Content

Starting and Charging System ............................................................................................................................................... 1

I、Summary ...................................................................................................................................................................... 1

（I）Structure outline................................................................................................................................................... 1

（II）Operating Principle ............................................................................................................................................. 2

（III）Technical Parameter .......................................................................................................................................... 3

（IV）Torque Parameter .............................................................................................................................................. 3

（V）Maintenance Caution ......................................................................................................................................... 4

II、Troubleshooting .......................................................................................................................................................... 4

（I）Troubleshooting List ............................................................................................................................................ 4

（II）Troubleshooting Flow Chart ................................................................................................................................... 6

III、Disconnection and Connection of Battery Electrode .............................................................................................. 10

（I）Disconnection .................................................................................................................................................... 10

（II）Connection ....................................................................................................................................................... 10

IV、Press plate of Battery .............................................................................................................................................. 11

（I）Removal ............................................................................................................................................................. 11

（II）Installation ........................................................................................................................................................ 11

V、Battery Assembly ..................................................................................................................................................... 12

（I）Removal ............................................................................................................................................................. 12

（II）Installation ........................................................................................................................................................ 12

（III）Inspection ........................................................................................................................................................ 12

VI、Battery Pallet .......................................................................................................................................................... 13

（I）Removal ............................................................................................................................................................. 13

（II）Inspection ......................................................................................................................................................... 13

（III）Installation ....................................................................................................................................................... 13

VII、Generator ............................................................................................................................................................... 14

（I）Removal ............................................................................................................................................................. 14

（II）Installation ........................................................................................................................................................ 14

VIII、Starter ................................................................................................................................................................... 15

（I）Removal ............................................................................................................................................................. 15

（II）Installation ........................................................................................................................................................ 15

Air-conditioning Device ................................................................................................................................................. 17

I、Summary .................................................................................................................................................................... 17

（I）System outline ................................................................................................................................................... 17

（II）Component Position ......................................................................................................................................... 19

（III）Operating Principle ......................................................................................................................................... 20

（IV）Maintenance Parameter/Technical Parameter ................................................................................................. 21

（V）Maintenance Note ............................................................................................................................................ 22

（VI）Special Tool .................................................................................................................................................... 22

Content

II、Troubleshooting ........................................................................................................................................................ 26

（I）Troubleshooting Flow Chart .............................................................................................................................. 28

III、A/C Check and Filling Refrigerant ......................................................................................................................... 31

（I）Special Tool ....................................................................................................................................................... 31

（II）Refrigerant Filling and Discharging ................................................................................................................. 32

IV、A/C Controller Assembly ....................................................................................................................................... 35

（I）Removal ............................................................................................................................................................. 35

（II）Installation ........................................................................................................................................................ 35

V、Speed Regulating Resistance ................................................................................................................................... 36

（I）Removal ............................................................................................................................................................. 36

（II）Installation ........................................................................................................................................................ 36

VI、Exhausting Pipe Assembly ..................................................................................................................................... 37

（I）Removal ............................................................................................................................................................. 37

（II）Installation ........................................................................................................................................................ 37

VII、Pipe and Expansion Valve Assembly..................................................................................................................... 38

（I）Removal ............................................................................................................................................................. 38

（II）Installation ........................................................................................................................................................ 39

VIII、Evaporator Core Intake/Outtake Shield Sleeve Assembly ................................................................................... 40

（I）Removal ............................................................................................................................................................. 40

（II）Installation ........................................................................................................................................................ 40

IX、Warm Air Inlet/Outlet Sheath Assembly ................................................................................................................. 41

（I）Removal ............................................................................................................................................................. 41

（II）Installation ........................................................................................................................................................ 41

X、Warm Air Inlet/Outlet Water Pipe Assembly ........................................................................................................... 42

（I）Removal ............................................................................................................................................................. 42

（II）Installation ........................................................................................................................................................ 42

XI、A/C Host Assembly ................................................................................................................................................ 44

（I）Removal ............................................................................................................................................................. 44

（II）Installation ........................................................................................................................................................ 45

XII、Temperature Motor Assembly ............................................................................................................................... 47

（I）Removal ............................................................................................................................................................. 47

（II）Installation ........................................................................................................................................................ 47

XIII、Mode Motor ......................................................................................................................................................... 49

（I）Removal ............................................................................................................................................................. 49

（II）Installation ........................................................................................................................................................ 49

XIV、Air Door Motor .................................................................................................................................................... 51

（I）Removal ............................................................................................................................................................. 51

（II）Installation ........................................................................................................................................................ 51

XV、Blower Motor ........................................................................................................................................................ 53

（I）Removal ............................................................................................................................................................. 53

Content

（II）Installation ........................................................................................................................................................ 53

XVI、Heater Core Assembly ......................................................................................................................................... 54

（I）Removal ............................................................................................................................................................. 54

（II）Installation ........................................................................................................................................................ 55

XVII、Evaporator Core Assembly ................................................................................................................................. 57

（I）Removal ............................................................................................................................................................. 57

（II）Installation ........................................................................................................................................................ 59

XVIII、Condenser .......................................................................................................................................................... 61

（I）Removal ............................................................................................................................................................. 61

（II）Installation ........................................................................................................................................................ 62

XIX、Air Filter .............................................................................................................................................................. 63

（I）Removal ............................................................................................................................................................. 63

（II）Installation ........................................................................................................................................................ 63

XX、Compressor Assembly ........................................................................................................................................... 64

（I）Removal ............................................................................................................................................................. 64

（II）Installation ........................................................................................................................................................ 64

XXI、Compressor Bracket ............................................................................................................................................. 66

（I）Removal ............................................................................................................................................................. 66

（II）Installation ........................................................................................................................................................ 66

XXII、Blowing Face Air Duct Assembly ...................................................................................................................... 67

（I）Removal ............................................................................................................................................................. 67

（II）Installation ........................................................................................................................................................ 68

XXIII

、

Defrost Air Pipe Assembly of Left/Right Side

................................................................................................... 69

（I）Removal ............................................................................................................................................................. 69

（II）Installation ........................................................................................................................................................ 70

XXIV、Front Defrost Air Pipe Assembly ...................................................................................................................... 71

（I）Removal ............................................................................................................................................................. 71

（II）Installation ........................................................................................................................................................ 72

Safety Auxiliary System ................................................................................................................................................. 73

I、Summary .................................................................................................................................................................... 73

（I）Summary of Safety Auxiliary System ............................................................................................................... 73

（II）Principle of Airbag System ............................................................................................................................... 74

（III）Airbag Control Module（ACU）Function .................................................................................................... 75

（IV）Maintenance Note ........................................................................................................................................... 75

（V）Special Tool List ............................................................................................................................................... 76

II、Troubleshooting ........................................................................................................................................................ 76

（I）Troubleshooting of Airbag System .................................................................................................................... 76

（II）Maintenance of Safety Airbag System ............................................................................................................. 76

III、Safety Airbag Assembly of Driver’s side （DAB）.............................................................................................. 77

（I）Removal ............................................................................................................................................................. 77

Content

（II）Installation ........................................................................................................................................................ 78

IV、Front Passenger’s Side Airbag Assembly ............................................................................................................... 79

（I）Removal ............................................................................................................................................................. 79

（II）Installation ........................................................................................................................................................ 79

V、Airbag Controller ..................................................................................................................................................... 81

（I）Removal ............................................................................................................................................................. 81

（II）Installation ........................................................................................................................................................ 81

BCM Device ................................................................................................................................................................... 82

I、Summary .................................................................................................................................................................... 82

（I）Structure Outline ................................................................................................................................................ 82

（II）Function Requirement ...................................................................................................................................... 83

（III）Technical Parameter ........................................................................................................................................ 90

（IV）Technical Parameter ........................................................................................................................................ 92

（V）Torque Parameter ............................................................................................................................................. 92

II、Troubleshooting........................................................................................................................................................ 93

（I）Troubleshooting List .......................................................................................................................................... 93

（II）Troubleshooting Flow Chart ............................................................................................................................. 93

III、BCM Controller Assembly ..................................................................................................................................... 94

（I）Removal ............................................................................................................................................................. 94

（II）Installation ........................................................................................................................................................ 94

Combination Switch, Alternation Switch ........................................................................................................................ 96

I、Summary .................................................................................................................................................................... 96

（I）Structure Outline ................................................................................................................................................ 96

（II）Operation Principle ........................................................................................................................................... 98

（III）Maintenance Note ........................................................................................................................................... 98

II、Troubleshooting ........................................................................................................................................................ 99

（I）Troubleshooting List .......................................................................................................................................... 99

III、Clock Spring ......................................................................................................................................................... 100

（I）Removal ........................................................................................................................................................... 100

（II）Installation ...................................................................................................................................................... 100

IV、Combination Switch ............................................................................................................................................. 101

（I）Removal ........................................................................................................................................................... 101

（II）Installation ...................................................................................................................................................... 101

（III）Test ................................................................................................................................................................ 101

V、Multifunction Steering Wheel Switch .................................................................................................................... 103

（I）Removal ........................................................................................................................................................... 103

（II）Installation ...................................................................................................................................................... 103

VI、Rearview Mirror Regulating Switch ..................................................................................................................... 104

（I）Removal ........................................................................................................................................................... 104

（II）Installation ...................................................................................................................................................... 104

Content

VII、Window Regulator Main Control Switch Assembly ........................................................................................... 105

（I）Removal ........................................................................................................................................................... 105

（II）Installation ...................................................................................................................................................... 105

VIII、Window Regulator Switch ................................................................................................................................. 106

（I）Removal ........................................................................................................................................................... 106

（II）Installation ...................................................................................................................................................... 106

IX、Tail Door Switch Assembly .................................................................................................................................. 107

（I）Removal ........................................................................................................................................................... 107

（II）Installation ...................................................................................................................................................... 107

X、Warning Light Switch ............................................................................................................................................ 108

（I）Removal ........................................................................................................................................................... 108

（II）Installation ...................................................................................................................................................... 108

XI、Headlight Height Regulating Switch .................................................................................................................... 109

（I）Removal ........................................................................................................................................................... 109

（II）Installation ...................................................................................................................................................... 109

XII、Light Regulating Switch ...................................................................................................................................... 110

（I）Removal ........................................................................................................................................................... 110

（II）Installation ...................................................................................................................................................... 110

XIII、Door Contact Switch .......................................................................................................................................... 111

（I）Removal ........................................................................................................................................................... 111

（II）Installation ...................................................................................................................................................... 111

XIV

、

ESP Switch

......................................................................................................................................................... 112

（I）Removal ........................................................................................................................................................... 112

（II）Installation ...................................................................................................................................................... 112

Illumination System ...................................................................................................................................................... 113

I、Summary .................................................................................................................................................................. 113

（I）Structure Overview .......................................................................................................................................... 113

（II）Operation Principle ......................................................................................................................................... 115

（III）Technical Parameter ...................................................................................................................................... 116

（IV）Torque Parameter .......................................................................................................................................... 117

（V）Maintenance Note .......................................................................................................................................... 117

II、Troubleshooting ...................................................................................................................................................... 118

（I）Troubleshooting List ........................................................................................................................................ 118

（II）Illumination system fuse, relay, wiring harness connector list ....................................................................... 118

（III）Troubleshooting Flow Chart ......................................................................................................................... 119

III、Front Combination Light Assembly ...................................................................................................................... 123

（I）Removal ........................................................................................................................................................... 123

（II）Installation ...................................................................................................................................................... 123

（III）Regulating ..................................................................................................................................................... 124

IV、Front Fog Light Assembly .................................................................................................................................... 125

Content

（I）Removal ........................................................................................................................................................... 125

（II）Installation ...................................................................................................................................................... 125

（III）Regulating ..................................................................................................................................................... 125

V、Daylight Driving Light Assembly .......................................................................................................................... 126

（I）Removal ........................................................................................................................................................... 126

（II）Installation ...................................................................................................................................................... 126

VI、Rear Side Wall Combination Light Assembly ...................................................................................................... 127

（I）Removal ........................................................................................................................................................... 127

（II）Installation ...................................................................................................................................................... 127

VII、Rear Tail Door Combination Light Assembly ..................................................................................................... 128

（I）Removal ........................................................................................................................................................... 128

（II）Installation ...................................................................................................................................................... 128

VIII、High Position Brake Light ................................................................................................................................. 129

（I）Removal ........................................................................................................................................................... 129

（II）Installation ...................................................................................................................................................... 130

IX、License Plate Light Assembly............................................................................................................................... 131

（I）Removal ........................................................................................................................................................... 131

（II）Check .............................................................................................................................................................. 132

（III）Installation ..................................................................................................................................................... 132

X、Front Top Light Assembly...................................................................................................................................... 133

（I）Removal ........................................................................................................................................................... 133

（II）Check .............................................................................................................................................................. 133

（III）Installation ..................................................................................................................................................... 133

XI、Trunk Light ........................................................................................................................................................... 135

（I）Removal ........................................................................................................................................................... 135

（II）Check .............................................................................................................................................................. 135

（III）Installation ..................................................................................................................................................... 135

XII、Rear Reflector Assembly ..................................................................................................................................... 136

（I）Removal ........................................................................................................................................................... 136

（II）Installation ...................................................................................................................................................... 136

XIII、Rear Reversing Light Assembly ......................................................................................................................... 137

（I）Removal ........................................................................................................................................................... 137

（II）Installation ...................................................................................................................................................... 137

XIV、Rear Fog Light Assembly .................................................................................................................................. 138

（I）Removal ........................................................................................................................................................... 138

（II）Installation ...................................................................................................................................................... 138

Electrical Horn .............................................................................................................................................................. 139

I、Summary .................................................................................................................................................................. 139

（I）Structure Overview .......................................................................................................................................... 139

（II）Operation Principle ......................................................................................................................................... 139

Content

II、Troubleshooting ...................................................................................................................................................... 140

（I）Troubleshooting List ........................................................................................................................................ 140

（II）Troubleshooting Flow Chart ........................................................................................................................... 141

III、High Pitch Horn Assembly ................................................................................................................................... 142

（I）Removal ........................................................................................................................................................... 142

（II）Installation ...................................................................................................................................................... 142

Power Supply on Vehicle .............................................................................................................................................. 143

I、Summary .................................................................................................................................................................. 143

（I）Structure Overview .......................................................................................................................................... 143

II、Troubleshooting ...................................................................................................................................................... 143

（I）Troubleshooting List ........................................................................................................................................ 143

III、Power supply on vehicle ....................................................................................................................................... 144

（I）Removal ........................................................................................................................................................... 144

（II）Installation ...................................................................................................................................................... 144

Combination Meter ....................................................................................................................................................... 145

I、Summary .................................................................................................................................................................. 145

（I）Structure Overview .......................................................................................................................................... 145

（II）Operation Principle ......................................................................................................................................... 146

（III）Torque Parameter .......................................................................................................................................... 155

II、Troubleshooting ...................................................................................................................................................... 156

（I）Troubleshooting List ........................................................................................................................................ 156

（II）Troubleshooting Flow Chart ........................................................................................................................... 156

III、Combination Meter Assembly .............................................................................................................................. 157

（I）Removal ........................................................................................................................................................... 157

（II）Installation ...................................................................................................................................................... 157

Reversing Radar Device................................................................................................................................................ 159

I、Summary .................................................................................................................................................................. 159

（I）Structure Overview .......................................................................................................................................... 159

（II）Operation principle ......................................................................................................................................... 160

II、Troubleshooting ...................................................................................................................................................... 160

（I）Troubleshooting List ........................................................................................................................................ 160

（II）Troubleshooting Flow Chart ........................................................................................................................... 161

III、Reversing Radar Controller Assembly .................................................................................................................. 163

（I）Removal ........................................................................................................................................................... 163

（II）Installation ...................................................................................................................................................... 163

IV、Sensor Assembly ................................................................................................................................................... 165

（I）Removal ........................................................................................................................................................... 165

（II）Installation ...................................................................................................................................................... 165

Wiper and Washer Device ................................................................................................................................................. 167

I、Summary .................................................................................................................................................................. 167

Content

（I）Structure Overview .......................................................................................................................................... 167

（II）Operation Principle ......................................................................................................................................... 168

（III）Torque Parameter .......................................................................................................................................... 168

（IV）Maintenance Note ......................................................................................................................................... 168

II、Troubleshooting ...................................................................................................................................................... 169

（I）Troubleshooting List ........................................................................................................................................ 169

（II）Troubleshooting Flow Chart ........................................................................................................................... 171

III、Front Wiper Blade Assembly ................................................................................................................................ 175

（I）Removal ........................................................................................................................................................... 175

（II）Installation ...................................................................................................................................................... 175

IV、Front Wiper Arm Assembly .................................................................................................................................. 176

（I）Removal ........................................................................................................................................................... 176

（II）Installation ...................................................................................................................................................... 176

V、Front Wiper Connecting Rode Mechanism Assembly ........................................................................................... 177

（I）Removal ........................................................................................................................................................... 177

（II）Installation ...................................................................................................................................................... 177

VI、Front Wiper Motor Assembly ............................................................................................................................... 178

（I）Removal ........................................................................................................................................................... 178

（II）Installation ...................................................................................................................................................... 178

VII、Front Windshield Nozzle ..................................................................................................................................... 179

（I）Removal ........................................................................................................................................................... 179

VIII、Front Washing Water Pipe Assembly ................................................................................................................. 180

（I）Removal ........................................................................................................................................................... 180

（II）Installation ...................................................................................................................................................... 180

IX、Rear Washing Water Pipe Assembly ..................................................................................................................... 181

（I）Removal ........................................................................................................................................................... 181

（II）Installation ...................................................................................................................................................... 182

X、Washing Liquid Pot and Motor Assembly ............................................................................................................. 183

（I）Removal ........................................................................................................................................................... 183

（II）Installation ...................................................................................................................................................... 183

XI、Rear Wiper Blade Assembly ................................................................................................................................. 184

（I）Removal ........................................................................................................................................................... 184

（II）Installation ...................................................................................................................................................... 184

XII、Rear Wiper Arm Assembly .................................................................................................................................. 185

（I）Removal ........................................................................................................................................................... 185

（II）Installation ...................................................................................................................................................... 185

XIII、Rear Wiper Motor Assembly .............................................................................................................................. 186

（I）Removal ........................................................................................................................................................... 186

（II）Installation ...................................................................................................................................................... 186

XIV、Rear Windshield Spraying Nozzle ..................................................................................................................... 188

Content

Engine Anti-theft System .................................................................................................................................................. 189

I、Summary .................................................................................................................................................................. 189

（I）Structure overview ........................................................................................................................................... 189

（II）Operation principle ......................................................................................................................................... 190

（III）Maintenance Note ......................................................................................................................................... 190

II、Troubleshooting ...................................................................................................................................................... 191

（I）Troubleshooting list ......................................................................................................................................... 191

（II）Troubleshooting Flow Chart ........................................................................................................................... 191

III、Anti-theft Controller ............................................................................................................................................. 193

（I）Removal ........................................................................................................................................................... 193

（II）Installation ...................................................................................................................................................... 194

IV、Anti-theft Interaction Coil .................................................................................................................................... 195

（I）Removal ........................................................................................................................................................... 195

（II）Installation ...................................................................................................................................................... 195

V、Transponder ............................................................................................................................................................ 196

（I）Removal ........................................................................................................................................................... 196

（II）Installation ...................................................................................................................................................... 196

Tire Pressure Monitoring System ...................................................................................................................................... 197

I、Summary .................................................................................................................................................................. 197

（I）Structure Summary .......................................................................................................................................... 197

（II）Operation Principle ......................................................................................................................................... 199

（III）Maintenance Note ......................................................................................................................................... 199

II、Troubleshooting ...................................................................................................................................................... 200

（I）Troubleshooting List ........................................................................................................................................ 200

（II）Troubleshooting Flow Chart ........................................................................................................................... 201

III、TPMS Controller ..................................................................................................................................................... 203

（I）Removal ........................................................................................................................................................... 203

（II）Installation ...................................................................................................................................................... 203

IV、TPMS Sensor ........................................................................................................................................................ 204

（I）Removal ........................................................................................................................................................... 204

（II）Installation ...................................................................................................................................................... 204

Starting and Charging System

Starting and Charging System 1

Starting and Charging System

I、Summary

（I）Structure outline

Starting system mainly includes battery, ignition switch, starter, starter relay and related lines.

Main components of charging system include: generator assembly (inbuilt voltage regulator), battery, battery

charging indicator light.

Starting System

As main component of starting system, starter consists of direct current motor, electromagnetic switch and

transmission mechanism. Direct current motor lead in current from battery and make driving gear wheel to turn;

transmission mechanism makes driving gear wheel mesh into flywheel gear ring, and also can automatically

disconnect after engine starting; starter circuit is controlled by electromagnetic switch.

Starting system has 2 separate circuits: one is to provide high current to starter, the other is low current control

circuit which controls starter relay.

Charging System

Main function of generator is to provide power to all electrical equipment (except starter) when engine running

normally, and also charge battery. Generator mainly consists of 5 parts: rotor, stator, voltage regulator, end cover.

The rotor and stator generate alternating current with electromagnetic cutting principle, generated alternating current

is transformed into 14V stabled direct current by rectification and voltage stabilization of voltage regulator.

Generator is driven by engine through engine belt and pulley device.

Battery

The vehicle uses free-maintenance battery, whose difference with traditional battery is there is no vent plug on

battery cover, and battery is completely sealed except small vent holes on both sides of battery. Small quantity of

gas produced by battery can be released from vent holes, small amount of gas will be released when electrolyte

inside battery has chemical reactions, and if there is no exhaust vent, internal pressure will increase continuously

along with air increase, and battery shell will crack down when pressure exceeds its limitation.

Compared to regular battery, free-maintenance battery has following advantages:

- No need to add water during battery service life.

- Overcharge protection.

- Power leakage is not as easy as regular battery.

- Smaller weight and volume, large capacity.

Battery has 3 main functions in whole electrical system:

- Supply starting power when engine starting.

- Work as electrical system voltage stabilizer.

- When generating capacity of generator can’t satisfy need of electrical system, battery can supply power in a

certain period of time.

Starting and Charging System

Starting and Charging System 2

Component Position

1. Battery 2. Starter 3. Generator

（II）Operating Principle

Operating principle of starter: Turn ignition switch to “START” → Contact plate connects electromagnetic

switch bolt (at the same time shifting fork knockout gear wheel and mesh with flywheel) → Battery positive

electrode (+) supplies power, main current flows into commutator from positive electrode brush → Rotor rotates

under the action of magnetic field → (Drive planet wheel to turn) → small gear wheel move forward along drive

shaft spline → Gear drive flywheel to turn → engine starts to work.

Operating principle of generator: Generator provides direct current voltage power to vehicle electrical system

and keep battery in charging state. Output of voltage is controlled by voltage regulator. When turn ignition switch

to “START”, current flows into excitation coil, which is initially motivated. When stator coil starts generating

electricity after engine starting, excitation coil is activated by output current from stator coil. Terminal “B” supplies

power to vehicle electrical system, and supply charge power to battery. Voltage regulator checks input voltage at

“S” terminal, and controls output voltage accordingly. If excitation current increases, output power of alternating

current generator increases, otherwise it decreases. When battery voltage (voltage of “S” terminal of alternating

current generator) reaches about 14.4V regulating voltage, excitation current is cut off. When battery voltage drops

below regulating voltage, voltage regulator regulates output voltage by controlling excitation current to maintain it

in constant level.

When ignition switch is turned on and engine not start, power supply connect to terminal of combination meter

charging indicator light through indoor electrical box, to combination meter terminal, through “L” terminal of

generator to “E” terminal to grounding joint, at the same time charging indicator light will be on.

After starting engine, when generator can work normally, voltage of power supply terminal of charging

indicator light is close to “L” terminal of engine, charging indicator light is off. If charging indicator light is still on

Starting and Charging System

Starting and Charging System 3

when engine running, it indicates there is fault. If there is no voltage or too high voltage when engine working,

indicating function of voltage regulator will start, and charging indicator light will be on.

Electrical Schematic Diagram

（III）Technical Parameter

Battery Specification

No.

Application

Description

1

Cool starting current

433A （SAE）

2

20 hours rate capacity

55Ah

3

Rated voltage

12V

Starter Specification

No.

Application

Description

1

Voltage

12V

2

Power

1.2KW

Generator Specification

No.

Application

Description

1

Current

90A

2

Voltage

14V

（IV）Torque Parameter

No.

Tighten part name

Torque

（N·m）

1

Generator regulating nut

20~25

Battery

Starting

switch

Generator

Combinati

on meter

Anti-theft

relay

Neutral gear

sensor (MT)

Starting

relay

Starter

Starting and Charging System

Starting and Charging System 4

2

Generator square-head bolt tighten nut

42~52

3

Battery pressing plate fixed nut

5~8

4

Generator power supply wiring harness fixed nut

10~14

（V）Maintenance Caution

Before maintaining any electrical component, ignition switch should be in “OFF”, and all electrical load must

be “OFF”, unless there is other description in operating procedure. If tool or device is easy to contact with exposed

energized electrical terminals, battery negative electrode should be disconnected. Violation of these security notice

could lead to personal injury or vehicle component damage.

1. Start with auxiliary battery

1). If need to use auxiliary and cross-wiring to start engine, please ensure to use 12V auxiliary battery. After

connecting battery cross-wiring, ensure cross-wiring is clamped to battery terminal and in good connection.

2. Method to prevent battery over-charging

1). Should always keep battery surface (especially top) clean and dry, connecting part of terminal should be

clean and tightened; if not use vehicle for a long period, battery negative electrode should be disconnected, and

check battery charging state periodically.

II、Troubleshooting

（I）Troubleshooting List

1. Check whether there is after-sales installation which will affect starting, charging or ignition system.

2. Check system components those are easy to be seen or contacted to check whether there is obvious damage

or easy to cause damage.

3. Check whether battery is installed correctly.

4. Test condition of battery, whose voltage should not be less than 11.5V.

5. Check whether there is damage on relevant wire, and check whether connections of starter motor, starter

electromagnetic switch, starting switch, battery and all relevant ground are reliable.

6. Check whether installation of generator is loosen or improperly installed, and whether driving belt tension

is normal or there is possibility for slip.

No.

Fault

phenomenon

Fault reason analysis

Solution

Remark

1

Starting

abnormal

Engine ignition, fuel system fault

Check engine ignition, fuel system

Refer to “Starter

not work”

Starter power supply fault

Check starter power supply

Starter fault

Replace starter

Starter electromagnetic switch fault

Replace starter electromagnetic switch

Engine mechanical binding

Check related machinery components

of engine

Starter electromagnetic switch power

supply circuit fault

Check related circuit

Starter ground wire fault

Check ground circuit

Starter control power supply circuit fault

Check related circuit

Starting relay fault

Replace starting relay

Anti-theft control system fault

Maintain anti-theft control system

Starting and Charging System

Starting and Charging System 5

Starting switch fault

Replace starting switch

2

Starter can’t

stop working

Starting relay fault

Replace starting relay

Starter fault

Replace starter

Starter switch fault

Replace starting switch

3

Starter noise

Flywheel gear ring damage (Gear crack,

missing or abrasion etc.)

Replace flywheel

Flywheel damage (flywheel deformation)

Replace flywheel

Starter fault (gear crack or abrasion, axle

sleeve abrasion)

Replace starter

4

Charging

indicator light

always on

Generator L terminal circuit fault

Check related circuit

Ground wire of combination meter power

supply fault

Check related circuit or replace

combination meter

Generator power supply circuit fault

Check related circuit

Generator fault

Replace generator

5

Charging

indicator light

not on

Generator L terminal circuit fault

Check related circuit

Generator fault

Replace generator

Ground wire of combination meter power

supply fault

Check related circuit or replace

combination meter

6

Generator noise

Generator fault

Replace generator

Generator installation fault

Install generator again

Generator belt fault

Install again or replace

Starting and Charging System

Starting and Charging System 6

（II）Troubleshooting Flow Chart

Starter not work (MT)

Fault phenomenon:

Starter not work

Check voltage of starter B+

terminal voltage

Standard voltage value:

11V-14V

Whether accord

with standard value

Whether accord

with standard value

Whether accord

with standard value

Whether accord

with standard value

Ignition switch to “ST”, check

voltage of starter wiring

harness connector B03-1

terminal

Voltage standard value: 11V-

14V

Check voltage of starter relay

ER01-30 terminal voltage

Standard voltage value: 11V-

14V

Check voltage of starter relay

ER01-85 terminal voltage

Standard voltage value: 11V-

14V

Short circuit starting relay

ER01-30/ER01-87 by special

short connector. Observe

working condition of starter

Check wiring harness between

starting relay ER01-86 and ECU

and ECU control fault

Fault removed

Check wiring harness fault

between starting relay ER01-

87 and starter wiring harness

connector

Check state of fuse EF02 and

circuit between starting relay

ER01-85 terminal and main

relay

Check state of fuse ESF07 and

circuit between starting relay

ER01-30 terminal and B+

Replace starter

Maintain circuit between

starter B+ terminal and

battery

Whether starter works

Yes

No

Starting and Charging System

Starting and Charging System 7

Starter not work (CVT)

Fault phenomenon:

Starter not work

Check voltage of starter B+

terminal voltage

Standard voltage value: 11V-14V

Ignition switch to “ST”, check

voltage of starter wiring harness

connector B03-1 terminal

Voltage standard value: 11V-

14V

Check voltage of starter relay

ER01-30 terminal voltage

Standard voltage value: 11V-

14V

Whether accord

with standard value

Whether accord

with standard value

Maintain circuit between

starter B+ terminal and

battery

Replace starter

Check state of fuse ESF07 and

circuit between starting relay

ER01-30 terminal and B+

Yes

No

Starting and Charging System

Starting and Charging System 8

Generator Charging Indicator Light not ON

Fault phenomenon: Charging

indicator light not on

Check generator wiring

harness connector B05-3

terminal, short circuit terminal

3 to ground

Check wiring harness resistance

between generator wiring

harness connector B05-3

terminal and combination meter

Resistance standard value: less

than 1Ω

Replace combination meter

Fault removed

Whether accord with

standard value

Observe whether

charging indicator

light is on

Replace generator

Maintain wiring harness

between generator wiring

harness connector B05-3

terminal and combination

meter and connector fault

Yes

No

Starting and Charging System

Starting and Charging System 9

Generator Charging Indicator Light Always On

Fault removed

Fault phenomenon: Charging

indicator light always on

Check generator wiring

harness connector B05,

disconnect connector B05

Check voltage of generator

wiring harness connector B05-

2 terminal

Voltage standard value: 11V-

14V

Check voltage of generator

wiring harness connector B05-

2 terminal

Voltage standard value: 11V-

14V

Whether accord with

standard value

Whether accord with

standard value

Replace generator

Maintain circuit fault between

generator B+ and battery and

state of generator fuse ESF13

Maintain wiring harness

between generator wiring

harness connector B05-2

terminal and fuse and state of

fuse

Maintain wiring harness

between generator wiring

harness connector B05-3

terminal and combination

meter

Observe whether

charging indicator

light is off

Yes

No

Starting and Charging System

Starting and Charging System 10

III、Disconnection and Connection of Battery Electrode

（I）Disconnection

1. Open engine cabin cover

2. Disconnect negative electrode of battery

1). Ensure ignition switch to be in “OFF”;

2). Loosen negative electrode nut ① of battery, and take

down negative electrode of battery;

3. Disconnect positive electrode of battery

1). Open electrode protection cover ②, loosen positive

electrode nut ③ of battery, and take down

positive electrode of battery；

（II）Connection

1. Connect positive electrode of battery

1). Ensure ignition switch to be in “OFF”;

2). Install positive electrode of battery, tighten nut ③, and close

positive protection cover

②;

Tighten torque 5~8N·m

Starting and Charging System

Starting and Charging System 11

2. Connect negative electrode of battery

1). Install negative electrode ① of battery,

tighten fixe nut of negative electrode;

Tighten torque 5~8N·m

3. Close engine cabin cover.

IV、Press plate of Battery

（I）Removal

1. Open engine cabin cover

2. Disconnect negative electrode of battery; refer to “Disconnection and connection of battery electrode”;

3. Remove press plate of battery;

1). Remove battery press rod nut ①, and take down press rod of battery and press plate of battery②;

（II）Installation

1. Install press plate of battery;

1). Install battery press rod and battery press plate ②, tighten

battery press plate nut ①;

Tighten torque 5~8N·m

2. Connect negative electrode of battery;

3. Close engine cabin cover;

Starting and Charging System

Starting and Charging System 12

V、Battery Assembly

（I）Removal

1. Open engine cabin cover;

2. Disconnect negative electrode of battery; refer to “Disconnection and connection of battery electrode”;

3. Disconnect positive electrode of battery; refer to “Disconnection and connection of battery electrode”;

4. Remove battery press plate; refer to “Removal of press plate of battery”;

5. Remove battery assembly;

1). Take down battery assembly;

S2-w4009b

（II）Installation

1. Install battery assembly;

1). Place battery assembly to battery pallet;

2. Install press plate of battery;

3. Connect positive electrode of battery;

4. Connect negative electrode of battery;

5. Close engine cabin cover;

（III）Inspection

1. Visually inspection

1). Check whether electrode is damaged; replace any damaged or electrode clamp deformed battery electrode;

2). Check whether battery baseplate and battery press plate or press rod are damaged; replace any damaged parts;

3). Check whether battery casing there is crack or other damage causing electrolyte leaking;

4). Check whether battery electrode is loose; replace any damaged parts;

5). Check test indicator observed hole (if equipped) inside battery, whether display battery condition. If battery

already discharged, please charge.

2. Voltage inspection

Starting and Charging System

Starting and Charging System 13

1). U>13.2V, please check electrical system;

2). 12.5V<U<12.9V, system is normal;

3). 11V<U<12.4V, please check charging system;

4). U<11V, indicates that battery is damaged or charging system fault, please check charging system and battery.

VI、Battery Pallet

（I）Removal

1. Open engine cabin cover;

2. Disconnect battery negative electrode; refer to “Disconnection and connection of battery negative electrode”;

3. Disconnect battery positive electrode; refer to “Disconnection and connection of battery electrode”;

4. Remove battery press plate; refer to “battery press plate”;

5. Remove battery assembly; refer to “battery assembly”;

6. Remove battery pallet;

1). Disconnect 4 buckles ① connected battery pallet and pipe

wiring harness;

2). Remove 2 connected bolts ② of battery pallet and lower

bracket of junction box;

3). Remove 4 bolts ③ of battery pallet and lower bracket hole of

pallet;

4). Remove fixed bolt ④ of battery pallet and vehicle body;

5). Take down battery pallet assembly;

（II）Inspection

1. Check battery pallet;

1). Check whether battery pallet corroded. If any, please clean with clean hot water.

（III）Installation

1. Install battery pallet;

1). Align battery pallet to installation hole of pallet lower bracket;

pre-tighten fixed bolt ④ connected battery pallet and vehicle

body;

Tighten torque 5~8N·m

2). Tighten 4 fixed bolts ③ connected battery pallet and pallet

lower bracket;

Tighten torque 12~15N·m

3). Tighten 2 bolts ② connected battery pallet and lower bracket

of junction box;

Tighten torque 5~8N·m

4). Connect 4 buckles ① connected battery pallet and pipe

wiring harness;

2. Install battery assembly;

3. Install battery press plate;

4. Connect battery positive electrode;

5. Connect battery negative electrode;

6. Close engine cabin cover;

Starting and Charging System

Starting and Charging System 14

VII、Generator

（I）Removal

1. Open engine cabin cover;

2. Disconnect battery negative electrode; refer to “Disconnection and connection of battery electrode”;

3. Remove engine intake hose; refer to “intake hose assembly”;

4. Remove air filter assembly; refer to “Air filter assembly”;

5. Remove electronic throttle valve; refer to “Electronic throttle valve”;

6. Remove intake manifold, refer to “intake manifold”;

7. Remove generator belt;

8. Remove generator

1). Disconnect generator wiring harness connector ①;

2). Remove fixed bolts ② of generator (power supply)

wiring harness connector

3). Remove lower nut ③ of generator, and take down

square-head

nut;

4). Remove generator regulating nut ④;

5). Rotate generator regulating nut ⑤ anticlockwise, and take down movable pin;

6). Take down generator;

（II）Installation

1. Install generator;

1). Place generator to installation position;

2). Install movable pin, tighten generator regulating nut ④;

Tighten torque 20~25N·m

3). Tighten generator regulating bot ⑤;

4). Install square-head bolt, and tighten fixed nut ③;

Tighten torque 42~52N·m

5). Install connected bolt ② of generator (power supply);

Tighten torque 10~14N·m

6). Connect engine wiring harness connector ①;

2. Install generator belt;

3. Install intake manifold;

4. Install electronic throttle valve;

5. Install air filter assembly;

6. Install engine intake hose;

7. Connect battery negative electrode;

8. Close engine cabin cover;

Starting and Charging System

Starting and Charging System 15

VIII、Starter

（I）Removal

1. Open engine cabin cover;

2. Disconnect battery negative electrode;

3. Remove engine intake hose; refer to “Intake hose assembly”;

4. Remove air filter assembly; refer to “Air filter assembly”;

5. Remove electronic throttle valve; refer to “Electronic throttle valve”;

6. Remove intake manifold; refer to “Intake manifold”;

7. Remove starter

1). Disconnect starter wiring harness connector①;

2). Remove fixed nut ② of starter (power supply) wiring

harness

connector;

3). Remove 2 fixed bolts ③ in upper and lower part of starter, and take down starter;

（II）Installation

1. Install starter

1). Tighten 2 fixed bolts ③ in upper and lower part of starter, and install starter;

2). Install fixed nut ② of started (power supply) wiring

harness

connector;

3). Connect wiring harness connector ① of starter;

Starting and Charging System

Starting and Charging System 16

2. Install intake manifold;

3. Install electronic throttle valve;

4. Install air filter assembly;

5. Install engine intake hose;

6. Connect battery negative electrode;

7. Close engine cabin cover.

Air-conditioning Device

Air-conditioning Device 17

Air-conditioning Device

I、Summary

（I）System outline

The vehicle applies manual control A/C system. A/C condenser applies supercooled type, thus improving cooling

performance. To enhance defrost performance, when choose mixing and defrost mode, it is manually switched to

A/C mode. Based on the vehicle speed, cooling water temperature, and different pressure of air conditioning

refrigerant, the condenser fan has two speed control modes - low and high speed control. The increase of the

blower air volume and the improvement of the air mixing capability will improve cooling and heating

performance.

Control Type and Performance Description of A/C Control Panel

A/C control applies manual control type, panel is integrated with rear defrost heating switch, panel illumination

applies backlight/LED, button symbol applies spray-paint laser engrave; button and knob function of A/C panel

are shown as picture below.

1. A/C switch 6. Intake internal and external circulation button

2. Defrost and demist mode button 7. Rear defrost button

3. Blowing rate regulating button 8. Temperature regulating button

4. Blowing face mode button 9. Blowing feet defrost mode button

5. Blowing face and feet mode button 10.Blowing feet mode button

System Component

1. A/C host assembly

A/C host assembly consists of blower, expansion valve, evaporator, heater and casing. Blower intakes external air and gets

into vehicle through evaporator and heater to realize A/C normal working.

2. Blower

Blower consists of motor and fan, using intake port air door motor to switch internal and external air circulation mode, and

intake internal air and external air. Function of intake port air door motor is realized by internal and external air button of

controller. When in internal circulation mode, intake from two intake port in the side; when in external circulation mode, intake

through filter on front guard cover of vehicle, at the same time using blower inletting air, and carry out heat exchange through

evaporator, refrigerated air getting into vehicle.

3. Speed regulating module

The system uses speed regulating resistance, totally divided 4 grade, not variable speed regulating.

4. Air door motor

Installed in blower assembly, controlled by A/C internal and external circulation selection button, drive internal and external

circulation air door to realize switch of air intake way.

A/C control panel (manual) diagrammatic sketch

Air-conditioning Device

Air-conditioning Device 18

5. Blower motor

Rotating fan forms A/C system required air quantity by vehicle power supply.

6. Evaporator temperature sensor

Detecting temperature of evaporator core, pass signal to controller to

prevent evaporator from freezing. It is installed in evaporator core. Sensor has a

negative temperature coefficient thermistor, thus resistance increase when

temperature decreases, and resistance decreases when temperature rises.

7. Evaporator and heater

Air sent by blower goes through evaporator and gets cooled, some air through the evaporator will be sent to heater core, and

the rest is supplied to upper portion of heater housing, according to opening and closing degree of temperature control damper. In

order to control indoor temperature regulation and air mixing, air from heater core will be mixed with the air of the upper portion

of the housing in the heater housing rear section. Controlled by the mode damper motor, the mixed air is sent to the required outlet

so as to realize the vehicle interior temperature regulation and defrost / defog function. In short, the heater assembly adjusts air

mixing, and controls temperature and wind direction.

8. Mode motor

Installed in the left part of the heater housing, controlled by signal of A/C panel (ETC) mode switch, it can start small motor

inside air door motor to adjust the position of mode air door. When motor starts, changes in the voltage difference will be sent to

ETC, and ETC will judge the feedback signal. When the air door moves to the required position, the motor will stop working.

9. Temperature motor assembly

Installed in the right part of heater housing, controlled by signal of A/C controller temperature knob, it can start small motor

to regulate position of temperature controlled air door. When motor starts, changes in the voltage difference will be reflected to

A/C controller, and A/C controller will judge the feedback signal. When air door moves to required position, motor will stop

working.

10. Condenser and drier

High temperature & high pressure gas refrigerant from compressor will be cooled down at normal temperature. Cooling of

the condenser relies on traveling wind and forced air volume of fan. This model uses a parallel flow condenser, combined with

drying bottles together. Undercooling can improve cooling performance, reducing the amount of refrigerant system needs, and also

reduce number of parts combining with drying bottles. When the system is contaminated, previously drying bottles would be

replaced. But for this model, you can just remove the cap of the lower part of the drying bottle and replace the desiccant.

11. Engine cooling system

After comparing inputted vehicle speed, A/C load, coolant temperature value, engine ECU is divided into two parts (high/low)

to control speed of cooling fan. When vehicle speed signal and coolant temperature sensor failure, driving cooling fan will be high

speed running at the same time. Cooling fan is integrated in front module, switching to high/low speed through collecting coolant

temperature, vehicle speed etc. related information.

Condenser fan equipped with 1.5 engine, when high speed, power is 180～220W; when low speed, power is 120～150W;

Condenser fan equipped with 1.3 engine, when high speed, power is 140～150W; when low speed, power is 120～130W.

12. Ternary pressure switch

Ternary pressure switch is to increase the medium pressure switch to conventional A/C binary pressure switch. When the

system pressure rises, the medium pressure switch is activated and sends signals to the engine control unit. At this moment, radiator

fan and condenser fan keep high speed; it can prevent performance degradation caused by the pressure rises. Also, air conditioning

systems will be protected when abnormal pressure (high/low pressure) occurs.

R-T Curve table

Resistance

Air-conditioning Device

Air-conditioning Device 19

（II）Component Position

1. Condenser assembly 4. A/C host assembly

2. Exhaust pipe assembly 5. A/C controller assembly

3. Pipe and expansion valve assembly 6. Heating air inlet/outlet water pipe assembly

Air-conditioning Device

Air-conditioning Device 20

（III）Operating Principle

A/C control system operating principle

Refrigerating principle diagram

Wind speed

button

Temperature

sensor

A/C switch

Temperature

knob

Mode switch

Internal/external

circulation

switch

Internal/external

circulation motor

Blower

A/C clutch

Pressure

switch

Cooling/heating

regulating motor

Wind direction

regulating motor

Feedback signal

Position signal

Defrost request

Defrost feedback signal

A/C

control

module

When the vaporific refrigerant

vaporizes into gas, it can absorb the

heat from the air through the

evaporator by the use of blower.

(lower down the surrounding

temperature)

Driven by the engine pulley,

it can turn the low

temperature and low pressure

gaseous refrigerant into high

temperature and high

pressure gas and send it to the

compressor, controlled by

the clutch.

Installed in the front of the car, it can turn the

gaseous refrigerant into high temperature and high

pressure liquid refrigerant.

The refrigerant rapidly

expands and turns into low

temperature and low

pressure liquid.

It can absorb the

moisture in the

refrigerant and store

the refrigerant.

Condenser

Expansion

valve

Receiver

drier

Evaporator

Air-conditioning Device

Air-conditioning Device 21

Air flow to be changed according to the following pattern:

Wind control

Operating position

Operation

Wind speed

regulating

Rotate fan control button, clockwise rotating knob can increase fan speed,

anticlockwise rotating knob can decrease fan speed.

Rear window defrost

Pressing the button can open or close rear window defrosting function.

A/C

Pressing the button can open or close A/C compressor. When pressing A/C button,

indicator light on button will be on, which indicates A/C compressor already starts

and begins to refrigerate; pressing the button again can close A/C compressor. When

weather is hot, open vehicle window to exhaust hot air in vehicle, and then close

vehicle window. It is helpful to shorten required time of vehicle refrigerating, and

also helpful to improve system running efficiency.

Internal circulation

mode

This mode is to prevent external air from getting into vehicle. It can be used to

prevent external air and abnormal smell from getting into vehicle, or used to increase

or decrease air temperature inside vehicle more fast. Pressing this button can open or

close internal circulation mode. Using internal circulation mode for long time may

cause window fogging. If window fogging, select defrost mode.

Mode regulating

This mode guides some air flow to floor air outlet, and guides some air flow to

front windshield and side window to defrost.

Mode regulating

This mode guide most air flow to floor air outlet. Make sure there is no obstacle

under front seat to guide air flow to the back of carriage.

This mode guides some air flow to front air outlet of dashboard, and guides some

air flow to floor air outlet.

This mode guides air flow to front air outlet of dashboard.

This mode guide most air flow to front windshield and side window to demist. This

mode guide most air flow to front windshield and side window to defrost.

（IV）Maintenance Parameter/Technical Parameter

Item

State

Parameter

Remark

Refrigerant filling

amount

Replace pipe

30cc

When replacing compressor, subtract

The result that minus the amount of refrigerant oil

discharged from old compressor in the amount of

120ml is the required amount that needs to be

discharged from new compressor.

Replace condenser

30cc

Replace evaporator

30cc

△Note Even though there is no refrigerant discharged from removed compressor, don’t discharge more than 50ml

refrigerant from new compressor.

Air-conditioning Device

Air-conditioning Device 22

（V）Maintenance Note

△Warning Please obey to the following notes when checking and maintaining A/C system, or else it may cause vehicle

damage and personal injury.

1. Freezing point of refrigerant is low, and volatility is high, thus must use gloves and glasses in order to prevent phenomenon of

skin pernio and blindness due to contact with skin.

2. If refrigerant splashed to eyes or contact with skin, should clean contact part with clean water immediately, and must go to

ophthalmology department and dermatology department to consult. Don’t kneading eyes by eyes or handkerchief.

3. When do operation related to refrigerant, place must be ventilated. A large amount of refrigerant discharged in enclosed place

will cause hypoxia phenomenon.

4. Refrigerant discharged permitted amount: 1000ppm (ppm is volume of the material contained in the air of the one million

volume) (4184mg/ ㎡); when discharged amount too much, it may cause heart and cardiovascular system, immune system

abnormal or irritability; respiratory system abnormal or skin disease.

5. When doing operation related to refrigerant, make sure there is no foreign matter of moisture and dust around, this foreign

matter will flow into A/C system and will be harmful to system.

6. When doing operation related to refrigerant, must prepare gas leakagemeter. When R-134a refrigerant contact with high

temperature obstacle, it will produce harmful gas, therefore pay attention to prevent leakage.

7. A/C system of the vehicle must use R-134a refrigerant. If using other refrigerant, it will cause bad influence to system

component.

8. R134a refrigerant and R-12 refrigerant are imcompatible, thus little amount can’t be mixed.

9. When doing operation related to refrigerant, make sure there is no pyrophorus or combustible obstacle around vehicle, and pay

special attention that refrigerant jar will cause bomb in heat source.

10. R134a container is high pressure state, must not be placed in high temperature environment, and must check whether storage

environment temperature is under 52℃.

11. A/C component generally uses dustproof cover in order to prevent drainage, dust, moisture flowing in. Dustproof cover should

be removed before operating and sealed after operating.

12. Synthetic oil (PAG) with R-134a is more easier to absorb water than R-12, and absorptivity is 10 times higher than mineral oil

(MINERAL). Too much water will infect compressor, lubrication function and durability.

13. Influence of moisture to A/C system is very bad, therefore it’s better to avoid operation in rain day.

14. When A/C system re-installed after removed, should spread refrigeration oil to O-type seal ring, especially bolt-type

connection part, should first be installed manually and then assemble with two spanners.

15. When assembling flange-type connection part, should push pipe slightly and connect nut and bolt.

16. When installing A/C, assembling with torque more than required torque or force of clamping O-type seal ring too large will

cause refrigerant leakage, therefore operate according to required.

17. Hose can’t be distorted.

18. Don’t separate A/C system before recycling refrigerant absolutely. If separated before recycling, it will discharge refrigerant

and refrigeration oil under the influence of system pressure, and it may pollute environment.

19. When replacing A/C component, must fill refrigeration oil (type: PAG) when filling refrigerant and refrigeration oil.

（VI）Special Tool

No.

Tool No.

Tool name

Outside drawing

Use

1

Digital multimeter

Air-conditioning Device

Air-conditioning Device 23

No.

Tool No.

Tool name

Outside drawing

Use

2

High strength invisible lights

3

Pliers

4

R-134a manifold gauge

5

Halogen leak detector

6

Tracer color syringe

7

R134a tracer pigment

8

Micro thermometer

9

Forward flow control valve

Air-conditioning Device

Air-conditioning Device 24

No.

Tool No.

Tool name

Outside drawing

Use

10

Seal protector device

11

50 pounds recycling tanks

12

Pressure test adapter

Connecting A/C

pressure tester and

A/C pipes

13

A/C system lip seal removal tool

Removal A/C

system lip seal

14

O-type seal removal tool

Remove O-type

seal ring

15

Valve core removal and installation tool

Remove and

install valve core

16

O-type seal ring installation tool

Install O-type seal

ring

17

Spring clip pliers

Remove and

install spring clip

Air-conditioning Device

Air-conditioning Device 25

No.

Tool No.

Tool name

Outside drawing

Use

18

Spring clip pliers

Remove and

install spring clip

19

Refrigerant recycle\ regeneration and

refilling system

Recycle and fill

refrigerant

20

Passive test lamp

A/C system

leakage inspection

Air-conditioning Device

Air-conditioning Device 26

II、Troubleshooting

Troubleshooting List

No.

Fault Phenomenon

Fault reason analysis

Solution

Remark

1

A/C system has no

refrigerant

System exists leakage

Check with eyes：

1. Observe whether there is oil stain in connection parts of all

components; if any, it indicates there is leakage here. Spread

suds to suspected part and observe whether there is bubble.

2. Observe whether there is abnormal failure, whether there is

scraping, flattening and bruise on surface of condenser and

evaporator core.

With vacuumizing mode, listen to the part position if there is

“zizi” sound, which indicates the leakage.

Check with instrument：

1. Electronic leak detector with high sensitivity;

2. Dye-guided detection method

2

System

refrigeration oil

not right amount

Replace system

component, fill or

reduce according to

rules

1. Firstly ensure specification of refrigeration oil, can’t

be mixed; generally using specification: PAG

2. After recycling refrigerant, replenish about 30g

refrigeration oil

3. Replace compressor, pour out all refrigeration oil in

compressor and fill the same refrigeration oil with

replaced compressor

4. Replace pipe: replenish about 30g refrigeration oil

5. Replace condenser: replenish about 60g refrigeration

oil

6. Replace evaporator: replenish about50g refrigeration

oil

7. Replace dryer: replenish about 10g refrigeration oil

3

Blowing rate

abnormal

A/C has no wind

Circuit fault Refer to “Blower not work”

Machinery fault

1. Blower motor damaged, replace motor

2. Temperature air door mechanism damaged, and

cannot adjust air door to refrigeration state

3. A/C controller damaged, replace A/C control module

4. Speed regulating resistance damaged, replace speed

control module

A/C blowing rate

small

1. Voltage not enough, check power supply

2. Whether air duct is blocked, whether grille is fully

opened

3. Check whether face air blow has leakage

4. Speed control module fault, replace speed control

module

5. Whether air filter has excessive windage, whether

there is dust and foreign matters blocked

6. Blower motor rotates in reverse direction, adjust

positive and negative electrode of connector

4

A/C not

refrigerate

System has no

refrigerant

Refer to “A/C system has no refrigerant”

Not blow

Refer to “Blowing rate abnormal”

Compressor not

work

Circuit fault Refer to “Compressor not work”

Machinery fault

1. Drive belt broken, replace

2. Compressor internal fault, replace

5

A/C refrigeration

is not good

Refrigerant not

enough

1. Check whether pressure is in normal value range; if

lack of refrigerant, refill it.

2. Check whether system has micro leakage

Refrigeration oil too

1. Discharge redundant refrigeration oil, and refill the

Air-conditioning Device

Air-conditioning Device 27

No.

Fault Phenomenon

Fault reason analysis

Solution

Remark

much

satisfactory amount of refrigeration oil

Compressor is

abnormal

1. Compressor belt or clutch slips

Blowing rate is

small

Refer to “Abnormal blowing rate”

Abnormal pressure

High pressure is lower than normal value, low pressure

is lower than normal value

1. Expansion valve is blocked, clear obstructions

2. Opening degree of expansion valve is not enough,

adjust expansion valve or replace

3. Refrigerant is little, add refrigerant

High pressure is higher than normal value, low pressure

is higher than normal value

1. Condenser radiating is not good; Check condenser

fan and replace faulted

2. Refrigerant is too much, release some

High pressure is lower than normal value, low pressure

is higher than normal value

1. Compressor malfunctions, lack of capacity, needs to

be replaced

2. Refrigerant not enough, add refrigerant

High pressure is higher than normal value, low pressure

is lower than normal value

1. There is impurity blocking in the system

6

A/C system no

heating

Heater core has no

hot water

Heating pipe gets blocked, clear obstacle

A/C not blowing

wind

Refer to “Blowing rate abnormal”

Controller fault

Temperature regulation of controller damaged, and

can’t adjust temperature air door to maximum heating,

replace controller

7

A/C system

heating is not

good

Heating water

circulation not

enough

Check whether engine coolant supply is insufficient,

engine failure

Poor circulation

inside heater core

Clear obstacle in heater core, or replace heater

Blowing rate is

small

Refer to “Blowing rate abnormal”

Mode air door is

wrong

Temperature air door’s rotation is not in place, and

there is a mix of cold and hot

8

A/C system has

abnormal sound

Compressor has

abnormal sound

Open A/C, compressor works; check whether there is

fractive sound in clutch; if any, please replace

compressor

Pipe expansion

valve has abnormal

sound

Start the A/C, check if there is flowing “chirps” sound

in the expansion valve. Adjust the expansion valve and

replace it.

Air door mechanism

has abnormal sound

If there is resistance when adjusting the damper bodies;

whether there is "ticking" or "giggle" sound; if there is

such phenomenon, smear lubrication oil in the damper

body or replace body parts.

Motor damaged

Replace motor

Temperature air

Replace temperature air door mechanism

Air-conditioning Device

Air-conditioning Device 28

No.

Fault Phenomenon

Fault reason analysis

Solution

Remark

door mechanism

damaged, and can’t

adjust air door to

refrigeration state

Blower has

abnormal sound

There is abnormal sound in blower

1. . A "humming" sound; confirm if the motor rotates

reversely; adjust plug-line;

2. "Creak" or "Zizi" sound; the motor is damaged, and

replace the motor;

3. "Pop" sound; if there is a foreign body in the volute,

remove and check the volute.

Blower is not installed firmly, resulting in vibration and

abnormal sound.

There is water sound

in heater core

1. 1. Idling and stepping on the accelerator (compressor

does not start) to the degree that the condenser fan

rotates at high speed;

2. Continue to step on the accelerator to the degree that

the engine speed exceeds 5000 rpm with the duration of

one minute;

3. Stop accelerating, idle and drastic acceleration to

confirm whether there is still water flow sound; if so,

follow step ② until no sound of water.

9

A/C system has

peculiar smell

Filter mildew

Remove the filter to check if the surface has serious

pollution, and timely replace it when necessary.

Radiator surface has

been polluted

Whether the surface of evaporator and heater contains

oil in production; if it has, remove and clean it.

Poor drainage of

condenser water

Condensate water cannot be excluded entirely, and

there is water in the case, resulting in deteriorating;

replace the outlet location.

（I）Troubleshooting Flow Chart

Blower not work

Step

Check content

Solution

Judgement

specification

Next step

Yes

No

1

Check blower

relay fuse

Remove blower relay fuse IF37, and

measure whether blower relay fuse IF37

is fused by multimeter.

Whether fuse is

fused?

Maintain

fuse short

circuit fault

and replace

fuse

Go to

step 3

2

Check voltage

value of blower

relay control

circuit

Measure voltage value between blower

relay ER2-86 terminal and reliable

ground.

Voltage standard

value: 11~14V

Next step

Replac

e relay

3

Check blower fuse

Remove blower relay fuse ESF04, and

measure whether blower relay fuse ESF04

is fused by multimeter.

Whether fuse is

fused?

Maintain

fuse short

circuit fault

and replace

fuse

Go to

step 3

4

Check voltage

value of blower

relay controlled

circuit

Measure voltage value between blower

relay ER2-30 terminal and reliable

ground.

Voltage standard

value: 11~14V

Next step

Mainta

in

failure

circuit

Air-conditioning Device

Air-conditioning Device 29

Step

Check content

Solution

Judgement

specification

Next step

Yes

No

5

Check connected

circuit between

blower relay and

blower wiring

harness

Measure resistance value between blower

wiring harness connector M44-2 terminal

and ER2-87 terminal.

Standard

resistance value:

less than 1Ω

Next step

Mainta

in

failure

circuit

6

Check connected

circuit between

blower wiring

harness and A/C

control panel

wiring harness

connector

Measure resistance value between blower

wiring harness connector M44-1 terminal

and A/C control panel wiring harness

connector M30-4 terminal.

Standard

resistance value:

less than 1Ω

Next step

Mainta

in

failure

circuit

7

Replace blower

Remove blower, and install new blower.

Adjust blowing rate button to check

whether blower works normally.

Blower works

normal

System is

normal

8

Ensure system is

normal

Compressor not work

Step

Check content

Solution

Judgement

specification

Next step

Yes

No

1

Check A/C

compressor relay

fuse

Remove A/C compressor relay fuse EF02,

and check whether blower relay fuse

EF02 is fused.

Whether fuse is

fused?

Maintain

fuse circuit

short circuit

fault, and

replace fuse

Go to

step 3

2

Check voltage

value of A/C

compressor relay

control circuit

Check voltage value between blower

relay ER2-86 terminal and reliable

ground.

Voltage standard

value: 11~14V

Next step

Replac

e relay

3

Check A/C

compressor fuse

Remove A/C compressor fuse EF04, and

check whether blower relay fuse EF04 is

fused.

Whether fuse is

fused?

Maintain

fuse circuit

short circuit

fault, and

replace fuse

Go to

step 3

4

Check voltage

value of A/C

compressor relay

controller circuit

Check voltage value between blower

relay ER05-30 terminal and reliable

ground.

Voltage standard

value: 11~14V

Next step

Mainta

in

failure

circuit

5

Check circuit

between A/C

compressor relay

and A/C

compressor wiring

harness connector

Measure resistance value between A/C

compressor connector B05-1 terminal and

ER05-87 terminal by multimeter.

Standard

resistance value:

less than 1Ω

Next step

Mainta

in

failure

circuit

6

Check circuit

between A/C

compressor relay

and ECU wiring

harness connector

Measure resistance value between A/C

compressor relay ER05-86 terminal and

ECU wiring harness connector A22-10

terminal by multimeter.

Standard

resistance value:

less than 1Ω

Next step

Mainta

in

failure

circuit

7

Replace ECU

Disconnect ECU wiring harness, remove

ECU, and replace new ECU. Check

whether A/C compressor works normally.

Whether

compressor

works normally?

System is

normal

Air-conditioning Device

Air-conditioning Device 30

Step

Check content

Solution

Judgement

specification

Next step

Yes

No

8

Replace A/C

pressure switch

Disconnect pressure switch wiring

harness connector, and replace A/C

pressure switch/

Whether

compressor

works normally?

System is

normal

9

Check circuit

between A/C

pressure switch

wiring harness

connector and ECU

wiring harness

connector

Use multimeter to respectively measure

resistance value of A/C pressure switch

wiring harness connector E15-2 terminal

and ECU wiring harness connector A22-

79 terminal, A/C pressure switch wiring

harness connector E15-4 terminal and

ECU wiring harness connector A22-40

terminal.

Standard

resistance value:

less than 1Ω

Next step

Mainta

in

failure

circuit

10

Check circuit

between A/C

pressure switch

wiring harness

connector and A/C

control panel

wiring harness

connector

Use multimeter to respectively measure

resistance value of A/C pressure switch

wiring harness connector E15-1/E15-3

terminal and A/C control panel wiring

harness connector M29-23 terminal.

Standard

resistance value:

less than 1Ω

Next step

Mainta

in

failure

circuit

11

Check circuit

between evaporator

temperature sensor

wiring harness

connector and A/C

control panel

wiring harness

connector

Use multimeter to respectively measure

resistance value of evaporator

temperature sensor wiring harness

connector M40-1 terminal and A/C

control panel wiring harness connector

M29-8 terminal, evaporator temperature

sensor wiring harness connector M40-2

terminal and A/C control panel wiring

harness connector M29-9 terminal.

Standard

resistance value:

less than 1Ω

Next step

Mainta

in

failure

circuit

12

Check evaporator

temperature sensor

Measure resistance value of evaporator

temperature sensor by multimeter.

Judge whether

resistance value

corresponding to

evaporator

temperature

sensor

temperature-

resistance list?

Next step

Replace

evaporator

temperature

sensor

13

Replace A/C

control panel

Remove fixed bolts of A/C control panel,

disconnect A/C control panel wiring

harness connector, and replace new A/C

control panel

Whether

compressor

works normally?

System is

normal

Next step

14

Replace A/C

compressor

Disconnect A/C pipe, remove fixed bolts

of compressor, and replace A/C

compressor

Whether

compressor

works normally?

System is

normal

Next step

15

Ensure system is

normal

Air-conditioning Device

Air-conditioning Device 31

III、A/C Check and Filling Refrigerant

（I）Special Tool

No.

Tool No.

Tool name

Tool diagram

1

Refrigerant recycling/ regeneration, refilling

system

2

Passive test lamp

3

R-134A manifold gauge

4

50 pounds recycling tank

5

Pressure test adapter

6

Microthermometer

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Air-conditioning Device 32

（II）Refrigerant Filling and Discharging

1. Install refrigerant filling instrument

1). Close manual valves at both ends of refrigerant filling instrument.

2). The filling pipe of the refrigerant filling instrument is installed in joints. Low-pressure pipe to the low pressure nozzle and

high pressure pipe to the high-pressure nozzle. Tighten the nut by hands after connection.

Low

High

Close

Open

2. Operations of discharging refrigerant

1). Connect the refrigerant filling instrument to the system.

2). Put a clean rag in the open part of central hose.

3). Gradually open the high pressure manual valve to discharge refrigerant.

△ Caution Exhausting gas velocity too fast may result in the discharging of the refrigeration oil from the compressor.

4). Check if there is the trace of refrigeration oil on the rag. If there is the trace, slightly close the manual valve.

5). When the filling instrument ruler decreases to 3.5kg/c㎡, slowly open the low pressure manual valve.

6). To reduce the system pressure, slowly open the high pressure and low pressure manual valve until the ruler indicates 0kg/c

㎡.

3. Vacuum operation for refrigeration system

△ Caution System must be vacuumized after discharging refrigerant. This operation is supposed to exclude the air and

moisture in the system, and it should be started in 15 minutes after all the parts are installed.

1). Confirm if the engine stays in “shut down”.

2). Connect the filling instrument to the compressor contact joint, and

close the two ends.

3). Confirm if the refrigerant is excluded from the system.

4). Central pipe is connected to the intake port of the vacuum pump.

5). Open the high pressure/low pressure valve of the filling instrument

after operating the vacuum pump.

6). After 10 minutes, the low pressure detector scale should be higher

than 0.96kg/c㎡ vacuum. Otherwise, the system has leakage and

should be repaired as following steps.

-Use refrigerant container filling system.

-Use leakage detector to check the leakage. If the leakage if detected,

repair it.

-Exclude the refrigerant and vacuumize the system.

- If the leakage does not occur, continue to vacuumize.

7). Operate the vacuum pump again.

8). Filling instrument scale for both ends should keep 0.96kg/c㎡ vacuum.

9). Continue to vacuumize until the ruler indicates 0.96kg/c㎡.

10). About 15 minutes after the implementation of vacuum operation, close the pressure valve of the filling instrument and stop

vacuumizing; separate pipes from the pump. In this way, refrigerant can be added.

Low

High

Close

Air

Vacuum pump

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Air-conditioning Device 33

4. Use refrigerant control valve

1). Before the valve is connected to the refrigerant container, completely turn the handle counterclockwise.

2). Turn counterclockwise until the disc reaches the highest position.

3). After connecting of the central pipe to the valve device, rotate the disc clockwise by hand.

4). Turn the handle clockwise and dill hole in the upper portion of

the sealing part.

5). Loosen the nuts connecting the filling instrument center

connector and pipe.

6). After a few seconds of exhaust, tighten the nut.

5. Adding refrigerant (Gaseous state)

△ Caution This operation is by means of the device on low

pressure side to add the gaseous refrigerant into the system. At this time the refrigerant

container should be put vertical so that the gaseous refrigerant would flow into the system.

1). Install the refrigerant container on the adjusting valve.

2). Open the low pressure valve; adjust the valve until the low pressure scale stays below 4.2kg/m

2

.

3). Start the engine and start the air condition.

△ Caution To prevent the liquid refrigerant flows into compressor through the intake port, put the

container vertical.

4). When add the regulated amount of refrigerant, close the low

pressure valve.

Regulated amount of filling refrigerant: 460±20g

5). If the refrigerant filling speed is too slow, you can put the

container into a container of water of about 40 ℃.

△ Caution Under any circumstances, do not keep the water

heated to above 52 ℃, and hot light should not

touch the container.

Low

Close

Open

Refr

iger

ant

Refrig

erant

Refri

gera

nt

Soak into water to

about 40℃

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Air-conditioning Device 34

6. Adding refrigerant (liquid state)

△ Caution This operation is by means of high pressure side filling. Upend the refrigerant container so that

the refrigerant would flow into the system.

1). After the system is vacuumized, completely close both ends of high/low pressure valve.

2). Install the adjusting valve of refrigerant container.

3). Upend the container after the high pressure valve is fully opened.

4). The exclude pressure will increase when the system is over filled. Therefore, when measure the refrigerant weight, fill with

correct amount and close the high pressure valve.

Regulated amount of filling refrigerant: 460±20g

5). After adding regulated amount of refrigerant, close the filling instrument valve.

6). Use leakage detector to check if there is leakage.

△ Caution When use high pressure side filling, the engine will not be started. By use of liquid refrigerant

filling, low pressure valve cannot be opened. Performance test should be conducted before

separating the filling instrument.

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Air-conditioning Device 35

IV、A/C Controller Assembly

（I）Removal

1. Open the engine compartment hood.

2. Disconnect the negative cable of the battery. Refer to “Disconnection and connection of battery electrode”

3. Disassemble the air condition control module assembly.

1). Pry out the air condition control module;

2). Disconnect the wiring harness connector of the air condition control module assembly;

3). Remove the air condition control module;

（II）Installation

1. Install air condition control module assembly

1). Connect the wiring harness connector of the air condition control module assembly;

2). Press the air condition control module with the installation panel assembly into the installation hole and make sure it is in

place;

2. Connect the cable to the negative pole of the battery;

3. Close the engine compartment hood;

Air-conditioning Device

Air-conditioning Device 36

V、Speed Regulating Resistance

（I）Removal

1. Open engine cabin cover;

2. Disconnect battery negative electrode; refer to “Disconnection and connection of battery electrode”

3. Remove glove box assembly; refer to “Glove box assembly”;

4. Remove speed regulating resistance;

1). Disconnect wiring harness connector ① of speed regulating

resistance;

2). Remove 2 fixed bolts ②;

3). Take down speed regulating resistance;

（II）Installation

1. Install speed regulating resistance

1). Place speed regulating resistance to installation position, and tighten

2 fixed bolts ②;

2). Connect wiring harness connector ① of speed regulating

resistance;

2. Install glove box assembly;

3. Connect battery negative electrode;

4. Close engine cabin cover;

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Air-conditioning Device 37

VI、Exhausting Pipe Assembly

（I）Removal

1. Open engine cabin cover

2. Remove intake hose; refer to “intake hose assembly”

3. Recycle refrigerant, refrigeration oil; refer to “Refrigerant, refrigeration oil”

4. Remove exhausting pipe assembly

1). Remove 1 fixed nut of exhausting pipe assembly and condenser assembly;

2). Remove 1 fixed bolt of exhausting pipe assembly and

compressor assembly;

3). Take down exhausting pipe assembly;

（II）Installation

1. Install exhausting pipe assembly

1). Place exhausting pipe assembly to installation place, and

tighten 1 fixed bolt of exhausting pipe assembly and

compressor assembly;

2). Tighten fixed nut of exhausting pipe assembly and condenser assembly;

2. Fill refrigerant and refrigeration oil

3. Install intake hose

4. Close engine cabin cover

Air-conditioning Device

Air-conditioning Device 38

VII、Pipe and Expansion Valve Assembly

（I）Removal

1. Open engine cabin cover

2. Disconnect battery negative electrode; refer to “Disconnection and connection of battery electrode”

3. Remove intake hose; Refer to “Intake hose assembly”

4. Recycle refrigerant, refrigeration oil; Refer to “Refrigerant and refrigeration oil”

5. Remove pipe and expansion valve assembly

1). Disconnect wiring harness connector of ternary pressure switch;

2). Remove 2 fixed bolts of expansion valve assembly and A/C

host;

3). Remove fixed bolt of pipe and expansion valve assembly and

vehicle body;

4). Remove fixed bolt of pipe and expansion valve assembly and

right front suspension;

5). Remove fixed bolt of pipe and expansion valve assembly

and condenser assembly;

6). Remove fixed bolt of pipe and expansion valve assembly and compressor assembly;

7). Take down pipe and expansion valve assembly;

Air-conditioning Device

Air-conditioning Device 39

（II）Installation

1. Install pipe and expansion valve assembly

1). Place pipe and expansion valve assembly to installation position, and tighten fixed bolt of compressor

assembly;

2). Tighten fixed nut of pipe and expansion valve assembly and condenser assembly;

3). Tighten fixed bolt of pipe and expansion valve assembly and right

front suspension.

4). Tighten fixed bolt of pipe and expansion valve assembly and

vehicle body suspension.

5). Tighten 2 fixed bolts of expansion valve assembly and A/C host.

6). Connect wiring harness of ternary pressure switch.

2. Fill refrigerant, refrigeration oil

3. Install intake hose

4. Connect battery negative electrode

5. Close engine cabin cover

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Air-conditioning Device 40

VIII、Evaporator Core Intake/Outtake Shield Sleeve Assembly

（I）Removal

1. Open engine cabin cover

2. Remove intake hose; refer to “Intake pipe assembly”

3. Recycle refrigerant, refrigeration oil; refer to “Refrigerant, refrigeration oil”

4. Remove pipe and expansion valve assembly; refer to “Pipe and expansion valve assembly”

5. Remove evaporator core intake/outtake shield sleeve assembly

1). Remove 2 fixed bolts of evaporator core intake/outtake shield sleeve assembly.

2). Take down evaporator core intake/outtake shield sleeve assembly.

（II）Installation

1. Install evaporator core intake/outtake shield sleeve assembly

1).

Place e

vaporator core intake/outtake shield sleeve assembly to

installation position, and tighten 2 fixed bolts.

2. Install pipe and expansion valve assembly

3. Fill refrigerant, refrigeration oil

4. Install intake hose

5. Close engine cabin cover

Air-conditioning Device

Air-conditioning Device 41

IX 、 Warm Air Inlet/Outlet Sheath

Assembly

（I）Removal

1. Open engine hood cover

2. Remove warm air inlet/outlet sheath assembly

1). Disconnect flexible clamp, and disconnect

connection of warm air inlet/outlet water pipe and

A/C host;

2). Remove 2 fixed bolts of warm air inlet/ outlet

sheath assembly;

3). Take down warm air inlet/outlet sheath

assembly;

（II）Installation

1. Install warm air inlet/outlet sheath assembly

1). Place warm air inlet/outlet sheath assembly to installation

position, and tighten 2 fixed bolts;

2). Connect connection of warm air inlet/outlet water pipe and

A/C host, and connect connection position by flexible clamp;

2. Close engine hood cover

Air-conditioning Device

Air-conditioning Device 42

X、Warm Air Inlet/Outlet Water Pipe Assembly

（I）Removal

1. Open engine hood cover

2. Remove warm air inlet/outlet water pipe assembly

1). Disconnect flexible clamp, and disconnect connection of warm air inlet/outlet water pipe and A/C host;

2). Disconnect flexible clamp, and disconnect connection of warm air inlet/outlet water pipe and engine inlet/outlet water pipe;

3). Disconnect connection of engine oil inlet pipe ① and warm air inlet/outlet water pipe clamp, and take down warm air

inlet/outlet water pipe assembly;

（II）Installation

1. Install warm air inlet/outlet water pipe assembly

1). Connect connection of warm air inlet/outlet water pipe and

A/C host, and connect connection position by flexible clamp;

1

Air-conditioning Device

Air-conditioning Device 43

2). Connect connection of warm air inlet/outlet water pipe and engine inlet/outlet water pipe, and connect connection position by

flexible clamp;

3). Clamp rotating pipe clamp of warm air inlet/outlet water pipe to engine inlet/outlet water pipe ①;

2. Close engine hood cover

1

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Air-conditioning Device 44

XI、A/C Host Assembly

（I）Removal

1. Open engine hood cover

2. Disconnect negative electrode of battery Refer to “Disconnection and connection of battery cable”

3. Recycle refrigerant, refrigeration oil Refer to “Refrigerant, refrigeration oil”

4. Remove front extension plate Refer to “Auxiliary dashboard assembly”

5. Remove saucer cover plate assembly Refer to “Auxiliary dashboard assembly”

6. Remove front storage box assembly Refer to “Auxiliary dashboard assembly”

7. Remove auxiliary dashboard assembly Refer to “Auxiliary dashboard assembly”

8. Remove driver’s side air bag assembly Refer to “Driver’s side air bag assembly”

9. Remove steering wheel assembly Refer to “Steering wheel assembly”

10. Remove jacketing of steering column Refer to “Jacketing of steering column”

11. Remove combination switch assembly Refer to “Combination switch”

12. Remove threshold guard plate assembly of front door Refer to “Threshold guard plate assembly of front door”

13. Remove lower trim plate assembly of A column Refer to “Lower trim plate assembly of A column”

14. Remove upper trim plate assembly of A column Refer to “Upper trim plate assembly of A column”

15. Remove end cover of dashboard Refer to “End cover of dashboard”

16. Remove central right trim plate assembly Refer to “Central right trim plate assembly”

17. Remove glove box assembly Refer to “Glove box assembly”

18. Remove A/C controller assembly Refer to “A/C controller assembly”

19. Remove audio panel assembly Refer to “Audio panel assembly”

20. Remove audio assembly Refer to “Audio assembly”

21. Remove central left trim plate assembly Refer to “Central left trim plate assembly”

22. Remove combination meter Refer to “Combination meter”

23. Remove lower guard plate assembly of driver’s side Refer to “lower guard plate assembly of driver’s side”

24. Remove central cover assembly Refer to “Central cover assembly”

25. Remove front passenger’s side air bag Refer to “front passenger’s side air bag”

26. Remove dashboard assembly Refer to “Dashboard assembly”

27. Remove front wiper arm assembly Refer to “Front wiper arm assembly”

28. Remove ventilation cover plate assembly Refer to “Ventilation cover plate assembly”

29. Remove main wiring harness assembly Refer to “Main wiring harness assembly”

30. Remove dashboard beam Refer to “Dashboard beam”

31. Remove A/C host assembly

1). Disconnect flexible clamp, and disconnect connection of warm air inlet/outlet water pipe and A/C host;

Air-conditioning Device

Air-conditioning Device 45

2). Remove 2 fixed bolts of pipe and expansion valve assembly and

A/C host;

3). Lift right carpet, and pull out weeping pipe①;

4). Remove 2 fixed bolts ② of A/C host assembly;

5). Take down A/C host assembly;

（II）Installation

1. Install A/C host assembly

1). Place A/C host to installation position, and tighten 2 fixed bolts

② of A/C host assembly

2). Install outlet water pipe ①, and cover carpet;

3). Tighten 2 fixed bolts of pipe and expansion valve assembly and

A/C host

Air-conditioning Device

Air-conditioning Device 46

4). Connect warm air inlet/outlet water pipe and A/C host, and tighten connection position by flexible clamp;

2. Install dashboard beam

3. Install main wiring harness assembly

4. Install ventilation cover plate assembly

5. Install front wiper arm assembly

6. Install dashboard assembly

7. Install front passenger’s side air bag

8. Install central cover assembly

9. Install lower guard plate assembly of driver’s side

10. Install combination meter

11. Install central left trim plate assembly

12. Install audio assembly

13. Install audio panel assembly

14. Install A/C controller assembly

15. Install glove box assembly

16. Install central right trim plate assembly

17. Install end cover of dashboard

18. Install upper trim plate assembly of A column

19. Install lower trim plate assembly of A column

20. Install threshold guard plate assembly of front door

21. Install combination switch assembly

22. Install jacketing of steering column

23. Install steering wheel assembly

24. Install driver’s side air bag assembly

25. Install auxiliary dashboard assembly

26. Install front storage box assembly

27. Install saucer cover plate assembly

28. Install front extension plate

29. Fill refrigerant, refrigeration oil

30. Connect negative electrode of battery

31. Close engine hood cover

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Air-conditioning Device 47

XII、Temperature Motor Assembly