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BYD AUTO Technical Monthly AUGUST, 2012

BYD AUTO Technical Monthly

Introduction
The BYD AUTO Technical Monthly is dedicated to providing better technical services and supports for BYD service centers and/ or service shops. This monthly contains TECHNOLOGY NOTICE TROUBLESHOOTING AND SPARE PARTS. It can help distributors, service centers and/or service shops settle technical problems and order spare parts rightly. All people should understand it clearly.

If any comments or suggestions about monthly, you can contact BYD AUTO by following ways: 1. Mailbox:BYDAUTOSERVICE@BYD.COM; 2. Tel: +86-755-89888888 ext.64555; 3. Service Engineers for your market.

BYD AUTO CO. LTD., 2012-8-31

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BYD AUTO Technical Monthly

CATALOG
TECHNOLOGY NOTICE .......................................................................................... 4 BYD vehicles shock absorber oil leakage, abnormal sound determination ..............4 Judging handbook of shock absorber abnormal noise-For all vehicles of BYD .......7 TROUBLESHOOTING............................................................................................ 11 Troubleshooting False Over-heating in F3 AT....................................................................11 SPARE PARTS ...................................................................................................... 13 DistinguishSpare parts of F0 2012 Model Type .................................................................13

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BYD AUTO Technical Monthly

TECHNOLOGY NOTICE
BYD vehicles shock absorber oil leakage, abnormal sound determination

1. Purpose and applicable range


For uniform shock absorber oil leakage, abnormal sound fault determination and acceptance in warranty, the technology notice is hereby formulated. This notice is suitable for BYD auto co., LTD., and 4S shop fault parts inspection in warranty. This notice is suitable for the hydraulic shock absorber produced be BYD automobile co., LTD.

2. Shock absorber oil leakage fault determination 1) Attention


i. Shock absorber oil seepage is a kind of normal phenomenon. In order to achieve the function of the shock absorber and use requirements, micro cracks exist on the shock absorber connecting rod surface (below), which can store a certain amount of oil forming oil film on the surface, thus wetting rod, wet friction is made between connecting rod and oil seal, in order to protect oil seal and prevent abnormal sound caused by dry friction, overall improve the use of shock absorber performance, and prolong service life, therefore, oil seepage oil is allowed, which does not affect the use of shock absorber.

Connecting rod surface microcrack


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BYD AUTO Technical Monthly

ii.

During the oil leakage criterion of shock absorber, please pay special attention to judge whether water stain or not, because the rain, snow and ice melt or after washing the car would affect your test results.

2) Shock absorber oil leakage appearance determination method:


i. Theres no obvious failure occurs on shock absorber, and oil pollution exists on the surface, but no oil droplets and no lots of sludge formatted. And the oil pollution stain leaking from oil cylinder seal doesnt reach the spring tray place (not reach 50 mm if no spring tray), hence define it as oil seepage, see illustrations below:

Seal cage

Oil seepage, not Spring replace tray

Oil seepage, not 50 mm replace

50 mm

Bottom mounting bracket

ii.

The oil pollution stain leaking from oil cylinder seal does reach even over the spring tray place (reach or over 50 mm if no spring tray), hence define it as oil leakage, see illustrations below:

Oil seal to spring tray Oil leakage, replace 50 mm

Oil leakage, replace

Seal cage

Spring tray

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BYD AUTO Technical Monthly

iii.

The scope from the oil cylinder seal to the spring tray (50 mm from the seal downward if no spring tray), peak-shaped oil drip trace cant be existed, otherwise, define it as oil leakage,
50 mm Oil leakage, replace Oil leakage, replace

see illustrations below:

iv.

All welding and static sealing parts located on the edge of oil cylinder seal are not allowed to appear oil leakage, otherwise they must be replaced. Note: Regard rear shock absorber of series 3 auto models as no spring tray ones to determine.

3. shock absorber abnormal sound fault determination method


1) Check the tire pressure: Automobile suspension overall damping performance would be reduced if the tire pressure is too high, check the tires using condition and keep the tire pressure standard; 2) Check shock absorber connecting joints: Looseness of transverse stabilizer bar rod & ball head assembly, the oscillating arm next ball head, bolt between the horizontal stabilizer bar rod & ball head assembly and the former damping connection parts, bolt between the upper part and lower part of shock absorber and etc all will lead to vehicles abnormal noise during driving, such as a looseness, the bolt with the moment requirements need to be fastened; 3) Check shock absorber spiral spring: If theres gap between the shock absorber spiral spring with the upper and lower spring seat, or contact between the spiral spring bracket ring with the first working ring car while the car is derived on the concave road with holes, may have collision sound, then replace shock absorber spiral spring; 4) Check the connecting bracket assembly of front shock absorber: Check the connecting bracket assembly if theres the "click, click" or other noise while the vehicle is steering.
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BYD AUTO Technical Monthly Replace the upper connecting bracket, if the shock absorber upper part sends out "click, click" sound, while shaking the connecting bracket assembly top of shock absorber.

Judging handbook of shock absorber abnormal noise-For all vehicles of BYD


Abnormal noise of shock absorber-judgment of the vehicle: before judging, check all the related chassis parts and find the source.
NO. Possible causes of Checking methods solution abnormal sound No previous collision, damage, deformation. The By sight replace the damaged appearance of the wheels and spare parts hubs is normal. Tire pressure is too high or Check if the tire pressure is Adjust tire pressure too low normal Abnormal sound kaka Press the trim board, check if caused by the friction of there is fit clearance and friction Increase the gasket wheel trim cover and the side between the trim board and the of tires side of tires Fasten the nuts and bolts to check if their torque has Fastening nuts and bolts on decreased. If their torque is Fasten nuts and bolts the chassis loosen lower than the standard or there is no torque, it means that nuts and bolts loosen Bolts on the front/rear axle Abnormal noise generates loosen, driving abnormal when shaking the car body Fastening torque sound, metal impact sound transversely. No abnormal noise when shaking the car body perpendicularly. Lift the car, hold the wheel and Ball head of swing arm loosen then rock it, check if the ball replace the swing or friction noise head of front swing arm has arm loosened or there is friction noise All bushings assembly and Check all the rubber parts if replace the damaged other rubber parts damaged they have damaged or parts or loosened loosened

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Ball pins of stabilizer bar and steering link loosen or damage Stabilizer bar bushings creak Steering with sudden abnormal noise, hub bearing with abnormal noise Continuous abnormal noise when steering, steering gear with noise

BYD AUTO Technical Monthly 1.whether the steering wheel vibrates when controlling it replace relative spare 2.remove the connecting nuts, parts shake the ball pin and check the ball head Press the engine hood heavily Replace rubber bushings Shake the car body when it is in Replace hub stationary state bearings Steering in situ in stationary state No abnormal noise with cold start. Tweets generates after 10 minutes driving. Steering in situ with abnormal noise after stopping Check if the heat insulation sheet has deformed and related with brake disc Clear metal clicking noise appears in low-speed driving and backing a car. No abnormal noise when pressing the car in vertical stationary state Harsh noise Full up the tank, and check if there is still abnormal noise

Fasten the steering connecting bolts. Other treatment if the bearings loosen

Steering abnormal noise

Heat insulation sheet with abnormal noise Main pin of brake loosens, its abnormal noise is similar to that of chassis torque loosen

Adjust the clearance between heat insulation sheet and brake disc Coat lubricating oil and then tighten the torque Polish the brake disc Normal sound

Braking with abnormal noise 9 The fuel in the tank vibrates

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Metal clicking noise generates Coat glue on the rivet because of the loosening of Check the rivet joint of fuel tank joint tank rivet Connecting bolts of shock Tighten the nuts absorber and steering Tighten it and check (bolts) knuckle loose Connecting bolts of shock Tighten it and check Tighten the nuts absorber and car body loose fault mounting place of helical Check the spring if it is mounted Adjust the spring spring on the spring seat or side frame Steering Shake the steering knuckle Replace knuckle with abnormal noise when driving with abnormal steering knuckle noise (F6 only)
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Stabilizer bar, rear side frame with abnormal noise Supporting cushion, buffer block and dust cover damage

BYD AUTO Technical Monthly Check the bolts of two sides of Tighten the nuts frame Remove the absorber, and Replace supporting check if the supporting cushion, cushion, buffer block buffer block and dust cover has and dust cover damaged Check if the connecting bolts of steering gear loose Adjust bolts of steering gear Reassemble it, tighten the nuts according to the standard torque

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Front (left or lower right) car body with abnormal noise when steering in stationary state Improper torque of tighten nuts of shock absorber causes abnormal noise

Test the torque according to the requirement with a wrench

Abnormal noise of shock absorber-judgment of the vehicle: eliminate all the failures above, investigate the abnormal noise of shock absorber as following chart.

Noise Type

Phenomenon Description

Judging Method We can hear the sound in normal circumstance when the vehicle is driving on gentle slope at a low speed.

conclusion The sound similar to that of airflow is caused by the air working inside the shock absorber. Its normal. Continuous clear sound DongDong may be abnormal noise of the shock absorber. Abnormal noise still exists after 5-8 minutes driving.

Sound chichichi

We can hear the sound in Sound normal circumstance when the dongdongdong vehicle is driving on gentle slope at a low speed.(not impact sound) Abnormal We can hear the sound in noise in Sound jijiji normal circumstance when the driving vehicle is driving on gentle slope at a low speed. We can hear the sound in Sound sisisi normal circumstance when the vehicle is driving on large slope at a low speed. Check if the springs Replace the helical spring collide obviously

Normal sound caused by rapid flow of fluid inside the shock absorber. Running-on and collision of helical spring. The Sound is similar to that of the friction
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Creak

Dust cover with abnormal noise

Scrape forms because of the friction between the plastic dust cover and the wall of oil reservoir

BYD AUTO Technical Monthly between metal and We can hear the sound when the rubber. Check all the vehicle is driving on large slope at rubber-metal hinged part a low speed, especially in cold on the chassis, especially day, more seriously so long as the the position of stabilizer vehicle knocks down, such as bar layering bushings. sudden brake. Metal crash wont exist except the shock absorber is destructively damaged. Remove the dust cover and observe it after it rotates at an angle if obvious noise forms by the friction of the dust Keep the car stationary on level cover and the wall of oil ground. Press the rear of the car reservoir. If friction places and observe if the dust cover are the same, it means collides with the oil reservoir bad tolerance of the car body and rear torque beam. If the friction places are change as the angle does, it means that we need to replace the dust cover.

Springs collide with abnormal noise

Helical spring collide

Replace helical springs. Check if the springs collide (little More than 1.5 parallel possibility) circles means that the vehicle overloaded heavily

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BYD AUTO Technical Monthly

TROUBLESHOOTING
Troubleshooting False Over-heating in F3 AT

Malfunction Description:
Dashboard water temperature gauge goes up abruptly, and up to the alert zone finally.

Malfunction Analysis:
Checking the whole cooling system, no problems found. Using BYD Diagnostic (ED300/ED400) to read the data when the malfunction appeared shows that its normal, it is not real over-heating. Then check the water temperature sensor its OK too.

At last, we analyzed and found that its the poor ground wire that finally leads the dashboard water temperature gauge in disorder.

Maintenance Process:

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BYD AUTO Technical Monthly

1 Please kindly confirm that there is no additional electronics in this vehicle. 2 Please check the ground wiring between power train (Engine & Transmission) and Body. But the simplest way to solve this malfunction is connecting a new ground wiring between Engine and Car Body.

3 Check the dashboard ground wiring. 4 Replace the dashboard. 5 Replace the wire harness of dashboard.

Applicable Model: F3 AT
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BYD AUTO Technical Monthly

SPARE PARTS
DistinguishSpare parts of F0 2012 Model Type
No 1 2 SAP 10136857-00 10782063-00 Part Name TRANSMISSION ASSY TRANSMISSION ASSY Suitable Model Former Model 2012 Model

No neutral gear switch Former Model

Add neutral gear switch 2012 Model

No 1 2

SAP 10124735-00 10739854-00

Part Name BRAKE CLUTCH PEDAL ASSY BRAKE CLUTCH PEDAL ASSY

Suitable Model Former Model 2012 Model

No clutch switch Former Model

Add clutch switch 2012 Model

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BYD AUTO Technical Monthly No 1 2 SAP 10150232-00 10756202-00 Part Name LOCK ASSY.,BACK DOOR LOCK ASSY.,BACK DOOR Suitable Model Former Model 2012 Model

No induction switch Former Model

Add induction switch 2012 Model

No 1 2

SAP 10209168-00 10763200-00

Part Name START BUTTON CONTROLLER ASSY., SMART KEY SYSTEM

Suitable Model 2012 Model 2012 Model

CONTROLLER ASSY., SMART KEY SYSTEM 2012 Model

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BYD AUTO Technical Monthly No 1 2 SAP 10007906-00 10763201-00 Part Name CENTRAL CONTROL MODULE WITH TELECONTROL BODY CONTROL MODULE ASSY Suitable Model Former Model 2012 Model

Former Model

2012 Model

No 1 2 3 4 5 6 7 8

SAP 10274341-00 10209162-00 10763398-00 10763399-00 10834835-00 10303138-00 10295381-00 10031059-00

Part Name CENTRAL DETECTING ANTENNA ASSY. INNER DETECTING ANTENNA ASSY OUTER DETECTING ANTENNA ASSY OUTER JIGGLE SWITCH ASSY REMOTE KEY CARD ELECTRONIC KEY KEY HIGH-FREQUENCY RECEIVER MODULE ELECTRIC STEERING COMULN LOCK ASSY.

Suitable Model 2012 Model 2012 Model 2012 Model 2012 Model 2012 Model 2012 Model 2012 Model 2012 Model

CENTRAL DETECTING ANTENNA ASSY.

INNER DETECTING ANTENNA ASSY

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Location: Left front door assy. OUTER DETECTING ANTENNA ASS

Location: Left front door assy. OUTER JIGGLE SWITCH ASSY

REMOTE KEY

CARD ELECTRONIC KEY

KEY HIGH-FREQUENCY RECEIVER MODULE

ELECTRIC STEERING COMULN LOCK ASSY.

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BYD AUTO Technical Monthly No 1 2 SAP 10762066-00 10762063-00 Part Name REAR LOGO ASSY MOUNTING SEAT, LED REAR LOGO ASSY MOUNTING SEAT, LED Suitable Model 2012 Model 2012 Model

Suitable Type: G-I & GL-I

Suitable Type: GLX-I

No 1 2

SAP 10238197-00 10776088-00

Part Name REAR LOGO REAR LOGO ASSY, LED

Suitable Model Former Model 2012 Model

Former Model

2012 Model

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BYD AUTO Technical Monthly No 1 2 SAP 10402937-00 10782864-00 Part Name LOWER SHIELD ASSY.,COMBINATION SWITCH LOWER GUARD BOARD ASSY., COMBINATION SWITCH Suitable Model Former Model 2012 Model

Suit for Mechanical Ignition Key Former Model

Suit for Start Button 2012 Model

No 1 2

SAP 10314599-00 10782064-00

Part Name DECORATING COVER,WHEEL WHEEL HUB CAP ASSY

Suitable Model Former Model 2012 Model

Former Model

2012 Model

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BYD AUTO Technical Monthly No 1 2 SAP 10143840-00 10070157-00 Part Name UPPER SHIELD ASSY.,INSTRUMENT PANEL UPPER SHIELD ASSY.,INSTRUMENT PANEL Suitable Model Former Model 2012 Model

Former Model

2012 Model

No 1 2

SAP 10143862-00 10725182-00

Part Name CENTRAL CONTROL PANEL ASSY. MIDDLE COVER BOARD ASSY, INSTRUMENT PANEL

Suitable Model Former Model 2012 Model

No vent Former Model

New design vent 2012 Model

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BYD AUTO Technical Monthly No 1 2 SAP 10048003-00 10772865-00 Part Name DRIVER SEAT ASSY DRIVER SEAT ASSY Suitable Model Former Model 2012 Model

No bracket and key bag Former Model

Add bracket and key bag 2012 Model

No 1 2

SAP 10048004-00 10772866-00

Part Name PASSENGER SEAT ASSY PASSENGER SEAT ASSY

Suitable Model Former Model 2012 Model

No bracket and key bag Former Model

Add bracket and key bag 2012 Model

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No 1

SAP 10249838-00

10774237-00

BYD AUTO Technical Monthly Part Name Suitable Model GLASS,BACK DOOR Former Model (WITHOUT ELECTRICALLY HEATED WIRE AND WIPER HOLE) BACK DOOR GLASS 2012 Model

No mounting hole for LED LOGO Former Model

Mounting hole for LED LOGO 2012 Model

No 1

SAP 10249839-00

10774236-00

Part Name GLASS,BACK DOOR(WITH ELECTRICALLY HEATED WIRE AND WIPER HOLE) BACK DOOR GLASS

Suitable Model Former Model

2012 Model

No mounting hole for LED LOGO Former Model

Mounting hole for LED LOGO 2012 Model

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BYD AUTO Technical Monthly No 1 2 SAP 10141832-00 10851763-00 Part Name FRONT DOOR ASSY.,L FRONT DOOR ASSY.,L Suitable Model Former Model 2012 Model

No mounting hole for micro switch Former Model

Mounting hole for micro switch 2012 Model

No 1 2

SAP 10782012-00 10782013-00

Part Name SPEEDOMETER AND INSTRUMENT PANEL JUNCTION BOX ASSY COMBINATION INSTRUMENT ASSY

Suitable Model 2012 Model/G-I 2012Model/GLX-I

Add key indicator, without SRS and ABS Former Model

Add key indicator, with SRS and ABS 2012 Model

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BYD AUTO Technical Monthly No 1 2 3 4 5 6 7 8 9 10 11 12 SAP 10781782-00 10781788-00 10782893-00 10782895-00 10782894-00 10781783-00 10781779-00 10781781-00 10781784-00 10781780-00 10775870-00 10775874-00 Part Name ENGINE WIRE FRONT DOOR WIRE, L INSTRUMENT PANEL WIRE INSTRUMENT PANEL WIRE INSTRUMENT PANEL WIRIE FLOOR WIRE FLOOR WIRE WIRING HARNESS, ENGINE CABIN WIRING HARNESS, ENGINE CABIN WIRING HARNESS, ENGINE CABIN REAR BACK DOOR WIRE, L REAR BACK DOOR WIRE, L Suitable Model 2012 Model/UAES 2012 Model 2012 Model/G-I 2012 Model/GL-I 2012 Model/GLX-I 2012 Model G-I/GL-I 2012 Model/GLX-I 2012 Model/G-I 2012 Model/GL-I 2012 Model/GLX-I 2012 Model/GLX-I 2012 Model G-I/GL-I

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