Beruflich Dokumente
Kultur Dokumente
Contents
Chapter 1 BYD473Q Engine ............................................................................................................ 3
Part 1 Engine............................................................................................................................. 4
Section 1 Introduction ........................................................................................................ 4
Section 2 Cylinder Head ...................................................................................................11
Section 3 Cylinder Block .................................................................................................. 38
Part 2 Lubricating System ....................................................................................................... 57
Part 3 Intake Manifold and Exhaust System ........................................................................... 63
Part 4 Engine Cooling System ................................................................................................ 64
Part 5 Fuel and Exhaust System ............................................................................................ 67
Chapter 2 476ZQA Engine ............................................................................................................. 70
Part 1 Engine........................................................................................................................... 71
Section 1 Overview .......................................................................................................... 71
Section 2 Belt Driving Device .......................................................................................... 76
Section 3 Crankshaft Rear Oil Seal Component ............................................................. 78
Section 4 Timing Chain .................................................................................................... 80
Section 5 Detection of the Sparkplug and Cylinder Compression Pressure ................... 82
Section 6 Engine .............................................................................................................. 84
Part 2 Lubrication System ......................................................................................................119
Section 1 Schematic Diagram of Engine Lubrication Circuit ..........................................119
Section 2 Inspection of Oil Pressure ............................................................................. 120
Section 3 Engine Oil ...................................................................................................... 121
Section 4 Oil Sump ........................................................................................................ 122
Section 5 Oil Pump ........................................................................................................ 123
Part 3 Cooling System .......................................................................................................... 124
Section 1 Schematic Diagram of Engine Cooling System ............................................ 124
Section 2 Thermolator.................................................................................................... 125
Section 3 Water Pump ................................................................................................... 126
Part 4 Clutch.......................................................................................................................... 128
Section 1 Clutch Device................................................................................................. 128
Section 2 Flywheel ......................................................................................................... 131
Chapter 3 Transmission ............................................................................................................... 132
Section 1 Structural parameters .................................................................................... 133
Section 2 Service Guidelines ......................................................................................... 134
Section 3 Service of transmission ................................................................................. 136
Section 4 Differential ...................................................................................................... 165
Chapter 4 6T25 Manual Transmission ......................................................................................... 170
Section 1 Introduction of Transmission ......................................................................... 171
Section 2 Transmission Operating Mechanism ............................................................. 175
Section 3 Transmission mechanism .............................................................................. 179
1
BYD AUTO BYD Suri Maintenance & Repair Manual
2
BYD AUTO BYD Suri Maintenance & Repair Manual
Contents
3
BYD AUTO BYD Suri Maintenance & Repair Manual
Part 1 Engine
Section 1 Introduction
1.1 Main Technical Parameters
BYD473QB/QE engine uses the electronic fuel injection (EFI) system developed by our company
and it has advanced self-diagnosis function. The injection system uses the multi-point sequential
injection which features high power per liter, low fuel consumption, low noise, less pollution and
compact structure. Under any working conditions, BYD473QB/QE engine can operate with the
best performance and the complete vehicle equipped with this kind of engine can ensure reliable
safety, driving comfort, fuel economy and perfect environmental performance.
Main technical parameters of BYD473QB/QE Engine are listed in the following table.
Model BYD473QB BYD473QE
Type 4-stroke, water-cooled, inline, SOHC and EFI
Number of Cylinders 4
Cylinder Bore (mm) 73
Piston Stroke (mm) 88.9 89.4
Compression Ratio 10.2 10.6
Firing Order 1-3-4-2
Nominal Power (kW) 79 (5800r/min) 79 (5800r/min)
Max. Torque (Nm) 144 (4800 r/min) 144 (4650r/min)
Nominal Speed (r/min) 5800
Min.Spec Fuel Consumption (g/kW h) 245 236
Oil Pressure (kPa) 340~490 (3000r/min±50r/min)
Min. Stable Speed (idle speed (r/min) 780±50
Total Displacement (L) 1.488 1.497
Oil and Fuel Consumption Ratio (%) 0.26
Dimension (mm) 587×543×700 587×543×700
(length×width×height)
Net Weight (kg) 92 97
CO≤0.15% HC≤40ppm (780±50r/min)
Emissions at Idle Speed CO≤0.15% HC≤40ppm (2500±50r/min)
GB18285-2005
The vehicle uses 93# unleaded gasoline
Fuel
(GB17930-1999)
SG 10W/30 (All seasons in southern China and
Lubricant Oil spring, summer and autumn in northern China) SG
5W/30 (Winter in northern China) (GB11121)
Coolant Glycol Cooling Fluid
dry-type, single disc, diaphragm spring, constant
Type
pressure
Clutch Clutch plate assembly φ200×8.9 mm (Free State)
Dimensions (mm)
Clutch cover assembly φ255×40.4 mm
Weight (kg) 4.314
with synchromesh unit, five forward gears and one
Transmission Type
reverse gear 3
1st gear 3.308
2nd gear 1.826
Transmission Gear Ratio
3rd gear 1.207
4th gear 0.939
4
BYD AUTO BYD Suri Maintenance & Repair Manual
5
BYD AUTO BYD Suri Maintenance & Repair Manual
Piston O.D. 13 mm
Clearance with
0.035~0.054 mm 0.06 mm
Cylinder
First Air Ring 1.02~1.04 mm 1.07 mm
Piston Ring Groove Second Air 1.21~1.23 mm 1.25 mm
Width Ring
Multi-piece Oil
2.01~2.03 mm 2.05 mm
Ring
Clearance between First Air Ring 0.03~0.07 mm 0.15 mm
Piston Ring and Second Air 0.02~0.06 mm 0.13 mm
Groove Ring
First Air Ring 0.20~0.35 mm 0.6 mm
Piston Ring
Second Air 0.35~0.5 mm 0.65 mm
Piston Ring End Gap Ring
Multi-piece Oil
0.2~0.7 mm 0.8 mm
Ring
O.D. 17.996~18 mm
Clearance between
Piston Pin
Piston Pin and Piston 0.005~0.015 mm
Pin Bore
Clearance between
Pin and small-end hole 0.015~0.037 mm
of Connecting Rod
Diameter of small-end
17.963~17.981
hole of Connecting
mm
Connecting Rod
Rod Diameter of big-end
hole of Connecting Normal 43~43.015 mm
Rod
Installed on End
Clearance of 0.15~0.3 mm 0.4 mm
Crankshaft
Diameter of Main
49.937~49.955mm
Journal
Diameter of
39.940~39.955
Connecting Rod
mm
Journal
Connecting Rod/Main
Crankshaft 0.005 mm 0.01 mm
Journal Taper
Connecting Rod/Out
of Roundness of Main 0.005 mm 0.01 mm
Journal
End Clearance 0.1~0.35 mm 0.45 mm
Runout Max. 0.03 mm 0.04 mm
Oil Film Clearance
between Main Shaft 0.028~0.049 mm 0.055 mm
Crankshaft Bearing and Journal
Bearing Clearance between
Connecting Rod 0.022~0.050 mm 0.055 mm
Bearings
Engine Lubrication
Name Measuring Item Measuring Standard Value Overhaul Limit
6
BYD AUTO BYD Suri Maintenance & Repair Manual
Condition
Engine
4.0 L
overhaul
Replace oil,
including oil 3.3 L
Engine Oil Capacity
filter
Replace oil,
excluding oil 2.9 L
filter
Clearance between
0.075 mm~0.15
Internal and External 0.18 mm
mm
Rotor
Clearance between
0.06 mm~0.136
Oil Pump Pump Housing and 0.18 mm
mm
External Rotor
Clearance between
0.028 mm~0.065
Pump Housing and 0.085 mm
mm
External Rotor Shaft
Relief Valve, Oil idle speed Min. 30 kPa
Relief Valve Pressure when oil
3000 rpm/min Min. 300 kPa
temperature is 80°C
Engine Cooling
Measuring
Name Measuring Item Standard Value Overhaul Limit
Condition
Coolant volume Engine
4.7 L
(including engine, Overhaul
Radiator
heater, hoses and Coolant
3.6 L
radiator) Replacement
Reservoir Coolant Volume 0.4 L
Radiator
Opening Pressure 93 kPa~123 kPa
Cap
Functioning Just open 76°C~80°C
Thermolator Temperature Full open 90°C
Valve Lift at full-open 8 mm
ON 91~95°C
Thermo Switching
Subtract 3~8°C of the temperature
Switch Temperature OFF
when the switch is ON
7
BYD AUTO BYD Suri Maintenance & Repair Manual
Cylinder Head
9 Bolt M10×1.25×12 30
Threaded Plug
Tensioning Link Plate Bolt
10 Tensioning Link Plate 22
Shaft
Camshaft Sprocket Bolt
11 Camshaft Sprocket 56
Assembly
12 Guide Link Plate Bolt M6×16 12
13 Tensioner Seat Bolt M6×30 12
Bolt M6×25 10
14 Oil Pump Assembly
Bolt M6×35 10
15 Water Pump Bolt M6×35 12
Bolt M6×12 10
16 Oil Collector
Nut M6 10
Bolt M6×30 12
17 Oil Sump Bolt M8×35 25
Bolt M6×50 12
Oil Filter 12
18 Oil Filter
Threaded Connecting Pipe 20
Welded Dipstick Tube
19 Bolt M6×12 10
Assembly
20 Water Outlet Tube Bolt M6×12 10
Bolt M8×50 25
21 Intake Manifold
Nut M8 25
Fuel Distributor
22 Bolt M6×12 10
Assembly
Intake Temperature Cross Recessed Pan Head
23 5
Pressure Sensor Screw M5×16
Bolt M6×30 12
24 Intake Valve Assembly
Bolt M6×35 12
25 Throttle Wire Bracket Bolt M6×12 12
Bolt M10×1.25×20 44
26 Exhaust Manifold
Bolt M10 44
Exhaust Manifold Heat
27 Bolt M6×25 10
Shield
Exhaust Manifold Bolt M8×20 25
28
Bracket Nut M8×25 25
29 Front Lambda Sensor M18×1.5-6e 45
30 Thermolator Cap Bolt M6×20 10
Camshaft Phase
31 Bolt M6×16 10
Sensor
Coolant Temperature
32 M12×1.5-6g 15
Sensor
33 Cylinder Head Cover Cylinder Head Cover Bolt Unit 12
34 Ignition Coil Bolt M6×25 10
Charcoal Canister
35 Bolt M6×12 10
Control Valve Bracket
Crankshaft Damper
36 Pulley Bolt and Gasket Unit 37 plus corner 90°
Pulley
37 Water Pump Pulley Bolt M6×12 14
Bolt M8×70 25
38 Generator
Bolt M8×25 25
39 Clutch Cover Hexagon Socket Head Cap 25
8
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembly Screw
Bolt M12×1.25×60 65
40 Transmission Bolt M12×1.25×65 65
Bolt M12×1.25×95 65
41 Starter Bolt M10×1.25×45 44
Bolt M10×1.25×20 44
Intake Manifold Bolt M6×16 12
42
Bracket Assembly Intake Manifold Bracket Big
12
Gasket Bolt M6×30
Hexagon Fit Bolt 25
Bolt M8×50 25
43 Timing Cover Bolt M8×80 25
Bolt M6×30 10
Bolt M12×1.25×12 20
44 Clutch Baffle Bolt M6×12 10
Camshaft Thrust
45 Bolt M6×20 10
Cover
Camshaft Target Hexagon Socket-head Cap
46 34
Wheel Bolt
Cylinder Head
47 M16×1.5-6h 45
Threaded Plug
48 EGR Valve Seat M8 Nut 25
49 EGR Valve M8 Nut 25
50 OCV Valve Assembly Bolt M6×55 12
Model
Name
Cylinder Head Assembly Processing BYD473QA-1003400 BYD473QE-1003400
Crankshaft BYD473QB-1005021 BYD473QD-1005021
Rocker Arm Mechanism BYD473QA-1003060 BYD473QE-1003060
Camshaft Assembly BYD473QA-1006010 BYD473QE-1006010
Intake Manifold Assembly BYD473QA-1008020 BYD473QE-1008020
Intake Manifold Bracket BYD473QA-1003601 BYD473QE-1003601
Intake Manifold Stud BYD473QA-1003054 BYD473QE-1003054
Fuel Distributor Assembly BYD473QA-1121010 BYD473QE-1121010
Charcoal Canister Control Valve BYD473QA-1130020 BYD473QE-1026300
Charcoal Canister Control Valve Bracket BYD473QA-1130015 BYD473QE-1130015
Water Outlet Tube Welding Unit II BYD473QA-1303200 BYD473QE-1303200
Throttle Body BYD473QA-1132020 BYD473QE-1132110
Throttle Valve Position Sensor BYD473QA-3611030 BYD473QE-3611700
Knock Sensor BYD473QA-3611040 BYD473QE-3611400
Crankshaft Position Sensor BYD473QA-3611050 BYD473QE-3611200
Coolant Temperature Sensor BYD473QA-3611060 BYD473QE-3611100
Intake Air Temperature and Pressure
BYD473QA-3611070 BYD473QE-3611500
Sensor
9
BYD AUTO BYD Suri Maintenance & Repair Manual
10
BYD AUTO BYD Suri Maintenance & Repair Manual
Note: The valve can be adjusted only when the temperature of the cylinder head is below
38°C.
11
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal
Installation
2.2.1 Clean the crankshaft damper pulley (A), 2.3.3 Remove the idler unit.
crankshaft (B), bolt (C) and washer (D),
and lubricate them as shown in the
illustration below.
2.3.1 Remove the belt. 2.3.7 Remove the crankshaft damper pulley.
2.3.2 Remove the assembling bolt 1 on the
generator’s adjusting arm and then loosen 2.3.8 Remove the oil sump.
generator's assembling bolt 2.
12
BYD AUTO BYD Suri Maintenance & Repair Manual
Installation
13
BYD AUTO BYD Suri Maintenance & Repair Manual
14
BYD AUTO BYD Suri Maintenance & Repair Manual
Apply 2 mm~3 mm wide flange sealant 2.3.14.18 Install the idler unit.
along the dotted lines.
2.3.14.19 Install the generator’s adjusting arm
Apply 3 mm~4 mm wide flange sealant on assembling bolts.
the upper surface of the cylinder block on
the timing cover.
15
BYD AUTO BYD Suri Maintenance & Repair Manual
Special tools needed: Guide rod for removal 2.5 Removal of Cylinder Head Cover
and installation
2.5.1 Remove the intake manifolds.
2.4.1 Using SST, tap a new oil seal into the
timing cover directly at the specified 2.5.2 Remove 4 ignition coils.
mounting height.
2.5.3 Remove the cylinder head cover.
2.4.2 Measure the distance between the timing
cover’s surface (contacting surface with
the cylinder block) and the oil seal.
Oil seal mounting height 34.5 mm~35.2
mm
16
BYD AUTO BYD Suri Maintenance & Repair Manual
Note:
4 injector connectors
17
BYD AUTO BYD Suri Maintenance & Repair Manual
2.6.13 Remove the assembling bolts on the 2.6.22 Install the crankshaft damper pulley
generator's mounting bracket and loosen loosely.
the generator's assembling bolts.
2.6.23 Apply engine oil on the sliding surface
2.6.14 Remove the idler unit. of the timing chain tensioner seat through
the oil return hole on the cylinder head.
2.6.15 Turn the crankshaft damper pulley and
align its top dead center (TDC) marker with
the pointer.
18
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal
2.6.27 Remove the bolt on the tensioning Note: Keep the timing chain away from the
chain guide plate. magnetic field.
19
BYD AUTO BYD Suri Maintenance & Repair Manual
Installation
20
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal
21
BYD AUTO BYD Suri Maintenance & Repair Manual
2.8.6.2 Hold the camshaft with an open-end 2.9.3.1 If the warp age is less than 0.08 mm,
wrench and then tighten the bolt to 34 Nm. the cylinder head needs no repair.
22
BYD AUTO BYD Suri Maintenance & Repair Manual
BYD473QB Engine
2.10 Removal of Rocker Arm Assembly
Note:
2.10.1 Remove the cylinder head cover.
2.11.1 To make sure each part is installed
2.10.2 Loosen the rocker arm adjusting in place, mark on each part when
screws. removing.
Rocker arm adjusting screws 2.11.2 Do remove or install the rocker
arms from the rocker shaft's timing
chain side.
23
BYD AUTO BYD Suri Maintenance & Repair Manual
2.11.7 Do remove or install the rocker arm 2.11.10 Before assembling, clean all parts
from the rocker shaft's timing chain with the solvent, dry them and then
side. apply grease on all contact points.
24
BYD AUTO BYD Suri Maintenance & Repair Manual
2.12.4 Measure the rocker arm’s I.D. with an 2.13.2 Remove the camshaft sprocket.
I.D. dial gauge and check its out of roundness.
2.13.3 Remove the rocker arm assembly.
Clearance between the rocker arm and the
rocker shaft: 2.13.4 Remove the connected wire harness
bolts and wire harnesses.
Standard: 0.019 mm~0.058 mm
2.13.5 Disconnect the camshaft phase sensor
Overhaul limit: 0.08 mm connector and remove the camshaft phase
sensor.
25
BYD AUTO BYD Suri Maintenance & Repair Manual
2.14.3 Place the rocker shaft on the cylinder If the oil film clearance is still beyond the
head and tighten the bolts to the specified overhaul limit, replace the cylinder head.
torque.
Camshaft's total runout
Specified Torque: 29 Nm
Standard: Max. 0.03 mm
Apply engine oil on the bolts’ thread and
flange. Overhaul limit: 0.04 mm
Exhaust: 35.39 mm
26
BYD AUTO BYD Suri Maintenance & Repair Manual
27
BYD AUTO BYD Suri Maintenance & Repair Manual
above operation.
Clearance between exhaust valve tappet This could tap some carbon out and
and valve guide: makes the removal easier.
Standard: 0.050 mm~0.080 mm When holding the air hammer, keep it and
the valve guide paralleled to avoid
Overhaul limit: 0.11 mm damaging the punch.
2.18 Replacement of Valve Guide 2.18.6 Turn the camshaft over and tap out the
valve guide toward the cylinder head's
Special tools needed: camshaft side.
28
BYD AUTO BYD Suri Maintenance & Repair Manual
29
BYD AUTO BYD Suri Maintenance & Repair Manual
30
BYD AUTO BYD Suri Maintenance & Repair Manual
2.20.1 Apply a layer of engine oil on the valve 2.20.5 Install the valve spring. Orient the valve
tappet and install the valve into the valve spring with more winding toward the
guide. cylinder head.
2.20.2 Check whether it's smooth for the valve 2.20.6 Install the spring upper seat.
to move up and down.
2.20.7 Install the valve spring compressor.
2.20.3 Install the spring lower seat on the Press the spring and install the valve
cylinder head. collet.
31
BYD AUTO BYD Suri Maintenance & Repair Manual
2.20.8 Tap each valve tappet 2 to 3 times 2.21.5 Install the rocker arm assembly.
slightly with a plastic hammer to make sure
that valves and valve collets are installed 2.21.6 Install the air cleaner.
in place. Only tap along the axial direction
of valve tappets to avoid deformation of 2.22 Installation of Rocker Arm
the valve tappets. Assembly
32
BYD AUTO BYD Suri Maintenance & Repair Manual
33
BYD AUTO BYD Suri Maintenance & Repair Manual
Note:
When turning the camshaft, the torque
should not be over 56 Nm.
34
BYD AUTO BYD Suri Maintenance & Repair Manual
2.23.16 Remove the old flange sealant on the applied on them. If not, clean the old
timing cover's mating surface, bolts and residue, reapply the flange sealant and
bolt holes. install the parts.
Note:
2.23.20 Put the edge of the timing cover and
Apply 2 mm~3 mm width flange the edge of the oil sump together and then
sealant along the dotted lines. install the timing cover on the cylinder
block.
Apply 3 mm~4 mm width flange
sealant on the upper surface of the Note: When installing the timing cover,
cylinder block on the timing cover. don't slide the undersurface of the oil
sump's assembling surface.
Note:
35
BYD AUTO BYD Suri Maintenance & Repair Manual
2.23.33 Install the heating hose. 2.23.36 Install the air cleaner.
36
BYD AUTO BYD Suri Maintenance & Repair Manual
37
BYD AUTO BYD Suri Maintenance & Repair Manual
38
BYD AUTO BYD Suri Maintenance & Repair Manual
39
BYD AUTO BYD Suri Maintenance & Repair Manual
3.1.4 Push the crankshaft away from the dial 3.2.3 Put a plastic clearance gauge between
gauge, place the dial gauge against the the two adjacent main journals.
crankshaft's end and turn it to zero. Then
pull back the crankshaft tightly against the 3.2.4 Reinstall the bearing shell and the
gauge: the reading should not exceed the crankshaft main bearing cap and tighten
overhaul limit. the bolt to 25 Nm +40°.
Crankshaft axial clearance: Note: Don’t turn the crankshaft during
inspection.
Standard value: 0.10 mm ~ 0.35 mm
3.2.5 Remove the crankshaft main bearing cap
Overhaul limit: 0.45 mm and the bearing shell again and measure
the widest area of the plastic clearance
gauge.
40
BYD AUTO BYD Suri Maintenance & Repair Manual
41
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection of Connecting Rod Bearing 3.3.6 Remove the connecting rod cap and the
Clearance bearing shell and then measure the widest
area of the plastic clearance gauge.
3.3.1 Inspect the oil film clearance between
the connecting rod bearing and the journal. Oil film clearance between the connecting
Remove the main bearing cap. rod bearing shell and the journal:
Standard value: 0.020 mm ~0.038 mm
3.3.2 Remove the connecting rod cap and the
connecting rod bearing shell. Overhaul limit: 0.050 mm
42
BYD AUTO BYD Suri Maintenance & Repair Manual
3.3.8.1 Check each connecting rod for cracks Location of Connecting Rod Journal's
or thermal deterioration. Grouping Codes
43
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembling table of seat hole, connecting rod bearing shell and connecting rod journal
3.4.1 Drain engine oil. 3.4.3 Remove the clutch baffle and then the 2
bolts (A) for tightening the transmission.
3.4.2 Move the dipstick tube.
44
BYD AUTO BYD Suri Maintenance & Repair Manual
45
BYD AUTO BYD Suri Maintenance & Repair Manual
3.512 Tap out the piston with the hammer's Out of roundness of the journal:
wooden handle. Hold the piston by one
hand when tapping. Standard value: Max. 0.005 mm
46
BYD AUTO BYD Suri Maintenance & Repair Manual
Journal's taper:
Diameter of the piston:
Standard value: Max. 0.005 mm Standard value: 72.955 mm~72.975 mm
Overhaul limit: 72.945 mm
Overhaul limit: 0.010 mm
Verticality
47
BYD AUTO BYD Suri Maintenance & Repair Manual
48
BYD AUTO BYD Suri Maintenance & Repair Manual
49
BYD AUTO BYD Suri Maintenance & Repair Manual
50
BYD AUTO BYD Suri Maintenance & Repair Manual
cleaner.
51
BYD AUTO BYD Suri Maintenance & Repair Manual
3.8.2.4.9.3 Orient the mark on the piston to the 3.8.2.4.9.8 Apply engine oil on the threads of
engine's timing chain side (front end). the bolt. Then install the connecting rod
cap with the bearing shell.
52
BYD AUTO BYD Suri Maintenance & Repair Manual
3.9.3 If the diameter difference is beyond the 3.10.11 Tighten the connecting rod bolt to 9.8
tolerance zone, replace the connecting rod Nm.
bolt.
3.10.12 Tighten the connecting rod bolt to 90°
3.10 Installation of Crankshaft corner.
3.10.1 Inspect the clearance of the connecting 3.10.13 Install the crankshaft rear seal. Apply
rod bearing with a plastic clearance gauge. grease on the inner groove of the oil seal
before installing and then install the oil seal
3.10.2 Inspect the clearance of the main on the crankshaft.
53
BYD AUTO BYD Suri Maintenance & Repair Manual
3.10.14 Measure the distance between the flange of the main bearing cap bolts.
crankshaft and the oil seal.
3.10.21 Tighten the bearing cap bolts to 25 Nm
Mounting height of oil seal: 7 mm~8 mm in the order shown in the illustration.
3.10.15 Install the main bearing cap and be 3.10.24 Install the dowel pin (A) and a new
aware of the marker's orientation. O-ring (B) on the oil pump (C), then align
the inner rotor with the crankshaft and
3.10.16 Remove the old flange sealant on the install the oil pump.
mating surface of the main bearing cap's
rear end.
3.10.20 Apply engine oil on the thread and 3.10.29 Install the engine.
54
BYD AUTO BYD Suri Maintenance & Repair Manual
3.11.2 Clean and dry the mating surface of the 3.11.5 Install oil sump A using dowel pin B and
oil sump and the cylinder block. a new O-ring.
55
BYD AUTO BYD Suri Maintenance & Repair Manual
10 Nm
10. Nm
56
BYD AUTO BYD Suri Maintenance & Repair Manual
57
BYD AUTO BYD Suri Maintenance & Repair Manual
58
BYD AUTO BYD Suri Maintenance & Repair Manual
Tightening Torque: 12 Nm
59
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection
60
BYD AUTO BYD Suri Maintenance & Repair Manual
Installation
Standard: 0.028~0.065 mm.
a Install the dowel pin (A) and a new O-ring
Overhaul limit: 0.085 mm. on the oil pump (C).
61
BYD AUTO BYD Suri Maintenance & Repair Manual
6×1.0 mm
12 Nm
62
BYD AUTO BYD Suri Maintenance & Repair Manual
63
BYD AUTO BYD Suri Maintenance & Repair Manual
64
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1.3 Measure the lifting height when the 1.3 Replacement of Water Pump
thermolator is on.
Standard thermolator: 1.3.1 Remove the belt.
Start to turn on: 76°C~80°C 1.3.3 Remove the water pump pulley.
Being on: 90°C 1.3.4 Remove the 5 bolts for tightening the
water pump and then remove the water
1.2 Inspection of Water Pump pump.
1.2.1 Remove the belt. 1.3.5 Inspect and clean the O-ring groove and
its mating surface with the cylinder block.
1.2.2 Remove the water pump pulley.
1.3.6 Install the water pump with a new O-ring
in the reverse order of removal.
65
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal
M6x 1.0 mm
10 Nm
66
BYD AUTO BYD Suri Maintenance & Repair Manual
BYD473QE Engine
67
BYD AUTO BYD Suri Maintenance & Repair Manual
System description:
Throttle body
Knock sensor
68
BYD AUTO BYD Suri Maintenance & Repair Manual
Parts location of the intake system d Pinch the PCV valve and intake manifold
slightly by the fingers or pliers at idle
The system supplies the engine with the speed and make sure a click sound occurs
air needed. When the air is inhaled into the from the PCV valve.
system, the resonance chamber in the
intake manifold can reduce noise. If no click sound is heard, check the PCV
valve retainer for cracks or damage. If the
retainer is ok, replace the PCV valve and
make another inspection.
PCV system
69
BYD AUTO BYD Suri Maintenance & Repair Manual
70
BYD AUTO BYD Suri Maintenance & Repair Manual
Part 1 Engine
Section 1 Overview
The BYD476ZQA engine adopts the advanced technologies of exhaust gas turbocharging,
gasoline in-cylinder direct injection, hydraulic tappet, all-aluminum engine body, intake VVT,
etc., and has the characteristics of high power per liter, low fuel consumption, little noise, low
pollution, compact structure. The BYD476ZQA engine can operate at its optimum states in
various working conditions, and ensure the reliable safety, comfortable driving, best
economic efficiency and perfect environment-friendly performance of the loaded complete
vehicle.
1. The main specifications of BYD473QB/QE Engine are listed in the following table.
Parameters Model
BYD476ZQA
Items
Inline four-cylinder, water-cooled, dual-overhead camshaft,
Type 16-valve and 4-stroke electronically-controlled fuel injection
engine
Nominal power 113 KW (5200 r/min)
Maximum torque/rotating
240 N·m (1750 r/min-3500 r/min)
speed
Cylinder diameter × route 76.5 mm×81.4 mm
Engine displacement 1.497 L
Compression ratio 10:1
Valve structure Silent chain drive, dual-overhead camshaft, 16-valve
93# unleaded gasoline (GB17930-1999) or above used for
Type of fuel
vehicle
Mode of fuel supply Electronically-controlled direct fuel injection
Ignition sequence 1—3—4—2
Engine oil Special oil designated and approved by the Department
exhaust emission system Three-way catalytic converter
Supercharging Exhaust gas turbo-charging
Camshaft regulation Intake VVT
Cylinder block material Aluminum alloy
71
BYD AUTO BYD Suri Maintenance & Repair Manual
72
BYD AUTO BYD Suri Maintenance & Repair Manual
threaded plug
assembly
Fixing and supporting
19 M10×16 hex flange bolt 1 44 Nm
plate assembly
Engine front lifting
20 M8×20 hex flange bolt 2 24 Nm
hook
Engine rear lifting
21 M8×20 hex flange bolt 2 24 Nm
hook
22 Exhaust manifold Stud 9 10 Nm
Camshaft rear end
23 M6×16 hex flange bolt 4 10 Nm
cover
Intake fitting bolt M6 hex socket head cap
24 2 7 Nm
assembly screw
Three-way catalytic
25 6 20 Nm
converter screw nut
26 Intake manifold M8×35 hex socket head bolt 5 24 Nm
Exhaust manifold heat
27 M6×12 hex flange bolt 2 10 Nm
shield
Semi-circular clamping Cross recessed pan-head
28 2 7 Nm
block tapping screw 63
Oil drain plug
29 1 25 Nm
assembly
30 Oil sump M6×20 hex flange bolt 20 10 Nm
31 Oil rule conduit tube M6×12 hex flange bolt 1 10 Nm
32 Oil collector M6×20 hex socket head bolt 2 10 Nm
33 Oil pump M8×50 hex flange bolt 3 24 Nm
M8×20 hex lobular socket
34 Oil cooler 5 24 Nm
head blot
Oil cooler water tube M6×20 hex socket head bolt 1 10 Nm
35
assembly M8×16 hex socket head bolt 1 24 Nm
PCV four-way
36 M6×20 hex socket head bolt 1 10 Nm
component
PCV breather tube
37 M6×20 hex socket head bolt 1 10 Nm
assembly I
38 Chain tension plate M8 chain plate fixing stud 1 20 Nm
39 Chain guide plate M8 chain plate fixing stud 3 20 Nm
Threaded tube for
40 1 35 Nm
mounting the oil filter
41 Oil filter 1 15 Nm
42 OCV valve M5×12 hex flange bolt 1 5 Nm
M8×50 hex flange bolt 7 24 Nm
M8×25 hex flange bolt 7 24 Nm
43 Timing cover M8×20 hex flange bolt 3 24 Nm
M10×80 hex flange bolt 3 44 Nm
Stud 1 10 Nm
44 Gas-oil separation M5×16 hex flange bolt 5 5 Nm
73
BYD AUTO BYD Suri Maintenance & Repair Manual
device
Tension pulley
45 M10×80 hex flange bolt 1 44 Nm
assembly
Hollow bolt M12×1.5 1 35 Nm
Supercharger oil inlet
46 Hollow bolt M10×1 1 30 Nm
pipe component
M6×12 hex flange bolt 1 10 Nm
Supercharger oil M6×12 hex socket head bolt 2 10 Nm
47
return pipe component M6×16 hex flange bolt 2 10 Nm
Supercharger water Hollow bolt M12×1.5 1 35 Nm
48
inlet pipe component M6×12 hex flange bolt 1 10 Nm
Supercharger water Hollow bolt M12×1.5 1 35 Nm
49
outlet pipe component M6×12 hex flange bolt 2 10 Nm
50 Supercharger stud 6 10 Nm
Supercharger heat
51 M6×12 hex flange bolt 3 10 Nm
shield
Solenoid valve for
Cross recessed pan-head
52 limiting supercharged 2 5 Nm
tapping screw 55
pressure
Cross recessed pan-head
53 Intercooler 6 7 Nm
tapping screw 63
M8×75 hex flange bolt 3 24 Nm
54 High-pressure fuel rail
M8×60 hex flange bolt 2 24 Nm
Oil inlet tube Screw nut M14×1.5 2 17 Nm
55
component M6×16 hex flange bolt 1 10 Nm
High-pressure fuel
56 M6×20 hex socket head bolt 2 10 Nm
pump
57 Throttle valve screw 4 7 Nm
58 Dual pipe component M8×12 hex flange bolt 1 24 Nm
Water inlet pipe
assembly for the
59 M6×12 hex flange bolt 2 10 Nm
electrically-driven
water pump
Thermolator
60 M6×25 hex flange bolt 4 10 Nm
component
61 Water pump pulley M8×12 hex flange bolt 3 24 Nm
M8×40 hex lobular socket
62 Water pump 5 24 Nm
head bolt
Motor-driven water M8×16 hex flange bolt 1 24 Nm
63
pump support M10×16 hex flange bolt 1 44 Nm
Motor-driven water
64 M6×20 hex socket head bolt 1 10 Nm
pump
Camshaft phase
65 M6×16 hex flange bolt 1 10 Nm
sensor
66 Knock sensor M8×30 hex flange bolt 1 20 Nm
Intake air temperature Cross recessed pan-head
67 4 5 Nm
and pressure sensor tapping screw 55
74
BYD AUTO BYD Suri Maintenance & Repair Manual
75
BYD AUTO BYD Suri Maintenance & Repair Manual
As Figure 1.1 shows, inspect the tension Installation of the crankshaft belt pulley:
pulleys with a tool, and replace the belt if position the flywheel with a special tool,
the tension pulley is in its ultimate state. screw up the crankshaft belt pulley bolt
with the tightening torque of a 150 Nm +
2.1.2.3 Inspection of the belt assemble 180ºrotating angle.
conditions
2.2.2 Electric generator
Reinstall the belt if any error in the
following figure occurs. Disassembly of the electric generator:
hold the generator gently by hand, screw
off the fixing bolts of the generator and
remove the generator;
76
BYD AUTO BYD Suri Maintenance & Repair Manual
Installation of the electric generator: aim 2.2.5 Air conditioner compressor and tension
the mounting holes on the generator at pulley
those on the timing cover, and make sure
the belt pulley is facing the front end of the Disassembly: Unscrew the mounting bolts
engine, then gently hold the generator and of the air conditioner compressor and
screw down bolts A and B as shown in the remove the AC compressor, then screw off
following figure with a tightening torque of the tension pulley mounting bolts and
24 Nm. remove the tension pulley, after that,
unfasten the tension pulley support
2.2.3 Idler pulley mounting bolts and remove the tension
pulley support;
Disassembly of the idler pulley: screw off Installation:
the idler pulley bolts and take down the
idler pulley; 2.2.5.1 Install the tension pulley support on the
Installation of the idler pulley: train on the cylinder block and screw up the bolts
mounting holes on the timing cover and
then screw up the idler pulley bolt. 2.2.5.2 Assemble the tension pulley into the
support seat hole from the front end,
Tightening torque: 44 Nm making sure the Dowel pin on the
tension pulley is well matched and
positioned with the pinhole inside the
support, and then screw up the
mounting bolts from the back end with
Idler pulley a tightening torque of 44 Nm.
bolt
Dowel pin
pinhole
77
BYD AUTO BYD Suri Maintenance & Repair Manual
Tightening torque: 30 Nm
Pinhole
Dowel pin
3.2 Assembly of the Crankshaft Rear
Oil Seal Component
78
BYD AUTO BYD Suri Maintenance & Repair Manual
a= 0.5
Tightening torque: 15 Nm
Crankshaft Rotating
Speed Signal Wheel
Tightening torque: 10 Nm
Dowel pin
0.3 mm≤a≤0.7 mm
79
BYD AUTO BYD Suri Maintenance & Repair Manual
4.1.1 Rotate the crankshaft clockwise to the shown in the figure, and lock the tensioner
adjacency of the top dead centers of the with a lock pin;
first and the fourth cylinders, and then
revolve the crankshaft 45 º. Then screw the
cylinder block threaded plug component off
the cylinder block, screw in the crankshaft
positioning tool, and rotate clockwise to fix
the crankshaft to the top dead centers of
the first and the fourth cylinders.
Tightening torque: 30 Nm
Positioning
Tool
Lock Pin
Positioning
Tool
80
BYD AUTO BYD Suri Maintenance & Repair Manual
Assemble the VVT component onto the 4.2.5 Keep the camshaft at the top dead center
intake camshaft, screw the VVT of cylinder 1 and fix the exhaust camshaft
component bolt in the position 2mm away sprocket with the special tool shown in the
from the abutted surface, keep the figure. Then tighten the bolts of the VVT
sprocket rotating freely and prevent it from components and exhaust camshaft
falling off; sprocket to the specified torque.
Hang the timing chain guide plate in place, Tightening torque: 50 Nm+90ºrotating
and apply a proper amount of lubricating oil angle
to the part contacting with the chain. Hang
the timing chain onto the exhaust camshaft
sprocket, the VVT component sprocket and
the crankshaft sprocket with the guide
plate;
Positioning
Tool
81
BYD AUTO BYD Suri Maintenance & Repair Manual
Ohmmeter
82
BYD AUTO BYD Suri Maintenance & Repair Manual
83
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 6 Engine
6.1 Disassembly of the Engine
84
BYD AUTO BYD Suri Maintenance & Repair Manual
6.1.5.2 Take off the charcoal canister vacuum Screw off four throttle valve fixing bolts,
pipe component from the intake manifold; and then remove the throttle valve.
6.1.5.3 And then remove the charcoal canister Throttle Valve Mounting Screws
vacuum pipe component, charcoal canister
connection hose, and charcoal canister
control valve.
One-way Valve
85
BYD AUTO BYD Suri Maintenance & Repair Manual
Note: The oil inlet tube component must be 6.1.12 Disassemble the supercharger water
placed in a clean and dust-free sealed bag, outlet tube assembly
and the connection between the
high-pressure fuel pump and the fuel inlet 6.1.12.1 Screw off two support plate fixing
of the high-pressure fuel rail must be bolts;
sealed immediately with a clean cover.
6.1.12.2 Screw off the hollow bolts and remove
the pipe assembly.
86
BYD AUTO BYD Suri Maintenance & Repair Manual
87
BYD AUTO BYD Suri Maintenance & Repair Manual
88
BYD AUTO BYD Suri Maintenance & Repair Manual
Roller Tappet
89
BYD AUTO BYD Suri Maintenance & Repair Manual
90
BYD AUTO BYD Suri Maintenance & Repair Manual
91
BYD AUTO BYD Suri Maintenance & Repair Manual
bolts;
Plastigauge
6.1.35 Inspect the connecting rod big end oil
film clearance
92
BYD AUTO BYD Suri Maintenance & Repair Manual
Replace the crankshaft if the measured Pry the crankshaft back and forth with a
value is still greater than the maximum oil screwdriver, and then measure the
film clearance after the bearing shell is crankshaft end clearance with a feeler
replaced. gauge.
Standard clearance: 0.07-0.18 mm,
6.1.35.7 Use the same method to measure the
oil film of other three connecting rods. Wear limit: 0.38 mm;
6.1.36 Remove the connecting rod Replace the thrust plate if the measured
value is greater than the maximum
Note: The connecting rod must be clearance;
replaced as a unit;
Replace the crankshaft if the measured
6.1.36.1 Screw off the connecting rod bolts, value is still greater than the maximum
and remove the connecting rod caps; clearance after the thrust plate is replaced.
93
BYD AUTO BYD Suri Maintenance & Repair Manual
6.1.38 Measure the oil film clearance of main 6.1.38.2 Clean the internal surface of main
journal bearing shell, the main bearing cap, the
main journal and the crankshaft;
Note: Do not turn the crankshaft during
measurement
Plastigauge
If it is difficult to remove the main bearing 6.1.38.4 Install the main bearing caps and
cap, lightly tap it back and forth with a screw in the bolts. Tighten the bolts in 2 – 3
rubber mallet to loosen it; steps in the order from 1 to 10 as shown to
a tightening torque of 50 Nm.
Hold the bolt with both hands as shown in
the figure, and shake the main bearing cap
94
BYD AUTO BYD Suri Maintenance & Repair Manual
Wear limit: 0.20 mm 6.1.40 Remove the fixing and supporting plate
assembly
Note: The plastigauge must be completely
removed from the bearing journal after the Unscrew the fixing bolts, and remove the
measurement fixing and supporting plate assembly.
Main Bearing Main Bearing Clearance 6.1.41 Remove the piston ring
Hole (Set No.) Shell (Set No.)
A A 0.024~ Remove the first air ring, second air ring
0.059 mm and the steel strip combination oil ring with
the piston ring expander.
B B 0.024~
0.059 mm
95
BYD AUTO BYD Suri Maintenance & Repair Manual
6.1.42.1 Remove the wire ring for holes on one Note: Do not scratch the sealing surfaces
side from the notch with spring pliers; when removing the sealant.
6.1.42.2 Push the piston pin out of the other 6.2.3 Inspect the timing chain and oil pump
side carefully. chain
96
BYD AUTO BYD Suri Maintenance & Repair Manual
0.5 mm
6.2.6 Inspect the chain guide plate and chain a Install the camshaft on the camshaft
tensioning plate housing;
Inspect the wear degree of the chain guide b Slightly move the camshaft back and forth,
plate and chain tensioning plate, and and measure the axial clearance with a dial
replace the plates if the wear is greater gauge.
than 0.5 mm.
New axial clearance: 0.1-0.3 mm;
Wear limit: 0.5 mm.
97
BYD AUTO BYD Suri Maintenance & Repair Manual
98
BYD AUTO BYD Suri Maintenance & Repair Manual
99
BYD AUTO BYD Suri Maintenance & Repair Manual
Insert a new piston ring into the piston ring 6.2.17.2 Measure the end gap of piston ring
groove, and inspect the clearance in the with a feeler gauge;
piston ring groove with a feeler gauge;
Standard End Gap
Standard Clearance (mm) First Air Ring 0.15-0.40 mm
Second Air Ring 0.40-0.60 mm
First Air Ring 0.065 ~ 0.095
Wear limit: 1.0 mm
Second Air
0.03 ~ 0.07 Replace the piston ring if the measured
Ring
value exceeds the maximum clearance;
Wear limit: 0.15 mm
Replace the cylinder block if the measured
Replace the piston if the measured value is still greater than the maximum
clearance is greater than the maximum clearance after the piston ring is replaced.
value.
6.2.17 Measure the end gap of piston ring 6.2.18 Inspect the crankshaft
6.2.17.1 Push a piston ring into the cylinder by 6.2.18.1 Measure the diameter of each main
45 mm with the piston, and then remove journal with a micrometer at the position as
the piston; shown in the right figure;
100
BYD AUTO BYD Suri Maintenance & Repair Manual
101
BYD AUTO BYD Suri Maintenance & Repair Manual
6.3.2.2 Apply the sealant with the diameter of then tighten it;
Φ2.5-Φ3.5 mm on the position as shown in
the figure without breaking point; Tightening torque: 20 Nm
Note: After the sealant is coated, the part Oil Limiting Plug
must be installed within five minutes. If not,
remove the residual and apply the sealant
again.
Tightening torque: 35 Nm
6.3.2.3 Tighten six bolts alternatively, and
install the oil return hole cover plate. Threaded plug I of
cylinder block
Tightening torque: 10 Nm
102
BYD AUTO BYD Suri Maintenance & Repair Manual
Locked Gap
6.3.4.2 Install the upper main bearing shell on 6.3.5.3 Apply oil on the lower main bearing
the main bearing support; shell, point the arrow on the main bearing
cap to the front of the engine, and install
Note: Clean the mounting surface of the the main bearing cap in the order of
bearing shell with a piece of silk cloth numerical markers from 1st to 5th gear.
before installation; Align the positioning lip
on the shell with the locked gap of the main
bearing support, and align the oil hole on
the shell with the oil hole of the main
bearing support;
Step 1: 20 Nm
Do not apply oil on the back of the bearing
shell and the mounting surface of the main Step 2: 50 Nm
bearing support. The main bearing shell
should be selected and matched in groups. Step 3: 90 ºrotating angle (1/4 circle)
6.3.5 Install the crankshaft
103
BYD AUTO BYD Suri Maintenance & Repair Manual
104
BYD AUTO BYD Suri Maintenance & Repair Manual
105
BYD AUTO BYD Suri Maintenance & Repair Manual
Mark
6.3.7.9 The crankshaft should be rotated freely 6.3.9.3 Install the valve, valve spring and valve
after installation, and the torque should not spring upper seat;
exceed 10 Nm.
Note: The valve spring can be installed at
6.3.8 Install the crankshaft rear oil seal any direction as it has equal pitch.
component
106
BYD AUTO BYD Suri Maintenance & Repair Manual
Special Tool
107
BYD AUTO BYD Suri Maintenance & Repair Manual
Step 1: 20 Nm
Step 2: 70 Nm
108
BYD AUTO BYD Suri Maintenance & Repair Manual
109
BYD AUTO BYD Suri Maintenance & Repair Manual
Tightening torque: 24 Nm
110
BYD AUTO BYD Suri Maintenance & Repair Manual
Tightening torque: 30 Nm
111
BYD AUTO BYD Suri Maintenance & Repair Manual
Special Tool
112
BYD AUTO BYD Suri Maintenance & Repair Manual
6.3.19.4 Tighten the oil drain plug. 6.3.21 Install the clutch
6.3.20.2 Alternatively and uniformly tighten the Tighten six bolts in the order as shown in
flywheel bolts in several times. the figure to fix the clutch pressure plate on
the flywheel.
Tightening torque: 60 Nm+90ºrotating
angle Tightening torque: 25 Nm
113
BYD AUTO BYD Suri Maintenance & Repair Manual
Tightening torque: 24 Nm
Tightening torque: 80 Nm
Packing Ring
114
BYD AUTO BYD Suri Maintenance & Repair Manual
Tightening torque: 10 Nm
115
BYD AUTO BYD Suri Maintenance & Repair Manual
Tightening torque: 24 Nm
116
BYD AUTO BYD Suri Maintenance & Repair Manual
6.3.29.1 Install the exhaust manifold, exhaust Note: It is necessary to fill oil into the oil
manifold gasket, fixed plate I and II in place, inlet during installation if the turbocharger
and then tighten the screw cap; has been left for a long time.
6.3.29.2 Respectively install the turbocharger 6.3.30 Install the crankshaft housing ventilator
oil return pipe and the turbocharger. Then and the fuel evaporative emission control
install the turbocharger on the exhaust system
manifold and tighten the turbocharger nuts;
6.3.30.1 Install the PCV four-way components,
6.3.29.3 Install the supporting plate assembly, and tighten the bolts;
turbocharger water inlet tube, turbocharger
water return tube and turbocharger oil inlet Note: Check if the O-rings of PCV four-way
pipe, and then tighten the hollow bolts; components are complete and smooth
Note: It is necessary to fill the oil of more without damage.
than 5 ml into the turbocharger oil inlet
before installing the turbocharger oil inlet 6.3.30.2 Install the PCV breather tube I, II and
pipe. the intake fitting rubber sleeve;
117
BYD AUTO BYD Suri Maintenance & Repair Manual
Check Valve
Camshaft housing
connection house
118
BYD AUTO BYD Suri Maintenance & Repair Manual
1st Gear
Camshaft
Journal
Exhaust
Side
119
BYD AUTO BYD Suri Maintenance & Repair Manual
1.0 ~ 2.0 mm
Sealant
Application
Area
4.0 ~ 6.0 mm
120
BYD AUTO BYD Suri Maintenance & Repair Manual
3.1 Engine Oil Inspection and then drain the oil into a suitable
container;
3.1.1 Park the vehicle on a level ground, and
stop the engine after it is started and the 3.2.3 Clean the drain plug. Check if the drain
normal working temperature is reached; plug gasket is complete and smooth, and
replace it if damaged. Tighten the drain
3.1.2 After five minutes, pull out the oil dipstick plug;
and observe the oil level and condition.
Check if the oil level is between A and B; Tightening torque: 25 Nm
Add or replace the oil if necessary 3.2.4 Install a new oil filter;
121
BYD AUTO BYD Suri Maintenance & Repair Manual
122
BYD AUTO BYD Suri Maintenance & Repair Manual
Tightening torque: 24 Nm
Tightening torque: 30 Nm
123
BYD AUTO BYD Suri Maintenance & Repair Manual
Water
Pump
Turbocharger
124
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 2 Thermolator
2.1 Removal of Thermolator
Thermolator I Thermolator II
Thermolat Thermolator
or I II
Opening 83 (+2/-1)
Temperature 95 (+2/-1)
(°C)
Full-open 98
Temperature 110
2.2 Inspection of Thermolator (°C)
2.2.1 Visually inspect whether the thermolator Full-open 7~10
meets the requirements; 7~10
Travel (mm)
Maximum 12
The mark on the thermolator indicates the 12
Travel (mm)
opening temperature. If the mark on the
thermolator does not match with the engine, Replace the thermolator if not as specified.
replace the thermolator.
Thermolator I: 83°C
Thermolator II: 95°C
125
BYD AUTO BYD Suri Maintenance & Repair Manual
3.1.3 Remove the water pump pulley; See P5 3.2.1.1 Inspection before the installation
Unscrew three fixing bolts and remove the Rotate the water pump by hand and check
water pump pulley. if the water pump emits abnormal noise. If
3.1.4 Remove the water pump; any, replace the water pump assembly;
3.1.4.1 Screw off five mounting bolts of the Check if the water pump gaskets are
water pump; damaged. If any, replace the water pump
gasket;
3.1.4.2 Remove the water pump and the water
pump gaskets. Carefully clean the sealing surfaces of the
water pump and cylinder block and water
pump gasket;
126
BYD AUTO BYD Suri Maintenance & Repair Manual
Tightening torque: 24 Nm
Tightening torque: 24 Nm
127
BYD AUTO BYD Suri Maintenance & Repair Manual
Part 4 Clutch
1.1.1 Remove the starter; 1.1.3.1 Insert the centering plug into the
crankshaft rear end bearing hole after
passing through the clutch driven plate
assembly;
128
BYD AUTO BYD Suri Maintenance & Repair Manual
1.2.1.2 Measure the circular run-out of the 1.2.3 Inspect the clutch cover assembly
friction disc with a magnetic stand dial
gauge and a deflection instrument; As shown in the figure below, check the
wear of the presure plate leaf spring with
The allowed maximum circular run-out is the vernier caliper;
0.8 mm.
Allowed maximum depth: 0.6 mm
129
BYD AUTO BYD Suri Maintenance & Repair Manual
Tightening torque: 25 Nm
130
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 2 Flywheel
2.1 Removal of Flywheel
131
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 3 Transmission
Contents
132
BYD AUTO BYD Suri Maintenance & Repair Manual
133
BYD AUTO BYD Suri Maintenance & Repair Manual
The materials listed in the following table are essential for maintaining the transmission.
Therefore, the materials should be prepared for use at any time. In addition, the washing
liquid and lubricant of specified type should be used.
134
BYD AUTO BYD Suri Maintenance & Repair Manual
135
BYD AUTO BYD Suri Maintenance & Repair Manual
(1) Differential assembly (13) Reverse gear shaft (24) Pull cable support
(2) Reverse gear lock cam (14) Idler gear assembly (25) Hexagon flange bolt
assembly (15) Mounting bolts (15 M8×45 (25 Nm)
(3) Mounting bolts (15 Nm) Nm) (26) Hexagon flange bolt
(4) Gear shifting fork (16) Reverse shaft fork M6×22 (10 Nm)
assembly assembly (27) Vehicle speed sensor
(5) Counter shaft assembly (17) Positioning pin assembly
(6) Main shaft assembly (18) Dust cover (28) O-ring
(7) Magnet assembly (19) Release arm (29) Vehicle speed sensor
(8) Slide bush (20) Release arm screw driven gear
(9) Cylindrical roller bearing (30 Nm) (30) Spring
(10) Oil guide plate 2 (21) Release arm spring (31) 8 mm washer
(11) 58 mm deep groove ball (22) Release bearing (32) Clamp spring
bearing (23) Differential right oil (33) 8 mm spring washer
(12) Main shaft oil seal seal (34) Fork shaft screw (25 Nm)
136
BYD AUTO BYD Suri Maintenance & Repair Manual
Note: The matching condition of the vehicle speed sensor, neutral switch, front casing and rear
casing is listed below.
137
BYD AUTO BYD Suri Maintenance & Repair Manual
Note: BYD5T-14-5A transmission has all the above components except the neutral switch
assembly
Note: Prop up the transmission front casing with two wood blocks thick enough to prevent the main
shaft from hitting the service stand.
138
BYD AUTO BYD Suri Maintenance & Repair Manual
139
BYD AUTO BYD Suri Maintenance & Repair Manual
3.1.5.1 Remove the sealing plug (A). 3.1.5.5 Remove the reverse shifting fork
assembly.
3.1.5.2 Open the counter shaft circlip (B) with
the circlip pliers, and then remove it
from the groove.
140
BYD AUTO BYD Suri Maintenance & Repair Manual
141
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard: 13.00-13.15 mm
Standard: 13.5-13.8 mm
142
BYD AUTO BYD Suri Maintenance & Repair Manual
Before the reassembly, wash all the parts with solvent, and then apply lithium grease for all the
contact surfaces (A, B, C and D) after they are dry.
10 Nm
Vent pipe
assembly
Gear shifting
arm cover
143
BYD AUTO BYD Suri Maintenance & Repair Manual
3.5 Disassembly and reassembly of manual gear shift assembly (Note: Applicable
for transmissions with neutral switch assembly)
Before the reassembly, wash all the parts with solvent, and then apply lithium grease for all the
contact surfaces (A, B, C and D) after they are dry.
Dust cover
144
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard:
1/2/3/4 gear shifting fork: 7.4-7.6 mm
5 gear shifting fork: 6.7-6.9 mm
145
BYD AUTO BYD Suri Maintenance & Repair Manual
Before the reassembly, wash all the parts with solvents, and then apply lithium grease on all
the contact surfaces after they are dry.
146
BYD AUTO BYD Suri Maintenance & Repair Manual
Note: Replace the synchronizer hub if the synchronizer gear sleeve is to be replaced.
3.8.1 Prop up the bearing inner race with a 3.8.4 Measure the clearance between the 4th
proper tube seat (A), and then push it gear (A) and the distance ring (B) with a dial
down to the main shaft (B). gage (C). If the clearance exceeds the repair
limit, go to step 5.
Standard: 0.10-0.25 mm
Repair limit: 0.40 mm
3.8.2.1 If the clearance exceeds the repair limit, 3.8.5 Measure the distance on the distance
go to step 3. ring.
3.8.2.2 If the clearance meets the repair limit, 3.8.5.1 If the distance does not meet the
go to step 4. standard, replace with a new distance ring.
Standard: 0.10-0.25 mm
Repair Limit: 0.40 mm 3.8.5.2 If distance meets the standard, go to
step 6.
3.8.3 Measure the thickness of 3rd gear Standard: 24.03-24.08 mm
147
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard: 26.88-26.93 mm
Standard: 12-12.05 mm
3.8.8 Measure the distance on the distance
ring.
3.8.8.2 If the distance meets the standard, 3.9 Disassembly of main shaft
go to step 9.
3.9.1 Remove the deep groove ball bearing,
Standard: 24.03-24.08 mm conical ring, main shaft distance ring,
reverse gear synchronizer ring and 5th
gear synchronizer gear sleeve.
148
BYD AUTO BYD Suri Maintenance & Repair Manual
Repair limit:
3.9.3 Prop up the 3rd gear (A) on a steel block,
and then press out the main shaft from the A: 25.95 mm
3rd/4th gear synchronizer hub (B) as a B: 28.95 mm
puller may damage the gear tooth. C: 34.92 mm
D: 25.95 mm
Standard:
149
BYD AUTO BYD Suri Maintenance & Repair Manual
Disassembly diagram
150
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard: 0.20-0.34 mm
Repair limit: 0.46 mm
Standard: 27.5-27.56 mm
Repair limit: 27.45 mm
3.12.2 Measure the thickness of 1st gear.
Standard: 26.84-26.9 mm
Standard: 27.21-27.3 mm
Repair limit: 27.18 mm
3.12.2.3 Measure the clearance between the
2nd gear (A) and the 3rd gear (B) with a
feeler gauge (C). If the clearance exceeds
the repair limit, go to step 4.
Standard: 0.20-0.35 mm
Repair limit: 0.47 mm
151
BYD AUTO BYD Suri Maintenance & Repair Manual
3.13.2 Use the chisel (A) to pry the lock nut lug
(B) from the counter shaft groove.
152
BYD AUTO BYD Suri Maintenance & Repair Manual
3.14.1 Inspect the gear surface and the 3.14.2 Prop up both ends of the counter shaft
bearing surface for wear or damage, and to inspect its run-outs. Rotate the counter
then measure the counter shaft at points A, shaft for 2 turns during measurement. If
B and C. If any part of the counter shaft is the run-out exceeds the repair limit,
less than the repair limit, replace with a replace with a new counter shaft.
new counter shaft.
Standard: Max. 0.02 mm
Standard: Repair limit: 0.05 mm
A (Ball bearing surface): 24.992-25 mm
B (Needle bearing surface): 37.989-38
mm
C (Needle bearing surface):
33.995-34.011 mm
Repair limit:
A: 24.942 mm
B: 37.939 mm
C: 33.945 mm
153
BYD AUTO BYD Suri Maintenance & Repair Manual
Disassembly diagram
Counter shaft distance ring
1st/2nd gear
synchronizer hub
1 st gear
Needle bearing
Needle bearing
Note: Refer to the disassembly diagram if necessary when performing the following steps.
154
BYD AUTO BYD Suri Maintenance & Repair Manual
155
BYD AUTO BYD Suri Maintenance & Repair Manual
156
BYD AUTO BYD Suri Maintenance & Repair Manual
157
BYD AUTO BYD Suri Maintenance & Repair Manual
Good Worn
Illustration of synchronizer gear sleeve
and gear teeth
Good Worn
158
BYD AUTO BYD Suri Maintenance & Repair Manual
159
BYD AUTO BYD Suri Maintenance & Repair Manual
160
BYD AUTO BYD Suri Maintenance & Repair Manual
15 Nm
161
BYD AUTO BYD Suri Maintenance & Repair Manual
Sealant
3.21.9 Apply sealant on the threads of the 3.21.12 Install the hexagon flange bolt (A) M8
sealing plug (25 Nm) (A), and then install it × 40 (25 Nm), high pressure steel pipe
onto the transmission rear casing. mounting bracket of clutch (B) and
hexagon flange bolt (C) M8 × 45 (25 Nm).
162
BYD AUTO BYD Suri Maintenance & Repair Manual
10 Nm
Sealant
163
BYD AUTO BYD Suri Maintenance & Repair Manual
164
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 4 Differential
4.1 Disassembly of differential
165
BYD AUTO BYD Suri Maintenance & Repair Manual
166
BYD AUTO BYD Suri Maintenance & Repair Manual
167
BYD AUTO BYD Suri Maintenance & Repair Manual
4.6.2 Close the transmission rear casing, and Select a proper gasket from the following
tighten the assembly bolts around the table.
differential alternatively in several steps.
Standard clearance: 0 mm - 0.10 mm
Tightening torque: 25 Nm
168
BYD AUTO BYD Suri Maintenance & Repair Manual
M 1.30 mm N 1.35 mm
Marker Thickness Marker Thickness
O 1.40 mm P 1.45 mm
A 0.70 mm B 0.75 mm
Q 1.50 mm - -
C 0.80 mm D 0.85 mm
169
BYD AUTO BYD Suri Maintenance & Repair Manual
170
BYD AUTO BYD Suri Maintenance & Repair Manual
Transmission
BYD6T25-1A
model
2nd 4th
Gear 1st gear 3rd gear 5th gear 6th gear Reverse gear
gear gear
Gear ratio 49/13 48/23 45/34 42/43 39/40 35/43 36/13×23/14
Drive ratio 3.769 2.087 1.324 0.977 0.975 0.814 4.549
Final drive gear
72/17 72/22
ratio
Final drive ratio 4.235 3.273
Total drive ratio 15.962 8.838 5.607 4.138 3.191 2.664 14.89
Transmission
BYD6T25
model
2nd 4th
Gear 1st gear 3rd gear 5th gear 6th gear Reverse gear
gear gear
Gear ratio 47/13 48/22 47/32 46/40 43/36 39/40 34/13×23/14
Drive ratio 3.615 2.182 1.469 1.150 1.194 0.975 4.297
Final drive gear
71/18 71/23
ratio
Final drive ratio 3.944 3.087
Total drive ratio 14.258 8.606 5.794 4.536 3.686 3.01 13.265
171
BYD AUTO BYD Suri Maintenance & Repair Manual
172
BYD AUTO BYD Suri Maintenance & Repair Manual
Model or
Fitting Position Grease application area
specification
Inner lip and outer ring of main shaft oil seal
Inner lip and outer ring of differential oil seal
Inner and outer rings of gear shifting shaft sleeve
Front box assembly
Counter shaft 1 front bearing outer ring
Counter shaft 2 front bearing outer ring No.2 lithium
Differential bearing outer ring grease (GB/T
Inner lip and outer ring of differential oil seal 7324-1984
Inner and outer rings of gear shifting shaft sleeve General lithium
Rear box assembly
Counter shaft rear bearing outer ring grease) or
Differential bearing outer ring verified
Inner and outer rings of shift lever oil seal equivalent
Shift lever shaft sleeve
Manual gear shift
Select lever bearing
assembly
Mating surface of gear shifting bracket assembly
and gear selecting fork head
Name, brand or
Part name Sealant application area specification of the
sealant
Gear shifting arm Flange sealant
Inside of the sealing surface edge
cover (Loctite 587 or verified
Front box Inside of the sealing surface edge equivalent)
Gear shifting steel ball
Bolt threads Thread sealant
assembly
(Loctite 567 or verified
Drain plug assembly Drain plug threads
equivalent)
Neutral switch Neutral switch threads
173
BYD AUTO BYD Suri Maintenance & Repair Manual
1.3.10 The transmission fasteners should be tightened to the specified tightening torque as
follows.
Part Tightening
Quantity
Part Bolt size No./International torque
per unit
Standard No. (Nm)
Hexagon flange
M8×25 Q1840825T1F6 2 20
bolt
Drain plug
M18×1.5 BYD6T25-1701680 2 30
assembly
Reversing light
M12×1.5 BYD6T25-4113010 1 35
switch assembly
Gear shifting
steel ball M27×1.5 BYD6T25-1701620 1 45
assembly
Release bearing
assembly M7×1 BYD6T25-1601111 3 15
mounting bolts
Neutral switch M18×1.5 BYD5T19-1-3781100 1 35
Hex nut M8 GB/T 41 1 23
Assembly bolt M8×1.5 BYD6T25-1701601 20 40
Stud bolt M12×1.25 BYD6T25-1701604 3 35
Hexagon flange
M6×20 Q1840620T1F3 1 15
bolt
Hexagonal head
bolt and spring M8×20 Q1420820T1F6 1 20
washer assembly
Hexagonal head
bolt and spring M8×25 Q1420825T1F6 1 20
washer assembly
174
BYD AUTO BYD Suri Maintenance & Repair Manual
175
BYD AUTO BYD Suri Maintenance & Repair Manual
176
BYD AUTO BYD Suri Maintenance & Repair Manual
2.3.2 Install the gear selecting bracket 2.3.3 Install the gear shifting bracket assembly,
assembly 4 and gear selecting fork head flat washer, spring washer and hex nut in
5. turns to finish installation of the manual
Note: The No.2 lithium grease (GB/T gear shift assembly.
7324-1994 General lithium grease) or Note: The tightening torque for the hex nut
verified equivalent should be applied on is 18 Nm.
the gear selecting fork head 5.
The split washer 3 is a disposable product
which should be replaced with a new part
after removal.
177
BYD AUTO BYD Suri Maintenance & Repair Manual
178
BYD AUTO BYD Suri Maintenance & Repair Manual
3.2.1 Assembly Overview 3.2.2.2 Press out the main shaft 5th gear
to finish the disassembly of main shaft
1 Main shaft rear bearing outer circlip components.
2 Rear box
3 Rear bearing circlip
4 Main shaft rear bearing
5 Main shaft 5th gear
6 Main shaft
7 Main shaft front bearing
8 Front box
179
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Front box
2 Oil deflector
3 Oil guide sleeve
4 Counter shaft 1 front bearing outer ring
5 Counter shaft 1 front bearing
6. Counter shaft 1
3.2.2.2 Press in the main shaft rear bearing. 7. 1st, 2nd and 4th gear needle bearing
The circlip groove should face upward 8 Counter shaft 2nd gear assembly
(indicated by A in the right figure). The 9 1st and 2nd gear synchronizer inner rings
bearing shoulder should face the main 10 1st and 2nd gear synchronizer middle
shaft 5th gear (indicated by B in the right steel rings
figure). 11 1st and 2nd gear synchronizer outer rings
Apply the grease before reassembly. 12 1st and 2nd gear synchronizer assembly
13 1st and 2nd gear synchronizer hub circlips
14 1st and 2nd gear synchronizer outer rings
15 1st and 2nd gear synchronizer middle
steel rings
16 1st and 2nd gear synchronizer inner rings
17 1st, 2nd and 4th gear needle bearings
18 Counter shaft 1st gear assembly
19 Counter shaft 1st gear snap-gauge
20 Counter shaft 1st gear snap-gauge outer
ring
21 1st, 2nd and 4th gear needle bearings
22 Counter shaft 4th gear assembly
23 4th gear synchronizer ring
24 3rd and 4th gear synchronizer assembly
25 3rd/4th gear synchronizer hub circlips
180
BYD AUTO BYD Suri Maintenance & Repair Manual
3.3.2.2 Remove the bearing circlip at the rear 3.3.2.7 Remove the counter shaft 1st gear
end of the counter shaft. assembly.
3.3.2.3 Use a tool to remove the counter shaft 3.3.2.8 Remove 1st/2nd gear synchronizer
rear bearing and remove the counter shaft outer ring C, 1st/2nd gear synchronizer
3rd gear assembly, 3rd gear needle middle steel ring B and 1st/2nd gear
bearing, 3rd gear synchronizer outer ring, synchronizer inner ring A in turns.
3rd gear synchronizer middle ring and 3rd
gear synchronizer inner ring in turns.
181
BYD AUTO BYD Suri Maintenance & Repair Manual
Repair
3.3.2.9 Press out the counter shaft 2nd gear Clearance a Standard size
limit
assembly and 1st/2nd gear synchronizer 1st/2nd gear
assembly. 0.75~1.25
synchronizer ring 0.5 mm
mm
assembly
3rd/4th gear
0.75~1.25
synchronizer ring 0.5 mm
mm
assembly
4th gear
1.0~1.7 mm 0.5 mm
synchronizer ring
182
BYD AUTO BYD Suri Maintenance & Repair Manual
The boss in the 3rd/4th gear synchronizer 3.3.4.2 Use a tool to press the 1st/2nd
hub should face upward (3rd gear synchronizer assembly into the
direction). The end with an identification corresponding position.
groove in the 3rd/4th synchronizer gear
sleeve should face upward (4th gear 3.3.4.3 Install the 1st/2nd gear synchronizer
direction). hub circlip of proper thickness.
183
BYD AUTO BYD Suri Maintenance & Repair Manual
h a'a (0.05~0.1)mm
a Front box
b Rear box
c Counter shaft 1 rear bearing
d Counter shaft 1 front bearing
e Counter shaft 1
184
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Front box
2 Counter shaft 2 front bearing outer ring
3 Counter shaft 2 front bearing
4 Counter shaft 2
5 Reverse gear synchronizer hub
6 Reverse gear synchronizer gear sleeve
(with reverse gear synchronizer ring)
7 Reverse gear needle bearing
8 Reverse gear assembly
9 Distance ring
10 Distance ring circlip
11 6th gear needle bearing
12 Counter shaft 6th gear assembly
13 5th/6th gear synchronizer ring
14 5th/6th gear synchronizer assembly
15 5th/6th gear synchronizer hub circlip 3.4.2 Disassembly of Counter Shaft 2
16 5th gear needle bearing Components
17 5th/6th gear synchronizer ring
18 Counter shaft 5th gear assembly 3.4.2.1 Remove the rear bearing circlip.
19 Counter shaft rear bearing
20 Rear bearing circlip 3.4.2.2 Pull out the counter shaft 2 rear
21 Counter shaft rear bearing outer ring bearing with the combination tools.
22 Counter shaft adjusting shim
23 Rear box 3.4.2.3 Remove the counter shaft 5th gear
24 5th/6th gear synchronizer spring assembly, 5th gear needle bearing and
25 5th/6th gear synchronizer gear sleeve 5th/6th gear synchronizer ring in turns.
26 5th/6th gear synchronizer gear hub
27 Synchronizer slide block 3.4.2.4 Remove the 5th/6th gear synchronizer
hub circlip.
185
BYD AUTO BYD Suri Maintenance & Repair Manual
3.4.2.5 Clamp the snap-gauge at the bottom of 3.4.2.11 Press out the reverse gear
counter shaft 6th gear assembly, and synchronizer hub with the combination
press out the shaft with a pressure lever. tools.
Remove the 5th/6th gear synchronizer
assembly, 5th/6th gear synchronizer ring
and counter shaft 6th gear assembly in
turns.
186
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Synchronizer spring
2 Slide block
3 Synchronizer gear sleeve
4 Synchronizer hub
187
BYD AUTO BYD Suri Maintenance & Repair Manual
3.4.4.5 Install the reverse gear needle bearing 3.4.4.11 Select a 5th/6th gear synchronizer
and reverse gear assembly. hub circlip with proper thickness and fix it
in the circlip groove.
188
BYD AUTO BYD Suri Maintenance & Repair Manual
h a'a (0.05~0.1)mm
For example:
3.4.4.14 Select a rear bearing circlip with
proper thickness and fix it in the circlip If a is 215.50 mm;
groove. If a' is 216.98 mm;
Front box
Rear box
Counter shaft 2 rear bearing
Counter shaft 2 front bearing
Counter shaft 2
The counter shaft 2 assembly adjusting
shim is selected as follows:
189
BYD AUTO BYD Suri Maintenance & Repair Manual
190
BYD AUTO BYD Suri Maintenance & Repair Manual
3.5.2 Disassembly of Differential Components 3.5.3.4 Install the differential planetary gear
shaft, and make sure to align it with the
3.5.2.1 Remove the differential bearing with carbon steel spring pin hole.
the tools.
191
BYD AUTO BYD Suri Maintenance & Repair Manual
a Front box
b Rear box
c Differential housing
d Differential bearing
h a'a (0.05~0.1)mm
For example:
If a is 57.74 mm;
If a' is 58.80 mm;
192
BYD AUTO BYD Suri Maintenance & Repair Manual
193
BYD AUTO BYD Suri Maintenance & Repair Manual
4.2.1 Remove the sealing cap. 4.2.7 Remove the main shaft rear bearing
outer circlip with circlip pliers.
The sealing cap is a disposable product
and must be replaced before the 4.2.8 Pry out the circlip at the connection of
reassembly. the T-tube assembly and release bearing
unit, and then remove the T-tube
4.2.2 Remove the neutral switch with a assembly.
wrench.
4.2.9 Remove the release bearing assembly
4.2.3 Use M22 sleeve to remove the gear mounting bolts and release bearing
selecting steel ball assembly. assembly.
194
BYD AUTO BYD Suri Maintenance & Repair Manual
195
BYD AUTO BYD Suri Maintenance & Repair Manual
196
BYD AUTO BYD Suri Maintenance & Repair Manual
197
BYD AUTO BYD Suri Maintenance & Repair Manual
198
BYD AUTO BYD Suri Maintenance & Repair Manual
199
BYD AUTO BYD Suri Maintenance & Repair Manual
200
BYD AUTO BYD Suri Maintenance & Repair Manual
201
BYD AUTO BYD Suri Maintenance & Repair Manual
4.4.11 Prepare the serviced rear box assembly 4.4.14 Install the assembly bolts.
with accessories.
Note: There are 20 assembly bolts in total,
Note: Press the differential bearing outer and their tightening torque is 25 Nm.
ring and its adjusting shim, counter shaft 1
rear bearing outer ring and its adjusting 4.4.15 Install the main shaft rear bearing outer
shim as well as counter shaft 2 rear circlip and main shaft sealing cap.
bearing outer ring and its adjusting shim
into the rear box together. 4.4.16 Install the mounting bolts of release
bearing unit and release bearing
4.4.11.1 For the selection of counter shaft 1 assembly.
rear bearing adjusting shim, refer to
section 3.3.5 ―Selection of Counter Shaft 1 Note: There are 3 mounting bolts for the
Rear Bearing Adjusting Shim‖ release bearing assembly, and their
tightening torque is 18 Nm.
4.4.11.2 For the selection of counter shaft 2
rear bearing adjusting shim, refer to section 4.4.17 Install the T-tube assembly.
3.4.5 ―Selection of Counter Shaft 2 Rear
Bearing Adjusting Shim‖
202
BYD AUTO BYD Suri Maintenance & Repair Manual
203
BYD AUTO BYD Suri Maintenance & Repair Manual
Contents
204
BYD AUTO BYD Suri Maintenance & Repair Manual
1.2.1.1 Prepare the parts kit and parts rack in 1.2.1.6 Use correct removal tools for
advance to store the removed and disassembly and assembly.
disassembled components. Put them in
order and make markers if necessary to 1.2.1.7 Refer to this service manual as much
avoid confusion and misplacement. as possible during work.
1.2.1.2 Be careful when servicing the 1.2.1.8 If you encounter any difficult technical
aluminum alloy parts to avoid damage to problems during servicing, it is
the machined surface. recommended to consult our aftersales
technical service department.
1.2.1.3 Prepare sufficient auxiliary materials
for use in the process of servicing. 1.2.2 Materials for Servicing
1.2.1.4 For the bolts and other fastening parts The materials listed in the following table
with standard tightening torque are essential for servicing the transmission
requirements, tighten them with special of this model. Therefore, they should be
tools in accordance with the required prepared for use at any time. In addition,
values. the washing liquid and lubricant of
specified models should be used.
1.2.1.5 After servicing, disposable supplies
should be scrapped and replaced with new
205
BYD AUTO BYD Suri Maintenance & Repair Manual
1.2.3 Precautions 1.2.3.3 Install the clean parts only and take out
the original parts from their package only when
1.2.3.1 Do not allow the contaminants to enter they are to be installed.
the transmission when the transmission is
disassembled. 1.2.3.4 The transmission has two fuel supply
systems with one for gears and shafts and the
1.2.3.2 Put removed parts on a clean work other one for the electric hydraulic control
stand and cover them with a piece of clean module. Do not add any additives into oil.
and fibreless cloth to protect them from
contamination. 1.2.3.5 The engine oil drained should not be
used for refilling. Dispose the waste oil
properly.
206
BYD AUTO BYD Suri Maintenance & Repair Manual
a Tips
The clutch has self-regulating function.
Vibration will influence the self-regulating
device. Therefore do not drop the clutch
into the transmission when installing the
clutch. Even when the electric hydraulic
control module has been removed, taking
out the screwdriver underneath the
engaging level could also have a negative 2.1.6.4 Remove the damping disc with the
effect on the self-regulating device. circlip pliers and screwdriver.
207
BYD AUTO BYD Suri Maintenance & Repair Manual
8 Connecting arm 1
9 Engaging bearing 1
208
BYD AUTO BYD Suri Maintenance & Repair Manual
10 Engaging bearing 1 gasket 2.2.3 Turn the lugs of the thrust ring indicated
by the arrows for 90°with respect to the
11 Engaging bearing 2 gasket connecting arm 2.
209
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembly
210
BYD AUTO BYD Suri Maintenance & Repair Manual
separately when performing adjustment. 2.1.3.5 The H plate -T1005 - should be kept in
this position in the following measurement.
The following contents will describe how to
determine all necessary dimensions on the 2.1.3.6 The depth gauge is placed on the main
transmission side so that a proper shaft.
adjusting shim can be selected. Then the
clutch tolerance can be determined by 2.1.3.7 Reset the depth gauge to zero
means of experience and the tolerance will
be used as a coefficient in the calculation 2.1.3.8 Measure the distance H
later. The thickness of adjusting shim is
determined by the tolerance of the
transmission side and the clutch.
a Tips
211
BYD AUTO BYD Suri Maintenance & Repair Manual
Unit: mm
Marker Thickness (Range for actual Marker Thickness (Range for actual shim
shim measurement) measurement)
100 1.0 (0.51~1.05) 160 1.6 (1.51~1.65)
115 1.15 (1.06~1.20) 175 1.75 (1.66~1.80)
130 1.3 (1.21~1.35) 190 1.9 (1.81~2.35)
145 1.45 (1.36~1.50)
Only 1 shim can be inserted during installation, 2.3.2.2 Check if the engaging bearing 2 is
instead of 2. correctly installed and if the groove
position is correct by turning.
2.3.2.1 Install the engaging bearing 2. 2.3.2.3 Install the gauge block -T1004- on the
engaging bearing 2.
Do not install the adjusting shim!
2.3.2.4 Place the depth gauge above the main
a The engaging bearing 2 can only be shaft.
installed in one position due to 4 grooves.
2.3.2.5 Reset the depth gauge to zero.
212
BYD AUTO BYD Suri Maintenance & Repair Manual
Marker Thickness Marker Thickness 2.4.3 Fix the sleeve using 2 new bolts.
(Range for (Range for Tightening torque: 10 Nm
actual shim actual shim
measurement) measurement)
50 0.5 (0.21~0.55) 95 0.95 (0.86~1.0)
65 0.65 (0.56~0.7) 110 1.1 (1.01~1.15)
80 0.8 (0.71~0.85)
213
BYD AUTO BYD Suri Maintenance & Repair Manual
d Tips
2.4.6 Check if the engaging bearing is installed Therefore do not allow the clutch to drop
correctly and if the mounting positions of into the transmission even when installing
the grooves are correct by turning the the clutch.
engaging bearing.
2.4.8 Install the mounting bracket -T1001- on
the transmission.
214
BYD AUTO BYD Suri Maintenance & Repair Manual
e Tips
215
BYD AUTO BYD Suri Maintenance & Repair Manual
If the gear oil leaks from transmission, 3.1.1.3.2 Mark the mounting position of
check for leaking area. operating lever and remove it from the
gear shifting shaft.
3.1.1.1. Drain the remaining gear oil and
dispose it properly. 3.1.1.3.3 Remove the P gear cover plate.
3.1.1.2. Repair the leaking area. 3.1.1.3.4 Fill 1.7L gear oil through the opening.
216
BYD AUTO BYD Suri Maintenance & Repair Manual
Tips opening.
3.1.2.1 Discharging
3.1.2.2 Filling
217
BYD AUTO BYD Suri Maintenance & Repair Manual
a Tips
b Tips
218
BYD AUTO BYD Suri Maintenance & Repair Manual
d Tips
219
BYD AUTO BYD Suri Maintenance & Repair Manual
R-Reverse gear
1- 1st gear
2- 2nd gear
3- 3rd gear
4- 4th gear
5- 5th gear
3.3.2 Tips
6- 6th gear
3.3.2.1 Adjust the position of gear shift
adjuster and keep it in "neutral position" or
the transmission cannot be shifted
normally!
Each gear shifting fork has 3 positions: 3.3.3.1 Replace with new bolts after removal.
"Engage a gear- Neutral - Engage a gear".
3.3.3.2 The tightening torque of the bolt is 10
- Engage each gear shifting fork to each Nm.
position once in order. Disengage all gears
220
BYD AUTO BYD Suri Maintenance & Repair Manual
3.4.1 Disassembly of Transmission 3.4.1.2 Remove the main shaft rear circlip
using circlip pliers.
3.4.1.1 Remove the sealing cap using a
screwdriver.
221
BYD AUTO BYD Suri Maintenance & Repair Manual
b Tips
c Tips
222
BYD AUTO BYD Suri Maintenance & Repair Manual
3.4.1.5 Pull out the shift fork and counter shaft When the gear sleeve is in 2nd and 3rd
1 -4- together. gear, measure the height h2 and h3 from
the upper surface of the gear sleeve to the
3.4.1.6 Pull out the shift fork as well as the joint surfaces of the box. Based on the
counter shaft 2 -7- and reverse shaft -6- height, the thickness t1 of counter shaft 1
together. front bearing adjusting shim can be
determined: t1= {(48.2-h2) + (131.3-h3)}/2
d Tips
When the synchronizer gear sleeve is in the counter shaft 2 gear ring, measure the height h7
from the upper surface of 5th gear synchronizer gear sleeve to the joint surfaces of the box.
Based on the height, the thickness t2 of counter shaft 2 front bearing adjusting shim can be
determined: t2=127.45-h7
223
BYD AUTO BYD Suri Maintenance & Repair Manual
Unit: mm
Marker Thickness Marker Thickness Marker Thickness
0.7 0.7 0.95 0.95 1.20 1.20
0.75 0.75 1.0 1.0 1.25 1.25
0.8 0.80 1.05 1.05 1.30 1.30
0.85 0.85 1.10 1.10 1.35 1.35
0.9 0.90 1.15 1.15 1.40 1.40
Unit: mm
Marker Thickness Marker Thickness Marker Thickness
0.7 0.7 0.95 0.95 1.20 1.20
0.75 0.75 1.0 1.0 1.25 1.25
0.8 0.8 1.05 1.05 1.30 1.30
0.85 0.85 1.10 1.10 1.35 1.35
0.9 0.9 1.15 1.15
3.4.2.3 Selection of Reverse Shaft Front 3.4.2.3.1 Install the special tools for of all the
Bearing Adjusting Shim: bearing outer rings in place in the front box
before adjusting the front box shim, or the
When the synchronizer gear sleeve is in shim adjustment accuracy will be affected.
reverse gear, measure the height hd from
the upper surface of synchronizer gear
sleeve to the joint surface of the box. 3.4.3 Selection of Rear Box Adjusting Shim
Based on the height, the thickness t3 of
reverse shaft front bearing adjusting shim The adjusting shims for the rear box
can be determined: t3=62.25-hd counter shaft, reverse shaft and differential
rear bearing are selected as follows:
224
BYD AUTO BYD Suri Maintenance & Repair Manual
tf1=Hf1-hf1+ (0.05~0.1);
tf2=Hf2-hf2+ (0.05~0.1);
td=Hd-hd+ (0.05~0.1);
tc=Hc-hc+ (0.05~0.1).
Refer to the table below for selection of tf1, tf2 and td shims;
Unit: mm
Unit: mm Marker Thickness Marker Thickness Marker Thickness
0.7 0.7 0.95 0.95 1.20 1.20
0.75 0.75 1.0 1.0 1.25 1.25
0.8 0.80 1.05 1.05 1.30 1.30
0.85 0.85 1.10 1.10 1.35 1.35
0.9 0.90 1.15 1.15 1.40 1.40
Unit: mm
Marker Thickness Marker Thickness Marker Thickness
0.8 0.8 1.05 1.05 1.30 1.30
0.85 0.85 1.1 1.1 1.35 1.35
0.9 0.9 1.15 1.15 1.40 1.40
0.95 0.95 1.20 1.20 1.45 1.45
1.0 1.0 1.25 1.25 1.50 1.50
3.4.3.1.2 After replacing the front box, After adjusting the shim, assemble the rear
adjust the shims of the front box. box and rotate the shafts and differential.
When you feel the pre-tensioning force, it
225
BYD AUTO BYD Suri Maintenance & Repair Manual
226
BYD AUTO BYD Suri Maintenance & Repair Manual
c Tips
d Tips
227
BYD AUTO BYD Suri Maintenance & Repair Manual
228
BYD AUTO BYD Suri Maintenance & Repair Manual
Snap-gauge - T1021 -
229
BYD AUTO BYD Suri Maintenance & Repair Manual
2 Main shaft 1;
230
BYD AUTO BYD Suri Maintenance & Repair Manual
Service
Assembly
231
BYD AUTO BYD Suri Maintenance & Repair Manual
2 Main shaft 2;
232
BYD AUTO BYD Suri Maintenance & Repair Manual
Disassembly Assembly
4.2.1 Remove the 4th/6th gear roller bearing 4.2.3.3.1 Install the main shaft 2 bearing
and the main shaft 2 oil seal. pressure plate and the main shaft 2
bearing.
Service
233
BYD AUTO BYD Suri Maintenance & Repair Manual
234
BYD AUTO BYD Suri Maintenance & Repair Manual
Service
235
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembly
236
BYD AUTO BYD Suri Maintenance & Repair Manual
a Place the shaft on the tool -T1012- to 4.3.4.5.13.3 Press the 2nd/4th gear
assemble the parts. synchronizer assembly on the shaft with
the tool -T1015. The flange of the
synchronizer outer ring must be in the
groove of the synchronizer. Pay attention
to the mounting direction of the
synchronizer.
237
BYD AUTO BYD Suri Maintenance & Repair Manual
238
BYD AUTO BYD Suri Maintenance & Repair Manual
4.3.4.5.13.13 Assemble the 1st/3rd gear 4.3.4.5.13.16 Install the counter shaft 1st gear
synchronizer ring assembly in place in the pressure plate and use the tool - T1018 -
order of outer ring, middle steel ring and to press fit the counter shaft conical
inner ring. bearing.
239
BYD AUTO BYD Suri Maintenance & Repair Manual
240
BYD AUTO BYD Suri Maintenance & Repair Manual
Disassembly
Assembly
4.4.2.2 Clip the 6th gear of the counter shaft 2
4.4.2.6.1 Use the special tool - T1013- to
assembly onto the snap-gauge - T1021-
assemble the gear oil guide sleeve.
as shown and press the tool -T1014- with
a press so as to remove the distance ring,
retainer, 6th gear and needle bearing.
241
BYD AUTO BYD Suri Maintenance & Repair Manual
242
BYD AUTO BYD Suri Maintenance & Repair Manual
Install 1 into 2.
243
BYD AUTO BYD Suri Maintenance & Repair Manual
244
BYD AUTO BYD Suri Maintenance & Repair Manual
4.4 2.6.7.8 Use the tool -T1017- to install the 4.4.2.6.7.10 After assembly, check if the gears
counter shaft 2 rear bearing. rotate smoothly and can be shifted without
stagnation.
245
BYD AUTO BYD Suri Maintenance & Repair Manual
Reverse Shaft
246
BYD AUTO BYD Suri Maintenance & Repair Manual
Disassembly
Assembly
247
BYD AUTO BYD Suri Maintenance & Repair Manual
248
BYD AUTO BYD Suri Maintenance & Repair Manual
4.5.11 Use the special tool -T1019- to press 4.5.13 After assembly, check if the gears rotate
the P gear ratchet onto the reverse shaft smoothly and can be shifted without
spline in place. stagnation.
249
BYD AUTO BYD Suri Maintenance & Repair Manual
1
BYD AUTO BYD Suri Maintenance & Repair Manual
2
BYD AUTO BYD Suri Maintenance & Repair Manual
Content
Part 1 Repair Requirements for Electronic Injection System ........................................................... 6
Section 1 General Repair Requirements .................................................................................. 6
Section 2 Precautions during Repair ........................................................................................ 6
Section 3 Summary of Repair Tools ......................................................................................... 7
Section 4 Meaning of Abbreviations in Repair Manual ............................................................. 9
Part 2 Introduction of ME17 System .............................................................................................. 10
Section 1 System Operation ................................................................................................... 10
Section 2 Control Signal: Input/Output Signals of ME17 System ........................................... 13
Section 3 Introduction of System Function ............................................................................. 14
Section 4 Introduction of System Diagnosis Function ............................................................ 16
Section 5 Description of Item Related Problems .................................................................... 17
Part 3 Structure, Theory and Trouble Analysis of ME17 System Components ............................ 18
Section 1 Layout of Engine Management System Components ............................................ 18
Section 2 Intake Pressure/Temperature Sensor .................................................................... 20
Section 3 Electronic Throttle Valve Body Assembly ............................................................... 23
Section 4 Coolant Temperature Sensor ................................................................................. 24
Section 5 Knock Sensor .......................................................................................................... 26
Section 6 Oxygen Sensor ....................................................................................................... 29
Section 7 Crankshaft Position Sensor .................................................................................... 34
Section 8 Camshaft Position Sensor ...................................................................................... 37
Section 9 Electronic Controller Unit ........................................................................................ 39
Section 11 Injector .................................................................................................................. 46
Section 12 Ignition Coil ........................................................................................................... 49
Section 13 Charcoal Canister Control Valve .......................................................................... 51
Section 14 Fuel Distribution Pipe Assembly ........................................................................... 55
Part 4 Diagnosis Flow for ME17 System in Accordance with Trouble Codes ............................... 56
Part 5 Diagnosis Flow for ME17 System in Accordance with Trouble Symptoms ........................ 74
Section 1 The engine does not rotate or rotates slowly when starting ................................... 74
Section 2 The engine can rotate, but cannot be started successfully .................................... 75
Section 3 Hot starting is difficult .............................................................................................. 76
Section 4 Cold starting is difficult ............................................................................................ 76
Section 5 Engine is difficult to start at any time, but the engine speed is normal .................. 77
Section 6 Engine can be started normally, but idle speed unstable at any time .................... 78
Section 7 Engine can be started normally, but idle speed unstable during warming up........ 79
Section 8 Engine can be started normally, but idle speed unstable after warming up .......... 80
Section 9 Engine can be started normally, but idle speed unstable or engine misfires under
some loads (for example, the air conditioning is on) .............................................................. 81
Section 10 Engine speed does not increase or the engine misfires during acceleration....... 81
Section 11 Response is slow during acceleration .................................................................. 82
3
BYD AUTO BYD Suri Maintenance & Repair Manual
4
BYD AUTO BYD Suri Maintenance & Repair Manual
Introduction
With the development of China's national economy, the automobile quantity is increasing
gradually and environmental regulations are becoming stricter. The combination of the
quantitative gasoline technique controlled by a closed loop and three-way catalytic converter may
reduce the emission of toxic substances by 92% or more, so it is an irreversible trend to replace
the carburetor with the electronically controlled gasoline injection technique. It marks the end of
the engine with a carburetor and the beginning of the engine with an electronically controlled
gasoline injection in the Chinese automobile industry.
The engine management system equipped in the BYD 473Q engine is the MOTRONIC system
provided by United Automotive Electronic Systems Co. Ltd. As the largest and most influential
provider of electronically controlled gasoline injection systems in China, United Automotive
Electronic Systems Co. Ltd. has been providing the Motronic series electronically controlled
injection system and other components introduced from Germany by BOSCH Company to
various automobile companies in China since 1996. Motronic is a trade name without a specific
meaning. The Motronic system has a technical feature which is a combination of engine
gasoline quantitative electronic control and an ignition timing electronic control system. Both
systems share a set consisting of a sensor, electronic control unit and power supply. It is
noticeable that the Motronic system has an ignition timing electronic control function which
naturally improves the engine performance.
As the other electronically controlled gasoline injection system, the Motronic system reduces the
vehicle emission significantly, but it makes things difficult for service personnel who are only
familiar with the engine with a conventional carburetor. The service personnel are familiar with the
structure of an engine with a carburetor. However, some electronic components replace the
familiar mechanical components in the engine with electronically controlled gasoline injection. In
the past, service personnel, or even the drivers could adjust the carburetor or distributor. But now
the data are stored in computer chips, general service personnel cannot repair the malfunction by
modifying the data with electronic instruments. A malfunction in the electronic components of the
system may not be visible from the appearance, and it should be detected with various
instruments. Therefore, service personnel do not know how to repair the engine with
electronically controlled gasoline injection. Based on this situation, we compiled the repair manual
with the aim of helping engineers in the engine plants or assembly plants to further understand
the electronic control system of the engine, and also to help local service personnel repair the
engine with electronically controlled gasoline injection.
The manual first of all introduces the composition and operation theory of the electronically
controlled gasoline injection system, and then it describes the construction and performance of
various components of the system in details.
In general, the diagnostic tester is an essential tool when repairing the electronically controlled
gasoline injection system. The diagnostic tester can recall the trouble information stored in the
ECU. To help the readers fully understand the meaning of each DTC, the manual lists the
conditions when the ECU sets a variety of trouble information. However some trouble cannot be
confirmed directly according to the recorded trouble information. The real trouble cause can be
found only after a series of analysis. Therefore, the repair manual uses more text to describe how
to find the real trouble according to the recorded trouble information.
The existence of electronic control components creates new engine trouble causes. In other
words, the same engine trouble may be caused by the mechanics and electronic components.
The real engine trouble cannot be detected with only the diagnostic tester. Therefore, the repair
manual helps find the trouble cause by describing the engine symptoms and combining the
electronic control system.
5
BYD AUTO BYD Suri Maintenance & Repair Manual
6
BYD AUTO BYD Suri Maintenance & Repair Manual
Tool Name:
Digital Multimeter
Function:
Check the characteristic parameters of the
electronically controlled injection system, such
as voltage, current and resistance.
Tool Name:
Vacuum Gauge
Function:
Check the pressure of the intake manifold.
Tool Name:
Cylinder Pressure Gauge
Function:
Check the pressure of each cylinder.
7
BYD AUTO BYD Suri Maintenance & Repair Manual
Tool Name:
Fuel Pressure Gauge
Function:
Check the pressure of the fuel system and
judge the operation of the fuel pump and fuel
pressure regulator in the fuel system.
Tool Name:
Exhaust Gas Analyzer
Function:
Check the exhaust emission of the vehicle to
help judge the trouble of the electronically
controlled injection system.
Tool Name:
Injector Washing Analyzer
Function:
Perform washing and analysis on the injector.
8
BYD AUTO BYD Suri Maintenance & Repair Manual
9
BYD AUTO BYD Suri Maintenance & Repair Manual
Engine
In the electronic engine control (EEC) system, Once trouble is detected and confirmed, a
the sensor is used as the input part to DTC is stored and the "limp home" function is
measure various physical signals recalled. When the trouble is eliminated, the
(temperature, pressure, etc.) and convert normal value will be restored.
them to the proper electrical signals. The ECU
receives the signals input by the sensor, The major feature of the ME17 electronic
performs calculation according to the set engine control management system is to use
procedures and outputs the generated control the torque-based control strategy. The aim of
signal to the power-driven circuit. The the torque-based control strategy is to
power-driven circuit performs different actions combine various different control targets. This
by driving each actuator so that the engine is the only method to integrate various
can operate according to predetermined functions in different variants of the ECU
control strategy. Meanwhile, the trouble according to the engine and vehicle models.
diagnosis system of the ECU monitors the The basic components of the ME17 electronic
components or control function of the system. engine control (EEC) system are as follows:
The ME17-Motronic engine management Basic management function of the engine with
system is an electronically operated gasoline a physical model applied
engine control system which provides many
control features related to the operator and Torque-based system structure
vehicle or device. The system combines the Cylinder load determined by intake
open loop and closed loop (feedback) controls pressure sensor/air flow sensor
to provide various control signals for the Improved mixture control function in static
operation of engine. and dynamic conditions
10
BYD AUTO BYD Suri Maintenance & Repair Manual
11
BYD AUTO BYD Suri Maintenance & Repair Manual
Compared with the conventional M series The basic feature of the model-based engine
engine electronic injection management is independent and the calibration process is
system, the main features of ME17 system simplified;
are as follows: The sequential fuel injection with the camshaft
position sensor can help improve the
The functional structure of the new emission;
torque-based engine is compatible with
other systems more easily and with Improve the driving performance by the
stronger expansibility; integrated coordination of various torque
requirements;
The new modular software and hardware The system can be expanded according to
structures have stronger portability; future demands, such as future emissions
regulations or electronic throttle valve.
12
BYD AUTO BYD Suri Maintenance & Repair Manual
2.5 Engine speed signal 2.12 Injection timing and injection duration
2.7 Knock sensor signal 2.14 Charcoal canister control valve opening
2.8 Oxygen sensor signal 2.15 Ignition coil dwell angle and ignition
advance angle
2.9 Vehicle speed signal
2.16 Cooling fan relay
2.10 Air conditioning pressure signal
13
BYD AUTO BYD Suri Maintenance & Repair Manual
14
BYD AUTO BYD Suri Maintenance & Repair Manual
required to maintain the desired idle speed in modify the control variable in response to the
any working condition according to the closed input signals (1=thin mixture, 1=rich
loop idle control. The output torque increases mixture), and generate the correction factor as
as the engine speed decreases, and a multiplier to correct the injection duration.
decreases as the engine speed increases.
The system responds to the new "interference 3.6 Evaporative Emission Control
factors" by demanding larger torque, such as
ON/OFF of the air conditioning compressor or Due to the delivery of external radiation heat
the automatic transmission gear shift. When and oil return heat, the fuel in the fuel tank is
the engine temperature is low, the torque must heated and the fuel vapor is formed. The
be increased to compensate more internal vapor containing a large amount of HC cannot
friction loss and/or maintain higher idle speed. be discharged to the atmosphere due to the
The total of the output torque demands is limit of evaporative emission regulations. In
transferred to the torque coordinator, and the the system, the fuel vapor is collected in the
charge density, mixture content and ignition charcoal canister through the duct, and then
timing are calculated by the torque purged and burned in the engine at the proper
coordinator. time. The purge air flow can be achieved
through the charcoal canister control valve
3.5 Closed loop control controlled by the ECU. The control functions
when the closed loop control system
The exhaust post-processing in the three-way operates.
catalytic converter is an effective method to
reduce the concentration of harmful 3.7 Knock Control
substances in the exhaust. The three-way
catalytic converter can reduce the The system detects the characteristic
hydrocarbons (HC), carbonic oxide (CO) and oscillation when the knock is detected by the
nitrogen oxides (NOx) by 98% or more, and knock sensor at the proper position of the
convert them to water (H2O), carbon dioxide engine, converts it to electronic signals and
(CO2) and nitrogen (N2). The high efficiency transfers them to the ECU for handling. The
can be reached only when the engine excess ECU uses a special processing algorithm to
air ratio is about 1. The target of closed detect the knock in each ignition cycle of each
loop control is to ensure the mixture cylinder. The closed loop control will be
concentration is within the range. triggered once the knock is detected. When
the knock danger is eliminated, the ignition of
The closed loop control system can function the affected cylinder will gradually advance to
only when equipped with an oxygen sensor. the predetermined ignition advance angle
The oxygen sensor monitors the oxygen again.
content in the exhaust at the position of the
three way catalytic converter. The thin mixture The threshold of the knock control can adapt to
(1) will generate a sensor voltage of about different working conditions and different types
100 mV, and the rich mixture (1) will of fuel.
generate a sensor voltage of about 900 mV.
When =1, the sensor voltage will have a step
transition. The closed loop control will
15
BYD AUTO BYD Suri Maintenance & Repair Manual
The electronic control unit constantly monitors The system uses "K" line communication
the sensor, actuator, related circuits, fault protocol and an ISO 9141-2 standard
indicator, battery voltage and even the diagnostic plug as shown in figure 2-4. The
electronic control unit itself, and detects the standard diagnostic plug is securely
reliability of output sensor signals, actuator connected to the engine wire harness. Pin No.
drive signals and internal signals (for example, 4, 7 and 16 on the standard diagnostic plug
closed loop control, coolant temperature, are used in the engine management system
knock control, idle speed control and battery (EMS). Pin No. 4 of the standard diagnostic
voltage control, etc.).Once the trouble is found plug is connected to the ground wire of the
in a cycle or some signal value is not reliable, vehicle. Pin No. 7 is connected to Pin No. 71
the electronic control unit will store the trouble of the ECU, i.e. engine data "K" line; Pin No.
information in the malfunction memory of RAM. 16 is connected to the battery positive.
The trouble information is stored in the form of
DTCs, and displayed in the order of trouble
occurrence.
16
BYD AUTO BYD Suri Maintenance & Repair Manual
17
BYD AUTO BYD Suri Maintenance & Repair Manual
473Q Engine
18
BYD AUTO BYD Suri Maintenance & Repair Manual
G: Knock Sensor
19
BYD AUTO BYD Suri Maintenance & Repair Manual
Sensor
Fig. 3-1 Intake Pressure/Temperature Sensor Fig. 3-2 Circuit Diagram of Intake
Pressure/Temperature Sensor
2.1 Installation Position formed. The active surface of the silicon chip
A sensor consisting of an intake manifold is subject to a pressure of nearly 0, and its
absolute pressure sensor and intake back is subject to an intake manifold absolute
temperature sensor is installed on the intake pressure introduced by a tube. The thickness
manifold. of the silicon chip is only several micrometers
(m), so the change of intake manifold
2.2 Operation Theory absolute pressure will cause the mechanical
The intake manifold absolute pressure sensor deformation of the silicon chip. The 4
consists of a silicon chip. A pressure piezoelectric resistors also deform and their
diaphragm is etched on the silicon chip. The resistance values change. The voltage signals
pressure diaphragm has 4 piezoelectric in linear relation with voltage will be generated
resistors which form a Wheatstone bridge as after the treatment of the signal processing
variable components. In addition to the circuit of the silicon chip.
pressure diaphragm, a signal processing
circuit is also integrated in the silicon chip. The intake temperature sensor is a resistor of
The silicon chip forms a closed reference negative temperature coefficient (NTC) which
space with a metal housing, with the absolute changes with the intake temperature. The
air pressure of the reference space close to 0. sensor will send a voltage signal indicating the
Thus a microelectronic mechanical system is intake temperature change to the controller.
1. Seal Ring
2. Stainless Bushing
3. PCB Plate
20
BYD AUTO BYD Suri Maintenance & Repair Manual
4. Sensor
5. Housing
6. Pressure Support
7. Welded Connection
8. Adhesive Connection
Fig. 3-4 Cross Section of Intake Manifold Absolute Pressure and Intake Temperature Sensor
Value
Items Unit
Min. Typical Max.
Withstand Voltage 16 V
Max. Allowed Pressure 500 kPa
Allowed Storage Temperature -40 +130 C
Value
Items Unit
Min. Typical Max.
Pressure Test Range 20 115 kPa
Operating Temperature -40 125 C
Operating Voltage 4.5 5.0 5.5 V
Current for US=5.0 V 6.0 9.0 12.5 mA
Load Current of Output Circuit -0.1 0.1 mA
Load Resistance to Ground or Battery 50 k
Response Time 0.2 ms
Weight 27 g
From the above formula, under atmospheric Rated resistance at 20C: 2.5 k 5%
pressure, the signal output voltage of the Temperature-time factor 63 in air, v=6 m/s:
pressure sensor is close to the power voltage. 45 s
If the power voltage is 5 V, the signal output
voltage of the pressure sensor is about 4 V
2.4 Precautions for installation
when the electronic throttle valve is fully
The sensor is designed to be installed on the
opened.
surface of the intake manifold in the engine.
The pressure tube and temperature sensor
2.3.4. Data Limit of Temperature Sensor
are integrated in the intake manifold and
sealed with an O-ring.
Storage temperature: -40/+130C
21
BYD AUTO BYD Suri Maintenance & Repair Manual
22
BYD AUTO BYD Suri Maintenance & Repair Manual
Pin definition:
1. Throttle position sensor 1;
2. 5 V power 2;
3. Positive terminal of electronic throttle
valve actuator;
4. Throttle position sensor 2;
5. Negative terminal of electronic throttle
valve actuator;
6. Throttle valve connected to ground.
Fig. 3-7 Circuit Diagram of Electronic Throttle 3.3 Self-learning must be performed when the
Valve Body Assembly electronic throttle body assembly is
replaced (Wait for 1 min after the vehicle
is powered ON.
23
BYD AUTO BYD Suri Maintenance & Repair Manual
Engine
ECM
Temperature
24
BYD AUTO BYD Suri Maintenance & Repair Manual
25
BYD AUTO BYD Suri Maintenance & Repair Manual
Frequency
26
BYD AUTO BYD Suri Maintenance & Repair Manual
27
BYD AUTO BYD Suri Maintenance & Repair Manual
28
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 3-20 Oxygen Sensor Fig. 3-21 Cross Section of Oxygen Sensor
1 Cable 2 Saucer Washer 3 Insulating Bushing 4 Protective Sleeve
5 Clamped Connector of Heating Element 6 Heating Rod
7 Contact Gasket 8 Sensor Base 9 Ceramic Probe 10 Protection Tube
Fig. 3-22 Circuit Diagram of Front Oxygen Fig. 3-23 Circuit Diagram of Rear Oxygen
Sensor Sensor
Pin definition:
Front oxygen sensor: Pin No. 1 connected to main relay;
29
BYD AUTO BYD Suri Maintenance & Repair Manual
The oxygen sensor is operated to convert the The concentration difference is converted to
difference of oxygen ion concentration inside potential difference so that the electrical signal
and outside of the sensing ceramic tube to is output. The variation range of the front
voltage signals and output them. When the oxygen sensor during idling is: 0-900 mV. If
temperature of the sensing ceramic tube the mixture is rich, the difference of oxygen
reaches 350ºC, it will have the characteristics ion concentration inside and outside the
of a solid electrolyte. Due to the special ceramic tube is high and the potential
material, the oxygen ion can penetrate the difference is too high. A large amount of
ceramic tube freely. With the characteristics, oxygen ions move from inside to outside and
the output voltage is high (close to 800
mV-1000 mV). If the mixture is thin, the
difference of oxygen ion concentration inside
and outside the ceramic tube is low and the
potential difference is too low. Few oxygen
ions move from inside to outside and the
output voltage is low (close to 100 mV). The
sudden change of signal voltage occurs
around the theoretical equivalent air-fuel ratio
(λ=1) as shown in figure 3-26.
30
BYD AUTO BYD Suri Maintenance & Repair Manual
Value
Items Unit
Min. Typical Max.
Storage temperature -40 +100 C
Ceramic tube 200 850 C
Housing hexagon head 570 C
Operating
Metal retaining ring of
temperature 250 C
cable and connecting cable
Connector 120 C
Max. temperature
Exhaust at ceramic tube
allowed when the 930 C
heating end
component is
energized (Up to
Housing hexagon head 630 C
10 min each time,
the cumulative
time is up to 40 Metal retaining ring of
280 C
hours) cable and connecting cable
Temperature change rate permitted at the
100 K/s
ceramic tube end
Temperature of the ceramic components
permitted when there is condensate water on 350 C
the exhaust side
Random vibration
800 m/s2
(Peak value)
Allowed housing Harmonic vibration
0.3 mm
vibration (Vibration displacement)
Harmonic vibration
300 m/s2
(Vibration acceleration)
Absolute
Constant DC current at 350C A
value10
Max. constant AC current when the exhaust
20 A
temperature is 350C and f1Hz
Lead free fuel or the lead tolerance of upt to
Permitted fuel additive
0.15g/L
The tolerance and data must be confirmed
Oil consumption and combustion by the customer through appropriate tests.
Standard value: 0.7L/1000km
31
BYD AUTO BYD Suri Maintenance & Repair Manual
32
BYD AUTO BYD Suri Maintenance & Repair Manual
Trouble symptom: poor idling, poor (With the connector removed) Turn the digital
acceleration, tail gas exceeds standard, high multimeter to the Ohms range, and connect
fuel consumption, etc. two probes to Pins 1 (C) and 2 (D) of the
sensor respectively. Under normal
6.4.1 l trouble cause: 1. Moisture in the temperature, its resistance is 8~10. (With
sensor. The temperature changes the connector connected). Under the idling
suddenly, and the probe is broken; 2. condition, when the operating temperature of
The oxygen sensor is "poisoned". (Pb, the oxygen sensor reaches 350ºC, turn the
S, Br, Si) digital multimeter to the DC voltage range and
6.4.2 Precautions for repair: Never use the connect two probes to Pins 3 (A) and 4 (B) of
cleaner, oily liquid or volatile solid on the sensor. At this time the voltage should
the oxygen sensor during repair. fluctuate quickly between 0.1~0.9 V.
6.4.3 Simple measurement method:
33
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 3-27 Crankshaft Position Sensor Fig. 3-30 Connectors of Crankshaft Position
Sensor
Crankshaft Position Sensor Pin definition: Pin No. 1 connected to Pin No.
15 of ECU;
Pin No. 2 connected to Pin No. 34 of ECU.
Engine
7.1 Installation Position
ECM
On the transmission housing
Fig. 3-28 Circuit Diagram of Crankshaft The crankshaft position sensor works with the
Position Sensor pulse wheel to provide the engine speed
information and crankshaft top dead center
information in the distributorless ignition
system. The crankshaft position sensor
consists of a permanent magnet and a coil
around the magnet. The pulse wheel is
installed on the crankshaft and rotates with
the crankshaft. When the tooth tip passes by
the end of the crankshaft position sensor, the
pulse wheel made of ferromagnetic material
cuts the magnetic field lines of the
permanent magnet in the crankshaft position
sensor and generates the induced voltage in
the coil as the speed signal.
34
BYD AUTO BYD Suri Maintenance & Repair Manual
Value
Items Unit
Min. Typical Max.
Coil area -40 +150 C
Transition area Mixed Mixed C
Wire area -40 +120 C
Storage temperature -20 +50 C
Acceptable
Ambient temperature when not
temperature -40 +120 C
operated
for PUR wire
Long-term ambient
and -40 +120 C
crankshaft temperature when operated
position Short-term 150 hours +150 C
sensor (See ambient
the figure temperature 380 hours +140 C
below) when operated
150 hours +150 C
Entire service life 380 hours +140 C
of wire area 1,130
+130 C
hours
Coil area -40 +150 C
Transition area Mixed Mixed C
Acceptable Wire area -40 +130 C
temperature Storage temperature -20 +50 C
for H&S wire
Ambient temperature when not
and -40 +130 C
operated
crankshaft
Long-term ambient
position -40 +130 C
temperature when operated
sensor (See
Short-term ambient
the figure +150 C
temperature when operated
below)
Entire service life 500 hours +150 C
of wire area 200 hours +160 C
Vibration resistance of 20 to 71 Hz Acceleration40 m/s2
each plane in 168 hours 71 to 220 Hz Amplitude0.2 mm
Allowed magnetic intensity of external 2 kA/m
magnetic field in reversed direction
Insulation resistance (10 New Status 1 M
s, test voltage 100 V) End of usage 100 k
period
Withstand voltage (1 to 3 s, AC 1,200 V) Breakdown is not allowed
35
BYD AUTO BYD Suri Maintenance & Repair Manual
7.4 Precautions for installation 7.5.2 General trouble cause: Human failure.
7.5.3 Precautions for repair: It should be
7.4.1 The crankshaft position sensor must installed by pressing it in, instead of
be removed from the packaging just hammering during repair.
before it is to be installed on the 7.5.4 Simple measurement method:
vehicle or test equipment.
7.4.2 The crankshaft position sensor should (With the connector removed) Turn the digital
be installed by pressing it in, instead multimeter to the Ohms range, and connect
of hammering. two probes to Pins 1 and 2 of the sensor
7.4.3 The bolt M612 is recommended for respectively. The rated resistance at 20ºC
fixing the crankshaft position sensor. should be 860Ω±10%. (With the connector
7.4.4 The tightening torque is 82 Nm. connected) Turn the digital multimeter to the
7.4.5 The air gap between the crankshaft AC voltage range, and connect two probes to
position sensor and tooth tip of pulse Pins 1 and 2 of sensor respectively. There is
wheel is 0.8 to 1.2 mm. voltage output when the engine is started.
(Check with an on-board oscilloscope)
7.5 Trouble Symptoms and Judgment
Method
7.5.1 Trouble symptom: Unable to start.
36
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 3-33 Camshaft Position Sensor Fig. 3-34 Circuit Diagram of Camshaft
Position Sensor
8.1 Installation Position compressors top dead center and exhaust top
On the end cap of camshaft dead center of the crankshaft.
8.2 Operation Theory The sensor uses the Hall Theory in which
The sensor works with the inductive sensor of voltage is generated by the change of
the pulse wheel under the distributorless magnetic induction intensity.
condition and provides the crankshaft phase
information to the ECU to distinguish the
Fig. 3-37 Schematic Diagram for Operation of Camshaft Position Sensor (1)
37
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 3-38 Schematic Diagram for Operation of Camshaft Position Sensor (2)
Data Limit
Value
Items Unit
Min. Typical Max.
Ambient temperature -30 +130 C
Mounting clearance 0.5 1.5 mm
Supply voltage 4.5 24 V
8.4 Precautions for installation 8.5.2 General trouble cause: Human failure.
The sensor housing has only 1 hole for fixing. 8.5.3 Simple measurement method:
8.5 Trouble Symptoms and Judgment (With the connector connected) Turn on the
Method ignition switch, but do not start the engine.
Turn the digital multimeter to DC voltage
8.5.1 Trouble symptom: The emissions range, and connect two probes to Pins 1 and
exceed the standards and the fuel 3 of the sensor respectively. Make sure there
consumption increases. is a reference voltage of 5 V. When the engine
is started, check if the signal of Pin No. 2 is
normal with an oscilloscope.
38
BYD AUTO BYD Suri Maintenance & Repair Manual
9.2.1 Function
• Multipoint sequential injection
• Ignition control
• Idle control
• Knock control
• Provide power supply for sensors
• Closed loop control with self-adaption
• Charcoal canister control valve control
• Air conditioner switch
• Engine malfunction indicator
• Fuel quantity correction
• Engine speed signal output
• Vehicle speed signal input
• Trouble self-diagnosis
• Receive the engine load signal, etc.
39
BYD AUTO BYD Suri Maintenance & Repair Manual
ACC→ON
Ignition switch
16 Non-continuous power supply 10-14 V
ACC→ON
Approx.
17 CANL interface Always
2.5 V
18 Diagnosis K line Engine running
Ignition switch
20 Continuous power supply 10-14 V
ACC→ON
21 Rear oxygen sensor Engine running —
23 Braking switch
Medium voltage switch of air Ignition switch Less than
24
conditioner ACC→ON 1V
25 Braking light
28 Air conditioner switch Engine running —
29 Blower compensation Engine running —
30 Acceleration pedal sensor signal 2
31 High-speed radiator fan relay Engine running
32 Anti-theft input
34 Engine speed output Engine running —
Ignition switch
35 Ignition switch 10-14 V
ACC→ON
36 Accelerator pedal 2, 5 V power
37 Accelerator pedal 1, 5 V power
Less than
41 Oil pump relay Engine running
1V
Ignition switch Less than
43 Rear oxygen sensor ground
ACC→ON 1V
45 Acceleration pedal sensor signal 1
Ignition switch Less than
47 Analog signal sensor ground
ACC→ON 1V
48 Rear oxygen sensor heating Engine running —
Low-speed radiator fan and
56 Engine running —
condenser fan relay
58 Air conditioner control Engine running —
Ignition switch Less than
59 Accelerator pedal ground
ACC→ON 1V
Ignition switch Less than
63 Power Ground 2
ACC→ON 1V
Ignition switch Less than
64 Power Ground 1
ACC→ON 1V
ENGINE SIDE
65 Vehicle speed output
67 Injector of cylinder 2 Engine running —
68 Injector of cylinder 1 Engine running —
69 Variable valve lift valve
71 EGR valve
72 Injector of cylinder 3 Engine running —
73 Front oxygen sensor heating Engine running —
74 Injector of cylinder 4 Engine running —
Positive terminal of electronic
75
throttle valve actuator
76 Ignition coil of cylinder 4 Engine running —
77 Throttle position sensor 1
40
BYD AUTO BYD Suri Maintenance & Repair Manual
Value
Items Unit
Min. Typical Max.
Normal operation 9.0 16.0 V
16.0 to
Battery Voltage Limited function 6.0 to 9.0 V
18.0
41
BYD AUTO BYD Suri Maintenance & Repair Manual
9.4 Precautions for installation Remove and store the ECU before
welding; 4. Never connect any circuit to
9.4.1 Discharge the static electricity during the connecting wire of the ECU.
installation
9.5.4 Simple measurement method:
9.4.2 Protect the Pins of connector
a (With the connector connected) Read the
9.5 Trouble Symptoms and Judgment engine malfunction record with the
Method diagnostic tester;
9.5.1 Trouble symptoms: Poor idling, poor b (With the connector removed) Check if the
acceleration, unable to start, high idle ECU connecting wire is in good condition
speed, emissions exceed standards, and if the ECU power supply and ground
difficult to start, air conditioner failure, circuit are normal;
injector control failure, misfire, etc.
c Check if the external sensor operates
9.5.2 General trouble causes: 1. Trouble is normally, the output signal is reliable and
caused by the internal parts burnout in the the circuit is in good condition;
ECU due to electric overload of external
devices; 2. The circuit board is corroded d Check if the actuator operates normally
as water enters the ECU. and the circuit is in good condition;
9.5.3 Precautions for repair: 1. Do not remove e Finally, replace the ECU and perform test.
Perform self-learning after ECU is
the ECU randomly during repair; 2.
Remove the battery terminal for more than replaced (Wait for 1 min after the vehicle
1 minute before the ECU is removed; 3. is powered on).
42
BYD AUTO BYD Suri Maintenance & Repair Manual
30 86
Fuel Pump
燃油泵 Relay
继电器
87 85
Fuel Pump M
电动燃油泵 69
ECU
接地
Fig. 3-40 Power Fuel Pump Fig. 3-41 Circuit Diagram of Power Fuel
Pump
Pin definition:
Pin No. 1 connected to ground;
Pin No. 2 connected to combination instrument;
Pin No. 3 connected to combination instrument;
Pin No. 4 connected to fuel pump relay.
10.1 Installation Position The pump and motor are installed coaxially in
a closed housing. The gasoline is fully filled
In the fuel tank around the pump and motor in the housing
which are cooled and lubricated by fuel. The
10.2 Operation Theory battery supplies power to the oil pump relay
and the relay will energize the power fuel
The power fuel pump consists of a DC motor, pump only when the engine is started and
vane pump and end cap (Integrated with running. When the engine is stopped due to
return valve, relief valve and components an accident, the fuel pump will stop operating
resistant to electromagnetic interference) as automatically.
shown in figure 3-43.
43
BYD AUTO BYD Suri Maintenance & Repair Manual
The maximum pressure at the outlet of the power fuel pump is determined by the relief valve
which is between 450 and 650 kPa. The overall pressure of the fuel system is determined by the
fuel pressure regulator which is usually 350 kPa.
The power fuel pump has different flow rates depending on the requirements of the engine, so do
not use the power fuel pump from other models.
44
BYD AUTO BYD Suri Maintenance & Repair Manual
installed in the vehicle, and the maximum 10.5 Trouble Symptoms and Judgment
storage time is 4 years if it is used as a spare Method
part. The performance data of the fuel pump
should be rechecked by the manufacturer 10.5.1 Trouble symptoms: Loud operating
when the above time is exceeded. The fuel noise, poor acceleration, unable to
pump should be protected from the start (difficult to start), etc.
atmospheric effects when stored. The original 10.5.2 General trouble cause: Due to the use
packaging should not be damaged during of poor-quality fuel: 1. the insulation
storage. layer is formed by colloid
accumulation; 2. the fuel pump axle
Install a fuel inlet screen with mesh with the bushing and armature lock; 3. the
size of 60 or less or determined with the components of fuel level sensor are
customers when the fuel pump is installed. Do corroded.
not allow the fuel from the vent hole to spray 10.5.3 Precautions for repair:
on the fuel inlet screen, fuel pump bracket and
fuel tank wall. Be careful to transport the fuel 10.5.3.1 The power fuel pump has
pump. Protect the fuel inlet screen from any different flow rates depending on the
load or impact. The fuel pump must be requirements of engine. The fuel
carefully removed from the plastic packaging pump which has the same profile and
during installation. The protective cover can can be installed may be incorrect. The
be removed only when the fuel pump is to be part No. of the fuel pump used must
installed. Never remove the fuel inlet screen. be the same as the original during
The fuel pump may be damaged if foreign repair. Do not mix use of them;
objects enter the fuel pump inlet or screen.
10.5.3.2 To prevent the unexpected
Keep clean when the fuel pipes are installed. damage to the fuel pump, do not
The interior of fuel pipes should be clean. operate it in dry state for a long time;
Only use new fuel pipe clamps. Confirm the
correct position of fuel pipe clamps and 10.5.3.3 When the fuel pump needs to be
observe the methods recommended by the replaced, clean the fuel tank and pipe
manufacturer. lines and replace the fuel filter.
Do not hold the fuel pump by the fuel pipe or 10.5.4 Simple measurement method:
fuel inlet screen.
(With the connector removed) Turn the digital
To prevent damage to the fuel pump, do not multimeter to the Ohms range, and connect
operate the fuel pump under the dry state. Do two probes to Pins 1 and 4 of the fuel pump
not use a damaged fuel pump or a fuel pump respectively. The resistance between the two
dropped on the ground. Replace the fuel Pins is about 1 Ω.
pump in the fuel tank if it is dropped on the
ground. (With the connector connected) Connect the
fuel pressure gauge to the oil inlet pipe, start
If the fuel pump is returned, please send back the engine and observe if the fuel pump
the supply list, check list and package label operates; If it does not operate, check if there
with it. The returned fuel pump must be is power voltage at Pin No. 4 and if Pin No. 1
packed as specified. If the fuel pump has is grounded. If it operates, check if the fuel
been used, wash it with test solution and dry it pressure is about 350 kPa during idling.
in the air instead of blowing it dry. Depress the accelerator pedal until the engine
speed reaches 2,500 rpm, and check if the
fuel pressure is about 350 kPa.
45
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 11 Injector
Diagram and Pin
To Main Relay
Injector
Injector
Injector
Injector
Fig. 3-44 Injector Fig. 3-45 Circuit Diagram of Injector
Pin definition: The model uses 4 injectors and each injector has 2 Pins. Pin No. 1 of each injector
is connected to the main relay and Pin No. 2 is connected to the ECU.
1. O-ring 2. Screen 3. Injector Body with Electric Connector 4. Coil 5. Spring 6. Valve Needle with Coil
Armature 7. Valve Seat with Nozzle Plate
On the intake manifold close to the intake The ECU sends the electric pulse to the
valve injector coil to form a magnetic field force.
When the magnetic field force is higher than
46
BYD AUTO BYD Suri Maintenance & Repair Manual
Value
Items Unit
Min. Typical Max.
Storage temperature (original packaging) -40 +70 C
Permitted temperature of injectors in the
vehicle +140 C
(When not operated)
Operating Continuous -40 +110 C
temperature of Short time after hot
injectors
+130 C
start (about 3 minutes)
Permitted Continuous +70 C
temperature of fuel Short time (about 3
at the injector inlet +100 C
minutes)
Temperature where the deviation of fuel flow
-40 +45 C
rate from that at 20C reaches 5%
Leakage permission for O-ring within -35 to Fuel wetness is permitted in the O-ring area,
-40C but dripping is not permitted
Permitted maximum vibration acceleration
400 m/s2
(Peak value)
Power supply voltage 6 16 V
Insulation resistance 1 M
Acceptable internal fuel pressure 1100 kPa
Acceptable bending stress 6 Nm
Acceptable axial stress 600 N
47
BYD AUTO BYD Suri Maintenance & Repair Manual
gasoline on the upper O-ring connected to the 11.4.5 The support washer of the O-ring
fuel distribution pipe. Do not allow the oil to should not be pulled out from the
contact the injector interior and nozzle. injector. Avoid damage to the inlet,
O-ring, support ring, nozzle plate and
11.4.2 Install the injector to the injector seat in electric connector of injector during
a direction perpendicular to the injector seat, installation. Do not use them if
and then fix the injector on the injector seat damaged.
with clips. Notes: 11.4.6 Perform a test on the tightness of the
fuel distribution pipe assembly after
11.4.2.1 The injector clips can be divided the injector is installed. It is acceptable
into an axial retaining clip and a radial when there is no leakage.
retaining clip according to the fixing 11.4.7 Remove the fault part by hand. First
method. Avoid mixing the use of them. remove the clips of the injector, and
then pull out the injector from the
11.4.2.2 For installation of axially fixed
injector seat.
injectors, make sure the center
Keep the injector clean after removal.
bayonet of the clip is fully clamped in
the injector slot, and the slots on both
sides of the clip are fully clamped on 11.5 Trouble Symptoms and Judgment
the outer edge hemming of the injector Method
seat.
11.5.1 Trouble symptoms: Poor idling, poor
11.4.2.3 When the injector must be fixed
acceleration, unable to start (difficult to
in axial and radial directions, the axial
start), etc.
and radial retaining clips should be
11.5.2 General trouble cause: The injector
used, and you must position the
fails to function due to the colloid
located block of the injector and dowel
accumulation in the injector caused by
pin of the injector seat in the proper
lack of maintenance.
slots on the retaining clip.
11.5.3 Precautions for repair: (Refer to
11.4.2.4 If the injector has two slots, be Precautions for installation)
careful not to confuse them. Refer to 11.5.4 Simple measurement method:
the installation position of the original
part. (With the connector removed) Turn the digital
multimeter to the Ohms range, and connect
11.4.3 The injector should be installed by two probes to Pins 1 and 2 of injector
hand. Never tap the injector with tools respectively. The rated resistance between
such as a hammer. the two Pins at 20ºC is 11~13 Ω.
11.4.4 The O-ring must be replaced when the
injector is removed and reinstalled. Do Advice: Thoroughly clean the injectors with a
not damage the sealing surface of the special washing analyzer for every 20,000 km.
injector.
48
BYD AUTO BYD Suri Maintenance & Repair Manual
Pin definition:
Pin No. 1 connected to main relay;
Pin No. 2 connected to ground;
Pin No. 3 connected to ECU;
F:Ignition Coil
49
BYD AUTO BYD Suri Maintenance & Repair Manual
Performance Data
50
BYD AUTO BYD Suri Maintenance & Repair Manual
51
BYD AUTO BYD Suri Maintenance & Repair Manual
The charcoal canister control valve consists of the solenoid coil, armature and valve. A screen is
set at the inlet. On one hand, the air flow of the charcoal canister control valve is related to the
duty cycle of the electric pulse output to the charcoal canister control valve by the ECU. On the
other hand, it is also related to the pressure difference between the inlet and outlet of the
charcoal canister control valve. When there is no electric pulse, the charcoal canister control
valve will close.
The flow rates of different charcoal canister control valves are different when the duty cycle is
100% (i.e. under fully opened condition). Figure 3-61 shows two typical flow curves. Under the
pressure difference of 200 mbar, the flow rate of type A charcoal canister control valve is 3.0m3/h
when fully opened and the flow rate of type B is 2.0m3/h when fully opened as shown in the figure.
(The project is type B)
52
BYD AUTO BYD Suri Maintenance & Repair Manual
Type A
Type B
Flow
Pressure Difference
Value
Items Unit
Min. Typical Max.
Working voltage 9 16 V
Overvoltage in 1 min 22 V
Min. starting voltage 7 V
Min. voltage drop 1.0 V
Allowed operation temperature -30 +120 C
Short-time allowed operating temperature +130 C
Allowed storage temperature -40 +130 C
Acceptable pressure difference between inlet
800 mbar
and outlet
8
Allowed switching cycles 10
Allowed vibration acceleration on the product 300 m/s2
Leakage rate when the pressure difference is
0.002 m3/h
400 mbar
Value
Items Unit
Min. Typical Max.
Rated voltage 13.5 V
Resistance at +20C 26
Current under rated voltage 0.5 A
Frequency of control pulse 30 Hz
Type A 7 ms
Typical control pulse width
Type B 6 ms
Flow rate when the pressure Type A 2.7 3.0 3.3 m3/h
difference is 200 mbar and the
Type B 1.7 2.0 2.3 m3/h
duty cycle is 100%
53
BYD AUTO BYD Suri Maintenance & Repair Manual
Refer to figure 3-60 for the connection of 13.5.2 General trouble cause: Corrosion or
charcoal canister control valve, charcoal poor tightness is caused as foreign
canister and intake manifold. materials enter the valve.
13.4.1 To avoid the transmission of 13.5.3 Precautions for repair: 1. The direction
solid-borne noise, it is recommended to of air flow must meet the requirements
hang the charcoal canister control valve during installation; 2. When the control
on the hose. valve is fault due to black particles in the
valve body and it needs to be replaced,
13.4.2 The direction of air flow must meet the please check the charcoal canister; 3.
requirements during installation. Prevent water or oil from entering the
valve during repair; 4. To avoid the
13.4.3 Proper measurements must be taken transmission of solid-borne noise, it is
(such as filtering and purging) to prevent recommended to hang the charcoal
foreign materials (such as particles) from canister control valve on the hose.
entering the charcoal canister control valve
from the charcoal canister or hose. 13.5.4 Simple measurement method:
13.4.4 It is recommended to install a proper (With the connector removed) Turn the digital
protective filter at the outlet of the charcoal multimeter to the Ohms range, and connect
canister (Mesh size50 m). two probes to two Pins of the charcoal
canister control valve respectively. The rated
13.5 Trouble Symptoms and Judgment resistance at 20ºC should be 22~30 Ω.
Method
54
BYD AUTO BYD Suri Maintenance & Repair Manual
Data Limit
Value
Items Unit
Min. Typical Max.
Operation temperature when the fuel distribution
-40 +120 C
pipe and O-ring are correctly connected
Max. operation temperature in 15 minutes under
+130 C
soaking status
Allowed maximum vibration acceleration (Peak
300 m/s2
value)
55
BYD AUTO BYD Suri Maintenance & Repair Manual
56
BYD AUTO BYD Suri Maintenance & Repair Manual
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Check if the "Intake Pressure" in the data flow is about Yes Go to step 5
2 1,000 hpa (The specific value is related to the
atmospheric pressure). No Next step
Remove the connector of the intake pressure sensor Yes Go to step 5
from the wire harness, and check, using the
3
multimeter, if the voltage between Pins No. 3 and 1 of No Next step
the connector is about 5 V.
Repair or
Check if the circuits between Pins No. 17, 33 and 37 Yes replace wire
4 of the ECU and Pins No. 1, 3 and 4 of the sensor harness
connector are short to ground.
No Next step
Start the engine and keep it idling. When the
accelerator pedal is slowly depressed to the fully Yes Diagnostic tips
opened position, observe the change of "Intake
Pressure" value on the diagnostic tester. The
5
displayed value does not change greatly. When the
accelerator pedal is quickly depressed to fully opened Replace the
No
position, the displayed value should reach more than sensor
900 hpa immediately.
57
BYD AUTO BYD Suri Maintenance & Repair Manual
58
BYD AUTO BYD Suri Maintenance & Repair Manual
59
BYD AUTO BYD Suri Maintenance & Repair Manual
60
BYD AUTO BYD Suri Maintenance & Repair Manual
(Note: The following diagnosis flow is suitable for DTCs without P0135. If DTC P0135 occurs at
the same time, first repair the malfunction indicated by it and then perform maintenance
according to the following flow.)
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Start the engine and keep it idling until the coolant
temperature reaches the normal value. Observe the Yes Diagnostic tips
2 change of "Oxygen sensor voltage" value on the
diagnostic tester. The displayed value should change No Next step
quickly between 100 mV~900 mV.
Repair or
Check if the circuits between Pins No. 36 and 18 of Yes replace wire
3 the ECU and Pins No. 3 and 4 of the sensor connector harness
are short to ground.
No Next step
Perform
A. Check the intake system for severe air leakage; maintenance
Yes
B. Check the injector for blockage; according to
4 C. Check the sparkplug for excessive clearance; the diagnosis
D. Check the inlet valve guide for wear;
Others No Diagnostic tips
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Start the engine and keep it idling until the coolant
temperature reaches the normal value. Observe the Yes Diagnostic tips
2 change of "Oxygen sensor voltage" value on the
diagnostic tester. The displayed value should change No Next step
quickly between 100 mV~900 mV.
Repair or
Check if the circuits between Pins No. 36 and 18 of Yes replace wire
3 the ECU and Pins No. 3 and 4 of the sensor connector harness
are short to power supply.
No Diagnostic tips
61
BYD AUTO BYD Suri Maintenance & Repair Manual
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Start the engine and keep it idling until the coolant Yes Diagnostic tips
temperature reaches the normal value. Observe the
2
change of "Oxygen sensor voltage" value on the
diagnostic tester. The displayed value should change No Next step
quickly between 100 mV~900 mV.
Repair or
Check if the circuits between Pins No. 36 and 18 of Yes replace wire
3 the ECU and Pins No. 3 and 4 of the sensor connector harness
are open.
No Diagnostic tips
Check, using the multimeter, if the resistance between Yes Next step
3 Pins No. 1 and 2 of the oxygen sensor at 20ºC is Replace the
No
between 8 and 10 Ω. sensor
Check if the circuits between Pin No. 48 of the ECU Repair or
and Pin No. 2 of the sensor connector, Pin No. Yes replace wire
4 B02-B18 of main relay and Pin No. 1 of the sensor harness
connector are open or short to power supply or
No Diagnostic tips
ground.
DTC: P0171 "Adaptive close-loop control of air-fuel ratio exceeds upper limit"
(Note: The following diagnosis flow is suitable for the condition when DTCs of the intake pressure
sensor, charcoal canister control valve and oxygen sensor do not occur at the same time. If they
occur at the same time, first repair the malfunctions indicated by them and then perform
maintenance according to the following flow.)
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Start the engine and keep it idling until the coolant
temperature reaches the normal value. Yes Next step
Observe the change of "Oxygen sensor voltage" value
2
on the diagnostic tester under all working conditions.
Check if the displayed value changes around 100 mV No Diagnostic tips
for a long time under some working conditions.
3 Connect the fuel pressure gauge to the oil inlet pipe of Yes Next step
62
BYD AUTO BYD Suri Maintenance & Repair Manual
the fuel system and check if the fuel pressure is about Overhaul the
No
350 kPa under all working conditions. fuel system
Repair or
Check if the circuits between Pins No. 36 and 18 of Yes replace wire
4 the ECU and Pins No. 3 and 4 of the sensor connector harness
are short to power supply.
No Next step
Perform
A. Check the intake system for severe air leakage; maintenance
Yes
B. Check the injector for blockage; according to
5 C. Check the sparkplug for excessive clearance; the diagnosis
D. Check the inlet valve guide for wear;
Others No Diagnostic tips
DTC: P0172 "Adaptive close-loop control of air-fuel ratio exceeds lower limit"
(Note: The following diagnosis flow is suitable for the condition when DTCs of the intake pressure
sensor, charcoal canister control valve and oxygen sensor do not occur at the same time. If they
occur at the same time, first repair the malfunctions indicated by them and then perform
maintenance according to the following flow.)
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Start the engine and keep it idling until the coolant
temperature reaches the normal value. Yes Next step
Observe the change of "Oxygen sensor voltage" value
2
on the diagnostic tester under all working conditions.
Check if the displayed value changes around 900 mV No Diagnostic tips
for a long time under some working conditions.
Connect the fuel pressure gauge to the oil inlet pipe of Yes Next step
3 the fuel system and check if the fuel pressure is about Overhaul the
350 kPa under all working conditions. No
fuel system
Repair or
Check if the circuits between Pins No. 36 and 18 of Yes replace wire
4 the ECU and Pins No. 3 and 4 of sensor connector harness
are short to power supply.
No Next step
Perform
maintenance
A. Check the injector for dripping; Yes
according to
B. Check the exhaust pipe for air leakage; the diagnosis
5
C. Check if the ignition timing is correct;
Others
No Diagnostic tips
Test
No. Operation Steps Follow-up Step
Result
63
BYD AUTO BYD Suri Maintenance & Repair Manual
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "ON". Next step
Remove the connector of cylinder 2 injector from the Yes Go to step 4
wire harness, and check, using the multimeter, if the
2
voltage between Pin No. 1 of the connector and the No Next step
negative terminal of power supply is about 12 V.
Repair or
Check if the circuit between Pin No. 1 of the cylinder 2 Yes replace wire
3 injector connector and the main relay is open or short harness
to ground.
No Go to step 2
Check, using the multimeter, if the resistance between Yes Next step
4 Pins No. 1 and 2 of the cylinder 2 injector at 20ºC is Replace the
No
between 11 and 13 Ω. injector
Check, using the multimeter, if the voltage between Yes Diagnostic tips
5 Pin No. 2 of the cylinder 2 injector connector and the
negative terminal of power supply is about 3.7 V. No Next step
Repair or
Check if the circuit between Pin No. 2 of the cylinder 2 Yes replace wire
6 injector connector and Pin No. 6 of the ECU is open or harness
short to power supply or ground.
No Diagnostic tips
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "ON". Next step
2 Remove the connector of cylinder 3 injector from the Yes Go to step 4
64
BYD AUTO BYD Suri Maintenance & Repair Manual
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "ON". Next step
Remove the connector of cylinder 4 injector from the Yes Go to step 4
wire harness, and check, using the multimeter, if the
2
voltage between Pin No. 1 of the connector and the No Next step
negative terminal of the power supply is about 12 V.
Repair or
Check if the circuit between Pin No. 1 of the cylinder 4 Yes replace wire
3 injector connector and main relay is open or short to harness
ground.
No Go to step 2
Check, using the multimeter, if the resistance between Yes Next step
4 Pins No. 1 and 2 of the cylinder 4 injector at 20ºC is Replace the
No
between 11 and 13 Ω. injector
Check, using the multimeter, if the voltage between Yes Diagnostic tips
5 pin No. 2 of the cylinder 4 injector connector and
negative terminal of power supply is about 3.7 V. No Next step
Repair or
Check if the circuit between Pin No. 2 of the cylinder 4 Yes replace wire
6 injector connector and pin No. 47 of the ECU is open harness
or short to power supply or ground.
No Diagnostic tips
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "OFF". Next step
Remove the fuel pump relay, position the ignition
2 Yes Go to step 4
switch to "ON" and check if the voltage between the
65
BYD AUTO BYD Suri Maintenance & Repair Manual
Repair or
Check if the circuit of the relay power supply terminal Yes replace wire
3 harness
is open or short to ground.
No Go to step 2
Replace the
Check, using the multimeter, if the voltage between Yes fuel pump
4 the control terminal of the fuel pump relay and relay
negative terminal of the power supply is about 3.7 V.
No Next step
Repair or
Check if the circuit between the relay control terminal
Yes replace wire
5 and Pin No. 69 of the ECU is open or short to power
harness
supply or ground.
No Diagnostic tips
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "OFF". Next step
Remove the connector of the knock sensor from the Yes Next step
wire harness, and check, using the multimeter, if the
2 Replace the
resistance between Pins No. 1 and 2 of the knock No
sensor
sensor is higher than 1 MΩ.
Repair or
Check if the circuits between Pins No. 1 and 2 of the Yes replace wire
3 knock sensor connector and Pins No. 19 and 20 of the harness
ECU are open or short to power supply or ground.
No Next step
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "OFF". Next step
Remove the connector of the crankshaft position
sensor from the wire harness, and check, using the Yes Next step
2 multimeter, if the resistance between Pins No. 1 and 2
of the crankshaft position sensor is between 770 and Replace the
No
950 Ω. sensor
Check if the circuits between Pins No. 1 and 2 of the Repair or
crankshaft position sensor connector and Pins No. 15 Yes replace wire
3 harness
and 34 of the ECU are open or short to power supply
or ground. No Next step
Yes Diagnostic tips
4 Check if the flywheel signal disc is in good condition. Replace the
No
signal disc
66
BYD AUTO BYD Suri Maintenance & Repair Manual
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "OFF". Next step
Remove the connector of the crankshaft position
sensor from the wire harness, and check, using the Yes Next step
2 multimeter, if the resistance between Pins No. 1 and 2
of the crankshaft position sensor is between 770 and Replace the
No
950 Ω. sensor
Check if the circuits between Pins No. 1 and 2 of the Repair or
crankshaft position sensor connector and Pins No. 15 Yes replace wire
3 harness
and 34 of ECU are open or short to power supply or
ground. No Next step
Yes Diagnostic tips
4 Check if the flywheel signal disc is in good condition. Replace the
No
signal disc
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Remove the connector of the camshaft position
sensor from the wire harness, and check, using the Yes Go to step 4
2 multimeter, if the voltage between pin No. 1 of the
camshaft position sensor connector and the negative No Next step
terminal of the power supply is about 5 V.
Repair or
Check if the circuit between pin No. 1 of the camshaft Yes replace wire
3 position sensor and pin No. 32 of ECU is open or harness
short to ground.
No Next step
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Remove the connector of the camshaft position
2 Yes Go to step 4
sensor from the wire harness, and check if the voltage
67
BYD AUTO BYD Suri Maintenance & Repair Manual
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Remove the connector of the camshaft position
sensor from the wire harness, and check, using the Yes Go to step 4
2 multimeter, if the voltage between pin No. 1 of the
camshaft position sensor connector and the negative No Next step
terminal of power supply is about 5 V.
Repair or
Check if the circuit between pin No. 1 of the camshaft Yes replace wire
3 position sensor and pin No. 32 of the ECU is open or harness
short to ground.
No Next step
DTC: P0443 "Charcoal canister control valve drive control circuit failure"
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch the "ON".
Remove the connector of the charcoal canister control Yes Go to step 4
valve from the wire harness, and check, using the
2 multimeter, if the voltage between pin No. 1 of the
connector and the negative terminal of the power No Next step
supply is about 12 V.
68
BYD AUTO BYD Suri Maintenance & Repair Manual
Repair or
Check if the circuit between pin No. 1 of charcoal Yes replace wire
3 canister control valve and main relay is open or short harness
to ground.
No Go to step 2
Check, using the multimeter, if the resistance between Yes Next step
4 Pins No. 1 and 2 of the charcoal canister control valve Replace the
at 20ºC is between 22 and 30 Ω. No
control valve
Repair or
Check if the circuit between pin No. 2 of the charcoal Yes replace wire
5 canister control valve and pin No. 46 of the ECU is harness
open.
No Diagnostic tips
DTC: P0444 "Charcoal canister control valve drive control circuit voltage is low"
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Remove the connector of the charcoal canister control Yes Go to step 4
valve from the wire harness, and check, using the
2 multimeter, if the voltage between pin No. 1 of the
connector and the negative terminal of the power No Next step
supply is about 12 V.
Repair or
Check if the circuit between pin No. 1 of the charcoal Yes replace wire
3 canister control valve and the main relay is open or harness
short to ground.
No Go to step 2
Check, using the multimeter, if the resistance between Yes Next step
4 Pins No. 1 and 2 of the charcoal canister control valve Replace the
at 20ºC is between 22 and 30 Ω. No
control valve
Repair or
Check if the circuit between pin No. 2 of the charcoal Yes replace wire
5 canister control valve and pin No. 46 of the ECU is harness
short to ground.
No Diagnostic tips
DTC: P0445 "Charcoal canister control valve drive control circuit voltage is high"
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Remove the connector of the charcoal canister control Yes Go to step 4
valve from the wire harness, and check, using the
2 multimeter, if the voltage between pin No. 1 of the
connector and the negative terminal of the power No Next step
supply is about 12 V.
Repair or
Check if the circuit between pin No. 1 of the charcoal Yes replace wire
3 canister control valve and the main relay is open or harness
short to ground.
No Go to step 2
4 Check, using the multimeter, if the resistance between Yes Next step
69
BYD AUTO BYD Suri Maintenance & Repair Manual
pin No. 1 and 2 of the charcoal canister control valve Replace the
No
at 20ºC is between 22 and 30 Ω. control valve
Repair or
Check if the circuit between pin No. 2 of the charcoal Yes replace wire
6 canister control valve and pin No. 46 of the ECU is harness
short to power supply.
No Diagnostic tips
DTC: P0480 "Air conditioner condenser cooling fan relay control circuit failure"
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "OFF". Next step
Remove the air conditioner condenser cooling fan
relay, position the ignition switch to "ON" and check if Yes Go to step 4
2 the voltage between the power supply terminals of the
relay and negative terminal of the power supply is No Next step
about 12 V.
Repair or
Check if the power supply terminal circuit of the air Yes replace wire
3 conditioner cooling fan relay is open or short to harness
ground.
No Go to step 2
Check, using the multimeter, if the voltage between Replace the
Yes
the control terminal of the air conditioner cooling fan relay
4
relay and the negative terminal of the power supply is
about 3.7 V. No Next step
Repair or
Check if the circuit between the relay control terminal Yes replace wire
5 B02-B65 and pin No. 50 of the ECU is open or short to harness
power supply or ground.
No Diagnostic tips
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "OFF". Next step
Yes Next step
Perform
Check if the electronic throttle valve operates necessary
2
normally. No overhauling
and
maintenance
Perform
A. Check if the pressure of the fuel supply system is Yes necessary
low; overhauling
3
B. Check the injector for blockage;
C. Check if the system exhaust is not smooth. No Diagnostic tips
Test
No. Operation Steps Follow-up Step
Result
70
BYD AUTO BYD Suri Maintenance & Repair Manual
DTC: P0508 "Electronic throttle body assembly control circuit voltage is low"
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Remove the connector of the electronic throttle body Yes Next step
assembly, and check, using the multimeter, if the
2 Repair or
resistance between Pins 3 and 5 of the electronic
throttle body assembly is about 10 Ω. No replace wire
harness
Repair or
Check if Pins 3 and 5 of the electronic throttle body Yes replace wire
3 harness
assembly connector are short to ground.
No Diagnostic tips
DTC: P0509 "Electronic throttle body assembly control circuit voltage is high"
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Remove the connector of the electronic throttle body Yes Next step
assembly, and check, using the multimeter, if the
2 Repair or
resistance between Pins 3 and 5 of the electronic
throttle body assembly is about 10 Ω. No replace wire
harness
Repair or
Check if Pins 3 and 5 of electronic throttle body Yes replace wire
3 harness
assembly connector are short to ground.
No Diagnostic tips
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
71
BYD AUTO BYD Suri Maintenance & Repair Manual
Remove the connector of the electronic throttle body Yes Next step
assembly, and check, using the multimeter, if the
2 Repair or
resistance between Pins 3 and 5 of the electronic
throttle body assembly is about 10 Ω. No replace wire
harness
Repair or
Check if Pins 3 and 5 of the electronic throttle body Yes replace wire
3 harness
assembly connector are short to ground.
No Diagnostic tips
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "OFF". Next step
Yes Next step
Check, using the multimeter, if the battery voltage is
2 Replace the
about 12 V. No
battery
Repair or
Check if the circuits between Pins No. 44, 45 and 63 Yes replace wire
3 of ECU and pin B02-B18 of main relay are open or harness
short to ground.
No Next step
Start the engine and check if the charging voltage of Yes Next step
4 the generator is between 9 and 16 V within different Replace the
speed range. No
generator
Yes Diagnostic tips
Check if the ground point of the engine wire harness is Repair or
5
in good condition. No replace wire
harness
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch to "OFF". Next step
Yes Next step
Check, using the multimeter, if the battery voltage is
2 Replace the
about 12 V. No
battery
Repair or
Check the circuits between Pins No. 44, 45 and 63 of Yes replace wire
3 the ECU and pin B02-B18 of the main relay for high harness
resistance.
No Next step
Start the engine and check if the charging voltage of Yes Next step
4 the generator is between 9 and 16 V within different Replace the
speed ranges. No
generator
Yes Diagnostic tips
Check if the ground point of the engine wire harness is Repair or
5
in good condition. No replace wire
harness
72
BYD AUTO BYD Suri Maintenance & Repair Manual
Test
No. Operation Steps Follow-up Step
Result
1 Position the ignition switch in "OFF". Next step
Yes Next step
Check, using the multimeter, if the battery voltage is
2 Replace the
about 12 V. No
battery
Start the engine and check if the charging voltage of Yes Next step
3 generator is between 9 and 16 V within different Replace the
speed ranges. No
generator
Yes Diagnostic tips
Check if the ground point of the engine wire harness is Repair or
4
in good condition. No replace wire
harness
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Clear the DTC and reconfirm if the malfunction is a Yes Next step
2
steady state malfunction. No Normal system
3 Replace the ECU. Completed
Test
No. Operation Steps Follow-up Step
Result
Connect the diagnostic tester and adapter, and then
1 Next step
position the ignition switch to "ON".
Clear the DTC and reconfirm if the malfunction is a Yes Next step
2
steady state malfunction. No Normal system
3 Replace the ECU. Completed
73
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 1 The engine does not rotate or rotates slowly when starting
General trouble area: 1. Battery; 2. Cranking motor; 3. Wire harness or ignition switch; 4. Engine
mechanics.
74
BYD AUTO BYD Suri Maintenance & Repair Manual
Keep the ignition switch in "Start" position, and Yes Next step
check if the voltage at the positive terminal of Repair or
2
cranking motor is more than 8 V with the No replace wire
multimeter. harness
Repair or
Remove the cranking motor and check its operation Yes replace the
3 condition. Check if the open circuit exists or it is cranking motor
stuck due to poor lubrication.
No Next step
If the trouble only occurs in winter, check if the Use the proper
resistance of cranking motor is too high due to Yes
4 lubricant
improper selection of engine lubricant and gearbox
oil. No Next step
Overhaul the
Check if the cranking motor does not rotate or Yes internal engine
5 rotates slowly due to the high internal mechanical resistance
resistance of the engine.
No Diagnostic tips
Connect the fuel pressure gauge (to front of fuel Yes Next step
distribution pipe assembly oil inlet pipe), start the
1 Overhaul the
engine and check if the fuel pressure is about 350
kPa. No fuel supply
system
Yes Next step
Connect the diagnostic tester for electronically
controlled injection system and observe the "Engine Overhaul the
2 circuit of
Speed" value. Start the engine and check if the No
speed signal outputs. crankshaft
position sensor
Remove the ignition coil of one cylinder, connect
the sparkplug and position the plug electrode about Yes Next step
3 5 mm from the engine block. Start the engine and
check if there is blue and white high-pressure Overhaul the
No
spark. ignition system
Repair the
mechanical
Check each cylinder of the engine for insufficient Yes
4 malfunction of
pressure. engine
No Next step
75
BYD AUTO BYD Suri Maintenance & Repair Manual
Connect the fuel pressure gauge (to front of fuel Yes Next step
distribution pipe assembly oil inlet pipe), start the
1 Overhaul the
engine and check if the fuel pressure is about
350 kPa. No fuel supply
system
Remove the ignition coil of one cylinder, connect
the sparkplug and position the plug electrode Yes Next step
2 about 5 mm from the engine block. Start the
engine and check if there is blue and white Overhaul the
No
high-pressure spark. ignition system
Remove the connector of coolant temperature Overhaul the
sensor, start the engine and check if the engine circuit or
Yes
can be started successfully. (Or connect a replace the
3 resistor of 300 ohms to the connector of coolant sensor
temperature sensor to replace the coolant
temperature sensor, and check if the engine can No Next step
be started successfully.)
Overhaul or
Yes
4 Check the power fuel pump for any damage. replace
No Next step
Replace the
Check the fuel condition to see if the trouble is Yes
5 fuel
caused immediately after the fuel is filled.
No Next step
Connect the fuel pressure gauge (to front of fuel Yes Next step
distribution pipe assembly oil inlet pipe), start the
1 Overhaul the
engine and check if the fuel pressure is about 350
kPa. No fuel supply
system
76
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 5 Engine is difficult to start at any time, but the engine speed is
normal
General trouble area: 1. Fuel with water; 2. Fuel pump; 3. Coolant temperature sensor; 4. Injector;
5. Ignition coil; 6. Electronic throttle body assembly; 7. Inlet passage; 8. Ignition timing; 9.
Sparkplug; 10. Engine mechanics
77
BYD AUTO BYD Suri Maintenance & Repair Manual
Remove the ignition coil of one cylinder, connect Yes Next step
the sparkplug and position the plug electrode about
3 5 mm from the engine block. Start the engine and Overhaul the
check if there is blue and white high-pressure No
ignition system
spark.
Yes Next step
Check if the type and gap of sparkplug in each
4 Adjust or
cylinder are as specified. No
replace
Overhaul the
Remove the connector of coolant temperature circuit or
Yes
5 sensor, start the engine and check if the engine can replace the
be started successfully. sensor
No Next step
Clean the
Lightly depress the accelerator pedal to see if the Yes
6 throttle valve
engine can be started easily.
No Next step
Remove the injector, and check the injector for any Replace the
Yes
7 leakage or blockage with the special washing faulty injector
analyzer. No Next step
Replace the
Check the fuel condition to see if the trouble is Yes
8 fuel
caused immediately after the fuel is filled.
No Next step
Repair the
mechanical
Check each cylinder of the engine for insufficient Yes
9 malfunction of
pressure.
engine
No Next step
Yes Next step
Check if the ignition sequence and ignition timing of
10 Overhaul the
engine are as specified. No
ignition timing
Section 6 Engine can be started normally, but idle speed unstable at any
time
General trouble area: 1. Fuel with water; 2. Fuel pump; 3. Sparkplug; 4. Electronic throttle body
assembly; 5. Inlet passage; 6. Ignition timing; 7. Engine mechanics.
78
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 7 Engine can be started normally, but idle speed unstable during
warming up
General trouble area: 1. Fuel with water; 2. Coolant temperature sensor; 3. Sparkplug; 4.
Electronic throttle body assembly; 5. Inlet passage; 6. Engine mechanics.
79
BYD AUTO BYD Suri Maintenance & Repair Manual
Replace the
Check the fuel condition to see if the trouble is Yes
6 fuel
caused immediately after the fuel is filled.
No Next step
Repair the
mechanical
Check if large pressure difference exists among Yes
7 malfunction of
each cylinder of the engine.
engine
No Next step
Section 8 Engine can be started normally, but idle speed unstable after
warming up
General trouble area: 1. Fuel with water; 2. Coolant temperature sensor; 3. Sparkplug; 4.
Electronic throttle body assembly; 5. Inlet passage; 8. Engine mechanics.
80
BYD AUTO BYD Suri Maintenance & Repair Manual
Overhaul
No
related circuits
Section 10 Engine speed does not increase or the engine misfires during
acceleration
General trouble area: 1. Fuel with water; 2. Intake pressure sensor and electronic throttle body
assembly; 3. Sparkplug; 4. Inlet passage; 5. Injector; 6. Ignition timing; 7. Exhaust pipe.
81
BYD AUTO BYD Suri Maintenance & Repair Manual
Connect the fuel pressure gauge (to front of fuel Yes Next step
distribution pipe assembly oil inlet pipe), start the
2 Overhaul the
engine and check if the fuel pressure is about 350
kPa during acceleration. No fuel supply
system
Yes Next step
Check if the type and gap of sparkplug in each
3 Adjust or
cylinder are as specified. No
replace
Remove the electronic throttle body assembly and Clean related
Yes
4 check the electronic throttle body assembly for components
carbon deposit. No Next step
Yes Next step
Overhaul the
Check if the intake pressure sensor, electronic
5 circuit or
throttle body assembly and their circuits are normal. No
replace the
sensor
Remove the injector, and check the injector for any Replace the
Yes
6 leakage or blockage with the special washing faulty injector
analyzer. No Next step
Replace the
Check the fuel condition to see if the trouble is Yes
7 fuel
caused immediately after the fuel is filled.
No Next step
Yes Next step
Check if the ignition sequence and ignition timing of
8 Overhaul the
engine are as specified. No
ignition timing
Yes Next step
Check if the exhaust gas is discharged smoothly Repair or
9
from the exhaust pipe. No replace the
exhaust pipe
Connect the fuel pressure gauge (to front of fuel Yes Next step
distribution pipe assembly oil inlet pipe), start the
2 Overhaul the
engine and check if the fuel pressure is about 350
kPa during acceleration. No fuel supply
system
82
BYD AUTO BYD Suri Maintenance & Repair Manual
Connect the fuel pressure gauge (to front of fuel Yes Next step
distribution pipe assembly oil inlet pipe), start the
3 Overhaul the
engine and check if the fuel pressure is about 350
kPa during acceleration. No fuel supply
system
83
BYD AUTO BYD Suri Maintenance & Repair Manual
84
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1.1 Preparation for using BYD-ED400 Description: If the power supply of diagnostic
socket in the tested vehicle is insufficient or its
1.1.1.1. General test conditions power supply Pins are damaged, the power
supply can be obtained through one of the
1.1.1.1.1 Turn on the vehicle power supply following methods:
switch;
1.1.1.2.4 Cigarette lighter cable: Remove the
1.1.1.1.2 The batter voltage of vehicle should cigarette lighter. Insert one end of the
be between 11 and 14 V and the rated cigarette lighter cable into the cigarette
voltage of BYD-ED400 is 12 V. lighter hole, and connect the other end to
the power plug of BYD-ED400 test
1.1.1.2 Connection of BYD-ED400 mainline. The BYD-ED400 should be
turned off before the ignition switch is
The BYD-ED400 is connected as follows: turned off to avoid illicit shutdown.
1.1.1.2.1 Insert the diagnostic card into the 1.1.1.2.5 Double clamp power cable: Clamp
diagnostic card slot of BYD-ED400. Note the power clamp of double clamp power
the surface with "UPSIDE" faces upward cable on the positive and negative
and make sure the diagnostic card is terminals of battery, and insert the other
inserted in place. end into the power plug of BYD-ED400
test mainline.
1.1.1.2.2 Insert the end DB15 of BYD-ED400
diagnostic connecting wire into the "DATA 1.1.1.2.6 Extension adapter cable: Connect
I/O" of host. the end DB25 of extension adapter cable
to the "extension interface" of host,
1.1.1.2.3 Connect the interface OBDII on the connect the terminal DV of extension
other end of BYD-ED400 diagnostic adapter cable to the switch power jack of
85
BYD AUTO BYD Suri Maintenance & Repair Manual
special power adapter, and then insert the 1.2 Start the vehicle diagnosis
other end of power adapter into the
100-240 V AC power socket. When the above preparation is done, perform
the diagnosis with the diagnostic tester.
86
BYD AUTO BYD Suri Maintenance & Repair Manual
The BYD-ED400 diagnostic tester is operated Number key 0-9: Menu selection; Number
through the membrane keys and simple input.
operation tips are provided on each displayed
page. The customer can also enter the Direction key ↑↓←→: The ↑ and ↓ keys are
"Operation Guide for Diagnostic Tester" for used to select the menu and the ← and →
basic operation modes which will not be keys are used to turn pages. When inputting
described below. numbers, pressing the ↑ key can increase by
1 and pressing the ↓ key can decrease by 1.
The membrane keys are arranged as follows: Pressing the ← key to backspace, which is to
delete the previous digit. When performing the
component operation test, the ← key is used
to turn off the component and the → key is
used to activate or turn on the component.
87
BYD AUTO BYD Suri Maintenance & Repair Manual
The display interface for the host of diagnostic tester is divided into 3 main areas: title bar, info
bar and help bar. See the figure below.
Title bar
Please select a function
Help bar
Press [] key to move up
Press [] key to move down
Press [OK] key to enter the sub-menu
The program update process is shown in Warning! During the program update, do
the right figure. The entire process takes not power off, reset the system with [RST]
about 1 to 2 minutes. and remove the diagnostic card. Otherwise
the program will fail to update, and the
system may break down. If the diagnostic
tester cannot be used due to such causes,
please send the hose and diagnostic card
to the BYD after-service department.
88
BYD AUTO BYD Suri Maintenance & Repair Manual
89
BYD AUTO BYD Suri Maintenance & Repair Manual
Select and enter the "DELPHI-MT20U2" The "Title bar" displays ECU-MT20U2 which
system as shown in the under figure. is the abbreviation of the system of which the
customer is diagnosing the communication.
Please select a system
The "Info bar" lists all the operation types
supported by the ECU, such as reading the
version No. and data flow. [→] indicates the
operations that can be performed under the
current condition. Press the [OK] key to
perform the operation.
90
BYD AUTO BYD Suri Maintenance & Repair Manual
Press [F2] key to print the current page Press[←] key to turn to the previous page
Press [ESC] key to return Press[→] key to turn to the next page
Press [F2] key to print
Press [ESC] key to exit
Description: The information comes from the Trouble information consists of 4 parts. The
ECU. The specific contents vary with the ECU. first part is a serial number without meaning.
When the customer performs the maintenance The second part is the trouble code which is
operation, please send the information to the compiled according to related standards, for
relevant departments of BYD AUTO CO. LTD. example "P0122". The first letter "P" indicates
the engine malfunction and it forms a trouble
3.3.1.2 Read DTCs code with the last 4 numbers "0122". The third
part is in the bracket which indicates the
The function can display the trouble detected trouble conditions. There are three conditions
by the ECU in the form of specific code (DTC). such as "Current DTC", "History DTC" and
"Intermittent DTC". "Current DTC" indicates
If the system is OK the trouble always exists and the DTC cannot
be cleared through the "Clear DTCs" function.
BYD-ED400 will display "System is OK" as "History DTC" indicates the trouble occurred
shown. in the past, but it has been repaired during the
diagnosis and the DTC can be cleared
DTC through the "Clear DTCs" function.
"Intermittent DTC" indicates the trouble is an
occasional malfunction which is caused by
poor contact and the DTC can be cleared
through the "Clear DTCs" function. The last
part is the complete description of trouble
System is OK information. If the trouble information is not
included in the BYD-ED400, it will display
"DTC Not Defined".
The "Info bar" will list all the DTCs and 3.3.1.3 Clear DTCs
corresponding trouble information as shown in
the under figure.
91
BYD AUTO BYD Suri Maintenance & Repair Manual
The function is used to clear some history or The "Info bar" area is displayed in the right
intermittent DTCs recorded in the ECU. The figure. The current display is Page 1. The
display in the right figure will be shown if the customer can view other data by pressing ←
operation is successful. The customer is and → keys.
recommended to perform the operation for 2
to 3 times to ensure the DTCs are cleared Graphical display mode
completely.
The graphical trend of two parameters can be
Clear DTCs displayed on each page under the graphical
display mode of BYD-ED400. The numbers in
the left of each graph are the maximum value,
median and minimum value from top to
bottom. The corresponding text will also be
displayed under the graph.
Trouble codes cleared
The graphical display achieves the dynamic
change by plotting the points from left to right
at regular time.
3.3.1.4 Read data flow The first is to plot points as shown in the
under figure.
The BYD-ED400 diagnostic tester supports
two display modes: normal display mode and Data Flow
graphical display mode. The ED400 with
convenient graphical display is more
advanced than the previous diagnostic tester
designed by BYD AUTO Co., Ltd. The two
modes can be switched according to the key
tips of "Help bar" in BYD-ED400.
Oxygen sensor 1 voltage:
Data Flow
92
BYD AUTO BYD Suri Maintenance & Repair Manual
93
BYD AUTO BYD Suri Maintenance & Repair Manual
When the customer inputs the value and Description: Be careful to perform the
presses the [OK] key, the fourth line will "component operation test". If you are not a
display the setting result. professional technician or service personnel,
do not use the function to avoid improper
operation and damage to the engine system.
If the customer wants to give up the control of
currently selected item, select other test items 3.3.1.6 System reset
simply by pressing the ↑ and ↓ keys, or exit
the current page by pressing [ESC] key. The system reset operation causes the ECU
to perform self-resetting once. If the system is
Component Operation Test reset successfully, the BYD-ED400 will
display "Reset Successfully".
Reset successfully
Activated/deactivated parameters
94
BYD AUTO BYD Suri Maintenance & Repair Manual
When programming the diagnostic card, two Warning: When programming, ensure the
conditions may occur depending on the PC entire process finishes naturally! Do not power
settings. off the host, reset the host by pressing the
[RST] key and remove the diagnostic card,
3.3.2.1 If the "Program File" is selected in the otherwise the diagnostic card will fail to
programming software, the diagnostic update and the diagnostic card may be
program of diagnostic card will be damaged. "Finish naturally" refers to the
updated. programming is finished by the host through
the special programming software
3.3.2.2 If the "Font File" is selected in the DTcard_Updata.exe and the screen displays
programming software, the font program "Programming Finished".
of diagnostic card will be updated. The
function is not commonly used. The 3.3.3 Diagnostic tester version information
desired simplified Chinese characters
(GB2312) font has been input in the Select and enter "Diagnostic Tester Version
diagnostic card in the factory. Information" from the main screen at
power-On. The screen will display the
Description: The diagnostic program and font software version, hardware version and
program are stored in two different areas of production date as shown in the under figure.
the diagnostic card. Therefore, the customer
must confirm which program needs to be
updated when updating the diagnostic card.
95
BYD AUTO BYD Suri Maintenance & Repair Manual
Diagnostic Tester Version Information 3.3.5 Operation guide for diagnostic tester
Basic operations:
Press any key to return Press [↑] key to move up
Press [↓] key to move down
Press [←] key to turn to the previous page
Press [→] key to turn to the next page
Press the key to display the help information
Press [F2] key to print the current page
Press [OK] key to enter the sub-menu
The customer can confirm the program Press [ESC] key to return to the previous
menu
version depending on these contents and view
the program version status by accessing the Operation skills:
Enter the menu by pressing the number keys
website of BYD AUTO Co., Ltd. corresponding to the numbers in front of the
menu items
Description: The displayed contents are only
Press [ESC] key to exit
for reference. These contents will be
displayed when the host of diagnostic tester is
powered on.
96
BYD AUTO BYD Suri Maintenance & Repair Manual
97
BYD AUTO BYD Suri Maintenance & Repair Manual
4.4.7 Hold the host securely when inserting 4.4.9 Be careful to operate the test to avoid
and removing the printer to prevent it impact. Remove the power cable
from dropping on the ground. when the tester is not in use.
4.4.8 Do not insert or remove the diagnostic 4.4.10 Put the cables and connectors back
card when the instrument is on! into the case when the BYD-ED400 is
Remove the diagnostic card after it is not in use to avoid missing.
ejected by pressing the ejector rob.
When inserting the diagnostic card, 4.4.11 Remove the plug while holding it,
align it with the socket and make sure instead of pulling the power cable.
it is inserted in place.
Part 7 Accessories
Section 1 Components Installation Torque Specification Table
No. Component Name Installation Torque (NM)
8 Injector 6
(Phase 1) 2±1
9 Electronic Throttle Body Assembly
(Phase 2) 7±1
2.1.2 The maintenance interval is determined by the odometer reading or the time interval,
whichever comes first;
2.1.3 The maintenance procedures are based on the assumption when the vehicle can be used
normally as designed, and should be strictly followed.
2.1.4 Mileage for inspection and replacement of sparkplug: Inspect the sparkplug when the
vehicle is driving for 13,000 km and 23,000 km. Replace it if it malfunctions; The
sparkplug must be replaced when the vehicle is driving for 33,000 km.
98
BYD AUTO BYD Suri Maintenance & Repair Manual
Mileage
10 20 30 40 50 60 70 80
Item x1000km
Month 3 6 9 12 15 18 21 24
Ignition Coil I I I I
Ignition Timing I I I I
Engine Idling I I I I
Fuel Tank I C
Gasoline Filter R R R R
Injector C* C* C* C*
Air Cleaner I R I R
Electronic Throttle Body
C C C C
Assembly
Emission Check I I I I
Diagnostic Tester Check I I I I
2.2 Taxi
Description:
2.2.2 The maintenance interval is determined by the odometer reading or the time interval,
whichever comes first;
2.2.3 The maintenance procedures are based on the assumption when the vehicle can be used
normally as designed, and should be strictly followed.
2.2.4 Mileage for inspection and replacement of sparkplug: Inspect the sparkplug when the
vehicle is driving for 13,000 km and 23,000 km. Replace it if it malfunctions; The
sparkplug must be replaced when the vehicle is driving for 33,000 km.
Mileage
20 40 60 80 100 120 140 160
Item x1000km
Month 3 6 9 12 15 18 21 24
Ignition Coil I I I I I I I I
Ignition Timing I I I I
Engine Idling I I I I
Fuel Tank C C
Gasoline Filter R R R R R R R R
Injector C* C* C* C* C* C* C* C*
Air Cleaner I R I R I R I R
Air Passage of Electronic
I C I C I C I C
Throttle Body Assembly
Electronic Throttle Body
I C I C I C I C
Assembly
Emission Check I I I I
Diagnostic Tester Check I I I I
Note: R-Replace
C-Clean
I-Inspect (Replace the malfunctioning components found during item inspection)
C*-It is recommended to use the special injector washing analyzer to clean and maintain the
injector
99
BYD AUTO BYD Suri Maintenance & Repair Manual
DTCs Table
DTC Malfunction
Description
Max. Min. Signal Irrational Type
Crankshaft position sensor signal
P0335 P0335 P0335 P0336
malfunction 33
Electronic throttle body assembly circuit
P0123 P0122 P0120 P0120
malfunction 31
Injector 1 control circuit malfunction P0201 P0201 P0201 P0201 31
Injector 2 control circuit malfunction P0203 P0203 P0203 P0203 31
Injector 3 control circuit malfunction P0204 P0204 P0204 P0204 31
Injector 4 control circuit malfunction P0202 P0202 P0202 P0202 31
λClosed loop control self-learning value
P0171 P0172 P0170 P0170
multiplication exceeds the limit 5
Oxygen sensor heater malfunction P0135 P0135 P0135 P0135 31
Fuel pump control circuit malfunction P0230 P0230 P0230 P0230 31
Knock zero test and diagnosis P0324 P0324 P0324 P0324 5
Knock offset diagnosis P0324 P0324 P0324 P0324 5
Knock test pulse diagnosis P0324 P0324 P0324 P0324 5
Knock sensor circuit malfunction P0325 P0325 P0325 P0325 31
Idle control speed deviates from target
P0507 P0506 P0505 P0505
speed 31
Intake pressure sensor malfunction P0108 P0107 P0105 P0106 31
Oxygen sensor malfunction P0132 P0131 P0134 P0130 31
Fan A control circuit malfunction P0480 P0480 P0480 P0480 31
Crankshaft position sensor malfunction P0335 P0335 P0335 P0336 33
Camshaft position sensor malfunction P0343 P0342 P0340 P0340 31
λClosed loop control self-learning value
P0171 P0172 P0170 P0170
addition exceeds the limit 5
Intake temperature sensor malfunction P0113 P0112 P0110 P0111 31
Charcoal canister control valve control
P0445 P0444 P0443 P0443
circuit malfunction 31
Water temperature sensor malfunction P0118 P0117 P0115 P0116 31
Power supply malfunction P0563 P0562 P0560 P0560 31
100
BYD AUTO BYD Suri Maintenance & Repair Manual
101
BYD AUTO BYD Suri Maintenance & Repair Manual
102
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1.1 Only use the digital multimeter to 1.2.4 Do not remove any components or
check the electronically controlled connectors of electronically controlled
injection system; injection system from the mounting
positions to avoid unexpected damage
1.1.2 Please use the original components or prevent the water, oil and dirt from
during repair, otherwise the normal entering the connectors, affecting the
operation of electronically controlled normal operation of electronically
injection system cannot be ensured; controlled injection system.
1.1.3 Only use the lead free fuel during 1.2.5 When the connectors are
repair; disconnected and connected, be sure
to turn the ignition switch to OFF, or
1.1.4 Please observe the repair diagnosis the electrical components may be
flow of specifications to perform repair; damaged.
1.1.5 Never disassemble the components of 1.2.6 When simulating the thermal condition
electronically controlled injection of trouble and performing other repairs
system during repair; which may cause the temperature to
rise, never allow the temperature of
1.1.6 Be careful not to drop the electronic electronic control unit to exceed 80°C;
components (Electronic control unit ,
sensor, etc.) on the ground during 1.2.7 When overhauling the fuel system or
repair; electrical system, disconnect the
battery first. No smoke and open fire
1.1.7 Effectively dispose the waste during around. The fire extinguisher must be
repair in consideration of prepared;
environmental protection.
1.2.8 The fuel supply pressure for the
1.2 Precautions During Repair electronically controlled injection
system is high (about 600 kPa);
1.2.1 Before working on the engine therefore the fuel lines use the
compartment, turn off the engine, high-pressure resistant fuel pipes. The
remove the ignition key, pull the brake higher fuel pressure is maintained in
lever, switch the shift lever to N or P the fuel line even if the engine does
position and keep the children away not operate. So do not remove the fuel
from the engine; pipes randomly during repair. When
the fuel system needs to be repaired,
1.2.2 Avoid short circuit in the electrical release the pressure of fuel system
system, especially in the battery to before removing the fuel pipes. The
prevent battery explosion. pressure relief method is as follows:
Remove the fuel pump relay, start the
1.2.3 It is more dangerous to overhaul the engine and keep it idling until the
engine when it is started or running. engine stalls. The removal of fuel
Always take care to prevent the pipes and replacement of fuel filter
rotating components such as drive belt, should be performed by the
generator and radiator fan and professional service personnel in
high-voltage ignition system from well-ventilated places;
causing injury or even death to the
operator. Never touch the electrical 1.2.9 Do not energize the fuel pump when
103
BYD AUTO BYD Suri Maintenance & Repair Manual
removing the power fuel pump from Function: Read/clear the DTCs for the
the fuel tank to avoid generating electronically controlled injection system,
electric sparks, causing fires; observe the data flow and perform the
component operation test, etc.
1.2.10 Do not perform operation test on the
fuel pump in the dry state or water, or
its life time may be reduced. Moreover,
do not reverse the positive and
negative terminals of the fuel pump;
1.2.14 Never ground the positive pole of 1.3.3 Tool Name: Ignition Timing Light
battery to avoid powering off the
electrical system of complete vehicle Function: Check the engine ignition timing,
and damage to the electronic etc.
components due to the burnout of
positive fuse;
1.2.17 Do not detect the input and output 1.3.4 Tool Name: Digital Multimeter
signals of components by piercing the
wire sheath. Function: Check the characteristic
parameters of electronically controlled
1.3 Recommended Service Tools injection system, such as voltage, current
and resistance.
1.3 Tool Name: BYD ED400 diagnostic tester
104
BYD AUTO BYD Suri Maintenance & Repair Manual
1.3.5 Tool Name: Vacuum Gauge 1.3.8 Tool Name: Exhaust Gas Analyzer
Function: Check the pressure of intake Function: Check the exhaust emission of
manifold. vehicle to help judge the trouble of
electronically controlled injection system.
105
BYD AUTO BYD Suri Maintenance & Repair Manual
106
BYD AUTO BYD Suri Maintenance & Repair Manual
107
BYD AUTO BYD Suri Maintenance & Repair Manual
The main system functions are as follows: Burglar alarm function, engine anti-theft,
operative work with KEYLESS system
2.1.1.1 Basic management function of engine
with physical model applied 2.1.1.3 On-board Diagnosis (OBD) II
108
BYD AUTO BYD Suri Maintenance & Repair Manual
109
BYD AUTO BYD Suri Maintenance & Repair Manual
2.2.17 Injection timing and injection duration When starting, the ignition angle changes
of high pressure injector with the engine temperature, intake
temperature and engine speed.
2.2.18 Time
2.3.2 Warming Up and Heating Control of
2.2.19 High pressure fuel pump control Three-way Catalytic Converter
signal
When the engine is started at low
2.2.20 Low pressure fuel pump control temperature, the cylinder charge, fuel
signal injection and electronic ignition are
adjusted to compensate the higher torque
2.2.21 Charcoal canister control valve demands of engine. The process
opening continues until the proper temperature
threshold is reached.
2.2.22 Ignition coil dwell angle and ignition The most important is to quickly heat the
advance angle three-way catalytic converter in the stage,
as the quick transition to three-way
2.2.23 Air conditioning compressor relay catalytic converter operation will reduce
the exhaust emission significantly. In the
2.2.24 Stepless fan control signal working condition, the three-way catalytic
converter should be heated with exhaust
2.2.25 Electronic water pump relay by properly delaying the ignition advance
angle.
2.2.26 Boost pressure limiting solenoid
2.3.3 Acceleration/Deceleration and Motoring
2.2.27 Air circulation valve Fuel Cutoff Control
The intake stroke injection is used during When the fuel cutoff during deceleration
starting. occurs under the motoring or towing
conditions, the power at the flywheel of
The fuel injection amount varies with the engine is negative. In this case, the
engine temperature. The "injection timing" engine friction and pump loss can be
is specified as the initial injection pulse. used to decelerate the vehicle. When the
The mixture must be enriched before the engine is in motoring or towing working
engine reaches a certain speed. condition, the fuel is cut off to reduce the
fuel consumption and exhaust emission,
Once the engine starts, the system will and the most important is to protect the
reduce the cranking enrichment until the three-way catalytic converter.
cranking enrichment is cancelled when
the starting is completed; After the engine Once the speed decreases to a specified
speed exceeds a limit value (for example speed above the idle speed, the injection
1,200 rpm), the injection timing will be system will supply fuel again. After the
changed to inject around the injection is restored, the torque-based
compressors top dead center. control system will increase the engine
110
BYD AUTO BYD Suri Maintenance & Repair Manual
torque slowly and stably (stable The target of λ closed loop control is to
transition). ensure the mixture concentration is within
the range.
2.3.4 Idle Control
The λ closed loop control system can
When idling, the engine does not provide function only when equipped with oxygen
torque to the flywheel. To ensure the sensor. The oxygen sensor monitors the
stable operation of engine at the lowest oxygen content in the exhaust at the
idle speed, the closed loop idle control position of three way catalytic converter.
system must maintain the balance The lean mixture (λ>1) will generate a
between the generated torque and engine sensor voltage of about 100 mV, and the
"power consumption". Certain amount of rich mixture (λ<1) will generate a sensor
power must be generated when idling to voltage of about 800 mV. When λ=1, the
meet various load requirements. They sensor voltage will have a step transition.
come from the engine crankshaft, valve The λ closed loop control will modify the
mechanism and ancillary components, control variable in response to the input
such as the internal friction of water signals (λ>1=thin mixture, λ<1=rich
pump. mixture), and generate the correction
factor as multiplier to correct the injection
The torque-based TB10 system control duration.
strategy confirms the engine output
torque required to maintain the desired 2.3.6 Evaporative Emission Control
idle speed in any working condition
according to the closed loop idle control. Due to the delivery of external radiation
The output torque increases as the heat and oil return heat, the fuel in the
engine speed decreases, and decreases fuel tank is heated and the fuel vapor is
as the engine speed increases. The formed. The vapor containing large
system responds to the new "interference amount of HC cannot be discharged to
factors" by demanding larger torque, such the atmosphere due to limit of
as ON/OFF of air conditioning evaporative emission regulations. In the
compressor and ON/OFF of the power system, the fuel vapor is collected in the
steering, etc. When the engine charcoal canister through the duct, and
temperature is low, the torque must be then purged and burned in the engine at
increased to compensate more internal the proper time. The purge air flow can be
friction loss and/or maintain higher idle achieved through the charcoal canister
speed. The total of output torque control valve controlled by ECU.
demands is transferred to the torque
coordinator, and the charge density, 2.3.7 High Pressure Fuel Pump Control
mixture content and ignition timing are
calculated by the torque coordinator. During the closed loop control of
high-pressure fuel pressure, the TB10
2.3.5 λ Closed Loop Control system adjusts the fuel pressure control
valve according to the preset MAP and
The exhaust post-processing in the performs closed loop correction via the
three-way catalytic converter is an high-pressure fuel rail pressure sensor to
effective method to reduce the match the current fuel pressure with the
concentration of harmful substance in the engine load.
exhaust. The three-way catalytic
converter can reduce the hydrocarbons The high pressure fuel pump is a
(HC), carbonic oxide (CO) and nitrogen mechanical pump which is driven by the
oxides (NOx) by 98% or more, and camshaft. The volume of fuel flowing into
convert them to water (H2O), carbon the high pressure fuel pump can
dioxide (CO2) and nitrogen (N2). The controlled by the fuel pressure control
high efficiency can be reached only when valve, thus achieving a stable fuel
the engine excess air ratio λ is about 1. pressure in the high pressure fuel rail;
111
BYD AUTO BYD Suri Maintenance & Repair Manual
The pressure limiting valve is integrated 2.3.11 Turbocharger Cooling System Control
in the high pressure fuel pump. When the
fuel pressure exceeds a preset value (for The heat is accumulated severely in the
example 200 bar), it will achieve turbocharger as it is exposed in the hot
mechanical pressure relief and send the environment for a long time. After the
fuel back to the low pressure fuel line. engine stops, the mechanical water pump
also stops to cool down the turbocharger
2.3.8 Boost Pressure Limiting Control for effective protection.
The torque model based TB10 system The system has the function to delay the
performs pulse width control on the boost power-off of electronic water pump. After
pressure limiting valve and adjusts the the engine stops, the electronic water
exhaust gas amount flowing through the pump will operate continuously for a while
turbo according to the current engine (for example, 8 min) to ensure the heat
speed and load demands. Therefore the dissipation and protection of
intake boost pressure is effectively turbocharger.
controlled to meet the demands of current
torque. 2.4 Introduction of System Trouble
Diagnosis Function
2.3.9 Boost Air Circulation Control
The on-board diagnosis system (OBD
When the boost pressure increases system for short) is integrated in the
suddenly due to rapid change of engine engine control system and monitors the
working conditions or other factors, TB10 faulty components affecting the exhaust
system will control the air circulation emission and the status of main engine
solenoid to enable the air continuity function. It can recognize, store and
before and after boosting and keep the display the trouble information through
pressure balance. the self-diagnosis malfunction indicator
lamp (MIL).
The control can effectively avoid
generating air noise and causing damage To ensure the durability of emission
to the impeller during fuel recovery, and it control performance during the use of
can also prevent the motoring brake or vehicle, China has clearly defined that "All
component damage caused by high the vehicles must be equipped with the
backpressure in the pressure cavity. on-board diagnosis (OBD) system which
can recognize the parts degradation or
2.3.10 Variable Intake Phase Control malfunction during the whole life cycle of
vehicle" in the "Limits and measurement
The torque model based system matches methods for emissions from light-duty
the current intake phase with the optimal vehicles (Chinese Phase IV)".
intake phase map according to the
current engine speed, load and OCV When repairing the vehicle with the OBD
solenoid control. Meanwhile, the intake system, the service personnel can locate
phase control and camshaft signal form the trouble area quickly and accurately
the closed loop control so as to ensure with the diagnostic tester, thus
the system control progress. significantly improving the repair
efficiency and quality.
The variable intake phase system can
effectively balance the fuel efficiency The OBD technique involves many
converted by the high and low speed of brand-new concepts. Some basic
engine and output performance to information about the OBD technique will
maximize the performance of complete be introduced first as so to better
vehicle. understand the follow-up contents.
112
BYD AUTO BYD Suri Maintenance & Repair Manual
2.4.1 Record Trouble Information control unit will store the trouble
information in the malfunction memory of
The electronic control unit constantly RAM. The trouble information is stored in
monitors the sensor, actuator, related the form of DTCs, and displayed in the
circuits, fault indicator, battery voltage order of trouble occurrence.
and even the electronic control unit itself,
and detects the reliability of output sensor The malfunctions can be divided into
signal, actuator drive signal and internal "steady state malfunction" and
signal (for example, λ closed loop control, "occasional malfunction" (caused by
coolant temperature, idle speed control temporary open circuit of wire harness or
and battery voltage control, etc.). Once poor contact of connectors) based on the
the trouble is found in a cycle or some occurrence frequency.
signal value is not reliable, the electronic
Fig. 2.4 Schematic Diagram of Electronically Controlled Injection System Trouble Diagnosis
113
BYD AUTO BYD Suri Maintenance & Repair Manual
114
BYD AUTO BYD Suri Maintenance & Repair Manual
2.4.5.1.2 Target speed, intake air flow, Engine function structure with torque as
fuel consumption, etc. variable;
115
BYD AUTO BYD Suri Maintenance & Repair Manual
116
BYD AUTO BYD Suri Maintenance & Repair Manual
117
BYD AUTO BYD Suri Maintenance & Repair Manual
Value
Parameter Unit
Min. Typical Max.
Pressure Test Range 10 250 kPa
Operation temperature -40 130 C
Power voltage 4.75 5.0 5.25 V
Power supply current for US=5.0 12.5 mA
V
118
BYD AUTO BYD Suri Maintenance & Repair Manual
Temperature T
3.1.5 Trouble Symptoms and Judgment
Method
Fig. 3-5 Characteristic Curve of Temperature 3.1.5.1 Trouble symptoms: misfire, poor idling,
Sensor R=f (T) etc.
3.1.4 Precautions for Installation General trouble cause: 1. Abnormal high
voltage or reverse high current during use;
3.1.4.1 The sensor must be installed on the 2. The vacuum components are damaged
surface of intake pipe in the engine. The during repair.
pressure tube and temperature sensor
are inserted into the intake pipe together 3.1.5.2 Precautions for repair: Never impact
and isolated from the atmosphere via the vacuum components with
O-ring. high-pressure air during repair. When
the sensor is replaced due to
3.1.4.2 The sensor must be installed in a malfunction, check if the output
correct way (extract pressure from the voltage and current of generator are
intake manifold, the pressure tube tilts normal.
down, etc.) to ensure the condensate
water will not accumulate in the 3.1.5.3 Simple measurement method:
pressure sensing components.
-- Temperature Sensor: (With the
3.1.4.3 The drilling and fixing of intake connector removed) Turn the digital
manifold must be designed according to multimeter to Ohms range, and connect
the vendor drawing to ensure long-term two probes to Pin No. 1 and 2 of sensor
tightness and corrosion resistance at the respectively. The rated resistance at
base of interface. 20°C is 2.5 kΩ±5%, and the other
resistance values can be measured
3.1.4.4 The back pressure may cause according to the above characteristic
measuring error; therefore the sensor curve. The simulation can be used when
should not be installed behind the measuring. The specific method is to
119
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 3-7 Electrical Schematic Diagram of Fig. 3-8 Electrical Schematic Diagram of
Engine Coolant Temperature Sensor Radiator Outlet Coolant Temperature
Sensor
Pin definition:
120
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 3-9 Characteristic Curve of Coolant General trouble cause: Human failure.
Temperature Sensor
Simple measurement method: (With the
3.2.4 Performance Parameter connector removed) Turn the digital
multimeter to the Ohms range, and
3.2.4.1 Power: The allowed power at connect two probes to Pins No. 1 and 2
both ends is 0.075 W (25°C). of the sensor respectively. The rated
resistance at 25°C is 1.825-2.155 kΩ,
3.2.4.2 Operation temperature: and the other resistance values can be
-40°C~+130°C measured according to the above
3.2.5 Precautions for Installation characteristic curve. The simulation can
be used when measuring. The specific
3.2.5.1 The sensor should be installed in a method is to put the sensor working area
position where the flow rate of cooling in the hot water (The soak time should
water is high and the water temperature be sufficient) and observe the change of
can be correctly detected. Make sure the sensor resistance. At this time the
fluid level is at least 10 mm higher than resistance should drop to below
the bottom surface as shown in figure 300Ω-400Ω (The specific values depend
3-10 so that the sensor can detect the on the temperature of hot water).
correct cooling water temperature in a
short response time.
121
BYD AUTO BYD Suri Maintenance & Repair Manual
Sensor Diagram
Pin definition:
Fig. 3-11 Oxygen Sensor Diagram
122
BYD AUTO BYD Suri Maintenance & Repair Manual
electrolyte which can ionize the oxygen at If the mixture is thin, the difference of
high temperature to generate the oxygen oxygen ion concentration inside and
ion. Its structure is shown in figure 3-14. outside the ceramic tube is low and the
One side of ceramic tube leads to the potential difference is too low. Few
exhaust gas of exhaust manifold and the oxygen ions move from inside to outside
other side leads to the atmosphere. As and the output voltage is low (close to
the oxygen concentration at both sides 100 mV). The sudden change of signal
differs greatly, the potential difference (i.e. voltage occurs around the theoretical
signal voltage) will be generated between equivalent air-fuel ratio (λ=1) as shown
the inside and outside of tube wall when below.
the ionization occurs.
Sensor Voltage
1 Wire
2 Protective Sleeve
3 Planar Sensing Component
4 Wire
5 Sensor Base λ<1: Rich mixture (Insufficient oxygen)
6 Seal Ring λ>1: Lean mixture (Excessive oxygen)
7 Double Layer Protection Tube
Fig. 3-15 Characteristic Curve of Oxygen
Fig. 3-14 Structural Diagram of Oxygen Sensor Voltage at 600°C
Sensor
3.3.3 Communication with ECU
If the mixture is rich, the difference of
oxygen ion concentration inside and Parameter Condition Min. Max. Unit
outside the ceramic tube is high and the Working
Input voltage 0 1 V
potential difference is too high. Large voltage
amount of oxygen ions move from inside Reference Open
420 480 mV
to outside and the output voltage is high voltage circuit
(close to 800 mV-1000 mV);
123
BYD AUTO BYD Suri Maintenance & Repair Manual
124
BYD AUTO BYD Suri Maintenance & Repair Manual
Failure judgment:
Fig. 3-16 Installation Plan for Oxygen Sensor 3.3.6.1 Check with diagnostic tester
The engine malfunction indicator is
3.3.5.2.2 Recommended material for the turned on to indicate the malfunction in
thread of exhaust pipe: Heat resistant the engine system, and the diagnostic
stainless steel, such as X 5 CrNi 18 9 DIN tester should be used to diagnose the
17440 1.4301, 1.4303 SAE30304 or SAE malfunction.
30305 (American standard). Note the
thread of sensor must be covered Use the diagnostic tester specified by the
completely. assembly plant to communicate with the
electronically controlled injection system
3.3.5.2.3 The protection tube of sensor should ECU and read the trouble data in the
be inserted into the exhaust gas as much ECU so as to judge the oxygen sensor
as possible, but the hemming of protection failure.
tube should not face the hot exhaust gas
directly. Make sure the protection tube of 3.3.6.2 Simple inspection method for electrical
sensor does not contact the opposite side performance:
of exhaust pipe. When it is installed at the
connection of exhaust manifold and twin - (With the connector removed) Turn the
tube, the materials with minimum digital multimeter to Ohms range, and
deformation to high temperature should be connect two probes to the Pins at both
selected. terminals (+) and (-) of the sensor heater
respectively. Under normal temperature,
3.3.5.2.4 The tightening torque for the oxygen its resistance is 9 Ω.
sensor is 40 to 50 Nm. The following
specified mounting grease should be used: -- (With the connector connected) Under
BOSCH material No. 5964080112 (120 the idling condition, when the operating
g/tank) or 5964080145 (450 g/tank). The temperature of oxygen sensor reaches
other mounting greases will cause oxygen 350°C, turn the digital multimeter to DC
sensor poisoning. voltage range and connect two probes to
the ground signal pin and positive signal
3.3.5.2.5 During mass production, ensure the pin of sensor respectively. At this time
design of exhaust pipe system meets the the voltage should fluctuate quickly
geometric accuracy and airtight between 0.1~0.9 V.
requirements for installation.
-- Shake the oxygen sensor near your ear.
3.3.5.2.6 The tool needed for removal is the If the abnormal noise can be heard, the
wrench M22. After the removal, clean the internal ceramic probe may be broken.
mounting surface and make sure no oil
exists. 3.4 Crankshaft Position Sensor
3.3.6 Trouble Symptoms and Judgment The crankshaft position sensor is
Method integrated with an auxiliary seal ring as
shown in figure 3-17. The crankshaft
Trouble symptom: poor idling, poor position sensor, seal ring and signal
acceleration, tail gas exceeds standard, wheel should be assembled as shown in
high fuel consumption, etc. figure 3-18.
General trouble cause: 1. The moisture Diagram of Sensor and Seal Ring
enters the sensor, the temperature
125
BYD AUTO BYD Suri Maintenance & Repair Manual
126
BYD AUTO BYD Suri Maintenance & Repair Manual
3.4.7 Trouble Symptoms and Judgment ignition switch, but do not start the
Method engine. Turn the digital multimeter to
DC voltage range, and connect two
3.4.7.1 Trouble symptom: The engine is probes to pin 1 and 3 of sensor
unable to start. respectively. Make sure there is a
reference voltage of 5 V. When the
3.4.7.2 General trouble cause: Human failure. engine is started, check if the signal of
pin No. 2 is normal with an
3.4.7.3 Simple measurement method: (With oscilloscope.
the connector connected) Turn on the
127
BYD AUTO BYD Suri Maintenance & Repair Manual
Sensor Diagram
3.5.1 Installation Position
Camshaft end
Pin definition:
128
BYD AUTO BYD Suri Maintenance & Repair Manual
Sensor
In the above figure, OP (Operating Point) refers to the falling edge of electrical signal and RP
(Release Point) refers to the rising edge of electrical signal.
129
BYD AUTO BYD Suri Maintenance & Repair Manual
130
BYD AUTO BYD Suri Maintenance & Repair Manual
131
BYD AUTO BYD Suri Maintenance & Repair Manual
132
BYD AUTO BYD Suri Maintenance & Repair Manual
133
BYD AUTO BYD Suri Maintenance & Repair Manual
134
BYD AUTO BYD Suri Maintenance & Repair Manual
135
BYD AUTO BYD Suri Maintenance & Repair Manual
Power supply voltage: UBi=5 V±10%; i=1, 2 Signal current: ISi, max≤50μA; i=1, 2
Power supply current: IBi≤10mA; i=1, 2 Short circuit protection: U=16 V; t=60 min
Nominal resistance:
Sensor 1 Sensor 2
Sensor resistance Rp1=1200±40% Rp2=1700±40%
Contact resistance and 1000±400≤RSi+RUi≤5000
dropping resistance (When operating for t>5 ms)
Limit value of sensor signal:
Sensor 1 Sensor 2
Minimum voltage 16.5 8.25
UAi/UBi*100/[%]
Maximum voltage <87.5 <43.75
UAi/UBi*100/[%]
136
BYD AUTO BYD Suri Maintenance & Repair Manual
137
BYD AUTO BYD Suri Maintenance & Repair Manual
138
BYD AUTO BYD Suri Maintenance & Repair Manual
3.9.2 Profile
139
BYD AUTO BYD Suri Maintenance & Repair Manual
140
BYD AUTO BYD Suri Maintenance & Repair Manual
141
BYD AUTO BYD Suri Maintenance & Repair Manual
Terminal B of knock
45 Input 106 Ignition signal 4 Input
sensor
Terminal A of knock
46 Input 107 Ignition signal 2 Input
sensor
47 Crankshaft sensor ground Ground 108 Power Ground 5 Ground
Accelerator pedal position CAN bus interface
48 Ground 109 Input Output
sensor 2 ground CAN-H
49 110
50 111
51 Electrical ground 1 Ground 112 Ignition switch Input
Continuous power
52 Throttle position sensor 2 Input 113 Input
supply
Intake manifold pressure
53 Ground 114 Injector 4 (Cylinder 4) Output
sensor signal ground
54 A/C request signal Input 115 Injector high side 1 Output
Upstream oxygen sensor
55 Ground 116 Injector high side 2 Output
ground
Downstream oxygen
56 Ground 117 Injector 1 (Cylinder 1) Output
sensor ground
Camshaft phase sensor
57 Ground 118 Injector 3 (Cylinder 3) Output
ground
Non-continuous power
58 Electrical ground 2 Ground 119 Input
supply 2
Electronic throttle valve Non-continuous power
59 Input 120 Input
motor control + supply 3
Electronic throttle valve
60 Input 121 Injector 2 (Cylinder 2) Output
motor control -
61 A/C permission signal Input
142
BYD AUTO BYD Suri Maintenance & Repair Manual
Parameter Limit
Items Value Unit
Min. Typical Max.
Battery Voltage 9.0 12 16.0 V
Operation Temperature -40 +105 C
Storage Temperature -40 +65 C
Product Quality 700 g
3.9.4.1 Discharge the static electricity during 2. (With the connector removed) Check if
installation the ECU connecting wire is in good
condition and if the ECU power supply
3.9.4.2 Protect the Pins of connector and ground circuit are normal;
3.9.5 Trouble Symptoms and Judgment 3. Check if the external sensor operates
Method normally, the output signal is reliable and
the circuit is in good condition;
a Trouble symptoms: Poor idling, poor
acceleration, unable to start, high idle 4. Check if the actuator operates normally
speed, emissions exceed standards, and the circuit is in good condition;
difficult to start, air conditioner failure,
injector control failure, misfire, etc. 5 Replace the ECU and perform test;
143
BYD AUTO BYD Suri Maintenance & Repair Manual
Value
Items Unit
Min. Typical Max.
Working voltage 12 V (DC)
System pressure 6 Bar
Ambient temperature
(Suitable for storage and -40 +80 C
transportation)
Allowed fuel temperature -30 +70 C
144
BYD AUTO BYD Suri Maintenance & Repair Manual
The power fuel pump should be stored in If the fuel pump is returned, please send
the closed original packing box. The back the supply list, check list and
allowed maximum storage time is 6 package label with it. The returned fuel
months after it is installed in the vehicle, pump must be packed as specified. If the
and the maximum storage time is 4 years fuel pump has been used, wash it with
if it is used as spare part. The test solution and dry it in the air instead of
performance data of fuel pump should be blowing it dry. For safety, the fuel pump
rechecked by the manufacturer when the with fuel is not accepted.
above time is exceeded. The fuel pump
should be protected from the atmospheric 3.10.5 Trouble Symptoms and Judgment
effects when stored. The original Method
packaging should not be damaged during
storage. 3.10.5.1 Trouble symptoms: Loud operating
noise, poor acceleration, unable to start
The power fuel pump is used only in the (difficult to start), etc.
fuel tank. Install a fuel inlet screen with
mesh size of 60 μ or less or determined 3.10.5.2 General trouble cause: Due to the
with the customers when the fuel pump is use of poor-quality fuel: 1. the insulation
installed. Do not allow the fuel from the layer is formed by colloid accumulation;
vent hole to spray on the fuel inlet screen, 2. the fuel pump axle bushing and
fuel pump bracket and fuel tank wall. Be armature lock; 3. the components of fuel
careful to transport the fuel pump. Protect level sensor are corroded.
the fuel inlet screen from any load or
impact. The fuel pump must be removed 3.10.5.3 Precautions for repair:
from the plastic packaging carefully
during installation. The protective cover 3.10.5.4 The power fuel pump has different
can be removed only when the fuel pump flow rates depending on the
is to be installed. Never remove the fuel requirements of engine. The fuel pump
inlet screen. The fuel pump may be which has the same profile and can be
damaged when the foreign objects enter installed may be improper. The part No.
the fuel pump inlet or screen. of fuel pump used must be the same as
the original during repair. Do not mix use
Keep clean when the fuel pipes are of them;
installed. The interior of fuel pipes should
be clean. Only use new fuel pipe clamps. 3.10.5.4.1 To prevent the unexpected
Confirm the correct position of fuel pipe damage to the fuel pump, do not
clamps and observe the methods operate it in dry state;
recommended by the manufacturer.
3.10.5.4.2 When the fuel pump needs to be
Do not hold the fuel pump at the fuel pipe replaced, clean the fuel tank and pipe
or fuel inlet screen. lines and replace the fuel filter.
145
BYD AUTO BYD Suri Maintenance & Repair Manual
Diagram
146
BYD AUTO BYD Suri Maintenance & Repair Manual
Performance Data
Items Value Unit
Min. Typical Max.
System pressure 2 15 MPa
Fuel supply pressure (Absolute) 0.65 0.9 MPa
Storage temperature -40 +70 C
Storage humidity 0 80 %
Ambient temperature for operation -40 +100 °C
Fuel temperature at oil inlet -40 +80 °C
Dry running 0 10 Min
Flow control valve Resistance 0.5 Ω
Insulation 10 MΩ
resistance
3.11.4 Precautions for Installation b General trouble cause: Due to the use of
poor-quality fuel
a The clean engine oil without silicone
must be used to lubricate the hole with c Precautions for maintenance:
a diameter of 35 mm in the fuel pump
flange before installing the fuel pump; 3.11.5.1 Use the specified fuel and fuel
additive;
b The parting plane is not allowed in the
seal area; 3.11.5.2 Fill the fuel before the volume
indicator light is turned on to reduce the
c The fuel pump supporting surface must effect of fuel deposits on the entire
be fully supported at the flange end. engine system;
d All the dropped parts must be 3.11.5.3 Release the fuel pressure when it is
discarded; \ necessary to replace the fuel pump.
147
BYD AUTO BYD Suri Maintenance & Repair Manual
148
BYD AUTO BYD Suri Maintenance & Repair Manual
complies with the National Standard of 3.12.4.2.4 If the injector has two slots, be
the People's Republic of China GB careful not to confuse them. Refer to the
17930-1999 "Unleaded Gasoline for installation position of original part.
Motor Vehicles" and National Standard
for Environmental Protection GWKB 3.12.4.3 The injector should be installed by
1-1999 "Hazardous Materials Control hand. Never tap the injector with tools
Standard for Motor Vehicle Gasoline", such as hammer.
and the detergent should be added in the
gasoline. Note that the gasoline will 3.12.4.4 The O-ring must be replaced when
deteriorate after stored for a long time. the injector is removed and reinstalled.
The temperature of fuel tank is very high Do not damage the sealing surface of
due to the continuous operation of fuel injector.
pump. If the gasoline is stored in the fuel
tank of such vehicle, it will be oxidized 3.12.4.5 The support washer of O-ring should
easily, causing the injector blockage and not be pulled out from the injector. Avoid
even damage. damage to the inlet, O-ring, support ring,
nozzle plate and electric connector of
3.12.4 Precautions for Installation injector during installation. Do not use
them if damaged.
3.12.4.1 Do not mix use of the injector
connectors. 3.12.4.6 Perform test on the tightness of fuel
distribution pipe assembly after the
3.12.4.2 For easy installation, it is injector is installed. It is acceptable
recommended to apply clean when no leakage exists.
silicone-free oil on the upper O-ring
connected to the fuel distribution pipe. 3.12.4.7 Remove the fault part by hand. First
Do not allow the oil to contact the remove the clips of injector, and then
injector interior and nozzle. pull out the injector from the injector seat.
Keep the injector clean after removal.
3.12.4.3 Install the injector to the injector seat
in a direction perpendicular to the 3.12.5 Trouble Symptoms and Judgment
injector seat, and then fix the injector on Method
the injector seat with clips.
3.12.5.1 Trouble symptoms: Poor idling, poor
Notes: acceleration, unable to start (difficult to
start), etc.
3.12.4.2.1 The injector clips can be divided into
axial retaining clip and radial retaining 3.12.5.2 General trouble cause: The injector
clip according to the fixing method. fails to function due to the colloid
Avoid mixing use of them. accumulation in the injector caused by
lack of maintenance.
3.12.4.2.2 For installation of axially fixed
injectors, make sure the center bayonet 3.12.5.3 Precautions for repair: (Refer to
of clip is fully clamped in the injector slot, Precautions for installation)
and the slots on both sides of clip are
fully clamped on the outer edge Advice: Clean the injectors with a special
hemming of injector seat. washing analyzer at regular intervals.
149
BYD AUTO BYD Suri Maintenance & Repair Manual
1) Parameter Limit
2) Performance Parameters
150
BYD AUTO BYD Suri Maintenance & Repair Manual
3.13.4.1 The engine may not operate normally 3.14 Electronic Throttle Valve Assembly
after the VVT valve body is removed
and repaired. The valve body assembly Diagram and Pin
must be replaced if it malfunctions.
3.13.4.3 The internal precision of VVT valve Fig. 3-51 Electronic Throttle Valve
body and OCV solenoid is very high. If
the non-original oil and oil filter are used,
the engine VVT system may operate
abnormally.
151
BYD AUTO BYD Suri Maintenance & Repair Manual
Performance Parameters
a Trouble symptoms: Difficult to start, Fig. 3-53 Turbocharger Air Circulation Valve
unstable idling, poor acceleration or " backfire",
abnormal exhaust emission
c Troubleshooting:
152
BYD AUTO BYD Suri Maintenance & Repair Manual
Items Value
Unit
Min. Typical Max.
Fuel temperature 205 °C
Ambient
-40 +160 °C
temperature
Working voltage 8 12 16 V
153
BYD AUTO BYD Suri Maintenance & Repair Manual
3.16.4.5 Replace the oil and oil filter at regular Fig. 3-58 Circuit Diagram of Single-spark
intervals; Ignition Coil
3.16.4.6 Check the flexibility of bypass valve Note: The system has four ignition coils.
regulator lever at regular intervals. Each ignition coil is connected to a
cylinder and the ignition sequence is
3.16.4.7 When the ignition switch is turned on 1-3-4-2.
and the engine is idling, the duty cycle of
boost pressure limiting valve displayed on the Pin definition:
154
BYD AUTO BYD Suri Maintenance & Repair Manual
1) Performance Data
2) Parameter Limit
155
BYD AUTO BYD Suri Maintenance & Repair Manual
Pin definition:
156
BYD AUTO BYD Suri Maintenance & Repair Manual
3.18.3 Technical Parameters 3.18.5.3 Check if the drive end of the water
pump is connected securely;
1) Performance Data
3.18.5.4 Check the water pump for blockage
Basic
Performance Value Unit
3.19 Charcoal Canister Solenoid Valve
Parameter
Diagram and Pin
Rated power 24 W
Rated voltage 12 V
Working current 2 A
2) Parameter Limit
157
BYD AUTO BYD Suri Maintenance & Repair Manual
158
BYD AUTO BYD Suri Maintenance & Repair Manual
159
BYD AUTO BYD Suri Maintenance & Repair Manual
Operation theory: l
Check the vacuum pipe for leakage 3.20.5.2.1 Replace the vacuum pipe if it is
after replacement; Check the brake aging or leaking
operation after the engine is started and
operated for 5 minutes. 3.20.5.2.2 Replace the vacuum pump after it
is damaged.
3.20.5 Trouble Symptoms and Judgment
Method
160
BYD AUTO BYD Suri Maintenance & Repair Manual
161
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The signal circuit of OCV solenoid (Camshaft control valve) is open. Measure the
resistance between the ECU and pin No. 2 of control valve signal line with the
multimeter.
Service tips:
a The camshaft control valve body is faulty or blocked. Check the camshaft control valve.
b The camshaft valve timing is incorrect. Check if the valve timing is correct and if the
timing chain is "jumping teeth".
Service tips:
a The circuit between pin No. 2 of front oxygen sensor and ECU pin is open. Measure the
resistance of circuit between the ECU and pin No. 2 of front oxygen sensor with the
multimeter.
b The circuit between pin No. 1 of front oxygen sensor and main relay is open. Measure
the resistance of circuit between the pin No. 1 of front oxygen sensor and main relay with
the multimeter.
c The internal circuit between pin No. 1 and 2 of front oxygen sensor is open. Measure the
resistance between the pin No. 1 and 2 of front oxygen sensor with the multimeter.
162
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The circuit between the front oxygen sensor and ECU pin is short to ground. Measure the
resistance of circuit between the ECU pin and ground with the multimeter.
Service tips:
a The circuit of ECU pin is short to the circuit of pin No. 1 of upstream oxygen sensor.
Measure the resistance of circuit between the ECU pin and pin No. 1 of upstream oxygen
sensor.
b The circuit of ECU pin is short to other power supply circuits. Measure the voltage of pin
No. 2 of oxygen sensor connector with the multimeter.
Service tips:
a The circuit between the bypass valve signal circuit and ECU pin is open. Measure the
resistance between the ECU pin and bypass valve signal circuit with the multimeter.
Service tips:
a The bypass valve signal circuit is short to ground. Measure the resistance between the
ECU pin and ground with the multimeter.
163
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The bypass valve signal circuit is short to the power supply. Measure the voltage of ECU
pin with the multimeter.
Service tips:
a The circuit between the ECU pin and pin No. 2 of rear oxygen sensor is open. Measure
the resistance of circuit between the ECU and pin No. 2 of rear oxygen sensor.
b The circuit between pin No. 1 of rear oxygen sensor and main relay is open. Measure the
resistance of circuit between the pin No. 1 of rear oxygen sensor and main relay.
c The circuit between pin No. 1 and 2 of rear oxygen sensor is open. Measure the
resistance between the pin No. 1 and 2 of rear oxygen sensor.
Service tips:
a The circuit between the pin No. 2 of rear oxygen sensor and ECU pin is short to ground.
Measure the resistance between the ECU pin and ground with the multimeter.
Service tips:
a The circuit of ECU pin is short to the circuit of pin No. 1 of rear oxygen sensor. Measure
the resistance of circuit between the ECU pin and pin No. 1 of rear oxygen sensor with
164
BYD AUTO BYD Suri Maintenance & Repair Manual
the multimeter.
b The circuit of ECU pin is short to other power supply circuits. Check if the voltage of ECU
pin is normal with the multimeter.
Service tips:
a The circuit between the control valve signal circuit and ECU pin is open. Measure the
resistance between the ECU pin and pin No. 2 of fuel pressure control valve with the
multimeter.
b The circuit between the control valve signal circuit and ECU is short to ground. Measure
the resistance between the ECU pin and ground with the multimeter.
c The circuit between the control valve signal circuit and ECU is short to the power supply.
Measure the voltage of ECU pin with the multimeter.
Service tips:
a The sensor signal circuit connected to the ECU pin is short to ground. Measure the
resistance between the sensor signal circuit of ECU pin and ground with the multimeter.
Service tips:
a The sensor signal circuit connected to the ECU pin is short to the power supply. Check if
the voltage of the sensor signal circuit of ECU pin is normal with the multimeter.
165
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
The malfunctions have been confirmed. The following malfunctions may exist
Service tips:
a The sensor signal circuit connected to the ECU pin is short to ground. Measure the
resistance between the sensor signal circuit of ECU pin and ground with the multimeter.
Service tips:
a The sensor signal circuit connected to the ECU pin is short to the power supply. Check if
the voltage of the sensor signal circuit of ECU pin is normal with the multimeter.
Service tips:
166
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The sensor signal circuit connected to the ECU pin is short to ground. Measure the
resistance between the sensor signal circuit of ECU pin and ground with the multimeter.
DTC: P0113 Intake temperature sensor circuit voltage is high or open circuit
Service tips:
a The sensor signal circuit connected to the ECU pin is short to the power supply. Check if
the voltage of the sensor signal circuit of ECU pin is normal with the multimeter.
Service tips:
Service tips:
a The sensor signal circuit connected to the ECU pin is short to ground. Measure the
resistance between the sensor signal circuit of ECU pin and ground with the multimeter.
Service tips:
a The sensor signal circuit connected to the ECU pin is short to the power supply. Check if
167
BYD AUTO BYD Suri Maintenance & Repair Manual
the voltage of the sensor signal circuit of ECU pin is normal with the multimeter.
Service tips:
a The electronic throttle valve position sensor is faulty and the electronic throttle valve
assembly should be replaced.
a The sensor 1 signal circuit connected to the ECU pin is short to ground. Measure the
resistance between the sensor 1 signal circuit of ECU pin and ground with the multimeter.
Service tips:
The sensor 1 signal circuit connected to the ECU pin is short to the power supply. Check if the
voltage of the sensor 1 signal circuit of ECU pin is normal with the multimeter.
Service tips:
a The sensor signal circuit connected to the ECU pin is short to ground. Measure the
resistance between the sensor signal circuit of ECU pin and ground with the multimeter.
168
BYD AUTO BYD Suri Maintenance & Repair Manual
Trouble cause description: The ECU measures the voltage of upstream oxygen sensor circuit
after the engine is started. When the signal voltage is higher than 1.5 V for a long time, the front
oxygen sensor circuit voltage is high.
Service tips:
a The signal circuit connected to the ECU pin is short to the pin No. 1 of oxygen sensor.
Measure the resistance between the signal circuit connected to the ECU pin and Pin No.
1 of the oxygen sensor connector with the multimeter.
b The signal circuit connected to the ECU pin is short to other power supply circuits.
Measure the voltage of signal circuit connected to the ECU pin.
Trouble cause description: The air-fuel ratio of fuel-air mixture switches between the rich and lean
states under normal conditions. Accordingly, the amplitude of oxygen sensor signal will jump
constantly. When the oxygen sensor is aging, the sensitivity to perceive the mixture decreases
and the signal fluctuation period will become long. The ECU will calculate the average period of
signal according to the relevant algorithm. If the period is longer than the preset threshold, the
sensor is judged to be aging.
Service tips:
Trouble cause description: The ECU measures the voltage of upstream oxygen sensor circuit
after the engine is started. When the signal voltage always changes between 0.4 and 0.6 V, the
system judges the front oxygen sensor circuit is open.
Service tips:
a The circuit between the oxygen sensor and ECU pin is open. Measure the resistance of
169
BYD AUTO BYD Suri Maintenance & Repair Manual
circuit between the ECU connector and pin No. 4 of oxygen sensor connector with the
multimeter.
b The oxygen sensor connector is not well connected. Check the connector.
Instructions for diagnosing oxygen sensor heater: The system confirms if the heater output is
correct by measuring the resistance of sensor heater. The heated sensor may be damaged by
the condensate under some unfavorable conditions, especially during the cold starting.
Therefore, the main sensors of the catalytic converter are directly heated after the engine is
started. The secondary sensors of the catalytic converter will be heated only when the theoretical
temperature in the catalytic converter is higher than 308°C.
Service tips:
a The upstream oxygen sensor heater malfunctions. Replace the oxygen sensor.
Service tips:
a The signal circuit connected to the ECU pin is short to ground. Measure the resistance
between the signal circuit connected to the ECU pin and the ground with the multimeter.
Trouble cause description: The ECU measures the voltage of downstream oxygen sensor circuit
after the engine is started. When the signal voltage is higher than 1.5 V for a long time, the rear
oxygen sensor circuit voltage is high.
Service tips:
a The signal circuit connected to the ECU pin is short to the pin No. 1 of the oxygen
sensor. Measure the resistance between the signal circuit connected to the ECU pin and
Pin No. 1 of the oxygen sensor connector with the multimeter.
b The signal circuit connected to the ECU pin is short to other power supply circuits.
170
BYD AUTO BYD Suri Maintenance & Repair Manual
Measure the voltage of signal circuit connected to the ECU pin with the multimeter.
Trouble cause description: The ECU measures the voltage of downstream oxygen sensor circuit
after the engine is started. When the signal voltage always changes between 0.4 and 0.6 V, the
system judges the rear oxygen sensor circuit is open.
Service tips:
a The circuit between the oxygen sensor and ECU pin is open. Measure the resistance of
circuit between the ECU connector and pin No. 4 of oxygen sensor connector with the
multimeter.
b Poor contact occurs at the relevant Pins of ECU or oxygen sensor connectors. Check the
connectors.
Instructions for diagnosing oxygen sensor heater: The system confirms if the heater output is
correct by measuring the resistance of sensor heater. The heated sensor may be damaged by
the condensate under some unfavorable conditions, especially during the cold starting.
Therefore, the main sensors of the catalytic converter are directly heated after the engine is
started. The secondary sensors of the catalytic converter will be heated only when the theoretical
temperature in the catalytic converter is higher than 308°C.
Service tips:
a The downstream oxygen sensor heater malfunctions. Replace the oxygen sensor.
Service tips:
171
BYD AUTO BYD Suri Maintenance & Repair Manual
a The signal circuit connected to the ECU pin is short to ground. Measure the resistance
between the signal circuit connected to the ECU pin and the ground with the multimeter.
Service tips:
a The sensor signal circuit connected to the ECU pin is short to the power supply. Measure
the voltage of the signal circuit connected to the ECU pin with the multimeter.
Service tips:
a The circuit between the pin No. 2 of injector connector and ECU pin is open. Measure the
resistance of circuit between the ECU connector and pin No. 2 of injector connector with
the multimeter.
b Poor contact occurs at the relevant Pins of ECU or injector connectors. Check the
connectors.
172
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The electronic throttle valve position sensor is faulty and the electronic throttle valve
assembly should be replaced.
Service tips:
a The sensor 2 signal circuit connected to the ECU pin is short to ground. Measure the
resistance between the sensor 2 signal circuit of ECU pin and ground with the
multimeter.
Service tips:
a The sensor 2 signal circuit connected to the ECU pin is short to the power supply. Check
if the voltage of the sensor 2 signal circuit of ECU pin is normal with the multimeter.
Service tips:
Service tips:
a The sensor 1 signal circuit connected to the ECU pin is short to ground. Measure the
173
BYD AUTO BYD Suri Maintenance & Repair Manual
resistance between the sensor 1 signal circuit of ECU pin and ground with the
multimeter.
Service tips:
a The sensor 1 signal circuit connected to the ECU pin is short to the power supply.
Measure the voltage of the signal circuit connected to the ECU pin with the multimeter.
Service tips:
a The sensing element in the boost pressure sensor leaks, the pressure sensor is
damaged, the installation position of pressure sensor leaks and the characteristic of
pressure sensor offsets.
Service tips:
a The sensor signal circuit connected to the ECU pin is short to ground. Measure the
resistance between the sensor signal circuit of ECU pin and ground with the multimeter.
Service tips:
a The sensor signal circuit connected to the ECU pin is short to the power supply. Measure
the voltage of the signal circuit connected to the ECU pin with the multimeter.
174
BYD AUTO BYD Suri Maintenance & Repair Manual
DTC: P0261 The voltage at the low side of No. 1 injection nozzle is low
DTC: P0264 The voltage at the low side of No. 2 injection nozzle is low
DTC: P0267 The voltage at the low side of No. 3 injection nozzle is low
DTC: P0270 The voltage at the low side of No. 4 injection nozzle is low
P0264 The voltage at the low side of No. 2 injection nozzle is low
P0267 The voltage at the low side of No. 3 injection nozzle is low
P0270 The voltage at the low side of No. 4 injection nozzle is low
Service tips:
a The low side circuit connected to the ECU pin is short to ground. Measure the resistance
between the circuit connected to the ECU pin and the ground with the multimeter.
DTC: P0262 The voltage at the low side of No. 1 injection nozzle is high
DTC: P0265 The voltage at low side of No. 2 injection nozzle is high
DTC: P0268 The voltage at the low side of No. 3 injection nozzle is high
DTC: P0271 The voltage at the low side of No. 4 injection nozzle is high
P0262 The voltage at the low side of No. 1 injection nozzle is high
P0265 The voltage at the low side of No. 2 injection nozzle is high
P0268 The voltage at the low side of No. 3 injection nozzle is high
P0271 The voltage at the low side of No. 4 injection nozzle is high
Service tips:
a The low side circuit connected to the ECU pin is short to the power supply. Measure the
voltage of the circuit connected to the relevant ECU pin with the multimeter.
175
BYD AUTO BYD Suri Maintenance & Repair Manual
DTC: P0263 Short circuit between the low and high side circuits of No. 1 injection nozzle
DTC: P0266 Short circuit between the low and high side circuits of No. 2 injection nozzle
DTC: P0269 Short circuit between the low and high side circuits of No. 3 injection nozzle
DTC: P0272 Short circuit between the low and high side circuits of No. 4 injection nozzle
P0263 Short circuit between the low and high side circuits of No. 1 injection nozzle
P0266 Short circuit between the low and high side circuits of No. 2 injection nozzle
P0269 Short circuit between the low and high side circuits of No. 3 injection nozzle
P0272 Short circuit between the low and high side circuits of No. 4 injection nozzle
Service tips:
a There is short circuit between Pins No. 1 and 2 of the injection nozzle. Measure the
resistance between Pins No. 1 and 2 of the injector with the multimeter.
Trouble cause description: The misfire refers to when the engine cannot release the ignition
energy effectively in the cylinder due to the ignition system (ignition failure). The injection quantity
deviation (concentration deviation of mixture), low cylinder compression pressure and other
reasons will cause the combustion in the cylinder to interrupt or disable the fuel combustion. The
misfire may cause the emissions to exceed the standards or damage the catalytic converter due
to overheat. For the OBD diagnostic test, the system will judge the misfire occurance when the
misfire times exceed the set value.
176
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
c The ignition system malfunctions. Check and replace the sparkplug and ignition coil on
the misfired cylinder, and check if the ignition coil circuit is open.
Trouble cause description: The ECU monitors the signals from the crankshaft position sensor and
phase sensor after the engine is started. If the signals from the phase sensor can be received
continuously, but the signals from the crankshaft position sensor cannot be received, the system
judges no signal is output from the crankshaft sensor circuit.
Service tips:
a The circuit between the crankshaft position sensor and ECU is open. Measure the
resistance of circuit between the crankshaft position sensor and ECU with the multimeter.
b There is open circuit inside the crankshaft position sensor. Measure the internal
resistance of crankshaft position sensor with the multimeter.
c Poor contact occurs at the Pins of ECU or sensor connectors. Check the connectors.
Service tips:
177
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The circuit between the camshaft sensor and ECU is open. Measure the resistance of
circuit between the camshaft sensor and ECU with the multimeter.
b There is open circuit inside the camshaft sensor. Measure the internal resistance of
camshaft sensor with the multimeter.
Trouble cause description: The camshaft sensor (phase sensor) uses the Hall elements to induce
a trigger wheel which rotates with the camshaft so as to monitor the camshaft position. The phase
signals received by the ECU should alternate regularly between the high level and low level. If the
ECU only detects the slow alternation between the high level and low level or irregular alternation,
the camshaft sensor signals are regarded as irrational.
Service tips:
Service tips:
178
BYD AUTO BYD Suri Maintenance & Repair Manual
a The circuit between the pin No. 2 of ignition coil connector and ECU pin is open.
Measure the resistance of circuit between the ECU connector and pin No. 2 of ignition
coil connector with the multimeter.
b The circuit between the ignition coil and main relay is open. Measure the resistance of
circuit between pin No. 3 of the ignition coil connector and main relay with the multimeter.
c Poor contact occurs at the relevant Pins of ECU or ignition coil connectors. Check the
connectors.
Service tips:
a The circuit between the pin No. 2 of charcoal canister solenoid valve connector and ECU
pin is open. Measure the resistance of circuit between the ECU connector and pin No. 2
of charcoal canister solenoid valve connector with the multimeter.
b The circuit between the charcoal canister solenoid valve and main relay is open.
Measure the resistance of circuit between pin No. 1 of the charcoal canister solenoid
valve connector and main relay with the multimeter.
c Poor contact occurs at the relevant Pins of ECU or charcoal canister solenoid valve
connectors. Check the connectors.
d The circuit between pin No. 1 and 2 of the charcoal canister solenoid valve is open.
Measure the resistance of circuit between pin No. 1 and 2 of the charcoal canister
solenoid valve connector with the multimeter.
DTC: P0458 Charcoal canister solenoid valve control circuit voltage is low
Service tips:
a The circuit between pin No. 2 of the charcoal canister solenoid valve connector and ECU
is short to ground. Measure the resistance between the circuit connected to the ECU pin
and the ground with the multimeter.
DTC: P0459 Charcoal canister solenoid valve control circuit voltage is high
179
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The circuit connected to the ECU is short to the circuit of pin No. 1 of charcoal canister
solenoid valve. Measure the resistance of circuit between the ECU pin and pin No. 1 of
charcoal canister solenoid valve with the multimeter.
b The circuit of ECU pin is short to other power supply circuits. Check if the voltage of ECU
pin is normal with the multimeter.
Service tips:
a The circuit between the pin No. 2 of boost pressure limiting solenoid connector and ECU
pin is open. Measure the resistance of circuit between the ECU connector and pin No. 2
of boost pressure limiting solenoid connector with the multimeter.
b The circuit between the boost pressure limiting solenoid and main relay is open. Measure
the resistance of circuit between pin No. 1 of the boost pressure limiting solenoid
connector and main relay with the multimeter.
c Poor contact occurs at the relevant Pins of ECU or boost pressure limiting solenoid
connectors. Check the connectors.
d The circuit between pin No. 1 and 2 of the boost pressure limiting solenoid is open.
Measure the resistance of circuit between pin No. 1 and 2 of the boost pressure limiting
solenoid connector with the multimeter.
DTC: P0477 Boost pressure limiting solenoid control circuit voltage is low
Service tips:
a The circuit between pin No. 2 of the boost pressure limiting solenoid and ECU is short to
ground. Measure the resistance between the circuit connected to the ECU pin and the
ground with the multimeter.
DTC: P0478 Boost pressure limiting solenoid control circuit voltage is high
180
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The circuit connected to the ECU is short to the circuit of pin No. 1 of boost pressure
limiting solenoid. Measure the resistance of circuit between the ECU pin and pin No. 1 of
boost pressure limiting solenoid with the multimeter.
b The circuit of ECU pin is short to other power supply circuits. Check if the voltage of ECU
pin is normal with the multimeter.
Service tips:
a The circuit between the stepless fan and ECU pin is open. Measure the resistance of
circuit between the ECU connector and stepless fan with the multimeter.
b Poor contact occurs at the relevant Pins of ECU or boost pressure limiting solenoid
connectors. Check the connectors.
a The generator cannot generate electricity due to damage or the battery leaks.
a The voltage is high as the generator regulator has been damaged so that it cannot
control the generated energy.
181
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The circuit between the generator and ECU is faulty (open circuit or low voltage). Check
the circuit.
Service tips:
a The circuit between the fuel pump relay control circuit connected to the ECU and fuel
pump relay is open. Measure the resistance of the fuel pump relay control circuit
connected to the ECU with the multimeter.
b The circuit between the relay and main relay is open. Measure the resistance of circuit
between the relay and main relay with the multimeter.
c The solenoid coil of relay is open. Measure the internal resistance of relay with the
multimeter.
a The circuit between the fuel pump relay control circuit connected to the ECU and fuel
pump relay is short to ground. Measure the resistance of circuit between the fuel pump
relay control circuit connected to the ECU and the ground with the multimeter.
a The circuit between the fuel pump relay control circuit connected to the ECU and fuel
pump relay is short to the power supply. Measure the voltage of the fuel pump relay
control circuit connected to the ECU with the multimeter.
182
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The intelligent key authentication fails due to the internal malfunction in the intelligent
key. Check the intelligent key.
Service tips:
a The air conditioning permission control circuit connected to the ECU is open. Measure
the resistance of the air conditioning permission control circuit connected to the ECU with
the multimeter.
a The air conditioning permission control circuit connected to the ECU is short to ground.
Measure the resistance of the circuit between the air conditioning permission control
circuit connected to the ECU and the ground with the multimeter.
a The air conditioning permission control circuit connected to the ECU is short to the power
supply. Measure the voltage of the air conditioning permission control circuit connected
to the ECU with the multimeter.
183
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The stepless fan control line connected to the ECU is short to ground. Measure the
resistance of the circuit between the stepless fan control line connected to the ECU and
the ground with the multimeter.
a The stepless fan control line connected to the ECU is short to the power supply. Measure
the voltage of the stepless fan control line connected to the ECU with the multimeter.
Service tips:
a The stepless fan is locked. Check if there is any foreign object blocking the fan.
c There is short circuit in the motor. Check the internal resistance of the motor.
Service tips:
184
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
Trouble cause description: As the intercooler system cannot operate normally, the intake air
temperature is very high after passing the intercooler. At this time, the intake temperature of
intake manifold is close to the intake temperature after boosting so that the engine performance is
reduced. When the ECU detects the difference between both temperatures is small, the
intercooler system is regarded as faulty.
Service tips:
a The coolant flow is blocked by the foreign objects or dirt inside the intercooler.
b The coolant cannot be circulated normally inside the intercooler due to the thermostat
failure in the intercooler cooling system. Check the thermostat.
185
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The circuit between the camshaft control valve control signal pin and ECU is short to
ground. Measure the resistance between the circuit connected to the ECU pin and the
ground with the multimeter.
Service tips:
a The circuit between pin No. 2 of camshaft control valve and ECU is short to the circuit of
pin No. 1 of camshaft control valve. Measure the resistance of circuit between the ECU
pin and pin No. 1 of camshaft control valve with the multimeter.
b The circuit between pin No. 2 of camshaft control valve and ECU is short to other power
supply circuits. Check if the voltage of pin No. 2 of camshaft control valve is normal with
the multimeter.
a The circuit between the throttle motor control circuit and ECU pin is open. Measure the
resistance between the ECU connector and throttle motor control circuit with the
multimeter.
b Poor contact occurs at the relevant Pins of ECU or throttle motor control circuit
connectors. Check the connectors.
Service tips:
a The circuit between the throttle motor control circuit and ECU is short to ground. Measure
186
BYD AUTO BYD Suri Maintenance & Repair Manual
the resistance between the circuit connected to the ECU pin and the ground with the
multimeter.
Service tips:
1) The throttle motor control circuit is short to the power supply. Measure the voltage of the
circuit connected to the ECU pin with the multimeter.
Service tips:
b There is short circuit between the positive and negative terminals of throttle motor
control. Measure the resistance between the positive and negative terminals of throttle motor
control with the multimeter.
c The voltage of throttle motor control positive terminal is too high. Measure the voltage
between the positive and negative terminals of throttle motor control with the multimeter.
187
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
Service tips:
a The circuit between the pedal position sensor 2 signal circuit and the ECU is short to
ground. Measure the resistance between the circuit connected to the ECU pin and the
ground with the multimeter.
a The pedal position sensor 2 signal circuit is short to the power supply. Measure the
voltage of the circuit connected to the ECU pin with the multimeter.
DTC: P2147 The voltage at the high side of No. 1 injection nozzle is low
DTC: P2150 The voltage at the high side of No. 2 injection nozzle is low
a The high side circuit connected to the ECU pin is short to ground. Measure the
resistance between the circuit connected to the ECU pin and the ground with the
multimeter.
DTC: P2148 The voltage at high side of No. 1 injection nozzle is high
DTC: P2151 The voltage at high side of No. 2 injection nozzle is high
188
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The high side circuit connected to the ECU pin is short to the power supply. Measure the
voltage of the circuit connected to the ECU pin with the multimeter.
DTC: P2184 The circuit voltage of coolant temperature sensor at radiator outlet is low
Service tips:
a The circuit between the signal circuit of the coolant temperature sensor at radiator outlet
is short to the ground. Measure the resistance between the circuit connected to the ECU
pin and the ground with the multimeter.
DTC: P2185 The circuit voltage of the coolant temperature sensor at radiator outlet is high
Service tips:
a The circuit between the signal circuit of the coolant temperature sensor at the radiator
outlet is short to the power supply. Measure the voltage of the circuit connected to the
ECU pin with the multimeter.
a The atmospheric pressure sensor integrated in the ECU is faulty. Replace the ECU.
189
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The atmospheric pressure sensor circuit integrated in the ECU is faulty. Replace the
ECU.
Service tips:
a The circuit connected to the ECU pin is short to ground. Measure the resistance between
the circuit connected to the ECU pin and the ground with the multimeter.
190
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a The circuit connected to the ECU pin is short to the power supply. Measure the voltage of
the circuit connected to the ECU pin with the multimeter.
Service tips:
a The cooling water pump signal circuit connected to the ECU is open. Measure the
resistance between the ECU pin and cooling water pump signal circuit with the multimeter.
Service tips:
a The cooling water pump signal circuit connected to the ECU is short to the ground.
Measure the resistance between the circuit connected to the ECU pin and the ground
with the multimeter.
a The cooling water pump signal circuit connected to the ECU is short to the power supply.
Measure the voltage of the circuit connected to the ECU pin with the multimeter.
DTC: U0164 Communication failure between ECM and air conditioning controller
191
BYD AUTO BYD Suri Maintenance & Repair Manual
Service tips:
a Check if the relevant systems are faulty and if the communication lines are short or open.
Perform preliminary check first before 5.3.6 Check the booster appearance for any
troubleshooting in accordance with the scratch; Check if the turbine shaft
engine trouble symptoms: components can rotate freely; Check
the impeller for any damaged due to
5.1 Make sure the engine malfunction impact;
indicator operates normally;
5.3.7 Check the turbine housing and related
5.2 Check that no diagnostic information is pipe connectors for any exhaust gas
recorded with a diagnostic tester; leakage and check the intake system
for any leakage;
5.3 Make sure the trouble symptom
complained by the car owner exists, 5.3.8 Check if the ground point of wire
and confirm the conditions when the harness is clean and secure;
trouble occurs.
Then check the appearance: 5.3.9 Check the connectors of the sensor
and actuator for looseness or poor
5.3.1 Check the fuel pipe line for any contact.
leakage;
Important Tips: If the above symptoms
5.3.2 Check if the vacuum line is broken, occur, perform repair for the trouble
kinked or correctly connected; symptoms, otherwise the subsequent
troubleshooting and repair will be
5.3.3 Check if the intake pipe line is blocked, affected.
leaked, flattened or damaged;
Diagnostic tips:
5.3.4 Check the appearance of ignition coil
for any bulges and scorification and 5.3.9.1 Make sure no malfunction is
check if the ignition sequence is recorded for the engine;
correct;
5.3.9.2 Make sure the trouble symptom
5.3.5 Check the cooling system pipe line for exists;
any blockage or leakage;
5.3.9.3 After the above check, no abnormal
192
BYD AUTO BYD Suri Maintenance & Repair Manual
condition is found;
5.3.9.5.6 The engine can be started normally,
5.3.9.4 Do not ignore the effect of car but the idle speed is unstable at any
maintenance, cylinder pressure, time.
ignition timing and fuel condition
imposed on the system during 5.3.9.5.7 The engine can be started normally,
maintenance; but the idle speed is unstable during
warming up.
5.3.9.5 Perform test after the ECU is
replaced. 5.3.9.5.8 The engine can be started normally,
but the idle speed is unstable after the
If the trouble symptom can be warming up ends.
eliminated, the trouble area is ECU. If
the trouble symptom still exists, install 5.3.9.5.9 The engine can be started normally,
the original ECU. Repeat the process but the idle speed is unstable or the
and perform maintenance again. engine misfires under some load (for
example, the air conditioning is on).
The repair manual lists the following 14
common malfunctions, and general 5.3.9.5.10 The engine can be started
diagnosis flows are provided only for normally, but the idle speed is too high.
reference:
5.3.9.5.11 The engine speed does not
5.3.9.5.1 The engine does not rotate or increase or the engine misfires during
rotates slowly when starting. acceleration.
5.3.9.5.2 The engine can rotate, but cannot 5.3.9.5.12 The response is slow during
be started successfully. acceleration.
5.3.9.5.3 Hot starting is difficult. 5.3.9.5.13 The engine power is low and
performance is poor during
acceleration.
5.3.9.5.4 Cold starting is difficult.
5.3.9.5.14 The vehicle pauses from time to
5.3.9.5.5 The engine is difficult to start at time and shakes during acceleration or
any time, but the engine speed is driving at constant speed.
normal.
193
BYD AUTO BYD Suri Maintenance & Repair Manual
5.4 The engine does not rotate or rotates slowly when starting.
General trouble area: 1. Battery; 2. Cranking motor; 3. Wire harness or ignition switch; 4.
Fuses or relays in front compartment wiring box and instrument wiring box; 5. Engine
mechanics.
Test
No. Operation Steps Follow-up Step
Result
Check if the voltage between two terminals of the Yes Next step
1 battery is about 8-12 V with the multimeter when Replace the
the engine is started. No
battery
Keep the ignition switch in "Start" position, and Yes Next step
check if the voltage at the positive terminal of
2 Repair or replace
cranking motor is more than 8 V with the No
multimeter. wire harness
Repair or replace
Remove the cranking motor and check its Yes the cranking
3 operation condition. Check if the open circuit motor
exists or it is stuck due to poor lubrication.
No Next step
Remove the positive and negative terminals of the Replace the
Yes
battery and check the fuses in the front relevant fuses
compartment wiring box (F1/5, F1/9, F1/18,
F1/22-1, F1/23-2) and the fuses in the instrument
4 wiring box (F2/3, F2/14, F2/22, F2/23, F2/24,
F2/25, F2/26) for continuity with the multimeter. No Next step
Confirm if the fuses have been blown. (For details
on the wiring box fuses and relay, refer to the
attachment 7.4)
When the engine is turned on, check the relays in Repair or replace
the instrument wiring box (K2-1, K2-4, K2-6) for Yes the relevant
5 actuation; When the engine is started, check the relays
relay in the instrument wiring box (K2-7) for
actuation. No Next step
If the trouble only occurs in winter, check if the Use the proper
resistance of cranking motor is too high due to Yes
6 lubricant
improper selection of engine lubricant and gearbox
oil. No Next step
Overhaul the
Yes internal engine
Check if the cranking motor does not rotate or resistance
7 rotates slowly due to the high internal mechanical
resistance of the engine. Repeat the above
No
procedures
194
BYD AUTO BYD Suri Maintenance & Repair Manual
General trouble area: 1. Empty fuel tank; 2. High pressure fuel pump; 3. Low pressure fuel
pump; 4. Speed sensor; 5. Ignition coil; 6. Fuses or relays in front compartment wiring box
and instrument wiring box; 7. Engine mechanics.
195
BYD AUTO BYD Suri Maintenance & Repair Manual
General trouble area: 1. Fuel with water; 2. High pressure fuel pump; 3. Low pressure fuel
pump; 4. Coolant temperature sensor; 5. Ignition coil.
196
BYD AUTO BYD Suri Maintenance & Repair Manual
General trouble area: 1. Fuel with water; 2. High pressure fuel pump; 3. Low pressure fuel
pump; 4. Coolant temperature sensor; 5. Injector; 6. Ignition coil; 7. Electronic throttle valve;
8. Engine mechanics.
5.8 The engine is difficult to start at any time, but the engine speed is normal.
General trouble area: 1. Fuel with water; 2. High pressure fuel pump; 3. Low pressure fuel
pump; 4. Coolant temperature sensor; 5. Injector; 6. Ignition coil; 7. Electronic throttle valve
assembly; 8. Inlet passage; 9. Ignition timing; 10. Sparkplug; 11. Engine mechanics.
197
BYD AUTO BYD Suri Maintenance & Repair Manual
Follow-up
No. Operation Steps Test Result
Step
Overhaul the
Check the air filter for blockage and check the inlet Yes intake
1 system
passage for air leakage.
No Next step
198
BYD AUTO BYD Suri Maintenance & Repair Manual
5.9 The engine can be started normally, but the idle speed is unstable at any time.
General trouble area: 1. Fuel with water; 2. Injector; 3. Sparkplug; 4. Electronic throttle body
assembly; 5. Inlet passage; 6. Ignition timing; 7. Sparkplug; 8. Engine mechanics.
Follow-up
No. Operation Steps Test Result
Step
Overhaul the
Check the air filter for blockage and check the inlet Yes intake
1 system
passage for air leakage.
No Next step
Yes Next step
Check if the type and gap of sparkplug in each
2 Adjust or
cylinder are as specified. No
replace
Check the electronic throttle body for carbon Yes Clean
3
deposit. No Next step
Replace the
Remove the injector, and check the injector for any
Yes faulty
4 leakage, blockage or poor flow with the special
injector
washing analyzer.
No Next step
Replace the
Check the fuel condition to see if the trouble is Yes
5 fuel
caused immediately after the fuel is filled.
No Next step
Repair the
mechanical
Check if large pressure difference exists among Yes
6 malfunction
each cylinder of the engine.
of engine
No Next step
Yes Next step
Check if the ignition sequence and ignition timing of Overhaul the
7
engine are as specified. No ignition
timing
Connect the ECI system adapter, turn on the Diagnostic
Yes
ignition switch and check if the power supply of pin tips
8 No. 113, 112, 3, 119 and 120 is normal; Check if Overhaul
the pin No. 51, 58, 2, 100, 103, 104 and 108 are No related
grounded normally. circuits
199
BYD AUTO BYD Suri Maintenance & Repair Manual
5.10 The engine can be started normally, but the idle speed is unstable during warming up.
General trouble area: 1. Fuel with water; 2. Coolant temperature sensor; 3. Sparkplug; 4.
Electronic throttle valve; 5. Inlet passage; 6. Engine mechanics.
200
BYD AUTO BYD Suri Maintenance & Repair Manual
5.11 The engine can be started normally, but the idle speed is unstable after the warming up
ends.
General trouble area: 1. Fuel with water; 2. Coolant temperature sensor; 3. Sparkplug; 4.
Electronic throttle valve; 5. Inlet passage; 8. Engine mechanics.
Follow-up
No. Operation Steps Test Result
Step
Overhaul the
Check the air filter for blockage and check the inlet Yes intake
1 system
passage for air leakage.
No Next step
Yes Next step
Check if the type and gap of sparkplug in each
2 Adjust or
cylinder are as specified. No
replace
Clean
Yes related
3 Check the throttle body for carbon deposit.
components
No Next step
Overhaul the
Remove the connector of coolant temperature circuit or
Yes
4 sensor, start the engine and check if the engine idle replace the
speed is unstable during warming up. sensor
No Next step
Replace the
Remove the injector, and check the injector for any
Yes faulty
5 leakage, blockage or poor flow with the special
injector
washing analyzer.
No Next step
Replace the
Check the fuel condition to see if the trouble is Yes
6 fuel
caused immediately after the fuel is filled.
No Next step
Repair the
mechanical
Check if large pressure difference exists among Yes
7 malfunction
each cylinder of the engine.
of engine
No Next step
Connect the ECI system adapter, turn on the Diagnostic
Yes
ignition switch and check if the power supply of pin tips
8 No. 113, 112, 3, 119 and 120 is normal; Check if Overhaul
the pin No. 51, 58, 2, 100, 103, 104 and 108 are No related
grounded normally. circuits
201
BYD AUTO BYD Suri Maintenance & Repair Manual
5.12 The engine can be started normally, but the idle speed is unstable or the engine misfires
under some load (for example, the air conditioning is on).
General trouble area: 1. Air conditioning system; 2. Electronic throttle valve; 3. Injector.
Follow-up
No. Operation Steps Test Result
Step
Clean
Check the electronic throttle body for carbon Yes related
1
deposit. components
No Next step
Check if the engine output power increases with the
Yes Go to step 4
air conditioning on, which is to observe the change
2 of ignition advance angle, injection pulse width and
intake air volume with the diagnostic tester for No Next step
electronically controlled injection system.
Yes Next step
Connect the ECI system adapter and disconnect
Overhaul the
the wire connected to pin No. 54 of electronic
3 air
control unit. Check the wire harness end for high No
conditioning
level signal with the air conditioning on.
system
Yes Next step
Check if the pressure of air conditioning system, Overhaul the
4 magnetic clutch of compressor and air conditioning air
No
compression pump are normal. conditioning
system
Replace the
Remove the injector, and check the injector for any
Yes faulty
5 leakage, blockage or poor flow with the special
injector
washing analyzer.
No Next step
Connect the ECI system adapter, turn on the Diagnostic
Yes
ignition switch and check if the power supply of pin tips
6 No. 113, 112, 3, 119 and 120 is normal; Check if Overhaul
the pin No. 51, 58, 2, 100, 103, 104 and 108 are No related
grounded normally. circuits
202
BYD AUTO BYD Suri Maintenance & Repair Manual
5.13 The engine can be started normally, but the idle speed is too high.
General trouble area: 1. Electronic throttle body assembly; 2. Vacuum pipe: 3. Coolant
temperature sensor; 4. Ignition timing.
Follow-up
No. Operation Steps Test Result
Step
Replace the
Check if the electronic accelerator pedal signal is Yes accelerator
1
output normally. pedal
No Next step
Overhaul the
Check the intake system and connected vacuum Yes intake
2 system
pipe line for air leakage.
No Next step
Clean
Check the electronic throttle body for carbon Yes related
3
deposit. components
No Next step
Overhaul the
Remove the connector of coolant temperature circuit or
Yes
4 sensor, start the engine and check if the idle speed replace the
of engine is too high. sensor
No Next step
Yes Next step
Overhaul the
5 Check if the ignition timing of engine is as specified.
No ignition
timing
Connect the ECI system adapter, turn on the Diagnostic
Yes
ignition switch and check if the power supply of pin tips
6 No. 113, 112, 3, 119 and 120 is normal; Check if Overhaul
the pin No. 51, 58, 2, 100, 103, 104 and 108 are No related
grounded normally. circuits
203
BYD AUTO BYD Suri Maintenance & Repair Manual
5.14 The engine speed does not increase or the engine misfires during acceleration.
General trouble area: 1. Fuel with water; 2. Intake pressure sensor; 3. Sparkplug; 4.
Electronic throttle body assembly; 5. Inlet passage; 6. Idle speed regulator; 7. Injector; 8.
Ignition timing; 9. Exhaust pipe; 10. Turbocharger.
Follow-up
No. Operation Steps Test Result
Step
Overhaul the
Yes intake
1 Check the air filter for any blockage. system
No Next step
204
BYD AUTO BYD Suri Maintenance & Repair Manual
Diagnostic
Yes
tips
Check the turbocharger operation for insufficient Overhaul the
11 boosting or air leakage. turbocharger
pipe line or
No
replace
related
components
General trouble area: 1. Fuel with water; 2. Intake pressure sensor; 3. Sparkplug; 4.
Electronic throttle body assembly; 5. Inlet passage; 6. Injector; 7. Ignition timing; 8. Exhaust
pipe; 9. Turbocharger.
Follow-up
No. Test Result
Operation Steps Step
Overhaul the
Yes intake
1 Check the air filter for any blockage. system
No Next step
205
BYD AUTO BYD Suri Maintenance & Repair Manual
206
BYD AUTO BYD Suri Maintenance & Repair Manual
5.16 The engine power is low and performance is poor during acceleration.
General trouble area: 1. Fuel with water; 2. Intake pressure sensor; 3. Sparkplug; 4. Ignition
coil; 5. Electronic throttle body; 6. Inlet passage; 7. Injector; 8. Ignition timing; 9. Exhaust pipe;
10. Turbocharger.
207
BYD AUTO BYD Suri Maintenance & Repair Manual
5.17 The vehicle pauses from time to time and shakes during acceleration or driving at constant
speed.
General trouble area: 1. The fuel or tire does not meet the technical requirements; 2. The air
filter and inlet passage is blocked; 3. Excessive carbon is deposited in the electronic throttle
body; 4. Low fuel pressure or no fuel pressure; 5. Ignition coil; 6. Sparkplug; 7. Injector; 8.
Ignition timing; 9. Exhaust pipe; 10. Turbocharger; 11. Charcoal canister blocked or charcoal
canister solenoid valve failure; 12. Sensors and circuits failure.
208
BYD AUTO BYD Suri Maintenance & Repair Manual
209
BYD AUTO BYD Suri Maintenance & Repair Manual
The values and related contents in the section are only for reference and the actual measurement
by the diagnosis program should prevail.
6.1.2 The operation buttons are on the right of RST: System reset. Note: Be careful to
the penal as follows: use the key. When using the key, press it
for 1 to 2 seconds and then release.
Number key 0-9: Menu selection; Number 6.3.2 System parameter display
input.
Direction key ↑↓← →:The ↑ and ↓ keys It mainly displays the main parameters,
are used to select the menu and the ← test items and sensor signal voltage;
and → keys are used to turn pages;
When inputting numbers, pressing the ↑ 6.3.3 System status
key can increase by 1 and pressing the ↓
key can decrease by 1. Pressing the ← It mainly displays the status of 10 items
210
BYD AUTO BYD Suri Maintenance & Repair Manual
6.3.5 Odometer
6.4 Instructions for Using Diagnostic 6.4.6 Select the model to be diagnosed (such
Tester as G6);
6.4.1 Connect the diagnostic cable; 6.4.7 Enter the diagnosis system selection
interface;
6.4.2 Power on the vehicle by pressing the
push-start button;
211
BYD AUTO BYD Suri Maintenance & Repair Manual
1. Read
2. Read
3. Clear
4. Read 6.4 10.3 If the system is faulty
5. Component”
The "Info bar" will list all the DTCs and
corresponding trouble information as
shown below.
DTC
212
BYD AUTO BYD Suri Maintenance & Repair Manual
213
BYD AUTO BYD Suri Maintenance & Repair Manual
a Switching parameters
The customer can press the [OK] key to
The switching parameters have two enter and set the relevant items.
states: On or Off. Therefore the customer
can complete relevant actions with simple
operations.
b Control parameters
The control parameters are some setting In the "Info bar" shown above, the first
parameters. Some internal variables of line is the setting value input by the
ECU can be changed by setting these customer, and the second line is the
parameters so as to change the operation range of setting value. The input value
condition of the engine. should not exceed the specified range, or
the operation may fail.
The symbol "" indicates the items that
can be set by the customer currently. The Description: Be careful to perform the
customer can select the parameter to be "component operation test". If you are not
set by pressing the ↑ and ↓ keys. a professional technician or service
214
BYD AUTO BYD Suri Maintenance & Repair Manual
215
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 7 Attachment
7.1 Periodic Maintenance Procedures for ECI System
Description:
7.1.2 The maintenance interval is determined by the odometer reading or the time interval,
whichever comes first;
7.1.3 The maintenance procedures are based on the assumption when the vehicle can be used
normally as designed, and should be strictly followed.
Mileage
10 15 20 25 30 35 40 45 50 55 60
Item x 1000km
Month 12 18 24 30 36 42 48 54 60 66 72
Ignition Coil I I I
Sparkplug I R I R I R
Ignition Timing I I I
Engine Idling I I I
Fuel Tank I
Gasoline Filter R R
Injector C* C* C*
Oil Filter R R R R R R
Air Cleaner I R I R I R
Electronic Throttle
C C C C C C
Valve Body
Emission Check I I I I I I
Diagnostic Tester
I I I
Check
Oxygen Sensor
I I I I I I
Check
Three Way Catalytic
I I I I I I
Converter Check
R-Replace
C-Clean
C*-It is recommended to use the special injector washing analyzer to clean and maintain the
injector
216
BYD AUTO BYD Suri Maintenance & Repair Manual
217
BYD AUTO BYD Suri Maintenance & Repair Manual
218
BYD AUTO BYD Suri Maintenance & Repair Manual
Refer to the relevant schematic diagram of wire harness for different models. When
troubleshooting and repairing, be sure to refer to the schematic diagram.
219
BYD AUTO BYD Suri Maintenance & Repair Manual
220
BYD AUTO BYD Suri Maintenance & Repair Manual
221
BYD AUTO BYD Suri Maintenance & Repair Manual
222
BYD AUTO BYD Suri Maintenance & Repair Manual
223
BYD AUTO BYD Suri Maintenance & Repair Manual
224
BYD AUTO BYD Suri Maintenance & Repair Manual
Electrical System
Contents
Chapter 1 Combination Instrument .................................................................................................. 5
1 Parts Location ........................................................................................................................ 6
2 System Diagram .................................................................................................................... 7
3 Information sheet ................................................................................................................... 8
4 System overview .................................................................................................................... 9
5 Diagnosis process ............................................................................................................... 12
6 Diagnosis Trouble Code Table ............................................................................................ 13
7 Problem Symptoms Chart.................................................................................................... 14
8 Terminal Diagnosis .............................................................................................................. 17
9 Removal ............................................................................................................................... 51
10 Installation .......................................................................................................................... 52
Chapter 2 Lighting System ............................................................................................................. 53
1 Position of the Assembly ..................................................................................................... 54
2 System Diagram .................................................................................................................. 58
3 System overview .................................................................................................................. 62
4 Diagnosis process ............................................................................................................... 63
5 Problem Symptoms Chart.................................................................................................... 65
6 Terminal Diagnosis .............................................................................................................. 68
7 Overall Diagnosis Procedure ............................................................................................... 72
8 Assembly & disassembly ...................................................................................................122
Chapter 3 Multimedia System ...................................................................................................... 128
1 Parts Location .................................................................................................................... 129
2 System Diagram ................................................................................................................ 131
3 System Description ............................................................................................................ 132
4 How to Troubleshoot.......................................................................................................... 134
5 Problem Symptoms Chart..................................................................................................136
6 ECU terminals .................................................................................................................... 138
7 Power Supply Circuit of the Multimedia Machine .............................................................. 162
8 Disassembly and Assembly of the Door Speakers ........................................................... 186
9 Assembly and Disassembly of the Front High Pitch Speakers ......................................... 187
10 Assembly and Disassembly of the Middle Pitch Speakers ............................................. 187
11 Assembly & disassembly of exterior power amplifier ...................................................... 188
12 Removal and Installation of the USB & AUX Interface ................................................... 188
13 Assembly and Disassembly of the Rear High Pitch Speakers........................................ 189
14 Assembly and Disassembly of the Mega Bass Speakers ............................................... 189
15 Removal and Installation of the Antenna Amplifier ......................................................... 190
16 Disassembly & Assembly of the Exterior Antenna .......................................................... 190
Chapter 4 Audio System .............................................................................................................. 192
1 Parts Location .................................................................................................................... 193
2 System Diagram ................................................................................................................ 196
1
BYD AUTO BYD Suri Maintenance & Repair Manual
2
BYD AUTO BYD Suri Maintenance & Repair Manual
3
BYD AUTO BYD Suri Maintenance & Repair Manual
4
BYD AUTO BYD Suri Maintenance & Repair Manual
5
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
Combination
Instrument
6
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Supplemental
Lighting System restraint system
Combination
Power generating
Instrument
system Multi-display
Parking brake
switch
Combination Switch
Oil Pressure Switch
7
BYD AUTO BYD Suri Maintenance & Repair Manual
3 Information sheet
Sending Transmission
Receiving node Information
node type
Front-left door status
Front-right door status
Rear-left door status
Rear-right door status
Combination Driver safety belt switch signal
BCM CAN
Instrument Complete vehicle status
Trunk signal
Smart key system warning light
signal
Buzzer control signal
Combination
SRS Fault indicator light drive signal CAN
Instrument
High beam switch signal
Combination Combination Front fog lamp switch signal
CAN
Switch Instrument Rear fog lamp switch signal
Sidelamp
Combination
Multi-display Dimming gear position signal CAN
Instrument
Combination
Multimedia System Parking braking switch signal CAN
Instrument
(MIL) emissions fault signal
Coolant temperature
Vehicle speed signal
Revolution speed of the engine
EBD fault signal
Combination ABS fault signal
Gateway CAN
Instrument Engine speed signal
Vehicle speed signal
Service warning light
Gear position signal
Instant fuel quantity
ESP
Power
Combination
generating Charging system lamp Hard wire
Instrument
system
Lighting Combination Left turn signal indicator
Hard wire
System Instrument Right turn signal indicator
Combination Interior Light
Backlight drive signal Hard wire
Instrument System
8
BYD AUTO BYD Suri Maintenance & Repair Manual
4 System overview
The combination instrument is an electromechanical
combination instrument located in front of the driver
and above the steering column. It includes mounting
parts and electrical connections. The circuits of all
combination instruments compose a wire harness,
which is connected to the back of the combination
instrument housing by via a connector. The dial and
the indicator light of the combination instrument are
arranged behind a whole transparent mask. The
transparent mask adopts a light shield, which
protects the instrument surface from light and
reflection, thus reducing glare.
Metering gages:
Name Description
Speedometer Based on the wheel speed sensor, ABS converts wheel speed signals
into vehicle speed signals, and transmits data to the combination
instrument via the CAN.
Tachometer Engine ECM sends rotation speed signals to the combination
instrument via the CAN line.
Thermometer of Engine ECM sends engine coolant temperature signal to combination
engine coolant instrument via the CAN line.
Fuel meter This combination instrument collects the oil level signal collected by
the oil level sensor via the hard wire.
9
BYD AUTO BYD Suri Maintenance & Repair Manual
Warning light Receives the charging system fault information from the
of charging charging system (hard wire)
system
ABS failure Receives the ABS system fault message from the gateway
warning and light up the indicator. CAN breakage ON.
indicator
Warning light Receives parking signals from the parking brake switch
for parking (hard wire); Receive the brake level signals from the brake
brake failure level switch (hard wire); The combination instrument
acquires "EBD fault" signals (CAN)
EPS failure Receives EPS failure signals (CAN)
warning (red)
indicator
SVS warning Receives complete vehicle status signal from BCM
lamp
Warning light Reads key message from intelligent key system (CAN)
for intelligent
key system
Theft deterrent (red) When the vehicle is asleep, the indicator is lit up and kept
indicator on; after a period of time, it starts flickering, which means
the vehicle has fallen asleep.
Front The combination instrument acquires the mode signal of
headlamp the front headlamp regulating unit (CAN)
regulating
indicator
(reserved)
Cruise master Operates the cruise button on the steering wheel. The
indicator instrument receives messages from the gateway and turns
(reserved) the ON/OFF the indicator.
Cruise control The instrument receives the gateway signal and turns
indicator ON/OFF the indicator to show whether the vehicle is in
(reserved) cruise mode.
Indicator of Receives status of doors and trunk from the BCM (CAN)
door and trunk
condition
Main warning Receives failure message and prompt (except backlight
light regulation, doors and trunk status)
Warning light Receives engine failure signal (CAN) CVTK wire from the
of engine gateway
failure
ESP failure Receives ESP failure signal from the ESP system (CAN)
warning
indicator
ESP OFF Receives the ESP system OFF signal (CAN)
warning lamp
10
BYD AUTO BYD Suri Maintenance & Repair Manual
Tire pressure Receives tire pressure failure signals from the tire pressure
failure warning monitoring system (CAN)
light (reserved)
11
BYD AUTO BYD Suri Maintenance & Repair Manual
5 Diagnosis process
1 Vehicle taken to the workshop
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
Result
Result Proceed to
Symptom isn't listed in problem symptoms table A
Symptom is listed in problem symptoms table B
B Go to step 5
5 Overall diagnosis
Next
Next
7 Confirmation test
Next
12
BYD AUTO BYD Suri Maintenance & Repair Manual
13
BYD AUTO BYD Suri Maintenance & Repair Manual
14
BYD AUTO BYD Suri Maintenance & Repair Manual
15
BYD AUTO BYD Suri Maintenance & Repair Manual
I-KEY ECU
Intelligent key system key BCM
position indicator
malfunction Combination instrument
CAN communication
Combination switch
Malfunctioning of sidelamp
Combination instrument
indicator
CAN communication
Generator
Malfunctioning of charging
Combination instrument
system indicator
Wire harness or connector
ECM
Engine failure indicator
malfunction (considering Combination instrument
CVT)
CAN communication
ECM
BCM
SVS indicator malfunction
Combination instrument
CAN communication
Gear shift mechanism
TCU
Abnormal display of gear
Gateway
positions
Combination instrument
CAN communication
Wheel speed sensor
16
BYD AUTO BYD Suri Maintenance & Repair Manual
8 Terminal Diagnosis
1. Check pins of the combination instrument
17
BYD AUTO BYD Suri Maintenance & Repair Manual
backlight
brightness.
G16-22-vehicle Br-vehicle body Steer right status
Steer right 11~14 V
body ground ground signal
G/O-vehicle body The hand brake
G16-23-vehicle ground is pulled on or
Parking signal Less than 1 Ω
body ground the brake fluid
level is too low.
Buoy sinks
G16-24-vehicle G/R-vehicle body Brake fluid level
(brake fluid level Less than 1 Ω
body ground ground signal
too low)
Sit down and
Passenger' safety fasten the Vacant
G16-27-vehicle R/B-vehicle body safety belt.
belt signal
body ground ground
acquisition No one is
Less than 1 V
seated.
Br/W-vehicle body Information switch
G16-28-vehicle
ground button signal Always Less than 1 V
body ground
ground
G16-33-vehicle R/L-vehicle body Steer left status 11~14V
Steer left
body ground ground signal
Y/R-vehicle body Flameout Less than 1 Ω
G16-34-vehicle ground Engine oil
body ground pressure signal More than 10
Start the engine
kΩ
Engine
G16-35-vehicle Y/L-vehicle body Charging system malfunction
Voltage signal
body ground ground warning signal (output voltage
too low)
L/W-vehicle body Less than 8.2
Press "OK".
ground kΩ
Message switch
G16-37-G16-28
button input Press "up" About 23.2 kΩ
Press "Down" About 50.2 kΩ
G16-38-vehicle Y-vehicle body
IG1 Power ON 11~14 V
body ground ground
G16-39-vehicle W/R-vehicle body
Battery Always 11~14 V
body ground ground
Seated, without
Passenger safety fastening the Less than 1 V
G16-40-vehicle L-vehicle body safety belt
belt indicator
body ground ground
control No one is
Vacant
seated.
18
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Battery
Power supply
for switch 2nd
Power Supply
gear
Battery
Combination Instrument
19
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect fuse
OK: Yes
NG Replace fuse
OK
Standard Voltage
Specified
Tester Connection Condition
Condition
G16-38-vehicle
Power ON 11 to 14 V
body ground
G16-39-vehicle
Always 11 to 14 V
body ground
Standard Resistance
Specified
Tester Connection Condition
Condition
G16-11-vehicle Less than 1
Always
body ground Ω
G16-12-vehicle Less than 1
Always
body ground Ω
NG
OK
20
BYD AUTO BYD Suri Maintenance & Repair Manual
Gateway Controller
Combination Instrument
Body
network
Shielding
layer
System
Check Procedures
1 Use the diagnostic unit to check diagnostic trouble codes (DTCs).
21
BYD AUTO BYD Suri Maintenance & Repair Manual
Combination Instrument
Result Proceed to
DTC is output A
No DTC is output C
ABS System
Result Proceed to
DTC is output B
No DTC is output C
22
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Gateway Controller
Shielding
layer
Body network
Combination
Instrument
Adapter
system
Check Procedures
1 Use the diagnostic unit to check diagnostic trouble codes (DTCs).
Result Proceed to
DTC is output A
No DTC is output C
23
BYD AUTO BYD Suri Maintenance & Repair Manual
ECM system
Result Proceed to
DTC is output B
No DTC is output C
24
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Combination Instrument
Oil level
sensor
Check Procedures
1 Check the oil level sensor
(a) Disconnect the oil level sensor connector K11.
Standard Resistance
Specified
Tester Connection Condition
Condition
K11-2-K11-3 Always 40-250 Ω
OK
25
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Resistance
Tester Specified
Condition
Connection Condition
G16-8-K11-3 Always Less than 1 Ω
G16-9-K11-2 Always Less than 1 Ω
G16-9-vehicle
Always Less than 1 Ω
body ground
NG
OK
26
BYD AUTO BYD Suri Maintenance & Repair Manual
Gateway Controller
Shielding
layer
Adapter
Coolant N/A
temperature
sensor
Combination
Instrument
27
BYD AUTO BYD Suri Maintenance & Repair Manual
Gateway Controller
Shielding
layer
Body
network
Adapter
Coolant temperature
sensor
Combination
Instrument
28
BYD AUTO BYD Suri Maintenance & Repair Manual
Check Procedures
1 Use the diagnostic unit to check diagnostic trouble codes (DTCs).
(a) Connect the diagnostic tester to DLC port and
read DTCs of systems.
Combination Instrument
Result Proceed to
DTC is output A
No DTC is output C
ECM system
Result Proceed to
DTC is output B
No DTC is output C
29
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Combination
Instrument
Combination
Switch
Check Procedures
1 Check the work condition of the high beam lamp
(a) Place the combination switch at high beam to
see whether the high beam works well.
NG
30
BYD AUTO BYD Suri Maintenance & Repair Manual
system.
Combination Instrument
Result Proceed to
DTC is output A
No DTC is output B
31
BYD AUTO BYD Suri Maintenance & Repair Manual
Check Procedures
1 Check the work condition of the door lamp
32
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
Result Proceed to
DTC is output A
No DTC is output B
33
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Combination
Instrument
Combination Switch
Check Procedures
1 Check the work condition of the rear fog lamp
NG
34
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
Combination Instrument
Result Proceed to
DTC is output A
No DTC is output B
35
BYD AUTO BYD Suri Maintenance & Repair Manual
Combination
Instrument
Combination
Switch
Check Procedures
1 Check the work condition of the front fog lamp
(a) Set the combination switch to front fog lamp to
see whether it works well.
NG
36
BYD AUTO BYD Suri Maintenance & Repair Manual
Combination Instrument
Result Proceed to
DTC is output A
No DTC is output B
37
BYD AUTO BYD Suri Maintenance & Repair Manual
Combination
Instrument
Combination
Switch
Check Procedures
1 Check the work condition of the sidelamp
NG
OK
38
BYD AUTO BYD Suri Maintenance & Repair Manual
instrument system.
Combination Instrument
Result Proceed to
DTC is output A
No DTC is output B
39
BYD AUTO BYD Suri Maintenance & Repair Manual
Combination
Instrument
Check Procedures
1 Check the engine oil pressure switch
(a) Disconnect the engine oil pressure sensor A36
connector.
Standard Resistance
Specified
Tester Connection Condition
Condition
Flameout Less than 1 Ω
A36-1-vehicle
body ground Start the
More than 10 kΩ
engine
NG
OK
40
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Resistance
Tester Specified
Condition
Connection Condition
G16-34-A36-1 Always Less than 1 Ω
G16-34-vehicle
Always More than 10 kΩ
body ground
NG
OK
41
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery
distributor box
Steer warning
Dashboard
light
Right
steering
lamp relay
Left
steering
lamp relay
Right
steering
light
Left
steering
light
42
BYD AUTO BYD Suri Maintenance & Repair Manual
Check Procedures
1 Check the work condition of the steering lamp
OK
Standard Resistance
Specified
Tester Connection Condition
Condition
G37-7-G16-33 Always Less than 1 Ω
G37-2-G16-22 Always Less than 1 Ω
NG
OK
43
BYD AUTO BYD Suri Maintenance & Repair Manual
Combination
Instrument
Generator
Check Procedures
1 Check the engine
Standard Voltage
Tester Specified
Condition
Connection Condition
A16-2-vehicle Engine
11 to 14 V
body ground running
A37-2-vehicle Engine
11 to 14 V
body ground running
44
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
Standard Resistance
Tester Specified
Condition
Connection Condition
G16-35-A16-2 Always Less than 1 Ω
G16-35-A37-2 Always Less than 1 Ω
NG
OK
45
BYD AUTO BYD Suri Maintenance & Repair Manual
Combination
Instrument
Parking brake
switch: (Close:
Pulled)
Check Procedures
1 Check the brake fluid
OK
(a) Lead wire from the back and measure G32 pin
resistance.
Standard Resistance
Specified
Tester Connection Condition
Condition
G32-1-vehicle Pull the Less than 1
body ground hand brake Ω
NG
46
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
Standard Resistance
Specified
Tester Connection Condition
Condition
G16-23-G32-1 Less than 1
Always
Ω
NG
OK
47
BYD AUTO BYD Suri Maintenance & Repair Manual
Driver's
safety belt
latch switch
(close:
locked)
Combination
Instrument
Check Procedures
1 Use the diagnostic unit to check diagnostic trouble codes (DTCs).
Result Proceed to
DTC is output A
No DTC is output B
A
Enter "CAN Diagnosis" for inspection
48
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Resistance
Tester Specified
Condition
Connection Condition
Safety belt is More than
fastened. 10 kΩ
KJ08-1-KJ08-2
Safety belt Less than 1
isn't fastened. Ω
NG
OK
Standard Resistance
Specified
Tester connection condition
condition
K2F-14-KJ08-1 Always Less than 1 Ω
KJ08-1-KJ08-2 Always Less than 1 Ω
NG
OK
49
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
50
BYD AUTO BYD Suri Maintenance & Repair Manual
9 Removal
1. Disconnect battery negative.
51
BYD AUTO BYD Suri Maintenance & Repair Manual
10 Installation
52
BYD AUTO BYD Suri Maintenance & Repair Manual
53
BYD AUTO BYD Suri Maintenance & Repair Manual
Turn light RH
Turn light LH
54
BYD AUTO BYD Suri Maintenance & Repair Manual
Trunk light
Right
combination
rear lamp
-Position lamp
-Braking light
-Rear fog light
-Reversing light
-Turn light
Left combination
rear lamp Reflex
-Position lamp Reflector
-Braking light
-Rear fog light
-Reversing light
-Turn light
Reflex
Reflector
55
BYD AUTO BYD Suri Maintenance & Repair Manual
Atmosphere lamp
(rear right)
Atmosphere lamp
(front right)
Front right
door light
Atmosphere
lamp (front left) Atmosphere lamp
(rear left)
Front left
door light
Dress-up mirror
light (left)
56
BYD AUTO BYD Suri Maintenance & Repair Manual
Emergency Warning
Light Switch
Braking Light
Switch
Storage light
switch
Clutch pedal
switch
Left foot Right foot light
light
Headlamp
Adjusting Switch
57
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Left atmosphere
lamp
Right atmosphere
lamp
All backlights
58
BYD AUTO BYD Suri Maintenance & Repair Manual
Combination
Switch
Trunk light
59
BYD AUTO BYD Suri Maintenance & Repair Manual
Braking
Light
Switch
Multiplex
integration
control
module
Left braking
light
Right braking
light
High braking
lamp
Left reversing
light
Right reversing
light
60
BYD AUTO BYD Suri Maintenance & Repair Manual
Emergency
Warning Light
Switch
Left regulating
motor Headlamp
Adjusting
Switch
Right regulating
motor
61
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System overview
The light system provides illumination for night
driving. Outside lights mainly include front
lights, reversing lights, plate light, fog light.
Inside lights mainly include indoor lights, door
lights and switch backlights. Different lights are
installed to meet different illumination needs.
They are served with their own control switch,
lines and fuse to form the light system. The
light system also provides a signal indication
function by generating light signals to warn
other cars and passengers in order to ensure
driving safety. It includes the steering signal,
braking signal, danger warning signal, outline
signal and reversing signal.
62
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis process
1 Vehicle brought to workshop
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before proceeding to the next step.
Next
Result Proceed
The fault is not recorded in A
the fault symptom table
The fault is recorded in the B
fault symptom table
B Go to Step 5
Next
Next
63
BYD AUTO BYD Suri Maintenance & Repair Manual
6 Confirmation test
Next
7 End
64
BYD AUTO BYD Suri Maintenance & Repair Manual
65
BYD AUTO BYD Suri Maintenance & Repair Manual
66
BYD AUTO BYD Suri Maintenance & Repair Manual
67
BYD AUTO BYD Suri Maintenance & Repair Manual
6 Terminal Diagnosis
1 Engine hood distributor box
68
BYD AUTO BYD Suri Maintenance & Repair Manual
69
BYD AUTO BYD Suri Maintenance & Repair Manual
Combination Switch
70
BYD AUTO BYD Suri Maintenance & Repair Manual
71
BYD AUTO BYD Suri Maintenance & Repair Manual
Power
Supply
Combination Switch
Inspection Procedure
72
BYD AUTO BYD Suri Maintenance & Repair Manual
DTC Implication
B24A0-00 Circuit malfunction of "OFF"
position of lighting master switch
B24A1-00 Circuit malfunction of "TALL"
position of lighting master switch
B24A2-00 Circuit malfunction of "AUTO"
position of lighting master switch
B24A4-00 Circuit malfunction of dimmer
switch
B24A5-00 Circuit malfunction of turn signal
switch
B24AA-00 Internal error of combination
switch control device
B24AC-00 Circuit malfunction of "ON"
position of lighting master switch
B24AE-00 Circuit malfunction of "ON"
position of rear fog lamp switch
OK:
No output of trouble code
NG
Replace combination switch
OK
OK
73
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
OK
74
BYD AUTO BYD Suri Maintenance & Repair Manual
Terminal Resistance
G24-1-G24-2 About 60 Ω
OK
OK
7 Circuit is ok.
75
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery
Right
Left low low
beam Internal
beam
low-beam
light relay
low-beam light
low-beam light
circuit
Front right
Front left
Inspection Procedure
OK:
Continuity in the fuse
NG Replace fuse
OK
76
BYD AUTO BYD Suri Maintenance & Repair Manual
OK:
Relay is ok.
OK
NG Change bulb
OK
77
BYD AUTO BYD Suri Maintenance & Repair Manual
Ground connection
OK
78
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery
Internal high-beam
Left high Right
high-beam light
Front left
Front right
high-beam
light
Inspection Procedure
OK:
Continuity in the fuse
NG Replace fuse
OK
79
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
NG Change bulb
OK
Ground connection
80
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
81
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery
Engine hood
distributor
box
Relay
control
module
82
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Check the fuse
OK:
Continuity in the fuse
NG Replace fuse
OK
(a) Pull out the front fog light relay KC-1 from the
relay control module
OK:
Relay is OK.
OK
NG Change bulb
OK
4 Check wire harness (front fog light relay - front fog light)
83
BYD AUTO BYD Suri Maintenance & Repair Manual
Ground connection
OK
OK:
System is OK
OK
84
BYD AUTO BYD Suri Maintenance & Repair Manual
Rear
right
Rear fog
left fog light
light
Inspection Procedure
1 Check the rear fog light bulb
85
BYD AUTO BYD Suri Maintenance & Repair Manual
K14-5-battery(+) Bulb on
K14-6-battery(-)
NG Change bulb
OK
OK
3 Replace BCM
86
BYD AUTO BYD Suri Maintenance & Repair Manual
Thunder
Multiplex integration
control module
Steer
warning light
Flash
light
relay
distribution box
Instrument
Rear
Engine turn
Multiplex Engine
distribut light
integration distribut
or box RH
control or box
module
Rear
turn
light
RH
Front
turn Front
light turn
LH light
RH
87
BYD AUTO BYD Suri Maintenance & Repair Manual
Emergency
Warning
Light
Switch
Right
steering
lamp
relay
Turn
light RH
Multiplex
integration
control Multiplex
Combination integration
instrument module
G16-22 G2Q-4 control
module
G2P-12
88
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Check the fuse
NG Replace fuse
OK
NG
C07-2-battery(+) Bulb on
C07-1-battery(-)
NG Change bulb
OK
89
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
Turn light LH
Turn light RH
90
BYD AUTO BYD Suri Maintenance & Repair Manual
Ground connection
OK
5 Replace BCM
91
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Battery
distributor box
Dashboard
Emergency Warning
Steer warning light
Light Switch
Inspection Procedure
NG
92
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
OK
3 Replace BCM
93
BYD AUTO BYD Suri Maintenance & Repair Manual
Horn, brake
Brake
switch
(closed
pedal
pressed
Right braking light
94
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Check the fuse
OK:
continuity in the fuse
NG Replace fuse
OK
NG
Replace the braking light switch
OK
95
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
4 Check the wire harness (braking light switch - front compartment distribution box)
NG
OK
96
BYD AUTO BYD Suri Maintenance & Repair Manual
Ground connection
OK
6 End
97
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery
Front
position
light
Internal
side light
relay
Front right side light
98
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Inspection Procedure
OK:
Continuity in the fuse
NG Replace fuse
OK
(a) Pull out the side light relay KI1-5 from the
relay control module
OK:
Continuity in the fuse
OK
NG Change bulb
OK
99
BYD AUTO BYD Suri Maintenance & Repair Manual
100
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
101
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
102
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
NG Replace BCM
OK
OK
4 Replace BCM
103
BYD AUTO BYD Suri Maintenance & Repair Manual
Indoor lighting
Left
ground
light
Inspection Procedure
1 Check the fuse
NG Replace fuse
OK
104
BYD AUTO BYD Suri Maintenance & Repair Manual
NG Replace BCM
OK
OK
4 Replace BCM
105
BYD AUTO BYD Suri Maintenance & Repair Manual
Check Procedure
1 Check the door lock feeding switch
106
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
OK
3 Replace BCM
107
BYD AUTO BYD Suri Maintenance & Repair Manual
Front right
door light
door light
Front left
Trunk light
108
BYD AUTO BYD Suri Maintenance & Repair Manual
Check Procedure
1 Check door lights
OK
NG Replace BCM
OK
109
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
4 Replace BCM
110
BYD AUTO
light
switch
Reading
Reading light switch
Circuit Diagram
Emergency rescue
switch backlight
Emergency rescue
indicating light
Dress-up light
Front interior light and atmospheric light circuit
111
BYD AUTO BYD Suri Maintenance & Repair Manual
Check Procedure
NG Replace fuse
OK
OK
112
BYD AUTO BYD Suri Maintenance & Repair Manual
on ON light on
P03-4-battery(-)
OK
NG Replace BCM
OK
5 End
113
BYD AUTO BYD Suri Maintenance & Repair Manual
Left Right
foot foot Front left Front right latch
light light latch atmospheric
atmospheric light
light
Instrument 6#
body ground
Instrument 4# Instrument 3#
body ground body ground
114
BYD AUTO BYD Suri Maintenance & Repair Manual
Check Procedure
1 Check the backlight
OK:
All backlights are on. Both foot lights and
atmospheric lights are on. If none of them
is on, check the vehicle backlights.
NG:
Some lights cannot be turned on.
OK Circuit is ok.
NG
OK:
Bulb on
NG Change bulb
OK
OK
4 Circuit is ok.
115
BYD AUTO BYD Suri Maintenance & Repair Manual
Left
regulating
motor
motor
Combination
Instrument
G16-22
116
BYD AUTO BYD Suri Maintenance & Repair Manual
Check Procedure
1 Check the Power Supply of the Headlamp Adjusting Switch
NG Go to step 5
OK
NG
OK
117
BYD AUTO BYD Suri Maintenance & Repair Manual
OK Go to step 5
NG
(b) Take out the lead from the back end of the
dashboard distribution box G2N-35 terminal.
OK
118
BYD AUTO BYD Suri Maintenance & Repair Manual
connector.
NG
OK
119
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Combination
Gateway
switch
Illumination intensity
sensor
Check Procedure
1 Check whether the manual headlamp is on.
120
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
OK
NG
OK
121
BYD AUTO BYD Suri Maintenance & Repair Manual
(a) Remove the upper two bolts and the Front fog light
one on the lateral side, as well as the
one on the water tank post with size-10
socket wrench Take the front left turn light as an example
Disassembly
(b) Disconnect all connectors on the left
combination light. 1. Remove the front fog light trim panel.
(c) Remove the rear left combination light. 2. Remove front bumper
Assembly
Assembly
122
BYD AUTO BYD Suri Maintenance & Repair Manual
1. Install the front left fog light. (b) Disconnect the connector.
(a) Align the front left fog light with the Remove the rear left combination light
mounting hole.
123
BYD AUTO BYD Suri Maintenance & Repair Manual
Disassembly Disassembly
1. Remove the rear shelf (a) Press the snap-fits on both sides.
2. Remove the high braking lamp (b) Remove the trunk light.
(b) M
ove the two snap-fits according to the
diagram and remove the high braking
light.
Assembly
Assembly
Plate lamp
Disassembly
124
BYD AUTO BYD Suri Maintenance & Repair Manual
(b) Eject the snap-fit from the inside of the b Connect the connector.
trunk cover.
(c) Remove the plate light from the mounting
hole with the trim strip of the rear plate
Front interior light
light on.
Disassembly
Plate lamp
Disassembly
Assembly
1. Remove the inner trim plate of the trunk.
Assemble in the reverse order.
2. Remove the plate light.
(d) Disconnect the connector. Side steering light
(e) Eject the snap-fit from the inside of the
trunk cover.
Please refer to assembly & disassembly of
(f) Remove the plate light from the
power outer rear view mirror.
mounting hole with the trim strip of the
rear plate light on.
Outer rear view mirror foot light
Assembly
Please refer to assembly & disassembly of
1 Install the plate light. power outer rear view mirror.
125
BYD AUTO BYD Suri Maintenance & Repair Manual
Disassembly
Disassembly
(a) Open the sun screen and you can see
the dress-up light.
Assembly
126
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembly
127
BYD AUTO BYD Suri Maintenance & Repair Manual
128
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
High Pitch
Speaker RH
Middle Pitch
Speaker
High Pitch
Speaker LH
Multimedia
Machine
129
BYD AUTO BYD Suri Maintenance & Repair Manual
130
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Steering
switch
Exterior
antenna
Multimedia Machine
Printed Printed
antenna antenna
Right
rearview
mirror
camera
Backup
camera
Speaker Exterior
amplifier
131
BYD AUTO BYD Suri Maintenance & Repair Manual
132
BYD AUTO BYD Suri Maintenance & Repair Manual
Dolly
interference
FM (Stereo)
FM (Non-Stereo)
PM
Ionosphere
133
BYD AUTO BYD Suri Maintenance & Repair Manual
4 How to Troubleshoot
Tips:
Use the following procedure to troubleshoot the
multimedia system.
*: Using the intelligent detecter.
1 Vehicle taken to the workshop
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before proceeding to the next step.
Next
Result Proceed to
No output of CAN communication system DTC A
CAN communication system DTC output B
5 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
134
BYD AUTO BYD Suri Maintenance & Repair Manual
B Go to step 8
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
B Go to step 8
Next
9 Confirmation test
Next
End
135
BYD AUTO BYD Suri Maintenance & Repair Manual
136
BYD AUTO BYD Suri Maintenance & Repair Manual
137
BYD AUTO BYD Suri Maintenance & Repair Manual
6 ECU terminals
138
BYD AUTO BYD Suri Maintenance & Repair Manual
ground
G29-9 -- N/A -- --
G29-10 -- N/A -- --
139
BYD AUTO BYD Suri Maintenance & Repair Manual
140
BYD AUTO BYD Suri Maintenance & Repair Manual
141
BYD AUTO BYD Suri Maintenance & Repair Manual
142
BYD AUTO BYD Suri Maintenance & Repair Manual
Terminal No.
Wire color Terminal description Option Specified condition
(Symbol)
G55-1 -- N/A -- --
G55-2 -- N/A -- --
G55-3 -- N/A -- --
G55-4-body Steering wheel Always, switch Corresponding
G/R
ground audio switch signal pressed switch resistance
G55-5-body Br Steering wheel Always, switch Corresponding
ground audio switch signal pressed switch resistance
G55-6 -- N/A -- --
143
BYD AUTO BYD Suri Maintenance & Repair Manual
ground
K26-3-body ACC power
R/L-body ground ACC 11-14 V
ground supply
K26-4-body Less than 1
B-body ground Battery ground Always
ground Ω
K26-5-body Less than 1
B-body ground Battery ground Always
ground Ω
K26-6-body
Y-body ground Power (+) Always 11-14 V
ground
K26-7-body
Y-body ground Power (+) Always 11-14 V
ground
K26-8-body -- --
P-body ground CAN_H
ground
K26-9-body -- --
V-body ground CAN_L
ground
K26-10-body -- -- -- --
ground
K26-11-body Less than 1
B-body ground Battery ground Always
ground Ω
K26-12-body Less than 1
B-body ground Battery ground Always
ground Ω
144
BYD AUTO BYD Suri Maintenance & Repair Manual
145
BYD AUTO BYD Suri Maintenance & Repair Manual
146
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
147
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect the Steering Switch
NG
2 Inspect the Circuit from the Steering Switch to the Multimedia Unit
148
BYD AUTO BYD Suri Maintenance & Repair Manual
2 Inspect Speakers
NG
149
BYD AUTO BYD Suri Maintenance & Repair Manual
150
BYD AUTO BYD Suri Maintenance & Repair Manual
OK System is OK
NG
2 Inspect Speakers
A
Replace the speakers with the abnormal sound
effects
B
NG
151
BYD AUTO BYD Suri Maintenance & Repair Manual
152
BYD AUTO BYD Suri Maintenance & Repair Manual
B
See page "No Sounds from Speakers in All
Mode"
A
153
BYD AUTO BYD Suri Maintenance & Repair Manual
OK System is OK
NG
OK System is OK
NG
154
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect the Disc
OK
NG
3 Inspect the Connectors Behind the Multimedia Unit for any Looseness
NG
155
BYD AUTO BYD Suri Maintenance & Repair Manual
OK System is OK
NG
OK System is OK
NG
NG
156
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
157
BYD AUTO BYD Suri Maintenance & Repair Manual
OK System is OK
NG
158
BYD AUTO BYD Suri Maintenance & Repair Manual
OK System is OK
NG
159
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect the Auto Search Function
NG
NG
160
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
161
BYD AUTO BYD Suri Maintenance & Repair Manual
Audio-Visual
System
Batter
yy Multimedia Machine
162
BYD AUTO BYD Suri Maintenance & Repair Manual
Audio-Visual
System
Inspection Procedure
1 Check the fuse
NG Replace fuse
OK
163
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Voltage
Specified
Tester Connection Option
Condition
G2N-10-body
ground
Always 11-14 V
G01-G12-body
ground
G2N-37-body
ground Power up to
11-14 V
G01-G02-body ACC position
ground
NG
OK
Standard Resistance
Specified
Tester Connection Option
Condition
G2N-10-G29-4
Always Less than 1 Ω
G01-G12- G29-4
G2N-37-G29-3
Always Less than 1 Ω
G01-G02-G29-3
G29-7-body
Always Less than 1 Ω
ground
164
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
4 Circuit is ok.
165
BYD AUTO BYD Suri Maintenance & Repair Manual
Audio-Visual System
Inspection Procedure
1 Check the fuse
NG Replace fuse
OK
166
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Voltage
Specified
Tester Connection Option
Condition
K2E-15 - body
Always 11 to 14 V
ground
G01-G02-body ACC power
11 to 14 V
ground supply
NG
OK
Standard Resistance
Specified
Tester Connection Option
Condition
K2E-15-K26-1 Always Less than 1 Ω
K2E-15-K26-2 Always Less than 1 Ω
K2E-15-K26-6 Always Less than 1 Ω
K2E-15-K26-7 Always Less than 1 Ω
G01-G02-K26-3 Always Less than 1 Ω
K26-4-body ground Always Less than 1 Ω
167
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
4 Circuit is ok.
168
BYD AUTO BYD Suri Maintenance & Repair Manual
Rear
Rear Right
Door Middle
Speaker Pitch
LH Speaker
169
BYD AUTO BYD Suri Maintenance & Repair Manual
Middle loudspeaker
Rear
Right
Middle
Pitch
Speaker
170
BYD AUTO BYD Suri Maintenance & Repair Manual
Dashboard
Dashboard Wire
Wire Harness
Harness Adapter
Adapter
Front
High
Front Door Pitch
Speaker RH Speaker
RH
171
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect Speakers
Standard Resistance
Tester Specified
Option
Connection Condition
1-2 Always About 4 Ω
NG Replace Speakers
OK
Standard Resistance
Tester Specified
Option
Connection Condition
V07-1-K27-6 Always Less than 1 Ω
V07-2-K27-5 Always Less than 1 Ω
K29-1-K27-6 Always Less than 1 Ω
K29-2-K27-5 Always Less than 1 Ω
K30-1-K27-4 Always Less than 1 Ω
K30-2-K27-3 Always Less than 1 Ω
W01-1-K27-4 Always Less than 1 Ω
W01-2-K27-3 Always Less than 1 Ω
172
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
173
BYD AUTO BYD Suri Maintenance & Repair Manual
Speaker LH
Speaker RH
Front Door
174
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect Speakers
Standard Resistance
Specified
Tester Connection Option
Condition
1-2 Always About 4Ω
NG Replace Speakers
OK
Standard Resistance
Tester Specified
Option
Connection Condition
U07-1-G29-5 Always Less than 1 Ω
U07-2-G29-1 Always Less than 1 Ω
T07-1-G29-6 Always Less than 1 Ω
T07-2-G29-2 Always Less than 1 Ω
V02-1-G30-6 Always Less than 1 Ω
V02-2-G30-2 Always Less than 1 Ω
W01-1-G30-3 Always Less than 1 Ω
W01-2-G30-1 Always Less than 1 Ω
NG
175
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
176
BYD AUTO
Circuit Diagram
Control Switch of
Steering Wheel Audio Clock spring
177
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect distribution box
Standard Resistance
Tester Specified
Option
Connection Condition
Do not push any
G55-4-G55-5 ∞
button
Less than
G55-4-G55-5 Push VOL+
1Ω
G55-4-G55-5 Push VOL- About 8.2 kΩ
About 23.2
G55-4-G55-5 Push CH+
kΩ
About 50.2
G55-4-G55-5 Push CH-
kΩ
About 132.2
G55-4-G55-5 Push MODE
kΩ
Do not push any
G55-5-G51-8 ∞
button
About 4.64
G55-5-G51-8 Press VIEW
kΩ
Press the
About 9.84
G55-5-G51-8 reversing camera
kΩ
switch OFF
G55-5-G51-8 Press HOOK About 1 kΩ
Press on-board
About 3.16
G55-5-G51-8 phone control
kΩ
switch OFF
NG
Replace the steering switch
OK
178
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Resistance
Tester Specified
Option
Connection Condition
X993-3-G51-8 Always Less than 1 Ω
X993-4-G55-5 Always Less than 1 Ω
X994-1-G51-8 Always Less than 1 Ω
X994-2-G55-5 Always Less than 1 Ω
X994-3-G55-4 Always Less than 1 Ω
NG
OK
179
BYD AUTO BYD Suri Maintenance & Repair Manual
Shielding
layer
Shielding
layer
Shielding
layer
Exterior power amplifier Multimedia machine
ne
Inspection Procedure
1 Inspect the multimedia machine terminal
Standard Resistance
Specified
Tester Connection Option
Condition
G51-30-body
Always Less than 1 Ω
ground
NG
OK
180
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Resistance
Tester
Option Specified Condition
Connection
G51-23-K37-14 Always Less than 1 Ω
G51-24-K37-10 Always Less than 1 Ω
G51-25-K37-9 Always Less than 1 Ω
G51-26-K37-11 Always Less than 1 Ω
G51-27-K37-12 Always Less than 1 Ω
G51-28-K37-5 Always Less than 1 Ω
G51-29-K37-13 Always Less than 1 Ω
NG
Replace wire harness or connector
OK
181
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
OK
182
BYD AUTO BYD Suri Maintenance & Repair Manual
Multimedia Machine
Screen
Battery ground
Battery
Inspection Procedure
1 Inspect Power Supply for Exterior Amplifier
Standard Voltage
183
BYD AUTO BYD Suri Maintenance & Repair Manual
Specified
Tester Connection Option
Condition
K26-1-body ground Always 11 to 14 V
K26-2-body ground Always 11 to 14 V
K26-6-body ground Always 11 to 14 V
K26-7-body ground Always 11 to 14 V
OK Go to Step 3
NG
NG Replace fuse
Standard Voltage
Specified
Tester Connection Option
Condition
G01-G12-body
Always 11 to 14 V
ground
K2E-15-body
Always 11 to 14 V
ground
NG
Change the distribution box
OK
Change the wire harness or the connector (Dashboard distributor box - exterior power amplifier)
184
BYD AUTO BYD Suri Maintenance & Repair Manual
OK: Recovered
OK Connectors loose
NG
OK: Recovered
OK
Exterior power amplifier is damaged and needs to
be replaced.
NG
185
BYD AUTO BYD Suri Maintenance & Repair Manual
Disassembly
Disassembly
Assembly
186
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembly
2. Install the Front Door Shield Inner LH
1. Install the Front High Pitch Speaker LH
9 Assembly and Disassembly
(a) Connect the connector.
of the Front High Pitch
Speakers (b) Install 2 screws.
Disassembly
Disassembly
187
BYD AUTO BYD Suri Maintenance & Repair Manual
(a) Remove the two screws with a crosshead 1. Install the exterior power amplifier
screw driver.
(a) Align the exterior power amplifier with the
(b) Disconnect the connector and remove the mounting hole;
middle pitch speaker.
(b) Mount 4 bolts.
(a) Remove 4 set bolts. 1. Pry up the back of the USB & AUX
interface with a straight screwdriver.
(b) Disconnect the connector.
2. Disconnect the connector.
(c) Take off the exterior power amplifier.
3. Remove the USB & AUX interface.
188
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembly
Assembly
1. Install the rear middle pitch speaker LH
1. Connect the connector.
(a) Align the rear middle pitch speaker LH
2. Snap the USB & AUX interfaces into the with the mounting holes.
secondary dashboard.
(b) Insert the bolts.
Disassembly
14 Assembly and Disassembly
of the Mega Bass Speakers
We take the rear middle pitch speaker LH as
an example Disassembly
1. Remove carrier
1. Remove the carrier
2. Remove the rear middle pitch speaker LH
2. Disassembly of the Mega Bass Speakers
(a) Remove the bolts with 8# socket wrench.
(a) Remove the 6 bolts with 8# socket
(b) Disconnect the connector. wrench.
(c) Remove the rear middle pitch speaker LH (b) Disconnect the connector.
189
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembly
Assembly
1. Install the Antenna Amplifier
1. Assembly of the Mega Bass Speakers
(a) Align the antenna amplifier with the
installation hole.
(a) Align the mega bass speaker with the
mounting holes.
(b) Install 1 set nut.
(b) Replace the 6 bolts.
(c) Connect the connector.
Disassembly Disassembly
(a) Remove a bolt with a 10# socket wrench. (a) Remove a nut with a 22# socket wrench.
(b) Disconnect the connector. (b) Disconnect the connector of the exterior
antenna
190
BYD AUTO BYD Suri Maintenance & Repair Manual
(c) Take out the antenna from the outside (b) Install 1 set nut
Assembly
2. Assembly of the ceiling
1. Assembly of the Exterior Antenna
191
BYD AUTO BYD Suri Maintenance & Repair Manual
192
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
193
BYD AUTO BYD Suri Maintenance & Repair Manual
Front Door
Speaker RH
194
BYD AUTO BYD Suri Maintenance & Repair Manual
Printed
Antenna
Antenna Amplifier
195
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Steering Switch
Printed Antenna CD
Antenna Amplifier Unit
Speaker
196
BYD AUTO BYD Suri Maintenance & Repair Manual
1. CD Unit Overview
Tips:
Apart from stereo, other issues, such as
"phase modulation", "multi-channel" and
"sound attenuation", are not caused by
electronic noises but by the transmission and
(c) CD/DVD cleaning
reception of signal.
Tips:
(1) PM
Do not use lens cleaner, because it may AM radio broadcast is easily interfered by
affect the unit. electromagnetic waves and other factors.
197
BYD AUTO BYD Suri Maintenance & Repair Manual
Signal Weakening
Multipath Interference
198
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
5 Inspect DTC*
Result
Result Proceed to
199
BYD AUTO BYD Suri Maintenance & Repair Manual
No DTC is output A
DTC is output B
B Go to step
Result
Result Proceed to
Fault is not listed in fault symptoms table A
Fault is listed in fault symptoms table B
B Go to step 8
Next
9 Confirmation Test
Next Completed
200
BYD AUTO BYD Suri Maintenance & Repair Manual
201
BYD AUTO BYD Suri Maintenance & Repair Manual
6 ECU Terminals
1 Inspect the ECU Terminals of CD Unit
202
BYD AUTO BYD Suri Maintenance & Repair Manual
203
BYD AUTO BYD Suri Maintenance & Repair Manual
Ground
G31-10- Power Supply
B- Body Ground Always 11 to 14 V
Body Ground
G31-11- USB signal wire
Gr- Body Ground
Body Ground
G31-12- Signal ground for
Br- Body Ground Always Less than 1 Ω
Body Ground USB
204
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
205
BYD AUTO BYD Suri Maintenance & Repair Manual
Completed
206
BYD AUTO BYD Suri Maintenance & Repair Manual
2 Inspect Speakers
207
BYD AUTO BYD Suri Maintenance & Repair Manual
2 Inspect Speakers
208
BYD AUTO BYD Suri Maintenance & Repair Manual
209
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
210
BYD AUTO BYD Suri Maintenance & Repair Manual
OK CD/DVD is damaged
NG
NG
211
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
There is dirt on the surface of CD/DVD.
NG
OK
NG
212
BYD AUTO BYD Suri Maintenance & Repair Manual
OK System Normal
NG
213
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect the Auto Search Function
OK
Influence from other electric devices
NG
214
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
215
BYD AUTO BYD Suri Maintenance & Repair Manual
Audio-Video System
Auxiliary Power Supply
Dashboard
Wire
Harness
Adapter
CD Unit
Inspection Procedure
1 Inspect the Fuses
216
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Voltage
Specified
Tester Connection Condition
Condition
G2N-10- Body
Always 11 to 14 V
Ground
G2N-37- Body Power up to
11 to 14 V
Ground ACC position
NG
OK
Standard Resistance
Tester Specified
Condition
Connection Condition
G2N-10-G29-4 Always Less than 1 Ω
G2N-37-G29-3 Always Less than 1 Ω
G29-7- Body
Always Less than 1 Ω
Ground
NG
Replace harness or connector
217
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
218
BYD AUTO
Front Door
Speaker RH
Circuit Diagram
CD Unit
Rear Door
Speaker LH
Rear Door
Speaker RH
BYD Suri Maintenance & Repair Manual
219
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect Speakers
Tips:
The inspection methods for all the speakers are the
same (connector may be different). We take the
front door LH as an example.
Standard Resistance
Specified
Tester Connection Condition
Condition
1-2 Always About 4 Ω
NG
Replace Speakers
OK
NG
220
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
221
BYD AUTO BYD Suri Maintenance & Repair Manual
Control
Switch of
Steering
Wheel
Audio
Clock
Spring
CD Unit
Inspection Procedure
1 Inspect the Steering Switch
Standard Resistance
Tester Specified
Condition
Connection Condition
Do not push
G30-4-G30-5 ∞
any button
Less than 1
G30-4-G30-5 Push VOL+
Ω
G30-4-G30-5 Push VOL- About 8.2
222
BYD AUTO BYD Suri Maintenance & Repair Manual
kΩ
About 23.2
G30-4-G30-5 Push CH+
kΩ
About 50.2
G30-4-G30-5 Push CH-
kΩ
About 132.2
G30-4-G30-5 Push MODE
kΩ
Standard Resistance
Specified
Tester Connection Condition
Condition
Less than 1
G25-7-X991-7 Always
Ω
Less than 1
G25-8-X991-8 Always
Ω
NG Replace the c
OK
Standard Resistance
Specified
Tester Connection Condition
Condition
Less
G25-4-G30-7 Always
than 1 Ω
223
BYD AUTO BYD Suri Maintenance & Repair Manual
Less
G25-5-G30-8 Always
than 1 Ω
NG Replace harne
OK
224
BYD AUTO BYD Suri Maintenance & Repair Manual
CD Unit
Inspection Procedure
1 Inspect the CD Unit
Specified
Tester Connection Condition
Condition
G31-12-Body Less than 1
Always
Ground V
G31-6-Body Less than 1
Always
Ground V
G31-10-Body
Always About 5 V
Ground
225
BYD AUTO BYD Suri Maintenance & Repair Manual
NG Replace the
OK
Standard Resistance
Tester Specified
Condition
Connection Condition
G43-2-G31-2 Always Less than 1 Ω
G43-3-G31-7 Always Less than 1 Ω
G43-4-G31-3 Always Less than 1 Ω
G43-5-G31-6 Always Less than 1 Ω
G43-7-G31-10 Always Less than 1 Ω
G43-8-G31-5 Always Less than 1 Ω
G43-9-G31-11 Always Less than 1 Ω
G43-10-G31-12 Always Less than 1 Ω
G43-1-Vehicle
Always Less than 1 Ω
Body Ground
G43-6-Vehicle
Always Less than 1 Ω
Body Ground
NG
OK
226
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal
Removal
1. Remove the Front Door Shield Inner LH
Installation
Installation
1. Install the Front Door Speaker LH
227
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal
11 Removal and Installation of
the USB&AUX Interface
1 Remove the Front High Pitch Speaker LH
Removal
(e) Remove the front door guard plate LH.
(g) Remove 2 screws with cross screwdriver. (a) Pry up the backside of USB&AUX
interface with a straight screwdriver.
(h) Take down the speaker.
(b) Disconnect the connector.
Installation
228
BYD AUTO BYD Suri Maintenance & Repair Manual
Installation
229
BYD AUTO BYD Suri Maintenance & Repair Manual
230
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
Multi-functional
display
231
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Combination
Instrument
Multimedia
Machine
Multi-
functional
display
232
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System Description
The vehicle is provided with a multi-functional
display which is arranged in the middle of the
dashboard protective plate, not blocking the driver's
view. The driver can acquire basic information of the
current vehicle from the display, and take
corresponding measures.
Time display
Exterior temperature display (CD host)
Interior temperature display (DVD host)
Reversing radar display
Front-row seats safety belt indicator
233
BYD AUTO BYD Suri Maintenance & Repair Manual
4 How to Troubleshoot
Tips:
Follow procedures below to troubleshoot the
multi-functional display.
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before proceeding to the next step.
Next
B
Go to CAN communication system
5 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
234
BYD AUTO BYD Suri Maintenance & Repair Manual
B Go to step 8
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
B Go to step 8
Next
9 Confirmation test
Next
Completed
235
BYD AUTO BYD Suri Maintenance & Repair Manual
236
BYD AUTO BYD Suri Maintenance & Repair Manual
6 ECU terminals
1. Check multi-functional display pins
Standard Resistance
Terminal No. Terminal Specified
Wire Color Condition
(Symbol) Description Condition
He03-2-body Less than 1
B-body ground Group Always
ground Ω
He03-8-body Less than 1
B-body ground Group Always
ground Ω
237
BYD AUTO BYD Suri Maintenance & Repair Manual
Less than 1
He03-16-body Passenger safety Indicator OFF
R/L V
ground belt indicator
Indicator ON 11 to 14 V
238
BYD AUTO BYD Suri Maintenance & Repair Manual
239
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Replace multi-functional display
Next
Completed
240
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram:
Multi-functional display
Inspection Procedure
1 Inspect CAN line
Standard Voltage
Specified
Tester Connection Condition
Condition
He03-3 -body 2.5 to 3.5 V
Always
ground
He03-4-body 1.5 to 2.5 V
Always
ground
NG
241
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
Next
Completed
242
BYD AUTO BYD Suri Maintenance & Repair Manual
Audio system
Auxiliary Power
Supply Adapter
Audio system
Multi-functional display
243
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect fuse
NG Replace fuse
OK
Standard Voltage
Specified
Tester Connection Condition
Condition
G2N-10 -body ground Always 11 to 14 V
G2N-37- body ground Gear ACC 11 to 14 V
NG
OK
Standard Voltage
244
BYD AUTO BYD Suri Maintenance & Repair Manual
Specified
Tester Connection Condition
Condition
G2N-10-He03-1 Always 11 to 14 V
G2N-37-He03-11 Gear ACC 11 to 14 V
Standard Resistance
Specified
Tester Connection Condition
Condition
He03-8-body Less than 1 Ω
Always
ground
He03-2-body Less than 1 Ω
Always
ground
NG
OK
Completed
245
BYD AUTO BYD Suri Maintenance & Repair Manual
8 Removal
9 Installation
246
BYD AUTO BYD Suri Maintenance & Repair Manual
247
BYD AUTO BYD Suri Maintenance & Repair Manual
Seat back
adjustment
motor
Seat height
adjustment motor
Seat horizontal
adjustment motor
Seat pan
adjustment motor
Adjusting switch of
motor-driven seat
248
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Seat horizontal
adjustment motor
Adjusting switch of
motor-driven seat
Seat pan
adjustment motor
Seat back
adjustment motor
Seat height
adjustment motor
249
BYD AUTO BYD Suri Maintenance & Repair Manual
3 Diagnosis process
1 Vehicle brought to workshop
Next
Next
Result Proceed
Symptom is not listed in A
problem symptoms table
Symptom is listed in B
problem symptoms table
B Go to Step 5
4 Overall Diagnosis
Next
Next
6 Confirmation test
Next
7 Completed
250
BYD AUTO BYD Suri Maintenance & Repair Manual
251
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram:
Battery
Power seat
Inspection Procedures:
1 Inspect fuse
(a) Check whether the power seat F1/20 fuse
has continuity with a multimeter
NG Replace fuse
OK
252
BYD AUTO BYD Suri Maintenance & Repair Manual
Wire Normal
Terminal Condition
Color Condition
B2B-3-body
L Always 11-14 V
ground
NG
OK
3 Completed
253
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram:
Power seat
Inspection Procedures:
1 Inspect fuse
(a) Check whether the power seat F2/8 and
F2/10 fuses have continuity with a multimeter
NG Replace fuse
OK
254
BYD AUTO BYD Suri Maintenance & Repair Manual
Wire Normal
Terminal Condition
Color Condition
Driver power
seat
adjustment
W/R Always 11-14 V
switch
4-pin-body
ground
Driver seat
waist
adjustment
R Always 11-14 V
switch
10-pin-body
ground
Driver power
seat
adjustment Less than
B Always
switch 1Ω
2-pin-body
ground
Driver power
seat
adjustment Less than
B/W Always
switch 1Ω
8-pin-body
ground
NG
OK
3 Completed
255
BYD AUTO BYD Suri Maintenance & Repair Manual
Power seat
Driver
power
seat
adjustme
nt switch Forward Backward
Inspection Procedures:
1 Output voltage of driver power seat adjustment switch
256
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Terminal Condition
Condition
Driver power Horizontal
seat adjustment backward
switch 7-pin- adjustment or
± (11-14) V
Driver power horizontal
seat adjustment forward
switch 11-pin adjustment
OK Go to step 4
NG
Normal
Terminal Condition
Condition
Backward
10-11 horizontal Less than 1 Ω
adjustment
Backward
7-8 horizontal Less than 1 Ω
adjustment
Forward horizontal
10-7 Less than 1 Ω
adjustment
Forward horizontal
11-8 Less than 1 Ω
adjustment
Seat pan adjustment
Normal
Terminal Condition
Condition
10-3 Upward adjustment Less than 1 Ω
9-8 Upward adjustment Less than 1 Ω
Downward
10-9 Less than 1 Ω
adjustment
Downward
3-8 Less than 1 Ω
adjustment
Seat back adjustment
Normal
Terminal Condition
Condition
Tilt forward
4-6 Less than 1 Ω
adjustment
257
BYD AUTO BYD Suri Maintenance & Repair Manual
Tilt forward
12-2 Less than 1 Ω
adjustment
Tilt backward
4-12 Less than 1 Ω
adjustment
Tilt backward
6-2 Less than 1 Ω
adjustment
Seat height adjustment
Normal
Terminal Condition
Condition
4-1 Upward adjustment Less than 1 Ω
5-2 Upward adjustment Less than 1 Ω
Downward
4-5 Less than 1 Ω
adjustment
Downward
1-2 Less than 1 Ω
adjustment
NG
OK
Normal
Terminal Condition
Condition
Horizontal
backward
1-2 adjustment or ± (11-14) V
horizontal forward
adjustment
NG
OK
258
BYD AUTO BYD Suri Maintenance & Repair Manual
OK NG
5 Completed
259
BYD AUTO BYD Suri Maintenance & Repair Manual
Power seat
Driver power
seat
adjustment Upward Downward
switch
Inspection Procedures:
1 Output voltage of driver power seat adjustment switch
(a) Lead wire from the back and measure the
output voltage of the driver seat adjustment
switch
260
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Terminal Condition
Condition
Driver power Horizontal
seat adjustment upward
switch 3-pin- adjustment or
± (11-14) V
Driver power horizontal
seat adjustment downward
switch 9-pin adjustment
OK Go to step 4
NG
Normal
Terminal Condition
Condition
Backward horizontal
10-11 Less than 1 Ω
adjustment
Backward horizontal
7-8 Less than 1 Ω
adjustment
Forward horizontal
10-7 Less than 1 Ω
adjustment
Forward horizontal
11-8 Less than 1 Ω
adjustment
Seat pan adjustment
Normal
Terminal Condition
Condition
10-3 Upward adjustment Less than 1 Ω
9-8 Upward adjustment Less than 1 Ω
Downward
10-9 Less than 1 Ω
adjustment
Downward
3-8 Less than 1 Ω
adjustment
261
BYD AUTO BYD Suri Maintenance & Repair Manual
Tilt backward
4-12 Less than 1 Ω
adjustment
Tilt backward
6-2 Less than 1 Ω
adjustment
Normal
Terminal Condition
Condition
4-1 Upward adjustment Less than 1 Ω
5-2 Upward adjustment Less than 1 Ω
Downward
4-5 Less than 1 Ω
adjustment
Downward
1-2 Less than 1 Ω
adjustment
NG
OK
Normal
Terminal Condition
Condition
Upward adjustment or
1-2 ± (11-14) V
backward adjustment
NG
OK Replace wire harness (switch-motor)
262
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
5 Completed
263
BYD AUTO BYD Suri Maintenance & Repair Manual
Power seat
Driver
power seat
adjustment
switch
Tilt Tilt
forward backward
264
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures:
1 Output voltage of driver power seat adjustment switch
(a) Lead wire from the back and measure the
output voltage of the driver seat adjustment
switch
Normal
Terminal Condition
Condition
Driver power
seat adjustment Tilt backward
switch 4-pin- adjustment or
± (11-14) V
Driver power tilt forward
seat adjustment adjustment
switch 2-pin
OK Go to step 4
NG
Normal
Terminal Condition
Condition
Backward
Less than 1
10-11 horizontal
Ω
adjustment
Backward
Less than 1
7-8 horizontal
Ω
adjustment
Forward horizontal Less than 1
10-7
adjustment Ω
Forward horizontal Less than 1
11-8
adjustment Ω
Normal
Terminal Condition
Condition
Less than 1
10-3 Upward adjustment
Ω
9-8 Upward adjustment Less than 1
265
BYD AUTO BYD Suri Maintenance & Repair Manual
Ω
Downward Less than 1
10-9
adjustment Ω
Downward Less than 1
3-8
adjustment Ω
Normal
Terminal Condition
Condition
Tilt forward Less than 1
4-6
adjustment Ω
Tilt forward Less than 1
12-2
adjustment Ω
Tilt backward Less than 1
4-12
adjustment Ω
Tilt backward Less than 1
6-2
adjustment Ω
Normal
Terminal Condition
Condition
Less than 1
4-1 Upward adjustment
Ω
Less than 1
5-2 Upward adjustment
Ω
Downward Less than 1
4-5
adjustment Ω
Downward Less than 1
1-2
adjustment Ω
NG
OK
Normal
Terminal Condition
Condition
Tilt forward
adjustment or tilt
1-2 ± (11-14) V
backward
adjustment
OK
266
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
NG
OK
5 Completed
267
BYD AUTO BYD Suri Maintenance & Repair Manual
Power seat
Driver power
seat
adjustment
switch
Down Upward
ward
268
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures:
1 Output voltage of driver power seat adjustment switch
(a) Lead wire from the back and measure the
output voltage of the driver seat adjustment
switch
Normal
Terminal Condition
Condition
Driver power
Upward
seat adjustment
adjustment
switch 4-pin-
or ± (11-14) V
Driver power
downward
seat adjustment
adjustment
switch 2-pin
OK Go to step 4
NG
Normal
Terminal Condition
Condition
Backward
10-11 horizontal Less than 1 Ω
adjustment
Backward
7-8 horizontal Less than 1 Ω
adjustment
Forward horizontal
10-7 Less than 1 Ω
adjustment
Forward horizontal
11-8 Less than 1 Ω
adjustment
Normal
Terminal Condition
Condition
10-3 Upward adjustment Less than 1 Ω
9-8 Upward adjustment Less than 1 Ω
10-9 Downward Less than 1 Ω
269
BYD AUTO BYD Suri Maintenance & Repair Manual
adjustment
Downward
3-8 Less than 1 Ω
adjustment
Seat back adjustment
Normal
Terminal Condition
Condition
Tilt forward
4-6 Less than 1 Ω
adjustment
Tilt forward
12-2 Less than 1 Ω
adjustment
Tilt backward
4-12 Less than 1 Ω
adjustment
Tilt backward
6-2 Less than 1 Ω
adjustment
NG
OK
Normal
Terminal Condition
Condition
Upward Upward
adjustment or adjustment or
± (11-14) V
downward downward
adjustment adjustment
NG
270
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
5 Completed
271
BYD AUTO BYD Suri Maintenance & Repair Manual
272
BYD AUTO BYD Suri Maintenance & Repair Manual
273
BYD AUTO BYD Suri Maintenance & Repair Manual
274
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Power window
Dashboard
distributor
relay
box
Front-left window
lifter motor
275
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System overview
In the power window system, windows can be The power window motor adopts the latest
regulated through the switch on the door trim processes, technologies and materials, such
panel. On the driver's seat, windows are as water sealing design. Gas-permeable
regulated through the main switch on the membranes are adopted (After temperature
front-left door window lifter switch trim panel. rises during motor running, there may be a
The locking switch of the power window is on pressure gap inside and outside the motor,
the front door trim panel on the driver's side. It which breaks the seal at the weakest point. At
enables the driver to disable all passenger this time, the motor needs a respiratory unit to
window switches. The power window system balance the pressure gap so that there is no
works only when the start button is at ON. By impact to the weakest point. The
using of automatic window lowering (AUTO), gas-permeable membrane just plays this role.
the window on the driver's side can be lowered It can balance the pressure gap via gas and
to the bottom. During operation, press the block the fluid outside the motor, so that the
switch of the window on the driver's side in motor can meet requirements of water
lowering direction towards another position. sealing.); Polymer PTC over-current protector
Then automatic lowering is started. Press the is adopted for overheat protection of the motor,
switch again in any direction to stop the which can protect the motor from being burnt
window and cancel automatic lowering. Some more quickly and effectively due to external
functions and features of the power window faults (such as switch fault); Special design is
system rely on electronic module control. adopted for the motor rotating shaft to reduce
These electronic modules are integrated in the noise. Wear-resistant and shock-damping
front-left door window lifter switch block. materials are adopted to ensure that there is
no noise of metal impact or friction when the
Power window system consists of the following motor is running at a high speed; In terms of
components: motor power wire connection, terminal
Window lifter switch interface is adopted to replace the power lead
Window lifter motor wire, thus avoiding faults caused by lead wires,
such as poor contact; DC bipolar PM structure
Power window delay: Close the front door. is adopted, dual-way turning. An overheat
Within 10 minutes after vehicle power is protector is arranged inside so there is no
switched from ON to OFF, the window control need of protection in outer circuit. After
switch can still work. Light on the switch electrifying the motor, it will rotate under the
backlight to regulate the door window: Once magnetic field force. Then low-speed big
any front door is opened, delay will be torque got on the output gear through a big
disabled. worm gearbox. When the motor is stuck or the
circuit fails, the overheat protector can cut off
Remote controlled window raising/lowering the power supply in time to protect the motor.
function:
276
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis process
1 Vehicle brought to workshop
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
Result Proceed to
The fault is not recorded in the A
fault symptom table
The fault is recorded in the fault B
symptom table
B Go to Step 5
Next
277
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
6 Confirmation test
7 Completed
278
BYD AUTO BYD Suri Maintenance & Repair Manual
279
BYD AUTO BYD Suri Maintenance & Repair Manual
6 Terminal Diagnosis
1. Inspect front window switch LH
(a) Remove the front-left window switch T03
connector.
(b) Measure the resistance or voltage
between the terminals of the wire harness
side connector.
OK:
Terminal No. Wire Terminal Description Condition Normal
Color Value
T03-1-Body ground G/R Front-left window motor Always 11 ~ 14 V
power supply (battery)
T03-14Body Y Power ON Switch power supply 11~14 V
ground to the ON position.
T03-19-Body W/R Battery Always 11 ~ 14 V
ground
T03-8-Body ground W/G Power window relay Always 11 ~ 14 V
T03-9-Body ground B Ground Always Less than
1V
T03-10-Body W/B Ground Always Less than
ground 1V
Tips:
If the test results are not consistent with the normal
value, it's likely that there is something wrong with
the corresponding wire harness.
280
BYD AUTO BYD Suri Maintenance & Repair Manual
Tips:
281
BYD AUTO BYD Suri Maintenance & Repair Manual
Description:
The window control system power supply is drawn out from the dashboard distributor box.
Circuit Diagram
Battery
Window Control
System
282
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect power supply
NG
OK
283
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Battery
Window Control
System
Front-left Power
window motor window
relay
Rear-right Front-right Rear-left
window window window
motor motor motor
Inspection Procedures
1 Inspect fuse
Terminal Result
F1/23-1 both ends Less than 1 Ω
F2/16both ends Less than 1 Ω
F2/17both ends Less than 1 Ω
F2/18both ends Less than 1 Ω
F2/19both ends Less than 1 Ω
284
BYD AUTO BYD Suri Maintenance & Repair Manual
NG Replace fuse
OK
OK
285
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
4 Inspect relay
Terminal Result
1 - Battery positive Continuity in 3 and 5
2 - Battery negative
286
BYD AUTO BYD Suri Maintenance & Repair Manual
NG Replace relay
OK
NG
Change the front-left window lifter switch block
OK
OK
7 Circuit is ok.
287
BYD AUTO BYD Suri Maintenance & Repair Manual
Only the front-left window lifter can work. Other lifters cannot.
Circuit Diagram
Battery
Window Control
System
Motor
Window
Relay
Front-right Rear-left Rear-right
window window window
motor motor motor
Inspection Procedures
1 Check front-left window lifter switch block
NG
288
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
OK
Terminal Result
1 - Battery positive Continuity in 3 and 5
2 - Battery negative
OK
4 End
289
BYD AUTO BYD Suri Maintenance & Repair Manual
Description:
When the engine is working or the start button is at ON position, the front-left window lifter switch
block (front-left window switch) can control the front-left, front-right, rear-left and rear-right
windows. The front-left window has four gears: ① Stop; ② Up I; ③ Down I; ④ Down II (AUTO).
Circuit Diagram:
Battery
Inspection Procedures
1 Inspect fuse
NG Replace fuse
OK
290
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
NG Change a motor
OK
291
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
NG
Replace wire harness or connector
OK
6 End
292
BYD AUTO BYD Suri Maintenance & Repair Manual
Description:
When the engine is working or the start button is at ON position, and the window lock switch is
bounced up, the front-right window switch can control the front-right window. The front-right
window switch has three gears: Stop; Up; Down.
Circuit Diagram:
Battery
Front-right
window lifter
motor
293
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Check front-right window lifter control switch power supply
OK Go to step 4
NG
NG
OK
294
BYD AUTO BYD Suri Maintenance & Repair Manual
3 Check the wire harness (distribution box - front-right window lifter switch)
OK
NG
OK
295
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Replace the front-right door motor
OK
6 Check the wire harness (front-right window lifter switch - front-right door motor)
OK
7 End
296
BYD AUTO BYD Suri Maintenance & Repair Manual
Description:
When the engine is working or the start button is at ON position, and the window lock switch is
bounced up, the rear-right window switch can control the rear-right window. The rear-right window
switch has three gears: Stop; Up; Down.
Circuit Diagram:
Battery
Window Control
System Power
Window
Relay
Front-right Rear-left Rear-right
window window window
motor motor motor
Rear-right window
switch
Rear-right
window lifter
motor
297
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Check rear-right window lifter control switch power supply
OK Go to step 4
NG
NG
OK
3 Check the wire harness (distribution box - rear-right window lifter switch)
298
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
NG
Replace rear-right window lifter switch
OK
299
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
Check the wire harness (rear-right window lifter switch - rear-right door/window
6
motor)
OK
7 End
300
BYD AUTO BYD Suri Maintenance & Repair Manual
Description:
When the engine is working or the start button is at ON position, and the window lock switch is
bounced up, the rear-left window switch can control the rear-left window. The rear-left window
switch has three gears: Stop; Up; Down.
Circuit Diagram:
Battery
Window Control
Power
System
Window
Relay
Front-right Rear-left Rear-right
window window window
motor motor motor
Rear-left
window lifter
motor
301
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Check rear-left window lifter control switch power supply
OK Go to step 4
NG
NG
OK
302
BYD AUTO BYD Suri Maintenance & Repair Manual
3 Check the wire harness (distribution box - rear-left window lifter switch)
OK
NG
OK
303
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
6 Check the wire harness (rear-left window lifter switch - rear-left door/window motor)
OK
7 End
304
BYD AUTO BYD Suri Maintenance & Repair Manual
Description:
When the engine is working or the start button is at ON position, and the window lock switch is
bounced up, the front-left window switch can control the front-right, rear-left and the rear-right
windows. The button on the front-left window switch that controls the front-right, rear-left and
rear-right windows has three gears: Stop; Up; Down.
Circuit Diagram:
Power window relay
Front-right
window motor
Front-right
window switch
Front-right
window lifter
motor
305
BYD AUTO BYD Suri Maintenance & Repair Manual
Power window
relay
Rear-left
window motor
Rear-left
window switch
Rear-left
window lifter
motor
306
BYD AUTO BYD Suri Maintenance & Repair Manual
Power window
relay
Rear-left
window motor
Rear-right
window
lifter motor
307
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 On-vehicle Inspection
A
Check the power supply of the window control
system.
B
Jump to the corresponding window lifter circuit
for inspection
OK
Front-right
Rear-right
Rear-left
308
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
309
BYD AUTO BYD Suri Maintenance & Repair Manual
Description:
When the engine is working or the start
button is switched to ON position, and when
the window lock switch is bounced up, the
front-right, the rear-right and the rear-left
window switches can control the
corresponding lifters independently. The
front-left switch can also control the
front-right, rear-right and the rear-left window
lifters. When the window lock switch is
pressed, the front-right, rear-right and
rear-left window switches don't work, and the
front-left switch cannot control the front-right,
rear-left and rear-right window lifters.
Inspection Procedures
1 Change the front-left window lifter switch block
Preparation of Tools
Gloves A pair
Wrench Size-10 socket wrench and ratchet wrench
Straight screwdriver One piece
Crosshead Screwdriver One piece
310
BYD AUTO BYD Suri Maintenance & Repair Manual
Disassembly
1. Disconnect battery negative.
2. Remove front-left door window lifter switch
3. Remove the Front Door Shield Inner LH
4. Disconnect the window lifter connector.
5. Remove the rear-left door window
a Switch on the rear-left window lifter and
adjust the height of the window. You can
see the window mounting point from the
two holes in the diagram. (a) Take out the window lifter assembly.
Assembly
b Remove 2 set nuts with the Size-10 socket 1. Install window lifter assembly.
wrench. (a) Put the window lifter assembly into the
door plate, aligned with the mounting
hole.
(b) Install seven set bolts.
311
BYD AUTO BYD Suri Maintenance & Repair Manual
Disassembly
1. Disconnect battery negative.
2. Remove front-left window control switch
(a) Prize the front-left window control switch
according to the diagram with a
screwdriver.
312
BYD AUTO BYD Suri Maintenance & Repair Manual
313
BYD AUTO BYD Suri Maintenance & Repair Manual
314
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
315
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System overview
The power outer rear view mirror system can
be controlled by the electrical switch on the
dashboard to the left of the driver's seat. When
the power outer rear view mirror is hit, the
housing will be unfolded to some extent in the
direction of force, so as to protect the rear view
mirror from damage. If the mirror is hit and
crashed, fragments will not leave the mirror
holder, so it's quite safe.
Auto folding:
(1) At OFF position, press the remote locking
button and the door is locked; BCM will
drive the power outer rear view mirror to
be folded automatically;
(2) At OFF position, press the remote
unlocking button and the door is unlocked.
BCM will drive the power outer rear view
mirror to be unfolded.
Main components:
Rear view mirror assembly
Control switch
BCM
316
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis process
1 Vehicle taken to the workshop
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
B Go to step 8
317
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
8 Confirmation test
Next
End
318
BYD AUTO BYD Suri Maintenance & Repair Manual
319
BYD AUTO BYD Suri Maintenance & Repair Manual
6 ECU terminals
1. Inspect dashboard distributor box
320
BYD AUTO BYD Suri Maintenance & Repair Manual
321
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Inspection Procedures
1 Inspect power supply
Normal
Terminal Wire Color
Condition
G41-8-body
Y/R 11-14 V
ground
NG
OK
322
BYD AUTO BYD Suri Maintenance & Repair Manual
Wire Normal
Terminal
Color Condition
G41-7-body
B Less than 1 V
ground
NG
OK
323
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Change the power outer rear view mirror switch
OK
324
BYD AUTO BYD Suri Maintenance & Repair Manual
Only the left power outer rear view mirror cannot be regulated.
Circuit Diagram
Left Up+
Right Down+
Inspection Procedures
1 Check the power outer rear view mirror switch
Test condition
Terminal Normal Value
(switch)
G41-8-G41-5 Leftward Less than 1Ω
325
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Change the power outer rear view mirror switch
OK
NG
OK
Check the wire harness (power outer rear view mirror switch - left power outer rear
3
view mirror)
326
BYD AUTO BYD Suri Maintenance & Repair Manual
Wire
Terminal Normal Condition
Color
G41-5-T05-4 R/Y Less than 1 Ω
G41-4-T05-3 W/R Less than 1 Ω
G41-6-T05-9 G/W Less than 1 Ω
OK
4 End
327
BYD AUTO BYD Suri Maintenance & Repair Manual
Only the right power outer rear view mirror doesn't work.
Circuit Diagram
Left+ Up+
Right + Down+
Inspection Procedures
1 Check the power outer rear view mirror switch
328
BYD AUTO BYD Suri Maintenance & Repair Manual
Test condition
Terminal Normal Value
(switch)
G41-8-G41-2 Leftward Less than 1 Ω
G41-7-G41-6 Leftward Less than 1 Ω
G41-2-G41-7 Rightward Less than 1 Ω
G41-8-G41-6 Rightward Less than 1 Ω
G41-8-G41-3 Upward Less than 1 Ω
G41-6-G41-7 Upward Less than 1 Ω
G41-3-G41-7 Downward Less than 1 Ω
G41-8-G41-6 Downward Less than 1 Ω
Between any Larger than 10
No direction
terminals KΩ
NG
OK
NG
329
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
Check the wire harness ( power outer rear view mirror switch - right power outer
3
rear view mirror)
OK
4 End
330
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Inspection Procedures
1 Check the power outer rear view mirror switch
331
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
2 Check the wire harness (power outer rear view mirror switch - BCM)
OK
332
BYD AUTO BYD Suri Maintenance & Repair Manual
G2X-2-body
O 11-14 V
ground Switch is
G2N-34-body pressed Less than
G
ground 1V
G2X-2-body Less than
O Switch is
ground 1V
bounced
G2N-34-body up
G 11-14 V
ground
NG Replace BCM
OK
NG
OK
5 Check the wire harness (BCM - power outer rear view mirror)
333
BYD AUTO BYD Suri Maintenance & Repair Manual
Wire
Terminal Normal Condition
Color
G2X-2-T05-8 O Less than 1 Ω
G2N-34-T05-2 G Less than 1 Ω
NG
OK
6 End
334
BYD AUTO BYD Suri Maintenance & Repair Manual
7 Disassembly 8 Assembly
Take the left outer rear view mirror assembly 1. Left outer rear view mirror assembly
for example. (a) Align the left outer rear view mirror
1. Remove the front-left door trim plate assembly with the mounting hole.
2. Remove the Front High Pitch Speaker LH (b) Align the front door speaker LH with the
trim plate mounting holes.
(a) Disconnect the connector. (c) Install 3 set screws.
(b) Remove 3 bolts with 10# socket wrench. (d) Connect the connector.
(c) Remove the outer rear view mirror
assembly.
335
BYD AUTO BYD Suri Maintenance & Repair Manual
336
BYD AUTO BYD Suri Maintenance & Repair Manual
1 System overview
The sun roof system is panoramic. The sun
roof control motor assembly opens, closes,
raises and lowers the sun roof by controlling
the forward/backward turning of the motor.
337
BYD AUTO BYD Suri Maintenance & Repair Manual
2 Diagnosis process
1 Vehicle brought to workshop
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
Result Proceed
The fault is not recorded in the A
fault symptom table
The fault is recorded in the B
fault symptom table
B Go to Step 5
Next
338
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
6 Confirmation test
Next
7 End
339
BYD AUTO BYD Suri Maintenance & Repair Manual
340
BYD AUTO BYD Suri Maintenance & Repair Manual
Description:
If the sun roof doesn't work completely, maybe the problem lies in the power supply.
Battery
Sun roof
Window Control
System
Check Procedures
1 Inspect fuse
341
BYD AUTO BYD Suri Maintenance & Repair Manual
NG Replace fuse
OK
(a) Take out the lead from the back end of the
dashboard distribution box G2X-19 terminal.
(b) Check the voltage of terminal.
Terminal Test Normal
Condition Value
G2X-19-body Always 11~14 V
ground
NG
OK
OK
4 Circuit is ok.
342
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Indoor lighting
Check Procedures
1 Inspect fuse
NG Replace fuse
OK
343
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
344
BYD AUTO BYD Suri Maintenance & Repair Manual
345
BYD AUTO BYD Suri Maintenance & Repair Manual
Wiper motor
Right
combination
switch
Washing motor
346
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Combination Switch
Front cabin
distribution Washing motor
box
Wiper motor
347
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System Description
Wiping and washing system for front
windshield is mainly composed of wiper arm
assembly, mechanical linkage for wiper, wiping
brush, wiper motor, washing pump, washing
water pot, washing duct and nozzles. The
system provides various functions, including
spot wiping, intermittent wiping, slow wiping
and fast wiping. This system is intended to
ensure the visual field for the driver by
providing convenient, secure and reliable
facility.
348
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis process
1 Vehicle taken to the workshop
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
Result
Result Proceed to
No output of CAN communication system DTC A
CAN communication system DTC output B
B Proceed to step 6
5 Overall Diagnosis
Next
Next
7 Confirmation test
349
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
8 Completed
350
BYD AUTO BYD Suri Maintenance & Repair Manual
351
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery
Combination Switch
352
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspect Procedure
1 Inspect the trouble codes
Normal
Abnormal
353
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Terminal Wire Color
Condition
G24-5 - Body
W/R 11-14 V
ground
G24-6 - Body
Y 11-14 V
ground
G24-3 - Body Less than 1
B
ground V
Abnormal
Abnormal
Normal
354
BYD AUTO BYD Suri Maintenance & Repair Manual
Terminal Resistance
G24-1-G24-2 56-64 Ω
Normal
Normal
Go to false list for next step, or replace relay control module, or inspect relay control
7
module
355
BYD AUTO BYD Suri Maintenance & Repair Manual
Wiper
Switch Motor
relay of relay of
internal internal
wiper wiper
Wiper
reset
Wiper
motor
356
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspect Procedure
1 Inspect the fuse
Normal
Normal
(a) Pull out the relay KI1-2 from the relay control
module.
357
BYD AUTO BYD Suri Maintenance & Repair Manual
and 2
Abnormal Replace relay
Normal
(a) Pull out the relay KI1-1 from the relay control
module.
(b) Inspect the relay terminal
Normal
Terminal State
Condition
Battery voltage applied Less than
3-5
to terminals 1 and 2 1Ω
Battery voltage not
More than
3-5 applied to terminals 1
10 KΩ
and 2
Battery voltage applied More than
3-4
to terminals 1 and 2 10 KΩ
Battery voltage not
Less than
3-4 applied to terminals 1
1Ω
and 2
Normal
Normal
Terminal State
Condition
2 - Battery
Running of
positive
-- the motor in
4-Battery
a low speed.
negative
1 - Battery Running of
positive -- the motor in
4 - Battery a high speed
358
BYD AUTO BYD Suri Maintenance & Repair Manual
negative
The motor not
More than
3-4 stops in idle
10 KΩ
position
The motor stops Less than 1
3-4
in idle position Ω
Abnormal
Normal
Wire
Terminal Normal Condition
Color
B01-2-B1J-4 L Less than 1 Ω
B01-1- B1J-5 Y Less than 1 Ω
B01-3- B1J-1 W Less than 1 Ω
B01-4 - Body
B More than 10 KΩ
ground
Normal
359
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Motor
relay of
internal
washer Washing
motor of
the front
window
360
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspect Procedure
1 Inspect the fuse
Normal
Normal
(a) Pull out the relay KI1-3 from the relay control
module.
(b) Measure the relay terminal.
Normal
Terminal Wire Color
Condition
Battery voltage
3-5 applied to Less than 1 Ω
terminals 1 and 2
Battery voltage not
More than 10
3-5 applied to
KΩ
terminals 1 and 2
361
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Abnormal
Normal
Abnormal
Normal
362
BYD AUTO BYD Suri Maintenance & Repair Manual
363
BYD AUTO BYD Suri Maintenance & Repair Manual
364
BYD AUTO BYD Suri Maintenance & Repair Manual
365
BYD AUTO BYD Suri Maintenance & Repair Manual
1 System overview
The rear LOGO assembly is arranged at the
rear part of the vehicle. It is obvious in
darkness and can be a reminder for vehicles
behind.
366
BYD AUTO BYD Suri Maintenance & Repair Manual
Sidelamp
小灯
K2F-12
R/B
0.85
1 K40
Rear LOGO后Logo灯
light
3 K40
K7
367
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures:
1 Check the sidelamps
OK
NG
OK
OK
368
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal Assembly
(a) Disconnect the negative electrode of the (a) Align the LOGO with the mounting holes
storage battery and install it.
(b) Prize the LOGO carefully with a (b) Connect the negative electrode of the
screwdriver. storage battery
369
BYD AUTO BYD Suri Maintenance & Repair Manual
370
BYD AUTO BYD Suri Maintenance & Repair Manual
Cruise instruction:
Cruise switch:
2 System overview
The vehicle is provided with a cruise control
system. Fixed speed cruise control enables
you to keep the speed higher than 40 km/h
without treading on the accelerator pedal.
This function is enabled when the car runs on
a straight and smooth highway.
371
BYD AUTO BYD Suri Maintenance & Repair Manual
3 Diagnosis process
1 Vehicle taken to the workshop
Next
Next
Next
Next
5 Confirmation test
Next
Completed
372
BYD AUTO BYD Suri Maintenance & Repair Manual
Cruise switch
Harness or connector
ECM
ECM
373
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Electronic
throttle
valve
body
374
BYD AUTO BYD Suri Maintenance & Repair Manual
Steering wheel
cruise switch
Clock spring
375
BYD AUTO BYD Suri Maintenance & Repair Manual
Check Procedures
1 Check whether cruise control works.
Situation Go to
The car cannot run normally. A
The car can run normally, but you
B
cannot enter cruise control mode.
You can enter cruise control mode,
C
but there are other faults.
A
Please check the engine management system.
C Go to step 4
Connection Normal
Condition
terminal Value
Press the cruise About 1000
10 - 11
switch Ω
Press the cruise About 3160
10 - 11
closing switch Ω
NG
OK
376
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal:
No vehicle speed malfunction
OK
Connection
Condition Normal Value
terminal
Tread the
1-2 Less than 1 Ω
brake pedal
Tread the
3-4 More than 1 MΩ
brake pedal
Release the
1-2 More than 1 MΩ
brake pedal
Release the
3-4 Less than 1 Ω
brake pedal
OK
377
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal:
The throttle openness changes with the
compression of the pedal.
NG
OK
Normal:
Throttle openness changes with times for
which the cruise switch is pressed.
NG
OK
NG
OK
8 End
378
BYD AUTO BYD Suri Maintenance & Repair Manual
379
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
Tire pressure
monitoring and
control module
Tire pressure
monitoring module
380
BYD AUTO BYD Suri Maintenance & Repair Manual
Seal Ring
Plastic
gasket
Metal gasket
Hex nut
Protective
cap
381
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
UHF 433.92MHZ
Tire
pressure
monitoring
module
Tire Tire
and
Display CAN control Tire
pressure
unit module monitoring
module
Tire
pressure
monitoring
module
382
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System Description
1. Tire pressure monitoring module
Arranged inside the tire, it measures the
tire pressure and transmits information via
wireless transmission. Integrated with the
valve, it can be divided into the monitoring
module body and the valve.
383
BYD AUTO BYD Suri Maintenance & Repair Manual
4 How to Troubleshoot
Tips:
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
5 Inspect DTC*
384
BYD AUTO BYD Suri Maintenance & Repair Manual
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
B Go to step 8
Next
9 Confirmation test
Next
End
385
BYD AUTO BYD Suri Maintenance & Repair Manual
386
BYD AUTO BYD Suri Maintenance & Repair Manual
6 ECU terminals
1 Check the pin of the tire pressure
monitoring and control module
Terminal Specified
Terminal No. (Symbol) Wire Color Condition
Description Condition
W/R-Vehicle Body
K35-1 - Body ground Power ON (IG1) Always 11 to 14 V
Ground
P-Vehicle Body
K35-6 - Body ground CAN-H Always About 2.5 V
Ground
V-Vehicle Body
K35-12 - Body ground CAN-L Always About 2.5 V
Ground
Standard Resistance
Terminal Specified
Terminal No. (Symbol) Wire Color Condition
Description Condition
B-Vehicle Body
K35-7 - Body ground Battery ground Always Less than 1 Ω
Ground
387
BYD AUTO BYD Suri Maintenance & Repair Manual
388
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Adapter
Inspection Procedures
1 Inspect CAN line
OK
Next
End
389
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect fuses
OK
390
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Voltage
Standard Resistance
Specified
Tester Connection Condition
Condition
Less than
K35-7 - Body ground Always
1Ω
Abnormal
OK
End
391
BYD AUTO BYD Suri Maintenance & Repair Manual
392
BYD AUTO BYD Suri Maintenance & Repair Manual
c Connect the connector. (d) Place the tire on the workbench of the tire
disassembly machine and chuck the rim.
2. Install the trim panel of right C column Remove the tire from the edge by using of
the tire remover. Remove the valve
assembly in the tire and place it at
designated position;
393
BYD AUTO BYD Suri Maintenance & Repair Manual
Note:
(c) Place the rim on the tire disassembly
Protective caps, valve cores, hex nuts, metal machine, as shown in the figure below:
gaskets and valve assemblies should be used rotate the rim clockwise and adjust the
repeatedly, so they should be well protected position of the rim to keep the mounting
during disassembly and then kept at head of the tire disassembly machine at
designated position; 12'o clock. The monitoring module must be
within the section line. Apply lubricant on
Plastic gaskets and seal rings are the hub and the tire, sleeve the rim with the
consumables and should be replaced when lower tire edge, rotate the rim and install
they're installed next time (unless otherwise the whole lower tire edge on the rim. Make
stipulated). sure that the tire edge doesn't touch the
monitoring module during installation
394
BYD AUTO BYD Suri Maintenance & Repair Manual
395
BYD AUTO BYD Suri Maintenance & Repair Manual
Backup camera
assembly
Rear-right
angle sensor
Rear-left angle
sensor Right-reverse
Left-reverse sensor
sensor
396
BYD AUTO BYD Suri Maintenance & Repair Manual
Auxiliary
parking
system
module
Front-right Front-left
corner corner
probe probe
397
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System overview
Vehicle parking system consists of parking When there is mud or snow on the
auxiliary system and parking imaging system. sensor (The sensor can be resumed
Parking auxiliary system is a vehicle after foreign matters have been
monitoring system that imitates bat's flight flushed by water.)
detection principles. Ultrasonic wave sensors The vehicle is exposed to sunshine
are arranged at the tail or head of the vehicle or extremely low temperature
to send or receive signals, and feedback The sensor may suffer wrong
information to the controller. The controller detection in any of the following
calculates the distance of the tested obstacle circumstances
according to the return time, and gives When the vehicle is on uneven road,
different audio warning and indicator warning gravel pavement or grassland
based on the distance to remind the driver of When there is horn of other vehicles,
the distance between the obstacle and the engine sound of motorcycles and air
vehicle, thus making reversing and parking brake sound of large vehicles
more convenient and safer;
Vehicles in heavy rain or with water
stain
The parking imaging system is a new
technology. The wide angle camera on the
Vehicles incline greatly
body takes photo of the view not easily When there is mud or snow on the
observed during parking. The multimedia sensor
displayer corrects and displays images for the The vehicle has a towing hook
driver. Meanwhile, the driver can switch views When another vehicle with a sensor
through the switching button on the steering approaches
wheel to choose the image needed, thus When the vehicle runs to high or
facilitating parking. right-angle curbs
(b) Due to the shape, features or material
1. Composition of the parking system: of the obstacle, the sensor may fail to
Auxiliary parking system module detect the following items:
Sensors (six, 2 at the front and 4 at the Linear objects, such as wires or
back) ropes
No.2 switch block (parking auxiliary Objects that absorb sound saves,
switch) such as cotton and snow, etc.
Multimedia Machine (flagship/luxury) Objects with sharp edges
Reversing light switch Object too low
Dashboard distributor box Object too high or upper part
Camera (front-right camera and backup projecting
camera) When the sensor is impacted or
Steering wheel switch (imaging switch) collided greatly
2. Notes for the parking auxiliary system: When the vehicle is too close to the
(a) Sensor detection may fail functioning step, the system cannot measure the
well in any of the following situations: distance between the bottom step
When there is mud or snow on the and the vehicle tail, thus causing
sensor (The sensor can be resumed damage to the fender.
after foreign matters have been (c) Notes for the parking imaging system:
flushed by water.) Don't hit the camera by hard objects,
When the sensor is blocked by or the camera may be damaged.
hands Don't wipe the lens with hands or
When the temperature outside is low hard cloth, or the lens may be
and the sensor fails due to icing, the scratched, thus affecting imaging.
scope of detection may change in Use fresh water or cleaning agent to
any of the following circumstances. clean the lens.
398
BYD AUTO BYD Suri Maintenance & Repair Manual
399
BYD AUTO BYD Suri Maintenance & Repair Manual
3 Diagnosis process
Tips:
Troubleshooting Procedures Are As Follows
Use the diagnostic unit for analysis for Step 4.
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
Result Proceed
The fault is not recorded in A
the fault symptom table
The fault is recorded in the B
fault symptom table
B Go to Step 5
Next
400
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
6 Confirmation test
Next
7 End
401
BYD AUTO BYD Suri Maintenance & Repair Manual
5 DTC table
DTC Implication Fault Area
B1B00-00 Front-left corner sensor cannot work well. Front-left corner sensor fails
B1B01-00 Front-right corner sensor cannot work well. Front-right corner sensor fails
B1B02-00 Rear-left corner sensor cannot work well. Rear-left corner sensor fails
B1B03-00 Rear-right corner sensor cannot work well. Rear-right corner sensor fails
B1B04-00 Left reverse sensor cannot work well. Rear-left reverse sensor fails
B1B05-00 Right reverse sensor cannot work well. Rear-right reverse sensor fails
402
BYD AUTO BYD Suri Maintenance & Repair Manual
6 Terminal Diagnosis
1. Check auxiliary parking system module
403
BYD AUTO BYD Suri Maintenance & Repair Manual
404
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnormal
Next
Next
405
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Auxiliary parking
system module
Front-left
corner sensor
406
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Check front-left corner sensor
Normal
Abnormal
Abnormal
Normal
407
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Auxiliary parking
system module
Front-right
corner sensor
Inspection Procedures
1 Check front-right corner sensor
Normal:
No trouble
Normal
Abnormal
408
BYD AUTO BYD Suri Maintenance & Repair Manual
Terminal Normal
Wire Color Resistance
Value
K17-16-C24-1 Y/G(G24Termin Less than 1
al wire color G) Ω
K17-31-C24-2 B/L Less than 1
Ω
Normal
409
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Auxiliary parking
system module
Rear-left corner
sensor
Inspection Procedures
1 Check rear-left corner sensor
Normal
Abnormal
410
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnormal
Normal
411
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Auxiliary parking
system module
Rear-right
corner sensor
Inspection Procedures
Normal
Abnormal
412
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
413
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Auxiliary parking
system module
Left-reverse
sensor
Inspection Procedures
1 Check left-reverse sensor
Normal
Abnormal
414
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnormal
Normal
415
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Auxiliary parking
system module
Right-reverse
sensor
Inspection Procedures
Normal
Abnormal
416
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
417
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Dashboard
Wire Harness
Adapter
Reversing radar
switch
Inspection Procedures
1 Inspect fuses
418
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Abnormal
Abnormal
Normal
419
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnormal
Normal
Abnormal
Normal
420
BYD AUTO BYD Suri Maintenance & Repair Manual
The sensor works well and the buzzer gives no alarm/ buzzer
gives alarm abnormally.
Circuit diagram
Adapter
Inspection Procedures
1 Check multi-functional display
Normal
Abnormal
421
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Normal:
No trouble
Normal
Normal
3 End
422
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Adapter
Inspection Procedures
1 Check sensor installation
Normal:
Normal
Normal
423
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal:
There is DTC output.
Normal
Abnormal
Normal:
No trouble
Normal
Abnormal
Normal:
No trouble
424
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Abnormal
Normal
6 End
425
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Adapter
Inspection Procedures
1 Check the display of parking auxiliary switch in No.2 switch block
Normal:
Sensors are installed correctly.
Normal
426
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnormal
Normal
Normal:
No trouble
Normal
Abnormal
427
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal:
No trouble
Normal
5 End
428
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
DVD host
Clock spring
Steering wheel
side camera
control switch
Inspection Procedures
1 Check the switch signal
429
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Abnormal
Replace the steering wheel switch.
Normal
Abnormal
Normal
4 End
430
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
DVD host
Shielding
layer
Inspection Procedures
1 Inspect power supply
Abnormal
431
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Abnormal
Normal
Normal:
Reverse image is OK.
Normal
4 Replace a camera
432
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
DVD host
Shielding
layer
Shielding
layer
Screen ground
Front-right camera
Inspection Procedures
1 Inspect power supply
Abnormal
Replace wire harness or connector
433
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Abnormal
Normal
Normal:
Abnormal
Replace DVD host
Normal
4 Replace a camera
434
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
DVD host
Shielding
layer
Shielding
layer
Screen ground
Front-right camera
Inspection Procedures
1 Check the signal line
Abnormal
Change the camera.
Normal
435
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal:
Reverse image is OK.
Normal
3 Replace a camera
436
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembly
1. Auxiliary parking system module
assembly
(a) Place the auxiliary parking system
module at the designated position.
(b) Install the two set bolts with No.10
ratchet wrench.
437
BYD AUTO BYD Suri Maintenance & Repair Manual
438
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 15 Accessories
439
BYD AUTO BYD Suri Maintenance & Repair Manual
Cigarette
lighter
440
BYD AUTO BYD Suri Maintenance & Repair Manual
Siren
441
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System overview
Accessories mainly include the cigarette
lighter, the electrical horns, the siren, the inner
rear view mirror direction display and the
onboard power supply, etc.
442
BYD AUTO BYD Suri Maintenance & Repair Manual
3 Diagnosis process
1 Vehicle taken to the workshop
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
443
BYD AUTO BYD Suri Maintenance & Repair Manual
B Go to step 8
Next
8 Confirmation test
Next
End
444
BYD AUTO BYD Suri Maintenance & Repair Manual
445
BYD AUTO BYD Suri Maintenance & Repair Manual
Cigarrette lighter
Cigarrette lighter
Cigarette
lighter
relay
Cigarette lighter
Cigarrette lighter
446
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect fuses
Normal
Connection Normal
Test condition
terminal Value
G2N-12-Body ACC power
11~14 V
ground supply
G01-1-Body ACC power
11~14 V
ground supply
Abnormal
Normal
Connection Normal
Wire Color
terminal Value
G22-2-Body
W/R 11~14 V
ground
G22-1-Body Less than
B
ground 1Ω
G22-3-Body
R/B 11-14 V
ground
447
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnormal
Normal
448
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Battery
Internal electric
horn relay
fanfare horn
fanfare horn
Right bass
Left bass
449
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Abnormal
Normal
Wire
Connection terminal Normal Value
Color
C1H-7-C09-1 L/R Less than 1 Ω
C1H-8-C27-1 G/R Less than 1 Ω
C08-5-Body ground B Less than 1 Ω
C14-1-Body ground B Less than 1 Ω
Normal
450
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Battery
Horn, brake
Clock
spring
Internal horn
relay Horn
switch
451
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Examine the electric horn
Normal:
The fuse is through.
Normal
Connection Normal
Test condition
terminal Value
Less than 1
Horn pressed
B1I-6-Body Ω
ground More than
Horn not pressed
10 kΩ
Abnormal
Test Normal
Connection terminal
condition Value
C1H-7-Body ground Horn
11~14 V
C1H-8-Body ground pressed
452
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnormal
Normal
453
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Battery
Horn,
braking light
Inner siren
relay
Siren
454
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect fuses
Normal:
The fuse is through.
Abnormal
Replace fuse
Normal
2 Inspect siren
Normal
Abnormal
455
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Connection Wire
Normal Value
terminal Color
B1I-1-B2D-11 V Less than 1 Ω
B1I-2-B2D-12 P Less than 1 Ω
Abnormal
Normal
Connection Normal
Test condition
terminal Value
B1I-4-Body
In alarm status 11~14 V
ground
B1I-4-Body Not in alarm Less than 1
ground status V
Abnormal
Normal
456
BYD AUTO BYD Suri Maintenance & Repair Manual
Connection
Wire Color Normal Value
terminal
B1I-4-K20-1 Br/Y 11~14 V
K20-2-Body
B Less than 1 V
ground
Abnormal
Normal
7 End
457
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembly
1. Install the cigarette lighter
(a) Place the cigarette lighter in the hole.
458
BYD AUTO BYD Suri Maintenance & Repair Manual
Content
1
BYD AUTO BYD Suri Maintenance & Repair Manual
2
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 1
Anti-theft system
Content
1 Parts location ............................................................................................................ 4
2 System diagram .......................................................................................................... 6
3 System overview ....................................................................................................... 7
4 Diagnosis flow ......................................................................................................... 10
5 Problem symptoms table ........................................................................................ 12
6 ECU terminals ......................................................................................................... 13
7 Removal and installation of siren ............................................................................ 29
3
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts location
Instrument panel
distribution box
4
BYD AUTO BYD Suri Maintenance & Repair Manual
Siren
Front
compartment
distribution
box
5
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System diagram
Anti-theft siren
Rear door latch RH
detection
Meter
6
BYD AUTO BYD Suri Maintenance & Repair Manual
3.1.2 The anti-theft system has 4 states: - The anti-theft system is operating
disarmed state, arming preparation state,
armed state and alarm state. Alarm state
Blinking
Theft warning indicator blinks
Frequency: 30 times/min
Blinking
Frequency: 85 times/min
Alarm methods Hazard warning indicator blinks Continues for 25 seconds and
5-second pause, in this cycle for 25
seconds
Sounding
Anti-theft siren sounds
Frequency: 150~200 times/min
Alarm duration Approximately 300 seconds
Tips:
7
BYD AUTO BYD Suri Maintenance & Repair Manual
Disarmed state
Condition Condition
3 1
Condition
2
Condition
4
Condition 6
Alarm state
8
BYD AUTO BYD Suri Maintenance & Repair Manual
Condition Event
In the disarmed state with all doors closed, the arming preparation
state can be entered by performing the following operations:
Lock by wireless operation
Lock by sensitive switch
Condition 1 (arming Automatic lock
preparation state When the engine hood or trunk lid is not closed, lock them by
entered) wireless operation or sensitive switch and then both of them are
detected to be closed.
When the trunk lid is opened by wireless operation or sensitive
switch in rear end of the vehicle, the vehicle turn from armed state
to disarmed state, and the trunk lid is detected to be closed
After entering the arming preparation state, the anti-theft indicator will
Condition 2 (armed
be turned on and last for 10 seconds, and after that the armed state
state entered)
will be entered with the anti-theft indicator blinking.
In the arming preparation state, perform the following operations to
cancel;
Open any door
Condition 3 (arming Open any door latch
preparation state Open the engine hood or trunk lid
canceled) Press the start button and detect the key in the vehicle
Open the trunk lid by wireless operation
Tips: After canceling the arming preparation state, the anti-theft
indicator will be turned off
In the armed state, an alarm will be triggered (turn light flashes,
frequency: 85 times/min, continues for 25 seconds, 5-second pause,
in this cycle for 10 times)if the following signals are detected;
Any door is open(except when the door is opened by wireless
Condition 4 (alarm
operation or sensitive switch)
cycled)
Open any door latch
Open the engine hood or trunk lid
IG1 voltage is detected
Reconnect the battery after it is disconnected
In the armed state, perform the following operations to cancel:
Unlock by wireless operation or sensitive switch
Condition 5 (armed Press the start button and detect the key in the vehicle
state canceled) Open the trunk lid by wireless operation
Tips: The anti-theft indicator will be turned off after canceling the
armed state; and the vehicle turned to the disarmed state
In the alarm state, perform the following operations to cancel:
Condition 6 (alarm Open a lock by wireless operation/sensitive switch
state canceled) Press the start button. And detect the key in the vehicle
Open the trunk lid by wireless operation
9
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis flow
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
B Go to step 8
10
BYD AUTO BYD Suri Maintenance & Repair Manual
ECU terminals
Next
Next
9 Confirmation test
Next
End
11
BYD AUTO BYD Suri Maintenance & Repair Manual
12
BYD AUTO BYD Suri Maintenance & Repair Manual
6 ECU terminals
a Inspect dashboard distributor box
Wire Terminal
Terminal No. Condition Normal value
color description
13
BYD AUTO BYD Suri Maintenance & Repair Manual
14
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Engine
Left front hood
door lock switch
motor (closed:
engine
hood
open)
15
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection procedures
OK
OK
Normal
Terminal Test condition
value
T03-4 - Body Front door lock Less than 1
ground LH unlocked Ω
T03-4 - Body Front door lock More than
ground LH locked 10 kΩ
Normal
Terminal Test condition
value
G2P-3 - Body Rear door lock Less than 1
ground LH unlocked Ω
G2P-3 - Body Rear door lock More than
ground LH locked 10 kΩ
16
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Terminal Test condition
value
G2Q-14 - Body Front door lock Less than 1
ground RH unlocked Ω
G2Q-14 - Body Front door lock More than
ground RH locked 10 kΩ
Normal
Terminal Test condition
value
G2P-2 - Body Rear door lock Less than 1
ground RH unlocked Ω
G2P-2 - Body Rear door lock More than
ground RH locked 10 kΩ
NG
OK
Normal
Terminal Test condition
value
C1H-2 - Body Engine hood Less than
ground open 1Ω
C1H-2 - Body Engine hood More than
ground closed 10 kΩ
Normal
Terminal Test condition
value
G2P-20 - Body Less than 1
Trunk lid open
ground Ω
G2P-20 - Body Trunk lid More than
17
BYD AUTO BYD Suri Maintenance & Repair Manual
ground closed 10 kΩ
NG
OK
Wire
Terminal Normal value
color
T03-17 - Body ground V Approx. 2.5 V
T03-18 - Body ground P Approx. 2.5 V
B1I-1 - Body ground V Approx. 2.5 V
B1I-2 - Body ground P Approx. 2.5 V
OK
6 Replace BCM
18
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
19
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection procedures
1 Inspect button switch latch of each door
Normal
Terminal Test condition
value
T03-4 - Body Front door lock Less than
ground LH unlocked 1Ω
T03-4 - Body Front door lock More than
ground LH locked 10 kΩ
Normal
Terminal Test condition
value
G2P-3 - Body Rear door lock Less than
ground LH unlocked 1Ω
G2P-3 - Body Rear door lock More than
ground LH locked 10 kΩ
Normal
Terminal Test condition
value
G2Q-14 - Front door lock Less than 1
Body ground RH unlocked Ω
G2Q-14 - Front door lock More than
Body ground RH locked 10 kΩ
Normal
Terminal Test condition
value
G2P-2 - Body Rear door lock Less than 1
ground RH unlocked Ω
G2P-2 - Body Rear door lock More than
ground RH locked 10 kΩ
20
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
Normal
Terminal Test condition
value
C1H-2 - Body Engine hood Less than 1
ground open Ω
C1H-2 - Body Engine hood More than
ground closed 10 kΩ
Normal
Terminal Test condition
value
G2P-20 - Less than 1
Trunk lid open
Body ground Ω
G2P-20 - More than
Trunk lid closed
Body ground 10 kΩ
NG
OK
21
BYD AUTO BYD Suri Maintenance & Repair Manual
Wire Normal
Terminal
color value
T03-17 - Body Approx. 2.5
V
ground V
T03-18 - Body Approx. 2.5
P
ground V
Approx. 2.5
B1I-1 - Body ground V
V
Approx. 2.5
B1I-2 - Body ground P
V
OK
4 Replace BCM
22
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Battery
Flasher
contact
Emerge
ncy
warning
switch
Turn light
relay RH
Turn light
RH
Engine
distribut
or box
Rear turns
light RH
Front turn
light RH
Multiplex Multiplex
integration integration
control control
Combination meter module module
23
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection procedures
OK
OK Go to step 6
NG
Normal
Terminal Wire color
value
G37-6 - Body ground W/B 11-14 V
G37-8 - Body ground W/B 11-14 V
G37-1 - Body ground W/B 11-14 V
G37-3 - Body ground W/B 11-14 V
OK
24
BYD AUTO BYD Suri Maintenance & Repair Manual
1 - Battery positive
3, 5 Continuity
2 - Battery negative
1, 2 Continuity
Battery disconnected
3, 5 No continuity
OK
8 Inspect wire harness (BCM - turn light, turn relay - turn light)
OK
9 Replace BCM
25
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Battery
Horn
braking
light
Inner
siren
relay
Siren
26
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection procedures
NG Replace fuse
OK
2 Inspect siren
NG Replace siren
OK
Wire Normal
Terminal Condition
color value
Less
K20-1 - B1I-4 Br/Y Always
than 1 Ω
K20-2 - Body Less
B Always
ground than 1 Ω
OK
27
BYD AUTO BYD Suri Maintenance & Repair Manual
3, 5 Continuity
NG Replace relay
OK
OK
Wire Normal
Terminal
color condition
B1I-1 - Body ground V Approx. 2.5 V
B1I-2 - Body ground P Approx. 2.5 V
OK
28
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal
7.1 Turn power switch to OFF Installation
7.2 Disconnect battery negative
7.3 Remove siren 1 Install siren
(a) Remove the trunk garnish inner LH (a) Connect the siren connector
(b) Disconnect the siren connector (b) Install the siren to the fixing position
(c) Using the 10# wrench, remove 2 set nuts (c) Install 2 set bolts with a wrench.
(d) Remove the siren from the sheet metal 2 Install trunk inner garnish LH
29
BYD AUTO BYD Suri Maintenance & Repair Manual
Contents
1 Parts location .......................................................................................................... 31
2 System diagram ...................................................................................................... 33
3 System overview ..................................................................................................... 35
4 Diagnosis flow ......................................................................................................... 36
5 Problem symptoms table ........................................................................................ 38
6 ECU terminals ......................................................................................................... 39
7 Removal and installation of front door lock LH ....................................................... 56
30
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts location
31
BYD AUTO BYD Suri Maintenance & Repair Manual
Instrument panel
distribution box
32
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System diagram
CAN line
33
BYD AUTO BYD Suri Maintenance & Repair Manual
CAN line
34
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System overview
The central locking system is a system to control the
unlock/lock operation of the power door locks by
BCM (the body control module), and it has 3 types
of operation methods as follow:
35
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis flow
1 Vehicle brought to workshop
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
Next battery before going to the next step.
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
B Go to step 8
36
BYD AUTO BYD Suri Maintenance & Repair Manual
ECU terminals
Next
Next
8 Confirmation test
Next
End
37
BYD AUTO BYD Suri Maintenance & Repair Manual
38
BYD AUTO BYD Suri Maintenance & Repair Manual
6 ECU terminals
1. Inspect dashboard distributor box
Wire
Terminal No. Terminal Description Condition Normal value
color
G2P-2 - Body Rear door latch RH
B/R Rear door RH locked Less than 1 V
ground position
G2P-3 - Body Rear door latch LH
W Rear door LH locked Less than 1 V
ground position
G2Q-14 - Body Br/W Front door latch RH Front door lock RH Less than 1 V
39
BYD AUTO BYD Suri Maintenance & Repair Manual
ground position
G2P-20 - Body
L/B Trunk light switch Trunk lid open Less than 1 V
ground
G2N-7 - Body Front door latch RH Front door RH
Y/B 11-14 V
ground lock power supply locked
Front door latch RH
G2N-8 - Body Front door RH
Y unlocked power 11-14 V
ground unlocked
supply
Wire
Terminal No. Terminal description Condition Normal value
color
K2H-4 - Body Rear door latch RH lock Rear door RH
Y/B 11-14 V
ground power supply locked
K2H-11 - Body Rear door latch RH Rear door RH
Y/R 11-14 V
ground unlock power supply unlocked
K2E-1 - Body Rear door latch LH lock Rear door LH
Y/B 11-14 V
ground power supply locked
K2E-8 - Body Rear door latch LH Rear door LH
Y 11-14 V
ground unlock power supply unlocked
Wire Normal
Terminal No. Terminal description Condition
color value
T2K-2 - Body Front door latch LH
Y/G Front door LH unlocked 11-14 V
ground unlocked power supply
T2K-8 - Body Front door latch LH lock
Y/B Front door LH lock 11-14 V
ground power supply
40
BYD AUTO BYD Suri Maintenance & Repair Manual
Gateway controller
41
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection procedures
Terminal Normal
G2T-5 - G2T-6 56-64 Ω
Normal
Terminal Wire color
condition
G2T-5 - Body
V Approx. 2.5 V
ground
G2T-6 - Body
P Approx. 2.5 V
ground
OK
2 Replace BCM
42
BYD AUTO BYD Suri Maintenance & Repair Manual
Gateway controller
Front window
control switch LH
43
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection procedures
DTC Meaning
Key cylinder switch malfunction
B2240-00
of driver side door lock
Main switch malfunction of driver
B2241-00
side door lock
Button switch malfunction of
B2242-00
driver side door lock
NG
Terminal Normal
T03-17 - T03-18 56-64 Ω
(c) Measure the wire harness side voltage.
44
BYD AUTO BYD Suri Maintenance & Repair Manual
Gateway controller
LH position
motor LH
45
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection procedures
Terminal Normal
Battery positive - T01-4 Door lock motor
Battery negative - T01-3 locked
Battery positive - T01-3 Door lock motor
Battery negative - T01-4 unlocked
NG
OK
Normal
Terminal Condition
condition
T01-2 - Front door lock More than 10
T01-1 LH locked kΩ
T01-1 - Front door lock
Less than 1 Ω
T01-2 LH unlocked
NG
OK
46
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
4 Inspect wire harness (front door latch LH - front window control switch LH)
OK
47
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
6 Replace BCM
48
BYD AUTO BYD Suri Maintenance & Repair Manual
Front door
locks motor
RH
49
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection procedures
Terminal Normal
Battery positive - U02-3 Door lock motor
Battery negative - U02-4 locked
Battery positive - U02-4 Door lock motor
Battery negative - U02-3 unlocked
NG
OK
Wire
Terminal Normal condition
color
G2N-7 - U02-3 Y/B Less than 1 Ω
G2N-8 - U02-4 Y Less than 1 Ω
OK
3 Replace BCM
50
BYD AUTO BYD Suri Maintenance & Repair Manual
Rear door
lock motor
LH
51
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection procedures
Terminal Normal
Battery positive - V05-4
Door latch locked
Battery negative - V05-3
Battery positive - V05-3
Door latch unlocked
Battery negative - V05-4
NG
OK
OK
6 Replace BCM
52
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Rear door
lock motor
LH
53
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection procedures
Terminal Normal
Battery positive - W02-3
Door latch locked
Battery negative - W02-4
Battery positive - W02-4 Door latch
Battery negative - W02-3 unlocked
NG
OK
OK
3 Replace BCM
54
BYD AUTO BYD Suri Maintenance & Repair Manual
After locking, the arming preparation state cannot be entered if the trunk lid or engine hood is not
closed, and also if the latch locks signals of the door locks are not detected by the BCM.
For details, refer to anti-theft system
55
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal
1. Disconnect battery negative
Installation
56
BYD AUTO BYD Suri Maintenance & Repair Manual
57
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 3
Intelligent Key System
Contents
1 Parts Location ......................................................................................................... 59
2 System Diagram ..................................................................................................... 61
3 System Overview .................................................................................................... 62
4 Diagnosis Flow ....................................................................................................... 63
5 Trouble Code Table ................................................................................................. 66
6 ECU terminals ......................................................................................................... 68
7 On-vehicle Inspection ............................................................................................. 70
8 Removal and Installation of Start Button ................................................................ 96
9 Removal and Installation of I-Key ECU .................................................................. 97
10 Removal and Installation of High-frequency Reception Module ............................ 98
11 Removal and Installation of Interior Detection Antenna (Rear) .............................. 99
12 Removal and Installation of Exterior Detection Antenna (Front Door LH) ............. 99
58
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
Steering
shaft lock Start button
59
BYD AUTO BYD Suri Maintenance & Repair Manual
Interior detection
antenna (rear)
High-frequency
reception
module
Interior detection
antenna (middle)
Interior detection
antenna (front)
60
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Intelligent key
Steering Gateway
shaft lock
Unlock driver
Start button
61
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System Overview
For controlling the door lock, apart from a Note:
traditional mechanical key and an electronic
intelligent key, the vehicle is also equipped a Do not leave the key at hot places.
with an electronic intelligent key system. When
carrying the electronic intelligent key, the b Do not hit the key with hard objects. Do
driver can open a door, unlock the steering not throw it or let it fall to hard ground.
shaft lock, and start the engine, etc. without
doing anything (like pressing a button, etc.) to c Keep the key far away from magnetic
the vehicle's key. fields.
The whole system is controlled by a Body d With doors locked and armed state
Control Module (BCM). When the on-board activated, please keep the key far away
antenna detects the key within a certain from the vehicle if the vehicle is not used,
detection range, it will validate the key and because the vehicle's card auto-search
send operation signals to related ECUs for function will consume battery power.
respective actions, to finish the work of whole
system. e The electronic intelligent key system may
fail in the following conditions
The detection system, composed of 6
detection antenna assemblies (4 in the vehicle, f The key battery is low.
2 out of the vehicle) and a high-frequency
reception module, is used to detect keys within g There is strong magnetic fields or electric
the effective range in the vehicle and a certain fields (such as a TV tower) near the
range outside the vehicle. detection system.
62
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis Flow
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
B Go to step 8
63
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
8 Confirmation test
Next
End
64
BYD AUTO BYD Suri Maintenance & Repair Manual
65
BYD AUTO BYD Suri Maintenance & Repair Manual
66
BYD AUTO BYD Suri Maintenance & Repair Manual
67
BYD AUTO BYD Suri Maintenance & Repair Manual
6 ECU terminals
6.1 Inspect I-key ECU
68
BYD AUTO BYD Suri Maintenance & Repair Manual
antenna
G49-21 ---- N/A ---- ----
G49-22 ---- N/A ---- ----
Wire
Terminal No. Terminal Description Condition Normal Value
Color
Front door
Door handle switch
G50-1 - G50-8 G/W-R/G sensitive switch Less than 1 Ω
(front door LH)
LH pressed
Front door
Door handle switch
G50-2 - G50-9 R/W-G/R sensitive switch Less than 1 Ω
(front door RH)
RH pressed
Rear sensitive
G50-3 - G50-10 R-Gr Rear sensitive switch Less than 1 Ω
switch pressed
G50-4 ---- N/A ---- ----
High-frequency data
G50-5 - G50-7 G/L-Sb ---- ----
signal
G50-6 - Body
V CAN_L Always Approx. 2.5 V
ground
G50-12 - Body
P CAN_H Always Approx. 2.5 V
ground
Signal ground for
G50-7 - Body high-frequency
Sb Always Less than 1 Ω
ground reception module of
key
High-frequency signal
G50-11 - G50-7 L/W-Sb ---- ----
monitor
69
BYD AUTO BYD Suri Maintenance & Repair Manual
7 On-vehicle Inspection
1 Inspect central locking
OK
2 Inspect key
OK:
The system operation can be ok with one
of the keys.
NG
Measurement Proceed to
Operates normally A
Operate abnormally B
70
BYD AUTO BYD Suri Maintenance & Repair Manual
71
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Normal
Terminal Wire Color
Condition
G49-11 -
L/W Less than 1 Ω
TJ02-1
G49-16 -
V/B Less than 1 Ω
TJ02-2
NG
OK
OK:
The unlock/lock operation is working
OK
3 Replace front door handle LH (with detection antenna and sensitive switch)
72
BYD AUTO BYD Suri Maintenance & Repair Manual
73
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Normal
Terminal Wire Color
Condition
G49-6 - UJ03-2 V/W Less than 1 Ω
G49-17 -
L/Y Less than 1 Ω
UJ03-1
NG
OK
OK:
The unlock/lock operation is working
OK
3 Replace front door handle RH (with detection antenna and sensitive switch)
74
BYD AUTO BYD Suri Maintenance & Repair Manual
Front
door
sensitiv
e switch
LH
75
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect front door sensitive switch LH
Normal
Terminal Condition
Condition
TJ02-5 - Sensitive
Less than 1 Ω
TJ02-6 switch pressed
Sensitive
TJ02-5 - More than 10
switch
TJ02-6 kΩ
released
NG
Replace front door handle LH (with sensitive
switch)
OK
Normal
Terminal Wire Color
Condition
G50-8 -
R/G Less than 1 Ω
TJ02-6
G50-1 -
G/R Less than 1 Ω
TJ02-5
NG
Replace wire harness or connector
OK
76
BYD AUTO BYD Suri Maintenance & Repair Manual
Front door
sensitive
switch LH
77
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Normal
Terminal Condition
Condition
UJ03-6 - Sensitive
Less than 1 Ω
UJ03-5 switch pressed
Sensitive
UJ03-6 - More than 10
switch
UJ03-5 kΩ
released
NG
Normal
Terminal Wire Color
Condition
G50-9 - UJ03-5 G/R Less than 1 Ω
G50-2 - UJ03-6 R/W Less than 1 Ω
NG
OK
78
BYD AUTO BYD Suri Maintenance & Repair Manual
79
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Normal
Terminal Wire Color
Condition
G49-19 - K18-1 Y/L Less than 1 Ω
G49-20 - K18-2 R Less than 1 Ω
NG
OK
OK:
The unlock/lock operation is working
OK
80
BYD AUTO BYD Suri Maintenance & Repair Manual
Start button
81
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
OK:
Cranking is ok
NG
OK
NG
Replace wire harness or connector
OK
82
BYD AUTO BYD Suri Maintenance & Repair Manual
83
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
NG
OK
OK:
The power-up or cranking operation is ok
OK
84
BYD AUTO BYD Suri Maintenance & Repair Manual
85
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Normal
Terminal Wire Color
Condition
K19-5 - G49-12 G Less than 1 Ω
K19-3 - G50-5 G/L Less than 1 Ω
K19-1 - G50-7 Br Less than 1 Ω
K19-2 - G50-11 L Less than 1 Ω
NG
OK
86
BYD AUTO BYD Suri Maintenance & Repair Manual
87
BYD AUTO BYD Suri Maintenance & Repair Manual
88
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Normal
Terminal Wire Color
Condition
G49-14 -
O Less than 1 Ω
G33-1
G49-4 -
W Less than 1 Ω
G33-2
NG
OK
OK:
The power-up or cranking operation is ok
OK
89
BYD AUTO BYD Suri Maintenance & Repair Manual
90
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
NG
OK
OK:
The power-up or cranking operation is ok
OK
91
BYD AUTO BYD Suri Maintenance & Repair Manual
92
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery
Horn, braking light
Battery Battery
93
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect fuses
OK:
There is continuity in the fuse.
NG Replace fuse
OK
Wire Normal
Terminal Condition
Color Condition
G49-1 -
R-B Always 11-14 V
G49-9
OK
NG
Wire Normal
Terminal Condition
Color Condition
B1D-10 - Less than
R/W-R Always
G49-1 1Ω
G49-9 -
Less than
Body B Always
1Ω
ground
94
BYD AUTO BYD Suri Maintenance & Repair Manual
G49-10 -
Less than
Body B Always
1Ω
ground
OK
4 Circuit normal
95
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Disconnect battery negative a Install the start button directly into the
dashboard assembly.
2 Remove dashboard assembly
b Connect the connector.
3 Remove start button
96
BYD AUTO BYD Suri Maintenance & Repair Manual
Installation
1 Install I-Key ECU
97
BYD AUTO BYD Suri Maintenance & Repair Manual
98
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal
1 Remove front door protector assembly LH
2 Install carrier
99
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 4
Remote Driving System
Contents
1 Parts Location ....................................................................................................... 101
2 System Diagram ................................................................................................... 103
3 System Overview .................................................................................................. 104
4 Diagnosis Flow ..................................................................................................... 105
5 Problem Symptoms Table ..................................................................................... 107
100
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
Start button
Steering shaft
lock
101
BYD AUTO BYD Suri Maintenance & Repair Manual
Interior detection
antenna (rear)
High-frequency
reception
module
Interior
Intelligent key detection
system controller antenna
(luggage
compartment)
Interior detection
antenna (middle)
Interior detection
antenna (front)
102
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Steering
angle
sensor
Gateway
P position
controller
CAN line
103
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System Overview
Remote driving is used to start the vehicle,
move it forward and backward, turn right and
left, and take control of it to move at a low
speed (less than 0.7 km/h) for a certain
distance, by using the remote control key
within the visible range (within 10 m around
the vehicle).
Notice:
104
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis Flow
1 Vehicle brought to workshop
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
B Go to step 8
105
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
Next
8 Confirmation test
Next
End
106
BYD AUTO BYD Suri Maintenance & Repair Manual
107
BYD AUTO BYD Suri Maintenance & Repair Manual
Gateway
108
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect key
OK
OK:
The start button indicator turns green and
the engine can be started.
OK
109
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
P position Gateway
controller
110
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect key
OK:
The power indicator on the key flashes.
OK
OK:
The vehicle can be driven normally.
OK
111
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Gateway
Steering
angle sensor
112
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect key
OK
OK:
The steering wheel can be turned easily.
OK
113
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 5
Steering Shaft Lock
Contents
1 Parts Location ........................................................................................................ 115
2 System Diagram ....................................................................................................116
3 System Overview ...................................................................................................117
4 Diagnosis Flow ........................................................................................................ 118
5 Diagnostic trouble code chart ................................................................................ 119
6 Terminal Diagnosis ............................................................................................... 120
7 Overall Diagnosis Flow ......................................................................................... 121
8 Removal and Installation ...................................................................................... 131
114
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
115
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Steering
shaft lock
116
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System Overview
As a part of the anti-theft system, the steering
shaft lock plays an important role in the system.
It drives the latch by a motor to lock the
steering column, so the steering wheel cannot
be rotated and theft prevention function is
achieved.
Operation:
117
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis Flow
1 Vehicle brought to workshop
NEXT
Result Proceed to
Symptom is not listed in problem
A
symptoms table
Symptom is listed in problem
B
symptoms table
B Go to step 5
4 Overall Diagnosis
NEXT
NEXT
6 Confirmation test
NEXT
7 End
118
BYD AUTO BYD Suri Maintenance & Repair Manual
119
BYD AUTO BYD Suri Maintenance & Repair Manual
6 Terminal Diagnosis
(a) Disconnect the connector G21.
Normal:
120
BYD AUTO BYD Suri Maintenance & Repair Manual
121
BYD AUTO BYD Suri Maintenance & Repair Manual
Power supply
Inspection Procedures:
Wire Normal
Terminal Condition
Color Condition
Carry a legal
key with power
off and press
G21-2- remote control 0 11~14
Y-B
G21-1 or sensitive V0
switch to lock
while all doors
are closed.
OK
Replace steering shaft lock
122
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Wire Normal
Terminal Condition
Color Condition
Carry a legal
key with power
off and press
G2P-30 - 0
remote control
Body ---- 11~14 V
or sensitive
ground 0
switch to lock
while all doors
are closed.
NG
Replace BCM
OK
NG
Replace wire harness
OK
123
BYD AUTO BYD Suri Maintenance & Repair Manual
Schematic Diagram:
Battery
To dashboard
distributor box
50A
Auxiliary
Relay power
supply
124
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures:
Wire Normal
Terminal Condition
Color Condition
G21-5 - Body Less than
Y/R OFF
ground 1V
NG
OK
End
Wire Normal
Terminal Condition
Color Condition
G2N-37 - Less than
---- OFF
Body ground 1V
NG
Wire Normal
Terminal Condition
Color Condition
G2A-4 - Body Less than
---- OFF
ground 1V
125
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Wire Normal
Terminal Condition
Color Condition
G37-2 - Body Less
W/R OFF
ground than 1 V
NG
OK
126
BYD AUTO BYD Suri Maintenance & Repair Manual
Wire Normal
Terminal Condition
Color Condition
G2P-9 - Less than 1
L/R OFF
Body ground V
7 Replace BCM
127
BYD AUTO BYD Suri Maintenance & Repair Manual
128
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures:
Wire Normal
Terminal Condition
Color Condition
G21-3 - Body Approx. 2.5
P Always
ground V
G21-6 - Body Approx. 2.5
V Always
ground V
NG
Replace wire harness
OK
2 End
129
BYD AUTO BYD Suri Maintenance & Repair Manual
Note: If the steering shaft lock is replaced, do rematch it with the I-K ECU as the matching process
below:
End
130
BYD AUTO BYD Suri Maintenance & Repair Manual
131
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 6
Gateway Controller
Content
1 Parts Location ....................................................................................................... 133
2 System Diagram ................................................................................................... 134
3 System Overview .................................................................................................. 135
4 Diagnosis Flow ..................................................................................................... 135
5 Terminal Diagnosis ............................................................................................... 136
6 Overall Diagnosis Flow ......................................................................................... 138
7 Removal ................................................................................................................ 151
8 Installation ............................................................................................................. 151
132
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
Gateway
controller
133
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
Multimedia
system
Air conditioner
Combination
Diagnostic meter
interface
Airbag
Vehicle speed Anti-lock
signal brake
system Steering shaft
lock
Gear position Transmissi
signal on module Body control
module 2
Steering On-board
Gear television
position angle
signal sensor
Multi-display
Sun roof
Tire pressure
monitoring
system
CAN line
134
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System Overview
Several networks exist in the vehicle need to
communicate with each other, and the gateway is
such an intermediate to sustain the communication.
1 Message routing:
2 Signal routing:
3 Network management:
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
Next
Next
135
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
End
5 Terminal Diagnosis
Inspect gateway controller pin
Standard Resistance
Terminal No. Terminal Specified
Wire Color Condition
(Symbol) Description Condition
G07-1 - Body B Signal ground Always Less than 1 Ω
ground
136
BYD AUTO BYD Suri Maintenance & Repair Manual
ground
G07-9 - Body V B-CANL2 Always 1.5 to 2.5 V
ground
G07-10 - Body V B-CANL1 Always 1.5 to 2.5 V
ground
G07-11 - Body B Shielded wire Always Less than 1 V
ground
G07-12 - Body V F-CANL Always 1.5 to 2.5 V
ground
137
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery
Gateway Power
network
Shielding
layer
Gateway controller
Start Body
netwo netwo
rk rk
Note: *3--476QZA+DCT
138
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures:
1 Inspect power supply
Standard Voltage
Standard Resistance
Terminal No. Specified
Condition
(Symbol) Condition
G07-1 - Body
Always Less than 1 Ω
ground
OK Go to step 3
NG
139
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Voltage
OK
140
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Resistance
NG
Standard Resistance
141
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Standard Resistance
NG
OK
142
BYD AUTO BYD Suri Maintenance & Repair Manual
Gateway controller
Body
netw
ork
Adapter
143
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures:
1 Inspect gateway terminal resistance
Standard Resistance
NG
OK
Standard Resistance
OK
144
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Resistance
NG
OK
145
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Resistance
OK
End
146
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram:
Gateway controller
Inspection Procedures:
Standard Resistance
OK
147
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Resistance
OK
Standard Resistance
OK
End
148
BYD AUTO BYD Suri Maintenance & Repair Manual
Power
network
Gateway controller
Inspection Procedures:
1 Inspect gateway terminal resistance
149
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Resistance
OK
Standard Resistance
Terminal No. Specified
Condition
(Symbol) Condition
11 - 12 Always Approx. 120 Ω
NG Replace ECM
OK
Standard Resistance
OK
End
150
BYD AUTO BYD Suri Maintenance & Repair Manual
7 Removal 8 Installation
1 Remove glove box
8.1Install gateway controller
2 Remove gateway controller
a Align the gateway controller with the
a Disconnect the connector. installation hole.
151
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 7
Air Conditioning System
Contents
1 Parts Location ....................................................................................................... 154
2 System Diagram ................................................................................................... 156
3 System Overview .................................................................................................. 157
4 Diagnosis Flow ..................................................................................................... 161
5 Problem Symptoms Table ..................................................................................... 163
6 ECU terminals ....................................................................................................... 165
7 On-vehicle Inspection ........................................................................................... 168
8 Removal and Installation of A/C Panel ................................................................. 219
9 Removal and Installation of A/C Case .................................................................. 220
10 Removal and Installation of A/C Compressor ....................................................... 221
11 Removal and Installation of Solar Sensor ............................................................ 221
152
BYD AUTO BYD Suri Maintenance & Repair Manual
Condenser and
Pressure bracket assembly
switch
Outside Compressor
temperature assembly
sensor
153
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
154
BYD AUTO BYD Suri Maintenance & Repair Manual
155
BYD AUTO BYD Suri Maintenance & Repair Manual
2 System Diagram
156
BYD AUTO BYD Suri Maintenance & Repair Manual
3 System Overview
3.1 Overview
157
BYD AUTO BYD Suri Maintenance & Repair Manual
Heat from
Heat from Condenser Evaporator the air to
the the
refrigerant refrigerant
to the air
158
BYD AUTO BYD Suri Maintenance & Repair Manual
High-tempera
Engine
ture coolant
Heat is
transferred
Heat to the air
Low-temperature exchanger
coolant
3.1 Fan control logic 3.11 When the A/C is ON, the fan will operate
at low speed; When the temperature of
3.2 473 fan control logic: the engine water outlet is above 98°C or
the
Fans are divided into radiator fan and
condenser fan. The speeds of the fans 3.12 Temperature of the radiator water outlet is
cannot be adjusted; above 80°C, the fan will operate at low
speed.
Operation condition of radiator fan:
HI operation condition:
3.3 When the A/C is ON, the radiator fan will
operate; 3.13 When the A/C is ON and the A/C
pressure is above 1.77 Mpa, the fan will
3.4 When the temperature of the engine operate at high speed;
coolant is above 93°C, the radiator fan will
operate. 3.14 When the temperature of the engine
water outlet is above 106°C or the
Operation condition of condenser fan: temperature of the radiator water outlet is
above 86°C, the fan will operate at high
3.5 When the A/C is ON and A/C pressure is speed.
above 1.77 Mpa, the condenser fan will
operate; Note: Before a HI operation, the fan must
operate at low speed for 2 seconds.
3.6 When the temperature of the engine
coolant is above 100°C, the condenser fan 3.15 Precautions when servicing air
will operate. conditioning system
3.7 476 fan control logic: 3.16 The maintenance of the air conditioning
system must be carried out by professional
Fans are double-pole speed governing technicians.
type, and can operate at high and low
speed. 3.17 The work area should be ventilated
LO operation condition: before servicing. Do not handle refrigerant
159
BYD AUTO BYD Suri Maintenance & Repair Manual
160
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis Flow
1 Vehicle brought to workshop
Next
Next
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before going to the next step.
Next
4 Inspect DTC*
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
A
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
B Go to step 8
A
161
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
8 Confirmation test
Next
End
162
BYD AUTO BYD Suri Maintenance & Repair Manual
163
BYD AUTO BYD Suri Maintenance & Repair Manual
164
BYD AUTO BYD Suri Maintenance & Repair Manual
6 ECU terminals
6.1 Inspect A/C control module
165
BYD AUTO BYD Suri Maintenance & Repair Manual
166
BYD AUTO BYD Suri Maintenance & Repair Manual
167
BYD AUTO BYD Suri Maintenance & Repair Manual
7 On-vehicle Inspection
1 Directly inspect
Tips:
OK
168
BYD AUTO BYD Suri Maintenance & Repair Manual
Turn the A/C switch ON, and touch the low pressure
terminal line and components of the air conditioning
system by hand when the refrigerant compressor
operates for 10~20 min. From the evaporator to the
compressor inlet, the temperature felt by hand
should turn from cool to cold.
Inspect line
Inspect if the wire harness connectors are
connected well by hand. There should be no
looseness or heat in each connector of the air
conditioning system line.
If the connectors are loose or the connector surface
temperatures felt by hand are very high (hot), it
indicates that there are poor contacts in the
connectors, causing the air conditioning system
inoperative or abnormal.
NG
OK
169
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
170
BYD AUTO BYD Suri Maintenance & Repair Manual
11
DTC Room temperature sensor open circuit
(B2A20)
12
DTC Room temperature sensor short circuit
(B2A21)
Circuit Diagram
Room
temper
ature
sensor
171
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Standard Value
Lower Upper
Terminal Condition
Limit (kΩ) Limit (kΩ)
-25°C 126.4 134.7
-10°C 54.60 57.65
0°C 32.25 33.69
1-2 10°C 19.68 20.35
20°C 12.37 12.67
30°C 7.95 8.14
50°C 3.51 3.66
NG
OK
Standard Value
Normal
Terminal Wire Color
Condition
G53-2 - G47-11 G/B Less than 1 Ω
G53-1 - Body
B Less than 1 Ω
ground
G53-1 - G53-2 -- More than 10 kΩ
172
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
173
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Engine hood
distributor box
Outside
temperature
sensor
Engine hood
distributor box
174
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Standard Value
Lower Upper
Terminal Condition
Limit (kΩ) Limit (kΩ)
-25°C 126.4 134.7
-10°C 54.60 57.65
0°C 32.25 33.69
1-2 10°C 19.68 20.35
20°C 12.37 12.67
30°C 7.95 8.14
50°C 3.51 3.66
NG
OK
Standard Value
Wire Normal
Terminal
Color Condition
C10-1 – G47-29 P-Sb Less than 1 Ω
C10-2 – Body R/B Less than 1 Ω
175
BYD AUTO BYD Suri Maintenance & Repair Manual
ground
More than 10
C10-1 – C10-2 -
kΩ
OK
176
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Evapo
rator
temper
ature
sensor
177
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Lower Upper
Terminal Condition
Limit (kΩ) Limit (kΩ)
-20°C 14.82 16.38
0°C 5.081 5.559
10°C 3.101 3.359
1-2 15°C 2.466 2.644
20°C 1.946 2.106
30°C 1.276 1.354
40°C 0.845 0.897
NG
OK
Standard Value
Wire
Terminal Normal Condition
Color
G47-10 - X981-2 Br Less than 1 Ω
X981-1 - Body
B Less than 1 Ω
ground
X981-1 - X981-2 -- More than 10 kΩ
NG Replace wire harness
178
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
179
BYD AUTO BYD Suri Maintenance & Repair Manual
17
DTC Outlet mode control motor malfunction
(B2A2A)
Circuit Diagram
Outlet
mode
damper
control
motor
180
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Notice:
OK Go to step 4
NG
Result Proceed to
Linkage and damper
A
move freely
Linkage and damper are
B
stuck or seized
181
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Value
Wire Normal
Terminal
Color Condition
X984-2 - G47-38 R/Y Less than 1 Ω
X984-3 - G47-27 R/L Less than 1 Ω
X984-4 - G47-36 W/L Less than 1 Ω
X984-5 - G47-17 Y/G Less than 1 Ω
OK
Standard Value
Wire Normal
Terminal
Color Condition
X984-1 - Body
B Less than 1 Ω
ground
182
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Terminal Wire Color
Condition
G47-27 - Body
R/L More than 10 kΩ
ground
G47-38 - Body
R/Y More than 10 kΩ
ground
G47-17 - Body
Y/G More than 10 kΩ
ground
G47-36 - Body
W/L More than 10 kΩ
ground
OK
7 Inspect AC ECU
(b) Turn the A/C on, and measure the output value.
Normal
Terminal Condition
Condition
G47-38 - Body
A/C ON Approx. 5 V
ground
FACE Approx. 0.2 V
OK
8 End
183
BYD AUTO BYD Suri Maintenance & Repair Manual
18
DTC Air mix motor malfunction
(B2A2B)
Circuit Diagram
Air mix
damper
motor
184
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Notice:
OK Go to step 4
NG
2 Inspect mechanism
Result Proceed to
Linkage and damper
A
move freely
Linkage and damper
B
are stuck or seized
185
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Value
Wire Normal
Terminal
Color Condition
X982-2 - G47-39 Gr Less than 1 Ω
X982-3 - G47-8 P/B Less than 1 Ω
X982-5 - G47-16 P/L Less than 1 Ω
X982-4 - G47-34 G Less than 1 Ω
NG
OK
Standard Value
Normal
Terminal Wire Color
Condition
X982-1 - Body
B Less than 1 Ω
ground
NG
186
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Value
Wire Normal
Terminal
Color Condition
G47-39 - Body
Gr More than 10 kΩ
ground
G47-8 - Body
P/B More than 10 kΩ
ground
G47-16 - Body
G More than 10 kΩ
ground
G47-34 - Body
P/L More than 10 kΩ
ground
NG
OK
(b) Turn the A/C on, and measure the output value.
Standard Value
Condition
Normal
Terminal (temperature
Condition
adjustment)
G47-39 -
A/C ON Approx. 5 V
Body ground
32°C Approx. 0.9 V
G47-8 - Body
25°C Approx. 1.9 V
ground
18°C Approx. 4.1 V
G47-16 - Temperature
11 ~ 14 V
G47-34 adjustment
OK
187
BYD AUTO BYD Suri Maintenance & Repair Manual
8 End
188
BYD AUTO BYD Suri Maintenance & Repair Manual
20
DTC Blower malfunction
(B2A2D)
Circuit Diagram
Battery Power ON
Blower
Blower
Blower
relay
Blower
governor
module
189
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect fuses
OK:
Continuity
NG Replace fuse
OK
2 Inspect blower
(a) Wire from the rear side to connect the jumper
wire NO.1 of connector G42 with the body
ground.
NG:
The blower does not operate
Go to step 6
NG
OK
Inspect wire harness (blower - governor module/AC ECU, governor module - AC ECU,
3
governor module - blower relay)
(a) Disconnect the blower connector G42,
governor module connector G38 and AC ECU
connector G47.
Standard Value
190
BYD AUTO BYD Suri Maintenance & Repair Manual
G42-1 -
G/W Less than 1 Ω
G47-26
NG
OK
Normal
Terminal Condition
Condition
Turn the
The voltage
blower on, and
G47-3 - Body changes
adjust the
ground between 1.9
volume from
and 2.3 V
low to high
OK
Standard Value
Wire Normal
Terminal Condition
Color Condition
G42-2 - Body Power
W/L 11 ~ 14 V
ground ON
OK Replace AC blower
191
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Standard Value
OK
Inspect wire harness (blower - relay, relay - dashboard distributor box, relay - body
8
ground)
(a) Disconnect the blower connector G42.
Standard Value
Wire
Terminal Normal Condition
Color
G42-2 - B1D-4 W/L Less than 1 Ω
B1E-10 - G47-14 B Less than 1 Ω
B1E-15 - B2D-14 B/Y Less than 1 Ω
NG
Replace or repair wire harness
OK
9 End
192
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Compressor
Inspection Procedures
1 Inspect fuse
NG Replace fuse
OK
193
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Value
Normal
Terminal Wire Color
Condition
C1F-3 - Body
R 11 ~ 14 V
ground
NG
OK
Standard Value
Normal
Terminal Condition
Condition
Refrigerant
B03-1 -
pipe line Less than 1 Ω
B03-4
pressure is OK
NG Go to step 8
OK
Standard Value
Normal
Terminal Wire Color
Condition
G47-23 - Body
R 11 ~ 14 V
ground
194
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Replace or repair wire harness
OK
OK
195
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Circulation
control
motor
196
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Notice:
OK Go to step 4
NG
2 Inspect mechanism
Result Proceed to
Linkage and damper move
A
freely
Linkage and damper are
B
stuck or seized
197
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal Value
Terminal Wire Color Normal Condition
G47-37 - Body
R/G More than 10 kΩ
ground
G47-18 - Body
R/W More than 10 kΩ
ground
NG
Repair or replace wire harness
OK
Standard Value
Normal
Terminal Wire Color
Condition
G47-18 - X985-1 G/W Less than 1 Ω
G47-37 - X985-5 Lg/R Less than 1 Ω
NG
Repair or replace wire harness
OK
6 Replace AC ECU
198
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Power ON Power ON
Note: *3--476QZA+DCT
199
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect fuses
OK:
Continuity
NG Replace fuse
OK
Standard Value
Wire Normal
Terminal Condition
Color Condition
G47-40 -
B/Y Power ON 11 ~ 14 V
Body ground
G47-33 - Less than
B Always
Body ground 1Ω
NG
OK
200
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Battery Battery
Condenser Radiat
fan or fan Conde
Radiat
nser or fan
fan relay
relay
Dashboard
distributor
box
Conde Radiat
nser or fan
fan motor
motor
Reserved
201
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect fuses
OK:
Continuity
NG Replace fuse
OK
2 Inspect fan
Standard Value
Normal
Terminal Condition
Condition
Fan moves
C02-2 - Battery (+)
-- smoothly at
C02-1 - Battery (-)
low speed
Fan moves
C15-2 - Battery (+)
-- smoothly at
C15-1 - Battery (-)
high speed
NG Replace fan
OK
Standard Value
Wire Normal
Terminal Condition
Color Condition
B1E-16 -
Body G Power ON 11 ~ 14 V
ground
202
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Replace or repair wire harness
OK
Standard Value
NG Replace relays
OK
5 Inspect wire harness (fan - relay, fan - body ground, relay - ECM)
Standard Value
Wire Normal
Terminal Condition
Color Condition
C15-2 - Less than 1
L/Y Always
C1F-14 Ω
C02-2 - Less than 1
L/W Always
C1F-16 Ω
Standard Value
Wire Normal
Terminal Condition
Color Condition
203
BYD AUTO BYD Suri Maintenance & Repair Manual
Relay – ECM
Standard Value
Wire Normal
Terminal Condition
Color Condition
B1E-16 -
Less than
A10-4 G Always
1Ω
(473)
OK
6 Replace ECM
204
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Power ON
Battery
Compressor
Dashbo
ard
Compre distribut
ssor or box
clutch
relay
Compre
ssor
clutch
A/C A/C
request permission
205
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Next
4 Inspect fuses
OK:
Continuity
NG Replace fuse
OK
Standard Value
Replace relay
206
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
6 Inspect compressor
NG:
No sound
NG
OK
Standard Value
Wire Normal
Terminal Condition
Color Condition
A47-1 - Less than
L/R Always
C1F-2 1Ω
Standard Value
Wire Normal
Terminal Condition
Color Condition
G47-31 - Less than
R Always
B1E-11 1Ω
NG
207
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
208
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
209
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
1 Inspect operation
Result Proceed to
Both rear and mirror
Step 2
defrosters do not operate
Only rear defroster does not
Step 9
operate
Only mirror defroster does not
Step 16
operate
2 Inspect fuse
OK:
Continuity
NG Replace fuse
OK
Tips:
Standard Value
Normal
Terminal Condition
Condition
G47-6 - Body Defrosting More than 9
ground function enabled V
NG Replace AC ECU
210
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
Normal Value
OK
5 Inspect MCU
Standard Value
Normal
Terminal Condition
Condition
B1E-14 - Body Turn power Less than 1
ground defroster ON V
OK End
211
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Standard Value
Normal
Terminal Wire Color
Condition
G47-2 - B1I-2 P Less than 1 Ω
G47-1 - B1I-1 V Less than 1 Ω
OK
7 Replace AC ECU
OK:
Malfunction does not recur
NG Replace MCU
OK
8 Replace AC ECU
9 Inspect fuse
OK:
Continuity
212
BYD AUTO BYD Suri Maintenance & Repair Manual
NG Replace fuse
OK
Standard Value
NG
OK
Standard Value
Test Normal
Terminal
Condition Condition
B1E-15 - Body
Power ON 11 ~ 14 V
ground
NG
OK
213
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Value
Normal
Terminal Test Condition
Condition
88 - Body
Battery 11 ~ 14 V
ground
86 - Body
Power ON 11 ~ 14 V
ground
Power ON,
85 - Body
turn power Less than 1 V
ground
defroster on
NG
OK
Standard Value
OK
14 Inspect wire harness (front compartment distributor box - rear defroster wire)
Standard Value
214
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Terminal Wire Color
Condition
B1D-2 -
B/Y Less than 1 Ω
X931-1
OK
15 End
16 Inspect fuse
OK:
There is continuity in the fuse
NG Replace fuse
OK
Standard Value
NG
OK
Inspect wire harness (dashboard distributor box - outer rear view mirror defroster
18
heater relay)
215
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Value
Normal
Terminal Wire Color
Condition
G37-11 - Body
Y/R 11 ~ 14 V
ground
G37-13 - Body
B/Y 11 ~ 14 V
ground
OK
Inspect wire harness (dashboard distributor box - outer rear view mirror defroster
19
heater relay)
(a) Disconnect the connector G37 of dashboard
wire harness.
Standard Value
OK
216
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Value
Test Normal
Terminal
Condition Condition
88 - Body ground Battery 11 ~ 14 V
86 - Body ground Power ON 11 ~ 14 V
Power ON,
Less than 1
85 - Body ground turn power
V
defroster on
NG
Standard Value
Standard Value
OK
Inspect wire harness (outer rear view mirror defroster heater relay - rear defroster
22
wire)
(a) Disconnect the relay connector G37.
217
BYD AUTO BYD Suri Maintenance & Repair Manual
Standard Value
Wire Normal
Terminal
Color Condition
T05-5 - G37-12 O Less than 1 Ω
T05-10 - Body
B Less than 1 Ω
ground
Standard Value
Normal
Terminal Wire Color
Condition
U05-5 - G37-12 O Less than 1 Ω
U05-10 - Body
B Less than 1 Ω
ground
Abnormal
OK
23 End
Preparation of Tools
Crosshead screwdriver 1
10# T-type socket or ratchet wrench 1
Flat-head screwdriver
218
BYD AUTO BYD Suri Maintenance & Repair Manual
219
BYD AUTO BYD Suri Maintenance & Repair Manual
9 Removal and Installation of fixing points between the A/C case and
cowl panel
A/C Case
Removal
9.1 Turn power switch off
220
BYD AUTO BYD Suri Maintenance & Repair Manual
Installation
1 Install compressor
221
BYD AUTO BYD Suri Maintenance & Repair Manual
Installation
222
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 8
SRS System
Contents
1 Parts Location ....................................................................................................... 224
2 System Overview .................................................................................................. 228
3 Safety Regulations for Repairing Supplemental Restraint System ...................... 231
4 Diagnosis Flow ..................................................................................................... 233
5 Diagnostic Trouble Code Chart ............................................................................ 235
6 Problem Symptoms Chart .................................................................................... 236
7 ECU terminals ....................................................................................................... 237
8 Entire System does not Operate .......................................................................... 240
9 Special Tool ........................................................................................................... 299
10 Removal and Installation ...................................................................................... 301
223
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Parts Location
Curtain Shield
Airbag RH
Rear collision
sensor LH
Rear collision
sensor RH
Front collision
sensor LH
Side collision
sensor LH
224
BYD AUTO BYD Suri Maintenance & Repair Manual
225
BYD AUTO BYD Suri Maintenance & Repair Manual
SRS electronic
control unit
226
BYD AUTO BYD Suri Maintenance & Repair Manual
Driver airbag
Front collision sensor
(DAB)
LH
Passenger airbag
Front collision sensor (PAB)
RH
Curtain Shield
Rear side collision Airbag RH
sensor LH
Combination
instrument
227
BYD AUTO BYD Suri Maintenance & Repair Manual
228
BYD AUTO BYD Suri Maintenance & Repair Manual
229
BYD AUTO BYD Suri Maintenance & Repair Manual
230
BYD AUTO BYD Suri Maintenance & Repair Manual
231
BYD AUTO BYD Suri Maintenance & Repair Manual
232
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Diagnosis Flow
Tips:
Standard voltage:
11 to 14 V
3 On-vehicle inspection
(a) Turn the power switch on, and enter the SRS
system self-diagnosis.
Result Proceed to
Illuminated for 5 seconds OK
and then goes off
Remains on NG
OK System is OK
NG
233
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
DTC is output A
No DTC is output B
B Go to step 5
Next
7 End
234
BYD AUTO BYD Suri Maintenance & Repair Manual
235
BYD AUTO BYD Suri Maintenance & Repair Manual
236
BYD AUTO BYD Suri Maintenance & Repair Manual
7 ECU terminals
Inspect ECU terminals of SRS system (plate end
connector)
(a) Wire the rear end of the connector K21 for SRS
ECU and measure the voltage or resistance of
each terminal.
237
BYD AUTO BYD Suri Maintenance & Repair Manual
(b) Wire the rear end of the connector G36 for SRS
ECU and measure the voltage or resistance of
each terminal.
Terminal No. Wire Color Terminal Description Test Condition Normal Value
G36-1 - Body R/B Power ON Power ON 11 V - 14 V
ground
G36-2 - G36-13 L/W-Br/W Front collision sensor ---- ----
LH (low - high)
G36-3 - G36-14 G/B-P- Front collision sensor ---- ----
RH (low - high)
G36-4 ---- N/A ---- ----
238
BYD AUTO BYD Suri Maintenance & Repair Manual
239
BYD AUTO BYD Suri Maintenance & Repair Manual
Power ON
240
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect fuse
NG Replace fuse
OK
NG
OK
241
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
242
BYD AUTO BYD Suri Maintenance & Repair Manual
1#Ignition switch
Relay Combination
instrument
Voltage regulator
Gene
rator Rectifier
Field coil
Battery
Engine
assembly Transmission assembly
243
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
1 Inspect generator
OK
OK
244
BYD AUTO BYD Suri Maintenance & Repair Manual
Power ON
Inspection Procedure
245
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
246
BYD AUTO BYD Suri Maintenance & Repair Manual
Clock
spring
Driver
airbag
Inspection Procedure
Result Proceed to
Trouble code does not A
reoccur
247
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspect driver airbag wire harness for short to GND or power supply (If this occurs,
2
this malfunction will also be displayed)
(a) Disconnect the driver airbag connector, and
measure the voltage and resistance between
wire harness terminal and ground.
NG
OK
248
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not A
reoccur
Trouble code reoccurs B
OK
5 Inspect if clock spring and airbag wire harness are securely connected
249
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not A
reoccur
Trouble code reoccurs B
NG
OK
250
BYD AUTO BYD Suri Maintenance & Repair Manual
Assist
ant
driver
airbag
Inspection Procedure
Check if butt connector between branch wire of assistant driver airbag module and
1
airbag wire harness is securely connected
(a) Disconnect and securely reconnect the butt
connector between the branch wire of the
assistant driver airbag module and airbag wire
harness.
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
251
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
Inspect assistant driver airbag wire harness for short to GND or power supply (If
3
this occurs, this malfunction will also be displayed)
(a) Disconnect the assistant driver airbag
connector, and measure the voltage and
resistance between wire harness terminal and
ground.
252
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
253
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Result Proceed to
Trouble code does not A
reoccur
Trouble code reoccurs B
6 Replace airbag wire harness (poor connection caused by airbag wire harness)
254
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Front
seat side
airbag
LH
Inspection Procedure
Inspect if butt connector between branch wire of front seat side airbag module LH
1
and airbag wire harness is securely connected
(a) Disconnect and securely reconnect the butt
connector between the branch wire of the front
seat side airbag module LH and airbag wire
harness.
255
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not A
reoccur
Trouble code reoccurs B
Result Proceed to
Trouble code does not A
reoccur
Trouble code reoccurs B
A
Replace airbag module (with branch wire)
Inspect wire harness of front seat side airbag module LH for short to GND or
3
power supply (If this occurs, this malfunction will also be displayed)
(a) Disconnect the connector of the front seat side
airbag module LH, and measure the voltage
and resistance between wire harness terminal
and ground.
256
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
257
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
6 Replace airbag wire harness (poor connection caused by airbag wire harness)
258
BYD AUTO BYD Suri Maintenance & Repair Manual
airbag RH
Front seat side
Inspection Procedure
Inspect if butt connector between branch wire of front seat side airbag module RH
1
and airbag wire harness is securely connected
(a) Disconnect and securely reconnect the butt
connector between the branch wire of the front
seat side airbag module RH and airbag wire
harness.
259
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
Inspect wire harness of front seat side airbag module RH for short to GND or
3
power supply (If this occurs, this malfunction will also be displayed)
(a) Disconnect the connector of front seat side
airbag module RH, and measure the voltage
and resistance between wire harness terminal
and ground.
260
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
261
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
6 Replace airbag wire harness (poor connection caused by airbag wire harness)
262
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Curt
ain
shiel
d
airba
g LH
Inspection Procedure
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
263
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspect wire harness of curtain shield airbag LH for short to GND or power supply
2
(If this occurs, this malfunction will also be displayed)
(a) Disconnect the connector of the curtain shield
airbag LH, and measure the voltage and
resistance between wire harness terminal and
ground.
OK
264
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
265
BYD AUTO BYD Suri Maintenance & Repair Manual
Curtain
shield
airbag RH
Inspection Procedure
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
266
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspect wire harness of curtain shield airbag RH for short to GND or power supply
2
(If this occurs, this malfunction will also be displayed)
a Disconnect the connector of the curtain shield
airbag RH, and measure the voltage and resistance
between wire harness terminal and ground.
NG
OK
267
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
268
BYD AUTO BYD Suri Maintenance & Repair Manual
Front
collisi
on
senso
r LH
Inspection Procedure
269
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
270
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
4 End
271
BYD AUTO BYD Suri Maintenance & Repair Manual
Front
collision
sensor
LH
Inspection Procedure
272
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
NG
OK
3 End
273
BYD AUTO BYD Suri Maintenance & Repair Manual
Front
collision
sensor
RH
Inspection Procedure
274
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
275
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
4 End
276
BYD AUTO BYD Suri Maintenance & Repair Manual
Front
collision
sensor
RH
Inspection Procedure
277
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
NG
OK
.3 End
278
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedure
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
279
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
NG
280
BYD AUTO BYD Suri Maintenance & Repair Manual
OK
4 End
281
BYD AUTO BYD Suri Maintenance & Repair Manual
Side
collisi
on
sens
or LH
Inspection Procedure
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
A
Replace side collision sensor LH
282
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
3 End
283
BYD AUTO BYD Suri Maintenance & Repair Manual
Rear side
collision
sensor LH
Inspection Procedure
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
284
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
285
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
4 End
286
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Rear
side
collision
sensor
LH
Inspection Procedure
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
A
Replace rear side collision sensor LH
287
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
3 End
288
BYD AUTO BYD Suri Maintenance & Repair Manual
Side collision
sensor RH
Inspection Procedure
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
289
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
290
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
4 End
291
BYD AUTO BYD Suri Maintenance & Repair Manual
Side
colli
sion
sens
or
RH
Inspection Procedure
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
292
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
3 End
293
BYD AUTO BYD Suri Maintenance & Repair Manual
Rear
side
collision
sensor
RH
Inspection Procedure
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
294
BYD AUTO BYD Suri Maintenance & Repair Manual
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
295
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
4 End
296
BYD AUTO BYD Suri Maintenance & Repair Manual
Rear
side
collision
sensor
RH
Inspection Procedure
Result Proceed to
Trouble code does not reoccur A
Trouble code reoccurs B
297
BYD AUTO BYD Suri Maintenance & Repair Manual
NG
OK
3 End
298
BYD AUTO BYD Suri Maintenance & Repair Manual
9 Special Tool
Malfunction
diagnostic tester
299
BYD AUTO BYD Suri Maintenance & Repair Manual
300
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal
(b) Using an Allen wrench, loosen the 2 set 10.4 Connect negative battery terminal.
screws as shown in the figure, without
taking them down.
Removal and Installation of ECU
Removal
Installation
301
BYD AUTO BYD Suri Maintenance & Repair Manual
Installation
10.9 Remove center air outlet of A/C.
1 Install the SRS ECU
302
BYD AUTO BYD Suri Maintenance & Repair Manual
303
BYD AUTO BYD Suri Maintenance & Repair Manual
installed in place.
(b) Install the 3 fixing points. 2 Install passenger side glove box.
304
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 9
Electrical Schematic Diagram
305
BYD AUTO BYD Suri Maintenance & Repair Manual
Code
Color Color Blue Brown Green Grey Light green Orange Pink Red Purple White Yellow
green
306
BYD AUTO BYD Suri Maintenance & Repair Manual
Note: The 473 configuration has no TCU, and the electronic injector ECU is at the same
position as the TCU motor power supply module.
307
BYD AUTO BYD Suri Maintenance & Repair Manual
308
BYD AUTO BYD Suri Maintenance & Repair Manual
4 High-frequency receiver
309
BYD AUTO BYD Suri Maintenance & Repair Manual
310
BYD AUTO BYD Suri Maintenance & Repair Manual
I C B D
X N F E H G
R
S Q
J K A
M T P
311
BYD AUTO BYD Suri Maintenance & Repair Manual
312
BYD AUTO BYD Suri Maintenance & Repair Manual
Fuses
No. F2/1 F2/2 F2/3 F2/4 F2/5 F2/6 F2/7 F2/8 F2/9 F2/10 F2/11
Specification 20A 7.5A 10A 15A 15A 7.5A 20A 20A 30A 20A 20A
Description Door lock Door Battery Exterior Reserved Rear fog Seat Power Power Power Stand
motor light, power power light heater seat seat seat by
exterior amplifier
light
No. F2/13 F2/14 F2/15 F2/16 F2/17 F2/18 F2/19 F2/20 F2/21 F2/22 F2/23
Specification 7.5A 10A 20A 20A 20A 20A 20A 7.5A 15A 20A 30A
Description Steering (Except Power Left front Right Left rear Right Auxiliary TCU Starter Main
shaft lock DCT) skylight window front window rear power relay 1
unlocked motor window motor window supply
motor motor
No. F2/25 F2/26 F2/27 F2/28 F2/29 F2/30 F2/31 F2/32 F2/33
Specification 15A 15A 10A 15A 7.5A 10A 7.5A 15A 30A
Description Main BMS EPS C Exterior EPB Power SRS Wiper
relay 2 rear-view for
mirror switch
heating 2nd
defroster gear
Relay
313
BYD AUTO BYD Suri Maintenance & Repair Manual
314
BYD AUTO BYD Suri Maintenance & Repair Manual
No. F2/1 F2/2 F2/3 F2/4 F2/5 F2/6 F2/7 F2/8 F2/9 F2/10 F2/11
Specification 20A 7.5A 10A 15A 15A 7.5A 20A 20A 30A 20A 20A
Description Door Door Battery Exterior Reserved Rear fog Seat Power Power Power Stand
lock light, power power light heater seat seat seat by
motor exterior amplifier
light
No. F2/13 F2/14 F2/15 F2/16 F2/17 F2/18 F2/19 F2/20 F2/21 F2/22 F2/23
Specification 7.5A 10A 20A 20A 20A 20A 20A 7.5A 15A 20A 30A
Description Steering (Excep Power Left front Right front Left rear Right Auxiliary TCU Starter Main
shaft t DCT) skylight window window window rear power relay 1
lock motor motor motor window supply
unlocked motor
No. F2/25 F2/26 F2/27 F2/28 F2/29 F2/30 F2/31 F2/32 F2/33
Specification 15A 15A 10A 15A 7.5A 10A 7.5A 15A 30A
Description Main BMS EPS C Exterior EPB Power SRS Wiper
relay 2 rear-view for
mirror switch
heating 2nd
defroster gear
315
BYD AUTO BYD Suri Maintenance & Repair Manual
316
BYD AUTO BYD Suri Maintenance & Repair Manual
F
E D
G
接蓄电池+
To 接发电机+
To battery
generator
317
318
BYD AUTO
Standby
F1/23-1 F1/21 备用
备用 Standby
K1-1 K1-2 K1-3 Standby
备用
F1/7
备用
F1/23-2 Standby F1/6
F1/12 F1/5
F1/18 F1/16
F1/9
F1/20
F1/4
F1/22-2 F1/11
F1/3
F1/19 F1/17 F1/15
F1/8
F1/10
F1/22-1 F1/2
F1/1
K1-5 K1-4
F1/14
F1/13
备用
Standby
BYD Suri Maintenance & Repair Manual
BYD AUTO BYD Suri Maintenance & Repair Manual
Fuses
No. F1/1 F1/2 F1/3 F1/4 F1/5 F1/6 F1/7 F1/8 F1/9 F1/10 F1/11 F1/12
Specification 10A 10A 10A 10A 15A 15A 7.5A 20A 15A 20/30A 15/20A 7.5A
Description High High Low beamLow beam Reserved/ Side MCU Reserved/ EMS Front fog Daytime Compress
beam RH beam LH RH Daytime lamp Front fog light/Low- running or
LH running light speed light/High-
light radiator speed
fan radiator fan
No. F1/13 F1/14 F1/15 F1/16 F1/17 F1/18 F1/19 F1/20 F1/21 F1/22-1 F1/22-2 F1/23-1
Specification 15A 20A 40A 40A 25A 40A 40A 50A 40A 125A 50A 40A
Description Steering Horn, Rear Illumination ABS Ems ABS Power Blower Main fuse Dashboard Window
warning braking defroster and CAN seat distribution control
light light module box system
auxiliary
power supply
No. F1/23-2
Specification 50A
Description Ignition
switch
Relay
319
BYD AUTO BYD Suri Maintenance & Repair Manual
320
BYD AUTO BYD Suri Maintenance & Repair Manual
No. F1/1 F1/ F1/3 F1/4 F1/5 F1/ F1/ F1/8 F1/9 F1/10 F1/11 F1/12
2 6 7
Specifi 10A 10A 10A 10A 15A 15A 7.5 20A 15A 20/30A 15/20A 7.5A
cation A
Descri High Hig Low Low Reserve Sid MC Reser EMS Front Daytime Comp
ption bea h bea beam d/Dayti e U ved/Fr fog running ressor
m bea m LH RH me lam ont light/Lo light/Hig
RH m running p fog w-speed h-speed
LH light light radiator radiator
fan fan
No. F1/1 F1/ F1/1 F1/16 F1/17 F1/ F1/ F1/20 F1/21 F1/22-1 F1/2 F1/23
3 14 5 18 19 2-2 -1
Specifi 15A 20A 40A 40A 25A 40A 40A 50A 40A 125A 50A 40A
cation
Descri Stee Hor Rear Illumin ABS Em AB Power Blowe Main Dashbo Windo
ption ring n, defro ation s S seat r fuse ard w
warn brak ster and distributi contro
ing ing CAN on box l
light light modul syste
e m
auxilia
ry
power
supply
No. F1/2
3-2
Specifi 50A
cation
Descri Igniti
ption on
switc
h
321
BYD AUTO BYD Suri Maintenance & Repair Manual
3.3 External Relay Socket and Fuse Box of Dashboard Wire Harness
(473 is the same as TI MT)
Schematic Diagram of External Relay Socket and Fuse Box for Dashboard Wire Harness
1 External relay socket 1 (Left/right steering light relay)
322
BYD AUTO BYD Suri Maintenance & Repair Manual
323
BYD AUTO BYD Suri Maintenance & Repair Manual
预留 预留 预留 预留 预留 预留
10A 10A 10A
KG4-2 F4/9
EPB
30A
F4/10
P档电
机
F4/11
key
less
F4/12
音响系
统15A
F4/13
预留
25A
F4/14
网关
7.5A
F4/15
P档电机
控制器
F4/16
预留
15A KG4-1
7.5A 7.5A
15A
常电
ACC IG2
324
BYD AUTO BYD Suri Maintenance & Repair Manual
Schematic Diagram of Small Relay Block and Fuse Box for Front Compartment
325
BYD AUTO BYD Suri Maintenance & Repair Manual
326
BYD AUTO BYD Suri Maintenance & Repair Manual
327
BYD AUTO BYD Suri Maintenance & Repair Manual
K3-1 K3-2
15A 15A
Vacuum brake pump relay (DCT Coolant circulation pump relay
equipped, MT reserved)
328
BYD AUTO BYD Suri Maintenance & Repair Manual
329
BYD AUTO BYD Suri Maintenance & Repair Manual
5 1
10 6
1 2
2 1
1 2
1 10
11 23
1 6
330
BYD AUTO BYD Suri Maintenance & Repair Manual
331
BYD AUTO BYD Suri Maintenance & Repair Manual
11 4 1
1 1 4
13
12 8 5
22 5 10
14 9
12
1 2
2 1
1 2
1 6
332
BYD AUTO BYD Suri Maintenance & Repair Manual
333
BYD AUTO BYD Suri Maintenance & Repair Manual
1 6
1 2
13 10
1
3
17 14
6 4
20 18
9 21 7
23
1 2
3 6
334
BYD AUTO BYD Suri Maintenance & Repair Manual
335
BYD AUTO BYD Suri Maintenance & Repair Manual
1 6
1 2
13 10
1
3
17 14
6 4
20 18
9 21 7
23
1 2
3 6
336
BYD AUTO BYD Suri Maintenance & Repair Manual
337
BYD AUTO BYD Suri Maintenance & Repair Manual
顶棚线束
PJ01
P2I
P02
1 4
13
8 1 5
5
14 12
9
P03
P06
P04 P05
3 4a 1d 1b 16
1 8
1 O R/B B 3 B Gr
1 2 0.5 0.5
0.5 0.5 0.5
9 16
P08 P07
1e 17
B Gr 17 4d
0.5 0.5 1 Gr R/B 2
0.5 0.5
338
BYD AUTO BYD Suri Maintenance & Repair Manual
339
BYD AUTO BYD Suri Maintenance & Repair Manual
HeJ01
340
BYD AUTO BYD Suri Maintenance & Repair Manual
HeJ01 He01
2 10 9 8 4 1
7 3 1
B Gr/L L/O W/G
R/L V P
0.5 0.5 0.5 0.5 0.5
0.5 0.5
5 12 11 7 9 10
6 1 L/O 4
13 B B O Y/R 8 Gr/L
Y
0.5 0.5 0.5 0.5 0.5 0.5
0.5
He03
He02
1 2 3 4 5 11 12
8 1 O B 2
1 W/G B P V B
0.5 0.5 0.5 0.5 0.5 0.5 0.5
6 7 8
Y Y/R R/L 16
0.5 0.5 0.5
341
BYD AUTO BYD Suri Maintenance & Repair Manual
342
BYD AUTO BYD Suri Maintenance & Repair Manual
仪表板线束(1)
G2X G2N
1 6
1 4
7 12
5 11
19
13
12 16 25
20 24
17 19
28 33
27
20 26
34
34 37 38 40
27 33
41 43 44 45
35
36 39
1 4
1 3
10 13
1 4
G2M 14
4 17
13 6 1 5
8
5
18 20
7 10
14 9 6
112 9 12 21 23
1 R 3
1.25
G2P
G2Q
343
BYD AUTO BYD Suri Maintenance & Repair Manual
仪表板线束(3)
G39 G2S
G2A G41
1 6
1 2
7 12
GJ08
1 2
3 6
G16 G59
12
GJ06
GJ13
GJ05
3
13 10
235 234 220 219
1
P G/B Br/W L/W
0.5 0.5 0.5 0.5
17 14
4
6
20 18
9 7
23 21
GJ15
1 2
4 1
13
8 5
14 1
9
12
10 5
G40
G21
G25
8
1
1 10 3
9 16
11 20 4 6
344
BYD AUTO BYD Suri Maintenance & Repair Manual
仪表板线束(4)
G65 G24
G57
G27 G03 G10
405 55c
1 B R/B 2
1 4 0.5 0.5
G28 1 4 2 1
G53
3
4
5 8
1 2
1 2
G62 G58
G36
1 1 6
13 24 7
G11B
1 9
10 21
BAT+
G22
G15A
G44
G23
G47 G31
G43
G81 G32 G23 G55
2
1 2
1 3
3 6
345
BYD AUTO BYD Suri Maintenance & Repair Manual
仪表板线束(5)
10 1
20 11
1 4
G35B
5 10 G46
1 2
G07
G42
G38
G63
6
1 4
1 2
7 12
G50
1 6
7 12
GJ09
G49
1
11 13
8
5
9 14 12
12 22
GJ11
16 5
4 1
28 17
346
BYD AUTO BYD Suri Maintenance & Repair Manual
347
BYD AUTO BYD Suri Maintenance & Repair Manual
348
BYD AUTO BYD Suri Maintenance & Repair Manual
349
BYD AUTO BYD Suri Maintenance & Repair Manual
地板线束(1)
K21
KJ14
KJ04 KJ15
KJ07
1
13 10 3
3 1
10 13
17 14 4
6
6
4 14 17
18
7
20 18 20 9
9 7
23 21 21 23
K17
K50
10 1
20 11 1 16
17 32
CANL
K37
K26
KJ08
4 1
151
Gr 13
1 8 5
0.3 8
146 147 148 149 150 152
9 Y/L Y/O Y/G L/W L/O L 18 14 9
0.3 0.3 0.3 0.3 0.3 0.3 12
350
BYD AUTO BYD Suri Maintenance & Repair Manual
地板线束(2)
K28
K27
KJ02 KJ01
K03
13 10
1 4 1 2
3 1
17 14
6
4 1 2
5 3 6
10 20 18
9
7
23 21
K38 K56
KJ05 K06
1
3
10 13
82 81
4 1 L/Y G/Y 2
6 0.5 0.5
14 17
7
18 20 9
1 2
21 23
K56
KJ08 KJ10
K36
KJ09
59 58
1 Y/L B/Y 2
60 61 173 169 170 0.5 0.5
1 2 168 172 171
1 L/Y L/B 2 132 138 L/B Y G Gr R/B B/W
0.5 0.5 W/R R 0.5 0.5 0.5 0.5 0.5 0.5
1.25 1.25
139 133
B/W B
1.25 1.25 175 177 176 174
B R/B R Y
0.5 0.5 0.5 0.5
K39
KJ06
K42
K04 K05
KJ13
145 26 1 2 1
2
1 Gr B 2
0.5 0.5 1 2 1 2
1 2
K11 K34
1 5
1 16
17 32
KJ11
K12
2 1
15
B/Y
3.0
351
BYD AUTO BYD Suri Maintenance & Repair Manual
地板线束(3)
K22
K19 K16
K15 KJ12
1 2
1 2 2
1
1 6
7 12
K20 K35
K24
1 2
1 3 1 6
4 6 7 12
K29 K30
K31
K08
1 4
K33
K5
K10
2
1
1 8 1 2
4 3
9 16
1 2
K41
K13
K09 K14
K43
1 3
2 1 2 4 6
141
Gr
140
R
1 3 1
0.5 0.5
K40
KJ03 K18
3 1
1 2
8 4
352
BYD AUTO BYD Suri Maintenance & Repair Manual
24 K7 To ground 1
25 K31 To mega bass speaker 1
26 K35 To tire pressure monitor module 1
27 K03 To left side collision sensor 1
28 K04 To right side collision sensor 1
29 K05 To right rear collision sensor 1
30 K06 To left rear collision sensor 1
31 K30 To right rear squawker 1
32 K08 To right side air curtain 1
33 K09 To left license plate light 1
34 K10 To trunk micro switch 1
35 K11 To fuel tank 1
36 K12 To rear fan heat wire 1
353
BYD AUTO BYD Suri Maintenance & Repair Manual
354
BYD AUTO BYD Suri Maintenance & Repair Manual
355
BYD AUTO BYD Suri Maintenance & Repair Manual
356
BYD AUTO BYD Suri Maintenance & Repair Manual
前舱线束
B2D B2C
BJ01
1
7 2
1
8 17 12
3
B1D
1 4
BJ08
B1C
B2B
B1G 5 10
B09
1 4
1 2
5 10 1 2
BJ10
B05
25 38 121 125
Gr
127
G
126
L
128
R 122
1
Gr 0.5 0.5 0.5 0.5 Y 6
131 132 133
1.25
1.25 W
0.5
O
0.5
Y/L
0.5
14 24
123 124
15 G/W W
1 13 1.25 1.25 20
2 12
1 2 4
盲 盲 6
1 4
堵 堵
1 2
BJ06 BJ07
BJ03
BJ02
2 1
1 4
4 3
3 BJ05
1
10 13
2 7
1 8
BJ04
17 9 14
4 14
6
4 1
15 21 22
16
18 20
8 5
7 2 1 23 28
9
21 23 12 9 36
29
30 35
16 13
BJ12
BJ11
B11
5 12
1 4
13 20
1 2
3 4
B1J
55 56
1 G/B
1 P 2
0.5 0.5 1 6
2 3
B1I
1 4
5 10
357
BYD AUTO BYD Suri Maintenance & Repair Manual
358
BYD AUTO BYD Suri Maintenance & Repair Manual
359
BYD AUTO BYD Suri Maintenance & Repair Manual
360
BYD AUTO BYD Suri Maintenance & Repair Manual
前横梁线束
C1F
C1H
C02
1 10
11 20
1 2
CJ01 CJ02
1 4
5 8 1 2
1 2
9 12
1 3 1 3
13 16
3 4
C08/C09/C14/C27
C04
C23 C24
C22 C20 C07 C12
37 23 2
29 24 31
1 B W/G 2 48a 4 5 1 B W/R 2 32 21
1.25 1.25 1 R/B L/W B 3 1 B R/L 2
1.25 1.25 B Y/B
0.5 0.5 0.5 0.5 0.5
0.85 0.85
C28
C30/C31
36 22 38 9 1 2
1 2 1 3
B R/G 1 B Br 2
1 2
1.25 1.25 0.5 0.5
C29 C11
C15(473)
C25 C36
1 3
1 2
361
BYD AUTO BYD Suri Maintenance & Repair Manual
362
BYD AUTO BYD Suri Maintenance & Repair Manual
476
363
BYD AUTO BYD Suri Maintenance & Repair Manual
476
364
BYD AUTO BYD Suri Maintenance & Repair Manual
473 Engine
A31 A10
A24
64
49 51 8 7
62 64
1 4
37 48
101 112 50 37 6 5
33
25 36 46 48
89 100 36 23
4 3
17 30
13 24 32
77 88
1 12
65 76
22
1
9
14 2
1
16
A05
20j 19
8 1 1 Y/B L/W 2 1 3
2 1 0.5 1 4
14 9 0.5
22
15
28 23
36
29
A21
A12
A29
A28 A22
1 3
1 3
1 4
1 4
4 6
25 28c
Gr/B B/O
1 0.5 0.85 2
A34
A27
A25
A23 A38 A11
A15/A18
1 2 1 2 1 2
1 3 1 3
A26
A16 A20 A19/A17 AJ06
27 26 29
1 Br/W B/R 2 B/W 1 2
1 4 0.5 0.5 3.0
58
B
20.0
365
BYD AUTO BYD Suri Maintenance & Repair Manual
366
BYD AUTO BYD Suri Maintenance & Repair Manual
476 Engine
A01
A02
A15
72
81 63 82 89
1 2
114 116
62 44 90 97
3 53
117 118 1 3
34
98 105
43 25
4 6
119 121
4 5 106 113
24 6
15
A07/08
A49
A52 A31 A48
1 4
1 4 1 2
59 1 8
1 1 3
5 G/B Sb Br
A34 0.5 0.5 0.5 A35
10 A45
6
1 8
103 102 1 2
B 9
2 L/B 1 16
0.85 0.85
A38
A20/21/22/23
1 2
1 2
8 1 6 1
14 9
A24
22
15
36
28 23
20 15 1 3
29
1 2
1 3
1 4
A12 1
60 46
L
35
3
1 3
Y G/Y
0.5 0.5 0.5
1 2
1 2 1 2
A37
A55 A41
99
A11 A47 B
A36 20.0
30 97
A43 1 Y/B G 2
A04 0.5 0.5
1 3 9
367
BYD AUTO BYD Suri Maintenance & Repair Manual
368
BYD AUTO BYD Suri Maintenance & Repair Manual
369
BYD AUTO BYD Suri Maintenance & Repair Manual
370
BYD AUTO BYD Suri Maintenance & Repair Manual
Fa02 Fa01
371
BYD AUTO BYD Suri Maintenance & Repair Manual
Ea01
Ea02
372
BYD AUTO BYD Suri Maintenance & Repair Manual
Fb02 Fb01
373
BYD AUTO BYD Suri Maintenance & Repair Manual
374
BYD AUTO BYD Suri Maintenance & Repair Manual
375
BYD AUTO BYD Suri Maintenance & Repair Manual
376
BYD AUTO BYD Suri Maintenance & Repair Manual
377
BYD AUTO BYD Suri Maintenance & Repair Manual
378
BYD AUTO BYD Suri Maintenance & Repair Manual
379
BYD AUTO BYD Suri Maintenance & Repair Manual
380
BYD AUTO BYD Suri Maintenance & Repair Manual
381
BYD AUTO BYD Suri Maintenance & Repair Manual
28. 476ZQA+DCT
29. EPS
30. Tire pressure monitor system
31. EPB
32. P position motor controller
33. Electronic cooling fan
382
BYD AUTO BYD Suri Maintenance & Repair Manual
476ZQA MT power supply, starter and generator Battery (Front of main fuse)
Battery (Rear of main fuse)
IG2Power Supply
Compressor
A IG1Power Supply
ACCPower Supply
W
5.0
Multiplex integrated W
2 B2B control module GJ11 2.0
MICU-Z4 17 BJ11 BJ01
K2-7 88 86 4 GJ05
F1/12 F2/22 W G W
5.0 Starter relay
Compressor Starter 0.5 W/B 1.25
7.5A 20A 0.5
88a 85
BJ07
2 B1G 31 AJ01 3 1 G08 1 2 G19 6 8 G08
4 G2T 6 2 4 G2A W/B W/R R
0.5 0.5 0.5
F1/23-2 88 86 88 86
KG-3 KG-1 KG-2 9 G2P 10 G2P11 G2P
1#Ignition 5 G2A 2 B2C 32 G2X
ACC IG1 IG2
switch50A Relay Main relay
2 A37 relay MICU-W23
GJ05 2 X335 88a 85 88a 85
Steering Shaft
5 BJ01 Generator FR G S L Lock Power
F1/22-1 Supply
Voltage regulator
Main fuse
BJ07 5 2 4 G374 3 G19 7 10 G37
125A
36 AJ01 MICU-W26 Sun roof position
A54 Front compartment Field coil Rectifier
relay block B11 Reserved B B
0.5 W/R R B/W B/R
EPSMotor 35.0 W/B
A1A 1.25 1.25 5.0 1.25
8 B2D 4 G2P
2.5
B B B B
R A18 A43
6.0 20.0 20.0 6.0
6.0 Starter B S
A42
B+
A15 Engine assembly Transmission assembly
1 X336 Fb01 Fa01
Battery
B B B B B
Ea01 15.0 0.5 0.5 0.5
15.0
B
20.0
B
35.0
383
BYD AUTO BYD Suri Maintenance & Repair Manual
IG2Power Supply
Compressor IG1Power Supply
A
ACCPower Supply
W
5.0
Combination instrument
G16-35 F1/5
Multiplex 2#Ignition
integrated F2/13
R switch W Steering
1 G2A control module 20A 1 G2M
2.0 5.0 Shaft Lock
MICU-W26
Unlock
3 G2A Y/L 7.5A
Dashboard 0.5
distributor box 1 B1D
Multiplex GJ11 W
integrated 17 BJ11 2.0
2 B2B control module
MICU-Z4 BJ01
K2-7 88 86 4 GJ05
Y/L
F1/12 F2/22 W 0.5 W
Compressor Starter 5.0 Starter relay W/B W
7.5A 1.25
20A 0.5 1.25
88a 85 BJ11
18 AJ01
2 B1G 3 1 G37 1 2 G19 6 8 G67
6 2 4 G2A W/B W/R R
4 G2T 0.5 0.5 0.5
A18 A19
Starter B S
B
20.0
Solenoid
coil
M
M
1.2KW
A26
B+
Battery A15 Engine assembly Transmission assembly
Fb01 Fa01
X901 B B
B
B B 0.5 0.5 0.5
15.0 15.0
B B
35.0 15.0
384
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2Power Supply
Compressor IG1Power Supply
A
ACCPower Supply
W
5.0
Multiplex
Combination instrument
integrated R
control
G16-35 W F2/13
1 G2A R 5.0 5.0
module 1 G2M Steering
2.0 1 B10
MICU-W26 Shaft
3 G2A To dashboard Lock
distributor boxⅡ Unlock
Y/L 7.5A
0.5
Multiplex
integrated
control
2 B2B GJ11
module
MICU-Z4 17 BJ11
K2-7 88 86
F1/12 F2/22 W Starter relay G
Compressor Starter 5.0 W/B
0.5
7.5A 20A 0.5
88a 85
BJ07
35 G01 2 B1G 24 G01 1 2 G19 27 G01
1 B10 31 AJ01
2 G2A W/B W/R R
4 G2T
0.5 0.5 0.5
F1/22-2 G 88 86 88 86
F1/23-2 KG4-2 KG-1 KG4-1 9 G2P 10 G2P11 G2P
Dashboard 5 G2A 2 B2C 32 G2X 0.5
1#Ignition ACC IG1 IG2
distributor
switch50A Relay Main Relay
boxⅡ
50A 2 A37 relay MICU-W23
GJ05 2 X335 88a 85 88a 85
Steering
5 BJ01 FR G S L Shaft Lock
Generator
F1/22-1 Power
Voltage regulator Supply
Main G23
G31 G01 4 3 G19 28 G01
fuse BJ07
125A 36 AJ01 MICU-W26 Sun roof position
A54 Front compartment Field coil Rectifier
B11 Reserved B B
relay block W/R R B/W B/R
EPSMotor 35.0 0.5
A1A W/B 1.25 1.25 5.0 1.25
8 B2D 4 G2P
2.5
B B B B
R A18 A43
6.0 20.0 20.0 6.0
6.0 Starter B S
A42
B+
A15 Engine assembly Transmission assembly
1 X336 Fb01 Fa01
Battery
B B B B B
Ea01 15.0 0.5 0.5 0.5
15.0
B
20.0
B
35.0
385
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2Power Supply
IG1Power Supply
HeJ01 HeJ01
6 GJ08 5 GJ08
Gr/L L/O
0.5
0.5
*1 *2
386
BYD AUTO BYD Suri Maintenance & Repair Manual
Auxiliary EMS
Power Supply AJ01-23 Power outer
A rear view Steering
Auxiliary Power Supply Braking light mirror control Independent
B Steering/warning light Interior light system Starting Shaft
F2/20 Start Button system gateway
Auxiliary Power Supply control system Reserved system SRS system Lock<
Auxiliary G2N-11
C G27-13 G27-12 G27-11 G27-7 G27-2 G44-2 G37-5/10 MICU-W27 1 A45 GJ10-8 T04-1 P04-1 G2A-5 G03-8 G2X-2 G2N-34 G07-8 G07-9 G21-3 G21-6
Power
Supply
MT
7.5A Lower reversing B-CAN B-CAN B-CAN
B-CAN
the light H H L
L
left switch 2 A45
and (Closed:
Emergency Reverse)) Y/G
right 0.85
Warning
steering
Light relay AJ01 AJ01
when 26 4 Collision
BJ07 BJ11 unlock
closing *2 *1 signal
a Y/G input
0.85
door
BJ02
21
GJ06 keyless-ECU keyless-ECU
G50-12 G50-6
L Gr/R W/G G/W Y G/R W/G W/L Y/G Y/L O Y/G V P V P
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
23 G2P 24 G2P 26 G2P 6 G2Q 12 G2Q 12 G2P 4 G2Q 27 G2P 9 G2Q 7 T2J 3 P2I 5 G2P 37 G2X 11 G2Q
5 G2T 6 G2T 1 G2T 2 G2T
B-CAN L B-CAN H
MICU-W19 MICU-W27 R position signal Right front door MICU-W7 MICU-W17 MICU-Z4 MICU-W18 MICU-W8 Rear view mirrorMICU-W9 MICU-W10
light drive Left front door Brake signal Rear view mirror returning drive
light drive
input folding drive
Trunk micro
Trunk light
MICU Left rear Right rear
MICU-Z3 MICU-W5 switch MICU-W2 MICU-W4 MICU-W3 door lock door lock
F-CAN-H F-CAN-L switch signal Speed signal input UNLOCK signal MICU-W22 UNLOCK LOCK UNLOCK detection detection
6 G2P 7 G2P 8 G2P 15 G2P 27 G2X 13 K2F 20 G2P 36 G2X 4 K2G 7 T2K 8 G2N 8 K2E 11 K2H 4 K2H 7 G2N 1 K2E 8 T2K 2 T2K 10 K2E 3 G2P 2 G2P
387
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2Power Supply
IG1Power Supply
ACCPower Supply
Combination
Window ControlWindow Control Combination Combination Instrument
Exterior Power Amplifier No. 1 CAN adapter No. 1 CAN adapter DLC System Switch SRS SRS
System Switch
G06-10 G06-20 G16-4 G16-5 G36-9 G36-8
K26-8 K26-9 G40-3 G40-11 T03-18 T03-17 G24-1 G24-2
B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN
H L H L H L H L H L H L H L
V P V P V P V P V P V P V P
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
1 K2G 2 K2G 39 G2N 38 G2N 31 G2N 30 G2N 14 T2J 13 T2J 14 G2X 13 G2X 23 G2X 24 G2X 2 G2R 1 G2R 11 B2D 12 B2D
Steering
MICU-W1 Steering shaft lock
Illumination Co-driver's seatBraking light shaft lock control
Door lock motor
MICU-W12 MICU-W11 MICU-W13 MICU-W14 MICU-W15 MICU-W16 ground MICU-W21 MICU-W20 drive belt signal switch signal unlock drive (Hall)
13 K2E 14 K2E 14 K2H 8 K2H 15 G2P 14 K2F 7 K2H 5 K2E 3 G2M 5 G2Q 1 G2P 21 G2P 30 G2P 29 G2P 13 G2Q 16 G2P 17 G2P
B
0.5
B
0.5
Exterior
T01-6 V05-1 U02-1 W02-1
Left front Right Right K2H-12 K2-8-4
light
K2-8-5 system G41-9 G41-10
Left rear G21-2 G21-4
door lock door lock front rear door Reserved Reserved Reserved Steering/warning light GJ10-7 Reserved Power outer rear view
motor motor door lock lock G2P-15 K1 K2H-7 K3 G2M-3 G2P-1 WG47 keyless WG47
motor motor
control system G2N-3 mirror control system
388
BYD AUTO BYD Suri Maintenance & Repair Manual
F2/31
Power supply for switch Washer system
Combination 2nd gear 7.5A C19-1 Interior light Exterior light
Wiper system F2/33 system Headlamp adjustment F1/6 F1/7
Switch system Reserved
F2/28 Wiper BJ05-1 Front MCU
G24-4 G24-8 B01-2 B01-1 B01-3 30A G25-2 G35B-10 P03-8 T2J-10 K14/24-2 C06-2 C04-2 C05-2 C17-2 position
7.5A
15A lights
G/Y 15A
3 B2D
0.5 低 高
速 速
Y 6 B2D
6 X991 0.5
时
钟 Y/G Y/G L Y W
弹 0.85 0.85 2.0 2.0 0.5
R/B R R/B
簧
8 G25 0.5 0.5 0.85
1 X992 8 B1E 4 5 B1J 1 B1J
W G/W
0.5 0.5 1 B2C
G/Y
KI1-5
0.5 KI1-2 KI1-1 35 G2N 5 P2I 10 T2J 12 K2F Internal
Relay KI1-3 Internal Internal Gr side
coil Internal wiper light
16 GJ06 15 GJ06 13 GJ06 washer
wiper 2.0
BJ02 BJ02 Horn BJ02 Power switch
2 B1J motor relay
supply motor relay
switch relay
ON relay
P V W G/W G/Y B
3 B1J 0.85
0.5 0.5 0.5 0.5 0.5 20 C1F 4 B2D 10 B1I 10 9 C1H
MCU
MCU-N1 MCU-N16 MCU-N13 MCU-N3 MCU-N27 MCU-N23 MCU-N26
Rear
defroster
heating
control 5 B1I 3 C1H 2 C1H 1 C1H 4 C1H
W/B G/B
0.5 L/B 0.5
0.5
Front
Engine 1 C11
fog
compartment
light
BJ02 cover
14 GJ06 relay 2 CJ02 switch
control BJ05 (Closed:
Cover 2 C11
open)
W/B L/B B
0.5 0.5 0.5
G2N-24
Air Conditioning
Relay control to B1E-7
System Reserved Reserved Reserved
ground WC20
K1-3-85
389
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2 Power Supply
IG1Power Supply
ACC Power Supply
KI1-7 KI1-6
Internal Internal
KI1-4 KI1-8
F1/2 F1/1 siren F1/3 F1/4 low-
Internal Internal
Left Right relay Left Right beam
electric electric
high- high- low- low- light
horn horn
beam beam relay
relay relay beam beam
light light light light circuit
Wiper
10A 10A 10A 10A Y/G W Y L
reset
0.85 0.5 2.0 2.0
7 8 C1H 4 B1I
Br/Y
MCU motor
0.85
2 C19 4 B01
GJ01
6 KJ01
Br/Y
0.85 B B
0.85 2.0
B B B
1.25 1.25 0.85
WC21 WC20
WC23 B07
390
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2Power Supply
IG1Power Supply
ACCPower Supply
Air
Conditioning
System Brake
System MICU
AJ01-20 G47-5 C1F-3 F2/25
AJ01-7 G47-6 G47-24 G18-1 G2P-21 electronic
injector
F2/24 main
WG49 Fuel relay
pump
215A
15A
F2/26 F1/9
EMS EMS
15A R
15A B
0.5
0.5 5 G2X
R/W G L/Y Y L/B W/B W/R W/G
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
3 B03 86 88
Medium K2-1
voltage 3 G02 DLC3 88 86
Driver electronic
switch of G40-16
15 G2X intent injector
9 B1E
air K2-6 Fuel main
G2X-16 conditioner switch
pump 85 88a
R/G relay 2
Gear shift (Closed: 2 B03 relay
mechanism 1.25 ≥1.47 4 G02
88a 85 30
Mpa) 11 G2X
GJ15 W/G B
3 W W
BJ08 0.85 0.85
0.5 0.5
WG9
Dashboard O O
GJ06 GJ06 GJ06
distributor 0.85 0.85
4 BJ02 5 BJ02 22 BJ02 B/O
R/G box
0.85
0.85 2E 2X
16 K2E 4 G2X
Front 1 A24 4 A29 Rear
oxygen oxygen
G16-14 sensor
G/Y 8 AJ01 sensor
GJ11 GJ11 GJ11 W/R W Combination 1 GJ15
Instrument 0.5 1 BJ08 8 BJ11
15 BJ11 13 BJ11 14 BJ11 0.5 0.5 Y/G
1.25
2 A24 4 A24 2 A29 1 A29 3 A29
3 A24
B/O
GJ06 0.85
6
1 K11 BJ02
Power Fuel
supply R
L/Y Y L/B G/B M pump Gr
0.85 G/W Sb V/W Sb W/B
ON 0.85 0.5 0.5 motor 0.5 0.5 0.5
0.5 0.5 0.5 0.85
G/Y
0.5 Shielding Shielding
5 K11 layer layer
BJ11 BJ11 BJ11 BJ11 BJ11
22 29
AJ01 AJ01 BJ11 BJ11 BJ11 BJ11 B
23 AJ01 21 AJ01 33 AJ01 B
26 AJ01 16 AJ01 25 AJ01 12 AJ01 BJ11 0.5
5 0.5
B AJ01
1.25
Battery
R/G R W/B G W
L/Y Y L/B G/B
0.85 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 G/Y
A09
0.5 A09
A45-1
Reversing light switch
K5
48 A10 33 A10 57 A10 4 A10 55 A10 24 A10 25 A10 29 A10 30 A10 28 A10 17 A10 42 A10 9 A31 40 A31 16 A31 32 A10 40 A10 5 A10
Low speed fan High speed fan A/C Rear defroster A/C permission - Medium voltage Brake Brake signal 1 Driver intent
control control permission compensation Low level effective switch signal 2 High level Switch signal
(Blower effective
compensation)
391
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2Power Supply
IG1Power Supply
ACCPower Supply
F2/12
7.5A
AJ01
15
BJ11
Dashboard Y/B Y/B Y/B
B/O B/O B/O
distributor N/A
0.85 0.85 0.85 1.5 1.5 1.5
box
2D
17 B2D O 2 A38 1 A01 1 A04
Filter
0.85 capacitor
Coolant temperature sensor 2 Camshaft position sensor Phase ICM ICM
2 A36 2 A28 A23 Ignition Ignition
Charcoal coil coil
Canister Linear No. No.
Control EGR 1 2
MIVEC valve t° t°
Valve
Valve
1 A28 1 A35 2 A35 3 A35 4 A35 5 A38 1 A23 3 A23 3 A12 2 A12 1 A12
1 A36
W/B L R/B L/R 3 A04
3 A01 2 A01 2 A04
0.5 0.5 0.5 0.5 Self-owned
support Cylinder
grounded Cylinder No.
Sb O L/R No. 2
0.5 0.5 0.5 1 sparkplug
Gr sparkplug
Br
1.25 1.25
Gr/B
Gr/B
0.5
0.5
B
L Y/W 1.25
0.5 0.5
A09
5 A31 30 A31 7 A31 39 A31 20 A31 37 A31 31 A31 29 A31 34 A31 36 A31 24 A31
392
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
F2/23
EMS
Main F1/18
relay30A EMS
40A
Dashboard
distributor
box
3 B1D
Y/B 88 86 B
1.5 K2-4 4.0
Main
relay 1 B2B
88a 85
Dashboard
distributor
box
Y/B Y/B Y/B Y/B Y/B Y/B
1.5 1.5 1.5 1.5 1.5 1.5
1 A02 1 A03
ICM ICM 2X Intake Pressure/Temperature Sensor
Ignition Ignition 1 A05 1 A06 1 A07 1 A08 17 29 G2X
coil coil Injector Injector Injector Injector
No. No. No. No. No. No.
3 4 1 2 3 4
u t°
2 A05 2 A06 2 A07 2 A08 3 A22 4 A22 1 A22 2 A22
Y/B B/W
3 A02 2 A02 3 A03 2 A03 1.5 0.5
BJ11
1
AJ01
L/W V/G G/R B/Y Y/B Y/B B/W
0.5 0.5 0.5 0.5 1.5 1.5 0.5
35 A31 12 A31 4 A31 3 A31 8 A31 10 A31 1 A10 2 A10 18 A10 45 A31 27 A31 21 A31 38 A31
EMS
393
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2 Power Supply
IG1 Power Supply
ACC Power Supply
Gateway Controller
DLC
G2X-27 G15A-3 G15A-20 G15A-17
A32 A09
Power assist
steering switch
(Closed:
Direction killed)
1 A32
Y
0.5
GJ11
accelerator 3
BJ02
pedal
position
crankshaft knock
sensors position S N sensor
sensor
(Engine
Electronic
speed)
3
Throttle A21 4 A21 1 A21 2 A21 5 A21 6 A21 1 B14 6 B14 5 B14 1 A11
2 B14 3 B14 4 B14 2 A11 2 A20 1 A20
Body
twisted twisted
pair pair BJ11 BJ11 BJ11
28 24 2 3
AJ01 AJ01 AJ01
BJ11 BJ11 BJ11 BJ11 BJ11 BJ11
6 AJ01 13 AJ01 14 AJ01 27 AJ01 19 AJ01 17 AJ01
394
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2 power supply
IG1 power supply
ACC power supply Air
Conditioning
High-speed Electronic fan System Brake MICU
C1F-3 System G2P-21
electronic fan speed G47-24 G47-5 G47-6
C01-10/C01-20 C01-5/C01-15 G18-1
F2/24
Fuel
15A
F2/26 F1/9
EMS EMS
15A 15A R
0.5
5 G2X
G/B L/W L/B L/Y B/Y W/B W/R W/G
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Medium
3 B03
空调中压
voltage
88 86
switch of air DLC3 F2/12
开关(闭
conditioner G40-16 oxygen
合:≥1.47Mpa)
(Closed:
9 B1E
≥1.47 K2-6 Sensor
15 G2X
*2 29 BJ07 25 BJ07 *3
Mpa)
Fuel pump 7.5A
2 B03 relay 29 AJ01 25 AJ01
88a 85
Y
0.85 Dashboard
distributor
box
CJ02 CJ02 GJ11 GJ11 GJ11 CJ16 GJ16 Y/B B/O
10 BJ05 9 BJ05 14 BJ11 15 BJ11 13 BJ11 3 BJ09 7 BJ09 0.85 0.85
Y/B Y/B
2E 2X 2D 0.85 0.85
16 K2E 4 G2X 17 B2D
1 K11
Y Fuel
GJ16
0.85
R G/B M pump
motor
8 BJ09
0.85 0.5
G/Y
BJ07
5 K11 0.5
23 AJ01
BJ07 BJ07 BJ07 BJ07 BJ07 BJ07 BJ07 BJ07 BJ07 BJ07
24 AJ01 3 AJ01 16 AJ01 12 AJ01 13 AJ01 33 AJ01 5 AJ01 4 AJ01 9 AJ01 10 AJ01
B
1.25
Y
0.5 R G/B L/W L/B L/Y B/Y W/B G G/Y W/G W/R Br Br/Y W B/G
G/B
0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Sb
A45-1 0.5
Reversing light
switch
54 A01 K5
112 A01 113 A01 40 A01 Low speed
79 A01 fan 61 A01 15 A01 19 A01 18 A01 36 A01 43 A01 62 A01 13 A01 55 A01 56 A01 33 A01 75 A01 81 A01
High speed fan control A/C A/C Medium Rear defroster Brake Brake
control request permission voltage switch compensation signal 2 signal 1
395
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2 power supply
IG1 power supply
ACC power supply
F2/25
electronic
injector
main
relay 2
15A
前舱继电器盒
A54
86 88
K2-1
11 A53 13 A53
electronic
injector F3/6
F3/5
main Coolant
85 88a Vacuum
relay 2 circulation
brake
positive pump
pump
30 11 G2X fuse 15A
15A
block 12 A53 14 A53
B 50A
0.85
WG9 B L/Y
8.0 2.0 1 3 A53 8 6 A53
B/O B/O Y/B Y/B Y/B Y/B
B/O B/O B/O
0.85 0.85 2.5 2.5 2.5 2.5
0.85 0.85 0.85 19 A54 86 88 K3-2 88 86
Coolant Vacuum
circulation brake
Boost Turbocharger pump 1 A20
pump 1 A21 1 A22 1 A23
pressure Air relay
relay ICM ICM ICM ICM
pressure 1 A25
Circulation
1 A26 Charcoal 1 A35 85 88a (DCT) 88a 85 2# 3# 4#
1#
1 GJ15 8 AJ01 limiting Valve Canister Ignition Ignition Ignition
8 BJ07 Ignition
1 BJ08 valve Control coil coil coil
15 18 A54 7 9 A54 coil
solenoid Valve
F3/4Pumps,
B/O F3/2 vacuum
2 A25 2 A26 2 A35
0.85 TCU pumps L/B
L/Y 2 A20 3 A20 2 A21 3 A21 2 A22 3 A22 2 A23 3 A23
30A 0.85
0.85 Cylinder Cylinder Cylinder Cylinder
No. 1 No. 2 No. 3 No. 3
4 A54 2 A54 sparkplug sparkplug sparkplug sparkplug
1 A33 2 A34
B B B B
R R
M Turbocharger M Vacuum 1.25 1.25 1.25 1.25
Air Circulation brake pump
2.5 2.5
Valve
G/W B B L/W
A45-1 A45-9 0.5 0.85 0.85 0.5 Y/W Y/R Y/L Y/G
O Sb Gr/B
0.5 0.5 0.5 DCT 0.5 0.5 0.5 0.5
A53 A53
22 A01 21 A01 78 A01 74 A01 73 A01 99 A01 107 A01 98 A01 106 A01
396
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ )
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2 Power Supply
IG1 Power Supply
ACC Power Supply
F2/23
EMS
Main F1/18
relay EMS
30A 40A
Dashboard
distributor
box
3 B1D
Dashboard
distributor
box
Y/B Y/B
2.5 2.5
Injector
Injector Injector Injector
No.
No. High *3
No. No.
2 A38 1 Brake
2 3 4 2X fuel
17 Coolant temperature sensor Radiator booster
1 A24 29 G2X pressure
Fuel outlet pressure
pressure coolant sensor
sensor
Filter regulating 1 A16 2 A161 A17 2 A18 1 A19 2 A19 temperature (DCT)
2 A17 1 A18
capacitor valve t° sensor t°
2 A24 1 A04 2 A04 1 C15 2 C15 1 A06 3 A06 1 A49 2 A49 3 A49
Y/B B/W 2 A06
3 A23
2.5 0.5
Self-owned
GJ15 GJ06 G B/L
support
7 BJ08 20 BJ09 G/B
grounded 0.5 0.5
0.5
CJ02 CJ02
Y/B B/W 15 BJ05 12 BJ05
2.5 0.5
G B/L
0.5 0.5
L V R/B G/R Y/B Y Y/B B/W Y/W B/Y G B/L B/R G/R G/B Sb Br
1.25 1.25 1.25 1.25 1.25 BJ05-13 0.5 0.5 0.5 0.5 0.5 0.5
Gr/Y 1.25 2.5 0.5 0.5 0.5 0.5
Fan relay
2.5 control
pin power
1 A01 117 A01 121 A01 116 A01 118 A01 115 114 120 119 A01 3 A01 102 A02 31 A01 68 A01 12 A01 69 A01 70 29 A01 95 50 A01 10 A01
ECM
397
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2 power supply
IG1 power supply
controls
the
idle Intake Intake
Crankshaft Position Sensor
(发动机转速)
speed manifold manifold
S N temperature temperature
Pressure Pressure
sensor sensor
3 A15 4 A15 1 A15 2 A15 5 A15 6 A15 t° u t° u
1 A10 2 A10 3 A10 electronic 2 B14 1 B14 6 B14 3 B14 4 B14 5 B14 2 A08 1 A08 4 A08 3 A08 2 A07 1 A07 4 A07 3 A07
throttle
Br L/R G/R L L/Y L/Y Y Y Y/L W/G Y L/G B/O G/Y B/W L/Y Gr Gr W G G/W R
Sb
0.5 0.5 0.5 0.5 0.85 0.5 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
0.5
86 A01 63 47 A01 71 A01 14 A01 88 A02 52 A01 5 A01 59 A01 4 60 A01 97 A01 27 A01 48 A01 87 A01 8 A01 72 A01 32 A01 66 A01 9 A01 89 65 11 A01 53 A01 28 A01 94 A01
398
BYD AUTO BYD Suri Maintenance & Repair Manual
399
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
20 G11B
Battery
39 G16 38 G16
Fuel gauge
Water thermometer
ODO/TRIP
gears
ESP failure warning indicator 、ESC OFF
Indicator
Warning light of engine failure
Rear Front Theft Smart Power Supply
Tire pressure warning light fog fog Deterrent High key
Main warning light
buzzer light light
Sidelamp Indicator
beam
system Circuit
Luggage Compartment Open Indicator Indicator indicator
indicator indicator warning
车速 转速 light
车身-控制器
局域网收发器
B-CAN H B-CAN L
4 G16 5 G16 15 G16 11 G16 37 G16 28 G16 18 G16 19 G16 20 G16 8 G16 9 G16 12 G16
400
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2 Power Supply
IG1 Power Supply
ACC Power Supply
Steering/warning light control system
Dashboard
wire
harness
G2N-40 G37-7 G2N-26 G37-2
adapter
Ⅳ 4 G35B 3 G35B 2 G35B 1 G35B
R R/L R/L Br Br
0.5 Left0.5 0.5 0.5
Steer 0.5
G47-22 right
G44-4( Warning turn
G29-9(CD) (Conditioning
Switch )
)
21 G16 33 G16 22 G16
背光调节输出
Backlight adjustment output
Battery
Parking discharge
brake indicator Cruise Indicator
warning SRS SVS control Major light of P/S
ABS Indicator Indicator indicator control driver Indicator
Indicator light indicator seat
of safety
cruise belt Left Right
control turn turn
indicator indicator
Combination Instrument
CPU
401
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
F1/14
Horn, braking light
B 20A high-frequency reception module
power
supply
电源 High-frequency
高频数据信号 signalRSSI Gateway
RCV_VC RFDA GND detection
5 K12 3 K19 1 K19 2 K19 controller
F4/11 G07-9 G07-8
2 2 K43 10 B1D 10A G Br
G/L L/W
micro- 0.5 0.5 0.5 0.5 B-CAN No battery mode clock output
R/W B-CAN
Moving 1.25 L H Signal ground
to
1 K43 2 BJ01 No battery mode data input
open GJ05
Start button Power input
Close G10 G01
R/W
1.25
R Gr
0.5 0.5
21 G2N
16 KJ01 KJ01
GJ01 17 *3
GJ01 *1 *2
12 KJ07
20 G2N 4 17 1 GJ07
R Gr R
0.5 0.5 R 0.85 V P Br/Y Sb Br/W Br/B
G G/L Sb L/W
0.85 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5
3 G50 10 G50 1 G49 1 G49 12 G49 5 G50 7 G50 11 G50 6 G50 12 G50 7 G49 8 G49 3 G49 2 G49
Battery Battery RCV_VC RFDA GND RSSI B-CAN L B-CAN H SCLK GND DATA VCC
keyless-ECU
19 G49 20 G49 13 G49 18 G49 14 G49 4 G49 15 G49 5 G49 11 G49 16 G49 6 G49 17 G49 9 G49 10 G49 8 G50 1 G50 9 G50 2 G50
G/W
G/Y Gr 0.5
Y/L R 0.5 0.5 L/W V/B V/W L/Y
0.5 0.5 0.5 0.5 0.5 0.5 3 GJ04
R/G G/R R/W
Y L O W TJ01
0.5 0.5 0.5
0.5 0.5 0.5 0.5 GJ07
23 8
GJ07 KJ07 GJ04 GJ10
15 6 1 2 TJ01 13 10 UJ01 GJ10
KJ07 16
UJ01
G/Y Gr GJ04 GJ10
4 TJ01 2
0.5 0.5 UJ01
L/W V/B V/W L/Y
0.5 0.5 0.5 0.5
B B R/G
0.5 0.5 0.5 G/R
Y/L R
0.5 0.5 R/W
0.5
0.5
G/R
0.5
5 TJ02 6 UJ03
1 K18 2 K18 1 G28 2 G28 1 G33 2 G33 1 K16 2 K16 1 TJ02 2 TJ02 2 UJ03 1 UJ03 Left Right
Front Front
Door Door
micro micro
6 TJ02 5 UJ03
Moving
Moving to
to open R/G open G/R
Close 0.5 Close 0.5
Detection antenna of exterior magnetic card - Interior magnetic probe Interior magnetic probe Magnetic probe antenna
Trunk antenna - Front
Interior magnetic probe Magnetic probe antenna outside WG46
antenna - Central antenna - rear the car - front left door outside the car - right front
door
402
BYD AUTO BYD Suri Maintenance & Repair Manual
403
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
G 13 G15A
R/G
0.85
0.5
1 G48
Backup radar switch
7 GJ01
KJ01 4 G48 2
B
V/W
0.5
GJ07 0.5
10 GJ07 14
KJ07 KJ07
G GJ01
21
0.5 KJ01
Backup WG49
signal P V P V V/W
0.5 0.5 0.5 0.5 0.5
ECU
Signal ground Signal ground Signal ground
28 K17 11 K17 13 K17 15 K17 12 K17 14 K17 29 K17 16 K17 31 K17 30 K17 32 K17
BJ05
5 6 3 4
CJ02
2 R01 1 R01 1 R02 2 R02 1 R04 2 R04 1 R03 2 R03 1 C25 2 C25 1 C24 2 C24
+ - - + - + - + - + - +
Left rear backup Left rear corner Right rear corner Right rear backup Left front corner 前右角间隙传感
sensor clearance sensor clearance sensor sensor clearance sensor 器
K2
404
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2power supply
IG1power supply
ACCpower supply
F1/14
Horn, braking light
A 20A
R/W W/B
0.85 ABS
1.25
B05-30 W/B
KJ08 0.85
21 G2N 10 QJ01
W/B
0.85 88 86
K2-3
20 G2N W/B W/B Cigarette
0.85 0.85 lighter
relay
R Right braking ligh Left braking light
1 K14 1 K24 1 KJ12 88a 85
1.25
High
braking
Braking 2 G18 light
light 12 G2N
switch
130Ω 82Ω 82Ω 82Ω 82Ω 82Ω 82Ω 130Ω 82Ω 82Ω 82Ω 82Ω 82Ω 82Ω
(Closed: 100Ω 100Ω 100Ω
/1W /1W /1W /1W /1W /1W /1W /1W /1W /1W /1W /1W /1W /1W 23 G2N
Pedal
/1W /1W /1W
depressed) 1 G18
2K/0.25W
2K/0.25W
2K/0.25W
2K/0.25W
2K/0.25W
W/B
1.25 R/B W/R R/B W/R
0.5 1.25 0.5 1.25
B
0.5
K7
K5 WG46 WG46
EMS Multiplex integration
control module No. 5 meter ground No. 5 meter ground
A01-18
MICU-W18
405
BYD AUTO BYD Suri Maintenance & Repair Manual
10.1 Interior light system (trunk light, glove box light, door light, ambient light, foot light, room dome light and back light) (1)
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2power supply
IG1power supply
ACCpower supply
F1/16
A Illumination, CAN
module, auxiliary G2N-35
power supply
40 A
F2/2
Interior illumination
R/B
7.5A R/B R/B R/B R/B R/B R/B R/B
0.5
0.5 0.5 0.5 0.5 0.5 0.5 0.5
4 P2I *4 *4
10 G35B
2 G65 2 G63 7 G25 7 G25 2 G25 3 G48
Right
Left step light step Backup
Clock Clock Clock
6 K2F 9 T2K 22 G2N 26 G2X *4 light *4 radar
Dashboard Wire Harness Adapter Ⅳ
spring spring spring
switch
R R 4 G35B
B
0.5 0.5
0.5 R
0.5
Cigarette
lighter
T2J-7 G2Q-9 backlight
Multiplex WG46 WG46
T05-6 U05-6 K41-3 power Combination Instrument
integration No. 5 meter ground Reserved No. 5 meter ground
Trunk lock supply
Exterior light control
Multiplex integration G16-21
system illumination module
control module G01-2
G2P-20
BCM(R-5)
406
BYD AUTO BYD Suri Maintenance & Repair Manual
10.2 Interior light system (trunk light, glove box light, door light, ambient light, foot light, room dome light and back light) (2)
Battery (Meter Ⅱ)
Battery (Front of front compartment mainfuse)
Battery (R ear of front compartment mainfuse)
F2/20
Auxiliary Power
A Supply
P2I-5 7.5A
2I
R 4 P2I 2 P2I
0.5
407
BYD AUTO BYD Suri Maintenance & Repair Manual
408
BYD AUTO BYD Suri Maintenance & Repair Manual
12. Exterior light system (headlamp, position light, fog light, license plate light and back-up light) control system
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
Left 6 T05
Right
6 U05
86 88 ground ground 17 T2J
light light
KC-1
Front 5W 5W
fog 11 T05 11 U05 R/L
light 0.5
relay
85 88a
16 C1F
7 B1E
L L R/Y W/R W/R R/B R/G W/G R/B R/B R/B R/B R/B R/B R/B R/W R/W G G
1.25 1.25 1.25 1.25 0.5 0.85 1.25 1.25 0.5 0.85 0.85 0.85 0.5 0.5 0.5 0.85 0.85 0.85 0.85
Left Left Left Left Right Right Right Right Left Right
front Rear
Right Left front front marker front front marker front rear rear Left Right Left Right Right Left
low-beam glow
front front high-beam low-beam light side high-beam light side side side license license rear rear reversing reversing
light light light light LOGO fog fog
fog fog light light light light plate plate light light
L/B light light light light light light
0.5 2 C16 2 C03 2 C12 2 C20 2 C06 2 C04 2 C13 2 C22 2 C05 2 C17 2 K24 2 K14 2 K09 2 K13 1 K40 5 K24 5 K14 4 K14 2 K24
0.5W 0.5W
55W 55W 55W 55W 55W 5W 55W 55W 5W 5W 5W 5W 5W 21W 21W 16W 16W
1 C16 1 C03 1 C12 1 C20 1 C06 1 C04 1 C13 1 C22 1 C05 1 C17 6 K24 6 K14 1 K09 1 K13 3 K40 6 K24 6 K14 6 K14 6 K24
B B B B B B B B B B B B B B B B B B B
1.25 1.25 1.25 1.25 0.5 0.85 1.25 1.25 0.5 0.85 0.85 0.85 0.5 0.5 0.5 0.85 0.85 0.85 0.85
2 BJ05
CJ02
L/B
0.5
Relay control
module
C1H-3 WC21 K7
WC23 WC21 WC23
409
BYD AUTO BYD Suri Maintenance & Repair Manual
410
BYD AUTO BYD Suri Maintenance & Repair Manual
14. ESP
411
BYD AUTO BYD Suri Maintenance & Repair Manual
15. SRS
412
BYD AUTO BYD Suri Maintenance & Repair Manual
16.1 Air conditioning system (including compressor, rear defroster and radiator fan control) (1)
413
BYD AUTO BYD Suri Maintenance & Repair Manual
16.2 Air conditioning system (including compressor, rear defroster and radiator fan control) (2)
414
BYD AUTO BYD Suri Maintenance & Repair Manual
Battery (Meter Ⅱ)
Battery (Front of front compartment main fuse)
Battery (Rear of front compartment main fuse)
IG2Power Supply
IG1 Power Supply
ACC Power Supply
*3
ABS No. 2 CAN adapter G2N-32 TCU TCU
F2/3 G15A-19
Reserved G2N-17 Reserved G15A-16
MICU
K50-14 K50-4 7.5A
F2/24 F2/28
A F4/14 Power
Fuel IG1 Gateway
network
L L pump 15A 7.5A
1 G15A W/R
0.5
19 18 GJ06
BJ02
keyless-ECU keyless-ECU
G50-6 G50-12
CAN H CAN L
Body
Start
network network
G2N-31 G2N-30 K6
G2T-5 G2T-6 G06-19 G06-9 B05-26 B05-14
G15A-15 G15A-18
Multiplex integration control WG46 Multiplex integration
No. 1 adapter ESC system
module WG49 WG49 ECU control module
415
BYD AUTO BYD Suri Maintenance & Repair Manual
4 T05 9 T05 3 T05 5 T05 8 T05 2 U05 5 U05 4 U05 9 U05 3 U05
Outer Outer B
rear Outer Side Fold Defroster Left + UP+ Outer rear 0.85
Left+ UP+ Fold GJ09 Side
view rear steering Defroster 12 UJ02 power
steering rear view
mirror view
mirror light M M power M M wire M M light view mirror
of mirror of
left
foot wire
right 6
UJ02
light foot GJ09
front front
Right + Down+ light
door Right + Down+ Return Return door
416
BYD AUTO BYD Suri Maintenance & Repair Manual
F2/31 Reserved
Power supply for switch
C 2nd gear
7.5A
No. 1 CAN
IG1 adapter 12 B2C
G11B-7 G06-16 G06-6
F1/23-1
Window W/L
F2/15 Control
Sun 3.0
System
roof 50A 3 T2J
20A B2B
V P 1 B1G 4
2B
0.5 0.5
Y
0.5
19 G2X 10 GJ02 9 GJ02
PJ01 PJ01
14 T03
Y
G 0.5
Door lock main switch
1.25
To ground
1 T01
Y W R/L Sb B Left front UNLOCK
0.5 0.5 0.5 0.5 1.25 door l LOCK
ock motor
2 T01
B
0.85
B-CAN L B-CAN H
M
T2J-14 T2J-13
T2K-6
Front Front interior light Front interio Front interior light
多路集成控制模块
interior light P03-13 r light P03-10
P03-11 P03-12 WG49
417
BYD AUTO BYD Suri Maintenance & Repair Manual
F2/3
B
MICUPower Supply
F2/16 10A
Left
K2-5 86 88
front Power
window window
motor relay
85 88a 1 T2K
20A
2K W/R
35 G2X 4 T2K 2J 0.5
2 T2J
G/R W/G
1.25 0.5
G2X-2 GJ09-11
Outer rear view mirror system
1 T03 8 T03 19 T03
Backlight Backlight
Backlight
Up/down
Power window control circuit
DMCU- Door multiplex controller
UP+ DN+
Left
front
M Dashboard
window distributor
lifter box
motor
2N 2E 2H
2 1 G2N 4 9 K2E 9 2 12 K2H
418
BYD AUTO BYD Suri Maintenance & Repair Manual
IG1
G11B-6
F2/18 F2/19 F2/17 L/W L/R G/B Y Br Br/W Y/L Br/Y L/O Y/L
Right Left Right 0.5 0.5 1.25 0.5 0.5 0.5 1.25 0.5 0.5 1.25
front rear rear
window window window
motor" motor motor
20A 20A 20A
2 U01 1 U01 9 U01 10 U01 1 V03 2 V03 4 V03 1 W03 2 W03 4 W03
Right
front Rear-left Left
window window rear
lifter lifter window
switch switch lifter
motor
Dashboard
下 上 下 上 下 上
Backlight Backlight
distributor Backlight
box
Reserved 2N 2E 2H
41 G2N 12 K2E 10 K2H
G2X-39
B B B
1.25 1.25 1.25
419
BYD AUTO BYD Suri Maintenance & Repair Manual
G/W W
0.5 0.5 Headlamp (Low beam)
9 10 5 G11B
W/R Y
0.5 0.5
BJ02
Battery
IG1 15 BJ02
G16-38 GJ08-8 GJ06 16
Combination GJ06
Instrument Multi-display
5 G24 6 G24 8 G24 4 G24
B
V P 3 st 2 st Dimmer 0.5
Wiper Front fog Turn Side
0.5 0.5 Washer gear gear OFF INT LO Fog light OFF light signal Near OFF light
signal signal 1st signal Rear fog Rear fog signal
OFF switch MIST HI switch Left Right switch AUTO Headlamp
switch ON 4st gear gear switch light light Far Crossing
Ground
CAN L CAN H
G2X-14 G2X-13
420
BYD AUTO BYD Suri Maintenance & Repair Manual
F1/20
Power
seat
40A F2/10 F2/8
Power Power
seat
F2/11"
seat
R 20A
Power
20A 1 K36 seat
1.25 W/R
2 K36 20A
1.25
9 B1D
L 10 K2F W/R 7 K2F
R
3.0 1.25
1.25
3 B2B
10 X941 4 X941
Driver 11 K2F
seat
electric
Back Forward Upward Downward Tilt Tilt Downward Upward
adjusting ward forward backward
3 G2X
switch 11 X941 7 X941 3 X941 9 X9418 X941 2 X941 6 X941 12 X941 1 X941 5 X941
2 1 1 2 3 K36 4 K36 2 1 1 2
M M M M
Seat horizontal adjustment Seat sink adjustment motor Seat back adjustment motor Seat height adjustment
motor
motor
K1
Reserved
K2F-11
421
BYD AUTO BYD Suri Maintenance & Repair Manual
R/B R/B
R/B
0.85 0.5
0.5
1 G45 3 G45
1 BJ05
1 CJ02
Headlamp Adjusting Switch
R/B
0.5
Y L/W
0.5 0.5
R/B
0.5 GJ06
8 GJ06 9
BJ02 BJ02
Y L/W
0.5 0.5
8 BJ05 11 BJ05
8 CJ02 11 CJ02
Y L/W
0.5 0.5
B R
0.5 0.5
1 C31 2 C31 1 C23 2 C23
Regulating Regulating
motor motor
LH M RH M
3 C31 3 C23
B B
0.5 0.5
Combination
Instrument
WC21 WC20 G59 G16-21
422
BYD AUTO BYD Suri Maintenance & Repair Manual
24. CD
Battery (Front of front compartment main fuse)
F1/16
C Illumination,
CAN module, 16 G35B
Auxiliary Power F2/20 Antenna
Supply 40A Dashboard Auxiliary
A Power
F2/4 wire
Supply Self-owned
Audio-visual harness
7.5A Support
system adapter
Ⅳ
37 G2N C Grounded
15A
17 15 G35B A
L=1.80uH
AM USB&AUX
Q=5.5 heatering
Antenna Amplifier 5V
TV FM C B USB-PWR GND_1 DP_U DM_U GND_4 GND-3 AUX-L AUX-R AUX-DEC GND-2 G43
10 G2N 7 10 9 8 6 1 2 3 4 5
后
A B
除
霜
电 Antenna Antenna
A 加
热
250W
B Feeder
丝 1 X931
Feeder
B/Y
2.0
L=1.80uH
Q=5.5
Antenna B/Y
Antenna
Y/R 2.0
0.5 1 G23 B Br Gr Y W L G R
W931 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Illumination, light intensity W/G
sensor, multi-display 0.85 Y/G
branch wire GJ08-1 0.5
4 G29 3 G29 8 G29 10 G31 12 G31 11 G31 5 G31 4 G31 1 G31 2 G31 7 G31 3 G31 6 G31
USB-PWR AUX-L AUX-R AUX-DEC GND-2
BAT ACC Antenna GND_1 DP_U DM_U
power supply
W L Y B B-CAN L B-CAN H
0.85 0.85 0.85 0.85
V P
0.5 0.5
G/R Br
0.5 0.5
G/Y Gr Lg GJ01 GJ07
G/B 2 3 5 2
0.85 0.85 0.85 KJ01
0.85 KJ07
W L Y B 7 G25 8 G25
时
0.85 0.85 0.85 0.85
钟
弹
13 G2N 14 G2N
GJ09 簧
8 7 Dashboard 2N 2N 7 X991 8 X991
UJ02
distributor
box
2K 2K
10 T2K 11 T2K Y B B R R/B
W L
0.85 0.85 0.85 0.85 0.85 0.5 0.5
3 X994 2 X994
VOL+
G/Y Gr G/B Lg
0.85 0.85 Steering
0.85 0.85 R2 8.2K
VOL-
Wheel
Audio
R4 15K
Control CH+
2 U03 1 U03 2 U07 1 U07 2 T02 1 T02 2 T07 1 T07 Switch Meter Meter
R6 27K
CH- short short
2 K29 1 K29 1 K30 2 K30
WG47 connector connector
Left Right Left Left No. Ⅳ No. Ⅳ
Left Right R6 82K
front front front front MODE G35B-8 G06-14 G06-4
rear rear G35B-2
high door high door
squawker squawker
pitch speaker pitch speaker
speake No. 1 CAN adapter
speaker
423
BYD AUTO BYD Suri Maintenance & Repair Manual
IG2Power Supply
IG1Power Supply
ACCPower Supply
F1/16
Illumination, CAN module 、 16 G35B
No. 2 CAN adapter
Auxiliary Power
F4/2
K50-3 K50-13 Supply 40A F4/12
Auxiliary Power Supply Dashboard
C 7.5A F2/4 Audio-visual wire
Audio-visual system15A harness
B-CAN B-CAN adapter
system
H L G02 G01 15A Ⅳ
17 15 G35B
G12 G01
R/L W/G
0.5 15 K2E
0.85
GJ14
8 1 2 KJ14
4 GJ01
KJ01
Shielding
Illumination, light intensity layer
B B B B B R/L Y Y Y Y Y sensor, multi-display R/B L/R
P V
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 branch wire 0.5 0.5
0.5 0.5 GJ08-1
5 K26 9 K26 10 K26 11 K26 12 K26 1 K37 2 K37 4 K26 1 K26 2 K26 6 K26 7 K26 8 K26 7 K37 16 K37 17 K37
B-CAN H B-CAN L Battery Battery Battery Battery Battery SPDIF_GND SPDIF+ SPDIF-
ACC
Exterior Power Amplifier
LR+ LR- SL_M+ SL_M- SR_M- SR_M+ RR- RR+ CE+ CE- SW+ SW2+ SW- SW2- LF+ LF- RF+ RF-
1 K28 2 K28 19 K28 18 K28 14 K28 15 K28 8 K28 7 K28 9 K28 10 K28 1 K27 2 K27 3 K27 4 K27 3 K28 4 K28 5 K27 6 K27
G/B Lg G/Y Gr
0.85 0.85 0.85 0.85
W L Y B
0.85 0.85 KJ01 KJ07
0.85 0.85 B/W L L/W B L/B Y 9 3 GJ01 9 3 GJ07
0.85 0.85 0.85 0.85 0.85 0.85
G/B Lg G/Y Gr
0.85 0.85 0.85 0.85
W L Y B 1 G35A 15 G35A
KJ05 0.85 0.85 0.85 0.85 KJ04 KJ07 18 G35A
5 6 6 5 2 5 12 G35A
VJ01 WJ01 GJ07 Dashboard Dashboard
Dashboard wire wire
wire Dashboard
harness harness
W L harness wire
adapter adapter
harness
0.85 0.85 adapter Ⅳ Ⅳ
Ⅳ adapter
Ⅳ
B/W L
Y B 0.85 0.85
0.85 0.85 14 20
2 16
G/B Lg
0.85 0.85 G/Y Gr
0.85 0.85
13 G2N 14 G2N GJ09
2N 2N 8 7 UJ02
Dashboard
distributor
box
2K 2K
10 T2K 11 T2K
G/B Lg
2 K29 1 K29 1 K30 0.85 0.85
2 K30
2 V07 2 U07 1 U03 2 U03
1 V07 1 W01 2 W01 2 G52 1 G52 1 K31 3 K31 2 K31 4 K31 2 T07 1 T07 1 T02 2 T02 1 U07
Right
Left Right Right Left
Rear front
Left rear rear rear Middle front Right
Subwoofer Left door
rear squawker squawker door loudspeaker door front
front speaker
door speaker High high
door
speaker Pitch pitch
speaker
Speaker speaker
424
BYD AUTO BYD Suri Maintenance & Repair Manual
1 GJ08
GJ08 8 GJ08
HeJ01 9 HeJ01 HeJ01
W/G
Y/R Y
0.5 0.5
0.5
Battery ACC IG1
1 He03 11 He03 9 He03
Multi-display CPU
B-CAN L B-CAN H
8 He03 2 He03 4 He03 3 He03 16 He03
B V P R/L
B
0.5 0.5 0.5 0.5
0.5
3 HeJ01 2 HeJ01
GJ08 GJ08 HeJ01
12 HeJ01 7 HeJ01 4
GJ08 GJ08 GJ08
G16-40
B-CAN B-CAN
H L
G06-17 G06-7
WG47
To No. 1 CAN
adapter
425
BYD AUTO BYD Suri Maintenance & Repair Manual
F1/16
C Illumination, CAN
module, auxiliary 16 G35B No. 1 CAN
power supply 40A adapter Antenna
F2/20
Auxiliary Power Supply G06-4 G06-14
Dashboard
Combination F2/4 A 7.5A
Instrument MICU BCM Pre-distribution wire
Audio Self-owned
G2X-33 harness
G2P-14 G2P-25 system
B-CAN B-CAN Support
adapter
15A
Ⅳ 37 G2N H L
C Grounded
17 15 G35B USB&AUX A
L=1.80uH
AM
Antenna Amplifier
5V Q=5.5 加热
Parking Reversing USB-PWR AUX-L AUX-R AUX-DEC GND-2 TV FM C B
GND_1 DP_U DM_U GND_4 GND-3 G43
signal signal
10 G2N 7 10 9 8 6 1 2 3 4 5
input input 后
除
A B
霜
电
A 加
热
丝 1
250W
X931
B Antenna
B/Y
Antenna lead
2.0
Feeder
L=1.80uH
Q=5.5
Antenna Antenna
L
B/Y
2.0
Y/R
0.5
0.5 B Br Gr Y W L G R 1 G23
0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 W931
FR+ FR- FL+ FL- RL+ RL- RR- RR+ KEY-AD2 GND KEY-AD3
1 G29 5 G29 2 G29 6 G29 2 G30 6 G30 3 G30 1 G30 7 G29 6 G31 16 G31 9 G31 1 G31 10 G31 5 G31 15 G31 3 G31 2 G31 11 G31 4 G55 5 G55 8 G51
W L Y B W
B/Y B W/B
0.85 0.85 0.85 0.85 Shielding 0.5
0.5 0.5 0.5
layer
Shielding
layer
19 10 22 GJ01 GJ01
13 KJ01 18 KJ01 G/R Br Br Sb Sb
0.5 0.5 0.5 0.5 0.5
G/Y Gr Lg GJ01 GJ07
G/B 2 3 5 2
0.85 0.85 0.85 KJ01 L G B W/L
0.85 KJ07
0.5 0.5 0.5 0.5
426
BYD AUTO BYD Suri Maintenance & Repair Manual
1 GJ08
GJ08 8 GJ08
HeJ01 9 HeJ01 HeJ01
W/G Y
Y/R
0.5 0.5
0.5
Battery ACC IG1
1 He03 11 He03 9 He03
Multi-display CPU
B-CAN L B-CAN H
8 He03 2 He03 4 He03 3 He03 16 He03
B V P R/L
B
0.5 0.5 0.5 0.5
0.5
3 HeJ01 2 HeJ01
GJ08 GJ08 HeJ01
12 HeJ01 7 HeJ01 4
GJ08 GJ08 GJ08
G16-40
B-CAN B-CAN
H L
G06-17 G06-7
WG47
To No. 1 CAN
adapter
427
BYD AUTO BYD Suri Maintenance & Repair Manual
Gateway Controller
G07-12 G07-6
F2/21
15A
33 G2N
R/L
0.85
GJ15
4 BJ08
GJ06 GJ06
18 BJ02 19 BJ02
EMS
Direction
A54-4 R/L sensor
1.25
V P
0.5 0.5 N
22 BJ07
22 AJ01 S
1 2
BJ07 BJ07 1 2 A48
R/L 19 AJ01 20 AJ01
1.25
V P L Y
0.5 0.5 0.5 0.5
R/L TCU
1.25
17 18 13 14 15
R R
17 A47 18 A47 13 A47 14 A47 15 A47 2 A47
2.5 2.5
Y/W R/Y Y/L W/G G/Y B
1.25 1.25 0.5 0.5 0.5 1.25
2 3 4 5 6 7 A46
A60 A60
M1 Brushless motor
428
BYD AUTO BYD Suri Maintenance & Repair Manual
29. EPS
F5/2
EPS
motor
Halla torque steering
70A angle sensor
7 G2X
B13 F2/27 4# 8# 5# 1# 7# 3# 6# 2#
EPS
module
10A
R Br Br
6.0 0.5 0.5
W G B R B/G L V B/R
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
D1 D2 D3 D4 D5 D6 D7 D8
1 B11 5 G59 11 G59
TQ1 GND1 TQ2 VCC1_+5V GND2 PWM_P PWM_S VCC2_+5V
BJ07 BJ07
32 AJ01 34 AJ01
G15A-17 G15A-30
G2X-27 Electronic Electronic M
injector injector(Ti)
CAN adapter A01-76 A01-37
EPS motor
B12
429
BYD AUTO BYD Suri Maintenance & Repair Manual
IG2Power Supply
IG1Power Supply
ACCPower Supply
Gr
2.5
13 GJ14
W/R 13 KJ08
0.5
K7 7 K56 11 K56
Ground
No. 7 W/B
0.5
K6
K2
Ground No. 2
430
BYD AUTO BYD Suri Maintenance & Repair Manual
IG2Power Supply
IG1 Power Supply
ACC Power Supply
F4/15
P
position F4/10
motor P
controller 7.5A position
BCM motor
Pre-distribution 15A
G2P-25
Y Y
0.5 1.25
08 G37 06 G37
KG-8 Gr
P 1.25
position
motor
controller 1 KJ15 8 KJ15 7 KJ15 6 GJ15
1 BJ12 8 BJ12 7 BJ12 6 BJ08
10 G37 07 G37
Y W W/R Gr
2 GJ14 3 GJ14 Y/B 1.25 1.25 1.25 1.25
2 KJ08 3 KJ08 0.5
6 BJ10 20 BJ10 15 BJ10 1 BJ10
4 GJ14 6 AJ02 20 AJ02 15 AJ02 1 AJ02
4 KJ08
L Y/R
0.5 Y/B Y/G Y/G Y/G L/B L/B L/B L/R L/R L/R Y W W/R Gr
0.5
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.25 1.25 1.25 1.25
17 K34 1 K34 5 K34 31 K34 32 K34 16 K34 11 K34 12 K34 27 K34 28 K34 29 K34 30 K34 7 A52 1 A52 6 A52 2 A52
Pre-distribution Battery Relay drive Phase A Phase A Phase A Phase B Phase B Phase B Phase C Phase C Phase C Phase A Phase B Phase C Motor
drive drive drive drive drive drive drive drive drive drive drive drive power
B B P V R Gr L G G L Gr W/B R
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
G15A-4 G15A-14
Ground Ground
K2 Dashboard wire harness Ⅲ short connector (CAN) A02
431
BYD AUTO BYD Suri Maintenance & Repair Manual
IG2Power Supply
IG1Power Supply
ACCPower Supply
F3/1
F2/23 F3/3 Condenser
EMS Cooling fan
Main Fan 30A
relay30A 30A
3 A54 5 A54
F1/11 F1/10 Reserved
Condenser K1-5 K1-4 1 B1E
Radiator
Condenser Radiator C1F-17
fan fan 88 86 86 88 B/W Y/B
fan fan 2.0 2.0
20A 30A 17 G2X
relay relay
1 BJ04 2 BJ04
CJ06 CJ06
G L/Y R/W
0.5 2.0 0.5
L/W
Winding! B/Y B/W B/Y W/R B/Y Y/B
2.0 B/Y
13 B2D 0.5 2.0 0.5 2.0 0.5 2.0 0.5
Dashboard 7 BJ11
AJ01 Y/B
distributor
0.5 3 C01 1 C01 8 C01 6 C01 13 C01 11 C01 18 C01 16 C01
box KC-1 KC-2 KC-3 KC-4Fan
Fan Fan Fan Relay
Relay Relay Relay No. 4
6 G2X No. 1 No. 2 No. 3
G R/W
0.5 0.5
5 C01 2 C01 10 C01 7 C01 9 C01 15 C01 B12 C01 20 C01 17 C01 19 C01
7 GJ06
BJ02 2 C15 2 C02 G/B B/R G L G/Y G/B B/R L/W
L
0.5 0.5 2.0 2.0 0.5 2.0 0.5 2.0 2.0
Radiator 1# 2#
G Condenser fan Regulating Regulating
0.5 fan M motor M Cooling 3 C28 resistor1 C30 Cooling 3 C29 resistor 1 C31
motor Fan Fan
M M
1 C15 1 C02
20 BJ11 1 C28 2 C30 1 C29 2 C31
AJ01
B B
2.0 2.0
10 CJ02
10 BJ05
L/W G/B B B
0.5 0.5 2.0 2.0
16 BJ07 3 BJ07
16 AJ01 3 AJ01
WC20 WC23
Ground No. 2 Ground No. 2
473 EMS 473 EMS
A10-4 A10-57 A01-79 A01-40
G2X-17 Reserved Low speed fan High speed
WC20 WC21 C1F-19 control fan control
432
BYD AUTO BYD Suri Maintenance & Repair Manual
F2/26
G2X-16 G35B-7
L/R R/B
0.5 0.5
WG61
No. 3 meter ground
B
0.5
1
2
4
7 G79 2 G79 3 G79 4 G79 5 G79 3 G74 5 G74 9 G74 10 G74
5
Manual/automatic
Gear
IG2 Manual/Automatic Manual control + Manual control - Shift Lock Relay Manual
6
converter P
Backlight shift
7
Gear sensor Low level effective switch
mode position
8
Manual upshift/downshift lock mechanism
Automatic switch + - circuit
Gear CANH CANL
GND GND
indicator 1 G79 10 G79 6 G79 8 G79 8 G74 6 G74 4 G74 11 G74
B1 B2 B3 B4 B5 B6 B7 B8
7 G74
panel
G Br Br/Y Br/W R
0.5 0.5 0.5 0.5 0.5
P V
0.5 0.5
B
0.5
WG61
No. 3 meter ground
G15A-1 G15A-11
To adapter III
G35B-1
Note: *1 - 473 Electronic injection system *2 - 476ZQA system *3 - 476ZQA+DCT *4 - Equipped in the flagship model
433
BYD AUTO BYD Suri Maintenance & Repair Manual
39 G2N 38 G2N 31 G2N 30 G2N 14 T2J 13 T2J 14 G2X 13 G2X 1 K2G 2 K2G 23 G2X 24 G2X 2 G2R 1 G2R 11 B2D 12 B2D 2 B1I 1 B1I
Terminal resistor
V P V P V P V P V P V P P V
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Air conditioning ECU CD/DVD Sun roof module Multi-display Gateway ECU Diagnosis interface
P02-7 P02-9 He03-4 He03-3 V P
G47-1 G47-2 G31-8/G51-6 G31-9/G51-7 G07-10 G07-4 G40-11 G40-3 0.5 0.5
B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN B-CAN
L H L H L H L H L H L H L H
B-CAN B-CAN
L H
Power Tire Backup
KJ07 KJ07
10 GJ07 amplifier pressure radar
14 GJ07
K26-9 K26-8 K35-6 K35-12 K17-1 K17-17
V P V
P
0.5 0.5 0.5
0.5
14 GJ07 10 GJ07
KJ07 KJ07 *4 *4 *4 *4
*4
P V P V P V P V P V P V P V P V
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
G06 3 13 4 14 6 16 7 17 9 19 10 20 5 15 8 18 K50 6 16 5 15 3 13 4 14 1 11
B-CAN-H B-CAN-H B-CAN-H B-CAN-H B-CAN-H B-CAN-H
B-CAN-L B-CAN-L
Meter No. 1 CAN adapte r Floor No. 2 CAN adapter *4
434
BYD AUTO BYD Suri Maintenance & Repair Manual
5 G2T 6 G2T
1 G2T 2 G2T
V P V P
0.5 0.5 0.5 0.5
keyless-ECU keyless-ECU
G50-12 G50-6
B-CAN B-CAN
B-CAN B-CAN
H L
H L
435
BYD AUTO BYD Suri Maintenance & Repair Manual
Gateway ECU
ABS/ESC
G07-6 G07-12 B05-14 B05-26
Terminal resistor
B-CAN B-CAN
H L
BJ02
18 19 GJ06
V P BJ07
20 19 AJ01
0.5 0.5
Terminal resistor
12 G15A 2 G15A
GJ14
10 9 KJ08
436
BYD AUTO BYD Suri Maintenance & Repair Manual
诊断接口
Diagnosis interface 0.5 0.5 IG1继电器
IGI relay
No.1仪表1#搭铁G57
meter ground G57
鼓风机调速模块
Blower governor module 3.0 1.25 点烟器
Cigarette lighter
437
BYD AUTO BYD Suri Maintenance & Repair Manual
Safety air bag ECU 0.5 0.5 Safety air bag ECU
安全气囊ECU
安全气囊ECU
438
BYD AUTO BYD Suri Maintenance & Repair Manual
仪表板线束转接头III-1
Dashboard wire harness 0.5 组合仪表
Combination instrument
connector III-1
仪表2#搭铁G59
No. 2 meter ground G59
439
BYD AUTO BYD Suri Maintenance & Repair Manual
Start Button
Start Button
440
BYD AUTO BYD Suri Maintenance & Repair Manual
441
BYD AUTO BYD Suri Maintenance & Repair Manual
442
BYD AUTO BYD Suri Maintenance & Repair Manual
左后组合灯
Left rear combination light (turn Right rear combination light
右后组合灯
light, braking light and position
(转向、制动、位置灯) (turn light, braking light and
(转向、制动、位置灯)
light) position light)
Siren 左后尾灯
Left rear tail lamp (fog light,
报警器 (雾灯、倒车灯)
back-up light)
右后尾灯
Right rear tail lamp (fog light, Liquid crystal solar film ECU
(雾灯、倒车灯)
back-up light)
443
BYD AUTO BYD Suri Maintenance & Repair Manual
车载冰箱
On-board refrigerator
1.25
444
BYD AUTO BYD Suri Maintenance & Repair Manual
Oil Pump
油泵
0.85
Front compartment
前舱配电盒E 0.85 0.85 前舱配电盒J
Front compartment
distribution box e distribution box j
445
BYD AUTO BYD Suri Maintenance & Repair Manual
4.0 2.5
ABS-ECU-13 ABS-ECU-38
446
BYD AUTO BYD Suri Maintenance & Repair Manual
1.25
TCU-4 *4
Engine ECU-53
发动机ECU-53 0.85 0.85 Engine ECU-51
发动机ECU-51
0.5 凸轮轴位置传感器
Camshaft position sensor
447
BYD AUTO BYD Suri Maintenance & Repair Manual
Contents
Chapter 1 Body Dimensions..............................................................................................................4
Chapter 2 Body Accessory System .................................................................................................13
Section 1 Seat.................................................................................................................. 14
Section 2 Safety Belt ....................................................................................................... 19
Section 3 Inner Rear View Mirror .................................................................................... 22
Section 4 Washing System Assembly ............................................................................. 23
Section 5 Wiper System Assembly.................................................................................. 24
Section 6 Windshield Glass Assembly ............................................................................ 25
Section 7 Rear Windshields Glass Assembly ................................................................. 28
Section 8 Sun Roof Assembly ......................................................................................... 29
Chapter 3 Door System Repair Manual ..........................................................................................33
Section 1 Door ................................................................................................................. 35
Section 2 Replacement of Outer Rear View Mirror ......................................................... 38
Section 3 Replacement of Outside Handle and Door Lock ............................................. 40
Section 4 Opener ............................................................................................................. 42
Section 5 Removal and Installation of Sealing Mechanism ............................................ 44
Section 6 Adjustment of Four Doors and Two Covers .................................................... 49
Chapter 4 Chassis ...........................................................................................................................51
Part 1 Intake System ................................................................................................................53
Part 2 Exhaust System.............................................................................................................57
Part 3 Cooling System .............................................................................................................60
Section 1 473QE Cooling System ................................................................................... 60
Section 2 476ZQA Cooling System ................................................................................. 62
Part 4 Fuel System...................................................................................................................65
Section 1 Fuel Supply System ......................................................................................... 65
Section 2 Fuel Evaporation and Cleaning System .......................................................... 71
Part 5 Suspension System .......................................................................................................73
Section 1 Components Layout and Description of Suspension System ......................... 73
Section 2 Repair Suspension System (473QE-5T14) ..................................................... 80
Section 3 Repair 5AC/5AI Suspension System............................................................... 85
Section 4 Installation of Relevant Engine Accessories ................................................... 91
Part 6 Suspension System .......................................................................................................92
Section 1 Suspension Overview ...................................................................................... 92
Section 2 Front Suspension............................................................................................. 95
Section 3 Rear Suspension ........................................................................................... 118
Part 7 Power Steering System ...............................................................................................132
Section 1 Special Tools ................................................................................................. 132
Section 2 Diagram of Hydraulic Steering System Component Location....................... 133
1
BYD AUTO BYD Suri Maintenance & Repair Manual
2
BYD AUTO BYD Suri Maintenance & Repair Manual
3
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 1
4
BYD AUTO BYD Suri Maintenance & Repair Manual
5
BYD AUTO BYD Suri Maintenance & Repair Manual
6
BYD AUTO BYD Suri Maintenance & Repair Manual
7
BYD AUTO BYD Suri Maintenance & Repair Manual
Body Dimension
E-e F-G or f-g G-g G-h or g-H
1152.0 1272.1 763.7 1611.9
(Three-dimensional distance)
8
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 5
Body Dimension
B-d or b-D C-e or c-E A-e C-E or c-e G-I 1 2
1148.0 1193.4 1100.5 883.9 736.1 100 100
Fig. 6
9
BYD AUTO BYD Suri Maintenance & Repair Manual
Left
Right
Fig. 7
Wheelbase 2660 1 2
100 100
10
BYD AUTO BYD Suri Maintenance & Repair Manual
F,f Front sub frame mounting nut N,n Rear shock absorber mounting hole
G,g Door sill connecting plate O,o Rear floor longitudinal beam front
standard hole section standard hole
H,h Front floor standard hole P,p Rear floor longitudinal beam rear
section standard hole
11
BYD AUTO BYD Suri Maintenance & Repair Manual
12
BYD AUTO BYD Suri Maintenance & Repair Manual
13
BYD AUTO BYD Suri Maintenance & Repair Manual
14
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1.2.1.3 Remove the left outer guard plate, for the operation, remove the seatback
front guard plate and power seat switch. cover first).
Note the snap-fits used to connect the left
outer guard plate and front guard plate
should be disengaged. The structure is
shown below.
15
BYD AUTO BYD Suri Maintenance & Repair Manual
16
BYD AUTO BYD Suri Maintenance & Repair Manual
17
BYD AUTO BYD Suri Maintenance & Repair Manual
1.2.1.2 Remove the rear seat back assembly. 1.2.2 Disassembly/Assembly of Rear Seat
Remove the mounting bolts, hexagonal
head bolt and the flat washer assembly 1.2.2.1 Pull out the left/right and center head
under the rear seat back. The specific rests of the rear seat. Then pull 2 buckles
structure and position are shown below. of the head rest sliding sleeve and head
rest height adjustment sliding sleeve
assembly outward along the center of
head rest rod while clamping them with
pliers in the direction as shown to remove
them (If it is not convenient for operation,
remove the seatback cover first).
18
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 2 Safety Belt 2.1.4 Remove the door sill pedal and lower
Diagram of Seat Belt Locations guard plate of the B pillar based on the
removal method of the side lining.
2.1.1 Disconnect the battery negative cable 2.1.6 The retractor can be removed after
and wait for at least 3 minutes. removing the pretension unit connector
and then the upper/lower set bolts of the
2.1.2 Slide the seat to the foremost position. retractor. The upper set bolt of the retractor
needs to be tightened and the lower set
2.1.3 Turn the bolt cover under the B pillar bolt should be tightened to the torque of 45
outward and remove it, and then remove Nm.
19
BYD AUTO BYD Suri Maintenance & Repair Manual
20
BYD AUTO BYD Suri Maintenance & Repair Manual
2.3.3 Do not bend or damage any parts of the 2.3.16 When the welder is used, the
buckle or locking plate. connectors of the safety airbag (gas
generator) and safety belt pretension
2.3.4 Do not bleach or dye the seat belt (clean (driver and co-driver) should be
the belt with only neutral soap and warm removed.
water).
2.3.17 Carefully paint the safety airbag
2.3.5 When installing the seat belts, system and related components to
pre-tighten the threaded rod manually to prevent the wire harness or connectors
avoid entangled threads. from being exposed in the paint mists.
2.3.6 Do not attempt to repair the retractor or Never directly expose the components of
retractor cover. Use the new assembly to safety airbag system in the hot air (Dry or bake
replace the ineffective assembly. the vehicle after painting) or near the flame.
21
BYD AUTO BYD Suri Maintenance & Repair Manual
22
BYD AUTO BYD Suri Maintenance & Repair Manual
4.2.2 Remove the washing hose and nozzle 4.2.4 Remove the washing liquid pot after the
from the front nozzle. washer motor is removed from the
washing liquid pot.
4.2.3 Remove the hose mounting bases I and
II with bent nose pliers. 4.2.5 Perform installation of the washing liquid
pot in the reverse order of removal.
4.2.4 Take out 5 hoses.
Notice:
4.2.5 Perform installation of the washer hose
in the reverse order of removal. Check the operation of the washer system
after installation, and check for washing liquid
Notice: leakage around the washer motor and the
connection by washing the hose.
Wipe all the connections and inner wall of the
hose clean before installation and apply 4.3 Replacement of Washer Motor
adhesives. Check if the hose leaks after the
adhesives are dry and the washer is energized. 4.3.1 Remove the washer motor from the
Reinstall the hose if it leaks. washing liquid pot after the washing liquid
pot is removed.
Notice:
Check the operation of the motor after it is
installed and energized to ensure the liquid
can be sprayed.
23
BYD AUTO BYD Suri Maintenance & Repair Manual
24
BYD AUTO BYD Suri Maintenance & Repair Manual
6.1.1.2 The following tools are needed to 6.1.1.3.4 The windshield sealing strip can be
remove the windshield glass: cut if necessary during removal.
a Drill
b Steel Wire
25
BYD AUTO BYD Suri Maintenance & Repair Manual
6.1.1.3.5 Drill a hole through the adhesive at 6.1.2.1.3 Using a new brush, apply sufficient
the corner of the windshield glass inside primer with a width of about 15 mm around
the vehicle, and thread a piano wire the surface of the glass to be connected to
through the hole and twine both ends of the body.
piano wire on the wood block.
6.1.2.1.4 Attach the windshield rubber strip to
6.1.1.3.6 An assistant outside the vehicle pulls the proper position around the windshield
the piano wire back and forth. Place the glass and apply adhesive with a spray gun.
piano wire as close to the glass as
possible to avoid scratching the body and 6.1.2.1.5 Hold the rubber clamps and align the
dashboard. Carefully saw off the sealant snap-fits on the inner surface of the glass
and rubber strip of the entire glass. with the holes on the body. Press the glass
into the body and adjust its position to
Notice: Place the piano wire as close to the make it symmetric. Tape the glass surface
glass as possible to avoid damage to the and tape to fit the glass in the body
vehicle. completely.
6.1.2.1 The installation steps are as follows: 6.1.2.1 6 Install the tone cover strip, vent cover
and wiper arm.
6.1.2.1 1 Scrape the adhesive stuck on the
vehicle flat with a knife to a width of 2 mm 6.1.2.1 7 After the adhesive becomes hard,
everywhere. spray water from a hose to the windows of
the vehicle to check for any water leakage.
Notice: If there is any, wipe water away from the
Do not scrape the body paint, or the adhesive glass and seal leakages with adhesive.
effect will be reduced. After filling, if there is still leakage, remove
Before fitting the glass back, remove the old the glass and restart installation according
sealing strips and adhesive on the glass. to the above procedures.
6.1.2.1.2 If the glass needs to be reinstalled, 6.1.2.1.8 After the adhesive becomes hard,
clean the inner surface and edge with install the inner rear view mirror and
adhesive applied around the glass with a connector.
sponge soaked in alcohol. Ensure no oil,
grease or water is left and dries them for at Notice:
least 10 minutes. a Do not use high-pressure water.
26
BYD AUTO BYD Suri Maintenance & Repair Manual
b When drying up adhesive, do not use b If the strip is not fully attached, press it
compressed air directly on parts applied with tape until the parts stuck with
with adhesive. adhesive are fully tight.
c For the drying process, do not use infrared c Each adhesive has its own setting time.
lamps or similar tools. Be sure to refer to the instruction manual
from the manufacturer. Check the setting
6.1.2.2 Observe the following precautions after time of the adhesive used, and observe
the above installation is completed: carefully to take necessary measures
before the parts stuck with adhesive are
a Before the parts stuck with adhesive are fully tight.
fixed tight, the sudden closing of the
door may cause the glass to loosen or Before the parts stuck with adhesive are
come off. Therefore, if a door is opened fully in place, do not drive the vehicle so
or closed before the parts stuck with that the adhesive can fully and completely
adhesive are fully tight, open all the door harden.
glass and use proper methods.
27
BYD AUTO BYD Suri Maintenance & Repair Manual
28
BYD AUTO BYD Suri Maintenance & Repair Manual
8.1.1.3 Check if the drain pipe and water outlet 8.1.5.6 Check if the relay malfunctions.
are connected tightly and if the clamps are
loose. 8.2 Replacement of Sun Roof Glass
8.1.1.4 Check for looseness between the lock The replacement steps for the sun roof glass
bolts and side wall. are as follows:
8.1.2.1 Check if the motor is loose; 8.2.2 Fully pull the sun screen back.
8.1.2.2 Check if the gear or bearing are worn; 8.2.3 Remove the sleeve, and then remove
the nut and gasket from the cam mounting
8.1.2.3 Check if the timing belt assembly is point as shown
deformed.
29
BYD AUTO BYD Suri Maintenance & Repair Manual
8.2.3.2 Install the sun roof glass in the reverse 8.3.3.2.1 Remove the roof headlining.
order of the removal procedures.
8.3.3.2.2 Place a rag at the front edge of the
8.3 Height Adjustment of Sun Roof Glass sun roof glass and hook a spring scale on
it.
The ceiling should be flush with the sealing
strip of the sun roof glass, and the deviation for 8.3.3.2.3 Press the switch to close the sun roof
compression of the sealing strip should be glass and measure the force desired to
within 1±mm. stop the glass. Read the reading on the
spring scale immediately after the glass
stops moving and then release the switch
and spring scale. The standard closing
force is 200-290 N.
30
BYD AUTO BYD Suri Maintenance & Repair Manual
31
BYD AUTO BYD Suri Maintenance & Repair Manual
8.6.3 Remove the rear water outlet 8.7 Replacement of Cam Assembly and
components Timing Belt
Be careful not to damage the sliding sleeve 8.7.3 Slide the cam assembly backward and
and sun screen. remove it from the frame. Then remove the
left/right timing belt. See the figure below
32
BYD AUTO BYD Suri Maintenance & Repair Manual
Contents
Section 1 Door .........................................................................................................................35
1.1 Removal and Installation of Power Window .............................................................. 35
1.2 Replacement of Rear Door Glass.............................................................................. 36
1.3 Replacement of Rear Triangular Window Glass ....................................................... 36
1.4 Replacement of Window Regulator ........................................................................... 37
1.5 Adjustment of Front and Rear Door Glasses ............................................................ 37
Section 2 Replacement of Outer Rear View Mirror .................................................................38
2.1 Diagram of Component Locations ............................................................................. 38
2.2 Replacement of Power Outer Rear View Mirror ........................................................ 38
2.3 Replacement of Outer Rear View Mirror Lens .......................................................... 39
Section 3 Replacement of Outside Handle and Door Lock .....................................................40
3.1 Replacement of Front Door Outside Handle and Door Lock .................................... 40
3.2 Replacement of Rear Door Outside Handle and Door Lock ..................................... 41
Section 4 Opener .....................................................................................................................42
4.1 Diagram of Component Locations ............................................................................. 42
4.2 Replacement of Engine Cover Lock .......................................................................... 42
4.3 Replacement of Engine Cover Opening Cable ......................................................... 42
4.4 Replacement of Engine Cover Opening Handle ....................................................... 42
4.5 Replacement of Trunk Lid Lock ................................................................................. 42
4.6 Replacement of Trunk Lid and Oil Filler Cap Opening Cables ................................. 42
4.7 Replacement of Trunk Lid and Oil Filler Cap Opening Handles ............................... 43
Section 5 Removal and Installation of Sealing Mechanism .....................................................44
5.1 Replacement of Front Door Outer Slot Seal.............................................................. 44
5.2 Replacement of Front Door Inner Slot Seal .............................................................. 44
5.3 Replacement of Front Door Sealing Strip.................................................................. 45
5.4 Replacement of Front Door Frame Sealing Strip ...................................................... 45
5.5 Replacement of Front Door Glass Mud Groove ........................................................ 45
5.6 Replacement of Upper and Lower Stop Blocks of Front Door .................................. 45
5.7 Replacement of Rear Movable Guide Rail Assembly of Front Door ......................... 45
5.8 Replacement of Rear Door Outer Slot Seal .............................................................. 46
5.9 Replacement of Rear Door Inner Slot Seal ............................................................... 46
5.10 Replacement of Rear Door Sealing Strip ................................................................ 46
5.11 Replacement of Rear Door Frame Sealing Strip..................................................... 46
5.12 Replacement of Rear Door Glass Mud Groove ...................................................... 47
5.13 Replacement of Rear Door Stop Block ................................................................... 47
5.14 Replacement of Movable Guide Rail of Rear Door ................................................. 47
5.15 Replacement of Vent Cover Sealing Strip RH ........................................................ 47
5.16 Replacement of Front Deck Lid Weather Strip ........................................................ 47
5.17 Replacement of Front Deck Buffer Block ................................................................ 47
33
BYD AUTO BYD Suri Maintenance & Repair Manual
34
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 1 Door
1.1 Removal and Installation of Power Window
1. Window regulator 2. Door lock 3. Glass guide rail 4. Front door glass 5. Front door outer slot
seal 6. Door sealing strip
7. Glass mud groove 8. Door limiter 9. Door hinge 10. Door buffer
1.1.1 Power Window Parts Location Remove the front door water-proof film.
The power window parts and their locations Turn on the window regulator switch and lower
are shown in figure 1-1. the front door widow to an appropriate position
(Expose two mounting holes of the glass).
1.1.2 Removal of Power Window Remove the glass mounting bolts.
1.1.2.1 Replacement of Front Door Glass Carefully remove the glass through the
window glass channel from outside of the door
1.1.2.1.1. Removal: and lift the rear end of the glass first to prevent
the glass from dropping into the door.
Remove the front door corner guard plate.
1.1.2.1.2. Installation:
Remove the front door window regulator
switch assembly. Install the door glass in the reverse order of
removal and note the following items:
Remove the front door guard plate assembly.
When installing the glass, check if the glass
top contacts with the glass channel evenly.
35
BYD AUTO BYD Suri Maintenance & Repair Manual
Drag the glass up and down and make sure it the movable guide rail of the glass
can go up and down smoothly without getting carefully, take down the entire glass mud
stuck. groove on the window frame as necessary
and remove the triangular window glass to
Adjust the glass position according to the avoid damage.
actual condition.
1.2.1.5 Take out the glass from inside of the
Securely attach the door water-proof film with door carefully and don't drop it into the
the adhesive. door.
1.1.2.2.1.2 Disconnect the motor wire harness Drag the glass up and down and make sure it
of the power window regulator. can move up and down smoothly without
getting stuck.
1.1.2.2.1.3 Remove the window regulator bolts
and take out the window regulator through Adjust the glass position according to the
the hole. actual condition.
1.1.2.2.3. Installation:
1.2.1 Removal:
36
BYD AUTO BYD Suri Maintenance & Repair Manual
glass and sealing strip in the direction from the When installing the glass, check if the glass
vehicle rear to front with even force to avoid top contacts with the glass channel evenly and
injury to your arm. if the glass can go up and down steadily.
Remove the rear triangular window glass from 1.5 Adjustment of Front and Rear Door
the rear triangular window sealing strip. Glasses
Install the rear triangular window glass in the
reverse order of removal and note the 1.5.1 Stop the vehicle on a solid and level
following: ground.
1.3.1 Adjust the angle of the rear triangular 15.2 Remove the following parts:
window glass slightly and make sure the Front and rear door guard plates
gap between the visible lip of the rear Front and rear door water-proof films
triangular window sealing strip and the
window frame is even; 1.5.3 Lift the glass up and down until the
tightening bolts are seen and loosen the
1.3.2 Make sure the rear triangular window tightening bolts.
glass is installed in place;
1.5.4 Move the glass against the guide rail
1.3.3 Spray water around the glass using a near pillar B and then tighten the tightening
water pipe and check for tightness. bolts.
1.4 Replacement of Window Regulator 1.5.5 Check whether the glass can go up and
down smoothly.
1.4.1. Removal:
1.5.6 Fully raise the glass and check whether
1.4.1.1 Remove the rear door glass with the glass contacts with the mud groove
reference to the removal procedures of the evenly.
"rear door glass".
1.5.7 Spray water around the glass using a
1.4.1.2 Disconnect the motor wire harness of hose with an inner diameter of 12 mm to
the power window regulator. check for water leakage. Note the
following:
1.4.1.3 Remove the window regulator bolts
and take out the window regulator through Do not use the injection nozzle;
the hole.
The height of water column should not exceed
1.4.2. Inspection: 0.5 m when the hose is spraying water
upward.
1.4.2.1 Inspect whether the sliding and rotating
parts of the window regulator should be Keep a distance of about 300 mm between the
lubricated. hose outlet and door glass.
1.4.3 Installation:
37
BYD AUTO BYD Suri Maintenance & Repair Manual
38
BYD AUTO BYD Suri Maintenance & Repair Manual
39
BYD AUTO BYD Suri Maintenance & Repair Manual
Refer to the figure 3-1 and 3-2 and remove the Install the left front door lock in the reverse
left front door lock according to the following order of the removal:
steps:
3.1.2.1 Install the lock and handle base in the
Remove the screws and bolts shown in figure right position through the through-hole on
3-2. If necessary, remove the corresponding the inner and outer panels of the door and
pastors and covers first; tighten one bolt on the handle base;
Take down the glass mud groove in the glass 3.1.2.2 Install the pull rod in the correct
guide rail and remove the glass guide rail; position on the lock; Install the outside
handle and key cylinder and tighten the
Remove the bolts for fixing the key cylinder bolts on the key cylinder;
through the pastern hole and take out the key
cylinder. Then take out the outside handle and 3.1.2.3 Insert the glass mud groove into the
remove the other bolt on the outside handle. At guide rail in segments;
last, remove the outside handle base;
Tighten all the screws and bolts, and attach
Remove the lock from the through-hole on the the pastern and install the covers.
inner and outer panels of the door.
3.1.3 The outside handle and door lock on the
The right front door lock is removed in the right front door are installed in the same
same way as the left front door lock. way as that on the left front door.
40
BYD AUTO BYD Suri Maintenance & Repair Manual
The right rear door lock is removed in the Fig. 3-4 Enlarged View of Left Front Door Lock
same way as the left rear door lock. Surrounding Areas
41
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 4 Opener
4.1 Diagram of Component Locations Remove the core wire jacket connected to the
engine cover lock from the engine cover lock
so as to remove the engine cover opening
cable.
42
BYD AUTO BYD Suri Maintenance & Repair Manual
Remove the following parts 4.6.2.5 Install the opening cable in the reverse
Trunk Lid and Oil Filler Cap Opening Handles order of the removal and note the following:
Left Rear Door Sill Inner Guard Plate Make sure the oil filler cap mounting base
Trunk Inner Panel of opening cable is installed in place and
Trunk Lid Panel the boss limiter can achieve the limiting
function.
Remove the core wire joint from the trunk lid
lock 4.7 Replacement of Trunk Lid and Oil Filler
Cap Opening Handles
Remove the opening cable from the clip and
trunk lid wire harness strapping tape, and pull 4.7.1 Remove the following parts
the opening cable inside the trunk towards the
rear of the vehicle to remove it. Left Front Door Sill Inner Guard Plate
Install the opening cable in the reverse order 4.7.2 Remove the retaining bolts on the trunk
of the removal and note the following: lid and oil filler cap opening handles.
Make sure the opening cable and the core wire
jacket joint used to connect the trunk lock and 4.7.3 The trunk lid and oil filler cap opening
opening handle are fully clamped in the slot. handle can be removed by removing the
core wire jacket joint of pull cable from the
4.6.2 Replacement of Oil Filler Cap Opening trunk lid and oil filler cap opening handle.
Cable
4.7.4 Install the trunk lid and oil filler cap
4.6.2.1 Remove the following parts opening handle in the reverse order of the
Trunk Lid and Oil Filler Cap Opening removal and note the following:
Handles Make sure the sleeve joint of trunk lid and
Left Rear Door Sill Inner Guard Plate oil filler cap opening handle is fully
Trunk Inner Panel clamped in the slot of opening handle.
4.6.2.2 Rotate the oil filler cap mounting base Fig. 4-2 Diagram of Trunk Lid and Oil Filler
from inside of the vehicle and remove it. Cap Pull Cables Locations
43
BYD AUTO BYD Suri Maintenance & Repair Manual
5.1.2 Remove the screws (as shown in the Slot Seal End
水切端部
figure) on the front door rear slot seal with
a star screwdriver and pry out the end of
outer slot seal with a straight screwdriver.
When the end is pried, pull it upward and
then remove the entire outer slot seal.
Be careful not to scratch the vehicle body Door
门框
Frame
during the removal.
44
BYD AUTO BYD Suri Maintenance & Repair Manual
5.3 Replacement of Front Door Sealing Strip Spray water around the door gap with a water
pipe and check for tightness.
Remove the limiter fastening bolts on the
lower part of pillar A. Remove the snap-fit from 5.5 Replacement of Front Door Glass Mud
the pillar B joint and remove the door sealing Groove
strip cards on both sides of the window frame.
Then remove the nylon fasteners from the Remove the front door guard plate and
door with the flat tongs. Be careful not to water-proof film.
scratch the metal plate of the door.
Remove the front door glass.
Remove the door sealing strip.
Remove the glass mud groove. Remove the
Install the front door sealing strip in the reverse mud groove from the window frame to both
order of the removal. Clamp the front door sides with even force. Be careful not to injure
sealing strip hook on the window frame to the your arms.
corresponding barb on the front door window
frame roller part and note the following: Install the glass mud groove. Install two corner
parts in place first and then install the window
Replace all the front door cards and nylon frame mud groove in place. At last install the
fasteners. mud groove on both sides of the guide rail
from top to bottom and note the following:
Make sure the door sealing strip hook is
installed in the metal plate barb. Make sure the mud groove is installed in
place.
Spray water around the door gap with a water
pipe and check for tightness. Raise and lower the glass several times to
check if the mud groove is installed in place
5.4 Replacement of Front Door Frame Sealing according to the glass movement. If the glass
Strip does not move smoothly, remove and reinstall
the mud groove.
5.4.1 Remove the front door sill inner guard
plate. Spray water around the glass using a water
pipe and check for tightness.
5.4.2 Remove the front door frame sealing
strip from the upper corner close to the 5.6 Replacement of Upper and Lower Stop
pillar B. Blocks of Front Door
5.4.3 Place the seam joint in the center of the 5.6.1 Remove the front door stop block with
door sill guard plate and align the paint plastic cutter pliers.
mark with the upper corner of pillar B.
Then install the door frame strips to the 5.6.2 Install a new stop block in the metal plate
metal plate of the body in order and note buckle.
the following:
5.7 Replacement of Rear Movable Guide Rail
Install the straight part after the corner part is Assembly of Front Door
installed in place.
5.7.1 Remove the front door guard plate and
Do not install the sealing strip in a fixed water-proof film.
direction to prevent the sealing strip from
being extended. The sealing strip cannot be 5.7.2 Remove the front door glass.
installed if it is extended. The door frame
sealing strip should be installed in place after it 5.7.3 Remove the bolt and washer assembly
is positioned properly. on the lower support of the rear movable
guide rail of the front door with a No. 10
sleeve.
45
BYD AUTO BYD Suri Maintenance & Repair Manual
5.8.2 Install the outer slot seal. Clamp the clip Fig. 5-6 Schematic Diagram for Removal of
on the slot seal to the metal plate bordure, Rear Door Inner Slot Seal
and move the slot seal to left and right to
align the screw holes on both cards of the 5.10 Replacement of Rear Door Sealing Strip
outer slot seal with the metal plate holes.
Tighten the screws to complete the Refer to the replacement procedure of front
installation. door sealing strip for details.
46
BYD AUTO BYD Suri Maintenance & Repair Manual
5.14.7 Install a new movable guide rail in the 5.15.2 Perform the installation in the reverse
reverse order of the above removal. order of the removal. Be careful not to
scratch the vehicle body.
47
BYD AUTO BYD Suri Maintenance & Repair Manual
make sure there is no flush between the 5.19.2 Replace with a new buffer block (stop
front compartment cover and the fender. block). Press the small end of the buffer
block into the metal plate hole with proper
5.18 Replacement of Trunk Lid Sealing Strip force to complete the installation. Adjust
the buffer block.
Remove the trunk sealing strip and do not
allow the sealing adhesive sticker to flow out. 5.20 Replacement of Left/Right Rear Door
Make sure the joint seam of the trunk sealing Corner Window Weather Strip
strip is in the centerline of the trunk lock ring
and install the trunk sealing strip. Make sure 5.20.1 Remove the inner guard plate and
the sealing strip is installed in place without water-proof film.
being twisted.
5.20.2 Remove the glass assembly.
Check for water leakage.
5.20.3 Remove the glass mud groove.
5.19 Replacement of Trunk Lid Hinge Buffer
Block, Trunk Lid Stop Block and Side Stop 5.20.4 Remove the movable guide rail.
Block
5.20.5 Remove the corner window glass and
5.19 1 Pull out the buffer block (stop block) take out the corner window sealing strip.
with the flat tongs. Be careful not to
scratch the vehicle body. 5.20.6 Install a new sealing strip in the reverse
order of the above removal.
48
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 6-1 Adjustment of Front and Rear Door 6.3.3.2 Adjust the trunk lid opening by moving
the lock catch so that the opening is level
6.2 Adjustment of Engine Cover and even.
49
BYD AUTO BYD Suri Maintenance & Repair Manual
6.3.5 Make sure the trunk lid can be opened 6.4.3 Remove the torsion bar retainer (A) from
normally and locked securely. the body.
6.3.6 Reinstall all the removed parts. 6.4.4 Install the torsion bar in the reverse order
of the removal and note the following:
6.4 Replacement of Trunk Lid Torsion Bar
6.4.4.1 The shape of the right torsion bar (D)
Notice: The special tool (B) is needed and left torsion bar (C) is shown in the
figure. Install them correctly;
6.4.1 Remove the torsion bar (D) and (C) from
the center retainer (A) on the torsion bar. 6.4.4.2 Adjust the torsion bar back and forth
with the torsion bar assembly tool (B);
50
BYD AUTO BYD Suri Maintenance & Repair Manual
Chapter 4 Chassis
Contents
Part 1 Intake System ..............................................................................................................................53
Part 2 Exhaust System ...........................................................................................................................57
Part 3 Cooling System ............................................................................................................................60
Section 1 473QE Cooling System ...........................................................................................60
Section 2 476ZQA Cooling System .........................................................................................62
Part 4 Fuel System .................................................................................................................................65
Section 1 Fuel Supply System .................................................................................................65
Section 2 Fuel Evaporation and Cleaning System ..................................................................71
Part 5 Suspension System .....................................................................................................................73
Section 1 Components Layout and Description of Suspension System .................................73
Section 2 Repair Suspension System (473QE-5T14) .............................................................80
Section 3 Repair 5AC/5AI Suspension System .......................................................................85
Section 4 Installation of Relevant Engine Accessories ...........................................................91
Part 6 Suspension System .....................................................................................................................92
Section 1 Suspension Overview ..............................................................................................92
Section 2 Front Suspension .....................................................................................................95
Section 3 Rear Suspension ................................................................................................... 118
Part 7 Power Steering System .............................................................................................................132
Section 1 Special Tools ..........................................................................................................132
Section 2 Diagram of Hydraulic Steering System Component Location ...............................133
Section 3 Symptoms and Troubleshooting ............................................................................135
Section 4 Troubleshooting .....................................................................................................137
Section 5 Overhauling of Steering Wheel, Steering Column and Universal Joint Assembly 140
Section 6 Power Steering Pump Pressure Test .....................................................................145
Section 7 Fluid Leakage Detection ........................................................................................146
Section 8 Steering Fluid Replacement...................................................................................148
Section 9 Power Steering Line Replacement ........................................................................149
Section 10 Pump Replacement .............................................................................................151
Section 11 Removal of Power Steering Gear ........................................................................153
Section 12 Installation of Power Steering Gear .....................................................................155
Section 13 Electric Power Steering (EPS) System ................................................................157
Part 8 Brake System .............................................................................................................................158
Section 1 Conventional Brake Components ..........................................................................158
Part 9 Drive Half Shaft ..........................................................................................................................176
Section 1 Half Shaft Detection ...............................................................................................176
Section 2 Half Shaft Removal ................................................................................................177
Section 3 Half Shaft Installation .............................................................................................178
Section 1 Half Shaft Detection ...............................................................................................179
51
BYD AUTO BYD Suri Maintenance & Repair Manual
52
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Q67580
Type A worm driven hose clamp
2 5A-1109311
Intake hose
3 BYDEG-1109118
Crank case vent pipe joint
4 5A-1109312
Crank case vent pipe
5 Q673B12F6
Steel band type elastic clamp
6 5A-1109313
Crank case vent pipe jacket
7 Q673B145F6
Steel band type elastic clamp
7 6
53
BYD AUTO BYD Suri Maintenance & Repair Manual
1
1
4 2 2
2
3
3
3
4
Fig. 1.1.3 Intake Air Guide Pipe Assembly Fig. 1.1.4 Air Filter Assembly
1 5A-1109113 1 5A-1109211
Air Cleaner Joint Sealing Sponge Air Filter Upper Housing
1.1.2.1 Remove the snap fastener 4 and take Removal and Installation
off the intake pipe 5;
1.1.3.1 Loosen the clamp spring 3 of upper
1.1.2.2 Remove the bolt 2 and take off the and lower housing fastener and remove
intake elbow 5 to remove the intake air the air filter upper housing 1.
guide pipe assembly;
1.1.3.2 Remove the air filter element 2.
1.1.2.3 Install each part in the reverse order of
removal. 1.1.3.3 Loosen the fastening bolt 5 on the
lower housing and remove the air filter
1.1.3 Removal/Installation Procedure of Air lower housing 4 to remove the air filter
Filter Assembly assembly.
54
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1.3.4 Install each part in the reverse order 1.2.1.1.1 Loosen the steel band type elastic
of removal. clamp 9 and pull out the crank case vent
pipe 7;
1.1.4 Replacement of Air Filter Element
1.2.1.1.2 Remove the connecting bolt 6 on the
The element is designed to be used for upper and lower housing, remove the air
20,000 km. It is recommended to clean the filter upper housing 10 and take out the air
element every 5,000 km. The cleaning filter element 5;
method is to tap the element by hand after it
is removed to remove the dust from the 1.2.1.1.3 Remove the bolt 1;
element. Do not allow the dust to enter the
intake elbow and engine throttle valve or 1.2.1.1.4 Remove the air filter lower
attach on the upper surface of the element housing 4;
when the element is cleaned.
1.2.1.1.5 Install each part in the reverse order
Replacement Procedure (Fig. 4): of removal.
1.1.4.1 Loosen the clamp spring 3 of the 1.2.1.2 Replacement of Air Filter Element (Fig.
upper and lower housing fastener and 1.2.2)
remove the air filter upper housing 1.
The element is designed to be used for 20,000
1.1.4.2 Remove the air filter element 4. km. It is recommended to clean the element
every 5,000 km. The cleaning method is to tap
1.1.4.3 Install each part in the reverse order the element by hand after it is removed to
of removal. remove the dust from the element. Do not
allow the dust to enter the intake elbow and
1.2 Intake System (476ZQA) engine throttle valve when the element is
cleaned.
Replacement Procedure:
Fig. 1.2.2
55
BYD AUTO BYD Suri Maintenance & Repair Manual
56
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1.1 Removal and Installation of Exhaust Remove the baffle assembly and remove
System the hexagon flange bolt at the connection
between the middle section of the exhaust
1.1.1.1 If the front section of exhaust pipe pipe assembly and the front section of the
assembly needs to be removed: exhaust pipe assembly. Then remove the
hexagon flange bolt at the connection
Remove the oxygen sensor, and then between the middle section of the exhaust
remove the hexagon flange bolt at the pipe assembly and the rear section of the
connection between the front section of exhaust pipe assembly. At last take out the
exhaust pipe assembly and the exhaust middle section of the exhaust pipe
manifold. At last remove the hexagon assembly from the lug;
flange bolt at the connection between the
front section of exhaust pipe assembly and 1.1.1.3 If the rear section of exhaust pipe
middle section of the exhaust pipe assembly needs to be removed:
assembly (Note the front section of the
exhaust pipe assembly is not hung by the Remove the hexagon flange bolt at the
lug); connection between the rear section of
exhaust pipe assembly and the middle
1.1.1.2 If the middle section of exhaust pipe section of the exhaust pipe assembly and
assembly needs to be removed: then take out the rear section of exhaust
pipe assembly from the lug;
57
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1.1.4 Install each part in the reverse order of b Use the specified mounting grease when
removal. the oxygen sensor is removed and reinstalled;
1.2.1 Removal and Installation of Exhaust section of exhaust pipe assembly (Note
System the front section of the exhaust pipe
assembly is not hung by the lug);
1.2.1.1 Remove the front section of exhaust
pipe assembly: 1.2.1.2 Remove the catalytic converter with
the exhaust pipe assembly:
Remove the rear oxygen sensor, and then
remove the hexagon flange nut at the Remove the wire harness on the front
connection between the front section of oxygen sensor and the catalytic converter
exhaust pipe assembly and the catalytic with the exhaust pipe assembly support.
converter with exhaust pipe assembly. Then remove the nut at the connection
Finally, remove the hexagon flange bolt at between the catalytic converter with the
the connection between the front section exhaust pipe assembly and the front
of exhaust pipe assembly and the middle section of the exhaust pipe assembly, and
58
BYD AUTO BYD Suri Maintenance & Repair Manual
remove the bolt at the connection between connection between the middle section of
the catalytic converter with the exhaust exhaust pipe assembly and the front
pipe assembly and the engine block. section of the exhaust pipe assembly.
Finally, remove the nut at the connection Then remove the hexagon flange bolt at
between the catalytic converter with the the connection between the middle section
exhaust pipe assembly and the of the exhaust pipe assembly and the rear
turbocharger (Note there is no lug on the section of the exhaust pipe assembly.
catalytic converter with the exhaust pipe Finally, take out the middle section of the
assembly); exhaust pipe assembly from the rubber lug
I;
1.2.1.3 Remove the exhaust pipe baffle
assembly: 1.2.1.5 Remove the rear section of the
exhaust pipe assembly:
The exhaust pipe baffle assembly can be
removed by removing the hexagon flange Remove the hexagon flange bolt at the
bolt for connecting the exhaust pipe baffle connection between the rear section of the
assembly and the body; exhaust pipe assembly and the middle
section of the exhaust pipe assembly, and
1.2.1.4 Remove the middle section of the then take out the rear section of the
exhaust pipe assembly: exhaust pipe assembly from the rubber lug
I;
Remove the exhaust pipe baffle assembly
and remove the hexagon flange bolt at the
59
BYD AUTO BYD Suri Maintenance & Repair Manual
A
1.4 Coolant Inspection B
60
BYD AUTO BYD Suri Maintenance & Repair Manual
check the cooling system for leakage. 1.4.2.10 Repeat steps (9) and (10) until it is not
necessary to add the coolant;
Notice: The expansion tank level must be
inspected after the vehicle cools down 1.4.2.11 Tighten the expansion tank cover,
completely to avoid being burnt. start the engine again and check for
leakage.
1.4.2 Coolant Replacement
1.5 Replacement of Electronic Cooling Fan,
1.4.2.1 Start the engine and keep it idling until Radiator and Expansion Tank
the thermostat is fully opened. Then stop
the power drive assembly and remove the 1.5.1 Stop the power drive assembly and
key; remove the key;
1.4.2.2 Remove the expansion tank cover after 1.5.2 Open the radiator water drainage valve
the vehicle cools down completely; and drain the coolant after the vehicle
cools down;
1.4.2.3 Loosen the water drainage valve and
drain the coolant; 1.5.3 Disconnect the electronic cooling fan
power connector;
1.4.2.4 After the coolant is drained, tighten the
radiator water drainage valve; 1.5.4 Remove the radiator hoses and
connecting pipes;
1.4.2.5 Remove, drain and reinstall the
expansion tank; 1.5.5 Remove the expansion tank;
1.4.2.6 Fill the expansion tank with the coolant 1.5.6 Remove the heat sink upper suspended
specified by BYD until the MAX marker is assembly, the body upper cross bearer
reached; and the radiator;
Notice: Be sure to use BYD specified coolant. 1.5.7 Remove the electronic cooling fan
Otherwise the components may be corroded, assembly on the radiator;
the pipe lines may be blocked and the cooling
system may operate abnormally or 1.5.8 Remove the overflowed coolant;
malfunction. Coolant refilling volume:
(7000±200) ML. 1.5.9 Install the expansion tank, electronic
cooling fan and radiator in the reverse
1.4.2.7 Install the expansion tank cover order of removal and make sure the upper
loosely; and lower suspension rubber sleeve is
installed in place and fixed reliably;
1.4.2.8 Start the engine at idle speed and
warm up the engine (the fan operates at 1.5.10 Fill the cooling system with coolant and
least twice); bleed the air from the cooling system.
61
BYD AUTO BYD Suri Maintenance & Repair Manual
1.2.2.1 When the engine and radiator cool 1.2.2.4 If the pressure decreases, replace the
down, remove the expansion tank cover expansion tank cover.
(A), apply some coolant on its seal ring
and then install the seal ring on the 1.2.3 Radiator Inspection
pressure instrument (B) (available in the
market). Install the expansion tank cover 1.2.3.1 Remove the high and low temperature
using a small mating part H-901122-09 (C) radiator after the vehicle cools down
(available in the market); completely;
1.2.2.2 Apply a pressure of 140 to 160 kPa; 1.2.4 Cooling Pipeline Inspection
1.2.2.3 Check if the pressure decreases; 1.2.4.1 After the engine cools down, remove
the expansion tank cover carefully and fill
62
BYD AUTO BYD Suri Maintenance & Repair Manual
the coolant in the system until the level is 1.5.2.1 Remove the expansion tank cover after
between the MAX marker (A) and MIN the vehicle cools down completely;
marker (B);
1.5.2.2 Remove the end of the high and low
1.2.4.2 Install the pressure instrument temperature radiator outlet hose
(available in the market) on the expansion connected to the radiator and drain the
tank. Connect the pressure instrument coolant;
using a small mating part H-901122-09
(available in the market); 1.5.2.3 Connect the high and low temperature
radiator outlet hose to the radiator after the
1.2.4.3 Apply a pressure of 140 to 160 kPa; coolant is drained;
1.2.4.4 Check each cooling water pipe end for 1.5.2.4 Remove, drain and reinstall the
coolant leakage; expansion tank;
1.2.4.5 Remove the instrument and reinstall 1.5.2.5 Fill the expansion tank with the coolant
the expansion tank cover; specified by BYD until the MAX marker is
reached;
1.2.4.6 Check if the engine oil and the coolant
are mixed. Notice: Be sure to use BYD specified coolant.
Otherwise the components may be corroded,
the pipe lines may be blocked and the cooling
system may operate abnormally or
malfunction.
63
BYD AUTO BYD Suri Maintenance & Repair Manual
1.2.6.3 Disconnect the electronic cooling fan 1.2.6.8 Remove the overflowed coolant;
power connector;
1.2.6.9 Install the expansion tank, electronic
1.2.6.4 Remove the cooling water pipe; cooling fan and radiator in the reverse
order of removal and make sure the upper
1.2.6.5 Remove the expansion tank; and lower suspension rubber sleeve is
installed in place and fixed reliably;
1.2.6.6 Remove the heat sink upper
suspended assembly and then remove the 1.2.6.10 Fill the cooling system with coolant
radiator; (refer to 3.5.2) and bleed the air from the
cooling system.
1.2.6.7 Remove the electronic cooling fan
assembly on the radiator;
64
BYD AUTO BYD Suri Maintenance & Repair Manual
(c) Select "Fuel Pump OFF" in the inspection 1.1.5 Switch the ignition switch to OFF.
menu of the BYD tester or BYD diagnosis
system and then keep the engine idling 1.1.6 Remove the fuel tank cap and release
until the fuel pump stops. the fuel pressure in the fuel tank.
(d) Switch the ignition switch to OFF. 1.1.7 Disconnect the negative cable from
battery (A).
Notice:
The DTCs or temporary DTCs can be set in 1.1.8 Loosen the type A worm clamp (A).
this procedure. Check the DTCs and clear
them if necessary.
65
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1.11 After the hose is disconnected, check If the fuel pump runs, go to step 5.
for dirt or damage. If the fuel pump does not run, overhaul the
fuel pump circuit failure (See page
1.1.12 Reconnect the negative cable to the 11-195).
battery and perform the following
operations:
Disconnect the hose joint (A). Connect the fuel Retaining support: If the fuel pressure does
pressure gauge device and fuel pressure not meet the technical requirements, replace
gauge. the fuel pressure regulator and fuel filter and
then recheck the fuel pressure.
a If the engine is started, go to step 5. Check all the retaining supports and pipe
b If the engine cannot be started, go to step clamps. Tighten them if necessary.
4
Notice: The oil supply hard tube, oil return hard
1.1.12.4 Check if the fuel pump runs. Remove tube, evaporation hard tube clamp and braking
the fuel tank cap and then monitor the fuel hard tube share some clamps which will be
filler. When the ignition switch is turned on clearly indicated in the brake system.
for the first time, the fuel pump should
operate for 2 seconds.
66
BYD AUTO BYD Suri Maintenance & Repair Manual
67
BYD AUTO BYD Suri Maintenance & Repair Manual
68
BYD AUTO BYD Suri Maintenance & Repair Manual
(b) Install the fuel filter and support assembly 1.4 Replacement of Fuel Tank
on the body with the mounting bolts in the
correct direction. Removal
(c) Tighten the retaining bolts. 1.4.1 Release the fuel pressure.
(d) Connect the oil inlet and outlet tubes to 1.4.2 Remove the fuel tank service hole cover.
both ends of the oil line fuel filter.
1.4.3 Remove the fuel pump electrical
(e) Tighten the fuel tank cap. connector.
(f) Reconnect the battery negative cable. 1.4.4 Disconnect the filling hose (A) and filling
vent hose II (B).
(g) Turn on the ignition switch for 2 seconds,
turn it off for 10 seconds and then turn it on
to check for fuel leakage.
69
BYD AUTO BYD Suri Maintenance & Repair Manual
1.4.6 Remove the hexagon flange bolt (A), fuel 1.4.7 Lower the fuel tank on the ground with
tank fixing band (B) and fuel tank retaining special tools such as the jack or support.
support (C).
Installation
70
BYD AUTO BYD Suri Maintenance & Repair Manual
2.1 Diagram of Component Locations 2.2.4 Install each part in the reverse order of
removal.
2.2 Replacement of Charcoal Canister
Acceleration Drive System
2.2.1 Disconnect the fuel evaporation exhaust
hose I (A) and fuel evaporation exhaust 2.3 Adjustment of Throttle Cable
hose II (B).
2.3.1 Check the free travel of the pull cable at
the throttle linkage. The free travel of the
pull cable (A) should be 10-12 mm.
71
BYD AUTO BYD Suri Maintenance & Repair Manual
2.4.4 Remove the throttle cable (A) from the 2.4.9 Remove the pull cable from the throttle
accelerator pedal (B). valve support (A). Reinstall the adjusting
nut (B) and tighten the locking nut (C).
72
BYD AUTO BYD Suri Maintenance & Repair Manual
73
BYD AUTO BYD Suri Maintenance & Repair Manual
74
BYD AUTO BYD Suri Maintenance & Repair Manual
75
BYD AUTO BYD Suri Maintenance & Repair Manual
76
BYD AUTO BYD Suri Maintenance & Repair Manual
77
BYD AUTO BYD Suri Maintenance & Repair Manual
Engine front suspension mounting holder Engine rear suspension mounting support
assembly: assembly:
In the model 5A, it is installed on the
In the model 5A, it is installed on the cross transmission housing with three
bearer of the front sub frame with two Q1841025TF3 hexagon flange bolts.
Q1841225TF3 hexagon flange bolts.
In the model 5AA, it is installed on the
Engine front suspension mounting support transmission housing with three
assembly: Q1841225TF3 hexagon flange bolts.
In the model 5A, it is installed on the In the model 5AP, it is installed on the
transmission housing with two Q1841025TF3 transmission housing with three
hexagon flange bolts. Q1841260TF3 hexagon flange bolts.
In the model 5AA, it is installed on the In the model 5A, the rear suspension mounting
transmission housing with two Q1841225TF3 holder and support are connected by a
hexagon flange bolts. BYDQ184D1090TF3 bolt.
In the model 5AP, it is installed on the In the model 5AA, the rear suspension
transmission housing with two Q1841225TF3 mounting holder and support are connected by
hexagon flange bolts. a BYDQ184D1090TF3 bolt.
In the model 5A, the front suspension In the model 5AP, the rear suspension
mounting holder and support are connected by mounting holder and support are connected by
a BYDQ184D10100TF3 bolt and a a BYDQ184D10100TF3 bolt.
BYDQ350A10T13F3 hex nut.
Engine left suspension mounting holder
In the model 5AA, the front suspension assembly:
mounting holder and support are connected by
a BYDQ184D10100TF3 bolt and a In the model 5A, it is installed on the
BYDQ350A10T13F3 hex nut. longitudinal beam welding assembly LH with
four BYDQ1841225TF3 hexagon flange bolts.
In the model 5AP, the front suspension
mounting holder and support are connected by In the model 5AA, it is installed on the
a BYDQ184A10100TF3 bolt and a longitudinal beam welding assembly LH with
BYDQ350A10T13F3 hex nut. four Q1841225TF3 hexagon flange bolts.
Engine rear suspension mounting holder In the model 5AP, it is installed on the
assembly: longitudinal beam welding assembly LH with
In the model 5A, it is installed on the front sub four Q1841225TF3 hexagon flange bolts.
frame with two BYDQ184B1265TF3 hexagon
flange bolts and two BYDQ32O12T13F3C Engine left suspension mounting support
hexagon flange nuts. assembly:
In the model 5AA, it is installed on the front In the model 5A, it is installed on the
sub frame with two BYDQ184B1265TF3 transmission with two Q1841045TF3 hexagon
hexagon flange bolts and two flange bolts and a Q1841035TF3 hexagon
BYDQ32O12T13F3C hexagon flange nuts. flange bolt.
In the model 5AP, it is installed on the front In the model 5AA, it is installed on the
sub frame with two BYDQ184B1265TF3 transmission with four Q32012T13F3C
hexagon flange bolts and two hexagon flange nuts.
78
BYD AUTO BYD Suri Maintenance & Repair Manual
In the model 5AP, it is installed on the In the model 5AA, it is installed on the body
transmission with three Q1841040TF3 and right suspension mounting base
hexagon flange bolts. respectively with a Q1841225TF3 hexagon
flange bolt and two Q1841025TF3 hexagon
In the model 5A, the left suspension mounting flange bolts. In addition, the right suspension
holder and support are connected by a support is installed on the engine flange bolt
BYDQ18410140TF3 bolt and a with two Q32012T13F3C hexagon flange nuts
Q32010T13F3C hexagon flange nut. and the right suspension mounting base is
installed on the longitudinal beam welding
In the model 5AA, the left suspension assembly RH with two Q1841250TF3 hexagon
mounting holder and support are connected by flange bolts.
a BYDQ184D10110TF3 hexagon flange bolt
and a BYDQ350A10T13F3 hex nut. In the model 5AP, it is installed on the body
and right suspension mounting base with three
In the model 5AP, the left suspension Q1841225TF3 hexagon flange bolts. In
mounting holder and support are connected by addition, the right suspension support is
a BYDQ18412140TF3 hexagon flange bolt. installed on the engine flange bolt with two
Q32012T13F3C hexagon flange nuts and the
Engine right suspension assembly: right suspension mounting base is installed on
the longitudinal beam welding assembly RH
In the model 5A, it is installed on the with three Q1841235TF3 hexagon flange
longitudinal beam welding assembly RH and bolts.
the body with three Q1841225TF3 hexagon
flange bolts. In addition, the right suspension
support is installed on the engine flange bolt
with two Q32010T13F3C hexagon flange nuts.
79
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 2.1.3
Fig. 2.1.2
80
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 2.3.3
Fig. 2.3.2
Fig. 2.3.4
2.3.3 Remove 4 hexagon flange bolts for
connecting the left suspension mounting 2.4 Installation of Engine Left Suspension
holder and the body as well as 1 through Assembly
bolt and 1 hex nut for connecting the
holder and the support (as shown in figure 2.4.1 Place the new engine left suspension
2.3.3) so as to remove the left suspension mounting support assembly in the position
mounting holder. as shown in figure 2.3.4 and then tighten 3
hexagon flange bolts.
81
BYD AUTO BYD Suri Maintenance & Repair Manual
82
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 2.8.1
Fig. 2.6.3
2.8.2 Remove 1 through bolt and 1 hex nut for
2.7 Installation of Engine Front Suspension connecting the engine rear suspension
Assembly mounting holder and the rear suspension
mounting support and 2 bolts on the
2.7.1 Place the new engine front suspension steering line support (as shown in figure
mounting support assembly in the 2.8.2) so as to remove the engine rear
installation position as shown in figure suspension mounting holder assembly.
2.6.3 and then install and tighten 2
hexagon flange bolts.
83
BYD AUTO BYD Suri Maintenance & Repair Manual
84
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 3.1.2
Fig. 3.1.1
Fig. 3.1.3
85
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 3.1.4
Fig. 5.3.1
3.2 Installation of Power Drive Assembly Right
Suspension Assembly 3.3.2 Remove 3 mounting bolts from the air
filter (as shown in figure 5.3.2) so as to
3.2.1 Place the new power drive assembly remove the air filter lower housing.
right suspension holder assembly in the
position as shown in figure 3.1.4, and then
install and tighten 2 hexagon flange bolts
and 2 hexagon flange nuts.
86
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 3.3.3
Fig. 3.3.4
87
BYD AUTO BYD Suri Maintenance & Repair Manual
88
BYD AUTO BYD Suri Maintenance & Repair Manual
89
BYD AUTO BYD Suri Maintenance & Repair Manual
90
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 4.2.1
Fig. 4.2.2
91
BYD AUTO BYD Suri Maintenance & Repair Manual
Note:
92
BYD AUTO BYD Suri Maintenance & Repair Manual
93
BYD AUTO BYD Suri Maintenance & Repair Manual
Rear
94
BYD AUTO BYD Suri Maintenance & Repair Manual
95
BYD AUTO BYD Suri Maintenance & Repair Manual
Notice: The left and right vibration damper 2.1.2.7 Remove the connecting nuts of the
assemblies can be operated according to the transversal stabilizer bar tie rod end and
following steps. the vibration damper.
2.1.2 Removal
2.1.2.4 Remove the wheel nuts and front 2.1.2.8 Remove the connecting bolts of the
wheel. vibration damper and the steering knuckle.
2.1.2.6 Remove the brake hose retaining 2.1.2.9 Remove 3 nuts for connecting the
bracket. vibration damper and the body.
96
BYD AUTO BYD Suri Maintenance & Repair Manual
Note:
97
BYD AUTO BYD Suri Maintenance & Repair Manual
2.1.5.2 Compress the front helical spring using 2.1.5.10 Loosen the special tool (Remove the
the special tools and install the spring on iron wire if it is used).
the vibration damper (Install the spring
directly if it is fastened by the iron wire). 2.1.6 Installation
Note:
2.1.5.3 Install the buffer unit. 2.1.6.2 Install the connecting bolts of the
vibration damper and steering knuckle.
2.1.5.4 Install the dust cover. Align the mounting holes of the vibration
damper and the steering knuckle, insert
2.1.5.5 Install the front vibration damper spring the bolt, install and tighten the nuts to the
upper seat unit. torque of 235 Nm.
98
BYD AUTO BYD Suri Maintenance & Repair Manual
Toe-in:
2.1.6.4 Install the brake oil pipe on the
vibration damper oil pipe support. C-D (mm)
0-2
99
BYD AUTO BYD Suri Maintenance & Repair Manual
Notice:
Tips:
100
BYD AUTO BYD Suri Maintenance & Repair Manual
2.2.2 Removal
101
BYD AUTO BYD Suri Maintenance & Repair Manual
2.2.3 Installation
102
BYD AUTO BYD Suri Maintenance & Repair Manual
103
BYD AUTO BYD Suri Maintenance & Repair Manual
2.3.2 Removal
104
BYD AUTO BYD Suri Maintenance & Repair Manual
105
BYD AUTO BYD Suri Maintenance & Repair Manual
2.3.3 Inspection
2.3.4 Installation
106
BYD AUTO BYD Suri Maintenance & Repair Manual
b Install a new split pin. a Install the brake caliper on the steering
knuckle with the tightening torque of 107
Notice: If the hole of the tie rod ball joint is not Nm.
aligned with the slot of the slotted nut, turn the
slotted nut.
107
BYD AUTO BYD Suri Maintenance & Repair Manual
108
BYD AUTO BYD Suri Maintenance & Repair Manual
109
BYD AUTO BYD Suri Maintenance & Repair Manual
2.4.2 Removal
2.4.3 Inspection
2.4.4 Installation
2.4.2.5 Remove the stabilizer-bar assembly. a Install the transversal stabilizer bar and
bush as shown in the figure.
a Pull out the stabilizer bar together with the
stabilizer bar bush from the sub frame.
110
BYD AUTO BYD Suri Maintenance & Repair Manual
111
BYD AUTO BYD Suri Maintenance & Repair Manual
112
BYD AUTO BYD Suri Maintenance & Repair Manual
113
BYD AUTO BYD Suri Maintenance & Repair Manual
2.5.2.9 Support the sub frame body assembly Notice: Pass an extension bar through the
using a lifting device. Remove four swinging arm sleeve to remove the bolts.
connecting bolts of the sub frame body
and longitudinal beam and six connecting 2.5.2.11 Lower the lifting device and lower the
bolts of the front sub frame bracket and the sub frame as well.
body.
2.5.2.12 Remove the front and rear mounting
a Support the sub frame using a small lifter. bolts of the left/right front lower swinging
arm and sub frame.
b Remove the connecting bolts of the
left/right longitudinal beam and sub frame a Remove the rear mounting bolt on the front
as shown in the figure A. lower swinging arm.
114
BYD AUTO BYD Suri Maintenance & Repair Manual
2.5.3 Inspection
b Remove the front mounting bolt on the Check the sub frame body assembly for
front lower swinging arm. deformation or cracks and check the rubber
bush for aging or damage. If the sub frame
body assembly is deformed or damaged or the
rubber bush is aged, replace the damaged sub
frame body or bush assembly. Do not try to
repair them.
2.5.4 Installation
115
BYD AUTO BYD Suri Maintenance & Repair Manual
116
BYD AUTO BYD Suri Maintenance & Repair Manual
2.5.4.8 Install the stabilizer bar and stabilizer 2.5.4.11 Install the wheel with the tightening
bar link lower connecting nuts and the torque of the wheel nut of 110 Nm.
tightening torque is 80 Nm.
2.5.4.12 Install the steering high pressure oil
pipe and engine steering pump.
117
BYD AUTO BYD Suri Maintenance & Repair Manual
118
BYD AUTO BYD Suri Maintenance & Repair Manual
3.1.2.1 Remove the rear wheel. b Remove the helical spring and the
upper/lower cushion of the helical spring.
3.1.2.2 Raise the vehicle.
3.1.2.6 Remove the right rear helical spring.
3.1.2.3 Detach the left rear vibration damper
assembly. Tips: The removal procedures for the right side
are the same as that of the left side.
a Support both ends of the rear torsion beam
with a jack and place a wood block 3.1.3 Installation
between the jack and rear torsion beam to
avoid damage. 3.1.3.1 Install the left rear helical spring.
119
BYD AUTO BYD Suri Maintenance & Repair Manual
120
BYD AUTO BYD Suri Maintenance & Repair Manual
121
BYD AUTO BYD Suri Maintenance & Repair Manual
b Remove the connecting bolts and nuts of 3.2.3.1 Check the upper supporting pad unit
the rear vibration damper and torsion and lower supporting pad for any damage.
beam. Replace them if necessary.
Note:
122
BYD AUTO BYD Suri Maintenance & Repair Manual
Notice:
As shown in the figure, tighten the nut until at
least 3 threads can be seen.
Note:
When dealing with the rear vibration damper:
3.2.4 Installation
c Fix the piston rod and install the nut. 3.4.3.3 Install the trunk side panel.
123
BYD AUTO BYD Suri Maintenance & Repair Manual
124
BYD AUTO BYD Suri Maintenance & Repair Manual
3.3.2 Removal
125
BYD AUTO BYD Suri Maintenance & Repair Manual
a Fix the left rear flexible hose with a wrench Tips: The removal procedures for the right side
and disconnect the brake pipe with a are the same as that of the left side.
connecting nut wrench.
3.3.2.10 Loosen the rear torsion beam
assembly.
126
BYD AUTO BYD Suri Maintenance & Repair Manual
Tips: The removal procedures for the right side b Remove all pipe lines.
are the same as that of the left side.
3.3.2.17 Remove the left/right rear brake
3.3.2.15 Remove the rear torsion beam assembly.
assembly.
3.3.3 Bush Replacement
a Remove two bolts and rear torsion beam
assembly. If the bush is damaged, replace it.
Tips:
Twist the bush fin until the paw of the special
tool is in the air. Marker
127
BYD AUTO BYD Suri Maintenance & Repair Manual
Tips:
The removal procedures for the right side are
the same as that of the left side.
Notice:
Note:
Tips:
The installation procedures for the right side
are the same as that of the left side.
3.3.4 Installation
128
BYD AUTO BYD Suri Maintenance & Repair Manual
129
BYD AUTO BYD Suri Maintenance & Repair Manual
Tips: Tips:
The installation procedures for the right side
The installation procedures for the right side are the same as that of the left side.
are the same as that of the left side.
3.3.4.10 Install the left rear brake hose with the
3.3.4.8 Install the left rear parking pull cable. tightening torque of 20 Nm.
Note:
Do not damage the rear brake pipe and
b Install a new E-shape clamp and connect flexible hose.
the cable and brake caliper.
3.3.4.11 Install the right rear brake hose to the
body.
Tips:
The installation procedures for the right side
are the same as that of the left side.
130
BYD AUTO BYD Suri Maintenance & Repair Manual
3.3.4.12 Install the left rear wheel speed (14) Fully tighten the left/right rear vibration
sensor. damper assembly. Fully tighten 2 bolts to
the torque of 115 Nm.
a Install the left rear wheel speed sensor on
the brake.
131
BYD AUTO BYD Suri Maintenance & Repair Manual
No. Name
(1) Ball Joint Remover 28 mm
(2) P/S Pressure Gauge
132
BYD AUTO BYD Suri Maintenance & Repair Manual
133
BYD AUTO BYD Suri Maintenance & Repair Manual
134
BYD AUTO BYD Suri Maintenance & Repair Manual
135
BYD AUTO BYD Suri Maintenance & Repair Manual
136
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 4 Troubleshooting
play 2) Suspension arm ball joints
4.1 Troubleshooting Precautions (worn)
3) Intermediate shaft, sliding
4.1.1 Be sure to replace the parts carefully and yoke (worn)
correctly. The incorrect replacement may 4) Front wheel bearing (worn)
reduce the performance of steering system, 5) Steering gear (faulty)
even causing accidents. 1) Power steering fluid (low)
2) Steering knuckles (worn)
4.1.2 Precautions for supplemental restraint Abnormal
3) Power steering vane pump
system (SRS). This vehicle is equipped noise
(faulty)
with a supplemental restraint system 4) Steering gear (faulty)
(SRS), such as the driver safety airbag
and front passenger safety airbag. Failure 4.3 Inspection of Steering Wheel Free Travel
to carry out operations in the correct
sequence may cause the safety airbag to The inspection methods of the steering wheel
unexpectedly deploy during servicing and free travel are as follows:
cause a serious accident. Therefore, be
sure to read the precautions for 4.3.1 Stop the vehicle with the wheels straight
supplemental restraint system before ahead;
servicing (including parts removal or
installation, inspection or replacement). 4.3.2 Gently turn the steering wheel, and
check the steering wheel free travel.
4.2 Troubleshooting
The maximum free travel of the steering wheel
The troubleshooting chart may help find the should be 30 mm as shown in figure 4-1.
cause of malfunction. The numbers in the
chart indicate order of possible trouble cause.
Please check every part in order. Repair or
replace these parts when necessary.
Troubleshoot the steering system as shown in
table 1-1.
137
BYD AUTO BYD Suri Maintenance & Repair Manual
Is the pressure 7,500~8,500 kPa or less? 4.4.6 Check if the oil cylinder piping deforms.
No-The power steering pump is faulty. 4.4.7 Check if the gear racks are bent.
4.4.4 Use a spring balance to measure power Yes--Replace the power steering gear.
assist in the left and right directions
respectively. No--The valve is faulty. Replace the
steering gear.
Are both measured values less than 29 N?
138
BYD AUTO BYD Suri Maintenance & Repair Manual
139
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 5-2
5.2 Removal and Installation of Steering 5.2.1.5.2 Remove the set bolts of the steering
Wheel, Steering Column and Universal Joint wheel with 14# sleeve as shown in figure 5-3.
Assembly
140
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 5-3
Fig. 5-4
141
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 5-7
Fig. 5-8
142
BYD AUTO BYD Suri Maintenance & Repair Manual
5.2.2.3.2 Loosen the angle adjusting handle of 5.2.2.7 Install the clock spring
steering column, align 2 installation holes Make sure the front wheels are straight
of the upper mounting bracket and install 2 ahead. Install the clock spring, engage the
nuts. snap-fit and connect the connector.
5.2.2.3.3 Tighten the bolt at the lower 5.2.2.8 Install the combination switch protector
mounting point to 35 Nm, and tighten the
nut at the upper mounting point to 25 Nm. 5.2.2.8.1 Install the lower protector, and
tighten 3 set bolts.
2.17.4.2.1 Connect the steering shaft lock
connector. 5.2.2.8.2 Install the upper protector, and attach
it to the lower protector.
5.2.2.4 Connect the countershaft and steering
gear input shaft 5.2.2.9 Center the clock spring
143
BYD AUTO BYD Suri Maintenance & Repair Manual
Notice: The clock spring may be damaged due 5.2.2.11.1 Connect the connector.
to incorrect installation. Therefore, make sure
to center the clock spring. When centering it, 5.2.2.11.2 Align the DAB module, and tighten
first turn the clock spring fully to the left, and the set bolts on both sides to 8.8 Nm.
then to the right and count the number of full
turns. Next, turn it to the left for haft of the total Notice:
turns (if the total number of turns is 7, turn it
back for 3.5 turns) so that the side with 5.2.2.11.2.1 Do not use safety airbag parts
connector on the clock spring faces upward. removed from another vehicle. When
See figure 5-13. replacing parts, be sure to use the new
ones.
144
BYD AUTO BYD Suri Maintenance & Repair Manual
145
BYD AUTO BYD Suri Maintenance & Repair Manual
146
BYD AUTO BYD Suri Maintenance & Repair Manual
Model 476ZQA
147
BYD AUTO BYD Suri Maintenance & Repair Manual
System capacity: 1 L
Fig. 8-2
Fig. 8-1
148
BYD AUTO BYD Suri Maintenance & Repair Manual
2.5 ~ 5.5 mm
Model 473
149
BYD AUTO BYD Suri Maintenance & Repair Manual
Model 476ZQA
150
BYD AUTO BYD Suri Maintenance & Repair Manual
151
BYD AUTO BYD Suri Maintenance & Repair Manual
Precautions:
152
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 11-3
153
BYD AUTO BYD Suri Maintenance & Repair Manual
H E
B
Fig. 11-6
Fig. 11-4
C
D
Fig. 11-7
Fig. 11-5
Fig. 11-8
154
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 12-2
Fig. 12-1
Fig. 12-3
155
BYD AUTO BYD Suri Maintenance & Repair Manual
12.9 Center the clock spring as follows: Rotate stationary point to another to and fro
the clock spring clockwise until it cannot be several times to heat the steering fluid.
turned, and then rotate it counterclockwise Check the power steering gear for leakage
(about 3.5 turns) until the arrow on the (Refer to Section 6 of the chapter).
label points upward. Loosely install the
steering wheel (Refer to Section 14 of the 12.11.2 Check the turning angle of the steering
chapter). wheel. If the left and right turning angles
are not equal (the steering wheel and gear
12.10 Fill the power steering fluid in the rack are not centered), remove and center
system. Discharge air from the system the steering wheel (Center the steering
(Refer to Section 7 of the chapter). wheel while slowly driving the vehicle in a
straight line), and then fix the steering
12.11 Perform the following checks after wheel.
installation
Inspect the toe-in and perform the four
12.11.1 Start the engine and keep it idling. wheel alignment again when necessary
Turn the steering wheel from one (Refer to Section 1 of Chapter 16).
156
BYD AUTO BYD Suri Maintenance & Repair Manual
157
BYD AUTO BYD Suri Maintenance & Repair Manual
158
BYD AUTO BYD Suri Maintenance & Repair Manual
When the brake is applied, the brake pedal (b) Switch on the power supply for the whole
goes down/gradually fails. vehicle, raise the vehicle with the lifting
machine and turn four wheels by hand.
1.1.2.1 Power on the complete vehicle, start
the engine and wait for the vacuum Inspect the wheels for any brake dragging.
booster to be vacuumized. Yes Go to step 3
No Look for other reasons for the wear on
1.1.2.2 Stick a light-tight adhesive tape of 2 brake pads, a too high brake pedal or
inches on the lower part of the steering vehicle vibration.
wheel and draw a horizontal reference line
on the adhesive tape. (c) Switch off power supply for the whole
vehicle, pump the brake pedal several
1.1.2.3 Gently push down the brake pedal and times to deplete the vacuum in the brake
keep this state (about the pressure needed booster, and then turn the wheels again to
for slow motion of the vehicle with A/T), check for any brake dragging.
then release the parking brake.
Inspect the wheels for any brake dragging.
1.1.2.4 While stepping on the brake pedal, nip Yes Go to step 4
the end of the tape measure behind it. No Replace the vacuum booster
Then pull the tape measure upwards until
the steering wheel. Pay attention to where (d) Without removing the brake line, loosen
the tape measure is in alignment with the the bolts and separate the brake master
reference line you have drawn on the cylinder and booster. Then turn the wheels
piece of tape. to check for any brake dragging.
1.1.2.5 Apply a stable pressure on the brake Inspect the wheels for any brake dragging.
pedal and maintain this state for 3 minutes. Yes Go to step 5
No Check the adjustment of the brake
1.1.2.6 Observe the tape measure. pedal position switch and the free
travel of the brake pedal.
1.1.2.6.1 If the offset is less than 10 mm, the
brake master cylinder is up to standard. (e) Loosen the hydraulic piping on the brake
master cylinder, and then turn the wheels
1.1.2.6.2 If the offset is more than 10 mm, to check for any brake dragging.
replace the brake master cylinder.
Inspect the wheels for any brake dragging.
Brake pads wear away quickly, and the vehicle Yes Go to step 6
vibrates (after running for a long time) or the No Replace the brake master cylinder.
brake pedal is too high to step on.
(f) Loosen the screws of the exhaust valve on
(a) Drive the vehicle until there is brake each brake caliper, and then turn the
dragging, or until the brake pedal is too wheels to check for any brake dragging.
high to step on. In a long test drive, you
may need to step on the brake pedal 20 Inspect the wheels for any brake dragging.
159
BYD AUTO BYD Suri Maintenance & Repair Manual
Yes Dismantle the brake caliper from the cut-out in the insulator to the left side of the
wheel with brake dragging and repair brake pad (B).
the failure.
No Inspect the seal ring of brake master Standard pedal height (with the carpet
cylinder cover for any expansion, removed): MT: 141 mm
whether the brake fluid in the brake AT: 153 mm
master cylinder discolors or is
contaminated and whether there is any 1.3.1.3 Loosen the lock nut of the push rod (A),
damage to the brake pipe. and screw the push rod in or out using
pliers until the standard pedal height from
In case any of the above items is damaged, the floor is reached. After adjustment,
please make a replacement. If all of the above tighten the lock nut.
items are intact, replace the ABS (or ESP)
control unit. Notice: Do not adjust the height of the brake
pedal with the push rod pressed down.
1.3 Adjustment of Brake Pedal and Brake
Pedal Lamp Switch
160
BYD AUTO BYD Suri Maintenance & Repair Manual
(a) Remove the dashboard. (g) Adjust the brake pedal and brake pedal
position switch.
(b) Take off the lock pin (A), pin roll (B) and
spring (C). 1.5 Inspection and Adjustment of Parking
Brake
1.5.1 Inspection
161
BYD AUTO BYD Suri Maintenance & Repair Manual
Notice: After the maintenance of the rear 1.5.2.6 Make sure the parking brake is fully
wheel brake, loosen the adjusting nut of the applied when the parking brake handle is
parking brake. Start the engine and depress pulled up.
the brake pedal several times to adjust the
clearance of the self-adjusting parking brake 1.5.2.7 Reinstall the console cover.
prior to the adjustment of the parking brake.
Disassembly Diagram
1.5.2.1 Raise the rear of the vehicle and make
sure the vehicle is securely supported. 1.6 Parking Brake Cable Replacement
1.5.2.2 Remove the console cover (Refer to 1.6.1 Removal Steps for Hand Brake Cable
Removal and Installation of Auxiliary
Instrument Panel). 1.6.1.1 Remove the auxiliary instrument panel.
1.5.2.3 Pull the parking brake handle up a 1.6.1.2 Loosen the adjusting nut of the pull
tooth (A click sound can be heard). cable and remove the pull cable from the
balancer.
162
BYD AUTO BYD Suri Maintenance & Repair Manual
1.7 Brake System Bleeding maximum level (Upper level). Check the
brake caliper after bleeding.
Note
1.7.5 Replenish the brake fluid as specified.
1.7.1 The discharged brake fluid cannot be
reused. (a) Make sure the brake fluid level in the
reservoir is at the maximum level ("MAX"
1.7.2 Always use the original DOT 4 brake upper level).
fluid. Failure to use the specified brake
fluid may cause corrosion and shorten the (b) Connect a clean drain pipe to the bleed
life time of the system. screw.
1.7.3 Do not splash the brake fluid on the (c) The assistant slowly depresses the brake
vehicle, or the paint may be damaged. If pedal several times and then applies
the brake fluid has been splashed on the constant force.
paint, wash it off with water immediately.
(d) Loosen the bleed screws of the brake from
1.7.4 When bleeding, the level in the reservoir the left rear to release air in the system,
of brake master cylinder must be at the and then tighten the bleed screws.
163
BYD AUTO BYD Suri Maintenance & Repair Manual
Draining order
164
BYD AUTO BYD Suri Maintenance & Repair Manual
1.9.2.1 Continuity exists when the brake lever 1.11.3 Inspect the hose, pipe connectors and
is pulled up. connections for any leakage, and do
retightening where necessary.
1.9.2.2 Continuity does not exist when the
brake lever is pressed down. 1.11.4 Inspect the brake master cylinder and
ABS/ESP control unit for any damage or
1.10 Detection of Brake Fluid Level Switch leakage.
Check the continuity of terminal (1) when the
float is in lower and upper positions. Notice: Once the brake line is overhauled,
replace the brake line clamp.
1.10.1 When all the brake fluid is discharged
from the reservoir, the float goes down and 1.12 Brake Hose Replacement
there is continuity between terminals.
Note:
1.10.2 When the brake fluid is filled in the
reservoir to reach the "MAX" (Highest 1.12.1 Before fitting the brake hose again,
Level) line (A), the float will go up and the inspect all components. There should be
terminals are disconnected. no dust or other foreign objects on the
surfaces.
165
BYD AUTO BYD Suri Maintenance & Repair Manual
166
BYD AUTO BYD Suri Maintenance & Repair Manual
Special Notes
The components of brake pads
contain poisonous substances.
Frequent inhalation of dust and
detritus from such substances is 1.13.1.3 If the thickness of either brake pad is
hazardous to your health. less than the repair limit, you should
● Avoid inhaling dust and replace the whole pair of brake pads.
detritus from brake pads.
● No suction hoses or hair 1.13.2 Replacement
brushes can be used for the
cleaning of brake assembly. 1.13.2.1 Raise the front part of the vehicle.
Instead, a vacuum cleaner Support the vehicle with safety support at
should be used. a suitable location. Remove the front
wheels.
1.13.1 Detection
1.13.2.2 Remove the mounting bolts of the
1.13.1.1 Raise the front part of the vehicle. brake hose.
Support the vehicle with safety support at
a suitable location and remove front 1.13.2.3 Clamp the pin with the wrench and
wheels. remove the flange bolt (A). The pin should
be clamped carefully to avoid damage to
1.13.1.2 Check the thickness of inner and the protective sleeve of pin. Screw out the
outer brake pads. The thickness of brake caliper (B) upward. Inspect the hose
gaskets is not included. and protective sleeve of the pin for any
damage or aging.
Brake pad thickness:
Standard: 17.55-18.05 mm
Repair limit: 8.8 mm
Detection of inner brake pad
167
BYD AUTO BYD Suri Maintenance & Repair Manual
1.13.2.8 Clean and install the brake plate boot. 1.13.2.11 Turn the brake caliper (B) downward
until it is in place. Install the flange bolt
(C), clamp the pin with the wrench and
tighten the flange bolt with the specified
torque. Be careful not to damage the
protective sleeve.
168
BYD AUTO BYD Suri Maintenance & Repair Manual
108 Nm
1.14.1.5 Place the dial gauge near the brake 1.14.2.4 If the minimum value measured is
169
BYD AUTO BYD Suri Maintenance & Repair Manual
Required torque:
Notice: Use an antirusting agent during
Connecting bolt of brake caliper and steering
removal. Do not remove the brake disc from
knuckle: 95 Nm
the hub forcibly, or the brake disc may be
Connecting bolt of wheel hub unit and steering
damaged. Polish both disc surfaces evenly
knuckle: 95 Nm
before installing the brake disc to ensure
sufficient wear margin. Notice: 2 brake discs
1.16 Replacement of Vacuum Booster with
on the same axle should be replaced at the
Master Cylinder Assembly
same time.
Notice: Do not splash the brake fluid on the
vehicle, or the paint may be damaged. If the
1.15 Replacement of Front Wheel Hub Unit
brake fluid has been splashed on the paint,
Assembly
wash it off with water immediately.
Remove the front wheel hub unit assembly
a Remove the battery assembly of the front
and fender:
compartment;
(a) Raise the vehicle;
b Remove the air filter assembly of the front
compartment;
(b) Remove the front wheels;
c Remove the wiper assembly;
(c) Remove the front brake caliper (B);
d Remove the vent cover assembly;
(d) Remove the front brake disc (A);
e Remove the wiper motor assembly;
(e) Loosen the bolt (C), and remove the front
hub unit assembly (E) and fender (D);
f Remove the gutter channel assembly;
(f) Perform installation in the reverse order of
g Open the reservoir cover, and drain the
removal.
brake fluid from the reservoir of the brake
master cylinder;
Take off the fixing pin roll and lock pin, and
then remove the connecting nut (A) of the
vacuum booster and brake pedal;
170
BYD AUTO BYD Suri Maintenance & Repair Manual
171
BYD AUTO BYD Suri Maintenance & Repair Manual
1.18.1 Detection
Standard: 14.85-15.35 mm
Repair limit: 8.1 mm
1.18.2 Replacement
172
BYD AUTO BYD Suri Maintenance & Repair Manual
1.19.1 Run-out
173
BYD AUTO BYD Suri Maintenance & Repair Manual
thoroughly and get rid of all rust and with an interval of about 45°between each
corrosion. two adjacent points. If the minimum value
measured is less than the repair limit,
1.19.1.4 Fit suitable flat washers (A) and replace the brake disc.
wheel nuts, and tighten the nuts with Brake disc thickness:
specified torques to make the brake disc Standard: 9.9-10.1 mm
touch the wheel hub closely. Repair limit: 8 mm
Maximum Deviation of Brake Disk
Parallelism: 0.05 mm
1.19.2.1 Raise the rear part of the vehicle. 1.20.1 Raise the vehicle;
Support the vehicle with the safety support
at a suitable location. Remove rear 1.20.2 Remove the rear wheels;
wheels.
1.20.3 Remove the wire harness of the rear
1.19.2.2 Remove the brake pad. wheel speed sensor;
1.19.2.3 Use a micrometer to measure the 1.20.4 Loosen the bolt (A), and remove the
thickness of the brake disc at 8 points 10 rear brake caliper (B);
mm from the outer edge of the brake disc
174
BYD AUTO BYD Suri Maintenance & Repair Manual
95 Nm
175
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1 Inspect the inner dust cover (A) and outer 1.2 Rotate the half shaft by hand to make sure
dust cover (B) on the half shaft (C) for any the outer spine (E) and inner spine of the
cracks, damage, grease leakage and differential are not engaged loosely.
inspect the dust cover clamp (D) for
looseness. If any defect is found, replace 1.3 Make sure there is no distortion, corrosion
the dust cover and dust cover clamp. or cracks on the half shaft, otherwise the
half shaft should be replaced.
176
BYD AUTO BYD Suri Maintenance & Repair Manual
2.4 Remove the split pin (B) from the half shaft
nut (A), and then remove the nut (A).
2.7 Pry out the inner ball cage (A) from the
differential with a crow bar, and remove the
half shaft as an assembly. Do not pull the
half shaft (B) forcibly, as the inner ball cage
dust cover may be broken. Pull out the half
shaft directly after the inner ball cage (A) is
pried out with a crow bar to avoid damage
to the oil seal.
2.7.1 Left half shaft
177
BYD AUTO BYD Suri Maintenance & Repair Manual
178
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1 Inspect the inner dust cover (A) and outer 1.2 Rotate the half shaft by hand to make sure
dust cover (B) on the half shaft (C) for any the inner spine (E) and outer spine of the
cracks, damage, grease leakage and differential are not engaged loosely.
inspect the dust cover clamp (D) for
looseness. If any defect is found, replace 1.3 Make sure there is no distortion, corrosion
the dust cover and dust cover clamp. or cracks on the half shaft, otherwise the
half shaft should be replaced.
179
BYD AUTO BYD Suri Maintenance & Repair Manual
2.4 Remove the split pin (C) from the half shaft
nut (B), and then remove the nut (B) and
washer (A).
2.7 Pry out the inner ball cage (A) from the
output shaft of the transmission with a
crow bar, and remove the half shaft as an
assembly. Do not pull the half shaft (B)
forcibly, as the inner ball cage dust cover
may be broken. Pull out the half shaft
directly after the inner ball cage (A) is pried
out with a crow bar.
180
BYD AUTO BYD Suri Maintenance & Repair Manual
181
BYD AUTO BYD Suri Maintenance & Repair Manual
182
BYD AUTO BYD Suri Maintenance & Repair Manual
1 - Split pin (Part No. 12); d. Fix the connector at the pull cable gear
2 - E-shape clamp (Part No. 14); shift mechanism on the gear shift
3 - Hexagon combination bolt (Part No. 13); mechanism holder, and attach the E-shape
4 - Pull cable support (Part No. 16, 17, 18); clamp (Part No. 14)
5 - Rubber dust cover and metal cover plate
assembly (Part No. 15); e. Clamp the connector on the swinging arm
6 - Combination bolt (Part No. 10); of the gear shift mechanism, and clamp
7 - Gear shift operating mechanism assembly the split lock pin at the same time.
(Part No. 1, 2, 3, 4, 5, 6, 7, 8, 9, 11);
1.3 Installation of Gear Shift Operating
1.2. Installation of Gear Shift Cable: Mechanism:
a. Fix the pull cable support on the body (Part Install each bolt in the correct mounting hole
No. 16, 15 Nm); after the gear shift mechanism is adjusted.
Pretension each bolt by applying small torque,
b. Fix the rubber pull cable dust cover and and then tighten the bolt (22 Nm) diagonally.
metal cover plate assembly (Part No. 15) Install the auxiliary instrument panel and
on the body with the hexagon combination clamp the hog ring of the dust cover.
bolt (Part No. 13, 15 Nm);
183
BYD AUTO BYD Suri Maintenance & Repair Manual
Fix the pull cable bracket on the body with the Install each bolt in the correct mounting hole,
hexagon flange nut (2 in the figure), and install pretension each bolt by applying small torque,
the sealing gasket to the body; and then tighten the bolts diagonally to a
Fix the pull cable on the transmission support torque of 22 Nm.
with the spring plate (as shown by 5), clamp
184
BYD AUTO BYD Suri Maintenance & Repair Manual
Figure 3
Fig. 1
Assembly:
3.1 Removal and Installation of Gear Shift
Fix the gear shift cable on the gear shift
Operating Mechanism
mechanism as shown in elliptical frame 1 and
3 of figure 3, and then tighten 4 hexagon
Removal:
flange bolts on the floor as shown in figure 2 to
20 Nm.
Remove 4 hexagon flange bolts connected to
the gear shift mechanism floor as shown in
3.2 Removal and Installation of Gear Shift
figure 2.
Cable
Removal:
A. Remove the connection of the gear shift
cable and gear shift mechanism as shown
in figure 3;
B. Remove 3 hexagon flange nuts of gear
shift cable sealing gasket as shown in
figure 4;
Figure 2
Figure 4
185
BYD AUTO BYD Suri Maintenance & Repair Manual
Assembly:
Figure 5
Figure 6
186
BYD AUTO BYD Suri Maintenance & Repair Manual
187
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 1 Precautions
(c) EPB automatic pull up function: When the
ABS (Anti-lock Brake System) vehicle is turned off or the shift position is
in P, EPB will be pulled up automatically
and the indicator light in the meter will
come on.
(a) Electronic Parking Switch ESP functions when the engine is started.
Three functional modules (ABS, VDC and
TCS) and two value-added sub functions
(HHC and HBA) are integrated in ESP.
188
BYD AUTO BYD Suri Maintenance & Repair Manual
TCS can prevent the slippage of the If the vehicle is stuck in snow or mud, the
drive wheels during accelerating by ESP system may decrease the power
reducing the engine power. If necessary, output to the wheels from the engine. You
the brake will be applied to prevent the may need to turn off the system to free the
drive wheel spinning. Under unfavorable stuck vehicle.
conditions, TCS enables the vehicle to
start, accelerate and climb the hill easily. Restart ESP system after turning off the
engine
HHC (Hill-start Assist Control)
After turning off the ESP system, restarting
When the brake pedal is released, HHC the engine will automatically turn on the
can keep the brake pressure applied by ESP system again.
the driver for up to 2 seconds. So the
driver can switch the foot from brake pedal ESP system activation linked with vehicle
to the accelerator pedal to prevent the speed
vehicle from slipping on the hill.
If ESP system is turned off, the vehicle will
HBA (Hydraulic Brake Assist) become extremely unstable when the
vehicle speed increases and exceeds the
When the driver depresses the brake threshold (80Km/h). At this time the ESP
pedal quickly, HBA will determine the system will start automatically.
vehicle is in an emergency. Increase the
brake pressure to the maximum quickly to 1.1 Precautions for Repair and Diagnosis
enable ABS, so as to shorten brake
distance effectively. ABS is a component related to driving
safety. When conducting repair and
When ESP system is operating diagnosis on it, observe the following
diagnosis precautions in addition to
If there is risk of slippage or reversing general safety and preventive measures.
when starting the vehicle on a slope, or
any drive wheel is spinning, the ESP
indicator light flashes, indicating ESP
189
BYD AUTO BYD Suri Maintenance & Repair Manual
DTC is not
Go to step 9
output
2.1.5 Confirm and duplicate malfunction: simulate malfunction condition. Read DTC again.
Yes Intermittent
malfunction.
Go to step 7
No Eliminated malfunction.
Go to step 9
192
BYD AUTO BYD Suri Maintenance & Repair Manual
2.1.8 Perform troubleshooting in accordance with trouble code table. Go to step 10.
End
2.1.11 Prevent it from occurring again
193
BYD AUTO BYD Suri Maintenance & Repair Manual
License Plate
Owner Number
Name
Model
Contact
Chassis No.
Number
Date of
/ / Odometer km
Entry
Date of
/ /
Malfunction Occurrence
Condition Frequency of
Often Sometimes ( times/day)
Occurrence
194
BYD AUTO BYD Suri Maintenance & Repair Manual
Fuse
(c) Check ABS fuses -- 10 A, 25 A and 40A.
Fusible
Link
(d) Make sure the battery is fully charged.
(e) Check if the battery connection is corroded
or if the post is loose.
195
BYD AUTO BYD Suri Maintenance & Repair Manual
196
BYD AUTO BYD Suri Maintenance & Repair Manual
To cancel the speed limit, refer to Page 34 "4.3.6 Set/Unset Diagnostic Communication Speed
Limit"
197
BYD AUTO BYD Suri Maintenance & Repair Manual
198
BYD AUTO BYD Suri Maintenance & Repair Manual
Bosch ABS9 system Read system malfunctions Current DTC and history DTC
1 Read computer version 1. C0032XX (Current): can be read via "Read System
2 Read system Left front wheel sensor Malfunction" option. At this time,
malfunctions signal or circuit current and history DTCs can be
3 Clear the trouble malfunctions. cleared via "Clear Trouble
codes Codes" option.
199
BYD AUTO BYD Suri Maintenance & Repair Manual
Bosch ABS9 system Read system malfunctions If the system is normal, "System
1 Read computer is OK" appears.
version
2 Read system
malfunctions
3 Clear the trouble
codes
4 Read data flow
5 Off-line test routine
6 Set/unset diagnostic
communication speed
System is OK
limit
7 Change filling status
Note:
Under normal conditions,
the communication
between the diagnostic
tester and ABS ECU will
be interrupted forcibly
when the vehicle speed
exceeds a specified value
to ensure safety.
Press [↑] key to move up Press any key to return
Press [↓] key to move
down
Press [OK] key to execute
Press [Esc] key to exit
200
BYD AUTO BYD Suri Maintenance & Repair Manual
201
BYD AUTO BYD Suri Maintenance & Repair Manual
Displayed
Classification Item Normal condition Note
value/range
Left front Actual wheel See Page 34
0~350 km/h
wheel speed speed*
Left rear wheel Actual wheel See Page 34
0~350 km/h
Wheel Speed speed speed*
Signal Right front Actual wheel See Page 34
0~350 km/h
wheel speed speed*
Right rear Actual wheel See Page 34
0~350 km/h
wheel speed speed*
Analog Status Battery 0~+20.40 V 3.9 V~16.9 V
Voltage
Left front oil Power Related to ABS
inlet valve On/Off working condition:
Left front oil Power Pressure increase: Oil
outlet valve On/Off inlet valve - Power off
Right front oil Power Oil outlet
Digital Status Turn the vehicle
inlet valve On/Off valve - Power off
on: Power Off
Right front oil Power Pressure hold: Oil inlet
Other working
outlet valve On/Off valve - power
condition:
Left rear oil Power on Oil outlet
Depending on
inlet valve On/Off valve - Power
control
Left rear oil Power off
outlet valve On/Off Pressure decrease:
Right rear oil Power Oil inlet valve - Power
inlet valve On/Off on
Right rear oil Power Oil outlet
outlet valve On/Off valve - Power on
Braking light Power Depress the
status On/Off brake pedal:
Power on
Release the
brake pedal:
Power off
Return pump Power
motor status On/Off
Solenoid valve Power Turn the vehicle
relay status On/Off on: Power on
Hydraulic New ABS Filled completely New part will display
Filling Status regulator filling hydraulic and normal "New ABS Hydraulic
status unit has Unit"
202
BYD AUTO BYD Suri Maintenance & Repair Manual
been filled
and
normal/New
ABS
hydraulic
unit has
been filled
and
abnormal.
*: When the speed is less than 2.6 km/h and the vehicle is stationary, the diagnostic tester will
display O km/h.
Read data flow Wheel Speed Signal Read wheel speed sensor
signal data.
√1. Wheel speed signal Left front wheel speed: 8.2km/h Note:
□2. Analog status Right front wheel speed: 8.2km/h a. Please refer to Page
□3 Digital status Left rear wheel speed: 8.2km/h 34 "Set/Unset Diagnostic
□4. Hydraulic unit filling Right rear wheel speed: 8.2km/h Communication Speed
status Limit"
Press [↑] key to move up Press [F2] to print current contents b.* When the speed is
Press [↓] key to move Press [Esc] key to return less than 2.6 km/h and the
down vehicle is stationary, the
Press [OK] key to execute diagnostic tester will
Press [Esc] key to exit display O km/h.
□1. Wheel speed signal Battery Voltage: 12.2V Normal value: 9.3 V~17.5
√2. Analog status V.
□3. Digital status If it is not within the range,
□4. Hydraulic unit filling see Page 63~65.
status
Press [↑] key to move up Press [F2] to print current contents
Press [↓] key to move Press [Esc] key to return
down
Press [OK] key to execute
Press [Esc] key to exit
Read data flow Digital Status Read digital status data.
□1. Wheel speed signal Left front oil inlet valve: Power off Normal Value: See Page
□2. Analog status Left front oil outlet valve: Power off 11.
√3. Digital status Right front oil inlet valve: Power off
□4. Hydraulic unit filling Right front oil outlet valve: Power
status off
Left rear oil inlet valve: Power off
Left rear oil outlet valve: Power off
Right rear oil inlet valve: Power off
Right rear oil outlet valve: Power
off
Braking light status: Power on
Return pump motor status: Power
on
Solenoid valve relay status: Power
on
203
BYD AUTO BYD Suri Maintenance & Repair Manual
204
BYD AUTO BYD Suri Maintenance & Repair Manual
Off-line test routine Vacuumizing and The diagnostic tester does not support
Filling Test vacuumizing and filling test function.
√1. Vacuumizing and
Filling Test
2. Brake Bleeding (The diagnostic
3. Dynamic Test tester does not
4. Action Test support the function)
5. Wheel Speed Sensor
Test
Press [↑] key to move up Press any key to
Press [↓] key to move return
down
Press [OK] key to execute
Press [Esc] key to exit
205
BYD AUTO BYD Suri Maintenance & Repair Manual
4.3.5.2.1 Preparation
Normal
Off-line test routine Brake Bleeding (a) Please note the prompt
on the diagnostic tester.
1. Vacuumizing and Preconditions and precautions:
Filling Test l. Two persons are needed for Press [OK] key to go to next
√2. Brake Bleeding the operation; step.
3. Dynamic Test 2. Fill 2 bar pressure in the
4. Action Test brake fluid reservoir of the
5. Wheel Speed vehicle;
Sensor Test 3. Life the vehicle safely;
206
BYD AUTO BYD Suri Maintenance & Repair Manual
207
BYD AUTO BYD Suri Maintenance & Repair Manual
(b) Precautions:
Next
4.3.5.2.3 Drain the first circuit using left rear wheel drain screw
208
BYD AUTO BYD Suri Maintenance & Repair Manual
vehicle;
3. Lift the vehicle safely;
4. Turn on the vehicle and start
the engine as necessary;
5. ABS system has no
malfunction; Return pump
motor stops operating;
Solenoid valve relay is on.
6. After pressing [OK] key, the
service personnel in the
vehicle should depress and
release the brake pedal every
3 seconds and generates a
pressure of higher than 15
bar.
Press [OK] key to execute Press [OK] key to
Press [Esc] key to exit execute
Press [Esc] key to
exit
Left rear brake bleeding Left rear brake (c) Press [OK] key to enter
bleeding bleeding procedure.
Release the drain screw of the left Bleeding left rear
rear wheel cylinder while pressing brake…
[OK] key Please wait for 25
seconds
Press [OK] key to execute Press [OK] key to
Press [Esc] key to exit execute
Press [Esc] key to
exit
(d) The service personnel in the
vehicle should release and
depress the brake pedal
every 3 seconds during the
entire process.
(e) The service personnel
outside the vehicle should
release the drain screw of the
left rear wheel immediately.
209
BYD AUTO BYD Suri Maintenance & Repair Manual
Torque: 12~14 Nm
Next
4.3.5.2.4 Drain the first circuit using left front wheel drain screw
210
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
4.3.5.2.5 Drain the first/second circuit using right front wheel drain screw
211
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
4.3.5.2.6 Drain the first/second circuit using right rear wheel drain screw
212
BYD AUTO BYD Suri Maintenance & Repair Manual
Torque: 12~14 Nm
Next
213
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
Precautions
214
BYD AUTO BYD Suri Maintenance & Repair Manual
Off-line test routine Front wheel dynamic test Role: Check if the regular brake system
1. Vacuumizing Preconditions and operates normally.
and Filling Test precautions: Normal: Press [OK] key to go to
2. Brake Bleeding (a) Drive the vehicle until next step
√3. Dynamic Test front wheels are on the
4. Action Test brake test bed which Abnormal: Press [Esc] key to exit
5. Wheel Speed can drive two wheels
Sensor Test separately
Check and repair the regular brake
(b) Turn on the power system malfunction:
supply of the brake test
bed and drive the (a) Brake system malfunctions
wheels
(b) Brake booster has no vacuum
(c) Depress the brake pressure
pedal until the
displayed brake force (c) When deterioration or air resistance
value of the brake test occurs
bed is:
Left front wheel: (d) Gross vehicle weight increases due
1500N<F<2000N to passenger or load weight
Right front wheel:
1500N<F<2000N (e) Brake shoe friction sheet may be
wet
215
BYD AUTO BYD Suri Maintenance & Repair Manual
216
BYD AUTO BYD Suri Maintenance & Repair Manual
Front wheel ABS dynamic test Role: Check if right front wheel solenoid valve in ABS and
Brake pedal: return pump motor operate normally
Firmly depressed Normal: Press [OK] key to go to next step
ABS hydraulic unit status:
Left front wheel: Pressure
increase Abnormal: Press [Esc] key to exit
Right front wheel: Pressure Check:
decrease
Observe the displayed brake (a) ABS hydraulic unit with ECU
force value: (b) Brake line and its connection
Left front wheel: 1000N<F
Right front wheel: 0N<F<400N Role: Check if solenoid valves of both front
wheels in ABS operate normally
Press [OK] key to perform
next step
Press [Esc] key to exit Normal: Press [OK] key to go to next step
Front wheel ABS dynamic test
Abnormal: Press [Esc] key to exit
Brake pedal: Check:
Firmly depressed (a) ABS hydraulic unit with ECU
ABS hydraulic unit status:
Left front wheel: Pressure Role: Check if solenoid valves of both front wheels in ABS
increase operate normally and if brake drag occurs
Right front wheel: Pressure Normal: Press [OK] key to go to next step
increase
Observe the displayed brake Abnormal: Press [Esc] key to exit
force value: Check:
Left front wheel: 1000N<F
Right front wheel: 1000N<F (a) ABS hydraulic unit with ECU
Press [OK] key to perform (b) Brake drag
next step
Press [Esc] key to exit Front wheel ABS dynamic test ends.
Front wheel ABS dynamic test Please stop brake test bed and drive the vehicle off the brake
Brake pedal: test bed.
Release Press [OK] key to read test results
ABS hydraulic unit status:
Solenoid valve stops Difference between left and right wheels is within 5%
operating Normal:
Observe the displayed brake Press [OK] key to go to next step
force value:
Left front wheel: 0N<F<200N
Right front wheel: 0N<F<200N Abnormal: Press [Esc] key to exit
Press [OK] key to perform
next step Check:
Press [Esc] key to exit
Front wheel ABS dynamic test 1. Wheel speed sensor body
Front wheel ABS dynamic test 2. Wheel speed sensor is incorrectly connected
ends.
Please stop brake test bed 3. If wheel speed sensor signal is interrupted
and drive the vehicle off the
brake test bed. 4. If the clearance between wheel speed sensor and gear
Press [OK] key to perform ring is too wide (Displacement caused by vibration)
next step
Press [Esc] key to exit 5. If wheel speed sensor and holder are corroded
Dynamic test result
217
BYD AUTO BYD Suri Maintenance & Repair Manual
Left front wheel speed 6 Gear ring malfunction (dirty, or tooth on the gear ring are
variation: 5km/h damaged)
Right front wheel speed
variation: 5km/h 7 Tire: size, pressure, tread pattern and depth
Left rear wheel speed
variation: 0km/h 8 Brake test bed: power train, cylinder condition, etc.
Right rear wheel speed
variation: 0km/h
Press [F2] key to print current
contents
Press [OK] key to perform
next step
Press [Esc] key to exit
218
BYD AUTO BYD Suri Maintenance & Repair Manual
Brake pedal:
(a) Brake system malfunctions
Firmly depressed
219
BYD AUTO BYD Suri Maintenance & Repair Manual
Check:
Check:
220
BYD AUTO BYD Suri Maintenance & Repair Manual
Check:
If abnormal, check:
221
BYD AUTO BYD Suri Maintenance & Repair Manual
222
BYD AUTO BYD Suri Maintenance & Repair Manual
Role:
Off-line test routine
Bosch ABSS system Perform component operation test on the
1. Vacuumizing and Filling
1.
2.
Read computer version
Read
malfunction
computer
2.
Test
Brake Bleeding
actuator controlled by ABS to determine if
3.
4.
5.
Clear the trouble codes
Read data flow
Off-line test routine
3.
4.
5.
Dynamic Test
Action Test
Wheel Speed Sensor Test
it can operate.
6. Set/unset diagnostic
communication speed limit
7. Change filling status
Press{↑}key to move up
Press{↓}key to move down
Press{↑}key to move up
Press{↓}key to move down
4.3, 5.4.1 ABS warning lamp operation
Press{ok}key to execute
Press{ESC}key to exit
Press{ok}key to execute
Press{ESC}key to exit test
Preconditions:
Abnormal:
223
BYD AUTO BYD Suri Maintenance & Repair Manual
Use [↑] and [↓] key to select and then press [OK]
1. ABS warning lamp ERD warning lamp
2. ERD warning lamp On
3. Return pump motor relay Off
4. Left front oil inlet valve
5. Left front oil outlet valve key to confirm.
6. Right front oil inlet valve
7. Right front oil outlet valve
8. Right rear oil inlet valve
9. Right rear oil outlet valve
10. Left rear oil inlet valve
11. Left rear oil outlet valve
Preconditions:
12. Overheat protection
13. Cut off solenoid valve relay
Press{↑}key to move up
Press{↑}key to move up
(a) Turn the vehicle on
Press{↓}key to move down
Press{ok}key to execute
Press{ESC}key to exit
Press{↓}key to move down
Press{ok}key to execute
Press{ESC}key to exit
(b) Battery Voltage > 11 V
(c) Diagnostic tester is correctly connected and
communication is normal
(d) The brake fluid in the brake fluid reservoir is
sufficient and level sensor is normal
(e) The parking brake is released
Description:
Normal:
Press{↑}key to move up Press{↑}key to move up (a) Check EBD warning lamp circuit
Press{↓}key to move down Press{↓}key to move down
Press{ok}key to execute
Press{ESC}key to exit
Press{ok}key to execute
Press{ESC}key to exit (b) Check the meter and bulb of EBD warning
lamp
(c) Check ABS hydraulic unit with ECU
Use [↑] and [↓] key to select and then press [OK]
key to confirm.
Preconditions:
224
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal:
Abnormal:
225
BYD AUTO BYD Suri Maintenance & Repair Manual
Component Operation Test Left front oil inlet valve Use [↑] and [↓] key to select and then press [OK]
1. ABS warning lamp Left front oil inlet valve operation test
Power On
key to confirm.
2. ERD warning lamp Power Off
3. Return pump motor relay
4. Left front oil inlet valve
5. Left front oil outlet valve Preconditions:
6. Right front oil inlet valve
7. Right front oil outlet valve
8. Right rear oil inlet valve
9. Right rear oil outlet valve
10. Left rear oil inlet valve
(a) Turn the vehicle on
11. Left rear oil outlet valve
12. Overheat protection
(b) Battery Voltage > 11 V
13. Cut off solenoid valve relay
(c) Diagnostic tester is correctly connected and
Press{↑}key to move up
Press{↓}key to move down
Press{↑}key to move up
Press{↓}key to move down communication is normal
Press{ok}key to execute Press{ok}key to execute
Press{ESC}key to exit Press{ESC}key to exit
Normal:
Abnormal:
226
BYD AUTO BYD Suri Maintenance & Repair Manual
Press{ok}key to execute
Press{ESC}key to exit
227
BYD AUTO BYD Suri Maintenance & Repair Manual
Front wheel speed sensor test (g) Generally, the cylinder needs to rotate 3 to
5 turns
(h) Stop the brake test bed
Front wheel speed sensor test
ends. (i) Press [OK] key to read test results
Press{ok}key to read test
results
Press{ok}key to continue
(j) Normal value
Press{ESC}key to exit
Press{ok}key to execute
Press{ESC}key to exit
228
BYD AUTO BYD Suri Maintenance & Repair Manual
Rear wheel speed sensor test (n) Then press [OK] key to perform test
results
Performing wheel speed sensor test (o) Generally, the cylinder needs to rotate 3 to 5
turns
(p) Stop the brake test bed
(q) Press [OK] key to read test results
229
BYD AUTO BYD Suri Maintenance & Repair Manual
Role:
Bosch ABSB system
Set/unset diagnostic communication
speed limit
For safety, do not diagnose ABS ECU when the
1. Computer version
2. Read system malfunctions
3. Clear the trouble codes
Under normal conditions,
communication between diagnostic
tester and ABS ECD will be
the
vehicle speed exceeds 10 km/h.
4. Read data flow interrupted forcibly when the vehicle
5. Off-line test routine speed exceeds a specified value to
6. Set/unset diagnostic ensure safety
communication speed limit
7. Change filling status
The function will cancel the limit. After
the vehicle speed exceeds the limit,
the wheel speed signal can be read
When some special repair and diagnosis are
Note: Under normal conditions, the
communication between diagnostic
tester and ABS ECD will be
and ABS stops operating, causing the
safety performance to reduce
Do you want to continue the test?
needed, the limit can be cancelled.
interrupted forcibly when the vehicle Note: When exiting the diagnosis, the
speed exceeds a specified value to diagnostic communication speed limit
ensure safety function will resume automatically.
Setting:
Special Notes:
Press{F2}key to print current contents
Press{ESC}key to return
230
BYD AUTO BYD Suri Maintenance & Repair Manual
Description:
Bosch ABSB system
Change filling status
1 After ABS hydraulic regulator with ECU
1. Computer version
ABS hydraulic unit
is replaced, the operation must be
2. Read system malfunctions
3. Clear the trouble codes
4. Read data flow Filled completely and normal performed to prevent unexpected
5. Off-line test routine
6. Set/unset diagnostic communication speed
limit
Filled completely and abnormal
accidents.
7. Change filling status
2 It only allows "New ECU" to be
changed to "Filled completely and
Note: Under normal conditions, the
communication between diagnostic tester and
ABS ECD will be interrupted forcibly when the
normal".
vehicle speed exceeds a specified value to
ensure safety 3 Though the data flow displays "Filled
completely and normal", actually it does
Press{↑}key to move down Press{↑}key to move down
not indicate hydraulic regulator is filled
Press{↓}key to move up
Press{↓}key to move up
Press{ok}key to execute
Press{ESC}key to exit
Press{ok}key to execute
Press{ESC}key to exit
completely and normal.
231
BYD AUTO BYD Suri Maintenance & Repair Manual
Description:
If no malfunction is detected during elements inspection, check ABS hydraulic regulator with
ECU and its earth point/power cables.
If a DTC is memorized, check the circuit indicated by the DTC. Refer to the applicable chapter
for the specific repair procedure of each DTC.
When two or more DTCs are memorized, first check the DTC and circuit related to the
malfunction.
Pag
DTC Detection Item Possible Fault Area
e
Left front wheel speed sensor signal Left front wheel speed sensor
C003108 malfunction Left front wheel speed sensor circuit
48
C003204 Left front wheel speed sensor circuit Left front wheel speed sensor gear
malfunction ring
Right front wheel speed sensor
Right front wheel speed sensor
Right front wheel speed sensor
C003408 signal malfunction
circuit 48
C003504 Right front wheel speed sensor
Right front wheel speed sensor
circuit malfunction
gear ring
Left rear wheel speed sensor signal Left front wheel speed sensor
C003708 malfunction Left front wheel speed sensor circuit
48
C003804 Left rear wheel speed sensor circuit Left front wheel speed sensor gear
malfunction ring
Right front wheel speed sensor
C003A0 Right rear wheel speed sensor
Right front wheel speed sensor
8 signal malfunction
circuit 48
C003B0 Right rear wheel speed sensor
Right front wheel speed sensor
4 circuit malfunction
gear ring
Left front oil inlet valve of hydraulic
C001004 ABS hydraulic regulator with ECU 50
regulator malfunction
Left front oil outlet valve of hydraulic
C001104 ABS hydraulic regulator with ECU 50
regulator malfunction
Right front oil inlet valve of hydraulic
C001404 ABS hydraulic regulator with ECU 50
regulator malfunction
Right front oil outlet valve of
C001504 ABS hydraulic regulator with ECU 50
hydraulic regulator malfunction
Left rear oil inlet valve of hydraulic
C001804 ABS hydraulic regulator with ECU 50
regulator malfunction
Left rear oil outlet valve of hydraulic
C001904 ABS hydraulic regulator with ECU 50
regulator malfunction
C001C0 Right rear oil inlet valve of hydraulic
ABS hydraulic regulator with ECU 50
4 regulator malfunction
232
BYD AUTO BYD Suri Maintenance & Repair Manual
233
BYD AUTO BYD Suri Maintenance & Repair Manual
234
BYD AUTO BYD Suri Maintenance & Repair Manual
I
llustration
1 Brake Pedal
2 Vacuum Booster
3 Brake Master Cylinder
4 Brake Fluid Reservoir
5 ESP Control Unit
6 Brake Hose
7 Brake Wheel Cylinder with Brake
8 Wheel Speed Sensor
9 ABS Control Unit
10 ABS Warning Lamp
11 Diagnostic Socket
235
BYD AUTO BYD Suri Maintenance & Repair Manual
236
BYD AUTO BYD Suri Maintenance & Repair Manual
237
BYD AUTO BYD Suri Maintenance & Repair Manual
Wire Harness
Side
238
BYD AUTO BYD Suri Maintenance & Repair Manual
239
BYD AUTO BYD Suri Maintenance & Repair Manual
Applicable for front wheel drive BYD Sari vehicles with brake lines in a diagonal direction
240
BYD AUTO BYD Suri Maintenance & Repair Manual
241
BYD AUTO BYD Suri Maintenance & Repair Manual
Refere
Trouble Symptom Inspection Area nce
Page
If the malfunction still exists when the following 1~4 are
normal, replace ABS hydraulic regulator with ECU: 10
1. Read trouble codes and confirm malfunction memory
ABS does not work 2. Start button power UZ (Pin 32) circuit 37
3. Wheel speed sensor circuit 30, 42
4. Check ABS with diagnostic tester. If abnormal, check if the
22
brake line leaks
If the malfunction still exists when the following 1~4 are
normal, replace ABS hydraulic regulator with ECU:
10
1. Read trouble codes and confirm no malfunction is
memorized
2. Wheel speed sensor circuit 30, 42
ABS does not work
3. Check ABS with diagnostic tester. If abnormal, check if the
well 6
brake line leaks
4. Read "Hydraulic Regulator Filling Status" with diagnostic
11
tester
5. Make sure the mounting bracket is secured correctly
(Driving comfort will reduce)
1. ABS warning lamp circuit 27, 37
ABS warning lamp
2. ABS hydraulic regulator with ECU 60
is abnormal
3. Battery voltage is low 62
If the malfunction still exists when the following 1~3 are
normal, replace ABS hydraulic regulator with ECU: 37
Trouble codes
1. ABS hydraulic regulator with ECU power/ground wire
cannot be read
2. DIAGK (Pin 17) wire of ABS hydraulic regulator with ECU 37
3. Diagnostic tester
Description:
If one of the following conditions occurs,
the malfunction is intermittent.
a The malfunction does not always occur;
b The malfunction cannot be duplicated;
c There is no current DTC, but history DTC
exists in memory.
242
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspecti
Operation
on
· Perform "Preliminary Inspection"
· Collect information about intermittent malfunction from the customer, such as:
· The speed range when the malfunction occurs.
· Does the malfunction occur after the after sales electric device is used?
· Does the malfunction occur when driving on rough or slippery roads?
· If the wheel speed sensor malfunctions only when driving on the slippery road,
Prelimin
check whether water enters the wheel speed sensor circuit. If the DTC is not
ary
output, perform the following operations to simulate the slippery road:
1. Mix 2 teaspoons of salt and 35 ml of water.
2. Spray the saline water on the suspected area.
3. Road test the vehicle on various roads.
4. Accelerate the vehicle to more than 40 km/h for at least 30 seconds.
5. If a current DTC is set by the suspected wheel speed sensor, refer to the
applicable trouble code table.
Check the intermittent malfunction using diagnostic tester as follows:
· Observe the data flow of detected circuit on diagnostic tester while swinging
the suspected wire harness and connector of ABS components. If the reading
on diagnostic tester fluctuates during the operation, check if the circuit
Check connection is loose.
with · Road test the vehicle under the conditions in which intermittent malfunctions
diagnos occur, and let the assistant observe the suspected specifications on the
tic tester diagnostic tester.
· When the malfunction occurs, capture and store the data using the snapshot
mode. The stored data can be played at low speed to assist diagnosis. The
signals can also be detected with an oscilloscope.
· Operate the suspected ABS components using the component test function of
diagnostic tester to test the operation of these components.
The following conditions may cause the warning lamp to illuminate intermittently
without setting the trouble codes.
· Electro Magnetic Interference (EMl) caused by fault components (for example,
relay).
· The after sales electric devices are abnormal or installation position is
incorrect, such as:
Warning
· Mobile phone
lamp
· Theft deterrent siren
· Light
· Radio equipment
· Audio amplifier
· The warning indicator light circuit is short to ground intermittently.
· ABS hydraulic regulator with ECU or meter ground point is loose.
· The speed is slow.
· Visually check if the wheel speed sensor and magnetic ring is loose, damaged,
and dirty or installed incorrectly. Replace the damaged component, remove
Wheel any foreign materials or fix the loose component.
Speed · Check if the route of front wheel speed sensor wire is correct. Make sure the
Sensor front wheel speed sensor wire is not close to the distributor.
· With help of the assistant, monitor the displayed wheel speed sensor data on
the diagnostic tester while road testing the vehicle. Check if there is wheel
speed sensor displaying abnormal speed range.
Addition · Check if the after sales electric devices are installed correctly. For example:
al test · Mobile phone
· Theft deterrent siren
243
BYD AUTO BYD Suri Maintenance & Repair Manual
· Light
· Radio equipment
· Audio amplifier
· Check if there is Electro Magnetic Interference (EMI) caused by fault
components (for example: when the relay or solenoid coil is energized).
· When the relay or solenoid coil is energized, test the air conditioner
compressor clutch and some relays containing clamp diode or resistance.
· When the relay or solenoid coil is energized, check if the generator rectifier
bridge has malfunction which causes air conditioner noise to enter the
electronic control unit circuit.
244
BYD AUTO BYD Suri Maintenance & Repair Manual
DTC C003A08 Right rear wheel speed sensor signal or circuit malfunction
Circuit description:
245
BYD AUTO BYD Suri Maintenance & Repair Manual
246
BYD AUTO BYD Suri Maintenance & Repair Manual
Test
DTC Setting Condition Possible Fault Area
Condition
When the following malfunctions
1 The connectors are
occur for more than 200 ms:
defective, dirty or wet
C003108 2 The wheel speed sensor
All working 1 The sensor circuit is open, short to
C003408 connectors are loose or
conditions ground or power supply
CO03708 broken
after the 2 The sensor connectors are loose
C003A08 3 The sensor circuit is short
vehicle is
CO24501 to ground
turned on At this time, the wheel speed sensor
4 The insulating layer of
current is out of range: the current is
sensor circuit is damaged
less than 1.1 mA or more than 39 mA
247
BYD AUTO BYD Suri Maintenance & Repair Manual
248
BYD AUTO BYD Suri Maintenance & Repair Manual
249
BYD AUTO BYD Suri Maintenance & Repair Manual
a Malfunction Confirmation
(a) Connect diagnostic tester to read and
record DTCs.
(b) Clear DTCs: Follow the instructions on
the diagnostic tester.
Note:
Yes Go to step 11
No Go to step 4
250
BYD AUTO BYD Suri Maintenance & Repair Manual
c Appearance Inspection
(a) Inspect the circuit from ABS hydraulic
regulator with ECU to wheel speed
sensor and all connectors. Replace as
necessary.
(b) Check the tires.
1 Check the specification of all tires,
and replace as necessary.
Standard: 20s/05R1594V
Optional: 205`60 R16 92V
2 Check if the tire and hub are
damaged. Repair or replace as
necessary.
3 Check the pressure of all tires, and
correct as necessary.
No
Normal Value:
Yes Go to step 10
251
BYD AUTO BYD Suri Maintenance & Repair Manual
d Use the diagnostic tester to read each wheel speed data flow
Nor Go to step 8
mal
Normal
Pin of
ABS Pin of
hydraulic wheel
Position Function
regulator speed
with sensor
ECU
Signal 22 1
Left front
Power
wheel 34 2
Supply
252
BYD AUTO BYD Suri Maintenance & Repair Manual
Right Signal 6 1
front Power
18 2
wheel Supply
Signal 20 1
Left rear
Power
wheel 33 2
Supply
Right Signal 31 1
rear Power
19 2
wheel Supply
g Check the wheel speed sensor and its wave form using an oscilloscope.
253
BYD AUTO BYD Suri Maintenance & Repair Manual
Note:
254
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Normal
255
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
Normal
(b) (Except DTC C024501) In 30 seconds after starting the vehicle, drive it straight at a speed of
more than 30 km/h for at least 10 seconds.
(DTC C024501) Accelerate the vehicle from 0 to 60 km/h, or drive the vehicle at a speed of 30
km/h for at least 7 seconds
After normal driving, turn the vehicle off. Confirm ABS does not memorize DTCs 30 seconds
after the vehicle is turned on.
DTC C001104 Left front oil outlet valve circuit of hydraulic regulator
malfunction
DTC C001004 Left front oil inlet valve circuit of hydraulic regulator
malfunction
DTC C001504 Right front oil outlet valve circuit of hydraulic regulator
malfunction
DTC C001404 Right front oil inlet valve circuit of hydraulic regulator
malfunction
DTC C001904 Left rear oil outlet valve circuit of hydraulic regulator
malfunction
DTC C001804 Left rear oil inlet valve circuit of hydraulic regulator
malfunction
256
BYD AUTO BYD Suri Maintenance & Repair Manual
DTC C001D04 Right rear oil outlet valve circuit of hydraulic regulator
malfunction
DTC C001C04 Right rear oil inlet valve circuit of hydraulic regulator
malfunction
Circuit description:
After the vehicle is turned on, the solenoid valve relay in the ABS hydraulic unit with ECU is
energized to supply battery voltage to one end of hydraulic regulator solenoid valve. When the
vehicle is turned off and ABS system is disabled, the solenoid valve relay keeps energized.
Its role is:
ABS ECU controls the solenoid valve operation by controlling the grounding of each solenoid
valve so as to adjust the brake pressure of each brake circuit.
Oil inlet valve: pulse width modulation type.
Oil outlet valve: switch type.
257
BYD AUTO BYD Suri Maintenance & Repair Manual
258
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Check ABS hydraulic regulator with ECU when the vehicle is stationary
(a) Turn the vehicle off for more than 10 s.
Abno Go to step 3
rmal
Normal
2 Perform component test on the solenoid valve in ABS hydraulic regulator with ECU using
diagnostic tester
259
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
260
BYD AUTO BYD Suri Maintenance & Repair Manual
2 Check pin voltage of ABS hydraulic regulator with ECU (Voltage of pin 25)
Normal: U=9.3~16.9 V
Note:
Abnormal
261
BYD AUTO BYD Suri Maintenance & Repair Manual
4 Check the connecting wire, connector and (c) DTC C001104, C001004, C001504,
40 A fuse C001404, C001904, C001804, C001D04
and C001C04 do not occur again 30 s
(a) Check if 25 A fuse is normal after the vehicle is turned on
(b) Check the charging system: (d) Perform step 2 in the diagnosis flow, and
generator/battery and their connecting the test result is normal
wire
Normal
5 Final Inspection
262
BYD AUTO BYD Suri Maintenance & Repair Manual
DTC C002004 Return pump motor malfunction: Unable to rotate or unable to stop
rotating
Circuit description:
ABS hydraulic unit with ECU integrates the return pump and return pump motor. When ABS does
not perform adjustment, the return pump relay will stop operating and the return pump is at rest.
When ABS is performing pressure reduction, ABS ECU controls the operation of return pump
motor by controlling the grounding of return pump relay.
Its role is:
ABS pressure reduction phase: The return pump operates to pump the brake fluid in the brake
wheel cylinder of locked wheel into the pipe of brake master cylinder, thus reducing the pressure in
brake wheel cylinder.
EBD pressure reduction phase: The accumulator stores the brake fluid returned from rear wheels.
However, if the accumulator is fully filled with brake fluid and the rear wheels decelerate more
quickly than the front wheels, ABS ECU will control the operation of return pump to pump the
excessive brake fluid into the pipe of brake master cylinder.
Note:
After troubleshooting, restart the vehicle and ABS and brake system warning lamps will turn off
automatically after the vehicle speed exceeds 12 km/h.
263
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
264
BYD AUTO BYD Suri Maintenance & Repair Manual
Abno Go to step 4
rmal
Normal
2 Check ABS hydraulic regulator with an ECU self-check and initialization procedure
(a) Start the engine.
Abnormal
If the trouble code is memorized, is there any
other DTC (except C0110)?
No Go to step 4
Normal
265
BYD AUTO BYD Suri Maintenance & Repair Manual
3 Perform component test on ABS hydraulic regulator with ECV using diagnostic tester
(a) Turn the vehicle off.
4 Check pin voltage of ABS hydraulic regulator with ECU (Voltage of pin 1)
When a junction box is used:
4 Check pin voltage of ABS hydraulic regulator with ECU (Voltage of pin 1)
266
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnor
mal
(b) Check the charging system: generator/battery and their connecting wire
Normal
6 Final Inspection
(b) ABS warning lamp and brake system warning lamp turn off within a short time after the vehicle
is turned on
(c) DTC C002004 does not occur again after the vehicle is started for 30 s
(d) Drive the vehicle at a speed of 10~15 km/h, and do not depress the brake pedal. DTC
C002004 does not occur again
Circuit description:
After the vehicle is turned on, the ABS solenoid valve relay with hydraulic controller is
energized to supply battery voltage to one end of hydraulic regulator solenoid valve. When the
vehicle is turned off or ABS system is disabled, the solenoid valve relay keeps energized.
Its role is:
ABS ECU controls the solenoid valve operation by controlling the grounding of each solenoid
valve so as to adjust the brake pressure of each brake circuit.
267
BYD AUTO BYD Suri Maintenance & Repair Manual
268
BYD AUTO BYD Suri Maintenance & Repair Manual
269
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Check ABS hydraulic regulator with ECU when the vehicle is stationary
(a) Turn the vehicle off for more than 10
seconds.
Abnor Go to step 3
mal
Normal
2 Perform component test on the solenoid valve in ABS hydraulic regulator with ECU using
diagnostic tester
270
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
3. Check pin voltage of ABS hydraulic regulator with ECU (Voltage of pin 25)
When a junction box is used:
Normal: U=9.3~16.9 V
271
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnormal
4 Check the connecting wire, connector and Perform next inspection according to "Trouble
40 A fuse Symptom Table"
(b) Check the charging system: (a) Clear the trouble codes
generator/battery and their connecting
wire (b) ABS and brake system warning lamps turn
off within a short time after the vehicle is
(c) Ensure the ground terminal (4) is well turned on
grounded
(c) DTC C012104 does not occur again after
Abnor Replace or repair the the vehicle is started for 30 seconds
connecting wire/connector
mal and fuse (d) Perform step 2 in the diagnosis flow, and
Normal the test result is normal
Circuit description:
When the brake pedal is depressed, the switch will be closed and the braking light switch will
supply +12 V signal voltage to the braking light signal circuit (BLS).
ABS ECU monitors the signal voltage of braking light switch to confirm the brake engagement time
and detect the braking light switch circuit.
272
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram:
273
BYD AUTO BYD Suri Maintenance & Repair Manual
Digital Status
(b) Check the braking light switch through
the data flow of diagnostic tester.
Left front oil inlet valve: Power off
Left front oil outlet valve: Power off
Right front oil inlet valve: Power off When the brake pedal is depressed: The
Right front oil outlet valve: Power off
Left rear oil inlet valve: Power off diagnostic tester displays "Engaged"
Left rear oil outlet valve: Power off
Right rear oil inlet valve: Power off
When the brake pedal is released: The
Right rear oil outlet valve: Power off
Braking light status: On
diagnostic tester displays "Disengaged"
Return pump motor status: Power on
Solenoid valve relay status: Power on
Abnormal Go to step 4
Press [F2] key to print current contents
Press [ESC] key to return
Normal
2 Check pin voltage of ABS hydraulic regulator with ECU (Voltage between pin 30 and 38)
274
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnormal
3 Check the connecting wire and connector (Braking light switch to ABS hydraulic regulator with
ECU)
(a) Check if the connecting wire and connector between the braking light switch and ABS
hydraulic regulator are short or open.
Normal
4 heck the connecting wire and connector (Braking light switch circuit)
Abnorm
al
Replace the connecting wire or connector
5 Final Inspection
(b) When driving at a speed of more than 20 km/h, confirm the malfunction does not occur again.
275
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit description:
ABS ECU installed in ABS hydraulic regulator with ECU is the control center of the entire ABS
system. ABS system stores the desired program and calibration data in the ROM of ABS ECU.
ABS ECU performs the self-check continuously to detect and monitor if ABS system malfunctions.
276
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram:
277
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Check ABS hydraulic regulator with ECU when the vehicle is stationary
(a) Turn the vehicle off for more than 10
seconds.
C055000 still
occurs
278
BYD AUTO BYD Suri Maintenance & Repair Manual
No
(b) After the engine is started for 30 seconds, ABS does not memorize any DTC.
Circuit description:
ABS ECU monitors the battery power voltage supplied to ABS ECU via Uz (Pin 32). If the voltage
supplied to ABS ECU is not within the specification, the following malfunctions may occur.
If the voltage supplied to ABS ECU is too low, ABS system operates abnormally.
If the voltage supplied to ABS ECU is too high, ABS components will be damaged.
The normal system operation voltage is 9.3 V~16.9 V when the return pump motor operates.
279
BYD AUTO BYD Suri Maintenance & Repair Manual
280
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
281
BYD AUTO BYD Suri Maintenance & Repair Manual
1 Check fuses
Normal: Continuity
No Check if all the wire harness and
Fusible Link components connected to the fuses
are short
Yes
282
BYD AUTO BYD Suri Maintenance & Repair Manual
Tips: When the return pump motor is controlled to measure UZ voltage, turn on and off
the electrical devices with higher power consumption (such as air conditioner,
headlamp) to observe the voltage change.
283
BYD AUTO BYD Suri Maintenance & Repair Manual
Tips: When measuring UZ voltage, turn on and off the electrical devices with higher power
consumption (such as air conditioner, headlamp) to observe the voltage change
Normal Abnormal Check and repair the circuit
Normal
6 Intermittent Malfunction
284
BYD AUTO BYD Suri Maintenance & Repair Manual
285
BYD AUTO BYD Suri Maintenance & Repair Manual
286
BYD AUTO BYD Suri Maintenance & Repair Manual
287
BYD AUTO BYD Suri Maintenance & Repair Manual
The electronic parking brake system features the following main functions:
Automatic parking: When the vehicle is turned off or the shift position is in P, the system will start
automatic parking.
Manual parking: When the electronic parking switch is pulled up by hand, the system will start
parking.
Automatic release parking: With the parking system on, when the vehicle is started and the
accelerator pedal is lightly depressed, the parking system will release automatically.
Manual release parking: With the parking system on, when the electronic parking switch is
pressed down by hand, the system will cancel parking.
Emergency braking function: While driving, the electronic parking brake system can be used to
apply brakes forcibly when the brakes are ineffective.
Main components:
Notice:
While driving, never operate the electronic parking switch unless emergency braking is
necessary.
Contact the dealer immediately after the parking indicator light turns on.
Never allow anyone who is not familiar with EPB to operate it to prevent accidents.
288
BYD AUTO BYD Suri Maintenance & Repair Manual
Next
Next
Standard voltage:
11 to 14 V
Result
Result Proceed to
No DTC is output A
DTC is output B
B Go to step 8
Result
Result Proceed to
Fault is not listed in problem symptoms table A
Fault is listed in problem symptoms table B
289
BYD AUTO BYD Suri Maintenance & Repair Manual
Go to step 8
B
A
Next
Next
End
290
BYD AUTO BYD Suri Maintenance & Repair Manual
291
BYD AUTO BYD Suri Maintenance & Repair Manual
EPB
C11A071 Actuator stuck
Cable
EPB
U007388 CAN bus OFF
Wire harness
EPB
U010087 Lost communication with EMC
EMC
EPB
U010187 Lost communication with TCU
TCU
EPB
U012987 Lost communication with BCS
TCU
EPB
U014087 Lost communication with BCM
TCU
EPB
U015387 Lost communication with ACM
ACM
EPB
U040186 Receive invalid data from EMS
EMS
EPB
U048186 Receive invalid data from BSM
BSM
C11A172 Motor Mosfet failure EPB
C11A113 Motor disconnection or failure EPB
Motor position sensor
C111029 EPB
circuit/signal
C11A11D Motor over-current EPB
Current sensor
C111115 EPB
disconnection/short circuit
C111129 Invalid current sensor signal EPB
C111286 Incorrect force sensor hardware EPB
C111229 Incorrect force sensor signal EPB
C116009 ECU hardware EPB
Equipped RUN-IN-EPB not
C116200 EPB
calibrated
C11A217 Motor operation time too long EPB
EPB
C110060 Power reboot
Wire harness
292
BYD AUTO BYD Suri Maintenance & Repair Manual
Wire
Terminal No. Terminal Description Condition Normal Value
Color
K55-1 - Body
Gr Constant voltage power Always 11-14 V
ground
K55-2 - Body
R/B Switch signal Power ON 11-14 V
ground
K55-3 - Body
L/B Switch signal Power ON 11-14 V
ground
K55-4 - Body
Y Switch signal Power ON 11-14 V
ground
K55-6 - Body
P CAN_H Always Approx. 2.5 V
ground
K55-8 - Body
B Ground Always Less than 1 V
ground
K55-9 - Body
B/W Switch signal Power ON 11-14 V
ground
K55-10 - Body
G Switch signal Power ON 11-14 V
ground
K55-11 - Body
Y/R IG1 Power ON 11-14 V
ground
K55-12 - Body
Gr Switch signal Power ON 11-14 V
ground
K55-14 - Body
V CAN_L Always Approx. 2.5 V
ground
293
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Constant Voltage
7# ground
Inspection Procedures
Normal
Terminal Wire Color
Condition
294
BYD AUTO BYD Suri Maintenance & Repair Manual
K55-1 - Body
Gr 11-14 V
ground
K55-11 (Power
Y/R 11-14 V
ON) - Body ground
K55-8 - Body Less than 1
B
ground Ω
Abnormal
Normal
Normal
295
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Abnormal
296
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Constant
Voltage
7# ground
Inspection Procedures
297
BYD AUTO BYD Suri Maintenance & Repair Manual
Abnormal
Normal
Normal
298
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Constant
Voltage
7# ground
Inspection Procedures
Yes
299
BYD AUTO BYD Suri Maintenance & Repair Manual
Test
Wire Normal
Terminal conditi
Color Condition
on
K55-11 - Body Power
Y/R 11-14 V
ground ON
Normal
300
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Lamp
power
supply
indicator
light
switch
switch
Backlight
2# ground
301
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Test Normal
Terminal
condition Condition
K56-1-K56-4- Less than 1 Ω
Switch is
K56-2-K56-3 not Less than 1 Ω
operated
K56-5-K56-6 Less than 1 Ω
K56-1-K56-4- Less than 1 Ω
More than 10
K56-2-K56-3 Switch is kΩ
pulled up
K56-5-K56-6 Less than 1 Ω
K56-3-K56-4 Less than 1 Ω
K56-1-K56-4- Less than 1 Ω
K56-2-K56-3 Less than 1 Ω
Switch is
pressed More than 10
K56-5-K56-6
kΩ
K56-6-K56-4 Less than 1 Ω
Normal
Wire Normal
Terminal
Color Condition
K56-1-K55-3 L/B Less than 1 Ω
K56-2-K55-4 Y Less than 1 Ω
302
BYD AUTO BYD Suri Maintenance & Repair Manual
Normal
303
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Normal
304
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Normal
305
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
Normal
306
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Inspection Procedures
307
BYD AUTO BYD Suri Maintenance & Repair Manual
No
Yes
Test Normal
Wire
Terminal condition Conditio
Color
n
K55-6 - Body Constant Approx.
P
ground Voltage 2.5 V
K55-14 - Body Constant Approx.
V
ground Voltage 2.5 V
Normal
Section 5 Removal and Installation 5.1.1.1 Turn the vehicle start button to ON
position or turn the ignition switch on
Removal method
5.1.1.2 Keep depressing the brake pedal
5.1 Removal method for repair
5.1.1.3 Press and hold EPB switch for 10
5.1.1 Fully release EPB (The connecting cable seconds and then release (After releasing,
is removable) EPB brake warning lamp begins flashing
for 5 seconds)
Method 1:
5 1.1.4 Within 5 seconds after the last
Using the diagnosis tool, enter [EPB operation ends (during warning lamp
Electronic Parking Brake System] -- flashing), press the EPB switch once (EPB
[Component Operation Test] -- [Release] brake warning lamp flashes continuously)
to release EPB.
Method 2: 5.1.1.5 EPB is fully released (EPB brake
warning lamp remains on)
308
BYD AUTO BYD Suri Maintenance & Repair Manual
Method 3:
Take off the seal plug (A) and turn the cable 5.1.2.3 Using M5 inner hexagon wrench,
rivet head (C) clockwise using M5 inner remove EPB module mounting bolts (A)
hexagon wrench (B), until it can be removed; and take off EPB module (B);
309
BYD AUTO BYD Suri Maintenance & Repair Manual
5.2.5 Check if the dust cover is installed 5.3 Precautions for installation
properly. If it is broken, repair it to prevent
water entering, causing the module 5.3.1 Before installing EPB, make sure the
damage; entire vehicle is powered off;
5.2.6 Initialize the module using diagnosis tool 5.3.2 When EPB is installed, perform
after other components (including left and initialization after the vehicle is powered on.
right cables) are installed. The specific operation is as follows. Using
the diagnosis tool, enter [EPB Electronic
Description: When the EPB module, EPB Parking Brake System] -- [Component
caliper, wires or brake disk (optional) are Operation Test] -- [Initialization] to perform
replaced, it is necessary to release and initialization.
initialize EPB to ensure the normal
operation of EPB.
310
BYD AUTO BYD Suri Maintenance & Repair Manual
311
BYD AUTO BYD Suri Maintenance & Repair Manual
When the vehicle is turning, the torque sensor sends the detected torque signal and the value &
312
BYD AUTO BYD Suri Maintenance & Repair Manual
direction of the steering wheel angle signal to EPS ECU after processing. At the same time, EPS
ECU will also receive the vehicle speed signal, detected by the vehicle speed sensor. Then, the
rotation direction of the motor and the amount of power assist torque will be determined according
to the signal of the vehicle speed sensor and torque sensor. In addition, the current sensor will
inspect the current of the circuit and monitor the drive circuit. Finally, it will operate the motor via
the drive circuit and perform power assist steering. This operation is shown in fig. 1-1.
313
BYD AUTO BYD Suri Maintenance & Repair Manual
Repair Circuit
EPS Motor
EPS Motor
Halla Torque Angle Sensor
EPS ECU
Speed Signal Input Indication of High Current Out
Electronic Electronic
Adapter Injector Injector EPS Motor
A01-37 A01-76
314
BYD AUTO BYD Suri Maintenance & Repair Manual
2.1 Definitions of the EPS System and Electrical Interface for Complete Vehicle Wiring
Wiring Measuring
Test Terminal Terminal Description Standard Value
Color Conditions
C1 - Body R Power (+) Always 9-16VDC
Resistance between it
C2 - Body B Ground Always and the body is less than
1Ω
C3 - Body None Vacant None None
C4 - Body None Vacant None None
A1 - Body B Motor (-) Power supply ON 0-12 V
A2 - Body R Motor (+) Power supply ON 0-12 V
B1 - Body None Vacant None None
The pulse signals are
B2 - Body V Speed signal Starting engine
input
B3 - Body None None None None
B5 - Body Br Ignition signal Power supply ON 10-14 V
B6 - Body P CAN_H Power supply ON 2.5 V or 3.5 V
Indication of high current High level is above 7 V,
B8 - Body G Power supply ON
out, low level effective low level is below 3 V
B9 - Body None None None None
B11 - Body Br Ignition signal Power supply ON 10-14 V
B12 - Body V CAN_L Power supply ON 1.5 V or 3.5 V
B4/B7/B10 -
-- -- -- --
Body
D1 - Body W Torque sensor signal 1 Power supply ON 0.5-4.5 V
D3 - Body B Torque sensor signal 2 Power supply ON 0.5-4.5 V
D4 - Body R Power supply signal 1 Power supply ON 5VDC
D6 - Body L PWM_P
D7 - Body V PWM_S
D8 - Body B/R Power supply signal 2 Power supply ON 5VDC
Resistance between it
D2/D5 -
Gr Ground wire Power supply ON and the body is less than
Body
1Ω
Notice: The connector should correspond with the wire terminal B - G59 C - B11
315
BYD AUTO BYD Suri Maintenance & Repair Manual
The keyless start button is shown in the figure on the right. The meanings of its light color are
shown in table 3-1.
Vehicle Condition
Description of Button Condition
Color of Indicator Light Engine Condition
The smart key is detected in the vehicle
Green OFF
and the engine can be started
The smart key is not detected in the vehicle
No light, OFF OFF
and the engine cannot be started
ACC/ON Gear Orange OFF
Engine started No light, OFF Start
316
BYD AUTO BYD Suri Maintenance & Repair Manual
angle signal with a tester and clear the 3.1.2.3.3 Do not release the angle adjusting
trouble code. handle before the installation of the
steering column assembly is complete in
3.1.2.2.2 After removing and replacing the the vehicle.
intermediate shaft assembly, drive the
vehicle in a straight line at low speed to 3.1.2.4 When disconnecting or reconnecting
center the steering wheel. After parking, the steering column assembly:
reset the steering wheel angle signal with
a tester and clear the trouble code. 3.1.2.41 Before disconnecting the steering
column or intermediate shaft from the
3.1.2.2.3 After removing and replacing the steering gear, the wheels should be
steering gear, perform four-wheel straight ahead with power off in the
alignment to adjust toe-in and drive the vehicle. Otherwise, the clock spring on the
vehicle in a straight line at low speed to steering column will deviate from the
center the steering wheel. After parking, neutral position and be damaged.
reset the steering wheel angle signal with
a tester and clear the trouble code. 3.1.2.4.2 Before disconnecting the steering
column or intermediate shaft, the vehicle
3.1.2.3 When operating the steering column should be powered off. After
assembly: disconnecting the components above, do
not move the wheels. Failure to observe
3.1.2.3.1 Avoid any impact to the steering these procedures may cause certain
column assembly, especially the motor component misalignment during
and reduction mechanism. If the steering installation.
column assembly is dropped or subjected
to a strong impact, replace it with a new 3.1.2.4.3 Do not hold the steering wheel in the
one. full turn position for more than 5 seconds,
otherwise damage to the motor may
3.1.2.3.2 Do not pull the wire harnesses when occur.
moving the steering column assembly.
317
BYD AUTO BYD Suri Maintenance & Repair Manual
The troubleshooting chart can help you find the cause of the malfunction. The numbers in the chart
indicate possible order when a malfunction occurs. Please check every part in order.
Repair/replace faulty parts or perform adjustments if necessary.
318
BYD AUTO BYD Suri Maintenance & Repair Manual
3.3 General Maintenance Information for 3.4.2 Gently turn the steering wheel right or left,
Malfunctions and check the steering wheel free travel.
The maximum free travel of the steering
EPS Indicator Light wheel should be no more than 30 mm as
shown in the figure 3-2.If the free travel
After starting the engine, the EPS indicator exceeds the maximum, inspect the
light will remain on for 2 to 3 seconds, and steering system.
then go off. It indicates that the EPS indicator
light and the system are operating normally.
319
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 4-1 Construction Figure of the Steering Wheel and Steering Column Assembly
320
BYD AUTO BYD Suri Maintenance & Repair Manual
4.1.2 Removal and Installation of the Steering Notice: Do not pull the airbag wire while
Wheel and Steering Column Assembly removing the DAB module assembly. Place
the DAB module assembly with the upper
4.1.2.1 Removal surface upward. Do not disassemble the DAB
module assembly.
Some service operations may affect the SRS
airbag system. Do read the precautionary 4.1.2.1.4 Remove the steering wheel
notices of the SRS airbag system before assembly.
servicing the steering column. (For the
removal procedures of the safety air bag, see 4.1.2.1.4.1 Pull out the remaining wire
chapter 6-8) connectors.
4.1.2.1.1 Check that the front wheels are 4.1.2.1.4.2 Loosen the hexagon flange bolt
straight ahead; that is securing the steering wheel. See
figure 4-3.
4.1.2.1.2 Disconnect the negative battery
terminal;
Notice:
Fig. 4-2
321
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 4-4
4.1.2.1.6 Remove the clock spring and the 4.1.2.1.9 Disconnect the connection of the
combination switch. intermediate shaft assembly and long
shaft assembly.
4.1.2.1.6.1 Remove all connectors connected
to the clock spring and combination 4.1.2.1.9.1 Match-mark on the fitting surface
switch. between the bottom of the intermediate
322
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 4-10
Fig. 4-11
Fig. 4-9
Fig. 4-12
323
BYD AUTO BYD Suri Maintenance & Repair Manual
Loosen the 2 theft deterrent bolts shown in 4.1.2.2.3.4 Connect the steering shaft lock
figure 4-11, and remove the steering shaft lock. connector.
4.1.2.2.1 Inspect for shaft lock malfunction. Do tighten the bolt from the side without thread.
Connect the removed shaft lock to the Tightening from the other side will result in
connector. When pressing down the start failure, and an accident may occur. There is a
button to power on, the steering shaft lock milled plane on the side without thread of the
will be unlocked. When pressing down the universal joint assembly. Tighten the bolt from
start button to power off, the steering shaft this side. See figure 4-12.
lock will be locked.
324
BYD AUTO BYD Suri Maintenance & Repair Manual
Fig. 4-14
4.1.2.2.6 Install the joint boot assembly I 4.1.2.2.11 Install the DAB module assembly
Install the dust cover in place, and engage 4.1.2.2.11.1 Connect the connector.
the plastic snap-fit.
4.1.2.2.11 2 Align with the position of the DAB
4.1.2.2.7 Install the combination switch and module, and tighten the set bolts on both
clock spring. sides to 8.8 Nm.
4.1.2.2.8.2 Install the upper protector, and (c) If the DAB module assembly has been
attach it to the lower protector. dropped or if any cracks, dents or other
defects are found on the housing or
4.1.2.2.9 Center the clock spring. connector, replace the assembly with a
new one.
Notice: Incorrect installation of the clock
spring may damage it. Make sure to (d) When installing the DAB module
center it. When centering it, first turn the assembly, do not allow the wire
clock spring fully to the left, then fully to harnesses to interfere with other parts or
the right and count the number of full be pinched by them.
turns. Next, turn it to the left in half turns
(if the total number of turns is 5, turn it 4.1.2.2.12 Connect the negative battery
325
BYD AUTO BYD Suri Maintenance & Repair Manual
terminal. Notice:
4.1.2.2.13 Inspect the SRS warning light. The motor wire harness should face the
correct direction, see Fig 4-16.
4.1.3 Inspection of the EPS Motor
Before tightening the bolts, turn the motor
Notice: During the removal and installation, do 45°to left and right for 2~3 times and
not allow any foreign matter such as dirt or check the contact situation of the motor
dust to enter the housing of the reduction fitting surface. Alternately tighten the
mechanism. Do not power on if the motor is bolts. Secure the motor.
not connected. Tightening torque: 25 Nm.
4.1.3.1 Removal
Fig. 4-16
Notice:
326
BYD AUTO BYD Suri Maintenance & Repair Manual
327
BYD AUTO BYD Suri Maintenance & Repair Manual
328
BYD AUTO BYD Suri Maintenance & Repair Manual
4.2.2 Removal
4.2.2.1 Face the front wheels straight ahead. 4.2.2.10 Remove the rear under cover RH of
the engine.
4.2.2.2 Secure the steering wheel.
4.2.2.11 Remove the lower reinforcement of
(a) Secure the steering wheel in place with the engine front mounting bracket.
the seat belt to prevent rotation.
4.2.2.12 Remove the reinforcement LH of the
Tips: front suspension cross bearer.
This operation helps prevent damage to the 4.2.2.13 Remove the reinforcement RH of the
spiral cable. front suspension cross bearer.
4.2.2.3 Remove the upper boot assembly of 4.2.2.14 Remove the front stabilizer link
the joint. assembly LH.
4.2.2.4 Disengage the lower steering shaft. 4.2.2.15 Remove the front stabilizer link
assembly RH.
4.2.2.5 Disengage the lower boot assembly of
the joint. 4.2.2.16 Disengage the outer link assembly LH
and the steering knuckle.
(a) Disengage the clips A and B of the joint
lower boot frame from the body. (a) Remove the split pin and hexagon slotted
nut.
Notice:
(b) Disengage the outer link assembly LH
Do not damage the clips of the frame. from the steering knuckle.
329
BYD AUTO BYD Suri Maintenance & Repair Manual
Match mark
4.2.2.19 Disengage the lower arm assembly of 4.2.2.25 Remove the mechanical steering
the front suspension RH. gear with tie rod assembly.
4.2.2.24 Remove the lower steering shaft. 4.2.2.27 Remove the outer link assembly LH.
(a) Match-mark on the lower steering shaft (a) Match-mark on the outer and inner link
and steering gear box. assembly LH.
(b) Remove the lower steering shaft from the (b) Remove the outer link assembly LH and
mechanical steering gear with tie rod the lock nut of the link.
assembly.
Tips:
Perform the same procedure as the LH side.
330
BYD AUTO BYD Suri Maintenance & Repair Manual
4.2.3.4 Check the bellows-type dust covers. (a) Install the mechanical steering gear with
tie rod assembly to the front sub frame
Rotate the pinion with a special tool, and assembly with 2 bolts and 2 nuts.
331
BYD AUTO BYD Suri Maintenance & Repair Manual
332
BYD AUTO BYD Suri Maintenance & Repair Manual
4.2.4.14 Install the link assembly of the front (a) Connect the clips on the frame of the
transversal stabilizer bar RH. lower boot assembly to the body front
panel.
4.2.4.15 Install the reinforcement of the front
suspension cross bearer LH. 4.2.4.23 Connect the joint assembly and lower
steering shaft.
4.2.4.16. Install the reinforcement of the front
suspension cross bearer RH. 4.2.4.24 Install the joint upper boot.
4.2.4 17 Install the lower reinforcement of the 4.2.4.25 Install the front wheels.
engine front suspension bracket.
Pre-tensioning torque: 108 Nm
4.2.4.18 Install the under cover of the engine
rear LH. 4.2.4.26. Adjust the four-wheel alignment.
333
BYD AUTO BYD Suri Maintenance & Repair Manual
When the EPS system is malfunctioning, read the trouble code (ED400) using a special hand-held
tester. Read the type of malfunction based on the tester.
a Connect the tester to the data link connector (DLC3) as shown in the figure below.
Table 5-1
A1 - Body B Motor (-) Power supply ON 0-12 V
A2 - Body R Motor (+) Power supply ON 0-12 V
Fig. 5-1
b Read the diagnostic trouble code (DTC) according to the display on the tester
The troubleshooting methods are as follows:
334
BYD AUTO BYD Suri Maintenance & Repair Manual
Malfunc or short, EPS ECU 2. Check whether the wire harness between EPS
tion internal error and battery is open. Yes: Repair the wire
harness; No: 3
3. Check whether the assist power supply is
abnormal or whether the battery voltage is too
low. Yes: Repair the power supply or replace a
new battery; No: 4
4. There is a malfunction in EPS ECU, replace it.
EPS ECU internal 1. Check the connector for looseness or
EPS error, system disconnection. Yes: Retighten; No: 2
ECU power supply 2. Check for an open or short circuit in the wire
C1B02
Malfunc abnormal, wire harness. Yes: Repair the wire harness; No: 3
tion harness open or 3. There is a malfunction in EPS ECU, replace it.
short
1. Check the connector for looseness or
disconnection. Yes: Retighten; No: 2
Assist motor 2. Check for an open or short circuit in the wire
malfunction, assist harness. Yes: Repair the wire harness; No: 3
Motor power supply 3. Check whether the assist power supply is
C1B03 Malfunc abnormal, wire abnormal or whether the battery voltage is too
tion harness open or low. Yes: Repair the circuit or replace with a
short, EPS ECU new battery; No: 4
internal error 4. Check the assist motor for malfunctions. Yes:
Replace the assist motor; No: 5
5. There is a malfunction in EPS ECU, replace it.
1. Check the connector for looseness or
Torque sensor disconnection. Yes: Retighten; No: 2
malfunction, 2. Check for an open or short circuit in the wire
Torque mechanical harness. Yes: Repair the wire harness; No: 3
Sensor assembly stuck or 3. Check whether the mechanical assembly is
C1B04
Malfunc loose, wire stuck or loose. Yes: Repair the malfunction;
tion harness open or No: 4
short, EPS ECU 4. Check the torque sensor for malfunctions.
internal error Yes: Replace the torque sensor; No: 5
5. There is a malfunction in EPS ECU, replace it.
1. Whether or not the steering wheel is turned for
Turning the
a long time in place. Yes: Stop turning, and
System steering wheel for wait until the EPS ECU cools down; No: 2
Temper a long time, EPS
2. Check for a short circuit in the wire harness.
C1B05 ature ECU internal
Yes: Repair the wire harness; No: 3
Too error , assist motor
3. Check the assist motor for malfunctions. Yes:
High or wire harness
Replace the motor; No: 4
short
4. There is a malfunction in EPS ECU, replace it.
1. Check the connector for looseness or
Vehicle disconnection. Yes: Retighten; No: 2
Speed CAN line open or 2. Check for an open or short circuit in the wire
C1B06 Sensor short, EPS ECU harness. Yes: Repair the wire harness; No: 3
Malfunc internal error 3. Check ABS for malfunctions. Yes: Check ABS
tion system; No: 4
4. There is a malfunction in EPS ECU, replace it.
Engine Engine speed 1. Check the connector for looseness or
C1B08
Speed sensor, wire disconnection. Yes: Retighten; No: 2
335
BYD AUTO BYD Suri Maintenance & Repair Manual
Sensor harness open or 2. Check for an open or short circuit in the wire
short, EPS ECU harness. Yes: Repair the wire harness; No: 3
internal error 3. Check the engine speed sensor for
malfunctions. Yes: Replace the sensor; No: 4
4. There is a malfunction in EPS sensor, replace
the EPS ECU.
1. Check the connector for looseness or
disconnection. Yes: Retighten; No: 2
Torque
No factory 2. Check for an open or short circuit in the wire
Sensor
calibration for the harness. Yes: Repair the wire harness; No: 3
C1B09 Calibrati
torque sensor is 3. Check the torque sensor for malfunctions.
on
performed Yes: Replace the torque sensor; No: 4
Undone
4. There is a malfunction in EPS sensor, replace
the EPS ECU.
1. Check the connector for looseness or
disconnection. Yes: Retighten; No: 2
Rotatio No calibration is
2. Whether the calibration can be performed with
n Angle performed for the
a diagnostic tester. Yes: calibrate the zero
Signal zero point of the
C1B0A point of the rotation angle; No: 3
Calibrati rotation angle
3. The calibration failed several times. Yes:
on signal when the
Replace the steering column; No: 4
Undone vehicle is offline
4. There is a malfunction in EPS controller,
replace the EPS ECU.
Malfunc 1. Check for an open or short circuit in the wire
Wire harness open
tion in harness. Yes: Repair the wire harness; No: 2
U0134 or short, EPS ECU
Module 2. There is a malfunction in EPS sensor, replace
internal error
Itself the EPS ECU.
Circuit Diagram
336
BYD AUTO BYD Suri Maintenance & Repair Manual
Repair Circuit
EPS Motor
EPS
Module
EPS ECU
Fig. 5-2
337
BYD AUTO BYD Suri Maintenance & Repair Manual
completed or
7 Replace EPS ECU Go to next step
not
trouble code
Clear the diagnostic trouble code System is
8 still present or Go to step 7
with a diagnostic tester OK
not
Circuit Diagram
Fig. 5-3
Inspection Procedures
338
BYD AUTO BYD Suri Maintenance & Repair Manual
Inspection Procedures
339
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
EPS ECU
Fig. 5-4
Inspection for Torque Sensor Malfunction
Steps Diagnostic Operation Standard Value Yes No
1 Check whether the connector and normal or not Go to step 3 Go to next
EPS ECU are connected normally step
2 Secure the connector completed or not Go to step 9
3 Check for an open or short circuit normal or not Go to step 5 Go to next
in the torque sensor wire harness step
4 Repair the wire harness completed or not Go to step 9
malfunction
5 Check whether the mechanical normal or not Go to step 7 Go to next
assembly is stuck or loose step
6 Replace the steering column completed or not Go to step 9
7 Check whether the torque sensor normal or not Go to step 6 Go to next
signal is normal with all the EPS step
ECU connectors connected
8 There is a malfunction in EPS completed or not Go to step 9
ECU, replace it
9 Clear the diagnostic trouble code trouble code still Go to step 1 System is
with a diagnostic tester occurs or not OK
340
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit diagram
Fig. 5-5
341
BYD AUTO BYD Suri Maintenance & Repair Manual
Circuit Diagram
Fig. 5-6
342
BYD AUTO BYD Suri Maintenance & Repair Manual
procedure step
2 1. Battery load test whether the Go to next Go to step 5
2. Charging system load test voltage is 10-14 V step
3 1. Turn off the power switch. normal or not Go to step 6 Go to step 4
2. Disconnect the wire
connectors in the EPS ECU
3. Check the connection
between connector B11-2 of
EPS ECU and body
4 Check the self-test circuit completed or not Go to step 1 Repair
5 Repair the battery or normal or not Go to step
charging system 10
6 Inspection of vehicle speed normal or not Go to next Go to step 9
input signal wire harness, step
measure the resistance
1. Is the resistance of
connector terminal
G59-2-A01-37 always less
than 1Ω
7 Inspection of malfunction normal or not Go to next Go to step 9
warning signal wire harness, step
measure if the resistances of
connector terminals
G2X-17-G59-2 and
A01-76-G59-8 are always
less than 1Ω
8 Inspection of wire harness of normal or not Go to step Go to step 9
CAN line 10
Remove the connector G59,
and measure the voltages of
wire harness terminals
G59-6 and G59-12
1. whether the voltage
between G59-6 and body
ground is always 2.5-3.5 V
2. whether the voltage
between G59-12 and body
ground is always 1.5-2.5 V
9 Replace the wire harness normal or not Go to next
step
10 Clear the diagnostic trouble trouble code still Go to step 1 System is
code with a diagnostic tester occurs or not OK
343
BYD AUTO BYD Suri Maintenance & Repair Manual
The EPS sensor is an integrated Hall sensor refer to the calibration process of the
for torque signal and steering angle signal. To steering angle signal in figure 2.
avoid abnormal EPS power assist due to
torque signal and steering angle signal 6.1.2.3 Clear the trouble codes. Due to the
calibration undone, the standard process of steering angle signal calibration undone,
the signal calibration is provided. EPS ECU will record this malfunction.
Therefore, the trouble codes recorded by
6.1.1 When a signal calibration is needed: the ECU should be cleared after steering
angle calibration. Clear remaining trouble
a) After four-wheel alignment with the codes after the vehicle is finally assembled
vehicle finally assembled and offline, the and offline. And it is very important for the
torque and steering angle signal further maintenance and troubleshooting
calibrations are needed; of the vehicle.
b) After replacement of power assist steering
column, the torque and steering angle
signal calibrations are needed;
c) After replacement of EPS ECU or update
of its software programs, the torque and
steering angle signal calibrations are
needed;
d) After removal or replacement of steering
wheel, joint and steering gear, the
steering angle signal calibration is
needed.
344
BYD AUTO BYD Suri Maintenance & Repair Manual
□ 1.……
□ 2.……
……
■ 6. BYD EPS
□ 7.……
Select diagnostic screen
of BYD EPS
Select
■ 6. Torque signal
calibration Enter the
screen of torque signal
calibration
Select
■ 2. Set the current Perform signal
torque as zero point calibration manually
345
BYD AUTO BYD Suri Maintenance & Repair Manual
□ 1.……
□ 2.……
……
■ 6. BYD EPS
□ 7.……
Select diagnostic screen
of BYD EPS
Select
■ 5. Steering angle signal
calibration Enter the
screen of steering angle
signal calibration
□ 1. Read the zero point of
steering angle
■ 2. Set the current steering
angle as zero point
Select
■ 2. Set the current steering angle as zero point
Perform the calibration of the steering angle
neutral point
Perform signal
calibration manually
346
BYD AUTO BYD Suri Maintenance & Repair Manual
□ 1.……
□ 2.……
……
■ 6. BYD EPS
□ 7.……
Select diagnostic screen
of BYD EPS
Select
■ 3. Clear the error
codes
Tester display:
Clear the error codes
Press any button to
return the previous
screen
Select
■ 2. Read system
malfunctions
Tester display:
System is OK
347
BYD AUTO BYD Suri Maintenance & Repair Manual
348
BYD AUTO BYD Suri Maintenance & Repair Manual
349
BYD AUTO BYD Suri Maintenance & Repair Manual
Section 1 Precautions
1.1 Precautions for Repair and Diagnosis
ESP is a component related to driving safety. When conducting repair and diagnosis on it, observe
the following diagnosis precautions in addition to general safety and preventive measures.
(a) ESP system should only be repaired by (c) The ESP assembly (ESP electronic
technicians who have received professional control unit and hydraulic regulator
training and mastered repair skill. Its parts assembly, excluding brake lines and
should only be replaced with original parts sensors, etc.) can only be replaced as a
of the manufacturer. whole and cannot be disassembled or
replaced partly. Bosch does not provide
individual spare parts or warranty the
disassembled ESP assembly. It is not
responsible for any consequence
caused by disassembly or partial
replacement of ESP hydraulic regulator.
350
BYD AUTO BYD Suri Maintenance & Repair Manual
351
BYD AUTO BYD Suri Maintenance & Repair Manual
2.5 Confirm and reproduce the malfunction: When the vehicle is restarted, accelerate it to
15 kHz and then read the DTCs.
2.7 Perform troubleshooting in accordance with trouble code table, and then go to step 9.
352
BYD AUTO BYD Suri Maintenance & Repair Manual
Quality Inspector
License Plate
Owner Number
Name
Model
Contact
Chassis No.
Number
Date of
/ / Odometer km
Entry
Date of
/ /
Occurrence
Malfunction
Condition Frequency
of Often □Sometimes ( times/day)
Occurrence
Troubleshooting
353
BYD AUTO BYD Suri Maintenance & Repair Manual
Before diagnosing the ESP system, first check the accessible components that may cause ESP
system malfunction. Visual inspection and appearance inspection procedures can confirm the
malfunction quickly with no need for further diagnosis.
354
BYD AUTO BYD Suri Maintenance & Repair Manual
355
BYD AUTO BYD Suri Maintenance & Repair Manual
ESP 9 consists of hydraulic module with electronic control unit and various sensors as shown
below.
356
BYD AUTO BYD Suri Maintenance & Repair Manual
The brake system uses X type layout as shown below. ESP 9 hydraulic regulator consists of a
motor, 2 return pumps, 2 accumulators, a pressure sensor and 12 solenoid valves.
MC1 Brake master cylinder first FLAV Left front wheel oil outlet
circuit valve
MC2 Brake master cylinder FREV Right front wheel oil inlet
second circuit valve
M Motor FRAV Right front wheel oil outlet
valve
RP1 Return pump 1 RLEV Left rear wheel oil inlet
valve
RP2 Return pump 2 RLAV Left rear wheel oil outlet
valve
A1 Accumulator 1 RREV Right rear wheel oil inlet
valve
A2 Accumulator 2 RRAV Right rear wheel oil outlet
valve
FL Left front wheel HSV1 High pressure valve
FR Right front wheel HSV2 High pressure valve
RL Left rear wheel USV1 Guide valve
RR Right rear wheel USV2 Guide valve
FLEV Left front wheel oil inlet P/U Pressure sensor
valve
357
BYD AUTO BYD Suri Maintenance & Repair Manual
358
BYD AUTO BYD Suri Maintenance & Repair Manual
Pin Function
1 Backlight positive
2 Signal input
3 Ground
4 Backlight negative
359
BYD AUTO BYD Suri Maintenance & Repair Manual
If the brake system malfunctions, but ESP 6.1.6 Booster malfunction (May cause the
does not store any DTC, the malfunction is hard or spongy feeling of brake pedal,
called non-DTC malfunction. Non-DTC long brake pedal travel, or even loss of
malfunction is usually caused by basic brake effectiveness)
brake system malfunctions, such as:
The brake line is connected incorrectly
6.1.1 Brake fluid leakage (May cause the (May cause ESP performance to reduce,
spongy feeling of brake pedal, long tailing and long braking distance). For
brake pedal travel, or even loss of correct installation method, refer to the
brake effectiveness) label near oil hole on the ESP hydraulic
regulator module: (MC1 represents No. 1
6.1.2 Brake fluid of poor quality is used Master Cylinder Pipeline; MC2 represents
(The brake fluid of poor quality may No. 2 Master Cylinder Pipeline; FL
cause the brake line and internal represents Left Front Wheel Cylinder
components of ESP hydraulic Pipeline; FR represents Right Front Wheel
regulator module to corrode, or even Cylinder Pipeline; RL represents Left Rear
loss of brake effectiveness) Wheel Cylinder Pipeline; RR represents
Right Rear Wheel Cylinder Pipeline)
6.1.3 Air in the brake line (May cause the
spongy feeling of brake pedal, or even Notice: When no power is supplied to ESP
loss of brake effectiveness) or the power supply is interrupted, ABS
and ESP warning lamps will remain on, but
6.1.4 The brake line is blocked (May cause no DTC is output.
hard feeling of brake pedal, or even
loss of brake effectiveness) Troubleshooting suggestion: Check the
applicable components related to the
6.1.5 Excessive wear of brake disk (May malfunction, and perform troubleshooting
cause the spongy feeling of brake according to the vehicle repair manual.
pedal and long brake pedal travel)
360
BYD AUTO BYD Suri Maintenance & Repair Manual
In the electrical system, poor contact may occur temporarily in the electrical circuit or the
position where signals are input and output, thus causing occasional malfunction. Sometimes,
the failure cause may disappear automatically so that it is hard to find the problem. When the
occasional malfunction occurs, simulate the malfunction as follows to check if it reoccurs.
If the malfunction does not occur at this time, the diagnosis and repair must be performed
next time when it reoccurs. Generally, the occasional malfunction may become
reproducible malfunction which will not disappear automatically.
361
BYD AUTO BYD Suri Maintenance & Repair Manual
362
BYD AUTO BYD Suri Maintenance & Repair Manual
363
BYD AUTO BYD Suri Maintenance & Repair Manual
If a malfunction occurs even if no malfunction is memorized when reading DTC, check the circuit
for each trouble symptom based on the order and reference page listed in the table below.
Notice:
8.1.1 Before checking and repairing ESP, make sure the regular brake system operates normally.
8.1.2 ESP hydraulic regulator with ECU, sensors and others need to be replaced, first turn the
364
BYD AUTO BYD Suri Maintenance & Repair Manual
vehicle off.
Trouble
Inspection Area Reference Page
Symptom
If the malfunction still exists when the following 1~4 are
normal, replace ESP hydraulic regulator with ECU: 10
1. Read trouble codes and confirm malfunction memory
ESP does not
work 2. Start button power UZ (Pin 32) circuit 37
3. Wheel speed sensor circuit 30, 42
4. Check ESP with diagnostic tester. If abnormal, check
22
if the brake line leaks
If the malfunction still exists when the following 1~4 are
normal, replace ESP hydraulic regulator with ECU:
10
1. Read trouble codes and confirm no malfunction is
memorized
2. Wheel speed sensor circuit 30, 42
ESP does not
3. Check ESP with diagnostic tester. If abnormal, check
work well 6
if the brake line leaks
4. Read "Hydraulic Regulator Filling Status" with
11
diagnostic tester
5. Make sure the mounting bracket is secured correctly
(Driving comfort will reduce)
ESP warning 1. ESP warning lamp circuit 27, 37
lamp is 2. ESP hydraulic regulator with ECU 60
abnormal 3. Battery voltage is low 62
If the malfunction still exists when the following 1~3 are
normal, replace ESP hydraulic regulator with ECU: 37
Trouble codes 1. ESP hydraulic regulator with ECU power/ground wire
cannot be read 2. DIAGK (Pin 17) wire of ESP hydraulic regulator with
37
ECU
3. Diagnostic tester
8.2 Intermittent Trouble Symptom Table
Description:
Inspection Operation
· Perform "Preliminary Inspection"
· Collect information about intermittent malfunction from the customer, such as:
· The speed range when the malfunction occurs.
· Does the malfunction occur after the after sales electric device is used?
· Does the malfunction occur when driving on rough or slippery roads?
Preliminary
· If the wheel speed sensor malfunctions only when driving on the slippery road,
check whether water enters the wheel speed sensor circuit. If the DTC is not
output, perform the following operations to simulate the slippery road:
1. Mix 2 teaspoons of salt and 35 ml of water.
2. Spray the saline water on the suspected area.
3. Road test the vehicle on various roads.
365
BYD AUTO BYD Suri Maintenance & Repair Manual
366
BYD AUTO BYD Suri Maintenance & Repair Manual
9.1.1 The voltage is lower than 4.5 V when the (b) The ECU is damaged.
vehicle is powered on.
Diagnostic steps:
9.2.1 The valve power supply malfunctions. (a) The solenoid valve is short to power or
(The power supply is short to ground or ground, or open circuit.
open)
(b) Fuse malfunction
9.2.2 The temperature of solenoid valve is too
high. (Overheat protection) (c) System overheat protection
9.2.3 More than 5 solenoid valves are short. (d) ESP is damaged.
(Fuse)
367
BYD AUTO BYD Suri Maintenance & Repair Manual
Diagnostic steps
Pump Motor Malfunction 9.3.4 The return pump motor relay stops
operating, and the return pump monitoring
DTC: C002004 detects voltage does not drop.
9.3.1 The pump motor operates at excessive (a) System overheat protection.
load and the temperature is too high.
(Overheat protection) (b) The power supply of pump motor is
abnormal.
9.3.2 After the return pump motor relay
operates for 60 ms, the return pump (c) The pump motor relay malfunctions
monitoring cannot detect the voltage (Fuse, external relay).
signal.
(d) The pump motor malfunctions.
9.3.3 The return pump motor relay does not
operate, and the return pump monitoring (e) The pump motor is poorly grounded.
detects voltage for more than 2.5 s.
Diagnostic steps
368
BYD AUTO BYD Suri Maintenance & Repair Manual
DTC: C003204, C003504, C003804, (a) The wheel speed sensor circuit is
C003B04 disconnected, and the connector is loose
and broken.
Malfunction setting conditions
(b) The signal wire and power cable of wheel
9.4.1 ECU detects the signal wire of wheel speed sensor are reversed.
speed sensor is short to ground.
(c) The signal wire is short to ground.
9.4.2 The wheel speed sensor circuit is open.
The air gap exceeds the specifications
Possible Cause
Diagnostic steps
369
BYD AUTO BYD Suri Maintenance & Repair Manual
(f) The wheel speed sensor is disturbed by (i) The tire size is not as specified.
outside magnetic field. (The wheel or axle
does not demagnetize) (j) The ECU is damaged.
Diagnostic steps
370
BYD AUTO BYD Suri Maintenance & Repair Manual
Diagnostic steps
The vehicle CAN bus communication, configuration information and wire harness malfunction.
Possible Cause
Diagnostic steps
371
BYD AUTO BYD Suri Maintenance & Repair Manual
DTC: C004601
9.8.2 The pressure value is abnormal. (Less than the original value)
Possible Cause
Diagnostic steps
372
BYD AUTO BYD Suri Maintenance & Repair Manual
Diagnostic steps
For ESP9 system, the yaw rate sensor is 9.10.2 The yaw rate sensor signal is abnormal.
installed outside. For ESP9i system, the yaw
rate sensor is installed inside (i.e. integrated 9.10.3 The yaw rate sensor malfunctions.
sensor).
Possible Cause
The yaw rate sensor contains lateral
acceleration signal, longitudinal acceleration (a) The sensor is not calibrated or calibration
signal and yaw velocity signal. is not as specified (It should be calibrated
on a flat ground).
DTC: C006108, C006208, C006308,
C019604, C00A800 (b) The installation error of sensor (i.e. ESP
module assembly) is great.
Diagnostic steps
373
BYD AUTO BYD Suri Maintenance & Repair Manual
repaired?
6 Perform diagnosis again and check if the -- Diagnosis
malfunction reoccurs. ends
Diagnostic steps
Possible Cause
Diagnostic steps
374
BYD AUTO BYD Suri Maintenance & Repair Manual
9.13.1 EPB message timeout. (b) EPB software versions do not match.
Diagnostic steps
DTC: C004C04
Possible Cause
Malfunction setting conditions
(a) The PATA switch is covered by some
9.14.1 Press and hold the PATA switch for items.
more than 10 seconds.
(b) The PATA switch is damaged.
9.14.2 The PATA activation signal is monitored
for more than 2 seconds during ignition.
Diagnostic steps
375
BYD AUTO BYD Suri Maintenance & Repair Manual
Diagnostic steps
376
BYD AUTO BYD Suri Maintenance & Repair Manual
Malfunction setting conditions (a) The wheel speed difference is too big.
9.17.1 ESP receives a command to operate (b) The sensor signal is incorrect.
continuously (more than 10 seconds).
The signals of steering angle sensor and
yaw velocity sensor are abnormal.
Diagnostic steps
9.18.1 The clutch signal is abnormal. (c) Driving habits of some drivers (The clutch
pedal is depressed for more than 5
Possible Cause minutes while driving).
Diagnostic steps
377
BYD AUTO BYD Suri Maintenance & Repair Manual
9.19. 1 The reverse gear signal is "1" when the (b) BCM communication malfunctions.
vehicle is moving forward.
(c) The reverse gear signal wire
9.19.2 The reverse gear signal is "0" when the malfunctions.
vehicle is reversing.
Diagnostic steps
378
BYD AUTO BYD Suri Maintenance & Repair Manual
10.1.2 Remove the wire harness from the ESP 10.2.5 The steering angle sensor and yaw rate
assembly. sensor (integrated sensor) must be
calibrated after the ESP assembly is
10.1.3 Fully depress the brake pedal and hold replaced.
it with the pedal bracket to prevent the
brake fluid outflow after the brake line is 10.3 Bleeding Instruction
removed from the brake master cylinder.
10.3.1 After the brake system components are
10.1.4 Remove the brake line and plug the replaced by the customer (when the brake
threaded hole on the ESP assembly and fluid, brake line or hydraulic unit is
the oil hole on the brake line to prevent replaced) or when the brake pedal feels
foreign materials from entering. spongy, the bleeding must be performed.
Remove the retaining bracket from ESP. 10.3.2 The hydraulic unit replaced by the
customer must be the fully filled ESP
10.2 Installation Procedures for ESP hydraulic regulator with ECU.
Assembly
10.3.3 When bleeding, ensure the brake
10.2.1 Install the ESP assembly to the bracket system structure is complete and the
and tighten it to 8±2 Nm. entire high-pressure hydraulic unit is well
connected.
10.2.2 Unplug the ESP threaded hole and
brake line, connect the brake line to ESP 10.3.4 The parking brake should be applied
assembly and tighten it to 16±2 Nm. before bleeding.
10.2. 3 Fill the brake fluid in the reservoir to the 10.3.5 The brake fluid is corrosive. If it
Max position and bleed using specified contacts your skin, wash it off.
methods.
ESP9i system integrates the yaw rate sensor which requires high installation precision. The
installation error must be less than ±5°when replacing, or the calibration cannot be performed.
a The maximum inclination of the test bed must be within the allowable range (The
inclination must meet the requirements in both calibration directions. For details, refer to
the chart below)
379
BYD AUTO BYD Suri Maintenance & Repair Manual
i Additional interferences (such as closing the door or engine hood) are not allowed
Note the maximum allowable inclination when performing IIS calibration! ±0.57°
Note
The delivered ESP has stored the predetermined offset in its EEPROM. During calibration,
ECU will write the newly measured data in EEPROM for use by ESP. ESP cannot determine
the above mentioned preconditions, so the customer must ensure the above calibration
conditions are satisfied. If the offset is too big, the system will reject the calibration. The vehicle
needs to be returned to the dealership for repair. IIS calibration must be performed after ESP9i
is replaced.
380
BYD AUTO BYD Suri Maintenance & Repair Manual
Model BYD 5 A
Brake Line Layout X type
Drive type Front wheel drive
System Bosch ESP 9
Brake fluid type Specified by BYD Mixed use is forbidden
No. of gear ring tooth 48
Internal resistance of wheel 3 M ~5 M
speed sensor
Air gap between the wheel 0.1~0.9 mm
speed sensor and gear ring
Front wheel
Rear wheel 0.2~0.7 mm
Standard: 205/65 R15 94V
Tire type Optional: 205/65 R16 92V
381
BYD AUTO BYD Suri Maintenance & Repair Manual
Contents
Section 1 Front Bumper System ............................................................................................383
1.1 Front Bumper ........................................................................................................... 383
1.3 Fender ...................................................................................................................... 390
1.4 Installation/Removal of Vent Cover ......................................................................... 393
1.5 Interior and Exterior Components............................................................................ 394
1.6 Auxiliary Instrument Panel Assembly ...................................................................... 406
1.7 Side Body................................................................................................................. 414
1.8 Back Trim ................................................................................................................. 418
1.9 Removal/Installation of Door Guard Plate ............................................................... 420
1.10 Removal/Installation of Sun Screen Assembly ..................................................... 427
1.11 Removal and Installation of Roof Handrail ............................................................ 428
1.12 Removal/Installation of Ceiling .............................................................................. 428
1.13 Removal/Installation of Carpet .............................................................................. 429
1.14 Removal/Installation of Heat Insulation Layer ....................................................... 430
1.15 Removal and Installation of Trunk System ............................................................ 431
1.16 Rear License Plate Lamp Trim Strip Assembly..................................................... 434
382
BYD AUTO BYD Suri Maintenance & Repair Manual
前LOGO
Front LOGO
前格栅
Front Grille
前保险杠右支架
Front Bumper Front Bumper
前保险杠左支架
Support RH Support LH
前格栅网格
Front Grille Mesh
Front Bumper
前保险杠
Front前保险杠右牵引口盖板
Bumper Right Towing Eyelet 前保险杠左牵引口盖板
Front Bumper Left Towing
Cover Plate Eyelet Cover Plate
383
BYD AUTO BYD Suri Maintenance & Repair Manual
Figure 4-1-1-2 Removal of Grille Upper Cover 1.1.2.3 Loosen the right front wheel fender
Plate
Tips: The removal method is the same as 2.
1.1.2.1 Remove the grille upper cover plate
384
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1.2.4..5 Loosen the engine lower fender as 1.1.2.6.1 Loosen the mounting clamps as
shown in figure 4-8-1-4; shown in figure 4-1-1-6 and pull the
outside of fog light trim panel outward.
1.1.2.4.6 Remove the front bumper assembly. Push the inside of fog light trim panel
outward after loosening the clamps. The
front bumper left and right fog light trim
panels each have 5 clamps;
385
BYD AUTO BYD Suri Maintenance & Repair Manual
1.1.2.8 Remove the front bumper support RH 1.1.2.9.2.4 Confirm the front bumper assembly
parts and front bumper assembly can be
Tips: The removal method is the same as 8. well connected with the surrounding parts.
386
BYD AUTO BYD Suri Maintenance & Repair Manual
1.25 Bumper
Reflex Reflector
387
BYD AUTO BYD Suri Maintenance & Repair Manual
388
BYD AUTO BYD Suri Maintenance & Repair Manual
389
BYD AUTO BYD Suri Maintenance & Repair Manual
1.3 Fender
1.3.1 General
To remove the front wheel fender, remove 4 cross recessed pan head tapping screw and big
washer assemblies indicated by 6 in the figure with a cross screwdriver.
Then remove 8 snap fasteners as shown in figure 5. Remove the male part by prying it with a
straight screwdriver.
Remove 1 E-shape snap-fit indicated by 4 in the figure with a straight screwdriver.
Remove 2 cross recessed hexagon head tapping screws and big washer assemblies indicated
by 3 in the figure with a cross screwdriver.
The front fender can be taken off after the above fasteners are removed.
The front wheel inner plate can be taken off when another 5 snap fasteners indicated by 1 in the
figure are removed.
390
BYD AUTO BYD Suri Maintenance & Repair Manual
To remove the rear wheel fender, remove 1 cross recessed pan head tapping screw and big
washer assembly indicated by 1 in the figure with a cross screwdriver. Then the rear wheel lower
plate can be taken off.
Then remove 10 snap fasteners from the rear wheel fender indicated by 2 in the figure. Remove
the male part by prying it with a straight screwdriver.
Remove 1 cross recessed pan head tapping screw and big washer assembly indicated by 5 in the
figure with a cross screwdriver.
Then the rear wheel fender and rear wheel small fender can be removed.
391
BYD AUTO BYD Suri Maintenance & Repair Manual
The removal of engine lower fender can be performed after the front wheel fender is removed. Due
to the special position of fender, the body should be raised with professional lifting devices for
convenient operation.
First, remove the engine lower rear fender indicated by 4 in the figure. The method is as follows:
Remove 2 hexagon head tapping screw and big washer assemblies indicated by 5 in the figure
with a sleeve. Then remove 5 snap fasteners indicated by 6 in the figure with a straight
screwdriver. Remove the male part by prying it with a straight screwdriver. At this time, the engine
lower rear fender can be taken off.
Second, remove the engine lower front fender indicated by 2 in the figure. Remove 2 cross
recessed pan head tapping screw and big washer assemblies indicated by 1 in the figure with a
cross screwdriver. Then remove 8 hexagon head tapping screw and big washer assemblies
indicated by 3 in the figure with a sleeve to take off the engine lower front fender.
392
BYD AUTO BYD Suri Maintenance & Repair Manual
1.4.2 Press the male part and remove the snap fastener A with a cross screwdriver.
1.4.3 Pull up the right vent cover near the front compartment to separate the clips from the metal
plate slot. Then use the same method to separate the left vent cover clips from the metal plate
slot. Then rotate the separated ends of left and right vent covers upward for proper angle and
then pull them along the front compartment to move the left and right vent covers away from
the windshield at the same time. Do not apply too much force, or the clips may be damaged.
1.4.4 Install the vent covers in the reverse order of the removal procedures.
A子母扣
Snap Fastener A
雨刮器检
Windshield
Wiper Access Right Vent Cover Upper
修盖板 右通风盖板上封板
Cover Plate
A 右通风盖板
Right Vent Cover
左通风盖板
Left Vent Cover A
393
BYD AUTO BYD Suri Maintenance & Repair Manual
described below.
1.5 Interior and Exterior Components
1.5.1 Removal/Installation of Combination
Dashboard Assembly Switch Upper/Lower Protector
Product surface;
(d) After installation, the clearance fit and
flush of all parts should meet the
requirements in appearance tolerance
table.
394
BYD AUTO BYD Suri Maintenance & Repair Manual
Figure 1.5.3 Schematic Diagram for Figure 1.5.5 Console Box Trim Strip (2)
Removal of Combination Switch
Removal:
Upper/Lower Protector
Installation: Pry all the snap-fits and clips from bottom to
top along the side seam of trim strip with a
(a) Install the combination switch lower straight screwdriver wrapped with flexible
protector, ensure both sides of lower tape as shown in figure 1.5.5. Pull up the
protector are attached to the trim strip by hand carefully to prevent the
combination switch body and tighten 3 snap-fits and clips from being broken.
screws;
Installation:
(b) Install the combination switch upper
protector, ensure the clips on the 1.5.2.1 Check if the removed snap-fit
upper and lower protector are aligned (BYDQ836A01) is installed in its
and carefully tap them until firmly original position;
secured.
1.5.2.2 Align 2 snap-fits on the top with the
1.5.2 Removal/Installation of Console Box mounting holes, and then align the
Trim Strip single-side clips in order;
Removal:
395
BYD AUTO BYD Suri Maintenance & Repair Manual
1.5.3.1.3 Slowly pull out the acoustic panel (a) Install the rear oblique pins of acoustic
in horizontal direction, until the rear panel to the mounting holes;
oblique pins are separated from the
mounting holes completely. (b) Slightly raise the front of acoustic
panel to align 3 front single-side clips
Installation: and mounting holes, and tap the clips
until they are assembled securely;
(a) Install the rear oblique pins of acoustic
panel to the mounting holes;
Removal:
396
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal:
(a) Check if 2 removed snap-fits 1.5.5.2 Remove the limited posts on both
(BYDQ836A01) are installed in the sides of glove box by compressing
original positions; them so that the lower body will not
limit the glove box;
(b) Align the structures to be installed
horizontally; 1.5.5.3 The glove box assembly can be
removed by disconnecting the hinge of
(c) Tap each assembly area until they are glove box assembly from the
fixed securely with excellent dashboard lower body.
appearance.
Installation:
1.5.5 Removal/Installation of Glove Box
Assembly The installation of glove box assembly is in
reverse order of removal.
397
BYD AUTO BYD Suri Maintenance & Repair Manual
Protector Assembly
Removal:
Notice:
The installation and removal methods of Put the top hemming into proper slot, align
pneumatic spring and lower body are the each snap-fit with its snap-fit hole and
same as that of pneumatic spring and glove carefully tap it in. Check if the exterior
box assembly. clearance is as specified after installation.
398
BYD AUTO BYD Suri Maintenance & Repair Manual
Installation:
399
BYD AUTO BYD Suri Maintenance & Repair Manual
1.5.9.3 Lift the center cover plate, (a) Check if the removed snap-fit
disconnect the connector of (BYDQ836A01) is installed in its
emergency alarm switch and then pull original position.
out the dashboard center cover plate
assembly. (b) Align each clip with its snap-fit hole
and tap it until assembled securely.
Installation:
(b) Align the structures to be installed 1.5.11.1 Left Dashboard Trim Strip
horizontally;
400
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal:
The right trim strip should be installed prior (b) Hold both left and right sides of center
to the right air inlet, align each snap-fit with upper cover plate by hands, and
its snap-fit hole and carefully press them in slowly pull it up until 5 clips as shown
by hands. Check if the clearance is good in the figure are pulled out completely.
after installation.
Installation:
1.5.12 Removal/Installation of Center Upper Align each clip with its mounting position
Cover Plate and tap them until they are fixed securely
with excellent appearance.
401
BYD AUTO BYD Suri Maintenance & Repair Manual
402
BYD AUTO BYD Suri Maintenance & Repair Manual
Notice:
Removal:
(c) Take out the dashboard upper body Notice: The tip of screwdriver must be
assembly in the direction indicated by wrapped with flexible tape to avoid damaging
the straight arrow. the product surface.
Installation: Removal:
The installation of dashboard upper body is in The PAB cover plate can be removed by
reverse order of removal. prying 10 single-side clips along the clearance
between the cover plate and upper body with a
1.5.14 Removal/Installation of Safety Airbag straight screwdriver wrapped with flexible
Reserved Cover Plate tape.
Installation:
403
BYD AUTO BYD Suri Maintenance & Repair Manual
Removal:
404
BYD AUTO BYD Suri Maintenance & Repair Manual
405
BYD AUTO BYD Suri Maintenance & Repair Manual
406
BYD AUTO BYD Suri Maintenance & Repair Manual
Notice:
Figure 1.6.2 Auxiliary Instrument Panel Body
Assembly 1 (a) All personnel for disassembly must be
very familiar with the structure of the
product to avoid any unexpected
As shown in figure 1.6.2 and 1.6.3: The circumstances during the process of
auxiliary instrument panel body assembly disassembly;
consists of the following components, such as
the auxiliary instrument panel body, auxiliary (b) The tip of straight screwdriver must be
instrument panel handrail components, central wrapped with flexible tape when prying
storage box spring switch mechanism to avoid damaging the product surface;
subassembly, rear ashtray subassembly, cup
holder hog ring assembly, cup holder (c) Ensure all the related wire harnesses are
ornament, hand brake sealing strip and rear disconnected before removal.
trim panel. (It also contains the auxiliary
instrument panel storage box rubber cushion, (d) Be careful during removal and
auxiliary instrument panel front/rear carpet cup installation to avoid scratching.
holder, and cup holder rubber cushion and
storage box carpet.)
1.6.2.1 Removal/Installation of Left/Right
Front Guard Assembly
407
BYD AUTO BYD Suri Maintenance & Repair Manual
408
BYD AUTO BYD Suri Maintenance & Repair Manual
409
BYD AUTO BYD Suri Maintenance & Repair Manual
410
BYD AUTO BYD Suri Maintenance & Repair Manual
a) Ensure the gear shifting lever is in Figure 1.6.15 Auxiliary Instrument Panel
neutral position and the hand brake is in Rear Mounting Bracket
the lock position of top dead center;
411
BYD AUTO BYD Suri Maintenance & Repair Manual
Notice:
412
BYD AUTO BYD Suri Maintenance & Repair Manual
Figure 1.6.19 Removal of Auxiliary (b) Pull out the storage box cushion
Instrument Panel Handrail Component from the handrail inner panel. See
figure 1.6.22;
413
BYD AUTO BYD Suri Maintenance & Repair Manual
Tools: essential special tools, operating Schematic diagram for removal of front door
equipment, tester and auxiliary tools sill inner/outer protector:
414
BYD AUTO BYD Suri Maintenance & Repair Manual
The removal method of rear door sill inner 1.7.5 Removal/Installation of B Pillar Lower
protector is the same as that of front door sill Protector
inner protector. The schematic diagram is as
follows: Remove the front seat and font/rear door sill
protector and tear the sealing strip. Disengage
the snap-fits on the B pillar lower protector and
clips fixed on the upper protector so that the B
pillar lower protector can be removed.
415
BYD AUTO BYD Suri Maintenance & Repair Manual
416
BYD AUTO BYD Suri Maintenance & Repair Manual
417
BYD AUTO BYD Suri Maintenance & Repair Manual
418
BYD AUTO BYD Suri Maintenance & Repair Manual
1.8.1.1 Confirm the C pillar left/right protector 1.8.1.3 The assembly of shelf is in reverse
and seats has been removed before order of removal and the damaged snap-fit
removing the shelf. Release the safety belt should be replaced. The left and right child
from the shelf opening as follows: safety lock covers can be operated in
random order.
419
BYD AUTO BYD Suri Maintenance & Repair Manual
Right Trunk
Panel
Trunk Tool
Box Back Pedal
420
BYD AUTO BYD Suri Maintenance & Repair Manual
Figure 1.9.1 Inner Handle Cover Plate The circled areas in the above figure
are connected with snap-fits.
1.9.1.2 Remove the inner wedging block cover
plate with a flat tip driver wrapped with 1.9.1.4 Pull out the wire harness connectors
protective tape. Do not scratch the inner on the window control panel in the
wedging block handle and lock button. direction indicated by the arrow.
421
BYD AUTO BYD Suri Maintenance & Repair Manual
1.9.1.7 Pry the door guard plate in the position Figure 1.9.8 Removal of Door Guard Plate
indicated by the arrow with a flat tip driver
wrapped with protective tape and remove 1.9.1.9 Pull out the unlocking cable from the
it from the door metal plate. The front door wedging block base in the direction
guard plate is connected by 10 snap-fits indicated by arrow 1, and then pull out the
which needs more force to remove. Do not pin at end of door lock wire harness from
scratch the door guard plate and metal the inner wedging block handle hole.
plate.
422
BYD AUTO BYD Suri Maintenance & Repair Manual
1.9.1.10 Remove the locking cable. The 1.9.1.12 The front door guard plate of luxury
removal and installation methods are the and flagship models has a door lamp.
same as that in the above figure.
Press the button on the connector in the
Ensure the position of 2 wire harnesses is direction indicated by arrow 1, and then pull
correct during assembly. Do not mix them. out the connector from the door lamp in the
direction indicated by arrow 2.
Figure 1.9.10 Removal of Locking Cable Figure 1.9.12 Removal of Door Lamp
423
BYD AUTO BYD Suri Maintenance & Repair Manual
1.9.2 Removal/Installation of Rear Door Guard 1.9.2.3 Remove the window control switch
Plate from rear to front with a flat tip driver
wrapped with protective tape. Do not
1.9.2.1 Remove the inner handle cover plate scratch the window control panel and door
with a flat tip screwdriver wrapped with guard plate. There is a large fastener on
protective tape. The edge of inner handle both front and rear of window control panel.
cover plate has a notch to make removal More force may be needed when removing
easier. Do not scratch the switch panel the window control panel. Do not scratch
and door guard plate. the handrail covering, window control
panel and door guard plate during
removal.
424
BYD AUTO BYD Suri Maintenance & Repair Manual
425
BYD AUTO BYD Suri Maintenance & Repair Manual
426
BYD AUTO BYD Suri Maintenance & Repair Manual
427
BYD AUTO BYD Suri Maintenance & Repair Manual
428
BYD AUTO BYD Suri Maintenance & Repair Manual
Notice:
429
BYD AUTO BYD Suri Maintenance & Repair Manual
b. The carpet can be removed after b. Remove all the components fixed on
taking out the foot rest, carpet foam the heat insulation layer of front
pad, lower spacer of carpet and compartment, and then separate the
rear spacer of carpet as shown in heat insulation layer of front
figure 1-13-3. compartment from the metal plate
(Note: The nut type plastic snap-fits
must be removed before the removal
of upper heat insulation layer of front
compartment).
Figure 1-14-1 Schematic Diagram for Heat a. Before the removal of cowl heat
Insulation Layer of Front Compartment insulation layer, the dashboard
assembly, auxiliary instrument panel
1.14.1.1 Removal of Heat Insulation Layer of assembly, carpet, tubular beam, and
Front Compartment DV, air conditioner and wire harness
installed on the tubular and
a. The power drive assembly, brake line, dashboard, brake pedal, clutch pedal,
wire harness of front compartment accelerator pedal and steering
and vacuum booster pump should be column should be removed; For
removed before the heat insulation removal method, refer to relevant
layer of front compartment is sections.
430
BYD AUTO BYD Suri Maintenance & Repair Manual
1.14.4 Removal and Installation of Heat Figure 1-15-1 Schematic Diagram for Trunk
Insulation Layer of Front Compartment System
431
BYD AUTO BYD Suri Maintenance & Repair Manual
Figure 1-15-2 Structure Figure of Back Pedal (c) The installation of trunk maintenance
cover is in reverse order of removal.
(a) The back pedal can removed after the 1.15.4 Removal/Installation of Left/Right
trunk cover plate assembly and trunk tool Trunk Panel
box are taken out:
432
BYD AUTO BYD Suri Maintenance & Repair Manual
Panel
1.15.5.1 The trunk lid panel can be taken off
1.15.4.1 The panel can removed after the after prying and removing all the
trunk cover plate, trunk back pedal and snap-fits with a straight screwdriver.
trunk tool box are taken out:
1.15.5.2 The installation is in reverse order of
1.15.4.2 Pry the head of snap-fit lightly with a removal.
straight screwdriver, and then take it out
by hand. The panel can be taken out
after 5 snap-fits in the figure are
removed.
BYDQ320S05
433
BYD AUTO BYD Suri Maintenance & Repair Manual
1.16.1 General
The structure and assembly position of rear license plate lamp trim strip are shown in the figure
below:
Prepare the remover, socket M8, M10 and flat Remove 6 hexagon flange nuts (as shown in
tip driver before removal. Please wear a pair of figure 1-16-2) with socket M8 or other tools.
gloves before removal to protect your hands.
Be careful not to scratch the body during
removal. Perform the removal according to the
following steps:
434
BYD AUTO BYD Suri Maintenance & Repair Manual
Figure 1-16-3
435