Chery S21 2007 2016 User Manual

Mando MGHAnti-Lock Brake

System

User’s Manual

CONTENT

Common Abbreviations and Acronyms in This Manual……… ………………………… 2

I. Product Instruction………………………………………………………………………. 3

1． ABS Overview ………………………… ……………… ……… …………………….. 3

1.1 System Function…………………………………… ……………………… ……… 3

1.2 Comparison between with and without ABS braking effects…………………... 3

2． System Structure………………… …………………… ……………… ……… …….. 5

3． System Functioning Theory…………………………………………………………. 6

3.1 ABS Control Theory………………………………………………… ……………… 6

3.2 ABS Control Mode……………………………………………………………….. 6

3.3 EBD Control Mode……………………………………………………………….. 9

II. Removal and Installation…………………………………………… …………………... 10

1． Spare Part Supply Status…………………...………………………………………. 10

2． Notices for Removal and Installation………………………………………………. 10

3． HECU Replacement…………………………………………………………………. 12

III. Trouble Diagnosis and Troubleshooting………………………………………………. 14

1． Checking Sequence…………………… ……………………………………...……… 14

2． Common Trouble Diagnosis and Troubleshooting of MGH-25 ABS……...……… 14

2.1 Checking of ABS and EBD Warning Lamp……………………...….…………... 14

2.2 Table for Common Troubles…………………….……………………………….. 14

2.3 Trouble Code Readout and Deletion without Trouble Diagnosis Instrument… 15

2.4 Trouble Checklist of Trouble Code……………………………………………… 17

2.5 Trouble Checklist without Trouble Code…………………...…………………… 25

IV. Air Discharge and Oil Refill……………………………...…………………………….. 30

1. Regular Operation Procedure………………………… ……………………………. 30

2. Checking Device……………………………………...… ……………………………… 30

3. Notices for Air Discharge and Oil Refill………………………………… ……………… 30

4. Determination Method for Vehicles with Air Discharge Trouble……...……………….. 31

5. Measures in Event of Troubles during Air Discharge and Oil Refill

(for internal dry status of brake system)………………………………………………… 31

6. Measures in Event of Trouble during Checking and ABS Functioning Test

(for internal wet status of brake system) ……………………………… ……………… 32

Annex I Malfunction Cases and Incorrect Repair Cases……… …………… ……… .. 34

Annex II ABS Basics…………… …………………… …………………………..……... 36

Annex III ABS Internal hydraulic Flow Diagram………………………………… .… 37

Annex IV Connector Pin Layout of MGH-25 ABS ECU……………….………….… 37

Page 1 of 38

Common Abbreviations and Acronyms in This Manual

FL——Front Left

FR——Front Right

——Rear Left

RL

RR——Rear Right

ABS——Anti-lock Brake System

EBD——Electronic Brake Distribution

ECU——Electronic Control Unit

HU、HCU——Hydraulic (Control) Unit

HECU——ECU+HCU

LPA ——Low Pressure Accumulator

MCP——Master Cylinder Primary, one of two outlet of master cylinder. P refers to

primary.

MCS——Master Cylinder Secondary, one of two outlet of master cylinder. S refers to

secondary

SDL——Serial Data Link

Page 2 of 38

I. Product Instruction

1． ABS Overview

1.1 System Function

① Promotion of vehicle stability;

Guarantee of vehicle steering ability; ②

Guarantee of shortest brake distance. ③

1.2 Comparison between with and without ABS braking effects

Without ABS

With ABS

Braking on Bisectional Roads (Split)

Without ABS

With ABS

Evading the obstacles during braking

Page 3 of 38

Brake Force

1.3 Tire Dynamic Characteristics

Slip Ratio

Steering Force

Slip Rate [%]

Page 4 of 38

2． System Structure

Motor

Including:

Electronic Control Unit

Hydraulic Unit

Sensor

Motor

The sensor will calculate the speed and acceleration/deceleration
of four wheels and judge the skid status of the wheels and
therefore drive the electromagnetic valve and motor, control the
pressure increment and pressure reduction, maintain the status,
and etc.
The basic hydraulic circuit is comprised of the 1st circuit and the
2nd circuit that is active only when the ABS is functioning and is
the integral part that controls the hydraulic parts transmitted to
various wheels.
Depending on the transmitted signal output of the sensor, the
ECU performs the calculation and judges the skid status to
determine if it’s necessary to run the ABS. Therefore, depending
on the control procedure of the ECU, the electromagnetic valve
and the motor will be started to control the pressure increment
and pressure reduction, maintain the status, and etc.
In order to make the ECU to calculate the speed and acceleration/
deceleration of the four wheels, it always transmits the revolution
measurement of the gear ring to the ECU.
When the ABS is functioning, the motor will rotate following the
ECU signal and convert the rotation movement into linear
reciprocated movement via the bearing to circulate the brake oil.

Page 5 of 38

3． System Functioning Theory

Start

Reduction

)

ta tus that the wheels

3.1 ABS Control Theory

ABS Control Range

Start
Pressure
Increment

λ= 0%: The status that the brake is

not functioning

Pressure

Skid Ratio

λ= 100%:

Slip Ratio

Body Speed – Wheel Speed

Body Speed

Tire braking force (µs)

Tire transversal friction force (µs

The s

are lock ed

3.2 ABS Control Mode

① Functioning Status of General Brake

For the vehicles equipped with ABS, if the braking pressure applied onto the wheels is not enough
to lock the wheels, the pressure generated by the general pump will transmit to the wheel branch
pump via the normal open valve to obtain the braking effects. When it’s unnecessary for further
braking, the driver will reduce the pressure on the brake pedal and then the brake liquid of various
wheels will return to the general pump to reduce the braking pressure.

Solenoid Valve Power Status Solenoid Valve Status
Normal Open Valve (NO Valve) OFF Open
Normal Close Valve (NC Valve) OFF Close

Page 6 of 38

ABS ② Functioning (Pressure Reduction) Status

For the vehicles equipped with ABS, if the applied braking pressure is too big, the wheels will
have rapider deceleration than that of vehicle body, which will be ready to result the lock of the
wheels. Under such case, the ECU will transmit the code for wheel pressure reduction to the HCU,
namely turn off the normal open valve and turn on the normal close valve to reduce the pressure of
wheel branch pump. In such case, the brake oil released by the wheel branch pump is temporarily
stored in the low pressure accumulator (LPA). The brake oil stored in the LPA will be sucked
back to the general pump by the oil pump started following the rotation of the motor. The brake
liquid will return to the high pressure accumulator (HPA) in the pipeline and reduce the high
pressure pulse generated by the running of the oil pump by means of the orifice hydraulic
resistance.

Solenoid Valve

Power Status

Solenoid Valve Status
Normal Open Valve (NO Valve) ON Close
Normal Close Valve (NC Valve) ON Open

ABS ③ Functioning (Maintaining) Status

When the branch pumps of the wheels are applied with proper pressure via the pressure reduction
or pressure increment, the normal open valve and the normal close valve will be turned off to
maintain the pressure of the wheel branch pumps. For the operations mentioned in above ~ ②④,
depending on that wheels are locked or not, the ABS will function till the vehicle is fully stopped
and therefore the safety and steering capability of the vehicle are guaranteed.

Solenoid Valve Power Status Solenoid Valve Status
Normal Open Valve (NO Valve) ON Close
Normal Close Valve (NC Valve) OFF Close

Page 7 of 38

ABS ④ Functioning (Pressure Increment) Status

During the implementation of the pressure reduction, if the excessive brake liquid is drained or the
friction coefficient between the wheels and the road is increased, it’s necessary to increase the
pressure of various wheels. Under such case, the ECU will transmit the code for wheel pressure
increment to the HCU, namely turn on the normal open valve and turn off the normal close valve to
increase the pressure of wheel branch pump. During the implementation of the pressure reduction,
the brake liquid stored in the low pressure accumulator (LPA) will continue to rotate the motor to
drain the brake liquid under the pressure increment status. In such case, the brake liquid is supplied
to branch pump of various wheels via the general pump and normal open valve. The brake liquid
will return to the high pressure accumulator (HPA) in the pipeline and reduce the high pressure pulse
generated by the running of the oil pump by means of the orifice hydraulic resistance.

Solenoid Valve Power Status Solenoid Valve Status
Normal Open Valve (NO Valve) OFF Open
Normal Close Valve (NC Valve) OFF Close

Page 8 of 38

3.3 EBD Control Mode

In order to guarantee the operation stability, the EBD function is designed in such manner that front
wheels are stopped ahead of the rear wheels. As the front brakes undertake more works than that of
the rear brakes, it will cause that the rear wheels will be stopped firstly when apply with same braking
pressure. In order to preventing the occurrence of above thing, a device to reduce the braking pressure
applied on the rear wheels under certain pressure is required, of which this function is fulfilled by the
pressure reducing valve (P-Valve). The special pressure reducing valve is not required for the vehicles
equipped with ABS as the procedure supplemented to the ABS will fulfill the control function on the
braking pressure of the rear wheels so as to effect the improvement of vehicle operation stability.

Page 9 of 38

II. Removal and Installation

1. Spare Part Supply Status

① Differentiation between Dry Type HECU and Wet Type HECU

The biggest differentiation between the dry type HECU and wet type HECU is that the no air
discharge is conducted in the 2nd circuit (namely the circuit from the normal close valve to the
general pump) of the dry type HECU. Therefore, when the spare part is of wet type HECU, it’s
only necessary to conduct the air discharge and oil refill in accordance with the regular brake
system after the replacement. When the spare part is of dry type HECU, besides that the air
discharge and oil refill are required in accordance with the regular brake system after the
replacement, it’s necessary to conduct the air discharge and oil refill to the 2nd circuit of the HECU.
In addition, for the appearance, the wet type HECU has the bolts for sealing purpose and the dry
type HECU has the protection film. The product label located on the motor is marked with the part
number of the products, through which the dry type HECU and wet type HECU can be
differentiated.
Take the S21 model for instance, the dry type Mando product number is BH601-086-00 and the wet
type Mando product number is BH602-386-00.

Dry Type Wet Type

② Notices

If the bolts on the wet type HECU are fallen off (such as during the transportation), besides that the
air discharge and oil refill must be conducted for 1st circuit, maybe it’s necessary to conduct the air
discharge and oil refill to the 2nd circuit.

2． Notices for Removal and Installation

① Notices for HECU Assembling

During the assembling of brake pipeline:

Remove the protection film attached onto the HECU

before the operation.

Confirm the pipeline of general pump and wheel branch

pump before the operation.

(General pump: MCP, MCS Wheel branch pump: FR,
FL, RR, RL)

Confirm if the brake hose is tightened to 120~160

kgf·cm with special tool or torque wrench.

Notice to keep away the impurity ingress into the

HECU hole and brake hose during operation.

Page 10 of 38

② Notices for HECU Bracket Assembling

Bracket

During the assembling of HECU bracket:

During the tightening of the bolt (3

pcs), it may cause the incorrect
assembling due to the friction
resistance of the cushion pad. It’s

Installation bolt

preferable to use the lubricating oil
with the physical properties that will
not impair the cushion pad.

Bumper block

Insert the bolts (3 pcs) onto the

cushion pad installed onto the bracket
before install to the HECU, which
will help the operation.

Confirm if the bolts (3 pcs) are tightened to 80~100 kgf·cm with special tool or torque

wrench.

③ Notices for Installation of HECU and Bracket Assembly

During the installation to vehicle body:

Attach the components of brake hose and

bracket to the HECU and install to the
vehicle body with the body fixing bolts.

Confirm if the body fixing bolts are

tightened to 190~260 kgf·cm with special
tool or torque wrench.

Again confirm if the pipeline installation

of general pump and wheel branch pump
is correct.

(General pump: MCP, MCS; Wheel branch pump: FR,
FL, RR, RL)

Tighten th e brake hose not full y tighte ned to the specified torque (120 ~ 160

kgf· cm) with special tool or torque wrench.

④ Other Notices

Find out the trouble cause with diagnosis instrument before repair.

The package of the spare parts should be unwrapped only before the installation.

Only use the parts supplied by the original manufacturer.

Notice the cleanliness during removal and only use the non-fuzz cloth for cleaning.

Use the detergent not containing the mineral oil to clean the appearance before removal.

Do not use the compressed air or move the vehicle when the system is opened.

After the removal of the ABS assembly, plug various hydraulic outlets with plugs as soon as

possible.

Remove other components interfering the operation.

Use DOT#3 brake liquid.

Immerse the seals with brake liquid, instead of engine oil or braking ointment.

Check all hydraulic connectors for leakage.

Page 11 of 38

3． HECU Replacement

① When the vehicle is stopped, remove the 25-pin connector and harness wiring of the HECU

located within the engine compartment.

25-Pin Connector Used in MGH-25 ABS

(P/No：AMP 368482-1)

② Screw off in counter clockwise direction the 6 bolts (M10x1.0) connected to the HECU brake

hose with 11mm tool (wrench) (rotate in clockwise direction during refit). The tightening torque for
the brake hose is 120 ~ 160 kgf·cm.

③ Screw off in counter clockwise direction the 3 bolts or nuts connected to the bracket with

12mm tool (wrench) (rotate in clockwise direction during refit). The tightening torque for the fixing
bolts or nuts of the bracket is 190 ~ 260 kgf·cm.

④ After the removal of the product, screw off in counter clockwise direction the 3 embedded

bolts (M6x1.0) attached to the HECU with 5mm tool (hex wrench) (see the figure in next page).

Page 12 of 38

⑤ Screw off in counter clockwise direction the 6 bolts from the after-service HECU with 6mm

tool (hex wrench).

⑥ Screw on in clockwise direction 3 embedded bolts to assemble the after-service HECU and

the bracket with 5mm tool (hex wrench). The tightening torque for the embedded bolts is 80 ~ 100
kgf·cm.

⑦ With reference to above item ~ ①③, install the replacement after-service HECU to the

vehicle in reverse order.

Page 13 of 38

Checking of wheel

ECU ID determination

hecking of valve

and terminal

Record checking

Sensor air gap determination

Trouble code

Valve status determination

•Pipeline assembling status

III. Trouble Diagnosis and Troubleshooting

1． Checking Sequence

Regular checking

•

• ECU trouble code

determination

• Warning lamp status

determination

speed sensor

•

• Sensor assembling status

determination

C

•

determination

result

•

determination

• Trouble code record

．

2

Trouble Diagnosis and Troubleshooting of MGH-25 ABS

2.1 Checking of ABS and EBD Warning Lamp

Check if the ABS and EBD warning lamps are illuminated in accordance with following:
① Rotate the vehicle key to turn on the power. The ABS warning lamp will illuminate and then
go off in 3s.
② It indicates the trouble if the status mentioned in ① is not present and it’s necessary to
check the trouble code with reference to the trouble code checklist.
③ If the warning lamps are completely not illuminated, please refer to the trouble checklist
without trouble code.

2.2 Table for Common Troubles

Position Cause Structure

Warning lamp

ABS EBD

Vehicle
harness

Incorrect assembling of

brake hose

Brake oil leakage Poor start of ABS and EBD

Incorrect wiring

installation

Locked wheels and brake off-

tracking

Off Off

Brake failure

Air discharge trouble Deteriorated ABS performance

Motor Motor trouble ABS start failure On Off

ECU

Trouble of ECU power line

Trouble of valve power

line

Poor grounding of ECU Start failure of ABS and EBD

Start failure of ABS and EBD

Start failure of ABS and EBD

On On

ECU trouble Start failure of ABS and EBD

Speed
sensor

Trouble of motor wire line

Sensor open-circuit/short-

circuit

Gear ring trouble, sensor

interference trouble, air gap

trouble

In event of whichever trouble: ABS

In event of both troubles: Start failure

In event of both troubles: Start failure

ABS start failure On Off

start failure

of ABS/EBD

In event of whichever trouble:

Incorrect start of ABS

of ABS/EBD

On Off

On On

On Off

On On

Page 14 of 38

2.3 Trouble Code Readout and Deletion without Trouble Diagnosis Instrument

① Purpose and condition of trouble code readout without trouble diagnosis instrument

If without the trouble diagnosis instrument, it may display the trouble status of the ABS via the
ABS warning lamp and read out the trouble code to facilitate the trouble determination and
troubleshooting. In such case, the trouble code will be displayed in 2-digit number. Please refer to
the numbers in parentheses in the trouble checklist of trouble code in succeeding section 2.4.

The service conditions are as follows:

Vehicle speed below 2km/h;
Without connection of trouble diagnosis instrument;
The line L (namely the pin 7 of interior diagnosis socket) should be always grounded

during the diagnosis process.

In addition, at finish of the trouble code readout, restore the ECU status of the ABS to the normal
mode (previously, it’s the diagnosis status), of which the method is as follows: At finish of the
diagnosis operation, disconnect the grounding status of the line L, rotate the key to power off status,
and then re-connect.

② Readout method of trouble code without trouble diagnosis instrument

Read out the trouble code in accordance with following procedure when the service conditions for
trouble code readout without trouble diagnosis instrument are met:

Line L

Ignition

Switch

ABS

warning

lamp

The display will be repeated without any new trouble code.

The steps in above figure are respectively:

A. Rotate the vehicle key to power on position after the line L is grounded;

B. When the ABS warnin g lamp illumi nates and lasts for 3s, it indicates t he start of
diagnosis;

C. When the ABS war ni ng lamp is off for 3s, it indic ates that it enters into the
trouble code display phase;

D. Trouble code display and readout;

E. Wh en th e AB S wa r ni ng la mp is off fo r 3 s , it i n di c at e s th a t it ent er s in to
ne xt tro u b le dis p l ay pha s e or circu l ated di s pl a y phas e ;

F. The display and readout of new trouble code and the circulated display of last trouble code.

Page 15 of 38

The meaning of symbols in the figure is as follows:

Line L

W

ithin

Ignition switch

Brake pedal

ABS warning lamp

3s Deletion period

3s Pedal depressing

Peda

l releasing

Within

(1 time)

W

ithin 2s

Within 2s

Within 2s

Within 2s

Code

T1

T2

T3

The symbol for diagnosis start. The warning lamp starts flashing
For differentiation of the duration of various trouble codes during
the display of multi trouble codes
Flashing interval of warning lamp at the presence of trouble code 0.5s

Symbol Description Duration

3.0s

3.0s

For differentiation of the interval of various digits of trouble code

T4

during the display of certain trouble code (for this interval, the
first digit is for tens digit and the second digit is for ones digit)

1.5s

Take the process shown in above figure for instance. Within the display span of the first trouble code,
before the presence of T4 (namely, 1.5s before the off of the warning lamp), since the warning lamp
flashes twice (the duration for each on and off is both T3, namely 0.5s), the first digit of the 2-digit
trouble code (tens digit) is at 2; after the presence of T4 (namely 1.5s after the off of the warning
lamp), since the warning lamp flashes once, the second digit of the 2-digit trouble code (ones digit) is
at 1. After that, the warning lamp will be off for 3s (namely T2 duration). Therefore, the display of
first trouble code is completed with the trouble code of 21. The detailed description of the trouble is
shown in the trouble code checklist in section 2.4. Also, the second trouble code of 22 can be
obtained.

③ Deletion of trouble code without trouble diagnosis instrument

After the trouble code readout and troubleshooting based on the trouble code checklist, it’s necessary
to delete the previous trouble code before the re-checking of the trouble code. The condition for
trouble code deletion is same with that of the trouble code readout. The detailed operation method is
as follows:

1s

2s

(2 times)

(3 times)

(4 times)

(5 times)

The steps in the above figure are respectively as follows:

A. After the brake pedal is depressed, ground the line L and rotate the vehicle key to the power on
position;
B. The ABS warning lamp illuminat ion and go off in 3 s;
C. Start to release the p edal wi thin 1s after the ABS war ning lamp goes off;
D. After the pedal is released for appr oximate 1s, re-dep ress the p edal for appr oximate
1s. Repeat the ab ove operation for 5 times. During this operation, the warni ng lamp will
not b e illuminated;
E. The ABS warning lamp illumi nates a nd lasts for 3s. During t his period, the trouble
code within thi s process will be deleted.

At the finish of the trouble code deletion, restore the ECU status of the ABS to the normal mode,

Page 16 of 38

of which the operation method is same with that of the trouble code diagnosis.

Ignition

Switch

warning

In addition, when the ECU of the ABS has no trouble code, ground the line L and rotate the
key to the power on position. The flashing of the ABS warning lamp is conducted in
accordance with the type in following figure, of which the symbol meaning is same with the
foregoing section.

Line L

ABS

lamp

2.4 Trouble Checklist of Trouble Code

① Contents of Trouble Code



Trouble

code

C1 200

(11)

Contents

Open-circuit/short-circuit of left
front sensor

Trouble

code

C1 206

(31)

Contents

Open-circuit/short-circuit of left rear
sensor

C1 201

C1 202

C1 203

C1 204

C1 205

C1 101

C1 102

C1 604

(12)

(13)

(21)

(22)

(23)

(51)

(52)

(53)

Interference of left front sensor or
gear ring

Air gap error of left front sensor

Open-circuit/short-circuit of right
front sensor

Interference of right front sensor
or gear ring

Air gap error of right front sensor

Battery voltage too high (above
17V)

Battery voltage too low (below

9.4V)

Trouble of ECU internal circuit or
electromagnetic valve coil

C1 207

(32)

C1 208

(33)

C1 209

(41)

C1 210

(42)

C1 211

(43)

C2 112

(54)

C2 402

(55)

Interference of left rear sensor or gear
ring

Air gap error of left rear sensor

Open-circuit/short-circuit of right rear
sensor

Interference of right rear sensor or
gear ring

Air gap error of right rear sensor

Trouble of electromagnetic valve fuse
or electromagnetic relay

Trouble of motor fuse or motor

Page 17 of 38

② Trouble checklist of trouble code

No

Remove the connector from the

harness and sensor, confirm t he

assembling status, and check t he

nnector

pins and correctly

Is powered on?

Replace sensor

Replace HECU

Is the problem

Determine and repair

wiring broken portion or

Determine i f t he t wo li nes between

r B

Trouble Code

C1 200(11) C1 203(21)
C1 206(31) C1 209(41)
Open-circuit/short-circuit of sensor:
At shor t- c ircuit or op e n-circuit

Possible Case

of ba tter y ano de or cat hode of
sens or.

Table 1
Note: If the malfunctions corresponding to
more than 2 trouble codes can be determined,
after the trouble codes are deleted (erasable
trouble codes), drive the vehicle to above
40km/h to determine the malfunctions to that
the trouble codes correspond and check in
accordance with the registered trouble codes
(determine the same one trouble code).

Troubleshooting
Flow

pins for deviation

Is status good?

Yes

harness side pin A and connecto
of sensor assembly are powered

Yes

still present?

No

Harness

Correct the co

assemble the connector

replace wiring

Sensor

Sensor Head

Yes

Page 18 of 38

Trouble Code C1 202(13) C1 205(23)

Replace sensor

Replace HECU

Is problem

Checking

Yes No

C1 208(33) C1 211(43)

Possible Case Air gap error:

Air gap too big or self short-circuit
of sensor (resistance value at 0) that
results no signal or the gear ring
not properly installed.

Troubleshooting

Flow

Table 2

Note: ①The air gap refers to the gap between
the gear ring and the sensor;
② If the malfunctions corresponding to more
than 2 trouble codes can be determined, after
the trouble codes are deleted (erasable trouble
codes), drive the vehicle to above 40km/h to
determine the malfunctions to that the trouble
codes correspond and check in accordance
with the registered trouble codes (determine
the same one trouble code).

still present?

complete

Page 19 of 38

Trouble Code C1 201(12) C1 204(22)

Replace sensor

Replace HECU

Yes No

C1 207(32) C1 210(42)

Possible Cause Interference of gear ring or sensor:

Occurred when installed with non­standard specification gear rings.

Troubleshooting

Flow

Table 3

Note: ① The sensor signal is not uniform
when the gears are adhered with engine oil
and the impurities such as slag;
② The air gap refers to the air gap between
the gear ring and the sensor;
③ If the malfunctions corresponding to more
than 2 trouble codes can be determined, after
the trouble codes are deleted (erasable trouble
codes), drive the vehicle to above 40km/h to
determine the malfunctions to that the trouble
codes correspond and check in accordance
with the registered trouble codes (determine
the same one trouble code).

Is problem

still present?

Checking complete

Page 20 of 38

Trouble

Yes Yes Yes Yes Yes Yes No No No No No No

Adjust connector pins

Correctly assemble

Replace HECU

Replace AC

Is below 9.4V?

Is above 17V?

Is status good?

Is status good?

Is between

Check and

Is below 1

Ω

?

Check and replace

Adjust s

tatus of

Measure the voltage

between battery terminal

(+) and (

-)

Remove harness side

connector and measure the

voltage between pin 4 (+) and

) and between pin 4(+) and

) when the entire vehicle

circuits are on.

Measure the re

sistance

between the harness side

connector pin 4(+) and

Confirm the assembling

status a nd pin displ acement

of harness side connector pin

Confirm and check

grounding status of harness

),

Measure the voltage between

) and

)

when the entire vehicle

circuits are on.

Re-check from

Code

Possible

Cause

C1 101(51) C1 102(52)

Abnormal battery voltage:
Occurred when the voltage is too high or too
low

8(­24(-

Table 4

Note: If the malfunctions corresponding to more
than 2 trouble codes can be determined, after the
trouble codes are deleted (erasable trouble codes),
drive the vehicle to above 40km/h to determine the
malfunctions to that the trouble codes correspond
and check in accordance with the registered
trouble codes (determine the same one trouble
code).

9.4V~17V?

4, 8, and 24

①

connectors

battery

battery (+) terminal

side connector pin 8 (­and 24 (+)

replace wiring

Troubleshooting Flow

grounding terminal

pin 4 (+) and 8(­between pin 4(+) and 24(-

item ①

generator

Page 21 of 38

Trouble Code C2 402(55)

(1) After the harness side

connector is removed, confirm

if the harness side pin 25 and

e

connected

Yes Yes Yes Yes Yes No No No No No Is status good?

Is status good?

Is it on?

Is it on?

Replace HECU

Is fuse (30A)

Confirm if the valve fuse

(30A) in the fuse box is

Re-check from item

①

Is forced drive good?

Forced drive the HECU with

diagnosis instrument ( valve rel ay and

Adjust the connector pins and

Confirm the assembling status and

pin displace ment of pin 25 of

Check a nd replace the wiring of

Check and replace

the wiring of harness

side pin 25.

Confirm if the harness side

pin 25 and the terminal in the

fuse box are connected

Possible Cause Malfunction of motor fuse/motor

Troubleshooting

Flow

the grounding wire ar

Table 5

Note: If the malfunctions corresponding to more
than 2 trouble codes can be determined, after the
trouble codes are deleted (erasable trouble codes),
drive the vehicle to above 40km/h to determine
the malfunctions to that the trouble codes
correspond and check in accordance with the
registered trouble codes (determine the same one
trouble code).

harness side pin 25

broken

normal?

harness side connector

motor start)

Check and replace the valve fuse

correctly assemble connector

Page 22 of 38

Trouble Code C2 112(54)

(1) After the h arness side

connector is removed, confirm

if the harness side pin 25 and

the grounding wire are

connected

Yes Yes Yes Yes Yes No No No No No Is status good?

Is it on?

Is it on?

Replace HECU

Is fuse (3

0A)

Confirm if the valve fuse

(30A) in the fuse box is

Re-check from item

①

Is forced drive good?

Forced drive the HECU with

diagnosis instrument (valve

Adjust the connector pins and

Confirm the assembling status and

pin displace ment of pin 25 of

Check and replace the valve

Check a nd replace the wiring of

Check and replace

the wiring of harness

side pin 25.

Confirm if the harness side

the

fuse box are connected

Possible Cause Malfunction of valve fuse and relay:

a) Broken of primary relay or fuse
b) Short-circuit of primary relay

Troubleshooting

Flow

pin 25 and the terminal in

broken

Table 6

Note: If the malfunctions corresponding to more
than 2 trouble codes can be determined, after the
trouble codes are deleted (erasable trouble codes),
drive the vehicle to above 40km/h to determine
the malfunctions to that the trouble codes
correspond and check in accordance with the
registered trouble codes (determine the same one
trouble code).

harness side pin 25

normal?

harness side connector

correctly assemble connector

relay and motor start)

fuse

Page 23 of 38

Trouble Code C1 604(53)

Yes No Replace HECU

Is i

t below 1

Ω

? Confirm and check the grounding

status between the harness side

) and 24(1)

Remove the harness side connector and measure

the resistance between t he harness side connector

ing wire and between the pin

Possible Cause Malfunction of ECU internal circuit

and valve coil

Troubleshooting

Flow

pin 8 ( -) and ground

24 (-) and grounding wire

Table 7

Note: If the malfunctions corresponding to
more than 2 trouble codes can be determined,
after the trouble codes are deleted (erasable
trouble codes), drive the vehicle to above
40km/h to determine the malfunctions to that
the trouble codes correspond and check in
accordance with the registered trouble codes
(determine the same one trouble code).

connector pin 8(­grounding terminal.

Page 24 of 38

control

No No No No No No Yes Yes Yes Yes Yes Yes Short-circuit?

Replace bulb

Check if warning lamp

of ABS

harness and grounding

wire are disconnected

Replace

Repair

Yes Is it normal?

Is it normal?

Does ABS

Is bulb

Replace fuse

Check and replace the

wiring of harness side

Check and replace

warning lamp drive

Check wa

rning lamp power

circuit and grounding

Check if the ABS

warning lamp bulb is

Is fuse normal?

Is socket normal?

Check fuse

socket of fuse

After the harness side connector

-

circuit between the harness side

pin 16 and warning lamp drive

Remove the harness side

connector and check the ABS

warning lamp when the entire

2.5 Trouble Checklist without Trouble Code

Trouble

Evidence

The ABS warning lamp doesn’t illuminate when the engine is started

Possible Cause ● Burn of fuse

● Open-circuit of power line

Troubleshooting

Flow

Check ABS warning

lamp fuse in fuse box

box

Table 1

● Burn of ABS warning lamp bulb

● Damage of ABS warning lamp

Repair fuse socket

warning lamp

illuminate?

is removed, check for short

component

damaged?

damaged?

power circuit

harness

pin 16

circuit connector

connector

component

Page 25 of 38

Yes Yes No No Replace HECU

Check and replace

ve

component

Check and replace

wiring of harness side

pin 16

After the harness side connector is

removed, confirm if it 's powered

t he harness side pin 16 and

Connect the harness side pin 16 to

n the entire

vehicle circuits are on.

I

s it powered?

Is warning lamp off?

Trouble
Evidence

The ABS warning lamp constantly illuminates after the vehicle start

Possible Cause ● Damage of ABS warning lamp control

● Open-circuit of ABS warning lamp control circuit

● ECU damage of ABS

Troubleshooting
Flow

between
warning lamp drive component.

Table 2

the grounding wire whe

warning lamp dri

Page 26 of 38

No No No No Yes Yes Yes Checking complete

Checking complete

Replace HECU or

connector

Replace sensor

Replace harness, connector or

HECU

Is problem

Is prob

lem

Is the sensor correctly

installed?

Re-install the sensor

Check if the ABS ECU

are normal

Trouble

Evidence

Abnormal functioning of ABS

Possible Cause ● Damage of sensor

● Improper installation of sensor

● Problem of sensor harness

● Impurity adherence on sensor

Troubleshooting

Flow

with correct method

still present?

Table 3

● Damage of gear ring

● Damage of wheel bearing

● HCU damage of ABS

● ECU damage of ABS

still present?

socket and connector

Page 27 of 38

No No No No Is it normal?

Yes Yes Yes Yes Is it normal?

Is it normal?

Re-conduct the air

discharge

Air discharge checking

Check handbrake regulator

Having leakage?

Ti

ghten pipe connector to

Trouble

Evidence

Brake pedal travel too long

Possible Cause ● Improper adjustment of handbrake

● Leakage of brake liquid

● Severe wearing of brake friction disc

● Leakage of normal close valve

● Air in the system

Troubleshooting

Flow

Check hydraulic pipe

connector for leakage

Check wearing of brake disc

Table 4

120~160kgf.cm

Replace brake disc

Replace handbrake regulator

Replace HECU

Page 28 of 38

No No No

Is it normal?

Yes Yes Yes Check and replace

Check and replace ABS

Check and replace

wiring of harness side

pin 7

Correctly install the

connector

Confirm the connection

between the diagnosis

or and

Is fuse (10A)

Confirm

if the ABS ECU

fuse (10A) in the fuse box

With

After the trouble number is

determined, take measures based

on the troubleshooting for

various tro

Correctly connect the harness

side connector and confirm

After the harness side conne ctor is

s powered

between the harness side pin 7 and

vehicle diagnosis

Trouble

Evidence

Without diagnosis code output (communication failure with trouble diagnosis
instrument)

Possible Cause ● Problem of diagnosis instrument

● Burn of fuse

● Broken of diagnosis line or loosening of connector

● ECU damage of ABS

Troubleshooting

Flow

instrument connect
vehicle diagnosis connector

removed, confirm if it’

connector pin 7

Is it powered?

Table 5

No

is burnt?

normal?

the communications.

communications?

ECU fuse

diagnosis instrument

Yes

uble numbers.

Page 29 of 38

IV. Air Discharge and Oil Refill

Normal

On

On

On

On

1. Regular Operation Procedure

Add brake fluid

Off

Vacuum

Off

Motor

Off

Close Valve

Off

Procedures

The regular operation procedure of air discharge and oil refill is shown in the figure, of which:

A : Move the vacuum device and brake oil refill device;
B : Start after connected with vacuum and brake oil refill device and SDL;
C : Drive normal close electromagnetic valve and apply the 1st vacuum;
D : Excessive leakage test;
E : Minor leakage test after the 1st vacuum cut-off;
F : Applicable for 2nd vacuum and drive motor;
G : After the oil refill and maintaining of pressurization on the brake oil, relieve the brake oil pressure, stop
the normal close electromagnetic valve and motor, and adjust the brake oil level;
H : Disconnect the vacuum device and brake liquid refiller;
I : Screw on the oil reservoir lid/disconnect the SDL;
J : Transfer to next step.

2. Checking Device

① The vacuum supplied to the oil reservoir should be as lower as possible, provided that the oil gun must

supply at least below 1mm Hg vacuum.

② Confirm if the air discharge screw portion of the rear wheel hydraulic device (drum brake or brake

caliper) forms the vacuum within the specified period. (It should be below 5~10mm Hg after connected
with vacuum for 20~25s).

③ Confirm if the working voltage supplied to the HECU is at specified 10~12V.

④ Confirm the circulation time (C/T). Confirm the working time setting of the electromagnetic valve

meets with the specified value.

C/T< 90: Run the electromagnetic valve continually;
 ≤C/T≥180: Start the electromagnetic valve for 2s and stop the electromagnetic valve for 2s.

continually repeat above cycles;

C/T>180: The total running period setting of the electromagnetic valve is below 90s.

3. Notices for Air Discharge and Oil Refill

Page 30 of 38

① During the refilling of brake oil, if the refilling pressure is not maintained for certain period or
above, the oil level within the oil reservoir will lower at the finish of the refilling. Therefore, it’s
required to refill more brake oil or maintain the refilling pressure for certain period.

② The time period marked in the regular operations refers to the general circulation period.

③The inside of after-service HECU is at moisture status, therefore, it may not conduct the air
discharge mode operation (see succeeding item 5⑥ for the definition of air discharge mode) but
directly conduct the air discharge operation on all wheels (However, in order to meet with the

performance and pedal comfort, it’s preferable to conduct the air discharge mode operation).

④ During the air discharge mode operation, the voltage supplied to HECU is preferably at

10~12V. However, during the use of checking devices, it will be OK to use the vehicle amounted
battery. (The repeated air discharge mode operation with high voltage may damage the coil of ECU
components).

4. Determination Method for Vehicles with Air Discharge Trouble

Differentiation

Category

ECU functioning or

not

Case 1 Normal functioning O.K O.K

Case 2 Normal functioning O.K N.G

Case 3 Normal functioning N.G N.G

Case 4 Not functioning O.K O.K

Case 5 Not functioning O.K N.G

Case 6 Not functioning N.G N.G

Leakage test

Excessive

leakage

Minor

leakage

Note

Normal functioning, no separate
repetition required
Abnormal functioning, separate
repetition required
Abnormal functioning, separate
repetition required
Abnormal functioning, separate
repetition required
Abnormal functioning, separate
repetition required
Abnormal functioning, separate
repetition required

Case 1 : The status at finish of normal functioning.
Case 2 : The status that the connection of brake (HECU hole portion/brake pipe/brake

hose) is poor and therefore needs rework.

Case 3 : The status same with Case 2, but it may cause the status incapable of

repetition when the leakage is really severe.

Case 4 : Internal circuit air discharge trouble of HECU. It's the status necessary for

repetition as the ABS may cause the sponge phenomenon after functioning for one time.

Case 5 : The comprehensive trouble of Case 2 and Case 4. The status necessary for

repetition.
Case 6: The status similar to Case 5, but it may cause the status incapable of repetition
when the leakage is really severe.

5. Measures in Event of Troubles during Air Discharge and Oil Refill (for internal dry
status of brake system)

① Implementation of trouble determination. It’s required to determine the connection portions of

all components from the general pump to the wheel branch pump: HECU hole portion, connection
portion of brake pipe, connection portion of brake hose, brake caliper and the air discharge screw
portion of brake, and etc.

② After the determination of the trouble, re-assemble in accordance with the provisions in order

to avoid the further occurrence of leakage.

③ Connect the repetition device to the 25-pin connector of the ECU or connect the checking

device to the line K (pin 7). Use the specific wiring to connect to the connectors. During the
connection to line K (pin 7), make the vehicle at power on or start status. The oil reservoir of the
general pump is connected with the device for continual supply of brake oil or it’s required that the
oil reservoir should have enough oil during the supply of brake oil.

Page 31 of 38

④. Check the HECU with repetition device or checking device and determine the existence of
trouble code. If with trouble code, firstly conduct the operation for deletion of the trouble code (if
the trouble in above item ① is not determined, it’s necessary to determine the existence of
trouble code). When the trouble code can’t be deleted, operate with reference to the Trouble
Checklist of Trouble Code in section 2.4 (In case of trouble of HU, motor and ECU, the air
discharge and oil refill can’t be conducted at the inside of the HECU).

⑤ After the brake pedal is depressed, open the air discharge screw attached onto the wheel brake

caliper or drum brake to discharge the air. Conduct this operation on all wheels, till that the brake
oil discharged from the air discharge screw is free of air and the brake pedal is properly rigid. Refer
to the operation in item ⑩ in using the repetition device capable of vacuum formation and
refilling of brake liquid.

⑥Conduct the air discharge mode by means of the repetition device or the checking device. If
there has no reaction force when the brake pedal is depressed, then repeat the operation of pedal
depressing and pedal releasing, till the air discharge mode is completed (air discharge mode: repeat
the start in 2s interval, stop the normal close valve of HECU for 1min, and continually drive the
motor. The repeated operation of pedal depressing and pedal releasing is conducted within the
period of normal close electromagnetic valve and motor drive).

⑦ The operation in item (air discharge) should be repeated for all wheels. ⑤

⑧ Measure the brake pedal travel. If not meet with the provisions, repeat the operations in item
⑥ (air discharge mode) and item ⑤ (air discharge). If the brake pedal travel doesn't meet with

the provisions after the air discharge mode and air discharge are repeated for above 10 times,
replace with after-service HECU (wet type) and then repeat the operations from the beginning.

⑨ Connect the repetition device and checking device to the HECU and again determine the

existence of trouble code. If with trouble code, delete the trouble code and then disconnect the
repetition device or checking device.

⑩ During the use of other repetition devices (the equipment capable of vacuum formation and

liquid refilling), the implementation method is as follows:

Conduct in accordance with the contents in above item ①～④;
When the vacuum pump is sufficiently driving for approximate 60s, the inside of brake

system will form the vacuum status.

Start the operation of air discharge mode in above item ⑥ 10s before the vacuum cut-off.
Without the repeated operations of pedal depressing and pedal releasing.

Conduct the brake liquid refilling operation (above 7bar/100Psi) for above 20s at the same

time of vacuum cut-off.

Complete the brake liquid refill and air discharge mode.
Conduct the operation based on the contents in above item ⑧～⑨.

6. Measures in Event of Trouble during Checking and ABS Functioning Test (for internal
wet status of brake system)

① Connect the repetition device or checking device. The following conditions must be

guaranteed:

Use the specific wiring while connecting to the 25-pin connector of ECU.
The vehicle should be at power on status or start status while connecting to line K (pin

7).

The oil reservoir of the general pump is connected with the device for continual supply

of brake oil or it’s required that the oil reservoir should have enough oil during the
supply of brake liquid.

Page 32 of 38

② Check the HECU with repetition device or checking device and determine if it has trouble

code.

If with trouble code, firstly conduct the operation to delete the trouble code.
If the trouble code can’t be deleted, implement with reference to section 2.4 “trouble

checklist of trouble code” (If the HU, motor or ECU has trouble, the inside of HECU
can’t conduct the air discharge and oil refill).

③ After the brake pedal is depressed, open the air discharge screw attached on the wheel brake

caliper or drum brake to discharge the internal air. It's required to conduct this operation on all
wheels, till that the brake oil discharged from the air discharge screw is free of air and the brake
pedal is properly rigid.

④ Conduct the air discharge mode by means of the repetition device or the checking device. If

there has no reaction force when the brake pedal is depressed, then repeat the operation of pedal
depressing and pedal releasing, till the air discharge mode is completed

⑤ The operation in item (air discharge) should be repeated for all wheels. ③

⑥ Measure the brake pedal travel. If not meet with the provisions, repeat the operations in item
④ (air discharge mode) and item ③ (air discharge). If the brake pedal travel doesn't meet with the
provisions after the air discharge mode and air discharge are repeated for above 10 times, replace
with after-service HECU (wet type) and then repeat the operations from the beginning.

⑦ Connect the repetition device and checking device to the HECU and again determine the

existence of trouble code. If with trouble code, delete the trouble code and then disconnect the
repetition device or checking device.

Page 33 of 38

Annex I Malfunction Cases and Incorrect Repair Cases

1. HECU Incorrect Repair Cases

① HECU replacement relating to ABS functioning noise

The HECU replacement case that deemed the noise of electromagnetic valve and motor as the
malfunction during the functioning of the ABS.

During the functioning of ABS, the noise generated during the relieving or enhancing

of the braking pressure on various wheels is of normal functioning status. The noise
level will vary depending on the braking pressure applied on various wheels, other than
the product malfunction. Therefore, we should persuade the customers to understand
that.

When the vehicle reaches 10km/h speed at the first time after vehicle start, the sensitive

customers may hear the noise at the time when the ECU diagnoses the motor drive,
which is also the normal functioning of the ABS.

② HECU replacement relating to EBD functioning noise

The HECU replacement case that deemed the clattering noise of rear wheels that other than
the ABS functioning noise during the braking as the malfunction.

The ABS is also equipped with EBD function, which will effect the relieving of

braking pressure on the rear wheels when the rear wheels are locked ahead of the front
wheels. T he noise generated during the above mentioned process is of normal
functioning status.

③ HECU replacement relating to braking off-tracking

HECU replacement case due to the vehicle braking off-tracking towards one side during the
braking.

ABS is the braking assisted device that functioning in such manner that the ECU will

calculate the speed of various wheels in order to maintain the best braking force and
control stability during the braking. In the event of malfunction of the HECU, the ECU
will illuminate the warning lamp by means of the diagnosis. Therefore, in the event of
braking off-tracking without the illumination of ABS warning lamp, it’s necessary to
check other braking hydraulic devices.

In the event of incorrect assembling of the braking hose, the braking off-tracking may

occur during the functioning of the ABS.

④ Replacement case that the ABS is functioning during barking at low speed (below 40km/h)

HECU and sensor replacement case that the ABS is always functioning during the braking at
low speed.

During the braking at low speed, the ABS may also function depending on the road

conditions and braking pressure. If the ABS is always functioning at each time, it’s
necessary to check if the sensor air gap of various wheels is too large, if it has
interference with the gear ring, and if the tooth shape of the gear ring is damaged.

Air gap adjustment method. For the improper air gap, after the determination of the

parts related to the problem, replace or grind the installation surface (junction portion)
of the sensor to the specified air gap; in the event of interference, place the thin gasket
onto the sensor installation surface so as to adjust to the specified air gap.

2. Incorrect Repair Cases for Wheel Speed Sensor

① Open-circuit and short-circuit related to sensor

The sensor replacement case without product checking when the ABS warning lamp is
illuminated and the trouble code of the vehicle is determined.

The ABS trouble code is prepared based on the ABS products. Therefore, during the

open-circuit or short-circuit of the sensor, it’s necessary to conduct the problem
checking, such as confirm the connection status from the ECU to the wiring and
connectors of the sensor, measure the sensor resistance, and etc. During the
malfunction checking of sensor, it’s preferable to use the tetrastyle jack, which will
facilitate the confirmation of short-circuit problems such as the pinned wiring.

Page 34 of 38

The union status of the sensor must be checked before the removal of the connectors

of connecting wiring (such as incomplete union, pin displacement, with impurity, and
etc.)After confirm that the sensor resistance and head are free of abnormalities,
centrally check the wiring and connectors.



② Notices for sensor checking

Case of sensor head line break arisen from over-pulling of sensor cable.

When the connectors are removed during the checking of sensor, the instantaneous

pulling of cable under the condition that the sensor head is fixed will cause the falloff
of the internal cable of the sensor head to cause line break problem. Therefore, during
the checking of sensor, do not pull the cable with the force above the specified one.

Sensor head cable: It may be damaged when applied with above 12kgf tension force;

Cable at connectors: it may be damaged when applied with above 4.5kgf tension force.

Page 35 of 38

Annex II ABS Basics

Will the braking distance be shortened when equipped with ABS?

The testing data show that the braking distance will be shortened on most road

conditions (approximately 5%~20%). However, under some special road conditions
(such as snowy road, non-asphalt road and rough road), the braking distance will be
lengthened. However, the steering stability can be guaranteed.

What’s the main objective of ABS?

The main objective of ABS is to prevent the wheels to be locked, which has following

effects:

① Maintain the vehicle stability on roads during the braking
② Capable of controlling the vehicle driving direction during braking in order to avoid the

occurrence of the collision.
③ Maintain the best braking pressure, disregarding the driving skills of the driver.

Why is the ABS warming lamp illuminated?

After the driver starts the vehicle, the warning lamp will be off when the automatic

diagnosis of ABS ECU shows no trouble. If the warning lamp is illuminated during
driving or the warning lamp is always on, it indicates the trouble of ABS. Please drive
your vehicle to the designated service station for checking of ABS as soon as possible.
However, when the warning lamp is illuminated that indicates the ABS trouble, the
brake system still has the basic braking capability.

Will there be free of accident when equipped with ABS?

ABS is the one device capable of increasing the driving safety, rather than the device

used to avoid the accidents arising from the driving mistake or variation of traffic
conditions. Therefore, insist on the safe driving all along rather than the excessive
reliance on the ABS.

The vehicle will lean to one side during braking on the one-side-slippery road, is this
phenomenon caused by ABS?

This phenomenon is resulted from the different friction coefficients between the left

and right wheels on the roads. Under such condition, the ABS will exert the special
effects on the stability of the vehicle body. However, even under such condition, make
sure to operate the steering wheel with car in order to avoid the occurrence of accidents.

The vehicle will present the slippery phenomenon before braking during the turning on the
slippery road, will the ABS function effectively when the brake pedal is depressed at that time?

The ABS will function effectively to provide certain help depending on the vehicle

speed. However, under most conditions, the outward cornering force is really big due
to the vehicle inertia and therefore the body correction will have limit even the ABS is
functioning.

Generally, the tires will be applied with two kinds of forces during cornering: One is

the force required by driving and braking; another is the force required for vehicle
steering and stability maintaining. In fact, the driving, braking and steering of the
vehicle are completed though the coordination of above two forces and the two forces
are in reverse ratio. Therefore, during the braking at cornering, the braking force will
be increased and the force required for steering and stability maintaining will be
reduced. The vehicles equipped with ABS will best coordinate these two forces. For the
vehicles without the ABS, the steering performance and the stability are really weak as
these two forces are not in good coordination.

However, under the condition that the above two forces are really small (such as: off-

tracking due to excessive speed during the vehicle skid), the force for body correction
is reall y small. Therefore, the ABS will not exert the effects. In conclusion,
deceleration in advance and safe cornering is the best method.

Page 36 of 38

Normal

Normal

F

ront

High pressure

Low-Pressure

F

ront

Rear

Rear

P

ower

supply

2

P

ower

supply

1

Grounding

wire

Grounding

Annex III ABS Internal hydraulic Flow Diagram

accumulator

Open Valve

Close Valve

right

left

Pump

Accumulator

Annex IV Connector Pin Layout of MGH-25 ABS ECU

right

K line

Ignition

left

wire

Page 37 of 38

Grounding wire

Motor pump

Motor

Motor

Ignition switch

to the status when the key is rotated

Grounding wire

Rear right wheel sensor

Rear left wheel sensor

Front right wheel sensor

Front left wheel sensor

Harness side

connector

(Front view)

cathode

Motor anode

Motor module

anode

Valve anode

anode

Warning lamp

Brake lamp

Wheel speed output

Trouble

diagnosis

instrument

Brake switch

Drive circuit

Ignition switch 1

Battery

Note: “Ignition switch 1” refers

to power on the vehicle but not to start the engine.

Page 38 of 38

Maintenance Manual of Chery A113

(Body Accessories & Dimensions)

After Sales Service Department of Chery Automobile Sales Co., Ltd



CONTENT

Chapter I Front Hood & Trunk ............................................................................................................. 6

I. Removal and Installation of Front Hood ................................................................................... 6

1. Preparations ...................................................................................................................... 6

2. Notes................................................................................................................................. 6

3. Removal and Installation of Front Hood Accessories....................................................... 6

3.1. Removal Steps........................................................................................................... 6

3.2. Installation Steps ....................................................................................................... 6

4. Removal & Adjustment of of Front Hood Assembly........................................................ 7

5. Removal and Installation of Air Inlet Grid Assembly ...................................................... 7

5.1. Removal Steps........................................................................................................... 7

5.2. Installation Steps ....................................................................................................... 7

6. Removal of Front Hood Lock........................................................................................... 8

6.1. Removal Steps........................................................................................................... 8

6.2. Installation Steps ....................................................................................................... 8

7. Removal & Adjustment of of Hood Cable........................................................................ 8

7.1. Removal & Adjustment Steps8 ................................................................................. 8

7.2. Installation Steps ....................................................................................................... 9

II. Removal and Installation of Rear Trunk Cover ....................................................................... 9

1. Preparations ...................................................................................................................... 9

2. Removal of Rear Decoration Plate ................................................................................... 9

3. Removal and Installation of Trunk Lock ........................................................................ 10

3.1. Removal Steps......................................................................................................... 10

3.2. Installation Steps ..................................................................................................... 11

4. Removal of Trunk Lock Cylinder................................................................................... 11

4.1. Removal Steps......................................................................................................... 11

4.2. Installation Steps ..................................................................................................... 11

5. Removal of Rear Wiper Nozzle ...................................................................................... 12

5.1. Removal Steps......................................................................................................... 12

5.2. Installation Steps ..................................................................................................... 13

6. Removal of Rear Wiper Motor ....................................................................................... 13

6.1. Removal Steps......................................................................................................... 13

6.2. Installation Steps ..................................................................................................... 14

Chapter II Removal and Installation of Trims .................................................................................... 15

I. Removal and Installation of Seat Belts ................................................................................... 15

1. Preparations .................................................................................................................... 15

2. Notes............................................................................................................................... 15

3. Removal Steps (Take Driver’s Seat belt as an Example)................................................ 15

4. Installation Steps............................................................................................................. 17

II. Removal and Installation of Seats.......................................................................................... 17

1. Removal of Front Seats .................................................................................................. 17

2. Removal of Rear Seats ................................................................................................... 18

3. Installation Steps............................................................................................................. 19

III. Removal and Installation of Auxiliary Instrument Panel...................................................... 19

1. Removal Steps ................................................................................................................ 19

2. Installation Steps............................................................................................................. 22

IV. Removal and Installation of Vehicle Carpet.......................................................................... 22

1. Removal Steps ................................................................................................................ 22

2. Installation Steps............................................................................................................. 24

V. Removal of Damping Mat...................................................................................................... 24

1. Removal Steps ................................................................................................................ 24

2. Installation Steps............................................................................................................. 25

Chapter III Removal & Maintenance of Vehicle Doors...................................................................... 26

I. Removal, Installation & Maintenance of Front Doors ............................................................ 26

1. System Constitution Diagram......................................................................................... 26

2. Preparations .................................................................................................................... 26

3. Notes............................................................................................................................... 27

4. Removal Steps ................................................................................................................ 27

5. Installation Steps............................................................................................................. 31

II. Removal & Installation of Rear Doors .................................................................................. 32

1. System Constitution Diagram......................................................................................... 32

2. Preparations .................................................................................................................... 32

3. Notes............................................................................................................................... 33

4. Removal Steps ................................................................................................................ 33

5. Installation Steps............................................................................................................. 36

Chapter IV Removal, Installation & Maintenance of Front/Rear Bumper ......................................... 37

I. Removal, Installation & Maintenance of Front Bumper ......................................................... 37

1. Preparations .................................................................................................................... 37

2. Notes............................................................................................................................... 37

3. Removal Steps ................................................................................................................ 37

4. Installation Steps............................................................................................................. 39

II. Removal, Installation & Maintenance of Rear Bumper ......................................................... 39

1. Preparations .................................................................................................................... 39

2. Notes............................................................................................................................... 39

3. Removal Steps ................................................................................................................ 39

4. Installation Steps............................................................................................................. 40

Chapter V Removal and Installation of Headlights Fog Lights & Tail Lights ................................... 41

1. Preparations ............................................................................................................................ 41

2. Notes....................................................................................................................................... 41

3. Removal Steps of Headlights.................................................................................................. 41

3.1. First open the front hood. .................................................................................................... 41

4. Removal of Front Fog Lights ................................................................................................. 44

5. Removal of Tail Lights ........................................................................................................... 45

6. Removal of License Plate Lights............................................................................................ 46

7. Installation & Adjustment of Headlights ................................................................................ 47

8. Installation & Adjustment of Front Fog Lights ...................................................................... 48

9. Installation of Tail Lights........................................................................................................ 48

Chapter VI Removal and Installation of Vehicle Ceiling ................................................................... 49

1. Preparations ............................................................................................................................ 49

2. Notes....................................................................................................................................... 49

3. Removal and Installation of Sun Visor ................................................................................... 49

3.1. Removal Steps ............................................................................................................. 49

3.2. Installation Steps.......................................................................................................... 49

4. Removal and Installation of Vehicle-top Armrest................................................................... 50

4.1. Removal Steps ............................................................................................................. 50

4.2. Installation Steps.......................................................................................................... 50

5. Removal and Installation of Front Ceiling light ..................................................................... 51

5.1. Removal Steps ............................................................................................................. 51

5.2. Installation Steps.......................................................................................................... 51

6. Removal and Installation of Reverse Radar Display.............................................................. 52

6.1. Removal Steps ............................................................................................................. 52

6.2. Installation Steps.......................................................................................................... 52

7. Removal and Installation of A-pillar Shield ........................................................................... 52

7.1. Removal Steps ............................................................................................................. 52

7.2. Installation Steps.......................................................................................................... 53

8. Removal and Installation of B-pillar Shield ........................................................................... 53

8.1. Removal Steps ............................................................................................................. 53

8.2. Installation Steps.......................................................................................................... 53

9. Removal and Installation of C-pillar Shield ........................................................................... 54

9.1. Removal Steps ............................................................................................................. 54

9.2. Installation Steps.......................................................................................................... 54

10. Removal and Installation of Vehicle Ceiling ........................................................................ 55

10.1. Removal Steps ........................................................................................................... 55

10.2. Installation Steps........................................................................................................ 56

Chapter VII Removal and Installation of Instrument Panel & Instrument Panel crossbeam.............. 57

I. Removal of Instrument Panel .................................................................................................. 57

1. Removal Steps ................................................................................................................ 57

2. Installation Steps............................................................................................................. 66

3. Methods for Clearing Instrument Maintenance Indicator............................................... 66

II. Removal of Instrument Panel crossbeam............................................................................... 66

1. Removal Steps ................................................................................................................ 66

2. Installation Steps............................................................................................................. 68

Chapter VIII Air Conditioning System............................................................................................... 69

I. System Constitution ................................................................................................................ 69

II. Removal of Evaporator Assembly ......................................................................................... 69

1. Preparations .................................................................................................................... 69

2. Removal and Installation Steps....................................................................................... 69

3. Installation of Evaporator Assembly .............................................................................. 72

4. Removal and Installation of Interior Evaporator ............................................................ 72

1. Replacement of Blower.............................................................................................. 72

2. Removal and Installation of Blower Speed Regulation Module ................................ 74

3. Removal and Installation of Heater Exchanger.......................................................... 74

4. Removal and Installation of Mode Throttle Related Mechanism .............................. 76

5. Removal and Installation of Blend Throttle Related Mechanism .............................. 77

6. Removal and Installation of Int./Ext. Throttle Motor & Related Mechanism............ 78

7. Removal and Installation of Evaporator..................................................................... 79

III. Trouble Shooting .................................................................................................................. 80

Chapter IX Body Dimension .............................................................................................................. 82

I. Basic Instructions on BIW Maintenance ................................................................................. 82

1. Vehicle Door Structure ................................................................................................... 83

2. Door panel Maintenance Process.................................................................................... 83

3. Main Contents of Door Panel Maintenance.................................................................... 84

4. Basic Methods for Door Panel Maintenance .................................................................. 85

4.1. Reconditioning of Dents ......................................................................................... 85

4.2. Restoration of Stretched Parts ................................................................................. 87

4.3. Restoration of Cutting & Patching.......................................................................... 88

4.4. Restoration of Wrinkled Parts ................................................................................. 89

4.5. Welding of Four Doors and Two Covers................................................................. 89

II. Vehicle Body Assembly Dimensions ..................................................................................... 90

1. Front View...................................................................................................................... 90

2. Left-front View ............................................................................................................... 94

3. Back View..................................................................................................................... 103

III. Engine Compartment Dimensions ...................................................................................... 107

IV. Various Opening Dimensions ............................................................................................. 108

V. Windscreen Dimensions....................................................................................................... 108

Chapter X Harness......................................................................................................................... 109

Section I Battery Negative Harness.......................................................................................... 109

I. Harness Sketch .............................................................................................................. 109

II. Instructions on Main Connectors ................................................................................. 109

III. Removal and Installation of Battery Harness ............................................................. 110

(I). Preparations............................................................................................................ 110

(II). Notes ..................................................................................................................... 110

(III). Removal Steps ..................................................................................................... 110

Section II Front Compartment Harness .................................................................................... 111

I. Harness Sketch .............................................................................................................. 111

II. Instructions on Main Connectors ................................................................................. 112

III. Removal and Installation of Front Compartment Harness.......................................... 113

(I). Preparations............................................................................................................ 113

(II). Notes ..................................................................................................................... 113

(III). Removal Steps ..................................................................................................... 113

Section III Removal and Installation of Electronic Fuel Injection Harness ............................. 120

I. Harness Sketch .............................................................................................................. 120

II. Instructions on Harness Connectors............................................................................. 121

III. Removal and Installation of Harness .......................................................................... 123

1. Removal Steps.......................................................................................................... 123

2. Installation of Harness ............................................................................................. 128

Section IV In-door harness: .................................................................................................... 129

I. Harness Sketch .............................................................................................................. 129

II. Instructions on Main Connectors ................................................................................. 130

III. Removal and Installation of In-door harness.............................................................. 131

(I). Preparations............................................................................................................ 131

(II). Notes ..................................................................................................................... 131

(III). Removal Steps ..................................................................................................... 131

Section V Removal and Installation of Instrument Panel Harness ........................................... 141

I. Harness sketch............................................................................................................... 141

II. Instructions on Main Connectors ................................................................................. 142

III. Removal and Installation Instrument Panel Harness .................................................. 151

(I). Preparation of Tools ............................................................................................... 151

(II). Notes ..................................................................................................................... 151

(III). Removal and Installation of instrument panel Harness ....................................... 151

Section VI Left-front Door Harness ......................................................................................... 154

I. Harness Sketch .............................................................................................................. 154

II. Instructions on Main Connectors ................................................................................. 155

III. Removal and Installation of Left-Front Door In-door harness ................................... 155

(I). Preparations............................................................................................................ 155

(II). Notes ..................................................................................................................... 155

(III). Removal Steps ..................................................................................................... 155

Section VII Right-front Door Harness...................................................................................... 158

I. Harness Sketch .............................................................................................................. 158

II. Instructions on Main Connectors ................................................................................. 159

III. Removal and Installation of Right-front Door In-door harness .................................. 159

Section VIII Rear Door Harness............................................................................................... 160

I. Harness Sketch .............................................................................................................. 160

II. Instructions on Main Connectors ................................................................................. 161

III. Removal and Installation of Right-rear Door In-door harness ................................... 161

(I). Preparations............................................................................................................ 161

(II). Notes ..................................................................................................................... 161

(III). Removal Steps ..................................................................................................... 161

Section IX Tail Door Harness ................................................................................................... 163

I. Harness Sketch .............................................................................................................. 163

II. Instructions on Main Connectors ................................................................................. 164

III. Removal and Installation of Tail Door In-door harness.............................................. 164

(I). Preparations............................................................................................................ 164

(II). Notes ..................................................................................................................... 164

(III). Removal and Installation Steps ........................................................................... 164

Section X Defroster Harness .................................................................................................... 167

I. Harness Sketch .............................................................................................................. 167

II. Instructions on Main Connectors ................................................................................. 168

III. Removal and Installation of Rear Defroster Harness ................................................. 168

(I). Preparations............................................................................................................ 168

(II). Notes ..................................................................................................................... 168

(III). Removal Steps ..................................................................................................... 168

(IV) Installation Steps .................................................................................................. 169

Chapter I Front Hood & Trunk

I. Removal and Installation of Front Hood

1. Preparations

Tools: Flat head/cross head screwdriver, socket wrench, snipe nose
pliers

2. Notes

2.1. During removal and installation, be particularly careful to apply
proper strength and no abrupt or violent operation is allowed.

2.2. During removal and installation of the trims, be particularly
careful to avoid surface scratch of them.

3. Removal and Installation of Front Hood Accessories

3.1. Removal Steps

3.1.1. Pull off the detergent
hose.

3.1.2. Press down the water nozzle clip from under the front hood,
and then push it up while removing the noozle outward.

3.2. Installation Steps

The installation steps are reverse to those for removal.

4. Removal & Adjustment of of Front Hood Assembly

Preparation of Tools: 13# sleeve, wheel wrench and extension bar

4.1. Turn and remove the four adjusting bolts off the front hood, and
then the front hood can be taken down. And the positing of the front
hood can be adjusted in all directions by loosening the four
adjusting bolts.

4.2. Installation of Front Hood Assembly:
The installation steps are reverse to those for removal.
Installation torque is 29±3Nm

5. Removal and Installation of Air Inlet Grid Assembly

5.1. Removal Steps

5.1.1. Use the wrench to remove the four fastening screws on the Air
Inlet Grid assembly as shown in the picture.

5.1.2. Remove the Air Inlet Grid.

5.2. Installation Steps

The installation steps are reverse to those for removal.
Installation torque is 5±0.5Nm

6. Removal of Front Hood Lock

6.1. Removal Steps

6.1.1. Turn and remove two screws off the front hood to take down
its lock.

6.1.2. Remove the front hood lock cable off the front hood lock
assembly.

6.2. Installation Steps

The installation steps are reverse to those for removal.

7. Removal & Adjustment of of Hood Cable

7.1. Removal & Adjustment of Steps

7.1.1. Remove the plastic nut behind the front hood handle in
driver’s cab.And you can also regulate the cable by adjusting this
nut.

7.1.2. Use snipe nose pliers to remove the front hood cable off the
pull cover.

7.1.3. Drag out the cable.

7.2. Installation Steps

The installation steps are reverse to those for removal.

II. Removal of Rear Trunk Cover

1. Preparations

Tools: flat head screwdriver, 13# sleeve, wrench and cross head
screwdriver
Material(s): Clip

2. Removal of Rear Decoration Plate

2.1. Pry up the rear decoration plate with a flat head screwdriver
before you take it apart.

2.2. Installation of Rear Decoration Plate
The installation steps are reverse to those for removal.

3. Removal and Installation of Trunk Lock

3.1. Removal Steps

3.1.1. Remove the pull rod off the upper lock.

3.1.2. Pull off the connector on top of the upper lock.

3.1.3. Use a cross head screwdriver to remove the three screws on
the upper lock.

3.1.4. Remove the trunk lock.

3.2. Installation Steps

The installation steps are reverse to those for removal.
Installation notes: Is the lock column deformed? Is the riveting
adequate? Is the lock jacket on the trunk in good condition? Or can
the lock tongue open and shut freely?

. Removal of Trunk Lock Cylinder

4

4.1. Removal Steps

4.1.1. Disengage the hitch bar from the lock core.

4.1.2. Pry open the clip on the lock core with a flat head screwdriver.

4.1.3. Push up the lock core to take it out.
Note: Do not throw away the washer of the lock core.

4.2. Installation Steps

The installation steps are reverse to those for removal.
Pay attention to assemble it to its correct position and joint to door
plate work.

5. Removal of Rear Wiper Nozzle

5.1. Removal Steps

5.1.1. Pry open the shield of the high mount ceiling light with a flat
head screwdriver.

5.1.2. Pull off the connector, and then use a cross head screwdriver
to remove the two screws on the high mount ceiling light and take it
down.

5.1.3. Remove the two nuts on the spoiler with 10# sleeve.

5.1.4. Remove the spoiler.

5.1.5. Pull off the rear water nozzle (You can pry with a flat head
screwdriver, but try to avoid any paint scratch), and then pull off the
water nozzle hose.

5.2. Installation Steps

The installation steps are reverse to those for removal.
Note: Water injection opening should be opposite to wiper motor
steering shaft.

6. Removal of Rear Wiper Motor

6.1. Removal Steps

6.1.1. Remove the rear wiper shield by hand.

6.1.2. Use a 10# sleeve wrench to loosen off the nut above the
motor, and remove the rear wiper blade.
Installation torque is 12±2Nm

6.1.3. Remove the three fixing bolts on the rear wiper motor.
Installation torque is 12±2Nm

6.1.4. Remove the motor.

6.2. Installation Steps

The installation steps are reverse to those for removal.

Chapter II Removal of Trims

I. Removal and Installation of Seat belts

1. Preparations

Tools: flat head screwdriver, wrench, sleeve wrench
Spare parts: disposable clip

2. Notes

Keep the seat belts clean and free of oil, and check them for any
damage.

3. Removal Steps (Take Driver’s Seat belt as an Example)

3.1. Carefully pry up the front sill plate with a flat head screwdriver.

3.2. Remove the front door weather strip by hand.

3.3. Remove the B-pillar plate with a flat head screwdriver.

3.4. Remove the decorative covers at the upper and lower ends of
the seat belt with a flat head screwdriver.

3.5. Use a 17# wrench to loosen the upper and lower fastening nuts
before you remove the seat belt.
Installation Torque: 50±5Nm

3.6. Pull off the seat belt warning light connector by hand.

3.7. Use a cross head screwdriver to remove the pre-tension belt
assembly.

4. Installation Steps

The installation steps are reverse to those for removal.
Note:

4.1. Keep the seat belt clean and free of oil, and check it for any
damage.

4.2. The pillar shield should fit securely with the vehicle body
without any looseness, and it should also fit well with the vehicle
ceiling and weather strip s.

4.3. The seat belt adjusting slide baffle of the upper B-pillar shield
should be able to move freely and won’t affect the adjustment of the
seat belt, and its fitting clearance with the lower shield should be
consistent and less than 1mm;

4.4. The fitting clearance between the lower B-pillar shield and the
front/rear sill plate should be consistent and less than 1mm;

II. Removal and Installation of Seats

Preparation of Tools: sleeve wrench

1. Removal of Front Seats

1.1. Move the seat by pulling at the movable handle below it, and
when the fixing bolts are shown, use a 13# socket wrench to remove
the bolts in the seat.
Torque: 25±3Nm

1.2. Pull off the seat connector and raise the seat.

2. Removal of Rear Seats

2.1. Use a 13# socket wrench to remove the fixing bolts in the rear
seat cushion.
Torque: 25±3Nm

2.2. There are two rear seat cushions, a left one and a right one,
secured by four bolts respectively.
Torque: 25±3Nm

2.3. The cushion can be dismounted when the four fixing bolts are
removed.

2.4. Pull up the pull button in the rear seat and the seat back can be
released forward (Take the left-rear seat as an example).

2.5. Use a 13# socket wrench to loosen off the two fixing bolts
below the seat back (Take the left-rear seat as an example).
Torque: 25±3Nm

2.6. Open the trunk and take out the trunk vehicle carpet.

2.7. Loosen off the fixing seat of the spare tire and take it out.

2.8. Use a 13# socket wrench to loosen off the fixing bolts in the
rear seat back, and then the rear seat back can be removed.
Torque: 25±3Nm

3. Installation Steps

The installation steps are reverse to those for removal.

III. Removal and Installation of auxiliary
Instrument Panel

Preparation of Tools: cross head screwdriver, flat head screwdriver

1. Removal Steps

1.1. Use a flat head screwdriver to pry open the shield at the hand
brake and gears.

2.6. Open the trunk and take out the trunk vehiclepet.

2.7. Loosen off the fixing seat of the spare tire and take it out.

2.8. Use a 13# socket wrench to loosen off the fixing bolts in the
rear seat back, and then the rear seat back can be removed.
Torque: 25±3Nm

3. Installation Steps

The installation steps are reverse to those for removal.

III. Removal of auxiliary Instrument Panel

Preparation of Tools: cross head screwdriver, flat head screwdriver

1. Removal Steps

1.1. Use a flat head screwdriver to pry open the shield at the hand
brake and gears.

1.2. Use a cross head screwdriver to loosen off the fixing screws of
the shield

1.3. Use a flat head screwdriver to pry open the shield at the hand
brake and gears.
Note: Please pry carefully.

1.4. Use a cross head screwdriver to remove the two fixing screws
below the shield.

1.5. Take out the gear selector shield upward by hand (The shield
and the auxiliary Instrument Panel are fixed with clips and no fixing
screws are used).

1.6. Use a cross head screwdriver to remove the front fixing screws
of the auxiliary Instrument Panel (One on the left and the other one
the right).

1.7. Use a cross head screwdriver to remove the rear fixing screws
of the auxiliary Instrument Panel (One on the left and the other one
the right), and then the suxiliary Instrument Panel can be
dismounted.

2. Installation Steps

The installation steps are reverse to those for removal.

IV. Removal and Installation of Vehicle Carpet

Tools: flat head screwdriver, cross head screwdriver; sleeve wrench

1. Removal Steps

1.1. Dismount the seats. (See Removal of Seat)

1.2. Disassemble the auxiliary Instrument Panel (See Removal of
auxiliary Instrument Panel)

1.3. Remove the seat belt shield. (See Removal of Seat belt)

1.4. Remove the front/rear sill plates, B pillar and the lower shield.

1.5. Use a flat head screwdriver to pry up the top cover of footrest
plate.

1.6. Use a 10# wrench to remove the footrest plate covers
Installation Torque: 7±1N.m

1.7. Remove the rear seat cushion (See Removal of Seats)
Use a cross head screwdriver to remove the left shield of the rear
seat cushion.

1.8. Take down the vehicle vehicle carpet by hand.

2. Installation Steps

2.1. Put the vehicle vehicle carpet inside the vehicle, and take out
the harness connected with the seats, and then press the vehicle
vehicle carpet besideds the middle passage tightly.

2.2. Keep the seat holes visible.

2.3. Spread the vehicle vehicle carpet till it gets to the footrest plate
and press it tightly.

2.4. Spread the left-rear part of the vehicle vehicle carpet according
to the shape of the vehicle floor, keep the installation holes of the
left-rear seats visible, and spread and press the rear part of the
vehicle vehicle carpet according to the shape of the vehicle floor.

V. Removal of Damping Mat

1. Removal Steps

1.1. Remove the vehicle vehicle carpet (See Removal of Vehicle
Vehicle carpet).

1.2. Take down each damping mat.

2. Installation Steps

2.1. The installation steps are reverse to those for removal.

2.2. Notes: When installing, sort out the harness, and at the same
time the damping mat should fit well with the vehicle body plate
work.

Chapter III Removal & Maintenance of Vehicle Doors

I. Removal, Installation & Maintenance of Front Doors

1. System Constitution Diagram

2. Preparations

Tools: flat head screwdriver, cross head screwdriver, 10#, 13# sleeve, wrench and pliers.

3. Notes

3.1. Please wear necessary labour protection supplies to avoid any
accident.

3.2. Disconnect the battery to avoid damaging the eletrical
equipment.

3.3 Use the correct method to disassemble and assemble the glass to
avoid damage.

4. Removal Steps

4.1. Remove the left-front vehicle door weather strip. The fixing clip
of the vehicle door weather strip are “-” shaped, and when
disassembling it, press the weather strip downward, and then push
the weather strip to one side till you can see part of the clip. And go
on to push it to the opposite direction to show another part of it.
Don’t pull the weather strip vertically so as not to damage the
weather strip.

4.2. Use a flat head screwdriver to pr y up the plastic decorative
block fixing the rearview mirror outside the vehicle door.

4.3. Use a 10# sleeve wrench to loosen off the two screws fixing the
outside rearview mirror.

4.4. Pull off the electrically-adjustable outside rearview mirror
harness connector and take off the outside rearview mirror assembly.

4.5. Use a cross head screwdriver to loosen off the four screws that
fix the shield inside the door.

4.6. Use a cross head screwdriver to loosen off the screw that fixes
the handle inside the vehicle door.

4.7. Use a flat head screwdriver to pry off the plastic cover of the
screw hole for the handle inside the vehicle door, and then remove
the fixing screw with a cross head screwdriver so as to disassemble
the lock assembly inside the door.

4.8. Pull of the vehicle alarm connector.

4.9. Remove the shield inside the door.

4.10. Pull off the power window up-down switch connector.

4.11. Use a cross head screwdriver to loosen off the two screws of
the front door handle fixing mount.

4.11. Tear off the anti-water plastic sheeting on the left-front door.

4.12. Connect the battery and plug in the window up-down switch
plug, lower the window glass to a proper position and loosen off the
two screws that fix the glass.

4.13. Take out the glass carefully.

4.14. Use a 10# sleeve to loosen off the five screws that fix the
window glass up-down regulator.

4.15. Loosen off the screws, and then pull off the window glass
up-down motor connector to take out the window glass up-down
regulator assembly.

4.16. Use a 10# sleeve wrench to loosen off the two fixing screws
and remove the lock outside the door.

4.17. Use a cross head screwdriver to loosen off the three screws
fixing the lock core and remove it.

4.18. Use a 13# sleeve wrench to loosen off the four fixing screws at
the hinge that fixes the vehicle door, and then the vehicle door can
be disassembled.

5. Installation Steps

The installation steps are reverse to those for removal.
Note: The removal steps for the right-front door are the same as
those for the left-front door.

II. Removal & Installation of Rear Doors

1. System Constitution Diagram

2. Preparations

Tools: flat head screwdriver, cross head screwdriver, and 10# / 13# sleeve, wrench.

3. Notes

3.1. Please wear necessary labor protection supplies to avoid
accidents.

3.2. Disconnect the battery so as to avoid damaging the eletrical
equipment.

3.3. Take correct steps during removal and installation of glass to
avoid any damage.

4. Removal Steps

4.1. Disassemble the right-rear door weather strip. The fixing clip of
the vehicle door weather strip are “-” shaped, and when
disassembling it, press the weather strip downward, and then push
the weather strip to one side till you can see part of the clip. And go
on to push it to the opposite direction till another corner of it is
exposed. Don’t pull the weather strip vertically so as not to damage
the weather strip.

4.2. Use a cross head screwdriver to loosen off the four screws that
fix the shield inside the door.

4.3. Use a flat head screwdriver to pry off the plastic cover of the
screws that fix the handle inside the vehicle door.

4.4. Use a cross head screwdriver to loosen off the screws that
secure the handle inside the door, and then disassemble it.

4.5. Use a cross head screwdriver to loosen off the screws that
secure the handle inside the vehicle door, and then disassemble the
handle inside the door.

4.6. Disassemble the shield inside the door by hand.

4.7. Pull off the power window up-down switch connector.

4.8. Use a cross head screwdriver to remove the two fixing screws in
the mount that fixes the rear door handle cover.

4.9. Tear off the anti-water plastic sheeting on the rear door.

4.10. Connect the battery, lower the window glass to a proper
position and loosen off the two screws that fix the glass, and then
carefully diassemble the glass.

4.11. Use a 10# wrench to loosen off the five screws that fix the
window up-down regulator and remove it.

4.12. Use a 10# sleeve wrench to loosen off the screw that fix the
handle outside the rear door and then remove it.

4.13. Use a cross head screwdriver to loosen off the three screws
that fix the rear door lock core and then remove it.

4.14. Use a 13# sleeve wrench to loosen off the four screws (at the
hinge) that fix the right-rear vehicle door and then remove it.

5. Installation Steps

The installation steps are reverse to those for removal.
Note: Removal of the left-rear door is similar to that of the right-rear
door.

Chapter IV Removal, Installation & Maintenance of Front/Rear

Bumper

I. Removal, Installation & Maintenance of
Front Bumper

1. Preparations

Tools: 8# wrench, 8#sleeve, cross head screwdriver, flat head
screwdriver
Spare parts: disposable clips

2. Notes

2.1. Please wear necessary labor protection supplies to avoid
accidents.

2.2. Try to avoid scratching the painted surface of the bumper during
the removal operation.

2.3. For removal in colder environment, operate gently to avoid
damaging the bumper.

3. Removal Steps

(Take the left side as an example)

3.1 Open the Front Hood.

3.2 Remove the headlights. (See Removal and Installation of
Headlights)

3.3 Use a cross head screwdriver to loosen off the four screws on the
grid fence.

3.4. Use a 8# sleeve wrench to loosen off the two bolts on the
bumper and the left wing sheet.
Torque: 11N·m

3.5. Use a cross head screwdriver to loosen off the 7 screws on the
bumper and the front compartment member.

3.6. Use a 8# sleeve wrench and a cross head screwdriver to loosen
off the screws and fixing screws below the mud fender and the
bumper.
Installation Torque: 2±0.5 Nm

3.7 Raise the vehicle with a hoister.

3.8. Use a cross head screwdriver and 8#sleeve to loosen off the
fixing bolts and the screws below the mud fenderand the bumper.
Installation Torque: 2±0.5N.m

3.9. Pull off the fog lights connector.

3.10. Remove the bumper.

4. Installation Steps

The installation steps are reverse to those for removal.

II. Removal, Installation & Maintenance of
Rear Bumper

1. Preparations

Tools: cross head screwdriver, flat head screwdriver, No.8 sleeve.
Spare parts: disposable clips.

2. Notes

2.1. Please wear necessary labor protection supplies to avoid
accidents.

2.2. Try to avoid scratching the painted surface of the bumper when
removing it.

2.3. When removing the bumper in colder environment, operate
gently to avoid damaging it.

3. Removal Steps

3.1 Disassemble the tail lights. (See Removal and Installation of Tail
Lights)

3.2. Open the trunk cover, and use a cross head screwdriver to
loosen off the four fixing clips on the rear bumper.

3.3. Use a cross head screwdriver to loosen off the three clips fixing
the rear bumper bottom and the vehicle body.
Note: Raise the vehicle with a hoister.

3.4 Use an 8# torque wrench to loosen the screws connecting the
wing sheet and the bumper.
Note: Two fixing screws on either side.

3.5 Pull off the connector of the rear license plate lights.

松

3.6 Disassemble the connector of the reverse radar and remove the
rear bumper assembly.

3.7 Unplug the reverse radar.

3.8 Use a cross head screwdriver to loosen the clip seat of the
reverse radar.

紧

4. Installation Steps

The installation steps are reverse to those for removal.

Chapter V Removal and Installation of Headlights, Fog Lights & Tail Lights

1. Preparations

Tools: 10# open-ended wrench, cross head screwdriver.

2. Notes

2.1. Please wear necessary labour protection supplies to avoid any
accidents.

2.2. Try to avoid scratching the painted surface of the bumper when
removing it.

2.3. When removing the bumper in colder environment, operate
gently to avoid cracking it.

2.4. When disassembling the headlights, violent operation may
damage their clips on the bumper, so operate properly.

2.5 Pay attention not to scratch the headlight surface when
disassembling and placing it.

3. Removal Steps of Headlights

3.1. First open the front hood.

3.2. Use a 10# open-ended wrench to loosen off the three fixing
screws of the right headlights on the front compartment member.

3.3. Hold the headlight with both hands and apply a forward force to
loosen off the right headlights.

3.4. Unplug the right headlights harness to take out the right
headlights assembly.

3.5. Turn open the the high beam headlight holder shield by hand.

3.6. Press down the bulb fixing clip by hand and turn the clip over to
take out the bulb.

3.7. Unplug the right-front position light harness to take out the
bump.

3.8. Turn open the low beam light holder shield by hand.

3.9. Unplug the low beam light harness.

3.10. Press down the bulb fixing clip by hand and turn the clip over
to take out the bulb.

3.11. Turn the right-front turning light shield counterclockwise to
disassemble the bulb.
(See the above steps for removal of the left headlight)

4. Removal of Front Fog Lights

4.1. Diassemble the bumper assembly. (Refer to removal of bumper)

4.2. Unplug the right-front fog lights harness connector.

4.3. Use a cross head screwdriver to loosen off the three screws that
fix the front fog light, and then disassemble the right-front fog light
assembly

4.4. Turn the right-front fog light holder and remove the bulb.
(See the above steps for removal of left-front fog lights)

5. Removal of Tail Lights

5.1. Open the rear door.

5.2. Use a cross head screwdriver to loosen off the screws fixing the
left tail light.

5.3. Remove the left tail light, unplug the left tail light harness
connector, and then disassemble the left tail light assembly.

5.4. Use a cross head screwdriver to loosen off the four screws that
fix the tail light holder and open it.

5.5. Turn the bulb counterclockwise by hand and then the bulb can
be removed.

6. Removal of License Plate Lights

6.1. Use a flat head screwdriver to pry off the license plate light.

6.2. Unplug the harness plug to disassemble the license plate light.

7. Installation & Adjustment of Headlights

1

7.1. Installation Steps for the Headlights
The installation steps of headlights are reverse to those for removal.

7.2. Functions of Headlights

7.2.1. Front view
See right figure:
1 High beam light
2 Position light
3 Low beam light
4 Turn light

7.2.2. Back view
1 High beam light holder
2 High beam adjusting nut
3 Low beam light holder
4 Low beam adjusting nut
5 High beam, low beam, position and turning light plugs
6 Turning light holder

8.3. Adjustment of Headlights

8.3.1 Pay attention to law and regulations and verify the following
items before adjustment:

1). The tire air pressure should comply with the related
standard;

2). Vehicle is unloaded (except for spare tire and equiping
tools, and include driver’s weight for sedan);

3). The vehicle should be parked on level and smooth road or
field;

4). The matched mirror surface of the headlight should be fresh
of dirt;

5). The power supply should work normally and the bulb
should be properly installed.

8.3.2. Insert a cross head screwdriver into related adjusting hole to
adjust the light.

4

4

3

2

2

3

4

5

6

8. Installation & Adjustment of Front Fog

4 1 2

3

Lights

8.1. The installation of front light
The installation steps of front fog light are reverse to those for
removal.

8.2. The adjustment of the front fog lights
The front fog lights can be adjusted b y turning the device with your
hand or a cross head screwdriver.

9. Installation of Tail Lights

9.1. Installation steps of the tail lights
The installation steps of tail lights are reverse to those for removal.

9.2. The functions of the tail lights

9.2.1. Front view
See right figure:

1). Left-rear turning light (21w)

2). Brake light (21w)

3). Position light (5-21w)

4). Rear Fog Light (21w)

See right figure:

1). Right-rear turning light (21w)

2). Brake light (21w)

3). Position light (5-21w)

4). Reverse indicator (21w)

1

2

3

Chapter VI Removal and Installtion of Vehicle Ceiling

1. Preparations

Tools: sleeve wrench, cross head screwdriver, flat head screwdriver

2. Notes

2.1. During the removal and installtion, make sure to apply proper
force and no violent operation is allowed.

2.2. During removal and installation of the inner decoration parts,
make sure to protect the decoration parts from being scratched.

3. Removal and Installation of Sun Visor

3.1. Removal Steps

3.1.1. Use a cross head screwdriver to loosen off the screws in the
sun visor on the left of the driver’s cab, and disassemble the sun
visor.
As shown in the figure:
Torque: 3±1Nm

3.1.2. The removal steps for the right sun visor are reverse to those
for removal of the left one.

3.2. Installation Steps

The installation steps are reverse to those for removal.

4. Removal and Installation of Vehicle-top
Armrest

4.1. Removal Steps

4.1.1. Open the ceiling armrest screw cover over the co-driver’s seat
by hand, and then use a cross head screwdriver to loosen off the left
and right fixing screws.
As shown in the figure:
Torque: 9±3Nm

4.1.2. Remove the ceiling armrest.

4.1.3. The removal of other ceiling armrests can follow the above
steps.

4.2. Installation Steps

The installation steps are reverse to those for removal.

5. Removal and Installation of Front Ceiling
light

5.1. Removal Steps

5.1.1. Align a flat head screwdriver with the groove along the ceiling
light edge to pry it open, as shown in the figure:
Note: Do not scratch part surface.

5.1.2. Remove the three fixing screws of the the front ceiling light.
Torque: 1.5±0.5Nm

5.1.3. Unplug the harness and disassemble the front ceiling light
assembly.

5.2. Installation Steps

The installation steps are reverse to those for removal.

6． Removal and Installation of Reverse Radar
Display

6.1. Removal Steps

6.1.1. Use a cross head screwdriver to loosen off the screws of the
reverse radar display.

6.1.2. Unplug the harness and remove the reverse radar display.

6.2. Installation Steps

The installation steps are reverse to those for removal.

7. Removal and Installation of A-pillar Shield

7.1. Removal Steps

7.1.1. Use a flat head screwdriver to pry open the weather strip of
the left A-pillar shield, and then take out the left A-pillar shield by
hand.

7.1.2. Take out the left A-pillar shield.

7.1.3. Follow the the removal steps of the right A-pillar shield for
that of the left one.

7.2. Installation Steps

The installation steps are reverse to those for removal.

8. Removal and Installation of B-pillar Shield

8.1. Removal Steps

8.1.1. Disassemble the shield below the left B-pillar (See Removal
and Installation of Seat belt).

8.1.2. Use a flat head screwdriver to pry open the B-pillar shield.
Note: protect the trim part surface from scratching.

8.1.3. Follow the removal steps of the left B-pillar shield for
removal of the right B-pillar shield.

8.2. Installation Steps

The installation steps are reverse to those for removal.

9. Removal and Installation of C-pillar Shield

9.1. Removal Steps

9.1.1. Use a sleeve wrench to loosen off the seat belt bolts (See
Removal and Installation of Rear Seats & Seat belts).

9.1.2. Use a flat head screwdriver to pry open the C-pillar upper
shield.

9.1.3. Remove the C-pillar upper shield.

9.1.4. Please follow the removal steps of left C-pillar upper shield
for that of the right C-pillar upper shield.

9.2. Installation Steps

The installation steps are reverse to those for removal.

10. Removal and Installation of Vehicle Ceiling

10.1. Removal Steps

10.1.1. Disassembling the left/right front sun visors. (See Removal
and Installation of Sun Visor)

10.1.2. Disaasembling the front ceiling light. (Refer to removal and
installation of front ceiling light)

10.1.3. Disassembling all interior ceiling armrests. (See removal and
installation of ceiling armrest)

10.1.4. Disassembling A/B/C-pillar shield. (See removal and
installation of A/B/C-Pillar Shield)

10.1.5. Use a flat head screwdriver to loosen off the vehicle ceiling
clip (4 in all).

10.1.6. Disassemble the four doors’ weather strip by hand.

10.1.7. Open the trunk and disassemble the vehicle ceiling.

10.2. Installation Steps

The installation steps are reverse to those for removal.

Chapter VII Removal and Installation of Instrument Panel &

Instrument Panel Crossbeam

I. Removal of Instrument Panel

Tools: 8 #sleeve, extension bar, 飞扳[MS1], cross head screwdriver,
flat head screwdriver, etc.

1. Removal Steps

1.1. Open the storage box over the console, and use a cross head
screwdriver to loosen off the two screws. Then use a flat head
screwdriver to pry open the storage box. See the right figure:

1.2. Use a cross head screwdriver to loosen off the two screws than
connect the emergency switch with the Instrument Panel, as shown
in the figure:

1.3. Pull out the top part b y hand, and then use a flat head
screwdriver to pr y open the lower part. Unplug the harness when
removing it, as shown in the figure:

1.4. Use a flat head screwdriver to pry open the control panel of the
airconditioner switch and take it out.

1.5. Use a cross head screwdriver to loosen off the four screws that
connect the airconditioner switch and the Instrument Panel.

1.6. When taking the airconditioner switch, unplug the two harness
plugs behind it and disassemble the two cables behind the switch.

1.7. Use a 8# sleeve wrench to loosen off the four fixing bolts that
connect the audio system with the Instrument Panel.

1.8. When taking out the audio system, unplug the antenna and
harness.

1.9. Use a cross head screwdriver to loosen off the two screws that
connect the cup-holder and the Instrument Panel, and then take out
the cup-holder.

1.10. Disassemble the auxiliary Instrument Panel (See Chapter I
Removal, Installation & Adjustment of of the Brake System).

1.11. Use a cross head screwdriver to pry open the decoration sheet
on the ash tray and take it out.

1.12. Use a cross head screwdriver to loosen off the four screws that
connect the cigarette lighter with the Instrument Panel, and unplug
the harness when removing the lighter.

1.13. Use a cross head screwdriver to loosen off the three screws
that connects the ashtray with the Instrument Panel and take out the
ashtray.

Note: When disassembling the console, the operations should be
carried out from top to bottom, and you should disassemble the
air-conditioner switch before disassembling the audio system.

1.14. Disassemble the steering wheel, combination switches and
ignition switch.

1.15. Use a cross head screwdriver to loosen off the two screws on
the instrument panel shield and the Instrument Panel, and then pull it
out with both hands.

1.16. Use a cross head screwdriver to loosen off the four screws on
the instrument panel and the Instrument Panel.

1.17. Use a flat head screwdriver to pry up the red clip and the
instrument panel harness plug can be taken out before the instrument
panel is taken out.