

connecting hose (1) between floor water pipe 2 3
front end and radiator outlet hose.
10. Loosen the clamp, and disconnect the 4
connecting hose (2) between floor water pipe
front end and A/C heater core. 1
11. Loosen the clamp, and disconnect the 5
connecting hose (3) between floor water pipe
front end and radiator inlet hose.
12. Disconnect the connecting hose (4) between M3104031
floor water pipe front end and water reservoir.
13. Loosen the hoop, and disconnect the
connecting hose (5) between floor water pipe
front end and vacuum booster.

14. Remove 4 retaining screws from the floor

water pipe, and remove the floor water pipe.
Torque: 10 ± 1 Nm

×4

M3104032

Installation
1. Installation is in the reverse order of removal.
CAUTION: Start engine to inspect cooling
system for any leaks.

M201 2014.01
3.1.4-41 Cooling System 3.1.4-41

Water Reservoir
Removal
1. Remove the water pipe and water reservoir
cap.
WARNING: To avoid the danger of being
scalded, do not drain the cooling system
when engine and radiator still hot. The
boiling liquid and steam may spurt out
under the pressure since the reservoir cap
opens earlier. FULL
LOW

M3104002

2. Pull up the water reservoir to remove it.

FULL
LOW

M3104016

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.5-1 Air Intake System 3.1.5-1

Specifications
3.1.5 Air Intake System

General Specifications
Item Specifications
Vacuum degree of intake manifold under engine idling 330 ± 20 kPa

Torque Specifications
Item Nm lb-ft lb-in
Intake manifold retaining bolt 23 ± 2 - -
Throttle body retaining bolt 10 ± 1 - -
Air filter retaining bolt 10 ± 1 - -
Retaining bolt of air intake pressure/
10 ± 1 - -
temperature sensor

M201 2014.01
3.1.5-2 Air Intake System 3.1.5-2

Description and Operation

System Overview
Ambient air enters the air filter first and then the
cylinder through the intake pipe, throttle body and
intake manifold after it has been filtered by air
filter element. The intake pipe is connected with a
crankcase vent pipe through which the exhaust
gas from the crankcase enters the cylinder with
fresh air.

Components Description
Air filter
The air filter consists of the following items:
• Air filter upper case
• Air filter element
• Air filter lower case
×4

M3105001

The dry air enters the air filter base and through
air filter element and then the clean air flows from
the air filter upper case.

M201 2014.01
3.1.5-3 Air Intake System 3.1.5-3

Components Exploded View

1
1

12 3

6
11
7

10

9 8

M3105002

Item Description Item Description

1 Intake manifold stud bolt 7 Throttle position sensor
2 Intake manifold gasket 8 No.4 wiring harness bracket
3 Small return hose 9 Throttle body assembly
4 Throttle body hoop 10 Idle stepper motor assembly
5 Intake manifold assembly 11 Intake manifold stiffener
6 Throttle body gasket 12 No.1 engine hook

M201 2014.01
3.1.5-4 Air Intake System 3.1.5-4

General Inspection
General Equipment

Vacuum gauge

CAUTION: The components of engine are

at high temperature when the engine is
running. Pay attention to the components
at high temperature during removal.
Otherwise, serious scalding will be
caused.

Vacuum Degree of Air Intake

System Inspection
1. Stop the engine and turn off the ignition
switch.
2. Detach the brake booster vacuum hose from
the intake manifold.
3. Connect 3-way connector, hose and special
tool (vacuum gauge and connector) between
intake manifold and vacuum hose detached.
4. Start the engine and measure the vacuum
degree of air intake system under engine
idling.
Standard value: 330 ± 20 kPa
5. Remove the vacuum gauge and reconnect
the vacuum hose.
6. If an observed or reported problem is obvious
and its cause has been found, solve the fault
before proceeding to the next step.
7. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
3.1.5-5 Air Intake System 3.1.5-5

Symptom Diagnosis and Testing

General Equipment

Vacuum gauge

Visual Inspection Chart

Mechanical
• Air filter set
• Air filter inlet pipe
• Air filter outlet pipe
• Throttle body
• Intake manifold

M201 2014.01
3.1.5-6 Air Intake System 3.1.5-6

Symptom Chart
If the fault occurs, but there is no DTC stored in ECM for this fault and the causes cannot be verified in
basic inspection, diagnose and repair it in order of the following table.

Symptom Possible Causes Solutions

• Air filter Refer to: Diagnosis Procedure
• Intake manifold for Intake Air Leak
(3.1.5 Air Intake
Intake air leak • Throttle body
System, Symptom
• Crankcase vent pipe Diagnosis and
• Component connections Testing).
• Inspect the air filter and replace when
necessary.

• Air filter element

Refer to: Air Filter Element (3.1.5
Air Intake System,
Removal and
Installation).
Intake blocking • Disassemble the air filter case and
inspect the air filter and intake pipe for
any possible foreign matters and remove.
• Foreign matters in intake pipe Refer to: Air Filter Element (3.1.5
Air Intake System,
Removal and
Installation).

M201 2014.01
3.1.5-7 Air Intake System 3.1.5-7

Diagnosis Procedure for Intake Air Leak

Intake air leak

Inspect for any leak noise

Is the fault Yes

confirmed

No
Inspect vacuum degree of air
intake system

Is the fault Yes

confirmed

No
Inspect intake manifold or
throttle body

End

M201 2014.01
3.1.5-8 Air Intake System 3.1.5-8

Test Conditions Details/Results/Actions

1. Inspect for any leak noise
A. Start the engine.
B. Inspect for any leak noise by listening.
Is there any leak noise like hiss?
Yes
Inspect the leaking point(s) and repair the leaked
component(s).
No
Go to step 2.

2. Inspect vacuum degree of air intake system

A. Carry out the inspection procedures for vacuum
degree of air intake system.
Is the vacuum degree normal?
Standard vacuum degree: 330 ± 20 kPa
Refer to: Vacuum Degree of Air Intake
System Inspection (3.1.5 Air
Intake System, General
inspection).
Yes
The system is normal.
No
Go to step 3.

3. Inspect intake manifold or throttle body

A. Inspect the intake manifold or throttle body for leak
tightness.
Does the intake manifold or throttle body leak?
Yes
Repair the seal of intake manifold or throttle body.
No
Inspect the engine valve train.
Refer to: Timing System (3.1.2 Mechanical
System, Removal and
Installation).

M201 2014.01
3.1.5-9 Air Intake System 3.1.5-9

Removal and Installation

Air Filter Element
Removal
1. Loosen the pipe clip, and disconnect the air
filter outlet pipe from the air filter.

M3105003

2. Remove 4 retaining screws from the air filter

upper case.

×4
M3105001

3. Remove the air filter upper case.

M3105004

M201 2014.01
3.1.5-10 Air Intake System 3.1.5-10

4. Remove the air filter element from the lower

case.

M3105005

5. Inspect the air filter element for any dirt.

6. Blow away the dirt from the air outlet of
element with compressed air if necessary. If
excessively dirty, replace the element.

M3105006

Installation
1. Installation is in the reverse order of removal.
CAUTION: Align the bulge of air filter case
with the groove of air filter outlet pipe.

M3105007

M201 2014.01
3.1.5-11 Air Intake System 3.1.5-11

Air Filter
Removal
1. Loosen the clamp, and disconnect the air
filter outlet pipe from the air filter.

M3105003

2. Remove 2 retaining bolts from the air filter.

Torque: 10 ± 1 Nm

×2

M3105008

Installation
1. Installation is in the reverse order of removal.
CAUTION: Align the bulge of air filter case
with the groove of air filter outlet pipe.

M3105007

M201 2014.01
3.1.5-12 Air Intake System 3.1.5-12

Throttle Body
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Loosen the clamps, and disconnect the air
filter outlet pipe from the throttle body and air
filter separately.

×2
M3105009

3. Disconnect the wiring harness connector

from the throttle body.
1 Disconnect the air intake pressure/ 1
temperature sensor wiring harness connector
(1).
2 Disconnect the throttle position sensor 2
wiring harness connector (2). 3

3 Disconnect the idling stepper motor wiring

harness connector (3).
M3105010

4. Remove 4 retaining bolts from the throttle

body, and remove the throttle body and
gasket. ×4
Torque: 10 ± 1 Nm

M3105031

M201 2014.01
3.1.5-13 Air Intake System 3.1.5-13

5. Separate the accelerator cable and throttle

body.

M3105012

6. Loosen the hoops, and remove the

preheating water pipe of throttle body.

M3105013

Installation
1. Installation is in the reverse order of removal.
1
CAUTION: Ensure that new parts are used
for sealing between throttle body and
intake manifold. 2

CAUTION: As shown in the figure, ensure

that the hoop closed line (1) overlaps with 3
T-mark line (3) of hose, and the hoop outer
line (2) is aligned with T-mark line (2) of
hose when tightening the hose.
M3105011

M201 2014.01
3.1.5-14 Air Intake System 3.1.5-14

Intake Manifold
Removal
1. Release the fuel pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
2. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

3. Remove the gearshift mechanism.

Refer to: Gearshift Mechanism (3.2.4
Manual Transmission External
Control, Removal and
Installation).
4. Disconnect the coolant temperature sensor
wiring harness connector.

M3105014

5. Loosen the radiator drain plug to drain the

cooling system.
Refer to: Coolant Draining and Filling
(3.1.4 Cooling System, General
Inspection).

6. Remove the water outlet pipe holder and

No.1 water outlet pipe.
1 Remove the retaining bolt of wiring harness
bracket from the water outlet pipe holder.
Torque: 10 ± 1 Nm

M3105015

M201 2014.01
3.1.5-15 Air Intake System 3.1.5-15

2 Remove 3 retaining bolts from the water

outlet pipe holder.
Torque: 20 ± 5 Nm

×3

M3105016

3 Pull out the water outlet holder and No.1

water outlet pipe to separate the No.1 water
outlet pipe and intake manifold.
7. Remove the throttle body.
Refer to: Throttle Body (3.1.5 Air intake
System, Removal and
Installation).

8. Remove the retaining bolt from the air intake

pressure/temperature sensor.
Torque: 8 ± 2 Nm

M3105017

9. Loosen the hoop, and disconnect the vacuum

booster hose.

M3105018

M201 2014.01
3.1.5-16 Air Intake System 3.1.5-16

10. Loosen the hoop, and disconnect the

crankcase vent hose and intake manifold
water hose separately.

M3105019

11. Remove the thermostat.

1 Disconnect the No.2 water outlet pipe from
the thermostat cap.
2 Loosen the hoop, and disconnect the
connecting hose between top radiator hose
and thermostat cap.

M3105022

3 Remove 2 retaining bolts from the

thermostat.
Torque: 23 ± 2 Nm

×2

M3105020

4 Remove the thermostat.

M3105021

M201 2014.01
3.1.5-17 Air Intake System 3.1.5-17

12. Loosen the hoop, and disconnect the

connecting hose between A/C warm water
outlet pipe and intake manifold.

M3105023

13. Remove the fuel main pipe.

Refer to: Fuel Main Pipe (3.1.7 Fuel
System, Removal and
Installation).
14. Separate the knock sensor wiring harness
connector from the crankcase vent pipe and
fuel main pipe.

M3105028

15. Remove 2 retaining bolts between crankcase

vent pipe and fuel pipe, and move the
crankcase vent pipe and fuel main pipe away.
Torque: 10 ± 1 Nm
×2

M3105024

M201 2014.01
3.1.5-18 Air Intake System 3.1.5-18

16. Loosen the hoop, and disconnect the

connecting hose between carbon canister
control valve and intake manifold.

M3105025

17. Remove the retaining bolt from the intake

manifold bracket.
Torque: 23 ± 2 Nm

M3105026

18. Remove the retaining bolts and nuts from the

intake manifold.
Torque: 23 ± 2 Nm
×2
×8

M3105029

19. Loosen the hoop, and disconnect the

preheating water pipe of throttle body from
the intake manifold.

M3105030

M201 2014.01
3.1.5-19 Air Intake System 3.1.5-19
Inspection
1. Inspect and clean the installing end face
between intake manifold and cylinder head.
2. Inspect the intake manifold end face. Using a
straight scale and a feeler gauge, inspect the
surface deformation at no less than 6
positions. If the deformation exceeds the limit
value, correct the surface or replace a new
intake manifold.
Deformation limit: 0.07 mm

Installation
1. Installation is in the reverse order of removal.
CAUTION: Inspect the intake manifold for
any possible leaks after installation.

Refer to: Diagnosis Procedure for Intake

Air Leak (3.1.5 Air Intake System,
Symptom Diagnosis and
Testing).

CAUTION: Inspect the fuel for leakage

after installation.

Refer to: Fuel System Pressure Test (3.1.7

Fuel System, General
Inspection).

CAUTION: Inspect the coolant for leakage

after installation.
CAUTION: As shown in the figure, ensure
that the hoop closed line (1) overlaps with 1
T-mark line (3) of hose, and the hoop outer
line (2) is aligned with T-mark line (2) of
2
hose when tightening the hose.

M3105011

M201 2014.01
3.1.6-1 Exhaust System 3.1.6-1

Specifications
3.1.6 Exhaust System

General Specifications
Item Specifications
Exhaust backpressure with engine full load speed
36 kPa or less
(engine speed 6000 rpm, throttle full open)

Torque Specifications
Item Nm lb-ft lb-in
Exhaust manifold retaining bolt 23 ± 2 - -
Exhaust manifold heat insulator 10 ± 1 - -
Connecting bolt between three-way
55 ± 5 - -
catalytic converter and exhaust manifold
Connecting bolt between muffler and
55 ± 5 - -
three-way catalytic converter
Oxygen sensor tightening torque 50 ± 10 - -
Retaining bolt between engine left
45 33 -
mounting and engine
Retaining nut between engine left
45 33 -
mounting and engine bracket

M201 2014.01
3.1.6-2 Exhaust System 3.1.6-2

Description and Operation

System Overview
Three-way Catalytic Converter
Poisoning
If fuel contains 5 mg or more lead per liter, it will
lead to the catalytic converter poisoning.
Therefore, strictly forbid using leaded gas for
vehicle equipped with a three-way catalytic
converter.
The zinc and phosphorus in the engine oil will
lead to catalytic converter poisoning if the engine
oil consumption is too high. H2S exhausted from
the three-way catalytic converter can be
perceived easily. It smells like a rotten egg. Such
problem can be solved by using other brands of
fuel. To reduce H2S emission, make sure that CO
emission at idle speed meets the standard and
the engine exhaust system works normally.
WARNING: The catalyst carrier will melt if
the temperature exceeds 900°C. The fault
should be fully analyzed and repaired to
prevent such fault occurrence.

Due to excessive backpressure, the melting of

catalyst often comes along with the power
reduction.

Components Description
Three-way Catalytic Converter
The three-way catalytic converter is shaped like a
small muffler. Due to the high working
temperature, the bodywork near the three-way
catalytic converter has been protected with heat
insulated panel. The three-way catalytic converter
controls three emissions: HC, CO and NOx.

M201 2014.01
3.1.6-3 Exhaust System 3.1.6-3

Components Location View

1 2 3

M3106014

Item Description Item Description

1 Exhaust manifold 3 Muffler
2 Three-way catalytic converter

M201 2014.01
3.1.6-4 Exhaust System 3.1.6-4

Components Exploded View

Exhaust Manifold

5
1

2 6

3 7

M3106012

Item Description Item Description

Exhaust manifold upper heat
1 5 Hexagon flange nut
insulator assembly
Exhaust manifold lower heat
2 Exhaust manifold gasket 6
insulator assembly
3 Exhaust manifold assembly 7 Hexagon flange bolt
Exhaust manifold assembly
4 8 Hexagon flange bolt
stud bolt

M201 2014.01
3.1.6-5 Exhaust System 3.1.6-5
Three-Way Catalytic Converter and Muffler

1 2 5 7 9 10 14

3 4 6 8 11 12 13

M3106013

Item Description Item Description

Three-way catalytic converter
1 Charcoal ring (cermet coating) 8
assembly
2 Pressure spring 9 Rubber shackle
3 Pressure spring bolt 10 Charcoal ring (cermet coating)
Three-way catalytic converter
4 11 Pressure spring
lower cover assembly
Three-way catalytic converter
5 12 Pressure spring bolt
upper cover assembly
Muffler with accessory
6 Nut 13
assembly
7 Hexagon head bolt 14 Rubber shackle

M201 2014.01
3.1.6-6 Exhaust System 3.1.6-6

General Inspection
General Equipment

Exhaust backpressure gauge

Exhaust Backpressure Test

1. Remove the front oxygen sensor.
2. Install the exhaust backpressure gauge.
3. Start the engine.
4. Measure the exhaust backpressure when the
engine is idling.
5. Measure the exhaust backpressure with engine
full load speed (engine speed 6000 rpm, throttle
full open).
Exhaust backpressure standard

Exhaust
Engine Speed (rpm)
Backpressure (kPa)
6000 36 kPa or less

6. Turn the ignition switch off and the engine

stops.
7. Remove the exhaust backpressure gauge
and install the oxygen sensor.

M201 2014.01
3.1.6-7 Exhaust System 3.1.6-7

Symptom Diagnosis and Testing

General Equipment

Exhaust backpressure gauge

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious mechanical or
electrical damage.
3. If an observed or reported problem is obvious
and its cause has been found, solve the fault
before proceeding to the next step.
4. If there is no obvious cause, verify the
symptom by referring to the Symptom Chart.
Visual Inspection Chart

Mechanical Electrical
• Damage or leakage of
exhaust system pipe
• Damage of three-way
• Oxygen sensor circuit
catalytic converter
fault
• Looseness of exhaust
• Oxygen sensor fault
pipe bolt
• Aging or damage of
exhaust pipe gasket

M201 2014.01
3.1.6-8 Exhaust System 3.1.6-8

Symptom Chart
If the fault occurs, but there is no DTC stored in ECM for this fault and the causes cannot be verified in
basic inspection, diagnose and repair it in order of the following table.

Symptom Possible Causes Solutions

• Exhaust pipe Refer to: Diagnosis Procedure for
• Three-way catalytic converter Exhaust System
Blockage (3.1.6 Exhaust
• Muffler
System, Symptom
Exhaust system blockage
• Exhaust port is blocked as rust Diagnosis and Testing).
heavy inside exhaust pipe
• Exhaust system component
connections
• Position and tighten each exhaust system
component to the specified torques.
• Component misalignment or wrong
installation of exhaust system Refer to: Torque Specifications
(3.1.6 Exhaust system,
• Sealing or gasket leak(s)
Specification).
1. Exhaust manifold and cylinder
head • Make sure that the exhaust pipe shackle
is located correctly and tightly.
2. Exhaust manifold and three-way
catalytic converter assembly • Replace the leaking sealing or gaskets
Exhaust system leak(s) 3. Three-way catalytic converter with new ones.
assembly and muffler assembly • Repair or replace the related components
• Irregular joint surface of flange joint when necessary.
connection • Replace the exhaust manifold.
• Cracked or disconnected exhaust Refer to: Exhaust manifold (3.1.6
manifold Exhaust System,
• Welded joint of exhaust system Removal and
component leak(s) Installation).

• Replace the leaking parts.

M201 2014.01
3.1.6-9 Exhaust System 3.1.6-9

Diagnosis Procedure for Exhaust System Blockage

Exhaust system blockage

Visually inspect exhaust port

Is the fault Yes

confirmed

No

Inspect exhaust backpressure

Is the fault Yes

confirmed

No
Inspect three-way catalytic
converter

Is the fault Yes

confirmed

No

Inspect muffler

End

M201 2014.01
3.1.6-10 Exhaust System 3.1.6-10

Test Conditions Details/Results/Actions

1. Visually inspect exhaust port
A. Inspect exhaust port for any foreign matters.
Is the exhaust port normal?
Yes
Clear foreign matters.
No
Go to step 2.

2. Inspect exhaust backpressure

A. Execute the inspection of exhaust backpressure.
Refer to: Exhaust Backpressure Test (3.1.6
Exhaust System, General
Inspection).
Is the exhaust backpressure normal?
Yes
The system is normal.
No
Go to step 3.

3. Inspect three-way catalytic converter

A. Remove the three-way catalytic converter.
Refer to: Three-way Catalytic Converter
(3.1.6 Exhaust System, Removal
and Installation).
B. Inspect the three-way catalytic converter.
Is the three-way catalytic converter normal?
Yes
Go to step 4.
No
Replace the three-way catalytic converter.
Refer to: Three-way Catalytic Converter
(3.1.6 Exhaust System, Removal
and Installation).
4. Inspect muffler
A. Remove the muffler.
B. Inspect the muffler.
Is the muffler normal?
Yes
Inspect the exhaust system component joints and
test the system for normal operation.
No
Replace the muffler.

M201 2014.01
3.1.6-11 Exhaust System 3.1.6-11

Removal and Installation

Exhaust Manifold
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Lift the vehicle.
Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).
3. Disconnect the front oxygen sensor wiring
harness connector.

M3106001

4. Use the engine bracket to hold engine and

remove the left bracket retaining bolts and
mounting pad assembly nut.
×5
Bolt torque: 45 Nm
Nut torque: 70 ± 5 Nm

M3106002

5. Remove 2 connecting bolts between exhaust

manifold and three-way catalytic converter.
Torque: 55 ± 5 Nm

×2

M3106003

M201 2014.01
3.1.6-12 Exhaust System 3.1.6-12

6. Remove the exhaust manifold lower heat

insulator.
1 Remove 4 retaining bolts from the exhaust

×4
manifold lower heat insulator.
Torque: 10 ± 1 Nm

M3106004

2 Remove the exhaust manifold lower heat

insulator.

7. Remove the exhaust manifold assembly.

1 Remove 3 retaining bolts and 3 retaining
nuts between exhaust manifold assembly and
engine.
Bolt Torque: 23 ± 2 Nm

×3
Nut torque: 50 ± 5 Nm

×3
M3106005

2 Remove the exhaust manifold assembly

with upper heat insulator.

8. Remove the exhaust manifold upper heat

insulator.
1 Remove 4 retaining bolts from the exhaust
×4

manifold upper heat insulator.

Torque: 10 ± 1 Nm

M3106006

2 Remove the exhaust manifold upper heat

insulator.

M201 2014.01
3.1.6-13 Exhaust System 3.1.6-13

9. Use the special tool to remove the front

oxygen sensor.
Torque: 50 ± 10 Nm
Special tool: Oxygen sensor sleeve CA301-
022 CA301 -022

M3106007

Installation
1. Installation is in the reverse order of removal.
CAUTION: Inspect for exhaust gas
leakage, and tighten the trouble part to
prevent leakage if leakage is present.
Replace the damaged components when
necessary.

M201 2014.01
3.1.6-14 Exhaust System 3.1.6-14

Three-way Catalytic Converter

Removal

1. Disconnect the negative battery cable.

Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Lift the vehicle.

Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).
3. Disconnect the rear oxygen sensor wiring
harness connector.

M3106008

4. Remove 2 connecting bolts between exhaust

manifold and three-way catalytic converter.
Torque: 55 ± 5 Nm

×2

M3106003

5. Remove 2 connecting bolts between three-

way catalytic converter and muffler.
×2

Torque: 55 ± 5 Nm

M3106009

M201 2014.01
3.1.6-15 Exhaust System 3.1.6-15
6. Remove the three-way catalytic converter
shackle and remove the three-way catalytic
converter.
7. Use the special tool to remove the rear
oxygen sensor.
Torque: 50 ± 10 Nm
Special tool: Oxygen sensor sleeve CA301-
022
CA301-022

M3106010

Installation
1. Installation is in the reverse order of removal.
CAUTION: Inspect for exhaust gas
leakage, and tighten the trouble part to
prevent leakage if leakage is present.
Replace the damaged components when
necessary.

M201 2014.01
3.1.6-16 Exhaust System 3.1.6-16

Muffler
Removal
1. Lift the vehicle.
Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).
2. Remove 2 connecting bolts between three-
way catalytic converter and muffler.

×2
Torque: 55 ± 5 Nm

M3106009

3. Remove 3 rubber shackles between muffler

and vehicle body.

×3

M3106011

4. Remove the muffler.

Installation
1. Installation is in the reverse order of removal.
CAUTION: Inspect for exhaust gas
leakage, and tighten the trouble part to
prevent leakage if leakage is present.
Replace the damaged components when
necessary.

M201 2014.01
3.1.7-1 Fuel System 3.1.7-1

Specifications
3.1.7 Fuel System

Component Specifications
Item Specifications
Fuel injector resistance 11.5 ~ 12.6 Ω at 20°C

General Specifications
Item Specifications
Fuel pipe pressure 0.4 Mbar

Torque Specifications
Item Nm lb-ft lb-in
Fuel tank retaining bolt 25 18 -
Fuel filter bracket bolt 10 - 89
Fuel pump flange bolt 10 - 89
Fuel main pipe retaining bolt 23 ± 2 - -
Accelerator pedal retaining bolt 10 ± 1 - -

M201 2014.01
3.1.7-2 Fuel System 3.1.7-2

Description and Operation Fuel Filter

System Overview The fuel filter is a tank structure, and installed on
the frame of engine side with bolts.
Fuel supply system with fuel pressure regulator
adopts the pressure differential adjusting method.
The fuel pump is installed in the fuel tank, and
form an assembly together with the fuel pump
level sensor. The engine control module controls
the fuel pump through the fuel pump relay. After
the fuel pump starts working, it supplies the fuel
injector rail with fuel of specified pressure. The
fuel system maintains a certain pressure when
the fuel pump stops working, to ensure that the
engine can start normally. Fuel supply system is
composed of fuel pump, fuel pipe, fuel filter, fuel M3107006
pressure regulator, fuel injector rail, fuel pump
relay and so on.

Components Description
Fuel Pump
The fuel pump is installed in the fuel tank, and
form an assembly together with the fuel level
sensor. It is installed through plastic locking ring
and sealed by rubber washer.

×6

M3107013

M201 2014.01
3.1.7-3 Fuel System 3.1.7-3

Components Location View

4 5 6 7
3

9
10

M3107001

Item Description Item Description

1 Fuel tank 7 Fuel vapor pipe
Carbon canister with accessory
2 Fuel pump assembly 8
assembly
3 Nylon fuel pipe assembly 9 Fuel filter assembly
4 Nylon return pipe assembly 10 Fuel filler cap assembly
5 Fuel vapor hose 11 Fuel filler pipe assembly

M201 2014.01
3.1.7-4 Fuel System 3.1.7-4

General Inspection 5. Connect the negative battery cable.

General Equipment 6. Connect a diagnostic tool to the diagnosis
connector.
Diagnostic tool
7. Turn the ignition switch to "ON".
Fuel pressure gauge
8. Select the Active Test function of the engine
WARNING: Gasoline or gasoline vapors is menu on the diagnostic tool, and then select
highly flammable. In order to avoid fire or "Fuel pump relay" to run the fuel pump and
explosion, please keep away from fire. keep it running for 10 s.
During this procedure, operation staffs are 9. Measure the fuel pipe pressure.
prohibited to use mobile phones. Never
Standard fuel pressure: 0.4 Mbar
drain or store gasoline in open container.
Please prepare a dry chemical fire 10. Stop the fuel pump.
extinguisher nearby during this 11. Measure the fuel holding pressure after 5
procedure. minutes.
Fuel System Pressure Testing Standard fuel holding pressure: 0.4 Mbar

WARNING: Fuel pipe overflowing and fuel 12. Remove the fuel pressure tester from the fuel
system leakage are extremely dangerous. system.
Fuel will catch fire, which lead to serious 13. Reconnect the fuel pipe, inspect the fuel pipe
injury and damage. To avoid this situation, for reliable connection.
carry out the following inspection when
the engine stops.

1. Remove the fuel pump relay, start the engine

until the engine stalls.
2. Install fuel pump relay.
3. Disconnect the negative battery cable.
4. Connect the fuel pressure gauge to the fuel
pipe.
WARNING: Wrap a cleaning cloth around
the joint of fuel pressure gauge and fuel
distribution pipe to absorb the leaking fuel
during connecting pressure gauge, so as
to reduce the risk of fire and personal
injury. Place a cleaning cloth into the
specified container after test is completed.
Clean the fuel pipe joint before removing
the fuel pipe.

M201 2014.01
3.1.7-5 Fuel System 3.1.7-5

Symptom Diagnosis and Testing

Inspection and Verification
1. Verify the customer concern.
2. Visually check if there is obvious mechanical
or electrical damage.
Visual Inspection Chart

Mechanical Electrical
• Fuel pipe damage
• Fuel leakage
• Fuel tank filler cap
damage
• Fuel pump circuit
• Fuel tank filler pipe
damage • Fuel pump relay
• Fuel line joint damage • Fuel pump
• Fuel pressure
regulator damage
• Fuel filter incorrect
installation

3. If an observed or reported problem is obvious

and the cause has been found, solve the fault
before proceeding to the next step.
4. If there is no obvious cause, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
3.1.7-6 Fuel System 3.1.7-6

Symptom Chart
If the fault occurs, but there is no DTC stored in ECM for this fault and the causes cannot be verified in
basic inspection, diagnose and repair it in order of the following table.

Symptom Possible Causes Solutions

• Fuel pump relay Refer to: Diagnosis Procedure
• Fuel Pump for Fuel Pump Fault
Fuel pump fault (3.1.7 Fuel System,
• Circuit
Symptom Diagnosis
• Engine control module (ECM) and Testing).
Low pressure in fuel • Fuel pump • Replace the fuel pump.
system • Pipe leakage • Repair the fuel line.

Low holding pressure in • Fuel pump • Replace the fuel pump.

fuel system • Fuel pipe leakage • Repair the fuel line.

High pressure in fuel • Fuel pipe clogging • Repair the fuel line.
system • Fuel pressure regulator • Replace the fuel pressure regulator.
• Filler cap Refer to: Diagnosis Procedure
• Fuel filter for Heavy Fuel Smell
(3.1.7 Fuel System,
• Fuel tank vent hole
Symptom Diagnosis
Heavy fuel smell • Carbon canister control valve and Testing).
• Carbon canister
• Fuel system leakage
• Fuel pressure

M201 2014.01
3.1.7-7 Fuel System 3.1.7-7

• MAP intake pressure sensor Refer to: Diagnosis Procedure

• Incorrect A/C system operation for Emergency during
Driving (3.1.12
• Air intake system component
Electronic Control
leakage
System - M7, Symptom
• Purge solenoid fault Diagnosis and
• Unstable signal from CKP sensor Testing).
• Vacuum leakage
• Poor fuel quality
• Intermittent fault of main relay and
Surging during driving fuel pump relay
• Throttle body fault
• Engine overheating
• Spark plug fault
• Ignition timing
• Exhaust system restrictions
• Inadequate fuel pressure
• Fuel pump mechanical fault
• Fuel injector
• Unstable signal from TP sensor

M201 2014.01
3.1.7-8 Fuel System 3.1.7-8

Diagnosis Procedure for Fuel Pump Fault

Fuel pump fault

General inspection
(Inspect each wiring harness
connector for damage, poor
contact, aging and looseness.)

Is the fault Yes

confirmed

No

Inspect fuse

Is the fault Yes

confirmed

No
Perform active test for fuel pump
relay

Is the fault Yes

confirmed

No

Inspect fuel pump grounding

circuit
Inspect fuel pump relay

Is the fault Yes

Is the fault confirmed
confirmed
No
No
Inspect engine control module
Inspect fuel pump relay power circuit
supply circuit
Inspect fuel pump relay control
circuit
Inspect fuel pump power supply
circuit

End

M201 2014.01
3.1.7-9 Fuel System 3.1.7-9

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect each relative wiring harness connector for
damage, poor contact, aging and looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect fuse
A. Inspect the fuse IF19 in the instrument panel fuse
box P40.
Fuse rated capacity: 15 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, replace the fuse.

3. Perform active test for fuel pump relay

A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON".
S01
C. Select the engine system on the diagnostic tool to
perform "Executor test" - "Fuel pump".
3 1 D. Measure the voltage between terminal 2 of fuel
pump wiring harness connector S01 and reliable
4 2 grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
M3107025
Go to step 4.
No
Go to step 5.

M201 2014.01
3.1.7-10 Fuel System 3.1.7-10

Test Conditions Details/Results/Actions

4. Inspect fuel pump grounding circuit
A. Measure the resistance between terminal 2 of fuel
pump wiring harness connector S01 and reliable
S01 grounding.
Standard resistance: less than 5 Ω
3 1 Is the resistance value normal?
Yes
4 2
Replace the fuel pump.
Refer to: Fuel Pump (3.1.7 Fuel System,
Removal and Installation).
M3107026 No
Repair the wiring harness between terminal 2 of
fuel pump wiring harness connector S01 and
grounding.

5. Inspect fuel pump relay

A. Replace the fuel pump relay with a normal one.
Is the fuel pump normal?
Yes
Replace the relay.
No
Go to step 6.

M201 2014.01
3.1.7-11 Fuel System 3.1.7-11

Test Conditions Details/Results/Actions

6. Inspect fuel pump relay power supply circuit
A. Turn the ignition switch to "ON".

P40 B. Measure the voltage between terminals 83, 84 of

fuel pump relay IR08 and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 7.
No
IR08
84 83
Inspect and repair the faulty circuit between
terminal 82 of feul pump relay IR08 and terminal 69
of main relay IR05.
Inspect and repair the faulty circuit between
terminal 83 of fuel pump relay IR08 and battery.

M3107027

M201 2014.01
3.1.7-12 Fuel System 3.1.7-12

Test Conditions Details/Results/Actions

7. Inspect fuel pump relay control circuit
A. Turn the ignition switch to "LOCK".

P40 B. Disconnect the engine control module wiring

harness connector E18.
C. Remove the fuel pump relay.
D. Measure the circuit resistance between terminal 60
of ECM wiring harness connector E18 and terminal
80 of fuel pump relay IR08.
Standard resistance: less than 5 Ω
Is the resistance value normal?
IR08 80
Yes
Go to step 8.
No
Inspect and repair the faulty circuit.
E18

1 2 9 22

3 4 23 36

5 6 37 50

7 8 51 60 64

M3107028

M201 2014.01
3.1.7-13 Fuel System 3.1.7-13

Test Conditions Details/Results/Actions

8. Inspect fuel pump power supply circuit
A. Turn the ignition switch to "LOCK".

P40 B. Disconnect the fuel pump wiring harness connector

S01.
C. Remove the fuel pump relay.
D. Measure the circuit resistance between terminal 4
of fuel pump wiring harness connector S01 and
terminal 84 of fuel pump relay IR08.
Standard resistance: less than 5 Ω
Is the resistance value normal?
IR08
84 Yes
Go to step 9.
No
Inspect and repair the faulty circuit.

S01

3 1

4 2

M3107029

9. Inspect engine control module circuit

A. Turn the ignition switch to "LOCK".
E18 B. Disconnect the ECM wiring harness connector E18.
C. Turn the ignition switch to "ON", inspect whether
power supply of terminal 8, 16, 17 and 51 is normal.
1 2 9 16 17 22
D. Turn the ignition switch to "LOCK", inspect whether
3 4 23 36
grounding of terminals 5, 43 and 48 is normal.
5 6 37 43 48 50
Is the engine control module circuit normal?
7 8 51 64
Yes
Replace the engine control module.

M3108011
Refer to: Engine Control Module (3.1.12
Electronic Control System - M7,
Removal and Installation).
No
Repair the circuit.

M201 2014.01
3.1.7-14 Fuel System 3.1.7-14

Diagnosis Procedure for Heavy Fuel Smell

WARNING: The following inspection flow chart includes the diagnosis and repair procedures
for fuel system. Read the following precautions before repairing the fuel system: fuel vapor is
very dangerous. It is highly inflammable to lead to serious injury and damage. Please always
keep fuel far away from spark and flames.

Heavy fuel smell

General inspection

Is the fault Yes

confirmed

No

Inspect fuel pressure

Is the fault Yes

confirmed

No

Inspect carbon canister control

valve sealing and carbon
canister

Yes
Is the fault
confirmed

No

Inspect carbon canister control

valve

End

M201 2014.01
3.1.7-15 Fuel System 3.1.7-15

Test Conditions Details/Results/Actions

1. General inspection
A. Visually inspect the fuel injector, O-ring and fuel
pipe for oil leaks.
B. Inspect the fuel filter sealing area and filter pipe
connecting area for leakage.
C. Inspect if the O-ring is fitted with the filler pipe
assembly correctly after the filler cap is properly
installed.
Is the insptction normal?
Yes
Go to step 2.
No
Repair the faulty part.

2. Inspect fuel pressure

A. Perform fuel system pressure inspection.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
Is the fuel pressure too high?
Yes
Repair the clogged fuel pipe, repair or replace the
fuel pressure regulator.
No
Go to step 3.

3. Inspect carbon canister control valve sealing and carbon canister

A. Inspect if the pipe connected with the carbon
canister control valve leaks.
B. Inspect if the carbon canister leaks.
Is the inspection normal?
Yes
Go to step 4.
No
Repair the leaking part, repair or replace the carbon
canister.

M201 2014.01
3.1.7-16 Fuel System 3.1.7-16

Test Conditions Details/Results/Actions

4. Inspect carbon canister control valve
A. Inspect the carbon canister control valve.
Refer to: DTC P0444, P0458, P0459 (3.1.12
Electronic Control System - M7,
DTC Diagnosis and Testing).
Is the carbon canister control valve normal?
Yes
Repair the fuel tank breather hole.
No
Repair or replace the carbon canister control valve
and the circuit.

M201 2014.01
3.1.7-17 Fuel System 3.1.7-17

Removal and Installation

Fuel Filter
Removal
WARNING: During operation of fuel
components, all types of open fire are
prohibited. High-flammable gas mixture
generated during the operation may be
ignited. Improper operation may cause
personal injury accident.
1. Release the fuel pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).

2. Disconnect the negative battery cable.

Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

3. Lift the vehicle.

Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).
4. Disconnect the fuel pipe wiring harness
connectors on both sides of fuel filter in
sequence.

×2

M3107004

M201 2014.01
3.1.7-18 Fuel System 3.1.7-18

1 Before disconnecting, inspect and confirm

that there is no dirt or other foreign matter
around the fuel pipe and wiring harness
connectors. Clean if necessary.
2 Remove the fuel connecting hose.

M3107002

3 Inspect and confirm that there is no dirt or

other foreign matter on the sealing surface of
disconnected fuel pipe. Clean if necessary.
4 Do not damage the disconnected fuel pipe
or wiring harness connectors, wrap them with
plastic bag (1) to prevent the entry of foreign
matter. 1

M3107005

M201 2014.01
3.1.7-19 Fuel System 3.1.7-19

5. Remove the fuel filter retaining bolt and then

remove the fuel filter.
Torque: 10 Nm

M3107006

Installation
1. Installation is in the reverse order of removal.
CAUTION: Do not reverse the installation
direction of fuel filter.

M201 2014.01
3.1.7-20 Fuel System 3.1.7-20

Fuel Tank
General Equipment

Flat jack

Removal
WARNING: This working process includes
fuel disposal. At any time, be aware of fuel
overflowing and follow the fuel disposal
precautions, or it may cause personal
injury.

WARNING: During operation of fuel

components, all types of open fire are
prohibited. High-flammable gas mixture
generated during the operation may be
ignited. Improper operation may cause
personal injury accident.

1. Disconnect the negative battery cable.

Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Drain the fuel tank.

3. Lift the vehicle.
Refer to: Lifting Vehicle (1.1.3 Traction and
Lifting).
4. Disconnect the fuel pump wiring harness
connector.

M3107008

M201 2014.01
3.1.7-21 Fuel System 3.1.7-21

5. Open the fuel tank cap and release the air in

fuel tank.

M3107003

6. Loosen the clamp and remove the fuel tank

filler hose.

M3107007

7. Loosen the hoop and disconnect the fuel tank

vent hose.

M3107009

8. Use a flat jack to support the fuel tank.

M3107010

M201 2014.01
3.1.7-22 Fuel System 3.1.7-22

9. Remove 4 retaining bolts from the fuel tank.

Torque: 25 Nm
WARNING: When removing the fuel tank, ×4
do not apply excessive strain force on the
fuel line and wiring harness.

M3107011

10. Slowly lower the fuel tank about 20 cm to

expose the joints of fuel pump, fuel outlet and
return pipe on the top of fuel tank.

20 cm
M3107012

M201 2014.01
3.1.7-23 Fuel System 3.1.7-23

11. Disconnect the joint (1) connecting fuel outlet

pipe and fuel pump. 3
12. Disconnect the joint (2) connecting fuel return 4
pipe and fuel pump.
13. Disconnect the joint (3) connecting carbon
canister and fuel pump end cap.
2
14. Disconnect the fuel pump wiring harness
connector (4). 1

WARNING: There maybe a little fuel

M3107024
flowing out after disconnecting the fuel
pipe. In order to reduce the possibility of
personal injury, wrap the nylon pipe with
cloth. After completing the disconnection,
be sure to put the cloth into a safe
container.

CAUTION: Before disconnecting the joint,

clear all dirt and foreign matters on the
retainer.

CAUTION: Do not apply excessive force to

bend or twist the fuel pipe.

CAUTION: Use plastic bags to wrap the

joint ends to avoid damage and
contamination.
15. Slowly lower the bracket to remove the fuel
tank.

M201 2014.01
3.1.7-24 Fuel System 3.1.7-24

Installation
1. Installation is in the reverse order of removal.
CAUTION: Reinstall the fuel pipe and fuel
tank vent hose to original position.
Otherwise, the friction caused by vehicle
vibration will damage fuel pipes and lead
to fuel leak.

CAUTION: Inspect if fuel pipes are

connected securely after installing the fuel
tank.

CAUTION: During installation, push fuel

pipe wiring harness connector until a
"click" sound is heard, and then inspect
and confirm that the fuel pipe joint clips
are located in fuel pipe joint collar. After
installing the fuel pipe joint clips, inspect
and confirm that the fuel pipe joint cannot
be pulled out. Be care not to damage the
joint. Replace with new ones if the clips
are damaged.

M201 2014.01
3.1.7-25 Fuel System 3.1.7-25

Fuel Pump
Removal
WARNING: Please release the pressure of
fuel supply system before repairing fuel
supply system components. When
repairing the vehicle or components
related to fuel supply system in a location
with well ventilation, smoking and
carrying lighted cigarette or open fire are
prohibited. High-flammable gas mixture
may appear anytime, any violation of rules
may lead to serious personal injury or
death. When operating related
components or working around the fuel
supply system, please do not carry
personal electrical devices (such as
mobile phones, BP or audio devices).
High-flammable gas mixture may appear
anytime, any violation of rules may lead to
serious personal injury or death.

WARNING: Operation precautions for fuel

supply system should be observed when
operating the fuel supply system. Make
preparation for accidental fuel leakage.
The leaking fuel may be ignited by hot
vehicle components or other fire sources.
Violating above descriptions may cause
serious personal injury or death.

CAUTION: Because the fuel pump

assembly is cooled through fuel, the low
fuel level in fuel tank will directly shorten
the service life of fuel pump.

CAUTION: When replacing the fuel pump

assembly, please keep fuel pump
assembly and working area clean,
otherwise, fuel pump filter element will be
blocked.

CAUTION: The new components of fuel

pump must have the same part number
with that of original fuel pump.

CAUTION: Do not operate fuel pump when

it is free of fuel or in water, otherwise, fuel
pump will be damaged.

M201 2014.01
3.1.7-26 Fuel System 3.1.7-26

CAUTION: Keep fuel tank and line clean; if

the fuel pump has been replaced, replace
the fuel filter at the same time.
1. Release the fuel system pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).

2. Disconnect the negative battery cable.

Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

3. Remove the fuel tank.

Refer to: Fuel Tank (3.1.7 Fuel System,
Removal and Installation).
4. Remove the fuel pump.
1 Remove 6 retaining bolts from the fuel
pump pressure cover.
Torque: 10 Nm

×6

M3107013

2 Pull upward the fuel pump to pull out the

fuel tank.

Inspection

1. Inspect the operating condition of fuel

pump.
1 Remove the fuel pump.

M201 2014.01
3.1.7-27 Fuel System 3.1.7-27

2 Apply battery voltage to terminal 2 and 4.

Inspect if the fuel pump works within 10 s. - +

Note: The test must be finished within

10 s to avoid burning coils.
1 3

Note: Keep fuel pump away from 2 4

battery as far as possible.

Note: Always turned on and off battery

voltage from the battery side (not
on the fuel pump side).
M3107015

Test Conditions Specifications

Battery positive (+) to
terminal 4
Fuel pump operates
Battery negative (-) to
terminal 2
Replace the fuel pump if it does not
operate.

M201 2014.01
3.1.7-28 Fuel System 3.1.7-28
Installation
1. Installation is in the reverse order of removal.
CAUTION: Inspect and confirm that there
is no scratch or foreign matter on
connecting components.

CAUTION: Inspect and confirm that fuel

pipe joint is securely inserted into the
pipe.

CAUTION: Turn the ignition switch to "ON"

(do not start engine) to apply fuel pressure
to fuel supply system, and then inspect
the connecting part for leakage.

CAUTION: During installation, push fuel

pipe wiring harness connector until a
"click" sound is heard, and then inspect
and confirm that the fuel pipe joint clips
are located in fuel pipe joint collar. After
installing the fuel pipe joint clips, inspect
and confirm that the fuel pipe joint clips
cannot be pulled out. Be care not to
damage the joint. Replace with new ones if
the clips are damaged.

M201 2014.01
3.1.7-29 Fuel System 3.1.7-29

Fuel Main Pipe

Removal
WARNING: Please release the pressure of
fuel supply system before repairing fuel
supply system components.

WARNING: After releasing the fuel system

pressure, some pressure still remains in
fuel line. When disconnecting the fuel line,
use a piece of cloth or equivalent to wrap
the joint so as to prevent fuel spilling out.

WARNING: Repair the vehicle in a location

with well ventilation and avoid fire source.

WARNING: No smoking when repairing

vehicle, otherwise, personal injury or
death may be caused.

CAUTION: Fuel injector is a high precision

component with good anti-blocking, anti-
contamination and anti-fogging
performance.

1. Disconnect the negative battery cable.

Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Release the fuel system pressure.

Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).

3. Turn over the driver side seat.

4. Remove the fuel main pipe.
1 Loosen the hoop, and then disconnect 2
crankcase vent hoses.
×2

M3107016

M201 2014.01
3.1.7-30 Fuel System 3.1.7-30

2 Loosen the hoop, disconnect fuel main pipe

joint.

M3107017

3 Remove the retaining bolt from fuel injector

wiring harness grounding point.
Torque: 10 ± 1 Nm

M3107018

4 Disconnect the fuel injector wiring harness

connectors in sequence.
×4

M3107019

5 Disconnect 2 fuel injector wiring harness

retaining clamps in sequence.

×2

M3107020

M201 2014.01
3.1.7-31 Fuel System 3.1.7-31

6 Remove the fuel main pipe retaining bolt

and then remove the fuel main pipe.
Torque: 23 ± 2 Nm

×2

M3107021

Installation
1. Installation is in the reverse order of removal.
CAUTION: Inspect and confirm that fuel
pipe joint is securely inserted into the
pipe.

CAUTION: Turn the ignition switch to "ON"

(do not start engine) to apply fuel pressure
to fuel supply system, and then inspect
the connecting part for leakage.

M201 2014.01
3.1.7-32 Fuel System 3.1.7-32

Accelerator Pedal Assembly

Removal
1. Pull the accelerator cable, and then separate
accelerator cable and accelerator pedal
assembly.

M3107022

2. Remove 2 retaining bolts from accelerator

pedal assembly and then remove the
accelerator pedal assembly.
Torque: 10 ± 1 Nm

×2

M3107023

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.8-1 Ignition System 3.1.8-1

Specifications
3.1.8 Ignition System

Component Specifications
Item Specifications
Spark plug type YR7DE HU10A70P
Spark plug clearance 0.85 ~ 0.95 mm
Ignition coil primary resistance 1 ± 0.1 Ω at 23°C ± 3°C

General Specifications
Item Specifications
Ignition type Sub-cylinder independent ignition
Ignition sequence 1-3-4-2

Torque Specifications
Item Nm lb-ft lb-in
Engine plaque 10 ± 1 - -
Spark plug tightening torque 22 ± 2 - -
Ignition coil retaining bolt 10 ± 1 - -

M201 2014.01
3.1.8-2 Ignition System 3.1.8-2

Description and Operation

System Overview
The ECM in electrical ignition system transmits
signals from each sensor to the electrical ignition
trigger (ignition module) inside the ECM. After the
signal generated by ignition controller is
processed by generator, it flows to control the
high-power transistors of igniter in ECM to switch
ON/OFF the primary current of ignition coil, thus
enhancing the ignition reliability, extend the
service life of spark plug and improving the
dynamic performance and economy of engine.
This secondary windings of the engine directly
connect to a spark plug.
The ignition system consists of following
components:
• ECM
ECM detects the engine and vehicle
conditions according to signals from each
sensor, and ignition trigger within ECM
determines the most appropriate ignition
timing and ignition duration based on
ignition signal transmitted within ECM,
which is output from ECM to switch on or
off the current flowing into the primary
coil.
• Ignition coil assembly
Ignition coil consists of primary winding,
secondary winding, iron core and
housing. The primary winding energized
when the grounding is connected, and
power is off once the circuit is cut off by
ECM. Meanwhile, high voltage generated
in secondary winding make the spark
plug discharge.
• Spark plug
DG sensor (speed sensor) use induction
type speed sensor to coordinate with
pulse wheel to provide the information of
engine speed and crankshaft top dead
center in the ignition system.

M201 2014.01
3.1.8-3 Ignition System 3.1.8-3

Components Location View

M3108001

Item Description Item Description

1 Engine trim cover 3 Spark plug

2 Ignition coil 4 Cylinder head cover

M201 2014.01
3.1.8-4 Ignition System 3.1.8-4

General Inspection Ignition Coil

Ignition Spark Test 1. Disconnect the negative battery cable.
1. When the transmission shift lever is at 2. Remove the bolts and take out the ignition
"Neutral", apply parking brake to prevent the coil from cylinder head cover.
wheel turning.
3. Use the ohmmeter range of multimeter to
2. Disconnect the fuel injector connector and measure the resistance of ignition coil
ignition coil connector. (terminal C and +B shown in the following
figure).
WARNING: If the fuel injector connector is
not disconnected, the inflammable gas will Coil primary resistance: 1 ± 0.1 Ω (23°C ± 3°C)
rush out from the spark plug hole during
testing, possibly leading to vehicle fire.
C CND +B
3. Remove the spark plug and inspect its state
and type.
4. If normal, connect the ignition coil connector,
and connect the spark plug to high voltage
connecting pipe and ground the spark plug.
5. Start engine to inspect if the sparks of spark
plugs is normal, if not (no sparking or
sparking abnormal), inspect related M3108009
components according to "Diagnosis". 4. Install ignition coil assembly to cylinder head
6. After inspection, install the spark plugs and and connect wiring harness connectors, and
ignition coil. connect the negative battery cable.
7. Connect the fuel injector wiring harness
connectors.

M201 2014.01
3.1.8-5 Ignition System 3.1.8-5

Symptom Diagnosis and Testing

General Equipment

Multimeter

Inspection and Verification

1. Verify the customer concern.
2. Visually check if there is obvious mechanical
or electrical damage.
3. If an obvious cause for an observed or
reported concern is found, solve the fault
before proceeding to the next step.
4. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.
Visual Inspection Chart

Electrical
• Return circuit
• Wiring harness
• Electrical connector
• Spark plug
• Ignition coil
• Engine control module (ECM)

M201 2014.01
3.1.8-6 Ignition System 3.1.8-6

Symptom Chart
If the fault occurs, but there is no DTC stored in the ECM for this fault and the causes cannot be verified
in basic inspection, diagnose and repair it in order of the following table.

Symptom Causes Solutions

• Battery is depleted • Inspect the battery fault.
• Inspect if the wiring
• Battery binding post looseness or
harness connection is
Rotate engine crankshaft poor contact
secured.
but cannot or difficult to
Engine
start the engine; or the • Ignition coil damage • Replace
cannot
engine stalls during
start • Inspect if the wiring
working and does not • Ignition coil wiring harness
harness connection is
work when restarting connector falls off
secured.
• Inspect the ECM fault or
• ECM fault
replace.
Blasting sound can be • Ignition coil wiring harness
• Replace or reassembly.
Certain heard and black smog connector loose
cylinder can be seen from exhaust
fault pipe when engine is • Certain spark plug poor working • Adjust, clean or replace.
working at different speed
• Refer to the last fault
• Certain cylinder fault
diagnosis.
Engine is difficult to start
Insufficient • Ignition coil electric leakage • Replace
and power is insufficient
engine
in accelerating and • Ignition coil wiring harness
power • Replace or reassembly.
climbing connector loose
• Severe spark plug carbon deposit • Adjust, clean or replace.

M201 2014.01
3.1.8-7 Ignition System 3.1.8-7
Fault Diagnosis Procedure Chart

Step Operation Yes No

Is the inspection based on diagnosis procedure for Go to the diagnosis
1 Go to step 2
engine fault procedure for engine fault
Go to the diagnosis
2 Is the fault lamp on Go to step 3
procedure for engine fault
DTC inspection
Go to the diagnosis
3 Read DTC through the diagnostic tool to inspect if Go to step 4
procedure for engine fault
there is "misfire" fault indication
After repairing fault, restart the engine to inspect if Go to the diagnosis
4 Go to step 5
there is "misfire" fault indication procedure for engine fault
Electrical connection inspection
1. Inspect if the connection of ignition coil wiring
harness connector is reliable and check the
5 Go to step 6 Reconnect
continuity of wiring harness
2. Inspect if the high voltage coil is securely
connected with spark plug
Ignition coil inspection
Replace the faulty ignition
6 Inspect the coil one by one and inspect if the Go to step 7
coil
results are consistent with requirements
Spark plug inspection Ignition system
Replace the faulty ignition
7 Inspect the spark plug one by one and inspect if is in good
coil
the results are consistent with requirements condition

M201 2014.01
3.1.8-8 Ignition System 3.1.8-8

Diagnosis Procedure for Spark Plug does not Flash Over

Spark plug does not

flash over

Inspect fuse

Is the fault Yes

confirmed

No

Inspect power supply of fuse IF15

Is the fault Yes

confirmed

No

Inspect engine DTC

Is the fault Yes

confirmed

No

Inspect spark plug

Is the fault Yes

confirmed
Inspect engine control module
circuit
No

Inspect ignition coil power supply

circuit Yes
Is the fault
confirmed

Is the fault No
confirmed
Inspect ignition coil signal circuit
No

End
Yes

M201 2014.01
3.1.8-9 Ignition System 3.1.8-9

Test Conditions Details/Results/Actions

1. Inspect fuse
A. Inspect the fuse of fuse box IF15.
Fuse rated capacity: 15 A
Is the fuse normal?
Yes
Go to step 2.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

2. Inspect power supply of fuse IF15

A. Turn the ignition switch to "ON".

P40 B. Use multimeter to measure the voltage between

terminal 29 of fuse IF15 and reliable grounding.
Standard voltage: 11 ~ 14 V
29
IF15 Is the voltage value normal?
30
Yes
Go to step 3.
No
Inspect and repair the ignition switch and fuse
power supply circuit.

M3108010

M201 2014.01
3.1.8-10 Ignition System 3.1.8-10

Test Conditions Details/Results/Actions

3. Inspect engine DTC
A. Turn the ignition switch to "LOCK".
B. Connect the diagnostic tool.
C. Turn the ignition switch to "ON".
D. Diagnose the engine system.
Is there any DTC?
Yes
Refer to: DTC Diagnosis Procedure Index
(3.1.12 Electronic Control
System - M7, DTC Diagnosis and
Testing).
No
Go to step 4.

4. Inspect spark plug

A. Turn the ignition switch to "LOCK".
B. Remove the spark plug.
C. Execute the testing procedure for spark plug.
Refer to: Spark Plug Test (3.1.8 Ignition
System, General Inspection).
Is the spark plug normal?
Yes
Go to step 5.
No
Replace the spark plug.

5. Inspect ignition coil

A. Carry out ignition coil inspection procedure.
Refer to: Ignition Coil Test (3.1.8 Ignition
System, General Inspection).
Is the ignition coil normal?
Yes
Go to step 6.
No
Replace the ignition coil.

M201 2014.01
3.1.8-11 Ignition System 3.1.8-11

Test Conditions Details/Results/Actions

6. Inspect ignition coil power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the ignition coil wiring harness
connector.
C. Turn the ignition switch to "ON". Measure the
voltage between terminal 1 of ignition coil wiring
connector and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 7.
No
Inspect and repair the open circuit fault between
instrument panel fuse box fuse IF01 terminal and
terminal 1 of ignition coil wiring harness connector.

7. Inspect engine control module circuit

A. Turn the ignition switch to "LOCK".
E18 B. Disconnect the ECM wiring harness connector E18.
C. Turn the ignition switch to "ON". Inspect if the
power supply of terminals 8, 16, 17 and 51 is
1 2 9 16 17 22
normal.
3 4 23 36
D. Turn the ignition switch to "LOCK". Inspect if the
5 6 37 43 48 50 grounding of terminals 5, 43 and 48 is normal.
7 8 51 64 Is the circuit of engine control module normal?
Yes
Go to step 8.
M3108011
No
Repair the circuit.

M201 2014.01
3.1.8-12 Ignition System 3.1.8-12

Test Conditions Details/Results/Actions

8. Inspect ignition coil signal circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the negative battery cable.
C. Disconnect the engine ignition coil wiring harness
connectors E08, E07, E05 and E03.
D. Disconnect the engine control module wiring
harness connector E18.
E. Measure the resistance between terminal 3 of
engine control module wiring harness connector
E18 and the terminal 1 of engine ignition coil wiring
harness connector E08, the resistance between
terminal 7 of engine control module wiring harness
connector E18 and the terminal 1 of engine ignition
coil wiring harness connector E07, the resistance
between terminal 6 of engine control module wiring
harness connector E18 and the terminal 1 of engine
ignition coil wiring harness connector E05 and the
resistance between terminal 1 of engine control
module wiring harness connector E18 and the
terminal 1 of engine ignition coil wiring harness
connector E03.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
Electronic Control System - M7,
Removal and Installation).
No
Inspect and repair the circuit.

M201 2014.01
3.1.8-13 Ignition System 3.1.8-13

Diagnosis Procedure for Insufficient Engine Power

Verify that the engine cylinder pressure is normal, ignition timing mark is correct, and no mechanical
damages of engine. Otherwise, repair the fault part first.

Insufficient engine power

Inspect engine DTC

Is the fault Yes

confirmed

No

Inspect spark plug

Is the fault Yes

confirmed

No

Inspect ignition coil signal circuit

Is the fault Yes

confirmed

No

Inspect ignition coil

Is the fault Yes

confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.8-14 Ignition System 3.1.8-14

Test Conditions Details/Results/Actions

1. Inspect engine DTC
A. Turn the ignition switch to "LOCK".
B. Connect the diagnostic tool.
C. Turn the ignition switch to "ON".
D. Diagnose the engine system.
Is there any DTC?
Yes
Refer to: DTC Diagnosis Procedure (3.1.12
Electronic Control System - M7,
DTC Diagnosis and Testing).
No
Go to step 2.

2. Inspect spark plug

A. Execute the testing procedure of spark plug
Refer to: Spark Plug Test (3.1.8 Ignition
System, General Inspection).
Is the spark plug normal?
Yes
Go to step 3.
No
Replace the spark plug.

M201 2014.01
3.1.8-15 Ignition System 3.1.8-15

Test Conditions Details/Results/Actions

3. Inspect ignition coil signal circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the negative battery cable.
C. Disconnect the engine ignition coil wiring harness
connectors E08, E07, E05 and E03.
D. Disconnect the engine control module wiring
harness connector E18.
E. Measure the resistance between terminal 3 of
engine control module wiring harness connector
E18 and the terminal 1 of engine ignition coil wiring
harness connector E08, the resistance between
terminal 7 of engine control module wiring harness
connector E18 and the terminal 1 of engine ignition
coil wiring harness connector E07, the resistance
between terminal 6 of engine control module wiring
harness connector E18 and the terminal 1 of engine
ignition coil wiring harness connector E05 and the
resistance between terminal 1 of engine control
module wiring harness connector E18 and the
terminal 1 of engine ignition coil wiring harness
connector E03.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
Electronic Control System - M7,
Removal and Installation).
No
Inspect and repair the circuit.

4. Inspect ignition coil

A. Carry out ignition coil testing procedure.
Refer to: Ignition Coil Test (3.1.8 Ignition
System, General Inspection).
Is the ignition coil normal?
Yes
Go to step 5.
No
Replace the ignition coil.
Refer to: Ignition Coil (3.1.8 Ignition
System, Removal and
Installation).

M201 2014.01
3.1.8-16 Ignition System 3.1.8-16

Test Conditions Details/Results/Actions

5. Inspect engine control module circuit
A. Turn the ignition switch to "LOCK".
B. Connect the ECM wiring harness connector.
C. Turn the ignition switch to "ON".
D. Inspect whether power supply ofterminals 8, 16, 17
and 51 is normal.
E. Turn the ignition switch to "LOCK". Inspect if the
grounding of terminals 5, 43 and 48 is normal.
Is the circuit of the engine control module normal?
Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
Electronic Control System - M7,
Removal and Installation).
No
Repair the circuit.

M201 2014.01
3.1.8-17 Ignition System 3.1.8-17

Removal and Installation

Ignition Coil
Removal
1. Remove the battery.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the engine trim cover.
1 Remove 3 retaining bolts from the engine
trim cover.
Torque: 10 ± 1 Nm
2 Remove the engine trim cover.

×3
M3108002

3. Disconnect 4 ignition coil wiring harness

connectors in sequence.
×4

M3108003

4. Remove 4 retaining bolts from the ignition

coil.
Torque: 8 ± 2 Nm
×4

M3108004

5. Disconnect 4 ignition coils in sequence.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.8-18 Ignition System 3.1.8-18

Spark Plug
Removal
1. Remove the ignition coil.
Refer to: Ignition Coil (3.1.8 Ignition
System, Removal and
Installation).
2. Use spark plug remover to remove 4 spark
plugs in sequence.
Torque: 22 ± 2 Nm

M3108005

Inspection
Inspect the spark plugs.
• Electrode wear
• Carbon deposit a
• Insulator damage
If abnormal condition has been found, adjust the
spark plug electrode clearance, use spark plug
cleaner to clean the spark plug or replace with a
corresponding specification one.
Spark plug electrode clearance "a": 0.85 mm ~
M3108008
0.95 mm

Installation
CAUTION: The junction surface of spark
plug and installation hole must be
absolutely free of foreign matters.

1. Installation is in the reverse order of removal.

M201 2014.01
3.1.8-19 Ignition System 3.1.8-19

Ignition Switch
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the steering wheel.

Refer to: Steering Wheel (2.4.3 Steering
Column, Removal and
Installation).
3. Remove 3 retaining screws from the steering
lock upper and lower housings.

×3

M4206022

4. Separate the upper and lower housings of

steering lock.

M4206023

5. Disconnect the ignition switch wiring harness

connector.

M3108006

M201 2014.01
3.1.8-20 Ignition System 3.1.8-20

6. Remove 2 retaining screws from the ignition

switch.
×2

M3108007

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.9-1 Starting System 3.1.9-1

Specifications
3.1.9 Starting System

Torque Specifications
Item Nm lb-ft lb-in
Starting motor retaining bolt 23 ± 2 - -
Starting motor main power supply wiring
10 ± 2 - -
harness retaining nut
Starting motor magnetic clutch wiring
7±1 - -
harness retaining nut

M201 2014.01
3.1.9-2 Starting System 3.1.9-2

Description and Operation Components Description

System Overview Starting Motor
Turn the start switch (ignition switch) to start
Starting motor includes the stator assembly,
position (ST), so that a little current flows into the
armature assembly, overdrive clutch assembly,
retention and traction coils of the magnetic switch
magnetic switch assembly, front/rear housing,
while starting. One circuit: battery positive →
brush holder and drive lever. Magnetic switch
starting switch → retention coil → grounding
assembly and its components on the starting
(battery negative); Another circuit: battery positive
motor are packaged inside the housing to prevent
→ start switch → traction coil → starting motor →
dirt and splashing.
grounding (battery negative). The motor starts to
operate since current flows into armature and
field windings. Due to current passes through the
magnetic switch, traction and retention coils
generate magnetic force, by which the core
overcomes return spring force to move right.
Motor rotates at a slower speed as the current is
smaller. When the core is pushed to right, the left
terminal moves drive lever to push clutch to the
left, so that the driving gear engages with flywheel
ring gear. The current from traction coil flows into
armature and field windings to produce certain
magnetic torque, so gears are engaged in slow
rotating process. The magnetic switch master
contactor on the core's right side is closed to
connect starting motor to battery directly while
gear and flywheel ring gear are fully engaged.
Large current provided by battery passes through
armature and field windings of the starting motor
to generate normal turning torque, and then the
gear and flywheel engages to rotate engine
crankshaft to start the engine. AT this point, the
traction coil is shorted and moving core position is
supported by the retention coil suction force, and
the drive lever still pushes gear by overcoming
spring force to make it engage with flywheel ring
gear.
Disconnect the starter switch and cut off retention
coil current after the engine is started. So
magnetic force disappears and the core moves
left quickly to its original position by the action of
return spring. Drive lever separates the drive gear
from flywheel ring gear by the action of torsional
spring, then master contactor is disconnected,
starter circuit is cut off. So the starting motor stops
running and the starting process of engine is
finished.

M201 2014.01
3.1.9-3 Starting System 3.1.9-3

Components Location View

Starting Motor

M3109003

M201 2014.01
3.1.9-4 Starting System 3.1.9-4

Components Exploded View

1 6
13

9
4
8
3

12
10 11
15

17

16
14

18
19
21
20

M3109004

M201 2014.01
3.1.9-5 Starting System 3.1.9-5

Item Description Item Description

1 Starting motor assembly 12 Bushing
2 Magnetic switch assembly 13 Drive lever
3 Nut 14 Housing
4 Nut 15 Brush holder plate
5 Spring washer 16 Bushing
6 Nut 17 Retaining screw
7 Rotor assembly 18 Spring
8 Overdrive clutch assembly 19 Retainer ring
9 Retainer ring 20 Protective cover
10 Special washer 21 Screw
11 Rotor front bracket assembly

M201 2014.01
3.1.9-6 Starting System 3.1.9-6

General Inspection 6. As mentioned above, connect the cable and

pinion moves outward, then remove the "M"
General Equipment terminal negative wire, inspect whether the
Multimeter pinion moves outward, otherwise, replace the
magnetic switch.
WARNING: Each test must be completed
within 3 ~ 5 s to avoid coil burnout.
M
Magnetic Switch Testing
CAUTION: Before testing, disconnect the
field coils from terminal "M".

1. Remove the starting motor armature wiring

harness from the magnetic switch.
2. Use a jumper wire to connect the starting
motor housing and magnetic switch housing M3109006
to the battery negative securely.
3. Connect one end of another jumper wire to Pinion Return Test
the battery positive and the other end to the 1. Use a jumper wire to connect the starting
terminal 1 of starting motor wiring harness motor housing and magnetic switch housing
connector S17. to the battery negative securely.
4. Starting motor pinion should move out. 2. Connect one end of another jumper wire to
5. Remove the "M" terminal negative cable, and the battery positive and the other end to the
starting motor pinion should not return to the terminal 1 of starting motor wiring harness
original position. connector S17.
3. Starting motor pinion should move out.

M 4. Disconnect the jumper wire from the positive

S17-1 battery, and the pinion should quickly return.

S17-1

M3109005

M3109007

M201 2014.01
3.1.9-7 Starting System 3.1.9-7

Test without Load

1. Ensure the battery is fully charged.
2. Connect the starting motor, battery and tester
as shown in the figure.
3. Start the starting motor and confirm that it
rotates smoothly.
If the starting motor does not rotate smoothly,
inspect starting motor device.
4. When the starting motor operates, measure
voltage and current.
5. If either of them is not within the specified
range, replace the starting motor.

M3109008

Item Specifications
Current without load 78 A
Voltage drop without load 11.6 V

M201 2014.01
3.1.9-8 Starting System 3.1.9-8

Symptom Diagnosis and Testing

General Equipment

Multimeter

Inspection and Verification

1. Verify the customer concern.
2. Visually check if there is obvious mechanical
or electrical damage.
Visual Inspection Chart

Mechanical Electrical
• Starting motor • Fuse
• Battery
• Wiring harness
• Connectors loose or
corroded

3. If an obvious cause for an observed or

reported concern has been found, solve the
fault before proceeding to the next step.
4. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
3.1.9-9 Starting System 3.1.9-9

Symptom Chart
If the fault occurs, but there is no DTC stored in ECM for this fault and the causes cannot be verified in
basic inspection, diagnose and repair it in order of the following table.

Symptom Possible Causes Solutions

• Diagnosis procedure for starting motor
• Battery fault.

Starting motor does not • Return circuit Refer to: Diagnosis Procedure
operate for Starting Motor Fault
• Starting motor
(3.1.9 Starting System,
• Ignition switch Symptom Diagnosis
and Testing).
• Diagnosis procedure for starting motor
fails to stop.

Starting motor fails to • Ignition switch Refer to: Diagnosis Procedure

stop for Starting Motor Fails
• Starting motor
to Stop (3.1.9 Starting
System, Symptom
Diagnosis and Testing).
• Diagnosis procedure for starting motor
slow run.
• Battery
Starting motor runs Refer to: Diagnosis Procedure
• Return circuit for Starting Motor Slow
slowly
• Starting motor Run (3.1.9 Starting
System, Symptom
Diagnosis and Testing).
• Inspect the flywheel ring gear for tooth
missing.
• Inspect whether the starting motor is
correctly secured. If the problem
Starting motor rotates but • Starting motor
continues, install a new starting motor.
engine does not run • Flywheel ring gear
Refer to: Starting Motor (3.1.9
Starting System,
Removal and
Installation).
• Inspect the flywheel ring gear.
• Inspect whether the starting motor is
Starting motor abnormal • Starting motor
properly aligned or the housing is cracked.
noise • Flywheel ring gear Ensure all the retaining bolts are well
locked. If necessary, replace new starting
motor or retaining bolts.

M201 2014.01
3.1.9-10 Starting System 3.1.9-10

Diagnosis Procedure for Starting Motor Fault

Starting motor fault

General inspection
(Inspect battery and starting
motor posts for contact)

Is the fault Yes

confirmed

No

Inspect battery voltage

Is the fault Yes

confirmed

No
Inspect magnetic switch power
supply voltage

Is the fault Yes

confirmed

Inspect magnetic switch power

No supply circuit

Inspect starting motor

Is the fault Yes

confirmed
Is the fault
confirmed No

Inspect ignition switch

No
Yes

End

M201 2014.01
3.1.9-11 Starting System 3.1.9-11

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect whether the battery positive & negative
wiring harness connectors and positive & negative
cables are damaged, oxidized, poorly contacted or
loose.
B. Inspect whether the starting motor wiring harness
connector and starting motor positive cable are
damaged, oxidized, poorly contacted or loosen.
Is the inspection result normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect battery voltage

A. Inspect the battery starting voltage.
Is the starting voltage higher than 10.5 V?
Yes
Go to step 3.
No
Charge the battery.
Refer to: Battery Charging (3.1.10
Charging System, General
Inspection).
Or replace with new battery.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
3. Inspect magnetic switch power supply voltage
A. Turn the ignition switch to "ST".
B. Measure the grounding voltage of terminal 1 of
starting motor magnetic switch wiring harness
connector S16.
Is the voltage higher than 10 V?
Yes
Go to step 4.
1
No

S16
Go to step 5.

M3109009

M201 2014.01
3.1.9-12 Starting System 3.1.9-12

Test Conditions Details/Results/Actions

4. Inspect starting motor
A. Test the magnetic switch.
Refer to: Magnetic Switch Testing (3.1.9
Starting System, General
inspection).
Is the starting motor testing normal?
Yes
Go to step 5.
No
Replace the starting motor.
Refer to: Starting Motor (3.1.9 Starting
System, Removal and
Installation).
5. Inspect magnetic switch power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the ignition switch wiring harness
connector P31.
C. Create a short circuit between terminal 6 of ignition
switch wiring harness connector P31 and reliable
power supply.
Is the starting motor normal?
Yes
Go to step 6.
No
Inspect and repair the open circuit fault between
terminal 6 of wiring harness connector P31 and
terminal 1 of starting motor wiring harness
connector S16.

M201 2014.01
3.1.9-13 Starting System 3.1.9-13

6. Inspect ignition switch

A. Disconnect the ignition switch connector.
B. Turn the ignition switch to "ST".
C. Measure the resistance between terminal 4 and
terminal 6 of the ignition switch wiring harness
P31 connector P31.
Is the resistance value lower than 1 Ω?
Yes
Repair the high resistance faults in the following
3 2 1
circuits.
6 5 4 • Circuit between terminal 1 of starting
motor wiring harness connector S17 and
terminal 1 of battery wiring harness
connector S19.
• Circuit between terminal 1 of battery
wiring harness connector S20 and
M3109010 grounding.
No
Replace the ignition switch.

M201 2014.01
3.1.9-14 Starting System 3.1.9-14

Diagnosis Procedure for Starting Motor Fails to Stop

Test Conditions Details/Results/Actions
1. Inspect ignition switch
A. Disconnect the ignition switch connector.
B. Turn the ignition switch to "ACC".
C. Measure the resistance between terminal 1 and
terminal 3 of the ignition switch wiring harness
connector P31.
Is the resistance value lower than 1 Ω?
Yes
Go to step 2.
No
Replace the ignition switch.
3 2 1

6 5 4

P31
M3109011

2. Inspect if there is short to power supply in magnetic switch circuit

A. Disconnect the starting motor magnetic switch
wiring harness connector S16.
B. Use multimeter to measure the voltage between
terminal 1 of starting motor magnetic switch wiring
harness connector S16 and reliable grounding.
S16
Standard voltage value: 0 V
1 Is the voltage value normal?
Yes
Replace the starting motor.
Refer to: Starting Motor (3.1.9 Starting
M31090012
System, Removal and
Installation).
No
Repair the power supply short circuit between
terminal 6 of ignition switch wiring harness
connector P31 and terminal 1 of starting motor
magnetic switch wiring harness connector S16.

M201 2014.01
3.1.9-15 Starting System 3.1.9-15

Diagnosis Procedure for Starting Motor Slow Run

Starting motor slow run

General inspection

Yes
Is the fault
confirmed

No

Inspect if resistance of cable

between battery and starting motor
magnetic switch is too high

Is the fault Yes

confirmed

No

Inspect if resistance of grounding

circuit between battery and starting
motor is too high

Yes
Is the fault
confirmed

No

Inspect battery and charging

system

End

M201 2014.01
3.1.9-16 Starting System 3.1.9-16

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect whether the battery positive & negative
wiring harness connectors and positive & negative
cables are damaged, oxidized, poorly contacted or
loose.
B. Inspect whether the starting motor wiring harness
connector and starting motor positive cable are
damaged, oxidized, poorly contacted or loose.
Is the inspection result normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect if resistance of cable between battery and starting motor magnetic switch is too high
A. Turn the ignition switch to "OFF" to measure the
resistance between starting motor housing and
battery negative terminal.
Is the resistance value lower than 1 Ω?
Yes
Go to step 4.
No
Refer to: Starting Motor (3.1.9 Starting
System, Removal and
Installation).
No
Clean and lock all the battery negative connectors
and tie band among starting motor holder, body and
engine grounding. Test if the system works
normally. If the problem continues, install new
negative battery cable.

M201 2014.01
3.1.9-17 Starting System 3.1.9-17

Test Conditions Details/Results/Actions

3. Inspect if resistance of grounding circuit between battery and starting motor is too high
A. Inspect the battery voltage.
Is the starting voltage higher than 10.5 V?
Yes
Go to step 4.
No
Charge the battery.
Refer to: Battery Inspection (3.1.10
Charging System, General
Inspection).
Or replace with new battery.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
4. Inspect battery and charging system
A. Inspect the battery and charging system.
Is the starting voltage higher than 10.5 V?
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
Is the fault solved?
Yes
Replace or repair the battery, repair the charging
system.

M201 2014.01
3.1.9-18 Starting System 3.1.9-18

Removal and Installation

Starting Motor
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Lift the vehicle.
Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).
3. Remove the retaining nut (1) from starting
motor main power supply wiring harness.
1
Torque: 10 ± 2 Nm
2
4. Remove the retaining nut (2) from starting
motor magnetic switch wiring harness.
Torque: 7 ± 1 Nm

M3109001

5. Remove the starting motor upper/lower

retaining bolts.
1 Disconnect the wiring harness from wiring
×2
harness retaining clamp.
2 Remove the starting motor retaining bolts.
Torque: 32 ± 2 Nm

M3109002

6. Remove the starting motor from the vehicle.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.9-19 Starting System 3.1.9-19

Disassembly and Assembly

Starting Motor
Disassembly
1. Remove the nut from magnetic switch and
disconnect the wiring harness.

M3109013

2. Remove 2 nuts, then pull the back part of

magnetic switch to remove it to disengage the
inner hook from drive lever.
CAUTION: Do not remove the magnetic
switch; replace in assembling process if
necessary.

3. Remove the housing bolts and pull out the

commutator end cap.
4. Remove the insulator and brush spring, then
remove the brush holder.
5. Remove the stator, armature and drive lever.

6. Use snap ring pliers and screwdriver to

remove the armature pressure plate, and
then pull out the pinion snap ring and
overdrive clutch.

M3109014

M201 2014.01
3.1.9-20 Starting System 3.1.9-20
Assembly
1. Inspect and replace the corresponding
components if necessary.
Refer to: (3.1.9 Starting System, General
Inspection).
2. Be sure to apply grease before installing the
overdrive clutch, then use the circlip to fix the
snap ring.
3. Apply grease to the drive lever and install it
together with the armature and then with the
drive end cover.
4. Install the stator and brush holder, and then
fix the four brushes with spring, and then
install the insulator.
CAUTION: When installing the brush,
make sure to remove the grease from the
brush and commutator completely.

CAUTION: Make sure that there is no

unnecessary contact between the brush
and other component.

M3109015

M201 2014.01
3.1.10-1 Charging System 3.1.10-1

Specifications
3.1.10 Charging System

Component Specifications
Battery Specifications

Item Specifications
Type Maintenance free
Nominal voltage DC 12 V

Alternator Specifications

Item Specifications
Rated working speed 5000 rpm
Voltage specifications 14 V
Rated current 70 A

Torque Specifications
Item Nm lb-ft lb-in
Battery retaining pressure plate retaining nut 8 - 71
Positive battery cable nut 9 - 80
Negative battery cable nut 8 - 71
Alternator upper retaining bolt 50 37 -
Alternator adjusting bracket bolt 2 23 17 -
Alternator charging cable retaining nut 9 - 80

M201 2014.01
3.1.10-2 Charging System 3.1.10-2

Description and Operation ring and frame, the set voltage of alternator
cannot be adjusted.
System Overview
Alternator rotor bearing with sufficient grease,
Battery Self-discharge and does not require regular lubrication. Two
brushes make the current go to the rotor field coil
Battery self-discharge is inevitable in theory. For
through two slip rings. In normal circumstances,
the maintenance-free battery, self-discharge is
the brush can be free of maintenance for a long
much less than ordinary battery, but still has a
time.
certain of self-discharge. The battery power will
reduce significantly even if not powered on for a The stator winding is assembled within the
long time. Battery self-discharge is mainly laminated iron core which is the alternator frame
affected by factors as follows: component. The rectifier connected to the stator
winding has six diodes, which converted the AC
1. The higher the temperature is, the higher the
voltage on the stator into DC voltage on the
self-discharge rate is. Generally, when the
alternator output terminal. The central diode is
temperature rises for every 10°C, the self-
used to convert the neutral point voltage into DC
discharge rate would also increase by about
to increase the alternator output.
2.7 times. The self-discharge rate of the
battery is different for the vehicle in summer The capacitor that installed in the regulator
and winter. assembly protects the diode voltage and
suppresses the radio wave interference.
2. The battery self-discharging may become
serious due to the storage place conditions, Components Description
such as high humidity and heavy dust.
Battery
Battery Capacity Loss after Loading
The vehicle adopts maintenance-free battery.
After loading, the power loss of the battery is Without vent plug on the battery cover, it is
mainly in the following aspects: completely sealed besides the two small vent
1. Power loss in commissioning. holes on both sides of the battery, which is
different from the conventional battery.
2. Power loss of some constant ON electrical
equipments in the vehicle, such as anti-theft Compared with conventional battery, this battery
alarm. has the following advantages:
3. Electricity leakage caused by poor insulation 1. Refilling liquid is not required within the
of the vehicle electrical components. battery service life.
4. Without disconnecting the negative cable, 2. Overcharging protection.
power loss caused by static current and 3. Electric leakage is not as easy as
current leakage in circuit. conventional battery.
CAUTION: The standing time of battery 4. Weight and volume is smaller, but with more
depends on many factors. Generally, fully capacity.
charged battery with the negative cable
disconnected can start the vehicle after If the battery test is normal, but such faults as
standing for 6 months. battery has insufficient voltage and vehicle cannot
be started after the night occur, the causes can be
Charging System considered from the following aspects:
Alternator is characterized by built-in solid state 1. Electrical equipment in the vehicle is not
regulator. All components of the regulator are turned off over the whole night.
installed in an sealed box. The regulator and
2. Slow speed and stop and go.
brush holder assembly are installed on the slip

M201 2014.01
3.1.10-3 Charging System 3.1.10-3
3. Vehicle electrical load exceeds the alternator point is rising; MIC turns on the VT1 from
output, especially when the vehicle is DCM to CCM, which increase the magnetic
equipped with after-sale devices. field current and raises the alternator voltage.
When MTC cuts VT2 off, the charging
4. Charging system has faults, such as short
indicator is off. Under the condition of vehicle
circuit, alternator belt slipping, alternator or
running and the alternator operating normally,
regulator fault.
if the alternator voltage exceeds the specified
5. Improper use of the battery, including fail to regulating voltage, regulator MIC sends
keep the battery cable terminals clean and control signal quickly to cut VT1 off. As cut off
tightened, or the pressure plate is loose. the magnetic field circuit, the magnetic field
6. Mechanical fault of the electrical system, current reduced quickly, and then the
such as wiring harness short circuit or alternator voltage is dropped. when the B
damaged. point voltage reduced the voltage falling
below the specified value, MIC turns VT1 on
Integrated Alternator Assembly to energize the magnetic circuit and raise the
operating Principle alternator voltage, then VT1 cut off again.
Repeated operation in cycles makes
B
alternator work normally.
SW
B

P C
IG Integrated Alternator Assembly Basic
6X3.4W
Parameter
F L
MIC 14V Conventional
VT1 VT2
Index
E Alternator
E Rated working speed 5000 rpm
Generating voltage
1 2 14 V
specifications
M3110014
Rated current 70 A

Item Description Item Description

Voltage
1 Alternator 2
regulator

1. When turn the ignition switch on with key, do

not start engine, but battery voltage is applied
on IG. After MIC detected that the IG voltage
is the battery voltage, turn the triode VT1 on
to energize primary field current through the
rotor coil, thus making preparation for
generating electricity. At this time, the
alternator has not generated electricity, and
regulator P point is 0. MIC sends signals to
turn VT2 on to illuminate the charging
indicator. When charge indicator on the meter
is on, it shows the energizing of motor is
normal.
2. After turn the ignition switch to ON with key to
start the engine, the alternator voltage is
lower than the regulating voltage, and
alternator starts to operate. At this time the P

M201 2014.01
3.1.10-4 Charging System 3.1.10-4

Components Location View

M3110015

M201 2014.01
3.1.10-5 Charging System 3.1.10-5

Components Exploded View

Alternator

9
7
10
5 12
4 8
1 2 3 6 11 14
13

18
22
24 20 16 15
23 21 17
25 19

M3110001

Item Description Item Description

1 Pulley 14 M5 nut
2 Front bearing 15 M5 bolt
3 Screw 16 Conducting plate
4 Rotor 17 Cover
5 Rear cover 18 M4 screw
6 Washer 19 Screw
7 Regulator 20 Rectifier
8 M5 nut 21 Stud bolt
9 M8 nut 22 Rear bearing
10 Insulation sleeve 23 Stator
11 Brush 24 Cover
12 M4 screw 25 Front cover
13 Rubber cover

M201 2014.01
3.1.10-6 Charging System 3.1.10-6
Battery and Accessory

2
3
4
6
5 1

M3110002

Item Description Item Description

Negative battery grounding
1 5 Battery assembly
cable
Battery retaining pressure plate
2 6 Positive battery cable
retaining nut
3 Battery retaining pressure plate 7 Battery tray
4 Battery retaining screw

M201 2014.01
3.1.10-7 Charging System 3.1.10-7

General Inspection Battery Charging

General Equipment WARNING: Keep the battery away from
Multimeter children. The battery includes sulphuric
acid. Keep it away from skin, eye or
Battery charger
clothes. Wear the goggles to avoid acidic
dissolution fluid spraying into the eyes
Battery Inspection when working near the battery. In case of
1. Battery appearance inspection: Battery acid solvent spraying to the skin or eyes,
should be free of leakage on the surface, wash immediately for at least 15 minutes
crack and damage in the housing, corrosion and seek for medical treatment
on the electrode, and the electrode wire is immediately. If acid solution is swallowed,
connected securely. please seek medical treatment
immediately. Failure to comply with the
2. Inspect with a discharge detector: Press the instructions may cause serious injury and
corresponding contact hardly on the battery death.
negative and positive. When the discharge
detector pointer is in the green range for WARNING: Battery may produce explosive
about 2 seconds, it indicates that the battery gases to cause personal injury and death.
capacity is sufficient to meet high current So keep the flame, spark or other
starting demands. When the discharge inflammable materials away from the
detector pointer in the red range and with no battery. When getting close to the
other abnormalities, it indicates the battery charging battery or working in that area,
capacity is insufficient and charging is wear protective mask to protect face and
required. eyes. Put the battery in a ventilated
location. Failure to comply with the
3. Use the voltmeter to inspect with headlamp
instructions may cause serious injury and
as the load: according to the battery voltage
death.
measuring method, connect the voltmeter to
the battery, and read the battery voltage WARNING: When using any charging
value, and then turn on the headlamp, if the device, comply with all the manufacturers'
battery voltage does not drop rapidly, and instructions. Failure to comply with the
keeps at 10 V or higher, the battery can start instructions may cause serious injury and
the vehicle after the charging fully. If the death.
headlamp is turned on and the battery
voltage decreases rapidly, charge the battery WARNING: The battery charger switch
to restore the function. If the standing time is must not be ON before connecting to the
too long, charge the battery for a relatively battery. Failure to comply with the
longer time. It is best to charge and discharge instructions may cause serious injury and
several times to make it fully activated. death.

CAUTION: It is improper to inspect the WARNING: Turn off the switch before
battery that just is charging, discharging removing the battery charger from the
or has just completed charging with battery. Failure to comply with the
discharge detector. Because the process instructions may cause serious injury and
of charging will generate a lot of hydrogen death.
gas, when the inspection is carried out by
discharging detector or resistance wire, it CAUTION: Do not charge the battery in the
will generate spark and cause the gas vehicle.
exploded causing injury and damage.

M201 2014.01
3.1.10-8 Charging System 3.1.10-8
CAUTION: Do not only use the alternator Connect the ammeter between alternator B
to charge the completely discharged terminal and battery positive terminal.
battery, as charging system must work
continuously more than 8 hours without
electrical load.
2
1. Remove the battery, and then put it in the - A+ B
water.

LOAD
1
2. Connect the battery charger to the battery,
3 v
charging as the following method.
Constant voltage current:
Constant voltage 14.8 V. When the charging
current drop to 3 A, continue to charge for 3 M3110006

hours to complete the charging process. Note

that the charging current should not exceed Item Description Item Description
25 A. Ammeter
Constant voltage current: 1 Load A measuring
range: 100 A
Charge it with 6 A until the voltage is 14.8 V,
Voltmeter
then with 3 A for 3 hours, and then the
2 Load switch V measuring
charging is completed.
range: 20 V
Battery Parasitic Current Test 3 Battery B
Alternator
output terminal
If the battery is out of power for a long time,
perform the following testing procedure to inspect
2. Test without load
whether the battery generates parasitic current.
Start the engine and run it from idle speed to
1. Disconnect the negative battery cable.
2000 rpm, and then read the meter readings.
2. Connect the positive probe of the multimeter
to positive battery cable and negative probe CAUTION: The voltage will be different as
to the negative battery cable. the temperature of voltage regulator varies
should be considered. Do not carry out
3. Ensure all electrical equipment are shut this test with the discharged battery.
down. Before the test, ensure that the battery is
4. Select the mA range of the multimeter to fully charged.
measure current.
CAUTION: When the engine running, do
5. Wait for vehicle module sleep, measure the not disconnect the battery terminal,
parasitic current. otherwise you may damage the electrical
components.
CAUTION: The module sleep time is
different depending on vehicles with Standard current: 10 A (Max.)
different configuration.
Standard voltage: 14.2 ~ 14.8 V at 25°C
Parasitic current standard value: 0.02 A or 3. Test with load
less
Running the engine at 2000 rpm, turn on the
Alternator Test headlamp and HVAC motors. Measure the
1. Connect the test equipment and select the current, if it is less than 20 A, repair or replace
appropriate range, connect the voltmeter the motor.
between alternator B terminal and grounding.

M201 2014.01
3.1.10-9 Charging System 3.1.10-9

Alternator Belt Tension

Inspection
WARNING: Disconnect the negative cable
before inspecting and adjusting the belt
tension.

WARNING: Read the "WARNING" content

of 3.1.4 Cooling System.

1. Inspect the belt for any cracks, cuts,

deformation, wear and dirty. Replace with a
new belt if necessary.
Refer to: Accessory Drive Belt (3.1.2
Mechanical System, Removal
and Installation).

2. Inspect the belt tension.

1 Inspect the belt tension with the sonic
tension meter (the sonic tension meter should
be located in the middle of the belt tension
side span, perpendicular to the belt, and
about 10 mm away from the belt).
CAUTION: Do not touch the belt before
inspecting the tension.

2 The alternator belt tension should be

controlled within 750 ± 50 N (before the
engine is starting).
3 If the belt tension is not as specified,
readjust the alternator belt tension until it is
within the specified range.

MASS = 4.4 g/m

Parameter setting WIDTH = 17.8 mm/R
SPAN = 208 mm

3. Connect the negative battery cable.

M201 2014.01
3.1.10-10 Charging System 3.1.10-10

Symptom Diagnosis and Testing

General Equipment

Multimeter

Inspection and Verification

1. Verify the customer concern.
2. Visually check if there is obvious mechanical
or electrical damage.
3. If an obvious cause for an observed or
reported concern is found, solve the fault
before proceeding to the next step.
4. If there is no obvious cause, verify the
symptom by referring to the Symptom Chart.
Visual Inspection Chart

Mechanical Electrical
• Fuse
• Wiring harness
• Electrical connector
• Accessory drive belt
• Battery
• Alternator
• Battery circuit
• Charging system warning
lamp

M201 2014.01
3.1.10-11 Charging System 3.1.10-11

Symptom Chart
If the fault occurs, but there is no DTC stored in the ECM for this fault and the causes cannot be verified
in basic inspection, diagnose and repair it in order of the following table.

Symptom Possible Causes Solutions

• Alternator belt
Insufficient • Diagnosis Procedure for Insufficient Battery
• Alternator regulator
battery charging Charging
• Alternator

Battery • Alternator regulator

• Diagnosis Procedure for Battery Overcharging
overcharging • Alternator

Charging • Drive belt loose or worn

• Diagnosis Procedure for Charging Indicator
indicator • Alternator
Constant ON
constant on
• Circuit fault
• Instrument cluster LED
• Instrument cluster
Charging • Circuit fault
• Diagnosis Procedure for Charging Indicator not on
indicator not on
• Poor contact between brushes and
slip rings
• Voltage regulator
• Belt
Alternator noise • Bearing • Diagnosis Procedure for Alternator Noise
• Stator and rotor

M201 2014.01
3.1.10-12 Charging System 3.1.10-12

Diagnosis Procedure for Insufficient Battery Charging

Insufficient battery
charging

Inspect alternator
charging voltage

Is the fault
confirmed

No

Inspect battery parasitic current

Yes

Is the fault
confirmed

No
Yes
Inspect alternator

End

M201 2014.01
3.1.10-13 Charging System 3.1.10-13

Test Conditions Details/Results/Actions

1. Inspect alternator charging voltage
A. Start the engine and run it from idle speed to
2000 rpm.
B. Use a multimeter to measure the voltage between
battery positive cable and negative.
Is the voltage not less than 14.2 V?
Yes
Go to step 2.
No
Go to step 3.

2. Inspect battery parasitic current

A. Perform the inspection procedure of battery
parasitic current.
Refer to: Battery Parasitic Current Testing
(3.1.10 Charging System,
General Inspection).
Is it normal?
Yes
Go to step 3.
No
Charge the battery.
Refer to: Battery Charging (3.1.10
Charging System, General
Inspection) or Battery (3.1.10
Charging System, Removal and
Installation).
3. Inspect alternator
A. Perform the alternator test procedures.
Is it normal?
Yes
Charge the battery.
No
Inspect the alternator.
Refer to: Diagnosis Procedure for
Charging Indicator Constant ON
(3.1.10 Charging System,
Symptom Diagnosis and
Testing).

M201 2014.01
3.1.10-14 Charging System 3.1.10-14

Diagnosis Procedure for Battery Overcharging

Test Conditions Details/Results/Actions
1. Inspect alternator charging voltage
A. Start the engine and run it from idle speed to
2000 rpm.
B. Use a multimeter to measure the voltage between
battery positive cable and negative.
Is the voltage higher than 14.8 V?
Yes
Go to step 2.
No
The system is normal.
2.Inspect alternator regulator
A. Replace the alternator regulator.
Is the alternator charging voltage normal?
Yes
The system is normal.
No
Disassemble and inspect the alternator.
Refer to: Alternator (3.1.10 Charging
System, Disassembly and
Assembly).

M201 2014.01
3.1.10-15 Charging System 3.1.10-15

Diagnosis Procedure for Charging Indicator Constant ON

Charging indicator
constant on

Inspect alternator belt

Is the fault Yes

confirmed

No
Inspect alternator charging
voltage

Is the fault Yes

confirmed

No
Inspect alternator regulator
power supply circuit

Is the fault Yes

confirmed

No

Inspect alternator regulator

End

M201 2014.01
3.1.10-16 Charging System 3.1.10-16

Test Conditions Details/Results/Actions

1. Inspect alternator belt
A. Inspect the alternator belt installation.
B. Inspect the tension of the alternator belt.
Refer to: Alternator Belt Tension
Inspection (3.1.10 Charging
System, General Inspection).
Is the alternator belt normal?
Yes
Go to step 2.
No
Adjust or replace the accessory drive belt or tension
pulley.

2. Inspect alternator charging voltage

A. Start the engine and run it at 2000 rpm.
B. Use a multimeter to measure the voltage between
terminal 1 of alternator output wiring harness
connector P04 and grounding.
P04 Is the output voltage between 14.2 and 14.8 V?
Yes
1
Repair the circuit between terminal 3 of alternator
wiring harness connector P03 and terminal 24 of
instrument cluster wiring harness connector P21.
No
M3110016 Go to step 3.

3. Inspect alternator regulator power supply circuit

A. Turn the ignition switch to "OFF".
B. Inspect the fuse IF33 and IF36.
C. Disconnect the alternator wiring harness connector
P03
P03.
D. Measure the voltage between terminal 2 of
3 2 1 alternator wiring harness connector P03 and
reliable grounding.
Standard voltage: 11 ~ 14 V.
E. Connect the alternator wiring harness connector
P03.
M3110017 Is the voltage value within the standard range?
Yes
Go to step 4.
No
Repair the alternator regulator power supply circuit.

M201 2014.01
3.1.10-17 Charging System 3.1.10-17

Test Conditions Details/Results/Actions

4. Inspect alternator regulator
A. Replace the alternator regulator.
Is the alternator charging voltage normal?
Yes
The system is normal.
No
Replace the alternator.

M201 2014.01
3.1.10-18 Charging System 3.1.10-18

Diagnosis Procedure for Charging Indicator Not ON

Charging indicator
not on

Inspect charging indicator LED

Is the fault Yes

confirmed

No

Inspect circuit resistance

between instrument cluster
and voltage regulator

Is the fault Yes

confirmed

No

Inspect circuit between

instrument cluster and voltage
regulator

Is the fault Yes

confirmed

No

Inspect alternator regulator

End

M201 2014.01
3.1.10-19 Charging System 3.1.10-19

Test Conditions Details/Results/Actions

1. Inspect charging indicator LED
A. Turn the ignition switch to "ON".
B. Visually inspect the charging indicator.
if it turns off after 2 seconds?
Yes
The system is normal.
No
Go to step 2.

2. Inspect circuit resistance between instrument cluster and voltage regulator

A. Turn the ignition switch to "LOCK".
Disconnect the instrument cluster wiring harness
connector P21, and measure the resistance
between terminal 24 and grounding.
Is the resistance value less than 1 Ω?
Yes
Repair or replace instrument cluster.
No
Go to step 3.

17 24 32
1 16

P21

M3110018

M201 2014.01
3.1.10-20 Charging System 3.1.10-20

Test Conditions Details/Results/Actions

3. Inspect circuit between instrument cluster and voltage regulator
A. Turn the ignition switch to "LOCK".
B. Disconnect the instrument cluster wiring harness
P21 connector P21, and measure the resistance
17 24 32 between terminal 24 and the terminal 3 of alternator
1 16
regulator wiring harness connector P03;
Is the resistance value less than 1 Ω?
Yes
Go to step 4.
No
Repair the circuit between regulator and instrument
cluster.

3 2 1

P03

M3110019

4. Inspect alternator regulator

A. Replace the alternator regulator.
Refer to: Alternator (3.1.10 Charging
System, Disassembly and
Assembly).
Does the fault solved?
Yes
End.
No
Replace the brush.
Refer to: Alternator (3.1.10 Charging
System, Disassembly and
Assembly).

M201 2014.01
3.1.10-21 Charging System 3.1.10-21

Diagnosis Procedure for Alternator Noise

Diagnosis Tips: Alternator noise may be caused by electrical or mechanical noise. Electrical noise
(electromagnetic vroom) usually varies with the alternator's electrical load. This is the normal operating
characteristics of all alternators, pay attention to distinguish them from each other, otherwise it will cause
unnecessary customer complaints. When diagnosing the alternator with mechanical noise, first inspect if
there are loose components around the alternator, mutual interference or other abnormal problems. In
some cases even if the light noise inside the cabin will be transferred into the passenger compartment, if
so, the alternators replacement cannot solve the fault, which lead to misjudgment.

Test Conditions Details/Results/Actions

1. Inspect alternator belt
A. Inspect the alternator belt installation.
B. Inspect the tension of the alternator belt.
Refer to: Alternator Belt Tension
Inspection (3.1.10 Charging
system, General Inspection).
Is the alternator belt normal?
Yes
Go to step 2.
No
Adjust or replace the alternator belt or tension
pulley.
2. Inspect alternator charging voltage
A. Remove the alternator belt.
B. Start the engine.
Does the alternator noise still exist?
Yes
Inspect the noise from compressor and booster
pump.
No
Repair the alternator.
Refer to: Alternator (3.1.10 Charging
System, Disassembly and
Assembly).

M201 2014.01
3.1.10-22 Charging System 3.1.10-22

Removal and Installation

Alternator
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Disconnect the alternator wiring harness
connector and remove the alternator charging
cable bolt.
Torque: 9 Nm

M3110003

3. Remove the alternator wiring harness bracket

retaining bolt.
Torque: 8 Nm

M3110004

4. Loosen the alternator upper retaining bolt (1),

and loosen the alternator adjusting bracket
bolt (2) and bolt (3) in sequence. 1

M3110005

M201 2014.01
3.1.10-23 Charging System 3.1.10-23

5. Rotate the alternator belt toward the engine

side until the belt can be disengaged, and
then remove it.

M3110007

6. Remove the connecting bolt between

alternator and alternator adjusting bracket.

M3110008

7. Remove the alternator upper retaining bolt.

Torque: 50 Nm

M3110009

Installation
1. Installation is in the reverse order of removal.
CAUTION: Inspect the alternator belt
tension.

Refer to: Alternator Belt Tension

Inspection (3.1.10 Charging
system, General Inspection).

M201 2014.01
3.1.10-24 Charging System 3.1.10-24

Battery
Removal
1. Disconnect the negative battery cable (1) and
positive cable (2). DOHC
Torque for positive cable: 9 Nm
Torque for negative cable: 8 Nm

1
2

M3110010

2. Remove the battery pressure plate retaining

nut. DOHC
Torque: 8 Nm

M3110011

3. Remove the battery.

DOHC

M3110012

M201 2014.01
3.1.10-25 Charging System 3.1.10-25

4. Remove the battery tray.

M3110013

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.10-26 Charging System 3.1.10-26

Disassembly and Assembly

Alternator
Disassembly
1. Remove the retaining bolts and conducting
plate at the rear cover.

×3

M3110020

2. Remove the alternator output terminal

insulation sleeve.

M3110021

3. Remove the brush.

1 Remove the brush dustproof cover.
2 Remove the brush retaining bolts. ×2

M3110022

M201 2014.01
3.1.10-27 Charging System 3.1.10-27

4. Remove the regulator retaining bolts, and

remove the regulator.
×3

M3110023

5. Remove the retaining screws from stator

output terminal and rectifier.

×4
M3110024

6. Remove the rubber cover.

M3110025

7. Remove the alternator pulley.

M3110026

M201 2014.01
3.1.10-28 Charging System 3.1.10-28

8. Separate the front and rear covers.

1 Remove the retaining nuts from the front
and rear covers.
2 Separate the front and rear covers.

×4

M3110027

9. Remove the stator, and measure the

resistance between stator output terminals
and alternator housing. It should be infinite, if
the resistance value is abnormal, replace the ×4
stator coil.

M3110028

10. Measure the resistance between rotor

conducting ring and rotor housing. It should
be infinite, if the resistance value is abnormal,
replace the rotor assembly.

M3110029

Assembly
1. Assembly is in the reverse order of disassembly.

M201 2014.01
3.1.11-1 Emission Control System 3.1.11-1

Description and Operation

3.1.11 Emission Control System

Positive
System Overview Manifold Crankcase
Blow-by Gas
Vacuum Ventilation
Flow
Positive Crankcase Ventilation (PCV) Degree Valve
System Opening

At the end of the combustion stroke, some Low Large Large

unburned mixture gas leaks from the piston High Small Small
rings into the crankcase under high pressure,
which is called "blow-by gas". The blow-by gas
contains nitrogen oxides, carbon monoxide and
Evaporative Emission (EVAP) Control
hydrocarbons. If the mixed gas is not System
exhausted, the oil in crankcase will be diluted Due to temperature, shaking and other factors,
and deteriorated to cause premature engine the fuel stored in fuel tank will generate fuel
component wear. The blow-by gas will escape vapor, which will escape from the fuel tank into
into atmosphere from the crankcase to cause atmosphere to cause pollution. In order to avoid
pollution. In order to avoid emission this situation, fuel evaporative emission (EVAP)
deterioration, blow-by gas getting into control system, which is an active carbon tank
atmosphere and oil deterioration, positive storage method, is adopted to control fuel vapor
crankcase ventilation system is adopted to emission. This method can transfer fuel vapor
conduct the blow-by gas in crankcase back to from fuel tank to the active carbon canister,
the air intake system, which go through the namely fuel vapor is transferred from the fuel tank
PCV valve and intake manifold into the to the fuel vapor recovery pipe, which will be
combustion chamber for burning. absorbed by carbon canister and stored when the
Positive crankcase ventilation system consists of vehicle is not running. When the engine is running
the following components: for a required period and the cleaning working
condition is met, engine control module provides
• Positive crankcase ventilation valve a grounding circuit, so that carbon canister control
• Crankcase ventilation vacuum tube valve energized to make the air inhaled into
• Hose and joint carbon canister and mixed with fuel vapor. Then
the mixture of fuel vapor is sucked out from the
The main control unit of engine crankcase blow- carbon core into the intake manifold, and
by gas is the positive crankcase ventilation (PCV) consumed in the combustion stroke inside
valve. Positive crankcase ventilation valve cylinder. The carbon canister control valve is
measures the blow-by gas flow based on the controlled by the pulse width modulation (PWM)
manifold vacuum signal. Positive crankcase signal to open or close. The PWM duty ratio of
ventilation valve allows some vacuum pressure to carbon canister control valve changes according
go through the internal orifice inside the valve to to the operating conditions determined by air flow,
form low pressure condition in the crankcase. The fuel regulator and intake air temperature.
blow-by gas in crankcase then is inhaled into the
air intake system and combusted during normal Components Description
combustion. The blow-by gas inhaled into intake
manifold is precisely controlled to maintain idle Positive Crankcase Ventilation Valve
quality. Use precisely calibrated positive (PCV)
crankcase ventilation valve. The relationship Positive crankcase ventilation valve includes
between flow rate of blow-by gas and vacuum valve body, valves, valve cover and spring.
degree of engine manifold is shown in the
following table: The positive crankcase ventilation valve below
the lower O-ring are partially exposed in the
intake manifold vacuum. The part between lower
and upper O-ring is exposed in the crankcase

M201 2014.01
3.1.11-2 Emission Control System 3.1.11-2
gas. As these conditions occur, the leakage Evaporative Emission Carbon Canister
beyond system capacity (caused by severe worn
Evaporative emission carbon canister is an
engine, continuous overload, etc.) enters into the
emission control device with active carbon
air intake pipe, and then is brought the engine.
particles, which is used to absorb and store the
The correct operation of crankcase ventilation fuel vapor. Fuel vapor is always stored in the
system depends on engine seals. If normal carbon canister. When meeting certain
oxidation or dilution and crankcase ventilation conditions, the engine control module will make
system is observed, inspect the engine to the carbon canister control valve energized to
determine the possible cause. Repair the make the fuel vapor inhaled into cylinder for
manifold vacuum degree problem. combustion.

M3111001 M3111013

Carbon Canister Control Valve The following conditions can lead to poor engine
Carbon canister control valve, which is a normal idle, stalling and poor driving performance:
close solenoid, controls the vapor flowing from • Carbon canister solenoid does not work.
the evaporative emission system into the intake
• The carbon canister is damaged.
manifold. The valve is controlled by the engine
control module through pulse width modulation • Hose is broken, cracked, or not properly
(PWM) to precisely control the fuel vapor flowing connected to the pipe.
into the engine.
In some testing processes of evaporative
emissions system, this valve will open to make
the engine vacuum enter the evaporative
emissions system.

M3211016

M201 2014.01
3.1.11-3 Emission Control System 3.1.11-3

Components Location View

M3111004

Item Description Item Description

1 Engine assembly 3 Air intake hose
2 PCV valve

M201 2014.01
3.1.11-4 Emission Control System 3.1.11-4

2
1

3
6

M3111005

Item Description Item Description

Carbon canister control valve
1 Carbon canister 4
emission outlet hose
2 Carbon canister gas outlet hose 5 Carbon canister control valve
Carbon canister control valve
3 Fuel vapor pipe 6
inlet hose

M201 2014.01
3.1.11-5 Emission Control System 3.1.11-5

General Inspection Carbon Canister Control Valve

General Equipment Inspection
Digital multimeter Perform the following procedures:
1. Remove the vacuum hose from carbon
PCV Valve Inspection canister control valve.
If the engine idle is unstable, inspect the 2. Run the engine at idle speed.
crankcase ventilation valve for blockage, the air
filter element for excessive dirty or the hose for 3. Put finger on the farther end of vacuum hose,
blockage. Perform the following procedures: inspect whether the tube is vacuum. If there is
no vacuum, inspect for the following faults:
1. Remove the crankcase ventilation valve from
the cylinder head cover. • Vacuum hose blocked
• Vacuum hose cracked
2. Run the engine at idle speed.
4. Use appropriate gas source to blow from the
3. Put finger on the valve end to inspect for
inlet of solenoid, the solenoid channel should
vacuum. If there is no vacuum, inspect for the
be blocked, if there is leakage, replace the
following faults:
solenoid.
• Hose blocked
5. Use a diagnostic tool to drive the solenoid,
• Manifold port blocked then use appropriate gas source to blow from
• Crankcase ventilation valve blocked the inlet of solenoid, the solenoid channel
should be unblocked, otherwise, inspect and
Clogged PCV valve or hose may cause the
repair the solenoid fault.
following faults:
• Engine idle is unstable Carbon Canister Inspection
• Engine stall or idle speed is too low 1. Inspect the filter on carbon canister
ventilation pipe for blockage, crack, or
• Engine oil leakage deformation, replace the filter.
• Oil into the air filter
2. Carbon canister visual inspection: replace if
• Oil dirt in engine there is crack or deformation.
• Engine crankcase pressure is too high 3. Remove and shake the carbon canister,
Clogged PCV valve or hose may cause the replace if there is abnormal noise.
following faults: 4. Inspect the connecting hose on the carbon
• Engine idle is unstable canister, replace if blocked or damaged is
found.
• Engine stalling
5. Use suitable air source to blow from one pipe
• Engine idle speed is too high
inlet of the carbon canister, gas should flow
• Engine oil leakage out from the other two orifices, otherwise,
replace the carbon canister.

M201 2014.01
3.1.11-6 Emission Control System 3.1.11-6

Symptom Diagnosis and Testing

General Equipment

Digital multimeter

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious mechanical or
electrical damage.
Visual Inspection Chart

Mechanical Electrical
• Hose/hose joint
• Electrical connector
• Washer
• Wiring harness
• Positive crankcase
ventilation valve • Fuse
(PCV)
• Relay
• Vacuum tube
• Carbon canister control
• Evaporative emission valve
carbon canister
• Engine control module
• Evaporative emission (ECM)
system pipe

3. If an obvious cause for an observed or

reported concern is found, solve the fault
before proceeding to the next step.
4. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
3.1.11-7 Emission Control System 3.1.11-7

Symptom Chart
If the fault occurs, but there is no DTC stored in the ECM for this fault, and can not confirm the cause by
basic inspection, diagnose and repair it in order of the following table.

Symptom Possible Causes Solutions

• PCV valve or hose blocked or
damaged • Inspect PCV system set for blockage,
• Crankcase ventilation oil separator clean or replace when necessary.
Crankcase pressure is
blocked
too high
Refer to: (3.1.2 Mechanical
• Engine set worn or damaged System, Disassembly
and Assembly).
Evaporative emission • Purge pipe cracked • Replace the purge pipe.
system leakage • Carbon canister broken • Replace the carbon canister.
• Clean the ventilation pipe.
• Ventilation pipe blocked • Replace the ventilation pipe.
• Replace the ventilation pipe filter.
Evaporative emission
• Clean the purge pipe port.
system is blocked • Purge pipe blocked
• Replace the purge pipe.
• Clean the solenoid pipe.
• Solenoid pipe blocked
• Replace the solenoid.
• Diagnose the DTC.
• Circuit fault • Inspect and repair the circuit.
Carbon canister control
• Carbon canister control valve fault • Replace the carbon canister control
valve fault
• ECM fault valve.
• Replace the ECM.

Diagnosis Procedure for Carbon Canister Control Solenoid Fault

Refer to: DTC P0444, P0458, P0459 (3.1.12 Electronic Control System - M7, DTC Diagnosis
and Testing).

M201 2014.01
3.1.11-8 Emission Control System 3.1.11-8

Removal and Installation

PCV Valve
Removal
1. Loosen the PCV valve vacuum tube hoop,
disconnect the PCV valve vacuum tube.

M3111007

2. Remove the PCV valve.

M3111008

3. Remove the PCV valve seal boot.

4. Inspect the PCV valve seal boot, replace
when necessary.

M3111001

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.11-9 Emission Control System 3.1.11-9

Carbon Canister Control Valve

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Disconnect the carbon canister control valve
wiring harness connector.

M3111010

3. Disconnect the carbon canister control valve

from carbon canister control valve support.

M3111011

4. Loosen the carbon canister control valve

hose retaining clamp and disconnect the
carbon canister control valve hose.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.11-10 Emission Control System 3.1.11-10

Active Carbon Canister

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Disconnect the active carbon canister hose.

M3111013

3. Remove the active carbon canister retaining

bolt, and then remove the active carbon
canister in the direction as shown in the
figure.
Torque: 10 ± 1 Nm

M3111014

Installation
CAUTION: When installing the active
carbon canister, it should not be installed
reversely and the airflow direction must be
as specified. Besides take appropriate
measures such as filtration or purification,
to prevent foreign objects (particles, etc.)
entering the carbon canister control valve
from carbon canister or hose.

1. Installation is in the reverse order of removal.

M201 2014.01
3.1.11-11 Emission Control System 3.1.11-11

Front Oxygen Sensor

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Disconnect the front oxygen sensor wiring
harness connector.

M3106001

3. Use the special tool to remove the front

oxygen sensor.
Torque: 50 ± 10 Nm
Special tool: oxygen sensor sleeve CA301-
022
CA301-022

M3111015

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.11-12 Emission Control System 3.1.11-12

Rear Oxygen Sensor

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Disconnect the rear oxygen sensor wiring
harness connector.

M3106008

3. Use the special tool to remove the rear

oxygen sensor.
Torque: 50 ± 10 Nm
Special tool: oxygen sensor sleeve CA301-
022
CA301-022

M3106010

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.12-1 Electronic Control System - M7 3.1.12-1

Specifications
3.1.12 Electronic Control System - M7

Torque Specifications
Item Nm lb-ft lb-in
Engine control module retaining nut 8±2 - -

Crankshaft position sensor retaining bolt 10 ± 2 - -

Throttle position sensor retaining bolt 1.5 - 2.5 - -

Idling stepper motor retaining bolt 4 ± 0.4 - -

Coolant temperature sensor 20 or less 15 or less -

Retaining bolt of intake pressure/temperature sensor 8±2 - -

Front oxygen sensor 50 ± 10 - -

Rear oxygen sensor 50 ± 10 - -

Knock sensor retaining bolt 20 ± 5 - -

M201 2014.01
3.1.12-2 Electronic Control System - M7 3.1.12-2

Description and Operation

System Overview
Engine electronic control system consists of the followings:
• Sensors that detect engine condition and operation.
• Engine control module that controls each actuator for electronic injection system according to
signals from each sensor.
• Electronically controlled actuators.

5
2

3 4
7

8
6 10
7
15
16 11 9

14

13
12

M3112001

Item Description Item Description

1 Carbon canister 9 Coolant temperature sensor

2 Carbon canister control valve 10 Knock sensor

Air intake pressure/temperature

3 11 Crankshaft position sensor
sensor

4 Fuel injector 12 Electrical fuel pump

5 Ignition coil 13 Malfunction indicator

6 Stepper motor 14 Data link connector

7 Oxygen sensor 15 ECM

8 Three-way catalytic converter 16 Throttle position sensor

M201 2014.01
3.1.12-3 Electronic Control System - M7 3.1.12-3

Control System Function angle; the other is non-synchronous injection,

which is controlled based on signals from the air
Overview intake pressure/temperature sensor and other
M7 System Input/Output Signals sensors.
1. Synchronous injection
The main sensor input signals of ECM in M7
system include: When the engine starts, air in the intake manifold
• Air pressure and temperature signal is static, the internal pressure of intake manifold
shows as the surrounding atmospheric pressure.
• Throttle rotation angle signal
The 4 injectors will inject synchronously in each
• Coolant temperature signal cycle of engine rotation. Fuel injection amount
• Engine speed signal varies according to the engine temperature.
Before the engine reaches a certain speed, the
• Knock sensor signal
mixture needs to be enriched. Once the engine is
• Oxygen sensor signal running, the system immediately begins to reduce
• A/C pressure signal the cranking enrichment, and it will be completely
After the above information goes into ECM, they canceled until the end of starting (600 ~ 700 rpm).
are processed and then the required actuator When a cylinder is in exhaust stroke after the
control signals are generated, which are amplified engine starts, the injector only in that cylinder
in the output drive circuit, and are transmitted to injects. ECM follows the order of cylinders 1, 3, 4,
corresponding actuator. These control signals 2 to control the injection order of injectors.
include:
2. Non-synchronous injection
• Injection timing and injection duration
All the injectors will not be controlled by the
• Fuel pump relay pressure/temperature sensor after the engine
• Carbon canister control valve opening starts and meets the following two conditions.
• Ignition coil close angle and ignition • Fuel injection system starts to inject when
advance angle fuel is cut off.
• A/C compressor relay • When the throttle opening rate is higher
• Fan relay than the specified value (throttle opens
too fast).
Electronic control system can be divided into the
Non-synchronous injection is generated quickly
following subsystems:
under the above two situations.
• Fuel injection control system
3. Injection time
• Idle speed control system
The main factor of identifying the fuel injection
• Fuel pump control system
time is the basic injection time value that
• Ignition timing control system calculated according to the engine speed, the
• Radiator-fan control system intake manifold pressure and temperature (air
intake flow), and the compensation value that is
• Fuel evaporative emission control system
determined by signals from various sensors used
• Heating, ventilation and air conditioning for detecting the engine and operating conditions.
system
4. Fuel cut-off
Fuel Injection Control
The injection stops (by stopping injector) while
ECM controls the injection duration and injection slowing down (for example, when throttle is on
timing based on various sensor signals, to ensure idling position and engine is running at high
that appropriate gas mixture is provided in speed). It ensures that unburned gas will not be
different driving conditions. There are two forms discharged and be started again under above
of injection timing, one is synchronous injection, different conditions.
which always injects at the same crankshaft

M201 2014.01
3.1.12-4 Electronic Control System - M7 3.1.12-4
Air-fuel Ratio Feedback Compensation (Closed-loop System)
The air-fuel mixture must be close to stoichiometric air-fuel ratio (14.7) to ensure that the three-way
catalytic conversion process is fully performed and high purification rate of CO, HC and NOx in
exhausting is reached.
λ closed loop control system can work only with oxygen sensor equipped. Oxygen sensor monitors the
oxygen content in the exhaust gas at the up/down location of three-way catalytic converter. Lean mixture
(λ is more than 1) generates about 100 mV sensor voltage and rich mixture (λ is less than 1) generates
about 800 mV sensor voltage. When λ is equal to 1, the sensor voltage will change greatly. The λ closed-
loop control responds to the input signal (λ is 1 or greater for too lean mixture, and 1 or less for too rich
mixture) to modify the control variables, resulting in correction factor as a multiplier to correct the fuel
injection duration.
When any of the following conditions is met, ECM exits from closed-loop control.
• When the engine starts and injection amount is increased after the engine starts.
• When the engine coolant temperature is too low.
• When the load is high and injection amount increases.
• When the fuel is cut off.
• When the oxygen sensor is cooled.

Signal to increase injection amount

Signal to decrease injection amount

Low voltage

ECM
High voltage

Fuel injector Oxygen sensor

Air-fuel mixture
Oxygen content
gets rich
decreases

Air-fuel mixture
Oxygen content increases
gets lean

M3112002

M201 2014.01
3.1.12-5 Electronic Control System - M7 3.1.12-5
Idle Speed Control
The control system uses ECM and idling stepper motor to achieve control purposes as follows: Engine
always keeps a certain speed under idling status. The idling speed of engine varies with reasons as
follows:
• Add load to the engine (electrical load, for example, turn on A/C switch).
• Engine itself changes with time.
• Improve the engine start performance.
• Adjust the air-fuel ratio during deceleration (reduction buffer function).
• When engine warms up, improve its performance.
Operation:
Idle speed control operates in accordance with effective information output from ECM, which detects
operation status of engine with sensors and switch signals, and controls air flow through idling stepper
motor.

Fuel Pump Control

ECM controls the fuel pump ON/OFF. In either of the following cases, it energizes the fuel pump through
fuel pump relay.
• Two seconds after the ignition switch is turned off.
• When engine starts (engine start signal output to ECM).

Ignition Timing Control

The system adopts distributorless, single-cylinder direct ignition, and each ignition coil is connected to
one spark plug directly. ECM controls the internal high power transistor of injector according to the
signals from sensors to cut on or off the ignition coil primary winding circuit, increasing the ignition
reliability and ignition coil life and improving the engine dynamic property and economy. The control
includes the following three different forms:
• Ignition timing when the engine starts (initial ignition timing)
• Engine after-start control
• Charge current time control
1. The ignition time after engine starts can be confirmed as follows, then the ignition occurs in the most
appropriate moment under different conditions of engine.

Various
Basic
Initial compens-
Ignition Ignition ignition
= ignition + + + ation
time timing advance
timing advance
angle
angles

When the throttle is at idle speed position, ignition time is calculated based on the initial ignition timing,
plus the basic ignition advance angle that is determined by engine speed and engine cooling
compensation, and the idle stability related advance compensation angle.
When the throttle opening is larger than that at idle speed position, it is also calculated based on the
initial ignition timing, plus the basic ignition advance angle that is determined by engine speed, air intake
pressure and engine cooling compensation, and the idle stability related advance compensation angle.

M201 2014.01
3.1.12-6 Electronic Control System - M7 3.1.12-6
Radiator-fan Control
The system controls radiator-fan motor ON/OFF, which is achieved through a relay controlled by ECM.
When air conditioning is running or stopped, the radiator-fan motor should be turned on or off
accordingly.

Fuel Evaporative Emission Control

Fuel evaporative emission control system is used to prevent fuel vapor from evaporating. This vapor,
generated from the fuel during engine run or stop, goes into the carbon canister through the tank
pressure control valve, and is absorbed or stored by carbon canister. Carbon canister control valve is
controlled by ECM based on various sensor signals.
Only when the following conditions are met, ECM will open the vacuum channel of carbon canister
control valve.
• When the engine is at normal operating temperature.
• When the engine speed is higher than the specified value.
• When the throttle opening is larger than that at idle speed position (throttle close position).
• When the engine is running within the required load.
The result is that the carbon canister is purified due to the air flow going through the carbon filter located
at the bottom of the canister.
Fuel tank pressure control valve is used to maintain constant tank pressure. This valve opens so that the
vapor goes into the carbon canister. On the contrary, when the tank pressure becomes negative and
reaches its specified value, the valve opens so that air goes into the tank.

M201 2014.01
3.1.12-7 Electronic Control System - M7 3.1.12-7

Fault Diagnosis Function malfunction indicator condition, A/C system

condition.
Overview
Active Test Function
Diagnostic Tool and Connection
Malfunction indicator, fuel pump, A/C relay, fan,
This system applies standard Data Link ignition, injection (single cylinder with fuel cut-off).
Connector (DLC), which is installed under the
ashtray of instrument panel in the cab. Terminals Odometer Display
12 and 13 of DLC are connected to ground wire;
Running mileage, running time.
terminal 15 is connected to terminal 15 of ECM,
i.e. engine data K-line; and terminal 8 is Edition Information Display
connected to battery positive.
Vehicle Identification Number (VIN) (for vehicle
with VIN code), ECM hardware number, ECM
software number.

Fault Display
8 7 6 5 4 3 2 1 Intake pressure sensor, intake temperature
sensor, engine coolant temperature sensor,
16 15 14 13 12 11 10 9
throttle position sensor, oxygen sensor, oxygen
sensor heating wires, air-fuel ratio correction, fuel
injector of each cylinder, fuel pump, knock sensor,
crankshaft position sensor, carbon canister
M3112108 control valve, cooling fan relay, vehicle speed
signal, idle speed, idle stepper motor, system
The diagnostic tool communicates with ECM via voltage, ECM, A/C compressor relay, evaporator
K-line, and the following operations can be temperature sensor, malfunction indicator.
performed with it (for details, refer to diagnostic
tool instruction manual):

Engine Parameter Display

1. Speed, coolant temperature, throttle opening,
ignition advance angle, injection pulse width,
intake pressure, intake temperature, vehicle
speed, system voltage, injection trim, carbon
canister scour rate, idle speed air control,
oxygen sensor wave.
2. Target speed, engine relative load, ambient
temperature, ignition close time, evaporator
temperature, intake flow, signal voltage of
throttle position sensor, signal voltage of
coolant temperature sensor, signal voltage of
intake temperature sensor, signal voltage of
intake pressure sensor.

Electronic Injection System Condition

Display
Cooling system condition, stable condition,
dynamic condition, emission control condition,
oxygen sensor condition, idle speed condition,

M201 2014.01
3.1.12-8 Electronic Control System - M7 3.1.12-8

Components Description and fuel in the cylinder. ECM controls the ground
of primary ignition coil.
Engine Control Module
Engine Control Module (ECM), installed under the
front passenger seat, receives input signals,
output control signals, detects system conditions,
record trouble code and illuminates the
malfunction indicator when a malfunction occurs.

M3112005

Crankshaft position sensor

Crankshaft position sensor is located on the
engine block, between water pump and A/C
compressor. The sensor is an electromagnetic
M3112003 induction sensor, and detects the position and
speed of crankshaft by the sensor plate on it.
Knock sensor
The knock sensor is directly installed on the
engine block and located at the bottom of intake
manifold. The knock sensor will record the
vibration when engine knocking happens. ECM
adjusts the ignition timing by using the knock
sensor signal to avoid knocking.

M3112006

M3112004

Ignition coil
The ignition coils are located on the cylinder head
cover. Each cylinder adopts an independent
ignition coil, which is connected to the spark plug
directly. The ignition coil transforms the low
voltage of primary winding into high voltage of
secondary winding, and the spark is discharged
through the spark plug, igniting the mixture of air

M201 2014.01
3.1.12-9 Electronic Control System - M7 3.1.12-9
Idling stepper motor the fuel mixture is lean or rich and performs
feedback control. A heater is built into the oxygen
Idling stepper motor, installed on the air passage
sensor and used to heat the sensor to working
of throttle body, can change the flow area of air
temperature when the cold engine is started.
by-pass passage through controlling the
adjustable head forward and backward on the
basis of signals from ECM to regulate the air
amount entering the engine, thus controlling the
engine idle speed.

M3112009

Fuel injector
Injector is located on the fuel rail and can inject
M3112007 atomized fuel to intake duct based on the
command from ECM.
Coolant temperature sensor
Coolant temperature sensor is mounted on the
water outlet pipe of thermostat. The sensor, in
which a thermistor with negative temperature
coefficient is built, transforms the change of
coolant temperature to that of thermistor
resistance value using the temperature sensitive
characteristic of thermistor, and then transforms it
to voltage signal by voltage division circuit, to
output to ECM.
M3112010

M3112008

Oxygen sensor
The vehicle is equipped with two oxygen sensors,
which are located in the front and rear of three-
way catalytic converter respectively. The oxygen
sensor can detect the oxygen content in the
exhaust gas, by which ECM determines whether

M201 2014.01
3.1.12-10 Electronic Control System - M7 3.1.12-10
Throttle position sensor
Throttle position sensor, located on the throttle
body, is used to detect the throttle opening angle
and output the voltage signal to ECM as engine
load signal, thus making a judgment of engine
operation.

M3112011

Air intake pressure/temperature

sensor
Air intake pressure/temperature sensor is located
on the intake manifold and integrated with
pressure sensor and temperature sensor. Based
on sensor signals and other information, ECM
regulates the injection amount.

M3112012

M201 2014.01
3.1.12-11 Electronic Control System - M7 3.1.12-11

Components Location View

1 9

5
3

M3112013

Item Description Item Description

Air intake pressure/temperature
1 Ignition coil 6
sensor

2 Oxygen sensor 7 Crankshaft position sensor

3 Coolant temperature sensor 8 Knock sensor

4 Idling stepper motor 9 Fuel injector

5 Throttle position sensor

M201 2014.01
3.1.12-12 Electronic Control System - M7 3.1.12-12

General Inspection
General Tool

Diagnostic tool

Multimeter

1 1 USE
WITH

2 2
3 3

M3112014

DTC Read Procedure

1. Carry out necessary vehicle preparation and
appearance inspection.
2. Connect the diagnostic tool to data link
connector in the cab.
3. Use the diagnostic tool to read the DTC.

Data Flow Read Procedure

1. Carry out necessary vehicle preparation and
appearance inspection.
2. Connect the diagnostic tool to data link
connector in the cab.
3. Use diagnostic tool to enter the engine
system to read the data flow.

Active Test Procedure

1. Carry out necessary vehicle preparation and
appearance inspection.
2. Connect the diagnostic tool to data link
connector in the cab.
3. Use the diagnostic tool to enter Actuators
menu, and carry out the desired active test.

M201 2014.01
3.1.12-13 Electronic Control System - M7 3.1.12-13

Symptom Diagnosis and Testing

General Equipment

Multimeter

Diagnostic tool

Exhaust backpressure gauge

Cylinder pressure gauge

Fuel pressure gauge

Inspection and Verification

1. Verify the customer concern.
2. Visually check if there is obvious mechanical
or electrical damage.
3. If an obvious cause for an observed or
reported concern has been found, solve the
fault before proceeding to the next step.
4. If the cause is not visually evident, verify the
symptom and diagnose the system with
diagnostic tool.
Visual Inspection Chart

Electrical

• Fuse
• Relay
• Wiring harness
• Electrical connector
• Sensor
• Switch
• Engine Control Module (ECM)

M201 2014.01
3.1.12-14 Electronic Control System - M7 3.1.12-14

Intermittent Malfunction Diagnosis Procedure

If the fault cannot be confirmed via DTC check, the symptom only occurs during application occasionally.
At this point, confirm all wires and parts that may cause fault. Mostly, fault area can be determined
quickly and effectively through basic inspection as shown in the diagram below. Especially the symptom,
such as poor contact of wiring harness connector.
Malfunction definition: This malfunction currently does not appear, but the historical DTC record
indicates that the malfunction occurred before. Or customer reports the malfunction, but as the
malfunction is not related to the diagnostic trouble code, and currently the malfunction symptom cannot
recur.

Test Conditions Details/Results/Actions

1.Vibration method

A. If driving on a rough road, a malfunction occurs or

becomes more serious, or engine starts to vibrate,
perform the following steps.
B. Electrical faults may be caused by vehicle or engine
vibration for some reasons. Inspect the following
items:
• Connector is not fully in position.
• Wiring harness does not have enough
space.
• Wiring harness comes across the
supports or moving components.
• Wiring harness too close to the high
temperature components.
C. Incorrect wiring layout, tight or loose wiring harness
will cause itself to be squeezed between the
components.
D. Connector joint, vibration location and wiring
harness location are all items for focus inspection,
such as: wiring harness through firewall and body
panels.

2. Inspection method for switch connector or wiring harness

A. Connect the diagnostic tool to data link connector.

B. Turn the ignition switch to "ON".
Note: If the malfunction occurs when
engine is running, carry out the
following procedure with the engine
idling.
C. Access to the data flow of switch that you are
inspecting.
D. Turn on the switch manually.
M3112015 E. When monitoring the data flow, gently shake the
connector or wiring harness of switch.
If the data flow value is unstable, please inspect if
there is a poor connection.

M201 2014.01
3.1.12-15 Electronic Control System - M7 3.1.12-15

Test Conditions Details/Results/Actions

3. Inspection method for sensor connector or wiring harness

A. Connect the diagnostic tool to data link connector.

B. Turn the ignition switch to "ON".
Note: If the malfunction occurs when
engine is running, carry out the
following procedure with the engine
idling.
C. Access to the data flow of sensor that you are
inspecting.
D. When monitoring the data flow, gently shake the
connector or wiring harness of sensor.
M3112016
If the data flow value is unstable, please inspect if
there is a bad connection.

4.Inspect method for actuator or relay

A. Connect the diagnostic tool to data link connector.

B. Turn the ignition switch to "ON".
Note: If the malfunction occurs when
engine is running, carry out the
following procedure with the engine
idling.
C. By diagnostic tool, turn on the actuator or relay that
you are inspecting.
D. Vibrate the actuator or relay with fingers for 3
seconds.
M3112017
If you hear unstable "clicking" sound, inspect if there
are poor connections or abnormal installation.
CAUTION: Strong vibration of relay may
open it.

M201 2014.01
3.1.12-16 Electronic Control System - M7 3.1.12-16

Test Conditions Details/Results/Actions

5.Water sprinkling method

If the malfunction only occurs in high humidity, or

snow/rain weather, the following steps should be
performed:
Spray water on the face of radiator to indirectly change
the temperature and humidity. If the vehicle easily
leaks, it may damage the control module. In detecting
the existence of vehicle leaking problem, special
precautions must be taken.
A. Connect the diagnostic tool to data link connector.
B. Turn the ignition switch to "ON".
M3112018 Note: If the malfunction occurs when
engine is running, carry out the
following procedure with the engine
idling.
C. Access to the data flow of sensor or switch.
D. If you want to inspect the switch, manually turn on it.
E. Spray water onto the vehicle, or drive the vehicle
through the car wash.
If the data flow value is unstable or fails, please
repair or replace the parts when necessary.

Symptom Chart
If the fault occurs, but there is no DTC stored in the ECM for this fault and the causes cannot be verified
in basic inspection, diagnose and repair in order of the following table.

Symptom Possible Causes Solutions

• Crankshaft position sensor Refer to: Diagnosis Procedure

for Engine not
• Fuel pump
Starting at Normal
Engine cannot start at normal • Ignition coil Start Speed (3.1.12
start speed • Exhaust system blocked Electronic Control
System - M7,
• Engine mechanical
Symptom Diagnosis
• ECM and Testing).
• Coolant temperature sensor Refer to: Diagnosis Procedure
• Spark plug for Cold Start
Problem (3.1.12
• Fuel pump
Electronic Control
Cold start problem • Fuel injector System - M7,
• Throttle body Symptom Diagnosis
and Testing).
• Engine mechanical
• Engine control module circuit

M201 2014.01
3.1.12-17 Electronic Control System - M7 3.1.12-17

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure

• Coolant temperature sensor
for Hot Start Problem
• Ignition system (3.1.12 Electronic
Hot start problem
• Fuel pump Control System - M7,
Symptom Diagnosis
• Engine control module circuit
and Testing).
• Air intake system Refer to: Diagnosis Procedure
• Ignition system for Start Normal but
Idle Speed Unstable
• Throttle body
Start normal but idle speed
at Any Time (3.1.12
• Ignition timing Electronic Control
unstable at any time
• Fuel system System - M7,
Symptom Diagnosis
• Engine mechanical
and Testing).
• Engine control module circuit

Refer to: Diagnosis Procedure

for Start Normal but
• Heating, ventilation and air Idle Speed Unstable
conditioning or Flameout with
Start normal, idle speed unstable
Partial Load (A/C ON)
or flameout with partial load • Throttle body
(3.1.12 Electronic
• Fuel injector Control System - M7,
Symptom Diagnosis
and Testing).

• Coolant temperature sensor

Refer to: Diagnosis Procedure
for Start Normal, Idle
• Throttle body Speed Too High
Start normal, idle speed too high • Vacuum tube (3.1.12 Electronic
• Ignition timing Control System - M7,
Symptom Diagnosis
• Engine control module circuit
and Testing).
• Air intake system Refer to: Diagnosis Procedure
• Air intake pressure sensor for Acceleration
Speed does not increase or
Fault (3.1.12
• Throttle body
flameout at acceleration Electronic Control
• Fuel injector System - M7,
Acceleration problem
• Spark plug Symptom Diagnosis
Acceleration slow reaction and Testing).
• Ignition timing
Acceleration weak, poor
performance • Fuel
• Exhaust blockage
• Engine control module circuit

M201 2014.01
3.1.12-18 Electronic Control System - M7 3.1.12-18

Symptom Possible Causes Solutions

• Oxygen sensor Refer to: Diagnosis Procedure
• Fuel injector for Unstable Engine
Operation (3.1.12
• Spark plug
Electronic Control
• Ignition timing System - M7,
Unstable engine operation Symptom Diagnosis
• Fuel pressure
and Testing).
• Retaining bolts loose or
engine mounting
components damaged
• Engine control module circuit

• Crankshaft position sensor Refer to: Diagnosis Procedure

• Fuel injector for Easy Flameout at
Start (3.1.12
• Spark plug
Electronic Control
Easy flameout at start • Ignition timing System - M7,
• Fuel pressure Symptom Diagnosis
and Testing).
• A/C compressor
• Engine control module circuit

• MAP sensor Refer to: Diagnosis Procedure

• Incorrect A/C system for Emergency
operation During Vehicle
Running (3.1.12
• Intake system components
Electronic Control
leakage
System - M7,
• Carbon canister control valve Symptom Diagnosis
• Unstable signal from CKP and Testing).
sensor
• Vacuum leakage
• Poor fuel quality
Emergency during vehicle
running • Main relay and fuel pump
relay intermittent fault
• Throttle body
• Engine overheating
• Spark plug
• Ignition timing
• Exhaust system restriction
• Fuel pressure inadequate
• Fuel pump mechanical
• Fuel injector

M201 2014.01
3.1.12-19 Electronic Control System - M7 3.1.12-19

Symptom Possible Causes Solutions

• Vacuum leakage Refer to: Diagnosis Procedure
• Intake system leakage for Flameout During
Coasting (3.1.12
• Air/fuel mixing ratio improper
Electronic Control
control
System - M7,
• Fuel evaporative emission Symptom Diagnosis
control system and Testing).
• TPS sensor or related circuit

Flameout during coasting • MAP sensor or related circuit

• Incorrect operation of A/C
magnetic clutch
• Fuel injector
• Spark plug
• Ignition timing
• Fuel
• Exhaust blockage

Refer to: Diagnosis Procedure

• Instrument cluster circuit
for DTC P0650
• Instrument cluster (3.1.12 Electronic
MIL indicator is always on
• ECM Control System - M7,
Symptom Diagnosis
• ECM circuit
and Testing).

Refer to: Diagnosis Procedure

• MIL indicator bulb
for DTC P0650
• Instrument cluster circuit (3.1.12 Electronic
MIL indicator is not on
• Instrument cluster Control System - M7,
Symptom Diagnosis
• ECM
and Testing).

M201 2014.01
3.1.12-20 Electronic Control System - M7 3.1.12-20

Diagnosis Procedure for Engine not Starting at Normal Start Speed

Engine not starting

at normal start speed

Inspect DTC

Is the fault Yes

confirmed

No

Inspect ignition system

Is the fault Yes

confirmed

No

Inspect fuel pressure

Is the fault Yes

confirmed

No

Inspect engine compression

pressure
Inspect water in fuel
Inspect air intake system and
exhaust system Is the fault Yes
confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-21 Electronic Control System - M7 3.1.12-21

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. Inspect ignition system

A. Turn the ignition switch to "LOCK".
B. Carry out the ignition spark test.
Refer to: Ignition Spark Test (3.1.8 Ignition
System, General Inspection).
Is the ignition spark test normal?
Yes
Go to step 3.
No
Inspect the ignition system.
Refer to: Diagnosis Procedure for Spark
Plugs not Flashing Over (3.1.8
Ignition System, Symptom
Diagnosis and Testing).

3. Inspect fuel pressure

A. Turn the ignition switch to "LOCK".
B. Measure the fuel pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
Is the fuel pressure normal?
Yes
Go to step 4.
No
Inspect the fuel system.

M201 2014.01
3.1.12-22 Electronic Control System - M7 3.1.12-22

Test Conditions Details/Results/Actions

4. Inspect engine compression pressure

A. Inspect the engine compression pressure.
Refer to: Cylinder Compression Pressure
Inspection (3.1.2 Mechanical
System, General Inspection).
Is the compression pressure normal?
Yes
Go to step 5.
No
Inspect the engine mechanical system.

5. Inspect water in fuel

A. Remove the fuel filter joints.
Refer to: Fuel Filter (3.1.7 Fuel System,
Removal and Installation).
B. Discharge the fuel in the filter and inspect the water
in the fuel.
Is there any water in the fuel?
Yes
Clean the fuel tank, and add qualified fuel.
No
Go to step 6.

6. Inspect air intake system and exhaust system

A. Remove intake system hose in front of throttle and
idling stepper motor, and inspect for dirt or clog due
to foreign matter.
B. Remove the exhaust pipe and three-way catalytic
converter, and inspect if there is foreign matter or
three-way catalytic converter which comes off due
to damage to get the emission system clogged.
Are they normal?
Yes
Go to step 7.
No
Clean or replace the fault parts.

M201 2014.01
3.1.12-23 Electronic Control System - M7 3.1.12-23

Test Conditions Details/Results/Actions

7. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-24 Electronic Control System - M7 3.1.12-24

Diagnosis Procedure for Cold Start Problem

Cold start problem

Inspect DTC

Is the fault Yes

confirmed

No

Inspect throttle

Is the fault Yes

confirmed

No

Inspect ignition system

Is the fault Yes

confirmed

No

Inspect fuel pressure

Inspect coolant temperature
sensor
Inspect compression pressure in
the cylinder Yes
Inspect fuel injector Is the fault
confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-25 Electronic Control System - M7 3.1.12-25

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. Inspect throttle
A. Start the engine by depressing the accelerator
pedal slightly.
Can the engine be started easily?
Yes
Clean the throttle, idling stepper motor. If the intake
system has thick carbon deposit, clean the throttle
and intake duct.
No
Go to step 3.

3. Inspect ignition system

A. Turn the ignition switch to "LOCK".
B. Carry out the ignition spark test.
Refer to: Ignition Spark Test (3.1.8 Ignition
System, General Inspection).
Is the ignition spark test normal?
Yes
Go to step 4.
No
Inspect the ignition system.
Refer to: Diagnosis Procedure for Spark
Plugs not Flashing Over (3.1.8
Ignition System, Symptom
Diagnosis and Testing).

M201 2014.01
3.1.12-26 Electronic Control System - M7 3.1.12-26

Test Conditions Details/Results/Actions

4. Inspect fuel pressure

A. Turn the ignition switch to "LOCK".
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
Is the fuel pressure normal?
Yes
Go to step 5.
No
Inspect the fuel system fault.

5. Inspect coolant temperature sensor

A. Disconnect the coolant temperature sensor
connector.
B. Connect a 2.5 kΩ resistor in series substituted for
coolant temperature sensor at the sensor
connector.
C. Start the cold engine.
Is the start smooth?
Yes
Replace the coolant temperature sensor.
No
Go to step 6.

6. Inspect compression pressure in the cylinder

A. Inspect the compression pressure in the cylinder.
Refer to: Cylinder Compression Pressure
Inspection (3.1.2 Mechanical
System, General Inspection).
Is the pressure insufficient in any cylinder?
Yes
Inspect the engine mechanical system.
No
Go to step 7.

7. Inspect fuel injector

A. Remove the fuel injectors.
B. Inspect the fuel injectors for leakage or blockage.
Are they normal?
Yes
Go to step 8.
No
Replace the fuel injector.

M201 2014.01
3.1.12-27 Electronic Control System - M7 3.1.12-27

Test Conditions Details/Results/Actions

8. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-28 Electronic Control System - M7 3.1.12-28

Diagnosis Procedure for Hot Start Problem

Hot start problem

Inspect DTC

Is the fault Yes

confirmed

No

Inspect ignition system

Is the fault Yes

confirmed

No

Inspect fuel pressure

Is the fault Yes

confirmed

No

Inspect coolant temperature

sensor
Inspect fuel

Is the fault Yes

confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-29 Electronic Control System - M7 3.1.12-29

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. Inspect ignition system

A. Turn the ignition switch to "LOCK".
B. Carry out the ignition spark test.
Refer to: Ignition Spark Test (3.1.8 Ignition
System, General Inspection).
Is the ignition spark test normal?
Yes
Go to step 3.
No
Inspect the ignition system.
Refer to: Diagnosis Procedure for Spark
Plugs not Flashing Over (3.1.8
Ignition System, Symptom
Diagnosis and Testing).

3. Inspect fuel pressure

A. Turn the ignition switch to "LOCK".
B. Measure the fuel pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
Is the fuel pressure normal?
Yes
Go to step 4.
No
Inspect the fuel system fault.

M201 2014.01
3.1.12-30 Electronic Control System - M7 3.1.12-30

Test Conditions Details/Results/Actions

4. Inspect coolant temperature sensor

A. Disconnect the coolant temperature sensor
connector.
B. Connect a 300 Ω resistor in series substituted for
coolant temperature sensor at the sensor
connector.
C. Start the engine.
Is the start smooth?
Yes
Replace the coolant temperature sensor.
No
Go to step 5.

5. Inspect fuel
A. Is the fault caused by just refueling?
Yes
Replace the fuel.
No
Go to step 6.

6. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-31 Electronic Control System - M7 3.1.12-31

Diagnosis Procedure for Start Normal but Idle Speed Unstable at

Any Time

Start normal but idle speed

unstable at any time

Inspect DTC

Is the fault Yes

confirmed

No

Inspect air intake system

Is the fault Yes

confirmed

No

Inspect throttle

Is the fault Yes

confirmed

No

Inspect spark plug

Inspect ignition coil
Inspect fuel injector
Inspect fuel
Inspect compression pressure Is the fault Yes
Inspect ignition timing confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-32 Electronic Control System - M7 3.1.12-32

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. Inspect air intake system

A. Turn the ignition switch to "LOCK".
B. Inspect the air intake system for blockage.
C. Inspect the air intake system for leakage.
Refer to: Diagnosis Procedure for Intake
Air Leak (3.1.5 Air Intake System,
Symptom Diagnosis and
Testing).
Is the air intake system normal?
Yes
Go to step 3.
No
Repair the air intake system.

3. Inspect throttle
A. Turn the ignition switch to "LOCK".
B. Inspect if the throttle is stuck.
Is the throttle normal?
Yes
Go to step 4.
No
Clean the throttle, idling stepper motor or replace
the throttle.

M201 2014.01
3.1.12-33 Electronic Control System - M7 3.1.12-33

Test Conditions Details/Results/Actions

4. Inspect spark plug

A. Remove the spark plug.
B. Inspect the spark plug in each cylinder, and observe
whether the model and clearance meet the
standard.
Refer to: Spark Plug (3.1.8 Ignition
System, removal and
Installation).
Is the spark plug in each cylinder normal?
Yes
Go to step 5.
No
Replace the spark plug.

5. Inspect ignition coil

A. Carry out the ignition coil inspection procedure.
Refer to: Ignition Coil Test (3.1.8 Ignition
System, General Inspection).
Is the ignition coil normal?
Yes
Go to step 6.
No
Replace the fuel injector.

6. Inspect fuel injector

A. Remove the fuel injectors.
B. Inspect the fuel injectors for leakage, blockage or
flow error.
Are they normal?
Yes
Go to step 7.
No
Replace the fuel injector.

7. Inspect fuel
A. Is the fault caused by just refueling?
Yes
Replace the fuel.
No
Go to step 8.

M201 2014.01
3.1.12-34 Electronic Control System - M7 3.1.12-34

Test Conditions Details/Results/Actions

8. Inspect compression pressure

A. Inspect the compression pressure in the cylinder.
Refer to: Cylinder Compression Pressure
Inspection (3.1.2 Mechanical
System, General Inspection).
Is there insufficient pressure or large difference
among cylinders?
Yes
Inspect the engine mechanical system.
No
Go to step 9.

9. Inspect ignition timing

A. Inspect the ignition timing.
Refer to: Timing Inspection (3.1.2
Mechanical System, General
Inspection).
Is the ignition timing normal?
Yes
Go to step 10.
No
Adjust the ignition timing.

M201 2014.01
3.1.12-35 Electronic Control System - M7 3.1.12-35

Test Conditions Details/Results/Actions

10.Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-36 Electronic Control System - M7 3.1.12-36

Diagnosis Procedure for Start Normal but Idle Speed Unstable or

Flameout with Partial Load (A/C ON)

Start normal but idle

speed unstable or
flameout with partial
load (A/C on)

Inspect DTC

Is the fault Yes

confirmed

No

Inspect throttle

Is the fault Yes

confirmed

No

Inspect if engine output power

increases when A/C is turned on

Is the fault Yes

confirmed

No

Inspect engine control module

A/C on signal
Inspect fuel injector
Is the fault Yes
confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-37 Electronic Control System - M7 3.1.12-37

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. Inspect throttle
A. Turn the ignition switch to "LOCK".
B. Inspect if the throttle is stuck.
C. Inspect the throttle and idling stepper motor for
carbon deposit.
Is the throttle normal?
Yes
Go to step 3.
No
Clean the throttle, idling stepper motor or replace
the throttle.

3. Inspect if engine output power increases when A/C is turned on

A. Turn the ignition switch to "LOCK".
B. Connect the diagnostic tool.
C. Start the engine, access to engine data flow menu,
select the parameters such as ignition advance
angle, fuel injection pulse width and intake pressure
sensor.
D. Turn on the A/C, observe the change of data flow
parameters.
Are there changes?
Yes
Go to step 4.
No
Inspect the A/C system.
Refer to: Diagnosis Procedure for
Insufficient A/C Refrigeration
(4.1.1 Heating, Ventilation and
Air Conditioning, Symptom
Diagnosis and Testing).

M201 2014.01
3.1.12-38 Electronic Control System - M7 3.1.12-38

Test Conditions Details/Results/Actions

4. Inspect engine control module A/C on signal

A. Turn the ignition switch to "ON".
E18 B. Turn on the A/C. Measure the voltages of terminals
10, 44 of engine control module wiring harness
connector E18 with the multimeter.
1 2 9 10 22
Are the voltages of terminals 10 and 44 about 12 V
3 4 23 36 when A/C is turned on?
5 6 37 44 50 Yes
7 8 51 64 Go to step 5.
No
Repair the circuit.
M3112107

5. Inspect fuel injector

A. Remove the fuel injectors.
B. Inspect the fuel injectors for leakage, blockage or
flow error.
Are they normal?
Yes
Go to step 6.
No
Replace the fuel injector.

6. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-39 Electronic Control System - M7 3.1.12-39

Diagnosis Procedure for Start Normal, Idle Speed too High

Start normal, idle

speed too high

Inspect DTC

Is the fault Yes

confirmed

No

Inspect if accelerator pedal or

cable is stuck or too tight

Is the fault Yes

confirmed

No

Inspect if idling stepper motor is

stuck

Is the fault Yes

confirmed

No

Inspect air intake system

Inspect coolant temperature
sensor
Inspect coolant temperature
sensor circuit Is the fault Yes
Inspect ignition timing confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-40 Electronic Control System - M7 3.1.12-40

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. Inspect if accelerator pedal or cable is stuck or too tight

A. Turn the ignition switch to "LOCK".
B. Inspect if the accelerator pedal is stuck or too tight.
C. Inspect if the accelerator cable is stuck or too tight.
Are they stuck or too tight?
Yes
Repair or replace the accelerator pedal or cable.
No
Go to step 3.

3. Inspect if idling stepper motor is stuck

A. Turn the ignition switch to "LOCK".
B. Inspect if the idling stepper motor has too much
carbon deposit.
C. Inspect if the idling stepper motor is stuck.
Yes
Clean the idling stepper motor, throttle or replace
the idling stepper motor.
No
Go to step 4.

4. Inspect air intake system

A. Inspect the air intake system for leakage.
Does the air intake system leak?
Yes
Repair the air intake system.
Refer to: Diagnosis Procedure for Intake
Air Leak (3.1.5 Air Intake System,
Symptom Diagnosis and
Testing).
No
Go to step 5.

M201 2014.01
3.1.12-41 Electronic Control System - M7 3.1.12-41

Test Conditions Details/Results/Actions

5. Inspect coolant temperature sensor

A. Disconnect the coolant temperature sensor wiring
harness connector.
B. Start the engine, and observe it.
Is the engine idle speed too high?
Yes
Go to step 7.
No
Go to step 6.

6. Inspect coolant temperature sensor circuit

A. Replace the coolant temperature sensor.
B. Start the engine, and observe it.
Is the engine idle speed too high?
Yes
Repair the coolant temperature sensor circuit.
No
The system is normal.

7. Inspect ignition timing

A. Inspect the ignition timing.
Refer to: Timing Inspection (3.1.2
Mechanical System, General
Inspection).

Is the ignition timing normal?

Yes
Go to step 8.
No
Adjust the ignition timing.

M201 2014.01
3.1.12-42 Electronic Control System - M7 3.1.12-42

Test Conditions Details/Results/Actions

8. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-43 Electronic Control System - M7 3.1.12-43

Diagnosis Procedure for Acceleration Fault

Acceleration fault

Inspect DTC

Is the fault Yes

confirmed

No

Inspect air intake system

Is the fault Yes

confirmed

No

Inspect throttle

Is the fault Yes

confirmed

No

Inspect spark plug

Inspect fuel injector
Inspect fuel
Inspect air intake pressure sensor
and throttle position sensor
Inspect ignition timing Yes
Inspect exhaust backpressure Is the fault
confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-44 Electronic Control System - M7 3.1.12-44

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. Inspect air intake system

A. Inspect the air intake system for blockage.
B. Inspect the air intake system for leakage.
Is the air intake system normal?
Yes
Go to step 3.
No
Repair the air intake system.

3. Inspect throttle
A. Turn the ignition switch to "LOCK".
B. Inspect if the throttle is stuck.
C. Inspect the throttle for carbon deposit.
Is the throttle normal?
Yes
Go to step 4.
No
Clean or replace the throttle.

4. Inspect spark plug

A. Remove the spark plug.
B. Inspect the spark plug in each cylinder, and observe
whether the model and clearance meet the
standard.
Refer to: Spark Plug (3.1.8 Ignition
System, removal and
Installation).
Is the spark plug in each cylinder normal?
Yes
Go to step 5.
No
Replace the spark plug.

M201 2014.01
3.1.12-45 Electronic Control System - M7 3.1.12-45

Test Conditions Details/Results/Actions

5. Inspect fuel injector

A. Remove the fuel injectors.
B. Inspect the fuel injectors for leakage, blockage or
flow error.
Are they normal?
Yes
Go to step 6.
No
Replace the fuel injector.

6. Inspect fuel
A. Is the fault caused by just refueling?
Yes
Replace the fuel.
No
Go to step 7.

7. Inspect air intake pressure sensor and throttle position sensor

A. Turn the ignition switch to "LOCK".
B. Connect the diagnostic tool.
C. Start engine and inspect the data flow for air intake
pressure sensor and throttle position sensor.
Are their data flows normal?
Yes
Go to step 8.
No
Replace the air intake pressure sensor and throttle
position sensor, or repair the sensor circuit.
Refer to: (3.1.12 Electronic Control
System - M7, Removal and
Installation).

M201 2014.01
3.1.12-46 Electronic Control System - M7 3.1.12-46

Test Conditions Details/Results/Actions

8. Inspect ignition timing

A. Inspect the ignition timing.
Refer to: Timing Inspection (3.1.2
Mechanical System, General
Inspection).
Is the ignition timing normal?
Yes
Go to step 9.
No
Adjust the ignition timing.

9. Inspect exhaust backpressure

A. Inspect the exhaust backpressure.
Refer to: Exhaust Backpressure Test
(3.1.6 Exhaust System, General
Inspection).
Is the exhaust backpressure normal?
Yes
Go to step 10.
No
Repair the exhaust system.

M201 2014.01
3.1.12-47 Electronic Control System - M7 3.1.12-47

Test Conditions Details/Results/Actions

10.Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-48 Electronic Control System - M7 3.1.12-48

Diagnosis Procedure for Unstable engine operation

Unstable engine operation

Inspect DTC

Is the fault Yes

confirmed

No

General inspection

Is the fault Yes

confirmed

No

Inspect oxygen sensor

Is the fault Yes

confirmed

No

Inspect spark plug

Inspect fuel injector
Inspect fuel pressure
Inspect air intake pressure sensor
and throttle position sensor
Inspect ignition timing Yes
Inspect engine support Is the fault
components confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-49 Electronic Control System - M7 3.1.12-49

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. General inspection
A. Turn the ignition switch to "LOCK".
B. Inspect the air intake system for blockage.
C. Inspect the air intake system for leakage.
Refer to: Diagnosis Procedure for Intake
Air Leak (3.1.5 Air Intake System,
Diagnosis and Testing).
Is it normal?
Yes
Go to step 3.
No
Repair the fault parts.

3. Inspect oxygen sensor

A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", operate the
diagnostic tool to access to the engine data flow
and read "O2 sensor voltage bank1 sensor 1, O2
sensor voltage bank1 sensor 2".
Is the data flow normal?
Yes
Go to step 4.
No
Repair or replace the oxygen sensor or circuit.

M201 2014.01
3.1.12-50 Electronic Control System - M7 3.1.12-50

Test Conditions Details/Results/Actions

4. Inspect spark plug

A. Remove the spark plug.
B. Inspect the spark plug in each cylinder, and observe
whether the model and clearance meet the
standard.
Refer to: Spark Plug (3.1.8 Ignition
System, removal and
Installation).
Is the spark plug in each cylinder normal?
Yes
Go to step 5.
No
Replace the spark plug.

5. Inspect fuel injector

A. Remove the fuel injectors.
B. Inspect the fuel injectors for leakage, blockage or
flow error.
Are they normal?
Yes
Go to step 6.
No
Replace the fuel injector.

6. Inspect fuel pressure

A. Turn the ignition switch to "LOCK".
B. Measure the fuel pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
Is the fuel pressure normal?
Yes
Go to step 7.
No
Inspect the fuel system.

M201 2014.01
3.1.12-51 Electronic Control System - M7 3.1.12-51

Test Conditions Details/Results/Actions

7. Inspect air intake pressure sensor and throttle position sensor

A. Turn the ignition switch to "LOCK".
B. Connect the diagnostic tool.
C. Start engine and inspect the data flow for air intake
pressure sensor and throttle position sensor.
Are their data flows normal?
Yes
Go to step 8.
No
Replace the air intake pressure sensor and throttle
position sensor, or repair the sensor circuit.
Refer to: (3.1.12 Electronic Control
System - M7, Removal and
Installation).

8. Inspect ignition timing

A. Inspect the ignition timing.
Refer to: Timing Inspection (3.1.2
Mechanical System, General
Inspection).
Is the ignition timing normal?
Yes
Go to step 9.
No
Adjust the ignition timing.

9. Inspect engine support components

A. Inspect the engine support components.
Is there crack, damage, or loose or lost bolt on the
engine support components?
Yes
Repair the fault parts.
No
Go to step 10.

M201 2014.01
3.1.12-52 Electronic Control System - M7 3.1.12-52

Test Conditions Details/Results/Actions

10.Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-53 Electronic Control System - M7 3.1.12-53

Diagnosis Procedure for Easy Flameout at Start

Easy flameout at start

Inspect DTC

Yes
Is the fault
confirmed

No

General inspection

Yes
Is the fault
confirmed

No

Inspect crankshaft position

sensor waveform

Yes
Is the fault
confirmed

No

Inspect crankshaft position sensor

terminal 2 circuit
Inspect crankshaft position sensor
terminal 3 circuit
Inspect spark plug
Inspect fuel injector Yes
Inspect fuel pressure Is the fault
Inspect air intake pressure sensor confirmed
and throttle position sensor
Inspect ignition timing No
Inspect engine control module
circuit

End

M201 2014.01
3.1.12-54 Electronic Control System - M7 3.1.12-54

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. General inspection
A. Turn the ignition switch to "LOCK".
B. Inspect the air intake system for blockage.
C. Inspect the air intake system for leakage.
D. Inspect wiring harness connectors of oxygen
sensor, fuel injector, crankshaft position sensor and
ignition coil for disconnection, looseness or
damage.
Are they normal?
Yes
Go to step 3.
No
Repair the fault parts.

3. Inspect crankshaft position sensor waveform

A. Measure the waveform between terminals 2 and 3
of sensor with an oscilloscope when engine idling.
Standard waveform is as shown in left figure.
5V
Is it normal?
Yes
Go to step 6.
No
Go to step 4.
0V

M3112106

M201 2014.01
3.1.12-55 Electronic Control System - M7 3.1.12-55

Test Conditions Details/Results/Actions

4. Inspect crankshaft position sensor terminal 2 circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the crankshaft position sensor wiring
E18 harness connector E17.
C. Disconnect the ECM wiring harness connector E18.
1 2 9 22 D. Measure the resistance between terminal 2 of
crankshaft position sensor wiring harness connector
3 4 23 36
E17 and terminal 47 of ECM wiring harness
5 6 37 47 50
connector E18. Inspect for open circuit.
7 8 51 64
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 2 of
crankshaft position sensor wiring harness connector
E17 and reliable grounding. Inspect for short to
ground.
Standard resistance: 10 MΩ or more
F. Measure the voltage between terminal 2 of
crankshaft position sensor wiring harness connector
E17 and reliable grounding. Inspect for short to
power supply.
Standard voltage: 0 V
Is the circuit normal?
1 2 3
Yes
E17 Go to step 5.

M3112021
No
Repair the fault circuit between terminal 2 of
crankshaft position sensor E17 and terminal 47 of
engine control module E18.

1 2 3

E17
M3112022

1 2 3

E17
M3112023

M201 2014.01
3.1.12-56 Electronic Control System - M7 3.1.12-56

Test Conditions Details/Results/Actions

5. Inspect crankshaft position sensor terminal 3 circuit

A. Turn the ignition switch to "LOCK".
E18 B. Disconnect the crankshaft position sensor wiring
harness connector E17.
C. Disconnect the ECM wiring harness connector E18.
1 2 9 22
D. Measure the resistance between terminal 3 of
3 4 23 36 crankshaft position sensor wiring harness connector
5 6 37 40 50
E17 and terminal 40 of ECM wiring harness
connector E18. Inspect for open circuit.
7 8 51 64
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 3 of
crankshaft position sensor wiring harness connector
E17 and reliable grounding. Inspect for short to
ground.
Standard resistance: 10 MΩ or more
F. Measure the voltage between terminal 3 of
crankshaft position sensor wiring harness connector
E17 and reliable grounding. Inspect for short to
power supply.
Standard voltage: 0 V
1 2 3 Is the circuit normal?
Yes
E17
Replace the crankshaft position sensor.

M3112024 Refer to: Crankshaft Position Sensor

(3.1.12 Electronic Control
System - M7, Removal and
Installation).
No
Repair the fault circuit between terminal 3 of
crankshaft position sensor E17 and terminal 40 of
engine control module E18.
1 2 3

E17
M3112025

1 2 3

E17
M3112026

M201 2014.01
3.1.12-57 Electronic Control System - M7 3.1.12-57

Test Conditions Details/Results/Actions

6. Inspect spark plug

A. Remove the spark plug.
B. Inspect the spark plug in each cylinder, and observe
whether the model and clearance meet the
standard.
Refer to: Spark Plug (3.1.8 Ignition
System, removal and
Installation).
Is the spark plug in each cylinder normal?
Yes
Go to step 7.
No
Replace the spark plug.

7. Inspect fuel injector

A. Remove the fuel injectors.
B. Inspect the fuel injectors for leakage, blockage or
flow error.
Are they normal?
Yes
Go to step 8.
No
Clean or replace the fuel injector.

8. Inspect fuel pressure

A. Turn the ignition switch to "LOCK".
B. Measure the fuel pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
Is the fuel pressure normal?
Yes
Go to step 9.
No
Inspect the fuel system.

M201 2014.01
3.1.12-58 Electronic Control System - M7 3.1.12-58

Test Conditions Details/Results/Actions

9. Inspect air intake pressure sensor and throttle position sensor

A. Turn the ignition switch to "LOCK".
B. Connect the diagnostic tool.
C. Start engine and inspect the data flow for air intake
pressure sensor and throttle position sensor.
Are their data flows normal?
Yes
Go to step 10.
No
Replace the air intake pressure sensor and throttle
position sensor, or repair the sensor circuit.
Refer to: (3.1.12 Electronic Control
System - M7, Removal and
Installation).

10.Inspect ignition timing

A. Inspect the ignition timing.
Refer to: Timing Inspection (3.1.2
Mechanical System, General
Inspection).
Is the ignition timing normal?
Yes
Go to step 11.
No
Adjust the ignition timing.

M201 2014.01
3.1.12-59 Electronic Control System - M7 3.1.12-59

Test Conditions Details/Results/Actions

11.Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-60 Electronic Control System - M7 3.1.12-60

Diagnosis Procedure for Emergency During Vehicle Running

Emergency during
vehicle running

General inspection

Is the fault Yes

confirmed

No

Inspect DTC

Is the fault Yes

confirmed

No

Inspect data flow

Is the fault Yes

confirmed

No

Inspect crankshaft position sensor

signal plate
Inspect spark plug
Inspect fuel injector
Inspect fuel pressure
Inspect ignition timing Yes
Inspect carbon canister system Is the fault
Inspect exhaust backpressure confirmed

No
Inspect engine control module
circuit

End

M201 2014.01
3.1.12-61 Electronic Control System - M7 3.1.12-61

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the following items:
• Vacuum pipeline connection
• Air cleaner element
• No leaks in air intake system
• No limitation for air intake system
• Proper seal for intake manifold and its
installed components
• Ignition circuit
• Qualified fuel
• Electrical connection
• Smooth operation of throttle
Are they normal?
Yes
Go to step 2.
No
Repair the fault parts.

2. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 3.

3. Inspect data flow

A. Connect the diagnostic tool.
B. Use the diagnostic tool to inspect the following data
flow of engine:
Engine speed
Actual intake manifold pressure
Throttle position angle signal
Knock sensor signal 1
Knock sensor signal 2
Does the data flow change normally in the specified
range?
Yes
Go to step 4.
No
Repair the corresponding fault.

M201 2014.01
3.1.12-62 Electronic Control System - M7 3.1.12-62

Test Conditions Details/Results/Actions

4. Inspect crankshaft position sensor signal plate

A. Visually inspect the crankshaft position sensor
signal plate.
Is it normal?
Yes
Go to step 5.
No
Replace the crankshaft position sensor signal plate.

5. Inspect spark plug

A. Remove the spark plug.
B. Inspect the spark plug in each cylinder, and observe
whether the model and clearance meet the
standard.
Refer to: Spark Plug (3.1.8 Ignition
System, removal and
Installation).

Is the spark plug in each cylinder normal?

Yes
Go to step 6.
No
Replace the spark plug.

6. Inspect fuel injector

A. Remove the fuel injectors.
B. Inspect the fuel injectors for leakage, blockage or
flow error.
Are they normal?
Yes
Go to step 7.
No
Replace the fuel injector.

M201 2014.01
3.1.12-63 Electronic Control System - M7 3.1.12-63

Test Conditions Details/Results/Actions

7. Inspect fuel pressure

A. Turn the ignition switch to "LOCK".
B. Measure the fuel pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
Is the fuel pressure normal?
Yes
Go to step 8.
No
Inspect the fuel system.

8. Inspect ignition timing

A. Inspect the ignition timing.
Refer to: Timing Inspection (3.1.2
Mechanical System, General
Inspection).

Is the ignition timing normal?

Yes
Go to step 9.
No
Adjust the ignition timing.

9. Inspect carbon canister system

A. Inspect the carbon canister system.
Refer to: Carbon Canister Inspection
(3.1.11 Emission Control System,
General Inspection).
Is the carbon canister system normal?
Yes
Go to step 10.
No
Repair the carbon canister system.

M201 2014.01
3.1.12-64 Electronic Control System - M7 3.1.12-64

Test Conditions Details/Results/Actions

10.Inspect exhaust backpressure

A. Inspect the exhaust backpressure.
Refer to: Exhaust Backpressure Test
(3.1.6 Exhaust System, General
Inspection).
Is the exhaust backpressure normal?
Yes
Go to step 11.
No
Repair the exhaust system.

11.Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-65 Electronic Control System - M7 3.1.12-65

Diagnosis Procedure for Flameout During Coasting

Flameout during coasting

General inspection

Is the fault Yes

confirmed

No

Inspect engine idle speed

Is the fault Yes

confirmed

No

Inspect the condition with A/C

compressor or electric fan off

Is the fault Yes

confirmed

No

Inspect DTC
Inspect spark plug
Inspect fuel injector
Inspect fuel

Is the fault Yes

confirmed
Is the fault
confirmed No

No Inspect engine control module

circuit
Inspect air intake pressure sensor
and throttle position sensor
Inspect ignition timing
Inspect exhaust backpressure

End

M201 2014.01
3.1.12-66 Electronic Control System - M7 3.1.12-66

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect that the vacuum pipeline is correctly
positioned without any damage.
B. Inspect that the intake system has no leakage.
Are they normal?
Yes
Go to step 2.
No
Repair the fault parts.

2. Inspect engine idle speed

A. Inspect the engine idle speed.
Is the engine idle speed unstable?
Yes
Refer to: Diagnosis Procedure for Start
Normal but Idle Speed Unstable
at Any Time (3.1.12 Electronic
Control System - M7, Symptom
Diagnosis and Testing).
No
Go to step 3.

3. Inspect the condition with A/C compressor or electric fan off

A. Turn the ignition switch to "LOCK".
B. Disconnect the A/C compressor magnetic clutch
wiring harness connector.
C. Disconnect the electric fan wiring harness
connector.
D. Is the A/C system normal?
Is the system normal after disconnecting the
magnetic clutch and fan wiring harness connectors?
Yes
Repair magnetic clutch connection fault.
No
Go to step 4.

M201 2014.01
3.1.12-67 Electronic Control System - M7 3.1.12-67

Test Conditions Details/Results/Actions

4. Inspect DTC
A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON", and diagnose the
engine system.
Is there DTC?
Yes
Go to DTC diagnosis procedure.
No
Go to step 5.

5. Inspect spark plug

A. Remove the spark plug.
B. Inspect the spark plug in each cylinder, and observe
whether the model and clearance meet the
standard.
Refer to: Spark Plug (3.1.8 Ignition
System, removal and
Installation).
Is the spark plug in each cylinder normal?
Yes
Go to step 6.
No
Replace the spark plug.

6. Inspect fuel injector

A. Remove the fuel injectors.
B. Inspect the fuel injectors for leakage, blockage or
flow error.
Are they normal?
Yes
Go to step 7.
No
Replace or clean the fuel injector.

7. Inspect fuel
A. Is the fault caused by just refueling?
Yes
Replace the fuel.
No
Go to step 8.

M201 2014.01
3.1.12-68 Electronic Control System - M7 3.1.12-68

Test Conditions Details/Results/Actions

8. Inspect air intake pressure sensor and throttle position sensor

A. Turn the ignition switch to "LOCK".
B. Connect the diagnostic tool.
C. Start engine and inspect the data flow for air intake
pressure sensor and throttle position sensor.
Are their data flows normal?
Yes
Go to step 9.
No
Replace the air intake pressure sensor and throttle
position sensor, or repair the sensor circuit.
Refer to: (3.1.12 Electronic Control
System - M7, Removal and
Installation).

9. Inspect ignition timing

A. Inspect the ignition timing.
Refer to: Timing Inspection (3.1.2
Mechanical System, General
Inspection).
Is the ignition timing normal?
Yes
Go to step 10.
No
Adjust the ignition timing.

10.Inspect exhaust backpressure

A. Inspect the exhaust backpressure.
Refer to: Exhaust Backpressure Test
(3.1.6 Exhaust System, General
Inspection).
Is the exhaust backpressure normal?
Yes
Go to step 11.
No
Repair the exhaust system.

M201 2014.01
3.1.12-69 Electronic Control System - M7 3.1.12-69

Test Conditions Details/Results/Actions

11.Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-70 Electronic Control System - M7 3.1.12-70

DTC Diagnosis and Testing

Engine Control Module Terminal List

1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22

3 4 23 24 25 26 27 28 29 30 31 32 33 34 35 36

37 38 39 40 41 42 43 44 45 46 47 48 49 50
5 6

7 8 51 52 53 54 55 56 57 58 59 60 61 62 63 64

M3112027

Terminal
Wire Diameter/Color Definition
No.
1 1.25 BK/RD Ignition coil of cylinder 4

2 0.85 YE/WH Front oxygen sensor heating

3 1.25 BK/YE Ignition coil of cylinder 1

4 0.85 WH Rear oxygen sensor heating

5 2.0 BK Ignition GND

6 1.25 BK/VT Ignition coil of cylinder 2

7 1.25 BK/BU Ignition coil of cylinder 3

8 1.25 RD/BU Non-continuous power supply

9 0.5 WH/BU Engine speed output

10 0.5 BU/BK A/C medium pressure switch

11 - -

12 0.5 LG/RD Blower switch

13 0.5 LG/BK Evaporator thermistor

14 - -

15 0.5 LG/WH Diagnosis K-line

16 0.5 PK/BU Continuous power supply

17 0.5 BU Ignition switch

18 0.5 BU/BN 5 V power supply 2

19 0.5 YE/BK 5 V power supply 1

M201 2014.01
3.1.12-71 Electronic Control System - M7 3.1.12-71

Terminal
Wire Diameter/Color Definition
No.
20 0.5 VT/YE MIL indicator

21 0.5 GY/YE Stepper motor phase B

22 0.5 GY/GN Stepper motor phase A

23 - -

24 0.5 RD/YE Headlamp switch

25 0.5 BU/GN Air intake temperature sensor

26 0.5 BU/WH Throttle position sensor

27 - -

28 - -

29 0.5 YE Rear oxygen sensor

30 0.5 RD Knock sensor A side

31 0.5 GN Knock sensor B side

32 0.5 BN/WH Main relay

33 - -

34 - -

35 0.5 GY Stepper motor phase C

36 0.5 GY/BK Stepper motor phase D

37 0.5 RD/WH Carbon canister control valve

38 - -

39 0.5 YE/GN Sensor GND 1

40 0.5 BU/RD Sensor GND 2

41 0.5 BN/YE Coolant temperature sensor

42 - -

43 0.5 BK Electrical GND 1

44 0.5 PK/BK A/C switch

45 0.5 BK/OG Front oxygen sensor

46 - -

47 0.5 BU/WH Crankshaft position sensor

48 0.5 BK Power GND 1

49 0.5 WH/GN Cylinder 3 fuel injector

50 0.5 WH/BN Cylinder 1 fuel injector

51 0.5 RD/BU Non-continuous power supply

52 0.5 BK/WH Radiator-fan relay

53 - -

M201 2014.01
3.1.12-72 Electronic Control System - M7 3.1.12-72

Terminal
Wire Diameter/Color Definition
No.
54 - -

55 - -

56 0.5 YE/WH Coolant temperature output

57 0.5 YE/GN Vehicle speed signal

58 - -

59 0.5 YE/BN Air intake pressure sensor

60 0.5 YE/RD Fuel pump relay

61 0.5 BK/YE A/C compressor relay

62 0.5 BK/RD A/C condenser-fan relay

63 0.5 WH/YE Cylinder 2 fuel injector

64 0.5 WH/BK Cylinder 4 fuel injector

Diagnostic Trouble Code (DTC) Type

DTC Type Definition
Type 0 If the DTC type is 0, no lamp is on and the system makes no diagnosis.

Diagnosis for misfire related failure generally is defined as 2. For the misfire fault that
will cause damage to catalytic converters, MIL will immediately flash to warn the driver;
Type 2 for the misfire fault that may cause the deterioration of emissions, if in 3 consecutive
driving cycles, the relative level of misfire is all fully detected, then MIL will come on; the
fault will be deleted after 40 continuous trouble-free warm-up cycles.

After the fault is detected in 3 consecutive driving cycles, MIL will come on; then off if it
Type 3 is detected to be repaired in 3 consecutive driving cycles; and the fault will be deleted
after 40 continuous trouble-free warm-up cycles.

MIL will come on 2.5 seconds after the fault occurs; if it is detected to be repaired in 3
Type 4 consecutive driving cycles, MIL will go off; and the fault will be deleted after 40 continuous
trouble-free warm-up cycles.

If the fault is detected in 3 consecutive driving cycles, it will be confirmed but without
Type 5 lamp on; if the fault is detected to be repaired in 3 consecutive driving cycles, it proves
to be repaired; then deleted after 40 continuous trouble-free warm-up cycles.

Once the fault occurs, it will be confirmed immediately; then deleted after 40 continuous
Type 6 trouble-free warm-up cycles. No lamp will come on and universal scan tool is
unreadable for the fault.

The external test tools can activate the fuel supply system fault diagnosis and are
Type 7 generally used only for offline test or repair station. No lamp will come on and universal
scan tool is unreadable for the fault.

It is a special diagnostic path for fuel supply system. After the fault is detected in 3
consecutive driving cycles, MIL will come on; then off if it is detected to be repaired in 4
Type 11
consecutive driving cycles; and the fault will be deleted after 40 continuous trouble-free
warm-up cycles.

M201 2014.01
3.1.12-73 Electronic Control System - M7 3.1.12-73

DTC Type Definition

Once the fault occurs, it will be confirmed immediately and SVS will come on; then off if
Type 12 the fault is repaired; and it will be deleted after 40 continuous trouble-free warm-up
cycles. The universal scan tool is unreadable.

Once the fault occurs, SVS will come on, then off if the fault is repaired; or when the
fault is detected in 3 consecutive driving cycles and is confirmed, SVS will go off and
Type 13
MIL will come on; then off if the fault is detected to be repaired in 4 consecutive driving
cycles; and the fault will be deleted after 40 continuous trouble-free warm-up cycles.

Once the fault occurs, it will be confirmed immediately and SVS will flash; then off if the
Type 35
fault is repaired; and it will be deleted after 20 continuous trouble-free warm-up cycles.

Once the fault occurs, it will be confirmed immediately but without SVS on; and it will be
Type 36
deleted after 20 continuous trouble-free warm-up cycles.

Once the fault occurs, it will be confirmed immediately and SVS will flash; then off if it is
Type 38
repaired; and the fault memory will not record this fault.

Once the fault occurs, it will be confirmed immediately but without SVS on; the fault
Type 39
memory will not record this fault.

DTC Code List

DTC Code Description DTC Type MIL ON
P0030 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1) 3 √

O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1)

P0031 3 √
Low

O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 1)

P0032 3 √
High

P0036 O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2) 3 √

O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2)
P0037 3 √
Low

O2 Sensor Heater Contr. Circ. (Bank1 (1) Sensor 2)

P0038 3 √
High

P0053 O2 Sensor Heater Resistance (Bank1 (1) Sensor 1) 3 √

P0054 O2 Sensor Heater Resistance (Bank1 (1) Sensor 2) 3 √
Manifold Absolute Pressure/Barometric Pressure
P0105 3 √
Circuit

Manifold Abs.Pressure or Bar. Pressure Range/

P0106 3 √
Performance

P0107 Manifold Abs. Pressure or Bar. Pressure Low Input 3 √

P0108 Manifold Abs. Pressure or Bar. Pressure High Input 3 √
P0112 Intake Air Temp. Circ. Low Input 3 √
P0113 Intake Air Temp. Circ. High Input 3 √
P0117 Engine Coolant Temp. Circ. Low Input 3 √

M201 2014.01
3.1.12-74 Electronic Control System - M7 3.1.12-74

DTC Code Description DTC Type MIL ON

P0118 Engine Coolant Temp. Circ. High Input 3 √
P0122 Throttle/Pedal Pos. Sensor A Circ. Low Input 3 √
P0123 Throttle/Pedal Pos. Sensor A Circ. High Input 3 √
P0130 O2 Sensor Circ., Bank1-Sensor1 Malfunction 3 √
P0131 O2 Sensor Circ., Bank1-Sensor1 Low Voltage 3 √
P0132 O2 Sensor Circ., Bank1-Sensor1 High Voltage 3 √
P0133 O2 Sensor Circ., Bank1-Sensor1 Slow Response 3 √
P0134 O2 Sensor Circ., Bank1-Sensor1 No Activity Detected 3 √
P0136 O2 Sensor Circ., Bank1-Sensor2 Malfunction 3 √
P0137 O2 Sensor Circ., Bank1-Sensor2 Low Voltage 3 √
P0138 O2 Sensor Circ., Bank1-Sensor2 High Voltage 3 √
P0140 O2 Sensor Circ., Bank1-Sensor2 No Activity Detected 3 √
P0170 Fuel Trim, Bank1 Malfunction 7 ×

P0171 Fuel Trim, Bank1 System too Lean 7 ×

P0172 Fuel Trim, Bank1 System too Rich 7 ×

P0201 Cylinder 1 - Injector Circuit 3 √

P0202 Cylinder 2 - Injector Circuit 3 √
P0203 Cylinder 3 - Injector Circuit 3 √
P0204 Cylinder 4 - Injector Circuit 3 √
P0261 Cylinder 1 - Injector Circuit Low 3 √
P0262 Cylinder 1 - Injector Circuit High 3 √
P0264 Cylinder 2 - Injector Circuit Low 3 √
P0265 Cylinder 2 - Injector Circuit High 3 √
P0267 Cylinder 3 - Injector Circuit Low 3 √
P0268 Cylinder 3 - Injector Circuit High 3 √
P0270 Cylinder 4 - Injector Circuit Low 3 √
P0271 Cylinder 4 - Injector Circuit High 3 √
P0300 Random/Multiple Cylinder Misfire Detected 2 √ or flash

P0301 Cyl.1 Misfire Detected 2 √ or flash

P0302 Cyl.2 Misfire Detected 2 √ or flash

P0303 Cyl.3 Misfire Detected 2 √ or flash

P0304 Cyl.4 Misfire Detected 2 √ or flash

Ign./Distributor Eng. Speed Inp. Circ. Range/

P0321 3 √
Performance

M201 2014.01
3.1.12-75 Electronic Control System - M7 3.1.12-75

DTC Code Description DTC Type MIL ON

P0322 Ign./Distributor Eng. Speed Inp. Circ. No Signal 4 √
P0327 Knock Sensor 1 Circ. Low Input 3 √
P0328 Knock Sensor 1 Circ. High Input 3 √
P0420 Catalyst System, Bank1 Efficiency Below Threshold 3 √
Evaporative Emiss. System Purge Control Valve Circ.
P0444 3 √
Open

Evaporative Emission System Purge Control Valve

P0458 3 √
Circuit Low

Evaporative Emission System Purge Control Valve

P0459 3 √
Circuit High

P0480 Cooling Fan 1 Control Circuit 5 ×

P0481 Cooling Fan 2 Control Circuit 5 ×

P0501 Vehicle Speed Sensor Range/Performance 3 √

P0506 Idle Control System RPM Lower than Expected 3 √
P0507 Idle Control System RPM Higher than Expected 3 √
P0508 Idle Air Control System Circuit Low 3 √
P0509 Idle Air Control System Circuit High 3 √
P0511 Idle Air Control Circuit 3 √
P0537 A/C Evaporator Temperature Sensor Circuit Low 5 ×

P0538 A/C Evaporator Temperature Sensor Circuit High 5 ×

P0560 System Voltage Malfunction 5 ×

P0562 System Voltage Low Voltage 5 ×

P0563 System Voltage High Voltage 5 ×

P0602 Control Module Programming Error 3 √

P0627 Fuel Pump "A" Control Circuit/Open 3 √
P0628 Fuel Pump "A" Control Circuit Low 3 √
P0629 Fuel Pump "A" Control Circuit High 3 √
P0645 AC Clutch Relais Circuit 5 ×

P0646 A/C Clutch Relay Control Circuit Low 5 ×

P0647 A/C Clutch Relay Control Circuit High 5 ×

P0650 Malfunction Indicator Lamp Control Circ. 3 √

P0691 Cooling Fan 1 Control Circuit Low 5 ×

P0692 Cooling Fan 1 Control Circuit High 5 ×

P0693 Cooling Fan 2 Control Circuit Low 5 ×

P0694 Cooling Fan 2 Control Circuit High 5 ×

M201 2014.01
3.1.12-76 Electronic Control System - M7 3.1.12-76

DTC Code Description DTC Type MIL ON

P2177 System Too Lean Off Idle 11 √
P2178 System Too Rich Off Idle 11 √
P2187 System Too Lean at Idle 11 √
P2188 System Too Rich at Idle 11 √
P2195 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 1 3 √
P2196 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 1 3 √
P2270 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 2 3 √
P2271 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 2 3 √

M201 2014.01
3.1.12-77 Electronic Control System - M7 3.1.12-77

Failure Protection List

Prerequisite of
Failure-Protection
DTC Code Description Releasing Failure
Operation
Protection
P0262, P0261, Repair the circuit fault
Cylinder 1 injector circuit fault -
P0201 or replace the injector.

P0268, P0267, Repair the circuit fault

Cylinder 2 injector circuit fault -
P0203 or replace the injector.

P0271, P0270, Repair the circuit fault

Cylinder 3 injector circuit fault -
P0204 or replace the injector.

P0265, P0264, Repair the circuit fault

Cylinder 4 injector circuit fault -
P0202 or replace the injector.

Repair the rear oxygen

• Rear oxygen sensor
P0038, P0037, Rear oxygen sensor heating circuit fault or replace
internal resistance
P0036 circuit fault the rear oxygen
reasonable diagnosis off
sensor.

Repair the front

• Turn off rear oxygen
P0032, P0031, Front oxygen sensor heating oxygen circuit fault or
sensor function and
P0030 circuit fault replace the front
diagnose
oxygen sensor.

P0647, P0646,
A/C circuit fault - Repair the circuit fault.
P0645

P0629, P0628,
Fuel pump relay circuit fault - Repair the circuit fault.
P0627

P0692, P0691,
Low speed fan control circuit fault - Repair the circuit fault.
P0480

P0694, P0693,
High speed fan control circuit fault - Repair the circuit fault.
P0481

P0650 MIL circuit fault - Repair the circuit fault.

M201 2014.01
3.1.12-78 Electronic Control System - M7 3.1.12-78

Prerequisite of
Failure-Protection
DTC Code Description Releasing Failure
Operation
Protection
• Turn rear oxygen control
function off
• Turn catalytic converter
diagnosis off
• Turn idle diagnosis off
• Turn front oxygen sensor
aging diagnosis off
• Turn rear oxygen sensor
P0459, P0458, Carbon canister valve control aging diagnosis off Repair the circuit fault.
P0444 circuit fault
• Turn front oxygen sensor
internal resistance
reasonable diagnosis off
• Turn rear oxygen sensor
internal resistance
reasonable diagnosis off
• Turn misfire detection fuel
supply self-learning
function off

Diagnose the Diagnostic Data

Repair the fault or
P0602 Identification (DDI) code -
update the data.
programming

1. Misfire fault (E_md = 1)

• Turn misfire detection fuel
supply self-learning
function off
2. B_mdarv set due to
misfire
• Turn off rear oxygen
control %LRHK
Repair the fault and
P0300, P0301, • Misfire detection fuel
One cylinder or multi-cylinder inspect the ignition
P0302, P0303, supply self-learning
misfire system and fuel supply
P0304
• Forbid air-fuel ratio self- system.
learning
• Forbid carbon canister
flushing
3. Maximum misfire fault is
detected and cylinder cut-
off operation is performed:
• Turn off Lambda closed
loop control

M201 2014.01
3.1.12-79 Electronic Control System - M7 3.1.12-79

Prerequisite of
Failure-Protection
DTC Code Description Releasing Failure
Operation
Protection
• Forbid catalytic converter
diagnosis
• Forbid front/rear oxygen
sensor aging diagnosis Repair the fault, and
• Forbid carbon canister inspect the fuel supply
P2177, P2178 Fuel supply system
passive detection components and
oxygen sensor circuit.
• Forbid rear oxygen closed
loop
• Forbid misfire detection
fuel supply self-learning

• Forbid front oxygen sensor

aging diagnosis
Repair the fault or
• Forbid catalytic converter
P0054 Rear oxygen sensor heating replace the rear
diagnosis
oxygen sensor.
• Forbid rear oxygen closed
loop control

• Forbid front oxygen sensor

aging diagnosis
• Forbid catalytic converter
diagnosis Repair the fault or
P0053 Front oxygen sensor heating replace the front
• Forbid rear oxygen closed oxygen sensor.
loop control
• Forbid fuel supply system
self-learning

• Forbid catalytic converter

diagnosis Repair the fault or
P2270, P2271 Rear oxygen sensor aging replace the oxygen
• Forbid rear oxygen sensor sensor.
closed loop control

Repair the fault or

P0133, P2195, • Forbid catalytic converter
Front oxygen sensor aging replace the oxygen
P2196 diagnosis
sensor.

• Forbid catalytic converter Repair the fault,

P0138, P0137, diagnosis inspect the sensor
Rear oxygen sensor circuit
P0136, P0140 • Forbid rear oxygen sensor circuit or replace the
aging diagnosis oxygen sensor.

M201 2014.01
3.1.12-80 Electronic Control System - M7 3.1.12-80

Prerequisite of
Failure-Protection
DTC Code Description Releasing Failure
Operation
Protection
• Forbid catalytic converter
diagnosis
• Forbid fuel supply system Repair the fault,
P0130, P0131, self-learning inspect the sensor
Front oxygen sensor circuit
P0132, P0134 • Forbid front oxygen sensor circuit or replace the
closed loop oxygen sensor.

• Forbid oxygen sensor

aging diagnosis

• Forbid rear oxygen closed

loop Repair the fault,
P0420 Catalytic converter • Forbid front oxygen sensor replace the catalytic
rational curves drift converter.
diagnosis

• Ignition angle of each

Repair the fault, and
cylinder is retarded for - 9
P0327 Knock sensor open fault inspect the knock
degrees when entering
sensor connection.
knock control

• Ignition angle of each

Repair the fault, and
cylinder is retarded for - 9
P0328 Knock sensor short fault inspect the knock
degrees when entering
sensor connection.
knock control

M201 2014.01
3.1.12-81 Electronic Control System - M7 3.1.12-81

Data Flow List

By reading the "Actual values" displayed on the diagnostic tool, the working state of switches, sensors,
and actuators can be inspected without removing any components. Before the fault diagnosis of
electronic control system, observing and analyzing the data first in troubleshooting can shorten the
troubleshooting time.
CAUTION: The following table lists the data under normal conditions, only for reference. Do
not depend solely on these reference values when deciding whether a part is faulty or not.
Generally, compare a normal vehicle to the diagnosing vehicle under the same state, to
determine whether the data of diagnosing vehicle under the current state is normal or not.

1. Allow the engine to reach normal operating temperature.

2. Turn the ignition switch to "LOCK".
3. Connect the diagnostic tool.
4. Turn the ignition switch to "ON", and turn on the diagnostic tool.
5. Select "UAES M788/Actual values/Diagnostic Data".
6. Refer to the chart below to inspect each item.

Ignition Switch Engine Speed

Item Idling
"ON" 2000 rpm
Battery voltage 11.62 V 13.65 V 13.65 V

Engine speed 0 rpm 902 rpm 2112 rpm

Desired idle speed [without offset] 900 rpm 900 rpm 900 rpm

Desired idle speed [with offset] 900 rpm 900 rpm 900 rpm

Vehicle speed 0 km/h 0 km/h 0 km/h

vehicle acceleration 0.0 m/s2 0.0 m/s2 0.0 m/s2

Engine coolant temperature sensor

0.88 V 0.66 V 0.68 V
voltage

Engine coolant temperature 66°C 78°C 78°C

Intake air temperature sensor voltage 2.38 V 2.38 V 2.38 V

Intake air temperature 27°C 27°C 27°C

Ambient temperature 9°C 9°C 9°C

AC sensor 1.74 V 1.74 V 1.74 V

AC temperature 16.4°C 16.4°C 16.4°C

Actual intake manifold pressure sensor

4.0 V 1.07 V 0.7 V
voltage

Actual intake manifold pressure 1010 hPa 340 hPa 260 hPa

Air mass flow filtered 0.0 kg/h 9.1 kg/h 13.6 kg/h

Desired position of stepper motor 122 64 47

ADC-signal throttle angle 0.52 V 0.52 V 0.68 V

M201 2014.01
3.1.12-82 Electronic Control System - M7 3.1.12-82

Ignition Switch Engine Speed

Item Idling
"ON" 2000 rpm
Throttle position angle signal 10.45% 10.45% 13.67%

Calculated throttle position 0.0% 0.0% 3.5%

Throttle motor PWM control signal 0.0% 0.0% 0.0%

Control valve canister purge valve 0.0% 0.0% 5.9%

Dwell time 4.4 ms 2.6 ms 3.3 ms

Average injector base pulse width 0.0 ms 2.9 ms 2.8 ms

Ignition timing advance cylinder 1 0.0° 5.0° 30.5°

Volumetric flow of fuel in l/h 0.0 L/h 0.75 L/h 1.174 L/h

Knock sensor signal bank1 0.0 V 0.0 V 0.0 V

Knock sensor signal bank2 0.0 V 0.0 V 0.0 V

Ignition retard knock control cylinder 1 -0.0 -0.0 -0.0

Ignition retard knock control cylinder 2 -0.0 -0.0 -0.0

Ignition retard knock control cylinder 3 -0.0 -0.0 -0.0

Ignition retard knock control cylinder 4 -0.0 -0.0 -0.0

O2 sensor integrator bank 1 [short term

1.00 0.9 1.04
fuel trim]

O2 sensor voltage bank 1, sensor 1 0.5 V 0.57 V 0.1 V

O2 sensor voltage bank 1, sensor 2 0.5 V 0.49 V 0.6 V

O2 sensor integrator bank 1 [long term

1.0 1.0 1.0
fuel trim]

Final long term corr. factor bank 1 0.0% 0.0% 0.0%

Modeled temperature at inlet valve 46.5°C 46.5°C 46.5°C

Relative engine load 100.0% 21.1% 16.2%

Idle torque control adapt -0.7% 2.6% 0.9%

Idle speed control desired torque change 0.0% -0.8% 0.0%

Relative fuel part of the purge control 0.0% 0.0% 1.2%

Canister purge rate 0.0% 0.0% 0.0%

Charcoal canister charge 0.0 0.0 12.6

Operating time since prime start 0 min 0 min 0 min

M201 2014.01
3.1.12-83 Electronic Control System - M7 3.1.12-83

Active Test List

Through the "Actuators" in the diagnostic tool, the working state of relays and actuators controlled by
ECM can be tested without removing any components. Before the fault diagnosis of electronic control
system, performing the active test first in troubleshooting can shorten the troubleshooting time.
CAUTION: The following table lists the data under normal conditions, only for reference. Do
not depend solely on these reference values when deciding whether a part is faulty or not.
Generally, compare a normal vehicle to the diagnosing vehicle under the same state, to
determine whether the data of diagnosing vehicle under the current state is normal or not.

1. Allow the engine to reach normal operating temperature.

2. Turn the ignition switch to "LOCK".
3. Connect the diagnostic tool.
4. Turn the ignition switch to "ON", and turn on the diagnostic tool.
5. Select "UAES M788/Actuators".
6. Refer to the chart below to perform active test.

Diagnostic Tool Control

Description Diagnosis Description
Display Range
Engine Indicator Enable the engine indicator
On/Off -
Lamp (MIL) lamp

Test conditions: The vehicle speed

must be equal to zero. There must not
Fuel Pump Relay Enable the fuel pump On/Off
be any vehicle speed sensor
malfunction detected.

Test conditions for Fan Relay Off: The

engine coolant temperature must be
below a unique calibration threshold
(lower than 100°C). Otherwise, the
Cooling Fan Relay ECM should turn on the fan to prevent
Enable the cooling fan #1 On/Off
#1 engine from overheating. Air
conditioning request is not allowed.
Test condition for Fan Relay On: No
device control limit for this case.

Test conditions for Fan Relay Off: The

engine coolant temperature must be
below a unique calibration threshold
(lower than 100°C). Otherwise, the
Cooling Fan Relay ECM should turn on the fan to prevent
Enable the cooling fan #2 On/Off
#2 engine from overheating. Air
conditioning request is not allowed.
Test condition for Fan Relay On: No
device control limit for this case.

Retard the ignition coil ignition

Spark Retard 0-7 -
angle

Set Stepper Test condition: No stepper actuator test

Set the stepper motor position 0-255
Position active.

M201 2014.01
3.1.12-84 Electronic Control System - M7 3.1.12-84

Diagnostic Tool Control

Description Diagnosis Description
Display Range
Canister Purge Control the carbon canister
0-100 -
Solenoid control valve duty ratio

Air Condition Clutch Engage the A/C clutch On/Off Test condition: Engine is not running.

Test conditions: The vehicle speed

Cylinder 1/
must be equal to zero. There must not
Fuel Injector Disable the injector fuel Cylinder 2/
be any vehicle speed sensor
Disable injection Cylinder 3/
malfunction detected. The oxygen
Cylinder 4
sensor state must be in "lean".

Test condition: The engine idle speed

Idle Speed Control Control the idle speed 0-2550
must be less than 1000 rpm.

Stepper Actuator Test condition: No set stepper position

Test the stepper motor On/Off
Test active.

DTC Diagnosis Procedure Index

DTC Code Description Diagnosis Procedures
O2 Sensor Heater Contr. Circ. (Bank1(1) Refer to: DTCs P0030, P0031,
P0030
Sensor 1) P0032, P0053
O2 Sensor Heater Contr. Circ. (Bank1 (1)
P0031
Sensor 1) Low

O2 Sensor Heater Contr. Circ. (Bank1(1)

P0032
Sensor 1) High

O2 Sensor Heater Contr. Circ. (Bank1 (1) Refer to: DTCs P0036, P0037,
P0036
Sensor 2) P0038, P0054
O2 Sensor Heater Contr. Circ. (Bank1 (1)
P0037
Sensor 2) Low

O2 Sensor Heater Contr. Circ. (Bank1 (1)

P0038
Sensor 2) High

O2 Sensor Heater Resistance (Bank1 (1) Refer to: DTCs P0030, P0031,
P0053
Sensor 1) P0032, P0053

O2 Sensor Heater Resistance (Bank1 (1) Refer to: DTCs P0036, P0037,
P0054
Sensor 2) P0038, P0054
Manifold Absolute Pressure/Barometric Refer to: DTCs P0105, P0106,
P0105
Pressure Circuit P0107, P0108
Manifold Abs. Pressure or Bar. Pressure
P0106
Range/Performance

Manifold Abs. Pressure or Bar. Pressure Low

P0107
Input

Manifold Abs. Pressure or Bar. Pressure High

P0108
Input

M201 2014.01
3.1.12-85 Electronic Control System - M7 3.1.12-85

DTC Code Description Diagnosis Procedures

P0112 Intake Air Temp. Circ. Low Input Refer to: DTCs P0112, P0113
P0113 Intake Air Temp. Circ. High Input

P0117 Engine Coolant Temp. Circ. Low Input Refer to: DTCs P0117, P0118
P0118 Engine Coolant Temp. Circ. High Input

P0122 Throttle/Pedal Pos. Sensor A Circ. Low Input Refer to: DTCs P0122, P0123
P0123 Throttle/Pedal Pos. Sensor A Circ. High Input

P0130 O2 Sensor Circ., Bank1-Sensor1 Malfunction Refer to: DTCs P0130, P0131,
P0131 O2 Sensor Circ., Bank1-Sensor1 Low Voltage P0132, P0133, P0134,
P2195, P2196
P0132 O2 Sensor Circ., Bank1-Sensor1 High Voltage

O2 Sensor Circ., Bank1-Sensor1 Slow

P0133
Response

O2 Sensor Circ., Bank1-Sensor1 No Activity

P0134
Detected

P0136 O2 Sensor Circ., Bank1-Sensor2 Malfunction Refer to: DTCs P0136, P0137,
P0137 O2 Sensor Circ., Bank1-Sensor2 Low Voltage P0138, P0140, P2270,
P2271
P0138 O2 Sensor Circ., Bank1-Sensor2 High Voltage

O2 Sensor Circ., Bank1-Sensor2 No Activity

P0140
Detected

P0201 Cylinder 1 - Injector Circuit Refer to: DTCs P0201, P0261,

P0202 Cylinder 2 - Injector Circuit P0262

P0203 Cylinder 3 - Injector Circuit

P0204 Cylinder 4 - Injector Circuit

P0261 Cylinder 1 - Injector Circuit Low

P0262 Cylinder 1 - Injector Circuit High

P0264 Cylinder 2 - Injector Circuit Low

P0265 Cylinder 2 - Injector Circuit High

P0267 Cylinder 3 - Injector Circuit Low

P0268 Cylinder 3 - Injector Circuit High

P0270 Cylinder 4 - Injector Circuit Low

P0271 Cylinder 4 - Injector Circuit High

P0300 Random/Multiple Cylinder Misfire Detected Refer to: DTCs P0300, P0301,
P0301 Cyl.1 Misfire Detected P0302, P0303, P0304

P0302 Cyl.2 Misfire Detected

P0303 Cyl.3 Misfire Detected

P0304 Cyl.4 Misfire Detected

M201 2014.01
3.1.12-86 Electronic Control System - M7 3.1.12-86

DTC Code Description Diagnosis Procedures

Ign./Distributor Eng. Speed Inp. Circ. Range/ Refer to: DTCs P0321, P0322
P0321
Performance

Ign./Distributor Eng. Speed Inp. Circ. No

P0322
Signal

P0327 Knock Sensor 1 Circ. Low Input Refer to: DTCs P0327, P0328
P0328 Knock Sensor 1 Circ. High Input

Catalyst System, Bank1 Efficiency Below Refer to: DTC P0420

P0420
Threshold

Evaporative Emiss. System Purge Control Refer to: DTCs P0444, P0458,
P0444
Valve Circ. Open P0459
Evaporative Emission System Purge Control
P0458
Valve Circuit Low

Evaporative Emission System Purge Control

P0459
Valve Circuit High

P0480 Cooling Fan 1 Control Circuit Refer to: DTCs P0480, P0691,
P0481 Cooling Fan 2 Control Circuit P0692

Idle Control System RPM Lower than Refer to: DTCs P0506, P0507
P0506
Expected

Idle Control System RPM Higher than

P0507
Expected

P0508 Idle Air Control System Circuit Low Refer to: DTCs P0508, P0509,
P0509 Idle Air Control System Circuit High P0511

P0511 Idle Air Control Circuit

P0560 System Voltage Malfunction Refer to: DTCs P0560, P0562,

P0562 System Voltage Low Voltage P0563

P0563 System Voltage High Voltage

P0602 Control Module Programming Error Refer to: DTC P0602

P0627 Fuel Pump "A" Control Circuit/Open Refer to: DTCs P0627, P0628,
P0628 Fuel Pump "A" Control Circuit Low P0629

P0629 Fuel Pump "A" Control Circuit High

P0645 AC Clutch Relais Circuit Refer to: DTCs P0645, P0646,

P0646 A/C Clutch Relay Control Circuit Low P0647

P0647 A/C Clutch Relay Control Circuit High

P0650 Malfunction Indicator Lamp Control Circ. Refer to: DTC P0650

M201 2014.01
3.1.12-87 Electronic Control System - M7 3.1.12-87

DTC Code Description Diagnosis Procedures

P0691 Cooling Fan 1 Control Circuit Low Refer to: DTCs P0480, P0691,
P0692 Cooling Fan 1 Control Circuit High P0692

P0693 Cooling Fan 2 Control Circuit Low

P0694 Cooling Fan 2 Control Circuit High

P2177 System Too Lean Off Idle Refer to: DTCs P2177, P2178,
P2178 System Too Rich Off Idle P2187, P2188

P2187 System Too Lean at Idle

P2188 System Too Rich at Idle

P2195 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 1 Refer to: DTCs P0130, P0131,
P0132, P0133, P0134,
P2196 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 1 P2195, P2196
P2270 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 2 Refer to: DTCs P0136, P0137,
P0138, P0140, P2270,
P2271 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 2 P2271

M201 2014.01
3.1.12-88 Electronic Control System - M7 3.1.12-88

DTCs P0030, P0031, P0032, P0053

1. DTC Description

DTC Code Description Definition

O2 Sensor Heater Contr. Circ.
P0030
(Bank1 (1) Sensor 1)
The working voltage of front oxygen sensor heater is
O2 Sensor Heater Contr. Circ. provided by the main relay that is controlled by ECM.
P0031
(Bank1 (1) Sensor 1) Low When the ignition switch is turned to "ON", battery
O2 Sensor Heater Contr. Circ. voltage is applied to the terminal 4 of front oxygen sensor
P0032 connector E01. ECM controls the working time of heater
(Bank1 (1) Sensor 1) High
by the terminal 2 of ECM connector E18.
O2 Sensor Heater Resistance
P0053
(Bank1 (1) Sensor 1)

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
P0030 • Open circuit
Hardware circuit
P0031 • Short to ground
inspection
P0032 • Short to power • Sensor circuit
• Exhaust temperature is within • Sensor
Present resistance value 250°C ~ 550°C • ECM
P0053 is greater than threshold • Front oxygen sensor internal
value resistance value is higher than
about 1600 Ω

M201 2014.01
3.1.12-89 Electronic Control System - M7 3.1.12-89
3. Diagnosis Procedure

P0030, P0031,
P0032, P0053

General inspection

Is the fault Yes

confirmed

No
Inspect front oxygen sensor
heater resistance
Inspect heater working voltage

No Is the fault
confirmed

Yes

Inspect heater power supply

circuit

Is the fault Yes

confirmed

No

Inspect heater control signal circuit

Is the fault Yes

confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-90 Electronic Control System - M7 3.1.12-90

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wire harness connector related to the
front oxygen sensor for damage, poor contact,
aging and looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect front oxygen sensor heater resistance

A. Turn the ignition switch to "LOCK".
B. Disconnect the front oxygen sensor wiring harness
connector.
C. Measure the resistance of heater between terminals
4 and 3 of front oxygen sensor .
Standard resistance: 7 ~ 14 Ω (normal
temperature)
Is the resistance value normal?
Yes
Go to step 3.
No
Replace the front oxygen sensor. Make sure the
system is normal.

3. Inspect heater working voltage

A. Turn the ignition switch to "LOCK".
B. Disconnect the front oxygen sensor wiring harness
connector E01.
1 3 C. Turn the ignition switch to "ON".
D. Measure the voltage between terminal 4 of front
2 4 oxygen sensor wiring harness connector E01 and
reliable grounding.
E01 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
M3112028
Go to step 5.
No
Go to step 4.

M201 2014.01
3.1.12-91 Electronic Control System - M7 3.1.12-91

Test Conditions Details/Results/Actions

4. Inspect heater power supply circuit

A. Remove the fuse IF30.
B. Inspect the fuse.
Is the fuse normal?
Yes
Inspect and repair the conductivity between terminal
4 of front oxygen sensor wiring harness connector
E01 and terminal 60 of fuse IF30 in the instrument
panel fuse box P40.
No
Replace the fuse. Go to step 5.

M201 2014.01
3.1.12-92 Electronic Control System - M7 3.1.12-92

Test Conditions Details/Results/Actions

5. Inspect heater control signal circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the front oxygen sensor wiring harness
connector E01.
C. Measure the voltage between terminal 3 of E01 and
reliable grounding.
1 3
Standard voltage: 0 V
2 4 D. Disconnect the ECM wiring harness connector E18.
E. Measure the resistance between terminal 3 of front
E01 oxygen sensor wiring harness connector E01 and
terminal 2 of ECM wiring harness connector E18.
M3112029 Inspect for open circuit.
Standard resistance: less than 5 Ω
F. Measure the resistance between terminal 3 of E01
and reliable grounding.
E01
Standard resistance: 10 MΩ or more
Are they normal?
1 3
Yes
2 4 Go to step 6.
No
Repair the fault circuit between terminal 3 of front
oxygen sensor wiring harness connector E01 and
terminal 2 of ECM wiring harness connector E18.
Verify that the system is normal.

1 2 9 22

3 4 23 36

5 6 37 50

7 8 51 64

E18

M3112030

1 3

2 4

E01

M3112031

M201 2014.01
3.1.12-93 Electronic Control System - M7 3.1.12-93

Test Conditions Details/Results/Actions

6. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-94 Electronic Control System - M7 3.1.12-94

DTCs P0036, P0037, P0038, P0054

1. DTC Description

DTC Code Description Definition

O2 Sensor Heater Contr. Circ.
P0036
(Bank1 (1) Sensor 2)
The working voltage of rear oxygen sensor heater is
O2 Sensor Heater Contr. Circ. provided by the main relay that is controlled by ECM.
P0037
(Bank1 (1) Sensor 2) Low When the ignition switch is turned to "ON", battery
O2 Sensor Heater Contr. Circ. voltage is applied to the terminal 3 of rear oxygen sensor
P0038 connector S14. ECM controls the working time of heater
(Bank1 (1) Sensor 2) High
by the terminal 4 of ECM wiring harness connector E18.
O2 Sensor Heater Resistance
P0054
(Bank1 (1) Sensor 2)

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
P0036 • Open circuit
Hardware circuit
P0037 • Short to ground
inspection
P0038 • Short to power • Sensor circuit
• Exhaust temperature is within • Sensor
Present resistance value 250°C ~ 550°C • ECM
P0054 is greater than threshold • Rear oxygen sensor internal
value resistance value is higher than
about 2200 Ω

M201 2014.01
3.1.12-95 Electronic Control System - M7 3.1.12-95
3. Diagnosis Procedure

P0036, P0037,
P0038, P0054

General inspection

Is the fault Yes

confirmed

No

Inspect rear oxygen sensor heater

resistance
Inspect heater working voltage

No Is the fault
confirmed

Yes

Inspect heater power supply circuit

Is the fault Yes

confirmed

No

Inspect heater control signal circuit

Is the fault Yes

confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-96 Electronic Control System - M7 3.1.12-96

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wire harness connector related to the
rear oxygen sensor for damage, poor contact, aging
and looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect rear oxygen sensor heater resistance

A. Turn the ignition switch to "LOCK".
B. Disconnect the rear oxygen sensor wiring harness
connector S14.
C. Measure the resistance of heater between terminals
1 and 3 of rear oxygen sensor.
Standard resistance: 7 ~ 14 Ω (normal
temperature)
Is it normal?
Yes
Go to step 3.
No
Replace the rear oxygen sensor. Make sure the
system is normal.

3. Inspect heater working voltage

A. Turn the ignition switch to "LOCK".
B. Disconnect the rear oxygen sensor wiring harness
connector S14.

2 1 C. Turn the ignition switch to "ON".

D. Measure the voltage between terminal 3 of rear
4 3 oxygen sensor wiring harness connector S14 and
reliable grounding.

S14 Standard voltage: 11 ~ 14 V

Is the voltage value normal?
Yes
M3112032
Go to step 5.
No
Go to step 4.

M201 2014.01
3.1.12-97 Electronic Control System - M7 3.1.12-97

Test Conditions Details/Results/Actions

4. Inspect heater power supply circuit

A. Remove the fuse IF30.
B. Inspect the fuse.
Standard resistance: less than 5 Ω
Is the fuse normal?
Yes
Inspect and repair the conductivity between terminal
3 of rear oxygen sensor wiring harness connector
S14 and terminal 60 of fuse IF30 in the instrument
panel fuse box P40.
No
Replace the fuse. Go to step 5.

M201 2014.01
3.1.12-98 Electronic Control System - M7 3.1.12-98

Test Conditions Details/Results/Actions

5. Inspect heater control signal circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the rear oxygen sensor wiring harness
connector S14.
C. Measure the voltage between terminal 1 of S14 and
reliable grounding.
2 1
Standard voltage: 0 V
4 3
D. Disconnect the ECM wiring harness connector E18.
E. Measure the resistance between terminal 1 of rear
S14 oxygen sensor wiring harness connector S14 and
terminal 4 of ECM wiring harness connector E18.
M3112033 Inspect for open circuit.
Standard resistance: less than 5 Ω
F. Measure the resistance between terminal 1 of S14
S14 and reliable grounding.
Standard resistance: 10 MΩ or more
2 1 Is it normal?
4 3 Yes
Go to step 6.
No
Repair the fault circuit between the terminal 1 of
rear oxygen sensor wiring harness connector S14
and terminal 4 of ECM wiring harness connector
E18.

1 9 22

3 4 23 36

5 6 37 50

7 8 51 64

E18

M3112034

2 1

4 3

S14

M3112035

M201 2014.01
3.1.12-99 Electronic Control System - M7 3.1.12-99

Test Conditions Details/Results/Actions

6. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-100 Electronic Control System - M7 3.1.12-100

DTCs P0105, P0106, P0107, P0108

1. DTC Description

DTC Code Description Definition

Manifold Absolute Pressure/
P0105 Air intake pressure/temperature sensor has four
Barometric Pressure Circuit
terminals. When the ignition switch is turned to
Manifold Abs.Pressure or Bar. "ON", the ECM provides 5 V to the terminal 3 of
P0106
Pressure Range/Performance sensor through terminal 19 of connector E18; the
Manifold Abs. Pressure or terminal 40 of E18 enables the terminal 1 of sensor
P0107 grounding; and the terminal 4 of sensor provides an
Bar.Pressure Low Input
signal that changes according to the air intake
Manifold Abs. Pressure or Bar. pressure to terminal 59 of ECM connector E18.
P0108
Pressure High Input

2. Possible Causes

Setting Conditions (Control

DTC Code Monitor Strategy Faulty Area
Strategy)
• Engine speed is more than 800
rpm
Signal inspection: no
P0105 • Pressure drops less than 20 hPa
pressure drop after start
after starting
• Last for more than 1 s

• Depend on engine speed and

P0106 signal non-plausible throttle opening • Sensor circuit
• Last for more than 1 s • Sensor
• Pressure sensor voltage is lower • ECM
Circuit inspection, lower than 0.195 V
P0107
limit exceeded
• Last for more than 1 s

• 1 s after start
Circuit inspection, upper • Pressure sensor voltage is more
P0108
limit exceeded than 4.883 V
• Last for more than 1 s

M201 2014.01
3.1.12-101 Electronic Control System - M7 3.1.12-101
3. Diagnosis Procedure

P0105, P0106,
P0107, P0108

General inspection

Is the fault Yes

confirmed

No

Inspect air intake pressure

sensor voltage

No Is the fault
confirmed

Yes

Inspect power supply circuit of

air intake pressure sensor

Is the fault Yes

confirmed

No

Inspect grounding circuit of air

intake pressure sensor

Is the fault Yes

confirmed

No

Inspect grounding circuit of air

intake pressure sensor
Inspect air intake pressure
sensor signal circuit
Inspect air intake pressure
sensor
Inspect engine control module
circuit

End

M201 2014.01
3.1.12-102 Electronic Control System - M7 3.1.12-102

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect for the following conditions:
• Sensor housing damaged, and vacuum
tube cracked
• Sensor sealing damaged
• Sensor loose or improperly installed
• Sensor vacuum tube blocked
Are they normal?
Yes
Go to step 2.
No
Repair the fault, and verify that the system is
normal.

2. Inspect air intake pressure sensor voltage

A. Turn the ignition switch to "LOCK".
B. Disconnect the air intake pressure/temperature
E15 sensor wiring harness connector E15.
C. Turn the ignition switch to "ON".
1 2 3 4 D. Measure the voltage between terminal 3 of air
intake pressure/temperature sensor wiring harness
connector E15 and reliable grounding.
Standard voltage: 4.5 ~ 5.5 V
Is the voltage value normal?
Yes
M3112036
Go to step 4.
No
Go to step 3.

M201 2014.01
3.1.12-103 Electronic Control System - M7 3.1.12-103

Test Conditions Details/Results/Actions

3. Inspect power supply circuit of air intake pressure sensor

A. Turn the ignition switch to "LOCK".
B. Disconnect the air intake pressure/temperature
E15
sensor wiring harness connector E15.
C. Disconnect the ECM wiring harness connector
1 2 3 4 E18.
D. Measure the resistance between terminal 3 of air
intake pressure/temperature sensor wiring harness
connector E15 and terminal 19 of ECM wiring
harness connector E18. Inspect for open circuit.
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 3 of air
intake pressure/temperature sensor wiring harness
connector E15 and reliable grounding. Inspect for
short to ground.
Standard resistance: 10 MΩ or more
1 2 9 19 22
F. Measure the voltage between terminal 3 of air
3 4 23 36 intake pressure/temperature sensor wiring harness
connector E15 and reliable grounding. Inspect for
5 6 37 50
short to power supply.
7 8 51 64
Standard voltage: 0 V
Are they normal?

E18 Yes
Go to step 4.
M3112037
No
Repair the fault circuit between terminal 3 of E15
E15 and terminal 19 of E18, and verify that the system
is normal.

1 2 3 4

M3112038

E15

1 2 3 4

M3112039

M201 2014.01
3.1.12-104 Electronic Control System - M7 3.1.12-104

Test Conditions Details/Results/Actions

4. Inspect grounding circuit of air intake pressure sensor

A. Turn the ignition switch to "LOCK".
B. Disconnect the air intake pressure/temperature
E15 sensor wiring harness connector E15.
C. Turn the ignition switch to "ON".
1 2 3 4 D. Measure the resistance between terminal 1 of air
intake pressure/temperature sensor wiring harness
connector E15 and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
M3112040
Go to step 6.
No
Go to step 5.

M201 2014.01
3.1.12-105 Electronic Control System - M7 3.1.12-105

Test Conditions Details/Results/Actions

5. Inspect grounding circuit of air intake pressure sensor

A. Turn the ignition switch to "LOCK".
B. Disconnect the air intake pressure/temperature
E15
sensor wiring harness connector E15.
C. Disconnect the ECM wiring harness connector
1 2 3 4 E18.
D. Measure the resistance between terminal 1 of air
intake pressure/temperature sensor wiring harness
connector E15 and terminal 40 of ECM wiring
harness connector E18. Inspect for open circuit.
Standard resistance: less than 5 Ω
E. Measure the voltage between terminal 1 of air
intake pressure/temperature sensor wiring harness
connector E15 and reliable grounding. Inspect for
short to power supply.
Standard voltage: 0 V
1 2 9 22
Is the resistance value normal?
3 4 23 36
Yes
5 6 37 40 50
Go to step 6.
7 8 51 64
No
Repair the fault circuit, and verify that the system is
normal.
E18

M3112041

E15

1 2 3 4

M3112042

M201 2014.01
3.1.12-106 Electronic Control System - M7 3.1.12-106

Test Conditions Details/Results/Actions

6. Inspect air intake pressure sensor signal circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the air intake pressure/temperature
E15
sensor wiring harness connector E15.
C. Disconnect the ECM wiring harness connector
1 2 3 4 E18.
D. Measure the resistance between terminal 4 of air
intake pressure/temperature sensor wiring harness
connector E15 and terminal 59 of ECM wiring
harness connector E18. Inspect for open circuit.
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 4 of air
intake pressure/temperature sensor wiring harness
connector E15 and reliable grounding. Inspect for
short to ground.
Standard resistance: 10 MΩ or more
1 2 9 22
F. Measure the voltage between terminal 4 of air
3 4 23 36 intake pressure/temperature sensor wiring harness
connector E15 and reliable grounding. Inspect for
5 6 37 50
short to power supply.
7 8 51 59 64
Standard voltage: 0 V
Are they normal?
E18 Yes
Go to step 7.
M3112043
No
Repair the circuit, and verify that the system is
E15 normal.

1 2 3 4

M3112044

E15

1 2 3 4

M3112045

M201 2014.01
3.1.12-107 Electronic Control System - M7 3.1.12-107

Test Conditions Details/Results/Actions

7. Inspect air intake pressure sensor

A. Turn the ignition switch to "LOCK".
B. Disconnect the air intake pressure/temperature
sensor wiring harness connector E15.
C. Turn the ignition switch to "ON".
D. Connect a jumper cable with 5 A fuse between
terminals 3 and 4 of E15.
E. Connect the diagnostic tool and enter engine data
flow and read the "actual intake manifold pressure"
parameter.
Standard parameter: 1050 kPa
Is the data normal?
Yes
Replace the air intake pressure sensor.
No
Go to step 8.

8. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-108 Electronic Control System - M7 3.1.12-108

DTCs P0112, P0113

1. DTC Description

DTC Code Description Definition

P0112 Intake Air Temp. Circ. Low Input Air intake temperature sensor is integrated into the
engine air intake pressure/temperature sensor to
measure the temperature of air that goes into the
engine. ECM internal pressure regulator circuit
provides 5 V reference voltage to terminal 2 of air
intake pressure/temperature sensor wiring harness
P0113 Intake Air Temp. Circ. High Input connector E15 via terminal 25 of ECM wiring
harness connector E18. The air intake temperature
sensor voltage-drop signal can be obtained in this
circuit. Set terminal 1 of intake pressure/temperature
sensor E15 to low potential via terminal 40 of E18.

2. Possible Causes

Setting Conditions (Control

DTC Code Monitor Strategy Faulty Area
Strategy)
• Air intake temperature is higher
Upper limit exceeded, than 128.25°C
P0112
short to ground
• Last for more than 1 s • Sensor circuit
• 240 s after start • Sensor
Lower limit exceeded, • Air intake temperature is lower • ECM
P0113
short to power than -38.25°C
• Last for more than 10 s

M201 2014.01
3.1.12-109 Electronic Control System - M7 3.1.12-109
3. Diagnosis Procedure

P0112, P0113

General inspection

Is the fault Yes

confirmed

No

Inspect air intake temperature

sensor resistance

Is the fault Yes

confirmed

No

Inspect air intake temperature

sensor signal circuit

Is the fault Yes

confirmed

No

Inspect air intake temperature

sensor grounding

Is the fault Yes

confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-110 Electronic Control System - M7 3.1.12-110

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect for the following conditions:
• Sensor housing damaged, and vacuum
tube cracked
• Sensor sealing damaged
• Sensor loose or improperly installed
• Sensor vacuum tube blocked
Are they normal?
Yes
Go to step 2.
No
Repair the fault, and verify that the system is
normal.

2. Inspect air intake temperature sensor resistance

A. Turn the ignition switch to "LOCK".
B. Disconnect the air intake pressure/temperature
sensor wiring harness connector E15.
C. Measure the resistance of air intake temperature
sensor (terminals 1 to 2).
Standard resistance:
2.5 kΩ ± 5% at 20°C
D. Connect the coolant temperature sensor wiring
harness connector E04.
Is it normal?
Yes
Go to step 3.
No
Replace the air intake pressure/temperature sensor.

M201 2014.01
3.1.12-111 Electronic Control System - M7 3.1.12-111

Test Conditions Details/Results/Actions

3. Inspect air intake temperature sensor signal circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the air intake pressure/temperature
E15
sensor wiring harness connector E15.
C. Turn the ignition switch to "ON".
1 2 3 4
D. Measure the voltage between terminal 2 of air
intake pressure/temperature sensor wiring harness
connector E15 and reliable grounding.
Standard voltage: 4.7 ~ 5.5 V
Is the voltage value normal?
Yes
M3112046
Go to step 4.
No
Repair the fault circuit between terminal 2 of air
intake pressure/temperature sensor wiring harness
connector E15 and terminal 25 of engine control
module wiring harness connector E18. Verify that
the system is normal.

4. Inspect air intake temperature sensor grounding

A. Turn the ignition switch to "LOCK".
B. Disconnect the air intake pressure/temperature
E15
sensor wiring harness connector E15.
C. Turn the ignition switch to "ON".
1 2 3 4
D. Measure the resistance between terminal 1 of air
intake pressure/temperature sensor wiring harness
connector E15 and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
M3112047
Go to step 5.
No
Repair the fault circuit between terminal 1 of air
intake pressure/temperature sensor E15 and
terminal 40 of engine control module wiring harness
connector E18. Verify that the system is normal.

M201 2014.01
3.1.12-112 Electronic Control System - M7 3.1.12-112

Test Conditions Details/Results/Actions

5. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-113 Electronic Control System - M7 3.1.12-113

DTCs P0117, P0118

1. DTC Description

DTC Code Description Definition

Engine Coolant Temp.Circ. Low Coolant temperature sensor, a variable resistor of
P0117
Input negative temperature coefficient, is used for
measuring engine coolant temperature. ECM
provides 5 V to the terminal 2 of coolant temperature
sensor wiring harness connector E11 via terminal 41
Engine Coolant Temp.Circ. High of ECM wiring harness connector E18, and obtains
P0118
Input sensor signals from terminal 41 of E18. ECM sets
terminal 1 of sensor connector E11 to low potential
via terminal 40 of E18.

2. Possible Causes

Setting Conditions (Control

DTC Code Monitor Strategy Faulty Area
Strategy)
Upper limit exceeded, Coolant temperature measured
P0117 • Sensor circuit
short to ground value is higher than 135°C for 2 s
• Sensor
Lower limit exceeded, Coolant temperature measured
P0118 • ECM
short to power value is lower than -37.5°C for 2 s

M201 2014.01
3.1.12-114 Electronic Control System - M7 3.1.12-114
3. Diagnosis Procedure

P0117, P0118

General inspection

Is the fault Yes

confirmed

No

Inspect coolant temperature

sensor resistance

Is the fault Yes

confirmed

No

Inspect coolant temperature sensor

signal circuit

Is the fault Yes

confirmed

No

Inspect coolant temperature

sensor grounding circuit

Is the fault Yes

confirmed

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-115 Electronic Control System - M7 3.1.12-115

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect if the engine coolant temperature sensor is
corroded, and if the coolant leaks through the
sensor.
B. Inspect if the level of engine coolant in cooling
system reservoir is proper.
C. Inspect the sensor for looseness or improper
installation.
Are they normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect coolant temperature sensor resistance

A. Turn the ignition switch to "LOCK".
B. Disconnect the coolant temperature sensor wiring
harness connector E11.
C. Measure the resistance of coolant temperature
sensor with a multimeter.
Standard resistance:
2.5 kΩ ± 5% for rated resistance at 20°C
Is it normal?
Yes
Go to step 3.
No
Replace the coolant temperature sensor.

M201 2014.01
3.1.12-116 Electronic Control System - M7 3.1.12-116

Test Conditions Details/Results/Actions

3. Inspect coolant temperature sensor signal circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the coolant temperature sensor wiring
harness connector E11.
C. Turn the ignition switch to "ON".
D. Measure the voltage between terminal 2 of coolant
1 2 temperature sensor wiring harness connector E11
and reliable grounding.
E11 Standard voltage: 4.7 ~ 5.5 V
Is the voltage value normal?
Yes
M3112048
Go to step 4.
No
Repair the fault circuit between terminal 2 of coolant
temperature wiring harness sensor E11 and
terminal 41 of engine control module wiring harness
connector E18.

4. Inspect coolant temperature sensor grounding circuit

A. Turn the ignition switch to "LOCK".
E11 B. Disconnect the coolant temperature sensor wiring
harness connector E11.
C. Turn the ignition switch to "ON".
1 2 D. Measure the resistance between terminal 1 of
coolant temperature sensor wiring harness
connector E11 and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
M3112049
Go to step 5.
No
Inspect and repair the fault circuit between terminal
1 of coolant temperature sensor wiring harness
connector E11 and terminal 40 of engine control
module wiring harness connector E18.

M201 2014.01
3.1.12-117 Electronic Control System - M7 3.1.12-117

Test Conditions Details/Results/Actions

5. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-118 Electronic Control System - M7 3.1.12-118

DTCs P0122, P0123

1. DTC Description

DTC Code Description Definition

ECM provides 5 V reference voltage to terminal 2 of TPS
Throttle/Pedal Pos.Sensor A Circ. sensor wiring harness connector E16 via terminal 18 of
P0122
Low Input ECM wiring harness connector E18. TPS sensor provides
sensor signal voltage to terminal 26 of ECM wiring
harness connector E18 via terminal 3 of E16. ECM sets
Throttle/Pedal Pos.Sensor A Circ. terminal 1 of TPS sensor wiring harness connector E16 to
P0123 low potential via terminal 39 of ECM wiring harness
High Input
connector E18.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• Engine speed is more than
Lower limit of throttle 600 rpm
P0122 position angle signal
exceeded • Throttle position angle signal
• Sensor circuit
is less than 1% for 1 s
• Sensor
• Engine speed is more than
Upper limit of throttle • ECM
600 rpm
P0123 position angle signal
exceeded • Throttle position angle signal
is more than 99% for 1 s

M201 2014.01
3.1.12-119 Electronic Control System - M7 3.1.12-119
3. Diagnosis Procedure

P0122, P0123

General inspection

Is the fault Yes

confirmed

No

Inspect throttle position sensor

Is the fault Yes

confirmed

No
Inspect throttle position sensor
power supply circuit

Is the fault Yes

confirmed

No
Inspect throttle position sensor
signal circuit

Is the fault Yes

confirmed

No

Inspect throttle position sensor

grounding
Inspect engine control module
circuit

End

M201 2014.01
3.1.12-120 Electronic Control System - M7 3.1.12-120

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the sensor wiring harness connector for
looseness.
B. Visually inspect the sensor for damage.
C. Measure the resistance of throttle position sensor.
Are they normal?
Yes
Go to step 2.
No
Repair the faulty area. Make sure the system is
normal.

2. Inspect throttle position sensor

A. Turn the ignition switch to "LOCK".
B. Disconnect the throttle position sensor wiring
harness connector E16.
C. Measure the resistance of throttle position sensor.
Standard resistance:
2 kΩ ± 20% between terminals 1 and 2
Is the resistance value normal?
Yes
Go to step 3.
No
Replace the throttle position sensor.

3. Inspect throttle position sensor power supply circuit

A. Turn the ignition switch to "LOCK".

E16 B. Disconnect the throttle position sensor wiring

harness connector E16.
C. Turn the ignition switch to "ON".
1 2 3
D. Measure the voltage between terminal 2 of throttle
position sensor E16 and reliable grounding.
Standard voltage: 4.5 ~ 5.5 V
Is the voltage value normal?
Yes

M3112050
Go to step 4.
No
Repair the fault circuit between terminal 2 of throttle
position sensor wiring harness connector E16 and
terminal 18 of engine control module wiring harness
connector E18. Verify that the system is normal.

M201 2014.01
3.1.12-121 Electronic Control System - M7 3.1.12-121

Test Conditions Details/Results/Actions

4. Inspect throttle position sensor signal circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the throttle position sensor wiring
harness connector E16.
C. Turn the ignition switch to "ON".
D. Connect a jumper cable with 5 A fuse between
terminals 1 and 3 of E16. Use the diagnostic tool to
observe the "ADC-signal throttle angle" parameter.
Standard voltage: 4.5 ~ 5.5 V
Is the voltage value normal?
Yes
Go to step 5.
No
Repair the fault circuit between terminal 3 of throttle
position sensor wiring harness connector E16 and
terminal 26 of engine control module wiring harness
connector E18. Verify that the system is normal.

5. Inspect throttle position sensor grounding

A. Turn the ignition switch to "LOCK".

E16 B. Disconnect the throttle position sensor wiring

harness connector E16.
C. Turn the ignition switch to "ON".
1 2 3
D. Measure the resistance between terminal 1 of
throttle position sensor wiring harness connector
E16 and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
M3112051
Go to step 6.
No
Inspect and repair the fault circuit between terminal
1 of throttle position sensor wiring harness
connector E16 and terminal 39 of engine control
module wiring harness connector E18. Verify that
the system is normal.

M201 2014.01
3.1.12-122 Electronic Control System - M7 3.1.12-122

Test Conditions Details/Results/Actions

6. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36
grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-123 Electronic Control System - M7 3.1.12-123

DTCs P0130, P0131, P0132, P0133, P0134, P2195, P2196

1. DTC Description

DTC Code Description Definition

O2 Sensor Circ., Bank1-Sensor1 After vehicle starts, the control module works in open
P0130
Malfunction loop mode, and it will ignore the front oxygen sensor
signal voltage in the calculation of air-fuel ratio. Control
O2 Sensor Circ., Bank1-Sensor1 module provides approximately 450 mV reference
P0131
Low Voltage voltage to the front oxygen sensor. When the engine is
running, the front oxygen sensor starts heating and
O2 Sensor Circ., Bank1-Sensor1 generating 0.1 ~ 0.9 V voltage. The voltage fluctuates up
P0132
High Voltage and down along the reference voltage. Once the control
module detects that the front oxygen sensor voltage
O2 Sensor Circ., Bank1-Sensor1 exceeds the set threshold, it will immediately enter closed
P0133
Slow Response loop mode. Control module determines the air-fuel ratio
based on the front oxygen sensor voltage. If the front
O2 Sensor Circ., Bank1-Sensor1 oxygen sensor voltage is higher than 0.45 V, it indicates
P0134
No Activity Detected that the mixture is too rich. If the front oxygen sensor
voltage is lower than 0.45 V, it indicates that the mixture
O2 Sensor Signal Stuck Lean; is too lean. ECM sets the terminal 2 of front oxygen
P2195 sensor E01 to low potential via terminal 39 of E18. When
Bank 1 Sensor 1
the oxygen sensor reaches normal working temperature,
O2 Sensor Signal Stuck Rich; it transmits oxygen sensor signal to the ECM via terminal
P2196 1 of E01 connected to terminal 45 of E18 of ECM.
Bank 1 Sensor 1

M201 2014.01
3.1.12-124 Electronic Control System - M7 3.1.12-124
2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• Front oxygen sensor reaches
Front oxygen sensor the working temperature
P0130
coupled with heater line • Front oxygen sensor output
voltage is higher than 2.0 V

• Front oxygen sensor output

P0131 Signal short to ground
voltage is less than 0.06 V

• Battery voltage is higher than

10.68 V • Sensor circuit

• Engine speed is more than • Sensor

25 rpm • ECM
• Target λ = 1
Front oxygen sensor
P0132 • Exhaust temperature is lower
voltage too high
than 800°C
• Front oxygen sensor reaches
working temperature for 150 s
• Front oxygen sensor output
voltage is higher than 1.5 V

M201 2014.01
3.1.12-125 Electronic Control System - M7 3.1.12-125

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• Cycle duration of front oxygen
sensor signal filtered is more
than 2.0 s
• Effective cycle count is more
than 14
• Front oxygen sensor closed
loop control active
• No pressure sensor fault
• No coolant temperature
sensor fault

Cycle duration of front • No air intake temperature

oxygen sensor signal sensor fault
P0133
filtered is more than • Basic mixture adaptation not
threshold disabled
• No diagnosis stop condition
• Engine speed is within
1800 ~ 2840 rpm
• Engine load is within 25 ~ 50
• Exhaust temperature model • Sensor circuit
value is greater than 500 • Sensor
• Front oxygen sensor heating • ECM
diagnosis passed
• CDLATP diagnosis function
on

• Front oxygen sensor reaches

the working temperature for
P0134 Signal open circuit 150 s
• Front oxygen sensor voltage
is within 0.40 ~ 0.60 V

• Diagnosis function on
Rear oxygen control
• Rear oxygen control active
P2195 integrator value exceeds
upper limit • Rear oxygen control integrator
value is greater than 1.0 s

• No catalytic converter fault

Rear oxygen control • No diagnosis stop condition

P2196 integrator value exceeds • Diagnosis time is 20 s
lower limit
• Rear oxygen control integrator
value is less than -1.0 s

M201 2014.01
3.1.12-126 Electronic Control System - M7 3.1.12-126
3. Diagnosis Procedure

P0130, P0131,
P0132, P0133,
P0134, P2195,
P2196

Inspect DTC

Is the fault Yes

confirmed

No
Inspect front oxygen sensor data
flow
Inspect oxygen sensor condition
(carry out oxygen sensor signal
test)

Is the fault Yes

confirmed

No

Inspect front oxygen sensor

signal circuit
Inspect front oxygen sensor
grounding circuit

Is the fault Yes

confirmed

No

Inspect front oxygen sensor

Inspect engine control module
circuit

End

M201 2014.01
3.1.12-127 Electronic Control System - M7 3.1.12-127

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Turn the ignition switch to "LOCK".
B. Connect the diagnostic tool.
C. Start the engine, and use the diagnostic tool to
inspect the engine system.
Is there any DTC besides P0130, P0131, P0132,
P0133, P0134, P2195 and P2196?
Yes
Go to DTC diagnosis procedure.
No
Repair the faulty area.

2. Inspect front oxygen sensor data flow

A. Start the engine, and run it till the engine coolant
temperature reaches above 80°C.
B. Use diagnostic tool to access to engine data flow,
and observe the "O2 sensor voltage bank 1, sensor
1" parameter.
Standard voltage: fluctuates between 0.1 ~ 0.9 V
Does the voltage of oxygen sensor fluctuate
between 0.1 ~ 0.9 V?
Yes
Refer to: Intermittent Malfunction
Diagnosis Procedure (3.1.12
Electronic Control System - M7,
Symptom Diagnosis and
Testing).
No
Go to step 3.

M201 2014.01
3.1.12-128 Electronic Control System - M7 3.1.12-128

Test Conditions Details/Results/Actions

3. Inspect oxygen sensor condition (carry out oxygen sensor signal test)
A. If the voltage displayed in data flow remains below
0.45 V (mixture too lean), inspect according to the
following steps:
• Jet a proper amount of propane into the inlet port.
• Observe if the front oxygen sensor voltage in data
flow changes obviously and the signal voltage rises
quickly.
B. If the voltage displayed in data flow remains above
0.45 V (mixture too rich), inspect according to the
following steps:
• Position the transmission at neutral gear.
• Apply the parking brake.
• Depress the accelerator pedal until the engine speed
suddenly increases to 4000 rpm and then quickly
release the accelerator pedal.
• Repeat the previous step more than 3 times.
• Observe if the front oxygen sensor voltage in data
flow changes obviously and the signal voltage drops
quickly.
• In the implementation of above test, the oxygen
sensor signal voltage should change significantly as
the test continues.
Does it change significantly?
Yes
Refer to: DTCs P2177, P2178, P2187,
P2188 (3.1.12 Electronic control
System - M7, DTC Diagnosis and
Testing).
No
Go to step 4.

M201 2014.01
3.1.12-129 Electronic Control System - M7 3.1.12-129

Test Conditions Details/Results/Actions

4. Inspect front oxygen sensor signal circuit

A. Inspect the front oxygen sensor signal circuit.
B. Turn the ignition switch to "LOCK".
C. Disconnect the front oxygen sensor wiring harness
connector E01.
D. Disconnect the ECM wiring harness connector E18.
1 3 E. Measure the resistance between terminal 1 of front
oxygen sensor wiring harness connector E01 and
2 4 terminal 45 of ECM wiring harness connector E18.
Inspect for open circuit.
E01 Standard resistance: less than 5 Ω
F. Measure the resistance between terminal 1 of front
oxygen sensor wiring harness connector E01 and
reliable grounding. Inspect for short to ground.
Standard resistance: 10 MΩ or more
1 2 9 22
G. Measure the voltage between terminal 1 of front
3 4 23 36 oxygen sensor wiring harness connector E01 and
5 6 37 45 50
reliable grounding. Inspect for short to power
supply.
7 8 51 64
Standard voltage: 0 V
Is it normal?
E18 Yes
Go to step 5.
M3112052 No
Repair the fault circuit between terminal 1 of front
oxygen sensor wiring harness connector E01 and
terminal 45 of ECM wiring harness connector E18.

1 3

2 4

E01
M3112053

1 3

2 4

E01
M3112054

M201 2014.01
3.1.12-130 Electronic Control System - M7 3.1.12-130

Test Conditions Details/Results/Actions

5. Inspect front oxygen sensor grounding circuit

A. Turn the ignition switch to "LOCK".
E01
B. Disconnect the front oxygen sensor wiring harness
connector E01.
1 3 C. Turn the ignition switch to "ON".

4 D. Measure the resistance between terminal 2 of E01

2
and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes

M3112055
Go to step 6.
No
Inspect and repair the fault circuit between terminal
2 of front oxygen sensor wiring harness connector
E01 and terminal 39 of ECM wiring harness
connector E18.

6. Inspect front oxygen sensor

A. Replace the front oxygen sensor.
Is the fault repaired?
Yes
Diagnosis completes. The system is normal.
No
Go to step 7.

M201 2014.01
3.1.12-131 Electronic Control System - M7 3.1.12-131

Test Conditions Details/Results/Actions

7. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36
grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-132 Electronic Control System - M7 3.1.12-132

DTCs P0136, P0137, P0138, P0140, P2270, P2271

1. DTC Description

DTC Code Description Definition

O2 Sensor Circ., Bank1-
P0136
Sensor2 Malfunction

O2 Sensor Circ., Bank1-

P0137
Sensor2 Low Voltage
ECM sets the terminal 4 of rear oxygen sensor S14
O2 Sensor Circ., Bank1- to low potential via terminal 39 of E18.
P0138
Sensor2 High Voltage
When the rear oxygen sensor reaches normal
O2 Sensor Circ., Bank1- working temperature, it transmits oxygen sensor
P0140
Sensor2 No Activity Detected signal to the ECM via terminal 2 of S14 connected to
terminal 29 of E18 of ECM.
O2 Sensor Signal Stuck Lean;
P2270
Bank 1 Sensor 2

O2 Sensor Signal Stuck Rich;

P2271
Bank 1 Sensor 2

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• Rear oxygen sensor reaches the
Rear oxygen working temperature
P0136 sensor coupled with
heater line • Rear oxygen sensor output voltage is
higher than 2.0 V

• Rear oxygen sensor reaches the

Signal short to working temperature
P0137
ground • Rear oxygen sensor voltage signal is
lower than 0.06 V

• Battery voltage is higher than 10.68 V

• Engine speed is more than 25 rpm • Sensor circuit

• Target λ = 1 • Sensor
Rear oxygen • Catalytic converter temperature is • ECM
P0138 sensor signal higher than 250°C
voltage too high
• Rear oxygen sensor reaches the
working temperature
• Rear oxygen sensor signal voltage is
higher than 1.5 V

• Rear oxygen sensor reaches the

Rear oxygen working temperature
P0140 sensor signal open
circuit • Rear oxygen sensor voltage is within
0.4 ~ 0.5 V

M201 2014.01
3.1.12-133 Electronic Control System - M7 3.1.12-133

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)

Rear oxygen • Rear oxygen sensor voltage is lower

P2270 sensor voltage is than 0.582 V
always low • Sensor circuit
• Access to diagnosis request
• Sensor
Rear oxygen • Rear oxygen sensor voltage is higher
• ECM
P2271 sensor voltage is than 0.619 V
always high • Access to diagnosis request

M201 2014.01
3.1.12-134 Electronic Control System - M7 3.1.12-134
3. Diagnosis Procedure

P0136, P0137,
P0138, P0140,
P2270, P2271

Inspect DTC

Is the fault Yes

confirmed

No

Inspect rear oxygen sensor data

flow

Is the fault Yes

confirmed

No

Inspect rear oxygen sensor

condition (carry out rear
oxygen sensor signal test)

Is the fault Yes

confirmed

No

Inspect rear oxygen sensor

signal circuit
Inspect rear oxygen sensor
grounding circuit Is the fault Yes
confirmed

Is the fault No
confirmed Inspect engine control module
circuit
No

Inspect rear oxygen sensor

End

M201 2014.01
3.1.12-135 Electronic Control System - M7 3.1.12-135

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Turn off the ignition switch and connect the
diagnostic tool.
B. Start the engine, and use the diagnostic tool to
inspect the engine system.
Is there any DTC besides P0136, P0137, P0138,
P0140, P2270 and P2271?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. Inspect rear oxygen sensor data flow

A. Start the engine, and run it till the engine coolant
temperature reaches above 80°C.
B. Use diagnostic tool to access to engine data flow,
and observe the "O2 sensor voltage bank 1, sensor
2" parameter.
Standard voltage: fluctuates around 0.5 V
Does the voltage of oxygen sensor fluctuate around
0.5 V?
Yes
Refer to: Intermittent Malfunction
Diagnosis Procedure (3.1.12
Electronic Control System - M7,
Symptom Diagnosis and
Testing).
No
Go to step 3.

M201 2014.01
3.1.12-136 Electronic Control System - M7 3.1.12-136

Test Conditions Details/Results/Actions

3. Inspect rear oxygen sensor condition (carry out rear oxygen sensor signal test)
A. If the voltage displayed in data flow remains below
0.45 V (mixture too lean), inspect according to the
following steps:
• Jet a proper amount of propane into the inlet port.
• Observe if the rear oxygen sensor voltage in data
flow changes obviously and the signal voltage rises
quickly.
B. If the voltage displayed in data flow remains above
0.45 V (mixture too rich), inspect according to the
following steps:
• Position the transmission at neutral gear.
• Apply the parking brake.
• Depress the accelerator pedal until the engine speed
suddenly increases to 4000 rpm and then quickly
release the accelerator pedal.
• Repeat the previous step more than 3 times.
• Observe if the rear oxygen sensor voltage in data
flow changes obviously and the signal voltage drops
quickly.
• In the implementation of above test, the oxygen
sensor signal voltage should change significantly as
the test continues.
Does it change significantly?
Yes
Refer to: DTCs P2177, P2178, P2187,
P2188 (3.1.12 Electronic control
System - M7, DTC Diagnosis and
Testing).
No
Go to step 4.

M201 2014.01
3.1.12-137 Electronic Control System - M7 3.1.12-137

Test Conditions Details/Results/Actions

4. Inspect rear oxygen sensor signal circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the rear oxygen sensor wiring harness
connector S14.
C. Disconnect the ECM wiring harness connector E18.
D. Measure the resistance between terminal 2 of rear
2 1 oxygen sensor wiring harness connector S14 and
terminal 29 of ECM wiring harness connector E18.
4 3 Inspect for open circuit.
Standard resistance: less than 5 Ω
S14 E. Measure the resistance between terminal 2 of rear
oxygen sensor wiring harness connector S14 and
reliable grounding. Inspect for short to ground.
Standard resistance: 10 MΩ or more
F. Measure the voltage between terminal 2 of rear
1 2 9 22 oxygen sensor wiring harness connector S14 and
reliable grounding. Inspect for short to power.
3 4 23 29 36
Standard voltage: 0 V
5 6 37 50
Is it normal?
7 8 51 64
Yes
Go to step 5.
E18 No
Inspect and repair the fault circuit between terminal
M3112056 2 of rear oxygen sensor wiring harness connector
S14 and terminal 29 of ECM wiring harness
connector E18. Verify that the system is normal.

2 1

4 3

S14
M3112057

2 1

4 3

S14
M3112058

M201 2014.01
3.1.12-138 Electronic Control System - M7 3.1.12-138

Test Conditions Details/Results/Actions

5. Inspect rear oxygen sensor grounding circuit

A. Turn the ignition switch to "LOCK".
S14
B. Disconnect the rear oxygen sensor wiring harness
connector S14.
2 1 C. Turn the ignition switch to "ON".
4 3 D. Measure the resistance between terminal 4 of rear
oxygen sensor S14 and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes

M3112059
Go to step 6.
No
Inspect and repair the fault circuit between terminal
4 of rear oxygen sensor wiring harness connector
S14 and terminal 39 of ECM wiring harness
connector E18.

6. Inspect rear oxygen sensor

A. Replace the rear oxygen sensor.
Refer to: Rear Oxygen Sensor (3.1.12
Electronic Control System - M7,
Removal and Installation).
Make sure the system is normal.
Yes
Diagnosis completes.
No
Go to step 7.

M201 2014.01
3.1.12-139 Electronic Control System - M7 3.1.12-139

Test Conditions Details/Results/Actions

7. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36
grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-140 Electronic Control System - M7 3.1.12-140

DTCs P0201, P0261, P0262

1. DTC Description

DTC Code Description Definition

Injector operating voltage is provided by the main

P0201 Cylinder 1 - Injector Circuit relay controlled by the ECM. Battery voltage is
transmitted to terminal 1 of each injector wiring
harness connector via terminal 69 of main relay
IR05 of instrument panel fuse box P40. ECM
controls the internal grounding of cylinder 1 injector
P0261 Cylinder 1 - Injector Circuit Low
via terminal 50 of ECM wiring harness connector
E18. ECM monitors the state of all injector drive
circuits. If the ECM detects that the voltage
corresponding to drive circuit command state is
P0262 Cylinder 1 - Injector Circuit High incorrect, it will set up a DTC indicating fuel injector
control circuit fault.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
P0201 • Open circuit • Injector circuit
Hardware circuit
P0261 • Short to ground • Fuel injector
inspection
P0262 • Short to power • ECM

M201 2014.01
3.1.12-141 Electronic Control System - M7 3.1.12-141
3. Diagnosis Procedure

P0201, P0261, P0262

General inspection

Is the fault Yes

confirmed

No

Inspect fuel injector

Inspect fuel injector working
voltage

Is the fault Yes

confirmed

No
Inspect fuel injector control
signal

No Is the fault
confirmed

Yes

Inspect fuel injector control

signal circuit

Is the fault Yes

confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-142 Electronic Control System - M7 3.1.12-142

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
fuel injectors for damage, poor contact, aging and
looseness.
Are they normal?
Yes
Go to step 2.
No
Repair the faulty area. Make sure the system is
normal.

2. Inspect fuel injector

A. Disconnect the fuel injector wiring harness
connector E09.
B. Measure the resistance between two terminals of
fuel injector.
Standard resistance: 11.5 ~ 12.6 Ω at 20°C
Is the resistance value normal?
Yes
Go to step 3.
No
Replace the fuel injector. Make sure the system is
normal.

3. Inspect fuel injector working voltage

A. Turn the ignition switch to "LOCK".
B. Disconnect the cylinder 1 injector wiring harness
connector E09.
C. Turn the ignition switch to "ON".
D. Measure the voltage between terminal 1 of cylinder
1 injector wiring harness connector E09 and reliable
grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 4.
No
Inspect and repair the faulty circuit between
terminal 1 of fuel injector wiring harness connector
E09 and terminal 69 of main relay IR05.

M201 2014.01
3.1.12-143 Electronic Control System - M7 3.1.12-143

Test Conditions Details/Results/Actions

4. Inspect fuel injector control signal

A. Turn the ignition switch to "LOCK".
B. Disconnect the cylinder 1 injector wiring harness
connector E09.
C. Connect the test pencil with LED to the terminals 1
and 2 of E09 according to specification.
CAUTION: LED must connect with 1 ~ 2 kΩ
resistor in series, otherwise the LED or
ECM may be damaged.
D. Start the engine.
E. Observe if the test lamp flashes normally.
Does the test lamp flash normally?
Yes
Go to step 6.
No
Go to step 5.

M201 2014.01
3.1.12-144 Electronic Control System - M7 3.1.12-144

Test Conditions Details/Results/Actions

5. Inspect fuel injector control signal circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the cylinder 1 injector wiring harness
connector E09.
C. Measure the voltage between terminal 2 of E09 and
reliable grounding.
1 2 Standard voltage: 0 V
D. Disconnect the ECM wiring harness connector E18.
E09
E. Measure the resistance between terminal 2 of
cylinder 1 injector wiring harness connector E09
and terminal 50 of ECM wiring harness connector
M3112060 E18. Inspect for open circuit.
Standard resistance: less than 5 Ω
E09 F. Measure the resistance between terminal 2 of E09
and reliable grounding.
Standard resistance: 10 MΩ or more
1 2
Is it normal?
Yes
Go to step 6.
No
1 2 9 22

3 4 23 36 Repair the fault circuit between the terminal 2 of

E09 and terminal 50 of ECM wiring harness
5 6 37 50
connector E18.
7 8 51 64

E18
M3112061

1 2

E09

M3112062

M201 2014.01
3.1.12-145 Electronic Control System - M7 3.1.12-145

Test Conditions Details/Results/Actions

6. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36
grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-146 Electronic Control System - M7 3.1.12-146

DTCs P0300, P0301, P0302, P0303, P0304

1. DTC Description

DTC Code Description Definition

Random/Multiple Cylinder ECM monitors the interval of CKP sensor input
P0300
Misfire Detected signal. ECM calculates the interval time change of
each cylinder. If the interval time change exceeds
P0301 Cyl.1 Misfire Detected preprogrammed standard, then ECM will detect poor
ignition of corresponding cylinder. When the engine
is running, ECM calculates the counts of ignition
P0302 Cyl.2 Misfire Detected
misfire at 200 and 1000 crankshaft revolutions, and
the misfire rate per crankshaft revolution. If the
P0303 Cyl.3 Misfire Detected misfire rate exceeds the preprogrammed standard,
then ECM will determine the occurrence of poor
ignition that can damage the catalytic converter or
P0304 Cyl.4 Misfire Detected affect emission performance.

M201 2014.01
3.1.12-147 Electronic Control System - M7 3.1.12-147
2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• Misfire rate that damages • Connector
the catalytic converter is looseness, poor
greater than 4% ~ 23% contact
Misfire rate that damages • Bad circuit not detected • Vacuum hose
catalytic converter broken, loose
• Fuel cut-off not active
• Ignition system
• Torque intervention not
active • Fuel injector

• Misfire rate that • Fuel pressure

deteriorates the emission • Air intake pressure
Misfire rate that deteriorates the is greater than 3.6% sensor
emission
P0300 • Engine speed is more than • Engine coolant
600 rpm, less than 5200 rpm temperature sensor
P0301
P0302 • Cylinder
compression
P0303
pressure
P0304
• Valve clearance
and timing
• Misfire rate that • Evaporative
deteriorates the emission emission control
Implausible fault is greater than 3.6% system
• Air intake temperature is • Positive crankcase
higher than -25°C ventilation system
• Air intake system
• Exhaust system air
vent clog
• ECM

M201 2014.01
3.1.12-148 Electronic Control System - M7 3.1.12-148
3. Diagnosis Procedure

P0300, P0301,
P0302, P0303
P0304

General inspection

Is the fault Yes

confirmed

No

Inspect DTC

Is the fault Yes

confirmed

No

Inspect data flow

Inspect spark plug

Is the fault Yes

confirmed

No

Inspect ignition coil

Inspect ignition system

Is the fault Yes

Is the fault confirmed
confirmed
No
No
Inspect engine control
Inspect fuel pressure module circuit
Inspect fuel injector control
circuit
Inspect fuel injector
Inspect compression pressure

End

M201 2014.01
3.1.12-149 Electronic Control System - M7 3.1.12-149
CAUTION: If the engine electronic control system stores DTCs other than misfire DTCs, carry
out troubleshooting for these DTCs first.

CAUTION: If misfire does not occur when the vehicle is taken to a service station, carry out
road test again to reproduce the misfire fault. And use the diagnostic tool to record the ECM
data when the misfire occurs in order to help analyze the cause of fault.

CAUTION: If the vehicle still stores no DTC related to misfire after long road test, the fault
may be caused by the following:
1. Fuel tank is overfull, and fuel goes into the engine evaporative emission control system,
causing misfire due to too rich mixture.
2. Misfire caused by insufficient combustion of improper fuel.
3. Misfire caused by ignition fault of contaminated spark plug.
4. Carry out basic inspection on the system according to the faulty area indicated by DTC.

CAUTION: After repair, road test the vehicle to confirm that no DTC is stored.

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors for damage,
poor contact, aging and looseness.
B. Inspect the vacuum tube for damage, looseness or
leakage.
C. Inspect the air intake system for leakage.
Are they normal?
Yes
Go to step 2.
No
Repair the fault parts. Make sure the system is
normal.

2. Inspect DTC
A. Connect the diagnostic tool.
B. Start the engine and diagnose the engine system.
C. Inspect DTC.
Is there any DTC besides P0300, P0301, P0302,
P0303 and P0304?
Yes
Go to DTC diagnosis procedure.
No
Go to step 3.

M201 2014.01
3.1.12-150 Electronic Control System - M7 3.1.12-150

Test Conditions Details/Results/Actions

3. Inspect data flow

A. Connect the diagnostic tool.
B. Start engine and access to the engine system data
flow on diagnostic tool.
C. Inspect the data flow for coolant temperature
sensor, air intake pressure sensor, engine speed
and throttle position.
Is the data flow normal?
Yes
Repair the abnormal data flow fault.
No
Go to step 4.

4. Inspect spark plug

A. Remove the spark plug from the misfire cylinder.
B. Inspect if the spark plug gap is too large or too
small.
Standard gap: 0.85 ~ 0.95 mm
C. Inspect if the spark plug electrode is burnt or
damaged.
D. Inspect spark plug skirt and electrode for moisture,
serious smell of gasoline.
E. Reinstall the spark plug.
Is the spark plug normal?
Yes
Go to step 5.
No
Repair or replace the spark plug.

5. Inspect ignition coil

A. Remove the ignition coil.
B. Inspect the ignition coil.
Refer to: Ignition Coil Test (3.1.8 Ignition
System, General Inspection).
Is the ignition coil normal?
Yes
Go to step 6.
No
Replace the ignition coil.
Refer to: Ignition Coil (3.1.8 Ignition System,
Remove and Installation).

M201 2014.01
3.1.12-151 Electronic Control System - M7 3.1.12-151

Test Conditions Details/Results/Actions

6. Inspect ignition system

A. Turn the ignition switch to "LOCK".
B. Carry out the ignition spark test.
Refer to: Ignition Spark Test (3.1.8 Ignition
System, General Inspection).
Is the ignition spark test normal?
Yes
Go to step 7.
No
Inspect the ignition system.
Refer to: Diagnosis Procedure for Spark
Plugs not Flashing Over (3.1.8
Ignition System, Symptom
Diagnosis and Testing).

7. Inspect fuel pressure

A. Turn the ignition switch to "LOCK".
B. Measure the fuel pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
Is the fuel pressure normal?
Yes
Go to step 8.
No
Inspect the fuel system.

M201 2014.01
3.1.12-152 Electronic Control System - M7 3.1.12-152

Test Conditions Details/Results/Actions

8. Inspect fuel injector control circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the misfire cylinder fuel injector wiring
harness connector.
C. Connect the test pen with LED to the terminals 1
and 2 of fuel injector connector according to
specification.
CAUTION: LED must connect with 1 ~ 2 kΩ
resistor in series, otherwise the LED or
ECM may be damaged.
D. Start the engine.
E. Observe if the test lamp flashes normally.
Does the test lamp flash normally?
Yes
Go to step 9.
No
Inspect the fuel injector wiring harness. Repair or
replace if necessary.

9. Inspect fuel injector

A. Remove the fuel injector from the misfire cylinder.
B. Use the fuel injectors on the other cylinders instead.
C. Start the engine and idle it.
Does the misfire DTC correspond to the fuel injector
in trouble.
Yes
Replace the failure injector.
No
Go to step 10.

10.Inspect compression pressure

A. Inspect the compression pressure in the cylinder.
Refer to: Cylinder Compression Pressure
Inspection (3.1.2 Mechanical
System, General Inspection).
B. Is the compression pressure normal?
Yes
Go to step 11.
No
Repair engine mechanical system fault.

M201 2014.01
3.1.12-153 Electronic Control System - M7 3.1.12-153

Test Conditions Details/Results/Actions

11.Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36
grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-154 Electronic Control System - M7 3.1.12-154

DTCs P0321, P0322

1. DTC Description

DTC Code Description Definition

CKP sensor signal informs ECM of the current
speed and position of crankshaft. This sensor
Ign./Distributor Eng.Speed detects the teeth and grooves of ferromagnetic
P0321
Inp.Circ. Range/Performance signal plate, and outputs the electric signals that
indicate the speed and position of signal plate. ECM
can calculate the ignition timing, injection timing and
knock control according to input signals of CKP
sensor. CKP sensor is also used for misfire
detection and tachometer display. CKP sensor
Ign./Distributor Eng.Speed signal is connected to terminals 19, 47, 40 of ECM
P0322
Inp.Circ. No Signal wiring harness connector E18 respectively via
terminals 1, 2, 3 of CKP sensor wiring harness
connector E17.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• Frequent gap correction
• Count of gap correction by plus one
by plus one tooth
tooth is greater than 250
• Frequent gap correction
• Count of gap correction by minus one
by minus one tooth • Crankshaft
tooth is greater than 250
P0321 • Speed sensor signal position sensor
• Count of no reference gaps detected is
exists but no reference • Crankshaft
greater than 6
mark is found position sensor
• Count of lost reference gaps is greater
• Frequent loss of reference circuit
than 2000
mark • ECM
No speed signal detected • Count of phase signal hop is greater
P0322 after a certain quantity of than 8
phase sensor signal • Low engine speed

M201 2014.01
3.1.12-155 Electronic Control System - M7 3.1.12-155
3. Diagnosis Procedure

P0321, P0322

General inspection

Is the fault Yes

confirmed

No

Read engine speed on

diagnostic tool

Is the fault Yes

confirmed

No

Inspect crankshaft position

sensor waveform

Is the fault
confirmed

Yes

Inspect crankshaft position

sensor terminal 1 circuit
Inspect crankshaft position
sensor terminal 2 circuit
Inspect crankshaft position
No sensor terminal 3 circuit

Is the fault Yes

confirmed

No
Inspect engine control module
circuit

End

M201 2014.01
3.1.12-156 Electronic Control System - M7 3.1.12-156

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the sensor wiring harness connector E17 for
looseness or poor contact.
B. Inspect the sensor for proper installation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area. Make sure the system is
normal.

2. Read engine speed on diagnostic tool

A. Connect the diagnostic tool.
B. Turn the ignition switch to "ON".
C. Select "UAES M788/Actual values/Diagnostic Data/
Engine speed".
D. Start the engine.
E. Read the engine speed data displayed on the
diagnostic tool when the engine is running.
Standard value: Refer to Data Flow List
F. If the engine cannot start, inspect the data when the
engine is running.
G. If the engine speed displayed on the diagnostic tool
is "0", it means the wiring harness between
crankshaft position sensor and ECM has open or
short circuit.
Is the data flow normal?
Yes
Intermittent fault.
Refer to: Intermittent Malfunction
Diagnosis Procedure (3.1.12
Electronic Control System - M7,
Symptom Diagnosis and
Testing).
No
Go to step 3.

M201 2014.01
3.1.12-157 Electronic Control System - M7 3.1.12-157

Test Conditions Details/Results/Actions

3. Inspect crankshaft position sensor waveform

A. Measure the waveform between terminals 2 and 3
of sensor with an oscilloscope when engine idling.
5V Standard waveform is shown in left figure.
Is it normal?
Yes
Go to step 7.
No

0V Go to step 4.

M3112106

M201 2014.01
3.1.12-158 Electronic Control System - M7 3.1.12-158

Test Conditions Details/Results/Actions

4. Inspect crankshaft position sensor terminal 1 circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the crankshaft position sensor wiring
E18 harness connector E17.
C. Disconnect the ECM wiring harness connector E18.
D. Measure the resistance between terminal 1 of
1 2 9 19 22
crankshaft position sensor wiring harness connector
3 4 23 36
E17 and terminal 19 of ECM wiring harness
5 6 37 50 connector E18.
7 8 51 64 Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 1 of
crankshaft position sensor wiring harness connector
E17 and reliable grounding.
Standard resistance: 10 MΩ or more
F. Measure the voltage between terminal 1 of
crankshaft position sensor wiring harness connector
E17 and reliable grounding.
Standard voltage: 0 V
Is the circuit normal?
1 2 3 Yes
Go to step 5.
E17
No
Repair the fault circuit between terminal 1 of
M3112063 crankshaft position sensor E17 and terminal 19 of
ECM wiring harness connector E18.

1 2 3

E17
M3112064

1 2 3

E17
M3112065

M201 2014.01
3.1.12-159 Electronic Control System - M7 3.1.12-159

Test Conditions Details/Results/Actions

5. Inspect crankshaft position sensor terminal 2 circuit

A. Turn the ignition switch to "LOCK".

E18 B. Disconnect the knock sensor wiring harness

connector E17.
C. Disconnect the ECM wiring harness connector E18.
1 2 9 22
D. Measure the resistance between terminal 2 of
3 4 23 36 crankshaft position sensor wiring harness connector
E17 and terminal 47 of ECM wiring harness
5 6 37 47 50
connector E18. Inspect for open circuit.
7 8 51 64
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 2 of
crankshaft position sensor wiring harness connector
E17 and reliable grounding. Inspect for short to
ground.
Standard resistance: 10 MΩ or more
F. Measure the voltage between terminal 2 of
crankshaft position sensor wiring harness connector
E17 and reliable grounding. Inspect for short to
power supply.
Standard voltage: 0 V
1 2 3
Is the circuit normal?

E17 Yes
Go to step 6.
M3112066 No
Repair the fault circuit between terminal 2 of
crankshaft position sensor E17 and terminal 47 of
engine control module E18.

1 2 3

E17
M3112067

1 2 3

E17
M3112068

M201 2014.01
3.1.12-160 Electronic Control System - M7 3.1.12-160

Test Conditions Details/Results/Actions

6. Inspect crankshaft position sensor terminal 3 circuit

A. Turn the ignition switch to "LOCK".
E18 B. Disconnect the crankshaft position sensor wiring
harness connector E17.
C. Disconnect the ECM wiring harness connector E18.
1 2 9 22
D. Measure the resistance between terminal 3 of
3 4 23 36
crankshaft position sensor wiring harness connector
5 6 37 40 50 E17 and terminal 40 of ECM wiring harness
connector E18.
7 8 51 64
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 3 of
crankshaft position sensor wiring harness connector
E17 and reliable grounding.
Standard resistance: 10 MΩ or more
F. Measure the voltage between terminal 3 of
crankshaft position sensor wiring harness connector
E17 and reliable grounding.
Standard voltage: 0 V
Is the circuit normal?
1 2 3 Yes
Replace the crankshaft position sensor.
E17
Refer to: Crankshaft Position Sensor
(3.1.12 Electronic Control
M3112069 System - M7, Removal and
Installation).
No
Repair the fault circuit between terminal 3 of
crankshaft position sensor E17 and terminal 40 of
ECM wiring harness connector E18.

1 2 3

E17
M3112070

1 2 3

E17
M3112071

M201 2014.01
3.1.12-161 Electronic Control System - M7 3.1.12-161

Test Conditions Details/Results/Actions

7. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36
grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-162 Electronic Control System - M7 3.1.12-162

DTCs P0327, P0328

1. DTC Description

DTC Code Description Definition

A piezoelectric ceramic is built into the knock
P0327 Knock Sensor 1 Circ. Low Input sensor. Using the special piezoelectric effect of
piezoelectric ceramic, it generates output voltage
with large amplitude when engine knocking occurs,
and transmits it to the electronic controller. Terminals
1 and 2 of knock sensor provides knock signal to
P0328 Knock Sensor 1 Circ. High Input ECM, and terminal 3 is grounded by wire for
shielding.

2. Possible Causes

Setting Conditions (Control

DTC Code Monitor Strategy Faulty Area
Strategy)
• Knock identification reference voltage
is lower than 0.5 V 30 times in
succession
Signal range check • Coolant temperature is higher than
P0327
low 40°C
• Engine speed is higher than 2600 rpm
• cylinder 1 identification is possible • Sensor circuit
• Knock identification reference voltage • Sensor
is higher than 320 V 30 times in
• ECM
succession
• No dynamics in engine speed
Signal range check
P0328 • No dynamics in engine load
high
• No knock control circuit fault
• Limp home not active
• Engine load is greater than 39.8%

M201 2014.01
3.1.12-163 Electronic Control System - M7 3.1.12-163
3. Diagnosis Procedure

P0327, P0328

General inspection

Is the fault Yes

confirmed

No

Inspect knock sensor

Is the fault Yes

confirmed

No

Inspect knock sensor signal

circuit 1

Is the fault Yes

confirmed

No

Inspect knock sensor signal

circuit 2

Is the fault Yes

Is the fault confirmed
confirmed
No
No Inspect engine control module
Inspect knock sensor shielded circuit
circuit

End

M201 2014.01
3.1.12-164 Electronic Control System - M7 3.1.12-164

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the knock sensor wiring harness connector
for looseness or damage.
B. Inspect the knock sensor for looseness or improper
installation.
C. Inspect the knock sensor for corrosion.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect knock sensor

A. Turn the ignition switch to "LOCK".
B. Disconnect the knock sensor wiring harness
connector E12.
C. Measure the resistance between terminals 1 and 2
of knock sensor with a multimeter.
Standard resistance: more than 1 MΩ at 25°C
Is it normal?
Yes
Go to step 3.
No
Replace the knock sensor.

M201 2014.01
3.1.12-165 Electronic Control System - M7 3.1.12-165

Test Conditions Details/Results/Actions

3. Inspect knock sensor signal circuit 1

A. Turn the ignition switch to "LOCK".
B. Disconnect the knock sensor wiring harness
E18 connector E12.
C. Disconnect the ECM wiring harness connector E18.
D. Measure the resistance between terminal 1 of
1 2 9 22
knock sensor wiring harness connector E12 and
3 4 23 30 36
terminal 30 of ECM wiring harness connector E18.
5 6 37 50 Inspect for open circuit.
7 8 51 64 Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 1 of
knock sensor wiring harness connector E12 and
reliable grounding. Inspect for short to ground.
Standard resistance: 10 MΩ or more
F. Measure the voltage between terminal 1 of knock
sensor wiring harness connector E12 and reliable
grounding. Inspect for short to power supply.
Standard voltage: 0 V
Are they normal?
1 2 3 Yes
Go to step 4.
E12
No
Repair the fault circuit between terminal 1 of knock
M3112072 sensor wiring harness connector E12 and terminal
30 of ECM wiring harness connector E18. Verify
that the system is normal.

1 2 3

E12
M3112073

1 2 3

E12
M3112074

M201 2014.01
3.1.12-166 Electronic Control System - M7 3.1.12-166

Test Conditions Details/Results/Actions

4. Inspect knock sensor signal circuit 2

A. Turn the ignition switch to "LOCK".

E18 B. Disconnect the knock sensor wiring harness

connector E12.
C. Disconnect the ECM wiring harness connector E18.
1 2 9 22
D. Measure the resistance between terminal 2 of
3 4 23 31 36 knock sensor wiring harness connector E12 and
terminal 31 of ECM wiring harness connector E18.
5 6 37 50
Inspect for open circuit.
7 8 51 64
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 2 of
knock sensor wiring harness connector E12 and
reliable grounding. Inspect for short to ground.
Standard resistance: 10 MΩ or more
F. Measure the voltage between terminal 2 of knock
sensor wiring harness connector E12 and reliable
grounding. Inspect for short to power supply.
Standard voltage: 0 V
Are they normal?
1 2 3 Yes
Go to step 5.
E12
No
Repair the fault circuit between terminal 2 of knock
M3112075 sensor wiring harness connector E12 and terminal
31 of ECM wiring harness connector E18. Verify
that the system is normal.

1 2 3

E12
M3112076

1 2 3

E12
M3112077

M201 2014.01
3.1.12-167 Electronic Control System - M7 3.1.12-167

Test Conditions Details/Results/Actions

5. Inspect knock sensor shielded circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the knock sensor wiring harness
connector E12.
C. Measure the resistance between terminal 3 of
knock sensor wiring harness connector E12 and
reliable grounding.
Standard resistance: less than 5 Ω
1 2 3 Is the resistance value normal?
Yes
E12
Go to step 6.
M3112078
No
Repair the fault circuit between terminal 3 of knock
sensor wiring harness connector E12 and
grounding point G301.

6. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36
grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-168 Electronic Control System - M7 3.1.12-168

DTC P0420
1. DTC Description
CAUTION: If oxygen sensor DTC and catalytic converter efficiency DTC are set
simultaneously, diagnose the oxygen sensor DTC first before proceeding.

CAUTION: Inspect for contamination that damages the oxygen sensor and catalytic
converter, such as dirty fuel, unqualified silicon resin, oil and coolant. Repair as necessary.

DTC Code Description Definition

Catalyst System, Bank1
P0420 -
Efficiency Below Threshold

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• Catalytic converter

Maximum limit • Active monitoring time for catalytic • Exhaust leakage

P0420
exceeded converter diagnosis is more than 40 s • Engine mechanical
• Oxygen sensor aging

M201 2014.01
3.1.12-169 Electronic Control System - M7 3.1.12-169
3. Diagnosis Procedure

P0420

General inspection

Is the fault Yes

confirmed

No

Inspect exhaust gas leakage

Is the fault Yes

confirmed

No
Inspect engine mechanical
problem

Is the fault Yes

confirmed

No

Inspect oxygen sensor aging

(when a new rear oxygen
sensor and an aged front
oxygen sensor work together, it
may lead to DTC set).

End

M201 2014.01
3.1.12-170 Electronic Control System - M7 3.1.12-170

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the catalytic converter for following defects.
Damage, dent or hole in catalytic converter.
Serious discoloration due to catalytic converter
overheating.
Breakage inside the catalytic converter.
Catalytic converter leakage.
Is it normal?
Yes
Go to step 2.
No
Replace the catalytic converter. Make sure the
system is normal.

2. Inspect exhaust gas leakage

A. Start the engine.
B. Inspect if there is exhaust gas leakage between
engine and front oxygen sensor.
C. Inspect if there is exhaust gas leakage between
engine and rear oxygen sensor.
Is there any exhaust gas leakage?
Yes
Repair the leakage fault. Make sure the system is
normal.
No
Go to step 3.

3. Inspect engine mechanical problem

A. Inspect the exhaust gas for excessive black smoke
and blue smoke due to the internal problems of
engine.
Is the exhaust gas with excessive black smoke and
blue smoke?
Yes
Repair the engine mechanical.
Make sure the system is normal.
No
Go to step 4.

M201 2014.01
3.1.12-171 Electronic Control System - M7 3.1.12-171

Test Conditions Details/Results/Actions

4. Inspect oxygen sensor aging (when a new rear oxygen sensor and an aged front oxygen sensor work
together, it may lead to DTC set).
A. Inspect the repair record to see if the oxygen sensor
has been replaced.
Has the rear oxygen sensor rather than front
oxygen sensor been replaced?
Yes
Replace the front oxygen sensor as needed.
No
Replace the catalytic converter.

M201 2014.01
3.1.12-172 Electronic Control System - M7 3.1.12-172

DTCs P0444, P0458, P0459

1. DTC Description

DTC Code Description Definition

Carbon canister control valve circuit includes the
Evaporative Emiss.System Purge following circuit:
P0444
Control Valve Circ. Open
• The operating voltage of carbon canister control valve is
provided by the main relay controlled by the ECM.
Battery voltage is transmitted to terminal 1 of carbon
Evaporative Emission System canister control valve wiring harness connector E13 via
P0458
Purge Control Valve Circuit Low terminal 69 of main relay IR05 of instrument panel fuse
box P40.
• Control circuit: ECM controls terminal 2 of carbon
Evaporative Emission System canister control valve wiring harness connector E13 to
P0459
Purge Control Valve Circuit High ground via terminal 37 of ECM wiring harness
connector E18.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
P0444 Open circuit • Solenoid valve
Hardware circuit
P0458 Short to ground • Solenoid valve circuit
inspection
P0459 Short to power supply • ECM

M201 2014.01
3.1.12-173 Electronic Control System - M7 3.1.12-173
3. Diagnosis Procedure

P0444, P0458
P0459

Perform carbon canister

control valve active test
with diagnostic tool

Is the fault Yes

confirmed

No
Inspect carbon canister control
valve resistance

Is the fault Yes

confirmed

No
Inspect carbon canister control
valve power supply circuit

Is the fault Yes

confirmed

No
Inspect carbon canister control
valve control circuit

Is the fault Yes

confirmed

No
Inspect engine control module
circuit

End

M201 2014.01
3.1.12-174 Electronic Control System - M7 3.1.12-174

Test Conditions Details/Results/Actions

1. Perform carbon canister control valve active test with diagnostic tool
A. Connect the diagnostic tool.
B. Disconnect the vacuum tube between carbon
canister control valve and carbon canister.
C. Start the engine, and turn on the diagnostic tool.
D. Access to menu as follows: "UAES M788/Actuators/
Carbon canister control valve".
E. Increase or decrease the "Carbon canister load"
with diagnostic tool to open the carbon canister
control valve. Cover the valve vacuum port with
fingers.
Is there vacuum suction?
Yes
Refer to: Intermittent Malfunction
Diagnosis Procedure (3.1.12
Electronic Control System - M7,
Symptom Diagnosis and
Testing).
No
Go to step 2.

2. Inspect carbon canister control valve resistance

A. Turn the ignition switch to "LOCK".
B. Disconnect the carbon canister control valve wiring
harness connector E13.
C. Measure the resistance between two terminals of
carbon canister control valve.
Standard resistance: 26 ± 4 Ω at 20°C
D. Connect the carbon canister control valve wiring
harness connector E13.
Is the resistance value normal?
Yes
Go to step 3.
No
Replace the carbon canister control valve.

M201 2014.01
3.1.12-175 Electronic Control System - M7 3.1.12-175

Test Conditions Details/Results/Actions

3. Inspect carbon canister control valve power supply circuit

A. Turn the ignition switch to "LOCK".
E13 B. Disconnect the carbon canister control valve wiring
harness connector E13.
C. Turn the ignition switch to "ON".
1 2 D. Measure the voltage between terminal 1 of carbon
canister control valve wiring harness connector E13
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
M3112079
Go to step 4.
No
Inspect and repair the fault circuit between terminal
1 of carbon canister control valve wiring harness
connector E13 and terminal 69 of main relay IR05 in
the instrument panel fuse box P40.

M201 2014.01
3.1.12-176 Electronic Control System - M7 3.1.12-176

Test Conditions Details/Results/Actions

4. Inspect carbon canister control valve control circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the carbon canister control valve wiring
harness connector E13.
E13
C. Disconnect the engine control module wiring
harness connector E18.
D. Measure the resistance between terminal 2 of
1 2
carbon canister control valve wiring harness
connector E13 and terminal 37 of ECM wiring
harness connector E18. Inspect for open circuit.
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 2 of
carbon canister control valve wiring harness
connector E13 and reliable grounding. Inspect for
short to ground.
1 2 9 22

3 4 23 36 Standard resistance: 10 MΩ or more

5 6 37 50
F. Measure the voltage between terminal 2 of carbon
canister control valve wiring harness connector E13
7 8 51 64
and reliable grounding. Inspect for short to power
supply.
Standard voltage: 0 V
E18
Is it normal?
Yes
Go to step 5.
M3112080
No
Repair the fault circuit between the terminal 2 of
carbon canister control valve wiring harness
connector E13 and terminal 37 of ECM wiring
harness connector E18. Replace when necessary.

1 2

E13

M3112081

1 2

E13

M3112082

M201 2014.01
3.1.12-177 Electronic Control System - M7 3.1.12-177

Test Conditions Details/Results/Actions

5. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36
grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-178 Electronic Control System - M7 3.1.12-178

DTCs P0480, P0691, P0692

1. DTC Description

DTC Code Description Definition

P0480 Cooling Fan 1 Control Circuit Operating power of cooling fan relay coil is supplied by
the main relay controlled by ECM. ECM controls the relay
P0691 Cooling Fan 1 Control Circuit Low
to operate via terminal 52 of ECM wiring harness
connector E18. There is a drive circuit control relay coil
equipped within the ECM for grounding. Drive circuit
P0692 Cooling Fan 1 Control Circuit High provides a feedback circuit to ECM, and ECM determines
if an open circuit, short to ground or power supply occurs
in control circuit by monitoring the feedback voltage.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
P0480 Open circuit • Relay
Hardware circuit
P0691 Short to ground • Relay circuit
inspection
P0692 Short to power supply • ECM

3. Diagnosis Procedure
Refer to: Diagnosis Procedure for Non-operation of Radiator-fan (3.1.4 Cooling System,
Symptom Diagnosis and Testing).

M201 2014.01
3.1.12-179 Electronic Control System - M7 3.1.12-179

DTCs P0506, P0507

1. DTC Description

DTC Code Description Definition

Idle Control System RPM Lower Idling stepper motor is controlled by Engine Control
P0506
than Expected Module (ECM). ECM controls the forward/backward
movement and amount of stepper motor valve via
digitized square signal to regulate the flow area of throttle
body air passage to control the air volume entering the
engine, thus realizing engine idling control. Engine
Control Module (ECM) calculates and controls the engine
Idle Control System RPM Higher target idle speed based on the coolant temperature,
P0507
than Expected vehicle speed compensation, deceleration adjustment,
voltage compensation.
Terminals 22, 21, 35, 36 of ECM wiring harness
connector E18 are connected to terminals 1, 2, 3, 4 of
idling stepper motor E14 respectively.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• Idle speed control integrator
reaches the maximum value
• Difference between static idle
Idling stepper motor stuck speed and actual speed is
P0506 in the position with small less than 100 U/min for 8 s
opening • Engine coolant temperature is
higher than 80.3°C
• Air intake temperature is
higher than 20.3°C

• Idle speed control integrator

reaches the minimum value • Air intake system
• Difference between static idle • Throttle body
speed and actual speed is • ECM
less than -200 U/min for 10 s
• At idle state
Idling stepper motor stuck
• Carbon canister is not at high
P0507 in the position with large
load
opening
• Vehicle speed sensor
diagnosis completes with no
fault
• Vehicle speed is 0
• Altitude correction factor is
greater than 0.703

M201 2014.01
3.1.12-180 Electronic Control System - M7 3.1.12-180
3. Diagnosis Procedure

P0506, P0507

Inspect DTC

Is the fault Yes

confirmed

No

Inspect air intake system

Is the fault Yes

confirmed

No

Inspect throttle body state

Is the fault Yes

confirmed

No

Inspect idling stepper motor and

throttle body

Is the fault Yes

confirmed

No

Inspect engine control module

circuit

End

M201 2014.01
3.1.12-181 Electronic Control System - M7 3.1.12-181

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool to data link connector.
B. Turn the ignition switch to "ON".
C. Select menu: "UAES M788/Read DTC", and read
the DTC.
Is there any DTC other than DTCs P0506 and
P0507?
Yes
Go to DTC diagnosis procedure.
No
Go to step 2.

2. Inspect air intake system

A. Inspect the air intake system for the followings.
Blockage: Air filter dirty, impurity trapped in the air
intake pipe, etc.
Leakage: Air intake pipe joint, air cleaner housing,
etc.
Is it normal?
Yes
Go to step 3.
No
Repair the faulty area.

3. Inspect throttle body state

A. Inspect the throttle body for carbon deposit and
foreign matter. If the throttle disc cannot close
completely, it may bend and need to be replaced.
B. Remove the idling stepper motor, and inspect the
valve body for carbon deposit and other objects,
and inspect if the stepper motor is stuck. If it is dirty
and stuck, clean the idling stepper motor. Replace
the throttle body assembly when necessary.
C. While the vehicle is running, knock idling stepper
motor gently with your hands, and listen to the
sound of idle speed rising.
Is it normal?
Yes
Go to step 4.
No
Repair the fault, and replace the idling stepper
motor or throttle body assembly when necessary.

M201 2014.01
3.1.12-182 Electronic Control System - M7 3.1.12-182

Test Conditions Details/Results/Actions

4. Inspect idling stepper motor and throttle body
A. Replace with a normal idling stepper motor or
throttle body assembly.
B. Clear the DTC.
Are they normal?
Yes
The system is normal.
No
Go to step 5.

5. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-183 Electronic Control System - M7 3.1.12-183

DTCs P0508, P0509, P0511

1. DTC Description

DTC Code Description Definition

P0508 Idle Air Control System Circuit Low ECM controls engine idle speed by adjusting the position
of IAC valve core shaft. IAC valve is a stepper motor that
Idle Air Control System Circuit
P0509 is driven by two internal coils. Movement of idling stepper
High
motor is electrically controlled by four circuits. Driver
inside ECM controls the polarity of two windings in the
idling stepper motor by these circuits, and ECM
commands the motor in the IAC valve to rotate clockwise
or counterclockwise. IAC valve motor is connected to
idling stepper motor core shaft by drive screws. Electrical
pulse delivered from ECM to IAC valve coil allows the
core shaft to stretch or contract into the passage of
throttle body. The air passes through the throttle valve by
P0511 Idle Air Control Circuit
contracting of core shaft to increase air flow and improve
engine speed. When the core shaft stretches, the air flow
is reduced and the engine speed is decreased. DTC will
be set if engine control module detects that engine speed
is not in the expected range. Terminals 22, 21, 35, 36 of
ECM wiring harness connector E18 are connected to
terminals 1, 2, 3, 4 of IAC valve wiring harness connector
E14 respectively.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
One terminal of stepper motor
P0508
is short to ground
• Stepper motor circuit
Hardware circuit One terminal of stepper motor
P0509 • Stepper motor
inspection is short to battery positive
• ECM
One terminal of stepper motor
P0511
is open

M201 2014.01
3.1.12-184 Electronic Control System - M7 3.1.12-184
3. Diagnosis Procedure

P0508, P0509, P0511

General inspection

Is the fault Yes

confirmed

No

Inspect idling stepper motor

Is the fault Yes

confirmed

No

Inspect wiring harness

connectors (terminal 1 of idling
stepper motor E14 - terminal
22 of ECM E18)

Is the fault Yes

confirmed

No

Inspect wiring harness Is the fault Yes

connectors (terminal 2 of idling confirmed
stepper motor E14 - terminal
21 of ECM E18)
Inspect wiring harness No
connectors (terminal 3 of idling
stepper motor E14 - terminal Inspect engine control module
35 of ECM E18) circuit
Inspect wiring harness
connectors (terminal 4 of idling
stepper motor E14 - terminal
36 of ECM E18)

End

M201 2014.01
3.1.12-185 Electronic Control System - M7 3.1.12-185

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the stepper motor wiring harness connector
E14 for looseness or poor contact.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect idling stepper motor

A. Turn the ignition switch to "LOCK".
B. Disconnect the idling stepper motor wiring harness
connector E14.
C. Measure the resistance of idling stepper motor.
Standard resistance:
53 ± 5.3 Ω between terminals A and D, B and C 10
MΩ or more between terminals A and C, B and D Is
resistance value normal?
Yes
Go to step 3.
No
Replace the idling stepper motor.

M201 2014.01
3.1.12-186 Electronic Control System - M7 3.1.12-186

Test Conditions Details/Results/Actions

3. Inspect wiring harness connectors (terminal 1 of idling stepper motor E14 - terminal 22 of ECM
E18)
A. Turn the ignition switch to "LOCK".
B. Disconnect the idling stepper motor wiring harness
E14 connector E14.
C. Disconnect the engine control module wiring
1 2 3 4
harness connector E18.
D. Measure the resistance between terminal 1 of idling
stepper motor wiring harness connector E14 and
terminal 22 of engine control module wiring harness
connector E18. Inspect for open circuit.
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 1 of idling
stepper motor wiring harness connector E14 and
reliable grounding. Inspect for short to ground.
1 2 9 22 Standard resistance: 10 MΩ or more
3 4 23 36 F. Measure the voltage between terminal 1 of idling
stepper motor wiring harness connector E14 and
5 6 37 50
reliable grounding. Inspect for short to power
7 8 51 64
supply.
Standard voltage: 0 V
Are they normal?
E18
Yes
Go to step 4.

M3112083
No
Repair the fault circuit between terminal 1 of idling
stepper motor wiring harness connector E14 and
E14 terminal 22 of engine control module wiring harness
connector E18.
1 2 3 4

M3112084

E14

1 2 3 4

M3112085

M201 2014.01
3.1.12-187 Electronic Control System - M7 3.1.12-187

Test Conditions Details/Results/Actions

4. Inspect wiring harness connectors (terminal 2 of idling stepper motor E14 - terminal 21 of ECM
E18)
A. Turn the ignition switch to "LOCK".
B. Disconnect the idling stepper motor wiring harness
E14 connector E14.
C. Disconnect the engine control module wiring
1 2 3 4
harness connector E18.
D. Measure the resistance between terminal 2 of idling
stepper motor wiring harness connector E14 and
terminal 21 of engine control module wiring harness
connector E18. Inspect for open circuit.
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 2 of idling
stepper motor wiring harness connector E14 and
reliable grounding. Inspect for short to ground.
1 2 9 21 22 Standard resistance: 10 MΩ or more
3 4 23 36 F. Measure the voltage between terminal 2 of idling
stepper motor wiring harness connector E14 and
5 6 37 50
reliable grounding. Inspect for short to power
7 8 51 64
supply.
Standard voltage: 0 V
Are they normal?
E18
Yes
Go to step 5.

M3112086
No
Repair the fault circuit between terminal 2 of idling
stepper motor wiring harness connector E14 and
E14 terminal 21 of engine control module wiring harness
connector E18.
1 2 3 4

M3112087

E14

1 2 3 4

M3112088

M201 2014.01
3.1.12-188 Electronic Control System - M7 3.1.12-188

Test Conditions Details/Results/Actions

5. Inspect wiring harness connectors (terminal 3 of idling stepper motor E14 - terminal 35 of ECM
E18)
A. Turn the ignition switch to "LOCK".
B. Disconnect the idling stepper motor wiring harness
E14 connector E14.
C. Disconnect the engine control module wiring
1 2 3 4
harness connector E18.
D. Measure the resistance between terminal 3 of idling
stepper motor wiring harness connector E14 and
terminal 35 of engine control module wiring harness
connector E18. Inspect for open circuit.
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 3 of idling
stepper motor wiring harness connector E14 and
reliable grounding. Inspect for short to ground.
1 2 9 22 Standard resistance: 10 MΩ or more
3 4 23 35 36 F. Measure the voltage between terminal 3 of idling
stepper motor wiring harness connector E14 and
5 6 37 50
reliable grounding. Inspect for short to power
7 8 51 64
supply.
Standard voltage: 0 V
Are they normal?
E18
Yes
Go to step 6.

M3112089
No
Repair the fault circuit between terminal 3 of idling
stepper motor wiring harness connector E14 and
E14 terminal 35 of engine control module wiring harness
connector E18.
1 2 3 4

M3112090

E14

1 2 3 4

M3112091

M201 2014.01
3.1.12-189 Electronic Control System - M7 3.1.12-189

Test Conditions Details/Results/Actions

6. Inspect wiring harness connectors (terminal 4 of idling stepper motor E14 - terminal 36 of ECM
E18)
A. Turn the ignition switch to "LOCK".
B. Disconnect the idling stepper motor wiring harness
E14 connector E14.
C. Disconnect the engine control module wiring
1 2 3 4
harness connector E18.
D. Measure the resistance between terminal 4 of idling
stepper motor wiring harness connector E14 and
terminal 36 of engine control module wiring harness
connector E18. Inspect for open circuit.
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 4 of idling
stepper motor wiring harness connector E14 and
reliable grounding. Inspect for short to ground.
1 2 9 22 Standard resistance: 10 MΩ or more
3 4 23 36 F. Measure the voltage between terminal 4 of idling
stepper motor wiring harness connector E14 and
5 6 37 50
reliable grounding. Inspect for short to power
7 8 51 64
supply.
Standard voltage: 0 V
Are they normal?
E18
Yes
Go to step 7.

M3112092
No
Repair the fault circuit between terminal 4 of idling
stepper motor wiring harness connector E14 and
E14 terminal 36 of engine control module wiring harness
connector E18.
1 2 3 4

M3112093

E14

1 2 3 4

M3112094

M201 2014.01
3.1.12-190 Electronic Control System - M7 3.1.12-190

Test Conditions Details/Results/Actions

7. Inspect engine control module circuit
A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-191 Electronic Control System - M7 3.1.12-191

DTCs P0560, P0562, P0563

1. DTC Description

DTC Code Description Definition

P0560 System Voltage Malfunction ECM power supply consists of the following circuits:

P0562 System Voltage Low Voltage Through the ECM fuse, constant battery power is
supplied to ECM via the terminal 16 of ECM wiring
harness connector E18.
When the ignition switch is turned to "ON", the fuse IF37
supplies power to terminal 17 of engine control module
wiring harness connector E18.

P0563 System Voltage High Voltage • When ECM detects battery voltage at terminal 17 of
ECM wiring harness connector E18, it controls the main
relay to close by internal grounding of E18 terminal 32.
• After the main relay is closed, the power from battery
supply main relay IR05 is supplied to ECM via E18
terminals 8, 51.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• ADC value of battery voltage
P0560 Implausibility check
is lower than 2.5 V

• Starting time is more than

180 s
Lower limit value
P0562 • ADC value of battery voltage
exceeded
is higher than 2.5 V, lower • Battery
than 10.02 V • ECM power supply and
grounding circuit
• ADC value of battery voltage
is higher than 17.02 V for • Charging system
0.2 s
Upper limit value
P0563 • Vehicle speed is greater than
exceeded
25 km/h
• Starting time is more than
180 s

M201 2014.01
3.1.12-192 Electronic Control System - M7 3.1.12-192
3. Diagnosis Procedure

P0560, P0562, P0563

Inspect ECM constant power

supply fuse and ignition
power supply fuse

Is the fault Yes

confirmed

No

Inspect ECM power supply voltage

No Is the fault
confirmed

Yes

Inspect ECM power supply circuit

Is the fault Yes

confirmed

No

Inspect ECM grounding circuit

Is the fault Yes

confirmed

No

Inspect charging system

End

M201 2014.01
3.1.12-193 Electronic Control System - M7 3.1.12-193

Test Conditions Details/Results/Actions

1. Inspect ECM constant power supply fuse and ignition power supply fuse
A. Turn the ignition switch to "LOCK".
B. Remove the ECM constant power supply fuse IF11
and ignition power supply fuse IF37 from the
instrument panel fuse box P40.
C. Inspect the conductivity between two terminals of
fuses with the multimeter.
Are the fuses normal?
Yes
Go to step 2.
No
Replace the fuses. Verify that the system is normal.

2. Inspect ECM power supply voltage

A. Turn the ignition switch to "ON".
E18 Make sure the main relay operates normally, or
replace it.
B. Measure the voltages between terminals 16, 17, 8,
1 2 9 16 17 22 51 of ECM wiring harness connector E18 and
3 4 23 36 reliable grounding from the backside.
5 6 37 50
Standard voltage: 11 ~ 14 V

7 8 51 64 Are the voltage values normal?

Yes
Go to step 4.
M3112095 No
Go to step 3.

M201 2014.01
3.1.12-194 Electronic Control System - M7 3.1.12-194

Test Conditions Details/Results/Actions

3. Inspect ECM power supply circuit
A. Turn the ignition switch to "LOCK".
B. Remove the ECM constant power supply fuse IF11.
P40
C. Remove the main relay IR05.
D. Measure the resistance between terminal 22 of
IF11
ECM constant power supply fuse IF11 and terminal
22
16 of ECM wiring harness connector E18.
IR05

69 Standard resistance: less than 5 Ω

IF37
E. Measure the resistance between terminal 74 of fuse
74
IF37 in the instrument panel fuse box P40 and
terminal 17 of ECM wiring harness connector E18.
Standard resistance: less than 5 Ω
F. Measure the resistances between terminal 69 of
main relay IR05 and terminals 8, 51 of ECM wiring
harness connector E18.
E18
Standard resistance: less than 5 Ω
Is the resistance value normal?
1 2 9 16 17 22

3 4 23 36 Yes
5 6 37 50 Go to step 4.
7 8 51 64
No
Repair related circuit. Make sure the system is
normal.

M3112096

M201 2014.01
3.1.12-195 Electronic Control System - M7 3.1.12-195

Test Conditions Details/Results/Actions

4. Inspect ECM grounding circuit
A. Turn the ignition switch to "LOCK".
E18 B. Disconnect the ECM wiring harness connector E18.
C. Measure the resistances between terminals 5, 43,
48 of ECM wiring harness E18 and reliable
1 2 9 22
grounding.
3 4 23 36
Standard resistance: less than 5 Ω
5 6 37 43 48 50
Are the resistance values normal?
7 8 51 64
Yes
Go to step 5.
No
M3112097
Repair the fault circuit between terminal 5 of ECM
wiring harness connector E18 and grounding point
G301, or between terminals 43, 48 of E18 and
grounding point G302.

5. Inspect charging system

A. Turn the ignition switch to "LOCK".
B. Inspect the battery voltage.
Standard voltage: 11 ~ 14 V
C. Start and run the engine to the normal temperature,
turn off all equipment, and change the engine
speed from idle speed to 4000 rpm.
D. Inspect the engine charging voltage.
Standard voltage: 11.5 ~ 14.5 V
Is the voltage value normal?
Yes
Refer to: Intermittent Malfunction
Diagnosis Procedure (3.1.12
Electronic Control System - M7,
Symptom Diagnosis and
Testing).
No
Repair battery or charging system fault.

M201 2014.01
3.1.12-196 Electronic Control System - M7 3.1.12-196

DTC P0602
1. DTC Description

DTC Code Description Definition

ECM internal program processing fault, ECM power
P0602 Control Module Programming Error
supply and grounding abnormal.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
Diagnose the Diagnostic • ECM circuit
P0602 Data Identification (DDI) -
code programming • ECM

M201 2014.01
3.1.12-197 Electronic Control System - M7 3.1.12-197
3. Diagnosis Procedure

Test Conditions Details/Results/Actions

1. Inspect DTC
A. Connect the diagnostic tool to data link connector.
B. Turn the ignition switch to "ON".
C. Diagnose the engine system.
Is there any DTC other than P0602?
Yes
Repair the DTC other than P0602.
No
Go to step 2.

2. Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-198 Electronic Control System - M7 3.1.12-198

DTCs P0627, P0628, P0629

1. DTC Description

DTC Code Description Definition

Fuel Pump "A" Control Circuit/ Working power of oil pump relay coil is supplied by main
P0627
Open relay controlled by ECM. ECM controls the grounding of
terminal 80 of oil pump relay IR08 via terminal 60 of ECM
P0628 Fuel Pump "A" Control Circuit Low
wiring harness connector E18 to close the oil pump relay.
There is a drive circuit in the ECM to control the relay coil
grounding. The drive circuit provides a feedback circuit to
P0629 Fuel Pump "A" Control Circuit High ECM, and ECM determines if an open circuit, short to
ground or power supply occurs in control circuit by
monitoring the feedback voltage.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
P0627 Open circuit • Relay
Hardware circuit
P0628 Short to ground • Relay circuit
inspection
P0629 Short to power supply • ECM

3. Diagnosis Procedure
Refer to: Diagnosis Procedure for Fuel Pump Failure (3.1.7 Fuel System, Symptom Diagnosis
and Testing).

M201 2014.01
3.1.12-199 Electronic Control System - M7 3.1.12-199

DTCs P0645, P0646, P0647

1. DTC Description

DTC Code Description Definition

P0645 AC Clutch Relays Circuit Working power of A/C compressor relay is supplied by
main relay controlled by ECM. ECM controls the internal
P0646 A/C Clutch Relay Control Circuit Low
grounding of A/C compressor relay via terminal 61 of
ECM wiring harness connector E18 to close the relay.
There is a drive circuit in the ECM to control the relay coil
grounding. The drive circuit provides a feedback circuit to
P0647 A/C Clutch Relay Control Circuit High
ECM, and ECM determines if an open circuit, short to
ground or power supply occurs in control circuit by
monitoring the feedback voltage.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
P0645 • Open circuit • Relay
Hardware circuit
P0646 • Short to ground • Relay circuit
inspection
P0647 • Short to power supply • ECM

3. Diagnosis Procedure
Refer to: Diagnosis Procedure for A/C Compressor Clutch Fault (4.1.1 Heating, Ventilation
and Air Conditioning, Symptom Diagnosis and Testing).

M201 2014.01
3.1.12-200 Electronic Control System - M7 3.1.12-200

DTC P0650
1. DTC Description

DTC Code Description Definition

Engine malfunction indicator lamp is controlled by ECM.
Malfunction Indicator Lamp Control
P0650 When ECM detects engine malfunction, it sets DTC and
Circ.
turns on MIL by setting it at low potential via special line.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• Open circuit • Instrument cluster
Hardware circuit
P0650 • Short to ground • MIL circuit
inspection
• Short to power supply • ECM

M201 2014.01
3.1.12-201 Electronic Control System - M7 3.1.12-201
3. Diagnosis Procedure

P0650

Inspect state of other warning

indicators on instrument cluster

No Is the fault
confirmed

Yes

Inspect instrument cluster power

supply circuit

Is the fault Yes

confirmed

No

Inspect instrument cluster fuse

Is the fault Yes

confirmed

No

Inspect drive circuit

Is the fault Yes

confirmed

No
Inspect engine control module
circuit

End

M201 2014.01
3.1.12-202 Electronic Control System - M7 3.1.12-202

Test Conditions Details/Results/Actions

1. Inspect state of other warning indicators on instrument cluster
A. Turn the ignition switch to "ON".
B. Inspect the status of all the warning indicators.
Is there any other warning indicator abnormal
besides MIL indicator?
Yes
Go to step 2.
No
Go to step 4.

2. Inspect instrument cluster power supply circuit

A. Turn the ignition switch to "LOCK".
P21
B. Disconnect the instrument cluster wiring harness
17 32
connector P21.
1 7 16
C. Turn the ignition switch to "ON".
D. Measure the voltage between terminal 7 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
M3112098
Replace the instrument cluster. Make sure the
system is normal.
No
Go to step 3.

3. Inspect instrument cluster fuse

A. Turn the ignition switch to "LOCK".
B. Remove the instrument cluster fuse IF35 from the
instrument panel fuse box P40.
C. Inspect the conductivity between two terminals of
fuse with the multimeter.
Is the fuse normal?
Yes
Inspect and repair the fault circuit between terminal
7 of instrument cluster wiring harness connector
P21 and fuse IF35.
No
Replace the fuse. Verify that the system is normal.

M201 2014.01
3.1.12-203 Electronic Control System - M7 3.1.12-203

Test Conditions Details/Results/Actions

4. Inspect drive circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the instrument cluster wiring harness
P21 connector P21.
17 28 32 C. Disconnect the engine control module wiring
1 16 harness connector E18.
D. Measure the resistance between the terminal 28 of
instrument cluster wiring harness connector P21
and terminal 20 of engine control module wiring
harness connector E18.
Standard resistance: less than 5 Ω
E. Measure the resistance between terminal 28 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard resistance: 10 MΩ or more
F. Measure the voltage between terminal 28 of
1 2 9 20 22
instrument cluster wiring harness connector P21
3 4 23 36
and reliable grounding.
5 6 37 50
Standard voltage: 0 V
7 8 51 64
Are they normal?
Yes
Go to step 5.
E18
No
M3112099 Repair the fault circuit between terminal 28 of
instrument panel wiring harness connector P21 and
P21 terminal 20 of engine control module wiring harness
17 28 32 connector E18.
1 16

M3112100

P21
17 28 32
1 16

M3112101

M201 2014.01
3.1.12-204 Electronic Control System - M7 3.1.12-204

Test Conditions Details/Results/Actions

5. Inspect engine control module circuit
A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-205 Electronic Control System - M7 3.1.12-205

DTCs P2177, P2178, P2187, P2188

1. DTC Description

DTC Code Description Definition

Engine Control Module (ECM) controls closed loop air-
P2177 System Too Lean Off Idle fuel ratio measuring system, achieving best cooperation
of drivability, fuel economy and emission control. In
closed loop mode, ECM monitors the signal voltage of
heated oxygen sensor (HO2S) and regulates the fuel
P2178 supply according to the signal voltage.
System Too Rich Off Idle
Changes in fuel supply will change the fuel trim values of
long term and short term. The fuel short term trim value
will change rapidly, responding to the change of heated
P2187 System Too Lean at Idle oxygen sensor signal voltage. These changes will finely
tune the engine fuel supply. The fuel long term trim value
changes in response to the fuel short term trim trend. The
fuel long term trim adjusts fuel supply roughly, in order to
return to the short term center fuel value, and to recover
the control to fuel short term trim.
System Too Rich at Idle Ideal value of the fuel trim is about 0%. If the fuel trim
P2188
value is positive, it shows the engine control module is
increasing fuel to compensate the condition that the fuel
mixture is too lean. If the fuel trim value is negative, it
shows the engine control module is decreasing fuel to
compensate the condition that the fuel mixture is too rich.

2. Possible Causes

Setting Conditions
DTC Code Monitor Strategy Faulty Area
(Control Strategy)
• Multiplicative adaption value
is more than 1.23 for 25 s
• Air-fuel ratio adaption on
Fuel trim high limits
P2177 • Engine speed is 1400 ~ 4000
exceeded • Air intake pressure sensor
rpm
• Air mass flow is 18 ~ 70 kg/h • Oxygen sensor

• Load is 16% ~ 70% • Sensor circuit

• Coolant temperature sensor
• Multiplicative adaption value
is less than 0.77 for 25 s • Fuel pressure
• Air-fuel ratio adaption on • Fuel injector and control
Fuel trim low limits circuit
P2178 • Engine speed is 1400 ~ 4000
exceeded
rpm • Engine mechanical
• Air mass flow is 18 ~ 70 kg/h • ECM
• Load is 16% ~ 70%

P2187 - -

P2188 - -

M201 2014.01
3.1.12-206 Electronic Control System - M7 3.1.12-206
3. Diagnosis Procedure

P2177, P2178,
P2187, P2188

General inspection

Is the fault Yes

confirmed

No

Inspect other DTC

Inspect data flow
Inspect front oxygen sensor
data flow

Is the fault Yes

confirmed

No

Inspect front oxygen sensor

condition (carry out oxygen
sensor signal test)

Is the fault Inspect fuel pressure

confirmed Inspect fuel injector control
circuit
Inspect fuel injector
No Inspect compression pressure
Inspect ignition timing
Inspect front oxygen sensor
signal circuit
Inspect front oxygen sensor
grounding circuit
Inspect air intake pressure sensor Is the fault Yes
Inspect coolant temperature confirmed
sensor
No
Inspect engine control
module circuit
Is the fault
confirmed

No

Yes
End

M201 2014.01
3.1.12-207 Electronic Control System - M7 3.1.12-207

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the oxygen sensor, air intake pressure/
temperature sensor, engine coolant temperature
sensor wiring harness connector for damage, poor
contact, aging, looseness and so on.
B. Inspect the vacuum tube for damage, looseness or
leakage.
C. Inspect the air intake system for leakage.
D. Inspect for contamination that may damage the
oxygen sensor: dirty fuel, unqualified silicone, oil
and coolant.
E. Inspect the engine PCV (Positive Crankcase
Ventilation) system.
F. Inspect the engine exhaust system for blockage or
leakage.
Are they normal?
Yes
Go to step 2.
No
Repair the fault, and verify that the system is
normal.

2. Inspect other DTC

A. Connect the diagnostic tool.
B. Start the engine and diagnose the engine system.
C. Inspect DTC.
Is there any DTC other than P2177, P2178, P2187
and P2188?
Yes
Go to DTC diagnosis procedure.
No
Go to step 3.

M201 2014.01
3.1.12-208 Electronic Control System - M7 3.1.12-208

Test Conditions Details/Results/Actions

3. Inspect data flow
A. Connect the diagnostic tool.
B. Start engine and access to the engine system data
flow on diagnostic tool.
C. Inspect the long, short and final long term fuel trim
values.
Are the values normal?
Yes
Go to step 4.
No
Refer to: Intermittent Malfunction
Diagnosis Procedure (3.1.12
Electronic Control System - M7,
Symptom Diagnosis and
Testing).
4. Inspect front oxygen sensor data flow
A. Start the engine, and run it till the engine coolant
temperature reaches above 80°C.
B. Use diagnostic tool to enter engine data flow, and
observe the "O2 sensor voltage bank 1, sensor 1"
parameter.
Standard voltage: fluctuates between 0.1 ~ 0.9 V.
C. Turn the ignition switch to "LOCK" after
measurement.
Does the voltage of oxygen sensor fluctuate
between 0.1 ~ 0.9 V?
Yes
Go to step 8.
No
Go to step 5.

M201 2014.01
3.1.12-209 Electronic Control System - M7 3.1.12-209

Test Conditions Details/Results/Actions

5. Inspect front oxygen sensor condition (carry out oxygen sensor signal test)
A. If the voltage displayed in data flow remains below
0.45 V (mixture too lean), inspect according to the
following steps:
• Jet a proper amount of propane into the
intake port.
• Observe if the front oxygen sensor
voltage in data flow changes obviously
and the signal voltage rises quickly.
B. If the voltage displayed in data flow remains above
0.45 V (mixture too rich), inspect according to the
following steps:
• Position the transmission at neutral gear.
• Apply the parking brake.
• Depress the accelerator pedal until the
engine speed suddenly increases to
4000 rpm and then quickly release the
accelerator pedal.
• Repeat the previous step more than 3
times.
• Observe if the front oxygen sensor
voltage in data flow changes obviously
and the signal voltage drops quickly.
In the implementation of above test, the oxygen
sensor signal voltage should change significantly
as the test continues.
Does it change significantly?
Yes
Go to step 6.
No
Replace the front oxygen sensor.
Refer to: Front Oxygen Sensor (3.1.12
Electronic Control System - M7,
Removal and Installation).

M201 2014.01
3.1.12-210 Electronic Control System - M7 3.1.12-210

Test Conditions Details/Results/Actions

6. Inspect front oxygen sensor signal circuit
A. Inspect the front oxygen sensor signal circuit.
B. Turn the ignition switch to "LOCK".
C. Disconnect the front oxygen sensor wiring harness
connector E01.
D. Disconnect the ECM wiring harness connector E18.
1 3 E. Measure the resistance between terminal 1 of front
oxygen sensor wiring harness connector E01 and
2 4 terminal 45 of ECM wiring harness connector E18.
Inspect for open circuit.
E01
Standard resistance: less than 5 Ω
F. Measure the resistance between terminal 1 of front
oxygen sensor wiring harness connector E01 and
reliable grounding. Inspect for short to ground.
Standard resistance: 10 MΩ or more
1 2 9 22 G. Measure the voltage between terminal 1 of front
oxygen sensor wiring harness connector E01 and
3 4 23 36
reliable grounding. Inspect for short to power
5 6 37 45 50
supply.
7 8 51 64
Standard voltage: 0 V
Is it normal?
Yes
E18
Go to step 7.
M3112102 No
Repair the fault circuit between terminal 1 of front
oxygen sensor wiring harness connector E01 and
terminal 45 of ECM wiring harness connector E18.

1 3

2 4

E01
M3112103

1 3

2 4

E01
M3112104

M201 2014.01
3.1.12-211 Electronic Control System - M7 3.1.12-211

Test Conditions Details/Results/Actions

7. Inspect front oxygen sensor grounding circuit
A. Turn the ignition switch to "LOCK".
E01
B. Disconnect the front oxygen sensor wiring harness
connector E01.
1 3
C. Turn the ignition switch to "ON".
2 4 D. Measure the resistance between terminal 2 of E01
and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 8.
M3112105
No
Inspect and repair the fault circuit between terminal
2 of front oxygen sensor wiring harness connector
E01 and terminal 39 of ECM wiring harness
connector E18.

8. Inspect air intake pressure sensor

A. Turn the ignition switch to "LOCK".
B. Connect a vacuum gauge to the intake manifold
vacuum source.
C. Start the engine and idle it.
D. Read the "Actual intake manifold pressure" data
flow with the diagnostic tool.
Is the difference between readings on the
diagnostic tool and vacuum gauge within 1 in (25
mm)?
Yes
Go to step 9.
No
Replace the air intake pressure/temperature
sensor, and clean the throttle and intake manifold.
Verify that the system is normal.

M201 2014.01
3.1.12-212 Electronic Control System - M7 3.1.12-212

Test Conditions Details/Results/Actions

9. Inspect coolant temperature sensor
CAUTION: To make the test effective, the
thermostat should work normally.

CAUTION: Carry out this test when the

engine is cold (cool it to the ambient
temperature).
A. Turn the ignition switch to "ON" with engine not
running.
B. Use the diagnostic tool to read the value of engine
coolant temperature (ECT) sensor. The
temperature should be close to the ambient
temperature.
C. Start the engine.
When the engine is warmed up, monitor the ECT
sensor value. Changes from start to normal
operating temperature (82°C (180°F)) should be
stable.
This value should be at least 82°C (180°F).
Is it normal?
Yes
Go to step 10.
No
Replace the coolant temperature sensor.

10.Inspect fuel pressure

A. Turn the ignition switch to "LOCK".
B. Measure the fuel pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
Is the fuel pressure normal?
Yes
Go to step 11.
No
Inspect the fuel system fault.
Refer to: Low Pressure in Fuel System
(3.3.7 Fuel System, Symptom
Diagnosis and Testing).

M201 2014.01
3.1.12-213 Electronic Control System - M7 3.1.12-213

Test Conditions Details/Results/Actions

11.Inspect fuel injector control circuit
A. Disconnect the fuel injector wiring harness
connector from the possible faulty cylinder.
B. Connect the test pen with LED to the fuel injector
terminal.
CAUTION: LED must connect with 1 ~ 2
kΩ resistor in series, otherwise the LED or
ECM may be damaged.
C. Inspect the LED state during engine start.
Does the LED flash?
Yes
Go to step 12.
No
Inspect the fuel injector wiring harness. Repair or
replace if necessary.

12.Inspect fuel injector

A. Remove the fuel injector.
B. Replace with a fuel injector in good condition.
C. Clear the DTC.
D. Start engine and carry out road test when
necessary.
E. Diagnose the engine system.
Are there DTCs P2177, P2178, P2187 and P2188?
No
Replace the fuel injector.
Yes
Go to step 13.

13.Inspect compression pressure

A. Inspect the engine compression pressure.
Refer to: Cylinder Compression Pressure
Inspection (3.1.2 Mechanical
System, General Inspection).
Is the compression pressure normal?
Yes
Go to step 14.
No
Inspect the cause of low compression pressure,
and Repair the faulty area.

M201 2014.01
3.1.12-214 Electronic Control System - M7 3.1.12-214

Test Conditions Details/Results/Actions

14.Inspect ignition timing
A. Inspect the ignition timing.
Refer to: Timing Inspection (3.1.2
Mechanical System, General
Inspection).
Is the ignition timing normal?
Yes
Go to step 15.
No
Repair the ignition timing fault. Verify that the
system is normal.

15.Inspect engine control module circuit

A. Connect the ECM wiring harness connector, and
E18 turn the ignition switch to "ON".
B. Inspect if the power supply for terminals 8, 16, 17
and 51 is normal with the multimeter.
1 2 9 16 17 22
C. Turn the ignition switch to "LOCK". Inspect if the
3 4 23 36 grounding for terminals 5, 43 and 48 is normal.
5 6 37 50 Is the engine control module circuit normal?
7 8 51 64 Yes
Replace the engine control module.
Refer to: Engine Control Module (3.1.12
M3112019
Electronic Control System - M7,
Removal and Installation).
E18
No
Repair the circuit.
1 2 9 22

3 4 23 36

5 6 37 43 48 50

7 8 51 64

M3112020

M201 2014.01
3.1.12-215 Electronic Control System - M7 3.1.12-215

Removal and Installation

Engine Control Module
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Disconnect the engine control module wiring
harness connector (1).

×4 2

M3112110

3. Remove the engine control module retaining

nut (2).
Torque: 8 ± 2 Nm

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.1.12-216 Electronic Control System - M7 3.1.12-216

Crankshaft Position Sensor

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Disconnect the crankshaft position sensor
wiring harness connector.

M3112120

3. Remove the air intake manifold.

Refer to: Intake Manifold (3.1.5 Air Intake
System, Removal and
Installation).
4. Remove the crankshaft position sensor
retaining bolt.
Torque: 10 ± 2 Nm

M3112130

Installation
1. Installation is in the reverse order of removal.

CAUTION: Before installation, apply

lubricant to the O-ring and press in the
sensor with hands.

M201 2014.01
3.1.12-217 Electronic Control System - M7 3.1.12-217

Throttle Position Sensor

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Disconnect the throttle position sensor wiring
harness connector (1).

×2 2

M3112140

3. Remove 2 retaining bolts (2) from the throttle

position sensor.
Torque: 1.5 ~ 2.5 Nm

Installation
1. Installation is in the reverse order of removal.

CAUTION: Make sure the seal ring of

sensor is fully inserted to the end and the
wiring harness connector is set in place
during installation.

M201 2014.01
3.1.12-218 Electronic Control System - M7 3.1.12-218

Idling Stepper Motor

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the throttle body.
Refer to: Throttle Body (3.1.5 Air Intake
System, Removal and
Installation).
3. Remove 2 retaining bolts from the idling
stepper motor.
Torque: 4 ± 0.4 Nm

×2

M3112150

Installation
1. Installation is in the reverse order of removal.

CAUTION: Pulling or pushing the shaft of

stepper motor is prohibited, or it will
cause permanent damage.

M201 2014.01
3.1.12-219 Electronic Control System - M7 3.1.12-219

Coolant Temperature Sensor

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Drain the coolant.

Refer to: Coolant Draining and Filling
(3.1.4 Cooling System, General
Inspection).
3. Disconnect the coolant temperature sensor
connector.
4. Remove the coolant temperature sensor.
Torque: 20 Nm or less

M3112160

Installation
1. Installation is in the reverse order of removal.

CAUTION: Make sure the sensor is fully

inserted to the end and there is no coolant
leakage.

M201 2014.01
3.1.12-220 Electronic Control System - M7 3.1.12-220

Air Intake Pressure/Temperature Sensor

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Disconnect the air intake pressure/
temperature sensor wiring harness connector
(1).

M3112170

3. Remove the retaining bolt (2) from the air

intake pressure/temperature sensor.
Torque: 8 ± 2 Nm

Installation
1. Installation is in the reverse order of removal.

CAUTION: Installing the sensor with any

impactive tool (such as hammer) is
prohibited. Avoid water, oil etc. entering
the sensor.

M201 2014.01
3.1.12-221 Electronic Control System - M7 3.1.12-221

Fuel Injector
Removal
1. Release the fuel pressure.
Refer to: Fuel System Pressure Test (3.1.7
Fuel System, General
Inspection).
2. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
3. Disengage 2 clamps and separate 2 hoses.

M3112180

4. Disconnect 4 connectors from the fuel

injectors.
×4

M3112190

5. Remove 2 retaining bolts from the fuel rail

and separate the fuel main pipe assembly
from the cylinder block.
×2

M3112200

M201 2014.01
3.1.12-222 Electronic Control System - M7 3.1.12-222

6. Loosen the retaining clips from the fuel

injector, and remove the fuel injector.

M3112210

Installation
1. Installation is in the reverse order of removal.

CAUTION: Replace the fuel injector clips

and seal rings during installation.
Before assembly, it is necessary to apply
clean lubricant to the injector lower seal
ring. Prevent the lubricant contaminating
the injector plate, and keep the injector
mounting hole on the engine clean.
Carefully install the fuel rail to the cylinder
block with an even force in the axial
direction of injector. Avoid applying
excessive impact during assembly.

M201 2014.01
3.1.12-223 Electronic Control System - M7 3.1.12-223

Front Oxygen Sensor

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Disconnect the front oxygen sensor wiring
harness connector.

M3112220

3. Remove the front oxygen sensor with a

suitable tool.
Torque: 50 ± 10 Nm

M3112230

Installation
1. Installation is in the reverse order of removal.

CAUTION: Applying washer fluid, oily

liquid or volatile solid on the oxygen
sensor is prohibited.

M201 2014.01
3.1.12-224 Electronic Control System - M7 3.1.12-224

Rear Oxygen Sensor

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and
2. Disconnect the rear oxygen sensor wiring
harness connector (1).

M3112240

3. Remove the rear oxygen sensor (2) with a

suitable tool.
Torque: 50 ± 10 Nm

Installation
1. Installation is in the reverse order of removal.

CAUTION: Applying washer fluid, oily

liquid or volatile solid on the oxygen
sensor is prohibited.

M201 2014.01
3.1.12-225 Electronic Control System - M7 3.1.12-225

Knock Sensor
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and, Removal and
Installation).
2. Disconnect the knock sensor wiring harness
connector.

M3112250

3. Remove the air intake manifold.

Refer to: Intake Manifold (3.1.5 Air Intake
System, Removal and
Installation).
4. Remove the retaining bolt from the knock
sensor.
Torque: 20 ± 5 Nm

M3112260

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure that the mounting
boss surface is clean with no oil stain. Any
type of washer shall not be used between
sensor and cylinder block when installing
the metal face to the cylinder block.

M201 2014.01
 Manual Transmission/Clutch

3.2 Manual Transmission/Clutch

2014 M201
Table of Contents Pages

3.2.1 Manual Transmission/Clutch - Overview

Specifications ................................................................................................................................... 3.2.1-1
Material Specifications.............................................................................................................. 3.2.1-1
Component Specifications ........................................................................................................ 3.2.1-1
General Specifications.............................................................................................................. 3.2.1-1
Torque Specifications................................................................................................................ 3.2.1-1
General Inspection........................................................................................................................... 3.2.1-2
Clutch Driven Disc Inspection................................................................................................... 3.2.1-2
Clutch Pressure Plate Inspection ............................................................................................. 3.2.1-2
Clutch Pedal Assembly and Cable Inspection.......................................................................... 3.2.1-2
Clutch Pedal Free Travel Inspection......................................................................................... 3.2.1-3
Symptom Diagnosis and Testing...................................................................................................... 3.2.1-4
Inspection and Verification........................................................................................................ 3.2.1-4
Symptom Chart......................................................................................................................... 3.2.1-4
Diagnosis Procedure for Clutch Slippage................................................................................. 3.2.1-8
Diagnosis Procedure for Clutch Clickety-clack or Judder....................................................... 3.2.1-12
Diagnosis Procedure for Clutch Drag ..................................................................................... 3.2.1-15
Diagnosis Procedure for Clutch Pedal Pulsation.................................................................... 3.2.1-18
Diagnosis Procedure for Clutch Vibration............................................................................... 3.2.1-21
Diagnosis Procedure for Difficult Gear Shifting ...................................................................... 3.2.1-25
Diagnosis Procedure for Excessive Noise.............................................................................. 3.2.1-28
Diagnosis Procedure for Abnormal Noises in Driving............................................................. 3.2.1-31
3.2.2 Clutch
Specifications ................................................................................................................................... 3.2.2-1
General Specifications.............................................................................................................. 3.2.2-1
Torque Specifications................................................................................................................ 3.2.2-1
Description and Operation ............................................................................................................... 3.2.2-2
System Overview...................................................................................................................... 3.2.2-2
Components Exploded View..................................................................................................... 3.2.2-4
Symptom Diagnosis and Testing...................................................................................................... 3.2.2-5
Removal and Installation.................................................................................................................. 3.2.2-6
Clutch Pressure Plate Assembly, Clutch Driven Disc Assembly .............................................. 3.2.2-6

M201 2014.01
 Manual Transmission/Clutch
Clutch Fork ...............................................................................................................................3.2.2-8
3.2.3 Manual Transmission
Specifications ...................................................................................................................................3.2.3-1
General Specifications ..............................................................................................................3.2.3-1
Torque Specifications................................................................................................................3.2.3-1
Description and Operation................................................................................................................3.2.3-3
System Overview ......................................................................................................................3.2.3-3
Components Location View ......................................................................................................3.2.3-6
Components Exploded View.....................................................................................................3.2.3-8
General Inspection .........................................................................................................................3.2.3-17
Transmission Maintenance Intervals ......................................................................................3.2.3-17
Inspection of Transmission Oil................................................................................................3.2.3-17
Replacement of Transmission Oil ...........................................................................................3.2.3-17
Symptom Diagnosis and Testing ....................................................................................................3.2.3-18
Removal and Installation ................................................................................................................3.2.3-19
Vehicle Speed Sensor.............................................................................................................3.2.3-19
Backup Lamp Switch ..............................................................................................................3.2.3-20
Manual Transmission..............................................................................................................3.2.3-21
Disassembly and Assembly ...........................................................................................................3.2.3-26
Disassembly of Transmission .................................................................................................3.2.3-26
Replacement of Input Shaft Oil Seal.......................................................................................3.2.3-34
Replacement of Extension Case Oil Seal ...............................................................................3.2.3-35
Disassembly of Input Shaft .....................................................................................................3.2.3-40
Disassembly of Output Shaft ..................................................................................................3.2.3-43
Disassembly of Intermediate Shaft .........................................................................................3.2.3-45
Assembly of Intermediate Shaft ..............................................................................................3.2.3-48
Assembly of Output Shaft .......................................................................................................3.2.3-52
Assembly of Input Shaft ..........................................................................................................3.2.3-54
Assembly of Transmission ......................................................................................................3.2.3-58

3.2.4 Manual Transmission External Control

Specifications ...................................................................................................................................3.2.4-1
Torque Specifications................................................................................................................3.2.4-1
Description and Operation................................................................................................................3.2.4-2
System Overview ......................................................................................................................3.2.4-2
Components Exploded View.....................................................................................................3.2.4-2
Symptom Diagnosis and Testing ......................................................................................................3.2.4-3

M201 2014.01
 Manual Transmission/Clutch
Inspection and Verification........................................................................................................ 3.2.4-3
Symptom Chart......................................................................................................................... 3.2.4-4
Diagnosis Procedure for Difficult Operation of Gearshift Mechanism....................................... 3.2.4-4
Removal and Installation.................................................................................................................. 3.2.4-5
Gearshift Mechanism................................................................................................................ 3.2.4-5

M201 2014.01
3.2.1-1 Manual Transmission/Clutch - Overview 3.2.1-1

Specifications
3.2.1 Manual Transmission/Clutch - Overview

Material Specifications
Item Specifications
Transmission oil API (GL-4) SAE 75W-90, Shell Spirax S4 GS

Component Specifications
Item Specifications
Clutch driven disc assembly diameter (outer/
200/130 mm
inner)
Clutch driven disc assembly wear limit 1.7 mm
Clutch pedal free travel standard value 5 ~ 11 mm

General Specifications
Item Specifications
Type Dry clutch with single disc diaphragm spring
Operation type Mechanical

Torque Specifications
Item Nm lb-ft lb-in
Clutch pressure plate retaining bolt 32 ± 2 - -

M201 2014.01
3.2.1-2 Manual Transmission/Clutch - Overview 3.2.1-2

General Inspection Clutch Pressure Plate

Clutch Driven Disc Inspection Inspection
WARNING: Do not clean the clutch driven 1. Clean the clutch pressure plate.
disc with wax-based cleaning agents or 2. Inspect whether the diaphragm spring (1) is
solvents. abnormally worn or damaged.
1. Clean the clutch driven disc. 3. Inspect whether the clutch pressure plate
2. Inspect the clutch driven disc for the assembly (2) is worn or has local hot spot.
following: 4. If any abnormality is found, replace the
• Oil stain assembly as diaphragm and pressure plate
cannot be disassembled.
• Scorch mark
• Thickness
• Spring (if it is damaged, replace the 2
clutch driven disc)
1

M3201003

Clutch Pedal Assembly and

Cable Inspection
M3201001
1. Inspect whether the bushing is worn or
damaged.
3. Measure the rivet head depth (the distance
between rivet head and clutch driven disc 2. Inspect whether the spacer bush is worn or
assembly surface), if any rivet head depth damaged.
exceeds the limit, replace the clutch driven
3. Inspect whether the pedal arm is damaged or
disc assembly.
deformed.
Rivet head depth
4. Inspect whether the torsion spring is
Standard: 1.15 ~ 1.65 mm deformed.
Limit: 0.5 mm 5. Inspect whether the pedal pad is worn or
damaged.
6. Inspect whether the clutch cable is worn,
deformed or damaged.

M3201002

M201 2014.01
3.2.1-3 Manual Transmission/Clutch - Overview 3.2.1-3

Clutch Pedal Free Travel

Inspection
1. Press clutch pedal with hand until resistance
begins to be felt (clutch pedal operation force
should not be more than 140 N) and measure
the distance (clutch pedal free travel).
2. Inspect the pedal travel.

Standard free travel: 5 ~ 11 mm

3. Adjust the clutch cable and clutch pedal when
necessary if free travel is not within the
specified range.
4. After inspection of clutch pedal free travel,
inspect whether clutch works normally while
engine is running. When the clutch pedal is
depressed, the clutch disengages completely
and returns in time after the pedal is released;
Slipping is forbidden after engaging and no
unusual noise during operation.

M201 2014.01
3.2.1-4 Manual Transmission/Clutch - Overview 3.2.1-4

Symptom Diagnosis and Testing

Inspection and Verification
1. Verify the customer concern.
2. Visually check if there is obvious mechanical fault.
3. If an obvious cause has been found, solve the fault before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom by referring to the Symptom Chart.
5. Inspect clutch operation: Place a piece of wood with thickness of 25 mm under clutch pedal, and
then depress the clutch pedal deeply. If the transmission can be shifted into 1st or 2nd gear when the
engine is running and the parking brake is applied, the clutch works normally. Otherwise, repair the
clutch.

Symptom Chart
If the fault occurs, but the causes cannot be verified in basic inspection, diagnose and repair it in order of
the following table.

Symptom Possible Causes Solutions

• Clutch pedal free travel Refer to: Diagnosis Procedure
• Clutch pedal bonding for Clutch Slippage
(3.2.1 Manual
• Diaphragm spring
Transmission/Clutch -
• Clutch pressure plate Overview, Symptom
• Clutch driven disc surface Diagnosis and Testing).
Clutch slippage
• Surface of clutch driven disc too
stiff or oily
• Flywheel
• Improper adjustment of clutch
cable
• Engine bracket Refer to: Diagnosis Procedure
• Oil stain on clutch driven disc for Clutch Clickety-
surface clack or Judder (3.2.1
Manual Transmission/
Clutch clickety-clack or • Diaphragm spring
Clutch - Overview,
shudder • Clutch pressure plate Symptom Diagnosis
• Clutch driven disc surface and Testing).
• Flywheel
• Clutch cable

M201 2014.01
3.2.1-5 Manual Transmission/Clutch - Overview 3.2.1-5

Symptom Possible Causes Solutions

• Clutch pedal free travel Refer to: Diagnosis Procedure
• Diaphragm spring for Clutch Drag (3.2.1
Manual Transmission/
• Clutch driven disc
Clutch - Overview,
• Clutch driven disc spline Symptom Diagnosis
Clutch drag and Testing).
• Oil stain on clutch driven disc
surface
• Clutch pedal
• Improper adjustment of clutch
cable

• Poor lubrication of clutch and Refer to: Diagnosis Procedure

brake pedal pivot for Clutch Pulsation
• Flywheel (3.2.1 Manual
Clutch pedal pulsation
Transmission/Clutch -
• Fatigue pressure plate spring
Overview, Symptom
• Clutch cable Diagnosis and Testing).
• Engine components in contact Refer to: Diagnosis Procedure
with frame for Clutch Vibration
• Drive belt (3.2.1 Manual
Transmission/Clutch -
• Flywheel bolt
Overview, Symptom
Clutch vibration • Flywheel Diagnosis and Testing).
• Clutch pressure plate out of
balance
• Mounting bush is weak, bolt or
nut of the engine is loose

Refer to: Diagnosis Procedure

• Improper adjustment of clutch for Difficult Gear
cable
Shifting (3.2.1 Manual
Difficult gear shifting
• Clutch pedal free travel Transmission/Clutch -
• Manual transmission fault Overview, Symptom
Diagnosis and Testing).
• Clutch pedal free travel Refer to: Diagnosis Procedure
• Clutch release bearing for Excessive Noise
(3.2.1 Manual
• Poor lubrication of clutch
Transmission/Clutch -
release bearing
Excessive noise Overview, Symptom
• Release bearing Diagnosis and Testing).
• Excessive crankshaft thrust
clearance
• Clutch cable

M201 2014.01
3.2.1-6 Manual Transmission/Clutch - Overview 3.2.1-6

Symptom Possible Causes Solutions

• Replace the clutch pressure plate.
Refer to: Clutch Pressure Plate
• Diaphragm spring too flexible Assembly and Clutch
Driven Disc Assembly
(3.2.2 Clutch, Removal
and Installation).
• Remove and reinstall the release fork
• Release fork loose
correctly.
• Exclude the cause of engine oil leak, and
replace the driven disc.

Clutch makes quack noise Refer to: Clutch Pressure Plate

• Oil on driven disc Assembly and Clutch
Driven Disc Assembly
(3.2.2 Clutch, Removal
and Installation).
• Replace the driven disc.
Refer to: Clutch Pressure Plate
• Damping spring of driven disc Assembly and Clutch
damaged Driven Disc Assembly
(3.2.2 Clutch, Removal
and Installation).
• Cable rust • Replace the clutch cable.
• Cable rust • Replace the clutch cable.
• Replace the clutch disc assembly.

Clutch stuck (pedal is Refer to: Clutch Pressure Plate

difficult to push) • Clutch disc is worn too thin Assembly and Clutch
Driven Disc Assembly
(3.2.2 Clutch, Removal
and Installation).

M201 2014.01
3.2.1-7 Manual Transmission/Clutch - Overview 3.2.1-7

Symptom Possible Causes Solutions

• Adjust the gearshift mechanism, replace
when necessary.
Refer to: Gearshift Mechanism
• Gearshift mechanism (3.2.4 Manual
Transmission External
Control, Removal and
Installation).
• Adjust or replace.
Out of gear
Refer to: Disassembly and
• Self-locking mechanism
Assembly of
• Synchronizer assembly Transmission (3.2.3
• Gearshift mechanism Manual Transmission,
Disassembly and
Assembly).
• Repair or replace the transmission or
• Transmission or engine support
engine support.
• Shift gear Refer to: Diagnosis Procedure
• Input shaft bearing for Abnormal Driving
Noise ((3.2.1 Manual
• Output shaft bearing
Transmission/Clutch -
Abnormal driving noise • Clutch Overview, Symptom
• Wheel bearing Diagnosis and Testing).
• Tire
• Universal joint

M201 2014.01
3.2.1-8 Manual Transmission/Clutch - Overview 3.2.1-8

Diagnosis Procedure for Clutch Slippage

Clutch slippage

Inspect clutch slippage

Is the fault Yes

confirmed

No

Inspect clutch pedal free travel

Is the fault Yes

confirmed

No

Inspect clutch pedal

maneuverability

Is the fault Yes

confirmed

No

Inspect whether clutch system is

contaminated by leaking oil Yes
Is the fault
Inspect clutch driven disc
confirmed

No

Inspect flywheel

End

M201 2014.01
3.2.1-9 Manual Transmission/Clutch - Overview 3.2.1-9

Test Conditions Details/Results/Actions

1. Inspect clutch slippage
A. Inspect the wheel and apply the parking brake.
B. Turn the ignition switch to "START".
C. Start engine, shift the transmission to the 4th gear.
D. Run the engine at 2000 rpm.
E. Release the clutch pedal slowly.
Whether the engine stalls when the clutch pedal is
released completely?
Yes
Clutch is normal.
No
Go to step 2.

2. Inspect clutch pedal free travel

A. Press the clutch pedal with hand until resistance
begins to be felt.
B. Inspect the pedal travel.
Is the measured dimension within 5 ~ 11 mm?
Yes
Go to step 3.
No
Adjust the clutch pedal free travel.

3. Inspect clutch pedal maneuverability

A. Inspect the lubrication.
Is the lubrication of clutch pedal pivot good?
Yes
Go to step 4.
No
Lubricate the clutch pedal pivot.

4. Inspect whether clutch system is contaminated by leaking oil

A. Remove the transmission.
Refer to: Manual Transmission (3.2.3
Manual Transmission, Removal
and Installation).
B. Inspect whether the clutch system is contaminated
by oil leak.
Is the clutch system contaminated by oil leak?
Yes
Repair the oil leak.
No
Go to step 5.

M201 2014.01
3.2.1-10 Manual Transmission/Clutch - Overview 3.2.1-10

Test Conditions Details/Results/Actions

5. Inspect clutch driven disc
A. Remove the clutch driven disc.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
B. Inspect whether the driven disc is oily, stiff or
damaged. Inspect the thickness of driven disc.
Refer to: Clutch Driven Disc Inspection
(3.2.1 Manual Transmission/
Clutch - Overview, General
Inspection).
Is it normal?
Yes
Go to step 6.
No
Replace the clutch driven disc.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).

M201 2014.01
3.2.1-11 Manual Transmission/Clutch - Overview 3.2.1-11

Test Conditions Details/Results/Actions

6. Inspect flywheel
A. Remove the clutch driven disc assembly and
pressure plate assembly.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
B. Inspect the junction surface of flywheel for blue,
grooved wear or cracks.
C. Inspect the end face runout of flywheel.
Is it normal?
Yes
Replace the clutch pressure plate with a new one.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
No
Repair or replace the flywheel.
Refer to: Main Bearing, Crankshaft and
Cylinder Block (3.1.2 Mechanical
System, Disassembly and
Assembly).

M201 2014.01
3.2.1-12 Manual Transmission/Clutch - Overview 3.2.1-12

Diagnosis Procedure for Clutch Clickety-clack or Judder

Clutch clickety-clack
or judder

Inspect clickety-clack or shudder

occurs in clutch

Is the fault Yes

confirmed

No

Inspect engine/transmission
mounting bracket bush
assembly

Is the fault Yes

confirmed

No

Inspect clutch pressure plate

Is the fault Yes

confirmed

No

Inspect clutch driven disc

End

M201 2014.01
3.2.1-13 Manual Transmission/Clutch - Overview 3.2.1-13

Test Conditions Details/Results/Actions

1. Inspect clickety-clack or shudder occurs in clutch
A. Turn the ignition switch to "START".
B. Start engine and shift to the 1st gear.
C. Run the engine at 1200 ~ 1500 rpm.
D. Release the clutch pedal slowly.
Does the vehicle shudder at start?
Yes
Go to step 2.
No
Clutch is normal.

2. Inspect engine/transmission mounting bracket bush assembly

A. Inspect the engine/manual transmission mounting
bush and bolt.
Are they loose or damaged?
Yes
Tighten the bolt or replace the damaged mounting
bush when necessary.
No
Go to step 3.

3. Inspect clutch pressure plate

A. Remove the clutch pressure plate.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
Is there any wear on the clutch pressure plate?
Yes
Replace the clutch pressure plate with a new one.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
No
Go to step 4.

M201 2014.01
3.2.1-14 Manual Transmission/Clutch - Overview 3.2.1-14

Test Conditions Details/Results/Actions

4. Inspect clutch driven disc
A. Inspect the clutch driven disc.
Refer to: Clutch Driven Disc Inspection
(3.2.1 Manual Transmission/
Clutch - Overview, General
Inspection).
Does the clutch driven disc have any oil stain or
scorch?
Yes
Replace the clutch driven disc with a new one.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
No
Inspect the flywheel.
Refer to: Main Bearing, Crankshaft and
Cylinder Block (3.1.2 Mechanical
System, Disassembly and
Assembly).

M201 2014.01
3.2.1-15 Manual Transmission/Clutch - Overview 3.2.1-15

Diagnosis Procedure for Clutch Drag

Clutch drag

Inspect clutch pedal free travel

Is the fault Yes

confirmed

No

Inspect backing ring of clutch

pressure plate diaphragm spring

Is the fault Yes

confirmed

No

Inspect splines of clutch driven

disc and transmission input shaft

End

M201 2014.01
3.2.1-16 Manual Transmission/Clutch - Overview 3.2.1-16

Test Conditions Details/Results/Actions

1. Inspect clutch pedal free travel
A. Inspect whether engine/transmission mounting
bush or bolt is damaged or loose.
B. Inspect the pedal travel.
Is the measured dimension within 5 ~ 11 mm?
Yes
Go to step 2.
No
Adjust the clutch cable or repair pedal fault.

2. Inspect backing ring of clutch pressure plate diaphragm spring

A. Remove the clutch pressure plate.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
Is there any wear on clutch pressure plate or
diaphragm spring backing ring?
Yes
Replace the clutch pressure plate with a new one.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
No
Go to step 3.

M201 2014.01
3.2.1-17 Manual Transmission/Clutch - Overview 3.2.1-17

Test Conditions Details/Results/Actions

3. Inspect splines of clutch driven disc and transmission input shaft
A. Remove the transmission.
Refer to: Manual Transmission (3.2.3
Manual Transmission, Removal
and Installation).
B. Inspect the splines of clutch driven disc and
transmission input shaft.
Are the splines of clutch driven disc and
transmission input shaft normal?
Yes
Go to step 4.
No
Repair or replace the clutch driven disc or
transmission input shaft.
Refer to: Manual Transmission (3.2.3
Manual Transmission, Removal
and Installation).

Refer to: Disassembly and Assembly of

Transmission (3.2.3 Manual
Transmission, Disassembly and
Assembly).

M201 2014.01
3.2.1-18 Manual Transmission/Clutch - Overview 3.2.1-18

Diagnosis Procedure for Clutch Pedal Pulsation

Clutch pedal pulsation

Inspect clutch pedal

Is the fault Yes

confirmed

No

Inspect clutch pressure plate

Is the fault Yes

confirmed

No

Inspect flywheel

Is the fault Yes

confirmed

No

Inspect clutch driven disc

End

M201 2014.01
3.2.1-19 Manual Transmission/Clutch - Overview 3.2.1-19

Test Conditions Details/Results/Actions

1. Inspect clutch pedal
A. Inspect the lubrication of clutch pedal mechanism.
Is the lubrication of clutch pedal pivot good?
Yes
Go to step 2.
No
Lubricate the clutch pedal pivot.

2. Inspect clutch pressure plate

A. Remove the clutch pressure plate.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
B. Inspect the end face runout of clutch pressure
plate.
C. Inspect the wear depth of clutch pressure plate
release lever.
Is it normal?
Yes
Go to step 3.
No
Replace the clutch pressure plate.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).

M201 2014.01
3.2.1-20 Manual Transmission/Clutch - Overview 3.2.1-20

Test Conditions Details/Results/Actions

3. Inspect flywheel
A. Remove the clutch driven disc assembly and
pressure plate assembly.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
B. Inspect the end face runout of flywheel.
C. Inspect the junction surface of flywheel for blue,
grooved wear or cracks.
Is the flywheel normal?
Yes
Go to step 4.
No
Replace the flywheel.
Refer to: Main Bearing, Crankshaft and
Cylinder Block (3.1.2 Mechanical
System, Disassembly and
Assembly).
4. Inspect clutch driven disc
A. Remove the clutch driven disc.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
B. Inspect whether the clutch driven disc is stiff or
distorted and its thickness reaches the limit.
C. Inspect the end face runout of clutch driven disc.
Is the clutch driven disc normal?
Yes
Replace the clutch release bearing.
No
Replace the clutch driven disc.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).

M201 2014.01
3.2.1-21 Manual Transmission/Clutch - Overview 3.2.1-21

Diagnosis Procedure for Clutch Vibration

Clutch vibration

Inspect interference between

engine components and vehicle
body

Is the fault Yes

confirmed

No

Inspect accessory drive belt

vibration

Is the fault Yes

confirmed

No

Inspect release bearing noise

Is the fault Yes

confirmed

No

Inspect clutch pressure plate

Inspect clutch driven disc

Is the fault Yes

confirmed

No

Inspect flywheel

End

M201 2014.01
3.2.1-22 Manual Transmission/Clutch - Overview 3.2.1-22

Test Conditions Details/Results/Actions

1. Inspect interference between engine components and vehicle body
A. Lift the vehicle.
Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).
B. Inspect whether there is interference between link
mechanism installed on the engine and vehicle
body or frame.
C. Inspect the interference between exhaust manifold
or other engine components and vehicle body or
frame.
D. Inspect if the mounting bush is weak, or the bolt or
nut of engine is loose.
Is it connected with vehicle body or frame normally?
Yes
Repair and replace when necessary.
No
Go to step 2.

2. Inspect accessory drive belt vibration

A. If the engine torque is changed, inspect the
accessory vibration when the clutch is disengaged
or engaged.
B. Loosen accessory drive belt to inspect the vibration.
Does the vibration stop when the accessory drive
belt is removed?
Yes
Repair or replace the accessory drive belt.
Refer to: Accessory Drive Belt (3.1.2
Mechanical System, Removal
and Installation).
No
Go to step 3.

3. Inspect release bearing noise

A. Turn the ignition switch to "START".
B. Depress and hold the clutch pedal.
Is there any harsh grating?
Yes
Replace the release bearing.
No
Go to step 4.

M201 2014.01
3.2.1-23 Manual Transmission/Clutch - Overview 3.2.1-23

Test Conditions Details/Results/Actions

4. Inspect clutch pressure plate
A. Remove the clutch pressure plate.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
B. Inspect the end face runout of clutch pressure
plate.
C. Inspect the wear depth of clutch pressure plate
release lever.
Is the clutch pressure plate normal?
Yes
Go to step 5.
No
Replace the clutch pressure plate with a new one.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
5. Inspect clutch driven disc
A. Remove the clutch driven disc.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
B. Inspect whether the clutch driven disc is stiff or
distorted and its thickness reaches the limit.
C. Inspect the end face runout of clutch driven disc.
Is the clutch driven disc normal?
Yes
Go to step 6.
No
Replace the clutch driven disc.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).

M201 2014.01
3.2.1-24 Manual Transmission/Clutch - Overview 3.2.1-24

Test Conditions Details/Results/Actions

6. Inspect flywheel
A. Remove the clutch driven disc assembly and
pressure plate assembly.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
B. Inspect whether the flywheel bolts are loose.
C. Inspect the flywheel roundness.
D. Inspect the end face runout of flywheel.
Is the flywheel normal?
Yes
Diagnose the fault of engine vibration.
No
Tighten or replace the flywheel.
Refer to: Main Bearing, Crankshaft and
Cylinder Block (3.1.2 Mechanical
System, Disassembly and
Assembly).

M201 2014.01
3.2.1-25 Manual Transmission/Clutch - Overview 3.2.1-25

Diagnosis Procedure for Difficult Gear Shifting

Difficult gear shifting

Inspect clutch system

Is the fault Yes

confirmed

No

Inspect gearshift mechanism

Is the fault Yes

confirmed

No

Inspect gear shift fork inside

transmission, fork shaft and
synchronizer assembly, self-
locking mechanism

End

M201 2014.01
3.2.1-26 Manual Transmission/Clutch - Overview 3.2.1-26

Test Conditions Details/Results/Actions

1. Inspect clutch system
A. Inspect whether the clutch system is completely
disengaged and engaged reliably.
Refer to: Diagnosis Procedure for Clutch
Drag (3.2.1 Manual
Transmission/Clutch - Overview,
Symptom Diagnosis and
Testing).
Is the clutch system normal?
Yes
Go to step 2.
No
Repair the clutch system.

2. Inspect gearshift mechanism

A. Inspect the gearshift mechanism.
Is the gearshift mechanism normal?
Yes
Go to step 3.
No
Adjust or replace the gearshift mechanism.
Refer to: Gearshift Mechanism (3.2.4
Manual Transmission External
Control, Removal and
Installation).

M201 2014.01
3.2.1-27 Manual Transmission/Clutch - Overview 3.2.1-27

3. Inspect gear shift fork inside transmission, fork shaft and synchronizer assembly, self-locking
mechanism
A. Remove the transmission.
Refer to: Manual Transmission (3.2.3
Manual Transmission, Removal
and Installation).
B. Disassemble the transmission.
Refer to: Disassembly and Assembly of
Transmission (3.2.3 Manual
Transmission, Disassembly and
Assembly).
C. Inspect whether the gear shift fork and fork shaft
are normal.
D. Inspect whether the synchronizer assembly is
normal.
E. Inspect the self-locking mechanism, gear shift fork
inside transmission, fork shaft and synchronizer.
Are they normal?
Yes
Replace the engine or transmission support.
No
Repair the transmission interior fault.

M201 2014.01
3.2.1-28 Manual Transmission/Clutch - Overview 3.2.1-28

Diagnosis Procedure for Excessive Noise

Excessive noise

General inspection
(Inspect engine, transmission and
transmission supports)

Is the fault
Yes
confirmed

No

Inspect noise in the early stage

of clutch disengagement

Is the fault Yes

confirmed

No

Inspect noise when the clutch is

completely disengaged

Is the fault Yes

confirmed

No
Inspect noise when the clutch is
engaged

Is the fault Yes

confirmed

No

Inspect noises at neutral and

other positions

End

M201 2014.01
3.2.1-29 Manual Transmission/Clutch - Overview 3.2.1-29

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect whether there is any crack, looseness and
damage on the engine and transmission supports.
B. Inspect whether the transmission interferes with
exhaust pipe and vehicle body, and the
transmission support has foreign material, such as
stones.
Is it normal?
Yes
Go to step 2.
No
Repair the fault part.

2. Inspect noise in the early stage of clutch disengagement

A. Start the engine.
B. Depress the clutch pedal lightly, but not to the
bottom.
Is there any noise?
Yes
Replace the clutch release bearing.
No
Go to step 3.

3. Inspect noise when the clutch is completely disengaged

A. Start the engine.
B. Depress the clutch pedal to the bottom.
C. Operate the accelerator pedal to change the engine
speed.
Is there any noise as the engine speed changes?
Yes
Replace the release bearing.
No
Go to step 4.

M201 2014.01
3.2.1-30 Manual Transmission/Clutch - Overview 3.2.1-30

Test Conditions Details/Results/Actions

4. Inspect noise when the clutch is engaged
A. Remove the clutch driven disc.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
B. Inspect the torsion spring wear.
Is there any wear?
Yes
Install the clutch driven disc with a new one.
Refer to: Clutch Pressure Plate Assembly
and Clutch Driven Disc
Assembly (3.2.2 Clutch,
Removal and Installation).
No
Go to step 5.

5. Inspect noises at neutral and other positions

WARNING: To avoid personal injury A. Turn the ignition switch to "START".
caused by out of control, road test should B. Start the engine at neutral gear.
be conducted by two persons together in C. Inspect noises at neutral or other positions.
order to maintain safe driving. Be sure to Is there any noise from the transmission?
control steering wheel properly. Failure to
Yes
follow these instructions may result in
Inspect and repair the transmission.
personal injury.
Refer to: Manual Transmission (3.2.3
Manual Transmission, Removal
and Installation).

Refer to: Disassembly and Assembly of

Transmission (3.2.3 Manual
Transmission, Disassembly and
Assembly).
No
Inspect the engine system noise.
Refer to: Abnormal Interior Noises under
Engine (3.1.2 Mechanical
System, Symptom Diagnosis
and Testing).

M201 2014.01
3.2.1-31 Manual Transmission/Clutch - Overview 3.2.1-31

Diagnosis Procedure for Abnormal Noises in Driving

Abnormal noises in
driving

General inspection
(Inspect tire, suspension and
universal joint)

Is the fault Yes

confirmed

No

Inspect wind noise

Is the fault Yes

confirmed

No

Inspect clutch system

Is the fault Yes

confirmed

No

Inspect transmission

End

M201 2014.01
3.2.1-32 Manual Transmission/Clutch - Overview 3.2.1-32

Test Conditions Details/Results/Actions

1. General inspection
A. Lift the vehicle.
Refer to: Lifting (1.1.3 Traction and
Lifting, Description and
Operation)
B. Inspect the wheel tire pressure, tire tread wear and
tire type.
C. Inspect the suspension retaining bolt, connecting
rubber bushing and ball joint.
D. Inspect whether the universal joint is loose.
Are they normal?
Yes
Go to step 2.
No
Repair or replace the fault component.

2. Inspect wind noise

WARNING: To avoid personal injury A. Carry out road test.
caused by out of control, road test should B. Inspect for the wind noise as the speed changes.
be conducted by two persons together in Is there wind noise as the speed changes?
order to maintain safe driving. Be sure to Yes
control steering wheel properly. Failure to
Repair the wind noise fault.
follow these instructions may result in
personal injury. No
Go to step 3.

3. Inspect clutch system

A. Start engine and keep it at the neutral position.
B. Operate the clutch. Inspect whether there is
abnormal noise during clutch engagement or
disengagement.
Is the clutch normal?
Yes
Go to step 4.
No
Before road test, repair and replace with new
components when necessary.

M201 2014.01
3.2.1-33 Manual Transmission/Clutch - Overview 3.2.1-33

Test Conditions Details/Results/Actions

4. Inspect transmission
WARNING: To avoid personal injury A. Carry out road test.
caused by out of control, road test should B. Inspect whether there is any gear impact noise
be conducted by two persons together in when shifting.
order to maintain safe driving. Be sure to C. Inspect whether there is any abnormal noise at
control steering wheel properly. Failure to each position.
follow these instructions may result in Is the transmission normal?
personal injury. Yes
Refer to: Diagnosis Procedures for Noise
(1.1.5 Noise, Vibration and
Harshness, Symptom Diagnosis
and Testing).
No
Repair the transmission.
Refer to: Manual Transmission (3.2.3
Manual Transmission, Removal
and Installation).

M201 2014.01
3.2.2-1 Clutch 3.2.2-1

Specifications
3.2.2 Clutch

General Specifications
Item Specifications
Clutch type Dry clutch with single disc diaphragm spring
Operation type Mechanical

Torque Specifications
Item Nm lb-ft lb-in
Clutch pressure plate retaining bolt 32 ± 2 - -

M201 2014.01
3.2.2-2 Clutch 3.2.2-2

Description and Operation

System Overview
Clutch includes one clutch driven disc assembly and one clutch pressure plate assembly fixed on the
flywheel. In the normal operating condition, through connecting with the flywheel ring gear assembly the
clutch driven disc assembly under the pressure of clutch pressure disc assembly transfers engine power
to the transmission assembly. When the clutch pedal is depressed completely, clutch pressure plate
assembly is disengaged from the clutch driven disc assembly. At this time clutch driven disc cannot
transfer engine power to the transmission assembly; when the pedal is completely released, clutch
pressure plate assembly compresses driven disc assembly, which transfers engine power to the
transmission assembly.
Function of clutch mainly involves: connecting engine with drive device gradually to ensure the smooth
start; disconnecting engine with drive device temporarily, to reduce shocks to transmission gear with
gear shifting and ensure the smooth operation of drive device and vehicle; absorbing energy by slippage
of clutch while applying emergency brakes, preventing drive device components from overloading and
damaging.

1 4
3

M3202004

M201 2014.01
3.2.2-3 Clutch 3.2.2-3

Item Description Item Description

1 Flywheel ring gear assembly 4 Clutch pressure plate assembly
2 Flywheel bolt 5 Pressure plate dowel pin
Clutch pressure plate retaining
3 Clutch driven disc assembly 6
bolt

M201 2014.01
3.2.2-4 Clutch 3.2.2-4

Components Exploded View

1 2 3 4 5 6 7 8

12 11 10 9

M3202005

Item Description Item Description

1 Clutch driven disc assembly 7 Clutch release bearing
2 Clutch pressure plate assembly 8 Transmission assembly
Clutch pressure plate retaining Clutch release fork return
3 9
bolt spring bracket
4 Clutch release bearing 10 Clutch release fork bracket bolt
Clutch release fork return
5 Clutch release fork 11
spring
6 Clutch release fork clip 12 Release bearing clip

M201 2014.01
3.2.2-5 Clutch 3.2.2-5

Symptom Diagnosis and Testing

Refer to: Symptom Chart (3.2.1 Manual
Transmission/Clutch - Overview,
Symptom Diagnosis and Testing).

M201 2014.01
3.2.2-6 Clutch 3.2.2-6

Removal and Installation

Clutch Pressure Plate Assembly, Clutch Driven Disc Assembly
Special Tool

Flywheel holding tool 09924-17810

Driven disc mounting
09923-36330
shaft

Removal
1. Remove the manual transmission.
Refer to: Manual Transmission (3.2.3
Manual Transmission, Removal
and Installation).
2. Remove the clutch pressure plate and clutch
driven disc assembly.
1 Use the special tool to hold the flywheel
assembly. 09924-17810

Special tool: 09924-17810

M3202006

2 Remove the clutch pressure plate retaining

bolts, then remove the clutch pressure plate
assembly and clutch driven disc assembly in
turn.

×6

M3202007

M201 2014.01
3.2.2-7 Clutch 3.2.2-7
Installation
CAUTION: When tightening the clutch
pressure plate retaining bolts, firmly press
the clutch driven disc with the special tool
to make sure that clutch driven disc
assembly is aligned with the center.

CAUTION: Diagonally tighten the clutch

pressure plate retaining bolts in order.

1. Inspect the joint surface of the flywheel and

driven disc.
2. Install the clutch pressure plate and driven
disc assembly.
1 Use the special tool to align the clutch
driven disc with the center of flywheel, install 09924-17810
the clutch pressure plate assembly and bolts,
and then tighten them to the specified torque.
Torque: 32 ± 2 Nm
Special tool: Driven disc mounting shaft 09923-36330
09923-36330
M3202008
Special tool: Flywheel holding tool 09924-
17810
CAUTION: When tightening the clutch
pressure plate retaining bolts, firmly press
the clutch driven disc with the special tool
09923-36330 to make sure that clutch
driven disc assembly is aligned with the
center.

CAUTION: Diagonally tighten the clutch

pressure plate retaining bolts in order.

3. Apply a small amount of grease to the input

shaft, and then connect the manual
transmission and engine.
"A": 99000-25210
CAUTION: While inserting the
transmission input shaft to the clutch A
driven disc, rotate the crankshaft with the
wrench from the front side until the
splines are engaged.
M3202016

M201 2014.01
3.2.2-8 Clutch 3.2.2-8

Clutch Fork
Removal
1. Remove the manual transmission.
Refer to: Manual Transmission (3.2.3
Manual Transmission, Removal
and Installation).
2. Remove the clutch fork return spring (3) and
fork (1) clip. 3 2
3. Remove the fork and release bearing (2)
1
together.

M3202009

4. Remove the clutch release bearing and clutch

fork clip.

Inspection
1. Inspect if the clutch release bearing rotates
smoothly, replace if any fault is found.
CAUTION: Do not clean release bearing to
flush out grease, which will damage the
bearing.

2. Inspect the clutch release fork and clip for

damage and deformation, as well as the
release fork return spring. Replace if any fault
is found.
M3202010

M201 2014.01
3.2.2-9 Clutch 3.2.2-9
Installation

1. Installation is in the reverse order of removal.

CAUTION: Apply the grease as shown in
the figure.

"A" : 99000-25010
"B" : 99000-25210
CAUTION: Install the release bearing,
A
return spring and clip to their original
position.

M3202011

M201 2014.01
3.2.3-1 Manual Transmission 3.2.3-1

Specifications
3.2.3 Manual Transmission

General Specifications
Item Specifications
Transmission type MR513C01
Operation type Single-disc, dry type
Transmission oil type API (GL-4) SAE 75W-90, Shell Spirax S4 GS
Transmission oil capacity 1.5 ~ 1.6 L
1st gear speed ratio 3.358
2nd gear speed ratio 1.858
3rd gear speed ratio 1.315
4th gear speed ratio 1
5th gear speed ratio 0.801
Reverse gear speed ratio 4.452
Maximum input torque 125 Nm

Torque Specifications
Item Nm lb-ft lb-in
Gearcase retaining bolt 23 ± 5 - -
Transmission gearshift mechanism
23 ± 5 - -
retaining bolt
Lock steel ball assembly 23 ± 5 - -
Gear shift and select cable bracket 23 ± 5 - -
Speedometer retaining bolt 23 ± 5 - -
Drain plug 5 ~ 10 - -
Inlet plug 5 ~ 10 - -
Self-locking bolt 13 ± 3 - -
Reverse gear shift fork assembly bolt 23 ± 5 - -
Interlock gasket retaining bolt 23 ± 5 - -
Reverse gear shaft bolt 23 ± 5 - -
Retaining bolt between front and rear
23 ± 5 - -
cases
Backup lamp switch assembly 15 ~ 22 11 ~ 16 -
Reverse gear bolt 23 ± 5 - -
Worm set retaining bolt 10 ± 2 - -
Vehicle speed sensor 10 - 89
No.1 wiring harness clamp bracket
10 ± 1 - -
retaining bolt
Transmission grounding wiring harness
10 ± 1 - -
retaining bolt

M201 2014.01
3.2.3-2 Manual Transmission 3.2.3-2

Item Nm lb-ft lb-in

Transmission dustproof board retaining
10 ± 1 - -
bolt
Connecting bolt and nut between
50 ± 5 - -
transmission and engine
Transmission rear mounting bolt 70 ± 5 - -

M201 2014.01
3.2.3-3 Manual Transmission 3.2.3-3

Description and Operation

System Overview
Transmission MR513C01 is a minicar mechanical transmission. It is a full-synchronization manual
mechanical transmission with five forward gears and one reverse gear. All the forward gears are
constant mesh type and reverse gear is sliding idler gear unit. It has the advantages of easy gearshift
without impact noise. The maximum input torque is 125 Nm. The important features, such as
transmission efficiency, synchronizer life, fatigue life, noise and cleanliness, are technically advanced as
anything in china's market. The transmission housing using front case, rear case and extension case,
are characterized by good rigidity structure, easy machining, convenient disassembly/assembly,
compact and rational construction. It uses inertia synchronizer, ensuring reliable shifting.
MR513C01 transmission has the following advantages:
1. As changing the gear ratio, it expands the engine drive torque and speed change range to suit the
power demand under various conditions and driving requirement, and to run the engine in good
working state;
2. Under the condition that the crankshaft rotation direction remains unchanged, the vehicle realizes
reverse driving requirements;
3. Engine power transfer can be cut off to meet the needs of short-run and coast, and to facilitate the
transmission shifting or power output.
Transmission MR513C01 is divided into 7 sets according to the function and position: front case, rear
case, extension case, input shaft set, intermediate shaft set, output shaft set and gear shift and select
set. It has three shafts inside. The input shaft and intermediate shaft are parallel to each other. Output
shaft and input shaft are in a straight line. Power inputs from the input shaft, then goes through the
intermediate shaft and outputs from the output shaft. Transmission MR513C01 moves the gear shaft
through the gear shift and select set, to realize the position-shift and the axial movement of shift lever
realizes the gear shift. The inertia synchronizer assures the flexible gear shifting.

M201 2014.01
3.2.3-4 Manual Transmission 3.2.3-4
Transmission MR513C01 uses different pairs of gears to realize variable speed, torque, and rotation
direction change. The specific transferring route is shown in the figure below:

4th
2 1st R 2nd 5st 3rd 4

M3203001

Item Description Item Description

1 Reverse gear shaft 3 Intermediate shaft
2 5th gear synchronizer 4 Output shaft

M201 2014.01
3.2.3-5 Manual Transmission 3.2.3-5
Appropriate Speed of Each Forward Gear:

Gear 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear
km/h 0 ~ 15 20 ~ 30 35 ~ 45 50 ~ 60 65 ~ 75

CAUTION: Gear shifting should be within speed ranges.

CAUTION: The speed at different gears varies with different vehicle with the transmission.

Gearshift Principle
As the vehicle is moving forward, you should shift as following: the shift up should be from 1st gear to 5th
gear gradually, while shift down from 5th gear to 1st gear. It is forbidden to shift into the reverse gear
when moving forward. The transmission is equipped with reverse lock to avoid shifting from 5th gear to
reverse gear by misoperation. In principle, the reverse gear should be shifted when the vehicle is
stationary and depressing the clutch pedal more than 3 seconds; Do not shift into the reverse gear when
the vehicle is moving forward and do not shift into the forward gear when the vehicle is reversing.
CAUTION: The gearshift principle of transmission can be ignored in emergency when driving.

M201 2014.01
3.2.3-6 Manual Transmission 3.2.3-6

Components Location View

Transmission Structure Chart

22 21 20 19 18 17 16 15 14 13 12

1 2 3 4 5 6 7 8 9 10 11

M3203002

M201 2014.01
3.2.3-7 Manual Transmission 3.2.3-7

Item Description Item Description

1 Input shaft 1st gear 12 Extension case
2 Reverse idler gear shaft 13 Intermediate shaft 4th gear
3 Reverse idler gear 14 2nd gear
4 Input shaft reverse gear 15 1st gear
5 Input shaft 2nd gear 16 Intermediate shaft
6 Input shaft 5th gear 17 Intermediate shaft 5th gear
7 5th gear synchronizer 18 Intermediate shaft 2nd gear
8 Input shaft 3rd gear 19 Low-speed synchronizer
9 High-speed synchronizer 20 Intermediate shaft 1st gear
10 Output shaft driven gear 21 Front case
11 Output shaft 22 Input shaft

M201 2014.01
3.2.3-8 Manual Transmission 3.2.3-8

Components Exploded View

1. Transmission Reverse Gear Shaft Set

2
3

M3203003

Item Description Qty. Item Description Qty.

1 Reverse idler gear assembly 1 3 Reverse gear shaft 1
2 Reverse gear shaft washer 1

M201 2014.01
3.2.3-9 Manual Transmission 3.2.3-9
2. Input Shaft Set

14 15
13

10 11 12

8 9
6

4 5 7
3
2

M3203004

Item Description Qty. Item Description Qty.

High-speed synchronizer 5th gear synchronizer gear
1 1 9 1
circlip ring
Input shaft 5th gear
2 High-speed synchronizer set 1 10 1
assembly
High-speed synchronizer Input shaft 5th gear needle
3 1 11 1
gear ring roller bearing
Input shaft 3rd gear
4 1 12 Input shaft 1
assembly
3rd gear needle roller
5 1 13 Input shaft front case circlip 1
bearing
6 Reverse gear ring 1 14 Input shaft bearing 1
7 5th gear synchronizer circlip 1 15 Input shaft bearing circlip 1
8 5th gear synchronizer set 1

M201 2014.01
3.2.3-10 Manual Transmission 3.2.3-10
3. Intermediate Shaft Set

12
1 2 3 4 5 6 7 8 9 10 11 13 14

M3203005

Item Description Qty. Item Description Qty.

Intermediate shaft front
1 1 8 Low-speed synchronizer set 1
bearing circlip
Intermediate shaft front 2nd gear synchronizer gear
2 1 9 1
bearing ring
Intermediate shaft front Intermediate shaft 2nd gear
3 1 10 1
bearing washer assembly
2nd gear needle roller
4 Intermediate shaft 1st gear 1 11 1
bearing
1st gear needle roller
5 1 12 Intermediate shaft 1
bearing
1st gear synchronizer gear
6 1 13 Steel ball (φ3) 1
ring
Low-speed synchronizer Intermediate shaft rear
7 1 14 1
circlip bearing

M201 2014.01
3.2.3-11 Manual Transmission 3.2.3-11
4. Transmission Output Shaft Set

10

1 2 3 4 5 7 8 9 11 12
6

M3203006

Item Description Qty. Item Description Qty.

Input shaft needle roller
1 1 7 Output shaft driven gear 1
bearing K182516
High-speed synchronizer
2 1 8 Output shaft rear bearing 1
wave spring
High-speed synchronizer Output shaft rear bearing
3 1 9 1
gear ring circlip
4 Output shaft 1 10 Worm steel ball 1
Output shaft front bearing
5 1 11 Worm 1
assembly
Output shaft front bearing
6 1 12 Worm circlip 1
circlip

M201 2014.01
3.2.3-12 Manual Transmission 3.2.3-12
5. Transmission Gearshift Mechanism

1
21
2
20
3 19
18
4 17
16
5 15

6 14

13
8

9
12

10 11

M3203007

Item Description Qty. Item Description Qty.

Reverse gear shift fork
1 1st-2nd gear shift fork pin 1 12 2
assembly bolt M8x30-6g
5th and reverse gear shift
2 1st-2nd gear shift fork 1 13 1
fork shaft
3 1st-2nd gear fork shaft 1 14 5th gear shift fork pin 1
4 1st-2nd gear fork shaft 1 15 5th gear shift fork 1
5th and reverse gear shift
5 1st-2nd gear shift lever 1 16 1
fork pin
5th and reverse gear shift
6 3rd-4th gear fork shaft 1 17 1
fork
7 1st-2nd gear shift lever pin 1 18 3rd-4th gear shift fork pin 1
8 Reverse gear select arm 1 19 3rd-4th gear shift fork 1
9 Reverse gear select arm pin 1 20 1st-2nd gear shift fork pin 1
Reverse gear select arm
10 1 21 1st-2nd gear shift fork 1
assembly
Reverse gear shift fork
11 2
assembly dowel pin 11x12

M201 2014.01
3.2.3-13 Manual Transmission 3.2.3-13
6. Transmission Gearcase Set

20
24
21 23
1
17
22
19
18 16
10 2
15 11
9
14

12

13 3
5
8 7
6 4

M3203008

Item Description Qty. Item Description Qty.

1 Lock steel ball assembly 1 13 Reverse gear lock pin 1
2 Gearcase retaining bolt 4 14 Select arm inner pin 1
3 Gearcase assembly 1 15 Select arm outer pin 1
4 Gearcase dowel pin 2 16 Interlock gasket 1
5 Reverse lock cam 1 17 Gear shift shaft 1
6 Reverse lock bolt 1 18 Gearcase oil seal 1
Reverse lock cam pin
7 1 19 Gear shift shaft boot 1
GB/T119.2 5x20
5th and reverse gear
8 1 20 Shift rocker assembly 1
interlock torsion spring
9 Gear shift shaft E circlip 2 21 Shift rocker inner pin 1
10 Gear shift shaft washer 2 22 Shift rocker outer pin 1
11 Return spring 2 23 Spacer 1
12 Gear select arm 1 24 Gear select set 1

M201 2014.01
3.2.3-14 Manual Transmission 3.2.3-14
7. Transmission Clutch Fork Set

4
5

M3203009

Item Description Qty. Item Description Qty.

1 Clutch release support 1 6 Clutch fork return spring 1
Clutch fork return spring
2 Clutch fork clip 1 7 1
bracket
Clutch fork bracket bolt
3 Clutch release bearing 1 8 1
M6X12
4 Release bearing clip 1 9 Clutch fork dust boot 1
5 Clutch fork 1

M201 2014.01
3.2.3-15 Manual Transmission 3.2.3-15
8. Transmission Extension Case and External Components

9
3

7
5 6 8

M3203010

Item Description Qty. Item Description Qty.

1 Inlet plug 1 6 Worm set 1
2 Extension case retaining bolt 8 7 External case dowel pin 2
3 Hook 1 8 Drain plug 1
4 Extension case assembly 1 9 Extension case oil seal 1
5 Worm bushing bolt 1

M201 2014.01
3.2.3-16 Manual Transmission 3.2.3-16
9. Transmission Front, Rear Case and External Components

13
2
12
3

11

10
5

M3203011

Item Description Qty. Item Description Qty.

No.2 wiring harness clamp
1 Rear case retaining bolt 9 8 1
bracket
2 Rear case 1 9 Stud bolt 2
3 Gear select self-locking bolt 4 10 Front case 1
Gear shift and select cable
4 2 11 Reverse gear shaft bolt 1
bracket bolt
Reverse gear shaft bolt
5 Vent plug 1 12 1
washer
No.1 wiring harness clamp No.4 wiring harness clamp
6 1 13 1
bracket bracket
Wiring harness clamp
7 2
bracket bolt

M201 2014.01
3.2.3-17 Manual Transmission 3.2.3-17

General Inspection 4. Inspect oil level. You can inspect oil level
roughly through inlet plug hole. If the oil is
Transmission Maintenance flush with or below the bottom of the inlet plug
Intervals hole, the oil level is normal. If not, add the
specified oil.
Regular maintenance interval is given in the
following table: Replacement of Transmission
First Oil Oil
Later Service Oil
Service Brand 1. Stop engine and lift vehicle horizontally
(km) Grade
(km) No. before replacing transmission oil.
Every 15000
Shell Refer to: Lifting (1.1.3 Traction and Lifting,
(inspect and 75W/90
7500 Brand Description and Operation).
replace as GL-4
SPIRAX
necessary) 2. Inspect oil level and leaking when lifting the
vehicle. Repair if necessary.
CAUTION: Transmission oil volume is
1.5 ~ 1.6 L. 3. Remove oil drain plug and drain waste oil.

CAUTION: For the first maintenance,

change the transmission oil for the first
time at 7500 km; and perform regular
maintenance in the future. The
maintenance should be performed in a
special maintenance station.

CAUTION: If the vehicle is lifting for other

repair work except changing the oil, the
transmission oil also should be checked
at the same time.
M3203013
Inspection of Transmission Oil
4. Apply the sealant to the oil drain plug and
1. Confirm that the vehicle is horizontal so as to tighten it to the specified torque.
inspect oil level.
Sealant: YT5699 (Yutai)
2. Inspect whether the transmission oil is
leaking. Repair if necessary. For the repair Torque: 5 ~ 10 Nm
method, refer to the Removal and Installation
5. Remove the inlet plug.
of Transmission to repair the leakage area.
6. Add the specified transmission oil until it
3. Remove the inlet plug.
comes out or reaches the visible level.
Torque: 5 ~ 10 Nm
7. Apply the sealant to the inlet plug and tighten
it to the specified torque.
CAUTION: If leakage of input shaft oil seal
is found when maintaining, replace the oil
seal.

CAUTION: If leakage of extension case oil

seal is found when maintaining, replace
the oil seal.

M3203012

M201 2014.01
3.2.3-18 Manual Transmission 3.2.3-18

Symptom Diagnosis and Testing

Refer to: Symptom Chart (3.2.1 Manual
Transmission/Clutch - Overview,
Symptom Diagnosis and
Testing).

M201 2014.01
3.2.3-19 Manual Transmission 3.2.3-19

Removal and Installation

Vehicle Speed Sensor
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Lift the vehicle.
Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).
3. Disconnect the vehicle speed sensor wiring
harness connector.

M3203128

4. Use a proper tool to remove the vehicle

speed sensor.
Torque: 10 Nm

M3203129

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.2.3-20 Manual Transmission 3.2.3-20

Backup Lamp Switch

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Lift the vehicle.

Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).
3. Disconnect the backup lamp switch wiring
harness connector.

M3203130

4. Use a proper tool to remove the backup lamp

switch.
Torque: 15 ~ 22 Nm

M3203131

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
3.2.3-21 Manual Transmission 3.2.3-21

Manual Transmission
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Lift the vehicle.

Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).

3. Drain the transmission oil.

Refer to: Replacement of Manual
Transmission Oil (3.2.3 Manual
Transmission, General
Inspection).
4. Disconnect the vehicle speed sensor wiring
harness connector.

M3203128

5. Disconnect the backup lamp switch wiring

harness connector.

M3203130

M201 2014.01
3.2.3-22 Manual Transmission 3.2.3-22

6. Detach the engine wiring harness from No.2

wiring harness clamp bracket.

M3203132

7. Remove the No.1 wiring harness clamp

bracket retaining bolt from the transmission.
Torque: 10 ± 1 Nm

M3203133

8. Remove the transmission grounding wiring

harness retaining bolt.
Torque: 8 ± 1 Nm

M3203134

9. Loosen the clutch cable retaining nut.

M3203135

M201 2014.01
3.2.3-23 Manual Transmission 3.2.3-23

10. Disconnect the clutch cable from the clutch

fork.

M3203136

11. Disconnect the transmission gear shift cable

(2) and gear select cable (1) from the
transmission. 1
Refer to: Gearshift Mechanism (3.2.4
Manual Transmission External
Control, Removal and
Installation).

M3203137

12. Remove the starting motor.

Refer to: Starting Motor (3.1.9 Starting
System, Removal and
Installation).

13. Remove the propeller shaft.

Refer to: Propeller Shaft (2.2.2 Propeller
Shaft, Removal and Installation).

14. Remove 2 transmission dustproof board

retaining bolts.
Torque: 10 ± 1 Nm

M3203138

M201 2014.01
3.2.3-24 Manual Transmission 3.2.3-24

15. Use the flat jack to support the transmission.

M3203139

16. Remove the connecting nut between engine

and transmission.
Torque: 50 ± 5 Nm

M3203140

17. Remove the connecting nut between engine

and transmission.
Torque: 50 ± 5 Nm

M3203141

18. Remove 4 connecting bolts between

transmission and engine from the side where
the starting motor is installed.
Torque: 50 ± 5 Nm

×4

M3203142

M201 2014.01
3.2.3-25 Manual Transmission 3.2.3-25

19. Remove 2 connecting bolts between

transmission and engine.
Torque: 50 ± 5 Nm

×2

M3203143

20. Remove the rear mounting.

1 Remove the connecting bolt and nut
between rear mounting bush and body.
Torque: 70 ± 5 Nm

M3203144

2 Remove 2 connecting bolts and 2

connecting nuts between rear mounting bush
and transmission.
Torque: 70 ± 5 Nm
×2 ×2

M3203145

21. Separate the transmission from the engine,

lower the flat jack slowly and remove the
transmission.

Installation
1. Installation is in the reverse order of removal.
2. Fill manual transmission oil, and inspect
transmission oil level.
CAUTION: Inspection of Transmission Oil
(3.2.3 Manual Transmission, General
Inspection).

M201 2014.01
3.2.3-26 Manual Transmission 3.2.3-26

Disassembly and Assembly

Disassembly of Transmission
Precautions
CAUTION: Keep the disassembly and
assembly site clean.

CAUTION: Be careful not to scratch the oil

seal lip while installing the propeller shaft.

CAUTION: It is better to use hexagon

sockets while disassembling and
assembling bolts.

CAUTION: The fitting surface of

components should be clean and
scatheless while disassembling and
assembling.

CAUTION: Components should be

classified and placed unifiedly while
disassembling and assembling.

CAUTION: Only use rubber hammer to

strike when disassembling the case.

General Equipment

Rubber hammer

Disassembly
1. Remove the manual transmission.
Refer to: Manual Transmission (3.2.3
Manual Transmission, Removal
and Installation).
2. Remove the vehicle speed sensor.

M3203129

M201 2014.01
3.2.3-27 Manual Transmission 3.2.3-27

3. Remove the worm set.

1 Remove the worm set retaining bolt.

2 Remove the worm set.

M3203014

4. Remove the extension case.

1 Remove 7 retaining bolts from extension
case.
×7
CAUTION: Extension case bolts should be
removed diagonally.

M3203015

2 Separate the extension case from rear case

with proper tool.
CAUTION: Avoid any damage to the
contact surface while separating the
extension case from rear case.

M3203016

5. Remove the output shaft set from the input

shaft.

M3203017

M201 2014.01
3.2.3-28 Manual Transmission 3.2.3-28

6. Remove input shaft needle roller bearing (1),

high-speed synchronizer gear ring (2) and
high-speed synchronizer wave spring in
sequence.

2 1

M3203018

7. Remove the transmission gearshift

mechanism.
1 Remove 4 retaining bolts from the
transmission gearshift mechanism.

×4
M3203019

2 Remove the transmission gearshift

mechanism.

8. Remove the reverse gear shaft bolt.

M3203020

M201 2014.01
3.2.3-29 Manual Transmission 3.2.3-29

9. Remove the transmission rear case.

1 Remove 9 retaining bolts from the
transmission rear case.
CAUTION: Rear case retaining bolts
should be removed diagonally.

×5

M3203021

×4

M3203022

2 Separate the front case from rear case with

proper tool.
CAUTION: Avoid any damage to the
contact surface while separating the front
case from rear case.

M3203023

10. Remove the interlock gasket and interlock

steel ball.
1 Remove 2 interlock gasket retaining bolts.

×2

M3203024

M201 2014.01
3.2.3-30 Manual Transmission 3.2.3-30

2 Remove the interlock gasket (1) and

interlock steel balls (2) in sequence.
1
2

M3203025

11. Remove the reverse gear shift fork.

1 Remove 2 retaining bolts from the reverse
gear shift fork.

×2

M3203026

2 Remove the reverse gear shift fork.

12. Remove the reverse gear shaft set.

1 Remove the reverse gear shaft.

M3203027

2 Remove the reverse idler gear.

M3203028

M201 2014.01
3.2.3-31 Manual Transmission 3.2.3-31

13. Remove the self-locking bolt, self-locking

spring and self-locking steel ball.
1 Remove 3 self-locking bolts.

×3
M3203029

2 Suck out 3 self-locking springs with

magnetic bar.

×3
M3203030

3 Suck out 3 self-locking steel balls with

magnetic bar.
×3

M3203031

14. Use magnetic screwdriver to suck out the

lever pin from the lower part of 3rd-4th gear
fork shaft.

M3203032

M201 2014.01
3.2.3-32 Manual Transmission 3.2.3-32

15. Remove the backup lamp switch.

M3203033

16. Remove the input shaft front case circlip.

M3203034

17. Remove the input shaft set, intermediate

shaft set, 1st-2nd gear fork shaft assembly,
1st-2nd gear shift fork assembly, 3rd-4th gear
fork shaft assembly, 5th and reverse gear
shift fork shaft assembly.
CAUTION: When tapping the front case
input shaft spline end slightly, tap out all
sets from it.

M3203035

M201 2014.01
3.2.3-33 Manual Transmission 3.2.3-33

18. Remove the gear shift and select cable

bracket.
1 Remove 2 retaining bolts from the gear shift
and select cable bracket.

×2

M3203036

2 Remove the gear shift and select cable

bracket.

M201 2014.01
3.2.3-34 Manual Transmission 3.2.3-34

Replacement of Input Shaft Oil Seal

1. Lift the vehicle.
Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).

2. Remove the manual transmission.

Refer to: Manual Transmission (3.2.3
Manual Transmission, Removal
and Installation).

3. Disassemble the transmission.

Refer to: Disassembly of Transmission
(3.2.3 Manual Transmission,
Disassembly and Assembly).
4. Use a proper tool to remove the oil seal.

M3203039

5. Use the input shaft oil seal assistant tool to

install the new input shaft oil seal.

M3203038

6. Apply the grease to the edge of oil seal, and

check the contact portion between input shaft
and oil seal to make sure it is even.
7. Assemble the transmission.
Refer to: Assembly of Transmission (3.2.3
Manual Transmission,
Disassembly and Assembly).

8. Add transmission oil as specified, and check

that the oil is sealed tightly by the oil seal.

M201 2014.01
3.2.3-35 Manual Transmission 3.2.3-35

Replacement of Extension Case Oil Seal

1. Drain the transmission oil.
Refer to: Replacement of Transmission Oil
(3.2.3 Manual Transmission,
General Inspection).

2. Remove the propeller shaft.

Refer to: Propeller Shaft (2.2.2 Propeller
Shaft, Removal and Installation).
3. Remove the transmission extension case oil
seal.
1 Use a proper tool to remove the oil seal.

M3203037

4. Install the transmission extension case oil

seal.
1 Apply gear oil to the lip of oil seal.
2 Install the new oil seal to the extension
case.
5. Install the propeller shaft.
6. Add transmission oil.

M201 2014.01
3.2.3-36 Manual Transmission 3.2.3-36
Inspection
1. Inspect the input shaft set.
• Inspect the input shaft gear teeth for
breakage and the tooth surface for
pitting, serious wear and gluing. Input
shaft must be replaced if any case above
occurs.

M3203040

• Inspect whether input shaft splines are

badly worn or damaged. Input shaft must
be replaced if it is badly worn or
damaged.
• Feel with finger to check whether bearing
rotation is inflexible and seized. Bearing
must be replaced if the troubles occur.
• Check for abnormality of high-speed
synchronizer, 5th gear synchronizer, and
replace if necessary.
• Check for abnormality of input shaft 3rd
gear assembly, 4th gear assembly, and if
they rotate flexibly, check the meshing
backlash between gear ring and gear.
Check the crowned tooth, ring and sleeve
of each gear, and replace if necessary.
(Theoretical backlash value: 0.8 ~ 1.2
mm)

M3203041

• Check for abnormality of each gear ring,

and replace if necessary.

M201 2014.01
3.2.3-37 Manual Transmission 3.2.3-37

2. Inspect the output shaft set.

• Inspect the output shaft gear teeth for
breakage and the tooth surface for
pitting, serious wear and gluing. Output
shaft must be replaced if any case above
occurs.
• Inspect whether output shaft splines are
badly worn or damaged. Output shaft
must be replaced if it is badly worn or
damaged.
M3203042
• Feel with finger to check whether bearing
rotation is inflexible and seized. Bearing
must be replaced if the troubles occur.

3. Inspect the intermediate shaft set.

• Inspect the intermediate shaft gear teeth
for breakage and the tooth surface for
pitting, serious wear and gluing.
Intermediate shaft must be replaced if
any case above occurs.
• Feel with finger to check whether bearing
rotation is inflexible and seized. Bearing
must be replaced if the troubles occur.

M3203043

4. Inspect the gear and synchronizer gear ring.

• Fit the synchronizer gear ring onto the
mating gear cone and inspect the
meshing backlash between gear and
gear ring. As for requirement details see
chart below. Components must be
replaced if backlash reaches or exceeds
limit value.
Theoretical
Backlash "a" Limit Value
Value a
between gear (mm)
(mm) M3203044
and gear ring
0.8 ~ 1.2 0.5

M201 2014.01
3.2.3-38 Manual Transmission 3.2.3-38

• Inspect whether the gear outer conical

surface and gear ring inner conical
surface are worn, the component must be
replaced if there is abnormal wear.

M3203045

5. Inspect the synchronizer set.

• Inspect the sliding flexibility of
synchronizer set, repair or replace if it is
seized.

M3203046

6. Inspect the gearcase set, shift lever set and

gearshift mechanism.
• Check for abnormality of gearcase set,
and replace if necessary.
• Check for abnormality of each shift lever
set and each dowel pin, and replace if
necessary.
• Check if the 1st-2nd gear shift lever
rotates freely, and replace if necessary.
• Check if the reverse gear shift fork M3203047
assembly rotates freely, and replace if
necessary.

M201 2014.01
3.2.3-39 Manual Transmission 3.2.3-39
7. Inspect the front case, rear case and
extension case set.
• Check for abnormality of each case, and
check if there are any cracks on the case
wall, and replace if necessary.
8. Inspect other components.
• Inspect whether the shift fork shaft is
deformed, and whether the self-locking or
interlock steel balls are damaged and
spring is deformed.
• Inspect whether the tip of synchronizer
sleeve synchronizer is worn or gear ring
key groove gets worn and wider.
• Inspect whether the bearing is loose,
damaged or gear thrust clearance is
excessive.
• Inspect whether the gear is badly worn or
engagement clearance is excessive.
• Inspect the clearance between fork and
hub sleeve.
• Inspect whether there is crack and
scratch on the oil seal lip.

M201 2014.01
3.2.3-40 Manual Transmission 3.2.3-40

Disassembly of Input Shaft

General Equipment

Puller

Disassembly
1. Use a proper tool to remove the input shaft
bearing circlip.
CAUTION: Place a cloth under the input
shaft set to prevent circlip from flying out.

M3203048

2. Use the puller to remove the input shaft

bearing.
CAUTION: Ensure that force bearing point
of bearing is at its inner ring while
removing bearing with the puller.

M3203049

3. Use a proper tool to remove the high-speed

synchronizer circlip.
CAUTION: Place a cloth under the input
shaft set to prevent circlip from flying out.

M3203050

M201 2014.01
3.2.3-41 Manual Transmission 3.2.3-41

4. Remove the high-speed synchronizer.

M3203051

5. Remove the high-speed synchronizer gear

ring.

M3203052

6. Remove the input shaft 3rd gear.

M3203053

7. Remove the 3rd gear needle roller bearing.

M3203054

M201 2014.01
3.2.3-42 Manual Transmission 3.2.3-42

8. Remove the reverse gear ring.

M3203055

9. Use the circlip pliers to remove the 5th gear

synchronizer circlip.

M3203056

10. Using the puller, pull out the 5th gear

synchronizer (1), 5th gear synchronizer gear
ring (2) together with input shaft 5th gear (3).
CAUTION: Ensure that force bearing point
of gear is at its inner ring while removing
the gear with puller.
1
2
3

M3203057

11. Remove the input shaft 5th gear needle roller

bearing.

M3203058

M201 2014.01
3.2.3-43 Manual Transmission 3.2.3-43

Disassembly of Output Shaft

General Equipment

Puller

Disassembly
1. Use a proper tool to remove the output shaft
worm circlip.
CAUTION: Place a cloth under the output
shaft set to prevent circlip from flying out.

M3203059

2. Remove the worm set.

1 Remove the worm (1).
2 Use magnetic screwdriver to suck out the
worm steel ball (2).
1

M3203060

3. Use a proper tool to remove the output shaft

rear bearing circlip.
CAUTION: Place a cloth under the output
shaft set to prevent circlip from flying out

M3203061

M201 2014.01
3.2.3-44 Manual Transmission 3.2.3-44

4. Use the puller to remove the output shaft rear

bearing.
CAUTION: Ensure that force bearing point
of bearing is at its inner ring while
removing bearing with the puller.

M3203062

5. Remove the output shaft driven gear.

M3203063

6. Using the puller, pull out the output shaft front

bearing (1) together with output shaft front
bearing circlip (2).
CAUTION: Ensure that force bearing point
of bearing is at its inner ring while
removing bearing with the puller.

1 2

M3203064

M201 2014.01
3.2.3-45 Manual Transmission 3.2.3-45

Disassembly of Intermediate Shaft

General Equipment

Puller

Disassembly
1. Use the puller to remove the intermediate
shaft rear bearing.
CAUTION: Ensure that force bearing point
of bearing is at its inner ring while
removing bearing with the puller.

M3203065

2. Use a proper tool to remove the intermediate

shaft front bearing circlip.
CAUTION: Place a cloth under the
intermediate shaft set to prevent circlip
from flying out.

M3203066

3. Use the puller to remove the intermediate

shaft front bearing.
CAUTION: Ensure that force bearing point
of bearing is at its inner ring while
removing bearing with the puller.

M3203067

M201 2014.01
3.2.3-46 Manual Transmission 3.2.3-46

4. Remove the intermediate shaft front bearing

washer.

M3203068

5. Remove the intermediate shaft 1st gear.

M3203069

6. Remove the intermediate shaft 1st gear

needle roller bearing.

M3203070

7. Remove the 1st gear synchronizer gear ring.

M3203071

M201 2014.01
3.2.3-47 Manual Transmission 3.2.3-47

8. Use a proper tool to remove the low-speed

synchronizer circlip.

M3203072

9. Using the puller, pull out the low-speed

synchronizer (1), 2nd gear synchronizer gear 1
ring (2) together with intermediate shaft 2nd
gear (3).
CAUTION: Ensure that force bearing point
of gear is at its inner ring while removing
the gear with puller. 2 3

M3203073

10. Remove the intermediate shaft 2nd gear

needle roller bearing.

M3203074

M201 2014.01
3.2.3-48 Manual Transmission 3.2.3-48

Assembly of Intermediate Shaft

Material

Item Specifications
Manual Transmission API (GL-4) SAE 75W-
Oil 90, Shell Spirax S4 GS

Assembly
1. Install the intermediate shaft 2nd gear needle
roller bearing.
CAUTION: Uniformly apply lubricant to the
part of needle roller end face that contacts
shaft journal.

M3203075

2. Install the intermediate shaft 2nd gear.

M3203076

3. Install the 2nd gear synchronizer gear ring.

CAUTION: The method to distinguish the
1st from 2nd gear synchronizer gear ring
is that 1st gear synchronizer gear ring has
eight teeth and 2nd gear synchronizer
gear ring has seven teeth.

M3203077

M201 2014.01
3.2.3-49 Manual Transmission 3.2.3-49

4. Use the low-speed synchronizer set pressing

assistant tool to install the low-speed
synchronizer.
CAUTION: Synchronizer slider is aligned
with gear ring slider slot while installation.
Gear rotation should be flexible and free
after installation.

CAUTION: All the gears and bearings have

positive and negative directions. Do not
mix them up. M3203078

CAUTION: Use the vise holder protector

all the time when using the vise.

5. Use the circlip pliers to install the low-speed

synchronizer circlip.
CAUTION: All the circlips must be
replaced with new ones after removal.
When inserting the circlip into the circlip
slot, both sides of circlip must hold the
circlip slot tightly.

M3203079

6. Install the 1st gear synchronizer gear ring.

CAUTION: Synchronizer gear ring slider
slot is aligned with synchronizer slider
while installation.

CAUTION: The method to distinguish the

1st from 2nd gear synchronizer gear ring
is that 1st gear synchronizer gear ring has
eight teeth and 2nd gear synchronizer
gear ring has seven teeth.
M3203080

M201 2014.01
3.2.3-50 Manual Transmission 3.2.3-50

7. Install the intermediate shaft 1st gear needle

roller bearing.
CAUTION: Uniformly apply lubricant to the
part of needle roller end face that contacts
shaft journal.

M3203081

8. Install the intermediate shaft 1st gear.

CAUTION: Use the vise holder protector
all the time when using the vise.

CAUTION: All the gears and bearings have

positive and negative directions. Do not
mix them up.

M3203082

9. Install the intermediate shaft front bearing

washer.

M3203083

M201 2014.01
3.2.3-51 Manual Transmission 3.2.3-51

10. Use the intermediate shaft front bearing

pressing assistant tool to install the
intermediate shaft front bearing.
CAUTION: All the gears and bearings have
positive and negative directions. Do not
mix them up.

CAUTION: Ensure that force bearing point

of bearing is at its inner ring while
installing the bearing with the tool.
M3203084
CAUTION: Use the vise holder protector
all the time when using the vise.

11. Use a proper tool to install the intermediate

shaft front bearing circlip.
CAUTION: All the circlips must be
replaced with new ones after removal.
When inserting the circlip into the circlip
slot, both sides of circlip must hold the
circlip slot tightly.

M3203085

12. Use the intermediate shaft rear bearing

pressing assistant tool to install the
intermediate shaft rear bearing.
CAUTION: All the gears and bearings have
positive and negative directions. Do not
mix them up.

CAUTION: Ensure that force bearing point

of bearing is at its inner ring while
installing the bearing with the tool.
M3203086
CAUTION: Use the vise holder protector
all the time when using the vise.

M201 2014.01
3.2.3-52 Manual Transmission 3.2.3-52

Assembly of Output Shaft

Material

Item Specifications
Manual Transmission API (GL-4) SAE 75W-
Oil 90, Shell Spirax S4 GS

Assembly
1. Use a proper tool to install the output shaft
front bearing and output shaft front bearing
circlip.
CAUTION: Ensure that force bearing point
of bearing is at its inner ring while
installing the bearing with the tool.

CAUTION: All the gears and bearings have

positive and negative directions. Do not
mix them up.
M3203087

2. Install the output shaft driven gear.

M3203088

3. Use the output shaft rear bearing pressing

assistant tool to install the output shaft rear
bearing.
CAUTION: Ensure that force bearing point
of bearing is at its inner ring while
installing the bearing with the tool.

CAUTION: All the gears and bearings have

positive and negative directions. Do not
mix them up.
M3203089

M201 2014.01
3.2.3-53 Manual Transmission 3.2.3-53

4. Use a proper tool to install the output shaft

rear bearing circlip.
CAUTION: All the circlips must be
replaced with new ones after removal.
When inserting the circlip into the circlip
slot, both sides of circlip must hold the
circlip slot tightly.

M3203090

5. Install the worm set.

1 Install the worm steel ball (1).
2 Install the worm (2).
CAUTION: Apply a small amount of grease
to the surface of steel ball when installing. 2

M3203091

6. Use a proper tool to install the worm circlip.

M201 2014.01
3.2.3-54 Manual Transmission 3.2.3-54

Assembly of Input Shaft

Material

Item Specifications
Manual Transmission API (GL-4) SAE 75W-
Oil 90, Shell Spirax S4 GS

Assembly
1. Install the input shaft 5th gear needle roller
bearing.
CAUTION: Uniformly apply lubricant to the
part of needle roller end face that contacts
shaft journal.

M3203092

2. Install the input shaft 5th gear.

CAUTION: All the gears and bearings have
positive and negative directions. Do not
mix them up.

M3203093

3. Install the 5th gear synchronizer gear ring.

M3203094

M201 2014.01
3.2.3-55 Manual Transmission 3.2.3-55

4. Use a proper tool to install the 5th gear

synchronizer.
CAUTION: 5th gear synchronizer boss
should face towards input shaft front end.

CAUTION: Synchronizer slider is aligned

with gear ring slider slot while installation.
Gear rotation should be flexible and free
after installation.

CAUTION: All the gears and bearings have M3203095

positive and negative directions. Do not
mix them up.

5. Use a proper tool to install the 5th gear

synchronizer circlip.
CAUTION: All the circlips must be
replaced with new ones after removal.
When inserting the circlip into the circlip
slot, both sides of circlip must hold the
circlip slot tightly.

M3203096

6. Install the reverse gear ring.

CAUTION: Reverse gear ring slider slot is
aligned with synchronizer slider while
installation.

M3203097

M201 2014.01
3.2.3-56 Manual Transmission 3.2.3-56

7. Install the 3rd gear needle roller bearing.

CAUTION: Uniformly apply lubricant to the
part of needle roller end face that contacts
shaft journal.

M3203098

8. Install the input shaft 3rd gear.

M3203099

9. Install the high-speed synchronizer gear ring.

M3203100

10. Install the high-speed synchronizer.

M3203101

M201 2014.01
3.2.3-57 Manual Transmission 3.2.3-57

11. Use a proper tool to install the high-speed

synchronizer circlip.
CAUTION: All the circlips must be
replaced with new ones after removal.
When inserting the circlip into the circlip
slot, both sides of circlip must hold the
circlip slot tightly.

M3203102

12. Use the input shaft bearing pressing assistant

tool to install the input shaft bearing.
CAUTION: Ensure that force bearing point
of bearing is at its inner ring while
installing the bearing with the tool.

CAUTION: All the gears and bearings have

positive and negative directions. Do not
mix them up.

M3203103

13. Use a proper tool to install the input shaft

bearing circlip.
CAUTION: All the circlips must be
replaced with new ones after removal.
When inserting the circlip into the circlip
slot, both sides of circlip must hold the
circlip slot tightly.

M3203104

M201 2014.01
3.2.3-58 Manual Transmission 3.2.3-58

Assembly of Transmission
Material

Item Specifications
Sealant YT5699 silicone sealant
Manual Transmission API (GL-4) SAE 75W-
Oil 90, Shell Spirax S4 GS

Precautions for transmission before assembling:

• Clean all the parts.
• Apply gear oil to part surface with relative movement.
• Apply grease to circular surface of needle roller bearing before assembling needle roller bearing.
• Apply grease to outer ring and inner ring of bearing before assembling deep groove ball bearing.
• Apply grease to lip while assembling oil seal.

Assembly
1. Install the gear shift and select cable bracket
and tighten it to the specified torque.
1 Install the gear shift and select cable
bracket.
2 Install 2 retaining bolts to the cable bracket.
×2
Torque: 18 ~ 28 Nm

M3203036

2. Install the input shaft front case circlip to the

input shaft.

M3203125

M201 2014.01
3.2.3-59 Manual Transmission 3.2.3-59

3. Install the input shaft set, intermediate shaft

set, 1st-2nd gear fork shaft assembly, 1st-2nd
gear shift fork assembly, 3rd-4th gear fork
shaft assembly together with 5th and reverse
gear shift fork shaft assembly to the front
case.
CAUTION: Fork must be stuck in the slot
of synchronizer sleeve and each of three
gear fork shafts must be placed into the
hole correspondingly.
M3203105

4. Tap the rear ends of input shaft and

intermediate shaft with rubber hammer lightly
to ensure that each set has been installed in
place.

M3203106

5. Use the circlip pliers to install the input shaft

front circlip.

M3203107

6. Install the backup lamp switch.

Torque: 15 ~ 22 Nm

M3203033

M201 2014.01
3.2.3-60 Manual Transmission 3.2.3-60

7. Use magnetic screwdriver to put the lever pin

into the transverse slot on the lower part of
3rd-4th gear fork shaft.

M3203108

8. Install the self-locking steel ball, self-locking

spring and self-locking bolt.
1 Install 3 self-locking steel balls.

×3
M3203031

2 Install 3 self-locking springs.

×3

M3203030

3 Apply adhesive to 3 self-locking bolts, and

then tighten them.
Torque: 10 ~ 16 Nm
×3

M3203029

M201 2014.01
3.2.3-61 Manual Transmission 3.2.3-61

9. Install the reverse gear shaft set.

1 Install the reverse idler gear.
CAUTION: While installing the reverse
gear shift fork, the reverse gear shift fork
must be stuck to the slot of reverse idler
gear sleeve.

M3203109

2 Install the reverse gear shaft.

CAUTION: While installing the reverse
gear shaft set, mark (1) on the reverse
gear shaft is in line with mark (2) on the
front case for easy installation of reverse 1
gear shaft bolts.

M3203110

10. Install the reverse gear shift fork, and tighten

it to the specified torque.
1 Install the reverse gear shift fork.

M3203111

M201 2014.01
3.2.3-62 Manual Transmission 3.2.3-62

2 Apply adhesive to 2 reverse gear shift fork

retaining bolts, and then tighten them.
Torque: 18 ~ 28 Nm

×2

M3203026

11. Install the interlock steel ball and interlock

gasket.
1
1 Install the interlock steel balls (2) and 2
interlock gasket (1).

M3203025

2 Install 2 interlock gasket retaining bolts.

Torque: 18 ~ 28 Nm

×2

M3203024

12. Engage the high-speed synchronizer wave

spring and high-speed synchronizer gear
ring.

M3203112

M201 2014.01
3.2.3-63 Manual Transmission 3.2.3-63

13. Put the high-speed synchronizer gear ring

onto the input shaft high-speed synchronizer.
CAUTION: Synchronizer gear ring slider
slot is aligned with synchronizer slider
while installation.

M3203113

14. Apply sealant to case contact surface.

CAUTION: Remove the remaining sealant
on the case contact surface with scraper
before applying. Be sure to apply evenly in
a continuous bead with 2 ~ 3 mm in
diameter. After applying, fit the cases
within specified time. Remove and reapply
if exceeding the specified time.

M3203114

15. Tighten the rear case to the specified torque

after installation.
Torque: 18 ~ 28 Nm
CAUTION: To ensure installing in place,
knock extension case knock pin lightly
with rubber hammer and do not tap the
case contact surface while installing rear
case.

CAUTION: Case bolts should be tightened

M3203115
diagonally.

16. Apply adhesive to the reverse gear shaft bolt,

and then tighten it.
Torque: 18 ~ 28 Nm

M3203116

M201 2014.01
3.2.3-64 Manual Transmission 3.2.3-64

17. Apply sealant to the junction surface between

transmission gearshift mechanism and rear
case.
CAUTION: Remove the remaining sealant
on the junction surface with scraper
before applying. Be sure to apply evenly in
a continuous bead with 2 ~ 3 mm in
diameter. After applying, fit the cases
within specified time. Remove and reapply
if exceeding the specified time.
M3203117

18. Install the transmission gearshift mechanism.

1 Install the gearshift case.

M3203118

2 Install the gear select set.

M3203119

3 Install 4 retaining bolts to the transmission

gearshift mechanism.
Torque: 18 ~ 28 Nm
×4

M3203019

M201 2014.01
3.2.3-65 Manual Transmission 3.2.3-65

19. Apply sealant to case contact surface.

CAUTION: Remove the remaining sealant
on the case contact surface with scraper
before applying. Be sure to apply evenly in
a continuous bead with 2 ~ 3 mm in
diameter. After applying, fit the cases
within specified time. Remove and reapply
if exceeding the specified time.

M3203120

20. Put the input shaft needle roller bearing onto

the input shaft.

M3203121

21. Put the output shaft onto the high-speed

synchronizer gear ring.

M3203122

M201 2014.01
3.2.3-66 Manual Transmission 3.2.3-66

22. Install the extension case and tighten to the

specified torque.
1 Install the extension case.
2 Tighten the extension case bolts to the
specified torque.
Torque: 18 ~ 28 Nm
CAUTION: Case bolts should comply with
diagonal tightening methods. If there is no
trace around the surface of extension case
M3203123
bolt hole, hanger bolt can be installed
here.

23. Install the worm set and tighten to the

specified torque.
1 Install the worm set.

M3203124

2 Install the worm set retaining bolt.

Torque: 8 ~ 12 Nm

M3203014

M201 2014.01
3.2.3-67 Manual Transmission 3.2.3-67

24. Install the vehicle speed sensor.

Torque: 10 Nm

M3203129

M201 2014.01
3.2.4-1 Manual Transmission External Control 3.2.4-1

Specifications
3.2.4 Manual Transmission External Control

Torque Specifications
Item Nm lb-ft lb-in
Connecting bolt between gearshift control
20 ± 2 - -
assembly and middle-compartment
Gear control cable grommet plate
9 - 80
retaining bolt

M201 2014.01
3.2.4-2 Manual Transmission External Control 3.2.4-2

Description and Operation

System Overview
Manual Transmission gearshift mechanism includes gearshift retainer assembly and gear control cables.
The gearshift retainer is connected with transmission via gear shift and select cables to isolate the
external gearshift mechanism from vehicle body, thus reducing the vibration.

Components Exploded View

11

12 5

7 4 8
1
6

10

M3204001

Item Description Item Description

Cross recessed pan head
1 Gearshift control assembly 7
screw
2 Gear shift cable assembly 8 Flexible clip
3 Gear select cable assembly 9 Plate washer
4 Gear control cable grommet 10 Plate washer
Gear control cable grommet
5 11 Hand knob assembly
plate
6 Bolt 12 Dust boot set

M201 2014.01
3.2.4-3 Manual Transmission External Control 3.2.4-3

Symptom Diagnosis and Testing

Inspection and Verification
1. Verify the customer concern and reproduce
the fault as necessary.
2. If the customer concern cannot be identified,
carry out road test or visual inspection
according to the table below.
3. If the fault can be identified obviously,
proceed to the repair process.
4. If the fault cannot be identified obviously,
carry out a precise inspection according to
the Symptom Chart.
Visual Inspection Chart

Mechanical
• Obviously damaged or worn components
• Loose or lost nuts or bolts

M201 2014.01
3.2.4-4 Manual Transmission External Control 3.2.4-4

Symptom Chart
If the fault occurs, but there is no DTC stored in the control module for this fault and the causes cannot
be verified in basic inspection, diagnose and repair it in order of the following table.

Symptom Possible Causes Solutions

• Distorted connection of external
• Adjust the external gearshift mechanism
gearshift mechanism
Difficult operation of
gearshift mechanism
• Damaged shift lever
• Diagnosis Procedure for Difficult
• Damaged gear shift and select Operation of Gearshift Mechanism
cables

Diagnosis Procedure for Difficult Operation of Gearshift

Mechanism
Test Conditions Details/Results/Actions
1. Inspect tire
A. Separate shift lever from transmission.
Does external gearshift mechanism operate
difficultly?
Yes
Remove the shift lever and find out fault
components.
Refer to: Gearshift Mechanism (3.2.4
Manual Transmission External
Control, Removal and
Installation).
No
Go to step 2.
2. Inspect gear shift and select cables
A. Remove the gear shift and select cables from
transmission.
Are the cables damaged?
Yes
Find out the fault, and replace the cables.
Refer to: Gearshift Mechanism (3.2.4
Manual Transmission External
Control, Removal and
Installation).
No
Transmission fault.

M201 2014.01
3.2.4-5 Manual Transmission External Control 3.2.4-5

Removal and Installation

Gearshift Mechanism
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the center console assembly.
Refer to: Console (5.1.6 Instrument Panel
and Console, Removal and
Installation).
3. Remove the gear control cable flexible clip (1)
and plate washer (2).
2

M3204003

4. Disconnect the gear shift and select cables

from the shift lever.

M3204004

M201 2014.01
3.2.4-6 Manual Transmission External Control 3.2.4-6

5. Separate the gear shift and select cables

from bottom of gearshift mechanism.
1 Push down the gear shift cable clamp to
separate the cable from the bottom of
gearshift mechanism as shown in the figure.

M3204005

2 Push down the gear select cable clamp to

separate the cable from the bottom of
gearshift mechanism as shown in the figure.

M3204006

6. Remove 4 retaining bolts from the gearshift

control assembly.
Torque: 20 ± 2 Nm

×4

M3204007

7. Remove 2 retaining bolts from the gear

control cable grommet plate.
Torque: 9 Nm
×2

M3204008

M201 2014.01
3.2.4-7 Manual Transmission External Control 3.2.4-7
8. Remove the gear control cable grommet plate
and grommet in order.
9. Remove the parking brake lever.
Refer to: Parking Brake Lever (2.3.4.
Parking Brake and Operation,
Removal and Installation).

10. Separate the connection between parking

brake No.1 cable (1) and middle-
compartment.
11. Press down the wiring harness fixing rubber
ring (2) to separate it from the middle-
2
compartment.

M3204012

12. Remove 4 retaining bolts from the gearshift

middle-compartment.
Torque: 20 ± 2 Nm
×4

M3204009

13. Remove the attachments from transmission

gearcase and gear control cables.
1
1 Remove the gear select cable (1) flexible
clip and plate washer.
2 Remove the gear shift cable (2) flexible clip
and plate washer.

M3204010

M201 2014.01
3.2.4-8 Manual Transmission External Control 3.2.4-8
14. Separate the gear shift cable (1) and gear
select cable (2) from the control cable 2
bracket.

M3204011

15. Remove the gear shift and select cables.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
 GROUP 4
Electrical
SECTION PAGE

4.1 Heating, Ventilation and Air Conditioning

4.1.1 Heating, Ventilation and Air Conditioning.......................................................................... 4.1.1-1

4.2 Body Electrical

4.2.1 Instrument Panel and Panel Illumination .......................................................................... 4.2.1-1
4.2.2 Instrument Cluster............................................................................................................. 4.2.2-1
4.2.3 Horn .................................................................................................................................. 4.2.3-1
4.2.4 Cigarette Lighter ............................................................................................................... 4.2.4-1
4.2.5 Information and Entertainment System............................................................................. 4.2.5-1
4.2.6 Lighting System ................................................................................................................ 4.2.6-1
4.2.7 Wiper and Washer ............................................................................................................ 4.2.7-1
4.2.8 Central Door Lock ............................................................................................................. 4.2.8-1
4.2.9 Power Window .................................................................................................................. 4.2.9-1
4.2.10 Body Control System .................................................................................................... 4.2.10-1
4.2.11 On-board Network ......................................................................................................... 4.2.11-1

M201 2014.01
 Heating, Ventilation and Air Conditioning

4.1 Heating, Ventilation and Air Conditioning

2014 M201
Table of Contents Pages

4.1.1 Heating, Ventilation and Air Conditioning

Specifications ................................................................................................................................... 4.1.1-1
General Specifications.............................................................................................................. 4.1.1-1
Torque Specifications................................................................................................................ 4.1.1-1
Description and Operation ............................................................................................................... 4.1.1-2
System Overview...................................................................................................................... 4.1.1-2
Components Description .......................................................................................................... 4.1.1-4
System Operation..................................................................................................................... 4.1.1-6
Components Location View ...................................................................................................... 4.1.1-9
General Inspection......................................................................................................................... 4.1.1-11
Refrigeration System Test ...................................................................................................... 4.1.1-11
Insufficient A/C Cooling Quick Inspection............................................................................... 4.1.1-12
Refrigeration System Pressure Inspection ............................................................................. 4.1.1-12
A/C System Performance Test ............................................................................................... 4.1.1-13
Symptom Diagnosis and Testing.................................................................................................... 4.1.1-18
Inspection and Verification...................................................................................................... 4.1.1-18
Symptom Chart....................................................................................................................... 4.1.1-19
Diagnosis Procedure for Insufficient A/C Cooling................................................................... 4.1.1-21
Diagnosis Procedure for Insufficient Heating of A/C .............................................................. 4.1.1-28
Diagnosis Procedure for Blower Fault .................................................................................... 4.1.1-31
Diagnosis Procedure for A/C Compressor Clutch Fault ......................................................... 4.1.1-36
Diagnosis Procedure for Condenser Fan Constantly Running ............................................... 4.1.1-45
Diagnosis Procedure for Condenser Fan Not Running .......................................................... 4.1.1-46
Removal and Installation................................................................................................................ 4.1.1-51
Compressor Belt..................................................................................................................... 4.1.1-51
Compressor ............................................................................................................................ 4.1.1-51
Condenser .............................................................................................................................. 4.1.1-53
Tristate Pressure Switch......................................................................................................... 4.1.1-56
A/C Pipeline............................................................................................................................ 4.1.1-57
A/C Controller ......................................................................................................................... 4.1.1-60
Governor Resistor .................................................................................................................. 4.1.1-62
HVAC Assembly ..................................................................................................................... 4.1.1-63
Overhead Evaporator ............................................................................................................. 4.1.1-66

M201 2014.01
 Heating, Ventilation and Air Conditioning
A/C Pipeline (with Overhead Evaporator) ...............................................................................4.1.1-69

M201 2014.01
4.1.1-1 Heating, Ventilation and Air Conditioning 4.1.1-1

Specifications
4.1.1 Heating, Ventilation and Air Conditioning

Item Specifications Capacity

Refrigerant oil PAG56 110 ml
500 ± 20 g (Single evaporator)
Refrigerant HFC-134a
700 ± 20 g (Double evaporator)

General Specifications
Compressor Specifications
Model WXH-066
Type Scroll
Displacement 66 cc/r
Electromagnetic clutch power Less than 48 W (20°C)
Voltage 12 V

Torque Specifications
Item Nm lb-ft lb-in
Retaining bolt between No.1 drain pipe
14 ~ 17 10 ~ 13 -
and compressor
Retaining bolt between No.1 suction pipe
14 ~ 17 10 ~ 13 -
and compressor
Compressor adjusting bolt 24 ~ 26 18 ~ 19 -
Compressor retaining bolt 25 ~ 30 18 ~ 22 -
Condenser retaining bolt 8 ~ 10 - 71 ~ 89
Condenser inlet pipe retaining bolt 8 ~ 10 - 71 ~ 89
Condenser outlet pipe retaining bolt 8 ~ 10 - 71 ~ 89
Retaining bolt between front evaporator
8 ~ 10 - 71 ~ 89
inlet/outlet pipe and expansion valve

M201 2014.01
4.1.1-2 Heating, Ventilation and Air Conditioning 4.1.1-2

Description and Operation

System Overview
The A/C system is designed to provide
passengers with excellent ride comfort regardless
of weather. The system can control the ventilation
of passenger compartment by actuating the
following functions:
• Cooling
• Dehumidification
• Heating
• Circulation
The fresh air goes from the air inlet housing
system, then pass through the HVAC assembly,
air channels to each vent and finally into the
interior space. The A/C system consists of the
following main components:
• Refrigeration system
• Heating system
• Air distribution system
• Air conditioning control system
The A/C system has the following characteristics:
• Fresh and dry air to make people feel
comfortable
• Power ventilation
The driver can select any of the following
functions on the control panel:
• Room temperature
• Fan speed
• Air inlet and outlet position

M201 2014.01
4.1.1-3 Heating, Ventilation and Air Conditioning 4.1.1-3
A/C Control Panel Function Description

1 2 3 4

1 1 USE
WITH

2 2
3 3

M4101001

Item Description Item Description

Air volume and inside/outside
1 Temperature control knob 3
circulation control knob
2 A/C switch 4 Mode selection knob

M201 2014.01
4.1.1-4 Heating, Ventilation and Air Conditioning 4.1.1-4
Temperature Setting Components Description
The temperature control knob is used to set the
Compressor
room temperature and control the temperature of
air at the vent. Turn to the blue area for cold air or The A/C compressor is driven by compressor
to the red for warm air. clutch pulley, which is driven through belt by
engine crankshaft. Before electromagnetic clutch
Air Volume and Inside/Outside coil power on, the compressor pulley rotates
Circulation Mode Setting freely and does not drive compressor shaft; after
The air volume and inside/outside circulation the coil power on, clutch plate and clutch hub will
mode setting are controlled by the same knob be pushed to the pulley, then clutch plate and
that can be turned left and right to select the pulley are locked as one by magnetic force to
inside or outside air circulation and blower speed drive the compressor shaft.
level. The compressor will be turned off under the
following conditions:
Vent Mode
1. Throttle fully open
The expected air flow can be reached with
ventilation mode selection switch, and the 2. Low idle speed
temperature distribution range will be affected by 3. Low ambient temperature
the interior space.
4. Coolant temperature too high
5 vent modes can be selected by the user:
5. Refrigerant pressure higher than 3.2 ± 0.2
1. Face MPa or lower than 0.2 ± 0.02 MPa
2. Face and footwell
Condenser, Refrigerant Drier
3. Footwell
The high-pressure and high-temperature
4. Footwell and defroster refrigerant vapor from the A/C compressor goes
5. Defroster into the condenser. The condenser is made of
aluminum pipes and cooling fins which allow the
high-pressure and high-temperature refrigerant
ON-OFF Mode
vapor to carry on quick heat transmission. The
The system ON/OFF control is realized by A/C high-pressure and high-temperature refrigerant
switch. Press the switch to send request signal of vapor is condensed into the high-pressure and
A/C system ON or OFF. middle-temperature fluid by the cooling fins
When the air volume control knob is not at "OFF", radiating. The refrigerant drier is located at the
press the A/C switch and its operation indicator right side of condenser. The design of its internal
will come on (system ON) or off (system OFF). construction will ensure that the high-pressure
and high-temperature gas-liquid mixture
A/C switch signal logic inspection: refrigerant enters the drier and only the high-
pressure and middle-temperature liquid
A/C Blower Evaporator A/C
refrigerant comes out from the drier. There is
Switch Switch Temperature Signal
desiccant in the drier to absorb the water content
OFF - - OFF in refrigeration system, and the desiccant cannot
ON ON Above 4°C ON be used repeatedly.
ON OFF - OFF
ON ON Below 2°C OFF

M201 2014.01
4.1.1-5 Heating, Ventilation and Air Conditioning 4.1.1-5
HVAC Assembly
The HVAC assembly is located inside the
instrument panel and consists of blower motor,
heater core, evaporator, expansion valve as well
as all kinds of air deflection dampers and vent
ducts.

Refrigerant HFC-134a and Lubricant

The refrigerant in A/C has the following functions:
• Absorbing heat
• Carrying heat
• Releasing heat
The refrigerant HFC-134a is used in the vehicle.
Make sure to follow the steps in instructions when
carrying out the following repairs:
• Refrigerant recovery and regeneration
• Add the refrigerant oil
• Vacuumize the refrigeration system
• Refill the refrigeration system

A/C Pressure Switch

The A/C pressure switch is a tristate pressure
switch to transmit the A/C pressure signal.
Pressure switch value:

Pressure
Item Signal Value
Value (MPa)
High pressure
3.0 ~ 3.4 OFF
switch
Medium
pressure 1.48 ~ 1.68 ON
switch
Low pressure
0.21 ~ 0.25 OFF
switch

M201 2014.01
4.1.1-6 Heating, Ventilation and Air Conditioning 4.1.1-6

System Operation
Ventilation

1
4
7

M4101002

Item Description Item Description

1 Heater core 5 Instrument panel outlet
2 Blower 6 Inside air
3 Defroster 7 Outside air
4 Floor outlet

M201 2014.01
4.1.1-7 Heating, Ventilation and Air Conditioning 4.1.1-7
Refrigeration System Operation

2
1

9 4

5
8

A
B
C
7 D
E

M4101003

Item Description Item Description

1 Overhead evaporator 8 Compressor
2 F type expansion valve 9 Overhead blower motor
Liquid with high pressure,
3 H type expansion valve A
middle temperature
Liquid with low pressure, low
4 Front evaporator B
temperature
Gas with low pressure, low
5 Front blower motor C
temperature
Gas with high pressure, high
6 Condenser D
temperature
Gas-liquid mixture with high
7 Condenser fan E
pressure, high temperature

M201 2014.01
4.1.1-8 Heating, Ventilation and Air Conditioning 4.1.1-8
High pressure side: The refrigerant is compressed into high-temperature and high-pressure gas from
low-pressure gas, and then flowed into the condenser with lubricant. As the high-temperature and high-
pressure gas flows through the condenser, its heat is released to the relatively cool ambient air that goes
though condenser pipes, and the vapor is condensed into liquid. The high-temperature and high-
pressure liquid continue to be condensed when it goes through the drier and then flows into the
expansion valve in which a small adjustable throttle valve restricts the gas from the compressor.
Low pressure side: The pressure and temperature of liquid refrigerant with high temperature and high
pressure decreases quickly after it goes through the expansion valve, and the refrigerant turns into the
low-temperature and low-pressure gas-liquid mixture. The blower makes the hot air inside the vehicle
through the evaporator for heat exchange and the refrigerant completely turns into gas. Therefore the air
from vents is cold. Finally, the low-temperature and low-pressure gas is absorbed by the compressor,
and A/C circulation starts again.

M201 2014.01
4.1.1-9 Heating, Ventilation and Air Conditioning 4.1.1-9

Components Location View

19

3
5

15
4 7
16
17

8
18

13 9

14

10

11
12

M4101004

M201 2014.01
4.1.1-10 Heating, Ventilation and Air Conditioning 4.1.1-10

Item Description Item Description

1 HVAC assembly 11 Overhead evaporator inlet pipe
2 A/C controller assembly 12 No.3 suction pipe
Overhead evaporator drain pipe
3 No.1 drain pipe 13
(right)
4 A/C three-way pipe 14 No.2 suction pipe
5 No.1 suction pipe 15 Front evaporator inlet pipe
6 Compressor 16 Front evaporator outlet pipe
Overhead evaporator garnish
7 17 Condenser inlet pipe
cover (right)
8 Overhead evaporator assembly 18 Condenser assembly
Overhead evaporator garnish
9 19 Condenser outlet pipe
cover (left)
Overhead evaporator drain pipe
10
(left)

M201 2014.01
4.1.1-11 Heating, Ventilation and Air Conditioning 4.1.1-11

General Inspection leaving factory. The sealed components

should not be unsealed until installation soon
General Equipment
starts. All the components should be at the
Digital multimeter room temperature before unsealed to prevent
Refrigerant recovery filling machine
water in the air from condensing on the
components and entering the system. Seal
the components again as fast as possible.
WARNING: Disconnect the negative
battery cable before repairing the CAUTION: A/C refrigerant – forbidden
electrical system. Do not weld or vapour operation:
clean on or near a vehicle with A/C pipes a. Do not store the refrigerant in
or components. sunniness or at places with heat source;
b. Do not let out the refrigerant into the air
CAUTION: Do not clean the air
in any case; c. Do not use different
conditioning system with water, caustic
refrigerants at the same time, such as R12
solvent or inflammable or explosive
(Freon).
solvent. It is recommended to use R-141b,
heptane and the like. CAUTION: Refrigerant oil - precautions:
Use the refrigerant oil with the designated
The operational efficiency and service life of air
type and grade of the compressor factory.
conditioning (A/C) system depend on the
Never use refrigerant oil of different types
chemical stability of refrigeration system. When
and grades together, or the compressor
the refrigeration system is contaminated by
will be damaged. The refrigerant oil is
foreign matters (such as dust, air or moisture), the
extremely absorbent of water, so shorten
stability of refrigerant and compressor oil will be
the exposure time of the oil in the air as
changed. Besides, the relationship between
much as possible.
pressure and temperature is also affected,
resulting in work efficiency reduction. It can cause Refrigeration System Test
interior corrosion and abnormal wear of the
components as well. Inspect as follows: Inspect the following items when the A/C system
may have problems:
1. Clean the oil on and around the joint before
opening it in order to reduce the possibility of 1. Inspect the outside surface of radiator and
oil entering the system. condenser cores to ensure that the air flow is
not blocked by the dust, leaves and other
2. Seal the both ends of joint with caps, plugs or foreign matters. Inspect the joint surface
adhesive tapes immediately after between condenser and radiator, and all the
disconnecting the joint to prevent the oil, outside surfaces.
foreign matters and moisture from entering
the system. 2. Inspect the condenser core, hose and
connecting pipes for blockage or twist.
3. Keep all the tools including manifold pressure
gauge components and all the replacement 3. Inspect the operation of blower fan.
components clean and dry. 4. Inspect all the air pipes for leakage or
4. Add refrigerant oil with clean and dry blockage. A small air flow may mean that the
conveyer device and container to protect the evaporator core is blocked.
refrigerant oil from moisture. 5. Inspect the compressor clutch for slippage.
5. Shorten the exposure time of A/C system in 6. Inspect the tension of accessory drive belt.
the air as far as possible in operation.
6. Drain and refill the A/C system again after its
interior is exposed to the air. All the service
components are dried and sealed before

M201 2014.01
4.1.1-12 Heating, Ventilation and Air Conditioning 4.1.1-12

Insufficient A/C Cooling Quick Refrigeration System Pressure

Inspection Inspection
Perform the following "hand feel" procedure to 1. Under normal conditions at room
see if the adding quantity of A/C system temperature.
refrigerant is appropriate. The air temperature
2. Turn off the ignition switch.
must be higher than 21°C in all the modes.
3. Install the A/C detecting and repairing device,
1. Warm up the engine. Keep the engine idling.
and connect the high/low pressure pipes of
2. Open the engine hood and all the doors. device to the high/low pressure pipes of A/C
3. Switch on the A/C. system of the tested vehicle.

4. Set the temperature control knob at coldest. 4. Measure the balance pressure reading of
high-pressure and low-pressure pipes of A/C
5. Set the blower speed at highest. system in the vehicle.
6. "Hand feel" the temperature at the outlet pipe Standard Balance Pressure: 0.7 MPa
of evaporator. It should be cool.
5. Start the engine and keep it running for 5
7. Inspect other faults. minutes.
8. Inspect if there is a leakage in the system. If 6. Press the A/C switch and keep A/C system
so, drain the system and do necessary repair. working for 2 minutes.
Drain the system and refill it with refrigerant
7. Keep the engine speed at 2000 rpm, and
again after repair.
measure the pressure reading of high-
9. If there is no leakage. pressure and low-pressure pipes of A/C
system.
Refer to: Symptom Chart (4.1.1 Heating,
Ventilation and Air Conditioning, The pressure standard values are as follows:
Symptom Diagnosis and
Standard Standard Standard
testing). Item
1 2 3
Ambient Higher Higher Higher
temp. than 16°C than 24°C than 33°C
Pressure 345 kPa 483 kPa 690 kPa

M201 2014.01
4.1.1-13 Heating, Ventilation and Air Conditioning 4.1.1-13

A/C System Performance Test

Test Instructions
This test is to measure the work efficiency of A/C
system under the following conditions:
• Current ambient temperature
• Current relative humidity
• A/C system high pressure
• A/C system low pressure
• Air temperature at instrument panel vent
Test conditions: doors and engine hood open, A/C
ON, inside circulation mode, the coldest state and
highest blower speed, no sunlight, wind speed
lower than 8 km/h.
CAUTION: The ambient temperature
should be at least 16°C. Do not let extra air
flow through the front of vehicle during
the test.

M201 2014.01
4.1.1-14 Heating, Ventilation and Air Conditioning 4.1.1-14
HFC-134a Pressure and Temperature Relationship List
Temperature Pressure Temperature Pressure
°C (°F) Psi °C (°F) Psi
-8 (17.6) 113.1 (16.4) 9 (48.2) 296.2 (43.0)
-7 (19.4) 121.5 (17.6) 10 (50.0) 309.6 (44.9)
-6 (21.2) 130.2 (18.9) 15 (59.0) 383.7 (55.7)
-5 (23.0) 139.1 (20.2) 20 (68.0) 467.7 (67.8)
-4 (24.8) 148.4 (21.5) 25 (77.0) 567.5 (82.3)
-3 (26.6) 157.9 (22.9) 30 (86.0) 667.8 (96.9)
-2 (28.4) 167.6 (24.3) 35 (95.0) 785.6 (113.9)
-1 (30.2) 177.8 (25.8) 40 (104.0) 916.4 (133.0)
0 (32.0) 188.2 (27.3) 45 (113.0) 1062.2 (154.0)
1 (33.8) 198.8 (28.8) 50 (122.0) 1222.1 (177.2)
2 (35.6) 209.9 (30.4) 55 (131.0) 1398.2 (202.8)
3 (37.4) 221.2 (32.1) 60 (140.0) 1589.6 (230.5)
4 (39.2) 232.9 (33.8) 65 (149.0) 1799.0 (260.9)
5 (41.0) 245.0 (35.5) 70 (158.0) 2026.6 (293.9)
6 (42.8) 257.4 (37.3) 75 (167.0) 2272.2 (329.5)
7 (44.8) 269.8 (39.1) 80 (176.0) 2544.0 (369.0)
8 (46.4) 282.9 (41.0) - -

M201 2014.01
4.1.1-15 Heating, Ventilation and Air Conditioning 4.1.1-15
Refrigeration System Leakage Test The access ports are protected by seal caps.
If you doubt that the system has a refrigerant Make sure that all caps are not lost or loose.
leakage, test it. You also should perform a Correct cap must be used for every port.
leakage test when your repair involves the Evaporator Core Test
pipelines or joints. The leakage usually appears
A leakage of evaporator core is hard to detect.
at the refrigerant joints or interfaces. The faults
Test the evaporator core according to the
leading to a leakage are usually as follows:
following procedure:
• Torque is not appropriate.
1. Set the blower speed at the highest and keep
• Seal ring is damaged. it working for 15 minutes.
• Seal ring has dust or fiber on it. 2. Turn off the blower.
General Test Method 3. Wait for 10 minutes.
1. Inspect along the entire pipelines of 4. Remove the blower motor speed control
refrigeration system using the electronic leak module.
detector.
5. Insert the leak detector probe as near the
CAUTION: The electronic leak detector is evaporator core as possible. The leak
sensitive to front windshield washing detector will give continuous alarm when it
liquid, solvent, cleaning agent and some detects a leakage.
vehicle adhesives. The surface must be
cleaned to ensure correct reading. Make Compressor Shaft Seal Test
sure that all surfaces are dry to avoid 1. Use compressed air from workshop to blow
damage to the leak detector. the rear part of compressor and the front part
of compressor clutch/ pulley for at least 15 s.
2. Move at a speed of 25 ~ 50 mm/s and detect
each joint in a full circle. 2. Wait for 1 ~ 2 minutes.
3. The detector tip is less than 6 mm away from 3. Detect the front part of pulley. The leak
the surface. detector will give continuous alarm when it
detects a leakage.
4. Do not block the gas inlet.
5. If a leakage is detected, the alarm changes to A/C Refrigerant Recycling and Filling
continuous alarm instead of 1 ~ 2 times per The refrigerant recovery filling machine can
second. Adjust the balance control to keep complete the discharging, draining and refilling of
the alarm at 1 ~ 2 times per second. A/C system at one connection. Filter the
6. Inspect all the following items even if one refrigerant during the recycling and draining to
leakage is detected: ensure the refrigerant filled in the A/C system
clean and dry.
• Inlet and outlet of evaporator
• Inlet and outlet of condenser
• Brazing and electric welding parts
• Damaged components
• Hose joint
• Front and rear covers of compressor
• All joints and interfaces
• Access ports/valves test

M4101007

M201 2014.01
4.1.1-16 Heating, Ventilation and Air Conditioning 4.1.1-16
WARNING: Do refrigerant-relative work in 11. If the pressure indicated by manometer in the
drafty environment. Avoid inhaling and low-pressure side is not 0, it means that some
sucking in the A/C refrigerant 134a refrigerant remains in system. Recover the
(Tetrafluoroethane) and refrigerant oil refrigerant residual. Repeat this process until
vapor or smog. The eyes, nose and the system pressure maintains 0 for 2
pharyngeal will be irritated if getting in minutes.
touch with them. Operate in the area with
good ventilation. Use repair device (HFC-
Filling
134a regeneration device) authenticated to CAUTION: Verify that there is no leakage
meet the requirement of the SAE (Society in the A/C system before filling. Drain a
of Automotive Engineers) to remove the little refrigerant oil in the A/C system when
HFC-134a in A/C system. The work area recycling the refrigerant. Make sure to
must be ventilated before going on with compensate for the lost refrigerant oil
the repair if the system has an accidental when filling the A/C system. Do not
drain. Further information about health overfill it with refrigerant. Otherwise the
and safety can be acquired from the compressor pressure will be excessively
refrigerant and refrigerant oil high, causing the noise of compressor
manufactures. and the fault of A/C system. Vacuumize the
system before refilling it with refrigerant.
Refrigerant Recycling
1. Connect high pressure side hose with quick 1. Connect the valve on the low-pressure side of
joint to the high-pressure side joint of vehicle compressor.
A/C system. 2. Connect the valve on the high-pressure side
2. Open high-pressure side joint valve. of compressor.

3. Connect low-pressure side hose with quick

joint to the low-pressure side joint of vehicle
A/C system.
4. Open low-pressure side joint valve.
5. Inspect manometer on the high-pressure side
and low-pressure side in the control panel of
refrigerant recovery filling machine to ensure
there is pressure in the system. If there is no
pressure, it indicates there is no recyclable
refrigerant in the system. M4101008

6. Open the valves on the high-pressure and

3. Connect the manometer filling pipe to the
low-pressure sides.
vacuum pump and vacuumize with the
7. Connect the refrigerant recovery filling vacuum pump.
machine to a suitable power outlet.
8. Switch on the main power switch.
9. Start the recovery process. Please refer to
the operation manual from manufacturer, try
to have a detailed knowledge of how to use
the refrigerant recovery filling machine.
10. Inspect the manometer in the low-pressure
side of control panel. If the pressure in the A/
C system is 0, it means the recovery process
is finished.

M201 2014.01
4.1.1-17 Heating, Ventilation and Air Conditioning 4.1.1-17
4 Open the low-pressure manual valve of
manometer and fill the refrigerant to A/C
system until there is no refrigerant flowing
into the system, and then close the manual
valve.
5 Start the engine and make the compressor
operate.
6 Open the low-pressure manual valve of
manometer and continue to fill the refrigerant
to the A/C system until the manometer
M4101009
reading reaches the specified condition, and
4. Close the high-pressure and low-pressure close the low-pressure manual valve.
manual valves of manometer after the 7 Disconnect the valve on the low-pressure
vacuum pump works for 10 minutes. side of compressor.
5. Wait for 10 minutes to inspect whether there 8 Disconnect the valve on the high-pressure
is a change in the vacuum degree of A/C side of compressor.
system. If there is a change, the A/C system
may have leakage faults, and should be
inspected and repaired. If there is no change,
the refrigerant oil should be filled.
6. Perform the vacuum pumping again for 20
minutes after filling an appropriate amount of
refrigerant oil, and close the high-pressure
and low-pressure manual valves of
manometer.
7. Fill the refrigerant.
1 Close the high-pressure and low-pressure
valves on the control panel of refrigerant
recovery filling machine.
2 Connect the manometer filling pipe to the
inverted refrigerant reservoir.

M4101010

3 Open the refrigerant reservoir valve and

loosen the manometer filling hose until
refrigerant gas discharging for 1 ~ 2 seconds,
and then tighten the filling pipe.

M201 2014.01
4.1.1-18 Heating, Ventilation and Air Conditioning 4.1.1-18

Symptom Diagnosis and Testing

General Equipment

Digital multimeter
Refrigerant recovery filling machine

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious mechanical or
electrical damage.
Visual Inspection Chart

Mechanical Electrical
• Circuit
• Compressor drive belt
• Refrigerant pressure
• Compressor switch
• A/C high and low • Blower and speed
pressure pipe control module
• Condenser • Electric fan
• Evaporator • Evaporator
temperature sensor
• Air channel
• ECM circuit
• HVAC
• ECM

3. Inspect the A/C system pipes which is

accessible or visible, to see if there is a leak
in the A/C system.
4. If an obvious cause for an observed or
reported concern has been found, solve the
fault before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
4.1.1-19 Heating, Ventilation and Air Conditioning 4.1.1-19

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and repair it in order of the
following table.

Symptom Possible Causes Solutions

• A/C system pressure does not Refer to: Diagnosis Procedure
meet the standard for Insufficient A/C
• Poor condenser heat dissipation Cooling (4.1.1 Heating,
Ventilation and Air
• Accessory drive belt slippage
Conditioning,
Insufficient refrigerant of • Clutch slippage Symptom Diagnosis
A/C • Pipes leakage and Testing).
• Blower fault
• Temperature vent fault
• Vent blockage or leakage
• Compressor worn
• Heater pipe Refer to: Diagnosis Procedure
• Heater water tank for Insufficient
Heating of A/C (4.1.1
• Blower
Heating, Ventilation
Insufficient heating of A/C • Temperature vent and Air Conditioning,
• Vent channel blockage or leakage Symptom Diagnosis
and Testing).
• Heater valve
• Engine

Refer to: Diagnosis Procedure

• Circuit
for Blower Fault (4.1.1
• Blower speed control module Heating, Ventilation
Blower fault
• Air volume control switch and Air Conditioning,
Symptom Diagnosis
• Blower
and Testing).
• Circuit Refer to: Diagnosis Procedure
• A/C system pressure low for A/C Compressor
Clutch Fault (4.1.1
• Pipe
Heating, Ventilation
• Refrigerant pressure switch and Air Conditioning,
A/C compressor clutch fault
• A/C switch Symptom Diagnosis
and Testing ).
• A/C relay
• Compressor temperature sensor
• ECM fault

M201 2014.01
4.1.1-20 Heating, Ventilation and Air Conditioning 4.1.1-20

Symptom Possible Causes Solutions

• Refrigerant pressure switch
indicates a signal which means • Repair the refrigerant pressure switch
the pressure in A/C does not wiring harness.
Signal abnormal of meet standard value
• Replace the refrigerant pressure switch.
refrigerant pressure switch
• Refrigerant pressure switch
• Inspect and repair ECM, replace when
wiring harness fault
necessary.
• ECM fault
• Drain the excessive refrigerant.
• Repair the fault of poor vehicle radiating.
• High pressure of A/C is over • Repair the fault of improper engine
3.2 MPa working.
• Inspect and repair the fault of pipes
Abnormal refrigerant
blockage inside the A/C system.
pressure
• Refill the refrigerant.
• Inspect and repair the fault of A/C
• Low pressure of A/C is below
system leakage.
0.2 MPa
• Inspect and repair the fault of pipes
blockage inside the A/C system.
• Connection fault between drain
pipe and HVAC assembly
• Inspect and repair the drain pipe.
Water leak from the A/C • Connection fault between drain
pipe and vehicle body • Replace the drain pipe.

• Drain pipe blockage

Blower cannot send the air
out under a high
• Thermal protection of speed • Replace the blower speed control
temperature, and can
control module module.
recover after lowering the
temperature and restarting

Refer to: Diagnosis Procedure

for Condenser Fan
• A/C switch
Constantly Running
Condenser fan constantly • Circuit (4.1.1 Heating,
runs • Relay Ventilation and Air
Conditioning,
• ECM fault
Symptom Diagnosis
and Testing).

• Fuse
Refer to: Diagnosis Procedure
for Condenser Fan Not
• Circuit Running (4.1.1
Condenser fan does not run • Relay Heating, Ventilation
• Electric fan and Air Conditioning,
Symptom Diagnosis
• ECM fault
and Testing ).

M201 2014.01
4.1.1-21 Heating, Ventilation and Air Conditioning 4.1.1-21

Diagnosis Procedure for Insufficient A/C Cooling

Insufficient A/C Cooling

General inspection

Is the fault Yes

confirmed

No

Inspect condenser fuse and

relay

Yes
Is the fault
confirmed

No

Measure air temperature at A/C

outlet vent
Inspect working pressure of
refrigerant

Is the fault Yes

confirmed

No

Inspect whether fan has high/low

speed when A/C is operating

Is the fault Yes

confirmed
Yes
Is the fault
No confirmed
Inspect refrigerant pressure
switch No
Inspect circuit between refrigerant
pressure switch and A/C switch Inspect evaporator
Inspect circuit between refrigerant temperature sensor
pressure switch and ECM
Inspect refrigerant pressure
switch grounding
Inspect inside/outside circulation
operation condition
End

M201 2014.01
4.1.1-22 Heating, Ventilation and Air Conditioning 4.1.1-22

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the condenser cleaness.
B. Inspect whether the fan blade is damaged.
C. Inspect the tension of A/C compressor belt.
D. Inspect the cleaness of A/C inlet vent.
E. Inspect whether the engine coolant temperature is
normal.
Is the result normal?
Yes
Go to step 2.
No
Clean the condenser, adjust the tension of
compressor belt, replace the fan blade, clean the A/
C inlet vent, and inspect the engine cooling system
when necessary.

2. Inspect condenser fuse and relay

A. Turn the ignition switch to "LOCK".
B. Inspect the condenser fan fuse IF04.
Fuse rated capacity: 20 A
C. Inspect the condenser fan relay IR04.
Are the fuse and relay normal?
Yes
Go to step 3.
No
Inspect and repair the fuse or relay circuit, and
replace the fuse or relay.

3. Measure air temperature at A/C outlet vent

A. Start the engine, and run it at 2000 rpm.
B. Turn air volume control switch and move the inside/
outside circulation control knob to the inside
circulation.
C. Turn the air volume to the medium speed and
measure the air temperature at A/C outlet vent.
Is the air temperature at A/C outlet vent normal?
Yes
The system is normal.
No
Go to step 4.

M201 2014.01
4.1.1-23 Heating, Ventilation and Air Conditioning 4.1.1-23

Test Conditions Details/Results/Actions

4. Inspect working pressure of refrigerant
A. Connect the A/C refrigerant pressure manometer
set to the high/low pressure pipes of A/C system,
and start the engine to run it at 2000 rpm and turn
on the A/C system, then measure the pressure on
the high-pressure and low-pressure sides.
Standard value: High pressure 1.4 ~ 1.75 MPa
Low pressure 0.25 ~ 0.35 MPa
Does the refrigerant pressure meet the standard?
Yes
Go to step 5.
No
Repair and adjust as below and make sure the
system is normal.
If the high pressure and low pressure are all too
high, drain the excessive refrigerant and refrigerant
oil. Replace with the refrigerant that conforms to
manufacturer's standard when necessary.
If the high pressure is higher but the low pressure is
lower than normal value, then clean A/C pipes, and
replace the expansion valve.
If the high pressure is lower but the low pressure is
higher than normal value, inspect and repair or
replace the A/C compressor.
If the high pressure and low pressure are all too
low, inspect and repair, replace the leaking
component of A/C system, and fill the refrigerant
and refrigerant oil as manufacturer's specified
standards.

M201 2014.01
4.1.1-24 Heating, Ventilation and Air Conditioning 4.1.1-24

Test Conditions Details/Results/Actions

5. Inspect whether fan has high/low speed when A/C is operating
A. Connect the A/C refrigerant pressure manometer
set to the high/low pressure pipes of A/C system,
and measure the pressure when the A/C is
operating.
B. Start the engine.
C. Turn the air volume control switch, press the A/C
switch, set the temperature control knob to cold air
and run the engine.
D. Inspect whether the A/C fan is operating at a low
speed when the A/C system pressure (high
pressure) is 1.25 ± 0.1 MPa.
E. Inspect whether the A/C fan is operating at a high
speed when the A/C system pressure (high
pressure) is 1.52 ± 0.1 MPa.
Is the result normal?
Yes
Go to step 11.
No
Go to step 6.

6. Inspect refrigerant pressure switch

A. Turn the ignition switch to "LOCK".
B. Disconnect the refrigerant pressure switch wiring
harness connector P09.
C. Replace the refrigerant pressure switch with a new
one and connect its wiring harness connector P09
properly.
Refer to: Tristate Pressure Switch (4.1.1
Heating, Ventilation and Air
Conditioning, Removal and
Installation).
D.Inspect the A/C fan is operating at a high speed.
Is the result normal?
Yes
Replace the refrigerant pressure switch.
No
Go to step 7.

M201 2014.01
4.1.1-25 Heating, Ventilation and Air Conditioning 4.1.1-25

Test Conditions Details/Results/Actions

7. Inspect circuit between refrigerant pressure switch and A/C switch
A. Turn the ignition switch to "LOCK".
B. Disconnect the refrigerant pressure switch wiring
harness connector P09.
C. Disconnect the A/C controller wiring harness
5 4 3 2 1 connector P26.
D. Measure the resistance between terminal 1 of
10 9 8 7 6 refrigerant pressure switch wiring harness
connector P09 and terminal 2 of A/C controller
wiring harness connector P26.
P26
E. Measure the resistance between terminal 2 of
refrigerant pressure switch wiring harness
connector P09 and terminal 9 of A/C controller
wiring harness connector P26.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 8.
No
1 Inspect and repair the open circuit fault between
3 4 terminal 1 of refrigerant pressure switch wiring
2
harness connector P09 and terminal 2 of A/C
controller wiring harness connector P26.
P09
Inspect and repair the open circuit fault between
M4101045 terminal 2 of refrigerant pressure switch wiring
harness connector P09 and terminal 9 of A/C
controller wiring harness connector P26.

M201 2014.01
4.1.1-26 Heating, Ventilation and Air Conditioning 4.1.1-26

Test Conditions Details/Results/Actions

8. Inspect circuit between refrigerant pressure switch and ECM
A. Turn the ignition switch to "LOCK" and disconnect
E18 the negative battery cable.
B. Disconnect the refrigerant pressure switch wiring
harness connector P09 and ECM wiring harness
1 2 9 22
connector E18.
3 4 23 36
C. Measure the resistance between terminal 4 of
5 6 37 50 refrigerant pressure switch wiring harness
connector P09 and terminal 10 of ECM wiring
7 8 51 64
harness connector E18.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 9.
No
Inspect and repair the open circuit fault between
P09
terminal 4 of refrigerant pressure switch wiring
harness connector P09 and terminal 10 of ECM
1 wiring harness connector E18.
3 4
2

M4101046

9. Inspect refrigerant pressure switch grounding

A. Turn the ignition switch to "LOCK".
B. Disconnect the refrigerant pressure switch wiring
harness connector P09.
C. Measure the resistance between terminal 3 of
refrigerant pressure switch wiring harness
connector P09 and reliable grounding.
1 Standard resistance: less than 5 Ω
3 4
2 Is the resistance value normal?
Yes
P09
Refer to: Diagnosis Procedure for Electric
M4101047
Fan Not Running (3.1.4 Cooling
system, Symptom Diagnosis
and Testing).
No
Inspect and repair the open circuit fault between
terminal 3 of refrigerant pressure switch wiring
harness connector P09 and G105.

M201 2014.01
4.1.1-27 Heating, Ventilation and Air Conditioning 4.1.1-27

Test Conditions Details/Results/Actions

10.Inspect inside/outside circulation operation condition
A. Turn the air volume control switch and change the
inside/outside circulation mode setting.
Is the inside/outside circulation vent working
condition normal?
Yes
Go to step 11.
No
Repair and adjust as below and make sure the
system is normal.
Inspect the inside/outside circulation vent
mechanism, adjust or replace the inside/outside
circulation cables and mechanical device when
necessary.
Inspect the air channel, repair and replace the air
leaking channel.
Inspect the inside/outside circulation control knob
and replace when necessary.

11.Inspect evaporator temperature sensor

A. Inspect whether the evaporator temperature sensor
is installed as the manufacturer's specified
standards.
B. Inspect whether the evaporator is frosted when the
A/C is operating.
Is the result normal?
Yes
The system is normal.
No
Replace the evaporator temperature sensor
Install a new evaporator temperature sensor as the
manufacturer's specified standard position.
The system is normal.

M201 2014.01
4.1.1-28 Heating, Ventilation and Air Conditioning 4.1.1-28

Diagnosis Procedure for Insufficient Heating of A/C

Insufficient heating
of A/C

General inspection

Is the fault Yes

confirmed

No

Inspect engine
coolant temperature

No

Is the fault Yes

confirmed

Inspect temperature vent

working condition

Is the fault Yes

confirmed

No

Inspect inside/outside circulation

vent operation condition

End

M201 2014.01
4.1.1-29 Heating, Ventilation and Air Conditioning 4.1.1-29

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the engine coolant level.
B. Inspect the cleaness of A/C inlet vent.
Is it normal?
Yes
Go to step 2.
No
Fill the coolant.
Refer to: Coolant Level Inspection (3.1.4
Cooling System, General
Inspection).
2. Inspect engine coolant temperature
A. Inspect the engine coolant temperature.
Does the engine coolant temperature reach 83°C?
Yes
Go to step 3.
No
Repair and adjust as below and make sure the
system is normal.
Prolong the engine running time.
Inspect, repair and replace the thermostat.
Discharge the air in the cooling system.
Inspect, repair and adjust the engine operation
condition.

3. Inspect temperature vent working condition

A. Inspect the A/C temperature vent working
condition.
Is the working condition of temperature vent
normal?
Yes
Go to step 4.
No
Repair and adjust as below and make sure the
system is normal.
Inspect the temperature vent mechanism, adjust or
replace when necessary.
Inspect the air channel, repair and replace the air
leaking channel.

M201 2014.01
4.1.1-30 Heating, Ventilation and Air Conditioning 4.1.1-30

Test Conditions Details/Results/Actions

4. Inspect inside/outside circulation vent operation condition
A. Inspect the operation condition of A/C inside/
outside circulation vent.
Is the operation condition of inside/outside
circulation vent normal?
Yes
The system is normal.
No
Carry out the following repair and adjustment. Make
sure the system is normal.
Inspect inside/outside circulation vent mechanism,
adjust or replace when necessary.
Inspect the air channel, repair and replace the air
leaking channel.

M201 2014.01
4.1.1-31 Heating, Ventilation and Air Conditioning 4.1.1-31

Diagnosis Procedure for Blower Fault

Blower fault

General inspection
(Inspect wiring harness
connectors related with blower
motor)

Is the fault Yes

confirmed

No

Inspect blower
Inspect blower power supply

Is the fault Yes

confirmed

No

Inspect blower fuse and relay

Inspect circuit between blower

and A/C controller
Is the fault Yes
confirmed

No Is the fault Yes

confirmed
Inspect relay power supply
No

Inspect circuit between governor

resistor and A/C controller
Is the fault Yes
confirmed

No Is the fault Yes

confirmed
Inspect relay grounding
No

Inspect A/C controller

grounding

End

M201 2014.01
4.1.1-32 Heating, Ventilation and Air Conditioning 4.1.1-32

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related with
the blower motor for damage, poor contact, aging
or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect blower
A. Turn the ignition switch to "LOCK".
B. Disconnect the blower motor wiring harness
connector P28.
C. Measure the voltage between terminal 1 and 2 of
blower motor wiring connector P28.
1 Standard voltage: 12 ~ 14 V
2 Is the voltage value normal?
Yes
P28
Replace the blower motor.
No
M4101048
Go to step 3.

3. Inspect blower power supply

A. Turn the ignition switch to "LOCK".
B. Disconnect the blower motor wiring harness
connector P28.
C. Measure the voltage between terminal 1 of blower
motor wiring harness connector P28 and reliable
grounding.
1 Standard voltage: 12 ~ 14 V
Is the voltage value normal?
2
Yes
P28 Go to step 7.
M4101049
No
Go to step 4.

M201 2014.01
4.1.1-33 Heating, Ventilation and Air Conditioning 4.1.1-33

Test Conditions Details/Results/Actions

4. Inspect blower fuse and relay
A. Inspect the instrument panel fuse box fuse IF07
and relay IR02.
Fuse rated capacity: 10 A
Is the result normal?
Yes
Go to step 5.
No
Inspect and repair the fuse or relay circuit, replace
the fuse with rated capacity or relay.

5. Inspect relay power supply

A. Remove the instrument panel fuse box relay IR02.
B. Measure the voltage between terminal 53 of relay
IR02 and reliable grounding.
P40
C. Measure the voltage between terminal 52 of relay
IR02 and reliable grounding.
Standard voltage: 12 ~ 14 V
IR02 Is the voltage value normal?
53
52 Yes
Go to step 6.
No
Inspect and repair the short circuit fault between
terminal 53 of relay IR02 and terminal 34 of fuse
IF17.
Inspect and repair the short circuit fault between
terminal 52 of relay IR02 and terminal 52 of fuse
IF26.

M4101050

M201 2014.01
4.1.1-34 Heating, Ventilation and Air Conditioning 4.1.1-34

Test Conditions Details/Results/Actions

6. Inspect relay grounding
A. Remove the instrument panel fuse box relay IR02.
B. Measure the resistance between terminal 50 of
relay IR02 and reliable grounding.
P40 Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
IR02 50
Inspect and repair the short circuit fault between
terminal 54 of relay IR02 and terminal 1 of blower
wiring harness connector P28.
No
Inspect and repair the short circuit fault between
terminal 50 of relay IR02 and grounding G103.

M4101051

7. Inspect circuit between blower and A/C controller

A. Turn the ignition switch to "LOCK".
B. Disconnect the blower motor wiring harness
connetor P28 and A/C controller wiring harness
1 connector P26.
C. Measure the resistance between terminal 2 of
2 blower motor wiring harness connector P28 and
terminal 6 of A/C controller wiring harness
P28 connector P26.
Standard resistance: less than 5 Ω
Is the resistance value normal?

5 4 3 2 1 Yes
Go to step 8.
10 9 8 7 6 No
P26 Inspect and repair the short circuit fault between
terminal 2 of blower motor wiring harness connector
M4101052 P28 and terminal 6 of A/C controller wiring harness
connector P26.

M201 2014.01
4.1.1-35 Heating, Ventilation and Air Conditioning 4.1.1-35

Test Conditions Details/Results/Actions

8. Inspect circuit between governor resistor and A/C controller
A. Turn the ignition switch to "LOCK".
B. Disconnect the governor resistor wiring harness
P38 connetor P38 and A/C controller wiring harness
connector P26.
2 1 C. Measure the resistance between terminals 1, 2, 4 of
governor resistor wiring harness connector P38 and
4 3 terminals 7, 8, 6 of A/C controller wiring harness
connector P26.
P26 Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
5 4 3 2 1
Go to step 9.
10 9 8 7 6 No
Inspect and repair the short circuit fault between
terminals 1, 2, 4 of governor resistor wiring harness
M4101053 connector P38 and terminals 7, 8, 6 of A/C
controller wiring harness connector P26.

9. Inspect A/C controller grounding

A. Turn the ignition switch to "LOCK".
B. Disconnect the A/C controller wiring harness
connector P26.
C. Measure the resistance between terminal 10 of A/C
controller wiring harness connector P26 and
reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
P26
Yes
Replace the A/C controller.
5 4 3 2 1 Refer to: A/C Controller (4.1.1 Heating,
Ventilation and Air Conditioning,
10 9 8 7 6
Removal and Installation).
No
M4101054 Inspect and repair the short circuit fault between
terminal 10 of A/C controller wiring harness
connector P26 and grounding G106.

M201 2014.01
4.1.1-36 Heating, Ventilation and Air Conditioning 4.1.1-36

Diagnosis Procedure for A/C Compressor Clutch Fault

A/C compressor
clutch fault

General inspection
(Inspect wiring harness
connectors related with
compressor)

Is the fault Yes

confirmed

No
Inspect fuse and relay
Inspect relay power supply
Inspect relay grounding
Inspect compressor power
supply

Is the fault Yes

confirmed

No
Inspect A/C switch power supply
Inspect A/C switch circuit
Inspect A/C switch grounding

Is the fault Yes

confirmed

No
Inspect circuit between tristate
pressure switch and ECM
Inspect circuit between tristate
pressure switch and A/C
controller
Inspect tristate pressure switch
grounding
Inspect circuit between Is the fault Yes
evaporator thermistor and ECM confirmed

No
Is the fault Yes
confirmed Inspect compressor
No
Inspect tristate pressure switch
Inspect evaporator thermistor
Inspect A/C controller

End

M201 2014.01
4.1.1-37 Heating, Ventilation and Air Conditioning 4.1.1-37

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related with
the compressor for damage, poor contact, aging or
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect fuse and relay

A. Inspect the instrument panel fuse box fuse IF18
and relay IR01.
Fuse rated capacity: 10 A
Is the result normal?
Yes
Go to step 3.
No
Inspect and repair the fuse or relay circuit, replace
the fuse with rated capacity or relay.

3. Inspect relay power supply

A. Remove instrument panel fuse box relay IR01.
B. Measure the resistance between terminals 47, 48 of
relay IR01 and reliable grounding.
P40
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
IR01
Go to step 4.
48
47
No
Repair the relay power supply circuit.

M4101055

M201 2014.01
4.1.1-38 Heating, Ventilation and Air Conditioning 4.1.1-38

Test Conditions Details/Results/Actions

4. Inspect relay grounding
A. Turn the ignition switch to "LOCK".
P40 B. Remove the instrument panel fuse box relay IR01
and disconnect the ECM wiring harness connector
E18.
C. Measure the resistance between terminal 45 of
IR01 45 instrument panel fuse box relay IR01 and terminal
61 of ECM wiring harness connector E18.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 5.
No
Inspect and repair the short circuit fault between
terminal 45 of instrument panel fuse box relay IR01
and terminal 61 of ECM wiring harness connector
E18.

1 2 9 22

3 4 23 36

5 6 37 50

7 8 51 61 64

E18
M4101056

M201 2014.01
4.1.1-39 Heating, Ventilation and Air Conditioning 4.1.1-39

Test Conditions Details/Results/Actions

5. Inspect compressor power supply
A. Turn the ignition switch to "LOCK".
B. Remove the instrument panel fuse box relay IR01
P40 and disconnect the compressor wiring harness
connector P02.
C. Measure the resistance between terminal 49 of
instrument panel fuse box relay IR01 and terminal 1
IR01 of compressor wiring harness connector P02.
49
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 6.
No
Inspect and repair the short circuit fault between
terminal 49 of instrument panel fuse box relay IR01
and terminal 1 of compressor wiring harness
connector P02.

P02

M4101057

6. Inspect A/C switch power supply

A. Disconnect the A/C controller wiring harness
connector P26.
B. Turn the ignition switch to "ON".
C. Measure the voltage between terminal 4 of A/C
controller wiring harness connector P26 and
reliable grounding.

5 4 3 2 1 Standard voltage: 12 ~ 14 V
Is the voltage value normal?
10 9 8 7 6 Yes
P26 Go to step 7.
M4101058
No
Inspect and repair the short circuit fault between
terminal 4 of A/C controller wiring harness
connector P26 and terminal 52 of instrument panel
fuse box fuse IF26.

M201 2014.01
4.1.1-40 Heating, Ventilation and Air Conditioning 4.1.1-40

Test Conditions Details/Results/Actions

7. Inspect A/C switch circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the A/C controller wiring harness
connector P26.
C. Measure the resistance between terminal 3 and 9
of A/C controller wiring harness connector P26.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
5 4 3 2 1 Go to step 8.
No
10 9 8 7 6
Inspect and repair the open circuit fault between
P26 terminal 3 and 9 of A/C controller wiring harness
connector P26.

M4101059

8. Inspect A/C switch grounding

A. Turn the ignition switch to "LOCK".
B. Disconnect the A/C controller wiring harness
connector P26.
C. Measure the resistance between terminal 10 of A/C
controller wiring harness connector P26 and
reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
P26
Yes
Go to step 9.
5 4 3 2 1 No
Inspect and repair the open circuit fault between
10 9 8 7 6 terminal 10 of A/C controller wiring harness
connector P26 and grounding G106.

M4101054

M201 2014.01
4.1.1-41 Heating, Ventilation and Air Conditioning 4.1.1-41

Test Conditions Details/Results/Actions

9. Inspect circuit between tristate pressure switch and ECM
A. Turn the ignition switch to "LOCK".
P09
B. Disconnect the tristate pressure switch wiring
harness connector P09 and ECM wiring harness
1 connector E18.
3 4
2 C. Measure the resistance between terminal 4 of
tristate pressure switch wiring harness connector
P09 and terminal 10 of ECM wiring harness
connector E18.
Standard resistance: less than 5 Ω
Is the resistance value normal?
1 2 9 10 22
Yes
3 4 23 36

5 6 37 50 Go to step 10.
7 8 51 64 No
Measure the open circuit fault between terminal 4 of
E18 tristate pressure switch wiring harness connector
M4101060 P09 and the terminal 10 of ECM wiring harness
connector E18.

10.Inspect circuit between tristate pressure switch and A/C controller

A. Turn the ignition switch to "LOCK".
B. Disconnect the tristate pressure switch wiring
harness connector P09 and A/C controller wiring
harness connector P26.
C. Measure the resistance between terminals 1, 2 of
tristate pressure switch wiring harness connector
P09 and terminals 3, 9 of A/C controller wiring
harness connector P26.
Standard resistance: less than 5 Ω
5 4 3 2 1 Is the resistance value normal?
1
3 4 Yes
2 10 9 8 7 6
Go to step 11.
P26 No
P09
Inspect and repair the open circuit fault between
terminals 1, 2 of tristate pressure switch wiring
M4101061 harness connector P09 and the terminals 3, 9 of A/
C controller wiring harness connector P26.

M201 2014.01
4.1.1-42 Heating, Ventilation and Air Conditioning 4.1.1-42

Test Conditions Details/Results/Actions

11.Inspect tristate pressure switch grounding
A. Turn the ignition switch to "LOCK".
B. Disconnect the tristate pressure switch wiring
harness connector P09.
C. Measure the resistance between terminal 3 of
tristate pressure switch wiring harness connector
P09 and reliable grounding.
Standard resistance: less than 5 Ω
1
3 4 Is the resistance value normal?
2
Yes
P09 Go to step 12.
M4101062
No
Inspect and repair the open circuit fault between
terminal 3 of tristate pressure switch wiring harness
connector P09 and grounding G105.

12.Inspect circuit between evaporator thermistor and ECM

A. Turn the ignition switch to "LOCK".
B. Disconnect the evaporator thermistor wiring
E18
harness connector P39 and ECM wiring harness
P39 connector E18.
1 2 9 13 22
C. Measure the resistance between terminals 1, 2 of
3 4 23 36
evaporator thermistor wiring harness connector
2 1 5 6 37 40 50 P39 and terminals 40, 13 of ECM wiring harness
7 8 51 64 connector E18.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 13.
No
Inspect and repair the open circuit fault between
terminals 1, 2 of evaporator thermistor wiring
M4101063 harness connector P39 and terminals 40, 13 of
ECM wiring harness connector E18.

M201 2014.01
4.1.1-43 Heating, Ventilation and Air Conditioning 4.1.1-43

Test Conditions Details/Results/Actions

13.Inspect tristate pressure switch
A. Replace the tristate pressure switch with a good
one.
Is the system normal?
Yes
Replace the tristate pressure switch.
Refer to: Tristate Pressure Switch (4.1.1
Heating, Ventilation and Air
Conditioning, Removal and
Installation).
No
Go to step 14.

14.Inspect evaporator thermistor

A. Replace the evaporator thermistor with a good one.
Is the system normal?
Yes
Replace the evaporator thermistor.
No
Go to step 15.

15.Inspect A/C controller

A. Replace the A/C controller with a good one.
Is the system normal?
Yes
Replace the A/C controller.
Refer to: A/C Controller (4.1.1 Heating,
Ventilation and Air Conditioning,
Removal and Installation).
No
Go to step 16.

M201 2014.01
4.1.1-44 Heating, Ventilation and Air Conditioning 4.1.1-44

Test Conditions Details/Results/Actions

16.Inspect compressor
A. Replace the compressor with a good one.
Is the system normal?
Yes
Replace the compressor.
Refer to: Compressor (4.1.1 Heating,
Ventilation and Air Conditioning,
Removal and Installation).
No
Replace the ECM.
Refer to: Engine Control Module (3.1.12
Electronic Control System - M7,
Removal and Installation).

M201 2014.01
4.1.1-45 Heating, Ventilation and Air Conditioning 4.1.1-45

Diagnosis Procedure for Condenser Fan Constantly Running

Test Conditions Details/Results/Actions
1. General inspection
A. Inspect the wiring harness connectors related with
the condenser fan for damage, poor contact, aging
or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect relay
A. Remove the instrument panel fuse box relay IR04.
Is the system normal?
Yes
Replace the instrument panel fuse box relay IR04.
No
Inspect and repair the short circuit fault between
terminal 1 of condenser fan wiring harness
connector P13 and the battery power supply.

M201 2014.01
4.1.1-46 Heating, Ventilation and Air Conditioning 4.1.1-46

Diagnosis Procedure for Condenser Fan Not Running

Condenser fan not

running

General inspection
(Inspect wiring harness connectors
related with condenser fan)

Is the fault Yes

confirmed

No

Inspect fuse and relay

Is the fault Yes

confirmed

No

Inspect relay power supply

Is the fault Yes

confirmed

No

Inspect relay grounding

Is the fault Yes

confirmed

No Inspect condenser fan grounding

Inspect condenser fan power

supply
Is the fault Yes
confirmed

Is the fault No
confirmed
Inspect condenser fan
Yes
No

End

M201 2014.01
4.1.1-47 Heating, Ventilation and Air Conditioning 4.1.1-47

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related with
the condenser fan for damage, poor contact, aging
or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect fuse and relay

A. Inspect the instrument panel fuse box fuse IF04
and relay IR04.
Fuse rated capacity: 20 A
Is the result normal?
Yes
Go to step 3.
No
Inspect and repair the fuse or relay circuit, replace
the fuse with rated capacity or relay.

3. Inspect relay power supply

A. Remove the instrument panel fuse box relay IR04.
B. Measure the voltage between terminal 63 of relay
P40 IR04 and reliable grounding.
C. Measure the voltage between terminal 62 of relay
IR04 and reliable grounding.
Standard voltage: 12 ~ 14 V
IR04

63 Is the voltage value normal?

62
Yes
Go to step 4.
No
Inspect and repair the short circuit fault between
terminal 63 of relay IR04 and terminal 8 of fuse
IF04.
Inspect and repair the short circuit fault between
terminal 62 of relay IR04 and terminal 69 of relay
IR05.

M4101064

M201 2014.01
4.1.1-48 Heating, Ventilation and Air Conditioning 4.1.1-48

Test Conditions Details/Results/Actions

4. Inspect relay grounding
A. Turn the ignition switch to "LOCK".
P40 B. Remove the instrument panel fuse box relay IR04
and disconnect the ECM wiring harness connector
E18.
C. Measure the resistance between terminal 60 of
IR04 60 instrument panel fuse box relay IR04 and terminal
62 of ECM wiring harness connector E18.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 5.
No
Inspect and repair the short circuit fault between
terminal 60 of instrument panel fuse box relay IR04
and terminal 62 of ECM wiring harness connector
E18.

1 2 9 22

3 4 23 36

5 6 37 50

7 8 51 62 64

E18
M4101065

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4.1.1-49 Heating, Ventilation and Air Conditioning 4.1.1-49

Test Conditions Details/Results/Actions

5. Inspect condenser fan power supply
A. Turn the ignition switch to "LOCK".
B. Remove the instrument panel fuse box relay IR04
and disconnect the condenser fan wiring harness
connector P13.
P40 C. Measure the resistance between terminal 64 of
instrument panel fuse box relay IR04 and terminal 1
of condenser fan wiring harness connector P13.
Standard resistance: less than 5 Ω
IR04 Is the resistance value normal?
64
Yes
Go to step 6.
No
Inspect and repair the short circuit fault between
terminal 64 of instrument panel fuse box relay IR04
and terminal 1 of condenser fan wiring harness
connector P13.

2 1

P13

M4101066

6. Inspect condenser fan grounding

A. Turn the ignition switch to "LOCK".
B. Disconnect the condenser fan wiring harness
connector P13.
C. Measure the resistance between terminal 2 of
condenser fan wiring harness connector P13 and
reliable grounding.
Standard resistance: less than 5 Ω
2 1 Is the resistance value normal?
Yes
P13 Go to step 7.
M4101067
No
Inspect and repair the short circuit fault between
terminal 2 of condenser fan wiring harness
connector P13 and grounding G103.

M201 2014.01
4.1.1-50 Heating, Ventilation and Air Conditioning 4.1.1-50

Test Conditions Details/Results/Actions

7. Inspect condenser fan
A. Replace the condenser fan with a good one.
B. Disconnect the condenser fan wiring harness
connector P13.
Is the system normal?
Yes
Replace the condenser fan.
Refer to: Condenser Fan (3.1.4 Cooling
System, Removal and
Installation).
No
Replace the ECM.
Refer to: Engine Control Module (3.1.12
Electronic Control System - M7,
Removal and Installation).

M201 2014.01
4.1.1-51 Heating, Ventilation and Air Conditioning 4.1.1-51

Removal and Installation

Compressor Belt
Refer to: Accessory Drive Belt (3.1.2
Mechanical System, Removal
and Installation).
Compressor
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Recycle the refrigerant.

Refer to: Refrigerant Recycling and Filling
(4.1.1 Heating, Ventilation and Air
Conditioning, General
Inspection).

3. Remove the compressor drive belt.

Refer to: Accessory Drive Belt (3.1.2
Mechanical System, Removal
and Installation).
4. Disconnect the compressor wiring harness
connector (1). 1
5. Remove the retaining bolts (2) from No. 1
drain pipe and No. 1 suction pipe, and 2
disconnect the pipeline. ×2

Torque: 14 ~ 17 Nm
CAUTION: Make sure to use new seal
rings.

M4101011

6. Remove the compressor adjusting bolt.

Torque: 24 ~ 26 Nm

M4101012

M201 2014.01
4.1.1-52 Heating, Ventilation and Air Conditioning 4.1.1-52

7. Remove 2 retaining bolts from the

compressor.
Torque: 25 ~ 30 Nm

M4101013

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new seal
rings.

2. Fill the refrigerant.

Refer to: Refrigerant Recycling and Filling
(4.1.1 Heating, Ventilation and Air
Conditioning, General
Inspection).

M201 2014.01
4.1.1-53 Heating, Ventilation and Air Conditioning 4.1.1-53

Condenser
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Recycle the refrigerant.

Refer to: Refrigerant Recycling and Filling
(4.1.1 Heating, Ventilation and Air
Conditioning, General
Inspection).

3. Remove the front bumper.

Refer to: Front Bumper (5.1.7 Bumper,
Removal and Installation).
4. Remove 3 retaining screws from the radiator
left air dam, and remove the left air dam.

×3

M4101015

M201 2014.01
4.1.1-54 Heating, Ventilation and Air Conditioning 4.1.1-54

5. Remove 3 retaining screws from the radiator

right air dam, and remove the right air dam.

×3

M4101014

6. Remove 2 condenser retaining bolts.

Torque: 8 ~ 10 Nm

×2

M4101016

7. Remove the retaining bolt from the condenser

inlet pipe and disconnect the pipe.
Torque: 8 ~ 10 Nm
CAUTION: Make sure to use new seal
rings.

M4101017

M201 2014.01
4.1.1-55 Heating, Ventilation and Air Conditioning 4.1.1-55

8. Remove the retaining bolt from the condenser

outlet pipe and disconnect the pipe.
Torque: 8 ~ 10 Nm

M4101018

9. Remove the condenser.

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new seal
rings.

2. Fill the refrigerant.

Refer to: Refrigerant Recycling and Filling
(4.1.1 Heating, Ventilation and Air
Conditioning, General
Inspection).

M201 2014.01
4.1.1-56 Heating, Ventilation and Air Conditioning 4.1.1-56

Tristate Pressure Switch

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Recycle the refrigerant.

Refer to: Refrigerant Recycling and Filling
(4.1.1 Heating, Ventilation and Air
Conditioning, General
Inspection).

3. Remove the reservoir.

Refer to: Reservoir (3.1.4 Cooling System,
Removal and Installation).
4. Disconnect the tristate pressure switch wiring
harness connector (1).
5. Remove the tristate pressure switch (2).
1

M4101019

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new seal
rings.

2. Fill the refrigerant.

Refer to: Refrigerant Recycling and Filling
(4.1.1 Heating, Ventilation and Air
Conditioning, General
Inspection).

M201 2014.01
4.1.1-57 Heating, Ventilation and Air Conditioning 4.1.1-57

A/C Pipeline
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Recycle the refrigerant.

Refer to: Refrigerant Recycling and Filling
(4.1.1 Heating, Ventilation and Air
Conditioning, General
Inspection).
3. Disconnect the A/C pipeline from the
compressor.
• Loosen the connecting nut (1) between
1
No.1 suction pipe and compressor. 2
Torque: 14 ~ 17 Nm
• Loosen the connecting nut (2) between
No.1 discharge and compressor.
Torque: 14 ~ 17 Nm

M4101020

4. Loosen the connecting nut between No.1

drain pipe and condenser inlet pipe.

M4101021

5. Loosen 3 connecting nuts between suction

three-way pipe (with overhead evaporator).
×3

M4101022
+

M201 2014.01
4.1.1-58 Heating, Ventilation and Air Conditioning 4.1.1-58

6. Remove 2 retaining bolts between A/C

pipeline and vehicle body.

×2
M4101023

7. Loosen the connecting nut between front

evaporator inlet pipe and No.2 suction pipe
assembly (with overhead evaporator).

M4101024

8. Disconnect A/C pipeline from the expansion

valve.
1 Remove the retaining nut (1) from the front
evaporator inlet pipe.
2 Remove the retaining bolt (2) from the front 2
evaporator inlet and outlet pipes and
expansion valve and disconnect the pipes.
Torque: 8 ~ 10 Nm 1

M4101025

9. Remove the tristate pressure switch.

Refer to: Tristate Pressure Switch (4.1.1
Heating, Ventilation and Air
Conditioning, Removal and
Installation).

M201 2014.01
4.1.1-59 Heating, Ventilation and Air Conditioning 4.1.1-59
10. Loosen the connecting nut between front
evaporator inlet pipe and condenser outlet
pipe (with overhead evaporator).

M4101026

11. Remove the retaining nut from the condenser

outlet pipe.

M4101027

12. Remove the condenser.

Refer to: Condenser (4.1.1 Heating,
Ventilation and Air Conditioning,
Removal and Installation).

13. Remove the A/C pipeline.

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new seal
rings.

Refer to: Condenser (4.1.1 Heating,

Ventilation and Air Conditioning,
Removal and Installation).

2. Fill the refrigerant.

Refer to: Refrigerant Recycling and Filling
(4.1.1 Heating, Ventilation and Air
Conditioning, General
Inspection).

M201 2014.01
4.1.1-60 Heating, Ventilation and Air Conditioning 4.1.1-60

A/C Controller
Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the glove box.

Refer to: Instrument Panel (5.1.6
Instrument Panel and Console,
Removal and Installation).
3. Use the special tool to pry the center control
panel.
Special tool: CA501-002

1 1 USE
WITH

2 2
3 3

M4206020

4. Remove the A/C controller.

1 Remove 4 retaining screws from the A/C
controller.

A/C
×4

M5106006

M201 2014.01
4.1.1-61 Heating, Ventilation and Air Conditioning 4.1.1-61

2 Disconnect the A/C inside/outside

circulation control cable.

M5106007

3 Disconnect the A/C mode vent control cable

(1) and A/C temperature vent control cable
(2).

M5106008

4 Disconnect the wiring harness connector

and remove the A/C controller.

M5106009

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure that the cables are
installed in their original positions and the
vent is turned easily and flexibly when
installing the cables.

M201 2014.01
4.1.1-62 Heating, Ventilation and Air Conditioning 4.1.1-62

Governor Resistor
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Disconnect the governor resistor wiring

harness connector (1).
3. Remove 2 retaining bolts (2) from the
governor resistor.
1

×2 2

M4101028

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.1.1-63 Heating, Ventilation and Air Conditioning 4.1.1-63

HVAC Assembly
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Recycle the refrigerant.

Refer to: Refrigeration System Pressure
Inspection (4.1.1 Heating,
Ventilation and Air Conditioning,
General Inspection).

3. Drain the engine coolant.

Refer to: Coolant Draining and Filling
(3.1.4 Cooling System, General
Inspection).

4. Remove the instrument panel.

Refer to: Instrument Panel (5.1.6
Instrument Panel and Console,
Removal and Installation).
5. Disconnect the A/C pipeline from the
expansion valve.
1 Remove the retaining nut (1) from the front
evaporator inlet pipe.
2 Remove the retaining bolt (2) between front 2
evaporator inlet and outlet pipes and
expansion valve and disconnect the pipes.
Torque: 8 ~ 10 Nm 1

M4101025

6. Remove the hose of heater water pipeline.

M4101029

M201 2014.01
4.1.1-64 Heating, Ventilation and Air Conditioning 4.1.1-64

7. Disconnect the governor resistor wiring

harness connector (1).
8. Disconnect the evaporator temperature 2
sensor wiring harness connector (2).
1

M4101030

9. Disconnect the blower motor wiring harness

connector.

M4101031

10. Disconnect the A/C drain hose.

M4101032

11. Remove the retaining bolt and nut on the left

side of HVAC.

M4101033

M201 2014.01
4.1.1-65 Heating, Ventilation and Air Conditioning 4.1.1-65

12. Remove 2 retaining bolts on the center of

HVAC.

×2

M4101034

13. Remove the retaining nut on the right side of

HVAC.

M4101035

14. Remove the HVAC assembly.

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new seal rings.

M201 2014.01
4.1.1-66 Heating, Ventilation and Air Conditioning 4.1.1-66

Overhead Evaporator
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Recycle the refrigerant.

Refer to: Refrigeration System Pressure
Inspection (4.1.1 Heating,
Ventilation and Air Conditioning,
General Inspection).
3. Remove the evaporator left garnish cover.
1 Remove 2 retaining screws from the left
garnish cover. ×2

M4101036

2 Disengage 2 clips and remove the left

garnish cover.
Note: The left garnish cover clip position
is shown in the figure.
×2

M4101037

4. Remove the evaporator right garnish cover.

Note: Removal procedure of the right
garnish cover is the same with that
of the left garnish cover.

M201 2014.01
4.1.1-67 Heating, Ventilation and Air Conditioning 4.1.1-67
5. Disconnect the overhead evaporator left drain
pipe.

M4101038

6. Disconnect the overhead evaporator right

drain pipe.
Note: Removal procedure of the right
drain pipe is the same with that of
the left drain pipe.
7. Loosen the connecting nut (1) between
overhead evaporator inlet pipe and overhead
evaporator.
8. Loosen the connecting nut (2) between No.3 1
suction pipe and overhead evaporator.

M4101039

9. Disconnect the wiring harness connector

from the overhead evaporator assembly.

M4101040

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4.1.1-68 Heating, Ventilation and Air Conditioning 4.1.1-68

10. Remove 4 retaining bolts from the overhead

evaporator and remove the overhead
evaporator.

×4
M4101041

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new seal rings.

M201 2014.01
4.1.1-69 Heating, Ventilation and Air Conditioning 4.1.1-69

A/C Pipeline (with Overhead Evaporator)

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Recycle the refrigerant.

Refer to: Refrigerant Recycling and Filling
(4.1.1 Heating, Ventilation and Air
Conditioning, General
Inspection).
3. Loosen the connecting nut between three-
way pipe and No.2 suction pipe assembly.

M4101042

4. Loosen the connecting nut between front

evaporator inlet pipe and No.2 suction pipe
assembly.

M4101024

5. Remove the retaining bolt from the No.2

suction pipe assembly.

M4101043

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6. Loosen the connecting nut (1) between No.2

suction pipe assembly and No.3 suction pipe.
7. Loosen the connecting nut (2) between No.2
suction pipe assembly and overhead
evaporator inlet pipe.
2
1

M4101044

8. Remove the evaporator left garnish cover.

1 Remove 2 retaining screws from the left
garnish cover.
2 Disengage 2 clips and remove the left ×2
garnish cover.

M4101036

Note: The left garnish cover clip position

is shown in the figure.
×2

M4101037

9. Disconnect the overhead evaporator left drain

pipe.

M4101038

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4.1.1-71 Heating, Ventilation and Air Conditioning 4.1.1-71

10. Loosen the connecting nut (1) between

overhead evaporator inlet pipe and overhead
evaporator.
11. Loosen the connecting nut (2) between No.3 1
suction pipe and overhead evaporator.

M4101039

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new seal rings.

M201 2014.01
 Body Electrical

4.2 Body Electrical

2014 M201
Table of Contents Pages

4.2.1 Instrument Panel and Panel Illumination

Specifications ................................................................................................................................... 4.2.1-1
General Specifications.............................................................................................................. 4.2.1-1
Description and Operation ............................................................................................................... 4.2.1-2
System Overview...................................................................................................................... 4.2.1-2
Symptom Diagnosis and Testing...................................................................................................... 4.2.1-3
Inspection and Verification........................................................................................................ 4.2.1-3
Symptom Chart......................................................................................................................... 4.2.1-4
Diagnosis Procedure for Inoperative A/C Control Panel Illumination ....................................... 4.2.1-5
Diagnosis Procedure for Inoperative Radio Illumination........................................................... 4.2.1-8
Diagnosis Procedure for Inoperative Hazard Warning Lamp Switch Illumination................... 4.2.1-11

4.2.2 Instrument Cluster

Specifications ................................................................................................................................... 4.2.2-1
General Specifications.............................................................................................................. 4.2.2-1
Description and Operation ............................................................................................................... 4.2.2-2
System Overview...................................................................................................................... 4.2.2-2
Components Location View ...................................................................................................... 4.2.2-4
Instrument Cluster Terminal List ............................................................................................... 4.2.2-5
Symptom Diagnosis and Testing...................................................................................................... 4.2.2-7
Inspection and Verification........................................................................................................ 4.2.2-7
Symptom Chart......................................................................................................................... 4.2.2-8
Diagnosis Procedure for Inoperative Instrument Cluster Illumination Lamp with Ignition
Switch "ON" and Position Lamp Operating ............................................................................ 4.2.2-11
Diagnosis Procedure for Inoperative Left Turn Indicator When Turning Left.......................... 4.2.2-13
Diagnosis Procedure for Inoperative Right Turn Indicator When Turning Right ..................... 4.2.2-15
Diagnosis Procedure for Inoperative Front Fog Indicator with Ignition Switch "ON" and
Front Fog Lamp Operating ..................................................................................................... 4.2.2-16
Diagnosis Procedure for Inoperative Rear Fog Indicator with Ignition Switch "ON" and
Rear Fog Lamp Operating...................................................................................................... 4.2.2-18
Diagnosis Procedure for Inoperative High Beam Indicator with Ignition Switch "ON" and
High Beam Lamp Operating ................................................................................................... 4.2.2-20
Diagnosis Procedure for Inoperative Low Beam Indicator with Ignition Switch "ON" and
Low Beam Lamp Operating.................................................................................................... 4.2.2-22
Diagnosis Procedure for Abnormal Speedometer Indication.................................................. 4.2.2-23

M201 2014.01
 Body Electrical
Diagnosis Procedure for Abnormal Coolant Temperature Gauge Indication ..........................4.2.2-27
Diagnosis Procedure for Abnormal Fuel Gauge Indication.....................................................4.2.2-31
Diagnosis Procedure for Inoperative Engine Malfunction Indicator with Ignition Switch
"ON" ........................................................................................................................................4.2.2-34
Diagnosis Procedure for Inoperative Oil Pressure Warning Indicator with Ignition Switch
"ON" ........................................................................................................................................4.2.2-37
Diagnosis Procedure for Inoperative Charging Indicator with Ignition Switch "ON"................4.2.2-40
Diagnosis Procedure for Inoperative Parking Brake Indicator with Ignition Switch "ON"
and Vehicle Parked .................................................................................................................4.2.2-43
Diagnosis Procedure for Inoperative Seat Belt Unfasten Indicator with Ignition Switch
"ON" ........................................................................................................................................4.2.2-46
Removal and Installation ................................................................................................................4.2.2-50
Instrument Cluster ..................................................................................................................4.2.2-50

4.2.3 Horn
Description and Operation................................................................................................................4.2.3-1
System Overview ......................................................................................................................4.2.3-1
Components Location View ......................................................................................................4.2.3-1
Symptom Diagnosis and Testing ......................................................................................................4.2.3-3
Inspection and Verification........................................................................................................4.2.3-3
Symptom Chart .........................................................................................................................4.2.3-4
Diagnosis Procedure for Horn Constantly Working ..................................................................4.2.3-5
Diagnosis Procedure for Horn Not Working..............................................................................4.2.3-7
Removal and Installation ................................................................................................................4.2.3-10
Horn ........................................................................................................................................4.2.3-10

4.2.4 Cigarette Lighter

Specifications ...................................................................................................................................4.2.4-1
General Specifications ..............................................................................................................4.2.4-1
Description and Operation................................................................................................................4.2.4-2
System Overview ......................................................................................................................4.2.4-2
Components Location View ......................................................................................................4.2.4-2
Symptom Diagnosis and Testing ......................................................................................................4.2.4-3
Inspection and Verification........................................................................................................4.2.4-3
Symptom Chart .........................................................................................................................4.2.4-4
Diagnosis Procedure for Cigarette Lighter Fault.......................................................................4.2.4-5
Removal and Installation ..................................................................................................................4.2.4-8
Cigarette Lighter .......................................................................................................................4.2.4-8

M201 2014.01
 Body Electrical
4.2.5 Information and Entertainment System
Specifications ................................................................................................................................... 4.2.5-1
General Specifications.............................................................................................................. 4.2.5-1
Torque Specifications................................................................................................................ 4.2.5-1
Description and Operation ............................................................................................................... 4.2.5-2
System Overview...................................................................................................................... 4.2.5-2
Components Description .......................................................................................................... 4.2.5-2
Radio Terminal List ................................................................................................................... 4.2.5-3
Symptom Diagnosis and Testing...................................................................................................... 4.2.5-4
Inspection and Verification........................................................................................................ 4.2.5-4
Symptom Chart......................................................................................................................... 4.2.5-5
Diagnosis Procedure for Function Disabled and Switch on Fault............................................. 4.2.5-6
Diagnosis Procedure for No Sound .......................................................................................... 4.2.5-9
Removal and Installation................................................................................................................ 4.2.5-12
Radio ...................................................................................................................................... 4.2.5-12
Speaker .................................................................................................................................. 4.2.5-13
Antenna .................................................................................................................................. 4.2.5-14

4.2.6 Lighting System

Specifications ................................................................................................................................... 4.2.6-1
Component Specifications ........................................................................................................ 4.2.6-1
Description and Operation ............................................................................................................... 4.2.6-2
System Overview...................................................................................................................... 4.2.6-2
Components Location View ...................................................................................................... 4.2.6-3
General Inspection........................................................................................................................... 4.2.6-7
Test for Lighting Combination Switch ....................................................................................... 4.2.6-7
Symptom Diagnosis and Testing.................................................................................................... 4.2.6-12
Inspection and Verification...................................................................................................... 4.2.6-12
Symptom Chart....................................................................................................................... 4.2.6-13
Diagnosis Procedure for Brake Lamp Fault............................................................................ 4.2.6-17
Diagnosis Procedure for Single Brake Lamp Fault................................................................. 4.2.6-20
Diagnosis Procedure for Brake Lamp Constant ON ............................................................... 4.2.6-23
Diagnosis Procedure for Turn Lamp Fault.............................................................................. 4.2.6-25
Diagnosis Procedure for One or More Turn Lamps Fault....................................................... 4.2.6-32
Diagnosis Procedure for One or More Turn Lamps Constant ON (No Blinking) .................... 4.2.6-35
Diagnosis Procedure for Hazard Warning Lamp Fault ........................................................... 4.2.6-36
Diagnosis Procedure for Position Lamp Fault ........................................................................ 4.2.6-43

M201 2014.01
 Body Electrical
Diagnosis Procedure for Position Lamp Constant ON............................................................4.2.6-48
Diagnosis Procedure for Front Fog Lamp Fault......................................................................4.2.6-49
Diagnosis Procedure for Front Fog Lamp Constant ON .........................................................4.2.6-54
Diagnosis Procedure for Rear Fog Lamp Fault ......................................................................4.2.6-57
Diagnosis Procedure for Rear Fog Lamp Constant ON..........................................................4.2.6-60
Diagnosis Procedure for Backup Lamp Fault .........................................................................4.2.6-61
Diagnosis Procedure for Backup Lamp Constant ON.............................................................4.2.6-65
Diagnosis Procedure for Low Beam Lamp Fault ....................................................................4.2.6-66
Diagnosis Procedure for One Side Low Beam Lamp Fault ....................................................4.2.6-70
Diagnosis Procedure for Low Beam Lamp Constant ON........................................................4.2.6-73
Diagnosis Procedure for High Beam Lamp Fault ...................................................................4.2.6-74
Diagnosis Procedure for One Side High Beam Lamp Fault....................................................4.2.6-78
Diagnosis Procedure for High Beam Lamp Constant ON.......................................................4.2.6-81
Diagnosis Procedure for Overtaking Lamp Fault ....................................................................4.2.6-81
Diagnosis Procedure for License Plate Lamp Fault................................................................4.2.6-82
Diagnosis Procedure for Front Roof Lamp Fault ....................................................................4.2.6-85
Diagnosis Procedure for Reading Lamp Fault ........................................................................4.2.6-88
Removal and Installation ................................................................................................................4.2.6-89
Lighting Combination Switch ..................................................................................................4.2.6-89
Lamp Angle Control Switch ....................................................................................................4.2.6-91
Hazard Warning Lamp Switch ................................................................................................4.2.6-93
Headlamp ...............................................................................................................................4.2.6-95
Front Fog Lamp ......................................................................................................................4.2.6-97
Rear Combination Lamp .........................................................................................................4.2.6-98
Backup Lamp........................................................................................................................4.2.6-100
Rear Fog Lamp .....................................................................................................................4.2.6-102
License Plate Lamp ..............................................................................................................4.2.6-103
Front Roof Lamp...................................................................................................................4.2.6-105
Reading Lamp ......................................................................................................................4.2.6-106
High Mounted Stop Lamp .....................................................................................................4.2.6-108

4.2.7 Wiper and Washer

Specifications ...................................................................................................................................4.2.7-1
General Specifications ..............................................................................................................4.2.7-1
Torque Specifications................................................................................................................4.2.7-1
Description and Operation................................................................................................................4.2.7-2
System Overview ......................................................................................................................4.2.7-2
Components Location View ......................................................................................................4.2.7-3

M201 2014.01
 Body Electrical
General Inspection........................................................................................................................... 4.2.7-6
Test for Wiper Combination Switch........................................................................................... 4.2.7-6
Wiper Abnormal Noise Treatment ............................................................................................ 4.2.7-6
Symptom Diagnosis and Testing...................................................................................................... 4.2.7-7
Inspection and Verification........................................................................................................ 4.2.7-7
Symptom Chart......................................................................................................................... 4.2.7-8
Diagnosis Procedure for Front Windshield Wiper Failure....................................................... 4.2.7-11
Diagnosis Procedure for Front Windshield Wiper Constantly Running .................................. 4.2.7-16
Diagnosis Procedure for Inoperative Wiper in Low Speed Level............................................ 4.2.7-20
Diagnosis Procedure for Inoperative Wiper in High Speed Level........................................... 4.2.7-23
Diagnosis Procedure for Inoperative Wiper in Intermittent Level ........................................... 4.2.7-26
Diagnosis Procedure for Wiper Constantly Running in Intermittent Level .............................. 4.2.7-29
Diagnosis Procedure for Windshield is Dirty after Wiping ...................................................... 4.2.7-33
Diagnosis Procedure for Shaking Wiper During Operation .................................................... 4.2.7-36
Diagnosis Procedure for Abnormal Noise During Wiping....................................................... 4.2.7-39
Diagnosis Procedure for Front Wiper cannot Go Back to Initial Position ............................... 4.2.7-42
Diagnosis Procedure for Inaccurate Water Injection .............................................................. 4.2.7-46
Diagnosis Procedure for Washer Fault................................................................................... 4.2.7-48
Removal and Installation................................................................................................................ 4.2.7-52
Wiper Combination Switch ..................................................................................................... 4.2.7-52
Wiper Motor and Drive Arm .................................................................................................... 4.2.7-54
Washer Equipment ................................................................................................................. 4.2.7-58

4.2.8 Central Door Lock

Description and Operation ............................................................................................................... 4.2.8-1
System Overview...................................................................................................................... 4.2.8-1
Components Location View ...................................................................................................... 4.2.8-2
Symptom Diagnosis and Testing...................................................................................................... 4.2.8-3
Inspection and Verification........................................................................................................ 4.2.8-3
Symptom Chart......................................................................................................................... 4.2.8-4
Diagnosis Procedure for Central Lock Failure.......................................................................... 4.2.8-6
Diagnosis Procedure for Driver Side Door Central Lock Failure ............................................ 4.2.8-11
Diagnosis Procedure for Passenger Side Door Central Lock Failure..................................... 4.2.8-14
Diagnosis Procedure for Remote Controller Failure with Central Lock Normal...................... 4.2.8-17
Removal and Installation................................................................................................................ 4.2.8-18
Front Door Lock Latch ............................................................................................................ 4.2.8-18
Rear Door Lock Latch............................................................................................................. 4.2.8-18
Rear Door Fastener................................................................................................................ 4.2.8-18

M201 2014.01
 Body Electrical
4.2.9 Power Window
Specifications ...................................................................................................................................4.2.9-1
General Specifications ..............................................................................................................4.2.9-1
Torque Specifications................................................................................................................4.2.9-1
Description and Operation................................................................................................................4.2.9-2
System Overview ......................................................................................................................4.2.9-2
Components Location View ......................................................................................................4.2.9-3
Driver Side Power Window Switch Terminal View ....................................................................4.2.9-5
Passenger Side Power Window Switch Terminal View.............................................................4.2.9-6
Symptom Diagnosis and Testing ......................................................................................................4.2.9-7
Inspection and Verification........................................................................................................4.2.9-7
Symptom Chart .........................................................................................................................4.2.9-8
Diagnosis Procedure for All Power Windows Failing to Work.................................................4.2.9-10
Diagnosis Procedure for Driver Side Power Window Failing to Work.....................................4.2.9-13
Diagnosis Procedure for Passenger Side Power Window Failing to Work .............................4.2.9-16
Diagnosis Procedure for Inching Down Function Fault...........................................................4.2.9-22
Removal and Installation ................................................................................................................4.2.9-23
Power Window Switch ............................................................................................................4.2.9-23
Front Door Glass Regulator ....................................................................................................4.2.9-25
Rear Door Glass Regulator ....................................................................................................4.2.9-26

4.2.10 Body Control System

Description and Operation..............................................................................................................4.2.10-1
Overview .................................................................................................................................4.2.10-1
Components Location View ....................................................................................................4.2.10-2
Terminal View..........................................................................................................................4.2.10-3
Central Lock Controller Terminal Definition.............................................................................4.2.10-3
Removal and Installation ................................................................................................................4.2.10-4
Central Lock Controller ...........................................................................................................4.2.10-4

4.2.11 On-board Network

Description and Operation.............................................................................................................. 4.2.11-1
General Description ................................................................................................................ 4.2.11-1
Description of K-LINE Bus ...................................................................................................... 4.2.11-1
Description of DLC.................................................................................................................. 4.2.11-1
DLC View ................................................................................................................................ 4.2.11-1
Symptom Diagnosis and Testing .................................................................................................... 4.2.11-2
Inspection and Verification...................................................................................................... 4.2.11-2

M201 2014.01
 Body Electrical
Symptom Chart....................................................................................................................... 4.2.11-3
Diagnosis Procedure for Disabled Communication between Diagnostic Tool and ECM ........ 4.2.11-4

M201 2014.01
4.2.1-1 Instrument Panel and Panel Illumination 4.2.1-1

Specifications
4.2.1 Instrument Panel and Panel Illumination

General Specifications
Item Rated Voltage Rated Power
Instrument cluster panel illumination 12 V (DV) -
Radio illumination 12 V (DV) -
A/C control panel illumination 12 V (DV) -
Hazard warning illumination 12 V (DV) -

M201 2014.01
4.2.1-2 Instrument Panel and Panel Illumination 4.2.1-2

Description and Operation

System Overview
When the lighting combination switch is turned to
the position lamp or headlamp position, the
following components have the panel illumination
function:
• Instrument cluster panel
• Radio
• A/C control panel
• Hazard warning lamp

M201 2014.01
4.2.1-3 Instrument Panel and Panel Illumination 4.2.1-3

Symptom Diagnosis and Testing

General Equipment

Digital multimeter

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious mechanical or
electrical damage or deformation.
Visual Inspection Chart

Mechanical Electrical
• Instrument panel
• Instrument cluster • Fuse
• Lighting combination • Circuit
switch
• Switch
• Accessory equipment
installation

3. Inspect the system circuit which is accessible

or visible.
4. If an obvious cause for an observed or
reported concern has been found, solve the
fault before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
4.2.1-4 Instrument Panel and Panel Illumination 4.2.1-4

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and repair it in order of the
following table.

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
for Inoperative
Instrument Cluster
• Fuse and circuit Illumination Lamp
Instrument cluster illumination
• Lighting combination switch with Position Lamp
fault
• Instrument cluster ON (4.2.2 Instrument
Cluster, Symptom
Diagnosis and
Testing).
Refer to: Diagnosis Procedure
for Inoperative A/C
Control Panel
• Fuse and circuit Illumination (4.2.1
A/C control panel illumination
• Lighting combination switch Instrument Panel
fault
• A/C control module and Panel
Illumination,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for Inoperative Radio
• Fuse and circuit Illumination (4.2.1
Instrument Panel
Radio illumination fault • Lighting combination switch
and Panel
• Radio host Illumination,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for Inoperative
Hazard Warning
• Fuse and circuit Lamp Switch
Hazard warning lamp switch Illumination (4.2.1
• Lighting combination switch
illumination fault Instrument Panel
• Hazard warning lamp switch and Panel
Illumination,
Symptom Diagnosis
and Testing).

M201 2014.01
4.2.1-5 Instrument Panel and Panel Illumination 4.2.1-5

Diagnosis Procedure for Inoperative A/C Control Panel

Illumination

Inoperative A/C control

panel illumination

General inspection
(Inspect A/C controller wiring
harness connector)

Is the fault Yes

confirmed

No
Inspect operation condition of
position lamp

Is the fault Yes

confirmed

No

Inspect other background lamps

Is the fault Yes

confirmed

No

Inspect A/C controller

illumination power supply circuit
Inspect A/C controller
illumination grounding circuit
Is the fault Yes
confirmed

No

Replace A/C controller

End

M201 2014.01
4.2.1-6 Instrument Panel and Panel Illumination 4.2.1-6

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the A/C controller wiring harness connector
for damage, poor contact, aging or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect operation condition of position lamp

A. Turn the ignition switch to "ON", and turn the
combination switch to position lamp.
Is the position lamp operating normally?
Yes
Go to step 3.
No
Inspect and repair the position lamp that does not
operate.
Refer to: Diagnosis Procedure for
Position Lamp Fault (4.2.6
Lighting System, Symptom
Diagnosis and Testing).
3. Inspect other background lamps
A. Inspect the radio background lamp illumination.
Is it normal?
Yes
Go to step 4.
No
Refer to: Symptom Chart (4.2.1
Instrument Panel and Panel
Illumination, Symptom
Diagnosis and Testing).

M201 2014.01
4.2.1-7 Instrument Panel and Panel Illumination 4.2.1-7

Test Conditions Details/Results/Actions

4. Inspect A/C controller illumination power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the A/C controller wiring harness
connector P26.
C. Turn the ignition switch to "ON", and turn the
combination switch to position lamp.
D. Measure the voltage between terminal 5 of A/C
controller wiring harness connector P26 and
5 4 3 2 1 reliable grounding.
10 9 8 7 6 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
P26
M4201001 Yes
Go to step 5.
No
Inspect and repair the open circuit fault between
terminal 5 of A/C controller wiring harness
connector P26 and terminal 8 of lighting
combination switch wiring harness connector P30.

5. Inspect A/C controller illumination grounding circuit

A. Turn the ignition switch to "LOCK".
P26
B. Disconnect the A/C controller wiring harness
connector P26.
5 4 3 2 1 C. Measure the resistance between terminal 10 of A/C
controller wiring harness connector P26 and
10 9 8 7 6 reliable grounding.
Standard resistance: less than 5 Ω
Is the circuit normal?
Yes
Go to step 6.
M4201002
No
Inspect and repair the short circuit fault between
terminal 10 of A/C controller wiring harness
connector P26 and grounding G106.

6. Replace A/C controller

A. Turn the ignition switch to "LOCK".
B. Replace the A/C controller.
Refer to: A/C Controller (4.1.1 Heating,
Ventilation and Air Conditioning,
Removal and Installation).
The system is normal.

M201 2014.01
4.2.1-8 Instrument Panel and Panel Illumination 4.2.1-8

Diagnosis Procedure for Inoperative Radio Illumination

Inoperative radio
illumination

General inspection
(Inspect radio wiring harness
connector)

Is the fault Yes

confirmed

No
Inspect operation condition of
position lamp

Is the fault Yes

confirmed

No

Inspect other background lamps

Is the fault Yes

confirmed

No

Inspect radio illumination power

supply circuit
Inspect radio grounding circuit

Is the fault Yes

confirmed

No

Replace radio

End

M201 2014.01
4.2.1-9 Instrument Panel and Panel Illumination 4.2.1-9

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the radio wiring harness connector for
damage, poor contact, aging or loose.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect operation condition of position lamp

A. Turn the ignition switch to "ON", and turn the
combination switch to position lamp.
Is the position lamp operating normally?
Yes
Go to step 3.
No
Inspect and repair the position lamp that does not
operate.
Refer to: Position Lamp Fault (4.2.6
Lighting System, Symptom
Diagnosis and Testing).
3. Inspect other background lamps
A. Inspect the A/C control panel background lamp
illumination.
Is it normal?
Yes
Go to step 4.
No
Refer to: Symptom Chart (4.2.1
Instrument Panel and Panel
Illumination, Symptom
Diagnosis and Testing).

M201 2014.01
4.2.1-10 Instrument Panel and Panel Illumination 4.2.1-10

Test Conditions Details/Results/Actions

4. Inspect radio illumination power supply circuit
A. Turn the ignition switch to "LOCK".
P34 B. Disconnect the radio wiring harness connector P34.
C. Turn the ignition switch to "ON", and turn the
3 2 1 combination switch to position lamp.
D. Measure the voltage between terminal 6 of radio
8 7 6 5 4
wiring harness connector P34 and reliable
grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
M4201003
Go to step 5.
No
Inspect and repair the open circuit fault between
terminal 6 of radio wiring harness connector P34
and terminal 8 of lighting combination switch wiring
harness connector P30.

5. Inspect radio grounding circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the radio wiring harness connector P34.
P34 C. Measure the resistance between terminal 4 of radio
wiring harness connector P34 and reliable
3 2 1 grounding.

8 7 6 5 4 Standard resistance: less than 5 Ω

Is the resistance value normal?
Yes
Go to step 6.
No
M4201004
Inspect and repair the open circuit fault between
terminal 4 of radio wiring harness connector P34
and grounding G106.

6. Replace radio
A. Turn the ignition switch to "LOCK".
B. Replace the radio.
Refer to: Radio (4.2.5 Information and
Entertainment System, Removal
and Installation).
The system is normal.

M201 2014.01
4.2.1-11 Instrument Panel and Panel Illumination 4.2.1-11

Diagnosis Procedure for Inoperative Hazard Warning Lamp Switch

Illumination

Inoperative hazard warning

lamp switch illumination

General Inspection
(Inspect hazard warning lamp switch
wiring harness connector)

Is the fault Yes

confirmed

No
Inspect operation condition of
position lamp

Is the fault Yes

confirmed

No

Inspect other background lamps

Is the fault Yes

confirmed

No

Inspect hazard warning lamp switch

illumination power supply circuit
Inspect hazard warning lamp switch
illumination grounding circuit
Is the fault Yes
confirmed

No

Replace hazard warning lamp

switch

End

M201 2014.01
4.2.1-12 Instrument Panel and Panel Illumination 4.2.1-12

Test Conditions Details/Results/Actions

1. General Inspection
A. Inspect the hazard warning lamp switch wiring
harness connector for damage, poor contact, aging
or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect operation condition of position lamp

A. Turn the ignition switch to "ON", and turn the
combination switch to position lamp.
Is the position lamp operating normally?
Yes
Go to step 3.
No
Inspect and repair the position lamp that does not
operate.
Refer to: Diagnosis Procedure for
Position Lamp Fault (4.2.6
Lighting System, Symptom
Diagnosis and Testing).
3. Inspect other background lamps
A. Inspect the radio background lamp illumination.
Is it normal?
Yes
Go to step 4.
No
Refer to: Symptom Chart (4.2.1
Instrument Panel and Panel
Illumination, Symptom
Diagnosis and Testing).

M201 2014.01
4.2.1-13 Instrument Panel and Panel Illumination 4.2.1-13

Test Conditions Details/Results/Actions

4. Inspect hazard warning lamp switch illumination power supply circuit
A. Turn the ignition switch to "LOCK".
P25
B. Disconnect the wiring harness connector P25 from
the hazard warning lamp switch.
3 2 1 C. Turn the ignition switch to "ON", and turn the
combination switch to position lamp.
8 7 6 5 4 D. Measure the voltage between terminal 5 of hazard
warning lamp switch wiring harness connector P25
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
M4201005 Yes
Go to step 5.
No
Inspect and repair the open circuit fault between
terminal 5 of hazard warning lamp switch wiring
harness connector P25 and terminal 8 of lighting
combination switch wiring harness connector P30.

5. Inspect hazard warning lamp switch illumination grounding circuit

A. Turn the ignition switch to "LOCK".
P25 B. Disconnect the hazard warning lamp switch wiring
harness connector P25.
C. Measure the resistance between terminal 4 of
3 2 1 hazard warning lamp switch wiring harness
connector P25 and grounding.
8 7 6 5 4
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 6.
M4201006
No
Inspect and repair the open circuit fault between
terminal 4 of hazard warning lamp switch wiring
harness connector P25 and grounding G106.

6. Replace hazard warning lamp switch

A. Turn the ignition switch to "LOCK".
B. Replace the hazard warning lamp switch.
Refer to: Hazard Warning Lamp Switch
(4.2.6 Lighting System, Removal
and Installation).
The system is normal.

M201 2014.01
4.2.2-1 Instrument Cluster 4.2.2-1

Specifications
4.2.2 Instrument Cluster

General Specifications
Item Rated Voltage Rated Power
Instrument cluster power supply 12 V (DC) -

M201 2014.01
4.2.2-2 Instrument Cluster 4.2.2-2

Description and Operation Fuel Gauge

System Overview The indicator dial of fuel gauge in the instrument
cluster is connected with the sensor in the fuel
The instrument cluster is located on the left side tank. The fuel gauge will indicate the volume of
of instrument panel and over the steering column. fuel in the fuel tank only when the ignition switch
The meters in the instrument cluster provide the is at "ON" or "ACC".
driver with information related to the vehicle
performance. When the ignition switch is at Temperature Gauge
"ACC" or "ON", some functions of instrument
The coolant temperature gauge consists of
cluster (IPC) will be tested to inspect if they are
coolant temperature indicator inside the
normal. Following situations will occur during the
instrument cluster and coolant temperature
test:
sensor installed on the engine.
• Charging system indicator is illuminated.
The coolant temperature sensor is a thermistor,
• Oil pressure indicator is illuminated. whose resistance value decreases as the
• Engine malfunction indicator is temperature goes up.
illuminated briefly. The temperature gauge in the instrument cluster
• Seat belt unfasten indicator is illuminated. indicates the coolant temperature based on the
signals from engine coolant temperature sensor
The instrument cluster includes temperature
ECT. After long driving or idling in hot weather, the
gauge, fuel gauge, speedometer and various
pointer of temperature gauge may point beyond
indicators.
the mid-scale position. If the pointer moves into
Speedometer/Odometer the red area of upper limit on the dial, then the
engine is overheating.
The speedometer is used to indicate the vehicle
speed in "km/h". The vehicle speed signal
received by the instrument cluster comes from the
vehicle speed sensor VSS at the rear of
transmission. The odometer is used to indicate
the accumulated vehicle mileage in "km". The trip
meter is used to indicate the vehicle mileage after
resetting to zero last time.

M201 2014.01
4.2.2-3 Instrument Cluster 4.2.2-3
Instrument Cluster Indicator
The indicators in the instrument cluster are used
to indicate the functions or possible malfunctions
of specific systems when driving. The indicators
in the instrument cluster provide the users with
warnings or instructions. The types of indicators
in the instrument cluster are as follows:

Indicator
Indicator Color
Symbol

Oil pressure warning

Red
lamp

Charging indicator Red

Engine malfunction
Amber
indicator

Driver seat belt

Red
unfasten indicator

Light
Low beam indicator
green

High beam indicator Dark blue

Front fog indicator Dark blue

Rear fog indicator Amber

Brake fluid level/parking

Red
brake indicator

Light
Left turn indicator
green

Light
Right turn indicator
green

Fuel level indicator Amber

Coolant temperature
Red
indicator

EPS indicator
EPS (reserved)
Amber

M201 2014.01
4.2.2-4 Instrument Cluster 4.2.2-4

Components Location View

1 1 USE
WITH

2 2
3 3

M4202001

Item Description Item Description

1 Instrument cluster 2 Dashboard

M201 2014.01
4.2.2-5 Instrument Cluster 4.2.2-5

Instrument Cluster Terminal List

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

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

M4202002

Terminal No. Connection Wire Terminal Description

P21-1 0.3 GN/YE Right turn lamp signal
P21-2 0.3 GN/RD Left turn lamp signal
P21-3 0.3 RD Low beam indicator signal
P21-4 0.3 RD/WH High beam indicator signal
P21-5 0.3 YE/GN Instrument cluster power supply (IG1)
P21-6 - -
P21-7 0.5 GN/BK Instrument cluster power supply (IG1)
P21-8 0.5 WH Instrument cluster power supply (B+)
P21-9 0.5 BK Instrument signal grounding
P21-10 0.3 YE/RD Fuel level sensor signal
P21-11 0.3 GN Vehicle speed signal input
P21-12 0.3 WH/BU Crankshaft position sensor signal
P21-13 0.3 YE/WH Coolant temperature sensor signal
P21-14 - -
P21-15 - -
P21-16 - -
P21-17 0.3 RD/YE Background lamp power supply
P21-18 0.5 BK Illumination grounding
P21-19 0.3 GY Rear fog indicator signal
P21-20 0.3 LG Front fog indicator signal
P21-21 0.3 BK/RD Door open indicator signal
P21-22 0.3 GY/BK Seat belt unfasten warning signal
P21-23 0.3 YE/BK Oil pressure signal

M201 2014.01
4.2.2-6 Instrument Cluster 4.2.2-6

Terminal No. Connection Wire Terminal Description

P21-24 0.3 WH/RD Battery charging indicator signal
P21-25 - -
P21-26 - -
P21-27 0.3 RD/BK Brake fluid level & parking brake indicator signal
P21-28 0.3 VT/YE Engine malfunction indicator signal
P21-29 - -
P21-30 - -
P21-31 - -
P21-32 - -

M201 2014.01
4.2.2-7 Instrument Cluster 4.2.2-7

Symptom Diagnosis and Testing

General Equipment

Digital multimeter
Diagnostic tool

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious mechanical or
electrical damage.
Visual Inspection Chart

Mechanical Electrical
• Fuse
• Instrument panel
• Circuit
• Instrument cluster trim
• Control switch
panel
• Instrument cluster

3. Inspect the system circuit which is accessible

or visible.
4. If an obvious cause for an observed or
reported concern has been found, solve the
fault before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
4.2.2-8 Instrument Cluster 4.2.2-8

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and repair it in order of the
following table.

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
for Inoperative
Instrument Cluster
Instrument cluster
Illumination Lamp with
illumination lamp does not • Circuit fault Ignition Switch "ON"
illuminate with ignition
switch "ON" and position • Instrument cluster and Position Lamp
lamp operating Operating (4.2.2
Instrument Cluster,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for Inoperative Left
• Circuit fault Turn Indicator When
Left turn indicator does not
Turning Left (4.2.2
blink when turning left • Instrument cluster
Instrument Cluster,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for Inoperative Right
Turning Indicator
Right turn indicator does not • Circuit fault When Turning Right
blink when turning right • Instrument cluster (4.2.2 Instrument
Cluster, Symptom
Diagnosis and
Testing).
Refer to: Diagnosis Procedure
for Inoperative Front
Fog Indicator with
Front fog indicator does not
• Circuit fault Ignition Switch "ON"
illuminate with ignition
and Front Fog Lamp
switch "ON" and front fog • Instrument cluster
lamp operating Operating (4.2.2
Instrument Cluster,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for Inoperative Rear
Fog Indicator with
Rear fog indicator does not
• Circuit fault Ignition Switch "ON"
illuminate with ignition
and Rear Fog Lamp
switch "ON" and rear fog • Instrument cluster
lamp operating Operating (4.2.2
Instrument Cluster,
Symptom Diagnosis
and Testing).

M201 2014.01
4.2.2-9 Instrument Cluster 4.2.2-9

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
for Inoperative High
Beam Indicator with
High beam indicator does • Circuit fault Ignition Switch "ON"
not illuminate with ignition
• Fuse and High Beam Lamp
switch "ON" and high beam
lamp operating • Instrument cluster Operating (4.2.2
Instrument Cluster,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for Inoperative Low
Beam Indicator with
Low beam indicator does • Circuit fault Ignition Switch "ON"
not illuminate with ignition
• Fuse and Low Beam Lamp
switch "ON" and low beam
lamp operating • Instrument cluster Operating (4.2.2
Instrument Cluster,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
• Fuse for Abnormal
• Circuit fault Speedometer
Abnormal speedometer
Indication (4.2.2
indication • Instrument cluster
Instrument Cluster,
• Vehicle speed sensor Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for Abnormal Coolant
Abnormal coolant • Circuit fault Temperature Gauge
temperature gauge • Instrument cluster Indication (4.2.2
indication Instrument Cluster,
• ECM
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for Abnormal Fuel
• Circuit fault Gauge Indication
Abnormal fuel gauge
• Instrument cluster (4.2.2 Instrument
indication
• Fuel level sensor Cluster, Symptom
Diagnosis and
Testing).

M201 2014.01
4.2.2-10 Instrument Cluster 4.2.2-10

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
for Inoperative Engine
• Circuit fault
Malfunction Indicator
Engine malfunction indicator • Fuse with Ignition Switch
does not illuminate with
ignition switch "ON" • Instrument cluster "ON" (4.2.2 Instrument
Cluster, Symptom
• ECM
Diagnosis and
Testing).
Refer to: Diagnosis Procedure
for Inoperative Oil
• Circuit fault
Pressure Warning
Oil pressure warning • Fuse Indicator with Ignition
indicator does not illuminate
with ignition switch "ON" • Instrument cluster Switch "ON" (4.2.2
Instrument Cluster,
• Oil pressure alarm
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
• Circuit fault for Inoperative
• Fuse Charging Indicator
Charging indicator does not
with Ignition Switch
illuminate with ignition • Instrument cluster
switch "ON"
"ON" (4.2.2 Instrument
• Voltage regulator Cluster, Symptom
• Alternator Diagnosis and
Testing).
Refer to: Diagnosis Procedure
for Inoperative Parking
• Circuit fault Brake Indicator with
Parking brake indicator
• Fuse Ignition Switch "ON"
does not illuminate with
and Vehicle Parked
ignition switch "ON" and • Instrument cluster
vehicle parked (4.2.2 Instrument
• Parking brake switch Cluster, Symptom
Diagnosis and
Testing).
Refer to: Diagnosis Procedure
for Inoperative Seat
• Circuit fault
Belt Unfasten
Seat belt unfasten indicator • Fuse Indicator with Ignition
does not illuminate with
ignition switch "ON" • Instrument cluster Switch "ON" (4.2.2
Instrument Cluster,
• Seat belt switch
Symptom Diagnosis
and Testing).

M201 2014.01
4.2.2-11 Instrument Cluster 4.2.2-11

Diagnosis Procedure for Inoperative Instrument Cluster Illumination

Lamp with Ignition Switch "ON" and Position Lamp Operating

Inoperative instrument cluster

illumination lamp with ignition switch
"ON" and position lamp operating

General inspection
(Inspect instrument cluster wiring
harness connector)

Is the fault Yes

confirmed

No
Inspect instrument cluster background
lamp power supply circuit

No
Yes
Is the fault
confirmed

No
Inspect instrument cluster
background lamp grounding circuit

End

M201 2014.01
4.2.2-12 Instrument Cluster 4.2.2-12

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect instrument cluster background lamp power supply circuit

A. Disconnect the instrument cluster wiring harness
connector P21.
B. Turn the ignition switch to "ON", and turn the
combination switch to position lamp.
C. Measure the voltage between terminal 17 of
instrument cluster wiring harness connector P21
and reliable grounding.
17 32 Standard voltage: 11 ~ 14 V
1 16 Is the voltage value normal?
P21 Yes
M4202003 Go to step 3.
No
Inspect and repair the open circuit fault between
terminal 8 of lighting combination switch wiring
harness connector P30 and terminal 17 of
instrument cluster wiring harness connector P21.

3. Inspect instrument cluster background lamp grounding circuit

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 18 32
connector P21.
1 16
C. Measure the resistance between terminal 18 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the instrument cluster.
M4202004
Refer to: Instrument Cluster (4.2.2
Instrument Cluster, Removal and
Installation).
No
Inspect and repair the open circuit fault between
terminal 18 of instrument cluster wiring harness
connector P21 and grounding G104.

M201 2014.01
4.2.2-13 Instrument Cluster 4.2.2-13

Diagnosis Procedure for Inoperative Left Turn Indicator When

Turning Left

Inoperative left turn indicator

when turning left

General Inspection
(Inspect the instrument cluster
wiring harness connector)

Is the fault Yes

confirmed

No
Inspect instrument cluster turn
indicator power supply circuit

Yes
Is the fault
confirmed

No
Inspect instrument cluster turn
indicator grounding circuit

End

M201 2014.01
4.2.2-14 Instrument Cluster 4.2.2-14

Test Conditions Details/Results/Actions

1. General Inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect instrument cluster turn indicator power supply circuit

A. Disconnect the instrument cluster wiring harness
P21 connector P21.
17 32
B. Turn the ignition switch to "ON", and turn the
1 2 16
combination switch to turn lamp.
C. Measure the voltage between terminal 2 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard voltage: changes from 0 V to 11 ~ 14 V
Is the voltage value normal?
Yes
M4202005 Go to step 3.
No
Inspect and repair the open circuit fault between
terminal 13 of lighting combination switch wiring
harness connector P30 and terminal 2 of instrument
cluster wiring harness connector P21.

3. Inspect instrument cluster turn indicator grounding circuit

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 18 32
connector P21.
1 16
C. Measure the resistance between terminal 18 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the instrument cluster.
M4202004
Refer to: Instrument Cluster (4.2.2
Instrument Cluster, Removal and
Installation).
No
Inspect and repair the open circuit fault between
terminal 18 of instrument cluster wiring harness
connector P21 and grounding G104.

M201 2014.01
4.2.2-15 Instrument Cluster 4.2.2-15

Diagnosis Procedure for Inoperative Right Turn Indicator When

Turning Right
CAUTION: Diagnosis procedure for inoperative right turn indicator is similar to that for left
turn indicator while the measured terminals are different.

M201 2014.01
4.2.2-16 Instrument Cluster 4.2.2-16

Diagnosis Procedure for Inoperative Front Fog Indicator with

Ignition Switch "ON" and Front Fog Lamp Operating

Inoperative front fog indicator

with ignition switch "ON" and
front fog lamp operating

General inspection
(Inspect instrument cluster wiring
harness connector)

Is the fault Yes

confirmed

No

Inspect instrument cluster front fog

indicator power supply circuit

Yes
Is the fault
confirmed

No

Inspect instrument cluster front fog

indicator grounding circuit

End

M201 2014.01
4.2.2-17 Instrument Cluster 4.2.2-17

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect instrument cluster front fog indicator power supply circuit

A. Disconnect the instrument cluster wiring harness
P21 connector P21.
17 20 32
B. Turn the ignition switch to "ON", and turn the
1 16
combination switch to front fog lamp.
C. Measure the voltage between terminal 20 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
M4202006 Go to step 3.
No
Inspect and repair the open circuit fault between
terminal 74 of instrument panel fuse box relay IR06
and terminal 20 of instrument cluster wiring harness
connector P21.

3. Inspect instrument cluster front fog indicator grounding circuit

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 18 32
connector P21.
1 16
C. Measure the resistance between terminal 18 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the instrument cluster.
M4202004
Refer to: Instrument Cluster (4.2.2
Instrument Cluster, Removal and
Installation).
No
Inspect and repair the open circuit fault between
terminal 18 of instrument cluster wiring harness
connector P21 and grounding G104.

M201 2014.01
4.2.2-18 Instrument Cluster 4.2.2-18

Diagnosis Procedure for Inoperative Rear Fog Indicator with

Ignition Switch "ON" and Rear Fog Lamp Operating

Inoperative rear fog indicator

with ignition switch "ON" and
rear fog lamp operating

General inspection
(Inspect instrument cluster wiring
harness connector)

Is the fault Yes

confirmed

No

Inspect instrument cluster rear fog

indicator power supply circuit

Yes
Is the fault
confirmed

No

Inspect instrument cluster rear fog

indicator grounding circuit

End

M201 2014.01
4.2.2-19 Instrument Cluster 4.2.2-19

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect instrument cluster rear fog indicator power supply circuit

A. Disconnect the instrument cluster wiring harness
P21 connector P21.
17 19 32
B. Turn the ignition switch to "ON", and turn the
1 16
combination switch to rear fog lamp.
C. Measure the voltage between terminal 19 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
M4202007 Go to step 3.
No
Inspect and repair the open circuit fault between
terminal 2 of lighting combination switch wiring
harness connector P30 and terminal 19 of
instrument cluster wiring harness connector P21.

3. Inspect instrument cluster rear fog indicator grounding circuit

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 18 32
connector P21.
1 16
C. Measure the resistance between terminal 18 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the instrument cluster.
M4202004
Refer to: Instrument Cluster (4.2.2
Instrument Cluster, Removal and
Installation).
No
Inspect and repair the open circuit fault between
terminal 18 of instrument cluster wiring harness
connector P21 and grounding G104.

M201 2014.01
4.2.2-20 Instrument Cluster 4.2.2-20

Diagnosis Procedure for Inoperative High Beam Indicator with

Ignition Switch "ON" and High Beam Lamp Operating

Inoperative high beam indicator

with ignition switch "ON" and
high beam lamp operating

General inspection
(Inspect instrument cluster wiring
harness connector)

Is the fault Yes

confirmed

No

Inspect fuse

Is the fault Yes

confirmed

No
Inspect instrument cluster high beam
indicator power supply circuit

Is the fault Yes

confirmed

No

Inspect instrument cluster high beam

indicator grounding circuit

End

M201 2014.01
4.2.2-21 Instrument Cluster 4.2.2-21

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect fuse
A. Inspect the instrument panel fuse box fuse IF07.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect instrument cluster high beam indicator power supply circuit

A. Disconnect the instrument cluster wiring harness
P21 connector P21.
17 32
B. Turn the ignition switch to "ON".
1 8 16
C. Measure the voltage between terminal 8 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 4.
M4202008
No
Inspect and repair the open circuit fault between
terminal 8 of instrument cluster wiring harness
connector P21 and terminal 14 of instrument panel
fuse box fuse IF07.

M201 2014.01
4.2.2-22 Instrument Cluster 4.2.2-22

Test Conditions Details/Results/Actions

4. Inspect instrument cluster high beam indicator grounding circuit
A. Turn the ignition switch to "OFF".
P30
B. Disconnect the instrument cluster wiring harness
connector P21 and lighting combination switch
4 3 2 1 wiring harness connector P30.
13 12 11 10 9 8 7 6 5 C. Measure the resistance between terminal 3 of
instrument cluster wiring harness connector P21
and terminal 9 of lighting combination switch wiring
harness connector P30.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the instrument cluster.
P21
17 32
Refer to: Instrument Cluster (4.2.2
1 3 16 Instrument Cluster, Removal and
Installation).
M4202009
No
Inspect and repair the open circuit fault between
terminal 3 of instrument cluster wiring harness
connector P21 and terminal 9 of lighting
combination switch wiring harness connector P30.

Diagnosis Procedure for Inoperative Low Beam Indicator with

Ignition Switch "ON" and Low Beam Lamp Operating
CAUTION: Diagnosis procedure for inoperative low beam indicator with ignition switch "ON"
and low beam lamp operating is similar to that for high beam indicator, but the measured
terminals are different.

M201 2014.01
4.2.2-23 Instrument Cluster 4.2.2-23

Diagnosis Procedure for Abnormal Speedometer Indication

Abnormal speedometer
indication

General inspection
(Inspect wiring harness connectors
related with speedometer)

Is the fault Yes

confirmed

No
Inspect vehicle speed sensor fuse
IF33

Is the fault Yes

confirmed

No
Inspect vehicle speed sensor
power supply circuit
Inspect vehicle speed sensor
grounding circuit

Is the fault Yes

confirmed

No Inspect instrument cluster

grounding circuit
Inspect circuit between vehicle speed
sensor and instrument cluster

Is the fault Yes

confirmed
Is the fault
confirmed
No

Inspect vehicle speed sensor

No
Yes

End

M201 2014.01
4.2.2-24 Instrument Cluster 4.2.2-24

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related with
the speedometer for damage, poor contact, aging
and looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect vehicle speed sensor fuse IF33

A. Inspect the vehicle speed sensor fuse IF33 in the
instrument panel fuse box.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect vehicle speed sensor power supply circuit

A. Disconnect the vehicle speed sensor wiring
harness connector S12.
S12
B. Turn the ignition switch to "ON".
C. Measure the voltage between terminal 1 of vehicle
1 2 3 speed sensor wiring harness connector S12 and
reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 4.
M4202010
No
Inspect and repair the open circuit fault between
terminal 1 of vehicle speed sensor wiring harness
connector S12 and terminal 66 of instrument panel
fuse box fuse IF33.

M201 2014.01
4.2.2-25 Instrument Cluster 4.2.2-25

Test Conditions Details/Results/Actions

4. Inspect vehicle speed sensor grounding circuit
A. Disconnect the vehicle speed sensor wiring
harness connector S12.
S12 B. Measure the resistance between terminal 2 of
vehicle speed sensor wiring harness connector S12
and reliable grounding.
1 2 3 Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 5.
No
M4202011
Inspect and repair the open circuit fault between
terminal 2 of vehicle speed sensor wiring harness
connector S12 and grounding G104.

5. Inspect circuit between vehicle speed sensor and instrument cluster

A. Turn the ignition switch to "OFF".
B. Disconnect the vehicle speed sensor wiring
S12 harness connector S12 and instrument cluster
wiring harness connector P21.
C. Measure the resistance between terminal 3 of
1 2 3 vehicle speed sensor wiring harness connector S12
and terminal 11 of instrument cluster wiring harness
connector P21.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
17 32 Go to step 6.
1 11 16
No
P21 Inspect and repair the open circuit fault between
terminal 3 of vehicle speed sensor wiring harness
M4202012 connector S12 and terminal 11 of instrument cluster
wiring harness connector P21.

M201 2014.01
4.2.2-26 Instrument Cluster 4.2.2-26

Test Conditions Details/Results/Actions

6. Inspect instrument cluster grounding circuit
A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 32
connector P21.
1 9 16
C. Measure the resistance between terminal 9 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 7.
M4202013
No
Inspect and repair the open circuit fault between
terminal 9 of instrument cluster wiring harness
connector P21 and grounding G104.

7. Inspect vehicle speed sensor

A. Replace the vehicle speed sensor with a good one.
Is the road test normal?
Yes
The system is normal.
No
Replace the instrument cluster.
Refer to: Instrument Cluster (4.2.2
Instrument Cluster, Removal and
Installation).

M201 2014.01
4.2.2-27 Instrument Cluster 4.2.2-27

Diagnosis Procedure for Abnormal Coolant Temperature Gauge

Indication

Abnormal coolant
temperature gauge
indication

General inspection
(Inspect instrument cluster wiring
harness connector)

Is the fault Yes

confirmed

No
Read related DTC with diagnostic
tool

Is the fault Yes

confirmed

No
Read data flow of coolant
temperature with diagnostic tool

Is the fault Yes

confirmed

No
Inspect circuit between instrument
cluster and ECM
Inspect instrument cluster
grounding circuit
Inspect instrument cluster
Inspect coolant temperature
sensor
Is the fault
confirmed

Yes No

End

M201 2014.01
4.2.2-28 Instrument Cluster 4.2.2-28

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Read related DTC with diagnostic tool

A. Connect the specific diagnostic tool.
B. Start the vehicle and read the engine DTC.
Is there any DTC related to coolant temperature
sensor?
Yes
Refer to: DTC Code List (3.1.12 Electronic
Control System - M7, DTC
Diagnosis and Testing).
No
Go to step 3.

3. Read data flow of coolant temperature with diagnostic tool

A. Connect the specific diagnostic tool.
B. Start the vehicle and read the data flow of engine
coolant temperature.
C. Measure the actual coolant temperature with a
measurement tool.
Is the data read from the diagnostic tool the same
with the actual coolant temperature?
Yes
Go to step 4.
No
Go to step 7.

M201 2014.01
4.2.2-29 Instrument Cluster 4.2.2-29

Test Conditions Details/Results/Actions

4. Inspect circuit between instrument cluster and ECM
A. Turn the ignition switch to "OFF" and disconnect the
negative battery cable.

P21 B. Disconnect the instrument cluster wiring harness

connector P21 and ECM wiring harness connector
17 32
E18.
1 13 16
C. Measure the resistance between terminal 13 of
instrument cluster wiring harness connector P21
and terminal 56 of ECM wiring harness connector
E18.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 5.
No
1 2 9 22 Inspect and repair the open circuit fault between
3 4 23 36 terminal 13 of instrument cluster wiring harness
connector P21 and terminal 56 of ECM wiring
5 6 37 50
harness connector E18.
7 8 51 56 64

E18

M4202014

5. Inspect instrument cluster grounding circuit

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 32
connector P21.
1 9 16
C. Measure the resistance between terminal 9 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 6.
M4202013
No
Inspect and repair the open circuit fault between
terminal 9 of instrument cluster wiring harness
connector P21 and grounding G104.

M201 2014.01
4.2.2-30 Instrument Cluster 4.2.2-30

Test Conditions Details/Results/Actions

6. Inspect instrument cluster
A. Replace the instrument cluster with a good one.
Is the coolant temperature gauge indication
normal?
Yes
The system is normal.
No
Go to step 7.

7. Inspect coolant temperature sensor

A. Replace the coolant temperature sensor with a
good one.
Is the coolant temperature gauge indication
normal?
Yes
The system is normal.
No
Replace the ECM.
Refer to: ECM (3.1.12 Electronic Control
System - M7, Removal and
Installation).

M201 2014.01
4.2.2-31 Instrument Cluster 4.2.2-31

Diagnosis Procedure for Abnormal Fuel Gauge Indication

Abnormal fuel gauge

indication

General inspection
(Inspect instrument cluster
wiring harness connector)

Is the fault Yes

confirmed

No
Inspect circuit between
instrument cluster and fuel level
sensor

Is the fault Yes

confirmed

No
Inspect fuel level sensor
grounding circuit

Is the fault Yes

confirmed

No

Inspect fuel level sensor

End

M201 2014.01
4.2.2-32 Instrument Cluster 4.2.2-32

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect circuit between instrument cluster and fuel level sensor

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 32
connector P21 and fuel level sensor wiring harness
1 10 16 connector S01.
C. Measure the resistance between terminal 10 of
instrument cluster wiring harness connector P21
and terminal 3 of fuel level sensor wiring harness
connector S01.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
3 1 Go to step 3.
4 2 No
Inspect and repair the open circuit fault between
S01 terminal 10 of instrument cluster wiring harness
M4202015 connector P21 and terminal 3 of fuel level sensor
wiring harness connector S01.

3. Inspect fuel level sensor grounding circuit

A. Turn the ignition switch to "OFF".
B. Disconnect the fuel level sensor wiring harness
connector S01.
C. Measure the resistance between terminal 1 of fuel
level sensor wiring harness connector S01 and
3 1 reliable grounding.
Standard resistance: less than 5 Ω
4 2
Is the resistance value normal?
S01 Yes
Go to step 4.
M4202016
No
Inspect and repair the open circuit fault between
terminal 1 of fuel level sensor wiring harness
connector S01 and grounding G104.

M201 2014.01
4.2.2-33 Instrument Cluster 4.2.2-33

Test Conditions Details/Results/Actions

4. Inspect fuel level sensor
A. Turn the ignition switch to "OFF".
B. Replace the fuel level sensor.
Refer to: Fuel Pump Assembly (3.1.7 Fuel
System, Removal and
Installation).
Is the fuel gauge indication normal?
Yes
The system is normal.
No
Replace the instrument cluster.
Refer to: Instrument Cluster (4.2.2
Instrument Cluster, Removal and
Installation).

M201 2014.01
4.2.2-34 Instrument Cluster 4.2.2-34

Diagnosis Procedure for Inoperative Engine Malfunction Indicator

with Ignition Switch "ON"

Inoperative engine malfunction

indicator with ignition switch
"ON"

General inspection
(Inspect instrument cluster wiring
harness connector)

Is the fault Yes

confirmed

No

Inspect instrument cluster fuse

Is the fault Yes

confirmed

No
Inspect instrument cluster power
supply

Is the fault Yes

confirmed

No
Inspect circuit between
instrument cluster and ECM

Is the fault Yes

confirmed

No

Inspect instrument cluster

End

M201 2014.01
4.2.2-35 Instrument Cluster 4.2.2-35

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect instrument cluster fuse

A. Inspect the instrument cluster fuse IF35.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect instrument cluster power supply

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 32
connector P21.
1 7 16
C. Measure the voltage between terminal 7 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 4.
M4202017
No
Inspect and repair the open circuit fault between
terminal 7 of instrument cluster wiring harness
connector P21 and terminal 70 of instrument panel
fuse box fuse IF35.

M201 2014.01
4.2.2-36 Instrument Cluster 4.2.2-36

Test Conditions Details/Results/Actions

4. Inspect circuit between instrument cluster and ECM
A. Turn the ignition switch to "OFF" and disconnect the
negative battery cable.

P21 B. Disconnect the ECM wiring harness connector E18.

17 28 32 C. Disconnect the instrument cluster wiring harness
1 16 connector P21.
D. Measure the resistance between terminal 20 of
ECM wiring harness connector E18 and terminal 28
of instrument cluster wiring harness connector P21.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 5.
No
Inspect and repair the open circuit fault between
1 2 9 20 22
terminal 20 of ECM wiring harness connector E18
3 4 23 36 and terminal 28 of instrument cluster wiring harness
5 6 37 50
connector P21.

7 8 51 64

E18

M4202018

5. Inspect instrument cluster

A. Replace the instrument cluster with a good one.
Is the indication normal?
Yes
The system is normal.
No
Replace the ECM.
Refer to: ECM (3.1.12 Electronic Control
System - M7, Removal and
Installation).

M201 2014.01
4.2.2-37 Instrument Cluster 4.2.2-37

Diagnosis Procedure for Inoperative Oil Pressure Warning

Indicator with Ignition Switch "ON"

Inoperative oil pressure

warning indicator with
ignition switch "ON"

General inspection
(Inspect instrument cluster wiring
harness connector)

Is the fault Yes

confirmed

No

Inspect instrument cluster fuse

Is the fault Yes

confirmed

No
Inspect instrument cluster power
supply

Is the fault Yes

confirmed

No

Inspect circuit between

instrument cluster and oil
pressure alarm
Is the fault Yes
confirmed

No

Inspect oil pressure alarm

End

M201 2014.01
4.2.2-38 Instrument Cluster 4.2.2-38

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect instrument cluster fuse

A. Inspect the instrument cluster fuse IF35.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect instrument cluster power supply

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 32
connector P21.
1 7 16
C. Measure the voltage between terminal 7 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 4.
M4202017
No
Inspect and repair the open circuit fault between
terminal 7 of instrument cluster wiring harness
connector P21 and terminal 70 of instrument panel
fuse box fuse IF35.

M201 2014.01
4.2.2-39 Instrument Cluster 4.2.2-39

Test Conditions Details/Results/Actions

4. Inspect circuit between instrument cluster and oil pressure alarm
A. Turn the ignition switch to "OFF".
P21 B. Disconnect the oil pressure alarm wiring harness
17 23 32 connector E10.
1 16 C. Disconnect the instrument cluster wiring harness
connector P21.
D. Measure the resistance between terminal 1 of oil
pressure alarm wiring harness connector E10 and
terminal 23 of instrument cluster wiring harness
connector P21.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
1 Go to step 5.
No
E10
Inspect and repair the open circuit fault between
M4202019 terminal 1 of oil pressure alarm wiring harness
connector E10 and terminal 23 of instrument cluster
wiring harness connector P21.

5. Inspect oil pressure alarm

A. Replace the oil pressure alarm with a good one.
Is the indication normal?
Yes
The system is normal.
No
Replace the instrument cluster.
Refer to: Instrument Cluster (4.2.2
Instrument Cluster, Removal and
Installation).

M201 2014.01
4.2.2-40 Instrument Cluster 4.2.2-40

Diagnosis Procedure for Inoperative Charging Indicator with

Ignition Switch "ON"

Inoperative charging indicator

with ignition switch "ON"

General inspection
(Inspect instrument cluster wiring
harness connector)

Is the fault Yes

confirmed

No

Inspect instrument cluster fuse

Is the fault Yes

confirmed

No
Inspect instrument cluster
power supply

Is the fault Yes

confirmed

No Inspect alternator regulator

Inspect circuit between instrument
cluster and alternator regulator

Is the fault Yes

confirmed
Is the fault
confirmed
No

Inspect alternator
No
Yes

End

M201 2014.01
4.2.2-41 Instrument Cluster 4.2.2-41

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect instrument cluster fuse

A. Inspect the instrument cluster fuse IF35.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect instrument cluster power supply

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 32
connector P21.
1 7 16
C. Measure the voltage between terminal 7 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 4.
M4202017
No
Inspect and repair the open circuit fault between
terminal 7 of instrument cluster wiring harness
connector P21 and terminal 70 of instrument panel
fuse box fuse IF35.

M201 2014.01
4.2.2-42 Instrument Cluster 4.2.2-42

Test Conditions Details/Results/Actions

4. Inspect circuit between instrument cluster and alternator regulator
A. Turn the ignition switch to "OFF".
P21 B. Disconnect the alternator wiring harness connector
17 24 32 P03.
1 16 C. Disconnect the instrument cluster wiring harness
connector P21.
D. Measure the resistance between terminal 3 of
alternator wiring harness connector P03 and
terminal 24 of instrument cluster wiring harness
connector P21.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes

3 2 1 Go to step 5.
No
P03 Inspect and repair the open circuit fault between
M4202020 terminal 3 of alternator wiring harness connector
P03 and terminal 24 of instrument cluster wiring
harness connector P21.

5. Inspect alternator regulator

A. Replace the alternator regulator with a good one.
Is the indication normal?
Yes
The system is normal.
No
Go to step 6.

6. Inspect alternator
A. Replace the alternator with a good one.
Is the indication normal?
Yes
The system is normal.
No
Replace the instrument cluster.
Refer to: Instrument Cluster (4.2.2
Instrument Cluster, Removal and
Installation).

M201 2014.01
4.2.2-43 Instrument Cluster 4.2.2-43

Diagnosis Procedure for Inoperative Parking Brake Indicator with

Ignition Switch "ON" and Vehicle Parked

Inoperative parking brake indicator

with ignition switch "ON" and vehicle
parked

General inspection
(Inspect instrument cluster wiring
harness connector)

Is the fault Yes

confirmed

No

Inspect instrument cluster fuse

Is the fault Yes

confirmed

No
Inspect instrument cluster power
supply

Is the fault Yes

confirmed

No
Inspect circuit between
instrument cluster and parking
brake switch
Is the fault Yes
confirmed

No

Inspect parking brake switch

End

M201 2014.01
4.2.2-44 Instrument Cluster 4.2.2-44

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect instrument cluster fuse

A. Inspect the instrument cluster fuse IF35.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect instrument cluster power supply

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 32
connector P21.
1 7 16
C. Measure the voltage between terminal 7 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 4.
M4202017
No
Inspect and repair the open circuit fault between
terminal 7 of instrument cluster wiring harness
connector P21 and terminal 70 of instrument panel
fuse box fuse IF35.

M201 2014.01
4.2.2-45 Instrument Cluster 4.2.2-45

Test Conditions Details/Results/Actions

4. Inspect circuit between instrument cluster and parking brake switch
A. Turn the ignition switch to "OFF".
P21 B. Disconnect the parking brake switch wiring harness
17 27 32 connector S18.
1 16 C. Disconnect the instrument cluster wiring harness
connector P21.
D. Measure the resistance between terminal 1 of
parking brake switch wiring harness connector S18
and terminal 27 of instrument cluster wiring harness
connector P21.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 5.
1
No
S18 Inspect and repair the open circuit fault between
M4202021 terminal 1 of parking brake switch wiring harness
connector S18 and terminal 27 of instrument cluster
wiring harness connector P21.

5. Inspect parking brake switch

A. Replace the parking brake switch with a good one.
Is the indication normal?
Yes
The system is normal.
No
Replace the instrument cluster.
Refer to: Instrument Cluster (4.2.2
Instrument Cluster, Removal and
Installation).

M201 2014.01
4.2.2-46 Instrument Cluster 4.2.2-46

Diagnosis Procedure for Inoperative Seat Belt Unfasten Indicator

with Ignition Switch "ON"

Inoperative seat belt unfasten

indicator with ignition switch
"ON"

General inspection
(Inspect instrument cluster wiring
harness connector)

Is the fault Yes

confirmed

No

Inspect instrument cluster fuse

Is the fault Yes

confirmed

No
Inspect instrument cluster power
supply

Is the fault Yes

confirmed

No Inspect seat belt switch

grounding circuit
Inspect circuit between instrument
cluster and seat belt switch

Is the fault Yes

confirmed
Is the fault
confirmed
No

Inspect seat belt switch

No
Yes

End

M201 2014.01
4.2.2-47 Instrument Cluster 4.2.2-47

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the instrument cluster wiring harness
connector for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect instrument cluster fuse

A. Inspect the instrument cluster fuse IF35.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect instrument cluster power supply

A. Turn the ignition switch to "OFF".
P21
B. Disconnect the instrument cluster wiring harness
17 32
connector P21.
1 7 16
C. Measure the voltage between terminal 7 of
instrument cluster wiring harness connector P21
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 4.
M4202017
No
Inspect and repair the open circuit fault between
terminal 7 of instrument cluster wiring harness
connector P21 and terminal 70 of instrument panel
fuse box fuse IF35.

M201 2014.01
4.2.2-48 Instrument Cluster 4.2.2-48

Test Conditions Details/Results/Actions

4. Inspect circuit between instrument cluster and seat belt switch
A. Turn the ignition switch to "OFF".
B. Disconnect the seat belt switch wiring harness
P21 connector S05.
17 22 32 C. Disconnect the instrument cluster wiring harness
1 16 connector P21.
D. Measure the resistance between terminal 2 of seat
belt switch wiring harness connector S05 and
terminal 22 of instrument cluster wiring harness
connector P21.
1 Standard resistance: less than 5 Ω
Is the resistance value normal?
2 Yes

S05 Go to step 5.
No
Inspect and repair the open circuit fault between
M4202022 terminal 2 of seat belt switch wiring harness
connector S05 and terminal 22 of instrument cluster
wiring harness connector P21.

5. Inspect seat belt switch grounding circuit

A. Disconnect the seat belt switch wiring harness
connector S05.
B. Measure the resistance between terminal 1 of seat
belt switch wiring harness connector S05 and
reliable grounding.
1
Standard resistance: less than 5 Ω
2 Is the resistance value normal?
Yes
S05
Go to step 6.
No
M4202023
Inspect and repair the open circuit fault between
seat belt switch wiring harness connector S05 and
the grounding G202.

M201 2014.01
4.2.2-49 Instrument Cluster 4.2.2-49

Test Conditions Details/Results/Actions

6. Inspect seat belt switch
A. Disconnect the seat belt switch wiring harness
connector S05.
B. Measure the resistance between terminals 1 and 2
of seat belt switch.
1 Standard resistance: less than 1 Ω
Is the resistance value normal?
2 Yes
Replace the instrument cluster.
S05
Refer to: Instrument Cluster (4.2.2
M4202024
Instrument Cluster, Removal and
Installation).
No
Replace the seat belt switch.

M201 2014.01
4.2.2-50 Instrument Cluster 4.2.2-50

Removal and Installation

Instrument Cluster
Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Use the special tool to remove the instrument
cluster cover.
Special tool: CA501-002

M5106001

3. Remove 4 retaining screws from the

instrument cluster.
×4

M5106002

M201 2014.01
4.2.2-51 Instrument Cluster 4.2.2-51

4. Disconnect the instrument cluster wiring

harness connector and remove the
instrument cluster.

M5106003

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.3-1 Horn 4.2.3-1

Description and Operation

4.2.3 Horn

System Overview
The horn is fixed on the crossmember in the front compartment and controlled by a relay which is
grounded by the steering wheel. The horn circuit is switched on and horn starts to sound when the horn
switch on the steering wheel is pressed.

Components Location View

Horn

M4203002

Item Description
1 Electrical horn assembly

M201 2014.01
4.2.3-2 Horn 4.2.3-2
Horn Switch

1 1
USE
WITH

2 2
3 3

M4203003

Item Description
1 Horn switch

M201 2014.01
4.2.3-3 Horn 4.2.3-3

Symptom Diagnosis and Testing

General Equipment

Digital multimeter

Inspection and Verification

1. Verify the customer concern.
2. Visually inspect for obvious mechanical or
electrical damage or collision.
Visual Inspection Chart

Mechanical Electrical
• Circuit
• Steering wheel
• Steering wheel horn
• Horn
switch

3. Inspect the system circuit which is accessible

or visible.
4. If an obvious cause for an observed or
reported concern has been found, solve the
fault before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
4.2.3-4 Horn 4.2.3-4

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and repair it in order of the
following table.

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
• Circuit for Horn Constantly
Horn constantly working • Horn Working (4.2.3 Horn,
• Horn switch Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
• Circuit for Horn Not Working
Horn does not work • Horn (4.2.3 Horn, Symptom
• Horn switch Diagnosis and
Testing).

M201 2014.01
4.2.3-5 Horn 4.2.3-5

Diagnosis Procedure for Horn Constantly Working

Horn constantly working

Inspect horn relay

Is the fault Yes

confirmed

No

Inspect horn switch

Is the fault Yes

confirmed

No

Inspect horn control circuit

End

M201 2014.01
4.2.3-6 Horn 4.2.3-6

Test Conditions Details/Results/Actions

1. Inspect horn relay
A. Inspect the horn relay IR09.
Is it normal?
Yes
Go to step 2.
No
Replace the horn relay IR09.

2. Inspect horn switch

A. Disconnect the horn switch wiring harness
connector P32.
Is the horn still sounding constantly?
Yes
Go to step 3.
No
Inspect and repair the horn switch, and replace the
horn switch wiring harness connector P32 when
necessary.

3. Inspect horn control circuit

A. Remove the instrument panel fuse box relay IR09.
B. Disconnect the horn wiring switch harness
connector P32.
C. Measure the resistance between terminal 1 of horn
switch wiring harness connector P32 and reliable
grounding.
1
Standard resistance: 10 MΩ or more
Is the resistance value normal?
P32
Yes
Inspect and repair the short circuit fault to power
M4203006 supply in terminal 2 of horn wiring harness
connector P12.
No
Inspect and repair the open circuit fault between
terminal 1 of horn switch wiring harness connector
P32 and terminal 85 of instrument panel fuse box
relay IR09.

M201 2014.01
4.2.3-7 Horn 4.2.3-7

Diagnosis Procedure for Horn Not Working

Horn not working

General inspection
(Inspect horn wiring
harness connector)

Is the fault Yes

confirmed

No

Inspect fuse and relay

Is the fault Yes

confirmed

No

Inspect horn power supply circuit

Is the fault Yes

confirmed

No

Inspect horn grounding circuit

End

M201 2014.01
4.2.3-8 Horn 4.2.3-8

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the horn switch wiring harness connector
for damage, poor contact, aging and looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect fuse and relay

A. Inspect the horn fuse IF12.
Fuse rated capacity: 15 A
B. Inspect the horn relay IR09.
Is it normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity or the relay.

3. Inspect horn power supply circuit

A. Disconnect the horn wiring harness connector P12.
B. Press the horn switch and measure the voltage
between terminal 2 of horn wiring harness
connector P12 and reliable grounding with the
multimeter.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?

2 1 Yes
Go to step 4.
P12
No
M4203005
Inspect and repair the horn switch and the circuit
fault between terminal 1 of horn switch wiring
harness connector P32 and terminal 2 of horn
wiring harness connector P12.

M201 2014.01
4.2.3-9 Horn 4.2.3-9

Test Conditions Details/Results/Actions

4. Inspect horn grounding circuit
A. Disconnect the horn wiring harness connector P12.
B. Measure the resistance between terminal 1 of horn
wiring harness connector P12 and reliable
grounding with the multimeter.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
2 1 Replace the horn assembly.

P12 Refer to: Horn (4.2.3 Horn, Removal and

Installation).
M4203004
No
Inspect and repair the faulty circuit between
terminal 1 of horn wiring harness connector P12
and grounding G105.

M201 2014.01
4.2.3-10 Horn 4.2.3-10

Removal and Installation

Horn
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the upper grille.
Refer to: Upper Grille (5.1.7 Bumper,
Removal and Installation).
3. Remove the horn.
1 Disconnect the horn wiring harness
connector.
2
2 Remove the horn retaining bolt and remove
the horn.

M4203001

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.4-1 Cigarette Lighter 4.2.4-1

Specifications
4.2.4 Cigarette Lighter

General Specifications
Item Rated Voltage Max. Current Reset Time Durability
Cigarette lighter 12 V (DC) 10 A Less than 18 s 5000

M201 2014.01
4.2.4-2 Cigarette Lighter 4.2.4-2

Description and Operation

System Overview
The cigarette lighter is installed on the instrument panel. It could be pulled out to use when it pops up
automatically after its heating element becomes hot in seconds upon pressing the button.
CAUTION: Be careful to avoid scalding from high temperature of the cigarette lighter in
energizing position.

Components Location View

1 1 USE
WITH

2 2
3 3

M4204004

Item Description Item Description

1 Center control panel assembly 2 Cigarette lighter

M201 2014.01
4.2.4-3 Cigarette Lighter 4.2.4-3

Symptom Diagnosis and Testing

General Equipment

Digital multimeter

Inspection and Verification

1. Verify the customer concern.
2. Visually check for obvious mechanical or
electrical damage and deformation due to
collision.
Visual Inspection Chart

Mechanical Electrical

• Instrument panel • Fuse

• Cigarette lighter • Circuit

retainer • Cigarette lighter

3. Inspect system circuit which is accessible or

visible.
4. If an obvious cause for an observed or
reported concern has been found, solve the
fault before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
4.2.4-4 Cigarette Lighter 4.2.4-4

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and repair it in order of the
following table.

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
for Cigarette Lighter
• Fuse and circuit Fault (4.2.4 Cigarette
Cigarette lighter fault
• Cigarette lighter Lighter, Symptom
Diagnosis and
Testing).
Cigarette lighter does not pop • Cigarette lighter • Replace the cigarette lighter
up • Cigarette lighter retainer • Replace the cigarette lighter retainer

M201 2014.01
4.2.4-5 Cigarette Lighter 4.2.4-5

Diagnosis Procedure for Cigarette Lighter Fault

Cigarette lighter fault

General inspection
(Inspect wiring harness connector
of cigarette lighter)

Is the fault Yes

confirmed

No

Inspect cigarette lighter fuse

Is the fault Yes

confirmed

No

Replace cigarette lighter

Is the fault Yes

confirmed

No

Inspect cigarette lighter power

supply circuit
Inspect cigarette lighter
grounding circuit
Is the fault Yes
confirmed

No

Replace cigarette lighter retainer

End

M201 2014.01
4.2.4-6 Cigarette Lighter 4.2.4-6

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connector of cigarette
lighter for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect cigarette lighter fuse

A. Inspect the cigarette lighter fuse IF40.
Fuse rated capacity: 15 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Replace cigarette lighter

A. Replace with a new cigarette lighter.
Does the cigarette lighter work normally?
Yes
Make sure that the system is normal.
No
Go to step 4.

4. Inspect cigarette lighter power supply circuit

A. Disconnect the cigarette lighter wiring harness
connector P37.
B. Turn the ignition switch to "ACC".
C. Measure the voltage between terminal 1 of
cigarette lighter wiring harness connector P37 and
reliable grounding.
Standard voltage: 11 ~ 14 V
1
Is the voltage value normal?
P37 Yes
Go to step 5.
M4204005
No
Inspect and repair the open circuit fault between
terminal 80 of instrument panel fuse box fuse IF40
and terminal 1 of cigarette lighter wiring harness
connector P37.

M201 2014.01
4.2.4-7 Cigarette Lighter 4.2.4-7

Test Conditions Details/Results/Actions

5. Inspect cigarette lighter grounding circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the cigarette lighter wiring harness
connector P36.
C. Measure the resistance between terminal 1 of
cigarette lighter wiring harness connector P36 and
reliable grounding.
Standard resistance: less than 5 Ω
1
Is the resistance value normal?
P36
Yes
Go to step 6.
M4204006
No
Inspect and repair the open circuit fault between
terminal 1 of cigarette lighter wiring harness
connector P36 and grounding G106.

6. Replace cigarette lighter retainer

A. Turn the ignition switch to "LOCK".
B. Replace the cigarette lighter retainer.
Refer to: Cigarette Lighter (4.2.4 Cigarette
Lighter, Removal and
Installation).
Make sure that the system is normal.

M201 2014.01
4.2.4-8 Cigarette Lighter 4.2.4-8

Removal and Installation

Cigarette Lighter
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the cigarette lighter from the center
control panel.

M4204001

3. Remove the A/C controller.

Refer to: A/C Controller (5.1.6 Instrument
Panel and Console, Removal and
Installation).
4. Disconnect the cigarette lighter wiring
harness connector.

M4204002

5. Turn the cigarette lighter retainer

counterclockwise, and remove the cigarette
lighter retainer from the control panel.

M4204003

M201 2014.01
4.2.4-9 Cigarette Lighter 4.2.4-9
Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.5-1 Information and Entertainment System 4.2.5-1

Specifications
4.2.5 Information and Entertainment System

General Specifications
Item Rated Voltage Rated Current
Radio power supply 12 V (DC) -

Torque Specifications
Item Nm lb-ft lb-in
Antenna retaining nut 4 - 35

M201 2014.01
4.2.5-2 Information and Entertainment System 4.2.5-2

Description and Operation

System Overview
When you turn on the radio and shift to "AM" or
"FM", the antenna receives radio signals and
sends them to the radio through feeder. The radio
receives the radio signals and filters wave to tune
the needed signals, then amplifies the audio
signals through amplifier and finally outputs them
through speakers.

Components Description
Roof Antenna
The roof antenna is located on the roof, and
receives radio signals.

Left and Right Speaker

The audio system of radio adopts two speakers
which are located inside the left and right door.

M201 2014.01
4.2.5-3 Information and Entertainment System 4.2.5-3

Radio Terminal List

3 2 1

8 7 6 5 4

M4205001

Terminal No. Connection Wire Terminal Description

P34-1 0.5 WH Radio power supply (+B)
P34-2 0.5 BU/RD Front right speaker positive
P34-3 0.5 RD Front left speaker positive
P34-4 0.85 BK Radio GND
P34-5 0.85 WH/BK Radio power supply (ACC)
P34-6 0.5 RD/YE Background lamp power supply
P34-7 0.5 BU/BK Front right speaker negative
P34-8 0.5 RD/BK Front Left speaker negative

M201 2014.01
4.2.5-4 Information and Entertainment System 4.2.5-4

Symptom Diagnosis and Testing

General Equipment

Digital multimeter

Inspection and Verification

CAUTION: When testing whether the
audio entertainment system has poor
reception or noise interference, park the
vehicle outdoors far from metal buildings
and power supply wires.
1. Verify the customer concern.
2. Visually check if there are obvious
mechanical or electrical damage and
deformation due to collision.
Visual Inspection Chart

Mechanical Electrical
• Fuse
• Antenna • Circuit
• Control panel • Audio circuit
• Antenna and feeder

3. Inspect system circuit that is accessible and

visible.
CAUTION: Twisted-pair cable can shield
electronic components effectively from
electrical interference. If the shielding
layer of original circuits is damaged,
install a new one.

4. If an observed or reported concern is obvious

and its cause has been found, solve the fault
before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
4.2.5-5 Information and Entertainment System 4.2.5-5

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and repair it in order of the
following table.

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
for Function Disabled
• Fuse and Switch on Fault
Function disabled, switch on (4.2.5 Information and
• Circuit
fault Entertainment
• Radio host System, Symptom
Diagnosis and
Testing).
Refer to: Diagnosis Procedure
for No Sound (4.2.5
• Fuse and circuit Information and
No sound • Speaker Entertainment
• Radio host System, Symptom
Diagnosis and
Testing).
• Inspect and repair the screen circuit
Wrong or no display on • Screen does not light fault.
screen • Screen fault • Inspect and repair or replace the
radio.
• Inspect and repair the circuit.
• Inspect and repair the antenna and
• Circuit interference feeder.
Sound is not clear • Antenna and feeder • Inspect and repair or replace the
• Radio host speaker.
• Inspect and repair or replace the
radio host.
• Change the place for receiving radio
• Interference or shield at signals.
Poor or no radio signal
some places • Inspect and repair, replace the
reception • Antenna and feeder antenna and feeder.
• Radio host • Inspect and repair or replace the
radio host.
• Inspect and repair the circuit.
• Audio circuit • Inspect and repair or replace the
Single track when playing • Speaker speaker.
• Radio host • Inspect and repair or replace the
radio host.

M201 2014.01
4.2.5-6 Information and Entertainment System 4.2.5-6

Diagnosis Procedure for Function Disabled and Switch on Fault

Function disabled and

switch on fault

General inspection
(Inspect wiring harness
connector of radio host,
antenna and feeder)

Is the fault Yes

confirmed

No

Inspect radio host fuse

Is the fault Yes

confirmed

No
Inspect radio host power
supply circuit

Is the fault Yes

confirmed

No
Inspect radio host
grounding circuit

Is the fault Yes

confirmed

No

Replace radio host

End

M201 2014.01
4.2.5-7 Information and Entertainment System 4.2.5-7

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connector of radio host,
antenna and feeder for damage, aging, poor
contact, looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect radio host fuse

A. Inspect the radio host fuse IF07, IF40.
Fuse rated capacity: 10 A (IF07), 15 A (IF40)
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit and replace the
fuse with rated capacity.

3. Inspect radio host power supply circuit

A. Disconnect the radio wiring harness connector P34.
B. Turn the ignition switch to "ACC".
C. Measure the voltage between terminals 1 and 5 of
radio host wiring harness connector P34.
P34 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
3 2 1 Yes
8 7 6 5 4 Go to step 4.
No
M4205009 Inspect and repair the open circuit fault of radio host
power supply circuit.

M201 2014.01
4.2.5-8 Information and Entertainment System 4.2.5-8

Test Conditions Details/Results/Actions

4. Inspect radio host grounding circuit
A. Turn the ignition switch to "LOCK".
B. Measure the resistance between terminal 4 of radio
host wiring harness connector P34 and reliable
grounding point.
P34 Standard resistance: less than 5 Ω
Is the resistance value normal?
3 2 1 Yes
8 7 6 5 4 Go to step 5.
No
Inspect and repair the open circuit fault between
M4205010
radio host grounding circuit and grounding point
G106.

5. Replace radio host

A. Turn the ignition switch to "LOCK".
B. Replace the radio host.
Refer to: Radio (4.2.5 Information and
Entertainment System, Removal
and Installation).
The system is normal.

M201 2014.01
4.2.5-9 Information and Entertainment System 4.2.5-9

Diagnosis Procedure for No Sound

No sound

General inspection
(Inspect wiring harness
connector of radio host,
antenna and feeder)

Is the fault Yes

confirmed

No

Inspect operation of all speakers

Yes Is the fault

confirmed

No
Inspect and repair circuit and
state of front left speaker

Is the fault Yes

confirmed

No
Inspect and repair circuit and state
of front right speaker

Is the fault Yes

confirmed

No

Replace radio host

End

M201 2014.01
4.2.5-10 Information and Entertainment System 4.2.5-10

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connector of radio host,
antenna and feeder for damage, aging, poor
contact, looseness and so on.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect operation of all speakers

A. Turn the ignition switch to "ACC".
B. Turn on the radio and enter playing state.
Do all the speakers not work?
Yes
Go to step 5.
No
Go to step 3.

3. Inspect and repair circuit and state of front left speaker

A. Turn the ignition switch to "LOCK".
B. Inspect and repair the front left speaker circuit,
eliminating situations such as short circuit to
ground, open circuit, loose wiring harness
connector.
C. Replace the front left speaker.
Refer to: Front Speaker (4.2.5 Information
and Entertainment System,
Removal and Installation).
Is the system normal?
Yes
The system is normal.
No
Go to step 4.

M201 2014.01
4.2.5-11 Information and Entertainment System 4.2.5-11

Test Conditions Details/Results/Actions

4. Inspect and repair circuit and state of front right speaker
A. Turn the ignition switch to "LOCK".
B. Inspect and repair the front right speaker circuit,
eliminating situations such as short circuit to
ground, open circuit, loose wiring harness
connector.
C.Replace the front right speaker.
Refer to: Front Speaker (4.2.5 Information
and Entertainment System,
Removal and Installation).
Is the system normal?
Yes
The system is normal.
No
Go to step 5.

5. Replace radio host

A. Turn the ignition switch to "LOCK".
B. Replace the radio host.
Refer to: Radio Host (4.2.5 Information
and Entertainment System,
Removal and Installation).
The system is normal.

M201 2014.01
4.2.5-12 Information and Entertainment System 4.2.5-12

Removal and Installation

Radio
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the center control panel.
Refer to: Hazard Warning Lamp (4.2.6
Lighting System, Removal and
Installation).
3. Remove 4 retaining bolts from the radio.

×4
1 1
USE
WITH

2 2
3 3

M4205002

4. Disconnect the radio wiring harness

connector 1.
2
5. Disconnect the radio antenna connector 2,
and remove the radio.

M4205003

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.5-13 Information and Entertainment System 4.2.5-13

Speaker
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the front door interior trim panel.
Refer to: Front Door Interior Trim Panel (5.1.2
Door, Removal and Installation).
3. Remove the front door water-proof film.
CAUTION: Be careful to prevent damage
to the water-proof film during removal. Do
not touch the adhesive surface to avoid
reduction in adhesion effect during
reassembly.

M5102021

4. Remove 4 retaining screws from the speaker.

×4

M4205004

5. Disconnect the speaker wiring harness

connector, and remove the speaker.

M4205005

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.5-14 Information and Entertainment System 4.2.5-14

Antenna
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the instrument panel.

Refer to: Instrument Panel (5.1.6
Instrument Panel and Console,
Removal and Installation).

3. Remove the left A pillar trim panel.

Refer to: A Pillar Trim Panel (5.1.9 Interior
Trim Panel and Ornamentation,
Removal and Installation).

4. Remove the roof lining.

Refer to: Roof Lining (5.1.9 Interior Trim
Panel and Ornamentation,
Removal and Installation).

5. Disconnect 3 retaining clips between antenna

and instrument panel crossmember.
6. Disconnect 5 retaining clips between antenna
and vehicle body.
×5

M4205006

7. Remove the antenna retaining nut.

Torque: 4 Nm

M4205007

M201 2014.01
4.2.5-15 Information and Entertainment System 4.2.5-15

8. Remove the antenna assembly from outside

of the vehicle.

M4205008

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-1 Lighting System 4.2.6-1

Specifications
4.2.6 Lighting System

Component Specifications
Item Bulb Name Specifications
Single beam tungsten halogen
Headlamp assembly - low beam bulb H7 12V 55W
bulb
Single beam tungsten halogen
Headlamp assembly - high beam bulb H7 12V 55W
bulb
Headlamp assembly - position lamp bulb Incandescent bulb W5W 12V
Headlamp assembly - turn lamp bulb Amber incandescent bulb PY21W 12V
Single beam tungsten halogen
Front fog lamp H3 12V 55W
bulb
Rear combination lamp - turn lamp Amber incandescent bulb PY21W 12V
Rear combination lamp - brake lamp Incandescent bulb P21/5W 12V
Rear combination lamp - position lamp Incandescent bulb P21/5W 12V
Rear fog lamp White incandescent bulb P21W 12W
Backup lamp White incandescent bulb P21W 12V
High mounted stop lamp LED -
License plate lamp Incandescent bulb W5W 12V
Single beam tube incandescent
Front roof lamp W10W 12V
bulb
Single beam tube incandescent
Reading lamp W5W 12V
bulb

M201 2014.01
4.2.6-2 Lighting System 4.2.6-2

Description and Operation the second segment with the end of lever in
the third position.
System Overview
Note: The rear fog lamp switch will also
Lighting Control be turned off automatically when
the headlamp switch is turned to
Lamps are illuminated when the knob at the end
"OFF".
of lighting combination switch control lever is
turned. There are 3 levels:
1. All lamps are off when the combination switch
is "OFF".
2. The position lamp, tail lamp, license plate
lamp and instrument panel background lamps
are all illuminated when the lighting
combination switch is in the middle.
3. Lamps including the above lamps as well as
the headlamps are illuminated when the
lighting combination switch is in the third
position.

High Beam Control

High beam control has two gears:
1. The high beam lamps are illuminated and the
high beam indicator on the instrument cluster
comes on when pushing the control lever to
high beam gear with the low beam lamps on.
2. When the gear is not at the position of high
beam, the high beam lamps are illuminated
with the control lever is lifted up, and come off
with the lever released, which can be used
when overtaking.

Turn Lamp
When the ignition switch is ON, the right turn lamp
is illuminated when the control lever is pushed up;
the left turn lamp is illuminated when the lever is
pushed down.

Fog Lamp Control

1. The front fog lamps are illuminated, and the
front fog lamp indicator on the instrument
panel comes on simultaneously when the
control lever is turned to the first gear on the
second segment with the end of lever in the
middle.
2. The rear fog lamps are illuminated, and the
rear fog lamp indicator on the instrument
panel comes on simultaneously when the
control lever is turned to the second gear on

M201 2014.01
4.2.6-3 Lighting System 4.2.6-3

Components Location View

Interior Component

1 1 USE
WITH

2 2
3 3

M4206030

Item Description Item Description

1 Lighting combination switch 3 Lamp angle control switch
2 Hazard warning lamp switch

M201 2014.01
4.2.6-4 Lighting System 4.2.6-4
Front Lighting

M4206031

Item Description Item Description

1 Headlamp assembly 2 Front fog lamp assembly

M201 2014.01
4.2.6-5 Lighting System 4.2.6-5
Rear Lighting

M4206032

Item Description Item Description

1 High mounted stop lamp 4 Rear fog lamp
2 Backup lamp 5 License plate lamp
3 Rear combination lamp

M201 2014.01
4.2.6-6 Lighting System 4.2.6-6
Interior Lighting

OFF
ON

M4206067

Item Description Item Description

1 Front roof lamp 2 Reading lamp

M201 2014.01
4.2.6-7 Lighting System 4.2.6-7

General Inspection
Test for Lighting Combination Switch

P T 1 2 3 4 5 6 7 8 9 10 11 1213
OFF
Position lamp
Low beam lamp
High beam lamp 1 2 3 4
Overtaking Lamp
Front fog lamp 5 6 7 8 9 10 11 12 13
Rear fog lamp
Left turn lamp
Right turn lamp

M4206033 M4206041

Test Conditions Details/Results/Actions

1. Inspect position lamp switch
A. Turn the lighting combination switch to the position
of position lamp.
B. Measure the continuity between terminals 5 and 8 of
lighting combination switch.
Standard resistance: less than 1 Ω
C. Turn off the lighting combination switch.
D. Measure the connection between terminals 5 and 8
of lighting combination switch.

1 2 3 4 Standard resistance: 10 MΩ or more

Is it normal?
5 6 7 8 9 10 11 12 13 Yes
Go to step 2.
No
Replace the lighting combination switch.
M4206034

M201 2014.01
4.2.6-8 Lighting System 4.2.6-8

Test Conditions Details/Results/Actions

2. Inspect low beam lamp switch
A. Turn the lighting combination switch to the position
of low beam lamp.
B. Measure the continuity between terminals 7 and 10
of lighting combination switch.
Standard resistance: less than 1 Ω
C. Turn off the lighting combination switch.
D. Measure the connection between terminals 7 and 10
of lighting combination switch.

1 2 3 4 Standard resistance: 10 MΩ or more

Is it normal?
5 6 7 8 9 10 11 12 13 Yes
Go to step 3.
No
Replace the lighting combination switch.
M4206035

3. Inspect high beam lamp switch

A. Turn the lighting combination switch to the position
of high beam lamp.
B. Measure the continuity between terminals 7 and 9 of
lighting combination switch.
Standard resistance: less than 1 Ω
1 2 3 4
C. Turn off the lighting combination switch.
5 6 7 8 9 10 11 12 13 D. Measure the connection between terminals 7 and 9
of lighting combination switch.
Standard resistance: 10 MΩ or more
Is it normal?
Yes
Go to step 4.
No
Replace the lighting combination switch.
M4206036

M201 2014.01
4.2.6-9 Lighting System 4.2.6-9

Test Conditions Details/Results/Actions

4. Inspect overtaking lamp switch
CAUTION: In this case, the lighting
combination switch should be turned off
first and then turned to the position of
overtaking lamp.
1 2 3 4 A. Turn the lighting combination switch to the position
of overtaking lamp.
5 6 7 8 9 10 11 12 13
B. Measure the continuity between terminals 7 and 9 of
lighting combination switch.
Standard resistance: less than 1 Ω
C. Turn off the lighting combination switch.
D. Measure the connection between terminals 7 and 9
of lighting combination switch.
Standard resistance: 10 MΩ or more
Is it normal?
M4206036 Yes
Go to step 5.
No
Replace the lighting combination switch.

5. Inspect front fog lamp switch

A. Turn on the front fog lamp switch of lighting
combination switch.
B. Measure the continuity between terminals 1 and 3 of
lighting combination switch.
Standard resistance: less than 1 Ω
C. Turn off the lighting combination switch.
D. Measure the connection between terminals 1 and 3
of lighting combination switch.
Standard resistance: 10 MΩ or more
Is it normal?
1 2 3 4 Yes

5 6 7 8 9 10 11 12 13 Go to step 6.
No
Replace the lighting combination switch.
M4206038

M201 2014.01
4.2.6-10 Lighting System 4.2.6-10

Test Conditions Details/Results/Actions

6. Inspect rear fog lamp switch
A. Turn on the rear fog lamp switch of lighting
combination switch.
B. Measure the continuity between terminals 1 and 2 of
lighting combination switch.
Standard resistance: less than 1 Ω
C. Turn off the lighting combination switch.
D. Measure the connection between terminals 1 and 2
of lighting combination switch.
Standard resistance: 10 MΩ or more
Is it normal?
1 2 3 4
Yes

5 6 7 8 9 10 11 12 13 Go to step 7.
No
Replace the lighting combination switch.
M4206039

7. Inspect left turn lamp switch

A. Turn on the left turn lamp switch of lighting
combination switch.
B. Measure the continuity between terminals 12 and 13
of lighting combination switch.
1 2 3 4
Standard resistance: less than 1 Ω
5 6 7 8 9 10 11 12 13 C. Turn off the left turn lamp switch.
D. Measure the connection between terminals 12 and
13 of lighting combination switch.
Standard resistance: 10 MΩ or more
Is it normal?
Yes
Go to step 8.
No
Replace the lighting combination switch.
M4206040

M201 2014.01
4.2.6-11 Lighting System 4.2.6-11

Test Conditions Details/Results/Actions

8. Inspect right turn lamp switch
A. Turn on the right turn lamp switch of lighting
combination switch.
B. Measure the continuity between terminals 11 and 12
of lighting combination switch.
Standard resistance: less than 1 Ω
C. Turn off the right turn lamp switch.
D. Measure the connection between terminals 11 and
12 of lighting combination switch.

1 2 3 4 Standard resistance: 10 MΩ or more

Is it normal?
5 6 7 8 9 10 11 12 13 Yes
Refer to: Symptom Chart (4.2.6 Lighting
System, Symptom Diagnosis and
Testing).
M4206041
No
Replace the lighting combination switch.

M201 2014.01
4.2.6-12 Lighting System 4.2.6-12

Symptom Diagnosis and Testing

General Equipment

Digital multimeter

Inspection and Verification

1. Verify the customer concern.
2. Visually check if there is obvious electrical
fault. Eliminate the cause of bulb damage.
3. Inspect system circuit which is accessible or
visible.
4. If an obvious cause for an observed or
reported concern has been found, solve the
fault before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.
Visual Inspection Chart

Electrical
• Fuse
• Circuit
• Switch
• Bulb

M201 2014.01
4.2.6-13 Lighting System 4.2.6-13

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and repair it in order of the
following table.

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
• Fuse
for Brake Lamp Fault
Diagnosis procedure for brake • Circuit (4.2.6 Lighting
lamp fault • Bulb System, Symptom
Diagnosis and
• Brake lamp switch
Testing).
Refer to: Diagnosis Procedure
for One or More Brake
Diagnosis procedure for • Circuit Lamps Fault (4.2.6
single brake lamp fault • Bulb Lighting System,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for Brake Lamp
Diagnosis procedure for brake • Brake lamp switch Constant ON (4.2.6
lamp constant on • Circuit Lighting System,
Symptom Diagnosis
and Testing).
• Fuse Refer to: Diagnosis Procedure
• Hazard warning lamp switch for Turn Lamp Fault
(4.2.6 Lighting
Diagnosis procedure for turn • Lighting combination switch
System, Symptom
lamp fault • Circuit Diagnosis and
• Bulb Testing).
• Turn lamp relay

Refer to: Diagnosis Procedure

• Lighting combination switch for One or More Turn
Diagnosis procedure for one Lamps Fault (4.2.6
• Circuit
or more turn lamps fault Lighting System,
• Bulb Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for One or More Turn
Diagnosis procedure for one • Lighting combination switch Lamps Fault (no
or more turn lamps constant blinking) (4.2.6
on (no blinking) • Circuit
Lighting System,
Symptom Diagnosis
and Testing).

M201 2014.01
4.2.6-14 Lighting System 4.2.6-14

Symptom Possible Causes Solutions

• Fuse Refer to: Diagnosis Procedure
• Hazard warning lamp switch for Hazard Warning
Diagnosis procedure for Lamp Fault (4.2.6
• Bulb
hazard warning lamp fault Lighting System,
• Circuit Symptom Diagnosis
• Turn lamp relay and Testing).

Refer to: Diagnosis Procedure

• Fuse
for Position Lamp
Diagnosis procedure for • Circuit Fault (4.2.6 Lighting
position lamp fault • Bulb System, Symptom
Diagnosis and
• Lighting combination switch
Testing).
Refer to: Diagnosis Procedure
for Position Lamp
Diagnosis procedure for • Circuit Constant ON (4.2.6
position lamp constant on • Lighting combination switch Lighting System,
Symptom Diagnosis
and Testing).
• Fuse Refer to: Diagnosis Procedure
• Circuit for Front Fog Lamp
Diagnosis procedure for front Fault (4.2.6 Lighting
• Bulb
fog lamp fault System, Symptom
• Front fog lamp relay Diagnosis and
• Lighting combination switch Testing).

Refer to: Diagnosis Procedure

• Front fog lamp relay for Front Fog Lamp
Diagnosis procedure for front Constant ON (4.2.6
• Lighting combination switch
fog lamp constant on Lighting System,
• Circuit Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
• Fuse
for Rear Fog Lamp
Diagnosis procedure for rear • Lighting combination switch Fault (4.2.6 Lighting
fog lamp fault • Circuit System, Symptom
Diagnosis and
• Bulb
Testing).
Refer to: Diagnosis Procedure
for Rear Fog Lamp
Diagnosis procedure for rear • Lighting combination switch Constant ON (4.2.6
fog lamp constant on • Circuit Lighting System,
Symptom Diagnosis
and Testing).

M201 2014.01
4.2.6-15 Lighting System 4.2.6-15

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
• Fuse
for Backup Lamp Fault
Diagnosis procedure for • Circuit (4.2.6 Lighting
backup lamp fault • Bulb System, Symptom
Diagnosis and
• Backup lamp switch
Testing).
Refer to: Diagnosis Procedure
for Backup Lamp
Diagnosis procedure for • Circuit Constant ON (4.2.6
backup lamp constant on • Backup lamp switch Lighting System,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
• Fuse
for Low Beam Lamp
Diagnosis procedure for low • Circuit Fault (4.2.6 Lighting
beam lamp fault • Bulb System, Symptom
Diagnosis and
• Lighting combination switch
Testing).
Refer to: Diagnosis Procedure
for One Side Low
• Fuse Beam Lamp Fault
Diagnosis procedure for one
• Circuit (4.2.6 Lighting
side low beam lamp fault
• Bulb System, Symptom
Diagnosis and
Testing).
Refer to: Diagnosis Procedure
for Low Beam Lamp
Diagnosis procedure for low • Circuit Constant ON (4.2.6
beam lamp constant on • Lighting combination switch Lighting System,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
• Fuse
for High Beam Lamp
Diagnosis procedure for high • Circuit Fault (4.2.6 Lighting
beam lamp fault • Bulb System, Symptom
Diagnosis and
• Lighting combination switch
Testing).
Refer to: Diagnosis Procedure
for One Side High
• Fuse Beam Lamp Fault
Diagnosis procedure for one
• Circuit (4.2.6 Lighting
side high beam lamp fault
• Bulb System, Symptom
Diagnosis and
Testing).

M201 2014.01
4.2.6-16 Lighting System 4.2.6-16

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
for High Beam Lamp
Diagnosis procedure for high • Circuit Constant ON (4.2.6
beam lamp constant on • Lighting combination switch Lighting System,
Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
• Fuse
for Overtaking Lamp
Diagnosis procedure for • Circuit Fault (4.2.6 Lighting
overtaking lamp fault • Bulb System, Symptom
Diagnosis and
• Lighting combination switch
Testing).
Refer to: Diagnosis Procedure
• Fuse
for License Plate
Diagnosis procedure for • Circuit Lamp Fault (4.2.6
license plate lamp fault • Bulb Lighting System,
Symptom Diagnosis
• Lighting combination switch
and Testing).
Refer to: Diagnosis Procedure
• Fuse
for Front Roof Lamp
Diagnosis procedure for front • Front roof lamp switch Fault (4.2.6 Lighting
roof lamp fault • Circuit System, Symptom
Diagnosis and
• Bulb
Testing).
Refer to: Diagnosis Procedure
• Fuse
for Reading Lamp
Diagnosis procedure for • Reading lamp switch Fault (4.2.6 Lighting
reading lamp fault • Circuit System, Symptom
Diagnosis and
• Bulb
Testing).

M201 2014.01
4.2.6-17 Lighting System 4.2.6-17

Diagnosis Procedure for Brake Lamp Fault

Brake lamp fault

General inspection
(Inspect wiring harness
connectors related to brake lamp)

Is the fault Yes

confirmed

No

Inspect brake lamp fuse IF10

Is the fault Yes

confirmed

No
Inspect brake lamp fuse IF10
power supply

Is the fault Yes

confirmed

No

Inspect brake lamp switch power

supply circuit
Inspect brake lamp switch

Is the fault Yes

confirmed

No

Inspect brake lamp power supply

circuit

End

M201 2014.01
4.2.6-18 Lighting System 4.2.6-18

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
brake lamp for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect brake lamp fuse IF10

A. Inspect the brake lamp fuse IF10.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect brake lamp fuse IF10 power supply

A. Measure the voltage between terminal 19 of
instrument panel fuse box fuse IF10 and reliable
P40 grounding.
Standard voltage: 11 ~ 14 V
19
IF10
Is the voltage value normal?
20
Yes
Go to step 4.
No
Inspect and repair the open circuit fault between
terminal 19 of instrument panel fuse box fuse IF10
and battery.

M4206042

M201 2014.01
4.2.6-19 Lighting System 4.2.6-19

Test Conditions Details/Results/Actions

4. Inspect brake lamp switch power supply circuit
A. Measure the voltage between terminal 1 of brake
lamp switch wiring harness connector P20 and
reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
1
Yes
2 Go to step 5.

P20 No
Inspect and repair the open circuit fault between
terminal 1 of brake lamp switch wiring harness
M4206043
connector P20 and terminal 20 of instrument panel
fuse box fuse IF10.

5. Inspect brake lamp switch

A. Depress the brake pedal.
B. Measure the voltage between terminal 2 of brake
lamp switch wiring harness connector P20 and
reliable grounding.
1 Standard voltage: 11 ~ 14 V

2 Is the voltage value normal?

Yes
P20
Go to step 6.
No
Replace the brake lamp switch.
M4206044

6. Inspect brake lamp power supply circuit

A. Disconnect the rear left combination lamp wiring
harness connector S10.
B. Technician A depresses the brake pedal.
C. Technician B measures the voltage between
terminal 2 of rear left combination lamp wiring
harness connector S10 and reliable grounding with
a multimeter.
1 2 3 4 Standard voltage: 11 ~ 14 V
Is the voltage value normal?

S10 Yes
M4206045 Inspect and repair the open circuit fault between
terminal 1 of rear left combination lamp wiring
harness connector S10 and the ground point G201.
No
Inspect and repair the open circuit fault between
terminal 2 of rear left combination lamp wiring
harness connector S10 and terminal 2 of brake
lamp switch wiring harness connector P20.

M201 2014.01
4.2.6-20 Lighting System 4.2.6-20

Diagnosis Procedure for Single Brake Lamp Fault

Single brake lamp fault

General inspection
(Inspect wiring harness
connectors related to brake lamp)

Yes
Is the fault
confirmed

No

Inspect failed brake lamp bulb

Is the fault Yes

confirmed

No

Inspect brake lamp power supply

circuit (take the rear left brake
lamp as an example)

Is the fault Yes

confirmed

No

Inspect brake lamp grounding

circuit

End

M201 2014.01
4.2.6-21 Lighting System 4.2.6-21

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
brake lamp for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect failed brake lamp bulb

A. Inspect the filament in the brake lamp bulb to see if
it is in good condition.
B. Inspect the brake lamp bulb contact for oxidation or
poor contact.
Is it abnormal?
Yes
Replace the brake lamp bulb, and solve the
problem of oxidation.
No
Go to step 3.

3. Inspect brake lamp power supply circuit (take the rear left brake lamp as an example)
A. Disconnect the rear left combination lamp wiring
harness connector S10.
B. Technician A depresses the brake pedal.
C. Technician B measures the voltage between
terminal 2 of rear left combination lamp wiring
harness connector S10 and reliable grounding with
a multimeter.
1 2 3 4 Standard voltage: 11 ~ 14 V
Is the voltage value normal?

S10 Yes
M4206045 Go to step 4
No
Inspect and repair the open circuit fault between
terminal 2 of rear left combination lamp wiring
harness connector S10 and terminal 2 of brake
lamp switch wiring harness connector P20.

M201 2014.01
4.2.6-22 Lighting System 4.2.6-22

Test Conditions Details/Results/Actions

4. Inspect brake lamp grounding circuit
A. Disconnect the rear left combination lamp wiring
harness connector S10.
B. Measure the resistance between terminal 1 of rear
left combination lamp wiring harness connector S10
and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
1 2 3 4 Yes
Replace the rear left combination lamp.
S10 Refer to: Rear Combination Lamp (4.2.6
M4206047 Lighting System, Removal and
Installation).
Make sure the maintenance has been finished.
No
Inspect and repair the open circuit fault between
terminal 1 of rear left combination lamp wiring
harness connector S10 and the ground point G201.

M201 2014.01
4.2.6-23 Lighting System 4.2.6-23

Diagnosis Procedure for Brake Lamp Constant ON

Brake lamp constant on

General inspection
(Inspect wiring harness
connectors related to brake lamp)

Is the fault Yes

confirmed

No

Inspect brake lamp switch

Yes
Is the fault
confirmed

No

Inspect brake lamp power supply

circuit

End

M201 2014.01
4.2.6-24 Lighting System 4.2.6-24

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
brake lamp for damage or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect brake lamp switch

A. Disconnect the brake lamp switch wiring harness
connector P20.
Has the brake lamp gone off?
Yes
Replace the brake lamp switch.
No
Go to step 3.

3. Inspect brake lamp power supply circuit

A. Disconnect the brake lamp switch wiring harness
connector P20.
B. Disconnect the rear combination lamp wiring
harness connector S08, S10 and high mounted
1 stop lamp wiring harness connector D13.
C. Measure the voltage between terminal 2 of brake
2 lamp switch wiring harness connector P20 and
P20 reliable grounding.
Standard voltage: 0 V
Is the voltage value normal?
M4206044 Yes
The system is normal.
No
Inspect and repair the short circuit fault between
power and terminal 2 of brake lamp switch wiring
harness connector P20.

M201 2014.01
4.2.6-25 Lighting System 4.2.6-25

Diagnosis Procedure for Turn Lamp Fault

Turn lamp fault

General inspection
(Inspect wiring harness connectors
related to turn lamp and inspect turn
lamp bulb)

Is the fault Yes

confirmed

No

Inspect turn lamp switch

Is the fault Yes

confirmed

No

Inspect turn lamp fuse

Inspect turn lamp fuse power
supply

Is the fault Yes

confirmed

No

Inspect hazard warning lamp

switch - turn lamp input power
supply circuit
Inspect hazard warning lamp
switch Yes
Is the fault
confirmed

No
Is the fault
confirmed Inspect front left turn lamp power
supply circuit
No

Inspect turn lamp relay power

supply circuit
Inspect turn lamp relay grounding
circuit
Inspect turn lamp relay End
Inspect turn lamp relay output
power supply circuit

M201 2014.01
4.2.6-26 Lighting System 4.2.6-26

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
turn lamp for damage, poor contact, aging and
looseness.
B. Inspect the filament and lamp holder of turn lamp
bulb for abnormal conditions such as damage and
oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect turn lamp switch

A. Inspect the turn lamp switch.
Refer to: Test for Lighting Combination
Switch (4.2.6 Lighting System,
General Inspection).
Is the lighting combination switch normal?
Yes
Go to step 3.
No
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).
3. Inspect turn lamp fuse
A. Inspect the turn lamp fuse IF34.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 4.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.6-27 Lighting System 4.2.6-27

Test Conditions Details/Results/Actions

4. Inspect turn lamp fuse power supply
A. Turn the ignition switch to "ON".

P40 B. Measure the voltage between terminal 67 of

instrument panel fuse box fuse IF34 and reliable
grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
67
IF34 Go to step 5.
No
Inspect and repair the open circuit fault between
terminal 67 of instrument panel fuse box fuse IF34
and ignition switch IG1.

M4206049

5. Inspect hazard warning lamp switch - turn lamp input power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the hazard warning lamp switch wiring
harness connector P25.
P25
C. Turn the ignition switch to "ON", and measure the
voltage between terminal 6 of hazard warning lamp
3 2 1 switch wiring harness connector P25 and reliable
grounding.
8 7 6 5 4 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
M4206050 Go to step 6.
No
Inspect and repair the open circuit fault between
terminal 6 of hazard warning lamp switch wiring
harness connector P25 and terminal 68 of
instrument panel fuse box fuse IF34.

M201 2014.01
4.2.6-28 Lighting System 4.2.6-28

Test Conditions Details/Results/Actions

6. Inspect hazard warning lamp switch
A. Turn the ignition switch to "LOCK".
B. Disconnect the hazard warning lamp switch wiring
harness connector P25.
C. Measure the resistance between terminals 6 and 8
of hazard warning lamp switch.
1 2 3 Standard resistance: less than 1 Ω
Is the resistance value normal?
4 5 6 7 8
Yes
Go to step 7.
No
M4206051
Replace the hazard warning lamp switch.
Refer to: Hazard Warning Lamp Switch
(4.2.6 Lighting System, Removal
and Installation).
7. Inspect turn lamp relay power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the hazard warning lamp switch wiring
P25 harness connector P25.
C. Disconnect the turn lamp relay wiring harness
connector P27.
3 2 1 D. Measure the resistance between terminal 2 of turn
lamp relay wiring harness connector P27 and
8 7 6 5 4 terminal 8 of hazard warning lamp switch wiring
harness connector P25.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 8.
No
Inspect and repair the open circuit fault between
terminal 2 of turn lamp relay wiring harness
1 connector P27 and terminal 8 of hazard warning
lamp switch wiring harness connector P25.
3 2

P27

M4206052

M201 2014.01
4.2.6-29 Lighting System 4.2.6-29

Test Conditions Details/Results/Actions

8. Inspect turn lamp relay grounding circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the turn lamp relay wiring harness
connector P27.
P27 C. Measure the resistance between terminal 3 of turn
lamp relay wiring harness connector P27 and
1 reliable grounding.
Standard resistance: less than 5 Ω
3 2
Is the resistance value normal?
Yes
Go to step 9.
M4206053
No
Inspect and repair the open circuit fault between
terminal 3 of turn lamp relay wiring harness
connector P27 and the ground point G105.

9. Inspect turn lamp relay

A. Turn the ignition switch to "ON".
B. Turn on the left turn lamp switch of lighting
combination switch.
C. Measure the voltage between terminal 1 of turn
P27 lamp relay wiring harness connector P27 and
reliable grounding from the back.
1
Standard voltage: changes from 0 V to 11 ~ 14 V

3 2 Is the voltage value normal?

Yes
Go to step 10.
M4206054
No
Replace the turn lamp relay.

M201 2014.01
4.2.6-30 Lighting System 4.2.6-30

Test Conditions Details/Results/Actions

10.Inspect turn lamp relay output power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the lighting combination switch wiring
P30 harness connector P30.
C. Disconnect the turn lamp relay wiring harness
connector P27.
4 3 2 1
D. Measure the resistance between terminal 1 of turn
lamp relay wiring harness connector P27 and
13 12 11 10 9 8 7 6 5 terminal 12 of lighting combination switch wiring
harness connector P30.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 11.
No
Inspect and repair the open circuit fault between
terminal 1 of turn lamp relay wiring harness
1 connector P27 and terminal 12 of lighting
combination switch wiring harness connector P30.
3 2

P27

M4206055

M201 2014.01
4.2.6-31 Lighting System 4.2.6-31

Test Conditions Details/Results/Actions

11.Inspect front left turn lamp power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the front left turn lamp wiring harness
connector P16.
C. Turn the ignition switch to "ON".
D. Turn on the left turn lamp switch of lighting
2 1 combination switch.
E. Measure the voltage between terminal 1 of front left
turn lamp wiring harness connector P16 and
P16 reliable grounding.
Standard voltage: changes from 0 V to 11 ~ 14 V
M4206056 Is the voltage value normal?
Yes
Inspect and repair the open circuit fault between
terminal 2 of front left turn lamp wiring harness
connector P16 and the ground point G103.
No
Inspect and repair the open circuit fault between
terminal 1 of front left turn lamp wiring harness
connector P16 and terminal 13 of lighting
combination switch wiring harness connector P30.
CAUTION: Use different terminals to
inspect other turn lamps in this way. Make
sure the system is normal.

M201 2014.01
4.2.6-32 Lighting System 4.2.6-32

Diagnosis Procedure for One or More Turn Lamps Fault

CAUTION: This process is carried out for left turn lamp fault only. Process for the right is
similar.

One or more turn signal

lamps fault

General inspection
(Inspect wiring harness
connectors related to turn lamp)

Yes
Is the fault
confirmed

No

Inspect failed turn lamp bulb

Yes
Is the fault
confirmed

No

Inspect left turn lamp switch

Yes
Is the fault
confirmed

No

Inspect front left turn lamp power

supply circuit

Is the fault Yes

confirmed

No

Inspect front left turn lamp

grounding circuit

End

M201 2014.01
4.2.6-33 Lighting System 4.2.6-33

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
turn lamp for damage, poor contact, aging and
looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect failed turn lamp bulb

A. Inspect the filament in the turn lamp bulb to see if it
is in good condition.
B. Inspect the turn lamp bulb contact for oxidation or
poor contact.
Is it abnormal?
Yes
Replace the turn lamp bulb, and solve the problem
of oxidation.
No
Go to step 3.

3. Inspect left turn lamp switch

A. Inspect the left turn lamp switch.
Refer to: Test for Lighting Combination
Switch (4.2.6 Lighting System,
General Inspection).
Is the lighting combination switch normal?
Yes
Go to step 4.
No
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).

M201 2014.01
4.2.6-34 Lighting System 4.2.6-34

Test Conditions Details/Results/Actions

4. Inspect front left turn lamp power supply circuit
CAUTION: Take the front left turn lamp as
an example.
A. Turn the ignition switch to "LOCK".
B. Disconnect the front left turn lamp wiring harness
connector P16.
2 1
C. Turn the ignition switch to "ON".
D. Turn on the left turn lamp switch of lighting
P16 combination switch.
E. Measure the voltage between terminal 1 of front left
turn lamp wiring harness connector P16 and
M4206056
reliable grounding.
Standard voltage: changes from 0 V to 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 5.
No
Inspect and repair the open circuit fault between
terminal 1 of front left turn lamp wiring harness
connector P16 and terminal 13 of lighting
combination switch wiring harness connector P30.

5. Inspect front left turn lamp grounding circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the front left turn lamp wiring harness
connector P16.
P16 C. Measure the resistance between terminal 2 of front
left turn lamp wiring harness connector P16 and
reliable grounding.
2 1 Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the left headlamp.
M4206058
Refer to: Headlamp (4.2.6 Lighting
System, Removal and
Installation).
No
Inspect and repair the open circuit fault between
terminal 2 of front left turn lamp wiring harness
connector P16 and the ground point G103.

M201 2014.01
4.2.6-35 Lighting System 4.2.6-35

Diagnosis Procedure for One or More Turn Lamps Constant ON

(No Blinking)
CAUTION: This process is carried out for rear left turn lamp constant on only. Process for the
others is similar.

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
turn lamp for damage or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect rear left turn lamp power supply circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the lighting combination switch wiring
harness connector P30.
C. Disconnect the rear left combination lamp wiring
harness connector S10.
D. Measure the voltage between terminal 3 of rear left
combination lamp wiring harness connector S10
and reliable grounding.
Standard voltage: changes from 0 V to 11 ~ 14 V
Is the voltage value normal?
1 2 3 4 Yes
Replace the rear left combination lamp.
Refer to: Rear Combination Lamp (4.2.6
S10 Lighting System, Removal and
Installation).
M4206059
No
Inspect and repair the short circuit fault between
power and terminal 3 of rear left combination lamp
wiring harness connector S10.

M201 2014.01
4.2.6-36 Lighting System 4.2.6-36

Diagnosis Procedure for Hazard Warning Lamp Fault

Hazard warning lamp fault

General inspection
(Inspect wiring harness connectors
related to hazard warning lamp and
inspect turn lamp bulb)

Is the fault Yes

confirmed

No

Inspect hazard warning lamp

switch

Is the fault Yes

confirmed

No

Inspect hazard warning lamp fuse

Inspect hazard warning lamp fuse
power supply

Is the fault Yes

confirmed

No

Inspect hazard warning lamp

switch - turn lamp input power
supply circuit
Yes
Is the fault
confirmed

Is the fault No
confirmed
No lamp power
Inspect front left turn
supply circuit
No
Inspect turn lamp relay power
supply circuit
Inspect turn lamp relay grounding
circuit
Inspect turn lamp relay
End
Inspect turn lamp relay output
power supply circuit

M201 2014.01
4.2.6-37 Lighting System 4.2.6-37

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
hazard warning lamp for damage, poor contact,
aging and looseness.
B. Inspect the filament and lamp holder of turn lamp
bulb for abnormal conditions such as damage and
oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect hazard warning lamp switch

A. Turn the ignition switch to "OFF", and disconnect
the hazard warning lamp switch wiring harness
connector P25.
1 2 3 B. Press the hazard warning lamp switch.
C. Measure the resistance between terminals 7 and 8
4 5 6 7 8
of hazard warning lamp switch.
D. Press the hazard warning lamp switch, and
measure the resistance between terminal 1 and
terminals 2, 3 of hazard warning lamp switch.
Standard resistance: less than 1 Ω
M4206060 Is the resistance value normal?
Yes
Go to step 3.
No
Replace the hazard warning lamp switch.
Refer to: Hazard Warning Lamp Switch
(4.2.6 Lighting System, Removal
and Installation).

1 2 3

4 5 6 7 8

M4206064

M201 2014.01
4.2.6-38 Lighting System 4.2.6-38

Test Conditions Details/Results/Actions

3. Inspect hazard warning lamp fuse
A. Inspect the hazard warning lamp fuse IF21.
Fuse rated capacity: 15 A
Is the fuse normal?
Yes
Go to step 4.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

4. Inspect hazard warning lamp fuse power supply

A. Measure the voltage between terminal 41 of
instrument panel fuse box fuse IF21 and reliable
P40 grounding.
Standard voltage: 11 ~ 14 V
41
IF21
Is the voltage value normal?
42
Yes
Go to step 5.
No
Inspect and repair the open circuit fault between
terminal 41 of instrument panel fuse box fuse IF21
and battery.

M4206061

M201 2014.01
4.2.6-39 Lighting System 4.2.6-39

Test Conditions Details/Results/Actions

5. Inspect hazard warning lamp switch - turn lamp input power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the hazard warning lamp switch wiring
P25
harness connector P25.
C. Turn the ignition switch to "ON", and measure the
voltage between terminal 7 of hazard warning lamp
3 2 1
switch wiring harness connector P25 and reliable
grounding.
8 7 6 5 4
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
M4206062 Go to step 6.
No
Inspect and repair the open circuit fault between
terminal 7 of hazard warning lamp switch wiring
harness connector P25 and terminal 42 of
instrument panel fuse box fuse IF21.

6. Inspect turn lamp relay power supply circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the hazard warning lamp switch wiring
P25 harness connector P25.
C. Disconnect the turn lamp relay wiring harness
connector P27.
3 2 1 D. Measure the resistance between terminal 2 of turn
lamp relay wiring harness connector P27 and
8 7 6 5 4 terminal 8 of hazard warning lamp switch wiring
harness connector P25.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 7.
No
Inspect and repair the open circuit fault between
terminal 2 of turn lamp relay wiring harness
1 connector P27 and terminal 8 of hazard warning
lamp switch wiring harness connector P25.
3 2

P27

M4206052

M201 2014.01
4.2.6-40 Lighting System 4.2.6-40

Test Conditions Details/Results/Actions

7. Inspect turn lamp relay grounding circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the turn lamp relay wiring harness
connector P27.
P27 C. Measure the resistance between terminal 3 of turn
lamp relay wiring harness connector P27 and
1 reliable grounding.
Standard resistance: less than 5 Ω
3 2
Is the resistance value normal?
Yes
Go to step 8.
M4206053
No
Inspect and repair the open circuit fault between
terminal 3 of turn lamp relay wiring harness
connector P27 and the ground point G105.

8. Inspect turn lamp relay

A. Turn the ignition switch to "ON".
B. Turn on the hazard warning lamp switch of lighting
combination switch.
C. Measure the voltage between terminal 1 of turn
P27 lamp relay wiring harness connector P27 and
reliable grounding from the back.
1
Standard voltage: changes from 0 V to 11 ~ 14 V

3 2 Is the voltage value normal?

Yes
Go to step 9.
M4206054
No
Replace the turn lamp relay.

M201 2014.01
4.2.6-41 Lighting System 4.2.6-41

Test Conditions Details/Results/Actions

9. Inspect turn lamp relay output power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the hazard warning lamp switch wiring
harness connector P25.
P27 C. Disconnect the turn lamp relay wiring harness
connector P27.
1
D. Measure the resistance between terminal 1 of turn
lamp relay wiring harness connector P27 and
3 2 terminal 1 of hazard warning lamp switch wiring
harness connector P25.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 10.
No
Inspect and repair the open circuit fault between
terminal 1 of turn lamp relay wiring harness
3 2 1 connector P27 and terminal 1 of hazard warning
lamp switch wiring harness connector P25.
8 7 6 5 4

P25

M4206066

M201 2014.01
4.2.6-42 Lighting System 4.2.6-42

Test Conditions Details/Results/Actions

10.Inspect front left turn lamp power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the front left turn lamp wiring harness
connector P16.
C. Turn the ignition switch to "ON".
D. Turn on the hazard warning lamp switch of lighting
2 1 combination switch.
E. Measure the voltage between terminal 1 of front left
turn lamp wiring harness connector P16 and
P16 reliable grounding.
Standard voltage: changes from 0 V to 11 ~ 14 V
M4206056 Is the voltage value normal?
Yes
Inspect and repair the open circuit fault between
terminal 2 of front left turn lamp wiring harness
connector P16 and the ground point G103.
No
Inspect and repair the open circuit fault between
terminal 1 of front left turn lamp wiring harness
connector P16 and terminal 3 of lighting
combination switch wiring harness connector P25.
CAUTION: Use different terminals to
inspect other turn lamps in this way. Make
sure the system is normal.

M201 2014.01
4.2.6-43 Lighting System 4.2.6-43

Diagnosis Procedure for Position Lamp Fault

Position lamp fault

General inspection
(Inspect wiring harness connectors
related to position lamp and
inspect position lamp bulb)

Yes
Is the fault
confirmed

No

Inspect position lamp fuse

Inspect position lamp fuse power
supply

Is the fault Yes

confirmed

No
Inspect position lamp switch input
power supply circuit

Yes
Is the fault
confirmed

No

Inspect position lamp switch

Is the fault Yes

Is the fault confirmed
confirmed
No
No
Inspect rear left position lamp
Inspect rear left position lamp grounding circuit
power supply circuit

End

M201 2014.01
4.2.6-44 Lighting System 4.2.6-44

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
position lamp for damage, poor contact, aging and
looseness.
B. Inspect the filament and lamp holder of position
lamp bulb for abnormal conditions such as damage
and oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect position lamp fuse

A. Inspect the fuse IF16.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.6-45 Lighting System 4.2.6-45

Test Conditions Details/Results/Actions

3. Inspect position lamp fuse power supply
A. Measure the voltage between terminal 31 of
instrument panel fuse box fuse IF16 and reliable
P40 grounding.
Standard voltage: 11 ~ 14 V
31
IF16
Is the voltage value normal?
32
Yes
Go to step 4.
No
Inspect and repair the open circuit fault between
terminal 31 of instrument panel fuse box fuse IF16
and battery.

M4206068

4. Inspect position lamp switch input power supply circuit

A. Turn the ignition switch to "LOCK".
P30 B. Disconnect the lighting combination switch wiring
harness connector P30.
4 3 2 1 C. Measure the voltage between terminal 5 of lighting
combination switch wiring harness connector P30
and reliable grounding.
13 12 11 10 9 8 7 6 5
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 5.
No
Inspect and repair the open circuit fault between
terminal 5 of lighting combination switch wiring
harness connector P30 and terminal 32 of
instrument panel fuse box fuse IF16.
M4206069

M201 2014.01
4.2.6-46 Lighting System 4.2.6-46

Test Conditions Details/Results/Actions

5. Inspect position lamp switch
A. Inspect the position lamp switch.
Refer to: Test for Lighting Combination
Switch (4.2.6 Lighting System,
General Inspection).
Is the lighting combination switch normal?
Yes
Go to step 6.
No
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).
6. Inspect rear left position lamp power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the rear left combination lamp wiring
harness connector S10.
C. Turn the ignition switch to "ON".
D. Turn on the position lamp.
E. Measure the voltage between terminal 4 of rear left
combination lamp wiring harness connector S10
S10 and reliable grounding with a multimeter.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
1 2 3 4 Yes
Go to step 7.
No
Inspect and repair the open circuit fault between
M4206070
terminal 8 of lighting combination switch wiring
harness connector P30 and terminal 4 of rear left
combination lamp wiring harness connector S10.

M201 2014.01
4.2.6-47 Lighting System 4.2.6-47

Test Conditions Details/Results/Actions

7. Inspect rear left position lamp grounding circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the rear left combination lamp wiring
harness connector S10.
C. Measure the resistance between terminal 1 of rear
left combination lamp wiring harness connector S10
and reliable grounding.
Standard resistance: less than 5 Ω
1 2 3 4 Is the resistance value normal?
Yes
S10 Replace the rear left combination lamp
M4206047
Refer to: Rear Combination Lamp (4.2.6
Lighting System, Removal and
Installation).
No
Inspect and repair the open circuit fault between
terminal 1 of rear left combination lamp wiring
harness connector S10 and the ground point G201.
CAUTION: Use different terminals to
inspect other position lamps in this way.
Make sure the system is normal.

M201 2014.01
4.2.6-48 Lighting System 4.2.6-48

Diagnosis Procedure for Position Lamp Constant ON

Test Conditions Details/Results/Actions
1. Inspect lighting combination switch
A. Disconnect the lighting combination switch wiring
harness connector P30.
Has the position lamp gone off?
Yes
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).
No
Go to step 2.

2. Inspect rear left position lamp power supply circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the rear left combination lamp wiring
harness connector S10.
C. Disconnect the lighting combination switch wiring
harness connector P30.
D. Measure the voltage between terminal 4 of rear left
combination lamp wiring harness connector S10
S10 and reliable grounding.
Standard voltage: 0 V
Is the voltage value normal?
Yes
1 2 3 4
The system is normal.
No
Inspect and repair the short circuit fault between
power and terminal 4 of rear left combination lamp
M4206070 wiring harness connector S10.

M201 2014.01
4.2.6-49 Lighting System 4.2.6-49

Diagnosis Procedure for Front Fog Lamp Fault

CAUTION: Normal work of front fog lamp is base on the normal work of position lamp, so the
position lamp must be inspected for normal operation before carrying out this diagnosis
procedure.

Front fog lamp fault

General inspection
(Inspect wiring harness connectors
related to front fog lamp and
inspect front fog lamp bulb)

Is the fault Yes

confirmed

No

Inspect front fog lamp fuse

Is the fault Yes

confirmed

No
Inspect front fog lamp switch
power supply circuit

Is the fault Yes

confirmed

No

Inspect front fog lamp switch

Is the fault
confirmed Is the fault Yes
confirmed
No
No
Inspect front fog lamp relay power
supply circuit Inspect front right fog lamp
Inspect front fog lamp relay grounding circuit
grounding circuit
Inspect front right fog lamp power
supply circuit

End

M201 2014.01
4.2.6-50 Lighting System 4.2.6-50

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
front fog lamp for damage, poor contact, aging and
looseness.
B. Inspect the filament and lamp holder of front fog
lamp bulb for abnormal conditions such as damage
and oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect front fog lamp fuse

A. Inspect the front fog lamp fuse IF14.
Fuse rated capacity: 15 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect front fog lamp switch power supply circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the lighting combination switch wiring
harness connector P30.
C. Measure the resistance between terminals 1 and 8
of lighting combination switch wiring harness
connector P30.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 4.
4 3 2 1
No
13 12 11 10 9 8 7 6 5 Inspect and repair the open circuit fault between
terminals 1 and 8 of lighting combination switch
wiring harness connector P30.
P30
M4206073

M201 2014.01
4.2.6-51 Lighting System 4.2.6-51

Test Conditions Details/Results/Actions

4. Inspect front fog lamp switch
A. Inspect the front fog lamp switch.
Refer to: Test for Lighting Combination
Switch (4.2.6 Lighting System,
General Inspection).
Is the lighting combination switch normal?
Yes
Go to step 5.
No
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).
5. Inspect front fog lamp relay power supply circuit
A. Remove the front fog lamp relay IR06.

P40 B. Turn the lighting combination switch to position

lamp.
C. Turn on the front fog lamp.
D. Separately measure the voltage between terminals
72, 73 of front fog lamp relay IR06 and reliable
grounding.
Standard voltage: 11 ~ 14 V

IR06
Is the voltage value normal?
73
72
Yes
Go to step 6.
No
Inspect and repair the open circuit fault between
terminal 72 of front fog lamp relay IR06 and
terminal 3 of lighting combination switch wiring
harness connector P30.
Inspect and repair the open circuit fault between
terminal 73 of front fog lamp relay IR06 and
terminal 28 of instrument panel fuse box fuse IF14.

M4206074

M201 2014.01
4.2.6-52 Lighting System 4.2.6-52

Test Conditions Details/Results/Actions

6. Inspect front fog lamp relay grounding circuit
A. Remove the front fog lamp relay.

P40 B. Measure the resistance between terminal 70 of

front fog lamp relay IR06 and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 7.
No
IR06 70
Inspect and repair the open circuit fault between
terminal 70 of front fog lamp relay IR06 and the
ground point G103.

M4206075

M201 2014.01
4.2.6-53 Lighting System 4.2.6-53

Test Conditions Details/Results/Actions

7. Inspect front right fog lamp power supply circuit
A. Remove the front fog lamp relay IR06.
B. Disconnect the front right fog lamp wiring harness
P40 connector P05.
C. Measure the resistance between terminal 1 of front
right fog lamp wiring harness connector P05 and
terminal 74 of front fog lamp relay IR06.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
IR06

74
Go to step 8.
No
Inspect and repair the open circuit fault between
terminal 1 of front right fog lamp wiring harness
connector P05 and terminal 74 of front fog lamp
relay IR06.

2 1

P05

M4206076

8. Inspect front right fog lamp grounding circuit

A. Disconnect the front right fog lamp wiring harness
connector P05.
P05
B. Measure the resistance between terminal 2 of front
right fog lamp wiring harness connector P05 and
reliable grounding.
2 1
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the front fog lamp relay.
No
M4206077
Inspect and repair the open circuit fault between
terminal 2 of front right fog lamp wiring harness
connector P05 and the ground point G106.
CAUTION: Use different terminals to
inspect the front left fog lamp in this way.
Make sure the system is normal.

M201 2014.01
4.2.6-54 Lighting System 4.2.6-54

Diagnosis Procedure for Front Fog Lamp Constant ON

CAUTION: Normal work of front fog lamp is base on the normal work of position lamp, so
inspect the position lamp must be inspected for normal operation before carrying out this
diagnosis procedure.

Front fog lamp constant on

General inspection
(Inspect wiring harness connectors
related to front fog lamp)

Is the fault Yes

confirmed

No

Inspect front fog lamp switch

Yes
Is the fault
confirmed

No
Inspect front fog lamp relay
control power supply circuit

Yes
Is the fault
confirmed

No
Inspect front fog lamp power
supply circuit

End

M201 2014.01
4.2.6-55 Lighting System 4.2.6-55

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
front fog lamp for damage or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect front fog lamp switch

A. Inspect the front fog lamp switch.
Refer to: Test for Lighting Combination
Switch (4.2.6 Lighting System,
General Inspection).
Is the lighting combination switch normal?
Yes
Go to step 3.
No
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).
3. Inspect front fog lamp relay control power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the lighting combination switch wiring
harness connector P30.
C. Disconnect the front fog lamp relay IR06.
D. Measure the voltage between terminal 3 of lighting
combination switch wiring harness connector P30
and reliable grounding.
Standard voltage: 0 V
Is the voltage value normal?
Yes
4 3 2 1
Go to step 4.
13 12 11 10 9 8 7 6 5 No
Inspect and repair the short circuit fault between
P30 power and terminal 3 of lighting combination switch
wiring harness connector P30.
M4206078

M201 2014.01
4.2.6-56 Lighting System 4.2.6-56

Test Conditions Details/Results/Actions

4. Inspect front fog lamp power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the front fog lamp relay IR06.
P05 C. Disconnect the front right fog lamp wiring harness
connector P05.
D. Disconnect the front left fog lamp wiring harness
2 1 connector P18.
E. Measure the voltage between terminal 1 of front
right fog lamp wiring harness connector P05 and
reliable grounding.
Standard voltage: 0 V
M4206079 Is the voltage value normal?
Yes
Replace the front fog lamp relay IR06.
No
Inspect and repair the short circuit fault between
power and terminal 1 of front right fog lamp wiring
harness connector P05.

M201 2014.01
4.2.6-57 Lighting System 4.2.6-57

Diagnosis Procedure for Rear Fog Lamp Fault

CAUTION: Normal work of rear fog lamp is base on the normal work of position lamp, so
inspect the position lamp must be inspected for normal operation before carrying out this
diagnosis procedure.

Rear fog lamp fault

General inspection
(Inspect wiring harness
connectors related to rear fog
lamp)

Yes
Is the fault
confirmed

No

Inspect rear fog lamp switch

Is the fault Yes

confirmed

No
Inspect rear fog lamp power
supply circuit

End

M201 2014.01
4.2.6-58 Lighting System 4.2.6-58

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
rear fog lamp for damage, poor contact, aging and
looseness.
B. Inspect the filament and lamp holder of rear fog
lamp bulb for abnormal conditions such as damage
and oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect rear fog lamp switch

A. Inspect the rear fog lamp switch.
Refer to: Test for Lighting Combination
Switch (4.2.6 Lighting System,
General Inspection).
Is the lighting combination switch normal?
Is the fuse normal?
Yes
Go to step 3.
No
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).

M201 2014.01
4.2.6-59 Lighting System 4.2.6-59

Test Conditions Details/Results/Actions

3. Inspect rear fog lamp power supply circuit
A. Disconnect the lighting combination switch wiring
harness connector P30.
B. Disconnect the rear left fog lamp wiring harness
connector S11.
S11 C. Measure the resistance between terminal 2 of
lighting combination switch wiring harness
connector P30 and terminal 1 of rear left fog lamp
wiring harness connector S11.
2 1
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Inspect and repair the open circuit fault between
terminal 2 of rear left fog lamp wiring harness
connector S11 and the ground point G201.
No
4 3 2 1 Inspect and repair the open circuit fault between
terminal 2 of lighting combination switch wiring
13 12 11 10 9 8 7 6 5 harness connector P30 and terminal 1 of rear left
fog lamp wiring harness connector S11.
P30

M4206080

M201 2014.01
4.2.6-60 Lighting System 4.2.6-60

Diagnosis Procedure for Rear Fog Lamp Constant ON

Test Conditions Details/Results/Actions
1. General inspection
A. Inspect the wiring harness connectors related to the
rear fog lamp for damage or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect rear fog lamp power supply circuit

A. Disconnect the rear right fog lamp wiring harness
connector S09.
B. Disconnect the lighting combination switch wiring
S09 harness connector P30.
C. Measure the voltage between terminal 1 of rear
2 1 right fog lamp wiring harness connector S09 and
reliable grounding.
Standard voltage: 0 V
Is the voltage value normal?
Yes
M4206081 Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).
No
Inspect and repair the short circuit fault between
power and terminal 1 of rear right fog lamp wiring
harness connector S09.

M201 2014.01
4.2.6-61 Lighting System 4.2.6-61

Diagnosis Procedure for Backup Lamp Fault

Backup lamp fault

General inspection
(Inspect wiring harness connectors
related to backup and inspect lamp
backup lamp bulb)

Is the fault Yes

confirmed

No

Inspect backup lamp fuse

Yes
Is the fault
confirmed

No
Inspect backup lamp fuse power
supply

Yes
Is the fault
confirmed

No

Inspect backup lamp switch

power supply circuit
Inspect backup lamp switch
Inspect backup lamp power
supply circuit Yes
Is the fault
confirmed

No
Inspect backup lamp grounding
circuit

End

M201 2014.01
4.2.6-62 Lighting System 4.2.6-62

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
backup lamp for damage, poor contact, aging and
looseness.
B. Inspect the filament and lamp holder of backup
lamp bulb for abnormal conditions such as damage
and oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect backup lamp fuse

A. Inspect the backup lamp fuse IF33.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.6-63 Lighting System 4.2.6-63

Test Conditions Details/Results/Actions

3. Inspect backup lamp fuse power supply
A. Turn the ignition switch to "ON".

P40 B. Measure the voltage between terminal 65 of

instrument panel fuse box fuse IF33 and reliable
grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
65
IF33 Go to step 4.
66
No
Inspect and repair the open circuit fault between
terminal 65 of instrument panel fuse box fuse IF33
and ignition switch IG1.

M4206082

4. Inspect backup lamp switch power supply circuit

A. Disconnect the backup lamp switch wiring harness
connector S15.
B. Turn the ignition switch to "ON".
C. Measure the voltage between terminal 1 of backup
lamp switch wiring harness connector S15 and
reliable grounding.
1 2
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes

S15 Go to step 5.
M4206083 No
Inspect and repair the open circuit fault between
terminal 1 of backup lamp switch wiring harness
connector S15 and terminal 66 of instrument panel
fuse box fuse IF33.

M201 2014.01
4.2.6-64 Lighting System 4.2.6-64

Test Conditions Details/Results/Actions

5. Inspect backup lamp switch
A. Disconnect the backup lamp switch wiring harness
connector S15.
B. Put the gear lever into the reversing gear.
C. Measure the resistance between terminals 1 and 2
of backup lamp switch connector on the component
side.
Standard resistance: less than 1 Ω

2 1 Is the resistance value normal?

Yes
Go to step 6.
M4206084
No
Replace the backup lamp switch.

6. Inspect backup lamp power supply circuit

A. Turn the ignition switch to "LOCK".
D12 B. Disconnect the left backup lamp wiring harness
connector D12.
C. Turn the ignition switch to "ON".
2 1
D. Put the gear lever into the reversing gear.
E. Measure the voltage between terminal 2 of left
backup lamp wiring harness connector D12 and
reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
M4206085
Yes
Go to step 7.
No
Inspect and repair the open circuit fault between
terminal 2 of left backup lamp wiring harness
connector D12 and terminal 2 of backup lamp
switch wiring harness connector S15.

M201 2014.01
4.2.6-65 Lighting System 4.2.6-65

Test Conditions Details/Results/Actions

7. Inspect backup lamp grounding circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the left backup lamp wiring harness
connector D12.
D12
C. Measure the resistance between terminal 1 of left
backup lamp wiring harness connector D12 and
2 1 reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the left backup lamp.
M4206086
Make sure the maintenance has been finished.
No
Inspect and repair the open circuit fault between
terminal 1 of left backup lamp wiring harness
connector D12 and the ground point G201.

Diagnosis Procedure for Backup Lamp Constant ON

Test Conditions Details/Results/Actions
1. General inspection
A. Inspect the wiring harness connectors related to the
backup lamp for damage or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect backup lamp switch

A. Disconnect the backup lamp switch wiring harness
connector S15.
B. Observe whether the backup lamp has gone off?
Has the backup lamp gone off?
Yes
Replace the backup lamp switch.
No
Inspect and repair the short circuit fault between
power and terminal 2 of backup lamp switch wiring
harness connector S15.

M201 2014.01
4.2.6-66 Lighting System 4.2.6-66

Diagnosis Procedure for Low Beam Lamp Fault

Low beam lamp fault

General inspection
(Inspect wiring harness connectors
related to low beam lamp and
inspect low beam lamp bulb)

Is the fault Yes

confirmed

No

Inspect headlamp fuse

Is the fault Yes

confirmed

No
Inspect headlamp fuse power
supply

Is the fault Yes

confirmed

No
Inspect lighting combination Inspect left headlamp power
switch - low beam lamp switch supply circuit

Is the fault Is the fault Yes

confirmed confirmed

No
No
Inspect circuit between left
Yes headlamp and lighting
combination switch

End

M201 2014.01
4.2.6-67 Lighting System 4.2.6-67

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
low beam lamp for damage, poor contact, aging
and looseness.
B. Inspect the filament and lamp holder of low beam
lamp bulb for abnormal conditions such as damage
and oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect headlamp fuse

A. Inspect the fuse IF08, IF09.
Fuse rated capacity: 15 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.6-68 Lighting System 4.2.6-68

Test Conditions Details/Results/Actions

3. Inspect headlamp fuse power supply
A. Measure the voltage between terminal 15 of
instrument panel fuse box fuse IF08, terminal 17 of
P40 IF09 and reliable grounding.
15
IF08
16 Standard voltage: 11 ~ 14 V
17
IF09
Is the voltage value normal?
18
Yes
Go to step 4.
No
Inspect and repair the open circuit fault between
terminal 15 of instrument panel fuse box fuse IF08
and battery.
Inspect and repair the open circuit fault between
terminal 17 of instrument panel fuse box fuse IF09
and battery.

M4206087

4. Inspect lighting combination switch - low beam lamp switch

A. Inspect the low beam lamp switch.
Refer to: Test for Lighting Combination
Switch (4.2.6 Lighting System,
General Inspection).
Is the lighting combination switch normal?
Yes
Go to step 5.
No
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).

M201 2014.01
4.2.6-69 Lighting System 4.2.6-69

Test Conditions Details/Results/Actions

5. Inspect left headlamp power supply circuit
CAUTION: Use different wiring harness
P14
terminals to inspect the low beam circuit
of right headlamp in this way.
3 2 1 A. Disconnect the left headlamp wiring harness
6 5 4 connector P14.
B. Measure the voltage between terminal 5 of left
headlamp wiring harness connector P14 and
reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
M4206088
Yes
Go to step 6.
No
Inspect and repair the open circuit fault between
terminal 5 of left headlamp wiring harness
connector P14 and terminal 16 of instrument panel
fuse box fuse IF08.

6. Inspect circuit between left headlamp and lighting combination switch

A. Disconnect the left headlamp wiring harness
connector P14.
P30
B. Disconnect the lighting combination switch wiring
harness connector P30.
4 3 2 1 C. Measure the resistance between terminal 4 of left
headlamp wiring harness connector P14 and
13 12 11 10 9 8 7 6 5 terminal 10 of lighting combination switch wiring
harness connector P30.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Inspect and repair the open circuit fault between
terminal 7 of lighting combination switch wiring
harness connector P30 and grounding point G103.
No
Inspect and repair the open circuit fault between
terminal 4 of left headlamp wiring harness
connector P14 and terminal 10 of lighting
3 2 1
combination switch wiring harness connector P30.
6 5 4

P14

M4206089

M201 2014.01
4.2.6-70 Lighting System 4.2.6-70

Diagnosis Procedure for One Side Low Beam Lamp Fault

CAUTION: This process is carried out for left low beam lamp fault only. Process for the right
is similar.

One side low beam lamp fault

General inspection
(Inspect wiring harness connectors
related to low beam lamp and
inspect low beam lamp bulb)

Is the fault Yes

confirmed

No

Inspect left headlamp fuse

Is the fault Yes

confirmed

No
Inspect left headlamp fuse power
supply

Is the fault Yes

confirmed

No
Inspect left headlamp power
supply circuit

End

M201 2014.01
4.2.6-71 Lighting System 4.2.6-71

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
low beam lamp for damage, poor contact, aging
and looseness.
B. Inspect the filament and lamp holder of low beam
lamp bulb for abnormal conditions such as damage
and oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect left headlamp fuse

A. Inspect the fuse IF08.
Fuse rated capacity: 15 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.6-72 Lighting System 4.2.6-72

Test Conditions Details/Results/Actions

3. Inspect left headlamp fuse power supply
A. Inspect the voltage between terminal 15 of
instrument panel fuse box fuse IF08 and reliable
grounding.
P40
Standard voltage: 11 ~ 14 V
15
IF08
16 Is the voltage value normal?
Yes
Go to step 4.
No
Inspect and repair the open circuit fault between
terminal 15 of instrument panel fuse box fuse IF08
and battery.

M4206090

4. Inspect left headlamp power supply circuit

A. Disconnect the left headlamp wiring harness
P14 connector P14.
B. Measure the voltage between terminal 5 of left
headlamp wiring harness connector P14 and
3 2 1 reliable grounding.
6 5 4 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Inspect and repair the open circuit fault between
terminal 4 of left headlamp wiring harness
M4206088
connector P14 and terminal 10 of lighting
combination switch wiring harness connector P30.
No
Inspect and repair the open circuit fault between
terminal 5 of left headlamp wiring harness
connector P14 and terminal 16 of instrument panel
fuse box fuse IF08.

M201 2014.01
4.2.6-73 Lighting System 4.2.6-73

Diagnosis Procedure for Low Beam Lamp Constant ON

Test Conditions Details/Results/Actions
1. General inspection
A. Inspect the wiring harness connectors related to the
low beam lamp for damage or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect lighting combination switch - low beam lamp switch

A. Inspect the low beam lamp switch.
Refer to: Test for Lighting Combination
Switch (4.2.6 Lighting System,
General Inspection).
Is the lighting combination switch normal?
Yes
Inspect and repair the short circuit fault to ground
between headlamp low beam and lighting
combination switch.
No
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).

M201 2014.01
4.2.6-74 Lighting System 4.2.6-74

Diagnosis Procedure for High Beam Lamp Fault

High beam lamp fault

General inspection
(Inspect wiring harness connectors
related to high beam lamp and
inspect high beam lamp bulb)

Is the fault Yes

confirmed

No

Inspect headlamp fuse

Is the fault Yes

confirmed

No
Inspect headlamp fuse power
supply

Is the fault Yes

confirmed

No
Inspect lighting combination Inspect left headlamp high
switch - high beam lamp switch beam power supply circuit

Is the fault Is the fault Yes

confirmed confirmed

No
No
Inspect circuit between left
Yes headlamp and lighting
combination switch

End

M201 2014.01
4.2.6-75 Lighting System 4.2.6-75

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
high beam lamp for damage, poor contact, aging
and looseness.
B. Inspect the filament and lamp holder of high beam
lamp bulb for abnormal conditions such as damage
and oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect headlamp fuse

A. Inspect the fuse IF08, IF09.
Fuse rated capacity: 15 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.6-76 Lighting System 4.2.6-76

Test Conditions Details/Results/Actions

3. Inspect headlamp fuse power supply
A. Measure the voltage between terminal 15 of
instrument panel fuse box fuse IF08, terminal 17 of
P40 IF09 and reliable grounding.
15
IF08
16 Standard voltage: 11 ~ 14 V
17
IF09
Is the voltage value normal?
18
Yes
Go to step 4.
No
Inspect and repair the open circuit fault between
terminal 15 of instrument panel fuse box fuse IF08
and battery.
Inspect and repair the open circuit fault between
terminal 17 of instrument panel fuse box fuse IF09
and battery.

M4206087

4. Inspect lighting combination switch - high beam lamp switch

A. Inspect the high beam lamp switch.
Refer to: Test for Lighting Combination
Switch (4.2.6 Lighting System,
General Inspection).
Is the lighting combination switch normal?
Yes
Go to step 5.
No
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).

M201 2014.01
4.2.6-77 Lighting System 4.2.6-77

Test Conditions Details/Results/Actions

5. Inspect left headlamp high beam power supply circuit
CAUTION: Use different wiring harness
P14
terminals to inspect the low beam circuit
of right headlamp in this way.
3 2 1 A. Disconnect the left headlamp wiring harness
6 5 4 connector P14.
B. Measure the voltage between terminal 5 of left
headlamp wiring harness connector P14 and
reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
M4206088
Yes
Go to step 6.
No
Inspect and repair the open circuit fault between
terminal 5 of left headlamp wiring harness
connector P14 and terminal 16 of instrument panel
fuse box fuse IF08.

6. Inspect circuit between left headlamp and lighting combination switch

A. Disconnect the left headlamp wiring harness
connector P14.
P14
B. Disconnect the lighting combination switch wiring
harness connector P30.
C. Measure the resistance between terminal 6 of left
3 2 1 headlamp wiring harness connector P14 and
terminal 9 of lighting combination switch wiring
6 5 4
harness connector P30.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Inspect and repair the open circuit fault between
terminal 7 of lighting combination switch wiring
harness connector P30 and grounding point G103.
No
Inspect and repair the open circuit fault between
4 3 2 1 terminal 6 of left headlamp wiring harness
connector P14 and terminal 9 of lighting
13 12 11 10 9 8 7 6 5 combination switch wiring harness connector P30.

P30

M4206094

M201 2014.01
4.2.6-78 Lighting System 4.2.6-78

Diagnosis Procedure for One Side High Beam Lamp Fault

CAUTION: This process is carried out for left high beam lamp fault only. Process for the right
is similar.

One side high beam lamp fault

General inspection
(Inspect wiring harness connectors
related to high beam lamp and
inspect high beam lamp bulb)

Yes
Is the fault
confirmed

No

Inspect left headlamp fuse

Is the fault Yes

confirmed

No
Inspect left headlamp fuse
power supply

Is the fault Yes

confirmed

No
Inspect left headlamp high beam
power supply circuit

End

M201 2014.01
4.2.6-79 Lighting System 4.2.6-79

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
high beam lamp for damage, poor contact, aging
and looseness.
B. Inspect the filament and lamp holder of high beam
lamp bulb for abnormal conditions such as damage
and oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect left headlamp fuse

A. Inspect the fuse IF08.
Fuse rated capacity: 15 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.6-80 Lighting System 4.2.6-80

Test Conditions Details/Results/Actions

3. Inspect left headlamp fuse power supply
A. Inspect the voltage between terminal 15 of
instrument panel fuse box fuse IF08 and reliable
grounding.
P40
Standard voltage: 11 ~ 14 V
15
IF08
16 Is the voltage value normal?
Yes
Go to step 4.
No
Inspect and repair the open circuit fault between
terminal 15 of instrument panel fuse box fuse IF08
and battery.

M4206090

4. Inspect left headlamp high beam power supply circuit

A. Disconnect the left headlamp wiring harness
P14 connector P14.
B. Measure the voltage between terminal 5 of left
headlamp wiring harness connector P14 and
3 2 1 reliable grounding.
6 5 4 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Inspect and repair the open circuit fault between
terminal 6 of left headlamp wiring harness
M4206088
connector P14 and terminal 9 of lighting
combination switch wiring harness connector P30.
No
Inspect and repair the open circuit fault between
terminal 5 of left headlamp wiring harness
connector P14 and terminal 16 of instrument panel
fuse box fuse IF08.

M201 2014.01
4.2.6-81 Lighting System 4.2.6-81

Diagnosis Procedure for High Beam Lamp Constant ON

Test Conditions Details/Results/Actions
1. General inspection
A. Inspect the wiring harness connectors related to the
high beam lamp for damage or looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect lighting combination switch - high beam lamp switch

A. Inspect the high beam lamp switch.
Refer to: Test for Lighting Combination
Switch (4.2.6 Lighting System,
General Inspection).
Is the lighting combination switch normal?
Yes
Inspect and repair the short circuit fault to ground
between headlamp high beam and lighting
combination switch.
No
Replace the lighting combination switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).

Diagnosis Procedure for Overtaking Lamp Fault

CAUTION: The overtaking lamp adopts the same control strategy as that of high beam, and
the diagnosis procedure for overtaking lamp fault can refer to that for high beam fault.

Refer to: Diagnosis Procedure for High Beam Lamp Fault (4.2.6 Lighting System, Symptom
Diagnosis and Testing).

M201 2014.01
4.2.6-82 Lighting System 4.2.6-82

Diagnosis Procedure for License Plate Lamp Fault

CAUTION: Before carrying out this diagnosis procedure, verify the working condition of
position lamp, and execute the diagnosis procedure for position lamp fault first when the
position lamp works abnormally.

CAUTION: The diagnosis procedure is carried out with the left license plate lamp as an
example. The diagnosis procedure for the right license plate lamp, similar to that of left
license plate lamp, only uses different wiring harness connector.

License plate lamp fault

General inspection
(Inspect wiring harness connectors
related to license plate lamp and
inspect license plate lamp bulb)

Is the fault Yes

confirmed

No
Inspect position lamp operating
state

Is the fault Yes

confirmed

No
Inspect license plate lamp
power supply circuit

Is the fault Yes

confirmed

No

Inspect license plate lamp

grounding circuit

End

M201 2014.01
4.2.6-83 Lighting System 4.2.6-83

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
license plate lamp for damage, poor contact, aging
and looseness.
B. Inspect the filament and lamp holder of license
plate lamp bulb for abnormal conditions such as
damage and oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect position lamp operating state

A. Inspect the operating state of position lamp.
Does the position lamp work normally?
Yes
Go to step 3.
No
Inspect the position lamp.
Refer to: Diagnosis Procedure for
Position Lamp Fault (4.2.6
Lighting System, Symptom
Diagnosis and Testing).
3. Inspect license plate lamp power supply circuit
A. Disconnect the left license plate lamp wiring
harness connector D11.
B. Turn the lighting combination switch to position
lamp.
C. Measure the voltage between terminal 1 of left
1 license plate lamp wiring harness connector D11
and reliable grounding.
2 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
D11
Yes
M4206097 Go to step 4.
No
Inspect and repair the open circuit fault between
terminal 1 of left license plate lamp wiring harness
connector D11 and terminal 8 of lighting
combination switch wiring harness connector P30.

M201 2014.01
4.2.6-84 Lighting System 4.2.6-84

Test Conditions Details/Results/Actions

4. Inspect license plate lamp grounding circuit
A. Disconnect the left license plate lamp wiring
harness connector D11.
B. Measure the resistance between terminal 2 of left
license plate lamp wiring harness connector D11
1 and reliable grounding.
Standard resistance: less than 5 Ω
2 Is the resistance value normal?
D11 Yes
The system is normal.
No
M4206098
Inspect and repair the open circuit fault between
terminal 2 of left license plate lamp wiring harness
connector D11 and the ground point G201.

M201 2014.01
4.2.6-85 Lighting System 4.2.6-85

Diagnosis Procedure for Front Roof Lamp Fault

Front roof lamp fault

General inspection
(Inspect wiring harness
connectors related to front roof
lamp and inspect roof lamp bulb)

Is the fault Yes

confirmed

No

Inspect roof lamp fuse

Yes
Is the fault
confirmed

No
Inspect front roof lamp fuse
power supply

Is the fault Yes

confirmed

No
Inspect front roof lamp power
supply circuit

End

M201 2014.01
4.2.6-86 Lighting System 4.2.6-86

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
front roof lamp for damage, poor contact, aging and
looseness.
B. Inspect the filament and lamp holder of front roof
lamp bulb for abnormal conditions such as damage
and oxidation.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect roof lamp fuse

A. Inspect the front roof lamp fuse IF07.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.6-87 Lighting System 4.2.6-87

Test Conditions Details/Results/Actions

3. Inspect front roof lamp fuse power supply
A. Measure the voltage between terminal 13 of
instrument panel fuse box fuse IF07 and reliable
grounding.
P40
Standard voltage: 11 ~ 14 V
13
Is the voltage value normal?
IF07
14

Yes
Go to step 4.
No
Inspect and repair the open circuit fault between
terminal 13 of instrument panel fuse box fuse IF07
and battery.

M4206099

4. Inspect front roof lamp power supply circuit

A. Disconnect the front roof lamp wiring harness
connector L01.
L01 B. Measure the voltage between terminal 2 of front
roof lamp wiring harness connector L01 and reliable
grounding.
1 2 3
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 5.
No
M4206100
Inspect and repair the open circuit fault between
terminal 2 of roof lamp wiring harness connector
L01 and terminal 14 of instrument panel fuse box
fuse IF07.

M201 2014.01
4.2.6-88 Lighting System 4.2.6-88

Test Conditions Details/Results/Actions

5. Inspect front roof lamp grounding circuit
A. Disconnect the front roof lamp wiring harness
connector L01.
L01 B. Measure the resistance between terminal 1 of front
roof lamp wiring harness connector L01 and reliable
grounding.
1 2 3
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the front roof lamp.
Refer to: Front Roof Lamp (4.2.6 Lighting
M4206110
System, Removal and
Installation).
No
Inspect and repair the open circuit fault between
terminal 1 of front roof lamp wiring harness
connector L01 and the ground point G106.

Diagnosis Procedure for Reading Lamp Fault

CAUTION: The reading lamp adopts the same control strategy as that of front roof lamp, and
use different wiring harness terminals.

Refer to: Diagnosis Procedure for Reading Lamp Fault (4.2.6 Lighting System, Symptom
Diagnosis and Testing).

M201 2014.01
4.2.6-89 Lighting System 4.2.6-89

Removal and Installation

Lighting Combination Switch
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove 3 retaining screws from the upper
and lower housings of steering lock.

×3

M4206022

3. Separate the upper and lower housings of

steering lock.

M4206023

4. Disconnect the lighting combination switch

wiring harness connector.

A/C

M4206024

M201 2014.01
4.2.6-90 Lighting System 4.2.6-90

5. Remove the lighting combination switch.

A/C

M4206025

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-91 Lighting System 4.2.6-91

Lamp Angle Control Switch

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Use the special tool to pry the lamp angle
control switch panel.
Special tool: CA501-002

M4206026

3. Disconnect the lamp angle control switch

wiring harness connector, and remove the
lamp control switch panel.

M4206027

M201 2014.01
4.2.6-92 Lighting System 4.2.6-92

4. Disengage 4 retaining clips from the lamp

angle control switch, and remove the lamp
angle control switch.

×4
M4206102

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-93 Lighting System 4.2.6-93

Hazard Warning Lamp Switch

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Use the special tool to pry the center control
panel.
Special tool: CA501-002

1 1 USE
WITH

2 2
3 3

M4206020

3. Disconnect the hazard warning lamp switch

wiring harness connector, and remove the
center control panel.

M4206021

M201 2014.01
4.2.6-94 Lighting System 4.2.6-94

4. Disengage 2 retaining clips from the hazard

warning lamp switch, and remove the hazard
warning lamp switch.

×2

M4206101

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-95 Lighting System 4.2.6-95

Headlamp
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the front bumper.

Refer to: Front Bumper (5.1.7 Bumper,
Removal and Installation).
3. Remove 2 retaining bolts from the upper part
of headlamp.
Torque: 9 Nm

×2
M4206001

4. Remove 2 retaining bolts from the lower part

of headlamp.
Torque: 9 Nm

×2

M4206002

5. Disconnect 3 wiring harnesses connectors

from the headlamp, and remove the
headlamp.

×3

M4206003

M201 2014.01
4.2.6-96 Lighting System 4.2.6-96
Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-97 Lighting System 4.2.6-97

Front Fog Lamp

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the front bumper.

Refer to: Front Bumper (5.1.7 Bumper,
Removal and Installation).
3. Disconnect the front fog lamp wiring harness
connector.

M4206028

4. Remove 3 retaining screws from the front fog

lamp, and remove the front fog lamp.

×3

M4206004

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-98 Lighting System 4.2.6-98

Rear Combination Lamp

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the rear quarter interior trim panel.

Refer to: Rear Quarter Interior Trim Panel
(5.1.9 Interior Trim Panel and
Ornamentation, Removal and
Installation).
3. Remove the rear quarter interior trim panel
water-proof film.
CAUTION: Be careful to prevent damage
to the water-proof film during removal. Do
not touch the adhesive surface to avoid
×2
reduction in adhesion effect during
reassembly.

4. Remove 2 retaining bolts from the rear

combination lamp.
Torque: 11 Nm or less M4206005

5. Disconnect the rear combination lamp wiring

harness connector.

M4206006

M201 2014.01
4.2.6-99 Lighting System 4.2.6-99

6. Use the special tool to pry the rear

combination lamp retaining clips, and remove
the rear combination lamp.
Special tool: CA501-002

M4206007

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure that the rear
combination lamp wiring harness seal ring
is installed in place when installing the
rear combination lamp.

M201 2014.01
4.2.6-100 Lighting System 4.2.6-100

Backup Lamp
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the license plate lamp cover.

Refer to: License Plate Lamp (4.2.6
License Plate Lamp, Removal
and Installation).

3. Remove the back door interior trim panel.

Refer to: Back Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
4. Remove the back door water-proof film.
CAUTION: Be careful to prevent damage
to the water-proof film during removal. Do
not touch the adhesive surface to avoid
reduction in adhesion effect during
reassembly.

M5108012

5. Remove 4 retaining nuts from the backup

lamp.
Torque: 11 Nm or less

×4

M4206008

M201 2014.01
4.2.6-101 Lighting System 4.2.6-101

6. Disconnect the backup lamp wiring harness

connector, and remove the backup lamp.

M4206009

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-102 Lighting System 4.2.6-102

Rear Fog Lamp

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the rear bumper.

Refer to: Rear Bumper (5.1.7 Bumper,
Removal and Installation).
3. Disconnect the rear fog lamp wiring harness
connector.

M4206029

4. Remove 3 retaining screws from the rear fog

lamp, and remove the rear fog lamp.
×3

M4206010

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-103 Lighting System 4.2.6-103

License Plate Lamp

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the back door interior trim panel.

Refer to: Back Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
3. Remove the back door water-proof film.
CAUTION: Be careful to prevent damage
to the water-proof film during removal. Do
not touch the adhesive surface to avoid
reduction in adhesion effect during
reassembly.

M5108012

4. Remove the license plate lamp cover.

1 Remove 4 retaining screws from the license
plate lamp cover.
2 Remove the license plate lamp cover.
×4

M5108028

5. Disconnect the license plate lamp wiring

harness connector.

M4206011

M201 2014.01
4.2.6-104 Lighting System 4.2.6-104

6. Press the clip firmly in the direction of arrow

shown in the figure, and remove it.
7. Remove the license plate lamp.

M4206012

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-105 Lighting System 4.2.6-105

Front Roof Lamp

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Using the special tool to pry the front roof
lamp.
Special tool: CA501-002

M4206013

3. Disconnect the front roof lamp wiring harness

connector, and remove the front roof lamp.

M4206014

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-106 Lighting System 4.2.6-106

Reading Lamp
Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Using the special tool to pry the reading lamp
cover.
Special tool: CA501-002 ON

OFF

M4206015

3. Remove 2 retaining screws from the reading

lamp.

21

2))
×2

M4206016

M201 2014.01
4.2.6-107 Lighting System 4.2.6-107

4. Disconnect the reading lamp wiring harness

connector, and remove the reading lamp.

M4206017

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.6-108 Lighting System 4.2.6-108

High Mounted Stop Lamp

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove 2 retaining screws from the high
mounted stop lamp.

×2
M4206018

3. Disconnect the high mounted stop lamp

wiring harness connector, and remove the
high mounted stop lamp.

M4206019

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.7-1 Wiper and Washer 4.2.7-1

Specifications
4.2.7 Wiper and Washer

General Specifications
Item Specifications Capacity (L)
ZT-30 (summer)
Washer fluid 1.5
ZT-30B (winter)
Master wiper 500 mm -
Sub wiper 425 mm -

Torque Specifications
Item Nm lb-ft lb-in
Front wiper drive arm nut 18 ~ 22 13 ~ 16 -
Wiper motor retaining bolt 13 ± 2 - -
Wiper linkage retaining nut 13 ± 2 - -
Washer reservoir retaining bolt 6~9 - 53 ~ 80

M201 2014.01
4.2.7-2 Wiper and Washer 4.2.7-2

Description and Operation

System Overview
The front wiper system consists of wiper motor,
link, wiper arm, blade as well as wiper/washer
switch. The front wiper circuit is equipped with an
automatic stop unit, which consists of a worm
gear and a cam disc. It intends to keep the
integrity of circuit temporarily when the wiper/
washer switch is turned off and to cut off circuit
until the wiper arm returns to original position.
The wiper system is driven by a permanent
magnet motor, and the front wiper motor is
installed on the cowl and directly connected with
the front wiper linkage. There are 2 wiper motor
speeds (high and low speed) with intermittent
operation available. The wiper switch is part of
the wiper/washer system. The front wiper switch
is fitted on the stalk on the right side of steering
column.
The front washer system consists of washer
reservoir, washer motor, hose, washer nozzle and
wiper/ wiper switch. The front washer reservoir is
installed under the left headlamp, and the washer
motor is connected to the washer reservoir. The
washer fluid is transported to the two washer
nozzles on the cowl ornamentation assembly. The
washer switch is a part of wiper combination
switch.

M201 2014.01
4.2.7-3 Wiper and Washer 4.2.7-3

Components Location View

Wiper Combination Switch

1
2

1 1 USE
WITH

2 2
3 3

M4207015

Item Description Item Description

1 Steering wheel 3 Wiper combination switch
2 Dashboard

M201 2014.01
4.2.7-4 Wiper and Washer 4.2.7-4
Front Wiper

M4207016

Item Description Item Description

1 Front wiper motor 2 Washer reservoir

M201 2014.01
4.2.7-5 Wiper and Washer 4.2.7-5
Components Exploded View

M4207017

Item Description Item Description

1 Front wiper linkage 4 Wiper arm port cover
2 Front wiper 5 Front wiper motor
3 Front wiper arm assembly

M201 2014.01
4.2.7-6 Wiper and Washer 4.2.7-6

General Inspection
Test for Wiper Combination Switch
The wiper combination switch can be tested according to the wiper combination switch level table to
determine the performance of the switch and provide further maintenance solution.

T
3 5 4 2 7 6
P
OFF

INT

1 2 3 4 5 6 7 8 9 10 LO
HI

WASH

M4207018

Wiper Abnormal Noise Treatment

Principles: To determine the location of the sound. Clean, adjust and repair the part making abnormal
noise, and replace the parts as necessary.
CAUTION: Do not use wiper to clean dust on the dry windshield, otherwise it may damage the
windshield and the wiper blade. It may also cause abnormal noise. Clear snow and frost on
the windshield before using wiper in winter.

Execute the following steps when the abnormal noise of wiper occurs.
1. Inspect the windshield, and clear foreign matter on it. Replace when there is a thick scratch or crack
on the windshield. Inspect whether the wiper blade and wiper arm are deformed or damaged. Repair
or replace according to the corresponding conditions.
2. Replace qualified washing fluid for the windshield to ensure normal operation of wiper blade.
3. Lift the wiper blade and wiper arm from the windshield, and repeat wiping operation, which is helpful
to determine whether the noise comes from the contact between wiper blade and windshield or the
malfunction of the wiper system itself.
4. Use qualified windshield washing fluid provided by Changan Automobile to clean the windshield.
After cleaning, if the water does not form droplets but evenly distributes throughout the glass
surface, it indicates that the glass is already clean.
5. When cleaning the wiper blade, lift each blade assembly from the windshield to wipe and clean the
blade with a piece of cloth soaked with washer fluid, until the black deposit disappears. Then wash
the wiper blade with clean drinking water.
6. Replace the failed components of wiper system.

M201 2014.01
4.2.7-7 Wiper and Washer 4.2.7-7

Symptom Diagnosis and Testing

General Equipment

Digital multimeter

Inspection and Verification

1. Verify the customer concern.
2. Visually check if there are obvious
mechanical or electrical damage and
deformation due to collision.
Visual Inspection Chart

Mechanical Electrical
• Front windshield
• Fuse
• Nozzle
• Circuit
• Washer fluid pipeline
• Wiper combination
• Washer fluid reservoir
switch
• Wiper blade
• Front wiper motor
• Wiper arm
• Front washer motor
• Wiper drive arm

3. Inspect system circuit that is accessible and

visible.
4. If an observed or reported concern is obvious
and its cause has been found, solve the fault
before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
4.2.7-8 Wiper and Washer 4.2.7-8

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and repair it in order of the
following table.

Symptom Possible Causes Solutions

• Circuit fault Refer to: Diagnosis Procedure
• Front wiper linkage is not for Front Windshield
installed in right place Wiper (4.2.7 Wiper and
Front windshield wiper failure Washer, Symptom
• Front wiper linkage fault
Diagnosis and
• Wiper combination switch Testing).
• Front wiper motor

Refer to: Diagnosis Procedure

• Circuit fault for Front Windshield
• Wiper return signal fault Wiper Constantly
Front windshield wiper cannot
Running (4.2.7 Wiper
be stopped • Wiper combination switch
and Washer, Symptom
• Front wiper motor Diagnosis and
Testing).
Refer to: Diagnosis Procedure
• Circuit fault for Inoperative Wiper
• Low speed level signal fault in Low Speed Level
Wiper does not work in low
(4.2.7 Wiper and
speed level • Wiper switch
Washer, Symptom
• Front wiper motor Diagnosis and
Testing).
Refer to: Diagnosis Procedure
• Circuit fault for Inoperative Wiper
• High speed level signal fault in High Speed Level
Wiper does not work in high
(4.2.7 Wiper and
speed level • Wiper switch
Washer, Symptom
• Front wiper motor Diagnosis and
Testing).
Refer to: Diagnosis Procedure
• Circuit fault for Inoperative Wiper
• Wiper switch in Intermittent Level
Wiper does not work in
(4.2.7 Wiper and
intermittent level • Wiper intermittent signal fault
Washer, Symptom
• Front wiper motor Diagnosis and
Testing).

M201 2014.01
4.2.7-9 Wiper and Washer 4.2.7-9

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
for Wiper Constantly
• Circuit fault
Running in
Wiper works constantly in • Wiper intermittent signal fault Intermittent Level
intermittent level • Wiper switch (4.2.7 Wiper and
Washer, Symptom
• Front wiper motor
Diagnosis and
Testing).
• Circuit fault Refer to: Diagnosis Procedure
• Washer fluid does not meet for Windshield is Dirty
standard after Wiping (4.2.7
Wiper and Washer,
• Battery voltage is low
Windshield is dirty after wiping Symptom Diagnosis
• Wiper blade fault and Testing).
• Windshield scratch, crack
• Wiper linkage fault
• Front wiper motor
• Circuit fault Refer to: Diagnosis Procedure
• Wiper linkage is not installed in for Shaking Wiper
right place During Operation
(4.2.7 Wiper and
• Washer fluid does not meet
Washer, Symptom
standard
Wiper is shaking during Diagnosis and
operation • Battery voltage is low Testing).
• Wiper blade fault
• Wiper linkage fault
• Windshield scratch, crack
• Front wiper motor
• Circuit fault Refer to: Diagnosis Procedure
• Washer fluid does not meet for Abnormal Noise
standard During Wiping (4.2.7
Wiper and Washer,
• Battery voltage is low
Symptom Diagnosis
• Wiper blade and Testing).
Abnormal noise during wiping
• Wiper linkage is not installed in
right place
• Wiper linkage fault
• Windshield scratch, crack
• Front wiper motor

M201 2014.01
4.2.7-10 Wiper and Washer 4.2.7-10

Symptom Possible Causes Solutions

• Wiper linkage is not installed in Refer to: Diagnosis Procedure
right place for Front Wiper cannot
• Wiper linkage fault Go Back to Initial
Position (4.2.7 Wiper
Front wiper cannot go back to • Circuit fault
and Washer, Symptom
initial position • Wiper switch Diagnosis and
• Front wiper motor return signal Testing).
fault
• Front wiper motor

Refer to: Diagnosis Procedure

• Insufficient washer fluid
for Inaccurate Water
Front spray cannot reach • Washer nozzle fault Injection (4.2.7 Wiper
windshield • Hose fault and Washer, Symptom
Diagnosis and
• Washer motor
Testing).
• Insufficient washer fluid Refer to: Diagnosis Procedure
• Washer nozzle fault for Inoperative Washer
(4.2.7 Wiper and
Washer does not work • Hose fault
Washer, Symptom
• Front washer switch Diagnosis and
• Front washer motor Testing).

M201 2014.01
4.2.7-11 Wiper and Washer 4.2.7-11

Diagnosis Procedure for Front Windshield Wiper Failure

Front windshield wiper

failure

General inspection
(Inspect wiring harness
connector related to wiper)

Is the fault Yes

confirmed

No

Inspect wiper fuse

Yes
Is the fault
confirmed

No
Inspect wiper combination
switch power supply circuit

Yes
Is the fault
confirmed

No
Inspect wiper combination switch
Inspect wiper motor low speed
Inspect wiper motor input
level wiring harness
voltage at low speed
Inspect wiper motor input
voltage at high speed

Is the fault Yes

confirmed
Is the fault
confirmed No

Inspect wiper motor high-speed

level wiring harness

Yes No

End

M201 2014.01
4.2.7-12 Wiper and Washer 4.2.7-12

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
wiper for damage, aging, poor contact and
looseness.
B. Inspect the wiper linkage installation position and
overall status.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect wiper fuse

A. Inspect the wiper combination switch fuse IF25.
Fuse rated capacity: 20 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect wiper combination switch power supply circuit

A. Turn the ignition switch to "LOCK", and disconnect
the wiper combination switch wiring harness
P33
connector P33.
B. Turn the ignition switch to "ON".
C. Measure the voltage between terminal 3 of
10 9 8 7 6 5 4 3 2 combination switch wiring harness connector P33
1
and body grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 4.
No
Inspect and repair the open circuit fault between
terminal 3 of combination switch wiring harness
connector P33 and terminal 50 of instrument panel
M4207019 fuse box fuse IF25.

M201 2014.01
4.2.7-13 Wiper and Washer 4.2.7-13

Test Conditions Details/Results/Actions

4. Inspect wiper motor input voltage at low speed
A. Turn the ignition switch to "LOCK", and disconnect
the wiper motor wiring harness connector P11.
B. Turn the ignition switch to "ON".
C. Turn the wiper combination switch to "LO".
2 1 D. Measure the voltage between terminal 1 of wiper
motor wiring harness connector P11 and reliable
4 3 grounding.
Standard voltage: 11 ~ 14 V
P11
Is the voltage value normal?
Yes
M4207020
Replace the wiper motor.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.
No
Go to step 5.

5. Inspect wiper motor input voltage at high speed

A. Turn the ignition switch to "LOCK".
B. Disconnect the wiper motor wiring harness
connector P11.
C. Turn the ignition switch to "ON".
D. Turn the wiper combination switch to "HI".
E. Measure the voltage between terminal 2 of wiper
2 1 motor wiring harness connector P11 and reliable
grounding.
4 3 Standard voltage: 11 ~ 14 V
P11 Is the voltage value normal?
M4207021 Yes
Replace the wiper motor.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.
No
Go to step 6.

M201 2014.01
4.2.7-14 Wiper and Washer 4.2.7-14

Test Conditions Details/Results/Actions

6. Inspect wiper combination switch
A. Turn the ignition switch to "LOCK".
B. Disconnect the wiper combination switch wiring
harness connector P33.
C. Inspect the wiper combination switch performance
in accordance with the wiper combination switch
level table.
Is it normal?
Yes
Go to step 7.
No
Replace the wiper combination switch.
Refer to: Wiper Combination Switch (4.2.7
Wiper and Washer, Removal and
Installation).
Make sure the system is normal.

7. Inspect wiper motor low speed level wiring harness

A. Turn the ignition switch to "LOCK".
B. Disconnect the wiper motor wiring harness
connector P11.
C. Disconnect the wiper combination switch wiring
10 9 8 7 6 5 4 3 2 1 harness connector P33.
D. Measure the resistance between terminal 4 of wiper
combination switch wiring harness connector P33
P33
and terminal 1 of wiper motor wiring harness
connector P11.
Standard resistance: less than 5 Ω
Is the resistance value normal?
2 1 Yes
Go to step 8.
4 3
No
P11 Repair or replace the wiring harness.
M4207022

M201 2014.01
4.2.7-15 Wiper and Washer 4.2.7-15

Test Conditions Details/Results/Actions

8. Inspect wiper motor high-speed level wiring harness
A. Turn the ignition switch to "LOCK".
B. Disconnect the wiper motor wiring harness
connector P11 and wiper combination switch wiring
harness connector P33.
C. Measure the resistance between terminal 2 of wiper
combination switch wiring harness connector P33
and terminal 2 of wiper motor wiring harness
10 9 8 7 6 5 4 3 2 1 connector P11.
Standard resistance: less than 5 Ω
P33 Is the resistance value normal?
Yes
Remove the wiper motor, inspect for any loose
attachments with the body and reinstall the wiper
motor.
Make sure the system is normal.
No

2 1 Repair or replace the wiring harness.

4 3

P11

M4207023

M201 2014.01
4.2.7-16 Wiper and Washer 4.2.7-16

Diagnosis Procedure for Front Windshield Wiper Constantly

Running

Front windshield wiper

constantly running

General inspection
(Inspect wiring harness
connectors related to wiper)

Is the fault Yes

confirmed

No

Inspect wiper motor for its return

and stop function

Yes
Is the fault
confirmed

No
Inspect wiper motor low speed
level power supply circuit

Is the fault Yes

confirmed

No

Inspect wiper motor high speed

level power supply circuit

End

M201 2014.01
4.2.7-17 Wiper and Washer 4.2.7-17

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
wiper for damage and aging.
B. Inspect the wiper linkage installation position and
overall status.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.
2. Inspect wiper motor for its return and stop function
A. Turn the ignition switch to "LOCK".
P11 B. Disconnect the wiper motor wiring harness
connector P11.
C. Measure the resistance between terminals 3 and 4
2 1 of wiper motor side wiring harness connector.
Standard resistance: 10 MΩ or more
4 3
Is the resistance value normal?
Yes
Go to step 3.
No
M4207024
Replace the wiper motor.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-18 Wiper and Washer 4.2.7-18

Test Conditions Details/Results/Actions

3. Inspect wiper motor low speed level power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the wiper combination switch wiring
harness connector P33.
C. Disconnect the wiper motor wiring harness
10 9 8 7 6 5 4 3 2 1 connector P11.
D. Measure the resistance between terminal 4 of wiper
combination switch wiring harness connector P33
P33
and terminal 1 of wiper motor wiring harness
connector P11.
Standard resistance: less than 5 Ω
E. Measure the voltage between terminal 1 of wiper
2 1 motor wiring harness connector P11 and reliable
grounding.
4 3 Standard voltage: 0 V

P11 Is it normal?
M4207022 Yes
Go to step 4.
No
Inspect and repair the faulty circuit between
terminal 1 of wiper motor wiring harness connector
2 1 P11 and terminal 4 of wiper combination switch
wiring harness connector P33.
4 3

P11

M4207020

M201 2014.01
4.2.7-19 Wiper and Washer 4.2.7-19

Test Conditions Details/Results/Actions

4. Inspect wiper motor high speed level power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the wiper combination switch wiring
harness connector P33.
C. Disconnect the wiper motor wiring harness
connector P11.
D. Measure the resistance between terminal 2 of wiper
combination switch wiring harness connector P33
10 9 8 7 6 5 4 3 2 1 and terminal 2 of wiper motor wiring harness
connector P11.
P33 Standard resistance: less than 5 Ω
E. Measure the voltage between terminal 2 of wiper
motor wiring harness connector P11 and reliable
grounding.
Standard voltage: 0 V
Is it normal?
Yes

2 1 Replace the wiper combination switch.

Refer to: Wiper Combination Switch (4.2.7
4 3 Wiper and Washer, Removal and
Installation).
P11
Make sure the system is normal.
No
M4207023
Inspect and repair the faulty circuit between
terminal 2 of wiper combination switch wiring
harness connector P33 and terminal 2 of wiper
motor wiring harness connector P11.

2 1

4 3

P11
M4207021

M201 2014.01
4.2.7-20 Wiper and Washer 4.2.7-20

Diagnosis Procedure for Inoperative Wiper in Low Speed Level

Inoperative wiper in
low speed level

General inspection
(Inspect wiring harness
connectors related to wiper)

Is the fault Yes

confirmed

No

Inspect wiper motor input

voltage at low speed

Yes
Is the fault
confirmed

No

Inspect wiper combination switch

End

M201 2014.01
4.2.7-21 Wiper and Washer 4.2.7-21

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
wiper for damage, aging, poor contact and
looseness.
B. Inspect the wiper linkage installation position and
overall status.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect wiper motor input voltage at low speed

A. Turn the ignition switch to "LOCK", and disconnect
the wiper motor wiring harness connector P11.
B. Turn the ignition switch to "ON".
C. Turn the wiper combination switch to "LO".
2 1 D. Measure the voltage between terminal 1 of wiper
motor wiring harness connector P11 and reliable
4 3 grounding.
Standard voltage: 11 ~ 14 V
P11
Is the voltage value normal?
Yes
M4207020
Replace the wiper motor.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.
No
Go to step 3.

M201 2014.01
4.2.7-22 Wiper and Washer 4.2.7-22

Test Conditions Details/Results/Actions

3. Inspect wiper combination switch
A. Turn the ignition switch to "LOCK".
B. Disconnect the wiper combination switch wiring
harness connector P33.
C. Inspect the wiper combination switch performance
in accordance with the wiper combination switch
level table.
Is it normal?
Yes
Inspect and repair the open circuit fault between
terminal 4 of wiper combination switch wiring
harness connector P33 and terminal 1 of wiper
motor wiring harness connector P11.
No
Replace the wiper combination switch.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-23 Wiper and Washer 4.2.7-23

Diagnosis Procedure for Inoperative Wiper in High Speed Level

Inoperative wiper in
high speed level

General inspection
(Inspect wiring harness
connectors related to wiper)

Is the fault Yes

confirmed

No
Inspect wiper motor input voltage
at high speed

Yes
Is the fault
confirmed

No

Inspect wiper combination switch

End

M201 2014.01
4.2.7-24 Wiper and Washer 4.2.7-24

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
wiper for damage, aging, poor contact and
looseness.
B. Inspect the wiper linkage installation position and
overall status.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect wiper motor input voltage at high speed

A. Turn the ignition switch to "LOCK", and disconnect
the wiper motor wiring harness connector P11.
B. Turn the ignition switch to "ON".
C. Turn the wiper combination switch to "HI".
D. Measure the voltage between terminal 2 of wiper
motor wiring harness connector P11 and reliable
2 1 grounding.
Standard voltage: 11 ~ 14 V
4 3
Is the voltage value normal?
P11 Yes
M4207021
Replace the wiper motor.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.
No
Go to step 3.

M201 2014.01
4.2.7-25 Wiper and Washer 4.2.7-25

Test Conditions Details/Results/Actions

3. Inspect wiper combination switch
A. Turn the ignition switch to "LOCK".
B. Disconnect the wiper combination switch wiring
harness connector P33.
C. Inspect the wiper combination switch performance
in accordance with the wiper combination switch
level table.
Is it normal?
Yes
Inspect and repair the open circuit fault between
terminal 2 of wiper combination switch wiring
harness connector P33 and terminal 2 of wiper
motor wiring harness connector P11.
No
Replace the wiper combination switch.
Refer to: Wiper Combination Switch (4.2.7
Wiper and Washer, Removal and
Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-26 Wiper and Washer 4.2.7-26

Diagnosis Procedure for Inoperative Wiper in Intermittent Level

CAUTION: Identify that the wiper motor works normally at low speed before this procedure is
carried out. Inoperative wiper motor at low speed, refer to: Diagnosis Procedure for
Inoperative Wiper at Low Speed (4.2.7 Wiper and Washer, Symptom Diagnosis and Testing).

Inoperative wiper in
intermittent level

General inspection
(Inspect wiring harness
connectors related to wiper)

Is the fault Yes

confirmed

No
Inspect wiper combination
switch grounding circuit

Yes
Is the fault
confirmed

No
Inspect circuit between wiper
combination switch and front
wiper motor

Is the fault Yes

confirmed

No

Inspect wiper combination

switch

End

M201 2014.01
4.2.7-27 Wiper and Washer 4.2.7-27

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
wiper for damage, aging, poor contact and
looseness.
B. Inspect the wiper linkage installation position and
overall status.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect wiper combination switch grounding circuit

A. Turn the ignition switch to "LOCK", and disconnect
P33 the wiper combination switch wiring harness
connector P33.
B. Measure the resistance between terminal 6 of wiper
combination switch wiring harness connector P33
10 9 8 7 6 5 4 3 2 and reliable grounding.
1
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 3.
No
Inspect and repair the open circuit fault between
terminal 6 of wiper combination switch wiring
harness connector P33 and grounding point G103.

M4207027

M201 2014.01
4.2.7-28 Wiper and Washer 4.2.7-28

Test Conditions Details/Results/Actions

3. Inspect circuit between wiper combination switch and front wiper motor
A. Turn the ignition switch to "LOCK".
B. Disconnect the wiper combination switch wiring
harness connector P33 and front wiper motor wiring
harness connector P11.
C. Measure the resistance between terminals 2, 4, 5 of
wiper combination switch wiring harness connector
P33 and terminals 2, 1, 4 of front wiper motor wiring
10 9 8 7 6 5 4 3 2 1 harness connector P11.
Standard resistance: less than 5 Ω
P33 Is the resistance value normal?
Yes
Go to step 4.
No
Inspect and repair the open circuit fault between
terminals 2, 4, 5 of wiper combination switch wiring
harness connector P33 and terminals 2, 1, 4 of
front wiper motor wiring harness connector P11.
2 1

4 3

P11

M4207028

4. Inspect wiper combination switch

A. Turn the ignition switch to "LOCK", and disconnect
the wiper combination switch wiring harness
connector P33.
B. Inspect the wiper combination switch performance
in accordance with the wiper combination switch
level table.
Is it normal?
Yes
Replace the wiper motor.
Make sure the system is normal.
Refer to: Wiper Motor (4.2.7 Wiper and
Washer, Removal and
Installation).
No
Replace the wiper combination switch.
Make sure the system is normal.
Refer to: Wiper Combination Switch (4.2.7
Wiper and Washer, Removal and
Installation).

M201 2014.01
4.2.7-29 Wiper and Washer 4.2.7-29

Diagnosis Procedure for Wiper Constantly Running in Intermittent

Level

Wiper constantly running

in intermittent level

General inspection
(Inspect wiring harness
connectors related to wiper)

Is the fault Yes

confirmed

No

Inspect if there is high-speed

power supply input under wiper
motor intermittent operation mode

Is the fault Yes

confirmed

No

InspectẔᶹ䲼ࠂ㒘ড়ᓔ݇
wiper combination switch

Is the fault Yes

confirmed

No
Inspect return power supply of front
wiper motor

Is the fault No
confirmed
Inspect front wiper motor for its
return and stop function

Yes No

End

M201 2014.01
4.2.7-30 Wiper and Washer 4.2.7-30

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
wiper for damage, aging, poor contact and
looseness.
B. Inspect the wiper linkage installation position and
overall status.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect if there is high-speed power supply input under wiper motor intermittent operation mode
A. Turn the ignition switch to "LOCK", and disconnect
the wiper motor wiring harness connector P11.
B. Turn the ignition switch to "ON".
C. Turn the wiper combination switch to "INT".
D. Measure the voltage between terminal 2 of wiper
motor wiring harness connector P11 and reliable
2 1 grounding.
Standard voltage: 0 V
4 3
Is the voltage value normal?
P11 Yes
M4207021
Go to step 3.
No
Replace the wiper combination switch.
Refer to: Wiper Combination Switch (4.2.7
Wiper and Washer, Removal and
Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-31 Wiper and Washer 4.2.7-31

Test Conditions Details/Results/Actions

3. Inspect wiper combination switch
A. Turn the ignition switch to "LOCK", and disconnect
the wiper combination switch wiring harness
connector P33.
B. Inspect the wiper combination switch performance
in accordance with the wiper combination switch
level table.
Is it normal?
Yes
Go to step 4.
No
Replace the wiper combination switch.
Refer to: Wiper Combination Switch (4.2.7
Wiper and Washer, Removal and
Installation).
Make sure the system is normal.

4. Inspect return power supply of front wiper motor

A. Turn the ignition switch to "LOCK", and disconnect
the front wiper motor wiring harness connector P11.
B. Turn the ignition switch to "ON".
C. Measure the voltage between terminal 3 of wiper
2 1 motor wiring harness connector P11 and reliable
grounding.
4 3
Standard voltage: 11 ~ 14 V
P11 Is the voltage value normal?
Yes
Go to step 5.
M4207029
No
Inspect and repair the open circuit fault between
terminal 3 of front wiper motor wiring harness
connector P11 and terminal 50 of instrument panel
fuse box fuse IF25.

M201 2014.01
4.2.7-32 Wiper and Washer 4.2.7-32

Test Conditions Details/Results/Actions

5. Inspect front wiper motor for its return and stop function
A. Turn the ignition switch to "LOCK" and disconnect
P11 the wiper motor wiring harness connector P11 when
the wiper motor is at moving position.
B. Measure the resistance between terminals 3 and 4
2 1 of wiper motor side.
Standard resistance: less than 5 Ω
4 3
Is the resistance value normal?
Yes
Inspect and repair the open circuit fault between
terminal 4 of front wiper motor wiring harness
M4207024 connector P11 and terminal 5 of wiper combination
switch wiring harness connector P33.
No
Replace the wiper motor.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-33 Wiper and Washer 4.2.7-33

Diagnosis Procedure for Windshield is Dirty after Wiping

Windshield is dirty after

wiping

General inspection
(Add standard washer fluid and
perform wiper operation)

Is the fault Yes

confirmed

No

Inspect wiper blade

Is the fault Yes

confirmed

No

Inspect wiper arm

Yes
Is the fault
confirmed

No Inspect wiper linkage

Inspect windshield

Is the fault Yes

confirmed
Is the fault
confirmed No

Replace wiper motor

No
Yes

End

M201 2014.01
4.2.7-34 Wiper and Washer 4.2.7-34

Test Conditions Details/Results/Actions

1. General inspection
A. Add washer fluid meeting the standard of Changan
Automobile and perform wiper operation.
Is it normal?
Yes
Make sure that the maintenance has been finished.
No
Go to step 2.

2. Inspect wiper blade

A. Inspect the cleanliness of wiper blade.
B. Inspect the wiper blade for deformation, aging and
damage.
Is the performance of wiper blade normal?
Yes
Go to step 3.
No
Clean the wiper blade with the special washing fluid
and replace as necessary.

3. Inspect wiper arm

A. Inspect the installation position of wiper arm.
B. Inspect the wiper arm for elasticity.
Is the performance of wiper arm normal?
Yes
Go to step 4.
No
Adjust the installation position of wiper arm and
replace as necessary.

4. Inspect windshield
A. Inspect the cleanliness of windshield.
B. Inspect the windshield for scratch and damage.
Is the performance of windshield normal?
Yes
Go to step 5.
No
Clean the front windshield with the special washing
fluid and replace as necessary.

M201 2014.01
4.2.7-35 Wiper and Washer 4.2.7-35

Test Conditions Details/Results/Actions

5. Inspect wiper linkage
A. Inspect the installation of wiper linkage.
B. Inspect the wiper linkage for deformation and
damage.
Is the performance of wiper arm normal?
Yes
Go to step 6.
No
Adjust the wiper linkage installation position, repair
the deformed parts and replace the damaged wiper
linkage.

6. Replace wiper motor

A. Replace the wiper motor.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-36 Wiper and Washer 4.2.7-36

Diagnosis Procedure for Shaking Wiper During Operation

Shaking wiper during

operation

General inspection
(Add standard washer fluid and
perform wiper operation)

Is the fault Yes

confirmed

No

Inspect wiper blade

Is the fault Yes

confirmed

No

Inspect wiper arm

Is the fault Yes

confirmed

No Inspect wiper linkage

Inspect windshield

Is the fault Yes

confirmed
Is the fault
confirmed
No

Replace wiper motor

No
Yes

End

M201 2014.01
4.2.7-37 Wiper and Washer 4.2.7-37

Test Conditions Details/Results/Actions

1. General inspection
A. Add washer fluid meeting the standard of Changan
Automobile and perform wiper operation.
Is it normal?
Yes
Repair is completed.
No
Go to step 2.

2. Inspect wiper blade

A. Inspect the cleanliness of wiper blade.
B. Inspect the wiper blade for deformation, aging and
damage.
Is the performance of wiper blade normal?
Yes
Go to step 3.
No
Clean the wiper blade with the special washing fluid
and replace as necessary.

3. Inspect wiper arm

A. Inspect the installation position of wiper arm.
B. Inspect the wiper arm for elasticity.
Is the performance of wiper arm normal?
Yes
Go to step 4.
No
Adjust the installation position of wiper arm and
replace as necessary.

4. Inspect windshield
A. Inspect the cleanliness of windshield.
B. Inspect the windshield for scratch and damage.
Is the performance of windshield normal?
Yes
Go to step 5.
No
Clean the front windshield with the special washing
fluid and replace as necessary.

M201 2014.01
4.2.7-38 Wiper and Washer 4.2.7-38

Test Conditions Details/Results/Actions

5. Inspect wiper linkage
A. Inspect the installation of wiper linkage.
B. Inspect the wiper linkage for deformation and
damage.
Is the wiper linkage normal?
Yes
Go to step 6.
No
Adjust the wiper linkage installation position, repair
the deformed parts and replace the damaged wiper
linkage.

6. Replace wiper motor

A. Replace the wiper motor.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-39 Wiper and Washer 4.2.7-39

Diagnosis Procedure for Abnormal Noise During Wiping

Abnormal noise during

wiping

Inspect wiper blade

Is the fault Yes

confirmed

No

Inspect windshield

Is the fault Yes

confirmed

No

Inspect washing condition

Is the fault Yes

confirmed

No Inspect wiper linkage

Inspect wiper arm

Yes
Is the fault
confirmed
Is the fault
confirmed
No

Replace wiper motor

No
Yes

End

M201 2014.01
4.2.7-40 Wiper and Washer 4.2.7-40

Test Conditions Details/Results/Actions

1. Inspect wiper blade
A. Inspect the cleanliness of wiper blade.
B. Inspect the wiper blade for deformation, aging and
damage.
Is the performance of wiper blade normal?
Yes
Go to step 2.
No
Clean the wiper blade with the special washing fluid
and replace as necessary.

2. Inspect windshield
A. Inspect the cleanliness of windshield.
B. Inspect the windshield for scratch and damage.
Is the performance of the windshield normal?
Yes
Go to step 3.
No
Clean the front windshield with the special washing
fluid and replace as necessary.

3. Inspect washing condition

A. Add washer fluid meeting the standard of Changan
Automobile and perform wiper operation.
Does the abnormal noise still exist?
Yes
Repair is completed.
No
Go to step 4.

4. Inspect wiper arm

A. Inspect the installation position of wiper arm.
B. Inspect the wiper arm for elasticity.
Is the performance of wiper arm normal?
Yes
Go to step 5.
No
Adjust the installation position of wiper arm and
replace as necessary.

M201 2014.01
4.2.7-41 Wiper and Washer 4.2.7-41

Test Conditions Details/Results/Actions

5. Inspect wiper linkage
A. Inspect the installation of wiper linkage.
B. Inspect the wiper linkage for deformation and
damage.
Is the performance of wiper linkage normal?
Yes
Go to step 6.
No
Adjust the wiper linkage installation position, repair
the deformed parts and replace the damaged wiper
linkage.

6. Replace wiper motor

A. Turn the ignition switch to "LOCK", and disconnect
the wiper motor wiring harness connector.
Replace the wiper motor.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-42 Wiper and Washer 4.2.7-42

Diagnosis Procedure for Front Wiper cannot Go Back to Initial

Position

Front wiper cannot go

back to initial position

General inspection
(Inspect wiring harness
connectors related to wiper)

Is the fault Yes

confirmed

No

Inspect wiper arm

Yes
Is the fault
confirmed

No

Inspect wiper linkage

Is the fault Yes

confirmed

No
Inspect front wiper motor for its
Inspect return power supply of return and stop function
front wiper motor

Is the fault Yes

Is the fault confirmed
confirmed
No

Inspect wiper combination switch

Yes No

End

M201 2014.01
4.2.7-43 Wiper and Washer 4.2.7-43

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
wiper for damage, aging, poor contact and
looseness.
B. Inspect the wiper linkage installation position and
overall status.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect wiper arm

A. Inspect the installation position of front wiper arm.
B. Inspect the front wiper arm for elasticity.
Is the performance of front wiper arm normal?
Yes
Go to step 3.
No
Adjust the installation position of front wiper arm
and replace as necessary.

3. Inspect wiper linkage

A. Inspect the installation condition of wiper linkage.
B. Inspect the wiper linkage for deformation and
damage.
Is the performance of wiper linkage normal?
Yes
Go to step 4.
No
Adjust the wiper linkage installation position, repair
the deformed parts and replace the wiper linkage as
necessary.

M201 2014.01
4.2.7-44 Wiper and Washer 4.2.7-44

Test Conditions Details/Results/Actions

4. Inspect return power supply of front wiper motor
A. Turn the ignition switch to "LOCK", and disconnect
the front wiper motor wiring harness connector P11.
B. Turn the ignition switch to "ON".
C. Measure the voltage between terminal 3 of wiper
2 1 motor wiring harness connector P11 and reliable
grounding.
4 3
Standard voltage: 11 ~ 14 V
P11 Is the voltage value normal?
Yes
Go to step 5.
M4207029
No
Inspect and repair the open circuit fault between
terminal 3 of front wiper motor wiring harness
connector P11 and terminal 50 of instrument panel
fuse box fuse IF25.

5. Inspect front wiper motor for its return and stop function
A. Turn the ignition switch to "ON".
P11 B. Turn the wiper combination switch to "LO".
C. Turn the ignition switch to "LOCK" and disconnect
the wiper motor wiring harness connector P11 when
2 1 the wiper motor is at moving position.
D. Measure the resistance between terminals 3 and 4
4 3 of wiper motor side.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
M4207024
Go to step 6.
No
Replace the wiper motor.
Refer to: Wiper Motor and Drive Arm
(4.2.7 Wiper and Washer,
Removal and Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-45 Wiper and Washer 4.2.7-45

Test Conditions Details/Results/Actions

6. Inspect wiper combination switch
A. Turn the ignition switch to "LOCK", and disconnect
the wiper combination switch wiring harness
connector P33.
B. Inspect the wiper combination switch performance
in accordance with the wiper combination switch
level table.
Is it normal?
Yes
Inspect and repair the open circuit fault between
terminal 4 of front wiper motor wiring harness
connector P11 and terminal 5 of wiper combination
switch wiring harness connector P33.
No
Replace the wiper combination switch.
Refer to: Wiper Combination Switch (4.2.7
Wiper and Washer, Removal and
Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-46 Wiper and Washer 4.2.7-46

Diagnosis Procedure for Inaccurate Water Injection

Inaccurate water
injection

General inspection
(Inspect the volume of washer fluid)

Is the fault Yes

confirmed

No

Inspect front washer nozzle

Yes
Is the fault
confirmed

No

Replace front washer nozzle

End

M201 2014.01
4.2.7-47 Wiper and Washer 4.2.7-47

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the volume of washer fluid.
B. Inspect the washer fluid pipe for any deformation,
bending and damage.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect front washer nozzle

A. Inspect the spray angle and position during
washing operation.
B. Adjust the washer nozzle.
Is it normal?
Yes
Make sure that the maintenance has been finished.
No
Go to step 3.

3. Replace front washer nozzle

A. Replace the washer nozzle.
Refer to: Washer Equipment (4.2.7 Wiper
and Washer, Removal and
Installation).
Make sure the system is normal.

M201 2014.01
4.2.7-48 Wiper and Washer 4.2.7-48

Diagnosis Procedure for Washer Fault

Washer fault

General inspection
(Inspect wiring harness
connectors related to washer)

Is the fault Yes

confirmed

No

Inspect washer equipment

Is the fault Yes

confirmed

No

Inspect washer fuse

Is the fault Yes

confirmed

No Inspect wiring harness between

front washer motor and wiper
Inspect front washer motor combination switch.
power supply
Inspect front washer motor

Yes
Is the fault
confirmed
Is the fault
confirmed No

Inspect wiper combination

switch
Yes No

End

M201 2014.01
4.2.7-49 Wiper and Washer 4.2.7-49

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors related to the
washer for damage, aging and looseness.
Is it normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect washer equipment

A. Inspect the volume of washer fluid.
B. Inspect the washer pipe for any deformation,
bending and damage.
C. Inspect the washer nozzle for any crack and
damage.
Is it normal?
Yes
Go to step 3.
No
Repair the faulty area.

3. Inspect washer fuse

A. Inspect the washer fuse IF25.
Fuse rated capacity: 20 A
Is the fuse normal?
Yes
Go to step 4.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.7-50 Wiper and Washer 4.2.7-50

Test Conditions Details/Results/Actions

4. Inspect front washer motor power supply
A. Turn the ignition switch to "LOCK", and disconnect
the front washer motor wiring harness connector
P17.
B. Measure the voltage between terminal 2 of front
1 washer motor wiring harness connector P17 and
reliable grounding.
2 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
P17 Yes
Go to step 5.
M4207030 No
Inspect and repair the open circuit fault between
terminal 2 of front washer motor wiring harness
connector P17 and terminal 50 of instrument panel
fuse box fuse IF25.

5. Inspect front washer motor

A. Turn the ignition switch to "LOCK", and disconnect
the front washer motor wiring harness connector
P17.
B. Turn the ignition switch to "ON".
1 C. Turn the wiper combination switch to "WASH".
D. Measure the voltage between terminals 1 and 2 of
front washer motor wiring harness connector P17.
2
Standard voltage: 11 ~ 14 V
P17 Is the voltage value normal?
Yes
M4207031
Replace the front washer motor.
Refer to: Washer Equipment (4.2.7 Wiper
and Washer, Removal and
Installation).
Make sure the system is normal.
No
Go to step 6.

M201 2014.01
4.2.7-51 Wiper and Washer 4.2.7-51

Test Conditions Details/Results/Actions

6. Inspect wiring harness between front washer motor and wiper combination switch.
A. Turn the ignition switch to "LOCK", disconnect the
wiper combination switch wiring harness connector
P33 and disconnect the front washer motor wiring
harness connector P17.
10 9 8 7 6 5 4 3 2 1 B. Measure the resistance between terminal 7 of wiper
combination switch wiring harness connector P33
and terminal 1 of front washer motor wiring harness
P33 connector P17.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
1
Go to step 7.
No
2
Inspect and repair the open circuit fault between
P17 terminal 7 of wiper combination switch wiring
M4207032 harness connector P33 and terminal 1 of front
washer motor wiring harness connector P17.

7. Inspect wiper combination switch

A. Disconnect the wiper combination switch wiring
harness connector P33.
B. Inspect the wiper combination switch performance
in accordance with the wiper combination switch
level table.
Is it normal?
Yes
Inspect and repair the open circuit fault between
terminal 6 of wiper combination switch wiring
harness connector P33 and grounding point G103.
No
Replace the wiper combination switch.
Refer to: Wiper Combination Switch (4.2.7
Wiper and Washer, Removal and
Installation).
The system is normal.

M201 2014.01
4.2.7-52 Wiper and Washer 4.2.7-52

Removal and Installation

Wiper Combination Switch
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the steering wheel.
Refer to: Steering Wheel (2.4.4 Steering
Column, Removal and
Installation).
3. Remove 3 retaining screws from the upper
and lower housings of steering lock.

×3

M4206022

4. Separate the upper and lower housings of

steering lock.

M4206023

M201 2014.01
4.2.7-53 Wiper and Washer 4.2.7-53

5. Disconnect the wiper combination switch

wiring harness connector.

A/C

M4207001

6. Remove the wiper combination switch.

A/C

M4207002

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.7-54 Wiper and Washer 4.2.7-54

Wiper Motor and Drive Arm

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove 2 retaining bolt covers from the
master and sub wiper arms.

M4207003

3. Remove 2 retaining nuts from the master and

sub wiper arms, and remove the wiper arm.
Torque: 18 ~ 22 Nm
×2

M4207004

M201 2014.01
4.2.7-55 Wiper and Washer 4.2.7-55

4. Remove the cowl ornamentation.

CAUTION: Do not damage the washer
hose when separating the cowl
ornamentation and front windshield.

1 Remove 4 retaining clips from the cowl

ornamentation.

×4
M4207035

2 Use the special tool to pry the cowl

ornamentation.
Special tool: CA501-002

M4207005

3 The clip position is as shown in the figure.

×7

M4207006

M201 2014.01
4.2.7-56 Wiper and Washer 4.2.7-56

5. Disconnect the washer hose from the washer

nozzle.

M4207014

6. Remove the wiper motor.

1 Disconnect the wiper motor wiring harness
connector.

M4207007

2 Remove 3 retaining bolts from the wiper

motor, and remove the wiper motor.
Torque: 13 ± 2 Nm
×3

M4207008

M201 2014.01
4.2.7-57 Wiper and Washer 4.2.7-57

7. Separate the wiper motor crank ball joint from

the wiper linkage.

M4207009

8. Remove the wiper linkage.

1 Remove 4 retaining nuts from the wiper

×4
linkage.
Torque: 13 ± 2 Nm
2 Remove the wiper linkage.

M4207033

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.7-58 Wiper and Washer 4.2.7-58

Washer Equipment
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the front bumper.

Refer to: Front Bumper (5.1.7 Bumper,
Removal and Installation).
3. Disconnect the washer wiring harness
connector.

M4207010

4. Disconnect the washer hose.

CAUTION: Drain the washer fluid before
disconnecting the washer hose.

M4207011

5. Remove the washer motor.

M4207034

M201 2014.01
4.2.7-59 Wiper and Washer 4.2.7-59

6. Remove the washer reservoir.

1 Remove 2 retaining bolts from the lower of
washer reservoir.
Torque: 6 ~ 9 Nm

×2

M4207012

2 Remove the retaining bolt from the upper of

washer reservoir, and remove the washer
reservoir.
Torque: 6 ~ 9 Nm

M4207013

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.8-1 Central Door Lock 4.2.8-1

Description and Operation

4.2.8 Central Door Lock

System Overview
Door Lock Function
When the ignition switch is turned to "OFF", or the
key is pulled out, press the "lock" button of remote
controller facing the vehicle, and all the doors will
be locked. Meanwhile, the turn lamps blink once.

Door Unlock Function

When the ignition switch is turned to "OFF", or the
key is pulled out, press the "unlock" button of
remote controller facing the vehicle, and all the
doors will be unlocked. Meanwhile, the turn lamps
blink twice.

Remote Control Disabling Function

When the key is inserted into the ignition lock and
turned to "ACC", the remote control function will
be disabled.

Central Control Function

When use the key to lock/unlock the front left door
lock, or operate the lock button of front left door
inside handle, the other door locks will do the
same operation together.

Remote Control Key Programming

Perform the key programming according to the
following procedures:
1. The ignition key switches five times between
"OFF" and "ACC" in 15 s;
2. It returns to "OFF", and the turn lamps remain
on, so that the learning key function is
enabled;
3. Meanwhile press the unlock button of remote
controller (it is effective if pressing within 10 s);
4. After key learning completion, the turn lamps
come off. Exit the learn mode.

M201 2014.01
4.2.8-2 Central Door Lock 4.2.8-2

Components Location View

1 2

5 4

M4208001

Item Description Item Description

Key with remote control
1 Rear door fastener 4
transmitter
2 Rear door lock latch 5 Mechanical key
3 Front door lock latch 6 Central lock controller

M201 2014.01
4.2.8-3 Central Door Lock 4.2.8-3

Symptom Diagnosis and Testing

General Equipment

Digital multimeter
Diagnostic tool

Inspection and Verification

1. Verify the customer concern.
2. Visually check if there are obvious
mechanical or electrical damage and
deformation due to collision.
3. Inspect system circuit that is accessible and
visible.
4. If an observed or reported concern is obvious
and its cause has been found, solve the fault
before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.
Visual Inspection Chart

Mechanical Electrical
• Lock latch
• Door lock actuator
• Door misaligned
• Battery
• Door inside handle
• Fuse
• Door outside handle
• Wiring harness or
• Remote controller
connector
• Door lock core
• Central lock controller
• Cable

M201 2014.01
4.2.8-4 Central Door Lock 4.2.8-4

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and repair it in order of the
following table.

Symptom Possible Causes Solutions

• Remote controller fails to match • Match the key again.
• Remote control distance is too
far, or strong interfering
• Eliminate the interference.
resource is nearby (mobile
phone, launching pad, etc.)
• Remote controller battery is
All functions of remote depleted
controller failure
• A poor contact between remote • Replace or reinstall the remote controller
controller and battery battery.
• Charge the battery, and replace as
• Low battery voltage
necessary.
• Remote controller is damaged • Replace the remote controller.
• Central lock controller • Replace the central lock controller.
• Wiring harness connector is
• Reconnect the wiring harness connector.
Single door lock does not loose
• Replace the door lock.
work • Door lock is damaged
• Replace the wiring harness.
• Wiring harness fault
One or more doors cannot be
• Door lock or door cable fault • Replace the door lock or door cable.
locked or opened
• Reassemble the lock core or replace the
• Lock core
Manual open and close door vehicle lock core.
functions failure • Door lock or outside handle
• Replace the door lock or outside handle
assembly
assembly.
• Door lock fuse Refer to: Diagnosis Procedure
• Thermal protection for the door for Central Lock
lock motor Failure (4.2.8 Central
Door Lock, Symptom
• Wiring harness connector is
Diagnosis and
Central control lock failure loose
Testing).
• Battery voltage
• Circuit
• Door lock motor
• Central lock controller

M201 2014.01
4.2.8-5 Central Door Lock 4.2.8-5

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
for Driver Side Door
• Door lock motor Central Lock Failure
Driver side door central lock
• Circuit (4.2.8 Central Door
failure
• Central lock controller Lock, Symptom
Diagnosis and
Testing).
Refer to: Diagnosis Procedure
for Passenger Side
• Door lock motor Door Central Lock
Passenger side door central
• Circuit Failure (4.2.8 Central
lock failure
• Central lock controller Door Lock, Symptom
Diagnosis and
Testing).
• Trunk cable • Replace the trunk cable.
Trunk lock opening failure • Trunk lock latch • Replace the trunk lock latch.
• Improper adjustment • Adjust the trunk lock.

Refer to: Diagnosis Procedure

• Remote controller fails to match for Remote Controller
correctly Failure with Central
Central lock is normal but
Lock Normal (4.2.8
remote controller fails. • Remote controller
Central Door Lock,
• Central lock controller Symptom Diagnosis
and Testing).

M201 2014.01
4.2.8-6 Central Door Lock 4.2.8-6

Diagnosis Procedure for Central Lock Failure

Central lock failure

Verify symptom

Inspect driver side inside handle Yes

unlock knob

Inspect fastener central switch

Is the fault Yes

confirmed

No

Inspect fastener central switch

grounding circuit

Is the fault Yes

confirmed

No

Inspect front left door fastener

unlock signal
Is the fault Yes
confirmed

Is the fault No
confirmed
Inspect central lock controller power
supply circuit
No

Inspect front left door fastener lock

signal
Inspect central lock controller fuse
Inspect central lock controller power
supply circuit End

M201 2014.01
4.2.8-7 Central Door Lock 4.2.8-7

Test Conditions Details/Results/Actions

1. Verify symptom
A. Press the lock button on the remote controller.
B. Press the unlock knob on the driver side inside
handle.
C. Use a mechanical key to execute the lock/unlock
function from the outside of driver side door.
D. Verify the operation result.
Does the central lock not work during all the
operations above?
Yes
Go to step 5.
No
If the central lock does not work when pressing the
lock button on the remote controller, inspect the
remote controller battery.
If the central lock does not work when pressing the
unlock knob on the driver side inside handle, go to
step 2.
If the central lock does not work when using a
mechanical key to execute the lock/unlock function
from the outside of driver side door, go to step 3.

2. Inspect driver side inside handle unlock knob

A. Remove the front left door trim panel.
Refer to: Front Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
B. Inspect the connection cable between unlock knob
on the driver side inside handle and door lock latch.
Is the connection normal?
Yes
Replace the front left door lock latch.
No
Inspect and repair the connection cable between
unlock knob on the driver side inside handle and
door lock latch, and replace as necessary.

M201 2014.01
4.2.8-8 Central Door Lock 4.2.8-8

Test Conditions Details/Results/Actions

3. Inspect fastener central switch
A. Turn the ignition switch to "LOCK".
B. Disconnect the front left door fastener wiring
harness connector D01, and take out terminals 1
and 2 from it.
C. Connect the front left door fastener wiring harness
connector D01, and insert the key into the front left
door lock core to perform unlock function.
D. Measure the resistance between terminals 1 and 2
1 2 3 of front left door fastener.
4 5 6 Standard resistance: less than 5 Ω
E. Take out the terminals 2 and 3 of front left door
D01 fastener wiring harness connector D01.
M4208002 F. Insert the key into the front left door lock core to
perform lock function, and measure the resistance
between terminals 2 and 3 of front left door
fastener.
Standard resistance: less than 5 Ω
Is the switch normal?
Yes
1 2 3
Go to step 4.
4 5 6 No
Replace the front left door lock latch.
D01
M4208012
Refer to: Front Door Lock Latch (4.2.8
Central Door Lock, Removal and
Installation).
4. Inspect fastener central switch grounding circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the front left door fastener wiring
harness connector D01.
C. Measure the resistance between terminal 2 of front
left door fastener wiring harness connector D01 and
reliable grounding.
Standard resistance: less than 5 Ω

1 2 3 Is the resistance value normal?

Yes
4 5 6
Go to step 5.
No
D01
M4208003 Inspect and repair the open circuit fault between
terminal 2 of front left door fastener wiring harness
connector D01 and grounding point G103.

M201 2014.01
4.2.8-9 Central Door Lock 4.2.8-9

Test Conditions Details/Results/Actions

5. Inspect front left door fastener unlock signal
A. Turn the ignition switch to "LOCK".
B. Disconnect the front left door fastener wiring
harness connector D01, and take out the terminal 4
from it.
D01 C. Connect the front left door fastener wiring harness
connector D01, and perform unlock function.
1 2 3 D. Measure the voltage between the removed terminal
4 and reliable grounding.
4 5 6
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 6.
No
M4208004
Inspect and repair the open circuit fault between
terminal 4 of front left door fastener wiring harness
connector D01 and terminal 8 of central lock
controller wiring harness connector P29.

6. Inspect front left door fastener lock signal

A. Turn the ignition switch to "LOCK".
B. Disconnect the front left door fastener wiring
harness connector D01, and take out the terminal 6
from it.
C. Connect the front left door fastener wiring harness
connector D01, and perform lock function.
D. Measure the voltage between the removed terminal
1 2 3
6 and reliable grounding.
4 5 6 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
D01 Yes
Go to step 7.
No
M4208005
Inspect and repair the open circuit fault between
terminal 6 of front left door fastener wiring harness
connector D01 and terminal 9 of central lock
controller wiring harness connector P29.

7. Inspect central lock controller fuse

A. Inspect the central lock controller fuse IF22, IF40.
Rated capacity: 20 A (IF22), 15A (IF40)
Is the fuse normal?
Yes
Go to step 8.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.8-10 Central Door Lock 4.2.8-10

Test Conditions Details/Results/Actions

8. Inspect central lock controller power supply circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the central lock controller wiring
harness connector P29.
C. Turn the ignition switch to "ON".
D. Measure the voltage between terminals 1 and 5 of
central lock controller wiring harness connector P29
and reliable grounding.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?

5 4 3 2 1 Yes
Go to step 9.
12 11 10 9 8 7 6 No
Inspect and repair the central lock controller power
P29
supply malfunction circuit.

M4208006

9. Inspect central lock controller power supply circuit

A. Turn the ignition switch to "LOCK", and disconnect
the negative battery cable.
B. Disconnect the central lock controller wiring
harness connector P29.
C. Measure the resistance between terminal 2 of
central lock controller wiring harness connector P29
and reliable grounding.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Replace the central lock controller.
5 4 3 2 1
Refer to: Central Lock Controller (4.2.10
Body Control System, Removal
12 11 10 9 8 7 6
and Installation).
P29 Make sure the system is normal.
No
M4208007
Inspect and repair the open circuit fault between
terminal 2 of central lock controller wiring harness
connector P29 and grounding point G105.

M201 2014.01
4.2.8-11 Central Door Lock 4.2.8-11

Diagnosis Procedure for Driver Side Door Central Lock Failure

Driver side door

central lock failure

Verify symptom

Yes
Is the fault
confirmed

No

Inspect front left door fastener

lock signal

Yes
Is the fault
confirmed

No

Inspect front left door fastener

unlock signal

End

M201 2014.01
4.2.8-12 Central Door Lock 4.2.8-12

Test Conditions Details/Results/Actions

1. Verify symptom
A. Press the unlock knob on the driver side inside
handle.
B. Verify the failure.
Does only the driver side door central lock fail?
Yes
Go to step 2.
No
Refer to: Symptom Chart (4.2.8 Central
Door Lock, Symptom Diagnosis
and Testing).
2. Inspect front left door fastener lock signal
A. Turn the ignition switch to "LOCK".
B. Disconnect the front left door fastener wiring
harness connector D01, and take out the terminal 6
from it.
C. Connect the front left door fastener wiring harness
connector D01, and perform lock function.
D. Measure the voltage between the removed terminal
1 2 3
6 and reliable grounding.
4 5 6 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
D01 Yes
Go to step 3.
No
M4208005
Inspect and repair the open circuit fault between
terminal 6 of front left door fastener wiring harness
connector D01 and terminal 9 of central lock
controller wiring harness connector P29.

M201 2014.01
4.2.8-13 Central Door Lock 4.2.8-13

Test Conditions Details/Results/Actions

3. Inspect front left door fastener unlock signal
A. Turn the ignition switch to "LOCK".
B. Disconnect the front left door fastener wiring
harness connector D01, and take out the terminal 4
from it.
D01 C. Connect the front left door fastener wiring harness
connector D01, and perform unlock function.
1 2 3 D. Measure the voltage between the removed terminal
4 and reliable grounding.
4 5 6
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Replace the front left door lock latch.
No
M4208004
Inspect and repair the open circuit fault between
terminal 4 of front left door fastener wiring harness
connector D01 and terminal 8 of central lock
controller wiring harness connector P29.

M201 2014.01
4.2.8-14 Central Door Lock 4.2.8-14

Diagnosis Procedure for Passenger Side Door Central Lock

Failure

Passenger side door

central lock failure

Verify symptom

Is the fault Yes

confirmed

No

Inspect front right door fastener

lock signal

Yes
Is the fault
confirmed

No

Inspect front right door fastener

unlock signal

End

M201 2014.01
4.2.8-15 Central Door Lock 4.2.8-15

Test Conditions Details/Results/Actions

1. Verify symptom
A. Press the unlock knob on the driver side inside
handle.
B. Verify the failure.
Does only the passenger side door central lock fail?
Yes
Go to step 2.
No
Refer to: Symptom Chart (4.2.8 Central
Door Lock, Symptom Diagnosis
and Testing).
2. Inspect front right door fastener lock signal
A. Turn the ignition switch to "LOCK".
B. Disconnect the front right door fastener wiring
harness connector D08, and take out the terminal 1
from it.
C. Connect the front right door fastener wiring harness
connector D08, and perform lock function.
D. Measure the voltage between the removed terminal
1 and reliable grounding.

2 1 Standard voltage: 11 ~ 14 V
Is the voltage value normal?

D08 Yes
Go to step 3.
No
M4208008
Inspect and repair the open circuit fault between
terminal 1 of front right door fastener wiring harness
connector D08 and terminal 9 of central lock
controller wiring harness connector P29.

M201 2014.01
4.2.8-16 Central Door Lock 4.2.8-16

Test Conditions Details/Results/Actions

3. Inspect front right door fastener unlock signal
A. Turn the ignition switch to "LOCK".
B. Disconnect the front right door fastener wiring
harness connector D08, and take out the terminal 2
from it.
C. Connect the front right door fastener wiring harness
D08 connector D08, and perform unlock function.
D. Measure the voltage between the removed terminal
2 and reliable grounding.

2 1 Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Replace the front right door lock latch.
No
M4208009
Inspect and repair the open circuit fault between
terminal 2 of front right door fastener wiring harness
connector D08 and terminal 8 of central lock
controller wiring harness connector P29.

M201 2014.01
4.2.8-17 Central Door Lock 4.2.8-17

Diagnosis Procedure for Remote Controller Failure with Central

Lock Normal
Test Conditions Details/Results/Actions
1. Inspect remote controller battery
A. Inspect the voltage of remote controller battery.
Standard voltage: more than 2.9 V
Is the voltage value normal?
Yes
Go to step 2.
No
Replace the remote controller battery.

2. Programme remote controller key again

A. Match the remote controller.
Refer to: Remote Control Key
Programming (4.2.8 Central
Door Lock, Description and
Operation).
Does it return to normal?
Yes
The system is normal.
No
Replace with a new remote controller and program
it.

M201 2014.01
4.2.8-18 Central Door Lock 4.2.8-18

Removal and Installation

Front Door Lock Latch
Refer to: Front Door Lock Latch (5.1.8
Handles, Locks and Latches,
Removal and Installation).

Rear Door Lock Latch

Refer to: Rear Door Lock Latch (5.1.8
Handles, Locks and Latches,
Removal and Installation)

Rear Door Fastener

Removal
1. Remove the rear door interior trim panel.
Refer to: Rear Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation)
2. Remove the rear door water-proof film.
CAUTION: Be careful to prevent damage
to the water-proof film during removal. Do
not touch the adhesive surface to avoid
reduction in adhesion effect during
reassembly.

M5102034

3. Disconnect the rear door fastener wiring

harness connector (1).
4. Remove 2 retaining bolts (2) from the rear
door fastener.
2
Torque: 8 ~ 12 Nm

M4208010

M201 2014.01
4.2.8-19 Central Door Lock 4.2.8-19
5. Disconnect the connection lever of rear door
fastener, and remove the rear door fastener.

M4208011

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.9-1 Power Window 4.2.9-1

Specifications
4.2.9 Power Window

General Specifications
Item Rated Voltage Rated Current
Window motor 12 V (DC) -

Torque Specifications
Item Nm lb-ft Lb-in
Window glass regulator 8 ~ 12 - -

M201 2014.01
4.2.9-2 Power Window 4.2.9-2

Description and Operation

System Overview
Power windows are provided for both the front
doors in the standard configuration, and just
press the glass regulator button when the door
glass up/down is needed. The power window
main switch is on the front left door interior trim
panel. The left button of power window main
switch controls the front left door glass up/down,
and the right button controls the front right door
glass up/down; the switches on the right door
control the right door glass. For the power window
switch, push it to lower the window glass
automatically (glass open). Pull it to raise the
window glass (glass closed).
Auto Down Function
The driver window has "Auto Down" function
which can be activated by pressing the driver
window switch fully and then releasing it. To stop
the window before it reaches the bottom, slightly
pull the switch.
Lock Switch Function
The driver door is equipped with a lock switch
used for the passenger windows. Once it is
pressed, the passenger windows cannot be
raised/lowered. To return to normal operation,
press the lock switch again and then release it.

M201 2014.01
4.2.9-3 Power Window 4.2.9-3

Components Location View

Power Window Switch

2
3

M4209001

Item Description Item Description

Passenger side window
1 Window lock switch 3
regulator switch
Driver side window regulator
2
switch

M201 2014.01
4.2.9-4 Power Window 4.2.9-4
Driver Side Door Component

M4209002

Item Description Item Description

1 Inside handle 4 Door lock motor assembly
2 Front door speaker 5 Rearview mirror
3 Window glass regulator

M201 2014.01
4.2.9-5 Power Window 4.2.9-5

Driver Side Power Window Switch Terminal View

3 2 1

8 7 6 5 4

D02

M4209003

Driver Side Power Window Switch Terminal Definition

Terminal No. Connection Wire Terminal Description

D02-1 2.0 BK GND
D02-2 2.0 RD/WH Passenger side door glass up control
D02-3 2.0 GN/WH Passenger side door glass down control
D02-4 2.0 RD Driver side door glass up power supply
D02-5 - -
D02-6 2.0 RD/YE Front right door control power supply output
D02-7 2.0 WH/BN Power window main switch power supply
D02-8 2.0 GN Driver side door glass down power supply

M201 2014.01
4.2.9-6 Power Window 4.2.9-6

Passenger Side Power Window Switch Terminal View

3 2 1

8 7 6 5 4

D07

M4209004

Passenger Side Power Window Switch Terminal Definition

Terminal No. Connection Wire Terminal Description

D07-1 2.0 RD Passenger side door glass up power supply
Passenger side glass down signal controlled by driver
D07-2 2.0 GN/WH
side
D07-3 2.0 GN Passenger side door glass down power supply
D07-4 2.0 BK GND
D07-5 - -
D07-6 2.0 RD/WH Passenger side glass up signal controlled by driver side
D07-7 2.0 RD/YE Front right door control power supply
D07-8 2.0 BU/YE Front right door power window switch power supply

M201 2014.01
4.2.9-7 Power Window 4.2.9-7

Symptom Diagnosis and Testing

General Equipment

Digital multimeter

Inspection and Verification

1. Verify the customer concern.
2. Visually check for obvious mechanical or
electrical damage and deformation due to
collision.
Visual Inspection Chart

Mechanical Electrical
• Fuse
• Window seal
• Window regulator
• Window frame motor
• Door • Circuit
• Door interior trim panel • Window regulator
switch

3. Inspect the system circuit which is accessible

or visible.
4. If an obvious cause for an observed or
reported concern has been found, solve the
fault before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.

M201 2014.01
4.2.9-8 Power Window 4.2.9-8

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and repair it in order of the
following table.

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
• Circuit fault for All Power Windows
Failing to Work (4.2.9
All power windows fail to work • Window switch
Power Window,
• Fuse Symptom Diagnosis
and Testing).
Refer to: Diagnosis Procedure
for Driver Side Power
Window Failing to
Work (4.2.9 Power
Window, Symptom
Diagnosis and
Only one power window fails • Circuit fault Testing).
to work • Window switch Refer to: Diagnosis Procedure
for Passenger Side
Power Window Failing
to Work (4.2.9 Power
Window, Symptom
Diagnosis and
Testing).
Refer to: Diagnosis Procedure
for Inching Down
Function Fault (4.2.9
Inching down function fault • Power window main switch fault
Power Window,
Symptom Diagnosis
and Testing).
• Inspect and repair the circuit.
• Circuit fault • Replace the window glass regulator
motor.
• Window glass regulator motor
Power window unable to • Inspect and repair or replace the glass
• Glass guide rail
reach top guide rail.
• Glass run
• Inspect and repair or replace the glass
• Door run.
• Inspect and repair the door.

M201 2014.01
4.2.9-9 Power Window 4.2.9-9

Symptom Possible Causes Solutions

• Replace the window glass regulator
motor.
• Window glass regulator motor
• Inspect and repair or replace the glass
Power window displacement • Glass guide rail
guide rail.
in regulating • Glass run
• Inspect and repair or replace the glass
• Door run.
• Inspect and repair the door.
• Inspect and repair the circuit.
• Inspect and repair the charging system.
• Circuit fault
• Replace the battery.
• Low battery voltage
• Inspect and repair or replace the glass
Power window regulating • Window glass regulator motor guide rail.
slowly • Glass guide rail • Inspect and repair or replace the glass
• Glass run run.

• Door • Inspect and repair the door.

• Replace the window glass regulator
motor.

M201 2014.01
4.2.9-10 Power Window 4.2.9-10

Diagnosis Procedure for All Power Windows Failing to Work

All power windows

failing to work

General inspection
(Inspect wiring harness connectors
of window switch and window
glass regulator motor)

Is the fault Yes

confirmed

No

Inspect battery voltage

Is the fault Yes

confirmed

No

Verify ignition switch status

Is the fault Yes

confirmed

No Inspect power window main

switch power supply
Inspect power window fuse

Is the fault Yes

confirmed
Is the fault
confirmed
No
Inspect power window main
switch grounding circuit
No
Yes

End

M201 2014.01
4.2.9-11 Power Window 4.2.9-11

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors of window
switch and window glass regulator motor for
damage, poor contact, aging or looseness.
Are they normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect battery voltage

A. Turn the ignition switch to "ON", and use the
multimeter to inspect the battery voltage.
Standard voltage: 11 ~ 14 V
Is the voltage value normal?
Yes
Go to step 3.
No
Inspect and repair the charging system.
Refer to: Battery Undercharge, Battery
Overcharge (3.1.10 Charging
System, Symptom Diagnosis
and Testing).
3. Verify ignition switch status
A. Turn the ignition switch to "ACC".
Is the ignition switch status normal?
Yes
Go to step 4.
No
Inspect and repair the ignition switch.

4. Inspect power window fuse

A. Inspect the power window fuse IF27 and IF28.
Fuse IF27 rated capacity: 30 A
Fuse IF28 rated capacity: 20 A
Are the fuses normal?
Yes
Go to step 5.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

M201 2014.01
4.2.9-12 Power Window 4.2.9-12

Test Conditions Details/Results/Actions

5. Inspect power window main switch power supply
A. Turn the ignition switch to "ON".
B. Disconnect the power window main switch wiring
D02 harness connector D02.
C. Measure the voltage between terminal 7 of power
window main switch wiring harness connector D02
3 2 1 and reliable grounding.
Standard voltage: 11 ~ 14 V
8 7 6 5 4
Is the voltage value normal?
Yes
Go to step 6.
M4209006
No
Inspect and repair the open circuit fault between
terminal 7 of power window main switch wiring
harness connector D02 and terminal 54 of
instrument panel fuse box fuse IF27.

6. Inspect power window main switch grounding circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the power window main switch wiring
D02 harness connector D02.
C. Measure the resistance between terminal 1 of
power window main switch wiring harness
3 2 1 connector D02 and reliable grounding.
Standard resistance: less than 5 Ω
8 7 6 5 4
Is the resistance value normal?
Yes
Replace the power window main switch.
M4209007
No
Inspect and repair the open circuit fault between
terminal 1 of power window main switch wiring
harness connector D02 and grounding G103.

M201 2014.01
4.2.9-13 Power Window 4.2.9-13

Diagnosis Procedure for Driver Side Power Window Failing to

Work

Driver side power window

falling to work

General inspection
(Inspect wiring harness connectors
of window switch and window
glass regulator motor)

Is the fault Yes

confirmed

No

Inspect left power window fuse

Is the fault Yes

confirmed

No
Inspect driver side window glass
regulator

Is the fault Yes

confirmed

No
Inspect circuit between power
window main switch and driver
side window glass regulator

Yes

End

M201 2014.01
4.2.9-14 Power Window 4.2.9-14

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors of window
switch and window glass regulator motor for
damage, poor contact, aging or looseness.
Are they normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect left power window fuse

A. Inspect the left power window fuse IF27.
Fuse rated capacity: 30 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect driver side window glass regulator

A. Turn the ignition switch to "LOCK".
B. Disconnect the driver side window glass regulator
wiring harness connector D03.
C. Apply power supply voltage of 12 V to the driver
side window glass regulator, and inspect the
window glass regulator operation.
Is the operation normal?
Yes
Go to step 4.
No
Replace the driver side window glass regulator.

M201 2014.01
4.2.9-15 Power Window 4.2.9-15

Test Conditions Details/Results/Actions

4. Inspect circuit between power window main switch and driver side window glass regulator
A. Turn the ignition switch to "LOCK".
B. Disconnect the power window main switch wiring
harness connector D02 and driver side window
glass regulator wiring harness connector D03.
C. Measure the resistance between terminals 4, 8 of
3 2 1 power window main switch wiring harness
connector D02 and terminals 2, 1 of driver side
8 7 6 5 4 window glass regulator wiring harness connector
D03.
D03 Yes
D02
Replace the power window main switch.

2 1 Refer to: Power Window Switch (4.2.9

Power Window, Removal and
Installation).
No
M4209008
Inspect and repair the open circuit fault between
terminals 4, 8 of power window main switch wiring
harness connector D02 and terminals 2, 1 of driver
side window glass regulator wiring harness
connector D03.

M201 2014.01
4.2.9-16 Power Window 4.2.9-16

Diagnosis Procedure for Passenger Side Power Window Failing to

Work

Passenger side power

window failing to work

General inspection
(Inspect wiring harness connectors
of window switch and window
glass regulator motor)

Is the fault Yes

confirmed

No

Inspect right power window fuse

Is the fault Yes

confirmed

No
Inspect passenger side power
window operation status

Inspect passenger side power Measure circuit between power

window switch up/down signal window main switch and passenger
circuit side power window switch

Inspect passenger side power

window switch power supply

Is the fault Yes

Yes confirmed
Is the fault
confirmed
No
No
Inspect passenger side power
Inspect passenger side power window switch
window switch grounding circuit
Inspect passenger side window glass
regulator
Inspect circuit between passenger
side power window switch and
passenger side window glass
regulator
End

M201 2014.01
4.2.9-17 Power Window 4.2.9-17

Test Conditions Details/Results/Actions

1. General inspection
A. Inspect the wiring harness connectors of window
switch and window glass regulator motor for
damage, poor contact, aging or looseness.
Are they normal?
Yes
Go to step 2.
No
Repair the faulty area.

2. Inspect right power window fuse

A. Inspect the right power window fuse IF28.
Fuse rated capacity: 20 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the fuse circuit, and replace the
fuse with rated capacity.

3. Inspect passenger side power window operation status

A. Turn the ignition switch to "ON".
B. Operate the power window main switch to control
the passenger side power window up/down.
C. Operate the passenger side power window switch
to control the passenger side power window up/
down.
D. Go to corresponding step according to the
passenger side power window up/down status.
The passenger side power window up/down can be
controlled only by the passenger side power
window switch.
Go to step 4.
The passenger side power window up/down can be
controlled only by the power window main switch.
Go to step 5.
The passenger side power window up/down can
not be controlled by both the power window main
switch and passenger side power window switch.
Go to step 7.

M201 2014.01
4.2.9-18 Power Window 4.2.9-18

Test Conditions Details/Results/Actions

4. Inspect passenger side power window switch up/down signal circuit
A. Turn the ignition switch to "LOCK".
B. Disconnect the power window switch wiring
D07 harness connector D02.
C. Disconnect the passenger side power window
switch wiring harness connector D07.
3 2 1 D. Measure the resistance between terminals 2, 3 of
power window main switch wiring harness
8 7 6 5 4 connector D02 and terminals 6, 2 of passenger side
power window switch wiring harness connector
D07.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 6.
No
Inspect and repair the open circuit fault between
terminals 2, 3 of power window main switch wiring
3 2 1 harness connector D02 and terminals 6, 2 of
passenger side power window switch wiring
8 7 6 5 4 harness connector D07.

D02

M4209009

M201 2014.01
4.2.9-19 Power Window 4.2.9-19

Test Conditions Details/Results/Actions

5. Measure circuit between power window main switch and passenger side power window switch
A. Turn the ignition switch to "LOCK".
B. Disconnect the power window main switch wiring
harness connector D02.
D07 D02
C. Disconnect the passenger side power window
switch wiring harness connector D07.
D. Measure the resistance between terminal 6 of
3 2 1 3 2 1 power window main switch wiring harness
connector D02 and terminal 7 of passenger side
8 7 6 5 4 8 7 6 5 4 power window switch wiring harness connector
D07.
Standard resistance: less than 5 Ω
Is the resistance value normal?
Yes
Go to step 6.
No
M4209010 Inspect and repair the open circuit fault between
terminal 6 of power window main switch wiring
harness connector D02 and terminal 7 of
passenger side power window switch wiring
harness connector D07.

6. Inspect passenger side power window switch

A. Replace the passenger side power window switch
with a good one.
Is the operation normal?
Yes
Replace the passenger side power window switch.
No
Replace the power window main switch.

M201 2014.01
4.2.9-20 Power Window 4.2.9-20

Test Conditions Details/Results/Actions

7. Inspect passenger side power window switch power supply
A. Turn the ignition switch to "ON".
B. Disconnect the passenger side power window
D07 switch wiring harness connector D07.
C. Measure the voltage between terminal 8 of
passenger side power window switch wiring
3 2 1 harness connector D07 and reliable grounding.
Standard voltage: 11 ~ 14 V
8 7 6 5 4
Is the voltage value normal?
Yes
Go to step 8.
No
Inspect and repair the open circuit fault between
terminal 8 of passenger side power window switch
wiring harness connector D07 and terminal 56 of
instrument panel fuse box fuse IF28.
M4209011

8. Inspect passenger side power window switch grounding circuit

A. Turn the ignition switch to "LOCK".
B. Disconnect the passenger side power window
D07 switch wiring harness connector D07.
C. Measure the resistance between terminal 4 of
passenger side power window switch wiring
3 2 1 harness connector D07 and reliable grounding.
Standard resistance: less than 5 Ω
8 7 6 5 4
Is the resistance value normal?
Yes
Go to step 9.
No
Inspect and repair the open circuit fault between
terminal 4 of passenger side power window switch
wiring harness connector D07 and grounding G105.

M4209012

M201 2014.01
4.2.9-21 Power Window 4.2.9-21

Test Conditions Details/Results/Actions

9. Inspect passenger side window glass regulator
A. Turn the ignition switch to "LOCK".
B. Disconnect the passenger side window glass
regulator wiring harness connector D06.
C. Apply power supply voltage of 12 V to the
passenger side window glass regulator, and inspect
the regulator operation.
Is the operation normal?
Yes
Go to step 10.
No
Replace the passenger side window glass
regulator.
Refer to: Glass Regulator (4.2.9 Power
Window, Removal and
Installation).
10.Inspect circuit between passenger side power window switch and passenger side window glass
regulator
A. Turn the ignition switch to "LOCK".
B. Disconnect the passenger side power window
switch wiring harness connector D07 and
D07
passenger side window glass regulator wiring
harness connector D06.
C. Measure the resistance between terminals 1, 3 of
3 2 1 passenger side power window switch wiring
harness connector D07 and terminals 2, 1 of
8 7 6 5 4 passenger side window glass regulator wiring
D06 harness connector D06.
Yes
Replace the passenger side power window switch.
2 1
Refer to: Power Window Switch (4.2.9
Power Window, Removal and
Installation).
M4209013 No
Inspect and repair the open circuit fault between
terminals 1, 3 of passenger side power window
switch wiring harness connector D07 and terminals
2, 1 of passenger side window glass regulator
wiring harness connector D06.

M201 2014.01
4.2.9-22 Power Window 4.2.9-22

Diagnosis Procedure for Inching Down Function Fault

Test Conditions Details/Results/Actions
1. Replace power window main switch
A. Turn the ignition switch to "LOCK".
B. Replace the window switch.
Refer to: Power Window Switch (4.2.9
Power Window, Removal and
Installation).
The system is normal.

M201 2014.01
4.2.9-23 Power Window 4.2.9-23

Removal and Installation

Power Window Switch
Removal
1. Disconnect the negative battery cable.
Refer to: Battery Inspection (3.1.10
Charging System, General
Inspection).
2. Remove the retaining screw from the inside
handle trim cover.

M5102007

3. Using a screwdriver with its tip wrapped with

protective tape, remove the inside handle trim
cover.

M5102008

4. Disconnect the power window switch wiring

harness connector.

M5102093

M201 2014.01
4.2.9-24 Power Window 4.2.9-24
5. Remove 3 retaining screws from the power
window switch and remove the power window
switch.

×3

M4209014

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.9-25 Power Window 4.2.9-25

Front Door Glass Regulator

Removal
1. Remove the front door glass.
Refer to: Front Door Glass (5.1.2 Door,
Removal and Installation).
2. Disconnect the front door glass regulator
wiring harness connector.

M5102025

3. Remove 6 retaining bolts from the front door

glass regulator.
Torque: 8 Nm
×6

M5102026

4. Remove the front door glass regulator.

M5102027

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.9-26 Power Window 4.2.9-26

Rear Door Glass Regulator

Removal
1. Remove the rear door glass.
Refer to: Rear Door Glass (5.1.2 Door,
Removal and Installation).
2. Remove 6 retaining bolts from the rear door
glass regulator and remove the rear door
glass regulator.
Torque: 8 ~ 12 Nm

×6
M5102029

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
4.2.10-1 Body Control System 4.2.10-1

Description and Operation

4.2.10 Body Control System

Overview
The body control system consists of central lock
controller, body remote key PCB, left turn lamp,
right turn lamp, four-door lock motor and other
components.
Main functions of central lock controller include:
• Turn lamp unlock signal
• Code learning mode
• Door locking function
• Door unlocking function
When the remote controller is locked, the double
flash indicator blinks once. When the remote
controller is unlocked, the double flash indicator
blinks twice.

M201 2014.01
4.2.10-2 Body Control System 4.2.10-2

Components Location View

1
2

1 1 USE
WITH

2 2
3 3

M4210001

Item Description Item Description

1 Steering wheel 3 Central lock controller
2 Dashboard

M201 2014.01
4.2.10-3 Body Control System 4.2.10-3

Terminal View

P29

5 4 3 2 1

12 11 10 9 8 7 6

M4210002

Central Lock Controller Terminal Definition

Connection
Terminal No. Terminal Description Input/Output
Wire
Central lock controller power
P29-1 1.25 RD/WH -
supply (B+)
P29-2 1.25 BK Central lock controller ground -
P29-3 - - -
P29-4 - - -
Central lock controller power
P29-5 1.25 WH/BK -
supply (ACC)
P29-6 0.5 GN/YE Right turn lamp Output
P29-7 0.5 GN/RD Left turn lamp Output
P29-8 0.85 WH Door unlocking power supply Output
P29-9 0.85 BU Door locking power supply Output
P29-10 0.5 BK/RD Door signal switch Input
P29-11 0.5 YE Locking switch signal A Input
P29-12 0.5 WH/YE Locking switch signal B Input

M201 2014.01
4.2.10-4 Body Control System 4.2.10-4

Removal and Installation

Central Lock Controller
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the instrument panel assembly.
Refer to: Instrument Panel (5.1.6
Instrument Panel and Console,
Removal and Installation).

3. Disconnect the central lock controller wiring

harness connector.

M4210003

4. Remove the retaining bolt from the central

lock controller, and remove the central lock
controller.

M4210004

M201 2014.01
4.2.10-5 Body Control System 4.2.10-5
Installation
1. Installation is in the reverse order of removal.
2. For models with remote controller, match a
key after replacing the remote controller with
a new one.
Refer to: Remote Control Key
Programming (4.2.8 Central Door
Lock, Description and
Operation).

M201 2014.01
4.2.11-1 On-board Network 4.2.11-1
4.2.11 On-board Network

Description and Operation Terminal Connection

Terminal Description
No. Wire
General Description
P35-1 - -
The vehicle only adopts a K-LINE communication
P35-2 - -
method currently.
P35-3 - -
Description of K-LINE Bus P35-4 - -
The K line is used for the diagnostic P35-5 - -
communication between the external testing tools
P35-6 - -
and the on-board ECM. The transmission rate is
10.47 kbps. The voltage switches between 0 V P35-7 - -
and 12 V when transmitting signals: 12 V, logic P35-8 0.5 PK/BU DLC Power supply
"1"; 0 V, logic "0".
P35-9 - -
Description of DLC P35-10 - -
Data Link Connector (DLC) is the result of the P35-11 - -
discussion and regulation among the automobile P35-12 0.5 BK GND
manufacturers in the world. This wiring harness
P35-13 0.5 BK GND
connector is needed when using diagnostic tool to
communicate with the vehicle and to program the P35-14 - -
communication system used on the vehicle. P35-15 0.5 LG/WH K-line
This wiring harness connector should meet the P35-16 - -
following requirements:
• It should be the standard 16-pin wiring
harness connector and can be connected
with all diagnostic tools.
• It always supplies battery power for
diagnostic tool through terminal 8.
• It always supplies grounding for
diagnostic tool through terminals 12 and
13.
• The terminal 15 is used to communicate
with the vehicle system.

DLC View

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

P35

M4211001

M201 2014.01
4.2.11-2 On-board Network 4.2.11-2

Symptom Diagnosis and Testing

General Equipment

Digital multimeter
Diagnostic tool

Inspection and Verification

1. Verify the customer concern.
2. Visually check if there is obvious mechanical
fault.
3. Inspect the system circuit which is accessible
or visible.
4. If an obvious cause for an observed or
reported concern has been found, solve the
fault before proceeding to the next step.
5. If the cause is not visually evident, verify the
symptom by referring to the Symptom Chart.
Visual Inspection Chart

Electrical

• Battery
• Fuse
• Wiring harness connector of electrical
equipment loose or corroded
• Wiring harness

M201 2014.01
4.2.11-3 On-board Network 4.2.11-3

Symptom Chart
If the fault occurs and cannot confirm the cause by basic inspection, diagnose and eliminate it in order of
the following table.

Symptom Possible Causes Solutions

Refer to: Diagnosis Procedure
for Disabled
• Diagnostic tool Communication
Diagnosis tool cannot between Diagnostic
• Circuit
communicate with ECM Tool and ECM (4.2.8
• ECM On-board Network
System, Diagnosis
and Testing).

M201 2014.01
4.2.11-4 On-board Network 4.2.11-4

Diagnosis Procedure for Disabled Communication between

Diagnostic Tool and ECM

Disabled communication between

diagnostic tool and ECM

Verify fault symptom

Is the fault Yes

confirmed

No

Inspect DLC fuse

Is the fault Yes

confirmed

No

Inspect DLC power supply circuit

Ẕᶹ䲼ࠂ⬉ᴎԢ䗳ḷ䕧ܹ⬉य़
Inspect DLC grounding circuit
Ẕᶹ䲼ࠂ⬉ᴎ催䗳ḷ䕧ܹ⬉य़

Is the fault Yes

confirmed
Inspect short circuit to grounding
No in diagnosis circuit
Inspect short circuit to power
supply in diagnosis circuit
Inspect circuit between DLC and Inspect ECM power supply circuit
ECM

Is the fault Yes

Is the fault confirmed
confirmed
No

Replace ECM

Yes No

End

M201 2014.01
4.2.11-5 On-board Network 4.2.11-5

Test Conditions Details/Results/Actions

1. Verify fault symptom
A. Use a normal vehicle.
B. Try to communicate with ECM.
Is the communication with ECM normal?
Yes
Go to step 2.
No
Replace with a new diagnostic tool.

2. Inspect DLC fuse

A. Inspect the DLC fuse IF11.
Fuse rated capacity: 10 A
Is the fuse normal?
Yes
Go to step 3.
No
Inspect and repair the circuit, and replace the fuse
with rated capacity.

3. Inspect DLC power supply circuit

A. Measure the voltage between terminal 8 of DLC
wiring harness connector P35 and reliable
grounding with a multimeter.
Standard voltage: 11 ~ 14 V
Is the voltage normal?
Yes
Go to step 4.
No
Inspect and repair the open circuit fault between
8 7 6 5 4 3 2 1 terminal 8 of DLC wiring harness connector P35
and terminal 22 of instrument panel fuse box fuse
16 15 14 13 12 11 10 9
IF11.

P35

M4211002

M201 2014.01
4.2.11-6 On-board Network 4.2.11-6

Test Conditions Details/Results/Actions

4. Inspect DLC grounding circuit
A. Measure the resistance between terminal 12 and
13 of DLC wiring harness connector P35 and
P35 reliable grounding with a multimeter.
Standard resistance value: less than 5 Ω

8 7 6 5 4 3 2 1 Is the resistance value normal?

Yes
16 15 14 13 12 11 10 9
Go to step 5.
No
Inspect and repair the open circuit fault between
terminal 12 and 13 of DLC wiring harness
connector P35 and grounding G106.

M4211003

5. Inspect circuit between DLC and ECM

A. Turn the ignition switch to "LOCK" and disconnect
P35 the negative battery cable.
B. Disconnect the ECM wiring harness connector E18.
8 7 6 5 4 3 2 1 C. Measure the resistance between terminal 15 of
ECM wiring harness connector E18 and terminal 15
16 15 14 13 12 11 10 9 of DLC wiring harness connector P35.
Standard resistance value: less than 5 Ω
Is the voltage normal?
Yes
Go to step 6.
No
Inspect and repair the open circuit fault between
terminal 15 of ECM wiring harness connector E18
and terminal 35 of DLC wiring harness connector
P35.
1 2 9 15 22

3 4 23 36

5 6 37 50

7 8 51 64

E18
M4211004

M201 2014.01
4.2.11-7 On-board Network 4.2.11-7

Test Conditions Details/Results/Actions

6. Inspect short circuit to grounding in diagnosis circuit
A. Turn the ignition switch to "LOCK" and disconnect
the negative battery cable.
P35
B. Disconnect the ECM wiring harness connector E18.
C. Measure the resistance between terminal 15 of
8 7 6 5 4 3 2 1 DLC wiring harness connector P35 and reliable
16 15 14 13 12 11 10 9 grounding.
Standard resistance: 10 MΩ or more
Is the resistance value normal?
Yes
Go to step 7.
No
Inspect and repair the short circuit to grounding
between terminal 15 of DLC wiring harness
connector P35 and terminal 15 of ECM wiring
harness connector E18.
M4211005

7. Inspect short circuit to power supply in diagnosis circuit

A. Turn the ignition switch to "LOCK" and disconnect
the negative battery cable.
P35
B. Disconnect the ECM wiring harness connector E18.
C. Turn the ignition switch to "ON".
8 7 6 5 4 3 2 1
D. Measure the voltage between terminal 15 of DLC
16 15 14 13 12 11 10 9 wiring harness connector P35 and reliable
grounding.
Standard voltage: 0 V
Is the voltage normal?
Yes
Go to step 8.
No
Inspect and repair the short circuit to power supply
between terminal 15 of DLC wiring harness
connector P35 and terminal 15 of ECM wiring
M4211006
harness connector E18.

M201 2014.01
4.2.11-8 On-board Network 4.2.11-8

Test Conditions Details/Results/Actions

8. Inspect ECM power supply circuit
A. Inspect ECM power supply circuit.
Refer to: DTC Diagnosis Procedure Index
(3.1.12 Electronic Control
System - M7, DTC Diagnosis and
Testing).
Is the power supply circuit normal?
Yes
Go to step 9.
No
Repair the fault part.

9. Replace ECM

M201 2014.01
 GROUP 5
Body
SECTION PAGE

5.1 Body and Accessories

5.1.1 Front/Rear Windshield ...................................................................................................... 5.1.1-1
5.1.2 Door .................................................................................................................................. 5.1.2-1
5.1.3 Seat................................................................................................................................... 5.1.3-1
5.1.4 Seat Belt ........................................................................................................................... 5.1.4-1
5.1.5 Rearview Mirror................................................................................................................. 5.1.5-1
5.1.6 Instrument Panel and Console.......................................................................................... 5.1.6-1
5.1.7 Bumper ............................................................................................................................. 5.1.6-1
5.1.8 Handles, Locks and Latches............................................................................................. 5.1.8-1
5.1.9 Interior Trim Panel and Ornamentation............................................................................. 5.1.9-1
5.1.10 Exterior Trim.................................................................................................................. 5.1.10-1

5.2 Body Repairs

5.2.1 Body Repairs .................................................................................................................... 5.2.1-1

M201 2014.01
 Body and Accessories

5.1 Body and Accessories

2014 M201
Table of Contents Pages

5.1.1 Front/Rear Windshield

Specifications ................................................................................................................................... 5.1.1-1
General Specifications.............................................................................................................. 5.1.1-1
Description and Operation ............................................................................................................... 5.1.1-2
System Overview...................................................................................................................... 5.1.1-2
Removal and Installation.................................................................................................................. 5.1.1-3
Front Windshield....................................................................................................................... 5.1.1-3
Back Door Glass....................................................................................................................... 5.1.1-8
Rear Quarter Glass ................................................................................................................ 5.1.1-12

5.1.2 Door
Specifications ................................................................................................................................... 5.1.2-1
Torque Specifications................................................................................................................ 5.1.2-1
Description and Operation ............................................................................................................... 5.1.2-2
Components Exploded View..................................................................................................... 5.1.2-2
Removal and Installation.................................................................................................................. 5.1.2-6
Front Door Interior Trim Panel (Models with Manual Regulator) .............................................. 5.1.2-6
Front Door Interior Trim Panel (Models with Power Regulator)................................................ 5.1.2-9
Rear Door Interior Trim Panel................................................................................................. 5.1.2-12
Back Door Interior Trim Panel ................................................................................................ 5.1.2-14
Front Door Glass .................................................................................................................... 5.1.2-15
Rear Door Glass..................................................................................................................... 5.1.2-17
Front Door Rear Slot .............................................................................................................. 5.1.2-19
Rear Door Front Slot .............................................................................................................. 5.1.2-20
Rear Door Rear Slot ............................................................................................................... 5.1.2-21
Front Door Glass Run............................................................................................................. 5.1.2-22
Rear Door Glass Run ............................................................................................................. 5.1.2-23

M201 2014.01
 Body and Accessories
5.1.3 Seat
Specifications ...................................................................................................................................5.1.3-1
Torque Specifications................................................................................................................5.1.3-1
Description and Operation................................................................................................................5.1.3-2
System Overview ......................................................................................................................5.1.3-2
Components Location View ......................................................................................................5.1.3-2
Removal and Installation ..................................................................................................................5.1.3-4
Front Seat .................................................................................................................................5.1.3-4
Second Seat .............................................................................................................................5.1.3-6
Third Seat .................................................................................................................................5.1.3-8

5.1.4 Seat Belt

Specifications ...................................................................................................................................5.1.4-1
Torque Specifications................................................................................................................5.1.4-1
Description and Operation................................................................................................................5.1.4-2
System Overview ......................................................................................................................5.1.4-2
Removal and Installation ..................................................................................................................5.1.4-3
Front Seat Belt..........................................................................................................................5.1.4-3
Second Seat Belt ......................................................................................................................5.1.4-7
Second Seat Belt (Two-point Type) ........................................................................................5.1.4-10
Third Seat Belt ........................................................................................................................5.1.4-12
Third Seat Belt (Two-point Type) ............................................................................................5.1.4-12

5.1.5 Rearview Mirror

Specifications ...................................................................................................................................5.1.5-1
Torque Specifications................................................................................................................5.1.5-1
Description and Operation................................................................................................................5.1.5-2
System Overview ......................................................................................................................5.1.5-2
Components Location View ......................................................................................................5.1.5-2
Removal and Installation ..................................................................................................................5.1.5-3
Interior Mirror ............................................................................................................................5.1.5-3
Exterior Mirror ...........................................................................................................................5.1.5-4

5.1.6 Instrument Panel and Console

Specifications ...................................................................................................................................5.1.6-1
Torque Specifications................................................................................................................5.1.6-1
Removal and Installation ..................................................................................................................5.1.6-2
Instrument Panel.......................................................................................................................5.1.6-2

M201 2014.01
 Body and Accessories
Console .................................................................................................................................... 5.1.6-9

5.1.7 Bumper
Specifications ................................................................................................................................... 5.1.7-1
Torque Specifications................................................................................................................ 5.1.7-1
Removal and Installation.................................................................................................................. 5.1.7-2
Front Bumper............................................................................................................................ 5.1.7-2
Rear Bumper ............................................................................................................................ 5.1.7-5

5.1.8 Handles, Locks and Latches

Specifications ................................................................................................................................... 5.1.8-1
Torque Specifications................................................................................................................ 5.1.8-1
Description and Operation ............................................................................................................... 5.1.8-2
System Overview...................................................................................................................... 5.1.8-2
Removal and Installation.................................................................................................................. 5.1.8-3
Front Hood Lock ....................................................................................................................... 5.1.8-3
Front Hood Lock Release Grip ................................................................................................. 5.1.8-4
Steering Lock Assembly ........................................................................................................... 5.1.8-5
Front Door Lock Core ............................................................................................................... 5.1.8-6
Back Door Lock Core ............................................................................................................... 5.1.8-8
Front Door Outside Handle....................................................................................................... 5.1.8-9
Rear Door Outside Handle ..................................................................................................... 5.1.8-11
Back Door Outside Handle ..................................................................................................... 5.1.8-13
Front Door Inside Handle ....................................................................................................... 5.1.8-15
Rear Door Lock Link Mechanism ........................................................................................... 5.1.8-16
Front Door Lock Latch ............................................................................................................ 5.1.8-17
Rear Door Lock Latch............................................................................................................. 5.1.8-19
Back Door Lock Latch ............................................................................................................ 5.1.8-21

5.1.9 Interior Trim Panel and Ornamentation

Removal and Installation.................................................................................................................. 5.1.9-1
A Pillar Trim Panel .................................................................................................................... 5.1.9-1
B Pillar Interior Trim Panel........................................................................................................ 5.1.9-3
Rear Quarter Interior Trim Panel .............................................................................................. 5.1.9-6
Front Doorsill Ornamentation ................................................................................................... 5.1.9-8
Rear Doorsill Ornamentation .................................................................................................... 5.1.9-9
Back Doorsill Ornamentation.................................................................................................. 5.1.9-10
Roof Panel Lining ................................................................................................................... 5.1.9-11

M201 2014.01
 Body and Accessories
5.1.10 Exterior Trim
Removal and Installation ................................................................................................................5.1.10-1
Front Fender Lining Plate .......................................................................................................5.1.10-1
Front Mud Guard ....................................................................................................................5.1.10-2
Rear Mud Guard .....................................................................................................................5.1.10-3
Front Wind Guiding Cover ......................................................................................................5.1.10-4
Rear Wind Guiding Cover .......................................................................................................5.1.10-5

M201 2014.01
5.1.1-1 Front/Rear Windshield 5.1.1-1

Specifications
5.1.1 Front/Rear Windshield

General Specifications
Item Specifications
1K adhesive WSKM-2G309-B
2K adhesive ESK-M2G369-A1
2K hardener ESK-M2G369-A2

M201 2014.01
5.1.1-2 Front/Rear Windshield 5.1.1-2

Description and Operation

System Overview
The front windshield is fixed to the body by
adhesive, which forms a driving space together
with the body, door and other windows, and also
offers a good view for the driver. The adhesive
can bond the front/rear windshield to the car
window frame, in the meantime, it can also form a
tight waterproof surface on the window frame.
Remove the adhesive on the window frame and
apply glue for fixing again when replacing the
front/rear windshield.

M201 2014.01
5.1.1-3 Front/Rear Windshield 5.1.1-3

Removal and Installation

Front Windshield
Special Tool

Windshield Glue-
Remover
CA501-001

CA501-001

General Equipment

Heat gun
Glass glue cutter
Glue gun

Removal
1. Remove the A pillar trim panels on both
sides.
Refer to: A Pillar Trim Panel (5.1.9 Interior
Trim Panel and Ornamentation,
Removal and Installation).
2. Remove the front cover ornamentation and
wiper arms.
Refer to: Wiper Motor and Drive Arm (4.2.7
Wiper and Washer, Removal and
Installation).

3. Remove the interior rearview mirror.

Refer to: Interior Rearview Mirror (5.1.5
Rearview Mirror, Removal and
Installation).
4. Use the special tool to remove the front
windshield.
Special tool: CA501-001
WARNING: Please wear gloves and
goggles when using the special tool to
protect against the fragments generated in
cutting. Wear earplugs when cutting.
Failure to follow the instructions may
cause personal injury.
M5101001

M201 2014.01
5.1.1-4 Front/Rear Windshield 5.1.1-4

5. Use the glass sucker to remove the front

windshield with the help of other technicians.
Special tool: CA501-001

CA501-001

M5101002

Installation
1. Remove the remaining adhesive in the slot
flange of front windshield.

M5101003

2. Use the scraper to remove the adhesive on

the glass and clean the glass.
WARNING: Please avoid touching the
cleaned surface, otherwise it will affect the
bonding effect.

M5101004

3. Inspect the damaged metal fragments, iron

rust, or any other irrelevant materials in the
welding seam seal area, which tend to cause
damage to the glass.

M201 2014.01
5.1.1-5 Front/Rear Windshield 5.1.1-5
4. Control the temperature of heat gun around
25°C, remove the moisture in the slot flange
of front windshield and glass glue.
General tool: heat gun
CAUTION: Remove all moisture in
adhesive surface to ensure the bonding
effect.

M5101005

5. Apply PU adhesive for about 8 ~ 10 mm in

width along adhesive line against the edge of
windshield frames.
CAUTION: If the ambient temperature is
below 10°C, heat the PU adhesive for
about 15 mins on the stove or use heat
gun to heat it to about 25°C.

CAUTION: Reapply adhesive for 20 mm

where has no adhesive tape in order to
protect against water leakage.

CAUTION: In order to reduce working M5101006

time, the first 100 mm of PU adhesive can
be abandoned.

6. Install the front windshield weatherstrip.

M5101010

M201 2014.01
5.1.1-6 Front/Rear Windshield 5.1.1-6

7. Use the glass sucker to install the front

windshield with the help of other technicians.
Special tool: CA501-001
WARNING: Please keep the door open
before installing the glass in case it may
affect bonding effect because the
CA501-001
pressure in the vehicle may increase if the
door is closed.

CAUTION: Press every part of the glass

M5101002
evenly, so that the glass can bond firmly
with adhesive.

8. Use scraper to remove the excessive or

overflowing adhesive.

M5101007

9. Press the glass tightly until adhesive

hardened.
CAUTION: If the normal temperature is
below 10°C, heat the surface (25°C) in a
distance of about 50 mm for 15 mins
(inside or outside of the vehicle) by using
heat gun.
50 mm

M5101008

M201 2014.01
5.1.1-7 Front/Rear Windshield 5.1.1-7

10. Install the interior rearview mirror.

Refer to: Interior Rearview Mirror (5.1.5
Rearview Mirror, Removal and
Installation).

11. Install the front cover ornamentation and

wiper arms.
Refer to: Wiper Motor and Drive Arm (4.2.7
Wiper and Washer, Removal and
Installation).

12. Install the A pillar trim panels on both sides.

Refer to: A Pillar Trim Panel (5.1.9 Interior
Trim Panel and Ornamentation,
Removal and Installation).

M201 2014.01
5.1.1-8 Front/Rear Windshield 5.1.1-8

Back Door Glass

Special Tool

Windshield Glue-
Remover
CA501-001

CA501-001

General Equipment

Heat gun
Glass glue cutter
Glue gun

Removal
1. Remove the high mounted stop lamp.
Refer to: High Mounted Stop Lamp (4.2.6
Lighting System, Removal and
Installation).
2. Use the special tool to remove the back door
glass.
Special tool: CA501-001
WARNING: Please wear gloves and
goggles when using the special tool to
protect against the fragments generated in
cutting. Wear earplugs when cutting.
Failure to follow the instructions may
cause personal injury.
M5101009

3. Use glass sucker to remove the back door

glass with the help of other technicians.
Special tool: CA501-001

CA501-001

M5101017

M201 2014.01
5.1.1-9 Front/Rear Windshield 5.1.1-9
Installation
1. Remove the remaining adhesive in the slot
flange of the back door glass.

M5101003

2. Use the scraper to remove the adhesive on

the glass and clean the glass.
WARNING: Please avoid touching the
cleaned surface, otherwise it will affect the
bonding effect.

M5101004

3. Inspect the damaged metal fragments, iron

rust, or any other irrelevant materials in the
welding seam seal area, which tend to cause
damage to the glass.
4. Control the temperature of heat gun around
25°C, remove the moisture in the slot flange
of back door glass and glass glue.
General tool: heat gun
CAUTION: Remove all moisture in
adhesive surface to ensure the bonding
effect.

M5101018

M201 2014.01
5.1.1-10 Front/Rear Windshield 5.1.1-10

5. Apply PU adhesive for about 8 ~ 10 mm in

width along adhesive line against the edge of
windshield frames.
CAUTION: If the ambient temperature is
below 10°C, heat the PU adhesive for
about 15 mins on the stove or use heat
gun to heat it to about 25°C.

CAUTION: Reapply adhesive for 20 mm

where has no adhesive tape in order to
protect against water leakage. M5101006

CAUTION: In order to reduce working

time, the first 100 mm of PU adhesive can
be abandoned.

6. Use glass sucker to install the back door

glass with the help of other technicians.
Special tool: CA501-001
WARNING: Please keep the door open
before installing the glass in case it may
affect bonding effect because the
pressure in the vehicle may increase if the CA501-001
door is closed.

CAUTION: Press every part of the glass

M5101017
evenly, so that the glass can bond firmly
with adhesive.

7. Use scraper to remove the excessive or

overflowing adhesive.

M5101007

M201 2014.01
5.1.1-11 Front/Rear Windshield 5.1.1-11

8. Press the glass tightly until adhesive

hardened.
CAUTION: If the normal temperature is
below 10°C, heat the surface (25°C) in a
distance of about 50 mm for 15 mins
(inside or outside of the vehicle) by using
heat gun.
50 mm

M5101008

9. Install the high mounted stop lamp.

Refer to: High Mounted Stop Lamp (4.2.6
Lighting System, Removal and
Installation).

M201 2014.01
5.1.1-12 Front/Rear Windshield 5.1.1-12

Rear Quarter Glass

Removal
CAUTION: Other technicians shall assist
to hold the strip from outside of the
vehicle when removing the rear quarter
glass. Otherwise, the glass may drop and
cause damage.

1. Remove the retaining screw between rear

quarter glass and glass switch.

M5101015

2. Remove 2 retaining screws from the rear

quarter glass hinge, and remove the rear
quarter glass. ×2

M5101016

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.2-1 Door 5.1.2-1

Specifications
5.1.2 Door

Torque Specifications
Item Nm lb-ft lb-in
Front door glass retaining bolt 5 - 44
Rear door glass retaining bolt 5 - 44

M201 2014.01
5.1.2-2 Door 5.1.2-2

Description and Operation

Components Exploded View
Front Door

M5102045

M201 2014.01
5.1.2-3 Door 5.1.2-3

1
7

11

10

9
8

M5102046

Item Description Item Description

1 Front door 7 Front door glass run
Front door quarter door
2 8 Front door glass regulator
garnish
3 Front door interior trim panel 9 Front door rear slot
4 Front door inside handle 10 Front door glass
Front door inside handle
5 11 Front door weatherstrip
protector
Front door inside handle trim
6
cover

M201 2014.01
5.1.2-4 Door 5.1.2-4
Rear Door

4
8 10
5
9

6
7

M5102047

M201 2014.01
5.1.2-5 Door 5.1.2-5

11

12
15

13

14

M5102048

Item Description Item Description

1 Rear Door 9 Rear door lock link mechanism
2 Rear door outer weatherstrip 10 Rear door outside handle
3 Rear door inner weatherstrip 11 Rear door glass run
4 Dust cover 12 Rear door glass
Rear door glass regulator
5 13 Rear door glass regulator
handle
6 Rear door inside handle 14 Rear door rear slot
7 Rear door interior trim panel 15 Rear door front slot
8 Lock switch

M201 2014.01
5.1.2-6 Door 5.1.2-6

Removal and Installation

Front Door Interior Trim Panel (Models with Manual Regulator)
Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Using a screwdriver wrapped with protective
tape, pry off the handle jump ring of front door
glass regulator, and remove the handle, jump
ring and dust cover.

M5102001

2. Remove 2 retaining screws from the front

door inside handle and remove the inside
handle.

M5102002

M201 2014.01
5.1.2-7 Door 5.1.2-7

3. Remove the retaining screw cover from the

front door inside handle.

M5103019

4. Remove the front door inside handle retaining

screw.

M5102003

5. Using a screwdriver wrapped with protective

tape, remove the front door inside handle
protector.

M5102010

6. Use the special tool to disengage the front

door interior trim panel clips and remove it.
Special tool: CA501-002

M5102005

M201 2014.01
5.1.2-8 Door 5.1.2-8

7. The front door interior trim panel clip position

is shown in the figure.

×1
1
M5102006

Installation
1. Installation is in the reverse order of removal.
CAUTION: Front door interior trim panel
clip is disposable component, install a
new one.

CAUTION: Put the jump ring on the handle

when installing the glass regulator. Then,
assemble the glass regulator.

M201 2014.01
5.1.2-9 Door 5.1.2-9

Front Door Interior Trim Panel (Models with Power Regulator)

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the front door inside handle trim
cover.
1 Remove the retaining screw from the front
door inside handle trim cover.

M5102007

2 Using a screwdriver wrapped with

protective tape, remove the front door inside
handle trim cover.

M5102008

M201 2014.01
5.1.2-10 Door 5.1.2-10

3. Disconnect the power window switch

connector.

M5102093

4. Remove the retaining screw cover from the

front door inside handle.

M5103019

5. Remove the front door inside handle retaining

screw.

M5102049

6. Using a screwdriver wrapped with protective

tape, remove the front door inside handle
protector.

M5102010

M201 2014.01
5.1.2-11 Door 5.1.2-11

7. Use the special tool to disengage the front

door interior trim panel clip and remove it.
Special tool: CA501-002

M5102011

8. The position of front door interior trim panel

clip is shown in the figure.

×9

M5102012

Installation
1. Installation is in the reverse order of removal.
CAUTION: Front door interior trim panel
clip is disposable component, install a
new one.

M201 2014.01
5.1.2-12 Door 5.1.2-12

Rear Door Interior Trim Panel

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Using a screwdriver wrapped with protective
tape, remove the rear door inside handle 1,
then remove it with jump ring. 2
1
2. Using a screwdriver wrapped with protective
tape, remove the rear door glass regulator
handle 2, then remove it with jump ring and
dust cover.

M5102015

3. Remove the screw from the lock trim cover

retaining screw and remove the cover.

M5102016

4. Use the special tool to disengage the rear

door interior trim panel clip and remove it.
Special tool: CA501-002

M5102017

M201 2014.01
5.1.2-13 Door 5.1.2-13

5. The position of rear door interior trim panel

clip is shown in the figure.

×1
1

M5102018

Installation
1. Installation is in the reverse order of removal.
CAUTION: The rear door interior trim panel
clip is disposable component, use a new
one when reinstalling.

CAUTION: Put the jump ring on the handle

when installing the glass regulator. Then,
assemble the glass regulator.

M201 2014.01
5.1.2-14 Door 5.1.2-14

Back Door Interior Trim Panel

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Use the special tool to disengage the back
door interior trim panel clips and remove it.
Special tool: CA501-002

M5102019

2. The back door interior trim pannel clip

position is shown in the figure.

×1
5

M5102020

Installation
1. Installation is in the reverse order of removal.
CAUTION: The back door interior trim
panel clip is disposable component, use a
new one when reinstalling.

M201 2014.01
5.1.2-15 Door 5.1.2-15

Front Door Glass

Removal
1. Remove the front door interior trim panel.
Refer to: Front Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Remove the front door water-proof film.
CAUTION: Be careful to prevent damaging
the water-proof film during removal. Do
not touch the adhesive surface to avoid
reduction in adhesion effect during
reassembly.

M5102021

3. Remove the front door rear slot.

Refer to: Front Door Rear Slot (5.1.2 Door,
Removal and Installation).
4. Adjust the height of front door glass for
convenient removal and installation.
5. Remove 2 retaining bolts from the front door
glass.
Torque: 5 Nm
CAUTION: Support the front door glass to
prevent it from dropping, causing damage.

M5102022

M201 2014.01
5.1.2-16 Door 5.1.2-16

6. Remove the front door glass.

CAUTION: When treating the glass, be
careful to prevent damage.

M5102044

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.2-17 Door 5.1.2-17

Rear Door Glass

Removal
1. Remove the rear door interior trim panel.
Refer to: Rear Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Remove the rear door lock link mechanism.
Refer to: Rear Door Lock Link Mechanism
(5.1.8 Handles, Locks, and
Latches, Removal and
Installation).

3. Remove the rear door front rail.

Refer to: Rear Door Front Rail (5.1.2 Door,
Removal and Installation).

4. Remove the rear door rear rail.

Refer to: Rear Door Rear Rail (5.1.2 Door,
Removal and Installation).

5. Remove the rear door glass run.

Refer to: Rear Door Glass Run (5.1.2 Door,
Removal and Installation).

6. Adjust the height of the rear door glass for

convenient removal and installation.
7. Remove 2 retaining bolts from the rear door
glass.
Torque: 5 Nm
CAUTION: Support the rear door glass to
prevent it from dropping, causing damage.
×2

M5102023

M201 2014.01
5.1.2-18 Door 5.1.2-18

8. Remove the rear door glass.

CAUTION: When treating the glass, be
careful to prevent damage.

M5102024

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.2-19 Door 5.1.2-19

Front Door Rear Slot

Removal
1. Remove the front door interior trim panel.
Refer to: Front Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Remove the front door water-proof film.
CAUTION: Be careful to prevent damaging
the water-proof film during removal. Do
not touch the adhesive surface to avoid
reduction in adhesion effect during
reassembly.

M5102021

3. Remove the retaining bolt from the front door

rear slot.

M5102032

4. Remove the front door rear slot.

M5102033

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.2-20 Door 5.1.2-20

Rear Door Front Slot

Removal
1. Remove the rear door interior trim panel.
Refer to: Rear Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Remove the rear door water-proof film.
CAUTION: Be careful to prevent damaging
the water-proof film during removal. Do
not touch the adhesive surface to avoid
reduction in adhesion effect during
reassembly.

M5102034

3. Remove the rear door lock link mechanism.

Refer to: Rear Door Lock Link Mechanism
(5.1.8 Handles, Locks, and
Latches, Removal and
Installation).
4. Remove 2 retaining bolts from the rear door
front slot and remove the rear door front slot.

×2

M5102035

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.2-21 Door 5.1.2-21

Rear Door Rear Slot

Removal
1. Remove the rear door interior trim panel.
Refer to: Rear Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Remove the rear door water-proof film.
CAUTION: Be careful to prevent damaging
the water-proof film during removal. Do
not touch the adhesive surface to avoid
reduction in adhesion effect during
reassembly.

M5102034

3. Remove 2 retaining bolts from the rear door

rear slot and remove the rear door rear slot.
×2

M5102038

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.2-22 Door 5.1.2-22

Front Door Glass Run

Removal
1. Remove the front door glass.
Refer to: Front Door Glass (5.1.2 Door,
Removal and Installation).
2. Remove the front door weatherstrip.
Note: For models with power glass
regulator, remove the outer
weatherstrip; For models with
manual glass regulator, remove the
inner and outer weatherstrips.

M5102040

3. Remove the front door glass run.

M5102041

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.2-23 Door 5.1.2-23

Rear Door Glass Run

Removal
1. Remove the rear door interior trim panel.
Refer to: Rear Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Remove the rear door weatherstrip.

M5102042

3. Remove the rear door glass run.

M5102043

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.3-1 Seat 5.1.3-1

Specifications
5.1.3 Seat

Torque Specifications
Item Nm lb-ft lb-in
Front seat rear hinge retaining bolt 25 ~ 45 18 ~ 33 -
Second and third seat retaining bolt 20 ~ 24 15 ~ 18 -

M201 2014.01
5.1.3-2 Seat 5.1.3-2

Description and Operation

System Overview
M201 is one model with three rows of seats. Front seats can slide forward and rearward and adjust the
backrest angle and headrest height. Second seat can only adjust the backrest angle and headrest
height. Third seat is a monolith type, which can adjust the backrest angle and be integrally folded
forward to enlarge the trunk space. It is convenient for riding and goods transport.

Components Location View

Front Seat

M5103001

Item Description Item Description

1 Headrest 3 Seat belt buckle
2 Seat

M201 2014.01
5.1.3-3 Seat 5.1.3-3
Second and Third Seats

M5103002

Item Description Item Description

1 Second Seat 2 Third Seat

M201 2014.01
5.1.3-4 Seat 5.1.3-4

Removal and Installation

Front Seat
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the console.
Refer to: Console (5.1.6 Instrument Panel
and Console, Removal and
Installation).
3. Disconnect the driver seat belt buckle wiring
harness connector.

M5103003

4. Fold down the front seat.

1 Pull up the seat angle adjusting handle and
fold down the front seat backrest.

M5103004

M201 2014.01
5.1.3-5 Seat 5.1.3-5

2 Unlock 2 hooks on the front side of front

seat.

M5103005

5. Remove 2 retaining bolts from the seat rear

hinge.
Torque: 25 ~ 45 Nm

M5103006

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.3-6 Seat 5.1.3-6

Second Seat
Removal
1. Pull up the seat angle adjusting handle and
fold down the second seat backrest.

M5103007

2. Turn over the floor carpet and remove 2

retaining bolts from front part of seat frame on
the left side.
Torque: 20 ~ 24 Nm

×2
M5103008

3. Turn back the floor carpet, and remove 2

retaining bolts from the front part of seat
frame on the right side.
Torque: 20 ~ 24 Nm
×2

M5103009

M201 2014.01
5.1.3-7 Seat 5.1.3-7

4. Turn over the floor carpet and remove 2

retaining bolts from the rear part of seat frame
on both sides.
Torque: 20 ~ 24 Nm

×2

M5103010

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.3-8 Seat 5.1.3-8

Third Seat
Removal
1. Remove 2 retaining bolts on the front side of
third seat front support leg.
Torque: 20 ~ 24 Nm

×2
M5103011

2. Pull out the lock pin from the front support

leg.
3. Pull back the floor lock release lever, fold
down the rear suppor leg and turn the third
seat over.

M5103012

4. Remove 2 retaining bolts on the rear side of

third seat front support leg.
Torque: 20 ~ 24 Nm
×2

M5103013

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.4-1 Seat Belt 5.1.4-1

Specifications
5.1.4 Seat Belt

Torque Specifications
Item Nm lb-ft lb-in
Seat belt retractor retaining bolt 45 ~ 60 33 ~ 44 -
Seat belt retractor retaining screw 9 - 80
Front seat belt buckle retaining bolt 45 ~ 60 33 ~ 44 -
Sencond seat belt double buckles
45 ~ 60 33 ~ 44 -
retaining bolt
Seat belt lower anchor retaining bolt 45 ~ 60 33 ~ 44 -
Seat belt upper anchor retaining bolt 45 ~ 60 33 ~ 44 -
Seat belt stopper retaining bolt 9 - 80

M201 2014.01
5.1.4-2 Seat Belt 5.1.4-2

Description and Operation

System Overview
The seat belt, which is equipped in the vehicle, is
the major device to protect the passenger. The
side seats of front, second and third seats use
three-diagonal-surrounding belt; the center seats
of second and third seats use two-point belt.
Front seat belt buckle is installed on seat frame
respectively, and second and third seat buckles
are installed on floor.
The seat belt is equipped with a retractor with
emergent locking function. The locking function
will be activated when the seat belt is completely
pulled out from retractor quickly. The locking
function can prevent seat belt from being pulled
out to an excessive length. When the seat belt is
rolled back to retractor completely, this function
can be cancelled. After cancelling the locking
function, the seat belt is unlocked and can be
pulled out from the retractor. The driver seat belt
indicator is located on the instrument cluster to
remind driver to fasten seat belt.
WARNING: Child seat, if equipped, can
only be used in forward seat position,
child seat should be installed and secured
as instructed by manufacturer.

WARNING: Inspect the seat belt system

carefully after every collision. The newly
installed seat belt can be used only after
an inspection of professional technician to
make sure there is no malfunction.

M201 2014.01
5.1.4-3 Seat Belt 5.1.4-3

Removal and Installation

Front Seat Belt
Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove the plastic cap from seat belt lower
anchor retaining bolt.

M5104001

3. Remove the seat belt lower anchor retaining

bolt.
Torque: 45 ~ 60 Nm
Note: Fold down backrest and move seat
to the foremost position.

CAUTION: There is a protective paper

washer on the seat belt anchor retaining
bolt. Please ensure that the septa and the
paper washer are always on the anchor in
the removal and installation process. M5104002

M201 2014.01
5.1.4-4 Seat Belt 5.1.4-4

4. Partly remove the weatherstrips on both sides

of the B pillar.

M5104003

5. Remove the B pillar lower interior trim panel

with special tool.
Special tool: CA501-002

M5104004

6. Using a screwdriver wrapped with protective

tape, pry the seat belt decorative cover.

M5104005

7. Remove the seat belt upper anchor retaining

bolt.
Torque: 45 ~ 60 Nm
CAUTION: There is a protective paper
washer on the seat belt anchor retaining
bolt. Please ensure that the septa and the
paper washer are always on the anchor in
the removal and installation process.

M5104006

M201 2014.01
5.1.4-5 Seat Belt 5.1.4-5

8. Remove the seat belt stopper.

Torque: 9 Nm

×2
M5104007

9. Remove the front seat belt retractor retaining

screw and bolt, and take off the front seat belt
retractor.
Torque for Screw: 9 Nm
Torque for Bolt: 45 ~ 60 Nm
CAUTION: There is a protective paper
washer on the seat belt anchor retaining
bolt. Please ensure that the septa and the
paper washer are always on the anchor in
the removal and installation process. M5104008

10. Remove the front retractor transparent cover.

M5104009

11. Remove the console.

Refer to: Console (5.1.6 Instrument Panel
and Console, Removal and
Installation).

M201 2014.01
5.1.4-6 Seat Belt 5.1.4-6
12. Disconnect the driver seat belt buckle wiring
harness connector.

M5103003

13. Remove the driver seat belt buckle retaining

bolt, and take off the driver seat belt buckle.
Torque: 45 ~ 60 Nm
CAUTION: There is a protective paper
washer on the seat belt buckle retaining
bolt. Please ensure that the septa and the
paper washer always on the seat belt
buckle in the removal and installation
process.
M5104010

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.4-7 Seat Belt 5.1.4-7

Second Seat Belt

Removal
1. Remove the plastic cap from seat belt lower
anchor retaining bolt.

M5104011

2. Remove the seat belt lower anchor retaining

bolt.
Torque: 45 ~ 60 Nm
CAUTION: There is a protective paper
washer on the seat belt anchor retaining
bolt. Please ensure that the septa and the
paper washer are always on the anchor in
the removal and installation process.

M5104012

3. Using a screwdriver wrapped with protective

tape to pry the seat belt decorative cover.

M5104013

M201 2014.01
5.1.4-8 Seat Belt 5.1.4-8

4. Remove the seat belt upper anchor retaining

bolt.
Torque: 45 ~ 60 Nm
CAUTION: There is a protective paper
washer on the seat belt anchor retaining
bolt. Please ensure that the septa and the
paper washer are always on the anchor in
the removal and installation process.

M5104014

5. Remove the rear quarter interior trim panel.

Refer to: Rear quarter interior trim panel
(5.1.9 Interior Trim Panel and
Ornamentation, Removal and
Installation).
6. Remove 2 retaining bolts from seat belt
retractor, and take off the retractor.
Upper Bolt Torque: 9 Nm
Lower Bolt Torque: 45 ~ 60 Nm

×2

M5104015

7. Pull out the sencond seat belt double buckles

from seat backrest and seat cushion.
8. Remove the plastic cap from the sencond
seat belt double buckles retaining bolt.

M5104016

M201 2014.01
5.1.4-9 Seat Belt 5.1.4-9

9. Remove the sencond seat belt double

buckles retaining bolt and take off the
buckles.
Torque: 45 ~ 60 Nm
CAUTION: There is a protective paper
washer on the seat belt anchor retaining
bolt. Please ensure that the septa and the
paper washer are always on the anchor in
the removal and installation process.
M5104017

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.4-10 Seat Belt 5.1.4-10

Second Seat Belt (Two-point Type)

Removal
1. Turn the second seat over.
2. Remove the plastic cap from the second seat
belt single tab retaining bolt.

M5104018

3. Remove the second seat belt single tab

retaining bolt and take off the second seat
belt single tab.
Torque: 45 ~ 60 Nm
CAUTION: There is a protective paper
washer on the seat belt anchor retaining
bolt. Please ensure that the septa and the
paper washer are always on the anchor in
the removal and installation process.
M5104019

4. Remove the plastic cap from the sencond

seat belt double buckles retaining bolt.

M5104016

M201 2014.01
5.1.4-11 Seat Belt 5.1.4-11

5. Remove the sencond seat belt double

buckles retaining bolt and take off the
buckles.
Torque: 45 ~ 60 Nm
CAUTION: There is a protective paper
washer on the seat belt anchor retaining
bolt. Please ensure that the septa and the
paper washer are always on the anchor in
the removal and installation process.
M5104017

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.4-12 Seat Belt 5.1.4-12

Third Seat Belt

Note: Removal and installation procedure of the third seat belt is the same with that of the
second seat belt.

Third Seat Belt (Two-point Type)

Note: Removal and installation procedure of the third seat two-point belt is the same with
that of the second seat belt.

M201 2014.01
5.1.5-1 Rearview Mirror 5.1.5-1

Specifications
5.1.5 Rearview Mirror

Torque Specifications
Item Nm lb-ft lb-in
Interior mirror retaining screw Less than 9 - Less than 80
Exterior mirror retaining bolt 9±1 - -

M201 2014.01
5.1.5-2 Rearview Mirror 5.1.5-2

Description and Operation

System Overview
Vehicle rearview mirror is a major safety device for driver to observe the rear and side rear. The rearview
mirrors include interior and exterior mirrors, the glasses of exterior mirror can be manually adjusted and
interior mirror cam be integratedly adjusted; driving requirements can be met through adjusting rearview
mirrors. The rearview mirror has greatly improved the safety and comfort of driver.

Components Location View

M5105001

Item Description
1 Exterior mirror assembly
2 Interior mirror assembly

M201 2014.01
5.1.5-3 Rearview Mirror 5.1.5-3

Removal and Installation

Interior Mirror
Removal
1. Loosen the interior mirror retaining bolt to
proper position.
Torque: less than 9 Nm
2. Hold the interior mirror by hand to slide it
upward along windshield, until the mirror
base slides out fully.

M5105002

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.5-4 Rearview Mirror 5.1.5-4

Exterior Mirror
Removal
1. Using a screwdriver wrapped with protective
tape, pry out the front door quarter window
ornamentation.

M5105003

2. Remove 3 exterior mirror retaining bolts.

Torque: 9±1 Nm

×3

M5105004

3. Hold the exterior mirror by both hands to pull

outwardly so that the exterior mirror can be
removed.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.6-1 Instrument Panel and Console 5.1.6-1

Specifications
5.1.6 Instrument Panel and Console

Torque Specifications
Item Nm lb-ft lb-in
Instrument panel crossmember retaining
25 ~ 30 18 ~ 22 -
bolt

M201 2014.01
5.1.6-2 Instrument Panel and Console 5.1.6-2

Removal and Installation

Instrument Panel
Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Put the steering wheel at horizontal position.
CAUTION: Make sure that the wheels are
in straight-ahead driving position.

2. Disconnect the negative battery cable.

Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
Installation).

3. Remove the steering column.

Refer to: Steering Column (2.4.3 Steering
Column, Removal and
Installation).
4. Remove the instrument cluster.
1 Use the special tool to remove the
instrument cluster cover.
Special tool: CA501-002

M5106001

M201 2014.01
5.1.6-3 Instrument Panel and Console 5.1.6-3

2 Remove 4 retaining screws from the

instrument cluster.

×4
M5106002

3 Disconnect the instrument cluster wiring

harness connector and remove the
instrument cluster.

M5106003

5. Remove the lamp angle control switch.

Refer to: Lamp Angle Control Switch
(4.2.6 Lighting System, Removal
and Installation).

6. Remove the radio assembly.

Refer to: Radio (4.2.5 Information and
Entertainment System, Removal
and Installation).

7. Disconnect the cigarette lighter wiring

harness connector.

M4204002

M201 2014.01
5.1.6-4 Instrument Panel and Console 5.1.6-4

8. Remove the glove box.

1 Open the glove box.
2 Pull the glove box out by pressing the left
and right panels firmly in the direction of the
arrow shown in the figure.

M5106004

3 Remove 2 retaining bolts from the glove

box, and remove the glove box.
×2

M5106005

9. Remove the A/C controller.

1 Remove 4 retaining screws from the A/C
controller.

A/C
×4

M5106006

2 Disconnect the A/C inside and outside

circulation control cable.

M5106007

M201 2014.01
5.1.6-5 Instrument Panel and Console 5.1.6-5

3 Disconnect the A/C mode vent control cable

(1) and A/C warm and cold vent control cable
(2).

M5106008

4 Disconnect the wiring harness connector

and remove the A/C controller.

M5106009

10. Remove the retaining bolt of small instrument

panel cover at front windshield. 1
1 Use the special tool to remove the small
instrument panel cover (1) at front windshield
and then remove the retaining bolt (2).
Special tool: CA501-002 2

M5106010

11. Remove the right and center small instrument

panel covers at the front windshield.
Note: Removal procedures of small
instrument panel covers on the
right side and center are the same
as that of cover on the left side.

M201 2014.01
5.1.6-6 Instrument Panel and Console 5.1.6-6
12. Remove the retaining bolt on the top of
instrument panel.

M5106011

13. Remove 4 retaining screws from the center of

instrument panel.

×4

M5106012

14. Remove 3 retaining screws on the right side

of instrument panel.

×3

M5106013

15. Remove the retaining screw on the lower left

side of instrument panel.

M5106014

M201 2014.01
5.1.6-7 Instrument Panel and Console 5.1.6-7

16. Remove 2 retaining bolts from the left side of

instrument panel crossmember.
Torque: 25 ~ 30 Nm

×2

M5106015

17. Remove 2 retaining bolts from the right side

of instrument panel crossmember.
Torque: 25 ~ 30 Nm

×2

M5106016

18. Disconnect the dome wiring harness

connector.

M5106017

19. Move the instrument panel outward to the

proper position and remove the retaining
screw on the upper left side.

M5106021

M201 2014.01
5.1.6-8 Instrument Panel and Console 5.1.6-8

20. Remove the retaining screw from the left air

pipe.

M5106018

21. Remove the retaining screw from the right air

pipe.

M5106019

22. Remove 2 retaining screws from the center

defroster pipe.

×2

M5106020

23. Remove the instrument panel.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.6-9 Instrument Panel and Console 5.1.6-9

Console
Removal
1. Use the special tool to remove the gear shift
mechanism dust cover.
Special tool: CA501-002

M5106022

2. Use the special tool to pry out the hand brake

cover.
Special tool: CA501-002

M5106023

3. Use the special tool to pry out the console

rear cup holder.
Special tool: CA501-002

M5106024

M201 2014.01
5.1.6-10 Instrument Panel and Console 5.1.6-10

4. Use the special tool to pry out the console

rear cover.
Special tool: CA501-002

M5106025

5. Turn over the front seats.

6. Remove the retaining screw (1) and 2
retaining bolts (2) from the front of console.

×2 2

M5106026

7. Remove 2 retaining bolts on the rear of

console.
×2

M5106027

8. Remove the console assembly.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.7-1 Bumper 5.1.7-1

Specifications
5.1.7 Bumper

Torque Specifications
Item Nm lb-ft lb-in
Front bumper upper retaining bolt 9 - 80
Front bumper lower retaining bolt 9 - 80
Upper grill retaining bolt 9 - 80

M201 2014.01
5.1.7-2 Bumper 5.1.7-2

Removal and Installation

Front Bumper
Removal
1. Disconnect the negative battery cable.

Refer to: Battery (3.1.10 Charging System,

Removal and Installation).
2. Remove the front bumper upper grill.
1 Remove the retaining bolts from the left and
right sides of bumper upper grill.
Torque: 9 Nm

×2

M5107001

2 Remove the clips from the center of bumper

upper grill, and then pull up the bumper upper
grill and remove it.
×2

M5107002

3. Remove 3 retaining bolts between front

bumper upper part and bumper
crossmember.
Torque: 9 Nm ×3

M5107003

M201 2014.01
5.1.7-3 Bumper 5.1.7-3

4. Remove 2 clips and retaining screw between

front fender lining and left side of front
bumper.

×2

M5107004

5. Remove 2 clips and retaining screw between

front fender lining and right side of front
bumper.

×2

M5107005

6. Remove the retaining screw from the lower

part of front bumper.

M5107006

7. Remove 4 retaining bolts from the lower part

of front bumper.
Torque: 9 Nm
×4

M5107007

M201 2014.01
5.1.7-4 Bumper 5.1.7-4

8. Disengage the front bumper from the bumper

mounting crossmember.
1 Using a screwdriver wrapped with
protective tape, pry out 6 claws on the left and
right sides of front bumper.
2 Disengage the hooks and pull out the front
bumper.

×2
M5107008

9. Disconnect the front fog lamp wiring harness

connector.

M5107009

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.7-5 Bumper 5.1.7-5

Rear Bumper
Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove 2 retaining screws between rear
wheel mud guard and left side of rear
bumper.

×2

M5107010

3. Remove 2 retaining screws between rear

wheel mud guard and right side of rear
bumper.

×2

M5107011

4. Remove 6 retaining screws from the upper

part of bumper.

×6

M5107012

M201 2014.01
5.1.7-6 Bumper 5.1.7-6

5. Remove 5 retaining screws from the lower

part of bumper.
×5

M5107013

6. Using a screwdriver wrapped with protective

tape, pry 10 claws on the left and right sides
of rear bumper.
7. Pull the flange on the center of bumper lightly
to seperate the rear bumper from the back
door lock pin.

M5107014

8. Disconnect the rear fog lamp wiring harness

connector and remove the rear bumper.

M5107015

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-1 Handles, Locks and Latches 5.1.8-1

Specifications
5.1.8 Handles, Locks and Latches

Torque Specifications
Item Nm lb-ft lb-in
Engine hood lock retaining bolt 10 - 89
Outside handle retaining bolt 10 - 89
Back door lock latch retaining bolt 9 - 80

M201 2014.01
5.1.8-2 Handles, Locks and Latches 5.1.8-2

Description and Operation

System Overview
The front hood lock, front, rear and back door
locks are traditional pin-fier design.The front, rear
and back door locks are usually controlled by the
control rod system, which is connected with
outside handle, and door lock remote control
system while the front door lock latch is
connected with door lock core. The remote door
lock device has a handle lever to lock and unlock
from the inside of vehicle. The front hood is
controlled by release grip, and the back door lock
is controlled by inside grip.

M201 2014.01
5.1.8-3 Handles, Locks and Latches 5.1.8-3

Removal and Installation

Front Hood Lock
Removal
1. Open the front hood.
2. Remove 2 retaining bolts from the front hood
lock.
Torque: 10 Nm

×2

M5108005

3. Remove the engine hood lock releasing

cable.

M5108006

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-4 Handles, Locks and Latches 5.1.8-4

Front Hood Lock Release Grip

Removal
1. Using a screwdriver wrapped with protective
tape to pry the engine hood lock release grip
from inside of the instrument panel in the
direction indicated by arrow.

M5108007

2. Remove the release grip.

M5108032

3. Loosen the front hood lock releasing cable.

M5108008

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-5 Handles, Locks and Latches 5.1.8-5

Steering Lock Assembly

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the steering wheel combination

switch.
Refer to: Lighting Combination Switch
(4.2.6 Lighting System, Removal
and Installation).
Wiper Combination Switch (4.2.7
Wiper and Washer, Removal and
Installation).

3. Remove the ignition switch.

Refer to: Ignition Switch (3.1.8 Ignition
System, Remove and
Installation).
4. Remove and discard the retaining anti-theft
bolts from the steering lock assembly.

×2

M5108009

Installation
1. Installation is in the reverse order of removal.
CAUTION: Anti-theft steering lock
assembly retaining bolt is disposable
component and replaced with new ones
after removal.

M201 2014.01
5.1.8-6 Handles, Locks and Latches 5.1.8-6

Front Door Lock Core

Removal
1. Remove the front door interior trim panel.
Refer to: Front Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Uncover the water-proof film.
CAUTION: Do not touch the adhesive
surface to avoid reduction in adhesion
effect during reassembly.

M5102021

3. Remove the front door rear slot.

Refer to: Front Door Rear Slot (5.1.2 Door,
Removal and Installation).
4. Disconnect the control lever from the front
door lock core.

M5108011

5. Remove the retaining plate from the front

door lock core.

M5108010

M201 2014.01
5.1.8-7 Handles, Locks and Latches 5.1.8-7
6. Take out the door lock core from the outside
of door.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-8 Handles, Locks and Latches 5.1.8-8

Back Door Lock Core

Removal
1. Remove the back door interior trim panel.
Refer to: Back Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Uncover the water-proof film.
CAUTION: Do not touch the adhesive
surface to avoid reduction in adhesion
effect during reassembly.

M5108012

3. Disconnect the control lever from the back

door lock core.

M5108013

4. Remove the retaining plate from the back

door lock core.

M5108014

5. Take out the door lock core from the outside

of back door.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-9 Handles, Locks and Latches 5.1.8-9

Front Door Outside Handle

Removal
1. Remove the front door interior trim panel.
Refer to: Front Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Uncover the water-proof film.
CAUTION: Do not touch the adhesive
surface to avoid reduction in adhesion
effect during reassembly.

M5102021

3. Remove the front door rear slot.

Refer to: Front Door Rear Slot (5.1.2 Door,
Removal and Installation).
4. Remove the front door lock latch and
fastener.
Refer to: Front Door Lock Latch (5.1.8
Handles, Locks and Latches,
Removal and Installation).
5. Remove the front door outside handle.
1 Remove the left retaining bolt plug.

M5108015

2 Remove 2 retaining bolts.

Torque: 9 Nm

M201 2014.01
5.1.8-10 Handles, Locks and Latches 5.1.8-10

6. Disconnect the control lever from the front

door outside handle.

M5108017

7. Take off the front door outside handle.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-11 Handles, Locks and Latches 5.1.8-11

Rear Door Outside Handle

Removal
1. Remove the rear door interior trim panel.
Refer to: Rear Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Uncover the water-proof film.
CAUTION: Do not touch the adhesive
surface to avoid reduction in adhesion
effect during reassembly.

M5102034

3. Remove the rear door fastener.

1 Disconnect the rear door fastener
connector.
2 Remove 2 retaining bolts from the rear door
fastener.
Torque: 9 Nm
×2

M5108018

3 Disconnect the lever.

4. Remove 3 retaining bolts from the rear door
lock link mechanism.
Torque: 9 Nm
×3

M5108019

M201 2014.01
5.1.8-12 Handles, Locks and Latches 5.1.8-12

5. Remove the rear door outside handle.

1 Remove the left retaining bolt plug.

M5108020

2 Remove 2 retaining bolts.

Torque: 9 Nm

×2

M5108021

3 Disconnect the connecting rod between

outside handle and rear door lock link
mechanism.

M5108022

4 Take off the outside handle from the outside

of rear door.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-13 Handles, Locks and Latches 5.1.8-13

Back Door Outside Handle

Removal
1. Remove the back door interior trim panel.
Refer to: Back Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Uncover the water-proof film.
CAUTION: Do not touch the adhesive
surface to avoid reduction in adhesion
effect during reassembly.

M5108012

3. Remove 4 retaining screws from the rear

license plate lamp cover.

×4

M5108028

4. Remove 2 retaining bolts from the outside

handle.
Torque: 9 Nm

×2

M5108029

M201 2014.01
5.1.8-14 Handles, Locks and Latches 5.1.8-14

5. Disconnect the outside handle connecting

rod.

M5108030

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-15 Handles, Locks and Latches 5.1.8-15

Front Door Inside Handle

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).

2. Remove the front door interior trim panel.

Refer to: Front Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
3. Uncover the water-proof film.
CAUTION: Do not touch the adhesive
surface to avoid reduction in adhesion
effect during reassembly.

M5102021

4. Remove the inside handle.

1 Disconnect the inside handle cable and
locking button cable.
2 Release 2 cable clips.
3 Slide and remove the inside handle.

M5108031

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-16 Handles, Locks and Latches 5.1.8-16

Rear Door Lock Link Mechanism

Removal
1. Remove the rear door interior trim panel.
Refer to: Rear Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Uncover the water-proof film.
CAUTION: Do not touch the adhesive
surface to avoid reduction in adhesion
effect during reassembly.

M5102034

3. Remove the rear door fastener.

Refer to: Rear Door Outside Handle (5.1.8
Handles, Locks and Latches,
Removal and Installation).
4. Remove 3 retaining bolts from the rear door
lock link mechanism, and take off the rear
door lock link mechanism.
Torque: 9 Nm
×3

M5108019

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-17 Handles, Locks and Latches 5.1.8-17

Front Door Lock Latch

Removal
1. Remove the front door interior trim panel.
Refer to: Front Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Uncover the water-proof film.
CAUTION: Do not touch the adhesive
surface to avoid reduction in adhesion
effect during reassembly.

M5102021

3. Remove the front door inside handle.

Refer to: Front Door Inside Handle (5.1.8
Handles, Locks and Latches,
Removal and Installation).

4. Remove the front door rear slot.

Refer to: Front Door Rear Slot (5.1.2 Door,
Removal and Installation).
5. Disconnect the control lever from the front
door lock core.

M5108011

M201 2014.01
5.1.8-18 Handles, Locks and Latches 5.1.8-18

6. Remove 3 retaining screws from the front

door lock latch.

×3

M5108023

7. Disconnect the front door outside handle

lever and take off the front door lock latch.
Refer to: Front Door Outside Handle (5.1.8
Handles, Locks and Latches,
Removal and Installation).

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-19 Handles, Locks and Latches 5.1.8-19

Rear Door Lock Latch

Removal
1. Remove the rear door interior trim panel.
Refer to: Rear Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Uncover the water-proof film.
CAUTION: Do not touch the adhesive
surface to avoid reduction in adhesion
effect during reassembly.

M5102034

3. Remove the rear door rear slot.

Refer to: Rear Door Rear Slot (5.1.2 Door,
Removal and Installation).
4. Disconnect the rear door lock connection
lever.

M5108024

5. Remove 3 retaining screws from the rear

door lock latch, and take off the rear door lock
latch.

×3

M5108025

M201 2014.01
5.1.8-20 Handles, Locks and Latches 5.1.8-20
Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.8-21 Handles, Locks and Latches 5.1.8-21

Back Door Lock Latch

Removal
1. Remove the back door interior trim panel.
Refer to: Back Door Interior Trim Panel
(5.1.2 Door, Removal and
Installation).
2. Uncover the water-proof film.

M5108012

3. Disconnect the back door lock connection

lever.
4. Disconnect the back door opener connection
lever.

M5108026

5. Remove 3 retaining bolts from the back door

lock latch, and take off the back door lock
latch.
Torque: 10 Nm
×3

M5108027

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.9-1 Interior Trim Panel and Ornamentation 5.1.9-1

Removal and Installation

5.1.9 Interior Trim Panel and Ornamentation

A Pillar Trim Panel

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Partly remove the front door frame
weatherstrip.

M5109001

2. Use the special tool to remove the A pillar

trim panel.
Special tool: CA501-002

M5109002

M201 2014.01
5.1.9-2 Interior Trim Panel and Ornamentation 5.1.9-2

3. The A pillar trim panel clip position is as

shown in the figure.

×3
M5109003

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new clip for A
pillar trim panel during installation.

M201 2014.01
5.1.9-3 Interior Trim Panel and Ornamentation 5.1.9-3

B Pillar Interior Trim Panel

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Partly remove the weatherstrips on both sides
of B pillar.

M5104003

2. Use the special tool to remove the B pillar

lower interior trim panel.
Special tool: CA501-002

M5104004

3. The B pillar lower interior trim panel clip

position is as shown in the figure.
×5

M5109004

M201 2014.01
5.1.9-4 Interior Trim Panel and Ornamentation 5.1.9-4

4. Using a screwdriver wrapped with protective

tape to pry the seat belt decorative cover.

M5104005

5. Remove the seat belt upper anchor retaining

bolt.
Torque: 45 ~ 60 Nm
CAUTION: There is a protective paper
washer on the seat belt anchor retaining
bolt. Please ensure that the septa and
paper washer are always on the anchor
during removal and installation.

M5104006

6. Remove the seat belt stopper.

Torque: 9 Nm
×2

M5104007

7. Use the special tool to remove the B pillar

upper interior trim panel.
Special tool: CA501-002

M5109005

M201 2014.01
5.1.9-5 Interior Trim Panel and Ornamentation 5.1.9-5

8. The B pillar upper interior trim panel clip

position is as shown in the figure.

×2
M5109006

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new clip for B
pillar interior trim panel during installation.

M201 2014.01
5.1.9-6 Interior Trim Panel and Ornamentation 5.1.9-6

Rear Quarter Interior Trim Panel

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Remove 2 retaining screws from the rear
quarter interior trim panel.

×2

M5109007

2. Use the special tool to pry out the retaining

clip from the rear quarter interior trim panel.
Special tool: CA501-002

M5109008

3. The rear quarter interior trim panel clip

position is as shown in the figure.
×14

M5109009

M201 2014.01
5.1.9-7 Interior Trim Panel and Ornamentation 5.1.9-7

4. Take out the seat belt from the rear quarter

interior trim panel.

M5109010

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new clip for
the rear quarter interior trim panel during
installation.

M201 2014.01
5.1.9-8 Interior Trim Panel and Ornamentation 5.1.9-8

Front Doorsill Ornamentation

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Partly remove the front door frame
weatherstrip.
2. Use the special tool to remove the front
doorsill ornamentation.
Special tool: CA501-002

M5109011

3. The front doorsill ornamentation clip position

is as shown in the figure.
×3

M5109012

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new clip for
the front doorsill ornamentation clip
during installation.

M201 2014.01
5.1.9-9 Interior Trim Panel and Ornamentation 5.1.9-9

Rear Doorsill Ornamentation

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Remove the B pillar lower interior trim panel.
Refer to: B Pillar Interior Trim Panel (5.1.9
Interior Trim Panel and
Ornamenamentation, Removal
and Installation).
2. Use the special tool to remove the rear
doorsill ornamentation.
Special tool: CA501-002

M5109013

3. The rear doorsill ornamentation clip position

is as shown in the figure. ×4

M5109014

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new clip for
the rear doorsill ornamentation during
installation.

M201 2014.01
5.1.9-10 Interior Trim Panel and Ornamentation 5.1.9-10

Back Doorsill Ornamentation

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Partly remove the back door frame
weatherstrip.
2. Use the special tool to remove the back
doorsill ornamentation.
Special tool: CA501-002

M5109015

3. The back doorsill ornamentation clip position

is as shown in the figure.

×5

M5109016

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new clip for
the back doorsill ornamentation during
installation.

M201 2014.01
5.1.9-11 Interior Trim Panel and Ornamentation 5.1.9-11

Roof Panel Lining

Special Tool

Interior and Exterior

Trim Panel Remover
CA501-002

CA501-002

Removal
1. Disconnect the negative battery cable.
Refer to: Battery (3.1.10 Charging System,
Removal and Installation).
2. Remove 3 retaining screws from the sun visor
and take off the sun visor.

×3
M5109017

3. Remove 2 retaining screws from the assistant

grip, and take off the assistant grip.
×2

M5109018

M201 2014.01
5.1.9-12 Interior Trim Panel and Ornamentation 5.1.9-12

4. Remove the front roof lamp.

Refer to: Front Roof Lamp (4.2.6 Lighting
System, Removal and
Installation).

5. Remove the reading lamp.

Refer to: Reading Lamp (4.2.6 Lighting
System, Removal and
Installation).

6. Remove the overhead evaporator.

Refer to: Overhead Evaporator (4.1.1 Air
Conditioning, Removal and
Installation).

7. Remove the A pillar trim panel.

Refer to: A Pillar Trim Panel (5.1.9 Interior
Trim Panel and Ornamentation,
Removal and Installation).

8. Remove the B pillar interior trim panel.

Refer to: B Pillar Trim Panel (5.1.9 Interior
Trim Panel and
Ornamenamentation, Removal
and Installation).

9. Use the special tool to remove 28 retaining

clips from the roof panel lining.
×28

Special tool: CA501-002

M5109019

10. Remove the roof panel lining.

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new clip for
the roof lining during installation.

M201 2014.01
5.1.10-1 Exterior Trim 5.1.10-1

Removal and Installation

5.1.10 Exterior Trim

Front Fender Lining Plate

Removal
1. Remove the front fender lining plate clip.
1 Remove 2 clips between front fender lining
plate and front bumper.

×7
2 Remove 2 clips between front fender lining
plate and fender flanging.
3 Remove 3 clips between front fender lining
plate and metal panel.

M5110001

2. Take out the front fender lining plate.

Installation
1. Installation is in the reverse order of removal.
CAUTION: Make sure to use new clip for
front fender lining plate during
installation.

M201 2014.01
5.1.10-2 Exterior Trim 5.1.10-2

Front Mud Guard

Removal
1. Remove 2 retaining screws from the front
mud guard.

M5110002

2. Remove the front mud guard.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.10-3 Exterior Trim 5.1.10-3

Rear Mud Guard

Removal
1. Remove 3 retaining screws from the rear mud
guard.

×3
M5110003

2. Remove the rear mud guard.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.10-4 Exterior Trim 5.1.10-4

Front Wind Guiding Cover

Removal
1. Lift the vehicle.
Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).
2. Remove 4 retaining bolts and 3 retaining
screws from the front wind guiding cover.
Torque: 10 Nm
×3
×4

M5110004

3. Remove the front wind guiding cover.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
5.1.10-5 Exterior Trim 5.1.10-5

Rear Wind Guiding Cover

Removal
1. Lift the vehicle.
Refer to: Lifting (1.1.3 Traction and Lifting,
Description and Operation).

2. Remove the front wind guiding cover.

Refer to: Front Wind Guiding Cover (5.1.10
Exterior Trim, Removal and
Installation).
3. Remove 4 bolts and 4 screws from the rear
wind guiding cover.
Torque: 10 Nm

×4
×4
M5110005

4. Remove the rear wind guiding cover.

Installation
1. Installation is in the reverse order of removal.

M201 2014.01
 Body Repairs

5.2 Body Repairs

2014 M201
Table of Contents Pages

5.2.1 Body Repairs

Description and Operation ............................................................................................................... 5.2.1-1
Noise, Vibration and Harshness ............................................................................................... 5.2.1-1
Plastic Components Type......................................................................................................... 5.2.1-2
Component State...................................................................................................................... 5.2.1-3
Welding Type ............................................................................................................................ 5.2.1-3
Body Size ................................................................................................................................. 5.2.1-4
Symptom Diagnosis and Testing...................................................................................................... 5.2.1-5
Diagnosis of Vehicle in Accident............................................................................................... 5.2.1-5
Removal and Installation.................................................................................................................. 5.2.1-6
Pit Repair Without Painting....................................................................................................... 5.2.1-6
Crash Repair ............................................................................................................................ 5.2.1-7
Anticorrosion Measures............................................................................................................ 5.2.1-8
Plastic Components Repair .................................................................................................... 5.2.1-10

M201 2014.01
5.2.1-1 Body Repairs 5.2.1-1

Description and Operation Methods of Sound Transmission

5.2.1 Body Repairs

Noise, Vibration and Harshness The sound can be transmitted via air or
substances. The sound travel speed in liquid or
Meaning of NVH in Automotive solid (such as vehicle body) depends on the
Engineering material features of substance. Generally, the
speed of sound in liquid or solid is 5 times that in
N = Noise - audible unpleasant sound. air. The noise can be transmitted in the vehicle via
V = Vibration - perceptible vibration. air and substance.

H = Harshness - audible and perceptible jittering Vibration

and vibration.
The vibration is a form of physical movement
Noise Type in Automotive Engineering commonly found in the nature. Vibration waves
with a frequency lower than 20 Hz (low
According to the sound intensity, the noise in the frequency) or higher than 20000 Hz (20 kHz, high
automotive engineering can be classified as frequency) cannot be heard by human ears.
following: slight noise, moderate noise and strong Generally, the low frequency vibration is visible.
noise. Slight noise mostly comes from engine and The high-frequency vibration is audible and
road surface, especially from rough road surface. palpable through floor and steering wheel. For
Strong noise is commonly generated by airflow or example, engine with flexible installation can
accessories (such as alternator, power steering relieve the vibration when vehicle runs on the
pump and drive belt). Chatter sound can be heard uneven road surface. However, when flexible
when vehicle runs on uneven road. The unstable installation of engine is in trouble, vibration will be
noise is usually caused by shock absorber, transmitted from engine to vehicle body and even
chassis components or loose components inside cab.
the vehicle.
Resonance
Requirements of NVH for Vehicle Body
Each object has its inherent vibration frequency. If
The vehicle body is one of the most important part a certain system vibrates with its inherent
involving NVH. The vehicle body not only causes vibration frequency, it will cause resonance. For
air noise, but also causes solid noise. The main example, when engine reaches resonance
components of NVH in the vehicle body are roof frequency, it will become unstable (engine critical
steel plate, quarter and floor. The vibration or speed). Once the engine speed exceeds the
noise shall be increased greatly due to the critical point, the engine will run stably
structure, just as an amplifier. NVH engineering immediately.
raises higher requirements for vehicle body:
• The vehicle body must absorb vibration
Damping Vibration
from all components, and try to ensure Damping has influence on the resonance of the
that the vibration is not transmitted to the objects or systems. Object vibration can be
interior of vehicle body. reduced if a damper is connected with spring in
• The structure can ensure the body rigidity parallel. The vehicle shock absorber is made
and provide excellent buffering based on the principle to reduce the body
performance in crash. vibration through damping.
• Spacious interior
• Corrosion resistance
• Light weight
• Excellent aerodynamic appearance

M201 2014.01
5.2.1-2 Body Repairs 5.2.1-2

Plastic Components Type

1 2 It is important to know the material characteristics
for plastic components in repair. The plastic
components can be generally divided into two
basic categories according to the materials:
thermoplastic plastic and thermosetting plastic.
Thermoplastic Plastic Components
The thermoplastic plastic components turn soft
when heated and harden when cooled. The
M5201001 process is reversible and can be proceeded
repeatedly. Therefore, thermplastic plastic
Item Description components can be formed and solidified
1 Non-damping vibration repeatedly by heating. The thermoplastic plastic
component scraps can be recycled. Most of the
2 Damping vibration
interior and exterior trim closures are made of
thermoplastic plastics.
Sound Insulation and Noise Reduction
Thermosetting Plastic Components
The sound insulation and noise reduction
technology is adopted in automotive engineering The thermosetting plastic components will turn
to minimize the noise. For example, engine is soft when first heated, but to a certain
installed on elastic supporting seat, so that the temperature, it will solidify due to chemical
vibration is transmitted into the vehicle body as reaction. This process is irreversible. Hereafter, it
little as possible. cannot turn soft when heated again. The
thermosetting plastic components are formed with
this feature. Using the plastifying flow in the first
heating, the material fills the cavity full to solidify
the components with the preset shape and
dimension under the pressure. The thermosetting
plastic components are harder and more fragile
than the thermoplastic components, and the state
does not change when heating. If continued
heating, thermosetting plastic components may
be damaged when temperature is higher than the
critical point. The thermosetting plastic
components are widely used as structure
components in electrical and safety components
with the purpose of heat isolation, anti-wear,
insulation and high voltage resistance.

M201 2014.01
5.2.1-3 Body Repairs 5.2.1-3

Component State
The surface must be flat with caulking and
polished with sand paper before the vehicle or
component is delivered to the workshop for
painting after repair. The metaler should be
responsible to prepare this process. The body
and floor are formed by cold stamping with steel
sheet. Therefore, the damaged part should be
recovered using the same method after the
accident. If the damaged component cannot be
recovered as the original shape, remove and
replace the damaged component as its integrity
after calibrating the adjacent part. Never cut the
component unit; otherwise, the vehicle rigidity,
driving safety and repair feasibility may be
influenced.

Welding Type
The general welding includes spot welding, gas
shielded welding and braze welding. It is not
allowed to reduce the spot quantity during spot
welding. If the spot welding device is unavailable,
apply gas shielded welding to plug after drilling.
When applying spot welding, the spot must be on
the original one if only external plate is replaced
for the three-layer plate. Single welding line,
double welding lines and double offset welding
lines can be formed in spot welding. Related
welding line, continuous welding line and
imtermittent welding line can be formed in gas
shielded welding. Braze welding is generally to
weld and repair the area with weak tension
strength and low thickness.

M201 2014.01
5.2.1-4 Body Repairs 5.2.1-4

Body Size

1890

27°
34°

2560

3980

M5201002

M201 2014.01
5.2.1-5 Body Repairs 5.2.1-5

Symptom Diagnosis and Testing

Diagnosis of Vehicle in
Accident
The professional technicians should use beam
calibrator, electrical measuring system, spot
welder and other grinding tools when repairing
the body to recover its geometrical dimension and
performance to the original state. However,
sometimes the symptoms of driving system and
suspension that can lead to serious fault may not
be found in repairing the vehicle in an accident.
Special attention must be paid to the following
components besides the geometrical dimension
inspection of the body:
• Ensure that the steering gear and the
steering column can work normally within
the steering wheel turning range. Visually
inspect components for any bending and
crack.
• Inspect all the components (for example:
Y-tube/trailing arm, suspension arm,
steering knuckle, stabilizer bar, frame and
mountings) in the driving system for
bending, twist and crack.
• Inspect the wheel and tire for any
damage, concentric rotating and out of
balance. Inspect the tire thread and wall
for cutting/Inspect the tire pressure.
• Inspect the engine/transmission/exhaust
system for damage.
Carry out the road test after repairing the body
and ensure the driving performance. Finally, hand
the vehicle over to the user.

M201 2014.01
5.2.1-6 Body Repairs 5.2.1-6

Removal and Installation Working Principle of Pressure

Correction
Pit Repair Without Painting
• In order to restore the surface shape, all
Damage Assessment the treatment must be completed for the
semicircle of pit.
Slight pit can be repaired with no impact on the
painting. The pit can be eliminated from inside • The operation collectively forms a
with special lever tool (pressure tool). The repair semicircular shape. Operate in the
requires that technicians must have rich specified order.
experience of using special tool and good • The untreated semicircle of pit is
material knowledge, and have ability of automatically restored through the stress
confirming the fault and taking the proper repair generated in the pressing process.
method. The pit should meet the following
CAUTION: Do not correct the shape from
requirements:
the center of pit. If so, the edge shall rise
• Only for the body with access from both and retain the protruding state (the
sides; this technology is uncommon for material is drawn to be longer). Once a
the dual-coating structure or closed bulging edge is formed, it requires a long
section. time to repair it.
• Only shallow and small pit can be
repaired perfectly. This method is
applicable for the damage caused by hail, 1
parking or shipment. 2 3

• The pit diameter should be less than 50 4 5

mm and the damage can be judged by
the pit size. 6 7

CAUTION: The material of pit center

cannot exceed the deformation limit.

M5201004

10 mm
Repair Procedures
1
1. Verify the repair method.
20 mm
2. The labeling of pit is helpful for identification.
CAUTION: Do not use pens with
2 50 mm dissolvability that can damage the paint.

3. Prepare the repair area.

M5201003
• It is unnecessary to open a hole for repair
if the inner side of pit can be touched.
Item Description
• Clean the damaged area of vehicle body.
1 Pit center
The careful inspection is important for
2 Pit edge successful repair.
• Polishing the repair surface if it is rough.
The decision can be made only when the
reflected light is strong enough.

M201 2014.01
5.2.1-7 Body Repairs 5.2.1-7
4. Install and adjust the illumination lamp. • Fix the vehicle on the lift before removing
the components to keep the gravity
• Arrange and adjust the illumination lamp,
center stable to ensure the operation
so that the pit (oval) can be seen clearly
safety.
in the reflected light of paint surface.
• Directly connect the grounding wire of
• If the elliptical shape is changed in cross
welder to the components to be welded.
lines when pressing the pit, the crossing
No conductive component is allowed
point is the working point for the pressure
between the grounding point and welding
tool.
point when operation.
• The grounding wire or welding electrode
is not allowed to contact the electrical
1
control unit and wire.
• The vehicle without any protection should
not be parked in the repair area. The
splashed spark will cause fire and
2 damage the painting and glass.
• Be careful when grinding and welding the
fuel tank or other components filled with
fuel. Remove all the suspicious
M5201005 components that may influence the
safety.
Item Description • Do not weld, hard or soft braze weld any
1 No pressure is exerted on the pit component of the A/C system with
2 Pressure is exerted on the pit
refrigerant, as well as other components
that may increase the temperature of A/C
system. It may cause explosion of the
5. Pressure tool position
A/C system. The refrigerant must be
• Place the peak of pressure tool on the recycled if welding is required near the
edge of the pit. refrigerant hose. The refrigerant will
deteriorate due to the invisible ultraviolet
• Slightly press the pit with the peak of
ray generated in welding.
pressure tool, move the pressure tool
back and forth, and the reflected light can • Disconnect the negative battery cable
show the pressure tool position. when repairing the airbag or calibrating
the body; the ambient temperature of
6. Restore the anti-corrosion protection.
airbag shall not exceed 100°C.
Crash Repair
Precautions for Crash Repair
Pay attention to the following when repairing the
body metal sheet:
• Wear protective clothes, goggles, gloves
and shoes when welding, cutting and
grinding the body.
• Good ventilation is required for the
welding area.
• Disconnect the battery and cover the
terminal before welding.
• Remove the battery if spark may appear
when working near the battery.

M201 2014.01
5.2.1-8 Body Repairs 5.2.1-8
CAUTION: Calibrate the body with the 6. Perform the corresponding welding.
general body calibrator to determine the 7. Clear all the welding surface.
damaged component before replacing the
key components of body. 8. Paint the coating.
9. Apply some sealant and anti-corrosion
CAUTION: Precise component alignment
coating as necessary.
is required before welding; then, measure
to confirm the body dimension before 10. Install all the related components.
welding.
Anticorrosion Measures
CAUTION: Measure frequently to ensure
the correct assembling in welding. Precautions for Anti-corrosion
Treatment:
CAUTION: Learn the welding assembling
relationship of body metal sheet before • Protective measures must be taken when
painting sound isolation or anti-corrosion
removal. It is not recommended to cut the
materials to avoid the painted component
component unit; otherwise, the vehicle
opening (such as lock, window slot,
rigidity, driving safety and repair feasibility regulator and seat belt retractor) and any
may be influenced. moving and rotating component,
especially the parking brake cable. All the
Removal Procedures
relief holes of body must be open after
1. Remove all the sheets and components painting.
related to the components to be replaced. • The foam sound isolation material of
2. Clear the sealant and anti-corrosion material repaired component must be removed
as necessary. when repairing the body with open fire.
Do not breathe in the harmful dust when
3. Align, mark and drill all the welding spots of reinstalling the sound isolation material.
the components to be replaced.
• Wear special goggles and gloves to avoid
4. Remove the damaged components. injury during operation.
5. Eliminate the remaining material. • The body metal sheet is treated by
electrophoresis and coating when
Installation Procedures exfactory. All the exposed metal surfaces
must be coated with anti-rust painting
1. Pretreat the matching surface as necessary.
after repairing and/or replacing the
2. Choose a correct welding method according components.
to the original state of vehicle. Apply • If the original cladding or anticorrosion
protective welding in the area where material is burnt during welding or
resistance welding is unavailable. Drill holes heating, clear the surface and carry out
on new components for welding line if corrosion resistance treatment.
choosing plug welding. The diameter and
• The metal may be exposed in crash
interval of holes should be determined by the
repair. Paint the surface with special anti-
original welding spot. corrosion material.
3. Put new component on the vehicle
temporarily.
4. Assemble and fix the new components with
calibrate retainer (correct alignment repair
plate).
5. Measure the new components positions to
ensure the correct assembling dimension.

M201 2014.01
5.2.1-9 Body Repairs 5.2.1-9
Anti-corrosion Treatment Principle 5. Use the cleaning agent silicone to completely
clear and dry.
• The standard anti-corrosion coating must
be formed with approved material after 6. Carry out anti-corrosion pretreatment for
repair. exposed areas.
• The coating must be painted inside and Anti-corrosion Treatment for Welding
outside the welding line before sealing.
Component
• Apply sealant on the coated metal sheet.
1. Clear the dip coat in the welding inner and
• Seal the joint metal sheet, edge, even outer areas with a rotary steel wire brush, and
joint welding line and welding seam with be careful not to damage the zinc coat.
sealant.
CAUTION: The grounding area should
• Apply long-term protective solute at the
bottom of body. be as small as possible, and the anti-
corrosion protection (negative coating)
• Repair the cavity with the protective of product should be preserved as
material in the repair area after painting. much as possible.
• Clean the drain port after the protective
material becomes dry. 2. Thoroughly clear the repairing area (with
silicone).
Anti-corrosion Protection for New
3. Use the welding primer component for all
Components the welding seams (new or old
Inspect all the new components for any scraps or components).
bruises caused in transport.
CAUTION: The welding primer should be
The following operations are required according thoroughly stirred before being used.
to the damage.
New components without damage:
Do not burnish the negative electrophoretic
coating. Completely clean the new components
with silicone cleaning agent and dry them.
New components with slightly damage:
1. Scrape off the scratching.
2. Slightly wipe the outer surface.
3. Use the cleaning agent silicone to completely M5201006
clear and dry.
4. Carry out the anti-corrosion pretreatment for
4. The welding operation cannot be performed
exposed areas.
until the welding primering is dried.
Damaged components (damaged through
5. Remove the welding slag after the welding is
collision and pressing):
completed, and be careful not to destroy the
1. Level the bruised area and grind exposed strength of the material.
metal.
6. All the scallops in welding seams are treated
2. Scrape polyester putty (only for the exposed with lead containing material filling method.
metal).
7. Clear and fill the sealed inner areas.
3. Scrape the putty (further fill).
8. Seal all welding areas and joints for full
4. Slightly grind the whole component. protection.

M201 2014.01
5.2.1-10 Body Repairs 5.2.1-10
Cavity Protection (Perform Cavity • Keep the repair materials away from the
Protection for Doorsill After Local clothes.
Repair) • Use the repair materials in place with
good ventilation, because the materials
may produce toxic dust and pollution.
2
1 • Close all the repair material containers
3 4 after using. The dust and moisture may
cause pollution to the materials and
impact on the repair.

Plastic Components Repair

This chapter introduces the repair method for the
plastic components only.

M5201007 Thermoplastic Plastic Component

Rectification (Slight Deformation)
Item Description The bumper is usually deformed at the elastic
1 Welding seam part, such as pit and bending. Most of the
deformation can be recovered by the hot air
2 Nozzle
pressure gun. The damaged component can be
3 Distant positioning heated up to about 200°C with the pressure gun.
4 Spray gun Heat the component from both sides if possible.
In addition, the wooden hammer and plastic
Drill a hole at a proper position when injecting wedge can be used for the rectification.
cavity protecting wax for areas that cannot reach,
and the hole diameter is defined according to the Thermoplastic Plastic Component
available hole sealing plug. It is important to Welding
remove the scrap iron from the cavity, because Plastic welding is the best way to repair
any residual scrap iron may cause rust. The edge thermoplastic plastic component, for example:
of hole should be treated with hole sealing wax, section with edge and corner, square section and
and finally, the bottom is sealed with a plug or small round section in the reinforced area.
sealant.
Take the bumper crack as an example:
Plastic Components Repair 1. Cut the crack into V section for welding.
Precautions for Plastic Component • Use a scraper to cut the V welding seam
Repair with opening of 60° ~ 70°.
• Apply protective cream on the naked skin • Use 3 mm driller to drill holes at the end
to avoid irritation. of crack to prevent extension. Repair the
crack beginning with caliper before
• Wear rubber gloves. welding if the seam edge is tough. Then,
• Wear goggles when using compressed drill holes at the end of the crack.
air and sanding.
• Immediately eliminate any mixture on the
skin since it becomes solid rapidly.
• Wear dust-proof mask and goggles when
grinding or sanding.
• Wash the skin with cold water to relieve
the slight irritating caused by resin dust.

M201 2014.01
5.2.1-11 Body Repairs 5.2.1-11

4-5 mm

0.5-1.5 mm
M5201008 M5201009

2. Set the welding temperature according to the • When moving the plastic welding gun,
manufacturer specification keep the welding rods vertical with the
(200°C ~ 700°C). The welding temperature is welding seams.
determined by the thickness of plastic
material and welding rod.
• Preheat the welder for 3 ~ 4 mins to
reach the preset welding temperature.
• Cut the welding front end incline and fill
the welding seam from the beginning. 90
3. Welding
• Push the welding rod with incline front
end into heated quick welding nozzle
cavity until the rod appears at bottom. M5201010
When the welding rods and components
to be welded are in the plastic state, start 4. Inspect the welding joint head.
welding. Stable welding speed and
pressure are required when welding
plastic components. Pressure is only 2
1
exerted to the welding rods when
welding.
• The lower end of the quick welding
nozzle shall move in parallel with the
repairing surface. Parallel moving along
the longer length direction is achieved
through suitable incline of the welding
device. 3
M5201011

Item Description
1 Edge bulge of welding seam
2 Welding seam remaining height
3 Welding seam root

The welding is good if only small or smooth bulge

is formed when welding the seam edge. It is
important for welding of the bevel seam. Inspect

M201 2014.01
5.2.1-12 Body Repairs 5.2.1-12
the seam from back for the following defects. Plastic Adhesive Bonding
Reweld it as necessary. It is applicable for the thermoplastic and
thermosetting plastic components. All
Item Description
thermoplastic plastic components must adopt the
Repaired position is excessively binder containing polyurethane. The reinforced
hot belts can be used for the welding seam and
Distortion Material is stretched when welding broken seam to ensure the initial extensibility.
is performed
1. Wash the part to be repaired
Plastic material is excessively thin
• Before repairing, use the high pressure
Welding temperature is water cleaner to clean both sides of the
excessively low plastic components, and then perform
Poor welding
Welding speed is excessively fast drying.
joint
Different materials are welded • Use the plastic cleaner to clean the
together surface of components to be repaired.
Welding seam Welding seam is excessively wide 2. Pretreatment
plastic filled
surface is
Pretreatment of scratches:
Welding temperature is
excessively excessively high • Use the track grinding machine and P80
low ~ P120 sand paper to thoroughly burnish
the scratches into flatness.
5. Reprocess the welding seam
• Use the track grinding machine and P120
• After cooling, use the angle grinding sand paper to perform fine burnish.
machine to burnish the bulging part of the • Use the plastic cleaner or tissue to
welding seam. Sand paper type: P80 thoroughly clean the surface to be
ROUGH SAND PAPER. Then, use the repaired.
track grinding machine to burnish the
surface. Sand paper type: P120 ~ P220 • Evenly spray the plastic primer on the
FINE SAND PAPER. surface to be repaired.
• Use the plastic cleaning brush to clean Pretreatment of crack:
and repair the surface. • Use the angle grinding machine or belt
• Spray the plastic primer on the repaired type grinding machine to burnish the front
surface. side of crack. The width of grinding
surface is 40 ~ 60 mm.
• Use the track grinding machine to burnish
again.
Sand paper type: P120.
• Use 3 mm driller to drill holes at the end
of crack to prevent extension.
• Burnish along the inner side of crack.
• Use the plastic cleaner or tissue to clean
the position to be repaired.
• Paint the plastic primer at the position to
be repaired.

M201 2014.01
5.2.1-13 Body Repairs 5.2.1-13
• Use the PE flake to prevent the binder
from spilling out of the front side of crack.
• Take off the PE flake after the binder is
1
dried.
• Apply the binder at the front side of
position to be repaired.
65 65
• Use the infrared heater or the dryer to
2 perform drying.
• Cool the binder to be at the room
M5201012 temperature to prevent the binder from
falling off and prevent the sand paper
from being excessively heated in the
Item Description burnishing progress.
1 Scratching preparation
4. Grinding
2 Crack preparation
• Use the track grinding machine to grind
off the bulging part of binder.
3. Adhesive bonding
Sand paper type: P120 ~ P220 ROUGH
Scratch bonding:
SAND PAPER.
• Use the binder to fill the crack after the
• Manually repair the sunken and bent
crack is cleaned and the primer is
areas.
painted.
• Use the grinding pads to rub the paint
• Use a flexible plastic clearance gauge to
surface.
lay open and flatten the binder.
• Thoroughly clean the plastic
• Use the infrared heater or dryer to
components.
perform drying.
• Paint the plastic primer after it is
Adhesive bonding and repairing crack:
thoroughly dried.
Reinforce the position to be repaired to
improve the anti-twisting intensity for large
area of crack or breaking. Therefore, suitable
reinforcing material (such as metal strip and
reinforced fiber) is attached at the back of
components.
• Use the PE flake or adhesive tape to
cover the front side of the crack.
• Use the plastic binder to stuff the welding
seam from inner side.
• Simultaneously, a wider reinforced fiber
and binder are stuffed into welding crack.
• Reinforce the end of crack by adding the
metal strips embedded in the plastic
components.
• Repair the upper surface of reinforcing
material to have the same height as the
whole surface to be repaired.
• Use the infrared heater or dryer to
perform drying.

M201 2014.01