1.1.1.1 Overview

The Service Manual for WH12 Series Vehicles is developed to ensure that the maintenance technicians can gain a comprehensive understanding of Windrose commercial vehicles, and maintenance technicians' vehicle identification and maintenance abilities can be enhanced. This manual introduces the maintenance and repair of Windrose commercial vehicles in a systematic manner, especially the common fault phenomena, fault detection methods, removal and installation steps, technical requirements of maintenance, etc. of the powertrain, chassis, frame and body interiors and exteriors. Please carefully read this manual when maintaining the Windrose commercial vehicles. You should be familiar with the performance and principles of the vehicles, and perform maintenance following the steps and standards described in this manual to ensure the safety and effectiveness of the maintenance. Windrose will provide updates and revisions to this manual as needed.Your suggestions and corrections would be appreciated. Keep in mind that the information in this manual may differ from the actual situation as Windrose commercial vehicles have been improved continuously.

1.1.2 Maintenance Information Instructions 1.1.2.1 Definition of Abbreviations Used in the Manual

1.1.2.2 Description of Arrow Symbols Used in This Manual

Legend 1. Indication arrow 4. Part number notation 2. Moving direction arrow 5. Partial enlargement frame 3. Rotation direction arrow 6. Fastener removal and installation sequence notation

1.2.1 Vehicle Identification Number 1.2.1.1 Vehicle Identification

Printing position of vehicle identification number (VIN) The vehicle identification number (VIN) is engraved near the centerline of the front axle at the outer side of the frame right side member.

1.2.1.2 VIN Deciphering

Composition of Vehicle VIN Deciphering: The VIN deciphering is made up of World Manufacturer Identifier （ WMI ） 、 Vehicle Description Section （ VDS ） 、 Check Digit （ CD ） and the Vehicle Indicator Section （ VIS ） is composed of four parts (17 digits in total). Taking the Vehicle Identification Number 1W94RBCD8RR698001 as an example, the meaning represented by each digit is shown in the following table:

1st~3rd Digit- World Manufacturer Identifier （ WMI ）

The first section (1st-3rd digit) of the vehicle identification number, where: 1W9 —— Windrose Technology Inc.

4st~8rd Digit- Vehicle Description Section

There are three types in total,Respectively4RBCD 、 4RBCF 、 4RACC,The explanations are as shown in the following table:

9th Digit - Check Digit

This digit is calculated by the manufacturer based on the remaining 16-digit code via a certain formula; It may be a number from 0 to 9 or letter "X",to verify the authenticity of the VIN, so as to ensure the uniqueness and validity of the VIN.

10th Digit- Model Year

Indicate the year.

11th Digit- Plant of Manufacture

Indicate the assembly plant.

12st~14rd Digit- WMI

698,Assigned by SAE 。

15st~17rd Digit- Sequentially Assigned

A 3-digit number to indicate the production sequence number of the vehicle. 1.2.1.3 Motor Nameplate Identification

Nameplate Location and Content

1. Location of motor nameplate 2. Location of motor SN

1.2.1.4 Vehicle Environmental Sign, Nameplate and VIN

Vehicle Nameplate 1. The nameplate is located on the right sliding door frame (C- pillar) of the vehicle. 2. The nameplate bears the full name of the manufacturer, the date of manufacture, the vehicle identification number (VIN), the maximum allowable gross mass of the fully loaded vehicle, the vehicle type, the axle load, the tire model, the rim size, the tire pressure, and the statement. Vehicle Emission Control Information (VECI) Label 1. The vehicle emission control information (VECI) label is affixed to the right sliding door frame (C-pillar) of the vehicle. 2. The vehicle emission control information (VECI) label contains the title, full name of the manufacturer, trademark, date of manufacture, emission control system, maximum allowable gross mass of the fully loaded vehicle, vehicle family name, vehicle category and statement. Zero-emission Power label 1. The zero-emission power label is located on the right sliding door frame (C-pillar) of the vehicle. 2. The zero-emission power label includes the title, name of manufacturer, trademark, date of manufacture, powertrain family name, model code and statement.

1.3.1 Specifications

1.3.1.1 Vehicle Appearance Dimension and Information

Vehicle Appearance Diagram

1.4.1 Description and Operation

1.4.1.1 Vehicle Lifting and Jacking

Note the Condition of Vehicle When jacking

1. Principle: Be sure to jack the vehicle in no-load state; Never jack the vehicle in loaded state. 2. The center of gravity of the vehicle will shift after removal of drive motor, high voltage battery box and other heavier parts. Make sure the vehicle supported properly to prevent the vehicle from overturning.

Precautions for Using Jack and Jack Stands

1. Be sure to follow the instructions in this manual for safe operation. 2. Never attempt to lift the tire with a crowbar so as to avoid damaging the wheels and tires. 3. Park the vehicle on level road surface and pull the parking brake. 4. Be sure to block the wheel on the other end of the diagonal that connects this wheel with the jacking position. 5. Use a jack with a rubber pad to jack the vehicle.

caution

If required, after jacking the vehicle with a jack, support the vehicle using a jack stands with rubber pad.

1.5.1 Warning and Precautions

1.5.1.1 Warnings and Precautions

Definitions of "Warning", "Caution" and "Tip"

"Warning", "Caution" and "Tip", both general and specific, are used for the diagnosis and repair procedures in this service manual. This manual, developed by Windrose, aims to provide repair information to help after-sales service technicians in diagnosis and repair of the systems so as to ensure normal operation of the vehicle. However, certain procedures may pose danger to technicians if they do not operate using the methods recommended herein. "Warning", "Caution", and "Tip" are given to prevent the above-mentioned dangers from happening, but not all dangers are foreseeable. This kind of information is prominently displayed in the service manual. This kind of information is prepared to avoid the following conditions: – Serious injury to personnel. – Vehicle damage. – Unnecessary vehicle repairs. – Unnecessary replacement of parts. – Improper repair or replacement of vehicle components.

Definition of "Warning"

"Warning" indicates that you must or you are prohibited to take measures as necessary. If the "Warning" is ignored, the following consequences may occur: – Serious injury to personnel. – Serious personal injury to the driver and/or passengers in the vehicle, in case the vehicle is not repaired properly.

Definition of "Caution"

"Caution" indicates that you must pay special attention to necessary or prohibited measures. If "Caution" is ignored, the following consequences may occur: – Vehicle damage. – Unnecessary vehicle repairs. – Unnecessary replacement of parts. – Abnormal operation or performance of the maintained systems or components. – Damage to related systems or parts. – Damage to fasteners, basic tools or special tools. – Leakage of coolant, lubricant or other major fluids.

Definition of "Tip"

"Tip" states or emphasizes the necessity of employing diagnosis or repair procedures, aiming to: – Define procedures. – Provide additional information for completing a procedure. – Describe the reason for operation as per the recommended procedures. – Provide information that facilitate the completion of the procedures in a more efficient manner. – Provide technicians with previous experiences to make the procedure easier.

Precautions for Charging

warning ！

1. High voltage and large current may be induced in the high voltage system during charging. Please strictly follow the operation procedures, otherwise there may be risk of electric shock. Read throughout the charging section carefully before charging. 2. If you have been implanted with a pacemaker or cardiovascular defibrillator, note the following while charging: – Do not stay in the vehicle; – Do not enter the vehicle. 3. Before charging, check the skin and shell of the charging cable are damaged; If so, please contact the authorized dealer of the vehicle for repair or replacement. use damaged charging cables. 4. minors are prohibited to use the charging plug because it is a high voltage electrical device. minors are prohibited to operate during charging. 5. Make sure the charging port and charging plug are free of water, other debris, rust or corrosion. If there is water or rust on the charging port or charging plug, do not charge avoid short circuit or electric shock, or even death. 6. Keep the power supply equipment, the vehicle to be charged, the charging cable and the charging plug away from rain, snow and water. Do not place them close to the fire source. 7. If there is moisture near the charging port during charging, disconnect the power supply and then the plug at the power supply end while ensuring safety (do not touch the metal sheet of the charging plug with your hands or other body parts, so as not to cause safety accidents in case the charging system is faulty),unplug charging plug at the vehicle end. Wear insulating gloves if necessary, and contact the authorized dealer of the vehicle as soon as possible for testing and confirmation. 8. If the vehicle has been exposed to wet conditions before charging, please dry the body near the charging port before opening the charging port for charging. Make sure there is no residual moisture in the charging socket and its vicinity. 9. When the charging system is working, do not use the charging device in an environment where gasoline, coatings and flammable items are used or stored, as sparks may be generated in the charging system. 10. Please keep the charging port dry and clean during charging, and take corresponding measures if necessary. 11. In case the weather changes (strong wind, rain or snow) abruptly during charging, check the charging plug is secure and dry; do not touch the charging cable and the body when encountering lightning. 12. Corresponding protective measures should be taken during minors. Children and other non-related personnel should be prevented from approaching the charging vehicle and charging cable as much as possible. 13. When charging, do not squeeze the charging cable to avoid electric shock or fire. 14. When charging, do not place the charging cable in the vehicle. 15. When charging, the charging cable must be kept away from fire source. 16. Note the following when charging: – Do not touch the metal part of the charging port and charging plug; – Do not touch the electric vehicle and any devices if electric sparks appear in an electric vehicle or on-board charger. Failure to do so will result in an electric shock, or even cause death or injury. 17. The ambient temperature of the vehicle is recommended to be 32*F - 95*F during charging of the vehicle. Do not charge the vehicle under low or high temperatures(it is not recommended to charge the vehicle out these parameters). 18. Do not charge the vehicle under direct sunlight and other high temperature environment in summer. 19. During charging, make sure the charging cable extends in a natural manner and do not hang the charging cable in the air. 20. When any unusual smell or smoke is detected on the vehicle, immediately disconnect the power supply in a safe manner. 21. Do not plug and unplug the charging plug with wet hands or standing in places with water, liquid, and snow. This may result in serious injury or death. 22. When removing the charging plug, you should hold the insulating part of the plug, Do not drag or pull the charging cable. 23. Do not remove or modify the charging port without permission. 24. Please read the operation manual on the charging equipment carefully before fast charging, and make sure

the fast charging plug is connected and locked. Failure to do so will cause malfunction of the vehicle or charging equipment. 25. Minors are prohibited from charging the vehicle. 26. Do not plug and unplug the fast charging plug without permission during charging. 27. Charging or stop of charging should be performed in strict accordance with the operating procedures indicated on the DC charging instructions. 28. If smoke or unusual odors are detected at the charging port or abnormality is found inside of the vehicle, you should press the emergency stop button on the DC charging pile in time to stop charging, evacuate the personnel around the vehicle and follow the on-site procedures. 29. Before fast charging, check for any debris, dust, water, etc. inside the fast charging socket (including the jack). If any, do not charge. Remove debris and dust inside the fast charging socket (including the jack) and dry the socket. The charging cannot proceed until the charging socket is made clean and dry. 30. Before fast charging, check the fast charging socket jack is damaged, ablated or discolored. In case any of the above phenomena is found, do not charge and contact an authorized dealer. 31. To prevent the charging system from malfunctioning, please note the following: – Close the protective cover of the vehicle charging socket and then the charging port cover; – Avoid collisions with the charging plug; – Avoid crushing the charging cable; – Do not pull or entangle the charging cable; – Do not place the charging cable near a heat sources. 32. After charging is completed, close the charging socket protective cover and the charging port cover. 33. Before starting the vehicle, make sure the charging plug is removed from the charging port. 34. As the fast charging plug is heavy, you should plug and unplug vertically as carefully as possible to prevent damage to the vehicle or the charging equipment. 35. The charging may stop if you accidentally touch the fast charging plug button during fast charging. When this occurs, you need to pull out the charging plug and recharge.

Precautions for Maintenance Safety

warning ！

1. The maintenance personnel should have received training on high voltage safety and passed relevant Courses by Windrose or an authorized partner. 2. The maintenance operator should not wear metal jewelry, such as watches and rings, and should not have metal objects in the pockets of work clothes, such as keys, metal shell pens, mobile phones, and coins. 3. The maintenance should be carried out in a dry environment by personnel who are kept dry as well. 4. The maintenance technician should ensure facilities and tools are in good condition, prior to starting work. 5. At least two people should be present when carrying out maintenance on the high voltage system of the vehicle. They can provide proper safety procedures and provide first aid and contact authorities if an incedent occurs. 6. Random access to high voltage components on the vehicle is not allowed in non-assembly or non-repair period. 7. Do not carry out maintenance in an environment with explosive, flammable, corrosive gases, steam, etc. Otherwise, it may cause fire, explosion and other accidents. 8. When maintaining the all-in-one controller, it must stop running, the low voltage power supply must be disconnected, and the high voltage must be cut off after 10 minutes (when the capacitor discharge of the MCU and between the positive and negative power supplies of other high voltage load end finishes). Otherwise it may cause personal injury. 9. The mounting bolts and lead connecting bolts must be tightened to appropriate torque. Otherwise, the MCU may face abnormality in use, causing personal injury and equipment damage. 10. If an abnormality is found in the vehicle when it is re- inspected after maintenance, stop operation in time and check the equipment. Otherwise, it may impose a risk of personnel injury or equipment damage. 11. When parking or storing the vehicle is to be maintained and under maintenance, keep away from environments.

Warning for Vehicle Lifting

warning ！

To avoid vehicle damage, serious personal injury, and even death, when disassembling main components from the vehicle and supporting the vehicle with a lift, a jack stand shall be used to support the vehicle at the position where the component is to be removed. Warning for Handling Anti-lock Braking System Components

warning ！

Certain parts of the ABS cannot be repaired alone, and attempting to remove or disconnect certain system parts may result in personal injury and/or improper system operation. Therefore, only components that are approved for removal and installation can be repaired. Warning for Equipment Permitted for Repair After Collision

warning ！

To avoid personal injury from exposure to toxic fumes generated in (zinc oxide) metal arc welding or plating when grinding/cutting any type of metal or sheet moulded parts, it is essential to work in a well-ventilated area and wear approved respirators, goggles, earplugs, welder gloves and protective clothing. Lock Out Tag Out

warning ！

When a technician is inspecting the reported faulty condition, the vehicle shall be locked out and tagged out by the repairing technician and may not be operated. Warning for Disconnecting Battery

warning ！

Before repairing any electrical components, confirm that the power supply of the start switch is in "OFF" mode, and all electrical loads are "OFF (turned off)" unless otherwise stated in the operating procedures. If tools or equipment can easily contact exposed live electrical terminals, disconnect the battery negative cable. Failure to follow of these safety instructions may result in personal injury and/or damage to the vehicle and vehicle components.

Warning for Brake Dust

warning ！

The following operations are not permitted when the wheel brake components are repaired:

– Cleaning of the wheel brake components with dry brush or compressed air.

warning ！

Certain models or after-sales brake components added may contain fibers which may be mixed in the dust and once inhaled will seriously damage human body. The dust accumulated on the brake components must be removed using a damp cloth. Warning for Replacement of Brake Air Pipe

warning ！

Install and fix the brake air pipe with care during replacement, and be sure to use the correct fasteners, otherwise the brake air pipe and the brake system may be damaged and thus cause personal injury. Warning for Inhalation of R-134a

warning ！

Do not inhale A/C refrigerant R-134a and lubricating oil vapour or mist, because they can irritate your eyes, nose and pharynx when exposed to them. Work in a well-ventilated area. When discharging R-134a from the A/C system, use repair equipment (R-134a recovery equipment) certified to meet the requirements of SAEJ2210. In the event of accidental fluid discharge in the system, the work area must be ventilated before repair works are continued. For additional information on health and safety, please contact the refrigerant and lubricant manufacturers.

Warning for Cracks on Windows

warning ！

Follow the state and federal DOT guidelines for window damage and replacement.

Warning for Handling of Window and Metal Plate

warning ！

When disposing any glass or metal plate with sharp edges or burrs, wear approved goggles and gloves so as to reduce the risk of personal injury.

Warning for Road Test

warning ！

Test the vehicle on the road in accordance with traffic regulations while ensuring safety. Never try any operation that may endanger vehicle control. Violating the above safety instructions will cause serious personal injury and damage to the vehicle. Precautions Regarding Removal of Exterior Label

caution

When removing labels/nameplates, use plastic flat- edged tools to avoid damage to paints. Precautions Regarding Fasteners

caution

Please use appropriate fasteners at the correct position. The number of the component to replace the fastener must be correct. For fasteners that need to be replaced or the fasteners that require the use of thread- locking adhesives or sealant, it is particularly specified in the repair procedures that, paints, lubricants, or corrosion inhibitors shall not be applied on fasteners or fastener attachment surfaces, unless otherwise noted. The coatings may affect the torque and clamping force of the fastener, thus damaging the fastener. When installing fasteners, you must follow the correct tightening sequence and tightening torque to avoid damage to parts and systems.

Precautions Regarding Disposing Electrostatic Discharge Sensitive Components

caution

Electrostatic discharge (ESD) can damage many solid- state electrical components. Components that are susceptible to electrostatic discharge are not always marked with an electrostatic discharge symbol, hence you must take care when disposing electrical components. Please observe the following safety instructions to avoid damage from electrostatic discharge:

• Before repairing any electronic components, disconnect the power line, and touch a metal ground point to discharge static electricity in your body (especially after sliding on a vehicle seat).

• Do not touch the exposed terminals which may be connected to a circuit that can be easily damaged by electrostatic discharge.

• When repairing the connector, do not touch the exposed terminals with tools.

• Do not remove components from the protective casing unless required.

• The following operations are not allowed unless specifically required by diagnostic procedures:

– axle or ground components or connectors. – Connect the test equipment probe to the component or the connector. When using the test probe, connect the ground lead at first.

Before opening the protective casing of the component, ground it first. Do not place solid components on a metal workbench or on top of a radio and other electrical equipment. Precautions Regarding Avoiding Twist or Bend When Installing Hoses

caution

The inlet and outlet hoses shall not be twisted during the installation process, and the hoses shall not be bent or deformed to facilitate installation, otherwise components may be damaged. Precautions Regarding Damage to Machined Surfaces

caution

Do not cut, scratch or damage the sealing surface. If the sealing surface is a machined surface, it may be damaged, resulting in leakage.

Precautions Regarding Power System Control Module and Electrostatic Discharge

caution

Do not touch the connector pins or welded components on the circuit board to prevent damage to the electronic control module on the vehicle as a result of electrostatic discharge.

Precautions Regarding Use of Scan Tool

caution

Before diagnosing the vehicle, you must pay attention to the following conditions, otherwise the control module may be damaged.

– The software version of the scan tool and terminals must be up to date.

– The vehicle battery must be fully charged with a voltage of 12-14V.

– The scan tool and terminal cables must be securely connected.

– When programming the control module, the battery charger must not be connected to the battery.

Precautions Regarding Steering Wheel in Steering Limit Position

caution

The steering wheel shall not be set to the steering limit position for more than 5s, otherwise the steering motor may be damaged.

Precautions Regarding Test Probe

caution

Do not insert test equipment probes (digital multimeter, etc.) into the harness connector or fuse box terminals. A majority of the terminals will be deformed as a result of the diameter of the test probes, leading to poor contact and system failure. Thus, special tools must be used to detect the terminals from the front. Never use a paper clip or other substitutes to detect the terminals.

caution

When using special tools to test the components, make sure that the selected terminal test adapter matches the size of the connector terminal. Do not choose the terminal test adapter visually, since the hole of certain connector terminals may be larger than the actual terminal in the hole. The use of large terminal test adapter can damage the terminals.

Precautions Regarding Damage to Edges of Windows

caution

To avoid damage to vehicle window due to impact of exposed edges, the window must be 1 mm (0.025 in.) lower than the sheet metal surface.

1.6.1 Description and Operation

1.6.1.1 Note

A number of operations related to vehicle maintenance and repair are dangerous, and can affect personal safety or health. This section specifies partial of the relevant hazardous operations, materials and equipment, and corresponding safety regulations to avoid these hazards. However, this section does not include all matters related to health and safety, therefore all operations and procedures as well as the disposing of materials shall be executed on the basis of ensuring safety and health. Before using any product, you should read the instructions for use of products provided by the manufacturer or supplier.

1.6.1.2 Acid and Alkali

The acid and alkali include corrosive sodium carbonate and sulfuric acid. They are used for cleaning of batteries and other materials. They can irritate or erode eyes, skin, sense of smell and throat, or burn human body and damage ordinary protective clothing. In order to prevent acid or alkali from splashing onto your eyes, skin and clothing, you should wear suitable protective clothing, gloves and goggles. Also, you should not inhale relevant sprays. Washing equipment, such as eye wash bottles, shower heads, and soap, shall be provided in the vicinity, so that you can use them immediately whenever a spill occurs. Warning marks indicating eye damage shall be placed at a conspicuous location.

1.6.1.3 A/C Refrigerant

If A/C refrigerant gets in your skin, it may cause frostbite. The instructions provided by the manufacturer must be followed. Avoid exposed skin from directly contacting the refrigerant. You must wear appropriate goggles and protective gloves when operating. If the refrigerant gets in your skin or eyes, immediately wash the affected area with water. Use suitable rinsing solution to wash your eyes. Do not rub, and seek medical assistance as needed.

A/C Refrigerant — Operations to be Avoided

Do not store refrigerant in a place exposed to sunlight or heat sources. – When filling refrigerant, do not place the refrigerant bottles upright, and their valves shall be facing downward. – Do not expose refrigerant bottles to frost and snow. – Do not drop the refrigerant bottle. – Under no circumstances should the refrigerant be discharged directly into the atmosphere. – Do not mix refrigerants, such as R12 (dichlorodifluoromethane) and R-134a (tetrafluoroethane).

1.6.1.4 Adhesives and Sealants

Cautions Regarding the Use of Adhesive/Sealant

Before using the adhesive/sealant, you must clean the surface of the position to be applied with adhesive/sealant and wipe it with a special cleaning agent to ensure the bonding effect. Do not allow room temperature curing sealant to enter the blind threaded hole, otherwise a hydraulic locking effect will be generated from the fastener during tightening, causing damage to the fastener and other components and making it impossible to obtain the correct clamping force when the fastener is used for tightening. Under such circumstance, the sealing effect may be weakened, making it impossible for the fastener to play the role of tightening correctly. Then the components will be loosened or separated, which will cause serious damage to the parts.

Health & safety

The materials used in adhesives/sealants contain harmful substances. Long-term exposure to them can cause acute and chronic poisoning, occupational and skin diseases and other diseases. When applying adhesive/sealant, use a ventilation device to maintain ventilation in the workplace; Wear protective gloves, masks, protective clothing, etc. during operation. Wash your hands carefully after work, and keep the workplace clean, tidy, and sanitary. – Waste adhesive/sealant or solvent-contaminated waste shall be removed in a timely manner and shall not be accumulated for a long time. – Generally, the products shall be stored in a non-smoking area, and care shall be taken when using them. Use an applicator or container for construction as much as possible.

Repair by Adhesives/Sealants

Generally, in the event of a failure or accident, the vehicle body will be deformed, the steel plate will be cracked, and welding spots will be falling off. Sometimes, the chassis and other assembly components may be damaged locally, resulting in the falling off and destruction of certain adhesive/

sealant products. In the process of vehicle repair, adhesives with same performance shall be selected according to the material and functional requirements of the components. The adhesives/sealants that can be used in the process of vehicle repair are listed below.

Body Repair

If adhesives applied on the vehicle body fall off or are cracked as a result of deformation or cracking of body interior trims and steel plates, during the repair process, the positions applied with adhesives shall be made up with new adhesives. – First you should remove the adhesives on the surface of the body using a knife, and the remaining adhesives can be wiped with alcohol; – Use a special cleaning agent to wipe the area applied with adhesives so that no impurities such as residual adhesive is kept on the surface applied with adhesives. – Then apply repair adhesive on the original position that is applied with adhesives to ensure the effect of bonding and sealing.

Parts Repair

If certain interior trim parts and other positions are damaged, repair shall be carried out through bonding and sealing. Before applying the sealant, clean the bonding surface so that the bonding effect will not be affected by burrs and cracks.

1.6.1.5 Asbestos

Inhaling asbestos dust can cause lung damage and eventually lead to cancer. Wet the asbestos dust waste during disposal, place it in a sealed container and mark clearly on the surface of the container for convenient and safe disposal. If you want to try cutting or drilling on materials containing asbestos, you should wet the materials and then use only hand tools or low-speed power tools.

1.6.1.6 Battery Acid

The gas released during charging is explosive. Never use open fire near the charged battery or the battery that has recently been charged. Good ventilation must be maintained.

1.6.1.7 Chemical Materials

Solvents, sealants, adhesives, coatings, resin foams, battery acid fluids, coolant, lubricants, greases and other chemical materials should be used, stored and handled with great care. They may be toxic, harmful, corrosive, irritating or highly flammable, and may produce peculiar smell and dust with high level of danger. The effects of long-term overexposure to the chemical environment may be immediate or chronic, transient or permanent, cumulative, superficial, life-threatening, or the lifespan may be affected.

Chemical Materials — Operations to be Executed

– Carefully read and follow the warnings and cautions specified on the raw material container, as well as any accompanying leaflets, posters, or other instructions for use. The health and safety information form for the raw material can be obtained from the manufacturer. – In case of contact with the chemical material, refer to the MSDS sheet for proper safety instructions and procedures. – Strictly follow the working procedure instructions and wear protective clothing to avoid direct contact with skin and eyes. – During the process of handling chemical materials, you must wash yourself before taking a break, eating, smoking, or using toilet facilities. – Keep the work area clean and tidy and do not spill chemical materials.

Chemical Materials — Operations to be Avoided

– Unless specified by the manufacturer, the chemical materials shall not be mixed at will; Certain chemicals will form other toxic or harmful chemicals, or release other toxic and harmful gases when mixed and may lead to other accidents such as explosions. – Do not spray chemical materials in an enclosed environment. – Unless specified by the manufacturer, the chemicals materials should not be heated, as certain chemical materials are highly flammable, and others may release toxic and harmful gases. – Do not leave the container of chemical materials open, because emitted gases from the container may accumulate to such an extent that toxicity, harm or explosion may occur. Some gases are heavier than air and thus they can accumulate in an enclosed space. – Do not put chemical materials in unlabeled containers. – Do not use chemical materials to clean your hands and clothing. Chemicals, especially solvents and fuels, can make the skin dry, cause allergies, skin inflammation or directly absorb toxic and harmful substances through the skin, affecting health. – Do not use empty containers to store other chemical materials at will, unless the containers have been cleaned under supervision. – Do not sniff or smell chemical materials at will. Short- term exposure to high concentrations of gas may still cause poisoning or injury.

1.6.1.8 Dust

Powder, ash and dust may be irritating, harmful or toxic. Do not inhale powdered chemical materials and raising dust

resulted from dry friction operations. In the condition of poor ventilation, wear protective equipment such as breathing mask to prevent inhalation of dust. Fine dust of flammable substances may lead to hazards such as explosion. Avoid explosions and fire sources.

1.6.1.9 Electric Shock

Improper use of electrical equipment without conforming to the instructions for use or misuse of equipment in good condition can both cause electric shock. Electrical equipment must be maintained within the specified time and tested frequently. Faulty equipment should be marked and preferably moved outside the work area. Wires, cables, plugs, and sockets shall not be worn, twisted, cut, cracked, or damaged in other ways. The electrical equipment and wires shall not come into contact with water. Ensure that electrical equipment is protected by appropriate fuse. It is forbidden to misuse electrical equipment, and do not use equipment with any hazard that may lead to a fault, otherwise personal safety may be affected. Ensure that the cables of mobile electrical equipment will not be pinched and damaged. Basic first aid training must be performed for specialized electrical operators. In the event of an electric shock: – Turn off the power supply before touching the victim. – If the power supply cannot be turned off, disconnect the power of the victim with dry insulator material. – If you have received specialized first aid training, perform on-site first aid immediately. – Seek medical assistance.

1.6.1.10 Fiber Isolation

It refers to isolation of noise and sound. The fibrous nature of the surface and sharp edges can cause skin allergy. During the operation, the operating procedure instructions shall be followed and you must wear gloves to avoid excessive skin contact with the fibers.

1.6.1.11 Fire

A large number of materials related to vehicle repair are extremely flammable. Some materials can produce toxic and harmful gases after ignition. Follow fire safety regulations when storing and handling flammable materials or solvents, especially near electrical equipment or welding operations. Before using electrical and welding equipment, confirm that there are no hazards of fire. When welding or using heating equipment, a suitable fire extinguisher should be prepared around the work area.

1.6.1.12 First Aid

Legal requirements shall be complied with, and it's better to provide personnel who have received specialized training in first aid in the workplace. If something splashes into your eyes, wash with water for at least 10 minutes. If your skin is contaminated, wash the contaminated area with soap and water. If you have frostbite, immerse the affected area in ice or cold water. Persons who inhale toxic gases should be immediately transferred to a place with fresh air. If adverse reactions continue to occur, they should be immediately sent to the hospital for medical assistance. If you accidentally swallow certain liquids, inform the physician of the information on the container or label. Do not induce vomiting unless instructed to do so by the label.

1.6.1.13 Polyurethane Foam

Cured foam is used as cushion pad material for seats and trims. Follow the manufacturer's instructions. Assemblies that have not gone through chemical actions are irritating and may be harmful to the skin and eyes. Thus, you should wear gloves and goggles during operation. People with chronic respiratory diseases, asthma, bronchial problems, etc., or those with hereditary allergies should not handle or approach uncured substances. The spare part, vapor or spray mist of uncured assemblies can cause direct irritation and allergic reactions and can be toxic and harmful. Do not breathe vapor or spray mist. These materials must be used in a well-ventilated area with breathing protections. Do not remove the mask immediately after spraying, which means you should wait for the vapor and spray mist to completely dissipate before you remove the mask.

The burning of uncured assemblies and cured foam will produce toxic and harmful gases. During foam operations, it is prohibited to smoke and use open flames and electrical equipment unless the vapor and the spray mist are completely removed. Thermal cutting of foam materials or other special foam materials should be performed in a well-ventilated environment.

1.6.1.14 General Tools and Equipment Used in Workshop

It is importance to always keep all tools and equipment in good working condition and operate them correctly in use. Only use tools for the intended use. The load on cranes, jacks, axle, chassis bracket, or slings and other equipment should not exceed the maximum limit load they can withstand. Damages caused by overloading may not emerge immediately and but they can cause serious accidents when they are used for the next time. Do not use tools or equipment that have been damaged or in poor working condition, especially some high speed equipment such as grinding wheels. Damaged grinding wheel can shatter without warning and cause serious injury. Wear appropriate personal protective equipment (PPE) when grinding wheels, chisels or blasting equipment. Wear an appropriatepersonal protective equipment (PPE) when using sandblasting equipment, handling asbestos- containing materials, or using spraying equipment. A ventilation equipment that is capable to control the content of dust, spray and soot in the environment should be provided.

1.6.1.15 Noises

Extremely high level noises may be heard when performing certain operations, which may result in hearing damage. In this case, you should wear appropriate hearing protection device.

1.7.1 Description and Operation

1.7.1.1 Diagnostic Information and Procedures

Wind/Air Noise

Note

When the technician checks the faulty position, the assistant should drive the vehicle, otherwise, it may cause personal injury.

To accurately determine the location of wind noise, it is necessary to test drive in the vehicle. Generally speaking, wind noise comes from major and minor leakages, and if the leakage is not eliminated during repair process, the only way is to reduce rather than eliminate the wind noise. During test drive, the maintenance personnel should carry the following tools to help diagnose the exact location of wind noise: • Echometer • Masking tape • Caulking strip • Marker pen • Screwdriver Carry out road test in accordance with the following procedures: • Select a route in which straight streets run in east, south, west, and north directions. • Select a street with less traffic or reduced noise to avoid affecting the test. • Conduct road tests under a speed at which the customer thinks the noise is the most obvious or the noise is heard. It is strictly forbidden to exceed the legal speed limit. • Wind noise heard in the following situations is deemed as exterior wind noise. – Wind noise can be heard when driving immediately after lowering the window. – The wind noise disappears immediately when pasting the tape to individual trim sealing strips and gaps. • Interior wind noise is attributable to air escaping from the vehicle. Adopt the following methods to eliminate the noise: – Paste tape to the pressure relief valve on the body door lock post once the location of leakage is detected. Air pressure can immediately establish in the vehicle, intensifying the wind noise. – Confirm the location of leakage using a echometer. – Paste masking tape to temporarily repair the leakage. – Keep performing the road test to check if the wind noise is completely eliminated or check for other locations of leakage. – After confirming all locations of leakage through road test, return to the repair workshop to carry out permanent repair using professional, reasonable positioning methods and sealing materials.

Vibration

Most of the high speed vibrations are caused by the loss of wheel dynamic balance. If vibrations maintain after dynamic balance, possible causes include: – The tire is out of round – The rim is out of round – There is hardness deviation in tires All causes of vibrations cannot be detected by measuring the free runout of tires and wheels. The three causes as mentioned above are called load radial runout. The faulty vehicle must be repaired by replacing the original tire and wheel assemblies with known tire and wheel assemblies in good condition. Low speed vibrations that occur at a speed below 64 km/h are usually caused by runout. High speed vibrations that occur at a speed above 64 km/h are usually caused by unbalance or runout.

Correction of Uneven Tires

Generally two ways can be used to correct tires that has been properly balanced but still vibrate. One way is to use an automatic machine tool to mount the tires on the machine tool and remove a small amount of rubber from the high points on the tread on the left and right sides of the tire by means of grinding. Corrections of tires in this way are usually permanent. Standardized operations will not have a noticeable impact on the appearance of the tire and the service life of the tire tread. It is not advisable to repair tires using edged machine tools during corrections of tires, as this will shorten the service life of the tires and cannot tackle the root of the problem. Another way is to remove the tire and rotate the tire 180° on the rim. This method can be used only when the cause of vibration is determined, i.e., the tire and wheel assembly through diagnosis and confirmation. Vibrations can occur in intact wheel assembly when using this method.

Abnormal Sound

The door squeaks in use Check whether the door hinge lacks lubrication. – Operate the door back and forth and listen carefully whether the door squeaks – Lubricate the door hinge with rust remover and apply grease.

1.7.1.2 Repair Guidance

Wind/Air Noise

Exterior wind noise Seal the clearance (if any) on the vehicle with special sealing strip.

Vibration

On-board balancing of wheels and tires On-board balancing can correct vibrations caused by unbalanced brake disc. 1. When performing dynamic balancing on the vehicle, it is forbidden to remove the balance weight installed during wheel dynamic balancing under the vehicle. 2. If the balance weight to be added for dynamic balancing weighs above 25 g (1 lb), two balance weights can be installed on the inner rim and the outer rim respectively. Under-car balancing of wheels and tires Carry out wheel dynamic balancing using an electronic under- car balancing machine. The dynamic balancing machine is easy to use and can be use for both static balancing and dynamic balancing. Unlike on-board balancing, the under-car balancing machine cannot be used for correction of unbalanced brake discs. The under-car balancing can overcome this weakness by fixing the wheels to the balancing machine and passing a cone through the back of the center hole rather than through the wheel nut hole. Directional assembly of wheels and tires Wheels and tires are assembled in the factory by matching the radially thick position of the tire (also known as the high point) to the position on wheel with minimum radius (also known as the low point). The high point of the tire is initially marked with red paint or a label is attached to the outer wall of the tire when leaving the factory. The low point of the wheel is at the position the valve core. Before removing the tire from the wheel, mark the position of the valve core on the tire to restore the tire to its original position.

Abnormal Sound

Repair of Abnormal Sounds Abnormal sounds mainly arise from relative movement between vehicle parts which actually should not exist. Three ways can be adopted to repair abnormal sounds: – Securely fasten the parts to eliminate relative movement during driving. – Separate the parts so that the parts do not contact each other while working. – Isolate the parts so that they do not make abnormal sounds during movement. Uniform, low-friction surfaces can eliminate viscous sliding between parts.

1.8.1 Description and Operation

1.8.1.1 Diagnostic Information and Procedures

Diagnosis of Water Leakage

caution

Repair cannot proceed until all positions with water leakage are detected. Random repair can only temporarily plug the leakage position, possibly increasing the difficulty in future repairs. Continue to carry out local tests within overall range to detect all positions with water leakage.

The repair of body water leakage should be performed through proper tests and diagnosis. Repair water leakage by adjusting incorrectly positioned parts and using appropriate repair materials. In the first place, determine the circumstances in which the water leakage may occur. For example, water leakage only occurs when the vehicle is parked on a slope. Second, if an approximate leakage position is found, use a water hose or breather hose to determine the exact leakage point. If the leakage position is not obvious, use a rain test bench to determine the exact leakage position. This may involve the removal of partial interior trim panels or partial parts.

Preparation for Water Leakage Test

– The vehicle is designed to operate under normal environmental conditions. – The design criteria for the sealing materials and parts have taken into account the sealing strength required for natural environmental factors. However, these specifications cannot take into account all human conditions. – The water leakage test procedures are related to natural environment and can determine the driving performance of the vehicle under normal conditions. – The first step of diagnosing leakage is to determine the conditions under which leakage occurs. If the approximate leakage position can be identified, isolate the exact water inlet using a water hose or breather hose. The repair of leakage may involve the removal of partial trim panels or parts. – Leakage in doors or windows may not be necessarily attributable to poor sealing of the sealing strip. Perhaps the water leakage in these positions can be repaired through adjustment at these positions.

Water Hose Test

Note

Do not use a water hose with a nozzle.

1. Arrange an assistant and let it enter the vehicle to determine the exact leakage position. 2. Carry out detection beginning from the bottom of the window. 3. Slowly move the hose upwards until it passes through the entire roof.

Breather Pipe Test

Note

Breather hose test is only applicable to fully cured adhesives. The adhesive layer may be damaged, increasing leakage points when applying this method.

1. Dilute the liquid cleaner in a certain percentage and fill it in a spray bottle to spray it onto the edge of the window. Spray at the bottom in the first place, and then gradually spray the entire roof in a bottom-up manner.

Note

The pressure of compressed air should not exceed 205 kPa (29.75 psi).

2. Let an assistant enter the vehicle while carrying an air hose. 3. Ask the assistant to aim the compressed air at the suspicious leakage position. If leakage is detected at a position, the liquid cleaner will turn to bubbles at the leakage position.

1.8.1.2 Repair Guidance

Repair of Water Leakage in Body

The repair of leakage may involve the removal of certain trim panels or parts depending on the leakage position. 1. Cut the adhesive applied to the seam in the leakage position from inside or outside the vehicle. 2. Clear and remove all old adhesive residues from the leakage position. 3. Apply sealant to the body and seams at the leakage position that have been cleaned. 4. Wait a few hours for the seam adhesive to fully cure. 5. Detect if the leakage persists. 6. Install the removed trim parts.

Repair of Water Leakage in Fixed Windows

The repair of leakage may involve the removal of certain trim panels or parts depending on the leakage position.

1. Determine the exact position of water leakage 2. If leakage is found on the edge of the front windshield, apply special seam adhesive to repair the leakage or replace the front windshield with new one that has been sealed. 3. If leakage is found on the side of a fixed window, apply special adhesive or replace the window with a new one that has been sealed.

1.9.1 Power Down of the High-Voltage System

1.9.1.1 High Voltage Removal from Inside the Vehicle

warning ！

1. Be sure to wear appropriate personal protective equipment when touching any high voltage components;

2. Do not touch the high voltage battery components even though the high voltage system has been deactivated. Be sure to wear appropriate personal protective equipment if it is necessary to operate the high voltage battery components;

3. If any damage is found in the high voltage components, be sure to wrap the damaged parts with the insulation tapes.

1. Park the vehicle, apply the EPB. 2. Open the trim cover plate on the lower left of the instrument panel, find and disconnect the low voltage maintenance disconnection connector, and the vehicle will automatically cut off the high voltage system.

1.9.1.2 High Voltage Removal from Outside the Vehicle

warning ！

1. Be sure to wear appropriate personal protective equipment when touching any high voltage components;

2.Do not touch the high voltage battery components even though the high voltage system has been deactivated. Be sure to wear appropriate personal protective equipment if it is necessary to operate the high voltage battery components;

3. If any damage is found in the high voltage components, be sure to wrap the damaged parts with the insulation tapes.

1. Park the vehicle, apply the EPB. 2. Open the door. 3. Open the front flip cover plate. 4. Find the low voltage MSD in the engine compartment and remove it, and the vehicle will deactivate the high voltage system automatically.

Objective

• After the vehicle leaves the factory, if it is necessary to perform calibration on the front view intelligent camera again, such as when the windshield is replaced or the front view intelligent camera is replaced, it is recommended to use the ONL after-sales calibration procedure. • The ONL after-sales calibration of the front view intelligent camera is carried out through dynamic driving on the road. The front view intelligent camera recognizes the lane markings and takes them as a reference to achieve the calibration of the installation tolerance of the front view intelligent camera. • If the calibration is not performed after the front view intelligent camera is reinstalled, it will affect the accuracy of image recognition.

The Following Principles Should Be Followed While Driving

• The vehicle speed should be no less than 22 mph (the recommended vehicle speed is between 22 mph and 35 mph). • Don't turn the steering wheel by a large margin (||yaw rate|| < 0.008 rad/s). • Keep driving smoothly before and after changing lanes. • Don't change lanes frequently.

Requirements For Lanes And Driving Environments

1. The lane on which the vehicle is traveling should be straight and flat, without slopes or turns. 2. Avoid performing calibration in traffic-congested areas and make sure that the lane markings are not blocked by adjacent vehicles. 3. Avoid performing calibration under adverse weather conditions (such as rain, snow, fog, etc.).

Requirements For The ONL After-Sales Calibration Scenarios Of The front view intelligent camera

1. The calibration test scenario must include two adjacent lanes of equal width. The lane markings can be either solid lines or dashed lines, but they should be clearly visible, as shown in the following figure. 2. Try to avoid the types of lanes shown in the following figure as much as possible.

The ONL After-sales Calibration Process for the front view intelligent camera.

The ONL after-sales calibration can be achieved through the UDS diagnostic service (RoutineControl $31). The host computer sends diagnostic instructions to the ECU of the front view intelligent camera to trigger the calibration mode. After the calibration is completed, the parameters will be written into the ECU and will be used after the next power-on. After the calibration is completed, obtain the calibration results and parameters through diagnostic service instructions as follows: – The online calibration time of ONL is 1 to 5 minutes, depending on the road conditions. – It is impossible to exit the ONL mode before the ONL calibration is completed. If the power is turned off during the process, it will be regarded as a failed end of the ONL calibration, and no new calibration parameters will be written into the ECU. – There are the following diagnostic service instructions: 1. RoutineControl $31: Send the calibration command (ONL/EOL) under 3212. 2. RoutineControl $31: 3213 Report the current working status (INIT/NORMAL/ONLING/EOLING). 3. RoutineControl $31: 3214 Report the currently used parameters. 4. RoutineControl $31: 3215 Report the new parameters after calibration is completed. Step 1: Ensure the correct installation of the front view intelligent camera and its covering parts, and check the condition of the vehicle. Step 2: Establish communication between the diagnostic device (or calibration computer) and the vehicle. Open the calibration service through the diagnostic equipment. Click "ONL Calibration" in the diagnostic device and send the calibration instruction to start the calibration. Step 3: Drive the vehicle according to the above requirements and complete the automatic calibration function according to the prompts on the diagnostic device. Step 4: The diagnostic device prompts "Calibration completed". Step 5: Return to the ONL mode. Step 6: The system will automatically write the new calibration parameters into the ECU. Step 7: Are there any new calibration parameters? – Yes ： Next step – No ： The ONL calibration fails. Step 8: The ONL calibration is successful.

1.11.1.2 Side MMW Radar Calibration Procedure

Notice

The reinstalled left and right radars should be calibrated before they can be used normally.

Calibration Description

Recalibration should be performed in the event of radar replacement, vehicle collision, etc. in the aftermarket. The recalibration is generally performed through dynamic calibration so that the radar can detect real surrounding environment during driving, determine the horizontal deviation between radar normal and vehicle driving axis by means of self-learning, and keep the deviation within the permissible range via algorithm compensation, thereby ensuring the calibrated radar is in compliance with relevant functional requirements.

Calibration Platform

• Radar to be calibrated. • Scan tool. • Calibrated vehicle. • Specially designed, dedicated calibration runway.

Calibration Error

The dynamic calibration error of radar includes measurement error, radar installation error, and error due to left and right skirt installation: • Prior to calibration after the radar is installed on the bracket, the angle of the radar antenna axis relative to the calibrated vehicle axis should be within the allowable error range of the design installation angle (±3°); • Both the horizontal and vertical installation errors of the radar relative to the body should be less than ±1mm; • The horizontal inaccuracy of active calibration should be less than ±0.5°.

Vehicle Requirements

The vehicle should meet the following requirements when carrying out radar calibration: • Four-wheel alignment has been completed before radar calibration; • The tire pressure on the vehicle is correct; • The vehicle is unloaded when performing calibration; • The radar and covering parts or left and right side skirts are installed correctly, check the oil, tire pressure, seat, etc. and ensure the safety of driving; • After the calibration is completed, no significant changes in body weight are allowed, as this will cause the deflection of the vehicle's driving axis (for example, the modification of the vehicle, the installation of liquefier tank, etc. after calibration will result in angle changes in vertical direction of the driving axis).

Environmental Requirements

When performing radar calibration, the environmental requirements are as follows: • The surface of the radar is clean, and free of covering such as snow or mud; • Do not calibrate in extreme rain and snow weather; • The metal guardrail should be mounted on the left side in the driving direction, and it should be 150m long and straight, to avoid the interference of other moving targets; • The surface of the driving road should be smooth without unevenness, snow, ice, mud and other road conditions that affect driving stability.

Vehicle Driving Behavior Requirements

When the dynamic driving calibration begins, the vehicle must be driven under the conditions specified in the following table to ensure the completion of the dynamic driving calibration;

Calibration Procedure

Step 1: Make sure the radar and covering parts or the left and right side skirts are properly installed and check the condition of the vehicle. Step 2: Establish communication between the scan tool (or calibration computer) and the vehicle, start the calibration beginning with diagnosis of the diagnostic equipment, and click "Start Dynamic Driving Calibration" in the scan tool to issue a calibration instruction for start of calibration. The ADU should be used for relevant conversions after the scan tool issues check commands. Step 3: Maintain communication between the scan tool and the vehicle, and drive the vehicle in accordance with the driving behavior requirements, within a single power-on/ignition cycle of the radar, until the calibration progress bar displays 100% in the scan tool. Step 4: Generally, the calibration progress should show 100% within 3 minutes. Step 5: If the calibration fails, Check the calibration environment, installation location, and driving behavior are in compliance with relevant requirements. If compliance with relevant requirements are confirmed, repeat the above steps. Step 6: The calibration ends when the calibrations on radars on both sides are successful.

1.11.1.3 Forward MMW Radar Calibration Procedure

Notice

The reinstalled front radars should be calibrated before they can be used normally.

Calibration Description

The forward millimeter-wave MMW radar after-sales service is generally performed through dynamic calibration. The automatic calibration is to measure the deviation angle between the radar axis and the body driving axis in horizontal and vertical directions based on the static object in the area around the vehicle (correction area) during straight driving of the vehicle, for the purpose of software compensation, thereby allowing the radar detection deviation to stay within the allowable range.

Correction Configuration

• Vehicle equipped with millimeter-wave radar. • The radar can obtain yaw rate information. • The radar can obtain acceleration information. • The vehicle keeps driving in a straight line. • The vehicle driving speed must be above 25 mph. • The radar installation deviation should be ≦ ±3° (horizontal) or ≦ ±2.4° (vertical).

Calibration Procedure

Step 1: Make sure the radar and covering parts or bumpers are properly installed and check the condition of the vehicle. Step 2: Establish communication between the scan tool (or calibration computer) and the vehicle, start the calibration beginning with diagnosis of the diagnostic equipment, and click "Start Dynamic Driving Calibration" in the scan tool to issue a calibration instruction for start of calibration. Step 3: Maintain communication between the scan tool and the vehicle, and drive the vehicle in accordance with the driving behavior requirements, within a single power-on/ignition cycle of the radar, until the calibration progress bar displays 100% in the scan tool. Step 4: Generally, the calibration progress should show 100% within 3 minutes. Step 5: If the calibration fails, Check the calibration environment, installation location, and driving behavior are in compliance with relevant requirements. If compliance with relevant requirements are confirmed, repeat the above steps. Step 6: The calibration ends when the radar calibration is successful.

1.11.1.4 AVM Calibration Procedure

Preparation for Equipment and Site

• Calibration cloth (3 in front, left, and right). • Level ground. • There is no light source that can cause the camera to be exposed by reflection or direct light

Arrangement of Vehicles and Calibration Equipment

Park the vehicle on calibration site and adjust the calibration cloth as required. 6 7 1 8 5 4 9 3 • ① Distance between front calibration cloth and vehicle: 1.5 ft • ⑥ Lateral distance of front calibration cloth: 21.5 ft • ⑦ Longitudinal distance of front calibration cloth: 6 ft • ⑤ Distance between front calibration cloth and left/right calibration cloth: 5 ft • ⑧ Width of left/right calibration cloth: 6 ft • ⑨ Length of left/right calibration cloth: 8 ft • ④ Distance from left/right calibration cloth: 10 ft

Note

The black grid on the three pieces of cloth is a square of edge length 1 ft. Align the edges (or the white edges of equal width) of the outermost black grids when aligning the cloth; A white edge of width 0.5 ft should be reserved at the edge of the three calibration cloths.

Precautions

1. Make sure the calibration patterns are visible through the camera and the position requirements stipulated in the calibration scheme are met; 2. The site should be free of reflections. If the photo is not clear due to reflection, use shielding cloth or shade to ensure that the black and white grids are clear; 3. If the calibration fails, export the corresponding photos and logs and send them to the manufacturer for analysis;

Calibration Procedure

1. "IVI Screen Menu" > "Factory Settings" > "AVM Function Debugging" > "270° AVM Debugging Interface" to select Open; 2. Click AVM icon on the main interface of the CAR screen to activate AVM; 3. When clicking "Calibration" button, the automatic calibration will start. You can wait for the automatic calibration to end, or manually click "End Calibration" to stop the current calibration; 4. When the calibration process (including calibration succeeded, calibration failed, and manual stop of calibration) ends, you should operate "Turn Off AVM", "Turn On AVM", and "Initialize AVM" to display the screen again. Then you can operate "Calibration" again according to the process same as step 1; 5. It is determined that the calibration is successfully if the 2D/3D function can be used normally, the splicing accuracy meets the requirements, and the calibration cloth is not misplaced from the perspective of the screen; 6. Click "Hide Debug" button to collapse the control bar, and click this button again to expand it. Prevent the debug button from blocking the picture and affecting the observation; 7. Click "Close Debug Interface" to exit the calibration interface, or re-enter the factory settings interface to open it; 8. Click "Collect Fusion Image" to collect the AVM fusion image (including the car model); 9. Click "Collect Left Image" to collect the left image, save it to path /sdcard/AvmDataCollect/LeftImage, and name it "cameraId" + "_id_Image_" + "Current System Boot Timestamp" + "Serial Number". 10. Click "Collect Front Image" to collect the front image, save it to path /sdcard/AvmDataCollect/FrontImage, and name it "cameraId" + "_id_Image_" + "Current System Boot Timestamp" + "Serial Number". 11. Click "Collect Right Image" to collect the right image, save it to path /sdcard/AvmDataCollect/RightImage, and name it "cameraId" + "_id_Image_" + "Current System Boot Timestamp" + "Serial Number". 12. Click "Collect Back Image" to collect the back image, save it to path /sdcard/AvmDataCollect/BackImage, and name it "cameraId" + "_id_Image_" + "Current System Boot Timestamp" + "Serial Number". 13. Click "Collect Four-way Image" to collect the left, front, right, and back images simultaneously, save them in respective directory, and name them "special_" + "cameraId" + "_id_Image_frame_" + "Serial Number" beginning with "special_"; For example: • Rear view: special_0_id_Image_frame_1.yuyv • Right view: special_5_id_Image_frame_1.yuyv • Front view: special_7_id_Image_frame_1.yuyv • Left view: special_8_id_Image_frame_1.yuyv cameraId mapping rules:

• cameraId =0 refers to AVM back image • cameraId =5 refers to AVM right image • cameraId =7 refers to AVM front image • cameraId =8 refers to AVM left image

Exporting Image Collection Footage

You can export or clear the footage by unzipping the "Attachment Script" file and executing the corresponding script.

Note

Select a practical dual male USB cable, and insert one end into the USB flash drive socket of the device host, and the other end into the computer. Concurrently, switch the current mode to ADB. Otherwise, the script cannot be executed normally.

Exporting steps: Click "Export AVM Collection Footage" in "AVM Image Collection Export Script" to export the file.

Click "Clear AVM Collection Footage" in "AVM Image Collection Export Script" to clear the export file. 1.11.1.5 Headlamp Light Adjustment

Preparation for Equipment and Site

– Tools: 10# hexagon socket and 8# hexagon socket, with a total length not exceeding 150mm. – Tape measure or laser rangefinder (electronic ruler). – Site: Dark site where the ground is level and flat, vehicles can enter, and the reference center of the headlamp is be at least 10m away from the screen. – Test screen: Thick white paper or white wall (in order to facilitate the observation of light shape, the test screen shall be more than 2m wider than the vehicle).

Vehicle Preparation

– Inflate the tire in accordance with the full load pressure specified in the technical conditions of the vehicle. – Replenish sufficient water and lubricating oil on the vehicle, and prepare all accessories and tools (spare tires, tools, etc.) for vehicle test. – Place a 75kg load on driver seat to simulate driver seat occupation. – Before measuring, make sure the vehicle is at natural standstill state, drive the vehicle to travel backwards for at least one wheel circumference and then forward over the same distance. – Make sure the outer cover of the lamps is clean. – Start the vehicle.

Light Measurement

1. Park the vehicle as shown in the figure with the distance L between the reference center of the headlamp and the screen being 10m.

h 1 L h 2 2. Adjust the low beam to the maximum highest on CAR screen. 3. Remove the wheel housing plug. 4. Draw O-line, A-line, and B-line on the screen. 90° B O A L 1 L 1 – A and B lines: Parallel to O line, where L1 is 39.5 in (low beam) or 40.25 in (high beam). 5. Draw A1, A2, B1, B2, h1, and h2 lines on the screen to form a green box as shown in the figure after completing drawing of all lines.

a 1 A O B a 2 b 1 b 2 • A1 and A2 lines: Parallel to line A, where L2 is 6.69 in and L3 is 13.75 in; • B1 and B2 lines: Parallel to line B, where L4 is 6.69 in and L5 is 13.75 in; • H1 and H2 lines: Horizontal lines parallel to the ground, where H1 is 33.7 in (low beam) or 35.55 in (high beam), and H2 is 23.86 in (low beam) or 25.28 in (high beam).

Light Adjustment

caution

To make it easier to observe the effect of light adjustment, you can block the light from one side side when adjusting the light on the other side. The light adjustment method on the left and right sides is the same. After the debugging is completed, the height of the left and right lights should be consistent.

Note

The left headlamp is taken as an example hereby. The light adjustment method of the left headlamp is the same as that of the right headlamp.

1. Low beam adjustment 1. Turn on the low beam. 2. Insert the 10# hexagon socket into the low beam dimming port ① , rotate the handle ① clockwise to adjust the light to the upper left, and turn the handle ① counterclockwise to adjust the light to the lower right; Insert the 8# hexagon socket into the low beam dimming port ② , rotate the handle ② clockwise to adjust the light downward, and turn the handle ② counterclockwise to adjust the light upward; 1 2 3. If the turning point of the low beam cut-off line is in the frame, it indicates the completion of dimming.

2. High beam adjustment 1. Turn on the high beam; 2. Insert the 10# hexagon socket into the high beam dimming port ③ , rotate the handle ③ clockwise to adjust the light to the upper left, and turn the handle ③ counterclockwise to adjust the light to the lower right; Insert the 10# hexagon socket into the higih beam dimming port ④ , rotate the handle ④ clockwise to adjust the light downward, and turn the handle ④ counterclockwise to adjust the light upward; 3 4 3. If the brightest point of the high beam is in the frame, it indicates the completion of dimming.

caution

After the adjustment of the high and low beams is completed, the brightest point of the high beam should be higher than the turning point of the low beam cut-off line.

1.11.1.6 TCU Self-Learning Program

Operation Process

Step 1: Check if the vehicle meets the following conditions? – Vehicle status is READY – Brake opening is 0 – Throttle opening is 0 – Handbrake pulled up -Yes: Next step -No: Adjust vehicle status. Step 2: Connect the diagnostic instrument and click on the "TCU self-learning instruction". Step 3: axle self-learning in TCU1. Step 4: 1-file self-learning. Step 5: Is the target gear met? -Yes: Next step -No: After restarting the vehicle power-on operation, perform the self-learning process again. If it fails after three attempts, report the fault and exit the self-learning program. Step 6: Explore the tolerance position and record the actual position. Step 7: 2-file self-learning. Step 8: Is the target gear met? -Yes: Next step -No: After restarting the vehicle power-on operation, perform the self-learning process again. If it fails after three attempts, report the fault and exit the self-learning program. Step 9: Explore the tolerance position and record the actual position. Step 10: Gear position check. Step 11: Parameters are written to EEPROM. Step 12: Send the self-learning completion flag. Step 13: End of self-learning. Step 14: TCU2 rear axle self-learning.

Step 15: 1 file self-learning. Step 16: Is the target gear satisfied? -Yes: Next step -No: After restarting the vehicle power-on operation, perform the self-learning process again. If it fails after three attempts, report the fault and exit the self-learning program. Step 17: Explore the tolerance position and record the actual position. Step 18: 2-file self-learning. Step 19: Is the target gear met? -Yes: Next step -No: After restarting the vehicle power-on operation, perform the self-learning process again. If it fails after three attempts, report the fault and exit the self-learning program. Step 20: Explore the tolerance position and record the actual position. Step 21: Gear position check. Step 22: Parameters are written to the EEPROM. Step 23: Send the self-learning completion flag. Step 24: End of self-learning.

1.11.1.7 Tire Pressure Calibration Procedure

Introduction to Preparation of Calibration Tools and Related Functions

1 6 7 2 3 4 5 – ① : Indicator – ② : Select tires – ③ : Upload function button – ④ : Select tires – ⑤ : Activate the sensor – ⑥ : Power switch – ⑦ : 12 – 24V charging interface

Description of Buttons on Calibration Tool

On/off: Turn the switch on the left to turn on the tool. The calibration tool goes into screen off and sleeping state if there is no operation within 3 minutes after power-on. Press any button to wake up the calibration tool.

Setting Standard Pressure (Note: Confirm Standard Tire Pressure Before Individual Operations)

1. Press and hold the LINK button on the left, press upward the power button on the left to turn on the tool, go into the interface for adjusting the standard pressure value, and press the "+" or "-" button according to the actual pressure standard to adjust. After the adjustment is completed, press and hold the LINK button for 3 seconds to save and return to the main interface. 2. After setting of the calibration tool is completed, power on the vehicle, walk to the right rear tire position of the vehicle (near the installation position of the tire pressure CAN module host), press and hold the SET button in the middle of the device for two seconds and upload information to the tire pressure CAN module host.

Sensor Detection Operation

1. Walk to the tire and press the "CODE" button on the rightmost of the calibration tool to enter the detection mode, and the display will show "Id LF"; Place the display of the calibration tool close to the tire sensor (generally near the valve, with the calibration tool be kept no more than 7.87 in from the tire); After reading the code, a long "Be" sound will be heard and the tire data will be shown: The six-digit ID code, temperature and pressure display in turn. 2. When the code reading fails, a short "Be-Be" sound will be heard with "Id Err" displayed, and then the screen will automatically return to standby state. In this case, you can readjust the position and reactivate.

Instructions for Calibration

1. Walk to the tire and press "+" button on the calibration tool to select the corresponding tire position. Concurrently, press the "CODE" button on the rightmost of the calibration tool to enter the code matching mode with "Id LF" displayed on the screen; Place the display of the calibration tool close to the tire sensor (generally near the valve, with the calibration tool be kept no more than 7.87 in from the tire); After reading the code, a long "Be" sound will be heard and the tire data will be shown: ID code, pressure and temperature under normal conditions, with black dots appeared on the corresponding position of the tire. If code reading is successful, continue to press the "+" button to select the corresponding tire position for the purpose of activating the sensor.

caution

There are 10 tires in total. Thus you should make sure data showing black dots on 10 tires is shown on the calibration tool. Considering that crosstalk is easy to occur in side-by-side tires after the sensor is activated, you should manually insert the equipment into the inner tube as far as possible when activating the inside tire and keep as far away as possible from the outer valve (7.87 in - 15.74 in) when activating the outside tire.

2. When the code reading fails, a short "Be-Be" sound will be heard with "Id Err" displayed, and then the screen will automatically return to standby state.

Uploading Data Read by Calibration Tool to CAN-based Tire Pressure Host

Locate the tire pressure CAN receiver installed on the vehicle (the host is near the inside of the right rear tire), stand on the right rear tire and press the middle upload button "SET" (about 1 second), and the calibration tool will upload the entire set of tire data to CAN receiver. The LCD flashes during the upload process, and after the uploading is completed, the calibration tool will display FINISH, and you can Check the tire pressure data on the instrument panel is updated.

caution

Make sure the data showing black dots on 10 tires is shown on the calibration tool. 8.3BAR=120 psi means that the current standard pressure is set to 120 psi.

1.11.1.8 Yaw Rate Sensor Calibration Procedure

Yaw Rate Sensor Calibration Scene

• Replace the slew rate sensor. • Replace the EBS ECU.

Vehicle Calibration Requirements

• Keep the wheels straight.

Calibration Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Automatically identify or select Windrose - Select corresponding model - Click the special function - Calibrate yaw rate on the scan tool. Step 4: Operate following the prompts on the scan tool interface. Step 5: Calibration is completed.

1.11.1.9 Steering Angle Sensor Calibration Procedure

Steering Angle Sensor Calibration Scene

• Replace the steering angle sensor. • Replace the EBS ECU.

Vehicle Calibration Requirements

• Keep the wheels straight.

Calibration Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC.

Step 3: Automatically identify or select Windrose - Select corresponding model - Click the special function - Calibrate steering angle on the scan tool. Step 4: Operate following the prompts on the scan tool interface. Step 5: Calibration is completed.

1.11.1.10 EPB Angle Zeroing Procedure

EPB Angle Zeroing Scene

• Replace the parking solenoid valve.

Vehicle Calibration Requirements

• The vehicle should be parked on level road.

Calibration Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Automatically identify or select Windrose on the scan tool - Select corresponding model - Click the special function - Angle zeroing. Step 4: Operate following the prompts on the scan tool interface. Step 5: Calibration is completed.

1.11.1.11 ECAS Calibration Procedure

Calibration Device

– Computer: Laptop running with WIN7 or higher operating system; – CAN adapter: Special USB-CAN adapter Connect the USB port of the computer and the OBD port of the vehicle through the adapter and adapter cable to communicate with ECAS ECU. The adapter cable is designed with three DB9 adapters that are compatible with CAN cables. Select appropriate adapters with adapter 9-pin interfaces according to the CAN pin definition of the OBD on real vehicles.

Function of ECAS Calibration Software

– Upon completion of installation of the ECAS, calibrate its initial height, including the normal height, the height upper limit and the height lower limit; – Diagnose faults; Modify ECU parameter configuration; – The auxiliary detection of ECAS EOL covers detection of ECAS solenoid valve movement, detection of height sensor installation and detection of signal, etc.

Software Startup

Connect the computer to ECU via a diagnostic cable, turn on the main power and key power, and then run the calibration software.

Software Main Interface

After the software is successfully connected to the ECAS ECU, you can read the power supply voltage, software version, fault information, etc. on the interface.

Parameter Configuration

Options: Modify Individual Parameters or Modify All Parameters are available as needed. The parameter value determines the structure configuration and function settings of ECAS. The parameters can be exported from the prototype or pre-documented and imported into a new ECU during configuration. Parameter configuration should be completed by specially trained calibrators.

Modification of Individual Parameters

1. Click "System" menu to select "Parameters", or directly click the button icon in the shortcut bar to enter the parameter configuration interface. 2. Click "Read From ECU" button to read current parameters in ECU and check the current value of the specified parameter. To modify the value of the specified parameter, you can directly enter the value in the blank of "Parameter Value", and then click "Write Into ECU" button. You will be prompted to enter a verification code during writing (the last four characters of ROOT code when registering the license).

Modification of All Parameters

You can import or export all ECU parameters via "ECU Replacement" function. In addition to the general parameters displayed on "Parameter Interface", CAN bus configuration, axle load information, default height characteristic parameters, etc. are included. Data bulk load or exporting calibration data for backup can be achieved through "ECU Replacement". After importing, click "ECU Reset" on the shortcut button bar to allow parameters to come into effect. You will be prompted to enter a verification code during importing.

Fault Inspection

Upon completion of parameter configuration and ECU reset, wait for more than 8 seconds to observe the calibration software interface and check if there is a fault prompt. If a fault occurs, determine the type of fault according to the current fault information read through the calibration software, and eliminate the fault step by step. After troubleshooting, click "ECU Reset", wait for more than 8 seconds again, and confirm that there is no DTC before proceeding to the next step for detection of solenoid valve and height sensor as well as height calibration.

Solenoid Valve and Sensor Control Detection

caution

The chassis may suddenly go up and down during lifting test and calibration. Thus, in this process, make sure the installation personnel is in a safe position!!!

Run the ECAS calibration software, click the "System" menu after successful connection, and select "Inflate/Deflate Solenoid Valve" to enter the detection interface. Select the installed airbag for testing. Operation method: Select the front axle airbag, left rear airbag, right rear airbag and other airbags separately on the interface, and click Inflate or Deflate to observe the shape and pressure change of the corresponding airbag are correct, and Check the solenoid valve channels are normal and whether the left and right pipelines are falsely connected. Check the air pressure value is normal and whether the connectors of the air pressure sensor (if any) are connected correctly. During inflation or deflation of the solenoid valve, observe the value of height sensor changes towards the correct direction and Check the height sensor is reversed while the chassis is rising or lowering;

caution

Calibrate "Lifting test" function of software. It disables the solenoid valve automatically when failed to prevent damages to the circuit as a result of short circuit.

Height Sensor Misconnection Detection

caution

The chassis may suddenly go up and down during lifting test and calibration. Thus, in this process, make sure the installation personnel is in a safe position!!!

Unplug the height sensor and observe the fault information on the main interface of the calibration software is correct. For example, after unplugging the left rear height sensor, refresh the main interface to see if the corresponding DTC appears in "Current Fault" window. (For ECAS with height sensors mounted on the left and right sides of the rear axle)

caution

Lock the vehicle during diagnosis of ECAS!

Automatic control and regulation may occur in ECAS during the diagnosis, causing sudden movement of the vehicle.

Height Calibration

caution

The chassis may suddenly go up and down during lifting test and calibration. Thus, in this process, make sure the installation personnel is in a safe position!!!

Principle of height calibration: – Before calibration, park the vehicle with normal tire pressure on level ground. – The calibration is generally performed on unloaded vehicle, making it difficult to descend during calibration. For this reason, it is necessary to release the handbrake once, or calibrate with the vehicle loaded. – After the calibration is completed, difference in the air pressure of the left and right airbags may be detected or even the unilateral airbag may be collapsed on the unloaded vehicle following road test and movement. This is generally attributed to the distribution error of left and right weight on the suspension. It returns to normal if the air pressure in left and right airbags is close after vehicle loading. – In addition, the difference in left and right air pressure may be present after the running-in of the vehicle. If the difference remains significant after loading, re-correct the zero point of the swing rod, or re-calibrate as necessary. Height calibration process: 1. Select "Calibrate Height Sensor" option: In the shortcut menu bar on the main interface, click shortcut button of "Calibrate Height Sensor" to enter the calibration. Two calibration methods are available: three-point height calibration (normal height, upper limit height and lower limit height calibration) and single-point height calibration (limited to normal height calibration; upper limit height and lower limit height are automatically calculated and written by calibration software on the basis of a new normal height according to the default upper and lower limit offset in ECU). 2. : Select the airbag to be adjusted, inflate and deflate it to normal height: After adjusting the airbag to normal position, visually check that the swing rod is level, and confirm the height value (2nd generation sensor: 270-330TT; 1st generation sensor 190- 240TT). No specific requirements are imposed on the difference in left and right height values. Make sure the difference is not more than 20TTwhen the swing rod maintains level through visual inspection.

caution

When two height sensors are available, the height adjustment on left and right must be selected simultaneously.

After the swing rod is leveled, fix it, and click to save the normal height. (When single-point calibration is selected, the upper limit and lower limit calibration will be automatically completed; When three-point calibration is selected, after the normal height is saved, you should raise the suspension to maximum height and save the upper limit height, and then lower the suspension to the minimum height and save the upper limit and lower limit height)

3. Fill in the real height value of chassis or airbag: If the automobile factory makes a request for writing the real current normal height, upper limit height, and lower limit height simultaneously when saving the height, you should fill in the corresponding height value (mm) in the pop-up window for filling. This function is only available in V1.3.2.5 and above version calibration software. 4. Click "End Calibration" to exit the calibration process. Click "ECU Reset" button in the shortcut menu bar to allow the new

height to come into effect. 1.11.1.12 BDCU Software Diagnosis Procedure

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC.

Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "BDCU" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "BDCU" repair or replacement. Step 12: End.

1.11.1.13 CDC Software Diagnosis Procedure

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "CDC" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "CDC" repair or replacement. Step 12: End.

1.11.1.14 CMU1 Software Diagnosis Procedures

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN

Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "CMU1" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "CMU1" repair or replacement. Step 12: End.

1.11.1.15 CMU2 Software Diagnosis Procedures

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "CMU2" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "CMU2" repair or replacement. Step 12: End.

1.11.1.16 CMU3 Software Diagnosis Procedures

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "CMU3" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool.

Step 11: Learn from the actual scenes of "CMU3" repair or replacement. Step 12: End.

1.11.1.17 CMU4 Software Diagnosis Procedures

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "CMU4" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "CMU4" repair or replacement. Step 12: End.

1.11.1.18 HUD Software Diagnosis Procedure

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "HUD" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "HUD" repair or replacement. Step 12: End.

1.11.1.19 IPC Software Diagnosis Procedure

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "IPC" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "IPC" repair or replacement. Step 12: End.

1.11.1.20 SSM Software Diagnosis Procedure

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "SSM" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "SSM" repair or replacement. Step 12: End.

1.11.1.21 TPMS Software Diagnosis Procedure

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool.

Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "TPMS" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "TPMS" repair or replacement. Step 12: End.

1.11.1.22 AC Software Diagnosis Procedure

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "AC" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "AC" repair or replacement. Step 12: End.

1.11.1.23 VDC Software Diagnosis Procedure

Diagnosis Procedure

Step 1: Perform vehicle power-on operations. Step 2: Connect the scan tool to the DLC. Step 3: Click "Traditional Diagnosis" in scan tool. Step 4: Select the corresponding Windrose vehicle in scan tool. Step 5: Check the VIN identified by the scan tool in the interface is consistent with the vehicle model? — Yes: Next step — No: Manually enter the VIN

Step 6: Click OK following the prompts on the interface of the scan tool. Step 7: Select "System Topology" on the interface of the scan tool. Step 8: Click "VDC" on the interface of the scan tool. Step 9: Select "Special Function". Step 10: Codes, reset, relearning and other special options will be displayed on the interface of the scan tool. Step 11: Learn from the actual scenes of "VDC" repair or replacement. Step 12: End.

2.1.1 Description and Operation

2.1.1.1 Inspections Items During Vehicle Operation

Operation of Horn

The horn shall be pressed occasionally to ensure that the horn is working properly, and all button positions shall be checked.

Operation of Braking System

When braking, pay attention to abnormal noises from the braking system, increased brake pedal stroke, or repetitive braking deviations. In addition, if the brake warning lamp is illuminated or flashing, it indicates that certain parts of the braking system may be failed.

Alignment of Tires and Vehicle

Pay attention to vibrations of steering wheel or seats when driving at normal road speeds. If the steering wheel or seats vibrate, it indicates that a wheel shall be balanced. In addition, if off-tracking is found of the vehicle running on a straight road, it indicates that the tire pressure shall be adjusted or the wheel alignment should be performed.

Operation of Steering System

Pay attention to changes in steering operations. If it is difficult to turn the steering wheel or there is a larger free travel, or abnormal sounds are heard when turning or parking, inspection shall be carried out. It is necessary to occasionally observe the light pattern of the headlamp in the event of focusing, and make adjustment if the beam focusing of the headlamp is incorrect.

2.1.1.2 Inspections Items During Refueling

If a system (except for the windshield washer) loses fuel, it indicates that the system fails, and it shall be inspected and repaired immediately.

Inspection of Coolant Level and Condition

Check the coolant level in the expansion tank, add coolant if necessary, check the coolant, and replace dirty coolant.

Inspection of Washer Fluid Level

Check the washer fluid level in the tank and add washer fluid if necessary.

2.1.1.3 Inspection Items At Least Once a Week

Tyre Inspection

Maintenance instructions: Check the tires for abnormal wear or damage and the wheels for damage, check the pressure of cold tires and the spare tires for vehicles equipped with spare tires, and maintain the recommended pressure indicated on the tire label. Maintenance interval: Check at least once a week, and increase the frequency of inspection according to the actual situation.

2.1.1.4 Inspection Items At Least Once a Month

Air Pressure Inspection of Tires and Wheels

Check the tires for abnormal wear or damage and the wheels for damage, check the pressure of cold tires and the spare tires for vehicles equipped with spare tires, and maintain the recommended pressure indicated on the tire label.

Operation of Lamps

Check the operations of license plate lamps,headlamps (including high and low beams), tail lamps,stop lamps, turn signal lamps, backup lamps, and hazard warning lamps.

Inspection of Oil Leakage

After the vehicle has been parked for a certain period of time, check whether there is water, oil or other liquids on the ground under the vehicle. It is normal for the A/C system to drip after use. If leakage of other liquids is found, investigate the cause and troubleshoot immediately.

2.1.1.5 Inspection Items At Least Twice a Year

Lubrication of Door and Window Sealing Strip

Apply a thin layer of silicone-based grease to the sealing strip with a clean rag.

2.1.1.6 Inspection Items At Least Once a Year

Condition and Operation of Seat Belt

Check the harness system, including braided straps, latches, lock plates, retractors, guide rings and fixtures.

Body Lubrication and Maintenance

Lubricate all door hinges and hydraulic locks.

Cooling System

Check the coolant. If the coolant is too dirty or rusty, you should drain and flush the cooling system and refill with new coolant. Maintain proper coolant concentration to ensure proper freezing, boiling and corrosion performances and operating temperatures. Check the hoses and replace hoses

that are cracked, swollen, or aged. Tighten the clamps, and clean the outside of the radiator and the A/C system condenser as well as the filler cap. Carry out pressure test the cooling system to ensure that the system is functioning properly.

2.2.1 Contents of Maintenance and Service

2.2.1.1 Maintenance Provisions

caution

If you have any questions about how to maintain your vehicle, please contact a Windrose authorized service station directly for help.

It is necessary to carry out routine maintenance and regular maintenance on the vehicle, which can ensure the normal use, efficiency, reliability of the vehicle and a good ride experience, and reduce the possible maintenance costs incurred. For the routine maintenance items that can be completed by the user himself according to the manual, the user can complete the routine maintenances in accordance with the relevant instructions of this manual. The systems installed on the vehicle are sophisticated and there are strict after-sales service requirements for new energy vehicles in accordance with national laws and regulations. Therefore, Windrose recommends that you should complete the regular maintenance of the vehicle at Windrose authorized service station.

caution

Please keep regular maintenance records as the basis for the "warranty".

2.2.1.2 First Maintenance

The first maintenance should be completed at an authorized maintenance service station after 6 months or 5,000km based on the vehicle model, and the users are requested to supervise the operation of the service station. The specific maintenance contents and technical requirements are as follows:

Vehicle Inspection

1. Check according to the Windrose Service Manual. 2. Check the date of sales and driving mileage of the vehicle are within the specified range.

High Voltage Battery System

1. Check the high voltage battery box and clean the box body to ensure that there is no obvious dust and the connector is not blocked. 2. Check that the high voltage battery connecting wire connector is firmly connected, and the skin insulation layer is not damaged. 3. Check that the fixing bolts of the high voltage battery box are free of looseness and falling off, and the box body is not deformed. 4. The surface and inside of the charging socket/charging gun are dry and free of dust and other foreign matters, and the cover plate is sealed reliably. 5. Check the terminals of the charging socket are yellow, blackened or ablated. 6. Check the SOC of battery packs is abnormal and confirm the battery fault feedback. 7. Check the maximum voltage, minimum voltage, average voltage, maximum differential voltage, maximum temperature, minimum temperature, average temperature and maximum temperature difference of the high voltage battery pack. 8. Carry out charging test on the vehicle in locked and sleeping state. After the vehicle is powered off and fall into sleeping state, insert the charging gun into the charging port to wake up the vehicle and read the charging current and charging power on the charging pile.

Electric Drive Axle System

1. Check the lubricating oil in electric drive axle. 2. Check the high voltage cables of the electric drive axle MCU, the low voltage harness of MCU and TCU and the harness of sensors are firm, whether the harness is damaged, and whether the fixing is protected in place. 3. Check the cooling water pipe and interface of the electric drive axle are leaking, bending, and whether the clamp is loose. 4. Check the insulation, ground wire, and low voltage connectors of the electric drive axle motor and MCU are normal. 5. Check the fastening bolts of the electric drive axle reducer, controller, motor and other axle parts for looseness, the filling and drain plugs for looseness and oil leakage, and the wheel side and reducer for oil leakage. 6. Connect the diagnostic device to read and record the operating parameters of the electric drive axle.

Motor Control System

1. Check the low voltage harness and connector terminals of the controller are loose and whether they are properly sealed.

2. Disconnect the high voltage and check whether the insulation resistance, harness, and ground of the MCU are normal. 3. Check the heat dissipation of the MCU is normal. 4. Connect the diagnostic device to read and record the operating parameters of the MCU.

PDU All-in-one System

1. Check the high voltage harnesses and aviation connectors are firmly connected, and whether the fixing protection is in place. 2. Check the low voltage harness and connector are firmly connected and fix the harness. 3. Check the insulation resistance value is normal. 4. Check the cooling water line and interface are leaking, bending, and whether the clamp is loose. 5. Check the ground cable is secure.

Electro-hydraulic Steering System

1. Check the clearance of the steering tie rod ball joint and cotter pins and tighten the fixing bolts of each component. 2. Check the electric steering pump is working properly, and the connecting wire and connector should be firmly connected. 3. Check the steering wheel locking bolts and steering shaft locking bolts are tightened reliably. 4. Check the steering fluid level or change the steering fluid and clean the filter element. 5. Check and lubricate the steering tie rod ball joint. 6. Check the steering free clearance is normal. 7. Check the oil pipe clamp is loose, and whether there is oil leakage. 8. Read and record the operating parameters of the electric power steering motor controller.

Electric Air Compressor System

1. Check the air filter element of the electric air compressor and purge and clean the air filter element. 2. Check the high voltage harness is damaged or falsely connected, and tighten the screws of the fixing bracket of the electric air compressor. 3. Check the insulation resistance of the air compressor and the high voltage harness is normal. 4. Check the dryer, condenser, four-circuit protection valve, and serpentine pipe for air leakage. 5. Read and record the operating parameters of the electric air compressor.

Battery Cooling System

1. Check the liquid level of the expanding tank for abnormalities. 2. Turn on "Left Battery Compressor" and "Right Battery Compressor" on the maintenance switch interface, read the data of battery and battery thermal management system, and check whether the refrigeration function is normal. 3. Check that the battery cooling system is filled up to standard without leakage or missing. 4. Check the battery cooling system, pipelines and control systems, connecting wires and connectors are firmly connected, whether the skin insulation layer is not damaged, and check related pipelines for faults and interferences. 5. Check the battery cooling water pump is working properly and whether the coolant filter is clogged with impurities.

Brake system

1. Check the effectiveness of the parking brake system. 2. Check the free travel of brake pedal. 3. Check the brake pipeline, front and rear axle modules, and electronic parking modules for air leakage. 4. Check the wear of the brake linings. 5. Check the tightening of the brake system bolts. 6. Drain the air reservoir (replace the drying tank if a large amount of water is detected in the air reservoir twice).

Chassis System

1. Check the airbag installation and tightening and check for wear. 2. Check the suspension height and the airbag for air leakage. 3. Check the shock absorber for oil leakage. 4. Check and fasten the bolts of the shock absorber fixing bracket and the shock absorber. 5. Check and fasten the bolts of the fastening limit block bracket. 6. Check and fasten the bolts of the X-shaped control arm, longitudinal thrust rod assembly, and thrust rod bracket. 7. Check and fasten the nuts of U-bolts.

8. Check and fasten the fixing bolts of height valve. 9. Check the brake air circuit for air leakage. 10. Check the air reservoir for air leakage. 11. Check the air pipe connected to the trailer for air leakage. 12. Read and record the EBS\ECAS\EPB DTCs.

Cab System

1. Check the front cover opens properly and smoothly. 2. Check the wipers, washers, rearview mirrors, window regulators, awning sunshade, front windshield shades, etc. are working properly. 3. Check the steering wheel, IVI, seat, etc. are working properly. 4. Check the door can open and close normally. 5. Check the left and right side wall trim panels, boarding steps, fenders, etc. are loose.

Electrical System

1. Check the fastening of the battery power line and ground wire. 2. Check the low voltage battery capacity. 3. Check the working condition of DC/DC and whether it can charge the low voltage battery normally. 4. Check various lamps, indicators, instrument and IVI systems are working properly. 5. Read and record vehicle DTCs and operating data. 6. Check the harness for scratches, interferences, open circuit and short circuit, and the harness should be kept away from the heat source. 7. Check the connection of the harnesses and the connectors of the electrical appliances. 8. Check the fuses, relays, lamps, and other electrical components are working properly. 9. Check the self-test of the electronic control system is normal and whether the system is faulty. 10. Check the modules are loose, and whether the connectors and pole ares tightly fastened.

A/C System

1. Check the A/C system is working properly. 2. Blow the A/C filter element.

Fifth Wheel System

1. Check the fifth wheel for damage, bending, omission, or cracks, etc. 2. Check the fifth wheel is functioning properly. 3. Check the mounting bolts that fix the fifth wheel. 4. Check the wear of the fifth wheel wear ring, lock hook, fifth wheel panel and trailer traction pin, and replace it if the wear is out of tolerance in a timely manner. 5. Check the filling of the grease.

2.2.1.3 Regular Maintenance

The regular inspection should be completed at an authorized maintenance service station based on the vehicle model, and the users are requested to supervise the operation of the service station. The specific maintenance contents and technical requirements are as follows:

Vehicle Inspection

1. Check according to the Windrose Service Manual. 2. Check the date of sales and driving mileage of the vehicle are within the specified range.

High Voltage Battery System

1. Check the high voltage battery box and clean the box body to ensure that there is no obvious dust and the connector is not blocked. 2. Check that the high voltage battery connecting wire connector is firmly connected, and the skin insulation layer is not damaged. 3. Check that the fixing bolts of the high voltage battery box are free of looseness and falling off, and the box body is not deformed. 4. The surface and inside of the charging socket/charging gun are dry and free of dust and other foreign matters, and the cover plate is sealed reliably. 5. Check the terminals of the charging socket are yellow, blackened or ablated. 6. Check the SOC of battery packs is abnormal and confirm the battery fault feedback. 7. Check the maximum voltage, minimum voltage, average voltage, maximum differential voltage, maximum temperature, minimum temperature, average temperature and maximum temperature difference of the high voltage battery pack.

8. Carry out charging test on the vehicle in locked and sleeping state. After the vehicle is powered off and fall into sleeping state, insert the charging gun into the charging port to wake up the vehicle and read the charging current and charging power on the charging pile. 9. The SOC of high voltage battery should be calibrated once per month; In case the vehicle has been parked for more than 3 weeks, SOC calibration should be performed at least once. 10. High voltage battery calibration method: Use the high voltage battery until its SOC becomes 20% – 25%; Fully charge the high voltage battery; Use the high voltage battery until its SOC becomes 40% – 60%.

Electric Drive Axle System

1. Change the lubricating oil in electric drive axle. 2. Check the high voltage cables of the electric drive axle MCU, the low voltage harness of MCU and TCU and the harness of sensors are firm, whether the harness is damaged, and the fixing is protected in place. 3. Check the cooling water pipe and interface of the electric drive axle are leaking, bending, and whether the clamp is loose. 4. Check the insulation, ground wire, and low voltage connectors of the electric drive axle motor and MCU are normal. 5. Check the fastening bolts of the electric drive axle reducer, controller, motor and other axle parts for looseness, the filling and drain plugs for looseness and oil leakage, and the wheel side and reducer for oil leakage. 6. Connect the diagnostic device to read and record the operating parameters of the electric drive axle.

Motor Control System

1. Check the low voltage harness and connector terminals of the controller are loose and whether they are properly sealed. 2. Disconnect the high voltage and check whether the insulation resistance, harness, and ground of the MCU are normal. 3. Check the heat dissipation of the MCU is normal. 4. Connect the diagnostic device to read and record the operating parameters of the MCU.

PDU All-in-one System

1. Check the high voltage harnesses and aviation connectors are firmly connected, and whether the fixing protection is in place. 2. Check the low voltage harness and connector are firmly connected and fix the harness. 3. Check the insulation resistance value is normal. 4. Check the cooling water line and interface are leaking, bending, and whether the clamp is loose. 5. Check the ground cable is secure.

Electro-hydraulic Steering System

1. Check the clearance of the steering tie rod ball joint and cotter pins and tighten the fixing bolts of each component. 2. Check the electric steering pump is working properly, and the connecting wire and connector should be firmly connected. 3. Check the steering wheel locking bolts and steering shaft locking bolts are tightened reliably. 4. Change the steering fluid level or the steering fluid and clean the filter element. 5. Check and lubricate the steering tie rod ball joint. 6. Check the steering free clearance is normal. 7. Check the oil pipe clamp is loose, and whether there is oil leakage. 8. Read and record the operating parameters of the electric power steering motor controller.

Electric Air Compressor System

1. Replace the air filter element of the electric air compressor. 2. Check the high voltage harness is damaged or falsely connected, and tighten the screws of the fixing bracket of the electric air compressor. 3. Check the insulation resistance of the air compressor and the high voltage harness is normal. 4. Check the dryer, condenser, four-circuit protection valve, and serpentine pipe for air leakage. 5. Read and record the operating parameters of the electric air compressor.

Battery Cooling System

1. Check the liquid level of the expanding tank for abnormalities.

2. Turn on "Left Battery Compressor" and "Right Battery Compressor" on the maintenance switch interface, read the data of battery and battery thermal management system, and check whether the refrigeration function is normal. 3. Change the battery cooling system coolant. 4. Check the battery cooling system, pipelines and control systems, connecting wires and connectors are firmly connected, the skin insulation layer is not damaged, and check related pipelines for faults and interferences. 5. Check the battery cooling water pump is working properly and the coolant filter is clogged with impurities.

Brake system

1. Check the effectiveness of the parking brake system. 2. Check the free travel of brake pedal. 3. Check the brake pipeline, front and rear axle modules, and electronic parking modules for air leakage. 4. Replace the brake lining. 5. Check the tightening of the brake system bolts. 6. Drain the air reservoir (replace the drying tank if a large amount of water is detected in the air reservoir twice).

Chassis System

1. Check the airbag installation and tightening and check for wear. 2. Check the suspension height and the airbag for air leakage. 3. Check the shock absorber for oil leakage. 4. Check and fasten the bolts of the shock absorber fixing bracket and the shock absorber. 5. Check and fasten the bolts of the fastening limit block bracket. 6. Check and fasten the bolts of the X-shaped control arm, longitudinal thrust rod assembly, and thrust rod bracket. 7. Check and fasten the nuts of U-bolts. 8. Check and fasten the fixing bolts of height valve. 9. Check the brake air circuit for air leakage. 10. Check the air reservoir for air leakage. 11. Check the air pipe connected to the trailer for air leakage. 12. Read and record the EBS\ECAS\EPB DTCs.

Cab System

1. Check the front cover opens properly and smoothly. 2. Check the wipers, washers, rearview mirrors, window regulators, awning sunshade, front windshield shades, etc. are working properly. 3. Check the steering wheel, IVI, seat, etc. are working properly. 4. Check the door can open and close normally. 5. Check the left and right side wall trim panels, boarding steps, fenders, etc. are loose.

Electrical System

1. Check the fastening of the battery power line and ground wire. 2. Check the low voltage battery capacity. 3. Check the working condition of DC/DC and whether it can charge the low voltage battery normally. 4. Check various lamps, indicators, instrument and IVI systems are working properly. 5. Read and record vehicle DTCs and operating data. 6. Check the harness for scratches, interferences, open circuit and short circuit, and the harness should be kept away from the heat source. 7. Check the connection of the harnesses and the connectors of the electrical appliances. 8. Check the fuses, relays, lamps, and other electrical components are working properly. 9. Check the self-test of the electronic control system is normal and whether the system is faulty. 10. Check the modules are loose, and whether the connectors and pole ares tightly fastened.

A/C System

1. Check the A/C system is working properly. 2. Replace the A/C filter element.

Fifth Wheel System

1. Check the fifth wheel for damage, bending, omission, or cracks, etc. 2. Check the fifth wheel is functioning properly. 3. Check the mounting bolts that fix the fifth wheel. 4. Check the wear of the fifth wheel wear ring, lock hook, fifth wheel panel and trailer traction pin, and replace it if the wear is out of tolerance in a timely manner. 5. Change the grease.

2.2.2 Specifications

2.2.2.1 Fluid Capacity

2.2.3 Maintenance Cycle

2.2.3.1 Maintenance Schedule

Normal Use of Vehicle

The maintenance items given in the maintenance schedule are conducive to: – The delivery of goods under the restrictions indicated on the tire label attached to the edge of the driver door. – The driving on appropriate roads and under legal operating restrictions.

Regular Maintenance Schedule (Tractor)

caution

The maintenance interval or mileage given, whichever comes first in the regular maintenance schedule shall prevail.

warning ！

The user should use special after-sales fluids and accessories designated by the OEM. Otherwise, paid services will be provided by OEM as to damages caused by violating the rules.

2.2.4 Quality Warranty Statement

2.2.4.1 Quality Warranty Statement

Windrose will warrant to the ultimate purchaser and each subsequent purchaser that the new vehicle, including all parts of its emission control system, meets three conditions: 1.It is designed, built, and equipped so it conforms at the time of sale to the ultimate purchaser with the requirements of 40CFR Part 1037.120 as well as with all applicable regulations adopted by the California Air Resourcers Board pursuant to its authority in chapters 1 and 2, Part 5, division 26 of the Health and Safety Code. 2.It is free from defects in materials and workmanship that could cause the vehicle to fail to conform to the regulated requirements or could cause failure of a warranted part during the applicable warranty period. 3.The powertrain is identical in all material respects to the zero-emission powertrain as described in the related powertrain application for certification. Additional items: – For emissions-related warranty (5 years or 100,000 miles) under “ powertrain ” list main components that need to be covered – motor, inverter, HV battery charging system, batteries and thermal management. – The emission-related warranty covers all components whose failure would increase a vehicle's emissions of air conditioning refrigerants. – Windrose warrants that its vehicles are (1) designed, built and equipped with tires that conform, at the time of sale, with requirements of vehicle manufacturers whose vehicles are designed to meet applicable 2014 and later, U.S. Environmental Protection Agency and National Highway Traffic and Safety Administration greenhouse gas and fuel efficiency standards, and (2) those tires are free from defects in material and workmanship which cause the vehicle to fail to conform with the vehicle manufacturer ’ s requirements for a period of 2 years or 24,000 miles, whichever occurs first.

3.1.1 Mechanical Fault Diagnosis Overview

3.1.1.1 Overview

Mechanical diagnosis is to troubleshoot faults in vehicle, analyze and make judgments in accordance with relevant technical standards with the use of special tools, instrument, equipment and software for the purpose of investigating the cause of the fault and confirming the location of the fault. In general, the fault diagnosis of vehicles is performed through intuitive experience and instrument and equipment. With the development of vehicle technology, especially the application of electronic technology and computer technology in vehicles, the fault diagnosis methods of vehicles have been developed from observation, hearing, smelling, touching, isolation, testing, comparison and other traditional experiences to the use of information technology-based complete, modern fault diagnosis technology systems for vehicles with the digital, integrated and intelligent diagnostic equipment as the auxiliary means. This section aims to analyze and eliminate common faults found during driving so as to make it easier for maintenance personnel to quickly find and eliminate the source of the fault.

3.1.1.2 Precautions

Cautions Regarding Mechanical Fault Diagnosis

warning ！

1. Park the vehicle on level ground or in a well-ventilated operation room. 2. Apply the parking brake and turn off the ignition switch to prevent the vehicle from slipping during maintenance. 3. Do not operate under the vehicle when it is lifted only with a jack or lift. Unless the vehicle is parked on a sturdy tripod or bracket suitable for lifting the vehicle. Place wedges at the wheels to prevent the wheels from rolling when the tires are not off the ground. 4. During maintenance, ensure safety and do not damage parts or operate in violation of regulations.

3.1.2 Integrated Vehicle Faults

3.1.2.1 Noises and Abnormal Sounds in Vehicle

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.2.2 Tire Wear

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.2.3 Insufficient Air Pressure Throughout the Vehicle

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.2.4 Steering Wheel Shaking at High Speeds

Fault Description:

The vehicle is unstable or swings, or even the steering wheel shakes at high speeds or at a certain high speed.

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.2.5 Driving Deviation

Fault Description:

Check for driving deviation as follows: Generally during driving, center the steering wheel, and then take your hands off the steering wheel to see if the vehicle is driving in a straight line. If not, it can be determined that the vehicle is deviating from the road.

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.3 Frame and Suspension Faults

3.1.3.1 Diagnosis of Faults in Frame and Suspension

Fault Description 1:

The front bottom contacts the ground or the riding height is low.

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

Fault Description 2:

The vehicle leans to one side.

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.4 Wheel and Tire Faults 3.1.4.1 Diagnosis of Driving Deviation

Fault Description:

When the vehicle is deviating to one side, the driver should hold the steering wheel with both hands or apply force on other side of the steering wheel to ensure normal driving. Otherwise it is easy for the vehicle to deviate from the driving direction.

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.4.2 Diagnosis of Front Wheel Vibrations

Fault Description:

The front wheels vibrate to left and right or bump vertically during driving. This will have a great impact on the vehicle speed, making it uncomfortable to sit in the vehicle.

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.5 Steering System Faults

3.1.5.1 Diagnosis of Steering Wheel Shaking

Fault Description:

The shaking steering wheel and vibrating front wheels can cause the car front end to shake while driving, and the driver has to slow down in serious condition.

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.5.2 Diagnosis of Abnormal Sounds in Steering System

Fault Description:

The abnormal sounds heard in the steering system while driving or high speed driving mainly come from the steering gear, electric steering pump, etc.

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.6 Brake System Faults

3.1.6.1 Diagnosis of Braking Deviation

Fault Description:

Braking deviation is a phenomenon that the vehicle deviates to one side while driving as the left and right braking effects on the same axle are not uniform. Braking deviation occurs when applying brake or emergency brake; When the car brakes, it may drift. Minor deviation is allowed, but serious deviation may cause accidents.

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.6.2 Diagnosis of Brake Failure

Fault Description:

Obvious insufficient deceleration is found when depressing the brake pedal to slow down or stop. The vehicle cannot stop quickly when applying emergency brake, and the braking time and braking distance are extended. No tire drag traces are found or the tire drag traces are extremely short during inspection on a parked vehicle

Fault Diagnosis and Troubleshooting

Check for possible causes of the fault one by one according to the following steps. Diagnose in a simple-to-complex progressive manner to effectively save time. Directly skip specific steps concerning the causes that are obviously impossible through analysis. This diagnostic step is used for reference only.

3.1.7 Vehicle Body Faults

3.1.7.1 Note

In the process of body repair, professional and technical personnel may use sheet metal repair machines, welding machines and various grinding and cutting tools to ensure that the vehicle can be restored to the original level in terms of geometric dimensions and usability. However, sometimes, you may not be able to find the faults in the driving system and assembly mounts that can lead to serious consequences when repairing an accident vehicle. Therefore, in addition to the necessary inspections of geometrical dimensions, special attention must be paid to the following components.

3.1.7.2 Fault Inspection

1. Check that the steering mechanism and steering rod system can be operated correctly within the number of turns of the steering wheel, and visually check for bent or cracked parts. 2. Check the wheels and tires for damage, concentric rotation and imbalance. Check the tire pattern and sidewall for cuts/ check the tire pressure. 3. After body repair, carry out a road test to ensure the driving ability of the vehicle, and finally hand over the vehicle to users.

3.1.7.3 Body Fault Assessment

Slight pits can be repaired without damaging the paint finish. It can be removed from inside the pit using a special lever tool (pressure tool). When performing this kind of repair, it requires that the technician has extensive experience in using special tools and sufficient knowledge about the materials, and is capable to identify faults and use correct repair methods. The pit should meet the following requirements: The pits should be limited to body positions that are easily accessible from both sides, as this repair method is rarely used for double-skinned parts or enclosed sections. Satisfactory repair results can be achieved for slight shallow pits with small deformation radius. This method is particularly applicable to damages caused by hail, or during parking or transportation. In case the diameter of the pit is less than 50mm, and the extent of damage can be assessed according to the size of the pit.

caution

The deformation of material in the center of the pit must not exceed the deformation limit.

4.1.1 Quality Warranty Statement

4.1.1.1 Emission Quality Warranty Statement

– For emissions-related warranty (5 years or 100,000 miles) under “ powertrain ” list main components that need to be covered – motor, inverter, HV battery charging system, batteries and thermal management. – The emission-related warranty covers all components whose failure would increase a vehicle's emissions of air conditioning refrigerants.

4.1.2 specifications

4.1.2.1 Fastener Specifications

4.1.2.2 Technical Parameters

Drive Motor

4.1.3 Decomposition Diagram

4.1.3.1 Decomposition Diagram

1. Axle Electric Drive Assy 2. Axle Electric Drive Assy

4.1.4 Inspect

4.1.4.1 Inspection of Electric Drive System

Before starting the vehicle, check whether the relevant data displayed on the instrument cluster is normal. If the data is abnormal, do not drive the vehicle. Instead, record the system fault type and related data, and report the information to the Windrose authorized service station.

caution

If the high voltage battery or motor system fails, please contact a Windrose authorized service station for repair in time.

4.1.5 System Schematic Diagram

4.1.5.1 Electrical Schematic Diagram

4.1.6 Diagnostic Information and Steps

4.1.6.1 Diagnosis Description

Before diagnosing faults in the integrated axle device, it is important to understand and familiarize oneself with the working principle of the integrated axle device, and then begin system diagnosis. This will help determine the correct fault diagnosis steps when a fault occurs, and more importantly, it will help determine whether the situation described by the customer belongs to normal operation. Any fault diagnosis of integrated axle devices should start with routine inspection, guiding maintenance personnel to take the next logical step for fault diagnosis. Understanding and correctly using the diagnostic process can shorten

the diagnosis time and avoid misjudgment of faulty parts. 4.1.6.2 Routine Inspection

• Check for aftermarket installation devices that may affect the operation of the integrated axle device system, ensuring that these devices do not affect the operation of the integrated axle device system.

• Inspect system components that are easily accessible or visible to make sure they are not visibly damaged or have conditions that could cause failure. 4.1.6.3 DTC Confirmation

1.Connect the diagnostic instrument to the diagnostic interface, read and record the DTC, and then clear the DTC. 2. Restart the vehicle. 3. Read the fault code of the control system again to confirm whether the system has a fault code output. – Yes:Diagnose based on the output fault code.

– No:Perform intermittent fault checks, refer to Inspection Of Intermittent Fault 4.1.6.4 Inspection Of Intermittent Faults

caution

• Clear DTC.

• Conduct mock tests.

• Check and shake the wiring harness, connector box terminals.

When the fault cannot be confirmed by DTC inspection, the fault phenomenon only occasionally occurs in use. This should confirm all circuits and components that may cause the failure. In many cases, the fault location can be quickly and efficiently identified by performing the basic checks shown in the flowchart below. Especially for faults such as poor contact of wiring harness connectors. Fault Definition: This fault is not currently occurring, but historical DTC records indicate that this fault has occurred. Or the customer has reported the fault to be repaired, but because the fault is not related to the DTC, the fault symptoms cannot be reproduced at this time. Diagnostic Steps: Step 1 Check the battery voltage. A. Perform vehicle power-up operation. B. Measure the voltage of the battery. C. According to the measured values, the corresponding diagnostic step is entered.

Check the main battery. Refer to Inspection Of Main Battery Step 2 Visual physical inspection. Performing this step is an important means to preliminarily determine the location of the fault: • Check the wiring harness is damaged, whether there are wear, broken skin and other faults. • Check the wiring harness is improperly arranged. It is strictly forbidden to close the wiring harness to high voltage or high current devices. • Check the positive and negative cables of the battery are connected reliably and whether there are any phenomena such as looseness, oxidation and corrosion. Step 3 Check the wiring harness, connectors. A. Many intermittent failures are caused by wire harness and connector movement caused by vibration, twisting, uneven road or component operation. B. If the circuit resistance is too high, the component may not work properly. Use the diagnostic instrument to force the actuator to drive. If it can't work normally, Check the relevant circuit has line faults such as excessive resistance. Step 4 Reproduce the fault and record the data of the control unit with the instrument. A. Connect the vehicle fault diagnosis instrument, and use the data recording function of the fault diagnosis instrument to record the data when intermittent faults occur on the road test vehicle. After pressing the button of the vehicle data logger, the control module data can be recorded in the event of intermittent failure, which can be used to identify the failure location. B. Another diagnostic method is to connect the digital multimeter to the suspicious circuit while the vehicle is running. The abnormal reading value of the digital multimeter may indicate the fault location. Step 5 The fault LED illuminates intermittently, but the system has no fault code set. No Yes Next Step Next Step Next Step

The following conditions may cause the fault LED to illuminate intermittently, but the system will not set a DTC: • Electromagnetic interference caused by abnormally working relays, solenoid valves or switches controlled by the control module. • Accessories that are not original or after-market, such as car phones, alarms, lights or radios, are not installed correctly. • The fault indicator control circuit is intermittently shorted to ground. • The control module ground point is loose. Step 6 Other checks. Check the charging system for the following conditions: • Is the output voltage of the high and low voltage charging system correct? If the DCDC1 output voltage is not around 27.5 V and the DCDC2 output voltage is not around 30.5 V, repair the charging system. Step 7 Go to the fault symptom table.

4.1.6.5 List Of Diagnostic Trouble Codes (DTCs)

MCU1 Next Step Next Step

MCU2

MCU3

MCU4

TCU

4.1.6.6 MCU1 Power Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides MCU1? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault – No: Next step Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive medium axle vehicle. Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle vehicle. Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 7:Clear and confirm DTC.

4.1.6.7 MCU1 Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle vehicle. Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 6:Clear and confirm DTC.

4.1.6.8 MCU1 Internal Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive medium axle vehicle. Step 4:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 5:Clear and confirm DTC.

4.1.6.9 MCU1 Overheating Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check the vehicle has any fault codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle vehicle. Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 7:Clear and confirm DTC.

4.1.6.10 MCU1 High Voltage Circuit Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high-voltage wiring harness of the low-voltage interface of the electric drive mid axle vehicle. Step 4:Check the internal insulation detection circuit of the low-voltage interface of the electric drive medium axle vehicle. Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle vehicle. Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 7:Clear and confirm DTC.

4.1.6.11 MCU2 Power Fault

1.DTC Monitoring Logic

2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides MCU2? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault – No: Next step Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive medium axle vehicle. Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle vehicle. Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 7:Clear and confirm DTC.

4.1.6.12 MCU2 Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle vehicle. Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 6:Clear and confirm DTC.

4.1.6.13 MCU2 Internal Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive medium axle vehicle. Step 4:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 5:Clear and confirm DTC.

4.1.6.14 MCU2 Overheating Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check the vehicle has any fault codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle vehicle. Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 7:Clear and confirm DTC.

4.1.6.15 MCU2 High Voltage Circuit Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high-voltage wiring harness of the low-voltage interface of the electric drive mid axle vehicle. Step 4:Check the internal insulation detection circuit of the low-voltage interface of the electric drive medium axle vehicle. Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle vehicle. Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 7:Clear and confirm DTC.

4.1.6.16 MCU3 Power Fault

1.DTC Monitoring Logic

2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Total body power supply B+ L22

Step 3:Check if there are any other module power fault codes besides MCU3? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault – No: Next step Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive rear axle vehicle. Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle vehicle. Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear axle Step 7:Clear and confirm DTC.

4.1.6.17 MCU3 Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity Total body power supply B+ L22

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle vehicle. Step 5:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear axle Step 6:Clear and confirm DTC.

4.1.6.18 MCU3 Internal Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle vehicle. Step 4:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear axle Step 5:Clear and confirm DTC.

4.1.6.19 MCU3 Overheating Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check the vehicle has any fault codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle vehicle. Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear axle Step 7:Clear and confirm DTC.

4.1.6.20 MCU3 High Voltage Circuit Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high-voltage wiring harness of the low-voltage interface of the electric drive rear axle vehicle. Step 4:Check the internal insulation detection circuit of the low-voltage interface of the electric drive rear axle vehicle. Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle vehicle. Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear axle Step 7:Clear and confirm DTC.

4.1.6.21 MCU4 Power Fault

1.DTC Monitoring Logic

2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Total body power supply B+ L22

Step 3:Check if there are any other module power fault codes besides MCU3? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault – No: Next step Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive rear axle vehicle. Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle vehicle. Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear axle Step 7:Clear and confirm DTC.

4.1.6.22 MCU4 Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity Total body power supply B+ L22

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle vehicle. Step 5:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear axle Step 6:Clear and confirm DTC.

4.1.6.23 MCU4 Internal Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle vehicle. Step 4:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear axle Step 5:Clear and confirm DTC.

4.1.6.24 MCU4 Overheating Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check the vehicle has any fault codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle vehicle. Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear axle Step 7:Clear and confirm DTC.

4.1.6.25 MCU4 High Voltage Circuit Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high-voltage wiring harness of the low-voltage interface of the electric drive rear axle vehicle. Step 4:Check the internal insulation detection circuit of the low-voltage interface of the electric drive rear axle vehicle. Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle vehicle. Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear axle Step 7:Clear and confirm DTC.

4.1.6.26 TCU Power Fault

1.DTC Monitoring Logic

2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides TCU? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault – No: Next step Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive medium axle vehicle. Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle vehicle. Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 7:Clear and confirm DTC.

4.1.6.27 TCU Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle vehicle. Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 6:Clear and confirm DTC.

4.1.6.28 TCU Internal Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC confirmation. Refer to DTC Confirmation Step 2:Routine inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive medium axle vehicle. Step 4:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Medium axle Step 5:Clear and confirm DTC.

4.1.7 Dismantling and Installation

4.1.7.1 Replacement of Integrated axle - Intermediate Axle

Removal Procedures 1 Release air pressure from the brake system. 2 Open the door. 3 Open the front flip cover plate. 4 Disconnect the battery negative cable. 5 Perform power-off of high voltage system. 6 Jack the rear end of the vehicle. 7 Drain coolant from the power system. 8 Removal the fifth wheel assembly. 9 Remove the corrugated plate. 10 Remove the drive wheel (front left). 11 Removal the rear wheel housing left front assembly. 12 Remove the rear air spring assembly - 260 (left front). 13 Remove the shock absorber assembly (rear). 14 Remove the rear air spring assembly - 280 (left front). 15 Remove the longitudinal thrust rod assembly. 16 Remove the rear spring U-bolt. 17 Remove the balance beam (left). 18 Remove the drive wheel (right front) 19 Remove the rear wheel housing right front assembly. 20 Remove the rear air spring assembly - 260 (right front). 21 Remove the rear air spring assembly - 280 (right front). 22 Remove the balance beam (right). 23 Remove the X-shaped control arm assembly (front).

24 Disconnect the 2 harness connectors of the integrated axle - intermediate axle. 25 Disconnect the 1 harness connectors of the integrated axle - intermediate axle.

26 Disconnect the 3 air pipes of the integrated axle - intermediate axle. 27 Remove the 2 straps.

28 Disconnect the 2 air pipes of the integrated axle - intermediate axle. 29 Remove the 2 straps.

30 Disconnect the 4 water pipes of the integrated axle - intermediate axle.

caution

Use a clean container to receive the discharged coolant.

31 Remove 1 fixing bolt of the high-voltage wire harness clamp on the integrated electric axle-intermediate axle.

32 Remove 10 fixing bolts on the integrated electric axle- intermediate axle.

33 Disconnect 1 wire harness connector of the integrated electric axle-intermediate axle. 34 Remove 2 fixing bolts of the fixed clamp for the high- voltage wire harness of the integrated electric axle- intermediate axle.

35 Using a lifting platform or other tools to remove the integrated axle - intermediate axle. Installation Procedures 1 Use a lifting platform or other tools to move the integrated axle - intermediate axle to the installation position. 2 Install two fixing bolts of the fixed clamp for the high- voltage wire harness on the integrated electric axle- intermediate axle.

Torque: (12 ft-lb +/- .36) ft-lb

3 Connect one wire harness connector of the integrated electric axle-intermediate axle.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

4 Install ten fixing bolts of the integrated electric axle- intermediate axle.

Torque: (18 ft-lb +/- 2 ft-lb) ft-lb

5 Install one fixing bolt of the high-voltage wire harness clamp on the integrated electric axle-intermediate axle.

Torque:(9 ft-lb +/- .5 ft-lb) ft-lb

6 Connect the 4 water pipes of the integrated axle - intermediate axle.

7 Install the 2 straps. 8 Connect the 2 air pipes of the integrated axle - intermediate axle.

9 Install the 2 straps. 10 Connect the 3 air pipes of the integrated axle - intermediate axle.

11 Connect 1 harness connector of the integrated axle - intermediate axle.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

12 Connect 2 harness connector of the integrated axle - intermediate axle.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

13 Install the X-shaped control arm assembly (front). 14 Install the balance beam (right). 15 Install the rear air spring assembly - 280 (right front). 16 Install the rear air spring assembly - 260 (right front). 17 Install the rear wheel housing right front assembly. 18 Install the drive wheel (right front). 19 Install the balance beam (left). 20 Install the rear spring U-bolt. 21 Install the longitudinal thrust rod assembly. 22 Install the rear air spring assembly - 280 (left front). 23 Install the shock absorber assembly (rear). 24 Install the rear air spring assembly - 260 (left front).

25 Install the rear wheel housing left front assembly. 26 Install the drive wheel (left front). 27 Install the corrugated plate. 28 Install the fifth wheel assembly. 29 Fill coolant in the power system. 30 Lower the rear end of the vehicle. 31 Perform power-on of the high voltage system. 32 Connect the battery negative cable. 33 Close the front flip cover plate. 34 Close the door.

4.1.7.2 Replacement of Integrated axle - Rear Axle

Removal Procedures 1 Release air pressure from the brake system. 2 Open the door. 3 Open the front flip cover plate. 4 Disconnect the battery negative cable. 5 Perform power-off of high voltage system. 6 Jack the rear end of the vehicle. 7 Drain coolant from the power system. 8 Remove the rear wheel housing upper body. 9 Remove the drive wheel (rear left). 10 Remove the height adjustment device assembly (left). 11 Remove the rear left wheel housing middle body assembly. 12 Remove the rear left wheel housing rear body assembly. 13 Remove the rear air spring assembly - 260 (rear left). 14 Remove the shock absorber assembly (rear). 15 Remove the rear air spring assembly - 280 (rear left). 16 Remove the longitudinal thrust rod assembly. 17 Remove the rear spring U-bolt. 18 Remove the rear spring U-bolt 2. 19 Remove the balance beam (left). 20 Remove the drive wheel (rear right). 21 Remove the height adjustment device assembly (right). 22 Remove the rear right wheel housing middle body assembly. 23 Remove the rear right wheel housing rear body assembly.

24 Remove the rear air spring assembly - 260 (rear right). 25 Remove the rear air spring assembly - 280 (rear right). 26 Remove the balance beam (right). 27 Remove the dual channel module assembly. 28 Remove the X-shaped control arm assembly (rear). 29 Disconnect the 2 harness connectors of the integrated axle - rear axle. 30 Remove the 4 straps of the integrated axle - rear axle.

31 Disconnect the 2 harness connectors of the integrated axle - rear axle. 32 Disconnect the 2 harness connectors of the integrated axle - rear axle. 33 Remove the 2 fixing bolts of the integrated axle - rear axle.

caution

Use a clean container to receive the discharged coolant.

34 Remove the 5 fixing bolts of the integrated electric axle - the rear axle. 35 Remove the 2 fixing bolts of the high-voltage wire harness clamp on the integrated electric axle - the rear axle. 39 Disconnect the 2 air pipes of the integrated axle - rear axle.

40 Remove the 2 straps of the integrated axle - rear axle. 41 Disconnect the 3 pipelines of the integrated axle - rear axle. 42 Remove the 2 straps of the integrated axle - rear axle. 43 Use a lifting platform or other tools to remove the integrated axle - rear axle.

Installation Procedures 1 Use a lifting platform or other tools to move the integrated axle - rear axle to the installation position. 2 Install the 2 straps of the integrated axle - rear axle. 3 Connect the 3 air pipes of the integrated axle - rear axle.

4 Install the 2 straps of the integrated axle - rear axle. 5 Connect the 2 air pipes of the integrated axle - rear axle. 9 Install the 2 fixing bolts of the high-voltage wire harness clamp on the integrated electric axle - the rear axle.

Torque: (9 ft-lb +/- .5 ft-lb) ft-lb

10 Install the 5 fixing bolts of the integrated electric axle - the rear axle.

Torque: (9 ft-lb +/- .5 ft-lb) ft-lb

11 Connect the 2 water pipes of the integrated axle - rear axle. 12 Connect 2 harness connector of the integrated axle - rear axle.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

13 Connect 2 harness connector of the integrated axle - rear axle.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

14 Install the 4 straps of the integrated axle - rear axle. 15 Connect 2 harness connector of the integrated axle - rear axle.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

16 Install the X-shaped control arm assembly (rear). 17 Install the dual channel module assembly. 18 Install the balance beam (right). 19 Install the rear air spring assembly - 280 (rear right). 20 Install the rear air spring assembly - 260 (rear right). 21 Install the rear right wheel housing rear body assembly. 22 Install the rear right wheel housing middle body assembly. 23 Install the height adjustment device assembly (right). 24 Install the drive wheel (rear right). 25 Install the balance beam (left). 26 Install the rear spring U-bolt 2. 27 Install the rear spring U-bolt. 28 Install the longitudinal thrust rod assembly. 29 Install the rear air spring assembly - 280 (rear left). 30 Install the shock absorber assembly (rear). 31 Install the rear air spring assembly - 260 (rear left). 32 Install the rear left wheel housing rear body assembly. 33 Install the rear left wheel housing middle body assembly. 34 Install the height adjustment device assembly (left). 35 Install the drive wheel (rear left). 36 Install the rear wheel housing upper body. 37 Fill coolant in the power system. 38 Lower the rear end of the vehicle. 39 Perform power-on of the high voltage system. 40 Connect the battery negative cable. 41 Close the front flip cover plate. 42 Close the door.

caution

After replacing the parts, it is necessary to recalibrate the height.

4.2.1 Specifications

4.2.1.1 Fastener Specifications

4.2.2 Decomposition Diagram

4.2.2.1 Decomposition Diagram

1. Differential Lock Solenoid Device 2. Hexagon Flange Bolt

4.2.3 Dismantling and Installation

4.2.3.1 Replacement of the Differential Lock Solenoid Valve

Removal Procedures 1 Release air pressure from the brake system. 2 Open the door. 3 Open the front flip cover plate. 4 Disconnect the battery negative cable.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

5 Disconnect 1 harness connector of the differential lock solenoid valve assembly with bracket. 6 Disconnect the 3 air pipes of the differential lock solenoid valve assembly with bracket.

7 Remove the 2 fixing bolts of the differential lock solenoid valve assembly with bracket. 8 Detach the differential lock solenoid valve. Installation Procedures 1 Move the differential lock solenoid valve assembly with bracket to the installation position. 2 Install the 2 fixing bolts of the differential lock solenoid valve assembly with bracket.

Torque: (11 ft-lb +/- .5 ft-lb) ft-lb

3 Connect the 3 air pipes of the differential lock solenoid valve assembly with bracket. 4 Connect 1 harness connector of the differential lock solenoid valve assembly with bracket.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

5 Connect the battery negative cable. 6 Close the front flip cover plate. 7 Close the door.

4.3.1 Description and Operation

4.3.1.1 Description and Operation

Accident

1. Handle traffic accidents in accordance with relevant provisions of State Local and Federal law on Road Traffic Safety. 2. Notify the vehicle after-sales service specialist. It is prohibited to reuse the vehicle before the after-sales department issues the battery safety judgment results. 3. If repair or painting is required after collision of the vehicle, it must be performed at an authorized dealer of the vehicle, and it is prohibited to remove the vehicle without permission. Before painting, remove the high voltage battery, high voltage harness, MCU and other high voltage components. This is because the service life of the high voltage battery can be affected when it is exposed to the higher temperature painting workshop. In addition, the high voltage battery on the vehicle may bring potential safety hazards to maintenance personnel who have not received professional training in maintenance of electric vehicles.

Catching Fire

1. Immediately turn off the emergency high voltage switch and low voltage power supply, and notify the manufacturer's after-sales personnel. 2. Do not touch the leaking electrolyte with your hands; If your skin or eyes come into contact with the electrolyte, rinse immediately with plenty of water, and seek medical attention immediately to avoid injury.

Falling in Water or Immersion in Water

1. Do not power on the vehicle. 2. Contact the service personnel.

Recovery and Tracing of High Voltage Battery

1. Car owners and enterprises shall dispose of batteries in accordance with the Interim Measures for the Management of Recovery and Utilization of New Energy Vehicle High Voltage Battery and the Interim Regulations on the Management of Recovery, Utilization and Tracing of New Energy Vehicle High Voltage Battery. 2. If repair or replacement of the high voltage battery is required, the owner of a new energy vehicle should send the new energy vehicle to an after-sales service organization recognized by our company with corresponding capabilities for repair and replacement. 3. When the new energy vehicle is eligible for scrapping, it should be sent to a company engaged in recovery and disassembly of scrapped vehicles approved by our company for removal of the high voltage battery. 4. The owner of high voltage battery (battery leasing and other operating enterprises) should hand over the waste high voltage batteries to a recycling service outlet approved by our company. 5. Do not disassemble, remove or discard the high voltage batteries without permission. Do not hand over waste high voltage batteries to other units or individuals. You will be held responsible for any environmental pollution or safety accidents caused by removing, disassembling or discarding high voltage batteries without permission.

Environmental Pollution

1. The electrode material of the waste battery in the environment will go through hydrolysis, decomposition, oxidation and other chemical reactions with the substances in the environment, producing heavy metal ions, strong alkali and negative electrode carbon dust which will result in heavy metal, alkali and dust pollutions. 2. The electrolyte of waste batteries in the environment can go through hydrolysis, decomposition, combustion and other chemical reactions, producing HF, arsenic-containing compounds and phosphorus-containing compounds, which will lead to fluorine and arsenic pollutions. 3. The solvent of waste batteries undergoes hydrolysis, combustion, decomposition and other chemical reactions, producing small molecule organic compounds such as formaldehyde, methanol, acetaldehyde, ethanol, or formic acid, which are easily soluble in water and can cause water pollution. 4. Other substances in the battery can cause organic matter and fluorine pollutions when they are in the environment. 5. When using the battery, some harmful substances produced after side reactions, including the products of solvent decomposition such as propylene, glycol, ethylene, and ethanol, the by-products generated via reaction between electrolyte and positive electrode such as HF, LiF, (CH2OCO2Li)2CH3OCO2Li, CH4, CO, and CH3OH, the products of side reaction between the negative electrode and the electrolyte, and additives added in the pretreatment process of electrode can directly or indirectly cause environmental pollution.

Harm to Human Health

1. Ingestion of harmful components in batteries can cause severe chemical burns to the mouth, esophagus, gastrointestinal tract, which will lead to upper respiratory tract and lung allergies. If you have ingested harmful ingredients, do not induce vomiting and do not eat or drink. Instead, you should seek medical attention immediately. 2. Skin contact and absorption of harmful components such as ethylene carbonate, diethyl carbonate, and dimethyl carbonate in battery packs may cause local inflammation or skin allergies and/or chemical burns. 3. Eye contact with the harmful components of the battery pack may cause severe allergies and chemical burns.

4.3.2 Specifications

4.3.2.1 Fastener Specifications

4.3.2.2 Technical Parameters

High Voltage Battery (NCM Lithium Battery)

High Voltage Battery (LFP Battery)

4.3.3 System Schematic Diagram

4.3.3.1 Electrical Schematic Diagram

4.3.4 Diagnostic Information and Steps

4.3.4.1 Diagnosis Description

Before diagnosing faults in the power battery system, refer to Description And Operation Understanding and familiarizing oneself with the working principle of the power battery device before starting system diagnosis can help determine the correct fault diagnosis steps in the event of a malfunction, and more importantly, it can help determine the situation described by the customer belongs to normal operation. Any fault diagnosis of the power battery device should start with routine inspection, guiding maintenance personnel to take the next logical step for fault diagnosis. Understanding and correctly using the diagnostic process

can shorten the diagnosis time and avoid misjudgment of faulty parts. 4.3.4.2 Routine Inspection

• Check for aftermarket devices that may affect the operation of the power battery system, ensuring that these devices do not affect the operation of the power battery system.

• Inspect system components that are easily accessible or visible to make sure they are not visibly damaged or have conditions that could cause failure. 4.3.4.3 DTC Confirmation

1.Connect the diagnostic instrument to the diagnostic interface, read and record the DTC, and then clear the DTC. 2. Restart the vehicle. 3. Read the malfunction code of the control system again to confirm whether the system has a malfunction code output. – Yes:Diagnose based on the output malfunction code.

– No:Perform intermittent malfunction checks, refer to Inspection Of Intermittent Fault 4.3.4.4 List Of Diagnostic Trouble Codes (DTCs)

CMU1

CMU2

CMU3

CMU4

4.3.4.5 CMU1 Power Fault

1.DTC Monitoring Logic

2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides CMU1? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Malfunction – No: Next step Step 4:Check the power and grounding harness of the upper left battery pack 1. Step 5:Rewrite the configuration code, reload the software, and upgrade the upper left battery pack 1. Step 6:Replace the upper left battery pack 1. Refer to Replacement Of NCM Battery Pack Assembly 1 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.6 CMU1 Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN2 bus communication harness. Refer to Inspection Of PCAN2 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the upper left battery pack 1. Step 5:Replace the upper left battery pack 1. Refer to Replacement Of NCM Battery Pack Assembly 1 (CALB 161Ah) Step 6:Clear and confirm DTC.

4.3.4.7 CMU1 Internal Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the upper left battery pack 1. Step 4:Replace the upper left battery pack 1. Refer to Replacement Of NCM Battery Pack Assembly 1 (CALB 161Ah) Step 5:Clear and confirm DTC.

4.3.4.8 CMU1 Temperature Abnormality

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check whether the vehicle has any malfunction codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Rewrite the configuration code, reload the software, and upgrade the upper left battery pack 1. Step 6:Replace the upper left battery pack 1. Refer to Replacement Of NCM Battery Pack Assembly 1 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.9 CMU1 High Voltage Circuit Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high-voltage harness of the upper left battery pack 1. Step 4:Check the insulation detection circuit inside the upper left battery pack 1. Step 5:Rewrite the configuration code, reload the software, and upgrade the upper left battery pack 1. Step 6:Replace the upper left battery pack 1. Refer to Replacement Of NCM Battery Pack Assembly 1 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.10 CMU1 High Voltage Interlock Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high-voltage wiring harness of each high-voltage component. Step 4:Check the high-voltage interlock harness of each high-voltage component. Step 5:Rewrite the configuration code, reload the software, and upgrade the upper left battery pack 1. Step 6:Replace the upper left battery pack 1. Refer to Replacement Of NCM Battery Pack Assembly 1 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.11 CMU1 Individual Voltage Abnormality

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the upper left battery pack 1. Step 4:Replace the upper left battery pack 1. Refer to Replacement Of NCM Battery Pack Assembly 1 (CALB 161Ah) Step 5:Clear and confirm DTC.

4.3.4.12 CMU1 Thermal Runaway Signal Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if the vehicle is experiencing thermal runaway? – Yes: A. Stop vehicle charging operations immediately. B. Park the vehicle in a suitable temperature environment and let it sit. C. Execute the operation to release the high voltage system. D. Check vehicle thermal management system malfunction codes. – No: Next step Step 4:Check the thermal runaway signal harness of the upper left battery pack 1. Step 5:Rewrite the configuration code, reload the software, and upgrade the upper left battery pack 1. Step 6:Replace the upper left battery pack 1. Refer to Replacement Of NCM Battery Pack Assembly 1 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.13 CMU2 Power Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides CMU2? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Malfunction – No: Next step Step 4:Check the power and grounding harness of the lower left battery pack 2. Step 5:Rewrite the configuration code, reload the software, and upgrade the lower left battery pack 2. Step 6:Replace the lower left battery pack 2. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.14 CMU2 Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN2 bus communication harness. Refer to Inspection Of PCAN2 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the lower left battery pack 2. Step 5:Replace the lower left battery pack 2. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 6:Clear and confirm DTC.

4.3.4.15 CMU2 Internal Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the lower left battery pack 2. Step 4:Replace the lower left battery pack 2. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 5:Clear and confirm DTC.

4.3.4.16 CMU2 Temperature Abnormality

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check if the vehicle has any malfunction codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Rewrite the configuration code, reload the software, and upgrade the lower left battery pack 2. Step 6:Replace the lower left battery pack 2. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.17 CMU2 High Voltage Circuit Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high voltage harness of the lower left battery pack 2. Step 4:Check the internal insulation detection circuit of the lower left battery pack 2. Step 5:Rewrite the configuration code, reload the software, and upgrade the lower left battery pack 2. Step 6:Replace the lower left battery pack 2. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.18 CMU2 High Voltage Interlock Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine inspection. Refer to Routine inspection Step 3:Check the high-voltage wiring harness of each high-voltage component. Step 4:Check the high-voltage interlock harness of each high-voltage component. Step 5:Rewrite the configuration code, reload the software, and upgrade the lower left battery pack 2. Step 6:Replace the lower left battery pack 2. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.19 CMU2 Individual Voltage Abnormality

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the lower left battery pack 2. Step 4:Replace the lower left battery pack 2. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 5:Clear and confirm DTC.

4.3.4.20 CMU2 Thermal Runaway Signal Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if the vehicle is experiencing thermal runaway? – Yes: A. Stop vehicle charging operations immediately. B. Park the vehicle in a suitable temperature environment and let it sit. C. Execute the operation to release the high voltage system. D. Check vehicle thermal management system malfunction codes. – No: Next step Step 4:Check the lower left battery pack 2 thermal runaway signal harness. Step 5:Rewrite the configuration code, reload the software, and upgrade the lower left battery pack 2. Step 6:Replace the lower left battery pack 2. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.21 CMU3 Power Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides CMU3? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Malfunction – No: Next step Step 4:Check the power and grounding harness of the upper right battery pack 3. Step 5:Rewrite the configuration code, reload the software, and upgrade the upper right battery pack 3. Step 6:Replace the upper right battery pack 3. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.22 CMU3 Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN2 bus communication harness. Refer to Inspection Of PCAN2 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the upper right battery pack 3. Step 5:Replace the upper right battery pack 3. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 6:Clear and confirm DTC.

4.3.4.23 CMU3 Internal Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the upper right battery pack 3. Step 4:Replace the upper right battery pack 3. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 5:Clear and confirm DTC.

4.3.4.24 CMU3 Temperature Abnormality

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine inspection. Refer to Routine inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check whether the vehicle has any malfunction codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Rewrite the configuration code, reload the software, and upgrade the upper right battery pack 3. Step 6:Replace the upper right battery pack 3. Refer to Replacement Of NCM Battery Pack Assembly 3 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.25 CMU3 High Voltage Circuit Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high-voltage harness of the upper right battery pack 3. Step 4:Check the insulation detection circuit inside the upper right battery pack 3. Step 5:Rewrite the configuration code, reload the software, and upgrade the upper right battery pack 3. Step 6:Replace the upper right battery pack 3. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.26 CMU3 High Voltage Interlock Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high-voltage wiring harness of each high-voltage component. Step 4:Check the high-voltage interlock harness of each high-voltage component. Step 5:Rewrite the configuration code, reload the software, and upgrade the upper right battery pack 3. Step 6:Replace the upper right battery pack 3. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.27 CMU3 Individual Voltage Abnormality

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the upper right battery pack 3. Step 4:Replace the upper right battery pack 3. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 5:Clear and confirm DTC.

4.3.4.28 CMU3 Thermal Runaway Signal Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if the vehicle is experiencing thermal runaway? – Yes: A. Stop vehicle charging operations immediately. B. Park the vehicle in a suitable temperature environment and let it sit. C. Execute the operation to release the high voltage system. D. Check vehicle thermal management system malfunction codes. – No: Next step Step 4:Check the thermal runaway signal harness of the upper right battery pack 3. Step 5:Rewrite the configuration code, reload the software, and upgrade the upper right battery pack 3. Step 6:Replace the upper right battery pack 3. Refer to Replacement Of NCM Battery Pack Assembly 2 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.29 CMU4 Power Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides CMU4? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault – No: Next step Step 4:Check the power and grounding harness of the lower right battery pack 4. Step 5:Rewrite the configuration code, reload the software, and upgrade the lower right battery pack 4. Step 6:Replace the lower right battery pack 4. Refer to Replacement Of NCM Battery Pack Assembly 4 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.30 CMU4 Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN2 bus communication harness. Refer to Inspection Of PCAN2 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the lower right battery pack 4. Step 5:Replace the lower right battery pack 4. Refer to Replacement Of NCM Battery Pack Assembly 4 (CALB 161Ah) Step 6:Clear and confirm DTC.

4.3.4.31 CMU4 Internal Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the lower right battery pack 4. Step 4:Replace the lower right battery pack 4. Refer to Replacement Of NCM Battery Pack Assembly 4 (CALB 161Ah) Step 5:Clear and confirm DTC.

4.3.4.32 CMU4 Temperature Abnormality

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check the vehicle has any malfunction codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Rewrite the configuration code, reload the software, and upgrade the lower right battery pack 4. Step 6:Replace the lower right battery pack 4. Refer to Replacement Of NCM Battery Pack Assembly 4 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.33 CMU4 High Voltage Circuit Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high-voltage harness of the lower right battery pack 4. Step 4:Check the insulation detection circuit inside the lower right battery pack 4. Step 5:Rewrite the configuration code, reload the software, and upgrade the lower right battery pack 4. Step 6:Replace the lower right battery pack 4. Refer to Replacement Of NCM Battery Pack Assembly 4 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.34 CMU4 High Voltage Interlock Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the high-voltage wiring harness of each high-voltage component. Step 4:Check the high-voltage interlock harness of each high-voltage component. Step 5:Rewrite the configuration code, reload the software, and upgrade the lower right battery pack 4. Step 6:Replace the lower right battery pack 4. Refer to Replacement Of NCM Battery Pack Assembly 4 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.4.35 Abnormal Voltage Of CMU4 Unit

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the lower right battery pack 4. Step 4:Replace the lower right battery pack 4. Refer to Replacement Of NCM Battery Pack Assembly 4 (CALB 161Ah) Step 5:Clear and confirm DTC.

4.3.4.36 CMU4 Thermal Runaway Signal Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if the vehicle is experiencing thermal runaway? – Yes: A. Stop vehicle charging operations immediately. B. Park the vehicle in a suitable temperature environment and let it sit. C. Execute the operation to release the high voltage system. D. Check vehicle thermal management system malfunction codes. – No: Next step Step 4:Check the thermal runaway signal harness of the lower right battery pack 4. Step 5:Rewrite the configuration code, reload the software, and upgrade the lower right battery pack 4. Step 6:Replace the lower right battery pack 4. Refer to Replacement Of NCM Battery Pack Assembly 4 (CALB 161Ah) Step 7:Clear and confirm DTC.

4.3.5 Dismantling and Installation

4.3.5.1 Replacement of NCM-battery Pack Assembly 1 (CALB 161Ah).

Removal Procedures 1 Open the door. 2 Open the front flip cover plate. 3 Disconnect the battery negative cable. 4 Perform power-off of high voltage system. 5 Jack the front end of the vehicle. 6 Jack the rear end of the vehicle. 7 Drain coolant from battery thermal management system. 8 Remove the left side wall lower trim panel assembly. 9 Remove the side wall upper mounting bracket assembly 2. 10 Remove the left side wall mounting bracket 1. 11 Remove the left side wall mounting bracket 2. 12 Remove the left side wall lower trim panel mounting frame assembly. 13 Remove the left skirt plate assembly. 14 Use the high voltage battery lifting platform to support the high voltage battery. 15 Remove the bottom front left inclined beam. 16 Remove the bottom middle inclined beam 1. 17 Remove the bottom middle cross beam. 18 Remove the bottom rear left inclined beam. 19 Remove the bottom middle inclined beam bracket 2. 20 Remove the outer battery bracket double hole (NCM). 21 Remove the outer battery mount (NCM). 22 Remove the NCM-battery pack assembly 2 (CALB 161Ah).

23 Disconnect the 3 harness connectors of the NCM-battery pack assembly 1 (CALB 161Ah). 24 Disconnect the 2 water pipes of the NCM-battery pack assembly 1 (CALB 161Ah).

caution

Use a clean container to receive the discharged coolant.

25 Remove 1 fixing bolt of the ground harness.

26 Jack the NCM-battery pack assembly 1 (CALB 161Ah). 27 Remove the 7 fixing bolts and nuts of the NCM-battery pack assembly 1 (CALB 161Ah) and detach the NCM- battery pack assembly 1 (CALB 161Ah). Installation Procedures

1 Use the high voltage battery lifting platform to support the high voltage battery, and move the NCM-battery pack assembly 1 (CALB 161Ah) to the installation position. 2 Jack the NCM-battery pack assembly 1 (CALB 161Ah). 3 Install the 7 fixing bolts and nuts of the NCM-battery pack assembly 1 (CALB 161Ah).

Torque:(148 ft-lb +/- 7 ft-lb) ft-lb

4 Install 1 fixing bolt of the ground harness.

Torque: (18.5 ft-lb +/- 2 ft-lb) ft-lb

5 Connect the 2 water pipes of the NCM-battery pack assembly 1 (CALB 161Ah). 6 Connect the 3 harness connectors of the NCM-battery pack assembly 1 (CALB 161Ah).

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

7 Install the NCM-battery pack assembly 2 (CALB 161Ah). 8 Install the outer battery mount (NCM). 9 Install the outer battery bracket double hole (NCM). 10 Install the bottom middle inclined beam bracket 2. 11 Install the bottom rear left inclined beam. 12 Install the bottom middle cross beam. 13 Install the bottom middle inclined beam 1. 14 Install the bottom front left inclined beam. 15 Install the left skirt plate assembly. 16 Install the left side wall lower trim panel mounting frame assembly. 17 Install the left side wall mounting bracket 2. 18 Install the left side wall mounting bracket 1.

19 Install the side wall upper mounting bracket assembly 2. 20 Install the left side wall lower trim panel assembly. 21 Fill coolant in the battery thermal management system. 22 Lower the rear end of the vehicle. 23 Lower the front end of the vehicle. 24 Perform power-on of the high voltage system. 25 Connect the battery negative cable. 26 Close the front flip cover plate. 27 Close the door.

4.3.5.2 Replacement of NCM-battery Pack Assembly 2 (CALB 161Ah).

Removal Procedures 1 Open the door. 2 Open the front flip cover plate. 3 Disconnect the battery negative cable. 4 Perform power-off of high voltage system. 5 Jack the front end of the vehicle. 6 Jack the rear end of the vehicle. 7 Drain coolant from battery thermal management system. 8 Remove the left side wall lower trim panel assembly. 9 Remove the side wall upper mounting bracket assembly 2. 10 Remove the left side wall mounting bracket 1. 11 Remove the left side wall mounting bracket 2. 12 Remove the left side wall lower trim panel mounting frame assembly. 13 Remove the left skirt plate assembly. 14 Use the high voltage battery lifting platform to support the high voltage battery. 15 Remove the bottom front left inclined beam. 16 Remove the bottom middle inclined beam 1. 17 Remove the bottom middle cross beam. 18 Remove the bottom rear left inclined beam. 19 Remove the bottom middle inclined beam bracket 2. 20 Remove the outer battery bracket double hole (NCM). 21 Remove the outer battery mount (NCM).

22 Disconnect the 3 harness connectors of the NCM-battery pack assembly 2 (CALB 161Ah). 23 Disconnect the 2 water pipes of the NCM-battery pack assembly 2 (CALB 161Ah).

caution

Use a clean container to receive the discharged coolant.

24 Jack the NCM-battery pack assembly 2 (CALB 161Ah).

25 Remove 1 fixing bolt of the ground harness. 26 Remove the 7 fixing bolts and nuts of the NCM-battery pack assembly 2 (CALB 161Ah) and detach the NCM- battery pack assembly 2 (CALB 161Ah).

Installation Procedures 1 Use the high voltage battery lifting platform to support the high voltage battery, and move the NCM-battery pack assembly 2 (CALB 161Ah) to the installation position. 2 Jack the NCM-battery pack assembly 2 (CALB 161Ah). 3 Install the 7 fixing bolts and nuts of the NCM-battery pack assembly 2 (CALB 161Ah).

Torque: (148 ft-lb +/- 7 ft-lb) ft-lb

4 Install 1 fixing bolt of the ground harness.

Torque:(18 ft-lb +/- 2 ft-lb) ft-lb

5 Connect the 2 water pipes of the NCM-battery pack assembly 2 (CALB 161Ah). 6 Connect the 3 harness connectors of the NCM-battery pack assembly 2 (CALB 161Ah).

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

7 Install the outer battery mount (NCM). 8 Install the outer battery bracket double hole (NCM). 9 Install the bottom middle inclined beam bracket 2. 10 Install the bottom rear left inclined beam. 11 Install the bottom middle cross beam. 12 Install the bottom middle inclined beam 1. 13 Install the bottom front left inclined beam. 14 Install the left skirt plate assembly. 15 Install the left side wall lower trim panel mounting frame assembly. 16 Install the left side wall mounting bracket 2. 17 Install the left side wall mounting bracket 1. 18 Install the side wall upper mounting bracket assembly 2. 19 Install the left side wall lower trim panel assembly. 20 Fill coolant in the battery thermal management system. 21 Lower the rear end of the vehicle. 22 Lower the front end of the vehicle. 23 Perform power-on of the high voltage system. 24 Connect the battery negative cable. 25 Close the front flip cover plate. 26 Close the door.

4.3.5.3 Replacement of NCM-Battery Pack Assembly 3 (CALB 161Ah).

Removal Procedures 1 Open the door. 2 Open the front flip cover plate. 3 Disconnect the battery negative cable. 4 Perform power-off of high voltage system. 5 Jack the front end of the vehicle. 6 Jack the rear end of the vehicle. 7 Drain coolant from battery thermal management system. 8 Remove the lamp (upper). 9 Remove the lamp (lower). 10 Remove the boarding step body assembly. 11 Remove the right side wall lower trim panel assembly. 12 Remove the right skirt plate assembly. 13 Use the high voltage battery lifting platform to support the high voltage battery. 14 Remove the bottom front right inclined beam.

15 Remove the bottom middle inclined beam 1. 16 Remove the bottom middle cross beam. 17 Remove the bottom rear left inclined beam. 18 Remove the bottom middle inclined beam bracket 2. 19 Remove the outer battery bracket double hole (NCM). 20 Remove the outer battery mount (NCM). 21 Remove the NCM-battery pack assembly 4 (CALB 161Ah). 23 Disconnect the 3 harness connectors of the NCM-battery pack assembly 3 (CALB 161Ah). 24 Disconnect the 2 water pipes of the NCM-battery pack assembly 3 (CALB 161Ah).

caution

Use a clean container to receive the discharged coolant.

25 Remove 1 fixing bolt of the ground harness. 26 Jack the NCM-battery pack assembly 3 (CALB 161Ah). 27 Remove the 7 fixing bolts and nuts of the NCM-battery pack assembly 3 (CALB 161Ah) and detach the NCM- battery pack assembly 3 (CALB 161Ah).

Installation Procedures 1 Use the high voltage battery lifting platform to support the high voltage battery, and move the NCM-battery pack assembly 3 (CALB 161Ah) to the installation position. 2 Jack the NCM-battery pack assembly 3 (CALB 161Ah). 3 Install the 7 fixing bolts and nuts of the NCM-battery pack assembly 3 (CALB 161Ah).

Torque: (148 ft-lb +/- 7 ft-lb) ft-lb

4 Install 1 fixing bolt of the ground harness.

Torque: (18 ft-lb +/- 2 ft-lb) ft-lb

5 Connect the 2 water pipes of the NCM-battery pack assembly 3 (CALB 161Ah).

6 Connect the 3 harness connectors of the NCM-battery pack assembly 3 (CALB 161Ah).

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

8 Install the NCM-battery pack assembly 4 (CALB 161Ah). 9 Install the outer battery mount (NCM). 10 Install the outer battery bracket double hole (NCM). 11 Install the bottom middle inclined beam bracket 2. 12 Install the bottom rear left inclined beam. 13 Install the bottom middle cross beam. 14 Install the bottom middle inclined beam 1. 15 Install the bottom front right inclined beam. 16 Install the right skirt plate assembly. 17 Attach the right side wall lower trim panel assembly. 18 Install the boarding step body assembly. 19 Install the lamp (lower). 20 Install the lamp (upper). 21 Fill coolant in the battery thermal management system. 22 Lower the rear end of the vehicle. 23 Lower the front end of the vehicle. 24 Perform power-on of the high voltage system. 25 Connect the battery negative cable. 26 Close the front flip cover plate. 27 Close the door.

4.3.5.4 Replacement of NCM-battery Pack Assembly 4 (CALB 161Ah).

Removal Procedures 1 Open the door. 2 Open the front flip cover plate.

3 Disconnect the battery negative cable. 4 Perform power-off of high voltage system. 5 Jack the front end of the vehicle. 6 Jack the rear end of the vehicle. 7 Drain coolant from battery thermal management system. 8 Remove the lamp (upper). 9 Remove the lamp (lower). 10 Remove the boarding step body assembly. 11 Remove the right side wall lower trim panel assembly. 12 Remove the right skirt plate assembly. 13 Use the high voltage battery lifting platform to support the high voltage battery. 14 Remove the bottom front right inclined beam. 15 Remove the bottom middle inclined beam 1. 16 Remove the bottom middle cross beam. 17 Remove the bottom rear left inclined beam. 18 Remove the bottom middle inclined beam bracket 2. 19 Remove the outer battery bracket double hole (NCM). 20 Remove the outer battery mount (NCM). 21 Disconnect the 3 harness connectors of the NCM-battery pack assembly 4 (CALB 161Ah).

22 Disconnect the 2 water pipes of the NCM-battery pack assembly 4 (CALB 161Ah).

caution

Use a clean container to receive the discharged coolant.

23 Remove 1 fixing bolt of the ground harness. 24 Jack the NCM-battery pack assembly 4 (CALB 161Ah).

25 Remove the 7 fixing bolts and nuts of the NCM-battery pack assembly 4 (CALB 161Ah) and detach the NCM- battery pack assembly 4 (CALB 161Ah). Installation Procedures

1 Use the high voltage battery lifting platform to support the high voltage battery, and move the NCM-battery pack assembly 4 (CALB 161Ah) to the installation position. 2 Jack the NCM-battery pack assembly 4 (CALB 161Ah). 3 Install the 7 fixing bolts and nuts of the NCM-battery pack assembly 4 (CALB 161Ah).

Torque:(148 ft-lb +/- 7 ft-lb) ft-lb

4 Install 1 fixing bolt of the ground harness.

Torque: (18 ft-lb +/- 2 ft-lb) ft-lb

5 Connect the 2 water pipes of the NCM-battery pack assembly 4 (CALB 161Ah). 6 Connect the 3 harness connectors of the NCM-battery pack assembly 4 (CALB 161Ah).

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

7 Install the outer battery mount (NCM). 8 Install the outer battery bracket double hole (NCM). 9 Install the bottom middle inclined beam bracket 2. 10 Install the bottom rear left inclined beam. 11 Install the bottom middle cross beam. 12 Install the bottom middle inclined beam 1. 13 Install the bottom front right inclined beam. 14 Install the right skirt plate assembly. 15 Attach the right side wall lower trim panel assembly. 16 Install the boarding step body assembly. 17 Install the lamp (lower). 18 Install the lamp (upper). 19 Fill coolant in the battery thermal management system.

20 Lower the rear end of the vehicle. 21 Lower the front end of the vehicle. 22 Perform power-on of the high voltage system. 23 Connect the battery negative cable. 24 Close the front flip cover plate. 25 Close the door.

4.4.1 Specifications

4.4.1.1 Fastener Specifications

4.4.2 Decomposition Diagram

4.4.2.1 Decomposition Diagram

1. FRont end Module

2. Hexagon Flange Lock Nut_all Metal 7. Hexagon Flange Bolt 3. Hexagon Flange Bolt 8. Hexagon Flange Bolt 4. Electronic Water Pump 9. Water Pump Fixing Bracket(Back) 5. Hexagon Flange Lock Nut_all Metal 10. Hexagon Flange Bolt 6. Water Pump Fixing Bracket(Front)

41. Water Refill Hose 47. Long Exhaust Pipe(l=5350) 42. One-hole Fixing Clamp 48. Water Refill Hose 2 43. Cable Ties 1 49. PDU & Water outlet Hose of the Air Pump 44. Pdu Water Outlet Hose 50. Water Inlet Hose of the Air Pump 45. Hose Hoop-type b and Type c 51. Water Outlet Hose of the Air Pump 46. Pdu Water Inlet Hose 52. Front end Module Outlet Nylon Pipe

29. Three-hole Fixing Clamp 55. Rear Water Pmp Otlet Hse 42. One-hole Fixing Clamp 56. Hose Btween Pmps 43. Cable Ties 1 57. Hose Hop-type b and Tpe c 46. Pdu Water Inlet Hose 58. Hydrating nylon tube 47. Long Exhaust Pipe(l=5350) 59. Water Pump Out Nylon Pipe 48. Water Refill Hose 2 60. Hexagon Flange Bolt 52. Front end Module Outlet Nylon Pipe 61. Hose Clamp 1 53. Front Pump - Water Inlet Hose 62. Hexagon Flange Bolt

42. One-hole Fixing Clamp 82. M2 Water Hose (With Protective Bra 45. Hose Hoop-type b and Type c 84. Water Outlet Rubber Hose of M2 & MCU2 (With Protective Braiding) 69. Mcu2 Outlet Hose(With Protective b 85. Mcu1 Water Inlet Hose (With Protec 70. M1 Water Inlet Hose 1 (With Protec 86. Transition Straight Through Hard p 71. Middle and Rear Axle Return Water 87. Mcu2 Connects to M3 House 1(With p 72. Combination Tee Hard Pipe 88. Mcu2 Connects to M3 House 2 (With 73. M3 Water Inlet Hose 1(With Protect 89. Mcu2 and M3 Connects Haerd Pipes 74. Middle and Rear Axle Return Waterr 90. M3 Water Inlet Hose Support 75. Middle and Rear Axle Combination h 91. Mcu2 Outlet Hose(With Protective b 77. M3 Water Inlet Hose 2 (With Protec 92. Hexagon Flange Bolt 78. Uble Hole Nylon Cable Tie （ Gtb-3 93. Hexagon Flange Bolt 80. Middle axle Mcu2 Hose Fixing Bra 94. Hard Mcu2 Outlet Pipe

48. Water Refill Hose 2 65. M1 Water Inlet Hose 49. Water Outlet Hose of PDU & Air Pump 66. Front-end Module Water Inlet Nylon 63. Hexagon Flange Bolt 67. Water Inlet Nylon Tube 1 of M & MCU 64. Three-hole Fixing Clamp 68. Fixed Thread Rolling Strip(t120rh

40. Expansion Tank (Plastic) 42A. Hexagon Flange Lock Nut_all Metal 41A. Hexagon Flange Bolt 43A. Hexagon Flange Bolt

4.4.3 Inspect

4.4.3.1 Inspection of Coolant

After the coolant temperature drops, check the coolant level in the reservoir is between the MIN to MAX marks; If the coolant is insufficient, the warning lamp on the instrument cluster will be illuminated to remind you to add coolant. If the coolant has suspended matter, sediment or discoloration, replace it with new coolant immediately. Regularly check the freezing point of the coolant to ensure that it meets the requirements of the local environment and replace it regularly.

4.4.4 The Working Principle of the System

4.4.4.1 System Working Principle

Three-motor Cooling Solution

1. Front end module total 7. Intermediate axle motor 2 2. Expansion tank 8. Intermediate axle MCU1 3. Electronic water pump 9. Intermediate axle MCU2 4. Inflation pump 11. Intermediate axle motor 1 5. PDU 13. Rear axle motor 2 6. Intermediate axle motor 1

Four-motor Cooling Solution

1. Front end module total 8. Intermediate axle MCU1 2. Expansion tank 9. Intermediate axle MCU2 3. Electronic water pump 10. Intermediate axle motor 1 4. Inflation pump 11. Rear axle MCU1 5. PDU 12. Rear axle MCU2 6. Intermediate axle motor 1 13. Rear axle motor 2 7. Intermediate axle motor 2

4.4.5 Dismantling and Installation

4.4.5.1 Change of Power System Coolant

Removal Procedures 1 Remove the back integrated bracket upper cover plate filler cap. 2 Detach the filler cap. 3 Disengage 1 clamp and disconnect the pipeline. 4 Drain coolant from the power system. Installation Procedures

1 Connect the pipeline and attach 1 clamp. 2 Fill coolant in the power system.

caution

1. The coolant must meet the requirements of the national standards, and the coolant of same model cannot be mixed. It is recommended to use coolant with a freezing point 14* F lower than the minimum temperature in local area.

3 Install the filler cap. 4 Install the back integrated bracket upper cover plate filler cap.

4.4.5.2 Change of Battery Thermal Management System Coolant

Removal Procedures

1 Remove the back integrated bracket upper cover plate filler cap. 2 Detach the filler cap. 3 Disengage the pipeline. 4 Drain coolant from battery thermal management system. Installation Procedures

1 Connect the pipeline. 2 Fill coolant in the battery thermal management system.

caution

1. The coolant must meet the requirements of the national standards, and the coolant of same model cannot be mixed. It is recommended to use coolant with a freezing point 14* F lower than the minimum temperature in local area.

2. Add coolant to the auxiliary water tank until the level is between the MIN and MAX marks. When filling coolant, the air in the coolant cavity must be discharged. For this reason, you should open the air release valve (if any) on the radiator (water tank), slowly add the coolant to prevent air blockage, and wait for 2 to 3 minutes to completely discharge air. The coolant should be filled into the bottom of the water filling port or liquid level inspection port of the radiator.

3 Install the filler cap. 4 Install the back integrated bracket upper cover plate filler cap.

4.4.5.3 Replacement of Front End Module

Removal Procedures 1 Open the door. 2 Open the front flip cover plate. 3 Disconnect the battery negative cable.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

4 Recycle A/C refrigerant. 5 Drain coolant from the power system. 6 Remove the engine compartment trim panel body. 7 Remove the through-type lamp. 8 Remove the front MMW radar shield. 9 Remove the forward MMW radar. 10 Remove the front MMW radar adapter bracket. 11 Remove the left cover plate of the corner radar. 12 Remove the right cover plate of the corner radar. 13 Remove the front bumper assembly. 14 Remove the electric horn assembly - low-pitch. 15 Remove the electric horn assembly - high-pitch. 16 Remove the sealing cross beam. 17 Remove the MMW radar bracket. 18 Remove the front lower protection assembly. 19 Remove the deflector assembly. 20 Remove the condenser. 21 Disconnect the 5 harness connectors of the front end module.

22 Disconnect the 3 water pipes of the front end module.

caution

Use a clean container to receive the discharged coolant.

23 Remove the 5 clamp fixing bolts of the front end module.

24 Remove the 4 fixing bolts of the front end module and detach the front end module.

caution

Due to the heavy weight of the front end module, it shall be removed with the help of an assistant.

Installation Procedures 1 Move the front end module to the installation position.

caution

Due to the heavy weight of the front end module, it shall be moved to the installation position with the help of an assistant.

2 Install the 4 fixing bolts of the front end module.

Torque:(66 ft-lb +/-3.5 ft-lb) ft-lb

3 Install the 5 clamp fixing bolts of the front end module.

Torque: (18 ft-lb +/- 2 ft-lb) ft-lb

4 Connect the 3 water pipes of the front end module.

5 Connect the 5 harness connectors of the front end module.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

6 Install the condenser. 7 Install the deflector assembly. 8 Install the front lower protection assembly. 9 Install the MMW radar bracket. 10 Install the sealing cross beam. 11 Install the electric horn assembly - high-pitch. 12 Install the electric horn assembly - low-pitch. 13 Install the front bumper assembly. 14 Install the right cover plate of the corner radar. 15 Install the left cover plate of the corner radar. 16 Install the front MMW radar adapter bracket. 17 Install the forward MMW radar. 18 Install the front MMW radar shield.

19 Install the through-type lamp. 20 Install the engine compartment trim panel body. 21 Fill coolant in the power system. 22 Fill with A/C refrigerant. 23 Connect the battery negative cable. 24 Close the front flip cover plate. 25 Close the door.

4.4.5.4 Replacement of Electronic Water Pump

Removal Procedures 1 Open the door. 2 Open the front flip cover plate. 3 Disconnect the battery negative cable.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

4 Drain coolant from the power system. 5 Disconnect 1 harness connector of the electronic water pump.

6 Disconnect the 2 water pipes of the electronic water pump.

caution

Use a clean container to receive the discharged coolant.

7 Remove the 4 fixing bolts and nuts of the electronic water pump. 8 Remove the electronic water pump. Installation Procedures

1 Move the electronic water pump to the installation position. 2 Install the 4 fixing bolts and nuts of the electronic water pump.

Torque:(18 ft-lb +/- 2 ft-lb) ft-lb

3 Connect the 2 water pipes of the electronic water pump. 4 Connect 1 harness connector of the electronic water pump.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

5 Fill coolant in the power system. 6 Connect the battery negative cable. 7 Close the front flip cover plate. 8 Close the door.

4.5.1 Specifications

4.5.1.1 Fastener Specifications

4.5.2 Decomposition Diagram

4.5.2.1 Decomposition Diagram

1. Expansion Tank (Plastic) 19. Right Water Filter Inlet Hose 2. Water Filter 20. Right Water Filter Outlet Hose 3. Thermal Management Unit-lh 21. Right Unit Water Replenishment Hos 5. Thermal Management Unit-rh 22. Right Unit Inlet Hose 8. Tee Joint （ t25 ） 48. Hexagon Flange Bolt 9. Expansion Kettle Water Outlet Hose 49. Hexagon Flange Bolt 10. Wptc Water Outlet Hose 50. Hexagon Flange Bolt 11. Left Unit Exhaust Hose 51. Hexagon Flange Bolt 12. Right Unit Exhaust Hose 52. Hexagon Flange Bolt 13. Left Chiller Water Outlet Hose 53. Hexagon Flange Bolt 14. Left Water Filter Inlet Hose 54. Hexagon Flange Bolt 15. Left Water Filter Outlet Hose 57. Hexagon Flange Lock Nut_all Metal 17. Left Unit Inlet Hose 58. Hexagon Flange Lock Nut_all Metal 18. Right Chiller Water Outlet Hose 61 Inside and Out Teeth Serrated Lock

4. Three-way Joint for Battery Piping 38. Right 1 Battery Pack Water Inlet n 23. Fixed Bracket for the Piping of the Left Battery Pack 39. Left 1 Battery Pack Water Outlet n 24. Right Battery Pack Line Fixing Bra 40. Right 1 Battery Pack Water Outlet 26. Right Unit Inlet Nylon Pipe 41. Water Inlet Nylon Tube of the Lower Battery Pack 27. Right Unit Water Outlet Nylon Pipe 42. Water Outlet Nylon Tube of the Lower Battery Pack 28. Left Unit Inlet Nylon Pipe 43. Left 2 Battery Pack Water Inlet Ny 29. Left Unit Water Outlet Nylon Pipe 44. Right 2 Battery Pack Water Inlet n 30. Left Battery Pack Connector Fixing 45. Left 2 Battery Pack Water Outlet n 31. Right Battery Pack Connector Fixin 1 46. Right 2 Battery Pack Water Outlet 32. Right Battery Pack Connector Fixin 2 47. Hexagon Flange Bolt 33. Battery Pack Pipeline Fixing Brack 1 55. Hexagon Flange Bolt 34. Battery Pack Pipeline Fixing Brack 2 56. Hexagon Flange Nut 35. Water Inlet Nylon Tube of the Upper Battery Pack 57. Hexagon Flange Lock Nut_all Metal 36. Water Outlet Nylon Tube of the Upper Battery Pack 60. Hexagon Flange Bolt 37. Left 1 Battery Pack Water Inlet Ny

4. Battery Pipeline 4-Way Connector 41. Right 1 Battery Pack Water Outlet 24. Right Battery Pack Connector Fixin 42. Right 2 Battery Pack Water Outlet 25. Right Battery Pack Line Fixing Bra 43. Right 3 Battery Pack Water Outlet 26. Right Unit Inlet Nylon Pipe 44. Right Battery Pack Water Outlet Ny 27. Right Unit Water Outlet Nylon Pipe 45. Right Battery Pack Water Inlet Nyl 38. Right 1 Battery Pack Water Inlet n 47. Hexagon Flange Bolt 39. Right 2 Battery Pack Water Inlet n 55. Hexagon Flange Bolt 40. Right 3 Battery Pack Water Inlet n 56. Hexagon Flange Nut

4.5.3 The Working Principle of the System

4.5.3.1 System Working Principle

4.5.4 Dismantling and Installation

4.5.4.1 Replacement of the Thermal Management Unit (left)

Removal Procedures 1 Release air pressure from the brake system. 2 Open the door. 3 Open the front flip cover plate. 4 Disconnect the battery negative cable. 5 Perform power-off of high voltage system. 6 Drain coolant from battery thermal management system. 7 Remove the back integrated bracket side cover plate assembly (left). 8 Remove the back integrated bracket side cover plate assembly (right). 9 Remove the back integrated bracket middle cover plate assembly. 10 Remove the back integrated bracket upper cover plate filler cap. 11 Remove the back integrated bracket upper cover plate. 12 Remove the left deflector lower body. 13 Remove the expansion tank (plastic) (left). 14 Remove the water filter. 15 Remove the rear working lamp. 16 Remove the 4 fixing bolts of the bracket.

17 Remove the 4 fixing bolts of the bracket.

18 Remove the 3 fixing nuts of the bracket. 19 Disconnect the 2 harness connectors of the thermal management unit (left).

20 Disconnect the 3 water pipes of the thermal management unit (left).

caution

Use a clean container to receive the discharged coolant.

21 Remove the 2 fixing bolts of the water pipe.

22 Remove the 12 fixing bolts and nuts of the thermal management unit (left) and detach the thermal management unit (left). Installation Procedures

1 Move the thermal management unit (left) to the installation position. 2 Install the 12 fixing bolts and nuts of the thermal management unit (left).

Torque: (18 ft-lb +/- 2 ft-lb) ft-lb

3 Install the 2 fixing bolts of the water pipe.

Torque: (18 ft-lb +/- 2 ft-lb) ft-lb

4 Connect the 3 water pipes of the thermal management unit (left). 5 Connect the 2 harness connectors of the thermal management unit (left).

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

6 Install the 3 fixing nuts of the bracket.

Torque: (18 ft-lb +/- 2ft-lb) ft-lb

7 Install the 4 fixing bolts of the bracket.

Torque: (88 ft-lb +/- 6 ft-lb) ft-lb

8 Install the 4 fixing bolts of the bracket.

Torque: (18 ft-lb +/- 2 ft-lb) ft-lb

9 Install the rear working lamp. 10 Install the water filter. 11 Install the expansion tank (plastic) (left). 12 Install the left deflector lower body. 13 Install the back integrated bracket upper cover plate. 14 Install the back integrated bracket upper cover plate filler cap. 15 Install the back integrated bracket middle cover plate assembly. 16 Install the back integrated bracket side cover plate assembly (right). 17 Install the back integrated bracket side cover plate assembly (left). 18 Fill coolant in the battery thermal management system. 19 Perform power-on of the high voltage system. 20 Connect the battery negative cable. 21 Close the front flip cover plate. 22 Close the door.

4.6.1 Specifications

4.6.1.1 Fastener Specifications

4.6.1.2 Technical Parameters

DC/DC

4.6.2 Decomposition Diagram

4.6.2.1 Decomposition Diagram

1. Hexagon Flange Nut 3. Hexagon Flange Bolt 2. Hexagon Flange Bolt 4. Auxiliary Drive All-in-One Assy

4.6.3 System Schematic Diagram

4.6.3.1 Electrical Schematic Diagram

4.6.4 Diagnostic Information and Steps

4.6.4.1 Diagnosis Description

Before diagnosing faults in multi in one power distribution equipment, Understanding and familiarizing oneself with the working principle of multi in one power distribution equipment before starting system diagnosis can help determine the correct fault diagnosis steps in the event of a fault, and more importantly, it can help determine whether the situation described by the customer belongs to normal operation. Any fault diagnosis of multi in one power distribution equipment should start with routine inspection, guiding maintenance personnel to take the next logical step for fault diagnosis. Understanding and correctly using the

diagnostic process can shorten the diagnosis time and avoid misjudgment of faulty parts. 4.6.4.2 Routine Inspection

• Check the after-sales installation devices that may affect the operation of the multi in one power distribution system to ensure that these devices do not affect the operation of the multi in one power distribution system.

• Inspect system components that are easily accessible or visible to make sure they are not visibly damaged or have conditions that could cause failure. 4.6.4.3 DTC Confirmation

1.Connect the diagnostic instrument to the diagnostic interface, read and record the DTC, and then clear the DTC. 2. Restart the vehicle. 3. Read the fault code of the control system again to confirm whether the system has a fault code output. – Yes:Diagnose based on the output fault code.

– No:Perform intermittent fault checks, refer to Inspection Of Intermittent Fault 4.6.4.4 List Of Diagnostic Trouble Codes (DTCs)

DCDC1 DCDC2

PDU

APU

4.6.4.5 DCDC1 Power Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power failure codes besides DCDC1? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Malfunction – No: Next step Step 4:Check the power distribution unit power supply and grounding harness. Step 5:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 6:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 7:Clear and confirm DTC.

4.6.4.6 DCDC1 Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN3 bus communication harness. Refer to Inspection of PCAN3 bus network integrity

Step 4:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 5:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 6:Clear and confirm DTC.

4.6.4.7 DCDC1 Internal Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the power distribution unit. Step 4:Replace the power distribution unit. Refer to Replacement of Multi in One Power Distribution Assembly Step 5:Clear and confirm DTC.

4.6.4.8 DCDC1 Overheating Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check the vehicle has any fault codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 6:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 7:Clear and confirm DTC.

4.6.4.9 DCDC1 Low-voltage Charging System Fault

1.DTC Monitoring Logic

2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the main battery. Refer to Inspection Of The Main Battery

Step 4:Check the low-voltage charging circuit of the power distribution unit (integrated DCDC). Step 5:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 6:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 7:Clear and confirm DTC.

4.6.4.10 DCDC1 High Voltage Circuit Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the power distribution unit high-voltage harness. Step 4:Check the internal insulation detection circuit of the power distribution unit. Step 5:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 6:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 7:Clear and confirm DTC.

4.6.4.11 DCDC2 Power Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC confirmation. Refer to DTC confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides DCDC2? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC Low-voltage Charging System Malfunction – No: Next step Step 4:Check the power distribution unit power supply and grounding harness. Step 5:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 6:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 7:Clear and confirm DTC.

4.6.4.12 DCDC2 Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN3 bus communication harness. Refer to Inspection Of PCAN3 Bus Network Integrity

Step 4:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 5:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 6:Clear and confirm DTC.

4.6.4.13 Internal Fault Of DCDC2

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the power distribution unit. Step 4:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 5:Clear and confirm DTC.

4.6.4.14 DCDC2 Overheating Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check the vehicle has any malfunction codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 6:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 7:Clear and confirm DTC.

4.6.4.15 DCDC2 Low-voltage Power Supply Sstem Fault

1.DTC Monitoring Logic

2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the low-voltage power supply line of the thermal management unit of the power distribution unit (integrated DCDC). Step 4:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 5:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 6:Clear and confirm DTC.

4.6.4.16 DCDC2 High Voltage Circuit Fault

1.DTC Monitoring Logic 2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the power distribution unit high-voltage harness. Step 4:Check the internal insulation detection circuit of the power distribution unit. Step 5:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 6:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 7:Clear and confirm DTC.

4.6.4.17 PDU Power Fault

1.DTC Monitoring Logic

2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides PDU? – Yes: Check the main battery. Refer to Inspection Of The Main Battery Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Malfunction – No: Next step Step 4:Check the power distribution unit power supply and grounding harness. Step 5:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 6:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 7:Clear and confirm DTC.

4.6.4.18 PDU Communication Fault

1.DTC Monitoring Logic 2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN3 bus communication harness. Refer to Inspection Of PCAN3 Bus Network Integrity

Step 4:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 5:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 6:Clear and confirm DTC.

4.6.4.19 Internal Fault Of PDU

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Rewrite the configuration code, reload the software, and upgrade the power distribution unit. Step 4:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 5:Clear and confirm DTC.

4.6.4.20 APU Communication Fault

1.DTC Monitoring Logic

2.Circuit Diagram

3. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Check the PCAN3 bus communication harness. Refer to Inspection Of PCAN3 Bus Network Integrity

Step 4:Rewrite the configuration code of the power distribution unit, reload the software, and upgrade. Step 5:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 6:Clear and confirm DTC.

4.6.4.21 APU Reports EHPS Related Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check the vehicle has any malfunction codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Check the high-voltage harness of the battery pack. Step 6:Check the internal insulation detection circuit of the battery pack. Step 7:Check the EHPS three-phase input harness. Step 8:Rewrite the configuration code, reload the software, and upgrade the EHPS. Step 9:Replace the EHPS. Refer to Replacement Of Integrated EHPS Assembly Step 10:Rewrite the configuration code, reload the software, and upgrade the power distribution unit. Step 11:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 12:Clear and confirm DTC.

4.6.4.22 APU Reports Air Compressor Related Fault

1.DTC Monitoring Logic

2. Diagnostic Steps Step 1:DTC Confirmation. Refer to DTC Confirmation Step 2:Routine Inspection. Refer to Routine Inspection Step 3:Move the vehicle to a normal temperature environment and let it sit for a while. Step 4:Check the vehicle has any malfunction codes related to the thermal management system? – Yes: Prioritize troubleshooting related to thermal management systems. – No: Next step Step 5:Check the high-voltage harness of the battery pack. Step 6:Check the internal insulation detection circuit of the battery pack. Step 7:Check the three-phase wiring harness of the air compressor. Step 8:Replace the air compressor. Refer to Replacement Of Air Compressor Assembly Step 9:Rewrite the configuration code, reload the software, and upgrade the power distribution unit. Step 10:Replace the power distribution unit. Refer to Replacement Of Multi In One Power Distribution Assembly Step 11:Clear and confirm DTC.

4.6.5 Dismantling and Installation

4.6.5.1 Replacement of the All-in-one Power Distribution Assembly

Removal Procedures 1 Open the door. 2 Open the front flip cover plate. 3 Disconnect the battery negative cable. 4 Perform power-off of high voltage system. 5 Drain coolant from the power system. 6 Remove the back integrated bracket side cover plate assembly (left). 7 Remove the back integrated bracket side cover plate assembly (right). 8 Remove the back integrated bracket middle cover plate assembly. 9 Remove the 10 fixing screws of the cover plate and detach the cover plate.

10 Remove the 8 fixing screws of the harness. 11 Remove the 8 fixing bolts of the harness. 12 Remove the 12 fixing screws of the cover plate and detach the 2 cover plates.

13 Remove the 12 fixing screws of the harness. 14 Remove the 12 fixing bolts of the harness. 15 Disconnect the 15 harness connectors of the all-in-one power distribution assembly.

16 Disconnect the 2 water pipes.

caution

Use a clean container to receive the discharged coolant.

17 Remove 2 fixing bolt of the ground harness. 18 Remove the 4 fixing bolts of the all-in-one power distribution assembly and detach the all-in-one power distribution assembly.

Installation Procedures 1 Move the all-in-one power distribution assembly to the installation location. 2 Install the 4 fixing bolts of the all-in-one power distribution assembly.

Torque:62 ft-lb +/- 6 ft-lb

3 Install 2 fixing bolt of the ground harness.

Torque:(18 ft-lb +/- 2ft-lb) ft-lb

4 Connect the 2 water pipes. 5 Connect the 15 harness connectors of the all-in-one power distribution assembly.

caution

The harness is firmly connected following the principal of "insert until a click is heard for confirmation".

6 Install the 12 fixing bolts of the harness.

Torque: (22 ft-lb +/- 2 ft-lb) ft-lb

7 Install the 12 fixing screws of the harness.

8 Install the 12 fixing screws of the cover plate. 9 Install the 8 fixing bolts of the harness.

Torque: (22 ft-lb +/- 2 ft-lb) ft-lb

10 Install the 8 fixing screws of the harness.

11 Install the 10 fixing screws of the cover plate. 12 Install the back integrated bracket middle cover plate assembly. 13 Install the back integrated bracket side cover plate assembly (right). 14 Install the back integrated bracket side cover plate assembly (left). 15 Fill coolant in the power system. 16 Perform power-on of the high voltage system. 17 Connect the battery negative cable. 18 Close the front flip cover plate. 19 Close the door.