V80service Manual（1）technical Guide Right Vi Jszn Y Y 02 64e4l

Service Workbook 500 130

Technical Guide

450 400

110

70

250 200

3RZHUU (PS)

90 300

50

150 30

100

rpm

0

3000

2500

2000

1500

50 1000

7RUTXHH (Nm)

350

2012Year

WARNING Warning: To reduce the possibility of personal injury and property damage, the following instructions must be observed: All six service workbooks provided by SMCV are dedicated for professional technicians. Trying to do service or repair work without appropriate trainings, tools or equipments may cause injury to you or others. It can also result in vehicle damage or abnormal operation. Correct service and repair work is essential to personal safety of service technicians, as well as safe and reliable operation of vehicles. If any part needs to be replaced, use the same part number or other part number(s) specified by SMCV only. Never use any replacement part which is not approved by SMCV. The repair instructions suggested and introduced in this workbook are beneficial for correct service and repair. And sometimes special tools are required. In this case, any use of the replacement parts, repair instructions or tools which are not suggested or approved by SMCV should not be allowed until it is proved that this has no threat to the personal safety or safe operation. This workbook provides technical data, illustrations and function descriptions of all components on Datong PV, MPV and VAN models and not to any particular vehicle in model year - 2012.For the specification of any particular vehicle, purchasers should consult their SMCV Distributor or Dealer. Throughout this workbook, WARNINGS and CAUTIONS are included which should be strictly observed for reducing personal injuries at the service and repair work. Any incorrect service or repair will cause damage to the vehicle, left hidden dangers. However, these WARNINGS and CAUTIONS are not complete. And it is impossible for SMCV to give warnings for all potential dangers resulting from violation of these instructions. In order to avoid accidental airbag deployment and relevant potential injury, it is recommended to service the airbag first when both the airbag and other systems need to be repaired. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form, whether electronic or mechanical, or by photocopying, recording or other means without prior permission in writing of SMCV

Error and Advice Reporting If any error is found in this service workbook, or any advice, you are encouraged to tell us. You can send any advice via letter or fax to SMCV After Sales at After Sales, SAIC Commercial Vehicle Co., Ltd #2500, Jungong Road, Shanghai City, China Postcode: 200438 The following information should be provided: · Your name ·Authorized repair center ·Tel. and fax of the authorized repair center ·Model year and model ·VIN ·Description of your concern(s) ·Necessary relevant information (e.g. sample or marked page) ·Any applicable electronic information part identification number

SMCV will give relevant response in the following ways: ·Submitting your concern to relevant service engineer ·Consulting relevant service engineer ·Satisfying your concern within 10 working days.

Datong s are encouraged to send your concerns to SMCV Customer Center at: 400-081-2011.

Content Overview ......................................................................................................... 1-1 Vehicle Overview ............................................................................................................................................... 1-1 Technical Data ................................................................................................................................................... 1-2 Vehicle Dimension ............................................................................................................................................. 1-6 Vehicle Identification .......................................................................................................................................... 1-8

Maintenance Information................................................................................. 2-1 Lift Point ............................................................................................................................................................. 2-1 Maintenance & Service ...................................................................................................................................... 2-2 Lubrication & Sealing ......................................................................................................................................... 2-3

Description & Operation .................................................................................. 3-1 Engine Mechanical............................................................................................................................................. 3-1 Engine Electrics ............................................................................................................................................... 3-10 Engine Cooling................................................................................................................................................. 3-13 Engine Control ................................................................................................................................................. 3-17 Fuel system...................................................................................................................................................... 3-23 Air intake & Exhaust System............................................................................................................................ 3-26 Transmission.................................................................................................................................................... 3-30 Clutch............................................................................................................................................................... 3-33 Drive Shaft ....................................................................................................................................................... 3-35 Front suspension ............................................................................................................................................. 3-38 Exploded diagram of front shock absorber ...................................................................................................... 3-40 Rear suspension .............................................................................................................................................. 3-42 Steering............................................................................................................................................................ 3-46 Brakes system ................................................................................................................................................. 3-51 Windows .......................................................................................................................................................... 3-58 Wiper and Washer ........................................................................................................................................... 3-60 Exterior mirror .................................................................................................................................................. 3-63 Seat.................................................................................................................................................................. 3-66 Illumination....................................................................................................................................................... 3-69 Instruments ...................................................................................................................................................... 3-72 Immobiliser system .......................................................................................................................................... 3-81 Body control unit .............................................................................................................................................. 3-84 Vehicle entertainment system.......................................................................................................................... 3-88 Parking distance control................................................................................................................................... 3-92 Seat belt........................................................................................................................................................... 3-95 Airbag restraint system .................................................................................................................................... 3-97 Heating / Ventilation....................................................................................................................................... 3-100 Air conditioner ................................................................................................................................................ 3-103

Tyre pressure detection system ...................................................................... 4-1 Overview ............................................................................................................................................................ 4-1

Content Operation principle ............................................................................................................................................. 4-1 System structure: ............................................................................................................................................... 4-1 Instrument display .................................................................................................................................... 4-1 Tyre pressure warning alarm.............................................................................................................................. 4-1 Tyre critical alarm ............................................................................................................................................... 4-3 Signal transmission mode .................................................................................................................................. 4-3 Function description of component parts: .......................................................................................................... 4-4 Functions of hand-held learning diagnostic tool ................................................................................................. 4-4 Introduction of hand-held learning diagnostic tool.............................................................................................. 4-4 1、 Menu and button.......................................................................................................................................... 4-5 1、 Button definition ........................................................................................................................................... 4-5 2、 Activation picture ......................................................................................................................................... 4-5 2、 Learn binding ............................................................................................................................................... 4-5 3、 Delete mode ................................................................................................................................................ 4-6 4、 Tyre change-over mode............................................................................................................................... 4-7 5、 Diagnostic test functions.............................................................................................................................. 4-8 6、 Precautions................................................................................................................................................ 4-11

Overview Overview

Vehicle Overview A proven, durable 2.5 litre common rail diesel engine with turbocharger and intercooler is equipped on V80 commercial vehicle. The engine is mounted transversely on the frame and provides the front wheel drive by transaxle transmission. The engine employs a program control fuel injection system for improved combustion efficiency, as well as low fuel consumption and low emission - Chinese Emission Standard IV, hence an economical and environmental innovation. Combined with excellent performance of SC25R Engine, 5MT is equipped on V80 commercial vehicle. The manual operated 5 Gear Transmission can significantly improve the acceleration performance; and the reliable operation control can ensure a stable and smooth driving. V80 commercial vehicle is equipped with four-wheel disc brakes. Both on the front and rear wheels are installed with ventilated disc brakes which have excellent heat dissipation and brake performance. In addition, with the improved rigidness of the brake pedal, brake friction disk with high COF and advanced tyres with strong adhesivity, outstanding brake performance can be ensured. To prevent wheel locking when an emergency braking is applied, V80 commercial vehicle is installed with Four-wheel Anti-lock Brake System (ABS). In this case, driving safety is guaranteed. V80 commercial vehicle is equipped with SRS Dual Air Bags to sense, analyze and initiate relevant program based on the crash condition. The initiator can, according to the crash severity, launch a short interval explosion on the purpose of controlling the initiation of the air bags. V80 commercial vehicle is installed with Front & Rear Air conditioning. Dedicated AC air outlet is equipped in each row of seats. For the rear AC, hidden design is applied which locates the cool air outlet on the top of the body. Both the temperature and air flow of rear AC can be adjusted by the control in the middle left of the enger compartment. The very strong monocoque body shell encloses: - Precise rack and pinion power steering. - A well proven Mherson strut front suspension. - A simple leaf spring rear suspension. - Comprehensive electronic management system. - Sophisticated vehicle security. - In addition, a great range of features which include: - Electric door locking and window operation. - Cab door mirrors power operated and heated. - Front enger air bag & seat belt pre-tensioner. - Pad wear audible indicators. - Audible warning device.

1-1

Overview Technical Data Main Technical Data - Whole vehicle Model

SH-50-A Low Roof

Middle Roof

Length

Internal Dimension (mm)

4950 1998 2132

Length

2345

Wheelbase (mm)

2345

2586

Width Height

High Roof

5700

Width Height

Middle Roof

4 × 2, Front-wheel

Drive Type External Dimension (mm)

SH-57-A

2552 3355

1770 1505

1710 3100

1925 3850

Front Track (mm) Rear Track (mm)

1734

Front Suspension (mm)

865

Rear Suspension (mm)

985

Approach Angle (°)

26

Departure Angle (°)

21(Van without rear step),17 (without rear step), 14 (with rear step)

Minimum Ground Clearance (mm)

1-2

1728

200 (Oilpan)

Overview Table 2 Main Technical Date - Whole Vehicle & Chassis Wheelbase

SH-50-A

SH-57-A

2～3

2 ～ 17

1830 ～ 1880

1930 ～ 2450

GVW （kg）

3500

3500 ～ 3760

Minimum Turning Radius (m)

12.4

14.8

Number of Seats GTW (kg)

Fuel Tank Capacity (L)

80

Top Speed (km/h)

》 150

Fuel consumption on comprehensive operation modes per 100km (L/100km)

9.1~9.3

Fuel consumption on six operation modes per 100km (L/ 100km)

<6

0-100km/h acceleration time (s)

23.3 ～ 28

Main Technical Data - Engine Model

SC25R136Q4

Type

SC25R120Q4

Inline 4-Cylinder CR, TCI Diesel

Number of Stroke

4

Bore (mm)

92.0

92.0

Stroke (mm)

94.0

94.0

Total Displacement (L) Compression Ratio

2.499 17.5:1

17.5:1

Rater Power (kW/r/min)

100/3800

88/3800

Max. Torque (Nm/r/min)

330/1800 ～ 2600

300/1800 ～ 2600

Fuel Type

Diesel

Cylinder Working Order

1-3-4-2

Weight (without starter and AC compressor)(kg) Emission Level Emission Device

230

230 Chinese Emission Standard Ⅳ Catalytic Converter + Intercooler EGR

1-3

Overview Main Data - Transmission Model

HTX-PVH

Type

5MT 1st

C

2nd

2.105

3rd

1.300

4th

0.941

5th

0.750

Rev

3.167

Final

4.188

Gear Ratio

Gear Ratio

Transmitted Torque (N.m)

330

Operation control

Long distance cables

Front-wheel Alignment Data Front-wheel Alignment Data

Item Wheel Camber

0.5 ± 1° (-0.5°～ 1.5°) the difference between Left and right (-0.5°～ 0.3°)

Kingpin Castor

0.6 ± 0.9° (-0.3°～ 1.5°) the difference between Left and right (-0.3°～ 0.3°)

Wheel Toe

Smgle toe -0.11°～ 0.02° generd toe -0.22°～ 0.04° the absolute dispersion between Left and right ≤ 0.05° 10 ± 2.5° (7.5°～ 12.5°)

Kingpin Inclination

Rear-wheel Alignment Data Rear-wheel Alignment Data

Item Left wheel (rear)

Right wheel (rear)

Wheel Camber

0°

0°

Wheel Toe

0°

0°

Rear-wheel Thrust Angle

1-4

0 ± 0.25°

Overview Suspension Date 13850 （free state）

Proof load (N) Max. load (N)

9900

164

-6

4400 ～ 4700N

Static load (N)

6110

100

58 ± 5

60.5 ± 7%

Empty load (N)

4400

73

85 ± 5

No load (N)

0

0

158 ± 6

Load name

Load N

Deformation mm

Camber mm

Rigidity N/mm

Wheel & Tyre Data Model

SH-50-A SH-57-A

Wheel Specification

16X6J 205/75R16C

Tyre Specification

Tyre Pressures (kPa) (Front Wheel / Rear Wheel)

215/75R16C

GVW=3.2t

380/420

GVW=3.5t

400/450

Available Body Colors White

Single white coat

Silver

Galaxy silver

Grey

Iron grey

Violet

Water crystal violet

Brown

Water brown metallic

1-5

Overview Vehicle Dimension

2132 2345

1998

3100(SWB) 4950

1734

1505

1998

1728

1-6

Overview

2345 2552

1998

3850(LWB) 1734

5700

1998

1728 1728

1-7

Overview Vehicle Identification Vehicle Identification Number (VIN) : VIN Example：

- LSK G 4 G C 1 9 A A200000 LSK

Identification code of the manufacturer Vehicle Brand

G Datong 4 = L<5.3 ; 5 = 5.3 < L < 6.0

4 Vehicle Length Engine Type

G G =60 ~ 149KWDiesel PV Type and Steering Wheel Layout

C C = Small PV(LEFT) ; L = Small PV (RIGHT) Engine Layout

1 1 = Front-engine

9

Check digit Model Year

A A = 2010 年 Assembly Plant

A A = Manufacturer

2 ××××× (6 Digits)

VIN - Position

VIN is inside the engine compartment

1-8

Production Serial Number

Maintenance Information Maintenance Information

Lift Point Vehicle lifting illustration

CAUTION: Since there is no independent chassis, the lift should be operated at the pivot point specified below to ensure no damage to the vehicle

S163035

S163035

2-1

Maintenance Information Maintenance & Service Maintenance & Service4 Item

Service contents (requirements)

Engie oil change

At first 5000km,then every 15000km

Renew oil filter

At first 5000km,then every 15000km

Renew air cleaner element

At first 10000km,then every 15000km

Renew fuel filter

At first 10000km,then every 15000km

Power steering oil change

Every 3 years(or every 80000km)

Renew timing belt

Every 60000km or every 5 years

Renew engine coolant

Every 2 years or every 60000km (Pay attention to coolant compositions)

Renew transmission oil

At the first 10000km, then every 80000km

Renew brake fluid

Every 2 years (or every 60000km)

Renew AC air cleaner element

Every 1 year

2-2

Maintenance Information Lubrication & Sealing Fuel, Lubricants and Working Fluids Fluid Name

Fluid Type

Fluid Amount

Note

Engine oil

CH-4 / 10W/40

6.5kg

Already existed in the engine

Brake fluid

DOT4

0.76L

Anti-freeze

JFL-3

9L without rear AC 10.5L with rear AC

ATF-DEXRON Ⅲ Type

0.96L

R134a

600 ± 30g

without rear AC

1450 ± 30g

SWB with rear AC

1750 ± 30g

2WB with rear AC Loaded in the AC compressor

Power steering fluid AC coolant

AC refrigerating oil

PAG

0.3kg

Transmission fluid

75W-85

2.3L

Diesel

80L

Universal lower freezing point washer fluid

3.5L

NLGI 2

As required

Fuel Windows washer fluid Lithium grease

Use only SMCV approved antifreeze

Sulfur content of less than 50ppm of the diesel

Hub bearing

Sealants / Thread locking adhesives Loctite 601

Bowl plug

Loctite 510

Turbocharger fuel return pipe adapter

Molykote 111

'O' rings (crankshaft rear bearing, rear bearing seat)

Polymer 400

Cylinder liner 'O' ring

Loctite 222

Water temperature sensor Screw plug Engine stud

Teflon grease

Vacuum pump one-way valve Oil pressure alarm switch

Molycote P – 1500 grease

Fuel injector

Loctite 5900

Crankshaft rear bearing seat Gear casing cover

CAUTION: It is essential that the correctly specified oil, grease, fluids etc. are used at all times.

2-3

Maintenance Information

2-4

Description & Operation Description & Operation

Engine Mechanical Illustrations Layout of block and cylinder power assembly 6 7 5 1

9 10

8

3

11 24 12

2 37

4 36 35

32

13

14

34

15

33 17

18

16

31 19 30 29

18

23

22 21

20

25

28 26 27

1

Cooling water pipe

10

Connection rod bush

2

Water pump

11 Connecting rod

3

Oil filter

12

4

Oil cooler

13 Rear main bearing seat

5

Fresh water pump inlet pipe and coolant inlet hose

14

6

Piston ring

7

Elastic retaining ring for holes

8

Gudgeon pin

9

Piston

Flywheel dust shield

Speed sensor

15 Flywheel dust shield 16

Crankshaft speed signal disc

17

Connection rod bearing bush

18 Main bearing seat

3-1

Description & Operation 19 Flywheel

29 Main bearing bush

20 Starter ring gear

30 Crankshaft

21 Crankshaft rear oil seal

31

Vacuum pump

22 Crankshaft rear ring spacer block

32

Crankshaft pulley/damper

23 O seal ring

33 Oil pump drive gear

24 Cylinder liner

34 Vacuum pump/oil pump drive gear

25 Crankcase oil baffle plate

35 Oil pump

26

36 Crankcase

Oil pan pad

27 Oil pan 28 Oil strainer/pick-up pipe

3-2

37 Oil pressure alarm switch

Description & Operation Layout of cylinder head, air intake & exhaust and fuel system assembly

1

2 4 3

9

6

7 8

11 13

5

10 12

36 14 35 33 32

34

15

31 30 29 28

16 18

27

17

26

20

19 21

25

24 22 23

1

Fuel injector return pipe

9

2

High pressure fuel return pipe (fuel rail to fuel injector)

10 Oil dipstick tube

3

Fuel rail

4

Fuel injector

5

Fuel rail pressure sensor

6

Oil filler cap

7

Oil/air separator

8

Camshaft position sensor

Oil dipstick

11 Camshaft plug 12

Air intake temperature & pressure sensor

13 Cylinder upper head 14 Cylinder upper head shim 15 Turbocharger air intake pipe 16

EGR air outlet pipe (EGR cooler to EGR valve)

17

Water temperature sensor

3-3

Description & Operation 18 Cylinder head

27

19 Cylinder head shim

28 Engine lifting eye

20 Air intake pipe (EGR valve to cylinder upper head)

29 Exhaust pipe shim

21 Heater plug 22 Vacuum pipe 23 Turbocharger oil return pipe 24 Turbocharger oil pickup pipe 25 Turbocharger 26 Thermostat and housing

3-4

Valve actuating system

30 Exhaust pipe 31 Exhaust pipe heat shield 32 Camshaft oil seal 33 Camshaft retaining ring 34 Inlet camshaft 35 Exhaust camshaft 36 Fuel rail oil return pipe

Description & Operation Layout of front end timing & accessories assembly

9

8 5

6

4 2

7

3 12

1

3

11

10

13

14

16

15

23 24 19

22

21

17

20 18 1

Engine front

13 Crankshaft timing pulley

2

Front end timing protective cover

14 Power steering pump

3

Timing drive belt idler pulley

15 High pressure fuel pump

4

Timing drive belt

16 AC alternator mounting

5

Exhaust camshaft timing pulley

17 Alternator

6

Inlet camshaft timing pulley

18 AC compressor

7

Timing pulley case

19 Front end accessory drive belt

8

Timing pulley case bush

20 Front end accessory drive idler pulley

9

Timing pulley case damping pad

21 Front end accessory drive tension pulley

10 Timing pulley case shim

22 Timing pulley case damping pad

11 High pressure fuel pump pulley

23 Crankshaft front seal

12 Timing drive belt tension pulley

24 Gear casing cover

3-5

Description & Operation Layout of timing belt

2

1

3

3

4

8

7

6 5

1

Exhaust camshaft drive gear

5

Timing belt

2

Inlet camshaft drive gear

6

Crankshaft drive gear

3

Idler pulley

7

Belt tensioner

4

Fuel pump drive gear

8

Water pump

3-6

Description & Operation Description Overview SC25R engine is a small and medium power diesel engine equipped with overhead camshaft, 16 valve direct injection, turbocharger & intercooler and electronically controlled high pressure common rail. It boasts an international advanced level of energy-saving and high efficient performance with a Chinese Emission Standard IV achieved by EGR. The engine is mainly composed of aluminum cylinder upper head & cylinder head, irony block and oil pan made of composite steel plates. The aluminum components ensure both the overall weight of the engine and outstanding heat dissipation. The irony components ensure an excellent rigidity of the engine block. The oil pan made of composite steels ensures an anti-corrosion property, as well as an excellent rigidity. Cylinder head parts

and cylinder head shim, the sealing of the cylinder head will be influenced by the head gasket. The aluminum thermal expansion piston is equipped with a semi-floating gudgeon pin and applies an interference fit at the small end of connection rod. The crankshaft is ed by five bearing bushes with eight balancing blocks. The upper half of connection rod bearing bush is equipped with oil sump which is filled from the oil hole on the crankshaft to the bearing bush of connection rod big end. The installation holes of oil pump and vacuum pump are located at the front end of the block. Lubrication System The lubrication system is composed of oil pan, oil pump, oil filter, relief valve and oil sensor, etc. The main function of lubrication system is to provide a certain

The cylinder head consists of cylinder head and

amount of oil onto the friction surfaces on the purpose of

cylinder upper head with 16 valves, center located fuel

lubricating, cooling, cleaning and sealing. The operation

injector and cold start heater plug.

process is to pump the oil upward from oil pan to all oil

The hydraulic valve tappet is assembled at the head and directly driven by the camshaft located in the cylinder upper head. Exhaust valve is used to prevent carbon deposit. The valve stem, the side surface of which is machined, can remove the carbon deposit in the combustion chamber and the valve guide end, so as to prevent the valve sticking. The stainless cylinder head gasket is used to seal the surrounding of coolants, air vents and oil holes.

holes on the crankshaft and cylinder block through the oil filter. This engine ·Oil pan: Oil pan is located at lower half of the crankcase, namely lower crankcase. Its purpose is to enclose the crankcase as the shell of oil sump, preventing the entry of inclusions and collecting and storing engine oil returning from diesel engine friction surfaces. ·Oil pump: Oil pump is used to raise oil pressure, ensure a certain amount of oil and forces oil to every frication

The camshaft position sensor is installed at the top

surface.

of the cylinder upper head. Cylinder block parts The cylinder block is equipped with wet cylinder liner. On the lower part of the wet cylinder liner are some steps to achieve the slide fit with the cylinder block. The liner steps are coated with a layer of sealant to keep the cylinder liner within the block. Since the top of cylinder liner is used as a section between combustion chamber ·Relief valve:

·Oil filter: During the engine operation, metal debris, dusts, carbon deposits oxidized at high temperature, gelatinous sludge and water are continuously mixed into the engine oil. Its purpose is to filter these mechanical inclusions and gelatinous matters, ensuring the cleanliness of engine oil and extending its lifetime. Relief valves are installed at the main oil channel or oil pump to prevent oil pressure too high in the lubrication

3-7

Description & Operation system which may result in increased engine power loss and even oil leakage at the seal of oil gallery. The purpose of relief valve is to limit the oil pressure of the lubrication system not to exceed its specification. ·Oil sensor: Oil sensor is used to measure the engine oil pressure. See the figure below for lubrication system oil flow.

3-8

Description & Operation Illustration of lubrication system oil flow

1

2

15

3 4

14

13

5

12

6 7

11

10 8

9

1

Camshaft bearing

9

Oil strainer

2

Cylinder head

10 Oil pump

3

Piston cooling nozzle

11 Oil pressure regulating valve

4

Connection rod journal

12 Modularized oil cooler

5

Crankshaft main bearing

13 Oil filter

6

Crankshaft

14 Main oil gallery

7

Oil pan

15 Turbocharger

8

Vacuum pump

3-9

Description & Operation Engine Electrics Illustrations Layout of starting & charging devices

1 2

1

Alternator

3-10

2

Starter motor

Description & Operation Control chart of starting & charging devices

2

1

7

3

8 9

6

5

4

1

Alternator

6

Pre-fuse box

2

Starter motor

7

Instrument cluster

3

Relay

8

Ignition switch

4

Battery

9

Ignition key

5

Cabin fuse box

3-11

Description & Operation Description

warning light remains on, check for any fault on the

Overview

charging system or the battery will be damaged.

The start system is equipped with a 12V starter

When the ignition switch is in the "ON" position, the

motor which drives the engine to start combustion to

coils will provide power to make the pinion ring gear and

transform electric energy to mechanical energy. The

flywheel ring gear coupled with each other. The pinion is

electric system must be able to provide enough energy to

screw rotated on the motor shaft, ensuring a smooth

ensure that the crankshaft can be driven by starter motor.

combination through the ring gear. On the starter motor,

The charging system is composed of one battery

motor drives the pinion via reduction gear, not

pack and one alternator. The battery must be able to

directly via the motor, proving a smooth combination

provide enough energy to drive starter motor and other

between starter one-way clutch and flywheel ring gear.

electric systems. The alternator charges the battery when the engine is in operation and when an increased output is required by the battery.

After the engine starts, when the ignition switch is released, the solenoid will provide enough energy to pull the pinion from the ring gear.

The instrument cluster is installed with charging warning light which is illuminated when the alternator has no or low output electric energy.

Battery: Battery is one of the most important parts on the vehicle which provides electric energy to start the vehicle

This system mainly consists of starter, alternator, battery, starter relay, starter switch and wiring harness,

and adjusts the unbalance between the alternator output and load.

etc. When the engine does not operate or operates at a Charging system and starter motor:

low speed, the battery will supply power to electric

The alternator uses self-excitation system where

equipments; When the power consumption of any

LED provides partial current generated by the alternator

electric equipment is above the alternator output power,

to the rotor. The alternator cannot provide initial current to

the supply will supply power to the electric equipment

start the charging procedure. The initial current provides

with the alternator; When the power consumption of any

and excites field winding with ignition switch on the

electric equipment is lower the alternator output power,

battery input terminal to start charging procedure.

the alternator will supply power both to the electric

When the ignition switch turns on, the battery voltage is also provided by the charging warning light and grounded by alternator field winding to illuminate the LED warning light. When the engine starts, the rotor within the stator rotates, generating 3-phase AC. When the rotation speed of the rotor increases, the output voltage raises rapidly, enlarging the potential difference at the field LED output terminal. As the voltage rises, the charging warning light is gradually dimmed. When the alternator output voltage is equal to the battery voltage, the warning light will light off. In this case, alternator generates enough self-excited current from the field LED to start charging for the battery. If the charging

3-12

equipment and the battery.

Description & Operation Engine Cooling Illustrations Layout of cooling system

1 2

3

17 15 16

8 9

7 7 18

4

10

5 6 11 12 13 14

CS110007 1

Engine cooling module assembly

7

Radiator top seal

2

Air conditioning condenser assembly

8

Radiator upper mounting bracket

3

Intercooler assembly

9

Radiator upper rubber strip

4

Radiator

10 Main fan (30A)

5

Radiator bottom rubber strip

11 Auxiliary fan (30A)

6

Radiator bottom seal

12 Nut - engine cooling module installation

3-13

Description & Operation 13 Big washer A level

16 Screw - radiator upper cross-member assembly

14 Bolt - engine cooling module installation

17 Bolt -radiator to body

15 Radiator upper cross-member assembly

18 Radiator upper cross-member mounting bracket assembly

3-14

Description & Operation Description Overview The main function of cooling system is to ensure a most suitable working temperature for the engine. The cooling system used in this model is a pressurized water forced circulation cooling which consists of cooling jacket, radiator, expansion tank, water pump, thermostat, cooling fan, water pipes, etc. Operation principle After absorbing heat in the jacket, the coolant is pumped to the radiator where the coolant is cooled down through the air flow from the cooling fan and driving. The cooled coolant is then pumped back to the engine. After the above circulation, the engine can be operated at a suitable temperature. Function description of component parts: ·Radiator To provide a suitable engine operating temperature, the radiator is used to adjust the temperature of coolant flowing within the engine cooling circuit. ·Expansion tank Since the coolant which flows within the engine cooling circuit will expand as temperature raises, the expansion tank is used to absorb these expansion. ·Water pump The water pump is equipped to circulate the coolant required by the engine. ·Thermostat The thermostat is used to alter the coolant circulation line to maintain a suitable coolant temperature. ·Cooling fan The cooling fan is installed to reduce the coolant temperature during the circulation to ensure a normal operation. The cooling fan is mainly used for heat radiation and temperature reduction. ·Water pipes The water pipes in the engine cooling circuit are used to absorbing engine vibration and reducing relevant motion of radiator.

3-15

Description & Operation See the figure below for cooling system coolant flow:

B

1

2

A

3

J 6

H

F 5 D 3 F

3-16

E

E

C

Description & Operation Engine Control Illustrations Layout of engine management system

13

5

12

4

2

3 6

11

7 1

8

9

10

1

Speed sensor connector

8

High pressure pump

2

Camshaft position sensor connector

9

Water temperature sensor connector

3

Fuel injector

4

Wiring harness carrier

10 Air intake temperature & pressure sensor connector

5

Wiring harness assembly

6

ECM connector

7

Glow plug connector

11 Fuel rail pressure sensor connector 12 Starter motor, EGR and TVA signal circuit interfaces 13 Preheating power

3-17

Description & Operation Control chart of engine management system

1

1

1

1

2

3

4

11 5

10

12 9 7

8

6

1 3 5 2 4 R

1

Fuel injector

7

Water temperature sensor

2

Glow plug

8

Fuel rail parts

3

Speed sensor

9

Fascia

4

Camshaft position sensor

10 Fuel pump parts

5

Solenoid valve

11 Pre-heating relay

6

EGR Throttle control parts

12 Engine control unit (ECM)

3-18

Description & Operation Diagnosis plug

1 3 5 2 4 R

3-19

Description & Operation ECM

IGN Switch EF3 30A EF28 10A

G104

FB10-02

FB10-01

FB10-04

FB10-03

FB10-06

FB10-05

EF31 15A

FB10-47 FB10-87 FB10-65

Main Relay

EF20 30A

EF18 10A

FB10-46 Brake Switch

FB10-66 FB10-88

EF29 10A

EF13 10A

FB10-38 EF28 10A

FB10-78

BCM

FB10-44

Cruise Lamp

FB10-51

FB10-41

Clutch Switch G203 Instrument

F13 10A

Glowplug Lamp

FB10-91

Cruise Switch

FB10-55

FB10-74

FB10-19

FB10-75

A/C Press Switch

FB10-48 ABS

FB10-43

FB10-37

FB10-42 Instrument

Glowplug Relay

EF1 60A

FB10-68 FB10-90

C/Fan Relay-3 M

G102

Accelerator M

FB10-28

C/Fan Relay-1

EF5 40A

C/Fan Relay-2

EF6 40A

FB10-81 FB10-67

FB10-92

FB10-22 FB10-60 FB10-58

FB10-93 Engine Error Lamp

FB10-70

Air Flow Sensor FB10-12 FB10-20 FB10-63 FB10-21

WIF Sensor FB10-77 G105

WIF Lamp FB10-73 OBD Lamp

FB10-71

EF7 30A FB10-29 Fuel Heater Relay

Starter Relay

EF2 40A

EN01-03 EN01-22

Starter

M

Crank Shaft Position Sensor

A/C Compressor Relay

EN01-20 EN01-13 EN01-14 EN01-56

Camshaft Position Sensor EN01-08 EN01-57 EN01-35

ECT EN01-44

Boost Pressure Sensor With Temp Sensor EN01-07 EN01-54 EN01-28

EN01-29

EGR

EN01-53

Rail Pressure Sensor EN01-06

EN01-60

EN01-52

EN01-16

EN01-40

EN01-47 EN01-17 EN01-33

High Pressure Pump Injector 1

Injector 4

Coolant Temp Sensor EN01-37

EN01-01

EN01-50

EN01-46 EN01-02 EN01-31

3-20

Injector 3

Injector 2

EF14 10A

Description & Operation

3-21

Description & Operation Description This system is composed of ECM, various sensors, wiring hardness assembly and actuating system, etc.(See table below). A series of sensors supply a constant flow of information to the Electronic Control Module (ECM) which allow it to control injector timing.

Sensors

Location

Function

Engine speed sensor (CKP)

Crankcase side

To determine crankshaft phase and engine speed

Camshaft position sensor (S)

On cylinder upper head

To determine camshaft phase

Air intake temperature & pressure sensor (MAP)

Upper surface of cylinder upper head

To measure air intake temperature and pressure

Coolant temperature sensor

Cylinder head air intake side, 4th cylinder

To measure coolant temperature

Fuel temperature sensor (FTS)

Filter head

To measure fuel pick-up temperature

Fuel rail pressure sensor

End face of fuel rail

To measure fuel pressure in the fuel rail

Mass air flow (MAF)

Air intake pipe behind air filter

To measure air flow

Vehicle speed sensor

Transaxle

To measure the driving speed

3-22

Description & Operation Fuel system Illustrations Layout of fuel system

11 10 9 8 7

2 1

5 6

3 4

1

Fuel tank assembly

8

Oil return pipe interior tube assembly

2

Fuel level sensor seal

9

Oil filter mount

3

Feed pipe assembly

10 Oil filter

4

Feed pipe cover

11 Oil pick-up pipe front tube assembly

5

Front fuel tank clamp

6

Rear fuel tank clamp

7

Oil pick-up pipe interior tube assembly

3-23

Description & Operation Description Overview The diesel fuel system is the core of the diesel

1

2

engine which has a decisive influence on engine's dynamics,

economy,

emission,

noises,

12

operation

10 11

reliability and durability. The system is used to inject finely

9

atomized and well distributed diesel into the combustion

4

3

8

chamber at a fixed time and amount according to engine

5

7

operation requirements and to mix with air for a sufficient

6

combustion. V80 is equipped with common rail fuel injection system. The fuel system is composed of (injection pump, fuel 1

Fuel metering unit

8

Fuel filter

2

Injector

9

Primer pump

3

Common rail

10 Fuel heater

4

Fuel rail pressure sensor

11 High pressure fuel pump

pressure fuel pump (12) draws fuel from the tank (7) and

5

One-way valve

12 Fuel pump

through the filter (9) where the primer pump (10) directs it

6

Fuel tank

to common rail (4) via fuel pipes for injection to the engine

7

Water sensor

injector, high pressure fuel pipes, pump injector) fuel tank, canister, fuel filter and fuel pump, etc. Operation principle: See right for operation principle of fuel system. High

block. Components (1), (3) and (5) is used respectively

in

fuel

for fuel metering, pressure control and fuel rail pressure sensing, etc. The excess fuel is piped back through the

ECM receives information from various other

one-way valve (6) to the fuel tank. The common rail

sensors (e.g. accelerator pedal position, road speed etc.)

allows the highly pressurized fuel to be 'stored', ready for

and decides on the fuel pressure requirement for any

delivery to the injector as required. The common rail

given road speed/load condition. Then ECM delivers the

contains a pressure control valve (3) and a rail pressure

signal to metering unit and pressure control valve to

sensor (5).The rail pressure sensor sends fuel pressure

adjust the common rail pressure and satisfy fuel pressure

information to the ECM.

requirements. The injector is located at the center position of the cylinder. They are opened electrically and the timing of this 'open' period is controlled precisely by the ECM. The high pressure in the common rail ensures finely atomized fuel at the injectors for clean combustion and high power. Electronic control of injector opening time ensures optimum fuel economy and performance. Parts function presentation The figure of common rail system as shown:

3-24

Description & Operation ·Advantages: ·Overall optimized fuel spray. ·Improved combustion efficiency. ·Reduced emission. ·Reduced wall impingement. ·Reduced thermal loading. ·Chinese Emission Standard IV.

S163035

WARNINGS: Do not work on any part of the fuel system when the engine is running. Diesel fuel is

1

Rail pressure sensor

delivered under extreme pressure in the fuel

2

Fuel pressure control valve

pipes from the injection pump to the injectors.

System properties:

This may be as high as 1600 bar. Use extreme caution when inspecting for leaks as fuel under

- Electronically controlled fuel metering unit.

that pressure can penetrate skin causing injury or

- Flexible injection pressure control range: 250 Pa to

death therefore any with fuel spray must

1600 Pa.

be avoided. Inspect for fuel leaks using thick card.

Wear

safety

goggles

and

adequate

- Injection pressure control independent from engine

protective clothing when serving the fuel system.

speed and load.

Do not smoke or allow open flame of any type

- Injection control.

when working on or near any fuel related components. Fuel vapor can ignite and cause

3 stages Pilot injection/Main injection/Post injection Advantages: - High pressure management independent from engine rpm and load.

damage and/or personal injury. ·Fuel filter: Fuel filter is used to remove solid impurities, such as ferric oxides and dusts in the fuel, so as to prevent blockage of fuel system (especially the injectors).In this

- Improved combustion efficiency - Improved emission control - Overall advantage of fuel consumption.

case, the mechanical wear can be reduced to ensure a stable and reliable engine operation. ·Fuel pump: The fuel pump draws fuel from the tank and delivers

- Pilot injection

it into the fuel pipes after pressurized to build a certain

- Gradual heat release

fuel pressure with the fuel pressure regulator. The fuel pump delivers high pressure fuel to distribution pipes to

- Significant noise reduction

ensure a continuous fuel supply to injectors.

- Improved cold starting - Simple operating system ·Injectors: Vertical direct injection, located at center of valve .

3-25

Description & Operation Air intake & Exhaust System Illustrations Layout of exhaust system

1

2

3

4

1

Catalytic converter

2

Exhaust silencer front pipe

3

Exhaust silencer assembly

3-26

4

Exhaust tail pipe assembly

Description & Operation Description

vacuum pump on the engine front and the EGR vacuum

Overview

regulator on the body.

The component parts picking up air and mixture gas into the engine cylinders are assembled as the engine air

Exhaust System: The exhaust system is composed of a series of steel

intake system.

components. The exhaust pipe front contains a DOC

The component parts discharging exhaust gas out of the engine cylinders are assembled as the engine exhaust system. Air intake & breathing system:

(Diesel

Oxidation

Catalytic

Converter)

which

is

connected with engine exhaust manifold with 3 bolts and 1 shim. In the front of DOC there is an exhaust pipe carrier to fix its front section onto the engine. At the tail of the exhaust pipe front assembly there is a hook to

The air intake & breathing system is composed of air

connect the body floor via a rubber hook. The silencer is

flow sensor, air filter, turbocharger, intercooler, PCV

connected with the exhaust pipe front assembly with a

valve, EGR vale and breathing pipes, etc.

clamp. At each side of the tail there is a hook to connect

Air enters through the air filter and the air pipe to the turbocharger. Then the high temperature & pressure air is forced through the intercooler and the air pipe to the air intake pipe. The air filter consists of upper/lower seals, filter element and bottom/side gaiters to provide the engine with clean air.

the body floor via a rubber hook. Exhaust tail pipe (LWB or SWB) is also connected with the silencer with a clamp. At the tail there is also a hook to connect the body floor via a rubber hook. The basis of a catalytic converter is a ceramic honeycomb structure coated with catalytic material which includes valuable metals such as platinum or palladium. The catalytic converter converts nitrogen oxide, carbon

The intercooler aims at cooling down the high

monoxide and hydrocarbons into the less dangerous

temperature/pressure air forced by the turbocharger to

nitrogen, carbon dioxide and water. A catalytic converter

prevent any knocking due to fuel precombustion. In

only works efficiently at high temperatures, and the

addition, the cooling operation for the inlet air can

reason it is located close to the engine is so it can benefit

increase air density and charging efficiency on the

from the engine's diffused heat.

purpose of improved engine power and reduced emission.

The exhaust silencer is installed with baffles and noise absorbing devices. On the one hand, through

PCV valve is installed on the cylinder upper head.

friction on noise absorbing devices such as glass fibers,

When the crankcase pressure is too high, it causes the

steel fibers and asbestos, the energy of exhaust gas is

diaphragm in the PCV valve to open against the spring,

decreased; on the other hand, after repeatedly

and allows crankcase ventilation to take place via the air

reflections, collisions, expansions in pipes of various

vent hose. It also separates the oil from the crankcase air

shapes and in the resonant cavity, the exhaust vibration

and returns it to the crankcase.

and noise are significantly reduced. After the treatment of

Air intake pipe is a kind of round aluminum component secured on the cylinder upper head with 4 studs and nuts. A shim is installed between the air intake pipe and the cylinder upper head for sealing purpose. Air

catalytic converter and exhaust silencer, the exhaust gas finally reaches the atmosphere. Function description of component parts: ·Throttle body:

intake pipe is installed with EGR and sealed with a shim.

The throttle body is the valve controlling the air

The digital control EGR valve accurately controls the

intake of the engine. The throttle body is basically divided

exhausted air entering into the air intake pipe to control

into three parts: The actuator, throttle blade and throttle

the cylinder temperature and NOX emissions. The

position sensor which are usually encapsulated as an

vacuum required by EGR valve is controlled by the

integral.

3-27

Description & Operation ·Air filter: It is a device to remove particle impurities in the air. The air filter consists of filter element and filter housing. The correct air filter should have high filter efficiency, low flow resistance and a long service time. ·Silencer: The silencer is a component to prevent sound transmission and to allow air flow which is essential to remove air power noise. ·Catalytic converter It is the most important outer purifier installed in the exhaust system which can convert discharged CO, HC and NOx and other harmful gas into harmless CO2 and H2O by oxidation and reduction.

3-28

Description & Operation Operation principle: See the figure below for air intake & exhaust system operation principle.

1 3 4

2

5

10 8 9 6

7 1

PCV diaphragm

2

Spring

3

Positive Crankcase Ventilation (PCV) valve

4

valve

Intake air vent hose

5

Hose

6

Turbocharger

7

Air hose

8

Air filter

9

Hose

10 Intercooler

Air enters through the air filter (8) and clean air hose (7) to the turbocharger (6).From the turbocharger it is forced via hose (9) to the intercooler (10), and from there into the engine air intake pipe via hose (5). Engine breathing is controlled by the Positive Crankcase Ventilation (PCV) valve (3) fitted to the cylinder upper head. When pressure builds up in the crankcase it causes the diaphragm (1) in the valve to open against a spring (2), and allows crankcase ventilation to take place via the intake air vent hose (4).Any oil in the crankcase air which reaches the PCV valve is separated out and returns to the crankcase.

3-29

Description & Operation Transmission Illustrations Sectional view of transmission

3-30

Description & Operation Description

transmitted to the driven shaft via the engagement

Overview

between the drive shaft reverse gear (integrated with the

The transmission is used to alter engine torque and engine speed to satisfy different requirements for driving wheel traction and road speed in different driving conditions, such as starting, accelerating, driving and overcoming various obstacles.

drive shaft) and the driven shaft reverse gear and to the transmission shaft via the engagement between the driven shaft final drive gear and the differential final drive driven gear and finally to the wheel for reverse operation. Note that the rotation of the drive shaft reverse gear is different from 1/2/3/4/5 gear.

V80 manual transmission (HTX-PVH) is a 5MT which allows a maximum transmitted torque of 330N.m.

Gear selector control

This 5MT is designed special for Front-engine Front-drive

When 1st gear speed output is required, shift the

(FF) vehicle. This transmission has 6 gears, namely 1st

gear lever to the "1st" position and the torque will be

gear, 2nd gear, 3rd gear, 4th gear, 5th gear and the

transmitted to the gear selection assembly via cables.

reverse gear. The 1st and 2nd are low speed gears,

The selection rocker pulls the gear selector shaft out

suitable for engine start or driving on rugged mountains

through the torque rotation of cables and the gear

or steep slopes. The 3rd and 4th are intermediated

selector shifting block on the shaft will move out

speed gears, suitable for driving on relatively smooth

accordingly to the groove position on 1/2 gear fork. At this

urban roads. The 5th is the top speed gear, suitable for

moment, the selector shifting block should be separated

driving on motorways and in good road conditions.

from the groove of 3/4 gear shifting block. One foot of the Interlock ring seizes the 3/4 and 5/R gear fork groove, the

Transmission box

other foot fully separates from the 1/2 gear fork groove.

The transmission box contains input shafts which

Then the selection rocker drives the rotation of gear

transmit the engine power to the powertrain. The

selector shaft through the cable torque. The gear selector

powertrain can alter the speed and rotation direction

shifting block rotates with the selector shaft and its one

through gear engagement between the drive shaft and

side initiates 1/2 gear fork to drive 1/2 gear synchromesh

driven shaft to generate five different forward gears and

for gear selection. The selections on other gears are

one reverse gear.

similar.

The powertrain transmits the power to the differential via the final drive driven gear and then to output via LH

Reverse block control The reverse block is used to: prevent direct shift

and RH drive shafts.

from 5th gear to the reverse gear. Control principle:

Power transmission

When 5th gear is selected, the reverse gear fork on the

When 1st gear is selected, the 1st synchromesh gear ring of the drive shaft will engage with 1st gear ring via the synchromesh sleeve. While due to the rolling bearing, other gears will not rotate and the input power will be transmitted to the driven shaft via the gear engagement between the drive shaft and the driven shaft and to the transmission shaft via the engagement between the driven shaft final drive gear and differential final drive driven gear and finally to the wheel. The transmission principles of 2nd, 3rd, 4th and 5th gears are similar to this and will not be discussed in detail. When the reverse gear is selected, the driven shaft

reverse block pushes one foot against the exterior of the reverse block washer (the torsion spring is producing torques); when 5th gear is shifted into, the foot releases from the exterior of the reverse block washer and returns to normal with the torques provided by the torsion spring (the foot has entered into the other side of the reverse block washer); when attempting a direct shift from 5th gear to the reverse gear, the other foot of the reverse gear fork will tend to rotate accordingly due to the rotation alternation, however, it will no longer rotate as soon as it hit the edge of the reverse block washer so as to prevent reverse gear engaging initiated by the gear selector shifting block..

reverse synchromesh gear ring will engage with the driven shaft reverse gear ring. The power will be

3-31

Description & Operation Power interruption When the release rocker is at free state, the clutch drive plate s tightly with engine flywheel and the power is transmitted to the transmission via the input shaft. As the release rocker rotates, the release fork is driven to force the release bearing axially moves against the diaphragm spring of the clutch disc so that the drive plate is separated from the flywheel and there is no power transmission through the input shaft, resulting in transmission operation interruption.

3-32

Description & Operation Clutch Illustrations Layout of clutch pedal and master cylinder

4

6

2 1

3

5

1

Clutch disc

4

Master cylinder

2

Drive plate

5

Slave cylinder and release mechanism

3

Release bearing

6

Clutch pedal

3-33

Description & Operation Description Overview Clutch

is

a

powertrain

component

directly

connecting with the engine and its function is to: ensure a stable combination or temporary separation between the engine power and the driving units and a reliable engine torque transmission for correct starting, parking or gear changing operations. V80 uses a push-type dry diaphragm spring clutch ( ￠258mm) which is equipped with hydraulic clutch release mechanism. It is powered by two sealing systems - pre-filled master cylinder and slave cylinder. The clutch does not need any adjustment if worn. The clutch is composed of clutch drive plate assembly, clutch disc assembly, release bearing and release fork, etc. Function description of component parts: ·Flywheel: The flywheel stores partial power transmitted to the crankshaft at the power stroke to overcome resistance at other strokes, in order to drive crank link mechanism to travel over the top dead centre (TDC) and the bottom dead centre (BDC), ensuring that the crank angular velocity and torque are as even as possible, and making it possible for the engine to overcome a short period overload.

The

flywheel

transmits

power

to

the

transmission via the clutch. There are 6 threaded holes on the flywheel to position the disc into place.

3-34

Description & Operation Drive Shaft Illustrations Layout of drive shaft

1 2

3

5 4

21

1

Retaining nut

4

Drive shaft (RH)

2

Hub washer

5

Bearing plate

3

Drive shaft (LH)

3-35

Description & Operation Exploded diagram of drive shaft

1 3 5 4 8

7 6 2

4 7 3

1

Left drive shaft

5

Tripod universal t (LH)

2

Right drive shaft

6

Tripod universal t (RH)

3

CV t

7

Tripod universal t gaiter

4

CV t gaiter

3-36

Description & Operation Description V80 model uses drive shafts with an equal length to transmit the power from the transaxle to drive wheels. The drive shaft consists of 2 permanent universal ts, 1 moveable universal t and 1 intermediate shaft. External CV ball t is composed of ball shell, retainer, starlike inner race and steel ball, etc. The starlink inner race splines are connected with the drive shaft. There are six grooves on the external surface for inner race and relevant grooves on the ball shell internal surface for outer race. Six steel balls run in each groove at the same plane sustained by the retainer. The three tripod universal ts are at the same plane as 120o. Their axes intersect at a certain point on the output shaft.

3-37

Description & Operation Front suspension Illustrations Layout of front suspension

1

1

2

3

3 4

4

1

Front strut and spring assembly

2

Front suspension anti roll bar

3

Anti roll bar link assembly

3-38

4

Control arm sub assembly

Description & Operation Exploded diagram of front suspension

1

3

2

4 6

5

1

Anti-roll bar

4

Anti-roll bar link

2

Anti-roll bar clamp

5

Control arm assembly

3

Clamp bush

6

Control arm rear pivot

3-39

Description & Operation Exploded diagram of front shock absorber

3

4

5

2

6

1

7

2

1

Strut sub assembly

5

Bump stop

2

Bolt spring

6

Bearing

3

Gaiter front spring retaining ring

7

Shock absorber

4

Upper spring seat assembly

3-40

Description & Operation Description Overview

Screw spring: Screw spring is a kind of buffer elements. When the

The suspension is the connection mechanism

impact force from the road to the wheel transmits to the

assembly between the frame (or the body) and wheel

screw spring; the spring will be deformed to absorb and

axle (or the wheel).Its function is to transmit the wheel

transform the wheel KE to spring's energy of position

force and torque applied by road to the frame (or the

which will effectively reduce the affect by the impact force

body) to ensure a normal driving.

from the road to the body.

V80 is equipped with a Mahersan independent

Front anti-roll bar:

front suspension which is composed of the spring and

When the body swaps, the suspension on two sides

the shock absorber assembly with race ball bearing at

will have different deformation. While the anti-roll bar will

the top. The lower part of the strut is installed on the

act as a lever to uniform the spring deformations on both

knuckle with a lower ball t. The ball t is connected

sides as close as possible, so as to reduce body sway

with the lower control arm on the large rubber bush, able

and vibration and to increase driving stability.

to rotating upward and downward on the sub-frame. This system consists of spring elements, shock absorber and guide mechanism, etc. The front suspension is composed of screw spring, front strut, bearing and upper spring seat, etc. and is connected with the body and the knuckle. Anti-roll bar, anti-roll bar link and control bar components are connected with the knuckle. Function description of component parts: ·Front shock absorber: To change the disturbing forces of vibration source and system transmission properties so as to achieve vibration reduction. See the exploded diagram of the front shock absorber.

3-41

Description & Operation Rear suspension Illustrations Layout of rear suspension

3 1

2 4 5

6 7

8 9 CS220000 1

Rear steel leaf spring assembly

6

Rear spring upper cover

2

Rear shock absorber assembly

7

Rear axle assembly

3

Rear steel leaf spring bump stop

8

Rear shock absorber to rear axle bolt

4

Rear suspension bump stop bolt

9

Rear steel leaf spring U bolt to rear axle nut

5

Rear steel leaf spring U bolt

3-42

Description & Operation Exploded diagram of rear suspension

11

7

10 8

8 7

3 3

9

6 5

1

13

12 2 4

CS220001 1

Rear steel leaf spring assembly

8

Rear steel leaf spring U bolt

2

Rear steel leaf spring eye rear bush

9

Rear steel leaf spring upper cover

3

Rear steel leaf spring eye front bush

10 Rear suspension bump stop attaching bolt

4

Rear steel leaf spring shackle assembly

11 Rear steel leaf spring bump stop

5

Rear steel leaf spring shackle bush

12 Rear steel leaf spring U bolt to rear axle nut

6

Steel leaf spring shackle cover

13 Rear steel leaf spring front attaching bolt

7

Rear steel leaf spring shackle nut

3-43

Description & Operation Exploded diagram of rear damper

2 1

3

4

1

Bolt (rear suspension shock absorber to body)

3

Shock absorber assembly

2

Nut (rear suspension shock absorber to body)

4

Bolt (rear shock absorber to rear axle)

3-44

Description & Operation Description Overview V80 uses transversal leaf spring dependant suspension. The leaf spring is a two-stage taper leaf spring with a spring span of 1450mm. It is composed of two leaf springs, the middle of which is fixed on the axle with two 'U' bolts. The leaf spring and front bracket are connected by the front spring eye using bolts; while the leaf spring and rear bracket are connected by the rear spring eye using lifting eyes. Function description of component parts: ·Rear leaf spring assembly: The leaf spring is the most widely used spring element for vehicle suspension. It is a kind of spring beam made up of several alloy spring pieces with the same width and different length (thickness can be the same or not) and its rigidity is almost the same as the individual piece.

3-45

Description & Operation Steering Illustrations Layout of steering column and power steering

6 8 1 9 2

3 7

5

4 CS210000 1

Steering wheel

6

Steering fluid reservoir

2

Steering column

7

Steering oil pipe assembly

3

Steering intermediate shaft

8

Fluid reservoir to steering pump oil pickup pipe

4

Steering gear assembly

9

Steering oil pump

5

Steering oil reservoir assembly

3-46

Description & Operation Exploded diagram of steering column

1

2

4

3

5

4

1

Steering column

4

Pinch bolt

2

Nut

5

Coupling shaft

3

Screw

3-47

Description & Operation Exploded diagram of power steering

3 2 4 6

1

2 5

3 4

4

5

1

Steering gear assembly

4

Gaiter assembly

2

Steering tie rod inner ball t

5

Steering tie rod outer ball t

3

Lock nut

3-48

Description & Operation Layout of power steering hydraulic system

1 2

4

3 5 4

6 7

8 9 9

1

Anti-roll bar clamping bracket

4

Anti-roll bar link

2

Anti-roll bar rubber bush

5

Steering gear assembly

3

Anti-roll bar

6

Sub-frame assembly

3-49

Description & Operation Description Steering is the dedicated system to alter driving directions. Power steering is equipped with additional hydraulic servo to the original mechanical steering. The hydraulic power steering includes steering wheel, steering column, power steering gear, steering oil pump, oil reservoir and oil galleries, etc. The outer t is connected with the knuckle. The toe out can be adjusted by slackening steering gear lock nut and turning steering tie rod. This model is equipped with front-wheel steering and pinion & rack hydraulic power steering gear. The steering wheel is constructed with metallic framework coated with foamed plastic; the diameter is 380mm. Steering gear ratio is 47mm/r; rack travel is 168mm. The power steering pump is mounted externally on the engine and is driven by the front end auxiliary drive (FEAD) belt. Each side of the steering tie rod includes two components. The outer rods (with ball ts) are a fixed length, and tracking adjustment is made at the inner rods, which must be adjusted to an equal length.

3-50

Description & Operation Brakes system Illustrations Layout of brake hydraulic system

3-51

Description & Operation Exploded diagram of front brakes

1

2 3

13

4

12

5

6

3 11

10

9 8 7

1

Brake caliper

8

Guide pin bush

2

Brake slipper

9

Guide pin

3

Piston

10 Pin gaiter

4

Rectangle seal

11 Pin shaft bolt

5

Piston gaiter

12 Bleed screw head

6

Setting pin

13 Bleed screw

7



3-52

Description & Operation Exploded diagram of rear brakes

1 3 2

4

15

5 6 7

14

8 10

9

13

11 12

1

Guide pin

9

Guide pin rubber bush

2

Bleed screw head

10

3

Bleed screw

11 Guide pin gaiter

4

Brake caliper

12 Brake slipper snap spring

5

Rectangle seal

13 Brake slipper

6

Piston

14 Mud flap

7

Piston gaiter

15 Bolt

8

Guide pin gaiter

3-53

Description & Operation Layout of handbrake system

1 11

10

9

8

7

3

4

2 5 6

12

1

Handbrake rear cable assembly

7

Handbrake cable tensioner

2

Handbrake rear cable conduit

8

Handbrake front cable

3

Handbrake adjuster

9

Handbrake adjusting nut

4

Rear brake shoes

10 Handbrake lever assembly

5

Rear brake drum tensioner

11 Handbrake warning switch

6

Rear brake plate assembly

12 Rear shaft power bumper

3-54

Description & Operation Control chart of brake system

8

1

1

7 6

2

2

5

9

3 4

1

Front ABS sensor

6

Ignition power fuse 27 (5A) - Cabin fuse box

2

Rear ABS sensor

7

3

Instrument cluster

Battery fuse 5 (40A) - Engine compartment fuse box

4

Diagnostic connector

8

Battery fuse 8 (50A) - Engine compartment fuse box

5

Brake light switch

9

DSC adjuster

3-55

Description & Operation · When braking is applied, ABS will not perform an

Description

anti-lock brake pressure adjustment until the

Overview

controlled wheel is to be locked. If the controlled

The brakes consist of all brake and deceleration

wheel is not to be locked, this brake operation will

systems installed on the vehicle to decelerate or stop the

be exactly same with the normal brake operations.

driving car or keep the parked vehicle motionless. · V80 brake system applies brake calipers (disc

ABS is equipped with self-diagnosis functions which are able to monitor the system operation

brakes, with floating calipers) at both the front and the

state and shut down ABS automatically if a fault

rear. Handbrake is equipped with brake drum which is

which has an effect on the system normal

combined with the rear brake. The former is hydraulic

operation is detected and illuminate ABS warning

controlled, while the latter is mechanically controlled by

light to send a driving warning signal. However,

handbrake cables. The front & rear hydraulic brake

this brake system can still perform the same brake

actuating mechanism is composed of brake pedal, push

operations as normal brake systems.

rod, vacuum servo, fluid reservoir, brake wheel cylinder ABS usage:

and pipes, etc.

·

The brake system consists of brakes and brake controls. The brakes generates the brake effect; the brake

actuating

mechanism

controls

the

brakes

operation; the front & rear brake calipers axially moves relatively to brake disc through connection with knuckle and rear axle with bolts. The brake caliper is equipped with oil cylinder only on the internal of cylinder disc and the external brake slipper is attached only to the caliper. When braking is applied, hydraulic oil flows into the brake cylinder through the inlet to drive the piston and the attached slipper moving to left and pressing on the brake disc and even making the cylinder and the caliper moving along the guide pin to right until the friction block on the left of brake disc also presses on and holds the disc to

When braking on the road with low adhesion coefficient, brake pedal should be applied to the end.

· The vehicle can be stopped at a shortest brake distance. ·

When braking is applied, high direction stability can still be ensured.

Operation principle of ABS: ABS monitors and effectively controls the braking state via its controls and continuously adjusts the braking force in the braking system, so as to build a most suitable condition for wheels to ensure an outstanding antisideslip ability, a shortest brake distance and an excellent driving safety.

make a brake operation. When braking is applied, the

CAUTION

brake pedal is pressed and the master cylinder piston

· In addition to the scheduled brake fluid change,

moves after the powering supplied by the servo to pump

periodic inspection of brake components is

the brake fluid out of the master cylinder and piped into

recommended. As the vehicle ages, and as a

front and rear wheel cylinders to shift the wheel pistons.

precaution against the effects of wear and

When braking is released, the brake pedal is released

deterioration, it is necessary to make a more

and the wheel cylinder piston returns with the return

searching

spring to release the braking operation.

necessary.

ABS：

inspection

and

renew

parts

as

· Use the recommended brake fluid.

ABS is usually composed of wheel speed sensor,

· Never leave fluid in unsealed containers. They can

brake pressure adjuster, electronic controls and ABS

rapidly absorb water in the air, so it is dangerous

warning lights. ABS is featured in following aspects:

to use them in the brake system.

· ABS will not perform an anti-lock brake pressure adjustment until vehicle speed is over a specified value (e.g. 5km/h or 8km/h).

3-56

Description & Operation · Fluid drained from the system or used for bleeding must not be re-used, and must be disposed of in an approved manner. Advices · Disc brake pads, drum brake linings, hoses and pipes should be examined at intervals no greater than those laid down in Scheduled Maintenance. · It is recommended that all flexible hoses should be renewed every 4 years or at the Scheduled Service nearest to 160, 000 miles (whichever occurs first).At the same time all hydraulic components should be thoroughly checked for leaks, damage etc., and new parts fitted where necessary.

3-57

Description & Operation Windows Control chart of window regulator

1

1

3

2

4

5

6

1

Electric window switch

4

Relay

2

Cabin electrical box

5

Electric window regulator of front left door

3

Battery

6

Electric window regulator of front right door

3-58

Description & Operation Description Overview Most electric windows consist of motor, speed reducer, guide rope, guide plate and glass mounting bracket. The windows are used for day lighting, transparency, separation and ventilation. Driver's master control switch assembly can control all electric window motors. Electric window switch is controlled by control unit of multiplex control system. Function description of component parts: Speed reducer: It is an enclosed actuator between prime motor and working machine, which is used to reduce rotational speed

and

increase

torque

to

meet

working

requirements.

3-59

Description & Operation Wiper and Washer Illustrations Layout of wiper and washer

3-60

Description & Operation Control chart of wiper and washe

1

2

3

4

7

8

5 6

1

Wiper motor

5

Ignition switch

2

Connector of wiper motor

6

Cabin fuse box

3

Wiping / washing rod switch

7

Engine compartment fuse

4

Front window washer pump

8

Body control unit (BCM)

3-61

Description & Operation Description

·

High speed wipe When the switch is on and locked in high speed

Overview Wiper of vehicle windscreen is to remove fog, frost,

position, the wiper will wipe continuously with high speed.

rain, snow, dust, dirt and other stains on the windscreen,

When the switch is moved to stop position, the wiper will

providing the driver with clear view to ensure safe driving.

come back to stop automatically.

Wiper and washer system starts to work after BCM

·

Intermittent wipe

receives command from the driver. All functions of wiper

Intermittent wipe function is controlled by BCM and

are controlled by multi-functional wiper rod switch

when the switch is in intermittent position, BCM will

installed on driver's right side.

measure the position of corresponding rotary switch and

Wiper and washer system includes:

vehicle speed position and timer corresponding to the vehicle speed. When BCM timer reaches to latency,

- Wiper motor - Wiper link mechanism - Two wiper arms and blades - Two washer jets - Washer and washer pump

wiper will operate one complete wipe with low speed and stops in stop position. Then BCM will start the timer for another selected latency before starting wiper again. ·

Intermittent delay adjustment If a long latency is selected for intermittent functions,

it will be applied in the next wipe operation. If a shorter one is selected, then wipe operation will be carried out

- Wiping and washing rod Functions of wiper are available when ignition switch is in 'IGN' position. Functions of wiper Wiper system s: - Inching wash and wipe - Low speed wipe - High speed wipe - Intermittent wipe - Intermittent delay adjustment ·

Inching wash and wipe When non-self-locking switch is pressed down

650ms above, washer pump will immediately jet out water to front window until washer switch released and front wiper will start to work at the same time. Wiper will operate three complete wipes with low speed until motor stops. ·

Low speed wipe When the switch is on and locked in low speed

position, the wiper will wipe continuously with low speed. When the switch is moved to stop position, the wiper will come back to stop automatically.

3-62

immediately after this selection. Four intervals are available for this switch.

Description & Operation Exterior mirror Illustrations Layout of exterior mirror

3-63

Description & Operation Control chart of exterior mirror

1

2

4 3

1

Cabin fuse box

3

Right exterior mirror

2

Driver door module (DDM)

4

Left exterior mirror

3-64

Description & Operation Description

When exterior mirror has reached to max

All models are equipped with exterior mirrors,

adjustment position in certain axial direction, a sliding

among which minibus Standard, kombi and van are

clutch mechanism can protect exterior mirror. Housing,

equipped with manual exterior mirrors and minibus

mirror ring, base plate, , shield, rotate

Luxury is equipped with heated electric exterior mirror

pivot, glass regulator, direction indicator etc are non-

while minibus Standard can be equipped with heated

maintenance parts and must be changed as assembly.

electric exterior mirror as option. Right-hand drive vehicle

Only main glass and auxiliary glass are repairable parts.

is equipped with electric exterior mirror. Every kind of

When disassembling main and auxiliary glasses,

exterior mirror only has leather-like part and integrates

slightly press the glass until one side tilting up and pry it

with direction indicator. Electric exterior mirror is

off glass regulator. Glass of heated electric exterior mirror

controlled by a four-direction switch on front door at

can be heated electrically to prevent fogging. Heater

driver's side and two left / right select switch. The heating

band is glued behind the glass and starts to work with

function of heated electric exterior mirror is controlled by combination switch on centre console. The mirror surface

normal operation temperature of 70 ℃ when ignition switch is in 'IGN' position. Two terminals on the heater

angle of manual exterior mirror can be adjusted manually

band can connect the heater band and door harness and

and direction indicator is controlled by BCM through

when disassembling glass, harness connector should be

switch on steering wheel.

pulled out of the terminal.

Every kind of exterior mirror is manually assembled

Exterior mirror housing can be manually folded

with same basic construction: main glass, auxiliary glass,

inward or outward to let the vehicle narrow area.

housing, mirror ring, base plate, , shield, rotate pivot, glass regulator, direction indicator etc,

Main and auxiliary glasses can be adjusted 8° upward, downward, leftward or rightward and electric mirror can

among which, main glass of heated electric exterior

be adjusted by a four-direction switch on the front side

mirror has heater band.

door and two left / right select switches.

There are three bolts fixed on every exterior mirror and when assembling, the three bolts the holes on inside and outside metal plates of the front side door and secure the on front side door with three nuts. These nuts can be assembled and removed after removing interior trim of inside plate of front side door. Exterior mirror housing is secured on the base plate with four screws and the base plate is installed on the by rotate pivot. This rotate pivot allows exterior mirror to rotate in two directions and to be folded manually or folded in any direction when obstructed. Exterior mirror housing is a molded plastic part, in which main and auxiliary glass regulators (main glass regulator has electric adjustment and manual adjustment while auxiliary only has manual adjustment) and main and auxiliary glasses. Mirror ring is installed on the mirror housing for sealing and decoration.

3-65

Description & Operation Seat Layout Layout of vehicle seats

Malaysia LWB Standard 12 Seater A085

C

F

LWB Standard 12 Seater A085

LWB Luxury 9 Seater A094

A

K

L

L

K

K

L

L

K

F

A

C

LWB VAN 12 Seater A066

C

A

C

SWB VAN 2 Seater A062

A

C

H

A

F

LWB VAN 5 Seater A065

C

A I

F

Seat Descnption A: 8-direction adjustable driver seat with armrest C: Front enger seat with armrest F: Rear row dual seat without armrest,non-adjustable backrest H: Rear row foldable three-person seat without armrest I : Rear row foldable three-person seat for Kombi without armrest J: Front row dual seat without armrest K: Rear row three-person seat with armrest,adjustable backrest L: Rear row wide single enger seat with armrest

South Africa SWB VAN 3 Seater

J

A

LWB VAN 3 Seater

J

LWB Standard 13 Seater

A

J

LWB Standard 17 Seater

A K K

F

3-66

F

C

A

N

L

L

K

L

L

J N

LWB Luxury 9 Seater

A

E

D

F

F

H

Description & Operation Function description of seats above is as the following: Name

Basic functions of seat Initial backres t angle

A 8- direction adjustable driver's seat

18°

Headrest

Armrest

Adjustment angle of backrest Forward

○

○

15°

Other functions

Backward

55°

Angle adjustment mechanism is single side locking; Cushion inclination can go up or down forward or backward and headrest can be adjusted for height. Single side armrest is added on right side

C Front singleenger seat

18°

○

○

15°

55°

Angle adjustment mechanism is single side locking; Headrest can be adjusted for height and single side armrest is added on right side

F Rear backrest unadjustable dual-enger seat

18°

○

-

-

-

Headrest can be adjusted for height

-

Backrest can be folded forward and headrest can be adjusted for height without armrest. Integral backrest and cushion.

H: Rear foldable threeenger seat

18°

○

-

-

I: Rear foldable threeenger seat (Logistics)

18°

○

-

-

-

Backrest can be folded forward and headrest can be adjusted for height without armrest. Integral backrest and cushion.

J: Front dualenger seat

13°/ 18°

○

-

-

-

Headrest can be adjusted for height

22°

Headrest can be adjusted for height and single side armrest is added on right side. Segregate backrest and integral cushion.

22°

Headrest can be adjusted for height and armrests are installed on both sides. Fixed points of seat belt are arranged on the seat.

K: Rear backrest adjustable threeenger seat L: Rear singleenger wide seat

18°

18°

○

○

○

○

15°

15°

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Description & Operation Description Overview V80 has many types of vehicle seats and the material has cotton flannel and knitted fabric.

·"Rear backrest unadjustable single-enger seat Cushion inclination is 7° and initial backrest angle is 18°;Headrest can be adjusted for height with three levels.

Function description of component parts: ·Driver's seat is 8-direction manual adjustable seat Initial backrest angle is 18°. Backrest angle can be adjusted 15° forward or 55° backward. Angle adjustment mechanism is single side locking and headrest can be adjusted for height. Cushion inclination is 7° and can go up or down forward or backward. Seat can be moved forward or backward. There is a fixed point of seat belt on right side. ·"Front single-enger seat Cushion inclination is 7° and initial backrest angle is 18°; Backrest angle can be adjusted 15° forward or 55° backward. Angle adjustment mechanism is single side locking. Headrest can be adjusted for height with three levels. There is a fixed point of seat belt on left side. ·"Rear backrest adjustable dual-enger seat Cushion inclination is 7° and initial backrest angle is 18°;Backrest angle can be adjusted 15° forward or 22° backward. Angle adjustment mechanism is single side locking. Headrest can be adjusted for height with

·"Rear foldable three-enger seat Seat backrest angle is 18°;Backrest can be folded forward and headrest can be adjusted for height without armrest. Fixed points of seat belt are arranged on the seat. Segregate backrest and integral cushion. ·"Front dual-enger seat Cushion inclination is 7° and initial backrest angle is 13°/ 18°;Headrest can be adjusted for height without armrest. Two fixed points of seat belt of seat next to the door are on B post. Segregate backrest and integral cushion. ·"Rear backrest adjustable three-enger seat Cushion inclination is 7° and initial backrest angle is 18°;Backrest angle can be adjusted 15° forward or 22° backward; Headrest can be adjusted for height with three levels. Segregate backrest and integral cushion. ·"Rear backrest unadjustable dual-enger seat Cushion inclination is 7° and initial backrest angle

three levels. Segregate backrest and integral cushion.

is 15°;Headrest can be adjusted for height with three levels. Segregate backrest and integral cushion.

·"Rear backrest adjustable single-enger seat

·"Rear single-enger wide seat

Cushion inclination is 7° and initial backrest angle

Initial angle of seat backrest is 18°;Backrest angle

is 18°;Backrest angle can be adjusted 15° forward or

can be adjusted 15° forward or 55° backward; Headrest can be adjusted for height with three levels.

22° backward. Angle adjustment mechanism is single side locking. Headrest can be adjusted for height with

Armrests are installed on both sides. Fixed points of seat

three levels. ·"Rear backrest unadjustable dual-enger seat Cushion inclination is 7° and initial backrest angle is 15°;Headrest can be adjusted for height without armrest. Segregate backrest and integral cushion.

3-68

belt are arranged on the seat.

Description & Operation Illumination Illustrations Layout of external illumination

1 2 3

5

4

6

8 9 10 11 7

1

Front direction indicator

7

Reflectors

2

Main beam and dipped beam

8

Brake lamp and position lamp

3

Position lamp

9

Rear direction indicator

4

Front fog light

10 Reverse light

5

Center high mount stop lamp (CHMSL)

11 Rear fog light

6

Rear number plate light

3-69

Description & Operation Layout of internal illumination

3

2

1

1

Step well light

2

Front roof internal vanity light

3-70

3

Rear roof internal vanity light

Description & Operation Description External illumination: Many external illumination and signal devices installed on the vehicle can provide vehicle with good view to ensure safety driving at night, in tunnel or foggy days.

·"Reflector It can reflect the light from external light source. Internal illumination Vehicle internal lights consist of front roof internal vanity light and rear roof internal vanity light and they are primarily used for internal illumination.

The system consists of external illumination devices and external signal devices. External illumination devices are: Headlamp, front fog light and number plate light etc. External signal devices are: Rear fog light, brake lamp, parking light, direction indicator tell-tale and reflector etc. ·Headlamps They are also called headlights and installed on both sides of vehicle head, illuminating the road when driving at night. Light color is white or yellow. ·Front fog light Fog light is used to make the vehicle visible to other vehicles during foggy days or rainy days when visibility is significantly affected. Light color is white or yellow. ·Number plate light Number plate light is used to illuminate rear number plate at night. Usually bulb is used as number plate light and the light color is white. ·"Rear fog light Rear fog light is used to indicate the existence of the vehicle to s of other road behind the vehicle. It is installed in the lower rear of vehicle and the light color is red. ·"Brake lamp Brake lamps are used to indicate the vehicle is slowing down or braking to s of other road behind the vehicle. They are installed on both sides of vehicle rear. The light source shall be striking red light that can be recognized clearly in day or at night to prevent rear-end collision.

3-71

Description & Operation Instruments Illustrations Layout of instrument cluster

3-72

Description & Operation Description Overview: The vehicle instrument system is driven by

Driving mode of pointe

Stepping motor

electronic stepping motor and consists of speedometer,

Speed gear ratio

2360 pulses / km (Option 2320 pulses / km)

Pulse number

4 pulses / turn

Signal source

Sensors

Response time of pointer

3 to 4 seconds

tachometer, fuel gauge, thermometer, alarm icons, dotarray LCD clock, sub-total, grand total and tyre pressure information.

·LCD display LCD interface displays clock, subtotal and grand F E

20

total of mileage (hereinafter referred as main interface),

3

80 100 60 120 140 40

2

4

1

5

160 180

0

0

km/h

H

6 1000r/mmin

c

Function description of component parts: ·"Speedometer

60 40

80 100 120 140

20

160 180

0 km/h

Basic requirements of speedometer Pointer indication range

0 ～ 180km/h

Minimum division value

10km/h

Speed gear ratio

1：590 （Option 1:580）

Type of input signal

Square wave (collector）

High level

Instrument power voltage

Max. low level

1V

Signal duty cycle (%)

30% ～ 70%

3-73

Description & Operation tyre pressure, temperature and tyre pressure alarm and LCD display mode is switched by buttons.

grand total remain unchanged and clock times. c. Subtotal displays o and grand remains unchanged after battery ignition switch disconnected and reconnected. Clock displays 12：00. format is 24-hour.

- Main interface - Tyre pressure interface a. Normal tyre pressure

·Tachometer

b. Normal temperature - LCD display overview

3 2

LCD display

LCD

Operating temperature

-30 ℃～ + ６ 5 ℃

LCD presentation mode

White on black

LCD driving mode

Driven by microprocessor

LCD display mode

Negative

LCD backlight

White

LCD display format

Dot array

4

1 0

5 6 1000r/mmin

Basic requirements of tachometer - Mileage range Parameters

Subtotal mileage

Grand total mileage

Indication range

0 ～ 1999.9km

0 ～ 999999km

Display digits

4 digits

6 digits

Min. display unit

0.1km

1km

Display leading

N/A

N/A

NOTE: Subtotal mileage: Subtotal mileage automatically returns to zero after reaching max reading (1999.9km). Grand total mileage: Grand total mileage remains unchanged after adding up to max reading (999999km). - Requirements of LCD work mode: a. LCD lights on after battery reconnected and reignited. b. LCD does not display after ignition off when battery connected. Subtotal and

3-74

Pointer indication range

0 ～ 6000r/min

Alarm range

4000 ～ 6000 r/min

Max. low level

1V

Minimum division value

500r/min

Driving mode of pointer

Stepping motor

Response time of pointer

3 to 4 seconds

Signal source

ECM

Output pulse of sensor (signal source)

2 pulses

Min. high level

8V

Signal duty cycle (%)

３ 0% ～７ 0%

Max. rotational speed

6000rpm

total and then Time

Description & Operation ·Fuel gauge

Data and indication angle of fuel gauge

F E

Indication point

Input resistance (Ω)

Indication error (°)

Indication angle (°)

E

300

-5 ～ 0

0

Alarm

265.6

-3 ～ +3

13

1/4

246.5

-3 ～ +3

26

1/2

170

-3 ～ +3

52

3/4

93.5

-4 ～ +4

78

F

40

-5 ～ +5

104

·Temperature gauge Basic requirements of fuel gauge Pointer indication range

E～F

Minimum division value

1/8(E ～ F)

Singal source

Fuel sensor

Input resistance range

300 Ω～ 40 Ω

Driving mode of pointer

Fuel sensor Stepping motor

Response time of pointer

See notes for detail

H c

NOTE: Response time of pointer: (1) IGN OFF ─ > ON :Response time: The time required for pointer moving from initial position to 90% of total scale is 3 seconds max. (2) IGN ON (no speed):Response time: Fuel gauge pointer 1s/1°. (3) IGN ON (with speed):Response time: Fuel gauge pointer 30s/1°. (4) IGN OFF: Pointer back to stop position.

Basic requirements of thermometer Pointer indication range

C～H

Minimum division value

1/8 of total radian

Max. low level

1V

Driving mode of pointer

Stepping motor

Signal source

ECM

Input PWM range

2% ～ 96%

PWM frequency

50Hz

Response time of pointer

See notes for detail

·Low fuel level alarm In the direction where resistance increases, resistance of fuel sensor ≥ 265.6 Ω , alarm indicator on; In the direction where resistance reduces,resistance of fuel sensor ≤ 260.6 Ω , alarm indicator off;

3-75

Description & Operation NOTE: Response time of pointer: (1) IGN OFF ─ > ON :Response time: The time required for pointer moving from initial position to 90% of total scale is 3 seconds max. (2)

IGN

ON

(vehicle

driving):Response

time:

Thermometer pointer 0.5s/1°. (3) IGN OFF: Pointer back to stop position. Data and indication angle of thermometer Indicatio n point

tempera ture ℃

Duty cycle 1) (%)

Indicatio n error

Indicatio n angle

(°)

(°)

C

50

５

0

0

1/4

70

20.7

-3 ～ +3

26

1/2

80

42

-3 ～ +3

52

3/4

90

53.2

-3 ～ +3

78

Alarm (red sector)

115

85.4

-3 ～ +3

91

H

120

93.4

-3 ～ +3

104

1) Duty cycle - high level is valid. If water temperature equal to or below 50 ℃ , the pointer stays at point C . If water temperature equal to or above 120 ℃, the pointer stays at point H ·High water temperature alarm In the direction where water increases, duty cycle of water temperature ≥ 85.4％, alarm indicator on; In the direction where water reduces, duty cycle of water temperature ≤ 69％, alarm indicator off; NOTE: Temperature of high water temperature alarm sensor sent to ECM shall be identified based on summer test and temperature range of water temperature sensor is from -40 ℃ to 140 ℃ . Duty cycle above shall prevail temporarily as the vehicle manufacturer cannot provide.

3-76

Description & Operation ·"Alarm requirements of bleeper Sound pressure level (SPL): (at 2048Hz, 12Vp-p, Square wave) : > 98 ± 3 dB Frequency：:2048Hz Alarm type

Sound condition

Connection mode of port

Sound mode

Ignition key in switch alarm / headlamp on alarm

Alarm signal BCM sent to instrument =ON (low level signal is valid) (Note: These two alarm signals are controlled by BCM and outputted by the same pin）

Battery =ON Signal port of alarm sound =ON (low level signal is valid)

Continuous alarm ( External BCM signal 1) Headlamp on alarm: with ignition switch switching from KL.15 to OFF, BCM instructs bleeper to sound alarm when dipped beam switch turned on. 2) Key in switch alarm: 1. key turns to OFF with driver side door open. 2. When key stays in any position of ignition switch, bleeper sounds alarm with RKE locking or driver's side key locking. Bleeper sounds with the cycle of 3S audible alarm and 1.5S stop)

Seat belt alarm

1. When speed >0 and seat belt unfastened (seat belt signal =OFF), bleeper sounds. 2. During driving: When the state of seat belt switch changes, above judgment condition is to be initiated again. 3. When speed =0, seat belt =ON or =OFF, bleeper turns off.

Battery = ON Ignition = ON Seat belt signal = OFF (lights on by earthling)

Continues alarm (constant sound)

Danger warning alarm

Danger warning signal (left and right turn =ON)

Battery = ON Ignition = OFF Left turn = ON

Continuous alarm Bleeper frequency 1600HZ_6ms_800HZ_8ms (325ms on, 325ms off (1.54HZ).This value can not be changed through diagnostic apparatus.) (Whether to ignite is controlled by BCM)

right turn ＝ ON Left and right turn alarm

Left turn =ON or right turn =ON

Battery = ON Ignition = ON Left turn = ON (right turn =ON)

TMPS bleeper critical alarm

Tyre fast air leakage alarm, low pressure alarm, high pressure alarm, high temperature alarm

Battery = ON Ignition = ON Tyre pressure = ON (normal input)

TMPS bleeper warning alarm

Low sensor battery, malfunction of TPMS system

Battery = ON Ignition = ON Tyre pressure = ON (normal input)

Continuous alarm Bleeper frequency 1600HZ _6ms_800HZ_8ms (When direction indicator works, it flashes with frequency of 75 flashes per minute (1.25HZ), but it is default value and can be changed by diagnostic apparatus. Frequency set by diagnostic apparatus will be observed to flash after change.

3-77

Description & Operation Priority order 1） Danger warning alarm 2） TPMS critical alarm 3） TPMS warning alarm 4） Driver's seat belt untied alarm 5） Left and right turn audible indication 6） Ignition key in switch alarm ·Requirements of tyre pressure TPMS pressure sensors are directly installed on the hub of each tyre and suitable for tyres without inner tube. The sensor can detect tyre pressure and temperature and transmit the data to receiver through wireless radio frequency. Receiver judges pressure and temperature values from sensor and low / high tyre pressure alarm or high tyre pressure alarm occurs, corresponding TPMS warning lights on. can switch display mode to TPMS normal display mode by button on instrument to display current tyre pressure or temperature on LCD at real time (alternative display). - Normal interface that displays tyre pressure is as below: - Normal interface that displays tyre temperature is as below: If the tyre is not learned, in information frame sent by TPMS to the instrument, high four-digit of tyre position means whether corresponding tyre position has been learned, if not, high four-digit is 0000 and instrument displays "ns" for corresponding tyre position and follow-up information does not need to be handled; If high four-digit is 1111, it means the tyre has been learned and the instrument needs to handle information of corresponding tyre. If high four-digit is 0000 in one piece of tyre position information, corresponding position displays "NS" and "wait for learning" beside.

3-78

Description & Operation ·"Illumination and alarm indicators Illumination and alarm indicators list No.

Function

1

Color

Control mode

Left turn

Green

Lights on when connected with battery +

2

Right left

Green

Lights on when connected with battery +

3

Main beam

Blue

Lights on when connected with battery +

4

Front fog light

Green

Lights on when connected with battery +

5

Rear fog light

Yellow

Lights on when connected with battery +

6

Low fuel level warning

Yellow

Controlled by SCM

7

High engine cooling water temperature warning

Red

Controlled by SCM

8

Water in fuel warning

Yellow

Lights on by earthing

9

Low oil pressure warning

Red

Lights on by earthing

Red

Lights on by earthing

10

Brake System Warning

Icon

11

Power system fault warning

Yellow

Lights on by earthing

12

OBD

Yellow

Lights on by earthing

Yellow

Lights on when connected with power supply + or untouched and off when connected with low level

13

ABS fault warning

3-79

Description & Operation

14

Airbag fault warning

Red

Lights on by earthing

15

Seat belt warning

Red

Lights on by earthing

16

Cruise control indicator

Green

Lights on by earthing

17

TPMS warning

Yellow

Controlled by SCM

18

Glow plug indicator

Yellow

Lights on by earthing

19

Door open warning

Red

Lights on by earthing

20

Alternator charging warning

Red

Lights on by earthing, exciting current 300mA

21

IMMO warning

Yellow

Lights on by earthing

22

Transmission box fault warning

Yellow

Lights on by earthing

23

ESP fault warning

Yellow

Lights on by earthing

24

Trailer light fault warning

Green

Lights on by earthing

Red

Lights on when connected with power supply + or untouched and off when connected with low level

25

EBD

ESP

EBD

Signal requirements of alarm indicator: High level within ９ V-16V and low level within 00.05V.

3-80

Description & Operation Immobiliser system Illustrations Immobiliser system layout

6 7

9

8

5

4 1

2

1. Information display

6. Keys

2. Instrument Cluster

7. Reader coil

4. Starter motor

8. Engine management system (ECM)

5. Horn

9. Body control module (BCM)

3-81

Description & Operation Control chart of immobilizer system

2 1

7 8 3

6 4

5

1

Reader coil

5

Diagnostic connection

2

Keys

6

Engine control module (ECM)

3

Ignition switch

7

Starter motor

4

Instrument cluster

8

Body control unit (BCM)

3-82

Description & Operation Description Overview Targeted to engine security directly, immobiliser system combines keys, electronic immobiliser, and engine control unit into an organized security system through perfect security strategy, greatly enhancing the overall vehicle safety. This immobilizer system is equipped with combined ECM and aerial installed on ignition switch core. Immobiliser system only accepts programmed ignition keys. If invalid key is used, start system

and

engine

management

system

are

unavailable. Immobiliser system consists of immobiliser, coil and transmitter. Covering the ignition switch core, the coil is connected to immobiliser by wiring. Transmitter is mounted in the handle of key. Operation principle Non- radio sensing technology is used for transmission, calculation and certification. Function description of component parts: ·Keys: The keys are primarily for activating the engine's immobiliser and starting systems, but will also lock / unlock the driver's door and rear door. Use of a key in either of these doors will lock/unlock that door only. The keys will also lock/unlock the fuel filler cap. ·Plip: control part of central door locking system used to lock / unlock all vehicle doors . ·Plip learning Refer to instructions of diagnostic apparatus. ·Immobiliser system matching Refer to instructions of diagnostic apparatus.

3-83

Description & Operation Body control unit Illustrations Layout of body control unit

1 3

4

2

5

1

Body control module (BCM)

4

Connector

2

Connector

5

Connector

3

Connector

3-84

Description & Operation Control chart of body control unit

1

2

9 3 10

4

8

5

6

7

1

Cabin fuse

7

Rear right door lock

2

Engine compartment fuse

8

Rear left door lock

3

Central door locking switch

9

Load space lid lock

4

Wireless remote controlled receiver

10 Body control unit (BCM)

5

Front enger side door lock

6

Driver side door lock

3-85

Description & Operation Rear Courtesy Roof Lamp

Z

BCM

$ Z

$

IP08-4 IP07-11 IP08-1 IP07-5

$ $ $

Batt

Z Timed Relay

Z

Tailgate Lock Relay Tailgate Unlock Relay

Power manage

IP08-11

５Ｖ

Lock Relay

Output relay IP05-1

control signal RKE Circuit

Unlock Relay

Station

Tailgate Solenoid

IP07-4

0

IP07-3

Left Sliding Door enger Door Driver Door Right Sliding Door

IP08-3

0

IP08-10

Relaydrive Dipped Beam Lamps

OUT IMMO DATA IMMO DATA SCK

Switch circuit

IP05-40 IP05-32

ECM

$

IP08-2

RH55w

K line drive

Batt

$

5 /LQH

IP06-5

Vehicle speed signal Engine running status

$

IP05-14 IP05-37

Security Lamp

Right Sliding Door Open Status SW Left Sliding Door Open Status SW Tailgate Open Status SW Front enger Door Status SW

Batt

IP06-3 $

High side signal

IP08-5 Front Fog Switch

/('

IP06-26

Batt HRW&Heater Mirror

KEY DriverDoor Open Status Switch

RH 55w

Front Fog Light

IP05-21 IP05-22 IP05-2

$

LH 55w

IGN

IP05-17

SRS

Batt

LH 55w

IP05-39

Diagnosis

IPK

0

0

0 $

Matching IP05-18 IP05-19

IP07-6

$

IP05-7 IP05-4 IP05-15 IP05-9 IP05-33 IP05-34 IP05-13

Low side output

MCU

Low side drive circuit

Alarm

$

IP06-16

Batt LH60w



$ Main Beam Lamps Relay $

RH60w



IP05-12

Side

Main Bean Lamps



Fault

)73 /R +,

IP05-24 IP05-10

FTP Beam

Signal manage

Batt

IP06-2 Batt

IP06-17

Low side signal

RH Front 5W

$

NO.Plate Lamps 5W

Position Lamps RH

LH 5W Rear 5W

IP05-29

$

Rear Fog Light Switch LH DI Switch RH DI Switch Hazard Warning Switch

IP05-31 IP05-11

IP08-9

IP05-30

IP06-12

Rear 5W

Audible Waming IPK Facial Illumination

Lock Status LED

Driver Door Key Unlock Switch

IP05-35

Driver Door Key Lock Switch

IP05-16

Rear Courtesy Lamp Switch

IP05-6

HRW&Heated Mirror Switch Master Lock Switch Lock Master Unlock Switch

Unlock

IP05-27 IP05-8 IP05-28

IP06-18

IGN

$

IGN

Front Wiper

Simulate signal





Batt

0

Front Wiper

High side output

Batt

0

Front Courtesy Roof Lamp

Washer Motor 2 )) ,17 /2: +,*

IGN

Map Lamp RH 5W

IP08-7

2 )) ,17 /2: +,*

Wiper SW

Ourtesy Roof Lamps

IP05-20

Map Lamp LH 5W Interval Front Wiper Delay

IP06-14 IP06-19

Fault

High side drive circuit

Footwell Lamps 5W

LH 21W

IP07-2

IGN Wash

IP05-23

Rear Fog Lamps

IP07-1

RH 21W Front 24W

RHDI Lamps Rear 21W

IP08-6

Side 5W

Front 24W

LHDI Lamps Rear 21W

Side 5W

3-86

Description & Operation Description Body control unit (BCM) is located behind glove box of front enger side. BCM is secured on cross-beam of instrument framework with two bolts and accessible after removing the glove box. BCM is in charge of a series of functions and communicates with other electronic monitoring element through K bus. BCM directly controls vehicle functions below: - Front / rear electric window; - Central door locking; - Wipers and washers; - Alarming and wireless receiving system; - Electric control air conditioning system; - Vehicle interior illumination; - Heated rear windows; - Power load management; - Flameout under unloading status; - Faults record and diagnosis

3-87

Description & Operation Vehicle entertainment system Illustrations Layout of vehicle entertainment system

4

2

1 3

7

6

9

8

5

1

DVD+ navigator (if fitted)

6

Rear right speaker

2

FM+MP3 player

7

GPS aerial (if fitted)

3

Instrument desk left side speaker

8

AM/FM aerial

4

Instrument desk right side speaker

9

Roof aerial connecting line assembly

5

Rear left speaker

3-88

Description & Operation

3-89

Description & Operation Control chart of vehicle entertainment system

1 2

6 3 4

5

1

Front speaker (left)

4

Rear speaker (right)

2

Front speaker (right)

5

Cabin fuse box

3

Rear speaker (left)

6

Radio (with MP3 function)

3-90

Description & Operation Description Two audio units are available for V80 to install. Standard feature is MP3 player with FM and AM radio functions and USB MP3 playing functions. Luxurious feature is GPS navigated MP5 player with GPS navigation function, FM and AM radio functions as well as streaming media functions of playing RM, RMVB, MPEG 1-4, avi, wmv and ASF format read by SD card and USB. Audio unit is located on central instrument with double DIN dimensions and body shortened. Depth is reduced to 70mm. A 16 - pin connector located under the unit provides various control signals required by audio input of power speaker. A separate aerial coaxial-cable socket located under the unit provides AM / FM signal. A 10A fuse protects against power overload. The system consists of: ICE system audio unit \ 4 speakers in the front, rear, left and right (2 coaxial speakers and 2 woofer speakers) \ overhead FM/AM aerial.

3-91

Description & Operation Parking distance control Illustrations Layout of parking sensor control system

1

2 3

4 5

1 PDC BCM 5 Jucket

3-92

4 PDC sensor

Description & Operation Control chart of parking sensor

1

2

2

3

2

4

2

1

Cabin fuse

3

Parking distance control BCM

2

Parking distance control sensor

4

Non-neutral start switch

3-93

Description & Operation Description Overview The full name of parking sensor is "reverse anticollision sensor" or "parking aids", consisting of ultrasonic sensor (nicknamed probe), controller and display (or bleeper). Function description of component parts: · Ultrasonic sensor: Transmit and receive ultrasonic signal and used to measure distance. · Host machine: Transmit sine wave pulse to ultrasonic sensor and handle received signal to calculate distance value before communicating the data to display. · Display or bleeper: Receive data from the host machine and display distance value based on distance and provide alarm sound for different level.

3-94

Description & Operation Seat belt Illustrations

3-95

Description & Operation Description Overview To ensure occupant security, seat belt, as one of

· 3-point emergency locking retractor (ELR) of enger seat Front dual seat and rear seat are equipped with 3-

restraint systems, can protect the occupants against high

point emergency locking retractor (ELR) seat belt as

deceleration during vehicle collision or overturn accident

standard feature. ELR seat belt has emergency locking

and restrain the occupants to avoid the second impact,

retractor mode. Generally, seat belt is in ELR mode for

playing an important role in reducing personal injury.

free activities of engers during non-emergency situations.

A seat belt pre-tensioner is fitted to the driver's side on this vehicle. Its purpose is to apply additional tension on the seat belt upon impact, and assist in holding the driver in the seat.

and retractor.

airbag. SRS BCM senses the impact and decides whether it is serious enough to deploy, and if so, times the deployment so that the pre-tensioner operates just

Function description of component parts: · Belt Refers to the flexible belt that can restrain occupant and force to fixed points of seat belt in seat belt assembly. · Buckle lock for

short,

refers

to

the

connection

mechanism that can not only restrain occupant in seat belt but also release quickly. · Guide part Refers to the part that is easy to arrange seat belt retractor and used to change the direction of belt to make the belt closely restrain the body effectively and improve the comfortability for occupants wearing seat belt. ·Retractor Refers to the device that used to retract and store part or all belt and plays specific role after adding some mechanism. · Seat belt pre-tensioner of front seat Seat belt pre-tensioner of front driver's seat is standard feature. It contains pyrotechnic retractor of mechanical control and will be triggered upon front collision or fore-end collision of certain angle to reduce looseness of seat belt. Seat belt pre-tensioner of front seat shall be replaced after triggered due to accident.

3-96

Electronic controlled pre-tensioner is controlled by SRS BCM that located under centre console beneath

This system consists of belt, buckle lock, guide part

Buckle

· Others

ahead of the air bag(s).

Description & Operation Airbag restraint system Illustrations Layout of airbag restraint system

3 1

4 2

1 Clock spring

3 Airbag BCM

3-97

Description & Operation Control chart of airbag restraint system

2

1

3

5

7 8 4

9

6

1

Front airbag module of front enger side

6

Ignition switch

2

Front airbag module of driver side

7

3

Rotary coupler

Restraint system warning light in instrument cluster

4

Cabin fuse

8

Diagnostic connector

5

Restraint system diagnostic and control unit (DCU)

9

Battery

3-98

Description & Operation Description Overview When the vehicle suffers front impact of adequate strength, supplementary restraint system (SRS) will be activated to protect the driver and front enger. Main circuit of SRS module senses the strength of impact force and ignites gas generator in the airbag assembly for gas charging when necessary to deploy airbag. If battery voltage is low or power supply is disconnected for collision, voltage regulator and spare supply circuit will keep constant voltage. The system consists of gas bag, gas generator, BCM and harness. Operation principle: BCM triggers gas generator after receiving trigger signal to release gas to fill up gas bag quickly. Under normal operation and storage conditions, the deployment of this vehicle airbag is controlled by SRS BCM located under centre console beneath airbag. If front collision occurs during normal vehicle driving, SRS BCM can detect collision information and decide whether it is serious enough to deploy airbag, and meanwhile, sends collision information to seat belt pre-tensioner of driver's seat for tension while deploying airbag. CAUTION: When collision occurs with collision surface angle beyond 30 degree of vehicle driving direction, airbag isn't sure to deploy.

3-99

Description & Operation Heating / Ventilation Illustrations Layout of heating and ventilation

2 4

1

1

2

3

5

1

Ventilation pipe assembly

4

Front defogging air duct

2

Side defogging air duct

5

Front heating control

3

Central ventilation grille assembly

3-100

Description & Operation Control chart of blower

1

2

3

4 6

7

5

A

1

Fresh / circulating air switch

5

Blower switch

2

Body control switch

6

Blower

3

Fresh / circulating air servo motor

7

Blower relay R5

4

Resistor assembly

3-101

Description & Operation Description Overview Heating and ventilation system can control vehicle internal temperature and provide internal air distribution to the vehicle. This system consists of filter assembly, heater core assembly, distributing pipe, control , cool and warm door, servo motor and blower. Operation principle: Heating is to take advantage of the heat of engine cooling water and transfer the heat to the vehicle by heater core to keep comfortable temperature. Electric water valve controls hot water volume that enters into heating system to adjust temperature in vehicle. Operation principle chart of heating and ventilation system

Heat release

Heat absorption Heating device

Engine

M

Cab

3-102

Description & Operation Air conditioner Illustrations Layout of air conditioner refrigerating system

Evaporator (low temperature and pressure gas) (liquidˉˉgas), heat absorption Expansion valve (low temperature and pressure fog) ntermediate temperature and high pressure gas Drier

Condenser (gasˉˉliquid), heat rele

Low temperature and pressure gas

High temperature and pressure gas

Compressor

3-103

Description & Operation Control chart of compressor and fan

2

1

3 10

12

9 11

4 8

7

6 5

1

Temperature sensor of evaporator

7

AC compressor

2

Body control unit (BCM)

8

Clutch relay of AC compressor

3

Air conditioner switch (Electronic controlled air conditioning system)

9

Main relay

4

Relay fuse of cooling fan

5

Relay module of cooling fan

6

Cooling fan

3-104

10 Control of air conditioning system 11 ECM 12 Pressure sensor

Description & Operation Description Overview Air conditioning system could create a comfortable vehicle space with fresh air and comfortable temperature for driver and engers. As there is great disparity of temperature range between various areas, thus greater refrigerating capacity, heating capacity and ventilation volume are required for vehicle air conditioning system. Air conditioning system applied in this vehicle can refrigerate quickly and meet 's requirements. Air conditioning system consists of compressor, condenser, expansion valve, evaporator, receiver drier assembly and pipeline assembly. Operation principle The circulation of refrigerant can reduce air temperature and remove water vapor in air by absorbing the heat in air to realize temperature reduction and moisture preservation. Meanwhile, cold and warm air drawn in by air conditioning system can remove frost and fog on windscreen and side windows.

3-105

Description & Operation Operation principle chart of air conditioning

Gas High pressure and temperature Low temperature and pressure High temperature and pressure gas

Compressor

Gas

Compress

Condenser

Evaporator Evaporate

Condense

Heat absorption Liquid

Heat release

Expand

Expansion valve

Fluid (High-pressure)

1

After the vehicle started, compressor, driven by engine, starts to work and propel refrigerant (HFC-134a) circularly flows in sealed air conditioning system to compress gaseous refrigerant to refrigerant gas of high temperature and pressure before expelling the refrigerant.

2

After refrigerant gas of high temperature and pressure flows to condenser through pipelines, liquid refrigerant of intermediate temperature and high pressure flows out with heat release and temperature reduction in condenser. (Condense is a heat release process where vapor is cooled to temperature equal to or below its saturation temperature to change gas to liquid by releasing heat).

3

Liquid refrigerant of intermediate temperature and high pressure flows into receiver drier through pipeline for drying and filtration before flowing to expansion valve.

4

After liquid refrigerant of intermediate temperature and high pressure throttled by expansion valve, it will change its state quickly, becoming fog refrigerant of low temperature and pressure.

3-106

5

Fog refrigerant of low temperature and pressure comes into evaporator immediately to absorb air heat from evaporator, thus reducing air temperature and blowing out cool wind to realize refrigeration. Refrigerant evaporates into gaseous refrigerant of low temperature and pressure due to heat absorption. (In refrigeration technique, evaporation is a heat absorption process where liquid changes to gas under simmer state by absorbing outside heat).

6

Gaseous refrigerant of low temperature and pressure is drawn into compressor again for compressing and preparing next circulation. As long as compressor works continuously, refrigerant will circulate in air conditioning system to realize refrigeration. If compressor stops working, refrigerant will not flow anymore and no refrigeration available.

Description & Operation Function description of component parts: · Compressor: It can compress low temperature and pressure gas into high temperature and pressure gas. It is located between evaporator and condenser and driven by vehicle engine. · Condenser: It can change gaseous refrigerant into liquid refrigerant. It is located between compressor and receiver drier. · Receiver drier: It can store liquid refrigerant from condenser temporarily. It can filter foreign objects and absorb moisture in refrigerant. It is equipped with pressure switch for system protection and sight glass for maintenance. · Expansion valve: It is a flow restriction device that separates system high pressure side and low pressure side. High pressure liquid refrigerant changes into mixing fog of low pressure and temperature gas and liquid that can absorb heat after throttled. It can measure the quantity of liquid refrigerant that enters into evaporator by detecting the temperature of evaporator outlet and adjust inlet clearance depending on situations. It can adjust refrigerant flow automatically based on thermal load to ensure that the evaporator works safely and effectively. · Evaporator: It can absorb heat from external air to heat and evaporate refrigerant from expansion valve into low temperature and pressure gas. At this moment, air around evaporator is cooled and cool wind is obtained by blower. The gas is sent back to compressor again for next circulation and new cooling work.

3-107

Description & Operation

3-108

Tyre pressure detection system Tyre pressure detection system

Overview

System structure:

Tyre pressure monitor system (TPMS) can monitor tyre internal pressure, temperature, battery voltage, tyre information etc. at real time. It can raise alarm when vehicle tyre pressure and temperature is abnormal or sensor battery voltage is below certain value, monitor

Tyre pressure sensor 1

Tyre pressure sensor 2

Tyre pressure sensor 3

Tyre pressure sensor 4

and warn abnormal tyre situations and system faults TPMS receiver

such as slow air leakage (reaching specified value), fast

Data transmission through serial port

air leakage, perforation etc. and point out tyre fault location. Display pressure and temperature data

TPMS sensor is installed on each hub and suitable for tyres without inner tube to monitor air pressure and temperature of tyre or slow air leakage at real time before

Display section is transmitted to instrument through

sending a frame of corresponding data through wireless

serial port and when tyre pressure or temperature is

(433.92MHZ). It consists of pressure sensor, temperature

abnormal, alarm is to be raised with alarm icon ISO 2575

sensor, and acceleration sensor, MCU, RF transmitting

displayed on instrument . TPMS at real time collects

chip, battery, LF receiving circuit and aerial. The sensor

pressure, temperature, sensor battery voltage signal to

can receive 125kHz LF waking signal and transmitter

transmit to the receiver by wireless way before the

switches between sleep mode and work mode to reduce

receiver sending to instrument for display through

power consumption based on LF waking signal or

serial port (RS232) When sensor battery voltage is

acceleration sensor signal.

abnormal, receiver sends various alert data through serial port and instrument gives out audible and

TPMS receiver sends pressure, temperature, battery

visual alarms to warn the .

voltage from transmitter to instrument through RS232 and when tyre pressure or temperature is

Instrument display

abnormal, receiver sends various alert data through

The can switch between TPMS and other LCD

serial port to instrument for audible and visual

display with buttons on instrument . If TPMS detects

alarms to warn the .

system faults, TPMS alarm LED lamp on instrument

Operation principle TPMS at real time collects pressure, temperature, sensor

cluster lights on (ISO2575 alarm icon) and when critical alarm has occurred, LCD automatically switches to alarm mode for words alarm and bleeper audible alarm.

battery voltage signal to transmit to receiver by wireless way before the receiver sending to instrument for

Normal pressure or temperature display:

display through serial port (RS232). When pressure,

can switch display mode to TPMS normal display

temperature, or sensor battery voltage is abnormal,

mode by button on instrument to display current

receiver sends various alert data through serial port to

tyre pressure or temperature on LCD at real time

instrument for audible and visual alarms to warn

(alternative display).

the .

Tyre pressure warning alarm Low sensor battery, system failure, tyre high temperature; For tyre warning alarm, bleeper sounds with the cycle of 0.5 second audible alarm and 1 second stop until the annually press left button briefly to switch to alert mode. Instrument alarm indicator lights on until the alarm is disarmed, but LCD display still remains alarm display ( can short press left button to switch to other display

4-1

Tyre pressure detection system and if TPMS alarm is disarmed, it will automatically

below under TPMS display modes with corresponding

switch to TPMS alarm display after 20 seconds).

tyre flashing and TPMS warning indicator on.

Normal driving

Cycles with 0.5 second audible alarm and 1 second stop

Warning alarm status

LCD is alarm display and TPMS alarm indicator constant on

Alert mode

When alarms for various tyres have occurred at the same time, LCD is to be switched to various alarm interfaces in accordance with priority.

For tyre high temperature alarm when tyre temperature is above 80 ℃ , temperature sensor sends temperature information to TPMS receiver before TPMS sending alarm signal to instrument to switch to LCD display interface as below first with corresponding tyre flashing and TPMS warning indicator on.

As for sensor low battery alarm when sensor battery below threshold value, sensor is to give out low battery alarm

information

before

TPMS

sending

alarm

information to instrument for LCD display interface as below with corresponding tyre flashing and TPMS warning indicator on.

As for system failure alarm when remind system that reminds sensor lost fails, instrument LCD displays as

4-2

Tyre pressure detection system recommended tyre pressure value), pressure sensor is to

Tyre critical alarm

transmit pressure information to TPMS receiver before

When fast air leakage alarm, low voltage alarm, high pressure alarm, tyre ultra-high temperature alarm sound, it shows that the tyre has been in critical alarm mode and

TPMS sending alarm signal to instrument to switch to LCD display interface as below first with corresponding tyre flashing and TPMS warning indicator on.

necessary measures shall be taken to remove faults as there are hidden dangers if driving continued. When system is in critical alarm mode, bleeper is to sound with the cycle of 1 second audible alarm and 1 second stop until the annually press left button briefly to switch to alert mode. Instrument alarm indicator lights on until alarm disarmed, but LCD display still remains alarm display ( can short press left button to switch to other display and if TPMS alarm is disarmed, it will automatically switch to TPMS alarm display after 20 seconds).

As for low tyre pressure when tyre pressure is 25% below standard pressure value (manufacturer recommended tyre pressure value), pressure sensor transmits pressure information to TPMS receiver before TPMS sending alarm signal to instrument to switch to LCD display interface as below first with corresponding tyre flashing and TPMS warning indicator on.

Normal driving

Critical alarm

Cycles with 1 second audible alarm and 1 second stop

LCD is alarm display and TPMS alarm indicator constant on

Press left button Alert mode

For tyre ultra-high temperature alarm when tyre As for tyre fast air leakage alarm when tyre pressure changes beyond 10kPa in one minute, system is to

temperature is above 80 ℃ , temperature sensor sends temperature information to TPMS receiver before TPMS

immediately raise air leakage alarm and pressure sensor

sending alarm signal to instrument to switch to LCD

is to quickly send change signal to TPMS receiver before

display interface as below first with corresponding tyre

TPMS sending air leakage signal to instrument to switch

flashing and TPMS warning indicator on.

to LCD display interface as below first with corresponding tyre flashing and TPMS warning indicator on.

Signal transmission mode As for high tyre pressure when tyre pressure is 40% above

standard

pressure

value

(manufacturer

Pressure sensor sends pressure and temperature information to TPMS receiver by wireless radio

4-3

Tyre pressure detection system frequency. TPMS receiver sends to instrument by wiring harness for display with dot-array LCD.

Introduction of hand-held learning diagnostic tool

Function description of component parts: Sensor: collecting relative air pressure and temperature of tyre and sending with RF wireless.

1

3

8

6

PWR

pressure, temperature sensor battery. When tyre

ENT ESC

LF

with accuracy reaching up to ± 1 minute; Monitor tyre pressure; receive dada from sensors and display tyre

PWR

Tyre pressure monitor: can be used as electronic clock

pressure or temperature beyond limits (pressure too high or too low, temperature too high), the system sounds alarm with corresponding tyre position indicator flashing.

2

4 5

7

Meanwhile, pressure or temperature value is displayed.

Functions of hand-held learning diagnostic tool Hand-held learning diagnostic tool mainly activates sensor by transmitting LF (125kHz) signal of certain power and timing sequence before receiving sensor ID and current tyre temperature and pressure value to learn tyre

position

binding,

tyre

rotation

and

sensor

replacement as required. After activation, receiver store such sensor ID to tyre position that corresponds with the receiver to achieve several tyres' ID binding for the system to learn vehicle assembly, wheel change over

① LCD display ② LF transmission telltale, illuminated after activation function selected ③ Power light, constant on while battery low ④ ESC, escape from current menu command ⑤ ENTER, enter current menu command ⑥ up, menu selection

and sensor replacement.

⑦ down, menu selection

Major functions of hand-held learning diagnostic tool:

⑧ power off / on, turned on after pressing 5 seconds

· After all assembly finished, hand-held tool can be used to read every sensor ID installed in tyre to realize sensor and receiver binding. No programming button required on receiving controller; · Check pressure and temperature value of any tyre at any time; · Exchange tyre position and reset sensor without sensor removal; · Replace sensor separately for any tyre position and send sensor information to receiver for new correspondence. · Sensor activation, learning sensor binding, sensor delete, sensor change over and downstream function detection

4-4

Tyre pressure detection system 1、 Menu and button

2、 Learn binding

1、 Button definition

1

ESC:escape button. Press this button to escape from current menu and back to previous menu

Select main menu mode and press △ up button or ▽ down button to switch learn binding mode interface

Function display interface of learn binding is as below △ : Up button. Press this button to increase value ▽ : Down button. Press this button to reduce value and enter next interface. ENT: enter button. Press this button to enter next menu and confirm next menu

① Learning mode Front left Front right Rear left Rear right Back OK

PWR: power off / on, turned on after pressing 5 seconds

2、 Activation picture

2

Press ENT button to enter next menu and default select learning front left tyre binding or press up button or down button to switch between four tyres or switch to different positions for system learning binding

If front left tyre is selected for learning binding, function display interface is as below:

注：请将激活器对在气芯向外的轮胎壁上方 10cm

Front left learning

Front right learning

→ Front left

Front right

Front left

→ Front right

Rear left

Rear right

Rear left

Rear right

Back

Activate

Back

Activate

4-5

Tyre pressure detection system 3

Press ENT button to enter next menu and if activation of front left tyre is required, approach tyre pressure sensor and press activation button to wait until tyre ID and pressure and temperature information displayed within 10 seconds maximum. If data shown in the right figure below does not appear, reactivation is required. NOTE: Bleeper sounds three tick - tick - ticks after successful activation

3、 Delete mode 1

Select main menu mode and press △ up button or ▽ down button in main menu to switch to delete mode interface

Delete mode interface is as below

②Delete mode Front left Front right Front left learning ID ? Pr ? TR ? Back Learning

ID information updated after sensor activated

Rear left Back

Front left learning ID 3662512 Pr 250kPa Tr28 Back Learning

2 4

Press ENT button to let tyre start to learn binding of tyre pressure sensor ID. For example: If front left tyre is learned successfully, display is as below:

Rear right OK

Press ENT button to enter next menu and default select front left tyre position delete or press up button or down button to switch between four tyre positions or switch to different position for system delete

If front left tyre delete is selected, function display interface is as below

Front left learning Front left tyre learning OK Back Learning

Front left delete Front right

Front left →

Front right

Rear left

Rear right

Rear left

Rear right

Back

5

4-6

Observe such binding learning procedures for activation of other tyres and back to second step for reselection of tyre positions for learning binding after learning finished.

Front right delete

→ Front left

Delete

Back

Delete

Tyre pressure detection system 3

Press ENT button to enter next menu and if delete of front left tyre is required, press delete button

4、 Tyre change-over mode 1

Select main menu mode and press △ up button or ▽ down button in main menu to switch to tyre change-over mode interface

Tyre change-over mode interface is as below

Front left delete

Back

Completed OK

ĸChange over Front left

Front right

Rear left

Rear right

Back

OK

CAUTION:If certain tyre is to be deleted, the tyre should be activated first for hand-held tool to obtain current tyre ID, otherwise the sensor cannot be deleted. If front left tyre is not activated, ID cannot be received and

2

interface below is to appear when deleting front left tyre:

Press ENT button to enter next menu and default select front left and front right tyre change-over or press up button or down button to switch between four tyre positions or select two different tyre positions for exchange

If exchange between front left and front right tyres is selected, function display interface is as below

Front left delete Can not complete Back OK Front left and front right exchange → Front left → Front right Rear left Back

3

Front left and front right exchange → Front left Front right

Rear right

→ Rear left

Rear right

Exchange

Back

Exchange

Press ENT button to enter next menu and if exchange between front left and front right

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Tyre pressure detection system positions is required, press change-over button and display below is to appear

5、 Diagnostic test functions 1

Select main menu mode and press △ up button or ▽ down button in main menu to switch to diagnostic test mode

Diagnostic test function interface is as below

Front left and front right exchange Exchange successfully Back OK ĺ Diagnostic test mode Front left Front right Rear left Rear right Back OK CAUTION:If certain two tyres are to be exchanged, one of the tyres should be activated first for hand-held tool to obtain current tyre ID, otherwise the sensor position can not be exchanged. If front left tyre is not activated, ID cannot be received and

2

interface below is to appear when exchanging front left and front right tyres:

Press ENT button to enter next menu and default select diagnostic test of front left tyre or press up button or down button to switch between four tyre positions or switch to different positions for system diagnostic test

If diagnostic test of front left tyre is selected, function display interface is as below

Front left and front right exchange Can not exchange Back OK Front right test

Front left test → Front left

Front right

Front left → Front right

Rear left

Rear right

Rear left

Back

3

4-8

OK

Back

Rear right OK

After selecting relative position for test, press ENT button to enter next menu and if front left test is selected currently, press OK to enter selected position and select corresponding

Tyre pressure detection system alarm. If front left tyre is selected for simulation test, function display interface is as below

7

模拟测试传感器低电量报警功能

Press △ up button or ▽ down button to switch between several alarms of selected tyres, switchable alarms are: 1

Simulation test of low pressure alarm function

Front left test

2

Simulation test of fast air leakage alarm function

Tyre high pressure alarm

3

Simulation test of high pressure alarm function

4

Simulation test of high temperature alarm function

5

Simulation test of ultra-high temperature alarm function

6

Simulation test of sensor low battery alarm function

ENT

Front left test ʽTest finished

Back

OK

Front left test Tyre low pressure alarm Back OK

Front left test Tyre under-inflation alarm Back OK

Tyre high pressure alarm ESC

ENT

ESC

ENT

ESC

Back

OK

Front left test ʽTest finished Tyre low pressure alarm Back OK

Front left test ʽTest finished Tyre under-inflation alarm Back OK

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Tyre pressure detection system

Front left test

ENT

Tyre ultra-high temperature alarm Back OK

ESC

Front left test ʽTest finished Tyre ultra-high temperature alarm Back OK

Front left test

ENT

ʽTest finishe Fast air leakage alarm Back

Front left test

ENT

Front left test ʽTest finished

Tyre high temperature alarm Back

OK

Front left test

Tyre high temperature alarm ESC

ENT

Back

OK

Front left test ʽTest finished

Low battery alarm Back

4-10

OK

Low battery alarm ESC

Back

OK

Front left test

OK

Fast air leakage alarm ESC

Back

OK

Tyre pressure detection system 6、 Precautions 1

If a tyre is to be deleted, the tyre should be activated first for obtaining corresponding tyre ID before deleting the tyre under delete mode. If front right tyre is to be deleted, front right tyre should be activated under learning mode first to receive tyre ID before entering front right mode to delete front right tyre.

2

Never freely change the position of the tyre where sensor is installed or delete programmed sensor and if above operations are performed carelessly, the sensor should be reprogrammed under the guidance of instruction book or professional staff.

3

As multi-functional diagnostic test tool is supplied by battery, power supply of the tool should be turn off when not in use or charged in time when red light illuminates to show low system voltage.

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