Mg5 ap32 service diagnosis and measurement manual p5

Tài liệu sửa chữa xe MG5 model A32, cung cấp các thông tin cần thiết cho việc sửa chữa được nhanh chóng, hiệu quả, chính xác.

Service Service Diagnosis Diagnosis and Diagnosis and and Measurement Measurement

For relevant information about product brands, part numbers or special tools mentioned in this manual, we recommendcontacting SAIC Motor Passenger Vehicle Co

SAIC Motor Passenger Vehicle Co

All Rights Reserved

Information is due at December, 2021

Without prior written approval from SAIC Motor Passenger Vehicle Co., no part of the manual shall be reproduced,stored in retrieval system or transmitted in any form or by any means (including but not limited to electronic, mechanical,photocopy and recording) The statement above applies to all texts, illustrations and tables

General Information 1

Diagnoses Strategy 1

Description on Diagnostic Procedure 1

Diagnostic System Check - Vehicle 2

Basic Methods of Circuit Inspection 3

Diagnosis Repair Verification 8

Vibration 9

Vibration Analysis 9

Vibration Diagnostic Aid 10

Noise 13

Air/Wind Noise 13

Tracing Powder or Chalk Test 13

Air Pressure Test 14

Soap Suds or Bubble Test 14

Squeak and Click 15

Water Leak 16

Water Leak Test Preparation 16

Dust Leaks 17

Water Hose Test 17

Air Hose Test 18

Precaution Information 19

General Precautions 19

Safety Precautions 20

Environmental Precautions 21

Fuel Handling Precautions 23

Electrical Precautions 24

SRS Precautions 25

Air Conditioning System Precautions 28

Phenomena-based Diagnosis 31

Engine 31

Engine mechanical system-NSE 1.5L 31

Engine Compression Pressure Test 31

Cylinder Leakage Test 32

Oil Consumption Diagnosis 33

Oil Pressure Diagnosis and Test 34

Symptom Table 35

Engine Backfire 38

Engine Blowout 40

Abnormal Exhaust (with white fume) 41

Abnormal Exhaust (with blue fume) 42

Abnormal Exhaust (with black fume) 43

Engine Misfire, and No Internal Noise 44

Engine Misfire, with Abnormal Noise from Lower Internal Part of Engine 46

Engine Misfire, with Abnormal Noise from Valve Train 47

Engine Misfire With Coolant Consumption 48

Engine Misfire With Excessive Oil Consumption 49

Engine Noise at Start-up, But Only Lasting Few Seconds 50

Noise from Upper Part of Engine, Regardless of Engine Speed 51

Noise from Lower Part of Engine, Regardless of Engine Speed 53

Noise from Engine under Load 54

Engine Unable to Start - Crankshaft Stuck 55

Ingress of Coolant into Combustion Chamber 56

Ingress of Coolant into Engine Oil 57

Oil Leakage Diagnosis 58

Crankcase Ventilation System Check/Diagnosis 60

Diagnosis on Drive Belt Chirp, Squeal and Whine 61

Diagnosis on Drive Belt Rumbling and Vibration 62

Diagnosis on Drive Belt Falling-off and Excessive Wear 63

Diagnosis on Drive Belt Tensioner 65

Engine Cooling System 66

Symptom Table 66

Cooling Fan Running All the Time 67

Cooling Fan Not Working Well / Not Working 68

Overheated Engine 70

Coolant Leakage 72

Engine Cannot Reach Normal Operating Temperature 73

Engine Fuel & Management 74

Symptom Table 74

Fuel Pump Does Not Work 75

Low Fuel System Pressure (Low Pressure Oil Circuit) 76

Low Fuel System Pressure (High Pressure Oil Circuit) 77

Low Fuel System Pressure Maintenance 78

High Fuel System Pressure 79

Intense Smell of Fuel 80

Surge During Driving 81

EVAP System Leakage 82

EVAP System Blockage 83

Fuel System Pressure Test 84

Engine Electrical System-NSE 1.5L 85

Symptom Table 85

Alternator Noise 87

Starter Motor Unable to Run 88

Starter Motor Unable to Stop Running 89

Starter Motor Running Slowly 90

Abnormal Starter Motor Noise 91

Engine Unable to Start at Normal Speed 92

Hard Cold Start 93

Hard Warm Start 94

Normal Start, but Idle Speed Unstable at All Times 95

Normal Start, with Unstable Idle Speed and Flameout Under Partial Load 96

Normal Start, With High Idle Speed 97

Engine Speed Not Increase or Flameout in Acceleration, Hard Acceleration, Slow Acceleration Response, Weak Acceleration and Poor Performance 98

Engine Running Unstable 99

Easy to Flameout at Start-off 100

Engine Chugs During Driving 101

Engine Manifold & Exhaust-NSE 1.5L 103

Engine Intake System Vacuum Test 103

Symptom Table 104

Air Intake Leakage 105

Intake Blockage 106

Blocked Exhaust System 107

Exhaust System Leakage 108

Transmission 109

Transmission-CVT 109

Road Test 109

Harness/Connector Check 111

Solenoid Valve and Sensor Check 112

Check and Confirmation 115

Symptom Table 116

Vehicle Unable to Run or Slip 120

Static Shift Delay 122

Engine Start Failure 123

Torque Converter Cannot be Locked 129

Kick-down Failure 130

Unable to Enter Manual\Economy Mode 131

Fluid Leak 132

Shift Impact 136

Vibration or Noise 138

HVAC System 140

HVAC System 140

Leak Testing 140

A/C Compressor Oil Diagnosis 142

Odour Diagnosis 144

Symptom Table 145

A/C Cooling Capacity Insufficient 147

A/C Heating Capacity Insufficient 150

Compressor Does Not Work 151

Compressor Cannot Automatically Stop 152

Compressor Clutch Intermittent Engagement 153

Abnormal Refrigerant Pressure 154

A/C Condensed Water Leakage 155

Air Outlet Insufficient 156

Blower Inoperative 157

Noise 158

Steering System 159

Steering System 159

Symptom Table 159

Shaking When Braking 160

Steering Wheel off Centre Position 161

Vehicle Off-track 162

Steering Wheel Vibration During Steering 163

Poor Steering Wheel Return-to-Centre 164

Noises from Steering Gear 165

Abnormal Sounds from Steering Column 166

Hard Steering 167

Suspension System 168

Front Suspension 168

Check and Confirmation 168

Abnormal Wear in Tyres 174

Hard Steering 175

Poor Steering Wheel Return-to-Centre 176

Vehicle Swings During Driving 177

Vehicle Jitters During Driving 178

Acceleration Deviation 179

Abnormal Noises During Driving 180

Rear Suspension 181

Symptom Table 181

Vehicle Off-track 182

Abnormal Sound 183

Body Shake 184

Body Tilted 185

Braking System 186

Brake 186

Symptom Table 186

Braking Deviation 188

Brake Judder 189

Brake Pedal Downward Rapidly 190

Brake Pedal Low or Soft 191

Braked Locked and ABS Starts to Work When Brake Is Slightly Depressed 192

Excessive Brake Pedal Travel 193

Step On the Pedal and Hold, the Pedal Goes Down Slowly 194

Brake Dragging 195

Poor Effect of Brake Boost 196

Abnormal Sound With Braking System 197

Park Brake 198

Symptom Table 198

Poor Effect of Parking Brake 199

Driveline/Axle 200

Driveline/Axle 200

Symptom Table 200

Abnormal Sound in Axle Shaft 201

Clunks When Accelerating from Coasting in Neutral 202

Vibration During High Speed Driving 203

Sway or Vibration During Acceleration 204

Click Noise In Turns 205

Interior Fitting 206

Seats 206

Check and Confirmation 206

Symptom Table 207

Power Seat Adjustment (Seat Height, Forward/Backward Adjustment, Seat Back Inclination) Failure 208

Seat Heater Failure (No Heating or Abnormal Heating Temperature) 210

Exterior Fitting 211

Fixed Windows 211

Check and Confirmation 211

Symptom Table 212

Heated Rear Window Failure 213

Mirrors 215

Symptom Table 215

Exterior Rearview Mirror Glasses Unable to Adjust 216

Exterior Rearview Mirrors Cannot be Heated 218

The outside rearview mirror cannot be folded 220

Roof 222

Check and Confirmation 222

Symptom Table 224

Sunroof Inoperative 225

Sunroof Anti-pinch Function Inoperative 227

Sunroof Leak 228

Sunroof Unable to Fully Open/Close (by sliding and tilting) 229

Abnormal Sound of Sunroof Glass/Motor 230

Wipers and Washer 231

Check and Confirmation 231

Symptom Table 232

Wiper Fails to Operate 233

Wiper Fails to Wipe Clean 235

Wiper Fails to Stop 236

Abnormal Sound/Shake During Wiper Movement 238

Wiper Fails to Return to Original Position 239

Front Washer Sprays Insufficiently 240

Front Washer Inoperative 241

Lighting Systems 243

Lighting 243

Check and Confirmation 243

Symptom Table 244

Front Reading Lamp Failure 245

Rear Reading Lamp Failure 246

Vanity Mirror Lamp Failure 247

Luggage Compartment Lamp Failure 248

Lamps 249

Check and Confirmation 249

Symptom Table 250

Low Beam Not Illuminated 252

Low Beam Always On 253

High Beam Not Illuminated 255

High Beam Always On 257

Headlamp Leveling Failure 258

Front Side Lamp Not Illuminated 260

Front Side Lamp Always On 261

Front Direction Indicator Lamp Not Illuminated 262

Daytime Running Lamp Not Illuminated 263

The all climate light doesn't work 264

The all climate lamp is always on 266

Hazard Warning Lamp Not Illuminated 268

All Hazard Warning Lamps Keep Flashing 269

Reverse Lamp Not Illuminated 270

Reverse Lamp Always On 271

Rear Side Lamp Not Illuminated 272

Rear Width Lamp Always On 273

Rear Direction Indicator Lamp Not Illuminated 274

License Plate Lamp Not Illuminated 275

License Plate Lamp Always On 277

Brake Lamp Not Illuminated 279

Brake Lamp Always On 280

Door System 281

Door System 281

Symptom Table 281

Check and Confirmation 282

Single Power Window Inoperative 283

Window Regulator Stuck 286

Body System 287

Horn 287

Check and Confirmation 287

Symptom Table 288

Horn Keeps Honking 289

Horn Inoperative 290

Check and Confirmation 293

Symptom Table 294

All Functions of Remote Key Fail 295

Fuel Filler Door Release Failure 296

Single Door Opening from Inside Failure 297

Single Door Opening from Outside Failure 298

Trunk Lid Release Failure (Manual Open Failure) 301

Trunk Lid Release Failure (Remote Key Open Failure) 303

Alarm System 305

Check and Confirmation 305

Symptom Table 306

Door Ajar Warning Function Unavailable During Locking 307

IMMO Triggered, Horn Inoperative 309

Seat Belts 310

Symptom Table 310

Seat Belt Failure (Unable to retract/pull out or limited pull-out) 311

Park Assistant System 312

Symptom Table 312

No Warning Given for Obstacle When Parking 313

No Obstacle Alarm When Parking 314

Inaccurate Measured Distance from the Obstacle When Parking 315

Rear View Camera Not Display 316

One of the Panoramic Cameras Not Display 318

Panoramic Camera Not Display 319

Incorrect Image Stitching of Panoramic Camera 321

Passive Entry and Passive Start 322

Check and Confirmation 322

Symptom Table 323

Keyless Unlocking Function Failure 325

Keyless Entry Coverage Abnormal 326

Keyless Locking Function Failure 327

Vehicle cannot start 328

Vehicle cannot stall 329 Vehicle Cannot Stall Without Long

Symptom Table 332

Failure to Start Up, Function Failure 333

No or Unclear Sound During Multimedia Player or Radio Working (with normal display, operation, multimedia playing or radio station search) 334

Poor or No Radio Signal Received and Radio Station Search Unavailable 335

Poor or No GPS Signal Received 336

Display Error or No Display 337

Bluetooth Connection Failure 338

The Other Side Cannot Hear You When Talking on the On-board Telephone 339

Cannot Hear Each Other When Talking on the On-board Telephone 340

Displays and Gages 341

Symptom Table 341

Instrument Pack Blank Screen / All Indicators Off 342

Speedometer Indicating Improperly 343

Tachometer Indicating Improperly 345

Fuel Gauge Indicating Improperly 346

Water Temperature Meter Indicating Improperly 347

Power and Signal 348

Data Communication 348

Check and Confirmation 348

Symptom Table 349

No Power Supplied to Scan Tool 350

Scan Tool Cannot Communicate with Bus 351

Cigar Lighter and Power Outlet 352

Check and Confirmation 352

Symptom Table 353

No Power to Power Socket 354

DTC Troubleshooting 355

Troubleshooting Process Description 355

Troubleshooting Process Description 355

Integrity Inspection of CAN Network 356

Integrity Inspection of Diagnosis CAN Network 356

Integrity Inspection of HS CAN Network 357

FTB List 358

FTB List 358

ECM-1.5L-CN5 361

DTC Category 361

DTC Category 361

DTC List 366

List 366

Diagnostic Information and Procedure 373

P000A, P0011, P0012, P0016 and P0026 373

P000B, P0014, P0015, P0017 and P0027 375

P0030, P0031, P0032 and P0053 377

P0036, P0037, P0038 and P0054 379

P0076 and P0077 381

P0079 and P0080 383

P0105, P0106, P0107 and P0108 385

P0111, P0112 and P0113 387

P0116, P0117 and P0118 389

P0122, P0123 and P2135 391

P0130, P0131, P0132, P0133, P0134, P2195 and P2196 393

P0136, P0137, P0138, P0140, P2270 and P2271 396

P0171 and P0172 398

P0197 and P0198 400

P0201, P0261 and P0262 402

P0202, P0264 and P0265 404

P0203, P0267 and P0268 406

P0204, P0270 and P0271 408

P0219 410

P0222, P0223 and P2135 412

P025A, P025C and P025D 414

P0300, P0301, P0302, P0303 and P0304 416

P0313 419

P0318 420

P0322 421

P0325, P0327 and P0328 423

P0341 425

P0366 427

P0420 429

P0462 and P0463 430

P0480, P0691 and P0692 432

P0481, P0693 and P0694 434

P0500 436

P0504 437

P0506 and P0507 439

P0557 and P0558 441

P0560, P0562 and P0563 443

P0564, P0568 and P0579 444

P0578 446

P0601 and P0606 448

P0604 and P0605 449

P0615, P0616 and P0617 450

P0615, P0616, P0617, P26E5, P26E6, P26F0 and P26F1 452

P0630 454

P0645, P0646 and P0647 455

P0686 and P0690 457

P0686 and P0690 459

P0700 461

P0830 462

P0851 and P0852 463

P1427, P1428, P1429 and P1479 464

P1523, P1683 and U0151 466

P1545 468

P1559, P1564 and P1579 470

P1610, P1613 and P1614 471

P2101 and P2106 472

P2127, P2128, P2132, P2133, P2138 and P2140 474

P300B 476

U0073 477

U0101 478

U0126 480

U0129 481

U0131 482

U0140 483

U0155 484

U0164 485

U0245 486

U0301 487

U1264 489

TCM-CVT-TS11 490

DTC List 490

List - CVT 490

Diagnostic Information and Procedure 495

P0563, P0702, U1562 and U1563 495

P0613 497

P0657, P0658 and P0659 498

P06B1 and P06B2 500

P06B4 and P06B5 502

P071A, P071D and P2805 509

P0730 511

P0746, P0747, P0960, P0961, P0962, P0963 and P2783 512

P0776, P0777, P0964, P0965, P0966 and P0967 515

P077B 518

P0791 and P0792 519

P0811 and P081E 521

P0841, P0842 and P0843 522

P0846, P0847 and P0848 524

P084F 526

P0968, P0969, P0970, P0971 and P0B0C 527

P16F3 529

P1801 and P1802 530

P1804 and P1805 532

P1846 and P1848 534

P1855 536

P215C, P2745 and P2746 537

P2669, P2670 and P2671 539

P2684, P2685 and P2686 541

P2714, P2715, P2718, P2719, P2720 and P2721 543

P2723, P2724, P2727, P2728, P2729 and P2730 545

P27E1 547

U0073 549

U0100, U16BE, U16C9, U16FB, U17A1, U17AA, U17BA, U17C3, U17DF, U178E, U19B1, U19C1, U19D1, U1AA3, U1AC1 and U1AF1 551

U0122, U1714, U177D, U1785, U17C7, U17E9, U17FC, U182A, U18F9, U1948, U194A and U1953 553

U0140 and U1B40 555

U0155, U17F3 and U1B41 557

HVAC 559

DTC List 559

List 559

Diagnostic Information and Procedure 560

B1411 560

B1419 562

B1431 564

B1472 572

B14E7 574

B14F1 and B14F2 576

U0073 577

U0100 578

U0140 579

U0146 580

U0155 582

U0245 584

U1562 and U1563 586

U2001 and U2002 587

EPS-Bosch 588

DTC List 588

List 588

Diagnostic Information and Procedure 591

C1661, C1662, C1663, C1664 and C1665 591

C16B1 593

C16B2 595

C16B3 597

C16B4 599

C16B5 601

U0073 603

U0100 and U0401 605

U0122, U0416, U177D, U1785, U17E9, U1951 and U1953 607

U0140, U0447 and U1B40 609

U17A9, U17AD, U17F1 and U191B 611

U0155 and U1B41 613

U0423 615

U1264 and U17FD 617

U1562 and U1563 619

SCS-EPB 621

DTC List 621

List 621

Diagnostic Information and Procedure 630

C0001 and C0003 630

C0002 and C0004 632

C0010 and C0011 634

C0014 and C0015 636

C0018 and C0019 638

C001C and C001D 640

C0020 642

C0030, C0033, C0036 and C0039 644

C0031 645

C0037 647

C0034 649

C003A 651

C0040 653

C0044, C0046 and C1117 655

C0047 and C1110 657

C0049 659

C0051 661

C0061, C0062 and C0063 663

C006B 665

C0089 666

C100A 667

C100B 668

C101C 669

C110B 670

C1112 and C1113 671

C1114 672

C1115 673

C1116 675

C1122 677

C1801 679

C1802 681

C1803 and C1804 683

C1805 685

C1806 687

C1807 and C1812 689

C1808 691

C1810, C1811 and C1813 692

C1815 694

C1816 696

C1817 and C1830 698

C1A41 700

U0073 701

U0074 702

U0100, U0401 and U17DF 703

U0101, U0402 and U16C7 705

U0103, U0404, U169D 707

U0126 and U0428 709

U0131, U0420 711

U0140, U1A6A and U1B18 713

U0146, U0447, U1844, U19F1 and U1B40 715

U0151 and U0452 717

U0155 and U1A63 719

U0245, U18F2 721 U0264, U169D, U16C9, U16F9, U1766,

U1767, U1769, U1794, U17AF, U17C3,

U17F1, U17F2, U181C, U18F2, U18F6,

U19B1, U19F5 and U1AC1 723

U0416 725

U1560, U1562 and U1563 726

U2001, U2100, U2107, U3000 and U0300 728

BCM 729

DTC List 729

List 729

Diagnostic Information and Procedure 736

B1040 736

B1043 738

B1045 740

B1049 742

B104A 744

B104B 746

B10AC and B10AD 748

B1053 749

B1055 and B1078 751

B1059 753

B105A and B105B 754

B105C 756

B105D 758

B1066 760

B10AC and B10AD 761

B1071 763

B1072 765

B1077 767

B1081 769

B1083 771

B1084 773

B1091 775

B10A1, B10A2 and B10A3 777

B10A6 778

B10AC and B10AD 780

B10B1 782

B10B2 784

B10B5 785

B1101 786

B1103 788

B1105 790

B1109 792

B1155 802

B1156 804

B1157 806

B115C 808

B115D 810

B1160 812

B1161 814

B1162 816

B1163 818

B1165 820

B1166 822

B1167 and B1169 824

B116A 826

B11A0 828

B11C0 830

B11C1, B11C2 and B11C3 832

B11C9 834

B1701, B1702 and B1705 836

B1706, B1707 and B1708 838

B1754 840

B1756 842

B1758 844

B1759 846

B1B00, B1B01, U1562 and U1563 848

B1B05 and B1B06 850

B1B80 and B1B81 852

C1A00 853

C1A01 854

C1A02, C1A03, C1A04 and C1A05 855

P0564 and P0589 857

P071A 860

P0826 861

P0955 863

P1900, P1901 and U1008 865

P1910 867

P1911 869

U0073, U0074 and U0075 871

U0100 873

U0101 875

U010F 877

U0120 879

U0121 880

U0155 886

U0169 888

U0198 889

U0222 891

U0245 892

U1500 and U1501 894

U2000, U2001, U2002 and U2004 895

U2020 and U2021 896

SDM 897

DTC List 897

List 897

Diagnostic Information and Procedure 900

B0001 900

B0010 902

B0020 904

B0021 906

B0028 908

B0029 910

B0050 912

B0052 914

B0079 916

B007A 918

B0090 920

B0091 922

B0095 924

B0096 926

B1920, B1924, B1932, B1933, B1934, B193E and B193F 928

B193C 929

U0073 930

U0100 932

U0122 934

U0128 936

U0131 938

U0140 940

U0146 942

U0155 944

U1562 and U1563 946

AVM 948

DTC List 948

List 948

Diagnostic Information and Procedure 949

B1AE0 949

B1AE1 951

B1AE2 953

B1AE3 955

U0073 957

U0100 958

U0122 959

U0126 960

U0140 961

U0155 962

U0245 963

U1562 and U1563 964

U2000 965

IPK 966

DTC List 966

List 966

Diagnostic Information and Procedure 968

B1200 968

B1201 970

B1220 and B1221 971

B1752 973

B1753 and B1764 975

B175A and B175B 977

B1955 and B1956 979

B1957 981

B1958 982

B195A 983

P0564, P0589 and P1A25 984

P0955 986

U0073 988

U0100 989

U0101 990

U0121 991

U0131 992

U0140 993

U0146 994

U0151 995

U0159 996

U0236 997

U0245 999

U1023 1000

U1500 1001

U1562 and U1563 1002

U2001 1004

FICM-CR 1005

DTC List 1005

List 1005

Diagnostic Information and Procedure 1007

B1A01, B1A02, B1A05, B1A06, B1A07, B1A08, B1A3E, B1A3F and B1A4B 1007

B1A10 1009

B1A20 1011

B1A21 1013

B1A22 1015

B1A23 1017

B1A24 1019

B1A26 1021

B1A43 and B1A44 1023

U0073 1025

U010F 1026

U0121 1027

U0131 1028

U0140 1029

U0155 1030

U1031 1031

U1562、U1563 1032

RDA 1033

DTC List 1033

List 1033

Diagnostic Information and Procedure 1034

B19A0 1034

B19A1 1035

B19A2 1036

B19A6 1037

B19A7 1038

B19A8 1039

B19B0 1040

B19B1 1042

U0073 1043

U0074 1044

U0100 1046

U0122 1047

U0131 1048

U0140 1049

U0146 1050

U0155 1051

U0245 1052

U1562 and U1563 1053

U2000, U2002 and U2004 1055

Appendix 1057

Real-time Display 1057

Real-time Display Parameter List - CVT 1066

HVAC 1071

Real-time Display Parameter List 1071

EPS-Bosch 1073

Real-time Display Parameter List - Bosch 1073

SCS 1075

Real-time Display Parameter List SCS-EPB 1075

BCM 1078

Real-time Display Parameter List 1078

SDM 1090

Real-time Display Parameter List 1090

AVM 1093

Real-time Display Parameter List 1093

IPK 1094

Real-time Display Parameter List 1094

FICM 1095

Real-time Display Parameter List 1095

RDA 1096

Real-time Display Parameter List 1096

Glossary List 1097

Diagnoses Strategy

Description on Diagnostic Procedure

1 Understand and confirm the problem reported by the

customer: The first step of this procedure is to know

as much as possible about the customer Working

conditions while the failure occurs, frequency of the

failure and service history shall be inquired The

technician shall have a good knowledge of the normal

working condition of the system prior to confirming any

customer claimed problem For details, please refer to

User Manual or Service Manual

2 The driving condition meets the design requirement: this

condition exists during normal driving The condition

described by the customer may be a normal condition

Under the same condition as described by the customer,

compare with the similar vehicles which are in normal

operation Explain the check results and system

operation conditions to the customer

3 Preliminary Check: Perform an overall visual check

Review the service history Check for any abnormal

noise or smell Collect the DTC information so as to

make effective repair

4 Perform a diagnostic system check - vehicle, confirm if

the system works normally This can help the technician

to take systematic diagnostic actions and determine

which diagnostic category shall be performed Refer to

"Diagnostic System Check - Vehicle"

5 Check and refer to the relevant service technicalinformation

6 Diagnostic category:

a Current DTC: Diagnose according to the designatedDTC so as to make a effective repair Refer to "DTCTroubleshooting"

b Symptom - No DTC is detected: Select aproper symptom diagnosis procedure Refer to "Phenomena-based Diagnosis"

c Intermittent DTC: Intermittent failure is a failure thatdoes not occur consecutively, is difficult to reappearand only occurs when the relevant conditionsare met Normally, intermittent failures arecaused by electrical connector and harness failure,component failure, electromagnetic/radio frequencyinterference, driving condition or aftermarket add-onequipments

7 Find out the root cause of the failure, then make repairand verify the result: after finding out the root cause ofthe failure, repair it and verify if the problem is solved in

a proper way Confirm that the DTC or symptom hasbeen solved, it may be required to perform a road test

on the vehicle

8 Recheck the problem reported by the customer: If thetechnician fails to find out the cause of the problem,

recheck as necessary Reconfirm the problem claimed

by the customer The problem could be an intermittent

failure, or a normal condition

9 Confirm that the customer claimed problem has been

solved, and clear the relevant DTC

Diagnostic System Check - Vehicle

Perform the diagnostic procedure in this manual on conditionthat all functions below conform to the design conventions

• 12 V battery is fully charged, cable is clean and secure

• The fuse is not blown

• The ground circuit in the area where the customer claimsrepair is clean, firm and in proper position

• All the connections/connectors of the faulty section are

in place

• No after-sale add-on equipments affect the systemoperation

• The scan tool is powered on

Diagnostic System Check

1 Confirm customer claimed problems - understand andconfirm customer claimed problems Check the visiblesystem parts for apparent damage or failure which hascaused the problem

2 Check the service technical information - read therelevant maintenance manual, maintenance bulletininformation

3 Mechanical system malfunction - Confirm if this symptom

is not caused by malfunction of the mechanical systemonly

4 Vehicle energize check - Place the START/STOP Switch in

"ON" position, and confirm the vehicle is powered on

5 Control module - use the scan tool, confirm there's atleast one control module can communicate with the scantool; confirm that the control module communicationDTCs is not set; confirm whether the vehicle has controlmodule that cannot communicate

6 Control module internal performance failure - Confirmthat DTCs for the control module internal hardwareperformance failure have not been set

7 Power mode failure - Confirm that no DTCs for controlmodule power mode have been set at the moment

8 Engine startup and run verification - Confirm enginestartup and run

9 Check for other DTCs - Confirm that no other DTCsare set

10 Emission related check/maintenance failure - If the vehiclehas recently been checked and maintained, confirmthat customer claimed problem is irrelevant to thecheck/maintenance

Basic Methods of Circuit Inspection

The basic method of circuit inspection contains the following

basic inspection information Using this information along

with the diagnostic procedures will identify the cause of the

• Inspection of Short to Ground

• Inspection of Short to Voltage

• Inspection of Intermittent Failure or Poor Contact

Voltage Measurement

The following procedure measures the voltage at a selected

point in a circuit

1 Disconnect the electrical harness connector for the

circuit being tested, if necessary

2 Enable the circuit and/or system being tested Use the

following methods:

a With the engine off, place the START/STOP Switch in

"ON" position

b Start the engine

c Connect the circuit and/or system with the "Forced

Output" function of a scan tool

d Turn ON the switch for the circuit and/or system

being tested

3 Select V (AC) or V (DC) position on a digital multimeter

4 Connect the positive lead of the digital multimeter to the

point of the circuit to be tested

5 Connect the negative lead of the digital multimeter to

a good ground

6 The digital multimeter displays the voltage measured at

that point

Voltage Drop Measurement

The following procedures are used to determine the voltage

drop between two points

1 Set the digital multimeter at V (DC) position

2 Connect the positive lead of the digital multimeter to a

point to be tested in the circuit

3 Connect the negative lead of the digital multimeter to

another point to be tested in the circuit

4 Power the circuit on

5 The digital multimeter will display the voltage dropbetween two points

Frequency Measurement

Apply a oscilloscope or other special frequency meter tomeasure the frequency The following part only introducesthe measuring method with a digital multimeter

The following procedure is available to determine thefrequency of a signal

1 Power the circuit on

2 Set the digital multimeter at V (AC) position

3 Connect the positive lead of the DMM to the circuit to

be tested

4 Connect the negative lead of the digital multimeter to

a good ground

5 Set the digital multimeter to Hz

6 The DMM will display the frequency measured

Inspection of Ground and Low Level Reference Voltage Circuit

When a digital multimeter is applied, there are many vehicleconditions affecting the conductivity test of ground and lowlevel voltage reference circuit If these conditions have notbeen met, testing the ground on a good circuit or the low levelreference voltage circuit may fail It may result in extendeddiagnostic time and incorrect component replacement.During the test, any current flowing through the ground or lowlevel reference voltage circuit may result in the conductivityreading deviation of the digital multimeter, or displaying areading higher than when there is no current flowing through.When performing conductivity test for ground or low levelreference voltage circuit, compared with any other groundreference points, the good ground or low level referencevoltage circuit test is most likely to fail at the vehicle batterynegative terminal The optimum ground test points should

be at the control module housing (if the control module has

a metal housing and is grounded), the door pillar lock catch(if connected with metal), lower part of the instrument panelmetal framework, the engine cylinder block or body groundstud (positions other than that at the battery negative cableconnection)

The typical ground or low level reference circuit conductivityreadings of a digital multimeter shall be 100Ω with theSTART/STOP Switch in "ON" position, and drop to 15～25Ωwith the START/STOP Switch in "OFF" position The readingwill drop below 10Ω after 30～40s and will drop below 5Ωafter 60s Once the vehicle completely enters into suspendstate (normally 3 - 10 minutes), the reading will drop below0.3Ω

The following conditions may be required to ensure the

conductivity readings of ground or low level reference voltage

circuit run valid

• Place the START/STOP Switch in "OFF" position

• The key is pulled out of the START/STOP Switch (no

remote door lock and remote starter equipped)

• Retained accessory power is turned off (after the

START/STOP Switch is turned off, open the driver door

and then close it)

• Charging rate of the battery charger is set to 2 A or lower

• Scan tool has no communication with any vehicle control

module (sometimes it is required to disconnect it from

the DLC)

• All Doors Closed

• Headlamp goes off (auto headlamp disabled)

• Any Delay Lamp Off

• HVAC System Off

• Any accessories which can work when the START/STOP

Use a digital multimeter

1 Set the digital multimeter in Ω position

2 Disconnect the connectors on both ends of suspected

circuit

3 Connect a lead of the digital multimeter to one end of

the circuit to be tested

4 Connect the other lead of the digital multimeter to the

other end of the circuit

5 If the digital multimeter displays little resistance or no

resistance, it indicates that the circuit conductivity is

good

Inspection of Short to Ground

The following procedures are used to test if the circuit is short

to ground

Take the use of a digital multimeter as an example:

1 Disconnect the connectors on both ends of suspected

circuit

2 Set the digital multimeter in Ω position

3 Connect a lead of the digital multimeter to one end of

5 If the resistance shown on the digital multimeter is notinfinite, it indicates that the circuit is short to ground.Fuse Powering Several Loads:

1 Review the system schematic and locate the fuse that isfused

2 Disconnect all connectors or switches between the fuseand each load

3 Connect the digital multimeter with both terminals of thefuse (ensure the fuse is energized)

If the digital multimeter shows a voltage when connectingthe first connector or switch, it indicates that the circuit

to the first connector or switch is short-circuited

4 Close the connector or switch one by one, till the digitalmultimeter shows a voltage, so as to find the shortedcircuit

Test the circuit for short to battery

The following procedure available to test a circuit for short tobattery

1 Disconnect the connectors on both ends of suspectedcircuit

2 Set the digital multimeter at V (DC) position

3 Connect the positive of the digital multimeter to one end

of the circuit to be tested

4 Connect the negative of the digital multimeter to a goodground

5 Place the START/STOP Switch in "ON" position, and haveall accessories operating

6 If the measured voltage value is higher than 1 V, itindicates that the circuit is short to battery

Inspection of Intermittent Failure and Poor Contact

Conditions Causing Intermittent Failure

Many intermittent open circuit and short circuit failure arearising from the movement of harness/connector due tovibration, engine torque, jerk/rough road etc If the failureseems arising from vibration, harness operations may berequired to reappear the failure reported by the customer.Circuit operation can consist of a wide variety of actions,including:

• Wiggling the harness

• Disconnecting a connector and reconnecting it

• Squeezing the mechanical connection of a connector

• Pull the harness or wire to judge if the wire inside the

All these actions should be performed with some goal in mind.

For example, with the scan tool connected, shake the wire

to find the failures in respect of control module input signal

It is possible to observe data information of corresponding

components via "Real-time Display"

Another method is: connect, shut off and shift related

connector and harness with "Force Output" component of

the scan tool and observe component operations Keep

the engine running, move related connector and harness,

meanwhile monitor the engine operation If the movement

of harness or connector affects the indicated data, the

component/system operation or the engine operation,

then inspect the harness/connector and repair them when

necessary

It may be required to load the vehicle to reappear the failure

It is available to use heavy load, floor jack, jack support, lift etc

Above methods can be used to control suspension or frame

so as to reappear the failure This method can effectively find

those harnesses which are too short, the connector on the

harness may be pulled open if the harness is too short, which

may result in poor contact

Certainly, using the senses of sight, smell, and hearing while

manipulating the circuit can provide good results as well

Sometimes, the target of reappearing failure cannot be

achieved only by circuit operation In this case, it is required

to expose the suspected circuit under other conditions

simultaneously when operating the harness This kind of

conditions include high humidity condition and extreme high

or low temperature condition

The following introduces how to expose the circuit under this

kind of conditions

• High Temperature Conditions

If the failure customer reported seems to have

connection with overheat, then heat gun can be applied

to simulate the failure condition Use the heat gun to

heat up the suspected area or component

Operate the harness under high temperature while

monitoring the scan tool or digital multimeter to find

out the failure

The high temperature condition may be achieved simply

by road test at normal operating temperature

If without a heat gun, consider this option to enhance

your diagnosis Whereas, this method is inconvenient for

related operations of components (such as harnesses)

• Low Temperature Conditions

Place a fan in the front of vehicle according to the failure

nature, and park the vehicle in the shade, then the desired

effect can be achieved

Once the vehicle, component, or harness hasbeen sufficiently cooled, manipulate the harness orcomponents in an effort to duplicate the concern.Duplicating Failure Conditions

1 If none of the previous tests are successful, attempt

to duplicate and/or capture the failure conditions

2 "Freeze Frame" data includes conditions appearing inthe setting of DTC (if applicable)

Inspection of Intermittent Failure and Poor Contact

If a fault does not occur at current time, but DTC historyrecord shows that it has occurred once, then it may be anintermittent fault Intermittent failure may also be the reasonwhy customer reported to repair, but the symptom cannot bereappeared

Most intermittent failures are caused by electrical connection

or wiring failure Check the following items:

• Wiring broken inside the insulation

• Positive terminal and negative terminal of connector is inpoor contact or not

• Poor terminal to wire connection - some conditionswhich fall under this description are poor crimps, poorsolder joints, crimping over the wire insulation ratherthan the wire itself, and corrosion in the wire to terminalcontact area, etc

• Piercing or destroying insulating layer may result inmoisture into wire then cause corrosion Conductor

in insulating layer may corrode, but it cannot be foundapparently Search if there are inflatable and hardenedwires in suspected circuit

• Wire stuck, cut or insulation layer abrasion may result inintermittent open circuit or short circuit (since exposedpart contacts with other harness or component onvehicle)

• Wire may contact with hot or exhaust components

• Reappear the failure to verify the failure customerreported

• Learn the testing procedures of intermittent open circuit,high resistance, short to ground and short to voltagefailure

1 Check terminal for fretting wearSome intermittent failures may be caused by wire terminalcontact corrosion When there is a minor movementbetween electrical connectors, contact corrosion isformed by insulating accumulation - oxidation wearfragment When oxidation wear fragment accumulated atelectrical connector to a certain degree, the resistance

at connector shall increase A minor movement from 10

to 100 micron on contact surface will result in contact

corrosion Imagine a piece of paper with a thickness of

100 micron, it turns out the contact corrosion is too

small to be seen Vibration as well as expansion and

contraction are the main causes for contact corrosion

movement Vehicle vibration and wide temperature

fluctuation are also sources for contact corrosion

movement Tin, copper, nickel and metal surface are easy

to be contact corrosion Contact corrosion is difficult

to be seen, but it seems like a small and black stain on

terminal contact surface In order to prevent corrosion,

disconnect suspected connector and add lubricant at two

sides of connector terminal (insulating lubricating grease)

Then reconnect connector and wipe off excessive

lubricant This may reduce terminal contact additional

resistance caused by terminal contact corrosion

2 Check for a good terminal contact

Before replacing suspicious components, test contact

conditions of terminal on component connector and

in-line connector Mating terminals must be inspected

to ensure good terminal contact Negative and positive

terminal of connector may be in poor connection due

to contamination or deformation Improper connection

of two halves of a connector may cause contamination

Absence or damage of connector seal element, damage

of connector itself or expose of terminal in moisture

or dust may also cause contamination Contamination,

usually in the underhood or underbody connectors,

leads to terminal corrosion, causing an open circuit

or intermittently open circuit Other reasons causing

terminal deformation include: improper connection of

connector two halves or repeated removal and refit of

connector two halves Deformation (often occurs in

contact tab on parent plug) will cause poor contact of

terminal and result in open circuit or intermittent open

circuit failure

3 Test if bus electrical centre terminal is in good contact

Test connector contact according to below procedures:

• Disconnect the connector

• Visually check if connector is contaminated

Contamination may result in a white or green build-up

within the connector body or between terminals This

causes high terminal resistance, intermittent contact,

or an open circuit If there is a sign of contamination

on connector under engine compartment or at vehicle

bottom, it should be replaced entirely: terminal, seal

element and connector body

Follow the procedure below in order to test terminalcontact:

• Remove suspected component

• Visually check if two sides of the connector have a sign

of contamination Avoid contacting with any side of theconnector, since grease on skin may also contaminate theconnector

• Visually check if the connector binding face at wire sidehas defects like disconnection, cracking or others that maycause poor connection of terminal Visually check theconnector at component side, ensure all terminals areconsistent and without damage or deformation

• Insert corresponding adapter into harness connector totest suspected circuit

4 Control Module/Component Voltage and GroundPoor power supply or ground contact will result in manydifferent symptoms

• Test power supply circuit of all control modules On manyvehicles, a control module is powered by several circuits.Other component in the system may have individual supplyvoltage circuit, which also needs to be tested Checkconnector between battery and module/component, fuseconnection and any intermediate junction Test lamp ordigital multimeter can display whether it has voltage ornot, but cannot be used to test if the circuit can transmit

a large enough current Operate the component to testthe circuit for capacity of transmitting enough current

• Test all control module ground and system ground circuit

A control module may has several ground circuits Othercomponent in the system may have individual ground,which may also need to be tested Ensure that ground

at all grounding points are clean and firmly connected

If possible, check connections on component and starconnector Operate the component to test the circuit forcapacity of transmitting enough current

5 Temperature SensitivityOnce component/connection reaches normal workingtemperature, intermittent failure may occur The failuremay only occur where component/connection is cold orhot

If corresponding "Freeze Frame", "DTC" or other data

of vehicle data recorder exists, it would be helpful fordetermination of this kind intermittent failure

• Underhood/engine generated heat

• Heat generated due to poor contact or large electrical

load

• Vehicle overload, for example, towing a vehicle, etc

If the intermittent failure occurs in cold, review if the

data is related to the following:

• Low ambient temperatures - In extremely low

temperatures, ice may form in a connection or

component Inspect for water intrusion

• The condition only occurs at cold start

• After vehicle warm up, this failure disappears

Information provided by customer is helpful for

determining if the failure pertains to temperature-related

type

If you suspect that temperature may be the premise of

intermittent failure, try to reappear the failure condition

6 Electromagnetic interference and electrical noise

Some electrical components/circuits are sensitive to

electromagnetic interference (EMI) or other types of

electrical noise Check for the following conditions:

• Improper harness wiring, too close with high voltage/high

current devices (e.g secondary ignition component,

motor, alternator etc.) - such components will induce

electrical noise in the circuit and interfere its normal

operation

• Electrical system interference caused by the failure of relay,

solenoid valve or switch which is driven by control module

- all these may result in intense surge Normally, the failure

will occur when faulty part works

• Improper refit of non-genuine after sales accessories

(e.g.car lamp, interphone, amplifier, motor, remote

starter, warning system, onboard telephone etc.) - these

accessories may generate interference during operation,

but no failure occurs when they are not in use

• Test for an open diode across the A/C compressor clutch

and for other open diodes Some relays may have clamping

diode

• Alternator may bring AC noise in the electrical system

7 Incorrect Control Module

• Control modules needs to be reprogrammed only under

the following situations: a new control module is fitted

during the service; control module from other vehicles

is fitted; upgrade software/calibration files specific to this

vehicle are released

• Ensure that control module is equipped with correct

standardization or configuration files If an incorrect

programming is found, apply the latest version ofsoftware/calibration files to reprogramme the controlmodule

Diagnosis Repair Verification

1 Refit all components or connectors removed or replaced

during diagnosis

2 Perform any adjustment, programming, or setup

procedures that are required when a component or

module is removed or replaced

3 Clear the DTC

4 Place the START/STOP Switch in OFF position, and turn

off all vehicle systems for at most 2 minutes

5 In case the repair is related with the DTC, reproduce

the operation conditions for running the DTC and

apply "Frozen Failure State/Failure Record" (if applied)

in order to confirm not to set the DTC If the DTC

resets, or another DTC is present, refer to the "DTC

Troubleshooting" and perform the appropriate diagnostic

procedure

6 In case the repair is related with the symptom, reproduce

the occurrence conditions of failure claimed by customer

to verify repair effects In case problems claimed by

customer reoccur or another symptom occurs, return

to "Phenomena-based Diagnosis" and perform related

symptom diagnosis procedure

Vibration Analysis

Noise and Vibration from Vehicle

Mechanical vibration is usually accompanied by noise and

roughness They occur simultaneously and dependently

Vehicle vibration sources mainly include: engine, transmission,

drive system, rough roads, etc Sound is generated by object

vibration, thus noise and vibration will not occur individually

in most occasions Vehicle is a system composed by excitation

source (the source generating noise and vibration, e.g

engine, transmission, etc.), vibration transmitter (consisting ofsuspension system and connector) and noise emitters (body).Vehicle noise sources mainly include: engine, exhaust system,wind noise, tyre noise and any other moving parts possiblymaking noise

Symptom Table

According to the most important features felt or heardwhen the customer's vibration problem occurs, refer to the

"Vibration Analysis" table in the following symptom tables

Vibration Symptoms that are Felt

TypicalFrequencyRange

Vehicle Speed SensitiveStill occurs during coast down inNEUTRAL

Tyres and Wheels

Vehicle Speed SensitiveAffected by torque/load or steeringinput

Propeller Shaft orSuspension

Shudder

Can sometimes be seen

or felt in the steeringwheel, seat or console

Related terminologies:

shimmy, wobble, waddle,shudder, hop

5～20Hz

Vehicle Speed SensitiveStill occurs during coast down inNEUTRAL

Tyres and Wheels

Vehicle Speed SensitiveAffected by torque/load or steeringinput

Propeller Shaft orSuspension

Roughness Similar to the feeling of

Vehicle Speed SensitiveAffected by torque/load or steeringinput

Propeller Shaft orSuspension

Surge

Similar to the feeling

of holding an electricrazor May be felt inthe hands through thesteering wheel, in thefeet through the floor, or

in the seat of the pants

50～100Hz

Vehicle Speed SensitiveAffected by torque/load or steeringinput

Propeller Shaft orSuspension

Tingling

May produce a "pins andneedles" sensation or mayput hands or feet "tosleep"

frequency range that can

be felt

Higher than100Hz

Vibration Symptoms that are Heard

TypicalFrequencyRange

Vehicle Speed SensitiveStill occurs during coast down inNEUTRAL

Tyres and Wheels

Boom

Usually heard as aninterior noise similar tothe noise of a bowling ballrolling down an alley, deepthunder, or a bass drum

• Relatedterminologies -droning, growling,moaning, roaring,rumbling, humming

Propeller Shaft orSuspension

Vehicle Speed SensitiveAffected by torque/load or steeringinput

Propeller Shaft orSuspension

Moaning or

Droning

Similar to the sound ofbumblebee or blowinginto the bottle neck

• Relatedterminologies -humming, droningand resonance

• May be accompanied

vibration, e.g surge

60～120Hz

Vehicle Speed SensitiveAffected by torque/load or steeringinput

Propeller Shaft orSuspension

Howl Similar to the sound of

Whine

Similar to the sound

of mosquitoes, turbineengines, or vacuumcleaners

300～500Hz Vehicle Speed Sensitive

Affected by torque/load

Transmission

Vibration Diagnostic Aid

Vibration Intermittent or Not Duplicated

If you have not been able to duplicate the vibration concern

or have only been able to duplicate the concern intermittently,

review the following information

Most vibration concerns that cannot be duplicated are due

Specific Conditions Affects the Condition

Consider the following conditions which may not have beenpresent while attempts were made to duplicate the vibrationconcern Attempt to obtain more specific information fromthe customer as to the exact conditions that are presentwhen they experience the vibration which they are concerned

Most attempts to duplicate a vibration concern are made after

the vehicle has been driven to the repair facility and perhaps

even sat inside the building for a time; the vehicle may be

too warm to detect the concern during duplication efforts

The opposite could also occur; perhaps the vehicle has sat

out in the cold for a time and fails to reach full operating

temperatures during attempts to duplicate the concern

Temperature, Ground-Out, Accessory Load

Flat Spots on Tyres

Tyres which have sat and been cool for a time can develop flat

spots

Irregular Wear on Tyre Treads

Tyres which have sat and been cool for a time will be stiffer

and any irregular wear conditions will be more noticeable than

they will be once the tyres have warmed and softened

Exhaust System Growth

Exhaust systems may exhibit a ground-out condition when

cool which goes away once the system is hot The opposite

may be true that the exhaust system is fine when cool but

a ground-out condition occurs once the system reaches

operating temperatures

Engine-Driven Accessory Noises

A stethoscopes equipped with a probe can be used as an

additional means to assist in identifying accessories which may

be causing or contributing to a vibration concern

• Belt Whipping - An engine accessory drive belt, or

belts could exhibit a whipping condition if a belt is

deteriorating and deposits are building up on the

underside of the belt

• Loose Mounting Brackets or Component Groundout

-Engine-driven accessories such as a generator, or an air

conditioning compressor could exhibit noise conditions

due to either loose mounting brackets or due to related

components of the system in a ground-out condition

during certain operation of that accessory system

• Cold State or Hot State - Accessories could exhibit noise

conditions when cool which go away once they are fully

warmed-up, or the opposite may be true

• Load on an Accessory Component - Accessories could

exhibit a noise condition while under a heavy load

-perhaps when combined with a cool or fully warmed-up

condition

• Bent or Misaligned Pulleys - Bent or mis-aligned pulleys

in one or more engine-driven accessory systems could

contribute to a noise or vibration condition

• Fluid Level in Accessory Systems - Accessories could

exhibit a noise condition due to an abnormal amount of

fluid contained in the system of which the accessory is apart

For example:

– An improper refrigerant level or an excessiverefrigerant oil could produce noises or possiblyvibrations in the air conditioning system

– Incorrect Fluid Type in Accessory Systems Accessories could exhibit a noise condition due tothe incorrect type of fluid contained in the system ofwhich the accessory is a part

-Vehicle Payload

The vibration concern may only occur when the vehicle iscarrying heavy payloads or towing a trailer The vehicle mayhave been empty during duplication efforts

Heavy Payload

The vehicle may have been empty during attempts toduplicate the vibration concern, but the customer may actuallyexperience the vibration concern while the vehicle is carrying

The customer may only experience the vibration on aparticular roadway Perhaps the roadway is overly crowned

or is very bumpy or rough

Vibration Duplicated, Component Not Identified Aftermarket Add-On Accessories

Aftermarket accessories which have been added to thevehicle can actually transmit and magnify inherent componentrotational frequencies, if the accessories were not fittedcorrectly

An accessory should be fitted in such a way that it is isolatedfrom becoming a possible transfer path into the rest of thevehicle by way of vibration isolation For example, if a set

of pedals has been fitted improperly and they are sensitive

to a particular frequency of a rotating component, the pedalscould begin to respond to the frequency and actually create

a disturbance once the amplitude of the frequency reaches ahigh enough point, probably at a higher vehicle speed

If the same set of pedals were fitted properly- isolated

properly- the transfer path would be removed and the

disturbance would no longer be present

Vibration Duplicated, Difficult to Isolate/Balance

Component

If you have duplicated the vibration concern but have had

difficulty in balancing a component or isolating a component,

refer to the following information

Most vibration concerns are corrected or eliminated through

correcting excessive runout of a component, correcting

balance of a component, or isolating a component which has

come into abnormal contact with another object/component

Components which can generate a lot of energy and are

experiencing excessive runout, imbalance, or ground-out can

produce a vibration with a strong enough amplitude that

the vibration can transmit to components which are closely

related This type of a condition is usually related to and

sensitive to torque-load The most likely system that could

exhibit this type of a condition is the driveline

Vibration Duplicated, Appears to be Potential

Operating Characteristic

If both of the following statements are true, then refer to

Service Bulletin for the condition identified If the condition

has already been identified and investigated prior to this

vehicle, and has been determined to be something that is

not truly an operating characteristic or that perhaps is not

design-intent, there will likely be adjustments or corrections

identified which will address the condition

• You carefully followed the steps indicated through

reviewing the Vibration Analysis tables identified and

you have duplicated the vibration concern

• You have come to the conclusion through comparison

with a same model, model year, equally-equipped, known

good vehicle that the customer's concern is a condition

that appears to be a potential operating characteristic of

the vehicle

Air/Wind Noise

To analyze a reported wind noise condition, test the driving

vehicle to determine the origin of the noise

Drive on normal flat straight road along four directions

respectively: north, south, east and west This area must be

of low traffic flow or low environmental noise to eliminate

outside interference to test

Caution: The noise may be caused by one main leakage

source and one or more secondary leakage source.If only

on leakage source is repaired, the noise can be reduced

only but not completely eliminated.

Drive the vehicle at the speed that the noise is most noticeable,

or until the noise is heard Maintain safe and legal speeds

Many of the water leak diagnosis tests are also used for the

wind noise diagnosis

Most wind noise is caused either by leaking seals or by

misaligned body surfaces

You can diagnose the following types of wind noise with the

aid of proper Chassis Ear or Leak Detector

• Wind whistle

• Wind roar

• Wind rush

When moving at highway speeds, air pressure inside the vehicle

becomes greater than the air pressure outside When a leak

occurs, the escaping air causes a hiss or a wind whistle

Wind roar occurs when air passes over or through an opening

between the 2 body surfaces To correct the condition, adjust

the alignment to the body panel

Wind rush occurs when air presses over the vehicle's body, and

is related to the aerodynamics of the vehicle Wind whistle and

wind roar are eliminable Rule out wind whistle and wind roar

before concluding that the wind noise is due to wind rush

Use the following inspections in order to aid in diagnosing wind

whistle or wind roar:

1 Note the details for wind noise:

• The perceived location

• The location where the noise is the loudest

• The time when noise occurs

• Speed

• The interior fan speed

• The position of the windows

• What the noise sounds like

2 Inspect the vehicle for the possible cause of the wind noise

3 Test drive the vehicle and determine if the wind noise isexternal or internal

4 Perform a visual inspection of the following components:

• Loose fasteners

• Cracked weatherstrips

• Broken welding points

• Sealer and/or adhesive skips

Tracing Powder or Chalk Test

Clean the weatherstrips and the contact surfaces with cleaningsolvent

1 Apply powder or chalk in an unbroken line to thecontact surface of the weatherstrip surrounding theperimeter of the suspected areas

2 Close the panel completely without slamming the panel.Closing the panel completely presses the weatherstripfirmly against the mating surface

3 Inspect the applied line on the weatherstrip Theapplied line is marred where contact is good Acorresponding imprint is on the mating surface

4 Gaps or irregularities in the powder or the chalk line

on the mating surface indicate the area with a poor seal

Air Pressure Test

1 Mask off both the pressure relief valves

2 Close all the windows

3 Turn the vehicles ventilation fan to the on position, with

the selector on high speed and in the defrost mode

4 Unlock and close the door

5 Listen for escaping air along the door and the window

seals with a stethoscope

Soap Suds or Bubble Test

1 Mask off the pressure relief valve

2 Close all the windows and the doors

3 Turn the vehicles ventilation fan to the on position, withthe selector on high speed and in the defrost mode

4 Unlock and close the door

5 Apply the soap solution to the potential leak areas

6 Look for bubbles

Squeak and Click

Caution: The squeak and click are caused by the improper

control of the relative movement between the parts.There

are 4 ways to prevent the squeak and click.

Use proper chassis ear or leak detector for auxiliary diagnosis

• Attach the component that squeaks or clicks securely

• Separate the components that squeak or click to prevent

contact

• Insulate the components that squeak or click

• Insulate uniform friction surfaces to eliminate stick-slip

movement

Water Leak

Water Leak Test Preparation

• This vehicle is designed to operate under normal

environmental conditions

• The design criteria for sealing materials and components

takes into consideration the sealing forces required to

withstand the natural elements These specifications

cannot take into consideration all artificial conditions,

e.g , high pressure car washes

• The water leak test procedure has been correlated to

the natural elements and will determine the ability of a

vehicle to perform under normal operating conditions

• The first step of water leak test is to determine leakage

conditions If the general leak area can be found, the

exact entry point can be isolated using a water hose or

an air hose Some trim panels or components may need

to be removed in order to repair the leak

• If leaks are found around the door, window, truck lid

or liftgate area, this does not necessarily indicate a poor

weatherstrip An adjustment to these areas may resolve

the condition

Water Spray Test Stand Assembly

Icon

5 Cross Fitting, Right Stand Only

6 Pipe to Hose Nipple, Right Stand Only

7 Female Hose Coupling

8 Input Hose, Right Stand Only

15 Hose Quick Connect

16 Pipe to Hose Nipple

17 Pipe

18 Water Pressure Gage, Right Stand Only

19 Full Jet Spray Nozzle

20 Pipe Fitting

Preparation Procedure

1 Assemble water spray stands as shown in the figure

2 Position the stands as shown in the figure

The water spray from the stands should overlap thevehicle as shown

3 Have an assistant inside of the vehicle during the test inorder to locate any leaks

4 The water pressure at the nozzle should maintain a 155kPa for at least 4 minutes

5 In order to check the windscreen, aim the water spray 30degrees down and 45 degrees toward the rear

Aim the water towards the corner of the windshield

6 In order to check the side windows for leaks, position

the water spray test stand towards the centre of the rear

quarter, aiming the water spray 30 degrees down and

45 degrees toward the rear

7 In order to check the rear window, aim the water spray

30 degrees down and 30 degrees toward the front

Dust Leaks

Dust may leak into the vehicle where water will not This

happens particularly in the lower portion of the interior

Forward motion of the vehicle can create a slight vacuum which

pulls air and dust into the vehicle

In order to determine the location of dust leaks, perform the

following steps:

1 Remove the carpet from the floor

2 Remove the carpet from the running board

3 Remove the vibration isolator from the floor

4 Remove the vibration isolator from the running board

5 Drive the vehicle on a dusty road

6 Examine the interior

Dust in the shape of a small cone or slit will usually be found

at the point of leakage

7 Mark the points of leakage

8 Illuminate the lamps on the underside of the floor and

the cowl panel

Caution: Keep the vehicle dark inside in this step.

9 Have an assistant mark any points inside of the vehicle

for any points where the light shines through

• Inspect the weld joints

• Inspect the body mounts

10 Seal any leaks with an air-drying, body-sealing

compound

Water Hose Test

Caution: Use the water hose without nozzle.

1 Have an assistant inside of the vehicle in order to locatethe leak

2 Begin testing at the base of the window or thewindshield

3 Slowly move the hose upward and across the top ofthe vehicle

Air Hose Test

Caution: The air hose test is used only for the

polyurethane adhesive completely solidified.Otherwise,

the sub of the polyurethane adhesive may be damaged

and leakage points may be increased.

1 Using a liquid detergent, diluted with water in a spray

bottle, spray the window at the edges Begin at the

bottom and gradually move up and across the top

2 Have an assistant inside of the vehicle with an air hose

Tip: The compressed air should not exceed 205 kPa (30

Precaution Information

General Precautions

Hazardous Substances

Modern vehicles have many substances or liquids, if handled

improperly, they may pose potential risk to human health and

environment

Warning: Many liquids and other substances used in

vehicles are poisonous and should under no circumstances

be consumed and should, as far as possible, be kept

from contact with the skin These liquids and substances

include acid, antifreeze, brake fluid, fuel, windscreen

washer additives, lubricants, refrigerants and various

adhesives.

Warning: Always read any instructions that accompany,

are printed on the label, or are stamped on components

very carefully Follow the instructions and guideline

carefully in order to avoid damage and personal injury.

Synthetic Rubber

Many O-rings, sealing parts, hoses, flexible pipes and other

similar items which appear to be natural rubber，but in fact,

are made of a kind of synthetic rubber (fluororubber) Under

normal conditions, these substances are safe and do not cause

harm However, these substances may dissolve and produce

highly corrosive fluorinated acid when they are damaged due

to combustion or high temperature

When contacting with skin, these fluorinated acids may cause

severe burns In case of skin contact, please observe the

followings:

• Take away the contaminated clothes immediately

• Wash the injured skin with plenty of cold water or lime

water for 15 - 60 minutes

• Seek medical assistance immediately

If the substance is burning or overheating, handle with great

care and wear protective clothing (seamless industrial gloves,

protective apron, etc.)

After use, clean and handle with the gloves immediately

Lubricating Fluid

Avoid excessive contact with used lubricating fluids, always

follow the health protection precautions

Warning: Avoid excessive skin contact with used engine

oil Used engine oil contains potentially harmful

contaminants which may cause skin cancer or other

serious skin disorders.

Warning: Avoid excessive skin contact with mineral oil.

Mineral oils remove the natural fats from the skin, leading

to dryness, irritation and dermatitis.

Preventive Measures

Always pay attention to the followings:

• Wear protective clothing, including impervious gloveswhen practicable

• Avoid over-exposure or repeated exposure to oils,especially used engine oils

• Do not put oily rags in pockets

• Avoid contaminating clothes (especially the underwear)with oil

• Comprehensive cleaning shall be done on a regularbasis Properly handle the contaminated clothes and oilimpregnated shoes

• Open wounds shall be handled at the earliest possibletime

• Before each operation, apply skin cream to avoid oilcontamination

• Clean with soap and water, make sure all the oilcontaminants are removed (any skin cleaner and nailbrush will be useful)

• After cleaning, apply skin lotion, prepare some woolgrease to compensate natural oil loss of the skin

• Do not wash the skin with petroleum/gasoline, kerosene,diesel, engine oil, diluent or solvent

• If possible, remove the oil contaminant before handling

• In case of skin damage due to imprudence, seekimmediate medical care and follow the medical advice

• If the operation will hurt eyes, wear eye protection (forexample, goggles or face shield) Eye cleaning device shall

be close to the working area

Safety Precautions

Lift

Caution: It is best to use the lift when working under the

vehicle Be sure to hold the wheels with chocks and apply

parking brake.

Always use the recommended jacking points

Ensure that the lift has sufficient load capacity for the weight

to be lifted

Ensure the lift is standing on level ground during the lifting or

jacking work

Apply hand brake and wedges to fix the wheels

Warning: Do not work on or under a vehicle supported

only by a jack.Always support the vehicle on safety stands.

Do not leave tools, lifting equipment and spilt oil, etc around

or in the work area Always keep a clean and tidy work area

Brake Shoes and Pads

Always use the correct gear and brake pads When replacing

brake pads and brake shoes, always replace as complete axle

sets

Brake Hydraulic System

Observe the following procedures when working on the brake

• Fix brake pipes securely with retaining clips and ensure

that the pipe will not contact a potential chafing point

• Containers for containing brake fluid must be kept clean

• Do not store brake fluid in an unsealed container,

otherwise it will absorb moisture in the air, which may

lower its burning point, and in this condition it is likely

to cause danger in its use

• Do not allow brake fluid to be contaminated by mineral

oil, or put new brake fluid in a container which has

previously contained mineral oil

• Do not re-use the brake fluid drained from the brake

system

• Always use clean brake fluid or a recommended

alternative to clean hydraulic components

• After disconnecting brake pipes and hoses, immediately

fit suitable end caps or plugs to prevent the ingress of

Cooling System Caps and Plugs

When the engine is still hot, especially when it is overheated,take particular care when removing expansion tank cap,coolant drain pipe or air bleed screws To avoid the possibility

of burns, you should wait for the engine to cool down beforeremoval

Environmental Precautions

Overview

This section provides general information which can help to

reduce the environmental impacts from the activities carried

out in workshops

Emissions to Air

Many of the activities that are carried out in workshops emit

gases and fumes which contribute to global warming, depletion

of the ozone layer and/or the formation of photochemical

smog at ground level By considering how the workshop

activities are carried out, these gases and fumes can be

minimized, thus reducing the impact on the environment

Exhaust Fumes

Running car engines is an essential part of workshop activities

and it shall be carried out in a well ventilated environment

However, the amount of time engines are running and the

position of the vehicle should be carefully considered at all

times, to reduce the release of poisonous gases and minimize

the inconvenience to people living nearby

Solvents

Some of the cleaning agents used are solvent based and will

evaporate to atmosphere if used improperly, or if cans are

left unsealed All solvent containers should be firmly closed

when not needed and solvent should be used sparingly Suitable

alternative materials may be available to replace some of the

commonly used solvents Similarly, many paints are solvent

based and the spray should be minimized to reduce solvent

emissions

Refrigerant

Discharge and replacement of refrigerant from air conditioning

units should only be carried out by using the correct

equipment

Engine

Always observe the following operations:

• Minimize the unnecessary running of the engine;

• Minimize testing times and check where the exhaust

fumes being blown

Thinners:

• Keep lids on containers of solvents

• Only use the minimum quantity

• Consider alternative materials

• Minimize over-spray when painting

Gas:

• Use the correct equipment for collecting refrigerants

• Don't burn rubbish on site

Water Discharge

Oil, petrol, solvent, acids, hydraulic oil, antifreeze and othersuch substances should never be poured down the drain andevery precaution must be taken to prevent spillage reachingthe drains

Handling of such materials must take place well away from thedrains and preferably in an area with a kerb or wall around it, toprevent discharge into the drain If a spillage occurs, it should

be soaked up immediately Having a spill kit available will makethis easier

PrecautionsAlways observe the following disposal and spillage preventioninstructions

• Never pour anything down a drain without first checkingthat it is environmentally safe to do so, and that it doesnot contravene any local regulations

• Store liquids in a walled area

• Make sure that taps on liquid containers are secure andcannot be accidentally turned on

• Protect bulk storage tanks from vandalism by locking thevalves

• Sealed pipelines are preferred to transfer liquids from onecontainer to another

• Ensure lids are replaced securely on containers

• Have spill kits available near to the spot of storage andhandling of liquids

Spill KitsSpecial materials are available to absorb a number of differentsubstances They can be in granular form, ready to use andbought in convenient containers for storage

PrecautionsAlways observe the following operations:

• Don't pour or spill anything onto the soil or bare ground

• Don't place waste materials on bare ground

Local Issues

A number of environmental issues will be of particular concern

to residents and other neighbors close to the site Thesensitivity of these issues will depend on the distance between

the site and their residences, the layout of the site and amount

of activity carried on at the site

Car alarm testing, panel beating, hammering and other such

noisy activities should, whenever possible, be carried out

indoors with doors and windows shut or as far away from

residential area as possible

Be sensitive to the time when these activities are carried out

and minimize the time of the noisy operation, particularly in

the early morning and late evening

Another local concern will be the smell from the various

materials used Using less solvent, paint and petrol could help

prevent this annoyance

Local residents and other business users will also be concerned

about traffic congestion, noise and exhaust fumes, be sensitive

to these concerns and try to minimize inconvenience from

deliveries and servicing operations

Checklist

Always observe the following operations:

• Identify where the neighbors who are likely to be affected

are situated

• Minimize noise, smells and traffic nuisance

• Prevent waste pollution by disposing the wastes in the

correct container

• Have waste containers emptied regularly

Waste Management

One of the major ways that pollution can be reduced is by the

careful handling, storage and disposal of all waste materials that

occur on sites This means that it is necessary to not only know

what the waste materials are, but also to have the necessary

documentation and to know local regulations that apply

Handling and Storage of Waste

Waste should be stored in a reasonable way as to prevent the

escape of the material to land, water or air

They must also be segregated into different types of waste

e.g oil, metals, batteries, used vehicle components This will

prevent any reaction between different materials and assist in

disposal

Disposal of Waste

Disposal of waste materials must only be to waste carriers who

are authorized to carry those particular waste materials and

have all the necessary documentation The waste carrier is

responsible for ensuring that the waste is taken to the correct

• Refrigerant: collect in special equipment and reuse

• Detergent: safe to pour down the foul drain if diluted

• Paint, thinners: keep separate and deliver to a specialistcontractor for disposal

• Components: send back to supplier for refurbishment,

or disassemble and reuse any suitable parts Dispose theremainder as ordinary waste

• Small parts: reuse any suitable parts, dispose theremainder in the ordinary way

• Metals: can be sold after being classified from generalwaste

• Tyres: keep separate and deliver to a specialistcontractor for disposal

• Packaging: compact as much as possible and dispose inthe ordinary way

• Asbestos material: keep separate and deliver to aspecialist contractor for disposal

• Oily and fuel wastes (e.g rags, used spill kit material):keep separate and deliver to a specialist contractor fordisposal

• Air filters: keep separate and deliver to a specialistcontractor for disposal

• Rubber/plastics: dispose in the ordinary way

• Water pipes: dispose in the ordinary way

• Batteries: keep separate and deliver to a specialistcontractor for disposal

• Airbags - explosives: keep separate and deliver to aspecialist contractor for disposal

• Electrical components: send back to supplier forrefurbishment, or disassemble and reuse any suitableparts Dispose the remainder as ordinary waste

• Catalysts: can be sold after being classified from generalwaste

• Used spill-absorbing material: keep separate and deliver

to a specialist contractor for disposal

Fuel Handling Precautions

Overview

Gasoline vapour is highly flammable and poisonous, which is

readily explosive in confined spaces The vapour is heavier

than air, so it always floats below The vapour can be easily

distributed throughout the workshop with air flow, therefore,

even a small spillage of fuel can be very dangerous

The following information is the basic precautions for handling

fuel safely Matters that may lead to danger and shall not be

neglected are also indicated This information is only a basic

introduction, if you have any question, please consult your local

fireman

When handling or draining the fuel, or removing the fuel

system, always have a fire extinguisher containing foam, carbon

dioxide, gas or powder close at hand Fire extinguishers

should also be located in areas where fuel containers are

stored

Always disconnect the battery before removing or draining the

fuel system

When handling, draining or storing the fuel, or removing the

fuel system, please turn off or remove all the ignition devices;

all the working lamps must be fireproof and leakage-free

Warning: No one should be permitted to repair

components associated with fuel without first having

specialist training.

Warning: Do not remove fuel system components while

the vehicle is over a pit.

Fuel Tank Draining

Fuel tank draining should be carried out in accordance with the

procedure outlined in the Fuel Delivery section of this manual

and observing the following precautions

Warning: Do not remove fuel system components while

the vehicle is over a pit Extraction or draining of fuel

must be carried out in a well ventilated area.

The capacity of the container must be larger than the fuel to

be drained The name of the stored liquid shall be clarified on

the container The liquid shall be stored in a safe area which

meets the local regulations and standards

Removal of Fuel Tank

When fixing the fuel pipe to the outlet of the fuel tank with

a spring steel clip, release the clip before the fuel pipe is

disconnected or the fuel tank is removed By doing so, the

vapour in the fuel tank will not be lit when the clip is released

Additional attention: A warning sign of "Gasoline Vapour" shall

be attached to the fuel tank when it is removed from the

vehicle

Fuel Tank Repair

Do not try to repair a plastic fuel tank If the structure of thefuel tank is damaged, fit a new one

Body Repair

Plastic fuel pipes are especially susceptible to heat It can bemelt down by heat from a long distance, even at a relativelylow temperature

When body repairs involve the use of heat, all fuel pipes nearthe repair area must be removed and the tank outlet must beblocked

Warning: If welding is to be carried out in the vicinity of the fuel tank, the fuel system must be drained and the tank removed before welding commences.

Electrical Precautions

Overview

The following instructions are intended to guarantee the

safety of operators and protect the electrical and electronic

components on the vehicle from damage When necessary,

please refer to the specific precautions described in this

manual

Device

Before starting any test on the vehicle, ensure that the

related test equipments work properly and all harnesses and

connectors are in good state In particular, check the wire and

plug of the operating equipment

Polarity

Do not reverse the battery polarity Always ensure the correct

polarity is connected when testing

High-voltage Circuit

Use insulating pliers to disconnect the alive circuit, do not allow

the exposed wire to contact any components, especially the

ECU Measure voltage of the ignition coil terminal when the

engine is running Special care shall be taken since the terminal

may generate high voltage

Connectors and Harnesses

For electrical components and connectors, the operating

environment in the engine compartment is awfully harsh:

• Before disconnecting and connecting the test equipment,

make sure that the relevant electrical components is dry

and oil-free

• Ensure the disconnected multi-plugs and sensors are

free of oil, coolant or other liquids Contamination may

impair working performance or result in catastrophic

failures

• Do not disconnect the connector by force with tools or

by pulling the harness

• Before disconnecting the connector, ensure that the

locking mechanism is unlocked and in the right position

for reconnection

• Ensure that all the protective devices (cap, insulating

material, etc.) are in good condition Once damaged,

replace it immediately

If any assembly fails:

• Turn off the START/STOP Switch and disconnect the

battery negative

• Remove the assembly, and secure the disconnected

Disconnecting the Battery

Before disconnecting the battery, turn off the alarm system andall the electrical equipments

Caution: To prevent damage to electrical components, always disconnect the battery when working on the vehicle's electrical system The ground lead must be disconnected first and reconnected last.

Caution: Always ensure that battery leads are routed correctly and are not close to any potential chafing points.

Battery Charging

Always ensure that the battery charging area is well ventilated,special care should be taken to keep it away from open flameand spark

Rules

Connect or disconnect other systems after the ignitionsystem is turned off, so as to avoid the surge generated bydisconnecting the "live" connection which may damage theelectronic components

Ensure that hands and working surface are clean and free of oil,swarf, etc Grease and dust may lead to leakage of electricity(short circuit) or open circuit

Do not remove or fit the connectors by force, especiallythe internal connectors Damaged circuits may lead to shortcircuit or open circuit

Before starting any test and when the periodical test isperformed, touch vehicle body to release the static electricity.Static electricity on operator's body is liable to cause damage

to some electronic components

When handling the PCB, only hold the edge of the PCBwith care Note that some electronic components are quitesusceptible to static electricity from the body

Electrical Connector Lubrication

To avoid corrosion, a special grease has been applied to someconnectors under the engine hood and vehicle body duringthe vehicle production If the grease is spoiled during themaintenance, repair or replacement, it should be applied again

SRS Precautions

General Precautions

If without correct service and handling, some parts in the

system will cause potential dangers to servicemen The

following instructions remind servicemen to be alert to these

potential dangers, and address the importance of complete

parts installed on SRS

Warning: It is imperative that before any work

is undertaken on the SRS system the appropriate

information is read thoroughly.

Warning: It is imperative that before any work

is undertaken on the SRS system the appropriate

information is read thoroughly.

Warning: The airbag module contains sodium azide which

is poisonous and extremely flammable Contact with

water, acid or heavy metals may produce harmful or

explosive compounds Do not dismantle, incinerate or

bring into contact with electricity, before the unit has

been deployed.

Warning: Always replace a seat belt assembly that has

withstood the strain of a severe vehicle impact, or if the

webbing shows signs of fraying.

Warning: Always disconnect the vehicle battery before

carrying out any electric welding on a vehicle fitted with

an SRS system.

Caution: Do not expose an airbag module or seat belt

pre-tensioner to heat exceeding 85℃.

Pay attention to operation cautions when maintaining SRS as

well as operating auxiliary system and components around SRS

component

Keep System Secure

When conducting the operation on and around the SRS

component, ensure the security of system according to the

following steps:

• Take the key from START/STOP Switch

• Disconnect the battery negative first, and then

disconnect the positive

• Wait for 10 minutes to discharge SRS ECU backup circuit

SRS system uses energy storage capacitor so that the system

can still work in case of power failure due to accident The

discharge time of capacitor shall be long enough (at least 10

minutes) to prevent the airbag from unexpected deployment

Caution: Disconnect the battery before starting the SRS

operation Disconnect the battery negative terminal first.

DO NOT disconnect the battery in the reverse order.

Refit

In order to ensure the integrity of system, it is required tocheck and maintain SRS system on a regular basis so that it canwork more effectively while impact occurs Check the SRScomponent carefully before refit Do not fit any part showingsigns of falling or improperly handled, such as depression, crack

or deformation

Warning: The integrity of the SRS system is critical for safety reasons.

Make sure to comply with the following operations:

• Do not fit the SRS component previously used on othervehicle, nor try to repair the SRS component

• Do not use any SRS component without mark or withillegible mark

• The airbag or SRS ECU that has already fallen off mustnot be used

• While repairing SRS system, only brand new originalcomponents can be used

• Do not power on SRS component, unless such test isotherwise specified in the instructions

• Ensure the tightening torque of screw is correct Whilereplacing SRS component, new fasteners must be used

• Make sure SRS ECU is correctly fit Gap is not allowedbetween SRS ECU and its bracket Improper installation

of SRS ECU may lead to system failure

• Do not power on SRS ECU before all SRS componentsare connected

Caution: Ensure SRS components are not contaminated with oil, grease, detergent or water.

Caution: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque.

Caution: Following seat belt pretensioner deployment, the seat belts can still be used as conventional seat belts, but will need to be replaced as soon as possible to re-establish full SRS protection.

Caution: If the SRS component is to be replaced, the bar code of the new unit must be recorded.

SRS Component Test PrecautionsSRS component is designed to be triggered with low workingcurrent, please always follow the precautions as below:

Warning: Do not use a multi-meter or other general purpose test equipment on SRS system components

or accidental deployment may occur Only use the recommended diagnostic equipment to diagnose system faults.

Warning: Do not use electrical test equipment on the SRS

harness while it is connected to any of the SRS system

components It may cause accidental deployment and

personal injury.

Handling and Storage

Always comply with the following handling precautions:

Warning: SRS components are sensitive and potentially

hazardous if not handled correctly; always comply with

the following handling precautions:

• The SRS ECU (SDM) and airbags must be stored in a

cabinet in a dry room at normal room temperatures

not exceeding 85℃ Ensure that heating, fire, water

and other chemical corrosive substances cannot

contaminate the stored SRS components.

• For safety reasons, do not store inflammable goods

close to the area where the SRS components are

stored.

• Keep new airbag modules in the original packaging,

until just before fitting.

• The storage area must comply with all legal

requirements It must have suitable fire extinguishers

or other fire extinguishing equipment.

• Never drop an SRS component The airbag

diagnostic control unit is a particularly shock

sensitive device and must be handled with extreme

care.

• Never wrap your arms around an airbag module If

an airbag module has to be carried, hold it by the

cover, with the cover uppermost and the base away

from your body.

• Never transport airbag modules or seat belt

pre-tensioners in the cabin of a vehicle.

Warning: Never attach anything to an airbag cover or any

trim component covering an airbag module Do not allow

anything to rest on top of an airbag module.

Warning: Store the airbag module with the deployment

side uppermost If it is stored deployment side down,

accidental deployment will propel the airbag module with

enough force to cause serious injury.

Warning: Airbag modules and seat belt pre-tensioners are

classed as explosive devices For overnight and longer

term storage, they must be stored in a secure steel cabinet

which has been approved as suitable for the purpose and

has been registered by the local authority.

Warning: Store the airbag module or seat belt pre-tensioners in a designated storage area.

Caution: Improper handling or storage can internally damage the airbag module, making it inoperative If you suspect the airbag module has been damaged, install

a new module and refer to theDeployment/Disposal Procedures for disposal of the damaged module.

SRS Harness and ConnectorWhen handling the harness of SRS system, comply with thefollowing operation steps:

• Do not try to modify, connect or repair SRS harness

• Do not fit any extra electronic equipment (e.g., mobilephone, two-way broadcast or on-board entertainmentsystem), which will cause electromagnetic interference

to airbag circuit Consult professional personnel forsuggestions prior to the fit of similar devices

Note: SRS system wiring can be identified by a special yellow outer sleeve protecting the wires (black with yellow stripe protective coverings are sometimes used).

Warning: Always ensure SRS wiring is routed correctly.

Be careful to avoidtrapping or pinching the SRS wiring.

Do not leave the connectors hanging loose or allow SRS components to hang from their harnesses Look for possible points of chafing.

Precautions during User's Operation

In order to ensure the airbag to restrain, users shall payattention to the following precautions related to the use ofairbag

The driver and passenger must use seat belt in a correctmanner Proper use of seat belt may protect human body andreduce the damage to body during accident

Do not fit any additional device that may hinder or damage seatbelt pretensioner or airbag without permission

Do not place any articles on the steering wheel and instrumentpanel, otherwise they will cut the airbag while inflating orbecome projectile to hurt human body

The seat cover is not allowed to add or incorrectly fit on seatwith side airbag

Children under the age of 12 is not allowed to be seated infront seat

Only original accessories are allowed to install

Only authorized personnel can remove the harness and

SRS system on each vehicle is matched and verified, and adding

or modifying SRS system and harness at will may harm human

body

Change in vehicle structure or SRS system is strictly prohibited,

otherwise it may result in false explosion or non-explosion of

airbag

Rotary Coupler Protection

Caution: Always follow the procedure for fitting and

checking the rotary coupler as instructed in the SRS

repairs section Comply with all safety and installation

procedures to ensure the system functions correctly.

Follow the following operation precautions:

• Do not unlock or rotate while removing rotary coupler

• Do not rotate wheels while removing rotary coupler

• Ensure that the rotary coupler is in the centre with front

wheel pointing to right ahead when carrying out removal

and refit For correct removal and refit procedures,

please refer to SRS Service section

• Ensure the locking piece is in good condition while fitting

new rotary coupler; do not use if it is damaged

Roadside Assistance

Traction - SRS Component Non-deployment

Normal traction will not lead to airbag deployment However,

as an preventive measure, it is required to turn off the

START/STOP Switch and disconnect the battery positive

and negative Disconnect the negative first at the time of

disconnection

Traction - SRS Component Deployment

Once the driver airbag deploys, the vehicle must be drawn with

front wheel lifted However, as an preventive measure, it is

required to turn off the START/STOP Switch and disconnect

the battery positive and negative Disconnect the negative first

at the time of disconnection

SRS Component Deployment

If the vehicle has unexpanded airbag module while being

scraped, deploy it manually

Comply with the following precautions:

Warning: Only personnel who have undergone the

appropriate training should undertake deployment of

airbag and seat belt pre-tensioner modules.

Warning: A deployed airbag or seat belt pre-tensioner is

very hot, DO NOT return to a deployed airbag module

until at least 30 minutes have elapsed since deployment.

Warning: Only use approved deployment equipment, and only deploy SRS components in a well-ventilated designated area Ensure SRS components are not damaged or ruptured before deployment.

Warning: Contact with chemicals from deployed and damaged SRS components could present a health hazard, wear protective clothing when handling DO NOT eat, drink or smoke when handling SRS components.

Warning: Deployment of airbag modules and seat belt pre-tensioners can cause injury to personnel in the close vicinity of the deploying unit In case of injury seek urgent medical advice Possible sources of injury include:

• impact - due to inflating airbag or pretensioner operation causing component 'kick'.

• hearing - due to noise produced by deploying airbags and seat belt pretensioner units.

• burns - hot component parts and gases.

• irritation to eyes and lungs - from deploying gases or combustion residue.

Warning: Ensure the SRS component to be deployed is securely fastened to its mounting.

Warning: Compliance with the following precautions

MUST be ensured:

• Only use deployment equipment approved for the

intended purpose.

• Before commencing any deployment procedure,

ensure the deployment tool functions properly.

• Deployment of any airbag/pre-tensioner modules

should be performed in a well ventilated area which

has been designated for the purpose.

• Ensure the airbag/pre-tensioner modules are not

damaged or ruptured before attempting to deploy

• Notify the relevant authorities of intention to deploy

airbag and pretensioner units.

• When deploying any airbag and seat belt

pre-tensioner units, ensure that all personnel are at

least 15 metres away from the deployment zone.

• When deploying seat belt pretensioners in the

vehicle, ensure the pre-tensioner unit is fully secured

to its fixing point.

• When removing deployed airbag and seat belt

pre-tensioner modules, wear protective clothing.

Use gloves and seal deployed units in a plastic bag.

• Following deployment of any component of the SRS

system within the vehicle, all SRS components must

be replaced DO NOT re-use or salvage any parts of

the SRS system.

• Do not lean over airbag modules or seat belt

pre-tensioner units when connecting deployment

equipment.

Air Conditioning System PrecautionsOverview

The fluids and components of air conditioning system could

be potentially hazardous to the service technician or theenvironment if they are not serviced or handled correctly.The following guidelines are intended to alert the serviceengineer to potential sources of danger and emphasize theimportance of ensuring the integrity of the air conditioningoperating conditions and components fitted to the vehicle.Where necessary, additional specific precautions are detailed

in the relevant sections of this Manual which should be referred

to prior to commencing repair operations

The refrigerant used in the air conditioning system is HFC-134a(Hydrofluorocarbon) R134a

Warning: Servicing must only be carried out by personnel familiar with both the vehicle system, the charging and testing equipment and hold the correct training certificates (as recommended by government bodies) All operations must be carried out in a well ventilated area away from open flame and heat sources.

Warning: Air conditioning refrigerant is a hazardous liquid and when handled incorrectly can cause serious injury Suitable protective clothing, consisting of face protection, heat-proof gloves, rubber boots and rubber apron or waterproof overalls, must be worn when carrying out operations on the air conditioning system.

• If liquid R134a is splashed onto the skin, run largequantities of water over the affected area to raisethe temperature Carry out the same measure ifthe skin comes in contact with discharge Wrapthe contaminated body parts in blankets (or similarmaterials) and seek immediate medical attention

• If inhalation of R134a vapour causes persons to beunconscious, move them away from the contaminatedarea to fresh air and apply artificial respiration and/oroxygen and seek immediate medical attention

Warning: Due to its low evaporating temperature, R134a

must be handled with care R134a splashed on any part

of the body will cause immediate freezing of that area.

Also, refrigerant cylinders and replenishment trolleys

when discharging will freeze skin to them if contact is

made.

Service Precautions

Observe the following precautions when handling components

used in the air conditioning system:

• Air conditioning units must not be lifted by their hoses,

pipes or capillary lines

• Hoses and lines must not be subjected to any twist or

stress; the efficiency of the system will be impaired by

kinks or restrictions Ensure that hoses are correctly

positioned before tightening couplings, and ensure that

all clips and supports are utilized

• Flexible hoses should not be positioned close to the

exhaust manifold (no less than 100 mm) unless protected

by heat shielding

• Completed assemblies must be checked for refrigeration

lines touching metal panels Any direct contact of

components and panels may transmit noise and so must

be eliminated

• The appropriate torque wrench must be used when

tightening refrigerant connections to the stipulated

value An additional spanner must be used to hold the

union to prevent twisting of the pipe when tightening

connections

• Before connecting any hose or pipe, ensure that

refrigerant oil is applied to the seat of the new O-rings,

but not to the threads of the connection

• All air conditioning system components must be stored

under seal until immediately prior to connection

• Ensure components are at room temperature before

uncapping, to prevent condensation of moisture from

the air that enters it

• Component seal must not remain uncapped for more

than 15 minutes In the event of a delay, the sealing

component must be fitted

• When disconnecting, immediately cap all air conditioning

pipes to prevent ingress of dirt and moisture into the

system

• The receiver/drier contains desiccant which absorbs

moisture It must be positively sealed at all times A

receiver/drier that has been left uncapped must not be

used, and fit a new unit

• The receiver/drier should be the last component

connected to the system to ensure optimum dehydration

and maximum moisture protection of the system

• Whenever the refrigerant system is opened, thedesiccant must be renewed immediately before refillingthe refrigerant

• Use alcohol and a clean lint-free cloth to clean dirtyconnections

• Ensure that all new parts fitted are marked for use withR134a

Refrigerant OilRefrigerant oil easily absorbs water and must not be stored forlong periods Do not pour unused refrigerant oil back into thecontainer Always use an approved refrigerant oil

When replacing components in the A/C system, drain therefrigerant oil from the component being replaced into

a graduated container On assembly, add the quantity oflubricating oil drained to the new component

Compressor

A new compressor is sealed and pressurized with nitrogen gas.When fitting a new compressor, slowly release the sealing cap;gas pressure should be heard to vent as the seal is broken

Caution: Do not remove the cap(s) until immediately prior to connecting the air conditioning pipes to the compressor.

Rapid Refrigerant Discharge

If the air conditioning system is involved in accident damageand the system is punctured, the refrigerant will dischargerapidly The rapid discharge of refrigerant will also result inthe loss of most of the oil from the system While removingthe compressor, drain the rest lubricating oil, and operate asinstructed in the air conditioning section of this manual

Precautions for Refrigerant Recovery, Recycling and Recharging

When the air conditioning system is recharged withrefrigerant, any existing refrigerant is first recovered from thesystem and recycled The system is then charged with therequired refrigerant and volume of lubricating oil

Warning: Refrigerant must always be recycled before re-use to ensure that the purity of the refrigerant is high enough for safe use in the air conditioning system Warning: Recycling should always be carried out with equipment which is design certified by Underwriter Laboratory Inc for compliance with SAE J1991 Other equipment may not recycle refrigerant to the required level of purity.

Warning: A R134a Refrigerant Recovery Recycling Recharging Station must not be used with any other type

of refrigerant.