Haval H5 Service Manual

Content

General Description of Complete Vehicle

Air Intake System

Exhaust System

Intercooler

Clutch

Transmission

Steering System

Body Electrical Appliance

Air Conditioning System

Airbag

Body Internal and External Trim

Body & Stamping Parts

General Description of Complete Vehicle-1

General Description of Complete Vehicle

Basic Parameters of Complete Vehicle .......................... 2

Structure Types and Technical Parameters of Main

Systems and Assemblies ................................................ 4

General Description of Complete Vehicle-2

Basic Parameters of Complete Vehicle

(1)

Model CC6461KM09 CC6461KM07 CC6461KM29 CC6461KM27
Mode 4×2 4×4
Rated passenger (person) 5
Curb weight of the complete vehicle (kg) 1725 1705 1805 1785
Max. gross mass (kg) 2200 2180 2280 2260
A x l e
l o a d
d ist r i­bution

O v e r a l l d i ­mensions

Axle base (mm) 2700

n o ­load
F u l l
load

Front axle (kg) 895 875 955 935
Rear axle (kg) 830 830 850 850
Front axle (kg) 995 975 1055 1035
Rear axle (kg) 1205 1205 1225 1225
Length (mm) 4649
Width (mm) 1810
Height (mm) 1745 1735

Wheel base

Min. ground clearance (mm) ≥180 ≥175

Min. turning diameter (m) ≤13

Front suspension (mm) 899

Rear suspension (mm) 1050

Approach angle (°) ≥22

Departure angle (°) ≥27.5

Four wheel alignment (no-load)

Toe-in of front wheel (mm) 0～2

Camber angle of front wheel (°) 0°±30′

Kingpin inclination angle (°) 12°30′±30′

Kingpin caster angle (°) 3°30′±30′

Front wheel steering angle (°) 32(inside)/28(outside)

Power performance:

Min. stable speed of direct drive (km/h) ≤25

Accelerating time of direct drive 30km/
h~100km/h (s)
Accelerating time of initial starting of
gear 1 shifting to 100km/h (s)

Top speed ( full load, km/h) 160

Front (mm) 1515

Rear (mm) 1520

≤32 ≤43 ≤32 ≤43

≤20

Max. climbing capacity (%) ≥35 ≥30 ≥35 ≥30

Economical efciency

Sliding distance with initial speed 50km/h
(m)
Fuel consumption under 90km/h cons­tant speed driving (L/100km)
Fuel consumption under 120km/h cons­tant speed driving (L/100km)

Fuel consumption combined(L/100km) ≤9.77 ≤9.5 ≤10.31 ≤9.5

≤8.65 ≤8.12 ≤8.65 ≤8.12

≤12.14 ≤10.92 ≤12.14 ≤10.92

≥500

General Description of Complete Vehicle-3

Brake performance

Service braking distance of initial braking
speed of 50km/h (m)
Emergency braking distance of initial
braking speed of 50km/h (m)
Grade p a r k in g brake ( %) (less tha n
5min)(%)

Noise

Outside noise when driving in accelera­tion speed dB (A)
Inside noise when driving in uniform
speed of 50km/h dB(A)

Parotid noise beside the driver dB(A) ≤90

≤19(no-load), ≤20(full load)

≤38

Under no-load, it can be kept xed-

ness on the road of the 20% grade

≤74

≤79

(2)

Model CC6461KM45 CC6461KM65
Mode 4×2 4×4
Rated passenger (person) 5
Curb weight of the complete vehicle (kg) 1825 1925
Max. gross mass (kg) 2510 2510

A x l e
l o a d
di st r i­bution

Overall dimen­sions

no-load

Full load

Front axle (kg) 990 1060
Rear axle (kg) 835 865

Front axle (kg) 1180 1180

Rear axle (kg) 1330 1330
Length (mm) 4649
Width (mm) 1810

Height (mm) 1745 1735

Axle base (mm) 2700

Wheel base

Min. ground clearance (mm) ≥180 ≥175

Min. turning diameter (m) ≤13

Front suspension (mm) 899

Rear suspension (mm) 1050

Approach angle (°) ≥22

Departure angle (°) ≥27.5

Four wheel alignment (no-load)

Toe-in of front wheel (mm) 0～2

Camber angle of front wheel (°) 0°±30′

Kingpin inclination angle (°) 12°30′±30′

Kingpin caster angle (°) 3°30′±30′

Front wheel steering angle (°) 32(inside)/28(outside)

Power performance:

Min. stable speed of direct drive (km/h) ≤25

Accelerating time of direct drive 30km/
h~100km/h (s)

Front (mm) 1515

Rear (mm) 1520

≤32

General Description of Complete Vehicle-4

Accelerating time of initial starting of
gear 1 shifting to 100km/h (s)

Top speed ( full load, km/h) ≥140

Max. climbing capacity (%) ≥45

Economical efciency

Sliding distance with initial speed 50km/
h (m)
Fuel consumption under 90km/h cons­tant speed driving (L/100km)
Fuel consumption under 120km/h cons­tant speed driving (L/100km)

Fuel consumption combined(L/100km) ≤8.53 ≤8.53

Brake performance

Service braking distance of initial bra­king speed of 50km/h (m)
Emergency braking distance of initial
braking speed of 50km/h (m)
Grade parking brake (%)(less than
5min)(%)

Noise

Outside noise when driving in accelera­tion speed dB (A)
Inside noise when driving in uniform
speed of 50km/h dB(A)

Parotid noise beside the driver dB(A) ≤90

≤6.83 ≤6.83

≤9.94 ≤9.94

≤19(no-load), ≤20(full load)

Under no-load, it can be kept xed-

ness on the road of the 20% grade

≤20

≥500

≤38

≤75

≤79

Structure Types and Technical Parameters of Main Systems and
Assemblies

Engine(1)

Vehicle type code CC6461KM09/CC6461KM29 CC6461KM07/CC6461KM27

Item Specications and parameters

Engine model 4G69S4N 4G63S4M

Mode

Cylinder diameter×stroke (mm) 87×100 85×88

Displacement (L) 2.378 1.997

Compression ratio 9.8:1 10:1

Rated power and corresponding
rotation speed (kW/r/min)
Max. torque and corresponding ro­tation speed (N·m/rpm)

Stable idle speed (r/min) 750±50 750±50

Max. net power (kW) 90 85

Four-cylinder, in-line, water cooling, single over-head camshaft,

four-stroke, multiple-point electro-injection gasoline engine

100/5250 90/5250

200/2500-3000 170/2500-3000

General Description of Complete Vehicle-5

Engine(2)

Vehicle type code CC6461KM45/CC6461KM65
Item Specications and parameters

Engine model GW2.5TCI

Mode

Cylinder diameter×stroke (mm) 93×92

Displacement (L) 2.499

Compression ratio 17.2:1
Rated power and corresponding
rotation speed (kW/r/min)

Max. torque and corresponding ro­tation speed (N·m/rpm)

Stable idle speed (r/min) 800±30

Max. net power (kW) 74

Four-cylinder, in-line, water cooling, four-stroke, superchar-

ge intercooling, high-pressure common rail diesel engine

80/3600

300/1800～2400

Air Intake System

CC6461KM09/CC6461KM29, CC6461KM07/CC6461KM27 Naturally intake air, air cleaner with reso­nance chamber.
CC6461KM45/CC6461KM65 Dry-type Air Cleaner, exhaust gas turbo charge inter-cooling system.

Exhaust System

CC6461KM09/CC6461KM29 It is equipped with rst-level silencer, with catalytic converter. For Euro

, it is equipped with OBD.

Ⅳ

CC6461KM07/CC6461KM27 It is equipped with rst-level silencer, with catalytic converter. For Euro

, it is equipped with OBD.

Ⅳ

CC6461KM45/CC6461KM65 It is equipped with rst-level silencer, with catalytic converter. For Euro

, it is equipped with OBD.

Ⅲ

Fuel Supply System

Fuel tank is plastic, with the capacity of 70L.
CC6461KM09/CC6461KM29, CC6461KM07/CC6461KM27 fuel supply control is mechanical pedal
type, with built-in electronic fuel pump.
CC6461KM45/CC6461KM65 fuel supply control is electronic control type.

Cooling System

Closed and forced water cooling, electronic fan or mechanical fan

Clutch

Friction type, disc type single plate, dry-type diaphragm spring clutch, with hydraulic control.

Transmission(1)

Vehicle type code CC6461KM09 CC6461KM29
Model ZM001DB ZM001DF

All synchronizer with manual me­chanical step speed transmission of
transfer case, 5 forward gears, 1 re-

verse gear, and direct control

Ⅰ
Ⅱ
Ⅲ
Ⅳ
Ⅴ

Gear H (high) 1.00

Gear L (low) 2.48

3.992

2.150

1.334

1.000

0.857

Mode

Speed ratio

Manual mechanical step speed trans-

mission of all synchronizer, 5 forward

gears, 1 reverse gear, and direct control

Gear

Ⅰ

Gear

Ⅱ

Gear

Ⅲ

Gear

Ⅳ

Gear

Ⅴ

Gear R (reverse) 4.22 Gear R (reverse) 4.22

3.992 Gear

2.150 Gear

1.334 Gear

1.000 Gear

0.857 Gear

General Description of Complete Vehicle-6

Transmission(2)

Vehicle type code CC6461KM45 CC6461KM65

Model 038M1 038M

All synchronizer with manual me­chanical step speed transmission of
transfer case, 5 forward gears, 1 re-

verse gear, and direct control

Ⅰ

Mode

Manual mechanical step speed trans-

mission of all synchronizer, 5 forward

gears, 1 reverse gear, and direct control

Gear

Ⅰ

3.8305 Gear

3.8305

Speed ratio

Transmission(3)

Vehicle type code

Model

Mode

gears, 1 reverse gear, and direct control

Gear

Ⅱ

Gear

Ⅲ

Gear

Ⅳ

Gear

Ⅴ

Gear R (reverse) 4.22 Gear R (reverse) 4.22

CC6461KM07 CC6461KM27

ZM001DB ZM001DF

Manual mechanical step speed trans-

mission of all synchronizer, 5 forward

Gear

Ⅰ 3.992

Gear

Ⅱ 2.150

Gear

Ⅲ 1.334

2.3300 Gear

1.4364 Gear

1.0000 Gear

0.7887 Gear

Gear H (high) 1.00

Gear L (low) 2.48

All synchronizer with manual me­chanical step speed transmission of
transfer case, 5 forward gears, 1 re-

verse gear, and direct control

Gear

Gear

Gear

Ⅱ

Ⅲ

Ⅳ

Ⅴ

Ⅰ 3.992

Ⅱ 2.150

Ⅲ 1.334

2.3300

1.4364

1.0000

0.7887

Speed ratio

Gear

Ⅳ 1.000

Gear

Ⅴ 0.857

Gear R (reverse)

4.22

Gear

Ⅳ 1.000

Gear

Ⅴ 0.857

Gear R (reverse)

Gear H (high)

Gear L (low)

4.22

1.00

2.48

Drive Shaft

The rear drive shaft assembly of CC6461KM09 and CC6461KM07 and CC6461KM45 wagon includes
three cross axle universal joints, two drive shafts, and maintenance-free sectional structure with ex­pansion spline and intermediate support.
The front and rear drive shaft assembly of CC6461KM29 and CC6461KM27 and CC6461KM65
wagon includes two cross axle universal joints, a drive shaft and maintenance-free integral structure
with expansion spline.

Front Axle

The front axle of CC6461KM09 and CC6461KM07 and CC6461KM45 and CC6461KM47 wagon is a
double-transverse arm independent suspension breakaway front axle.
For CC6461KM29 and CC6461KM27 wagon, it is equipped with double-transverse arm independent
suspension breakaway steering drive axle, hyperbolic gear single-stage main reducing gear, common
bevel gear differential, universal drive half axle. The main reducing ratio i0=4.22.

General Description of Complete Vehicle-7

For CC6461KM65 wagon, it is equipped with double-transverse arm independent suspension
breakaway steering drive axle, hyperbolic gear single-stage main reducing gear, common bevel gear
differential, universal drive half axle. The main reducing ratio i0=3.9.

Rear Axle

CC6461KM09/CC6461KM29, CC6461KM07/CC6461KM27 It is equipped with integral drive axle,
punching welding axle case, hyperbolic gear single-stage main reducing gear, common bevel gear di-

fferential, and semi-oating half axle. The main reducing ratio i0=4.22.

CC6461KM45/CC6461KM65 It is equipped with integral drive axle, punching welding axle case, hy-

perbolic gear single-stage main reducing gear, common bevel gear differential, and semi-oating half

axle. The main reducing ratio i0=3.9.

Wheel and Tyre

Tyre type Tyre specication Rim specication Tyre pressure Wheel offset

Tubeless

Radial tyre

235/65 R17

P235/65 R17

235/70 R16

P235/70 R16

5°deep-groove rim

17×7J (2WD)

5°deep-groove rim

16×7J (4WD)

230kPa +38mm

230kPa +38mm

Suspension

The front suspension is equipped with torsion bar spring, double-transverse arm independent suspen­sion.

The rear suspension is equipped with ve-bar linkage, coil spring and dependent suspension.

Frame

It is equipped with peripheral trapezoidal frame, and welded by two box-shaped section longitudinal
beams and several box-shaped or pipe-shaped section beams.

Steering System

It is equipped with rack and pinion power steering system, energy-absorbing steering column and ad­justable steering wheel angle.

Brake System

It is equipped with hydraulic dual-circuit layout, vacuum booster, and ABS anti-lock braking system.
The front wheel brake is ventilated disc brake, and rear wheel brake is disc-drum brake. The type of
parking brake is mechanical cable, which acts on drum brake of rear wheel.

Electrical System

System Structure and parameters

Combination meter Electronic

Ins trument sys­tem

P o w e r s u p p l y,
starting and char­ging system

Signal system Horn Basin, bi-tone horn

Auxiliary electri­cal system

Indicator light LED
S e n so r an d di mm i n g

switch

Circuit

Generator Built-in adjuster
Starter
A/C system Cold-warm automatic A/C
Battery 80Ah

Audible equipment DVD player, optional CD player
Cigar lighter 12V, 1
Rear window defrost Rear windshield is electric heating windscreen
Central control door lock With remote control
Glass lifter Electric

ABS electric control sys­tem

Conform to related system

One wire system, ground earth with negative pole, vol­tage direct current of 12V

12V, 1.2kW(gasoline); 12V, 2.8KW(diesel)

BOSCH ABS8.0 version, with EBD function (Electroni­cally Brake Distribution)

General Description of Complete Vehicle-8

Body and Interior/exterior trim

No. Item Structure and parameters

1 Vehicle body

1.1 Type of vehicle body

1.2 White body Punching, welding, all-metal close type structure

1.3 Door assembly

1.4 Engine hood With upward and backward openings and single arm hinge
2 Interior and exterior trim of body and accessories

2.1 Interior trim

2.2 Instrument panel Injection structure, metal skeleton

2.3

2.4 Handrail in the vehicle

2.5 Windshield

2.6 Rear-view mirror

2.7 Seat

2.8 Safety belt

2.9 Front and rear bumpers Integral design, PP injection molding

A, B, C columns and door
inner panel

Cab-behind-engine, two-carriage, four doors, five seats, all­metal close type, hard-top body-chassis frame construction

Framed and clamping-plate door lock, hinge with side anti-co­llision lever, four side doors with positive opening; rear tail door
with outward opening. Central control door lock, motor glass
lifter

Softening design, conform to the requirements of ergonomics
and comfort

Injection molding, glove box mounted on door panel

Metal skeleton, PVC case, with PUR foaming layer in the
middle

Panoramic bent windshield. Front windshield: Hyperbolic and
interlayer glass. Rear windshield: Hyperbolic and toughened
glass, with electric heating defrosting

Exterior rear-view mirror: Electric and electric heating defros­ting, with convex reflectors on both sides. Interior rear-view
mirror: Manual, non-glare, plane interior mirror

Seats for driver and auxiliary driver: Independent seat, with ad­justable front and rear/upper and lower position, backrest angle
and seat headrest. Rear seat: Independent seat, the backrest
can be turned and folded.

Fixing in two points for rear middle seat, emergency locking

mechanical safety belt xed by three points for other seats

A/C System

No. Item

1 Structure type Automatic warm-cold A/C, vapor compression refrigeration, hot water heating

2

3 Control

4 Refrigerant HFC-134a

5 Compressor

6 Condenser Parallel stream structure, with at-tube thickness of 20mm

7 Evaporator

8

9

10 Sensor
11 Pressure switch Tri-state pressure switch

P e r f o r m a n c e
parameters

Dry fluid reser­voir

R e f r i g e r a t i o n
pipe a n d hea ­ting water pipe

Refrigerating output of 4.5kW, heat exchange output of 4.5kW, air flow of
450m3/h

Control board button control, temperature automatic control, air door micro­motor drive, with automatic control of interior temperature, and selection and
adjustment function of air outlet position mode, heating/refrigeration mode,
interior/exterior circulation mode of air, air speed and temperature

SD7V16 variable displacement com­pressor, with max. displacement of

161.3ml

Two-box structure, layered evapora­tor, F-type expansion valve, centrifu­gal blower

Outer diameter of φ32mm

Refrigeration pipe: combined type of rubber cooling hose and aluminium
pipe. Heating water pipe: rubber molding pipe

Outdoor temperature sensor, indoor temperature sensor, evaporator temperature sensor

GW2.5TCI 4G69

Structure and parameters

Mitsubishi 105A fixed-displacement
compressor, with displacement of
105ml

Two-box structure, layered evapora­tor, H-type expansion valve, centrifu­gal blower

General Description of Complete Vehicle-9

Grades and Specifications of Operating Agent for Operating Parts of
Wagon(gasoline engine)

No. Operating parts Quantity Specications

1 Engine fuel (RON) 70L±3L

2

3 Coolant

4 Clutch uid

5

6

7 Rear drive axle 2.7L±0.1L API GL-5 grade hyperbolic gear oil

8

9 Brake uid

10 Battery terminal 1.0g Industrial vaseline

11

12 A/C Refrigerant 650g±20g HFC134a

13

Lubricating oil for
engine

Manual transmis­sion

Front drive axle 1.4L±0.1L
E l e ct r i c c o nt r o l

shift fork of front
axle

P o w e r s t e e r i n g

uid

Windshield w as ­hing solution

Other motion fric­tion pair

4.0L±0.1L (filled with
oil of 4.3L if replace

oil lter)

Main filling quantity:

6.5L±0.5L
Auxiliary lling quanti-

ty: 0.7L±0.1L
0 . 1 5 L (w i t h i n th e

mark)

2.4L±0.1L (2WD)

2.5L±0.1L (4WD)

0.19L±0.01L

791mL±32mL (within
the mark)

0. 5 2 5 L ( wi t hi n th e
mark)

2.5L±0.2L

- Universal lithium-based grease for 3# vehicle

Use lead free gasoline for the vehicles of high
quality above 93# (GB 17930—2006)

Above SAE SJ grade, choose oil according to
season

Ethylene— -35℃ ethylene glycol based antifreeze
coolant

DOT4 synthetic brake uid

API GL-4 grade hyperbolic gear oil

API GL-5 grade hyperbolic gear oil

ATF DEXRON III hydraulic transmission oil

DOT4 synthetic brake uid

Normal temperature: use cleaning water with har­dness less than 205g/1000kg. Low temperature
(-18℃±3℃): use methanol aqueous solution with
concentration of 50%

Grades and Specifications of Operating Agent for Operating Parts of
Wagon(diesel engine)

No. Operating parts Quantity Specications

0# light diesel oil (choose -10#, -20# or -35#

1 Engine fuel (RON) 70L±3L

2

3 Coolant

4 Clutch uid

5

6

Lubricating oil for
engine

Manual transmis­sion

Front drive axle 1.4L±0.1L

El ec t r i c con tr o l
shift fork of front
axle

4.2L±0.1L

Main filling quantity:

8.5L±0.5L
Auxiliary lling quanti-

ty: 0.7L±0.1L
0 . 1 5L (w i t h i n th e

mark)
2WD: 2.5L±0.1L
4WD: 2.5L±0.1L

0.19L±0.01L

according to the temperature i n the winter)
(GB252-2000)

Conform to API standard: above CI grade, with
viscosity of 15W-40 and 5W-40 or conform to
A-CEA standard: A3/B4 15W-50, 5W-40 (specifi­cally choose according to the local temperature)

-35℃ ethylene glycol based antifreeze coolant

DOT4 synthetic brake uid

API GL-4 grade hyperbolic gear oil

API GL-5 grade hyperbolic gear oil

General Description of Complete Vehicle-10

7 Rear drive axle 2.7L±0.1L API GL-5 grade hyperbolic gear oil

8

9 Brake uid

10 Battery terminal 1.0g Industrial vaseline

11

12 A/C Refrigerant 570g±20g HFC134a

13

Po w e r st ee ri n g

uid

Wi ndshield was­hing solution

Other motion fric­tion pair

775mL±32mL ATF DEXRON III hydraulic transmission oil

0 . 5 2 5 L ( w i t h i n th e
mark)

2.5L±0.2L

- Universal lithium-based grease for 2# vehicle

DOT4 synthetic brake uid

Normal temperature: use cleaning water with har­dness less than 205g/1000kg. Low temperature
(-18℃±3℃): use methanol aqueous solution with
concentration of 50%

Air Intake System-1

Air Intake System

Operating Instructions to Air Filter ..................................... 2

Parts Renewal ................................................................... 2

Air Intake System-2

Air Intake System

Operating Instructions to Air Filter

It i

1.

s requested to check and renew air lter element on a regular basis in compliance with ma-

intenance regulations and clean air lter element timely according to regulations of the routine

maintenance table.

2. Clean air ensures normal engine operation.

3. Driving without air lter element is strictly prohibited because this may damage engine.

4. Air lter element is tted in the air lter assembly on the left side of engine.

Parts Renewal

Type B worm drive type
hose hoop

Engine iron inlet pipe

Outlet pipe of air lter

(4G69 and 4G63 engine)

1. Remove air lter outlet pipe

(a) Unscrew type B worm drive type hose hoop bolts

between air filter casing and air filter outlet pipe
interface;

(b) Unscrew type B worm drive type hose hoop bolts

between engine iron inlet pipe and air lter outlet

pipe interface;

(c) Unplug air lter outlet pipe and remove it.

Air lter inlet pipe

He x ag o n he ad bo l t ,
elastic washer and plain
washer assembly parts

Inlet pipe bracket

Hexagon-head e d bol t ,
elastic washer and plain
washer assembly parts

2. Remove air lter inlet pipe

(a) Unscrew type B worm drive type hose hoop bolts

between lower air filter casing and air filter inlet
pipe interface;

(b) Unscrew hexagon head bolt, elastic washer and

plain washer assembly parts at the joint of air lter

inlet pipe and inlet pipe bracket, 1 off;

(c) Unplug air lter inlet pipe and remove it.

3. Remove air lter

(a) Unscrew hexagon head bolt, elastic washer and

plain washer assembly parts at the joint of air lter

and right front splashboard, 3 off;

(b) Remove air lter from engine compartment.

Upper air lter casing

Air lter element assembly

Lower casing of air lter

4. Remove air lter

(a) Unscrew seven xing bolts between upper casing

and lower casing of air lter;
(b) Detach upper casing and lower casing of air lter;
(c) Remove air lter element assembly.

Air Intake System-3

Groove

Partition plate

5. Renew air lter element assembly

(a) Use a piece of wet cloth to clean inner side of upper

casing and lower casing of air lter;

(b) Renew with new air lter element assembly.

6. Fit air lter assembly

Fitting steps are opposite to disassembly or removal
steps.

Attention:

1. Air filter element must be fitted to designed posi­tion.

(a) Partition plate of lower casing shall be necessarily

plugged into groove.

Filter element seal ring

(b) Filter element seal ring has to be assembled into

limiting part of lower casing.

2. Firstly plug three limiting edges on upper casing
of air filter into spacing grooves on lower casing
of air filter, align these edges with these grooves
and then screw down 7 bolts on upper casing of air
lter to t the upper casing of air lter. The tighte­ning torque is 1.6±0.2N•m.

Hexagon-head e d bol t ,
elastic washer and plain
washer assembly parts

3. Tightening torque of three hexagon head bolt, elas­tic washer and plain washer assembly parts at the

joint between air lter and right front splashboard

is 14±2N•m.

Air Intake System-4

Type B worm drive type hose hoop

Air lter outlet pipe

Air ow sensor unit

Type B worm drive
type hose hoop

Crankcase venti­lating hose

Engine inlet hose

(2.5TCI engine)

1. Detach air lter outlet pipe, air ow sensor unit and

engine inlet hose

(a) Remove wiring harness plug of air flow sensor

unit;

(b) Remove clips between engine inlet hose and

crankcase ventilating hose and unplug crankcase
ventilating hose;

(c) Unscrew type B worm drive type hose hoop bolts

between upper casing of air lter and air lter out­let pipe connector;

(d) Unscrew type B worm drive type hose hoop bolts

between engine inlet hose and turbocharger inlet;

(e) Unplug one end of air lter outlet pipe connected

with upper casing of air lter, remove one end of

engine inlet hose connected with turbocharger
and detach joint among air filter outlet pipe, air

ow sensor unit and engine inlet hose.

Air lter inlet pipe

He x a go n hea d bol t ,
elastic washer and plain
washer assembly parts

Inlet pipe bracket

Hexagon head bolt, elastic
washer and plain washer
assembly parts

2. Remove air lter inlet pipe

(a) Unscrew type B worm drive type hose hoop bolts

between lower casing of air lter and air lter inlet

pipe;

(b) Unscrew hexagon head bolt, elastic washer and

plain washer assembly parts at the joint of air lter

inlet pipe and inlet pipe bracket, 1 off;

(c) Unplug air lter inlet pipe and remove it.

3. Remove air lter

(a) Unscrew hexagon head bolt, elastic washer and

plain washer assembly parts at the joint between

air lter and right front splashboard, 3 off;

(b) Remove air lter from engine compartment.

Upper air lter casing

Air lter element assembly

Lower casing of air lter

4. Disassemble air lter

(a) Unscrew seven fixing bolts on upper casing and

lower casing of air lter;
(b) Detach upper casing and lower casing of air lter;
(c) Disassemble air lter element assembly.

Air Intake System-5

Groove

Partition plate

5. Renew air lter element assembly

(a) Use a piece of wet cloth to clean inner side of upper

casing and lower casing of air lter;

(b) Renew with new air lter element assembly.

6. Fit air lter assembly

Fitting steps are opposite to disassembly or removal
steps.

Attention:

1. Air filter element must be fitted to designed posi­tion.

(a) Partition plate of lower casing shall be necessarily

plugged into groove.

Filter element seal ring

(b) Filter element seal ring has to be assembled into

limiting part of lower casing.

2. Firstly plug three limiting edges on upper casing
of air filter into spacing grooves on lower casing
of air filter, align these edges with these grooves
and then screw down 7 bolts on upper casing of air
lter to t the upper casing of air lter. The tighte­ning torque is 1.6±0.2N•m.

Hexagon-head e d bol t ,
elastic washer and plain
washer assembly parts

3. Tightening torque of three hexagon head bolt, elas­tic washer and plain washer assembly parts at the

joint between air lter and right front splashboard

is 14±2N•m.

Exhaust System-1

Exhaust System

Part Drawing of Exhaust System (2.5TCI Left-hand Drive) 2

Remove exhaust system assembly .................................... 3

Fit exhaust system assembly ............................................ 4

Exhaust System-2

Part Drawing of Exhaust System (2.5TCI Left-hand Drive)

Exhaust System

Hexagon ange bolts

Hexagon ange nuts

Hexagon head bolt

Catalytic converter washer I

Hexagon ange nuts

Particle trap assembly

Oxygen catalytic converter assembly

Hexagon ange nuts

Exhaust pipe outlet gasket

Three-hole rubber block

Hexagon ange nuts

Three-hole rubber block

Catalytic converter washer II

Hexagon ange bolts

Silencer assembly

Silencer washer

Hexagon ange nuts

Rear section assembly of exhaust pipe

Three-hole rubber block

Hexagon ange bolts

Three-hole rubber block

Exhaust System-3

Warning: Disassembling and removal of all parts in

exhaust system shall be necessarily fullled 30min

after parking to prevent high-temperature parts
causing personal injury.

Remove exhaust system assembly

1. Remove rear section assembly of exhaust pipe

(a) Firstly use M15 sleeve wrench or ratchet wrench

and extension bar to remove silencer assembly
and then anges and connecting nuts in rear sec­tion of exhaust pipe and finally remove gaskets

between anges.

(b) Remove three-hole rubber blocks in back part of

rear section of exhaust pipe.

(c) Remove three-hole rubber blocks in front part of

rear section of exhaust pipe.

Attention: silencer washers between rear silencer

ange and rear ange of exhaust pipe mainly serve
as a sealing element. After being tted once, they

may encounter stressed deformation and poor sea­ling. Therefore, these washers can not be reused.

2. Remove silencer assembly

(a) If necessary, rstly remove rear section of exhaust

pipe according to steps of disassembling rear sec­tion of exhaust pipe. If not necessary, only uns-

crew connecting nuts between silencer and ange

in rear section of exhaust pipe.

(b) Use M15 sleeve, ratchet wrench or open-end

wrench (double offset ring wrench) to unscrew

connecting bolts and nuts between front ange of
silencer assembly and ange of particle trap ass-

embly. Special personnel shall be arranged to su­pport the silencer during the operation to prevent
it falling down and injuring the operator.

(c) Remove three-hole rubber blocks and then remo-

ve silencer assembly.

Attention: Catalytic converter washer II between
silencer and particle trap assembly mainly serves

as a sealing element. After being tted once, it may

encounter stressed deformation and poor sealing.
Therefore, these washers can not be reused.

3. Remove particle trap assembly

(a) If necessary, rstly remove rear section of exhaust

pipe and silencer according to steps of disassem­bling rear section of exhaust pipe and silencer. If
not necessary, only unscrew connecting bolts and
connecting nuts between silencer assembly and
particle trap assembly.

(b) Unscrew connecting nuts between front ange of

particle trap and rear flange of oxygen catalytic
converter.

Exhaust System-4

(c) Remove three-hole rubber blocks.
(d) Remove particle trap assembly.

Attention: Catalytic converter washer I between
particle trap assembly and oxygen catalytic con­verter mainly serves as a sealing element. After be­ing fitted once, it may encounter drastic stressed
deformation and poor sealing. Therefore, the was­her can not be reused.

4. Remove oxygen catalytic converter assembly

(a) Use M13 and M15 double offset ring wrench to

unscrew connecting bolts and nuts between front
flange of particle trap assembly and oxygen ca­talytic converter.

(b) Use M13 sleeve, large-sized extension bar and

ratchet wrench to loosen and remove bolts at ex­haust elbow outlet of turbocharger and then remo­ve oxygen catalytic converter assembly.

Attention: Two flat flanges are connected by joint
gasket assembly. Such assembly is comprised
of stainless steel pressing and can be used only
once.

Fit exhaust system assembly

1. Keep clearance of exhaust pipe assembly towards
parts on both sides more than 15mm.

2. A proper amount of silicon oil is applied to three­hole rubber block mounting holes. After being t­ted, the rubber blocks shall be evenly stressed.

3. Nut tightening torque of front exhaust pipe section
and exhaust manifold is 70±5N•m.

Intercooler

Part Drawing of Intercooler ................................................. 2

Overview of Intercooler....................................................... 2

Function of Intercooler ...................................................... 2

Classication of Intercooler .............................................. 3

Removal of Intercooler ...................................................... 3

Intercooler tting ................................................................ 3

Intercooler Maintenance .................................................... 3

Intercooler-1

Intercooler-2

Type B worm drive type hose hoop

Type A worm drive type hose hoop

Q67565

Intercooler rubber tube sleeve

Hexagon ange bolts

Q1840616FD

Rubber tube bracket

Intercooler

Part Drawing of Intercooler

Hexagon ange bolts

Q1840845FD

Q67683

Intercooler assembly

Hexagon ange bolts

Q1840845FD

Hexagon ange bolts

Intercooler bracket

Intercooler connecting hose

Type A worm drive type hose hoop

Q1841025FD

Q67565

Radiator suspen­sion rubber bloc

Hexagon ange bolts

Q1841025FD

Intercooler bracket II

Rubber tube bracket II

Big washer
Q40208FD

Intercooler mounting rubber block

Type B worm drive type hose hoop

Q67683

Hexagon ange bolts

Q1841025FD

Intercooler rubber
tube sleeve II

Intercooler rubber
tube sleeve II

Hexagon ange bolts

Q1840816FD

Overview of Intercooler

An intercooler can be seen only in a vehicle equipped with turbocharger because it is actually an auxi-

liary part of turbocharger and aims to improve the air exchange efciency of engine.

One of the reasons enabling a turbocharger engine to be more powerful than a common engine lies in
higher air exchange efciency than a common engine featuring natural inow. After owing into turbo­charger, air temperature rises drastically and air density reduces correspondingly. Thus, an intercooler

cools air. High-temperature air is rstly cooled by intercooler and then ows into engine. Without an in­tercooler, pressurized high-temperature air will directly ow into engine, degrading engine power and

boosting fuel consumption consequently.

Function of Intercooler

The intercooler in a turbocharger engine plays a signicant role in reducing engine air intake tempera­ture, improving engine air intake volume and fully burning fuels, thus boosting engine power.

1. An engine emits high-temperature exhaust gas. Due to heat transmission through turbochar­ger, the air intake temperature rises. Moreover, air density is strengthened after being com-

pressed, making air temperature rise inevitably and having an impact on induction efciency
of engine. Greater progress in induction efciency calls for lower air intake temperature. Re-

Intercooler-3

lated data indicates that reducing the temperature of turbocharged air by 10℃ will increase

engine power efciency by 3% to 5% at the same air-fuel delivery ratio and a specic range of

temperature.

2. Turbocharged air never being cooled owing into combustion chamber will not only have an
adverse impact on induction efciency of engine but also easily cause excessively high com-

bustion temperature and engine knock, etc. Besides, this will increase NOx contents in ex­haust gas and accordingly lead to air pollution.

In order to eliminate the adverse impact of temperature rise of turbocharged air, an intercooler shall

be tted to reduce temperature of air intake.

Classication of Intercooler

In general, an intercooler is made from aluminum alloys. Common intercoolers can be divided into air­cooled intercooler and water-cooled intercooler in terms of cooling medium. The vehicle is equipped
with air-cooled intercooler.

Removal of Intercooler

1. Remove intercooler connecting hose

(a) Unfasten type A worm drive type hose hoop between intercooler connecting hose and engine air

intake elbow and unplug one end of intercooler connecting hose that is connected with engine air

intake elbow;
(b) Remove front bumper;
(c) Unfasten type B worm drive type hose hoop between intercooler connecting hose and intercooler

connector and unplug one end of intercooler connecting hose that is connected with intercooler

connector;

(d) Unscrew hexagon ange bolts on intercooler connecting hose bracket;

(e) Remove intercooler connecting hose.

2. Removal of Intercooler Connecting Hose II

(a) Unfasten type A worm drive type hose hoop between intercooler connecting hose II and turbo-

charger and unplug one end of intercooler connecting hose II connected with turbocharger;
(b) Unfasten type B worm drive type hose hoop between intercooler connecting hose II and inter-

cooler connector and unplug one end of intercooler connecting hose II connected with intercooler

connector;

(c) Unscrew hexagon ange bolts on intercooler connecting hose bracket;

(d) Remove intercooler connecting hose II.

3. Removal of Intercooler Assembly

(a) Unscrew ange bolts between intercooler assembly and intercooler bracket;
(b) Unscrew ange bolts between intercooler assembly and intercooler bracket II;

(c) Remove intercooler assembly.

4. Removal of Intercooler Bracket

(a) Unscrew two hexagon ange bolts among intercooler bracket, crash-proof steel beam and vehi-

cle frame;
(b) Remove intercooler bracket.

5. Removal of Intercooler Bracket II

(a) Unscrew two hexagon ange bolts among intercooler bracket II, crash-proof steel beam and ve-

hicle frame;
(b) Remove intercooler bracket II.

6. Removal of Intercooler Rubber Tube Sleeve and Intercooler Rubber Tube Sleeve II

(a) Remove intercooler rubber tube sleeve and intercooler rubber tube sleeve II respectively from

headlamp plate. Fitting steps are opposite to removal steps.

Intercooler tting

Refer to reverse sequences of disassembling for tting.

Intercooler Maintenance

Air-cooled intercooler is integrated with water tank radiator in the front of engine. An intercooler reali-

Intercooler-4

zes cooling relying on fan and vehicle ventilating surface. Unfavorable cooling by intercooler will result
in low engine power and high fuel consumption. Therefore, you are kindly requested to check and
maintain intercooler on a regular basis.

1. External cleaning (Cleaning without disassembling the vehicle)

Intercooler is arranged at the forefront of a vehicle. Intercooler radiating ribs are usually clogged by

leaves, oil sludge (hydraulic oil overowed from steering oil tank) and other substances, disabling heat

radiation. Therefore, it shall be regularly cleaned. It is proposed to keep a washing gun of not high
pressure vertical towards the intercooler plane for low-speed washing from top to bottom or bottom to
top. But, inclined washing is strictly prohibited to protect the intercooler.

2. Internal cleaning and check (Disassembly-based cleaning)

Oil sludge, gel and other pollutants usually adhere to internal pipelines of intercooler, narrowing the
air circulation passageway and weakening capacity of heat exchange for cooling. Thus, maintenance
and cleaning are really needed. In general, internal parts of intercooler shall be cleaned and checked
every year or at the same time with engine overhaul and water tank welding and repair.
As for cleaning methods, add water solution (with temperature ranging from 70℃ to 80℃) containing
2% pure soda into intercooler and fully ll it, wait for 15min and observe whether the intercooler en­counters water leakage. If water leakage exists, disassemble intercooler and weld it (just like repairing

water tank). Upon no water leakage, shake it several times, discharge water solution, rell it with clean

water solution containing 2% pure soda for washing till the water is clean, and add clean hot water (at
temperature of 80℃ to 90℃) till the discharged water is clean.
Cleaning with water containing soda is proposed once intercooler is externally polluted by oil stains. In
detail, submerge the parts with oil stain into soda solution and eliminate oil stain by means of brush till
intercooler is completely clean.
After cleaning, dry internal parts of intercooler or naturally dry or keep intercooler and engine connec-

ting pipe disconnected temporarily during tting intercooler by using compressed air, start engine and
keep it running till no water ows from intercooler air outlet and then connect induction pipe of engine.
If intercooler core is seriously polluted, please check whether air lter and induction pipe suffer from

leakage and remove failures.

Clutch

Cluch control mechanism................................................ 2

Clutch-1

Clutch-2

Cluch control mechanism

Components(2.5TCI Left Hand Drive)

25-30

Clutch master cylinder pipe

Hex ange nut

23±3

Clutch master cylinder

Pipe clip

20

Snap ring

Clutch hose

Bolt with hole for hose connection

35±2

Clutch release cylinder (with transmission)

Spring clip

Hex bolt assembly (with transmission)

N·m

Seal washer

:specied torque

Transmission (5DYG)

Transmission (5DYG)

Page

Overview.................................................................... MT-73

Transmission Assembly ........................................ MT-73

Areas of Importance ............................................. MT-73

Problem Diagnosis ................................................ MT-73

Technical Parameters ................................................ MT-74

Proper Use and Care................................................. MT-74

Troubleshooting ......................................................... MT-75

Transmission Removal .............................................. MT-75

Transmission Installation ........................................... MT-78

Technical Specications for Adjustment .................... MT-90

Installation Precautions ............................................. MT-90

Threaded Part Tightening Torque Table .................... MT-91

MT - 1

MT - 2

Transmission (5DYG)

Overview

Transmission Assembly

The 5DYG vehicle transmission is a triaxial step mechanical transmission. The forward gear has adopted the in-

ertia synchronizer gear-shifting mechanism, which offers smooth and easy gear shifting, reduces noise dramati-

cally, and improves the gear service life.

Input shaft

Front cover

3rd & 4th gear sleeve

Case

Intermediate shaft

3rd gear

Reverse
gear shaft

Reverse
gear idler

2nd gear

1st & 2nd
gear sleeve

Inermediate
plate

1st gear

5th gear

5th gear
sleeve

Rear body

Manipulation lid

Odometer

Shift lever

Output shaft

Clutch housing

Intermediate
5th gear

Areas of Importance

Pay attention to the items below when using surface sealing materials:

1. When applied after removal, rst remove the sealant overowing from the junction surface and the in-

side with a scraper.

2. The joint surface should be free of oil, dirt, and other contaminants.

3. The coating position is the center of the sealing face. In case of holes, apply the sealant to the center

of the inside.

4. The amount of sealant should be such that a uniform sealant lm is formed on the joint surface and

a small amount overows the periphery after installation. The rubber line should be continuous and

have a cross-sectional diameter of around φ1.2.

5. Tighten the bolt within 10 minitues after sealant application and installation.

Problem Diagnosis

Symptom Possible cause Troubleshooting Page

Difcult or unable to

shift gears

Transmission disengaged Transmission malfunction

The input shaft spline is dirty or
has adhesions
Transmission malfunction

Repair as required
Disassemble and check the
transmission

Disassemble and check the
transmission

4

4

MT - 3

Transmission (5DYG)

Technical Parameters

Center distance (mm) 72

Input torque (N·m) 200

Net weight (kg) 40.2

1st 2nd 3rd 4th 5th

Variable speed ratio

3.992 2.15 1.334 1.00 0.862

Odometer speed ratio 18/6

Lubricant type Lubricant 75W/90 (GL-4)

Lubricant capacity (L) 2.4

Match engine 4G63/4G64/4G69

Control type Floor control

1st 3rd 5th

Gear mode

2nd 4th Rev

Rev

4.22

Proper Use and Care

1. Correct gear shifting

(a) Choose an appropriate opportunity to shift gears properly according to the vehicle speed and road condi-

tion. During gear shifting, separate the clutch sufciently and shift the gear gently, not excessively, in order

to avoid synchronization failure.

(b) To avoid breaking the teeth, do not start at a high speed.

(c) To avoid premature abrasion of the gear shift fork, do not always rest your hand on the shift lever while

driving.

(d) When backing the vehicle, to avoid gear shifting noise and gear damage, stop the vehicle before shifting

gears.

2. Sufcient lubrication

(a) Use the specied lubricant, whose number is: SAE 75W/90 GL-4. Do not use an unqualied lubricant. Do

not mix lubricants of different numbers.

(b) The product adopts a splash lubrication method. Add lubricant (2.4 L) according to the requirements, i.e.,

park the vehicle on a at road surface and add lubricant until the liquid level is ush with the oil ller.

(c) For new vehicles (in the break-in period), the transmission's lubricant should be replaced after 1,500 km.

3. Three-level maintenance

(a) During the rst level of maintenance, the liquid level of the lubricant should be checked. If not sufcient,

add lubricant to the specied position. Check and clean the breather plug to make it clean and expedite the

maintenance. If the breather plug is clogged, transmission leakage will occur.

(b) Level-two maintenance: The transmission's lubricant should be replaced the rst time that the vehicle un-

dergoes the second level of maintenance. The quality of the lubricant should be inspected during the future

second level of maintenance practises. The lubricant should be replaced if diluted, gummy, or dirty.

(c) During the third level of maintenance, it should be removed for inspection, cleaning, and oil changing.

MT - 4

Transmission (5DYG)

Troubleshooting

Symptom

Damaged bearing Replace the bearing

Gear surface has been knocked or has pitting corrosion Repair or replace the gear

The axial position or clearance of the gear is improper, or

Noise is too loud

or abnormal

Difcult gear

engagement

Leakage

Gear disengage-

ment

Wrong gear The interlocking pin is lost or seriously damaged Replace

Abnormal failure

of the bearing

internal components knock each other

Lubricant level too low or insufcient lubrication Fill oil to the marked level

The lubricant used does not meet the quality requirements

Damage of the components in the clutch Check, repair, and adjust

Improper adjustment and insufficient separation of the

clutch

Improper adjustment of the control mechanism Adjust

Serious abrasion of the synchronizer ring Replace the gear ring

The oil seal is worn or damaged Replace the oil seal

Too much oil is added, oil level too high Check and adjust

Non-uniform application of sealant or damaged gasket Recoat or replace the gasket

Joint surface damaged and not repaired in time Repair

Breather plug blocked Clean and penetrate

The gear sleeve or joint tooth is seriously worn out Replace

The control mechanism is installed improperly or damaged Check, adjust, or replace

The fork is seriously deformed or worn out Replace

The positioning spring or steel ball is seriously deformed or

damaged

Too much gear axial clearance Check and adjust

Insufcient lubrication or unqualied lubricant Check and replace

Lubricant is too dirty Replace

Poor cleanliness of the parts in the case Clean

Unqualied bearing Replace

Possible cause Troubleshooting

Check, repair, and adjust

Replace with the specied lu-

bricant

Adjust

Check and replace

Transmission Removal

1. Remove the clutch housing, front cover subassembly, input shaft and intermediate shaft front bearing

stopper ring, manipulation rod assembly, manipulation lid subassembly, position mechanism subas-

sembly, rear body subassembly (before removing the rear body subassembly, the 5th gear positioning

steel ball, spring, and shift shaft set screw should be removed), and the case in sequence. This is the

reverse of transmission installation steps 19 – 29.

2. Remove the control part of the intermediate plate subassembly (take out the positioning plug, spring,

steel ball, fork set screw, elastic spring, fork shaft, and fork of each gear in sequence). Refer to the

gure for details.

The steps are as follows:

MT - 5

Transmission (5DYG)

(a) Remove the fork shaft positioning plugs, springs, and

steel balls.

(b) Remove the shift fork lock pin subassemblies, elastic

cylindrical pins, 1st & 2nd gear shift fork set screws,

and grip rings. When removing the shift fork lock pin

subassemblies and elastic cylindrical pins, use a punch

smaller than Φ5 (for example, Φ4.5) to knock out the

pin from the other side as shown in the gure.

(c) Remove the 5th reverse gear shift fork shaft, 5th gear

shift fork shaft, and 5th gear shift fork in sequence.

(d) Take out the interlocking steel ball in the 5th reverse

gear shift guide block and the interlocking steel ball

in the intermediate plate. Remove the 5th reverse gear

shift guide block, reverse gear shift fork shaft, and re-

verse gear shift block arm subassembly. After removing

the reverse gear shift fork shaft, take out the interlock-

ing guide pin.

(e) Take out the interlocking pin, remove the 1st & 2nd

gear shift fork shaft, and then take out the interlocking

guide pin.

MT - 6

Transmission (5DYG)

(f) Take out the short interlocking pin and remove the 3rd

& 4th gear shift fork shaft, 1st & 2nd gear shift fork,

and the 3rd & 4th gear shift fork.

3. Remove the operating components of the intermediate

plate subassembly.

(a) Remove the intermediate shaft rear shaft retainer, 5th

gear coupling gear, intermediate shaft 5th gear subas-

sembly, intermediate 5th gear needle bearing, 5th gear

thrust washer, and steel ball (Φ6.35) in sequence.

(b) Remove the odometer drive gear retainer, odometer

drive gear, output shaft rear bearing plate, and output

shaft rear bearing stopper ring in sequence.

(c) Remove the reverse gear arm bracket subassembly and

reverse gear idler shaft plate. Then remove the reverse

gear idler subassembly and reverse gear idler shaft.

(d) Remove the intermediate shaft subassembly and its rear

bearing.

MT - 7

Transmission (5DYG)

(e) Remove the input shaft subassembly (be careful not

to lose the needles in the shaft) and the 3rd & 4th gear

synchronizer ring.

(f) Remove the output shaft subassembly.

4. Finally, disassemble the shafts in sequence as shown

in the gure. Refer to the aftermentioned transmission

installation (the disassembly sequence is the reverse

of the installation sequence).

Transmission Installation

1. Install the output shaft assembly.

(a) As shown in the gure, install the 3rd & 4th gear syn-

chronizer subassembly, then install the 3rd gear needle

bearing, 3rd gear subassembly, 3rd, 4th & 5th gear

synchronizer ring, and the 3rd & 4th gear synchronizer

subassembly in sequence. Finally install the 3rd & 4th

gear hub shaft retainer.

Caution: The side with a 45º step of the 3rd & 4th gear

synchronizer gear hub should be directed towards the

input shaft. The side with a big chamfer of the 3rd & 4th

gear synchronizer gear sleeve should be directed to-

wards the input shaft. The openings of the two 3rd & 4th

gear synchronizer spring expansion rings should alter-

nate.

MT - 8

Transmission (5DYG)

(b) As shown in the gure, install the 1st & 2nd gear syn-

chronizer subassembly, install the 2nd gear needle bear-

ing, 2nd gear subassembly, 1st & 2nd gear synchronizer

ring, and the 1st & 2nd gear synchronizer subassembly

in sequence. Coat the steel ball (Φ6.35) with grease

and install it into the output shaft, and then install the

1st gear, 1st gear sleeve, bearing, and 5th gear. Finally,

install the 5th gear shaft retainer.

Caution: The installation direction of the 1st & 2nd gear

synchronizer subassembly in relation to the output

shaft should be such that the side with fork slot is di-

rected towards the intermediate plate and the openings

of the two 1st & 2nd gear synchronizer spring expan-

sion rings alternate.

2. Install the output shaft into the intermediate plate.

(a) Pull the output shaft and at the same time tap on the

intermediate plate to install the output shaft into the in-

termediate plate.

(b) Install the output shaft rear bearing stopper ring with

clasp pliers.

Remark: The stopper ring should be pressed closely against

the surface of the intermediate plate.

3. Install the input shaft into the output shaft.

(a) Install the input shaft bearing on the input shaft and use

clasp pliers to install the input shaft retainer.

MT - 9

Transmission (5DYG)

(b) Coat 13 needle bearings with grease, install the needle

rollers into the input shaft, and then place the 3rd, 4th

& 5th gear synchronizer ring.

Align

(c) Install the input shaft into the output shaft, aligning the

three grooves of the synchronizer ring with the syn-

chronizer slider.

4. Install the intermediate shaft into the intermediate plate.

(a) Install the stopper ring on the intermediate shaft rear

bearing.

SST

(b) Install the intermediate shaft into the intermediate plate

and, at the same time, hold the intermediate shaft and

install the intermediate shaft rear bearing.

5. Install the rear bearing plate.

Install and tighten the screw with a torque socket wrench.

Tightening torque: See the table

MT - 1 0

Transmission (5DYG)

6. Install the reverse gear idler and shaft.

(a) Install the reverse gear idler and shaft.

(b) Install the reverse gear idler shaft plate and tighten the

bolt.

Tightening torque: See the table

Lock ball

7. Install the reverse gear arm bracket.

Place two small hollow position pins on the intermediate

plate, install the reverse gear arm bracket, and tighten 2 bolts.

Tightening torque: See the table

8. Install the lock ball and 5th gear thrust washer.

9. Install the intermediate shaft 5th gear with 5th gear en-

gagement sleeve assembly and needle bearing.

(a) Install the intermediate shaft 5th gear assembly as

shown in the gure.

Caution: The side with chamfer of the spline in the syn-

chronizer gear sleeve should be directed towards the

rear body. The openings of the two synchronizer spring

expansion rings should alternate.

MT - 1 1

Transmission (5DYG)

(b) Coat the needle bearing with gear oil.

(c) Install the intermediate shaft 5th gear with the 5th gear

engagement sleeve and needle bearing.

10. Install the synchronizer ring and 5th gear coupling gear.

(a) Put the synchronizer ring on the conical surface of the

5th gear coupling gear.

(b) Remove the intermediate plate from the table vice.

(c) As shown in the gure, place the transmission upright

and install the 5th gear coupling gear, aligning the syn-

chronizer ring groove with the synchronizer slider.

(d) Select a split ring which can minimize the axial clear-

ance.

(e) Use a copper rod and hammer to install the split ring.

MT - 1 2

Transmission (5DYG)

11. Measure the axial clearance of the intermediate shaft

5th gear.

Measure the axial clearance of the intermediate shaft 5th

gear with a feeler gauge.

Standard clearance: 0.1-0.3

Maximum clearance: 0.3

12. Install the 3rd & 4th gear shift fork shaft and 1st & 2nd

gear and 3rd & 4th gear shift forks.

(a) Install the 1st & 2nd gear and 3rd & 4th gear shift

forks. Install the 3rd & 4th gear shift fork shaft into the

intermediate plate and shift fork.

(b) Use a punch and hammer to install the shift fork lock

pin subassembly.

13. Install the 1st & 2nd gear shift fork shaft and 1st & 2nd

gear shift fork.

(a) Coat the interlocking guide pin with MP grease and in-

stall it on the 1st & 2nd gear shift fork shaft.

(b) Use a magnetic rod to install the short interlocking pin

into the intermediate plate. Install the 1st & 2nd gear

shift fork shaft into the 1st & 2nd gear shift fork and

intermediate plate.

MT - 1 3

Transmission (5DYG)

(c) Install the 1st & 2nd gear shift mounting bolt and tight-

en the bolt.

Tightening torque: See the table

14. Install the reverse gear shift fork shaft, reverse gear

shift lever, reverse gear arm and shift block.

(a) Install the reverse gear shift block on the reverse gear

arm and attach it with a split ring. Install the reverse

gear shift lever on the reverse gear arm and x it with an

E-ring. Install the open end of the reverse gear arm on

the reverse gear arm bracket.

(b) Coat the interlocking guide pin with MP grease and in-

stall it on the reverse gear shift fork shaft.

(c) Use a magnetic rod to install the short interlocking pin

into the intermediate plate. Install the reverse gear shift

fork shaft into the reverse gear shift lever and interme-

diate plate.

15. Install the 5th reverse gear shift guide block, 5th gear

shift fork, and the 4th & 5th gear shift fork shaft.

(a) Install the 5th reverse gear shift guide block on the re-

verse gear shift fork shaft. Install the 5th gear shift fork.

MT - 1 4

Transmission (5DYG)

(b) Use a magnetic rod to install the lock ball into the 5th

reverse gear shift guide block. Install the 5th gear shift

fork shaft as shown in the gure.

(c) Use a magnetic rod to install the interlocking steel ball

into the intermediate plate. Install the 5th gear shift

fork shaft into the intermediate plate.

(d) Install the 1st & 2nd gear shift mounting bolt and tight-

en the bolt.

Tightening torque: See the table

(e) Install the 5th reverse gear shift fork shaft into the 5th

reverse gear shift guide block and intermediate plate.

(f) Use a punch and hammer to knock the elastic cylindri-

cal pin in the 5th reverse gear shift guide block.

MT - 1 5

Transmission (5DYG)

16. Install the shift fork shaft split rings and use a steel rod

and hammer to knock in the split rings (3).

5th speed

17. Install the lock ball, spring, and plug.

(a) Install the lock balls and springs (4 lock balls and 4

springs).

Remark: Install the short spring on the bottom of the inter-

mediate plate.

(b) Coat the thread of the plug with sealant. Install and

tighten the plug with a torque socket wrench.

Tightening torque: See the table

18. Install the odometer drive gear.

MT - 1 6

Transmission (5DYG)

19. Install the transmission case.

(a) As shown in the gure, coat the transmission case with

sealing material.

Sealing
material

(b) As shown in the gure, place the intermediate plate up-

right.

(c) As shown in the gure, install the transmission case on

the intermediate plate.

(d) Use clasp pliers to install the 2 stopper rings on the in-

put shaft bearing and intermediate shaft front bearing.

20. Install the front cover.

Coating

Coat the thread of the bolt with sealant.

Install and tighten the bolt.

Tightening torque: See the table

Sealing
material

21. Install the rear body, shift shaft, and shift block.

(a) Before closing the case, install the components in the

rear body, such as the limiting mechanism and oil drain

slot.

(b) As shown in the gure, coat the rear body with sealing

material.

MT - 1 7

Transmission (5DYG)

(c) Install the shift shaft with shift lever into the rear body.

Do not put it in place. Engage the 3rd gear of the trans­mission.

(d) Put in the shift block from the opening of the rear case

so that the shift shaft is put through the shift block. Do
not tighten the bolt for the moment.

(e) Insert the shift lever into the 3rd & 4th gear fork shaft

groove, align the 5th reverse gear shift fork shaft with the
rear case mounting hole, and then push in the rear case.

(f) Install and tighten the rear body bolt.

Tightening torque: See the table

(g) Install and tighten the shift block bolt.

Tightening torque: See the table

22. Install the 5th gear self-locking steel ball, spring, and

plug.

(a) Coat the thread of the plug with sealant.

(b) Install the lock ball, spring, and plug.

Tightening torque: See the table

23. After installing the rear body or transmission case,

check the following items:

(a) Check whether the rotation of the input shaft and out-

put shaft is exible.

(b) Check whether the gear shifting is clear and reliable

and whether there is a reverse gear lock function.

24. Install the position mechanism subassembly.

Tightening torque: See the table

MT - 1 8

Transmission (5DYG)

25. Install the reverse gear switch.

Tightening torque: See the table

26. Install the transmission manipulation lid of the trans-

mission.

(a) Apply sealant before installing the transmission ma-

nipulation lid.

(b) Install and tighten the bolt.

Tightening torque: See the table

27. Install the odometer driven gear.

(a) Install the speedometer driven gear.

(b) Install and tighten the bolt.

Tightening torque: See the bolt tightening torque table

28. Install the external parts: Oil lling/drain plug, breather

plug, manipulation rod.

29. Inspection.

MT - 1 9

Transmission (5DYG)

Technical Specications for Adjustment

Check the synchronizer ring allowance δ of each gear ac-

cording to the table below.

Shift position 1st & 2nd gear 3rd, 4th & 5th gear

Standard clear-

ance (mm)

Limit clearance

(mm)

Check the clearance of each gear according to the table below.

1 – 2 1 – 2

0.8 0.8

Shift position 1st, 2nd & 3rd

gear

Axial clearance

(mm)

0.1 – 0.25 0.1 – 0.3

5th gear

Installation Precautions

1. All oil seals, shaft retainers, and elastic pins should not

be reused.

2. Keep all parts clean and free of dust, chips, rust corro-

sion, oil build-up, or any other contaminants.

3. All rubbing surfaces must be coated with lubricant.

4. The openings of all oil seals should be coated with

grease and each oil seal should be pressed in vertically.

5. During installation of the bearings, do not use any kind

of rolling element to transmit pressure.

6. During the installation of synchronizer components, the

two sides of the spring piston's openings should alter-

nate.

7. During the transportion and installation of the assem-

bly, engage a gear and never erect the assembly or

subject it to strong impacts in the neutral position.

MT - 2 0

Transmission (5DYG)

Threaded Part Tightening Torque Table

Fastening piece designation Quantity Tightening torque (N·m)

1st & 2nd gear shift fork set screw 1 13-17

Odometer bracket bolt with washer 1 15-20

Reverse gear arm bracket bolt with washer 2 17-22

Output rear bearing plate lobular screw 4 17-22

Reverse gear idler shaft plate (and intermediate

plate) hexagon head bolt with washer

Front cover hexagon head bolt with washer 8 15-20

Manipulation lid hexagon head bolt with washer 6 15-20

Case, intermediate plate, and rear body bolts 7 30-45

Case, intermediate plate, and rear body bolts 1 30-45

Positioning spring plug 6 17-22

Reverse gear switch 1 30-50

Oil lling plug 1 30-50

Oil drain plug 1 30-50

Oil drain slot hexagon head bolt with washer 1 15-20

Oil box hexagon head bolt with washer 2 5-10

1 15-20

Gear shift block set bolt 1 15-20

Position mechanism assembly 2 30-50

Transmission (5DYM26)

MT-11

Transmission (5DYM26)

Page

Overview....................................................................... MT-93

Transmission Assembly ........................................... MT-93

Areas of Importance ................................................ MT-93

Problem Diagnosis .................................................. MT-93

Technical Parameters .................................................. MT-94

Proper Use and Care................................................... MT-94

Troubleshooting ............................................................ MT-95

Transmission Removal ................................................. MT-95

Transmission Installation .............................................. MT-98

Technical Specications for Adjustment ..................... MT-109

Installation Precautions .............................................. MT-109

Threaded Part Tightening Torque Table ..................... MT-110

MT-22

Transmission (5DYM26)

Overview

Transmission Assembly

The 5DYM26 vehicle transmission is a tri-axial step mechanical transmission. The forward gear has adopted the

inertia synchronizer gear-shifting mechanism, which offers smooth and easy gear shifting, reduces noise dra-

matically, and improves the gear service life.

Clutch housing

Front cover

Input shaft

3rd & 4th
gear sleeve

Case

Intermediate shaft

3rd gear

Reverse
gear shaft

Reverse
gear idler

2nd gear

1st & 2nd
gear sleeve

Intermediate
plate assy

Intermediate 5th gear

1st gear

5th gear

5th gear sleeve

Manipulation lid

Shift lever

Output shaft

Rear body

Areas of Importance

Pay attention to the items below when using surface sealing materials:

1. When applied after removal, first remove the sealant overflowing from the junction surface and the in­side with a scraper.

2. The joint surface should be free of oil, dirt, and other contaminants.

3. The coating position is the center of the sealing face. In case of holes, apply the sealant to the center
of the inside.

4. The amount of sealant should be such that a uniform sealant film is formed on the joint surface and
a small amount overflows the periphery after installation. The rubber line should be continuous and

have a cross-sectional diameter of around Φ1.2.

5. Tighten the bolt within 10 minitues after sealant application and installation.

Problem Diagnosis

Symptom Possible cause Troubleshooting Page

Difficult or unable to shift
gears

Transmission demeshing Transmission malfunction Disassemble and check the transmission 4

The input shaft spline is
dirty or has adhesions
Transmission malfunction

Repair as required

Disassemble and check the transmission 4

MT-33

Transmission (5DYM26)

Technical Parameters

Center distance (mm) 72

Input torque (N·m) 200

Net weight (kg) 42

1st 2nd 3rd 4th 5th

Variable speed ratio

3.992 2.15 1.334 1.00 0.862

Lubricant number 75W/90 GL-4

Lubricant capacity (L) 2.5

Match engine 4G63/4G64/4G69

Control type Floor control

1st 3rd 5th

Gear mode

2nd 4th Rev

Proper Use and Care

Rev

4.22

1. Correct gear shifting

(a) Choose an appropriate opportunity to shift gears properly according to the vehicle speed and road condi-

tion. During gear shifting, separate the clutch sufficiently and shift the gear gently, not excessively, in order

to avoid synchronization failure.

(b) To avoid breaking the teeth, do not start with high speed.

(c) To avoid premature abrasion of the gear shift fork, do not always rest your hand on the shift lever while

driving.

(d) When backing the vehicle, to avoid gear shifting noise and gear damage, stop the vehicle before shifting

gears.

2. Sufficient lubrication

(a) Use the specified lubricant, whose number is: 75W/90 GL-4. Do not use an unqualified lubricant. Do not

mix lubricants of different numbers.

(b) The product adopts a splash lubrication method. Add lubricant (2.5 L) according to the requirements, i.e.,

park the vehicle on a flat road surface and add lubricant until the liquid level is flush with the oil filler.

(c) For new vehicles (in the run-in period), the transmission's lubricant should be replaced after 1,500 km.

3. Three-level maintenance

(a) During the first level of maintenance, the liquid level of the lubricant should be checked. If not sufficient,

add lubricant to the specified position. Check and clean the breather plug to make it clean and expedite. If

the breather plug is clogged, transmission leakage will occur.

(b) Level-two maintenance: The transmission's lubricant should be replaced the first time that the vehicle un-

dergoes the second level of maintenance. The quality of the lubricant should be inspected during the future

second level of maintenance practices. The lubricant should be replaced if diluted, gummy, or dirty.

(c) During the third level of maintenance, it should be removed for inspection, cleaning, and oil changing.

MT-44

Transmission (5DYM26)

Troubleshooting

Symptom Possible cause Troubleshooting

Damaged bearing Replace the bearing

The gear surface has been knocked or has corrosive pitting Repair or replace the gear

The axial position or clearance of the gear is improper, or

Noise is too loud

or abnormal

Difficult gear

engagement

Leakage

Gear disen-

gagement

Wrong gear The interlocking pin is lost or seriously damaged Replace

Abnormal

failure of the

bearing

internal components knock each other

Lubricant level too low or insufficient lubrication Fill oil to the marked level

The lubricant used does not meet the quality requirements

Damage of the components in the clutch Check, repair, and adjust

Improper adjustment and insufficient separation of the

clutch

Improper adjustment of the control mechanism Adjust

Serious abrasion of the synchronizer ring Replace the gear ring

The oil seal is worn or damaged Replace the oil seal

Too much oil is added, oil level too high Check and adjust

Non-uniform application of sealant or damaged gasket Recoat or replace the gasket

Joint surface damaged and not repaired in time Repair

Breather plug blocked Clean and penetrate

The gear sleeve or joint tooth is seriouly worn out Replace

The control mechanism is installed improperly or dam-

aged

The shift fork is seriously deformed or worn out Replace

The positioning spring or steel ball is seriouly deformed

or damaged

Too much gear axial clearance Check and adjust

Insufficient lubrication or unqualified lubricant Check and replace

Lubricant is too dirty Replace

Poor cleanliness of the parts in the case Clean

Unqualified bearing Replace

Check, repair, and adjust

Replace with the specified

lubricant

Adjust

Check, adjust, or replace

Check and replace

Transmission Removal

1. Remove the clutch housing, front cover subassembly, input shaft, and intermediate shaft front bearing

stopper ring, manipulation rod assembly, manipulation lid subassembly, position mechanism subas-

sembly, rear body subassembly (before removing the rear body subassembly, the 5th gear positioning

steel ball, spring and shift shaft set screw should be removed), and the case in sequence. This is the

reverse of transmission installation steps 19 – 29.

2. Remove the control part of the intermediate plate subassembly (take out the positioning plug, spring,

steel ball, fork set screw, elastic spring, fork shaft, and fork of each gear in sequence). Refer to the fig-

ure for details.

The steps are as follows:

MT-55

Transmission (5DYM26)

(a) Remove the fork shaft positioning plugs, springs, and

steel balls.

(b) Remove the shift fork lock pin subassemblies, elastic

cylindrical pins, 1st & 2nd gear shift fork set screws,

and grip rings. When removing the shift fork lock pin

subassemblies and elastic cylindrical pins, use a punch

smaller than Φ5 (for example, Φ4.5) to knock out the

pin from the other side as shown in the figure.

(c) Remove the 5th reverse gear shift fork shaft, 5th gear

shift fork shaft, and 5th gear shift fork in sequence.

(d) Take out the interlocking steel ball in the 5th reverse

gear shift guide block and the interlocking steel ball

in the intermediate plate. Remove the 5th reverse gear

shift guide block, reverse gear shift fork shaft, and re-

verse gear shift block arm subassembly. After removing

the reverse gear shift fork shaft, take out the interlock-

ing guide pin.

(e) Take out the interlocking pin, remove the 1st & 2nd

gear shift fork shaft, and then take out the interlocking

guide pin.

MT-66

Transmission (5DYM26)

(f) Take out the short interlocking pin and remove the 3rd

& 4th gear shift fork shaft, 1st & 2nd gear shift fork,

and 3rd & 4th gear shift fork.

3. Remove the operating components of the intermediate

plate subassembly.

(a) Remove the intermediate shaft rear shaft retainer, 5th

gear coupling gear, intermediate shaft 5th gear subas-

sembly, intermediate 5th gear needle bearing, 5th gear

thrust washer, and steel ball (Φ6.35) in sequence.

(b) Remove the output shaft rear bearing plate and output

shaft rear bearing stopper ring in sequence.

(c) Remove the reverse gear arm bracket subassembly and

reverse gear idler shaft plate. Then, remove the reverse

gear idler subassembly and reverse gear idler shaft.

(d) Remove the intermediate shaft subassembly and its rear

bearing.

MT-77

Transmission (5DYM26)

(e) Remove the input shaft subassembly (be careful not

to lose the needles in the shaft) and the 3rd & 4th gear

synchronizer ring.

(f) Remove the output shaft subassembly.

4. Finally, disassemble the shafts in sequence as shown

in the figure. Refer to the aftermentioned transmission

installation (the disassembly sequence is the reverse

of the installation sequence).

Transmission Installation

1. Install the output shaft assembly.

(a) As shown in the figure, install the 3rd & 4th gear syn-

chronizer subassembly, then install the 3rd gear needle

bearing, 3rd gear subassembly, 3rd, 4th & 5th gear

synchronizer ring, and the 3rd & 4th gear synchronizer

subassembly in sequence, and finally install the 3rd &

4th gear hub shaft retainer.

Caution: The side with a 45º step of the 3rd & 4th gear

synchronizer gear hub should be directed towards the

input shaft. The side with a big chamfer of the 3rd &

4th gear synchronizer gear sleeve should be directed

towards the input shaft. The openings of the two 3rd &

4th gear synchronizer spring expansion rings should

alternate.

MT-88

Transmission (5DYM26)

(b) As shown in the figure, install the 1st & 2nd gear syn-

chronizer subassembly, install the 2nd gear needle bear-

ing, 2nd gear subassembly, 1st & 2nd gear synchronizer

ring, and the 1st & 2nd gear synchronizer subassembly

in sequence. Coat the steel ball (Φ6.35) with greaseoat the steel ball (Φ6.35) with grease

and install it into the output shaft and then install the

1st gear, 1st gear sleeve, bearing and 5th gear. Finally,

install the 5th gear shaft retainer.

Caution: The installation direction of the 1st & 2nd gear

synchronizer subassembly in relation to the output

shaft should be such that the side with fork slot is di-

rected towards the intermediate plate and the openings

of the two 1st & 2nd gear synchronizer spring expan-

sion rings alternate.

2. Install the output shaft into the intermediate plate.

(a) Pull the output shaft and at the same time tap on the

intermediate plate to install the output shaft into the in-

termediate plate.

(b) Install the output shaft rear bearing stopper ring with

clasp pliers.

Remark: The stopper ring should be pressed closely against

the surface of the intermediate plate.

3. Install the input shaft into the output shaft.

(a) Install the input shaft bearing on the input shaft and use

clasp pliers to install the input shaft retainer.

MT-99

Transmission (5DYM26)

(b) Coat the 13 needle bearings with grease, install the

needle rollers into the input shaft, and then set the 3rd,

4th & 5th gear synchronizer ring.

Align

(c) Install the input shaft into the output shaft, aligning the

three grooves of the synchronizer ring with the syn-

chronizer slider.

4. Install the intermediate shaft into the intermediate plate.

(a) Install the stopper ring on the intermediate shaft rear

bearing.

SST

(b) Install the intermediate shaft into the intermediate plate

and, at the same time, hold the intermediate shaft and

install the intermediate shaft rear bearing.

5. Install the rear bearing plate.

Install and tighten the screw with a torque socket wrench.

Tightening torque: See the table

MT-1010

Transmission (5DYM26)

6. Install the reverse gear idler and shaft.

(a) Install the reverse gear idler and shaft.

(b) Install the reverse gear idler shaft plate and tighten the

bolt.

Tightening torque: See the table

Lock ball

7. Install the reverse gear arm bracket.

Place two small hollow position pins on the intermediate

plate, install the reverse gear arm bracket, and tighten 2 bolts.

Tightening torque: See the table

8. Install the lock ball and 5th gear thrust washer.

9. Install the intermediate shaft 5th gear with the 5th gear

engagement sleeve assembly and needle bearing.

(a) Install the intermediate shaft 5th gear assembly as

shown in the figure.

Caution: The side with the chamfer of the spline in the

synchronizer gear sleeve should be directed towards

the rear body. The openings of the two synchronizer

spring expansion rings should alternate.

MT-1111

Transmission (5DYM26)

(b) Coat the needle bearing with gear oil.

(c) Install the intermediate shaft 5th gear with the 5th gear

engagement sleeve and needle bearing.

10. Install the synchronizer ring and 5th gear coupling gear.

(a) Put the synchronizer ring on the conical surface of the

5th gear coupling gear.

(b) Remove the intermediate plate from the table vice.

(c) As shown in the figure, place the transmission upright

and install the 5th gear coupling gear, aligning the syn-

chronizer ring groove with the synchronizer slider.

(d) Select a split ring which can minimize the axial clear-

ance.

(e) Use a copper rod and hammer to install the split ring.

MT-1212

Transmission (5DYM26)

11. Measure the axial clearance of the intermediate shaft

5th gear.

Measure the axial clearance of the intermediate shaft 5th

gear with a feeler gauge.

Standard clearance: 0.1-0.3

Maximum clearance: 0.3

12. Install the 3rd & 4th gear shift fork shaft and the 1st &

2nd gear and 3rd & 4th gear shift forks.

(a) Install the 1st & 2nd gear and 3rd & 4th gear shift

forks. Install the 3rd & 4th gear shift fork shaft into the

intermediate plate and shift fork.

(b) Install and tighten the fork set screw with a torque

socket wrench.

Tightening torque: See the table

13. Install the 1st & 2nd gear shift fork shaft and 1st & 2nd

gear shift fork.

(a) Coat the interlocking guide pin with grease and install

it on the 1st & 2nd gear shift fork shaft.

(b) Use a magnetic rod to install the short interlocking pin

into the intermediate plate. Install the 1st & 2nd gear

shift fork shaft into the 1st & 2nd gear shift fork and

intermediate plate.

MT-1313

Transmission (5DYM26)

(c) Install the 1st & 2nd gear shift fork mounting bolt and

tighten the bolt.

Tightening torque: See the table

14. Install the reverse gear shift fork shaft, reverse gear

shift lever, reverse gear arm and shift block.

(a) Install the reverse gear shift block on the reverse gear

arm and attach it with a split ring. Install the reverse

gear shift lever on the reverse gear arm and attach it

with an E-ring. Install the open end of the reverse gear

arm on the reverse gear arm bracket.

(b) Coat the interlocking guide pin with grease and install

it on the reverse gear shift fork shaft.

(c) Use a magnetic rod to install the short interlocking pin

into the intermediate plate. Install the reverse gear shift

fork shaft into the reverse gear shift lever and interme-

diate plate.

15. Install the 5th reverse gear shift guide block, 5th gear

shift fork, 5th gear shift fork shaft, and 5th reverse gear

shift fork shaft.

(a) Install the 5th reverse gear shift guide block on the

reverse gear shift fork shaft. Install the 5th gear shift

fork.

MT-1414

Transmission (5DYM26)

(b) Use a magnetic rod to install the lock ball into the 5th

reverse gear shift guide block. Install the 5th gear shift

fork shaft as shown in the figure.

(c) Use a magnetic rod to install the interlocking steel ball

into the intermediate plate. Install the 5th gear shift

fork shaft into the intermediate plate.

(d) Install the 1st & 2nd gear shift set screw and tighten the

screw.

Tightening torque: See the table

(e) Install the 5th reverse gear shift fork shaft into the 5th

reverse gear shift guide block and intermediate plate.

(f) Use a punch and hammer to knock the elastic cylindri-

cal pin in the 5th reverse gear shift guide block.

MT-1515

Transmission (5DYM26)

16. Install the shift fork shaft split rings and use a steel rod

and hammer to knock in the split rings (3).

5th speed

17. Install the lock ball, spring, and plug.

(a) Install the lock balls and springs (4 lock balls and 4

springs).

Remark: Install the short spring on the bottom of the inter-

mediate plate.

(b) Coat the thread of the plug with sealant. Install and

tighten the plug with a torque socket wrench.

Tightening torque: See the table

Sealing
material

18. Install the transmission case.

(a) As shown in the figure, coat the transmission case with

sealing material.

MT-1616

Transmission (5DYM26)

(b) As shown in the figure, place the intermediate plate up-

right.

(c) As shown in the figure, install the transmission case on

the intermediate plate.

(d) Use clasp pliers to install the 2 stopper rings on the in-

put shaft bearing and intermediate shaft front bearing.

Sealing
material

19. Install the front cover.

Coating:

Coat the thread of the bolt with sealant.

Install and tighten the bolt.

Tightening torque: See the table

20. Install the rear body, shift shaft, and shift block.

(a) Before closing the case, install the components in the

rear body, such as the limiting mechanism and guide

nozzle.

(b) As shown in the figure, coat the rear body with sealing

material.

(c) First, put the shift shaft into the rear body from the hole

on the back end of the rear body, then use a punch and
hammer to knock the elastic cylindrical pin into the
connecting hole between the shift lever and the shift
shaft through the hole of the rear body to connect the
shift shaft with the shift lever, finally put on the plug.

After that, engage the 3rd gear of the transmission.

(d) Put in the shift block from the opening of the rear case

so that the shift shaft is put through the shift block. Do
not tighten the bolt for the moment.

MT-1717

Transmission (5DYM26)

(e) Insert the shift lever into the 3rd & 4th gear fork shaft

groove, align the 5th reverse gear shift fork shaft with the

rear case mounting hole, and then push in the rear case.

(f) Install and tighten the rear body bolt.

Tightening torque: See the table

(g) Install and tighten the shift block bolt.

Tightening torque: See the table

(h) Put a bowl-shaped tabular plug in the hole on the back

end of the rear body.

21. Install the 5th gear self-locking steel ball, spring, and

plug.

(a) Coat the thread of the plug with sealant.

(b) Install the lock ball, spring, and plug.

Tightening torque: See the table

22. After installing the rear body or transmission case, check

the following items:

(a) Check whether the rotation of the input shaft and out-

put shaft is flexible.

(b) Check whether the gear shifting is clear and reliable

and whether there is a reverse gear lock function.

23. Install the position mechanism subassembly.

Tightening torque: See the table

24. Install the reverse gear switch.

Tightening torque: See the table

25. Install the transmission manipulation lid of the trans-

mission.

(a) Apply sealant before installing the transmission ma-

nipulation lid.

(b) Install and tighten the bolt.

Tightening torque: See the table

MT-1818

Transmission (5DYM26)

26. Install the external parts: Oil filling/drain plug, breather

plug, and shift lever subassembly.

27. Inspection.

Technical Specifications for Adjustment

Check the synchronizer ring allowance δ of each gear ac-

cording to the table below.

Shift position

Standard clear-

ance (mm)

Limit clear-

ance (mm)

Check the gear clearance of each gear according to the table

below.

Shift position 1st, 2nd &

Axial clear-

ance (mm)

1st & 2nd

gear

1 – 2 1 – 2

0.8 0.8

3rd gear

0.1 – 0.25 0.1 – 0.3

3rd, 4th &

5th gear

5th gear

Installation Precautions

1. All oil seals, shaft retainers, and elastic pins should not

be reused.

2. Keep all parts clean and free of dust, chips, rust corro-

sion, oil build-up, or any other contaminants.

3. All rubbing surfaces must be coated with lubricant.

4. The openings of all oil seals should be coated with

grease and each oil seal should be pressed in vertically.

5. During installation of the bearings, do not use any kind

of rolling element to transmit pressure.

6. During the installation of synchronizer components, the

two sides of the spring piston's openings should alter-

nate.

7. During the transportion and installation of the assem-

bly, engage a gear and never erect the assembly or

subject it to strong impacts in the neutral position.

MT-1919

Transmission (5DYM26)

Threaded Part Tightening Torque Table

Fastening piece name Quantity

Tightening

torque (N·m)

Gear shift fork set screw 3 13-17

Reverse gear arm bracket bolt with washer 2 17-22

Output rear bearing plate lobular screw 4 17-22

Reverse gear idler shaft plate (and intermediate plate) hexagon

head bolt with washer

Front cover hexagon head bolt with washer 8 15-20

Manipulation lid hexagon head bolt with washer 6 15-20

Case, intermediate plate, and rear body bolts 7 30-45

Case, intermediate plate, and rear body bolts 1 30-45

Positioning spring plug 6 17-22

1 15-20

Reverse gear switch 1 30-50

Oil filling plug 1 30-50

Oil drain plug 1 30-50

Gear shift block set bolt 1 15-20

Position mechanism assembly 2 30-50

Steering System-1

Steering System

Components Diagram(4G69 Left-hand Drive) ................ 2

Components Diagram(2.5TCI Left-hand Drive) .............. 3

Disassembly and Installation of Steering Pipe

Column .............................................................................. 4

Disassembly and Installation of Steering Gear ............. 5

Disassembly and Installation of Steering Lower

Transmission Shaft .......................................................... 6

Disassembly and Installation of Steering Oil Pump...... 6

Disassembly and Installation of Steering Oil Pipe ........ 8

Removal of Steering Oil Tank and Steering Oil Tank

Bracket .............................................................................. 9

Steering System-2

Steering Drive Device

Components Diagram(4G69 Left-hand Drive)

Fixing screw of cover plate

25±3

Steering pipe column assembly

25±3

Cover plate assembly
of steering wheel

25±3

Ball head assembly

Lower transmission shaft assembly

Assembly of power steering gear with tie rod

25±3

100±10

He x a g on nu t a n d
conic elastic washer
subassembly

Steering wheel body assembly

120±10

160±10

Ribbed belt 4PK1100

Power steering oil tank assembly

Power steering oil tank bracket assembly

：specied torque

N·m

Fuel intake hose

27.5±2.5

Power steering oil pump with bracket assembly

17.5±2.5

Inlet oil return pipe stack of power steering gear

Hexagon ange bolt

Q1840616FD

Steering System-3

Components Diagram(2.5TCI Left-hand Drive)

Fixing screw of cover plate

25±3

Steering pipe column assembly

25±3

Ball head assembly

25±3

Lower transmission shaft assembly

Assembly of power steering gear with tie rod

25±3

100±10

Cover plate assembly
of steering wheel

He x a g on nu t a n d
conic elastic washer
subassembly

Steering wheel body assembly

120±10

160±10

6PK ribbed belt

Power steering oil pump assembly

Hexagon-head bolt
Q150B1055

H e xa g o n -h e a d b o l t,
spring washer and plain
washer assemblies
Q1461030

Hexagon ange bolt

Q1840616FD

Hollow bolt

30±5

B worm drive hose
clamping ring

17.5±2.5

Hexagon ange bolt

Q1840616FD

：specied torque

N·m

Inlet oil return pipe stack of power steering gear

Steering System-4

Disassembly and Installation of Steering Pipe Column

Hexagon nut and conic elastic washer subassembly

Steering pipe column assembly

Fixing screw of cover plate

Hexagon ange nut

Q32008FD

Hexagon-head bolt, spring
wa she r an d large wa sher
assemblies
Q1460825FD(Q40208)

Hexagon ange bolt

Q1840835

Steering wheel body assembly

Cover plate assembly
of steering wheel

Lower transmission shaft assembly

1. Disassembly

(a) Loosen the xing screw of cover plate by an inner hexagonal wrench only for the steering wheel,

then remove the cover plate assembly of steering wheel.

(b) After disassembling the hexagon nut and conic elastic washer subassembly by a M18 socket

wrench, take off the steering wheel body assembly.

(c) Remove the hexagon ange bolt (Q1840835) for connecting the steering pipe column and lower

transmission shaft assembly by a M10 socket wrench to disconnect them.

(d) Remove the (Hexagon-head bolt, spring washer and large washer assemblies) (Q1460825FD)

for connecting the steering pipe column and front wall and the hexagon ange nut (Q32008FD)

for connecting the steering pipe column and instrument panel reinforcement by a M13 socket
wrench.

(e) Draw out the pipe column upward along the axial line of the upper shaft of pipe column.

2. Installation

(a) Insert downwards the pipe column assembly along the axial line of the upper shaft of pipe co-

lumn.

(b) Connect the steering pipe column to the lower transmission shaft. Install the hexagon ange bolt

(Q1840835) for connecting the steering pipe column and lower transmission shaft by a M10 soc­ket wrench.

Tightening Torque: 25±3N•m

(c) Install the (Hexagon-head bolt, spring washer and large washer assemblies) (Q1460825FD) for

connecting the steering pipe column and front wall and the hexagon ange nut (Q32008FD) for

connecting the steering pipe column and instrument panel reinforcement by a M13 socket wren­ch.

Tightening Torque: 25±3N•m

Steering System-5

Disassembly and Installation of Steering Gear

Hexagon-head bolt

Q150B0832

Spring washer

Q40308

Steering lower transmission
shaft assembly

Assembly of power steering gear with tie rod

Ball head assembly

Hexagon ange bolt-oversized series

Q1861225FD

I-shaped hexagon nut

Q341B16

Hexagon-head bolt-ne pitch thread

Q151B16190

Split pin

Plain

washer

Inle t oi l re t urn p i p e
stack of power steering

Hexagon slotted nut

1. Disassembly

(a) Remove the hexagon-head bolt and spring washer for connecting the steering lower transmis-

sion shaft and steering gear by a M13 open end wrench.

(b) Remove the high/low pressure fuel pipe for connecting the steering gear and inlet oil return pipe

stack of power steering and completely discharge steering power-assistance oil.

(c) Remove the two hexagon ange bolts-oversized series for connecting the steering gear and ve-

hicle frame by a M18 socket wrench.

(d) Remove the two I-shaped hexagon nuts (Q341B16) for connecting the steering gear and vehicle

frame by a M24 socket wrench.

(e) When only disassembling the steering gear assembly, loosen the I-shaped hexagon nut

(Q341B14) by a M14 open end wrench and M21 open end wrench and remove the steering tie
rod from the ball head.

(f) About disassembling the ball head assembly, rst remove the split pin by pliers, and then remove

the ball head assembly by a M21 socket wrench.

(g) Take off the steering gear assembly.

2. Installation

(a) Install the steering gear assembly to vehicle frame. Simultaneously, install the hexagon-head bolt

and spring washer for connecting the steering gear and lower transmission shaft assembly by a
M13 open end wrench.

Tightening Torque: 25±3N•m

(b) Install the two hexagon ange bolts-oversized series for connecting the steering gear and vehicle

frame by a M18 socket wrench.

Tightening Torque: 100±10N•m

(c) Install the two I-shaped hexagon nuts (Q341B16) for connecting the steering gear and vehicle

frame by a M24 socket wrench.

Tightening Torque: 160±10N•m

(d) Install the high/low pressure fuel pipe for connecting the steering gear and inlet oil return pipe

stack of power steering and ll it with steering power-assistance oil.

Tightening Torque: 17.5±2.5N•m

(e) When only installing the steering gear assembly, screw the steering tie rod into the ball head and

then install the I-shaped hexagon nut by a M14 open end wrench and M21 open end wrench.

(f) About installing the ball head assembly, rst install it by a M21 socket wrench, then install the

split pin by pliers.

(g) After accomplishing the above installation, carry out the exhaust of the steering hydraulic system.

Then re-check the four-wheel parameters of complete vehicle on the four-wheel alignment instru­ment and align the steering wheel.

Steering System-6

Disassembly and Installation of Steering Lower Transmission Shaft

Hexagon-head bolt

Q150B0832

Spring washer

Q40308

Assembly of power steering gear with tie rod

Hexagon ange bolt

Q1840835

Steering pipe column assembly

Lower transmission shaft assembly

1. Disassembly

(a) Remove the hexagon ange bolt (Q1840835) for connecting the steering pipe column and lower

transmission shaft by a M10 socket wrench to disconnect them.

(b) Remove the hexagon-head bolt and spring washer for connecting the lower transmission shaft

assembly and assembly of power steering gear with tie rod by a M13 socket wrench.

(c) Draw out upwards along the axial line of the lower transmission shaft.

2. Installation

(a) Insert downwards the lower transmission shaft assembly along the axial line of the lower trans-

mission shaft.

(b) Connect the lower transmission shaft to the steering pipe column. Install the hexagon ange bolt

(Q1840835) for connecting the steering pipe column and lower shaft by a M10 socket wrench.

Tightening Torque: 25±3N•m

(c) Install the hexagon-head bolt and spring washer for connecting the lower transmission shaft ass-

embly and assembly of power steering gear with tie rod by a M13 socket wrench.

Tightening Torque: 25±3N•m

Disassembly and Installation of Steering Oil Pump

4G69 Left-hand Drive

Power steering oil pump bracket

Hexagon ange bolt

Q18408105

Power steering oil pump assembly

Steel-strip elastic clamping ring

Q673B205

Fuel intake hose

Hexagon-head bolt and plain gasket
sub-assemblyQ1400820FD

Inlet oil return pipe stack of power steering

Steering System-7

1. Disassembly

(a) Remove the high pressure fuel pipe for connecting the inlet oil return pipe stack of power stee-

ring and steering oil pump by a M17 open end wrench and completely discharge steering power-

assistance oil.
(b) Remove the fuel intake hose from the steering oil pump.
(c) Remove the tension bolt (Q1400820FD) at the oil pump by a M13 socket wrench or M13 open

end wrench.
(d) Remove the fastening bolt (Q18408105) at the oil pump by a M10 socket wrench or M10 open

end wrench.
(e) Take off the 4PK1100 ribbed belt.
(f) Take off the power steering oil pump.
(g) Remove the fastening bolt for connecting the oil pump bracket and engine by a M13 socket wren-

ch.
(h) Take off the power steering oil pump bracket.

2. Installation

(a) Fasten the Hexagon-head bolt and plain gasket sub-assembly (Q1400820FD) for connecting the

oil pump bracket and engine by a M13 socket wrench.
(b) Install the oil pump to the correct position according to the loading position. Install the tension

bolt (Q1400820FD) and fastening bolt (Q18408105) but not screw them down.
(c) Install the 4PK1100 ribbed belt.
(d) Tension the belt by the required tension force. Simultaneously, fasten the tension bolt

(Q1400820FD) and fastening bolt (Q18408105) of the oil pump by a M13 open end wrench and

M10 socket wrench.
(e) Install the fuel intake hose.
(f) Fasten the high pressure oil pipe of inlet oil return pipe stack of power steering to the power stee-

ring oil pump by a M17 open end wrench.

Tightening Torque: 27.5±2.5N•m

(g)

Fill steering power-assistance uid as required and completely discharge air in the hydraulic system.

2.5TCI Left-hand Drive

Ribbed belt 6PK1510

Hexagon-head bolt

Q150B1055

Hexagon-head bolt,
sp r ing washe r and
plain washer assem­blies Q1461030

B worm drive hose clamping ring

Power steering oil pump assembly

Hollow bolt

Inle t oi l re t urn p i p e
stack of power steering

1. Disassembly

(a) Loosen the hexagon-head bolt (Q1461030) for connecting the power steering oil pump and

power steering oil pump bracket and the tension bolt (Q150B1055) at the steering oil pump by a

M16 socket wrench.
(b) Take off the ribbed belt 6PK1510 belt.
(c) Loosen the B worm drive hose clamping ring for connecting the oil return hose of the inlet oil re-

turn pipe stack of power steering and the steering oil tank by a at head screwdriver and cross

head screwdriver.
(d) Draw out the oil return hose of the inlet oil return pipe stack of power steering and completely dis-

charge the oil uid in it.

(e) Remove the hollow bolt of the high pressure oil pipe of the inlet oil return pipe stack of power

steering by a M20 open end wrench or M20 socket wrench.

Steering System-8

(f) Take off the power steering oil pump.

2. Installation

(a) Install the power steering oil pump to the correct position.
(b) Install the ribbed belt 6PK1510 belt.
(c) Install the hexagon-head bolt (Q1461030) for connecting the power steering oil pump and power

steering oil pump bracket and the tension bolt (Q150B1055) at the steering oil pump by a M16

socket wrench to make the 6KB ribbed belt reach the specied tension

Tightening torque of the hexagon-head bolt (Q1461030): 65±5N•m

(d) Screw down the hollow bolt of the high pressure oil pipe of the inlet oil return pipe stack of power

steering by a M20 open end wrench or M20 socket wrench.

Tightening Torque: 30±5N•m

(e) Insert downwards the oil return hose of the inlet oil return pipe stack of power steering.
(f) Screw down the B worm drive hose clamping ring for connecting the oil return hose of the inlet oil

return pipe stack of power steering and the steering oil tank by a at head screwdriver and cross

head screwdriver.

(g) Fill the steering uid as required and completely discharge air in it.

Disassembly and Installation of Steering Oil Pipe

4G69 Left-hand Drive

Power steering oil tank assembly

Fuel intake hose

Assembly of power steering gear with tie rod

Power steering oil pump
with bracket assembly

Hexagon ange bolt

Q1840616FD

In l e t o i l ret u r n p i p e
stack of power steering

1. Disassembly

(a) Loosen the mounting position of the high/low pressure oil pipe and steering gear by a M17 open

end wrench.

(b) Completely discharge oil uid.
(c) Remove the two hexagon ange bolts (Q1840616) for connecting the inlet oil return pipe stack of

power steering and vehicle frame by a M8 socket wrench.

(d) Loosen the bolt for connecting the inlet oil pipe of power steering gear and power steering oil

pump by a M17 open end wrench.

(e) Remove the fuel intake hose (for connecting the steering oil pump and power steering oil tank)

and oil return pipe of steering gear (connected with the power steering oil tank).

(f) Remove the inlet oil return pipe stack of power steering and fuel intake hose.

2. Installation

(a) Tighten the mounting point of the high/low pressure oil pipe and steering gear according to the

required torque by a M17 open end wrench.

Tightening Torque: 17.5±2.5N•m

(b) Tighten the two hexagon ange bolts (Q1840616) for connecting the inlet oil return pipe stack of

power steering and vehicle frame by a M8 socket wrench.

(c) Tighten the bolt for connecting the inlet oil pipe of power steering gear and power steering oil

pump according to the required torque by a M17 open end wrench.

Tightening Torque: 27.5±2.5N•m

(d) Connect the power steering oil return hose to the power steering oil tank. Connect the power

steering oil pump to the power steering oil tank by the fuel intake hose.

(e) Install the fuel intake hose (for connecting the steering oil pump and power steering oil tank) and

oil return pipe of steering gear (for connecting the power steering oil tank).

(f)

Fill fresh oil uid into the power steering oil tank and completely discharge air in the hydraulic system.

Steering System-9

2.5TCI Left-hand Drive

Power steering oil pump assembly

Hollow bolt

30±5

B worm drive hose clamping ring

Hexagon ange bolt

Q1840616FD

Assembly of power steering gear with tie rod

17.5±2.5

Hexagon ange bolt

Q1840616FD

Inlet oil return pipe stack of power steering

1. Disassembly

(a) Loosen the mounting position of the high/low pressure oil pipe and steering gear by a M17 open

end wrench.

(b) Completely discharge the oil uid.
(c) Remove the hexagon ange bolt (Q1840616FD) for connecting the inlet oil return pipe stack of

power steering and vehicle frame by a M8 socket wrench.
(d) Loosen the hollow bolt for connecting the inlet oil pipe of power steering gear and power steering

oil pump by a M20 open end wrench.
(e) Loosen the B worm drive hose clamping ring by a at head screwdriver and cross head screwdri-

ver.
(f) Remove the inlet oil return pipe stack of power steering.

2. Installation

(a) Tighten the mounting point of the high/low pressure oil pipe and power steering gear according to

the required torque by a M17 open end wrench.
(b) Tighten the three hexagon flange bolts (Q1840616FD) for connecting the inlet oil return pipe

stack of power steering and vehicle frame by a M8 socket wrench.
(c) Tighten the hollow bolt for connecting the inlet oil pipe of power steering gear and power steering

oil pump according to the required torque by a M20 open end wrench.
(d) Insert downwards the oil return hose of the inlet oil return pipe stack of power steering.
(e) Screw down the B worm drive hose clamping ring by a flat head screwdriver and cross head

screwdriver.

(f) Fill fresh oil uid into the power steering oil tank and discharge air in it as required.

Removal of Steering Oil Tank and Steering Oil Tank Bracket

4G69 Left-hand Drive

Steel-strip elastic clamping ring

Q673B205

Fuel intake hose

Power steering oil tank bracket assembly

Steel-strip elastic clamping ring

Q673B155

Inlet oil return pipe stack of power steering

Hexagon ange bolt

Q1840616FD

Steering System-10

1. Disassembly

(a) Remove the fuel intake hose.

(b) Completely discharge the power steering uid.

(c) Remove the oil return hose of inlet oil return pipe stack of power steering.
(d) Draw out the power steering oil tank assembly upward along the center line of the steering oil

tank.

(e) Remove the hexagon ange bolt (Q1840616FD) for connecting the power steering oil tank and

vehicle body by a M8 socket wrench.

(f) Take off the power steering oil tank bracket assembly.

2. Installation

(a) Install the power steering oil tank bracket assembly. Fasten the hexagon flange bolts

(Q1840616FD) for connecting the power steering oil tank bracket assembly and vehicle body by
a M8 socket wrench.

(b) Insert downwards the power steering oil tank assembly along the center line of the steering oil

tank.
(c) Install the fuel intake hose.
(d) Install the oil return hose of the inlet oil return pipe stack of power steering.

(e) Fill the power steering uid as required and completely discharge air in it.

Body Electrical Appliance (K5)-1

Body Electrical Appliance (K5)

Schematic Diagram of Harness Mid-Connection

Numbering and Pin Function 1 ....................................... 2

Schematic Diagram of Harness Mid-Connection

Numbering and Pin Function 2 ....................................... 3

Schematic Diagram of Harness Mid-Connection

Numbering and Pin Function 3 ....................................... 4

Schematic Diagram of Harness Mid-Connection

Numbering and Pin Function 4 ....................................... 5

Schematic Diagram of Harness Mid-Connection

Numbering and Pin Function 5 ....................................... 6

Schematic Diagram of Harness Mid-Connection

Numbering and Pin Function 6 ....................................... 7

No. 1 Fuse Box (gasoline) ................................................ 9

No. 2 Fuse Box (gasoline) ................................................ 11

Storage Battery/Starter/Generator .................................. 13

Engine Electronic Control System.................................. 14

Anti-theft / Airbag ............................................................. 16

ABS EBD Electronic Control System ............................. 17

TCS Electronic Control System ...................................... 18

Reversing Radar / Reversing Display ............................. 19

AWD Electronic Control System ..................................... 20

Electric Horn / Combination instrument ......................... 21

Cigar Lighter/Power Rear-View Mirror/Rear

wiper/Washer .................................................................... 22

A/C ..................................................................................... 24

Power Window .................................................................. 25

Electric Heating Power Seat/Power Socket/Sunroof..... 27

New airbag control system .............................................. 28

Central Lock System ........................................................ 29

Body Control Module ...................................................... 30

Reversing Camera System .............................................. 38

Lighting system ............................................................... 40

Schematic Diagram of Harness Relationship and

Plug Connection Numbering ........................................... 43

BCM/Lamp/Front washer and wiper ............................... 44

Body Electrical Appliance (K5)-2

C02

3 B/R

C04

199

3.0
R

46

0.5
W/R

0.5
Y/B

0.5
G/Y

C01

C03

C05

Schematic Diagram of Harness Mid-Connection Numbering and
Pin Function 1

Connecting the power
supply harness 1

Connecting the engine
room harness 1

Connecting the power
supply harness B

Connecting the engine harness 1

Connecting the engine
room harness 2

Connecting the engine room harness 1

Connecting the engine harness 2

Connecting the instrument harness 2

Connecting the engine room harness 2

Connecting the engine room harness 2

Body Electrical Appliance (K5)-3

C10

0.5
G/W

0.85
G/Y

0.5
Gr/B

0.85
G/V

T02

0.5
Br

T41

0.5

Br/R

T32

0.5
Br/Gr

T51

0.5
Br/G

2.0
R

T01

0.5
Br/L

2.0

Br

E

0.5
B/Y

0.85
W/G

0.85
B/W

0.5
G/B

0.5
Gr/R

0.5
W/L

T31

0.5

Br/Y

T42

0.5

Br/W

T52

0.5

Br/B

0.5

0.5

0.85

L/W

0.5
Gr/Br

0.5
Br/R

1.25
L/Y

1.25
Y

0.5

0.5

0.5

Br/B

50Y

2.0
B

C13

C06

C09

517

C/O

0.5

0.5

G/B

318B01

0.85

R/P

Y/G

0.85

38

B02

0.85
B/R

B03

0.5

B/R

Br

2.0

315

A42

0.5
Br/G

A39

0.5
Br/B

106

1.25
L/W

73

0.5
L/R

318

0.5

G/B

R/P

0.85

B01

B/R

0.85

B02

B/R

0.5

B03

38

0.85
Y/G

315

2.0
Br

Br/G

0.5

A42

A39

0.5

Br/B

L/W

1.25

106

R/Y

0.85

E44A

D44B

0.85
R/L

315

2.0
Br

E44A

0.85
R/Y

R/L

0.85

D44B

Br

2.0

315

Schematic Diagram of Harness Mid-Connection Numbering and
Pin Function 2

Connecting the instrument panel
and console harness 1

Connecting the engine
room harness 1

Connecting the oor harness

Connecting the oor harness 2

Connecting the engine room harness

Connecting the instrument harness 2

Connecting MT harness assembly

Connecting the instrument harness

Body Electrical Appliance (K5)-4

C07

C08

C

11

C12

Schematic Diagram of Harness Mid-Connection Numbering and
Pin Function 3

Connecting the instrument harness 4

Connecting the instrument harness 3

Connecting the engine room harness 4

Connecting the engine room harness 3

Connecting
t h e f l o o r
harness 1A

Connecting
t h e f l o o r
harness 1B

Connecting the instrument harness

DJ7031-6.3-11

C o n n e c t i n g
the instrument
harness 1A

Connecting the instrument harness

DJ7031-6.3-11

C o n n e c t i n g
the instrument
harness 1B

Body Electrical Appliance (K5)-5

C1

7

C1

4

C1

5

C1

8

0.5
V/L

0.85
L/Y

0.85
W/G

0.85

B/W

W

T02
T12

T01
T11

T42
T42A

0.5
V/L

0.85

G

0.5
Gr/R

W

0.5
Gr/B

T41
T41A

0.85
B/G

0.85

R/L

0.85
Y/R

261

2.0
R

0.85
W/G

2.0
B

0.85

L/Y

0.85
B/W

1.25
L/R

504

0.5
V/L

0.5
W

0.5
R/L

50X

0.85
B

0.85
L/W

A

0.85

G

5

0.5
V/L

T42

0.5
Br/W

T41

0.5
Br/R

W

0.5
Gr/R

0.5
Gr/B

B

0.85
L/Y

M

2.0
B

0.85
Y/R

C

0.85
R/L

2.0
R

0.85
B/G

E

0.85
W/G

E

0.85
B/W

612

0.5
G/Br

0.5
Y/R

L

1.25
B

0.85
G/Y

611

0.5
G/L

610

0.5
G/R

609

0.5
G/B

1.25
Y

A

0.5
G/R

0.85
L/Y

0.85
W/G

0.85
B/W

T01

0.5
Br/L

504

0.5
V/L

T02

0.5
Br

W

0.5
Y/R

0.85
G/Y

1.25
B

0.5

G/R

0.5

G/L

0.5
G/Br

0.5
G/

B

1.25
Y

C16

0.5
Gr/B

0.5
Gr/w

0.5
Gr/w

0.5
Gr/B

Schematic Diagram of Harness Mid-Connection Numbering and
Pin Function 4

Connecting the right front door harness 1

Connecting the ceiling harness

Connecting the right front door harness 2

Connecting the cabin harness

Connecting the cabin harness 1

Connecting the oor harness 2

Connecting the chassis harness

Connecting the left front door harness 1

Connecting the cabin harness

Connecting the oor harness 1

Body Electrical Appliance (K5)-6

T31
T31A

T32
T32A

Y/W

U

B

R/Y

Gr/R

260B

R/G

Gr/B

R/L

G

C20

C21

C1

9

C22

0.85
Gr/B

0.85
Gr/R

0.85
G

0.85
Y/W

0.85
R/Y

260

2.0
R/G

0.85

R/L

2.0
B

N

2.0

B

B

0.85
W/G

A

2.0
R

B

0.85
B/W

T32

0.5
Br/Gr

W

T31

0.5
Br/Y

504

0.5
V/L

A

0.85

R/L

6C

0.85
W/G

7C

0.85
B/W

T51

0.5
Br/G

T52

0.5
Br/B

B

2.0

B

260A

2.0
R/G

B

0.85

R/L

5

0.5
V/L

0.5
W

W

0.85
R/L

504

0.5
V/L

Schematic Diagram of Harness Mid-Connection Numbering and
Pin Function 5

Connecting the left
front door harness 2

Connecting the cabin harness 2

Connecting the right
rear door harness

Connecting the right
rear door harness

Connecting the cabin harness

Connecting the cabin harness

Connecting the left
rear door harness

Connecting the cabin harness

Body Electrical Appliance (K5)-7

B73
W/G

A

L/Y

B74
B/W

O/G

Y/L

H

B

O/G

Y/L

B

L/Y

C

24

C

23

C2

6

C

25

B74
B/W

B73
W/G

A

0.5
W

0.85
O

C

0.85
R/B

C

0.85
R/B

0.85
O

A

0.5
W

C2

7

Schematic Diagram of Harness Mid-Connection Numbering and
Pin Function 6

Connecting the tail-gate
transition harness

Connecting the tail-gate
transition harness

Connecting the cabin harness

Connecting the cabin harness

Connecting the tail gate

Connecting the tail gate

Connecting the reversing
radar transition harness

Connecting the tail-gate
transition harness

Connecting the tail-gate
transition harness

Connecting the cabin harness

Body Electrical Appliance (K5)-8

C2

8

C2

9

Connecting the transition harness 1

Connecting the transition harness 2

Connecting the reversing radar harness 1

Connecting the reversing radar harness 2

Body Electrical Appliance (K5)-9

Label of fuse box

No. 1 Fuse Box (gasoline)

Spare

Spare

Brake
lamp

Spare

Right-

side

power

window

Left-side

power

window

Defrost

Rear door

motor relay

Spare

Spare

Central
control

door
lock

Sunroof

Audio

Tail gate

motor

Defrost relay

Combination

instrument

Back pin diagram of fuse box

Cigar
lighter

Central control door
lock relay

Spare Spare

Power

seat

IG unlo a ding
relay

Reserved

A/C

Airbag

Rear
wiper
motor

Reserved

Reserved

Front wiper relay

Front
wiper
motor

Body Electrical Appliance (K5)-10

R

Connecting No.1 fuse box E

Connecting fuse box A

Connecting fuse box C

Connecting No.1 fuse box D

Connecting fuse box B

Body Electrical Appliance (K5)-11

Control

Front

Body

Label of fuse box

No. 2 Fuse Box (gasoline)

Fuel pump relay

Compressor

Fuel pump

Main relay of

Main relay of engine

Start
power of 1# fuse box

engine

Blower

Starting
relay

Compressor

relay

Lower

beam

relay

Sunroof

Great Wall Motor Company Limited

Back pin diagram of fuse box

B l o w e r
relay

Electric heating seat

Electric horn

high

beam

relay

Electric horn
relay

High-speed relay for
blower

Room lamp

Reversing lamp

high beam

Left lower beam

Right lower beam

F ro n t f og
lamp relay

Power of
1# fuse box

Power of
1# fuse box

Front fog lamp

15A

Normal power supply of ECU

Power management

Po wer man a-

gement relay

SpareSpareSpareSpare

Body Electrical Appliance (K5)-12

Connecting No.2 fuse box D

Connecting No.2 fuse box A

Connecting No.2 fuse box B

Connecting No.2 fuse box G

Body Electrical Appliance (K5)-13

>

Storage Battery/Starter/Generator

From ECU fuse

Red

White
/Red

R e d /
Blue

Red/
Green

Ignition switch

Position of

pulled

the key

Outgoing

Status of

the switch

terminal

Red

Key

out

Key plugged in

Red

R e d /
White

R e d /
Black

B lu e /
White

Green

B la c k /
Red

Gr ee n/
Yellow

No such wire for engine

Charging indicator lamp

Yellow

Starting relay

Storage battery

Black

R e d /
Yellow

Starter

R e d /
Blue

G re en /
Yellow

W h it e /
Red

Bl ac k/
Red

Generator

Ignition switch

CD-H005

Body Electrical Appliance (K5)-14

From the

BC M 42

pin

pin

the

From

BCM39

Brown/White

Brown/White

pin

the

From

From

the ECU

power

normal

From

From the

TCU9

fuse

supply

no rm al

p o we r

From ECU fuse

From the

mid-pressure

the low

pressure

From ECU fuse

speedometer

From the

tachometer

power

supply

Normal

power

supply

Normal

supply

switch

switch

Red

Black/Red

Green/Yellow

White/Red

Blue/White

Brown/Red

Brown/Black

Green/Yellow

Brown

White/Black

Red/Green

Red

Red

Green/Yellow

Red

ECU normal power supply fuse

Low-speed fan relay

High-speed fan relay

Maintenance indicator lamp

Malfunction indicator lamp

Red

Compressor relay

Green/Black

Green/White

Red/White

Red/Grey

Grey/Black

Blue/Yellow

Cooling fan

White/Red

Blue/White

Brown/Red

Brown/Black

Green

Blue

Brown

White/Black

Compressor

Electromagnetic clutch

Red

Brown/White

Blue/Red

White/Black

Black/White

Blue/Black

Black/Red

White

Red/Yellow

Blue/Red

Blue/White

Black/White

Black/White

Blue

Diagnostic plug

Low acceleration sensor

Pressure and temperature sensor for

air intake manifold

Throttle valve position sensor

Knock sensor

Blue/White

ECU fuse

From IG1

Charcoal canister cleaning control solenoid valve

Spark plug

Green/Yellow

Red/White

Grey/Red

Fuel injector 4

Engine Electronic Control System

Grey/White

Fuel injector 3

Red

Green/Yellow

Red

From ECU fuse

Black/Yellow

Black/Yellow

Green/Yellow

Red/Yellow

Fuel pump relay

Pink/Black

Yellow

PCP ignition coil

Pink/White

Main relay

Pink/Brown

Fuel pump

Fuel injector 2

Fuel injector 1

Black/Yellow

Black/Blue

Grey/Brown

Grey/Green

Red/Blue

Green/White

Red/Yellow

Black/White

Violet/Black

White/Red

White/Black

Brown/Black

Brown

Violet

Green/Red

Coolant temperature sensor

Black

White

Crankshaft position sensor

Idle control valve

OSP rear oxygen sensor

OSP front oxygen sensor

Body Electrical Appliance (K5)-15

36

0.5

Y/R

0.5

A42

Br/G

A39

0.5

Br/B

1.25
Y

0.5
Y/R

B

0.5
B

A

1.25
B

Connecting ECU engine

Connecting the engine
room harness 1

Connecting the
ignition coil

Connecting the
compressor

Connecting the engine
room harness 2

Connecting the ac­celeration sensor

Co nnect ing the fuel
injection nozzle I

Connecting the fuel pump

Connecting the diagnostic equipment

Connecting the radiator fan

Connecting the fuel
injection nozzle II

Connecting the idle
control valve

Connecting the fuel
injection nozzle III

Connecting the front
oxygen sensor

Connecting the
water tempera­ture plug

C o n n e c t i n g t h e
temperat ure se n­sor

Connecting the fuel
injection nozzle IV

Connecting the throttle
valve position sensor

Connecting the charcoal
canister control valve

Connecting the intake temperature
and pressure sensor

Connect i n g th e
knock sensor

Co n n e ct i ng th e
crankshaft position
sensor

Body Electrical Appliance (K5)-16

0.5
R/G

0.5
V/W

0.5
B/W

0.5
W/B

Anti-theft / Airbag

Green/
Yellow

Red

Brow n/
White

Anti-theft ECU
assembly

Red

Anti-theft indicator lamp

Gre en/
Red

To the diag nosis
connector

Brown/White

Blue/Red

Blue/Yellow

From IG1

Clock spring

Blue/White

Driver seat belt indicator lamp

Red

Airbag ECU

From ECU fuse

Yellow/Red

Yellow

Blue/White

Yellow/Black

Green/

Warning lamp of airbag

Seat belt warning lamp

To the BCM

Impact unlocking

White/Red

Seat belt switch

White/

Green

Seat belt switch

From

Passenger seat belt indicator lamp

Warning lamp

Key detection

Driver airbag

Connecting PAB switch

Assistant driver’
s side airbag

接安全气囊

Connecting airbag

T:DJ621-G2.3*0.6A 2EA

anti-theft module

0-0282366-1
0-0173850-1

Passenger seat belt

pretensioning

Con nect ing PAB
generator (yellow)

Driver seat belt

pretensioning

Seat sensor

Connecting the
cl o c k sp ri n g
(yellow)

Body Electrical Appliance (K5)-17

0.5
G/Br

0.5
G/L

0.5

G/R

0.5

G/

B

ABS EBD Electronic Control System

Ac ce le ra tio n s en sor
(4WD)

Brown/Black

Green/Brown

Brown/Red

To the
diagnosis
connector

From the brake
lamp switch

Brown/White

Brown/White

Red/Black

Red/Black

From ECU fuse

Green/Yellow

Normal power
supply

Red

Red/Black

Normal power
supply

Red

Red/Green

From ECU fuse

Alarm lamp

Green/Yellow

Brown/Red

Alarm lamp

Brown/Black

Green/Brown

Green/Blue

Yellow/Black

Left front (2WD)

Green/Brown

Yellow/Black

Yellow/Red

Left front (4WD) Right front

ABS right rear sensor

AMP A1-967644-1

Green/Yellow

Yellow/Blue

Yellow/Brown

Yellow/Red

Left rear

Wheel speed sensor

Band

Green/Red

Green/Black

Green/Blue

Right rear

Green/Brown

ABS left rear sensor

AMP A1-967644-1

Oil pump motor

Control solenoid valve

Integrated ABS control module assembly

Right front ABS-FR sensor

Left front ABS-FL sensor

A1-967644-1

ABS-ECU

1 928 D00 981

Leading out from this side

Body Electrical Appliance (K5)-18

TCS Electronic Control System

Brown/
White

Acceleration sensor(4WD)

Re d /
Black

Gr een /
Yellow

Red

Red

Gr een /
Yellow

Gr een/
Blue

Br ow n/
Black

G re e n/
Brown

Green/
Brown

Gr ee n/
Brown

Br own/
Red

Gr een /
Yellow

Yell ow/
Blue

Switch

Gr een /
White

Yel low/
Brown

Br own/
White

Gr ee n/
Black

Gre en/
Red

R ed /
Black

Gre en/
Blue

Green/
Brown

R e d /
Black

Ala rm
lamp

R e d /
Green

Br ow n/
Red

Oil pump motor

Br ow n/
Black

Ala rm
lamp

In di ca to r
lamp

G re en /
Yellow

Yellow/
Black

Left front (2WD)

Yellow/
Red

Yellow/

Yellow/

Black

Red

Left front (4WD)

Wheel speed sensor

Band

Right front

Left rear

Control solenoid valve

Integrated TCS control module assembly

Right rear

TCS-ECU

Body Electrical Appliance (K5)-19

3

BrW

Yellow/
Green

From IG1

Blue/
White

Fuse for reversing lamp

Reversing Radar / Reversing Display

To DVDc1-1 pin

Green/
White

Reversing radar ECU

To DVDc1-4 pin

Negative pole of video

Positive pole of video

From DVD

From DVD

Green/
White

Reversing lamp

Left side

Ye ll ow /
Black

Left middle

Yel low/
Blue

Right middle

Ultrasonic sensor

Connecting ECU

Gr een /
Red

Yellow/
Red

Right side

Green/
Blue

Connecting the
cabin harness

Reversing display

Connecting the re­versing camera
H:MG610159

Connecting the
left side probe

Connec ting the
left middle probe

Co n ne ct i ng t he
right middle probe

Connecting the
right side probe

Body Electrical Appliance (K5)-20

To the diagnosis
connector

Brown/ White

Normal power supply

AWD Electronic Control System

From the reversing
lamp fuse

Red

Yellow/Green

Blue/Green

To BCM

Blue/Green

From power

management

From ECU fuse

Green/Yellow

Cigar lighter illumination

relay

Small lamp

Red/Blue

White

Green/Yellow

Green/White

Center control switch

Green/

White

White/

Green

Indicator lamp

Seat belt untying indicator lamp

Closing indicator lamp

White

Green/

Speed sensor

Power clutch

4WD motor unit

Center control switch

Body Electrical Appliance (K5)-21

Electric Horn / Combination instrument

Normal power supply

Red

Horn relay

Red/White

Horn switch

Orange/Blue

Electric horn

From BCM

From BCM

Yellow

Yellow

Door indicator lamp

Power clutch indicator lamp

From BCM

Parking brake indicator lamp

Instrument illumination lamp

White/Blue

Parking brake switch

From ECU fuse

Red/Green

Combination instrument

Engine oil pressure indicator lamp

Brake malfunction indicator lamp

Fuel gauge

Yellow/Red

Yellow/Black

Blue/Black

Engine oil pressure switch

Brake uid level switch

Fuel sensor

Fuel alarm lamp

Water temperature gauge

Brown/Grey

Water temperature sensor

To ECU pin 3

Speedometer

Brown/Green

Brown

To ECU pin 45

White/Black

Tachometer

Red/Green

Speed sensor

Left electric horn

Right electric horn

Combination instrument B

H:1318774-1

Combination instrument A

H:1318389-1

Body Electrical Appliance (K5)-22

Cigar Lighter/Power Rear-View Mirror/Rear wiper/Washer

From the

center

Red/Blue

control
switch

From No.1 fuse box

Red/White

From IG2

Red/Yellow

Black/Yellow

From IG unloading relay

Yellow

Orange/
Green

Turn off

Cigar lighter

Left rear-view mirror

Middle

Left

Right

Upper

Lower

Middle

Left

Right

Upper

Lower

Middle

Left

Right

Upper

Lower

Vertical

Horizontal

Yellow/White

Green

Black/Green

Power rear-view mirror switch

Yellow/Red

Red/Yellow

Vertical

Horizontal

Right rear-view mirror

Rear washer

Rear wiper

Wiping intermittent relay

Green/Red

Rear washer motor

Orange

Rear wiper switch

Yellow/Blue

Rear wiper motor

Power rear-view mirror switch

Left power rear-view mirror

Rear washer motor

Right power rear-view mirror

Body Electrical Appliance (K5)-23

T02

0.5
Br

T01

0.5
Br/L

T41

0.5
Br/R
T42

0.5
Br/W

T31

0.5
Br/Y

T32

0.5
Br/Gr

T51

0.5
Br/G

T52

0.5
Br/B

From BCM adjustment light

R ed /
Blue

Liquid crystal
display

Left front speaker

Brown

Left rear speaker

DVD机

Negative pole of video

Positive pole of video

Brown

Speed detection

Brown/Blue

DVD player assembly

Key-control grounding

Key-control input A

Brown/

Brown/

Green

Black

Gr een /

Yellow

White

Red/
Blue

BCM adjustment light

Blue/
Red

Reversing detection

White

Blue/

Normal power supply

Red

Right front speaker

Brown/

Brown/

Red

White

USB interface

Blue

Signal feed line

Brown/
Yellow

Dedic ated c ommunica tion
cable

Brow n/
Grey

Right rear speaker

Co n n e ct i n g t h e
line-control transi­tion harness

USB interface

DVD player A

Conne c t i n g
the left front
speaker

DVD player B

Con n e c ting
the right front
speaker

Connecting
the left rear
speaker

Overhead antenna

Connecting DVD player

Co n nect i ng
the right rear
speaker

Connecting
the antenna

Body Electrical Appliance (K5)-24

A/C

Blue

Blue/Yellow

Defrost indication

Brown/Grey

Brown

Water temperature sensor

Speed sensor

White/Black

White/Black

Adjustment light illumination

Engine rotation speed

Red/Black

Blue

White/Black

Blue

Green

A/C ECU assembly

Pink/Red

White/Blue

Red/White

Cold and warm air actuator

Indoor temperature sensor

Brown

Blue

Yellow/Black

White

Outdoor temperature sensor

Green/Black

Blue/Black

Blue/Yellow

Pink/Yellow

Internal and external circulation actuator

Mode actuator

To ECU pin 39

To ECU pin 9

Blue/White

Green/Black

Defrost request

Evaporator temperature sensor

Green/Black

Blue/Red

White/Red

Tri-state pressure switch

Blue/Orange

From the A/C fuse

Green

Blower high-speed relay

Normal

Blue

power
supply

Red

Black/Yellow

Blower

Red/Black

Blower relay

Speed governing module

A/C mode actuator

H:DJ7072-3-21

A/C ECU

Evaporator
temperature
sensor

Brown

Brown

Speed

governing

module

A/C Cold and

warm air actuator

H:DJ7072-3-21

Internal and external
circulation actuator

Body Electrical Appliance (K5)-25

0.85
W/G

0.85
B/W

0.85
W/G

0.85

B/W

0.85
W/G

0.85
B/W

0.5
Gr/B

A

0.85
B

0.5
Gr/w

A

0.5
B

D

0.5
B

B24

Gr/W

To BCM

To BCM

To BCM

From IG1

IG unloading relay

Grey/Red

Grey/Black

Power Window

Normal

power

supply

Red/Blue

Red/Black

Red/Green

Left fron t door
window switch

Normal

power

supply

White/Red

Left rear door
window switch

Blue/White

Right front door
window switch

Red/White

Blue/White

Right rear door
window switch

Red/White

Blue/White

Yellow

Red

Red/White

Left front door integrated
door lock assembly (locking
mechanism assembly)

Red/Blue

Ant i-pi nch
ECU I

Left front door motor

Right front door integrated
door lock assembly (locking
mechanism assembly)

Anti-pinch

ECU II

Left rear door motor

Left rear door integrated
door lock assembly (locking
mechanism assembly)

Ant i-pi nch
ECU III

Right front door motor

An ti- pi nch
ECU IV

Right rear door motor

Right rear door integrated
door lock assembly (loc­king mechanism assembly)
CD-H054

Left front regulator
(rocker type)

Right front regulator
(rocker type)

Left rear regulator
(rocker type)

Right rear regulator
(rocker type)