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1 Vehicle overview
1
1 Vehicle overview........................................1
1.1 Warning and precaution ....................... 3
1.1.1 Description and operation..................3
1.1.1 Warning and precaution ........................ 3
1.2 Vehicle inspection................................. 13
1.2.1 Description and operation................13
1.2.1.1 When drive vehicle, first shall be
check items................................................... 13
1.2.1.2 Items to be checked during each oil
filling............................................................ 13
1.2.1.3 Check items one time every months at
least .............................................................. 14
1.2.1.4 Check items two times every year at
least .............................................................. 14
1.2.1.5 Check items at least once a year ...... 14
1.3 Lifting vehicle.......................................16
1.3.1 Description and operation................16
1.3.1.1 Lifting vehicle.................................. 16
1.4 Maintenance ......................................... 18
1.4.1 Specifications..................................... 18
1.4.1.1 Oil and fluid capacity....................... 18
1.4.1.2 Recommended oil lubricating oil..... 18
1.4.2 Description and operation................18
1.4.2.1 Fluid maintenance schedule............. 18
1.4.2.2 Periodic maintenance schedule under
the general condition.................................... 19
1.4.2.3 Regular maintenance schedule under
harsh driving condition ................................ 20
1.6 Health and safety..................................26
1.6.1 Description and operation................26
1.6.1.1 Specification.....................................26
1.6.1.2 Acids and bases ................................ 26
1.6.1.3 Airbag............................................... 26
1.6.1.4 A/C refrigerant .................................27
1.6.1.5 Adhesives and sealant ......................28
1.6.1.6 Engine coolant.................................. 31
1.6.1.7 Asbestos ...........................................31
1.6.1.8 Battery acid fluid..............................31
1.6.1.9 Brake fluid........................................ 31
1.6.1.10 Chemical materials.........................32
1.6.1.11 Dust ................................................32
1.6.1.12 Electric shock ................................. 32
1.6.1.13 Gas.................................................. 33
1.6.1.14 Isolation fiber .................................33
1.6.1.15 Fire .................................................33
1.6.1.16 Emergency treatment...................... 33
1.6.1.17 Foam- polyurethane........................34
1.6.1.18 Fuel................................................. 34
1.6.1.19 Gas cylinder....................................34
1.6.1.20 Generate workshop tool and
equipment.....................................................35
1.6.1.21 Lubrication and grease ...................35
1.6.1.22 Noise...............................................36
1.7 Standards and measurement...............37
1.4.2.4 Periodic maintenance schedule under
the general condition ................................... 20
1.4.2.5Periodic maintenance description ..... 22
1.4.2.6 Tire rotation descripition.................. 23
1.5 Maintenance information system........25
1.5.1 Description and operation................25
1.5.1.1 Usage specification of arrow and
symbol in the manual................................... 25
1.7.1 Description and operation................37
1.7.1.1 English system/metric unit converter37
1.8 Complete vehicle specification.............39
1.8.1 Specifications .....................................39
1.8.1.1 Complete vehicle size.......................39
1.8.1.2 Fastener specifications .....................40
1.9 Vehicle identification number.............64
1.9.1 Description and operation................64
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1.9.1.1 Vehicle Identification....................... 64
2
1.10.1.2 Maintenance guidance....................76
1.9.1.2 Vehicle identification (VIN)
specification ................................................. 65
1.9.1.3 Lable—vehicle certificate ................ 70
1.9.1.4 Tire message billboard..................... 71
1.9.1.5 Engine mark No.and position........... 71
1.9.1.6 Identification numberand position of
manual transmission..................................... 72
1.10 Noise, vibration and abnormal sound74
1.10.1 Description and operation..............74
1.10.1.1 Diagnostic information and
procedures.................................................... 74
1.11 Water Leakage....................................78
1.11.1 Description and operation ..............78
1.11.1.1 Diagnostic information and
procedures ....................................................78
1.11.1.2 Maintenance guidance....................79
1.12 Special tool list....................................80
1.12.1 Special tools and equipment...........80
1.12.1.1 Special tool for powertrain ............. 80
1.12.1.2 Special tool of chassis and body.....85
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1.1 Warning and precaution
1.1.1 Description and operation
1.1.1 Warning and precaution
Definition relating to "Warnings", "Important precaution" and "Notes
Diagnosis and maintenance procedure in this manual include general and specific "Warnings",
"Important precaution " and " Notes". Geely takes efforts to provide maintenance information to
help after-sales technicians diagnose and repair the system and ensure the vehicle can run
normally. But some procedures may present danger to technicians if they do not perform
operations following the recommended methods.“Warning”, “Important precaution” and “Notes”
are to prevent the occurrence of such danger. Not all risks are foreseeable. They are at apparent
position s in the maintenance manual. This information is prepared to prevent the following cases:
– Severe personal injury
– Vehicle damage
– Unnecessary vehicle repair
– Unnecessary replacement of components
– Improper maintenance or components replacement
Definition of "Warning
A "Warning" means a procedure that must be taken or a prohibited procedure. If a "warning" is
ignored, it may have the following consequences:
– Severe personal injury
– If a vehicle is not properly repaired, it may cause severe personal injury to the driver and / or
passengers.
Definition of “Important precaution”
“Important precaution” requires paying special attention to a procedure which must be taken or a
prohibited procedure. If an “Important precaution” is ignored, it may have the following
consequences:
– Vehicle damage
– Unnecessary vehicle repair
– Unnecessary replacement of components
– Improper operation of the repaired systems or components and abnormal performance
– Damage to related systems or components
– Damaged to fasteners, tools or special tools
– Engine coolant, lubricating oil or other main fluid leakage
"Notes" definition
"Notes" the statement stressed necessity of diagnosis or maintenance procedure, "Notes"
Statement object as follow:
– Clarify the procedures
– Provide additional information for completing a procedure
– Clarify the recommended procedures for operational reasons
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– Provide information help for technicians to complete the repair in more effective way
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– Provided empirical information with technician to complete easily process
Warning for lifting vehicle
To avoid any vehicle damage, serious personal injury or death when major components are
dismantled from the vehicle and the vehicle is supported by a hoist, support with jack the
components standing at the opposite end from which the components are being dismantled of the
vehicle.
Warning for ABS system component handling
Warning: Certain components in the anti-lock brake system (ABS) are not intended to be serviced
individually. Attempting to dismantle or disconnect certain system components may result in
personal injury and/or improper system operation. Only those components with approved removal
and installation procedures should be serviced.
Warning for approved equipment for collision repair
Warning: To avoid personal injury because exposed to welding flashes or to galvanized (Zinc
Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound,
you must work in a properly ventilated area, wearing an approved respirator, protective goggles,
earplugs, welding gloves, and protective clothing.
Warning for assistant driving
Warning: An assistant should drive the vehicle while the technician inspects the position of the
reported condition. Otherwise, personal injury could occur.
Warning for battery disconnection
Warning: unless directed otherwise in the operating procedures, the ignition key must be at the
OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical
component. Disconnect the negative battery cable if a tool or any equipment easily comes in
contact with an exposed electrical terminal. Failure to follow these precautions may result in
personal injury and/or damage to the vehicle or its components.
Warning: Before maintaining airbag, the battery negative shall be disconnected for 90 seconds at
least.
Warning of brake dust
Warning: When repairing the wheel brake part, please avoid the following operations:
– Do not polish brake friction lining
– Do not polish brake friction lining by abrasive paper
– Do not clean wheel brake part by dry brush or compressed air
Warning : some model or after-sale retrofitting brake part may has fiber, fiber mix in the dust,
some dust with fiber was breathed to cause badly bodily injury, please clean any dust on the brake
part by wet cloth.
Warning for brake fluid
Warn: The brake fluid is extremely easy to absorb humidity and moisture. Do not use the brake
fluid that may be polluted by water in open container, because the use of improper or
contaminated brake fluid may lead to system failure, losing control of the vehicle and personal
injury.
Warning for brake fluid irritation
The brake fluid has irritation to skin and eyes. If contact, you shall adopted measures as follow:
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– Eye contact - completely wash with clean water.
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– Skin contact – use soap water or clean water to wash.
Warn for brake pipe replacement
Warning: carefully route and retain the brake pipes replacement. Always use the correct fasteners.
Otherwise, it may cause damage to the brake pipes and brake system resulting in personal injury.
Warning for suction R134a
Warning: To avoid inbreathing A/C coolant 134a (R134a) and lubrication oil steam or mist,
touching them can irritate eyes, nose and throat. It should work in area with favorable ventilation.
Qualified maintenance equipment (R134a recycling equipment) that meets the requirements of
SAEJ2210 should be adopted when R134a is discharged from air conditioner system. If the
system discharges accidentally, ventilate the work area prior to continuing to repair. Other
information related to health and safety can be obtained from the coolant and lubrication oil
manufacturers.
Warning of brake dust
When servicing clutch components, do not create dust by grinding or sanding the clutch disc or by
cleaning parts with a dry brush or with compressed air. A water-dampened cloth (NOT SOAKED)
-should be used. Clutch disc may contain fiber, which can be mixed into air if dust is produced
during maintenanc; Inbreathing dust containing fiber can damage your health severely.
Warning for collision section
Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if
the vehicle is in a collision.
Warning for window crack
If part of glass for vehicle window is cracked but still intact, crisscross the glass for vehicle
window with masking tape in order to reduce the risk of damage or personal injury.
Warning: Warning for exhaust maintenance
Warning: In order to avoid scalding, please do not repair exhaust system when it is hot.。
Please perform maintenance after the exha
Warning for window lifting function
Operate the power window switch when working inside the driver door. When operated, the Quick
Lifting function allows the window to move very quickly without stopping, which could cause
personal injury.
Warning for eye protection
Warning: Please wear permissive eye protective glasses and gloves to minimize health risk when
executing this procedure.
Warnings for acoustic insulation foam material
Warning: when fire is to be used during vehicle maintenance, acoustic insulation foam material
within range of 152.4mm (6 in) from the fire must be cleared. To avoid inbreathing dust when
repacking the acoustic insulation foam material, otherwise it will be harmful to your health.
Warnings for fuel oil and evaporation drain pipe
Warning: In order to minimize fire and health risk, please abide by the follows:
– Replace all fuel pipes that are nicked, scratched or damaged during installation, do not
attempt to repair the fuel pipes.
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– Do not hammer directly on the clips of fuel harness body when installing new fuel pipes.
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– When using welding gun to conduct operation near fuel steam pipe, it is necessary to use wet
cloth to cover the fuel steam pipe. In addition, neither start the vehicle and expose it under
the temperature of above 115℃ (239 °F) for more than 1h, nor stay a long time under the
temperature of above 90℃ (194 °F).
- Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel
pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During
normal operation, the O-rings located in the female connector will swell and may prevent
proper reconnection if not lubricated.)
Warning for fuel gauge leakage
Warning: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire
and personal injury. The towel will absorb any fuel leakage that occurs during the connection of
the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel
pressure gauge is complete.
Warning for fuel pipe connector
Warning: Always apply a few drops of clean engine oil to the male pipe ends before connecting
the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper
reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the
female connector will swell and may prevent proper reconnection if not lubricated.
Warning for fuelstorage
Warning: Do not drain the fuel into an open container, never store the fuel in an open container
due to the possibility of a fire or an explosion.
Warning for fuel vapor in the evaporative emission components
Warning: Do not breathe the air through the EVAP or hoses. The fuel vapors inside the EVAP
may cause personal injury.
Warning for gasoline/gasoline vapors
Warning: Gasoline and gasoline vapor is highly flammable. In order to avoid fire or explosion,
please select to keep away from a fire. Never drain or store gasoline or diesel fuel in an open
container, due to the possibility of fire or explosion. Have a dry chemical fire extinguisher
prepared nearby.
Warning for glass and sheet metal handling
Warning: When handling any glass or metal plate with sharp edges or burrs, please wear
permissive safety goggles and gloves to reduce the personal injury risk.
Warning for halogen bulb
Warning: Halogen bulbs contain gas under high pressure. Handling a bulb improperly could cause
it to shatter into flying glass fragments. To help avoid personal injury:
– Turn off the lamp switch and allow the bulb to cool before replacing the bulb.
– Leave the lamp switch OFF until the bulb replacement is complete.
– Always wear protective goggles when replacing a halogen bulb.
– Handle the bulb only by its base. Avoid touching the glass.
– Keep dirt and moisture off the bulb.
– Properly dispose of the used bulb.
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– Keep halogen bulbs out of the reach of children.
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Warning for injector O-ring dismantle
Warning: inspect the lower (small) O-seal ring of various oil sprayers, which can not be retained
on the lower manifold branch to reduce the fire and personal injury risk.
Warning: If the O-ring is not dismantled with the injector, the replacement injector with new
O-rings will not seat properly in the injector socket. Improper seating could cause a fuel leakage.
Warning for moving component and hot surface
Warning: Avoid contacting with moving components and hot surfaces while working around a
running engine in order to prevent personal injury.
Warning for protective goggle and glove
Warning: Approved protective goggles and gloves should be worn when removing the exhaust
system components, or else the sharp edge or the iron rust dropped down from the exhaust system
components may cause serious personal injury.
Warning for fluid reservoir cover
Warning: To avoid being burned, do not remove the fluid reservoir cover while the engine is hot.
If the reservoir cap is dismantled when the engine and the radiator are still hot, the cooling system
will drainscalding high-pressure fluid and steam.
Warning for cooling system maintenance
Warning: provided that there is pressure in the cooling system, the solution temperature is higher
more than the boiling temperature even if the solution in the radiator is not boiling. If pressure cap
is removed while the engine is still hot and under pressure during maintenance, the engine coolant
will boil immediately and spray into the operator's body, causing serious burns.
Warning ofr drain fuel pressure
Warning: Remove the fuel tank cap and drain the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you drain the fuel system pressure, a
small amount of fuel may drain when servicing the fuel circuit, the fuel injector, or the
connections. In order to reduce personal injury
Harmful risk: wrap the fuel system component with a rag prior to disconnection. This will catch
any fuel that may leak out. Place the towel in an approved container when the disconnection is
complete.
Warning for road test
Warning: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not
attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these
precautions could lead to serious personal injury and vehicle damage.
Warning for safety goggles and fuel
Warning: be sure to wear the safety goggles when processing the fuel in order to avoid the fuel
from splashing into the eyes.
Warning for airbag system
Warning: this vehicle is equipped with the SRS system; the following conditions may be caused if
not following the correct operation procedure:
– Airbag unfold
– Preloader blister
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– Injured person
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– Unnecessary airbag system maintenance
Warning: comply with the following criteria in order to avoid the above situations:
– Refer to airbag system component views in order to determine if you are performing service
on or near the airbag system components or the airbag system wiring.
– If you are doing the repair on the airbag system components, surrounding components or the
circuits, remove the airbag system.
Warning for high temeprature of deployed airbag module
Warning: After deployment, the metal surfaces of the airbag system component may be very hot.
To help avoid a fire or personal injury:
– Allow sufficient time for cooling before touching any metal surface of the airbag system
component.
– Do not place the deployed airbag system component near any flammable objects.
Warning for airbag system clock spring
Warning: Improper installation of the clock spring assembly may damage the spiral coil inside the
clock spring. This may result in a malfunction of the coil which may make the airbag module do
not work normally and cause personal injury.
Warning for airbag system module disposal
Warning: In order to prevent accidental deployment of the safety system and avoid the risk of
personal injury, do not dispose of an unexpanded airbag module as normal shop waste.
Unexpanded airbag modules contain substances that could cause severe illness or personal injury
if their sealed containers are damaged during disposal. Use the following deployment procedures
to safely dispose of an unexpanded airbag module.
Warning for taking and storing airbag system module
Warning: When carrying an unexpanded airbag module:
– Do not carry the airbag module by the wires or connector.
– Make sure the airbag opening do not point towards you and others.
Warning: when storing unexpanded airbag module, ensure the opening does not face the surface
on which it will be placed. Do not point the airbag opening to the ground. Do not place any items
onto the airbag module. Provide free space for the airbag to expand in case of an accidental
deployment.
Do not have the unexpanded airbag module soaked in water or come into contact with other
liquids.
Do not place the unexpanded airbag module near the fire source or a high-temperature area.
Prevent personal injury caused by accidental airbag deployment.
Warning for handling airbag system collision sensor
Warning: Do not hit or shake airbag system collision sensors. Before supplying power to the
collision sensors, ensure the collision sensors are firmly tightened. Failure to follow the correct
procedures may cause airbag accidental deployment or inoperative, resulting in personal injury.
Important precaution for filling fluid to the brake system
Important precaution: When filling fluid to the brake master cylinder reservoir, use DOT4 brake
fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the
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recommended type of brake fluid may cause contamination which could result in damage to the
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internal rubber seals and/ or rubber linings of hydraulic brake system components.
Important precaution for Anti-corrosion materials
Important precaution: If the power steering system has been serviced, an accurate fluid level
reading cannot be obtained unless air is bled from the steering system. The air in the fluid may
cause pump cavitation noise and may cause power steering pump damage over a period of time.
Important precaution for belt dressing
Important precaution: Do not use belt dressing on the drive belt. Belt dressing causes the
breakdown of the composition of the drive belt. Failure to follow this recommendation will
damage the drive belt.
Important precaution for brake caliper
Important precaution: Support the caliper with a piece of wire when removing the brake caliper to
prevent damage to the brake line.
Important precaution of brake fluid effects on the paint and electrical parts
Important precaution: Avoid spilling brake fluid onto painted surfaces, electrical connections,
wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical
components. If any brake fluid comes in contact with painted surfaces, immediately flush the area
with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, uses
a clean shop cloth to wipe away the fluid.
Important precaution for damage to fuel tank straps
Important precaution: Do not bend the fuel tank straps. Bending the fuel tank straps may damage
the straps.
Important precaution for engine emissions
Important precaution: Modifications made to the following systems can effect the vehicle's
emission controls and may cause the Malfunction Indicator Lamp (MIL) or “Inspect Engine
Lamp” to illuminate.
– Engine
– Transmission
– Exhuast System
– Fuel system
Important precaution: if the replaced tire is not accorded with the performance standard of the
original tire, the emission control of the vehicle may also be affected, which may also result in
turning on the malfunction indicator lamp (MIL), and "check engine" indicator lamp.
Important precaution: Modifications to these systems or the installation of tires with incorrect TPC
could lead to repairs that are not covered by the manufacturer's warranty. This may also cause a
required Emission Inspection/Maintenance test to fail.
Important precaution for engine lifting
Important precaution: When raising or supporting the engine for any reason, do not use a jack
under the oil pan, any sheet metal, or the crankshaft pulley. Lifting the engine in an unapproved
manner may cause component damage.
Important precaution for engine bracket
Important precaution: Broken engine bracket s can cause misalignment of certain drive-train
components which then will cause eventual destruction of the drive-train components.
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Important precaution: If one engine bracket breaks, the rest engine bracket s will have increased
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stress put on them. This could cause the rest of the engine bracket s to break.
Important precaution for excessive adhesive on flywheel bolts
Important precaution: Apply the proper amount of the sealant to the fastener when assembling this
component. Excessive use of the sealant can prohibit the component from being assembled
properly or allow the fastener to loosen. A component or fastener that is not assembled properly
can loosen or fall off leading to extensive engine damage.
Important precaution for exhaust manifold and Oxygen sensor
Important precaution: The oxygen sensor may be difficult to remove when the engine temperature
is above 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the
exhaust pipe.
Important precaution for exhaust system inspection
Important precaution: When inspecting or replacing exhaust system components, make sure there
is adequate clearance from all points on the underbody to prevent overheating of the floor pan and
possible damage to the passenger compartment insulation and trim materials.
Important precaution for torque reaction against timing drive chain
Important precaution: A wrench must be used on the hex of the camshaft when removing or
installing in order to prevent component damage. Failure to prevent the torque reaction against the
timing drive chain can lead to timing drive chain failure.
Important precaution for dismantling external logo
Important precaution: Use a plastic, flat-bladed tool to prevent paint damage when removing an
emblem/name plate.
Important precaution for fastener
Important precaution: Use the correct fastener in the correct position . part number of replaced
fasteners must be correct. Fasteners requiring replacement of or fasteners requiring the use of
thread locking compound or sealant are identified in the service procedure. Do not use paints,
lubrication oil, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage the fastener. Use
the correct tightening sequence and tightening torque when installing fasteners in order to avoid
damage to parts and systems.
Important precaution for fuel pressure
Important precaution: Do not allow the fuel pressure to exceed the specified value because it may
lead to damage to the fuel pressure regulator or fuel pressure gauge.
Important precaution on Handling Electrostatic Discharge Sensitive Components
Important precaution: Electrostatic discharge (ESD) can damage many solid- state electrical
components. ESD susceptible components may not be labeled with the ESD symbol. Handle all
electrical components carefully. Use the following precautions in order to avoid ESD damage:
– Touch a metal ground point in order to remove your body's static charge before servicing any
electronic component (especially after sliding across the vehicle seat).
– Do not touch exposed terminals. Terminals may connect to circuits susceptible The ESD
damage.
– Do not allow tools to contact exposed terminals when servicing connectors.
– Do not remove components from their protective packaging until required to do so.
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– Avoid the following actions unless required by the diagnostic procedure:
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– Make connector jumper and ground
– Connecting test equipment probes to components or connectors. Connect the ground lead
first when using test probes.
Ground the protective packaging of any component before opening it. Do not rest solid-state
components on metal workbenches, or on top of TVs, radios, or other electrical equipments.
Important precaution for heat-type oxygen sensor and oxygen sensor
Important precaution: Do not remove the leading line from either the oxygen sensor (HO2S).
Removing the leading line or the connector will affect sensor operation.
Important precaution: Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the
in-line electrical connector and the louvered end free of grease, dirt, or other contaminants.
Do not use cleaning agent of any type.
Important precaution: Do not repair the wiring, connector or terminals.
Replace the oxygen sensor if the leading line, connector, or terminal is damaged.
Important precaution: This external clean air reference is obtained by way of the oxygen sensor
signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in
the obstruction of the air reference and degraded sensor performance.
Important precaution: The following guidelines should be used when servicing the oxygen sensor:
– Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors.
These materials may get into the sensor to cause poor performance.
– Do not damage the sensor leading line and harness wires in such a way that the wires inside
are exposed. This could provide a path for foreign materials to enter the sensor and cause
performance problems.
– Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks
could block the reference air path through the lead wire.
– Ensure that the peripheral seal remains intact on the vehicle harness connector in order to
prevent damage due to water intrusion
Important precaution for ignition OFF when disconnecting battery
Important precaution: when connecting or disconnecting the battery cable and the battery charger
or crossover cable, be sure to turn the ignition switch to the position OFF. Failing to do so may
damage the control module or other electronic components.
Important precaution for installing hoses without twists or bends
Important precaution: The inlet and outlet hoses must not be twisted during installation. Do not
bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these
procedures could result in component damage.
Important precaution for machined surface damage
Important precaution: Do not carve, scratch or damage the sealing surface. The sealing surface is
machining surface; and leakage may be caused by the damage to the machining surface.
Important precaution for power system control module and electrostatic discharge
Important precaution: Do not touch the connector pins or soldered components on the circuit
board in order to prevent possible electrostatic discharge (ESD) damage to the PCM.
Important precaution for power steering system hose disconnection
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Important precaution: Do not start the vehicle with any power steering gear inlet or outlet hoses
12
disconnected. When disconnected, plug or cap all openings of components. Failure to do so could
result in contamination or loss of power steering fluid and damage to the system.
Important precaution for ring gear dismantle
Important precaution: Do not pry the gear ring from the differential housing. The gear ring and/or
the differential housing may be damaged by prying the gear ring from the differential housing.
Important precaution for sealant
Important precaution: Do not let the room temperature hardening sealant into the threaded blind
hole; if the room temperature hardening sealant enters into the threaded blind hole, the fastener
produces hydraulic lock-up effect when fastening; the fastener and/or the other compartments may
be damaged due to hydraulic lock-up of the fastener; moreover, the fastener will not obtain a
correct clamping force when fastening; the part is unable to seal correctly due to wrong clamping
force, thereby resulting in leakage; and the fastened can not be properly tightened, so that the part
is loose or separates, thereby resulting in serious damage to the engine.
Important precaution for fault diagnosis tester usage
Important precaution: Before perform vehicle diagnostic, pay attention to the following,otherwise
it may cause damage to the engine control module.
– The fault diagnosis tester and the software must be up to date.
– Vehicle battery must be fully charged and battery voltage should be 12-14V.
– Fault diagnosis and tester terminals must be firmly connected.
– When programming the engine control module, do not connect the battery to the charger.
Important precaution on steering wheel in the Steering limiting position
Important precaution : do not hold the steering wheel in the steering limiting position longer
than 5ｓ, as damage to the steering pump may result.
Important precaution for test probe
Important precaution: Do not insert test equipment probes (DMM etc.) into any connector or fuse
block terminal. The diameter of the test probes will deform most terminals. A deformed terminal
will cause a poor connection, which will result in a system failure. Always use approved
terminal test kit in order to front probe terminals. Do not use paper clips or other substitutes to
probe terminals.
Important precaution: When using the approved terminal test the components, ensure the terminal
test adapter choice is the correct dimension for the connector terminal. Do not visually choose the
terminal test adapter because some connector terminal cavities may appear larger than the actual
terminal in the cavity. Using a larger terminal test adapter will damage the terminal.
Important precaution for using proper power steering fluid
Important precaution: When filling fluid or making a complete fluid change, always use
DEXRONⅢ power steering fluid. Failure to use the proper fluid will cause hose and seal damage
and fluid leaks.
Important precaution for window edge damage
Important precautions: the window is damaged by bumper due to exposed edge and must be lower
1mm (0.025 in) than the metal plate surface in order to avoid the damage to the window.
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1.2 Vehicle inspection
13
1.2.1 Description and operation
1.2.1.1 When drive vehicle, first shall be check items
Horn operation
Occasionally press the horn to ensure the speaker is working properly, inspect all the button
positions.
Brake system operation
Be aware of any abnormal noise when braking, brake pedal travel increase and repeatedly
occurred wheel slip when braking. In addition, if the brake warning light illuminates or flashes, it
indicates a fault in the brake system.
Operation of exhaust system
Be aware of the sound change in the exhaust system and odors. These indicate that the system may
be leaking or overheating. Inspect the system immediately and repair if necessary.
Tire, vehicle and positioning operation
Be aware of the steering wheel and seats vibration when traveling under normal conditions. It
indicates that there may be a need to balance the wheels. In addition, the wheel slip on even roads
indicates that there may be a need for tire pressure adjustment or wheel alignment.
Steering system operation
Be on guard against the steering change; when the steering wheel is difficultly revolved, or the
free stroke is too long, or there is abnormal sound in steering or parking, need to check. The light
pattern shall be observed occasionally for headlamp focusing; if the headlamp focuses wrongly,
adjust.
1.2.1.2 Items to be checked during each oil filling.
Any system fluid leak (except the windshield washer) indicates that the system may be faulty.
Inspect the system immediately and repair it if necessary.
Inspect engine oil level
Inspect the engine oil level and add the engine oil if necessary. It would be best to inspect when
the engine oil is hot.
1. When the engine is shut down, engine oil will flow back to the bottom of the oil pan after a
few minutes.
2. Pull out the dipstick.
3. Wipe clean the dipstick and then insert it back.
4. Pull out the dipstick and inspect the oil level.
5. If necessary, add engine oil, so that the oil level maintained between MIN (minimum) line
and the MAX (maximum) line. Do not fill an excessive amount of engine oil; otherwise it
may cause damage to the engine.
6. After reading the engine oil level, reinstall the dipstick to the engine. If inspecting the engine
oil level when the engine is cold; do not start the cold engine. The cold engine oil will not
quickly return to the oil pan, thus the correct oil level reading will not be obtained.
Check engine coolant level and conditions
Page 14
Check the level of expansion tank and add engine coolant if necessary. Check the engine coolant,
14
replace the dirty engine coolant.
Check the front windshield washer fluid level.
Check the washer fluid level and add fluid if necessary.
1.2.1.3 Check items one time every months at least
Tire, wheel and tire Pressure Inspection
Inspect for abnormal tire wear or damage. Inspect the wheels for damage. Inspect the tire pressure
when cold, also inspect the spare tire. Maintain tire pressure as recommended on the label.
Vehicle lamp operation
Inspect the operation of license lamps, headlamps (including the high/low beam lamps), parking
lamps, fog lamps, tail lamps, brake lamps, steering lamps, reversing lamps and hazard warning
flasher.
Oil and fluid leaks
When the vehicle is parked, regularly inspect whether there is water, engine oil, fuel or other
liquids on the ground underneath the vehicle. Water dripping from A/C system after use is normal.
If oil leaks or smoke is found, identify the reason and repair if necessary.
1.2.1.4 Check items two times every year at least
Power steering system fluid level
Inspect power steering fluid surface to maintain the correct power steering fluid level.
Brake master cylinder fluid level
Inspect the brake fluid level and maintain the correct fluid level. If the fluid level is too low, it
indicates that the disc brake has been worn and needs repairing. Inspect the vent lid to ensure that
no dirt and air path blockage.
Clutch pedal free travel
Inspect the free clutch pedal stroke; and adjust if necessary. Measure the distance from the center
of the clutch pedal to the floor when not stepping on the clutch pedal. Then, step on the clutch
pedal in the end and measure the distance from the center of the clutch pedal to the floor, wherein
the difference between the center of the clutch pedal and the floor must be more than 127mm
(5.07 in).
Doors and windows seals lubrication
With a clean cloth to apply a layer of silicon lubrication grease coated film.
1.2.1.5 Check items at least once a year
The condition and operation of seat belts
Inspect seat belt system, including the woven belt, buckle, drainbutton, retractor, guide ring and
fixtures.
Spare tire and jack storage
Be on guard against quack at the rear of the vehicle; spare tire, all lifting equipment and tools must
be always fixed; and the jack ratchet or helical mechanism is lubricated by engine oil after each
use.
Key lock maintenance
Lubrication key cylinder
Page 15
Body lubrication maintenance
15
Lubricate all door hinges, including the engine hood, the fuel filler door, compartment (back-door)
hinges and locking latch, glove box, console door and any folding seat parts.
Wash the behicle underbody
Firstly, loose the sediment in the vehicle block zones, and then rinse the underbody with clean
water. After winter, the underbody is washed at least once a year. The corrosive materials used for
deicing and anti-dust will be washed away when we wash the underbody.
Engine cooling system
Warning!
When working around the running engine, avoid contacting with moving components and hot
surfaces to prevent injuries.
Inspect the engine coolant. If the engine coolant is too dirty or rusty, drain the engine coolant.
Flush the engine cooling system and refill the new engine coolant. Maintain an appropriate
concentration of engine coolant in order to ensure the correct antifreeze, anti-corrosion properties
and engine operating temperature. Inspect the hoses. Replace the cracked, expanded, or aged
hoses.
Inspect fastening clip, cleaning radiators and A/C system condenser outside. Clean filler cap and
filler neck tube. Test the pressure in the cooling system and cover to ensure that the system
operates properly.
Page 16
16
1.3 Lifting vehicle
1.3.1 Description and operation
1.3.1.1 Lifting vehicle
Warning!
Refer to "warning for Lifting vehicle " in "Warnings and important precaution s".
To avoid personal injury, always use jack stands when you are working on or under any vehicle
that is supported only by a jack.
Notes:
When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be
certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If
such contact occurs, vehicle damage or unsatisfactory vehicle performance may result. Before you
begin any lifting procedure, be sure the vehicle is on a clean, hard and level surface. Be sure all
the lifting equipment meets weight standards and is in good working order. Be sure all the vehicle
loads are equally distributed and secure. If you are only supporting the vehicle at the frame side
rails, make sure the lifting equipment does not put too much stress on or weaken the frame side
rails.
Lifting vehicle positions
Lifting vehicle - Frame contact hoist
Rear hoist pads
NL01-0001b
Page 17
NL01-0002b
17
Notes:
The rear hoist pads and arms must not contact the rocker panels to the outside of the side frame
rails or the floor pan.
Position the rear hoist pads as follows:
– Under the junction between the rear frame rails and the side frame rails.
NL01-0003b
Page 18
1.4 Maintenance
18
1.4.1 Specifications
1.4.1.1 Oil and fluid capacity
Applications Specification
Brake Fluid and Clutch Fluid 0.665L(1.174 pt)
Engine oil(JL4G18-E, JLD-4G20, JLD-4G24) 4L(7.04 pt)
Engine coolant(JL4G18-E, JLD-4G20, JLD-4G24) 6.5L(11.44 pt)
Engine Coolant 6.5L(11.44 pt)
Manual Transmission Axle 2.2L(3.87 pt)
Automatic transaxle 7 . 5L13 . 2 pt)
Power steering system 0.91L(1.58 pt)
Refrigerant 550g(1 . 22 b)
Washer fluid 2L(3 . 52 pt.)
1.4.1.2 Recommended oil lubricating oil
Applications Oil and fluid/ lubrication oil
Brake fluid and clutch fluid DOT4 (HZY4)
Clutch linkage pivot grease Universal lithium grease
Engine coolant Glycol type engine coolant(coolant), freezing
point≤-40℃
Engine oil
SAE10W-3
winter), with API quality class of SL or above. SAE15W-40
(quality class of SL or above) or SAE20W-50 (quality class of SJ
or above) for tropic region.
0 or SAE15W-40 (SAE5W-30 for cold region in
Floor shift linkage grease Universal lithium grease
Hood and truck hinges, fuel filler door
hinges, compartment door hinge
Manual transmission axle
Universal lithium grease
liant with JT/T 224; API quality class: GL-4; viscosity: SAE 75W-90
Comp
Automatic transaxle Fuch FES 209-3292
Power steering system
ATF DEXRON Ⅲ auto/drive fluid
Doors and windows sealing strip grease Silicon lubrication grease
A/c refrigerant R134a
1.4.2 Description and operation
1.4.2.1 Fluid maintenance schedule.
Notes:
– *1 Refer to the harsh conditions maintenance schedule.
– *2 Only ""Geely produced long-efficiency engine coolant"" or equivalent high-quality
ethylene glycol engine coolant can be used. It is not allowed to use common water.
Page 19
S/N Oil and fluid name
19
Maintenance mileage (ehichever
comes first)
Remarks:
First time :5000 km or 3 months
1 Engine oil *1
replacement ,replace every 5000
km or 6 months (or required
according with detail condition )
2 Automotive gear oil
3
Automatic
transmission oil
First time:5000km replacement ,
every 2 years or 40000km later on
Every 60000km or 3years
API SJ grade or above
grade as the same
time ,replace oil
cleaning *1
4 Power steering oil Every 40000km or 2years
5 Brake fluid Every 30000km or 2 years
6 Engine coolant *2 Every 30000km or 1 years
1.4.2.2 Periodic maintenance schedule under the general condition
Maintenance item:
Notes:
– I: Mean inspection and required adjustment or replace
– R: means replacement.
– *1 Means to inspect the situation of valve noise and engine vibration. If necessray, adjust
them.
– *2 Means to inspect once at every 80,000km or 48 months, or every 20,000km or 12 months.
– *3 Means to inspect whether radiator and condenser are blocked by leaf, dust or insect, and
then clean the connection of hose.
– *4 Means to inspect once at every 80,000km or 48 months, or every 20,000km or 12 months.
– *5 After initial 60,000km, replace it. Later, after each 30,000km , replace it.
– *6 Only the coolant which is in accordance with SH0521 {freezing point ≤-40℃(-40 ºF) can
be used.
Maintenance
period (the
odometer
reading or
month
number shall
be primarily
based on the
first comer)
Engine elements
1. Valve play . . . I . . . I . . . I . . . I . 96
2. CVVT oil duct filter
net
3. Driving belt R R R R R R R R R R R R R R R R R 12
4. Engine oil R R R R R R R R R R R R R R R R R 12
5. Oil Filter . . . I . . . I . . . I . . .I . I 24
6. Cooling, heating
system hose and
connector
×1000 kilometers
Odometer reading
15
7.5
. I . I . I . I . I . I . I . I . 24
. I I I I R I I I I I R I R I I I —
30
22.5
45
37.5
60
53.5
75
67.5
90
82.5
105
97.5
120
112.5
127.5
Month
Page 20
7. Engine coolant . I . R . I . R . I . R . I . R . —
20
8. Exhaust pipe and
fixed frame
Ignition System
9. Spark plug . . . R . . . R . . . R . . . R R
10. Battery I I I I I I I I I I I I I I I I I 12
Fuel and exhaust control system
11. Fuel filter . . . R . . . R . . . R . . . R . -
12. Core of air filter I R I R I R I R I R I R I R I R I
13. fuel tank
cover/pipe/evaporation
14. Activated carbon
canister
Chassis and Body
15. Brake pedal and
parking brake
16.Brake shoe and
brake puck
17. Brake fluid I I I R I I I R I I I R I I I R I
. I I I I I I I I I I I I I I I I 12
I:6R: 24
. . . I . . . I . . . I . . . I . 24
. . . . . . . I . . . I . . . I . 60
I I I I I I I I I I I I I I I I I 6
I I I I I I I I I I I I I I I I I 6
I:6R: 24
18. Brake pipe and
hose
19. Power steering oil I I I I I I I I I I I I I I I I I 6
20. Steering wheel,
Steering pull rod and
gear box oil
21. Drive shaft boot I I I I I I I I I I I I I I I I I 24
22. Ball joint and dust
jacket
23 . Transmission oil . I I R . I I R . I I R . I I R . 24
24. Front and Rear
Suspension
25. Tire and tire
pressure
26. All the light, horns,
wipers and sprinklers
27 . A/C filter element . . R . . R . . R . . R . R . . R 12
28. A/C system and
cooling media
. I I I I I I I I I I I I I I I I 12
. I I I I I I I I I I I I I I I I 12
. I I I I I I I I I I I I I I I I 12
I I I I I I I I I I I I I I I I I 12
I I I I I I I I I I I I I I I I I 6
I I I I I I I I I I I I I I I I I 6
. I . I . I . I . I . I . I . I . 12
1.4.2.3 Regular maintenance schedule under harsh driving condition
– Harsh driving conditions are listed in the following table. Increase the frequency of service.
– Not otherwise provided items reference
1.4.2.4 Periodic maintenance schedule under the general condition .
A-1: Driving on uneven, muddy, or melting snow road
– Check brake pad and brake disc Every 5000km or 3 mouths
– Check brake pipeline and hose Every 10000km or 6 mouths
Page 21
– check ball joint and anti-dust cover Every 10000km or 6 mouths
21
– Check drive shaft anti-dust bushing Every 10000km or 12 mouths
– Inspect steering wheel, steering tie rod
and transmission oil
– Check front rear suspension Every 10000km or 6 mouths
A-2: Driving on the dusty section.
– Replace engine oil Every 5000km or 3 mouths
– Replace oil cleaner Every 5000km or 3 mouths
– Check or replace air filter filter
element
– Check brake pad and brake disc R: every 1000km or 6 months
– Replace A/C filter element Every 5000km or 3 mouths
Every 15000km
B-1: Towing, used camping frame or roof mounting
– Replace engine oil Every 5000 km or 3 mouths
– Replace oil cleaner Every 5000 km or 3 mouths
– Check brake pad and brake disc Every 5000km or 3 mouths
– Check or replace transmission oil Check gear oil every 5000km or 3 mouths replace it
Every 5000 km or 3 mouths
I:every 2500 km or 3 months
every 30, 000 km or every 18 months
– Check front rear suspension Every 10,000km or 6 mouths
– Lock bolt and screw cap between
chassis and body
B-2: Repeated short-distance driving within 8km and the outdoor temperature is below 0°C
– Replace engine oil
– Replace oil cleaner
B-3: Vehicles always drive for a long distance at idle speed or low speed, such as police cars,
taxies or door-to-door delivery vehicles.
– Replace engine oil
– Replace oil cleaner
– Check PCV valve and pipeline
– Check brake pad and brake disc
B-4: Frequent high speed driving for more than 2h (80% of the maximum vehicle speed)
– Replace engine oil
– Replace oil cleaner
– Replace transmission oil
B-5: Extended period of idle, low speed and frequent acceleration and deceleration, such as a
driving training vehicle.
Every 10,000km or 6 mouths
Every 5000km or 3 mouths
Every 5000km or 3 mouths
Every 5,000 km or 3 mouths
Every 5,000 km or 3 mouths
Every 5,000 km or 6 mouths
Every 5,000 km or 3 mouths
Every 5000km or 3 mouths
Every 5000km or 3 mouths
Every 20000 km or 12 mouths
– Replace engine oil
– Replace oil cleaner
– Check PVC valve and pipeline
Every 5,000 km or 3 mouths
Every 5,000 km or 3 mouths
Every 3000km or 3 mouths
Page 22
1.4.2.5Periodic maintenance description
22
Normal use of the vehicle
Maintenance schedule assumes that the vehicle is used for the following purposes:
– Transporting passengers and cargo according to the tire label at the edge of driver's door.
– Driving within the limits of the proper operation on suitable roads.
Maintenance schedule description
Service items are explained in more details below. When servicing, make sure replace all the parts
and complete all necessary repairs before drive the vehicle. Make sure use the suitable oil, fluids
and lubrication oil.
Drive belt inspection
Inspect the drive belt for cracking, wear and tear as well as the proper tension force. If necessary,
adjust or replace the drive belt.
Replacement of engine oil and oil filter
Engine oil must be used with API quality grades SJ or above grade engine oil,
Engine oil viscosity
Notes:
Using engine oil other than the recommended ones will damage the engine.
Engine oil viscosity (consistency) will affect the fuel economy and operations in cold weather.
The lower the engine oil viscosity, the better the vehicle's fuel economy and the better cold
weather performance. In high temperatures, engine oil with higher viscosity must be used to
achieve the desired lubrication effect. Using engine oil other than the recommended ones will
damage the engine.
Cooling system maintenance
Drain, rinse the cooling system and refill the new engine coolant. Refer to 1.4.1.2 Recommended
Oil and fluid and lubrication.
Replacement of fuel filter
Replace fuel filter every 30,000 km. The fuel filter is located at the bottom of the rear end of the
vehicle, close to the canister.
Replacement of air cleaner filter
Replace air cleaner filter every 1 5,000 km. Under dusty conditions, reduce the replacement of air
filter intervals.
Replacement of spark plug
Use only genuine Geely parts for replacements. Refer to 1.4.2.2 regular maintenance schedule
under normal driving condition.
Replacement of spark plug high voltage damper
Clean up the spark plug wire and inspect for burnt, cracking or other damage. Make sure the spark
plug wire is installed directly on the ignition system module and the spark plug. If necessary,
replace the spark plug wire.
Maintenance for brake system
Check disc-type brake lining block every 50000km or 6 months, carefully check thickness of
brake lining block. If the brake pads can not last until the next scheduled service, they should be
Page 23
replaced. Inspect the brake fluid tank lid vent to ensure that there is no dirt and the path is
23
unblocked.
Maintenance for transaxle
Auto-transmission: Check transmission fluid every 20000km or 12 mouths, replace transmission
fluid every 60000km or 36 mouths,,
Manual transmission: first time: 5000km replacement, every 2 years or 40000km later on;
Inspection and rotation of tire and wheel
Inspect whether there is abnormal tire wear or damage. To make tire wear evenly and to extend
tire life, rotate the tire positions. If there is abnormal or premature wear, wheel alignment should
be Inspected, and then inspect the wheels for damage.
1.4.2.6 Tire rotation descripition
Notes:
If there is obviously uneven tire wear, the faults for this should be eliminated.
When rotating the tires, it is recommended at the same time to inspect the tire and wheel assembly
balance.
1. It is recommended that tire rotation be carried out when brake inspections are performed, as
per the "maintenance schedule” outlined in the User’s Manual or when: Difference in tread
depth between front and rear tires exceed 1.5 mm (0.08 in).
2. Lifting and support vehicles, refer to 1.3.1.1 lifting vehicle .
Notes:
Record the original position of each tire and wheel assembly in relation to the vehicle.
3. Remove the tire and wheel assembly, refer to 4.4.5.1 replacement of wheel.
4. Rotate the tire and wheel assembly as shown in the following diagrams.
Notes:
For " No direction of rotation" tires, carry out rotation as shown below.
Page 24
Notes:
24
For "No direction of rotation" tires, carry out rotation as shown below.
NL01-0004b
5. Install the tire and wheel assembly, refer to 4.4.5.1 replacement of wheel.
6. Remove the safety stands.
7. Lower the vehicle.
8. Check and adjust the tire inflation pressure.
NL01-0005b
Page 25
1.5 Maintenance information system
25
1.5.1 Description and operation
1.5.1.1 Usage specification of arrow and symbol in the manual
1
2
2
2
2
2
2
3 4
2
2
2
2
2
2
5
2
Legend
1. Arrow
2. Motion direction arrow
3. Rotation direction arrow
4. Component code notes
5. Enlarged area
NL01-0006b
Page 26
26
1.6 Health and safety
1.6.1 Description and operation
1.6.1.1 Specification
Various operations relating to vehicle maintenance and repair may affect on personal safety or
health; part of relevant hazardous operations as well as materials and equipment are listed in the
section; moreover, safety rules to avoid such hazards are further listed.
This section does not include all the health and safety issues, so that all operations, procedures,
and material handling should be carried out, provided that safety and health is to be ensured. Prior
to the use of any product, inspect the manufacturer or supplier product instructions.
1.6.1.2 Acids and bases
Refer to 1.6.1.8 battery acid Fluid.
For example, battery has a corrosive sodium carbonate, sulfuric acid.
Batteries and other materials cleaning agent.
Battery has irritation and/or erosion affect on the eyes, skin, nose and throat. It may cause burns in
human body and damage to normal clothing. To avoid battery acid fluid splashing in the eyes, skin
and clothing, always wear appropriate protective clothing, gloves and protective goggles to
prevent inhaling acid fog.
Be sure to be equipment washing equipment nearby, such as: eye washing bottle, shower nozzle
and soap, etc. It is convenient to timely help somebody in trouble at any time when splashing.
Prominently mark eye danger sign.
1.6.1.3 Airbag
Refer to 1.6.1.15 fire and 1.6.1.10 chemical materials.
For highly flammable and explosive - to comply with the smoking ban.
Airbags are installed in the steering wheel, in the front passenger seat and inside the instrument
panel in front of the front passenger as well as the post A, post B, post C as a supplementary safety
system.
The airbag expander contains a gas that produces a very high temperature when igniting the
high-energy propellant (2,500ºC/4532 ºF).
This propellant is stored in airtight sealed components and fills the airbag when the airbag is
deployed. It is prohibited to open airbags during maintenance, as this would lead to dangerous
contact with the propellant. If the gas containers happen to break, wear full protective clothing
when handling the overflow materials.
After deploying airbags, wear protective goggles and gloves when handling the airbags.
Deployed airbags must be handled according to the relevant local laws.
If come into direct contact with gas derivatives, you must:
– Use clean water to rinse contact position.
– Call for emergency medical help as per condition
Airbag-shall execute operation (for your own safety, please wear the safety appliance to the
greatest extent prior to the execution of the following operation; the ignition switch of the vehicle
must be turned to "LOCK" status when dismantling the airbag, pull up the key and disconnect the
battery negative cable, then dismantle after waiting for 90s).
Page 27
Lay the air bag components and store it upwards.
27
– When storing, keep the air bag components dry.
– When carrying airbag components, do not touch the electrode and keep the airbag away from
body as far as possible.
– When placing air bag components, put the protective cover upwards.
– Check if airbag component was damaged carefully.
– Disconnect the battery negative before connecting airbags cable. Wait 60s, standing beside
airbag components.
– Correct adjusted and maintenance all equipment
– After deploying an airbag, make sure wash your hands.
Airbag-- operations to be avoided
– Do not store flammable materials and components together with gas generator.
– Do not immerse the airbag assembly in water or let airbag assembly contact with other
liquids.
– Gas generator can not be stored under the ambient temperature above 80ºC/176ºF
– Can not stored as an upside-down way
– Can not be try to open gas generator housing
– Do not expose the gas generator to flame or heat.
– Do not place other items on the components cover.
– Can not used damaged module
– Do not touch the component or the gas generator within 10 min of airbag being deployed.
– Do not use electrical probe in the return circuit.
1.6.1.4 A/C refrigerant
Refer to 1.6.1.10 chemical materials.
Skin contact may cause frostbite.
Must comply with the instructions provided by the manufacturer to avoid the exposed lights. Wear
suitable protective goggles and protective gloves.
If refrigerant come into contact with skin or eyes, you should immediately wash the contacted area
with water.
Apply the appropriate cleaning solution and rinse the eyes. Do not rub, as the case may need to
seek medical assistance.
A/C Refrigerant- operations to be avoided
– Do not store refrigerant at a place with direct sunlight or heat sources.
– When filling, the refrigerant bottles must not be upright, keep valves down.
– Refrigerant cylinder can not exposed in the snow area
– Can not be drop off refrigerant cylinder
– Do not.in any case. Directly discharge refrigerant to the atmosphere.
Page 28
– Can not be mix refrigerant. For example: R12 (dichlorodifluoromethane) and R134a
28
(tetrafluoroethane).
1.6.1.5 Adhesives and sealant
Precaution of adhesive and sealant
Before applying adhesive/sealant, the surface shall be cleaned and special detergent shall be used
to avoid the result of adhesive/sealant. Do not let the room-temperature curable glue into the
threaded blind hole when using sealant; if the room-temperature curable sealant enters into the
threaded blind hole, the fastener during fastening may produce the hydraulic locking effect,
thereby resulting in the damage to the fastener and (or) the other components; moreover, the
fastener during fastening is unable to obtain a correct clamping force, so that the sealing effect of
the sealant is worse, thereby leading to that the fastener can not be fastened correctly to loose or
separate the part and further resulting in seriously damage to the parts of the engine and the like.
Health and safety
The material in adhesive/sealant contains harmful substances. Prolonged exposure may cause
acute or chronic intoxication, occupational disease and skin disease. When applying, air
ventilation device shall be used to keep ventilated. When operating, it is necessary to wear
protective gloves, mask and protective clothing.
– Remove waste adhesive or wastes polluted by solvent. They are not allowed to accumulate
for a long time.
– Adhesive/sealant shall be stored in non-smoking area. Before using, clean them and apply
them with applicator or container.
Maintenance for adhesive/sealant
When the vehicle faults or has an accident, the body will be deformed, the steel plate will be
cracked, and the welding spot will be fallen off; at times, the engine, the chassis and the other
assemblies are further locally damaged, thereby resulting in shedding and damage of some
adhesive/sealant products. During the course of maintenance, adhesives with the same
performance shall be selected according to materials and functions of components.
Adhesive/sealant that can be used during the course of maintenance can be used as follows.
Body maintenance
After interior and steel plate is deformed or cracked, adhesive applied on the body falls off or is
cracked. During the course of maintenance, the damaged position shall be applied by adhesive
again.
– First remove adhesive on the surface of body with a small knife. Remaining adhesive shall be
cleaned with alcohol;
– Use special detergent to clean the applied position to avoid any foreign material on the
surface to be applied.
– Apply adhesive on the original position again to achieve bonding and sealing result.
Adhesive for body maintenance
Products Material Function
Recommended
model
Vehicle sealant
Mono-component
polyurethane
Bonding of body skin, interior and
exterior trim and body structure
and other components.
The adhesive has strong binding
strength and cohesion as well as
good adhesion with metal and a
Tianshan
TONSAN
:1922, 1923/
Page 29
Welded seam
29
sealant
Chip-resistant
primer
Mono-component
polyurethane
Rubber and Resin
variety of painted surface, etc.
1. Room temperature curing
adhesive is used for sealing of
welding joint inside vehicle
body. Use brush to apply
adhesive manually.
2. Indoor temperature curing
adhesive is used for sealing of
foldable end of engine hood,
boot and door. Use special
glue gun to apply adhesive
along the line.
Anti-collision glue for protecting
the room temperature curing-type
chassis forms a permanent
anti-aging flexible
corrosion-resistant protect coating
in the underbody and the wheel
guard.
Such products can replace the PVC
coating and have excellent
anti-rusting, sound insulation and
rock impact resistance.
Chinese
automotive
components
industry
company:C8802
Chinese
automotive
components
industry
company:C312DW
Windscreen glue
Detergent ——
Pressure-sensitive
adhesive tape
Heat-Sensitive
Adhesive Tape
Mono-component
polyurethane
Acrylic adhesive
tape
Acrylic adhesive
tape
Polyurethane adhesive cured at
room temperature is used for
sealing glass for vehicle window.
This glue has good bonding
property and can react with
moisture in the air. The glue has
strong strength, age resistance,
vibration and fatigue resistance,
low temperature resistance and no
corrosion and other good
properties after curing.
Clean all interface contact with
base coating and adhesives,
It is used for bonding of rubbing
strips, nameplates, guard plates,
splash guard, door protection,
body, various trim strips and so on.
This adhesive tape is excellently
weather endurable and durable and
is mainly used for bonding rubber
sealing strip system on a vehicle.
This adhesive tape has very strong
bonding force which can avoid
clearance and corrosion caused by
unsecured adhesion and it can
provide strong sealing effect.
Tianshan.Kesaier
: 1956、1924
3M 4229P、4215、
4221L
3M 4237P
Adhesive with
primer
——
Different primers are selected for
different materials of bonding
surface. The bonding surface must
3M C-100、
K-500\520、N-200
Page 30
be clean, the primer is uniformly
30
applied on the sticky surface via a
brush after completely drying, and
the adhesive tape is pasted after
driving.
Component maintenance
After components, engine and transmission are damaged, it is necessary to apply cohesive and
sealant again. Before applying, please clean all the surfaces to remove burr and crack.
Adhesive and sealant for components
Description Function
Be used for the plane sealing of the large
clearance and the flexible connecting piece,
such as the box body, the flange, the joint
surface of the bottom shell and the end cover
and other parts; clean up the adhesive residue of
the sealing surface prior to gluing, apply sealing
glue line with proper diameter on the sealing
Silicon rubber plane
sealant
Anaerobic thread
sealant
surface (or gasket) after cleaning and drying,
align and close the part immediately after gluing
to avoid misplacing, tighten the bolt, wipe the
unnecessary extrusive glue or clean up by the
blade after curing.
This kind of sealant does not contain solvent
and become curing at room temperature, with
corrosion resistance, impact resistance, medium
resistance and temperature resistance.
Used to tighten and lock bolts, nuts and screws.
Before applying, please clean all engaged
surfaces. After it becomes dry, apply sealant on
engaged surface.
After it becomes curing, it has good impact
resistance, vibration resistance, no leakage,
corrosion resistance.
Recommended
model
Tianshan.Kesaier
1596/1598～1596
Tianshan.Kesaier
1243、1242
:
:
Used to seal flat surface which has small
clearance and is required to be cured without
Anaerobic sealant
Other maintenance materials
Description Function Material No.
Locking adhesives
Corrosion inhibitor
air, and lock bolts.
It has performances such as waterproof, oil
resistance and corrosion resistance.
Used to lock tightening thread with maximum
dimension M6, like door window regulator
handle
It is a kind of corrosion inhibitor that is mainly
made of plastic. It is used for soundproof and
corrosion resistance treatment for chassis, with
corrosion resistance and soundproof.
Loctite 204，
Tianshan.kesaie
1510
Loctite thread
locking adhesive
Fudun
:
Page 31
Precaution for construction
31
– Adhesive/sealant is mainly used to prevent water and dust from going into the vehicle. In
addition, it has corrosion resistance. Original sealing joints are obvious. If they are damaged,
it is necessary to apply sealant again. When using adhesive/sealant to close the seam, packing
with high viscosity shall be selected. Apply it according to instructions for selected material.
– When applying adhesive/sealant, preventative measures shall be taken to avoid
adhesive/sealant from going into openings (such as door lock, window lifting slot, window
regulator, seat safety belt retractor) and any moving and rotating components, especially
parking brake cable. After applying adhesive/sealant, ensure all drainage holes on the body
are opened.
– When applying, it is necessary to wear goggles and gloves to avoid personal hurt.
– Before delivery, all metal plates have been coated. After maintenance and/or replacement,
any exposed metal surface shall be painted by primer and then applied by adhesive and
sealant.
– After applying, some of adhesives/sealants are required to be dried and cured. Drying
conditions are (70~80)℃, 20~30min.
1.6.1.6 Engine coolant
Refer to 1.6.1.15 Fire.
For example, isopropyl alcohol, ethylene glycol, methanol.
Extremely easily fired inflammables.
Used in the vehicle engine coolant circulation system, windshield washer fluid.
When heated, engine coolant (ethylene glycol) may produce steam. Avoid inhaling the vapor.
After direct contact with engine coolant through the skin, directly absorbed dose may reach toxic
or harmful dose. If swallowing engine coolant, it may be life-threatening. The person must be
taken to hospital and seek medical treatment immediately. These products must not be used in
conjunction with the ordinary food processing or connected with the drinking water supply
system.
1.6.1.7 Asbestos
Inhaling asbestos dust likely to cause lung damage, and even cause cancer.
Asbestos waste should be wet before handling. Place in sealed containers and mark clearly at the
surface of the container to facilitate safe handling. If you need to try to cut or drill materials
containing asbestos, you should make the materials wet first, and only use low-speed hand tools or
power tools.
1.6.1.8 Battery acid fluid
Refer to 1.6.1.2 acid and alkali.
The gas released when charging is explosive. Do not conduct fire operations near a charging
battery or a recently charged battery.
Maintain good ventilation.
1.6.1.9 Brake fluid
Refer to 1.6.1.15 Fire.
It is a little irritating when comes into contact with the skin and eyes. avoid the brake fluid coming
to contact with eyes, skin. The risk of inhaling brake fluid at room temperature is not high,
because its pressure is very low.
Page 32
1.6.1.10 Chemical materials
32
Pay attention, when using, storing and handling chemical material, such as, solvents, sealants,
adhesives, coatings, resin foam, battery acid, engine coolant, brake fluid, fuel, engine oil, gear oil,
automatic transmission fluid, lubrication oil and grease. They may be toxic, harmful, corrosive,
and irritating or highly flammable, and there is a high risk of odor and dust. The impact of long
term exposure to chemicals may be acute or chronic, temporary or permanent, cumulative,
superficial, life-threatening, or may affect life expectancy.
Chemical materials - operations to be performed
– Carefully read and follow the warnings on the containers of raw materials and any
accompanying leaflets, posters or other instructions. Raw materials health and safety
information forms can be obtained from the manufacturer.
– After coming to contact with chemical materials, remove it from the skin and clothing as
soon as possible. Immediately replace serious immersed clothing, and clean thoroughly.
– Strictly follow instructions. Wear protective clothing, in order to avoid direct contact with
skin and eyes,
– When handling with chemical materials before a break, diet, smoking, or using toilet
facilities must wash hands.
– Keep work area clean, tidy and non-chemical material spill.
Chemical materials - operation to be avoided
– Unless there is manufacturer's instruction, do not mix chemical materials; Certain chemicals
mixture will form other toxic or harmful chemical substances. When mixing, other toxic and
harmful gases may be released and it may cause an explosion and other accidents.
– Do not spray chemical materials in a closed environment.
– Unless there is manufacturer's instruction, do not heat chemical materials. Some chemicals
are highly flammable and others may draintoxic and harmful gases.
– Do not keep chemical materials containers open. Emitted gas may accumulate to a toxic,
hazardous or explosive level. Some gases are heavier than air and they will accumulate in a
closed space.
– Do not store chemical materials in an unlabeled container.
– Do not use chemical materials clean hands and clothing. Chemicals, especially solvents and
fuel will make the skin dry. It may cause allergies, skin infection. Chemicals directly
contacted with the skin will affect human health.
– Unless the empty container has been cleaned under supervision, do not use the container to
store other chemical materials.
– Can not be not free smell chemical materials Short-term exposure to high concentrations of
gas may still have the possibility of poisoning or hurt.
1.6.1.11 Dust
Powder and dust may be irritating, harmful or toxic. Avoid inhaling the chemical material powder
stirred up dry friction. If the ventilation is poor, wear a breathing mask protective equipment in
order to prevent inhaling dust.
Flammable fine dust may cause explosion. Keep them away from an explosion or a fire.
1.6.1.12 Electric shock
Failure to follow instructions when using electrical equipment or misuse of the equipment in good
condition may cause electrical shock.
Page 33
Maintenance electrical equipments within the specified time and run regular tests.
33
Failure of equipment should be noted. Move the failed equipment out of working area.
Do not use wires, cables, plugs and sockets that are wear and tear, kink, cut, broken or damaged.
Do not let electrical equipment and wiring contact with water.
Make sure the electrical equipment protected by the correct fuse.
Do not misuse electrical equipment. Do not use any faulty equipment, which may affect personal
safety.
Make sure mobile electrical equipment cable will not be damaged.
Must provide first aid training to the specialized electrical equipment operator.
In the event of electrical shock:
– Before contacting with the injured, disconnect the power supply.
– If the power can not be switched off, use dry insulation material to insulate the victim.
– If you have received special first-aid training, provide on-site first aid immediately.
– Request medical support error aid help support.
1.6.1.13 Gas
Exhaust contains toxic and hazardous chemicals, such as carbon oxides, nitrogen oxides,
acetaldehyde, and lead and aromatic hydrocarbon type material. Only run the engine at a place
with good ventilation or an open space.
1.6.1.14 Isolation fiber
Refer to 1.6.1.11 Dust.
Used to isolate the noise and sound.
The surface of the fiber substance and the sharp edges can cause skin irritations.
During operating procedures, follow instructions and wear gloves to avoid excessive skin contact
with the fibers.
1.6.1.15 Fire
Many materials related to vehicle maintenance are extremely flammable. Some materials will
produce toxic and harmful gases after burnt.
When storing and handling flammable materials or solvents, follow the fire safety rules, especially
near the electrical equipment or the welding operation areas.
Before use electric welding equipment, make sure there is no fire hazard.
When conducting welding or using heating equipment, always have an appropriate fire
extinguisher ready in the area around the job.
1.6.1.16 Emergency treatment
Not only comply with the law, but also have first aid trained personnel ready in the work area.
If the eyes are splashed, rinse eyes with fresh water for at least 10 min.
If the skin is contaminated, you need to use soap and fresh water to clean the contaminated area.
If you get frostbite, immerse the frostbite body part in ice water or cold water.
Page 34
If a staff inhaled toxic gases, that staff should be immediately transported to a place with fresh air.
34
If that staff still has symptoms of inhaling toxic gases, the staff should be immediately taken to a
hospital for medical treatment.
If you accidentally swallow the liquid, inform the doctor the information marked on the container
label. Unless there are instructions on the label, the affected person can not be guided vomit.
1.6.1.17 Foam- polyurethane
Refer to 1.6.1.15 fire.
Cured foam is used for seat cushion with the decoration.
Comply with manufacturers instructions.
Components that are not treated through chemical reactions may be irritating. They may be
harmful to the skin and eyes. Wear gloves and protective goggles when operating.
Staff with chronic respiratory diseases, asthma, bronchial problems, or suffering from hereditary
allergies should not deal with or come close to the uncured substances.
Certain spare parts, steam or spray may cause allergy. They may be toxic and harmful.
Remember that do not inhale vapor or spray. These materials must be used at a well ventilated
place or with respiratory protection measures. Do not immediately remove the mask after spraying.
Wait for the steam and the spray completely dissipated.
Uncured components and cured foam will produce toxic and harmful gases, during the bubble
operation. Unless the steam and the spray has been completely removed, do not smoke or use fire
and electrical equipment. Any foam material or special foam cutting should be carried out at a
well-ventilated place.
1.6.1.18 Fuel
Minimize direct contact with the skin of fuel. Immediately wash the skin with soap and clean
water after direct contact with fuel.
Gasoline
Highly flammable - comply with the smoking ban.
If swallowed, gasoline can cause irritation to the mouth and throat. If absorbed in stomach,
gasoline can lead to weakness and unconsciousness. Only a small amount of gasoline will affect
the lives of children. If the gasoline enters into the lungs, it is very dangerous.
Gasoline will cause dry skin. Prolonged or frequent contact with gasoline will cause skin allergies
and skin infection. Gasoline entering the eye will cause severe eye pain.
Motor vehicle used gasoline contains a large amount of benzene. Inhaling gasoline can cause
poisoning. The concentration of gasoline vapor must be kept at low. High concentration of
gasoline vapor can cause eye, nose and throat irritation as well as nausea, headache, depression,
physical discomfort and drunken behavior. High concentration of gasoline vapor will lead to rapid
loss of consciousness.
When handling gasoline, we must maintain good ventilation, with special attention to operate in a
confined space. Avoid splashing when pouring gasoline to reduce the risk caused by inhaling
gasoline vapor.
Pay special attention when cleaning and carrying out maintenance of gas storage equipment.
Gasoline can not be used as cleaning agents. Do not suck gasoline.
1.6.1.19 Gas cylinder
Refer to 1.6.1.15 Fire.
Page 35
Oxygen, acetylene, argon and propane-like gas, is usually stored under 13.8 Mpa (2001 psi)
35
pressure in the gas cylinder. When handling these cylinders, you must be really careful. Avoid
mechanical damage to the cylinder or valve.
Clearly mark the label with the gas filled inside the cylinder.
Cylinders should be stored in well ventilated areas and avoid placing in snow or under direct
sunlight. Fuel gases, such as acetylene and propane should not be stored together with oxygen
cylinders.
Pay special attention to the leakage from gas cylinders or pipeline. Avoid a fire source.
Only professionally trained personnel can carry out the gas cylinder related work.
1.6.1.20 Generate workshop tool and equipment
Always keep all of the tools and equipment in good working order. It is also very important to
operate correctly.
Do not use tools or equipment for unintended purposes.
The load over the crane, jack, vehicle shaft and chassis frame or suspension line must not exceed
the maximum limit that they can bear. The damage caused by overload is not necessarily apparent
immediately, being likely to result in severe accident when in use in the next time.
Do not use damaged or improperly worked tools or equipment, especially in certain high-speed
devices such as: grinding wheel. Damaged wheel will be broken without a warning and can cause
serious injury.
When using a grinding wheel, a chisel or sand blasting equipment, wear proper eye protection
devices.
When using a blasting equipment to handle asbestos-containing materials or using spray
equipment, wear the appropriate breathing mask.
There must be equipment that can control dust, spray and dust content.
1.6.1.21 Lubrication and grease
Avoid prolonged and repeated contact with mineral oils. All the lubrication oil and grease are
irritated to eyes and the skin.
Used engine oil
Prolonged and repeated contact with mineral oils will cause the loss of the natural skin oils,
causing dry, irritation and skin diseases. In addition, used engine oil is very likely to contain
harmful substances that can lead to skin cancer. Make sure use the skin protective equipment and
be equipped with adequate washing facilities.
Do not be used engine oil as lubrication oil, or any other purpose that has direct contact with the
skin.
Health and safety rules
– Avoid prolonged and repeated contact with engine oil, especially the used engine oil.
– Wear protective clothing, including impermeable gloves.
– Do not put the cleaning cloth stained with engine oil into the pocket.
– Prevent engine oil contaminating clothing, especially clothing next to the skin.
– Can not be wear cloth and shoes was seriously polluted by engine oil Overalls must be
cleaned regularly and kept clean.
– Immediate treatment to open wounds shall be received.
Page 36
– Put protective cream on the skin to avoid skin direct contact with the engine oil.
36
– Wash with soap and fresh water to remove all of the engine oil. Apply the protective agent
containing lanolin will help replace the skin's natural oils.
– If a skin disease occurs, you should immediately seek for medical treatment.
– Clear deposited oil and grease as soon as possible before working
– If there is a possibility of direct eye contact with chemicals, wear protective goggles, such as
chemical goggles or face masks. Eye wash equipment should also be equipped.
Environment precaution
Used or waste engine oil and oil filter should be recycled by authorized or licensed waste disposal
companies. If in doubt, please contact your local authorities.
Pouring used or waste engine oil directly into the ground, sewer or drainage facilities or into water
pipe is illegal.
1.6.1.22 Noise
Operating certain equipments will produce high-decibel noise and may cause hearing damage.
You should wear appropriate hearing protection devices.
Page 37
37
1.7 Standards and measurement
1.7.1 Description and operation
1.7.1.1 English system/metric unit converter
English system/metric units conversion
English system Multiply / divide (Metric)
English system measurement unit’s calculation, divided by the number in the middle column.
Metric measurement unit’s calculation, multiplied by the number in the middle column.
Length
Inch 25.4 mm3
Inch 0.3048
Code 0.9144
Mile 1.609 km
Area
Square inch
Square foot 0.0929
Square yard 0.8361
Volume
Cubic inch (in3)
Quart 0.9464
Gallon 3.7854
Cubic yard (yd3) 0.764
Weight
645.2 mm2
6.45 mm2
16,387.0 mm3
16.387 mm3
0.0164 Up
m
m2
m
3
Pound (lb) 0.4536
907.18
United kingdom ton
0.907 MT
Force
Kilogram force 9.807
Ounce force 0.2780
Pound force 4.448
Acceleration
Inch/ s2 0.3048 m/ s2
Kg
Newton (N)
Page 38
Inch/ s2 0.0254
38
Torque:
Pound Inch (lb-in) 0.11298
lb ft 1.3558
Power
Horsepower 0.745 KW
Pressure (stress)
Inch water column 0.2488
Pound/ square inch 6.895
Energy (Power)
English system thermal unit (Btu) 1055.0
lb ft 1.3558
Kilowatt-hour (kWh) 3,600,000.0
Light
Foot-Candle (fc) 10.764 lumen / m2
Speed
Mile / hour (mil/h) 1.6093 kg/hour
Temperature
N·m
KPa
Joule(1 joule= 1
watt-sec)
(°F - 32)* 5/9 = °C
°F = (9/5 *°C + 32)
Page 39
39
1.8 Complete vehicle specification
1.8.1 Specifications
1.8.1.1 Complete vehicle size
Front view
Front wheel track 1560mm (61in)
Body width 1833mm (72in)
NL01-0007b
Side view
Body length 4541mm (178in)
Approachangle24° Departure angle24°
Minimum ground clearance180mm (7in) (No-Load)/140mm (5.5in)(Full load)
NL01-0008b
Page 40
Rear view
40
Rear wheel track 1560mm (61in)
Body height 1700mm (67in)
NL01-0009b
1.8.1.2 Fastener specifications
Fasten specification diagram
4.6 4.8 5.8 8.8 9.8 10.8
NL01-0010b
Geely automotive engineering standards have adopted some parts of the definition of the standard
ISO metric fastener dimension with the aimed at reducing the number of different dimension
fasteners used while maintaining the best thread quality for each dimension. Metric bolts are
shown above, and the intensity level increases as the number increases.
Page 41
Fastener specification of complete vehicle
41
Component name Application
Model and
specification
Torque range
Metric
(N.m)
English
system
(lb-ft)
Combination member
of hexagon head bolt
and spring washer
Hexagon flange nut Pipe system assembly M6 8 - 10 5.9 - 7.4
Hexagon flange nut Fuse box of front cabin M6 8 - 10 5.9 - 7.4
Hexagon flange nut Hexagon flange nut M6 8 - 10 5.9 - 7.4
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt,
spring washer and
plain washer
assembly
Better negative
grounding wire
Instrument panel harness
assembly
Engine harness assembly M6×16 7 - 9 5.2 - 6.6
Better negative
grounding wire
Engine compartment
harness assembly
M8×20 13 - 17 9.6 - 12.6
M6×16 7 - 9 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
Hexagon flange bolt,
spring washer and
plain washer
assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed head
self-tapping screw
Hexagon flange nut
Hexagon flange nut
Back door harness
assembly
Front fog lamp assembly ST4. 8×16 4 - 6 3 - 4.4
Combination instrument
assembly
Defrost switch ST4. 2×13 2 - 4 1.5 - 3
Left rear combination
lamp assembly
Right rear combination
lamp assembly
M6×16 7 - 9 5.2 - 6.6
ST4. 8×16 4 - 6 3 - 4.4
M5 4 - 6 3 - 4.4
M5 4 - 6 3 - 4.4
Page 42
Hexagon bolt and
42
plain washer
assembly.
Central door lock
electrical device
M6×16 7 - 9 5.2 - 6.6
Hexagon bolt and
plain washer
assembly.
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt Pipe system assembly M6×12 8 - 10 5.9 - 7.4
Combination member
of hexagon head nut
and enlarged taper
washer
Hexagon head bolt
spring washer and flat
washer combination
member
Cross recess hexagon
head bolts and flat
washer combination
part
Cross recess hexagon
head bolts and flat
washer combination
part
Electric anti-theft
electrical device
Single disc assembly
with MPS main machine
A/C Motor Assembly M6 7 - 9 5.2 - 6.6
Base plate harness
assembly
Left front combination
lamp assembly
Right front combination
lamp assembly
M6×16 7 - 9 5.2 - 6.6
M6×20 7 - 9 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
Cross recessed head
self-tapping screw
Combination member
of hexagon head cross
recess bolt. spring
washer and flat
washer
Hexagon bolt Compressor assembly M8×105 18-22 13.3-16.2
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt Condenser assembly M6×16 8-10 5.9-7 . 4
Hexagon flange bolt
Hexagon flange bolt Pipe system assembly M6×20 8-10 5.9-7 . 4
Hexagon flange bolt Pipe system assembly M6×20 22-24 16.2-17.8
Front tweeter ST2. 5×8 1-3 0.7-2.2
Parking motor main
engine
Electric horn device M8×16 18-22 13.3-16.2
Main machine device of
air conditioning
M5×16 3-5 2.2-3.6
M6×16 8-10 5.9-7 . 4
Page 43
Cross recessed pan
43
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head screw and flat
washer combination
part
Cross recessed pan
head screw and flat
washer combination
part
Cross recessed pan
head self-tapping
screw and plain
washer assembly
A/C control panel ST4. 2×16 2-4 1.5-3
Multi-function
instrument assembly
Left rear fog lamp
assembly
Right rear fog lamp
assembly
Single disc with MP
main machine
ST4. 2×9.5 2-4 1.5-3
ST4. 8×13 4-6 3-4.4
ST4. 8×13 3-5 2.2-3.6
ST5. 5×16 7-9 5.2-6.6
Cross recessed head
self-tapping screw
Cross recessed head
self-tapping screw
Cross recessed pan
head self tapping
screw-F type
Cross recessed pan
head self tapping
screw-F type
Cross recess cup head
square self tapping
screw
Cross recess cup head
square self tapping
screw
Cross recess cup head
square self tapping
screw
Combination member
of hexagon head nut
and taper washer
Rear reading lamp
assembly
Front reading lamp ST4. 2×16 2-4 1.5-3
Control switch of main
driver glass lifter with
panel assembly
Co-driver glass lifter
control switch with panel
assembly
Control switch of main
driver glass lifter with
panel assembly
Left rear combination
lamp assembly
Right rear combination
lamp assembly
Wiper device of rear
windscreen
ST4. 2×16 2-4 1.5-3
ST4. 8×13 4-6 3-4.4
ST4. 8×13 4-6 3-4.4
ST4. 8×13 4-6 3-4.4
ST4. 8×13 4-6 3-4.4
ST4. 8×13 4-6 3-4.4
M6 7-9 5.2-6.6
Combination member
of hexagon head nut
and taper washer
Combination member
of hexagon head nut
and taper washer
Central door lock
electrical device
Central door lock
electrical device
M6 7-9 5.2-6.6
M6 7-9 5.2-6.6
Page 44
Combination member
44
of hexagon head nut
and taper washer
locking nut Engine harness assembly M6 18-22 13.3-16.3
Electric anti-theft
controller support
M6 7-9 5.2-6.6
Hexagon flange bolt
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Combination member
of hexagon head nut
and enlarged taper
washer
Hexagon bolt and
plain washer
assembly.
Hexagon flange nut
Combination member
of hexagon head bolt .
hexagon nut with
flower washer
BMBS main engine
support
Rear wiper M6×25 7-9 5.2-6.6
Engine ECU device M6×25 7-9 5.2-6.6
wiper motor and
connecting rod assembly
A/C system M6×16 7-9 5.2-6.6
Windshield washer M6×20 7-9 5.2-6.6
Terminal wiring of
battery
Auxiliary instrument
subassembly
M6×10 8-10 5.9-7 . 4
M6×25 7-9 5.2-6.6
M8 18-22 13.3-16.3
M6 7-9 5.2-6.6
Hexagon flange nut
Hexagon flange nut Rear spoiler assembly M6 8 - 10 5.9 - 7.4
Cross recess hexagon
head bolt and big flat
washer combination
Cross recess hexagon
head bolt and big flat
washer combination
Cross recess hexagon
head bolt and big flat
washer combination
Cross recess hexagon
head bolts and flat
washer combination
part
Cross recess hexagon
head bolts and flat
washer combination
Cross beam of instrument
panel assembly
Front bumper device M6×20 7 - 9 5.2 - 6.6
Left right mounting
support of front bumper
Upper trim plate of front
bumper
Engine bottom shield M6×14 7 - 9 5.2 - 6.6
Front bumper assembly M6×20 7 - 9 5.2 - 6.6
M6 8-10 5.9-7 . 4
M6×20 7 - 9 5.2 - 6.6
M6×20 7 - 9 5.2 - 6.6
Page 45
part
45
Cross recess hexagon
head bolts and flat
washer combination
part
Cross recess hexagon
head bolts and flat
washer combination
part
Cross recess hexagon
head bolts and flat
washer combination
part
Cross recess hexagon
head bolts and flat
washer combination
part
Cross recess hexagon
head bolts and flat
washer combination
part
Venting cover plate
device
Left rear wheel pipe
guard plate
Engine bottom Shield M6×20 7 - 9 5.2 - 6.6
Base guard plate of
carbon canister
Engine right guard plate M6×20 7 - 9 5.2 - 6.6
M6×20 7 - 9 5.2 - 6.6
M6×20 7 - 9 5.2 - 6.6
M6×20 7 - 9 5.2 - 6.6
Hexagon flange bolt
Cross recess hexagon
head screw and flat
washer combination
part
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
Auxiliary instrument
subassembly
Left side wall rear trim
plate
Right side wall rear trim
plate
Left rear fender lining
plate
Right rear fender lining
plate
M6×18 8 - 10 5.9 - 7.4
ST4. 8×19 4 - 6 3 - 4.4
ST4. 8×19 4 - 6 3 - 4.4
ST6. 3×19 10 - 12 7.4 - 8.9
ST6. 3×19 10 - 12 7.4 - 8.9
Cross recess hexagon
head bolts and flat
washer combination
part
Lower trim plate of front
bumper
ST4. 8×16 4 - 6 3 - 4.4
Page 46
Cross recess hexagon
46
head bolts and flat
washer combination
part
Cross recess hexagon
head bolts and flat
washer combination
part
Front bumper device ST4. 8×16 4 - 6 3 - 4.4
Left right mounting
support of front bumper
ST4. 8×16 4 - 6 3 - 4.4
Cross recess hexagon
head bolts and flat
washer combination
part
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
Right installing support
assembly of rear
bumper
Right installing support
assembly of rear
bumper
Left front fender liner ST4. 8×19 4 - 6 3 - 4.4
Right front fender lining
plate
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×19 4 - 6 3 - 4.4
ST4. 8×19 4 - 6 3 - 4.4
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
JQ2235519 Cross
recessed cavity
hexagon head
Left outer doorsill lower
trim plate
Right outer doorsill
lower trim plate
Left rear fender lining
plate
Right rear fender lining
plate
ST4. 8×19 4 - 6 3 - 4.4
ST4. 8×19 4 - 6 3 - 4.4
ST4. 8×19 4 - 6 3 - 4.4
ST4. 8×19 4 - 6 3 - 4.4
Page 47
self-tapping screw
47
and big flat washer
assembly
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
JQ2235519 Cross
recessed cavity
hexagon head
self-tapping screw
and big flat washer
assembly
Left guard plate of
engine
Engine right guard plate ST4. 8×19 4 - 6 3 - 4.4
ST4. 8×19 4 - 6 3 - 4.4
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Cross beam of instrument
panel assembly
Left center post (with air
curtain mark )
Right central post upper
trim plate assembly(with
air curtain mark )
Left rear pillar upper trim
plate assembly (with air
curtain mark )
Right rear post upper
trim plate assembly(with
air curtain mark )
Left center post M6×16 7 - 9 5.2 - 6.6
Right central post upper
trim plate assembly
M8×20 18 - 22 13.3 - 16.3
M6×16 7 - 9 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon flange bolt
Hexagon flange face
bolt －Enlarged
series
Left rear pillar upper trim
plate assembly
Right rear post upper
trim plate assembly
Muffler block bolt sheath
of door
Cross beam of instrument
panel assembly
M6×16 7 - 9 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
M8×30 22 - 26 16.3 - 19.2
M8×16 22 - 26 16.3 - 19.2
Page 48
Cross recessed pan
48
head self-tapping
screw and plain
washer assembly
Shift anti-dust cover
frame
M6×20 2 - 4 1.5 - 3
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Mounting support of
front door inner trim
plate
Right front door inner
trim plate handle
mounting support(I)
Right front door inner
trim plate handle
mounting support(II)
Left rear door inner trim
plate handle mounting
support
Left rear door inner trim
plate handle installing
seat
Right rear door inner trim
plate handle mounting
support
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Right rear door inner trim
plate handle installing
seat
Left upper trim plate
assembly of back-door
Back-door right upper
inner trim plate assembly
Inner trim plate handle of
back door
Lower guard plate
assembly of instrument
panel
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
Page 49
Cross recessed pan
49
head self-tapping
screw and plain
washer assembly
Auxiliary instrument
subassembly
ST4. 8×16 4 - 6 3 - 4.4
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Cross recessed head
self-tapping screw
Right front door inner
trim plate handle cover
plate
Left rear post lower trim
plate assembly
Right rear post lower
trim plate assembly
Left rear post lower trim
plate assembly
Right rear post lower
trim plate assembly
Second row intermediate
safety belt lock tongue
box trim plate
ST4. 8×22 4 - 6 3 - 4.4
ST4. 8×22 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×13 2 - 4 1.5 - 3
Cross recessed head
self-tapping screw
cross recessed
countersunk head self
tapping screw
Hexagon flange nut
Hexagon flange nut
Square nut
Combination member
of hexagon head nut
and enlarged taper
washer
Hexagon flange bolt
Cross recessed head
self-tapping screw
Second row intermediate
safety belt lock tongue
box trim plate
Right installing support
assembly of rear
bumper
Back-door trim strip
assembly
Engine hood trim strip
assembly
Outer trim plate of back
door
Base guard plate of
carbon canister
Intermediate right trim
plate of instrument panel
Left rear door exterior
angle trim
ST4. 8×13 2 - 4 1.5 - 3
ST4. 2×16 2 - 4 3 - 4.4
M5 4 - 6 3 - 4.4
M5 4 - 6 3 - 4.4
M5 4 - 6 3 - 4.4
M6 7 - 9 5.2 - 6.6
M6×16 8 - 10 5.9 - 7.4
ST4. 2×16 2 - 4 1.5 - 3
Cross recessed head Right rear door exterior
ST4. 2×16 2 - 4 1.5 - 3
Page 50
self-tapping screw angle trim
50
Cross recess hexagon
head bolts. spring
washer and flat
washer combination
part
Extinguisher support M6×20 7 - 9 5.2 - 6.6
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Flush-mounted Plastic
Nut with A Through
Hole
Flush-mounted Plastic
Nut with A Through
Hole
Flush-mounted Plastic
Nut with A Through
Hole
Flush-mounted Plastic
Nut with A Through
Hole
Cross recess pan head
flange face self
tapping screw
Outer open handle
assembly of back door
Back door lock cylinder
assembly
Exterior rear view mirror
assembly
Left door inner open
handle assembly
Right door inner open
handle assembly
Left door inner open
handle assembly
Right door inner open
handle assembly
Left door inner open
handle assembly
M6 8 - 10 5.9 - 7.4
M6 8 - 10 5.9 - 7.4
M6 8 - 10 5.9 - 7.4
8. 8×8. 6 — —
8. 8×8. 6 — 3 - 4.4
8. 8×8. 6 — —
8. 8×8. 6 — —
ST4. 8×16 4 - 6 3 - 4.4
Cross recess pan head
flange face self
tapping screw
Cross recess pan head
flange face self
tapping screw
Cross recess pan head
flange face self
tapping screw
Hexagon flange face
with gear nut
Hexagon flange face
with gear nut
Hexagon flange face
with gear nut
Hexagon flange face
with gear nut
Hexagon bolt and
plain washer
assembly.
Right door inner open
handle assembly
Left door inner open
handle assembly
Right door inner open
handle assembly
Front door limiter
assembly
Front door limiter
assembly
Rear door limiter
assembly
Rear door limiter
assembly
Engine hood gas spring
assembly
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 3 - 4.4
ST4. 8×16 4 - 6 5.9 - 7.4
M6 8 - 10 5.9 - 7.4
M6 8 - 10 5.9 - 7.4
M6 8 - 10 5.9 - 7.4
M6 8 - 10 5.2 - 6.6
M6×16 7 - 9 5.2 - 6.6
Page 51
Hexagon bolt and
51
plain washer
assembly.
Gas spring assembly of
backdoor
M6×16 7 - 9 5.2 - 6.6
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Left front seat
assembly(manual )and
front floor
Left front seat
assembly(electric
heating/waist/electric)and
front floor
Right front seat assembly
(manual )and front floor
Right front seat assembly
( power )and front floor
Left middle seat
assembly and rear floor
Right central seat
assembly and rear floor
Left rear seat assembly
and rear floor
Right rear seat assembly
and rear floor
M10×1.25×30 40 - 50 29.6 - 37
M10×1.25×30 40 - 50 29.6 - 37
M10×1.25×30 40 - 50 29.6 - 37
M10×1.25×30 40 - 50 29.6 - 37
M10×1.25×25 40 - 50 29.6 - 37
M10×1.25×25 40 - 50 29.6 - 37
M10×1.25×25 40 - 50 29.6 - 37
M10×1.25×25 40 - 50 29.6 - 37
Hexagon flange bolt
Hexagon flange bolt,
spring washer and
plain washer
assembly
Combination member
of hexagon flange
face bolt. hexagon
flange face bolt flat
washer
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Filler cap open handle
assembly
Back door lock body
assembly
Front door limiter
assembly
Front door limiter
assembly
Rear door limiter
assembly
Rear door limiter
assembly
Engine hood handle and
cable assembly
Left front door glass
lifter assembly
M6×20 7 - 9 5.2 - 6.6
M6×12 8 - 10 5.9 - 7.4
M8×20 22 - 26 16.3 - 19.2
M8×20 22 - 26 16.3 - 19.2
M8×20 22 - 26 16.3 - 19.2
M8×20 22 - 26 16.3 - 19.2
M12×25 68 - 82 50.3 - 60.7
M6×12 8 - 10 5.9 - 7.4
Page 52
Hexagon flange bolt
52
Right front door glass
lifter assembly
M6×12 8 - 10 5.9 - 7.4
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt Hood lock second lock M6×16 8 - 10 5.9 - 7.4
Cross recessed pan
head screw
Cross recessed pan
head screw
Hexagon spline raised
countersunk head
screw
Hexagon spline raised
countersunk head
screw
Hexagon spline raised
countersunk head
screw
Left rear door glass lifter
assembly
Right rear door glass
lifter assembly
Engine hood lock
assembly
Rear safety handle
assembly
Sunvisor buckle M6×25 7 - 9 5.2 - 6.6
Door lock M6×16 7 - 9 5.2 - 6.6
Door lock M6×16 7 - 9 5.2 - 6.6
Door lock M6×16 7 - 9 5.2 - 6.6
M6×12 8 - 10 5.9 - 7.4
M6×12 8 - 10 5.9 - 7.4
M6×16 8 - 10 5.9 - 7.4
M5×35 3 - 5 2.2 - 3.7
Hexagon spline raised
countersunk head
screw
Hex lobular socket
countersunk head
screws
Hex lobular socket
countersunk head
screws
Hex lobular socket
countersunk head
screws
Hex lobular socket
countersunk head
screws
Hex lobular socket
countersunk head
screws
Open type
countersunk blind
rivets
Door lock M6×16 7 - 9 5.2 - 6.6
Door latch assembly M8×22 18 - 22 13.2 - 16.3
Door latch assembly M8×22 18 - 22 13.2 - 16.3
Door latch assembly M8×22 18 - 22 13.2 - 16.3
Door latch assembly M8×22 18 - 22 13.2 - 16.3
Back door latch assembly M8×22 18 - 22 13.2 - 16.3
Ex-factory nameplate φ3×7 — —
Hexagon flange bolt Luggage rack M6×12 8 - 10 5.9 - 7.4
Page 53
Cross recess hexagon
53
head self tapping
screw and flat washer
combination part
Hexagon flange Bolt
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt,
spring washer and
plain washer
assembly
Cross recessed pan
head self-tapping
screw and plain
washer assembly
Tighten passenger airbag
and instrument
Fasten the Beams of
passenger airbag and
Instruments
Fasten Side guard curtain
Airbag
Fasten driver knee airbag M6×16 7 - 9 5.2 - 6.6
Fasten driver knee
Airbag
ST4. 8×16 4 - 6 3 - 4.4
M8×16 22 - 26 16.3 - 19.2
M6×16 7 - 9 5.2 - 6.6
ST4. 8×16 4 - 6 3 - 4.4
Hexagon flange Nut
Cross recess pan head
flange face
self-tapping nut
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Tighten steering wheel
and steering column
Tighten clock spring and
steering column
Tighten front/side crash
sensor
Tighten airbag electric
control unit
Engine right damping
cushion assembly and
body
Front cross beam of
engine front damping
cushion assembly
Engine front support and
transmission
Engine rear support and
transmission
Engine right damping
cushion assembly and
body
M12×1.25 36 - 44
ST4. 8×16 4 - 6 3 - 4.4
M6×30 7 - 9 5.2 - 6.6
M6×20 7 - 9 5.2 - 6.6
M12×1.25×20 47 - 57 34. 8 - 42. 2
M10×1.25×22 47 - 57 34. 8 - 42. 2
M10×1.25×22 47 - 57 34. 8 - 42. 2
M10×1.25×22 47 - 57 34. 8 - 42 . 2
M10×1.25×22 47 - 57 34. 8 - 42. 2
26 . 6 - 32 .
6
Hexagon flange bolt
Hexagon flange bolt
Left damping cushion
assembly and body of
engine
Left support and
transmission of engine
M10×1.25×22 47 - 57 34. 8 - 42. 2
M10×1.25×40 50 - 60 37 - 44. 4
Page 54
Hexagon flange bolt
54
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Engine right damping
cushion assembly and
engine support
Engine rear damping
cushion assembly and
subframe
Rear support and rear
damping cushion
assembly of engine
Engine front damping
cushion assembly and
front support
Engine rear damping
cushion assembly and
subframe
Engine right damping
cushion assembly and
engine support
Left support and left
damping cushion
assembly of engine
M10×1.25×50 50 - 60 37 - 44. 4
M10×1.25×70 50 - 60 37 - 44. 4
M10×1.25×90 75 - 85 55. 5 - 62. 9
M10×1.25×90 75 - 85 55. 5 - 62. 9
M10×1.25 50 - 60 37 - 44. 4
M10×1.25 70 - 90 51. 8 - 66. 6
M14×1.5 110 - 130 81. 4 - 96. 2
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt
Combination member
of hexagon head bolt .
hexagon nut with
flower washer
Powertrain M10×1.25×40 53 - 65 39. 2 - 48. 1
Powertrain M10×1.25×45 53 - 65 39. 2 - 48. 1
Powertrain M10×1.25×60 36 - 44 26. 6 - 32. 6
JL4G18 type engine
assembly
Power assembly
(JL4G18-E+JL-S170B)
Engine ECU device M6 8 - 12 5. 9 - 8. 9
M10×1. 25×80 36 - 44 26. 6 - 32. 6
M12×1. 25×50 96 - 110 71 - 81. 4
Hexagon bolt and
plain washer
assembly.
Hexagon flange bolt,
spring washer and
plain washer
Engine ECU device M6×25 8 - 12 5. 9 - 8. 9
Exhaust Device M10×1.25×40 30 - 40 22. 2 - 29. 6
Page 55
assembly
55
Hexagon flange face
with washer shaft bolt
Combination member
of hexagon head bolt .
hexagon nut with
flower washer
Hexagon bolt and
plain washer
assembly.
B-type worm drive
hose hoop
Steel strip—elastic
ring hoop
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Exhaust device M10×1.25×58 47 - 57 34. 8 - 42. 2
Exhaust device M6 8 - 10 5.9 - 7.4
Air intake device M6×12 8 - 10 5.9 - 7.4
Air intake device Ф8. 3 3 - 5 2.2 - 3.7
Air intake device Ф18 — —
Air intake device M6×12 8—10 5.9 - 7.4
Air intake device M6×16 8 - 10 5.9 - 7.4
Engine cooling device
( radiator)
M6×20 6 - 12 4. 4 - 8. 9
Hexagon bolt and
plain washer
assembly.
Hexagon flange bolt Engine cooling device M8×25 20 - 26 14.8 - 19.2
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt,
spring washer and
plain washer
assembly
Cross recess hexagon
head bolts and flat
washer combination
part
Hexagon bolt and
plain washer
assembly.
Hexagon flange bolt Oil filling pipe assembly M8×16 22 - 26 16.3 - 19.2
Engine cooling device
( expansion tank)
Fuel tank device M10×30 40 - 45 29. 6 - 33. 3
Fuel pump assembly M6×16 7 - 9 5.2 - 6.6
Fuel level sensor
assembly
Carbon canister
assembly,
M6×20 6 - 12 4. 4 - 8. 9
M5×10 3 - 5 2.2 - 3.7
M8×20 18 - 22 13.3 - 16.3
Pin shaft
Clutch master pump
assembly
Ф8×24 — —
Page 56
Double end stud of
56
hexagon bolt and flat
washer combination
part
Shift flexible shaft
pressure plate
M6×20 6 - 12 4. 4 - 8. 9
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Connect rear subframe
rear point with body
Rear upper swing arm
and spindle head
mounting bolt flat washer
combination member
Rear upper swing arm
and spindle head
mounting bolt flat washer
combination member
Rear shock absorber,
spindle head mounting
bolt and flat washer
combination member
Rear shock absorber,
spindle head mounting
bolt and flat washer
combination member
M14×1. 5×95 180 - 220
M12×1.
25×100
M12×1.25×100 82 - 98 60. 7 - 72. 5
M12×1.25×25 72 - 88 53. 3 - 65. 1
M12×1. 25×25 72 - 88 53. 3 - 65. 1
82 - 98 60. 7 - 72. 5
133.2 -
162.8
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon bolt and
plain washer
assembly.
Hexagon flange bolt,
spring washer and
plain washer
Composite member of
front suspension
reinforcement plate. body
connecting bolt and flat
washer
Composite member of
front suspension
reinforcement plate. body
connecting bolt and flat
washer
Mounting nut of rear
upper swing arm and
subframe
Mounting nut of rear
upper swing arm and
subframe
Rear suspension
reinforcement plate
mounting bolt and flat
washer combination
member
Rear suspension
reinforcement plate
mounting bolt and flat
M12×1. 25×30 101 81 . 4
M12×1. 25×30 101 81. 4
M12×1. 25×70 72 - 88 53. 3 - 65. 1
M12×1. 25×70 72 - 88 53. 3 - 65. 1
M10×1. 25×26 101 81. 4
M10×1. 25×26 101 81. 4
Page 57
assembly
57
washer combination
member
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Support and body of oil
can
Connecting bolt of cross
beam trailing arm and
body
Connecting bolt of
longitudinal beams and
sub-frame
Connecting bolt of
longitudinal beams and
sub-frame
Mounting support
mounting bolt of front
stabilizer rod
Mounting support
mounting bolt of front
stabilizer rod
Connecting rear tailing
arm mounting support
with body
Connecting rear tailing
arm mounting support
with body
M6×30 8 - 10 5.9 - 7.4
M12×1.25×103 88 - 104 65. 1 - 77
M12×1 . 25×25 79 - 95 58. 5 - 70. 3
M12×1 . 25×25 79 - 95 58. 5 - 70. 3
M12×1 . 25×30 79 - 95 58. 5 - 70. 3
M12×1 . 25×30 79 - 95 58. 5 - 70. 3
M12×1. 25×33 45 - 55 33. 3 - 40. 7
M12×1 . 25×33 45 - 55 33. 3 - 40. 7
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
Connecting bolt of cross
beam and body
Install rear shock
absorber and rear
subframe
Mounting nut of rear
shock absorber and its
support
Power steering pump and
engine
Connecting bolt of rear
tailing arm and mounting
support
Connecting bolt of rear
tailing arm and mounting
support
Front mounting bolt of
front lower swing arm
Front mounting bolt of
front lower swing arm
M12×1. 25×33 88 - 104 65. 1 - 77
M12×1. 25×65 72 - 88 53. 3 - 65. 1
M12×1. 25×70 72 - 88 53. 3 - 65. 1
M10×1.
25×122
M14×1. 5×80 135 - 165
M14×1. 5×80 135 - 165
M16×1. 5×100 213 - 253
M16×1. 5×100 213 - 253
48 - 52 35. 5 - 38. 5
99. 9 - 122.
1
99. 9 - 122.
1
157.6 -
187.2
157.6 -
187.2
Page 58
Hexagon flange bolt
58
Mounting bolt of rear
tailing arm and spindle
head
M16×1. 5×60 180 - 220
133.2 -
162.8
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt
and plain washer
assembly
Hexagon flange bolt
and plain washer
assembly
Hexagon flange bolt
and plain washer
assembly
Hexagon flange bolt
and plain washer
assembly
Mounting bolt of rear
tailing arm and spindle
head
Lower mounting bolt of
front shock absorber
Lower mounting bolt of
front shock absorber
Mounting bolt and flat
washer combination
member of No. 1 swing
arm of rear suspension
and subframe
Mounting bolt and flat
washer combination
member of No. 2 swing
arm of rear suspension
and spindle head
Mounting bolt and flat
washer combination
member of No. 2 swing
arm of rear suspension
and spindle head
M16×1. 5×60 180 - 220
M17×1. 5×62 220 - 260
M17×1. 5×62 220 - 260
M12×1. 25×65 80 - 90 59. 2 - 66.6
M12×1. 25×85 80 - 90 59. 2 - 66.6
M12×1. 25×85 80 - 90 59. 2 - 66.6
133.2 -
162.8
162.8 -
192.4
162.8 -
192.4
Hexagon flange bolt
and plain washer
assembly
Hexagon flange bolt
and plain washer
assembly
Hexagon flange bolt
and plain washer
assembly
Hexagon flange bolt
and plain washer
assembly
Hexagon flange bolt
and plain washer
assembly
Hexagon flange nut
with lock
Mounting bolt flat
washer combination
member of No. 2 swing
arm of rear suspension
and subframe
Mounting bolt flat
washer combination
member of No. 2 swing
arm of rear suspension
and subframe
Front mounting bolt of
front sub-frame
Front mounting bolt flat
washer combination
member of rear subframe
Combination part of front
mounting bolt of front
sub-frame and flat
washer
Mounting nut of rear
shock absorber and rear
subframe
M12×1. 25×95 80 - 90 59. 2 - 66.6
M12×1. 25×95 80 - 90 59. 2 - 66.6
M14×1. 5×133 133 - 157
M14×1. 5×90 138 - 162
M14×1. 5×95 133 - 157
M12×1.25 72 - 88 53. 3 - 65. 1
98. 4 - 116.
2
102.1 -
119.9
98. 4 - 116.
2
Page 59
Hexagon flange nut
59
with lock
Mounting bolt of rear
shock absorber and its
support
M12×1.25 72 - 88 53. 3 - 65. 1
Hexagon flange nut
with lock
Hexagon flange nut
with lock
Hexagon flange nut
with lock
Hexagon flange nut
with lock
Hexagon flange nut
with lock
Hexagon flange nut
with lock
Hexagon flange nut
with lock
Mounting nut of rear
upper swing arm and
subframe
Mounting nut of rear
upper swing arm and
subframe
Mounting nut of No. 1
swing arm of rear
suspension and subframe
Mounting nut of rear
upper swing arm and
spindle head
Mounting nut of rear
upper swing arm and
spindle head
Front stabilizer rod and
connecting rod
Front stabilizer rod
connecting rod and shock
absorber
M12×1.25 80 - 100 59. 2 - 74
M12×1.25 80 - 100 59. 2 - 74
M12×1.25 80 - 100 59. 2 - 74
M12×1.25 80 - 100 59. 2 - 74
M12×1.25 80 - 100 59. 2 - 74
M12×1.25 69 - 79 51. 1 - 58 . 5
M12×1.25 69 - 79 51. 1 - 58 . 5
Hexagon flange nut
with lock
Hexagon flange nut
with lock
Hexagon flange nut
with lock
Hexagon flange nut
with lock
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Mounting nut of No. 2
swing arm of rear
suspension and subframe
Mounting nut of No. 2
swing arm of rear
suspension and subframe
Mounting nut of No. 1
swing arm of rear
suspension and spindle
head
Connecting rod of rear
stabilizer rod and
connecting nut of
stabilizer rod
Mounting nut of rear
stabilizer rod fixing
frame
Power steering pump and
engine
Connecting nut of rear
tailing arm and mounting
support
M12×1.25 80 - 100 59. 2 - 74
M12×1.25 80 - 100 59. 2 - 74
M12×1.25 90 - 110 66.6 - 81. 4
M12×1.25 69 - 79 51. 1 - 58. 5
M12×1.25 55 - 65 40. 7 - 48. 1
M10×1.25 47 - 53 34. 8 - 39. 2
M14×1.5 140 - 160
103.6 -
118.4
Hexagon flange nut
Connecting nut of rear
tailing arm and mounting
M14×1.5 140 - 160
103.6 -
118.4
Page 60
support
60
Hexagon flange nut
Full metal hexagon
flange lock nut
Hexagon flange nut
Hexagon flange nut
Automatic pin nut of
hexagon flange face
Thicken nut of
hexagon flange face
Thicken nut of
hexagon flange face
Hexagon flange nut
Hexagon flange nut
Rear mounting nut of
rear sub frame
Power steering gear
fixing device
Rear mounting nut of
front lower swing arm
Rear mounting nut of
front lower swing arm
Connecting rod of rear
stabilizer rod and
mounting nut of No,2
swing nut
Install nut of post and
body
Install nut of post and
body
Lower mounting nut of
front shock absorber
Lower mounting nut of
front shock absorber
M14×1.5 180 - 220
M14×1.5 122 - 128 90. 3 - 94. 7
M16×1. 5 213 - 253
M16×1. 5 213 - 253
M10×1.25 27 - 33 20 - 24. 4
M10×1.25 45 - 55 33. 3 - 40. 7
M10×1.25 45 - 55 33. 3 - 40. 7
M17×1. 5 220 - 260
M17×1. 5 220 - 260
133.2 -
162.8
157.6 -
187.2
157.6 -
187.2
162.8 -
192.4
162.8 -
192.4
Vehicle wheel nut
GB9074 . 14M8*35
Hexagon bolt flat
washer
Hexagon head bolt
spring washer
combination member
Combination member
of hexagon head bolt
and spring washer
Combination member
of hexagon head bolt
and spring washer
Combination member
of hexagon head bolt
and spring washer
Combination member
of hexagon head bolt
and spring washer
Hexagon flange bolt
Brake and wheel
assembly
Manual shifter M8×35 17 - 26 12.6 - 19.2
Parking brake cable M6×16 6 - 12 4. 4 - 8. 9
Parking brake lever M8×20 17 - 26 12.6 - 19.2
Brake pedal with support
assembly
Extension shaft and gear
shaft
Universal joint yoke M8×32 22 - 26 16.3 - 19.2
Support and cross beam
of column
M12×1. 5 93 - 113 68. 8 - 83. 6
M8×20 17 - 26 12.6 - 19.2
M8×25 22 - 26 16.3 - 19.2
M8×70 23 - 27 17 - 20
Hexagon flange nut
Spline anti-dust cover
and front wall plate
M6 8 - 10 5.9 - 7.4
Page 61
Hexagon flange nut
61
Oil return pipe clamper
and steering gear
M6 8 - 10 5.9 - 7.4
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Hexagon with tapper
washer nut
Hexagon with tapper
washer nut
Fixing bolt of shift shaft
flexible
Electronic accelerator
pedal
Fixed speed sensor
support
Parking brake control
device
Mechanical steering
column assembly
One fixed duplex fitting
with support assembly
Two fixing HECU
controller assembly
Vacuum booster, front
wall and brake pedal
support
Vacuum booster, front
wall and brake pedal
support
M6 8 - 10 5.9 - 7.4
M6 8 - 10 5.9 - 7.4
M6 8 - 10 5.9 - 7.4
M6 8 - 10 5.9 - 7.4
M8 23 - 27 17 - 20
M8 14 - 18 10.4 - 13.3
M8 14 - 18 10.4 - 13.3
M8 18 - 26 13.3 - 19.2
M8 18 - 26 13.3 - 19.2
Slotted nut of
hexagon flange face
Slotted nut of
hexagon flange face
Hexagon slotted
nut.style 1
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon bolt and
plain washer
assembly.
Hexagon flange bolt,
spring washer and
plain washer
assembly
Flat washer
Hexagon flange face
bolt three stage bolt
and flat washer
combination part
Low swing arm round
head slotted nut
Low swing arm round
head slotted nut
Outer-end ball head and
knuckle of steering gear
tie rod
Power steering
inlet/outlet pipe/hose
Assembly
Fixed speed sensor
support
One fixed HECU
controller assembly,6
fixed brake hose
Fixing bolt of steering
gear
Fixing bolt of steering
gear
M14×1.5 123 - 143 91 - 105. 8
M14×1.5 123 - 143 91 - 105. 8
M12×1.25 31 - 35 22. 9 - 25. 9
M6×20 8 - 10 5.9 - 7.4
M6×18 16 - 20 11.8 - 14.8
M8×20 15 - 21 11.1 - 22.2
Ф14 — —
M14×1. 5×132 117 - 133 86. 6 - 98. 4
Page 62
Hexagon bolt and
62
plain washer
assembly.
Rear hook M12×1. 25×30 56 - 84 41. 4 - 62. 2
Hexagon bolt and
plain washer
assembly.
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon flange bolt Right rear door assembly M8×23 22 - 26 16.3 - 19.2
Hexagon flange bolt Left rear door assembly M8×23 22 - 26 16.3 - 19.2
Hexagon flange bolt
Hexagon flange bolt Left front door assembly M8×23 22 - 26 16.3 - 19.2
Hexagon flange bolt
and plain washer
assembly
Hexagon flange bolt
and plain washer
assembly
Hexagon flange bolt
and plain washer
assembly
Lower assembly of front
cross beam
Body in white assembly M10×1. 25×25 18 - 22 13.3 - 16.3
Right front door
assembly
Upper hinge assembly of
left front door
Right front door upper
hinge assembly
Right front door low
hinge assembly
M10×1. 25×25 52 - 78 38. 5 - 57. 7
M8×23 22 - 26 16.3 - 19.2
M8×30 26 - 38 19.2 - 28.1
M8×30 26 - 38 19.2 - 28.1
M8×30 26 - 38 19.2 - 28.1
Hexagon flange bolt
and plain washer
assembly
Hexagon flange bolt,
spring washer and
plain washer
assembly
Hexagon head bolt .
spring washer and
Hexagon flange bolts
of flat washer
combination part
Hexagon flange bolt Right rear door assembly M6×12 8 - 10 5.9 - 7.4
Hexagon flange bolt Left rear door assembly M6×12 8 - 10 5.9 - 7.4
Hexagon flange bolt Body in white assembly M6×12 8 - 10 5.9 - 7.4
Hexagon flange bolt
Hexagon flange bolt Left/right fender M6×16 8 - 10 5.9 - 7.4
Lower hinge assembly of
left front door
Rear cross beam
assembly
Front cross beam
Assembly
Left front door assembly M6×12 8 - 10 5.9 - 7.4
Right front door
assembly
M8×30 26 - 38 19.2 - 28.1
M8×25 15 - 25 11.1 - 18.5
M8×25 15 - 25 11.1 - 18.5
M6×12 8 - 10 5.9 - 7.4
Hexagon flange bolt
Engine compartment
assembly
M6×16 8 - 10 5.9 - 7.4
Page 63
Hexagon flange bolt Body assembly M6×16 8 - 10 5.9 - 7.4
63
Hexagon flange bolt Body in white assembly M6×16 8 - 10 5.9 - 7.4
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt Right longitudinal beam M8×16 22 - 26 16.3 - 19.2
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange bolt Right longitudinal beam M8×20 22 - 26 16.3 - 19.2
Hexagon flange bolt
Hexagon flange bolt Battery bracket assembly M8×20 22 - 26 16.3 - 19.2
Hexagon flange bolt
Hexagon flange bolt
Left front damper
support assembly
Left longitudinal beam
assembly
Back door hinge
assembly
Left longitudinal beam
assembly
Lower cross beam of
radiator
Left connecting plate
assembly of front wall
frame
Right connecting plate
assembly of front wall
frame
M6×20 8 - 10 5.9 - 7.4
M8×16 22 - 26 16.3 - 19.2
M8×16 22 - 26 16.3 - 19.2
M8×20 22 - 26 16.3 - 19.2
M8×20 22 - 26 16.3 - 19.2
M8×20 22 - 26 16.3 - 19.2
M8×20 22 - 26 16.3 - 19.2
Hexagon flange bolt Engine hood assembly M8×20 22 - 26 16.3 - 19.2
Left /right connecting
Hexagon flange bolt
Hexagon flange bolt
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut
Hexagon flange nut Back-door assembly M6 22 - 26 16.3 - 19.2
plate of celling No . 2
cross beam
Engine hood right hanger
assembly
Right rear door glass rear
guide rail assembly
Left rear door glass rear
guide rail assembly
Left connecting plate
assembly of front wall
frame
Right connecting plate
assembly of front wall
frame
M8×20 22 - 26 16.3 - 19.2
M8×20 22 - 26 16.3 - 19.2
M6 8——10 5.9 - 7.4
M6 8——10 5.9 - 7.4
M6 22 - 26 16.3 - 19.2
M6 22 - 26 16.3 - 19.2
Page 64
64
1.9 Vehicle identification number
1.9.1 Description and operation
1.9.1.1 Vehicle Identification
Vehicle identification number
NL01-0011b
Vehicle identification number (VIN) plate is a statutory marker.
Vehicle identification number (VIN) Body Stamping
5
NL01-0013b
A vehicle identification number (VIN) is stamped on the top right of the firewall.
Label position
Page 65
NL01-0012b
g
p
r
65
A vehicle identification number (VIN) plate is located at the upper left corner of the instrument
panel, viewed through the front windshield.
1.9.1.2 Vehicle identification (VIN) specification
The vehicle identification number consists of:
World's manufacturer identification code (WMI), vehicle description section (VDS) and vehicle
parts instructions (VIS) three parts (17 bit), as shown below:
Geographic
ion
re
Nationality
Manufacturer
WMI
WMI
(Part I)
VDS
VDS
(Part II)
Vehicle features.
VIS
VIS
(Part III)
Assembly
lant
Years
Inspectionstation
Productions
erial numbe
NL01-0014b
Vehicle identification number L6T7844S68N138894, for example, the meaning of each figure
represents the following table:
Vehicle identification number L6T7844S68N138894, for example, the meaning of each figure
represents the following table:
Position Definition Number/Letter Descriptions
Worldwide
1-3
manufacturer
L6T Zhejiang Geely Automotive Co., Ltd.
identification code
Page 66
4 Vehicle type code 7 Passenger car
66
5
6 Engine type 4
7 Body types
8 Drive type S Front drive, manual transmission
9 Inspection number 6 VIN check code
Model year code 8 2008
11 Manufacturer code N Geely Automotive Co., Ltd.
12-17
Worldwide manufacturing identification code (WMI)
First part (first-third digit) of vehicle identification number, of which:
L6T - Zhejiang Geely Automotive Co., Ltd.
LJU - Shanghai Huapu Automotive Co., Ltd.
LB3 - Zhejiang Haoqing Automotive Manufacturing Co., Ltd.
Vehicle main
specification code
Manufacturer plant
code
8 Vehicle longer than 4.6~4.8 m
Front positioned petrol engine,
displacement 1.7-1.9 L
4 Sedan/four-door
2 Hatchback/ 5 Door
138894 Plant sequence number
The fourth code specification
Vehicle type code list
S/N Vehicle type Code
1 Chassis(non-complete vehicle 0
2 Truck 1
3 Special automobile 5
4 Bus 6
5
6
7
The fifth code specification
Main parameter code list of vehicle
Passenger car
Wheelbase＜2.5m
Wheelbase＞2.5m～
Wheelbase＞2.7m
2.7m
7
8
9
Passenger car /bus Truck /special vehicle
Length :m Code Length :m Code
≤3.5
0
＞4.0~4.2
5
Gross
weight:kg
≤1000
Code
K
Gross
weight:kg
＞3000~3500
Code
R
Page 67
＞3.5~3.6
67
1
＞4.2~4.4
6
＞1000~1500
L
＞3500~4000
S
＞3.6~3.7
＞3.7~3.8
＞3.8~4.0
The sixth code specification
S/N
1
2
3
4
5
6
7
8
2
3
4
Engine
position
Front
mounting
＞4.4~4.6
＞4.6~4.8
7
＞1500~2000
8
＞2000~2500
＞4.8
Fuel Engine displacement :L Code
Gasoline
9
＞2500~3000
≤1
＞1~1.3
＞1.3~1.5
＞1.5~1.7
＞1.7~1.9
＞1.9~2.1
＞2.1
≤1.3
M
N
P
＞4000~4500
＞4500~5000
＞5000
T
U
V
0
1
2
3
4
5
6
A
9
10
11
12
13
14
15
16
S/N Power source
1
2
3
4
5
6
Rear
mounting
Double-fuels
Diesel oil
Gasoline
Diesel oil
Hybrid
Gasoline/quefied
petroleum gas(LPG)
Gasoline/ Compressed
natural gas gas(LPG)
＞1.3~2.5
＞1.3~2.5
＞2.5
≤1
＞1~1.3
＞1.3
≤1.3
＞2.5
displacement :L
＞1.3~3.0
＞1.3~3.0
＞1.3~3.0
Engine
≤1.3
≤1.3
≤1.3
B
C
L
M
N
T
U
V
Code
E
F
G
H
J
K
Page 68
The seventh code specification
68
S/N
1 Hatch/double-door
2 Hatch/5-door
3 Hatch+half-coach/5-door
4 Sedan/4-doors
5 Hatch/double-door √
6 Hatch/5-door √
7 Hatch+half-coach/4-door √
8 Sedan/4-doors √
9 Hatch/double-door
10 Hatch/5-door
11 Hatch+half-coach/4-door
12
13 Hatch/double-door
Load
type
Load
type
Coach numbers/door
numbers
Sedan/4-doors
Drop head Open-topped Code
— —
— —
— —
— —
—
—
—
—
— —
1
2
3
4
—
—
—
—
√ R
√ S
√ T
√ U
A
B
C
D
6
14 Hatch/5-door
15 Hatch+half-coach/4-door
16 Sedan/4-doors
17 Hatch/double-door √
18 Hatch/5-door √
19 Hatch+half-coach/4-door √
20 Sedan/4-doors √
21 Hatch/double-door
22 Hatch/5-door
23 Hatch+half-coach/4-door
24
Notes: “√” means this type:”-“ mean non-thistype
S/N Cab type Coach type Code
1 Rack-body 1
2
Sedan/4-doors
Flat head
— —
— —
— —
—
—
—
—
—
—
—
—
Coach-type 3
√ L
√ M
√ N
√ P
7
8
9
F
G
H
J
3 Rack-body 5
4
Dolichocephaly
Coach-type 7
Page 69
69
The Eighth code specification
S/N Drive type Transmission type Code
1 Manual transmission S
2
3 Manual transmission A
4
The Ninth code specification
It is the value calculated by the manufacture through certain formula according to other 16th-digit
values. It may be any number from 0 to 9 or letter "X" and used to verify the authenticity of a VIN
code, to ensure the unique and effectiveness of a VIN code.
The Tenth code specification
It is used to distinguish the year. The year code is used according to Table 11 (Repeat in a 30-year
cycle).
Years code table
Years Code Years Code Years Code Years Code
Front drive
Auto-transmission Z
Rear drive
Auto-transmission B
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
The 11th code specification
It is used to distinguish different assembly plants.
Code list of assembly plant
S/N Name Code
1 Haoqing Automobile Manufacturing Co. Ltd H
2 Haoqing 1st Subsidiary L
1
2
3
4
5
6
7
8
9
A
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
B
C
D
E
F
G
H
J
K
L
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
M
N
P
R
S
T
V
W
X
Y
2031
2032
2033
2034
2035
2036
2037
2038
2039
2040
1
2
3
4
5
6
7
8
9
A
3 Geely Automobile Manufacturing Co. Ltd N
4 Huapu Automobile Manufacturing Co. Ltd S
Page 70
5 Cixi Automobile Manufacturing Co. Ltd C
N
70
6 Haoqing company-Xiangtan Subsidiary X
7 Gansu Lanzhou Subsigdiary G
Specification from twentieth to seventeen code
It is used as vehicle production numbers. According to the sequence of vehicles manufactured in
the same year, it starts from 000001 on-ward. The 12th digit of VIN can also be used as the month
code.
Refer to the following table:
S/N Months Code S/N Months Code
1 January 1 July 7
2 February 2 August 8
3 March 3 September 9
4 April 4 October 0
5 May 5 November A
6 June 6 December B
1.9.1.3 Lable—vehicle certificate
Made by China Shanghai Huapu Automobile Co.,ltd
1
Complete vehicle
model:
Max.design gross
weight:
Ex-factory dates:
umberof the
transportable people:
7
9
Brand:
Engine model:
Rated power of
engine:
Enginedisplacement:
2
8
Geely brand
1. Vehicle identification number(VIN)
2. Brand
3
4
5
6
NL01-0015b
3. Complete vehicle model
4. Gross weight
5. Manufacturing dates
6. Numbers of passenger
Page 71
7. Engine model
71
8. Engine rated power
9. Engine displacement
Made by China Zhejiang Haoqing Automobile
中国浙江豪情汽车制造有限公司制造
Brand Complete vehicle model
Engine model Max.design gross weight
Rated power of engine Ex-factory dates
Engine displacement Numberof the
Manufacturing co. , lt d
transportable people
NL01-0016b
The conformity certification label is located at the topside of the driver-side front frame plate.
1.9.1.4 Tire message billboard
Tire pressure
Tire model
Air
pressure
NL01-0017b
Tire placard is located on the vehicle body surface under the driver door striker. For tire
information. Please refer to tire placard. Wheel and tire dimensions (including spare tire), inflation
pressures (including spare tire) and load capacity are specified on a tire placard.
1.9.1.5 Engine mark No.and position
Engine mark No,(JL4G18-E)
Page 72
– JL: Enterprise code
72
– A: years (A means 2010)
– 4: months
– N: Ningbo base
– E: 4G18E
– 00001: S/N
Engine identification number position
NL01-0018b
NL01-0019b
Engine identification number is stamped on the platform at the edge of cylinder on the side of air
inlet at engine flywheel end.
Notes: JLD-4G20、JLD-4G24 engine mark No. Position is same with JL4G18E.
1.9.1.6 Identification numberand position of manual transmission
Identification number label of manual transmission (JL-S170BⅡ)
Page 73
Product certificate of
73
Zhejiang Geely Motor
Group Ltd
Product model:
Product name: Transmission
Inspecter:
Ex-factory
date:
This product is permitted to leave the
factory after strict inspection
NL01-0020b
1. JL: Enterprise code
2. S: Operation type
3. 170: Torque number
4. B: Improved code
Manual transmission Identification number label and its position
NL01-0021b
Notes: DSI transmission mark No. is same with JL-S170BⅡ.
Page 74
74
1.10 Noise, vibration and abnormal sound
1.10.1 Description and operation
1.10.1.1 Diagnostic information and procedures
Wind noise/air sound
Warning!
Refer to "warning on assistant driving" in "warnings and precautions".
Notes:
When the technician checks the fault part to be repaired, the assistant shall drive the vehicle;
otherwise, it may cause personal injury.
A test drive is needed in order to identify the position of wind noise. In general, the wind noise
includes major leaks and minor leaks. If the repair process does not fix all the leaks, it will only
reduce wind noise, but not completely eliminate the wind noise.
A technician must bring the following tools to help diagnose the specific position of wind noise:
– Stethoscope
– Masking tape
– Plug strip
– Marking pen
– Screwdriver
A road test should be carried out as following:
– Select an even and straight road, with an east, a south, a west and a north exit.
– Select a road with minimal traffic and noise in order to avoid affecting the test.
– Test the vehicle at the speed when the noise is most obviously heard. Do not speed above
speed limit.
– The noise can be identified as external wind noise, under the following conditions as soon as
lowering the windows of the running vehicle; the wind noise can be heard.
• You may hear wind noise when drive vehicle after reduced window glass .
• Internal wind noise is caused by air escaping from the car. The repair should take the
following approaches:
– When trying to determine the leak position, attach tapes to the body pressure relief valve.
• With confirm leakage position, Tape was sticked on the relief valve of door lock post. Use
stethoscope to identify the leak position.
• Use masking tapes for temporary repair.
• Continue the road test to confirm whether all the wind noise has been eliminated or there are
still leaks at other parts.
• Return to workshop after having identified all the leaks during road test.
• Use specialized methods and sealing material to carry out permanent repair,adopted special
position method and sealing material to permanent repair
Page 75
Vibration
75
Most of the high-speed vibrations are due to lack of wheel dynamic balance. If there still is
vibration after balancing the wheels, the reasons are:
– Tire is output shaft
– Rim is output shaft
– Tire has hardness deviation
Measuring the amount of free jumping of tires and wheels can not determine all the reasons
leading to vibration. The above mentioned three reasons are known as the radial load. You must
use known good tires and wheels to replace the old ones and carry out the maintenance.
The low-speed vibration which occurred at the speed of 64 km/h is usually caused by free jumping.
The high-speed vibration occurring at the speed higher than 64 km/h is usually caused by
imbalances or jumping.
Correct uneven tires
There are usually two ways to correct the wheels with right balance but still with tire vibration.
One way is to use automatic machine tools. Install the tire onto a tire machine. Grind a small
amount of rubber off from the high point of the tire. This method is permanent. If following the
operation instructions, it will not affect the tire appearance and tire tread life. Correction using a
blade is not recommended, since this method will shorten the tire life and can not fundamentally
solve the issue.
Another method is to dismantle the tire and turn the tire 180 ° on the rim. Use this method only
after tire and wheel assembly has been confirmed as the cause of vibration. This is because this
method may result vibration with good tires, and can not solve the problem completely.
Abnormal sound
At high engine speed, inspect whether the insulation shield comes into contact with the
underbody.
– Lifted vehicle and carried out visual inspection
– Slightly bent insulation panels to create a gap between the panels and the underbody.
Squeak sound from the front of the vehicle in cold weather
Inspect the front stabilizer bar isolation sleeve.
– Road test the vehicle when engine is cold and drive the vehicle through potholes to make the
front suspension reach the maximum travel limit.
– Dismantle the front stabilizer bar isolation sleeve, wrap tapes around the bar and install the
front stabilizer bar isolation sleeve.
Abnormal sound from the rear of the vehicle when the vehicle is bumping
Inspect whether the spare tire is properly secured.
– Opening the rear compartment and inspect the spare tire and the driver’s tools.
– Fixed spare tire and attachment tools again.
– Check if road test vehicle abnormal noise cleared
The rear window percussion sound when driving on rough roads
Inspect whether the rear door buckle is adjusted properly
– Check this condition by road test vehicle
Page 76
– Loosed latch nut and adjust latch
76
Door squish
Inspect whether the inner trim plate harness connector has the squish sound.
– Tap the inner trim plate and carefully observe whether squish sound is heard.
– Dismantle the inner trim plate and wrap foam pad to around the harness connector.
Door squeak
Inspect whether the door hinge is lack of lubrication.
– Operate the door back and forth and listen carefully to the door whether there is squeak
sound.
– Use smear grease to lubricate the door hinge.
Manual transmission gearshift squeak (in the cold weather or when the engine is cold)
Inspect the Manual shifter assembly lower sheath of manual transmission
– Switch between gears and verify the squeak.
– Dismantle the floor console gearshift lever, lubricate it and install it.
1.10.1.2 Maintenance guidance
Wind/air noise
External wind noise
The wind noise leak repair is very similar to that of water leaking. Refer to 1.10.1.1 Diagnostic
Information and Procedures. The actual maintenance procedure depends on the type of seal
elements.
Vibration
Tire and wheel balancing (on-vehicle)
Carry out the balancing on the electronic wheel balancing machine. Dynamic balancing machine
is easy to use and can be used both for static balance and dynamic balance. Unlike the balancing
on vehicle, the off vehicle balancing can not correct the brake disc imbalance. However, the
accuracy of the off vehicle balancing can overcome this issue. Make a cone through the center
hole on the back, rather than through the wheel nut holes.
Tire and wheel balancing (off-vehicle)
On-vehicle tire and wheel balancing can correct the imbalance caused by disc brake vibration.
Warning!
Support the control arm at the normal position to avoid damage to drive axle. When the wheels
travel to the maximum low position, do not shift the gear lever.
1. Do not dismantle the balance weights during on vehicle tire and wheel balancing.
2. If the balance weight is more than 25g (1lb), divide it into two blocks and install one onto the
inner wheel rim and the other onto the outer wheel rim.
3. Engine driven gear and gear assembly.
Tires and wheels directional installation
Tires and wheels are installed at the factory with the radial tires thicker parts (also known as the
high point) pointing to the minimum radius wheels (also known as low points).
Page 77
Red paint marks or labels are at high points along the outer of the tires when just delivery.
77
Valve core at the lower position of the wheel.
Before dismantling the tire, mark the position of the valve to make sure it can be installed back to
the original position. Before dismantling the tire, mark the position of the valve to make sure it
can be installed back to the original position.
Abnormal sound
Abnormal sound repair
Abnormal sound mainly comes from parts that should not have relative motion. To repair
abnormal sound, there are three ways:
– Tighten the fasteners components, so that there is no relative motion.
– Separate components, so that components do not contact.
– Isolated parts, so that there is no abnormal noise when components moving.Even low friction
surfaces can be used to eliminate viscosity between the sliding components.
Page 78
78
1.11 Water Leakage
1.11.1 Description and operation
1.11.1.1 Diagnostic information and procedures
Water leakages diagnosis
Notes:
Identify all water leaking parts before repair. Random repair may only be a temporary solution and
could lead to more difficult repair in the future. Continue testing to identify all water leaking parts.
To repair water leakage , proper testing and diagnosis is needed. Adjust the position of the
incorrectly positioned components and use proper materials to carry out the repair.
Firstly, determine in what circumstances there is water leakage. For example: only when the
vehicle remains in the slope there is water leakage. Secondly, if the water leakage area has been
found, use water hose to locate exact position where water leakage . If water leakage is not
obvious, use a water leakages testing machine to identify specific positions. May be dismantle
partial interior tram plate or partial component to found water leakage position.
Water leakages test preparation
– The vehicle is designed for running under normal conditions.
– The sealing materials and components design has taken into account the natural environment
to achieve the seal strength. But these specification standard can not was took into account by
all person as condition
– Water leakages test is related to the natural environment and can be used to determine the
vehicle driving performance under normal conditions.
– The first step of the diagnosis process is to determine water leakage occurred under what
conditions. If you can determine the approximate water leakage area, you can use a water
hose to isolate the exact position. To repair water leakage , you may need to dismantle certain
components of the trim plates or components.
– If the water leakage appears in the door, trunk door or window, it is not necessary that the
water leakage is created by sealing strip. Adjusting these parts might correct the water
leakage .
Testing with water supply hose
Notes:
Do not use water supply hosee with a nozzle.
1. Let an assistant inside the vehicle to confirm the exact position of water leakage .
2. Start testing from the bottom of the window or the windshield.
3. Move the hose slowly upward, until cover the entire roof.
Water supply hose test
Notes:
Ventilation hose test can only be used for completely cured the adhesive. Otherwise, the usage of
this method will damage the adhesive layer, leaving increased water leakage spots.
1. Pour liquid cleaning agent into a spray bottle according to a certain percentage, then spray it
to window edge. Spray from the bottom, gradually upward and through the entire roof.
Notes:
Page 79
The pressure of compressed air can not exceed 205kPa (29.75 psi).
79
2. Let an assistant bring the air hose into the vehicle.
3. Let the assistant use the compressed air targeting suspected leaking area. If there is leakage,
air bubbles will appear.
1.11.1.2 Maintenance guidance
Water leaking repair for body
Depending on the position of water leakage, certain components may need to be dismantled.
1. From the inside or outside the vehicle slit open the seam adhesive.
2. Clean and remove all the old adhesive residues from the leaking area.
3. Apply body and joint sealant on the cleaned area.
4. Wait for several hours so that the sealant is fully cured.
5. Inspect whether there are water leakage.
6. Install previous dismantle component.
Fixed water leakage repair for window
Depending on the position of water leakage, certain components may need to be dismantled.
1. Determine the specific position of water leakage .
2. If the front windshield edge water leakage use a dedicated seam adhesive to repair or replace
the windshield.
3. If it is fixed windows side-water leakage, use a dedicated seam adhesive to repair or replace
the windshield.
Page 80
80
1.12 Special tool list
1.12.1 Special tools and equipment
1.12.1.1 Special tool for powertrain
S/N Illustration Tool No. Description
1
FE01-2001b
GL201
Tool for tightening
input shaft
2
FE01-2002b
GL201
Tool for installing input
shaft oil seal
3
GL201
Tool for installing
input/output shaft parts
FE01-2003b
Tool for installing and
4
GL201
removing input shaft
transmission head
bearing
FE01-2004b
Page 81
Tool for dismantling
81
5
GL201
output shaft clutch head
bearing outer ring
FE01-2005b
Tool for installing
6
GL201
output shaft bearing
outer ring
FE01-2006b
Tool for installing and
7
GL201
removing output shaft
bearing
FE01-2007b
8
FE01-2008b
GL201
Tool for adjusting
output shaft
Tool for installing and
9
GL201
removing differential
clutch housing oil seal
FE01-2009b
Page 82
10
82
GL201
Tool for installing and
removing differential
transmission housing
oil seal
11
12
FE01-2010b
FE01-2011b
FE01-2028b
Tool for installing and
GL201
dismantling differential
bearing
Tool for installing
GL201
manual shifter
assembly oil seal
13
14
FE01-2014b
FE01-2015b
GT301 Oil seal handle
Tool for installing and
GT301
dismantling valve oil
seal
Page 83
15
83
GT301
Tool for installing
valve oil seal
16
17
FE01-2016b
FE01-2017b
FE01-2018b
Tool for installing and
GT301
removing valve guide
pipe
GT301
Tool for installing front
oil seal of crankshaft
18
19
FE01-2019b
FE01-2020b
GT301
Crankshaft rear oil seal
Installation Tool
GT301
Tool for installing and
removing piston pin
Page 84
20
84
GT301 Clutch assembly tool
21
22
FE01-2021b
FE01-2022b
FE01-2029b
GT301
Tool for locating
camshaft
GT301
Tool for locating
crankshaft belt disc
23
GT301
FE01-2023b
Tool for tightening
flywheel
24
GT301
FE01-2024b
Tool for tightening
timing chain
Page 85
85
1.12.1.2 Special tool of chassis and body
S/N Illustration Tool No. Description
1
FE01-2025b
GL401
Front axle wheel hub
bearing dismantle
2
FE01-2026b
GL401
Tool for arc type
remover o`f drive shaft
Tool for installing and
3
GL401
removing rear axle
rubber sleeve
FE01-2027b
Page 86
2.1 Warnings and notices .......................................... 89
2.2.7.9 Data Flow Table ......................................... 141
2.1.1 Warning and precaution .................................. .89
2.2 Control system (4G20/4G24 with Delphi systems).
.................................................................................. 91
2.2.1 Specifications ................................................... 91
2.2.1.1 Fastener specifications .................................. 91
2.2.1.2 Relation of temperature sensor temperature
and resistance .......................................................... 93
2.2.1.3 Relation of altitude and atmospheric pressure
................................................................................. .94
2.2.2 Description and Operation ............................. 95
2.2.2.1 Overview ...................................................... 95
2.2.2.2 Components Description. ............................. 96
2.2.3 System operating principle ............................. .99
2.2.3.1 Electronic Throttle Body (ETC) Operating
Principle .................................................................. 99
2.2.3.2 ECM Controlled Fuel Supply System ........ 101
2.2.3.3 ECM Controlled Ignition System ............... 103
2.2.3.4 Electronic Throttle Body Function Restrictions
................................................................................ 104
2.2.3.6 Knock Control ............................................ 106
2.2.3.7 Air-conditioning Switch off Control ........... 107
2.2.3.8 Canister Solenoid Valve Control .............. 107
2.2.4 Component Location ..................................... 109
2.2.4.1 Engine Coolant Temperature Sensor,
Electronic Throttle Body, Intake Pressure
Temperature Sensor ................................................ 109
2.2.7.10 Action Test List ........................................ 144
2.2.7.11 Learning on Crankshaft Position Sensor
(CKP). .................................................................... 147
2.2.7.12 Electronic Throttle Body (ETC) Inspection
................................................................................ 148
2.2.7.13 Acceleration Pedal Position Sensor (APP)
Inspection ............................................................... 149
2.2.7.14 DTC Chapter Index. ................................. 151
2.2.7.15 DTC P0011 P0012 P0016 P0026 ............. 156
2.2.7.16 DTC P0068 P0106 ................................... .161
2.2.7.17 DTC P0076 P0077. ................................... 165
2.2.7.18 P0107 P0108 ............................................ 169
2.2.7.19 DTC P0112 P0113 .................................... 175
2.2.7.20 DTC P0117 P0118 .................................... 179
2.2.7.21 DTC P0122 P0123. ................................... 184
2.2.7.22 DTC P0131 P0132 P0133 P0134 ............. 188
2.2.7.23 DTC P0135 ............................................... 195
2.2.7.24 DTC P0137 P0138 P0140 ........................ 199
2.2.7.25 DTC P0141 ............................................... 205
2.2.7.26 DTC P0171 P0172 P1167 P1171 P2187
P2188 ...................................................................... 209
2.2.7.27 DTC P0222 P0223 .................................... 213
2.2.7.28 DTC P0230 ............................................... 216
2.2.7.29 DTC P0261 P0262 .................................... 217
2.2.7.30 DTC P0264 P0265 .................................... 222
2.2.5 Disassemble drawings. .................................. 110
2.2.5.1 Electronic throttle body disassembly drawing
................................................................................ 110
2.2.6 Electrical schematic diagram ......................... 111
2.2.6.1 Electrical schematic diagram ...................... 111
2.2.7 Diagnostic information and procedures ......... 112
2.2.7.1 Diagnosis descriptions .............................. 112
2.2.7.2 Inspection of control system ....................... 112
2.2.7.3 Intermittent fault inspection ........................ 112
2.2.7.4 Fault symptom table ................................... 115
2.2.7.5 List of ECM Terminal Definition ............... 124
2.2.7.6 DTC Type Definition .................................. 128
2.2.7.7 Fault Diagnosis Code (DTC) List ............... 128
2.2.7.8 DTC Fail-Safe List. .................................... 133
2.2.7.31 DTC P0267 P0268 .................................... 227
2.2.7.32 DTC P0270 P0271 .................................... 232
2.2.7.33 DTC P0300 ............................................... 237
34 DTC P0324, P0325 ................................... 245
2.2.7.
2.2.7.35 DTC P0335, P0336 ................................... 250
2.2.7.36 DTC P0340 P0341 .................................... 255
2.2.7.37 DTC P0351 P0352 P0353 P0354 ............. 261
2.2.7.38 DTC P0420 ............................................... 263
2.2.7.39 DTC P0458 P0459 .................................... 267
2.2.7.40 DTC P0480 P0481 .................................... 272
2.2.7.41 DTC P0502 ............................................... 273
2.2.7.42 DTC P0506 P0507. ................................... 278
Page 87
2.2.7.43 DTC P0562 P0563 .................................... 281
2.6 Mechanical system (4G20/4G24) ..................... 413
2.2.7.44 DTC P0571 ............................................... 287
2.2.7.45 DTC P0601 P0602 P1516 P2101 .............. 289
2.2.7.46 DTC P0641 P0651 .................................... 291
2.2.7.47 DTC P0646, P0647 ................................... 294
2.2.8 Removal and installation ............................... 329
2.2.8.1 Replacement of Engine Control Module .. 329
2.2.8.2 Engine coolant temperature sensor ............. 330
2.2.8.3 Replacement of Intake Pressure Temperature
Sensor ..................................................................... 331
2.2.8.4 Replacement of Electronic Acceleration Pedal
Assembly ................................................................ 332
2.3 Fuel System. ..................................................... 337
2.3.1 Specifications ................................................. 337
2.3.1.1 Fastener Specifications ............................... 337
2.3.2 Description and Operation ........................... 338
2.3.3 System operating principle. ........................... 340
2.3.4 Component position ..................................... 341
2.3.5 Disassemble drawings ................................... 345
2.3.6 Electrical schematic diagram ......................... 346
2.3.7 Diagnostic Procedures and Description ......... 347
2.3.8 Removal and installation ............................... 349
2.4 Auxiliary Emission Control Device .................. 361
2.4.1 Specifications ................................................. 361
2.4.2 Description and Operation ............................. 362
2.4.3 System operating principle ............................ 364
2.4.4 Component position ....................................... 365
2.4.5 Electrical schematic diagram ......................... 367
2.4.6 Diagnostic message and steps ...................... 368
2.4.6 Removal and installation ............................... 373
2.5 Engine Anti-theft System ............................... 377
2.5.1 Specifications ................................................. 377
2.5.2 Description and Operation ............................. 377
2.5.3 System operating principle. ........................... 379
2.5.4 Component position ..................................... 380
2.5.5 Disassemble drawings. .................................. 381
2.5.6 Electrical schematic diagram ......................... 382
2.5.7 diagnostic message and steps ......................... 383
2.6.1 Specifications .............................................. 413
2.6.2 Description and operation ............................. 422
2.6.3 System operating principle ............................ 423
2.6.4 Component position ...................................... 426
2.6.5 Part disassembly drawing .............................. 427
2.6.6 Electrical schematic diagram ......................... 431
2.6.7 Diagnostic information and procedures ......... 432
2.6.8 Removal and installation ............................... 446
2.6.9 Special Tools and Equipment ........................ 511
2.7 Exhaust System ................................................ 514
2.7.1 Specifications .............................................. 514
2.8 Cooling system ................................................. 534
2.8.1 Specifications ................................................ 534
2 . 9 Lubrication system (4G20/4G24) ................... 588
2.9.1 Specifications ................................................ 588
2.10 Ignition System ............................................. .607
2.10.1 Specifications ............................................ 607
2.11 Start Charging System .................................... 624
2.11.1 Specifications .............................................. 624
2.11.2 Description and operation ........................... 626
2.11.3 System operating principle .......................... 628
2.11.4 Part position figure ...................................... 630
2.11.5 Diagnostic information and procedures ....... 632
2.11.6 Removal and installation ............................. 639
2.12 control system (4G18 with Delphi systems)... 645
2.12.1 Specifications ............................................ 645
2.12.2 Description and Operation ........................... 650
2.12.3 System operating principle .......................... 654
2.12.4 Component Location ................................... 664
2.12.5 Disassemble drawings ................................. 666
2.12.6 Electrical schematic diagram ....................... 667
2.2.7 Diagnostic information and procedures ......... 674
2.12.8 Removal and installation ........................... 918
2.13 Mechanical system(4G18) .............................. 927
2.13.1 Specifications .............................................. 927
2.13.2 Description and Operation ........................... 936
2.5.8 Removal and installation. ............................. .410
Page 88
2.13.3 System Operating Principle ......................... 937
2.14.2.1 Operated and description. ...................... .1062
2.13.4 Component position ..................................... 940
2.13.5 Part disassembly drawing ............................ 941
2.13.6 Electrical schematic diagram ....................... 946
2.13.7 Diagnostic Information and Procedures ...... 947
2.13.7.1 Diagnosis Descriptions ............................. 947
2.13.7.2 Visual Inspection ...................................... 947
2.13.8 Removal andinstallation. ............................. 966
2.13.9 Special Tools and Equipment .................... 1058
2.13.9.1 Special Tools List ................................... 1058
2.14 Lubrication system (4G18) ........................... 1061
2.14.1 Specifications ............................................. 1061
2.14.1.1 Fastener Tightening Specification ........ 1061
2.14.2 Description and Operation ......................... 1062
2.14.3 System operating principle ........................ 1063
2.14.3.1 Lubrication Schematic ............................ 1063
2.14.4 Component position ................................ 1064
2.14.4.1 Component position ............................... 1064
2.14.5 Disassemble drawings ............................... 1065
2.14.5.1 Disassembly diagram ........................... 1065
2.14.6 Electrical schematic diagram ..................... 1066
2.14 .6.1 Electrical Schematic Diagram ............... 1066
2.14.7 Diagnostic message and steps ................. 1067
2.14.7.1 Diagnosis descriptions ............................ 1067
2.14.7.2 Visual inspection .................................... 1067
2.14.8 Removal and installation ........................... 1072
2.14.8.1 Replacement of Oil Pump ...................... 1072
Page 89
2.1 Warnings and notices
89
2.1.1 Warning and precaution
Warning on Battery Disconnection
Warning: Unless directed otherwise in the operating procedures, the ignition key must be at the
OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical
component. Disconnect the negative battery cable if a tool or any equipment easily comes in
contact within exposed electrical terminal. Failure to follow these precautions may result in
personal injury and/or damage to the vehicle or its components.
Warning for air exhaust system maintenance
Warning: When air exhaust system is too hot, please do not repaired air exhaust system to avoid
scald Please repair it after air exhaust system cooled
Warning for fuel and evaporation air exhaust pipe
Warning: reduce fire and personal injury, please you are comply with ways as follow:
z Replace all fuel pipes that are nicked, scratched or damaged during installation, do not
attempt to repair the fuel pipes.
z Do not hammer directly on the clips of fuel harness body when installing new fuel pipes.
z Always cover fuel vapor pipes with a wet towel before using a torch near them. Also, never
expose the vehicle to temperature higher than 115℃ (239℉) for more than one hour, or
higher than 90℃ (194℉) for any extended period.
z Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel
pipe fittings, which will ensure proper reconnection and prevent a possible fuel leakage.
(During normal operation, the O-rings located in the female connector will swell and may
prevent proper reconnection if not lubricated.)
Fuel Gage Leak Warning
Warning: Wrap a shop towel around the fuel pressure connection in order to reduce the risks of
fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection
of the fuel pressure gage. Place the towel in a proper container when the connection of the fuel
pressure gage is complete.
Fuel Pipe Fitting Warning
Warning: Always apply a few drops of clean engine oil to the male pipe ends before connecting
the fuel pipe fittings in order to reduce the risks of fire and personal injury. This will ensure proper
reconnection and prevent a possible fuel leakage. During normal operation, the O-rings located in
the female connector will swell and may prevent proper reconnection if not lubricated.
Warning on Installing Stop Bracket of Fuel Distributing Pipe
Warning: The stop bracket of fuel distributing pipe must be installed on the engine assembly.
When vehicle’s frontal collision happens, stop bracket can be considered as a guard board of fuel
distributing pipe. If stop bracket of fuel distributing pipe is not installed, fuel injection may
cause fire and result in personal burn when vehicle’s frontal collision happens.
Fuel Storage Warning
Warning: Do not drain the fuel into an open container. Never store the fuel in an open container
due to the possibility of a fire or an explosion.
Warning on Fuel Vapors in Evaporative Emission Components
Warning: Do not breathe the air through the EVAP tubes or hoses. The fuel vapors inside the
EVAP components may cause personal injury.
Gasoline/Gasoline Vapors Warning
Page 90
Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition
90
source is present. Never drain or store gasoline or diesel fuel in an open container, due to the
possibility of fire or explosion. Have a dry chemical fire extinguisher prepared nearby.
Warning on Lower O-ring Removal of Fuel Injector
Warning: Verify that the lower (small) O-ring of each injector does not remain in the lower
manifold in order to reduce the risks of fire and personal injury. If the O-ring is not dismantled
with the injector, the replaced injector with new O-rings will not be seated properly in the injector
socket. Improper seating could cause fuel leakage. When reassembling the injector, replace the
lower O-ring together.
Warning relating to the disassemble of radiator cap
Warning: To avoid being burned, do not remove the radiator cap while the engine is still hot. The
cooling system will release scalding fluid and steam under high pressure if radiator cap is removed
while the engine and radiator are still hot.
Warning on Cooling System Maintenance
If pressure cap is removed while the engine is still hot and under pressure during maintenance, the
engine coolant will boil immediately and spray into the operator's body, causing serious burns.
Releasing Fuel Pressure Warning
Warning: Remove the fuel tank cap and release the fuel system pressure before servicing the fuel
system in order to reduce the risk of personal injury. After you release the fuel system pressure, a
small amount of fuel may release when servicing the fuel circuit, the fuel injection pump, or the
connections. In order to reduce the risk of personal injury, cover the fuel system components with
a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in
an approved container when the disconnection is complete.
Road Test Warning
Warning: Take a road test under safe conditions while obeying all traffic laws. Do not attempt any
operation that could jeopardize vehicle control. Failure to obey these precautions will lead to
serious personal injury and vehicle damage.
Page 91
2.2 Control system (4G20/4G24 with Delphi systems)
91
2.2.1 Specifications
2.2.1.1 Fastener specifications
Tightening Torque
Fastener Name Specification
Camshaft Position Sensor
Bolts
Fixing Bolts of Crankshaft
Position Sensor
Fixing Bolts of Ignition
Coil
Engine Control Module
Bolts
Temperature sensor of
engine coolant bolts
Evaporative Emission
Canister
Evaporative Emission
Canister Solenoid Valve
Bracket Bolts
M6×14 8-10 6-7.4
M6×12 8-10 6-7.4
M6×35 7-11 5.2-7.8
M6×16 8-10 6-7.4
M12×1.5×6 15 11
M6×20 7-9 5.2-6.7
M6×20 7-9 5.2-6.7
Metric (N.m)
English system
(lb-ft)
Fuel Filter Mounting
Bracket Assembly Bolts
Fuel Filter Mounting
Bracket Bolts
Fixing Bolts of Fuel
Distributing Pipe
Fixing Bolts of Fuel Tank M10×30 38-46 28.1-34
Fixing Bolts of Idle Speed
Control Valve
Bolts of Knock Sensor M8×30 15-22 10.7-16
Fixing Bolts of Intake
Manifold Absolute Pressure
and Temperature Sensors
Oxygen Sensor Bolts M18×8 44 32.6
M6×16 8-10 6-7.4
M6×16 8-10 6-7.4
M6×20 10 7
M4×10 2-3 1.5-2.4
M6×12 8-10 6-7.4
Page 92
Air-conditioning
92
compressor mounting
bracket bolt
Spark Plug M14×1.25×22 20-30 14.8-22.4
M8×80 25 18.2
Throttle Body Retaining
Nut
M8 20-25 14.8-18.5
Page 93
2.2.1.2 Relation of temperature sensor temperature and resistance
93
Temperature (℃) /(℉)
-30/-22 26000
-25/-13 19000
-20/-4 15000
-15/5 11800
-10/14 9000
-5/23 7000
0/32 5600
5/41 4600
10/50 3600
15/59 3000
20/68 2400
25/77 2000
30/86 1700
Resistance (Ω)
35/95 1400
40/104 1180
45/113 950
50/122 800
55/131 700
60/140 600
65/149 510
70/158 425
80/176 320
90/194 240
100/212 180
110/230 140
120/248 110
130/266 90
Page 94
2.2.1.3 Relation of altitude and atmospheric pressure
94
Altitude (m)/(ft) Atmospheric Pressure (kPa)/(psi)
4200/13780 55/8
3900/12795 58/8.4
3600/11811 61/8.8
3300/10827 64/9.3
3000/9843 66/9.6
2700/8858 69/10
2400/7874 71/10.3
2100/6890 74/10.7
1800/5906 77/11.2
1500/4921 80/11.6
1200/3937 83/12
900/2953 87/12.6
600/1969 90/13.1
300/984 93/13.5
0 100/14.5
2.4.1.4 Intake Pressure Sensor Voltage and Pressure Diagram
Output voltage
输出电压
V
4.65
0.4
20
Absolute pressure
绝对压力
115
CE02-0001b
kPa
Page 95
2.2.2 Description and Operation
95
2.2.2.1 Overview
This engine control system uses Delphi MT22.1 Control System. Its main characteristic is that the
engine control module (ECM) acts as the core system. The traditional mechanical throttle pedal
and mechanical throttle body are replaced by more advanced electronic throttle acceleration pedal
sensor assembly and the electronic throttle body assembly. Due to this advanced system, ECM
torque control over the engine is more convenient. In addition, MT22.1 control system also
incorporates multi-point sequential fuel injection, group direct ignition without electricity
distributions, variable valve timing control and three-way catalytic converter post-processing,
capable to meet the increasingly stringent emission regulations.
The system’s main functions include:
1. Engine torque output control mode: ECM calculates the gas flow through the intake air
temperature sensor and intake manifold pressure sensor signals, making the Air-Fuel ratio
closer to the current engine’s operating condition demand.
2. Torque control mode: ECM calculates the current required output torque and controls the
engine output power, according to the acceleration pedal position sensor signal.
3. Main relay control of Complete Vehicle.
4. Close-loop control multi-point sequential fuel injection: A close-loop fuel control can
precisely control the engine air- fuel ratio, and therefore efficiently controls emissions. Closeloop control can effectively eliminate the system and related mechanical component swear
and tear due to manufacturing error and improves vehicle consistency.
5. Variable Valve Timing (VVT) control: Variable valve timing control system uses VVT
actuator to change the relative positions between intake camshaft and crankshaft. Engine
management system calculates the best valve timing based on engine operating conditions,
and controls VVT solenoid valve movement, allowing flow and direction of oil pressure in
VVT actuator to change, and ultimately promoting the camshaft movement to the desired
position.
6. Fuel supply control without fuel return.
7. Fuel pump working control.
8. ECM has built-in ignition drive module and group direct ignition without electricity
distributions.
9. Knock Control: When the knock sensor detects a knock occurring, the system will calculate
the ignition advance angle delay based on the current conditions, knock intensity and other
necessary information, and defers the ignition advance angle, so as to avoid or reduce knock.
Electronic Throttle Control: Since the system uses an electronic throttle, highly precise idle
control can be achieved. Taking the electrical load compensation as an example, when there
is electrical load or the load is cut off, due to the sudden increase or decrease in engine load
which results in engine speed fluctuation in a certain range, therefore, we add the electrical
load control adjustments. When the load increases or decreases, adjust the air flow rate and
/or the ignition advance angle accordingly to make sure that the idle speed remains steady at
the best condition.
10. Canister Solenoid Valve Control
11. Cooling fan relay control
12. System self-diagnostic function: After the system enters working condition, ECM controls all
system components working, and tests them in real time. Once the system or component
malfunction occurs, the system will light up the engine malfunction lamp to remind the driver
to repair or service the vehicle on time. In the mean time, ECM will start fault protection
mode.
13. System over-voltage protection: When the charging system malfunction causes the voltage
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too high, the system will enter protection mode to restrict the engine speed to prevent ECM
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damage.
2.2.2.2 Components Description
1. Engine Control Module (ECM)
Engine control module is a microprocessor with a single chip as the core. Its function is to process
data from various vehicle sensors to determine the engine's working condition, and controls each
engine actuator through various actuators.
ECM Normal work voltage is 9.0 V–16 V
Notes:
Although ECM has the over-voltage and reverse polarity voltage protection function, during the
repair process it is prohibited to connect the battery positive and negative wrong or apply voltage
higher than 15 V. Otherwise, it will cause damage to ECM and other electrical equipments.
2. Crankshaft Position Sensor
The crankshaft position sensor output can be used to determine crankshaft position and rotation
speed. The engine rotation speed and crankshaft position sensor are magnetic-electric sensors
installed near the crankshaft. When the crankshaft rotates, they work together with the 58X gear
on the crankshaft. The 58x tooth top and the alveolar pass through the sensor in different distances
when the crankshaft rotates. The sensor senses the reluctance change; the alternating reluctance
generates an alternating output signal. The 58x gear plate gap position aligns with engine top dead
center. When the cylinder No.1 reaches top dead center, the sensor aligns with the 20th tooth lower
edge. ECM uses this signal to determine crankshaft position and rotation speed.
Resistance Value of the Sensor: 20-30℃（68-86℉）900-1100Ω.
Output Voltage: 400 mV at 60 rpm, the voltage increases as the speed increases.
3. Intake Air Pressure/Temperature Sensor:
This sensor detects intake manifold pressure change caused by engine load and speed changes.
These changes will be converted to the voltage output. When the engine decelerates, the throttle
body closes to result in a relatively low intake manifold absolute pressure output. Intake manifold
absolute pressure and vacuum degree is opposite. When the manifold pressure is high, the vacuum
degree is low. MAP sensor is also used to measure atmospheric pressure. This measurement is
completed as part of the MAP sensor calculation. When the ignition switch is turned on and the
engine is not running, the engine control module reads the intake manifold pressure as
atmospheric pressure, and adjusts the Air-Fuel ratio accordingly. With this kind of altitude
compensation, the system can maintain a low emission while maintaining maneuverability.
4. Camshaft Position Sensor (CMP)
Camshaft position sensor is a Hall-effect sensor which is installed in the vicinity of the intake
camshaft, and works together with camshaft signal wheel. The signal wheel is corresponding to
the specific engine position. ECM measures digital voltage signal through this sensor, therefore
determining the working cylinder of the engine and implementing one-to-one control. Engine
control module then calculates the actual sequence of fuel injection. If the engine is running when
the camshaft position sensor signal is lost, the fuel injection system will be converted to the
sequential fuel injection mode based on the final fuel injection pulse, while the engine continues to
run. If the engine starts after being shut down, the fuel injection sequence will be converted from
sequential injection to group injection. Even if the fault exists, the engine can be restarted.
5. Engine Coolant Temperature (ECT) Sensor
Engine coolant temperature (ECT) sensor is used to detect the engine operating temperature. ECM
provides the best control scheme depending on the temperature. The sensor uses a negative
temperature coefficient thermostat as the sensing element, when the coolant temperature rises, the
resistance decreases. At -30°C the resistance is 52,594 Ω; at 130 °C, the resistance is 77.5 Ω. The
sensors are installed in the main coolant path. The coolant temperature signal is important to the
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ignition timing and fuel injection adjustment, while the signal is also transmitted to the instrument
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panel (IP) and used to display the current engine working temperature.
6. Knock Sensor (KS)
Knock sensor is a frequency response sensor, installed at the engine block’s most sensitive part to
knocking under the intake manifold. ECM uses knock sensor to detect knock intensity, so as to
adjust the ignition advance angle to effectively control knocking and optimize the engine power,
fuel economy and emission levels. If the engine knocking occurs, ECM will receive this signal,
filter out the non-knock signals and make the calculation. It determines the engine’s position in the
working cycle through the camshaft and crankshaft position sensor signals, according to which the
ECM figures out the knocking cylinder and then delays the ignition advance angle for this cylinder
until the knocking disappears. Then ECM advances the ignition advance angle until the ignition
angle is best suited for the operating conditions at that time. Due to weak sensor signals, the sensor
lead has a shielded cable. Its resistance is over 1M Ω (20-30℃) with the output signal greater than
17 mV/g in any case.
7. Oxygen Sensor
Oxygen sensor is an important symbolic component in a close-loop fuel control system, which
adjusts and maintains the ideal Air-Fuel ratio, so that three-way catalytic converter achieves the
best conversion efficiency. When the Air-Fuel ratio for engine burning becomes thin, the oxygen
content in the exhaust increases, and oxygen sensor output voltage is reduced. On the contrary, the
output voltage increases to feedback the air- fuel ratio to ECM.
Oxygen sensor sensing material is Zirconia, hollow with an external sensing part. When the
Zirconia components are heated (>300℃) for activation, the reference air enters the hollow part of
the Zirconia component through the lead wire. The exhaust passes through the outer electrode, and
the oxygen ions move from the center of the zirconia to the outer electrode, which thus consists of
a simple atomic battery with a voltage between two electrodes; the Zirconia can alternate the
output voltage according to the oxygen concentration in the exhaust and therefore determine the
oxygen content of exhaust gas. Usually, the oxygen sensor is designed to generate a voltage
amplitude jump in the vicinity of the exhaust theoretical Air-Fuel ratio of (14.7:1) to help the ECM
determine the Air-Fuel ratio accurately.
8. Fuel Injectors
The injector nozzle’s structure is an electromagnetic switch ball valve device. The both electrodes
from the coil are connected to the ECM and the power supply through the engine wiring harnesses.
When the coil is controlled by ECM to connect to the system ground, the resulting magnetic force
overcomes the spring force, fuel pressure and manifold vacuum suction to draw up the valve core.
The fuel sprays from the guide hole through the valve seat hole mistily to the intake valve. When
the power supply is cut off, the magnetic force disappears. Under the spring force and the fuel
pressure, the injector nozzle closes. The top of the fuel injector has the reliable fuel pressure
sealing generated by the rubber seal ring and the fuel rail interface; the lower part also uses the
rubber seal ring and engine air intake manifold to form the air sealing. Fuel injector resistance is
11.4-12.6 Ω.
Note: When the fuel injector is blocked or not closed tightly, the engine malfunction lamp may
be lit, but the detection fault code is: oxygen sensor distortion, erratic signal, abnormal Air-Fuel
ratio and other faults. At this time, the failure component should be carefully judged. Because
when the fuel injector is blocked or leaking, the amount of fuel injected is not controlled by the
ECM pulse width, the mixed air concentration signals of the oxygen sensor feedback to ECM
will be very different from the ECM control target. When ECM detects this signal, it will
determine whether the oxygen sensor is working properly. But the system cannot determine
whether the fault comes from the oxygen sensor itself or other associated malfunction due to the
damage of other parts. Therefore, at the service of such malfunctions, the failed components
must be carefully identified.
9. Fuel Pump Assembly
The fuel pump is turbine single-stage electric fuel pump under the control of the ECM via the fuel
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pump relay. It has a check valve at the outlet of the fuel pump. When the engine is not running, the
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remaining oil in the pipeline will not quickly return to the fuel tank, so as to ensure the re-starting
performance. Fuel level sensor is a variable sliding resistance type.
10. Ignition Coil
Cylinder 1 and 4 have their ignition coils located at the top of the Cylinder 4’s spark plug opening.
Cylinder 2 and 3 have their ignition coils located at the top of the Cylinder 2’s spark plug opening.
Ignition coil primary winding low voltage will be transformed into the secondary winding high
voltage. The spark plug discharges spark, igniting the air and fuel mixture inside the cylinder.
Ignition occurs when one piston is at the compression TDC and the other is at exhaust TDC. For
the internal air pressure in the cylinder near the exhaust TDC is low but the temperature is high.
Less energy will enable the ignition through electrode puncture at the spark plug with less energy,
known as redundant ignition. While, the cylinder mixture density and pressure is high at the
compression TDC, more ignition energy is required for spark plug ignition making the mixture
quickly ignited for power. Therefore, this cylinder ignition is called the effective ignition.
11. Electronic Throttle Body (ETC)
The electronic throttle valve assembly opening is determined by ECM according to the
driver-controlled throttle pedal control input signals, and other input signals after calculating the
vehicle currently needed engine output power to control the fuel supply (spray) amount, and then
adjusting the control parameters based on feedback signals to make sure that the engine works
under the best controlled status. Electronic throttle valve body adds the drive motor, gear drive
mechanism and other components, as well as a throttle position sensor with enhanced functionality
and reliability.
12. Canister Solenoid Valve (EVAP)
The canister control valve is located at the side of the engine cylinder head (transmission side) and
is used to control the canister purge flow. ECM controls intake manifold gasoline vapor volume
through canister solenoid valve. ECM sends square pulse wave. Air flow volume and control pulse
square wave relationship is linear.
ECM changes canister working time and rate according to engine speed and load conditions.
Solenoid valve coil resistance: 11 - 22 Ω.
13. Variable Valve Timing Solenoid Valve (VVT)
VVT solenoid valve is located at the intake manifold side near the engine front. VVT magnetic
valve is a 4-digit 4-channel solenoid valve with the working power supplied from main relay
controlled by ECM. ECM controls VVT solenoid valve grounding with a pulse width modulation
signal. The crankshaft to the camshaft timing relations can be continuously changed. The best
valve timing control can be achieved at different engine running conditions. This will help to
increase engine efficiency, improve idle stability, and provide more torque and power, while
helping to improve the fuel economy and lower emissions of hydrocarbons and nitrogen oxides.
Solenoid valve resistance: 7.2 Ω at 20°C (68℉)
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2.2.3 System operating principle
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2.2.3.1 Electronic Throttle Body (ETC) Operating Principle
Accelerator position
油门踏板位置
sensor assembly
传感器总成
Engine control
发动机
module
控制模块
Electric control throttle
电子控制
body assembly
节气门体总成
NL02-2014b
Electronic throttle body assembly must be used dedicatedly to the engine electronic control
module (ECM) with ETC system-driven feature hardware as the core control element. System
control software usually uses the computer algorithms mode, basing on the engine torque output
control. At the same time, due to the cancellation of the traditional mechanical throttle valve
control of mechanical pull cables, ETC is equipped with a acceleration pedal position sensor (APP)
with a resistive potentiometer device, in order to provide vehicle handling demand information
and other information for the driver to control the vehicle to the engine electronic control module
(ECM).
Electronic throttle body opening is determined by ECM according to the acceleration pedal control
input signals. With other engines and vehicles sensor input signals, ECM analyzes the driver's
intention in advance and calculates the needed engine output power and accordingly adjusts the
engine throttle opening and fuel supply (injection) amount. At the same time, the electronically
controlled throttle position sensor can detect the actual throttle opening and send the feedback to
ECM. ECM then, based on this feedback signal, adjusts the vehicle control parameters. This
control process ensures that the engine and vehicle work in the ideally controlled conditions. Due
to the rapid development of modern science and technology, High-Speed ECM can quickly
analyze the driver's intention and calculate the basic throttle opening parameter values, based on
the throttle pedal signal, the signal variation and signal change rate. At the same time, ECM
adjusts and optimizes the throttle opening parameter, based on various sensors input signal status,
so that the system further calculates the optimum throttle opening control parameters and
implements the actual throttle control. ECM sends the output control signal to the ETC motor
drive circuit to open the throttle according to the calculated opening parameter, based on the
revised throttle opening and pre-determined control strategy. Because of the high speed calculation,
the system enables smooth engine speed changes under transition engine operating conditions. The
whole control process only requires a few milliseconds, achieving excellent vehicle performance.
The application of automotive electronic technology makes it difficult to directly judge the
electronic drive control throttle valve body assembly diagnosis by conventional visual inspection
method. In the event of electronic controlled throttle body malfunction, the system needs to
provide a Jolt-limited function. It allows the driver to drive the vehicle to a repair station for
repair.
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Jolt-limited control has the following two kinds of control modes
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1. Jolt-limited control with the system unable to control the engine power
ECM will limit the engine power output, and the system can not control the throttle opening and
closing. The throttle opening is automatically adjusted to the system pre-determined position.
ECM will shut down the engine ignition output. At this time, the ECM internal fault occurs and
the system can not control the engine torque output. The throttle body adjusts the opening to (zero
position) off status. The system will fully turn off the ignition control function.
2. Jolt-limited control with the system unable to monitor the driver's intention
ECM will limit the engine power output. At this point, the system loses the ability to determine
and monitor the driver's intention. In order to prevent damage to the engine, ECM will limit the
engine power output and lower engine power increment and velocity increment. When braking,
ECM will adjust the engine speed to idle speed and adjust the throttle opening to the system
pre-determined position.
ECM will force the engine working at idle running status. When the system loses the ability to
determine and monitor the driver's intention, ECM will force the engine working at idle running
status, and system will work at pre-determined position controlled the idle speed.
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