Edition：January 2015

Volume 1
Printing：January 2015 Preface 01

Pulication NO：FXSW-201501 Preparation 02

Maintenance Specification 03

Diagnosis 04

Vehicle Service 05A

Vehicle Service 05B

Volume 2
Volume 3

2015 Beiqi Foton Motor Co.,Ltd

All right reserved.No part of this service manual may

be reproduced or stored in a retrieval system,or
transmitted in any form,or by any
means,electronic,mechanical,photo-copying,recording
or otherwise,without the proir written permission of
Foton.
 01
Preface
How to Use the Manual.........................01-1
Overview.............................................01-1
Identification Information.....................01-6
Vehicle Identification Number (VIN)....01-6
Serial Number (SN)............................01-7
General Principles of Maintenance
Operation...............................................01-8
Cautions for Operation........................01-8
Vehicle Lift and Support Locations....01-16
How to troubleshoot the vehicle........01-17
Overview...........................................01-17
Circuit Detection...............................01-26
Index.....................................................01-32
Glossary Index..................................01-32
01
 Preface - How to Use the Manual 01-1

01
How to Use the Manual
Overview
1. Introduction
(a) The manual gives a general description of maintenance operations. Following the
instructions in this manual ensures maintenance quality and efficiency.
(b) Generally, maintenance operations can be mainly divided into the following parts:
• Diagnosis.
• Replacement (removal and installation), disassembly and assembly, (on-vehicle)
inspection and adjustment.
(c) The manual illustrates "Diagnosis" (see Chapter 04 Diagnosis) and "Replacement
(removal and installation), disassembly and assembly, (on-vehicle) inspection and
adjustment" except "Final Inspection".
(d) It does not mention the following indispensable operation in actual maintenance:
• Use a jack or car lift to operate.
• Clean dismantled parts as necessary.
• Do a visual inspection.
2. Index
At the end of the manual, there is a Glossary Index for reference.
3. Caution
In Chapter 02 Caution , it lists special tools, recommended tools, equipment or
accessories that maintenance service required. Please strictly follow operating
procedures and properly use them.
4. Maintenance Steps
(a) Component diagrams are inserted to illustrate the system if a chapter needs.
(b) In the form of exploded views, component diagrams clearly explain the assembly
relations among all the parts and then show parts name in the following list.
 01-2 Preface - How to Use the Manual

01 Example:

Component diagram
Fuel system Assembly relation

12

14

15
13
5

6
7

8
1

10

11

2 4

9
3

fpwx120080

1 Oil tank assembly 9 Oil tank cover assembly

2 Electric fuel oil pump assembly 10 Oil filler pipe assembly
3 Fuel pump 11 Oil filler breather hose
4 Fuel level sensor 12 Carbon canister
5 Nylon oil delivery pipe assembly 13 Carbon canister carrier
Breather hose between the carbon canister
6 Nylon oil return pipe assembly 14 and the canister solenoid
Breather hose between the oil tank and the
7 Fuel filter assembly 15 carbon canister
8 Nylon oil delivery pipe assembly

Parts list
fpwx010001
 Preface - How to Use the Manual 01-3

(c) If installation steps are opposite to dismantlement steps, it only describes the important 01
part.
(d) Maintenance steps in this manual just focus on the important part and represent
operation objects and operating procedure in illustrations. Besides, it also introduces
specific operating methods, standard values, operation cautions, etc..
(e) Some similar vehicles are possible to use the same illustration in this manual. In this
case, relevant information may differ from that of the actual vehicle.
(f) Operating steps are presented in the following way:
• Illustrations of the operating steps indicate what to do and where to do.
• Titles of the operation steps show what to do.
• Instructions of the operation steps tell how to do, and provide information like
maintenance specification, maintenance warning, etc.
Example:

Operation procedure title Operation procedure description

5. Installation of drive shaft assembly

(a) Place the drive shaft to its proper position
according to the installation mark
Note
• Do install according to the installation marks.
• Rotate the flange plate assembly of the main reducer
to align it with the installation mark as needed.

fpwx340010
Warning information for repair

(b) Install and tighten up the bolts and nuts

connecting the drive shaft with the main reducer.

Torque: 25±3N• m
Note
(25±3N·m)
Do replace with new bolts and nuts.

fpwx340011 Warning information for repair

Operation procedure illustration

fpwx010002

5. Maintenance Specification
In the manual, maintenance specification is displayed in bold, so you need not put
down the work at hand to find it. Chapter 03 Maintenance Specification offers relevant
information for quick locating.
 01-4 Preface - How to Use the Manual

01 6. Term Definition
In bold. It indicates that there is a possibility to cause per-
Danger
sonal injury to you or others.
In bold. It indicates that there is a possibility to damage
Warning
the repairing parts or devices in use.
In bold. It provides further explanation for maintenance
Caution
operation.

7. International System of Units

The units in this manual adopts the International System of Units (SIUNIT).
Example:
Torque: 30N•m
8. Applicable Models Table.
Driving way Models Engine Transmission For example
6393MD31A- G03-
MR513B52 6393MD31A-CAZA01
CA 1.0L
5023XXY00- G03-
MR513B52 5023XXY00-CAZA01
CA 1.0L
6393MD32A- G03- 6393MD32A-AAZA02
MR513B52
AA 1.2L 6393MD32A-AAZA03
5023XXY00- G03- 5023XXY00-AAZA01
MR513B52
AA 1.2L 5023XXY00-ABZA03
6425MD32A-AAZA01
6425MD32A-AAZA02
6425MD32A-AAZA03
Left-hand 6425MD32A- G03-
MR513B52 6425MD32A-AAZA04
drive AA 1.2L
6425MD32A-AAZA07
6425MD32A-AAZA08
6425MD32A-AAZA09
5023XXY00- G03-
MR513B52 5023XXY00-ABZA04
AB 1.2L
5023XXY00-ABZA01
6393MD31A-DAZA04
6393MD31A- G03- 6393MD31A-DAZA05
MR513B52
DA 1.2L 6393MD31A-DAZA06
6393MD31A-DAZA08
6393MD31A-DAZA09
 Preface - How to Use the Manual 01-5

01
Driving way Models Engine Transmission For example
6393MD31A-DAZA10
6393MD31A-DAZA11
6393MD31A-DAZA12
6393MD31A-DAZA13
6393MD31A-DAZA14
6393MD31A-DAZA15
5023XXY00-
LJ465 MR508A95 5023XXY00-ABZA01
DA
6393MD31A-
LJ465 MR508A95 6393MD31A-DAZA01
DA
5023XXY00-DAZA04
5023XXY00-DAZA01
5023XXY00-
LJ465 MR508A95 5023XXY00-DAZA02
DA
5023XXY00-DAZA05
5023XXY00-DAZA06
 01-6 Preface - Identification Information

01
Identification Information
Vehicle Identification Number (VIN)
1. Vehicle Identification Number (VIN).
The vehicle identification number is stamped on the vehicle identification number label
(VIN label) and vehicle identification number plate (VIN plate).
• Vehicle identification number label (VIN label) ——On the front left side of the
instrument panel, it can be seen through the front windshield.
• Vehicle identification number plate (VIN plate) ——Above the right B pillar of
the vehicle, it also can be seen.
• Tire inflation pressure label is located at the bottom of B pillar and can be seen
when the front left door is opened.

Manufacturer: China Foton

Brand Foton Vehicle model

Manufacturing country: China Number of passenger:

Engine model Engine max power Kw

Engine displacement L Maximum authorized total mass Kg

Manufacturing time: xx month, xx year

VIN

Tyre charge pressure

Tyre model: 165/70R13C 88/86S

Front wheels rear wheels

xxxxxxxxxxxxxxxx
no-load 220kpa 250kpa

full load 280kpa 340kpa

fpwx010003
 Preface - Identification Information 01-7

01
Serial Number (SN)
1. Final drive serial number
The final drive serial number is stamped on
the front housing of the final drive.

fpwx010004

2. The engine serial number is printed on the

left of the cylinder (looking from the end
of the engine).

fpwx010005
 01-8 Preface - General Principles of Maintenance Operation

01
General Principles of Maintenance Operation
Cautions for Operation
1. Cautions for basic maintenance
(a) Cautions for maintenance

4
6

fpwx010007

• Always wear clean uniforms.

1 Attire
• Always wear safety helmets and safety shoes.
• Prepare a grille cover, fender cover, seat cover and floor mat
2 Vehicle protection before starting the operation.
• When working with 2 or more persons, be sure to consider for
others' safety.
• When working with the engine running, make sure to provide
3 Safe operation ventilation for the workshop.
• When working on high temperature, rotating, moving, or vibrat-
ing parts, wear essential productive equipment to avoid getting
burnt or injured.
 Preface - General Principles of Maintenance Operation 01-9

01
• When jacking up the vehicle, be sure to hold the specified lo-
cation and support it firmly.
• When lifting up the vehicle, use safe and qualified equipment.

Preparation for tools • Before starting operation, prepare tool stands, special tools,
4 and measuring instru- measuring instruments, auxiliary materials for a vehicle,
ments washing cloth and parts for replacement.
• Comprehensively analyze and diagnose the fault symptom,
and then take effective measures.
Removal and installa- • Before removing parts, check them for deformation and dam-
tion, disassembly age.
5
and assembly opera- • When the structure is complicated, record operation steps or
tions put assembly marks to avoid damaging the functions.
• Clean and wash the removed parts if necessary, and assemble
them after a thorough check.
• Place removed parts in sequence to avoid mixing them up or
getting contaminated.
• For non-reusable parts such as O-rings, and self-locking
6 Removed parts screws, replace them with new ones as instructed in this
manual.
• Retain the removed parts for customer inspection.

(b) Jacking up and supporting a vehicle

• Special care must be taken when jacking up and supporting the vehicle. Be
sure to lift and support the vehicle at the proper locations. (Refer to01 Preface
- General Principles of Maintenance Operation, Vehicle Lift and Support
Locations)
(c) Precoated parts
• Precoated parts are bolts and nuts that are coated with a sealant at the factory.
• If a precoated part need loosen, retighten or move in any way, it must be
recoated with the specified sealant.
• When reusing precoated parts, clean off the old sealant and dry the part with
compressed air. Then apply the specified sealant to the bolt, nut or threads.
Danger

Check the torque with the lower limit of the torque requirement.

• When applying the sealant, it is necessary to leave it for a while until it solidifies.
(d) Gaskets
• Add a seal ring on the gasket to prevent leaks as necessary.
(e) Bolts, nuts and screws
• Strictly observe the specifications for tightening torques and tighten with a torque
wrench.
 01-10 Preface - General Principles of Maintenance Operation

01 (f) Fuses
Same amount of current When replacing fuses, ensure that the
•
rated current of a new fuse meets the
requirements. Never use the fuse with
higher or lower rated current.

fpwx010008

Illustration Symbol Part Name

Fuse
fpwx010009
fpwx010008 fpwx010012
fpwx010008

Fuse
fpwx010010
fpwx010008 fpwx010013
fpwx010008

(g) Clips
• The removal and installation methods of typical clips used in body parts are
shown as follows.
Note

If the clip is damaged during the operation, always replace it with a new clip.

Shape (Example) Removal/Installation

Pliers

Clip remover

fpwx010015 fpwx010021

Protective belt

Screwdriver

fpwx010016 fpwx010022
 Preface - General Principles of Maintenance Operation 01-11

01
Shape (Example) Removal/Installation

Protective belt

Scraper

fpwx010017 fpwx010023

Removal Installation

fpwx010018 fpwx010024

Removal Installation

fpwx010019 fpwx010025

Removal Installation

fpwx010020 fpwx010026

(h) Removal and installation of vacuum hoses

• When disconnecting vacuum hoses,
always hold the end of the hoses and
never pull the middle of the hose.

Incorrect correct
fpwx010027
 01-12 Preface - General Principles of Maintenance Operation

01 • When disconnecting the connectors of

vacuum hoses, use tags to identify where
they should be reconnected.
• After the operation, make a double check
whether the vacuum hoses are properly
connected.
• When using a vacuum gauge, never force
the hose onto a connector that is too large.
fpwx010028
Use a special adapter for adjustment. Once
the hose has been stretched, it may leak
air.

(i) Using torque wrenches with extension

handles
• When a torque wrench with a special
service tool or a extension handle is
used, the reading of the torque wrench
reaches the specified torque value,
which indicates that the actual torque
is excessive.
fpwx010029
• In this manual, only the specified
torque is described. When using a
torque wrench with a special service
tool or a extension handle, calculate
torque values by the following formula

• Formula: T＇=T×L2/（L1＋L2）
Reading of torque
T＇
wrench (N•m)
Actual torque
T
(N•m)
Length of a special
fpwx010030 service tool or
L1
extension handle
(mm)
Length of torque
L2
wrench (mm)
 Preface - General Principles of Maintenance Operation 01-13

2. Electrical control 01
(a) Disconnecting and connecting the battery
negative cable.
• Before performing electrical work,
disconnect the battery negative cable
to prevent accidents by short circuits.
• Before disconnecting and connecting
fpwx010033
the cable, turn off the ignition switch
and lightingswitch, loosen the cable
nuts completely, and never twist or pry
the cable during the operation.
• When disconnecting the battery
negative cable, all the memories of the
clock and radio will be erased. Record
all necessary data before repairing.

(b) Handling electrical components

• Do not open the case of the ECU
unless absolutely necessary (If the IC
terminals are touched, they may be
damaged by the electrostatic
interaction).
• Pull the connector itself rather than the
Incorrect wires when disconnecting the
fpwx010034
connectors.
• Be careful not to drop electrical
components (like sensors, relays etc.).
If they are dropped on a hard floor, they
should be replaced and not be reused
again.
• When cleaning the engine with steam,
protect the electrical components, air
filter and emission control components
from water.
• Never use an impact wrench to remove
or install temperature switches or
temperature sensors.
• When checking the conduction of the
wire connector, insert the probe
carefully to prevent terminals from
bending or damaging.
• Check the functions of electrical
components and ensure their normal
functions after replacing electrical
components.

3. Removal and installation of fuel control parts

 01-14 Preface - General Principles of Maintenance Operation

01 (a) Place for removing and installing of fuel system parts.

• Choose a place with good air ventilation. And ensure there is no equipment or
objects in the surroundings such as weld, grinder, drill, electric motor or stove
which may have open flames.
• Never work in or near a gas station as vaporized fuel may fill the whole space.
(b) Removal and installation of fuel system parts
• Prepare a fire extinguisher before starting the operation.
• To prevent static electricity, install a ground wire to the vehicle and fuel tank
and keep the floor dry to prevent slipping.
• Never use any electrical equipment like an electric motor or a working light to
avoid sparks or high temperature.
• Never use an iron hammer, as it may cause sparks.
• Dispose fuel-contaminated cloth in a fireproof container.
4. Removal and installation of engine intake parts
Note

If any metal debris is mixed in the intake pipe, it will damage the engine.

(a) When removing and installing the intake system parts, close the opening of the removed
parts with a clean cloth or adhesive tape.
(b) When installing intake system parts, ensure that there is no metal debris.

5. Handling of hose clamps

Spring clamp
(a) Before removing the hose, check the insertion
depth of connectors and clamp position so
that it can be reinstalled in the same position.
(b) Replace a deformed or dented hose with a
new one.
(c) When reusing a hose, attach the spring type
Clamp print clamp on the print of the hose.
fpwx010036
(d) For a spring type clamp, make adjustment by
adding force to the arrow mark direction after
the installation.

6. Three-way catalytic converter

Note

If a large amount of unburned fuel flows into the converter, it may cause it to overheat
and create a fire hazard. To prevent this, observe the following precautions during the
operation.

(a) Only use unleaded gasoline (for the gasoline engine).

(b) Avoid idling the engine for more than 20 minutes.
(c) Avoid performing unnecessary spark jump tests.
• Never perform a spark jump test unless absolutely necessary. Perform this test
as rapidly as possible.
 Preface - General Principles of Maintenance Operation 01-15

• Never forcefully press the accelerator pedal when performing this test. 01

(d) Avoid a prolonged engine compression measurement and complete it as rapidly as

possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine
to misfire and create an extra load for the converter.
 01-16 Preface - General Principles of Maintenance Operation

01
Vehicle Lift and Support Locations
1. Notice about vehicle condition when lifting up the vehicle
(a) Principle: Please lift up the vehicle in no load condition. Never operate it in load
condition.
(b) The vehicle's gravity center will shift when removing heavy parts such as the engine
and transmission. Be sure to place a balance weight to avoid the vehicle overturning,
or support the specified position with a jack.
2. Notice for Using a Jack and 4 Post Lift
(a) Perform the safety operation as the instruction in the manual.
(b) Never lift wheels by tire levers to avoid damaging wheels and tires.
(c) Place the vehicle in the flat road and tighten the parking brake.
(d) Put the shift lever to the reverse position.
(e) Use wheel chocks to block the wheels on the diagonal where a lifting tool works.
(f) Use a jack or 4 post lift with a rubber attachment to jack up the vehicle.
Danger

Lift up the vehicle on its specified location.

fpwx010038
 Preface - How to troubleshoot the vehicle 01-17

01
How to troubleshoot the vehicle
Overview
The vehicle features a lot of circuits. Generally speaking, to troubleshoot the faults in the
various circuits requires extensive expertise and know-how on the maintenance workers.
However, most faults can be traced via following their circuit diagrams. When the maintenance
workers have an adequate knowledge of all the vehicle systems and have acquired the basics
of circuit diagrams, they can conduct accurate diagnosis and required maintenance work to
troubleshoot the faults.
The manual here serves to meet the above principles, to provide accurate, effective
troubleshooting solutions.
For the troubleshooting steps, please refer to the detailed description in the following chapters
and sections.

System Refer to
Anti-lock Braking System 04 Diagnosis, Anti-lock Braking System
Electric Window Control System 04 Diagnosis, Electric Windows
Electric Door Lock Control System 04 Diagnosis, Electric Door Lock
Engine Control System 04 Diagnosis, Engine Control System
Wipers and Washers 04 Diagnosis, Wipers and Washers
Horn 04 Diagnosis, Horn
04 Diagnosis, Heating Ventilation and Air
Heating Ventilation and Air Conditioning
Conditioning
Sound System 04 Diagnosis, Sound System
Lighting System 04 Diagnosis, Lighting System
Instrument Cluster 04 Diagnosis, Instrument Cluster

About How to Use the Tester

Note

• Before using the tester, read the user manual carefully as required.
• Connect the diagnosis harness connector to the tester and set the ignition to
the ON mode. If the tester cannot communicate with the control module, both
the vehicle and the test can be faulty.
• If the tester functions well when connected to another vehicle, check the the
diagnosis harness of the tester or the power supply circuit of the control module.
• If the tester cannot establish communication with the other vehicle, it indicates
the tester itself is very likely to be faulty. Please follow the self-diagnostic
procedures described in the tester's user manual.

How to Troubleshoot Faults

 01-18 Preface - How to troubleshoot the vehicle

01 Note

• Here only lists the most basic procedures.

• Troubleshoot the faults according to the following steps.
• The manual provides the most effective method for each circuit diagram. (See
Chapter 04 Diagnosis)
• Before carrying out the maintenance operations, you must make sure the
troubleshooting steps for the relevant circuit diagrams are clear.

1. The faulty vehicle arrives at the workshop.

2. Analyze the fault based on customer description.
Ask the customer about the vehicle and ambient state when the fault occurred.
3. Conform the fault symptoms and perform DTC (including data flow) inspection.
(a) Measure the battery voltage.
Voltage: 11~14V (with engine OFF)
(b) Visual check the harnesses, connectors and fuses for open or short circuit.
(c) Start the engine and warm it up to the normal operating temperature.
(d) Conform the fault symptoms and settings, and check the DTC.
DTC occurs?
Yes> Go to step 4.
No> Go to step 5.
4. Check the DTC chart.
Check the DTC from step 3, check the DTC chart and specify inspection procedures
based on the "Fault Location" of the vehicle system or component.
Go to step 6.
5. Check the Fault Symptom Table.
Check the fault symptom from step 3, check the DTC chart and specify inspection
procedures based on the "Suspicious Positions" of the vehicle system or component.
6. Check the current circuit and component.
(a) Check the suspected faulty system circuit or component from step 4 and step 5.
(b) Locate the faulty circuit or component.
7. Repair.
According to the results from step 6, adjust, repair or replace the faulty circuit or
component.
8. Test to confirm the fault is cleared.
(a) After the maintenance work is completed, make sure the fault has been cleared.
(b) If the fault doesn't occur again, simulate the vehicle and ambient state and perform
confirmatory test.
9. Completed.
Fault Analysis based on Customer Description
 Preface - How to troubleshoot the vehicle 01-19

Note 01

• During the troubleshooting process, avoid preconceptions.Your judgment must

be accurate while verifying fault symptoms.
• Ask the customer about the vehicle and ambient state when the fault occurred,
as this is very crucial.
• Some irrelevant faults or maintenance history can be helpful to fault analysis.
Collect information as much as possible; some related information can serve
as reference for fault troubleshooting.
• To identify the symptoms accurately, pay special to the following five aspects
when analyzing faults based on customer description.

What? Vehicle model, system name

When? date, time, frequency
Where? road condition
Operation condition, driving condition, climate
Under what condition?
condition
How? Fault symptoms

Fault Symptom Conformation and DTC (including Data Flow) Inspection

Note
The diagnostic system has many features.
• The first function is Diagnostic Trouble Code (DTC) test function.The fault signal
from the control module circuit will be stored in the control module memory as
a code.The maintenance workers can check the DTC history during their practice.
• The other feature is input signal examination function. It can examine whether
the signal of each switch has been sent to the control module accurately.
These features can help to narrow down the troubleshooting scope quickly and improve
maintenance efficiency.

Description Diagnostic Signal

Symptom
System of the Trouble Examination Data Flow
Diagnosis
System Code (DTC) (Sensor)
Anti-lock
Braking — O O O O
System
Engine
Control O O O O O
System
Electric
Window
— — — — O
Control
System
 01-20 Preface - How to troubleshoot the vehicle

01
Description Diagnostic Signal
Symptom
System of the Trouble Examination Data Flow
Diagnosis
System Code (DTC) (Sensor)
Electric Door
Lock Control — — — — O
System
Wipers and
— — — — O
washers
Rear
Windshield
— — — — O
Defrosting
System
Horn — — — — O
Heating
Ventilation
— — — — O
and Air
Conditioning
Sound
— — — — O
System
Lighting
— — — — O
System
Instrument
— — — — O
Cluster

(a) While examining the DTC, it is extremely important to judge whether the DTC fault is
present now or it restores to normal state after the DTC fault occurs. Besides, when
confirming the fault symptoms, you must check whether the fault symptom is directly
related to the fault.Therefore, the DTC must be examined before and after the symptom
inspection, to assess the current vehicle state. If not, diagnosis and troubleshooting
otherwise unnecessary will be required, which will make troubleshooting more difficult
or led to irrelevant maintenance operations. Therefore, follow the DTC test steps
exactly.
(b) The process regarding how to troubleshoot faults with the help of the DTC test function
is illustrated in the following picture. It illustrates how to use the DTC test function
efficiently. Last, it shows how to troubleshoot faults with the help of the DTC chart and
fault symptom table.
1. Inspect the DTC.
2. Record the DTC that occurs and clear the DTC.
Note

If the DTC occurs during the first DTC inspection process, it indicates the circuit
harness or connector was likely to be faulty before. Please check the relevant harness
or connector. (See Chapter 01 Introduction – How to Troubleshoot the Vehicle, Circuit
Inspection)
 Preface - How to troubleshoot the vehicle 01-21

3. Confirm fault symptoms. 01

Is the fault symptom still present?
Yes> Go to next step.
No> Go to step 5.
4. Conduct inspection by simulating fault symptoms. (See 01 Preface - How to
troubleshoot the vehicle, Overview)
5. Inspect the DTC again.
DTC occurs?
Yes> Troubleshoot the DTC fault.
No> Go to next step.
6. Confirm fault symptoms.
Is the fault symptom present?
Yes> Go to next step.
No> Normal system.
7. Troubleshoot with the help of the fault symptom table.
The fault that occurs exceeds the test scope of the vehicle diagnostic system (the
historic DTC might indicate the fault that has been present before or it is not the key
issue).
8. Completed.
Inspection by Simulating Fault Symptoms
 01-22 Preface - How to troubleshoot the vehicle

01 Note

• The most difficult thing for troubleshooting is that no symptoms are detected.
In this case, the conduct a thorough analysis on the fault described by the
customer. Then stimulate the vehicle and ambient state for the time when the
fault occurred. For a maintenance worker, no matter how experienced and skilled
they are, if they cannot verify the fault symptom during the troubleshooting
process, they will neglect some important information during their maintenance
operations and make wrong judgment, which will delay maintenance or repair.
• For example, for those faults that only occur under cold engine condition or that
can only be caused by driving the vehicle on rough road, they can never be
detected under hot engine condition or when the vehicle is still. As vibration,
high temperature, water leakage (damp) can be common fault causes which are
difficult to reproduce reliably, the fault symptom simulation inspection method
is introduced here. When the vehicle is parked, it is an effective way to simulate
the ambient state for troubleshooting.

1. Key Points for Fault Symptom Simulation:

(a) First, verify the fault symptoms and locate the fault part or component. To do this,
connect the tester before performing fault symptom simulation inspection and narrow
down the troubleshooting scope of the faulty circuit as much as possible based on the
fault symptoms.
(b) Next, the perform fault symptom simulation inspection. Determine whether the tested
circuit is damaged or functioning well. Verify the fault symptom at the same time. Check
the system fault symptom table and narrow down the possible cause scope.

2. Shaking —— for faults that might be

Shake gently
caused by vibration.
(a) Parts and sensors.
• Shake the suspected faulty sensor with
finger to see whether the fault occurs.
Note

Do not shake the sensor too hard, as this may

lead to open circuit with the relay.
(b) Connectors.
• Shake the connect gently, horizontally
Shake gently
or vertically.
(c) Wiring harnesses.
• Shake the harness gently, horizontally
or vertically. The joint parts of the
Shake gently harnesses and connectors are key
fpwx010039
areas requiring careful examination.
 Preface - How to troubleshoot the vehicle 01-23

3. Heating —— for faults that might be 01

caused by being heated.
Heat the suspected faulty parts with a hair
drier or else to check whether the fault occurs.
Note

• Do not allow the temperature to be higher

fpwx010040 than 60℃, in case the part gets damaged.
• DO NOT heat up the parts in the control
module directly.

4. Showering —— for faults that might be

caused by rain or surroundings with high
humidity.
Spray water onto the vehicle to check whether
the fault occurs.
Note

fpwx010041 • DO NOT spray water onto the engine hood

directly. Alternatively, you can spray water
onto the radiator, and the engine
temperature and humidity can be changed
intermediately.
• DO NOT spray water onto electrical
components.
• If there is leakage with the vehicle, the
leaked liquid might soil the control
module. Pay special attention to this when
conducting showing test.

5. High electric loads —— for faults that might be caused by excessive loads on
electric equipment.
Turn on all the electric equipment including the A/C, headlights, rear windshield heating
feature to check whether the fault occurs.
Diagnostic Trouble Code (DTC) Chart
Take the DTC table for the engine control system for example, which illustrated as follows.
The table lists the DTCs and the corresponding inspection procedures. Refer to this table
while troubleshooting will improve the efficiency and accuracy greatly.
 01-24 Preface - How to troubleshoot the vehicle

01

DTC list
Note
Check DTC in check mode, if one DTC is shown, check the circuits of listed codes in the
following table. As regards to the detailed information of this DTC, please refer to the
corresponding page.

DTC DTC information Suspected faulty circuits or parts

Fault codes Diagnostic（item (DTC definition) Fault position

• Intake manifold pressure sensor
• Poor connection with the intake manifold
P0106 Intake pressure/throttle pressure sensor connector; Sensor line is
position signal: Logic failure open-circuited or short-circuited.
• ECM
Intake manifold pressure sensor
•
Poor connection with the intake manifold
•
P0107 进气压力传感器线路低电压或断 pressure sensor connector; Sensor line is
open-circuited or short-circuited.
• ECM
Intake manifold pressure sensor
•
Poor connection with the intake manifold
•
P0108 进气压力传感器线路高电压 pressure sensor connector; Sensor line is
open-circuited or short-circuited.
• ECM
• 进气温度传感器
• 进气温度传感器接插件接触不良，传感器
P0112 进气温度传感器低电压
线束存在短路
• ECM

• 进气温度传感器
fpwx010043

Fault Symptom Table

The fault symptom table shows the possible causes (current circuit, components, etc.) for
each fault symptom, as the following table. If the fault still exists while the diagnostic tester
shows that the system is functioning well, you can troubleshoot with the help of the fault
symptom table. The serial number stands for the inspection sequence for current circuits or
components.
Note
If the vehicle diagnostic tester cannot detect the fault yet the fault does exists, it means that
the fault exceeds the test scope of the vehicle diagnostic system.
 Preface - How to troubleshoot the vehicle 01-25

01

Fault Symptom List

Use the following list to help you find the fault causes. The serial number indicates the possibility sequence for
the fault causes. Check every parts according to this sequence, and replace where necessary.

Fault symptom Suspect part Refer to

1. Fuse -
The front wipers are out of Chapter 60 Steering Mechanism-
work 2. Wiper and washer switch combination switch assembly,
replacement

Chapter 65 Wiper and Washer-wiper

3. Wiper motor motor, replacement

4. Harness -
Chapter 65 Wiper and Washer-wiper
1. Wiper motor motor, replacement
Front wiper does not work at
low-speed gear Chapter 60 Steering Mechanism-
2. Wiper and washer switch combination switch assembly,
replacement

3. Harness -

Chapter 65 Wiper and Washer-wiper

1. Wiper motor motor, replacement
Front wiper does not work at
Chapter 60 Steering Mechanism-
high-speed gear
2. Wiper and washer switch combination switch assembly,
replacement

3. Harness -

Chapter 65 Wiper and Washer- -刮

1. 刮水器电机 wiper motor, replacement
ftwx010044
 01-26 Preface - How to troubleshoot the vehicle

01
Circuit Detection
Read and use the circuit detection part in this manual as follows:

DTC or fault symptom

Rear windshield defrosting system
Circuit diagram
Diagnostic procedure

Fuse check

Disconnect the battery negative cable.

Check the rear defrosting fuse (25A) in the fuse

box (A003) on the front passenger's side.
Check the interior rear view mirror fuse (7.5A) in
the fuse box (A003) on the front passenger's
side.

Check whether the fuse current is normal.

Circuit diagram Yes > Proceed to next step.

Single color or twin color is used to distinguish No > If the rear defrosting fuse or the interior rear view mirror fuse is blown, replace it.

and identify different electric wires, which is Check the rear defrosting relay

convenient to query. Disconnect the battery negative cable.

Disconnect the rear defrosting relay
Check the rear defrosting relay based on the
values in the following table

Diagnostic procedure Condition Multimeter connecting pin Specified value

Including diagnostic procedure title, diagnostic Normal state Energized
procedure description and diagnostic procedure Apply power voltage
on the wire between
decision. pin 85 and pin 86.

Check whether the fuse current is normal.

Yes > Proceed to next step.
No > Replace the rear defrosting relay

fpwx888888

1. Basic Inspection.
(a) Resistance measurement conditions for electrical components.
• All resistance measurement should be operated in 20℃ ambient temperature
unless otherwise specified.
• The running vehicle will produce high temperature, and in such condition the
measured resistance value may exceed the specified range. So measuring
resistance should be perform after the engine becomes cold.
 Preface - How to troubleshoot the vehicle 01-27

(b) Operation cautions for connectors. 01

• When dismantling latch connectors,

slightly extrude the connector toward
the direction of connection and then
gently press the hasp and open the
latch.
• Hold the connector and never pull the
harness when dismantling the
connector.
• Check the connector of deformation,
damage or missing pins when
connecting the connector.
• Ensure "Click" sound and firm
connection when connecting the latch
connector.
• Check with a micro-probe at the back
(one side of the harness) of connectors
fpwx010046 during the inspection of connectors with
a multimeter.
Note

• Perform the inspection after connecting

the auxiliary harness as waterproof
connectors can not be checked from the
back side.
• Be careful NOT to damage the connector
pins when moving the probes. Main points
for checking connectors

(c) Main points for checking connectors

Roll rim loose
When connecting connectors, please check
the following item:
Core of conductor
• Hold the connector to check the
inserting and locking condition (i.e.
Pin bent connection condition).
Pull slightly
When disconnecting connectors,
fpwx010047
please check the following items:
• Lightly pull the harness, check pins for
missing, deformation or whether the
central harness is broken.
• Visually check whether connectors are
rusted, mixed with metal debris or
water, and whether pins are bent,
rusted, mixed with foreign material or
deformed.
 01-28 Preface - How to troubleshoot the vehicle

01 Check pins contact pressure:

• Prepare a male connector, insert it into a
female connector and check their
connection condition and sliding
resistance.
Note
Same material
Use a gilt male connector when detecting the
fpwx010048
gilt female connector.

(d) Maintenance method for the connector pins.

• If there are oil stains on the connecting
point, you should use air guns or
washing cloth to clean and never polish
with emery cloth, otherwise it may
damage the plating layer.
• If the contact pressure is abnormal, you
Correct Incorrect
should replace the female connector.
fpwx010049
If the male connector is gilt, you should
replace with a gilt female connector; if
the male connector is silvered, you
should replace with a silvered female
connector.

(e) Operation cautions for harness.

Incorrect • Check the harness and the tied position
for the harness to help reinstall before
dismantling the harness.
• Never excessively twist, pull or hang
the harness.
• Never contact the harness with hot,
rotating, moving, shaking or sharp (like
fpwx010050
the panel edge, screw tips etc. ) parts.
• Never squeeze or clamp the harness
when installing parts.
• Never cut or damage harness
insulation sleeve. Replace the harness
or wrap the broken area with insulation
cloth if it is accidentally damaged.

2. Open-circuit inspection.
 Preface - How to troubleshoot the vehicle 01-29

(a) Circuit (on the left) Perform the conduction 01

and voltage test in step (2) and step (3) to
identify the open-circuit location.
Open circuit
Sensor

fpwx010051

(b) Conduction inspection.

• Disconnect connectors A and C, and
+ - measure the resistance.
Resistance: ＜2Ω
Sensor
Note

Gently shake the harness horizontally and

fpwx010052 vertically and measure the resistance.

Take the circuit as an example:

Resistance between the pin 1 of the
connector A and C: ≥1MΩ
Resistance between the pin 2 of the
connector A and C: ＜2Ω
It can be concluded that there are open
circuits between the pin 1 of the
connector A and C.

• Disconnect the connector B and measure

the resistance between the connectors.
+ Take the circuit as an example:
Sensor

Resistance between the pin 1 of the connector

A and B1: ＜2Ω
Resistance between the pin 1 of the connector
fpwx010053
B2 and C: ≥1MΩ
It can be concluded that there are open
circuits between the pin 1 of the connector
B2 and C.
 01-30 Preface - How to troubleshoot the vehicle

01 (c) Voltage Inspection.

• When circuits are powered up,
+ checking the voltage can confirm
whether the loop is open.
Sensor
• Take the circuit as an example, all
connectors still keep connecting.
Measure the voltage between the
connector A pin 1, the connector B pin
fpwx010054
1, the connector C pin 1 at the control
module 5V output voltage pin and the
ground in sequence.
If the measuring results show as
follows:
Voltage between the connector A pin
1 and the ground: 5V
Voltage between the connector B pin
1 and the ground: 5V
Voltage between the connector C pin
1 and the ground: 0V
It can be concluded that there are open
circuits between the pin 1 of the
connector B and C.

3. Short-circuit inspection.
(a) The harness is shorted to the ground as
Short circuit shown in the left. Perform a conduction test
Sensor
between the harness and the ground in step
2 to confirm the short circuit location.

fpwx010055

(b) Conduction inspection.

• Disconnect the connector A and C, and
measure the resistance between the
connector A pin 1, pin 2 and the ground
Sensor respectively.
Resistance: ≥1MΩ
Note
fpwx010056

Gently shake the harness horizontally and

vertically and measure the resistance.

Take the circuit as an example:

 Preface - How to troubleshoot the vehicle 01-31

Resistance between the connector A 01

pin 1 and the ground: ＜2Ω

Resistance between the connector A
pin 2 and the ground: ≥1MΩ
It can be concluded that there are short
circuits between the pin 1 of the
connector A and C.

• Disconnect the connector B, and measure

the resistance between the pin 1 of the
connector A and B2 and the ground
+
respectively.
Sensor Take the circuit as an example:
Resistance between the connector A pin 1
and the ground: ≥1MΩ
Resistance between the connector B2 pin 1
and the ground: ＜2Ω
It can be concluded that there are short
+ circuits between the pin 1 of the connector
B2 and C.

fpwx010057
 01-32 Preface - Index

01
Index
Glossary Index
ABS Anti-lock Brake System
BTDC Before Top Dead Center
CKP Crankshaft position sensor
CMP Crankshaft Position Sensor
DTC Diagnostic Trouble Code
ECM Engine Control Module
WTS Water Temperature Sensor
EFI Engine Fuel Injection System
EGR Exhaust Gas Recirculation
EVAP Evaporative Emission Control System
HVAC Heating Ventilation and Air Conditioning
IAT Air inlet temperature sensor
ISC Idle Speed Control
KS Knock Sensor
MAF Mass Air Flow
NO Number
O2S Oxygen sensor
OBD On-Board Diagnostics
PCV Positive Crankcase Ventilation
SFI Sequential Fuel Injection
TPS Throttle Position Sensor
 Preparation
02
Diagnosis.............................................02-1 Preparation.....................................02-18
Preparation.......................................02-1 Parking Brake....................................02-20
Engine Control System.......................02-2 Parking Brake.................................02-20
Preparation.......................................02-2 Transmission.....................................02-21
Fuel.......................................................02-3 Preparation.....................................02-21
Preparation.......................................02-3 Clutch.................................................02-23
Exhaust Control System.....................02-4 Preparation.....................................02-23
Preparation.......................................02-4 Steering Gear.....................................02-24
Air intake..............................................02-5 Preparation.....................................02-24
Preparation.......................................02-5 Heating Ventilation and Air
Engine Mechanism..............................02-6 Conditioning......................................02-25
Preparation.......................................02-6 Preparation.....................................02-25
Air Exhaust..........................................02-8 Seat Belt.............................................02-26
Preparation.......................................02-8 Preparation.....................................02-26
Cooling.................................................02-9 Wipers and Washers.........................02-27
Preparation.......................................02-9 Preparation.....................................02-27
Lubrication.........................................02-10 Windshield / Window / Rearview
Preparation.....................................02-10 Mirror..................................................02-28
Starting and Charging .....................02-11 Preparation.....................................02-28
Preparation.....................................02-11 Instrument Panel/ Instrument..........02-30
Front Suspension..............................02-12 Preparation.....................................02-30
Preparation.....................................02-12 Seats...................................................02-31
Rear Suspension ..............................02-13 Preparation.....................................02-31
Preparation.....................................02-13 Door Lock..........................................02-32
Wheels and Tires ..............................02-14 Preparation.....................................02-32
Preparation.....................................02-14 Car Door.............................................02-33
Transaxle and Drive Shaft................02-15 Preparation.....................................02-33
Preparation.....................................02-15 Vehicle Control System....................02-34
Driving Brake ....................................02-18 Preparation.....................................02-34
02
 Preparation - Diagnosis 02-1

Diagnosis
Preparation 02
Recommended tools

Comprehensive Intelligent
Engine Control System
Diagnosis Instrument

fpwx010058

The engine control system,

anti-lock braking system,
airbag, heating ventilation
and air conditioning, lighting
system, wipers and washers,
Digital Multimeter
multimedia system, accessory
power supply, horn, electric
fpwx010059
door window, defrosting
system, instrument cluster
and the electric door lock.

Torque Wrench —

fpwx010061

The engine control system,

anti-lock braking system,
airbag, heating ventilation
and air conditioning, lighting
system, wipers and washers,
Test Lead Set
multimedia system, accessory
power supply, horn, electric
fpwx010060
door window, defrosting
system, instrument cluster
and the electric door lock.
 02-2 Preparation - Engine Control System

Engine Control System

02 Preparation
Recommended tools

Fuel injection system, ignition

Comprehensive Intelligent
system, sensors, actuators
Diagnosis Instrument
and ECM
fpwx010058

Digital Multimeter Sensors, actuators and ECM

fpwx010059

Test Lead Set Sensors, actuators and ECM

fpwx010060

Torque Wrench —

fpwx010061

Equipment
Oscilloscope —

Accessory
Item Amount Specification
Thread sealant — 3M、NO.4171 or similar one.
 Preparation - Fuel 02-3

Fuel
Preparation 02
Recommended tools

Sharp-nose Plier Fuel pressure regulator

fpwx010062

Injector, fuel pump connector

Digital Multimeter
or fuel pump harness

fpwx010059

Torque Wrench Air Filter Assembly

fpwx010061

Hydraulic Lift Jack Oil Tank Assembly

fpwx010063

Equipment
Injector Nozzle Leakage Test Bed —

Accessory
Item Amount Specification
Lubricating Grease — —
 02-4 Preparation - Exhaust Control System

Exhaust Control System

02 Preparation
Recommended tools

Canister, canister solenoid

High pressure air gun valvepositive crankcase
ventilation valve
fpwx010065

Digital multimeter Canister solenoid valve

fpwx010059
 Preparation - Air intake 02-5

Air intake
Preparation 02
Recommended tools

Torque Wrench —

fpwx010061

Accessory
Item Amount Specification
Intake manifold sealant
Sealant —
specified by Foton
 02-6 Preparation - Engine Mechanism

Engine Mechanism
02 Preparation
Special tools

Cylinder Head Bolt Extractor Cylinder head bolt

fpwx010066

Jack Engine

fpwx010063

Clearance Gauge —

fpwx010072

Vernier Caliper —

fpwx010071

Dial gauge —

fpwx010068

Micrometer —

fpwx010069
 Preparation - Engine Mechanism 02-7

02
Circlip Plier —

fpwx010070

Sharp-nose Plier —

fpwx010062

Accessory
Item Amount Specification
Sealant — Special sealant specified by Foton
Coolant 3L Special coolant specified by Foton
Ambient temperature:
SL10W-30
-25～30℃
Ambient temperature:
SL15W-40
-20～40℃
Ambient temperature:
Engine Oil 4L SL5W-30
-30～30℃
Ambient temperature: CH-4 grade and
-20～40℃ above 15W-40
Ambient temperature: CH-4 grade and
-20～30℃ above 15W-40
Carb Cleaner — — —
 02-8 Preparation - Air Exhaust

Air Exhaust
02 Preparation
Recommended tools

Clearance Gauge Exhaust Manifold

fpwx010072

Torque Wrench —

fpwx010061

Accessory
Item Amount Specification
Exhaust manifold sealant
Exhaust Manifold Sealant —
specified by Foton
 Preparation - Cooling 02-9

Cooling
Preparation 02
Recommended tools

High Pressure Air Gun Radiator

fpwx010065

Thermometer Thermostat

fpwx010074

Torque Wrench Radiator, thermostat

fpwx010061

EquipmentAccessory
Steam Cleaner —

Item Amount Specification

Special sealant specified by
Sealant —
Foton
Add coolant to the level Special coolant specified by
Coolant
between MIN and MAXlines Foton
 02-10 Preparation - Lubrication

Lubrication
02 Preparation
Recommended tools

Oil pan
Engine oil pump
Torque wrench
Oil filter
Oil pressure inductive plug
fpwx010061

Rubber hammer Oil pan

fpwx010093

Clearance gauge —

fpwx010072

Accessory
Item Amount Specification
Special sealant specified by
Sealant —
Foton
Oil for Gasoline Engine 3.3L Applicable for a whole year
 Preparation - Starting and Charging 02-11

Starting and Charging

Preparation 02
Recommended toolsEquipment

Generator
Digital Multimeter
Starter

fpwx010059

Test Lead Set Engine, Starter

fpwx010060

Torque Wrench —

fpwx010061

Battery Charger —
Discharge Tongs —
 02-12 Preparation - Front Suspension

Front Suspension
02 Preparation
Recommended tools

Torque wrench —

fpwx010061

EquipmentAccessory
Four-wheel alignment Wheel alignment
Tire changer Remove the tire
Tire balancing machine Dynamic balance of tires

Item Amount Specification

Lubricating grease — —
 Preparation - Rear Suspension 02-13

Rear Suspension
Preparation 02
Recommended tools

Spring scale —

fpwx010081

Hammer —

fpwx010075

Torque wrench —

fpwx010061

Equipment
Four-wheel alignment Wheel alignment
Tire changer Remove the tire
Tire balancing machine Dynamic balance of tires

Accessory
Item Amount Specification
Lubricating grease specified
Lubricating grease —
by Foton
 02-14 Preparation - Wheels and Tires

Wheels and Tires

02 Preparation
Recommended tools

Tire pressure gauge Measure tires pressure

fpwx010078

Torque Wrench Remove the accessory

fpwx010061

Equipment
Four-wheel alignment — Wheel alignment
Tire Changer — Remove the tire
Tire balancing machine — Dynamic balance of tires

Accessory
Item Amount Specification
Balance weight — —
 Preparation - Transaxle and Drive Shaft 02-15

Transaxle and Drive Shaft

Preparation 02
Recommended toolsEquipmentAccessory

Tire pressure gauge Tires

fpwx010078

Drive shaft, spline, axle shaft

Clearance gauge
gear

fpwx010072

Drive shaft, universal joint,

intermediate bearing, front
Hammer wheel hub cover / rear hub
bearing, knuckle, differential
fpwx010075 bevel gear shaft

Drive shaft, universal joint,

intermediate bearing, front
Copper rod wheel hub cover / rear hub
bearing, knuckle, differential
fpwx010079 bevel gear shaft

Drive shaft, universal joint,

Micrometer
cross axle

fpwx010069

Drive shaft, universal joint,

front wheel hub cover, rear
hub bearing, driving gear,
Dial gauge
driven gear, axle shaft gear,
planetary gear and driving
fpwx010068
gear flange plate
 02-16 Preparation - Transaxle and Drive Shaft

02 Drive shaft, universal joint,

Circlip plier rear wheel hub bearing, final
drive output flange
fpwx010070

Drive shaft Y-fitting, axle shaft

Puller bearing and driving gear
bearing
fpwx010076

Front wheel hub bearing

Grease gun Rear wheel hub bearing
Knuckle
fpwx010080

Hydraulic lift jack Final drive assembly

fpwx010063

Starting torque of the driving

Torque wrench
gear

fpwx010061

Axle shaft thrust washer

Vernier caliper Planetary shaft thrust washer
Driving gear adjusting washer
fpwx010071

Tape measure Total rear axle clearance

fpwx010082
 Preparation - Transaxle and Drive Shaft 02-17

Driving gear adjusting washer 02

Spring scale Starting force of slewing rear
wheel hub
fpwx010081

V-stage –
Drive Shaft Balancing Machine –
Bench Press –
Bench Vice –

Item Amount Specification

Lubricating Grease
Drive shaft universal joint
Intermediate bearing
Universal joint
Front wheel hub
– No.2 lithium base grease
Rear wheel hub
Drive axle
Final drive, output flange, oil
seal
Driving gear, oil seal
Final drive gear oil 2.5L GL-580W/90
Sealant
Final drive, output flange, bolt
Loctite 204
Driven gear bolt
Differential bearing bolt

Drive shaft balance weight – –

 02-18 Preparation - Driving Brake

Driving Brake
02 Preparation
Recommended tools

Micrometer Brake disc

fpwx010069

Dial gauge Brake disc

fpwx010068

Rear brake drum

Micrometer
Rear brake shoe

fpwx010071

Rear brake shoe

Sharp-nose Plier
Brake cylinder

fpwx010062

Circlip plier Master brake cylinder

fpwx010070

Grease gun Rear wheel hub

fpwx010080
 Preparation - Driving Brake 02-19

02
Rear wheel hub, rear wheel
Puller
hub oil seal, axle shaft

fpwx010076

Torque Wrench —

fpwx010061

Accessory
Item Amount Specification
Brake fluid — DOT3/DOT4
 02-20 Preparation - Parking Brake

Parking Brake
02 Parking Brake
Recommended tools

Rear brake drum

Vernier Caliper
Rear brake shoe

fpwx010071

Front parking brake cable

Rear left parking brake cable
Sharp-nose Plier
Rear right parking brake
cable
fpwx010062

Torque wrench —

fpwx010061

Equipment
Bench Vice —
 Preparation - Transmission 02-21

Transmission
Preparation 02
Recommended tools

Synchronizer, intermediate
Clearance Gauge shaft
Adjusting washer
fpwx010072

Sharp-nose Plier Return spring

fpwx010062

Copper rod Reverse gear shaft

fpwx010079

Hammer Reverse gear shaft

fpwx010075

Dial gauge Output shaft

fpwx010068

Input shaft adjusting washer

Micrometer
Output shaft

fpwx010069
 02-22 Preparation - Transmission

02 Input shaft assembly

Circlip Plier Output shaft assembly
Gearshift
fpwx010070

Shifting fork
Vernier Caliper
Synchronizer

fpwx010071

Front bearing of output shaft

Intermediate bearing of
Puller output shaft
Rear bearing of output shaft
fpwx010076

Torque Wrench —

fpwx010061

Equipment
V-stage —
Bench Vice —

Accessory
Item Amount Specification
Lubricating Grease — Foton
85W/90 GL-4 or GL-5 gear
Transmission oil — oil, GB13895-92 or No.18
hyperbolic gear oil.
Sealant — Foton
Adhesive — Foton
 Preparation - Clutch 02-23

Clutch
Preparation 02
Recommended tools

Flywheel
DialGauge
Friction plate

fpwx010068

Flywheel
Vernier Caliper
Friction plate

fpwx010071

Circlip Plier Clutch master cylinder

fpwx010070

Torque Wrench —

fpwx010061

Equipment
Bench Vice —

Accessory
Item Amount Specification
Brake fluid 700±50g V3/V4
Lubricating Grease — No.0101011
 02-24 Preparation - Steering Gear

Steering Gear
02 Preparation
Recommended toolsEquipment

Tape measure Driving deviation

fpwx010082

Allen key Horn button assembly

fpwx010083

Steering force of the steering

Spring scale
wheel

fpwx010081

Steering shaft driving

Dial gauge
universal joint

fpwx010068

Torque Wrench —

fpwx010061

V-stage —
 Preparation - Heating Ventilation and Air Conditioning 02-25

Heating Ventilation and Air Conditioning

Preparation 02
Recommended tools

Refrigerant Filling Rubber Refrigerant and compressor

Hose assembly

fpwx010084

Gas leak detector Refrigerant

fpwx010085

Vacuum pump Air conditioning pipes

fpwx010088

Refrigerant Filling and

Recovery Machine (If it is Refrigerant and compressor
equipped, vacuum pump will assembly
be unnecessary)
fpwx010087

Accessory
Item Amount Specification
Refrigerant
600±20g
Front and rear air conditioning R-134a
450±20g
Only front air conditioning

Refrigerant Oil 120g —

 02-26 Preparation - Seat Belt

Seat Belt
02 Preparation
Recommended tools

Torque Wrench —

fpwx010061
 Preparation - Wipers and Washers 02-27

Wipers and Washers

Preparation 02
Recommended tools

Torque Wrench —

fpwx010061
 02-28 Preparation - Windshield / Window / Rearview Mirror

Windshield / Window / Rearview Mirror

02 Preparation
Recommended tools

Windshield
Plastic Scraper Side window
Rear window
fpwx010089

Windshield
Glass Sucker Side window
Rear window
fpwx010090

Windshield
Cutter Side window
Rear window
fpwx010091

Windshield
Caulking Gun Side window
Rear window
fpwx010092

Windshield
Rubber Hammer Side window
Rear window
fpwx010093

Accessory
Item Amount Specification
Protective Tape — —
Wood Block — —
Plastic Paper — —
Fine Wire — —
Nylon Rope — —
 Preparation - Windshield / Window / Rearview Mirror 02-29

Item Amount Specification

Adhesive Tape — — 02

Primer — Black etch polyester primer

Glass Cement — Black polyurethane
 02-30 Preparation - Instrument Panel/ Instrument

Instrument Panel/ Instrument

02 Preparation
Recommended tools

Allen key —

fpwx010083

Torque Wrench —

fpwx010061

Sharp-nose Plier —

fpwx010062

Comprehensive Intelligent
—
Diagnosis Instrument

fpwx010058

Digital Multimeter Instrument Cluster

fpwx010059
 Preparation - Seats 02-31

Seats
Preparation 02
Recommended tools

Allen key —

fpwx010083

Sharp-nose Plier —

fpwx010062

Torque Wrench —

fpwx010061
 02-32 Preparation - Door Lock

Door Lock
02 Preparation
Recommended toolsAccessory

Circlip Plier Lock core

fpwx010070

Item Amount Specification

Lubricating Grease — No.2 lithium base grease
 Preparation - Car Door 02-33

Car Door
Preparation 02
Recommended tools

Grease Gun Car Door

fpwx010080

Torque Wrench —

fpwx010061

Accessory
Item Amount Specification
Lubricating Grease — No.2 lithium base grease
 02-34 Preparation - Vehicle Control System

Vehicle Control System

02 Preparation
Recommended tools

Digital Multimeter Ignition switch assembly

fpwx010059

Torque Wrench —

fpwx010061
 Maintenance Specification
Engine Control System.......................03-1 Maintenance Data...........................03-16
Maintenance Data.............................03-1 Transaxle and Drive Shaft................03-17 03
Fuel.......................................................03-2 Maintenance Data...........................03-17
Maintenance Data.............................03-2 Driving Brake.....................................03-18
Exhaust Control System.....................03-3 Maintenance Data...........................03-18
Torque Requirement.........................03-3 Parking Brake....................................03-19
Engine Mechanism..............................03-4 Torque requirement.........................03-19
Maintenance Data.............................03-4 Transmission.....................................03-20
Air intake..............................................03-8 Maintenance Data...........................03-20
Torque requirement...........................03-8 Clutch.................................................03-22
Air Exhaust..........................................03-9 Maintenance Data...........................03-22
Torque requirement...........................03-9 Steering Gear.....................................03-23
Cooling...............................................03-10 Torque requirement.........................03-23
Maintenance Data...........................03-10 A/C system.........................................03-24
Lubrication.........................................03-11 Maintenance Data...........................03-24
Torque requirement.........................03-11 Seat Belt.............................................03-25
Ignition...............................................03-12 Torque requirement.........................03-25
Maintenance Data...........................03-12 Lighting System................................03-26
Starting and Charging......................03-13 Torque requirement.........................03-26
Maintenance Data...........................03-13 Seats...................................................03-27
Front Suspension..............................03-14 Torque requirement.........................03-27
Maintenance Data...........................03-14 Door/ Engine Cover...........................03-28
Rear Suspension...............................03-15 Torque requirement.........................03-28
Torque Requirement.......................03-15 Interior/Exterior Trims.......................03-29
Wheels and Tires...............................03-16 Torque requirement.........................03-29
03
 Maintenance Specification - Engine Control System 03-1

Engine Control System

Maintenance Data
Gasoline engine (4W12/4W10/LJ465QR1E1)
03
Water temperature sen-
Standard Value 3511Ω±2.6% (20℃)
sor (WTS) resistance
850±50r/min(LJ465)
Engine idle speed Standard Value
750±50r/min（4W12/4W10）
Idle stepper motor coil
Standard Value 12V(–40～125℃)
voltage
TPS voltage Standard Value 5±1V(-40～125℃)
Voltage range 10kPa～115 kPa

Air Intake Pressure/Tem- Ultimate Pressure 655 kPa

perature Sensor Working voltage 5±1V
Working temperature -40～125℃
Knock sensor resistance Standard Value >1MΩ(25±5℃)

Front oxygen sensor Standard Value 650～800 ℃

temperature Limit value 1000 ℃

Rear oxygen sensor tem- Standard Value 650～800℃

perature Limit value 1000 ℃
Canister solenoid valve 19～22Ω(4W12/LJ465) 23～
Standard Value
resistance 29Ω(4W10)
Working voltage 9～16 V
Engine Control Module
Working temperature -40～105 ℃
(ECM)
Overvoltage protection -14～24 V
Working temperature -40～150 ℃

Crankshaft position sen- Air Clearance 0.5 - 1.5 mm

sor Coil resistance 1000±100 Ω
Coil induction 290±30mH@1kHz

Torque requirement
Fastener N•m
Water temperature sensor (WTS) × engine
24±2
cylinder block
 03-2 Maintenance Specification - Fuel

Fuel
Maintenance Data
03
Nozzle system
Fuel system pressure 300kPa
Pulse width 2.5ms
Coil resistance 12±6 Ω
Fuel pressure regulator
Pressure setting 350±2％ kPa
Working temperature -40～105℃
Min. 5g/s
Pressure regulating flow limit
Max. 60g/s
Oil rail assembly
Working temperature -30～125℃
Proof pressure system 900
 Maintenance Specification - Exhaust Control System 03-3

Exhaust Control System

Torque Requirement
Fastener N•m 03
Fixing nuts of the EGR valve (4W10.4W12
20±2
engine)
 03-4 Maintenance Specification - Engine Mechanism

Engine Mechanism
Maintenance Data
Gasoline engine（4W12/4W10/LJ465QR1E1）
03
Engine assembly
In-line four-cylinder, four-stroke,
Type water-cooled, multi-points sequential
injection
Number of cylinders 4
Combustion chamber Roof
Displacement 1.206L/0.995L/0.998L
Cylinder diameter 69.7mm/68.5mm/65.5mm
Travel 79mm/67.5mm/74mm
Max. torque (Nm) 112N•m/90N•m/85N•m
Output power 63kW/50kW/45kW
9.8:1 (4W12-1.2L/4W10-1.0L)
Compression ratio
9.5:1 (LJ465QR1E1)
Oil pump Rotor pump
Camshaft
39.99±0.06mm (4W12M)
Air intake Standard value 39.52±0.06mm (4W10M)
34.0662±0.08mm (LJ465)
Cam height
39.45±0.06mm (4W12M)
Air Exhaust Standard value 39.44±0.06mm (4W10M)
33.7727±0.08mm (LJ465)

No.1 journal Standard value φ23 (-0.04/-0.061)

No.2 journal Standard value φ23 (-0.04/-0.061)
No.3 journal Standard value φ23 (-0.04/-0.061)
No.4 journal Standard value φ23 (-0.04/-0.061)
No.5 journal Standard value φ23 (-0.04/-0.061)
Camshaft runout Limit value 0.03mm
Cylinder Head
Flatness of cylinder head bot-
Limit value 0.03mm
tom surface
Valve
 Maintenance Specification - Engine Mechanism 03-5

Standard value 2.8mm

Air intake
Edge thick- Limit value 2.7 - 3.1mm
ness Standard value 2.45mm
Exhaust 03
Limit value 2.35 - 2.75mm
Standard value φ4.972mm
Air intake
Valve stem Limit value φ4.965～φ4.979mm
diameter Standard value φ4.963mm
Exhaust
Limit value φ4.956～φ4.970mm
0.028mm (4W12-1.2L/4W10-1.0L)
Standard value
0.020～0.047mm (LJ465QR1E1)
Air intake
Radial clear- 0.021～0.047mm (4W12-
ance between Limit value
1.2L/4W10-1.0L)
the valve
stem and 0.037mm (4W12-1.2L/4W10-1.0L)
Standard value
duct 0.045～0.077mm (LJ465QR1E1)
Air Exhaust
0.030～0.056mm (4W12-
Limit value
1.2L/4W10-1.0L)
Inclination an- Air intake Standard value 15°
gle Air exhaust Standard value 16.5°
64.17mm (4W12-1.2L/4W10-1.0L)
Air intake Standard value
Length of the 107.2mm (LJ465QR1E1)
valve stem 80mm (4W12-1.2L/4W10-1.0L)
Air exhaust Standard value
106.2mm (LJ465QR1E1)

φ5 (0,0.012)mm (4W12-1.2L/4W10-
Increased by 1.0L)
Bore of the valve duct
0.05mm
φ11 (LJ465QR1E1)
99.17mm(4W12-1.2L/4W10-1.0L)
Standard value
109.5mm (LJ465QR1E1)
Air intake
98.945～99.395mm(4W12-
Limit value
1.2L/4W10-1.0L)
Valve height
100.01mm (4W12-1.2L/4W10-1.0L)
Standard value
108.5mm (LJ465QR1E1)
Air exhaust
99.785～100.235mm (4W12-
Limit value
1.2L/4W10-1.0L)
Valve spring
 03-6 Maintenance Specification - Engine Mechanism

43.57mm (4W12-1.2L/4W10-1.0L)
Standard value
50.94mm (+0.3/-0.9) (LJ465QR1E1)
Free height
43.49～43.65mm (4W12-
03 Limit value
1.2L/4W10-1.0L)

Pre-tightening force/ working Standard value 109N/33.23mm

height Limit value 104.64～113.36N/33.23mm
Perpendicularity Standard value 1°
Piston
Clearance between the piston
Standard value 0.03～0.08mm (LJ465QR1E1)
ring and piston ring groove
No.1 compres-
Standard value 0.15～0.30mm (LJ465QR1E1)
sion ring
Piston ring
No.2 compres-
gap Standard value 0.23～0.38mm (LJ465QR1E1)
sion ring
Oil control ring Standard value 0.25～0.75mm (LJ465QR1E1)
Backlash of the connecting rod
Standard value 0.1～0.2mm (LJ465QR1E1)
big end
Crankshaft
0.11～0.31mm (4W12-1.2L/4W10-
Axial clearance Standard value 1.0L)
0.08～0.26mm (LJ465QR1E1)

0.12～0.32mm (4W12-1.2L/4W10-
Assembling clearance between
Standard value 1.0L)
the main journal and bearing
0.02～0.04mm (LJ465QR1E1)

φ49 (0/-0.006)
Standard value
φ49 (-0.0061/-0.012)
(4W12/4W10)
φ49 (-0.0121/-0.018)

φ43.5 (-0.05/-0.075)
Diameter of the main journal
φ43.7 (-0.05/-0.075)
Standard value
φ43.9 (-0.05/-0.075)
(LJ465)
φ44.1 (-0.05/-0.075)
φ44.3 (-0.05/-0.075)
Cylinder Block
0.03mm (4W12/4W10L)
Flatness of the top surface Standard value
0.05mm (LJ465QR1E1)

Bore of the cylinder Standard value 69.7 (+0.01/+0.02)mm (4W12M)

 Maintenance Specification - Engine Mechanism 03-7

68.5 (+0.01/+0.02)mm (4W10M)

65.5 (+0.03/0)mm (LJ465)
Clearance between the cylinder
Standard value 0.025～0.045mm (LJ465QR1E1) 03
and piston

Torque requirement
Fastener N•m
Bolts of the crankshaft timing belt pulley（4W10/4W12） 150±5
Valve chamber cover（4W10/4W12） 10±2
Fixing bolts of the camshaft（4W10/4W12） 13±1
M8 bolts: 20±2
Fixing bolts of the oil pump（4W10/4W12）
M6 bolts: 10±2

Fixing bolts of the camshaft pulley（4W10/4W12） 35±3

Fixing bolts of the cylinder head（4W10/4W12） 70±5
Fixing nuts of the connecting rod bearing cap
37±3
（4W10/4W12）
Fixing bolts of the flywheel（4W10/4W12） 55±5
Fixing bolts of the crankshaft bearing cap（4W10/4W12） 65±3
 03-8 Maintenance Specification - Air intake

Air intake
Torque requirement
03
Fastener N•m
Intake manifold bolts 10±2
Throttle body bolts 10±2
 Maintenance Specification - Air Exhaust 03-9

Air Exhaust
Torque requirement
Fastener N•m 03
Front-row exhaust pipe × exhaust manifold 50±5
Front-row exhaust pipe × three-way catalytic
50±5
converter
 03-10 Maintenance Specification - Cooling

Cooling
Maintenance Data
Maintenance Data
03
Thermostat valve opening temperature 87℃
Thermostat valve lift ≥8mm

Torque requirement
Fastener N•m
Bolts of the thermostat housing 10±2
Fixing bolts of the electric fan 5±1
Bolts of the water pump pulley 10±1
Fixing bolts of the water pump 30±2
 Maintenance Specification - Lubrication 03-11

Lubrication
Torque requirement
Gasoline engine
03
Fastener N•m
4W10/4W12 25～30
Drain plug
LJ465QR1E1 30～35
4W10/4W12 10±2
Oil pan
LJ465QR1E1 7～9
4W10/4W12 10±2
Oil strainer bolt
LJ465QR1E1 7～9
Tighten 3/4～1 turn after the
4W10/4W12 oil filter contacts the joint
Oil Filter surface of the cylinder block
LJ465QR1E1 12～16
 03-12 Maintenance Specification - Ignition

Ignition
Maintenance Data
Maintenance Data
03
Parameter of the Ignition Coil
Primary resistance 0.7±0.07Ω
Secondary resistance 9840±980Ω
Working temperature -40～125℃
Resistance of the high-voltage line with
2500Ω
minimum resistance
Primary charging time 3.32ms
Voltage range 6～16V
Secondary output voltage 34KV (Min.)
Min. ignition duration 0.85ms
Spark plug gap 1 - 1.1mm

Torque requirement
Fastener N•m
Spark plug 27±2
Ignition coil 10±2
 Maintenance Specification - Starting and Charging 03-13

Starting and Charging

Maintenance Data
Maintenance Data
03
Generator
Standard voltage 12V
Polarity Negative ground
Operation mode Continuous rated operation
Starter
12V20m internal resistance
Voltage
of power supply
Output power 1.0kW
Counterclockwise from the
Direction of rotation
drive end
Starter drive gear trip Standard value 13±0.5mm
Starter armature out of Standard value 0.004mm
roundness Limit value 0.008mm
Standard value 45.5mm
Starter armature diameter
Limit value 45.46 - 45.54mm
Carbon brush wear value Limit value 2 mm to the brush lead
Generator
Standard voltage 12V
Rated capacity 45Ah
Reserve capacity 125CCA

Torque requirement
Fastener N•m
Generator bracket bolts 30±5
Generator adjusting bolts 55±5
Generator fixing bolts 30±5
Fixing bolts of the starter housing 6～9
Fixing bolts of the solenoid switch 4～6
Fixing nuts of the magnetic coil Permanent magnet motor
Starter motor × wiring of power end Power end : 13±2
Starter motor fixing bolts 30±2
Battery fixing bracket 10±1
 03-14 Maintenance Specification - Front Suspension

Front Suspension
Maintenance Data
Maintenance Data
03
Front wheel toe-in 10′±6′
Camber angle 32′±40′
Inclination angle 8°39′±1′
Caster angle 3°33′±45′

Torque requirement
Fastener N•m
Front shock absorber × frame 45±5
Front shock absorber × lower arm 80±8
Torsion bar × frame Adjusting nuts 25±3
Lower cross arm × frame 65±6
Stabilizer bar column connecting rod × stabilizer bar 45±3
Stabilizer bar bracket × frame 45±5
Thrust rod × lower cross arm 45±5
 Maintenance Specification - Rear Suspension 03-15

Rear Suspension
Torque Requirement
Fastener N•m 03
Rear shock absorber × rear plate spring plank 45±5
Rear shock absorber × frame 45±5
Upper bolts of plate spring lug pin 45±5
Lower bolts of plate spring lug pin 45±5
Lower nuts of plate spring pin 80±8
U-bolts 45±5
 03-16 Maintenance Specification - Wheels and Tires

Wheels and Tires

Maintenance Data
Maintenance Data
03
Tires 165/70R13C 88/86S
Front Wheel 210
Tire pressure Rear Wheel 250
Spare Tire 250

Torque requirement
Fastener N•m
Tire nuts 95±10
 Maintenance Specification - Transaxle and Drive Shaft 03-17

Transaxle and Drive Shaft

Maintenance Data
Maintenance Data
03
Drive Shaft Assembly
Drive shaft runout Standard value 153mm
Rear Axle Assembly
Rear thread 1300mm

Torque requirement
Fastener N•m
Final drive driving gear flange × drive shaft 25±3
Rear brake line assembly × rear brake cylinder 18±3
Knuckle × lower swing arm ball-and-socket joint 45±5
Knuckle tie rod × knuckle arm 40±4
Final drive drain plug 10±1
Final drive filler plug 10±1
Final drive vent plug 10±1
 03-18 Maintenance Specification - Driving Brake

Driving Brake
Maintenance Data
Maintenance Data
03
Brake Pedal
Brake pedal height Standard Value 127.5mm
Brake pedal free travel Standard Value 1 - 8mm
Front brake
Brake lining thickness Standard Value 10mm
Brake disc thickness Standard Value 18mm
Brake disc oscillating quantity Standard Value <0.08mm
Rear brake
Brake shoe thickness Standard Value 5mm
Internal diameter of the brake drum 240mm
Clearance between the brake
Standard Value 0.2 - 0.3mm
shoe and drum

Torque requirement
Fastener N•m
Brake caliper bleeder screw 12
Brake cylinder bleeder screw 12
Fixing nuts of the brake master cylinder 25±3
Brake master cylinder pipe connector nuts 12
Brake caliper pipe inlet screws 12
Brake cylinder pipe connector nuts 12
Fixing nuts of speed sensor 10±1
ABS pipe connector nuts 18±2
 Maintenance Specification - Parking Brake 03-19

Parking Brake
Torque requirement
Fastener N•m 03
Fixing bolts of the parking brake assembly 25±3
Parking brake rocker bracket 25±3
 03-20 Maintenance Specification - Transmission

Transmission
Maintenance Data
Transmission (MR513B52)
03
GL-4 90 gear oil GB 13895-
1992 or the oil grade deter-
Transmission oil
mined by the environment and
temperature in special areas
1st gear ratio 3.652
2nd gear ratio 1.948
3rd gear ratio 1.424
4th gear ratio 1
5th gear ratio 0.795 or 0.788
R gear ratio 3.466
Max recommended speed in 1st gear 15km/h
Max recommended speed in 2nd gear 25km/h
Max recommended speed in 3rd gear 40km/h
Max recommended speed in 4th gear 70km/h
Max recommended speed in 5th gear 80km/h
Clearance between engaging Standard value 0.8 - 1.2mm
gears and the ring gear end
face Limit value 0.5mm

Self-locking spring length 39.5mm

Torque requirement
Fastener N•m
Oil drain plug 10～25
Shifting lock bolts 10～16
Extension box bolts 18～28
Clutch disengaging support 22～35
Bolts of the clutch fork bracket 8～12
Bolts of the cable bracket 18～28
Bolts of the reverse fork assembly 18～28
No.1 bolts of the front and rear box 15～22
No.2 bolts of the front and rear box 15～22
Bolts of the rear box cover 18～28
 Maintenance Specification - Transmission 03-21

Fastener N•m
Reverse light switch assembly 6～9
Screws of the reverse gear 18～28
03
Nuts of the intermediate shaft 60～75
Bolts of 5th gear fork 8～12
Bolts of 5th gear shift lever 18～28
 03-22 Maintenance Specification - Clutch

Clutch
Maintenance Data
Maintenance Data
03
Clutch Pedal
Clutch pedal height Standard Value 165mm
Clutch pedal free travel Standard Value 5 - 10mm
Clutch pedal push rod travel Standard Value 26.4mm
Clutch disc
Single plate, dry, single disc,
Type diaphragm spring and normal
pressure
Driven disc assembly
Overall size φ180×7.9(Free state)
Weight 3.12kg

Torque requirement
Fastener N•m
Stop nuts of the clutch pedal 25±3
Bolts of the clutch cover 25～29
 Maintenance Specification - Steering Gear 03-23

Steering Gear
Torque requirement
Fastener N•m 03
Nuts of the steering wheel 35±5
Steering column assembly 25±3
Steering drive shaft assembly × steering
25±3
column assembly
Steering drive shaft assembly × steering box
25±3
assembly
Steering box assembly 40±4
 03-24 Maintenance Specification - A/C system

A/C system
Maintenance Data
Maintenance Data
03
Refrigerant oil filling volume
The compressor has its own
When replacing the compressor refrigerant oil, no need to
add.
Double distilled 600±20g
Refrigerant filling volume
Single distilled 450±20g
Refrigerant oil filling volume 120g
Pressure in low pressure side 0.16MPa
Pressure in high pressure side 1.5MPa

Torque requirement
Fastener N•m
High-pressure pipe 12±2
Low-pressure pipe 12±2
 Maintenance Specification - Seat Belt 03-25

Seat Belt
Torque requirement
Fastener N•m 03
Driver / passenger seat retractor × body 50±5
Driver / front passenger seat retractor
50±5
webbing bottom anchor × body
 03-26 Maintenance Specification - Lighting System

Lighting System
Torque requirement
03
Fastener N•m
Front combination light assembly × frame 9±1
Rear combination light assembly × frame 9±1
 Maintenance Specification - Seats 03-27

Seats
Torque requirement
Fastener N•m 03
Fixing bolt of the driver seat assembly 46±5
Fixing bolt of the front passenger seat
46±5
assembly
Fixing bolt of the passenger seat assembly 46±5
 03-28 Maintenance Specification - Door/ Engine Cover

Door/ Engine Cover

Torque requirement
03
Fastener N•m
Front door hinge × door 23±2
Fixing bolt of the front door lock catch 23±2
Upper bracket of the slide door × door 23±2
Lock body of the slide door × door 23±2
Bolts of the back door hinge 23±2
Lock catch of the back door × body 23±2
 Maintenance Specification - Interior/Exterior Trims 03-29

Interior/Exterior Trims
Torque requirement
Fastener N•m 03
Sun visor fixing bracket bolts 5±1
Fixing screws of the trim strip for the carpet 5±1
Fixing bolts of the front bumper 10±1
Fixing bolts of the rear bumper 10±1
Bolts of the front wiper 10±1
 03-30 Maintenance Specification - Interior/Exterior Trims

03
 Diagnosis
Engine Control System.......................04-1 Front A/C not Cooling...................04-186
Precautions.......................................04-1 Lighting System..............................04-193
Component Diagrams.......................04-5 Precautions...................................04-193
How to Analyze Faults......................04-8 Basic Inspection............................04-194 04
Intermittent Fault.............................04-11 Component Diagrams...................04-195
Basic Inspection..............................04-14 Fault Symptom Table.....................04-196
ECM Terminal Layout......................04-15 Single Low Beam OFF..................04-201
Diagnostic System..........................04-25 Both Low Beams OFF...................04-204
Reading and Clearing DTCs...........04-27 Single High Beam OFF.................04-209
Capturing Data................................04-29 Both high beams OFF...................04-212
Fail-safe chart.................................04-30 Front Fog Light OFF......................04-217
Data Flow Sheet, Motion Test.........04-32 Front Fog Light Always ON...........04-222
Diagnostic Trouble Code Table........04-38 Rear Fog Light OFF......................04-226
Diagnosing the Diagnostic Trouble Code Rear Fog Light Always ON............04-230
(DTC)..............................................04-45 Danger Warning Light OFF (Turning Lights
Fault Symptom Table.....................04-127 Normal).........................................04-233
Diagnostic Test for Engine Turning Lights OFF (Danger Warning Light
Symptoms.....................................04-129 Normal).........................................04-238
No Communication between KT600 Turning Lights & Danger Warning Light
Intelligent Diagnosis Instrument and OFF ..............................................04-244
ECM..............................................04-132 All Brake Lights OFF.....................04-255
Engine cannot Start but Rotate.....04-135 One of the Reverse Lights OFF....04-261
Cold starting is difficult and the vehicle Both Reverse Lights OFF.............04-263
vibrates.........................................04-139 Front Interior Light OFF................04-268
Unstable Idling (Speed Width Light OFF............................04-270
Fluctuation)...................................04-143 Tail Light OFF................................04-274
Excessive Idling............................04-148 License Plate Light OFF...............04-278
Engine stalling in the cold state (at Wipers and Washers.......................04-281
idling)............................................04-151 Wipers and Washers.....................04-281
Slow response, retarded acceleration and Component Diagrams...................04-282
acceleration imbalance.................04-155 Basic Inspection............................04-283
Poor Performance of Accelerating .04-159 Fault Symptom Table.....................04-284
Supplemental Restraint System....04-163 Wipers out of Work.......................04-286
Precautions...................................04-163 Wipers at the Low-speed Mode out of
Airbag Warning Light Always ON...04-164 Work..............................................04-290
Airbag Warning Light OFF............04-166 Wipers at the High-speed Mode out of
Heating Ventilation and Air Work..............................................04-292
Conditioning....................................04-168 Washers out of Work.....................04-294
Precautions...................................04-168 Sound System.................................04-297
Basic Inspection............................04-169 Precautions...................................04-297
Component Diagrams...................04-170 Component Diagrams...................04-298
Fault Symptom Table.....................04-171 Basic Inspection............................04-299
Air Conditioning Power Supply System Fault Symptom Table.....................04-300
Fault..............................................04-173 Radio out of Work.........................04-301
Front Blower out of Work...............04-177 Bad Radio Reception....................04-304
Rear Evaporator Blower Failure....04-182 Poor Radio Sound Quality............04-305
 Speaker out of Work.....................04-306 Fuel Gauge Fault / Fuel Level Alarm
Accessory Power Supply...............04-309 Indicator OFF or Always ON.........04-344
Component Diagrams...................04-309 Water Temperature Gauge Fault....04-346
Fault Symptom Table.....................04-310 Low oil Pressure Indicator OFF/ always
Cigar Lighter out of Work..............04-311 ON................................................04-348
Horn..................................................04-314 Parking brake indicator OFF/ always
04 Component Diagrams...................04-314 ON................................................04-350
Fault Symptom Table.....................04-315 Electric Door Lock..........................04-352
Horn out of Work...........................04-316 Precautions...................................04-352
Horn Always Sounding..................04-320 Basic Inspection............................04-353
Electric Windows.............................04-322 Fault Symptom Table.....................04-354
Precautions...................................04-322 Front Door Lock Fastener Failure..04-355
Component Diagrams...................04-323 Rear Slide Door Lock Fastener
Basic Inspection............................04-324 Failure...........................................04-360
Fault Symptom Table.....................04-326 Anti-lock Braking System...............04-363
All Electric Door Windows out of Precautions...................................04-363
Work..............................................04-328 Component Diagrams...................04-365
EPS Electric Power Steering Diagnostic Trouble Code (DTC)
System.............................................04-333 Chart.............................................04-366
Electric Power Steering (EPS) out of Fault Symptom Table.....................04-369
Work..............................................04-333 Precheck.......................................04-370
Instrument Cluster..........................04-337 High or Low Power Supply
Component Diagrams...................04-337 Voltage..........................................04-371
Fault Symptom Table.....................04-338 Wheel Speed Sensor Wiring Fault.04-372
Speedometer Fault.......................04-340 Wheel Speed Sensor Signal Fault.04-374
Tachometer fault...........................04-342 ABS out of Work...........................04-377
 Diagnosis - Engine Control System 04-1

Engine Control System

Precautions
1. Cut off the power supply.
• Before removing or installing any electrical equipment, especially for those tools
or equipment accessible to the exposed electrical terminals, make sure to
04
disconnect the battery negative cable first and connect the negative cable at
last, as this can protect people or the vehicle from damage.
• If not otherwise specified, you must turn off the ignition switch.
Danger
Before connecting or disconnecting the negative battery cable, be sure to turn off the
ignition switch and light switches. (Failure to do so may damage the semiconductor
element)
Note
If the central door lock is installed, you should not leave the key in the vehicle to avoid
getting the door locked before disconnecting the battery negative cable.
2. Dismantling the instrument cluster or disconnecting the battery negative cable
will reset the trip meter in the instrument cluster.
Danger
The odometer will not be reset.
3. Disconnecting the battery negative cable will make the sound system lose the
saved setting.
4. Ignition switch description.
Ignition switch (location) Ignition switch description
LOCK Ignition switch: OFF (lock the steering wheel)
ACC Power on the multimedia system and accessory power supply
Power on the multimedia system, accessory power supply,
IG1
lights, instrument cluster and airbags
Power on the multimedia system, accessory power supply,
IG2
lights, instrument cluster, airbags and A/C
START Start the engine

5. Precautions on engine control system overhaul.

(a) DO NOT cut off the battery while the engine is running at a high speed, in case transient
overvoltage damage the ECM and sensors.
(b) To weld on the vehicle body, cut off the ECM power supply first. Pay special attention
to this while conducting maintenance work on the vehicle body nearby the ECM or
sensors.
(c) When faults occur at the terminal contacts or during component installation, the system
may completely or temporarily return to normal by dismantling or reinstalling the
suspected faulty components.
 04-2 Diagnosis - Engine Control System

(d) Unless otherwise specified in the testing process, you should not test the ECM and
the sensors with a pointer type multimeter, but with a high impedance digital multimeter.
(e) Do not use a test lamp to test any electrical equipment connected to the ECM.
(f) The battery negative terminal and positive terminal can never be mixed; the negative
terminal must be grounded.
(g) The ECM and sensors must be kept from moisture. Avoid any damage to the sealing
04
element of the ECM or sensors. Never wash the ECM and sensors with water.
(h) Avoid exposing the computer to the static electricity from human body. While inspecting
the ECM or replacing the chip, the operator should be grounded, that is, wear a
anti-static wrist strap with grounding wire, with the grounding wire clamped onto the
vehicle.
(i) Be sure to check the vehicle condition when faults occur in order to identify the fault
location. For example, you can perform some inspection by outputting DTCs and record
this information before disconnecting each connector or disassemble and installing
components.
(j) Be sure to disassemble and install ABS control module, ECM actuator and each sensor
when the ignition switch is turned off unless otherwise specified in checking steps.
(k) If reinstalling the disassembled and installed ECM, actuator or sensors, be sure to
check whether the system works properly after completing the installation. Use a
delicate tester to check the DTC.
(l) Inspection on engine ECM terminals with a digital multimeter.
• Connect the fine tips onto the probes of the multimeter.
• Connect the fine tips to the terminals of the each ECM connector (from inside
the harness), and measure the voltage on each terminal according to the
checklist.
 Diagnosis - Engine Control System 04-3

Note

• During the diagnosis, while the ignition is switched to the ON mode with the
connectors disconnected, other system will store the DTC. Upon completion,
verify the DTCs of all systems. If there are DTCs, delete them all.When connecting
or disconnecting connectors, set the ignition to "LOCK" (OFF) mode.
• The test probes cannot be inserted into the harnesses, as this would reduce 04
their waterproofness and results in corrosion. Use special tools such as test
harness, harness connector or inspection harness.
• To inspect regular (non-waterproof) connectors with a harness connector, insert
the test probe from the harness. If the connector is too small to insert the test
probe (e.g. ECM connector), do not attempt to do this.
• To perform inspection (on the male terminal) without the harness connector:
• Be careful not to short out the connector terminals with the test probes.
Otherwise, it will lead to damages to circuits in the ECM.
• If the connector is disconnected, the system to be inspected or some other
systems will store the DTC.
• To perform inspection (on the female terminal) without the connector:
• Use the special tool inspection harness. Inserting the test probe forcefully will
lead to poor contact.
• If the connector is disconnected, the system to be inspected or some other
systems will store the DTC.
• If the test probe is inserted into the wrong terminal and leads to short circuit
during the inspection, the harness, sensor, ECM or other components will be
damaged. Be careful!
• You don't have to conduct inspection according to the order specified in the
checklist.
• If the voltage results differ from the standard value, check the corresponding
sensor, actuator and harness. Repair or replace them as necessary.
• After the repair or replacement, check the voltage with a voltmeter, to make
sure the fault has been cleared.

(m) Check the resistance and conduction between ECM terminals with a multimeter.
• Ignition switch: OFF.
• Remove the ECM harness connectors.
• Check the resistance and conduction between the terminals of the ECM harness
connectors with a multimeter.
 04-4 Diagnosis - Engine Control System

Note

• Check the resistance and conduction between terminals with a dedicated test
lead. DO NOT use the ordinary test bar lest the contact pressure of the terminals
be affected.
• You don't have to conduct inspection according to the order specified in the
04 checklist.
• While checking the resistance and conduction between terminals, if the test
probe is inserted into the wrong terminal or the connector terminal is shorted
to the ground by accident, the vehicle body harness, sensors, ECM or multimeter
might be damaged. Be careful!
• If the results differ from the standard value, check the corresponding sensor,
actuator and harness. Repair or replace them as necessary.
• After the repair or replacement, check again, to make sure the fault has been
cleared.

(n) Earthing (Grounding) inspection

• Remove the grounding bolt or screw.
• Check all the contact surface with stains, dirts, rust, corrosion, etc.
• Clean them to ensure good contact if necessary.
• Re-install the bolt or screw and make sure it is reliable.
• Check whether there are "extra" accessories that are likely to interfere the
grounding circuit.
• If several leads are press-fitted into the same grounding hole, check if the
press-fitting is done correctly. Make sure all the circuits are clean, reliable and
well-grounded. If several wires are installed into the same grounding hole, make
sure the grounding wires have no lengthy wire insulations.
• Before replacing the ECM, conduct extensive diagnosis and identify other causes.
The ECM is expensive yet very reliable; it won't get damaged easily.
Note

• Grounding is very important to the normal operation of electrical equipment and

electronic circuits. The ground is often exposed to damp, dirts or corrosive
chemicals.The corrosion (rust) functions as an extra resistor.This extra resistor
changes the performance and characteristics of the circuit.
• The ECM circuits are very sensitive to improper grounding. Loose grounding
or corrosion will affect the ECM circuits greatly. Poor grounding or corrosion
affect the circuits easily. Even if the ground looks clean, its surface might be
covered with a thin layer of rust.
 Diagnosis - Engine Control System 04-5

Component Diagrams

E005 E101
E012 E004 04
E014 E006
E102

E008

E007
E013

E026

E019

E015

E021
E011 E103 E009

E016

E023

E018

E017

E001

fpwx710315

E Engine harness (LJ465)－Electrical components

E001 Engine control module E014 Ignition coil

E004 Fuel injector 1 E015 Vehicle speed sensor
E005 Fuel injector 2 E016 Canister solenoid valve
E006 Fuel injector 3 E017 Idle control valve
E007 Fuel injector 4 E018 Throttle position sensor
E008 Crankshaft position sensor E019 Water temperature sensor
E009 Knock sensor E021 Generator
E011 Air intake pressure/temperature E023 Compressor
sensor E026 Oil pressure switch
E012 Front oxygen sensor
E013 Rear oxygen sensor
 04-6 Diagnosis - Engine Control System

E027

E006
E007 E101
E005
E004

E012
E102
04
E029

E014
E030

E019
E009

E008

E011
E013

E022
E015

E017

E023

E025 E035
E031
E103 E018
E003

E002 fpwx710316

E Engine harness (4W10)－Electrical components

E002 Engine control module connector 1 E015 Vehicle speed sensor

E003 Engine control module connector 2 E016 Canister solenoid valve
E004 Fuel injector 1 E017 Idle control valve
E005 Fuel injector 2 E018 Throttle position sensor
E006 Fuel injector 3 E019 Water temperature sensor
E007 Fuel injector 4 E022 Generator
E008 Crankshaft position sensor E023 Compressor
E009 Knock sensor E025 Gearbox reverse switch
E011 Air intake pressure/temperature E027 Oil pressure switch
sensor E029 Camshaft position sensor
E012 Front oxygen sensor E030 Linear exhaust gas recirculation
E013 Rear oxygen sensor valve
E014 Ignition coil E031 Variable intake solenoid valve
 Diagnosis - Engine Control System 04-7

E027

E019

E004 E005
E029 E101
E006
E030
04
E102
E012
E007

E014

E103
E009

E011
E013

E022

E015
E017

E018
E025

E034 E031 E023

E008

E010

E001

fpwx710314

E Engine harness (4W12)－Electrical components

E001 Engine control module E015 Vehicle speed sensor

E004 Fuel injector 1 E016 Canister solenoid valve
E005 Fuel injector 2 E017 Idle control valve
E006 Fuel injector 3 E018 Throttle position sensor
E007 Fuel injector 4 E019 Water temperature sensor
E008 Crankshaft position sensor E022 Generator
E009 Knock sensor E023 Compressor
E010 Intake air temperature sensor E027 Oil pressure switch
E011 Air inlet pressure sensor E029 Camshaft position sensor
E012 Front oxygen sensor E030 Linear exhaust gas recirculation
E013 Rear oxygen sensor valve
E014 Ignition coil E031 Variable intake solenoid valve
 04-8 Diagnosis - Engine Control System

How to Analyze Faults

Note
Diagnose the vehicle with a diagnosis tester.
1. Drive the vehicle to a garage.
04 Yes> Go to next step.
2. Collect and analyze faults symptoms customers said.
Yes> Go to next step.
3. Connect the diagnosis tester to DLC.
Yes> Go to next step.
4. Check DTC and freeze-frame data.
Yes> Go to next step.
5. Clear DTC and freeze-frame data.
Yes> Go to next step.
6. Do a visual inspection.
Yes> Go to next step.
7. Confirm fault symptoms.
Check results (If engine stops, first check whether there is DTC and then do basic
inspections)

Result Go to
No faults Go to next step
Faults Go to step 9

8. Simulate fault symptoms.

Result Go to
No faults Go to step 11
Faults Go to next step

9. Check whether there is DTC.

Inspection result

Result Go to
DTC Go to next step
No DTC Go to step 11

10 . Refer to DTC chart.

Yes> Go to step 13.
11 . Do basic Inspection.
Inspection result
 Diagnosis - Engine Control System 04-9

Result Go to
Unable to determine the faulty part Go to next step
Able to determine the faulty part Go to step 16

12 . Refer to the Fault Symptom Table

Inspection result 04

Result Go to
Unable to determine the faulty part Go to next step
Able to determine the faulty part Go to step 15

13 . Check ECM power line.

Yes> Go to next step.
14 . Check the circuit.
Inspection result

Result Go to
Unable to determine the faulty part Go to next step
Able to determine the faulty part Go to step 17

15 . Check the intermittent fault.

Yes> Go to step 17.
16 . Check parts and components.
Yes> Go to next step.
17 . Confirm faults.
Yes> Go to next step.
18 . Adjust or repair.
Yes> Go to next step.
19 . Perform a test to confirm the fault.
Yes> Finish.
Main points for checking and repairing the blown fuse
DTC may be saved as the fuse is blown.
 04-10 Diagnosis - Engine Control System

Remove the blown fuse and then measure the

resistance between the load side of the fuse and the
ground. Turn off all the switches connecting to the
line related to the fuse. If the resistance is almost 0,
there is short circuit. If the resistance is not 0, there
04 is no short circuit. However, temporary short circuit
may cause the fuse to burn.

fpwx040056

Main causes of short circuit:

• The harness is clamped by the body.
• The outside covering is broken for wear or heat.
• There is water in the connector or circuit.
• Human error (short circuit by wrong operation)

1 Battery
2 Fuse
3 Load switch
4 Blown fuse
5 Short-circuit location
 Diagnosis - Engine Control System 04-11

Intermittent Fault
When an intermittent fault occurs, please diagnose according to the following steps:
Note

If intermittent faults occur, in most cases, faults will be eliminated by itself (Parts or
circuit function returns to normal without intervention). It should be noted that the 04
problems customers complain about may not occur when DTC is detected. And the
commonest causes of intermittent faults are poor connectors of electrical appliance.
As a result, when faults occur, the situation may be not quite clear. So the inspection
of circuit, as a part of standard diagnostic procedure may not locate the specific fault
area.

In this case, you should learn of the situation when faults occur in detail from
customers, ask the driver about specific driving information, weather condition,
occurrence, and faults symptoms, do some analysis, reproduce the faults in the same
or similar conditions, and then confirm whether faults are caused by vibration,
temperature or other factors.

Even if maintenance workers have rich experience and great skills, they may overlook
some key factors, make wrong guesses and then take a roundabout course in repair
or fail to solve the problem on the condition that workers analyze faults without
verification.

The following inspection will help find such faults.

1. Vibration Method
When vibration is considered as the main reason of faults, it is necessary to check the
connectors and components to identify whether faults will occur. Fault can be simulated
according to the following methods:

(a) Connectors: Slightly shake connectors

vertically or horizontally to check whether the
connector of the harness between connectors
and related parts is loose, whether terminals
are dirty, rusted, corrosive or bent, and
whether loose contact is caused by the
stretched terminal.

fpwx041001
 04-12 Diagnosis - Engine Control System

(b) Harness: Slightly shake connectors vertically

or horizontally to thoroughly check the
vibration connection of connectors and
disconnection of harness in the engine/
instrument in the cockpit.

04

fpwx041002

(c) Relay: Parts and sensors. Pat suspect

sensors, relay or parts to check whether they
work normally. Never hard pat relays,
otherwise it may make the relay open-circuit.

fpwx041000

2. Heating Method
When faults occur in suspect area, the component which most likely causes faults can
be heated with an electric hair dryer or similar devices to check whether faults occur.

Note
Never heat over 60 ℃ (within the limit of the temperature hands can touch), never heat
electronic control modules.
3. Water Spray Method
When faults occur in rainy day or wet weather, you can spray water to the vehicle to
check whether faults occur.

Note

• Never directly spay water onto the engine but water the front of the radiator to
indirectly change temperature and humidity.
• Never spray water onto electronic components.
• Carefully water the leaky vehicle as leaky water may damage ECM.

4. Connecting All Electrical Appliances

When faults may be caused by electricity heavy load, you should connect all electrical
load including heater blower, headlights and rear defroster to check whether faults
occur.
In the simulative fault reproduction test, it is necessary to find fault location or faulty
parts when identifying the faulty symptoms. To do that, you should narrow the suspect
circuit range according to fault symptoms when the test begins or before connecting
the tester, and then perform the reproduction test to judge whether the detected circuit
is normal.
 Diagnosis - Engine Control System 04-13

When complicated faults occur, you can make full use of troubleshooting and diagnosing
codes chart to analyze and diagnose faults to reduce fault range and quickly find fault
location. This method is quite practical and effective.
5. Freezing Data Flows with a Tester.
Use the function of capturing data flow with a tester. Simulate the fault condition
according to the faults frozen data condition recorded in the tester. 04

6. Oscilloscope method.
It helps find intermittent faults to capture waves with a oscilloscope.
7. Other methods.
Replacement Method. Before replacing ECM or other control modules, it is necessary
to completely diagnose other external reasons as control modules are reliable and
expensive products.

Note
When replacement may damage control units, control units which may get damaged
should be installed in a good vehicle to test. Never install a new control unit in a faulty
vehicle to do the test to avoid damaging control units.
 04-14 Diagnosis - Engine Control System

Basic Inspection
When the inspection of DTC can not troubleshoot, all the circuits probably resulting in
malfunctions should be checked and analyzed. In many cases, performing the basic inspection
of the engine as indicated in the following flow chart can quickly and effectively find the fault
location. Therefore, it is quite necessary to adopt this inspection method in troubleshooting
04 the engine malfunction.
1. Inspect the battery voltage.
Note
Perform the inspection when the engine stops or the ignition switch is OFF.
Inspection result

Result Go to
11V or higher Next step
Lower than 11V Recharge or replace the battery

2. Check whether theengine starts.

Is the result normal?
Yes> Go to next step.
No> Refer to the Fault Symptom Table
3. Check the air filter.
Is the result normal(is there any dust, dirt or oil) ?
Yes> Go to next step.
No> Replace or clean the filter.
4. Check the idle speed.
Is the result normal?
Yes> Go to next step.
No> Refer to the Fault Symptom Table
5. Check fuel pressure.
Is the result normal?
Yes> Go to next step.
No> Troubleshoot the fuel pressure fault, go to nest step.
6. Check the ignition.
Is the result normal?
Yes> Go to next step.
No> Troubleshoot the ignition system.
 Diagnosis - Engine Control System 04-15

ECM Terminal Layout

1 2 81 63 04
62 44

43 25

4 5 24 6

E001-LJ465 Engine Electronic Control Module

No. Color Function Remark No. Color Function Remark
Cylinders 2 & 3
Red-yel- White- Idle control valve
1 ignition coil con- 42
low purple B (low)
trol cable
2 Black Grounding 43 - - -
Purple- Main relay con-
3 Black Grounding 44
white trol
Cylinders 1 & 4
4 Red-green ignition coil con- 45 - - -
trol cable
5 - - - 46 - - -
Black- Front oxygen
6 Blue-white Injector 1 47
purple sensor signal
Rear oxygen
7 Blue-black Injector 3 48 Gray-red
sensor signal
Red-yel- Purple- Water tempera-
8 Injector 2 49
low green ture sensor +
Fuel pump relay
9 Gray-blue 50 - - -
control
Orange- A/C compressor Gray-yel- Vehicle speed
10 51
green relay control low sensor
Crankshaft posi- Purple- Water tempera-
11 Blue-white 52
tion (low) black ture sensor -
Brown- SVS service indi-
12 53 - - -
blue cator
 04-16 Diagnosis - Engine Control System

No. Color Function Remark No. Color Function Remark

Grey- Intake air pres-
13 - - - 54
purple sure signal
14 - - - 55 - - -

04 15 - - - 56 - - -
16 - - - 57 - - -
High-speed elec-
Knock sensor
17 Blue-black tronic fan control 58 Green
signal grounded
terminal
Transmitting to
18 Brown-red engine tachome- 59 - -
ter
Brown- Malfunction Indi-
19 60 - -
white cator Light (MIL)
Connecting to
Idle control valve
20 Yellow 61 - the water temper- -
A (high)
ature gauge
Yellow- Idle control valve
21 62 - - -
blue A (low)
22 - - - 63 - - -
Heating wire
Purple-yel- control for the Gray- Canister solenoid
23 64
low rear oxygen sen- brown valve
sor
Heating wire
Brown-yel- control for the Low-speed elec-
24 65 Blue-red
low front oxygen tronic fan control
sensor
5V power supply
Red- for the intake
25 Blue-red Injector 4 66
black pressure & tem-
perature sensor
26 - - - 67 Red Power supply
Power supply for
27 Green-red TPS signal 68 Orange the ignition
switch
Evaporator tem-
Green-yel-
28 perature sensor 69 - - -
low
signal
Red- 5V power supply
29 - - 70
white for the TPS
 Diagnosis - Engine Control System 04-17

No. Color Function Remark No. Color Function Remark

Blue-yel- Crankshaft posi- Green- Intake air temper-
30 71
low tion (high) orange ature signal
31 - - - 72 - - -
Oxygen sensor 04
32 - - - 73 White
signal grounding
Gray-
33 - - - 74 TPS grounding
black
Lighting load in-
34 Brown-red 75 Blue K-line diagnosis
put
Intake air temper-
Yellow- Gray-
35 Blower load input 76 ature & pressure
white green
sensor grounding
36 - - - 77 - - -
Green- Knock sensor
37 78 - - -
white signal
A/C high and low
voltage switch
38 - - - 79 Brown
(controlling the
compressor)
Engine revolution Re-
39 - - - 80
signal output serve
A/C medium
Green- switch (control-
40 81 - - -
black ling the electron-
ic fan)
Orange- Idle control valve
41
white B (high)

1 2 81 63

62 44

43 25

4 5 24 6
 04-18 Diagnosis - Engine Control System

E001-4W12 Engine Electronic Control Module

No. Color Function Remark No. Color Function Remark
Cylinders 2 & 3
Red-yel- White- Idle control valve
1 ignition coil con- 42
low purple B (low)
trol cable
04
Variable intake
Gray-
2 Black Grounding 43 solenoid valve
green
control
Purple- Main relay con-
3 Black Grounding 44
white trol
Cylinders 1 & 4
4 Red-green ignition coil con- 45 - - -
trol cable
Power supply:
5 Yellow 46 - - -
12V
Black- Front oxygen
6 Blue-white Injector 1 47
purple sensor signal
Rear oxygen
7 Blue-black Injector 3 48 Gray-red
sensor signal
Red-yel- Purple- Water tempera-
8 Injector 2 49
low green ture sensor +
Fuel pump relay
9 Gray-blue 50 - - -
control
Orange- A/C compressor Gray-yel- Vehicle speed
10 51
green relay control low sensor
Crankshaft posi-
11 Blue-white 52 - -
tion signal (low)
Brown- SVS service indi-
12 53 - - -
blue cator
Intake air pres-
Grey-pur-
13 - - - 54 sure sensor sig-
ple
nal
White- EGR feedback
14 - - - 55
blue signal
15 - - - 56 - - -
16 - - - 57 - - -
High-speed elec-
17 Blue-black tronic fan control 58 - -
terminal
18 - - - 59 - - -
 Diagnosis - Engine Control System 04-19

No. Color Function Remark No. Color Function Remark

Brown- Malfunction Indi- Power steering Option-
19 60 -
white cator Light (MIL) switch signal al
Idle control valve Brown- Water tempera-
20 Yellow 61 -
A (high) yellow ture gauge
04
Yellow- Idle control valve
21 62 - - -
blue A (low)
Linear exhaust
Orange-
22 gas recirculation 63 - - -
gray
valve output
Heating wire con-
Purple-yel- Green- Canister
23 trol for the rear 64
low brown solenoid valve
oxygen sensor
Heating wire con-
Brown-yel- Low-speed elec-
24 trol for the front 65 Blue-red
low tronic fan control
oxygen sensor
5V power supply
Red-
25 Blue-red Injector 4 66 for the intake
black
pressure sensor
26 - - - 67 Red Power supply
Power supply for
27 Green-red TPS signal 68 Orange the ignition
switch
Evaporator tem-
Green-yel-
28 perature sensor 69 - - -
low
signal
Red- 5V power supply
29 - - - 70
white for the TPS
Intake air temper-
Blue-yel- Crankshaft posi- Green-or-
30 71 ature sensor sig-
low tion signal (high) ange
nal
31 - - - 72 - - -
Oxygen sensor
32 - - - 73 White
signal grounding
Grey-
33 - - - 74 TPS grounding
black
Lighting load in- Re-
34 Brown-red 75 Blue K-line diagnosis
put serve
Intake air pres-
Yellow- Re- Grey-
35 Blower load input 76 sure sensor
white serve green
grounding
 04-20 Diagnosis - Engine Control System

No. Color Function Remark No. Color Function Remark

Knock sensor White- Camshaft posi-
36 Green 77
signal (high) yellow tion signal
Green- Knock sensor Wheel speed Option-
37 78 -
white signal (low) signal al
04
A/C high and low
Green-pur- voltage switch
38 CAN-L 79 Brown
ple (controlling the
compressor)
Brown- Engine revolu-
39 Purple CAN-H 80
red tion signal output
A/C medium
Green- switch (control- Option-
40 81 - - -
black ling the electronic al
fan)
Orange- Idle control valve
41
white B (high)

Q P O N M L K J H G F E D C B A
1

E002-4W10 Engine Electronic Control Module Connector B

No. Color Function Remark No. Color Function Remark
Power supply for
Knock sensor Blue-
A1 Blue J1 camshaft posi-
shield grounding green
tion sensor
Battery power
A2 Orange supply (After the J2 - - -
ignition switch)
Downstream
Blue- High-speed fan
A3 Grey-red oxygen sensor J3
black relay control
signal
 Diagnosis - Engine Control System 04-21

No. Color Function Remark No. Color Function Remark

Knock sensor ERG valve con-
A4 Green J4 Green
input trol
TPS power sup-
B1 - - - K1 Red-white
ply
04
Green- Knock sensor
B2 K2 - - -
white grounding
Purple-
B3 - - - K3 Main relay
white
Green- A/C evaporator Red-yel- 2-cylinder fuel in-
B4 K4
yellow temperature low jector
Engine water
Upstream oxy-
Black- Brown- temperature ex-
C1 gen sensor sig- L1
purple yellow ported to the in-
nal
strument
A/C evaporator
Grey- temperature
C2 L2 - -
black sensor ground-
ing
White- Camshaft posi-
C3 L3 - -
yellow tion signal
Blue- 1-cylinder fuel in-
C4 - - - L4
white jector
Gray-yel- Vehicle speed
D1 M1 - - -
low signal
Camshaft posi-
Grey- Grey-
D2 TPS grounding M2 tion sensor
black black
grounding
Green- 4-cylinder fuel in-
D3 TPS signal M3 Blue-red
red jector
Blue- 3-cylinder fuel in-
D4 - - - M4
black jector
E1 - - - N1 - - -
Downstream
White- Orange- A/C compressor
E2 oxygen sensor N2
purple green relay
grounding
Grey- Variable cross-
E3 - - - N3
green section control
Upstream oxy-
Yellow-
E4 - - - N4 gen sensor heat-
black
ing
 04-22 Diagnosis - Engine Control System

No. Color Function Remark No. Color Function Remark

Brown-
F1 - - - O1 SVS light
blue
Upstream oxy-
Green- Canister control
F2 White gen sensor O2
04 brown valve
grounding
F3 - - - O3 - - -
Downstream
Purple-
F4 - - - O4 oxygen sensor
yellow
heating
White- EGR position Power grounding
G1 P1 Black
blue signal 1
Power grounding
G2 - - - P2 Black
2
Crankshaft posi-
Blue-yel- Battery power
G3 tion sensor sig- P3 Red
low supply
nal +
Battery power
Gray-
G4 Oil pump relay P4 Yellow supply (Behind
blue
the main relay)
H1 - - - Q1 - - -
Grey- EGR position
H2 Q2 - - -
black grounding
Blue- Crankshaft posi- Low-speed fan
H3 Q3 Blue-red
white tion sensor - relay control
Engine speed
Brown- Malfunction Indi- Brown-
H4 Q4 exported to the
white cator Light (MIL) red
instrument
 Diagnosis - Engine Control System 04-23

4 04

3
2

1
A B C D E F H I

E003-4W10 Engine Electronic Control Module Connector A

No. Color Function Remark No. Color Function Remark
A1 Purple CAN-H E1 - - -
A/C medium
Green- switch (control-
A2 E2 - - -
black ling the electron-
ic fan)
Orange- Stepper motor
A3 - - - E3
white B+
Green-or- Intake air tem-
A4 Blue Diagnosis K-line E4
ange perature signal
Green- Yellow- Stepper motor
B1 CAN-L F1
purple blue A-
Water tempera-
Grey-
B2 ture signal F2 - - -
black
grounding
Brown-
B3 Headlight switch F3 - - -
red
Intake air temper-
Power supply
Grey- ature & pressure Blue-pur-
B4 F4 for EGR posi-
green sensor ground- ple
tion sensor
ing
 04-24 Diagnosis - Engine Control System

No. Color Function Remark No. Color Function Remark

Stepper motor
C1 - - - G1 Yellow
A+
Gray- Intake air pres-
C2 - - - G2
brown sure signal
04
Yellow- White-pur- Stepper motor
C3 Blower switch G3
white ple B+
Power ground-
C4 - - - G4 Black
ing 3
A/C request sig-
D1 Brown H1 - - -
nal
Engine water
Purple- Red-yel- Ignition signal
D2 temperature sig- H2
green low of Cylinder 2 ,3
nal
D3 - - - H3 - - -
Power supply for
Red- Ignition signal
D4 Red-black the intake pres- H4
green of Cylinder 1 ,4
sure sensor
 Diagnosis - Engine Control System 04-25

Diagnostic System

04

4 80 100
3 5 60 120
x1000r/min 6 km/h
2 SVS 40 140

1 7 20 160
C H

0 8 E F 0 180

fpwx042000

1. The fault of the engine electronic control system can be divided into two types:
(a) One is to light up MIL (OBD fault indicator), indicating that there is a fault in the exhaust
control system and then the system enter the limp mode. When the MIL on the
instrument lights up, it needs to handle immediately according to the related
requirements of the State, or the system will restrict the fuel and speed of the engine,
which will affect the normal usage of the vehicle.
(b) The other is to light up SVS fault indicator, indicating that there is a fault in the electronic
control system and that it needs repairing in time.
(c) These two types both need the diagnostic tester or the special device with the similar
function to perform some inspection.
2. SVS and MIL is controlled by the ECM, before and after starting, the specific
information that SVS and MIL light up is described as follows:
• If the system has no faults, when the ignition switch is turned ON, MIL and SVS
light (System self-checking); after the self-checking, MIL keeps on and SVS
goes out. After starting or flaming out, both SVS and MIL go out.
• If the system has faults, when the ignition switch is turned ON, MIL and SVS
keep on(System self-checking); After starting, if SVS is defined as ON, it will
keep on after the conditions for lighting up SVS are met; if MIL is defined as
ON, it will keep on after the conditions for lighting up MIL are met; the engine
shuts down and the ignition switch is turned OFF, they both go out during the
AFTERRUN (max. 90s).
 04-26 Diagnosis - Engine Control System

3. If you need to troubleshoot an engine fault probably related to the electronic

control fuel injection system, first you should check whether the fault is related
to the electronic control fuel injection system or not. If the engine has faults and
fault indicator is not lit, generally the fault is unrelated to the electronic control
fuel injection system.
(a) The diagnostic codes and data related to the sensor and actuator in the ECM can be
04
read by the diagnosis instrument KT600 (Its application version is V03.79 or the updated
version. In addition, the actuator can be forced to drive in some special condition by
the tester.
(b) DLC- Data Link Connector
Terminal number Name
4 Grounding
5 Grounding
6 CAN_H
7 Diagnostic communication K
14 CAN_L
15 LIN
16 Battery power supply
 Diagnosis - Engine Control System 04-27

Reading and Clearing DTCs

Note
Faults are detected by the engine control system and saved in the engine control
module (ECM). They may be the present faults or historical faults.
1. Present faults: presently saved in ECM, eg. Coolant temperature sensor line is
04
open. Present faults must be handled, or they can not be cleared from the
memory.
2. Historical faults: two storage types
• Faults has been repaired and actual faults do not exist, but their memory has
not been cleared from ECM.
• Faults which occurred in the past do not exist, but they may occur again. Eg.
Wires are bad contacted. Saved faults are not present faults, so it is unnecessary
to repair before they are cleared from the memory, or you can refer to the
troubleshooting method of Intermittent Faults to handle them.
Note

• If the battery voltage is excessively low and codes in ECM can't normally output,
battery voltage should be detected first and no less than 11V before inspection.
• When the battery is disconnected or ECM connector is unplugged, trouble codes
in ECM will be cleared.
• Ensure the ignition switch is OFF (LOCK) before connecting or disconnecting
KT600 intelligent diagnosis instrument.

Note
Use a special detection tool when reading engine trouble codes: Kingtec KT600
intelligent diagnosis instrument with V03.79 application version or the updated one.
Read DTC with the diagnosis instrument:
1. Check and ensure the following
conditions:
• Throttle is fully open.
• A/C switch is OFF.
• Transmission is in neutral position.

fpwx041004

2. Turn the ignition switch to OFF.

3. Connect the diagnostic unit to the troubleshooting connectors (16-pin) on the
bottom of the front passenger seat.
4. Turn the ignition switch to ON, and then turn on the diagnosis instrument - use
the latest soft version.
5. Choose the menu item: [Beiqi Foton] - [Microvan] - [Gratour] - [Engine] - [Delphi
MT22.1.1 (LJ465 engine)/Delphi MT22.1 (4W12 engine)/Continental Easy U2 (4W10
engine)] - [Read trouble codes].
 04-28 Diagnosis - Engine Control System

6. Check DTC and data stream, record and then delete(If DTC can't be cleared,
perform diagnostic procedures to repair faults according to the Trouble Code
Checklist ).
7. Start the engine and operate it to normal operating temperature.
8. Run the engine until MIL lights in one of the following conditions:
• Simulate the designed conditions of DTC.
04
• Simulate the fault condition described by customers.
• Simulate the condition where the diagnosis instrument reads freeze-frame data.
9. Read DTC recorded by ECM with the diagnosis instrument.
10 . If there is DTC record and yet data or functions are normal, please consult the
troubleshooting method of Diagnostic Help - Intermittent Faults; If there is DTC
record and data or functions are abnormal, please perform diagnostic procedures
to repair faults according to the Trouble Code Checklist .
Note

• Read and capture data with the diagnosis instrument. Once DTC is saved, ECM
will record the information on the vehicle and driving condition in the freeze
frame. In troubleshooting, data capture can help identify whether the vehicle is
running or static, whether the engine warms up or not, whether the air-fuel ratio
is rich or lean and other data when faults occur.
• Resigned conditions of DTC including but not limited to:
(a) Engine revolution.
(b) Speed.
(c) Engine coolant temperature sensor.
(d) Manifold absolute pressure sensor.
(e) Intake air temperature sensor.
(f) Throttle position.
(g) Canister emission.
(h) Fuel adjustment.
(i) A/C switch.

Methods of clearing the trouble codes

1. Turn the ignition switch to OFF.
2. Connect the diagnostic unit to the troubleshooting connectors (16-pin) on the
bottom of the front passenger seat.
3. Turn the ignition switch to ON, and then turn on the diagnosis instrument - use
the latest soft version.
4. Choose the menu item: [Beiqi Foton] - [Microvan] - [Gratour] - [Engine] - [Delphi
MT22.1.1 (LJ465 engine)/Delphi MT22.1 (4W12 engine)/Continental Easy U2 (4W10
engine)] - [Read trouble codes] - [Clear trouble codes].
 Diagnosis - Engine Control System 04-29

Capturing Data
Note

• Once DTC is saved, ECM will record the information on the vehicle and driving
condition in the freeze frame. In troubleshooting, the freeze-frame data can help
determine whether the vehicle is driving or stops, the air-fuel ratio is rich or lean
04
and other data are saved or not.
• Even if DTC is detected, the fault is stilled unable to be reproduced. At that time,
you should confirm the freeze-frame data. ECM records the engine condition at
regular intervals in the freeze frame. The tester can help read some groups of
freeze-frame data respectively and KT600 tester offers powerful functions for
helping handle random data stream. Choose the Read the Data Stream function
in the 5/4W10/4W12 engine system, enter the Data Stream Test Result interface
and click the Help button to popup the following windows:
• Driving Record Playback.
• Calculator.
• Data Range Reference.
• Data Capture.
• Data Comparison.
• Data Stream Associated Settings.
• Driving Recorder Menu.
• These data can be used to simulate the vehicle conditions where the fault occurs.
They can also help identify the causes of the faults and judge whether they are
sporadic faults.
 04-30 Diagnosis - Engine Control System

Fail-safe chart
When on-board diagnostics of the engine control system detect main sensors fault, the
system sets a DTC and the vehicle will be controlled by the preset control logic loop to ensure
its driving in safe condition. In addition, when sensors or actuators fail, the vehicle will have
the following symptoms:
04

No. Fault Item Control Item during the Fault

• Fault indicator ON
• Unstable idling
1 Fuel injector • Underpower
• Difficult start
• Poor accelerating
• Fault indicator ON
2 Relay • System OFF
• Engine unable to start
• Fault indicator ON
• Fuel pump running with noise
3 Fuel pump
• Poor accelerating
• Engine unable to start
• Fault indicator ON
• Stopping injecting oil to the relevant cylinder
• Target idle speed increasing
• Unstable idling
4 Ignition coil
• Underpower
• Worse fuel economy
• Emissions exceeding the standard
• Poor ignition
• Fault indicator ON
• System late for entering the closed-loop time
• Worse fuel economy
5 Oxygen sensor
• Emissions exceeding the standard
• Slow acceleration
• Weak driving force
• Fault indicator ON
• Close the canister solenoid valve
Canister solenoid • System shuts down the closed-loop fuel control program.
6
valve
• System closes the idle air control self-learning program
• Unstable idle or high idle
• Fault indicator ON
7 Knock sensor • Using the safe ignition advance angle
• Engine knocking
 Diagnosis - Engine Control System 04-31

No. Fault Item Control Item during the Fault

• Engine overheating
• Emissions exceeding the standard
• Worse fuel economy
04
• Fault indicator ON
Vehicle speed sen- • No speed information
8
sor
• Worse fuel economy
• Fault indicator ON
• Engine unable to start
• Revolution limited, after engine starting
Crankshaft position • Max. revolution under about 4000 RPM
9
sensor • Emissions exceeding the standard
• No ignition signal to ECM
• Tachometer fault
• Engine violently running
• Fault indicator ON
• Setting the openness of the throttle position sensor to 0%,
Throttle position the openness changing with revolution in other rotating
10 speed.
sensor
• No more fuel injection quantity in accelerating, poor acceler-
ation
• Fault indicator ON
• When starting, engine adopts intake temperature saved in
ECM
• Difficult start with engine cold
Air Intake Pres- • Difficult start with engine warm
11 sure/Temperature • Weak driving force
Sensor • If the circuit of coolant temperature sensor and power supply
short out, engine works in default
• Cooling fan constantly running at high speed
• High temperature blinking when instrument indicating high
temperature
 04-32 Diagnosis - Engine Control System

Data Flow Sheet, Motion Test

1. Data flow sheet
Note

• Check the data values of switches, sensors and actuators by reading the data
04 sheet displayed in the diagnostic tester. Reading the data sheet is the first step
to cleat a fault and is one way to shorten the diagnosis time.
• The data under normal condition is shown in the following sheet and can be
considered as a reference. Do not decide whether a part is faulty or not just
according to these reference values.

Procedure to read the data sheet:

(a) Start the engine and make it run to normal operating temperature.
(b) Turn the ignition switch to OFF.
(c) Connect the diagnostic unit to the troubleshooting connectors (16-pin) on the bottom
of the front passenger seat.
(d) Turn the ignition switch to ON, and then turn on the diagnosis instrument - use the
latest soft version.
(e) Choose the following menu item: [Beiqi Foton] - [Microvan] - [Gratour] - [Engine] -
[Delphi MT22.1.1 (LJ465 engine)/Delphi MT22.1 (4W12 engine)/Continental Easy U2
(4W10 engine)] - [Read the data flow].
(f) Refer to the following sheet to check the data. The following sheet is the values of test
items detected by KT600 under different conditions.
• If no idling state is specified, the shift lever should be in N position, and the
switches of A/C and other accessories should be in OFF position.
• The injector drive time is the time when the crankshaft rotation speed is less
than 2500RPM and the power voltage is 11V.
• For new vehicles (the driving distance is within 500km), the drive time may be
10％ longer than the standard time.
• For new vehicles (the driving distance is within 500km), the step length of the
idle stepper motor may be 3 steps more than its standard value.

Diagnostic unit display items Checks (Range) Normal conditions

• Engine: From 3000RPM,
warming engine speed ≤200mV
up state decreases.
• Air-fuel
ratio:
leaner
Oxygen sensor
while de- When suddenly
celerat- accelerate the 400 - 1000mV
ing, rich- engine
er while
accelerat-
ing
 Diagnosis - Engine Control System 04-33

Diagnostic unit display items Checks (Range) Normal conditions

• Engine: When engine is
≤400mV
warming idling
up state
• Use the
oxygen 04
sensor to
check
the air-fu- When the en-
el ratio, gine speed is 400-1000mV
and use 2500RPM
ECU to
check
the con-
trol condi-
tions.
• Engine When engine is
—
coolant idling
tempera-
When the en-
ture: 80 -
gine speed is —
95℃ 2500RPM
Intake manifold pressure • Light and
sensor all acces-
sories:
When the en-
OFF
gine is accelerat- —
• Transmis- ing
sion: N
gear
Intake tempera-
-20℃
ture: -20℃
Intake tempera-
• Ignition 0℃
Switch: ture: 0℃
ON Intake tempera-
Air inlet temperature sensor 20℃
• or engine ture: 20℃
is operat-
Intake tempera-
ing 40℃
ture: 40℃
Intake tempera-
80℃
ture: 80℃
Idle position 300 - 1000m
Ignition Increase in direct
Throttle position sensor Switch: The throttle proportion to the
ON gradually open throttle opening
angle
 04-34 Diagnosis - Engine Control System

Diagnostic unit display items Checks (Range) Normal conditions

Full open 4500～500mV
Power voltage Ignition Switch: ON System voltage
Ignition Engine: OFF OFF
04 Ignition switch Switch:
ON Engine: ON ON

Intake tempera-
-20℃
ture: -20℃
Intake tempera-
0℃
Ignition ture: 0℃
Switch:
Intake tempera-
Water Temperature Sensor ON or the 20℃
ture: 20℃
engine is
running Intake tempera-
40℃
ture: 40℃
Intake tempera-
80℃
ture: 80℃
Engine: at A/C switch: OFF OFF
idling
(with A/C
switch
A/C switch
ON, the A/C switch: ON ON
compres-
sor starts
to work)
Cooling temper-
60～90ms
ature: 0℃
Engine: Cooling temper-
Fuel injector 30～5ms
running ature: 20℃
Cooling temper-
6.7～10.1ms
ature: 80℃
• Engine Engine: idling 2.2～3.4ms
coolant
tempera- 2500RPM 1.9～3.1ms
ture: 80 -
95℃
• Light and
Fuel injector
all acces- Engine sudden
sories: idling at high Time increase
OFF speed
• Transmis-
sion:
Neutral
 Diagnosis - Engine Control System 04-35

Diagnostic unit display items Checks (Range) Normal conditions

• Engine: Engine idling —
warming
up state
• Timing
light: ON 04
(Turn the
Ignition timing
timing 2000RPM —
light on
to check
the exact
ignition
time)
• Engine A/C switch: OFF —
coolant
tempera-
ture: 80 -
95℃
• Light and
all acces-
sories:
OFF
• Transmis-
sion:
Idle stepper motor A/C switch:
Neutral —
• Engine: OFF→ON
idling
• When
A/C
switch is
ON, A/C
compres-
sor
should
work

2. Motion test
Note
Perform motion tests to relays, actuators and other components and do the operation
learning without disassembling them. Perform motion test by using a diagnostic tester.
Making the motion test as the first step to clear the fault can shorten the diagnosis
time.
The data sheet can also be displayed when the motion test is performed.
(a) Connect the diagnostic unit to the troubleshooting connectors (16-pin) on the bottom
of the front passenger seat.
 04-36 Diagnosis - Engine Control System

(b) Turn the ignition switch to ON, and then turn on the diagnosis instrument - use the
latest soft version.
(c) Choose the menu item: [Beiqi Foton] - [Microvan] - [Gratour] - [Engine] - [Delphi
MT22.1.1 (LJ465 engine)/Delphi MT22.1 (4W12 engine)/Continental Easy U2 (4W10
engine)] - [Motion test].
(d) Refer to the following sheet to perform the motion test. The following sheet shows the
04
motion test items detected by diagnostic tester KT600.
(e) Use the motion test function to check the engine. If any abnormal symptom exists.
check and repair the related harness or components.
(f) Use KT600 to test again after repair, and make sure the fault is cleared.
(g) Clear the diagnostic trouble code.
(h) Remove the diagnostic tester KT600.
(i) Start the engine again and perform the test to ensure the fault is cleared.
Diagnostic unit Tested parts Control range Diagnosis notes
display
Failure indicator Failure indicator ON/OFF —
Canister solenoid
Carbon Canister ON/OFF —
valve control
Fuel pump relay Fuel pump relay ON/OFF —
Control low-speed
Low-speed fan ON/OFF —
fan
Control high-speed
High-speed fan ON/OFF —
fan
A/C relay A/C OFF relay ON/OFF —
Control the steps of
Idle air control
the idle stepper — —
motor (Stepper)
motor
Idle air control Control the rotation
motor (Rotation speed of the idle — —
speed) stepper motor
Control the reset of
Idle air control
the idle stepper — —
motor reset
motor
Ignition advance Control ignition
— —
angle advance angle
Tooth error learning 58X learning — —
Injector (A/B/C/D) Control the fuel cut ON/OFF —
BLM learning — — —
BLM reset — — —
Fuel open loop
open loop control — —
control
 Diagnosis - Engine Control System 04-37

Diagnostic unit Tested parts Control range Diagnosis notes

display
Catalyst monitoring Catalyst monitoring
— —
at idling at idling
Oxygen sensor Oxygen sensor
— — 04
response response
 04-38 Diagnosis - Engine Control System

Diagnostic Trouble Code Table

Note
When inspecting the DTC in check mode, some DTC indicates the inspection of the
relevant circuit according to the DTC code listed in the following chart. Refer to
corresponding pages for DTC introduction in detail.
04
Fault Codes Diagnostic Item (DTC Definition) Fault Location
• Intake Air Pressure/Temperature
Sensor
Reasonable fault with intake air • Poor contact at intake air pressure/tem-
P0106 perature sensor connector; open/short
pressure/accelerator position signal
circuit at sensor harness
• ECM
• Intake manifold pressure sensor
Intake air pressure/temperature • Poor contact at intake air manifold
P0107 sensor circuit low voltage or open pressure sensor connector; open/short
circuit circuit at sensor harness
• ECM
• Intake manifold pressure sensor
• Poor contact at intake manifold pres-
Intake air pressure sensor circuit sure sensor connector; open/short cir-
P0108
high voltage cuit at sensor harness
• ECM
• Air inlet temperature sensor
• Poor contact at intake air temperature
Intake air temperature sensor cir- sensor connector; short circuit at sen-
P0112
cuit low voltage sor harness
• ECM
• Air inlet temperature sensor
• Poor contact at intake air temperature
Intake air sensor circuit high volt- sensor connector; open/short circuit
P0113
age at sensor harness
• ECM
• Engine Water Temperature Sensor
• Poor contact at engine water tempera-
Water temperature sensor circuit ture sensor connector; open/short cir-
P0117
low voltage cuit at sensor harness
• ECM
• Engine Water Temperature Sensor
• Poor contact at engine water tempera-
Water temperature sensor circuit ture sensor connector; open/short cir-
P0118
high voltage cuit at sensor harness
• ECM
 Diagnosis - Engine Control System 04-39

Fault Codes Diagnostic Item (DTC Definition) Fault Location

• Throttle position sensor fault or disor-
der
Throttle position sensor circuit low • Poor contact at throttle position sensor
P0122 connector; open/short circuit at sensor
voltage
harness 04
• ECM
• Throttle position sensor fault or disor-
der
Throttle position sensor circuit high • Poor contact at throttle position sensor
P0123 connector; open/short circuit at sensor
voltage
harness
• ECM
• Front oxygen sensor
• Poor contact at front oxygen sensor
Front oxygen sensor heater short connector; open/short circuit at sensor
P0031
to low voltage harness
• ECM
• Front oxygen sensor
• Poor contact at front oxygen sensor
Front oxygen sensor heater short connector; open/short circuit at sensor
P0032
to high voltage harness
• ECM
• Front oxygen sensor
• Poor contact at front oxygen sensor
Front oxygen sensor short to connector; open/short circuit at sensor
P0131
ground harness
• ECM
• Front oxygen sensor
• Poor contact at front oxygen sensor
Front oxygen sensor short to power connector; open/short circuit at sensor
P0132
supply harness
• ECM
• Front oxygen sensor
• Poor contact at front oxygen sensor
Slow front oxygen sensor response connector; open/short circuit at sensor
P0133
fault harness
• ECM
• Front oxygen sensor
• Poor contact in the front oxygen sen-
P0134 Front oxygen sensor open circuit
sor connector; open circuit at sensor
harness
 04-40 Diagnosis - Engine Control System

Fault Codes Diagnostic Item (DTC Definition) Fault Location

• ECM
• Front Oxygen Sensor Heater
• Poor contact in the front oxygen sen-
P0135 Front oxygen sensor heating fault sor connector; open circuit at sensor
04
harness
• ECM
• Rear oxygen sensor
Rear oxygen sensor short to • Poor contact in the rear oxygen sensor
P0137 connector, the sensor circuit open
ground
• ECM
 Diagnosis - Engine Control System 04-41

Fault Codes Diagnostic Item (DTC Definition) Fault Location

• Rear oxygen sensor
Rear oxygen sensor short to power • Poor contact in the rear oxygen sensor
P0138 connector, the sensor circuit open
supply
• ECM
04
• Rear oxygen sensor
Rear oxygen sensor inactive or • Poor contact in the rear oxygen sensor
P0140 connector, the sensor circuit open
open-circuited
• ECM
• Rear Oxygen Sensor Heater
• Poor contact in the rear oxygen sensor
P0141 Rear oxygen sensor heating fault connector, the sensor circuit open
• ECM
• Air Intake System
• Fuel injector blocked
• Manifold pressure sensor
• WTS
• Fuel system pressure
• Air leak in exhaust system
• Oxygen sensor harness circuit open
P0171 Fuel system too lean or short
• Oxygen sensor
• Oxygen Sensor Heater
• Relay and harness
• Ventilation hose connection
• Ventilation valve and hose
• ECM
• Fuel injector leaking or blocked
• Manifold pressure sensor
• Water Temperature Sensor
• Ignition System
• Fuel pressure
• Air leak in exhaust system
P0172 Fuel system too rich
• Oxygen sensor harness circuit open
or short
• Oxygen sensor
• Sensor Heater
• Relay and harness
• ECM
 04-42 Diagnosis - Engine Control System

Fault Codes Diagnostic Item (DTC Definition) Fault Location

• Fuel injector A
P0201 Circuit fault with injector A • Fuel injector harness
• ECM

04
• Fuel injector B
P0202 Circuit fault with injector B • Fuel injector harness
• ECM
• Fuel injector C
P0203 Circuit fault with injector C • Fuel injector harness
• ECM
• Fuel injector D
P0204 Circuit fault with injector D • Fuel injector harness
• ECM
• Relay
P0230 Fuel pump relay • Fuel pump relay harness
• ECM
• Engine control system harness circuit
open or short
• Connector connection
• Vacuum hose connection
• The Ignition System
• Fuel injector
• Fuel pressure
• Manifold pressure sensor
P0300 Misfire • WTS
• Compression pressure
• Valve clearance
• Valve timing
• Ventilation valve and hose
• Ventilation hose connection
• Air Intake System
• ECM
• Knock sensor harness
P0325 Knock control system fault • Knock Sensor
• ECM
 Diagnosis - Engine Control System 04-43

Fault Codes Diagnostic Item (DTC Definition) Fault Location

• Poor contact at crankshaft position
Crankshaft position sensor circuit sensor connector; open/short circuit
P0336 at sensor harness
interference signal
• ECM
04
• Crankshaft position sensor
Crankshaft position sensor no sig- • Poor contact at harness connector,
P0335 open/short circuit at sensor harness
nal
• ECM
• Ignition coil
• Poor contact at harness connector,
P0351 Ignition coil 1 fault open/short circuit
• ECM
• Ignition coil
• Poor contact at harness connector,
P0352 Ignition coil 2 fault open/short circuit
• ECM
• Canister control harness circuit open
or short
P0443 Canister control valve fault • Canister Control Valve
• ECM
• Low-speed /high-speed relay
P0691 Cooling fan relay 1 line open circuit • Wiring harness
• ECM
• Low-speed /high-speed relay
Cooling fan relay 1 line short to • Wiring harness
P0692
ground
• ECM
• Circuit with ECM power line: poor
contact or open circuit
P0562 Inadequate system voltage • Circuit with ECM ground: poor contact
or open circuit
• ECM
• Circuit with ECM power line: poor
contact or open circuit
P0563 Excessive system voltage • Circuit with ECM ground: poor contact
or open circuit
• ECM
• Throttle position sensor
P0506 Inadequate idle speed • Idle motor
• Air Inlet Pipe
 04-44 Diagnosis - Engine Control System

Fault Codes Diagnostic Item (DTC Definition) Fault Location

• Air Intake Pressure/Temperature
Sensor
• ECM
• Throttle position sensor
04
• Idle motor
• Air Inlet Pipe
P0507 Excessive idle speed
• Air Intake Pressure/Temperature
Sensor
• ECM
• Circuit with ECM power line: poor
contact or open circuit
• Circuit with ECM ground: poor contact
or open circuit
A/C clutch circuit output short to low • Circuit fault between pressure switch
P0646
voltage or short-circuited and ECM
• A/C compressor clutch coil fault
• ECM
• A/C Compressor
• Circuit with ECM power line: poor
contact or open circuit
• Circuit with ECM ground: poor contact
or open circuit
A/C clutch circuit output short to • Circuit fault between pressure switch
P0647
high voltage and ECM
• A/C compressor clutch coil fault
• ECM
• A/C Compressor
• Failure indicator
P0650 Failure indicator fault • Failure indicator harness
• ECM
• Main relay
P0685 Main relay output fault • Main relay harness
• ECM
• Replace the ECU or crankshaft gear
ring; or adjust the gear ring to the cor-
responding location of 58X sensor
P1336 Require tooth error learning • Poor contact at crankshaft position
sensor connector; open/short circuit
at sensor harness
• ECM
 Diagnosis - Engine Control System 04-45

Diagnosing the Diagnostic Trouble Code (DTC)

P0105-Intake Air Pressure Sensor Signal Unchanged (frozen)
P0106-Reasonable Fault with Intake Air Pressure/Accelerator Position
Signal
P0107-Intake Air Pressure Sensor Circuit Low Voltage
P0108-Intake Air Pressure Sensor Circuit High Voltage 04

4.65
Instruction
The system adopts the mass air flow speed-density
measurement in order to detect air volume entering
the engine and then control the fuel injection pulse
width, which controls the engine power output.

0.4

20 115kPa
fpwx041005

Circuit Diagram

Engine electronic Engine electronic Engine electronic

control module control module control module
E001 (4W12) E003 (4W10) E001 (LJ465)

Power Pressure Temperature Power Pressure Temperature Power Pressure Temperature

supply 5V signal signal supply 5V signal Grounding signal supply 5V signal Grounding signal
Grounding
66 54 76 71 D4 G2 B4 E4 66 54 76 71

Blue-black Gray-purple Gray-green Green-orange

Red-black Gray-brown Gray-green Green-orange
Red-black Gray-purple

3 4 1 2 B A D C
3 4 1 A B

Air Intake Pressure/ Air Intake Pressure/

Air inlet pressure Air inlet temperature
Temperature Sensor Temperature Sensor
sensor sensor
E010 E011 E011
E011

fpwx041007
 04-46 Diagnosis - Engine Control System

DTC Code DTC Definition DTC Inspection Condition Fault Location

• MAP sensor
• Poor contact in the sensor
connector
04 • Open circuits or high resis-
tance in the sensor signal
circuit.
• Engine running
• Sensor signal cable short to
Intake air pres- • No TPS faults ground.
P0105 sure sensor sig- • ECM detects that MAP in-
• 5V reference voltage line
nal unchanged put signal remains un-
open
changed.
• Sensor ground wire open
• Sensor 5V reference voltage
line and ground wire reverse-
ly connected (This fault can
damage the sensor).
• • ECM
• MAP sensor
• Poor contact in the sensor
connector
• Open circuits or high resis-
tance in the sensor signal
circuit.
Reasonable • Engine running • Sensor signal cable short to
fault with air in- • No TPS faults ground.
P0106 take pressure/ac- • ECM detects that MAP in- • 5V reference voltage line
celerator posi- put signal remains unrea- open
tion signal sonable. • Sensor ground wire open
• Sensor 5V reference voltage
line and ground wire reverse-
ly connected (This fault can
damage the sensor).
• Throttle position sensor
• • ECM
• MAP sensor
• Poor contact in the sensor
connector
• Ignition Switch: ON • Open circuits or high resis-
Intake pressure • No TPS faults tance in the sensor signal
P0107 sensor circuit • ECM detects that MAP in- circuit.
low voltage put signal is below the set • Sensor signal cable short to
MIN value. ground.
• 5V reference voltage line
open
• Sensor ground wire open
 Diagnosis - Engine Control System 04-47

DTC Code DTC Definition DTC Inspection Condition Fault Location

• Sensor 5V reference voltage
line and ground wire reverse-
ly connected (This fault can
damage the sensor). 04
• • ECM
• • MAP sensor
• Engine running • • Sensor signal circuit short
Intake pressure • No TPS faults to12V power supply
P0108 sensor circuit • ECM detects that MAP in- • Sensor 5V reference voltage
high voltage put signal is above the set line short to 12V power sup-
MAX value. ply
• ECM

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• Turn on the ignition switch, engine does not run and manifold pressure is equal
to the atmospheric pressure. Sensor signal outputs high voltage.

Diagnostic Steps
Take 4W10 engine as an example

1. Read DTC and data on the tester.

(a) Start the engine and operate it to normal operating temperature.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Read MAP sensor data shown on the diagnosis tester.
Shown DTC and temperature Go to Status
• P0107
• Pressure ≤ 10kPa Next step Open or short to ground

• P0107
• Pressure ≥115kPa Next step Short to the voltage line

• P0105
Intake air pressure sensor
• Pressure between 10kPa and Next step
fault
115kPa, unchanged.
 04-48 Diagnosis - Engine Control System

Shown DTC and temperature Go to Status

• P0106
• Pressure sometimes more than Intake air pressure sensor
Next step
115kPa or less than10kPa, unsta- fault or pipeline air leakage
ble
04
• P0107 or P0108
Diagnostic Help Intermittent Fault
• Normal pressure

2. Check the reference voltage of the intake air pressure sensor

(a) Turn the ignition switch to OFF.
(b) Disconnect MAP sensor connector E011.
(c) Turn the ignition switch to ON.
E011
(d) Measure the voltage between the pin 3 of the
MAP sensor connector E011 and the ground.
1 2 3 4 Standard voltage

Multimeter Connection Specified Condition

E011(3)-Ground 5.0±0.25V

fpwx041008

Is the result normal?

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

3. Check the harness and connectors (Intake air temperature/pressure sensor -

Engine control module)
(a) Turn the ignition switch to ON.
(b) Disconnect the MAP sensor connector E011
and ECM connector E003.
E011
E003
(c) Measure the resistance between the pin 1
and 4 of MAP sensor connector E011 and the
1 2 3 4
pin B4 and G2 of the connector E003.
G2 B4
Resistance: ＜2Ω

fpwx041009
 Diagnosis - Engine Control System 04-49

Is the result normal?

No> Repair or replace the connector or harness.
Yes> Go to next step.

4. Check MAP pressure signal cable (do not start the engine)
04
(a) Turn the ignition switch to ON.
(b) Measure the voltage between the pin 4 of the
MAP sensor connector E011 and the ground
E011 from the back of E011.
Voltage: about 4V
1 2 3 4

fpwx041010

Is the result normal?

No> Repair or replace the connector or harness.
Yes> Go to next step.

5. Check MAP signal (start the engine)

(a) Connect MAP sensor connector E011.
(b) Start the engine, set the digital multimeter in
DC voltage, connect the black probe to the
E011
ground, the red probe to the pin 3 or 4 of MAP
sensor connector respectively.
1 2 3 4
(c) In idle state, the pin 3 should have 5V
reference voltage and pin 4 should have about
1.3V voltage.
v
(d) In no-load state, slowly open the throttle and
the voltage of pin 4 slightly changes. Quickly
open the throttle, the voltage of pin 4 instantly
reaches about 4V and then falls to about 1.5V.
fpwx041012 Multimeter Connection Specified Condition
E011(3)-Ground • Idling: 5.0±0.25V
• Idling: 1.3V
• In no-load condition,
E011(4)-Ground
slowly open the
throttle: 1.3V
 04-50 Diagnosis - Engine Control System

Multimeter Connection Specified Condition

• Quickly open: 4V
—>1.5V

04 Is the result normal?

Yes> Go to next step.
No> Repair or replace the sensor harness, connector or MAP sensor.

6. Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester.
(c) Read the sensor data flows. Ensure there are no DTCs and the data are normal.
P0112-Intake Air Temperature Sensor Circuit Low Voltage
P0113-Intake Air Temperature Sensor Circuit High Voltage
Instruction
• The intake air temperature sensor is a
negative temperature coefficient resistor.
When the intake air temperature rises, the
104 resistance reduces.
• When the resistance increases, the output
voltage of the intake air temperature
103
sensor increases, and vice verse.

102
-40 0 40 80 120 C

fpwx041013
 Diagnosis - Engine Control System 04-51

Circuit Diagram

Engine electronic Engine electronic Engine electronic

control module control module control module
E001 (4W12) E003 (4W10) E001 (LJ465)

Power Pressure Temperature Power Pressure Temperature Power Pressure Temperature

supply 5V signal signal supply 5V signal Grounding signal supply 5V signal Grounding signal 04
Grounding
66 54 76 71 D4 G2 B4 E4 66 54 76 71

Blue-black Gray-purple Gray-green Green-orange

Red-black Gray-brown Gray-green Green-orange
Red-black Gray-purple

3 4 1 2 B A D C
3 4 1 A B

Air Intake Pressure/ Air Intake Pressure/

Air inlet pressure Air inlet temperature
Temperature Sensor Temperature Sensor
sensor sensor
E010 E011 E011
E011

fpwx041007
 04-52 Diagnosis - Engine Control System

DTC Code DTC Definition DTC Inspection Condition Fault Location

• Ignition Switch: ON
• Wait for 120s after turning on the • IAT sensor
Intake air tem- ignition switch or after the en- • IAT sensor 5V refer-
perature sensor gine is started. ence voltage line short
P0112
04
circuit low volt- • The output voltage of the sensor to the ground
age is below 0.2V (corresponding to • ECM
over 125℃ intake air) for 4s.
• IAT sensor
• Ignition Switch: ON • Poor contact in the IAT
• Wait for 60s after turning on the sensor connector
Intake air sen- ignition switch or after the en- • Sensor circuit open or
P0113 sor circuit high gine is started. high resistance
voltage • The output voltage of the sensor • 5V reference voltage
is below 4.6V (corresponding to line short to 12V power
over -45℃ intake air) for 4s. supply
• ECM

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.

Diagnostic Steps
Take 4W12 engine as an example

1. Read DTC and data on the tester.

(a) Start the engine and operate it to normal operating temperature.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Read IAT sensor data shown on the diagnosis tester.
Shown DTC and temperature Go to Status
• P0113 Open or short to the volt-
• < -40℃ Go to next step
age line
• P0112
• > 140℃ Step 5 Short to ground

• P0112 or P0113
Diagnostic Help Intermittent Fault
• Normal temperature
 Diagnosis - Engine Control System 04-53

2. Read data on the tester.

(a) Turn the ignition switch to ON.
(b) Disconnect IAT sensor connector.
E010
(c) Connect the pin A and B of the IAT sensor
connector E010. 04
(d) Turn the ignition switch to ON.
A B (e) Read the IAT sensor value shown on the
diagnosis tester.

fpwx041014
Temperature: about 140℃

Is the result normal?

Yes> Confirm that the sensor well connects. If it is well connected, replace the intake
air temperature sensor.
No> Go to next step.

3. Check the reference voltage of the intake air temperature sensor

(a) Disconnect the IAT sensor connector E010.
(b) Turn on the ignition switch and measure the
voltage between the pin B of the IAT sensor
connector E010 and the ground.
E010
Voltage: 4.5～5.0V

A B

fpwx041015

Is the result normal?

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

4. Check the conduction between the IAT sensor and ECM.

 04-54 Diagnosis - Engine Control System

(a) Disconnect the IAT sensor connector E010

and ECM connector E001.
(b) Measure the resistance between the pin A
and B of IAT sensor connector E010 and the
E001 terminal 76 and 71 of ECM connector E001.
E010

04 Resistance: < 2Ω
76 71

A B

fpwx041016

Is the result normal?

Yes> Go to step 7.
No> Repair or replace the connector or harness.

5. Read data on the tester.

(a) Turn the ignition switch to OFF.
(b) Disconnect the intake air temperature sensor connector.
(c) Turn the ignition switch to ON.
(d) Read the IAT sensor value shown on the diagnosis tester.
Temperature: about -40℃

Is the result normal?

Yes> Confirm that the sensor well connects. If it is well connected, replace the intake
air temperature sensor.
No> Go to next step.

6. Check the harness and connectors.

(a) Turn the ignition switch to OFF.
(b) Disconnect the IAT sensor connector E010
and ECM connector E001 and measure the
E010 resistance between the harness of IAT sensor
and the ground.

A B
Multimeter Connection Specified Condition
E010(A)- Ground
≥1MΩ
E010(B)-Ground
Ω

fpwx041017
 Diagnosis - Engine Control System 04-55

Is the result normal?

Yes> Go to next step.
No> Repair or replace the connector or harness.

7. Replace ECM.
(a) Replace ECM. 04
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.
P0117-P0117-Water Temperature Sensor Circuit Low Voltage
P0118-P0117-Water Temperature Sensor Circuit High Voltage
Instruction
1. Engine water temperature sensor is a
negative temperature coefficient resistor.
When the engine coolant temperature
rises, the resistance reduces.
2. When the resistance increases, the output
voltage of the engine coolant temperature
fpwx041019
sensor increases, and vice verse.

Circuit Diagram

Engine electronic Engine electronic Engine electronic

control module control module control module
E003 (4W10) E001 (LJ465) E001 (4W12)

Power Internal
Power Internal Power Internal
supply 5V ground wire
supply 5V ground wire supply 5V ground wire
D3 B2 49 52 49 74

Purple- Gray- Purple- Gray- Purple- Gray-

green black green black green black

A B A B A B

Water temperature Water temperature Water temperature

sensor sensor sensor
E019 E019 E019

fpwx041022
 04-56 Diagnosis - Engine Control System

DTC Code DTC Definition DTC Inspection Condition Fault Location

• Ignition Switch: ON
• Wait for 60s after turning on the
• WTS
Water tempera- ignition switch or after the engine
• WTS circuit short to
04 P0117 ture sensor circuit is started.
the ground
low voltage • WTS output voltage is below 0.1V
• ECM
(corresponding to over 145℃
coolant) for 4s.
• Ignition Switch: ON • WTS
• Wait for 60s after turning on the • Poor contact in the
Water tempera- ignition switch or after the engine WTS connector
P0118 ture sensor circuit is started. • WTS circuit open or
high voltage • WTS output voltage is above short to 12V power
4.6V (corresponding to below - supply
45℃ coolant) for 4s. • ECM

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• Once each of DTCP0117 and P0118 is detected, ECM enters the fail-safe mode.
In the fail-safe mode, ECM sets WTS value as default and meanwhile the cooling
fan is running at high speed when the ignition switch is ON. The fail-safe mode
keeps until ECM detects the qualified condition.

Diagnostic Steps
Take 4W12 engine WTS as an example

1. Read DTC and data on the tester.

(a) Start the engine and operate it to normal operating temperature.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Read the WTS value shown on the diagnosis tester.
Shown DTC and
Go to Status
temperature
• P0118 Open or short to the power
• About -40℃ Next step
line
• P0117
• About 140℃ or higher Step 5 Short to ground
 Diagnosis - Engine Control System 04-57

Shown DTC and

Go to Status
temperature
• P0117 or P0118
• Between 80℃ and 100℃ Diagnostic Help Intermittent Fault

04

2. Read data on the tester.

(a) Turn the ignition switch to OFF.
(b) Disconnect WTS connector.
E019
(c) Connect the pin A and B of the WTS
connector E019.
A B (d) Turn the ignition switch to ON.
(e) Read the coolant temperature value shown
on the diagnosis tester.
fpwx041023 Temperature: about 140℃

Is the result normal?

Yes> Confirm that the sensor well connects. If it is well connected, replace the WTS.
No> Go to next step.

3. Check the reference voltage of WTS

(a) Disconnect WTS connector E019.
(b) Turn on the ignition switch and measure the
voltage between the pin A of the WTS
connector E019 and the ground.
E019
Voltage: 4.5～5.0V
A B

fpwx041024

Is the result normal?

Yes> Go to next step.
No> Replace the WTS harness. If the harness is normal, replace ECM.

4. Check WTS ground wire.

 04-58 Diagnosis - Engine Control System

(a) Disconnect WTS connector E019.

(b) Measure the resistance between the pin B of
the WTS connector E019 and the ground.
E019 Resistance: ＜2Ω

04 A B

fpwx041025

Is the result normal?

Yes> Go to step 7.
No> Repair or replace the connector or harness.

5. Read data on the tester.

(a) Turn the ignition switch to OFF.
(b) Disconnect WTS connector.
(c) Turn the ignition switch to ON.
(d) Read the coolant temperature value shown on the diagnosis tester.
Temperature: about -40℃

Is the result normal?

Yes> Confirm that the sensor well connects. If it is well connected, replace the WTS.
No> Go to next step.

6. Check the harness and connectors.

(a) Turn the ignition switch to OFF.
(b) Disconnect ECM connector E001 and WTS
connector E019.
(c) Measure the resistance of WTS harness.
E019
Multimeter Connection Specified Condition
A B
E019(A)- Ground
≥1MΩ
E019(B)-Ground
Ω

fpwx041026

Is the result normal?

 Diagnosis - Engine Control System 04-59

Yes> Go to next step.

No> Repair or replace the connector or harness.

7. Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester. 04
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.
P0122-Throttle position sensor circuit low voltage
P0123-Throttle position sensor circuit high voltage
Instruction
ECM offers 5V reference voltage signal and the grounding to the throttle position sensor
(TPS). TPS sends a feedback voltage signal of the throttle opening to ECM. The throttle
signal voltage changes from about 0.5V at closed throttle to about 4.5V at fully open throttle.
Circuit Diagram

Engine electronic Engine electronic Engine electronic

control module control module control module
E002 (4W10) E001 (LJ465) E001 (4W12)

Power Internal Power Internal Power Internal

supply signal ground wire supply signal ground wire supply signal ground wire
K1 D3 D2 70 27 74 70 27 74

Red- Green- Gray- Red- Green- Gray- Red- Green- Gray-

white red black white red black white red black

A C B A C B A C B

Throttle position Throttle position Throttle position

sensor sensor sensor
E018 E018 E018

fpwx041027

DTC DTC Definition DTC Inspection Condition Fault Location

• Ignition Switch: ON
Throttle position • TPS or disorder
• Wait for 60s after turning on the
P0122 sensor circuit low • Poor contact in the TPS
ignition switch or after the engine
voltage connector, the sensor
is started.
 04-60 Diagnosis - Engine Control System

DTC DTC Definition DTC Inspection Condition Fault Location

• When engine is idling, the output harness open or short to
voltage of the sensor is below ground
0.35V for 4s. • ECM
04
• Ignition Switch: ON
• TPS
• Wait for 60s after turning on the
• Poor contact in the TPS
Throttle position ignition switch or after the engine
connector, the sensor
P0123 sensor circuit is started.
harness open or short to
high voltage • When engine is idling, the output
the power supply
voltage of the sensor is above
• ECM
4.8V for 4s.

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Steps
Take 4W12 engine as an example

1. Read DTC and data on the tester.

(a) Start the engine and operate it to normal operating temperature.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Slowly press the accelerator pedal until the throttle fully opens
(e) Read the throttle signal data shown on the tester.
The voltage continuously changes between 0.35V and 4.8V.

Is the result normal?

Yes> Intermittent Faults, refer to the Diagnostic Help.
No> If the voltage does not continuously change, please replace TPS. If the voltage
is constant, go to next step.

2. Check the reference voltage of the throttle position sensor.

 Diagnosis - Engine Control System 04-61

(a) Turn the ignition switch to OFF.

(b) Disconnect the TPS connector E018.
(c) Turn the ignition switch to ON.
E018 (d) Measure the voltage of the pin A of the TPS
connector E018.
Standard voltage 04
B A
Multimeter Connection Specified Condition
C
E018(A) - Ground 4.5～5.0V

fpwx041028

Is the result normal?

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

3. Check the conduction of the harness between the throttle position sensor and
ECM.
(a) Turn the ignition switch to OFF.
(b) Disconnect the TPS connector E018 and ECM
connector E001.
E018
(c) Measure the resistance between the pin B
E001 and C of TPS connector and the terminal 74
and 27 of ECM E001.
B A

C 74 27 Resistance: ＜2Ω

fpwx041029

Is the result normal?

No> Repair or replace the harness.
Yes> Go to next step.

4. Check the TPS sensor signal

 04-62 Diagnosis - Engine Control System

(a) Connect the TPS connector E018.

(b) Start the engine.
(c) Measure the voltage between the terminal C
E018 and the reliable ground point at the back of
TPS connector E018.
(d) Press or loosen the accelerator pedal and
04
observe whether the throttle position signal
B A
voltage changes.
C
(e) The throttle signal voltage will increase as the
throttle opens. The voltage continuously
changes between 0.35V and 4.8V.

fpwx041030

Is the result normal?

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

5. Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.
P1167-Front Oxygen Sensor Air-fuel Ratio Rich During deceleration
P1171-Front Oxygen Sensor Air-fuel Ratio Lean During acceleration
P0131-Front Oxygen Sensor Low Voltage
P0132-Front Oxygen Sensor High Voltage
P0133-Front Oxygen Sensor Response Fault
P0134-Front Oxygen Sensor Open
P0135-Front Oxygen Sensor Heating Fault
Instruction
1000 ECM offers about 450mV voltage to the ECM pin
47 and 73. As air exhaust becomes from rich to lean,
800
the voltage range of oxygen sensor changes from
600
about 1V to about 0.1V. When temperature becomes
Sensor
voltage/
below 350°C, the oxygen sensor won't normally
mV 400 work. A open oxygen sensor and low temperature
oxygen sensor will make the system into open loop
200
condition.
0
Theoretical air fuel ratio Air fuel ratio
Rich Lean

fpwx041031
 Diagnosis - Engine Control System 04-63

Circuit Diagram
Battery
Red E101
1
Red V103
Red

4 1 04
Yellow
F22
Fuel injector/
Main relay oxygen sensor fuse
10A

2 3

V103
7 Front oxygen Rear oxygen
E101 sensor sensor
E012 E013
B A C D B A C D
Yellow Yellow
Purple- Black- White Brown- Gray- White Purple-
white purple yellow red yellow

44 47 73 24 48 23
Front oxygen Internal ground Heater wire Rear oxygen Heater wire Engine electronic
sensor signal wire wire control sensor signal wire control
control module
E001 (4W12/LJ465)
fpwx041033

Battery
Red E101
1
Red V103
Red

4 1
Yellow
F22
Fuel injector/
Main relay oxygen sensor fuse
10A

2 3

V103
7 Front oxygen Rear oxygen
E101 sensor sensor
E012 E013
1 2 3 4 1 2 3 4
Yellow Yellow
Purple- Black- White Brown- Gray- White- Purple-
white purple yellow red purple yellow

K3 C1 F2 N4 A3 E2 O4
Front oxygen Internal ground Heater wire Rear oxygen Internal ground Heater wire
sensor signal wire wire control sensor signal wire wire control Engine electronic
control module
E002 (4W10)
fpwx041034
 04-64 Diagnosis - Engine Control System

DTC DTC Definition DTC Inspection Condition Fault Location

• Engine control system in
closed loop
• Engine speed is less than
• Front oxygen sensor
04 6000rpm.
Front oxygen sen- • Front oxygen sensor har-
P0131 • Front oxygen sensor voltage
sor short to ground ness short to ground
below 0.03V for at least 25s
• ECM
• DTCP0107, P0108, P0117,
P0118, P0122, P0123, P0335
dose not exist.
• Front oxygen sensor voltage
• Front oxygen sensor
Front oxygen sen- above 2.5V for at least 25s
• Front oxygen sensor har-
P0132 sor short to power • DTCP0107, P0108, P0117, ness short to power supply
supply P0118, P0122, P0123, P0335
• ECM
dose not exist.
• Front oxygen sensor
• Feedback voltage of front • Poor contact in the front
Front oxygen sen- oxygen sensor between oxygen sensor connector,
P0134
sor open circuit 0.42V and 0.48V the sensor circuit open
• ECM
• Front oxygen sensor
• Front oxygen sensor voltage • Poor contact in the front
Front oxygen sen- below 0.07V for at least 40s oxygen sensor connector,
P0133
sor response fault the sensor circuit open
• P0135, P01167 does not exist
• ECM
• Front oxygen sensor
• Front oxygen sensor voltage
• Poor contact in the front
Front oxygen sen- below 0.07V for at least 40s
P0135 oxygen sensor connector,
sor heating fault • P0133, PP1167, P1171 does the sensor circuit open
not exist
• ECM
• Front oxygen sensor
Front oxygen sen- • Front oxygen sensor voltage • Poor contact in the front
sor air-fuel ratio below 0.07V for at least 40s oxygen sensor connector,
P1167
rich during deceler- the sensor circuit open
• P1171, P0133 does not exist
ation
• ECM
• Front oxygen sensor
Front oxygen sen- • Front oxygen sensor voltage • Poor contact in the front
sor air-fuel ratio below 0.07V for at least 40s oxygen sensor connector,
P1171
lean during acceler- the sensor circuit open
• P1167, P0135 does not exist
ation
• ECM
 Diagnosis - Engine Control System 04-65

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring, 04
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Help
• Closed loop voltage range of the oxygen sensor shown on the good tester
changes from 0.1V to 1.0V.
• Check the oxygen sensor harness for oxygen sensor may be improperly installed
and touch the exhaust pipe.
• Check the intermittent grounding of the harness between ECM and the sensor.
• Perform a balance test for the injector and check whether the blocked injector
will cause the mixture to become lean.
• Vacuum leakage for the crankcase causes the lean air-fuel ratio condition.
• Leakage of the exhaust manifold washer causes the outside air to enter the
exhaust pipe and pass the sensor.
Diagnostic Steps
Take LJ465 engine as an example

1. Read DTC on the tester.

(a) Start the engine and operate it to normal operating temperature.
(b) Identify DTC with the tester.
(c) Read the sensor data flows with a tester.
(d) Engine is at idling.
(e) Read the oxygen sensor signal data shown on the tester.
Result

Shown DTC and voltage Go to Status

• P0131 (＜0.03V) Go to step 6. Short to ground
• P0132 (>2.5V) Go to step 7. Short to power supply
• P0134 (1.3V～2.5V) Go to next step Open circuit

2. Check oxygen sensor signal circuit (Check whether there is open circuit)
 04-66 Diagnosis - Engine Control System

(a) Turn the ignition switch to OFF.

(b) Disconnect the oxygen sensor connector
E012.
(c) Turn the ignition switch to ON.
(d) Measure the voltage between the pin A and
A B C D B of the oxygen sensor connector E012.
04
Voltage: 0.45V

fpwx041035

Is the result normal?

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

3. Check the voltage of oxygen sensor signal

(a) Turn the ignition switch to OFF.
(b) Connect the pin A of the oxygen sensor
connector E012 and the ground.
(c) Turn the ignition switch to ON.
(d) Measure the voltage between the pin A of the
oxygen sensor connector E012 and the
A B C D
ground.
Voltage: 0.45V

fpwx041038

Is the result normal?

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

4. Check the harness and connector (Front oxygen sensor- Engine ECM)
 Diagnosis - Engine Control System 04-67

(a) Turn the ignition switch to OFF.

(b) Disconnect the connector E001 of the ECM.
(c) Measure the resistance between the pin A
E001
and B of oxygen sensor connector E012 and
the terminal 73 and 47 of ECM connector
A B C D
E001.
04
47 73
Resistance: ＜2Ω

fpwx041600

Is the result normal?

Yes> Go to next step.
No> Replace or repair the oxygen sensor signal harness.

5. Check the harness and connector (Front oxygen sensor - Ground)

(a) Ignition switch: OFF.
(b) Disconnect the connector E001 of the engine ECM.
(c) Disconnect the connector E012 of the front oxygen sensor.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)
Multimeter Connection Standard Value
E012(A) - Ground
A B C D ≥1MΩ
E012(B) - Ground

fpwx041040

Is the result normal?

Yes> Go to next step.
No> Replace or repair the oxygen sensor signal harness.

5. Check the power line of the oxygen sensor heating wire.

 04-68 Diagnosis - Engine Control System

(a) Turn the ignition switch to OFF, disconnect

the connector E012 of the front oxygen
sensor.
(b) Turn the ignition switch to ON.
(c) Measure the voltage between the pin D of the
oxygen sensor connector E012 and the
04 A B C D
ground.
Voltage: about 12V

fpwx041041

Is the result normal?

Yes> Go to next step.
No> Replace or repair the harness between the oxygen sensor and the main relay.

6. Check the control line of the oxygen sensor heating wire.

(a) Turn the ignition switch to OFF, disconnect
the connector E012 of the front oxygen
sensor.
(b) Disconnect the connector E001 of the ECM.
E001
(c) Measure the resistance between the pin C of
A B C D
the oxygen sensor connector E012 and the
23 ECM connector E001 pin 23.
StandardResistance:＜2Ω

fpwx041042

Is the result normal?

No> Repair or replace the harness and connector.
Yes> Go to next step.

7. Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.
 Diagnosis - Engine Control System 04-69

P0037-Downstream oxygen sensor heater control circuit open

P0038-Downstream oxygen sensor heater control circuit short to power
supply
P0140-Rear oxygen sensor circuit open
P0141-Implausible downstream oxygen sensor heating circuit
P0136-Downstream oxygen sensor circuit open 04
P0137-Downstream oxygen sensor circuit short to ground
P0138-Downstream oxygen sensor circuit short to power supply
P0420-Insufficient catalyst conversion efficiency
Instruction
1000 ECM offers about 450mV voltage to the ECM pin
48 and 73. As air exhaust becomes from rich to lean,
800
the voltage range of oxygen sensor changes from
600
about 1V to about 0.1V. When temperature becomes
Sensor
voltage/
below 350°C, the oxygen sensor won't normally
mV 400 work. A open oxygen sensor and low temperature
oxygen sensor will make the system into open loop
200
condition.
0
Theoretical air fuel ratio Air fuel ratio
Rich Lean

fpwx041031
 04-70 Diagnosis - Engine Control System

Circuit Diagram
Battery
Red E101
1
Red V103
Red

04 4 1
Yellow
F22
Fuel injector/
Main relay oxygen sensor fuse
10A

2 3

V103
7 Front oxygen Rear oxygen
E101 sensor sensor
E012 E013
B A C D B A C D
Yellow Yellow
Purple- Black- White Brown- Gray- White Purple-
white purple yellow red yellow

44 47 73 24 48 23
Front oxygen Internal ground Heater wire Rear oxygen Heater wire Engine electronic
sensor signal wire wire control sensor signal wire control
control module
E001 (4W12/LJ465)
fpwx041033

Battery
Red E101
1
Red V103
Red

4 1
Yellow
F22
Fuel injector/
Main relay oxygen sensor fuse
10A

2 3

V103
7 Front oxygen Rear oxygen
E101 sensor sensor
E012 E013
1 2 3 4 1 2 3 4
Yellow Yellow
Purple- Black- White Brown- Gray- White- Purple-
white purple yellow red purple yellow

K3 C1 F2 N4 A3 E2 O4
Front oxygen Internal ground Heater wire Rear oxygen Internal ground Heater wire
sensor signal wire wire control sensor signal wire wire control Engine electronic
control module
E002 (4W10)
fpwx041034
 Diagnosis - Engine Control System 04-71

DTC Code DTC Definition DTC Inspection Condition Fault Location

• Engine control system in
closed loop • Rear oxygen sensor
Downstream oxy- • Engine speed less than • Rear oxygen sensor har-
P0037 gen sensor heater 6000RPM ness short to ground 04
control circuit open
• Engine detecting no rear • ECM
oxygen sensor signal
• Engine control system in
• Rear oxygen sensor
Downstream oxy- closed loop
• Rear oxygen sensor har-
gen sensor heater • Engine speed less than ness short to power sup-
P0038 6000RPM
control circuit short ply
to power supply • Engine detecting no rear
• ECM
oxygen sensor signal
• Engine control system in • Rear oxygen sensor
closed loop • Poor contact in the rear
Downstream oxy- • Engine speed less than oxygen sensor connec-
P0140 gen sensor circuit 6000RPM tor, the sensor harness
open circuit open
• Engine detecting no rear
oxygen sensor signal • ECM
• Engine control system in • Rear oxygen sensor
Implausible down- closed loop • Poor contact in the rear
stream oxygen • Engine speed less than oxygen sensor connec-
P0141 6000RPM tor, the sensor harness
sensor heating cir-
cuit • Engine detecting no rear circuit open
oxygen sensor signal • ECM
• Engine control system in • Rear oxygen sensor
closed loop • Poor contact in the rear
Downstream oxy- • Engine speed less than oxygen sensor connec-
P0136 gen sensor circuit 6000RPM tor, the sensor harness
open circuit open
• Engine detecting no rear
oxygen sensor signal • ECM
• Engine control system in • Rear oxygen sensor
closed loop • Poor contact in the rear
Downstream oxy- • Engine speed less than oxygen sensor connec-
P0137 gen sensor circuit 6000RPM tor, the sensor harness
short to ground circuit open
• Engine detecting no rear
oxygen sensor signal • ECM
• Rear oxygen sensor
Downstream oxy- • Engine control system in
closed loop • Poor contact in the rear
gen sensor circuit
P0138 oxygen sensor connec-
short to power • Engine speed less than
tor, the sensor harness
supply 6000RPM
circuit open
 04-72 Diagnosis - Engine Control System

DTC Code DTC Definition DTC Inspection Condition Fault Location

• Engine detecting no rear
• ECM
oxygen sensor signal

04 Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pins are broken, loose or rusted before measuring,
and then ensure good contact for the pins.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Help
• Closed loop voltage range of the oxygen sensor shown on the good tester
changes from 0.1V to 1.0V.
• Check the oxygen sensor harness for oxygen sensor may be improperly installed
and touch the exhaust pipe.
• Check the intermittent grounding of the harness between ECM and the sensor.
• Perform a balance test for the injector and check whether the blocked injector
will cause the mixture to become lean.
• Vacuum leakage for the crankcase causes the lean air-fuel ratio condition.
• Leakage of the exhaust manifold washer causes the outside air to enter the
exhaust pipe and pass the sensor.
• The three-way catalytic converter is broken.
Diagnostic Steps
Take LJ465 engine as an example

1. Read DTC on the tester.

(a) Start the engine and operate it to normal operating temperature.
(b) Identify DTC with the tester.
(c) Read the sensor data flows with a tester.
(d) Engine at idling.
Is the data displayed normal?
Yes> Refer to the intermittent fault inspection.
No> Go to next step.

2. Checking oxygen sensor signal circuit (Check whether there is open circuit)
 Diagnosis - Engine Control System 04-73

(a) Turn the ignition switch to OFF.

(b) Disconnect the oxygen sensor connector
E013.
(c) Turn the ignition switch to ON.
(d) Measure the voltage between the pin A and
A B C D B of the oxygen sensor connector E013.
04
Voltage: 0.45V

fpwx041035

Is the result normal?

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

3. Checking the voltage of oxygen sensor signal

(a) Turn the ignition switch to OFF.
(b) Connect the pin A of the oxygen sensor
connector E013 and the ground.
(c) Turn the ignition switch to ON.
(d) Measure the voltage between the pin A of the
oxygen sensor connector E013 and the
A B C D
ground.
Voltage: 0.45V

fpwx041038

Is the result normal?

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

4. Checking the harness and connector (Rear oxygen sensor- Engine ECM)
 04-74 Diagnosis - Engine Control System

(a) Turn the ignition switch to OFF.

(b) Disconnect the connector E001 of the ECM.
(c) Measure the resistance between the pin A
E001
and B of oxygen sensor connector E013 and
the terminal 73 and 48 of ECM connector
A B C D
E001.
04
48 73
Resistance: ＜2Ω

fpwx041039

Is the result normal?

Yes> Go to next step.
No> Replace or repair the oxygen sensor signal harness.

5. Checking the harness and connector (Rear oxygen sensor - Ground)

(a) Ignition switch: OFF.
(b) Disconnect the connector E001 of the engine ECM.
(c) Disconnect the rear oxygen sensor connector E0012.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there are short circuits)
Multimeter Connection Standard Value
E013(A) - Ground
A B C D ≥1MΩ
E013(B) - Ground

fpwx041040

Is the result normal?

Yes> Go to next step.
No> Replace or repair the oxygen sensor signal harness.

6. Check the power line of the oxygen sensor heating wire.

 Diagnosis - Engine Control System 04-75

(a) Turn the ignition switch to OFF, disconnect

the connector E013 of the rear oxygen sensor.
(b) Turn the ignition switch to ON.
(c) Measure the voltage between the pin D of the
oxygen sensor connector E013 and the
ground.
A B C D 04
Voltage: about 12V

fpwx041041

Is the result normal?

Yes> Go to next step.
No> Replace or repair the harness between the oxygen sensor and the main relay.

7. Check the control line of the oxygen sensor heating wire.

(a) Turn the ignition switch to OFF, disconnect
the connector E013 of the rear oxygen sensor.
(b) Disconnect the connector E001 of the ECM.
E001
(c) Measure the resistance between the pin C of
the oxygen sensor connector E013 and the
A B C D
ECM connector E001 pin 23.
23
StandardResistance:＜2Ω

fpwx041042

Is the result normal?

No> Repair or replace the harness and connector.
Yes> Go to next step.

8. Check the three-way catalytic converter for blockage or damage.

(a) Dismount the three-way catalytic converter.
(b) Check whether the three-way catalytic converter is intact with a flashlight.
Yes> Replace the three-way catalytic converter.
Yes> Go to next step.

9. Replacing the ECM

 04-76 Diagnosis - Engine Control System

(a) Replace the ECM.

(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.

04
P0324-Knock Control System Fault
P0325-Knock Sensor Fault
Instruction
Knock sensor(KS) which is installed between the
engine cylinder 3 and cylinder 4 is used to detect
the vibration of engine. When the engine vibrates,
it adjusts the ignition advance angle, and KS
generates a AC signal.
GND

fpwx041045

Circuit Diagram

Engine electronic Engine electronic Engine electronic

control module control module control module
E002 (4W10) E001 (4W12) E001 (LJ465)

KNOCK HI KNOCK LI KNOCK HI KNOCK LI KNOCK HI

KNOCK HI Shielding
B2 A4 37 36 37 36
G3

Green-
Green Green- Green Green- Green
white
white white

2 1 3 2 1 2 1

Knock sensor Knock sensor Knock sensor

E009 E009 E009

fpwx041044
 Diagnosis - Engine Control System 04-77

DTC DTC Definition DTC Inspection Condition Fault Location

• Water temperature is higher than • KS
80℃ • Poor contact in the KS
Konck system • Engine speed is higher than connector
P0325
faults 2,500RPM • KS harness short or 04
• ECM detects that the voltage of KS open
input signal is lower than 0.2V • ECM
• Water temperature is higher than
• KS
80℃
• Poor contact in the KS
Knock sensor • Engine speed is higher than connector
P0324
fault 2,500RPM
• KS harness short
• ECM detects that the KS input sig-
• ECM
nal is out of the specified range

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Steps
Take 4W12 engine as an example

1. Check the resistance of the knock sensor

(a) Turn the ignition switch to OFF.
(b) Disconnect the KS connector E009.
(c) Measure the resistance of the KS pin.
Standard Resistance
E009
Multimeter Connection Specified Condition
A B
E009(A)-E009(B)
E009(A)- Housing ＞1MΩ
E009(B)- Housing

fpwx041046

Is the result normal?

 04-78 Diagnosis - Engine Control System

Yes> Go to next step.

No> Replace the KS.

2. Check KS harness (check whether there is open-circuit between KS and ECM)

(a) Turn the ignition switch to OFF.
04 (b) Disconnect the connector E001 of the ECM.
(c) Measure the resistance of the pin of the KS
connector E009.
E009
E001 Standard Resistance
A B

37 36
Multimeter Connection Specified Condition
E009(A)-E001(36)
＜2Ω
E009(B)-E001(37)

fpwx041047

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness and connector.

3. Check KS harness (check whether there is short-circuit between KS and ECM)

(a) Measure the resistance between the pin of
the KS connector E009 and the ground.
Standard Resistance
E009 Multimeter Connection Specified Condition
E009(A)-Ground
A B
＞1MΩ
E009(B)- Ground

fpwx041048

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness and connector.

4. Check KS harness (check whether the harness between KS and ECM is shorted
to the power supply)
 Diagnosis - Engine Control System 04-79

(a) Turn the ignition switch to ON.

(b) Measure the voltage between the pin of the
KS connector E009 and the ground.
E009
Standard voltage

Multimeter Connection Specified Condition

A B 04
E009(A)-Ground
0V
V E009(B)- Ground

fpwx041049

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness and connector.

5. Replace with a good knock sensor.

(a) Check the knock sensor wave when the
engine is idling.
(b) Connect the tester and clear the trouble code.

fpwx041050

Is the DTC cleared?

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

6. Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester:
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.
P0335-Crankshaft Sensor Signal Circuit Open
P0336-No Signal for Crankshaft Sensor
P0373-Improper Crankshaft Sensor Signal
P1336-58X Crankshaft Position Tooth Error Not Learned
Instruction
 04-80 Diagnosis - Engine Control System

Crankshaft position(CKP) sensor generates 58X reference signal. ECM calculates engine
revolution with 58X reference signal. ECM keeps detecting pulses on the 58X reference
signal and makes a comparison with the received manifold pressure(MAP) signals. If ECM
receives wrong pulses on the 58X reference harness, DTCP0336, P0335, P0373 and P1336
will be set.
04
 Diagnosis - Engine Control System 04-81

Circuit Diagram

Engine electronic Engine electronic

control module control module
Signal high Signal low E001 (LJ465) E002 (4W10)
Signal high Signal low Power supply 5V Signal internal grounding
30 11 G3 H3 J1 C3 M2 04

Blue- Blue- Blue- Blue-

yellow white yellow white

Blue- White- Gray-

green yellow black
Black Black

A B C
A B C C A B

E201
Crankshaft position E201
Crankshaft position Crankshaft Position
sensor
sensor Sensor
E008
E008 E029

Engine electronic
control module
Signal high Signal low Power supply 5V Signal Internal ground wire E001 (4W12)
30 11 70 77 74

Blue- Blue-
yellow white

Brown- White- Gray-

green yellow black
Black

A B C C A B

Crankshaft Crankshaft
position sensor position sensor
E008 E029

E201
fpwx041052
 04-82 Diagnosis - Engine Control System

DTC Inspection
DTC Code DTC Definition Fault Location
Condition
• Ignition Switch: ON • CKP sensor
• ECM unable to • Poor contact in the
Crankshaft sensor receive signal CKP connector
P0335
04 signal circuit open • ECM received • CKP harness short
wrong signal or no or open
signal • ECM
• CKP sensor
• Poor contact in the
No signal for • ECM unable to CKP connector
P0336 receive signal
crankshaft sensor • CKP harness short
or open
• ECM
• CKP sensor
• Engine start-up • Poor contact in the
• ECM unable to CKP connector
Improper crankshaft receive signal • CKP harness short
P0373 or open
sensor signal • ECM received
wrong signal or no • Crankshaft signal
signal dial
• ECM
• Performing learning
program without a
tester
• CKP sensor
58X crankshaft • Poor contact in the
• ECM receiving
P1336 position tooth error CKP connector
unmatched signal
not learned • CKP harness short
or open
• Crankshaft signal
dial
• ECM

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.
 Diagnosis - Engine Control System 04-83

Diagnostic Steps
Take 4W12 engine as an example

1. Read DTC and CKP signal on the tester.

(a) Start the engine and operate it to normal operating temperature.
(b) Identify DTC with the tester. 04
(c) Read the sensor data flows with a tester.
(d) Engine runs at idle speed.
(e) Read the CKP sensor wave with a tester.
Is the result normal?
Yes> There is intermittent fault, please refer to Diagnostic Help.
No> Go to next step.

2. Check CKP signal with a oscilloscope

(a) Check CKP sensor signal wave with a
oscilloscope

fpwx041053

Is the result normal?

Yes> Clear the trouble codes.
No> Go to next step.

3. Check the resistance of CKP sensor

(a) Disconnect CKP sensor connector E008.
(b) Turn the ignition switch to OFF.
(c) Measure the resistance between the pin A
E008 and B of CKP sensor connector E008.
Resistance: 1000±100 Ω
C B A

fpwx041054

Is the result normal?

 04-84 Diagnosis - Engine Control System

No> Replace CKP sensor.

Yes> Go to next step.

4. Check CKP sensor harness (Check whether there are open or short circuits)
(a) Turn the ignition switch to OFF.
04 (b) Disconnect the ECM connector E001.
(c) Measure the resistance between CKP sensor
connector E008 and ECM connector E001.
E008 E001

Multimeter ConnectionSpecified Condition

30 11
C B A E008(A)-E001(30)
＜2Ω
E008(B)-E001(11)

fpwx041055

Is the result normal?

No> Repair or replace the harness and connector.
Yes> Go to next step.

5. Check whether CKP sensor harness is open or short to the ground

(a) Turn off the ignition switch, and disconnect
CKP sensor connector E008 and ECM
connector E001.
(b) Measure the resistance between CKP sensor
E008
connector E008 and the ground.
Standard resistance (Check whether there
C B A is short to ground)

Multimeter Connection Specified Condition

E008(A)-Ground
≥1MΩ
E008(B)- Ground

fpwx041056

Is the result normal?

No> Repair or replace the harness and connector.
Yes> Go to next step.

6. Replace the CKP on the vehicle with a good one

 Diagnosis - Engine Control System 04-85

(a) Check CKP sensor signal wave with a

oscilloscope

04

fpwx041053

Is the result normal?

No> Replace CKP sensor.
No> Go to next step.

7. Check CKP sensor harness (Check whether it is shorted to the power supply)
(a) Turn the ignition switch to ON.
(b) Measure the voltage between CKP sensor
connector E008and the ground.

E008
Standard voltage (Check whether there is
short to power supply)

Multimeter Connection Specified Condition

C B A
V E021(A) - Ground
0V
E021(B) - Ground

fpwx041057

Is the result normal?

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

8. Check CKP sensor signal dial

(a) Turn the ignition switch to OFF.
(b) Check 58X sensor signal gear for debris, oil
or foreign materials, signal dial for fixing
condition.
(c) Check the installation clearance of CKP
sensor.
Clearance: 0.3 - 1.5mm
fpwx041058

Is the result normal?

Yes> Go to next step.
 04-86 Diagnosis - Engine Control System

No> Remove all the foreign material and clean 58X sensor signal gear. If there is any
damage, please replace the 58X sensor signal dial.

9. Learn the 58X crankshaft position tooth error.

(a) Connect the diagnostic tester.
(b) Implement the tooth error learning program.
04
(c) Ensure there are no DTCs and the data are normal.
Is the system normal?
Yes> The system is normal.
No> Go to next step.

10 . Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.
P0341-Intake camshaft position sensor (CPS) signal implausible
P0017-Unreasonable correlation of crankshaft position and exhaust
camshaft position
P0016-Unreasonable correlation of crankshaft position and intake camshaft
position
P0014-Exhaust camshaft position offset in stable condition
P0011-Intake camshaft position offset in stable condition
P0365-Exhaust cam shaft position synchronizing signal implausible
P0340-Intake camshaft position synchronizing signal implausible
Instruction
The camshaft position sensor is also called synchronization signal sensor. It is a cylinder
location device which inputs camshaft position signal, the main signal for ignition control, to
the ECU. The camshaft position sensor of the 4W10/4W12 engine is installed on the intake
side to detect the intake and exhaust camshaft locations.
 Diagnosis - Engine Control System 04-87

Circuit Diagram

Engine electronic Engine electronic

control module control module
Signal high Signal low E001 (LJ465) E002 (4W10)
Signal high Signal low Power supply 5V Signal internal grounding
30 11 G3 H3 J1 C3 M2 04

Blue- Blue- Blue- Blue-

yellow white yellow white

Blue- White- Gray-

green yellow black
Black Black

A B C
A B C C A B

E201
Crankshaft position E201
Crankshaft position Crankshaft Position
sensor
sensor Sensor
E008
E008 E029

Engine electronic
control module
Signal high Signal low Power supply 5V Signal Internal ground wire E001 (4W12)
30 11 70 77 74

Blue- Blue-
yellow white

Brown- White- Gray-

green yellow black
Black

A B C C A B

Crankshaft Crankshaft
position sensor position sensor
E008 E029

E201
fpwx041052
 04-88 Diagnosis - Engine Control System

DTC Inspection
DTC DTC Definition Fault Location
Condition
• CPS
• Poor contact in the
• Ignition Switch: ON
CPS connector
• ECM unable to
04 Intake camshaft • Short or open
receive signal
P0341 position sensor (CPS) circuit in CPS
• ECM received
signal implausible harness
wrong signal or no
• Intake/exhaust cam
signal
shaft
• ECM
• CPS
• Poor contact in the
CPS connector
• Ignition Switch: ON
Unreasonable • Short or open
• ECM unable to
correlation of circuit in CPS
receive signal
P0017 crankshaft position harness
• ECM received
and exhaust camshaft • Intake/exhaust cam
wrong signal or no
position shaft
signal
• Crankshaft
• Timing Chain
• ECM
• CPS
• Poor contact in the
CPS connector
• Engine start-up
Unreasonable • Short or open
• ECM unable to
correlation of circuit in CPS
receive signal
P0016 crankshaft position harness
• ECM received
and intake camshaft • Intake/exhaust cam
wrong signal or no
position shaft
signal
• Crankshaft
• Timing Chain
• ECM
• CPS
• Poor contact in the
CPS connector
• Short or open
Exhaust camshaft circuit in CPS
• ECM receiving
P0014 position offset in harness
wrong signal
stable condition • Intake/exhaust cam
shaft
• Crankshaft
• Timing Chain
• ECM
 Diagnosis - Engine Control System 04-89

DTC Inspection
DTC DTC Definition Fault Location
Condition
• CPS
• Poor contact in the
CPS connector
• Short or open 04
Intake camshaft circuit in CPS
• ECM receiving
P0011 position offset in harness
wrong signal
stable condition • Intake/exhaust cam
shaft
• Crankshaft
• Timing Chain
• ECM
• CPS
• Poor contact in the
CPS connector
• Short or open
Exhaust cam shaft circuit in CPS
position • ECM receiving
P0365 harness
synchronizing signal wrong signal
• Intake/exhaust cam
implausible shaft
• Crankshaft
• Timing Chain
• ECM
• CPS
• Poor contact in the
CPS connector
• Short or open
Intake cam shaft circuit in CPS
position • ECM receiving
P0340 harness
synchronizing signal wrong signal
• Intake/exhaust cam
implausible shaft
• Crankshaft
• Timing Chain
• ECM
 04-90 Diagnosis - Engine Control System

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
04 • Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Steps
Take 4W12 engine as an example

1. Read DTC and CPS signal on the tester.

(a) Start the engine and operate it to normal operating temperature.
(b) Identify DTC with the tester.
(c) Read the sensor data flows with a tester.
(d) Engine is running idling.
(e) Read the CPS waveform with a tester.
Is the result normal?
Yes> Intermittent Faults, refer to the Diagnostic Help.
No> Go to next step.

2. Check CPS signal with a oscilloscope

(a) Check CPS signal waveform with a
oscilloscope

fpwx041053

Is the result normal?

Yes> Clear the trouble codes.
No> Go to next step.

3. Check the supply voltage of CPS

 Diagnosis - Engine Control System 04-91

(a) Disconnect CPD E029

(b) Turn the ignition switch to ON.
ON
(c) Measure the voltage of E029 terminal C
E029

A B C
04

fpwx041088

Standard voltage: about 5V

Is the result normal?
Yes> Go to step 6.
No> Go to next step.

4. Check CPS line (whether it is open-circuited or short-circuited)

(a) Turn the ignition switch to OFF.
(b) Disconnect the ECM connector E001 and the
CPS E029.
E029 (c) Measure the resistance between CPS
E001
connector E029 and ECM connector E001.
A B C
70 74 77
Multimeter ConnectionSpecified Condition
E029(A) - E001(77)
E029(B) -E001(74) ＜2Ω
E029(C) -E001(70)
fpwx041085

Is the result normal?

No> Repair or replace the harness and connector.
Yes> Go to next step.

5. Check whether CPS wire is shorted to the ground.

 04-92 Diagnosis - Engine Control System

(a) Turn off the ignition switch, and disconnect

CPS connector E029 and ECM connector
E001.
E029 (b) Measure the resistance between CPS
connector E029 and the grounding.
A B C Standard resistance (Check whether there
04
is short to ground)

Multimeter Connection Specified Condition

Ω

E029(A) - Ground
E029(B) - Ground ≥1MΩ
fpwx041086
E029(C) - Ground

Is the result normal?

No> Repair or replace the harness and connector.
Yes> Go to next step.

6. Replace the CPS on the vehicle with a good one

(a) Check CPS signal waveform with a
oscilloscope

fpwx041053

Is the result normal?

Yes> Replace the CPS.
No> Go to next step.

7. Check the CPS harness (for short circuit to power supply)

 Diagnosis - Engine Control System 04-93

(a) Turn the ignition switch to ON.

(b) Measure the voltage between the CPS
connector E029 and the ground.
E029 Standard voltage (Check whether there is
short to power supply)
A B C
Multimeter Connection Specified Condition 04

E029(A) - Ground
V E029(B) - Ground 0V
E029(C) - Ground

fpwx041087

Is the result normal?

No> Repair or replace the harness between the CPS and the ECM.
Yes> Go to next step.

8. Check the CPS signal dial

(a) Turn the ignition switch to OFF.
(b) Check the sensor's signal gear for debris, oil stains, foreign bodies and looseness.
(c) Check the installation clearance of the CPS.
Clearance: 0.3 - 1.5mm
Is the result normal?
Yes> Go to next step.
No> Clear all the foreign bodies; replace the damaged intake/exhaust camshaft (if any).

9. Conduct tooth error learning.

(a) Connect the diagnostic tester.
(b) Implement the tooth error learning program.
(c) Ensure there are no DTCs and the data are normal.
Is the system normal?
Yes> The system is normal.
No> Go to next step.

10 . Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.
P0691-Cooling Fan Relay Circuit 1 open
P0692-Cooling Fan Relay Circuit 1 Short to Power Supply
Instruction
 04-94 Diagnosis - Engine Control System

Cooling fan is used to cool the engine system and the condenser after A/C is turned on. The
fan is controlled by the signal sent by WTS to ECM. When the coolant temperature is high
(out of ECM set value), the high speed fan runs. When the coolant temperature is low (out
of ECM set value), the low speed fan runs. When A/C is on, the fan starts at low speed.
Circuit Diagram
04
Battery LJ465/4W12 engine system

Red
Red
F5
Fan fuse
25A Red-yellow Red-
Red yellow
Red Red
4 3
4 1 4 1
F20
Fuel pump fuse High-speed fan relay
Main relay 10A Low-speed
K8 fan relay
K2 K5
2 1
2 3 3 2

V035 Red-blue
Fuse relay box Red- Blue-
Blue- B green red
V103 black
7
E101 C V102
E101
8 7
Radiator fan E102
Purple- V103
V003
white
A

17 65
44 V202
Main relay control High-speed fan control Low-speed
fan control

E001Engine Control Module (ECM) fpwx041060

 Diagnosis - Engine Control System 04-95

Battery 4W10 engine system

Red
Red
F5
Fan fuse
Red- Red-
25A
yellow Red yellow
Red 04
Red
4 3
4 1 4 1
F20
Fuel pump fuse High-speed
Main relay 10A fan relay Low-speed
K8 fan relay
K2 K5
2 1
2 3 3 2

V035
Fuse relay box Red- Blue-
Red- B
Blue- green red
blue
V103 black
7
E101 C V102
E101
8 7
Radiator fan E102
Purple- V103
V003
white
A

K3 J3 V202 Q3
Main relay control High-speed fan control Low-speed
fan control

4W10 engine control module connector E002 fpwx041061

DTC Code DTC Definition DTC Inspection Condition Fault Location

• Low speed fan relay K5
• High speed fan relay K2
• Engine is running. • Open circuit between ECM
Cooling fan relay • ECM detects that there is and high/low speed fan re-
P0691 lay
circuit 1 open fault in the relay K2 or K5
drive harness for above 3s • Short or open circuit in
K5/K2 drive harness
• ECM
• Low speed fan relay K5
• Engine is running.
Cooling fan relay • High speed fan relay K2
• ECM detects that there is
P0692 circuit 1 short to • Short to the power supply in
fault in the relay K2 or K5
power supply K5/K2 drive harness
drive harness for above 3s
• ECM
 04-96 Diagnosis - Engine Control System

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
04 • Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Steps
Take LJ465 engine as an example

1. Perform a test (running the fan) with the tester.

(a) Connect the tester to DLC.
(b) Start the engine and operate it to normal operating temperature.
(c) Read the fan data flows with a tester.
Standard: the value changes

Tester Operation Specified Condition

Low speed fan: ON • The fan is running at low speed

Low speed fan: OFF • The fan does not run

High speed fan: ON • The fan is running at high speed

High speed fan: OFF • The fan does not run

Is the result normal?

Yes> There is intermittent fault, please refer to Diagnostic Help.
No> Go to next step.

2. Check the circuit from the fuel pump fuse F20 to the relay K5/K2.
(a) Unplug the low speed fan relay K5 and high
speed fan relay K2 from the fuse box.
(b) Turn the ignition switch to ON.
(c) Measure the voltage between the relay K2/K5
1
and the ground.
High-speed fan relay

1 2
Low-speed fan relay

K2 4 2
K5 3 V035 Standard resistance
3
4

Multimeter Connection Specified Condition

K2(4)–Ground
Approximately 12V
V
K5(1)–Ground

fpwx041065
 Diagnosis - Engine Control System 04-97

Is the result normal?

No> Repair or replace the harness and connector. Replace the fuse box as necessary.
Yes> Go to next step.

3. Check the conduction between the high/low speed fan relay and ECM.
04
(a) Unplug the low speed fan relay K5 and high
speed fan relay K2 from the fuse box.
(b) Disconnect the ECM connector E001.
(c) Check the resistance between the high/low
speed fan relay and ECM.
High-speed fan relay

Low-speed fan relay

1 1 2
K2 4 2
K5 3 V035 E001
3
4
Standard resistance

17 65
Multimeter Connection Specified Condition
K5(2)–E001(65)
＜2Ω
Ω
K2(2)–E001(17)

fpwx041064

Is the result normal?

No> Repair or replace the harness and connector.
Yes> Go to next step.

4. Check whether the circuit between the high/low speed fan relay and ECM is short
to power supply.
(a) Unplug the low speed fan relay K5 and high
speed fan relay K2 from the fuse box.
(b) Disconnect the ECM connector E001.
(c) Turn the ignition switch to ON.
E001 (d) Measure the voltage between ECM pin 65
and 17 and the ground.
65 17
Standard voltage

Multimeter Connection Specified Condition

E001(65)-Ground
V
0V
E001(17)-Ground

fpwx041066

Is the result normal?

No> Repair or replace the harness.
Yes> Go to next step.

5. Check the relay K5 and K2.

 04-98 Diagnosis - Engine Control System

(a) Unplug the low speed fan relay K5 and high speed fan relay K2 from the fuse box.
(b) Unplug the front fog light relay K7 and horn relay K6 from the fuse box.
(c) Replace K5and K2 with K6 and K7
Check whether the fault is eliminated.
Yes> Replace K5/K2
04 No> Go to next step.

6. Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.
P0201-1-Cylinder injector fault
P0202-2-Cylinder injector fault
P0203-3-Cylinder injector fault
P0204-4-Cylinder injector fault
P0261-1-Cylinder injector short to ground
P0267-2-Cylinder injector short to ground
P0270-3-Cylinder injector short to ground
P0264-4-Cylinder injector short to ground
P0262-1-Cylinder injector short to power supply
P0268-2-Cylinder injector short to power supply
P0271-3-Cylinder injector short to power supply
P0265-4-Cylinder injector short to power supply
Instruction
Injector is a solenoid valve. When current passes through the electromagnetic coil, it produces
attractive force, so the valve is sucked, orifice opens and the fuel sprays in high speed through
the top of the valve.
 Diagnosis - Engine Control System 04-99

Circuit Diagram

LJ465/4W12 engine system

Battery
04

Red
Purple

Yellow

E102
12 E101
V102 1
V103

Red Red

4 1
F21 F22
Ignition Fuel injector/
Main relay coil fuse oxygen sensor fuse
15A 10A
V035

2 3

Yellow Yellow Yellow Yellow Yellow

V103 A A A A B
7
Canister Ignition
E101 Fuel Fuel Fuel Fuel solenoid coil
injector1 injector2 injector3 injector4 valve E014
E004 E005 E006 E007 E016 A B C
B B B B A
Purple-
white Red- Purple Red-
Blue- Red- Blue- Blue- Green- green yellow
white yellow black red brown

44 6 8 7 25 64 4 1
Main relay Fuel injection control Fuel injection control Fuel injection control Fuel injection control Carbon canister control 1, 4 cylinder control 2, 3 cylinder control
control

E001 Engine electronic control module

fpwx041067
 04-100 Diagnosis - Engine Control System

4W10 engine system

Battery

04

Red
Purple

Yellow

E102
12 E101
V102 1
V103

Red Red

4 1
F21 F22
Ignition Fuel injector/
Main relay coil fuse oxygen sensor fuse
15A 10A
V035

2 3

Yellow Yellow Yellow Yellow Yellow

V103 A A A A B
7
Canister Ignition
E101 Fuel Fuel Fuel Fuel solenoid coil
injector1 injector2 injector3 injector4 valve E014
E004 E005 E006 E007 E016 A B C
B B B B A
Purple-
white Red- Purple Red-
Blue- Red- Blue- Blue- Green- gree yellow
white yellow black red brown

K3 L4 K4 M4 M3 Q2 H4 H2
Main relay Fuel injection Fuel injection control Fuel injection control Fuel injection control Carbon canister 1, 4 cylinder 2, 3 cylinder
control control control control E003 control
E002

Engine electronic control module

fpwx041068

DTC Code DTC Definition DTC Inspection Condition Fault Location

1-cylinder injector
P0201 • Engine running time > 0.5s • Fuel injector A
fault
 Diagnosis - Engine Control System 04-101

DTC Code DTC Definition DTC Inspection Condition Fault Location

• Feul pump works normally • Fuel injector har-
• Duration > 5s, no working signal ness
for injectors is detected • ECM
04
• Engine running time > 0.5s • Fuel injector A
2-cylinder injector • Feul pump works normally • Fuel injector har-
P0202 ness
fault • Duration > 5s, no working signal
for injectors is detected • ECM
• Engine running time > 0.5s • Fuel injector A
3-cylinder injector • Feul pump works normally • Fuel injector har-
P0203 ness
fault • Duration > 5s, no working signal
for injectors is detected • ECM
• Engine running time > 0.5s • Fuel injector A
4-cylinder injector • Feul pump works normally • Fuel injector har-
P0204 ness
fault • Duration > 5s, no working signal
for injectors is detected • ECM
• Engine running time > 0.5s • Fuel injector A
1-cylinder injector • Feul pump works normally • Fuel injector har-
P0261 circuit short to ness
• Duration > 0.5s, the injector
ground
keeps working • ECM
• Engine running time > 0.5s • Fuel injector A
2-cylinder injector • Feul pump works normally • Fuel injector har-
P0267 circuit short to ness
• Duration > 0.5s, the injector
ground
keeps working • ECM
• Engine running time > 0.5s • Fuel injector A
3-cylinder injector • Feul pump works normally • Fuel injector har-
P0270 circuit short to ness
• Duration > 0.5s, the injector
ground
keeps working • ECM
• Engine running time > 0.5s • Fuel injector A
4-cylinder injector • Feul pump works normally • Fuel injector har-
P0264 circuit short to ness
• Duration > 5s, no working signal
ground
for injectors is detected • ECM
• Engine running time > 0.5s • Fuel injector A
1-cylinder injector • Feul pump works normally • Fuel injector har-
P0262 circuit short to ness
• Duration > 5s, no working signal
power supply
for injectors is detected • ECM
• Engine running time > 0.5s • Fuel injector A
2-cylinder injector • Feul pump works normally • Fuel injector har-
P0268 circuit short to ness
• Duration > 5s, no working signal
power supply
for injectors is detected • ECM
 04-102 Diagnosis - Engine Control System

DTC Code DTC Definition DTC Inspection Condition Fault Location

• Engine running time > 0.5s • Fuel injector A
3-cylinder injector • Feul pump works normally • Fuel injector har-
P0271 circuit short to ness
• Duration > 5s, no working signal
power supply
04 for injectors is detected • ECM
• Engine running time > 0.5s • Fuel injector A
4-cylinder injector • Feul pump works normally • Fuel injector har-
P0265 circuit short to ness
• Duration > 5s, no working signal
power supply
for injectors is detected • ECM

Note

• Make sure ECM is properly grounded before performing the following steps.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Steps

1. Check the resistance of fuel injector A

(a) Turn the ignition switch to OFF.
(b) Disconnect the connector E004 of the injector
1.
(c) Measure the resistance between the pin A
E004/E005/E006/E007
and B of the fuel injector 1.
A B Coil resistance: 12Ω±0.6Ω

fpwx041069

Is the result normal?

Yes> Go to next step.
No > Replace fuel injector 1.

2. Check the resistance between the fuel injector 1 and ECM.

 Diagnosis - Engine Control System 04-103

(a) Turn the ignition switch to OFF.

(b) Disconnect the connector E001 of the ECM.
(c) Measure the resistance of the injector E004
E004 E001
terminal A and the engine E001terminal 6.
Standard Resistance
A B
Multimeter Connection Specified Condition 04
6

E004(A)-E001(6) ＜2Ω

fpwx041070

Is the result normal?

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

3. Check whether the injector 1 harness is shorted to power supply

(a) Disconnect the connector E004 of the injector
1.
(b) Turn the ignition switch to ON.
(c) Measure the voltage between the pin B of the
E004
fuel injector 1 connector E004 and the ground.
A B Standard Voltage

Multimeter Connection Specified Condition

V
E004(B)- Ground 0V

fpwx041071

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

4. Check the voltage of the injector 1 power line

 04-104 Diagnosis - Engine Control System

(a) Turn the ignition switch to ON.

(b) Measure the voltage between the pin A of the
fuel injector 1 connector E004 and the ground.
E004
Standard Voltage

A B
Multimeter Connection Specified Condition
04
E004(A)-Ground Battery voltage

fpwx041072

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

5. Replace the ECM.

(a) Replace the ECM.
(b) Identify the DTC with a tester.
(c) Read the sensor data flows.
(d) Ensure no DTC and the data normal.
P0443-Canister solenoid valve fault
P0444-Canister control valve circuit open
P0458-Canister control valve circuit short to ground
P0459- Canister control valve circuit short to power supply
Instruction
Canister solenoid valve opens after it receives ECM signal. It takes in air from the canister
inlet with manifold vacuum and then the canister gets desorption.
 Diagnosis - Engine Control System 04-105

Circuit Diagram

LJ465/4W12 engine system

Battery
04

Red
Purple

Yellow

E102
12 E101
V102 1
V103

Red Red

4 1
F21 F22
Ignition Fuel injector/
Main relay coil fuse oxygen sensor fuse
15A 10A
V035

2 3

Yellow Yellow Yellow Yellow Yellow

V103 A A A A B
7
Canister Ignition
E101 Fuel Fuel Fuel Fuel solenoid coil
injector1 injector2 injector3 injector4 valve E014
E004 E005 E006 E007 E016 A B C
B B B B A
Purple-
white Red- Purple Red-
Blue- Red- Blue- Blue- Green- green yellow
white yellow black red brown

44 6 8 7 25 64 4 1
Main relay Fuel injection control Fuel injection control Fuel injection control Fuel injection control Carbon canister control 1, 4 cylinder control 2, 3 cylinder control
control

E001 Engine electronic control module

fpwx041067
 04-106 Diagnosis - Engine Control System

4W10 engine system

Battery

04

Red
Purple

Yellow

E102
12 E101
V102 1
V103

Red Red

4 1
F21 F22
Ignition Fuel injector/
Main relay coil fuse oxygen sensor fuse
15A 10A
V035

2 3

Yellow Yellow Yellow Yellow Yellow

V103 A A A A B
7
Canister Ignition
E101 Fuel Fuel Fuel Fuel solenoid coil
injector1 injector2 injector3 injector4 valve E014
E004 E005 E006 E007 E016 A B C
B B B B A
Purple-
white Red- Purple Red-
Blue- Red- Blue- Blue- Green- gree yellow
white yellow black red brown

K3 L4 K4 M4 M3 Q2 H4 H2
Main relay Fuel injection Fuel injection control Fuel injection control Fuel injection control Carbon canister 1, 4 cylinder 2, 3 cylinder
control control control control E003 control
E002

Engine electronic control module

fpwx041068

DTC Code DTC Definition DTC Inspection Condition Fault Location

Canister solenoid • Canister solenoid har-
P0443 • Engine running time > 0.5s
valve fault ness open or short
 Diagnosis - Engine Control System 04-107

DTC Code DTC Definition DTC Inspection Condition Fault Location

• System voltage between
• Canister solenoid valve
11V and 16V
• ECM
• Duration > 5s
04
• Engine running time > 0.5s • Canister solenoid har-
Canister solenoid • System voltage between ness open or short
P0444 11V and 16V • Canister solenoid valve
valve harness open
• Duration > 5s • ECM
• Engine running time > 0.5s • Canister solenoid har-
Canister control • System voltage between ness open or short
P0458 valve circuit short to 11V and 16V • Canister solenoid valve
ground
• Duration > 5s • ECM
• Engine running time > 0.5s • Canister solenoid har-
Canister control • System voltage between ness open or short
P0459 valve circuit short to 11V and 16V • Canister solenoid valve
power supply
• Duration > 5s • ECM

Note

• Make sure ECM is properly grounded before performing the following steps.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Steps
Take LJ465 engine as an example

1. Check the canister solenoid valve resistance

 04-108 Diagnosis - Engine Control System

(a) Turn the ignition switch to OFF.

(b) Disconnect the connector E016 of the canister
solenoid valve.
E016 (c) Measure the resistance between the pin A
and B of the canister solenoid valve.
04 A B Impedance: 19～22Ω

fpwx041075

Is the result normal?

Yes> Go to next step.
No> Replace the canister solenoid valve.

2. Check the resistance between the canister solenoid valve and ECM.
(a) Turn the ignition switch to OFF.
(b) Disconnect the connector E001 of the ECM.
(c) Measure the resistance between the terminal
E016 E001
A of the canister solenoid valve connector
E016 and the terminal 64 of the engine control
module E001.
A B
64
Standard resistance

Multimeter Connection Specified Condition

E016(A)-E001(64) ＜2Ω

fpwx041076

Is the result normal?

Yes> Go to next step.
No> Replace the canister solenoid valve harness.

3. Check whether the control line of the canister solenoid valve is short to the
power supply or not.
 Diagnosis - Engine Control System 04-109

(a) Disconnect the connector E016 of the canister

solenoid valve and E001 of the ECM.
(b) Turn the ignition switch to ON.
E016 (c) Measure the voltage between the pin A of the
canister solenoid valve connector E016 and
B
the ground.
A
04
Standard voltage

Multimeter Connection Specified Condition

V

E016(A)-Ground 0V

fpwx041077

Is the result normal?

Yes> Go to next step.
No> Replace the canister solenoid valve harness.

4. Check the power line voltage of the canister solenoid valve.

(a) Turn the ignition switch to ON.
(b) Disconnect the connector E016 of the canister
solenoid valve.
E016 (c) Measure the voltage between the pin B of the
canister solenoid valve connector E016 and
B
the ground.
A

Standard voltage

Multimeter Connection Specified Condition

V

E016(B)-Ground Battery voltage

fpwx041078

Is the result normal?

Yes> Go to next step.
No> Replace the harness between the canister solenoid valve and fuel injector F22
fuse, and replace the fuse box if necessary.

5. Replace the ECM.

(a) Replace the ECM.
(b) Identify the DTC with a tester.
(c) Read the sensor data flows.
(d) Ensure no DTC and the data normal.
 04-110 Diagnosis - Engine Control System

P0351-1-cylinder ignition coil open circuit

P0352-4-cylinder ignition coil open circuit
P0353-2-cylinder ignition coil open circuit
P0354-3-cylinder ignition coil open circuit
P2300-1-cylinder ignition coil short to ground
04 P2306-2-cylinder ignition coil short to ground
P2309-3-cylinder ignition coil short to ground
P2303-4-cylinder ignition coil short to ground
P2301-1-cylinder ignition coil short to power supply
P2307-2-cylinder ignition coil short to power supply
P2310-3-cylinder ignition coil short to power supply
P2304-4-cylinder ignition coil short to power supply
P0301-Misfire 0(1-cylinder)
P0303-Misfire 1(2-cylinder)
P0304-Misfire 2(3-cylinder)
P0302-Misfire 3(4-cylinder)
P0313-Misfire caused by low fuel level
P0300-Multiple misfires
P0318-Misfire detected on rough road
Instruction
The present system adopts a group injection method. The ignition coil is composed of two
sets of coils. Each of them provides ignition energy for two cylinder spark plugs which have
a difference of 360° in crankshaft angle to each other. The installation location: above the
timing belt housing.
 Diagnosis - Engine Control System 04-111

Circuit Diagram

LJ465/4W12 engine system

Battery
04

Red
Purple

Yellow

E102
12 E101
V102 1
V103

Red Red

4 1
F21 F22
Ignition Fuel injector/
Main relay coil fuse oxygen sensor fuse
15A 10A
V035

2 3

Yellow Yellow Yellow Yellow Yellow

V103 A A A A B
7
Canister Ignition
E101 Fuel Fuel Fuel Fuel solenoid coil
injector1 injector2 injector3 injector4 valve E014
E004 E005 E006 E007 E016 A B C
B B B B A
Purple-
white Red- Purple Red-
Blue- Red- Blue- Blue- Green- green yellow
white yellow black red brown

44 6 8 7 25 64 4 1
Main relay Fuel injection control Fuel injection control Fuel injection control Fuel injection control Carbon canister control 1, 4 cylinder control 2, 3 cylinder control
control

E001 Engine electronic control module

fpwx041067
 04-112 Diagnosis - Engine Control System

4W10 engine system

Battery

04

Red
Purple

Yellow

E102
12 E101
V102 1
V103

Red Red

4 1
F21 F22
Ignition Fuel injector/
Main relay coil fuse oxygen sensor fuse
15A 10A
V035

2 3

Yellow Yellow Yellow Yellow Yellow

V103 A A A A B
7
Canister Ignition
E101 Fuel Fuel Fuel Fuel solenoid coil
injector1 injector2 injector3 injector4 valve E014
E004 E005 E006 E007 E016 A B C
B B B B A
Purple-
white Red- Purple Red-
Blue- Red- Blue- Blue- Green- gree yellow
white yellow black red brown

K3 L4 K4 M4 M3 Q2 H4 H2
Main relay Fuel injection Fuel injection control Fuel injection control Fuel injection control Carbon canister 1, 4 cylinder 2, 3 cylinder
control control control control E003 control
E002

Engine electronic control module

fpwx041068

DTC DTC Definition DTC Inspection Condition Fault Location

1-cylinder ignition
P0351 • Engine running • Ignition coil
coil open circuit
 Diagnosis - Engine Control System 04-113

DTC DTC Definition DTC Inspection Condition Fault Location

• Abnormal voltage at primary • Ignition system harness
ignition coil circuit detected open circuit or short circuit
by ECM • ECM
04
• Engine running • Ignition coil
4-cylinder ignition • Abnormal voltage at primary • Ignition system harness
P0352 open circuit or short circuit
coil open circuit ignition coil circuit detected
by ECM • ECM

• Engine running • Ignition coil

2-cylinder ignition • Abnormal voltage at primary • Ignition system harness
P0353 open circuit or short circuit
coil open circuit ignition coil circuit detected
by ECM • ECM

• Engine running • Ignition coil

3-cylinder ignition • Abnormal voltage at primary • Ignition system harness
P0354 open circuit or short circuit
coil open circuit ignition coil circuit detected
by ECM • ECM

• Engine running • Ignition coil

1-cylinder ignition • Abnormal voltage at primary • Ignition system harness
P2300 open circuit or short circuit
coil short to ground ignition coil circuit detected
by ECM • ECM

• Engine running • Ignition coil

2-cylinder ignition • Abnormal voltage at primary • Ignition system harness
P2306 open circuit or short circuit
coil short to ground ignition coil circuit detected
by ECM • ECM

• Engine running • Ignition coil

3-cylinder ignition • Abnormal voltage at primary • Ignition system harness
P2309 open circuit or short circuit
coil short to ground ignition coil circuit detected
by ECM • ECM

• Engine running • Ignition coil

4-cylinder ignition • Abnormal voltage at primary • Ignition system harness
P2303 open circuit or short circuit
coil short to ground ignition coil circuit detected
by ECM • ECM

• Engine running • Ignition coil

1-cylinder ignition
• Abnormal voltage at primary • Ignition system harness
P2310 coil short to power open circuit or short circuit
ignition coil circuit detected
supply
by ECM • ECM

• Engine running • Ignition coil

1-cylinder ignition
• Abnormal voltage at primary • Ignition system harness
P2301 coil short to power open circuit or short circuit
ignition coil circuit detected
supply
by ECM • ECM
 04-114 Diagnosis - Engine Control System

DTC DTC Definition DTC Inspection Condition Fault Location

• Engine running • Ignition coil
Misfire 1 (2-cylin- • Abnormal voltage at primary • Ignition system harness
P0303 open circuit or short circuit
der) ignition coil circuit detected
04 by ECM • ECM

• Engine running • Ignition coil

Misfire 3 (4-cylin- • Abnormal voltage at primary • Ignition system harness
P0302 open circuit or short circuit
der) ignition coil circuit detected
by ECM • ECM

• Engine running • Ignition coil

Misfire at low fuel • Abnormal voltage at primary • Ignition system harness
P0313 open circuit or short circuit
level ignition coil circuit detected
by ECM • ECM

• Engine running • Ignition coil

• Abnormal voltage at primary • Ignition system harness
P0300 Multiple misfires open circuit or short circuit
ignition coil circuit detected
by ECM • ECM

• Engine running • Ignition coil

Misfire at rough • Abnormal voltage at primary • Ignition system harness
P0318 open circuit or short circuit
road test ignition coil circuit detected
by ECM • ECM

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Steps

1. Check the spark plug

(a) Disconnect the ignition coil connector E014.
(b) Dismantle the spark plug.
(c) Check the spark plug for carbon deposit or severe ablation.
Yes> Replace the spark plug
No> Go to the next step

2. Checking the power supply for the ignition coil

 Diagnosis - Engine Control System 04-115

(a) Disconnect the ignition coil connector E014.

(b) Turn the ignition switch to ON.
E014
(c) Measure the voltage between pin B of the
ignition coil E014 and the ground.
Standard voltage: about 12V
C B A
04

fpwx041102

Is the result normal?

No> Repair the power supply circuit of the ignition coil.
Yes> Go to the next step.

3. Check the conduction between the ignition coil and ECM.

(a) Turn the ignition switch to OFF.
(b) Disconnect ECM connector E001 and the
ignition coil connector E014.
E014
E001
(c) Measure the resistance between the ignition
coil and the pins of E001.
Standard resistance
C B A 4 1

Multimeter Connection Specified Condition

E014(A) - E001(4)
＜2Ω
E014(C) - E001(1)

fpwx041105

Is the result normal?

Yes> Go to next step.
No> Replace the ignition coil A circuit.

4. Check whether the ignition coil harness is shorted to the power supply.
 04-116 Diagnosis - Engine Control System

(a) Disconnect the ignition coil connector E014

and ECM connector E001.
(b) Turn the ignition switch to ON.
E014
(c) Measure the voltage between the pin C & pin
A of the ignition coil connector E014 and the
ground.
04 C B A
Standard voltage

Multimeter Connection Specified Condition

E014(A) - Ground
0V
V E014(C) - Ground

fpwx041103

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness and connector.

5. Check whether the ignition coil harness is shorted to the ground.

(a) Disconnect the ignition coil connector E014
and ECM connector E001.
(b) Turn the ignition switch to OFF.
E014
(c) Measure the resistance between the pin C &
pin A of the ignition coil connector E014 and
the ground.
C B A
Standard voltage

Multimeter Connection Specified Condition

E014(A) - Ground
greater than 1MΩ
Ω E014(C) - Ground

fpwx041104

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness and connector.

6. Replace the ignition coil with a good one.

Check whether the fault is eliminated.
Yes> Replace the ignition coil.
No> Go to next step

7. Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester.
 Diagnosis - Engine Control System 04-117

(c) Read the sensor data flows.

(d) Ensure there are no DTCs and the data are normal.

P2009–Variable intake solenoid valve circuit open or low voltage

P2010–Variable intake solenoid valve circuit high voltage
Instruction 04

For the variable intake solenoid valve, thin and long inlets make the engine idling stability
while short and thick inlets help improve engine power in high load or speed (The longer the
intake manifold is, the lower vibrating frequency of air in the intake manifold becomes, and
vice verse.) There is a flap to switch between long and short inlets in the intake manifold.
Long inlets are used at idle or under part load condition. The variable intake solenoid valve
opens in heavy load, when the low pressure air in the inlet comes to the right side of the
aneroid chamber while the left side of the aneroid chamber is open to the atmosphere. In
this way, pressure difference is formed. So the flap can rotate to switch the long inlet into
the short inlet which helps reduce air intake resistance and improve air intake efficiency.
Installation position: near the right side of intake manifold.
Circuit Diagram
4W10 engine system
Battery

Red E101
Yellow
1
V103 A
Red Red
Variable intake
4 1 solenoid valve
F22 E031
Fuel injector/
Main relay oxygen sensor fuse B
10A

2 3

Linear EGR valve E030 Gray-green

V103
7
E101

6 2 3 1 4
Purple-
white Green Gray- White- Blue-
black blue purple
K3 J4 H2 G1 F4 N3
control Linear EGR valve Grounding Feedback E003 Power supply control line E002 Engine electronic
control signal control module
E002 E002
E003
fpwx041090
 04-118 Diagnosis - Engine Control System

4W12 engine system

Battery

Red E101
Yellow
1
V103 A
Red Red
Variable intake
04 4 1 solenoid valve
F22 E031
Fuel injector/
Main relay oxygen sensor fuse B
10A

2 3

Linear EGR valve E030 Gray-green

V103
7
E101

6 2 3 1 4
Purple-
white Green Gray- White- Blue-
black blue purple
44 22 74 55 70 43
Control Linear EGR Grounding EGRFeedback Power supply control line
valve control signal Engine electronic
control module
E001
fpwx041091

DTC Inspection
DTC DTC Definition Fault Location
Condition
• Variable intake
solenoid valve
• Variable intake
• Engine running
solenoid valve
• ECM unable to
Variable intake connector bad
detect reasonable
P2009 solenoid valve line connected.
voltage in the
open or low voltage • Variable intake
control end of the
solenoid valve
solenoid valve.
circuit short or
open.
• ECM
• Variable intake
solenoid valve
• Engine running • Variable intake
• ECM unable to solenoid valve
Variable intake
detect reasonable connector bad
P2010 solenoid valve circuit
voltage in the connected.
high voltage
control end of the • Variable intake
solenoid valve. solenoid valve
circuit short or
open.
 Diagnosis - Engine Control System 04-119

DTC Inspection
DTC DTC Definition Fault Location
Condition
• ECM

Note
04
• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Steps
Take 4W12 engine as an example

1. Check the power line of the variable intake solenoid valve

(a) Disconnect the connector E031 of the variable
intake solenoid valve.
(b) Turn the ignition switch to ON.
E031 (c) Measure the voltage between E031 terminal
A and the reliable ground.
Standard voltage: about 12V
A B

fpwx041100

Is the result normal?

No> Repair the power line of the variable intake solenoid valve
Yes> Go to next step.

2. Check the control line of the variable intake solenoid valve

(a) Disconnect the connector E031 of the variable intake solenoid valve and ECM connector
E001.
(b) Turn the ignition switch to ON.
(c) Measure the voltage between E031 terminal B and the reliable ground.
Standard voltage: 0V
(d) Measure the resistance between E031 terminal B and the reliable ground.
 04-120 Diagnosis - Engine Control System

Standard resistance: >1MΩ

(e) Measure the resistance between E031 terminal B and E001 terminal 43.
Standard resistance: < 2Ω
Is the result normal?
04 No> Repair or replace the harness.
Yes> Go to next step.

3. Replace the variable intake solenoid valve on the vehicle with a good variable
intake solenoid valve
(a) Connect the tester to clear the trouble code.
Is the system normal? Is the fault eliminated?
Yes> Replace the variable intake solenoid valve
No> Go to next step.

4. Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.
P0405-EGR Position Sensor Circuit Low Voltage Fault
P0406-EGR Position Sensor Circuit High Voltage Fault
P1404-EGR Closed Position Improper
P0401-EGR Flow Insufficient
P0402-EGR Flow Excessive
P0403-EGR Control Circuit Fault
P0404-EGR Open Position Improper
Instruction
Exhaust Gas Recirculation is a kind of technology (technique or method) which is used in
small internal combustion engine in order to separate some exhaust gas and makes it reenter
the inlet pipe to burn again. It is mainly use to reduce NOx in the exhaust gas and improve
fuel combustion efficiency when sharing part of load. Generally, it is known as EGR, the
abbreviation of the exhaust gas recirculation.
 Diagnosis - Engine Control System 04-121

Circuit Diagram
4W10 engine system
Battery

Red E101
Yellow
1
V103 A
Red Red 04
Variable intake
4 1 solenoid valve
F22 E031
Fuel injector/
Main relay oxygen sensor fuse B
10A

2 3

Linear EGR valve E030 Gray-green

V103
7
E101

6 2 3 1 4
Purple-
white Green Gray- White- Blue-
black blue purple
K3 J4 H2 G1 F4 N3
control Linear EGR valve Grounding Feedback E003 Power supply control line E002 Engine electronic
control signal control module
E002 E002
E003
fpwx041090

4W12 engine system

Battery

Red E101
Yellow
1
V103 A
Red Red
Variable intake
4 1 solenoid valve
F22 E031
Fuel injector/
Main relay oxygen sensor fuse B
10A

2 3

Linear EGR valve E030 Gray-green

V103
7
E101

6 2 3 1 4
Purple-
white Green Gray- White- Blue-
black blue purple
44 22 74 55 70 43
Control Linear EGR Grounding EGRFeedback Power supply control line
valve control signal Engine electronic
control module
E001
fpwx041091
 04-122 Diagnosis - Engine Control System

DTC Inspection
DTC DTC Definition Fault Location
Condition
• EGR Valve
• Poor contact in the
• Engine running
EGR valve
• EGR valve position
04 P0401 EGR flow insufficient connector
signal excessively
• EGR harness short
low
or open
• ECM
• EGR Valve
• Poor contact in the
• Engine running
EGR valve
• EGR valve position
P0402 EGR flow excessive connector
signal excessively
• EGR harness short
high
or open
• ECM
• EGR Valve
• Engine start-up • Poor contact in the
• ECM unable to EGR valve
EGR control circuit receive signal connector
P0403
fault
• ECM received • EGR harness short
wrong signal or open
• ECM
• EGR Valve
• ECM receiving • Poor contact in the
wrong signal EGR valve
EGR open position connector
P0404 • EGR valve position
improper
signal excessively • EGR harness short
high or low or open
• ECM
• EGR Valve
• Poor contact in the
• ECM receiving no
EGR position sensor EGR valve
EGR position signal
P0405 circuit low voltage connector
• ECM receiving
fault • EGR harness short
wrong signal
or open
• ECM
• EGR Valve
• Poor contact in the
• ECM receiving no
EGR position sensor EGR valve
EGR position signal
P0406 circuit high voltage connector
• ECM receiving
fault • EGR harness short
wrong signal
or open
• ECM
 Diagnosis - Engine Control System 04-123

DTC Inspection
DTC DTC Definition Fault Location
Condition
• EGR Valve
• Poor contact in the
• Ignition switch ON EGR valve
EGR closed position connector
P1404 • ECM receiving 04
improper
wrong signal • EGR harness short
or open
• ECM

Note

• Ensure ECM is well connected to the ground before performing the following
procedures.
• Refer to the circuit diagrams and components information when performing
electronic diagnosis and test.
• Check whether the connector pin is broken, loose or rusted before measuring,
and then ensure its good contact.
• If it well connects, check the signal voltage of the sensor when moving the
connector and harness. If fault occurs, the voltage in the tester will change.

Diagnostic Steps
Take 4W12 engine as an example

1. Check the power line of EGR valve

(a) Disconnect the EGR valve connector E030.
(b) Turn the ignition switch to ON.
(c) Measure the voltage between E030 terminal
4 and the reliable ground.
E030
Standard voltage: about 12V
1 3

4 6

fpwx041092

Is the result normal?

No> Repair the power line of EGR valve
Yes> Go to next step.

2. Check the control line of EGR valve

(a) Disconnect EGR connector E030 and ECM connector E001.
 04-124 Diagnosis - Engine Control System

(b) Turn the ignition switch to ON.

(c) Measure the voltage between E030 terminal 6 and the reliable ground.
Standard voltage: 0V
(d) Measure the resistance between E030 terminal 6 and the reliable ground.
Standard resistance: >1MΩ
04
(e) Measure the resistance between E030 terminal 6 and E001 terminal 22.
Standard resistance: < 2Ω
Is the result normal?
No> Repair or replace the harness.
Yes> Go to next step.

3. Check the conduction of the harness between the EGR valve position sensor
and ECM.
(a) Turn the ignition switch to OFF.
(b) Disconnect ECM connector E001 and EGR
valve connector E030.
E030
E001
(c) Measure the resistance between ECM
connector E001 and EGR valve connector
1 2 3 E030.
4 6
55 47 70

Multimeter ConnectionSpecified Condition

E030(2) - E001(47)
E030(3) - E001(55) ＜2Ω
E030(1) - E001(70)
fpwx041095

Is the result normal?

No> Repair or replace the harness and connector.
Yes> Go to next step.

4. Check whether EGR valve harness is shorted to the ground.

 Diagnosis - Engine Control System 04-125

(a) Turn off the ignition switch, and disconnect

EGR valve connector E030 and ECM
connector E001.
E030
(b) Measure the resistance between E030
terminal 1, 2, 3 and the ground.
1 2 3
Standard resistance (Check whether there
4 6 04
is short to ground)

Multimeter Connection Specified Condition

E030(1) - Ground
E030(2) - Ground ≥1MΩ
fpwx041096
E030(3) - Ground

Is the result normal?

No> Repair or replace the harness and connector.
Yes> Go to next step.

5. Check whether EGR valve harness is shorted to the power supply.

(a) Turn off the ignition switch, and disconnect
EGR valve connector E030 and ECM
connector E001.
E030
(b) Turn the ignition switch to ON.
(c) Measure the voltage between E030 terminal
1 2 3 1, 2, 3 and the ground.
4 6
Standard resistance (Check whether there
is short to ground)

Multimeter Connection Specified Condition

V E030(1) - Ground
E030(2) - Ground 0V
fpwx041097
E030(3) - Ground

Is the result normal?

No> Repair or replace the harness and connector.
Yes> Go to next step.

6. Replace the EGR on the vehicle with a good one

(a) Connect the tester to clear the trouble code.
Is the system normal? Is the fault eliminated?
Yes> Replace the EGR valve.
No> Go to next step.
 04-126 Diagnosis - Engine Control System

7. Replace ECM.
(a) Replace ECM.
(b) Identify DTC with the tester.
(c) Read the sensor data flows.
(d) Ensure there are no DTCs and the data are normal.
04
 Diagnosis - Engine Control System 04-127

Fault Symptom Table

If the fault is not confirmed when checking DTC and causes of the fault can not be confirmed
in basic inspection, troubleshooting should be performed by the order in the following table
and then troubleshoot according to the relevant pages.
Fault symptom of gasoline engine control system
04
Fault Symptom Check Sequence
Unable to use KT600
No communication between KT600 intelligent
intelligent diagnosis
diagnosis instrument(Its application version is 1
instrument to commu-
V03.79 or the updated version) and ECM
nicate
Engine can not start but rotate. 2
Start up
Cold starting is difficult and the vehicle vibrates. 3
Unstable idling (speed fluctuation) 4
Idle stability (poor
idling) Excessive high idling (engine speed out of the
5
specified value)
Idle stability (engine Engine stalls in the cold state (at idling) 6
stalling) Engine stalls when starting 7
Slow response, retarded acceleration and accel-
8
Driving eration imbalance
Poor accelerating and performance 9

Fault symptom of engine control system

Item Fault Symptom

When the starter rotates the engine, there is no
Unable to start combustion in the cylinder and the engine can't
Start up start.
Difficult start It starts until the starter rotates for a long time
Idle stabili- Unstable idling Engine revolution can't be kept stable.
ty (poor
idling) Excessive idling Engine runs in abnormal idle speed

Engine stalls in the cold Engine easily stalls when it starts and the coolant
Idle stabili- state (at idling) temperature is quite low
ty (engine
stalling) Engine stalls as soon as the accelerator pedal is
Engine stalls when starting
pressed
When accelerating is needed in driving and the
Slow response, retarded
accelerator pedal is pressed, speed can't rise im-
Driving acceleration and accelera-
mediately, acceleration is slow or engine revolution
tion imbalance
temporarily falls.
 04-128 Diagnosis - Engine Control System

Item Fault Symptom

The vehicle can't get the corresponding accelera-
Poor accelerating and perfor- tion (even though acceleration is smooth)according
mance to the openness of the throttle or it can't reach the
max. speed.
04
 Diagnosis - Engine Control System 04-129

Diagnostic Test for Engine Symptoms

Note
The diagnostic procedures for some symptoms requires visual inspection and exterior
inspection. The visual inspection and exterior inspection must be performed at the
very beginning of each test. Such inspections may get a problem solved without any
further test and save time for other problems. 04

1. After receiving the vehicle, collect the following information from the owner.
(a) The first time when the failure occurs.
(b) The engine temperature when the failure occurs.
(c) The mileage of the vehicle.
(d) Road condition the driver often faces and his/her driving habits
(e) Service and maintenance history of the vehicle.
(f) Repair history of the vehicle.
(g) Any add-on devices? The information above helps to arrives at the initial assessment
and shorten inspection time.
2. Before taking the diagnostic steps based on the engine fault symptoms, carry
out preliminary examination first.
(a) Make sure the engine failure indicator functions well. If not, eliminate the engine failure
indicator fault first.
(b) Make sure no engine TDC has been stored in the Engine Control Module (ECM). If
any, check the corresponding DTC chart and clear the DTC. Read the DTC (record
both the current and historical DTCs) — Clear the DTC — Operate (here, reproduce
the condition where the fault occurred) — Read the DTC Again. Refer to the DTC chart
in the Repair Manual for the possible causes, influences and troubleshooting method
of the DTC. Never neglect intermittent faults.
(c) Examine the idling data of the hot engine indicated in the electronic control system
with a diagnostic tester; make sure all the data is within the normal range.
(d) Make sure the faults are current, not historical, faults and their causes do exist.
(e) While conducting maintenance work on the vehicle, check the maintenance and repair
history, the cylinder compression pressure of the engine, the mechanical timing of the
engine and the fuel state.
3. Visual inspection and exterior inspection
(a) Check the connection of the ECM grounding wire.
(b) Check the connecting pipe of the engine vacuum system for cracks and distortion;
check whether it has been correctly connected, flattened or damaged.
(c) Check whether the the engine oil gauge and filler cap have been installed correctly.
(d) Check whether the engine grounding is clean and reliable.
(e) Check connecting interface of the engine intake manifold for air leak; check whether
the sealing surface between the throttle body and the intake manifold is intact.
(f) Check the high-voltage ignition wire for cracks, aging and carbon deposit; check
whether the wire arrangement is correct. Check whether the contact is in good condition
and the connection is firm and reliable.
(g) Check the engine fuel system for any kind of leakage.
(h) Check whether the fuel has gone bad or contains water.
 04-130 Diagnosis - Engine Control System

(i) Check the connectors of the engine sensors and actuators for good contact and firm
connection.
4. The carbon deposit accumulated on the back of the valves will directly lead to
poor performance in acceleration and unstable idling, sometimes accompanied
by intake manifold explosion , cold start difficulty, etc.
04 (a) Valve and combustion carbon deposit.
Governed by the engine control characteristics, the cylinder inject fuel first and then
ignite. The moment the engine stops, the ignition will be cut off. However, the gasoline
that has been injected in the circulation cannot be withdrawn but adheres onto the
intake valves and combustion chamber wall. The gasoline volatilizes easily, yet the
wax and colloids remain there. As time goes by, those wax and colloids get thicker
and thicker, which become carbon deposit after being heated repeatedly and hardening
up.
If the engine burns engine oils, or the refilled gasoline is of poor quality or has many
impurities, the carbon deposit on the valves will become more severe and accumulates
faster.
As the carbon deposit resembles sponge in structure, part of the fuel will be adsorbed
to the carbon deposit already there every time the fuel is injected. This will thin out the
mixture that actually enters the cylinder, resulting in poor engine performance, difficult
startup, unstable idling, poor performance in acceleration, backfire under quick
acceleration, emission non-compliance, increasing fuel consumption, etc. Even worse,
the carbon deposit might lead to poor valve sealing, which cause certain cylinder to
stop working due to lack of cylinder pressure, or even the valve cannot return for being
stuck. In this case, motion interference will occur between the valve and the piston
and get the engine damaged eventually.
(b) Carbon deposits at the intake pipe.
As all the engine pistons work asynchronously, when the engine stops, some intake
valves can not completely close, unburned fuel will constantly evaporate and oxidate,
which will produce some soft black carbon deposit at the intake pipe, especially at the
back of the throttle.
On one hand, these carbon deposits will make the wall of intake pipes rough and intake
air will generate a vortex at the rough area so that air intake and air mixture quality
will be affected.
On the other hand, these carbon deposits will also block the idle channel to make the
idle speed control equipment stuck or out of the adjusting range, which will cause low
idle speed or idle vibration.
5. Methods for judging carbon deposits in the cylinder:
(a) Observe the cylinder state inside the cylinder with an autoscope.
(b) Read the variation of the oxygen sensor feedback voltage with a tester to indirectly
inspect carbon deposits.
 Diagnosis - Engine Control System 04-131

Once there are carbon deposits on the valve, the feedback voltage of the oxygen
sensor will widely change, from 0.3～0.7V to 0.1～0.9V. And the voltage center value
will become larger while the frequency changes more slowly.
(c) Disassembly method.
Note
04
If there are excessive carbon deposits in the engine cylinder, generally the pressure
in the cylinder is rather high. However, the vehicle with many carbon deposits drives
quite long distance and the wear will make the pressure reduce. So it is infeasible to
judge carbon deposit condition in the cylinder according to the cylinder pressure.
6. For the harm of carbon deposit, please pay attention to the following:
(a) Add high-quality gasoline.
(b) Never idle for a long time.
(c) Drive in high speed and manage to improve shifting speed of the manual transmission
vehicle.
 04-132 Diagnosis - Engine Control System

No Communication between KT600 Intelligent Diagnosis

Instrument and ECM
Symptom Diagnostic Logic Possible cause
• No power supply for ECM • Bad ECM power supply
04 • ECM faults loop
KT600 intelligent diagnosis • Open loop between ECM
• Poor connecting wires
instrument can not and KT600 intelligent
between ECM and KT600
communicate with ECM diagnosis instrument
intelligent diagnosis
instrument • ECM

Circuit Diagram

LJ465 engine system 4W12 engine system 4W10 engine system

Battery Battery Battery

F8 F8
Fuse box in F8
Fuse box
Diagnose Fuse box in Diagnose Diagnose
interface/ interface/ driver’s cab in driver’s
driver’s cab interface/
instrument/ instrument/ V035 instrument/ cab
ECU fuse V035 ECU fuse ECU fuse
7.5A 7.5A 7.5A V035

Red Red
Red
Red
Red Red 16 16 Red
16 Red
Red
Diagnose Diagnose
Diagnose interface V103
interface V103 interface V103
V019 10 V019 10
V019 10
E101 4 5 7 14 6 E101
E101 4 5 7 14 6
4 5 7 Black Black Green- Purple
Black Black Green- Blue
Black Black Blue purple Purple purple
Blue

V204 V204
V204
75 67 75 38 39 67 A4 B1 A1 P3
K diagnostic line CAN-L CAN-H K CAN-L CAN-H
K
diagnostic line diagnostic line

Engine electronic E003 Engine electronic

Engine electronic
control module E001 control module connector A
control module E001 fpwx041080

Diagnostic procedure for fault symptom

1. Checking engine data
(a) Turn the ignition switch to OFF.
(b) Connect the diagnostic unit to the troubleshooting connectors (16-pin) on the bottom
of the front passenger seat.
 Diagnosis - Engine Control System 04-133

(c) Turn the ignition switch to ON, and then turn on the diagnosis instrument - use the
latest soft version.
(d) Read engine data shown on the diagnosis instrument.
Can the diagnosis instrument read data stream in ECM?
Yes> Intermittent Faults, refer to the Diagnostic Help.
04
No> Go to next step.

2. Check data in other modules.

(a) Read airbag or ABS data shown on the diagnosis instrument.
(b) Read data shown on the diagnosis instrument.
Can the diagnosis instrument read data stream related to airbags or ABS?
Yes> Go to step 5.
No> Go to next step.

3. Check the K-line for ECM diagnostic communication.

(a) Turn the ignition switch to OFF.
(b) Disconnect ECM connector.
(c) Measure the conduction between the terminal 7 of the diagnostic box V019 and ECM
terminal 75 with a multimeter.
Resistance: ＜2Ω
(d) Measure the conduction between the terminal 7 of the diagnostic box V019 and the
ground with a multimeter.
Resistance: ≥1MΩ
(e) Turn the ignition switch to ON, measure the voltage of the terminal 7 of the diagnostic
box V019 with a multimeter.
Voltage: 0V

Is the result normal?

Yes> Go to next step.
No> Check the K-line for ECM diagnostic communication.

4. Check ECM communication CAN.

(a) Turn the ignition switch to OFF.
(b) Disconnect ECM connector.
(c) Measure the conduction between the terminal 38, 39 of the diagnostic box V019 and
ECM terminal 14,6 with a multimeter.
Resistance: ＜2Ω
(d) Measure the conduction between the terminal 14, 6 of the diagnostic box V019 and
the ground with a multimeter.
Resistance: ≥1MΩ
(e) Turn the ignition switch to ON, measure the voltage of the terminal 14, 6 of the
diagnostic box V019 with a multimeter.
 04-134 Diagnosis - Engine Control System

Voltage: 0V

Is the result normal?

Yes> Go to next step.
No> Repair CAN communication line of ECM.
04
5. Check the power supply and grounding of ECM.
(a) Check ECM power supply.
(b) Check the grounding of ECM.
Is the result normal?
Yes> Go to next step.
No> Repair the power supply or grounding of ECM.

5. Replace ECM.
(a) Replace ECM. Refer toChapter11 Engine Control System - Engine Control Module,
Replacement)
(b) Read engine data shown on the diagnosis instrument. Confirm that KT600 intelligent
diagnosis instrument can communicate with ECM.
 Diagnosis - Engine Control System 04-135

Engine cannot Start but Rotate

Symptom Status Diagnostic Logic Possible Causes
Air leak in intake
system: inadequate
• Crankshaft rotating fuel pressure, 04
speed normal blockage in air filter,
• Battery fully fault in WTS, fault in
charged • Defective spark air flow meter, fault in
The starter can keep plug idle control valve or
• Engine alarming
the engine rotating at auxiliary air valve,
indicator functioning • No fuel in the
a normal speed and combustion injectors not working
well
the vehicle looks like chamber at cold start, fuel
• When the starter
having been started, leakage in injectors,
rotates the engine, • Abnormal pressure
yet it cannot move. incorrect ignition
there is no in the cylinder
timing, open circuit
combustion in the
between start switch
cylinder and the
and computer,
engine can't start.
inadequate
compression
pressure

Diagnostic procedure for fault symptom

1. Checking the engine failure indicator signal and DTC

(a) Read DTC with the diagnosis instrument.
Is the DTC present?
Yes> Refer to the DTC chart, and perform the DTC fault diagnostic procedure.
No> Go to next step.

2. Checking the secondary ignition system

(a) Pull out the injector fuse.
(b) Pull out the high-voltage line, and remove the spark plug.
(c) Connect the spark plug to the high-voltage line, and bring the negative terminal of the
spark plug to contact with the cylinder body.
(d) Start the engine to test the secondary ignition system.
Expected result: while the engine is running, there are strong blue/white sparks
on each spark plug.

Is the result normal?

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

3. Checking the secondary ignition system

(a) Check the resistance in the high-voltage coil, and clean the connector terminals.
Resistance: ≥ 4kΩ
 04-136 Diagnosis - Engine Control System

(b) Check the spark plug for carbon deposit or carbon trace, check the ceramic insulation
part for cracks and electric leakage, check whether the gaps are normal, check whether
the positive and negative terminals are ablated, and clean the spark plug.
Is the result normal?

04
Yes> Go to next step.
No> Clean or replace the faulty component.

4. Checking the crankshaft position sensor

(a) Use the tester to check the engine CKP sensor and read the data flow; the reading
must reach the specified value.
Is the result normal?
Yes> Go to next step.
No> Check whether the sensor is installed correctly (refer to Engine Control System
- Removal and Installation of Sensors); repair or replace the harness, connector or
defective component.

5. Checking the throttle

(a) Press down the accelerator pedal gently, and start the engine. Check whether the
engine can be started.
Can the engine be started?
Yes> Check the throttle and idle channel, and clear the carbon deposit. Pull out the
connector of the idle stepper motor and measure the connector terminals; there should
be a voltage of 12V.The normal resistance range under 20℃ is 28～33Ω. Check whether
the idle stepper motor is stuck; repair or replace it as necessary.
No> Go to next step.

6. Checking the water temperature sensor and intake manifold's absolute

pressure/temperature sensor
(a) Check whether the intake manifold absolute pressure/temperature sensor have been
installed correctly.
(b) Remove the intake manifold absolute pressure/temperature sensor.
(c) Check the probe hole for blockage; check whether the resistances between each
terminal are equal to the standard value.
(d) Check the temperature sensor for contamination.
(e) Ignition switch: ON. Read the data flows of the engine intake manifold absolute pressure
(MAP)/temperature sensor and water temperature sensor indicated on the diagnosis
tester.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component. Go to step 11.

7. Checking the fuel system circuit

(a) Ignition switch: ON.
 Diagnosis - Engine Control System 04-137

(b) Check whether fuel pump relay and fuel pump function well.
Is the result normal?
Yes> Go to next step.
No> Repair or replace the fuel pump harness.
04
8. Checking the fuel system pressure
(a) Check the fuel system pressure. (See "Chapter 12A Fuel System - Precautions")
Is the result normal?
Yes> Go to step 10.
No> Repair or replace the components or circuit in the fuel system; if the fuel pressure
is lower than 300 kPa, go to the next step.

9. Checking the fuel supply of the fuel system

(a) Check the fuel inlets for leakage or blockage.
(b) Check the gasoline filter for blockage.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

10 . Checking the fuel injectors

(a) Pull out the connectors of the fuel injectors.
(b) Pull out the fuel distribution pipes and fuel injector altogether.
(c) Apply the 12V voltage of the battery onto the fuel injectors.
(d) All injector are supposed to inject a standard amount of fuel and evenly atomized.
Note
While checking the fuel injection, if the fuel injected is in columnar shape, not in cone
shape, or the fuel volume injected from each of the four cylinder varies greatly (over
5ml) from each other, the injectors should be replaced. Check the fuel injection nozzle
for gel-like substance; if any, bathe and spray resin it with cleaning agent; otherwise
it will lead to inadequate fuel injection or poor performance in acceleration.
Danger
While testing the fuel system:
• Place a sign read "Caution: Flammable" at the workplace.
• It is required to conduct maintenance work at the well-ventilated place, with a
carbon dioxide fire extinguisher.
• NO SMOKING is allowed while fuel system maintenance is involved. The
workplace should be far away from open flames and sparks.
• Collect the drained fuel in a explosion-proof container.

Is the result normal?

Yes> Go to next step.
 04-138 Diagnosis - Engine Control System

NO> Clean the injectors. Check the working condition of the injectors again. If the
injectors fail to work well, replace the injectors.

11 . Checking the cylinder pressure

(a) Perform pressure test on cylinder compression feature.
04 Pressure in each cylinder: 1200±200kPa
Limit value for each cylinder: 1000kPa
Limit pressure difference between each cylinder: ≤ 98kPa

Is the result normal?

Yes> Go to step 13.
No> Go to next step.

12 . Checking the engine valve timing

(a) Check whether the engine timing gear marks has been properly aligned and check for
gear damage, loose belt, timing jump.
Is the result normal?
Yes> Go to next step.
No> Perform timing belt alignment or replace the timing belt.

13 . Checking the engine's mechanical parts

(a) Observe the cylinder state inside the cylinder with an autoscope.
(b) Observe the feedback voltage variation.
(c) Disassemble the engine and repair its internal mechanical fault.
Clean the carbon deposit or disassemble and check the cylinder heads. Check the
valves and intake manifold for carbon deposit. E.g." excessive gap between the piston
and cylinder, poor sealing, air leak at cylinder gaskets, lax valve closing, carbon deposit.

Is the result normal?

Yes> Go to next step.
No> Repair the engine's internal mechanical fault.

14 . Checking the start signal sent to the computer from the start switch
(a) Check the computer harness connector to see whether there is signal sent to the
computer from the start switch.
Is the result normal?
Yes> Go to next step.
No> Repair or replace the faulty parts.

15 . Replace ECM.
(a) Replace ECM. Refer toChapter11 Engine Control System - Engine Control Module,
Replacement)
(b) Check the engine data flow, and make sure the internal engine fault is absent and the
system functions well.
 Diagnosis - Engine Control System 04-139

Cold starting is difficult and the vehicle vibrates.

Symptom Status Diagnostic Logic Possible Causes
Air leak in intake
system: inadequate
• Mixing ratio fuel pressure, 04
• Crankshaft rotating improper blockage in air filter,
speed normal fault in WTS, fault in
• carbon deposits at
• Engine alarming valve and air inlet air flow meter, fault in
indicator functioning idle control valve or
• Coolant
well auxiliary air valve,
Cold starting is temperature sensor
• In cold start, the injectors not working
difficult and the fault
starter will drive the at cold start, fuel
vehicle vibrates. • Intake manifold
engine rotate, and leakage in injectors,
absolute
only after several incorrect ignition
pressure/temperature
starts can the timing, open circuit
sensor
engine start to between start switch
• Idle stepper motor and computer,
work.
• Oil quality inadequate
compression
pressure.

Diagnostic procedure for fault symptom

1. Check the engine failure indicator signal and DTC

(a) Read DTC with the diagnosis instrument.
Is the DTC present?
Yes> Refer to the DTC, and perform the DTC fault diagnostic procedure.
No> Go to next step.

2. Checking the battery

(a) After starting the engine, check the battery voltage.
Battery voltage: ≥ 9.6 V

Is the result normal?

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

3. Check the starter

(a) Check whether the starter or its circuits has fault or not.
Is the result normal?
Yes> Go to next step.
No> Eliminate the faults, and make sure those symptoms no longer exist.

4. Check the crankshaft position sensor

 04-140 Diagnosis - Engine Control System

(a) Use the tester to check the engine CKP sensor and read the data flow; the reading
must reach the specified value.
Is the result normal?
Yes> Go to next step.
04 No> Check whether the sensor is installed correctly (refer to Engine Control System
- Removal and Installation of Sensors); repair or replace the harness, connector or
defective component.

5. Check the water temperature sensor and intake manifold's absolute

pressure/temperature sensor
(a) Check whether the water temperature sensor and intake manifold absolute
pressure/temperature sensor have been installed correctly.
(b) Remove the intake manifold absolute pressure/temperature sensor.
(c) Check the probe hole for blockage; check whether the resistances between each
terminal are equal to the standard value.
(d) Check the temperature sensor for contamination.
(e) Ignition switch: ON. Read the data flows of the engine intake manifold absolute pressure
(MAP)/temperature sensor and water temperature sensor indicated on the diagnosis
tester.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

6. Check air inlet system

(a) Check the vacuum degree inside the air inlet at idling.
(b) Check all the joints, washers and vacuum hose of the air inlet, and the EGR system
and the fuel evaporation system.
(c) Check whether the air filter element is blocked.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

7. Check the throttle.

(a) Depress the accelerator pedal and start the engine. Check whether the engine can
start.
Can the engine be started?
Yes > check the throttle and the idling passage, and clear up the carbon deposition.
Pull out the connector of the idle stepper motor and measure the connector terminals;
there should be a voltage of 12V. The normal resistance range under 20℃ is 28～33Ω.
Check whether the stepper motor is stuck. Repair or replace it as needed.
No> Go to next step.

8. Check the idle stepper motor.

 Diagnosis - Engine Control System 04-141

(a) With the ignition ON, check whether the idle stepper motor flexes.
(b) With the ignition switch OFF, check whether the idle stepper motor can work properly.
If it works normally, the opening angle should be at the max.
Is the result normal?
Yes> Go to next step. 04
No> Repair or replace the connector, harness or idle stepper motor.

9. Check the fuel system pressure

(a) Check the fuel system pressure. (See Chapter 12A Fuel System - Precautions)
Is the result normal?
Yes> Go to step 11.
No> Repair or replace the components or circuit in the fuel system; if the fuel pressure
is lower than 300 kPa, go to the next step.

10 . Check the fuel supply of the fuel system

(a) Check the fuel inlets for leakage or blockage.
(b) Check the gasoline filter for blockage.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

11 . Check the fuel injectors

(a) Pull out the connectors of the fuel injectors.
(b) Pull out the fuel distribution pipes and fuel injector altogether.
(c) Apply the 12V voltage of the battery onto the fuel injectors.
(d) All injector are supposed to inject a standard amount of fuel and evenly atomized.
Note
While checking the fuel injection, if the fuel injected is in columnar shape, not in cone
shape, or the fuel volume injected from each of the four cylinder varies greatly (over
5ml) from each other, the injectors should be replaced. Check the fuel injection nozzle
for gel-like substance; if any, bathe and spray resin it with cleaning agent; otherwise
it will lead to inadequate fuel injection or poor performance in acceleration.
Danger
While testing the fuel system:
• Place a sign read "Caution: Flammable" at the workplace.
• It is required to conduct maintenance work at the well-ventilated place, with a
carbon dioxide fire extinguisher.
• NO SMOKING is allowed while fuel system maintenance is involved. The
workplace should be far away from open flames and sparks.
• Collect the drained fuel in a explosion-proof container.

Is the result normal?

 04-142 Diagnosis - Engine Control System

Yes> Go to next step.

NO> Clean the injectors. Check the working condition of the injectors again. If the
injectors fail to work well, replace the injectors.

12 . Check the cylinder pressure

04 (a) Perform pressure test on cylinder compression feature.
Pressure in each cylinder: 1200±200kPa
Limit value for each cylinder: 1000kPa
Limit pressure difference between each cylinder: ≤ 98kPa

Is the result normal?

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

13 . Check the engine valve timing

(a) Check whether the engine timing gear marks has been properly aligned and check for
gear damage, loose belt, timing jump.
Is the result normal?
Yes> Go to next step.
No> Perform timing belt alignment or replace the timing belt.

14 . Check the engine's mechanical parts

(a) Observe the cylinder state inside the cylinder with an autoscope.
(b) Observe the feedback voltage variation.
(c) Disassemble the engine and repair its internal mechanical fault.
Clean the carbon deposit or disassemble and check the cylinder heads. Check the
valves and intake manifold for carbon deposit. E.g." excessive gap between the piston
and cylinder, poor sealing, air leak at cylinder gaskets, lax valve closing, carbon deposit.

Is the result normal?

Yes> Go to next step.
No> Repair the engine's internal mechanical fault.

15 . Replace the ECM.

(a) Replace the ECM. Refer toChapter11 Engine Control System - Engine Control Module,
Replacement)
(b) Check the engine data flow, and make sure the internal engine fault is absent and the
system functions well.
 Diagnosis - Engine Control System 04-143

Unstable Idling (Speed Fluctuation)

Symptom Status Diagnostic Logic Possible Causes
• The Ignition System
• Air-fuel ratio
• The Ignition System • Idle stepper motor 04
• Air-fuel ratio fault
• Idle stepper motor • Inadequate
Unstable Idling Engine revolution
fault compression
(Speed Fluctuation) can't be kept stable.
• Inadequate pressure
compression • Front oxygen
pressure sensor and rear
oxygen sensor
transposed

Note
With the engine idling, if the air-fuel ratio in the mixture is imbalanced, there's leakage
in the air intake system, or certain cylinder doesn't work due to fault in the ignition
system, faults like no idling speed, excessive idling speed, unstable idling and poor
performance in high-speed idling may occur.
Diagnostic procedure for fault symptom

1. Checking the engine failure indicator signal and DTC

Is the DTC present?
Yes> Refer to the DTC, and perform the DTC fault diagnostic procedure.
No> Go to next step.

2. Visual inspection and exterior inspection

(a) Observe the engine operation and shaking intensity.
(b) Meanwhile, observe the swing amplitude of the engine tachometer indicator, to see
whether it deviates from the target value for idle speed.
(c) Observe whether the idle shaking is within the normal range or it is shaking due to
overload. (Turn on the A/C and lights, engage the gearshift lever, turn the steering
wheel, etc.)
(d) Whether the external components of the engine are in good state; whether the vacuum
pipe falls off or get damaged; whether the harness connectors get loose.
(e) Whether there is any leakage of fuel/oil, water, air or electricity.
(f) Whether there are abnormal symptoms such as chugging exhaust pipe (which indicates
poor combustion), black smoke in the exhaust, unburnt engine oil smell from the
exhaust.
Is the result normal?
Yes> Go to next step.
No> Eliminate the external faults, and make sure those symptoms no longer exist.

3. Checking the throttle body and the idle stepper motor

 04-144 Diagnosis - Engine Control System

(a) Check the throttle and the inlets surrounding it for oil stain and carbon deposit, check
whether the throttle sticks, and check the idle stepper motor for carbon deposit.
(b) Start the engine and keep it idling.
(c) Inspect the idling stepper motor with the tester.
(d) When the idle stepper motor is flexing under the control of the tester, the engine RPM
04 varies along with it, getting higher or lower. (Touch the idle stepper motor by hand and
you can fell vibration.)
(e) Pull out the connector of the idle stepper motor and measure the connector terminals;
there should be a voltage of 12V.
(f) With the ignition ON, check whether the idle stepper motor flexes.
(g) With the ignition OFF, check whether the idle stepper motor moves.
Is the result normal?
Yes> Go to next step.
No> Clean, repair or replace the harness, connector or idle stepper motor.

4. Checking the engine ignition system

(a) Keep the engine idling, and cut off the fuel supply cylinder by cylinder to observe
whether the engine RPM changes.
(b) During each cylinder cutoff process, the engine RPM should show the same extent of
obvious decrease or shake to the same extent.
Is the result normal?
Yes> Go to step 11.
No> Go to next step.

5. Checking the secondary ignition system

(a) Check the resistance in the high-voltage coil, and clean the connector terminals.
Resistance: ≥ 4 kΩ
(b) Check the spark plug for carbon deposit or carbon trace, check the ceramic insulation
part for cracks and electric leakage, check whether the gaps are normal, check whether
the positive and negative terminals are ablated, and clean the spark plug.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

6. Checking the fuel injectors

(a) Pull out the connectors of the fuel injectors.
(b) Pull out the fuel distribution pipes and fuel injector altogether.
(c) Apply the 12V voltage of the battery onto the fuel injectors.
(d) All injector are supposed to inject a standard amount of fuel and evenly atomized.
 Diagnosis - Engine Control System 04-145

Note
While checking the fuel injection, if the fuel injected is in columnar shape, not in cone
shape, or the fuel volume injected from each of the four cylinder varies greatly (over
5ml) from each other, the injectors should be replaced. Check the fuel injection nozzle
for gel-like substance; if any, bathe and spray resin it with cleaning agent; otherwise
04
it will lead to inadequate fuel injection or poor performance in acceleration.
Danger
While testing the fuel system:
• Place a sign read "Caution: Flammable" at the workplace.
• It is required to conduct maintenance work at the well-ventilated place, with a
carbon dioxide fire extinguisher.
• NO SMOKING is allowed while fuel system maintenance is involved. The
workplace should be far away from open flames and sparks.
• Collect the drained fuel in a explosion-proof container.

Is the result normal?

Yes> Go to next step.
NO> Clean the injectors. Check the working condition of the injectors again. If the
injectors fail to work well, replace the injectors.

7. Checking the fuel system pressure

(a) Check the fuel system pressure. (See Chapter 12A Fuel System - Precautions)
Is the result normal?
Yes> Go to step 9.
No> Repair or replace the components or circuit in the fuel system; if the fuel pressure
is lower than 300 kPa, go to the next step.

8. Checking the fuel supply of the fuel system

(a) Check the fuel inlets for leakage or blockage.
(b) Check the gasoline filter for blockage.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

9. Checking the intake/exhaust system

(a) Check the air intake system of the engine for leakage.
(b) Check the air intake pipe for falling-off connection, cracks, deformation and aging
sealing.
(c) Clamp the boost vacuum hose or pull out the rear plug to see whether there are
changes in the idling speed.
(d) Check the air intake pipe for "sizzling" air leaks while the engine is running.
 04-146 Diagnosis - Engine Control System

(e) Check the positive crankcase ventilation valve (PCV) hose for air leak; check whether
the PCV opening is too great.
(f) Check the vacuum hose of the evaporative emission control system for air leak.
(g) Check the vacuum hose of the fuel pressure regulator for breakage, falling off and
cracks.
04 (h) Check the three-way catalytic converter for blockage.
(i) Check the seal of the throttle body for air leak.
(j) Check the gasket of the intake manifold for air leak.
Is the result normal?
Yes> Go to next step.
No> Repair or replace the faulty parts.

10 . Check the water temperature sensor and intake manifold's absolute

pressure/temperature sensor
(a) Check whether the water temperature sensor and intake manifold absolute
pressure/temperature sensor have been installed correctly.
(b) Remove the intake manifold absolute pressure/temperature sensor.
(c) Check the probe hole for blockage; check whether the resistances between each
terminal are equal to the standard value.
(d) Check the temperature sensor for contamination.
(e) Ignition switch: ON. Read the data flows of the engine intake manifold absolute pressure
(MAP)/temperature sensor and water temperature sensor indicated on the diagnosis
tester.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

11 . Checking the oxygen sensor

(a) Check whether the front and rear oxygen sensors have been installed correctly.
(b) Keep the engine idling and check the data flow on the tester. When the coolant
temperature reach the normal level when the closed-loop control is activated, observe
whether the sensor functions well.
Normal oxygen sensor data: fluctuate between 0~1 V. Within 10 seconds, the
readings alternate between the maximum and minimum values for 8 times.

Is the result normal?

Yes> Go to next step.
No> Repair or replace the faulty parts.

12 . Checking the cylinder pressure

(a) Perform pressure test on cylinder compression feature.
Pressure in each cylinder: 1200±200kPa
Limit value for each cylinder: 1000kPa
Limit pressure difference between each cylinder: ≤ 98kPa
 Diagnosis - Engine Control System 04-147

Is the result normal?

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

13 . Checking the engine valve timing

(a) Check whether the engine timing gear marks has been properly aligned and check for 04
gear damage, loose belt, timing jump.
Is the result normal?
Yes> Go to next step.
No> Perform timing belt alignment or replace the timing belt.

14 . Checking the engine's mechanical parts

(a) Observe the cylinder state inside the cylinder with an autoscope.
(b) Observe the feedback voltage variation.
(c) Disassemble the engine and repair its internal mechanical fault.
Clean the carbon deposit or disassemble and check the cylinder heads. Check the
valves and intake manifold for carbon deposit. E.g." excessive gap between the piston
and cylinder, poor sealing, air leak at cylinder gaskets, lax valve closing, carbon deposit.

Is the result normal?

Yes> Go to next step.
No> Repair the engine's internal mechanical fault.

15 . Replacing the ECM

(a) Replace the ECM. Refer toChapter11 Engine Control System - Engine Control Module,
Replacement)
(b) Check the engine data flow, and make sure the internal engine fault is absent and the
system functions well.
 04-148 Diagnosis - Engine Control System

Excessive Idling
Symptom Status Diagnostic Logic Possible Causes
• Idle stepper motor
fault
04 Excessive high idling • Vacuum leakage
Excessive engine Excessive intake air • Too tight throttle
(Idling speed out of
revolution at idling cable
the specified value)
• Throttle fault
• ECM

Note
With the engine idling, if the air-fuel ratio in the mixture is imbalanced, there's leakage
in the air intake system, or certain cylinder doesn't work due to fault in the ignition
system, the faults may occur like no idling speed, excessive idling speed, unstable
idling and poor performance in high-speed idling.
Diagnostic procedure for fault symptom

1. Check the engine failure indicator signal and DTC

(a) Read DTC with the diagnosis instrument.
Is the DTC present?
Yes> Refer to the DTC chart, and perform the DTC fault diagnostic procedure.
No> Go to next step.

2. Perform the visual inspection and exterior inspection

(a) Perform the visual inspection and exterior inspection
Is the result normal?
Yes> Go to next step.
No> Eliminate the external faults, and make sure those symptoms no longer exist.

3. Check air inlet system

(a) Check the air intake system of the engine for leakage.
(b) Check the air intake pipe for "sizzling" air leakage while the engine is running.
(c) Check the air intake pipe for falling-off connection, cracks, deformation and aging
sealing.
Check the air intake pipe for falling-off connection, cracks, deformation and aging
sealing. Is the result normal?
Yes> Go to next step.
No> Repair, replace or reinstall.

4. Check related accessories.

(a) Check whether the vacuum hose for the canister control valve is firmly connected or
broken.
 Diagnosis - Engine Control System 04-149

(b) Check whether the vacuum adjusting hose for the fuel pressure regulator is firmly
installed or broken.
(c) Check whether the vacuum hose for the positive crankcase ventilation is firmly installed
or broken.
(d) Check whether the vacuum booster hose for the braking system is firmly installed or
broken. 04

Is the result normal?

Yes> Go to next step.
No> Adjustment or replacement.

5. Check the throttle body and the idle stepper motor

(a) Check whether the throttle cable is too tight.
(b) Check the throttle and the inlets surrounding it for oil stain and carbon deposit, check
whether the throttle sticks and whether there is carbon deposit in the idle stepper
motor.
(c) Start the engine and keep it idling.
(d) Inspect the idling stepper motor with the tester.
(e) When the idle stepper motor is flexing under the control of the tester, the engine RPM
varies along with it, getting higher or lower. (Touch the idle stepper motor by hand and
you can feel vibration.)
(f) Unplug the connector of the idle stepper motor and measure the connector terminals;
there should be a voltage of 12V.
(g) With the ignition ON, check whether the idle stepper motor flexes.
(h) With the ignition OFF, check whether the idle stepper motor moves.
Is the result normal?
Yes> Go to next step.
No> Clean, repair or replace the harness, connector or idle stepper motor.

6. Check the water temperature sensor and intake manifold absolute

pressure/temperature sensor
(a) Check whether the water temperature sensor and intake manifold absolute
pressure/temperature sensor have been installed correctly.
(b) Remove the intake manifold absolute pressure/temperature sensor.
(c) Check the probe hole for blockage; check whether the resistance between each terminal
meets the standards.
(d) Check the temperature sensor for contamination.
(e) Ignition switch: ON. Read the data flows of the engine intake manifold absolute pressure
(MAP)/temperature sensor and water temperature sensor indicated on the diagnosis
tester.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

7. Check the fuel system pressure

 04-150 Diagnosis - Engine Control System

(a) Check the fuel system pressure. (See Chapter 12A Fuel System - Precautions)
Is the result normal?
Yes> Go to next step.
No> Repair or replace the components or circuit in the fuel system.
04
8. Check the fuel injectors
(a) Pull out the connectors of the fuel injectors.
(b) Pull out the fuel distribution pipes and fuel injector altogether.
(c) Apply the 12V voltage of the battery onto the fuel injectors.
(d) All injectors are supposed to inject a standard amount of fuel and evenly atomized.
Note
While checking the fuel injection, if the injected fuel is in columnar shape, not in cone
shape, or the fuel volume injected from each of the four cylinders varies greatly (over
5ml) from each other under the same conditions, the injectors should be replaced.
Check the fuel injection nozzle for gel-like substance; if any, bathe and spray with
cleaning agent; otherwise it will lead to inadequate fuel injection or poor performance
in acceleration.
Danger
While testing the fuel system:
• Place a sign "Caution: Flammable" at the workplace.
• It is required to conduct maintenance work at the well-ventilated place, with a
carbon dioxide fire extinguisher.
• NO SMOKING is a must while fuel system maintenance is involved.The workplace
should be far away from open flames and sparks.
• Collect the drained fuel in a explosion-proof container.

Is the result normal?

Yes> Go to next step.
NO> Clean the injectors. Check the working condition of the injectors again. If the
injectors fail to work well, replace the injectors.

9. Replace the ECM.

(a) Replace the ECM. Refer toChapter11 Engine Control System - Engine Control Module,
Replacement)
(b) Check the engine data flow, and make sure the engine fault is absent and the system
functions well.
 Diagnosis - Engine Control System 04-151

Engine stalling in the cold state (at idling)

Symptom Status Diagnostic Logic Possible Causes
• Ignition system fault
• Air-fuel ratio control
system fault (at 04
• The Ignition System
idling)
• Air-fuel ratio
• Air intake system
• Idle stepper motor
Engine stalling in the Engine revolution fault
fault
cold state (at idling) unable to keep stable. • Inadequate
• Inadequate
compression
compression
pressure
pressure
• Exhaust control
system fault
• ECM

Diagnostic procedure for fault symptom

1. Check the engine failure indicator signal and DTC

(a) Read DTC with the diagnosis tester.
Is the DTC present?
Yes> Refer to the DTC chart, and perform the DTC fault diagnostic procedure.
No> Go to next step.

2. Perform the visual inspection and exterior inspection

(a) Observe the engine operation and shaking intensity.
(b) Meanwhile, observe the swing amplitude of the engine tachometer indicator and
revolutions when engine stalls.
(c) Observe whether it is normal idling stop or idling stop in loaded condition (Turn on the
A/C and lights, engage the gearshift lever, turn the steering wheel, etc.)
(d) Whether the external components of the engine are in good state; whether the vacuum
pipe falls off or gets damaged; whether the harness connectors get loose.
Is the result normal?
Yes> Go to next step.
No> Eliminate the external faults, and make sure those symptoms no longer exist.

3. Check the throttle body and the idle stepper motor

(a) Check the throttle and the inlets surrounding it for oil stain and carbon deposit, check
whether the throttle sticks, and check the idle stepper motor for carbon deposit.
(b) Start the engine and keep it idling.
(c) Inspect the idling stepper motor with the tester.
(d) When the idle stepper motor is flexing under the control of the tester, the engine RPM
varies along with it, getting higher or lower. (Touch the idle stepper motor by hand and
you can feel vibration.)
 04-152 Diagnosis - Engine Control System

(e) Unplug the connector of the idle stepper motor and measure the connector terminals;
there should be a voltage of 12V.
(f) With the ignition ON, check whether the idle stepper motor flexes.
(g) With the ignition OFF, check whether the idle stepper motor moves.
Is the result normal?
04
Yes> Go to next step.
No> Clean, repair or replace the harness, connector or idle stepper motor.

4. Check the water temperature sensor

(a) Check whether the resistance between terminals of the water temperature sensor
meets the standards.
(b) Check the water temperature sensor for contamination.
(c) Ignition switch: ON. Read the data flows of the water temperature sensor indicated on
the diagnosis tester.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

5. Check the intake air temperature sensor

(a) Check whether the resistance between terminals of the intake air temperature sensor
meets the standards.
(b) Check the intake air temperature sensor for contamination.
(c) Ignition switch: ON. Read the data flows of the intake air temperature sensor indicated
on the diagnosis tester.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

6. Check the fuel injectors

(a) Pull out the connectors of the fuel injectors.
(b) Pull out the fuel distribution pipes and fuel injector altogether.
(c) Apply the 12V voltage of the battery onto the fuel injectors.
(d) All injectors are supposed to inject a standard amount of fuel and evenly atomized.
Note
While checking the fuel injection, if the injected fuel is in columnar shape, not in cone
shape, or the fuel volume injected from each of the four cylinders varies greatly (over
5ml) from each other under the same conditions, the injectors should be replaced.
Check the fuel injection nozzle for gel-like substance; if any, bathe and spray with
cleaning agent; otherwise it will lead to inadequate fuel injection or poor performance
in acceleration.
 Diagnosis - Engine Control System 04-153

Danger
While testing the fuel system:
• Place a sign "Caution: Flammable" at the workplace.
• It is required to conduct maintenance work at the well-ventilated place, with a
carbon dioxide fire extinguisher.
• NO SMOKING is a must while fuel system maintenance is involved.The workplace 04
should be far away from open flames and sparks.
• Collect the drained fuel in a explosion-proof container.

Is the result normal?

Yes> Go to next step.
NO> Clean the injectors. Check the working condition of the injectors again. If the
injectors fail to work well, replace the injectors.

7. Check the fuel system pressure

(a) Check the fuel system pressure. (See Chapter 12A Fuel System - Precautions)
Is the result normal?
Yes> Go to step 9.
No> Repair or replace the components or circuit in the fuel system; if the fuel pressure
is lower than 300 kPa, go to the next step.

8. Check the fuel supply of the fuel system

(a) Check the fuel inlets for leakage or blockage.
(b) Check the gasoline filter for blockage.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

9. Check the cylinder pressure

(a) Perform pressure test on cylinder compression feature.
Pressure in each cylinder: 1200±200kPa
Limit value for each cylinder: 1000kPa
Limit pressure difference between each cylinder: ≤ 98kPa

Is the result normal?

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

10 . Check the engine valve timing

(a) Check whether the engine timing gear marks have been properly aligned and check
for gear damage, loose belt, timing jump.
Is the result normal?
 04-154 Diagnosis - Engine Control System

Yes> Go to next step.

No> Perform timing belt alignment or replace the timing belt.

11 . Check the engine's mechanical parts

(a) Observe the internal cylinder state with an autoscope.
04 (b) Observe the feedback voltage variation.
(c) Disassemble the engine and repair its internal mechanical fault.
Clean the carbon deposit or disassemble and check the cylinder heads. Check the
valves and intake manifold for carbon deposit. Such as excessive gap and poor sealing
between the piston ring and cylinder block, air leak at cylinder gaskets, loose valve
guide, lax valve closing, carbon deposit.

Is the result normal?

Yes> Go to next step.
No> Repair the engine's internal mechanical fault.

12 . Replace the ECM.

(a) Replace the ECM. Refer toChapter11 Engine Control System - Engine Control Module,
Replacement)
(b) Check the engine data flow, and make sure the engine fault is absent and the system
functions well.
 Diagnosis - Engine Control System 04-155

Slow response, retarded acceleration and acceleration imbalance

Symptom Status Diagnostic Logic Possible Causes
• Air-fuel ratio control
When the accelerator system fault
pedal is pressed, • Fuel supply system
Slow response, 04
speed can't rise Improper air-fuel ratio fault
retarded acceleration
immediately, or poor compression
and acceleration • Excessively low
acceleration is slow pressure
imbalance compression
or engine revolution
pressure
temporarily falls.
• ECM

Diagnostic procedure for fault symptom

1. Check the engine failure indicator signal and DTC

(a) Read DTC with the diagnosis instrument.
Is the DTC present?
Yes> Refer to the DTC, and perform the DTC fault diagnostic procedure.
No> Go to next step.

2. Check air inlet system

(a) Check each connector, gasket and vacuum hose of intake pipes, exhaust gas
recirculation system and evaporative emission control system.
(b) Check the air filter for element blockage.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

3. Check the idle speed

(a) Check whether engine normally runs at idle speed.
Is the result normal?
Yes> Go to next step.
No> Refer to the engine symptom diagnosis chart - troubleshoot idling faults and
confirm that no faults occur.

4. Check the water temperature sensor and intake manifold absolute

pressure/temperature sensor
(a) Check whether the water temperature sensor and intake manifold absolute
pressure/temperature sensor have been installed correctly.
(b) Remove the intake manifold absolute pressure/temperature sensor.
(c) Check the probe hole for blockage; check whether the resistance between each terminal
meets the standards.
(d) Check the temperature sensor for contamination.
 04-156 Diagnosis - Engine Control System

(e) Ignition switch: ON. Read the data flows of the engine intake manifold absolute pressure
(MAP)/temperature sensor and water temperature sensor indicated on the diagnosis
tester.
Is the result normal?

04
Yes> Go to next step.
No> Clean or replace the faulty component.

5. Check the throttle position

(a) Use a diagnostic tester to check whether the throttle is normal.
(b) Check whether the throttle position is normal when the accelerator pedal is depressed.
Is the result normal?
Yes> Go to next step.
No> Repair or replace the faulty parts.

6. Check the fuel injectors

(a) Pull out the connectors of the fuel injectors.
(b) Pull out the fuel distribution pipes and fuel injector altogether.
(c) Apply the 12V voltage of the battery onto the fuel injectors.
(d) All injectors are supposed to inject a standard amount of fuel and evenly atomized.
Note
While checking the fuel injection, if the injected fuel is in columnar shape, not in cone
shape, or the fuel volume injected from each of the four cylinders varies greatly (over
5ml) from each other under the same conditions, the injectors should be replaced.
Check the fuel injection nozzle for gel-like substance; if any, bathe and spray with
cleaning agent; otherwise it will lead to inadequate fuel injection or poor performance
in acceleration.
Danger
While checking the fuel injection, if the injected fuel is in columnar shape, not in cone
shape, or the fuel volume injected from each of the four cylinders varies greatly (over
5ml) from each other under the same conditions, the injectors should be replaced.
Check the fuel injection nozzle for gel-like substance; if any, bathe and spray with
cleaning agent; otherwise it will lead to inadequate fuel injection or poor performance
in acceleration.
• Place a sign "Caution: Flammable" at the workplace.
• It is required to conduct maintenance work at the well-ventilated place, with a
carbon dioxide fire extinguisher.
• NO SMOKING is a must while fuel system maintenance is involved.The workplace
should be far away from open flames and sparks.
• Collect the drained fuel in a explosion-proof container.

Is the result normal?

Yes> Go to next step.
 Diagnosis - Engine Control System 04-157

NO> Clean the injectors. Check the working condition of the injectors again. If the
injectors fail to work well, replace the injectors.

7. Check the fuel system pressure

(a) Check the fuel system pressure. (SeeChapter 12A Fuel System - Precautions)
Is the result normal? 04
Yes> Go to step 9.
No> Repair or replace the components or circuit in the fuel system; if the fuel pressure
is lower than 300 kPa, go to the next step.

8. Check the fuel supply of the fuel system

(a) Check the fuel inlets for leakage or blockage.
(b) Check the gasoline filter for blockage.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

9. Checking the exhaust system

(a) Checking the exhaust system and three-way catalytic converter.
(b) Check exhaust pipes for blockage with a exhaust back pressure gauge.

10 . Check the cylinder pressure

(a) Perform pressure test on cylinder compression feature.
Pressure in each cylinder: 1200±200kPa
Limit value for each cylinder: 1000kPa
Limit pressure difference between each cylinder: ≤ 98kPa

Is the result normal?

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

11 . Check the engine valve timing

(a) Check whether the engine timing gear marks have been properly aligned and check
for gear damage, loose belt, timing jump.
Is the result normal?
Yes> Go to next step.
No> Perform timing belt alignment or replace the timing belt.

12 . Check the engine's mechanical parts

(a) Observe the internal cylinder state with an autoscope.
(b) Observe the feedback voltage variation.
(c) Disassemble the engine and repair its internal mechanical fault.
 04-158 Diagnosis - Engine Control System

Clean the carbon deposit or disassemble and check the cylinder heads. Check the
valves and intake manifold for carbon deposit. Such as excessive gap and poor sealing
between the piston ring and cylinder block, air leak at cylinder gaskets, loose valve
guide, lax valve closing, carbon deposit.

04 Is the result normal?

Yes> Go to next step.
No> Repair the engine's internal mechanical fault.

13 . Replace the ECM.

(a) Replace the ECM. Refer toChapter11 Engine Control System - Engine Control Module,
Replacement)
(b) Check the engine data flow, and make sure the engine fault is absent and the system
functions well.
 Diagnosis - Engine Control System 04-159

Poor Performance of Accelerating

Symptom Status Diagnostic Logic Possible Causes
The accelerating
performance can not
be reflected by the • Ignition system fault 04
position of accelerator • Air fuel ratio control
pedal, though you system fault
can depress the It may cause by • Fuel supply system
pedal smoothly, the ignition system fault, fault
Poor performance of
expected accelerating improper air-fuel ratio
accelerating • Compression
effect or the max or compression
pressure too low
speed cannot be pressure.
• Exhaust system
achieved. The engine
blocked
misfire, backfire,
• ECM
vehicle sudden stop
or speed changing
may happen.

Diagnostic procedure for fault symptom

1. Check the engine failure indicator signal and DTC

(a) Read DTC with the diagnosis instrument.
Is the DTC present?
Yes> Refer to the DTC, and perform the DTC fault diagnostic procedure.
No> Go to next step.

2. Perform the visual inspection and exterior inspection

(a) Make an external visual check.
(b) Check whether the hand brake is released.
(c) Check whether the clutch is slipping.
(d) Check whether the four-wheel alignment of the chassis is normal.
(e) Check whether all the tyres belong to the same model and the air pressure is normal.
(f) Check whether the brake system works properly. Clear braking drag fault, brake wheel
cylinder return fault and ABS fault.
Is the result normal?
Yes> Go to next step.
No> Eliminate the external faults, and make sure those symptoms no longer exist.

3. Check the throttle position

(a) Use a diagnostic tester to check whether the throttle is normal.
(b) Check whether the throttle position is normal when the accelerator pedal is depressed.
Is the result normal?
Yes> Go to next step.
 04-160 Diagnosis - Engine Control System

No> Repair or replace the faulty parts.

4. Check the water temperature sensor and intake manifold's absolute

pressure/temperature sensor
(a) Check whether the water temperature sensor and intake manifold absolute
pressure/temperature sensor have been installed correctly.
04
(b) Remove the intake manifold absolute pressure/temperature sensor.
(c) Check the probe hole for blockage; check whether the resistances between each
terminal are equal to the standard value.
(d) Check the temperature sensor for contamination.
(e) Ignition switch: ON. Read the data flows of the engine intake manifold absolute pressure
(MAP)/temperature sensor and water temperature sensor indicated on the diagnosis
tester.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

5. Check the fuel system pressure

(a) Check the fuel system pressure. (See Chapter 12A Fuel System - Precautions)
Is the result normal?
Yes> Go to step 9.
No> Repair or replace the components or circuit in the fuel system; if the fuel pressure
is lower than 300 kPa, go to the next step.

6. Check the fuel supply of the fuel system

(a) Check the fuel inlets for leakage or blockage.
(b) Check the gasoline filter for blockage.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

7. Check the fuel injectors

(a) Pull out the connectors of the fuel injectors.
(b) Pull out the fuel distribution pipes and fuel injector altogether.
(c) Apply the 12V voltage of the battery onto the fuel injectors.
(d) All injector are supposed to inject a standard amount of fuel and evenly atomized.
Note
While checking the fuel injection, if the fuel injected is in columnar shape, not in cone
shape, or the fuel volume injected from each of the four cylinder varies greatly (over
5ml) from each other, the injectors should be replaced. Check the fuel injection nozzle
for gel-like substance; if any, bathe and spray resin it with cleaning agent; otherwise
it will lead to inadequate fuel injection or poor performance in acceleration.
 Diagnosis - Engine Control System 04-161

Danger
While checking the fuel injection, if the fuel injected is in columnar shape, not in cone
shape, or the fuel volume injected from each of the four cylinder varies greatly (over
5ml) from each other, the injectors should be replaced. Check the fuel injection nozzle
for gel-like substance; if any, bathe and spray resin it with cleaning agent; otherwise
it will lead to inadequate fuel injection or poor performance in acceleration. 04
• Place a sign read "Caution: Flammable" at the workplace.
• It is required to conduct maintenance work at the well-ventilated place, with a
carbon dioxide fire extinguisher.
• NO SMOKING is allowed while fuel system maintenance is involved. The
workplace should be far away from open flames and sparks.
• Collect the drained fuel in a explosion-proof container.

Is the result normal?

Yes> Go to next step.
NO> Clean the injectors. Check the working condition of the injectors again. If the
injectors fail to work well, replace the injectors.

8. Check the secondary ignition system

(a) Pull out the injector fuse.
(b) Pull out the high-voltage power line and remove the spark plug.
(c) Connect the spark plug to the high-voltage wire, and make its negative terminal contact
the cylinder body.
(d) Start the engine to test the secondary ignition system.
Expected result: when the engine is rotating, you can see strong blue-white
sparks on each spark plug.

Is the result normal?

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

9. Check the secondary ignition system

(a) Check the resistance in the high-voltage coil, and clean the connector terminals.
Resistance: ≥ 4 kΩ
(b) Check the spark plug for carbon deposit or carbon trace, check the ceramic insulation
part for cracks and electric leakage, check whether the gaps are normal, check whether
the positive and negative terminals are ablated, and clean the spark plug.
Is the result normal?
Yes> Go to next step.
No> Clean or replace the faulty component.

10 . Check the cylinder pressure

(a) Perform pressure test on cylinder compression feature.
Pressure in each cylinder: 1200±200kPa
 04-162 Diagnosis - Engine Control System

Limit value for each cylinder: 1000kPa

Limit pressure difference between each cylinder: ≤ 98kPa

Is the result normal?

Yes> Go to step 12.
04
No> Go to next step.

11 . Check the engine valve timing

(a) Check whether the engine timing gear marks has been properly aligned and check for
gear damage, loose belt, timing jump.
Is the result normal?
Yes> Go to next step.
No> Perform timing belt alignment or replace the timing belt.

12 . Check the engine's mechanical parts

(a) Observe the cylinder state inside the cylinder with an autoscope.
(b) Observe the feedback voltage variation.
(c) Disassemble the engine and repair its internal mechanical fault.
Clean the carbon deposit or disassemble and check the cylinder heads. Check the
valves and intake manifold for carbon deposit. E.g." excessive gap between the piston
and cylinder, poor sealing, air leak at cylinder gaskets, lax valve closing, carbon deposit.

Is the result normal?

Yes> Go to next step.
No> Repair the engine's internal mechanical fault.

13 . Replace the ECM.

(a) Replace the ECM. Refer toChapter11 Engine Control System - Engine Control Module,
Replacement)
(b) Check the engine data flow, and make sure the internal engine fault is absent and the
system functions well.
 Diagnosis - Supplemental Restraint System 04-163

Supplemental Restraint System

Precautions
Danger

• Failure to follow the correct steps to carry out the service operations could cause
the airbag to unexpectedly deploy. It may lead to a serious accident. Furthermore, 04
if a mistake is made in servicing the airbag system, it is possible that the airbag
will fail to operate when required.
• Work must be started after 90 seconds from the time the ignition switch is turned
off and the positive and negative terminal cables are disconnected from the
battery. The supplemental restraint system is equipped with a back–up power
supply, so, if work is started within 90 seconds after disconnecting the positive
and negative terminal cables from the battery, the airbag may suddenly deploy.
• Do not directly expose the horn button assembly to hot air or flames.

Note

• Malfunctions symptoms of the airbag system are difficult to confirm, so the

diagnostic trouble codes (DTC) are the most important source of important when
troubleshooting. When troubleshooting the airbag system, always check the the
diagnostic trouble codes (DTC) before disconnecting the battery.
• Use the tester to clear the diagnostic trouble code after finishing the service; If
clearing the the DTC fails, please replace the airbag control unit. And check
again for the DTC.
• Even in case of a minor collision where the airbag does not deploy, the horn
button assembly and the airbag ECM should be inspected.
• Always disconnect the ECM connector of the airbag control unit, if shocks are
likely to be applied to the ECM of the airbag control unit during repairs.
• Never use the airbag related parts from another vehicle. When replacing parts,
replace them with new parts.
• Never disassemble the horn button assembly.
• If the horn button assembly dropped, or if there are cracks,dent or other defects
in the case, replace them with new ones.
• Use a multimeter with high impedance for troubleshooting of an electrical circuit.
• Information labels are attached to the airbag components. Follow the instructions
on the notices of the label during repairs.
• Check the the airbag warning light after completing the operation of the airbag
system.
• When the negative terminal cable is disconnected from the battery, the memory
of the electronic clock and audio systems will be eliminated. Record all necessary
data before repairing. Reset the audio system and adjust the electronic clock
after repairing. Never use a back-up power supply from another vehicle to avoid
losing data in the each memory system. The back-up power supplies electricity
to the airbag system, which may cause the airbag to unexpectedly deploy.
 04-164 Diagnosis - Supplemental Restraint System

Airbag Warning Light Always ON

Circuit Diagram

Airbag fuse

04
Ignition switch
ACC/ON

Red-black

Red-black Red-black

F12 F17
Airbag fuse Instrument
cluster fuse
7.5A 7.5A

Brown-red

32

Instrument Diagnose interface

cluster V019
Yellow V011
3 7

Yellow-gray Blue

1 17 22

Airbag module
V046

3 4 6 5 16

Yellow- Yellow-black Yellow- Yellow-green

red blue Black
a2 b2
Clock spring
V049

Yellow- Yellow-black
red

_ _
+ +

Driver airbag Passenger airbag

V047 V048 V205
fpwx710077

Diagnostic Steps
 Diagnosis - Supplemental Restraint System 04-165

1. Check the harness and connector (Instrument Cluster - Airbag Control Unit)
(a) Ensure that the ignition switch is turn off and battery negative terminal is disconnected
for more than 90s.
(b) Disconnect the connector V011 of the instrument cluster.
(c) Disconnect the connector V046 of the airbag control unit.
04
(d) Measure the resistance according to the value
in the following table.
Standard resistance (Check whether there
are short circuits)
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Multimeter Connection Standard Value

V046
V046 （17）- Ground ≥ 1 MΩ

fpwx040011

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness and connector.

2. Inspect the instrument cluster

(a) Ignition switch: OFF.
(b) Disconnect the connector V011 of the instrument cluster.
(c) Replace with a functional instrument cluster.
(d) Ignition switch: ON.
Observe whether the airbag warning light is always on.
No - Replace the instrument cluster.
Yes> Replace the airbag control unit.
 04-166 Diagnosis - Supplemental Restraint System

Airbag Warning Light OFF

Circuit Diagram

Airbag fuse

04
Ignition switch
ACC/ON

Red-black

Red-black Red-black

F12 F17
Airbag fuse Instrument
cluster fuse
7.5A 7.5A

Brown-red

32

Instrument Diagnose interface

cluster V019
Yellow V011
3 7

Yellow-gray Blue

1 17 22

Airbag module
V046

3 4 6 5 16

Yellow- Yellow-black Yellow- Yellow-green

red blue Black
a2 b2
Clock spring
V049

Yellow- Yellow-black
red

_ _
+ +

Driver airbag Passenger airbag

V047 V048 V205
fpwx710077

Diagnostic Steps
 Diagnosis - Supplemental Restraint System 04-167

1. Check the harness and connector (Instrument Cluster - Airbag Control Unit)
(a) Ensure that the ignition switch is turn off and battery negative terminal is disconnected
for more than 90s.
(b) Disconnect the connector V011 of the instrument cluster.
(c) Disconnect the connector V046 of the airbag control unit.
04
(d) Measure the resistance according to the value
in the following table.
Standard resistance (Check whether there
is open circuit)
V046
V011 Multimeter Connection Standard Value
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

＜2Ω
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
3 V011(3)-V046(17)

fpwx040012

Is the result normal?

Yes> Replace the airbag control unit.
No> Repair or replace the harness and connector.

2. Inspect the instrument cluster

(a) Ignition switch: OFF.
(b) Disconnect the connector V011 of the instrument cluster.
(c) Replace with a functional instrument cluster.
(d) Ignition switch: ON.
Observe whether the airbag warning light first comes onand then goes out.
Yes> Replace the instruction cluster.
No> Replace the airbag control unit.
 04-168 Diagnosis - Heating Ventilation and Air Conditioning

Heating Ventilation and Air Conditioning

Precautions
1. Do not handle refrigerant in the enclosed place or near open flames.
2. Must wear eye protective equipment.
3. Be careful not to expose eyes or skin to the liquid refrigerant. In case that eyes
04
or skin is in contact:
(a) Rinse with plenty of water.
(b) Apply the clear Vaseline on the skin.
(c) Visit the doctor or go to hospital for a professional treatment soon.
4. Never heat the container or make it exposed near open flames.
5. Never drop or strike the container.
6. If there is inadequate refrigerant in the cooling system, stop the compressor.
(a) There is not enough refrigerant or insufficient lubrication in the A/C system, which
probably damages the compressor.
7. Never add excessive refrigerant to the system.
(a) Excessive refrigerant will cause some problems, like weak refrigeration performance,
poor fuel economy, etc.
8. Never run the compressor without refrigerant.
 Diagnosis - Heating Ventilation and Air Conditioning 04-169

Basic Inspection
Step Inspection item Measure
Check for the refrigerant. Yes Go to next step.
• Loosen the protective cover of ser-
1 vice valves in the A/C cooling system 04
and press the valve core. No Add the refrigerant.
Is the result normal?
Check the A/C control panel. Yes Go to next step.
• Unscrew the air volume knob of the
A/C control panel air and press the
2 A/C switch. Refer to the Fault Symptom Ta-
• Visually inspect whether the A/C op- No
ble
erating indicator lights up.
Is the result normal?
Inspect the electromagnetic clutch. Yes Go to next step.
• Inspect whether the electromagnetic
3 clutch properly pulls in. Refer to the Fault Symptom Ta-
No
Is the result normal? ble

Inspect the drive belt. Yes Go to next step.

• Inspect whether the drive belt is
4 Refer to the Fault Symptom Ta-
slippery. No
ble
Is the result normal?
Inspect the compressor. Yes Go to next step.
• Inspect whether there is abnormal
5 Refer to the Fault Symptom Ta-
noise when the compressor works. No
ble
Is the result normal?
Inspect the condenser. Yes Go to next step.
• Inspect whether there are impurities
between the condenser and the radi-
ator.
6 Clear the impurities or replace
• Inspect whether the condenser fan No
works properly. the condenser fan.
Inspect whether the condenser fan
works properly.
Inspect the pipe and line. Refer to the Fault Symptom Ta-
Yes
• Inspect whether the bent or twisted ble
7 pipe or line will cause blockage
problem. No Lay the pipe and line again.
Is the result normal?
 04-170 Diagnosis - Heating Ventilation and Air Conditioning

Component Diagrams

5
04 1

2
4
fpwx040200

1 Temperature switch 4 Indoor/outdoor circulation loop

2 Air volume switch switch
3 Mode switch 5 AC Switch
 Diagnosis - Heating Ventilation and Air Conditioning 04-171

Fault Symptom Table

The following table will help to you find the cause of the fault. The serial number indicates
the possibility sequence for the fault causes. Check every parts according to this sequence,
and replace where necessary.

Fault symptom Suspicious positions Refer to 04

1. Fuse -
Functions of air
conditioning 2. Relay -
system failure
3. Harness -
1. Fuse -
2. Relay -
Chapter 61 Heating Ventilation and Air Con-
3. Front blower switch ditioning-Multimedia and A/C Controller As-
Front blower
sembly, Replacement
failure
Chapter 61 Heating Ventilation and Air Con-
4. Blower speed resistor ditioning-Front A/C Control Module, Replace-
ment
5. Harness -
1. Fuse -
Rear evaporator Chapter 61 Heating Ventilation and Air Con-
blower motor 2. Rear A/C volume switch ditioning-Rear A/C Volume Switch, Replace-
failure ment
3. Harness -
Chapter 61 Heating Ventilation and Air Con-
1. A/C control panel (blower
ditioning-Multimedia and A/C Controller As-
speed control switch )
sembly, Replacement
Chapter 61 Heating Ventilation and Air Con-
2. Front blower speed resis-
ditioning-Front A/C Control Module, Replace-
tor
Insufficient air ment
volume for front
Chapter 61 Heating Ventilation and Air Con-
row
3. Front blower motor ditioning-Front A/C Control Module, Replace-
ment
Chapter 61 Heating Ventilation and Air Con-
4. Air outlets in the front row
ditioning- Instrument Vents, Replacement
5. Harness- -
Insufficient air Chapter 61 Heating Ventilation and Air Con-
1. Top evaporator air vol-
volume for rear ditioning-Rear A/C Volume Switch, Replace-
ume switch
row ment
 04-172 Diagnosis - Heating Ventilation and Air Conditioning

Fault symptom Suspicious positions Refer to

Chapter 61 Heating Ventilation and Air Con-
2. Rear A/C speed resistor ditioning-Rear A/C Speed Resistor, Replace-
ment
3. Harness -
04
1. Fuse -
2. Relay -
Chapter 61 Heating Ventilation and Air Con-
3. A/C compressor
ditioning-A/C Compressor, Maintenance
Chapter 61 Heating Ventilation and Air Con-
4. Check the A/C control
Front A/C not ditioning-Multimedia and A/C Controller As-
panel
cooling sembly, Replacement
Chapter 61 Heating Ventilation and Air Con-
5. Refrigerant
ditioning- Refrigerant, Replacement
Chapter 61 Heating Ventilation and Air Con-
6. Pressure switch
ditioning- Pressure switch, Replacement
7. Harness -
 Diagnosis - Heating Ventilation and Air Conditioning 04-173

Air Conditioning Power Supply System Fault

Circuit Diagram

A/C system
A
04
Ignition switch
IG1 Battery The Engine Control Unit
Yellow-purple (ECU)
Yellow-red Orange-green

4 2
Fuse box on
F26 F16 F11
Overhead Compressor driver’s side
IG.S Compressor
blower fuse fuse fuse relay V035
7.5A 10A
7.5A
3 1

Orange Orange
Yellow-white
The Engine Control Unit
(ECU)

Yellow-white
Yellow-white
B
F101
1 Green
C102
Interior back light
C101
11
Green-white V105
Yellow-white
Serial V103
No. 2 6 4 1 5 3 5
Gear E101

OFF A/C switch

V014 Interior back light

ON

Yellow-blue
Compressor
E023
Yellow-
Yellow-blue Black
blue
2 3
Medium
voltage
Dual switch Pressure switch
voltage V013
switch

4 1
Brown

Green-black Engine Control Unit

Black (ECU)

Black
Self grounding
V204
fpwx710055
 04-174 Diagnosis - Heating Ventilation and Air Conditioning

A/C system

A
04
Ignition switch
IG2

Yellow-purple
Fuse box on
F25
Blower driver’s side
fuse V035
25A

Yellow-red
B
V105
11 Serial
C101 No. 1 2 3 4 7 6
Gear
Yellow-white
C102 OFF
1
F101
1

A/C control
2 panel
V026

Serial
GND 1 2 3
Gear No. Yellow- Yellow- Yellow- Yellow
OFF green black blue
Overhead
1 evaporator
F002 Yellow-black
2
Yellow-black 4 3 1 2
3
1
Speed
Black regulation
Front resistance
F101
blower V027
6 V025
C102
2
Black
Black

C201
V201

fpwx710056

Diagnostic Steps

1. Check the fuse.

(a) Disconnect the battery cable at the negative end.
 Diagnosis - Heating Ventilation and Air Conditioning 04-175

(b) Check the fuse F11 in the fuse box by the

driver side: 10 A.
(c) Check the fuse F16 in the fuse box by the
driver side: 7.5A.

04

fpwx040013

Is th fuse blown?
Yes> Replace the fuse.
No> Go to next step.

2. Check the harness and connector(compressor relay - fuse)

(a) Ignition switch: OFF.
(b) Unplug the air conditioning relay.
(c) Ignition switch: ON.
(d) Measure the voltage according to the value
in the following table.
Standard voltage
1
Compressor relay

F6 F5 25A
4 2

3 K1
Front fog light
Fan
Multimeter Connection Standard Value
F7 15A
Diagnosis Instrument ECU

F8 7.5A
Horn/brake light/interior light
F11(10A)-
1
High-speed fan relay

4 2
F9 10A
Danger warning BCM compressor relay Battery voltage
3 K2 F10 10A

F11
Compressor

10A
K1(4)
Airbag

F12 7.5A
1 width light Rear fog light
Lighting relay

K3 4 2 F13 10A
Starter
3 F14 30A

fpwx040014

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

3. Check the harness and connector (compressor relay - fuse)

(a) Ignition switch: OFF.
(b) Unplug the air conditioning relay.
(c) Ignition switch: ON.
 04-176 Diagnosis - Heating Ventilation and Air Conditioning

(d) Measure the voltage according to the value

in the following table.
Standard voltage

1
Multimeter Connection Standard Value
Compressor relay

F6 F5 25A F4 F3 40A
4 2

04
K1 3
Front fog light
Fan

Turn light Reverse light

AM1
F16(7.5A)-relay(1) Battery voltage
F7 15A F15 10A
Diagnosis Instrument ECU IG.S

F8 7.5A F16 7.5A

Instrument cluster
1 Horn Brake light/interior light
High-speed fan relay

F9 10A F17 7.5A

K2 4 2 Hazard warning BCM Low Beam

3 F10 10A F18 15A

Compressor High beam

F11 10A F19 15A

Airbag Fuel pump

F12 7.5A F20 10A

1 Clearance light Rear fog light Ignition coil

4 2 F21 15A
Light relay

K3 F13 10A
Fuel injector/oxygen sensor
Starter
3 F22 10A
F14 30A

fpwx040015

Is the result normal?

Yes> Replace the compressor relay.
No> Repair or replace the harness.
 Diagnosis - Heating Ventilation and Air Conditioning 04-177

Front Blower out of Work

Circuit Diagram

A/C system
A
04
Ignition switch
IG1 Battery The Engine Control Unit
Yellow-purple (ECU)
Yellow-red Orange-green

4 2
Fuse box on
F26 F16 F11
Overhead Compressor driver’s side
IG.S Compressor
blower fuse fuse fuse relay V035
7.5A 10A
7.5A
3 1

Orange Orange
Yellow-white
The Engine Control Unit
(ECU)

Yellow-white
Yellow-white
B
F101
1 Green
C102
Interior back light
C101
11
Green-white V105
Yellow-white
Serial V103
No. 2 6 4 1 5 3 5
Gear E101

OFF A/C switch

V014 Interior back light

ON

Yellow-blue
Compressor
E023
Yellow-
Yellow-blue Black
blue
2 3
Medium
voltage
Dual switch Pressure switch
voltage V013
switch

4 1
Brown

Green-black Engine Control Unit

Black (ECU)

Black
Self grounding
V204
fpwx710055
 04-178 Diagnosis - Heating Ventilation and Air Conditioning

A/C system

A
04
Ignition switch
IG2

Yellow-purple
Fuse box on
F25
Blower driver’s side
fuse V035
25A

Yellow-red
B
V105
11 Serial
C101 No. 1 2 3 4 7 6
Gear
Yellow-white
C102 OFF
1
F101
1

A/C control
2 panel
V026

Serial
GND 1 2 3
Gear No. Yellow- Yellow- Yellow- Yellow
OFF green black blue
Overhead
1 evaporator
F002 Yellow-black
2
Yellow-black 4 3 1 2
3
1
Speed
Black regulation
Front resistance
F101
blower V027
6 V025
C102
2
Black
Black

C201
V201

fpwx710056

Diagnostic Steps

1. Check the fuse.

(a) Disconnect the battery cable at the negative end.
 Diagnosis - Heating Ventilation and Air Conditioning 04-179

(b) Check the blower fuse F25 in the fuse box by

the driver side: 25A.

04

fpwx040016

Is the result normal?

Yes> Go to next step.
No> Replace the fuse.

2. Check the harness and connector (Speed resistor - Blower)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V025 of the blower motor.
(c) Disconnect the connector V027 of the speed resistor.
(d) Measure the resistance according to the value
in the following table.
Standard resistance (Check whether there
is open circuit):

V025 V027 Multimeter Connection Standard Value

2 4 3
V025(1)-V027(2) ＜2Ω
1 2 1

fpwx040017

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

3. Check the harness and connector (Blower- Ground)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the blower connector V025.
 04-180 Diagnosis - Heating Ventilation and Air Conditioning

(c) Measure the resistance according to the value

in the following table.
Standard resistance (Check whether there
is open circuit):
V025

1
Multimeter Connection Standard Value
04
2
V025 (2)- Ground ＜2Ω

fpwx040019

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
4. Check the harness and connector (Speed resistor - A/C control panel)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the blower speed resistor V027.
(c) Disconnect the connector V026 of A/C control panel.
(d) Measure the resistance according to the value
in the following table.
Standard resistance (Check whether there
V026 V027 is open circuit):
8 5
4 3 1
1 2
Multimeter Connection Standard Value
3 4

V026(3)-V027(4)
＜2Ω
V026(4)-V027(3)

fpwx040020
 Diagnosis - Heating Ventilation and Air Conditioning 04-181

Standard resistance (Check whether there is

open circuit):
Multimeter Connection Standard Value
V026 V027
V026(7)-V027(1)
1 4 4 3 ＜2Ω
5 6 7 8
2 1
V026(6)-V027(2) 04

fpwx040021

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

5. Check the harness and connector (Front blower - A/C control panel)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V025 of the front blower.
(c) Disconnect the connector of A/C control panel.
(d) Measure the resistance according to the value
in the following table.
Standard resistance (Check whether there
is open circuit):

V025 V026 Multimeter Connection Standard Value

2

1
1
5 6
4
8
V025(1)-V026(6) ＜2Ω

fpwx040022

Is the result normal?

Yes> Replace the front blower or speed resistor.
No> Repair or replace the harness.
 04-182 Diagnosis - Heating Ventilation and Air Conditioning

Rear Evaporator Blower Failure

Circuit Diagram

A/C system
A
04
Ignition switch
IG1 Battery The Engine Control Unit
Yellow-purple (ECU)
Yellow-red Orange-green

4 2
Fuse box on
F26 F16 F11
Overhead Compressor driver’s side
IG.S Compressor
blower fuse fuse fuse relay V035
7.5A 10A
7.5A
3 1

Orange Orange
Yellow-white
The Engine Control Unit
(ECU)

Yellow-white
Yellow-white
B
F101
1 Green
C102
Interior back light
C101
11
Green-white V105
Yellow-white
Serial V103
No. 2 6 4 1 5 3 5
Gear E101

OFF A/C switch

V014 Interior back light

ON

Yellow-blue
Compressor
E023
Yellow-
Yellow-blue Black
blue
2 3
Medium
voltage
Dual switch Pressure switch
voltage V013
switch

4 1
Brown

Green-black Engine Control Unit

Black (ECU)

Black
Self grounding
V204
fpwx710055
 Diagnosis - Heating Ventilation and Air Conditioning 04-183

A/C system

A
04
Ignition switch
IG2

Yellow-purple
Fuse box on
F25
Blower driver’s side
fuse V035
25A

Yellow-red
B
V105
11 Serial
C101 No. 1 2 3 4 7 6
Gear
Yellow-white
C102 OFF
1
F101
1

A/C control
2 panel
V026

Serial
GND 1 2 3
Gear No. Yellow- Yellow- Yellow- Yellow
OFF green black blue
Overhead
1 evaporator
F002 Yellow-black
2
Yellow-black 4 3 1 2
3
1
Speed
Black regulation
Front resistance
F101
blower V027
6 V025
C102
2
Black
Black

C201
V201

fpwx710056

Diagnostic Steps

1. Check the fuse.

(a) Disconnect the battery cable at the negative end.
 04-184 Diagnosis - Heating Ventilation and Air Conditioning

(b) Check the top blower fuse of the fuse box F26
by the front passenger side: 7.5A.

04

fpwx040023

Is the result normal?

Yes> Go to next step.
No> Replace the fuse.

2. Check the top evaporator air volume switch.

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the top evaporator air volume switch connector.

fpwx040056

(c) Check the top evaporator air volume switch according to the value in the following
table.
Switch location Multimeter Connecting Pin Standardvalue
1th Gear GND-1 ＜2Ω
 Diagnosis - Heating Ventilation and Air Conditioning 04-185

Switch location Multimeter Connecting Pin Standardvalue

2nd Gear GND-2
3rd Gear GND-3

Is the result normal?

04
Yes> Go to next step.
No> Replace the top evaporator air volume switch.

3. Check the harness and connector (Top evaporator air volume switch- Ground)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the top evaporator air volume switch connector F002.
(c) Measure the resistance according to the value in the following table.
Standard resistance (Check whether there is open circuit)

Multimeter Connection Standard Value

F002/GND-Ground ＜2Ω

Is the result normal?

Yes> Replace the rear top evaporator air volume switch.
No> Repair or replace the harness.
 04-186 Diagnosis - Heating Ventilation and Air Conditioning

Front A/C not Cooling

Circuit Diagram

A/C system
A
04
Ignition switch
IG1 Battery The Engine Control Unit
Yellow-purple (ECU)
Yellow-red Orange-green

4 2
Fuse box on
F26 F16 F11
Overhead Compressor driver’s side
IG.S Compressor
blower fuse fuse fuse relay V035
7.5A 10A
7.5A
3 1

Orange Orange
Yellow-white
The Engine Control Unit
(ECU)

Yellow-white
Yellow-white
B
F101
1 Green
C102
Interior back light
C101
11
Green-white V105
Yellow-white
Serial V103
No. 2 6 4 1 5 3 5
Gear E101

OFF A/C switch

V014 Interior back light

ON

Yellow-blue
Compressor
E023
Yellow-
Yellow-blue Black
blue
2 3
Medium
voltage
Dual switch Pressure switch
voltage V013
switch

4 1
Brown

Green-black Engine Control Unit

Black (ECU)

Black
Self grounding
V204
fpwx710055
 Diagnosis - Heating Ventilation and Air Conditioning 04-187

A/C system

A
04
Ignition switch
IG2

Yellow-purple
Fuse box on
F25
Blower driver’s side
fuse V035
25A

Yellow-red
B
V105
11 Serial
C101 No. 1 2 3 4 7 6
Gear
Yellow-white
C102 OFF
1
F101
1

A/C control
2 panel
V026

Serial
GND 1 2 3
Gear No. Yellow- Yellow- Yellow- Yellow
OFF green black blue
Overhead
1 evaporator
F002 Yellow-black
2
Yellow-black 4 3 1 2
3
1
Speed
Black regulation
Front resistance
F101
blower V027
6 V025
C102
2
Black
Black

C201
V201

fpwx710056

Diagnostic Steps

1. Check the compressor relay.

(a) Disconnect the battery cable at the negative end.
 04-188 Diagnosis - Heating Ventilation and Air Conditioning

(b) Unplug the compressor relay.

(c) Check the compressor relay according to the
value in the following table.
Conditions
Multimeter Connecting
Specified
Pin Value
1
Under normal
Compressor relay

25A
04 4 2
F6 F5 F4 F3 40A

K1 3
Fan
1-2 Breakover
Front fog light Turn light Reverse light
AM1
conditions
F7 15A F15 10A
Diagnosis instrument ECU IG.S
F8 7.5A F16
7.5A
Instrument cluster
Apply the
1 Horn Brake light/interior light

power supply
High-speed fan relay

F9 10A F17
7.5A
4 2 Hazard warning BCM Low beam

K2 3 F10 10A F18 15A

Compressor High beam voltage
F11 10A F19 15A 4-3 ＜2Ω
F12
Airbag

7.5A F20
Fuel pump

10A
between the
1 Ignition coil

4 2
Width light Rear Fog Light

15A pin 1 and pin

Light relay

F21
F13 10A
Fuel injector/oxygen sensor
K3 3 Starter
F14 30A F22 10A
2
fpwx040024

Is the result normal?

Yes> Go to next step.
No> Replace the compressor relay.

2. Check the harness and connector (Compressor relay - Ground)

(a) Ignition switch: OFF.
(b) Unplug the compressor relay.
(c) Ignition switch: ON.
(d) Measure the voltage according to the value
in the following table.
Standard voltage

Multimeter Connection Standard Value

1
25A 40A
Compressor relay (4) -
Compressor relay

F6 F5 F4 F3
4 2

K1 3 Fan AM1
Ground
F7
Front fog light

15A F15
Turn light Reverse light

10A Battery voltage

F8
Diagnosis instrument ECU

7.5A
Horn Brake light/interior light
F16
IG.S
7.5A
Instrument cluster
Compressor relay (1) -
1
10A F17 7.5A
Ground
High-speed fan relay

F9
K2 4 2 Hazard warning BCM Low beam

3 F10 10A F18 15A

Compressor High beam

F11 10A F19 15A

Airbag Fuel pump

F12 7.5A F20 10A

1 Ignition coil
Width light Rear Fog Light

4 2 F21 15A
Light relay

K3 F13 10A
Fuel injector/oxygen sensor
Starter
3 F22 10A
F14 30A
fpwx040025

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

3. Check the harness and connector (Compressor - Ground)

(a) Ignition switch: OFF.
(b) Disconnect the compressor connector E023.
(c) Start the engine and turn on the front A/C.
 Diagnosis - Heating Ventilation and Air Conditioning 04-189

(d) Measure the voltage according to the value

in the following table.
Standard voltage

Multimeter Connection Standard Value

E023(1)- Ground Battery voltage 04

1 E023

fpwx040026

Is the result normal?

Yes> Replace the compressor.
No> Go to next step.

4. Check the harness and connector (Compressor relay - Electronic control module
of the engine/ Engine ECM)
(a) Disconnect the battery cable at the negative end.
(b) Unplug the compressor relay.
(c) Disconnect the connector E001(LJ465QR1E1) and E002(4W10) of Engine ECM.
(d) Measure the resistance according to the value
in the following table.
Standard resistance (Check whether there
is open circuit):
E001 E002 Multimeter Connection Standard Value

1 2 N2 Compressor relay (2)

Compressor relay

4 2
- E001(2)
＜2Ω
K1 3 Compressor relay (2)
- E001(N2)

fpwx040027

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

5. Check the pressure switch

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V013 of the pressure switch.
 04-190 Diagnosis - Heating Ventilation and Air Conditioning

(c) Check the pressure switch according to the

value in the following table.
Multimeter Connection Standard Value
V013
V013(2)-V013(4)
＜2Ω
04 1 V013(1)-V013(3)
2 3
4

fpwx040028

Is the result normal?

Yes> Go to next step.
No> Replace the pressure switch.

6. Check the harness and connector (Pressure switch - Electronic control module
of the engine/ Engine ECM (LJ465QR1E1)(4W10))
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V013 of the pressure switch.
(c) Disconnect the connector E001(LJ465QR1E1) and E003(4W10) of Engine ECM.
(d) Measure the resistance according to the value
in the following table.
Standard resistance (Check whether there
V013 is open circuit):
E001
40 79 Multimeter Connection Standard Value
1
2 3
4
V013(4)-E001(40)
V013(1)-E001(79)
＜2Ω
V013(4)-E003(A2)
D1 A2
V013(1)-E003(D1)
E003

fpwx040029

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

7. Check the harness and connector (Pressure switch - A/C control panel)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V013 of the pressure switch.
(c) Disconnect the connector V014 of the A/C control panel.
 Diagnosis - Heating Ventilation and Air Conditioning 04-191

(d) Measure the resistance according to the value

in the following table.
Measure the resistance according to the
value in the following table.

V014 V013
Multimeter Connection Standard Value
04
2
6 4
1
3 1
V014(4)-V013(2/3) ＜2Ω
2 3
4

fpwx040030

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

8. Check the harness and connector (Pressure switch - Ground)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V013 of the pressure switch.
(c) Measure the resistance according to the value
in the following table.
Standard resistance (Check whether there
is open circuit):
V013
Multimeter Connection Standard Value
1
2 3
4 V013(2/3) - Ground ＞1mΩ

fpwx040031

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

9. Check the harness and connector (Pressure switch - Engine ECM (4W12)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V013 of the pressure switch.
(c) Disconnect the connector E001 of the engine ECM.
 04-192 Diagnosis - Heating Ventilation and Air Conditioning

(d) Measure the resistance according to the value

in the following table.
Standard resistance (Check whether there
is open circuit):
E001 V013 Multimeter Connection Standard Value
04
40 79 2
1

4
3 V103(1/4)-E001(40/79) ＜2Ω

fpwx040032

Is the result normal?

Yes> Check the ECM.
No> Repair or replace the harness.
 Diagnosis - Lighting System 04-193

Lighting System
Precautions
1. Cautions for using the battery during the inspection.
During the inspection, if you use the battery, never let the positive probe and negative
one of the tester come too close, or it will cause short circuits. 04
2. Cautions for changing the headlight bulb.
(a) As the halogen bulb will burst in high temperature, even bulbs with a thin layer of oil
film may be broken, too.
(b) A new bulb is always prepared to use as necessary. When changing bulbs, if bulbs
are removed from the vehicle and put aside for a long time, there will be dirt or humidity
on the light cover.
(c) Replace with bulbs with the same wattage.
(d) After changing the bulb, firmly install the light holder. The gap around the light holder
may lead to the problems as the light cover blurs or there is water in the light
compartment.
 04-194 Diagnosis - Lighting System

Basic Inspection
Step Inspection Item Measure
Inspect the battery voltage Yes Go to step 2.
The battery voltage should not be Charge or replace the battery. Refer
1
04 lower than 12V. Is the result nor- No toChapter 20 Starting and Charging
mal? - Battery, Replacement
Inspect the low beam. Yes Go to step 3.
Ignition switch: ON.
2 Turn on the low beam by the
combination switch. Is the result No Refer to the Fault Symptom Table
normal?
Inspect the high beam. Yes Go to step 4.
Turn on the high beam by the
3
combination switch. Is the result No Refer to the Fault Symptom Table
normal?
Inspect the turn light Yes Go to step 5.
Turn on the turn light by the com-
4
bination switch. Is the result nor- No Refer to the Fault Symptom Table
mal?
Inspect the danger warning light. Yes Go to step 6.
Turn on the danger warning light
5
by the danger warning light No Refer to the Fault Symptom Table
switch. Is the result normal?
Inspect the interior light Yes Inspect the harness.
Turn on the interior light by the
6
interior light switch. Is the result No Refer to the Fault Symptom Table
normal?
 Diagnosis - Lighting System 04-195

Component Diagrams

10 04

5 6
7

4 8
3
1

fpwx040033

1 Front right fog light assembly 6 Left width light

2 Front left fog light assembly 7 Rear right combination light
3 Front right combination light assembly
assembly 8 Rear left combination light assembly
4 Front left combination light assembly 9 High-mounted brake light
5 Right width light 10 License plate light assembly
 04-196 Diagnosis - Lighting System

Fault Symptom Table

1. The following table will help you locate the fault. The serial number indicates
the possibility sequence for the fault causes. Check every parts according to
this sequence, and replace where necessary.
Fault symptom Suspicious positions Refer to
04
1. Fuse -
Single low beam OFF
2. Harness -
1. Fuse -
2. Relay -

Both low beams OFF 3. Harness -

Chapter 64 Lighting -
4. Combination switch Combination Switch,
Replacement
1. Fuse -
Single high beam OFF
2. Harness -
1. Fuse -
2. Relay -

Both high beams OFF Chapter 64 Lighting -

3. Combination switch Combination Switch,
Replacement
4. Harness -
Chapter 64 Lighting - Front
Single high and low beam 1. Bulbs Combination Light Assembly,
OFF Replacement
2. Harness -
1. Fuse -
2. Relay -
Chapter 64 Lighting -
3. Combination switch Combination Switch,
Both high and low beam OFF Replacement
Chapter 64 Lighting - Front
4. Bulbs Combination Light Assembly,
Replacement
5. Harness -
1. Fuse -

Front fog light OFF Chapter 64 Lighting -

2. Combination switch Combination Switch,
Replacement
 Diagnosis - Lighting System 04-197

Fault symptom Suspicious positions Refer to

Chapter 64 Lighting - Front
3. Bulbs Combination Light Assembly,
Replacement
4. Relay -
04
5. Harness -
Chapter 64 Lighting - Front
1. Combination switch Fog Light Assembly,
Front fog light always ON Replacement
2. Front fog light relay -
1. Fuse -
Chapter 64 Lighting —
2. Combination switch Combination Switch,
Replacement
Rear fog light OFF Chapter 64 Lighting - Rear
3. Bulbs Combination Light Assembly,
Replacement
4. Relay -
5. Harness -
Chapter 64 Lighting —
1. Combination switch Combination Switch,
Rear Fog Light Always ON Replacement
2. Rear fog light relay -
1. Fuse -
2. Relay -
Chapter 64 Lighting - Front
Fog Light Assembly,
Replacement
3. Bulbs
Both front and rear fog lights Chapter 64 Lighting - Rear
OFF Combination Light Assembly,
Replacement

Chapter 64 Lighting —
4. Combination switch Combination Switch,
Replacement
5. Harness -
1. Fuse -
Danger warning light OFF
2. Danger warning light switch -
(Turning lights normal)
3. Harness -
 04-198 Diagnosis - Lighting System

Fault symptom Suspicious positions Refer to

1. Fuse -
Chapter 64 Lighting —
Turning lights OFF (Danger 2. Combination switch Combination Switch,
warning light normal) Replacement
04
3. Danger warning light switch -
4. Harness -
1. Fuse -
2. Danger warning light switch -
3. Flasher -
Chapter 64 Lighting - Front
Combination Light Assembly,
Replacement
Turning lights & danger 4. Bulbs
warning light OFF Chapter 64 Lighting - Rear
Combination Light Assembly,
Replacement

Chapter 64 Lighting —
5. Combination switch Combination Switch,
Replacement
6. Harness -
Chapter 64 Lighting —
1. Combination switch Combination Switch,
Replacement
Chapter 64 Lighting - Front
Combination Light Assembly,
Single cornering light OFF Replacement
2. Bulbs
Chapter 64 Lighting - Rear
Combination Light Assembly,
Replacement
3. Harness -
Danger warning light always 1. Danger warning light switch -
ON 2. Flasher -
1. Fuse -
Chapter 35 Driving Brake -
2. Brake light switch
Brake Pedal, Replacement
All brake lights OFF
Chapter 64 Lighting - Rear
3. Bulbs Combination Light Assembly,
Replacement
 Diagnosis - Lighting System 04-199

Fault symptom Suspicious positions Refer to

Chapter 64 Lighting -
High-mounted Brake Light
Assembly, Replacement
4. Harness -
04
Chapter 64 Lighting - Rear
1. Bulbs Combination Light Assembly,
Singe brake light OFF Replacement
2. Harness -
Chapter 64 Lighting -
High-mounted brake light 1. Bulbs High-mounted Brake Light
OFF Assembly, Replacement
2. Harness -
Chapter 64 Lighting - Rear
1. Bulbs Combination Light Assembly,
Both reverse lights OFF Replacement
2. Harness -
1. Fuse -
Chapter 41 Transmission -
2. Reverse light switch Transmission Assembly,
One of the Reverse Lights Replacement
OFF Chapter 64 Lighting - Rear
3. Bulbs Combination Light Assembly,
Replacement
4. Harness -
Chapter 64 Lighting - Front
1. Bulbs
Front Interior Light OFF Interior Light , Replacement
2. Harness -
1. Fuse -
2. Relay -

All interior back light OFF Chapter 64 Lighting —

3. Combination switch Combination Switch,
Replacement
4. Harness -
1. Fuse -
Chapter 83 Instrument Panel
Back light of the instrument
2. Instrument Cluster / Instrument — Instrument
cluster OFF
Cluster, Replacement
3. Harness -
 04-200 Diagnosis - Lighting System

Fault symptom Suspicious positions Refer to

Back light of the roof light 1. Roof light switch -
switch OFF 2. Harness -
1. Instrument dimmer switch
Back light of the instrument -
04 OFF
dimmer switch OFF
2. Harness -
Back light of the danger 1. Danger warning light switch -
warning light switch OFF 2. Harness -
Chapter 64 Lighting - Front
1. Bulbs Combination Light Assembly,
Width light OFF Replacement
2. Harness -
Chapter 64 Lighting - Rear
1. Bulbs Combination Light Assembly,
Tail light OFF Replacement
2. Harness -
Chapter 64 Lighting - License
1. Bulbs
License Plate Light OFF Plate Light , Replacement
2. Harness -
1. Fuse -
2. Relay -
Width light, tail light and Chapter 64 Lighting —
license plate light OFF 3. Combination switch Combination Switch,
Replacement
4. Harness -
 Diagnosis - Lighting System 04-201

Single Low Beam OFF

Circuit Diagram

Headlight lighting system

04

Battery

Red Red

4 3
F2 F13
F18 F19
Light Clearance
light/rear Headlight relay Low High Fuse box in
main fuse beam fuse
20A
fog light fuse
beam fuse
driver’s cab
10A 15A 15A V035
2 1

Red Green Blue-white

Blue- Blue-
green yellow
Green Light combination
Black Red switch
V034
Serial
Terminal
No. 2 3 1 Switch 7 6 5 4 3 2 1
Gear (position)

OFF overtaking

Clearance
Clearance light switch Low beam
light V032

Headlight High beam

OFF

Steering
and
hazard
warning
light
V201

fpwx710027
 04-202 Diagnosis - Lighting System

Headlight lighting system

Red-green
04 A
Instrument
Blue-red cluster
B

Blue- Blue-green
yellow
Green-white Interior back
light
3

Headlight height adjusting switch

V036

1 4 5 2 6
Red- Blue- Blue- Black Black
green brown purple

Blue-
yellow

Blue- Red- Red- Red- Blue- Red-

red green green Blue-purple green red green Blue-brown
1 3 4 5 3 1 4 5
V039 V016 V005 V004
Front right
combination light
V016 Front left combination light
V039 V004
V005
V016 V039 V004 V005 Black
2 6 2 2 6 2

Black Black Black Black Black Black

Black Black

V203 V202 V201

fpwx710028

Diagnostic Steps
• Diagnostic steps take the left low beam example, and the diagnosis of the right
low beam is the same as that of the left one.

1. Check bulbs
 Diagnosis - Lighting System 04-203

(a) Disconnect the battery cable at the negative end.

(b) Disconnect the connector of the left headlight.
(c) Replace the left headlight bulb.
(d) Connect the battery negative cable.
Check whether it works properly.
04
Yes> Replace the left headlight bulb.
No> Go to next step.

2. Check the harness and connector (Left low beam fuse - Left headlight)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector of the left headlight.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):
1
Multimeter
Compressor relay

F6 F5 25A F4 F3 40A
4 2

K1 3 Fan AM1 Standard Value

F7
Front fog light

15A F15
Turn light Reverse light

10A V005
Connection
Diagnosis instrument ECU IG.S

7.5A F16 7.5A

1
F8
Horn Brake light/interior light Instrument cluster
3 Left low beam fuse
＜2Ω
High-speed fan relay

F9 10A F17 7.5A

K2 4 2

3 F10
Hazard warning BCM

10A
Compressor
F18
Low beam

15A
High beam 1 2
F18(15A)-V005(3)
F11 10A F19 15A
Airbag Fuel pump

F12 7.5A F20 10A

1 Ignition coil
Width light Rear Fog Light

15A
Light relay

K3 4 2 F13 10A
F21

Fuel injector/oxygen sensor

Starter
3 F22 10A
F14 30A

fpwx040034

3. Check whether low beams are well

connected to the ground.
V005 Multimeter
Standard Value
3 Connection
1 2 V005 (2)-Ground ＜2Ω

Is the result normal?

Yes> Replace the light holder of the low
beam, replace the combination light if
necessary.
fpwx040035 No> Repair or replace the harness.
 04-204 Diagnosis - Lighting System

Both Low Beams OFF

Circuit Diagram

Headlight lighting system

04

Battery

Red Red

4 3
F2 F13
F18 F19
Light Clearance
light/rear Headlight relay Low High Fuse box in
main fuse beam fuse
20A
fog light fuse
beam fuse
driver’s cab
10A 15A 15A V035
2 1

Red Green Blue-white

Blue- Blue-
green yellow
Green Light combination
Black Red switch
V034
Serial
Terminal
No. 2 3 1 Switch 7 6 5 4 3 2 1
Gear (position)

OFF overtaking

Clearance
Clearance light switch Low beam
light V032

Headlight High beam

OFF

Steering
and
hazard
warning
light
V201

fpwx710027
 Diagnosis - Lighting System 04-205

Headlight lighting system

Red-green
A 04
Instrument
Blue-red cluster
B

Blue- Blue-green
yellow
Green-white Interior back
light
3

Headlight height adjusting switch

V036

1 4 5 2 6
Red- Blue- Blue- Black Black
green brown purple

Blue-
yellow

Blue- Red- Red- Red- Blue- Red-

red green green Blue-purple green red green Blue-brown
1 3 4 5 3 1 4 5
V039 V016 V005 V004
Front right
combination light
V016 Front left combination light
V039 V004
V005
V016 V039 V004 V005 Black
2 6 2 2 6 2

Black Black Black Black Black Black

Black Black

V203 V202 V201

fpwx710028

Diagnostic Steps
1. Check right and left headlight bulbs.
(a) Disconnect the battery cable at the negative end.
 04-206 Diagnosis - Lighting System

(b) Disconnect the connector of the left headlight.

(c) Replace the left headlight bulb.
(d) Disconnect the connector of the right headlight.
(e) Replace the right headlight bulb.
(f) Connect the battery negative cable.
04 Is the result normal?
Yes> Replace the right and left headlight bulbs.
No> Go to next step.

2. Check the lighting relay.

(a) Disconnect the battery cable at the negative end.
(b) Unplug the headlight relay in the fuse box by the driver side.

1
(c) Check the low beam relay according to the
Compressor relay

4 2
F6 F5 25A F4 F3 40A value in the following table.
K1 3 Fan AM1

Front fog light

F7 15A
Turn light Reverse light

F15 10A Multimeter

Diagnosis instrument ECU IG.S Specified
F8 7.5A F16 7.5A Conditions Connecting
1 Horn Brake light/interior light Instrument cluster Value
Pin
High-speed fan relay

F9 10A F17 7.5A

K2 4 2 Hazard warning BCM Low beam

3 F10 10A F18 15A

Compressor High beam Under normal
F11 10A F19 15A 4-2 Breakover
F12
Airbag

7.5A F20
Fuel pump

10A
conditions
1 Ignition coil
Width light Rear Fog Light

K3 4 2 F21 15A Apply the

Light relay

F13 10A
Fuel injector/oxygen sensor
Starter
3 10A
F14
30A F22
battery
voltage
1-3 ＜2Ω
between the
fpwx040036
pin 4 and pin
2

Is the result normal?

Yes> Go to next step.
No> Replace the headlight relay

3. Check the lighting combination switch

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the combination switch (lighting) connector V034.
 Diagnosis - Lighting System 04-207

(c) Check the lighting combination switch

according to the value in the following table.
Multimeter
Specified
Conditions Connecting
V034 Value
Pin
1 3
Turn off the 04
4 5 6 7
low beam ≥1MΩ
switch.
6-5
Turn on the
low beam ＜2Ω
switch.
fpwx040037
Is the result normal?
Yes> Go to next step.
No> Replace the combination switch

4. Check the harness and connector (Low beam relay - lighting combination switch)
(a) Unplug the low beam relay in the fuse box by the driver side.
(b) Disconnect the combination switch (lighting) connector V034.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):

1 Multimeter
Standard Value
Compressor relay

F6 F5 25A F4 F3 40A
V034
4 2

K1 3 Fan

Front fog light Turn light Reverse light

AM1
Connection
F7 15A F15 10A

1 3
Diagnosis instrument ECU IG.S
7.5A
Lighting
F16
F8 7.5A
Instrument cluster
1
Horn Brake light/interior light

4 7
＜2Ω
High-speed fan relay

4 2
F9 10A F17 7.5A
6
K2 Hazard warning BCM Low beam

3 F10 10A
Compressor
F18 15A
High beam

15A
relay(1)-V034(6)
F11 10A F19

Airbag Fuel pump

F12 7.5A F20 10A

1 Ignition coil
Width light Rear Fog Light
Light relay

15A
4 2
Is the result normal?
F21
K3 F13 10A
Fuel injector/oxygen sensor
Starter
3 F22 10A
F14 30A

Yes> Go to next step.

No> Repair or replace the harness.
fpwx040038

5. Check the harness and connectors (Right and left low beam fuse - Right and left
low beam)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V005 of the left headlight.
(c) Disconnect the connector V039 of the right headlight.
 04-208 Diagnosis - Lighting System

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):
Multimeter
Standard Value
1
V005 V039 Connection
Compressor relay

F6 F5 25A F4 F3 40A 3
4 2
3
04 K1 3 Fan AM1
1 2 Left low beam
Front fog light Turn light Reverse light 1 2
F7 15A F15 10A

F8
Diagnosis instrument ECU

7.5A F16
IG.S
7.5A fuse(15A)-V005(3)
1
Horn Brake light/interior light Instrument cluster

＜2Ω
High-speed fan relay

F9 10A F17 7.5A

K2 4 2

3 F10
Hazard warning BCM

10A
Compressor
F18
Low beam

15A
High beam
Right low beam
15A
F11

F12
10A
Airbag

7.5A
F19

F20
Fuel pump

10A
fuse(15A)-V039(3)
1 Ignition coil
Width light Rear Fog Light

4 15A
Light relay

K3 2 F13 10A
F21

Fuel injector/oxygen sensor

Starter
3 F22 10A
F14 30A

fpwx040039

6. Check whether the power line of the right

and left low beams are shorted to the
ground.
V039 Multimeter
V005
3
Standard Value
3 Connection
1 2
1 2
V005 (3)-Ground
≥1MΩ
V039(3)-Ground

Is the result normal?

Yes> Replace the fuse (15A) of right and left
fpwx040040 low beams in the fuse box by the driver side.
No> Repair or replace the harness.
 Diagnosis - Lighting System 04-209

Single High Beam OFF

Circuit Diagram

Headlight lighting system

04

Battery

Red Red

4 3
F2 F13
F18 F19
Light Clearance
light/rear Headlight relay Low High Fuse box in
main fuse beam fuse
20A
fog light fuse
beam fuse
driver’s cab
10A 15A 15A V035
2 1

Red Green Blue-white

Blue- Blue-
green yellow
Green Light combination
Black Red switch
V034
Serial
Terminal
No. 2 3 1 Switch 7 6 5 4 3 2 1
Gear (position)

OFF overtaking

Clearance
Clearance light switch Low beam
light V032

Headlight High beam

OFF

Steering
and
hazard
warning
light
V201

fpwx710027
 04-210 Diagnosis - Lighting System

Headlight lighting system

Red-green
04 A
Instrument
Blue-red cluster
B

Blue- Blue-green
yellow
Green-white Interior back
light
3

Headlight height adjusting switch

V036

1 4 5 2 6
Red- Blue- Blue- Black Black
green brown purple

Blue-
yellow

Blue- Red- Red- Red- Blue- Red-

red green green Blue-purple green red green Blue-brown
1 3 4 5 3 1 4 5
V039 V016 V005 V004
Front right
combination light
V016 Front left combination light
V039 V004
V005
V016 V039 V004 V005 Black
2 6 2 2 6 2

Black Black Black Black Black Black

Black Black

V203 V202 V201

fpwx710028

Diagnostic Steps
• Diagnostic steps take the left high beam example, and the diagnosis of the right
high beam is the same as that of the left one.

1. Check bulbs
 Diagnosis - Lighting System 04-211

(a) Disconnect the battery cable at the negative end.

(b) Disconnect the connector V005 of the left headlight.
(c) Replace the left headlight bulb.
(d) Connect the battery negative cable.
Check whether it works properly.
04
Yes> Replace the left headlight bulb.
No> Go to next step.

2. Check the harness and connector (Left headlight- Ground)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V005 of the left headlight.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):
V005
Multimeter
3 Standard Value
Connection
1 2
V005 (2)-Ground ＜2Ω

Is the result normal?

Yes> Replace the bulb.
No> Repair or replace the harness.

fpwx040042
 04-212 Diagnosis - Lighting System

Both high beams OFF

Circuit Diagram

Headlight lighting system

04

Battery

Red Red

4 3
F2 F13
F18 F19
Light Clearance
light/rear Headlight relay Low High Fuse box in
main fuse beam fuse
20A
fog light fuse
beam fuse
driver’s cab
10A 15A 15A V035
2 1

Red Green Blue-white

Blue- Blue-
green yellow
Green Light combination
Black Red switch
V034
Serial
Terminal
No. 2 3 1 Switch 7 6 5 4 3 2 1
Gear (position)

OFF overtaking

Clearance
Clearance light switch Low beam
light V032

Headlight High beam

OFF

Steering
and
hazard
warning
light
V201

fpwx710027
 Diagnosis - Lighting System 04-213

Headlight lighting system

Red-green
A 04
Instrument
Blue-red cluster
B

Blue- Blue-green
yellow
Green-white Interior back
light
3

Headlight height adjusting switch

V036

1 4 5 2 6
Red- Blue- Blue- Black Black
green brown purple

Blue-
yellow

Blue- Red- Red- Red- Blue- Red-

red green green Blue-purple green red green Blue-brown
1 3 4 5 3 1 4 5
V039 V016 V005 V004
Front right
combination light
V016 Front left combination light
V039 V004
V005
V016 V039 V004 V005 Black
2 6 2 2 6 2

Black Black Black Black Black Black

Black Black

V203 V202 V201

fpwx710028

Diagnostic Steps
1. Check right and left headlight bulbs
(a) Disconnect the battery cable at the negative end.
 04-214 Diagnosis - Lighting System

(b) Disconnect the connector V005 of the left headlight.

(c) Replace the left headlight bulb.
(d) Disconnect the connector V039 of the right headlight.
(e) Replace the right headlight bulb.
(f) Connect the battery negative cable.
04 Is the result normal?
Yes> Replace the right and left headlight bulbs.
No> Go to next step.

2. Check the high beam relay.

(a) Disconnect the battery cable at the negative end.
(b) Unplug the high beam relay in the fuse box V035 by the driver side.

(c) Check the high beam relay according to the

1
value in the following table.
Compressor relay

4 2
F6 F5 25A F4 F3 40A

K1 3 Fan AM1
Multimeter
Front fog light

15A
Cornering light/reverse light
F15 10A Specified
F7
Diagnosis Instrument ECU IG.S Conditions Connecting
F8 7.5A F16 7.5A Value
1 Horn/brake light/interior light Instrument Cluster Pin
High-speed fan relay

F9 10A F17 7.5A

K2 4 2 Danger warning BCM Low beam

3 F10 10A F18 15A Under normal

Compressor High beam

15A
4-2 Breakover
F11 10A
Airbag
F19

Fuel pump
conditions
F12 7.5A F20 10A
1 Ignition coil
Width light/Rear fog light
Apply the
Lighting relay

K3 4 2 F13 10A
F21 15A
Starter Fuel injector/oxygen sensor
3 F14
30A F22 10A
battery
voltage
1-3 ＜2Ω
between the
fpwx040043
pin 4 and pin
2

Is the result normal?

Yes> Go to next step.
No> Replace the high beam relay.

3. Check the lighting combination switch

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the combination switch (lighting) connector V034.
 Diagnosis - Lighting System 04-215

(c) Check the lighting combination switch

according to the value in the following table.
Multimeter
V034 Specified
Conditions Connecting
Value
1 3 Pin
4 5 6 7
Turn off the 04
high beam ≥1MΩ
switch.
6-4
Turn on the
high beam ＜2Ω
switch.
fpwx040044
Is the result normal?
Yes> Go to next step.
No> Replace the combination switch

4. Check the harness and connector (Hight beam relay - lighting combination
switch)
(a) Disconnect the battery cable at the negative end.
(b) Unplug the high beam relay in the fuse box V035 by the driver side.
(c) Disconnect the combination switch (lighting) connector V005.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
1 Multimeter
压

Standard Value
Compressor relay

25A 40A
40A
V034
缩 F6 F5 F4
F4 F3
F3
4 2 机

K1 3
继
电
器

Front
前雾灯fog light
Fan
风扇

Cornering
转向灯倒车灯
F15 10A
light/reverse light
AM1
AM1
connection
F7 15A
Diagnosis
诊断 Instrument
仪表 ECU ECU
F16
IG.S
IG.S
7.5A
1 3
11
F8 7.5A
Horn/brake
喇叭 制动灯/light/interior
室内灯 light Instrument
组合仪表 Cluster
Lighting
4 7
＜2Ω
高

6
High-speed fan relay

速 F9
F9 10A F17 7.5A
风
K2
K2 44 22 扇 Danger warning BCM
危险警告BCM Low
近光灯beam

33
继
电
器
F10
F10 10A
Compressor
压缩机
F18 15A
High
远光灯

15A
beam
relay(1)-V034(6)
F11
F11 10A
10A F19
F19

Airbag
安全气囊 Fuel
燃油泵 pump

F12
F12 7.5A
7.5A F20
F20 10A
11 点火线圈
Ignition coil
灯 Width
小灯 后雾灯
light/Rear fog light
Lighting relay

光 F21 15A
15A
K3 44 22
Is the result normal?
F21
K3 继 F13
F13 10A
10A
电 Fuel喷油器/氧传感器
injector/oxygen sensor
器 Starter
起动机
33 F22 10A
10A
F14
F14 30A
30A F22

Yes> Go to next step.

No> Repair or replace the harness.
fpwx040045

5. Check the harness and connectors (Right and left high beam fuse - Right and
left high beam)
(a) Disconnect the battery negative cable.
(b) Disconnect the connector V039 of the left headlight.
(c) Disconnect the connector V005 of the right headlight.
 04-216 Diagnosis - Lighting System

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
V005 V039 connection
1 压 3 3
25A 40A
04 4

K1 3
2
缩
机
继
电
器
F6 F5

风扇
F4 F3

AM1
1 2 1 2
Left high beam
前雾灯 转向灯倒车灯
10A
F7 15A
诊断 仪表 ECU
F15

F16
IG.S
7.5A
fuse(15A)-V005(1)
＜2Ω
F8 7.5A
喇叭 制动灯/ 室内灯 组合仪表
1 高
速 F9 10A F17 7.5A
K2 4

3
2
风
扇
继
电
器
F10
危险警告BCM

10A F18
近光灯

15A
Right high beam
压缩机 远光灯

F11 10A
安全气囊
F19 15A
燃油泵
fuse(15A)-V039(1)
F12 7.5A F20 10A
1 点火线圈
灯 小灯 后雾灯

K3 4 2 光
继 F13 10A
F21 15A
电 喷油器/氧传感器
器 起动机
3 F22 10A
F14 30A

fpwx040046

6. Check the conduction between the high

beam and the reliable grounding.
Multimeter
Standard Value
V005 V039 connection
3
3
1 2
1 2 V039(1)-Ground
＜2Ω
V005 (1)-Ground

Is the result normal?

Yes> Replace the lighter holder, replace the
combination light as necessary.
fpwx040047 No> Repair or replace the harness.
 Diagnosis - Lighting System 04-217

Front Fog Light OFF

Circuit Diagram

Fog Light
04

Battery

Red
A

B
Red

Green- Green-
Blue-
White White
purple

1 2
4 1
F7 Front fog Fuse box
Front fog light relay
light fuse in driver's cab Blue- Front fog light switch
15A V035 yellow V038
3 2

4 3 6

Blue- Black Black Black

grey

Blue- Blue- Instrument Cluster

grey grey
2 2

Front left fog light Front right fog light

V006 V017

1 1
Black

Black Black

V201 V203 V201

fpwx710035
 04-218 Diagnosis - Lighting System

Fog Light

A
04

B
Red

Green-
white

Green- Green- Brown-

white white red No.
5 1 3 1 3 2
Gear
Combination
Width
ON

Rear fog light Switch

light F13 Fuse box
OFF
switch V032 Width light/ in driver's cab
V037 rear fog
Headlight V035
light fuse
10A

2 4 Brown- Green
red Green
Blue

V105
16
C101
Blue
Blue
Instrument
Cluster
Black Blue Blue
1 1

Rear left combination light Rear right combination light

C003 C002

4 4

Black Black

V201 C202 C203

fpwx710036

Diagnostic Steps
1. Check the fuse.
(a) Disconnect the battery cable at the negative end.
 Diagnosis - Lighting System 04-219

(b) Check the fuse F7 of the front fog light in the

fuse box by the driver side: 15A.
Is the fuse good?
Yes> Go to next step.
No> Replace the fuse.
04

fpwx040048

2. Check the front fog light bulb.

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V006 of the front left fog light.
(c) Replace the front left fog light bulb.
(d) Disconnect the connector V017 of the front right fog light.
(e) Replace the front right fog light bulb.
(f) Connect the battery negative cable.
(g) Open the front fog light switch.
(h) Connect the harness and connector of the front fog light.
Does the front fog light work properly?
Yes> Replace the front right and left fog light bulbs.
No> Go to next step.

3. Check the front fog light switch.

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V038 of the front fog light switch.

(c) Check the front fog light switch according to

the following table.
Multimeter
Specified
V038 Conditions Connecting
Value
Pin
2 1
6 4 3 Turn on the
front fog light 1-4 ＜2Ω
switch
Close the
front fog light 1-4 ≥1MΩ
switch
fpwx040050
Is the result normal?
 04-220 Diagnosis - Lighting System

Yes> Go to next step.

No> Replace the front fog light switch.

4. Check the harness and connector (Front fog light relay - Front fog light switch)
(a) Disconnect the battery cable at the negative end.
04
(b) Unplug the front fog light relay in the fuse box V035 by the driver side.
(c) Disconnect the connector V037 of the fog light switch (lighting).

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):
Multimeter
V038 Standard Value
Connection
2 1
Front fog light
6 4 3
＜2Ω
F3 40A

AM1
F2 20A

Main fuse
for the lighting
F1 20A

BCM relay(1)-V038(4)
1 2 1 2
Fuel pump relay

Horn relay

3 3
K4 K6 1 2
Front fog light relay

4 4

F23 15A F24 15A

K7
3
4 Is the result normal?
Paddle shifter

Cigar lighter
Wipers
Radio
and

F25 25A
Washers

1
Yes> Go to next step.
1 2 Blower
Low-speed fan relay

Main relay

K8 4 2
K5
No> Repair or replace the harness.
3 F26 7.5A 3
4
Top blower

fpwx040051

5. Check the harness and connector (Front fog light relay - Front fog light)
(a) Disconnect the battery cable at the negative end.
(b) Unplug the front fog light relay in the fuse box V035 by the driver side.
(c) Disconnect the connector V006 of the front left fog light.
(d) Disconnect the connector V017 of the front right fog light.

(e) Measure the resistance according to the value

in the following table. (Check whether there
is open circuit)
Multimeter
Standard Value
V006 V017 Connection
F3 40A F2 20A F1 20A

AM1 Main fuse

for the lighting
BCM
1 2 1 2 Front fog light
1 2 1 2
Fuel pump relay

relay(3)-V006(2)
Horn relay

3 3
K4 K6 1 2
＜2Ω
Front fog light relay

4 4
3

F23 15A F24 15A

K7
4 Front fog light
Paddle shifter

Cigar lighter
Radio
Wipers
and
Washers
relay(3)-V017(2)
F25 25A

1
1 2 Blower
Low-speed fan relay

Main relay

K5 3 F26 7.5A
K8 4
3
2
Is the result normal?
4
Top blower

fpwx040052 Yes> Go to next step.

No> Repair or replace the harness.

6. Check the harness and connector (Front fog light- Ground)

 Diagnosis - Lighting System 04-221

(a) Disconnect the battery cable at the negative end.

(b) Disconnect the connector V006 of the front left fog light.
(c) Disconnect the connector V017 of the front right fog light.

(d) Measure the resistance according to the value

in the following table. Standard resistance 04
(Check whether there is open circuit):
Multimeter
V006 V017 Standard Value
Connection
1 2 1 2 V006 (1)-Ground
＜2Ω
V017(1)-Ground

Is the result normal?

Yes> Replace the front fog light relay.
No> Repair or replace the harness.
fpwx040053
 04-222 Diagnosis - Lighting System

Front Fog Light Always ON

Circuit Diagram

Fog Light
04

Battery

Red
A

B
Red

Green- Green-
Blue-
White White
purple

1 2
4 1
F7 Front fog Fuse box
Front fog light relay
light fuse in driver's cab Blue- Front fog light switch
15A V035 yellow V038
3 2

4 3 6

Blue- Black Black Black

grey

Blue- Blue- Instrument Cluster

grey grey
2 2

Front left fog light Front right fog light

V006 V017

1 1
Black

Black Black

V201 V203 V201

fpwx710035
 Diagnosis - Lighting System 04-223

Fog Light

A
04

B
Red

Green-
white

Green- Green- Brown-

white white red No.
5 1 3 1 3 2
Gear
Combination
Width
ON

Rear fog light Switch

light F13 Fuse box
OFF
switch V032 Width light/ in driver's cab
V037 rear fog
Headlight V035
light fuse
10A

2 4 Brown- Green
red Green
Blue

V105
16
C101
Blue
Blue
Instrument
Cluster
Black Blue Blue
1 1

Rear left combination light Rear right combination light

C003 C002

4 4

Black Black

V201 C202 C203

fpwx710036

Diagnostic Steps
1. Check the fog light switch (lighting)
(a) Disconnect the battery cable at the negative end.
 04-224 Diagnosis - Lighting System

(b) Disconnect the connector V038 of the fog light switch.

(c) Check the front fog light switch according to

the following table.
Multimeter
04 Specified
Conditions Connecting
2 1
Value
6 4 3
Pin
Turn on the
front fog light 1 - 4 < 2C
switch
Turn off the
front fog light 1 - 4 ≥1MΩ
switch
fpwx040054
Is the result normal?
Yes> Go to next step.
No> Replace the combination switch.

2. Check the harness and connector (Combination switch - Front fog light switch)
(a) Disconnect the battery cable at the negative end.
(b) Unplug the front fog light relay in the fuse box by the driver side.
(c) Disconnect the connector V032 of the combination switch.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there are short circuits)

V032 V038
Multimeter
Standard Value
1 2 2 1
Connection
6 3
3
V032 (3)- V038 (1) ＜2Ω

Is the result normal?

Yes> Replace the combination switch.
No> Repair or replace the harness.

fpwx040055

3. Check the harness and connector (Front fog light relay - Front fog light)
(a) Disconnect the battery cable at the negative end.
(b) Unplug the front fog light relay in the fuse box by the driver side.
(c) Connect the battery negative cable, check whether the harness is shorted to the power
supply.
 Diagnosis - Lighting System 04-225

Note
Do not turn on the fog light.
Is the result normal?
Yes> Replace the relay of the front fog light.
04
No> Repair or replace the harness.
 04-226 Diagnosis - Lighting System

Rear Fog Light OFF

Circuit Diagram

Fog Light
04

Battery

Red
A

B
Red

Green- Green-
Blue-
White White
purple

1 2
4 1
F7 Front fog Fuse box
Front fog light relay
light fuse in driver's cab Blue- Front fog light switch
15A V035 yellow V038
3 2

4 3 6

Blue- Black Black Black

grey

Blue- Blue- Instrument Cluster

grey grey
2 2

Front left fog light Front right fog light

V006 V017

1 1
Black

Black Black

V201 V203 V201

fpwx710035
 Diagnosis - Lighting System 04-227

Fog Light

A
04

B
Red

Green-
white

Green- Green- Brown-

white white red No.
5 1 3 1 3 2
Gear
Combination
Width
ON

Rear fog light Switch

light F13 Fuse box
OFF
switch V032 Width light/ in driver's cab
V037 rear fog
Headlight V035
light fuse
10A

2 4 Brown- Green
red Green
Blue

V105
16
C101
Blue
Blue
Instrument
Cluster
Black Blue Blue
1 1

Rear left combination light Rear right combination light

C003 C002

4 4

Black Black

V201 C202 C203

fpwx710036

Diagnostic Steps
1. Check the fuse.
(a) Disconnect the battery cable at the negative end.
 04-228 Diagnosis - Lighting System

(b) Check the fuse F13 of the rear fog light in the
fuse box by the driver side: 10 A.
Is th fuse normal?
No> Replace the fuse.
Yes> Go to next step.
04

fpwx040056

2. Check the rear fog light bulb

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the rear left combination light connector C003.
(c) Replace the left rear fog light bulb.
(d) Disconnect the connector C002 of the rear right combination light.
(e) Replace the right rear fog light bulb.
(f) Connect the battery negative cable.
Is the result normal?
Yes> Replace the right and left rear fog light bulbs.
No> Go to next step.

3. Check the harness and connector (Rear fog light- Ground)

(a) Disconnect the battery negative cable.
(b) Disconnect the rear left combination light connector C003.
(c) Disconnect the connector C002 of the rear right combination light.
 Diagnosis - Lighting System 04-229

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):
C003 Multimeter
C002 Standard Value
1 3
Connection
1 3

4 6
4 6
C003(4)-Ground 04
≥1MΩ
C002(4)-Ground

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040059

4. Check the rear fog light switch ground and the power line.
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V037 of the rear fog light switch.
(c) Measure the resistance between the terminal 2 of the rear fog light switch connector
V037and the ground.
(d) Measure the resistance between the connector V037 of the rear fog light switch and
the connector V032 of the combination switch.
Standard Resistance: ＜2Ω
Confirm whether it conforms to the standard value.
No> Repair or replace the harness and connector.
Yes> Replace the rear fog light switch
 04-230 Diagnosis - Lighting System

Rear Fog Light Always ON

Circuit Diagram

Fog Light
04

Battery

Red
A

B
Red

Green- Green-
Blue-
White White
purple

1 2
4 1
F7 Front fog Fuse box
Front fog light relay
light fuse in driver's cab Blue- Front fog light switch
15A V035 yellow V038
3 2

4 3 6

Blue- Black Black Black

grey

Blue- Blue- Instrument Cluster

grey grey
2 2

Front left fog light Front right fog light

V006 V017

1 1
Black

Black Black

V201 V203 V201

fpwx710035
 Diagnosis - Lighting System 04-231

Fog Light

A
04

B
Red

Green-
white

Green- Green- Brown-

white white red No.
5 1 3 1 3 2
Gear
Combination
Width
ON

Rear fog light Switch

light F13 Fuse box
OFF
switch V032 Width light/ in driver's cab
V037 rear fog
Headlight V035
light fuse
10A

2 4 Brown- Green
red Green
Blue

V105
16
C101
Blue
Blue
Instrument
Cluster
Black Blue Blue
1 1

Rear left combination light Rear right combination light

C003 C002

4 4

Black Black

V201 C202 C203

fpwx710036

Diagnostic Steps
1. Check the rear fog light switch (lighting)
(a) Disconnect the battery cable at the negative end.
 04-232 Diagnosis - Lighting System

(b) Disconnect the rear fog light switch V037.

(c) Check the rear fog light switch according to

the following table.
Multimeter
04 Specified
Conditions Connecting
1 3 Value
4 7 Pin
Turn on the
rear fog light 3-4 ＜2Ω
switch
Turn off the
rear fog light 3-4 ≥1MΩ
switch
fpwx040060
Is the result normal?
Yes> Go to next step.
No> Replace the rear fog light switch

2. Check the harness and connector (rear fog light switches)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the combination switch (lighting) connector V037.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)
Multimeter
Standard Value
Connection
1 3

4 7 V037（3）
≥1MΩ
-Ground

Is the result normal?

Yes> Replace the rear fog light switch
No> Repair or replace the harness.
fpwx040061
 Diagnosis - Lighting System 04-233

Danger Warning Light OFF (Turning Lights Normal)

Circuit Diagram

Turning Lights & Danger Warning Light

04

Ignition switch Battery

ON/START
A

MF1 Positive terminal

80A fuse box
Black
E

Flasher relay
L V028

F15 F10 Red- Green-

Cornering light/ Danger warning/ Fuse box
reverse light fuse BCM fuse in driver's cab yellow grey
10A
10A
V035 B
Green- Green- V201
yellow black
C

Green- Green- Green-

red yellow brown

No.
1 2 3
Gear

Left Lighting combination switch

V034

Right

fpwx710037
 04-234 Diagnosis - Lighting System

Turning Lights & Danger Warning Light

Interior
back light

04 A

B Green- Green-
red red

1 1
Front left Left side
Green- Red- Green-
combination cornering
grey yellow white
light light
V004 V007
4
6 8 7 2 1 3
Danger 2 2
Green- Black
warning light Black
red
switch OFF
Black
V012
ON V202
5
Green-
C black
Green- Green- Green- Black
brown yellow red BCM
V042
D
10 9
V204
E

Green-
F
Green- red
brown
Green- Green- V105 V105
brown brown
3 Green- Green- 2
C101 brown red C101
1 1
Green- Green-
Front right Right side brown red
combination cornering
light 6 4 5 2
light
V016 V018 Rear left
Rear right
combination
combination
light
light
2 2 C003
C002
Black Black
4 Instrument Cluster 4
Black V011 Black

V203 C203 C202

fpwx710038

Diagnostic Steps
1. Check the fuse.
(a) Disconnect the battery cable at the negative end.
 Diagnosis - Lighting System 04-235

(b) Check the fuse of the danger warning light in

the fuse box by the driver side: 10 A.

04

fpwx040005

2. Check the harness and connector (Danger warning light fuse - Danger warning
light switch)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V012 of the danger warning light switch.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)
Multimeter
Standard Value
Connection
3 1

8 7 4

V012
≥1MΩ
(7)-Ground

Is the result normal?

Yes> Replace the fuse.
No> Repair or replace the harness and
fpwx040062 replace the fuse.

3. Check the harness and connector (Danger warning light switch - Flasher)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the flasher connector V028.
(c) Disconnect the connector V012 of the danger warning light switch.
 04-236 Diagnosis - Lighting System

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

V012 V028
Multimeter
Standard Value
3 1
L Connection
E B
8 4
04 V012(8)-V028(B) ＜2Ω

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040063

4. Check the harness and connector (Danger warning light fuse - Danger warning
light switch)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V012 of the danger warning light switch.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
4
1
2
F6 F5 25A F4 F3 40A Connection
K1 3 AM1

F7 15A F15 10A

1
F8

F9
7.5A

10A
F16

F17
IG.S
7.5A

7.5A
3
8 7
1
4
Danger warning light
K2 4 2

3 F10

F11
10A

10A
F18

F19
15A

15A
fuse ＜2Ω
7.5A 10A

F10(10A)-V012(7)
F12 F20
1

K3 4 2 F13 10A
F21 15A

3 F22 10A
F14 30A

Is the result normal?

Yes> Go to next step.
fpwx040064 No> Repair or replace the harness.

5. Check the harness and connector (danger warning light switch - front left, rear
left, front right, rear right turning light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V012 of the danger warning light switch.
(c) Disconnect the connector V007of the front left turning light.
(d) Disconnect the rear left combination light connector C003.
(e) Disconnect the connector V018 of the front right turning light.
(f) Disconnect the connector C002 of the rear right combination light.
 Diagnosis - Lighting System 04-237

(g) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
V012 V007 Standard Value
Connection
1 2 3
3 1

8 4 4 6
1 2
V012(3)-V007(1) 04
C003
＜2Ω
C003(2)-V007(1)

fpwx040065

(h) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
V012 C002 V018 Standard Value
Connection
3 2 1 1 3
1 2
8 4 4 6
V012(2)-V018(1)
＜2Ω
V012(2)-C002(6)

Is the result normal?

Yes> Replace the danger warning switch.
No> Repair or replace the harness.
fpwx040066
 04-238 Diagnosis - Lighting System

Turning Lights OFF (Danger Warning Light Normal)

Circuit Diagram

Turning Lights & Danger Warning Light

04

Ignition switch Battery

ON/START
A

MF1 Positive terminal

80A fuse box
Black
E

Flasher relay
L V028

F15 F10 Red- Green-

Cornering light/ Danger warning/ Fuse box
reverse light fuse BCM fuse in driver's cab yellow grey
10A
10A
V035 B
Green- Green- V201
yellow black
C

Green- Green- Green-

red yellow brown

No.
1 2 3
Gear

Left Lighting combination switch

V034

Right

fpwx710037
 Diagnosis - Lighting System 04-239

Turning Lights & Danger Warning Light

Interior
back light

A 04

B Green- Green-
red red

1 1
Front left Left side
Green- Red- Green-
combination cornering
grey yellow white
light light
V004 V007
4
6 8 7 2 1 3
Danger 2 2
Green- Black
warning light Black
red
switch OFF
Black
V012
ON V202
5
Green-
C black
Green- Green- Green- Black
brown yellow red BCM
V042
D
10 9
V204
E

Green-
F
Green- red
brown
Green- Green- V105 V105
brown brown
3 Green- Green- 2
C101 brown red C101
1 1
Green- Green-
Front right Right side brown red
combination cornering
light 6 4 5 2
light
V016 V018 Rear left
Rear right
combination
combination
light
light
2 2 C003
C002
Black Black
4 Instrument Cluster 4
Black V011 Black

V203 C203 C202

fpwx710038

Diagnostic Steps
1. Check the fuse.
(a) Disconnect the battery cable at the negative end.
 04-240 Diagnosis - Lighting System

(b) Check the fuse of the turning light in the fuse

box by the driver side: 10 A.

04

fpwx040056

2. Check the harness and connector (Turning light fuse - Turning light switch )
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V012 of the danger warning light switch.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)
Multimeter
Standard Value
Connection
3 1

8 7 4

V012
≥1mΩ
(7)-Ground

Is the result normal?

Yes> Replace the fuse.
No> Repair or replace the harness.
fpwx040067

3. Check the combination switch (Turning light switch)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the combination switch (lighting) connector V034.
 Diagnosis - Lighting System 04-241

(c) Check the combination switch according to

the value in the following table. (Turning light
switch)
Multimeter
Specified
Conditions Connecting
1 2 3
Value
4 7 Pin 04

Turning light 1-2

≥1MΩ
switch: OFF 2-3
Turn the left
turning light 1-2
switch
fpwx040068 ＜2Ω
Turn the right
turning light 2-3
switch

Is the result normal?

Yes> Go to next step.
No> Replace the combination switch

4. Check the harness and connector (Turning light fuse - Danger warning light
switch )
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V034 of the danger warning light switch.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
4
1
2
F6 F5 25A F4 F3 40A Connection
K1 3 AM1

F7 15A F15 10A

F8 7.5A F16
IG.S
7.5A 3 1
Turning light fuse
K2 4
1
2
F9 10A F17 7.5A 8 6 4
＜2Ω
3 F10

F11
10A

10A
F18

F19
15A

15A
F15(10A)-V012(6)
F12 7.5A F20 10A
1

K3 4 2 F13 10A
F21 15A

3 F22 10A
F14 30A

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040069

5. Check the harness and connector (Flasher - Lighting combination switch)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the flasher connector V028.
(c) Disconnect the combination switch (turning light switch) connector V034.
 04-242 Diagnosis - Lighting System

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
1 2 3 L Connection
4 7 E B
04
V034
V034(2)-V028(L) ＜2Ω
V028

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040070

6. Check the harness and connector (combination switch - front left, rear left, front
right, rear right turning light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the combination switch (turning light switch) connector V034.
(c) Disconnect the connector V007of the front left turning light.
(d) Disconnect the rear left combination light connector C003.
(e) Disconnect the connector V018 of the front right turning light.
(f) Disconnect the connector C002 of the rear right combination light.

(g) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)
Multimeter
V034 V007 Standard Value
Connection
1 2 3
1 2 3
1 2
4 7
4 6
V034(1)- V007(1)
C003 ＜2Ω
V034(1)-C003(2)

fpwx040071
 Diagnosis - Lighting System 04-243

(h) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
V034 C002 V018 Standard Value
Connection
1 2 3
1 3
4 7
4 6
1 2
V034(3)- V018(1) 04
＜2Ω
V034(3)-C002(6)

Is the result normal?

Yes> Replace the danger warning switch.
No> Repair or replace the harness.
pwx040072
 04-244 Diagnosis - Lighting System

Turning Lights & Danger Warning Light OFF

Circuit Diagram

Turning Lights & Danger Warning Light

04

Ignition switch Battery

ON/START
A

MF1 Positive terminal

80A fuse box
Black
E

Flasher relay
L V028

F15 F10 Red- Green-

Cornering light/ Danger warning/ Fuse box
reverse light fuse BCM fuse in driver's cab yellow grey
10A
10A
V035 B
Green- Green- V201
yellow black
C

Green- Green- Green-

red yellow brown

No.
1 2 3
Gear

Left Lighting combination switch

V034

Right

fpwx710037
 Diagnosis - Lighting System 04-245

Turning Lights & Danger Warning Light

Interior
back light

A 04

B Green- Green-
red red

1 1
Front left Left side
Green- Red- Green-
combination cornering
grey yellow white
light light
V004 V007
4
6 8 7 2 1 3
Danger 2 2
Green- Black
warning light Black
red
switch OFF
Black
V012
ON V202
5
Green-
C black
Green- Green- Green- Black
brown yellow red BCM
V042
D
10 9
V204
E

Green-
F
Green- red
brown
Green- Green- V105 V105
brown brown
3 Green- Green- 2
C101 brown red C101
1 1
Green- Green-
Front right Right side brown red
combination cornering
light 6 4 5 2
light
V016 V018 Rear left
Rear right
combination
combination
light
light
2 2 C003
C002
Black Black
4 Instrument Cluster 4
Black V011 Black

V203 C203 C202

fpwx710038

Diagnostic Steps
1. Checking the fuse
(a) Disconnect the battery cable at the negative end.
 04-246 Diagnosis - Lighting System

(b) Check the fuse of the turning light in the fuse

box by the driver side: 10 A.
(c) Check the fuse of the turning light in the fuse
box F10 by the driver side: 10 A.

04

fpwx040005

2. Checking the harness and connector (Danger warning light fuse - Danger warning
light switch)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V012 of the danger warning light switch.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)

V012 Multimeter
Standard Value
Connection
3 1
V012
8 7 4 ≥1MΩ
(7)-Ground

Is the result normal?

Yes> Replace the fuse.
No> Repair or replace the harness.
fpwx040073

3. Checking the harness and connector (Turning light fuse - Danger warning light
switch )
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V012 of the danger warning light switch.
 Diagnosis - Lighting System 04-247

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)

V012 Multimeter
Standard Value
Connection
3 1 04
V012 (6)-Ground ≥1MΩ
8 7 6 4

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040074

4. Checking the harness and connector (Danger warning light switch - Flasher)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the flasher connector V028.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
V028 Multimeter
L
Standard Value
Connection
E B

V028（B）-Ground ≥1MΩ

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness and
replace the fuse.
fpwx040075

5. Checking the danger warning light switch

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V012 of the danger warning light switch.
 04-248 Diagnosis - Lighting System

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

V012 Multimeter
Specified
Conditions Connecting
Value
04 3 1 Pin
8 6 4 Turn off the
danger 6-8
warning light.
＜2Ω
Turn on the 7-8
danger
fpwx040076
warning light. 2-1-3

Is the result normal?

Yes> Go to next step.
No> Replace the danger warning light switch.

6. Checking the harness and connector (Flasher- Ground)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the flasher connector V028.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

V028 Multimeter
Standard Value
L Connection
E B
V028（E）-Ground ＜2Ω

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040077

7. Checking the harness and connector (Danger warning light switch - Flasher)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V012 of the danger warning light switch.
(c) Disconnect the flasher connector V028.
 Diagnosis - Lighting System 04-249

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
3 1 L Connection
8 4 E B
04
V012(8)-V028(B) ＜2Ω
V012 V028

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040078

8. Checking the harness and connector (Danger warning light switch - Danger
warning fuse, turning light fuse)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V012 of the danger warning light switch.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
4
1
2
F6 F5 25A F4 F3 40A
V012 Standard Value
K1 3 AM1
Connection
F7 15A F15 10A
IG.S
7.5A 3 1
V012(7)-Turning light
F16
F8 7.5A
1

＜2Ω
7.5A
8 7 4
F9 10A F17

K2 4 2

3 F10

F11
10A

10A
F18

F19
15A

15A
fuse(10A)
F12 7.5A F20 10A
1

K3 4 2 F13 10A
F21 15A

3 F14 30A F22 10A Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040079

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
1 V012 Standard Value
4 2
F6 F5 25A F4 F3 40A
Connection
K1 3 AM1

15A F15 10A 3 1

F7
IG.S
V012(6)-Danger
7.5A
6 4
＜2Ω
F16
F8 7.5A
8
1

K2 4 2
F9

F10
10A

10A
F17

F18
7.5A

15A
warning fuse(10A)
3

F11 10A F19 15A

7.5A F20 10A

K3 4
1
2
F12

F13 10A
F21 15A
Is the result normal?
3 F22 10A
F14 30A

Yes> Go to next step.

No> Repair or replace the harness.
fpwx040080
 04-250 Diagnosis - Lighting System

9. Checking the flasher

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the flasher connector V028.
(c) Replace the flasher.
(d) Connect the battery negative cable.
04
Is the result normal?
Yes> Replace the flasher.
No> Go to next step.

10 . Checking the harness and connector (Flasher - Combination switch)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the flasher connector V028.
(c) Disconnect the combination switch (turning light switch) connector V034.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
1 2 3 L Connection
4 7 E B
V028(L)-V034(2) ＜2Ω
V034 V028
Is the result normal?
Yes> Replace the fuse (15A) of right and left
high beams in the fuse box by the driver side.
No> Repair or replace the harness.
fpwx040081

11 . Checking the combination switch

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the combination switch (turning light switch) connector V034.
 Diagnosis - Lighting System 04-251

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Specified
Conditions Connecting
1 2 3 Value
4 7
Pin 04
V034 Turning light 1-2
≥1MΩ
switch: OFF 2-3
Turn the left
turning light 1-2
switch
fpwx040082 ＜2Ω
Turn the right
turning light 2-3
switch

Is the result normal?

Yes> Go to next step.
No> Replace the combination switch.

12 . Checking the harness and connector (Turning light - Ground)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V007of the front left turning light.
(c) Disconnect the rear left combination light connector C003.
(d) Disconnect the connector V018 of the front right turning light.
(e) Disconnect the connector C002 of the rear right combination light.

(f) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

V007 C003 Multimeter

Standard Value
1 3
Connection
1 2 4 6 V007 (2)-Ground
＜2Ω
C003（4）-Ground

fpwx040083
 04-252 Diagnosis - Lighting System

(g) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

V018 C002 Multimeter

Standard Value
1 3 Connection
1 2 4 6

04 V018 (2)-Ground
＜2Ω
C002(4)-Ground

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040084

13 . Checking the harness and connector (danger warning light switch - front left,
rear left, front right, rear right turning light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V012 of the danger warning light switch.
(c) Disconnect the connector V007of the front left turning light.
(d) Disconnect the rear left combination light connector C003.
(e) Disconnect the connector V018 of the front right turning light.
(f) Disconnect the connector C002 of the rear right combination light.

(g) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
V012 V007 Standard Value
Connection
1 2 3
3 1
1 2
8 4 4 6
V012(3)-V007(1)
C003
＜2Ω
V012(3)-C003(2)

fpwx040085
 Diagnosis - Lighting System 04-253

(h) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
V012 C002 V018 Standard Value
Connection
3 2 1 1 3

8 4 4 6
1 2
V012(2)-V018(1) 04
＜2Ω
V012(2)-C002(6)

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040086

14 . Checking the harness and connector (combination switch (turning light switch)
- front left, rear left, front right, rear right turning light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the combination switch (turning light switch) connector V034.
(c) Disconnect the connector V007of the front left turning light.
(d) Disconnect the rear left combination light connector C003.
(e) Disconnect the connector V018 of the front right turning light.
(f) Disconnect the connector C002 of the rear right combination light.

(g) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
V034 V007 Standard Value
Connection
1 2 3
1 2 3
1 2
4 7
4 6
V034(1)- V007(1)
C003 ＜2Ω
V034(1)-C003(2)

fpwx040087
 04-254 Diagnosis - Lighting System

(h) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
V034 C002 V018 Standard Value
Connection
1 2 3
1 3

04 4 7
4 6
1 2
V034(3)- V018(1)
＜2Ω
V034(3)-C002(6)

Is the result normal?

Yes> Replace 4 turning light bulbs.
No> Repair or replace the harness.
pwx040088
 Diagnosis - Lighting System 04-255

All Brake Lights OFF

Circuit Diagram

Brake Light System

04

Battery

F9 Fuse box
Horn/brake light/
interior light fuse in driver's cab
10A V035

Brown-
blue
1

Brake light switch

V031

2
Brown-green
V105
14
C101
Brown-green

ABS Control Unit

Brown-green
C102
5 Brown-green
Brown-green
F101

3 F102 3
3
G101
Rear right Rear right
Brown-green
combination light combination light
2
C003 C002
High-mounted
brake light
G001
4 4

Black 1 Black
Black

C202 C201 C203

fpwx710050

Diagnostic Steps
 04-256 Diagnosis - Lighting System

1. Check the fuse.

(a) Disconnect the battery cable at the negative end.

(b) Check the fuse F9 of the brake light in the

fuse box by the driver side: 10 A.
04 Is the result normal?
No> Replace the fuse.
Yes> Go to next step.

fpwx040089

2. Check the harness and connector (Brake light fuse- Reserve light switch)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V031 of the parking brake switch.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)
Multimeter
Standard Value
Connection
1 2

V031(1)-Ground ≥1MΩ

Is the result normal?

Yes> Replace the fuse.
No> Repair or replace the harness.

fpwx040090

3. Check the harness and connector (Brake light switch- Brake light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the rear left combination light connector C003.
(c) Disconnect the connector C002 of the rear right combination light.
(d) Disconnect the connector G001 of the high-mounted brake light.
 Diagnosis - Lighting System 04-257

(e) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)
Multimeter
Standard Value
C003 Connection
04
1 3
C003（3）-Ground ≥1MΩ
4 6

Is the result normal?

Yes> Replace the fuse.
No> Repair or replace the harness and
replace the fuse.
fpwx040091

4. Check the brake light switch.

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V031 of the brake light switch.

(c) Check the brake light switch according to the

value in the following table.
Multimeter
V031
Specified
Conditions Connecting
Value
Pin
1 2 Turn off the
brake light 1-2 ≥1MΩ
switch
Turn on the
brake light 1-2 ＜2Ω
switch
fpwx040092
Is the result normal?
Yes> Go to next step.
No> Replace the brake light switch.

5. Check the harness and connectors (Brake light fuse- Parking brake switch)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V031 of the parking brake switch.
 04-258 Diagnosis - Lighting System

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
V031 Standard Value
1
F6 F5 25A F4 F3 40A
4 2

K1 3 AM1
Connection
F7 15A F15 10A

04
IG.S

F8 7.5A F16 7.5A

1 2 Brake light fuse F9
＜2Ω
1
F9 10A F17 7.5A
K2 4 2

3 F10 10A F18 15A

15A
(10A) - V031(1)
F11 10A F19

F12 7.5A F20 10A

1
15A
Is the result normal?
F21
K3 4 2 F13 10A
3 F22 10A
F14 30A

Yes> Go to next step.

No> Repair or replace the harness.
fpwx040093

6. Check the harness and connector (Brake light switch- Brake light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V031 of the brake light switch.
(c) Disconnect the rear left combination light connector C003.
(d) Disconnect the connector C002 of the rear right combination light.
(e) Disconnect the connector G001 of the high-mounted brake light.

(f) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
V031 C003
Standard Value
C002 Connection
1 3
1 3

1 2 4 6
V031(2)-C003(3)
＜2Ω
4 6

V031(2)-C002(3)

fpwx040094
 Diagnosis - Lighting System 04-259

(g) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

G001 Multimeter Standard

V031
Connection Value
04
1 2
1 2 V031(2)-G001(2) ＜2Ω

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040095

7. Check the harness and connector (Brake light- Ground)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector C003 of the rear left combination light .
(c) Disconnect the connector C002 of the rear right combination light.
(d) Disconnect the connector G001 of the high-mounted brake light.

(e) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

C002 C003 Multimeter

Standard Value
1 3 1 3 Connection
4 6 4 6

C003(4)-Ground
＜2Ω
C002(4)-Ground

fpwx040096
 04-260 Diagnosis - Lighting System

(f) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

G001 Multimeter Standard

Connection Value
04 1 2 G001(1)-
＜2Ω
Ground

Is the result normal?

Yes> Replace the brake light bulb.
No> Repair or replace the harness.
fpwx040097
 Diagnosis - Lighting System 04-261

One of the Reverse Lights OFF

Circuit Diagram

Reverse Light
*Applicable to LJ4651QR1E Engine
Ignition switch **Applicable to 4W10 and 4W12 Engine 04
ON/START

F15
Fuse box
Reverse
light fuse in driver's cab
V035
10A

Green-
grey
V103
13
E101
Green-
grey
1

Reverse
light switch
E024 *
E025 **

2
Green-red
E101
14
V103

V105
4
C101

Green-red Green-red
2 2

Left Right
combination combination
light light
C003 C002

4 4

Black Black

C202 C203

fpwx710031

Diagnostic Steps
 04-262 Diagnosis - Lighting System

• Diagnostic steps take the left reverse light as an example, and the diagnosis of
the right reverse light is the same as that of the left one.

1. Check the harness and connector (Reverse light- Ground)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the rear left combination light connector C003.
04
(c) Measure the resistance according to the value
in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
1 3
Connection
＜2Ω
4 6
C003（4）-Ground

Is the result normal?

Yes> Replace the fuse.
No> Repair or replace the harness.

fpwx040098

2. Check the harness and connector (Reverse light switch- Reserve light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the reverse light switch connector E024.
(c) Disconnect the rear left combination light connector C003.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

E024
Multimeter
Standard Value
Connection
1 1 2 3

2
4 6
E024（2）
C003 ＜2Ω
-C003（2）

Is the result normal?

Yes> Replace the reverse light bulb.
No> Repair or replace the harness.
fpwx040099
 Diagnosis - Lighting System 04-263

Both Reverse Lights OFF

Circuit Diagram

Reverse Light
*Applicable to LJ4651QR1E Engine
Ignition switch **Applicable to 4W10 and 4W12 Engine 04
ON/START

F15
Fuse box
Reverse
light fuse in driver's cab
V035
10A

Green-
grey
V103
13
E101
Green-
grey
1

Reverse
light switch
E024 *
E025 **

2
Green-red
E101
14
V103

V105
4
C101

Green-red Green-red
2 2

Left Right
combination combination
light light
C003 C002

4 4

Black Black

C202 C203

fpwx710031

Diagnostic Steps
 04-264 Diagnosis - Lighting System

1. Check the fuse.

(a) Disconnect the battery cable at the negative end.

(b) Check the fuse F15 of the reverse light in the

fuse box by the driver side: 10 A.
04 Is the result normal?
No> Replace the fuse.
Yes> Go to next step.

fpwx040100

2. Check the harness and connector (Reverse light fuse- Reserve light switch)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the reverse light switch connector E024.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there are short circuits)
Multimeter
E024 Standard Value
Connection
1
2
E024(1)-
≥1MΩ
Ground

Is the result normal?

Yes> Replace the fuse.
No> Repair or replace the harness.
fpwx040101

3. Check the harness and connector (Reverse light switch- Reserve light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the rear left combination light connector C003.
(c) Disconnect the connector C002 of the rear right combination light.
 Diagnosis - Lighting System 04-265

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there are short circuits):
Multimeter
Standard Value
1 2 3 1 2 3
Connection
4 6 4 6

C003(2)/C002(2)-Ground ≥1MΩ 04
C002 C003

Is the result normal?

Yes> Replace the fuse.
No> Repair or replace the harness.

fpwx040102

4. Check the reverse light switch

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the reverse light switch connector E024.

(c) Check the reverse light switch according to

the value in the following table.
Multimeter
E024 Specified
Conditions Connecting
Value
1 Pin
2
Turn off the
reverse light 1-2 ≥1MΩ
switch
Turn on the
reverse light 1-2 ＜2Ω
switch
fpwx040103
Is the result normal?
Yes> Go to next step.
No> Replace the reverse light switch.

5. Check the harness and connector (Reverse light fuse- Reserve light switch)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the reverse light switch connector E024.
 04-266 Diagnosis - Lighting System

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):
Multimeter
1
E024 Standard Value
4

K1 3
2
F6 F5 25A F4 F3 40A

AM1
Connection
1
04 F7 15A F15 10A
IG.S
Reverse light fuse
2
7.5A
＜2Ω
F16
F8 7.5A

K2 4
1
2
F9 10A F17 7.5A
F15(10A)-E024(1)
3 F10 10A F18 15A

F11 10A F19 15A

1
F12 7.5A F20 10A Is the result normal?
K3 4 2 F13 10A
F21 15A

3 F14 30A F22 10A Yes> Go to next step.

No> Repair or replace the harness.
fpwx040104

6. Check the harness and connector (Reverse light switch- Reserve light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the reverse light switch connector E024.
(c) Disconnect the connector C003 of the rear left combination light.
(d) Disconnect the connector C002 of the rear right combination light.

(e) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there are short circuits):
E024 Multimeter
Standard Value
1 1 2 3 1 2 3
Connection
4 6 4 6

2
C002 C003
E024(2)-C003(2)
＜2Ω
E024(2)-C002(2)

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040105

7. Check the harness and connector (Reverse light- Ground).

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector C003 of the rear left combination light.
(c) Disconnect the connector C002 of the rear right combination light.
 Diagnosis - Lighting System 04-267

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):

C002 C003 Multimeter

Standard Value
1 3 1 3 Connection
4 6 4 6

C003(4)-Ground 04
＜2Ω
C002(4)-Ground

Is the result normal?

Yes> Replace the reverse light bulb.
No> Repair or replace the harness.
fpwx040106
 04-268 Diagnosis - Lighting System

Front Interior Light OFF

Circuit Diagram

Interior Light
04

Battery

F9 Fuse box
Horn/ in driver's cab
brake light/
interior light V035
10A

Blue-grey

V105
7
C101

Blue-grey

C102
2
F101
Blue-grey
Blue-grey
1 1

Front roof light Rear roof light

F001 F003
OFF OFF
ON ON

3 3

Black Black

Black

F101
6
C102

Black

C201

fpwx710034

Diagnostic Steps
 Diagnosis - Lighting System 04-269

1. Check the harness and connector (Interior light fuse- interior light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the interior light connector F001

(c) Measure the resistance according to the value

in the following table. Standard resistance 04
(Check whether there is open circuit)
1
F001 F003 Multimeter
4 2
F6 F5 25A F4 F3 40A
Standard Value
K1 3 AM1
Connection
F7 15A F15 10A
IG.S 1 2 3 1 2 3

1
F8

F9
7.5A

10A
F16

F17
7.5A

7.5A
Interior light fuse
K2 4 2

3 F10 10A F18 15A F9(10A) - F001(1)

F11 10A F19 15A
＜2Ω
1
F12 7.5A F20 10A Interior light fuse
K3 4 2 10A
F21 15A
F9(10A) - F003(1)
F13

3 F22 10A
F14 30A

Is the result normal?

fpwx040107 Yes> Replace the fuse.
No> Repair or replace the harness.
 04-270 Diagnosis - Lighting System

Width Light OFF

Circuit Diagram

Width Light Lighting System

04

Battery

Interior
back light

Green-
white

V105
F13 Green- Green- 6
C101
Width light/ Fuse box white white
rear fog in driver's cab
V035 A
light fuse
Green-
10A
white

3 3 5

Front left Front right Rear left

combination combination combination
light light light
Green C003
V004 V016

Green- 2 2 4
white
No.
2 3 1
Gear

OFF

Width light
Width
switch
Light
V032
Black Black Black
Headlight

V201 V203 C202

fpwx710029
 Diagnosis - Lighting System 04-271

Width Light Lighting System

Green- 04
white
C102
4
F101

Green-
Green- white
white
F102
Green- 1
white
A G101
Green-
white
Green- Green-
white white
5 1 1

Rear right
combination License plate License plate
light ligh A ligh B
C002 G002 G003

4 2 2

Black Black

Black

G101
2
Black F102

Black

F101
6
C102

Black

C203 C201

fpwx710030

Diagnostic Steps
1. Check the harness and connector (Width light- Ground)
 04-272 Diagnosis - Lighting System

Note

• If only left width light is not lit, you should not perform step c.
• If only right width light is not lit, you should not perform step b.

04 (a) Disconnect the battery cable at the negative end.

(b) Disconnect the connector V004 of the front left position light.
(c) Disconnect the connector V016 of the front right position light.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):
Multimeter
Standard Value
Connection
1 2 3
1 2 3
4 6 V004 (2)-Ground
4 6
＜2Ω
V004 V016 (2)-Ground
V016

Note

• If only left width light is not lit, you should

fpwx040108
perform a test between V004(2) and the
ground.
• If only right width light is not lit, you
should perform a test between V016(2) and
the ground.

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

2. Check the harness and connector (Width light fuse- width light)
Note

• If only left width light is not lit, you should not perform step c.
• If only right width light is not lit, you should not perform step b.

(a) Disconnect the battery cable at the negative end.

(b) Disconnect the connector V004 of the front left position light.
(c) Disconnect the connector V016 of the front right position light.
 Diagnosis - Lighting System 04-273

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):
V004 V016 Multimeter
4
1
2
F6 F5 25A F4 F3 40A
Standard Value
K1 3 风扇 AM1
1 3 1 3 Connection
F7 15A F15 10A
IG.S 4 6 4 6

1
F8 7.5A F16 7.5A
Width light 04
F9 10A F17 7.5A
K2 4 2

3 F10

F11
10A

10A
F18

F19
15A

15A
fuse
1
F12 7.5A F20 10A F13(10A)-V004(3)
K3 4
3
2 F13 10A
F21

F22
15A

10A
＜2Ω
30A
Width light
F14

fuse
F13(10A)-V016(3)
fpwx040109

Note

• If only left width light is not lit, you should

perform a test between the width light fuse
(10A) and V004(3).
• If only right width light is not lit, you
should perform a test between the width
light fuse (10A) and V016(3).

Is the result normal?

Yes> Replace the fuse.
No> Repair or replace the harness.
 04-274 Diagnosis - Lighting System

Tail Light OFF

Circuit Diagram

Width Light Lighting System

04

Battery

Interior
back light

Green-
white

V105
F13 Green- Green- 6
C101
Width light/ Fuse box white white
rear fog in driver's cab
V035 A
light fuse
Green-
10A
white

3 3 5

Front left Front right Rear left

combination combination combination
light light light
Green C003
V004 V016

Green- 2 2 4
white
No.
2 3 1
Gear

OFF

Width light
Width
switch
Light
V032
Black Black Black
Headlight

V201 V203 C202

fpwx710029
 Diagnosis - Lighting System 04-275

Width Light Lighting System

Green- 04
white
C102
4
F101

Green-
Green- white
white
F102
Green- 1
white
A G101
Green-
white
Green- Green-
white white
5 1 1

Rear right
combination License plate License plate
light ligh A ligh B
C002 G002 G003

4 2 2

Black Black

Black

G101
2
Black F102

Black

F101
6
C102

Black

C203 C201

fpwx710030

Diagnostic Steps
1. Check the harness and connector (Tail light- Ground)
 04-276 Diagnosis - Lighting System

Note

• If only left tail light is not lit, you should not perform step c.
• If only right tail light is not lit, you should not not perform step b.

04 (a) Disconnect the battery cable at the negative end.

(b) Disconnect the rear left combination light connector C003.
(c) Disconnect the connector C002 of the rear right combination light.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
C002 C003 Multimeter
Standard Value
1 3 1 3
Connection
4 6 4 6

C003（4）-Ground
＜2Ω
C002(4)-Ground

Note

• If only left tail light is not lit, you should

fpwx040110 perform a test between C003(4) and the
ground.
• If only right tail light is not lit, you should
perform a test between C002(4) and the
ground.

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

2. Check the harness and connector (Lighting combination switch - Tail light)
Note

• If only left tail light is not lit, you should not perform step c.
• If only right tail light is not lit, you should not not perform step b.

(a) Disconnect the battery cable at the negative end.

(b) Disconnect the rear left combination light connector C003.
(c) Disconnect the connector C002 of the rear right combination light.
 Diagnosis - Lighting System 04-277

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
C002 C003 Standard Value
4
1
2
F6 F5 25A
1 3 1
Connection
3
K1 3

F7 15A
4 5 6 4 5 6
Width light 04
7.5A
1
F8

F9 10A
fuse
K2 4 2

3 F10 10A F13(10A)-C003(5)

F11 10A ＜2
1
F12 7.5A Width light
K3 4
3
2 F13

F14
10A

30A
fuse
F13(10A)-C002(5)
fpwx040111
Is the result normal?
Yes> Replace the tail light bulb.
No> Repair or replace the harness.
 04-278 Diagnosis - Lighting System

License Plate Light OFF

Circuit Diagram

Width Light Lighting System

04

Battery

Interior
back light

Green-
white

V105
F13 Green- Green- 6
C101
Width light/ Fuse box white white
rear fog in driver's cab
V035 A
light fuse
Green-
10A
white

3 3 5

Front left Front right Rear left

combination combination combination
light light light
Green C003
V004 V016

Green- 2 2 4
white
No.
2 3 1
Gear

OFF

Width light
Width
switch
Light
V032
Black Black Black
Headlight

V201 V203 C202

fpwx710029
 Diagnosis - Lighting System 04-279

Width Light Lighting System

Green- 04
white
C102
4
F101

Green-
Green- white
white
F102
Green- 1
white
A G101
Green-
white
Green- Green-
white white
5 1 1

Rear right
combination License plate License plate
light ligh A ligh B
C002 G002 G003

4 2 2

Black Black

Black

G101
2
Black F102

Black

F101
6
C102

Black

C203 C201

fpwx710030

Diagnostic Steps
1. Check the harness and connector (License plate light- Ground)
(a) Disconnect the battery negative cable.
 04-280 Diagnosis - Lighting System

(b) Disconnect the license plate light connector G003/G002.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
G002 G003
04 Multimeter
Standard Value
Connection
1 2 1 2

G002(2)/G003(2)-Ground ＜2Ω

Is the result normal?

No> Repair or replace the harness.
Yes> Go to next step.

fpwx040112

2. Check the harness and connector (Switch connector- License plate light)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the license plate light connector G002/G003.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
1
F6 F5 25A
4 2

K1 3 G002 G003 Multimeter

Standard Value
F7

F8
15A

7.5A
Connection
1
10A 1 2 1 2
G002(1)/G003(1)-Wd
i th
F9
K2 4 2

3 F10 10A

F11 10A
light fuse ＜2Ω
F12 7.5A

K3 4
1
2 F13 10A
F13(10A)
3 F14 30A

Is the result normal?

Yes> Replace the fuse.
fpwx040113 No> Repair or replace the harness.
 Diagnosis - Wipers and Washers 04-281

Wipers and Washers

Wipers and Washers
1. Cut off the power supply.
(a) Before removing or installing any electrical equipment, especially for those tools or
equipment accessible to the exposed electrical terminals, make sure to disconnect
04
the battery negative cable to protect people or the vehicle from damage.
(b) If not otherwise specified, you must turn off the ignition switch.
 04-282 Diagnosis - Wipers and Washers

Component Diagrams

1 2
04

fpwx040201

1 Right wiper arm assembly of the 2 Left wiper arm assembly of the front
front wipers wipers
 Diagnosis - Wipers and Washers 04-283

Basic Inspection
Step Inspection item Measure
Yes Go to step 2.
Inspect the battery voltage.
Charge or replace the battery.
1. • Battery voltage should not be lower than Refer toChapter 20A Starting 04
12V. Is the result normal? No
and Charging - Battery, Re-
placement
Inspect the wiper at the high-speed mode. Yes Go to step 3.
• Turn on the wiper at the high-speed
2. Refer to the Fault Symptom
mode by the combination switch. Is the No
result normal? Table

Inspect the wiper at the low-speed mode. Yes Go to step 4.

• Ignition switch: ON.
3. • Turn on the wiper at the low-speed mode Refer to the Fault Symptom
by the combination switch. Is the result No
Table
normal?
Inspect the wiper at the intermittent mode. Yes Inspect the front wiper motor.
• Turn on the wiper at the intermittent
4. Refer to the Fault Symptom
mode by the combination switch. Is the No
result normal? Table
 04-284 Diagnosis - Wipers and Washers

Fault Symptom Table

1. The following table will help to you find the cause of the fault.The serial number
indicates the possibility sequence for the fault causes. Check every parts
according to this sequence, and replace where necessary.
Fault symptom Suspicious positions Refer to
04
1. Fuse -
Chapter 64 Lighting System
2. Combination switch - Combination Switch
The front wipers are out of Assembly, Replacement
work Chapter 65 Wipers and
3. Wiper motor Washers - Wipers Motor,
Replacement
4. Harness -
Chapter 65 Wipers and
1. Wiper motor Washers - Wipers Motor,
Replacement
Front wiper at the low-speed
Chapter 64 Lighting System
mode out of work
2. Combination switch - Combination Switch
Assembly, Replacement
3. Harness -
Chapter 65 Wipers and
1. Wiper motor Washers - Wipers Motor,
Replacement
Front wiper at the high-speed
Chapter 64 Lighting System
mode out of work
2. Combination switch - Combination Switch
Assembly, Replacement
3. Harness -
Chapter 65 Wipers and
1. Wiper motor Washers - Wipers Motor,
Replacement
Front wiper at the intermittent
Chapter 64 Lighting System
mode out of work
2. Combination switch - Combination Switch
Assembly, Replacement
4. Harness -
Chapter 64 Lighting System
1. Combination switch - Combination Switch
Assembly, Replacement
Front washer out of work Chapter 65 Wipers and
2. Front washer motor Washers - Wipers Motor,
Replacement
3. Harness -
 Diagnosis - Wipers and Washers 04-285

Fault symptom Suspicious positions Refer to

Chapter 65 Wipers and
1. Front wiper assembly Washers - Wipers Motor,
Replacement
When the switch of the front
wiper is OFF, the wiper gets Chapter 64 Lighting System
struck. 2. Combination switch - Combination Switch 04
Assembly, Replacement
3. Harness -
 04-286 Diagnosis - Wipers and Washers

Wipers out of Work

Circuit Diagram

Wiper System
04

Ignition switch Combination switch of wipers and washers

ACC/ON V029
Contact
Red-blue 1 2 3 4 5 6 7
Code
High
F24 Fuse box speed
Wipers and in driver's cab
washers fuse V035 Low
15A speed

Intermi
Gear
ttent

OFF
Wiper
intermittent
relay Washer

V022

2 1 3 5 6 4
Grey Grey- Grey- Grey-
Grey-blue yellow red black

Grey-red 3 2

4
1

Grey-
Wiper motor red
Grey-red V015

Grey-red

Grey-black

Grey-green
2
Grey-brown Grey-
black
Grey-red Washer
motor
V040

Black

V201 V204

fpwx710070

Diagnostic Steps
 Diagnosis - Wipers and Washers 04-287

1. Check the fuse.

(a) Ignition switch: OFF.

(b) Check the fuse F24 of the front wiper in the

fuse box (V035) by the driver side: 15A.
Is the fuse good? 04

No> Replace the fuse.

Yes> Go to next step.

fpwx040114

2. Check the harness and connector (Wiper fuse - Wiper motor)

(a) Ignition switch: OFF.
(b) Disconnect the connector V015 of the wiper assembly.

(c) Measure the resistance according to the value

in the following table. Standard Resistance

V015
Multimeter
Standard Value
F1 20A
Connection
BCM

2 Wipers and
1 2
1

3
K6
4
1

3
2
washers fuse <2Ω
K7
F23 15A F24 15A 4
3 4 F24(15A)-V015(1)
F25 25A

F26 7.5A
K8 4 2 Is the result normal?
3

Yes> Go to next step.

No> Repair or replace the harness.
fpwx040115

3. Check the harness and connector (Wiper fuse - Combination switch)

(a) Ignition switch: OFF.
(b) Disconnect the combination switch connector V029.
 04-288 Diagnosis - Wipers and Washers

(c) Measure the resistance according to the value

in the following table. Standard Resistance
Multimeter
V029 Standard Value
Connection
20A F1 20A

9 6
F2

BCM
Front wipers and
04 1 2
5 2 1
K6
3
1 2
washers fuse <2Ω
4

K7
3 F24(15A)-V029(2)
F23 15A F24 15A 4

25A Is the result normal?

1

K8 4 2
7.5A 3
Yes> Replace the fuse.
No> Repair or replace the harness.
fpwx040116

4. Check the harness and connector (Combination switch - Wiper motor assembly)
(a) Ignition switch: OFF.
(b) Disconnect the combination switch (wiper control) connector V029.
(c) Disconnect the connector V015 of the wiper motor assembly.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
V015
V029 Multimeter
Standard Value
9 6 Connection
5 1 1 2
V029(1)-V015(4)
3 4 ＜2Ω
V029(5)-V015(2)

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040117

5. Replace the wiper assembly.

(a) Ignition switch: OFF.
(b) Disconnect the connector V015 of the wiper motor. V015
 Diagnosis - Wipers and Washers 04-289

(c) Check the wiper assembly at the high-speed

mode.

V015 Multimeter
Specified
Conditions Connecting
Value
Pin
1 2
Wiper 04
3 4 Apply the
assembly
power supply
4 - Ground runs at the
voltage on
high-speed
the pin 4
mode.

(d) Check the wiper assembly at the low-speed

fpwx040118
mode.
Multimeter
Specified
Conditions Connecting
Value
Pin
Wiper
Apply the
assembly
power supply
2 - Ground runs at the
voltage on
low-speed
the pin 2
mode.

Is the result normal?

Yes> Check the wiper combination switch.
No> Repair or replace the wiper assembly.
 04-290 Diagnosis - Wipers and Washers

Wipers at the Low-speed Mode out of Work

Circuit Diagram

Wiper System
04

Ignition switch Combination switch of wipers and washers

ACC/ON V029
Contact
Red-blue 1 2 3 4 5 6 7
Code
High
F24 Fuse box speed
Wipers and in driver's cab
washers fuse V035 Low
15A speed

Intermi
Gear
ttent

OFF
Wiper
intermittent
relay Washer

V022

2 1 3 5 6 4
Grey Grey- Grey- Grey-
Grey-blue yellow red black

Grey-red 3 2

4
1

Grey-
Wiper motor red
Grey-red V015

Grey-red

Grey-black

Grey-green
2
Grey-brown Grey-
black
Grey-red Washer
motor
V040

Black

V201 V204

fpwx710070

Diagnostic Steps
 Diagnosis - Wipers and Washers 04-291

1. Check the combination switch.

(a) Ignition switch: OFF.
(b) Disconnect the combination switch (wiper control) connector V029.

(c) Check the combination switch(wiper control).

04
Multimeter
Specified
Conditions Connecting
V029 Value
Pin
9 6
Turn off the
5 4 2 1 4-5 ≥1MΩ
wiper switch.
Turn the
wiper switch
to the 2-5 ＜2Ω
low-speed
mode.
fpwx040119
Is the result normal?
Yes> Go to next step.
No> Replace the combination switch.

2. Check the harness and connector (Combination switch of wipers and washers
- Wiper assembly)
(a) Ignition switch: OFF.
(b) Disconnect the connector V015 of the wiper motor.
(c) Disconnect the combination switch V029 of wipers and washers.

(d) Measure the resistance according to the value

in the following table. Standard Resistance
Multimeter
Standard Value
Connection
V029 V015
V029(5)-V015(2) <2Ω
9 6 1 2
5 1
3 4 Is the result normal?
Yes> Replace the wiper assembly.
No> Repair or replace the harness.

fpwx040121
 04-292 Diagnosis - Wipers and Washers

Wipers at the High-speed Mode out of Work

Circuit Diagram

Wiper System
04

Ignition switch Combination switch of wipers and washers

ACC/ON V029
Contact
Red-blue 1 2 3 4 5 6 7
Code
High
F24 Fuse box speed
Wipers and in driver's cab
washers fuse V035 Low
15A speed

Intermi
Gear
ttent

OFF
Wiper
intermittent
relay Washer

V022

2 1 3 5 6 4
Grey Grey- Grey- Grey-
Grey-blue yellow red black

Grey-red 3 2

4
1

Grey-
Wiper motor red
Grey-red V015

Grey-red

Grey-black

Grey-green
2
Grey-brown Grey-
black
Grey-red Washer
motor
V040

Black

V201 V204

fpwx710070

Diagnostic Steps
 Diagnosis - Wipers and Washers 04-293

1. Check the combination switch.

(a) Ignition switch: OFF.
(b) Disconnect the combination switch (wiper control) connector V029.

(c) Check the combination switch(wiper control).

04
Multimeter
Specified
Conditions Connecting
V029 Value
Pin
9 6 Turn off the
1-2 ≥1MΩ
5 2 1 wiper switch.
Turn the
wiper switch
to the 1-2 ＜2Ω
high-speed
mode.
fpwx040122
Is the result normal?
Yes> Go to next step.
No> Replace the combination switch.

2. Check the harness and connector (Combination switch - Wiper assembly)

(a) Ignition switch: OFF.
(b) Disconnect the combination switch (wiper control) connector V029.
(c) Wiper assembly V015.

(d) Measure the resistance according to the value

in the following table. Standard Resistance
Multimeter
Standard Value
Connection
V015
V029 V029(1)-V015(4) <2Ω
1 2
9 6
3 4
5 1 Is the result normal?
Yes> Replace the wiper assembly.
No> Repair or replace the harness.

fpwx040123
 04-294 Diagnosis - Wipers and Washers

Washers out of Work

Circuit Diagram

Wiper System
04

Ignition switch Combination switch of wipers and washers

ACC/ON V029
Contact
Red-blue 1 2 3 4 5 6 7
Code
High
F24 Fuse box speed
Wipers and in driver's cab
washers fuse V035 Low
15A speed

Intermi
Gear
ttent

OFF
Wiper
intermittent
relay Washer

V022

2 1 3 5 6 4
Grey Grey- Grey- Grey-
Grey-blue yellow red black

Grey-red 3 2

4
1

Grey-
Wiper motor red
Grey-red V015

Grey-red

Grey-black

Grey-green
2
Grey-brown Grey-
black
Grey-red Washer
motor
V040

Black

V201 V204

fpwx710070

Diagnostic Steps
 Diagnosis - Wipers and Washers 04-295

1. Check the fuse.

(a) Ignition switch: OFF.

(b) Check the fuse F24 of wipers and washers in

the fuse box by the driver side: 15A.
Is the result normal? 04

No> Replace the fuse.

Yes> Go to next step.

fpwx040114

2. Check the combination switch.

(a) Ignition switch: OFF.
(b) Disconnect the combination switch (wiper control) connector V029.

(c) Check the combination switch(wiper control).

Multimeter
Specified
Conditions Connecting
V029 Value
Pin
9 6 Turn off the
4-5 ≥1MΩ
5 4 2 1 wiper switch.
Turn the
wiper switch
to the 4-5 ＜2Ω
washing
gear.
fpwx040124
Is the result normal?
Yes> Go to next step.
No> Replace the combination switch.

3. Check the harness and connector (Washing motor - combination switch)

(a) Ignition switch: OFF.
 04-296 Diagnosis - Wipers and Washers

(b) Disconnect the connector V040 of the front washing motor.

(c) Disconnect the combination switch (wiper control) connector V029.

(d) Measure the resistance according to the value

in the following table. Standard Resistance
04 Multimeter
Standard Value
Connection
V040
V040(2)-V029(7) ＜2Ω
1
9 7 6
2

5 1
Is the result normal?
Yes> Replace the fuse.
V029
No> Repair or replace the harness.

fpwx040125

4. Check the harness and connector (Washing motor - Ground)

(a) Ignition switch: OFF.
(b) Disconnect the connector V040 of the washing motor.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter Standard
Connection Value
1
V040(1)-
2 ＜2Ω
Ground

Is the result normal?

Yes> Replace the washing motor.
No> Repair or replace the harness.
fpwx040126
 Diagnosis - Sound System 04-297

Sound System
Precautions
1. Never refit the sound system or add other audio devices.
2. The sound systemapplies the following radio band.
Radio wave AM FM 04
Method of Modula-
Amplitude Modulation Frequency Modulation
tion
Band AM1 AM2 FM1 FM2 FM3

3. Cut off the power supply.

(a) Before removing or installing any electrical equipment, especially for those tools or
equipment accessible to the exposed electrical terminals, make sure to disconnect
the battery negative cable to protect people or the vehicle from damage.
(b) If not otherwise specified, you must turn off the ignition switch.
 04-298 Diagnosis - Sound System

Component Diagrams

04
2

fpwx040202

1 Radio antenna 3 Radioassembly

2 Right speaker 4 Left speaker
 Diagnosis - Sound System 04-299

Basic Inspection
Step Inspection item Measure
Inspect the battery voltage Yes Go to next step.
• Battery voltage should not be Charge or replace the battery. Refer
1.
lower than 12V. Is the result No toChapter 20A Starting and Charging 04
normal? - Battery
Inspect the antenna Yes Go to next step.
• Whether there are foreign ob-
jects covering the antenna.
2.
• Whether the antenna is bent No Repair or replace the antenna.
or deformed. Is the result nor-
mal?
Inspect the radio Yes Go to next step.
• Press the power switch of the
3. radio, and check whether the
radio works. Is the result nor- No Refer to the Fault Symptom Table
mal?
Inspect the speaker Yes Go to next step.
• Turn up to 5 VOL or more, and
4.
check whether the speaker No Refer to the Fault Symptom Table
sounds. Is the result normal?
Yes Refer to the Fault Symptom Table
Is the checking result of radio
5. Move the vehicle to a good signal
wave normal? No
place.
 04-300 Diagnosis - Sound System

Fault Symptom Table

1. The following table will help to you find the cause of the fault.The serial number
indicates the possibility sequence for the fault causes. Check every parts
according to this sequence, and replace where necessary.
Fault symptom Suspicious positions Refer to
04
1. Fuse -
2. Harness -
Radio: Not working
Chapter 66 Sound System -
Radio Sound System Assembly,
Replacement
1. Improper radio settings -
2. Antenna fault -

Bad Radio Reception 3. Radio signal -

Chapter 66 Sound System -
4. Radio Sound System Assembly,
Replacement
1. Improper radio settings -
2. Antenna fault -
3. Radio signal -
Poor Radio Sound Quality
4. Speaker -
Chapter 66 Sound System -
5. Radio Sound System Assembly,
Replacement
1. Improper radio settings -
2. Speaker -

Speaker out of Work 3. Harness -

Chapter 66 Sound System -
4. Radio Sound System Assembly,
Replacement
 Diagnosis - Sound System 04-301

Radio out of Work

Circuit Diagram

Sound System

04

Ignition switch
Battery ACC/ON

Red Red-blue

F8 F23 Fuse box

Diagnosis/ Cigar lighter/ in driver's cab
Instrument/ECU Radio fuse V035
7.5A 15A

Interior back light

Antenna

Red Purple-yellow Green-white

2 1 3

Radio
V020

- + - +
11 10 13 12 4

V106 V101
2 1 2 1
A101 D101
Purple- Purple-
black Purple-white green Purple-blue Black
1 2 1 2

Front right speaker Front left speaker

A001 D001
V204

fpwx710046

Diagnostic Steps
 04-302 Diagnosis - Sound System

1. Check the radio fuse.

(a) Ignition switch: OFF.

(b) Check the radio fuse F23 in the fuse box by

the driver side: 15A.
04 (c) Check the radio fuse F8 in the fuse box by
the driver side: 7.5A.

fpwx040127

2. Check the harness and connector (Radio - Ground)

(a) Ignition switch: ON.

(c) Measure the voltage from the back of the

radio V020according to the value in the
following table. Standard voltage (Check
whether there is short circuit)

V020 Multimeter
Standard Value
2 4 6 8 10 12
Connection
1 3 5 7 9 11 13
V020 (1)-
Battery voltage
V
Ground
V020 (2)-
Battery voltage
Ground

fpwx040128
Is the result normal?
Yes> Go to next step.
No> Repair or replace the harness.

3. Check the harness and connector (Radio - Ground)

(a) Ignition switch: OFF.
 Diagnosis - Sound System 04-303

(b) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
Connection
V020
04
2 4 6 8 10 12 V020 (4)- Ground ＜2Ω
1 3 5 7 9 11 13

Is the result normal?

Yes> Replace the radio.
No> Repair or replace the harness.

fpwx040129
 04-304 Diagnosis - Sound System

Bad Radio Reception

Diagnostic Steps
1. Check the radio settings.
(a) Ignition switch: OFF.
04 (b) Press the power switch of the radio.
(c) Turn up the radio to 5 VOL or more.
(d) Turn the knob and search radio stations.
Check whether the radio settings are normal.
Yes> Go to next step.
No> Change the radio settings.

2. Check the radio signal.

(a) Drive the vehicle to a good signal place.
(b) Ignition switch: ON.
(c) Press the power switch of the radio.
(d) Turn up the radio to 5 VOL or more.
(e) Turn the knob and search radio stations.
Check whether the radio normally receives.
Yes> Normal system.
No> Go to next step.
Note

• AM and FM radio broadcasting have quite different coverage areas. Sometimes

you can clearly receive AM radio broadcasting but not for FM stereo. FM stereo
has minimum coverage areas and is vulnerable to the electromagnetic
interference.
• At night, AM radio will receive another type of interference as its radio signal
will be reflected by the ionized layer at night. These radio signals will interfere
with the vehicle directly receiving signals from a radio transmitter
• When signals from the radio transmitter are reflected by a mountain or high
building, it will affect the vehicle directly receiving signals from the radio
transmitter.

3. Check the radio antenna.

(a) Check the antenna for bend or deformation.
(b) Check whether the fine wire of the antenna is broken.
(c) Check whether the connector of the antenna is firmly installed.
Check whether the radio normally receives after the adjustment of the antenna.
Yes> Repair or replace the antenna.
No> Replace the radio.
 Diagnosis - Sound System 04-305

Poor Radio Sound Quality

Diagnostic Steps
1. Check the radio settings.
(a) Ignition switch: ON.
(b) Press the power switch of the radio. 04
(c) Turn up the radio to 5 VOL or more.
(d) Turn the knob and search radio stations.
Check whether the radio settings are normal.
Yes> Go to next step.
No> Change the radio settings.

2. Check the radio signal.

(a) Drive the vehicle to a good signal place.
(b) Ignition switch: ON.
(c) Press the power switch of the radio.
(d) Turn up the radio to 5 VOL or more.
(e) Turn the knob and search radio stations.
Check whether the radio normally receives.
Yes> Normal system.
No> Go to next step.

3. Check the radio antenna.

(a) Check the antenna for bend or deformation.
(b) Check whether the fine wire of the antenna is broken.
(c) Check whether the connector of the antenna is firmly installed.
Check whether the radio normally receives after the adjustment of the antenna.
Yes> Repair or replace the antenna.
No> Go to next step.

4. Inspect the speaker

(a) Ignition switch: OFF.
(b) Dismantle the speaker. (Refer to Chapter 66 Sound System - Front Speaker Assembly,
Replacement )
(c) Check whether there are foreign objects absorbed on the speaker.
(d) Check whether there is dirt on the speaker cone.
(e) Check whether the speaker cone is broken.
(f) Perform a test with a good speaker.
Check whether the radio sound quality is normal.
Yes> Repair or replace the speaker.
No> Replace the radio.
 04-306 Diagnosis - Sound System

Speaker out of Work

Circuit Diagram

Sound System

04

Ignition switch
Battery ACC/ON

Red Red-blue

F8 F23 Fuse box

Diagnosis/ Cigar lighter/ in driver's cab
Instrument/ECU Radio fuse V035
7.5A 15A

Interior back light

Antenna

Red Purple-yellow Green-white

2 1 3

Radio
V020

- + - +
11 10 13 12 4

V106 V101
2 1 2 1
A101 D101
Purple- Purple-
black Purple-white green Purple-blue Black
1 2 1 2

Front right speaker Front left speaker

A001 D001
V204

fpwx710046

Diagnostic Steps
 Diagnosis - Sound System 04-307

1. Check the radio settings.

(a) Ignition switch: ON.
(b) Press the power switch of the radio.
(c) Turn up the radio to 5 VOL or more.
(d) Turn the knob and search radio stations.
04
Check whether the radio settings are normal.
Yes> Go to next step.
No> Change the radio settings.

2. Check the harness and connector (Radio - Ground)

(a) Ignition switch: OFF.
(b) Disconnect the radio connector.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
Connection
V020
V024 (4)- Ground ＜2Ω
2 4 6 8 10 12
1 3 5 7 9 11 13 Is the result normal?
Yes> Go to next step.
No> Repair or replace the harness.

fpwx040130

3. Check the harness and connector (Radio - Speaker)

(a) Ignition switch: OFF.
(b) Disconnect the speaker connector. A001.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
A001 Standard Value
Connection
2 4 6 8 10 12
1 2
1 3 5 7 9 11 13
V020 (11) - A001 (1)
V020
＜2Ω
V020 (10) - A001 (2)

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040131
 04-308 Diagnosis - Sound System

4. Check the harness and connector (Radio - Speaker)

(a) Ignition switch: OFF.
(b) Disconnect the speaker connector D001.

(c) Measure the resistance according to the value

04 in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
A001 Standard Value
Connection
2 4 6 8 10 12
1 2
1 3 5 7 9 11 13
V020 (13) - D001 (1)
V020
＜2Ω
V020 (12) - D001 (2)

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040132

5. Inspect the speaker

(a) Disconnect the radio connector.
(b) Perform a test with a good speaker.
Check whether the speaker works properly.
Yes> Replace the speaker.
No> Replace the radio.
 Diagnosis - Accessory Power Supply 04-309

Accessory Power Supply

Component Diagrams

04

2
1

fpwx040203

1 Cigar lighter 2 12V power supply output socket

 04-310 Diagnosis - Accessory Power Supply

Fault Symptom Table

1. The following table will help to you find the cause of the fault.The serial number
indicates the possibility sequence for the fault causes. Check every parts
according to this sequence, and replace where necessary.
Fault symptom Suspicious positions Refer to
04
1. Fuse –
Cigar lighter out of work 2. Cigar lighter –
3. Harness –
1. Relay –
12V power supply output
2. Fuse –
socket out of work
3. Harness –
 Diagnosis - Accessory Power Supply 04-311

Cigar Lighter out of Work

Circuit Diagram

Auxiliary Power Supply

Ignition Switch
ON/START 04

Red-blue

F23 Fuse box

Cigar lighter/
in driver's cab
Radio fuse
V035
15A

Purple-yellow

Cigar lighter
V024

Black

V204
fpwx710041

Diagnostic Steps
1. Check the fuse.
(a) Disconnect the battery cable at the negative end.
 04-312 Diagnosis - Accessory Power Supply

(b) Check the cigar lighter fuse F23 in the fuse

box: 15A

04

fpwx040133

2. Check the harness and connector (Cigar lighter- Ground)

(a) Ignition switch: OFF.
(b) Disconnect the connector V024 of the cigar lighter.

(c) Measure the resistance according to the value

in the following table. Standard Resistance
Multimeter
Standard Value
Connection
1 V024 (2)-
≥1MΩ
2
Ground

Is the result normal?

Yes> Go to next step.
No> Replace the fuse.

fpwx040134

3. Check the harness and connector (Cigar lighter fuse - Cigar lighter)
(a) Ignition switch: OFF.
(b) Disconnect the connector V024 of the cigar lighter.
 Diagnosis - Accessory Power Supply 04-313

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
F3 40A F2 20A F1 20A

AM1 BCM Multimeter

1 2 1 2 Standard Value
K4
3
K6
3
2
Connection
1
4 4
1
K7
3
4 Cigar lighter fuse 04
＜2Ω
F23 15A F24 15A
2

F25 25A
F23–V024 (2)
1
1 2
K8 4 2
K5 3
4
F26 7.5A 3
Is the result normal?
Yes> Go to next step.
No> Repair or replace the harness.
fpwx040135

4. Check the harness and connector (Cigar lighter- Ground)

(a) Ignition switch: OFF.
(b) Disconnect the connector V024 of the cigar lighter.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
Connection
1 V024 (1)- (Ground) ＜2Ω
2
Is the result normal?
Yes> Replace the cigar lighter.
No> Repair or replace the harness.

fpwx040136
 04-314 Diagnosis - Horn

Horn
Component Diagrams

04

fpwx040204

1 Horn button 2 Horn

 Diagnosis - Horn 04-315

Fault Symptom Table

1. The following table will help to you find the cause of the fault.The serial number
indicates the possibility sequence for the fault causes. Check every parts
according to this sequence, and replace where necessary.
Fault symptom Suspicious positions Refer to
04
1. Fuse –
Chapter 60 Steering Gear - Steering
Horn out of Work 2. Horn switch
Wheel, Maintenance
3. Harness –
Chapter 60Steering Gear - Steering
1. Horn switch
Wheel, Maintenance
Horn Always
Sounding 2. Harness –
3. Central door lock controller –
 04-316 Diagnosis - Horn

Horn out of Work

Circuit Diagram

Speaker system_with airbag

04
Battery

Brown- Brown- Brown-

Red blue blue blue

F9 1 4
Horn/Brake light/ Driver's cab
Interior light K6 Fuse box
Horn
Fuse Relay V035
10A
3 2

Brown-red Brown-black

2 Tweeter speaker f2
Clock spring
V002 V049
Brown-black
1

Speaker switch
V033

Black

V204 Self ground wire fpwx710069

Diagnostic Steps
1. Check the fuse.
(a) Disconnect the battery cable at the negative end.
 Diagnosis - Horn 04-317

(b) Check the horn fuse F9 in the fuse box by the

driver side: 10A

04

fpwx040137

2. Inspect the horn relay

(a) Disconnect the battery cable at the negative end.
(b) Unplug the horn relay K6.

(c) Inspect the horn relay. Standard Resistance:

F3 40A F2 20A F1 20A Multimeter
AM1 Light main fuse BCM
Conditions Connecting Specified Value
1 2 1 2
Pin
Fuel pump relay

Horn relay

3 3
K4 K6 1 2
Front fog light relay

4 4
3
Constant 4-2 Breakover
K7
F23 15A F24 15A
4
Apply the
Paddle shifter

Cigar lighter Radio Wiper and washer

power
F25 25A

1 supply
1 2 Blower
Low-speed fan relay

4 2
K8
＜2Ω
Main relay

K5 3
voltage 1-3
F26 7.5A 3
4
Overhead blower
between
the pin 4
fpwx040138 and pin2

Is the result normal?

Yes> Go to next step.
No> Replace the horn relay.

3. Check the harness and connector (Horn relay - Clock spring)

(a) Ignition switch: OFF.
(b) Disconnect the battery cable.
(c) Disconnect the connector of the horn relay.
(d) Disconnect the connector V049 of the clock spring.
 04-318 Diagnosis - Horn

(e) Measure the resistance according to the value

in the following table. Standard Resistance
Multimeter
Standard Value
Connection
F3 40A F2 20A F1 20A

AM1 BCM

Horn relay (2) - V049

＜2Ω
1 2 1 2

04 K4
3
4
K6
3
4
1 2
1 (2)
3
K7
F23 15A F24 15A 4
2
F25 25A
Is the result normal?
1
1 2

K5 3 F26 7.5A
K8 4
3
2
Yes> Go to next step.
4

No> Repair or replace the harness.

fpwx040140

4. Inspect the clock spring (high-end vehicle)

(a) Disconnect the battery cable at the negative end.
(b) Replace the clock spring.
(c) Connect the battery negative cable.
Does the horn sound?
Yes> Replace the clock spring.
No> Go to next step.

5. Inspect the horn switch.

(a) Remove the horn switch. (Refer toChapter 60 Steering Gear - Steering Wheel,
Maintenance)
(b) Inspect whether the horn switch is obviously ablated or bad contacted.
(c) Replace the horn switch. (Refer toChapter 60 Steering Gear - Steering Wheel,
Maintenance)
(d) Press the horn switch.
Does the horn sound?
Yes> Repair or replace the horn switch.
No> Go to next step.

6. Check the harness and connector (Horn relay - Horn)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V002 of the tweeter.
Multimeter Connection Standard Value
Horn relay K6 (3) - V002 (1) ＜2Ω

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
 Diagnosis - Horn 04-319

7. Check the harness and connector (Horn - Ground)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V002 of the tweeter.

(c) Measure the resistance according to the value

in the following table. Standard resistance 04
(Check whether there is open circuit)
Multimeter Connection Standard Value

1
V002 (2)-Ground ＜2Ω
2
Is the result normal?
Yes> Replace the horn.
No> Repair or replace the harness.

fpwx040141
 04-320 Diagnosis - Horn

Horn Always Sounding

Circuit Diagram

Speaker system_with airbag

04
Battery

Brown- Brown- Brown-

Red blue blue blue

F9 1 4
Horn/Brake light/ Driver's cab
Interior light K6 Fuse box
Horn
Fuse Relay V035
10A
3 2

Brown-red Brown-black

2 Tweeter speaker f2
Clock spring
V002 V049
Brown-black
1

Speaker switch
V033

Black

V204 Self ground wire fpwx710069

Diagnostic Steps
1. Inspect the horn relay
(a) Disconnect the battery cable at the negative end.
(b) Unplug the horn relay
 Diagnosis - Horn 04-321

(c) Inspect the horn relay. Standard Resistance:

F3 40A F2 20A F1 20A Multimeter
Specified
AM1 Light main fuse BCM
Conditions Connecting
1 2 1 2 Value
Pin

Fuel pump relay

Horn relay
3 3
K4 K6 1 2

Front fog light relay

4 4
3
Constant 4-2 Breakover
K7 04
F23 15A F24 15A
4

Paddle shifter
Apply the
Cigar lighter Radio Wiper and washer

power supply
F25 25A

1 voltage
1 2 Blower
1-3 ＜2Ω
Low-speed fan relay

K8 4 2

Main relay
K5 3
between the
F26 7.5A 3
4
Overhead blower
pin 4 and
pin2
fpwx040138
Is the result normal?
Yes> Go to next step.
No> Replace the horn relay.

2. Inspect the clock spring (high-end vehicle)

(a) Disconnect the battery cable at the negative end.
(b) Replace the clock spring.
(c) Connect the battery negative cable.
Does the horn work properly?
Yes> Replace the clock spring.
No> Go to next step.

3. Inspect the horn switch.

(a) Remove the horn switch. (Refer toChapter 60 Steering Gear - Steering Wheel,
Maintenance)
(b) Inspect whether the horn switch is obviously shorted to ground.
(c) Replace the horn switch. (Refer toChapter 60Steering Gear - Steering Wheel,
Maintenance)
Does the horn work properly?
Yes> Replace the horn.
No> Replace the horn switch.
 04-322 Diagnosis - Electric Windows

Electric Windows
Precautions
1. Cut off the power supply.
(a) Before removing or installing any electrical equipment, especially for those tools or
equipment accessible to the exposed electrical terminals, make sure to disconnect
04
the battery negative cable to protect people or the vehicle from damage.
Note
Before disconnecting the battery negative cable, do not put the key in the car to avoid
locking the door.
(b) Turn off the ignition switch except special requirement.
2. Disconnecting the battery negative cable will reset the trip meter in the instrument
cluster.
Note
The odometer will not be reset.
3. Disconnecting the battery negative cable will make the sound system lose the
saved setting.
Note
Reset the sound system after connecting the battery negative cable again.
 Diagnosis - Electric Windows 04-323

Component Diagrams

1 04

fpwx040205

1 Left front electric door window 2 Right front electric door window
regulator regulator
 04-324 Diagnosis - Electric Windows

Basic Inspection
Step Inspection item Measure
1. Inspect the battery Yes Go to step 2.
voltage
Charge or replace the
04 • Battery voltage battery. Refer to
should not be lower No "Chapter 20A Starting
than 12V. Is the and Charging -
result normal? Battery"
Check left window Yes Go to step 3.
glass lifter motor
• Ignition switch: ON.
• Use the left electric
door window switch
2. Refer to the Fault
to make the front No
left window glass Symptom Table
lifter motor to wind
down and up. Is the
result normal?
Check left windows Yes Go to step 4.
for the automatic
lowering function
• Ignition switch: ON.
• Use the left electric
door window switch
3. Refer to the Fault
to make the front No
left window glass Symptom Table
lifter moto
automatically lower.
Is the result
normal?
Check right window Yes Go to step 5.
glass lifter motor
• Use the right
electric door
window switch to
4. Refer to the Fault
make the front right No
window glass lifter Symptom Table
motor to wind down
and up. Is the result
normal?

Use the right electric Yes Replace the window

door window switch glass lifter motor.
5.
to make the front right Refer to the Fault
window glass lifter No
Symptom Table
 Diagnosis - Electric Windows 04-325

motor to wind down

and up. Is the result
normal?
• Use the right
electric door
window switch to 04
make the front right
window glass lifter
motor to wind down
and up. Is the result
normal?
 04-326 Diagnosis - Electric Windows

Fault Symptom Table

1. The following table will help you locate the fault. The serial number indicates
the possibility sequence for the fault causes. Check every parts according to
this sequence, and replace where necessary.
Fault symptom Suspicious positions Refer to
04
Chapter 20A Starting and
1. Battery, grounded circuit Charging - Battery,
Replacement
Chapter 82 Windshield /
Window / Rearview Mirror -
2. Master control door switch
All electric door windows out Electric Window Glass,
of work Replacement
Chapter 82 Windshield /
3. Left and right window glass Window / Rearview Mirror -
lifter motors Electric Window Glass,
Replacement
4. Harness -
Chapter 20A Starting and
1. Battery, grounded circuit Charging - Battery,
Replacement
Chapter 82 Windshield /
Window / Rearview Mirror -
2. Master control door switch
Electric Window Glass,
Replacement
Front left electric door window
Chapter 85B Door Lock -
out of work 3. Electric window glass
Anti-theft Controller
control motor
Assembly, Replacement
Chapter 82 Windshield /
4. Left window glass lifter Window / Rearview Mirror -
motor Electric Window Glass,
Replacement
5. Harness -
Chapter 82 Windshield /
Window / Rearview Mirror -
1. Master control door switch
Electric Window Glass,
Replacement
Front left electric door window
unable to wind down Chapter 85 Door Lock -
2. Central door lock controller
Anti-theft Controller
assembly
Assembly, Replacement
3. Harness -
Front left electric door window Chapter 82 Windshield /
1. Master control door switch
unable to window up Window / Rearview Mirror -
 Diagnosis - Electric Windows 04-327

Fault symptom Suspicious positions Refer to

Electric Window Glass,
Replacement
Chapter 85 Door Lock -
2. Central door lock controller
Anti-theft Controller
assembly 04
Assembly, Replacement
3. Harness -
Chapter 64 Lighting System-
Single high and low beam 1. Bulbs Front Combination Light
OFF Assembly, Adjustment)
2. Harness -
Chapter 20A Starting and
1. Battery, grounded circuit Charging - Battery,
Replacement
Chapter 82 Windshield /
Window / Rearview Mirror -
2. Master control door switch
Electric Window Glass,
Replacement
Chapter 82 Windshield /
Front right electric door 3. Right window control Window / Rearview Mirror -
window out of work (use the switch Electric Window Glass,
master control door switch) Replacement
Chapter 82 Windshield /
4. Right window glass lifter Window / Rearview Mirror -
motor Electric Window Glass,
Replacement
Chapter 82 Windshield /
Window / Rearview Mirror -
5. Harness
Electric Window Glass,
Replacement
Chapter 82 Windshield /
1. Right window control Window / Rearview Mirror -
switch Electric Window Glass,
Replacement
Front right electric door
window out of work (use the 2. Harness -
right window control switch)
Chapter 82 Windshield /
3. Right window glass lifter Window / Rearview Mirror -
motor Electric Window Glass,
Replacement
 04-328 Diagnosis - Electric Windows

All Electric Door Windows out of Work

Circuit Diagram

Electric window/Lock control system

04
Window lift switch on
driver/front passenger side
D003
D004 Black Black
Ignition switch Battery
Window control on Window control on
ON/START
driver side door front passenger side door
D003 D004
Serial Serial
Gear
No. 2 5 4 3 1 Gear
No. 2 5 4 3 1
UP UP

Red OFF OFF

DOWN DOWN

Red Red
Blue- Blue-black Yellow- Yellow-black Black
white white

F17
F1 F10 Fuse box in D102 D102
Instrument cluster
BCM Hazard warning driver's cab 3 4 2 1
Fuse /BCM
7.5A
20A Fuse V035 V107 V107
10A

Blue- Blue-black Yellow- Yellow-black

Brown-red Red-grey Red-yellow white white

V201

1 1 6 2 3 4 5
V041 V042 V041 BCM
V041
V042 V041 V042 V042
11 12 7 8 7
Grey-black
Black Black White Grey-black Grey-black V105
V107 V108 12
3 5 5 C101
D102 A102 Grey-black
White Grey-black Grey-black
2 1
A C D Rear right
Rear right Grey-white
sliding door
Door lock Front right sliding door lock
lock
controller on door lock
driver side controller C004 C005
D005 A004 1 2
Black Grey-white
B D C
D102 A102 C101
4 6 6 8
V107 Grey-white V108 Grey-white V105
Black

V204 V201
fpwx710074
 Diagnosis - Electric Windows 04-329

Electric window/Lock control system

04

Window lift switch

on front right door
A003
Serial
Gear No. 2 5 4 3 1
UP
OFF
DOWN

Steering and hazard warning light

Yellow- Yellow-brown Black

red

A102
2 1 4
V108 Green- Green-
brown red

Yellow- Yellow- V204

red brown

15 6 10 9
V041 V042 BCM
V041
V042 V042
4 5 2 3

Green- White-
Green-black White-black
red red

V107 V108
8 7 8 7
D102 A102
Green- White-
Green-black White-black
red red
2 1 2 1
Window lifter motor Window lifter motor
on driver side door on front right door
D002 A002

fpwx710075

Diagnostic Steps
1. Check the power supply fuse of electric door windows
(a) Ignition switch: OFF.
 04-330 Diagnosis - Electric Windows

(b) Check the fuse F1 in the fuse box by the

driver side: 20A.

04

fpwx040143

2. Check the harness and connector (Master control door switch - Ground)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector D003 of the master control door switch.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)
Multimeter
Standard Value
Connection
2 1
D003(5-3)-
5 3 ≥1MΩ
Ground

Is the result normal?

Yes> Replace the fuse.
No> Repair or replace the harness.
fpwx040144

3. Check the master control door switch

(a) Ignition switch: OFF.
(b) Disconnect the connector D005 of the master control door switch.
(c) Replace with a new master control door switch.
(d) Ignition switch: ON.

4. Check the harness and connector (BCM - Master control door switch)
(a) Ignition switch: OFF.
(b) Disconnect the connector D003 of the master control door switch and BCM connector
V041.
 Diagnosis - Electric Windows 04-331

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
D003
Standard Value
Connection
1 2 3 4 5 6 7 8
2 1
9 10 11 12 13 14 15 16 D003(5)-V041(2) 04
5 3
V041
＜2Ω
D003(3)–V041(3)

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040145

5. Check the harness and connector (Master control door switch - Ground)
(a) Ignition switch: OFF.
(b) Disconnect the connector D003 of the master control door switch.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
Connection
2 1

5 4 3
D003(4)-
＜2Ω
Ground

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040146

6. Check left and right window glass lifter motors

(a) Ignition switch: OFF.
(b) Disconnect the connector D002 of the left window glass lifter motor.
(c) Disconnect the connector A002 of the right window glass lifter motor.
(d) Replace with new left and right window glass lifter motors.
(e) Ignition switch: ON.
Does the electric door window work properly?
Yes> Replace left and right window glass lifter motors.
No> Go to next step.

7. Check the harness and connector (BCM - Left and right window glass lifter
motors)
 04-332 Diagnosis - Electric Windows

(a) Ignition switch: OFF.

(b) Disconnect BCM connector V042.
(c) Disconnect the connector D002 of the left window glass lifter motor.
(d) Disconnect the connector A002 of the right window glass lifter motor.

04 (e) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

D002
Multimeter Connection Standard Value
V042

2 1 V042(4)-D002(2)
1 2 3 4 5 ＜2Ω
6 7 8 9 10 11 12
V042(5)-D002(1)

fpwx040147

(f) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

D002
Multimeter Connection Standard Value
V042

2 1 V042(2)-A002(2)
1 2 3 4 5 ＜2Ω
6 7 8 9 10 11 12
V042(3)-A002(1)

Is the result normal?

Yes> Replace BCM (anti-theft controller).
No> Repair or replace the harness.

fpwx040148
 Diagnosis - EPS Electric Power Steering System 04-333

EPS Electric Power Steering System

Electric Power Steering (EPS) out of Work
Circuit Diagram
* Apply to 4W10 engine
EPS electric power steering system **Apply to 4W12 and LJ4651QR1E engine 04

Battery

Ignition switch
ON/START Engine control unit Instrument
E001 V011

Red-black Q4* 51 30 10
80**

F17 Brown-green
Red Instrument Brown- Yellow
F4 Fuse box
cluster green
EPS Fuse in driver's cab
40A Fuse
7.5A V035

Brown-
red Vehicle speed
sensor
E102 Brown- E015
6 green 1 3
Grey-yellow Black
V102
Red-blue Brown-red E101
Brown-red 9
V103
Grey-yellow E201
7 6 4 5 3

EPS
V050

1 8

Blue Black

M
V019
Motor Steering torque sensor Diagnose V201
interface
fpwx710071
 04-334 Diagnosis - EPS Electric Power Steering System

Diagnostic Steps
1. Check the fuse.
(a) Ignition switch: OFF.

(b) Check the fuse F4 in the fuse box by the

04
driver side: 40A.

fpwx040114

2. Check the harness and connector (Fuse - EPS control unit)

(a) Ignition switch: OFF.
(b) Remove the fuse F4.
(c) Disconnect the EPS connector V050.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
4
1
2
F6 F5 25A F4 F3 40A connection
K1 3 AM1

F7 15A F15 10A 7 8

F8 7.5A F16
IG.S
7.5A
1 2 3 4 5 6 EPS
<2Ω
1
F9 10A F17 7.5A
K2 4 2

3 F10

F11
10A

10A
F18

F19
15A

15A fuse(40A)–V050(7)
F12 7.5A F20 10A
1

K3 4 2 F13 10A
F21 15A

3 F22 10A
F14 30A

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040150

3. Check the harness and connector (EPS control unit - Ground)

(a) Ignition switch: OFF.
(b) Disconnect the EPS connector V050.
 Diagnosis - EPS Electric Power Steering System 04-335

(c) Measure the resistance according to the value

in the following table. Standard resistance
Multimeter
Standard Value
connection
V050(8)- Ground <2Ω
04
7 8
Is the result normal?
1 2 3 4 5 6
Yes> Go to next step.
No> Repair or replace the harness.

fpwx040151

4. Check the harness and connector (ECU - EPS control unit)

(a) Ignition switch: OFF.
(b) Disconnect the engine control unit connector T73.
(c) Disconnect the connector V050 of EPS control unit.
(d) Disconnect the connector E015 of the speed sensor.

(e) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

V050 Multimeter
Standard Value
E001 connection
7 8
80/Q4 E001(80/Q4)-V050(4) ＜2Ω
1 2 3 4 5 6

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040152

5. Check the harness and connector (ECU - Speed sensor)

(a) Ignition switch: OFF.
(b) Disconnect the engine control unit connector T73.
(c) Disconnect the connector E015 of the speed sensor.
 04-336 Diagnosis - EPS Electric Power Steering System

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
E015 connection
E001
04
1 3
E001(51)-E015(1) ＜2Ω
51

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040153

6. Check the harness and connector (ECU - Speed sensor)

(a) Ignition switch: OFF.
(b) Disconnect the connector E015 of the speed sensor.
(c) Disconnect the connector V050 of EPS control unit.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
V050 E015 Standard Value
connection
7 8
1 3 E015(3)-V050(5) ＜2Ω
1 2 3 4 5 6

Is the result normal?

Yes> Replace EPS control unit.
No> Repair or replace the harness.

fpwx040154
 Diagnosis - Instrument Cluster 04-337

Instrument Cluster
Component Diagrams

04

fpwx040206

1 Instrument Cluster
 04-338 Diagnosis - Instrument Cluster

Fault Symptom Table

1. The following table will help to you find the cause of the fault.The serial number
indicates the possibility sequence for the fault causes. Check every parts
according to this sequence, and replace where necessary.
Fault symptom Suspicious positions Refer to
04
1. Speedometer sensor
04 Diagnosis - Instrument
Speedometer fault 2. Speedometer circuit
Cluster, Tachometer fault
3. Speedometer
1. Fuel level sensor 04 Diagnosis - Instrument
Cluster, Fuel Gauge Fault /
Fuel gauge fault 2. Fuel gauge circuit
Fuel Level Alarm Indicator
3. Fuel gauge OFF or Always ON
1. Water temperature sensor
04 Diagnosis - Instrument
Water temperature gauge 2. Water temperature gauge
Cluster, Water Temperature
fault circuit
Gauge Fault
3. Water temperature gauge
1. Engine electronic control
system
04 Diagnosis - Engine Control
Check engine indicator OFF/ 2. Check engine indicator
System, Diagnostic Trouble
always ON circuit
Code Table
3. Instrument cluster
assembly
1. Supplemental restrain
system indicator switch
Supplemental restrain system 2. Supplemental restrain 04 Diagnosis, Supplemental
indicator OFF/ always ON system indicator switch circuit Restraint System
3. Instrument cluster
assembly
1. ABS system fault
ABS indicator OFF/ always 2. ABS indicator circuit 04 Diagnosis, Anti-lock
ON Braking System
3. Instrument cluster
assembly
1. Engine oil pressure sensor
2. Engine oil pressure sensor 04 Diagnosis - Instrument
Low oil pressure indicator
circuit Cluster, Low oil Pressure
OFF/ always ON
Indicator OFF/ always ON
3. Instrument cluster
assembly
 Diagnosis - Instrument Cluster 04-339

Fault symptom Suspicious positions Refer to

1. Seat belt warning switch
2. Seat belt warning switch Chapter 04 Diagnosis -
Seat belt indicator OFF/
circuit Instrument Cluster, Seat Belt
always ON
Indicator OFF/ Always ON
3. Instrument cluster 04
assembly
1. Parking brake indicator
OFF/ always ON
04 Diagnosis - Lighting
Parking brake indicator OFF/ 2. Parking brake indicator
System, Fault Symptom
always ON circuit
Table
3. Instrument cluster
assembly
1. Fuse
2. Combination switch 04 Diagnosis - Lighting
assembly System, Fault Symptom
Table(If the outside turning
Turning indicator / danger 3. Danger warning light switch
indicator/danger warning light
warning light OFF/ always ON
4. Turning indicator / danger works properly, please check
warning light circuit for open circuit or replace
5. Instrument cluster instrument cluster assembly)
assembly
1. Fuse 04 Diagnosis - Lighting
2. Combination switch System, Fault Symptom
assembly Table(If the high beam
High beam indicator OFF/
indicator works properly,
always ON 3. High beam indicator circuit please check for open circuit
4. Instrument cluster or replace instrument cluster
assembly assembly)
 04-340 Diagnosis - Instrument Cluster

Speedometer Fault
Circuit Diagram

4W12Engine system

04 A G

B H

C I

D J
Ignition switch
IG1

E K

Yellow-red Red- Red

Yellow-red yellow
Orange

1 4 4 3
Fuse box in
F16 Compressor F11 High-speed fan
driver's cab IG.SFuse Compressor fuse
relay relay
V035 7.5A 10A

2 3 2 1

Red-blue
F
Red-white Green Blue-black M

V105 Orang- N
20 green V011 Instrument cluster
C101
Yellow-
brown V102
3 4
C101 V102 8
Fuel pump 10 3 E102
26 28 21 22 29 27
C001 V105 E102 Grey- Brown- Brown- Brown- Brown-
Yellow- yellow white blue red yellow
1 2 brown V103
Green-black 9 5 2 6 1
C101 E101
15 10 51 19 12 80 61 17 Engine
Black V105 electronic
control
Black module
E001

C201 V204
fpwx710081

Diagnostic Steps
 Diagnosis - Instrument Cluster 04-341

1. Check the harness and connectors (Instrument cluster- Ground)

(a) Ignition switch: OFF.
(b) Disconnect the connector V011 of the instrument cluster.

(c) Measure the resistance according to the value

in the following table. Standard resistance 04
(Check whether there is open circuit)
Multimeter
Standard Value
Connection
V011（28）
<2Ω
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
-Ground
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040155

2. Check the harness and connectors (Instrument cluster - Engine control unit)
(a) Ignition switch: OFF.
(b) Disconnect the connector V011 of the instrument cluster.
(c) Disconnect the engine control unit connector T73.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
E001 Multimeter
Standard Value
Connection
V011 51
V011（28）
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
<2Ω
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-E001（51）

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040156

3. Check the speedometer sensor.

(a) Ignition switch: OFF.
(b) Remove the speedometer sensor.
(c) Replace with a functional sensor.
Is the result normal?
Yes> Replace the instruction cluster.
No> Remove the speedometer sensor.
 04-342 Diagnosis - Instrument Cluster

Tachometer fault
Circuit Diagram

4W12Engine system

04 A G

B H

C I

D J
Ignition switch
IG1

E K

Yellow-red Red- Red

Yellow-red yellow
Orange

1 4 4 3
Fuse box in
F16 Compressor F11 High-speed fan
driver's cab IG.SFuse Compressor fuse
relay relay
V035 7.5A 10A

2 3 2 1

Red-blue
F
Red-white Green Blue-black M

V105 Orang- N
20 green V011 Instrument cluster
C101
Yellow-
brown V102
3 4
C101 V102 8
Fuel pump 10 3 E102
26 28 21 22 29 27
C001 V105 E102 Grey- Brown- Brown- Brown- Brown-
Yellow- yellow white blue red yellow
1 2 brown V103
Green-black 9 5 2 6 1
C101 E101
15 10 51 19 12 80 61 17 Engine
Black V105 electronic
control
Black module
E001

C201 V204
fpwx710081

Diagnostic Steps
 Diagnosis - Instrument Cluster 04-343

Note
Note that unstable running of the engine will cause the tachometer to jitter.
Check whether the vehicle can start properly.

Yes> Go to step 1.
04
No> Refer to "Chapter 04 Diagnosis -Engine Control System, Fault Symptom Table”

1. Check the harness and connectors (Instrument cluster - Engine control unit)
(a) Ignition switch: OFF.
(b) Disconnect the connector V011 of the instrument cluster.
(c) Disconnect the connector E001 (4W12) of the engine electronic control unit.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

E001 Multimeter
Standard Value
Connection
80
V011 V011(29)-E001(80) <2Ω
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Is the result normal?

Yes> Replace the instruction cluster
assembly.
No> Repair or replace the harness.
fpwx040157
 04-344 Diagnosis - Instrument Cluster

Fuel Gauge Fault / Fuel Level Alarm Indicator OFF or Always ON

Circuit Diagram

4W12Engine system

04 A G

B H

C I

D J
Ignition switch
IG1

E K

Yellow-red Red- Red

Yellow-red yellow
Orange

1 4 4 3
Fuse box in
F16 Compressor F11 High-speed fan
driver's cab IG.SFuse Compressor fuse
relay relay
V035 7.5A 10A

2 3 2 1

Red-blue
F
Red-white Green Blue-black M

V105 Orang- N
20 green V011 Instrument cluster
C101
Yellow-
brown V102
3 4
C101 V102 8
Fuel pump 10 3 E102
26 28 21 22 29 27
C001 V105 E102 Grey- Brown- Brown- Brown- Brown-
Yellow- yellow white blue red yellow
1 2 brown V103
Green-black 9 5 2 6 1
C101 E101
15 10 51 19 12 80 61 17 Engine
Black V105 electronic
control
Black module
E001

C201 V204
fpwx710081

Diagnostic Steps
• Ignition switch: ON, confirm that fuel tank has enough fuel(above 1/4 fuel level).
 Diagnosis - Instrument Cluster 04-345

• When the level in the fuel tank is lower than 1/4 fuel level, the fuel alarm indicator
lights up.
• When the level in the fuel tank is higher than 1/4 fuel level, the fuel alarm indicator
goes out.

1. Check the harness and connectors (Instrument cluster- Ground)

(a) Ignition switch: OFF. 04
(b) Disconnect the connector V011 of the instrument cluster.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
Connection
V011（26）
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
<2Ω
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-Ground

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040158

2. Check the harness and connectors (Instrument cluster - Fuel level sensor)
(a) Ignition switch: OFF.
(b) Disconnect the connector V011 of the instrument cluster.
(c) Disconnect the connector C001 of the fuel level sensor.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
C001 Multimeter
V011 Standard Value
1 2 Connection
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 3 4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
V011（26）
<2Ω
-C001（4）

Is the result normal?

Yes> Replace the instruction cluster.
No> Repair or replace the harness.
fpwx040159
 04-346 Diagnosis - Instrument Cluster

Water Temperature Gauge Fault

Circuit Diagram

4W12Engine system

04 A G

B H

C I

D J
Ignition switch
IG1

E K

Yellow-red Red- Red

Yellow-red yellow
Orange

1 4 4 3
Fuse box in
F16 Compressor F11 High-speed fan
driver's cab IG.SFuse Compressor fuse
relay relay
V035 7.5A 10A

2 3 2 1

Red-blue
F
Red-white Green Blue-black M

V105 Orang- N
20 green V011 Instrument cluster
C101
Yellow-
brown V102
3 4
C101 V102 8
Fuel pump 10 3 E102
26 28 21 22 29 27
C001 V105 E102 Grey- Brown- Brown- Brown- Brown-
Yellow- yellow white blue red yellow
1 2 brown V103
Green-black 9 5 2 6 1
C101 E101
15 10 51 19 12 80 61 17 Engine
Black V105 electronic
control
Black module
E001

C201 V204
fpwx710081

Diagnostic Steps
• Ensure that the coolant level is in the standard range.
 Diagnosis - Instrument Cluster 04-347

• Ensure that water temperature is normal.

• Ignition switch: ON.

1. Check the harness and connectors (Instrument cluster - Water temperature

sensor)
(a) Ignition switch: OFF.
04
(b) Disconnect the connector V011 of the instrument cluster.
(c) Disconnect the connector E001(4W12) of the water temperature sensor.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
E001 Multimeter
Standard Value
Connection
V011 61
V011（27）
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 <2Ω
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 -E001(61)

Is the result normal?

Yes> Replace the instruction cluster.
No> Repair or replace the harness.
fpwx040160
 04-348 Diagnosis - Instrument Cluster

Low oil Pressure Indicator OFF/ always ON

Diagnostic Steps
• Ignition switch: ON, the indicator lights up.
• After the engine starts, the indicator goes out.
Note
04
If the indicator keeps on, even after the engine starts, please turn off the engine
immediately and check the oil level. If the level is not in normal range, please exclude
this fault.
Check whether the low oil pressure indicator is always ON or OFF.
Yes> (Alway ON) Go to step 1.
No> (OFF) Go to step 3.

1. Check the low oil pressure indicator

(a) Ignition switch: OFF.
(b) Disconnect the connector E026 of the oil pressure switch.
(c) Ignition switch: ON.
Check whether the low oil pressure indicator goes out.
Yes> Replace the oil pressure switch.
No> Go to next step.

2. Check the harness and connectors (Oil pressure switch- Ground)

(a) Ignition switch: OFF.
(b) Disconnect the connector E027 of the oil pressure switch.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)
Multimeter
Standard Value
Connection
E027（1）-
1 <2Ω
Ground

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040161

3. Check the harness and connectors (Instrument cluster - Oil pressure switch)
(a) Ignition switch: OFF.
(b) Disconnect the connector E026 of the oil pressure switch.
(c) Disconnect the connector V011 of the instrument cluster.
 Diagnosis - Instrument Cluster 04-349

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
E027 Multimeter
V011 Standard Value
Connection
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 04
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
E027（1）
<2Ω
-V011（17）

Is the result normal?

Yes> Replace the instruction cluster.
No> Repair or replace the harness.
fpwx040162
 04-350 Diagnosis - Instrument Cluster

Parking brake indicator OFF/ always ON

Diagnostic Steps
• Use wheel chocks to secure four wheels.
• Ignition switch: ON.
• Release and apply the parking brake respectively.
04
1. Check the parking brake indicator.
(a) Ignition switch: OFF.
(b) Release the parking brake .
(c) Disconnect the connector A026 of the parking brake switch.
(d) Ignition switch: ON.
Check whether the parking brake indicator goes out.
Yes> Replace the parking brake switch.
No> Go to next step.

2. Check the harness and connectors.

(a) Ignition switch: OFF.
(b) Disconnect the connector H002 of the parking brake switch.
(c) Disconnect the connector V011 of the instrument cluster.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
H002 Standard Value
V011 Connection
1
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 H002(1)-V011(19) <2Ω
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040163

3. Check the harness and connectors (Parking brake switch- Ground)

(a) Ignition switch: OFF.
(b) Disconnect the connector H002 of the parking brake switch.
 Diagnosis - Instrument Cluster 04-351

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
Connection
1
H002(1)- 04
≥1MΩ
Ground

Is the result normal?

Yes> Replace the instruction cluster.
No> Repair or replace the harness.
fpwx040164
 04-352 Diagnosis - Electric Door Lock

Electric Door Lock

Precautions
1. Cut off the power supply.
(a) Before removing or installing any electrical equipment, especially for those tools or
equipment accessible to the exposed electrical terminals, make sure to disconnect
04
the battery negative cable to protect people or the vehicle from damage.
Note
Before disconnecting the battery negative cable, do not put the key in the car to avoid
locking the door.
(b) Turn off the ignition switch except special requirement.
2. Disconnecting the battery negative cable will reset the trip meter in the instrument
cluster.
Note
The odometer will not be reset.
3. Disconnecting the battery negative cable will make the sound system lose the
saved setting.
Note
Reset the sound system after connecting the battery negative cable again. (Refer to
"Chinese and English instruction for the sound system")
 Diagnosis - Electric Door Lock 04-353

Basic Inspection
Step Inspection item Measure
Inspect the battery Yes Go to step 2.
voltage
Charge or replace the
• Battery voltage battery. Refer 04
1.
should not be lower No toChapter 20A
than 12V. Is the Starting and
result normal? Charging- Battery
Inspect the basic Yes Go to step 3.
function
• Use the key to lock
the door at the
driver side, all the
doors should be
2. locked. Refer to the Fault
• Use the key to No
Symptom Table
unlock the door at
the driver side, all
the doors should be
unlocked. Is the
result normal?
Inspect the remote Refer to the Fault
Yes
control function Symptom Table
• Close all the doors
with the RKE and
all the doors should
be locked
3. simultaneously.
• Close all the doors No Replace the RKE
with the RKE and
all the doors should
be locked
simultaneously. Is
the result normal?
 04-354 Diagnosis - Electric Door Lock

Fault Symptom Table

1. The following table will help to you find the cause of the fault.The serial number
indicates the possibility sequence for the fault causes. Check every parts
according to this sequence, and replace where necessary.
Fault symptom Suspicious positions Refer to
04
1. Battery, grounded circuit Chapter 04 Diagnosis -
RKE unable to open the Electric Door Lock Control
2. Central door lock controller
central door lock System, RKE unable to open
3. Harness the central door lock
1. Harness Chapter 04 Diagnosis -
RKE able to open only one Electric Door Lock Control
2. Door lock assembly
door's central door lock System, RKE unable to open
3. Central door lock controller the central door lock
1. Central door lock controller
2. Harness Chapter 04 Diagnosis -
RKE unable to lock/unlock the Electric Door Lock Control
3. Door lock assembly
door System, RKE unable to
4. RKE lock/unlock the door
5. Car door lock remote
 Diagnosis - Electric Door Lock 04-355

Front Door Lock Fastener Failure

Circuit Diagram

Electric window/Lock control system

04
Window lift switch on
driver/front passenger side
D003
D004 Black Black
Ignition switch Battery
Window control on Window control on
ON/START
driver side door front passenger side door
D003 D004
Serial Serial
Gear
No. 2 5 4 3 1 Gear
No. 2 5 4 3 1
UP UP

Red OFF OFF

DOWN DOWN

Red Red
Blue- Blue-black Yellow- Yellow-black Black
white white

F17
F1 F10 Fuse box in D102 D102
Instrument cluster
BCM Hazard warning driver's cab 3 4 2 1
Fuse /BCM
7.5A
20A Fuse V035 V107 V107
10A

Blue- Blue-black Yellow- Yellow-black

Brown-red Red-grey Red-yellow white white

V201

1 1 6 2 3 4 5
V041 V042 V041 BCM
V041
V042 V041 V042 V042
11 12 7 8 7
Grey-black
Black Black White Grey-black Grey-black V105
V107 V108 12
3 5 5 C101
D102 A102 Grey-black
White Grey-black Grey-black
2 1
A C D Rear right
Rear right Grey-white
sliding door
Door lock Front right sliding door lock
lock
controller on door lock
driver side controller C004 C005
D005 A004 1 2
Black Grey-white
B D C
D102 A102 C101
4 6 6 8
V107 Grey-white V108 Grey-white V105
Black

V204 V201
fpwx710074
 04-356 Diagnosis - Electric Door Lock

Electric window/Lock control system

04

Window lift switch

on front right door
A003
Serial
Gear No. 2 5 4 3 1
UP
OFF
DOWN

Steering and hazard warning light

Yellow- Yellow-brown Black

red

A102
2 1 4
V108 Green- Green-
brown red

Yellow- Yellow- V204

red brown

15 6 10 9
V041 V042 BCM
V041
V042 V042
4 5 2 3

Green- White-
Green-black White-black
red red

V107 V108
8 7 8 7
D102 A102
Green- White-
Green-black White-black
red red
2 1 2 1
Window lifter motor Window lifter motor
on driver side door on front right door
D002 A002

fpwx710075

Diagnostic Steps
1. Check the fuse.
 Diagnosis - Electric Door Lock 04-357

(a) Disconnect the battery cable at the negative

end.
(b) Rated current of the fuse in the fuse box (F17)
: 7.5A.
(c) Rated current of the fuse in the fuse box (F1)
: 20A.
04
(d) Rated current of the fuse in the fuse box (F10)
: 10A.
Is the result normal?
Yes> Go to next step.
No> Replace the fuse.

fpwx040005

2. Check the harness and connectors (BCM- driver's door fastener assembly)
(a) Ignition switch: OFF.
(b) Disconnect the connector D005 of the driver's door lock fastener.
(c) Disconnect the connector V042 of the BCM.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)

V042 D005 Multimeter

Standard Value
Connection
1 2 3 4 5
B C

6 7 8 9 10 11 12
V042(8)-D005(C) <2Ω
A D

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040166

3. Check the harness and connectors (BCM- driver's door lock fastener assembly)
(a) Ignition switch: OFF.
(b) Disconnect the connector D005 of the driver's door lock fastener assembly.
 04-358 Diagnosis - Electric Door Lock

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)

D005
Multimeter
Standard Value
Connection
04
B C D005(A)–D005(B) ≥1MΩ (connecting)
A D
D005(A)–D005(B) <2Ω(closed)

Is the result normal?

Yes> Go to next step.

fpwx040167
No> Repair or replace the harness.

4. Check the harness and connectors (BCM- driver's door lock fastener assembly)
(a) Ignition switch: OFF.
(b) Disconnect the connector D005 of the driver's door lock fastener assembly.
(c) Disconnect the connector V042 of the BCM.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
D005 Multimeter
V042 Standard Value
Connection
1 2 3 4 5 B C

6 7 8 9 10 11 12 A D D005(D)–V042(7) <2Ω

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

fpwx040168

5. Check the harness and connectors (Driver's door lock fastener - Ground)
(a) Ignition switch: OFF.
(b) Disconnect the connector D005 of the driver's door lock fastener assembly.
 Diagnosis - Electric Door Lock 04-359

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Multimeter
Standard Value
D005 Connection
D005(B)- 04
B C <2Ω
A
Ground
D

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040169

6. Check the front left door lock assembly.

(a) Ignition switch: OFF.
(b) Disconnect the connector D005 of the driver's door lock fastener assembly.
(c) Replace with a new front left door lock assembly.
Is the result normal?
Yes> Replace with a new front left door lock assembly.
No> Go to next step.

7. Check the front right door lock fastener assembly.

(a) Ignition switch: OFF.
(b) Disconnect the connector A004 of the front right door lock fastener.
(c) Disconnect the connector V042 of the BCM.

(d) Measure the voltage according to the value

in the following table. Standard voltage
Multimeter
Standard Value
V042 A004 Connection
1 2 3 4 5

B C
V042(8)–A004(D) <2Ω
6 7 8 9 10 11 12

A D
V042(7)–A004(C) <2Ω

Is the result normal?

Yes> Repair or replace the front right door
lock fastener.
fpwx040170
No> Repair or replace the harness.
 04-360 Diagnosis - Electric Door Lock

Rear Slide Door Lock Fastener Failure

Circuit Diagram

Electric window/Lock control system

04
Window lift switch on
driver/front passenger side
D003
D004 Black Black
Ignition switch Battery
Window control on Window control on
ON/START
driver side door front passenger side door
D003 D004
Serial Serial
Gear
No. 2 5 4 3 1 Gear
No. 2 5 4 3 1
UP UP

Red OFF OFF

DOWN DOWN

Red Red
Blue- Blue-black Yellow- Yellow-black Black
white white

F17
F1 F10 Fuse box in D102 D102
Instrument cluster
BCM Hazard warning driver's cab 3 4 2 1
Fuse /BCM
7.5A
20A Fuse V035 V107 V107
10A

Blue- Blue-black Yellow- Yellow-black

Brown-red Red-grey Red-yellow white white

V201

1 1 6 2 3 4 5
V041 V042 V041 BCM
V041
V042 V041 V042 V042
11 12 7 8 7
Grey-black
Black Black White Grey-black Grey-black V105
V107 V108 12
3 5 5 C101
D102 A102 Grey-black
White Grey-black Grey-black
2 1
A C D Rear right
Rear right Grey-white
sliding door
Door lock Front right sliding door lock
lock
controller on door lock
driver side controller C004 C005
D005 A004 1 2
Black Grey-white
B D C
D102 A102 C101
4 6 6 8
V107 Grey-white V108 Grey-white V105
Black

V204 V201
fpwx710074
 Diagnosis - Electric Door Lock 04-361

Electric window/Lock control system

04

Window lift switch

on front right door
A003
Serial
Gear No. 2 5 4 3 1
UP
OFF
DOWN

Steering and hazard warning light

Yellow- Yellow-brown Black

red

A102
2 1 4
V108 Green- Green-
brown red

Yellow- Yellow- V204

red brown

15 6 10 9
V041 V042 BCM
V041
V042 V042
4 5 2 3

Green- White-
Green-black White-black
red red

V107 V108
8 7 8 7
D102 A102
Green- White-
Green-black White-black
red red
2 1 2 1
Window lifter motor Window lifter motor
on driver side door on front right door
D002 A002

fpwx710075

Diagnostic Steps
1. Check the harness and connectors (BCM- rear slide door lock fastener)
(a) Disconnect the connector C004/C005 of the rear slide door lock fastener.
 04-362 Diagnosis - Electric Door Lock

(b) Measure the voltage according to the value

in the following table. Standard voltage
Multimeter
Standard Value
V042 C004
Connection
C005

1 2 3 4 5 V042(8)–C004(2) <2Ω
04 6 7 8 9 10 11 12
1 2 1 2

V042(8)–C005(1) <2Ω

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040171

2. Check the harness and connectors (BCM- rear slide door lock fastener)
(a) Ignition switch: OFF.
(b) Disconnect the connector C004/C005 of the rear slide door lock fastener.
(c) Disconnect the connector V042 of the BCM.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
V042 C005 C004 Multimeter
Standard Value
1 2 3 4 5 Connection
1 2 1 2
6 7 8 9 10 11 12
V042(7)-C004(1)
<2Ω
V042(7)-C005(2)

Is the result normal?

Yes> Replace the rear slide door lock
fastener.
fpwx040172
No> Repair or replace the harness.
Note
If the rear slide door lock fastener is damaged
on one side, please replace the fastener on that
side.
 Diagnosis - Anti-lock Braking System 04-363

Anti-lock Braking System

Precautions
1. Electronic control.
(a) Before removing or installing any electrical equipment, especially for those tools or
equipment accessible to the exposed electrical terminals, make sure to disconnect
04
the battery negative cable to protect people or the vehicle from damage.
(b) If not otherwise specified, you must turn off the ignition switch.
Note
If the central door lock is installed, you should not leave the key in the vehicle to avoid
getting the door locked before disconnecting the battery negative cable.
2. Dismantling the instrument cluster or disconnecting the battery negative cable
will reset the trip meter in the instrument cluster.
Note
The odometer will not be reset.
3. Disconnecting the battery negative cable will make the sound system lose the
saved setting.
Note
Reset the sound system after connecting the battery negative cable again.
4. Cautions for checking ABS
(a) When faults occur in the installation of connectors or components, the system may
completely or temporarily return to normal by dismantling or reinstalling the suspected
faulty components.
(b) Be sure to check the vehicle condition when faults occur in order to identify the fault
location. For example, you can perform some inspection by outputting DTCs and record
this information before disconnecting each connector or dismantling and installing
components.
(c) Be sure to dismantle and install ABS control module, sensors and actuator when the
ignition switch is turned off unless otherwise specified in checking steps.
(d) If reinstalling the dismantled and installed ABS control module, sensors and actuator,
be sure to check whether the system works properly (observe ABS indicator on the
instrument cluster )after completing the installation.
(e) Never directly measure the pins of ABS control module with a multimeter.
(f) Repairing ABS must be performed by the technician with specified training and
maintenance skills and only original parts and components can be used to replace.
(g) Before ABS is diagnosed, if faults occur in the basic braking system, the following
must be eliminated:
• Braking system makes noise.
• Brake pedal is too stiff.
• Bake pedal or the body vibrates in the conventional brake.
• Vehicle gets braking deviation.
• Faults occur in the parking brake system.
 04-364 Diagnosis - Anti-lock Braking System

(h) Only replace ABS assembly (the assembly of ABS electronic control unit and hydraulic
regulator assembly, excluding brake pipeline, sensors and other attachments) as a
whole rather than dismantle or replace /exchange part of ABS.
(i) Faults are detected in ABS in those two cases, as follows:
• After the ignition switch is turned on and then the system finishes self-checking,
the warning light still keeps on.
04
• Warning light keeps on during driving. Now a driver can have a conventional
brake and yet try to reduce the braking force to avoid locking wheels. If the
warning light is lit, the driver should carefully drive and immediately go to a
special service station for check and repair to prevent more faults which may
cause accidents.
(j) When connecting ABS sensor harness, please pay attention to the following:
• Before removing ABS harness and sensor harness, be sure to disconnect the
ignition switch.
• Ensure that connectors are dry and clean, prevent any foreign materials.
• ABS harness connector must be installed horizontally and vertically to avoid
damaging the connector.
(k) When connecting ABS brake pipeline, be sure to properly connect. As ABS control
module can not judge whether the brake pipeline is properly connected. Wrong
connection may cause serious accidents. Be sure to follow marks on ABS assembly
when connecting the brake pipeline:
• MC1: connect brake pipe 1 of the brake master cylinder;
• MC2: connect brake pipe 2 of the brake master cylinder;
• FL: connect the brake pipe of front left wheel brake cylinder;
• FR: connect the brake pipe of front right wheel brake cylinder;
• RL: connect the brake pipe of rear left wheel brake cylinder;
• FR: connect the brake pipe of rear right wheel brake cylinder;
(l) ABS will make noise in the following cases:
• It makes short buzzing noise after the vehicle gets power or engine is started,
which is the sound ABS gives in self-checking. It is normal phenomenon.
• ABS sounds in normal operation as follows:
Sound from motors, solenoid valve and reflux pump in ABS hydraulic unit.
Sound from the brake pedal rebound.
Sound from the suspension striking against the body for emergency braking.
 Diagnosis - Anti-lock Braking System 04-365

Component Diagrams

04

fpwx040208

1 Rear wheel speed sensor 3 ABS pump assembly

2 Front wheel speed sensor
 04-366 Diagnosis - Anti-lock Braking System

Diagnostic Trouble Code (DTC) Chart

Note
When inspecting the DTC in check mode, some DTC indicates the inspection of the
relevant circuit according to the DTC code listed in the following chart. Refer to
corresponding pages for DTC introduction in detail.
04
DTC Diagnostic Item (DTC Definition)
C000011 ABS warning light fault
C000012 Brake warning light fault
C000014 System relay open or short to ground
C000017 ECU pump motor current input open-circuit
C000018 High grounding resistance in the pump
Front left wheel speed = 0 km/h (active
C000021
sensor)
Front right wheel speed = 0 km/h (active
C000022
sensor)
Rear left wheel speed = 0 km/h (active
C000023
sensor)
Rear right wheel speed = 0 km/h (active
C000024
sensor)
Front left wheel speed intermittent signal
C000025
(active sensor)
Front right wheel speed intermittent signal
C000026
(active sensor)
Rear left wheel speed intermittent signal
C000027
(active sensor)
Rear right wheel speed intermittent signal
C000028
(active sensor)
Front left wheel speed hardware fault (active
C000032
sensor)
Front right wheel speed hardware fault (active
C000033
sensor)
Rear left wheel speed hardware fault (active
C000034
sensor)
Rear right wheel speed hardware fault (active
C000035
sensor)
C000036 Low system voltage
C000037 High system voltage
C000042 Pump motor open-circuit
 Diagnosis - Anti-lock Braking System 04-367

DTC Diagnostic Item (DTC Definition)

C000043 Pump motor stalling
C000048 DRP fault
C000055 ECU internal fault
C000056 System relay always connecting 04

C000091 Brake pedal not working during deceleration

Brake pedal not working in the last ignition
C000093
circle during deceleration
C000094 Brake pedal working when not decelerating
C000095 Brake switch / light open-circuit
Front left, front right, rear left or rear right
C000121
pressure increasing solenoid control fault
Front left, front right, rear left or rear right
C000122
pressure reducing solenoid control fault
Brake pedal always working in the last
C000127
ignition circle when not decelerating
C000134 High grounding resistance in the ECU
C000147 CAN Bus fault
C000151 Front left wheel pressure relief for a long time
C000153 Rear left wheel pressure relief for a long time
Rear right wheel pressure relief for a long
C000154
time
C000155 Rear left wheel pressure relief for a long time
C000166 Longitudinal speed sensor out of range
C000167 Longitudinal speed sensor yaw rate fault
C000191 No pump motor starting current
C000192 Pump motor overcurrent
C000194 Pump motor current short-circuit
Misfire pulse width modulation output fault
C000198
on bumpy road
C000205 Low battery voltage
Front left wheel speed frequency out of range
C000206
(passivesensor)
Front right wheel speed frequency out of
C000207
range (active sensor)
Rear left wheel speed frequency out of range
C000208
(active sensor)
 04-368 Diagnosis - Anti-lock Braking System

DTC Diagnostic Item (DTC Definition)

Rear right wheel speed frequency out of
C000211
range (active sensor)
C000217 Motor temperature out of range

04 C000218 Motor temperature over the limit

Abnormal working temperature of the motor
C000221
driver
 Diagnosis - Anti-lock Braking System 04-369

Fault Symptom Table

1. The following table will help to you find the cause of the fault.The serial number
indicates the possibility sequence for the fault causes. Check every parts
according to this sequence, and replace where necessary.
Fault symptom Suspicious positions Refer to
04
1. Leaky or broken brake line -
2. Lack of brake fluid -
Chapter 34 Transaxle and
Drive Shaft, Differential
3. Differential fault
Assembly, Inspection and
Adjustment
Chapter 35 Driving Brake -
4. Front wheels braking fault Rear Disc Brake,
Maintenance
Chapter 35 Driving Brake -
5. Rear wheels braking fault Rear Disc Brake,
Maintenance
6. Hydraulic regulator
-
assembly fault

ABS failure 7. Braking fluid level warning

-
fault
Chapter 35 Driving Brake -
8. Driving brake switch fault
Brake Pedal, Replacement
04 Diagnosis - Anti-lock
9. ABS speed sensor fault Braking System, Wheel
Speed Sensor Signal Fault
04 Diagnosis - Anti-lock
10. ABS stop valves fault Braking System, ABS out of
Work
04 Diagnosis - Anti-lock
11. ABS pressure relief
Braking System, ABS out of
valves fault
Work
04 Diagnosis - Anti-lock
12. ABS control module
Braking System, ABS out of
power supply fault
Work
04 Diagnosis - Anti-lock
13. ABS control module
Braking System, ABS out of
ABS failure grounding fault
Work
14. ABS control module fault -
 04-370 Diagnosis - Anti-lock Braking System

Precheck
Before diagnosing the ABS, first check reachable parts which may cause ABS fault, and then
visually check and use the visual inspection procedure to quickly identify faults. As a result,
further diagnosis will be unnecessary.
1. Check the tyre.
04
Ensure only tires or hubs with suggested size are installed on the vehicle. Tires on the
same axle must have the same pattern and depth. Refer to the vehicle manual for
specific tire types.
2. Check fuses of ABS and ensure the fuse is good and correct type. ABS has two
fuses:
• V035(F17)(7.5A)
• V035(F9)(10A)
3. Check the battery voltage, and whether the battery terminals are corrosive or
loose. Normal working voltage range of ABS is 9.3V–16.8V.
4. Check ABS ground wire.
(a) Check whether the ground point of ABS ground wire is loose and whether the ground
location is changed.
(b) ABS ground wire should be well sealed to avoid water or humidity with the
capillary(siphon) effect seeping into the connector of ABS control module by pores in
the harness as it could cause function failure.
5. Perform a visual check or external check for the following electrical components:
(a) Whether the harness and connector related to ABS are properly connected, pinched
or cut.
(b) Whether the wiring is too close to the equipment with high voltage or current, like high
voltage or components with high voltage, generator and motor, aftermarket
stereo-amplifier.
Note
The equipment with high voltage or current may make wires produce induced noise
and then interfere with normal operation of the wires.
(c) ABS components are sensitive to electromagnetic interference (EMI). If there are
intermittent faults, check whether the aftermarket anti-theft device, lights or mobile
phone are properly installed.
6. If ABS has loud noise, there are possible reasons as follows:
(a) The connection between ABS assembly and ABS brackets is loose.
(b) The connection between ABS bracket and the body is loose.
(c) The plastic washer of ABS bracket is lost or broken.
 Diagnosis - Anti-lock Braking System 04-371

High or Low Power Supply Voltage

Trouble code: C000036; C000037
Fault condition
When the power supply voltage of the ECU meets one of the following conditions, the fault
will occur:
04
(a) The voltage is less than 4.5V when the vehicle starts.
(b) The ignition switch is ON, and the voltage is less than 7.7V or more than 16.8V.
(c) The vehicle speed is more than 6km/h and voltage is between 7.7V and 9.2V.
Diagnostic Steps
1. Perform the precheck steps
Is the result normal?
Yes> Go to next step.
No> Repair or replace the related parts.

2. Checking the battery

(a) Ignition switch: ON.
(b) Measure the battery voltage.
Is the result normal?
Yes> Go to next step.
No> Repair or replace the battery.

3. Cross validation
(a) Ignition switch: OFF.
(b) Remove the ABS actuators. (Refer to "Chapter 35 Driving Brake - ABS actuators,
Replacement")
(c) Remove the ABS and then install it to another vehicle of the same type without faults.
(You can only link the ECU connector and do not install the pipeline, but make sure
the connector will not loosen in driving. )
(d) Start the engine and ensure the speed is no less than 20km/h, and make ABS perform
dynamic tests.
Is the result normal?
Yes> Replace the ABS control module.
No> Replace the ABS actuators.
 04-372 Diagnosis - Anti-lock Braking System

Wheel Speed Sensor Wiring Fault

Trouble Code:
C000021;C000026;C000027;C000028;C000032;C000033;C000034;C000035;
Fault condition
04 When the power supply voltage of the ECU meets one of the following conditions, the fault
will occur:
(a) ECU detects that the signal cable of the wheel speed sensor is shorted to the ground.
(b) Wheel speed sensor wiring is open.
(c) Wheel speed sensor signal is abnormal.
Possible causes
(a) The line of the wheel speed sensor is broken, or the connector is loose or damaged.
(b) The signal cable and power line of the wheel speed sensor is reversely connected.
(c) The signal cable is shorted to the ground.
(d) Sensor head or pins are broken.
Diagnostic Steps
1. Perform the precheck steps
Is the result normal?
Yes> Go to next step.
No> Repair or replace the related parts.

2. Read DTC and data on the tester.

(a) Choose to read the Data Stream Mode on the tester.
(b) Detect whether the speed shown on the speedometer of the instrument is consistent
with that on the tester when the vehicle is running.
Note
Error in speed value shown on the instrument and that on the tester is within ±10%,
which belongs to normal range. Is the result normal?
Yes> Clear the trouble codes.
No> Go to next step.

3. Cross validation
(a) Ignition switch: OFF.
(b) Remove the ABS actuators. (Refer toChapter 35 Driving Brake - ABS actuators,
Replacement)
(c) Remove the ABS and then install it to another vehicle of the same type without faults.
(You can only link the ECU connector and do not install the pipeline, but make sure
the connector will not loosen in driving. )
(d) Start the engine and ensure the speed is no less than 20km/h, and make ABS perform
dynamic tests.
Is the result normal?
 Diagnosis - Anti-lock Braking System 04-373

No> Replace the ABS actuators.

4. Check the harness and connector (Speed sensor- Ground)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V044 of the front left wheel speed sensor.
04
(c) Disconnect the connector V043 of the ABS control module.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is short circuit)
V044

Multimeter
1 2 Standard Value
Connection
V044(1)- Ground
≥1MΩ
fpwx040001
V044(2)- Ground

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.

5. Check the harness and connector (Wheel speed sensor - ABS control module)
(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V044 of the front left wheel speed sensor.
(c) Disconnect the connector V043 of the ABS control module.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit):

V044 V043
Multimeter
Standard Value
Connection
1 2
9 21
V044(1)-V043(9)
＜2Ω
V044(2)-V043(21)

Is the result normal?

Yes> Replace the ABS control module.
No> Repair or replace the harness.
fpwx040002
 04-374 Diagnosis - Anti-lock Braking System

Wheel Speed Sensor Signal Fault

Trouble Code:
C000021;C000022;C000023;C000024;
Fault condition
04 (a) ECU detects that the signal cable of the wheel speed sensor is shorted to the power
supply.
(b) ECU detects that the power line of the wheel speed sensor is shorted to the ground.
(c) Wheel speed sensor signal is abnormal.
Possible causes
(a) The line of the wheel speed sensor is broken, or the connector is loose or damaged.
(b) The signal cable of the wheel speed sensor is shorted to the power supply.
(c) The power line of the wheel speed sensor is shorted to the ground.
(d) Gear ring is not installed, or it is lost, soiled, demagnetized or deviated.
(e) The gap between the sensor and the gear ring is excessive.
(f) The wheel speed sensor is interfered with the external magnetic field. (Wheels or axle
is not demagnetized.)
(g) The wheel speed sensor fails.
(h) Teeth number of the gear ring is wrong.
(i) Tire size does not meet standards.
(j) ECU is damaged.
Diagnostic Steps
1. Perform the precheck steps
Is the result normal?
Yes> Go to next step.
No> Repair or replace the related parts.

2. Check the speed sensor.

(a) Ignition switch: OFF.
(b) Lift the vehicle.
(c) Check whether ABS speed sensor is properly installed.
(d) Check whether the connector of ABS speed sensor is loose.
(e) Check whether the mounting bolts of ABS speed sensor are loose.
(f) Remove ABS speed sensor, check whether the speed sensor is damaged or whether
there is dirt on the surface.
Is the result normal?
Yes> Go to next step.
No> Replace the speed sensor.

3. Read DTC and data on the tester.

(a) Choose to read the Data Stream Mode on the tester.
 Diagnosis - Anti-lock Braking System 04-375

(b) Detect whether the speed shown on the speedometer of the instrument is consistent
with that on the tester when the vehicle is running.
Note
Error in speed value shown on the instrument and that on the tester is within ±10%,
which belongs to normal range. Is the result normal? 04
Yes> Clear the trouble codes.
No> Go to next step.

4. Check the wheel speed sensor.

(a) Check the installation of the wheel speed sensor.
Note
Properly tighten the mounting bolts and level the position for installing the sensor.
Is the result normal?
Yes> Go to next step.
No> Replace the wheel speed sensor.

5. Check the signal end of the wheel speed sensor.

(a) Remove the wheel speed sensor.
(b) Check the signal end of the front right wheel speed sensor.
(c) Check the signal end of the wheel speed sensor.
Note
There should be no scratch or metal debris on the signal end of the sensor.
Is the result normal?
Yes> Go to next step.
No> Replace the wheel speed sensor.

6. Check the signal gear of the wheel speed sensor.

Check the signal gear teeth.
Note
There should be no scratch, metal dust or foreign objects on the signal gear. If there
are foreign materials, please remove them and then check the output voltage.
Is the result normal?
Yes> Go to next step.
No> Replace the sensor signal gear.

7. Check the harness and connector (Speed sensor- Ground)

(a) Disconnect the battery cable at the negative end.
(b) Disconnect the connector V044 of the front left wheel speed sensor.
(c) Disconnect the connector V043 of the ABS control module.
 04-376 Diagnosis - Anti-lock Braking System

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there are short circuits)

V043 Multimeter Connection Standard Value

21
V044(1)-V043(21) ＜2Ω
04
Is the result normal?
Yes> Replace the ABS control module.
No> Repair or replace the harness.
1 2

fpwx040004
V044
 Diagnosis - Anti-lock Braking System 04-377

ABS out of Work

Circuit Diagram

ABS System
04

Ignition switch
Battery ACC/ON

Red

Red Red-black

F9 F17
Red Horn/Brake light Instrument cluster Fuse box in driver's cab
/Interior light Fuse Fuse V035
10A 7.5A

Brown-red

Brown-blue
Diagnose interface Brown-red
V019
1 32
Brake light switch
V031 Instrument cluster
Red White V011
2
7
6 9

Blue Brown-green Brown-red Green Brown-black

6 25 1 15 18 14 5

ABSModule
V043

21 9 22 10 23 11 24 12 13 38
Grey- Yellow-red Black- White-blue
red green
V105 V105
22 21 19 18 Black Black
Grey- C101 Black- C101
White- Black-red White Red green
red
black Yellow-red White-blue

1 2 1 2 1 2 1 2

Black

Front left wheel Front right wheel Rear left wheel Rear right wheel
speed sensor speed sensor speed sensor speed sensor
V202
V044 V045 C008 C009
fpwx710051

Diagnostic Steps
 04-378 Diagnosis - Anti-lock Braking System

1. Check the fuse.

(a) Disconnect the battery cable at the negative
end.
(b) Rated current of the fuse in the fuse box (F17)
: 7.5A.
04
(c) Fuse (F9 in the fuse box: 10A.
Is the result normal?
Yes> Go to next step.
No> Replace the fuse.

fpwx040005

2. Check the brake light switch.

(a) Disconnect the connector V031 of the brake light switch.

(b) Check the brake light switch according to the

value in the following table.
Multimeter Standard
V031 Conditions
Connection Value

1 2
Press the
brake pedal
and turn on 1-2 ≥1MΩ
the brake
switch.
Loosen the
brake pedal
fpwx040006
and turn off 1-2 ＜2Ω
the brake
switch.

Is the result normal?

Yes> Go to next step.
No> Replace the brake light switch.

3. Check the harness and connector (ABS control module - Ground)

(a) Disconnect the battery cable at the negative end.
 Diagnosis - Anti-lock Braking System 04-379

(b) Disconnect the connector V043 of the ABS control module.

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Check whether there is open circuit)
Standard 04
V043 Multimeter Connection
Value
13 38 V043(13)- Ground
＜2Ω
V043(38)- Ground

Is the result normal?

Yes> Go to next step.
No> Repair or replace the harness.
fpwx040007

4. Check the ABS control module power supply

(a) Ignition switch: ON.

(b) Measure the voltage according to the value

in the following table. Standard voltage
Multimeter Connection Standard Value
1
Fuse (F17) in the
Compressor relay

4 2
F6 F5 25A F4 F3 40A
Battery voltage
K1 3 Fan AM1 fuse box - Ground
Front fog light Turn light Reverse light

F7 15A F15 10A

Diagnosis instrument ECU IG.S
F16 7.5A
1
F8 7.5A
Horn Brake light/interior light Instrument cluster
Is the result normal?
High-speed fan relay

F9 10A F17 7.5A

K2 4 2

3 F10
Hazard warning BCM

10A F18
Low beam

15A Yes> Go to next step.

Compressor High beam

10A F19 15A

F11

Airbag Fuel pump No> Repair or replace the harness.

F12 7.5A F20 10A
1 Ignition coil
Width light Rear Fog Light

15A
Light relay

K3 4 2 F13 10A
F21

Fuel injector/oxygen sensor

Starter
3 F22 10A
F14 30A

fpwx040008

5. Check the harness and connector (Brake light fuse- Reserve light switch)
(a) Ignition switch: ON.
(b) Disconnect the connector V031 of the brake light switch.
 04-380 Diagnosis - Anti-lock Braking System

(c) Measure the resistance according to the value

in the following table. Standard resistance
(Measure whether there is open circuit)
1
Compressor relay

F6 F5 25A F4 F3 40A
4 2

K1 3 Fan AM1
Multimeter Connection Standard Value
V031
Front fog light Turn light Reverse light

F7 15A F15 10A

Diagnosis instrument ECU IG.S

F8 7.5A F16 7.5A

Brake light fuse F9 -
1
Horn Brake light/interior light Instrument cluster

＜2Ω
High-speed fan relay

7.5A
04 K2 4 2
F9
10A
Hazard warning BCM
F17

Low beam
V031(1)
3 F10 10A
Compressor
F18 15A
High beam
1 2
F11 10A F19 15A
Airbag Fuel pump

7.5A F20 10A

4
1
F12

Width light Rear Fog Light

Ignition coil

15A
Is the result normal?
Light relay

K3 2 F13 10A
F21

Fuel injector/oxygen sensor

Starter
3 F22 10A
F14 30A
Yes> Go to next step.
No> Repair or replace the harness.

fpwx040009

6. Check the harness and connector (ABS control module - Brake light switch)
(a) Ignition switch: ON.
(b) Disconnect the connector V043 of the ABS control module.
(c) Disconnect the connector V031 of the brake light switch.

(d) Measure the resistance according to the value

in the following table. Standard resistance
(Measure whether there is open circuit)
V031
V043 Multimeter Standard
Connection Value
1 2 15
V043(15)-V031(2) ＜2Ω

Is the result normal?

Yes> Check the power supply of the system
or ABS control module.
No> Repair or replace the harness.
fpwx040010
Vehicle Service
Service Schedule................................05A-1
Precautions......................................05A-1
Service and Cycle Under Normal
Conditions........................................05A-3
Checking.............................................05A-6
05A
Checking the Electrical System........05A-6
Checking the battery........................05A-7
Checking the Seat Belt.....................05A-8
Checking the Parking Brake and Brake
Pedal..............................................05A-10
Checking the Door Stopper, Lock and
Hinge..............................................05A-11
Checking the Components of the Engine
Compartment.................................05A-13
Checking the Timing Belt................05A-14
Checking the Accessory Belt.........05A-16
Checking the Steering Tie Rod Knob and
Dust Shield.....................................05A-17
Checking and Tightening the Chassis Bolts
with the Specified Torque...............05A-18
Checking the Front Headlight.........05A-19
Checking Wipers and Washing
Equipment......................................05A-20
Checking the Vehicle Bottom..........05A-22
Checking the Suspension
Components...................................05A-23
Checking the Suspension Ball Joint and
Dust Shield.....................................05A-24
Checking the Braking System........05A-25
Checking the Brake Disc, Brake Drum and
Brake Lining...................................05A-26
Checking Tires................................05A-27
Checking Exhaust System.............05A-28
Checking the Oil Level of the
Engine............................................05A-29
Replacement.....................................05A-30
Replacing the Air Filter Element.....05A-30
Replacing the Engine Oil................05A-31
Replacing the Oil Filter...................05A-33
Replacing the Spark Plug...............05A-35
Replacing the Fuel Filter
Assembly........................................05A-37
Replacing the Coolant....................05A-38
Replacing the Brake Fluid..............05A-40
Replacing the Transmission
Lubricant........................................05A-42
 Replacing the Gear Oil of the Front Final
Drive...............................................05A-43

05A
 Vehicle Service - Service Schedule 05A-1

Service Schedule
Precautions
Service Note
1. Safety
(a) Preparation Before Service.
• If necessary, the staff will wear safety shoes, gloves and goggles.
Ensure the site ventilative and clean, keep tools and instruments neat.Provide 05A
•
a fire extinguisher as necessary.
• Inspect the safe working conditions of the apparatus, like the lifting equipment
and jack.
• Inspect the vehicle driving safety and ensure the vehicle can get service.
(b) Caution in the service.
• Before the vehicle comes to the lift stand, make sure there is enough distance
between the bottom and sides of the vehicle and the lift to avoid scratches.
• Before lifting the vehicle, make sure the wight of the vehicle is no more than the
rated load of the lift.
• Choose the right supporting location when lifting the vehicle.
• When lifting the vehicle, never start the engine and put the vehicle in gear on
the condition that there are driving wheels on the ground, otherwise operators
and the vehicle will be in danger.
• Operators must strictly follow all the safety regulations and rules in service,
otherwise the operator and vehicle will be in danger.
• When replacing parts and consuming products, you should use products
authorized by Foton to ensure the driving safety and performance of the vehicle.
(c) Cautions after the service
• After the service, inspect the vehicle by a test run , especially pay attention to
the brake system and safety restraint system.
• The vehicle can only be handed over to the customer after the fault memories
in the fault storage unit are completely cleared.
2. Schedule
(a) The interval of service and maintenance depends on mileage or time interval, whichever
comes earlier, as shown in the schedule.
(b) The time interval before next service shall be equal to that from the last service until
present.
(c) For service intervals of each parts, you can refer to the service schedule.
(d) Some parts are especially important service objects. Replace the hoses immediately
if they are aging or broken. Please note that rubber hoses age over time, which will
lead to swelling, scratching or cracking.
(e) After a vehicle drives across the sand, mud or water, check the following parts and
perform service or repair if necessary.
• Brake lining and brake drum.
• Brake pad and brake disc.
• Brake line and rubber hose.
 05A-2 Vehicle Service - Service Schedule

• Oil and working fluid oftransmission and differential.

• Air filter element.

Maintenance Condition
1. Under ordinary conditions, the vehicle gets service according to the service
cycle.
2. If the vehicle mainly runs under one or several of the following special conditions,
05A some parts should get service more frequently (Refer to service conditions in
extreme situation ).
(a) Road conditions:
• Uneven, muddy or thawy road.
• Dusty road.
• Saline road.
(b) Driving conditions:
• Tow a vehicle, use camping rack or parcel shelf.
• Repeat the short trip within 8 km below 0℃.
• Idle or drive at low speed for a long time, like the police car, taxi or door-door
delivery car.
• Often drive at high speed over 2 hours (driving in 80% of the max. speed).
 Vehicle Service - Service Schedule 05A-3

Service and Cycle Under Normal Conditions

Usage cycle and service of the gasoline engine LJ465QR1E1
Meaning of symbols in the table:
"A": adjust or check; "L": lubricate; "R": replace; "I": inspect, if necessary, adjust or replace;
"T": check with a special torque wrench

Usage cycle should be Kilometer×1000 2.5 10 20 30 40 50 60 70 80

judged by the odome- 05A
ter or months, Month 2 6 12 18 24 30 36 42 48
whichever comes first.
Alternator belt (check for elasticity
1 A - I - R - I - R
and wear)
Synchronous toothed belt (check
2 - - I - I - I - I
for damage or wear)
Intake and exhaust valve clear-
3 A - A - A - A - A
ance
Tightening torque for the bolts of
the cylinder head and the bolts
4 T - T - T - T - T
and nuts for fixing the intake and
exhaust manifold
5 Oil Filter R R R R R R R R R
6 Gasoline engine oil Replace once every 5000km
Fuel rubber hose and connector
7 (aging rubber hose, cracked or I I I I I I I I I
broken connector)
Rubber hose and connector of
8 cooling system for gasoline engine - - I - - I - - I
(water leakage, damage, etc.)
High voltage damping cable (dete-
9 - - I - - I - - I
riorated and broken)
10 Spark plug - R R R R R R R R
11 Gasoline pump (oil leakage) - - I - I - I - I
Clear it every 10000km on the asphalt road,
12 Air filter 2500km on the dirt road; replace it every 40000km
in normal conditions.
Accelerator control cable and I I I I I I I I
13 -
throttle valve body L L L L L L L L
14 Idling or idling emission A A A A A A A A A
15 PCV - I I I I I I I I
16 Clutch clearance - I I I I I I I I
 05A-4 Vehicle Service - Service Schedule

Transmission gear oil (check for

17 R I I I R I I I R
oil leakage in a level surface )

Time and mileage (whichever comes first)

Interval
Time (month) 5 10 15 20 25 30 35 40
Item
Mileage (*1000km) 5 10 15 20 25 30 35 40
05A Chassis and Body
Parking brake function and travel I I I I I I I I
Steering wheel and tie-rod - I I I I I I I
Seat belt, buckle and supporting seats I - I - I - I -
Lock, hinge and door stopper, lubricate
- I I I I I I I
as necessary
Check the free travel of the brake pedal - I I I I I I I
Brake fluid ① I I I I I I R I
Brake pipeline (including vacuum boaster) I I I I I I I I
Tightening bolts and nuts of the chassis
I I I I I I I I
and vehicle bottom
Tightening bolts of engine suspension I I I I I I I I
Front and rear shock absorber I I I I I I I I
Wheel alignment Checkthe following items in abnormal conditions
Tire condition and tire pressure (including
I I I I I I I I
the spare tire)②
Power steering switch ① I I I I R I I I
Power steering pipeline I I I I I I I I
Protective jacket of the drive shaft - I I I I I I I
Transmission oil ① R I I I R I I I
Rear axle lubricant① R I I I R I I I
Front wheel brake disc and related com-
I I I I I I I I
ponents
Rear wheel brake drum and related com-
I I I I I I I I
ponents
Tightening wheel nuts I I I I I I I I

Routine Maintenance
Routine Maintenance is an important job for your driving to keep the vehicle in good condition.
You should develop a habit to inspect the vehicle before or after daily driving or long driving
in order to instantly find unusual problems and properly solve them.
 Vehicle Service - Service Schedule 05A-5

1. Check the radiator coolant;

2. Check the engine oil level;
3. Check the battery indicator;
4. Check whether all the lights and horns work properly;
5. Check whether the tire pressure is normal or whether there is unusual wear;
6. Check wheels and other chassis bolts and nuts for tightening.
7. Check fuel, oil, transmission gear oil, brake fluid and coolant for leakage;
8. Check whether the clutch, brake pedal work properly. 05A
9. Check whether the parking brake works properly;
10 . Check whether switches work properly;
11 . Check whether instruments work properly;
12 . Check the level of the power steering fluid reservoir.
 05A-6 Vehicle Service - Checking

Checking
Checking the Electrical System
• Check the brightness and operation of the front combination light, front fog
light, turn signal light, danger warning light, rear combination light, rear fog
light, reverse light and parking light.
• Check the operation of the interior light.
• Check the operation of the buzzer, control unit, central channel, all the switches
05A
on the instrument and horn.
• Check the operation of the electric door windows, exterior rearview mirrors and
the central door lock controller.
• Check the reception and interference resistance of the radio and examine the
speakers.
 Vehicle Service - Checking 05A-7

Checking the battery

Note

• Keep the battery cable clean, and firm installation of the battery cable is helpful
for the battery performance and service life.
• When fastening the battery cable, pay attention to installing the battery cable
firmly and properly, or it will affect the usage of electrical appliances and the
battery service life . 05A

1. Turn over the driver seat.

2. Check the battery.

(a) Check whether the battery housing and cable
is corroded or broken. Replace them as
CAMEL necessary.
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(b) Shake the battery cable to check whether it

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is firmly installed.
(c) If the battery positive cable is not firmly
fpwx05A0002
installed, you should disconnect the battery
negative cable, tighten the battery positive
cable and then install and tighten nuts of the
battery negative cable again.

3. Check the battery power.

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fpwx05A0003
 05A-8 Vehicle Service - Checking

Checking the Seat Belt

Note

• Completely pull out the seat belt from the seat belt retractor during the inspection.
• Check the cleanliness of the seat belt and wash it in mild soap solution if needed.

1. Check the seat belt for the following

05A damage, or else replace it.
(a) Broken, torn or scratched.

fpwx05A0004

(b) Torn fabric at the edge of belt.

fpwx05A0005

(c) Burn marks, such as cigarette burns.

fpwx05A0006

(d) Distortion on one side or wave-like edge.

fpwx05A0007
 Vehicle Service - Checking 05A-9

2. Checking the seat belt buckle

(a) Quickly pull the seat belt downward and check
whether the buckle is sensitive. If it can not
quickly fasten, please replace it.

fpwx05A0008 05A

3. Check the guide buckle and lock tongue.

(a) Check whether the casing of the guide buckle
is deformed, dropped off or cracked. If any
damage, replace it.

fpwx05A0009

(b) Check the lock tongue for deformation or

crack. If any damage, replace it.
(c) Insert the lock tongue into the guide buckle,
check whether the lock tongue is locked and
repeat it for over 5 times. It should be
replaced if the lock tongue can not be locked
in the guide buckle once.

fpwx05A0010
 05A-10 Vehicle Service - Checking

Checking the Parking Brake and Brake Pedal

1. Check the parking brake and brake pedal
(a) Check whether the parking brake is flexible,
whether the force for pulling the lever is
normal and whether the cable is worn.
Maintain them as necessary.
05A

fpwx05A0011

(b) Checkwhether the brake pedal is loose and

whether the free travel is normal. Maintain it
as necessary.
Free travel: 1 - 3mm

fpwx05A0012

2. Perform a road test and check the operation of the parking brake and brake
pedal. Maintain them again as necessary.
 Vehicle Service - Checking 05A-11

Checking the Door Stopper, Lock and Hinge

1. Check the door stopper.
Check whether the door stopper works
properly and apply grease to the moving parts
if needed.

05A

fpwx05A0013

2. Check the lock and safety button.

(a) Lock the door and check whether the safety
button works properly.
(b) Press the safety button and then close the
door, the button will eject and this can avoid
locking the door by mistake.

fpwx05A0014

3. Check the lock cylinder.

(a) Insert the key into the door lock.
(b) Turn the key clockwise and counterclockwise,
the lock cylinder can rotate smoothly.

fpwx05A0015

4. Check the engine hood and back door.

(a) Repeatedly open and close the engine hood,
check whether the hinge moves smoothly and
apply grease to the moving parts if needed.

fpwx05A0016
 05A-12 Vehicle Service - Checking

(b) Check the back door for opening and closing.

Check the back door lock catch.

05A fpwx05A0017

(c) Repeatedly open and close the back door,

check whether the hydraulic tappet is stuck
and apply grease to the moving parts if
needed.

fpwx05A0018
 Vehicle Service - Checking 05A-13

Checking the Components of the Engine Compartment

Note

• Immediately troubleshoot the fault.

• Timely refill the fluid and eliminate the leaky pipeline.

1. Open the engine hood.

2. Check the following ducts, hoses, and connection for leakage, damage or aging.
05A
Check whether the gap between the pipeline and the body is proper. Adjust or
change as necessary.
(a) Fuel system.
(b) A/C system line and cooling system line.
(c) Brake devices and line.
 05A-14 Vehicle Service - Checking

Checking the Timing Belt

1. Turn off the ignition switch.
2. Remove the bolts fixing the front upper
cover for the timing belt, take out the front
upper cover for the timing belt.

05A

fpwx05A0020

3. Check the timing belt for the following cases, replace as necessary:
Note

• The timing belt with water or grease will abruptly reduce the service life of the
timing belt. If there are grease stains on the belt and it is seriously polluted,
please do not clean but replace with a new one.
• When you find grease stains on the timing belt, please check the engine for oil
leakage.

(a) The back-side rubber is aging and can reflects

light, no trace is left after the fingernails
scratching.

fpwx05A0021

(b) Canvas for cracks or plucking

(c) Back rubber cracks.
(d) The bottom of the belt is damaged or cracked.
(e) The side of the belt is damaged or cracked.

fpwx05A0022
 Vehicle Service - Checking 05A-15

(f) Sides of the belt for abnormal wear.

fpwx05A0023 05A

(g) Belt for abnormal wear.

(h) Tooth loss.

fpwx05A0024

4. Install the timing belt front cover and

tighten the fixing bolts.

fpwx05A0025
 05A-16 Vehicle Service - Checking

Checking the Accessory Belt

1. Turn off the ignition switch.
2. Turn over the seat in the cockpit.
3. Check the accessory belt for cracks and
aging. Replace it as necessary.

05A

fpwx05A0026

Note

• The belt with water or grease will abruptly reduce the service life of the belt. If
there are grease stains on the belt and it is seriously polluted, please do not
clean but replace with a new one.
• When you find grease stains on the belt, please check the engine for oil leakage.

4. Put down the seat.

 Vehicle Service - Checking 05A-17

Checking the Steering Tie Rod Knob and Dust Shield

1. Lift the vehicle.
2. Shake the tie rod and no gap should be
felt.
3. Check whether the fixing nuts of the tie
rod knob is firm enough.
05A

fpwx05A0027

4. Check whether the dust shield of the

steering tie rod and knob rubber are
damaged. If any damage, please replace
them.

fpwx05A0028
 05A-18 Vehicle Service - Checking

Checking and Tightening the Chassis Bolts with the Specified

Torque
Note

• Prevent foreign materials like dust, sand, etc. from falling into one's eyes when
looking up to the chassis.
• When tightening the chassis bolts, take safety precautions like wearing safety
05A helmet and gloves.

1. Turn off all the electrical appliances and ignition switch.

2. Lift the vehicle.
3. Check whether the fixing bolts and nuts of the chassis are loose or rusted.
4. Tighten all the fixing bolts and nuts again with the specified torque.
 Vehicle Service - Checking 05A-19

Checking the Front Headlight

1. Preparation for checking the front headlight :
(a) Place the vehicle on a level surface.
(b) A driver sits in the vehicle (or 73kg additional weight) and the fuel tank stores more
than half of the fuel.
(c) Normal tire pressure.
(d) Normal internal structure of the headlight.
05A
2. Checking the headlight:
(a) Check whether the headlight assembly is damaged, replace as necessary.
(b) Test the headlight functions. Replace bulbs if any damage. Check whether the adjusting
function of the headlight is normal.
(c) Check whether there is any vapor or other foreign objects in the headlight.
(d) If the headlight illuminates beyond the normal range, please adjust the headlight.
(Refer toChapter 64 Lighting - Front Combination Assembly, Adjustment)
 05A-20 Vehicle Service - Checking

Checking Wipers and Washing Equipment

1. Check the limit position of the windscreen wiper blade:
Note

• The wiper blade should be in a resting position during the inspection. And please
make some adjustment if necessary.
• Tightening torque of the wiper arm: 18～21N•m
05A
(a) Driver side.
• The distance between the rubber edge
of the wiper blade and the lower edge
of the windscreen is 30mm.
• If necessary, move the wiper arm to
make some adjustment.

fpwx05A0029

(b) Front passenger side.

• The distance between the rubber edge
of the wiper blade and the lower edge
of the windscreen is 45mm.
• If necessary, move the wiper arm to
make some adjustment.

fpwx05A0030

2. Replace the wiper blade.

(a) Place the wiper arm in the service position,
press the locking button of the wiper blade,
take out the wiper blade downward.
(b) Install the wiper blade and make the locking
button in the locking position.
(c) Turn on the ignition switch and operate the
fpwx05A0031
wiper arm for a while to make the windscreen
wiper to the end again.

3. Check the windscreen washer fluid.

(a) The level of the windscreen washer fluid
should be about 10cm from the opening, add
the fluid if necessary.
Note
The windscreen washer fluid is easy to consume.
Please check regularly.
fpwx05A0032
 Vehicle Service - Checking 05A-21

4. Check the water spray for the windscreen.

(a) The normal water spray area is shown on the
left.

fpwx05A0033 05A

(b) If water spray deviates, the adjustment of the

spray nozzle is necessary.

fpwx05A0034
 05A-22 Vehicle Service - Checking

Checking the Vehicle Bottom

1. Lift the vehicle.
2. Check whether the fuel pipeline and brake pipeline leak.
3. Check whether the bottom guard, wheel cover and side beam are damaged.
4. Visually check whether there is any signs of aging in the installation lug of the
exhaust pipe and confirm that it is secured.

05A
 Vehicle Service - Checking 05A-23

Checking the Suspension Components

1. Lift the vehicle.
2. Check whether all the connecting sleeves are aging or damaged.
3. Tighten all the connecting bolts and nuts with the specified torque.
4. Check each connecting part for deformation and crack.
5. Check the shock absorber for leakage, and the dust shield for damage.

05A
 05A-24 Vehicle Service - Checking

Checking the Suspension Ball Joint and Dust Shield

Check the dust cover of the lower swing arm ball for
damage. Replace it as necessary.

05A

fpwx05A0035
 Vehicle Service - Checking 05A-25

Checking the Braking System

Note

• Only use the brake fluid authorized by BAIC.

• The brake fluid can not be mixed with other fluid, or it will damage the pipeline
of the braking system and even affect driving safety.
• Determine whether refilling the brake fluid is necessary depending on the wear
of the brake lining. 05A

1. Open the engine hood.

2. Checking the brake fluid level of the reservoir:
(a) When the brake lining is worn to the limit, the fluid is close to the lowest level.
(b) When the brake lining is seldom worn, the fluid is close to the highest level.
3. Checking the following parts for damage or leakage:
(a) Master brake cylinder.
(b) Brake booster.
(c) Brake caliper.
(d) Brake line.
4. Check whether the gap between the brake hose and the body is proper, whether
the brake hose is abraded, and whether the connection and fixing devices of
the brake line is firm enough.
 05A-26 Vehicle Service - Checking

Checking the Brake Disc, Brake Drum and Brake Lining

Note
If the thickness of the brake disc, brake drum and brake lining reaches the wear limit,
it is necessary to tell the customer to change.
1. Checking the front brake disc and brake lining:
(a) Remove front wheels. (Refer toChapter 33 Wheels and Tires - Front Wheels and Tires,
05A Replacement)

(b) Measure the thickness of the brake lining

(without the backing plate) and brake disc.
• Standard thickness of the brake lining
(without the backing plate) : 10mm, the
limit thickness: 2mm.

fpwx05A0036

(c) Install front wheels. (Refer toChapter 33 Wheels and Tires - Front Wheels and Tires,
Replacement)
2. Checking the rear brake drum and brake lining:
(a) Remove rear wheels.

(b) Measure the thickness of the brake lining

(without the backing plate) and brake drum.

fpwx05A0037

(c) Install rear wheels.

 Vehicle Service - Checking 05A-27

Checking Tires
Note
When tires wear to the limit or the wear affects driving safety, customers should be
told to replace tires.
1. Check whether the rolling surface and tire wall are damaged or has foreign
objects, whether the tire wall is loose and porous; or whether there are any cuts
or piercings.
05A
2. Check the rolling surface for unilateral wear. If it gets serious unilateral wear, it
is necessary to perform four-wheel alignment to adjust.
3. Check the pattern depth (including spare
tire), ensure the tread depth is higher than
the position of wear marks and that the
triangle wear mark on the tire sidewall
does not wear out.
Min. pattern depth: 1.6mm.

fpwx05A0038
 05A-28 Vehicle Service - Checking

Checking Exhaust System

Note
Be careful not to get burnt when operating the exhaust system.
1. Lift the vehicle.
2. Check the front and rear exhaust pipes, muffler and catalytic converter shell for
damage.
05A 3. Check the connection among the parts of the exhaust system for leakage of air.
4. Check the lifting lug for aging or crack.
 Vehicle Service - Checking 05A-29

Checking the Oil Level of the Engine

1. Place the vehicle on a level surface.
2. Warm up the engine to normal working temperature.
3. Turn off the ignition switch.
4. Wait for about 3 minutes.
5. Turn over the driver seat in the cockpit.
6. Slowly pull out the oil gauge. 05A

fpwx05A0040

7. Check the oil level of the engine, and it

should be in the marked range of the oil
gauge.

fpwx05A0041

8. Check the oil quality of the engine. If the oil is too dirty or becomes thin, you
can exclude the fault and then change the oil.
9. Insert the oil gauge again.

fpwx05A0042

10 . Put down the driver seat and fasten the seatbuckle.

 05A-30 Vehicle Service - Replacement

Replacement
Replacing the Air Filter Element
1. Replacing the air filter element.
(a) Remove two fixing screws of the air filter.

05A

fpwx05A0043

(b) Open the air filter cover and take out the air
element.
Note
The air element is made of paper materials. Clean
the air element with a high pressure air gun from
inside to outside if necessary. Do not clean the
air filter with water.
fpwx05A0044 (c) Clean or replace the air filter element.

2. Install the air filter cover and tighten the

fixing screws.

fpwx05a0045
 Vehicle Service - Replacement 05A-31

Replacing the Engine Oil

1. Start the engine and warm up the vehicle.
2. Close the engine and wait for 10 minutes.
3. Turn over the the driver seat.

05A

fpwx05A0046

4. Unscrew the the engine oil filler cap.

fpwx05A0047

5. Lift the vehicle.

6. Loosen the drain bolt of the oil pan and
then drain the engine oil.
Tool: 15mm sleeve

Note

• Be careful not to be burnt as the engine

oil is very hot.
fpwx05A0048 • It may cause skin cancer to repeatedly get
exposed to the waste oil for a long time,
so you should protect your skin from
direct contact with the waste engine oil. If
you contact with it, please throughly clean
yourself with soap and cleanser as soon
as possible.
• Collect the waste oil with the special
container and dispose it as specified.
 05A-32 Vehicle Service - Replacement

7. Replace with new gaskets of the oil drain

bolt and then tighten the bolt.
Tool: 15mm sleeve
Torque: 25～30N·m
(25～30N·m)

05A fpwx05A0049

8. Put down the vehicle.

9. Add a fixed amount of oil.
Engine oil: 3.3L

Note

• Use SF15W/40 GB11121-2006 gasoline engine oil (or API SG SAE15W40 gasoline
engine oil) if ambient temperature > -20℃.
• Use SF5W/30 GB11121-2006 gasoline engine oil (or API SG SAE5W30 gasoline
engine oil) if ambient temperature > -20℃.

10 . Tightenthe engine oil filler cap.

11 . Park the vehicle on an level surface, start the engine to warm up the vehicle.
And check whether there is oil leakage around the oil drain bolts and oil filter.
12 . Close the engine and wait for 10 minutes.
13 . Check the oil level.
(a) Pull out the oil dipstick and clean it.
(b) Insert the oil dipstick and ensure the engine
oil level in the range as shown.

fpwx05A0050

14 . Put down the driver seat and fasten the driver seat buckle.
 Vehicle Service - Replacement 05A-33

Replacing the Oil Filter

Note
If no special circumstances exist, the oil filter should be replaced together with the
engine oil to avoid polluting the engine oil and affecting engine running.
1. Start the engine and warm up the vehicle.
2. Turn over the driver seat.
05A
(a) Loosen the fixing buckle of driver seat.
(b) Flip the driver seat.

fpwx05A0051

3. Unscrew the the engine oil filler cap.

4. Lift the vehicle.
5. Drain the engine oil. (Refer toChapter 18A Lubrication - Engine Oil, Replacement)
6. Remove the oil filter with a special tool.

fpwx05A0052

7. Clear the foreign objects on the mounting surface of the oil filter.
8. Apply the engine oil on the oil seal surface
of the new oil filter.

fpwx05A0053
 05A-34 Vehicle Service - Replacement

9. Screw the oil filter to the mounting surface

by hand and then tighten 2/3 turn or use
a tool to screw the filter with specified
torque.
Torque: 12～16N•m

(12～16N·m)

05A fpwx05A0054

10 . Install the oil drain bolt.

Tool: 15mm socket
Torque: 25～30N·m
11 . Put down the vehicle.
12 . Open the engine oil filler cap to fill the oil to the specified level.
13 . Install the the engine oil filler cap.
14 . Park the vehicle on an level surface, start the engine to warm up the vehicle.
15 . Check and ensure that there is no oil leakage of the oil filter.
16 . Close the engine and wait for 10 minutes.
17 . Pull out the oil dipstick and check whether the oil level is within the specified
range.
 Vehicle Service - Replacement 05A-35

Replacing the Spark Plug

1. Turn off the ignition switch.
2. Turn over the driver seat.

05A

fpwx05A0055

3. Dismantle the high voltage line.

Gently rotate the high voltage line from the
cylinder and then pull out the line.

fpwx05A0056

4. Dismantle the spark plug.

(a) Dismantle the spark plug with the special
socket.
(b) Remove the spark plug.

fpwx05A0057

5. Install the spark plug.

Tighten the spark plug with the special socket.
(27±2N·m)
Torque: 27±2N•m

Note
Tightening torque should meet the Foton
technical specifications. Never screw too loosely
fpwx05A0058 or tightly in order to avoid leaking air or
damaging the spark plug and its hole.
 05A-36 Vehicle Service - Replacement

6. Install the high voltage line.

(a) Assemble the high voltage line on the ignition
module according to the mark on the ignition
module.
(b) Install the high voltage line to the spark plug
of each cylinder.
Note
05A fpwx05A0059
Ensure that the click is heard, it indicated the
high voltage line is installed properly.

7. Put down the driver seat and fasten the driver seat buckle.
8. Start the engine and check whether the engine works properly.
 Vehicle Service - Replacement 05A-37

Replacing the Fuel Filter Assembly

1. Relieve the fuel pressure. (Refer toChapter12A Fuel - Fuel System, Releasing
the Fuel System Pressure）
2. Lift the vehicle to the proper height.
3. Dismantle the fuel filter.
(a) Remove the retaining clips of the fuel filter
inlet pipe and outlet pipe. 05A

fpwx05A0060

(b) Loosen the bolt of the fuel filter fixing strap.

Tool: 10mm sleeve
(c) Remove the fuel filter.

fpwx05A0061

4. Install a new fuel filter.

Note
Install the fuel filter according to the direction
indicated by the arrow.
(a) Tighten the bolt of the fuel filter fixing strap.
Tool: 10mm sleeve
(23±2N·m)

fpwx05A0062 Torque: 10±1N•m

(b) Fasten the fixing clips on the sides of the fuel
filter.

5. Lower the vehicle.

6. Inspect the fuel line.
(a) Turn on the ignition switch, apply pressure on the fuel line and check the connection
for leakage.
(b) Start the engine, increase the speed and ensure there is no oil leakage on the fuel
line connection.
 05A-38 Vehicle Service - Replacement

Replacing the Coolant

Note

Never open the pressure cap when warming up the engine. Open the pressure cap
until the coolant drops to below 50℃, otherwise the hot coolant or steam may cause
personal injury.

1. Cool the engine to normal room temperature.

05A
2. Unscrew the pressure cap of the
expansion tank.
Note

Wrap thick cloth around the radiator cover,

carefully unscrew it. First rotate 1/4 turn to
relieve the pressure in the radiator. And then
fully unscrew the cap.
fpwx05A0063

3. Lift the vehicle.

4. Loosen the drain valve to discharge the
coolant.
Note
The coolant is corrosive, so please put it in the
special sealed container. Collect the residual
coolant with the special container. When
stopping using it, please dispose the coolant as
fpwx05A0064 specified.

5. Inspect the coolant.

(a) Inspect the discharged engine coolant for rust, corrosion or discoloration.
(b) If it is polluted, please wash the engine cooling system.
6. Wash the cooling system.
(a) Screw the drain valve of the radiator.
Note
Clean the drain valve of the radiator and replace with a new O ring.
(b) Add water in the expansion tank to normal height.
(c) Run the engine to warm it up to normal operating temperature.
(d) Accelerate the engine speed under no-load condition for two or three times.
(e) Turn off the engine and wait for it to cool down.
(f) Drain the water in the cooling system.
(g) Repeat the steps until clear water comes from the radiator.
7. Fill the engine coolant.
(a) Screw the drain valve of the radiator.
(b) Slowly fill the Foton SLLC (super long-lasting coolant) into the expansion tank.
 Vehicle Service - Replacement 05A-39

(c) Press the inlet hose and outlet hose of the radiator by hand for several times to inspect
the coolant level. If the coolant level is low, it is necessary to add the coolant.
(d) Screw the pressure cap of the expansion tank.
(e) Start the engine and warm up it or make the fan running at high speed.
(f) Stop the engine and wait until the engine coolant cools down.
(g) Inspect whether the coolant level in the expansion tank is in the specified position.
Add the coolant to the specified position as necessary.
Note 05A
It is unnecessary to bleed air as air in the cooling system can be automatically
discharged through the expansion tank.
 05A-40 Vehicle Service - Replacement

Replacing the Brake Fluid

Danger
Never splash the brake fluid on the surface of the paint or skin, otherwise clean with
water immediately.

1. Add some brake fluid to the oil cup.

Brake fluid: DOT-3 or DOT-4 synthetic
05A brake fluid

Danger
Never splash the brake fluid on the surface of
the paint or skin, otherwise clean with water
fpwx05A0065
immediately.

2. Bleed air for the master brake cylinder.

(a) Loosen the pipe connector nuts and
connectors from the master brake cylinder.
Tool：10mm wrench

Note
If the master brake cylinder has been dismantled
fpwx05A0066 or the oil cup is empty, it is necessary to bleed
air in the master brake cylinder.

(b) Compress the brake pedal several time and

hold a while.

fpwx05A0067

(c) Block the hole with a finger from the outside

and release the brake pedal.
(d) Repeat (b) and (c) for 3 or 4 times until the
air in the master brake cylinder is fully bled.

fpwx05A0068
 Vehicle Service - Replacement 05A-41

3. Bleed air for the brake line.

(a) Connect the rubber hose to the bleed screw
of the rear brake cylinder.
(18±3N·m)
(b) Quickly press the brake pedal several times,
hold it in position and then loosen the bleed
screw.
(c) Tighten the bleed screw when the outflow of
the brake fluid reduces, and release the brake 05A
pedal.
Torque: 18±3N•m
(d) Repeat (b) and (c) until the air of the brake
fluid is fully bled.
fpwx05A0069

(e) Connect the rubber hose to the exhaust screw

of the brake caliper.
(f) Compress the brake pedal several time and
hold a while, and then loosen the exhaust
(18±3N·m)
screw.
(g) Tighten the bleed screw when the outflow of
the brake fluid reduces, and release the brake
pedal.
Torque: 18±3N•m
(h) Repeat (f) and (g) until the air of the brake
fluid is fully bled.
(i) Repeat the above steps until the air of the
fpwx05A0070 brake fluid is fully bled.
Note
Air bleed order for the brake line: rear left - rear
right - front right - front left

4. Inspect the fluid level of the oil cup.

(a) Inspect the brake fluid level, and add the fluid
as necessary.
Brake fluid: DOT3 or DOT4 brake fluid

fpwx05A0071
 05A-42 Vehicle Service - Replacement

Replacing the Transmission Lubricant

1. Unscrew the oil drain plug of the bottom
of the transmission, drain the transmission
oil, and then tighten the oil drain plug.
Tool: T55 (Allen key)
Torque: 10～25N·m
(10～25N·m)
05A
Note
fpwx05A0072
• Ensure the vent plug is unblocked and
then unscrew the oil drain plug before
draining the oil. Please drain the oil when
the engine is hot, so that the transmission
oil can be drained as much as possible.
• When draining the transmission oil, please
collect the oil with the special container
and dispose it as specified.

2. Unscrew the filler plug, fill the

transmission oil and then tighten the filler
plug.
(10～25N·m) Tool: T55 (Allen key)
Torque: 10～25N·m
Note
fpwx05A0073
• Filling quantity is 1L.
• Transmission oil: 85W/90 GL-4 or GL-5
gear oil, GB13895-92 or No.18 hyperbolic
gear oil.
Note
For gasoline engine and transmission, lubricant
should be properly used, which will ensure their
good operation and service life. Users should
also notice that the oil of different origins, brands
and specifications can not be mixed, as chemical
reactions between different types of oils will
affect the operation of the gasoline engine. Never
use the oil which is not specified, especially for
the imported oil.
• When inspecting the oil level, make sure
the vehicle must be on a level surface and
the oil level should not be lower 5mm than
the lower end of the filler plug.
 Vehicle Service - Replacement 05A-43

Replacing the Gear Oil of the Front Final Drive

1. Turn off the ignition switch.
2. Lift the vehicle.
3. Unscrew the filler bolt of the final drive.

05A

fpwx05A0077

4. Unscrew the oil drain bolt of the final drive

and discharge the gear oil of the final
drive.
Note
The discharged gear oil of the final drive should
be collected and disposed as specified.

fpwx05A0075

5. After draining the gear oil of the final drive,

replace the oil drain bolt gasket and
tighten the drain bolt.
(25±3N·m) Tool: 24mm socket
Tightening torque: 25±3N•m

fpwx05A0078

6. Fill the gear oil of the final drive through

its filling hole with a tool.
Gear oil: GL-585W/90 Filling quantity:
about 1.2L
Note
Only use the gear oil of the final drive authorized
by Foton.
fpwx05A0076
 05A-44 Vehicle Service - Replacement

7. Replace the filler bolt gasket, tighten the

filler bolt and clean oil stains.
Tool: 24mm socket
(25±3N·m) Tightening torque: 25±3N•m

05A fpwx05A0078

8. Inspect the bolt connection for oil leakage.

9. Put down the vehicle.
Vehicle Service
Service Schedule................................05B-1
Precautions......................................05B-1
Service and Cycle Under Normal
Conditions........................................05B-3
Checking.............................................05B-6
Checking the Electrical System........05B-6
Checking the battery........................05B-7
05B
Checking the Seat Belt.....................05B-8
Checking the Parking Brake and Brake
Pedal..............................................05B-10
Checking the Door Stopper, Lock and
Hinge..............................................05B-11
Checking the Front Windscreen Guide
Groove............................................05B-13
Checking the Components of the Engine
Compartment.................................05B-14
Checking the Accessory Belt.........05B-15
Checking the Steering Tie Rod Knob and
Dust Shield.....................................05B-16
Checking and Tightening the Chassis Bolts
with the Specified Torque...............05B-17
Checking the Front Headlight.........05B-18
Checking Wipers and Washing
Equipment......................................05B-19
Checking the Vehicle Bottom..........05B-21
Checking the Suspension
Components...................................05B-22
Checking the Suspension Ball Joint and
Dust Shield.....................................05B-23
Checking the Braking System........05B-24
Checking the Brake Disc, Brake Drum and
Brake Lining...................................05B-25
Checking Tires................................05B-26
Checking Exhaust System.............05B-27
Checking the Coolant Level of the
Reservoir........................................05B-28
Checking the Oil Level of the
Engine............................................05B-29
Replacement.....................................05B-30
Replacing the Air Filter Element.....05B-30
Replacing the Engine Oil................05B-31
Replacing the Oil Filter...................05B-33
Replacing the Spark Plug
(4W10/4W12).................................05B-35
Replacing the Fuel Filter
Assembly........................................05B-36
 Replacing the Coolant....................05B-37
Replacing the Brake Fluid..............05B-39
Replacing the Transmission
Lubricant........................................05B-41
Replacing the Gear Oil of the Front Final
Drive...............................................05B-42

05B
 Vehicle Service - Service Schedule 05B-1

Service Schedule
Precautions
Service Note
1. Safety
(a) Preparation Before Service.
• If necessary, the staff will wear safety shoes, gloves and goggles.
• Ensure the site ventilative and clean, keep tools and instruments neat.Provide
a fire extinguisher as necessary.
05B
• Inspect the safe working conditions of the apparatus, like the lifting equipment
and jack.
• Inspect the vehicle driving safety and ensure the vehicle can get service.
(b) Caution in the service.
• Before the vehicle comes to the lift stand, make sure there is enough distance
between the bottom and sides of the vehicle and the lift to avoid scratches.
• Before lifting the vehicle, make sure the wight of the vehicle is no more than the
rated load of the lift.
• Choose the right supporting location when lifting the vehicle.
• When lifting the vehicle, never start the engine and put the vehicle in gear on
the condition that there are driving wheels on the ground, otherwise operators
and the vehicle will be in danger.
• Operators must strictly follow all the safety regulations and rules in service,
otherwise the operator and vehicle will be in danger.
• When replacing parts and consuming products, you should use products
authorized by Foton to ensure the driving safety and performance of the vehicle.
(c) Cautions after the service.
• After the service, inspect the vehicle by a test run , especially pay attention to
the brake system and safety restraint system.
• The vehicle can only be handed over to the customer after the fault memories
in the fault storage unit are completely cleared.
2. Schedule
(a) The interval of service and maintenance depends on mileage or time interval, whichever
comes earlier, as shown in the schedule.
(b) The time interval before next service shall be equal to that from the last service until
present.
(c) For service intervals of each parts, you can refer to the service schedule.
(d) Some parts are especially important service objects. Replace the hoses immediately
if they are aging or broken. Please note that rubber hoses age over time, which will
lead to swelling, scratching or cracking.
(e) After a vehicle drives across the sand, mud or water, check the following parts and
perform service or repair if necessary.
• Brake lining and brake drum.
• Brake pad and brake disc.
• Brake line and rubber hose.
 05B-2 Vehicle Service - Service Schedule

• Oil and working fluid of transmission, transfer case and differential.

• Air filter element.

Maintenance Condition
1. Under ordinary conditions, the vehicle gets service according to the service
cycle.
2. If the vehicle mainly runs under one or several of the following special conditions,
some parts should get service more frequently (Refer to service conditions in
extreme situation ).
05B (a) Road conditions:
• Uneven, muddy or thawy road.
• Dusty road.
• Saline road.
(b) Driving conditions:
• Tow a vehicle, use camping rack or parcel shelf.
• Repeat the short trip within 8 km below 0℃.
• Idle or drive at low speed for a long time, like the police car, taxi or door-door
delivery car.
• Often drive at high speed over 2 hours (driving in 80% of the max. speed).
 Vehicle Service - Service Schedule 05B-3

Service and Cycle Under Normal Conditions

Usage cycle and service of the gasoline engine 4W10/4W12
Meaning of symbols in the table:
"R": replace or change; "I": inspect the items and related parts, if necessary, calibrate, clean,
supplement, adjust or replace; "①": -refer to "recommended fluid specifications and capacity
table" in the User Manual; "②": -rotate or balance the wheels as necessary.

Regular Maintenance Specification Table

Time and mileage (whichever comes first) 05B
Interval
Time (month) 5 10 15 20 25 30 35 40
Item
Mileage (*1000km) 5 10 15 20 25 30 35 40
Engine
Oil and oil filter① R R R R R R R R
Fuel Filter - R I R I R I R
Air filter element I I R I R I R I
Spark plug - I - I R I R I
Engine coolant ① I I I I R I I I
Intake and exhaust manifold I - I - I - I -
Drive belt and tensioner pulley I I - I - I - I
Fuel pipeline and connectors I I I I I I I I
Tightening bolts of engine suspension I I I I I I I I
Engine harness and sensors I - I - I - I -
Positive vrankcase ventilation system I I I I I I I I
Fuel tank, fuel evaporation pipe and
I I I I I I I I
canister
A/C and electronic
A/C (including cooling fan and A/C
I - I - - I - I
control switches)
Lighting and signal devices I I I I I I I I
Washing system for windshield (includ-
I I I I I I I I
ing wipers and reservoir)
Battery I I I I I I I I

Time and mileage (whichever comes first)

Interval
Time (month) 5 10 15 20 25 30 35 40
Item
Mileage (*1000km) 5 10 15 20 25 30 35 40
 05B-4 Vehicle Service - Service Schedule

Chassis and body

Parking brake function and travel I I I I I I I I
Steering wheel and tie-rod - I I I I I I I
Seat belt, buckle and supporting seats I - I - I - I -
Lock, hinge and door stopper, lubricate
- I I I I I I I
as necessary
Check the free travel of the brake pedal - I I I I I I I
05B Brake fluid ① I I I I I I R I
Brake pipeline (including vacuum boaster) I I I I I I I I
Tightening bolts and nuts of the chassis
I I I I I I I I
and vehicle bottom
Tightening bolts of engine suspension I I I I I I I I
Front and rear shock absorber I I I I I I I I
Wheel alignment Check the following items in abnormal conditions
Tire condition and tire pressure (including
I I I I I I I I
the spare tire)②
Power steering switch ① I I I I R I I I
Power steering pipe I I I I I I I I
Protective jacket of the drive shaft - I I I I I I I
Transmission oil ① R I I I R I I I
Rear axle lubricant① R I I I R I I I
Front wheel brake disc and related com-
I I I I I I I I
ponents
Rear wheel brake drum and related com-
I I I I I I I I
ponents
Tightening wheel nuts I I I I I I I I

Routine Maintenance
Routine Maintenance is an important job for your driving to keep the vehicle in good condition.
You should develop a habit to inspect the vehicle before or after daily driving or long driving
in order to instantly find unusual problems and properly solve them.
1. Check the radiator coolant;
2. Check the engine oil level;
3. Check the battery indicator;
4. Check whether all the lights and horns work properly;
5. Check whether the tire pressure is normal or whether there is unusual wear;
6. Check wheels and other chassis bolts and nuts for tightening.
7. Check fuel, oil, transmission gear oil, brake fluid and coolant for leakage;
 Vehicle Service - Service Schedule 05B-5

8. Check whether the clutch, brake pedal work properly.

9. Check whether the parking brake works properly;
10 . Check whether switches work properly;
11 . Check whether instruments work properly;
12 . Check the level of the power steering fluid reservoir.

05B
 05B-6 Vehicle Service - Checking

Checking
Checking the Electrical System
• Check the brightness and operation of the front combination light, front fog
light, turn signal light, danger warning light, rear combination light, rear fog
light, reverse light and parking light.
• Check the operation of the interior light.
• Check the operation of the buzzer, control unit, central channel, all the switches
on the instrument and horn.
• Check the operation of the electric door windows, exterior rearview mirrors and
05B
the central door lock controller.
• Check the reception and interference resistance of the radio and examine the
speakers.
 Vehicle Service - Checking 05B-7

Checking the battery

Note

• Keep the battery cable clean, and firm installation of the battery cable is helpful
for the battery performance and service life.
• When fastening the battery cable, pay attention to installing the battery cable
firmly and properly, or it will affect the usage of electrical appliances and the
battery service life .

1. Turn over the driver seat. 05B

2. Check the battery.
(a) Check whether the battery housing and cable
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线：400-189-9507

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(b) Shake the battery cable to check whether it

is firmly installed.
fpwx05B0001
(c) If the battery positive cable is not firmly
fastened, you should disconnect the battery
negative cable, tighten the battery positive
cable and then install and tighten nuts of the
battery negative cable again.

3. Check the battery power.

CO.,LTD. CAMEL GHOUP

生产许可证：000-00-00000
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EXPLOSIVE READ DIRECTION KEEPP OUT OFREACH SUFURIC ACID SHIELD EYES FLAMMABLE RECYCLE Pb
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免费服务热线：400-189-9507
CAMEL
电话：0710-7611540
厂址：湖北省谷城县石花镇武当路82号

fpwx05B0002
 05B-8 Vehicle Service - Checking

Checking the Seat Belt

Note

• Completely pull out the seat belt from the seat belt retractor during the inspection.
• Check the cleanliness of the seat belt and wash it in mild soap solution if needed.

1. Check the seat belt for the following

damage, or else replace it.
(a) Broken, torn or scratched.
05B

fpwx05B0003

(b) Torn fabric at the edge of belt.

fpwx05B0004

(c) Burn marks, such as cigarette burns.

fpwx05B0005

(d) Distortion on one side or wave-like edge.

fpwx05B0006
 Vehicle Service - Checking 05B-9

2. Checking the seat belt buckle

Quickly pull the seat belt downward and check
whether the buckle is sensitive. If it can not
quickly fasten, please replace it.

fpwx05B0007

3. Check the guide buckle and lock tongue. 05B

(a) Check whether the casing of the guide buckle
is deformed, dropped off or cracked. If any
damage, replace it.

fpwx05B0008

(b) Check the lock tongue for deformation or

crack. If any damage, replace it.
(c) Insert the lock tongue into the guide buckle,
check whether the lock tongue is locked and
repeat it for over 5 times. It should be
replaced if the lock tongue can not be locked
in the guide buckle once.

fpwx05B0009
 05B-10 Vehicle Service - Checking

Checking the Parking Brake and Brake Pedal

1. Check the parking brake and brake pedal
(a) Check whether the parking brake is flexible,
whether the force for pulling the lever is
normal and whether the cable is worn.
Maintain them as necessary.

05B fpwx05B0010

(b) Check whether the brake pedal is loose and

whether the free travel is normal. Maintain it
as necessary.
Free travel: 1～3mm

fpwx05B0011

2. Perform a road test and check the operation of the parking brake and brake
pedal. Maintain them again as necessary.
 Vehicle Service - Checking 05B-11

Checking the Door Stopper, Lock and Hinge

1. Check the door stopper.
(a) Check whether the door stopper works
properly and apply grease to the moving parts
if needed.

fpwx05B0012 05B

2. Check the lock and safety button.

(a) Lock the door and check whether the safety
button works properly.
(b) Press the safety button and then close the
door, the button will eject and this can avoid
locking the door by mistake.

fpwx05B0014

3. Check the lock cylinder.

(a) Insert the key into the door lock.
(b) Turn the key clockwise and counterclockwise,
the lock cylinder can rotate smoothly.

fpwx05B0014

4. Check the engine hood and back door.

(a) Repeatedly open and close the engine hood,
check whether the hinge moves smoothly and
apply grease to the moving parts if needed.

fpwx05B0015
 05B-12 Vehicle Service - Checking

(b) Check the back door for opening and closing.

Check the back door lock catch.

fpwx05B0016

05B (c) Repeatedly open and close the back door,

check whether the hydraulic tappet is stuck
and apply grease to the moving parts if
needed.

fpwx05B0017
 Vehicle Service - Checking 05B-13

Checking the Front Windscreen Guide Groove

1. Open the engine hood.
2. Check the front windscreen guide groove
for impurities and blockage.
3. Check the sealing strip of damage.

05B
fpwx05B0018

4. Close the engine hood.

 05B-14 Vehicle Service - Checking

Checking the Components of the Engine Compartment

Note

• Immediately troubleshoot the fault.

• Timely refill the fluid and eliminate the leaky pipeline.

1. Open the engine hood.

2. Check the following ducts, hoses, and connection for leakage, damage or aging.
Check whether the gap between the pipeline and the body is proper. Adjust or
change as necessary.
05B
(a) Fuel system.
(b) A/C system line and cooling system line.
(c) Brake devices and line.
 Vehicle Service - Checking 05B-15

Checking the Accessory Belt

1. Turn off the ignition switch.
2. Turn over the seat in the cockpit.
3. Check the accessory belt for cracks and
aging. Replace it as necessary.

05B

fpwx05B0019

Note

• The belt with water or grease will abruptly reduce the service life of the belt. If
there are grease stains on the belt and it is seriously polluted, please do not
clean but replace with a new one.
• When you find grease stains on the belt, please check the engine for oil leakage.

4. Put down the seat.

 05B-16 Vehicle Service - Checking

Checking the Steering Tie Rod Knob and Dust Shield

1. Lift the vehicle.
2. Shake the tie rod and no gap should be
felt.
3. Check whether the fixing nuts of the tie
rod knob is firm enough.

05B
fpwx05B0020

4. Check whether the dust shield of the

steering tie rod and knob rubber are
damaged. If any damage, please replace
them.

fpwx05B0021
 Vehicle Service - Checking 05B-17

Checking and Tightening the Chassis Bolts with the Specified

Torque
Note

• Prevent foreign materials like dust, sand, etc. from falling into one's eyes when
looking up to the chassis.
• When tightening the chassis bolts, take safety precautions like wearing safety
helmet and gloves.

1. Turn off all the electrical appliances and ignition switch. 05B
2. Lift the vehicle.
3. Check whether the fixing bolts and nuts of the chassis are loose or rusted.
4. Tighten all the fixing bolts and nuts again with the specified torque.
 05B-18 Vehicle Service - Checking

Checking the Front Headlight

1. Preparation for checking the front headlight :
(a) Place the vehicle on a level surface.
(b) A driver sits in the vehicle (or 73kg additional weight) and the fuel tank stores more
than half of the fuel.
(c) Normal tire pressure.
(d) Normal internal structure of the headlight.
2. Checking the headlight:
05B (a) Check whether the headlight assembly is damaged, replace as necessary.
(b) Test the headlight functions. Replace bulbs if any damage. Check whether the adjusting
function of the headlight is normal.
(c) Check whether there is any vapor or other foreign objects in the headlight.
(d) If the headlight illuminates beyond the normal range, please adjust the headlight.
(Refer to "Chapter 64 Lighting - Front Left Combination Assembly, Adjustment")
 Vehicle Service - Checking 05B-19

Checking Wipers and Washing Equipment

1. Check the limit position of the windscreen wiper blade:
Note

• The wiper blade should be in a resting position during the inspection. And please
make some adjustment if necessary.
• Tightening torque of the wiper arm: 18～21N•m

(a) Driver side.

05B
• The distance between the rubber edge
of the wiper blade and the lower edge
of the windscreen is 30mm.
• If necessary, move the wiper arm to
make some adjustment.

fpwx05B0022

(b) Front passenger side.

• The distance between the rubber edge
of the wiper blade and the lower edge
of the windscreen is 45mm.
• If necessary, move the wiper arm to
make some adjustment.

fpwx05B0023

2. Replace the wiper blade.

(a) Place the wiper arm in the service position,
press the locking button of the wiper blade,
take out the wiper blade downward.
(b) Install the wiper blade and make the locking
button in the locking position.
(c) Turn on the ignition switch and operate the
fpwx05B0024
wiper arm for a while to make the windscreen
wiper to the end again.

3. Check the windscreen washer fluid.

(a) The level of the windscreen washer fluid
should be about 10cm from the opening, add
the fluid if necessary.
Note
The windscreen washer fluid is easy to consume.
Please check regularly.
fpwx05B0025
 05B-20 Vehicle Service - Checking

4. Check the water spray for the windscreen.

(a) The normal water spray area is shown on the
left.

fpwx05B0026

05B (b) If water spray deviates, the adjustment of the

spray nozzle is necessary.

fpwx05B0027
 Vehicle Service - Checking 05B-21

Checking the Vehicle Bottom

1. Lift the vehicle.
2. Check whether the fuel pipeline and brake pipeline leak.
3. Check whether the bottom guard, wheel cover and side beam are damaged.
4. Visually check whether there is any signs of aging in the installation lug of the
exhaust pipe and confirm that it is secured.

05B
 05B-22 Vehicle Service - Checking

Checking the Suspension Components

1. Lift the vehicle.
2. Check whether all the connecting sleeves are aging or damaged.
3. Tighten all the connecting bolts and nuts with the specified torque.
4. Check each connecting part for deformation and crack.
5. Check the shock absorber for leakage, and the dust shield for damage.

05B
 Vehicle Service - Checking 05B-23

Checking the Suspension Ball Joint and Dust Shield

1. Check the dust cover of the lower swing
arm ball for damage. Replace it as
necessary.

fpwx05B0028 05B
 05B-24 Vehicle Service - Checking

Checking the Braking System

Note

• Only use the brake fluid authorized by BAIC.

• The brake fluid can not be mixed with other fluid, or it will damage the pipeline
of the braking system and even affect driving safety.
• Determine whether refilling the brake fluid is necessary depending on the wear
of the brake lining.

1. Open the engine hood.

05B
2. Checking the brake fluid level of the reservoir:
(a) When the brake lining is worn to the limit, the fluid is close to the lowest level.
(b) When the brake lining is seldom worn, the fluid is close to the highest level.
3. Checking the following parts for damage or leakage:
(a) Master brake cylinder.
(b) Brake booster.
(c) Brake caliper.
(d) Brake line.
4. Check whether the gap between the brake hose and the body is proper, whether
the brake hose is abraded, and whether the connection and fixing devices of
the brake line is firm enough.
 Vehicle Service - Checking 05B-25

Checking the Brake Disc, Brake Drum and Brake Lining

Note
If the thickness of the brake disc, brake drum and brake lining reaches the wear limit,
it is necessary to tell the customer to change.
1. Checking the front brake disc and brake lining:
(a) Remove front wheels. (Refer to "Chapter 33 Wheels and Tires - Front Wheels and
Tires, Replacement")

(b) Measure the thickness of the brake lining 05B

(without the backing plate) and brake disc.
• Standard thickness of the brake lining
(without the backing plate) : 12mm, the
limit thickness: 2mm.

fpwx05B0029

(c) Install front wheels. (Refer to "Chapter 33 Wheels and Tires - Front Wheels and Tires,
Replacement")
2. Checking the rear brake drum and brake lining:
(a) Remove rear wheels.

(b) Measure the thickness of the brake lining

(without the backing plate) and brake drum.

fpwx05B0030

(c) Install rear wheels. (Refer to "Chapter 33 Wheels and Tires - Rear Wheels and Tires,
Replacement")
 05B-26 Vehicle Service - Checking

Checking Tires
Note
When tires wear to the limit or the wear affects driving safety, customers should be
told to replace tires.
1. Check whether the rolling surface and tire wall are damaged or has foreign
objects, whether the tire wall is loose and porous; or whether there are any cuts
or piercings.
2. Check the rolling surface for unilateral wear. If it gets serious unilateral wear, it
05B is necessary to perform four-wheel alignment to adjust.
3. Check the pattern depth (including spare
tire), ensure the tread depth is higher than
the position of wear marks and that the
triangle wear mark on the tire sidewall
does not wear out.
Min. pattern depth: 1.6mm.

fpwx05B0031
 Vehicle Service - Checking 05B-27

Checking Exhaust System

Note
Be careful not to get burnt when operating the exhaust system.
1. Lift the vehicle.
2. Check the front and rear exhaust pipes, muffler and catalytic converter shell for
damage.
3. Check the connection among the parts of the exhaust system for leakage of air.
4. Check the lifting lug for aging or crack.
05B
 05B-28 Vehicle Service - Checking

Checking the Coolant Level of the Reservoir

Note

• Be careful not to be burnt by the hot water or steam when operating the cooling
steam.
• Only add the coolant authorized by BAIC.

1. Turn off the ignition switch.

2. Wait until the engine is cooled to ambient temperature.
05B
3. Open the engine hood.
4. Check the coolant level, and it should be
between MIN and MAX.

fpwx05B0032

5. Close the engine hood.

 Vehicle Service - Checking 05B-29

Checking the Oil Level of the Engine

1. Place the vehicle on a level surface.
2. Warm up the engine to normal working temperature.
3. Turn off the ignition switch.
4. Wait for about 3 minutes.
5. Turn over the driver seat in the cockpit.
6. Slowly pull out the oil gauge.

05B

fpwx05B0033

7. Check the oil level of the engine, and it

should be in the marked range of the oil
gauge.

fpwx05B0034

8. Check the oil quality of the engine. If the oil is too dirty or becomes thin, you
can exclude the fault and then change the oil.
9. Insert the oil gauge again.

fpwx05B0033

10 . Put down the driver seat and fasten the seat buckle.
 05B-30 Vehicle Service - Replacement

Replacement
Replacing the Air Filter Element
1. Replacing the air filter element.
(a) Remove two fixing screws of the air filter.

05B

fpwx05B0036

(b) Open the air filter cover and take out the air
element.
Note
The air element is made of paper materials. Clean
the air element with a high pressure air gun from
inside to outside if necessary. Do not clean the
air filter with water.
fpwx05B0037 (c) Clean or replace the air filter element.

2. Install the air filter cover and tighten the

fixing screws.

fpwx05B0038
 Vehicle Service - Replacement 05B-31

Replacing the Engine Oil

1. Start the engine and warm up the vehicle.
2. Close the engine and wait for 10 minutes.
3. Turn over the the driver seat.
4. Unscrew the the engine oil filler cap.

05B

fpwx05b0039

5. Lift the vehicle.

6. Loosen the drain bolt of the oil pan.
(a) Drain the engine oil.
Note

• Be careful not to be burnt as the engine

oil is very hot.
• It may cause skin cancer to repeatedly get
fpwx05B0040 exposed to the waste oil for a long time,
so you should protect your skin from
direct contact with the waste engine oil. If
you contact with it, please throughly clean
yourself with soap and cleanser as soon
as possible.
• Collect the waste oil with the special
container and dispose it as specified.

7. Replace with new gaskets of the oil drain

bolt and then tighten the bolt.
Torque: 25～30N·m

(25～30N·m)

fpwx05B0041

8. Put down the vehicle.

9. Add a fixed amount of oil.
Engine oil: 2.7L
 05B-32 Vehicle Service - Replacement

Note

• Use SF15W/40 GB11121-2006 gasoline engine oil (or API SG SAE15W40 gasoline
engine oil) if ambient temperature > -20℃.
• Use SF5W/30 GB11121-2006 gasoline engine oil (or API SG SAE5W30 gasoline
engine oil) if ambient temperature > -20℃.

10 . Install the the engine oil filler cap.

11 . Park the vehicle on an level surface, start the engine to warm up the vehicle.
And check whether there is oil leakage around the oil drain bolts and oil filter.
05B
12 . Close the engine and wait for 10 minutes.
13 . Check the oil level.
(a) Pull out the oil dipstick and clean it.
(b) Insert the oil dipstick and ensure the engine
oil level in the range as shown.

fpwx05B0042

14 . Turn down the main engine cover and lock the fixing buckle of driver seat.
 Vehicle Service - Replacement 05B-33

Replacing the Oil Filter

Note
If no special circumstances exist, the oil filter should be replaced together with the
engine oil to avoid polluting the engine oil and affecting engine running.
1. Start the engine and warm up the vehicle.
2. Turn over the driver seat.
3. Unscrew the the engine oil filler cap.
4. Lift the vehicle.
5. Drain the engine oil. (Refer to05B Vehicle Service - Replacement, Replacing the 05B
Engine Oil)
6. Remove the oil filter with a special tool.

fpwx05B0043

7. Clear the foreign objects on the mounting surface of the oil filter.
8. Apply the engine oil on the oil seal surface
of the new oil filter.

fpwx05B0044

9. Screw the oil filter to the mounting surface

by hand and then tighten 2/3 turn or use
a tool to screw the filter with specified
torque.
(12～16N•m)

Torque: 12～16N·m

fpwx05B0045

10 . Install the oil drain bolt.

Torque: 25～30N·m
11 . Put down the vehicle.
12 . Open the engine oil filler cap to fill the oil to the specified level.
13 . Install the the engine oil filler cap.
 05B-34 Vehicle Service - Replacement

14 . Park the vehicle on an level surface, start the engine to warm up the vehicle.
15 . Check and ensure that there is no oil leakage of the oil filter.
16 . Close the engine and wait for 10 minutes.
17 . Pull out the oil dipstick and check whether the oil level is within the specified
range.

05B
 Vehicle Service - Replacement 05B-35

Replacing the Spark Plug (4W10/4W12)

1. Turn off the ignition switch.
2. Turn over the driver seat.
3. Dismantle the high voltage line.
(a) Gently rotate the high voltage line from the
cylinder and then pull out the line.

05B
fpwx05b0046

4. Dismantle the spark plug.

(a) Dismantle the spark plug with the special
socket.
(b) Remove the spark plug.

fpwx05b0047

5. Install the spark plug.

(a) Tighten the spark plug with the special socket.
Torque:27±2N·m

Note
(27±2N·m)

Tightening torque should meet the Foton

technical specifications. Never screw too loosely
fpwx05b0048 or tightly in order to avoid leaking air or
damaging the spark plug and its hole.

6. Install the high voltage line.

(a) Assemble the high voltage line on the ignition
module according to the mark on the ignition
module.
(b) Install the high voltage line to the spark plug
of each cylinder
Note
fpwx05b0049
Ensure that the click is heard, it indicated the
high voltage line is installed properly.

7. Put down the driver seat and fasten the driver seat buckle.
8. Start the engine and check whether the engine works properly.
 05B-36 Vehicle Service - Replacement

Replacing the Fuel Filter Assembly

1. Discharge the pressure in the fuel system. (Refer to "Chapter 12A Fuel - Fuel
System, Releasing the Fuel System Pressure")
2. Lift the vehicle to the proper height.
3. Dismantle the fuel filter.
(a) Remove the retaining clips of the fuel filter
inlet pipe and outlet pipe.

05B

fpwx05B0050

(b) Loosen the bolt of the fuel filter fixing strap.

Tool: 10mm sleeve
(c) Remove the fuel filter.

fpwx05B0051

4. Install a new fuel filter.

Note
(10±1N·m)
Install the fuel filter according to the direction
indicated by the arrow.
(a) Tighten the bolt of the fuel filter fixing strap.
Torque: 10±1N•m
fpwx05B0052 (b) Fasten the fixing clips on the sides of the fuel
filter.

5. Lower the vehicle.

6. Check the fuel pipe.
(a) Turn on the ignition switch so that fuel pressure is applied to the fuel line, check the
connections for leaks.
(b) Start the engine and increase the RPM, make sure there is no fuel leak at the fuel pipe
joint.
 Vehicle Service - Replacement 05B-37

Replacing the Coolant

Note

Do not open the pressure cap when the engine is heat. Do not open the radiator cover
until the engine cools down below 50°C. Otherwise, hot coolant or steam may lead to
personal injury.

1. Cool the engine to normal ambient temperature.

2. Unscrew the pressure cap of the
expansion tank. 05B
Note

Wrap thick cloth around the radiator cover,

carefully unscrew it. First rotate 1/4 turn to
relieve the pressure in the radiator. And then
fully unscrew the cap.
fpwx05B0053

3. Lift the vehicle.

4. Loosen the drain valve to discharge the
coolant.
Note
The coolant is corrosive, so please put it in the
special sealed container. Collect the residual
coolant with the special container. When
stopping using it, please dispose the coolant as
fpwx05B0054 specified.

5. Inspect the coolant.

(a) Inspect the discharged engine coolant for rust, corrosion or discoloration.
(b) If it is polluted, please wash the engine cooling system.
6. Wash the cooling system.
(a) Screw the drain valve of the radiator.
Note
Clean the drain valve of the radiator and replace with a new O ring.
(b) Add water in the expansion tank to normal height.
(c) Run the engine to warm it up to normal operating temperature.
(d) Accelerate the engine speed under no-load condition for two or three times.
(e) Turn off the engine and wait for it to cool down.
(f) Drain the water in the cooling system.
(g) Repeat the steps until clear water comes from the radiator.
7. Fill the engine coolant.
(a) Screw the drain valve of the radiator.
(b) Slowly fill the Foton SLLC (super long-lasting coolant) into the expansion tank.
 05B-38 Vehicle Service - Replacement

(c) Press the inlet hose and outlet hose of the radiator by hand for several times to inspect
the coolant level. If the coolant level is low, it is necessary to add the coolant.
(d) Screw the pressure cap of the expansion tank.
(e) Start the engine and warm up it or make the fan running at high speed.
(f) Stop the engine and wait until the engine coolant cools down.
(g) Inspect whether the coolant level in the expansion tank is in the specified position.
Add the coolant to the specified position as necessary.
Note
It is unnecessary to bleed air as air in the cooling system can be automatically
05B discharged through the expansion tank.
 Vehicle Service - Replacement 05B-39

Replacing the Brake Fluid

Danger
Do not splash the brake fluid onto the paint or the skin surface, otherwise you should
clean it up.

1. Add some brake fluid to the oil cup.

Brake fluid: DOT-3 or DOT-4 synthetic brake
fluid

Danger 05B

Never splash the brake fluid on the surface of

the paint or skin, otherwise clean with water
fpwx05B0055
immediately.

2. Bleed air for the master brake cylinder.

(a) Loosen the pipe connector nuts and
connectors from the master brake cylinder.
Tool: 10mm wrench

Note
If the master brake cylinder has been dismantled
fpwx05B0056 or the oil cup is empty, it is necessary to bleed
air in the master brake cylinder.

(b) Compress the brake pedal several time and

hold a while.

fpwx05B0057

(c) Block the hole with a finger from the outside

and release the brake pedal.
(d) Repeat (b) and (c) for 3 or 4 times until the
air in the master brake cylinder is fully bled.

fpwx05B0058
 05B-40 Vehicle Service - Replacement

3. Bleed air for the brake line.

(a) Connect the rubber hose to the bleed screw
of the rear brake cylinder.
(18±3N•m)
(b) Quickly press the brake pedal several times,
hold it in position and then loosen the bleed
screw.
(c) Tighten the bleed screw when the outflow of
the brake fluid reduces, and release the brake
pedal.
05B Torque: 18±3N•m
(d) Repeat (b) and (c) until the air of the brake
fluid is fully bled.
fpwx05B0059

(e) Connect the rubber hose to the exhaust screw

of the brake caliper.
(f) Compress the brake pedal several time and
hold a while, and then loosen the exhaust
(18±3N•m)
screw.
(g) Tighten the bleed screw when the outflow of
the brake fluid reduces, and release the brake
pedal.
Torque: 18±3N•m
(h) Repeat (f) and (g) until the air of the brake
fluid is fully bled.
(i) Repeat the above steps until the air of the
fpwx05B0060 brake fluid is fully bled.
Note
Air bleed order for the brake line: rear left - rear
right - front right - front left

4. Inspect the fluid level of the oil cup.

(a) Inspect the brake fluid level, and add the fluid
as necessary. Brake fluid: DOT3 or DOT4
brake fluid

fpwx05B0061
 Vehicle Service - Replacement 05B-41

Replacing the Transmission Lubricant

1. Unscrew the oil drain plug of the bottom
of the transmission, drain the transmission
(25±3N•m)
oil, and then tighten the oil drain plug.
Torque: 25±3 N•m
Tool: T55

Note
fpwx05B0062
• Ensure the vent plug is unblocked, then 05B
unscrew the oil drain plug before draining
the oil. Please drain the oil when the
engine is hot, so that the transmission oil
can be drained as much as possible.
• When draining the transmission oil, please
collect the oil with the special container
and dispose it as specified.

2. Unscrew the filler plug, fill the

transmission oil and then tighten the filler
plug.
Torque: 25±3 N•m
Tool: T55
Note
(25±3N•m)
fpwx05B0063 • Filling quantity is1.3L.
• Transmission oil: GL-4 85W/90 for above
-10℃, or GL-4 75W/90 for below -10℃ .
Note
For gasoline engine and transmission, lubricant
should be properly used, which will ensure their
good operation and service life. Users should
also notice that the oil of different origins, brands
and specifications can not be mixed, as chemical
reactions between different types of oils will
affect the operation of the gasoline engine. Never
use the oil which is not specified, especially for
the imported oil.
• When inspecting the oil level, make sure
the vehicle must be on a level surface and
the oil level should not be lower 5mm than
the lower end of the filler plug.
 05B-42 Vehicle Service - Replacement

Replacing the Gear Oil of the Front Final Drive

1. Precautions (Refer to Chapter 34 Transaxle and Drive Shaft - Rear axle assembly,
Caution)
2. Lift the vehicle.
3. Drain the rear axle gear oil.
(a) Release the air plug.

05B

fpwx05B0064

(b) Loosen the oil drain plug with a wrench.

Tool: 24mm wrench
(c) Drain the gear oil completely.

fpwx05B0065

(d) Use a socket to tighten the oil drain plug.

Tool：24mm wrench
Torque: 25±3N•m

(25±3N·m)

fpwx05B0066
 Vehicle Service - Replacement 05B-43

(e) Unscrew the filler bolt of the finial drive and

then fill gear oil of the final drive through its
filling hole.
Gear oil: GL-5 85W/90 Filling quantity:
about 1.2L
Tool: 24mm wrench
Note
fpwx05B0067
Only use the gear oil of the front final drive
authorized by BAIC. 05B

(f) Replace the filler bolt gasket, tighten the filler

bolt and clean oil stains.
(25±3N·m) Torque: 25±3N•m

fpwx05B0068

4. Inspect the bolt connection for oil leakage.

5. Put down the vehicle.
 05B-44 Vehicle Service - Replacement

05B
 Index
Symbol Both high beams OFF (Lighting
System)..........................................04 - 212
(Accessory Power Supply).............04 - 309 Both Low Beam OFF (Lighting
(Electric Door Lock).......................04 - 352 System)..........................................04 - 204
(EPS Electric Power Steering Both reverse lights OFF (Lighting
System)..........................................04 - 333 System)..........................................04 - 263
(Horn).............................................04 - 314
(Instrument cluster)........................04 - 337 C
(lighting system).............................04 - 193
Capturing data (Engine Control
A System)............................................04 - 29
Car Door..........................................02 - 33
A/C system.......................................03 - 24 cautions for operation (General Principles
ABS out of work (Anti-lock Braking of Maintenance Operation)................01 - 8
System)..........................................04 - 377 Checking..................................0505B - 6, 6
Air Exhaust.................................0203 - 8, 9 checking and tightening the chassis bolts
Air intake....................................0203 - 5, 8 with the specified torque
Airbag warning light always ON (Airbag (Checking).....................................05B - 17
System)..........................................04 - 164 Checking and tightening the chassis bolts
Airbag warning light OFF (Airbag with the specified torque
System)..........................................04 - 166 (Checking)........................................05 - 18
All brake lights OFF (Lighting checking exhaust system
System)..........................................04 - 255 (Checking).....................................05B - 27
All electric door windows out of work (Electric Checking exhaust system
Door Windows)...............................04 - 328 (Checking)........................................05 - 28
Anti-lock Braking System...............04 - 363 checking the accessory belt
(Checking).....................................05B - 15
B Checking the accessory belt
Bad Radio Reception.....................04 - 304 (Checking)........................................05 - 16
Basic inspection (Electric Door Checking the battery
Lock)..............................................04 - 353 (Checking)...............................0505B - 7, 7
Basic Inspection (Electric checking the brake disc, brake drum and
Windows).......................................04 - 324 brake lining (Checking)..................05B - 25
Basic inspection (Engine Control Checking the brake disc, brake drum and
System)............................................04 - 14 brake lining (Checking)....................05 - 26
Basic inspection (Heating Ventilation and Air checking the braking system
Conditioning)..........................04 - 169, 170 (Checking).....................................05B - 24
Basic inspection (Lighting Checking the braking system
System)..........................................04 - 194 (Checking)........................................05 - 25
Basic inspection (Sound System)...04 - 299 checking the components of the engine
Basic inspection (Wipers and compartment (Checking)...............05B - 14
Washers)........................................04 - 283 Checking the components of the engine
compartment (Checking).................05 - 13

A-1-
checking the coolant level of the reservoir Clutch.....................................0203 - 23, 22
(Checking).....................................05B - 28 Cold starting is difficult and the vehicle
Checking the door stopper, lock and hinge vibrates (engine control system)....04 - 139
(Checking)...........................0505B - 11, 11 Component diagram (Lighting
checking the electrical system System)..........................................04 - 195
(Checking).......................................05B - 6 Component diagram (Sound
Checking the electrical system system)..........................................04 - 298
(Checking)..........................................05 - 6 Component diagrams (Accessory Power
checking the front headlight Supply)...........................................04 - 309
(Checking).....................................05B - 18 Component diagrams (Anti-lock Braking
Checking the front headlight System)..........................................04 - 365
(Checking)........................................05 - 19 Component diagrams (Electric Door
checking the front windscreen guide groove Windows).......................................04 - 323
(Checking).....................................05B - 13 Component Diagrams (Engine Control
checking the oil level of the engine System)..............................................04 - 5
(Checking)...........................0505B - 29, 29 Component diagrams (Horn).........04 - 314
Checking the parking brake and brake pedal Component diagrams (Instrument
(Checking)........................................05 - 10 cluster)...........................................04 - 337
Checking the Parking brake and brake pedal Component diagrams (Wipers and
(Checking).....................................05B - 10 Washers)........................................04 - 282
checking the seat belt (Checking)....05B - 8 Cooling.....................................0203 - 9, 10
Checking the seat belt (Checking).....05 - 8
checking the steering tie rod knob and dust D
shield (Checking)...........................05B - 16
Data flow sheet, motion test (engine control
Checking the steering tie rod knob and dust
system)............................................04 - 32
shield (Checking).............................05 - 17
diagnosing the diagnostic trouble code
checking the suspension ball joint and dust
(DTC) (Engine Control System).......04 - 45
shield (Checking)...........................05B - 23
Diagnosis...........................................02 - 1
Checking the suspension ball joint and dust
Diagnostic System (Engine Control
shield (Checking).............................05 - 24
System)............................................04 - 25
checking the suspension components
Diagnostic Test for Engine Symptoms
(Checking).....................................05B - 22
(Engine Control System)................04 - 129
Checking the suspension components
Diagnostic trouble code (DTC) chart
(Checking)........................................05 - 23
(Anti-lock Braking System).............04 - 366
Checking the timing belt (Checking).05 - 14
Diagnostic trouble code table (Engine
checking the vehicle bottom
Control System)...............................04 - 38
(Checking).....................................05B - 21
Door Lock.........................................02 - 32
Checking the vehicle bottom
Door/ Engine Cover.........................03 - 28
(Checking)........................................05 - 22
Driving Brake.........................0203 - 18, 18
checking tires (Checking)..............05B - 26
Checking tires (Checking)................05 - 27
E
checking wipers and washing equipment
(Checking).....................................05B - 19 ECM terminal layout (Engine Control
Checking wipers and washing equipment System)............................................04 - 15
(Checking)........................................05 - 20 electric power steering (EPS) out of work
Cigar lighter out of work (Accessory Power (Electric Power Steering (EPS) System
Supply)...........................................04 - 311 )......................................................04 - 333
Circuit detection procedure (How to Electric Windows............................04 - 322
troubleshoot the vehicle)..................01 - 26

A-2-
Engine cannot Start but Rotate (Engine Fuel gauge fault / fuel level alarm indicator
Control System).............................04 - 135 OFF or always ON (Instrument
Engine Control System......020304 - 2, 1, 1 Cluster)..........................................04 - 344
Engine Mechanism....................0203 - 6, 4 Functions of air conditioning system failure
Engine stalling in the cold state (at (Heating Ventilation and Air
idling).............................................04 - 151 Conditioning)..................................04 - 173
Excessive Idling (Engine Control
System)..........................................04 - 148 G
Exhaust Control System............0203 - 4, 3
General Principles of Maintenance
Operation...........................................01 - 8
F
glossary index (Index)......................01 - 32
Fail-safe chart (Engine Control
System)............................................04 - 30 H
Fault symptom table (Anti-lock Braking
Heating Ventilation and Air
System)..........................................04 - 369
Conditioning.....................................02 - 25
Fault symptom table (Electric Door
Heating ventilation and air conditioning
Lock)..............................................04 - 354
(Heating Ventilation and Air
Fault Symptom Table (Electric Door
Conditioning)..................................04 - 168
Windows).......................................04 - 326
High or low power supply voltage
Fault symptom table (Engine Control
(Anti-locking Braking System)........04 - 371
System)..........................................04 - 127
Horn always sounding (Horn)........04 - 320
Fault symptom table (Heating Ventilation
Horn out of work (Horn).................04 - 316
and Air Conditioning).....................04 - 171
How to analyze faults (Engine Control
Fault symptom table (Horn)...........04 - 315
System)..............................................04 - 8
Fault Symptom Table (Instrument
How to troubleshoot the vehicle..01 - 17, 32
Cluster)..........................................04 - 338
How to Use the Manual......................01 - 1
Fault symptom table (Lighting
System)..........................................04 - 196
I
Fault symptom table (Multimedia)...04 - 300
Fault system table (Accessory Power Identification Information....................01 - 6
Supply)...........................................04 - 310 Ignition.............................................03 - 12
Fault system table (Wipers and Instrument Panel/ Instrument...........02 - 30
Washers)........................................04 - 284 Interior/Exterior Trims.......................03 - 29
Front A/C not cooling (Heating Ventilation Intermittent Fault (Engine Control
and Air Conditioning).....................04 - 186 System)............................................04 - 11
Front blower out of work (Heating Ventilation
and Air Conditioning).....................04 - 177 L
Front door lock fastener failure (Electric Door
license plate light OFF (Lighting
Lock)..............................................04 - 355
System)..........................................04 - 278
Front fog light always ON (Lighting
Lighting System...............................03 - 26
System)..........................................04 - 222
Low oil pressure indicator OFF/ always ON
Front fog light OFF (Lighting
(Instrument Cluster).......................04 - 348
System)..........................................04 - 217
Lubrication.............................0203 - 10, 11
Front interior light OFF (Lighting
System)..........................................04 - 268
M
Front Suspension...................0203 - 12, 14
Fuel............................................0203 - 3, 2 Maintenance data (A/C System)......03 - 24
Maintenance data (Clutch)...............03 - 22
Maintenance data (Cooling).............03 - 10

A-3-
Maintenance data (Driving Brake)....03 - 18 P0201/P0202/P0203/P0204/P0261/P0267
/P0270/P0264/P0262/P0268/P0271/P0265 (Diagnosing
Maintenance data (Engine Control the diagnostic trouble code) (Engine Control System) (继
System)..............................................03 - 1 续)
Maintenance data (Engine (Diagnosing the diagnostic trouble code)
Mechanism).......................................03 - 4 (Engine Control System)..................04 - 98
Maintenance Data (Front P0324/P0325 (Diagnosing the diagnostic
Suspension).....................................03 - 14 trouble code) (Engine Control
Maintenance data (Fuel)....................03 - 2 System)............................................04 - 76
Maintenance data (Ignition).............03 - 12 P0335/P0336/P0373/P1336 (Diagnosing the
Maintenance data (Starting and diagnostic trouble code (DTC)) (Engine
Charging).........................................03 - 13 Control System)...............................04 - 79
Maintenance data (Transaxle and Drive P0341/P0017/P0016/P0014/P0011/P0365
Shaft)...............................................03 - 17 /P0340 (Diagnosing the diagnostic trouble
Maintenance data (Transmission)....03 - 20 code (DTC)) (Engine Control
Maintenance data (Wheels and System)............................................04 - 86
Tires)................................................03 - 16 P0351/P0352/P0353/P0354/P2300/P2306
/P2309/P2303/P2301/P2307/P2310/P2304
N /P0301/P0303/P0304/P0302/P0313/P0300
No communication between KT600 /P0318 (Diagnosis) (Engine Control
intelligent diagnosis instrument and ECM System)..........................................04 - 110
(Engine Control System)................04 - 132 P0405-EGR / P1404-EGR / P0402-EGR /
P0404-EGR (Diagnosing the diagnostic
O trouble code (DTC)) (Engine Control
System)..........................................04 - 120
One of the Reverse Lights OFF (Lighting P0443/P0444/P0458/P0459 (Diagnosing the
System)..........................................04 - 261 diagnostic trouble code (DTC)) (Engine
Overview (How to troubleshoot the Control System).............................04 - 104
vehicle).............................................01 - 17 P0691/P0692 (Diagnosing the diagnostic
Overview (How to Use the Manual)....01 - 1 trouble code (DTC)) (Engine Control
System)............................................04 - 93
P P1167/P1171/P0131/P0132/P0133/P0134
P0037/P0038/P0140/P0141/P0136/P0137 /P0135 (Diagnosing the diagnostic trouble
/P0138/P0420 (Diagnosing the Diagnostic code (DTC)) (Engine Control
Trouble Code (DTC)) (Engine Control System)............................................04 - 62
System)............................................04 - 69 P2009/P2010 (Diagnosing the diagnostic
P0105/P0106/P0107/P0108 (Diagnosing the trouble code (DTC)) (Engine Control
diagnostic trouble code (DTC)) (Engine System)..........................................04 - 117
Control System)...............................04 - 45 Parking Brake.........................0203 - 20, 19
P0112/P0113 (Diagnosing the diagnostic Parking brake indicator OFF/ always ON
trouble code (DTC)) (Engine Control (Instrument Cluster).......................04 - 350
System)............................................04 - 50 Poor accelerating and performance (Engine
P0117/P0118 (Diagnosing the diagnostic Control System).............................04 - 159
trouble code (DTC)) (Engine Control Poor radio sound quality
System)............................................04 - 55 (Multimedia)...................................04 - 305
P0122/P0123 (Diagnosing the diagnostic Precautions (Airbag System).........04 - 163
trouble code (DTC)) (Engine Control Precautions (Anti-lock Braking
System)............................................04 - 59 System)..........................................04 - 363
P0201/P0202/P0203/P0204/P0261/P0267 Precautions (Electric Door Lock)....04 - 352
/P0270/P0264/P0262/P0268/P0271/P0265

A-4-
Precautions (Electric Door reading and clearing DTCs (Engine Control
Windows).......................................04 - 322 System)............................................04 - 27
Precautions (Engine Control Rear Evaporator Blower Failure (Heating
System)..............................................04 - 1 Ventilation and Air Conditioning)....04 - 182
Precautions (Heating Ventilation and Air Rear fog light always ON (Light
Conditioning)..................................04 - 168 System)..........................................04 - 230
Precautions (Lighting System).......04 - 193 Rear fog light off (Light System)....04 - 233
Precautions (Service Rear fog light off (Lighting
Schedule)................................0505B - 1, 1 System)..........................................04 - 226
Precautions (Sound System).........04 - 297 Rear slide door lock fastener failure (Electric
Precautions (Wipersand Washers).04 - 281 Door Lock).....................................04 - 360
Precheck (Anti-lock Braking Rear Suspension...................0203 - 13, 15
System)..........................................04 - 370 Replacement.......................0505B - 30, 30
Preparation (Air Exhaust)...................02 - 8 replacing the air filter element
Preparation (Air Intake)......................02 - 5 (Replacement)...............................05B - 30
Preparation (Car Door)....................02 - 33 Replacing the air filter element
Preparation (Clutch).........................02 - 23 (Replacement).................................05 - 30
Preparation (Cooling).........................02 - 9 Replacing the brake fluid
Preparation (Door Lock)...................02 - 32 (Replacement).....................0505B - 40, 39
Preparation (Driving Brake).............02 - 18 Replacing the coolant
Preparation (Engine Control System).02 - 2 (Replacement).....................0505B - 38, 37
Preparation (Engine Mechanism)......02 - 6 Replacing the engine oil
Preparation (Exhaust Control (Replacement).....................0505B - 31, 31
System)..............................................02 - 4 replacing the fuel filter assembly
Preparation (Front Suspension).......02 - 12 (Replacement)...............................05B - 36
Preparation (Fuel)..............................02 - 3 Replacing the fuel filter assembly
Preparation (Heating Ventilation and Air (Replacement).................................05 - 37
Conditioning)....................................02 - 25 replacing the gear oil of the front final drive
Preparation (Instrument/Instrument (Replacement)...............................05B - 42
Panel)...............................................02 - 30 Replacing the gear oil of the front final drive
Preparation (Lubrication).................02 - 10 (Replacement).................................05 - 43
Preparation (Parking Brake).......02 - 20, 34 Replacing the oil filter
Preparation (Rear Suspension).......02 - 13 (Replacement).....................0505B - 33, 33
Preparation (Seat Belt)....................02 - 26 Replacing the Spark Plug (4G69)
Preparation (Seats)..........................02 - 31 (Replacement)...............................05B - 35
Preparation (Starting and Replacing the spark plug (LJ465)
Charging).........................................02 - 11 (Replacement).................................05 - 35
Preparation (Steering Gear).............02 - 24 Replacing the transmission lubricant
Preparation (Transaxle and Drive (Replacement).....................0505B - 42, 41
Shaft)...............................................02 - 15
Preparation (Transmission)..............02 - 21 S
Preparation (Wheels and Tires).......02 - 14
Seat Belt................................0203 - 26, 25
Preparation (Windshield / Window /
Seats......................................0203 - 31, 27
Rearview Mirror)..............................02 - 28
serial number (SN) (Identification
preparation(Diagnosis).......................02 - 1
information)........................................01 - 7
Preparation(Wipers and Washers)....02 - 27
Service and cycle under normal conditions
(Service Schedule)..................0505B - 3, 3
R
Service Schedule....................0505B - 1, 1
Radio out of work (Multimedia)......04 - 301

A-5-
Single high beam OFF (Lighting Transmission..........................0203 - 21, 20
System)..........................................04 - 209 Turning lights & danger warning light OFF
single low beam OFF (Lighting (Lighting System)...........................04 - 244
System)..........................................04 - 201 Turning lights OFF (danger warning light
Slow response, retarded acceleration and normal) (Lighting System)..............04 - 238
acceleration imbalance (Engine Control
System)..........................................04 - 155 U
Sound System................................04 - 297
Unstable Idling (Speed Fluctuation) (Engine
Speaker out of work (Multimedia)...04 - 306
Control System).............................04 - 143
Speedometer fault (Instrument
cluster)...........................................04 - 340
V
Starting and Charging............0203 - 11, 13
Steering Gear........................0203 - 24, 23 Vehicle Control System....................02 - 34
Supplemental restraint system Vehicle identification number (VIN)
(Supplemental Restraint System)...04 - 163 (Identification Information).................01 - 6
Vehicle lift and support locations (General
T Principles of Maintenance
Operation)........................................01 - 16
Tachometer fault (Instrument
Cluster)..........................................04 - 342
W
Tail light OFF (Lighting System).....04 - 274
Torque requirement (Air Exhaust)......03 - 9 Washers out of work (Wipers and
Torque requirement (Air Intake).........03 - 8 Washers)........................................04 - 294
Torque requirement (Door/ Engine Water temperature gauge fault (Instrument
cover)...............................................03 - 28 Cluster)..........................................04 - 346
Torque requirement (Exhaust Control wheel speed sensor signal fault (Anti-lock
System)..............................................03 - 3 Braking System).............................04 - 374
Torque requirement (Interior/Exterior Wheel speed sensor wiring fault (Anti-lock
Trims)...............................................03 - 29 Braking System).............................04 - 372
Torque requirement (Light System)...03 - 26 Wheels and Tires...................0203 - 14, 16
Torque requirement (Lubrication).....03 - 11 Width light OFF (Lighting System)..04 - 270
Torque requirement (Parking Windshield / Window / Rearview
brake)...............................................03 - 19 Mirror................................................02 - 28
Torque requirement (Rear Wipers and Washers............0204 - 27, 281
Suspension).....................................03 - 15 Wipers at the high-speed mode out of work
Torque requirement (Seat Belt)........03 - 25 (Wipers and Washers)...................04 - 292
Torque requirement (Seats).............03 - 27 Wipers at the low-speed mode out of work
Torque requirement (Steering (Wipers and Washers)...................04 - 290
Gear)................................................03 - 23 Wipers out of work (Wipers and
Transaxle and Drive Shaft......0203 - 15, 17 Washers)........................................04 - 286

A-6-