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Service Manual For

CHERY QQ6

(Body Accessories and Dimensions)

After Sales Service Department of Chery

Automobile Sales Co., Ltd

Summary of content (171 pages)

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Service Manual For CHERY QQ6 (Body Accessories and Dimensions) After Sales Service Department of Chery Automobile Sales Co.
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TABLE OF CONTENTS Chapter 1 Engine Hood and Luggage Compartment ........................................................................8 I. Removal of Engine Hood ......................................................................................................8 1. Preparation ....................................................................................................................8 2. Precautions.................................................................................................
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IV. Disassembly/Reassembly of Carpet ..................................................................................22 1. Removal Step ..............................................................................................................22 2. Installation Step...........................................................................................................22 V. Removal of Cushion Pad ....................................................................................................23 1.
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Chapter 6 Disassembly/Reassembly of Ceiling ...........................................................................56 1. Preparation ..........................................................................................................................56 2. Precautions..........................................................................................................................56 3. Disassembly/Reassembly of Sun Visor.........................................................................
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1.1. Removal Step ...................................................................................................65 1.2. Installation Step................................................................................................67 2. Removal of Instrument Panel cross beam.............................................................68 2.1. Removal Step ...................................................................................................68 2.2. Installation Step........................
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(I). Preparation ......................................................................................................127 (II). Precautions.....................................................................................................127 (III). Removal Procedure ......................................................................................127 Section 4 Interior Harness................................................................................................133 I.
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IV. Disassembly/Reassembly of Rear Right Door Inner Harness .................................164 Section 10 Back Door Harness ..........................................................................................165 I. Schematic Diagram of Harness .................................................................................165 II. Main Connectors Description...................................................................................166 III. Disassembly/Reassembly of Back Door Inner Harness ..
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Chapter 1 Engine Hood and Luggage Compartment I. Removal of Engine Hood 1. Preparation Tool: flat head screwdriver, pliers, wrench 2. Precautions 2.1. During the removal, pay more attention to the application of appropriate strength. No rude operation. 2.2. During the removal/reassembly of trim, especially pay more attention to the protection of surface ornaments so that any ornament may not be damaged. 3. Disassembly/Reassembly of engine hood accessories 3.1. Removal Step 3.1.1.
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4. Disassembly and adjustment of the engine hood assy. Preparation of tool(s): 13# wrench 4.1. Take off four adjusting bolts from engine hood. And remove the engine hood. At the same time, unscrew four adjusting bolts to adjust the front/rear position and right/left position of the engine hood. 4.2. Installation of engine hood assy.: The installing steps are reverse to those for removal. Installation torque is 30±1Nm 5. Disassembly and assembly of air intake grille assy.
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6. Adjustment and assembly of the engine hood lock Preparation of tool(s): 10# wrench 6.1. Removal Step 6.1.1. Unscrew three centering bolts from the engine hood, and then remove the engine hood lock. Also unscrew these three bolts to adjust the position of engine hood lock. Torque: 9±1 Nm 6.1.2. Remove the lock cable of front engine hood from engine hood lock assy. 6.2. Installation of engine hood lock The installing steps are reverse to those for removal. Installation torque is 9±1Nm 7.
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7.1.3. Remove the hood lock and detach the engine hood lock control cable from the hood lock assy.. 7.1.4. Remove three clips used to fix the control cable by hand or with a flat head screwdriver. 7.1.5. Draw out the control cable from the engine compartment.
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7.2. Installation Step The installing steps are reverse to those for removal. CAUTION: In case of installation, the groove on control cable shall be inserted into the pull groove; the control cable penerates into driver’s cab through the engine compartment, and shall passes through a small hole and then enters into the cab, as shown in the figure. II. Disassembly/Reassembly Small hole of rear boot lid 1.
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3.1.2. Detach two locating bolts from the luggage boot lock (the installation torque is 9±1 Nm) 3.1.3. Remove the luggage boot lock core. 3.1.4. Remove two fixing bolts from the trunk (i.e. luggage boot) lock body with a socket wrench. 3.1.5. Take off the trunk lock body. 3.2. Installation Step The installing steps are reverse to those for removal.
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4.1.3. Disconnet the connecting plugs from the right and left license plate lamps and then take off the license plate lamp assy. 4.1.4. Remove two fix screws from the license plate lamp with a cross screwdriver. 4.1.5. Take off the license plate lamp 4.1.6. Take off the bulb from the license plate lamp. 4.2. Installation Step The installing steps are reverse to those for removal.
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Chapter 2 Disassembly/Reassembly of Interior Decorations I. Disassembly/Reassembly of Seat Belt 1. Preparation Tools: flat head screwdriver, wrench, sleeve. Parts: disposable clips. 2. Precautions Keep the seat belt clean, avoid the oil stain, and check whether the seat belt is damaged. 3. Removal Step (Driver’s seat belt is taken as an example) Prize the front threshold pressing carefully with a flat head screwdriver. plate 3.2. Remove the weatherproof rubber strip of the front door opening. 3.3.
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3.4. Remove the weatherproof rubber strip of the rear door opening. 3.5. Remove the seat belt lower ornament cover. 3.6. Unscrew the fixing nuts with a 17# sleeve, and detach the B pillar lower trim. Installation torque is 50±5Nm 3.7. Unclench the ornament cover on the seat belt regulator with a flat head screwdriver. CAUTION: Pay attention to the breakage of clip inside the regulator. 3.8. Loosen the fixing nuts with a 17# sleeve, and then take off the seat belt.
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3.9. Unclench the B pillar trim with a right-angled screwdriver. 3.10. Take off the B pillar trim. 3.11. Remove the fix screws from the seat belt with a cross screwdriver. 3.12. Loosen the fixing nuts with a 17# sleeve, and then take off the seat belt. 4. Installation Step The installing steps are reverse to those for removal. Note: 4.1. Keep the seat belt clean, avoid the oil stain, and check whether the seat belt is damaged. 4.2.
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II. Disassembly/Reassembly of Seat Tool: 16# sleeve 1. Front passenger seat removal step 1.1. Pull the moveable handle under the left seat to move the left seat backwards and reveal the fixing bolts under the seat. 1.2. Remove two fixing bolts before the seat. by sleeve 1.3. Turn the moveable handle and pull forwards the seat, and expose two fixing bolts on the rear of seat. 1.4 Disassemble two fixing bolts at the back of seat with sleeve. 1.5 Pull off the inserter under seat and take away the seat.
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2.3. Loosen the front fixing bolts at the right side of rear right seat with an open-end wrench. 2.4. Loosen the front fixing bolts at the left side of rear right seat with an open-end wrench. 2.5. Pull up the ring-pull of rear right seat, and lay down the seat forwards. 2.6. Loosen the rear fixing bolts at the right side of rear right seat with an open-end wrench. 2.7. Loosen the rear fixing bolts at the left side of rear right seat with an open-end wrench, and then remove the rear right seat.
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2.8. Loosen the front fixing bolts of rear right seat with a open-end wrench. 2.9. Pull up the ring-pull of rear left seat, and lay down the seat forwards. 3.0. Loosen the rear fixing bolt of rear left seat with a sleeve, and then remove the rear left seat. 3. Installation Step The installing steps are reverse to those for removal. Installation torque is 25±3Nm III. Disassembly/Reassembly of Console Tool: cross head screwdriver 1. Removal Step 1.1.
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1.2. Remove the bolts used to joint the console and body lower guard plate with a cross screwdriver. (The tightening torque is 2±0.5N.m) 1.3. Detach the console hand brake ornament plate by hand. 1.4. Pull out the cigarette lighter plug on the console by hand. 1.5. Take off the console. 2. Installation Step The installing steps are reverse to those for removal.
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IV. Disassembly/Reassembly of Carpet Tool: flat head screwdriver, screwdriver; sleeve cross head 1. Removal Step 1.1. Remove the seat. (See Disassembly of Seat) 1.2. Remove the scuff plate, lower trims of B and C pillars. (See Disassembly of B and C Pillars) 1.3. Remove the A pillar lower trim. 1.4. Remove the armrest box and console. (See Disassembly of Armrest Box and Console) 1.5. Prize the cover on the driver pedal with flat head screwdriver. 1.6.
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2.3. Lay the right central rear part of carpet according to the shape of the vehicle bottom, and reveal the installation holes of front right rear seat and lay the carpet reliably. 2.4. Lay well the rear part of carpet according to the shape of vehicle bottom. V. Removal of Cushion Pad 1. Removal Step 1.1. Disassemble the carpet (See disassembly of carpet) 1.2. Take off all cushion pads.
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2. Installation Step 2.1. The installing steps are reverse to those for removal. 2.2. Precautions on reassembly of cushion pad: 2.2.1. Take out the connector harness from the seat and rear oxygen sensors when the cushion pad is laid. 2.2.2. Make the shock absorber lower surface joint tightly with plate work.
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Chapter 3 Removal and Maintenance of Door I. Disassembly/Reassembly and Maitenance of Front Door 1.
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2. Preparation Tools: right-angled screwdriver, cross screwdriver, 7#, 10# and 13# sleeves, plier. 3. Precautions 3.1 Please wear necessary labor protection supplies to avoid accidents. 3.2 Power off accumulator to avoid damage the electrical units. 3.3 Use the correct method to disassemble and assemble the glass to avoid damage. 4. Disassembly/Reassembly Step 4.1. Unclench the protecting cover of glass drive switch on the door inner guard plate with a right-angled screwdriver. 4.2.
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4.5. Separate the inner bar from the inner handle with a right-angled screwdriver. 4.6. Remove the fix screws from the front door inner guard plate with a cross screwdriver. 4.7. Lift up the door inner guard plate from the lower to upper by both hands. 4.8. Directly take out the door inner guard plate by both hands. 4.9. Tear down front door water-proof plastic clothing.
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4.10. Take off the interior set square of the exterior rear-view mirror by hand. 4.11. Pull out the connector of the exterior rear-view mirror by hand. 4.12. Remove three fix screws from the exterior rear-view mirror with a sleeve. 4.13 Remove three fix screws from the exterior rear-view mirror with a sleeve. 4.14 Take off the exterior rear-view mirror assy by hand.
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4.15. Unscrew four fixing screws from front door sound box by cross head screwdriver. Take out sound box assy. 4.16 Pull out the connector of the front door sound box. 4.17 Reinsert the glass drive switch into the harness, and descend the front door glass down to its lowest position. 4.18. Loose two fixing screws on the glass by cross head screwdriver. And take out the glass assembly. Torque: 4.5±0.5 N.m. 4.19 When the glass assy is being taken, erect the glass assy so as to easily take off it.
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4.20 Remove six fixing bolts from the window glass regulator with a 10# sleeve. Torque: 9±1 N·m. 4.21 Pull out the connector of window glass regulator by hand. 4.22 Take off the window glass regulator assy. 4.23 Separate the upper fixing clips of front door lock core rod from the lock by hand. 4.24 Separate the lower fixing clips of front door lock core rod from the lock by hand.
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4.25 Loosen the fix screws of front door exterior handle with a sleeve. 4.26. Take out lock core and handle assy. 4.27 Remove three fix screws from the front door lock core with a cross screwdriver. Installation torque: 9±1 Nm 4.28 Pull out the fastener connector and then take off the fastener. 4.29 Loosen two upper fixing bolts of front door hinge from the door with a 13# wrench. Torque: 36±4N.m.
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4.30 Loosen two lower fixing bolts of front door hinge from the door with a 13# wrench. Torque: 36±4N.m. 4.31 Remove the fixing bolts of door limiter from the door with a 10# sleeve. Torque: 10±1 N.m 4.32 Remove the fixing bolts of door limiter from the body with a 10# sleeve, and then take off the door limiter. Torque: 10±1 N.m 4.33 Pull out the door harness, and then take off the door body.
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5. Installation and Adjustment Step 5.1. The installing steps are reverse to those for removal. 5.2. Adjustment of door 5.2.1. After the installation of door, check the horizontial and vertical clearances and the closing force of door. If the clearance is incorrect and the closing force is big, timely adjust the clearnace and force. See Body Dimension for the adjustment of door clearance. 5.2.2. The door clearance is adjusted by regulating the fixing bolts of hinge at the body. 5.2.3.
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II. Disassembly/Reassembly and Maintenance of Rear Door 1. Preparation Flat head screwdriver, cross head screwdriver, No.7, 10, 13 sleeves and pliers. 2. Precautions 2.1 Please wear necessary labor protection supplies to avoid accidents. 2.2 Power off accumulator to avoid damage the electrical units. 2.3 Use the correct method to disassemble and assemble the glass to avoid damage. 3. Removal Step 3.1. Prize two rear door glass slot protecting boards with flat head screwdriver.
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3.5. Unclench the protecting cover of glass drive switch from the door inner guard plate with a right-angled screwdriver. 3.6. Pull out the connector of glass drive switch by hand. 3.7. Remove the fix screws from the front door inner guard plate with a cross screwdriver. 3.8. Directly take off the door inner guard plate by both hands. 3.9. Tear down front door water proof plastic clothing.
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3.10. Unscrew four fixing screws from front door sound box with cross head screwdriver. Take out sound box assembly. 3.11. Pull out the connector of front door sound box. 3.12. Reinsert the glass drive switch into the harness, and then descend the front door window glass down to its lowest position. 3.13 Loosen two fixing screws on the glass with cross head screwdriver. And take out the glass assembly. Torque: 4.5±0.5 N.m. 3.14.
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3.15. Remove six fixing bolts from the window glass regulator with a 10# sleeve. Torque: 7±1 N·m. 3.16. Pull out the connector of window glass regulator by hand. 3.17. Take off the window glass regulator assy. 3.18. Push aside the fixed mounting of lock core rod from the door with a right-angled screwdriver. 3.19. Separate the fixing clips of lock core rod from the lock by hand.
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3.20. Take off the lock core rod by hand. 3.21. Separate the upper fixing clips of front door lock core rod from the lock by hand. 3.22. Separate the lower fixing clips of front door lock core rod from the lock by hand. 3.23. Loosen the fix screws of front door exterior handle with a cross screwdriver. 3.24. Take out lock core and handle assy.
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3.25. Remove three fix screws from the front door lock with a cross screwdriver. 3.26. Pull out the fastener connector, and then take off the fastener. 3.27. Remove the fixing bolt from the door limiter with a 10# sleeve. Torque: 10±1 N.m 3.28. Remove the other fixing bolt from the door limiter with a 10# sleeve, and then take off the door limiter. Torque: 10±1 N.m 3.29. Loosen two upper fixing bolts of front door hinge from the door with a 13# wrench. Torque: 36±4N.m.
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3.30. Loosen two lower fixing bolts of front door hinge from the door with a 13# wrench. Torque: 36±4N.m. 3.31 Pull out the door harness, and then take off the door body. 4. Installation and Adjustment Step 4.1. The installing steps are reverse to those for removal. 4.2. Adjustment of door 4.1.1 Rear door clearance can not be adjusted by hinge adjustment. If the door clearance is improper, correct the body only to ensure the clearance. (See Body Dimension) 4.1.2 Please refer to Front Door Adjustment.
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Chapter 4 Disassembly/Reassembly and Maintenance of Front/Rear Bumper I. Disassembly/Reassembly and Maintenance of Front Bumper 1. System Composition Diagram Front/Rear Bumper 2. Preparation No.7 and No10 sleeve, cross head screwdriver and flat head screwdriver. 3. Precautions 3.1. Please wear necessary labor protection supplies to avoid accidents. 3.2. To prevent scratch the bumper surface paint. 3.3.
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4. Removal Step 4.1 Open the front engine hood by hand. 4.2 Loosen the fixing bolts of front bumper from the right and left sides of radiator cross beam with a 10# sleeve. (The left side is taken as an example) Torque: 11N·m 4.3 Loosen the fixing bolts of front bumper from the intermediate part of radiator cross beam with a 10# sleeve. Torque: 11N·m 4.4 Loosen two fixing bolts under the bumper from the mud guard with a 7# sleeve. Installation torque: 2±0.5 Nm 4.5.
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4.6 Remove the fixing bolts of mud guard from the side of bumper with a cross screwdriver. 4.7 Pull out the bumper from the fixed mounting at the fender by hand. 4.8. Pull out fog lamp plug by hand, and take out bumper assy. 4.9 Remove three screws applied to joint the fog lamp and bumper with a cross screwdriver. 4.10 Remove the bumper body assy.
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4.11 Loosen three fixing bolts and a fixing nut used to secure the front bumper stiffening beam with a 13# sleeve. Torque: 25±3N.m 4.12 Loosen intake grille fixing screws from both sides of bumper with a cross screwdriver. 5. Installation and Maintenance 5.1. The installing steps are reverse to those for removal.
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II. Disassembly/Reassembly and Maintenance of Rear Bumper 1. System Composition Diagram Front/Rear Bumper 2. Preparation Tools: cross screwdriver, 7# sleeve. 3. Precautions 3.1. Please wear necessary labor protection supplies to avoid accidents. 3.2. To prevent scratch the bumper surface paint. 3.3. When the rear bumper is disassembled/reassembled in the low temperature environment, the force applied can’t be big so as to avoid the breakage of the bumper.
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4. Removal Step 4.1. Open the luggage boot lid, and loosen two fixing clips from the rear bumper with a cross screwdriver. See right figure. 4.2. Loosen the fix screws and clips of rear bumper and rear mud guard with a 7# sleeve. Torque: 7N·m 4.3. Loosen the fix screws at the left side of rear mud guard and rear bumper with a 7# sleeve. 4.4. Loosen the fix screws at the right side of rear mud guard and rear bumper with a 7# sleeve. 4.5.
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4.6 Pull out the bumper from the fixed mounting at the fender by hand. 4.7. Take off rear bumper assy. 5. Installation Step The installing steps are reverse to those for removal.
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Chapter 5 Disassembly/Reassembly and Maintenance of Headlamp and Fog Lamp 1.
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2. Preparation No.10 sleeve and No.7 open end wrench, cross head screwdriver and flat head screwdriver. 3. Precautions 3.1 Please wear necessary labor protection supplies to avoid accidents. 3.2 To prevent scratch the bumper surface paint. 3.3. In case of disassembly/reassembly in the low temperature environment, the force applied can’t be big so as to avoid the breakage of the bumper. Disconnect the control switch of corresponding lamps, and remove the wire connected to the battery. 3.4.
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4.3. Remove the fixing bolts under the headlamp with a cross screwdriver. Torque: 1.8±0.2N·m 4.4. Pull out the plug from the headlamp, and then take off the headlamp assy. 4.5. Open the lamp holder clips by hand. 4.6. Pull out two harness connectors by hand. 4.7. Remove two fix screws with a cross screwdriver.
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4.8. Hold the bulb seat by hand, and take off the bulb from the headlamp. CAUTION: In case that the bulb is replaced, DO NOT contact the bulb by hand, otherwise the fingerprint remained on the bulb is heated and volatilzes after the lamp lights, and then deposits on the mirror surface, which may result that the reflector darkens. 4.9. Screw off headlamp high beam seat cover. 4.10. Pull out two harness connectors by hand. 4.11. Remove two fix screws with a cross screwdriver.
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4.12. Hold the bulb seat by hand, and take off the bulb from the headlamp. CAUTION: In case that the bulb is replaced, DO NOT contact the bulb by hand, otherwise the fingerprint remained on the bulb is heated and volatilzes after the lamp lights, and then deposits on the mirror surface, which may result that the reflector darkens. 5. Removal of Fog Lamp 5.1. Remove the bumper assy. Refer to Disassembly of Bumper. 5.2. Pull out the plug of fog lamp. 5.3.
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6. Installation and Adjustment of Headlamp 6.1. headlamp Installation Step The installing steps of headlamp are reverse to those for removal. 2 6.2. Introduction to headlamp function 6.2.1. Front view 1 See right figure: 1 Low beam light 2 Position light 3 High beam 4 Turn light 4 6.2.2.
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Adjust the governing mechanism equipped on the lamps to implement the adjustment rightward and leftward, upward and downward of the lamp beam, according to the required values in national standards. The coarse and fine adjustment upward and downward is integrated into one entity, which is located at the upper edge of housing while the rightward and leftward adjustment mechanism is located at the central lower edge of the housing. It needs take off headlamp cover to adjust right headlamp.
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7. Tail Lamp Removal Step 7.1. Remove the fix screws from the tail lamp with a cross screwdriver. 7.2. Open the trunk, and lift up the carpet of trunk. 7.3. Remove the upper seat fixing nuts from tail lamp with a fix wrench. 7.4. Remove the lower seat fixing nuts from tail lamp with a fix wrench. 7.5. Pull out the tail lamp harness connector, and the take off the tail lamp assy.
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Chapter 6 Disassembly/Reassembly of Ceiling 1. Preparation Tools: socket wrench, cross screwdriver, flat head screwdriver 2. Precautions 2.1. During the disassembly/reassembly, pay more attention to the application of appropriate force, without crude operation. 2.2. During the disassembly/reassembly of interior ornaments, especially pay more attention to the protection of surface ornaments so as to avoid the damage of the ornaments. 3. Disassembly/Reassembly of Sun Visor 3.1. Removal Step 3.1.1.
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4. Disassembly/Reassembly of Roof Hand-Hold 4.1. Removal Step 4.1.1. Remove the right/left fix screws with a cross screwdriver. Torque: 9±3Nm 4.1.2. Take off the hand-hold. 4.2. Installation Step The installing steps are reverse to those for removal. 4.3 Refer to Disassembly/Reassembly of Front Right Hand-Hold for other hand-holds. 5. Disassembly/Reassembly of Front Ceiling Lamp 5.1. Removal Step 5.1.1. Remove the front ceiling lamp cover with a flat head screwdriver.
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5.1.3. Pull out the harness connector, and then take off the front ceiling lamp assy. 5.2. Installation Step The installing steps are reverse to those for removal. 6. Disassembly/Reassembly of A Pillar Trim 6.1. Removal Step 6.1.1. Prize A pillar protective board with a flat head screwdriver. 6.1.2. Take off the A pillar trim. 6.2. Installation Step The installing steps are reverse to those for removal. 7. Disassembly/Reassembly of B Pillar Trim 7.1. Removal Step 7.1.
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7.1.2. Remove the B pillar upper trim with a flat head screwdriver. Note: protect the trim part surface from scratching. 7.2. Installation Step The installing steps are reverse to those for removal. 8. Disassembly/Reassembly of C Pillar Trim 8.1. Removal Step 8.1.1. Refer to Disassembly/Reassembly of Rear Passenger Seat and Seat Belt. 8.1.2. Remove the C pillar upper trim with a flat head screwdriver. 8.1.3. Remove the C pillar lower trim with a flat head screwdriver. 8.2.
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9.1.4. Remove the A/B/C pillar trim. (Refer to Disassembly/Reassembly of A/B/C Pillart Trim) 9.1.5. Remove the ceiling clips (5 pcs in total) with a flat head screwdriver. 9.1.6. Remove the wheatherproof rubber strip of four door opening by hand. 9.1.7. Open the trunk, and then remove the ceiling. It is convenient to take off the ceiling from the trunk and not easy to damage the ceiling. 9.2. Installation Step The installing steps are reverse to those for removal.
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Chapter 7 Disassembly/Reassembly of Instrument Panel I. Removal of Instrument Panel Accessories 1. Preparation Tool: socket spanner, cross head screwdriver, flat head screwdriver Note: disconnect accumulator cathode before disassemble electrical parts 2. Disassembly/Reassembly of Central Console Panel, Audio Unit, Emergency Switch, A/C Control Switch, Ashtray 2.1. Removal Step 2.1.1. Remove the central console panel by hand. 2.1.2.
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2.1.6. Remove four fix screws used to joint the A/C control switch and instrument panel body with a cross screwdriver. Torque: 3.5±0.5 Nm 2.1.7. Remove the fix screws (at the bottom of ashtray) from the console, take off the cigarette lighter connecting wire, and remove the console assy. Bolts under the astray 2.1.8. Remove the A/C control switch cable and harness, and then take off the A/C control switch. 2.2. Installation Step The installing steps are reverse to those for removal. 3.
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3.1.2. Remove one fix screw from the bottom of front ashtray guide run with a cross screwdriver. Torque: 10±1 Nm Bolts under the astray 3.1.3. Remove two fix screws from the front of front ashtray guide run with a cross screwdriver. Torque: 3±1 Nm 3.1.4. Take off the front ashtray guide run. 3.2. Installation Step The installing steps are reverse to those for removal. 4. Disassembly/Reassembly of Glove Case 4.1. Removal Step 4.1.1.
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5.1.2. Remove four fix screws from the combination instrument with a cross screwdriver. Torque: 2±0.3Nm 5.1.3. Disconnec to the combination instrument harness connector, and then take off the combination instrument. 5.2. Installation Step The installing steps are reverse to those for removal. 6. Disassembly/Reassembly of Combination Switch, Wiper Switch, Ignition Switch, Heliax Cable Please refer to Disassembly/Reassembly of Steering Column in the Service Manual of Chassis.
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II. Removal of Instrument Panel 1. Disassembly/Reassembly Instrument Panel of 1.1. Removal Step 1.1.1. Remove the steering wheel and combination switch (see Remova of Steering Wheel). 1.1.2 Remove glove box (Refer to Removal of glove box) 1.1.3. Remove the console panel, audio unit, emergency switch, A/C control switch, ashtray, console (refer to Disassembly/Reassembly and Removal of Console Panel, Audio Unit, Emergency Switch, A/C Control Switch, Ashtray). 1.1.
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1.1.7. Remove the left and right air outlet covers and exterior rear-view mirror regulating switch with a flat head screwdriver. 1.1.10. Take off the ornament cover, and remove two fix screws from the right and left front parts of upper instrument panel body and seven fix screws from the lower instrument panel body with a cross screwdriver, and then take off the upper instrument panel assy together with the right and left air outlets. Torque: 3±0.5 Nm 1.1.11.
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1.1.12. Remove two cross beams from the instrument panel and the fixing bolts from the soleplate with a 10# sleeve. Torque: 10±1 Nm 1.1.13. Obliquely place the instrument panel and instrument panel cross beam, remove the fixing bolts from the left, middle and right sides of instrument panel with a 10# sleeve, and take off the bond strap. Torque: 4±0.5 Nm 1.1.12. Detach any related harness connector. 1.1.13. Lift out the instrument panel and instrument panel cross beam by two operators. 1.2.
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1.2.4. The glove case switch shall be flexible, without the interference, clamped or locking untightened symptom. 2. Removal of Instrument Panel beam cross 2.1. Removal Step 2.1.1. Disassemble instrument panel assembly (Refer to Disassembly of Instrument Panel) 2.1.2. Remove seven fix screws from the air duct as shown in the figure, and then take off the air duct.
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2.1.3. Remove the four fix screws from both sides of instrument panel and cross beam with a cross screwdriver. Torque: 3±1 Nm 2.1.4. Take off the cross beam and air duct. 2.1.5. Remove two screws used to fasten the air duct from the cross beam with a cross screwdriver.
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2.1.6. Take off the air duct, and detach the harness as required. 2.2. Installation Step Refer to Removal Step and install it in reverse order.
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Chapter 8 Air Conditioning (A/C) System I. System Composition Air adjustment and distributing system: HVAC air mixing and distributor part, inside/outside circulation air inlet, air outlet, outside circulation air filter. Control system: control panel assy, wire drawing, micro-motor, fan, resistor, high/low voltage switch Heating system: heater, hot water pipe, engine cooling water system. Cooling system: compressor, condenser, reservoir dryer, expansion valve, evaporator, and pipe.
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(2) Do not splash the refrigerant into eyes and skin. 2.2. Disassemble instrument panel assy and front cross beam. Pull out the related electrical connectors. 2.3. Loose fixing bolts on high/low pressure pipe with spanner. Torque: 5±1 Nm 2.4. Loosen two fixing bolts used to connect the high/low pressure pipe to the expansion valve, and pull outwards the high/low pressure pipe. Torque: 8±1 Nm 2.5. Loosen three fixing bolts of evaporator and front side. Torque: 3.5±0.5 Nm 2.6.
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3. Installation of Evaporator Assy The installing steps are reverse to those for removal. 4. Disassembly/Reassembly Evaporator Interior of Preparation of tool(s): cross screwdriver, socket wrench 4.1. Removal Step 4.1.1. Refer to the Removal of Evaporator Assy, and take off the evaporator assy. 4.1.2. Remove the harness and connector from the evaporator. 4.1.3. Remove three screws from the intermediate part of the evaporator, and partition the evaporator into two parts. 4.1.4.
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4.1.5. Remove eight housing connection screws from the distributor with a cross screwdriver (as shown in the figure). Torque: 1.5±0.5 Nm 4.1.6. Detach the distributor. In this case, take off the air baffle from the interior. 4.1.7Remove four fix screws from the air inlet with a cross screwdriver, and take off the air inlet. Torque: 1.5±0.5 Nm 4.1.
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4.1.9. Remove nine housing connection screws from the other side of the evaporator with a cross screwdriver (as shown in the figure). Torque: 1.5±0.5 Nm 4.1.10. Remove four screws from two fixed iron sheets of A/C heater pipe with a cross screwdriver. 4.1.11. Remove two clips from the evaporator with a flat head screwdriver. 4.1.12. Separate the upper part of the housing from the lower part by both hands.
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4.1.13. Take off the evaporator and expansion valve from the lower housing. 4.1.14. Remove the fixing nuts from the fan impeller with a 10# sleeve, and take off the fan impeller. Torque: 5±0.5 Nm 4.1.15. Remove the fix screws from two fan motors with a cross screwdriver. Torque: 5±0.5 Nm 4.1.16. Pull out the fan motor by hand.
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4.2. Installation Step The installing steps are reverse to those for removal. Carry out checks for system evacuating, keep pressure, antifreeze leakage. Check if the radiator is blocked. If the radiator is blocked, utilize the compressed air to clean it. III. Troubleshooting Types of pressure deviation 1.
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under the range as shown; the air conditioner is under refrigeration. The pressure at the high pressure side is The refrigerant in the Evacuate the refrigerant higher than the specified value or is too high; refrigerant pipelines is ● If the volume of the refrigerant is normal the pressure at the low pressure side is too excessive 1. Replace the expansion valve high; the air conditioner is under The expansion valve 2.
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Chapter 9 Body Dimension I. Chassis Control Point Unit: mm 1.
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2.
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3.
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II. Body Assembly Dimension 1.
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1.1 Clearance between high beam lamp and engine hood at AA-AA: 5±1 mm Engine Hood Outer Plate Uniformity:1.0 High Beam Lamp 1.2 Clearance between high beam lamp and front bumper at AB-AB: 3±1mm High Beam Lamp Uniformity:1.
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a) Clearance between low beam lamp and front fender at X-X: 2±1mm Fender Uniformity:1.0 Low Beam Lamp 1.4 Clearance between low beam lamp and front bumper at Y-Y: 8±1mm Low Beam Lamp Front Bumper Uniformity:1.
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2.
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a) Clearance between tail lamp and back door at AC-AC: 4±1mm Tail Lamp Uniformity: 1.
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2.2 Fit clearance between tail lamp and rear bumper at AD-AD: 3±1mm Tail Lamp Uniformity:0.5 Uniformity:0.
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2.3 Fit clearance between license plate lamp trim board and back door outer panel at AE-AE: 6±1mm Back Door Lock License Plate Lamp Ornament Plate Back Door outer panel 2.4 Fit dimension of back door and body at Q-Q: Back Door inner panel Back Door outer panel Uniformity: 1.0 Uniformity:1.
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3.
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3.1 Clearance between side outer plate and fender at A-A: 2.5±0.5mm Side Outer Plate Uniformity: 0.5 c 3.2 Clearance between front fender and front door outer panel at B-B: 5.5±0.5mm Front Part of Front Door inner panel Front Fender Uniformity: 1.0 91 Front Door outer panel Uniformity: 0.
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3.3 Clearance between the front door outer panel and rear door outer panel at C-C: 4.5±0.75mm Rear Part of Front Door inner panel Front Part of Rear Door inner panel Rear Door outer panel Front Door outer panel Uniformity:1.0 3.4 Uniformity:0.5 Clearance between the A pillar and small quarter window glass at D-D: 3±1mm Rear Part of Front Door inner panel Front Door outer panel Uniformity: 0.5 Uniformity: 1.
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3.5 Installation dimension of top cap and top cap trim at E-E: 0.75±0.75mm Installation dimension of side outer plate and top cap trim: 4.75±0.75mm Installation dimension of side outer plate and rear door window frame: 4.5±0.75mm Top Cap Trim Top Cap Side Outer Plate Uniformity: 1.0 Uniformity: 0.
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3.6 Clearances of rear windscreen and side outer plate at F-F are: 5.5±0.5 mm; 4±1mm, respectively. Back Door Outer Panel Rear Windscreen Rear Windscreen Fixing Glue Uniformity: 1.0 Uniformity: 1.
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3.7 Clearance between rear door outer panel and side outer plate at G-G: 4.5±0.75mm Rear Part of Rear Door Inner Panel Side Outer Plate Rear Door Outer Panel Uniformity: 0.5 Uniformity: 1.0 3.8 Installation clearances of back door outer panel and side outer plate at H-H are: 3.75±0.75 mm; 1.75±0.75 mm, respectively. Back Door Outer Panel Uniformity: 1.0 Back Door Inner Panel Uniformity: 0.
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3.9 The clearances of tail lamp and side outer plate at I-I are: 3±1mm; 0.25±0.25mm, respectively. Tail Lamp Side Outer Plate Uniformity: 0.5 Uniformity: 0.
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3.10 The installation clearances of side outer plate and rear bumper at J-J are: 1.25±0.75mm; 0.25±0.25mm, respectively. Uniformity: 0.5 Uniformity: 0.
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3.11 Installation dimension of top cap and top cap trim at R-R: 0.75±0.75mm Installation dimension of side outer plate and top cap trim: 4.75±0.75mm Installation dimension of side outer plate and front door window frame: 2.5±0.5mm; 4.5±0.75mm, respectively Top Cap Side Outer Plate Top Cap Trim Uniformity: 1.0 Uniformity: 1.0 Front Door Window Frame 3.12 Clearance between the upper part of front left door and the upper part of front right door at S-S: 4.5±0.
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3.13 The fit clearances of rear door outer trim board and side outer plate at T1-T1 are: 4.75±0.25mm; 9.5±0.5mm, respectively. Uniformity: 0.5 Uniformity: 1.0 Rear Door Outer Trim Board Side Outer Plate 3.14 The fit dimensions of front door outer quarter window and front door window frame at T2-T2 are: 5±1mm; 5±1mm, respectively. Uniformity: 0.5 Uniformity: 0.
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3.15 The clearance between the fender and bumper at U-U: 0.5±0.5mm Fender Uniformity: 0.5 Uniformity: 0.5 Front Bumper 3.16 The fit clearances of rear door outer panel and side skirt outer plate at V-V are: 6±0.5mm; 1.75±0.75mm, respectively. Uniformity: 1.0 Uniformity: 1.
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3.17 The fit dimensions of side outer plate and fuel filler opening door outer panel at W-W are: 4±1mm; 4±0.5mm; 0.25±0.25mm, respectively side outer plate fuel filler opening door outer panel side outer plate Uniformity: 0.5 Uniformity: 1.0 Uniformity: 1.0 Uniformity: 0.
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3.18 The fit dimensions of front door window glass and front door window frame at AF-AF are: 3.5±0.5mm; 6.5±0.5mm; 2.5±0.5mm, respectively; The fit dimensions of front door window frame and A pillar outer panel are: 4.5±0.5mm The fit dimensions of front windscreen and A pillar outer panel are: 4.5±0.5mm; 5±1mm Front Door Window Glass Front Door Window Frame A Pillar Inner Panel Uniformity: 0.5 A Pillar Reinforcement Plate Uniformity: 1.0 A Pillar Outer Panel Front Windscreen Uniformity: 1.
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3.19 The fit dimensions of side outer plate and fender at AG-AG are: 1.75±0.75mm; 0.25±0.25mm, respectively. Side Inner Plate Fender Side Outer Plate Uniformity: 1.0 103 Uniformity: 0.
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4.
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4.1 Clearances of grille and hood outer panel at K-K are: 0.25±0.25mm; 1.5±0.5mm, respectively. Clearances of hood outer panel and front bumper are: 6±1mm; 1.75±0.75mm, respectively. Grille Uniformity: 0.5 Uniformity: 1.0 Hood Inner Panel Hood Outer Panel Uniformity: 1.0 Uniformity: 0.
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4.2 The fit clearances of top cap and front windscreen at U-U are: 4±0.5mm; 4.5±0.5mm, respectively. Top Cap Front Windscreen Uniformity: 0.5 Uniformity: 1.
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4.3 Clearance of top cap and rea windscreen at M-M are: 1±0.5mm; 6.75±0.75mm respectively. Top Cap Uniformity: 1.0 Uniformity: 0.5 Rear Windscreen Rear Windscreen Fixing Glue Back Door Outer Panel Back Door Inner Panel 4.4 Clearances of rear windscreen and back door outer panel at N-N are: 1±0.5 mm; 4±0.5 mm respectively. Rear Windscreen Rear Windscreen Fixing Glue Uniformity: 0.5 Uniformity: 1.
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4.5 Clearance between the hood outer panel and low beam lamp at O-O: 4±1mm Hood Outer Panel Hood Inner Panel Uniformity: 1.
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4.6 Clearances of Hood Outer Panel and fender at P-P are: 4±1mm; 0.75±0.75mm. Hood Inner Panel Hood Outer Panel Uniformity: 1.0 Uniformity: 0.
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III.
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Windscreen Dimension 111
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V.
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Chapter 10 Section 1 Wire Harness Battery Negative Electrode Harness I. Schematic Diagram of Harness Eyelet Terminal Body Ground II. Main Connectors Description No Connector Description Numbe r of Pin Connection 1 Eyelet terminal 1 Battery negative 2 Body ground 1 Body III. Disassembly/Reassembly Harness of Remark Under the front left fender Battery Part Number: S21-3724040 (I). Preparation Tools: socket wrench (II).
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1.2. Remove the negative of battery. 1.3. Remove the grounding point of battery negative harness at the body, and take off the battery negative harness. 2. Installation Install it in the reverse order of removal.
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Section 2 Engine Compartment Harness I.
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II.
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III. Disassembly/Reassembly Compartment Harness of Engine Part Number: S21-3724010 (I). Preparation Tools: socket wrench, cross screwdriver, flat head screwdriver (II). Precautions: Power OFF before the electrical elements and harnesses are removed. The ignition switch must be in OFF state. (III). Removal Procedure 1. Removal 1.1.1. Remove the lower left guard plate from the instrument panel. (See Disassembly/Reassembly of Instrument Panel) 1.1.2. Pull out the ECU’s connector. 1.1.3.
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1.1.5. Pull out the connector to the instrument harness connector A. 1.1.6. Pull out the connector to instrument harness connector B. 1.1.7. Pull out the connector to instrument harness connector C. 1.1.8. Pull out the connector of interior harness. 1.1.9. Pull out the connectorof electronic accelerator pedal.
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1.1.10. Pull out the connector of wiper motor. 1.1.11. Pull out the connector of A/C high/low pressure switch. 1.1.12. Pull out the connector of right front wheel sensor. 1.1.13. Pull out the connector of ABS controller. 1.1.14. Remove the ABS controller, Remove the ABS grounding point.
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1.1.15. Remove the upper fixing bolts from the left fender with a 10# socket wrench. 1.1.16. Remove the lower fixing bolts from the left fender with a 10# socket wrench. 1.1.17. Remove the fixing bolts from the exterior rear-view mirror support at the left fender with a10# socket wrench. 1.1.18. Remove the front bumper mounting with a cross screwdriver. 1.1.19. Pull out the connector of washer motor.
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1.1.20. Remove the grounding point from the left side member. (Near the cansiter) 1.1.21. Pull out the connector of front left wheel sensor. 1.1.22. Pull out the connector of brake fluid level sensor. 1.1.23. Remove the battery positive connector. 1.1.24. Remove the connector to the starter.
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1.1.25. Pull out two connectors A and B from the fan motor. 1.1.26. Pull out the connector of left headlamp. 1.1.27. Pull out the connector of front left fog lamp. 1.1.28. Remove the grounding point of fan motor. (At the front part of left side member, and near the headlamp) 1.1.29. Pull out the high-tone horn connector.
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1.1.30. Pull out the low-tone horn connector. 1.1.31. Pull out the right fog lamp connector. 1.1.32. Pull out the right headlamp connector. 1.1.33. Pull out the engine compartment harness and engine electronic injector harness connectors. 1.1.34. Remove the bolts used to secure the left side of fuse box with a socket wrench.
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1.1.35. Remove the bolts used to secure the right side of fuse box with a socket wrench. 1.1.36. Take off the engine compartment harness. 2. Installation Install it in the reverse order of removal.
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Section 3 Electronic Injector Harness I.
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II.
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III. Disassembly/Reassembly Harness of Engine Part Number: S21-3724180 (I). Preparation Tools: socket wrench, cross screwdriver, flat head screwdriver (II). Precautions Power OFF before the electrical elements and harnesses are removed. The ignition switch must be in OFF state. (III). Removal Procedure 1. Disassembly/Reassembly of Battery and Air Cleaner. 1.1.1. Remove the positive of battery. 1.1.2. Remove the negative of battery, and take off the battery assy. 1.1.3.
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1.1.5. Pull out the hose used to connect the air cleaner with engine intake manifold by hand. 1.1.6. Take off the air cleaner . 1.1.7. Remove the fixed seat from the battery. 1.2. Installation Install it in the reverse order of removal. 2. Disconnect the connection of all engine harness connectors. 2.1.1. Remove the connectors from the electronic injector harness and engine compartment harness. 2.1.2. Remove the connector from the electronic throttle.
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2.1.3. Remove the connectors from the ignition coil. 2.1.4. Remove the connector from the camshaft sensor. 2.1.5. Remove the connector from the cansiter solenoid valve connector. 2.1.6. Remove the connector from the air pressure sensor. 2.1.7. Remove four connectors from the injector nozzle.
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2.1.8. Remove the connector from the charging indicator. 2.1.9. Remove the connector from the generator. 2.1.10. Remove the starter connector and battery connector. 2.1.11. Pull out the connector from the A/C compressor. 2.1.12. Remove the connector from the oil pressure switch.
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2.1.13. Remove the connector from the power steering pump. 2.1.14. Remove the connector from the knock sensor. 2.1.15. Remove the connector from the backup lamp switch. 2.1.16. Remove the connector from the water temperature sensor. 2.1.17. Remove the connector from the front rear oxygen sensor.
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2.1.18. Remove the connector from the vehicle speed sensor. 2.1.19. Remove the connector from the engine speed sensor. 2.1.20. Take off the electronic injector harness assy. 2.2. Installation Install it in the reverse order of removal.
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Section 4 Interior Harness I.
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II.
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III. Disassembly/Reassembly Floor Harness of Interior Part Number: S21-3724050 (I). Preparation Tools: Socket wrench, screwdriver cross screwdriver, flat head (II). Precautions Power OFF before the electrical elements and harnesses are removed. The ignition switch must be in OFF state. (III). Removal Procedure 1. Removal of Harness at Left Side of Interior Floor. 1.1.1. Remove the lower left guard plate from the instrument panel. (See Disassembly/Reassembly of Instrument Panel) 1.1.2.
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1.1.5. Remove the A pillar lower trim with a cross screwdriver. 1.1.6. Pull out the connector of front left door harness A. 1.1.7. Pull out the connector of front left door harness B. 1.1.8. Remove the grounding point. (under the A pillar) 1.1.9. Remove the console. (See Disassembly/Reassembly of Console) 1.1.10. Remove the connector from the hand brake switch.
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1.1.11. Remove the connector from main seat belt switch. 1.1.12. Remove the seat and carpet. (See Disassembly/Reassembly of Seat and Carpet) 1.1.13. Pull out two connectors A and B of the window regulator. 1.1.14. Remove the grounding point. 1.1.15. Remove the B pillar trim. (See Disassembly/Reassembly of Seat Belt) 1.1.16. Remove the front left door contact switch.
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1.1.17. Pull out the connectors A and B to the right and left rear door harnesses. 1.1.18. Remove the ceiling. Disassembly/Reassembly of Ceiling) 1.1.19. Pull out the ceiling lampconnector. (See 1.1.20. Remove the rear seat. (See Disassembly/Reassembly of Rear Seat) 1.1.21. Take off the upper protecting cover of oil pump. 1.1.22. Pull out the connector to the fuel pump. 1.1.23. Pull out the connector of rear left wheel speed sensor.
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1.1.24. Remove the C pillar trim. Disassembly/Reassembly of Ceiling) 1.1.25. Pull out the rear left door contact switch. (See 1.1.26. Pull out the connector to the back door harness. 1.1.27. Pull out the connector of rear trunk lamp. 1.1.28. Remove the left grounding point from the luggage boot. 1. 1.29. Remove the connector of left tail lamp. 1.2 Install it in the reverse order of removal.
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2. Removal of harness at right side of interior floor. 2.1.1. Remove the glove case. (See Disassembly/Reassembly of Instrument Panel) 2.1.2. Pull out the connector of front right door harness. 2.1.3. Remove the right B pillar trim. (See Disassembly/Reassembly of Seat Belt) 2.1.4. Pull out the connector of front right door contact switch. 2.1.5. Pull out the connectors A and B of rear right door harness. 2.1.6. Pull out the connector of auxiliary seat belt switch. 2.1.7.
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2.1.8. Remove the C pillar trim. Disassembly/Reassembly of Ceiling) 2.1.9. Pull out the rear right door contact switch. (See 2.1.10. Remove the grounding point. 2.1.11. Take off the upper protecting cover of oil pump. 2.1.12. Pull out the connector of right tail lamp. 2.2. Installation. Install it in the reverse order of removal.
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Section 5 Instrument Harness Assy I.
PAGE 143
II.
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Electric Rearview Mirror Switch Connect to the interior harness connectorA (black) 10 Combined Instruments 11 Combined Instruments 12 Combined Instruments 13 Combined Instruments 14 Combined Instruments 15 Combined Instruments 16 Instrument Electric Device Box 1 271(JOINT) 2 Connect to interior harness B 3 Connect to interior harness B 4 Connect to interior harness B 5 Connect to interior harness B 6 Connect to interior harness B 7 138(JOINT) 8 302(JOINT) 9 —— 10 —— 1 Au
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Connect to the interior harness connectorA Self-diagno stic 1 Electric Rearview Mirror Switch 2 Electric Rearview Mirror Switch 3 Electric Rearview Mirror Switch 4 Electric Rearview Mirror Switch 5 Electric Rearview Mirror Switch 6 Connect to air bag harness 7 —— 8 Punch the card at the location near the diagnostic connector 1 CAN (LOW) High Line 2 Function Reserved 3 Function Reserved 4 302(JOINT) 5 302(JOINT) 6 CAN (HIGH) High Line 7 K Line IGNITION ON(+15) CAN (LOW) Low Lin
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Brake lamp Switch Clutch switch Air Bag Connector 10 Nightlight Switch 1 Instrument Electrical Box f5 2 Instrument Electrical Box f17 3 90(JOINT) 4 Connect to engine compartment harness A 1 302(JOINT) 2 Connect to engine compartment harness B 1 Instrument Electrical Box f15 2 Combined Instruments 3 Combined Instruments 4 —— 5 Connect to interior harness B 6 Punch the card at the location near the diagnostic connector 1 Anti-theft Module 2 302(JOINT) 3 —— 4 5 6 7 Punch the
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Switch A/C Switch COMBINE D INSTRUM ENTS 2 —— 3 138(JOINT) 4 248(JOINT) 5 Connect to engine compartment harness A 6 Wiper Intermittern Relay 7 Wiper Intermittern Relay 8 138(JOINT) 9 Connect to engine compartment harness A 1 303(JOINT) 2 116(JOINT) 3 271(JOINT) 4 303(JOINT) 5 Connect to engine compartment harness A 1 Connect to interior harness A 2 303(JOINT) 3 303(JOINT) 4 —— 5 303(JOINT) 6 247(JOINT) 7 Connect to engine compartment harness B 8 Connect to air bag
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31 Connect to engine compartment harness A 32 235(JOINT) 1 303(JOINT) 2 Connect to interior harness A 3 Connect to interior harness A 4 Connect to interior harness A 5 Connect to interior harness A 6 Connect to interior harness A 7 Connect to interior harness A 8 Connect to interior harness A 9 Connect to interior harness A 10 —— 11 Connect to antenna 12 —— 13 —— 14 271(JOINT) 15 Instrument Electrical Box f8 16 Instrument Electrical Box f6 1 274(JOINT) 2 233(JOINT) 3
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Panel Indicator Light Cigar Lighter Connect to A/C harness 6 271(JOINT) 1 309(JOINT) 2 271(JOINT) 1 309(JOINT) 2 Instrument Electrical Box f9 3 271(JOINT) 1 Connect to engine compartment harness A 2 301(JOINT) 3 Connect to engine compartment harness A 4 Fan Switch 5 Fan Switch 6 Fan Switch 7 Fan Switch 8 116(JOINT) 149
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III. Disassembly/Reassembly of Instrument Harness (I). Preparation Tools: 10＃/13＃ socket wrench, cross screwdriver, flat head screwdriver (II). Precautions Power OFF before the electrical elements and harnesses are removed. The ignition switch must be in OFF state. (III). Removal Procedure 1. Removal 1.1. Remove the console. 1.2. Remove the instrument panel. (See Disassembly/Reassembly of Instrument Panel) 1.3. Pull out the related connectors connected with the instrument harness. 1.4.
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1.6. Loosen four screws used to fix the instrument panel from the both sides. 1.7. Take off the cross beam and rear air duct. 1.8. Remove the harness with 10＃socket wrench and flat head screwdriver. 2. Installation Install it in the reverse order of removal.
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Section 6 Evaporator Harness Complete Vehicle Connector I. Schematic Diagram of Harness Fan Power Supply Governor Resistor Temperature Sensor Fan Power Supply Fan Relay II.
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III. Disassembly/Reassembly of Evaporator Harness (I). Preparation Tools: 8＃/10＃socket wrench, flat head screwdriver (II). Precautions Power OFF before the electrical elements and harnesses are removed. The ignition switch must be in OFF state. (III). Removal Procedure 1. Removal 1.1. Remove the instrument panel assy. Disassembly/Reassembly of Instrument Panel) 1.2. Remove the evaporator assy. Disassembly/Reassembly of Evaporater) (See (See 1.3.
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1.5. Take off the evaporator harness. 2. Installation Install it in the reverse order of removal.
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Section 7 Front Left Door Harness I.
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II.
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III. Disassembly/Reassembly of Front Left Door Inner Harness Part Number: S21-3724070 (I). Preparation Tools: socket wrench, cross screwdriver, flat head screwdriver. (二) , Precautions Power OFF before the electrical elements and harnesses are removed. The ignition switch must be in OFF state. (III). Removal Procedure 1. Removal 1.1. Remove the door inner guard plate. (See Removal of Door Inner Guard Plate) 1.2. Take off the door inner protective film. 1.3. Pull out the lift motor connector. 1.4.
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1.5. Pull out the exterior rear-view mirror harness connector. 1.6. Pull out the connector of front door sound box. 1.7. Pull out the door inner harness and interior floor harness connector. (See Disassembly/Reassembly of Interior Harness) 1.8. Unclench the harness fixing clips with a screwdriver. 1.9. Take off the door inner harness protector. 1.10. Take off the door inner harness assy from the interior of door. 2. Installation. Install it in the reverse order of removal.
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Section 8 Front Right Door Harness I.
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II.
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Section 9 Rear Door Harness I.
PAGE 162
II.
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III. Disassembly/Reassembly of Rear Left Door Inner Harness Part Number: S21-3724180 (I). Preparation Tools: socket wrench, cross screwdriver, flat head screwdriver (II). Precautions Power OFF before the electrical elements and harnesses are removed. The ignition switch must be in OFF state. (III). Removal Procedure 1. Removal. 1.1. Remove the rear left door inner guard plate . (See Disassembly/Reassembly of Door Inner Guard Plate) 1.2. Take off the rear left door inner protective film. 1.3.
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1.4. Pull out the door lock harness connector. 1.5. Pull out the Door Inner harness and vehicle interior harness connectors. 1.6. Unclench the harness fixing clips. 1.8. Unclench the Door Inner harness rubber jacket. 1.9. Take off the harness assy. from the internal of door. 2. Installation. Install it in the reverse order of removal. IV. Disassembly/Reassembly of Rear Right Door Inner Harness 1. Removal. Refer to Removal of Rear Left Door Inner Harness. 2. Installation.
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Section 10 Back Door Harness I.
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II.
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III. Disassembly/Reassembly of Back Door Inner Harness Part Number: S21-3724160 (I). Preparation Tools: socket wrench, cross screwdriver, flat head screwdriver (II). Precautions DO NOT apply too big force when the harness is going across the body paintwork hole so as to avoid the harness breakage and short-circuit. Power OFF before the electrical elements and harnesses are removed. The ignition switch must be in OFF state. (III). Removal Procedure 1. Removal. 1.1.1.
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1.1.4. Pull out the connector of rear door contact switch. 1.1.5. Remove the back Door Inner ornament plate. (See Disassembly/Reassembly of Luggage Boot) 1.1.6. Pull out the connector of rear defroster positive harness, and connector to the high-mount stop lamp circuit. 1.1.7. Pull out the connector of high-mount stop lamp, and then remove the harness from high-mount stop lamp. 1.1.8. Pull out the connector to the license plate lamp. 1.1.9. Remove the grounding point from the back door harness.
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1.1.10. Remove the fixing clips used to fasten the back door harness. 1.1.11. Take off the back door inner harness. 2. Installation. Install it in the reverse order of removal, and implement this installation with a special auxiliary tool (small steel wire) and other tools.
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Section 11 Defroster Harness I. Schematic Diagram of Defroster Positive Harness To Defroster Positive II. Schematic Diagram of Defroster Negative Harness Defroster Negative Ground III.
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IV. Disassembly/Reassembly Defroster Harness Defroster harness S21-3724530 Defroster harness S21-3724540 of Rear positive (+), part number: negative (-), part number: (I). Preparation Tools: socket wrench, cross screwdriver, flat head screwdriver (II). Precautions Power OFF before the electrical elements and harnesses are removed. The ignition switch must be in OFF state. (III). Removal Procedure 1. Removal of Defroster Positive Harness 1.1.