1Vehicle Ele ctric Equipment Distributing Figure 2 2Figure Rea ding Description 3 3Connector Note 5 4Position of Front Engine Compartment Electric Equipment 7 5Position of Four Doors Electric Equipment 8 6Position of Instrume nt Electr ic Equipment9 7Position of Trunk Electric Equipment 10 8Starting and Charging System 11 9ECU System 13 10ABS System 22 11Airbag System 23 12Auto A/C System 24 13Manual A /C System 26 14Front ISU System 27 15Rear ISU System 33 16Instrument System 36 17Wiper System 37 18Power Re ar View Mirror System 38 19Power Window of Front Door & Pow er Door Lock System 39 20Electric S eat Syste m 40 21Seat Heater System 42 22Audio System 43 23Sun roof & Cigarette Lighte r System 44 24Circuit of the Front Engine Compartment Fuse Box 45 NoteThis circuit manual is based on 484model,if there are any incompatibilities please refer to the vehicle.

1

Figu re reading descript ion

1Instruction of Main Circuit Symbols

2Distribution of Various Earth points and Main Modules

Connector

Wi rin g jo in t

Gro und

G7 G4ABS

G11ECU

G5H eaterM otor Oxy gen Senso r

+

_

G9 G2 G8 G10 G3 G1 G6

Spir al Cable

Spea ker

E le ct rom agne tic co il

S w i tc h co nt ro l

R es is tan c e u n it

LE D

ZE10

3PIN Definition ExplanationS hi el dRelay

The PIN definition of the circuit theory diagramFor instance as follows:Ins trument ha rn ess and indoor ha rnessfro nt Co n nector de tailed exp lication Co n nector de tailed exp lication PIN de tailed e xplication Co n nector na me

F U SF 7 10A

F us e p o siti on a n d sp e ci fi ca tion

Ignition Coil

Brak e Sw itch

Co nnectorD8 D7 D6 C8 B8 D5 C7 B7 A5 D4 C6 B6 A4 C5 B5 D3 C4 B4 A3 D2 C3 B3 A2 D1 C2 B2 A1 C1 B1

30 5 7 75 15 50Ignition s witch C i garette Lighte r

C 12 C 11 C 10 C 9 B1 2 B11 B1 0 B9MSta rte r

A8

A7

A6

IP 1

_

+

To IP A/5 indicates to #5 PIN of plug A of IP Module To ECU5 indicatesto #5 PIN of ECU

Noz zle

Bu lb

Ba tter y

3

Figu re reading descript ion

1Instruction of Main Circuit Symbols

2Distribution of Various Earth points and Main Modules

Connector

Wi rin g jo in t

Gro und

G7 G4ABS

G11ECU

G5H eaterM otor Oxy gen Senso r

+

_

G9 G2 G8 G10 G3 G1 G6

Spir al Cable

Spea ker

E le ct rom agne tic co il

S w i tc h co nt ro l

R es is tan c e u n it

LE D

ZE10

3PIN Definition ExplanationS hi el dRelay

The PIN definition of the circuit theory diagramFor instance as follows:Ins trument ha rn ess and indoor ha rnessfro nt Co n nector de tailed exp lication Co n nector de tailed exp lication PIN de tailed e xplication Co n nector na me

F U SF 7 10A

F us e p o siti on a n d sp e ci fi ca tion

Ignition Coil

Brak e Sw itch

Co nnectorD8 D7 D6 C8 B8 D5 C7 B7 A5 D4 C6 B6 A4 C5 B5 D3 C4 B4 A3 D2 C3 B3 A2 D1 C2 B2 A1 C1 B1

30 5 7 75 15 50Ignition s witch C i garette Lighte r

C 12 C 11 C 10 C 9 B1 2 B11 B1 0 B9MSta rte r

A8

A7

A6

IP 1

_

+

To IP A/5 indicates to #5 PIN of plug A of IP Module To ECU5 indicatesto #5 PIN of ECU

Noz zle

Bu lb

Ba tter y

3

4. Number o f main c ircuit bo ard

31: Ground Wire

7. Notes to connector terminals for front and rear ISU Front ISU PE1 is port A, PE2 is port B, PP3 is port C,PP4 is port D, PP5 is port E, PP6 is port F. Rear ISU PE1 is port A, PP3 is port B, PP5 is port C, PP6 is port D.

9.Note This circuit diagram is mainly designed to provide reference for model 2.0/1.6 automatic basic configuration type.As limited time is likely to give rise to international.LR

4

}

with in relay box 30From the battery 15Ignition Switch IGN ACC1: Ignition Switch ACC ( To Mainly Provide The Air-Conditioning System With Power ACC2: Ignition Switch ACCTo Provide The Wiper System, Cigarette Light, and External Power Supply Socket With Power ILLUM: Luminous Power Line

30 15 ACC1 ACC2 31 ILLUM9 9

6 . Groun d points on the v ehicle ( actual l ines sha ll prevail). 1st. Negative of the battery 7th pin. Near the left rear speaker 2nd. Near the right combination headlamp 8th. Near the left pillar A 3nd. Engine hood Ground 9th pin. Near the handbrake 4th. Near the ABS 10th. Near the clutch 5th. Near the steering column 11th#. Near the front right speaker 6th. Near the rear seat belt 8. The colors of the wire are as follow:LH MRR OR RH M IR ROR LH M IR ROR

B 8

5Fuse Numb er The f use numbe r within th e front com partment relay box is exp ressed by FB +numberandSB+ number. FB +numberis small fu se SB +numberis big fuse

FB2 7.5A L19 7 0 1

LEFT RIGHT

LEF T RIGHT

DOWN

UP DOWN UP

Power Rear View Mirror Switch

RH MIRRO R

B=B lack W=W hite6 R Elec tric equipments pow er/circuit power supply

4 To F ron t ISU P P3 16# W/B

2 LGFront Ground /Front Left /13

5 R

3 R

G=G reen R=R ed V=Violet Y=Yellow P=Pi nk Br=B rown

Front Gr ound/ Fron Lef t t/ 15 Front Gr ound/ Front Right /14

Actuator /control signal

Front G round/Front Ri ght / 15 Front Ground/ Front Right /13 Front G round/Front Left 1/ 14 Front Ground/ Front Left /14

Gr=G rey O=O range Lg=L ight G reen Sb=L ivid

Sensor/feedback signal

10. Not es to plu g-in un itM MRear Right View MirrorLR

MUD

MUD

R ear Left View Mi rror

9

For example: Front ground/front Left/13 means the No.13 terminal for front ground harness and front Left compartment harness connectors. (Perform lookup according to the notes to connectors)

Connector NotePin

Engine control unit pin descriptionConnect point Oxygen se nsor heat ing Ignition co il 2 Ignition co il to groun d Oxygen se nsor heat ing Ignition co il 1 Injection n ozzle 4(th e 2nd cyli nder) Injection n ozzle 2 (t he 3rd cyli nder) Engine sp eed Coolant te mperatur e Fuel cons umption Trouble in dicator Persisten t power Ignition sw itch Main relay Engine sp eed senso r A Pedal acc elerator position sen sor Sensor gr ound 1 Upper oxy gen senso r Knock sen sor A Knock sen sor B Brake lam p Accelerat ing sensor Pin 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 Injection n ozzle 1(th e 1st cylin der) 68 69 70 71 EOBD ins pect lamp 5V power 2 5V power 1 Engine sp eed senso r (B) Sensor gr ound 3 Sensor gr ound 2 Air flow se nsor Electric th rottle pos ition Engine c oolant t em per ature s ensor Accelera te pedal po sition sen sor A/C pres sure 72 73 74 75 76 77 78 79 80 81 Ant i-theft equ ipment Clu tch switch A/C switch Pow er turn sw itch Headlamp sw itch Sen sor groun d Pha se sensor Pow er ground 2 CAN commun ication Connect point Inle t temperature Non- Persiste nt power Non- Persiste nt power Canister purg e valve Inje ction nozz le 3 (the 4 th cylinde r) 1 2 3 481 80 79 78 77 76 75 74 73 72 71 70 69 68 676 6 656 4 63

ECU plug-in unit

1 3 4

262 61 60 59 58 57 56 55 54 53 52 51 50 49 484 7 464 5 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 292 8 272 6 25

5 6 7 8 9 10 11 12 13 14

524 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6

Fan control 1 Ele ctric groun d 2 Ele ctric groun d 1 Ele ctric thrott le position Low er oxygen sensor

1 3 4

2

81 62

63 44 25 6

15 16 17 18 19 20 21 22 23 24 25 26

5

43 24

Bra ke switch Veh icle speed signal Mid -pressure switch Pow er ground 1 CAN commun ication Non-continua nce powe r Ele ctric thrott le control Ele ctric thrott le control Ele ctric thrott le control Ele ctric thrott le control Cooling fan A/C relay Fue l pump relay Dia gnose K w ire

ECU and I nstrument Har ness Plug-In UnitH 7 6 5 4 16 15 14 13 12 S 3 2 A 1 J

A H 1 3 4 5 6 7 9 10 11 12 13 14 15 J S

27 28 29 30 31 32

ECU/A1

ECU/A2

Engine and Front Ground Harness Plug-In Unit

33 34 35 36

A 1 9 J 2 3 4 10 11 1 2 5 6 7 8 13 14 15 16

H

37 38 39 40 41

S

EC U/Front G round

5

ABS plug-in unit3030 31 32 18 3 44 29 45 4618 29

Front G round and Ro of Harness Plug-I n Unit31 32 44 45 46

Front Groun d and F ront Right Door Harness Plug-InH A 1 9 J

A H

B G

C F

D

7 6 5 4 16 15 1 4 1 3 12 S

3 2 11 10

1

2

15

16

171 2 3 15 16 17

Front Ground/R oof

Front G round/ Fron t Right Door

Front G round and Re ar Ground Harness Plug-In U nit

Instrument and Front Ground Harness Plug-In UnitAA H B G C D 1 9 2 10 3 11 4 12 5 13 6 14 7 15

H

D0 8 D8 D7 D6 D5 C1 2 C12 C11 C10 C9 C8 C7 B1 2 B12 B11 B10 B9 B8 B7 A8 A 7 A6 A5 A8

D4 D3 C6 C5 C4 B6 B5 B 4 A4 A 3

D 2 D1 C3 C 2 C 1 B3 B 2 B1 A2 A1

D1 C1 B1 A1

A 1 9 J

2

H 3 4 5 6 7 8 11 12 13 14 15 16 S

Fro nt/Rear

J

Fro nt/Rear

S

Fro nt Gr ound/Instrument

Front Ground/ Instr um ent

Front G round and Front Left Door Harness Plug-In Unit

Instrument and Air Conditioner Plug-In Unit

A 1 9 J 2 10 3 11 4 12 5 13 6 14 8

H

A 1 2 3 11 4 12 5 13 6 14 7 15 8 16

H

S Fr ont G round/Left 1

J Front Gr ound/ Left 2

S

1

2 10

3 11

4 12

5

6

7 14

8 15

Inst rument/Air C onditioner

Rear Ground and Rea r Left Door H arness Plug-In Unit

Rear Ground and Rear Right Door Harness Plug-In Unit

Front Ground and Front Engine Compartment Har ness Plug-In U nit8 7 10 4 3 6 9 2 4 5 8 7 10 3 6 9 2 5

A 1 8 H

2 9

3 10

4 11

5 12

6 13

G 7 14 P

F ront Ground /Front Engi ne Compartment Rear Gr ound/ Rear L eft Rear Grou nd/ Rear Ri ght

6

P osition of front engine com partme nt electric equ ipmentWiper Mot or

A/C high/low pressure switch Fuel injector High pressu re wire Cam sha ft p osi ti on se nso r Ig nition coil

Knock sensor

Only for 2.0L engine

Coolant temperatur e sensor

Air flow m eter

Position of wiper motor

Positive of powerFront e ngine compar t ment electric equipment box

Negat ive of po wer

Front left he ad lamp

Positive fus e box

Tur n Light: 12V 5W F/R high beam Head lamp High Be am:12 V 55 W Gene rator Electric throttle Front rig ht headlam p

Side Light: 12 V 5W F/ R low beam Headlamp Lower Beam:12V 55W Fan con trol module Batte ry

7

Posi tion of Four D oors Electric Equipm ent

F/L door wind ow regul ator assemb ly

R/L door win dow reg ulator as sembly

F/R door win dow reg ulator as sembly

Fron t left do or Front right do or

Rear left do or

Rear right doo r

Fro nt left do or lock

R ea r left do or lock

R/R door w indow r egulator assemb ly

Rear righ t door l ock

Front right do or lock

8

Position of instrument electric equipment

Co mbination instrument Electr ic rear view m irror

Horn switc h

Key hole illuminat ion lamp

Mirror for m ake up

Re ar window heating Switch

Warn ing lamp switch A ssem bly

Front fo g lamp Swi tch

R ear fog lamp Switch

F ront passen ger side airb ag

Ce nter control button

Audio System

ECUEMSEngine

Tr unk Switch

Hea dlamp Night lamp adjustin g Switch adjustin g switch

The frontwards and backward s sliding dynamoto r

A/C Control panel assembly

C wire plug 20

E powe r D wire plug 12 F gr ound

The upward s and downwards adj usting dynamotor of the seat rear p art

A w ire plug 32

B wire plug 32

T he upwards and downwar ds adjusti ng dynam otor of th e seat front part

Rear seat heating switch

F /R seat heating switch

F/L seat h eating switc h

Front ISU

El ectric seat

Diagnosis plug

The installation position of seat heating switch

9

Posi tion of trunk electric equipment

Rear left lamp

High- mounted brake lamp

Re ar right l am p

Turn Light

Back up L ight

Bra ke Lamp/Si de Light Bulbs:12V 21W /5W Rear Fog Light Bulb s:12V 21W

Re ar ISU

Re ar Repro ducer

Tail Lamp Assembly

10

Starting and Charging System

1Circuit diagram30 15 ACC1 ACC2 31 IL LUM FB24 5A 86To Fr ont IS U P P 5

Ignition switch 1. 1# and 6# pin of ignition switch is the power of battery 30. 2. When the ignition switch is at the ACC position, the 1#3# pin of ignition switch is connected, and ACC1 and ACC2 relay both get electricity. The contact point close, 30th live wire-87# pin of ACC1 relay-30# pin of ACC1 relay-ACC1 wire get electricity; 30th live wire-87# pin of ACC2 relay-30# pin of ACC2 relay-ACC2 wire get electricity. 3. When the ignition switch is at the ON position, the 1# 3# 5#pin of ignition

S B2 3 0A 30 Rela y A CC2 85To R ear IS U P P 5

switch is connected, and ACC1 and ACC2 wire both get electricity; the 2#6#pin of ignition switch connected,30th live wire5Afuse Fb246# pin of ignition switch 2# pin of ignition86 30 Ign it ion S witch Rel ay

86

30

G5

Relay ACC1 87

switch 85# pin of ignition relay 86# pin of ignition relay 31 ground. The ignition relay get electricity at the time, and contact point close, 30th live wire 87# pin of ignition relay 30# pin of ignition relay, then the 15th line get electricity.

85

87

85Instr ume nt/ Fron t Grou nd 1/D2

87

G 11S eat H eater P ower S upply To IS U P P3 Plug- In Unit (Control the R adi o) Instrum ent/Front G round 1/A 1 To Ignition Switch

Fu se Bo x G Pl ug-In Un it 15# Instrum ent/Fr ont Gr ound 1/B 1

V/ WSpareFB 33 40 A FB 32 FB 31 FB 30 FB 29 F B2 8 40 A 5 0 A 8 0 A 80 A 1 20A

Lg 5 1

Y/L 2

Lg 6 4

TE RMIN A L POS ITIO N L O CK A CC ON S TART

3

P osit ive F use Box

Position of ignition sw it chI gniti on S witchL/RI nstrum ent/Front G round 1/D 1 G 12

Ignitio n sw itchTechnical dat a of sta rterVoltage Output power Ti me of starting 12V 0.8K w 30sec s Clockwise from the pinion side 19 m(0.650in) 9 Condition 11V 9.5V 0.7Kg.m 7.7V Guarantee Less than 55A, mo re than 5000r/ m Less th an 270A, more than 1200 r/m Less than 600 A, 1.3Kgm (94scales/fee t)more than M ore than 8 V

To The Fan Speed C on trol M odule

30 Baterry Gene rator B ECU/A2/14 1 IG To instrument 16# D+ To F use Box K Plug -In Unit 7# (Yello w Wire) 87J8

85 Sta rt e r Relay 86

Rotate direction Le ngth of brush

Sta rter

Gears of pinion wh en starting Speciality N o-Load

2

RE GUL A TOR

Star ter

Temperature

Load Br ake

M3

31

Figure8-1 Start ing a nd Charg ing System Circuit Diagram

Work ing volta ge of electromagnetic swit ch

11

2Equipment position figure of starting and charging circuitIgn ition switch relay Starter motor 30A fuse Sb2 Starter rela y

3Starting and Charging System Circuit analy seThe start ing and charg ing circui t is shown as figure 8-1. The charging system is a system charging t he batter y with the output el ectricity o f the AC generator . When the i gnition s witch is connected, curren t flows into the excitation coil, and the coil is initially powere d. When the engine starts , stator coi l begin to generate electricity , the exci tation coil is powered by the output current of st ator coil. The output power of th e AC gen erator inc reases with the augment of

Ignition s witch 5A fu se Fb24

A CC Rel ay

Front relay box

excitation current. And dec reases wi th the fal l of the current. W hen the battery voltage the voltage of the S end of AC gene rator) reaches the adjusting voltage, the exci t ation curr ent is cut off. And when the battery voltage is less than the adjusting volta ge , the v oltage adjustor controls the excitation current t o adjust the output voltage and keep it i nvariableness. 1 Chargin g circuit Gnerator B 1#pin of starter positive connectio n fuse box FB28battery positive polevehic le body gr oundengine ground ground line. 2 Starting circuit 1The first grade control circuit When the ignition switch is at the ST posit ion, battery voltage-positive line fuse box 80A fuse Fb29 5A fuse Fb24 6# pin of ignition switch 4# pin of ignition switch 85# pin of starter relay 86# pin of starter relay 31ground line 2 The second gr ade contr ol circuit battery voltage posi tive line fuse box 80A fuse Fb29 30A fuse Sb230# pin of starter relay 87# pin of starter relay2# pin of starterStart suction coil starter-ground. 2# pin of starterkeep coil ground. 3Main circuit battery voltage posit ive line fuse box 120A fuse Fb28 1# pin of starter electromagnetic swit chstarterground.

Generator

P ositive fu se box

Tim e for b atterry to take in the charging current un der each voltage: Vo ltage A more than 16........4 h B 14-15.9................. .......8hBatt ery

C less than 13.9........ ........16h

Notic e for Maintain Ge nerator 1.Do n ot mistake the polarit y of IG con nection po le and L co nnection pole. 2.The line between IG conn ection pole and L co nnection pole should not be sho rt circuit, do remember to pass through the charging indicator la mp when connect th em. 3. There should b e no load between th e IG coil an d E pole.

12

ECU System Circuit30 15 ACC1 ACC2 31 ILL UMFB5 5A FB15 7.5AFuse Box K10#

8 SB1 30AFuse Box J10#

1

3

5

30 15 ACC1 ACC2 31 ILLUM

FB16 15A

FB31 60A

This Fuse W ire is Within the Positive Fu se Box

FB32 60A

This Fuse Wire is FB20 Within the Positive Fuse Box 15A

FB9 10A 30

FB8 10AFuse Box K Plug-In Unit 17# Fuse Box K Plug-In Unit 18#

86

30EMS Relay

86Fuel Pump Relay

30

86

30Fan Control Module

86

30Compressor Relay

86

(O nly f or 2.0L engin e )

Air flow meter

85Fuse Box K8#

87

85Fuse Box Plug-In Unit K10#

87

85

A6

87

85

A5

87

85

87 B/W 2 2 3 1 5 4 3 1 2 1 t

O/B Gr 3 2

G/W

ECU/A2/9

ECU/A2/12

Fuse Box K16#

Front G round/ DC/2

Fuse Box Plug-In Unit K9#

3

M ECU/A2/13 2 O 13 P/Br 12 P/B 14 Br 47 7 2 G 2 L 6 2 O 274 35 24

M ECU/ B/2 B/O 68 W 50

M

4

1

4

ECU/B/13 G/R 46 V V6 25

V 6344

V 70

R 69

V

V

Br 79

V 4

P 55

G/B P/Br 1 18

44 45

39 17 42 37

ECUEMSEngineABS 6#1 2 81 33

21 58 B/Y L/W ECU/A2/8 ECU/A2/1 W/BBrake Switch

2 O/B

5 P

59 P

76 L

77 P

74 Sb/B

51 53 3 61 80 34 15 P B

20 19

62 81

31 O ECU/ A1/7

71 P

75 60

35 64 67 66 65 78 38 54 Gr L/W ECU/ A1/1 1 4 2 5 6 3Electronic Throttle

32 Y/B ECU/ A1/2

40 Lg/B

36 33 Gr Y

16 P/B

G/W B/W W W/B

V/W Br/B B

Sb Y V

ECU/ A1/6

Ignition Coil

ECU/A2/6

Front Ground/9

ECU/ A1/5 1 5 6

ECU/ A1/3 4

EC U/ A1/ 4

L/W

2Front Ground/QC/3

3

3

ECU/A1/7Cranksha ft Kn ock Position Sensor Sensor

A4 A1A5

A8

Anti-theft Control

2 TO Front ISUPE2/22# ECU/A1/16Ignition Coil

3

1To The Instrument 27# To Front Combination Headlamp Plug-In Unit

A2 B1 B2 B3 A7

1

4

2 Ele ct ron ic a cc el era te p anel se nso rTo The Air Co nditioner Module B19 (AC S witch) To The Diag nosis Port 7#

1

3 2

Speed Sensor

Power Steering Switch

Clutch Pedal Sw itch

Coil

Electronic Th rottle Sensor

31 CAN_H CAN_L

3

10

5

10

Ground CAN_H CAN_L

Figure9-1 ECU System Circu it Diag ram

13

Engine management system is mainly composed of sensorelectronic control unitECU and actuator three parts. It controls the basic air intake volumefuel inject volume and ignition advance angle when then engine is running. The A5 automobile apply the ME7.9.7 electric control system, the constitution is shown as figure 9-2

Air int ake press ure temp erature s ensor Fuel distribution pipe assembly Carbon canister control Valve Spark plug Phase sensor Front oxygen senso r Front catalyst Rear o xygen se nsor Thr ottle valv e

Accelarate pedal position sensor

Coolant temperature sensor Mai n catalyst Cran kshaft position se nsor

Electric fuel pu mp

Figure 9-2 M E7.9.7 Electric Cont rol System Constitu tion

14

Engine ECUECU receives and deals with the engine state signal s which is inputted by each sensor, and drive each actuator work . It enable s the engine work a ccording to establi shed proc edure and insures the wel l motivityfuel economy and drain performance.

CODE. For example: the flashing of P0203 is : flash 10 times continuously-intermission-flash 2 times continuously-intermission-flash 10 times continuously-intermission-flash 3 times continuously. 2 Remove the plug check whether the ECU connect lines are well, and whether the ECU powerground is normal. 3 Check whether the working of outer sensor is normal, whether the output signal is creditable and whether the line is well. 4Check whether the working of actuator is normal and whether the line is well. 5Finally replace the ECU to test.

Input sign alECUEMSEngine Engin e computer is installed at the passenger side The inst allation po sition of engin e computer

1Air Flow MeterThe air flow mete r MAF sensor m easures the volum e of air that inhal ed into th e engine. Engine control module ECMuses the da ta to calc ulate the spout tim eignitio n timin g and engine load.To main r elay Air flow me terOnly for 2. 0L engine

Figure9 -3 Engine ECU

Fau lt descri ption Idle speed no t stable can not well accelerate can not start idle speed is too highthe exhaust e xceeds the standar d starts difficult A/C invalidation fuel in jector control in validation flameout and etc. Trouble Analysis 1 The over loadi ng of outer conne ct set re sults in the burn of ECU inner components, which leads to i nvalidation. 2Water gets into t he ECU and results in the rus t in the line board.

3

2 Air flow meter 1 5

4

A ir intake te mperature sensorOnly for 1.6 L engine

17RemarkThere is no air flow meter in t he 1.6L engine elctronic control sy stem,and what instead is the air temperatur e sensor.

42 EC U

37

33

Figure9 -5 Air f low met er and its circuit d iagram

Trouble analysis Sensor invalidation result from the pollution of dustoil and water. TroubleshootFigure9- 4 Diagn osis plu gs

Troubleshoot 1 con nect the plug u se the e ngine da ta K wir e to read engine fault record Start the ignition switch, use the engine data K wire the standard diagnosis plug 7# pin ) ground that's to connect the 4# and 7# pin of diagnosis plug with a lead over 2.5s, if there is DTC in the ECU fault memorizer, the engine fault lamp will output the flash code, that's P-

Static st ate testzero flu x test The 1st pin is air intake temperatur e pressure sensor, connectin g to the 42nd pin of ECU; the 3rd pin grou nds and connects to the 17 th pin of ECU;the 4th pin inputs 5 V refer ence volta ge, and c onnect to 33rd pin of ECU; the 2nd pin input s 14V rati ng voltag e; the 5 th pin is output vo ltage, and connects to the 37 th pin of ECU. Check the output voltage of 5th pin, if it is over 1.0 25V, the n the sen sor will be disqualification. Dynami c test If it is p rimarily diagnosed as the s ensor's t rouble, c onnect th e emission analyzer and c heck the performan ce in the two working cond ition.

15

2Electric throttle and accelarate pedal position sensorThe driver offer the engine real time torque requirement to ECU with the help of accelerate pedal, ECU send the impulse signal to the electric throttle according to the information it gained.Therefore, the motor in the electric throttle run and the throttle open to the required angle.ECU 32 35 40 16 33 36

The crankshaft position sensor is to supply engine speed crankshaft rotating angle and TDC signal to ECU. I t is used to control the engine ignition and fuel eject timing.ECU34 15

the 1st pin connect to screen the 2 nd 3rd pin supply signal to ECU, and connect to the 15th34th pin respectively.Cr a nkshaft pos ition sensor

P

B

Crankshaft Position Sensor

Figure9- 7 Cranks haft posit ion sensor and its ci rcuit diag ramaccelarate pedal position sensor Accelarate pedal position sensor

Fau lt descript ionfault phenomeno n. Trou bleshoot remove t he plug, set the multimeter at the OHM position , the two pens conn ect to the 2nd3rd pi n respectiv ely. The rat ing resistance will be 860 10 % when it is 20.

Descripti on of the pins of throttle positio n sensor 1#2# pin is 5V reference voltage anode; 3#5# pin is 5V reference voltage cathode; 4#6# pin is signal output voltage signal.ECU 64 67 66 65 78 38 54 32 Gr L/W 1 4 2 5 6 3 Sb Y V Y/B ECU/A 1/2

4Phase sensor camshaft position sensorThe sensor supply the crankshaft phase information to ECU, that's to distinguish the compression TDC and exhaust TDC.Conne ct to ground

Ele ctric throttle

79Th ere are three pins of phase sensor: th e 1st pin connect to g round; the 2nd is signal output,connect to the 79th pin ; the 3rd pin connect to the power anode.

Electronic Throttle ValveECU

321

Figure9 -6 Electr ic throttle position sensor and its circuit diagram

Phase s ensor

Phase s enso r Connect to main relay

Descr iption of e lectric thr ottle pin The 1st pin is the motor anod e, connect to the 66th and 67th pi n of ECU; The 2n d pin is the potentiom eter cathode, conenct t o the 78th pin of ECU; The 3r d pin is the potentiome ter anode, connect to t he 32nd pin of ECU, 5V power; The 4t h pin is the motor catho de, connec t to the 64t h and 65th pin of ECU; The 5t h pin is the signal output 1, conne ct to the 38 th pin of EC U. The 6th pin is the signal out put 2, conn ect to the 5 4th pin of ECU.

Figure9 -8 Phase sensor an d its circu it diagram

Fault description can not start, emission exceed standard, fuel consumption increased and so on. Troubleshoot connect the plug start the ignition switch but not the engine, set the multimeter at the DC volt position, connecting the two pens to the 3rd1st pin of sensor, confirm that there is a reference voltage of 12V. Start the engine, then check whether the 2nd pin signal is normal by using the oscillograph.

3Crankshaft position sensor

16

5Knock sensorThe knock sensor supply engine knock information to ECU, and control the knock.19Knock sens or

7Oxygen s ensorThe oxygen s ensor is used to detect th e content of oxygen in th e exhaust,the transmits a signal to ECU, a ccording to the in formation ECU wi ll make t he fuel closed loop control so that the eng ine can w ork in th e best C ondition, and mak e the CO, HC, N Ox comp ound tran sformed and depurated mo stly by the three-w ay catalytic converter .EC UKnock s ensor

20

Rear Oxygen Sensor G/B P/Br 1 2Main relay

There ar e 3 pins on the sensor , the 1st 2nd pin connec t to the 19t h20th pi n of ECU; the 3 rd pin con nect to scre en.

ECU

1 18

Figure9- 9 Knock sensor and its c ircuit dia gram

4

3

Front Oxygen Sensor

Fault description It can not accelerate well

There are 4 pins on this oxy gen senso r No.1 c onnect to h eating power positiv e white No.2 c onnects to heating po wer negat ive whit e No.3 c onnects to signal neg ativegra y No.4 c onnects to signal pos itive bla ck Front oxygen sensor

Fault analysis Several k inds of f luid such as fuel coolant brake fluid water c ontact to sensor fo r long time wil result in the erode of sensor.Troubleshoot: Remove the plug Set the multimeter to the ohm position,

connecting the two pens to the 1st2nd and 1st3rd pin respectively, and the resistance in normal temperature should be more than 1M. Set the multimeter at the mV position, and knock the knock sensor with a hammer gently, then there will be voltage signal output .

6Coolant te mperature s ensorThe coolant temperature sensor supply coolant signal to ECU, so as to enable the start idle speed ignition timing and injection impulse width modify. There are two pins, and they can exchange to use. Fault descrip tion : Sta rt difficultly Troubleshoot Remove the plug Set the multimeter at the ohm shift, the two pens connect to the 1st 2nd pin of sensor respectively, the rating resistance is 2.5k5% when it is 20. The other temperatures please refer to table 8-1.Co olant temperature sensor

Ta ble 8-1Te mp er atu re -10 20 80 Resis tance k 8.6210.28 2.372.63 0.2990.345

17

39

1

2

ECU

C oolant tempe rature sen sor

Rear oxyg en sensor

Figu re9-10 Coolant tem pe rature sensor and its circuit

Figure9 -11 Oxygen sensor and its circuit

17

Fault descriptio n: Badnes s idle speed, badness acceleration, badness tail gas, over fuel consume et c. Fault analysis Moist ure enterin g inside of s ensor, then the temper ature is ch anged and t he pin is br oken; the sensor i s poisoned Pb,S,Br,Si Troubleshoot : 1 Disassemble joint Put digital multimeter to ohm shift, connect meter pen to No.1 whiteand No.2white pins of the sensor. Normally the resistance value is 1~6. 2 Connect the joint and keep it at idle speed status. When the oxygen sensor reaches to its working temperature 350, keep digital m ultimeter to DC volt shift and connect meter pen to No.3 gray and No.4 black pins of sensor. Now the voltage should be fluctuate between 0.1- 0.9V quickly the data also can be gotten from data f low inspected by diagnosis meter.

10Clutch pedal switchThe 1st pin of clutch pedal swit ch is connec tted to the 74 th pin of ECU, and the other pin is connect ted to grou nd.Clutch pedal switch

ECU 74 Sb/B

ECU/A1/7

Clutch Pedal Switch

8Vehicle speed sensorVehicl e speed sen sorT o fuse FB5 ECU 59

Figu re9-14 Clutch pedal swit ch and it s circuit

11 Power steering switchT he 1st pin of the vehicle speed s ensor connect t o power T he 2nd pin conn ect to ground T he 3rd pin is th e vehicle speed s ignal, it conne c t to the 59 th pin of engin e ECU. 1 3 2 Ve hicle spe ed senso r E CU 76 L

Figur e9-12 Ve hicle spee d sensor a nd its circ uit

9A/C pressure switchECU 75 60V/W 2 Br/B 3

The 1st pin of the power steering switch is connectted to the 76th pin of engine ECU, and the other pin is connectted to ground.

In stallation position of power steering switch

Pow er Steering Switch

A/ C high/low pr essure switch The 2nd pin of A/C high/l ow pressure swit ch connect to the 75th pin of ECU; the 3rd pin conne ct to the 60th pin of ECU; the 1st 4th pin connect to the B19 switch of A/C module.

High/Low pressure Switch1 4

Figure9-15 Power St eering switch and it s circuit

Fig ure9-13 A/C pressure switch and its ci rcuit

To The Air Conditioner Module B19 (AC Switch)

18

Actuator1Ignition coilThe ign ition coil transfor ms the low pressu re DC of battery to the hig h pressure elec tricity, w hich gets through the spark plug and brings o ut spark to burn the mixtur e in th e cylinde r.Th e1st coil prim ary windin g is connect ted to the 5th pin o f ECU The 2nd coil pri mary windin g is con nectted to th e 2nd pin of ECU. The 3rd pi n is connectted to the anode of pow er The 4th pin is em pty.

2Fuel injectorECU sends electric impulse to the coil of injec tor and forms the magnetic field power.Wh en the power incre ases enough to overcome the combined force o f release spring pressure needle v alve grav ity and fri ction, the needle va lve begin to rise and the fuel inject procedure start. Wh en the fu el injection impulse stops, the pressure of relea se spring closes the needle valve again.

Connects to 87# of main re lay

2 Br

2 G 7

2 L 6 ECU

2 O 27

Table 2C apacity Primary winding Resistance 20-25Elementary winding Seco ndary winding

47 Cost Model 14 0.5 13.0 4.1 32.0 Unit V 0.58 14.8 4.8 37.5 k mH H kV kV

Min 0.4 2 11. 2 3.4 26. 5 30 23

Ma x

F uel injector

Electromagnetic induction Elementary winding 20-25 Seco ndary winding

Ig nition coil

Volta ge

Load 50pF Load50p F//1M

F igure9-1 6 Ignit ion coil

P ins: each f uel injector has two p ins . The o ne which is marked w ith "+" at one side o f the shell c onnects to the 87th pin of main r elay output port; the o ther conne cts to the 2 7th 6th 7th 47th p in of ECU.

Fault description can not start.

Figure9 -17 Fue l injecto r and its circuit

Fault analysis T he current is too h igh to burn dama ge by ou tside forc e. M aintain n otice It is forbidden to try the "short circuit test way" to test the ignition function, so as to avoid the damage to ele ctric controller.Tr oubleshoot :

Fault d escription Idle speed is not wel l accel erate not well can not st art

(sta rt difficult)and etc. Fault analysis Because of th e lackness of maintainen ce, there is coll oid accumulate in the fuel injector and result in the i nvalidati on.Troubl eshoot : Remove the plug set the multim eter at the ohm p osition, the

Remove the plug set the multim eter at th e OHM position, connecti ng two pens to the two p ins of primary win ding resp ectively. When it is 20, the resistance is 0.42-0.58and the se condary winding i s 11.2-14 .8k. Refer to ta ble 20

two pens connect to the two pin s of fuel injector, the rating resistance is 12 when it is 20. Adviceclean the fuel injector with specialized cle an analyzer.

19

3Fuel pump relayThe battery supplies power to electr ic fuel pum p through fuel pump relay, the relay can only p ut through the electric fuel pum p circuit when startin g or the engine is run ning. When the engine stop running a ccidently, the fuel pu mp will also stop automatically.

4A/C rela yThe A/C switch open, blower switch open , the A/C pressure is normal, the evaporator temperature sensor detects the correct data, the A/C requir ement signal is sent to ECU via these switches. After receiving the signal, ECU controls the A/C relay to close and sends the speed increasing signal to the stepper motor at the same time, and start the electric fan, then the A/C system will start working.

To m ain relay

To power

FB16 15ATo main relay To main pow er

86Fuel Pump Relay

30 A/C relay

Fron t engine com partment box

85V 70

87

A /C compres sorM

EC U

Fuel pump

Figure9- 18 Fuel p ump relay circuit di agram

E lectromagn etic clutch69 ECU

Faul t descript ion Loud noise when running can not well acce lerate ca n not

startstart difficult and etc. Fau lt analysis For t he using of bad fuel: 1C olloid accumulate and form insulated surface 2fuel pump b ushing and armature locked 3fuel sensor unit erode. Trou bleshoot Remove the pl ug set th e multimeter at the ohm pos ition, connectin g the two pens to the two pins of fuel pump, test the inner resistance, it is not 0 orthat's to say it is not short c ircuit or op en circuit state. Co nnect the plugconnect the fuel pressure gauge at th e oil intak e pipe, sta rt the engine, ch eck whether the fuel pump work; if it is not work, c heck the + pin t o see whether th ere is pow er voltage; if it works, observe the working conditions of engine to see whether th e fuel pres sure is about 300kPa.

Figure9-1 9 A/C relay

Common troubles 1 The blower mot or fault fuse burnt, relay circuit open circuit or short circuit 2The A /C pressur e is abnorm al high pressure is too high and low pressure is too low the evaporator temperatu re sensor fault 3A/C relay line fault short circuit to grounds hort circuit to poweropen circuit

20

5Cooling fan control moduleECU Controls the running of fan according to the engin e coolan t temperature and A/C requirement signa l, it contr ols the re lay of fan system if conditio ns are met.

6Canister purge valveCanister purge valv e controls the volume of cleaning air flow from c harcoal canister to air int ake main pipe. Th e adsorb ing capab ility of carbon canister is l imited, if the oil steam ad sorbed in the carb on canister can't be consumpt, the oil will volatilize to outside and pollute the air.46 To main relay

To Main Re lay

To M ain Power

To Ground

The carbon canister only has two pins, with one connecting to t he 87th p in of mai n electric equipment output port , and the othe r connecting to the 5th pin of ECU.

ECU86 30High electrical fan relay

86

30Low electrical fan relay

Fan control m odule

Canister pur ge valve

85

A6

87

85

A5

87

FrontGround/ DC/2

M

M

Ca nister purge valve

B/O 68

W

Figure8-2 1 Canister purge valvean d its circuit

ECU

50

Fault description The fuel pressure is too low or too high, and start difficultly.

Figure8-2 0 Coolin g fan co ntrol mo dule circ uit

Fault analysis Because lacking of maintenance for a long time, it results in that: 1The filter screen jammed ; 2 Grain impurity result in the serious leakage; 3 Manmade mechanical damage and so on. Notice for maintenance In the maintain procedure: 1It is forbidden to impact the diaphragm with high pressure gas; 2It is forbidden to clean it with causticity fluid; 3 It is forbidden to force on it and result in distortion.Troubleshoot

Co mmon tr oubles 1High spe ed relay line is short circui t to power 2High spe ed relay line is short circui t to groun d 3High spe ed relay line is op en circuit 4Low spee d relay li ne is sho rt circuit to power 5Low spee d relay li ne is sho rt circuit to ground 6Low spee d relay li ne is ope n circuit 7Engine c oolant temperatur e sensor f ault 8Engine a ir intake temperat ure senso r fault

Connect the fuel pressure gauge at the oil intake pipe and start the engine to let it work on idle speed, check whether the fuel pressure is about 350kPa; step the accelerate pedal until the engine reaches the speed of 2500rpm, check whether the fuel pressure is about 350kPa then.

21

ABS System30 15 A CC 1 ACC 2 31 ILLUM

ABS brake down partsBrake lamp switch Brake pedal ABS control unit Hydraulic pressure pump electromotor ABS hydraulic pressure unit with low pressure reservior Execute parts Sensor Control unit

To The FB1 Brake Switch, 5A ECU21#, Front ISU PE2 22# K7

SB4 40A

SB5 40A El ec tr oma gnetic v alv e A2 A1

Position of ABS control m odule Installation position of ABS control assemblyLg 6 32 Rear wheel speed sensor ABS warning indicator lamp L/W 31 R 2 R Front wheel speed sensor Self-diagnosis connector

ABS Control module41 B 42 Y 43 V 44 V /W 12 G 13 Y/B 26 R 27 Br 3 W 18 W /B 16 B 45 B

ECU/Front Ground/4

ECU/Front ECU/Front Ground/3 Ground/12

ECU/Front Ground/ 11

ECU/Front Ground/15

ECU/ Front Ground/7

ECU/Front Ground/16

Front/Rear 1/14

Front/ Rear 6

Front/Rear 1/15

Front/ Rear 17

ECU/Front Ground/8

Rear Left Wheel Speed Sensor

Rear Right Wheel Speed Sensor

Front Left Wheel S peed SensorR ear L ef t Wheel Speed Sensor R ear Right Wheel Speed Sens or

Front R ight W heel Speed Sensor

31 C AN_ H C AN_L

Figure1 0 -1 ABS System Circu it

Circuit analysis: for the cars with no ABS, when forcibly s teps down the brake pedal during driving, the wheel speed will decrease suddenly. Once the brake force is more than the friction between wheels and floor, wheels will be braked. T he wholly braked wheels will decrease the friction between t ire and floor, if the front wheels have braked, driver can hardly control the running direction of the car; and if the rear w heels have braked, the car will swing. The ABS is used to restrain the skidding phenomenon of wheel specially. It will supervise the speed of each wheel and control the hydraulic pressure when braking. This can enable the driver to keep the stability of direction and help the car possess better steering capabil ity. The circuit diagram is shown as figure 10-1. The voltage of the 30th wire supply to the 31st pin of ABS control unit via the 40A fuse Sb4; The voltage of the 30th wire supply to the 2nd pin of ABS control unit via the 40A fuse SB5; The voltage of the 15th wire supply to the 32nd pin of ABS control unit via the 5A fuse Fb1. Th e 12 13 26 27 41 42 43 44 of ABS control unit connec t to the F/L F/R R/L R/R w heel speed sensor respectively; w hen the w heel runnin g, the sensor produces voltage signal which changes with the increas e of speed. Th e 6th pin of ABS contro l unit connect to the br ake switch s ignal; the 16th45th pin of ABS control unit connects to g round. Th e 3rd pin of ABS control unit connect to CAN- H wire, an d connects t o the 30th pin of combi nation inst rument 62nd pin of engine ECU respectively. The18t h pin of A BS control unit connec ts to CAN -L wire, and connects to the 29th pin of combination instrume nt81st pin of engine ECU respectively.

22

Airbag System

circuit analysis:T he circuit of airbag is shown as figure 11-1. When there is serious frontal crash, to avoid the driver or front passenger bumping onto the steering wheel or instrument panel, there will be an airbag expand on the steering wheel and instrument panel so as to protect the driver and front passenger. The SRS Airbag system include: driver side airbag module passenger side airbag moduleairbag control modulehelix cablewiring harness and SRS fault warning lamp. When the ignition switch is set at the position of ON or ST, the voltage of battery supply to the 25th pin of SRS control module via FB4 fuse. T he 2nd 1st pin of the airba g module are connectted to t he front driver side airbag via helix cab le; the 17 th16th pin of airb ag module are conn ectted to the driver side airb ag directl y; the front passenger side ai rbag conn ect to the 3rd 4th pin of air bag module directly; the pass enger sid e airbag c onnect to the 18th 19th pin of airbag module di rectly; the 21st22 nd23rd and 24th pin of airb ag module connect to the side airbag crash sensor. The 12nd37th pin of airbag module connect to pa ssenger side airbag lock. T he 10th pin of the airbag modul e output the airbag warning signal, it connects to the 17th pin of instrument; the 47th pin of the airbag module output the side airbag warning signal, it connects to the 24th pin of instrument; when the ignition switch is at the position of ON, the SRS warning lamp in the instrument panel flash for 6s with the frequency of 1Hz and then off. If the SRS warning lamp didn't flash for 6s or it keeps shining , Taht's to say the SRS system is not in good working condition .

30 15 ACC 1 AC C2 31 ILLU M

30 15 AC C1 ACC2 31 ILLUM

FB 4 5ASpiral Cable

F ront E ngine Com partm ent E lectri cal Bo xL9

In strum ent/F ront Grou nd/14

F ront Passe nger Side Airbag Driver AirbagIn strum ent/A irbag /A

Driv er Sid e Airb ag

R S piral C able G Gr 25 1 2 21 22 3 4 23 24 R B

Pa ssenger S ide AirbagFront Pass en ger Side Ai rbag

D river A irbag

Lef t I mpac t Sensor

L L/R

O/B O/G

Right Impac tSens or

Airbag Control

18 19

O O/W

Front Passenger Side Ai rbag

Driver side Airbag

L/W G/B

16 17

37 12

G G/W

Fr ont Passenger Airbag Lock Switch

Tem por arily Use less

Sef ty Belt

Sefty Bel tTo ISU PE 2/16In strum ent/F ro nt G roun d/B10 Instr umen t/ Airb ag/C

8 9 47 48 11 10 46 11 B G To Istrumen t 24#

P/B

To Instrument 17# To Diagnostic C onnector 7# 31

Br /W V

Fron t P as seng er Airb ag Lo ck S w itch

Figure11-1 Airbag S ystem Circuit

23

A uto A/C System30 15 AC C1 ACC2 31 1 LLUMT O Wiper motor 2# To Instrument 7#

F b13 30 A L14

Fb7 10 A

External Temperature Sensor

To Wiper Switch 9#

G20

Fr ont Gr oun d/F ron t En gin eCom pa rt ment /D

Instrument /Air Conditioner /14

MI nst r um ent/ F r on tG round/ A4

Sunlight Sens or

T O FRONT T O FRONT IS U PE1 IS U PP3 28# 15#

I nst rum en t / A irC ondit ioner/ 11

ECU/A2/4

Instrument/ Front Ground/15

I nstrument/F ron t Ground/b6

Ins tr um e nt/F ron t Gro und / B1 0

A nti-Theft I ndicator L ightLine

Temp erature Senso r

B lower Spee d Co ntrol ModuleSunlight Sens orIn strum en t/A ir C o nd it ion e r/1 5 In s trum e nt/A ir C o n di-ti o ne r/ 1 In strum en t/A ir C on d i-tion er/6 In strum en t /A ir C o nd itio ne r/1 2 Ins tru me nt/Air C o nd it ion e r/ 2

Internal Temperature Sensor

Coolant Temperature Sensor

Coo la nt Te mperat ure Senso rBr /W A4 B r/Y A5

Blower Sp eed Control M oduleA9

O/W

Y/O A1 0 B1 6

Lg

R/W B1

Y/ Br A1 8

Y/R A19

Y/G A 15 A14

Y/W

Y/ B A2

A ir Conditi oner Cont roller

Air Conditio ner Controlle r

B1 5 Lg /B

B5 G/R

B6 G /W

B7 V/ B

B9 W

A1 7 V /W

B4 L

B3 L/B

A1

A16 L/W

A11 V /R

B1 4 O I nst r um en t/ A ir C ond it i oner / 8

B11 W

B13 Br

B2 B

B9 B

B 10 B

V /Y

Inte rnal & Extern al Circula tion Control M otor

2 M

1

3

1

6

2

5

1

3

6

2

5

I nst r um en t/ F ro nt G r oun d/B 11

M

M

Inte rnal & Exte rnal Circulat ion Control Motor 31

Tem perature C ontrol Motor

Mode Cont rol Motor

T O FRONT ISU PE2 32#

To The Diagnosis Port 7#

To The High/Low Voltage Switch 1 # and 4# Of Air Conditioner

Figure12-1 Air Cond itioning System Circuit Diagram

24

Auto A/C System Circuit AnalyseThe Auto A/C is shown as figure12-1. When the ignition switch is at the position of ON, the ACC1 and the 15th wire gets electricity. The 15th line supplies power to the B1 pin of A/C controller via Fb7 fuse; the A18 A2 B2 B9B10B16 pin of A/C controller connect to ground. The voltage of A CC1 wire supplies power to the 5th pin of blower speed adjusting module via the Fb13 fuse; the 7th8th pin of blower adjusting module is connected to the blower motor; the 6th pin connects to ground; the 3rd pin is the blower speed adjusting signal, and connects to the A5 pin of A/C controller; the 2nd pin is the blower voltage feedback signal, and connects to the A4 pin of A/C controller. The B5B6 pin of A/C controller connect to inner/outer circulation control motor, the control panel drives the circulate wind door connecting pole move pole by the control of inner/outer circulation servor motor , and also move the big small wind door and thereby it realize the control of inner/outer circulate wind. The B7B8 pin of A/C controller connect to the cool/warm control motor, the control pa nel drives the dial and the pole in the temperature adjusting unit by controlling the blend door servor motor, and also move the blend door and thereby it realized the different proportional air mixture. The B3B4 pin of A/C c ontroller connect to the mode control motor, the control panel drives the dial and the pole in the wind direction adjusting unit by controlling the mode wind door servor motor, different pole control the open and close of different wind door and thereby it realizes the control of air. The A18 pin of A/C controller connects the outer temperature sensor. The outer temperature sensor is one of the important sensor of auto A/C. It will influence the air temperature of the wind outlet portwind volume of the wind outlet portthe position of mode door and the po sition of air intake port. For the inspection of outer temperature, you can dismantle the connector of the sensor and test the DC voltage of the the front ground/front engine compartment/D end o f the wiring harness, the normal value is 5V, if not, that's to say there is something wrong with the wiring harness or A/C computer. The A15 pin of A/C controller connects the inner temperature sensor. The inner temperature sensor is one of the important sensors of auto A/C.It will influence the air temperature of the wind outlet portwind volume of the wind outlet portthe position of mode door and the po sition of air intake port. For the inspection of inner temperature, you can dismantle the connector of the sensor and test the DC voltage of the two ends of the wiring harnes s, the normal value is 5V, if not, that's to say there is something wrong with the wiring harness or A/C computer. The A14 pin of the A/C controller connects to the coolant temperature sensor. The coolant temperature sensor is to test the temperature of heater core and modify the position of the blend door. It can avoid the working of compressor when the engine is in high temperature; it can also

control the blower, when the coolant temperature is too low, the system will start the preheat control. That's to say when the coolant temperature is too low and it is in warming working condition , to prevent the cool wind from blowing out, if the coolant temperature is lower than the system set temperature, the blower will work in low speed or doesn't work. The A19 pin of A/C controller connects to sunshine sensor. The sunshine sensor induce the the strong or weak of the sunshine to modify the position of blend door and speed of blower. To inspect the sunshine sensor, you can read fault code or in the way of testing the resistance or voltage. 1Te st the resistance Test in strong su nshine, th e resistan ce will be 4k , co ver the s unshine s ensor, the resist ance will be . 2Te st the vol tage The volta ge in stro ng sunshin e is norm ally lower than 1V, cover the sunshine s ensor, the volta ge will be over 4V.

B7

B8 A17 W V /B V/WTO lower S peed Control M odule

Air Conditio ner Contr oller

B4 L

B3 L/B

A1

V/Y

A16 A11 L/W V/R

3

1

6

2

5

1

3

6

2

5

Tem perature Co ntro l Motor

Mod e Co ntro l Moto r

Te mpera tur e Cont rol Motor Mode Cont rol Motor

25

Manual A/C System30 15 ACC1 ACC2 31 IL LU M T O ECU75# TO ECU 60# FB7 5A Fuse box /G/ 20# R/LF7 A/C 15th line power fuse A/C Blower fuse F 13

Manual A/C System Circu it AnalyseThe manual A/ C is shown as figure13-1. When the ignition switch is at the position of ON, the ACC1 and the 15th line get electricity. The 15th line supplies power to the A20 pin of A/C controller . The ACC1 line supplies power to t he blower relay coil; the blower relay coil g et electricity and the contact closed, the voltage of the 30th lineFB13blower relay contact pointblower motorthe 2nd pin of b lower s peed a djust ing r esistance . The two ends o f blower motor and h igh speed relay cont act point the 3rd4th parallel connected, the high speed relay coil the 2nd p in connect to the B1 pi n of A/C c ontroller, when the high speed relay coi l get electricity, the conta ct closed. The volta ge of the 3 0th line FB13 bl ower relay coil blower motor connect to ground. Then the blo wer motor will run in high speed . The 3 rd pin of t he b lower s peed a djusting re sistance is connectt ed to the B4 pi n of A/C controlle r, the 1s t pin of b lower speed adjusting r esistance is connec tted to the B2 pin of the A/C controller, the 4th pin of b lower s peed a djust ing r esist ance are connectted to the B3 pin of the A/C controller, the running speed of the blower mot or is controlled by A/C controller. The A9A12 pin of A/C controller are connectted to the inner/o uter circulation control motor, the control pa nel drive the circulation wind door connecting barshi ft lever by controlling the inner/outer circulation servo motor so as to drive the movement of the largesmall wind door and realize the control of inner/o uter circulation wind. The A13A14 pin of A/C controller are connectted to the cool/w arm control mo tor, the c ontrol panel drive t he conne cting bar shift lever of temperature adjusti ng control mechani sm by controlling t he blend door servo moto r so as to drive the movement of the bl end door and realize the mixture of different r atio of air and gas. The A18 A1 9 pin of A/C contr oller are connectted to the mode control mo tor, the control panel drive the connecting bar shift lever of wind direc tion adjusting control mechan ism by co ntrolling the mode wind door servo motor, dif ferent shif t lever control the open and cl ose of diffe rent wind door and thereb y realize t he control of air. The A3 pin o f A/C controller is connectt ed to the A/C Pres sure Switch .

FB13 30A

A/ C p res sure Switch

Bl ower RelayFuse bos /L/14#Front Eng ine Compartment Fuse Box

IP1/B6 B A/C 4 W A/ C 6 R A/C 12

IP1/A4 A/C 11

ECU /E Y/G A/C 7

A/C press ure S witch

1

Br

3

B

Gr ound

2 A5 A3 A/C S witch A9 A12 A14 A13 A6 A15 A2 A18 A19 A 4 A8 A1 B3 B2 B4 A7 A10 A 11 A20 B5 B6 B1

4

H igh sp ee d Rela y

+Blower

-

2

R1 3 E4 E2 D 1 D3 D6 D2 D5 C1 C3 C6 C2 C5 1 R2

-

+

-

+

-

+4

R3

In tern al&ext ernal Cir culation c ont rol Mot or

Temperature Control Motor

Mode control MotorMode Con trol Motor

Blowe r spe ed adj usti ng r esistance

Temper ature Control Motor

Figure13-1 A ir Conditioning System Cir cuit Diagram

26

Front ISU System30 15 ACC1 ACC2 31 ILLUM 30 15 ACC1 ACC2 31 ILLUM

10

2

2

10

10

10

9

9

10

FB22 7.5A To Ins trument 11 FB30 80A G7 G4 Inst rume nt/ Front Ground/ A2

Y 1 W L/W 4 3 1 W L/W 4 3 1 W L/W 4 3 1 Br 6

2

(2)31

(3)58bHigh Beam Rel ay Low Be am Relay

5 W 4 Hazard SwitchT o ig nit io n Inst rumen t FROM swi tc h 3 # 31# FRONT LEFT TURN To F ront Ground/ In strument /A 1Wip er S witc h3 #To

To Fron t E ngi ne Compartment Fus e Box G1 3

L11 (1)58L1 2

6

5 2

6To Au tom a tic Air C o nd itio ne r

5 2

6

5 2

TO To key Instrument Switch 13#Front Grou nd/ In st rume nt /2

FB25 10AInstr ument / FrontGround/9 Front Gro und/ Front Eng ine Compar tmen t /10

FB26 10A P5 Lg Sb M Sb G/W(2 .5ko ) H/LP LEVEL'G DEVICE SW

FB27 15A

FB14 15A P11In s trum ent /Front Ground/9ON OFF ON OFF

P7

W MF/R high/ Low beam

Instrument/ Air Conditi -oner/8

Fr ont Ground/ Instrument /B7

Fr ont Ground/ I nstrument / B8

F/L high/ Low beam

L/ B B7

L A11 E

V C11

Lg C10 F8 10A

Br/W A19

Gr A17

R C14

R A23

P/L C6

I nst rument /Fro nt G ro und/ G

Front Ground/ Instrument /B11

Fr ont Gr ound/ Left 2/ 8

Front Ground/ Right Front /5

To ACC Relay

G

Y

Br/ B

L

R G/L

L

G R

O B14

W B30

A10 A13 B32

A22 A18 B29 A24 A12B13

Y A3

V C4

Gr G A2 A15

F10 7.5A F8 10A

F12 7.5A

F1 25A A25 F C7 A25 W/G P P C8 G/L C20 C9 Br I nstr ument /Fr ontG rou nd / 11

Front ISUC15 A28 P Lg/ B B12 O/B B1 B28 B4 B19

A26 W/ B R

C13

C3 R

A29 R

A30 B22 B16 B5 O/ B Lg/B P/B V V/W

A8 R

A4 V/ B

B3

B24 Sb P/BFrom illum l ine

C12

A31

Lg/ W

L/W Br/W G/W

L

To Radio 16#

Front Ground/ Front En gine Compartment /13

Front Ground/ Front Engine Compartment /16

To Hazard Warning Lamp Switch 6#

O/BTerminal FunctionCle ara nce Lam p Hea d Lam p Low Be am Bea m Ch ange Sw it ch High (Tu rnO n Bea m Th e OvertaHe adla mp) king Main Li ght Sw it c OFF

Lg/ W

L/W8 7

Br /B6 5

G/W

P16 8 7 L 6

W/B15 14 13 5 12 4

DIAGNOSIS CONNECTOR 11 1 0 9 3 2 1

4 3

2

1 13 12 11 10 9

W/G

Hor n

Ant i-theft Hor n

Steering Swit ch

L R 6To In st ru m en t 15 #

T o E ngi ne AntiT hef t Modu le To Ins trument 1 5

Po i n t p ower(W)

1 20 1 20 4211 1 1

421 1

To Air Bag 46 To Automaitc Air Conditioner B11

31

8

2

2

9

3

2

10

3

11

10

10

Ground CAN_H CAN_L

CAN_H CAN_L

Figure14-1 Fr ont ISU System Circuit Diagram

27

A5 has two veh icle body compute r, one is front IS U shown as fig ure 14-2 the other is rear ISU .

,

electricity. W hen the ignition p ower is of f, open one door, the inner il lumination lamp wi ll light on until the door is c losed, and will cont inue to lig ht for 15s after the door closed. W hen the i gnition po wer on, the inner ill umination lamp will light on only when t he door is open, a nd be off w hen the door is clos ed. T he A23 p in of front ISU is t he key hole illumin ation lamp signal output pin, when the ignition power is off, the key illumination lamp will light on if open the drive r 's door. E ven if the driver's door is closed, the lamp will continue to light on for 8s. Shown as figu re 14-3.

1Front ISUThe parts that co ntrolled by the front ISU h ave the f ollowing functions: 1In ner lamp control an d steering lamphe adlamp high/low beam; 2Central con trol lock f unction 3Button-typ e electric window o peration function 4In termission time con trol of window wip er 5Delay the cl ose time o f electric window when the ignition sw itch is of f 6Rear view mirror heating control fuction (the adju stment o f the moto r is Con trolled by switch ) 7Key not pull out warning 8Warning and anti-th eft 9CAN-BUS data trans fer(with i nstrumentengineABS computer)

Keyhole Light30 15 ACC1 ACC2 31 ILLUM

Clove Box Switch

Front Ceiling Light

10

9

9

C wire plug 20

E power D wire plug 12 F gr oundFB29 80A Instrument/FrontGround/A2

Rear Windshield Warmer Switch

A wire plug 32

B w ire plug 32ON O FF ON O FF

Figure14- 2 Front ISUClove Box SwitchFront Ground/ Left 2 /8 Front Gr ound/ Front R ight /5

2Vehicle inner illu mination lampThe 30th power line sup ply power to the fro nt ISU via the fuse F B 29, and then via the fuse F10 and output from the C14 pin of ISU to supply power to key hole ill umination lampglove box lampma ke up mir ror front roof lamprear roo f lamp. The B14 of fro nt ISU is t he F/L contact switc h; the B30 of front ISU is the F /R contac t switch. When the indoor illumination lamp switch is at the left side or right side (door control position), the front I SU computer will control the i nner illum ination lamp (roof lamp work). When the igni tion powe r is off, if o ne of the 4 doors is open, the inner illum ination lamp will light on; while afte r 15 min, the inn er illumination lamp will be off automatically to saveE R C14 R A23 F1 0 7.5A P/L C6

Instrument/FrontGround/G

O B14

W B30

Front ISU

F igure14- 3 Vehicle inner illumina tion lamp circuit

28

3Turn lamp and hazard warning light circuit1Turn lamp and dangerous warning lamp circuit As shown in figure 14-4, the 30th power line supply power to the E pin of front ISU via fuse Fb29 and then fuse FB25, and output from the C20 pin of front ISU to suppply power to F/R turn lamp and right side turn lamp; the voltage output from the the C9 pin of front ISU supply power to F/L turn lamp and left side turn lamp; it also supply power to the 4th pin of dangerous warning lamp. If one turn lamp cause trouble , then the other turn lamp of the same side will speed up the flashing frequency, and it will be twice of that in normal condition. But the side turn signal lamp will not be influenced. 2 Anti-theft activate lamp warning There are two modes of vehicle lamp warning system: activate or unchain mode. When the vehicle lamps connected, open the driver's door (system activate), the buzzer will warning. If you close the driver's door or turn off the vehicle lamp switch when the buzzer is warning , it will stop.30 15 ACC1 ACC2 31 ILLUMFB30 80A

4Headlamp circuit1High Beam Circuit High Be am Contr ol Circuit The vo ltage of 30 th linefu se FB22h igh beam r elay coilthe A19 pi n of front I SU, wh en the high beam relay coil get el ectricity, the contact point will c lose. High Be am Main C ircuit The vol tage of 30th lineline after the h igh beam relay contac t point get into two li nes: one line via th e FB25F/L high bea m, the oth er line via the FB26F/R high beam, the h igh bea m light on then. 2Lo w Beam C ircuit Low Be am Contro l Circuit The voltage of 30t h linefus e Fb22lo w beam re lay coilt he A17 pin of front I SU, wh en the low beam relay coil get ele ctricity, th e contact p oint will cl ose. Low Bea m Main Ci rcuit The volt age of 30th lineline after the lo w beam re lay contact point get i nto three li nes: one line via the FB27 F/L low beam and F/ L lamp ad justing mo tor , the 2 nd line supply pow er to head lamp adjusting switch ; the 3rd line via the FB14F/R low beam and F/R la mp adju sting moto r , the low beam ligh t on then. 3La mp Comb ination Sw itch Lamp C hanging S witch When th e switch is set at th e high beam positio n, the 10t h and 13t h pin of la mp com bination s witch are c onnectted, the 12nd8th and 11 st pin are c onnectted, the B1 pi n of fron t ISU th e 10th pin of lamp c ombinatio n switch the 13rd pin of lamp combina tion switchgroun d, the B12 pin of fro nt ISU the 12nd pi n of lamp c ombinatio n switch the 11st pin of lam p combina tion switchground. When t he switch is set at th e low beam position , the 12n d and 11th pin of la mp com bination s witch are c onnectted, the 12nd11st and 9 th pin are connectted . When t he switch is set at t he overtake position , the 10th and 13rd pin of la mp com bination s witch are c onnectted. Lamp M ain Switch2

231

E F1 25A C7 C8 C20 C9

Front ISUA3 Y To Haz ard W a rni ng l ig ht Swit ch 6# P G/L Br

P

I nstr ume nt/Front Ground/ 11

Front Ground/Front Engine Compartment/13

Fron t G round/ Fr ont En gin e Com part ment /16

Hazard Sw itch

Le f t Side Turn Li ght

Y 1 Br 6

From ILLUMRight Side Turn Light

5 W 4

From Front Left Turn

When t he switch is set at the dimme r position , the 10th and 13th pin of la mp com bination s witch are c onnectted; and when the switch is set at th e headlam p position, the 10th and 13rd pin of lamp combinat ion switch are connec tted, and th e 12nd1 1st and 8th pin are connectted . Steering Switch When th e switch is set at the L position, the 6th and 5th pin of lamp comb ination sw itch are connectted; and when the swit ch is set a t the R po sition, the 6th and 7 th pin of la mp com bination s witch are c onnectted. The circui t is shown a s figure 14 -5.

31

Figu re14-4 T urn lamp circuit

29

30 15 ACC1 ACC2 31 ILLUMFB22 7.5A To Ins trum ent 11 G7 G4

2

Right low beam

High Beam Relay

Low Beam Relay

L 12 I nstrum en t / Fr ont G ro und /9

FB25 10AF/R Low beam

FB27 15A

FB26 10A P5

FB14 15A P11

L11

P7

Ins tru me nt / Fro nt Gr oun d/ 9

Lg SbLeft high beam Right high beam Left low beam

SbM

G/W( 2.5ko)

WMHe adlamp adjusting switch

F/L h i gh / lo w bea mBr/WA19

H/LP LEVEL'G DEVICE SW

F/ R hig h /lo w bea m

Gr A17

Front ISUB12 B1 B28 B4 B19

F/L low beam

O/B

Lg/W

L/W

Br/W

G/W

F/L high beamTer m ina l F unct ionM a in L ig h t S w itc B ea m C h a n ge S wit c h ( Tu rn On T he H e a d la m p) O FF Cle a ra n c e Lamp Hea d Lamp Low Beam H ig h Beam O v e rt a k in g

O/B4 3 2 1 13 12 11

Lg/W10 9

L/W8 7

Br/B6

G/W5

L

Installat ion position of high /low b eam

St e e r in g Sw it c h

R

( W)

611

120 12011

4211

42

Lamp combina tion swit ch31ToInstrument 15#11

Figure14-5 Head lamp Circuit

30

5Night lamp adjusting circuitT he n i g ht l am p a djus t i n g c ir cu it i s show n as fi gur e 146 , t he br i g ht nes s ad j ustme nt of t he da r k l ight ( n i ght l am p ) i s c o ntro ll e d by t he k nob a t t h e l ef t l o w e r par t o f i ns t rum ent. T he da rkl i ght m ai n power i s suppl i ed by the C 1 1 pin of f r ont I S U.Instal lation posit ion of night lamp and headlamp ad justing sw itch

30 15 ACC1 ACC2 31 ILLUM

Front f og lamp s witch

W

L/W

W

L/W

WRear Fog Light Sw itch

L/W

ILLUM

4

3

1

GND

Rear Wi ndshield Warmer Switch

4

3

1

4

3

1

Front F og Light Switch

6

5

2

6

5

2Fr ont Ground/ Instrument /B7

6

5

2Front Ground/ Inst rum ent / B8

(2)31

(3)58b

To In st ru ment 13#

(1)58FrontGround/ Inst rument/ 2

L

RC14

G

Y

Br /B

L

R

G /L

L

G

R

A10 A13 B32

A22 A18B29

A24 A12 B13

VC11

F10 7.5A F1 25A

Front ISUF C7 C8

Fro nt I SUNight lamp adjus ting switch

P

P

Front fo g lamp

Installation p osition of F /R fog lamp

Figure14-6 Nig ht lam p adju sting c ircuit

F ront Gro und /Fr o nt Engi ne Comp artmen t/13

6Fog lamp circuitThe 30th power line fuse FB29 the E pin of front ISU fuse F1 the C7 C8 pin of front ISU to output, supply power to the front /rear fog l amp. The 30t h power line fuse Fb29 the E pin of front ISU fuse F10the C14 pin of front ISU to ou tputsup ply power to the 3rd pin of front /rear fog l amp switch . The fog lamp circu it is show n as figure 14-7.

Front R ight Fog Lig ht

Front Left Fog Light

Installation position of F/L fog lam p

Installat ion position of R/L fog lamp

F igure14- 7 Fog La mp Circuit

31

7CAN-BUS main lineThe CA N data bus designed by the BOSCH c ompany is applied b y Chery A5, sh own as fig ure 14-8. This enables the data communication of eac h compute r, and for ms the on-board network syst em. The in strument is con nectted to the engine EMSA BSfront ISU computer by C AN line and sha re the dat a. The CA N end of instrumen t is 2930 the C AN end of eng ine ECU i s 6281and the C AN end of front ISU is A25A26. Mainta in way o f the CAN data tra nsmissio n system BUS line test The in spect of c onnect ca pability open circ uit or sho rt circuit com puter po wer or gro und. Clo se the ign ition swi tch, cont rol the u nit plug, and do no t con nect the wiring harness plug at the tim e. Test th e resistan ce between the 62nd and 81st pin of A5 en gine con trol unit, this is th e resistan ce val ue of the d ata trasmission end port, the prescripti ve value is 123, if it is n ot so, plea se replace the engin e control unit. DTC logical d ecision. Sign al wavefor m test.

8Other position circuit diagram

An ti-Theft Horn

Door Con tact Swit ch

Fro n t ISU Fus eFront Engine Compar tment Cover Switch

Horn Sw itch

Fr ont ISU A26 A25

Co mbination In strument 30 29

ECU 62 81

Front IS UC AN-H CAN-L F ront turn Lamp

I nstallatio n position of front e ngine co mpartmen t cover a nd trunk switch

Figu re14-8 CAN-BUS main li ne

Trunk Sw itch

Installation pos iti on of night l amp and headlamp adjusting switch

Diagnos is Plug

32

Rear ISU System30 15 ACC1 ACC2 31 ILLUM 30 15 ACC1 ACC2 31 ILLUM

7

7

7

To front ISU A29

FB31 50A

FB3 7.5A

To front ISU A30 Re ar Wind sh ield G lass Hea te r r esisst or Conta ct Swi tch o f R ea r Lef t Do o r Contact Switch of Rear Right DoorM

Trunk Lid LockMotorUP DOWN

Regulator Switch of Rear Right Door

L10 To the Front ISU Pe1 11# and Instrument, Combination Switch 2#

DOWN

UP

Regulator Switch of Rear Left Door

Trunk Lam pRear G round/Rear R ight Door/9 L BrB11 FR 1 25A FR3 1 5A FR4 15 A FR5 15A A9

Rear Ground/Rear Right Door6 V Y/BA12

Rear Ground/ Rear Left Door /6 BrA 11

Rear Ground/ Rear Left Door/10 GA13

RA6

RC1

Lg/BA16

LgA8

G/W

G/WB3

OB12

WA7

A22

A10

F R2 30A

Rear ISU

HBRIDGE

HBR IDGE

D1

B19

B20

B8

B9

B4

B1

B13

B15

B16

B5

A 4 A19

B

Br

G

P

Y

Y

L

Gr

Gr

Br

O/B

L/W

Y

Rear Ground/ Right Rear Door/4

Rear Ground/Rear Right Door/8 Rear Ground/ Rear Right Door/9 Rear Ground/Rear Right Door/6

Rear Ground/ Rear fuse/E Rear Ground/ Rear fuse/F

Rear Ground/Rear fuse/D

Gr M M

Y

G

L

Br

Br

L

Br/B

O/B

Gr 1

Gr L/W Y 5 13 16 7 8 15 V/W Lg/B GLeft Probe Middle Probe Right Probe

Rear Left Regu lator Motor

Reg ulator M otor o f Rear Right Door

31 CAN_H CAN_L

Rear Combination Light System

Radar M odule

Figure15-1 Rear ISU Syste m Circuit Diagram

33

1Rear ISUThe parts that controlled by the rear ISU have the following functions: Rear window galvanothermy wire time control Rear trunk lock motor Rear trunk illuminat ion lamp Reverse radar system Vehicle outside rear lamp brakelampfog lampreverse lamp license plate lamp and so on The rear leftright door window lifter motor Data transfer with front ISU

1Reverse warning control unit 2Reverse warning R/L sensor 3Reverse warning m id sensor 4Reverse warning R/R sensor 5Rear ISU computer 6Reverse switch The 1st pin of the reverse warning control unit is the pow er supply pin, it connects the B15 pin of rear ISU; the 5th pin is CLK it connects to the A4 pin of rear ISU; the 13th pin is DAT it connects to the A19 pin of rear ISU;the 16th pin is GND th e 7th pin connect to the reverse warning R/L sensor; the 8th pin is connectted to the reverse w arning mid sensor;the 15th pin i s connectted to the reverse warning R/R sensor. The reverse warning system start to self-check when the ignition switch is turned on, if the ignition switch is not turned off, the reverse warning system will keep in active state, but the distance control fuction could only be started when the vehicle is put into gear. When the reverse warning system is in active state, the buzzer in the instrument will make a short signal sound. If the control unit finds trouble in the system during the self-check procedure, the buzzer will generate a 5s continuous sound. When put into the reverse gear, and if the vehicle is 1.5m away from the roadblock, the buzzer will start to warning. The sound frequency will increase with the shorten of the distance. And when there is only 25mm, the buzzer will generate continuous sound.Rear ISUB15 Gr A4 L/W A19 YRear ground/ Rear fuse/D

D Ground

A wire plug 32

To 31st line

B plug 20

Rear ground/ Rear fuse/E

CpowerGr L/W Y 16 GND Radar Module 7 8 15 V/W Lg/B G

Rear ISU fuse

1 POWER

5 13 CLK DATA

Fig ure15-2 Rear ISU Configuration

2Reverse radar systemTh e Advanced reverse warning system is setted into The A5 , it is composed of the following parts:Reverse warning sensor

Left Probe

Middle Probe

Right Probe

Figure15-3 Reverse Radar System Circuit

34

3Brake lamp a nd rev ersing lamp circuitThe 30th wi re suppl ies power to the C1 pin of rear ISU via fuse Fb31, th e rear ISU gets el ectricity. The B1 pin of rear ISU is connect ted to th e left bra ke lamph igh-mou nted bra ke lamp and righ t brake la mp; the B4 pin is connect ted to th e rear left turn la mp; the B 15 pin i s connec tted to th e rear left reversing lamprear right reversin g lamp an d the 1st pin of reversing r adar ; B1 6 is connectted to the rear l eft dimmerlicen se plate lamp and rear righ t dimme r.30

FB31 50A RC1

Posit ive fuse box

FR3 15A

FR4 15A

FR 5 15A

Rear ISU

B4

B1

B13

B15

B16

B5

Instal la ti on p o siti on o f re ar right lam p

Y

L

Gr

Gr

Rear Combination Light System

Br

O/B

The in stallation p osition of rea r left lamp

Gr

Y

G

L

Br

Br

L

Br/B

O/B

Gr

Re versing lam p

Rear fo g lamp

Bra ke lam p (dimm er)

License plate lamp

High -mounted brake lamp

Turn lamp 31

Figure15 -4 Bra ke L am p a nd R evers in g L amp C ircuit

35

Instrument System30 15 ACC1 ACC2 31 ILLUMFB22 7.5A FB3 7.5A

30 15 ACC1 ACC2 31 ILLUM

Circuit AnalysisThe A5 aut omobile c ombination instrum ent contains serie s of instr uments and met ers that show the vehicle statusall k inds of warning lamp that supervise the vehi cle to pre vent abno rmal performance and inform the driv er and indicator lamps th at show the driver how each part wor ks and al so illume the instr uments and met ers. The c ircuit is shown as figure 16-1. Th e Voltage of the battery supply to the 11th pin of combin ation inst rument via fuse FB22. The voltage of the 15 th wire w hich has gone thro ugh the i gnition switch supply to the 13th p in of com bination i nstrument via fuse FB3, it is for the fuel war ning lamp door open warn ing lamp engine oil warni ng lamp brake system w arning lampABS warning lampai r bag warning lamp and so on . Once the othe r end of these indica tors gain electricit y, they'll w ork. The 29th30t h pin of the combination inst rument ar e connect ted to CA N wire, instruments are c onnectted to engin e EMS ABS fro nt ISU co mputer by CAN wire, they share data inf ormation. The inst rument s ystem ca n read D TC by apparat us, the 15t h pin of the combination instrument is diagnose wire.

To Air Bag To Module Dynamo 10# Fuse Box L Plug-In Unit 10# Instrument/Front Ground/B4

To ECU 59#

To To Air Conditioner Handbrak e Control Panel Module 10# Instrument/Air Conditioner/1

To Brake Shoe Thic kness Sensor

Fuse Box G Plug-In Unit 4#

ECU /A2/ 6

Fuse Box G Plug-In Unit 7#

To Sunroof Module 3# Instrument/ FrontGround/2

T o Fron t I SU Pl ug-In Un it 11# Instrument/Front Ground/B5 To Combination Switch2# Instrum ent/Air Bag/D# ECU/A2/16 Instrument/Front Ground/13

Front Ground/Roof/4 Instrument/Front Ground/1

11 N ormal Live Wire

13 Ignition Switch Power Supply

12 Backl ight Power Supply

17 Air Bag Alarm

16 Charge Indicator Light

27 Vehicle Speed Signal Input

18 Handbrake Indicator Light

7 Vehicle Speed Signal Output

32 Brake Shoe Alarm

To Combination InstrumentEngine Oil Pressure Alarm 9 Brake Fluid Level Alarm 2

3

5

30

29

26

Position of combination Ins trumentSide Air Bag Warning Lamp 24 Diagnosis O il Level Signal Input Line 21 15 CAN Line Wake Input 31

ECU/A2/11

ECU/A 1/ 15

Instrument/ AirBag/B# Engine Oil Pressure Switch Brake Fluid Level Sensor TO Bag Module 47# To Diagnosis Port 7#

Instrument/Front Ground/12 Front Ground/Rear Ground B/D# Fuel Level Sensor To Front ISU PEI Plug-In Unit 2#

Engine Oil Pressure Switch10 6 10 3

Brake F luid Leve l Sensor

Fuel Leve l Sensor8

Ground CAN-H CAN-L

Figure16-1

Instrument System Ci rcuit D iagram

36

Wiper System30 15 ACC1 ACC2 31 ILLUM

FB12 15AW ip e r Mo to r P la ce W ip e r Mo to r

Wip e r Mo tor b u ild in P lac e

W iper System Circu it Analysis:The wi per system ciruit is s hown as fi gure 17-1 . The ACC2 power supply w ire supplies power to the C19 of front ISUthe 3r d7th8th pin of w iper switch via fuse F B12. When the wiper switch is set at the HI positio n, the 2nd3rd pin of the wiper switch are conne ctted, the ACC2 pow er supply wirethe 3rd pin of wiper sw itchthe 2nd pin of wiper swit chthe 2 nd pin of w iper motorthe 5th pin of wiper motor the 31st line are connectted to ground. The wipe r motor wi ll work in high speed then. When the wiper motor is set at the position o f LO, the 3rd 4th pin of wiper switch are conne ctted, the ACC2 pow er supply wirethe 3rd pin of wiper sw itchthe 4th pin of wiper swi tchthe 4 th pin of w iper moto rthe 5th pin of wiper motor the 31st line are connectted to ground. The wipe r motor wi ll work in low speed then. When the wiper switch is set at the W ASH position, the 8t h and 9th pin are connectted, the ACC2 power supply wire8t h pin of wiper switch9th pin of wiper switchwashing motorthe 31st line are connectted to ground. T he washing motor will spew wat er then. When the wiper switch is at the position of INT, the 4th 5th pin are connectted, 6th7th pin are connectted, when the wiper switch input intermission signal to the front ISU via A15pin, the inner relay of front ISU will electrify for 0.5s. After 0.5s,The ACC2 power supply wirethe 1st pin of wiper Motorthe 3rd pin of wiper Motor the C18 pin of front ISUthe C17 pin of front ISU the 5th pin of wiper switchthe 4th pin of wiper switchthe 4th pin of wiper motorthe 5th pin of wiper motorthe 31st line are connectted to ground. The wiper motor wi ll work in low speed then. the motor will operate for one circle and stop at the stop position with the contr ol of wiper motor cam plate switch circuit. If the i nput time of washer switch is over 0.3s , the inner washer o f front ISU will elec trify. Whe n the was her switch is in the connect position, the wiper motor will continue to work. If the washer switch i s disconn ected aga in, the motor will co ntinue to o perate for 2 circles.

2MIST OFF

3

4

5

6

7

8

9

5

M

Wiper Switch

INT LO HI WASH

W iper M otor

M WasherMotor

2 4

3 1

Wiper Sw itch

C17

A15

B23

C19

C18

Front ISUFigur e17-1 Wiper System Circu it Diag ram

37

Powe r Rea r View Mirr or Sys tem30 15 ACC1 ACC2 31 ILLUM

Power Rear View Mirror System Circuit analyseThe power rear view mirror is shown as figure 18-1. When the ignition switch is set to the position of ON or ST, the voltage of the battery gets to the 15th wire7.5A fuse Fb27th pin of9 9

power rear view mirror switch, the power rear view mirror get voltage. 1The rear left view mirror incline to up and down, turn left and right circuit 1Rear left view mirror Rear left view mirror upwards: choose the L button on the control switch panel, press the UP key of the control switch, the 7th and 6th pin of rear view mirror switch are connectted, the 3rd and 8th pin are connectted, the power go through the 7th pin of control switch 6th pinrear left view up and down control motor 3rd pin of rear view mirror 8th pin ground. The rear left view mirror will move upwards then. Rear left view mirror downwards: press the DOWN key of the control switch, the 7th and 3rd pin of rear view mirror switch are connectted, the 6th and 8th pin are connectted, the power go through the 7th pin of control switch 3rd pin rear left view up and down control motor 6th pin of rear view mirror 8th pin ground. The rear left view mirror will move down-wards then. Rear left view mirror move to left press the LEFT key of the control switch, the 7th

FB2 7.5A B 8

Power Rear V iew Mirror Switch

L19 7 0 1

LEFT RIGHT

LEFT RIG HT

DO WN

UP

DO WN UP

RH MIRR DR

LH MRRDR

RH MIRRDR

L H Mirr or

To Front ISU PP3 16#

4 W/B

2 LG

5 R

3 R

6 R

Powe r Rear V iew M irror S witch

and 6th pin of rear view mirror switch are connectted, the 2nd and 8th pin are connectted, the power go through the 7th pin of rear view mirror 6th pin rear left view left and right control motor 2nd pin of rear view mirror 8th pin ground. The rear left view mirror will move left then. Rear left view mirror move to right press the RIGHT key of the control switch, the 7th and 2nd pin of rear view mirror switch are connectted, the 6th and 8th pin are connectted, the power go through the 7th pin of rear view mirror 2nd pin rear left view left and right

Front Ground/ Front Left 1/5 Front Grou nd/Front Left 1 /3 Front Ground/ Front Right/14 Fron t Ground/Front Right/15 Fr ont Ground/ Fr ont Right /13 Front Ground / Front Left 1/4

control motor 6th pin of rear view mirror 8th pin ground. The rear left view mirror willRe ar Left V iew M irror

R ear Right Vie w Mirro r

Front Ground/ Front Left 1/14

move right then. 2The rear right view mirrorRear Left Vi ew Mirror

- LR + + UD + + -

M

Re a r Right V iew Mi rror

+

LR

+ -

M M

M

+ UD + -

The working principle of the right rear view mirror is the same with the left. Choose the R button on the control switch panel, when press the UP button , the 7th and 6th pin of rear view mirror switch are connectted, the 5th and 8th pin are connectted; when press the DOWN button, the 7th and 5th pin of the rear view mirror are connectted, the 6th and 8th are connectted; when press the LEFT button, the 7th and 6th pin of the rear view mirror are connectted, the 4th and 8th are connectted; when press the RIGHT button, the 7th and 4th pin of the rear view mirror are connectted, the 6th and 8th are connectted. 2Demist part circuit There is demist circuit in the left and right power rear view mirror, when press the demist switch, voltage from the ISU PP3 16# connect to 31st ground wire via rear left right view mirror heating wire.

Figure18-1 Pow er Rear View Mirror Circuit Diagram

38

Power Window of Fr ont Door & P ower D oor Lock System30 15 AC C1 ACC2 31 ILLU M

Re ar Righ t Do or Lo ck M ot or

Rea r Le ft D oor L ock M otor

Fro nt R igh t Doo r Loc k M oto r

F ron t Le ft D oor Lo ck Mo torMo tor contr ol wire Door contact switch

M

M

M

M

B

Cen ter Con tro l Fr ont Rig ht Do or P ower W indo w Bu ttonMo tor

Front L eft Do or Power Window M otor

MRear G round/ Rear Left /3 Rea r Grou nd/ Rea r Left/7 Fron t Ground / Fron t Right / 7Fro nt Gr ound / Lef t 2/6

MDOWN UP DO WN

1

2Door lock switc h

DC en ter Con tro l Bu tton

A

Re ar Ground / Rear Right /3

R ear Gro und/ R ear Rig ht /7 Front G round/ R ear Gro und/3 Front Groun d/ Rear Ground/2 Front Groun d/ Fron t Right /6Fro nt Left Door Loc k Motor

C

UP

F ro nt Gro un d/ L eft 2 /7 Fron t Groeund/ Left 1/13 Front Grou nd/ Left 1/12 Fr on t Gro un d/ Le ft 2/ 5 F ro nt G r ou n d / F ro nt R ig ht /9

Front Ground/ Front Right /6

Elevato r Mo torFront Ground/ Left 1/ 9Front Ground / Lef t 1/1 T o Wi per S witch 3# T o Wiper Switch 4#

Fro nt G round/ R ear Gr ound/11

Front G round/ R ear Gro und/3

L D5

Y D4

P/L B31

L B15

R B18

V/R D 10

V/W D9

Y

P

G A15

O/G B23

D 12 D11

C wire plug 20

E power D wire plug 12

Fro nt IS UA wire p lug 32A 20 A21 Y/B In strument/ FrontGrou nd/C 7 V/B Ins trument/ Front Ground/C9 F ront Gr ound/ F ront Ri ght Doo r/B

F ground B wire plug 32B2 W B9 B26 LG B25 Br B11 P B10 B27 G Y

Fro nt IS U

A5

A6

C 19 LG Ins trument/ Front Ground/C7

C18 B/W

C 17 B

Gr/W

B/W V Instr ument/ Front Grou nd/C 7

Front Ground/Front Right Door/C

Fron t Grou nd/2/16

Fro nt Grou nd/ Left 2/3

Front Ground/ Front G round/ Left 2/15 L eft 2/12

Front G round/ Front Gro und/ Left 2/1 4 Left 2/4

Front Ground / Front Ground/ Front Left Door 2/1 Left 2 / 2

Front Ground / Front Left Door 2 /14

6

7

3

16

4

15

5

8

6

7

Front Right Door Power Window Switch

13

Ch ild Safety Lo ck

F ro nt Lef t D oo r

T o W iper S witc h 2#

To W ipe r Swit ch 3 #

To Wip er Sw itch 6#

C en tral control buttonR ear Rig ht Do or Po wer W in d ow S w itc h R e ar L eft Do or Po we r Win do wS wit ch F ron t R igh t D o or P ow er Wi ndo w Sw itc h F ro nt R igh t D oo r Po we rWi ndo wS wi tch

9 31

Figure19-1

Power Window of Front Door & Power Door Lock System Diagram

39

Power W indow of Front Do or & P ower Door L ock Cir cuit analyseThe circuit analysis of fron t door window lifter and four doors lock. Please re fer to fig ure 19- 1. 1p ower w indowThe power window system c ircuit is composed of power wi ndow main switch tha t set at the front left doorthree p ower wi ndow switches th at set at the th ree doorsfour window motor and frontrear ISU computer. The power w indow button o peration set is th e device to have the F/L F /R R/ L R/R window go up a nd down automa tically. In th e 40s aft er turning off the ignition power, the wind ows' mo vement c an b e controlled, and after 40s , there will be no response. The front ISU receives the up or down signal fr om the p ower wi ndow main switch to drive the power w indow motor wo rk to open or clo se the wi ndow. The 2nd pin of ISU is connect ted to the children safety l ock. Wh en press the safety switch on the power window main switch, signal is sent to the front ISU,whic h cut off the rear door power window motor to p revent t he rear seat window working. This will enable the pas senger, especially childre n to misso pen the window and resu lt in accident.

Electric Seat System30 15 ACC1 ACC2 31 I LLUM

FB21 30A C4 1

The upwards and dow nwards adjust ing swi tch of the seat front par t

Seat back rest incline adjusting switch

The forwards and backwards sliding s witch of seat The upwards and downwards adjusting swi tch of the seat rear part

Reg ulate switch

2 FWD BKD U D U D FWD BKD

3

4

5

6

7

8

9

10

2Central lockThe vehicle d oor control set i s at the d river sea t side. W hen the driver op en o r close th e door, the open and clo se signal from the minisiz e switch in the do or lo ck will be sent to the B31 and B15 pin of f ront ISU. The ISU computer cont rol th e door l ock mot or work accordin g to the open or close signal from the D4 a nd D 5 pin of ISU. If us e the ma nual keyouter or button at the drive si deinner to lock o r unlock, the four doors w ill response imme diately. If pr ess the lo ck/unlock button on the remote controlle r when pull out the ig nition k ey from the lock core, the four doo rs will b e locked immedia tely. Th en, th e anti- theft sys tem will get into the acti vation or release state. If one doo r is n ot closed well, then use th e remot e controller to lo ck, all th e four doors will be lo cked or unlocked right aw ay .

M

M

T he upwards a nd The upwards and downwards downwa rds adjusting d ynamotor adjusting dy namoto r of the of the seat front part seat rear par t

M The forw ards and backward s sliding dynam otor

M Se at backrest incl ine adjusting dynamotor

Figure20-1 Elec tric se at 8 D irection al A djust C ircuit

40

Electric Seat System C ircuit Analys isThe driver seat of A5 is elec tric adjust able seat. It has four adjusting m otor and adjust control switc h. The adj usting mot or is perma nent magnet motor. I t realizes t he the circ umvolve from frontisp iece to inv erse with t he differen t electrifi ed directio n of each m otor . So, the four adjusting motors enabl e the seat t o move towards 8 directions suc h as frontrearup down grad ient and so on. The 8 directions adjustabl e seat circu it is shown as figure 20-1. The pos itive voltage of batterypositi ve fuse box 120A fuse Fb2830th line3 0A fuse Fb21the 1 st pin of electric seat adjusting switch.

3Up wards an d downw ards of s eat rear partWhen press the UP button of t he seat's r ear part, battery voltage that r eaches the 1st p in of adjusting switch via the U P contact point of s eat's adjus ting switc hthe 7th pin o f seat's adjusting sw itchthe front seat up and down motor the 8th pin of seat's adjusting switchthe UP contact point of seat's adjustin g switch the 2nd p in of seat's adjusting switchthe ground point near the h and brakeNegativ e of batter y, then the rear part of seat will move upwards. When pre ss the DO WN button of the sea t's rear pa rt, battery voltage th at reaches the 1 st pin of a djusting switch