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BYD AUTO
Foreword
This Repair Manual provides information about diagnosis and
repair procedures, adjustment and specifications for repair
technicians. Please use this Repair Manual together with structural
drawings book when necessary.
If you need information about product brand, part number or
special tool mentioned in this Repair Manual, please feel free to
contact BYD Auto Co., Ltd. All information, illustrations and product
description used in this Manual are applicable to situation when
this Manual is going to publish. BYD reserve rights to change
information in this Manual at any time without further Notes and any
restraint.
Without permission of BYD Auto Co., Ltd., do not copy, store any
part of this manual on retrieval system or spread it by means of
electronic, mechanical, copy or recording methods. The abovementioned is applicable to words, graphs and tables, etc.
BYD AUTO
Caution
Warning: in order to reduce possibility that person and/or property is damaged, please
observe the following descriptions:
1.
This Manual is prepared by BYD Auto Co., Ltd. for qualified professional technicians. Anyone
without proper training, tools and equipment who tries to repair and maintain this car may
cause self or other persons to be injured.
2.
Correct repair and maintenance methods are important for the personal safety of repair
technicians, safe and reliable operation of the motor vehicle. Please use the same original
part as one part which you need to replace, or the part specified by BYD Auto Co., Ltd.. Do
not use replacement parts unauthorized by BYD Auto Co., Ltd..
3.
Repair procedures recommended or described in this Manual are effective methods for
repair and maintenance. A specially designed tool needs to be used in some procedures.
Therefore, you must ensure that personal safety or safe operation of vehicle will not be
threatened when you use replacement parts, repair procedures or tools which have not
authorized or accepted by BYD Auto Co., Ltd..
4.
This Manual contains information under "Warning", "Special Note" and "Notes" which
should be complied with to avoid injury in repair and maintenance. Improper maintenance
may damage vehicle or bring potential risk to the vehicle. These "warning", "special notes"
and "Notes"do not cover all cases. BYD Auto Co., Ltd. cannot give warning and compensate
for potential risk due to violation of these notes.
5.
This Manual includes repair procedures for vehicle equipped with safe airbag system
(hereinafter referred to as the "air bag"). Refer to "Warning", "Special Notes", "Notes" and
"Warnings" in "Protection Device ". Please refer to parts of air bag and line position drawing
in "Protection Equipment" before repairing parts of air bag or its line or adjacent to the airbag.
Violation of information under "Warning" will cause the air bag deployment, personal injury or
unnecessary repair of airbag.
Violation of information under "Warning" will cause the air bag deployment, personal injury or
unnecessary repair of airbag.
BYD AUTO
Your name
of
Dealer Name
Subject
Description of problem
Revision comments
Publication Date
Reporter name
BYD AUTO
Table of Contents
Table of Contents............................................................................................................................1
Section 1 Technical Performance and Parameters of Finished Automobile.....................3
1.1. Main technical parameters of finished automobile:..............................................3
1.2. Engine performance parameter:.............................................................................4
1.3. Engine accessory and chassis assembly type and parameter:..........................4
1.4. Body structure type..................................................................................................5
1.5. Body accessory........................................................................................................5
1.6. A/C system structure and parameter......................................................................6
1.7. Electric System Structure and Parameters............................................................6
1.8. Lubricating oil and fuel, and capacity....................................................................8
Section 2 Vehicle identification.............................................................................................9
2.1. Vehicle identification number(VIN).........................................................................9
2.2 Warning note label position:.................................................................................10
Section 3 Maintenance rule..................................................................................................11
3.1. Warning and notes..................................................................................................11
3.2. Instructions:............................................................................................................11
Section 4 Overhaul Specification........................................................................................30
4.1. Troubleshooting method........................................................................................30
4.2. Electric control system..........................................................................................31
4.3. Corrective maintenance procedure......................................................................38
Section 5 Abbreviations and Color Symbols of Electric Wires........................................40
5.1. Abbreviations..........................................................................................................40
5.2. Color symbols of electric wires............................................................................43
1.
main
Diagnosis
Visual inspection
Dismantle/install,
replace,
disassembly/assemble, check and adjust
2.
Preparation
Final inspection
BYD AUTO
4.
Repair specification
Repair steps
5.
Definition of terms
6.
Design parameter
Internal code
Product model
Basic type
Drive type
Outline
dimension
(mm)
Width
Height
(without
load)
Axle distance (mm)
Wheel track
(mm)
Front
Rear
Front overhang(mm)
Rear overhang(mm)
Minimum ground clearance
(mm)
Model
Complete
Mass
vehicle
parameters
kerb
(kg)
mass
Full load
mass
Rated seating
capacity (pc.)
Approach
Trafficability
angle
characteristics
Departur
(full load)
e angle
Minimum
diameter of
turning circle
(m)
Luggage
compartment
capacity (L)
Maximum
gradeability (%)
Unit
Model
BYD483QB
Type
Electronic fuel
injection system
type
BYD488QA
4G69S4M
In-line four-cylinder,
forced water cooling
cycle, double
overhead camshafts
DOHC, four stroke
Cylinder bore
88
Stroke
96
Displacement
2.362 L
Compression ratio
9.81
Rated power
123 /6000
Maximum torque
234/40004500
Minimum specific
fuel consumption
250+10
Ignition type
Structure parameter
Exhaust system
Intake system
Including fuel tank, fuel pump, fuel filter, fuel pipe, accelerator pedal,
accelerator cable and fuel tank.
Cooling system
Transmission
Model
Clutch
type
BYD483QB
Dry single plate,
diaphragm spring
constant pressure
Manual
Type
Model
Gear ratio 1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Reverse
4G69S4M
Automatic
BYD488QA
Dry single plate,
diaphragm spring
constant pressure
Manual
Final ratio
Final ratio
Drive shaft
Suspension
Type
Breaking type
Front suspension
Rear suspension
Tyre type
Wheel and
tyre
Steering
Tyre size
Steering gear type
Steering gear
Status
No load
Front wheel
camber
Front wheel toe-in
Wheel
alignment
Angle of toe-in of
kingpin
Kingpin inclination
Rear wheel
camber
Rear wheel toe-in
Structure type
Front brake
Rear brake
Brake
system
Design parameters
Body type
Door assembly
Engine cover
Luggage compartment
1.5.Body accessory
Content
Design parameters
Door lock
Front/rear bumpers
Instrument panel
Injection moulding
ABC pillars
Roof
Sun visor
Windscreen
Front angle window: double curved surface, full tempered glass, 3.5mm thick
Rear windscreen: hyperboloid, full-tempered glasses,3.5mm thick
Side window: double curved surface, area tempered glass, 3.5mm thick,
electric window regulator
Sunroof
Rearview mirror
Outside rearview mirror: convex reflectors on the left and right, electrically
regulated, heatable, foldable (economy, comfortable and honourable
versions are manual, foldable and heatable; flagship version is electric,
foldable and heatable, with a camera).
Inside rearview mirror: manual anti-dazzle type, double position inside
mirror, direction indicator
Front row seat: electric 6-direction adjusting luxury leather driver seat, with
heating function and headrest; electric 4-direction adjusting luxury leather
auxiliary driver seat, with headrest.
Seat
Middle row seat: 6:4 backrest foldable, cushion adjustable back and forth,
luxury leather seat, with headrest;
Rear row seat: optional
Front row seat is provided with three-point seat belt (each for main and
auxiliary driver seats), middle row seat is provided with three-point seat belt
Seat belt
Air conditioning
system
Design parameters
Structure type
Operation
Automatic constant temperature air conditioner, multizone separate temperature adjustment, with humidity
adjustment function and air filter.
Refrigerating fluid
Compressor
Parameters
Blower
Design parameters
Circuit
Generator
Power supply,
starter, charging
system
Starter
Electric fan
Battery
Front
combination
light
Side steering
lamp
Front fog light
Rear
combination
lamp
Rear license
Power: 12V-5W, 2 sets
lamp
Front/rear
Power: 12V-5W, 6 sets
interior lamps
Top lamp
Power: 12V-8W
Lighting, signal
system
Rear interior
Power: 12V-5W,2 sets
light
Rear luggage
compartment
Power: 12V-5W, 2 sets
lamp
Door courtesy
Power: 12V-1.08W
lamp
Foot
illumination
Power: 12V-0.54W, 2 sets
light
Door lamp
12V-5W, 4 sets
Combination
instrument
LED
lamp
High-mounted
12V-5W,2 sets
brake lamp
Instrument
Combination
Combination instrument: fuel meter, speedometer, engine
system
instrument
tachometer and coolant temperature gauge etc.
Indicator lamp Including: left/right steering indicator lamp, low fuel warning
on combination lamp, high beam indicator lamp, parking brake indicator lamp,
instrument
safety system indicator lamp, seat belt indicator lamp,
supplement restraint system indicator lamp, door and trunk
opening indicator lamp, ABS brake indicator lamp, constant
speed cruise control indicator lamp(2.4 AT Luxury type), rear
fog lamp indicator lamp, front fog indicator lamp, low engine oil
pressure indicator lamp, intelligent key system warning lamp,
small lamp indicator lamp, charging system warning lamp,
engine malfunction indicator lamp, SVS indicator lamp etc.
Audio
Electrical
auxiliary system
Communication
Lubricant
Content
Engine oil
Design parameters
4G69: about 3.3~4.3L; API class: SG, SH or SJ
483QB: replace engine oil filter and fill 3.3L, do not replace engine
oil filter and fill 3.0L, SG grade and above
488QA: Replace engine oil filter and fill 4.3L, do not replace
engine oil and fill 4.1L, net fill 5.0L, SG grade and above
2.
Li-based
Fuel
Content
Design parameters
Fuel type
70
Brand
DEXRON-III
DOT3
Coolant
HFC-134a(R134a)
Capacity
About 4.5L
Assembly plant
Year
Check digit
Engine characteristics
Body type
Vehicle brand
Manufacturer
VIN
4 Vehicle
nameplate
is
on
left
shock
Nameplate of
complete
vehicle
SRS warning
sign
Child protection
device
2)
3)
4)
5)
2.
Vehicle
part
maintenance
or
replacement improper. Any warning or
special remarks in general information is
quoted from each maintenance category.
Warning definition
2)
3)
3.
Note Definition
Clear program
2)
3)
4)
Provide information
procedure in a more
provide experience to
as to complete the
easily
3.2.Instructions:
that completes
effective manner;
the maintainer so
procedure more
1.
Operation requirements
1) Clothing: keep clean.
2) Vehicle protection
Before operation, prepare:
Fender hood
4) Prepare maintenance
measuring instruments
tools
and
3) Safety operation
keep
good
(6) Fuse
When replacing fuse, new fuse with
appropriate rated current shall be used.
Rated value shall not too high or low.
(7) Buckle
(4) Washer
Error
Correct
2.
Negative
terminal
effect due to
93), air bag
DAB, PAB, SAB
be removed and
Correct
Correct
Error
Error
Electrical control
Special remarks
sensitive parts
for
handling
ESD
Before
maintaining
any
electronic
component, especially after your body
slides with the seat, first touch metal
earth point to discharge static electricity in
your body.
Otherwise
specified
in
diagnosis
procedure, the following procedures shall
be avoided:
4.
5.
(8) Clutch
(1) When maintaining clutch parts, do not
grind or polish clutch disc, do not clean
parts with a dry brush or compressed air
because dust will be generated. Wet cloth
shall be used (but not immersed in
water). Clutch disc contains asbestos
fiber. If dust is generated, these fibers will
be mixed in the air. Dust containing
asbestos fiber is harmful to health.
(2) It is forbidden to use mineral oil or
paroline in hydraulic system of the clutch.
This oil will damage rubber parts in oil
cylinder.
(9) Exhaust system
Exhaust
Engine transmission
system Fuel system
parts
(1) Only use brake liquid in a clean and
sealed container or BYD special DOT 3
brake fluid. Do not use brake fluid in an
open container because brake fluid may
become damp.
If any other type of brake fluid except
recommended model or contaminated fluid
may damage hydraulic brake system
component or lead to brake failure, even
personal hurt.
Brake has irritation to eyes and skin. Once it
contact eyes or skin, the following measures
shall be taken:
6.
A/C system
Dismantle
accessory
and
assemble
body
and
mobile
11. Others
(1) When executing this procedure, you have
to wear allowed safety goggle and gloves
to reduce the risk of personal hurt.
(2) In order to avoid hurting your body when
you are exposed in welding light or plated
metal poisonous smoke during the course
of grinding/cutting any type of metal or
compound moulded parts, you have to
work in a place with good ventilation and
wear allowed gas mask, safety goggles,
ear plugs, welding gloves and protection
clothes.
attention to:
Please
notes:
-
observe the
following safety
Rubber accesory
Section 4 Overhaul
Specification
Position of Jack
Vehicle's center of gravity (no load)
Surport position; strentch the jack position
Adopt supporting
accessory.
arm
with
rubber
4.1.Troubleshooting method
b.
Knock slightly
(2) Troubleshooting
Basic procedure is to determine the procedure
for troubleshooting of related circuit in
advance.
(3) Fault simulation
Its the most difficult thing that no fault
symptoms are found during troubleshooting.
In this case, thorough analysis must be made
for described fault of the car. Then the same
or similar condition and fault environment of
the car shall be simulated. For technical
personnel, no matter how experienced and
proficient they are, their failure to analyze or
confirm fault symptom may cause delay in
repair, miss or misoperation.
At the time of simulation test for fault
symptom, please confirm fault symptom and
find out faulty position, part or component.
Please contract the doubtable scope
according to fault symptom, connect fault
diagnosis instrument for symptom simulation
test, and judge whether the examined system
is damaged, meanwhile, confirm fault
symptom, finally find out the cause of fault
referring to system fault code table.
1
Vibration method
Shake slightly
Swing slightly
B.
C.
Heating method
fault.
Fault
Caution:
A.
B.
Water-spraying method
B.
C.
Error
Error
Correct
Correct
Error
Joint inspection
Disassembly
harness
and
assembly
of
wire
Error
Error
Error
Specified
conditions
10k or more
1
Figure 1
Sensor
Open
circuit
the
Specified conditions
1
10k or more
Sensor
Resistance inspection
Sensor
Test connection
Joint A terminal 1
joint B1 terminal 1
Joint B2 terminal 1
joint C terminal 1
measure
Voltage inspection
Sensor
Sensor
Result example:
Test connection
Specified
conditions
5V
Test connection
Joint A terminal 1car
body grounding
Joint A terminal 2joint
C terminal 2
Specified
conditions
1
10k or more
5V
5V
Test connection
Short circuit
Specified
conditions
10k or more
1
car
body
grounding
Caution:
Eg.
Grounding
ECU side
Grounding
W/H side
Grounding
A/C
ACL
Air filter
A/F
Air-fuel ratio
ALR
ALT
AC generator
AMP
Ampere
ANT
Antenna
API
APPROX
ASSY
A/T
ATDC
Approximate
Assembly
Automatic transmission
After top dead center
ATF
ATT
Accessory
ATTS
AUTO
Automatic
AUX
Accessory
BARO
Atmospheric pressure
BAT
Accumulator
BDC
BTDC
CARB
Carburetor
CAT/CATA
Catalytic converter
CHG
Charge
CKG
CKP
Crankshaft position
CO
Carbon monoxide
COMP
CPB
Complete
Clutch pressure return
CPC
CPU
CVT
Continuous change
DPSF
DTC
DPSF
EBD
ECM
ECT
EGR
ELD
EPR
EPS
EVAP
EX
F
Exhaust
Front
FIA
FL
Front left
FP
Fuel pump
FR
Front right
FSR
Fail-safe relay
FWD
GAL
Gallon
GND
Ground
GPS
(Satellite) GPS
H/B
HC
Hydrocarbon
HID
HO2S
IAB
IAC
IACV
IAR
IAT
ICM
ID
Identification
ID or I.D.
Inside diameter
IG or IGN
Ignition
IMA
IMMOBI.
Anti-start unit
IN
Intake air
INJ
Injection air
INT
Intermittence
KS
Knock sensor
Left side
L/C
Locking clutch
LCD
LCD
LED
LED
LEV
LF
Front left
LH
LHD
LR
LHD
Left rear
LSD
L-4
MAP
MAX.
Maximum value
MBS
MCK
Motor inspection
MCU
MIL
MIN.
Minimum value
MPI
M/S
Manual steering
M/T
Manual transmission
Neutral
NOX
Oxynitride
OBD
On-board diagnostic
O2S
Oxygen sensor
OD or O.D.
P
Outside diameter
Parking
PAIR
PCM
PCV
PDU
PGM-FI
PGM-IG
Programmed ignition
PH
Pressure high
PL
PMR
P/N
Part number
PRI
Primary
P/S
Power steering
PSF
PSP
PSW
Pressure switch
Qty
Qty.
Right side
REF
Reference
RH
RHD
RL
RON
RR
RHD
Left rear
Theoretical octane number
Right Rear
SAE
SCS
SEC
Second
Secondary
SOHC
SOL
SPEC
S/R
Sunroof
SRS
STD
Standard
SW
Switch
Torque:
TB
Throttle body
T/B
Timing belt
TC
Torque converter
TCM
TCS
TDC
TFT
T/N
Tool number
TP
Throttle position
TWC
VC
Viscous coupling
VIN
VSC
Volume (net)
VSS
VTEC
VVIS
Equipped
W/O
Unequipped
WOT
Wide-open throttle
2WD
Two-wheel drive
4AT
5MT
6MT
O/D
st
Overdrive gear
1st gear
2nd
2nd gear
rd
3rd gear
4th
4th gear
5th
5th gear
Black
Blue
Br
Brown
Green
Gr
Grey
Lg
Tender green
Orange
Pink
Red
Purple
White
Yellow