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TABLE OF CONTENTS
Chapter I Front Compartment Cover & Trunk..............................................................................8
I. Disassembly of the front compartment cover........................................................................8
1. Preparation..................................................................................................................8
2. Attention.......................................................................................................................8
3. Disassembly of the front compartment cover accessories........................................8
3.1. Disassembly steps..............................................................................................8
3.3. Assembly steps...................................................................................................8
4. Disassembly & adjustment of the front compartment cover assembly..................9
5. Disassembly & assembly of the air intake grille assembly ......................................9
5.1. Disassembly steps..............................................................................................9
5.2. Assembly steps...................................................................................................9
6. Adjustment & assembly of the front compartment cover lock................................9
6.1. Disassembly steps..............................................................................................9
6.2. Assembly steps.................................................................................................10
7. Disassembly of the compartment cover back guy.......................................................10
7.1. Disassembly steps............................................................................................10
7.2. Assembly steps.................................................................................................11
II. Disassembly of the rear door..............................................................................................11
1. Preparation................................................................................................................11
2. Disassembly of the rear cover trim panel................................................................12
2.1. Disassembly steps............................................................................................12
2.2. Assembly steps.................................................................................................12
3. Disassembly & assembly of the knob lock of the rear door...................................12
3.1. Disassembly steps............................................................................................12
3.2. Assembly steps.................................................................................................12
4. Disassembly of the lock core of the rear door.............................................................13
4.1. Disassembly steps............................................................................................13
4.2. Assembly steps.................................................................................................13
5. Disassembly of the trim of the license plate lamp...................................................14
5.1. Disassembly steps............................................................................................14
5.2. Assembly steps.................................................................................................14
6. Disassembly of the rear door handle .......................................................................14
6.1 Disassembly steps.............................................................................................14
6.2. Assembly steps.................................................................................................15
7. Disassembly of the license plate lamp........................................................................15
7.1. Disassembly steps............................................................................................15
7.2. Assembly steps.................................................................................................16
Chapter Ⅱ Disassembly & Assembly of the Internal Trim Parts..................................................17
I. Disassembly & assembly of the safety belt.........................................................................17
1. Preparation................................................................................................................17
2. Attention.....................................................................................................................17
3. Disassembly steps (e.g. driver’s safety belt).......................................................17
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4. Assembly steps....................................................................................................19
Assemble according to the inverted sequence of the disassembly.............................19
II. Disassembly & assembly of the seat..................................................................................20
2. Disassembly steps of middle row seats ....................................................................20
3. Disassembly steps of the back row seat...................................................................21
4. Assembly steps....................................................................................................22
III. Disassembly & assembly of the console...........................................................................22
1. Disassembly steps......................................................................................................22
2. Assembly steps...........................................................................................................23
IV. Disassembly & assembly of the carpet..............................................................................24
1. Disassembly steps......................................................................................................24
2. Assembly steps...........................................................................................................26
V. Disassembly of the shock pad.............................................................................................26
1. Disassembly steps......................................................................................................26
2. Assembly steps...........................................................................................................26
Chapter III Disassembly & Maintenance of the Car Door..............................................................27
I. Disassembly, assembly & maintenance of the front door....................................................27
1. Lamp system constitution diagram .........................................................................27
2. Preparation................................................................................................................28
3. Attentions...................................................................................................................28
4. Disassembly steps......................................................................................................28
5. Assembly & adjustment steps ..................................................................................32
II. Disassembly, Assembly & Maintenance of the Side Door.................................................33
1. Preparation................................................................................................................33
2. Attentions...................................................................................................................33
3. Disassembly & assembly steps.................................................................................33
4. Assembly steps...........................................................................................................36
Chapter IV Disassembly, Assembly & Maintenance of the Front & Rear Bumper........................37
I. Disassembly, assembly & maintenance of the front bumper...............................................37
1. Preparation................................................................................................................37
2. Attentions...................................................................................................................37
3. Disassembly steps......................................................................................................37
4. Assembly steps...........................................................................................................39
II. Disassembly, assembly & maintenance of the rear bumper...............................................39
1. Preparation................................................................................................................39
2. Attentions...................................................................................................................39
3. Disassembly steps......................................................................................................40
4. Assembly steps...........................................................................................................41
Chapter V Disassembly, Assembly & Maintenance of the Front Headlamp, Fog Lamp & Tail
Lamp...............................................................................................................................................42
1. Lamp system constitutional diagram......................................................................42
2. Preparation................................................................................................................42
3. Attentions...................................................................................................................42
4. Disassembly steps of the front headlamp................................................................42
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5. Disassembly of the front fog lamp ...........................................................................44
6. Disassembly of the rear fog lamp................................................................................46
7. Disassembly steps of the rear tail lamp...................................................................47
Chapter VI Disassembly& assembly of the Roof...........................................................................48
1. Preparation................................................................................................................48
2. Attentions............................................................................................................................48
3. Disassembly & assembly of the sunshade panel.................................................................48
3.1. Disassembly steps...................................................................................................48
3.2. Assembly steps........................................................................................................48
4. Disassembly & assembly of the roof handrail....................................................................48
4.1. Disassembly steps...................................................................................................48
4.2. Assembly steps........................................................................................................49
5. Disassembly & assembly of the front & rear ceiling lamp.................................................49
5.1. Disassembly & assembly of the front ceiling lamp..............................................49
5.1.1. Disassembly steps.........................................................................................49
5.1.2. Assembly steps..............................................................................................49
5.2. Disassembly & assembly of the rear ceiling lamp ...............................................50
5.2.1. Disassembly steps.........................................................................................50
5.2.2. Assembly steps..............................................................................................50
6. Disassembly & assembly of A pillar shield.........................................................................51
6.1. Disassembly steps...................................................................................................51
6.2. Assembly steps........................................................................................................51
7. Disassembly & assembly of side shield of the roof............................................................51
7.1. Disassembly steps...................................................................................................51
7.2. Assembly steps........................................................................................................51
8. Disassembly & assembly of B pillar shield........................................................................52
8.1. Disassembly steps...................................................................................................52
8.2. Assembly steps........................................................................................................52
9. Disassembly & assembly of the bottom board front storage box........................................52
9.1. Disassembly steps...................................................................................................52
9.2. Assembly steps........................................................................................................53
10. Disassembly & assembly of the roof................................................................................53
10.1. Disassembly steps.................................................................................................53
10.2. Assembly steps......................................................................................................53
Chapter VII Disassembly & Assembly of the Instrument Panel.....................................................54
Section I Instrument panel system constitutional diagram....................................................54
Section ⅡDisassembly & assembly of the instrument panel................................................55
I. Disassembly & assembly of the instrument panel accessories...............................55
1. Preparation................................................................................................................55
2. Attention..............................................................................................................55
3. Disassembly & assembly of the radio & tape player..........................................55
3.1. Disassembly steps...................................................................................55
3.2. Assembly steps........................................................................................56
4. Disassembly & assembly of the air conditioner controlled panel.......................56
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4.1. Disassembly steps...................................................................................56
4.2. Assembly steps........................................................................................56
5. Disassembly & assembly of the glove box.........................................................56
5.1. Disassembly steps...................................................................................56
5.2. Assembly steps........................................................................................57
6. Disassembly & assembly of the combined instruments......................................57
6.1. Disassembly steps...................................................................................57
6.2. Assembly steps........................................................................................59
7. Disassembly & assembly of the steering wheel..................................................59
8. Disassembly & assembly of combined switches, wiper switch and ignition
switch......................................................................................................................60
II. Disassembly & assembly of the main parts of the instrument panel ...................60
1. Preparation..........................................................................................................60
2. Attention..............................................................................................................60
3. Disassembly & assembly of the main parts of the instrument panel...................60
3.1. Disassembly steps...................................................................................60
3.2. Assembly steps........................................................................................62
Chapter VIII Air Conditioner System.............................................................................................63
I. System combination............................................................................................................63
II. Disassembly & assembly of the evaporator assembly........................................................63
1. Preparation................................................................................................................63
2. Disassembly steps......................................................................................................64
3. Assembly of the evaporator assembly......................................................................65
4. Disassembly & assembly of the interior evaporating tank....................................65
4.1. Disassembly steps............................................................................................65
4.2. Assembly steps.................................................................................................68
III. Standard sides pressure value of high pressure & low pressure of the air conditioner
system.....................................................................................................................................69
IV. Frequent Troubleshooting.................................................................................................69
Chapter IX Disassembly & Assembly of the Wiper System...........................................................72
I. Wiper system constitutional diagram...................................................................................72
II. Disassembly & assembly of the wiper mechanism............................................................72
1. Preparation................................................................................................................72
2. Attention.....................................................................................................................73
3. Disassembly steps......................................................................................................73
4. Assembly steps...........................................................................................................74
Chapter X Carbody Dimension....................................................................................................75
I.Main beam dimension..........................................................................................................75
II. Carbody assembly dimension.............................................................................................76
1. Right front view.........................................................................................................76
2. Right side view...........................................................................................................81
3. Rear view.................................................................................................................106
III. Engine room dimension..................................................................................................111
IV. Windscreen dimension....................................................................................................112
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V. Open size dimension of each part.....................................................................................114
Chapter Ⅺ Disassembly & Assembly of the Wiring Harness.....................................................115
Section I Wiring Harness of the Left Front Compartment....................................................115
I. Wiring harness sketch.............................................................................................115
II. Main plug-in units explanation.............................................................................116
III. Disassembly & assembly of the left front compartment ....................................119
(I).Preparation.......................................................................................................119
(II).Attentions........................................................................................................120
(III).Disassembly steps..........................................................................................120
(III).Assembly steps..............................................................................................124
Section ⅡWiring Harness of the Front Compartment.........................................................125
I. Wiring harness sketch.............................................................................................125
II. Main plug-in units explanation.............................................................................126
III. Disassembly & assembly of the right front compartment wiring harness.......127
(I).Preparation.......................................................................................................127
(II).Attentions........................................................................................................127
(III).Disassembly steps........................................................................................127
(IV).Assembly steps..............................................................................................129
Section III Electrical Spray Wiring Harness of the Engine...................................................130
I. Wiring harness sketch.............................................................................................130
II. Main plug-in units explanation.............................................................................131
(I).Preparation.......................................................................................................133
(II).Attention.........................................................................................................133
(III).Disassembly steps..........................................................................................133
(IV).Assembly steps..............................................................................................136
Section IV Wiring Harness of the Instrument.......................................................................137
I.Wiring harness sketch..............................................................................................137
II. Main plug-in units explanation.............................................................................138
III. Disassembly & assembly of the instrument wiring harness ..............................139
(I).Preparation.......................................................................................................139
(II) .Attentions.......................................................................................................139
(III).Disassembly steps..........................................................................................139
(IV).Assembly steps..............................................................................................140
Section V Wiring Harness of the left front door...................................................................141
I. Wiring harness sketch.............................................................................................141
II. Main plug-in units explanation.............................................................................142
III. Disassembly & assembly of the wiring harness of the left front door ..............142
(I).Preparation.......................................................................................................143
(II).Attentions........................................................................................................143
(III).Disassembly steps..........................................................................................143
(IV).Assembly steps..............................................................................................144
Section VI Wiring Harness of the Right Front Door.............................................................145
I. Wiring harness sketch.............................................................................................145
II. Main plug-in units explanation.............................................................................146
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III. Disassembly & assembly of the wiring harness of the right front door............146
(I).Preparation.......................................................................................................146
(II).Attentions........................................................................................................146
(III).Disassembly steps..........................................................................................147
(IV).Assembly steps..............................................................................................148
Section VII Roof Wiring Harness.........................................................................................149
I. Wiring harness sketch.............................................................................................149
II. Main plug-in units explanation.............................................................................150
III. Disassembly & assembly of the roof wiring harness..........................................150
(I).Preparation.......................................................................................................150
(II).Attentions........................................................................................................150
(III).Disassembly steps..........................................................................................150
(IV).Assembly steps..............................................................................................151
Section VIII Wiring Harness Inside Floor.............................................................................152
I. Wiring harness sketch.............................................................................................152
II. Main plug-in units explanation.............................................................................153
III. Disassembly & assembly of the inside floor wiring harness..............................157
(I).Preparation.......................................................................................................157
(II).Attentions........................................................................................................157
(III).Disassembly steps..........................................................................................157
(IV).Assembly steps..............................................................................................165
Section IX Wiring Harness of the Rear Trunk Door.............................................................166
I. Wiring harness sketch.............................................................................................166
II. Main plug-in units explanation.............................................................................167
III. Disassembly & assembly of the rear door wiring harness.................................167
(I).Attentions.........................................................................................................167
(II).Disassembly steps...........................................................................................167
(III)。Assembly steps...........................................................................................169
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Chapter I Front Compartment Cover & Trunk
I. Disassembly of the front compartment cover
1. Preparation
Tools: Socket wrench 10#, connecting rod, ratchet wrench, ring wrench 8#
2. Attention
In the process of the disassembly, pay particular attention to the suitable force using and the
careless operation is forbidden.
3. Disassembly of the front compartment cover accessories
3.1. Disassembly steps
3.1.1. Disassemble the earthed bolts with the tool, which is
shown as the figure
3.3.2. Take out the washing hose of the washing liquid
3.3.2. Press clips of 2 water nozzles below the front
compartment cover, drive water nozzles from the beneath
the front compartment cover and then take out water
nozzles from the outside
3.3. Assembly steps
Assemble according to the inverted sequence of the
disassembly
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4. Disassembly & adjustment of the front
compartment cover assembly
4.1.Unscrew 4 bolts of the front compartment cover, which can
take out the front compartment cover (At the same time, through
loosening 4 bolts, the front & rear positions and left & right
positions of the front compartment cover can be adjusted).
4.2. Assembly of the front compartment cover assembly
Assemble according to the inverted sequence of the disassembly
Assembly moment：（ 10±1）Nm
5. Disassembly & assembly of the air intake grille assembly
Tool: Ring wrench 8#
5.1. Disassembly steps
5.1.1. Unscrew 6 fixing bolts of the air intake grille
assembly shown as the figure with the wrench
5.1.2. Just take out the air intake grille assembly
5.2. Assembly steps
Assemble according to the inverted sequence of the disassembly
Assembly moment：（ 8 ± 0.5）Nm
6. Adjustment & assembly of the front compartment cover lock
Tools: A drill bit with 6mm diameter & electric drill
6.1. Disassembly steps
6.1.1. The lock device under the front compartment cover
is riveted with the cross bar of the water tank through the
rivet and normally not need to disassemble it, but should
take out the rivet when required disassembly
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6.1.2. Take out the back guy of the front compartment
cover lock from the lock assembly under the front
compartment cover
6.2. Assembly steps
Assemble according to the inverted sequence of the disassembly
7. Disassembly of the compartment cover back guy
Tools: Phillips screwdriver
7.1. Disassembly steps
7.1.1. Disassemble 2 fixing bolts of the handle which
can open the front compartment cover in the car cab
Assembly moment：5±0.5Nm
7.1.2 .Take out the back guy from its cover
7.1.3. Take out the back guy head from the lock device
under the front compartment cover
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7.1.4. Take out 2 buckles which can fix the back guy
with the Phillips screwdriver
7.1.5. Take out the back guy from the closure which is
from the front compartment through the car
7.1.6. Pull out the back guy
7.2. Assembly steps
Assemble according to the inverted sequence of the disassembly
Attention: When assembling, embed the slot of the back guy into the kerf
II. Disassembly of the rear door
1. Preparation
Tools: Phillips screwdriver, ring wrench 13#, socket wrench 10#, connecting
rod, ratchet wrench, flat-end screwdriver
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2. Disassembly of the rear cover trim panel
2.1. Disassembly steps
2.1.1. Just take out the buck one by one of the internal
trim panel of the rear door
2.2. Assembly steps
Assemble according to the inverted sequence of the
disassembly
3. Disassembly & assembly of the knob lock of the rear door
3.1. Disassembly steps
Tool: Flat-end screwdriver
3.1.1. Take 2 pull rods connecting with the lock of the
rear door
3.1.2. Unscrew 3 position-fixing bolts of the knob lock
with the Ring wrench 8#, and then may take out the
lock. (Assembly Moment is 9±1Nm）
3.2. Assembly steps
Assemble according to the inverted sequence of the
disassembly
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4. Disassembly of the lock core of the rear door
Preparation tool: Flat-end screwdriver
4.1. Disassembly steps
4.1.1. Separate the lock core with the connecting rod
4.1.2. Prize up the positioning clip with the flat-end
screwdriver, take it out and then just take out the lock core
Attention: Do not throw the washer of the lock core
4.2. Assembly steps
Assemble according to the inverted sequence of the
disassembly
Pay attention to right assembly which is completely jointed
with the plate work of the car door.
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5. Disassembly of the trim of the license plate lamp
Tool: Ring wrench 10#
5.1. Disassembly steps
5.1.1. Unscrew 2 bolts of the trim panel with ring wrench 10#
5.1.2. Take out the trim panel
5.2. Assembly steps
Assemble according to the inverted sequence of the
disassembly(Assembly moment: 10±1Nm）
6. Disassembly of the rear door handle
Tool: Ring wrench 10#
6.1 Disassembly steps
6.1.1. Disassemble the pull rod of the handle, and then
unscrew 2 positioning bolts of the handle with the tool.
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6.1.2. Take out the rear handle
6.2. Assembly steps
Assemble according to the inverted sequence of the
disassembly
7. Disassembly of the license plate lamp
Tool: Phillips screwdriver
7.1. Disassembly steps
7.1.1. Take out the connector of the left & right license plate
lamps
7.1.2. Align the bolts of the license plate with the Phillips
screwdriver, unscrew them and there are 4 bolts in all.
7.1.3. Take out license plate lamps
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Chapter Disassembly & Assembly of the Internal TrimⅡ Parts
I. Disassembly & assembly of the safety belt
1. Preparation
Tools: Slotted screwdriver, wrench and socket wrench
Parts: one-time buckle
2. Attention
Keep the safety belt clean, avoid being stained with the
oil and check whether the safety belt is spoiled or not
3. Disassembly steps (e.g. driver’s safety belt)
3.1. Prize up the protective cover of the bolts above the
safety belt with the slotted screwdriver
3.2. Unscrew fixing bolts above the safety belt with the
socket wrench 17#
Moment：50±10N·m
3.3. Carefully prize the protective cover of bolts below
the safety belt with the slotted screwdriver
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3.4. Unscrew fixing bolts below the safety belt with the
socket wrench 17#
Moment: 50±10N·m
3.5. Partially disassemble the rubber strip at the driver’s
side door
3.6. Prize up the upper shield of the B pillar with the
slotted screwdriver
3.7. Prize up the pressing panel of the threshold with the
slotted screwdriver
Attention: The inside is fixed by the clip.
3.8. Unscrew 3 fixing bolts of the down shield of the B
pillar with the slotted screwdriver
Moment: 3±0.5Nm
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3.9. Take out the down shield of the B pillar
3.10. Loosen fixing bolts with the socket wrench 17#
and take out the safety belt
Moment：50±10N·m
4. Assembly steps
Assemble according to the inverted sequence of the disassembly
Attention：
4.1. Keep the safety belt clean, avoid being stained with
the oil and check whether the safety belt is spoiled or not;
4.2. The pillar shield fits with the carbody firmly, flexible
phenomenon is not allowed to start; and it should fit with
the roof, sealing strip well;
4.3.The safety belt adjusting slide way baffle plate of the
upper shield of the B pillar should move smoothly, not
affect the adjustment of the safety belt and the fit clearance
with the down shield is even and less than 1mm;
4.4. The fit clearance between the down shield of the B
pillar & the threshold pressing panel of the front and rear
door should be less than 1mm;
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II. Disassembly & assembly of the seat
Preparation tools: Ring wrench 10#, socket wrench 17#
and slotted screwdriver
1. Disassembly of front row seats
1.1. Make the seat move forward through pulling the
moving handle below the seat and uncover the fixing
bolts under the seat
1.2. Unscrew 1 fixing bolt after seats with the socket
wrench 17#
Moment：25±3N·m
1.3. Unscrew the limiting bolts of the slide way under
seats with the ring wrench 10#
1.4. Move back seats through pulling the moving
handle under seats and take out seats
2. Disassembly steps of middle row seats
2.1. Pull up the cushion of the rear row seat by hands
and separate the cushion from the buckle of the
chassis of carbody.
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