J4 Service Manual
J4 Service Manual
Foreword Master Table of Contents
Overview and maintenance
Engine
Chassis
Body Electrical &
Structure
Circuit Troubleshooting
This manual is intended to help the
professional maintenance technicians
authorized by JAC Passenger Car Sales
Company provide effective and correct
maintenance and service for JAC B-Class
series models. The warm service and proper
operation from the professional maintenance
technicians of JAC passenger cars are essential
for ensuring customer satisfaction to JAC
passenger car products. Thus, maintenance
technicians should fully understand this
manual. This manual should be placed in a
handy place for your convenient reference.
All the contents in this manual have been
updated including pictures and technical
parameters .In case maintenance works are
affected due to product improvement, JAC
Passenger Car Sales Company will provide
technical bulletins or supplementary volumes.
Therefore, you should use this manual and pay
close attention to obtaining latest update
relevant information. JAC Passenger Car Sales
Company reserves the rights to change, add or
improve designs of its products.
No part of this manual is allowed to be
reproduced or modified in any form, including
but not limited to electronic media, paper,
sound and image, and mechanical media,
without written authorization from JAC
Passenger Car Sales Company.
Chapter 1 Overview
Chapter 2 Maintenance
Chapter 1 Engine mechanical
Chapter 2 Engine electronics
Chapter 3 Engine Electronic
Control System
Chapter 1 Transmission system
Chapter 2 Clutch system
Chapter 3 Drive system
第三章 悬架系统
Chapter 1 Body Electrical
Chapter 2 Body Structure
Chapter 4 Suspension system
第三章 悬架系统
Chapter 5 Brake system
第三章 悬架系统
Chapter 6 Steering system
第三章 悬架系统
Chapter 3 Body data
J4 Service Manual body electrical and structural
directory
Body Electrical & Structure
Body Electrical
SRS - 1
Safety Auxiliary
System ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
SRS - 1
Precautions
SRS - 1
Preparations
SRS - 1
Summary of Safety Airbag System
SRS - 2
Fundamental principle of safety airbag system
SRS - 3
Driver Side Airbag
Front Passenger Side Airbag
Safety belt
Safety belt pretensioner in the front row
Safety airbag Timer-spring
Safety airbag control module (SDM)
Fault diagnosis
Safety airbag System Servicing
SRS - 5
SRS - 6
SRS - 8
SRS - 11
SRS - 11
SRS - 15
SRS - 17
SRS - 24
Disposal method of abandoned safety airbag system
component
SRS -26
AC Air Conditioning System
AC - 1
Precautions
AC - 1
Service tools
AC - 3
J4 Service Manual body electrical and structural
directory
Inspection of Air Conditioning System and Filling of
Refrigerant
System Control
Functions, Positions, and Inspection of System Components
System Removal and Installation
Periodic Maintenance
Failure analysis and troubleshooting summary table
AC - 5
AC - 8
AC - 13
AC - 21
AC - 25
AC - 26
ETACS Information and time Electronic Control System
ETACS -
1
Precautions
ETACS -
1
Layout of Components
ETACS -
1
Function Description
ETACS -
2
Replacement of ETACS control module and alarm speaker
ETACS -
14
Definition of ETACS control module terminal
ETACS -
15
Operation instruction of ETACS remote control key code
selection
ETACS -
16
ETACS common failure analysis
ETACS -
J4 Service Manual body electrical and structural
directory
17
Technical parameters
ETACS -
20
Combination
Switch………………………………………………………
CSW - 1
Descriptions
Component check
Replacement of combination switch
CSW - 1
CSW - 3
CSW - 4
Check after installation
CSW - 4
Lighting System
LT - 1
Precautions:
LT - 1
The front combination Light Replacement
Front fog lamp
Taillight
High-mounted stop
lamp ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
License plate light
Rear fog lamp
The dome
light ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Maintenance data and specification
LT - 1
LT - 5
LT - 7
LT - 10
LT - 10
LT - 11
LT - 12
LT - 13
Combination meter
CM - 1
J4 Service Manual body electrical and structural
directory
Summary
CM - 1
Instrumentation
features ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
CM - 3
Operating instructions
CM - 5
Combination meter connector and pin
definition ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
CM - 7
The driver information
display ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
CM - 8
installation and disassembly of Combination meter
CM - 10
Wiper and Washer
WW-1
Wiper
System ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Washing system
Rear window defroster
Trouble inspection and repair
WW - 1
WW - 5
WW - 7
WW - 9
HORN
HORN-1
Component position
Schematic
Horn check
Trouble inspection and repair
Removal and Replacement of horn
Replacement of horn button
HORN-1
HORN-1
HORN-1
HORN-2
HORN-3
HORN-4
J4 Service Manual body electrical and structural
directory
Cigar Lighter
CTGAR
- 1
Component position
CTGAR -
1
Schematic
CTGAR -
1
Trouble inspection and repair
CTGAR -
2
AV Audio System
AV-1
Layout of Components
Horn system Schematic
Audio unit
Audio unit and antenna replacement
Sedan Rear Speaker
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Replacement of Front and Rear Loudspeakers
AV - 1
AV - 1
AV - 2
AV - 2
AV - 4
AV - 4
PTS – Parking Aid System
PTS-1
Layout of Components
System Block Diagram and
Schematic ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
System Interface Definition
PTS - 1
PTS - 2
PTS - 2
PTS - 3
J4 Service Manual body electrical and structural
directory
description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Sensor
Replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Mirror ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
PM - 1
Descriptions
Layout of Components
Schematic
Component check
Replacement of inside rear view mirror
Replacement of outside rear view mirror
Mirror adjustment
switch ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
PM - 1
PM - 1
PM - 2
PM - 3
PM - 4
PM - 6
PM - 7
Electric windows and doors
PW - 1
Summary
Component description
Function Description
Schematic
Element
Replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..
. ...
Fault diagnosis
PW - 1
PW - 1
PW - 2
PW - 3
PW - 4
PW - 15
Body Structure
BODY-1
J4 Service Manual body electrical and structural
directory
Engine Cover and Doors
BODY-1
Precautions:
Engine Hood Assembly
Fenders
The replacement of front door assembly :
The replacement of rear door assembly :
Trunk lid
Oil filler of fuel tank
Locking system
BODY-1
BODY-1
BODY-4
BODY-4
BODY-8
BODY-1
2
BODY-1
3
BODY-1
5
Interior & Exterior Trims
EI -1
Precautions:
EI - 1
Front bumper replacement
Front bumper beam replacement
Rear bumper replacement
Sun visor replacement
A column upper guard plate replacement
Replacements of front door sill protect board assembly.
A column lower guard plate replacement
Replacements of rear door sill protect plate assembly.
EI-1
EI-3
EI-4
EI-5
EI-6
EI-7
EI-7
EI-8
J4 Service Manual body electrical and structural
directory
B-pillar Garnish
C-pillar upper guard plate replacement
Top armrest
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Ceiling
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
...
Carpet
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
...
coat rack assembly
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Luggage assembly
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Seat
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
...
Signage
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
...
Front windshield
EI-9
EI-10
EI-11
EI-11
EI-13
EI-15
EI-16
EI-18
EI-19
EI-20
J4 Service Manual body electrical and structural
directory
Console
IP-1
Precautions:
IP-1
Driver Side Airbag replacement
IP-1
Steering wheel replacement
IP-3
Tube post Shield
Replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
IP-4
Safety airbag Timer-spring
IP-5
Driver side instrument panel replacement
IP-7
Ignition switch replacement
IP-9
Glove box replacement
IP-11
Console replacement
IP - 12
Steering column replacement
IP-13
Combination instrument replacement
IP-15
A/C control panel replacement
IP-16
Dashboard replacement
IP-17
Dashboard Support
Replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
IP-20
Body Dimension Data
Data - 1
Body data:
Data - 1
Engine compartment data:
Data - 2
Side member data:
Data - 3
J4 Service Manual body electrical and structural
directory
J4 Workshop Manual safety assistant System
Electric device
Fundamental principle of safety airbag system
Precautions
Warning:
■Airbags can explode accidently and cause severe damage, if you don’t operate
as correct procedures while maintaining.
■Airbags may not be exploded and cause severe damage while maintaining
■Before maintenance (including remove, install, exam and replace parts),
following tips must be obeyed, and operate according to Maintenance Manual
1. Do not decompose airbag component, including driving and passenger side
airbag.
2. Do not manitain the following parts, only replace
1) Driving side airbag
2) Passenger side airbag
3) Safety belt tenser
4) Safety airbag control module;
5) Clock spring
3. Do not expose airbag under high temperature or near flame
4. If airbags are stained by liquid such as grease/detergent/engine oil/water, they
should be wiped by dry cloth immediately
5. Do not let airbags fall down Do not use airbags that has fallen down
6. Use original parts from authorized distributor,only.
7. If decompose airbags, put them on even place, Do not load any goods on its
top.
8. Verify if the replacement ID no. is correct. Do not use the component of other
cars as the substitute.
9. Remember to dispose airbags before discarding cars or safety airbags.
10. After the detonation of safety airbag, the charging device would become very
hot, and won't be handled until it naturally cools down. Do not lower the temperature
J4 Workshop Manual safety assistant System
with water.
11.It is prohibited to measure the electric resistance of safety airbag module as
this may detonate the safety airbag.
Preparations
Common and special tools necessary for the maintenance
List of Special Tools
Tool
Diagram
Purpose
Simulator
Simulator-joint of
for check of harness
resistance
Summary of Safety Airbag System
The safety airbag system is composed of the main safety airbag, passenger safety
airbag, clock spring, safety airbag module, explosive released pretensioner of
driver-sided safety belt and passenger-sided safety belt, side airbag switch of
passenger side. The passenger airbag can be turned off temporally by the switch off
passenger airbag button, which will turn on the PAB (passenger Safety airbag)
warning light on the dashboard. If driver doesn't fasten safety belt, ETACS will
receive signal and alarm light on dashboard will turn on. If the driver fastens the
safety belt, the alarm light of safety belt will turn off.
When the ignition switch turns to 2nd gear, safety airbag system activates, ECU
will check as fixed procedure automatically. If the alarm light is off after 4 seconds, it
means the system is normal after self-check, then ECU will start monitoring. if the
alarm light flash or keeps on, it means self-check fails and system is abnormal. During
the normal process of driving (incl. all road condition and interferences), ECU does
not give the ignition order, the airbag plays no roll；In case of severe forward
collision, ECU will issue in time the incentive ignition, stimulating the airbag
component to open the airbag and absorbing the partial impact energy from the driver
J4 Workshop Manual safety assistant System
and front row passenger, alleviating the possible damage of passenger. driving and
passenger side safety belt precaution device will be activated,safety belt will be
tightened, pulling passenger who are away from seats because of inertia back to seats
to protect them.
Fundamental principle of safety airbag system
Condition of safety airbag opening
Impact Angle Diagram Enabling the Opening of Safety Airbag
The frontal impact in sufficient power occurred within the range at 30ºdeviation
from the centerline of car may open the airbag.
Layout of Safety Airbag System Components
J4 Workshop Manual safety assistant System
Layout of Safety Airbag Components
1-driving airbag 2-passenger airbag 3-Safety airbag control module position
3. Principle of restraint system
Collision of car will cause abrupt change in the speed. Due to the inertia effect,
the passenger in the car continues to move forward, causing the impact between the
inboard passenger and interior panels. The Passenger Restraint System (SRS) is
designated to use the restraint system (incl. the seats, safety belt and safety airbag etc.)
to prevent or decrease the injury caused by the impact between the passenger and
interior panels.
1) Schematic Diagram of Restraint System
Impact
Sensor
Control/diag
nose system
Explosion
Airbag
Driver/passe
nger
Restr
ain
Fundamental principle of safety airbag system
Safety belt pretension system
Precaution
Loading
limit
S
e
at
b
el
ts
Restr
ain
Sign
al
1
3
2
J4 Workshop Manual safety assistant System
Schematic diagram of Control system
2) Principle of safety airbag
Prior to the impact occurred between the inside passenger and hardware, an
air-charged airbag is rapidly inserted between the passenger and the hardware,
absorbing the dynamic energy of passenger
with the air bag inherent permeability and the
exhaust throttling of deflating hole, retarding
the violent impact and isolating the passenger
from the interior hardware to protect
passenger .
3) Principle of safety belt
At first, retract instantly, at the first time of the accident occurrence, the
passenger will be “pressed” down on the seats by the impact acceleration, inclination
angle of car and acceleration of webbing straining;
Then appropriately relaxe, the safety belt properly loosened until the impact peak
elapsed, or passenger subject of the airbag protection.
Driver Side Airbag
1. Components
Driver side airbag is located on the steering wheel.
2. Specification
■Airbag capacity: 50L
Note:
■The front face of pad shall face upwards, when old driver side airbag is
SRS001
SRS001
J4 Workshop Manual safety assistant System
demounted or new airbag is mounted.
■It is not allowed to measure the electric resistance of airbag, which may
possibly give rise to accidental ignition of airbag.
■The driver side airbag shall be stored in a place with ambient temperature lower
than 80℃ and far away from electrical noise.
■During the welding operation, the negative (-) of battery should be turned off
and the connector of airbag disconnected.
■When discarding car or safety airbag, the special tool should be used to
detonate the airbag.
3. Removal
1) Disconnect the negative pole (-) of battery for more than 3 minutes.
Disconnect DAB
2) Schematic diagram of disconnecting DAB(3 steps), disconnecting tool is a
straight screwdriver with length of 15cm.
Disconnect 3H hole
Rotate handwheel 90°anticlockwise, disconnect 3H hole's Groove with
screwdriver (for detailed structure showed in diagram)
Disconnect 6H hole
Rotate handwheel 90°anticlockwise, disconnect 6H hole's Groove with
screwdriver (for detailed structure showed in diagram)
Disconnect 9H hole
Put the driving wheel back to middle, rotate it 90°clockwise, disconnect 6H
hole's Groove with screwdriver(for detailed structure showed in diagram)
9H disassembly hole
6H disassembly hole
3H disassembly hole
J4 Workshop Manual safety assistant System
3) Disassemble the connector and take out the
safety airbag module.
4) Place the safety airbag module
properly as required, shown as in figure.
4. Installation
Installation is in the opposite order of removal.
Front Passenger Side Airbag
1. Component schematic
Front passenger side airbag is embedded
on the passenger side instrument panel.
Driver side instrument panel
Note:
■Please don't put or paste anything on the surface of airbag.
2. Specification
■Airbag capacity: 90L
SRS005
SRS004
SRS003
J4 Workshop Manual safety assistant System
Note:
■Please refer to the “Driver Side Airbag” for notices.
3. Removal:
1) Disconnect the negative pole(-) of
battery for more than 3 minutes.
2) Remove the glove box.
3) Remove the lamp of glove box.
4) Remove 2 screws fixing Passenger-sided safety airbag; disconnect wiring
connector, bring down passenger side airbag
4. Installation
Installation is in the opposite order of removal.
Safety belt
Note:
■Make sure Retractor won't be damaged when remove safety airbag.
SRS006
SRS007
SRS008
J4 Workshop Manual safety assistant System
■Replace the damaged buckle on fender apron
■Adjust hight
1. Safety belt in the front row
1) Removal
①First, remove shield both in front door and back door
②Remove lower cover, twist off lower
fixing screw
■Stipulated torque: 45N.m-55N.m
③ Remove lower trim pane on B pillar
④ Remove uper trim panel on B pillar
⑤ Twist off upper fixing screw
■Stipulated torque: 45N.m-55N.m.
⑥ Twist off screws, remove Retractor.
■Stipulated torque: 45N.m-55N.m.
⑦ Twist off screw and bolt on guide bracket.
■Stipulated torque: 6N.m-8N.m
2) Installation.
Installation is in the opposite order of removal.
SRS009
SRS010
B pillar top hood panel
B pillar below hood panel
Front door panel
below door panel
B
ack door
panel
Upper fixing bolt
Guide bracket screw
ALR
lower fixing bolt
J4 Workshop Manual safety assistant System
2. Mortise lock of front safety belt
1) Removal
① Remove front seats (refer to seat)
② Bottom seat up, separate wiring plug (driver seat).
③ Twist off fixing screws, remove gasket and mortise lock of front safety belt.
■Stipulated torque: 45N.m-55N.m.
2) Installation
Installation is in the opposite order of removal.
3. Safety belt in the rear row
1) Removal
① Remove rear seats (Refer to Rear seat)
② Remove the coat rack.
③ Twist off fixing screw, remove lower fixing screws on rear safety belt.
■Stipulated torque: 45N.m-55N.m.
The seat belt latch
nut
gasket
wiring
J4 Workshop Manual safety assistant System
④ Twist off assembling bolt, remove rear safety belt, can refer to front safety
belt.
■Stipulated torque: 45N.m-55N.m.
2) Installation
Installation is in the opposite order of removal.
4. Mortise lock on rear safety belt
1) Removal
① Remove rear seats (refer to Rear seat)
② Twist off fixing screw, remove buckle on safety belt.
■stipulated torque: 45N.m-55N.m.
2) Installation
SRS011
SRS012
hallstand
Lower fixing bolt
J4 Workshop Manual safety assistant System
Installation is in the opposite order of removal.
Safety belt pretensioner in the front row
1. Specification
■Ambient temperature of using gas Generator:-35℃～+105℃
Note:
■Aux. restraint system (e.g. “safety airbag” and “safety belt pretensioner”) and
the safety belt used together, helping mitigating impact and injury risk of driver and
the front-row passenger.
■To prevent and decrease the risk of being injured and death due to invalidation
of safety airbag system, all maintenance operations should be made in the service
center of JAC authorized shop.
■Improper maintenance, incl. incorrect removal and installation of safety belt
pretensioner will cause the mis-action of the system, and result in the accidental
personnel injury and death.
■Except the operations stated in the Manual, electrical test equipment is not
allowed to use to test any of the circuits of safety airbag system.
2. Removal and installation of the safety belt pretensioner in the front row
Please refer to the “Removal and Installation of Front-Row Safety Belt”.
Note:
■Prior to the removal or installation, be sure that the ignition switch is off and
the negative (-) of battery disconnected, then wait for more than 3 minutes.
■Do not use the electrical test equipment to test the pretensioner of safety belt
Safety airbag Timer-spring
1. 1.Component schematic
SRS013
J4 Workshop Manual safety assistant System
2. Safety airbag Timer-spring
1) Removal
① Disconnect the negative pole (-) of
battery for more than 3 minutes.
② Remove the driver safety airbag
module, take off Connector.
③ Remove screws and take off steering
wheel.
Steering wheel
Note:
■The fixing nuts can be fully taken out until the steering wheel is loosened,
otherwise the steering wheel may cause personnel injury.
SRS014
SRS015
SRS016
J4 Workshop Manual safety assistant System
④ Disconnect the connector of horn.
⑤ Poke the three bayonets embedded in combination switch of the clock spring
Note:
■Be sure 3 bayonets completely loose, and then take off timer-spring, which
needs to be careful because it is easily to get damaged.
⑥ Take out the timer-spring of safety airbag.
2) Installation
Install according to the reverse order of removal.
Note:
SRS017
SRS018
SRS019
J4 Workshop Manual safety assistant System
■ Take out the safety airbag timer-spring from the package and check if it is in
intact state and the dowel pin inserted on the part.
■Open the connector cover, and insert the wiring connector of safety airbag into
the connector hole, then close the cover.
■Prior to the installation of safety airbag timer-spring, be sure that the front
wheel is located in the center (orientation).
■Prior to the installation of safety airbag timer-spring, be sure that the
timer-spring is located in center (twist clockwise to the end, then turn back
anticlockwise, for 2.5 cycles)
Definition of connector of timer-spring
J4 Workshop Manual safety assistant System
Safety airbag control module (SDM)
1. Specification and function of the safety airbag control module (SDM)
1) Induction of car collision.
2) Detonation of driver- and passenger-sided safety airbags.
3) Detonation of driver and passenger-sided pretensioning safety belts.
J4 Workshop Manual safety assistant System
4) Monitoring safety airbag system.
5) Inform driver state of safety airbag system via the warning indicator: ready or
malfunction.
6) Run the diagnosis and maintenance through the serial diagnosis
communication port.
7) Record the impact related data and operating state of airbag system
components after collision.
8）Transmit impact signal to the ETACS module after collision and enable the
ETACS module to open the locked door to ease passenger to escape.
2. Safety airbag control module (SDM) pins
SDM Terminal Diagram
Description of SDM terminals
3. Circuit diagram of safety airbag
J4 Workshop Manual safety assistant System
\
Fault diagnosis
1. Safety airbag system diagnosis
安全气囊-1
L-1
0.75R
5 9
诊断
M-1
0.5 OW
0.5 O
17 16 1413
0.5 0V
0.5 OR
0.5 OW
12 12
0.75B
6
M82
1
2
安全气囊模块
安全气囊
ECU
0.35 O
46
H-4
驾驶员侧
安全带预紧
副驾驶员侧
安全带预紧
时钟弹簧
助手席气囊
驾驶员侧
安全带预紧
副驾驶员侧
安全带预紧
1
2
M92M89
M84
M84
M89 M92
057
149
10 9 8 7 6 5 4 3 2 1111213141516171819202122232425
2627282930333435363738394041424344454647484950
1 2 3 4
PAB
M83
1 2
0.35 BR
7
安全气囊
D-10
093
ECU_72
BCM_B21
046
A-7
FS21保险
驾驶员气囊
10
11
DAB+
DAB-
0.5 OR
0.5 OG
M82
4
3
助手席气囊
PAB+
PAB-
18
19
0.5 OL
0.5 OB
M83
1 2
K_LINE
P-3
150
警示灯
G_SRS
M86
Safety airbag module
Safety airbag
Driver Safety airbag
passenger Safety airbag
Diagnostic
Driver safety belt
pretensioner
passenger safety
belt pretensioner
Safety airbag
indicator
J4 Workshop Manual safety assistant System
After the ignition switch is turned to the position “ON”, the safety airbag
indicator on the dashboard flashes for several seconds and goes out, it indicates the
safety airbag system operates in normal condition. Provided the ignition switch is
turned to the position “ON” and the safety airbag indicator doesn't flash or always
flashes, it means there is failure in the airbag system. To further confirm the failure
cause, special diagnostic scanner should be applied for diagnosis.
1) Fault code read by diagnostic scanner.
2) Maintenance implemented according to the prompt of fault code
3) Fault code elimination by diagnostic scanner.
Note:
■After the failure elimination, the diagnostic scanner has to be used to clean out
the fault code left in the system.
2. Table of Trouble Codes
Trouble code
Trouble description
B1000
ECU internal fault
B1001
Configuration error
B0026
Too high resistance value of driver’s safety airbag
B0022
Too low resistance value of driver’s safety airbag
B0024
Line-to-ground short-circuit or line contact of driver’s
safety airbag
B0025
Power short-circuit of driver’s safety airbag
B0017
Too high resistance value of co-pilot’s safety airbag
B0016
Too low resistance value of co-pilot’s safety airbag
B0018
Line-to-ground short-circuit or line contact of co-pilot’s
safety airbag
B0019
Power short-circuit of co-pilot’s safety airbag
B0065
Too high resistance value of driver’s safety belt
pretensioner.
J4 Workshop Manual safety assistant System
B0064
Too low resistance value of driver’s safety belt
pretensioner.
B0066
Line-to-ground short-circuit or line contact of driver’s
safety belt pretensioner.
B0067
Power short-circuit of driver’s safety belt pretensioner.
B0058
Too high resistance value of co-pilot’s safety belt
pretensioner.
B0057
Too low resistance value of co-pilot’s safety belt
pretensioner.
B0059
Line-to-ground short-circuit or line contact of co-pilot’s
safety belt pretensioner.
B0060
Power short-circuit of co-pilot’s safety belt pretensioner.
B1328
Power voltage too high.
B1327
Power voltage too low.
B0671
Line-to-ground short/open-circuit or line contact of system
fault.
B0673
Power short-circuit of system fault.
B0051
Front airbag detonated .
B0052
Max. operation limit reached by the safety airbag controller
and no further use allowed.
B0049
Output line to power short-circuit by impact.
B0048
Output line to ground short/open-circuit by impact.
B1000 ECU internal faults
steps
Measures
Yes
No
1
Visually observe if the ground wiring
connection of safety airbag ECU power is
normal.
To step 3
To step 2
2
To step 3
3
Replace the ECU of safety airbag.
J4 Workshop Manual safety assistant System
B1001 Configuration error
steps
Measures
Yes
No
1
Replace the ECU of safety airbag.
B0026 Too high resistance value of driver’s safety airbag
steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the safety airbag
wiring.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
Timer-spring replaced.
To step 4
4
Whether the failure is eliminated after the
driver’s safety airbag replaced.
To step 5
5
Replace the ECU of safety airbag.
B0022 Too low resistance value of driver’s safety airbag
steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the safety airbag
wiring.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
Timer-spring replaced.
To step 4
4
Whether the failure is eliminated after the
driver’s safety airbag replaced.
To step 5
5
Replace the ECU of safety airbag.
B0024 Ground short-circuit or line contact of driver’s safety airbag
steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the safety airbag
wiring.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
Timer-spring replaced.
To step 4
4
Whether the failure is eliminated after the
To step 5
J4 Workshop Manual safety assistant System
driver’s safety airbag replaced.
5
Replace the ECU of safety airbag.
B0025 Power short-circuit of driver’s safety airbag
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the safety airbag
wiring.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
Timer-spring replaced.
To step 4
4
Whether the failure is eliminated after the
driver’s safety airbag replaced.
To step 5
5
Replace the ECU of safety airbag.
B0017 Too high resistance value of co-pilot’s safety airbag
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the co-pilot’s safety
airbag harness.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
co-pilot safety airbag replaced.
To step 4
4
Replace the ECU of safety airbag.
B0016 Too low resistance value of co-pilot’s safety airbag
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the co-pilot’s safety
airbag harness.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
co-pilot safety airbag replaced.
To step 4
4
Replace the ECU of safety airbag.
B0018 Ground short-circuit or line contact of co-pilot safety airbag
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the co-pilot’s safety
To step 3
To step 2
J4 Workshop Manual safety assistant System
airbag harness.
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
co-pilot safety airbag replaced.
To step 4
4
Replace the ECU of safety airbag.
B0019 Power circuit of co-pilot safety airbag
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the co-pilot’s safety
airbag harness.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
co-pilot safety airbag replaced.
To step 4
4
Replace the ECU of safety airbag.
B0065 Too high resistance value of driver’s safety belt pretensioner
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the pretensioner
harness of driver’s safety belt.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
driver’s safety belt pretensioner replaced.
To step 4
4
Replace the ECU of safety airbag.
B0064 Too low resistance value of driver’s safety belt pretensioner
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the pretensioner
harness of driver’s safety belt.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
driver’s safety belt pretensioner replaced.
To step 4
4
Replace the ECU of safety airbag.
B0066 Ground short-circuit or line contact of driver’s safety belt pretensioner
Steps
Measures
Yes
No
J4 Workshop Manual safety assistant System
1
Visually observe if the ECU of safety airbag is
in normal connection with the pretensioner
harness of driver’s safety belt.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
driver’s safety belt pretensioner replaced.
To step 4
4
Replace the ECU of safety airbag.
B0067 Power short-circuit of driver’s safety belt pretensioner
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the pretensioner
harness of driver’s safety belt.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
driver’s safety belt pretensioner replaced.
To step 4
4
Replace the ECU of safety airbag.
B0058 Too high resistance value of co-pilot’s safety belt pretensioner
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the pretensioner
harness of co-pilot’s safety belt.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
co-pilot’s safety belt pretensioner replaced.
To step 4
4
Replace the ECU of safety airbag.
B0057 Too low resistance value of co-pilot’s safety belt pretensioner
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the pretensioner
harness of co-pilot’s safety belt.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
co-pilot’s safety belt pretensioner replaced.
To step 4
J4 Workshop Manual safety assistant System
4
Replace the ECU of safety airbag.
B0059 Ground short-circuit or line contact of co-pilot’s safety belt pretensioner
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the pretensioner
harness of co-pilot’s safety belt.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
co-pilot’s safety belt pretensioner replaced.
To step 4
4
Replace the ECU of safety airbag.
B0060 Power short-circuit of co-pilot’s safety belt pretensioner
Steps
Measures
Yes
No
1
Visually observe if the ECU of safety airbag is
in normal connection with the pretensioner
harness of co-pilot’s safety belt.
To step 3
To step 2
2
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 3
3
Whether the failure is eliminated after the
co-pilot’s safety belt pretensioner replaced.
To step 4
4
Replace the ECU of safety airbag.
B1328 Too high power voltage
Steps
Measures
Yes
No
1
Check if the battery is in normal voltage
Ignition switch ON :12.56V
Engine run:14V
To step 3
To step 2
2
Whether the failure is eliminated after the
battery replaced.
To step 3
3
Visually observe if the power harness of
safety airbag ECU is in normal condition.
To step 5
To step 4
4
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 5
5
Replace the ECU of safety airbag.
B1327 Too low power voltage
Steps
Measures
Yes
No
J4 Workshop Manual safety assistant System
1
Check if the battery is in normal voltage
Ignition switch ON :12.56V
Engine run:14V
To step 3
To step 2
2
Whether the failure is eliminated after the
battery replaced.
To step 3
3
Visually observe if the power harness of
safety airbag ECU is in normal condition.
To step 5
To step 4
4
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 5
5
Replace the ECU of safety airbag.
B0673 Power short-circuit of system failure lamp
Steps
Measures
Yes
No
1
Check if the connection line of the terminal 1
of safety airbag ECU is conductive with the
failure lamp of airbag on instrument.
To step 3
To step 2
2
Whether the failure is eliminated after the
connection line replaced.
To step 3
3
Check if the power and contact line of safety
airbag is normal.
To step 5
To step 4
4
Whether the failure is eliminated after the
fault harness replaced.
To step 5
5
Replace the ECU of safety airbag.
B0051 Front airbag already detonated
Steps
Measures
Yes
No
1
Verify if the front airbag has been detonated
To step 2
To step 3
2
Whether the failure is eliminated after the
front safety airbag replaced.
To step 3
3
Whether the failure is eliminated after the
front airbag and connection harness of safety
airbag replaced.
To step 4
4
Replace the ECU of safety airbag.
B0052 safety airbag controller reaching Max. operation limit and no further use
allowed
Steps
Measures
Yes
No
1
Replace the ECU of safety airbag.
J4 Workshop Manual safety assistant System
B0049 impact output line short-circuit to power
Steps
Measures
Yes
No
1
Check if the connection line between the
connector terminal 5 of safety airbag ECU
and the terminal 21 of ETACS plug M37 is in
normal condition
To step 3
To step 2
2
Replace the ECU of safety airbag and ETACS
connection harness
To step 3
3
Visually observe if the power harness of
safety airbag ECU is in normal condition.
To step 5
To step 4
4
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 5
5
Replace the ECU of safety airbag.
B0048 Ground short/open-circuit of impact output line
Steps
Measures
Yes
No
1
Check if the connection line between the
connector terminal 5 of safety airbag ECU
and the terminal 21 of ETACS plug M37 is in
normal condition
To step 3
To step 2
2
Replace the ECU of safety airbag and ETACS
connection harness
To step 3
3
Visually observe if the power harness of
safety airbag ECU is in normal condition.
To step 5
To step 4
4
Whether the failure is eliminated after the
safety airbag harness replaced.
To step 5
5
Replace the ECU of safety airbag.
Other than the operations stated in the Manual, it is not allowed to use electric
equipment for testing any of the SRS system circuits. The SRS line harnesses may be
identified through Yellow and/or Orange harnesses or harness connectors. Do not try
to repair, connect or modify the SRS harnesses. If harness is damage, it should be
replaced by new one. The grounding place should be kept clean. The diagnosis
performance may read out SRS self-diagnostic result through the X431 diagnosis
scanner. The diagnosis mode may help the service technician position and check the
fault parts and components.
J4 Workshop Manual safety assistant System
Safety airbag System Servicing
1. Precautions to be taken after the collision occurrence
Note:
■After occurrence of any impacts, the safety belt assemblies of all seats incl. the
retractors and other metal parts and components should be checked.
■We suggest replacing all safety belt assemblies used during the collision,
otherwise they may cause serious personal injury in the accident. In case of the frontal
impact detonating the airbag, even if the safety belt has not been used, the safety belt
pretensioner should be replaced.
In following cases, please replace the safety belt assembly (incl. fixing bolts):
■The safety belt is in use upon the occurrence of impact (except the impact is
very soft and the safety belt, retractor and clip ring show no damage and in normal
performance)
■The safety belt has been fully damaged in the accident (i.e. safety belt damaged,
retractor distorted or slide slots).
■The fixing point of safety belt has been fully damaged in the accident. Check
the fixed area of safety belt for damage or deformation before installing new safety
belt assembly. If necessary, service.
■Deformation or wear of fixing bolts.
2. In case of accidents, where the middle and side impact occurred during the
low-speed collision, rollover and rear-end collision etc., and the airbag not detonated,
the following items should be checked:
■Check the SDM housing and installation bracket for any dents, cracks or deformation.
■ Check the connectors for any damage and the terminals for any deformation.
Check if the installation bolts and earth line are intact.
3. Maintenance and check of safety airbag system
1) Safety airbag module
① Check the liner cowl for any dents, cracks or deformation.
② Check if the connector is damaged, the terminals deformed and wires
clipped.
J4 Workshop Manual safety assistant System
③ Check the gas generator housing of safety airbag for any dents, cracks or
deformation.
④ Install the safety airbag components on the steering wheel and check the
match-up or alignment with the steering wheel.
2) Timer-spring
① Check the connectors of timer-spring and sheath for any damage and the
terminals for any deformation.
②Visually check the housing for any damages.
3) Steering wheel and steering column
① Check the electric wiring (fit inside the steering wheel) and the connectors
for any damage and the terminals for any deformation.
② Install the safety airbag components on the steering wheel and check the
match-up or alignment with the steering wheel.
③ Check the steering wheel for any noise, the steering for flexible control and
excessive clearance.
Note:
■Align first the timer-spring on bottom of the steering wheel, then install the
steering wheel on the column.
■Method of timer-spring alignment:
Turn the timer-spring to the end clockwise, then return it more than 2.5 cycles to
make the arrow on the timer-spring in alignment.
4）Other parts and components
■ Check the wiring for any jamming, the connectors for any damage and poor
connection and the terminals for any deformation.
■All safety airbag components after detection of faults have to be replaced
instead of use after reparation.
■If the parts and components of safety airbag system are required to be removed
or replaced due to maintenance and troubleshooting etc. the operation sequences
should be followed respectively.
5) Warning/Notice labels
J4 Workshop Manual safety assistant System
There are many SRS Warning/Notice labels on the car, which are attached on:
■Steering wheel framework
■Driver-sided safety airbag components
■Timer-spring
■Passenger-sided safety airbag components
■Safety airbag control module (SDM)
■Sun visor above the front windshield
■The instructions on the labels should be followed when servicing SRS. If
contaminated or damaged, they should be replaced.
6) Safety airbag control module (SDM)
Note:
■After the occurrence of SDM faults, the replacement has to be made instead of
reparation.
Disposal method of abandoned safety airbag system component
Prior to discarding the safety airbag or the car fitted with the safety airbag, the
following process measures should be taken for detonation.
1.
1) If the car is going to be discarded, the safety airbag needs to detonate inside
the car. If the car continues to be used and only the safety airbag module discarded,
the detonation of safety airbag should be made outside the car.
2) Because of great amount of smoke produced from the safety airbag explosion,
cares should be taken to prevent from breathing it in, for it is irritating and possibly
choking to your throat. The residence area should be kept off as much as possible.
3) As the explosion noise of safety airbag is extremely loud, thus the residence
areas should be kept off far away as much as possible. In case of human approaching,
the warning of imminent noise should be given.
4) Only one airbag module can be trigged per time.
5) When the airbag module and the safety belt pretensioner are ready for
detonation, personnel should stay at least 10m away from the component to be
J4 Workshop Manual safety assistant System
detonated.
6) After the explosion, the airbag module should be set aside at least more than
30 minutes due to the high temperature.
7) The personnel assigned to perform this task or the field staff should be
protected with the suitable ear protective equipment.
2. Disposal method of detonation inside the car (when discarded)
1) Remove the car to an isolated site.
2) Disconnect both positive (+)/negative (-) cables from the battery terminals,
then remove the battery from the car.
Note:
■After the negative (-) detached from the battery, you should wait at least for 3 minutes,
then continues the next procedure.
3) Detonation of safety airbag module (driver-sided):
① Remove the lower cowl of steering column.
② Disconnect the connection between the connector of safety airbag
timer-spring and that of safety airbag harness.
Note:
■After the connector of safety airbag timer-spring disconnected from the body
harness of safety airbag, the positive (+) of timer-spring connector will be
automatically short-circuited, to prevent the safety airbag from unexpected detonation
due to the electrostatic.
4) Connect two wires in length of more than 10meters to two leads of safety
airbag adapter wiring and wrap up the joint with the insulation tape. The other ends of
those two wires should link to each other (short-circuit) to prevent the safety airbag
from unexpected explosion.
5) Connect the pin access plug of safety airbag with the safety airbag adaptor
wiring and extend the detonating cord to the outside.
6) In order to minimize the detonation noise, all doors and windows of car should
be closed and the car should be protected with cover.
Note:
J4 Workshop Manual safety assistant System
■If the window glass has any damage trace, they may be broken down during the
detonation. Thus ensure that the car is protected with cover.
7) At a site as far as possible away from the car, detach two wires each from
other, and connect them respectively with two terminals of battery (this battery has
been already removed from the car) so as to detonate the safety airbag.
Note:
■Prior to the detonation of safety airbag with above method, you should check
and be sure no persons in or nearby the car.
■Please wear the safety goggles.
■The gas charger is still hot after detonation, thus you should wait for at least 30
minutes until it cools down and move it. Though the gas released from the detonated
safety airbag is non-toxic, it is irrespirable. For the moving rules of the detonated
safety airbag, please refer to the Discard Method of Safety Airbag already Detonated.
■If the safety airbag component cannot be detonated by the above-stated method,
do not approach them. Please get into contact with the local dealer.
8) After detonation or operation, please discard the safety airbag component
according to the Discard Method of Safety Airbag Already Detonated.
3. Disposal method of detonation outside the car
1) This should be performed on a free plane terrain at distance of more than 10m
away from the obstacles and other persons.
2) Even if in breeze weather, the safety airbag module should be detonated at
the downwind of the battery.
① Disconnect both positive (+)/negative (-) cables from battery terminals, then
remove the battery from the car.
Note:
■After the battery cables detached, you should wait for at least 3 minutes before
the next procedure.
② Remove safety airbag module from the car
Note:
J4 Workshop Manual safety assistant System
■ Place the safety airbag component on a flat ground and keep the liner upward.
Do not place any objects on its top.
3) When detonating the driver-sided safety airbag module:
Connect two wires in length of more than 10m to two leads of safety airbag
adaptor wiring and wrap the joint up with insulation tapes. The other ends of those
two wires should link to each other (short-circuit) to prevent the safety airbag from
unexpected explosion.
4) Set up the safety airbag module as follows:
① Hold the safety airbag adaptor connected to the above wires, pass it through
underneath of prepared used tire assembly, and further connect to the safety airbag
module.
② Pass the thick wire through the mount hole of safety airbag component, then
fix the safety airbag component on the used tire of wheel, keeping the liner on the
airbag component upward.
Note:
■ Save space for the adaptor wiring below the wheel. If such space not is
available, the reaction force from the safety airbag detonation may damage the wiring
of adaptor
③ Stack three used tires without rims on the top fixing the tire of safety airbag
component.
④ At the site as far as possible away from the safety airbag module and
screened places, disconnect two connected wires from each other and connect them
respectively to two terminals of battery (the battery already removed from the car)so
as to detonate the safety airbag.
Note:
■Prior to detonation, carefully check and be sure that nobody nearby.
■As the detonated gas generator is very hot, you should wait for at least 30
minutes and move it until it cools down. Though the gas released from the detonated
safety airbag is non-toxic, it is irrespirable. For the moving rules of the detonated
safety airbag, please refer to the Discard Method of Safety Airbag already Detonated.
J4 Workshop Manual safety assistant System
SRS020
■If the safety airbag component cannot be detonated by the above-stated method,
do not approach them.
■After detonation or operation, please discard the safety airbag component
according to the Discard Method of Safety Airbag Already Detonated.
4. Disposal method of the safety airbag already detonated
Discard the detonated safety airbag in accordance with the enforced local laws
and (or) regulations as other parts and components. In case of discard, special cares
should be taken for the following points:
1) As the detonated gas generator is very hot, you should wait for at least 30
minutes and move it until it cools down.
2) Do not spray water or oil on the safety airbag detonated.
3) Possible substances irritating to the eyes and skin may be attached on the
detonated safety airbag components, thus, wear the gloves and goggles while handling
the detonated safety airbag components.
Note:
■ If substances still entered into eyes or attached on skin after following those
precautions, you should rinse those parts by great amount of clean water. If the skin
becomes inflamed, handle it by medical treatment immediately.
4) Tightly seal up the vigorous PVS bag containing the discarded safety airbag
component.
5) Wash your hands after completion of this work.
5. Removal of safety airbag control module.
1) Turn off the ignition switch, disconnect the negative (-) of battery and wait for
at least more than 3 minutes until the energy storage capacitor of inbuilt SDM
Complete the discharge.
2) Remove auxiliary dashboard (see Removal and Installation of Auxiliary
Dashboard)
of Auxiliary Dashboard)
3) Remove 2 screws fixing SDM
Loosen and pull out wiring connector of SDM
J4 Workshop Manual safety assistant System
Take out SDM.
Note:
■ Do not let the SDM drop or bump.
6.Install as the opposite order of
removal of safety airbag control module
(SDM)
Note:
■When installing, pay attention to the
SDM direction, and align the arrow on SDM to the same direction of car driving.
SRS021
J4 Service Manual Air Conditioning System
AC-1
AC Air Conditioning System
Precautions:
It is required to observe the following notices when air conditioning system is
inspected and maintained, or otherwise it may cause vehicle damage and personal
injury.
■ It is required to use gloves and goggles so as to avoid chilblain, blindness, and other
effects on skin during skin contact, as the freezing point of refrigerant is low but the volatility is
strong.
■ It is required to flush the contact place immediately with clear water, and
required to go to ophthalmology and dermatology for diagnosis and treatment, in case
when refrigerant splashes into the eye or gets in touch with the skin. It is not allowed
to rub the eye with hand or handkerchief.
■ The site must be ventilated, during refrigerant related operations. Discharge of
refrigerant in large quantities at enclosed site may lead to oxygen deficiency.
■ Refrigerant Discharge Allowance: 1000ppm (4184mg/m2)
It may give rise to anomaly or susceptibility of heart and cardiovascular system,
as well as immune system, and anomaly of respiratory system or skin diseases, if the
quantity of discharge is excessive.
■ It is not allowed for moisture, dust, and other extraneous substances to be
present in the surrounding environment, during refrigerant related operations, and
these extraneous substances may be harmful to the air conditioning system when they
flow inside.
■ Gas leak detector shall be prepared when operations related to refrigerant are
conducted. R-134a refrigerant may generate harmful gas when it gets into contact
with high-temperature objects, and therefore attention shall be paid to leak prevention.
■ R-134a refrigerant must be used for the air conditioning system of this vehicle
type. It may cause adverse impact on the system parts if other refrigerants are used.
■ R-134a refrigerant and R-12 refrigerant are incompatible, and so blending is
not allowed even in a very little quantity.
J4 Service Manual Air Conditioning System
AC-2
■ It is not allowed for pyrophorus or ignitable materials to be present around the
vehicle, during operations related to refrigerant, and special attention shall be paid, as
explosion may be aroused in the case when refrigerant tank is exposed into heat
source.
■ R134a container is in the high-pressure state, and it is absolutely not allowed to
be placed under high-temperature environment. Moreover it is required to check
whether or not the temperature of storage environment is below 52℃.
■ Dust covers are generally used for air conditioning parts in order to prevent the
inflow of sewage, dust, and water content. Dust covers shall be removed before
operation and sealed after operation.
■ The refrigeration oil synthetic oil (PAG) applicable to R-134a is easier to
absorb moisture than R-12, and the absorptivity is higher by 10 times than the
refrigeration oil of mineral oil. It will affect the compressor, the lubricating function,
and the durability when moisture is excessive.
■ Humidity produces extremely bad impact on air conditioning system, and
therefore it is advisable to avoid operation on rainy days.
Refrigeration oil must be coated on “O”-ring, when air conditioning system is
re-assembled after removal, and especially, the bolt connected parts shall be manual
installed before they are installed by two wrenches.
■ When flange connecting parts are assembled,
the nuts and bolts shall be connected at the same time
while the pipeline is gently pushed
■ When the air-conditioner is installed, applying
torque above the standard to assemble or clamping “O”-ring with excessive force
will lead to the leak of refrigerant, and therefore
operations should be in accordance with the provisions.
■ It is not allowed for hose to be twisted.
■ It is absolutely not allowed to separate the air conditioning system before
refrigerant is fully recovered. Refrigerant and refrigeration oil will discharge under
the impact of system pressure, which will pollute the surrounding environment, if the
AC001
Bolt locating pin
Positive connecting part Negative connecting part
Nut
push
J4 Service Manual Air Conditioning System
AC-3
system is separated before recovery.
■ Refrigeration oil (Model: PAG) must be added when refrigerant is refilled,
during replacement of air conditioning parts.
Table for Filling Capacity of Refrigeration Oil
refrigerant pipe
10 cc
Replacement of
Evaporator
30 cc
Replacement of
Condenser
30 cc
Replacement of Pipeline
30 cc
Replacement of Drying
Bottle
30 cc
-
-
When replacing the compressor, the required amount 120ML shall reduce the amount
of discharged refrigeration oil from the old compressor, and the result is the amount of
refrigeration oil needed to be discharged from the new compressor.
Specified amount - the amount of refrigeration oil discharged from the old compressor
= the amount of refrigeration oil discharged from the new compressor.
Note: Even if there is no discharged oil from the removed compressor, it is not
allowed to discharge the oil from the new compressor more than 50ML.
Service tools:
Common and special tools necessary for the maintenance
Table of Special Tools for Inspection and Maintenance of Air Conditioning System
Name of Tool
Picture of Tool
Name of
Tool
Picture of Tool
Digital
Multimeter
High-Streng
th Lamp of
Invisible
Light
J4 Service Manual Air Conditioning System
AC-4
Ripping Pincers
R-134A
Manifold
Measuring
Apparatus
Halogen
Leakage
Detector
Tracing
Color
Injector
R134A Tracing
Paint
Microtherm
ometer
Positive Flow
Control Valve
Shaft Seal
Protection
Device
50lb Refillable
Recovery Tank
Pressure
Test
Adapter
Name of
Tool
Picture of Tool
Name of
Tool
Picture of Tool
Air
Conditioni
ng System
Lip Seal
Detaching
Tool
“O”-Ring
Detaching
Tool
J4 Service Manual Air Conditioning System
AC-5
Valve
Core
Removal
and
Installation
Tool
“O”-Ring
Installation
Tool
Spring
Caliper
Spring
Caliper
refrigerant
Recovery/
Regenerati
on, and
Refilling
System
passive
Test
Light
J4 Service Manual Air Conditioning System
AC-6
Inspection of Air Conditioning System and Filling of Refrigerant
1. Installation of refrigerant filling instrument
1) Close the manual valves on both ends of
refrigerant filling instrument.
2) Install the filling pipe of refrigerant filling
instrument in the connecting place. Connect the LP
pipe at LP pipe nozzle and the HP pipe at HP pipe
nozzle, and then tighten the nuts with hand.
2. Operation of Refrigerant Discharge
1) Connect the refrigerant filling instrument to the system.
2) Put the cleanly cleaning cloth in the open place of central hose.
3) Gradually open the HP manual valve and discharge the refrigerant.
Caution:
The compressor refrigeration oil will discharge from the system, if the exhaust
velocity is too fast.
4) Check whether or not the trace of refrigeration oil is present on the cleaning
cloth, and slightly close the manual valve when trace is present.
5) Slowly open the LP manual valve, after the measuring scale of filling instrument is
dropped to 3.5kg/cm2.
6) It is required to slowly open the HP and LP manual valves, in order to reduce
system pressure, until the measuring scale displays 0 kg/ cm2.
3. Evacuation Operation of Refrigeration System
Caution:
■ The system must be evacuated after refrigerant discharge. It is to remove the
air and moisture through this operation, for 15 minutes after respective parts have
been assembled.
1) Confirm whether or not engine is under “Close” status.
2) Connect the filling instrument to the joint place of compressor, and close the
two ends.
3) Confirm whether or not refrigerant is discharge from the system.
AC002
low
high
off
on
low
J4 Service Manual Air Conditioning System
AC-7
4) Connect the central pipeline to the air suction place of vacuum pump.
5) Open the HP and LP valves of filling instrument after vacuum pump is
operated.
6) The measuring scale of LP detector is larger than 0.96kg/ cm2 vacuum after
10 minutes, otherwise air leak exists with the system, repair as follows.
Make use of the filling system for the refrigerant container.
Inspect the leak place with leak detector, and repair it if any.
Discharge the refrigerant and evacuate the system.
Continue evacuation, if no leak evidence
is found.
7) Re-operate vacuum pump.
8）The measuring scales of filling
instrument on both ends shall maintain
0.96kg/cm2 vacuum
8) Continue evacuation until measuring
scale displays 0.96kg/cm2.
Stop evacuation after 15 minutes of evacuation and close the pressure valve of
filling instrument, then disconnect pipes from the pump. This allows refrigerant to be
filled.
4. Use of Refrigerant Control Valve
Fully turn the Handle in counterclockwise
direction, before valve and refrigerant
container are connected.
2) Place the disc to the top position in
counterclockwise direction.
3) Turn the disc with hand in clockwise
direction, after central pipeline is connected to
valve device.
4) Turn the handle in clockwise direction and drill in the upper part of the seal.
AC003
AC004
low
high
close
close
air
Vacuum pump
J4 Service Manual Air Conditioning System
AC-8
5) Loosen the nut of connecting pipeline for connecting joint of filling
instrument.
6) Tighten the nut after exhaust for several seconds.
5. Filling of Refrigerant (in Gaseous
State)
Caution:
■ It is to fill the gas refrigerant to the system through LP end device, and the
refrigerant in gaseous state will flow into the system, when the refrigerant
container is placed in a straight way.
1) Install the refrigerant container to the regulating valve.
2) Open the LP valve, and adjust the valve for the LP measuring scale to be
controlled below 4.2kg/cm2.
3) Start the engine and turn on the air conditioning system.
Caution:
■ Place the container in a straight way, in order to prevent the liquid refrigerant
from being filled into compressor through air suction port.
4) Close the LP valve after specified quantity is filled.
■ Specified Refrigerant Filling Capacity:480±20g
5) The container may be put into a water
tank of about 40℃, if refrigerant filling speed
is too slow.
AC005
AC006
low
on
off
Refrigerant
Refrigerant
Immerging in water, and heat the
water to approximate 40℃
J4 Service Manual Air Conditioning System
AC-9
Caution:
■ It is not allowed to heat water up to higher than 52℃, under whatever
circumstances.
■ It is not allowed for high-temperature light to get in touch with the container.
6. Filling of Refrigerant (in Liquid State)
Caution:
■ This operation is to be used for filling through HP end. Upend the refrigerant
container, and the refrigerant will then be able to enter into the system.
1) Close the two ends of HP and LP valves completely, after system is
evacuated.
2) Install the regulating valve for refrigerant container.
3) Fully open the HP valve and then upend the container.
4) Excessive system filling will increase discharge pressure,
and therefore, it is required to fill refrigerant and close the HP valve with correct
capacity at the same time while the weight of refrigerant is measured.
■ Specified Refrigerant Filling Capacity:480±20g
5) Close the valve of filling instrument after specified refrigerant is filled.
6) Check whether or not air leak exists by leak detector.
Caution:
■ Don’t start the engine when HP end is used for filling.
■ It is not allowed to open the LP valve when liquid refrigerant is used for
filling.
■ Performance test must be made before separation of filling detector.
AC007
Refrigerant
J4 Service Manual Air Conditioning System
AC-10
System Control
1. System Overview
Electric controlled air conditioning system is applied to this vehicle type.
Supercooling type is used for air conditioning condenser, and therefore the refrigeration
performance is enhanced. In order to contribute to defrosting performance, automatic
switch to external circulation mode is selected during the mixed and defrosting pattern.
Control of condenser fan is divided into low and high two phases according to vehicle
speed, temperature of cooling water, and difference in pressures of air conditioning
refrigerant. Increase in air delivery and air mixing capacity of blower may improve the
refrigerating and heating performances.
Drawing for Control Panel of Electric Air Conditioning System
J4 Service Manual Air Conditioning System
AC-11
2. Schematic Drawing for Refrigeration
Condenser
Installed in the front of
vehicle, it is supposed to
convert refrigerant of gas
state into liquid refrigerant
of high temperature and
high pressure.
Drying Bottle
Absorb the moisture in
refrigerant, and store
refrigerant.
Compressor
Driven by the engine pulley, it
can convert the
low-temperature low-pressure
gas refrigerant into high
pressure and temperature gas
and send to compressor,
controlled by the clutch.
Expansion Valve
It allows refrigerant to expand rapidly
and convert it into low-temperature
low-pressure liquid.
Blower
Send the air into the evaporator and
send the cooled air into the vehicle.
Evaporator
During the process of vaporific refrigerant
changing into gas, heat will be absorbed from the
air passing through the evaporator by making use
of blower.
(the drop of surrounding temperature)
High
temperature
and high
pressure gas
High
temperature
and high
pressure
liquid
low-temperature and
low-pressure liquid
low-temperature and
low-pressure gas
J4 Service Manual Air Conditioning System
AC-12
3. Schematic Drawing of Components
Schematic Drawing for Components of Air Conditioning System
1- lower air passage II 2 - Air conditioner assembly 3 - Warm Air water pipe assembly 4 -
condenser and guide plate assembly
5 - exhaust pipe assembly 6-pipeline and expansion valve bracket 7-Compressor bracket
8-Compressor Assembly
9-lower air passage I 10-lower air passage III 11 - AC controller assembly
4. Control Form of Air Conditioning Control Panel and Description about
Functions
Fully electric control method is applied to air conditioning control, and the rear
defrosting/reversing/rearview mirror heating switch is integrated on the panel, while
servo motor control is applied to the internal and external air circulation patterns as
well as air blowing pattern. Backlight/LED is used for panel illumination, and the key
symbols are spray painted and radium carved. The functions of keys and knobs on air
conditioning panel are indicated as in the following figure.
2
6
5
4
8
7
3
9
1
10
11
J4 Service Manual Air Conditioning System
AC-13
Schematic Drawing for Air Conditioning Control Panel
1 - internal and external air circulation patterns switch 2 - air-conditioning Mode Knob 3 - A/C
air conditioning switch
4 - air blower knob 5 - Temperature Control knob 6 - Rear defrosting heating switch
Schematic Drawing of Control Circuit and Description about Connecting Pins
Diagram of Control Module Terminals
I/NO
USE
Connector type NO .
Remark
A
A/C control
panel
KET 050 23M
MG 642,179
1
2
AC output signal
3
Evaporation sensor (5V)
4
Blower switch on signal
5
Temperature motor positive
pole
6
Motor temperature feedback
voltage
7
Temperature motor negative
pole
8
Rear defrosting open/close
signal
9
Rear defrosting switch
indicator
10
11
12
Backlight negative pole
13
Backlight positive pole
14
New Air Blow Motor negative
pole
15
New Air Blow Motor positive
pole
16
Sensor bottom wire
Connector type
Connector type of air blow
controller
J4 Service Manual Air Conditioning System
AC-14
17
Mode Motor Reference
Voltage (5V)
18
Mode Motor feedback voltage
19
Mode motor negative pole
20
Mode motor positive pole
21
ground wire
22
Battery positive pole
23
Ignition switch
B
Airflow
switch
plug-in
KET 250 6MKET
250 6M
1
Medium and high speed
2
Public end
3
Ground
4
High Speed
5
Medium and low speed
6
Low speed
Schematic Diagram of Control Circuit
Blower motor
Speed regulation
resistance
Mode motor
Temperature
motor
Circulation air door
motor
Evaporation sensor
Rear defrosting switch
Three-way-
pressure
switch
J4 Service Manual Air Conditioning System
AC-15
Functions, Positions, and Inspection of System Components
1. Air conditioner assembly
Air conditioner assembly consists of the blower, expansion valve and evaporator,
heater, and housing, and so forth. The air from the outside sucked by blower, passes
through evaporator, heater, etc, entering the vehicle, in order to achieve
air-conditioning normal performance.
1- defrosting outlet sponge 2 - heater water inlet/oulet hose bracket 3-air-cycle inlet left housing
4-air-cycle inlet sponge 5-air-cycle inlet right-shell 6 - circulation air door 7 - Filter Element 8
Explosive view air conditioner
assembly
1
9
8
7
6
5
3
2
4
10
11
18
12
14
15
16
17
19
20
21
13
J4 Service Manual Air Conditioning System
AC-16
-circulation air door motor 9 - blower upper housing 10 - Blower Assembly 11 - speed resistor 12
- blower lower housing
13 - weep pipe 14-lower air passage throttle 15 - evaporator core 16 - Temperature throttle 17 -
heater core 18 - Temperature throttle motor 19 - distribution box 20 - Mode Motor 21 - mode
damper
2. Blower
The blower comprises motor and fan, and the air door motor at air suction port is
used to transit internal/external air mode, and to suck in the internal air or the external
air.
The function of air door motor at air suction port is achieved through the button
for internal/external air of controller. The air enters through the two side intakes,
when it is in the internal circulation mode, and the air enters through the filter on the
front-end shield of vehicle while it is in the external circulation mode. The blower is
used to suck in the air at this point, and for heat exchange through evaporator, for the
refrigerated air to enter into the vehicle.
3. Speed Regulation Resistor
1) Function
To randomly regulate the blower motor speed according to the change in output
current
2) Installation Position
The installation position of speed regulation resistor is indicated as in the figure
AC008
3) Appearance
The appearance of the speed regulation
resistor is indicated as in the figure AC009
AC009
AC008
J4 Service Manual Air Conditioning System
AC-17
4. Internal/External Circulation Air Door Motor
1) Function
To be installed on blower assembly, and controlled by the internal/external
circulation selection button on automatic air conditioner, to actuate the
internal/external circulation air door, and to achieve the transition of air inlet mode.
2) Installation Position
The installation position is indicated as in the figure AC010.
5. Blower Motor
1) Function
Rotate the fan to form the air delivery required by air conditioning system by
making use of the vehicle power supply.
2) Drawing of Component
3) Test Method:
Add random voltage to “+” terminal, and inspect it after “-” terminal is earthed.
It is namely normal when the rotating speed of blower is faster if higher voltage is
applied.
6. Evaporator Temperature Sensor
1) Function
AC010
J4 Service Manual Air Conditioning System
AC-18
Sense the temperature of evaporator core and transmit it to FATC to prevent
freezing of evaporator
2) Installation Position
It is assembled inside the evaporator core as im the figure. The sensor is
internally provided with thermosensitive resistor for negative temperature coefficient,
and therefore the resistance increases when temperature drops, while the resistance
drops when temperature rises.
3) Table of Parameters (Temperature – Resistance – Output Voltage)
The compressor will disconnect when the temperature stays at 0 degrees C (6.9
K Ω) compressor, and will actuate when the temperature reaches 3.5 °C (5.9 K Ω).
Table of Parameters for Evaporator Temperature Sensor AC012.
AC011
AC012
J4 Service Manual Air Conditioning System
AC-19
7. Evaporator & Heater
The air delivered by blower will firstly be
cooled down through evaporator.
According to the different open & close degree of
temperature control air door, part of the air through
the evaporator will be sent to heater core, and the
rest air will be sent to the upper housing. In order to
control indoor temperature and air mixing, the rear part of heater housing is the place
for the mixture of the air through the heater core and the air into the upper housing.
Thus mixed air through the effect of mode air door motor is sent to the required air
outlet, to achieve the performance of indoor temperature adjustment amd
defrosting/demisting. Namely the heater assembly adjusts air mixing, temperature
control, and air outlet direction.
8. Mode Air Door Motor
1) Function
To be assembled in the left part of heater shell, controlled by the signal of mode
switch for air conditioning panel (FATC), to start the position of air door with
small-sized motor in regulation mode inside the air door motor - The changing
differences in voltage when motor is started are reflected to FATC, and FATC judges
the feedback signal. When air door reaches required position, the work of motor will
stop.
2) Installation Position
3）Schematic Diagram of Control Circuit
AC014
AC013
J4 Service Manual Air Conditioning System
AC-20
Diagram for Circuit of Mode Air Door Motor
9. Temperature Control Air Door Motor
1) Function
To be installed on the right side of heater shell, controlled by the operating signal
of temperature control knob on AC controller, to start the small-sized motor to
regulate the position of temperature control air door - The changing differences in
motor voltage when motor is started are reflected to AC Controller, which will judge
the reflected signal. When air door reaches required position, the work of motor will
stop.
2) Installation Position
Schematic Diagram of Control Circuit
AC015
J4 Service Manual Air Conditioning System
AC-21
Diagram for Circuit of Temperature Control Air Door Motor
10. Condenser and Drying Bottle
1) Function
The HTHP gas refrigerant from compressor cools down at normal temperature.
Cooling of condenser depends on the forced air delivery of running air and fan. The
condenser for this vehicle type is in the parallel flow type, combined together with
drying bottle. The refrigerating performance is enhanced, the quantity of refrigerant
required by the system is reduced, through cooling, and the number of parts is reduced
through combination with drying bottle. It used to replace drying bottle in the past,
when contamination arises with system, but it is only required to replace the drying
agent after the cover of drying bottle in the lower-end part is detached for this vehicle
type.
2) Installation Position
11. Engine Cooling System
1） Concept of Cooling Fan Control
The engine cooling unit (ECU) controls the rotating speed of cooling fan by two
phases (High/Low) after the input vehicle speed, air conditioner load, and temperature
AC016
Feedback voltage
J4 Service Manual Air Conditioning System
AC-22
value of cooling water are compared.
When vehicle speed sensor and cooling water temperature sensor are confronted
with failure, it drives the cooling fan, and as high-speed operation at the same time.
2) Cooling Fan picture
Cooling fan is integrated into the front-end module, and it switches high/low
speed operation by acquiring cooling water temperature, speed, and related
information.
The power of cooing fan at high speed is 180 to 220 W, and at low speeds is 120 to
150 W.
3） Cooling Fan Control circuit
Cooling Fan Control circuit
POWER
LOW SPEED
POWER
J4 Service Manual Air Conditioning System
AC-23
Cooling Fan Pin Definition
NO.
PART NO.
PART NAME
CONNECTOR TYPE
WIRING HARNESS END
PART END
1
1308113U8510
FAN
ASSEMBLY
JACKET: FCI 60402501
INSERTING SLICE: FCI 60040441
JACKET: FCI 60500901
INSERTING SLICE: LEAR
26691.330.710
SEALING PLUG: LEAR
16697.627.626
2
FAN
ASSEMBLY
JACKET: DJ70328-6.3-21
INSERTING SLICE: DJ6218-E6.3B
SEALING PLUG:
JACKET: DJ70328-6.3-11
INSERTING SLICE:
DJ6116 6.3B
SEALING PLUG: DJ9011
3
4
THE SHAPE OF THE CONNECTOR
DEFINITION OF THE CONNECTOR (PART END)
1
HIGH SPEED
GEAR
POSITIVE
2
LOW SPEED
GEAR
POSITIVE
3
NEGATIVE
NEGATIVE
12. Three-Way Pressure Switch
J4 Service Manual Air Conditioning System
AC-24
1) Function
Medium-pressure switch is added in the past air conditioning two-way pressures
for the three-way pressure switch, and the medium-pressure switch is started and
sends signal to the engine control unit, when system pressure rises. At this point the
water tank fan and the condenser fan are under the high-speed status, thereby to
prevent the performance drop arising when pressure rises, and to be able to protect the
air conditioning system when pressure (HP/LP) is under anomalous condition.
2) Installation Position
The installation position is indicated as in the figure.
3） Circuit Diagram
Diagram for Circuits of Three-Phase Pressure Switch
4） Specifications and Parameters
Table of Specifications and Parameters for Three-Phase Pressure Switch
HFC - 134 a
High-pressure
OFF
3.14 Mpa
medium-pressure
ON
1.77 Mpa
Low-pressure
OFF
0.196 Mpa
System Removal and Installation
1. Removal and installation of air
conditioner assembly
1) Removal
AC018
AC017
J4 Service Manual Air Conditioning System
AC-25
① Recover the refrigerant in the system with special refrigerant recovery
equipment.
② Disconnect the batter negative connection.
③ Open the engine compartment, and disconnect the warm air water pipe joint.
④ Remove the fastening bolts for expansion valve.
⑤ Remove the instrument panel assembly.
⑥ Loosen the bolts for bracket of instrument panel, and carry off the bracket of
instrument panel.
⑦ Remove the fastening bolts and nuts for the air conditioner assembly.
⑧ Disconnect the circuit plug-in connector, and take out the air conditioner
assembly.
2) Installation.
Assembly is the reversed order of removal.
2. Removal and installation of Temperature Control Motor
1) Removal
① Disconnect the battery negative connection.
② Remove the instrument panel.
③ Disconnect the plug-in connector, and remove
the fastening screws for temperature control motor.
④ Take off the temperature control motor.
2) Installation.
Assembly is the reversed order of removal.
3. Removal and installation of mode damper motor
1）Removal:
① Disconnect the battery negative connection.
② Remove the instrument panel.
③ Disconnect the plug-in connector, and remove the fastening screws for mode
damper motor.
AC020
AC019
J4 Service Manual Air Conditioning System
AC-26
④ Take out the mode damper motor.
2) Installation.
Assembly is the reversed order of removal.
4. Removal and installation of internal/external
circulation air door motor.
1) Removal
① Disconnect the battery negative connection.
② Remove the instrument panel.
③ Disconnect the plug-in connector, and remove the fastening screws for
internal/external circulation air door motor.
④ Take out the internal/external air door motor.
2) Installation.
Assembly is the reversed order of removal.
5. Removal and installation of Heater
1) Removal
① Remove air conditioner assembly
② Remove the fastening bolts for heater.
③ Take off the stationary baffle, and pull out the heater outwards.
2) Installation
Assembly is the reversed order of
removal.
6. Removal and installation of
Evaporator
1) Removal
① Remove air conditioner assembly
② Remove the screw and buckle in the middle of the distribution box assembly
AC021
AC022
AC023
J4 Service Manual Air Conditioning System
AC-27
(Not all included in the picture).
③ Remove the fastening screws around
the evaporator.
④ Pull apart the evaporator and the
heater assembly from the middle, and take
out the evaporator.
2) Installation
Assembly is the reversed order of removal.
7. Removal and installation of Air
Conditioning Panel
1) Removal
① Unclench the edge frame of air
conditioning panel by slotted screwdriver.
② Pull out the controller (all the buckles
in connection).
③ Pull out the air conditioning control panel outwards and disconnect the two
plug-in connectors behind.
2) Installation.
Assembly is in the reversed order of removal.
8. Removal and installation of Condenser
1) Removal
① Recover the refrigerant in the system with special refrigerant recovery
equipment.
② Disconnect the batter negative connection.
③ Remove the front bumper.
④ Remove the framework of front bumper.
⑤ Discharge the refrigerant and disconnect the connection with respective
pipelines.
AC024
AC025
J4 Service Manual Air Conditioning System
AC-28
⑥ Remove the front-end module assembly.
⑦ Remove the mounting bolts for condenser.
⑧ Take out the condenser assembly.
2) Assembly is the reversed order of removal.
9. Removal and installation of Air Conditioning Filter
1) Function
Foreign matters outside the car will be prevented entering inside so as to keep a
comfortable inner environment by the use of the air-conditioning filters.
2）Replacement Cycle
It may cause blockage with extraneous matters, increase in noise of blower,
reduction of air outlet delivery, and other failures, if the filter is not replaced for a
long time.
The replacement cycle is 5000~12000 km, and it shall be frequently inspected
and replaced in the areas where atmospheric pollution is severe or road conditions are
not good. Frequent wash and change is recommended.
3) Replacement Steps
① Hold down the two sides of storage box and remove it downwards.
② Press down and Pull out the buckle of the air conditioning filter cover, and
remove the cover.
③ Take our the air conditioning filter from air conditioning filter cover.
AC026
J4 Service Manual Air Conditioning System
AC-29
④ The air conditioning filter installation is the reversed order of the above
mentioned.
Caution:
■ To replace the filter, put the concave side upwards, and cannot be reversed.
J4 Service Manual Air Conditioning System
AC-30
Periodic Maintenance
Notice: ★ indicates the checking, adjustment, repair and replace if necessary.
To replace refrigeration oil, the compressor shall replace the new oil according to the
Maintenance item Content
Maintenance cycle
Eve
ry
day
Ev
ery
we
ek
E
v
er
y
M
o
nt
h
E
v
e
r
y
q
u
a
rt
e
r
E
ve
ry
ye
ar
Refrigeration System
Refrigerant
amount
to observe whether or not the flowing liquid has
bubbles through the observation glass.
★
Pipeline
Whether or not hoses have cracks or damage
★
Whether or not there is leak in each joint place
★
Whether or not each fixed clamp has loose or
damage.
★
Compressor
Refrigeration Oil Refrigeration Oil Replacement
★
Belt Check the belt tension and whether there is wear
★
Compressor
Bracket
Check whether there is any loose bolts and
damaged brackets
★
Condenser
Condenser Core
Check whether there is dirt clogged, and clean if
necessary
★
Fan Motor
Whether it functions well and whether it has
strange sound.
★
Evaporator
Water
Inlet/Outlet Hose
Check whether the clamp has loose.
★
Fan Motor
Whether it functions well and whether it has
strange sound.
★
Electrical apparatus components
Control box
Check whether the electrical apparatus
components are intact
★
plug-in
connector
Check whether the wire head and the plug-in
connector have loose or got off.
★
Pressure Switch
Check whether the high and low pressure is
normal
★
Temperature
Control
Check whether the wind speed is normal in
Position 3.
★
Electromagnetic
Clutch
Check whether it can properly close or
disconnect
★
J4 Service Manual Air Conditioning System
AC-31
regulations.
Failure analysis and troubleshooting summary table
Symptom
Possible fault Cause
Solution
AC System without
refrigerant
Leakage exists in the
system
1. Check with eyes:
① To observe whether there is oil stain in
the connection place of each part, once
there is oil stain, which means the
system has leakage. Soap water can be
applied to the suspicious area, and
then observe whether there are
bubbles..
② Observe each part to detect the
abnormal fault. For instance, there are
scratches, squash and impact damage
on the surface of the condenser and
evaporator core.
2. Through the vacuum method, listen
carefully near the parts to catch sizzle
sound; if any, there is leakage here.
3. Inspect with equipment:
① Apply electronic Leak detector of high
sensitivity.
② Dye tracing for leakage.
Improper amount of
refrigeration oil in
system.
Replacement of the system
parts, increase or reduce in
accordance with the
regulations.
1. First confirm refrigeration oil specifications
and should not be blended; specifications of
common use: PAG;
2. After recovering refrigerant: add
approximately 30 g refrigeration oil.
3. To replace the compressor, pour out all the
refrigeration oil in the compressor, and add the
oil same as that in the changed compressor.
4. Replacement of pipeline: add approximately
30g refrigeration oil.
5. Replacement of condenser: add
approximately 60g refrigeration oil.
6. Replacement of evaporator: add
approximately 50g refrigeration oil.
7. Replacement of drying agent: add
approximately 10g refrigeration oil.
Airflow is abnormal
Air conditioning without
wind.
1. Circuit Fault.
① Check whether the motor circuit or
plug-in connector has loose or got off.
② If fuse gets off or damaged, replace it.
If relay breaks down, replace it..
2. Mechanical Failure
① IF motor breaks down, replace it.
② If temperature air door mechanism
gets damaged, unable to adjust throttle
to the cooling state, replace it;
③ If controller breaks down, replace it.
If the speed regulation module is damaged,
replace it.
J4 Service Manual Air Conditioning System
AC-32
Airflow of air conditioning
is slightly small.
1. Low voltage, check the Power Supply
Battery.
2. Whether the air duct is congested, and
whether all the grilles are opened.
3. Whether the blow surface has leakage, check.
4. The speed regulation module fails and needs
to be replaced
5. Whether the wind resistance of the air filter is
excessive, resulting in the block of dust and
extraneous matters.
6. Reversed direction of motor rotation , switch
the positive and negative pole of the plug-in
connector.
Air Conditioning
without Cooling
System without refrigerant
Pressure gage test, please refer to check of
refrigerant leak.
No air blow
Please refer to Check of abnormal airflow.
Compressor does not work
1. Electromagnetic Clutch does not work
① Fuse blown, replace it;
② If the plug-in connector in the circuit
gets off and damaged, check the
circuit and replace it.
③ Replace the burnt relay.
④ Remove the damaged clutch assembly,
repair or replace.
2. If drive belt is broken, replace it.
3. Signal is not clear.
① Pressure switch is damaged, no
pressure signal; by short circuit signal
detection, if damaged, replace it.;
② ECU failure, inspection and
maintenance.
4. If the compressor has an internal damage,
replace it.
Air conditioning
cooling is not very
good
Insufficient refrigerant
1. Test the pressure to see whether it is in the
normal range of values; refill the refrigerant if it
is insufficient.
2. Check whether the system has a
microleakage.
Excessive refrigeration Oil
1. Discharge superfluous refrigeration oil and
fill the required amount of refrigeration oil.
Compressor is not in
normal state
1. The slip of compressor belt or clutch.
Airflow of air conditioning
is slightly small.
Please refer to Check of abnormal airflow.
Pressure is not normal
1. High pressure is lower than normal value,
and low pressure is lower than normal
value
① If there is blockage in the expansion
valve, clear obstructions.
② If expansion valve is not fully opened,
adjust the valve or replace it.
③ Add the refrigerant if it is insufficient.
J4 Service Manual Air Conditioning System
AC-33
2. High pressure is higher than normal value,
and low pressure is higher than normal
value
① If the condenser cooling is poor, check
the condenser fan airflow and replace
the defective parts;
② If refrigerant is excessive, discharge
some.
3. High pressure is lower than normal value,
and low pressure is higher than normal
value
① compressor failure, lack of capacity
and necessary to be replaced.
② Insufficient refrigerant, and refill.
4. High pressure is higher than normal value,
and low pressure is lower than normal
value
① The impurity exists in the system,
leading to congestion.
No heating
performance in AC
System
no hot water in the core
There is blockage in the warm air water pipe.
Clear the blockage.
Water valve is damaged, resulting in the
blockage for water to enter into the core for
circulation; inspection and maintenance is
needed.
The wrong outlet position of water from the
engine prevents water entering into the core for
circulation; inspection and maintenance is
needed.
No air blow in AC system
Please refer to Check of abnormal airflow.
Failure control
Temperature control of controller is damaged so
as not to adjust the temperature damper to the
maximum heating. Replace the controller.
Poor heating
performance in AC
System
insufficient hot water
circulation
Check whether the water supply to the engine is
sufficient, or the engine failure.
The internal flow of hot
core is not smooth.
Clear the internal blockage or a replace heat
exchanger.
Small airflow.
Please refer to Check of abnormal airflow.
Mode damper is not correct
The rotation of temperature damper is not in
place, with the mixture of heat and coldness.
AC System with
abnormal sound
Compressor with abnormal
sound
Turn on the air conditioner and start the
compressor to see if the clutch has grinding
noise. If there is abnormal sound, replace the
compressor.
Pipeline expansion valve
with abnormal sound
Whether there is flowing chirps sound in the
expansion valve after the air conditioner is
started; adjust expansion valve and replace.
Damper mechanism with
abnormal sound
Whether there is resistance when adjusting the
damper mechanism, and whether there is "tick"
or "chuckling" sound; in such a situation, the
damper mechanism shall be coated with
lubricating oil or some parts shall be replaced;
J4 Service Manual Air Conditioning System
AC-34
Blower with abnormal
sound
Abnormal sound in the blower volute:
① There is a booming sound, check the
motor has no reversed rotation; adjust
plug-in circuit.
② "Creak" or "sizzle" sound comes,
indicating motor damage. Replace the
motor.
③ A "bang-bang" sound indicates the
extraneous matters in the volute.
Remove and check.
The blower is not installed firmly, resulting in
vibration sounds.
AC System with
peculiar smell
Filter with mildew
Remove the filter and check whether there is
serious contamination on the surface. Replace
in time.
Radiator surface
contamination
Whether there is oil stain on the surface of
evaporator and heater in production. Replace
and clean if necessary;
Discharge of condensate
water is not smooth
Condensate water is not fully discharged,
resulting in water deteriorating in the housing.
Replace drain port location.
J4 Workshop Manual ETACS control system
ETACS-1
ETACS information and Electronic Time Alarm Control System
Precautions
■Prior to removal of electric connector, the battery negative has to be removed
and wait for at least more than 1 minute, otherwise it will cause vehicle damage.
■When removing and installing component, protect the parts from being
detached with cloth so as to prevent damage.
■ Be careful not to damage the body components.
■In case where the removal/installation of some components cannot be achieved
by one person, then two should be available for operation so as to prevent drop-down.
■Do not use excessive force when removing and installing some trim parts, for it
may cause the part deformation.
Layout of Components
2
1
J4 Workshop Manual ETACS control system
ETACS-2
1-tweeter（anti-theft） 2-ETACS module
Function Description
1. Front washer-linked wiper control
ON
Ignition switch
IGN.S/W OFF
> 0.6s T3
ON
Front washer switch
OFF
T1 T2 T3
ON
Front wiper
OFF
T1：0.6±0.1s T2：2.5—3.8s T3：0.2—0.6s （MAX） T4：one period of wiper.
If the washer switch turns on for more than 0.6s with the ignition switch on the
position “ON”, the wiper will act at T1 (0.6±0.1s) after the activation of washer
switch until the washer switch turns off with the wiper continuously brushing for 3 T2
circles ( 3times);wiper wipe once if the washer switch is at T3(0.2～0.6s).
2.Speed induction type intermittent control
Turn front wiper to intermittent position, adjust time of intermittence by
receiving Real-time speed signal and front wiper intermittent adjustment signal.
ON
Ignition switch
IGN.S/W OFF
ON
Front intermittent switch
OFF
ON
Front wiper
OFF
T1 T2 T3
Layout of ETACS
Components
J4 Workshop Manual ETACS control system
ETACS-3
T1：0.3s T2：4/3s T3: Intermittent time
Intermittent
grade
Value of
resistance
of
pisition
Intermittence
time(speed≤100km/h)
Intermittence
time(speed>100km/h)
’’Level 1’’
0
4s
4s
’’Level 2’’
12.5K
6s
5s
’’Level 3’’
25.2K
8s
6s
’’Level 4’’
37.9K
10s
7s
’’Level 5’’
50K
12s
8s
3. Locked rotor protection of front wiper
If there is no return signal from wiper in 18 seconds, close relay output of front
wiper.
4. Time control of rear windshield defrost
ON
Generator
Terminal “L” OFF
ON
Defrost switch
OFF
ON
Defrost relay
OFF
T1 T1 T1
T1：20±2ms
Generator is working, charging indicator is off, turn on defrost switch, defrost
relay starts to work, lasting T1（20±2min）, If the interval between two times of press
down the defrost switch is shorter than T1, then the defrost performance will be
deleted by pressing down the defrost switch for the second time.
J4 Workshop Manual ETACS control system
ETACS-4
5. Ignition keyhole lighting control
When the ignition switch is on the position “OFF“, any of the front doors LH/RL
is opened, the ignition lock lamp lights up and goes out in T1 (10±1s) after the door
closed up;if front door is open, ignition switch turns to "ON", lamp goes off.
O
N
Ignition switch
IGN.S/W OFF
ON
Front door switch
DR S/W OFF
ON
Ignition keyhole
lighting
OFF
T1 T1 T2
T1：10±1s T2：0—10s
Left/right door open time lasts > 15min, Ignition keyhole lighting goes off.
6. Lighting control of driver’s front dome light
Turn front dome light on DOOR,open front door, front dome light goes on; after closing
door,if ignition switch is on ACC/OFF,front dome light will go off after T1 （30±2s）,T2
（5.5±0.5s). if ignition switch is on,front dome light goes off.
J4 Workshop Manual ETACS control system
ETACS-5
T1：30±2s T2 5.5±0.5s T3 15min
If door keeps open more than 15mins, innner dome light goes off for 5.5s;
7. Power window time control
When the ignition switch is on the position of ON, front door closes, power
window can be operated. When the ignition switch is on the position LOCK or ACC,
the power window is operable within T1 (30±3s); if the front door opens within T1
(30±3s), the power window is inoperable.
ON
Ignition switch
OFF
ON
Front door switch DR
S/W
OFF
ON
Power window
generator
OFF
T1 T1
T1：30±3s
8. Taillight auto-off control
Under any situation where the lighting switch (combination switch LH) shifts
from “OFF” to “ON”, the taillight lights up.
The taillight will go out under some of the following controls, when:
1) The lighting switch (combination switch, LH) shifts from “ON” to “OFF”;
2) The key is taken out coinciding with the driver-sided door opened, the taillight
will go out; if the key is inserted again, the taillight lights up.
Notes: Here the taillight refers to the small light system.
Insert
Ignition key
Pull up
ON
Small light switch
OFF
ON
Driver-sided door
switch
J4 Workshop Manual ETACS control system
ETACS-6
OFF
ON
Taillight relay
OFF
9. Front fog lamp control
Ognition on, small lamp opens, open front door switch, front fog lamp lights up, small lamp
switch to OFF or front fog lamp switch off, front fog lamp goes off.
10. Rear fog lamp control
When the ignition switch is on the position “OFF” with the light switch
(combination switch LH) and the front fog lamp switch turned on, turn on the rear fog
lamp switch on the A/C control panel, it will not light up; when the ignition switch is
on the position “ON”, with the light switch shifted to small light (combination switch
LH) and the front fog lamp switch turned on, the rear fog lamp will light up by
turning on the rear fog lamp switch, where if the front fog lamp turned off, the rear
fog lamp will be also put out; when the light switch shits to other light positions, the
rear fog lamp will be not subject the control of front fog lamp, i.e. the front fog lamp
switch is turned off, and the rear fog lamp switch may freely control the rear fog
lamp.
ON
Taillight relay
OFF
ON
Ignition switch
OFF
ON
Front fog lamp switch
OFF
ON
Rear fog lamp switch
OFF
ON
Rear fog lamp
OFF
J4 Workshop Manual ETACS control system
ETACS-7
11. Electric door lock control
Remote Control Central Lock can be controlled in driver side, when it is closed,
fastener outputs signal of locking, doors will be locked; when it is opened, fastener
outputs signal of unlocking, doors will be opened.
Pull
out
Driver-sided door switch
Press down
Pull
out
Passenger-sided door
switch
Press down
ON
Door locking output
OFF
ON
Door unlocking output
OFF
12. Key management control
With key inserted to car and driver-side door open, fastener output unlocking
signal, so doors can't be locked; if keep pressing fastener switch, fastener will output
unlocking signal after T2, and output unlocking signal 3 times afterwards; within T3
(0s<T3<0.5s) pressing fastener switch, driver-side door closes, loosen fastener in the
meantime, outputting unlocking signal, doors will not be locked.
Insert
Ignition key
Pull up
J4 Workshop Manual ETACS control system
ETACS-8
Turn on
Driver-sided door switch
Turn off
Locking
Door locking switch
The
unlocking
ON
Front door unlocking
Output OFF
T1 T2 T1 T1
T1：0.5±0.1s T2：1±0.1s T3：0 s<T3<0.5s
13. unlock automatically while impact.
Airbag explodes after impact, and airbag control module outputs signal of 240ms
to ETACS, 200ms is low level, 40ms is high level,BCM will outputs T3(5sec)
unlocking motion after T2(40msec), then doors will be open. Now, indoor dome light
opens, alert warning light glitters (period is 0.72s,duty cycle 50%). When hazard
warning lamp is glittering, ignition switch OFF or doors open will relieve hazard
alerting.
14. Automatic locking
If the ignition switch is on the position “ON” with the door unlocked, the door
will be automatically locked when the speed is over 40Km after T1 (1±0.3s); if
fastener unlocks while driving, door will be locked automatically again after T1
(1±0.3s).
T3
“ON”
Impact
signal
ON
OFF
Unlocking
signal output
ON
OFF
J4 Workshop Manual ETACS control system
ETACS-9
ON
Ignition switch
OFF
40km/h higher than
Vehicle Speed Sensor
40km/h lower than
The unlocking
All doors locking switch
Locking T1 T1
ON
Locking relay
OFF
T1：1±3s
15. Auto-unlocking with the key pulled up
When the doors are in the locking state, the locking relay will give a T1
(0.5±0.1s) unlocking signal after the key is pulled up, afterward the doors will stay in
unlocking state.
Insert
Ignition key
Pull up
The unlocking
All doors locking switch
Locking
ON
Locking relay
OFF T1
T1：0.5±0.1s
16. Alert function
All doors and engine cover closed, lock door with remote controller or
mechanical key,hazard warning light glitter once T1(1.0±0.2s), warning light rings
once（100ms）, alert state starts; with doors and back trunk closed, door locks if use
remote control to lock, but hazard warning light doesn't glitter, it is not in the state of
alert. With all doors closed, hazard warning light glitters once T1(1.0±0.2s), warning
horn rings once（100ms）, state of alerting starts.
J4 Workshop Manual ETACS control system
ETACS-10
Open
All doors front cover
Close
ON
Remote controller locking
OFF
ON
Locking relay
OFF
Alert
Alert state
Non-alert
ON
Hazard warning light T1
OFF
T1：1.0±0.2s
17. Alert relieve function
Relieve alerting state with remote controller or mechanical key, door unlocks,
hazard warning light glitters T1 (0.5±0.2s), another glitter occurs after T2（0.5±0.1s）,
indoor dome light opens if it stay on“DOOR”, Unlock with remote controller and
mechanical key, no doors will be locked within 30s after the door unlocked by the
remote controller, and enter automatically into alert state, indoor lamp (“DOOR”)
goes off.
This function is set to prevent the doors from triggering by misconduct.
ON
Remote controller unlocking
OFF
ON
Unlocking relay
OFF
Alert
Alert state
Non-alert
ON
Hazard warning light T1 T2 T3
J4 Workshop Manual ETACS control system
ETACS-11
OFF
ON T4 T4
Driver dome lighting
OFF
ON
Door switch DR S/W
OFF
ON
Locking relay
OFF
T1：0.5±0.1s T2：0.5±0.1s T3：1±0.1s T4：30±1s
18. Alarm function
When car stays in alerting state, open doors and engine cover, warning siren
rings T1(27±2s), then rings(T1) again after T2(10±1s), after 3 times, hazard warning
light glitter at T3（0.5±0.1s）,duty cycle 50%, time is the same as warning siren.
Alert
Alert state
Non-alert
Open
All doors front cover
Rear trunk door closed
ON
Warning siren T1 T2
OFF
ON
Hazard warning light T3
OFF
T1：27±2s T2：10±1s T3：0.5±0.1s
19. New abnormal conditions occurred in alert state
While in alerting state, if doors and engine cover open, warning siren rings,
Hazard warning lights flashes; It will finish 3 alarms and enter into alarm state if there
are doors activated within the time of 3 alarms.
Open
All doors front cover
Rear trunk door closed
ON
J4 Workshop Manual ETACS control system
ETACS-12
Start relay
OFF
ON
Warning siren
OFF
ON
Hazard warning light
OFF
20. While warning, relieve alarm with remote controller or mechanic key.
In alarm state, use the remote controller or mechanic key to relieve the alarm.
The unlocking relay outputs an unlocking signal, the doors stay in unlocking state;
Relieve the alarm state, the warning siren stops buzzing and the hazard warning stops
after flashing two times. Stay in alarm-relieved state.
ON
Remote controller unlocking
OFF
ON
Unlocking relay
OFF
Alert
Alert state
Non-alert
ON
Start relay
OFF
ON
Warning siren
OFF
ON
Hazard warning light
OFF
T1 T2
T1：0.5±0.1s T2：0.5±0.1s
21. In alarm state, use the remote controller locking with the door closed.
In alarm state, while door closed, use remote controller or mechanical key to lock.
Activate relay to cut off the power, the hazard warning light will go out after flashing
for T1 (1±0.2s). Stay in alarm set state.
Open
J4 Workshop Manual ETACS control system
ETACS-13
All doors front cover
Rear trunk door closed
ON
Remote controller locking
OFF
ON
Locking relay T1
OFF
ON
Start relay
OFF
ON
Hazard warning light T1
OFF
T1：1±0.2s
22.In alarm state, use the remote controller locking with the door opened
In alarm state, use remote controller or mechanical key to lock with the door
opened, the locking relay will output an locking signal to start relay for power cut-off;
if all doors are closed at this time, the hazard warning light will flash once T1
(1±0.2s), horn rings once, then alarm state starts.
Open
All doors front cover
Rear trunk door closed
ON
Remote controller locking
OFF
ON
Locking relay
OFF
ON
Start relay
OFF
ON
Hazard warning light T1
OFF
T1：1±0.2s
J4 Workshop Manual ETACS control system
ETACS-14
23. In alarm state, relieve the alert in absence of the remote control key
In alarm state, the alarm may be relieved in 30s with the ignition switch on the
position “ON”.
Insert
Ignition key
Pull up
ON
Ignition switch
OFF 30 s
ON
Warning siren
OFF
Alert
Alert state
Non-alert
24. Doors abnormally opened after the alarm is relieved
After the alarm relieves, the alarm buzzs continuously and restores its initial state
when the doors abnormally opened.
Open
All doors front cover
Rear trunk door closed
ON
Start relay
OFF
ON
Warning siren
OFF
ON
Hazard warning light
OFF
25. Remove/install the battery in both alert and alarm states
After the battery removed in alert and alarm states, the warning siren buzzs by
refitting the battery, as it stays in alert state at this moment.
J4 Workshop Manual ETACS control system
ETACS-15
Alert
Alert state
Non-alert
Open
All doors front cover
Rear trunk door closed
Remove
Battery
Installation
ON
Start relay
OFF
ON
Warning siren
OFF
26. Remove/install the battery in the process of alarm relief
After the battery removed during the alarm relief, refit up it again, the alarm state
will be set.
Remove
Battery
Installation
Alert
Alert state
Non-alert
27. Lock Protection Function
If it keeps lock and unlock for 8 times within 10s, close door lock output (now
it is unlocked), restores after 15s.
28. Searching car function
Warning horn rings for 3 times(500ms rings, 500ms stops) if receiving wireless remote control
signal>0.5s, duty cycle 50%, and warning alert lamp glitters for 3 times, same frenquency with
alarming horn.
Replacement of ETACS control module and alarm speaker
1. Remove the battery negative pole (-).
2. Open and remove glove box with hands
J4 Workshop Manual ETACS control system
ETACS-16
3. Remove Parking restrictions on both sides of glove box with hands
4. Remove ETACS MODULE fixing bolt.
5. Disconnect the ETACS module connector and remove the ETACS module.
6. Removal of alarm speaker assembly.
1) Remove the front bumper.
2) Remove the bolts on the tweeters, disconnect the connector and remove the
tweeter assembly
7. Installation in the reverse order of removal.
Definition of ETACS control module terminal
ETACS001
ETACS002
ETACS003
ETACS004
J4 Workshop Manual ETACS control system
ETACS-17
Diagram of ETACS Control Module Terminals
Definition Table of ETACS Control Module Terminals
Definition of connector A (white)
Definition of connector A (white)
1
Interior lights
13
Small light relay
2
Alarm relay
14
Anti-theft alarm
3
Front wiper relay
15
Power window relay
4
Rear defrost relay
16
front fog lamp relay
5
high spped relay of front
wiper
17
Co-pilot’s seat door switch
6
Rear fog lamp relay
18
hazard warning relay
7
return signal of front wiper
19
Ground
8
Door locking relay
20
Keyhole light
9
Buzzer power
supply(reserved)
21
NC
10
B+
22
NC
11
Door unlocking relay
23
NC
12
Trunk switch
24
Speed signal
B
A
J4 Workshop Manual ETACS control system
ETACS-18
Operation instruction of ETACS remote control key code selection
1. Connect the code selector to the diagnosis interface.
2. Press down the training button.
The indicator (green) on the code selector lights up
While the body turning indicator lights up. The remote controller code selection gets
ready.
3. Press down any button on the remote controller (key).
Hold down 1s until the turn light dies out, which means the remote controller
code selection is achieved.
Next, press down any button on the second remote controller for the training of
second one.
Definition of connector B (grey) Definition of connector B (grey)
1 Driver seat door switch 13 Small light switch
2 Rear fog lamp switch 14
Driver seat door lock
switch
3 Low speed of front wiper 15
High speed switch of front
wiper
4 Front sprinkler switch 16
Inching switch of front
wiper
5
Mechanical key unlock
switch
17 Storage code
6
Mechanical key lock
switch
18 IG1
7 Defrost signal 19
Front wiper intermittent
switch
8 Front fog lamp switch 20 Engine hood switch
9 IG2 21 Safety airbag signal
10 Four-door Switch 22
Front wiper intermittent
adjustment
11 Key insert switch signal 23 Generator L
12 Headlight switch 24 Outside antenna
ETACS005
J4 Workshop Manual ETACS control system
ETACS-19
4. Pull up the connector plug of code selector after waiting for 5s, exit from the
code selection state (The process of code selection will be effective by completion
within 5s, otherwise ineffective).
Then, the two remote controllers of successful code selection may be applied.
Note:
■For each code selection operation, only the training of two remote controllers is
allowed. If the third button is pressed down, the first trained remote controller will be
automatically ineffective. If the fourth is pressed down, the second trained
auto-lapsed.
■The time for each code selection operation is limited to 5s. Please complete two
code selections within 5s. It will exit automatically from the code selection mode after
5s.
■If the owner lose the remote controller, he/she can renew the training for two
new remote controllers. The previously trained two will be automatically lapsed.
Fault diagnosis
1. If the training button pressed down, the turning light does not light up, which
means the connection failed.
1) Please check if the connector of code selector is in proper contact.
2) Repress the training button until the turning light turns on.
2. If the turn light shines but does not go out after the remote controller pressed
down, please change another remote controller. If it continues shining, please check
if the body controller (ETACS) is damaged.
ETACS common failure analysis
1. Controller ineffective (lock/unlock and flash)
A. Is it controllable with another controller?
Yes, it means there is a failure in this remote controller or it has not been set in
this Intrusion Alarms System (it is possible that the new duplicated remote controller
has deleted this remote controller).
No, then refer to the next step as follows.
J4 Workshop Manual ETACS control system
ETACS-20
Notes: It is rather rare that two remote controllers fail at the same time.
B. If both remote controllers are inoperable, please check: door warning
switch(key inserting switch)
① Check the pin of “door warning”with the multi-meter. If this pin is under
high voltage power, the controller will be not effective.
② The controller is ineffective with the key in the ignition lock.
2. The controller can only unlock instead of locking.
A. Check if the center lock system can perform the locking. If yes, there is a
failure in ETACS. If not, a failure is in the locking relay.
B. Check if the central lock system can perform the locking. If it is relocked,
there might be a failure in the lock device. Under such circumstance, the central lock
switch in the lock device is functional.
3. After the door is locked by the remote controller, no flashing and horn prompt
will be given.
This case occurs generally due to a certain door switch not closed (the door
unclosed). See input of “Locking by the remote controller with the doors not closed”:
switch of 4 doors/ engine hood switch/trunk switch
4. Alarm rings period after locking doors remotely
Please check engine hood indicator/door indicator/indoor light/courtesy
lamp/courtesy lamp on dash board, if one of them is on, it means door switch or trunk
switch is not well conductive. Please close all doors/ hood or replace switch or adjust
door/trunk.
5. Remote controller unable to set into ETACS
While the remote controller is set up, all remote controllers should be reset again,
Because the previous setting of remote controller will be deleted with the first remote
controller successfully set.
6. Close distance of remote control
A. try another remote controller, if the remote control distance is too far away,
then change the battery of remote controller.
B. If the second one is still close, please check if the position of Intrusion Alarms
J4 Workshop Manual ETACS control system
ETACS-21
antenna is proper. If still in such case, it is necessary to change ETACS.
C. Note: The remote control distance is set commonly beyond 5m. If the remote
control distance is too far, it is easy to press wrong button of remote controller and
cause, in consequence, inside goods lost. Besides, the battery lifecycle of remote
controller will be shortened.
7. Interior lights constantly shining
A. It is generally due to the doors, engine hood and tailgate not closed
completely, or the switch damaged. Please check all doors or replace the switch. At
this moment, there will be no light flashing or horning if locking by remote control.
B. Interior lights switch stay in permanent ON, or the interior lights switch
grounds.
8. Horn doesn't ring
Both terminals of the alarm speaker present the polarity. Horn will not ring in
case of reverse connection.
9. No fast locking function
A. If the remote control locking is in normal function, but no fast locking
performance available, then the speed signal has not accessed into the ETACS
MODULE.
B. The failure of lock devices in the front doors LH/RH causes signal delivered
by the lock device on the locking position, thus the “Fast Auto-Lock” won’t operate.
10. When the car is driving at more than 40km/h, the lock device repeats the
cycles of locking for several times:
A. When the car starts driving, the “Speed Auto-Lock Function” will take effect
for auto-lock (lock-up). The car stays in locking state. If, in this moment, the doors are
unlocked, the interlock function of “ignition switch and door locks (prevent key from
locking in the car)” takes effect and automatically unlocks. In such way, the lock
device repeatedly performs unlocking/locking And it seems that car repeats locking,
unlocking and relocking.... and so on.
B. When the car starts driving, the “Speed Auto-Lock Function” will take effect
and lock automatically (lock-up). At this moment, if the lock device is not in position,
J4 Workshop Manual ETACS control system
ETACS-22
the lock device switch remains on the unlocking position, the “Speed Auto-Lock
Function” remains functional and relocks. At this moment, it seems that the car
always performs locking.
C. When car starts driving, the “Speed Auto-Lock Function” will take effect and
automatically locks (lock-up). At this moment, if the lock device rebound after
locking and shifts the lock device back on the unlocking position, the “Remote
Control Central Lock Function” will take effect and automatically unlock. In such
way, the lock device repeatedly performs unlocking/locking And it seems that car
repeats locking, unlocking and relocking.... and so on.
Note: Uncompleted tapping or rebound of lock device is probably caused by
mechanical fault: lock is frozen or can not move fluently, increasing resistance.
11."Coo-coo" noise inside the door
It is commonly the skidding sound from the lock device made during locking.
Please replace the lock device.
12. Auto-lock-up by the central remote control
A. After unlocking by the remote control, the door is not opened, then the
auto-lock will enter into alert state in 30s. At this time, the alarm will rings if
manually opening the door.
B. Possibly a central control signal of locking given by the lock device.
C. In some cases, the vehicle speed signal has failure while idle and give a speed
signal, which causes speed automatically lock up.
13. The alarm buzzer horn alarms automatically within a period of time after the
locking
It might be a failure in the 4 D switch, engine hood switch or tailgate switch
which automatically locks up, triggering the alarm.
16. The failure of window up-down, wiper blockage, central remote control
ineffective and intrusion alarms out of run.
A. Take out the ETACS, and reinsert it to see if the failure disappears.
Sometime, the poor contact of connector will cause the system out of power supply
and operation.
J4 Workshop Manual ETACS control system
ETACS-23
B. If the system stays inoperable, the ETACS has a failure and should be
replaced.
17. Angle difference in the remote controller
It is normal that the remote controller has the angle difference because the radio
transmission is subject of obstruction effect and reflection point stack. But anyway,
the “No blind area within 6m in any directions” should be guaranteed.
18. Failure of window up-down
Short-circuit of relay burns out the driving components which drive the power
window relay.
19. Other cases causing the ETACS output damage
• Relay short-circuits and connects directly with the power supply, resulting in
damage on some driver components.
• Harness short-circuits and causes damage on some driver components.
• Harness short-circuits and causes some outputs out of control.
Technical parameters
Table of Technical Specification
Items Specification
Voltage DC12V
Voltage range
DC9V ～DC16V
Static current MAX 6Ma (at 12.8V)
Insulation resistance 100MΩ (DC500V tramegger)
Operation temperature
-40ºC～85ºC
Storage temperature
-40ºC～85ºC
Front wiper relay DC 12V, 200mA (relay load)
Front wiper relay(high spped) DC 12V, 200mA (relay load)
Rear windshield defrost relay DC 12V, 200mA (relay load)
Ignition keyhole lighting DC 12V, 1.4W (bulb load)
Driver dome lighting DC 12V, 10W×2 (bulb load)
Power window relay DC 12V, 200mA (relay load)
Taillight relay DC 12V, 200mA (relay load)
Rear fog lamp relay DC 12V, 200mA (relay load)
Electic door locker relay DC 12V, 200mA (relay load)
Alarm speaker DC 12V, 200mA (relay load)
Front fog lamp relay DC 12V, 200mA (relay load)
J4 Service Manual Combination Switch
CSW-1
Combination Switch
Combination Switch Assembly Diagram
1. Lighting control switch 2. Wiper control switch
2. Lighting control switch
It controls the signals from the turn lights LH/RH, headlight, front fog lamp, side
turn light and overtaking light.
It controls the signals from the side turn light and overtaking light. The headlights
work in operation mode of headlight, it can also implement the conversion of two
functions from the high beam to low beam, from the low beam to high beam.
1) Turn light
There are two Up-positions (Right turn)
and two Down-positions (Left turn) on the
turn signal lever, which are used to deliver
the turn signal.
To deliver a change lane signal, push the operating lever up or down till the end.
When the turn is finished, the operating lever will automatically retract. There are two
flashing arrows on the combination instrument, which display the turn direction
signals.
It is still required to push the operating rod upward or downward thoroughly and
2
1
Descriptions
CSW001
J4 Service Manual Combination Switch
CSW-2
loosen the operating rod, to send out the lane-changing signal. The operating rod will
automatically reset, when vehicle lane-changing operation is completed. When driver
sends out turning or lane-changing signal, if turn arrow flashes too fast, the signal
light may possibly have burned out, and other drivers will not be able to see the sent
turning signal. If certain bulb is burned out, it shall be replaced, to avoid traffic
accident. The bulb shall be checked as to whether or not it is burned out, and then the
fuse is to be inspected, if turn arrow on the instrument fails to flash when driver sends
out turning or lane-changing signal.
2) Headlight/low beam converter
If you wish to convert the headlight from the low beam to high beam, push the
turn signal/multi-function operating lever deviated from the driver. With the high
beam connected, the combination instrument will display the high beam signal if the
ignition switch is communicated.
If you wish to convert the headlight from the high beam to low beam, push the
turn signal/multi-function operating lever toward the driver.
3) Overtaking flash
This function enables the driver to deliver the overtaking signal to the headed
driver by using the high beam headlight. In use of this function, pull the turn signal
/multi-function operating lever toward the driver until the headlight high beam starts
shining, and then release the operating lever to turn off the headlight.
4) Front fog lamp
Front and rear fog light switch is located on the turn signal lever. When
the end of the bucket switch is in the position, you can rotate the lever
central knob to turn the front fog lights, position open the rear fog lights on, at
this point in the instrument cluster * (front and rear fog light indicator light goes on as
a reminder . Turn to the position "OFF" to shut down the fog lights.
2. Wiper control switch
1）Wiper operating control modes
(wash, intermittent, low-speed and
CSW002
J4 Service Manual Combination Switch
CSW-3
high-speed.
Clearance, low-speed, high-speed). Wiper in clearance document
When the wiper is located on the space gear, there are three mode options as high,
mid and low.
Use the operating lever on right side of steering column to operate the front
windshield wiper.
Windshield wiper is only with the ignition switch communicated that the front
windshield wiper can be operated.
Front windshield
Turn the operating lever to this position, allowing the high-speed wiping.
Turn the operating lever to this position, allowing the low-speed wiping.
Turn the operating lever to this position, allowing the option for a circle of
delayed wiping.
Move the mid-section of wiper operating lever to the LO, allowing the increased
delay, and to the HI, allowing the decreased delay. It is only with the operating lever
on the INT position that the wiper speed can be regulated.
2) Front windshield washing liquid
To wipe the front windshield, pull the washing liquid operating lever of front
windshield wiper toward the driver with the ignition switch already communicated.
Caution:
■In freezing weather, the wiper will not be operated without preheating the front
windshield. Otherwise the washing liquid will freeze on the front windshield and
obstruct the driver’s view.
■When the operating lever is released, the scrubber will stop working, but the
wiper will continues to run about three circles, then stop wiping or restore the initial
wiping speed previously used by the driver
Component check
J4 Service Manual Combination Switch
CSW-4
According to the table below, check the conductivity between the terminals of
wire connectors. If the conductivity between the wiring connectors and all terminals is
non-conform to that as stated in the diagram, change the switch.
Light lever switch continuity figure
Wiper lever switch continuity figure
Replacement of combination switch
Caution:
■Before removing the electrical connectors, the battery negative pole has to be
removed and wait for at least more than 3m, otherwise it will damage the car.
■When removing and installing component, protect the parts to be detached with
Steering switch
Light switch
Passing
switch
fog switch
Alarm lamp switch
Internal link
Wiper switch
Washing switch
J4 Service Manual Combination Switch
CSW-5
cloth so as to prevent damage.
■When removing the metal clamps from the trim parts, wrap the flat screwdriver
edge with cloth.
■ Be careful not to damage the body components.
■ When installing the body trim parts, first confirm clamps securely fitted in the
plate orifice on the body, then carefully press them in.
■ In case where the removal/installation of some larger components cannot be
achieved by one person, then two should be available for operation so as to prevent
the drop-down.
■ Do not use excessive force when removing and installing some trim parts, for it
may cause the part deformation.
1. Removal
1) Disconnect the battery negative pole and wait for at least 3m.
2) Remove the steering wheel air bag module
3) Remove the steering wheel.
4) Remove the top/lower covers of steering column.
5) Remove air bag clock spring, and the clock spring is easy to be damaged,
make sure 3 pins have been completely parted from the clock spring before removing
it.
6) Disconnect the combination switch connector.
7) Remove three fixing screws of combination switch.
8) Take out the combination switch assembly.
2. Installation.
Installation is the reverse order of removal.
■Tightening torque of fixing screw: 4 N·m
Check after installation
1. Operate the lighting handle of combination switch and check all lights and
switches for proper working condition:
2. When the lighting handle on the position “OFF”, all exterior lights and the
J4 Service Manual Combination Switch
CSW-6
night guide lamp of interior electric equipment should go out.
3. When the lighting handle on the small light, the marker lamps, F/R position
lamps, license plate lamp, instrument lighting and the night guide lamp of interior
electric equipment should light up.
4. When the lighting handle on the small light, press down the front (rear) fog
lamp switch, all front (rear) fog lamps should light up.
5. When the lighting handle on the position large light, the low beam of headlight
should light up, and all clearance lights remain in shining state.At this time, push
down the handle, the high beam of headlight will light up; return the handle to the
original position, then pull it up , the high beam lights up, and it will reset
automatically when is released.
6. When the lighting handle turned forward (backward) about 12°, all right (left)
turn lights start flashing, and the right (left) turn indicators on the instrument starts
flashing, it will stop flashing when the handle reset on the original position. When the
handle turned forward (backward) about 9°, the right (left) turn light flashes, and reset
automatically when the handle released.
7. When the alarm switch is pressed, all turn lights should flash together while
the L/R turn indicator lights on the instrument should do the same.
8. Operate the wiper/wash of combination switch and check the wiper, scrubber
for proper operation:
1) When the handle on the position OFF, the wiper and scrubber are motionless.
2) When the handle on the position INT, the wiper bar moves intermittently
according to a fixed interval.
3) When the interval regulating button turned to enables the time to vary between
FAST and SLOW, the interval of wiper bar movement changes.
4) When the handle on the position LO, the wiper bar keeps moving at lower
speed.
5) When the handle on the position HI, the wiper bar keeps moving at higher
speed.
6) Press down the wash button at the end of handle during the wiper operation,
J4 Service Manual Combination Switch
CSW-7
toggle the operating handle RH of combination switch about 6° toward your body, the
scrubber nozzle will sprinkle the wash liquid on the front windshield.
J4 Service Manual Lighting System
LT -1
Lighting System
Precautions:
■ Before removing the electrical connectors, the battery negative pole has to be
removed and wait for at least 1m, otherwise it will damage the car.
■ When removing and installing component, protect the parts to be detached
with cloth so as to prevent damage.
■ When removing the metal clamps from the trim parts, wrap the flat
screwdriver edge with cloth.
■ Be careful not to damage the body components.
■ In case where the removal/installation of some components cannot be
achieved by one person, then two should be available for operation so as to prevent
the drop-down.
■ Do not use excessive force when removing and installing some trim parts, for
it may cause the part deformation.
The combination light
1. Layout of Components
Layout of front light Components
J4 Service Manual Lighting System
LT -2
2. The front combination Light Replacement
1) Removal
① Disconnect battery negative pole.
② Remove front bumper, see "front bumper replacement".
③ Remove mounting screws of the front combination light in 3 installation
points
■ The removal torque is from 9 N•m to 11 N•m .
④ Carefully move the front combination light, remove the electric connector.
⑤ Remove the front combination light assembly.
2) Installation.
① Connect the electric connector of headlight assembly.
② Install the headlight assembly and fix bolts.
③ Remove front bumper, see "front bumper replacement".
④ Refit up the battery negative.
⑤ Check if the lighting conforms to the requirements.
■ If non-conform, see "The Combination Light Adjustment".
3. Replacement of high/low beam bulbs:
■ Do not expose the headlight too long time after detached from the reflector, as
the dust, damp and smoke etc may ingress into the lamp and affect the light
performance. Should install a new bulb and let the rear cover back in place after
High/low beam bulbs
Position lights
Turning light
J4 Service Manual Lighting System
LT -3
removing the bulb or the back cover immediately after
■ The headlight is in shape of semi-enclosed light beam and uses the replaceable
halogen bulb. The bulb replacement may be made inside the engine compartment, but
preferably after the removal.
■ When working on the bulb, only hold on the plastic holder of bulb instead of
contacting the glass shelf.
■ Do not shake or rotate the bulb when removing.
1) Removal
① Disconnect battery negative.
② Nearly optical/far from the back cover from the light in the counterclockwise
direction.
③ Disconnect the connector from behind the bulb and loosen the buckle.
④ Carefully remove the low and high beam bulb.
⑤ Do not shake or rotate the bulb when removing.
2) Installation.
Installation is the reverse order of removal.
Caution:
Do not expose the headlight too long time after detached from the reflector, as the dust, damp
and smoke etc may ingress into the lamp and affect the light performance.
■ The new bulb should be installed at once after the old one is removed from the
headlight reflector.
4. Replacement of the turn light bulb of headlight:
Caution:
■ Do not expose the headlight too long time after detached from the reflector, as
the dust, damp and smoke etc may ingress into the lamp and affect the light
performance.
■ New bulb should be installed at once after the old one is removed from the
headlight reflector.
■ Headlight is in shape of semi-enclosed light beam and uses the replaceable
halogen bulb. The bulb replacement may be made inside the engine compartment, but
J4 Service Manual Lighting System
LT -4
preferably after the removal.
■ When working on the bulb, only hold on the plastic holder of bulb instead of
contacting the glass shelf.
■ Do not shake or rotate the bulb when removing.
1) Removal
① Disconnect battery negative pole
② Unscrew, in clockwise, the turn light holder.
③ Counter-clockwise turn signal light bulb from the lamp.
④ Replace turn light bulb.
2) Installation.
Installation is the reverse order of removal.
5. Replacement of the turn light bulb of headlight:
Caution:
■ Do not expose the headlight too long time after detached from the reflector, as
the dust, damp and smoke etc may ingress into the lamp and affect the light
performance.
■ New bulb should be installed at once after the old one removed from the
headlight reflector.
■ Headlight is in shape of semi-enclosed light beam and uses the replaceable
halogen bulb. The bulb replacement may be made inside the engine compartment, but
preferably after the removal.
■ When working on the bulb, only hold on the plastic holder of bulb instead of
contacting the glass shelf.
■ Do not shake or rotate the bulb when removing.
1) Removal
① Disconnect battery negative pole.
② Counter-clockwise direction from near and far removed from the rear cover to
remove position lights.
③ Remove the position light bulb.
J4 Service Manual Lighting System
LT -5
④ Change the position of light bulb.
2) Installation.
Installation is the reverse order of removal.
6. Adjustment of headlight:
1) Confirm if all of tire pressure are in normal state.
2) Place the car and tester on the same flat surface.
3) Confirm that the car is on free of load condition except the driver (or equal
weight on the driver position) .
4) Turn on the headlight low beam.
5) Use the adjusting screw to regulate the lighting.
Low Beam, High Beam adjusted up or down in a spot, you can adjust their upper
and lower height; Low Beam, High Beam adjusted up or down in a spot, you can
adjust their the height from the left to right. If the front part of body has been repaired
and/or the headlight assembly replaced, the lighting alignment should be checked,use
light detection scanner to adjust it.
6) Focus the light according to the beam-focusing table until it gets in place.
Front fog lamp
1. Layout of Components
J4 Service Manual Lighting System
LT -6
Location plan of front fog lamp elements
2. Replacement of front fog lamp
1) Removal
① Disconnect battery negative pole.
② Remove front bumper. See
Front bumper replacement
③ Remove the fixing screws
on the fog lamp of front bumper.
④ Disconnect the electric connector and remove the fog lamp assembly.
2) Installation.
① Install the fog lamp assembly.
② Connect the electric connector.
③ Remove front bumper, see "front bumper replacement".
④ Reinstall the battery negative and check the lighting. If non-conform to the
requirements, the adjustment should be made. See"Adjustment of the Front Fog Lamp
Light Beam"
The screw tightening torque: 2 N•m
3. Replacement of the front fog lamp bulb
1）Removal
① Remove the bumper.
② Rotate the bulb seat cover counterclockwise. Remove the lamp cover.
③ Remove the fog light bulb from the
light bulb
④ Replace the fog light bulb.
LT001
LT002
J4 Service Manual Lighting System
LT -7
2) Installation.
Installation is the reversed order of removal.
■ After installation, check the lighting. If non-conform to the requirements, the
adjustment should be made. See"Adjustment of the Front Fog Lamp Light Beam"
4. Adjustment of the front fog lamplight beam
Caution:
■ Front fog lamplight beam can provide the correct road lighting only after the
adjustment.
■ Prior or after the installation of a new fog lamp assembly and the vehicle
maintenance or reparation, the installing bracket of front fog lamp may be possibly
disturbed, therefore, the front fog lamplight beam has to be checked and adjusted.
■ The front fog lamp assembly light beam of this model is unable to make
horizontal adjustment.
1) In order to ensure that the vertical light beam of front fog lamp is accurately
adjusted, prepare the car at first according to the following procedure.
① If the maintenance on other subjects was made on the car, confirm at first, that
all parts and component of the car are in place.
② Be sure that the fuel is at full level or slight lower.
③ Park the car on a level ground at distance of 1.52m from the target screen.
④ Stop all other operations on the car.
⑤ Shake the body suspension in place. .
⑥ Cover the front combination lamps when adjusting the fog light beam
2) Turn on the front fog lamp.
3) Through the space under the bottom of
front bumper
Insert the cross screwdriver to get close to the
vertical adjustment screw of fog lamp.
LT003
J4 Service Manual Lighting System
LT -8
4）Adjust up or down fog lamp
So that the top edge of highlight zone on the
screen is at 102mm lower than the horizontal
center line (2) extends from 0mm (3) below
the horizontal center line to the ground limit
(5).
Turn off the front fog lamp.
Taillight
1. Layout of Components
1 - brake/Position Lights (outside) 2 - Turn Signal Lights (outside) 3 - Reverse light (inside)
Location plan of taillight elements
2. Replacement of Reversing Lamp
1) Removal
① Disconnect battery negative pole.
② Open the rear door.
③ Open the reversing light repair holes on the
trunk carpet.
1
3
2
LT004
LT005
J4 Service Manual Lighting System
LT -9
④ Remove 3 tail light mounting nuts.
⑤ Replace the lamp or reverse light bulb.
2) Installation.
Installation is the reversed order of
removal.
Caution:
■Before installations make sure the
taillight is intact.
■During installation the tail lights cannot be damaged.
■After installation, check if fender has been installed in place and if fits
clearance between it and body is appropriate.
3. Replacement of taillight
1) Removal
① Disconnect battery negative pole.
② Open the rear door.
③ Remove the rear tail light mounting
LT007
LT006
LT007
LT008
J4 Service Manual Lighting System
LT -10
screws.
④ Pull out the outside tail light with both hands along the direction the vehicle is
heading for.
⑤ Counter-clockwise unscrew the bulb socket; replace the Light or Rear
Position Light/Brake Light, Turn Signal Light Bulb.
2) Installation.
Installation is the reversed order of removal.
Caution:
■Before installations make sure the taillight is intact.
■During installation the tail lights cannot be damaged.
■After installation, check if fender has been installed in place and if fit clearance
between it and body is appropriate.
High-mounted stop lamp
1. Layout of Components
Layout of High Mounted Brake Light Components
2. High-mounted brake lamp replacement
1) Removal
① Disconnect battery negative pole.
② Remove coat rack.
③ Disconnect the connector.
④ Use cross screwdriver to remove mounting screws.
J4 Service Manual Lighting System
LT -11
⑤ Take off the high-position brake lamp.
2) Installation.
Assembly is the reversed order of removal.
License plate light
1. Layout of Components
Layout of License Plate Light Components
2. Replacement of license plate light
1) Removal
① Disconnect the power supply.
② Use cross screwdriver to remove mounting screws
③ Take out the license plate light
④ Remove connector plug-ins, and replace license plate light.
2) Installation.
Installation is the reversed order of removal.
Caution:
■ Before installation make sure the taillight is intact.
■ Install the lamp base to the mounting holes.
■ Check it after installation.
Rear fog lamp
1.Layout of Components
J4 Service Manual Lighting System
LT -12
Location plan of rear fog lamp elements
Rear fog lamp Replacement
1) Removal
① Disconnect battery negative pole.
② Remove rear bumper.
③ Unscrew the mounting screws, and remove the rear fog lights.
④ Replace the rear fog lamp assembly
2) Installation.
Installation is the reversed order of removal.
Caution:
■ Before installation make sure the taillight is intact.
■ During installation the tail lights cannot be damaged.
■ After installation, check if fender has been installed in place and if fits
clearance between it and body is appropriate.
The dome light
1. Layout of Components
J4 Service Manual Lighting System
LT -13
Location plan of dome light components
Replacement of the rear dome light.
1) Removal
① Take out Dome light cover
② Remove the dome light 2 internal mounting screws.
③ Carefully from the car ceiling remove the dome light, breaking the plug-ins.
④ Replace the lamp.
2) Installation.
Installation is the reversed order of removal.
Caution:
■ Based on actual operation to select the bulb to be replaced
■ Before installation make sure the taillight is intact.
■ The light bulb in the base must be set at position.
■ Check after installation to make sure it meets the requirements.
Maintenance data and specification
Lamp Wattage and light color
Lighting Parameters table
J4 Service Manual Lighting System
LT -14
J4 Workshop Manual combination instrument
CM-1
Combination instrument
Summary
Combination instrument is in front of driver, in dash board upside of steering
column. Rest part of combination instrument includes installation parts and electrical
connector, are covered under combination instrument frame. Besides analogue
instrument and indicator, there are also some alarming or reminding hint and diagnose
information.
This instrument applys 4 clocks, with planar construction, left is tachometer,
right is speedometer, in the middle is fuel meter and water-thermometer. Central LCD
screen is driving information, including time/ overall mileage/ Mileage subtotal/
instant fuel consumption/remaining mileage, etc.
1. Tachometer
Square signal from revolving speed sensor connects directly to connector pin on
combined instrument, which will transfer to revolving speed.
Engine tachometer and frequency diagram:
Engine revolving speed
(r/min)
Error value
(r/min)
Input frequency
(Hz)
0
0
0
750
--
25
1000
±50
33.3
1500
--
50
3000
±150
100
J4 Workshop Manual combination instrument
CM-2
4500
--
150
6000
±300
200
7500
--
250
2. Speedometer
Square signal from ABS sensor connects directly to connector pin on combined
instrument
Adius of tyre(r): 302 mm
Pulse of tyre rotating one round (P):48
PPK: P * 1km / 2πr = 25296
Instrument will convert the input frequency signal to speed.
Speed and frequency diagram:
Speed
(Km/h)
Error value
(Km/h)
Input frequency
(Hz)
0
0
0
20
--
140
40
--
280
60
61 – 65
420
80
--
560
100
--
700
120
123 – 127
840
140
--
980
160
--
1120
180
185 – 189
1260
200
--
1400
220
--
1540
3. Fuel gauge
Electric resistance signal from fuel sensor connects directly to connector Pin on
combined instrument
Remaining fuel and electric resistance diagram
scale line indicator
Ohms(Ω)
Fuel volume
J4 Workshop Manual combination instrument
CM-3
4. Water-thermometer
Instrument receives PWM signal sent from engine ECU through connector pin,
signal frequency: 50Hz
Engine water degree will be indicated by the following diagram.
Instrument function introduction
Alarming signal
Nu
mb
er
NAME
Type
Symbol
Color
Control
method
Connect
to
Softw
are
Self-d
iagno
sis
Remark
1
Low fuel
alarm
LED
Yellow
Resistan
ce signal
Ignition
√
Triode
enlarging
at clip
port
2
Water degree
alarming
LED
Red
PWM
signal
Ignition
√
3
EOBD
LED
Yellow
Direct
(low
voltage)
Ignition
With
positive
side
connectin
g to
power
supply of
relay
J4 Workshop Manual combination instrument
CM-4
4
Low oil
pressure
LED
Red
Direct
(low
voltage)
Ignition
5
Parking brake
LED
Red
Direct
(low
voltage)
Ignition
EBD
input
efficiency
Brake fluid
level problem
Direct
(low
voltage)
Ignition
6
Driver’s
airbag
LED
Red
Direct
(low
voltage)
Ignition
7
Engine
self-diagnosis
LED
Yellow
Direct
(low
voltage)
Ignition
With
positive
side
connectin
g to
power
supply of
relay
8
ABS
LED
Yellow
Direct
(high
voltage
or
suspende
d)
Ignition
9
Charging
battery
LED
Red
Direct
(low
voltage)
Ignition
With
input side
protected
by diode
10
Left turning
LED
True
green
direct
(high
voltage)
Instrum
ent
ground
11
Right turning
LED
True
green
Direct
(high
voltage)
Instrum
ent
ground
12
Door open
alarm
LED
Red
Direct
(low
voltage)
Battery
Still work
even
ignition
turned off
13
Front fog
lamp
LED
Green
Direct
(high
voltage)
Instrum
ent
ground
J4 Workshop Manual combination instrument
CM-5
14
Rear fog lamp
LED
Yellow
Direct
(high
voltage)
Instrum
ent
ground
15
Engine
anti-theft
LED
Yellow
Direct
(low
voltage)
Battery
Still work
even
ignition
turned off
16
High beam of
headlight
LED
Blue
Direct
(high
voltage)
Instrum
ent
ground
17
Safety belt
LED
Red
Direct
(low
voltage)
Ignition
18
Cover of
luggage
compartment
LED
Red
Direct
(low
voltage)
Battery
Still work
even
ignition
turned off
19
Cruise
LED
Green
Direct
(low
voltage)
Ignition
With
cruise
20
ABS failure
LED
Yellow
High
electric
power or
high
resistanc
e
efficienc
y
Ignition
21
Front
passenger
seat belt
LED
Red
Sear
sensor:
load <
150Ω,
empty>8
kΩ
(low
voltage)
Ignition
22
Tyre pressure
alarming
LED
Yellow
Direct
(low
voltage)
Ignition
With
TPMS
23
TPMS failure
LED
Yellow
Direct
(low
voltage)
Ignition
J4 Workshop Manual combination instrument
CM-6
24
EPS
LED
Red
Direct
(low
voltage)
Operation description
1. Speedometer and odometer subtotal
Speedometer is showed in km/h. odometer is the mileage that car has be driven.
2. Total mileage
Total mileage is the total mileage that has been driven.
3. Tachometer
Tachometer is engine rotating speed, measured in 1000r/min.
4. Safety belt indicator
Always on until safety belt is shackled. Off after safety belt is shackled.
5. Safety belt warning tone
Short warning tone will occur when ignite the care, reminding people fastening
safety belt. Warning tone will be off after driver has fastened safety belt.
6. Airbag indicator
Airbag indicator indicates on instrument, airbag symbol. System will check if
there is breakdown on airbag system. The indicator can tell if there is problem with
airbag system. Checking content includes: airbag sensor/ airbag module/ circuit and
diagnosis module. This indicator will be on when car starts for several seconds, and
then off. It means airbag system is ready. If the indicator is always on or on when
driving, it means there is problem in airbag system.
7. Charging system indicator
As part of inspection, charging system indicator is on for short time means
normal when connect ignition switch and before car starts. The indicator should be off
after car starts. If indicator is always on or on whling driving, it means charging
system may have problem. If driving with this indicator on, electric will be used out.
Shut down all other equipments, such as radio/ AC, if insist on driving with this
indicator on.
J4 Workshop Manual combination instrument
CM-7
8. ABS indicator
ABS indicator will be on for several seconds when ignition switch connects. This
is normal. If ABS indicator is always on, then put ignition switch to LOCK position.
Or, if ABS indicator is on, pull over ASAP and shut down ignition switch. Restart
engine to restore system. If ABS indicator is still on or keeps on while driving, then
this needs to be repaired. If the braking system alarming indicator is off, then car can
still be braked, but without ABS. When ignition switch connects, ABS indicator will
be on for short time, which is normal. If the indicator is off, problem should be
eliminated, making it send out alarming with malfunction.
9. Engine coolant temperature.
When ignition switch connects, water-themometer shows the temperature of
cooling liquid of engine.
10. Oil pressure alarm
If oil pressure is too low, alarming indicator will be always on after ignition, or
on while driving.
It means engine oil is not enough. Engine oil may be too low, or other
malfunction. Oil indicator can be on under the following 3 situations:
1) As part of inspection, this indicator will be on when ignition switch connects
but engine doesn't start to work. This indicator will be off after engine starts. If
indicator is off when ignition switch connects, fuse or bulb may have problem.
2) Wben engine is idle running, indicator will twinkleand off afterwards. This
indicator will be on if brake urgently. This is normal.
Warning：
■Do not drive when engine oil pressure is too low.
Note:
■If engine oil lacks maintenance, it may damage engine.
11. High beam indicator light
This indicator is on when High beam connects.
12. Open-door alarm
This indicator is always on if door is open.
J4 Workshop Manual combination instrument
CM-8
13. Open-trunk indicator
This indicator will be on when trunk is not closed well.
14. Fuel gauge
When ignition switch connects, fuel gauge shows the remaining oil. If the fuel
tank is nearly empty, warning indicator will be on, although there is still a little fuel.
15. EPS problem indicator
When ignition switch in ON, this indicator will be on, now there is no assistance
on steering wheel, steering will be hard.
Combined instrument connector and pin definition
NO
connetor A(green)
NO
connetor B (blue)
1
TPMS Failure
1
Speed signal output
2
Immobilizer
2
empty
3
Driver-Seat-Belt
3
empty
4
Co-Driver-Seat-Belt
4
empty
5
ABS
5
Co-driver seat sensor1
6
Parking Brake and Brake Oil Warning Lamp
6
fuel imatation
7
empty
7
empty
8
Cruise
8
empty
9
empty
9
empty
10
empty
10
empty
11
empty
11
empty
12
empty
12
Parking Light
13
Stop and Go Failure
13
empty
J4 Workshop Manual combination instrument
CM-9
14
EPC
14
Air bag
15
Oil pressure warning
15
Ignition
16
Tire pressure
16
dashboard
17
Right Turn
17
Left-Turn
18
empty
18
empty
19
empty
19
empty
20
EBD
20
empty
21
Left front door open
21
Co-driver seat sensor2
22
Right front door open
22
Fuel Signal
23
Right rear door open
23
Reverse Radar
24
Trunk door open
24
Speed signal
25
Engine cover open
25
Rotate speed Signal
26
Left rear door open
26
Water temperature Signal
27
Illumination
27
Instaneous fuel consumption
28
EOBD
28
Rear fog light
29
Main relay power
29
empty
30
Charging indicator
30
EPS
31
empty
31
Front fog light
32
High Beam
32
Battery
Driver information display
1. LCD display
J4 Workshop Manual combination instrument
CM-10
Black background and red character on LCD display, showing: door-open,
remaining mileage, driving time, mileage subtotal, instant consumption, overall
mileage.
1) Door open: combined instrument receives signal of door-open (including 4
doors and engine cover, trunk cover),and display it on LCD screen.
2) Clock: 24-hour, error is less than ±1 second/day.
3) Instant consumption: combined instrument receives signal from engine ECU,
if car is not started or ignition switch is on, speed ＜3km/h, LCD display only
shows:--.-L/100km；when speed ≥3km/h, LCD display only shows number. highest
limit of instant consumption is 20L/100km, refresh every 0.5s.
4) Remaining mileage: count through the remaining fuel and instant consumption,
refresh every 10s.
5) Mileage subtotal:0～999.9km，accuracy 0.1km.
6) Mileage subtotal:0～999.9km，accuracy 1km, error ≤±2％/10km.
Information switch or adjustment through adjustment lever, order is
M1-M2-M3-M4-M1, through short press on adjustment lever.
M1: Display clock and overall mileage, long press can adjust clock;
M2: Display clock and subtotal mileage, long press can reset.
M3: Display instant consumption and overall mileage;
M4: Display remaining mileage and overall mileage:
If some information can be reset, then it will be zero, otherwise, nothing changes.
It will come back to M1 automatically after resetting instrument
2. Total mileage
Total mileage shows lower side on LCD display.
CM001
J4 Workshop Manual combination instrument
CM-11
Display overall mileage (0～999，999km)，it will stop at 999，999km.
3. Mileage subtotal
Mileage subtotal and overall mileage will be displayed on the same line, mileage
subtotal is the mileage beginning from resetting or voltage cut down. Display range is
0~999.9kms，accuracy is 0.1km, if instrument power supply is cut down(not ignition
power), mileage subtotal will be resetted.
4. Mileage subtotal clearance
Mileage subtotal willl be resetted to zero, if press adjustment lever for more
than 2 seconds.
5. Time
24-hour can be set through adjustment lever.
6. Time set
Short
press
Set hour
Increase
automatically
every second
5h
Increase 1 h
No operation
for 5s
Set min
Increase
automatically
every second
5 mins
Increase 1
min
No operation for 5s
Short
press
Short
press
Long
press
Long
press
CM002
J4 Workshop Manual combination instrument
CM-12
7. Mileage subtotal reset
Reset pole can be used to switch mileage subtotal, by pressing towards instrument.
Press lightly on adjustment pole(more than 300 millisecond and less than 2 seconds),
mileage subtotal will be switched between TRIP A and TRIP B; press more than 2
seconds can reset mileage subtotal to zero.
Removal and installation of Combination instrument
1. Removal
1) Remove instrument cover.
Adjust steering wheel to the bottom before removing instrument cover
(easy to remove), instrument cover is fixed by 2 bolts,
Remove bolts with short cross screwdriver,
take off cover.
2) Remove combination instrument
Combination instrument is fixed by 4 bolts,
Remove one by one with cross screwdriver.
CM003
CM004
Note:
■ Use the following definition:
press for short time = < 2 Secs but > 300mS
press for long time > 2 Secs but
■ Time displays on LCD when ignition switch closes.
■ Functions before will be restored when
ignition switch restarts.
J4 Workshop Manual combination instrument
CM-13
3) Pull out instrument, take off 2 connector of instrument harness(green and
blue).
2. Installation.
Assembly is the reversed order of removal.
CM005
J4 Workshop Manual windscreen wiper/Wiper washing
WW-1
Wiper washing system
Wiper system
1. Component location
2. Schematic diagram
J4 Workshop Manual windscreen wiper/Wiper washing
WW-2
3. Disassembly
1) Confirm the ignition switch is in
off position. Then, use flathead
screwdriver to pry apart two blanking caps(A) located near front wiper . After that,
use wrench to loosen two nuts and disassemble front wiper mountings and blades.
2）After unscrewing nuts, disassemble front wiper mountings and black assembly, the
specific method is described as follows, press B position of the below figure with
appropriate force until wiper arm become loose. Then, use the other hand uplift C
position and adjust strength according real situation until the wiper arm and blade
assembly be disassembled.
3) Disassemble ventilation panel, the specific method is detailed in service section of
ventilation panel.
4) Up plug connector between wiper wiring harness and wiper motor.
5) Unscrew two set bolts of wiper motor and linkage assembly, disassemble the
assembly from middle C-slot to finish the disassembly of motor and rod assembly; So
far, the whole front wiper disassembly has been finished.
WW001
J4 Workshop Manual windscreen wiper/Wiper washing
WW-3
6) Disassemble wiper blade separately as follows: After making sure the engine cover
is closed, uplift the wiper arm to lock position, then use thumb and index finger to
press on locking blocks at the junction position of wiper blade and arm. In the
meantime, uplift locking blocks to open it. After that, use one hand to hold the middle
position of wiper blade and use the other hand to hold U-shape hook position of wiper
arm, use strength to opposite directions to remove the wiper blade from wiper arm.
Caution：
■ Please make sure connecting rod stopped at automatic stop position before
disassembling wiper blade and connecting rod assembly。
■ In the process of disassembly, do not operate violently, to avoid damage
wiper blade and influence the effect of wiping.
4. Installment
Installment is converse process of disassembly, this instruction won’t explain it
in detail, important points and process are as follows:
Caution:
■ Connect the connector between wiper motor and wiring harness before
assembling wiper motor and rod assembly. There is a “click” sound when connection
is finished.
■ The tightening torque of fixed bolts of wiper motor and connecting rod
assembly is 11N.m±1N.m.c
J4 Workshop Manual windscreen wiper/Wiper washing
WW-4
■ Supply power to wiper motor before assembling wiper arm and blade
assembly. After wiper motor working about10s，operate combination switch to turn
off the wiper and make wiper motor stop at “OFF” position.
■ Wiper blade edge should be coincided with anchor point of windshield.
■ The tightening torque of mounting nut of wiper arm is 15N.m±2N.m.
5. Checking
Speed operation checking
1) Separate connector of wiper motor.
NO.
1
2
3
4
definitio
n
Ground
connecti
on
Off
position
Low
speed
High
speed
NO.1、3、4 terminal connect positive pole of accumulator，NO.1 terminal
connect negative pole of accumulator.
2) Follow the table as below, check whether the motor is normal.
Caution:
Position
1 2 3 4
OFF
LO
HI
J4 Workshop Manual windscreen wiper/Wiper washing
WW-5
■ Generally, the pollutants are from insect, sap and hot wax process using
commercial vehicle scrub solution.
6. Operation of checking wiper automatic stop.
1) Use joystick to operate motor at low speed.
2) Separate NO. 3 terminal of motor wire connector, make the motor stopped
at any position except OFF position.
3) Connect NO.2 and NO.3 terminal.
4) Connect positive pole to NO.1 terminal and connect negative pole to NO.4
terminal.
5) Check if the motor stopped at OFF position.
Washing system
1. Examination
1) Connect wash motor to water tank, add water to water tank.
Caution;
■ Before adding water to liquid reservoir, make sure there is no impurities on
filter and the filter has not been polluted. Clean the filter as needed.
2) Connect positive pole wire and negative pole wire of accumulator to positive pole
and negative pole terminals.
3) If the washing motor works normally, check if washing pipeline is damaged
or detached by stages. This checking should gradually from washing motor to
WW003
J4 Workshop Manual windscreen wiper/Wiper washing
WW-6
nozzle.
2. Disassembly
Caution:
■ Be careful not to damage seal of washer pump when it been repairing.
■Do not operate washer pump before adding liquid to washer pump reservoir.
1) Disassemble negative pole of accumulator.
2) Disassemble front bumper assembly, see service manual of front bumper.
3) Disassemble front washing pipe (A), disconnect the connector of wash motor
(B).
4) Disassemble wash motor.
5) Unscrew 2 bolts(A)and one nut(B), disassemble washing liquid pot(C).
6) Fowllow direction of pipeline, disassemble washing pipe assembly(A)
WW006
WW005
J4 Workshop Manual windscreen wiper/Wiper washing
WW-7
3. Installment
1) Assemble washing liquid pot.
Caution:
Before installing wash motor, make sure there is no impurities and
contamination, clean the filter and wash motor if needed.
2) Connect wash motor and flexible hose for washing.
3) Install wash motor.
4) Install nozzle of front washing system.
5) Install front bumper assembly.
Rear window defroster
1. Check
Caution:
Twine tinfoil around lead of multimeter to prevent it being damaged, use your finger
to press on tinfoil and slide it follow grid lines.
WW007
WW009
6V(normal)
J4 Workshop Manual windscreen wiper/Wiper washing
WW-8
1) Turn on the switch of defroster and use multimeter to measure voltage of every
heater strip at middle of rear window.
1) If open
Circuit happened between central point and positive pole,
volt value will be 12V.
2) If open circuit happened between central point and
negative pole, volt value will be 0 V.
4) When you find the direction of circuit break, move test
probe towards that direction, until there is abrupt voltage or
voltage becomes 0V, which is circuit break.
5) Examine resistance between measuring terminal and
midpoint of heating wire or this terminal and adjacent wire
by using an ohmmeter.
Resistance of wires with broken point should be double times
of that of other wires.
WW012
WW013
WW010
WW011
12V (normal)
Here Voltage is 0V
terminal
Voltage will change at this open-circuit
When test from the negative pole
Grille doesn’t have open-circuit
Positive
terminal
central
Test electronic no is double
Grille has open-circuit
J4 Workshop Manual windscreen wiper/Wiper washing
WW-9
Move probe slowly through that portions resistance affected to find the point at which
resistance changes suddenly.
Trouble inspection and repair
1. List of common faults of wiper and washer system
Common
faults
Cause and solution
Stopped
1. moving part jammed
2. 2 No power supply, broken wire
of connector
3. 3 Damaged motor
1. eliminate failure of
stuck
2.connect power
3 Replace motor
Abnormal noise;
malfunction
1.1 Internal noise of motor
2 Interference between moving parts
3 Abnormal noise arises between
blade and windscreen
1. 1 Replace motor
2. 2 eliminate failure of
interference
3. Clean windscreen
Trembling during
wiping
Add detergent into kettle to reduce friction during wiping.
The blade can not
get to horizontal
position when
returned
Reinstall wiper arm to make blade horizontal after motor returned
The windscreen
cannot get fully
clean
1. Dirty windscreen
2. Seriously damaged blade
1. Clean windscreen
2. Replace blade (It is
recommended to replace blade
every three months)
2. Systematic inspection of washer
Steps
Measures
Normal
Abnormal
1
Turn ignition switch to
ON position. Maintain
switch of washer at ON
position.
Run wiper with lower speed.
Water should be injected onto
windscreen with switch at ON
position. Wiper stops after 2-4
more circles when washer
switched off.
Washer does not
work
2
Put switch at relay
position (pulsed mode).
The wiper should wait for 1-2
seconds after one circle of wiping
and then starts to wipe again.
Wiper does not work
at pulsed mode.
Wiper does not work
in defrosting mode,
relay mode or lower
speed mode.
3
Put switch at relay
position (pulsed mode).
The washer continues to inject
water on windscreen with switch
Washer does not
work
J4 Workshop Manual windscreen wiper/Wiper washing
WW-10
Allow wiper to operate
for about 1–2s with
switch turned on.
at turned on position. The
wiper will operate 2-4 circles
after switch of washer is
released. And then returns to
pulsed operation.
Wiper does not work
at pulsed mode.
Wiper does not work
in defrosting mode,
relay mode or lower
speed mode.
4
Turn wiper switch to
lower speed position.
Wiper works continuously in
lower speed mode.
Wiper does not work
in defrosting mode,
relay mode or lower
speed mode.
5
Turn wiper switch to
higher speed position
(HI).
Wiper works continuously in
higher speed mode.
Wiper does not work
in higher speed mode
due to failure while
work normally in
lower speed mode.
6
Turn wiper switch to
OFF position.
Wiper returns with lower speed.
Wiper scraper works
continuously on
windscreen.
Wiper works
continuously.
3. Diagnostic procedure of wiper/washer system
Malfunction mode: The wiper or washer does not work in any mode.
steps
Measures
Yes
No
1
Check if fuse of fuse box in engine compartment/ fuse of
internal fuse box are fused
To step 2
To step 3
2
After the elimination of the factor of other circuits, replace
the fuse to see if the fault has been eliminated.
To step 3
3
With ignition switch turned on, check for normal function
of power circuit and grounding of motor.
Voltage between terminal 3 and ground of wiper motor
should be 12V and terminal 1 is grounded, in low speed.
Voltage between terminal 4 and ground of washer motor
should be 12V, in high speed.
To step 4
4
Replace wiper motor or washer motor. Does failure
disappear?
To step 5
5
Replace wiper switch.
4. Malfunction mode: only higher speed range does not work
steps
Measures
Yes
No
1
Check for electrical connectivity between terminal 4 and
terminal 1 of wiper motor.
To step 3
To step 2
2
Replace wiper motor
To step 3
J4 Workshop Manual windscreen wiper/Wiper washing
WW-11
3
Check for normal function of circuit between Terminal 4 of
wiper motor and the combined switches.
To step 5
To step 4
4
Repair or replace circuit between terminal 4 of motor and
combined switches. Does failure disappear?
To step 5
5
With combined switches turn to higher speed position,
check for connectivity of combined switches between
terminal 9 and terminal 10. Is it OK?
To step 7
To step 6
6
Change combined switches. Does failure disappear?
To step 7
7
Repair or replace circuit between terminal 10 of combined
switches and ground.
5. Malfunction mode: front wiper does not work only low speed range
steps
Measures
Yes
No
1
Check for electrical connectivity between terminal 3 and
terminal 1 of wiper motor.
To step 3
To step 2
2
Replace wiper motor
To step 3
3
Check for normal function of circuit between terminal 3 of
wiper motor and the combined switches.
To step 5
To step 4
4
Repair or replace circuit between terminal 3 of motor and
combined switches. Does failure disappear?
To step 5
5
With switch turned to lower speed position, check for
electrical connectivity between terminal 3 and terminal 10 of
switch. Is it OK?
To step7
To step6
6
Change combined switches. Does failure disappear?
To step7
7
Repair or replace circuit between terminal 10 of combined
switches and ground.
6. Malfunction mode: front wiper does not work only intermittently
steps
Measures
Yes
No
1
With switch turned to intermittent mode, check electrical
connectivity between terminal 2 and terminal 3, terminal 10
and terminal 8 of switch. Is it OK?
To step3
To step2
2
Change combined switches. Does failure disappear?
To step3
3
Check electrical connectivity between terminal 8 of
combined switches and BCM. Is it OK?
To step5
To step4
4
Repair or replace circuit between terminal 8 of combined
switches and BCM. Does failure disappear?
To step5
5
Check for electrical connectivity between terminal of wiper
relay and BCM. Is it OK?
To step7
To step6
6
Repair or replace circuit between wiper Relay and BCM.
Does failure disappear?
To step7
J4 Workshop Manual windscreen wiper/Wiper washing
WW-12
7
With ignition at position ON, turn wiper switch to
intermittent mode to check for electrical connectivity
between terminal of wiper relay and ground. Is it OK?
To step9
To step8
8
Replace BCM. to see if the fault has been eliminated.
To step9
9
Change wiper relay.
7. Malfunction mode: wiper cannot stop
steps
Measures
Yes
No
1
Check for electrical connectivity of combined switches in
each operation position.
To step3
To step2
2
Change wiper combined switches. to see if the fault has
been eliminated.
To step3
3
Check for normal connection between combined switches
and wiper motor.
To step5
To step4
4
Repair or replace circuit between combined switches and
wiper motor. Does failure disappear?
To step5
5
Replace wiper motor
8. Malfunction mode: washer does not work
steps
Measures
Yes
No
1
Check power supply of washer motor; turn on ignition,
battery voltage should be detected between positive pole
(+) of motor and ground.
To step3
To step2
2
Repair or replace power circuit of washer motor, does
failure disappear?
To step3
3
With combined switches turned to washing position, check
for its electrical connectivity. Terminal 10 and 11 should be
electrical connected.
To step5
To step4
4
Change combined switches. Does failure disappear?
To step5
5
Check circuit of combined switches and washer motor for
normal connection
To step7
To step6
6
Repair or change electrical circuit of combined switches or
washer motor. to see if the fault has been eliminated.
To step7
7
Change washer motor
J4 Service Manual HORN
horn-1
Horn
Component position
Schematic
Horn system Schematic
Horn check
1. Remove the front bumper. Front bumper replacement
2. Disconnect the horn connector.
HORN001
High
-ton
e
Horn
Horn
button
Battery
J4 Service Manual HORN
horn-2
3. Connect the horn terminal no.1 with the battery positive, the terminal no. 2
with the battery negative, horn should beep
4. If the horn doesn’t beep, it should be replaced.
Trouble inspection and repair
Check List of Horn
Step
s
Measures
Sound outcome
Abnormal outcome
1
Press and release the
horn button
When the horn button is pressed,
the horn will beep. When the
horn button is released, the horn
stops beeping.
Horn inoperable.
Horn-abnormal beeping.
1. Horn out of operation
Check List of the Horn out of Operation
Steps
Measures
Yes
No
1
Check if the fuse of fuse box F09 in the engine
housing is blown out.
To step 3
To step 2
2
1. Pull up the connector of horn assembly.
2. Contact with the test lamp, the horn assembly
connectors between the terminals no.1 and 2.
3. Press down the horn button, while observing the
test lamp to prove if it is bright.
Test lamp if it is lit
To step 4
To step 5
3
After the failures due to other circuit reasons
eliminated, replace the horn fuse to see if the
failure has been eliminated.
To step 2
4
Replace the horn assembly
5
1. Reconnect the horn.
2. Disconnect the horn replay.
3. Establish the contact between the relay pins 4
and 5 with the test lamp to see if the horn beeps.
Does horn sound?
To step 8
To step 6
6
Check the wirings between the horn, relay and
ground line are normal.
To step 4
To step 7
7
Repair or replace the wirings between the horn,
relay and ground line to see if the failure has been
eliminated.
To step 4
8
1. Refit up the horn relay.
2. Disconnect the circuit system of safety airbag.
3. Remove the horn switch conductor from the
To step 9
To step 10
J4 Service Manual HORN
horn-3
steering wheel.
4. Establish the contact between horn button
connector no.1 & 2 with the test lamp to see .
Does horn sound?
9
Replace the horn button.
10
Check if the wirings between the horn buttons,
relays and ground line are normal.
To step 12
To step 11
11
Repair or replace the wirings between the horn
buttons, relay and ground line to see if the failure
has been eliminated.
To step 12
12
Replace the horn relay.
2. Abnormal of horn beeping
1) Operate the horn to verify if the horn operates properly.
2) If the horn beeping is apparently abnormal, carry out the routine test as
follows:
① Check if the terminal is in sound contact；Repair any of detected poor
contacts.
② Check the ground line. If any poor contacts detected, repair them.
③ Be sure of the fixing bolts of horn assembly properly tightened.
④ Be sure of no contact of horn assembly with any of other objects; if any
contacts present, reconfirm the correct positions of other objects or any bent horn
assembly bracket as necessary.
3）Operate the horn to verify if the problem persists. If the problem apparently
present, please verify the type of sound quality produced by the horn:
■Tone loudness
■Tone sharp stridently weak
①If the tone apparently loud, it means the current is too high and the circuit
should be checked. The horn assembly should be replaced when the circuit becomes
normal.
② If the tone apparently strident and weak, the horn is possibly stuck with some
foreign matters, remove the horn assembly and check if any foreign matters exist.
③ Clean out any adhesions and reinstall the horn assembly.
④ If any of foreign adhesions is detected, or those adhesions nor removable,
J4 Service Manual HORN
horn-4
replace the horn assembly.
4) Operate the horn to verify all concerns have been settled down.
Removal and Replacement of horn
Caution:
■ Precautions for strict compliance with
the operation of safety airbag system.
1. Removal:
1）Disconnect the horn connector A.
2）Remove the fixing bolts of horn.
3）Remove horn assembly.
2. Installation
1）Install the horn assembly.
■ Tightening torque: 5 N.m
2）Connect the connectors of horn assembly.
3）Cover up the engine hood
Replacement of horn button
1. Removal
1) Place the ignition switch on the position “OFF”.
2) Remove the battery negative.
3) Disconnect DAB
HORN004
HORN002
A
B
J4 Service Manual HORN
horn-5
Schematic diagram of disconnecting DAB(3 steps), disconnecting tool is a straight
screwdriver with length of 15cm.
① Rotate handwheel 90°anticlockwise, disconnect 3H hole's Groove with screwdriver(for
detailed structure showed in diagram)
② Rotate handwheel 90°anticlockwise, disconnect 6H hole's Groove with screwdriver(for
detailed structure showed in diagram)
③ Put the driving wheel back to middle, rotate it 90°clockwise, disconnect 6H hole's
Groove with screwdriver(for detailed structure showed in diagram)
4) Disconnect the plug-in connectors for airbag module, and remove the driver
side airbag module.
5) Disconnect the button connector on the steering wheel.
6) Remove steering wheel, see "the steering wheel replacement".
7) Remove the horn control assembly (3 plastic tabs) from the back of steering
wheel.
HORN006
HORN005
6H Detachment hole
3H Detachment hole
6H Detachment hole
J4 Service Manual HORN
horn-6
8) Take out the horn button assembly.
2. Installation
Installation is the reverse order of removal. Thereinto, regarding DAB
installation, you can simply press down the connect region of DAB and steering
wheel, and check if they fit evenly.
HORN007
J4 Service Manual cigar lighter
CIGAR-1
Cigarette Lighter
Component position
Schematic
ACC系统-点烟器
F-3
1.5R
点烟器
1.5B
2
1
车载电源
M30
1.5R
G_LH3
2
1
M28
0.35G
2
点烟器照明
M29
1.5R
034
A-6
FS06保险
2
1
M30 车载电源
1
M29 点烟器照明
2
1
M28 点烟器
101
G-3
ILL+
M42
PS06 Fuse
Power
supply
lighter lighting
lighter
J4 Service Manual cigar lighter
CIGAR-2
Schematic Diagram of Cigar Lighter
Fault diagnosis
1. Inspection of Cigar Lighter System
Steps
Measures
Sound outcome
Abnormal
outcome
1
Push lighter into socket till click
sound
Lighter will be kicked out of
socket when power supplied to
negative side
Malfunction
2
Open the small lamps
Cigarette Lighter lights is on
Cigarette
lighter light is
off
2. Malfunction
Step
s
Measures
Yes
No
1
Check if the fuse is in proper state?
Is fuse blown ?
To step 4
To step 2
2
Connect a testing lamp on both sides of lighter. to
see if the lamp is lit up.
Test lamp lights?
To step 5
To step 3
3
Is Cigarette Lighter light on?
To step 6
To step 7
4
Replace the fuse
-
To Inspection of
Cigar Lighter
System
5
Replace cigar lighter
-
To Inspection of
Cigar Lighter
System
6
Replace cigar lighter bulb
-
To Inspection of
Cigar Lighter
System
7
Repair poor contact connection
-
To Inspection of
Cigar Lighter
System
J4 Workshop Manual parking assistant System
PTS-1
Parking assistant System
Layout of Components
Layout of control module PTS001：
Note： control module is installed to 2 weld bolts on Body panel through support, fixed by
nut, distance between installation support can be adjusted through body assembly.
The appearance of sensor is indicated as in the figure:
Note: sensor is installed on back bumper by shackle.
Systemic schematic
PTS001
J4 Workshop Manual parking assistant System
PTS-2
Parking assistant Systemic diagram
Parking assistant Systemic schematic
As showed below, it is composed of several parts followingL
■ Control Module
■ Sensor module
■ Buzzer
Instruction of system connector
1. Control module connector:
J4 Workshop Manual parking assistant System
PTS-3
Diagram 1, signal definition of control module connector
Connector schematic
Pin
Signal
name
Function
Remark
01
R_shift
Power supply positive
Parking power
supply signal
02
N.C.
03
N.C.
04
N.C.
05 N.C.
06 N.C.
07 SEN_L Sensor power supply
and signal transmission
Rear Left
detector
08 N.C.
09 N.C.
10
N.C.
11
N.C.
12
N.C.
13
N.C.
14
Buzzer
Buzzer power supply
positive
control buzzer
alarming
15
SEN_R
Sensor power supply and
signal transmission
rear Right
detector
16
GND
Power supply ground
Remark: type of connector on control module harness terminal is: YAZAKI 7123-7169
J4 Workshop Manual parking assistant System
PTS-4
2. Connector of detector:
Diagram 2 signal definition of detector connector
Diagram of connector
Pin
Signal
name
Function
Remark
Connector type:MG610320
（KET）
01
SENS
OR
Detector power supply
and signal
transmission
Detector
positive
02
GND
Ground
Detector
negative
Remark: type of connector on sensor harness terminal is :KET MG640322
Replacement of sensor
1. Removal:
1）Remove the electric connector.
2) Rotate 90°to remove shackle
3) Remove adjusting panel, remove sensor from outside.
2. Installation
1) Penetrate sensor from outside of bumper, install adjusting panel to sensor.
2) Rotate 90°to fasten shackle.
3) Connect the electric connector.
PTS002
PTS003
PTS002
J4 Workshop Manual rear view mirror
PM-1
Rear view mirror
Descriptions
The outside mirrors are divided into the inside rear view mirror and outside rear
view mirror respectively fixed on the top, and at the RH/LH outsides of the front
windshield which are used to observe the inside and rear part of body.
Layout of Components
1. Power rear view mirror assembly 2.Power rear view mirror switch
Note:
■The outside mirrors will be damaged by excessive forward tilt.
■When the folded switch is operated to fold the outside mirror from the central
position to completely folded (rear limit), slight noise can be heard by moving, this is
a normal situation.
PM001
PM002
J4 Workshop Manual rear view mirror
PM-2
Schematic diagram
DOWN
UP
DOWN
UP
RIGHT LEFT LEFTRIGHT
LEFTRIGHT RIGHT L EFT
M
M
UP/DOWN
LEFT/RIGHT
LEFT/RIGHT
UP/DOWN
M
M
UP/DOWN开关
LEFT/RIGHT开关
左、右外后视镜选择开关
接地
左外后视镜
右外后视镜
外后视镜开
关控制面板
ACC/ON电源
Schematic of Power Rear View Mirror
Component check
Outside rear
mirror
control panel
Outside rear mirror
choosing switch
ground
Left rear mirror
right rear mirror
J4 Workshop Manual rear view mirror
PM-3
1. Check of power outside rear view mirror
1) Press down the rear LH/RH regulation button of outside mirror,
which should turn smoothly on the right or left.
2）Press down the rear LH/RH regulation button of outside mirror,
which should turn smoothly on the right or left. If it is still not normal, keep checking.
2. Check of power rear view mirror switch
According to the table below, check the conductivity between the terminals of
wire connectors. If the conductivity between the wiring connectors and all terminals
is non-conform to that as stated in the diagram, change the switch.
上
下
左
右
R
7
右
左
下
上
L
0.5R
8 1 3 6 4 5
M46
电动后视镜开关
0.5WL
M46
A-6
032
0.5Lg
FS05保险
PM003
Power mirror switch
J4 Workshop Manual rear view mirror
PM-4
Diagram of Power Rear View Mirror Switch Terminal
Replacement of inside rear view mirror
1. Removal:
Remove the inside rear view mirror from
the mirror support with a small flat
screwdriver.
2. Installation.
1) Clamp the inside rear view mirror into the mirror base, and confirm it is
securely installed.
2) Install inside rear view mirror base.
Note:
■The inside rear view mirror is connected on the inside rear view mirror base. The
inside rear view mirror base is bounded on the windshield with the plastic polyvinyl
butyral adhesive. If install an independent inside rear view mirror base or a new part,
the following goods will be needed:
■ Loctite™ adhesive 312.
■ (Prepare according to the installation procedures 4 &5) Original inside rear
view mirror base, or replaced one.
■ Wax markers or crayon.
■ Isopropyl Alcohol.
■ Clean tissue.
■Grit abrasive paper or abrasive paper (320 or 360)
① Measure the size from the top of windshield (1) to that of inside rear view
mirror base (2), which should be 105mm.
PM004
J4 Workshop Manual rear view mirror
PM-5
Schematic of Installing Inside Rear View Mirror Base
② Use a wax marker or crayon to mark the outside position of windshield.
Draw a large circle on the windshield outer surface (3) along the inside rear view
mirror base.
Schematic of Installing Inside Rear View Mirror Base
③ Clean this large circle on the inside surface of windshield with the tissues
soaked with the general typed glass cleaner and common part number or polishes.
Scrub this position until completely cleaned and dried. After drying, clean this portion
with tissue wetted by isopropyl alcohol to eliminate the traces of washing powder or
detergent.
Note:
■If the original inside rear view mirror base reused, all traces of factory installed
adhesive have to be eliminated before installation.
④ Polish the new inside rear view mirror or the adhesive surface of
factory-installed original inside rear view mirror base with a piece of grit abrasive
paper (320 or 360) or abrasive paper.
⑤ Wipe clean the inside rear view mirror base with the clean tissues soaked by
J4 Workshop Manual rear view mirror
PM-6
isopropyl alcohol and let it dried.
⑥ Before the windshield is installed, prepare the inside rear view mirror base
according to the assembly description of manufacturer.
⑦ Place the inside rear view mirror properly on the pre-marked location, and no
presence of upward semi-circled hole is allowed; press the inside rear view mirror
base on the windshield for 30-60s, loading on the windshield with constant pressure.
⑧ In 5 minutes, clean the extra-adhesive with the isopropyl alcohol or tissues
wetted by window detergent.
⑨ Reinstall the inside rear view mirror.
Replacement of outside rear view mirror
Note:
■Ensure the gasket positioned correctly
1. Removal
1) Disconnect the battery negative.
2) Pry up carefully the outside mirror plate with the flat screwdriver.
3) Disconnect the outside mirror connector.
4)Remove three fixing nuts on the outside mirror.
PM007
PM005
PM006
J4 Workshop Manual rear view mirror
PM-7
5) Remove the outside mirror assembly.
2. Installation
Installation is the reversed order of removal.
Note:
■When installing the outside mirrors, get the connector plug of outside mirror assembly
through the door, get the pad closer to the door, screw the nut on the stud bolts of outside mirror
and firmly connect the outside mirror fixing base with the door.
■Connect the outside mirror assembly plug with the wiring socket.
■Connect the outside mirror assembly with the door pads to enable the function of shock
absorption and sealing.
Rear view mirror switch
Rear view mirror switch is used to adjust angle of left/right rear view mirror
switch according to driver's need. Adjust the central gear to left/right, then rear view
mirror switch can be adjusted to 4 directions.
1. 1.Component schematic
2. Removal:
1) Remove left lower fender apron of driver seat.
PM008
PM009
J4 Workshop Manual rear view mirror
PM-8
2）Remove rear view mirror switch connector
3）Remove 3 bolts with cross screwdriver, and remove switch
3. Installation
Installing shall accord with the reversed order of removal.
Note:
■ It can be used only after the central gear is pushed to both sides, no use on the
central position.
4. Pin of rear view mirror switch definition:
1
2
3
7
J4 Workshop Manual rear view mirror
PM-9
5. Connecting wire theory:
6. Disconnect gear:
Check all gears when switch doesn't work, analyse the nessesary of replacement.
ground
Left rear mirror
up and down motor
Left and right motor
Left rear mirror
up and down motor
Left and right motor
Left
rear
mirror
Right
rear
mirror
J4 Workshop Manual power windows
PW-1
Power windows
Summary
1. By operating the PW system on each trim panel, the PW system can rise or
lower the corresponding window glass.
2. The main switch on the driver-sided trim panel enables the driver to lift or
lower each occupant-sided window glass and lock up all independent switches on the
doors.
3. The PW system can accept the battery voltage through the circuit breaker in
the junction box only when the ignition switch is on the position “ON”.
4. The PW system includes the PW switch and ETACS control module on every
trim panel and PW motor inside each door.
5. The PW motor and window glass regulator is an assembly. If necessary to
renew the PW motor, then the window glass regulator should be replaced.
Component description
1. PW switch
The PW are controlled by the PW switches on each front trim panel. The
driver-sided PW switch enables the driver to control all PWs. All occupant-sided
windows are powered and grounded by the battery through the PW switch circuit.
When the lock-up switch of driver-sided PW switch is on the position “Lock Up”, the
battery power supply on other door PW switches are interrupted except the
driver-sided PW switch.
2. PW motor
The reversible permanent magnet motor drives the window glass regulator
through the incorporated gear box mechanism. Both battery positive and negative are
connected to two terminals of the motor, which orientate the motor rotation in the
same direction. The motor may rotate in reverse driven by the reverse current from
two of the same junctions. In addition, all PW motors are equipped with the
incorporated self-reset circuit breaker so as to prevent the excessive motor load.
Function Description
J4 Workshop Manual power windows
PW-2
1. PW rise and drop
Operation of PW: Manual Up and Down, Auto-Down (only applicable to the
driver-sided PW switch).
Manual up, by pressing the button Window-Up, the corresponding window will
automatically rise and will stop rising by button release.
Manual down: By pressing the button Window-Down, the corresponding window
will automatically lower and will stop lowering by button release.
Automatic drop: By pressing the driver-sided Window-Down button till the end,
the driver-sided window will lower down to the end or until the Window-Down button
is repressed.
After the ignition switch turned off, the PW stay operable, but it becomes
inoperable when the following cases occur:
1) The OFF time of ignition switch is over 30s.
2) A random door is opened.
3) Door locked-up from outside.
2. PW lock-up
The PW lock-up switch can restrain the PW buttons on the front door RH, rear
door LH and rear door RH.
Schematic diagram
电动门窗
继电器
4
2
1
3
3735907U1010
右后电动门
窗开关
左后电动
门窗开关
M
左后电动门窗电机
M
右前门窗开关
6
5 9
左后门窗开关
右后门窗开关
01
8
7
2.0
2.0
2.0
2.0
2.0
2.0
3 1
2
1
1
2
玻璃升降
锁止开关
Tail
右前电动门
窗开关
FS（I）01
25A
FS(I)04
25A
至BCM
左前电动门窗电机
右后电动门窗电机
右前电动门窗电机
M
M
11
10
02
4
自动升
降控制
单元
DOWN
UP
13
14
自动门锁
继电器
闭锁
开锁
自动门锁
继电器
DOWN
UP
DOWN
UP
DOWN
UP
DOWN UP
UP
DOWN
12
DOWN
UP
DOWN
UP
03
2.0
2.0
4
6
8
4
8
6
13
21
46
8
2
1
13
5
7
ILL+
ILL-
5
7
ILL+
ILL-
5
7
ILL+
ILL-
J4 Workshop Manual power windows
PW-3
Component replacement
1. Outside water splitting of front window replacement
1) Removal
① Lower window glass to the bottom
② Remove fixing bolt of outside water splitting.
③ Remove rear mirror.
④ Remove outside water splitting of front door.
Note:
■Please do not apply excessive force during removal, otherwise it may result in
parts deformation.
■ After removal, check gib with eyes. If it is found deformed, please replace.
2) Installation.
① Array outside water splitting of front door with door frame of B pillar, install
it from one end to the other end slowly.
② Fix bolt of outside water splitting of front door.
■Tightening torque: 3~5 N.m
③ Install rear mirror, refer to "Replacement of rear view mirror".
2. Replacement of front window glass
1) Removal
PW001
PW002
J4 Workshop Manual power windows
PW-4
① Remove door trim panel. Refer to "Front door trim replacement"
② Remove waterproof membrane. Refer to "Front door waterproof membrane
replacement"
③ Take off inside rubber strip of front door. Refer to "The replacement of inside
rubber strip of front door"
④ Refit the window glass regulator switch.
Regulate the window glass on the appropriate position so as to ease the
removal/installation of front window glass fixing bolts.
⑤ Remove bolts securing front window glass.
⑥ Take off window glass.
2) Installation.
① Reinstall window regulator switch, and lift glass to an appropriate position to
facilitate installation of bolts securing window glass.
② Put window glass onto door, right to installation hole.
③ Install bolts securing window glass.
■Tightening torque: (7~11) N.m
④ Install inside rubber strip of front door refer to "The replacement of inside rubber strip
of front door"
⑤ Install waterproof membrane refer to "Front door waterproof membrane
replacement"
PW003
PW004
J4 Workshop Manual power windows
PW-5
⑥ Install door trim panel. Refer to "Front door trim replacement"
3. Replacement of the front window glass regulator
1) Removal
① Remove door trim panel. Refer to "Front door trim replacement"
② Remove waterproof membrane. Refer to "Front door waterproof membrane
replacement"
③ Take off inside rubber strip of front door. Refer to "The replacement of inside
rubber strip of front door"
④ Remove window glass. Refer to “Front window glass replacement”.
⑤ Remove the 4 fixing nut of glass
support.
⑥ Remove 3 nuts securing window
regulator motor.
⑦ Disconnect window regulator motor connector.
⑧ Take out window regulator.
PW007
PW005
PW006
J4 Workshop Manual power windows
PW-6
2) Installation.
① Install glass hatchway, connect connector of front glass regulator, put into glass
assembly.
② Install the fixing nut of front window glass support.
■Tightening torque: 7~11 N.m
③ Install the fixing nuts on the glass regulator motor.
■Tightening torque: 7~11 N.m
④ Install bolts securing window glass. Refer to “Front window glass
replacement”.
⑤ Install inside rubber strip of front door refer to "The replacement of inside rubber strip
of front door".
⑥ Install waterproof membrane refer to "Front door waterproof membrane
replacement"
⑦ Install door trim panel. Refer to "Front door trim replacement"
4. Replacement of front window glass slot
1) Removal
① Remove door trim panel. Refer to "Front door trim replacement"
② Remove waterproof membrane. Refer to "Front door waterproof membrane
replacement"
③ Take off inside rubber strip of front door. Refer to "The replacement of inside
rubber strip of front door"
④ Remove rear view mirror, refer to "Replacement of rear view mirror".
⑤ Remove outside water splitting of front window. Refer to "outside water
splitting of front window replacement:
⑥ Remove window glass. Refer to “Front window glass replacement”.
⑦ Remove the front window glass regulator Refer to “Front window regulator
replacement”.
PW008
J4 Workshop Manual power windows
PW-7
⑧ Remove the front window glass slot.
2) Installation.
① Install front window glass slot, install 2 foot part first.
② Install outside water splitting of front window Refer to "outside water splitting of
front window"
■ Tightening torque: 3~5 N.m
③ Front door window regulator Refer to “Front window regulator replacement”.
■Tightening torque: 7~11 N.m
④ Install bolts securing window glass. Refer to “Front window glass
replacement”.
⑤ Install outside rear view mirror. Refer to "Replacement of outside rear view
mirror".
⑥ Install inside rubber strip of front door Refer to "The replacement of inside rubber strip
of front door".
⑦ Install waterproof membrane Refer to "Front door waterproof membrane
replacement"
⑧ install door trim panel. Refer to "Front door trim replacement"
5. Replacement of male drawer guide of front window glass
1) Removal
① Remove door trim panel. Refer to "Front door trim replacement"
② Remove waterproof membrane. Refer to "Front door waterproof membrane
replacement"
③ Take off inside rubber strip of front door. Refer to "The replacement of inside
rubber strip of front door"
④ Remove outside water splitting of front window. refer to "outside water
splitting of front window replacement:
⑤ Remove window glass. Refer to “Front window glass replacement”.
⑥ Remove the front window glass regulator Refer to “Front window regulator
replacement”.
J4 Workshop Manual power windows
PW-8
⑧ Remove the front window glass slot. Refer to "Replacement of front window
glass slot".
Loosen fixing bolt of male drawer guide, remove the guide.
2) Installation.
① Install guide, tighten fixing bolt of guide.
■Tightening torque: 6~10 N.m
② Install front window glass slot, install 2 foot part first.
③ Install outside water splitting of front window, refer to "water splitting of
front window".
■Tightening torque: 3~5 N.m
④ Install Front window regulator,refer to “Front window regulator
replacement”.
■Tightening torque: 7~11 N.m
⑤ Install window glass. Refer to “Front window glass replacement”.
⑥ Install inside rubber strip of front door Refer to "The replacement of inside rubber strip
of front door".
⑦ Install waterproof membrane Refer to "Front door waterproof membrane
replacement"
⑧ Install door trim panel. Refer to "Front door trim replacement"
6. Outside water splitting of rear window replacement
1) Removal
J4 Workshop Manual power windows
PW-9
① Lower window glass to the bottom
② Remove 2 fixing bolts of outside water splitting.
③ Remove outside water splitting of rear door.
Note:
■Please do not apply excessive force during removal, otherwise it may result in
parts deformation.
2) Installation.
① Array outside water splitting of front door with door frame of B pillar, install it
from one end to the other end slowly.
② Fix bolt of outside water splitting of rear door.
■ Tightening torque: 3~5 N.m
7. Replacement of the rear window glass
1) Removal
1. Remove door trim panel. Refer to The replacement of the interior trimming
PW009
PW010
PW011
J4 Workshop Manual power windows
PW-10
panel of rear door.
② Remove waterproof membrane. Refer to "rear door waterproof membrane
replacement"
③ take off inside rubber strip of rear door. Refer to "The replacement of inside
rubber strip of rear door".
④ Refit the window glass regulator switch.
Regulate the window glass on the appropriate position so as to ease the
removal/installation of rear window glass fixing bolts.
removal of fixing bolts
⑤ Remove bolts securing rear window glass.
⑥ Remove fixing bolt of male drawer guide of rear window glass.
⑦ Take off window glass.
2) Installation.
PW014
PW012
PW013
J4 Workshop Manual power windows
PW-11
① Reinstall window regulator switch, and lift glass to an appropriate position to
facilitate installation of bolts securing window glass.
② put window glass in the door, right to installation hole.
③ Install bolts securing window glass.
■Tightening torque: 7~11 N.m
Install fixing bolt of rear guide
■Tightening torque: 6~10 N.m
⑤ Install inside rubber strip of rear door Refer to "The replacement of inside rubber strip of
rear door".
⑥ Install waterproof membrane Refer to "rear door waterproof membrane
replacement"
⑦ Install door trim panel. Refer to The replacement of the interior trimming panel of
rear door.
8. Replacement of the rear window glass regulator
1) Removal
① Remove door trim panel. Refer to The replacement of the interior trimming
panel of rear door.
② Remove waterproof membrane. Refer to "rear door waterproof membrane
replacement"
③ Take off inside rubber strip of rear door. Refer to "The replacement of inside
rubber strip of rear door".
④ Remove window glass. Refer to “rear window glass replacement”.
⑤ Disconnect window regulator motor connector.
⑥ Remove the fixing nut of glass support.
PW015
15
J4 Workshop Manual power windows
PW-12
⑦ Remove nuts securing window regulator motor.
⑧ Take out window regulator.
2) Installation.
① Put in window regulator, install the fixing nut of rear window glass support.
■ Tightening torque: 7~11 N.m
② install the fixing nuts on the rear glass regulator motor.
■ Tightening torque: 7~11 N.m
③ Install rear window glass. Refer to “rear window glass replacement”.
④ Connect connector of rear glass regulator.
⑤ Install waterproof membrane Refer to "rear door waterproof membrane
replacement"
⑥ Install inside rubber strip of rear door refer to "The replacement of inside rubber strip of
rear door".
⑦ Install door trim panel. Refer to The replacement of the interior trimming panel of
rear door.
9. Replacement of the rear window glass slot.
1) Removal
PW016
PW017
J4 Workshop Manual power windows
PW-13
① Remove door trim panel. Refer to The replacement of the interior trimming
panel of rear door.
② Remove waterproof membrane. Refer to "rear door waterproof membrane
replacement"
③ Take off inside rubber strip of rear door. Refer to "The replacement of inside
rubber strip of rear door".
④ Remove window glass. Refer to “rear window glass replacement”.
⑤ Remove outside water splitting of rear window. refer to "outside water
splitting of rear window replacement"
⑥ Remove the rear window glass slot.
2) Installation.
① Install rear window glass slot, install 2 foot part first.
② Install window glass. Refer to “rear window glass replacement”.
③ Install inside rubber strip of rear door refer to "The replacement of inside rubber strip of
rear door".
④ Install outside water splitting of window glass. Refer to "outside water
splitting of rear window replacement"
■Tightening torque: 3~5 N.m
⑤ Install waterproof membrane refer to "rear door waterproof membrane
replacement"
⑥ Install door trim panel. Refer to The replacement of the interior trimming panel of rear
door.
10. Replacement of male drawer guide of rear window glass
1) Removal
PW018
J4 Workshop Manual power windows
PW-14
① Remove door trim panel. Refer to The replacement of the interior trimming
panel of rear door.
② Remove waterproof membrane. Refer to "rear door waterproof membrane
replacement"
③ Take off inside rubber strip of rear door. Refer to "The replacement of inside
rubber strip of rear door".
④ Remove window glass. Refer to “rear window glass replacement”.
⑤ Remove outside water splitting of rear window. Refer to "outside water
splitting of rear window replacement"
⑥ Remove the rear window glass slot.
⑦ Loosen fixing bolt of male drawer guide, remove the guide.
2) Installation.
① Install male drawer guide, tighten upper fixing bolt, not lower one.
■Tightening torque: 6~10 N.m
② Install rear window glass slot, install 2 foot part first.
③ Install rear window glass. Refer to “rear window glass replacement”.
④ Tighten fixing bolt of the guide
■Tightening torque: 6~10 N.m
⑤ Install inside rubber strip of rear door refer to "The replacement of inside rubber strip of
rear door".
⑥ Install outside water splitting of window glass. Refer to "outside water splitting of
J4 Workshop Manual power windows
PW-15
rear window replacement"
■Tightening torque: 3~5 N.m
⑦ Install waterproof membrane Refer to "rear door waterproof membrane
replacement"
⑧ Install door trim panel. Refer to The replacement of the interior trimming panel of
rear door.
Fault diagnosis
1. All door PW inoperable
Steps
Measures
Yes
No
1
Check if the 30A fuse No. F31of engine compartment fuse
box, the 15A fuse No. F29, 10A fuse No. F12 and 10A fuse
No. F7 of instrument fuse box are Disconnected.
To step 8
To step 2
2
Check if the power supply of ETACS is normal.
(1) Turn down the ignition switch, The voltage between the
terminal No.10 of ETACS plug M36 and the grounding
should be equal to the battery voltage.
(2) Turn on ignition switch, The voltage between the
terminals No.18 & 9 of ETACS plug M37 and the
grounding should be equal to the battery voltage.
To step 3
To step 9
3
Check if the ETACS grounding is normal.
Turn down the ignition switch, disconnect ETACS
plug,The terminal No.19 of plug M36 should be
conductive with the grounding.
To step 4
To step 10
4
Check if the PW relay operates normally.
（1）The terminals No. 2 & 4 of relay are of the city power
supply.
（2）Turn ignition switch to on. The terminal No. 1 of
relay should be equal to the battery voltage.
To step
7
To step 5
5
Turn on the ignition switch and check if the terminal No.3
of PW relay is grounding.
To step
11
To step 6
6
Check if the ETACS is conductive with the PW relay
harness.
The terminal No.15 of ETACS plug M36 should be
conductive with the terminal No. 3 of relay.
To step
13
To step 14
7
Check if the power supply and ground line of PW switch
on the front door LH are normal.
(1)Turn on ignition switch, The battery voltage should
exist between the terminal No.11 of plug D04 on the PW
switch of front door LH and the grounding
(2)The terminal No. 10 of Plug D04 on the PW switch of
To step
12
To step 15
J4 Workshop Manual power windows
PW-16
front door LH should be conductive with the grounding.
8
After the failure due to the circuit reason checked, change
the fuse to see if the failure has been eliminated.
To step 2
9
Repair the open/short-circuit of ETACS power line to see
if the failure has been eliminated.
To step 3
10
Check if the ETACS grounding circuit is open-circuited.
To step 4
11
Repair the circuit failure and change the PW relay to see if
failure has been eliminated.
To step 7
12
Replace the PW switch of front door LH.
13
Replace ETACS.
To step 7
14
Repair the connection line between the ETACS and PW to
see if the failure has been eliminated.
To step 13
15
Repair the PW switch harness of front door LH to see if the
failure has been eliminated.
To step 12
2. PW of front door LH inoperable
Steps
Measures
Yes
No
1
Check if the signal output of PW main switch of front door
LH is normal.
Disconnect the motor plug of PW of LH door, when the
PW main switch of front door LH is shifted up, the voltage
between the terminal No. 2 of PW motor plug D08 of front
door LH and the grounding should be equal to the battery
voltage, 0V between the terminal No.1 and the grounding,
and vice versa when shifted down.
To step 2
To step 3
2
Change the PW motor of front door LH
Steps
Measures
Yes
No
3
Check if the harness connection between the PW switch of
front door LH and motor is normal.
To step 2
To step 4
4
Repair the harness connector between the PW switch of
front door LH and the motor to see if the failure has been
eliminated.
To step 2
3. PW of front door RH inoperable
Steps
Measures
Yes
No
1
Check if the signal output of PW main switch of front door
LH is normal.
Disconnect the motor plug of PW of RH door, when the
PW main switch of front door RH is shifted up, the voltage
between the terminal No. 1 of PW motor plug D15 of front
door LH and the grounding should be equal to the battery
voltage, 0V between the terminal No.2 and the grounding,
To step 2
To step 3
J4 Workshop Manual power windows
PW-17
and vice versa when shifted down.
2
Change the PW motor of front door RH
3
Check if the conductivity of the PW switch on the front
door RH is normal.
Disconnect the PW switch plug 12 of front door RH and
check the conductivity between the terminals 4, 6, 8 and 1,
3. Going up, terminal 1 & 6 are conductive, 2 & 8 also;
going down, terminal 3& 6 are conductive, 1&4 also; when
stable, terminal 3 & 8 are conductive, 1 & 4 also.
To step 5
To step 4
4
Change the PW switch of front door RH.
5
Check if the harness connection between the PW switch of
front door RH and PW motor of front door RH is normal.
The terminals No.3 & 1 of PW switch plug D12 on the
front door RH should be conductive respectively with the
terminals No.2 &1 of PW motor plug D15 on the front
door RH.
To step 7
to step 6
6
Repair or replace the PW switch of front door RH and PW
motor harness of front door RH To see if the fault has been
eliminated.
To step 7
7
Check the power supply of the PW switch on the front
door RH is normal
turn on ignition switch, the voltage between the terminal
No. 6 of PW switch plug D12 on the front door RH and the
grounding should be equal to the battery voltage,
To step 4
To step 8
8
Check if the terminal No.1 of PW switch plug D04 on the
front door LH is conductive with the terminal No.6 of PW
switch plug D12 on the front door RH.
To step
10
To step 9
9
Repair or replace the PW switch plug on the front door LH
And PW switch plug connecting cable on the front door
RH to see if the fault has been eliminated.
To step 10
10
Change the PW switch on the front door LH.
4. PW of rear door RH inoperable
steps
Measures
Yes
No
1
Check if the signal output of PW main switch of front door
LH is normal.
Disconnect the motor plug of PW of rear RH door, turn
on ignition switch, when the PW main switch of front door
RH is shifted up, the voltage between the terminal No. 2 of
PW motor plug D21-2 of front door LH and the grounding
should be equal to the battery voltage, 0V between the
terminal No.1 and the grounding, and vice versa when
shifted down.
To step 2
To step 3
J4 Workshop Manual power windows
PW-18
Steps
Measures
Yes
No
2
Change the PW motor of rear door RH
3
Check if the conductivity of the PW switch on the rear
door RH is normal.
Disconnect the PW switch plug 18-2 of rear door RH and
check the conductivity between the terminals 4, 6, 8 and 1,
3. Going up, terminal 3 & 6 are conductive, 1 & 8 also;
going down, terminal 1& 6 are conductive, 3&4 also; when
stable, terminal 1 & 8 are conductive, 3 & 4 also.
To step 5
To step 4
4
Change the PW switch of rear door RH.
5
Check if the harness connection between the PW switch of
rear door RH and PW motor of rear door RH is normal.
The terminals No.1 & 3 of PW switch plug D18-2 on the
rear door RH should be conductive respectively with the
terminals No.1 &2 of PW motor plug D21-2 on the rear
door RH.
To step 7
To step 6
6
Repair or replace the PW switch of rear door RH and
PW motor harness of rear door RH To see if the fault has
been eliminated.
To step 7
7
Check the power supply of the PW switch on the rear door
RH is normal.
Turn on ignition switch, the voltage between the terminal
No. 6 of PW switch plug D18-2 on the rear door RH and
the grounding should be equal to the battery voltage,
To step 4
To step 8
8
Check if the terminal No. 1 of PW switch plug D04 on the
front door LH is conductive with the terminal No.6 of PW
switch plug D18-2 on the rear door RH.
To step
10
To step 9
9
Repair or replace the PW switch plug on the front door LH
And PW switch plug connecting cable on the rear door RH
To see if the fault has been eliminated.
to step 10
10
Change the PW switch on the front door LH.
5. PW of rear door LH inoperable
Steps
Measures
Yes
No
1
Check if the signal output of PW main switch of rear LH
door is normal.
Disconnect the motor plug of PW of rear LH door, turn on
ignition switch, when the PW main switch of front door
LH is shifted up, the voltage between the terminal No. 1 of
PW motor plug D21-1 of front door LH and the grounding
should be equal to the battery voltage, 0V between the
terminal No.2 and the grounding, and vice versa when
shifted down.
To step 2
To step 3
J4 Workshop Manual power windows
PW-19
2
Change the PW motor of rear door LH
3
Check if the conductivity of the PW switch on the rear
door LH is normal.
Disconnect the PW switch plug D12 of rear door LH and
check the conductivity between the terminals 4, 6, 8 and 1,
3. Going up, terminal 3 & 6 are conductive, 1 & 8 also;
going down, terminal 1& 6 are conductive, 3&4 also; when
stable, terminal 3 & 4 are conductive, 1 & 8 also.
To step 5
To step 4
4
Change the PW switch of rear door LH.
5
Check if the harness connection between the PW switch of
rear door LH and PW motor of rear door LH is normal.
The terminals No.1 & 3 of PW switch plug D18-1 on the
rear door LH should be conductive respectively with the
terminals No.1 &2 of PW motor plug D21-1 on the rear
door LH.
To step 7
To step 6
6
Repair or replace the PW switch of rear door LH and PW
motor harness of rear t door LH To see if the fault has been
eliminated.
To step 7
Steps
Measures
Yes
No
7
Check the power supply of the PW switch on the rear door
LH is normal
Turn on ignition switch, the voltage between the terminal
No. 6 of PW switch plug D18-1 on the front door RH and
the grounding should be equal to the battery voltage,
To step 4
To step 8
8
Check if the terminal No.1 of PW switch plug D04 on the
front door LH is conductive with the terminal No.6 of PW
switch plug D18-1 on the front door RH.
To step
10
To step 9
9
Repair or replace the PW switch plug on the front door LH
And PW switch plug connecting cable on the rear door RH
To see if the fault has been eliminated.
To step 10
10
Change the PW switch on the front door LH.
6. PW lock-up switch ineffective
Steps
Measures
Yes
No
1
Replace the PW switch on the front door LH and check its
normal operation. If the PW lockup is operable?
To step 2
To step 3
2
Replace the PW switch of front door LH.
3
Check the harness and connectors.
7. PW Auto-Down on the front door LH ineffective
Steps
Measures
Yes
No
1
Replace the PW switch on the front door LH and check its
To step 2
J4 Workshop Manual power windows
PW-20
normal operation. If the Auto-Down is operable?
2
Replace the PW switch of front door LH.
J4 Repair Manual Engine Cover and Doors
BODY-1
Body Structure
Engine Cover and Doors
Precautions:
■When removing and installing a component, avoid damage or scratch.
■When removing a clip from a trim part, wrap head of flat screwdriver with cloth.
■When installing body trims, firstly make sure their clips have been installed in plate holes
on body firmly, and then press them in carefully.
■When removing and installing large parts and components, have two persons work
together so as to avoid dropping.
■When removing and installing some rubber trims, please do not use excessive force.
Engine Hood Assembly
1. The Replacement of Engine Compartment Hood
1) Removal
① Open and support the engine compartment hood by a serviceman
② Mark the relative position of the hinge to the engine compartment, in order to
locate when installing.
③ The second serviceman uses 10 and 12 of socket or wrench to remove the
fixed bolt, connecting one side of the Engine Compartment hood and Hinge, and lift
engine compartment hood by hands to avoid the surrounding parts.
④ The third serviceman uses No. 10 and No. 12 socket or wrench to remove the
fixed bolt, connecting the other side of the Engine Compartment hood and Hinge
By the cooperation of these three persons, the engine compartment hood is
removed from the hinge.
J4 Repair Manual Engine Cover and Doors
BODY-2
Tightening torque: 9~11 N.m, 16.7~25.5N.m
2) Installation.
Installing shall accord with the reversed order of removal.
2. The replacement of engine hood rod
Caution:
■ When removing or installing an engine hood rod, additional support must be
used to avoid vehicle damage or personal injury.
1) Removal
① Open and support engine hood.
② Remove the two bolts in rod with 10 of socket or wrench.
③ Remove the ball pin of support rod, and take off the rod.
■ Tightening torque: 9~11 N.m
2) Installation.
Installing shall accord with the reversed order of
removal.
3. The Replacement of the Hinge of Engine
Compartment Hood
BODY001
BODY002
J4 Repair Manual Engine Cover and Doors
BODY-3
1) Removal
① Removing engine compartment cover,
please refer to The Replacement of Engine Compartment Hood
② Use No. 10 socket or wrench to remove and assembly the two fixed bolts on
fender.
③ Use No. 10 and 12 socket or wrench to remove the fixed bolts, bolting the
hinge and the body.
2) Installation
Installation is the reversed order of removal.
■ Tightening torque: 16.7~25.5 N.m
4. The Replacement of weather strip:
1) Removal
① Use hand or tool to lever up one end of weather strip.
② Remove weather strips.
Caution:
■ To remove it, do not pull hard.
2) Installation.
① Firstly, install two ends of the strip, sticking to the ventilation cap through the
diagonal cut
② Install it in the card slot on the ventilation cap
from two ends to the middle.
③ Use a rubber hammer to knock on the weather
strip to fix it well.
BODY003
BODY004
J4 Repair Manual Engine Cover and Doors
BODY-4
Caution:
■ To install, do not apply to much strength to knock on the weather7 strip with
the rubber hammer in case of damaging it.
5. The Replacement of weather strip on the front engine hood:
1) Removal
① Use the tool to remove buckles and weather strip in sequence.
2) Installation.
① Connect the buckles of weather strip to mounting holes on the inner board to
fix it well.
Note: When installing, the buckle shall align to the hole to prevent damaging the
buckle.
Fenders
1. Removal:
① Remove front wheel cover.
② Remove front bumper.
③ Interior triangular cover board
④ Use No. 10. socket of 6 angles to remove 8 combination bolts in the fender.
Caution:
■ Follow the same way to remove and install door assemblies.
■ When remove and install a door assembly, protective measures should be taken
to avoid door and body scratches.
■ After a door assembly is installed, be sure to perform fitting adjustment to
Anterior
triangular
cover
board
Front
wheel
cover
BODY005
J4 Repair Manual Engine Cover and Doors
BODY-5
make sure it can be opened/closed normally, at the same time, heads of hinge
assembly bolts shall be repainted (body color).
■ Check rotating parts of hinges for poor lubrication. If necessary, apply
“grease”.
■ Door components are heavy, so have several persons work together during
removal.
2) Installation
Installation is the reversed order of removal.
The replacement of front door assembly:
1. The replacement of front door limiting stopper
1) Removal
① Use No. 12 socket to remove the fixing bolts, connecting the body and the
limiting stopper. .
■ Tightening torque: 16.7~25.5 N.m
② Use No. 10 socket or wrench to remove the two fixing bolts, connecting the
door and the limiting stopper. .
■ Tightening torque: 7.8~11.8 N.m
2) Installation
Installation is the reversed order of removal.
2. The replacement of front door assembly
1) Removal
① The replacement of door limiting stopper, please refer to The replacement of
front door limiting stopper
BODY006
J4 Repair Manual Engine Cover and Doors
BODY-6
② Use No. 12 wrench to remove the fixed bolts, connecting the hinge and the
door.
■ Tightening torque: 16.7~25.5 N.m
Caution:
■ Remove in steps, never loosen at a time.
■ Remove from bottom to top.
③ Unplug door harness rubber sleeve and disconnect door electrical connector.
④ With a helper’s aid, lift off door and put it at an appropriate place.
2) Installation.
Installing shall accord with the reversed order of removal.
Caution:
■ Tighten in steps when installing, never tighten at a time.
3. The replacement of the interior trimming panel of front door:
1) Removal
① Open the front door, first use a slotted screwdriver to
pry a buckle of four metal claws and a plastic buckle on the triangular window with
rear-view mirror remove the buckle connecting
the bottom and the door trim assembly and disconnect the wire
harness plug of the rear-view mirror.
BODY007
BODY008
Plastic
buckle
Buck
le
claw
Buckle of four
metal claws
J4 Repair Manual Engine Cover and Doors
BODY-7
② Loosen the fixed bolts in the rear door internal handle, and remove internal
handle, please refer to “The replacement of
front door inner handle”.
③ Use a slotted screwdriver to pry up
the bolt cover on the armrest panel and then
use a Phillips screwdriver to unscrew the
captive bolt; use a slotted screwdriver to pry
up the buckle claw between front armrest
panel and door trim assembly, remove the armrest panel, and disconnect the connector
of the switch assembly
④ Use a Phillips screwdriver to unscrew
two fixed bolts in front door interior trim panel
and a grommet screw.
⑤ Use a slotted screwdriver to pry up the 8 buckles on the front door interior trim panel,
and take off the front door interior trim panel
from the inside rubber strip.
⑥ Remove the dragline of the front door inner handle, please refer to The
replacement of front door inner handle.
⑦ Disconnect the front door light harness plug, please refer to "The replacement
of front door light.
⑧ Remove front door inner trim panel
2) Installation
First, connect door light wire harness and inner handle dragline, then align the
BODY011
Screw
BODY009
BODY010
Screw
The grommet screws
J4 Repair Manual Engine Cover and Doors
BODY-8
door trim panel fixed clip to the holes in the metal plate of the door, and press down
firmly in sequence. Tighten three screws.
4. The replacement of front door hinge
1) Removal
① The removal of front door assembly, please refer to The replacement of front
door assembly
② Use No.10 wrench to remove the fixed bolts, connecting the hinge and the
body.
■ Tightening torque: 9~11 N.m
2) Installation
Installing shall accord with the reversed order of removal.
5. The replacement of waterproof film of front door:
1) Removal
① Remove door trim panel.
② Disconnect clip securing harness.
③ Separate waterproof film and take it off.
2) Installation.
Installation is the reversed order of removal.
Caution:
■ Do not touch adhesive surface so as to avoid
impairing re-bonding effect.
■ When taking waterproof film, take care to avoid
damage to it.
6. The replacement of inside rubber strip of front door
BODY012
BODY013
J4 Repair Manual Engine Cover and Doors
BODY-9
1) Removal
① Remove door trim panel. Refer to "Front door trim panel replacement:
② Use hand to take one end, and then both hands slowly take off inside rubber
strip of front door
Caution:
■ Please do not apply excessive force during removal, otherwise it may result in
parts deformation.
2) Installation.
① Align the inside rubber strip of front door to B pillar card slot, maintaining
clearance 1 ~2 MM; first install the rear end, and then slowly place the inside rubber
strip of front door into position.
The replacement of rear door assembly:
1. The replacement of rear door limiting stopper
1) Removal
① Use No. 12 socket to remove the fixing bolts, connecting the body and the
limiting stopper. .
■ Tightening torque: 16.7~25.5 N.m
② Use No. 10 socket or wrench to remove the two fixing bolts, connecting the
door and the limiting stopper. .
■ Tightening torque: 7.8~11.8 N.m
2) Installation.
Installation is in the reversed order of removal.
2. The replacement of rear door assembly
1) Removal
BODY014
J4 Repair Manual Engine Cover and Doors
BODY-10
① The removal of door limiting stopper, please refer to The replacement of
front door limiting stopper
② Use No. 12 wrench to remove the
fixed bolts, connecting the hinge and the door.
■ Tightening torque: 16.7~25.5 N.m
Caution:
■ Remove in steps, never loosen at a time.
■ Remove from bottom to top.
③ Unplug door harness rubber sleeve and disconnect door electrical connector.
④ With a helper’s aid, lift off door and put it at an appropriate place.
2) Installation.
Installing shall accord with the reversed order of removal.
Caution:
Tighten in steps when installing, never tighten at a time.
3. The replacement of the interior trimming panel of rear door:
1) Removal
① Open the front door, first use a slotted
screwdriver to pry three buckles on the triangular
window with rear-view mirror and then pull out the
triangular board with strength.
② Unscrew the fixed bolts in the rear door inner
handle, and remove inner handle, please refer to “The
replacement of front door inner handle”.
③ Use a slotted screwdriver to pry up the bolt cover on the armrest panel
and then use a Phillips screwdriver to unscrew the captive bolt; use a slotted
BODY015
BODY016
J4 Repair Manual Engine Cover and Doors
BODY-11
screwdriver to pry up the buckle claw between front armrest panel and door trim
assembly, remove the armrest panel, and disconnect the connector of the switch
assembly
④ Use a Phillips screwdriver to unscrew a grommet screw and a bolt in the
bottom in sequence.
⑤ Use a slotted screwdriver to pry up the rear door interior trim panel, and take
off the rear door interior trim panel from the inside rubber strip.
⑥ Remove the dragline of the rear door inner handle, please refer to The
replacement of rear door inner handle.
⑦ Disconnect glass elevator switch harness connector, please refer to The
replacement of rear door glass elevator switch.
⑧ Remove rear door inner trim panel
2) Installation
First, connect door light wire harness and inner handle dragline, then align the
door trim panel fixed clip to the holes in the metal plate of the door, and press down
firmly in sequence. Tighten two screws.
4. The replacement of rear door hinge
1) Removal
① The removal of rear door assembly, please refer to The replacement of rear
door assembly
② Use No. 12 wrench to remove the fixed bolts, connecting the hinge and the
body.
■ Tightening torque: 16.7~25.5 N.m.
BODY017
Screw
The grommet screw
J4 Repair Manual Engine Cover and Doors
BODY-12
2) Installation
Installing shall accord with the reversed order of removal.
5. The replacement of rear door waterproof film:
1) Removal
① Remove rear door interior trim panel.
② Disconnect clip securing harness.
③ Separate waterproof film and take it off.
2) Installation.
Installation is the reversed order of removal.
Caution:
■ When assembling the waterproof film, do not allow it to cover clip pilot holes
on door trim.
■ Do not touch adhesive surface so as to avoid impairing re-bonding effect.
6. The replacement of inside rubber strip of rear door
1) Removal
1. Remove door trim panel.
① Refer to The replacement of the interior trimming
panel of rear door:
② Use hand to take one end, and then both hands
slowly, take off inside rubber strip of rear door.
Caution:
■ Please do not apply excessive force during removal, otherwise it may result in
BODY018
BODY019
J4 Repair Manual Engine Cover and Doors
BODY-13
parts deformation.
2) Installation.
① Align the inside rubber strip of rear door to B pillar card slot, maintaining clearance 1 ~2
MM; first install the front end, and then slowly place the inside rubber strip of rear door into
position.
Trunk lid
1. The replacement of trunk lid
1) Removal
① Open the trunk lid.
② Remove trunk interior trim.
③ Remove the connecting wire harness in the trunk lid.
④ Use No. 10 socket or wrench to remove the trunk lid fixed bolts.
⑤ Lift off trunk lid.
2) Installation.
Assembly is the reversed order of removal.
■ Tightening torque: 6.9~10.8 N.m
Caution:
■ After finishing trunk lid assembly, you should adjust trunk lid to ensure
satisfactory clearances to the left and right and surface difference and free open-close
without interference.
2. The replacement of trunk lid hinge
1) Removal
① Remove the trunk lid., please refer to The replacement of trunk lid
② Use No. 10 socket or wrench to remove the trunk lid fixed bolts.
■ Tightening torque: 6.9~10.8 N.m
BODY020
BODY021
BODY021
J4 Repair Manual Engine Cover and Doors
BODY-14
2）Installation
Installing shall accord with the reversed order of removal.
3. The Replacement of trunk lid weather strip:
1) Removal
① Remove the tail lamp. Refer to "Automobile tail lamp replacement.
② Use the tool to pry up weather strip.
③ Remove weather strips slowly.
Caution:
■ To remove it, do not pull hard.
2) Installation.
① Align the weather strip butt seam to the trunk lid button
② Use hand to fix the weather strip guide slot to the body, and pay attention to
the clamping of the round corner.
③ Use a rubber hammer to knock on the weather strip to fix it well.
④ The installation of the taillight. Refer to "Automobile tail lamp replacement.
Caution:
■ To install, do not apply to much strength to knock on the weather7 strip with
the rubber hammer in case of damaging it.
Oil filler of fuel tank
BODY022
J4 Repair Manual Engine Cover and Doors
BODY-15
1. Filler cover plate replacement
1) Removal
① Open filler cover plate.
② Disconnect the drawstring connecting filler cap with filler cover plate.
③ Remove screws securing filler cover plate.
■ The bolt tightening torque of 7.8 ~11.8 N • M
④ Remove filler cover plate.
2) Installation.
Installation is in the reversed order of removal.
2. Filler cap replacement
① Open filler cover plate.
② Remove the drawstring connecting filler cap with filler cover plate.
③ Remove filler cap.
2) Installation.
Installation is the reversed order of removal.
BODY023
BODY025
BODY024
J4 Repair Manual Engine Cover and Doors
BODY-16
Locking system
1. The replacement of engine hood lock
1) Removal
① Open engine hood.
② Remove front bumper.
③ Remove bolts securing lock.
④ Disconnect lock cable and take off
engine hood lock.
2) Installation.
Installation is in the reversed order of removal.
2. The replacement of engine hood open-close handle
1) Removal
① Remove the fixed bolts securing open handle base seat of engine hood.
② Disconnect engine hood handle cable.
③ Take off engine hood open-close handle.
2）Installation
Installation is the reversed order of removal.
BODY026
J4 Service Manual Interiors and Exteriors
EI - 1
EI Interior & Exterior Trims
Precautions:
■ When removing and installing parts and components, take protective measures
to avoid scratching and damaging parts and components.
■ When removing a trim clip, wrap blade of flat screwdriver with cloth to avoid
scratching body and trim panels.
■ When installing body trims, make sure their clips have been installed in plate holes on
body correctly, and then press them in carefully.
■ When removing and installing large parts and components, have several persons work
together to avoid dropping which could cause components damage and personal injury.
■ When removing and installing trims, please do not apply excessive force so as to avoid
part deformation and damage.
Front bumper replacement
Front bumper assembly diagram
1 - Front bumper body 2 -Up grille 3 -Up grille decoration strip,
4 - Down grille decoration strip, 5 - Down grille 6 - Left fog lamp cover
7 - Left hand bracket of front bumper assembly 8 - Buffer beam assembly of Front
1
2
3
4
9
8
7
5
6
J4 Service Manual Interiors and Exteriors
EI - 2
Bumper 9 -Front bumper energy absorbing pad
1. Removal
1) Lift vehicle to an appropriate height, and remove screws securing front
bumper and front-end module.
2) Remove the rubber and plastic snaps connecting the front bumper and the
side mudguards.
3) Remove the fixed screws securing the front bumper and the side mudguards.
4) Remove the snaps connecting the front bumper to the front-end module.
5) Move away front bumper and disconnect front fog light connector.
6) Take off the front bumper.
EI001
EI002
EI003
EI004
J4 Service Manual Interiors and Exteriors
EI - 3
2. Installation.
Installation is in the reversed order of removal.
Caution:
■ Check after installation for surface difference and clearance at matching place
of bumper and body.
Front bumper beam replacement
1. Removal
1) Remove screws securing the front bumper beam.
2) Remove the front bumper beam.
2. Installation
Installation is the reversed order of removal.
Caution:
■ The front bumper beam is fixed to the body by 8 bolts through the location of
the location pin on the front-end module.
■ Tightening torque: 9～11 N.m, 15～20 N.m
EI005
J4 Service Manual Interiors and Exteriors
EI - 4
Rear bumper replacement
Rear bumper assembly diagram
1 - Rear Bumper body 2 - Right hand bracket of rear bumper assembly
3 - Rear bumper beam assembly
4 - Left hand bracket of rear bumper assembly 5 - Left energy absorbing pad 6-Right
energy absorbing pad
Caution:
■ The bumper trim panel is made from resin material.Please do not apply strong
force to it, and avoid contact with oils
■ During removal and installation, do not scratch outer surface of bumper.
1. Removal
1) Place your vehicle on a lift and lift it to an appropriate height, and then remove
fixed screws from lower part of rear bumper.
1
2
3
5
4
6
EI006
J4 Service Manual Interiors and Exteriors
EI - 5
2) Remove taillight.
3) Remove screws connecting rear bumper with body from under left and right
taillights.
4) Remove fixed screws of rear bumper at both left and right sides in sequence.
5) Remove the fixed screws and rubber plastic snaps of the rear bumper.
6) Disconnect parking assist system sensor electronic connector.
7) Take off rear bumper.
2. Installation
Installation is in the reversed order of removal.
Sun visor replacement
1. Removal:
1) Remove screws securing sun visor.
EI008
EI007
EI009
J4 Service Manual Interiors and Exteriors
EI - 6
2) Disconnect connecting wire inside sun visor.
3) Take off sun visor.
2. Installation
Install in the reversed order of removal of sun visor.
Caution:
■ Follow same steps to replace left and right sun visors.
A column upper guard plate replacement
1. Removal
1) Remove front door sill protect board assembly.
2) Remove the front doorframe rubber strip, please refer to "The replacement of
front doorframe rubber strip".
3) Use a slotted screwdriver to pry up the top of A column upper guard plate,
remove a special plastic buckle and a iron clip in sequence, and take off A column
upper guard plate from the matching place of dashboard.
Special plastic
buckle
Iron clip
EI010
J4 Service Manual Interiors and Exteriors
EI - 7
2. Installation
Snap the bottom of A column upper guard plate into the dashboard, align and
insert the buckle into body holes, and press firmly.
Replacement of front door sill protect board assembly.
1. Removal
Use a slotted screwdriver to pry up the matching structure between the front end
of the front door sill protecting plate and A column lower protect plate, and then, in
turn, remove three door sill buckles. Use a slotted screwdriver to pry up the matching
structure between the rear end of the front door sill protecting plate and B column
lower protect plate, and then take off the front door sill protecting plate.
2. Installation
After the installation of doorframe rubber strip, align the buckle structure of front
door sill protect plate front/rear end to the lower protect plate of A/B column, and
align and press the door sill buckle to the door sill buckle holes with force.
B column
lower protect
plate
A column
lower protect
plate
Buckle
joint
Door sill
buckle
J4 Service Manual Interiors and Exteriors
EI - 8
A column lower guard plate replacement
1. Removal
1) Remove front door sill protect board assembly.
2) Remove the front doorframe rubber strip, please refer to "The replacement of
front doorframe rubber strip".
3) Remove the open handle of engine hood, use a slotted screwdriver to pry up
two fixed buckles in the vehicle body, and pull out A column lower protect plate from
the vehicle.
2. Installation
Align A column lower protect plate to the holes in the body and press down the
buckles of A column lower protect plate into the holes with force.
Replacement of rear door sill protect plate assembly.
1. Removal
1) Remove back-row seats, please refer to "Back-row seats replacement".
2) use a Phillips screwdriver to remove three screws, and when it is finished, use
a slotted screwdriver to pry up the matching place between the rear end of rear door
sill protect plate and the B column lower protect plate. Then, remove the buckling of
door sill buckle, and take off the rear door sill protect plate.
J4 Service Manual Interiors and Exteriors
EI - 9
2. Installation
After the installation of the rear door frame rubber strip, align and insert the
buckling structure of the front/rear end of rear door sill protect plate into the holes of
B column lower protect plate and door sill buckle. Press down firmly. And also align
it to the plastic expansion buckle of the body and tighten the screws with a Phillips
screwdriver.
B-pillar trim panel replacement
1. The replacement of B pillar lower trim panel assembly
1) Removal
① Adjust the front seat position, and remove the front seat belts, please refer to
"Front seat belt replacement.
② Remove front door sill protect board assembly.
③ Remove the front doorframe rubber strip; please refer to "The replacement
of front doorframe rubber strip".
④ Remove rear door sill protect plate assembly.
⑤ Remove the rear doorframe rubber strip, please refer to "The replacement of
rear doorframe rubber strip".
⑥ Adjust the front seat to the front position and remove the lower fixed points
Screw
B column
lower
protect
plate
Buckle joint
J4 Service Manual Interiors and Exteriors
EI - 10
of front seat belts; use a slotted screwdriver to pry up the matching structure of the
upper end of B pillar lower protect plate and B pillar upper protect plate. Remove 5
buckles fixed in the body and take off B pillar lower protect plate finally.
2) Installation.
Align and press down firmly the fixed buckles of B pillar lower protect plate to
the body holes; and then press it tightly with B pillar upper protect plate matching
structure.
2. B pillar upper protect plate replacement
1) Removal
① Remove B pillar lower protect plate, please refer to "B pillar lower protect
plate replacement.
② Use a slotted screwdriver to pry up 3 buckles fixing B pillar upper protect
plate to the body, and then remove B pillar upper protect plate.
J4 Service Manual Interiors and Exteriors
EI - 11
2) Installation.
Align and press down firmly the fixed buckles of B pillar upper protect plate to
the body holes; and then press it tightly.
C pillar upper guard plate replacement
1. Removal:
1) Remove C pillar lower protect plate assembly , please refer to "C pillar lower
protect plate replacement".
② Use a slotted screwdriver to pry up 1 iron clamp and 3 buckles fixing C
pillar upper protect plate to the body, and then remove C pillar upper protect plate.
2. Installation
Insert the lower end of C pillar protect plate into the holes of hall stand assembly
firstly; align and press down firmly the fixed buckles to the body holes; and then press
it tightly.
Iron clip
J4 Service Manual Interiors and Exteriors
EI - 12
Top handle replacement
1. Removal
1）Open the bolt decoration cap of top handle
2) Remove fixed screws of top handle.
3) Remove the top handle.
2. Installation
Installation is in the reversed order of removal steps.
Ceiling body replacement
1. Removal
1) Remove the fixed screws of sun visor main bracket and auxiliary bracket, and
take off the visor.
2) Remove screws securing middle ceiling light and disconnect connectors, and
then take off middle ceiling Light.
EI013
EI014
EI011
EI012
J4 Service Manual Interiors and Exteriors
EI - 13
3) Remove all auxiliary handle in the vehicle.
4) Remove door sealing strip.
5) Remove A-pillar upper trim panel
6) Remove B-pillar upper trim panel
7) Remove C-pillar upper trim panel
8) Remove clips securing ceiling body.
EI015
EI016
EI017
EI018
J4 Service Manual Interiors and Exteriors
EI - 14
9) Remove ceiling assembly gently and move it out of rear door.
2. Installation
Installation is in the reversed order of removal.
Caution:
■ When installing, do not bend ceiling assembly excessively.
■ When installing ceiling assembly, align sun visor holes on ceiling assembly
and the last 2 clip fixing holes with their respective holes on body first and then
install.
Carpet replacement
1. Removal
1) Remove fixing bolt of front seat and disconnect seat connector, and then
move out the seat.
2) Remove rear seat and their brackets.
3) Remove front and rear door threshold trim plate.
EI019
EI021
EI020
Front headrest
Left front seat assembly
Installation screw
Back fixing bolts
Cushion fixing buckle
Rear seat back
J4 Service Manual Interiors and Exteriors
EI - 15
4) Remove A, B, C pillar lower trim
plate.
5) Remove auxiliary dashboard
6) Remove carpet buckles.
7) Remove the carpet.
2. Installation
1) Place the rear carpet into the vehicle, align it to the
holes and fix it with buckles.
2) Place the front carpet into the vehicle, set it
into place and expose the corresponding holes for
seat installation.
3) Fish out the seat connect wiring harness below the carpet, compact the carpet beside
middle gangway and fix the carpet with buckles.
EI022
EI023
EI024
J4 Service Manual Interiors and Exteriors
EI - 16
Hall stand assembly replacement
1. Removal
Use special tools to remove 6 buckles in the front of hall stand assembly, push
the hall stand assembly vertically upward until the front part totally gets off the body,
and take off the hall stand assembly by moving it in front direction.
Caution:
■ The high brake lamp connector must be pulled put before removal.
2. Installation
Installation is the reversed order of removal.
Luggage trunk assembly replacement
1. Replacement of trunk door sill protect plate assembly.
1) Removal
Take out the spare tire cover and remove the threshold sealing strip; use special
tools to remove 3 buckles of the protect plate and pull out the protect plate assembly
vertically upward.
Buckle
J4 Service Manual Interiors and Exteriors
EI - 17
2) Installation.
Installation is the reversed order of removal.
2. Luggage trunk front trim panel replacement
1) Removal
Use a special tool to remove 4 buckles of front trim panel and pull it out.
2) Installation.
Installation is the reversed order of removal.
3. Luggage trunk side trim panel replacement
1) Removal
Use a special tool to remove 8 buckles of left/right trim panel, remove 2
self-tapping screws in the bottom part with a Phillips screwdriver, and pull the
left/right trim panel out.
Buckle
Buckle
J4 Service Manual Interiors and Exteriors
EI - 18
2) Installation.
Installation is the reversed order of removal.
4. Replacement of trunk lid protect plate
1) Removal
Use a special tool to remove the 15 buckles, and then remove the cover.
2) Installation.
Installation is the reversed order of removal.
Seat replacement
1. Front seat replacement
1) Removal
EI025
buckle
buckle
Front headrest
Left front seat assembly
Installation bolt
J4 Service Manual Interiors and Exteriors
EI - 19
① Unscrew the seat assembly mounting bolts, and remove the seat assembly
and the headrest.
■Stipulated torque: 45N.m-55N.m.
② Separate safety belt-lock wire.
③ Adjust seat back to an appropriate position so that the seat can be moved out
easily.
④ Move out the seat and reinstall bolts.
2) Installation.
Installation is in the reversed order of removal steps.
2. Rear seat replacement
1) Removal
① Remove the seat cushion and the seat cushion snaps.
② Unscrew the back mounting bolts, lift up the back to get off the hook, and
then take out the back.
■ Stipulated torque: 45N.m-60N.m.
2) Installation
Installation is the reversed order of removal.
Rear seat back
Back fixing bolt
Cushion fixing bolt
J4 Service Manual Interiors and Exteriors
EI - 20
Label replacement
1. Removal
1) Before removal, heat label (name plate) at a distance of approx. 152mm
from it surface in a circular motion for approx. 30 seconds.
2) Use tape to protect mounting surface.
3) Use a flat edge tool, lift or remove label from surface of panel board.
Caution:
■ Do not damage body paintwork.
2. Installation
1) Clear mounting area of label and dry it thoroughly.
2) Heat mounting surface to approx. 27~41℃.
3) Tear off tape protecting layer from back of label and press label into correct
position.
Caution:
■ Stick label in a dustless environment as far as possible. Dust or other foreign
materials may cause unfavorable adhesion.
Front windshield replacement
1 - front
windshield
assembly 2- left ventilating cover plate assembly 3 -right ventilating cover plate assembly 4 -
J4 Service Manual Interiors and Exteriors
EI - 21
lower ventilating cover plate assembly
5-Front wall sealing strip assembly
1. Removal
1) Open engine hood.
2) Mask surrounding area of front windshield to protect paintwork and roof
interior.
3) Remove front windshield wiper arms and blades.
4) Remove A-pillar upper trim panel
5) Remove front windshield garnish strip.
Caution:
■ During removal of windshield, the only suitable lubricant is fresh water.
EI026
EI027
EI028
J4 Service Manual Interiors and Exteriors
EI - 22
6) Use glass sealant remover or windshield stationary window glass remover to
remove the windshield.
7) With a helper’s aid, remove front
windshield from the vehicle.
8) Check the following components that may result in a broken windshield:
① Windshield sash edge
② Windshield garnish strip
③ Windshield
9) Check windshield sash and adhesive flanging.
10) Clear front shroud, seats, floor, and defroster ducts of all cullets. Clear inner
surface edge of windshield with a lint-free cleaning cloth wetted in a mixture of
isopropyl alcohol and water of 50/50 in volume.
2. Installation
Perform the following operations after windshield sash is handled as required:
1) Stir pressed welding primer for at least 1 minute.
2) Use a new dauber, apply pressed welding primer
to surface (1) of bonding area.
EI029
EI035
EI031
J4 Service Manual Interiors and Exteriors
EI - 23
3) Wait about 10 minutes for primer to dry. Make sure all scratches and abrasions
have been covered.
4) Install washer and VIN plate filler strip.
5) Install garnish strip to edge of windshield.
If original window garnish is damaged, be sure to replace it.
6) With the help of an assistant, adapt windshield to sash to determine correct
location mode of front windshield in its sash.
7) Use tape (1) to mark position of
windshield in its sash
EI032
EI033
EI034
EI035
J4 Service Manual Interiors and Exteriors
EI - 24
8) Cut off tape from top edge of windshield.
9) With a helper’s aid, remove windshield from its sash using suction cup.
10) Put windshield on a clean and safe surface with its inner face up.
11) If the original windshield is to be reused, clear its surface of almost all
polyurethane adhesive with a multi-purpose knife or razor blade, but retain a film.
12) Clear inner surface edge of windshield with a lint-free cleaning cloth wetted
in a mixture of isopropyl alcohol and water of 50/50 in volume.
Caution:
■ Never clear all traces of adhesive. Clear all accumulated or scattered
polyurethane adhesive debris.
13) If long-term method is used, clear blank welding flanging of almost all
adhesive while retaining approx. 2mm.
14) Stir pressed welding primer for at least 1 minute.
15) Use a new dauber, apply primer to surface of blank welding flanging.
16) Allow clamping welding primer to dry for approx. 10 minutes.
Caution:
■ When applying glass protectant (transparent) to windshield, please be cautious
and careful. Such primer almost dries immediately, so visual area of windshield may
be contaminated in the case of uneven application.
17) Apply approx. 10~16mm glass protectant along outer edge of whole window
inner surface with a new dauber.
18) Apply the second layer of glass protectant to corresponding area on the glass.
19) Wipe up the area coated with primer with a lint-free clean rag immediately.
20) Stir glass protectant for at least 1 minute.
EI036
J4 Service Manual Interiors and Exteriors
EI - 25
21) Use a new dauber, apply glass primer to
the same area of glass protectant application. Glass
primer can be used after 8 hours since it has been
applied to the glass. The glass surface for primer
application must be kept clean.
22) Wait about 10 minutes for glass primer to dry.
23) Cut off nozzle of applicator to form
a 6.0mm flanging.
24) Use barrel caulking gun,
coat glass cement flanging evenly and
continuously.
25) Smear glass cement on existing
glass cement on body.
26) With the help of an assistant,
use suction cup to install windshield
into its sash
27) Align tape lines (1) on windshield
and body.
EI038
EI039
EI040
EI041
EI037
J4 Service Manual Interiors and Exteriors
EI - 26
28) Press windshield into place.
29) Stick windshield to body using tape to reduce movement until glass cement
cures.
30) Clear body of all redundant glass cement.
Caution:
■ Do not spay high pressure water stream on glass cement just applied directly.
31）Perform watertight test to windshield with soft warm water.
32）Check windshield for leakage.
33）If leakage is found, smear more glass cement on the leaky point with a plastic
scraper.
34) Wait until glass cement cures and then recheck front windshield for leakage.
Warning:
■ Approx. 24 hours are required for service materials to cure completely. Before
this, never interfere in the repaired area. In the case of inadequate curing of glass
cement, occupants who do not take protective measures may be thrown out of the
vehicle resulting in personal injury.
Remove protective tape and mask from windshield zone.
Caution:
■ After finishing windshield installation, be sure to wait more than 1 hour for
sealant to cure.
■ After windshield is installed, park your vehicle on a flat ground for more than 4
hours. ■ If you need to run your car at this time, you must drive it slowly within 8
hours.
■ It is not allowed to slam a door with all door windows closed.
■ After windshield installation, do not subject your vehicle to large load within
2-3 days (e.g. driving on irregular and rugged roads).
J4 Service Manual Dashboard
IP-1
Dashboard
Precautions:
■ Strictly observe precautions for operation of air bag system, otherwise vehicle
damage and personal injury may result.
■ Before removal of an electrical connector, be sure to remove battery negative (-)
and wait at least 1 minute; otherwise, vehicle damage may result.
■ When removing and installing a component, prevent damage or scratches to the
components removed.
■ When removing the metal clamps from the trim parts, wrap the flat screwdriver
edge with cloth.
■ When installing the body trim parts, first confirm clamps securely fitted in the
plate orifice on the body, then carefully press them in.
■ When removing and installing a large component, be sure to have 2 persons
work together so as to avoid dropping.
■ When removing and installing a garnish, please do not use excessive force.
Driver side airbag module replacement
1. Removal
1) Disconnect the negative pole (-) of battery for more than 3 minutes.
2) Remove airbag module (DAB).
IP001
J4 Service Manual Dashboard
IP-2
Schematic diagram of removing DAB (3 steps), disconnecting tool is a slotted screwdriver
with length of 15cm.
① Disconnect 3H hole
Rotate steering wheel 90°anticlockwise, pry up 3H hole's groove with
screwdriver (for detailed structure showed in diagram) and separate the DAB buckle
with steering wheel framework.
② Disconnect 6H hole
Rotate steering 90°anticlockwise, pry up 6H hole's groove with screwdriver(for
detailed structure showed in diagram) and separate the DAB buckle with steering
wheel framework.
③ Disconnect 9H hole
Put the steering wheel back to middle, rotate it 90°clockwise, pry up 6H hole's
groove with screwdriver(for detailed structure showed in diagram) and separate the
DAB buckle with steering wheel framework.
3) Disassemble the connector and take out the safety airbag module.
4) Place the safety airbag module properly as required. As shown in figure.
IP002
9H remove hole
3H remove hole
6H remove hole
J4 Service Manual Dashboard
IP-3
2. Installation
Installation is in the reversed order of removal.
Steering wheel replacement
1. Removal
1) Place the ignition switch on the position “OFF”.
2) Remove negative (-) of battery.
3) Remove driver side air bag module, and disconnect driver side airbag module connector.
4) Disconnect horn button connector.
5) Draw a position mark on steering wheel hub and align this mark with the score on steering
shaft spline.
IP005
IP003
IP006
IP006
IP004
J4 Service Manual Dashboard
IP-4
6) Loosen steering wheel nut.
Caution:
■Do not loosen nuts completely until steering wheel is loosened so as to avoid
personal injury caused by excessive forced applied during steering wheel removal.
7) Take off steering wheel.
2. Installation.
Installation is in the reversed order of removal. Note: When install DAB, just align
the DAB to the steering wheel corresponding buckling place and press down. Meanwhile, check
whether the matching gap is even.
■ Tightening torque of steering wheel nut:42～52 N•m
Caution:
■ After finishing installation, make sure horn switch works normally and no
interference and abnormal sound exist when you turn steering wheel.
■ After installation is completed, test air bag system using JAC special
diagnostic tester to ensure the system works normally.
■ Steering wheel must be right in the middle with wheels in straight-ahead
position.
Steering column protect cover replacement
1. Removal
1) Disconnect the battery negative.
IP007
IP008
J4 Service Manual Dashboard
IP-5
2) Remove steering wheel assembly, please refer to "Steering wheel
replacement"
3) Remove 3 fixing bolts on the
steering column lower housing.
4) Remove steering column upper and lower housing.
2. Installation.
Installation is in the reversed order of removal.
Safety airbag Timer-spring replacement
IP009
IP011
IP010
J4 Service Manual Dashboard
IP-6
1. Removal:
1) Disconnect the negative pole (-) of battery for more than 3 minutes.
2) Remove the driver safety airbag module, and take off Connector.
Refer to "Driver side airbag module replacement"
3) Remove screws securing the steering wheel and take off steering wheel.
IP012
IP013
IP014
IP015
J4 Service Manual Dashboard
IP-7
Caution:
■The fixing nuts can be fully taken out until the steering wheel is loosened,
otherwise the steering wheel may cause personnel injury.
4) Disconnect the connector of horn.
5) Poke the three bayonets embedded in combination switch of the clock spring
Caution:
■ Be sure 3 bayonets completely loose, and then take off timer-spring, which
needs to be careful because it is easily to get damaged.
6) Take out the timer-spring of safety airbag.
IP016
IP017
IP018
J4 Service Manual Dashboard
IP-8
2) Installation
Installing shall accord with the reversed order of removal.
Caution:
■ Take out the safety airbag timer-spring from the package and check if it is in
intact state and the dowel pin inserted on the part.
■ Open the connector cover, and insert the wiring connector of safety airbag into
the connector hole, then close the cover.
■ Prior to the installation of safety airbag timer-spring, be sure that the front
wheel is located in the center (orientation).
■ Prior to the installation of safety airbag timer-spring, be sure that the
timer-spring is located in center (twist clockwise to the end, then turn back
anticlockwise, for 2.5 cycles)
Driver side instrument panel lower protect panel replacement
1. Removal
1) Remove dashboard left end cover.
2) Remove 4 screws on the driver side lower cover
IP019
IP020
J4 Service Manual Dashboard
IP-9
3）Remove driver side lower guard board assembly.
4) Disconnect various plug-in connectors on the driver side lower guard board .
2. Installation
Installation is in the reversed order of removal.
Ignition switch replacement
1. Brief principle
As shown in the figure, the combined steering wheel lock/ignition switch has the
following 4 key positions (LOCK---ACC---ON---START) as well as reminder
switch and night illumination features:
1) “LOCK” (lock)
Ignition switch is turned OFF and steering wheel is locked. In this position, you
can insert or take out your car key. When the key is turned back to “LOCK” position,
the engine will stop running. When the key is pulled out of ignition switch, the
steering wheel lock will be activated to lock the steering wheel.
IP021
J4 Service Manual Dashboard
IP-10
2) “ACC” (accessory)
Steering system is unlocked; electrical accessory circuits are switched on;
small electrical appliances such as interior lights are operable; but both ignition
switch and main electrical circuits are deenergized. The ignition switch key should
not overstay in this position so as to avoid battery exhaust.
3) “ON” (turn on)
Ignition circuit is turned ON and all electrical circuits can work. Alarming
lights and indicator lights should come on. This is the normal position of the key
during driving.
4) “START” (start)
Turn starting motor on to start engine. When the lockhole is in this position, both
headlights and electrical equipment of large power consumption are cut off. After start,
let go of the key and it will rebound to “ON” position automatically.
Caution:
■ After the engine is started, be sure to release the key immediately. Do not let the key
overstay in “START” position.
5) Reminder switch
This light will come on as soon as the key is inserted. After your vehicle is
stopped, it will remind you to pull out the key.
6) Night light
The night light is installed around the ignition key hole. If either front door is
opened, this light will light up to assist the driver to insert the ignition key into the
key hole.
2. Electrical system schematic and connectors information:
J4 Service Manual Dashboard
IP-11
Schematic Diagram of Ignition Switch
3. Removal
1) Disconnect the battery negative.
2) Remove the driver-side safety airbag module
3) Remove steering wheel
4) Remove upper and lower decoration cover
5) Remove the safety airbag timer spring
6) Remove connector from ignition switch assembly
7) Remove assembly bolts from ignition switch assembly and key alarm switch
assembly.
IP022
IP023
IP024
Function
No.
load switch
Power switch
Night sight
Insert the key
Remove the key
J4 Service Manual Dashboard
IP-12
4. Installation.
Installation is in the reversed order of removal. When installing, ensure correct
and secure wiring.
Glove box replacement
1. Removal
1) Remove the glove box buckling part.
2)Pull out glove box from opening of instrument panel.
2. Installation.
Installation is in the reversed order of
removal.
Sub dashboard replacement
1. Removal
1) Remove joystick cover.
2) Remove joystick jacket.
IP027
IP028
IP025
IP026
J4 Service Manual Dashboard
IP-13
3) Remove 2 fixing bolts in the front of sub dashboard.
5) Remove a bolt securing instrument panel and body.
2. Installation.
Installing shall accord with the reversed order of removal.
Steering Column replacement
1. Diagram of Steering Column Assembly:
1
2
IP029
IP030
J4 Service Manual Dashboard
IP-14
Diagram of Steering Column Assembly
1 - steering column assembly 2 - Intermediate Shaft Assembly
Caution:
■ Never apply excessive axial force to the steering column assembly during the
removal and installation.
■ Never move the steering gear when removing the steering column.
2. Removal
1) Straightly park the vehicle.
2) Disconnect the cathode terminal of battery and wait for more than 3min.
3) Remove the driver-side safety airbag module
4) Remove steering wheel
5) Remove the upper and lower guards of steering column and the lower portion
of driver instrument panel.
6) Remove the combined switch assembly and clock spring from the steering
column.
7) Disconnect every harness connector from the steering column and remove the
harness from the steering column assembly.
8) Remove bolts connecting steering column and lower shaft separate the steering
column and steering gear.
■ Tightening torque: 30～35 N.m
9) Remove the fixing nuts of steering column assembly, lower the steering
column, and remove the steering column assembly.
■ Tightening torque: 20～30N·m
3. Inspection after disassembly
IP031
IP032
J4 Service Manual Dashboard
IP-15
1) Check the steering column for crack, deformation and other damage and
replace in event of any above defect.
2) Check the spline of steering column shaft for wear and tooth breakage and
replace in event of any above defect.
4. Disassembly
1) Disassembly
① Loosen the connecting bolts between steering column and connecting shaft
universal joint and remove the universal joint.
② When necessary, remove the steering lock.
Caution:
■ When reinstalling the steering lock, make sure to replace the special bolts.
③ When necessary, remove the adjustable steering column and support.
2) Disassembly key points
Removal of special bolts:
① Drill with the electric drill on the special bolts
one hole
enough to accommodate the screw tap.
② Remove the special bolts with the left-handed
screw tap.
3) Inspection after disassembly
① Check the adjusting support and spring for crack and damage.
② Check the steering lock mechanism for normal functioning.
4) Assembly
Assemble the steering lock assembly, steering
lock support and the special bolts.
Caution:
■ When install the steering lock assembly and
IP034
IP033
Special bolt
Steering lock
bracket
Steering lock
Screw tap
J4 Service Manual Dashboard
IP-16
steering lock support
onto the steering column assembly, align them to the locking
gap in the steering column to lock the steering lock temporarily.
■ After confirming the correct action of the steering lock, lock the special bolts,
till the bolt heads are broken.
lock the special bolts, till the bolt heads are broken.
5. Installation.
Installation is in the reversed order removal.
Caution:
■ Never re-use the components not intended for re-use.
■ Install the steering column assembly when maintaining the steering wheel at
neutral position.
■ When installing the connecting shaft onto the steering column, pay attention to
the installing location.
6. Inspection after installation:
Under the condition that the vehicle is straightly parked, rotate the steering wheel
leftward and rightward to limit point for several times to confirm the smooth
operation of the steering wheel.
Combination instrument replacement
1. Removal
1) Remove negative (-) of battery.
2) Remove the combination instrument panel decoration board
IP036
IP035
J4 Service Manual Dashboard
IP-17
3) Remove screws securing combination instrument.
4) Unplug connectors of combination instrument remove instrument assembly.
2. Installation
Installation is in the reversed order of removal.
A/C control panel replacement
1. Removal:
1) Disconnect the battery negative.
2) Remove A/C central control panel group shroud.
IP038
IP037
IP039
IP040
J4 Service Manual Dashboard
IP-18
3) Pull out the air conditioning control panel outwards and disconnect
related connectors, and take off the AC control panel.
2. Installation.
Installation is the reversed order of removal.
Dashboard replacement
1. Removal
1) Disconnect the battery negative.
2) Remove A/C control panel assembly.
3) Remove central A/C air outlet assembly.
IP048
IP041
IP042
IP043
IP0044
J4 Service Manual Dashboard
IP-19
4) Remove audio deck.
5) Remove left and right moldings of front door.
6) Remove left and right threshold trim plate of front door.
7) Remove upper and lower garnishes plate at left and right of A-pillar.
8) Remove left and right fixing bolts from upper part of dashboard.
IP046
IP047
IP045
J4 Service Manual Dashboard
IP-20
9) Remove driver side instrument panel.
10) Remove engine hood handle.
11) Remove passenger side glove box.
12) Remove bolts and screws securing fixing bracket of glove box, and dismantle
the bracket fixing the glove box.
13) Remove steering wheel assembly.
14) Remove combination switch.
15) Remove instrument assembly.
16) Remove fixing nut of locating hole on
instrument behind the dashboard.
17) Remove left and right fixing nuts of dashboard.
18) Remove bolts securing passenger side air bag, dashboard and its bracket.
IP052
IP051
IP049
IP050
J4 Service Manual Dashboard
IP-21
19) With a helper's aid, lift off ithe dashboard.
2. Installation.
Installation is in the reversed order of removal.
Instrument Panel Support Replacement
1. Removal
1) Disconnect all electrical equipment
connected with instrument panel support.
2) Disconnect instrument panel harness.
3) Remove fixing bolt from left side of instrument panel support.
4) Remove fixing bolt from right side of instrument panel support.
5) With a helper’s aid, lift off instrument panel support.
2. Installation.
Installation is in the reversed order of removal.
IP053
J4 Service Manual Body Size Data
Data -1
Body Size Data
Body data:
During maintenance and service, in order to guarantee various working
performance of vehicle and for better service, please check the body size according to
the data listed below:
Measurement
data point
Location information
Value (mm)
A
The distance between the middle of overhead cover and the
middle of ventilator cover upper plate
791.6
B
Space of R angular between left/right side panel and
windshield seam allowance.
1278.2
C
A pillar front door frame seam allowance length .
610.7
D
The front threshold upper seam allowance width.
685
E
Space between front door frame seam allowance upper R
angular of A/B pillar
978.8
F
Space between front door frame seam allowance upper R
angular of B/C pillar
656.3
G
The rear threshold upper seam allowance width.
414.3
H
Rear door frame height
924.5
I
The length of the diagonal between the front-lower part and
rear-upper part of front door frame
1295.7
J
The length of the diagonal between the front-upper part and
rear-lower part of front door frame
937.8
J4 Service Manual Body Size Data
Data -2
K
The length of the diagonal between the front-lower part and
rear-upper part of rear door frame
1133.6
L
The length of the diagonal between the front-upper part and
rear-lower part of rear door frame
1015.4
M
The distance between the middle of overhead cover and front
windshield lower seam allowance
958.8
N
The distance between the middle of ventilator cover upper
plate and front windshield upper seam allowance
964.3
J4 Service Manual Body Size Data
Data -3
Engine compartment data
During maintenance and service, in order to guarantee various working
performance of vehicle and for better service, please check the body size according to
the data listed below:
Measurement
data point
Location information
Value (mm)
A
The maximum width between the left/right side panel and
engine compartment
1474.6
B
Space of left/ right front absorber mounting plate holes
1104
C
The maximum length of the connecting part between front wall
crossbeam and engine compartment
737.5
D
Space of left/right engine compartment longitudinal beam
front end mounting plate holes
930
E
Right front suspension strengthen girder length
527.2
F
Left front suspension strengthen girder length
527.4
G
Across corner length of right engine compartment
longitudinal beam and front wall crossbeam
1162.5
H
Across corner length of left engine compartment longitudinal
beam and front wall crossbeam
1162.5
I
Left/right front suspension strengthen girder length
1332.2
J4 Service Manual Body Size Data
Data -4
J
Right suspension installed back mounting bracket to the engine
compartment width
968.4
Side member data:
Measurement
data point
Location information Value (mm)
A
Space between left/right front longitudinal beam and inner
wall
888.3
B Space of left/right front sub-frame mounting holes 953
C Space of left/right rear sub-frame mounting holes 1071
D
Space of the leaking holes in right engine compartment rear
longitudinal beam front/ rear end
465.1
J4 Service Manual Body Size Data
Data -5
E
Space of the leaking holes in left/right engine compartment
rear longitudinal beam rear end
760
F
The distance between front floor girders leaking hole and
left engine compartment rear longitudinal beam leaking hole
660
G
The distance between rear floor left and right girders leaking
hole
980