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Foreword
This Repair Manual provides information about diagnosis and repair procedures, adjust-
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If you need information about product brand, part number or special tool mentioned in this
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mation, illustrations and product description used in this Manual are applicable to situa-
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Without permission of BYD Auto Industry Company Limited, do not copy, store any part of
this manual on retrieval system or spread it by means of electronic, mechanical, copy or
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BYD Auto Industry Company Limited
Date
1
BYD S6, S6A, S6K Service Manual
Engine Accessories
Contents
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BYD S6, S6A, S6K Service Manual
Caution
Warning: in order to reduce possibility that person and/or property is damaged, please observe
the following descriptions:
1. This Manual is prepared by BYD Auto Industry Company Limited. for qualified professional
technicians. Anyone without proper training, tools and equipment who tries to repair and
maintain this car may cause self or other persons to be injured.
2. Correct repair and maintenance methods are important for the personal safety of repair
technicians, safe and reliable operation of the motor vehicle. Please use the same origi-
nal part as one part which you need to replace, or the part specified by BYD Auto Industry
Company Limited. Do not use replacement parts unauthorized by BYD Auto Industry Com-
pany Limited.
3. Repair procedures recommended or described in this Manual are effective methods for re-
pair and maintenance. A specially designed tool needs to be used in some procedures.
Therefore, you must ensure that personal safety or safe operation of vehicle will not be
threatened when you use replacement parts, repair procedures or tools which have not au-
thorized or accepted by BYD Auto Industry Company Limited.
4. This Manual contains information under “Warning”, “Special Note” and “Notes” which
should be complied with to avoid injury in repair and maintenance. Improper maintenance
may damage vehicle or bring potential risk to the vehicle. These “warning”, “special notes”
and “Notes”do not cover all cases. BYD Auto Industry Company Limited. cannot give warn-
ing and compensate for potential risk due to violation of these notes.
5. This Manual includes repair procedures for vehicle equipped with safe airbag system
(hereinafter referred to as the “air bag”). Refer to “Warning”, “Special Notes”, “Notes” and
“Warnings” in “Protection Device ”. Please refer to parts of air bag and line position draw-
ing in “Protection Equipment” before repairing parts of air bag or its line or adjacent to the
airbag. Violation of information under “Warning” will cause the air bag deployment, personal
injury or unnecessary repair of airbag.
Violation of information under “Warning” will cause the air bag deployment, personal injury
or unnecessary repair of airbag.
II
BYD S6, S6A, S6K Service Manual
If you find any error in this Repair Manual or have any recommendation for this Repair Manual,
please contact BYD Auto Industry Company Limited. by letter or fax. Details of contact are as fol-
lowing:
Address: Room 1-446#, BYD Auto, Pingshan Industrial Park, Longgang District, Shenzhen
Fax: 0755-8992-4437
Your name
BYD Auto Industry Company Limited. will answer your questions in follow procedure:
5HSDLU0DQXDO4XDOLW\5HSRUW
Subject
Description of problem
Revision comments
III
BYD S6, S6A, S6K Service Manual
I Epitome
Contents
1-I
BYD S6, S6A, S6K Service Manual
(4) This Manual does not describe the fol- “Specification Description” is indicated
lowing basic operations which should in bold type in necessary position of
be complied with strictly in practice: this Manual.
ĸ Wash removed parts when neces- Warnings indicate that it may cause se-
sary rious personal hurt to a maintainer.
3. Repair steps
1-II
BYD S6, S6A, S6K Service Manual
Length 4810
Outline dimension Width 1855
(mm) Height (without
1725 (1680 with luggage rack) (without load)
load)
Front 1580
Wheel track (mm)
Rear 1555
Minimum diameter
of turning circle 11.8
(m)
Luggage compart-
˄ 1084L/ lay down the second row seats 2398L ˅±5 L
ment capacity (L)
Maximum grade-
30
ability (%)
1-1
BYD S6, S6A, S6K Service Manual
Cylinder bore mm 83 88
Stroke mm 92 96
1-2
BYD S6, S6A, S6K Service Manual
Status No load
1-3
BYD S6, S6A, S6K Service Manual
Rear side wall window: double curved surface, full tempered glass, right
printed antenna, 4mm thickness
Front angle window: double curved surface, full tempered glass, 3.5mm
Windscreen
thick
Side window: double curved surface, area tempered glass, 3.5mm thick,
electric window regulator
Outside rearview mirror: convex reflectors on the left and right, electri-
cally regulated, heatable, foldable (economy, comfortable and honour-
able versions are manual, foldable and heatable; flagship version is
Rearview mirror electric, foldable and heatable, with a camera).
Front row seat: electric 6-direction adjusting luxury leather driver seat,
with heating function and headrest; electric 4-direction adjusting luxury
leather auxiliary driver seat, with headrest.
Seat
Middle row seat: 6:4 backrest foldable, cushion adjustable back and
forth, luxury leather seat, with headrest;
Front row seat is provided with three-point seat belt (each for main and
Seat belt auxiliary driver seats), middle row seat is provided with three-point seat
belt
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BYD S6, S6A, S6K Service Manual
Front/rear
Power: 12V-5W, 6 sets
interior lamps
Rear luggage
compartment Power: 12V-5W, 2 sets
lamp
Door courtesy
Power: 12V-1.08W
lamp
Foot illumina-
Power: 12V-0.54W, 2 sets
tion light
Combination
instrument LED
lamp
High-mounted
12V-5W,2 sets
brake lamp
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BYD S6, S6A, S6K Service Manual
2. Fuel
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
L G X C 1 4 C G X X X X X X X X X
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Manufacturer Production sequence number
Vehicle brand
Body type
Engine characteristics
Check digit
Year
Assembly plant
Identification number position: 4ˊ Vehicle nameplate is on left shock
absorber support. Vehicle nameplate
There are several identification numbers on contains vehicle identification number
the vehicle on different positions. (VIN), engine, vehicle type, engine
1ˊ Engine model/engine number stamped displacement, maximum design total
on the engine set. mass, date of production, etc.
VIN
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
ƺ watch
3) Safety operation
Do not lean against the body; do not When the engine runs, keep good
step on the bumper ventilation in workshop.
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
Shape˄eg.) Dismantling/installation
Jaw vise
Clamp puller
Protective belt
Screwdriver
Protective belt
Scraper
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BYD S6, S6A, S6K Service Manual
ShapeDŽeg) Dismantling/installation
Dismantling Installation
Screwdriver
Press
Clamp puller
Dismantling Installation
Screwdriver
Press
Clamp puller
Dismantling Installation
Press
Screwdriver
Clamp puller
1-14
BYD S6, S6A, S6K Service Manual
(8) Hose dismantling and disassembling SRS faults, fault code is the most im-
portant maintenance basis. When over-
When disconnecting hose, first pinch hauling the system, please record the
hose end and entwist to pull it down. status before dismantling the battery
Do not pinch the middle to pull it negative ground wire, because DTC in
forcedly. Otherwise, it may damage other systems will be lost when disman-
the hose. tling the battery negative ground wire.
Negative
terminal
In order to reassemble the hose, make
a label for easy identification when
disconnecting.
BYD S6 is provided with supplementary re- Ĺ After a minor collision, you should check
straint system (SRS) and seat belt pretensioner. the airbag system to be checked even if
the air bag is not deployed.
If correct operation procedures are carried
out during the repair of the airbag system, it ĺ Do not use airbag parts removed from an-
might cause accidental deployment of airbag, other car. If it is required to replace compo-
leading to serious accident. nents, new components shall be used.
In addition, if mis-operation occurs during the Ļ You should remove the airbag ECU be-
course of maintaining system, air bag cannot fore repair if the vehicle might be vibrat-
expand normally. Therefore, before mainte- ed when repairing the airbag system or
nance (including dismantling and installing its components.
parts, check or replacement), please read the
ļ It is forbidden to disassemble and re-
following notes carefully and observe correct
pair DABǃPABǃSABand install air
operation procedures:
bag electronic control unit for reusing
(1) General notes and other reasons.
ķ Because it is very difficult to determine Ľ If DAB, PAB and airbag ECU and other
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BYD S6, S6A, S6K Service Manual
components fall down to the ground, control unit, DAB, PAB, SAB and clock
or are vibrated or knocked, or if their spring shall be removed and kept well.
housing, bracket or connector have
crack, indent or other damage, replace Ŀ Do not use detection lamp, common
the relevant parts. voltmeter and ohmmeter when detecting.
Voltmeter and ohmmeter shall be high
ľ It is forbidden to put DAB, PAB, SAB, resistant (minimum 10k¡/V). Do not use
air bag electronic control unit into heat- an ohmmeter on DAB, PAB, SAB or pre-
ing air or flame directly. tensioner, as shown in the Fig.
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BYD S6, S6A, S6K Service Manual
Tighten all fasteners and support fas- ļ In order to prevent air bag module from
teners of air bag module to the speci- expanding unexpectedly, do not dis-
fied torque value. pose unexpanded air inflation module
in the same way of common waste.
During the course of discarding, if the
container is damaged, some substanc-
Correct Error es in unexpanded air inflation module
will lead to serious disease or personal
hurt. According to expanding procedure
in the chapter, unexpanded air inflation
module is discarded safely. If you do
not observe discarding regulation, you
may disobey related regulations and
may lead to personal hurt.
Corr-
ect Error Ľ After air bag expands, if instrument
panel is damaged, replace it.
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BYD S6, S6A, S6K Service Manual
Ŀ After repair of the airbag system, do done in safety area away from electri-
not hurry to connect the airbag module cal noise.
into the circuit. Firstly you should check
electrical circuit and then connect the Ľ Because seat belt pretensioner will
airbag module when you confirm that be heated after activation, it shall be
everything is correct. cooled before discarding. But, do not
cool it with water.
(4) Seat belt pretensioner
ľ Do not spray oil or water onto outside
ķ Do not measure seat belt pretensioner seat belt of front seat. Do not wash
resistance. This may activate pre- outside seat belt of front seat with any
tensioner, which may lead to personal detergent.
hurt.
(5) Air bag electronic control unit (ECU)
ĸ Do not disassemble seat belt preten-
sioner. ķ It is forbidden to reuse ECU dismantled
from other vehicles.
Ĺ Do not install the seat belt pretensioner
to other vehicles. ĸ Before maintenance, first turn ignition
switch to LOCK, and disconnect the
In order to avoid damaged and unrepaired air battery negative ground wire, then wait
bag due to collision from personal hurt, check for more than 90s. Otherwise, air bag
each seat belt system for safety. If you have may expand unexpectedly.
any doubt about system parts, you have to
replace seat belt system. Ĺ Air bag electronic control unit connec-
tor, clock spring connector, DAB con-
ĺ Ambient temperature for storing seat nector, PAB connector, SAB connector
belt pretensioner shall be below 80°C and pretensioner connector are pro-
(176°F). Do not store it in high humidity, vided with protection mechanism that
keep away from electrical noise. prevents air bag from expanding unex-
pectedly.
When taking away unexpanded seat
belt pretensioner: (6) Wire harness and joint
Do not lift up seat belt pretensioner by All wire harness and joints in the sys-
wire or connector. tem are standard yellow. If system wire
harness or joint is damaged due to ac-
Take seat belt pretensioner through cident or other reasons, it shall be re-
piston pipe. Two hands and fingers placed.
shall keep away from the cable.
3. Electrical control
Make sure open end of seat belt pre-
tensioner is back on to you and oth- (1) Battery dismantling and assembling
ers.
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BYD S6, S6A, S6K Service Manual
or vehicle maintenance, first disconnect Do not place the battery near open fire
battery negative cable in order to pre- or spark.
vent tool or equipment from contacting
exposed live terminal, which leads to Do not let the battery acid liquid con-
short circuit, personal hurt and/or ve- tact eyes or skin. Once it contact eyes
hicle control system control module or or skin, the following items shall be
other electrical parts damaged. done:
ĸ When connecting or disconnecting the Wash contact sites with water as soon
battery cable, the battery charger or as possible.
bridging the cable, ignition key shall be See a doctor as soon as possible.
turned off, and all electrical loads shall
be turned off, otherwise specified in (2) Dismantling and assembling electronic
Operation Procedure. parts
1-19
BYD S6, S6A, S6K Service Manual
part, first ground it. Do not place solid- 4. Dismantle and install fuel system part
state part on metal working table or
on the top of television, radio or other (1) Dismantling and installing site for fuel
electrical equipment. system part
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BYD S6, S6A, S6K Service Manual
When installing new fuel pipe, do not When lifting or supporting the engine, do
knock fuel pipe clamps with a hammer not put a jack under oil pan, any metal plate
directly. Fuel pipe damage will lead to or crankshaft pulley. Lifting the engine in a
fuel leakage. wrong way will damage parts.
When heating and maintaining near a (2) Special remarks for engine support
steam discharge pipe, use a wet towel
to cover the steam discharge pipe. At If engine support is broken, it can lead to dis-
the same time, do not expose the ve- location of some parts in drive system. Dis-
hicle at 85°C above for more than one location of drive system parts may damage
hour or expose it at 60°C above for a drive system parts in the end.
long period. Special remarks: if an engine support is
Before connecting fuel pipe joint, broken, the stress applied on other engine
make sure fuel pipe joint is clean so supports will increase. This may cause other
as to reconnect it correctly and avoid engine supports to be broken.
fuel leakage. (3) Special remarks for fault diagnosis tes-
Ļ Do not breathe air in evaporation dis- ter with fault
charge pipe or hose. Fuel steam in A special fault diagnosis tester for BYD au-
evaporation discharge part may lead to tomobile shall be used. At the same time,
personal hurt. any fault for fault diagnosis tester during the
ļ When checking fuel tank, it is neces- course of using shall be indicated. Fault diag-
sary to tighten strap fasteners gradu- nosis tester that has a fault will lead to wrong
ally and alternately until it reaches the diagnosis and unnecessary part replacement.
specified torque. If strap fasteners are (4) Cooling fan
not tightened according to the specifi-
cation, fuel tank bottom will bend up. ķ In order to avoid personal hurt and ve-
When fuel tank has no fuel, fuel gauge hicle damage, if fan blade or fan cover
still indicates that there is fuel. is bent, cracked or damaged, replace it
immediately.
Ľ Do not use fuel containing methyl alco-
hol to avoid damaging or corroding fuel ĸ Even if the engine does not run, elec-
system. tronic fan in the engine compartment,
which may lead to personal hurt. Two
ľ Do not try to straighten any twisted ny- hands, clothes and tools shall keep
lon fuel pipe. Replace any twisted nylon away from electronic fan in the engine
fuel pipe to damage the vehicle. compartment.
Ŀ In order to prevent static electricity, (5) When maintaining the engine cooling
fuel pump, fuel tank and vehicle shall system, in order to avoid scalds, do not
be grounded. Do not water in this area dismantle radiator cover or liquid accu-
to prevent slipping. Do not wash spill- mulator or pipe joint before the engine
age and gasoline with water to avoid cools. If radiator cover or liquid accu-
spreading and fire risk. Put oily cloth mulator cover or pipe joint is opened
into fireproof container. before the engine and radiator do not
ŀ It is forbidden to use electrical equip- become cool, cooling system will give
ment, like electric motor or work lamp, out hot high pressure liquid and steam.
and hammer to avoid spark or high (6) Intake system parts
temperature.
ķ When maintaining intake system, use
5. Dismantle and assemble engine parts clean cloth, adhesive tape or other
(1) Special remarks for lifting engine appropriate materials to cover intake
1-21
BYD S6, S6A, S6K Service Manual
system opening and engine opening to tain exhaust system when exhaust
avoid foreign matters from entering into system is very hot. Please maintain the
the system. exhaust system after cooling.
1-22
BYD S6, S6A, S6K Service Manual
ķ Take the oxygen sensor with care to (2) Do not use a container containing pe-
avoid damaging parts. Do not drop or troleum base brake fluid because petro-
mis-operate the oxygen sensor. leum base brake fluid will expand and
age rubber parts in hydraulic brake sys-
ĸ Electrical connector and exhaust port tem while water and brake fluid mixture
are not contaminated. Do not use any will lower boiling point. All brake fluid
detergent to clean the sensor. container shall be covered to prevent
contamination.
Ĺ Do not repair conductor, connector or
terminal. If leading wire, connector or (3) When maintaining wheel brake parts,
terminal is damaged, replace the oxy- please avoid the following operations:
gen sensor.
Do not grind brake lining.
ĺ When maintaining the oxygen sensor,
the following rules shall be observed: Do not grind brake lining with sand
paper.
Do not dismantle or remove oxygen
sensor ground wire (if existing). The Do not clean wheel brake component
vehicle using ground sensor may use with a dry brush or compressed air.
this ground wire as only one ground
(4) When overhauling, a piece of steel wire
point of the sensor. Dismantling
shall be used to support brake caliper
ground wire will lead to poor engine
1-23
BYD S6, S6A, S6K Service Manual
to avoid damaging brake pipe. liquid level reading. Air in steering liquid
can lead to cavitation in steering pump
(5) Avoid brake fluid from splashing onto and steering pump will be damaged af-
paint surface, electrical joint, wire or ter a period of running.
cable. Brake fluid will damage paint
surface and corrode electrical parts. (5) Do not start the vehicle when any inlet
If brake fluid contacts paint surface, or outlet hose of power steering en-
wash it off with water immediately. If gine is disconnected. When the hose
brake fluid contacts electrical joint, wire disconnects, openings of all parts shall
or cable, repair cloth, appropriate con- be plugged or covered. Otherwise, it
tainer and fender cover shall be used will contaminate or lose power steering
to prevent brake fluid from contacting fluid and damage the system.
these surfaces. Seal it again and wash
off brake fluid to avoid overflowing. (6) When filling steering fluid or replace
steering fluid completely, it is necessary
(6) Some components in anti-lock brake to use DEXRON ċ power steering liq-
system (ABS) can be repaired sepa- uid or equivalent.
rately. Trying to dismantle or disconnect
some components of the system may If you do not use correct power steering fluid,
lead to personal hurt and/or abnormal power steering hose and seals may be dam-
operation of the system. Only maintain aged, steering fluid leaks and steering fluid
parts that can be dismantled and in- pump has a fault.
stalled. 8. A/C system
7. Dismantle and assemble steering sys- (1) Avoid inhaling A/C system refrigerating
tem parts fluid 134a (R134a) and lubricating oil
(1) Before disconnecting steering column steam or oil fog. These fluids will irritate
or middle shaft from steering engine, eyes, nose and throat. Operation shall
the wheels shall be right ahead and be made in a place with good ventila-
steering column shall be at LOCK posi- tion. In order to remove R134a from
tion. Otherwise, clock spring in steering A/C system, you have to use mainte-
column will deviate from the center, nance equipment with SAE J2210 cer-
which damage clock spring. tification (R134a regenerative facilities).
If the system has leakage, working area
(2) Before disconnecting the following shall be ventilated before maintenance.
parts, steering column shall at LOCK Other health and safety information is
position: available from refrigerating fluid and lu-
bricating oil manufacturer.
ƺ Steering column ƺ Middle shaft
(2) After broken glass falls into defroster air
ƺ Lower steering shaft outlet, it may be blown into passenger
After disconnecting the above-men- compartment, which leads to personal
tioned parts, do not move front wheel hurt.
tyre and wheel. If you do not follow 9. Dismantle and assemble body and ac-
these procedures, these parts are not cessory
aligned properly.
(1) Dismantle or connect engine cover sup-
(3) Steering wheel is turned to the limit po- port, the pressure is only applied on its
sition for not more than 3 seconds. Oth- end. It is forbidden to apply pressure in
erwise, it will damage steering pump. the middle of the bar. Otherwise, it will
(4) If power-assisted steering system is be damaged or bent.
repaired, air in steering system shall be (2) When dismantling or installing engine
discharged to obtain correct steering
1-24
BYD S6, S6A, S6K Service Manual
compartment cover stay bar, other de- gloves to reduce the risk of personal
vices shall be used to support engine hurt.
compartment cover to avoid vehicle
damage or personal hurt. (2) In order to avoid hurting your body
when you are exposed in welding light
(3) If a door or windscreen is cracked but or plated metal poisonous smoke dur-
intact, protective tape is crosswise ing the course of grinding/cutting any
pasted to the door or windscreen to type of metal or compound moulded
avoid the door or windscreen from be- parts, you have to work in a place with
ing damaged or personal hurt. good ventilation and wear allowed gas
mask, safety goggles, ear plugs, weld-
(4) When installing front windshield glass, ing gloves and protection clothes.
do not use gaskets. Stress generated
from the gaskets will damage front (3) When you work around running engine,
windshield glass. you cannot contact moving parts and
hot surface to avoid being hurt.
(5) In order to avoid personal hurt or ve-
hicle damage, the carpet whose thick- (4) Curing time for maintenance material
ness and size are the same as that is 24 hours at least. Before solidifying,
of original carpet shall be used when do not touch repaired part. If adhesive
repairing or replacing the carpet. Make agent is not completely cured, it may
sure the carpet is installed in original lead to personal hurt.
position.
(5) Correct fasteners shall be used at cor-
(6) When you remove adhesive or foreign rect positions. Part number of alterna-
matters with a shaver blade or other tive fastener shall be correct, which is
sharp tools or cotton cloth, you shall applicable to the application occasion.
be careful to avoid damaging body sur- For parts that require thread sealant,
face. lubricating oil, preservatives or sealant
shall be specially pointed out in Main-
10. For vehicles with mobile communica- tenance Procedure. Unless otherwise
tion system specified, do not apply paint, lubricating
(1) An antenna shall keep away from ECU oil or preservatives on fasteners or joint
and sensor of electronic system on the surface of fasteners. These substances
vehicle. will affect fastener torque and clamping
force of the joint, and may damage fas-
(2) Antenna feeder shall keep 20cm from teners. When installing fasteners, follow
ECU and sensor of electronic system correct tightening sequence to avoid
on the vehicle. damaging parts and system.
(3) Keep antenna and feeder away from (6) When moving flexible separation joint
other wire. To prevent communication from normal installation position, do not
equipment signal and other equipment bend excessively or damage flexible
of the vehicle from mutual interference. separation joint. The maximum bend-
ing for flexible separation joint is 6°.
(4) Check if antenna and antenna feeder It means moving 1 inch per one foot
are debugged correctly. pipe section. The maximum amount of
(5) Do not install high–power mobile com- movement for 3 feet pipe shall not ex-
munication system. ceed 3 inches.
11. Others (7) Do not bend the hose during the course
of installation. In order to facilitate in-
(1) When executing this procedure, you stallation, bend or deform the hose.
have to wear allowed safety goggle and Otherwise, it will damage parts.
1-25
BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
Safety support with rubber accessory The vehicle on the lifter shall be level
shall be used. as far as possible, and lifter groove
and supporting position of rigid brack-
Vehicle's center et are aligned.
of gravity
1-27
BYD S6, S6A, S6K Service Manual
Only applicable to faults with the same 2 Electric control system
symptom in the same model of car or
the same kind of system. A lot of ECU control systems are applied
1-28
BYD S6, S6A, S6K Service Manual
to BYD S6. Usually ECU control system is tom, please confirm fault symptom and find
viewed as a kind of very complicated system out faulty position, part or component. Please
needing high level professional technical contract the doubtable scope according to
knowledge and skill for troubleshooting. In fault symptom, connect fault diagnosis instru-
fact, if you fully know the system and have ment for symptom simulation test, and judge
basic electrical knowledge, then you can whether the examined system is damaged,
make accurate judgment and necessary re- meanwhile, confirm fault symptom, finally find
pair for troubleshooting. For further details of out the cause of fault referring to system fault
ECU control system of BYD S6, please refer code table.
to relevant chapters.
ķ Vibration method
(1) Use of detection instrument
(2) Troubleshooting
1-29
BYD S6, S6A, S6K Service Manual
3) Wire harness: lightly swing the wire ĺ High voltage load method
harness up and down. Inspection shall
lay stress on the connection part of joint The method is used in such a case that the
and fulcrum position of swing. fault may possibly arises from electronic com-
ponent overloading.
ĸ Heating method
Open the warm air blower, headlight, rear
The method is used in such a case that it is windshield defroster and all the other electric
doubtful that some parts have a fault arising devices, and then inspect whether there is a
from temperature increase. fault.
Ĺ Water-spraying method
1-30
BYD S6, S6A, S6K Service Manual
claw, and disconnect the joint. port and insert it into socket; inspect them
whether there is good tightness when insert-
- When disconnecting the joint, strictly ed and after fully engaged.
prohibit withdrawing and pulling the
wire harness. The joint shall be directly Maintenance method of joint terminal
held to disconnect it.
Correct Error
- Before connecting the joint, inspect it
whether there is deformation, damage
and port loss.
Error Error
1-31
BYD S6, S6A, S6K Service Manual
Open
Sensor circuit
1-32
BYD S6, S6A, S6K Service Manual
Short circuit
Sensor
If the result accords with the above example, If wire harness is grounded short cir-
it shows it is open circuit between joint C ter- cuit (as shown in figure), inspect the
minal 1 and joint B2 terminal 1. resistance of car body grounding to
find out the short-circuit part.
Voltage inspection
Inspection of car body grounding con-
- When the circuit is electrified, (ECU ductivity
joint terminal is electrified)
ECU side
Grounding
Grounding
1-33
BYD S6, S6A, S6K Service Manual
CAUTION
After the joint is connected with
ECU, inspect the joint from its If the circuit has a fault, it shall be repaired; if
EDFNRQRQHVLGHRIZLUHKDUQHVV the circuit is normal, it shows ECU may pos-
If no special detection conditions sibly have a fault, it shall be replaced with a
are specified, make the engine new ECU, and then inspect whether the fault
stall and turn ignition switch to occurs again.
“ON”DQGWKHQEHJLQWRGHWHFWLW
Inspect the joint whether it is com- - Measure the resistance between
pletely connected; inspect the line ECU grounding terminal and car body
whether there is looseness, corro- grounding: the resistance shall be less
VLRQRUEUHDNDJH than 1¡.
1-34
BYD S6, S6A, S6K Service Manual
not be stained with any other matter resistance may possibly be higher. If
that may possibly obstruct normal any abnormal phenomenon is found,
connection of binding post. However, immediately repair or replace it.
strictly prohibit using sand paper or
similar articles to clean the binding
post.
1-35
BYD S6, S6A, S6K Service Manual
Abnormal
To next page
1-36
BYD S6, S6A, S6K Service Manual
Continued
End
1-37
BYD S6, S6A, S6K Service Manual
ABS Anti-Lock Brake System (ABS) CPU Central processing unit (CPU)
A/C Air conditioning and air conditioner CVT Continuous change
ACL Air filter DPSF Double pump system fluid
A/F Air-fuel ratio DTC Diagnostic trouble code (DTC)
ALR Automatic locking tighetner DPSF Double pump system fluid
ALT AC generator
AMP Ampere Electronic brake force distribution
EBD
(EBD)
ANT Antenna
ECM Engine control unit
API American Petroleum Institute
ECT Engine coolant temperature
APPROX Approximate
EGR Exhaust gas recirculation (EGR)
ASSY Assembly
ELD Electrical load detector
A/T Automatic transmission Evaporator pressure regulator
EPR
ATDC After top dead center (EPR)
EPS Electrical power steering
ATF Automatic transmission oil
Evaporative emission control sys-
ATT Accessory EVAP
tem (EVAP)
ATTS Active torque transmission system EX Exhaust
AUTO Automatic
AUX Accessory F Front
FIA Fuel injection air
BARO Atmospheric pressure FL Front left
BAT Accumulator FP Fuel pump
BDC Bottom dead center FR Front right
BTDC Before top dead center FSR Fail-safe relay
FWD Front wheel drive
CARB Carburetor
CAT/CATA Catalytic converter GAL Gallon
CHG Charge GND Ground
Crankshaft rotating speed fluctua- GPS (Satellite) GPS
CKG
tion
CKP Crankshaft position
H/B Glide back (car body)
CO Carbon monoxide
HC Hydrocarbon
COMP Complete
HID High intensity discharge
CPB Clutch pressure return
HO2S Heated oxygen sensor
CPC Clutch pressure control
1-38
BYD S6, S6A, S6K Service Manual
1-39
BYD S6, S6A, S6K Service Manual
W Equipped
W/O Unequipped
WOT Wide-open throttle
2WD Two-wheel drive
4AT 4-speed automatic transmission
5MT 5-speed automatic transmission
6MT 6-speed automatic transmission
Parking
Reverse
Neutral
1-40
BYD S6, S6A, S6K Service Manual
Foreword
Thanks for purchasing the BYD483QA or BYD483QB EFI Gasoline Engine (hereinafter referred
to as BYD483QA/QB Gasoline Engine or the Gasoline Engine) manufactured by BYD Auto Indus-
try Company Limited. Please read this manual carefully before using.
BYD483QA/QB Gasoline Engine adopts the electronic fuel injection system independently devel-
oped by BYD, featuring advanced self-diagnosis, high power per liter, low fuel consumption, low
noise, low pollution and compact size. The key components are made by world-renowned auto-
motive electronics manufacturers. BYD483QA/QB Gasoline Engine can achieve the best state
under various conditions, and ensures the reliable security, comfortable driving, the best economy
and perfect environmental performance of the automobile.
This manual outlines the main performance, technical parameters, and use, maintenance and
repair methods of BYD483QA/QB Gasoline Engine. 3lease read this manual carefully before
using BYD4A/4B Gasoline Engine, to keep the power system of your automobile in good
condition, having better function and bringing greater economic benefits. If you find that the
maintenance methods for gasoline engine in other materials are different from or conflict
with this manual, please follow this manual
In order to continuously improve the performance and quality of the products and provide better
services, any suggestion and improvement opinions about the problems found in the process of
using the EFI gasoline engine are appreciated. Thanks for your supervision.
It is your best choice to buy the passenger cars powered by BYD EFI Gasoline Engine.
Explanation of Symbols
“ ƾ ƾ ƾ ” relates to the personal safety of drivers and passenger; please pay special attention
and strictly abide;
“ ƾƾ ” relates to the security and maintenance of the gasoline engine, and must be strictly imple-
mented;
1
BYD S6, S6A, S6K Service Manual
Contents
Section 1 3erformance, Main Technical 3arameters and Structure of Gasoline Engine 2-1
1.1 Performance and main technical parameters...................................................2-1
1.2. External characteristic curve of BYD483QB Gasoline Engine .........................2-2
1.3. Use of Gasoline Engine ...................................................................................2-4
Section 2 Gasoline Engine Maintenance 2-
2.1 Maintenance of gasoline engine lubricating system.........................................2-8
2.2 Maintenance of gasoline engine cooling system ...........................................2-10
2.3 Maintenance of ribbed belts .......................................................................... 2-11
2.4 Maintenance of the ignition system ...............................................................2-12
2.5 Checking and adjusting the valve gear .........................................................2-12
2.6 Maintenance of positive crankcase ventilation valve (PCV valve) .................2-13
2.7 Checking and maintenance of electrical system ...........................................2-13
0DLQWHQDQFHRIDLU¿OWHU .................................................................................2-14
0DLQWHQDQFHRIIXHO¿OWHU ...............................................................................2-14
2.10 Maintenance of fuel vapor recovery system ..............................................2-14
2.11Maintenance of catalytic converter ................................................................2-15
Section Regular Inspection of Gasoline Engine 2-16
3.1 Maintenance cycle and content of gasoline engine ......................................2-16
3.2 Main tightening torque of the gasoline engine ..............................................2-17
Section Gasoline Engine Troubleshooting 2-1
4.1 Considerations for gasoline engine use and maintenance ...........................2-18
4.2 Gasoline engine troubleshooting ...................................................................2-19
4.3 Emission troubleshooting ...............................................................................2-25
Section 5 Gasoline Engine Sealing and Unsealing 2-26
5.1 Gasoline engine sealing .................................................................................2-26
5.2 Gasoline engine unsealing .............................................................................2-26
2-I
BYD S6, S6A, S6K Service Manual
Model BYD4B
Electronically controlled multi-point sequential fuel injection, inline,
Type four-stroke, water cooling, roof combustion chamber, dual overhead
camshafts, 16 valves, electronic ignition system
Number of cylinders 4
Cylinder diameter (mm) 83
Piston stroke (mm) 92
Total displacement (L) 1.991
Compression ratio 9.6:1
Ignition sequence 1-3-4-2
Rated power (kW) / speed (r/min) 103/6000
186
Maximum torque (N m)
(4000r/min~4500r/min)
Minimum fuel consumption rate
275
(g/kWh)
Engine oil pressure (kPa) 300~490 (3000r/min±50r/min)
Minimum steady speed (idle) (r/min) 750±50
Gasoline engine lubricant capacity (L) 3.5
Engine oil fuel ratio (%) 0.25
Dimensions (excluding transmission)
600 × 610 × 640
(mm) (L × W × H)
Net weight (excluding transmission)
130
(kg)
CO 0.15% HC 40 × (750r/min±50r/min)
Emission
CO 0.15% HC 40 × (2000r/min±50r/min)
Fuel 93 grade or higher unleaded gasoline (GB17930)
SG grade, 10W-30 (for all seasons in the South and summer in the
Gasoline engine oil north)
SG grade, 5W-30 (for winter in the north)
Coolant Glycol coolant
Type Dry-type, single disc, diaphragm spring, atmospheric style
Dimensions Clutch plate assembly ¶215 × 7.8 (free state)
Clutch
(mm) Clutch cover assembly ¶257.5 × 44
Weight Clutch assembly: 4.8kg
2-1
BYD S6, S6A, S6K Service Manual
150
140
90
70
50
(Fuel consumption)
30 g/kW·
410
10 390
370
350
330
310
290
270
250
(Speed) 2000 2500 3000 3500 4000 4500 5000 5500 6000 r/min
2-2
BYD S6, S6A, S6K Service Manual
([WHUQDOFKDUDFWHULVWLFFXUYHRI%<'4%*DVROLQH(QJLQH
190
180
170
160
Effective power of
calibration Peo kW
100
80
60
40
Fuel consumption
Gf kg/h
20 35
30
25
20
15
10
290
270
250
2-3
BYD S6, S6A, S6K Service Manual
1 Manual
Read this manual carefully before use, and strictly follow the provisions recommended in this
manual for use and maintenance.
2 Coolant
Check the coolant of the gasoline engine, and add coolant according to the method in Chapter 3,
Section 2 if necessary.
ƾƾ
:KHQWKHJDVROLQHLVUXQQLQJWKHFRROLQJV\VWHPPXVWKDYHVXI¿FLHQWFRRODQWWRHQVXUH
that the gasoline engine works normally, or else “boiling”ZLOORFFXULQWKHJDVROLQHHQJLQH
The service life of the gasoline engine will be affected if it is overheated, and even cause
F\OLQGHUVFRULQJDQGRWKHUVLJQL¿FDQWIDLOXUHV
Check the level of gasoline engine oil in the gasoline engine, and refill in time. See Chapter 3
Section 1 for the method to check and fill gasoline engine oil.
ƾƾ
4 Fuel
ƾƾ
The automobile must use high quality unleaded conforming gasoline, or else it will result
in fatal damage to EFI system of the engine, catalytic converter and oxygen sensor, and re-
GXFHWKHHQYLURQPHQWDOSHUIRUPDQFHDQGSRZHUSHUIRUPDQFHRIWKHDXWRPRELOH
To start the gasoline engine, turn the ignition switch key of the automobile to “START” and start
the gasoline engine with the starter. Once the gasoline engine is ignited, release the key and cut
off the power supply of the starter immediately.
ƾƾ
Since the gasoline engine management system will provide the appropriate gas mixture
and engine spark advance in any condition, it is unnecessary to depress the accelerator
SHGDOEHIRUHVWDUWLQJLQDQ\FOLPDWHDQGHQYLURQPHQW
ƾƾ
If the gasoline engine isn’t started for several times, the gasoline engine may have spark
SOXJVKRUWFLUFXLWIDXOWGXHWRRLOSLOOH[FHVVUHVLGXDOIXHOLQF\OLQGHU$WWKLVPRPHQWGH-
press the accelerator to the bottom and then start the gasoline engine, and the high speed
2-4
BYD S6, S6A, S6K Service Manual
DLUÀRZZLOOEORZWKHRLOVSLOOLQ¿YHVHFRQGV7KHQUHOHDVHWKHDFFHOHUDWRUSHGDODQGWKHQ
UHVWDUWWKHJDVROLQHHQJLQH
If the automobile is started for the first time (new gasoline engine or the fuel supply system of the
gasoline engine has been repaired), it may take longer time to start, so that the fuel supply line
will be filled with oil and establish a normal working pressure, supply gasoline and appropriate
fuel gas mixture to ensure normal work of the gasoline engine.
ƾƾ
6 Idle
After started, the gasoline engine should run for 3~5 minutes at idle, no-load condition to warm up
the gasoline engine.
ƾƾ
The idle speed of our gasoline engine is 750r/min±UPLQ 7KH LGOH PHFKDQLVP RI WKH
JDVROLQHHQJLQHKDVEHHQDGMXVWHGDWWKHIDFWRU\)RUDGMXVWPHQWSOHDVHFRQWDFWRXUDX-
WKRUL]HGPDLQWHQDQFHFHQWHUIRUKHOS
While measuring emission, the gasoline engine should be in warming up state, that is, the
FRRODQWWHPSHUDWXUHLV°C±5°C
7 Driving
While driving, the coolant temperature should be kept at 85°C±5°C. At medium speed, the pres-
sure of gasoline engine oil shouldn’t be lower than 300kPa.
8 Parking
After working, especially high speed heavy load running, the gasoline engine shouldn’t be shut
down immediately; please wait for 3~5 minutes in idle state and then shut down the engine.
9. Warming up in winter
The temperature in winter is low, the viscosity of the gasoline engine oil increases, and the lubri-
cation effect of the gasoline engine is worse than in summer. Therefore, do not drive the auto-
mobile immediately after the gasoline engine is started, especially at high speed or under heavy
load. Please warm up the engine at idle for ten minutes to rise the temperature of the gasoline
engine oil and coolant and fully lubricate the gasoline engine before driving.
ƾƾ
If the automobile is driven before the gasoline engine is fully lubricated in winter, it may
FDXVHH[FHVVLYHZHDURIPRYLQJSDUWVDQGVKRUWHQWKHOLIHRIWKHJDVROLQHHQJLQH
If you drive on the road accumulating water after raining or wade through a river, make sure that
2-5
BYD S6, S6A, S6K Service Manual
the air filter is well sealed, or else water may enter into the cylinder of the gasoline engine, and
damage the connecting and other moving parts.
ƾƾ
If water enters into the cylinder, the connecting rod will withstand tens times of normal op-
erating pressure due to the inertia effect of the automobile, resulting bending or breaking
RIWKHFRQQHFWLQJURG
ƾƾ
7RSUHYHQW¿UHGXHWRJDVROLQHOHDNDJHSOHDVHUHJXODUO\FKHFNWKHJDVROLQHOLQHDQGFOHDQ
up the oil; replace immediately if there is any problem such as rubber aging, connector
FUDFNLQJGDPDJHDQGORRVLQJ
While checking the fuel line, do not start the gasoline engine if the oil high-pressure hose
DQGRLOORZSUHVVXUHKRVHDUHUHPRYHGRUHOVHLWPD\FDXVH¿UHGXHWRJDVROLQHOHDNDJH
5XQQLQJLQRIQHZJDVROLQHHQJLQH
The life of the gasoline engine depends on the early state of use to a great extent. The new gaso-
line engine should be run in strictly in accordance with the specification.
The running in of gasoline engine on the automobile shall be implemented in accordance with the
automobile instructions; check and maintain the gasoline engine according to the following re-
quirements during running in:
1 Checking
Check whether the gasoline engine oil, coolant, gasoline, and battery electrolyte are sufficient; if
there is insufficiency or leakage, please refill and eliminate immediately.
2 Road surface
The automobile should drive on cement or asphalt road and avoid driving on muddy or sand road.
3 Maintenance
Carry out maintenance for the gasoline engine of the new automobile in accordance with the
items in the table below after strict running in.
Maintenance Items of New Gasoline Engine after Running-in
ƾƾƾ
2-6
BYD S6, S6A, S6K Service Manual
ORZRLOSUHVVXUHRULIWKHUHLVDEQRUPDOVRXQG:KHQWKHJDVROLQHHQJLQHLVUXQQLQJRU
just shuts down, do not touch the exhaust manifold or other heat radiating parts; when the
engine is warming up, do not open the radiator cover; the new gasoline engine shouldn’t
EHSXWLQWRQRUPDOXVHEHIRUHUXQQLQJLQ
2-7
BYD S6, S6A, S6K Service Manual
ƾƾ
After running in of the new gasoline engine, replace the gasoline engine oil after normally
GULYLQJNPHYHU\WLPH
ƾƾ
2QO\XVHTXDOL¿HGJDVROLQHHQJLQHRLOGRQRWPL[WKHJDVROLQHHQJLQHRLORIGLIIHUHQWJUDGHV
XVH:JDVROLQHHQJLQHRLOXQGHUFROGFRQGLWLRQV'RQRWXVHJDVROLQHHQJLQHRLODQWLZHDU
DGGLWLYHVRIGLIIHUHQWJUDGH,IWKHJDVROLQHHQJLQHRLOLVQ’WVXI¿FLHQWWKHHQJLQHRLOSUHVVXUH
will be too low, resulting in poor lubrication, increased wear of gasoline engine and poor cool-
LQJZKLFKZLOOHDVLO\FDXVHIDLOXUHDQGDIIHFWWKHOLIHRIWKHJDVROLQHHQJLQH
Use oil gauge to measure the gasoline engine oil level in the oil pan. Measure in three minutes
after the gasoline engine has stopped, take out the oil gauge, wipe the gasoline engine oil with
clean cloth, and then insert into the oil pan to measure the level of the gasoline engine oil. The
level of the gasoline engine oil should be between “F” and “L” of the oil gauge; if the oil level is
at or below the lower limit, refill the gasoline engine oil to the upper limit. Before driving and after
driving 300km~500km every time, check the level of the gasoline engine oil.
Replace the gasoline engine oil once after driving 8,000km on the asphalt or cement road; if driv-
ing on sand road or under other poor conditions, check regularly and replace according to the oil
quality; however, replace at least once every 5,000km.
When replace the gasoline engine oil, warm up the gasoline engine for ten minutes, shut down
and open the fill inlet cap, loosen the oil drain plug in the bottom of the oil pan, drain the oil and
tighten the oil drain plug. Fill in 3.0L new gasoline engine oil through the fill inlet, and tighten the
fill inlet cap (see Fig.2-1).
Start the gasoline engine and run for five minutes; check whether the oil drain plug leaks, then
stop the engine and check the oil level after five minutes; refill to the upper limit of the oil gauge if
the oil level is too low.
Fig.2-1
2-8
BYD S6, S6A, S6K Service Manual
ƾƾƾ
3D\DWWHQWLRQWRDYRLGEHLQJVFDOGHGE\WKHJDVROLQHHQJLQHRLOZKHQORRVHQWKHRLOGUDLQ
SOXJ
If excessive amount of impurities are accumulated in the oil pan, please clean the gasoline engine
lubricating system with light spindle oil.
When clean the interior of the gasoline engine, fill 2.5L light spindle oil into the gasoline engine
through the filler inlet, start the gasoline with the starter and run for 2~3 times at idle, one minute
each time, then quickly drain the cleaning spindle oil, and refill the gasoline engine oil into the
gasoline engine as specified.
After replacing with new gasoline engine oil every time, run the gasoline engine at no-load state
for 3~5 minutes to ensure that the lubricating system and all oil supply parts are fully lubricated.
ƾƾ
,WLVSURKLELWHGWRXVHJDVROLQHRUNHURVHQHIRUFOHDQLQJ
ƾƾ
The reasonable use of gasoline engine oil is the important factor to ensure its good work-
LQJDQGVHUYLFHOLIH3D\VSHFLDODWWHQWLRQWRWKHRLOVHOHFWLRQDQGGRQRWPL[WKHJDVROLQH
engine oil of different grades, places of origin and standards to prevent chemical reaction
GXHWRGLIIHUHQWRLOW\SHVDQGDIIHFWLQJWKHQRUPDOZRUNLQJRIWKHJDVROLQHHQJLQH
Replace the engine oil filter every 8,000km. The tightening torque is 25 N·m~30Nm.
Under normal condition, when the power switch (key) is turned to “ON”, the engine oil pressure
indicator is lit, indicating that there is no engine oil pressure; continue to turn the switch to “START”,
the gasoline engine starts and enters idle state, and the engine oil pressure indicator automati-
cally turns off, indicating that the engine oil pressure is normal. If the engine oil pressure indicator
doesn’t turn off, which indicates that the engine oil pressure in the lubricating system is abnormal,
please stop immediately and check whether the gasoline engine oil in the engine is sufficient.
2-9
BYD S6, S6A, S6K Service Manual
ƾƾ
:KHQWKHJDVROLQHLVUXQQLQJWKHFRROLQJV\VWHPPXVWKDYHVXI¿FLHQWFRRODQWWRHQVXUH
that the gasoline engine works normally, or else “boiling”ZLOORFFXULQWKHJDVROLQHHQJLQH
The service life of the gasoline engine will be affected if it is overheated, and even cause
F\OLQGHUVFRULQJDQGRWKHUVLJQL¿FDQWIDLOXUHV
1 Coolant
The gasoline engine uses ethylene glycol coolant, the freezing point of which should be 5°C lower
than the minimum ambient temperature. Do not mix different grades of coolant or use counterfeit
coolant and avoid using river water, well water and other hard water.
ƾƾ
After frozen, the water will expand and burst the sealed radiator, water pump, cylinder
KHDGDQGF\OLQGHUEORFN
2 Filling coolant
(1) Unscrew the radiator cover and fill in coolant, until the level in the water reservoir reaches
“FULL” mark. Do not let the level exceed “FULL” mark.
(3) Start the gasoline engine and run 3~5 minutes at idle; if the coolant level drops, open the
cap of the water reservoir, and fill the coolant to “FULL” mark.
(4) Put on and tighten the cap of the water reservoir, and then the gasoline engine can work normally.
ƾƾƾ
:KHQWKHJDVROLQHHQJLQHLVKRWGRQRWRSHQWKHUDGLDWRUFDSWRDYRLGEHLQJVFDOGHG
3 Filling coolant
After long time of use, if the coolant level in the water reservoir is below the “LOW” mark, fill the
coolant in the water reservoir to “FULL”.
If the coolant reduces too much in short period of time, check whether the cooling system leaks.
After long time of use, if the coolant should be replaced due to coolant deterioration or repair,
please follow the steps below.
(1) Unscrew the radiator cap, and open the water drain valve in the bottom of the radiator to
discharge the coolant.
(3) Install the water reservoir and water drain valve of the radiator as original, and fill in coolant
as described in Chapter 3 Section 2 Item 2.
2-10
BYD S6, S6A, S6K Service Manual
ƾƾ
7KHDXWRPRELOHVKRXOGEHSDUNHGLQKRUL]RQWDOSRVLWLRQZKHQUHSODFLQJWKHFRRODQW
ƾƾ
If the temperature regulator assembly isn’t installed, the warming up time of the gasoline
engine will be extended; if the gasoline engine works under low temperature for a long
WLPHWKHZHDURIWKHPHFKDQLFDOSDUWVZLOOEHZRUVHQHGWKXVDIIHFWLQJWKHVHUYLFHOLIH
ƾƾ
If the ribbed belt doesn’t have sufficient tension or is damaged, it may cause problems
such as gasoline engine overheating, reduced generating capacity, no steering power and
LQDGHTXDWHDLUFRQGLWLRQLQJDQGFRROLQJ
1 Adjustment method
Stop the gasoline engine, and tighten the adjusting bolts on the position adjusting block of the
generator and the power steering pump.
As shown in Fig.2-2, apply 98N force to the ribbed belt, the press amount of which should be
6mm~9mm.
Damping pulley
Air conditioner
compressor
Damping pulley Measuring point
Fig.2-2
3 Appearance
Check the ribbed belt for cracks, wear and fiber cloth aliquation, and replace if necessary.
2-11
BYD S6, S6A, S6K Service Manual
Replace the spark plug every 30,000km. Replace immediately in case of any damage found in
daily check. Please replace with K6RTC or 3923-8 spark plug.
Both polar surfaces of the spark plug should be clean and smooth; regularly clean the carbon de-
posit between the two poles, and use fine sandpaper if necessary. The spark plug gap should be
0.80mm~0.90mm, and the gap should be uniform on the whole electrode plane.
The gasoline engine management system integrated in the gasoline engine adopts advanced
ignition system. During normal use, except timely replacement of spark plug and checking high
pressure damping line, it doesn’t require additional maintenance.
ƾƾ
When the ignition system has fault and causes gasoline engine stalling, do not forcibly run
WKHJDVROLQHHQJLQHRUHOVHLWPD\GDPDJHWKHFDWDO\WLFFRQYHUWHU
When the gasoline is running, do not remove the high voltage line of the spark plug to do
ÀDVKRYHUWHVWRUHOVHLWPD\GDPDJHWKHFDWDO\WLFFRQYHUWHU
Remove the front cover of the engine, rotate the crankshaft clockwise, so that the grooves in the
crankshaft timing pulley aligns to the bar at the boss of the engine oil pump (see Fig.2-3); at this
time, the two horizontal line marks on the two camshaft pulleys should be aligned, and maintain
level; please note that the camshaft pulley mark I on the intake side is inward, and the camshaft
pulley mark E on the exhaust side is also inward (see Fig.2-3). Otherwise, adjust till they are
aligned. At this moment, the primary piston of the gasoline engine (on the side of crankshaft tim-
ing pulley) should be on the top dead center of the compression stroke.
2-12
BYD S6, S6A, S6K Service Manual
Intake sid e
Exhaust side
Fig.2-3
2 Timing belt
Check the timing belt, eliminate the fault, and replace the belt if necessary.
The clearance between intake and exhaust valves is 0.23~0.29mm in cold state; when measuring
the clearance, the surface of the adjusting pad should be close to the cam base circle.
ƾƾ
If the valve clearance is too small, it will affect the power performance of the gasoline en-
JLQHDQGVKRUWHQWKHOLIHRIR[\JHQVHQVRUDQGFDWDO\WLFFRQYHUWHUGXHWRYDOYHOHDNDJH
ƾƾ
The maintenance described in this section should be carried out in our authorized mainte-
QDQFHFHQWHU
ƾƾ
If the gasoline engine has any fault, do not cut off the power supply of ECU, or else the
IDLOXUHLQIRUPDWLRQZLOOEHORVW'RQRWUXQWKHIDLOVDIHV\VWHPRIWKHJDVROLQHHQJLQHFRQ-
WLQXRXVO\IRUDORQJWLPHWRDYRLGJUHDWHUORVVHV
2-13
BYD S6, S6A, S6K Service Manual
Take out and clean the element of the air filter regularly. Clean the element once every 10,000km
and replace every 40,000km on asphalt road; clean once every 2,500km and replace every
40,000km on sand road; in dusty environment, replace the element more often.
ƾƾ
7KHIXHO¿OWHUVKRXOGEHUHSODFHGLQZHOOYHQWLODWHGSODFHDQG¿UHLVVWULFWO\SURKLELWHG
ƾƾƾ
Follow the precautions below before any maintenance of the fuel system:
2. Smoking is prohibited. Set up a “No Smoking” sign near the operation area.
5. To relieve the pressure of the fuel vapor in the fuel tank, remove the filler inlet cap and then
reinstall the cap.
6. Even when the gasoline engine stops running, the fuel line is still under high pressure; if the
fuel line is loosened or disconnected immediately, it may cause fuel injection at the opening.
Therefore, make sure that the pressure has been relieved before loosening or disconnect-
ing the fuel line.
7. When the fuel line is removed, there will be a small amount of fuel spillage. Therefore,
place the empty fuel container under the fuel filter or enwrap the fuel filter with waste cloth,
to let the fuel flow into the empty container or absorbed by the waste cloth. Put the waste
cloth after oil absorption into specified container.
9. If the fuel line has any crack, damage or excessive bending, please replace immediately.
11. Take out the fuel pump from the fuel tank. Do not connect the power of the fuel tank when it
is exposed to air, to avoid sparks and resulting in fire.
2-14
BYD S6, S6A, S6K Service Manual
ƾƾƾ
The catalytic converter is easily damaged due to overheating when the gasoline engine is work-
ing. Pay attention to the following to protect the catalytic converter:
2. Ensure good resistance to pressure ( 0.3MPa) and anti-leak characteristics of the fuel
supply system lines.
5. Do not drive when the fuel is insufficient, or else it may damage the electric fuel pump when
the fuel is run out.
6. Prevent the exhaust system leaking, and ensure particularly that the connection between
exhaust manifold in front of the catalytic and the muffle shouldn’t leak.
7. Do not start the gasoline engine by pushing or trailing the automobile forcibly; if the battery
voltage is low, start the gasoline engine with the secondary battery.
8. Do not perform system ignition function diagnosis by removing any spark plug or high volt-
age damper wire when the gasoline engine is running.
9. If the gasoline engine is unstable at idle or can’t start the gasoline engine after a long time,
do not run the gasoline engine forcibly.
10. If the performance of the gasoline engine drops significantly or the gasoline engine doesn’t
operate properly, e.g. fuel supply system or ignition system doesn’t work normally, shut
down the engine immediately. If the engine can’t be shut down immediately, slow down and
ask qualified maintenance center or our After-service Department for inspection.
2-15
BYD S6, S6A, S6K Service Manual
By mileage or km ×
2 10 20 0 0 50 60 70 0
No month, whichever 1000
expires first Month 1 6 12 1 2 0 6 2
Ribbed belt
1ƹ J.T J.T.G G J.T.G G
(Tension and wear)
Timing belt
2ƹ Replace every 100,000km
(Wear or damage)
3ƹ Intake/exhaust valve clearance J.T J.T J.T J.T J.T
Tightening torque of gasoline en-
4ƹ gine bolts, intake/exhaust manifold N N N N N
fixing nuts
5 Engine oil filter G Replace every 8,000km
6 Gasoline engine oil G Replace every 8,000km
7 Gasoline engine coolant G G
Gasoline engine line and fitting
8 J.T.G J.T.G J.T.G
(leak)
9 Fuel filter Replace every 8,000km
10 ƹ Idle J.T J.T J.T J.T J.T
Transmission lubricant
11 ƹ G J.T.G J.T.G J.T.G G J.T.G J.T.G J.T.G G
(Oil level and leaking)
Crankcase ventilation valve Remove to check and clean every 50,000km, and replace if neces-
12 ƹ
(PCV valve) sary
Fuel evaporation control system
14 ƹ J.T.G J.T.G J.T.G J.T.G
hose and connection
Cooling system hose and fittings
15 J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
(Leaking and wear)
16 Emission and purifying device J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
High voltage damper wire (deterio-
17 J.G J.G J.G J.G J.G J.G J.G J.G J.G
ration or damage)
18 Spark plug J.T.G Replace every 30,000km
19 Various types of sensors J.G J.G J.G J.G J.G J.G J.G J.G
20 Fuel injector J.T.G J.T.G J.T.G J.T.G
21 Throttle control cable Every 10,000km, J.T.G.R
Asphalt
Clean once every 10,000km, and replace every 40,000km
road
23 Air filter
Clean once every 2,500km and replace every 40,000km; in dusty
Sand road
environment, replace the element more often.
J.T: Check and adjust J.T.G.: Check and adjust, and replace if necessary
(2) The replacing time of engine oil filter can be shortened according to the dirty degree of the
gasoline engine.
2-16
BYD S6, S6A, S6K Service Manual
ƾƾ
Tightening torque
No 3art (component) name
(Nm)
First time: 18~22
1 Cylinder head bolt Second time: +85°~95°
Third time: +85°~95°
2 Spark plug 25~30
3 Intake pipe bolt 21~25
4 Exhaust pipe bolt 25~30 (twice)
5 Camshaft pulley bolt 45~55
6 Crankshaft pulley bolt 122~149
First time: 22~27
7 Connecting rod bolt
Second time: +85°~95°
First time: 18~22
8 Main bearing bolt
Second time: +85°~95°
9 Flywheel belt 86~103
10 Oil drain plug 35~40
11 Cylinder head cover bolt 9~11 (twice)
12 Oil pan bolt 21~25
13 Tensioner pulley bolt 45~55
14 Engine oil pump mounting bolt 21~25
15 Throttle mounting bolt 21~25
17 Knock sensor mounting bolt 21~25
18 Engine oil filter 25~30
19 Clutch pressure plate screw 21~25
20 Engine oil pressure alarm 15~20
21 Water temperature sensor 25~30
2-17
BYD S6, S6A, S6K Service Manual
2. Connect the anode and cathode of the battery properly to avoid damaging the electronic
components.
3. Do not remove the battery, connecting cable and connector when the gasoline engine is running.
6. Take out the fuel pump from the fuel tank. Do not connect the power of the electric fuel tank
when it is exposed to air, to avoid sparks and resulting in fire.
7. Connect the positive pole and negative pole of the electric fuel pump properly.
8. Do not install devices that may cause radio interference (e.g. radio antenna) near the ECU
to avoid interference.
9. Do not let water enter into the gasoline engine or spill on the electronic circuit when repair
or clean the gasoline engine in rainy days.
10. It is prohibited to carry out the test by discharging the mixed gas from the cylinder into the
exhaust pipe without burning.
11. The fuel pressure is high. Relieve the pressure before repairing the line: remove the insur-
ance device of the fuel pump, start the gasoline engine and run at idle until stall.
12. Before removing any component, remember to turn off the ignition switch and disconnect
the cathode cable of the battery.
13. Since catalytic converter is used, it is required to use unleaded gasoline; if leaded or low-
leaded gasoline is used, it will damage the catalytic converter and weaken the performance
of the purification system.
14. It is not allowed to test the electrical signal by piercing the wire wrapping.
15. The fuel line clamp is disposable. Reuse is prohibited to prevent fuel leakage.
16. Since high voltage ignition coil is used, do not touch with hands directly when the gasoline
engine is working.
17. The idle adjustment of the gasoline engine is finished by the EFI system, and the idle sys-
tem doesn’t require mechanical maintenance.
18. Before the first start after ECU or idle regulator is replaced, turn the ignition switch to ON
and start after 20 seconds, so that the system or idle regulator will adapt.
19. The electronic control unit will provide appropriate air-fuel ratio for the gasoline engine in
any case to make the gasoline engine work normally. Therefore, do not operate any mecha-
nism on the gasoline engine (including the accelerator) when it is started.
20. The system integrates fail-safe function. However, the gasoline engine isn’t suitable for
long-term continuous operation; therefore, it is necessary to eliminate the fault immediately
when the MIL is lit, to avoid more serious damage of the gasoline engine.
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
2-25
BYD S6, S6A, S6K Service Manual
1. Fill 2.5L anti-rust lubricant into the gasoline engine, and then unscrew the spark plug of
each cylinder, to keep all the pistons of the gasoline engine between the top dead center
and bottom dead center. Fill 0.006L anti-rust lubricant into each cylinder, and drive the gas-
oline engine with the starter to run for 3~4 times, about 15 seconds each time.
2. Unscrew the oil drain plug in the oil pan to drain the anti-rust lubricant, reinstall the oil drain
plug and spark plug and torque with specified torque.
3. Drain the coolant, remove the injector nozzle, clean and seal with dust cover, and then plug
the exhaust pipe, throttle opening, gasoline engine water inlet/outlet, and injector hole with
wax paper or plastic cover.
3. Unscrew the spark plug, idle the gasoline engine and drain the anti-rust lubricant in the cyl-
inder.
5. Fill in coolant.
2-26
BYD S6, S6A, S6K Service Manual
Customer Feedback
Dear Users,
Thanks for purchasing BYD Gasoline Engine. In order to continuously improve the performance
and quality of the products and provide better services, any suggestion and improvement opin-
ions about the problems found in the process of using the EFI gasoline engine are appreciated.
Please contact us through the phone, fax, or e-mail listed in the back cover. Please send letters to
the following address and fill out the Customer Feedback.
3RVWDOFRGH
1R%<'5G1HZ,QGXVWULDO3DUN;L’DQ+LJKWHFK=RQH6KDDQ[L3URYLQFH
To
After-service Department
%<'$XWR6DOHV&R/WG
Address: __________________
2-27
BYD S6, S6A, S6K Service Manual
Customer Feedback
Year
Gasoline engine No. Date of Manufacture
Month
Contact Tel
FAX/E-MAIL
2-28
BYD S6, S6A, S6K Service Manual
Contents
3-I
BYD S6, S6A, S6K Service Manual
3-II
BYD S6, S6A, S6K Service Manual
BYD483QB gasoline engine can operate optimally under any condition. This ensures the vehicle
with reliable security, comfortable drivability, best fuel economy and environment-friendly perfor-
mance.
BYD483QB
4-Cylinder, in line, water-cooled, double overhead camshaft, 16-valve,
Type 4-stroke
Closed loop electronic fuel injection gasoline engine
Rated power 95kW˄5800r/min˅
Max. torque/speed 172N.M/4750r/min
Min. fuel consumption 275 g/kW·h
Bore × stroke 83 mm × 92 mm
Displacement 1.991 L
Compression ratio 9.6
Valve mechanism Synchronized belt drive, 16-valve DOHC
Combustion chamber type Pent roof
Fuel type Octane No. 93 or higher (Research)
Idle speed (750±50)r/min
Cylinder compression pressure 1.2 MPa~1.5 MPa(400 r/min)
Fuel supply Electronic sequential multiport fuel injection
Injection pressure (differential
pressure before and after the in- 350 kPa
jection)
Ignition order 1—3—4—2
Ignition timing BTDC 10°±1 when idling
Lubricating method Forced and splash lubrication
SG 10W-30 (For four seasons in the South and Summer in the North)
Engine oil
SG 5W-30 (For Winter in the North)
Exhaust emission system Two-level three-way catalytic converter
Oil pressure 300 kPa~490 kPa.(3000 r/min)
Gasoline engine mass 130 kg
Dimension (length × width ×
600 mm × 610 mm × 640 mm
height)
Emission regulation China IV
3-1
BYD S6, S6A, S6K Service Manual
3-2
BYD S6, S6A, S6K Service Manual
3-3
BYD S6, S6A, S6K Service Manual
3-4
BYD S6, S6A, S6K Service Manual
Compressor
Crankshaft pulley Crankshaft pulley
During measuring
Generator +
750~800 450~550
water pump
3-5
BYD S6, S6A, S6K Service Manual
3-6
BYD S6, S6A, S6K Service Manual
2 Valve clearance adjustment New gasket thickness = used gasket thick-
ness + measured valve clearance –
This procedure is for all the valves that need standard valve clearance (0.26 mm)
to adjust the clearance.
6. Put the adjusting gasket into valve tap-
1. Rotate the camshaft clockwise to turn pet.
the peach-tip of the camshaft upward
and hold it at a suitable position for ad- 7. Loosen the bolt A for the favor of valve
justment, then adjust the tappet open- tappet movement.
ing to the inside of the cylinder head.
8. Loosen the bolt securing the special
2. Unscrew 1 bolt on the outside of cam- tool and remove the special tool.
shaft cap.
9. After removing the special tool, retight-
Note: As long as you remove the bolt outside en the cam bearing cap bolt. Tightening
of corresponding camshaft cap, the gasket torque: 12 Nm - 14Nm.
can be replaced accordingly.
10. Check the valve clearance according to
3. Press the valve tappet with the special 1.3 in this section.
tool eject-rod and secure the special
tool on the camshaft cap with bolt which CAUTION
removed recently.
When pressing the valve tappet, it is pos-
VLEOHWRGDPDJHWKHF\OLQGHUKHDG
Bolt A
Bolt A
3-7
BYD S6, S6A, S6K Service Manual
3-8
BYD S6, S6A, S6K Service Manual
NOTICE
It will damage the belt or shorten its ser-
YLFHOLIHE\ZLQGLQJWKHEHOW¿UPO\RULILW
LVDGKHUHGZLWKRLORUJUHDVH
3-9
BYD S6, S6A, S6K Service Manual
NOTICE
Do not strain the tensioner pulley spring,
otherwise it will over tighten the timing
EHOW
Guide Pulley
Tensioner pulley and tensioner pulley
spring installation instruction:
3-10
BYD S6, S6A, S6K Service Manual
NOTICE
After installing the drive belt (engine
EHOWWLJKWHQWKHZDWHUSXPSSXOOH\EROW
7RUTXH1ÂP
3-11
BYD S6, S6A, S6K Service Manual
3-12
BYD S6, S6A, S6K Service Manual
CAUTION
For the camshaft installation clearance
is so small, ensure its levelness when
LQVWDOOLQJ2WKHUZLVHWKHFRQWDFWVXUIDFH
between shaft and bearing will generate
QRLVH IRU WKH UHDVRQ RI KLJK SUHVVXUH
3OHDVHREVHUYHWKHSURFHGXUHVEHORZWR
Cylinder head insvtallation instruction DYRLGWKHVLWXDWLRQVRFFXU
1. Measure the bolt length of each cyl- 1. Install the camshaft into the cylinder
inder head. If it exceeds the standard head.
value, please replace it.
2. Install the camshaft bearing cap.
Standard length: 104.2 mm-104.8 mm
3. Apply the sealant on the areas shown
Max. length: 105.5 mm in the illustration. Pay attention to that
the sealant diameter is 1 mm-2
mm, it is even and continuous. Make
sure the camshaft surface is clean to
avoid gasoline engine damage.
Loctite 5699
2. Tighten the cylinder head bolts in the
order given in the illustration below.
First tightening torque: 20±2 N·m. Loctite 5699
Loctite 5699
Mark
9. Add the clean oil to the camshaft oil
Step 1 groove.
3-13
BYD S6, S6A, S6K Service Manual
Special tool
Camshaft oil seal
Position pin
72 Crankshaft Front Oil Seal Re-
moval Instructions
1. Cut off the oil seal edge with blade.
3-14
BYD S6, S6A, S6K Service Manual
7 Crankshaft Front Oil Installation 2. Install the oil seal manually.
Instructions
3. Press the oil seal with the special tool
1. Apply appropriate clean gasoline en- and hammer.
gine oil on the oil seal lip.
Oil pump
Hammer
1. Cut off the oil seal lip with blade. Heating return pipe
3-15
BYD S6, S6A, S6K Service Manual
3-16
BYD S6, S6A, S6K Service Manual
Section Gasoline Engine Oil 7. Start the gasoline engine and check for
the oil leak.
1 Oil Inspection
8. Check the gasoline engine oil level and
1. Park the vehicle on a level surface. add oil as required.
6. Check if the O-ring on the oil dipstick Gasoline engine oil grade SG or higher:
tip is in good condition.
Oil viscosity choice
Oil grade
7. Reinsert the oil dipstick. standard
Above -25°C SG 10W-30
2 Oil Change
-30°C-37°C SG 5W-30
WARNING
The oil temperature of the hot en-
JLQHLVYHU\KLJK%HFDUHIXOQRWWR
EHVFDOGHG
If the vehicle is not raised to the safe
location, it will drop off and result in
GHDWK7KXVLWLVIRUELGGHQWRZRUN
under or around the vehicle if it is not
VXSSRUWHGSHUIHFWO\
3-17
BYD S6, S6A, S6K Service Manual
2. Wipe off the oil filter surface with a 2. Remove the sealants on the thread.
piece of clean cloth.
3. Screw a bolt in the welded nut, leave a
3. Install the oil filter firmly according to narrow clearance between the oil pan
the instruction procedure on the filter or and floor.
packing case. Torque: 25-30 N·m.
NOTICE
When replacing oil filter, make sure the
accumulator cathode is disconnected
DQG UHSODFH LW DV WKH DERYH SURFHGXUH
Avoid damaging electrical parts because
of short circuit in the process of replace- 4. Remove the oil pan with a remover.
PHQW
3-18
BYD S6, S6A, S6K Service Manual
Oil pan
O-ring
Oil pump
Loctite 5699 Loctite 5699
Loctite 5699
Bolt
3-19
BYD S6, S6A, S6K Service Manual
Loctite 5699
Thickness: 2.0-3.0mm
Loctite 5699
Loctite 5699
Loctite 5699
Oil pump installation instructions Tighten the skirt rack bolts (Tightening torque:
21-25 N·m) in 2 to 3 times in the order given
1. Apply the clean oil on the outer oil seal. in the illustration below. Finally tighten the
bolt A: 9-11 N·m.
2. Install the oil seal manually.
Hold-down
Device
SST
Thickness: 1.0-2.0 mm
3-20
BYD S6, S6A, S6K Service Manual
3UHVVXUHOLPLWHGYDOYHVSULQJLQVSHFWLRQ
Front cover
Apply pressure to the spring and inspect its
Oil pump cover plate height. Replace the spring if necessary.
Outer rotor
Pressure: 97.7-107.4 N·m
Inner rotor
Pressure limited valve element Standard height: 33.50 mm
Pressure limited valve spring
3-21
BYD S6, S6A, S6K Service Manual
Chapter Cooling System side flows in left and right line along the water cav-
ity of the cylinder block vertically, one line flows
vertically and the other flows up to the cylinder
Section 1 Gasoline Engine head. The coolant from exhaut side to cylinder
Cooling System Schematic head will cool down the 2 exhaust pipes. Then it
Drawing will be divided into two parts, one part cools down
the cylinder spark plug and the rest conflows to
Gasoline engine cooling system in the whole the vertical lines of spark plug both sides in next
vehicle pipe line system is as follow: cylinder. The coolant from intake side to cylinder
head will cool down the two intake pipes. Then it
The coolant pumped by the water pump flows will be divided into two parts, one part cools down
into the cylinder block from the front side and the cylinder spark plug and the rest conflows to
then into the cylinder head. And it flows out the vertical lines of spark plug both sides in next
from the cylinder head rear end. cylinder. The coolant to the cylinder head will flow
laterally at first. After conflowing into the central
The thermostat (opening temperature is 82°C) path from the intake and exhaust sides, the cool-
is mounted on the water pump inlet. The coolant ant will flow vertically.
refilled from the middle of the cylinder block front
Expansion
tank
Warm air
Cylinder head
Inlet water
Water
Cylinder pipe
A/C
A/C
Hose
Compressor
A/C radiator
3-22
BYD S6, S6A, S6K Service Manual
Power steering
pump regulator
3-23
BYD S6, S6A, S6K Service Manual
Chapter Clutch
O-ring Replace
Lock pin
Clutch pedal
Adjustment
Replace
Pedal pin
Retaining
clamp Clutch master cylinder
Replace
Clutch hose
Section Adjustment of Clutch til it cannot contact with the clutch pedal
(C).
3edal and Its Bolts
NOTICE
Remove the driver side floor mat
EHIRUHDGMXVWLQJWKHFOXWFKSHGDO
The clutch will make self-adjust-
PHQWWRFRPSHQVDWHWKHZRUQ
If there is no clearance between
the master pump piston and push
rod, the releasing bearing will
contact with diaphragm spring
WLJKWO\,QWKLVVLWXDWLRQWKHFOXWFK
1. Loosen the lock nut (D) of clutch push
will slip or some other problems
rod, then screw in and out the push rod
ZLOORFFXU
(E) to reach the specified pedal height
(F), stroke (G), free play (H) and sepa-
1. Loosen the lock nut (A) and unscrew
the clutch pedal adjustment bolt (B) un- ration height (I).
3-24
BYD S6, S6A, S6K Service Manual
Clutch pedal stroke: 130-140 mm (B) and master cylinder installation nut
(C).
Clutch pedal free play: 10-18 mm
2. Apply grease on the pedal pin (D).
Clutch pedal height: 187 mm Then, install the pedal pin and new lock
Clutch pedal separation height: 91 pin (E) on the clutch release fork.
mm
Section 5 Clutch Master Cylin-
1. Tighten the clutch push rod lock nut (D). der Replacement
2. Release the clutch pedal. Screw in the
clutch pedal adjustment bolt (B) until it NOTICE
contacts with the clutch pedal (C). Never spill the brake fluid on the vehicle,
RWKHUZLVHLWZLOOGDPDJHWKHSDLQW,ILWKDS-
3. Then, screw in the clutch pedal adjust- SHQVSOHDVHULQVHZLWKZDWHULPPHGLDWHO\
ment bolt (B) for 3/4 to 1 circle.
4. Tighten the clutch pedal adjustment 1. Drain the brake fluid in the clutch mas-
bolt lock nut (A). ter cylinder reservoir with sucker.
1. Pry out the lock pin (A). Then, pull out the 4. Pry out the lock pin (A). Then, pull out
pedal pin (B) from clutch release fork. the pedal pin (B) from clutch release
fork. Remove the master cylinder lock
nut (C).
3-25
BYD S6, S6A, S6K Service Manual
6. Remove the clutch pipe bracket (B). 12. Pry off the clamping ring end (B) with a
screwdriver to avoid clamping ring (A)
7. Remove the clutch master cylinder (C). dropping down.
8. Disconnect the reservoir hose (A),
remove the retaining clamp (B) and
remove the clutch pipe (C) from clutch
master cylinder (D). Seal the reservoir
hose and clutch pipe ends with cloth for
service to avoid the brake overflow.
NOTICE
The reservoir refilling is included in the
EOHHGLQJSURFHGXUH
Gasket
Pipe
3-26
BYD S6, S6A, S6K Service Manual
2. Disconnect the clutch pipe and plug the Section 7 Clutch Replacement
end of clutch pipe line with service cloth
to avoid brake fluid spilling out. 71 Clutch specification
3. Install the clutch release cylinder in the Basic specification
reverse order of the removal.
Item Specification
4. Pull the protecting cover (A) out, apply
grease for brake assembly to the cover Clutch operation type Hydraulic romote control
and the clutch release cylinder rod (B), Clutch plate type Dry and single plate
and reinstall the cover. Clutch plate size
Outer dia. × Inner dia. 215x154
Diameter
Clutch cover type Diaphragm spring
3-27
BYD S6, S6A, S6K Service Manual
3-28
BYD S6, S6A, S6K Service Manual
Release cylinder:
3-29
BYD S6, S6A, S6K Service Manual
0~0.4mm
3LORWEHDULQJLQVWDOODWLRQLQVWUXFWLRQV
NOTICE
Install the pilot bearing according to the
LQVWUXFWLRQVEHORZ
3-30
BYD S6, S6A, S6K Service Manual
Foreword
Welcome to use BYD488QA EFI engine (hereinafter referred to as BYD488QA engine) manu-
factured by BYD Auto Industry Company Limited. Before operating, please read this Operation
Manual carefully.
BYD488QA engine adopts electronic control fuel injection system developed by our company,
is provided with advanced self-diagnosis function. Key components are from world-famous auto
electronic companies. It has characteristics of high power, low fuel consumption, low noise, low
pollution and compact structure. Under various working conditions, BYD488QA engine can work
at the optimum state. It can ensure reliable safety, comfortable driving, optimum economy and
perfect environment protection performance.
This manual describes main performance, technical parameters, operation and maintenance and
maintenance methods of BYD488QA engine. Before you operate BYD488QA engine, please read
this manual carefully to ensure power system of your vehicle is in a good state to play a more im-
portant role and produce higher economic benefit. When you read this manual, if you find any
difference from the same maintenance method of the engine in other documents or mutual
contradiction, please follow the maintenance method in this manual
In order to improve product performance and quality, serve the customers better, our company
hopes you will inform us of problems that you find during the course of using electronic injection
engine and suggestions at any time.
It is your best choice to buy passenger vehicles with BYD electronic ejection engines.
Symbol description
“ ƾƾƾ ” is involved in personal safety of driver and passenger. Please pay special attention and
follow it;
1
BYD S6, S6A, S6K Service Manual
Contents
Chapter 1 3erformance, main technical parameters and structure of the engine -1
Section 1 Performance and main technical parameters of the engine.................................... 4-1
Section 2 External characteristic curve for BYD488QA engine............................................... 4-2
Chapter 2 Engine operation -
Section 1 Notes for engine operation ......................................................................................4-3
Section 2 New engine running-in ............................................................................................4-5
Chapter Engine maintenance -6
Section 1 Engine lubrication system maintenance..................................................................4-6
Section 2 engine cooling system maintenance .......................................................................4-7
Section 3 V-ribbed belt maintenance ......................................................................................4-9
Section 4 Ignition system maintenance...................................................................................4-9
Section 5 Check and adjustment for valve timing mechanism ................................................ 4-9
Section 6 Crankcase forced ventilation valve (PCV) maintenance ....................................... 4-10
Section 7 Electrical system check and maintenance ............................................................4-10
Section 8 Air filter maintenance............................................................................................. 4-11
Section 9 Gasoline filter maintenance................................................................................... 4-11
Section 10 Fuel vapour collecting system maintenance ......................................................... 4-11
Section 11 Three-way catalytic converter maintenance..........................................................4-12
Chapter Regular check of the engine -1
Section 1 Engine maintenance period and items..................................................................4-13
Section 2 Main tightening torque of the engine.....................................................................4-14
Chapter 5 Main fault and troubleshooting method of the engine -15
Section 1 Notes for engine operation and maintenance ....................................................... 4-15
Section 2 Main fault and troubleshooting method of the engine ........................................... 4-16
Section 3 Abnormal emission and troubleshooting ...............................................................4-23
Chapter 6 Engine sealing and unsealing-2
Section 1 Engine sealing and storage...................................................................................4-24
Section 2 Unseal the engine .................................................................................................4-24
4-I
BYD S6, S6A, S6K Service Manual
4-1
BYD S6, S6A, S6K Service Manual
4-2
BYD S6, S6A, S6K Service Manual
Before operating, please read Operation Manual, operate and maintain the machine in strict ac-
cordance with regulations in this manual.
2 Coolant
Check engine coolant. If necessary, please fill coolant according to Section 2 in Chapter 3.
ƾƾ
When the engine is running, cooling system shall have enough coolant to ensure the
HQJLQHZRUNVQRUPDOO\2WKHUZLVHWKHHQJLQHZLOOEHFRPH“boiling”,IWKHHQJLQHLVRYHU-
KHDWHGVHUYLFHOLIHRIWKHHQJLQHZLOOEHDIIHFWHG6HULRXVO\VFXI¿QJRIF\OLQGHUERUHPD\
RFFXU
3 Engine oil
Check engine oil level. If engine oil is not enough, please refill it immediately. Please check and
refill engine oil according to Section 1 in Chapter 3.
ƾƾ
,IHQJLQHRLOLVQRWHQRXJKHQJLQHRLOSUHVVXUHLVWRRORZDQGOXEULFDWLRQLVSRRU7KHHQ-
JLQHLVZRUQH[FHVVLYHO\DQGFRROLQJLVSRRU$VDUHVXOWDIDXOWRFFXUVHDVLO\ZKLFKDI-
IHFWVVHUYLFHOLIHRIWKHHQJLQH
4 Fuel
ƾƾ
7KHYHKLFOHVKDOOXVHVWDQGDUGTXDOLW\OHDGIUHHJDVROLQH2WKHUZLVHHOHFWURQLFFRQWUROIXHO
injection system, three-way catalytic converter and oxygen sensor of the engine will be
damaged heavily to degrade environmental protection performance and dynamic perfor-
PDQFH
When starting the engine, turn ignition switch key to “Start” position, and start the engine by the
starter. Once the engine starts, release the key to shut off starter power.
ƾƾ
Because the engine management system can provide appropriate gas mixture and ignition
advance angle, it is not necessary to step on accelerator pedal before starting under any
FOLPDWH
ƾƾ
If the engine cannot start several times, spark plug has short circuit because the engine
RLORYHUÀRZV1RZVWHSRQWKHDFFHOHUDWRUFRPSOHWHO\VWDUWWKHHQJLQHDQGMHWVWHDPFDQ
EORZRIIRYHUÀRZLQJRLOZLWKLQV1RZUHOHDVHDFFHOHUDWRUSHGDODQGUHVWDUWWKHHQJLQH
4-3
BYD S6, S6A, S6K Service Manual
If a vehicle starts initially (new engine or engine with fuel supply system repaired), starting time may be
longer so as to fill fuel supply system pipe and build up normal working pressure, supply gasoline and
appropriate fuel gas mixture to ensure the engine works normally.
ƾƾ
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6 Idle speed
After the engine starts, it shall run idly for 3~5 minutes without load to warm it up.
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When measuring the emission, the engine shall be in heating state, i.e., the coolant shall be
85°C±5°C.
7 Driving
During the course of driving, keep the coolant temperature between 85°C±5°C. At medium speed,
engine oil pressure shall not be less than 300kPa.
8 Stop
After the engine runs, especially after it runs at high speed with high load, it cannot stop immedi-
ately. It shall run idly for 3~5 and then stop.
9. Warming up in winter
In winter, because the temperature is very low, engine oil viscosity increases. Now, the engine
lubrication is worse than that in summer. Therefore, after the engine starts, the vehicle cannot
drive immediately and the engine cannot run at high speed with high load. It shall run idly for 10
minutes for warming up to increase engine oil temperature and coolant temperature. The engine
is enough lubricated and then the vehicle drives.
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In winter, if the vehicle drives when the engine is not lubricated enough, moving parts may
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On a rainy day, if the vehicle drives in water or wades, air filter shall be sealed well. Otherwise,
rain water may go into the engine cylinder, which damages moving parts, such as connecting rod.
ƾƾ
4-4
BYD S6, S6A, S6K Service Manual
After water goes into one cylinder, connection rod may be applied by dozens of times of
normal working pressure due to inertial effect of the vehicle, which bends or breaks up the
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In order to prevent gasoline from leaking, it is necessary to check gasoline pipe, clean oil
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When checking fuel pipe, it is forbidden to start the engine after removing fuel inlet/return
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The engine on the vehicle shall run in according to Operator Manual of the vehicle. Please check
and maintain the engine according to the following requirements during the course of running-in:
1 Check
Check if engine oil, coolant, gasoline and battery electrolyte is sufficient. If it is insufficient, refill it
in time.
2 Road
It would be best to drive on cement or asphalt roads. Try to avoid driving on a muddy or sandy
road.
3 Maintenance
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4-5
BYD S6, S6A, S6K Service Manual
SJ grade and above 10W-30 (in spring, summer and autumn in the north and in each season in
the south)
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Measure engine oil on oil pan with an oil level gauge. After the engine runs for 3 minutes, mea-
sure it and take out the oil level gauge, wipe off engine oil on it with a cleaning cloth, then insert it
on oil pan to measure engine oil level. Engine oil level shall be between two points of the oil level
gauge. If oil level is close or lower than lower limit, please refill engine oil to upper limit. Before
driving and every 300km~500 km, check engine oil level.
Replace engine oil every 8000km on asphalt or cement road; it is necessary to check frequently
on extremely sandy soil roads. Replace it more frequently. But, replace it every 5000km.
When replacing engine oil, warm up the engine for 10 minutes, open filler cap after stopping, un-
screw drain plug on the bottom of oil pan to discharge oil and then tighten drain plug. Fill new en-
gine oil 5.0L through oil filler cap and tighten oil filler cap. (See figure 4-1)
Start the engine and run for 5 minutes. Check if drain plug leaks. Then shut down and wait for 5
minutes, check oil level. If oil is insufficient, refill oil to upper limit of oil level gauge.
Drain plug
Filler-cap flap
Figure 4-1
ƾƾƾ
4-6
BYD S6, S6A, S6K Service Manual
:KHQXQVFUHZLQJGUDLQSOXJDYRLGVFDOGVIURPHQJLQHRLO
If there are excessive impurities on oil pan, clean engine lubrication system with light spindle oil.
When washing inside the engine, fill 2.5L light spindle oil into the engine, start the engine by
starter to run idly 2~3 times. Run idly for one minute every time. Then discharge light spindle oil
immediately. Fill engine oil into the engine according to the specification.
After replacing engine oil every time, run the engine idly without load for 3~5 minutes to ensure
lubrication system and lubricating positions are lubricated sufficiently.
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areas and standards to avoid oil from chemical reaction, which affects normal work of the
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Every 8000km, replace engine oil filter once. When installing, tightening torque is 13 N·m.
Normally, when power switch (key) is turned to “ON” position, engine oil pressure indicator lamp
is lit, which means no engine oil pressure; turn the switch to “START” position, and then the en-
gine goes into idling state. Now, engine oil pressure indicator lamp goes out automatically, which
means engine oil pressure is normal. If engine oil pressure indicator lamp does not go out, it
means engine oil pressure in engine lubrication system is abnormal. It is necessary to stop the
engine to check if engine oil is sufficient.
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When the engine is running, cooling system shall have enough coolant to ensure the en-
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1 Coolant
Engine coolant adopts glycol coolant. Freezing point is 5°C lower than the lowest temperature in
application area. Different brands of coolant cannot be mixed. It is forbidden to use fake and poor
quality coolant. River water or well water is forbidden.
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After water is frozen, the volume will be expanded to burst sealed radiator, water pump,
4-7
BYD S6, S6A, S6K Service Manual
F\OLQGHUKHDGDQGF\OLQGHUEORFN
2 Fill coolant
(1) Unscrew radiator cover and fill coolant, keep water level of the pot at “FULL” scale. Do not
exceed “FULL” scale.
(3) Start the engine and run idly for 3~5 minutes; if coolant level reduces, open water pot cover
and fill coolant to “FULL” position.
(4) Place water pot cover and tighten it. Then the engine can work normally.
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After a long time, if the coolant level in water pot is lower than “LOW”, fill coolant into water pot to
“FULL” position.
If a lot of coolant reduces in a short time, cooling system may leak. Please check it carefully.
After a long time, if it is necessary to replace the coolant due to deterioration or repair, replace it
according to the following procedures.
(1) Unscrew radiator cover, open water drain valve on the bottom of radiator to discharge the
coolant.
(3) Reinstall water pot and water drain valve of the radiator in original positions. Fill coolant ac-
cording to Item 2 of section 2 in Chapter 3.
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IHFWVLWVVHUYLFHOLIH
4-8
BYD S6, S6A, S6K Service Manual
ƾƾ
If V-ribbed belt tension is not enough or damaged, the engine will be overheated, generat-
ing capacity will be reduced; steering has no power assistance and A/C refrigeration is in-
VXI¿FLHQW
1 Adjustment method
Stop the engine, tighten adjusting bolt on position adjusting block of the generator and adjusting
bolt on power-assisted steering pump.
2 Measure tension
3 Appearance
Check if V-ribbed is cracking and worn, if fibre cloth is flaking. Replace it if necessary.
The surfaces of two electrodes for spark plug shall be clean and smooth. Remove carbon deposi-
tion on two electrodes with fine sand paper. Spark plug clearance shall be 1.0mm ~1.1mm. The
clearance shall be smooth on electrode surface.
Engine management system adopts an advanvced ignition system. During the course of normal
operation, only replace spark plug and check high voltage damper. No other maintenance is re-
quired.
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When the engine is running, do not dismantle spark plug high voltage line to make spark-
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Remove ignition coil, PCV vent pipe assembly and cylinder head assembly.
Adjust cylinder #1 to compression TDC: rotate crankshaft vibration damping pulley until white
mark groove on the pulley aligns with timing mark “0” on timing cover. Check if intake/exhaust
4-9
BYD S6, S6A, S6K Service Manual
cam shaft timing sprocket wheel aligns with timing mark on corresponding cam bearing cap. As
shown in Fig.4-2, if they do not align, rotate crankshaft by one turn (360°), and align timing marks
according to the procedure above.
Timing marks
Timing marks
Slot
Figure 4-2
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oxygen sensor and three-way catalytic converter will be shortened greatly due to valve
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4-10
BYD S6, S6A, S6K Service Manual
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Air filter element shall be dismantled for cleaning frequently. On asphalt road, clean it once every
10000km, replace it once every 40000km; on sandy soil road, clean it once every 2500km, re-
place it once every 40000km; it is required to replace it more frequently in dusty environment.
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2. Smoking is prohibited. “No Smoking” nameplate is placed near the operation area.
4. Operation shall be in a place with good ventilation and keep away from open flame.
5. In order to release fuel vapour pressure in fuel tank, remove fuel filler cap and then install it.
6. Even if the engine stops, fuel pipe is still in high pressure state. If fuel pipe is released or
dismantled immediately, fuel injection may occur. Dangerous ʽ Therefore, before releasing
or dismantling fuel pipe, first confirm if the pressure is released.
7. When dismantling fuel pipe, a small amount of fuel overflows. Therefore, place empty fuel
container under gasoline filter or wrap gasoline filter with to make fuel return to the empty
container or be absorbed by waste cloth. Place waste cloth with fuel into specified contain-
er.
4-11
BYD S6, S6A, S6K Service Manual
11. Take out fuel pump from fuel tank and expose it in the air. Do not energize fuel pump to
avoid spark and fire.
ƾƾƾ
Three-way catalytic converter is easily damaged due to overheating when the engine
ZRUNV,QRUGHUWRSURWHFWWKUHHZD\FDWDO\WLFFRQYHUWHUWKHGULYHUVKDOOREVHUYHWKHIROORZ-
ing items:
1 Only use 92# lead-free gasoline or above
2 Good resistance to pressure of fuel supply system (not less than 0M3a) and leak-
proof characteristic
5 When fuel is insufficient, do not drive a vehicle Otherwise, electric fuel pump may be
damaged after the fuel is used up
6 3revent exhaust system from leaking, especially, ensure the connection between ex-
haust manifold before three-way catalytic converter and the muffler is airproof
7 Do not push or tow the vehicle to start the engine If the battery power is low, please
use auxiliary battery to start the engine
When the engine is running, do not dismantle any spark plug or high voltage damper
to make system ignition function diagnosis
9 When the engine runs idly unstably or cannot start in a long time, do not operate the
engine forcedly
10 If the engine performance reduces greatly or the engine runs abnormally, for ex-
ample, fuel supply system or ignition system works abnormally, please stop the en-
gine immediately If it is impossible to stop the engine immediately, slowdown and go
to professional maintenance department or specified service station for check and
maintenance
4-12
BYD S6, S6A, S6K Service Manual
(2) Shorten replacement period of engine oil filter according to dirt degree of the engine.
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It is suggested that maintenance items with ƹ shall be made by special service station of
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4-13
BYD S6, S6A, S6K Service Manual
4-14
BYD S6, S6A, S6K Service Manual
2. Positive and negative electrodes of the battery shall not be reversed to avoid electronic ele-
ments.
3. When the engine is running, do not dismantle the battery, connect wire and a connector.
5. Before welding on the vehicle, the battery shall be taken away from the body.
6. Take out electric fuel pump from fuel tank and expose it in the air. Do not energize electric
fuel pump to avoid spark and fire.
7. Positive and negative electrodes of electric fuel pump shall not be reversed.
8. Equipment that may generate radio interference, like radio antenna shall not be installed
near ECU to avoid mutual interference.
9. On a rainy day, when maintaining and washing the engine, do not let water go into the en-
gine or splash water onto electronic circuit.
10. Prohibit the use of detection method that gas mixture in the cylinder does not burn and then
go into exhaust pipe.
11. If fuel pressure is high, first release the pressure before maintaining the pipe. The method:
dismantle fuel pump fuse, start the engine, run it idly unit it flames out.
12. Before removing any part, first switch off ignition switch and remove negative cable of
the battery.
13. Because three-way catalytic converter will be installed, lead-free gasoline shall be used. If
lead gasoline or low-lead gasoline is used, three-way catalytic converter will be damaged
and purifying result of purification system will be reduced.
15. Fuel pipe clamp is disposable. It is forbidden to reuse to avoid fuel leakage.
16. Because high voltage ignition coil is used, do not contact it by hand when the engine works.
17. Idling adjustment of the engine is completely made by electronic fuel injection system. There is
no need to make mechanical maintenance for idling adjustment and idling system.
18. After replacing ECU or idle speed regulator, before first start, turn ignition switch to ON for
20s and then start it to make the system or idle speed regulator complete self-adaption.
19. Electronic control system can provide appropriate air-fuel ratio to the engine in any case to
make the engine work normally. Therefore, when starting the engine, do not operate any
mechanism of the engine (including accelerator).
20. The system has fault safety function. Note: although the engine system has fault safety
function, it is not appropriate to run for a long time. Therefore, when MIL is lit, it is required
to make troubleshooting immediately to avoid serious damage of the engine.
4-15
BYD S6, S6A, S6K Service Manual
The engine does 3.5 Electric fuel pump does not work Replace
not work (difficult 3.6 Fuel filter clogged Clean or replace it
to start)
3.7 Air in fuel pipe Repeated starting
3.8 Fuel nozzle blocked Replace or wash
3.9 Insufficient fuel pressure Check and adjust
3.10 Fuel hose or fuel pipe blockage Clean or replace it
3.11 Inlet/return oil reversed Check and adjust
3.12 ECU interface loose Reinstall
3.13 Intake manifold loose Tighten
4. Internal state of the engine is abnormal
4.1 Cylinder head gasket damaged Replace
4.2 Valve clearance incorrect Adjust it
4.3 Valve spring weakened or damaged Replace
4.4 Timing chain damaged Replace
4.5 Valve gaping Repair or replace
4-16
BYD S6, S6A, S6K Service Manual
4-17
BYD S6, S6A, S6K Service Manual
4-18
BYD S6, S6A, S6K Service Manual
4-19
BYD S6, S6A, S6K Service Manual
4-20
BYD S6, S6A, S6K Service Manual
4-21
BYD S6, S6A, S6K Service Manual
4-22
BYD S6, S6A, S6K Service Manual
4-23
BYD S6, S6A, S6K Service Manual
1. Fill 2.5L anti-rust lubricating oil into the engine to be sealed, then remove each spark plug,
keep the piston for each cylinder of the engine between TDC and BDC. Fill 0.006L anti-rust
lubricating oil into each cylinder, drive the engine by start motor to run 3~4 times and run for
15s every time.
2. Unscrew oil pan drain plug, discharge anti-rust lubricating oil, reinstall drain plug and spark
plug, and tighten with specified torque.
3. Discharge the coolant, remove engine cooling nozzle, clean it, and seal it with dust cover.
Then cover exhaust pipe, throttle opening, engine water inlet/outlet, fuel injector hole with
wax paper or rubber cover.
3. Remove spark plug, run the engine idly and discharge anti-rust oil in the cylinder.
5. Fill coolant.
4-24
BYD S6, S6A, S6K Service Manual
Thank you for choosing BYD engine! In order to improve product performance and quality, serve
the customers better, our company hopes you will inform us of problems that you find during the
course of using the engine and suggestions at any time.
Please contact us by phone, fax or E-mail listed on the back cover of this Operation Manual. The
mail address is as following. Please fill Paper of User Opinion in detail.
Sender address:___________
4-25
BYD S6, S6A, S6K Service Manual
4-26
BYD S6, S6A, S6K Service Manual
V BYD4A Engine
Contents
5-I
BYD S6, S6A, S6K Service Manual
Model
3arameter BYD4A
Item
In-line four cylinder, forced cycle water cooling, double overhead camshafts
Type
and four strokes
Rated power 118kW˄5800r/min˅
Maximum torque/speed 229N.M(4000r/min)
The lowest fuel consumption 250+10 g/kW·h
Cylinder bore × stroke 88.5 mm × 96 mm
Gasoline engine displacement 2.362 L
Compression ratio 9.8: 1
Variable valve timing mechanism (VVT), double overhead camshafts
Valve mechanism
(DOHC), chain drive, 16 valves
Fuel types 92# lead-free gasoline or above
Stable idle speed ˄700±50˅r/min
Compression pressure of cylinder 0.98MPa~1.46 MPa˄400 r/min±10 r/min˅
Fuel supply type Electronic control multipoint sequence fuel injection
Ignition sequence 1—3—4—2
Lubrication type Pressure and splashing combined type
Exhaust emission system Three-way catalytic converter
Oil Pressure: 170kPa~550kPa ˄3000 r/min±50 r/min˅
Engine quality 131 kg (transmission excluded)
Outline dimension (L × W × H) 600mm × 640mm × 680mm (excluding transmission)
Working conditions and emission State IV
5-1
BYD S6, S6A, S6K Service Manual
Item Standard
Cylinder diameter mm
Cylinder cylindricity 0.008 mm
0.05mm
Cylinder block Flatness of cylinder deck
100: 0.03
Cylinder verticality 0.04
Compression pressure of cylinder 0.98MPa~1.46MPa˄400 r/min˅
Diameter of piston skirt mm
Piston Diameter of piston pin hole mm
Fit clearance between piston and cylinder 0.021~0.041 mm
Piston pin diameter mm
Piston pin
Fit clearance between piston pin and piston pin hole 0.001~0.007 mm
Piston ring end gap:
Piston ring 1st compression ring
0.20~0.35 mm˗
Piston ring gap/
Piston ring end gap:
side clearance 2nd compression ring
0.3~0.45 mm˗
Diameter of connecting-rod small end mm
Connecting rod Fit clearance between piston pin and connecting-rod
0.005~0.011 mm
small end
Main shaft journal diameter mm
Connecting rod journal diameter mm
Journal cylindricity 0.0065mm
Crankshaft
Crankshaft radial circle run-out 0.04mm
Connecting-rod big-end axial clearance 0.16~0.362 mm
Crankshaft thrust clearance 0.04~0.24 mm
Flywheel axial circle run-out 0.06mm
Temperature when thermostat beginning to open and fully opening 82 ± 2 °C, 95 °C fully open
Spark plug clearance 1.0~1.1mm
0.04 mm
Cylinder-head lower face flatness
100/0.02
Manifold joint surface flatness 0.05 mm
Cylinder-head intake camshaft first-bearing hole
mm
diameter
Cylinder-head intake camshaft second~fifth-bearing
Cylinder head mm
hole diameter
Cylinder-head exhaust camshaft first-bearing hole
mm
diameter
Cylinder-head exhaust camshaft second~fifth-bearing
mm
hole diameter
Cylinder-head bolt length 142±0.8mm
5-2
BYD S6, S6A, S6K Service Manual
Item Standard
Intake camshaft first-journal diameter mm
Intake camshaft second~fifth-journal diameter mm
Exhaust camshaft first-journal diameter mm
Exhaust camshaft second~fifth-journal diameter mm
Camshaft journal cylindricity 0.005mm
Radial clearance between intake camshaft first jour-
0.007~0.038mm
Camshaft nal and bearing hole
Radial clearance between intake camshaft
0.025~0.062mm
second~fifth-journal and bearing hole
Radial clearance between exhaust camshaft first
0.015~0.056mm
journal and bearing hole
Radial clearance between exhaust camshaft
0.025~0.062mm
second~fifth-journal and bearing hole
Intake camshaft axial clearance 0.129~0.2mm
Exhaust camshaft axial clearance 0.129~0.2mm
Diameter of intake valve 34±0.1mm
Diameter of exhaust valve 29.5±0.1mm
Intake valve: mm
Valve stem diameter
Exhaust valve: mm
Valve system Valve guide diameter mm
Intake valve: 0.030 ~ 0.065 mm;
Clearance between valve stem and valve guide
Exhaust valve: 0.040 ~ 0.075 mm
Free length of valve spring 47.43±0.5mm
Intake valve 0.19 ~ 0.29mm;
Intake/exhaust valve clearance (cold)
Exhaust valve 0.38 ~ 0.48mm
B.1 Key dimensions and group table of crankshaft main journals, main bearing bores and main
bearing shells
Bearing shell group number=3-Main journal group number+Main bearing cap hole group number
5-3
BYD S6, S6A, S6K Service Manual
B.2 Key dimensions and group table of crankshaft connecting-rod journal, connecting-rod big-end
hole and connecting-rod bearing shells
Group number for connecting-rod bearing shell=2-Group number for crankshaft connecting-rod
journal+Group number for connecting-rod big-end hole
B.3 Key dimensions and group table of intake camshaft Ibearing hole, camshaft bearing shell and
camshaft Ijournal
Fastening Number of
Torque
S/N parts or Bolt specification 3art number pieces for Note
(N·m)
components each unit
A Key torque
1ST:30
2ND:70
1 Cylinder head Cylinder head bolt BYD488QA-1003401 10
Rotating
by 90°
1ST: 20
Main bearing
2 Main bearing cap bolt BYD488QA-1002101 10 2ND: 40
cap
turn 90°
25
Connecting
3 Connecting rod bolt BYD488QA-1004101 8 Rotating
rod cap
by 90°
4 Flywheel Flywheel bolt BYD488QA-1005011 8 98
5 Spark plug M14 × 1.25 BYD488QA-3707100 4 25
Crankshaft pulley bolt as-
6 Crankshaft BYD488QA-1025200 1 170
sembly
Camshaft
7 Camshaft bearing cap (I) bolt BYD488QA-1003118 4 30
bearing cap (I)
Cylinder-head Cylinder-head screw plug
8 BYD488QA-1003500 2 86
screw plug cluster
B Main torque
9 Oil filter cluster Screw plug BYD371QA-1003032 1 30
Hexagon flange bolts M6 x
10 Oil pan cluster Q1840612T1F6 14 9
12
5-4
BYD S6, S6A, S6K Service Manual
Fastening Number of
Torque
S/N parts or Bolt specification 3art number pieces for Note
(N·m)
components each unit
Hexagon flange bolts M6 x
Q1860616T1F6 1 9
Heater water- 16
11 return pipe Stud M6 BYDQ120F0615T1F6 2 5
cluster
Hexagon flange nut M6 Q32006T2F6C 2 9
Oil-cooling Hexagon socket cap head
12 Q218B0612TF2 4 7
nozzle screw screw M6 x 12
Chain guide Hexagon flange bolts M6 x
13 Q1840612T1F6 2 9
plate 12
Chain tension-
14 Chain tensioner plate bolt BYD371QA-1021014 19
er plate
Chain tension- Stud M6 BYDQ120G0615T1F6 2 5
15
er Hexagon flange nut M6 Q32006T2F6C 2 9
Small washers M6 + hexa-
Engine oil col- Q40006T16F6 +
16 gon socket cap head screw 2 9
lector Q218B0625T1F6
M6 x 25
Hexagon flange bolts M6 x
17 OCV valve Q1840612T1F6 1 9
12
Hexagon socket cap head
18 Clutch screw screw Q218B0825TF6 6 40
M8 × 25
Hexagon flange bolts M6 x
19 Dipstick tube Q1860616T1F6 1 9
16
Hexagon bolt and spring-
20 Starter washer assemblies M10 × Q1421040T1F6P1.25 2 39
1.25 × 40
Hexagon flange bolts M6 x
Q1860620T1F6Q 4 9
20
21 Water pump Stud M6 BYDQ120F0620T1F6 2 5
Hexagon flange nut M6 Q32006T2F6C 2 9
Water pump
22 Hexagon flange bolt M8 x 16 Q1840816T1F6 4 26
pulley
Hexagon flange bolts M6 x 30 Q1840630T1F6Q 1 9
Hexagon flange bolt M8 x 30 Q1840830T1F6Q 8 25
Hexagon flange bolt M10 ×
23 Timing cover Q1841040T1F6P1.25 3 55
1.25 × 40
Stud M6 BYDQ120F0620T1F6 2 5
Hexagon flange nut M6 Q32006T2F6C 2 11
Hexagon flange bolt M10 ×
Q1841065T1F6P1.25 2 54
1.25 × 65
24 Front bracket
Hexagon flange bolt M10 ×
Q1841040T1F6P1.25 1 54
1.25 × 40
5-5
BYD S6, S6A, S6K Service Manual
Fastening Number of
Torque
S/N parts or Bolt specification 3art number pieces for Note
(N·m)
components each unit
Hexagon flange bolt - En-
Q1860630T1F6 7 11
larged series M6 × 30
Hexagon flange bolts - En-
Q1860660T1F6 2 14
larged series M6 × 60
BY-
Stud M6 2 5
DQ120G0630T1F6
Hexagon flange nut M6 (for
Cylinder head
25 studs used to install cylinder- Q32006T2F6C 2 11
hood
head cover)
Stud M6 BYDQ120F0615T1F6 2 5
Hexagon flange nut M6 (for
studs used to install cylinder- Q32006T2F6C 2 9
head cover)
Cylinder-head cover bolt BYD488QA-1003015 4 9
Hexagon flange bolt M8 x 35 Q1860835T1F6 5 30
Intake mani-
26 Stud M8 BYDQ120F0833T1F6 2 9.5
fold
Hexagon flange nut M8 Q32008T2F6C 2 30
Hexagon flange bolts M6 x
27 Throttle valve Q1840655T1F6 4 9
55
Oil drain plug
28 Oil drain plug cluster BYD488QA-1009200 1 40
seat
Vacuum-
Vacuum-booster-pipe
29 booster-pipe 1 7
bracket bolt
bracket
Hexagon flange bolt M10 ×
Q1841085T1F6P1.25 1 52
30 Generator 1.25 × 85
Hexagon flange bolt M8 x 40 Q1840840T1F6 1 21
Hexagon flange bolts M6 x
31 Ignition coil Q1860625T1F6Q 4 9
25
Hexagon flange bolt M8 x 45 Q1840845T1F6 6 24
Cylinder block
32 Hexagon flange bolt M8 x 120 Q18408120T1F6 5 24
frame
Hexagon tapered bolt NPT3 / 8 Q619B03F6 1 25
5-6
BYD S6, S6A, S6K Service Manual
Fastening Number of
Torque
S/N parts or Bolt specification 3art number pieces for Note
(N·m)
components each unit
Idler bracket Hexagon flange bolt M8 ×
38 Q18408100T1F6 2 24
bolt 1.25 × 100
Hexagon flange bolt M10 ×
Q1841085T1F6P1.25 1 60
1.25 × 85
Tensioner clus- BY-
39 Stud M8 1 9.5
ter DQ120G08645T1F6
Hexagon flange nut M8 Q32008T2F6C 1 30
Stud M6 BYDQ120F0620T1F6 2 5
40 Thermostat
Nut M6 Q32006T2F6C 2 9
Camshaft
Camshaft bearing cap bolt
41 bearing cap Q1400635TF2 16 9
cluster
bolt cluster
Exhaust cam-
Camshaft sprocket bolt sub-
42 shaft compo- BYD488QA-1021300 1 54
assembly
nent
Intake cam-
43 shaft compo- Hex flange bolt Q1841040TF2P1.25 1 54
nent
Oil filter connecting thread-
44 BYD488QA-1017011 1 30
Engine oil filter ed-pipe
45 Oil filter assembly BYD473QA-1017010 1 13
Fuel distributor
46 Fuel distributor bolt BYD488QA-1003013 2 20
assembly
Knock Sensor stud BYD488QA-3611011 1 9.5
47 Knock sensor
Hexagon flange nut M8 Q32008T2F6C 1 20
Cross recessed countersunk
head screw Q2540609T1F6P0.75 2 7
M6 × 0.75 × 9
Hexagon flange bolts M6 x
Q1860625T1F6Q 1 7
25
Hexagon flange bolt M8 x 50 Q1840850T1F6 1 9
48 Oil pump
Hexagon flange bolt M8 ×
Q1840816T1F6P0.75 3 9
0.75 × 16
Hexagon flange bolt M8 ×
Q1840820T1F6P0.75 2 9
0.75 × 20
Pressure-limiting valve
BYD488QA-1011107 1 45
spring seat
Hexagonal head bolt and
spring washer cluster M12 × Q1421265T1F6P1.25 1 54
Transmission 1.25 × 65
connecting Hexagonal head bolt and
49
bolt(reverse spring washer cluster M12 × Q1421270T1F6P1.25 2 54
direction) 1.25 × 70
Hexagon flange bolt M10 ×
Q1841065T1F6 2 54
1.25 × 65
Hexagon flange bolt M10 ×
Q1841065T1F6P1.25 1 54
Transmission 1.25 × 65
connecting Hexagon flange bolt M10 ×
50 Q1841020T1F6P1.25 1 54
bolt( forward 1.25 × 20
direction) Hexagon flange bolt M10 × Q1841040T-
3 54
1.25 × 40 1F6QP1.25
5-7
BYD S6, S6A, S6K Service Manual
Fastening Number of
Torque
S/N parts or Bolt specification 3art number pieces for Note
(N·m)
components each unit
Engine oil
51 pressure Engine oil pressure switch BYD483QA-3611030 1 15
switch
Front
52 Front oxygen sensor 371QA-3611600 1 44
oxygen sensor
Canister
Hexagon flange bolts M6 x
53 control valve Q1840612T1F6 1 9
12
bracket bolt
Intake pres-
Hexagon flange bolts M6 x
54 sure tempera- Q1840616T1F6 1 9
16
ture sensor
Camshaft Hexagon flange bolts M6 x
55 Q1840612T1F6 1 9
phase sensor 12
Crankshaft Hexagon flange bolts M6 x Q1840614T1F6 (all-
56 1 9
position sensor 14 threaded)
Coolant Temp
57 Coolant Temp Sensor 0999CN0020 1 15
Sensor
5-8
BYD S6, S6A, S6K Service Manual
Hex head of
Tension
mechanism
assembly
5-9
BYD S6, S6A, S6K Service Manual
Timing marks
Slot
5-10
BYD S6, S6A, S6K Service Manual
Intake
(2) Mark the timing mark positions on the Note: In the whole process of the removal,
timing chain and camshaft sprocket be sure to prevent the chain from falling
with a marker. RIIIURPWKHFUDQNVKDIWVSURFNHW
Slot
(3) Remove the chain tensioner. 3) To make the valve clearance be within
the specified range, calculate the thick-
(4) Remove the bolts of exhaust camshaft
ness of the new tappet through the fol-
sprocket and the exhaust camshaft
lowing methods:
sprocket. Meanwhile, tighten the chain
upwards to prevent it from falling off Intake: A=B+˄C-0.24mm˅˗
from the crankshaft sprocket.
Exhaust: A=B+˄C-0.43mm˅˗
(5) Remove the intake/exhaust camshaft
bearing cap bolts in the order as shown A: Thickness of new tappet
in the figure.
B: Thickness of used tappet
5-11
BYD S6, S6A, S6K Service Manual
C: Measured valve clearance 1) Coat a thin layer of engine oil onto the
journal of intake camshaft.
Examples:
2) Mount the timing chain onto the sprocket
Measured valve clearance on the intake side: of the intake VVT cluster and make the
0.40mm˗ chain piece with paint mark align to the
0.40mm-0.24mm=0.16mm (measured clear- timing mark on the sprocket of the intake
ance-standard clearance=clearance deviation VVT cluster, as shown in the figure.
value)
Painting marks
Thickness of used tappet: 5.35mm
5.35mm+0.16mm=5.51mm
5-12
BYD S6, S6A, S6K Service Manual
6) Make sure that the timing mark on the bearing cap bolts.
sprocket of the intake camshaft is in
alignment with that on the camshaft 12) As shown in the figure, tighten the ten
bearing cap. bolts in sequence.
Painting marks
Exhaust
Fix
10) Check the forward mark and number of 15) Check whether the timing mark on the
the exhaust camshaft bearing cap, and camshaft sprocket is in alignment with
check their sequences as shown in the that on the crankshaft vibration-damp-
figure. ing pulley. Rotate the crankshaft vibra-
tion-damping pulley by 2 turns, and
then check whether the timing mark on
the camshaft sprocket is in alignment
with that on the crankshaft vibration-
damping pulley again.
5-13
BYD S6, S6A, S6K Service Manual
7 seg.
Painting marks Painting marks
Slot
cylinder-head cover.
5-14
BYD S6, S6A, S6K Service Manual
Note: Be sure to avoid any damage to the 10) Remove the tensioner cluster.
contact surfaces between cylinder block Remove the bolts and nuts, and then take out
IUDPHDQGRLOSDQ the tensioner cluster.
8) Remove the chain tensioner.
5-15
BYD S6, S6A, S6K Service Manual
12) Remove the engine oil pump. (4) Remove the plane sealant thoroughly
from the joint surfaces between the tim-
(1) Remove the studs of the drive-tension- ing cover and the cylinder head or cyl-
er cluster from the cylinder block with inder block with a blade.
the E6 ring wrench.
Note: Be sure to avoid any scratch to the
(2) Remove the bolt(M6), 8 bolts(M8), 3 joint surfaces of the cylinder block, cylin-
bolts(M10) and 2 nuts (M6) in the order GHUKHDGRUWLPLQJFRYHU%HVXUHWRZUDS
from outside to inside as well as from the screwdriver with adhesive tape before
both sides to the middle. XVLQJLW
Stud
5-16
BYD S6, S6A, S6K Service Manual
1) Install the half-round key and the crank- key is upward. Mount the chain onto the
shaft sprocket. crankshaft sprocket, and make sure that
the coloured chain piece on the chain is
2) Install the chain guide plate. in alignment with the timing mark on the
(1) Install the chain guide plate with the exhaust camshaft sprocket.
2 bolts. Coat thread sealant onto the
bolt A mounted on the cylinder block.
Half-roun
Torque: 9.0 N·mDŽ d key
Timing marks
Torque: 19 N·m
Timing marks
Timing marks
(3) Using the crankshaft pulley bolt cluster, 5) Install the oil pump.
rotate the crankshaft until the half-round
5-17
BYD S6, S6A, S6K Service Manual
Seal diameter
Seal diameter
Seal
diameter
Seal diameter
5-18
BYD S6, S6A, S6K Service Manual
6) Install the chain tensioner assembly. chain tensioner while checking whether
the chain tensioner’s plunger is moving.
(1) Be sure to ensure that the 2 studs on Make sure that the chain tensioner has
the timing cover have been installed been installed in place.
in place before installing the chain
tensioner. Lubricate the plunger of the 7) Install the front bracket cluster.
chain tensioner before installation.
Install the front bracket cluster with the 3
(2) Loosen the limit stop, and push into the bolts.
plunger completely and use the hasp
to hook the hanger pin to enable the Torque: 54N·m.
plunger to stay at the position as shown
in the figure.
Lift
Clipper
Hook
Pin
Torque
Nut: 30 N·m.
Bolt: 60 N.m
Front part
of engine
5-19
BYD S6, S6A, S6K Service Manual
(4) Tighten the 14 bolts in the order as (3) As shown in the figure, coat sealant
shown in the figure. Wipe off the sur- onto the roots of the crankshaft pulley
plus sealing materials extruded with a bolts, and then install the crankshaft
5-20
BYD S6, S6A, S6K Service Manual
pulley bolt cluster to the front end of the (4) As shown in the figure, install the cylin-
crankshaft. Torque:170 N·m der-head cover bolts in the order.
Torque:
Paint a round of plane sealant on the
back and front of gasket
Bolt 1,2: 14 N.m
(2) Coat sealant onto the joint surfaces Torque: 9.0 N·m
between the cylinder head and the tim-
14) Install the alternator assembly.
ing cover, with a colloid diameter of
4.0~4.5 mm, i.e., the 2 positions as 15) Install the V-shaped multi-wedge belt.
shown in the figure.
16) Add oil to the engine.
Note: Be sure to remove any oil on the
FRQWDFWVXUIDFHV$IWHUFRDWLQJSODQHVHDO- 17) Check the engine oil for leakage.
ant, make sure to install the cylinder-head
FRYHU ZLWKLQ PLQXWHV 2WKHUZLVH LW LV 25 Inspection of spark plugs
proper to remove the used residue and re- Note: When the engine is hot, its oil tem-
FRDWVHDODQW$IWHULQVWDOOLQJWKHF\OLQGHU SHUDWXUH LV KLJK :KHQ UHPRYLQJ DQG
head cover, don’t add oil to the engine installing the components, be sure to be
XQWLOKRXUVODWHU FDUHIXOQRWWREHEXUQW
5-21
BYD S6, S6A, S6K Service Manual
Grounding
1.0 to 1.1mm
(1) Increase the engine speed to 4000rpm If there would be any deposited carbon on
quickly, and repeat 5 times. the spark plug electrode, be sure to clean it
with the spark plug cleaner. Barometric pres-
(2) Remove the spark plug, and observe sure: 588 kPa; Duration: not more than 20
the spark plug electrode. seconds.
5-22
BYD S6, S6A, S6K Service Manual
5-23
BYD S6, S6A, S6K Service Manual
5-24
BYD S6, S6A, S6K Service Manual
PCV valve
washer
5-25
BYD S6, S6A, S6K Service Manual
Dipstick
Dipstick tube
Dipstick tube
O-ring
5-26
BYD S6, S6A, S6K Service Manual
(1) Inspection of clutch plate assembly (1) Measure the run-out of the rear end
of the flywheel with a magnetic frame
Measure the depth of the rivet heads type dial gauge. Allowed maximum run-
on the friction lining with a vernier out:0.1 mm If necessary, replace the
caliper. Minimum depth: 0.3 mm. If flywheel.
necessary, replace the clutch plate as-
sembly. 2.6.13 Disconnect the terminal connector
from the ignition coil. Remove the
Measure the run-out of friction lining mounting bolts of the ignition coil.
with a magnetic frame type dial gauge Remove the ignition coil. Remove the
and a deflection tester. Allowed maxi- spark plug.
mum run-out: 0.8 mm.
5-27
BYD S6, S6A, S6K Service Manual
Stud
5-28
BYD S6, S6A, S6K Service Manual
Exhaust
Intake
5-29
BYD S6, S6A, S6K Service Manual
Retard side
path
Advanced
side path
Recommendation: Only turn the camshaft
timing gear to the side of advance angle
ZLWKDLUSUHVVXUH0HDQZKLOHLILWZDVGLI-
ficult to apply a pressure due to air leak-
age at the interface, it would be not easy
Off Open circuit
WRXQORFN
Open Off
Remove the bolts of the camshaft tim-
circuit
ing gear.
5-30
BYD S6, S6A, S6K Service Manual
5-31
BYD S6, S6A, S6K Service Manual
0.129~0.2mm.
5-32
BYD S6, S6A, S6K Service Manual
5-33
BYD S6, S6A, S6K Service Manual
Compress and remove the valve col- (5) Remove the valve-spring retainer (lower)
lets with the tool T and wooden block.
Using compressed air to blow air onto the
valve-spring retainer (lower), remove it
with the magnetic probe.
Block
5-34
BYD S6, S6A, S6K Service Manual
PDNHVZDWHURULVHURGHGUHSODFHLW
(7) Remove the studs. (1) Check the flatness of the cylinder head.
(8) Removal of intake valve guide (2) Using the precision straightedge and
feeler gauge, check and measure the
Heat the cylinder head up to flatness of the contact surfaces with the
80~100°C. cylinder block and the exhaust mani-
fold.
Put the cylinder head on the wooden
block.
5-35
BYD S6, S6A, S6K Service Manual
Note
5-36
BYD S6, S6A, S6K Service Manual
Specified condi-
Item
(7) Inspection of camshaft oil clearance tions
Intake camshaft bearing
0.070mm
Clean the bearing cap and the cam- hole (first journal)
shaft journal. Exhaust camshaft bear-
0.100mm
ing hole (first journal)
Put the camshaft on the cylinder head. Other journal of cam-
0.12mm
shaft
Put a plastigauge across each cam-
shaft journal. If the oil clearance exceeds the maxi-
mum value, replace the camshaft. If
Install the camshaft bearing cap. necessary, replace the cylinder head.
Note If the oil clearance of the first journal
Don’WURWDWHWKHFDPVKDIW of the camshaft exceeds the maxi-
mum value, select and install a new
Remove the bearing cap. camshaft bearing shell.
Measure the widest point of oil clear-
ance with the plastigauge.
5-37
BYD S6, S6A, S6K Service Manual
Grouping of intake camshaft bearing hole (first (9) Check the intake valve.
journal)
Scrape off the deposited carbon on
Specified condi- the top of the intake valve with the
Item gasket scraper.
tions
Group A of intake cam-
40.000~40.008mm
shaft bearing hole
Group B of intake cam-
40.008~40.017mm
shaft bearing hole
Group C of intake cam-
40.017~40.025mm
shaft bearing hole
Specified condi-
Item
tions
Group A 2.000~2.004mm
Group B 2.004~2.008mm Measure the full length of intake valve
Group C 2.008~2.012mm with the vernier caliper.
Standard full-length:101.7mm.
(8) Check the internal compression spring.
Minimum full-length:101.2mm.
Measure the free length of valve
spring with the vernier caliper. Free If the full-length is less than the minimum
length:47.43mm. If the free length is value, replace the intake valve.
inconsistent with the specified value,
replace the valve spring.
Overall
length
Deviation
Measure the intake valve stem
diameter with the micrometer
screw gauge. Intake valve stem
diameter:5.465~5.480mm. If the in-
take valve diameter is inconsistent
with the specified value, check the oil
clearance.
5-38
BYD S6, S6A, S6K Service Manual
Overall
length
5-39
BYD S6, S6A, S6K Service Manual
Subtract the measured diameter of If the oil clearance is more than the maximum
the exhaust valve stem from the mea- value, replace the tappet. If necessary, re-
sured inner diameter of the exhaust place the cylinder head.
valve guide.
(14) Check the cylinder-head bolts.
Standard oil clearance:0.04~0.075mm.
Measure the length from the bolt seat
Maximum oil clearance: 0.100mm. to the bolt end of the cylinder-head
bolt with the vernier caliper.
If the clearance is more than the maximum
value, replace the exhaust valve and the ex-
haust valve guide.
Length
5-40
BYD S6, S6A, S6K Service Manual
5-41
BYD S6, S6A, S6K Service Manual
4) Check the connecting-rod bolts. Note: Because the piston and piston pin
are in pairs, be sure to put the piston, pis-
Measure the diameter of the connecting-rod ton pin, piston rings, connecting rod and
bolt shank with a vernier caliper. There are EHDULQJVKHOOVLQDSURSHURUGHU
two types of bolts, with a minimum diameter
of ¶8.3mm or ¶7.5mm, respectively. 9) Check the piston.
5) Remove the connecting rod. (1) Clean up the deposited carbon on the
piston with a used piston ring or other
Push the piston and connecting-rod assembly similar tool.
as well as the connecting-rod bearing shell
(upper) to allow it to pass through the cylin- (2) Remove the residual deposited carbon
der bore. Take out the piston and connecting- on the piston with special solvent.
rod assembly from the upper end face of the Note: When operating, be sure to wear a
cylinder block. In turn, take out the four piston SDLURISURWHFWLYHJODVVHV0HDQZKLOHPDNH
and connecting-rod assemblies. VXUHWRDYRLGVFUDWFKWRWKHSLVWRQVXUIDFH
Note: Install the removed connecting rod (3) Measurement of piston skirt.
DQGFRQQHFWLQJURGEHDULQJVKHOOLQSODFH
Mark the piston and connecting-rod as- As shown in the figure, perpendicular to the
semblies based on the cylinder sequence, piston pin, at a distance 12mm from the pis-
DQGSXWWKHPLQSODFH ton bottom, measure the size of piston skirt.
Piston skirt diameter:¶88.469~88.489mm.
6) Remove the piston ring kit.
5-42
BYD S6, S6A, S6K Service Manual
(4) Check the piston ring play. Measure the piston-pin diameter with a mi-
crometer. Standard piston-pin diameter:
Insert a new piston ring into the piston ring
groove and check the clearance in the piston ¶21.997~¶22.006DŽ
ring groove with a feeler.
Group number 3iston pin
Standard clearance A ¶22˄-0.003, 0˅
Item
(mm)
1st compression ring 0.03 ~ 0.07 B ¶22˄0, +0.003˅
5-43
BYD S6, S6A, S6K Service Manual
Note: Don’WURWDWHWKHFUDQNVKDIW
5-44
BYD S6, S6A, S6K Service Manual
Filter screen
Shim
Screw
plug
5-45
BYD S6, S6A, S6K Service Manual
from the cylinder deck, measure the Front side Lower side
Pin A
Extruding
Pin B
height
Check the piston oil clearance. Pin C
Pin D
1) Clean the components of engine thor- 4) Install the double end studs of the cylin-
oughly. Make sure that there is no der block.
impurity in the oil passages or water
channels. Install the double end studs of the thermostat
cover, heater water-return pipe and water
2) Install the oil cooling nozzle. pump with a tightening torque: 5 N · m.
Before installation, lubricate the mounting 5) Install the oil filter cluster.
valve of the oil cooling nozzle. Screw in the 4
hexagon socket cap head screws (M6 × 12). Install the strainer screen fitting, gasket and
Tightening torque: 7 N.m screw plug of the filter in the main oil pas-
sage. Coat the screw plug with thread seal-
ant. Tightening torque: 30N.m.
Front
engine(the
side with water
pump scroll
casing)
Gasket
Screw plug
Install the positioning cylindrical pin in place 6) Assemble the main bearing shell.
at the position as shown in the figure. Install the main bearing shell (upper) with oil
5-46
BYD S6, S6A, S6K Service Manual
When installing the crankshaft, make sure to Note: Before screwing in the bolts of main
allow the crankshaft main journal to be con- bearing cap, be sure to coat some oil onto
sistent with the main journal mounting pedes- WKHEROWWKUHDG
tal in the cylinder block. 4) After completion of assembly, rotate the
2) Install the crankshaft thrust plates. crankshaft. Make sure that the crank-
shaft can turn freely and smoothly.
After installing the crankshaft thrust plates, be
sure to paint the right amount of gasoline en- 5) Install the half-round key in the crank-
gine oil into their oil grooves. shaft.
Note: Make sure to enable the oil groove 2.7.3 Installation of piston and connecting-
surfaces of the two thrust plates to face rod assembly
WKHFUDQNDUP 1) Select new round wire snap rings for
3) Install the main bearing cap. hole. Install the round wire snap ring for
hole at the end of piston pin hole. Stag-
(1) Install the main bearing shell (lower) ger the end notch of the snap ring with
into the main bearing cap. Meanwhile, the notch portion of the piston pin hole.
coat the right amount of gasoline en-
gine oil onto the friction surface of the
main bearing shell. Assemble the main
bearing cap according to the number of
bearing seat. Make sure to enable the
arrow mark on the main bearing cap to
direct to the front end of cylinder block
(i.e., the end with water-pump volute).
5-47
BYD S6, S6A, S6K Service Manual
Forward mark
Front engine Piston pin center
Round indentation
mark on the top of
piston
5-48
BYD S6, S6A, S6K Service Manual
5-49
BYD S6, S6A, S6K Service Manual
Standard diameter:10.3~10.318mm.
Alignment
position (2) Shrink the valve guide with cold liq-
uid nitrogen before pressing it into the
Drain plug valve guide hole in the cylinder head.
Extruding
height
5-50
BYD S6, S6A, S6K Service Manual
Wrong
Correct
5-51
BYD S6, S6A, S6K Service Manual
2.7.8 Put the adjusted tappet into the cylin- 3) Coat a layer of engine oil onto the
der-head tappet hole in the specified camshaft journal, and install it onto the
order. cylinder head. Put back the camshaft
bearing caps in the specified order, and
2.7.9 Install the intake and exhaust cam- tighten them in the order as shown in
shafts separately. the figure. Bearing cap(first journal):30
1) Installation of intake VVT cluster N·m, others:9 N·m.
Straight pin
Key slot
5-52
BYD S6, S6A, S6K Service Manual
(2) As shown in the figure, coat seal- Note: After completion of installation of
ing materials within the continu - water pump, make sure that the water
ous coating line. Standard sealing pump can rotate smoothly without any ab-
diameter:2.2~2.5mm. QRUPDOQRLVH
Note
5-53
BYD S6, S6A, S6K Service Manual
No breakpoint is permitted. Install the surface of the seal ring of the oil filter.
oil pan assembly within 3 minutes after
coating sealing materials. 3) Accordingly, screw in the connecting
threaded pipe to the end to the torque
of 13N·m. If the work environment is
not spacious enough to use a torque
Plane sealant
wrench, you can screw the oil filter
gently in the connecting threaded pipe
at first, until it adjoins the mounting sur-
face, and then screw in it to 3/4 ~1 turn
again.
Bolt:60 N·m.
5-54
BYD S6, S6A, S6K Service Manual
Hex head of
Tension mechanism
assembly
5-55
BYD S6, S6A, S6K Service Manual
ing cover with sealant. Make sure to al- 2.7.25 Installation of flywheel cluster
low the colloid diameter to be between
3mm~4mm. 1) Make sure that the surface of flywheel
cluster is clean. No oil dirt is permitted.
Note: Remove any oil on the contact sur- Before installation, make sure that the
IDFHV 0DNH VXUH WKDW WKHUH LV QR RLO RU flywheel positioning pins (M6 × 12) on
impurity on the contact surfaces of the the crankshaft have been installed in
cylinder head and timing cover before place.
FRDWLQJ VHDODQW RQ WKHP$IWHU FRDWLQJ
plane sealant, be sure to perform instal- 2) Put the flywheel cluster in place.
ODWLRQ ZLWKLQ PLQXWHV 2WKHUZLVH LW LV 3) Install the 8 bolts which have been pre-
proper to remove the used residue and re- coated with the right amount of anaero-
FRDWVHDODQW$IWHULQVWDOOLQJWKHF\OLQGHU bic thread sealant into the flywheel. Fix
head cover, don’t add oil to the engine the crankshaft with the special assis-
XQWLOKRXUVODWHU tant tool. Tighten the bolts to the speci-
fied torque in the diagonal direction in
several steps with the cross method, as
shown in the figure. Torque: 98 N · m.
Torque:
Bolts 1 and 2: 14 N · m;
5-56
BYD S6, S6A, S6K Service Manual
O - ring
2) Install the oil pressure switch with a
long socket wrench. Torque: 15 N · m.
Engine oil
pressure switch
Coolant Temp Sensor
2.7.28 Installation of coolant temperature
sensor
5-57
BYD S6, S6A, S6K Service Manual
Upper part
5-58
BYD S6, S6A, S6K Service Manual
Upwards
Vent valve
2) Fit the canister control valve and its
mounting sleeve into the bracket. Con-
nect the canister control valve with the
intake manifold through the canister
connecting pipe, and clamp it with the
wire-type elastic hoop. 3) Install the thermostat cover and tighten
its nuts. As shown in the figure, be sure
3) Fit the vacuum booster bracket into the to make the thermostat cover’s bending
intake manifold cluster bracket, and angle downward. Torque:9 N·m.
tighten the bolts. Torque:9 N·m.
5-59
BYD S6, S6A, S6K Service Manual
2.7.39 Installation of exhaust manifold and its 5) Install the two exhaust manifold
heat shield brackets(left and right) in place and
tighten the nuts and bolts. Tightening
1) Install the front oxygen sensor in place. torque: 44 N.m
Its mounting position is shown in the
figure. Tighten it to the specified torque. 2.7.40 Installation of starter and crankshaft
Torque: 44 N · m. position sensor Install the starter in the
position as shown in the figure with the
2) Install the exhaust manifold heat shield two bolts. Torque: 39 N · m.
II and three-way catalytic converter
heat shield onto the exhaust manifold,
and tighten the bolts.
5-60
BYD S6, S6A, S6K Service Manual
Note: Don’WDGGRLOWRH[FHHGWKH%PDUN 3.3.4 Remove the oil filter with the special
tool.
Special tool
SJ grade and above 10W-30 (in spring, sum- 3) Accordingly, screw in the connecting
mer and autumn in the north and in each sea- threaded pipe to the end to the torque
son in the south) of 13N·m. If the work environment is
not spacious enough to use a torque
SJ grade and above 5W-30 ( used for North- wrench, you can screw the oil filter
ern regions in winter) gently in the connecting threaded pipe
at first, until it adjoins the mounting sur-
Replacement of the engine oil face, and then screw in it to 3/4 ~1 turn
again.
Note:
When the engine is hot, the oil tem- 4) Refill the engine with the recommended
perature is high, be sure to avoid oil.
VFDOGLQJ\RX
:DVWHRLOFDQEHFDUFLQRJHQLF$IWHU
replacement of oil, wash your skin
5-61
BYD S6, S6A, S6K Service Manual
7) Check the engine oil level. If necessary, 1) Shut off the engine and let it cool down.
add oil to the engine.
2) Remove the oil pressure gauge and
Checking engine oil pressure commutator.
Note: When the engine is hot, its oil tem- 3) As shown in the figure, coat the oil
SHUDWXUH LV KLJK ZKLFK FDQ VFDOG \RX pressure switch thread with thread
Always shut off the engine and let it cool sealant.
GRZQEHIRUHSHUIRUPLQJRSHUDWLRQ
5-62
BYD S6, S6A, S6K Service Manual
5-63
BYD S6, S6A, S6K Service Manual
External
rotor
Internal
rotor
Engine oil
Front crankshaft
pump cover
oil seal
Relief
al e
Engine oil
collector
Relief valve
Timing spring
cover body
Pressure-limiting
valve spring seat
Maximum clearance:0.1mm.
2) Check the radial fit clearance between 4) As for inspection of pressure limiting
the external rotor and the oil pump valve spring, apply a certain pressure
body. The standard clearance is be- to the spring and check the spring
tween 0.160~0.236 mm. height. If necessary, replace the pres-
Maximum clearance:0.32mm. sure limiting valve spring.
5-64
BYD S6, S6A, S6K Service Manual
Pressure-limiting
valve spring seat Hexagon Oil collector components
socket cap
head
screw
5-65
BYD S6, S6A, S6K Service Manual
Cylindrical
location pin
Nut Nut
Seal diameter
Stud
Seal diameter
Seal
diameter
Seal diameter
10) Install the chain tensioner assembly.
Seal diameter
units
(1) Be sure to ensure that the 2 studs on
the timing cover have been installed
in place before installing the chain
8) As shown in the figure, coat the joint
tensioner. Lubricate the plunger of the
surfaces between the cylinder block
chain tensioner before installation.
and the cylinder head as well as be-
tween the cylinder block and its frame (2) Loosen the limit stop, and push into the
with sealant. Make sure to allow plunger completely and use the hasp
the sealant diameter to be between to hook the hanger pin to enable the
4.0~4.5mm. plunger to stay at the position as shown
in the figure.
Seal material Seal material
Lift
Clipper
Seal material
Seal material
Hook
Pin
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BYD S6, S6A, S6K Service Manual
5-67
BYD S6, S6A, S6K Service Manual
DUHFRROEHIRUHUHPRYLQJWKHUDGLDWRUFDS Recommendations:
Avoid scalding caused by high pressure
DQGWHPSHUDWXUHHQJLQHFRRODQWRUYDSRU 3XW WKH XVHG FRRODQW LQ DQ DSSURSULDWH
container and dispose of it according to
2) Check whether there is excessive rust WKHORFDOUHJXODWLRQV
or scale deposit around the radiator cap
and the radiator filler opening. Mean- 4.2.2 Adding engine coolant
while, no oil in coolant is permitted. If 1) Screw in the drain plug of the radiator
there is excessive dirt, clean the cool- and reinstall the two drain bolts of the
ant passage and replace the coolant. cylinder block.
3) Reinstall the radiator cap. 2) Pour coolant into the radiator slowly up
2 Replacement and refilling of to the FULL line.
coolant Note: Don’W XVH ZDWHU LQVWHDG RI FRRODQW
5H¿OOLQJLPSURSHUFRRODQWFDQFDXVHGDP-
Note: DJHWRWKHHQJLQHFRROLQJV\VWHP
When the engine is running, cool-
ing system shall have enough cool- 3) Push down the inlet and outlet of radia-
ant to ensure the engine works nor- tor hose several times by hand, and
PDOO\ 2WKHUZLVH WKH YHKLFOH ZLOO check the coolant level. If the level is at
become “boiling” or below the LOW line, add coolant to
bring it up to the FULL line.
If the engine is overheated, service
OLIH RI WKH HQJLQH ZLOO EH DIIHFWHG 4) Reinstall the radiator cap subassembly
6HULRXVO\VFXI¿QJRIF\OLQGHUERUH and the reserve tank cap.
PD\RFFXU
To avoid scalding, don’t remove the 5) Start the engine to enable the fan to
UDGLDWRUFDSZKHQWKHHQJLQHLVKRW work.
4.2.1 Draining engine coolant When the engine is hot, set the air condition-
ing according to the following requirements:
1) Remove the radiator cap subassembly Air conditioning air-supply speed setting: Ar-
from the radiator assembly. bitrary setting except closing air supply.
2) Loosen the drain plug on the bottom of Temperature setting: Heating.
the radiator and remove the drain bolts
from the cylinder block to drain the Air conditioning switch: OFF.
coolant. 6) Shut off the engine and let the engine
coolant cool down.
Radiator cover
Cylinder exhaust
Notices for replacing and adding the en-
stopcock JLQHFRRODQW:KHQUH¿OOLQJDGGLQJRUUH-
Radiator exhaust
stopcock placing the coolant, make sure that the car
LVSDUNHGRQOHYHOJURXQG
Thermostat
4.3.1 Removal of thermostat
5-68
BYD S6, S6A, S6K Service Manual
battery terminal.
Upwards
Vent valve
5-69
BYD S6, S6A, S6K Service Manual
5) Check the coolant for leakage. (1) Remove the 4 bolts and 2 nuts.
(4) Remove the harness clamp. Note: Be careful not to cause damage to
the contact surfaces between the water
(5) Remove the 2 bolts and the alternator SXPS DQG WKH F\OLQGHU EORFN :UDS WKH
assembly. screwdriver tip with adhesive tape before
XVLQJWKHVFUHZGULYHU
5-70
BYD S6, S6A, S6K Service Manual
Air hole
Exhaust hole
5-71
BYD S6, S6A, S6K Service Manual
5-72
BYD S6, S6A, S6K Service Manual
Contents
Section 1 Reserve
Section 2 S6—Fuel Supply System, Intake System, Mounting System 6-22
1. S6 Fuel Supply System .................................................................................6-24
2. S6 Intake System ...........................................................................................6-32
3. S6 Mounting System ......................................................................................6-34
Section S6A, S6K— Fuel Supply System, Intake System, Mounting System 6-0
1. S6A, S6K Fuel Supply System.......................................................................6-42
2. S6A, S6K Intake System................................................................................6-50
3. S6A, S6K Mounting System...........................................................................6-52
Section Engine Cooling System 6-59
1. Component Location Index ............................................................................6-59
2. Radiator cover test .........................................................................................6-61
3. Radiator test ..................................................................................................6-61
4. Fan motor test ...............................................................................................6-61
5. Water pump test ............................................................................................6-61
6. Replacing water pump....................................................................................6-62
7. Checking and replacing coolant .....................................................................6-62
8. Testing and replacing thermostat ..................................................................6-63
9. Replacing radiator and fan ............................................................................6-64
10. Installing the waterway ..................................................................................6-64
Section 5 Exhaust System6-65
1. S6 Exhaust System ........................................................................................6-65
2. Reserve
3. S6A, S6K Exhaust System .............................................................................6-67
6-I
BYD S6, S6A, S6K Service Manual
Label Tool No Name 4ty (1) Start the engine and check MIL (A).
O2 Sensor
ķ 07LAA-PT50101 1
Socket Wrench
Oil Pressure
ĸ 07NAJ-P070100 Gauge Acces- 1
sories
Fuel Pressure
Ĺ 07ZAJ-S5A0100 1
Gauge Device
Fuel Hose At-
ĺ 07ZAJ-S7C0100 1
tachment
Hoses, Engine
Ļ 07ZAJ-S5A0200 1
Oil Pressure
(2) If MIL is constantly lit, connect the PGM
Low Pressure
ļ 07406-0070001 1 tester or BYD diagnostic apparatus to
Gauge
Fuel Pressure the data link connector (DLC) (A) below
Ľ 07406-0040002 1 the instrument panel at driver’s side.
Gauge
6-22
BYD S6, S6A, S6K Service Manual
3OHDVHUHIHUWRWKH8VHU’s Manual of
BYD tester or BYD diagnostic appa-
UDWXVIRUVSHFL¿FRSHUDWLRQ
(5) If DTC is found, go to MIL troubleshoot-
ing.
6-23
BYD S6, S6A, S6K Service Manual
6-24
BYD S6, S6A, S6K Service Manual
If you suspect that the fuel pump has a fault, (4) Turn the ignition switch to OFF.
please check whether the pump is running:
when it is turned on, there a sound near the Note:
fill inlet if the cap is removed. When the igni- This program allows setting DTC
tion switch is connected for the first time, the RU WHPSRUDU\ '7& &KHFN WKH '7&
fuel pump should run for two seconds. If the DQGFOHDULIQHFHVVDU\
fuel pump doesn’t sound, perform the follow- Do not use BYD tester or BYD diag-
ing checks: nostic apparatus
(1) Turn the ignition switch to OFF. Before disconnecting fuel pipeline
or hose, disconnect the fuel pipe in
(2) Remove the stepboard, and then take the engine compartment and thus
out PGM-FI MAIN RELAY 2 (FUEL release the fuel pressure in the
PUMP) (A) from the fuse/relay box un- V\VWHP
der the cap.
(1) Make sure that you have known the
password of audio and navigation sys-
tem, and then record the frequency of
customer’s radio channel presetting
button.
6-25
BYD S6, S6A, S6K Service Manual
(10) Unplug the hose (A) from the joint, and If the engine isn’t started, go to step
prevent the remaining fuel outflowing (4).
from the fuel distributor or hose with the (4) Check whether the fuel pump is run-
rag or maintenance cloth. ning: remove the fuel tank cover and
Do not use any tool, to avoid damaging listen in the filler inlet. When the ignition
the hose. switch is connected for the first time,
the fuel pump should run for two sec-
(11) After the nylon pipe is disconnected, onds.
check whether there is any dirt or dam-
age. If the fuel pump is running, go to step
(5).
(12) Reconnect the negative cable to the
battery and do the following: If the fuel pump isn’t running, imple-
ment fuel pump circuit troubleshooting
ECM/PCM idle learning process (see pp. 11-195).
Electric window control unit resetting process (5) Read the fuel pressure gauge, the read-
ing of which should be 320-370kPa.
Enter the password of radio device and navi-
gation system, and then enter the preset fre- If the fuel pressure is normal, finish
quency of radio channel. the test.
6-26
BYD S6, S6A, S6K Service Manual
15 Draining the fuel tank nector (G) are not heat resistant; do
not damage these parts while welding
Remove the fuel pump assembly. or other heating operations.
Use hand pump, hose and container suitable Fuel delivery hose (B), fuel line (C),
for gasoline to draw the fuel from the fuel fuel delivery hose (E) and quick con-
tank. nector (G) are not heat resistant; do
not contact these parts with the towel
for wiping battery electrolyte. Replace
any part that contacts the electrolyte
or similar liquid.
6-27
BYD S6, S6A, S6K Service Manual
6-28
BYD S6, S6A, S6K Service Manual
17 Replacing fuel filter (6) Take out the fuel pump from the tank
(3) Loosen the mounting bolts of fuel filter Install the new fuel pump in the reverse order.
and bracket assembly.
Note: when install the new fuel pump,
(4) Take out the fuel filter and bracket as- make sure that the O-ring of the pump is
sembly from the vehicle. LQVWDOOHGLQSRVLWLRQ
Installing fuel filter 19 Replacing fuel tank
(1) Remove the protective cover of the new Disassembly
fuel filter.
(1) Release fuel pressure.
(2) Install the fuel filter and bracket assem-
bly to the vehicle in proper direction (2) Remove the manhole cap of the fuel tank
with mounting bolts.
(3) Remove the electrical connector of the
(3) Tighten the fixing bolts. fuel pump
(3) Connect the fuel inlet/outlet pipe on (4) Disconnect the filler hose (A) and filler
both sides of the fuel filter. ventilation hose II (B).
6-29
BYD S6, S6A, S6K Service Manual
(5) Disconnect the fuel inlet nylon pipe I 110 Fuel Evaporation and 3urification
(A) from the fuel filter (C), disconnect System
the oil return nylon pipe (B) from the oil
return pipe (D), and disconnect the fuel
evaporation hose III (E) from the oil re-
turn pipe (F) in sequence.
Installing
6-30
BYD S6, S6A, S6K Service Manual
Silicone grease
6-31
BYD S6, S6A, S6K Service Manual
Replacement steps:
6-32
BYD S6, S6A, S6K Service Manual
1 2 3 4 5
Fig.7-18
6-33
BYD S6, S6A, S6K Service Manual
S6 Mounting System
1 3arts Location and Distribution Description
11 3arts Location
6-34
BYD S6, S6A, S6K Service Manual
Engine left mounting bracket assembly: 2) Remove the two bolts that connect the
installed onto the left longeron of the body front mounting support assembly and
with four Q1841225TF3 bolts. the cross member of sub-frame (as
shown in Fig.7-20 below), and then
They are connected with one take out the engine front mounting sup-
BYDQ184A12125TF3 bolt and one port assembly.
BYD450A12T1F hexagonal nut
Fig.7-20
6-35
BYD S6, S6A, S6K Service Manual
Fig.7-22
Fig.7-24
6-36
BYD S6, S6A, S6K Service Manual
2 Installing Engine Rear Mounting As- train assembly with crane.
sembly
26 Disassembling Engine Right Mount-
1) Tighten the three bolts to the replaced ing Assembly
the engine rear mounting bracket as-
sembly as shown in Fig.7-24, and tight- 1) Remove the two nuts and one bolt that
en the torque. connect the engine right mounting as-
sembly and the engine (as shown in
2) Place the replaced engine rear mount- Fig.7-25).
ing support assembly into the installa-
tion position as shown in Fig.7-23, and
tighten the two bolts connected to rear
mounting support and cross member of
sub-frame. Then, tighten the cross bolt
connected to rear mounting bracket as-
sembly and rear mounting support as-
sembly.
25 Torque Check
6-37
BYD S6, S6A, S6K Service Manual
Fig.7-29
Fig.7-27
Fig.7-30
Fig.7-28
Fig.7-31
6-38
BYD S6, S6A, S6K Service Manual
29 Installing Engine Left Mounting As- Installing Related Engine Accesso-
sembly ries
1) Place the replaced engine left mounting 1 Installing Air Filter
support assembly in the position shown
in Fig.7-31 and then tighten the four 1) Place the removed lower housing of the
nuts on the transmission flange bolts. air filter to the position shown in Fig.7-
32, align to the three mounting holes
2) Place the replaced engine left mount- in the left mounting support and then
ing bracket assembly into the position tighten the three bolts respectively.
shown in Fig.7-30, tighten the four bolts
into the mounting holes respectively,
and tighten the torque.
2) Tighten the torque of the two nuts and 2) Insert the intake elbow into the air in-
one nut on the engine right mounting take in the engine, tighten the clamp,
bracket and engine flange bolt to 85N. insert the filter element, put on the up-
m (as shown in Fig.12-7). per housing of the air filter, and clamp
the four snaps on the air filter housing.
3) Tight the torque of the four bolts con-
necting the engine left mounting sup-
port assembly and the body to 85N.m
(as shown in Fig.7-30).
6-39
BYD S6, S6A, S6K Service Manual
6-40
BYD S6, S6A, S6K Service Manual
6-41
BYD S6, S6A, S6K Service Manual
1 S6A,S6K FuelSupplySystem
1) Component Location Index
6-42
BYD S6, S6A, S6K Service Manual
If you suspect that the fuel pump has a fault, (4) Turn the ignition switch to OFF.
please check whether the pump is running:
when it is turned on, there a sound near the Note:
filler inlet if the cap is removed. When the This program allows setting DTC
ignition switch is connected for the first time, RU WHPSRUDU\ '7& &KHFN WKH '7&
the fuel pump should run for two seconds. If DQGFOHDULIQHFHVVDU\
the fuel pump doesn’t sound, perform the fol- Do not use BYD tester or BYD diag-
lowing checks: nostic apparatus
(1) Turn the ignition switch to OFF. Before disconnecting fuel pipeline
or hose, disconnect the fuel pipe in
(2) Remove the stepboard, and then take the engine compartment and thus
out PGM-FI MAIN RELAY 2 (FUEL release the fuel pressure in the
PUMP) (A) from the fuse/relay box un- V\VWHP
der the cap.
(1) Make sure that you have known the
password of audio and navigation sys-
tem, and then record the frequency of
customer’s radio channel presetting
button.
6-43
BYD S6, S6A, S6K Service Manual
(8) Put a piece of rag or maintenance cloth (3) Start the engine and let it idle.
on the nylon pipe fitting (A).
If the engine is started, go to step (5).
(9) Unplug the nylon pipe fitting (A) from
the joint, and prevent the remaining fuel If the engine isn’t started, go to step
outflowing from the fuel distributor or (4).
hose with the rag or maintenance cloth.
(4) Check whether the fuel pump is run-
Do not use any tool, to avoid damaging ning: remove the fuel tank cover and
the nylon pipe. listen in the filler inlet. When the ignition
switch is connected for the first time,
(10) After the nylon pipe is disconnected, the fuel pump should run for two sec-
check whether there is any dirt or dam- onds.
age.
If the fuel pump is running, go to step (5).
(11) Reconnect the negative cable to the
battery and do the following: If the fuel pump isn’t running, imple-
ment fuel pump circuit troubleshooting
ECM/PCM idle learning process (see pp. 11-195).
Electric window control unit resetting (5) Read the fuel pressure gauge, the read-
process ing of which should be 320-370kPa.
Enter the password of radio device and If the fuel pressure is normal, finish
navigation system, and then enter the the test.
preset frequency of radio channel.
If the fuel pressure doesn’t comply
Reset the clock. with the technical requirement, replace
the fuel pressure regulator and fuel fil-
) Fuel pressure test ter, and then re-test the fuel pressure.
Special tools required: 5) Draining the fuel tank
Fuel Pressure Gauge 07406-0040002
Remove the fuel pump assembly.
Fuel Pressure Gauge Device 07ZAJ-
Use hand pump, hose and container suitable
S5A0100
for gasoline to draw the fuel from the fuel
(1) Release fuel pressure. tank.
6-44
BYD S6, S6A, S6K Service Manual
6-45
BYD S6, S6A, S6K Service Manual
the direction of arrow with two fingers. (1) Check whether the contact area (A)
Unplug the male connector from the of the line (B) has dirt or damage, and
quick connector along the axial direc- clean or replace if necessary.
tion of the pipe.
6-46
BYD S6, S6A, S6K Service Manual
(4) Take out the fuel filter and bracket as- Note: when install the new fuel pump,
sembly from the vehicle. make sure that the O-ring of the pump is
LQVWDOOHGLQSRVLWLRQ
Installing fuel filter
9) Replacing fuel tank
(1) Remove the protective cover of the new
fuel filter. Disassembly
(2) Install the fuel filter and bracket assem- (1) Release fuel pressure.
bly to the vehicle in proper direction
with mounting bolts. (2) Remove the manhole cap of the fuel
tank
(3) Tighten the fixing bolts.
(3) Remove the electrical connector of the
(3) Connect the fuel inlet/outlet pipe on fuel pump
both sides of the fuel filter.
(4) Disconnect the filler hose (A) and filler
(4) Tighten the fuel tank cover. ventilation hose II (B).
(5) Re-connect the negative cable of the
battery.
(3) Remove the electrical connector of the (5) Disconnect the fuel inlet nylon pipe I
fuel pump (A) from the fuel filter (C), disconnect
the oil return nylon pipe (B) from the oil
(4) Remove the inlet/outlet nylon pipe of return pipe (D), and disconnect the fuel
the fuel pump evaporation hose III (E) from the oil re-
(5) Remove the elastic ring of the fuel turn pipe (F) in sequence.
pump with circlip pliers
Positioni
ng bulge Fuel inlet pipe
Harness
socket Oil return pipe
Elastic
ring Electric
fuel pump
6-47
BYD S6, S6A, S6K Service Manual
Installing
6-48
BYD S6, S6A, S6K Service Manual
(1) Disconnect fuel evaporative emission (1) Disconnect the connector of electronic
hose I (A), fuel evaporative emis- accelerator pedal
sion hose II (B) and charcoal canister
breather pipe assembly (C).
(3) Replace the charcoal canister (E). (3) Replace the electronic accelerator ped-
al (C).
(4) Install the parts in the reverse order as
removing. (4) Install the parts in the reverse order as
removing.
6-49
BYD S6, S6A, S6K Service Manual
2 S6A,S6K IntakeSystem
21 Component Location Index
Intake elbow
Air filter
Crankcase ventilation pipe
Resonator
6-50
BYD S6, S6A, S6K Service Manual
22 Replacing air filter for intake system (2) Take out filter element (6) from the air
filter chamber; Fig.7-33
221 Replacing air filter and intake hose
(3) Install the parts in the reverse order as
1) Removing/installing air filter of the removing.
intake system (Fig7-)
) Replacing intake hose (Fig7-)
(1) Loosen worm drive hose clamp, type A
(18); Unplug crankcase ventilation tube (13), loos-
en worm drive hose clamp, type A (16) and
(2) Open clip (9) that connects upper (18), and remove the intake hose (17).
housing and lower housing, remove the
upper housing (5) of the air filter 222 Removing/installing intake pipes and
and take out the filter element (6); resonator (Fig162)
(3) Remove bolt (7) (1) Remove the bolt (5), uninstall the fix-
ture at position (3), and take out the
(4) Remove lower housing (10) of the air resonator (4);
filter;
(2) Remove the bolt (6), and then take out
(5) Install the parts in the reverse order as front intake pipe (2);
removing.
(3) Remove the bolt (2), and then take out
rear intake pipe (1);
Fig.7-33
2) Replacing element of the air filter
(Fig7-)
Replacement steps:
6-51
BYD S6, S6A, S6K Service Manual
S6A,S6K MountingSystem
1 3arts Location and Distribution Description
11 3arts Location
6-52
BYD S6, S6A, S6K Service Manual
12 Distribution Description ron welding assembly and body with two
Q1841225TF6 and one Q1841230TF6
Front mounting support, powertrain as- bolt; installed onto the engine with two
sembly: installed onto the cross member of Q32012T13F6 and one Q32010T13F6 nut.
front sub-frame with two Q1841225TF6 bolts.
2 Maintenance of Mounting System
Front mounting bracket, powertrain as-
sembly: installed onto the transmission case Before disassembling the front and rear
with two Q1841225TF6 bolts. mounting of the powertrain assembly, lift the
car with a lifting gear first.
They are connected with one BYDQ184A-
10110TF6 bolt and one BYDQ350A10T13F6 21 Disassembling Front Mounting,
hexagonal nut. 3owertrain Assembly
Rear mounting support, powertrain as- 1) Remove the cross bolt and the hexago-
sembly: installed onto the front sub-frame nal nut that connect the front mounting
with three Q1841225TF6 bolts. bracket, powertrain assembly and front
mounting support, powertrain assembly
Rear mounting bracket, powertrain assem-
(as shown in Fig.7-35 below)
bly: installed onto the transmission case with
three Q1841285TF6 bolts.
6-53
BYD S6, S6A, S6K Service Manual
Fig.7-36
Fig.7-38
Fig.7-37
22 Installing Front Mounting, 3ower-
train Assembly
6-54
BYD S6, S6A, S6K Service Manual
6-55
BYD S6, S6A, S6K Service Manual
Fig.7-43
6-56
BYD S6, S6A, S6K Service Manual
Fig.7-45
6-57
BYD S6, S6A, S6K Service Manual
6-58
BYD S6, S6A, S6K Service Manual
Expansion tank
Connecting pipeassembly Expansion
assembly tank bracket
Powertrain assembly
6-59
BYD S6, S6A, S6K Service Manual
Expansion tank
bracket assembly
Powertrain assembly
6-60
BYD S6, S6A, S6K Service Manual
(2) Apply 95kPa~125kPa pressure. (2) Connect the battery anode with the
high speed terminal, and connect the
(3) Check whether the pressure drops. cathode to the grounding terminal to
(4) If the pressure drops, replace the radia- test the motor.
tor cover. (3) If the motor doesn’t run or can’t run
Radiator test smoothly, replace the electronic fan as-
sembly.
(1) When the engine is cooled, remove the
radiator cover, and fill engine coolant
5 Water pump test
into the radiator until the filler inlet. (1) Remove the timing belt.
(2) Use a small mating part H-90 122-09 (2) Rotate the water pump pulley counter-
(C) (commercially available) to install clockwise and check whether the rota-
the pressure tester (commercially avail- tion is smooth.
able) to the radiator.
(3) Check whether there is sign of seal leak-
(3) Apply 95kPa~125kPa pressure. age. It is normal that the drain hole (A)
(4) Check whether engine coolant leaks has small amount of seepage.
and whether the pressure drops.
6-61
BYD S6, S6A, S6K Service Manual
Replacing coolant
6-62
BYD S6, S6A, S6K Service Manual
(10) Shut down the engine. Check the liquid (3) Remove the steel strip elastic clamp,
level in the radiator, and refill the cool- and then unplug the radiator water pipe
ant if necessary. from the engine inlet connector of the
thermostat cover.
(11) Tighten the radiator cover, restart the
engine and check whether there is
leakage.
Standard thermostat:
6-63
BYD S6, S6A, S6K Service Manual
10x1.25mm
44N· (4.5kgf· m,33 lbf· ft
6-64
BYD S6, S6A, S6K Service Manual
Sealed gasket
Heat shield, front floor replacement
Hexagonal flange
nutM10×1.25 Big washer
56N.m Oxygen sensor
Replacement Hexagonal flange installation
nutM10×1.25 45N.m
Open type oval
56N.m
head blind rivet
Replacement
Primarymuffler
Plane sealing ring
replacement
Heat shield,rear floor
Big washer
Plane sealing ring
replacement
Secondarymuffler
6-65
BYD S6, S6A, S6K Service Manual
(4) Take out the lug rod of the front exhaust pipe from the lug;
(1) Take out the lug rod of the middle exhaust pipe from the lug;
(1) Take out the lug rod of the rear exhaust pipe from the lug;
(1) Take out the lug rod of the last exhaust pipe from the lug;
5HPRYLQJLQVWDOOLQJKHDWVKLHOGFHQWHUÀRRU
(2) Remove the open type oval head blind rivet, and take out the heat shield
5HPRYLQJLQVWDOOLQJKHDWVKLHOGUHDUÀRRU
(2) Remove the open type oval head blind rivet, and take out the heat shield
,QVWDOOWKHSDUWVLQWKHUHYHUVHRUGHUDVUHPRYLQJ
1RWH(YHU\WLPHWKHH[KDXVWSLSHDVVHPEO\LVUHLQVWDOOHGLWLVQHFHVVDU\WRUHSODFHWKH
ÀDQJHVHDOHGJDVNHWWRHQVXUHWKDWWKHWLJKWQHVVRIWKHH[KDXVWV\VWHPPHHWVWKHUHTXLUH-
PHQW
Use specified installation grease when the oxygen sensor is removed and reinstalled.
6-66
BYD S6, S6A, S6K Service Manual
S6A,S6K ExhaustSystem
Spring I
ᔍㇻĉ
Oxygen sensor
⇻Ӵᛳ఼ᅝ㺙
installation
45 N.m 45N.m
Spherical
⧗䴶ᆚᇕ ring
replacement
ᤶ
HeatЁഄᵓ䱨⛁ᵓ
shield, center floor 䖲㶎ᷧĉ
Big washer Connecting b
olt I
ൿ
45±5N.m
45±5N.m
Replacement
ᤶ
Open type oval head
ᓔষൟ᠕༈
blind rivet
ᢑ㢃䪚䩝 ݁㾦⊩݄䴶㶎ᷧ
Hexagonal flange nut
M10×1.25
M10×1.25
݁㾦⊩݄䴶㶎ᷧ 56N.m
56 N.m
M10×1.25 Replacement
ᤶ
Hexagonal flange nut
56 N.m
M10×1.25
ᤶ
56N.m
Replacement ᑇ䴶ᆚᇕĉ
Plane sealing ring I
ᤶ
replacement
Primarymuffler
Џ⍜ໄ఼
ৢഄᵓ䱨⛁ᵓ
Heat shield, rear floor
ᓔষൟ᠕༈ᢑ
Open type oval head
㢃䪚䩝
blind rivet
Big ൿ
washer
ᑇ䴶ᆚᇕĉ
Plane sealing ring I ࡃ⍜ໄ఼
Secondarymuffler
replacement
ᤶ
(4) Take out the lug rod of the front exhaust pipe from the lug;
(2) Take out the lug rod of the rear exhaust pipe from the lug;
(2) Take out the lug rod of the last exhaust pipe from the lug;
6-67
BYD S6, S6A, S6K Service Manual
5HPRYLQJLQVWDOOLQJKHDWVKLHOGFHQWHUÀRRU
(2) Remove the open type oval head blind rivet, and take out the heat shield
5HPRYLQJLQVWDOOLQJKHDWVKLHOGUHDUÀRRU
(2) Remove the open type oval head blind rivet, and take out the heat shield
,QVWDOOWKHSDUWVLQWKHUHYHUVHRUGHUDVUHPRYLQJ
1RWH(YHU\WLPHWKHH[KDXVWSLSHDVVHPEO\LVUHLQVWDOOHGLWLVQHFHVVDU\WRUHSODFHWKH
ÀDQJHVHDOHGJDVNHWWRHQVXUHWKDWWKHWLJKWQHVVRIWKHH[KDXVWV\VWHPPHHWVWKHUHTXLUH-
PHQW
Use specified installation grease when the oxygen sensor is removed and reinstalled.
6-68
Engine Control & Management
System
BYD S6, S6A, S6K Service Manual
I
BYD S6, S6A, S6K Service Manual
1. Summary
The system is electronic control multi-point sequence fuel injection, the engine electronic unit
(called computer ECU) measure all parameters of engine by all kinds of sensor which are in-
stalled on different position, make the engine get the best concentration mix gas under all kinds of
condition by controlling fuel injector to precisely control fuel injecting amount according to set con-
trol program in computer in advance. In addition, the electronic control fuel injection system can
carry out the functions such as start enhance, warm up engine enhance, acceleration enhance,
full load enhance, deceleration dilution, compulsively idle fuel cut-off and automatic idle speed
control by the program which is in computer and meet the request that engine special condition
need mix gas to make engine get better fuel economy and emission, meanwhile improve vehicle
performance. And the ECU also has several kinds of trouble diagnostic mode to simple the work
to ¿nd out trouble.
ECU control fuel injector drive time and injection timing to make the engine get the best concen-
tration mix gas. Intake of every cylinder is equipped with a fuel injector, the fuel pump send fuel
to fuel distribution pipe; fuel pressure adjuster makes fuel pressure stable and injector make the
fuel into air passage of every cylinder. In the engine every work circle ( crankshaft rotate for both
circles), every cylinder injects fuel one time ( the sequence is 1-3-4-2), the way is called sequence
injection. When engine runs under cooling state or high load, to keep better performance ECU
carry out open-loop control to supply stronger mix gas; When engine work normally (medium-
light load), ECU carry out closed-loop control to get the best air/fuel ratio and make the three-way
catalyze converter get to the best puri¿catory ef¿ciency by signal which is fed back by oxygen
sensor.
Throttle system is electronic control, engine ECU measures acceleration pedal journey by accel-
eration pedal sensor and control servo motor action on the throttle to get to drive condition and
make throttle target opening get to set value in advance.
Control throttle bypass air amount according to idle condition and engine load change under idle
to keep best idle speed. ECU drives idle to control servo system according to engine coolant tem-
perature and A/C load to make the engine run under set target idle speed. In addition, when en-
gine runs under idle, open or close A/C switch, then idle control servo system will adjust bypass
air amount according to engine load condition to avoid idle unstable.
Electronic control unit control the open and close of power transistor to control the conduction of
ignition coil primary current. The purpose of ignition timing control is to obtain the best ignition
time to meet engine change condition request. ECU determines the ignition time according to
engine speed, intake amount, intake temperature, engine cooling water temperature and air pres-
sure.
Self-diagnosis operation
(1) When ¿nding out that a sensor and actuator is abnormal, engine trouble lamp will be on to
remind driver.
1
BYD S6, S6A, S6K Service Manual
(2) When ¿nding out that a sensor and actuator is abnormal, the DTC which is related with trou-
ble situation will be output.
(3) The RAM data in ECU which has the relationship with sensor and actuator will be read by
MUT-III.
When engine starts and runs, fuel pump relay opens to pass current to fuel pump.
(2) A/C relay control
To keep consistent of cylinder work and engine speed, ECU impacts closed-loop control by oil
control valve; Under the control, oil control valve turns on different valve angles according to dif-
ferent working conditions to make the amount of oil different which goes into camshaft transfer
intake rocker arm shaft. It achieves that intake and exhaust valve open and closed time adjust in
time with engine speed and ensure that engine works in best condition.
(4) Fan motor control
Engine coolant temperature and speed signal control the rotate of radiator and condenser fan.
(5) Alternator output current control
The purpose is to avoiding alternator output current increasing suddenly and idle decreasing any-
time. For example, when opening front headlamp, engine load is increased, and alternator output
current control will input ECU current signal.ECU will control speed to compensate the changes
after detecting this signal.
(6) Puri¿cation solenoid control
Puri¿cation emission control system can prevent fuel vapor which is produced by fuel tank to en-
ter into air. Fuel vapor in fuel tank is temporarily stored in charcoal canister by pressure control
valve and ventilation hose. When vehicle drives, the fuel vapor which is stored in charcoal canis-
ter enter into inlet manifold and be sent into combustion chamber by puri¿cation control solenoid
and puri¿er; when engine water temperature is lower or intake is smaller ( for example, idle),
ECU closes puri¿cation solenoid to prevent fuel vapor to enter into inlet manifold. This can make
sure drive performance under engine cooling state or low load and make exhaust emission stable.
(7) EGR solenoid control
EGR low the NOx emission amount ; When air and fuel mixture temperature is high, combustion
chamber produces a lot of NOx. So EGR recycle to make part of exhaust sent into inlet manifold
from outlet on cylinder head to decrease mix gas temperature and further low NOx amount. EGR
valve control exhaust Àow not to low drive performance.
2
BYD S6, S6A, S6K Service Manual
Speed sensor
M/T
Anti-manual
shift switch A/T
3
BYD S6, S6A, S6K Service Manual
Fuel pressure
adjuser
From fuel pump
4
BYD S6, S6A, S6K Service Manual
Items Speci¿cation
Throttle hole diameter mm 60
Throttle Throttle position sensor Hall type
Idle control servo mechanism DC motor model
Engine electronic unit <M/T> ECU model
Engine electronic unit <A/T> ECU model
AirÀow sensor Thermo sensitive type
Air pressure sensor Semiconductor type
Intake temperature sensor Thermo sensitive-resistance type
Water temperature sensor Thermo sensitive-resistance type
Oxygen sensor Zirconia type
Accelerate pedal position sensor Slide resistance type
Sensor
Speed sensor <M/T> Magneto resistance type
Anti-manual shift switch <A/T> Contact switch type
Camshaft position sensor Magneto resistance type
Crankshaft corner sensor Magneto resistance type
Knock sensor Piezoelectricity type
power turning hydraulic switch Semiconductor type
Engine control relay type Contact switch type
Fuel pump relay Contact switch type
The type and amount of fuel injec-
Electromagnetic type, four
tor
5
BYD S6, S6A, S6K Service Manual
Items Speci¿cation
-20°C 13 - 17
0°C 5.3 - 6.7
20°C 2.3 - 3.0
Intake temperature sensor resistance k¡
40°C 1.0 - 1.5
60°C 0.56 - 0.76
80°C 0.30 - 0.45
-20°C 14 - 17
0°C 5.1 - 6.5
20°C 2.1 - 2.7
Water temperature sensor resistance k¡
40°C 0.9 - 1.3
60°C 0.48 - 0.68
80°C 0.26 - 0.36
Oxygen sensor output voltage ( running) V 0.6 - 1.0
Oxygen sensor heater resistance (at the 20°C) ¡ 11 - 18
Vacuum hose taken off In basic idle about 324 - 334
Fuel pressure kPa
Vacuum hos collected In basic idle about 248
Fuel injector coil resistance (at the 20°C) ¡ 10.5 - 13.5
Throttle control servo coil resistance (at the 20°C) ¡ 0.3 - 80
Oil control valve (at the 20°C) ¡ 6.9 - 7.9
3.3 Sealant
6
BYD S6, S6A, S6K Service Manual
7
BYD S6, S6A, S6K Service Manual
'LDJQRVLVVSHFL¿FDWLRQ
NOTICE
Within diagnosis, if the ignition switch is open, but connector is disconnected, a DTC re-
lated with other systems is produced. After diagnosis, record all the DTC and erase them.
NOTICE
<RXPXVW¿UVWFORVHLJQLWLRQVZLWFKDQG
then connect or disconnect connective
wire of diagnostic tester.
NOTICE
3OHDVHUHIHUWR087,,,RSHUDWLRQVSHFL¿-
cation to use MUT-III.
8
BYD S6, S6A, S6K Service Manual
NOTICE
After opening diagnostic tester power,
the green indicator will be on.
8. Read DTC
Erase DTC
NOTICE
<RXPXVW¿UVWFORVHLJQLWLRQVZLWFKDQG
then connect or disconnect diagnostic
tester connective wire.
AC310120AB
9
BYD S6, S6A, S6K Service Manual
AC310121AB
Initialization program
1. Turn ignition switch to “LOCK” (OFF) position, connect MUT-III diagnostic tester to diagnostic
connector.
Repair Items
Replace engine assembly *1, *2 All components
*3
- Related with mis¿re
*2
The learn on replacing injector Learn air/fuel ratio
*2
The learn on replacing throttle body Related with idle
The learn on replacing knock sensor Learn knock
NOTICE
*1
: be suitable for learn on automatic transmission
NOTICE
*2
: after learn, carry out the learn on engine idle
NOTICE
*3
: MUT-III only is displaying item of apparatus, and don’t use
Purpose
After replacing engine electronic control unit or initializing learn, idle may be unstable, so carry out
the learn on engine idle.
Learn program
10
BYD S6, S6A, S6K Service Manual
5. Engine run for 10 minutes under idle, the idle learn is ¿nished.
Engine-ECU
Accelerate pedal position sensor (main)
Accelerate pedal position sensor (sub)
AirÀow sensor
Alternator
Air pressure sensor
Camshaft position sensor
Crankshaft corner sensor
Cylinder mis¿re
Knock sensor
Electronic throttle system
Water temperature sensor
Fuel injector
Intake temperature sensor
Oxygen sensor
Throttle position sensor (main)
Throttle position sensor (sub)
Speed sensor <M/T>
11
BYD S6, S6A, S6K Service Manual
Diagnostic mode 2
NOTICE
Close ignition switch, engine electronic
control unit will be changed from diag-
nostic mode 2 to mode 1.
5. Erase DTC.
&KHFNZLWK087,,,GDWDÀRZDQGDFWXDWRU
When testing main sensor trouble, control vehicle with set control logical circuit which is used to
keep drive safe condition.
12
BYD S6, S6A, S6K Service Manual
13
BYD S6, S6A, S6K Service Manual
14
BYD S6, S6A, S6K Service Manual
15
BYD S6, S6A, S6K Service Manual
NOTICE
Before replacing engine electronic unit, make sure to check if the terminal is short
circuit or open circuit.
Before replacing engine electronic unit, make sure to check if the grounding end is
¿QH
16
BYD S6, S6A, S6K Service Manual
NOTICE
Don’t directly point washing liquid at throttle.
Make sure the washing liquid doesn’t enter into motor from bypass port and does’t
enter into sensor from shaft.
17
BYD S6, S6A, S6K Service Manual
13 - 17 kˮ (at -20°C)
Device side connecto 5.3 - 6.7 kˮ (at 0°C)
Standard value
18
BYD S6, S6A, S6K Service Manual
NOTICE
Water When disassembly or assembly, don’t
temperatur makee the tool touch connector (pitch
sensor
part).
Standard value:
14 - 17 kˮ (at -20°C)
19
BYD S6, S6A, S6K Service Manual
Upstream cylinder
oxygen sensor
Equipment side
connector
20
BYD S6, S6A, S6K Service Manual
NOTIE
Connect test wire, don’t hurt oxygen
sensor.
The input voltage of oxygen sensor
heater must be less than or equal
12V, or it will be hurt.
NOTICE
If can’t get to temperature (over 400°C),
even the oxygen sensor is normal, when
the air/fuel ratio is thick, it may be very
low. So, if the output voltage is low,
separately connect the wire to 1#( red
probe), to power (+) and 3# terminal( blue
probe) and to power (-), then check it.
NOTICE
Even the injector hasn’t action, you may
also hear sound from others injector ac-
tion.
NOTICE
If can’t hear sound, check injector work
circuit.
Measure resistance:
3. Connect injector.
21
BYD S6, S6A, S6K Service Manual
Check injector
3. Disassemble injector.
High pressure fuel pipe 11. Stop injector action, check injector noz-
zle leakage situation, turn ignition switch
to “LOCK OFF” position, disassemble
MUT-III.
22
BYD S6, S6A, S6K Service Manual
Check work
Checking work
NOTICE
For avoid burning coil, keep voltage
Oil control solenoid stable as possible as you soon. (disas-
sembly action must be fast).
23
BYD S6, S6A, S6K Service Manual
2. Insert thin probe to all connector terminal of ECU, and refer to checking table to measure re-
sistance value of all terminals.
NOTICE
1. Measure voltage when ECU terminal is connected with wire harness connector.
2. Pull out wire harness connector a little from ECU terminal to make probe contact
connector terminal easily and check conveniently.
3. It is no necessary to check it as sequence in checking table.
NOTICE
If generate short circuit because insert into wrong terminal, the wire harness, sensor,
ECU or other elements will be hurt, so you must check it carefully.
3. If the consequence checking voltage value is different from standard value, check related
sensor, actuator and wire harness, if it is necessary to repair or replace it.
4. After repair or replace, check it once more with voltage meter to make sure whether the trou-
ble has been eliminated.
Different from M7.9 system, ECM of Mitsubishi system is consisted of ¿ve small connectors com-
position: A46, A47, A48, A49, A50 respectively, and each connector is numbered independently.
1. A46 connector
24
BYD S6, S6A, S6K Service Manual
2. A47 Connector
25
BYD S6, S6A, S6K Service Manual
3. A48Connector
26
BYD S6, S6A, S6K Service Manual
4. A49 Connector
27
BYD S6, S6A, S6K Service Manual
5. A50 Connector
28
BYD S6, S6A, S6K Service Manual
29
BYD S6, S6A, S6K Service Manual
30
BYD S6, S6A, S6K Service Manual
EMS
Main
relay
Main
relay
Front oxygen
sensor
Shielding layer
Shielding layer
CIRCUIT OPERATION:
Front oxygen sensor (terminal 3#) are grounded with ECU (A49-19)
PRINCIPLE FUNCTION:
Front oxygen sensor transforms the oxygen concentration of emission to voltage signal and
output it to ECU.
When the air fuel ratio is more than air fuel ratio in theory, the output voltage of front oxygen
sensor is approximately 1V. When the air fuel ratio is less than air fuel ration theory, the out-
put voltage is 0V.
The reaction signal of ECU make the air fuel ratio more closed the air fuel ratio in theory.
31
BYD S6, S6A, S6K Service Manual
JUDGEMENT CRITERION:
When the ECU input 5 volts to oxygen sensor, output voltage of oxygen sensor is approxi-
mately 4.5 volts.
Diagnosis process
32
BYD S6, S6A, S6K Service Manual
33
BYD S6, S6A, S6K Service Manual
Main relay
PRINCIPLE FUNCTION:
The intake air temperature sensor transforms intake air temperature into voltage signal and
outputs signal to ECU.
Intake air temperature sensor is a kind of resistance. The resistance value is decreased
34
BYD S6, S6A, S6K Service Manual
when the temperature rises. So the output voltage of sensor varies with the intake air tem-
perature. Namely when the intake air temperature rises, the voltage is decreased.
JUDGEMENT CRITERION:
Output voltage of sensor 4.6 V and maintain 4seconds (intake air temperature -40°C) or
Output voltage of sensor 0.2 V and maintain 4seconds s(intake air temperature 120°C)
Diagnosis Process
Standard valve: 2 ¡
35
BYD S6, S6A, S6K Service Manual
NOTICE
Before checking harness, first check
middle connector, If necessary, replace
it.
36
BYD S6, S6A, S6K Service Manual
37
BYD S6, S6A, S6K Service Manual
CIRCUIT OPERATION:
ECU (terminal A49-21#) provides 5 volts for electronic control throttle (terminal 2#)
Electronic control throttle (terminal 4#) is grounded with ECU (terminal A49-22#)
Electronic control throttle (terminal A17-3#) outputs signal to ECU (terminal A49-28#)
PRINCIPLE FUNCTION:
Throttle position sensor (TPS) transform the throttle position for voltage signal and input it to
ECU.
JUDGEMENT CEITERION:
Output voltage of throttle position sensor(main) 2.5 V and output voltage of throttle position
sensor (sub) 4.2 V.
38
BYD S6, S6A, S6K Service Manual
Diagnosis Process
39
BYD S6, S6A, S6K Service Manual
40
BYD S6, S6A, S6K Service Manual
41
BYD S6, S6A, S6K Service Manual
Coolant temperature
sensor system
ECM
CIRCUIT OPERATION:
ECU (terminal A49-12#) outputs 5 volts to the output terminal (terminal 2#) of engine water
temperature sensor
The engine water temperature sensor (terminal 1#) is grounded with ECU A49-14.
PRINCIPLE FUNCTION
The engine water temperature sensor transforms the water temperature to voltage signal
and inputs to ECU
ECU output signal to control the fuel injection quantity, and controls the high idle speed when
cooling states
Engine water temperature sensor is a kind of resistance whose resistance value will de-
crease with the water temperature increase, so the output voltage changes with the tempera-
ture changes, that is the water temperature increase will decrease the resistance.
42
BYD S6, S6A, S6K Service Manual
Diagnosis Process:
43
BYD S6, S6A, S6K Service Manual
CAUTION
Should check middle connector ACJ05
before check the harness, replace it if
necessary
Ignition switch: ON
44
BYD S6, S6A, S6K Service Manual
Ignition switch: ON
Ignition switch: ON
45
BYD S6, S6A, S6K Service Manual
Main
relay
Crankshaft position sensor
CIRCUIT OPERATION:
Power is provided for crankshaft angle sensor(terminal 3#) from engine control relay (terminal
1#), and terminal 1# is grounded with ECU (terminal A48-24#)
ECU (terminal A48-8#) provides 5 volts power for crankshaft angle sensor (terminal 2#)
PRINCIPLE FUNCTION:
Crankshaft angle sensor detects the crankshaft angle (position) and input a pulse signal to
ECU
46
BYD S6, S6A, S6K Service Manual
JUDGEMENT CRITERION:
The no change times of crankshaft angle sensor output voltage maintain 2 seconds (no
pulse signal)
Diagnosis Process:
Ignition switch: ON
Ignition switch: ON
47
BYD S6, S6A, S6K Service Manual
Connector: B-15X Relay box’s 10. Check the connector G2X-29 of engine
triangle marks relay.
48
BYD S6, S6A, S6K Service Manual
CAUTION
Should check middle connector AcJ04
before check the harness, replace if nec-
C-112 (GR)
essary.
<R.H. drive vehicles> Check the power cord damaged
49
BYD S6, S6A, S6K Service Manual
Connector: B-15X Relay box’s 15. Check the connector B-15X of engine
triangle marks control relay.
CAUTION
Should check middle connector AcJ04
before check the harness, replace if nec-
essary.
50
BYD S6, S6A, S6K Service Manual
Main relay
Camshaft position
sensor
CIRCUIT OPERATION:
Engine control relay (terminal 1#) outputs power source to camshaft position sensor (terminal
1#), the camshaft position sensor (terminal 2#) is grounded with ECU (terminal 24#)
A 5 volts voltage is applied on the camshaft position sensor output terminal (terminal 2#)
from the ECU (termina7#)
51
BYD S6, S6A, S6K Service Manual
PRINCIPLE FUNCTION:
The camshaft position sensor detects the top dead center position of the number 1 cylinder
dam to convert that data to pulse signals that are input to the ECU
JUDGEMENT CRITERION:
The times of camshaft position sensor output voltage (no pulse signals) is unchanged and
maintain 2 seconds or more
Diagnosis Process:
Ignition switch: ON
52
BYD S6, S6A, S6K Service Manual
Ignition switch: ON
B-114 (B)
Measure the voltage between ter-
minal 2# and ground
Ignition switch: ON
53
BYD S6, S6A, S6K Service Manual
CAUTION
Should check the connector AJ54 before
check the wires, replace if necessary.
Engine: idle
54
BYD S6, S6A, S6K Service Manual
Connecor: B-15X Relay box’s 14. Check the engine relay connector G2X-
triangle marks 29.
CAUTION
Should check the connector AcJ08 be-
fore checking the wires, replace it if nec-
essary.
CAUTION
Should check connector AcJ08 before
checking wires, replace it if necessary.
CAUTION
Should check the connector AcJ08 be-
fore checking the wires, replace it if nec-
essary.
55
BYD S6, S6A, S6K Service Manual
Harness side
connector
PRINCIPLE FUNCTION:
Senor converts the atmospheric pressure to voltage signal and input to ECU
JUDGEMENT CRITERION:
Sensor output voltage 4.5V (atmospheric pressure 114Kpa) and maintain 2 seconds or
more
Sensor output voltage 0.2V (atmospheric pressure 53Kpa) and maintain 2 seconds or
more
Diagnosis Process:
56
BYD S6, S6A, S6K Service Manual
layer
Shield
layer
Shield
Knock sensor
CIRCUIT OPERATION:
PRINCIPLE FUNCTION
Knock sensor detects the vibration of cylinder and inputs signal to ECU
ECU reacts signals to delay the ignition timing when knock occurs
JUDGEMENT CRITERION:
Knock sensor output voltage (knock sensor peak voltage) has not changed more than 0.06
volts in the consecutive 200 periods.
57
BYD S6, S6A, S6K Service Manual
Diagnosis Process:
58
BYD S6, S6A, S6K Service Manual
Accumulator
EMS
Relay
15A
Main
relay
Shield layer
Shield layer
CIRCUIT OPERATION:
Downstream oxygen sensor (terminal 3#) output signal to ECU (terminal A49-27#).
Downstream oxygen sensor (terminal 2#) are grounded with ECU (terminal A46-16#)
PRINCIPLE FUNCTION
Downstream oxygen sensor detects the concentration of oxygen in the exhaust gas and con-
verts those data to voltage signal to input to the ECU.
When the air fuel ratio is higher than theory air fuel ratio, downstream oxygen sensor output
voltage is approximately 1 volt. When the air fuel ratio theory air fuel ratio, the output volt-
age is 0 volt.
ECU react signals to control the injection quantity to make the air fuel ratio closed theory air
fuel ratio.
JUDGEMENT CRITERION:
When 5 volts voltage is applied on the oxygen sensor, the oxygen sensor output voltage 4.5V
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BYD S6, S6A, S6K Service Manual
Diagnosis Process
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BYD S6, S6A, S6K Service Manual
Accumulator
EMS
Relay
15A
Main
relay
Fuel injector
Fuel injector
Fuel injector
Fuel injector
CIRCUIT OPERATION:
Engine control relay (terminal G2X-17#) outputs power to the injector (terminal 2#)
The ECU (terminal A46-4#, 13#, 20#, 27#) outputs currents to the injector (terminal 2#) by
turning the power transistor on
JUDGEMENT CRITERION:
Injector coil surge voltage (battery positive voltage +2 volts) has not been detected for 4 sec-
onds
PRINCIPLE FUNCTION
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Diagnosis Process
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Connectors: V-101, B-102, B-104, B-105 4. Measure the voltage of injector connec-
tor.
If normal,
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BYD S6, S6A, S6K Service Manual
Connectors: V-101, B-102, B-104, B-105 Check the short or open circuit for power
cord
CAUTION
Should check middle connector ACJ05
before check the harness, replace it nec-
essary.
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BYD S6, S6A, S6K Service Manual
Connectors: V-101, B-102, B-104, B-105 2) Check the harness between 2# in-
jector connector A10 (terminal 2#)
and ECU connector A46 (terminal
13#).
PRINCIPLE FUNCTION
The engine speed will immediately change when the mis¿re occurs while the engine is run-
ning.
Mis¿re has occurred more frequently than allowed during the last 200 revolutions when the
catalyst temperature is higher than 950°C
Mis¿re has occurred in 15 times or more of the last 1, 000 revolutions (corresponding to 1.5
times the limit of emission standard)
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BYD S6, S6A, S6K Service Manual
Diagnosis Process:
Connector: B-15X Relay box’s 5. Check the harness between engine relay
triangle marks connector G2X-17 and misfire injector
connector (terminal 2#).
CAUTION
Should check the middle connector
Harness side ACJ05 before check the harness, replace
connector it if necessary.
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BYD S6, S6A, S6K Service Manual
CAUTION
Make sure the communication of computer is normal.
Diagnosis Process:
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BYD S6, S6A, S6K Service Manual
CAUTION
Should make sure the communication of computer is normal after replaced the ECU.
JUDGEMENT CRITERION:
Can not receive the signal from the ABS electronic control unit through the bus
Diagnosis Process:
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COMMENT: A diagnostic output is made from the ECU (terminal A48-22#) to the diagnostic out-
put terminal (terminal 7#) of the data link connector.
Diagnostic procedure:
CAUTION
Should the connector Ac05 before check
the harness wire, if abnormal, repair it.
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BYD S6, S6A, S6K Service Manual
Inspection Procedure 2: Ignition switch is to ON, the engine warning lamp does not illumi-
nate right
Diagnostic procedure:
1. Use the MUT-III to read the DTC. If the DTC occurred, refer to DTC procedure. If no DTC, go
to next step.
2. Check the malfunction symptom, if the malfunction continual exist, replace the instrument
panel assy.. if not continual, intermittent defect.
Diagnostic procedure:
1. Use the MUT-III to read DTC. If the DTC occurred, refer to DTC procedure. If no DTC, go to
next step.
2. Check the malfunction symptom, if it continual exist, replace the instrument panel. If not con-
tinual, that is intermittent defect.
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Diagnostic procedure:
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Inspection Procedure 5: Can not start (can ignition, can not start the engine) ; can not start
(start use long time)
Diagnostic procedure:
1. Check the battery. If normal, run at idle speed 10 minutes after warmed engine up. If abnor-
mal, go to next step.
2. Check the battery voltage. Standard value: 8V If abnormal, check the battery. If normal,
go to next step.
3. MUT-III DTC. If the DTC occurred, refer to the inspection procedure of DTC. If no DTC, go to next step.
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7. MUT-III data stream inspection. Item 25: air pressure sensor If abnormal, replace it. If nor-
mal, go to next step.
8. Check the dirty of throttle body. If abnormal, clean the throttle body. If normal, go to next
step.
MUT-III executer test. Item 07: fuel pump Standard: can heat the action voice If abnor-
mal, check the fuel pump system. If normal, go to next step.
9. Check the intake air condition of intake pipe and intake manifold. If abnormal, repair it. If nor-
mal, go to next step.
10. Check the action voice of injector. If abnormal, check the malfunction injector. If normal, go to
next step.
11. Check the timing mark of timing belt. If abnormal, adjust the timing mark. If normal, go to
next step.
12. Check the ignition coils. If abnormal, check the ignition circuit (refer to the inspection proce-
dure 26). If normal, go to next step.
13. Check the injector atomizing condition. If abnormal, repair the injector. If normal, go to next
step.
14. Check the fuel pressure. If abnormal, repair it. If normal, go to next step.
15. Check the EGR solenoid valve(step motor). If abnormal, replace it. If normal, go to next step.
16. Replace the engine ECU. Check the malfunction symptom again after replaced it. Malfunc-
tion disappears, inspection ends. Malfunction continual, check if there is water or other impu-
rity in the fuel.
Inspection Procedure 6: Unstable idle, high idle or low idle, go out at idle.
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Diagnostic procedure:
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CAUTION
Should check the middle connector B-17
before check the harness wire.
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BYD S6, S6A, S6K Service Manual
Diagnostic procedure:
1. Use the MUT-III to read the DTC. If the DTC occurred, refer to the DTC inspection proce-
dure. If no DTC, go to next step.
3. Check the EGR solenoid valve (step motor). If abnormal, replace it. If normal, go to next
step.
4. Check the intake air state of the intake pipe and intake manifold. If abnormal, repair it. If nor-
mal, go to next step.
5. Check the spark plug. If abnormal, replace it. If normal, go to next step.
6. Check the spark coils. If abnormal, check the ignition circuit system. If normal, replace the
ECU.
Diagnostic procedure:
1. Using the MUT-III to read the DTC. If the DTC occurred, refer to the DTC procedure. If no
DTC, go to next step.
3. Check the EGR solenoid valve (step motor). If abnormal, replace it. If normal, go to next step.
4. Check the smudginess of the throttle body. If abnormal, clean the throttle body. If normal, go
to next step.
5. Check the spark plug. If abnormal, replace it. If normal, go to next step.
6. Check the spark plug. If abnormal, check the ignition circuit system. If normal, replace the
ECU.
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BYD S6, S6A, S6K Service Manual
Diagnostic procedure:
1. Using the MUT-III to read DTC. If the DTC occurred, refer to the DTC procedure. If no DTC,
go to next step.
3. Check the ignition coil. If abnormal, check the ignition circuit system (refer to the inspection
procedure 26). If normal, go to next step.
4. Check the timing mark of timing belt. If abnormal, adjust the timing mark. If normal, go to
next step.
5. Check the spark plug. If abnormal, replace it. If normal, go to next step.
6. Fuel pressure measurement. If abnormal, repair it. If normal, replace the engine ECU.
Diagnostic procedure:
1. Using the MUT-III to read the DTC. If the DTC occurred, refer to the DTC procedure. If no
DTC, go to next step.
2. Check the action sound of injector. If abnormal, check the injector of failed cylinder. If normal,
go to next step.
4. MUT-III DATA STREAM INSPECTION. Item 25: air pressure sensor If abnormal, replace the
ECU. If normal, go to next step.
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BYD S6, S6A, S6K Service Manual
5. Check the carbon tank control solenoid valve. If abnormal, replace it. If normal, go to next
step.
6. Check the EGR solenoid valve (step motor). If abnormal, replace it. If normal, go to next
step.
8. Check the spark plug. If abnormal, replace it. If normal, go to next step.
9. Check the ignition coil. If abnormal, check the ignition circuit system (refer to the inspection
procedure 26). If normal, go to next step.
10. Check the smudginess of throttle body. If abnormal, clean the throttle body. If normal, go to
next step.
11. Measure the fuel pressure. If abnormal, repair it. If normal, go to next step.
12. Check the compression. If abnormal, repair it. If normal, replace the engine ECU.
Diagnostic procedure:
1. Using the MUT-III to read the DTC. If the DTC occurred, refer to the DTC procedure. If no
DTC, go to next step.
2. Make the MUT-III data steam inspection. Refer to the data list
3. Check the smudginess of throttle body. If abnormal, clean the throttle body. If normal, go to
next step.
4. Check the speak plug. If abnormal, replace it. If normal, go to next step.
5. Check the ignition coil. If abnormal, check the ignition circuit system (refer to the inspection
procedure 26. If normal, replace the engine ECU.
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BYD S6, S6A, S6K Service Manual
Diagnostic procedure:
1. Using the MUT-III to read the DTC. If the DTC occurred, refer to the DTC procedure. If no
DTC, go to next step.
2. Make the MUT-III DATA STREAM INSPECTION. Refer to the data list
3. Check the smudginess of the throttle body. If abnormal, clean the throttle body. If normal, re-
place the ECU.
4. Check the spark plug. If abnormal, replace it. If normal, go to next step.
5. Check the spark coil. If abnormal, check the ignition circuit system (refer to the inspection
procedure 26). If normal, replace the engine ECU.
Diagnostic procedure:
1. Using the MUT-III to read the DTC. If the DTC occurred, refer to the DTC procedure. If no
DTC, go to next step.
2. Check the spark plug. If abnormal, replace it. If normal, go to next step.
3. Check the ignition coil. If abnormal, check the ignition circuit system (refer to the inspection
procedure 26). If normal, check the knock sensor.
Diagnostic procedure:
1. Using the MUT-III to read the DTC. If the DTC occurred, refer to the DTC procedure. If no
DTC, go to next step.
2. Measure the output waveform of the crankshaft angle sensor and camshaft position sensor
(use oscillograph).
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BYD S6, S6A, S6K Service Manual
Transmission: N or P
Harness side
connector Measure the voltage between terminal
2# and the ground
Engine: Idle
Harness side
Transmission: N or P
connector
Measure the voltage between terminal
2# and the ground
3. Check the malfunction symptom. If the malfunction still exists, replace the engine ECU. If the
malfunction disappears, that is intermittent defect.
4. Check the mounted of the crankshaft angle sensor and camshaft position sensor. If abnor-
mal, repair it. If normal, go to next step.
5. Check the timing mark of the timing belt. If abnormal, adjust the timing mark. If normal, go to
next step.
6. Check the crankshaft sensing blead.If abnormal, replace it. If normal, go to next step.
7. Check the camshaft sensing blead. If abnormal, replace it. If normal, go to next step.
8. Replace a new crankshaft angle sensor. Check the malfunction symptom again after re-
placed. If the malfunction disappears, check ends. If the malfunction still exists, go to next
step.
9. Replace the camshaft position sensor. Check the malfunction symptom again after replaced,
if the malfunction disappear, that is intermittent defect. If the malfunction still exists, replace
the ECU.
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Diagnostic procedure:
Check the atomization status of injector. Check the atomization status of each injector. If abnor-
mal, replace the injector. If normal, replace the engine ECU.
Inspection Procedure 16: Exhaust smell bad, white or black smoke, too high CO or HC
concentration while idling
Diagnostic procedure:
1. MUT-III DTC. If the DTC occurred, refer to the DTC procedure. If no DTC, go to next step.
2. Check the action sound of the injector. If abnormal, check the injector of the failed cylinder. If
normal, go to next step.
3. Check the ignition timing. If abnormal, check the offsetting ignition timing (refer to the inspec-
tion procedure 16). If normal, go to next step.
5. MUT-III DATA STREAM INSPECTION. Item 25: Air pressure sensor If abnormal, replace the
ECU.If normal, go to next step.
6. Check the intake air of the intake pipe and intake manifold. If abnormal, repair it. If normal,
go to next step.
7. Check fuel gas leak of the exhaust manifold. If abnormal, repair it. If normal, go to next step.
8. Check the smudginess of the throttle body. If abnormal, clean the throttle body. If normal, go
to next step.
10. Check the carbon tank control solenoid valve. If abnormal, replace it. If normal, go to next
step.
11. Check the EGR solenoid valve (step motor). If abnormal, replace it. If normal, go to next
step.
12. Check the fuel pressure. If abnormal, repair it. If normal, go to next step.
13. Check the PCV valve. If abnormal, replace it. If normal, go to next step.
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BYD S6, S6A, S6K Service Manual
14. Check the spark plug. If abnormal, replace it. If normal, go to next step.
15. Check the ignition coil. If abnormal, check the ignition circuit system (refer to the inspection
procedure 26). If normal, go to next step.
16. Check the compression pressure. If abnormal, repair it. If normal, go to next step.
17. Check the atomization of the injector. If abnormal, replace the injector. If normal, go to next
step.
18. Replace the catalytic converter. Check the malfunction symptom again after replaced. If the
malfunction disappeared, check ends. If the malfunction still exist, replace the engine ECU.
Diagnostic procedure:
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Transmission: N or P
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BYD S6, S6A, S6K Service Manual
Diagnostic procedure:
1. MUT-III DTC. If the DTC occurred, refer to the DTC inspection procedure. If no DTC, go to
next step.
2. Check the engine cooling water. If abnormal, replace or add cooling water. If normal, go to
next step.
CAUTION
If the over low surface of the cooling water, check the leakage position.
3. MUT-III executer.
If abnormal, check the fan controller relay system (refer to inspection procedure 24). If nor-
mal, go to next step.
4. MUT-III DATA STREAM INSPECTION. Refer to data list. Item 21: Engine water temperature
sensor
Standard value: Cooling: Atmosphere temperature (air temperature)
Warming: 80 - 110°C
If abnormal, check the water temperature sensor system. If normal, go to next step.
5. Check the thermostat. If abnormal, replace the thermostat. If normal, go to next step.
6. Check the water pump. If abnormal, replace the water pump. If normal, replace the radiator.
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COMMENT:
Engine ECU (terminal 17# or terminal 9#) outputs one control signal to fan controller.
Diagnostic procedure:
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CAUTION
Check the connector A-16 before check
the harness wire, if failed, repair it.
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BYD S6, S6A, S6K Service Manual
Fuel bump
Fuel pump
motor
CIRCUIT OPERATION:
Battery voltage is applied to the fuel pump relay 1 (terminal 86#) from accumulator ,to ECM
from fuel bump relay 1 (terminal 85#).
Battery voltage is applied to the fuel pump relay 1 (terminal 88a#) and the fuel pump relay
2(terminal 4#) from the fuel pump relay (1) terminal 88 # .
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Diagnostic procedure:
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Ignition switch: ON
CAUTION
Before checking harness, check the mid-
Relay box’s dle connector.
triangle marks
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BYD S6, S6A, S6K Service Manual
IG1 electricity
Ignition
coil
15A
Ignition coil
Ignition coin
Ignition coin
Ignition coin
1# 2# 3# 4#
Igniting Igniting Igniting Igniting
coin coin coin coin
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BYD S6, S6A, S6K Service Manual
Diagnostic procedure:
Connectors: B-02, B-03, B-04, B-05 1. Check the spark plug. If abnormal, re-
place it. If normal, go to next step.
Ignition switch: ON
2) Engine: Running
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
Connectors: B-02, B-03, B-04, B-05 2) Check the harness wire between
the 1# ignition coil connector A08
(terminal 1#) and engine ECU con-
nector A47 (terminal 3#).
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BYD S6, S6A, S6K Service Manual
Connectors: B-02, B-03, B-04, B-05 8) Check and repair the harness wire
between the 4# ignition coil con-
nector A35 (terminal 2#) and the
ground chassis.
Connector: C-307
10. Check the harness wire between the ig-
<L.H.drive vehicle> nition coil connector and the engine ECU
connector.
CIRCUIT OPERATION:
Engine control relay (terminal 85#) outputs the power to the heater power terminal (terminal
2#) of upstream cylinder oxygen sensor heater.
The engines ECU (terminal 8#) monitor the power transistor to control the upstream cylinder
oxygen sensor heater (terminal 4#).
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BYD S6, S6A, S6K Service Manual
Accumulator
EMS
Relay
15A
Main
relay
Front oxygen sensor
Shield
layer
Shield
layer
Diagnostic procedure:
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BYD S6, S6A, S6K Service Manual
Start
Start
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BYD S6, S6A, S6K Service Manual
CAUTION
Should check the middle connector be-
fore checking harness wire.
CIRCUIT OPERATION:
Engine control relay 88a outputs the power to the downstream oxygen sensor heater power
terminal (terminal 2#)
The power transistor of engine ECU (terminal 16#) controls the downstream oxygen sensor
heater (terminal 4#).
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BYD S6, S6A, S6K Service Manual
Accumulator
EMS
Relay
15A
Main
relay
Rear oxygen sensor
Shield layer
Shield layer
Diagnostic procedure:
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BYD S6, S6A, S6K Service Manual
Ignition switch: ON
101
BYD S6, S6A, S6K Service Manual
CAUTION
Should check the middle connector be-
fore check the harness wire.
Harness side
connector Check the damage for the power
cord
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BYD S6, S6A, S6K Service Manual
Accumulator
EMS
Relay
15A
Main
relay
ECR
valve
CIRCUIT OPERATION:
Engine control relay (terminal 88a#) outputs the power to EGR valve (terminal 2# and termi-
nal 5#).
Engine ECU (terminal 6#, 2#, 15#, 22#) turns the power crystal ON, the current through to
the EGR valve (terminal 1#, 3#, 4#, 6#).
Diagnostic procedure:
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BYD S6, S6A, S6K Service Manual
Start
Connector: B-15X Relay box’s 4. Check the engine control relay connec-
triangle marks tor G2X-29.
Start
Harness side connector
Measure the voltage between terminal
6#, 2#, 15#, 22# and the ground terminal
Standard value: System voltage
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
CAUTION
Should check the middle connector
C-116.
Accumulator
EMS
Relay
15A
Main
relay
Canister control valve
CIRCUIT OPERATION:
Engine controls relay (terminal 88a #) outputs power to canister control solenoid valve (ter-
minal 1#).
Engine ECU (terminal 25#) turns the power crystal ON, the current through to canister con-
trol solenoid valve (terminal 2#).
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BYD S6, S6A, S6K Service Manual
Diagnostic procedure:
Start
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BYD S6, S6A, S6K Service Manual
CAUTION
Should check the middle connector C-116
before checking the harness.
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BYD S6, S6A, S6K Service Manual
Diagnostic procedure:
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BYD S6, S6A, S6K Service Manual
Accumulato
EMS
Relay
15A
Main
relay
Oil control valve
COMMENT:
Engine control relay (terminal 88a#) output electrical source to oil control valve (terminal 2#).
Engine ECU (terminal1#) turns ON the power crystal, the current through to oil control valve
(terminal 1#).
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BYD S6, S6A, S6K Service Manual
Diagnostic procedure:
Power: ON
Connector: B-15X Relay box’s 4. Check the engine control relay connec-
triangle marks tor G2X-29.
Power: ON
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BYD S6, S6A, S6K Service Manual
Connector: B-15X Relay box’s 9. Check the engine control relay connec-
triangle marks tor B-15X. If abnormal, repair or replace
it. If normal, go to next step.
CAUTION
Should check the middle connector be-
fore check the harness wire
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BYD S6, S6A, S6K Service Manual
5. Ignition System
5.1 Summary
This system has four ignition coils with power transistor inside them, they separately act on every
cylinder. Cutting off the primary side current of ignition coil maybe generate high voltage at the
secondary side of ignition coil. The high voltage adds on the spark plug and generate spark. The
engine-ECU makes the two power transistors inside the ignition coils connect and disconnect al-
ternately. The result is that the primary current in the ignition coil is connected and disconnected
alternately, so ignite every cylinder according to the sequence of 1-3-4-2.
Engine-ECU uses the signals which are sent out from the cam position sensor and crankshaft
angle sensor to con¿rm the controlled ignition coil. It also tests crankshaft position, according to
this to provide ignition timing which is best suitable for engine running working condition. When
the engine is running in cold condition or under high altitude, the ignition timing is a little advanc-
ing to ensure the best performance under running working condition. Besides, when happening
the shock, the ignition timing is deferred greatly until the shock disappears.
System diagram
Cylinder
,JQLWLRQFRLOVSHFL¿FDWLRQ
Item Speci¿cation
Ignition coil Moulding four coils
6SDUNSOXJVSHFL¿FDWLRQ
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Item Speci¿cation
NGK LZFR6AI
Special tool
NOTICE
Use simulation type ohmmeter
Connect the cathode (-) of multime-
ter to 1# end
NOTICE
This test should be completed rapidly (in
10 seconds).
To avoid burning the coil and damaging
the power transistor.
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BYD S6, S6A, S6K Service Manual
7. If using new spark plug can generate spark, replace old ignition coil. If no spark is still gener-
ated, check ignition circuit.
NOTICE
Don not try to adjust center elec-
trode clearance of iridic gold.
Cleaning with the tool should be
Iridic gold completed In 20 seconds. Do not
uses wire brush.
NOTICE
Do not let the impurity into cylinder.
Disassembly steps
2. Ignition coil
3. Spark plug
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BYD S6, S6A, S6K Service Manual
Disassembly steps
2. Camshaft position
sensor
3. O type ring
Disassembly step
2. Crankshaft position
sensor
NOTICE
Do not make the shock sensor fall down or impact any other parts, if the condition above
is happened, replace shock sensor.
Disassembly step
5. Shock sensor
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BYD S6, S6A, S6K Service Manual
6. Charging system
6.1 Summary
Charging system is the system that using the output energy of alternator to charge battery, and
make the battery keep the constant charging amount under different loads.
About 14.5V
Voltage
Time
Working principle
Rotation of motivated excitation coil in stator generates AC voltage. This AC current is commuted
into DC voltage by diode which has the waveform showing as the left picture. Average output volt-
age has small Àuctuation under load condition of alternator.
When the ignition switch is putting through, the current inÀows into excitation coil, the excitation
coil is initial motivated. When the stator is starting to generate power after the engine starts, the
excitation coil is motivated by output current of stator coil. If excitation current is increasing, the
output power of alternator increases; if the excitation current is decreasing, the output power de-
creases. When the battery voltage (S end’s voltage of alternator) is up to regulation voltage about
14.4V, excitation current is cut off. When the battery voltage is dropping down to lower than regu-
lation voltage, voltage regulator adjusts the output voltage through the method of controlling exci-
tation current, and make it keep constant level.
In addition, when the excitation current is constant, output voltage of alternator is increasing along
with the engine speed increasing.
System diagram
Stator coil
Engin-ECU
Excitation coil
Voltage
regulator Ignition switch
Battery
Charging alarm lamp
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BYD S6, S6A, S6K Service Manual
$OWHUQDWRUVSHFL¿FDWLRQ
Item Speci¿cation
Type Battery voltage test type
Rating output power V/A 12/110
Voltage regulator Inside electronic regulation type
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BYD S6, S6A, S6K Service Manual
The objective of test is that ¿nd out whether the wiring (including fuse) of alternator B end and
battery (+) end is normal.
2) Driving belt tension degree of alternator. (refer to the sequence of repair and regulation)
3) State of fuse.
4. Connect a caliper DC ammeter (range: 0-150A) to the output line of alternator B end.
NOTICE
Because of the inadequate connection between “B” end and output line, the method of
using the output line of disassembling alternator to connect ammeter can not find the
problem of output current decreasing.
5. Connect a digital voltmeter between alternator end “B” and battery jar (+) end. (Connect volt-
age (+) conductor to end “B”, connect voltage ( ϔ ) conductor to battery jar (+) end.)
10. Under the state of the engine speed is 2500rpm/min, use the method of turning on or turn-
ing off the headlight and any other lamps to adjust the load of alternator, and make ammeter
¿nger point at the value more than 30A. Decrease the engine speed slowly and make the
indicator value of ammeter become 30A, and read the indicator value of voltmeter now. Limit
value: Max. 0.3V
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BYD S6, S6A, S6K Service Manual
NOTICE
When the output power of alternator is big and can not make the indicator value of am-
meter decrease to 30A, adjust to 40A and read the indicator value of voltage difference.
The limit value is turning to max 0.4V now.
11. If the indicator value of voltmeter is higher than limit value; can consider that the output line
of alternator is not good, so check the wiring (including fuse) between alternator end “B” and
battery (+) end. If ¿nd the problem that the end is becoming Àexible and the wiring is turning
color because of too hat, repair and test again.
12. After the test, make the engine running in idle speed.
17. Disassemble the ammeter and voltmeter which are used to test.
Load
Voltmeter Ammter (caliper)
Combination instrument
Ignitiong seitch Charging alarm
lamp
Alternator
Engine ECU
Battery jar
The objective of this test is that ¿nd out whether the output current of alternator is normal.
NOTICE
Battery jar needs to be discharged a little. Sometimes using full charged battery jar can
not do the test accurately because of lacking of electric load.
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BYD S6, S6A, S6K Service Manual
Tension degree of driving belt. (refer to the sequence of repair and regulation)
State of fuse.
4. Connect a caliper DC ammeter (range: 0-150A) to the output line of alternator B end.
NOTICE
Because of the inadequate connection between “B” end and output line, the method of
using the output line of disassembling alternator to connect ammeter can not find the
problem of output current decreasing.
5. Connect a 0-20 V testing voltmeter between end “B” and ground. (Connect voltage (+) con-
ductor to end “B”, connect voltage ( ϔ ) conductor to ground.)
9. Check the reading of voltmeter whether it is same to the voltage of battery jar.
NOTICE
If the voltage is 0V, consider that the connection between alternator end “B” and battery (+)
end disconnected or the fuse burned.
10. After turning on the lighting switch and headlight, start engine.
11. Turn the headlight to high beam position, turn the warmer switch to large air flow, and
then rise the speed to 2500 r/min, measure the max output current value on the ammeter.
Limit value: 70% of rating output current
NOTICE
The rating output current value is explaining on the nameplate of alternator.
Because the charge current may decrease rapidly after engine starting, you must
read the max current value quickly.
The output current is changing along with the size of load or temperature of
alternator.
When testing; if the electric load of vehicle is small, although the alternator is nor-
mal, it can not obtain the stated output current. Under this condition, you can adopt
to open the headlight to make the battery jar discharge or use the lamp on other ve-
hicle to increase the electric load, then do the test.
When the temperature of alternator or surrounding environment is too high, some-
times can not reach the stated output current. Under this condition, do the test after
the engine is cooling.
12. The reading of ammeter should be more than limit value. If it is less than the limit value but
the output line of alternator is normal, disassemble the alternator from engine and check it.
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BYD S6, S6A, S6K Service Manual
Load
Ammeter (caliper)
Combination instrument
Ignition seitch Charging
alarm lamp
Black
Alternator
Engine Blue
Battery jar ECU Red Yellow
Voltmeter (digital)
The objective of this test is that whether the voltage regulator can control the output voltage of al-
ternator or not.
Tension degree of driving belt. (refer to the sequence of repair and regulation)
State of fuse.
4. Use special tool (alternator test line MB991519) to connect digital voltmeter to alternator “S”
end and ground (Connect voltage (+) conductor to end “B”, connect voltage ( ϔ ) conductor
to ground or battery jar cathode).
5. Connect a caliper DC ammeter (range: 0-150A) to the output line of alternator B end.
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BYD S6, S6A, S6K Service Manual
NOTICE
Because of the inadequate connection between “B” end and output line, the method of
using the output line of disassembling alternator to connect ammeter can not find the
problem of output current decreasing.
8. Turn on the ignition switch, check the reading of voltmeter whether it is same to the voltage
of battery jar.
NOTICE
If the voltage is 0V, consider that the connection between alternator end “B” and battery (+)
end disconnected or the fuse burned.
12. Read the indicator value of voltmeter when decreasing the output current of alternator under
10A.
13. If the reading voltage value is same to the value in the voltage regulation table, it shows that
the function of voltage regulator is normal.
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Disassembly step
1. Oxygen sensor joint
2. Oxygen sensor joint
clip
<Vehicles for Hong Kong and Singapore>
3. A/C compressor as-
sembly joint
<Except for Hong Kong and Singapore>
4. A/C compressor joint
clip
5. Alternator joint
6. Alternator end
7. Joint bracket
8. Line clip
9. Alternator assembly.
Timing belt lower cov-
er
10. Alternator assembly
bracket
Disassembly step
1. Front bracket assem-
bly
2. Engine wheel
3. Rotor
4. Rear bearing
5. Rear holder
6. Front bearing
7. Front bracket
8. Stator
9. Fixing plate
10. Regulator
11. Brush
12. Rubber gasket
13. Recti¿er
14. Rear bracket
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BYD S6, S6A, S6K Service Manual
NOTICE
Do not insert the screw driver too deep,
avoid damaging stator iron core.
2. Disassembly of pulley
NOTICE
Do not injure rotor.
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NOTICE
Insert the wire to fasten the brush, it is
more easy to install the rotor.
Rear bracket
Brush
Line
2. Installation of rotor
Inspection:
Rotor
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Stator
5HFWL¿HUDVVHPEO\
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Brush
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7. Starting system
7.1 Summary
Turn the ignition switch to “start” position, the current inputs into the coil in the electromagnetic
switch to attract the iron core, the iron core is attracted, the bar connecting with the iron core is
doing to make the starter clutch connect. On the other hand, attracted iron core make the electro-
magnetic switch guide circuit, and make the B end and D end guide circuit, so the current make
the engine work. When the ignition switch turn to “ON” position again, starter clutch disconnect
from gear ring.
There is a over speed clutch between pinion and armature shaft, use to prevent the starter dam-
aged.
6WDUWHUVSHFL¿FDWLRQ
Item Speci¿cation
Type Planetary gear subtrahend driving
Rating output power kW/V 1.4/12
Gear number 8
5HSDLUVSHFL¿FDWLRQ
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Disassembly step
1. Oil pipe
2. O type ring
3. Radiator pipe clip
4. Service pipe
5. Return pipe
6. ATF warmer
7. Starter cover
8. Wiring harness clip
9. Starter joint
10. Starter end
11. Starter
12. Starter cover bracket
Battery jar
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BYD S6, S6A, S6K Service Manual
Small gear
Small gear clearance
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NOTICE
Battery jar
Starting Test must be rapid (less than 10 sec-
Line
motor onds), prevent burning the coil.
NOTICE
Battery jar
Starting Test must be rapid (less than 10 sec-
motor Line
onds), prevent burning the coil.
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WARNING
Take care of your finger when pushing
the gear.
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Disassembly step
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BYD S6, S6A, S6K Service Manual
NOTICE
Mafnetic switch S end
Do not use the pliers to clip the magnetic
component.
B end
Disassemble the lead wire from M end of
M end electromagnetic switch.
Excatation
coil head
Overspeed
clutch
1. Parts can not clean in the cleaning 2. Driving parts can not clean in the clean-
agent, putting the component of magnet- ing agent, the overspeed clutch have
ic, excitation coil in the cleaning agent been oiled before leaving factory, when
can damage its insulating. cleaning in the cleaning agent, the clean-
ing agent may wash away the lubrication
oil in the clutch.
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Clip spring
Rotor
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BYD S6, S6A, S6K Service Manual
Brush bracket
Overspeed clutch
Lock
Brush
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Armature coil
NOTICE
Do the test after cleaning the rotor sur-
face drastically.
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1. Troubleshooting Procedures
Procedure 1: Communication with ECU Dif¿culty
Notice: There shall be data communication between 7# terminal at the output end of diag-
nostic connector and the A48-22# terminal of engine ECU.
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Diagnostic procedures:
NOTICE
Check the Ac05 connector before check-
ing the wire harness; if abnormal, repair
¿UVW
Procedure 2:Engine Warning Light Isn’t Illuminated When Ignition Switch Turned to ON
Diagnostic procedures:
1. Read DTC with MUT-III. If any DTC, refer to the diagnostic procedures. If no DTC, go to next
step.
2. Check the symptom of malfunction. If it still exists, replace the instrument panel assembly. If
not, it is an intermittent malfunction.
Procedure 3: Engine Warning Light Doesn’t Go Out
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BYD S6, S6A, S6K Service Manual
Diagnostic procedures:
1. Read DTC with MUT-III. If any DTC, refer to the diagnostic procedures. If no DTC, go to next
step.
2. Check the symptom of malfunction. If it still exists, replace the instrument panel assembly. If
not, it is an intermittent malfunction.
Procedure 3: Engine Cannot Start (Starter Running with No Ignition )
Diagnostic procedures:
Engine: running
Standard value: camshaft rotating
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BYD S6, S6A, S6K Service Manual
Procedure 4: Engine Cannot Start (Car Does Not Start Even with Ignition On) Engine Can-
not Start (Long-Time Start)
Diagnostic procedures:
1. Check the battery status. If normal, let the engine idle for 10 minutes after it gets hot. If ab-
normal, go to next step.
2. Check the battery voltage. Standard value: 8V. If abnormal, check the battery. If normal,
go to next step.
3. MUT-III DTC. If any DTC, refer to the troubleshooting procedures. If no DTC, go to next step.
4. Check data stream with MUT-III. Refer to the data stream table. If abnormal, check abnormal
sensor. If normal, go to next step.
5. Check data stream with MUT-III. Item 25: Atmospheric Pressure Sensor. If abnormal, replace
it. If normal, go to next step.
6. Check if the throttle body is dirty. If abnormal, clean the throttle body. If normal, go to next
step.
Test the actuator with MUT-III. Item 07: Fuel Pump. Standard: the sound of fuel pump
working can be heard. If abnormal, check the fuel pump system. If normal, go to next step.
7. Check the intake pipe and the intake manifold for intake condition. If abnormal, repair it. If
normal, go to the next step.
8. Check the fuel nozzle for working sound. If abnormal, check the fuel injector of the faulty cyl-
inder. If normal, go to next step.
9. Check the timing belt for timing mark. If abnormal, adjust the timing mark. If normal, go to
next step.
10. Check the ignition coil. Check the ignition coil. If abnormal, check the ignition circuit (Refer to
Procedure 26). If normal, go to next step.
11. Check the injection nozzle for the atomizing condition. If abnormal, repair the nozzle. If nor-
mal, go to next step.
12. Check the fuel pressure. If abnormal, repair it. If normal, go to next step.
13. Check the EGR solenoid valve (stepper motor). If abnormal, replace it. If normal, go to next
step.
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BYD S6, S6A, S6K Service Manual
14. Replace the engine ECU. After it is replaced, check the symptom of malfunction again. If it dis-
appears, stop checking. If it still exists, check if there is water or other impurities in the fuel.
Procedure 5: Unstable Idling, Too High&Low Idle Speed, Engine Stall in Idle
Diagnostic procedures:
1. Check the battery status. If the battery
terminals are disassembled, leave the
engine idling for 10 minutes after pre-
heated.
If not disassembled, go to next step.
2. Check if any DTC exists by the “Self-Di-
agnosis” function on the MUT-III. If any
DTC, refer to the diagnostic procedures.
If no DTC, go to next step.
3. Check the data stream with MUT-III.
Refer to the data stream table.If
abnormal,check abnormal sensor. If nor-
mal, go to next step.
4. Check data stream with MUT-III. Item
25: Atmospheric Pressure Sensor. If ab-
normal, replace the ECU. If normal, go
to next step.
5. Check the intake pipe and the intake
manifold for intake condition. If abnor-
mal, repair it. If normal, go to next step.
6. Check the timing belt for timing mark. If
abnormal, adjust the timing mark. If nor-
mal, go to next step.
7. Check if the throttle body is dirty. If ab-
normal, clean the throttle body. If nor-
mal, go to next step.
8. Check data stream with MUT-III.
If abnormal, check the abnormal sensor
.If normal, go to next step.
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Transmission: N or P gear
NOTICE
Check the intermediate connector B-17
before checking the wire harness.
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BYD S6, S6A, S6K Service Manual
Diagnostic procedures:
1. Read DTC with MUT-III. If any DTC, refer to the diagnostic procedures. If no DTC, go to next
step.
2. Check data stream with MUT-III. Refer to data stream test table:
3. Check the EGR solenoid valve (stepper motor). If abnormal, replace it. If normal, go to next
step.
4. Check the intake pipe and the intake manifold for intake condition. If abnormal, repair it. If
normal, go to next step.
5. Check the spark plug. If abnormal, replace it. If normal, go to next step.
6. Check the ignition coil. If abnormal, check the ignition circuit system. If normal, replace the
ECU.
Procedure 7: Engine Stalling in Acceleration
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BYD S6, S6A, S6K Service Manual
Diagnostic procedures:
1. Read DTC with MUT-III. If any DTC, refer to the diagnostic procedures. If no DTC, go to next
step.
2. Check data stream with MUT-III. Refer to data stream test table.
3. Check the EGR solenoid valve (stepper motor). If abnormal, replace it. If normal, go to next
step.
4. Check if the throttle body is dirty. If abnormal, clean the throttle body. If normal, go to next
step.
5. Check the spark plug. If abnormal, replace it. If normal, go to next step.
6. Check the ignition coil. If abnormal, check the ignition circuit system. If normal, replace the
ECU.
Procedure 7: Engine Fails to Accelerate
Diagnostic procedures:
1. Read DTC with MUT-III. If any DTC, refer to DTC procedures. If no DTC, go to next step.
2. Test data stream with MUT-III. Refer to data stream test table:
3. Check the ignition coil. If abnormal, check the ignition circuit system. (Refer to Procedure
26). If normal, go to next step.
4. Check the timing belt for timing mark. If abnormal, adjust the timing mark. If normal, go to
next step.
5. Check the spark plug. If abnormal, replace it. If normal, go to next step.
6. Measure fuel pressure. If abnormal, repair it. If normal, replace the ECU.
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BYD S6, S6A, S6K Service Manual
Diagnostic procedures:
1. Read DTC with MUT-III. If any DTC, follow troubleshooting procedures. If no DTC, go to next
step.
2. Check the noises when the fuel injector is working. If abnormal, check the fuel injector of the
faulty cylinder. If normal, go to next step.
3. Check data stream with MUT-III. Refer to data stream test table:
4. Check data stream with MUT-III. Item 25: Atmospheric Pressure Sensor. If abnormal, replace
the ECU. If normal, go to next step.
5. Check canister control solenoid valve If abnormal, replace it. If normal, go to next step.
6. Check the EGR solenoid valve (stepper motor). If abnormal, replace it. If normal, go to next
step.
8. Check the spark plug. If abnormal, replace it. If normal, go to next step.
9. Check the ignition coil. If abnormal, check the ignition circuit system. (Refer to Procedure
26). If normal, go to next step.
10. Check if the throttle body is dirty. If abnormal, clean the throttle body. If normal, go to next
step.
11. Measure fuel pressure If abnormal, repair it. If normal, go to next step.
12. Check the compressor pressure. If abnormal, repair it. If normal, replace the ECU.
Procedure 9: Impact or Vibration Is Felt in Acceleration
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BYD S6, S6A, S6K Service Manual
Diagnostic procedures:
1. Read DTC with MUT-III. If any DTC, refer to the diagnostic procedures. If no DTC, go to next
step.
2. Check the data stream with MUT-III. Refer to the data stream table.
3. Check if the throttle body is dirty. If abnormal, clean the throttle body. If normal, go to next
step.
4. Check the spark plug. If abnormal, replace it. If normal, go to next step.
5. Check the ignition coil. If abnormal, check the ignition circuit system. (Refer to Procedure
26). If normal, replace the ECU.
Procedure 10: Impact or Vibration Is Felt in Deceleration
Diagnostic procedures:
1. Read DTC with MUT-III. If any DTC, refer to DTC procedures. If no DTC, go to next step.
2. Check the data stream with MUT-III. Refer to the data stream table.
3. Check if the throttle body is dirty. If abnormal, clean the throttle body. If normal, replace the
ECU.
4. Check the spark plug. If abnormal, replace it. If normal, go to next step.
5. Check the ignition coil. If abnormal, check the ignition circuit system. (Refer to Procedure
26). If normal, replace the ECU.
Procedure 11: Knock
Diagnostic procedures:
1. Read DTC with MUT-III. If any DTC, refer to DTC procedures. If no DTC, go to next step.
2. Check the spark plug. If abnormal, replace it. If normal, go to next step.
3. Check the ignition coil. If abnormal, check the ignition circuit system. (Refer to Procedure
26). If normal, check the knock sensor.
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BYD S6, S6A, S6K Service Manual
Diagnostic procedures:
1. Read DTC with MUT-III. If any DTC, refer to DTC procedures. If no DTC, go to next step.
2. Measure the output waveform of crankshaft angle sensor or camshaft position sensor (with
an oscilloscope).
Engine: idle
Transmission: N or P gear
Engine: idling
Transmission: N or P gear
3. Check the symptom of malfunction. If it still exists, replace the engine ECU. It means inter-
mittent fault if the fault disappears.
4. Check if the crankshaft angle sensor and the camshaft position sensor are properly installed.
If abnormal, repair. If normal, go to next step.
5. Check the timing belt for timing mark. If abnormal, adjust the timing mark. If normal, go to
next step.
6. Check the signal wheel of crankshaft. If abnormal, change it. If normal, go to next step.
7. Check the signal wheel of camshaft and if abnormal, change it. If normal, go to next step.
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BYD S6, S6A, S6K Service Manual
8. Replace the crankshaft angle sensor. After replacing, check the symptom of malfunction
again. If it disappears, the check is completed. If it still exists, go to next step.
9. Replace the camshaft position sensor. After replacing, check the symptom of malfunction
again. If it disappears, it is an intermittent malfunction. If it still exists, replace the engine
ECU.
Procedure 13: After-Burning
Diagnostic procedures:
Check the injection nozzle for the atomizing condition. Check each fuel injector for atomizing con-
dition. If abnormal, replace the nozzle. If normal, replace the ECU.
Procedure 14: Pungent Exhaust Smell, White or Black Smoke, Too High CO or HC Concen-
tration in Idling
Diagnostic procedures:
1. MUT-III DTC. If any DTC, refer to DTC troubleshooting procedures. If no DTC, go to next
step.
2. Check the fuel nozzle for working sound. If abnormal, check the fuel injector of the faulty cyl-
inder. If normal, go to next step.
3. Check ignition timing. If abnormal, check the ignition timing shifting (refer to Procedure 16). If
normal, go to next step.
4. Check data stream with MUT-III. Refer to the data stream table.
5. Check data stream with MUT-III. Item 25: atmospheric pressure sensor. If abnormal, replace
the ECU. If normal, go to next step.
6. Check the intake pipe and the intake manifold for intake condition. If abnormal, repair it. If
normal, go to next step.
7. Check the exhaust manifold for fuel leakage. If abnormal, repair it. If normal, go to next step.
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BYD S6, S6A, S6K Service Manual
8. Check if the throttle body is dirty. If abnormal, clean the throttle body. If normal, go to next
step.
10. Check canister control solenoid valve. If abnormal, replace it. If normal, go to next step.
11. Check the EGR solenoid valve (stepper motor). If abnormal, replace it. If normal, go to next
step.
12. Check the fuel pressure. If abnormal, repair it. If normal, go to next step.
13. Check the PCV valve. If abnormal, replace it. If normal, go to next step.
14. Check the spark plug. If abnormal, replace it. If normal, go to next step.
15. Check the ignition coil. If abnormal, check the ignition circuit system. (Refer to Procedure
26). If normal, go to next step.
16. Check the compressor pressure. If abnormal, repair it. If normal, go to next step.
17. Check the injection nozzle for atomizing condition. If abnormal, replace the nozzle. If normal,
go to next step.
18. Replace the catalytic converter. After replacing, check the symptom of malfunction again. It if
disappears, the check is completed. If it still exists, replace the engine ECU.
Procedure 15: Battery Leakage
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BYD S6, S6A, S6K Service Manual
Diagnostic procedures:
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BYD S6, S6A, S6K Service Manual
Transmission: N or P gear
Diagnostic procedures:
1. MUT-III DTC. If any DTC, refer to DTC troubleshooting procedures. If no DTC, go to next
step.
2. Check the engine water coolant. If abnormal, replace or add water coolant. If normal, go to
next step.
NOTICE
If the coolant level is too low, check for leaking point and repair.
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BYD S6, S6A, S6K Service Manual
If abnormal, check the fan control relay system (refer to Procedure 24). If normal, go to next
step.
4. Check data stream with MUT-III. Refer to the data stream table.
If abnormal, check the water temperature sensor system.If normal, go to next step.
6. Check the water pump If abnormal, replace it. If normal, replace the radiator.
Procedure 17: Fan Abnormal Rotation
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Description:
The 17# terminal or 9# terminal of engine ECU outputs a control signal to the fan controller.
Diagnostic procedures:
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BYD S6, S6A, S6K Service Manual
NOTICE
Check the connector A-16 before check-
ing the wire harness. If it is defect, repair
LW¿UVW
Oil bump
Fuel pump
relay
Fuel pump motor
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BYD S6, S6A, S6K Service Manual
Description:
The battery voltage is transmitted from the battery to the 86# terminal of fuel pump relay (1)
and then from the 85# terminal of fuel pump relay (1) to the ECM.
The battery voltage is transmitted from the 88# terminal of fuel pump relay (1) to the
88a#terminal of fuel pump relay (1) and the 4# terminal of fuel pump relay (2).
Diagnostic procedures:
Dismantle relay
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BYD S6, S6A, S6K Service Manual
Start
NOTICE
Check the intermediate connector before
checking the wire harness.
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Electricity
Ignition
coil
Ignition coil
Ignition coil
Ignition coil
Ignition coil
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BYD S6, S6A, S6K Service Manual
Diagnostic procedures:
Engine: running
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Engine: running
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Description:
The power supply is transmitted from the engine control relay (85# terminal) to the power ter-
minal (2# terminal) of oxygen sensor heater for upstream cylinder.
The power transistor of engine ECU (8# terminal) controls the oxygen sensor heater (4# ter-
minal) for cylinder 1.
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BYD S6, S6A, S6K Service Manual
Battery
Main
relay
15A
Main
relay
Shield layer
Shield layer
Diagnostic procedures:
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BYD S6, S6A, S6K Service Manual
Start
4. Check the engine control relay connector G2X-29. If abnormal, repair or replace it.
If normal, check the intermediate connector; if not, repair. If normal, check and repair the
wire harness between upstream oxygen sensor connector A20 (2# terminal) and the engine
control relay connector G2X-29 (1# terminal).
Start
6. Check the engine ECU connector A46. If abnormal, repair or replace it. If normal, go to next
step.
7. Check the wire harness between upstream oxygen sensor connector A20 (4# terminal) and
engine ECU connector A46 (8# terminal).
8. Check the engine ECU connector A46. If abnormal, repair or replace it. If normal, go to next
step.
9. Check the wire harness between upstream oxygen sensor connector A20 (2# terminal) and
engine control relay connector G2X-29.
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BYD S6, S6A, S6K Service Manual
NOTICE
Check the intermediate connector before checking the wire harness.
9. Check the wire harness between upstream oxygen sensor connector A20 (4# terminal) and
engine ECU connector A46 (8# terminal).
10. Check the symptom of malfunction. If it still exists, replace the engine ECU. If the malfunc-
tion disappears, it is an intermittent malfunction.
Procedure 23: Downstream Oxygen Sensor Heater System
Description:
The power supply is transmitted from the engine control relay 88a to the power terminal (2#
terminal) of oxygen sensor heater of downstream cylinder.
The power transistor of engine ECU (16# terminal) controls downstream oxygen sensor
heater (4# terminal).
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BYD S6, S6A, S6K Service Manual
Battery
EMS
main
relay
15A
Main
relay
Shield layer
Shield layer
Diagnostic procedures:
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BYD S6, S6A, S6K Service Manual
4. Check the engine control relay connector G2X-29. If abnormal, repair or replace it.
If normal, check the middle connector; if not, repair it ¿rstly. If normal, check and repair the
wire harness between downstream oxygen sensor connector A06 (1# terminal) and the en-
gine control relay connector G2X-29.
Start
6. Check the engine ECU connector A46. If abnormal, repair or replace it. If normal, go to next
step.
7. Check the wire harness between 2,3 #cylinder oxygen sensor connector A06 (4# terminal)
and engine ECU connector A46(16# terminal).
8. Check the engine ECU connector A46. If abnormal, repair or replace it. If normal, go to next
step.
9. Check the wire harness between downstream oxygen sensor connector A06 (2# terminal)
and engine control relay connector G2X-29.
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NOTICE
Check the intermediate connector before checking the wire harness.
10 Check the wire harness between 2,3 # cylinder oxygen sensor connector A06 (4# terminal)
and engine ECU connector A46(16# terminal).
11. Check the symptom of malfunction. If it still exists, replace the engine ECU. If the malfunc-
tion disappears, it is intermittent malfunction.
Procedure 24: EGR (Exhaust Gas Recycling) System
Battery
Main
relay
Main
relay
EGR
valve
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BYD S6, S6A, S6K Service Manual
Description:
The power supply is transmitted from the engine control relay (88a# terminal) to the EGR
valve (2# and 5# terminal).
The power transistor is turned on under the action of engine ECU (6#,2#,15#and 22# termi-
nal) so as to make the current pass through the EGR valve (1#, 3#, 4# and 6# terminal).
Diagnostic procedures:
Start
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BYD S6, S6A, S6K Service Manual
Start
3) Check the wire harness between the EGR valve connector A39 (4# terminal) and the engine
ECU connector A46 (22# terminal).
4) Check the wire harness between the EGR valve connector A39 (6# terminal) and the engine
ECU connector A46 (15# terminal).
7. Check the engine ECU connector A46. If abnormal, repair or replace it. If normal, go to next
step.
8. Check the wire harness between the EGR valve connector A39 and the engine ECU connec-
tor A46.
1) Check the wire harness between the EGR valve connector A39 (1# terminal) and the
engine ECU connector A46 (6# terminal).
2) Check the wire harness between the EGR valve connector A39 (3# terminal) and the
engine ECU connector A46 (2# terminal).
3) Check the wire harness between the EGR valve connector A39 (4# terminal) and the
engine ECU connector A46 (22# terminal).
4) Check the wire harness between the EGR valve connector A39 (6# terminal) and the
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8. Check the wire harness between the EGR valve connector A39 (2# and 5# terminal) and the
engine control relay connector G2X-29.
NOTICE
Check the intermediate connector before checking the wire harness.
Check the damage of power line. If it is not damaged, change engine ECU. If the
power line is worn, repair it.
Procedure 25: Canister Control Solenoid Valve System
Battery
Main
relay
Main
relay
Carbon Canister Control Valve
Description:
The power supply is transmitted from the engine control relay (88a# terminal) to carbon can-
ister control solenoid valve (1# terminal).
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The power transistor is turned on under the action of engine ECU (25# terminal) to make the
current pass through the canister control solenoid valve (2# terminal).
Diagnostic procedures:
4. Measure the executive voltage of canister control solenoid valve connector A13.
Start
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If normal, check the intermediate connector. If any malfunction, repair it ¿rst and then check
the wire harness between carbon canister control solenoid valve connector A13 (2# terminal)
and the engine control relay connector G2X-29 .
If abnormal, check and repair the wire harness between carbon canister control solenoid
valve connector A13 (2# terminal) and the engine ECU connector A46 (25# terminal).
8. Check the wire harness between the canister control solenoid valve connector A13 (2# termi-
nal) and the engine ECU connector A46(25# terminal).
9. Check the wire harness between carbon canister control solenoid valve connector A13 (1#
terminal) and the engine control relay G2X-29.
NOTICE
Check the intermediate connector C-116 before checking the wire harness.
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Power
steering
switch
Diagnostic procedures:
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Battery
Main
relay
Main
relay
Engine oil control valve
Description:
The power supply is transmitted from the engine control relay (88a# terminal) to engine oil
control valve (2# terminal).
The power transistor is turned on under the action of engine ECU (1# terminal) to make the
current pass to the oil control valve (1# terminal).
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Diagnostic procedures:
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NOTICE
Check the intermediate connector before
checking the wire harness.
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2. Ignition System
2.1 Overview
Four ignition coils with built-in power transistors are in the system, which apply on each cylinder
respectively. The interruption of the current at the preliminary side of the ignition coil will generate
high voltage electricity at the secondary side of the ignition coil. The high voltage generated will
be applied to the spark plug to generate spark. The engine ECU alternately turns on and off the
two power transistors inside the ignition coil.Thus, the primary current inside the ignition coils is
turned on and off so as to ignite for each cylinder in the order of 1—3—4—2.
The engine ECU determines the controlled ignition coil as per the signals sent out from the cam-
shaft position sensor and crankshaft angle sensor. It also detects the crankshaft position thus to
provide the optimum ignition timing for engine operating. When the engine is cold or operating at
high elevation, the ignition timing must be advanced slightly so as to ensure the optimum perfor-
mance in the running conditions. In addition, when knock occurs, the ignition timing is greatly de-
layed till knock disappears.
System Diagram
Ignition switch
Battery
Air flow sensor
Spark plug
Cylinder
,JQLWLRQFRLOVSHFL¿FDWLRQ
Item Speci¿cation
Ignition coil Moulded four coil
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6SDUNSOXJVSHFL¿FDWLRQ
Item Speci¿cation
NGK LZFR6AI
Special tool
NOTICE
Use analog ohmmeter
NOTICE
The test shall be completed rapidly (with-
in 10 seconds), so as to avoid coil burn
and power transistor damage.
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2. Remove the ignition coil and install a new spark plug on it.
6. If no spark is generated, replace with a new ignition coil and then check the spark.
7. If spark can be generated with the new spark coil, replace the old ignition coil. If still no
spark, check the ignition circuit.
NOTICE
Do not attempt to adjust the central
electrode gap of iridium.
Iraurita Cleaning with tools should be com-
electrodes pleted within 20 seconds and do not
use wire brush.
NOTICE
Prevent the impurities entering into the
cylinder.
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Disassemble Procedure
1 Ignition coil connector
2 Ignition coil
3 Spark plug
Disassemble Procedure
1 Camshaft position sensor
connector
2 Camshaft position sensor
3 O-Ring
Disassemble Procedure
1 Timing belt lower cover
2 Crankshaft position sensor
NOTICE
Do not let the knock sensor drops down or impacts with other components. If above-
mentioned cases are happened, please replace the knock sensor.
Disassemble Procedure
1 Knock sensor connector
2 Knock sensor clamp
3 Wire harness clamp
4 Intake manifold cover
5 Knock sensor
6 Knock sensor clamp
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3. Charging system
3.1 Overview
The charging system utilizes the electric energy output from the alternating- current generator to
charge the battery so as to keep a constant charging under different loads.
Voltage
About
Time
Action Principle
Rotation of the excited ¿eld coil generates an AC voltage in the stator. This alternating current is
recti¿ed through the diodes to DC voltage with its waveform illustrated on the left ¿gure. The aver-
age output voltage Àuctuates slightly with the alternator load condition.
When the ignition switch is turned on, current Àows in the ¿eld coil and initial excitation of the ¿eld
coil occurs. When the stator coil begins to generate power after the engine is started, the ¿eld
coil is excited by the output current of the stator coil. The alternator output power rises as the ¿eld
current increases and it falls as the ¿eld current decreases. When the battery voltage (alternator
S terminal voltage) reaches a regulated voltage of approximately 14.4V, the ¿eld current is cut off.
When the battery voltage drops below the regulated voltage, the voltage regulator regulates the
output voltage to keep constant level by controlling the ¿eld current.
In addition, when the ¿eld current is constant, the alternator output voltage rises as the engine
speed increases.
System Diagram
Stator coil
Engine ECU
Field coil
Voltage
regulator Ignition switch
Battery
Charging indicator light
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Alternator speci¿cation
Item Speci¿cation
Type Battery voltage check type
Rated output power V/A 12/110
Standard
Item Limit Value
Value
Voltage drop of alternator output line (30A) V Maximum 0.3
Voltage regulation range -20ć 14.2 ~ 15.4
Operating temperature of volt-
age regulator 20ć 13.9 ~ 14.9
60ć 13.4 ~ 14.6
80ć 13.1 ~ 14.5
Output current 70% of rated output current
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Ammeter (tong-type)
Generator
Voltmeter (digital)
Battery
Terminal B
This test is intended to test whether the cable (including fuse) between the alternator terminal B
and battery positive (+) terminal is normal.
3) Fuse status.
4. Connect a tong-type DC ammeter (range: 0-150A) to the output line of alternator B terminal.
NOTICE
With poor connection between “B” terminal and output line, problem of output current
drop cannot be found by means of removing the alternator output line and reconnecting
the ammeter.
5. Connect a digital voltmeter between the alternator terminal B and battery positive (+) termi-
nal. (Positive (+) wire of voltmeter is connected to terminal B and the negative (-) wire is con-
nected to battery positive (+) terminal.)
10. At 2500 rpm/min engine speed, adjust the alternator load by turning on or off the headlight
and other lights to make the ammeter pointer point at a value a bit higher than 30A. Slowly
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reduce the engine speed to make the ammeter pointer point at 30A and then read the value dis-
played on the voltmeter. Limit value: max. 0.3V.
NOTICE
When the alternator output power is too high to reduce the indicated value to 30A on the
ammeter, adjust it to 40A and read the value displayed on the voltmeter. Then, the limit
value is became maximum value 0.4 V.
11. If the displayed value is higher than the limit value, the alternator output line may be poor.
Therefore, check the cable (including fuse) between the alternator terminal B and battery
positive (+) terminal. If such abnormalities as loose terminal or discolored cable due to over-
heat are found, repair it ¿rst and then make test.
12. Make engine idle running after the test is completed.
13. Turn off all the lights.
14. Power supply OFF
15. Remove the MUT-III.
16. Remove the battery negative cable.
17. Remove the ammeter and voltmeter used for test.
Load
Combination instrument
Ignition switch Charging
-IG warning light
Generator
Engine-ECU
Battery
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The purpose of test is to check whether the alternator output current is normal.
NOTICE
The battery should be slightly discharged. A fully-charged battery is unable to pro-
YLGHVXI¿FLHQWORDGQHHGHGIRUDQDFFXUDWHWHVW
Fuse status.
4. Connect a DC tong-type ammeter (range: 0-150A) to the output line of alternator B terminal.
NOTICE
With poor connection between “B” terminal and output line, problem of output cur-
rent drop cannot be found by means of removing the alternator output line and re-
connecting the ammeter.
5. Connect a 0-20V voltmeter used for test between terminal B and grounding. (Positive (+)
wire of voltmeter is connected to terminal B; negative (-) wire is connected to grounding.)
NOTICE
If the voltage is 0 V, the cable between alternator terminal B and battery positive (+)
terminal may be disconnected or the fuse may be burnt.
10. Turn on the lighting switch and the headlight switch, and start the engine.
11. Set the headlight to the high beam and turn the heater blower switch to big volume position,
increase the engine speed to 2500 r/min and read the maximum output current value dis-
played on the ammeter.
Limit value: 70% of rated output current value
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NOTICE
)RUUDWHGRXWSXWFXUUHQWYDOXHUHIHUWRVSHFL¿FDWLRQVRQDOWHUQDWRUQDPHSODWH
Because charging current from the battery will soon drop after the engine is
started, you must read the maximum current value as quickly as possible.
The output current value varies with electrical load and temperature of alterna-
tor body.
,I WKH HOHFWULFDO ORDG RI WKH YHKLFOH LV VPDOO ZKLOH WHVWLQJ WKH VSHFL¿HG RXWSXW
current may not be able to obtain even though the alternator is normal. In such
cases, increase the electrical load by turning the headlight on to discharge the
battery or by using the lighting system in another vehicle, and then test again.
7KHVSHFL¿HGRXWSXWFXUUHQWPD\DOVRQRWEHDEOHWRREWDLQLIWKHWHPSHUDWXUH
of the alternator body or the ambient temperature is too high. In such cases,
cool the alternator and then test again.
12. The reading on the ammeter should be greater than the limit value. If it is lower than the limit
value and the alternator output line is normal, remove the alternator from engine and check
it.
13. Make engine idle running after the test is completed.
14. Power supply OFF.
15. Remove the MUT-III tester.
16. Remove the battery negative cable.
17. Remove the ammeter and voltmeter used for test.
18. Connect the battery negative cable.
3.6 Voltage regulation test
Load
Ammeter (tong-type)
Combination instrument
Black
Generator
Blue
Engine-ECU
Red Yellow
Battery
Voltmeter (digital)
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The purpose of test is to check whether the voltage regulator can properly control the alternator
output voltage.
Fuse status.
4. Connect the digital voltmeter between alternator S terminal and grounding with alternator
test cable (MB991519) by special tool (Positive (+) wire of voltmeter is connected to terminal
B and the negative (-) wire is connected to grounding or battery negative electrode.)
NOTICE
With poor connection between “B” terminal and output line, problem of output cur-
rent drop cannot be found by means of removing the alternator output line and re-
connecting the ammeter.
NOTICE
If the voltage is 0 V, the cable between the alternator terminal B and the positive (+)
battery terminal may be disconnected or the fuse may be burnt.
12. Read the value displayed on the voltmeter when the alternator output current reduces to 10A
or less.
13. If reading of voltage value is same as the value in the voltage regulation table, the voltage
regulator is working normally.
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Disassemble procedure
1 Oxygen sensor connec-
tor
2 Oxygen sensor connec-
tor clamp
3 A/C compressor as-
sembly connector
4 A/C compressor con-
nector clamp
5 Alternator connector
6 Alternator terminal
7 Connector bracket
8 Cable clamp
9 Alternator assembly
ƽ Timing belt lower cover
10 Alternator assembling
bracket
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BYD S6, S6A, S6K Service Manual
Disassemble procedure
1. Front bracket assembly
2. Alternator wheel
3. Rotor
4. Rear bearing
5. Rear clamp holder
6. Front bearing
7. Front bracket
8. Stator
9. Fixing plate
10. Adjuster
11. Electric brush
12. Rubber gasket
13. Recti¿er
14. Rear bracket
NOTICE
Do not insert screwdriver too
o deep in or-
der to avoid damage stator core.
NOTICE
Do not damage the rotor.
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BYD S6, S6A, S6K Service Manual
NOTICE
After unsoldering in four seconds
with 180 - 250W electric soldering
iron. Do not weld for long time as the
Weldment heat of the electric iron may transmit
to the diodes
Do not pull the leads of diodes with
too much force
1). 8QVROGHUWKHVWDWRUIURPWKHUHFWL¿HUDV-
sembly.
2). DisassembleWKHUHFWL¿HUIURPUHJXODWRU,
unsolder all the soldered points of recti-
¿HU
After Installing
ing the regulator assembly prop-
erly, push in the brush and insert metal wire
into the rear bracket hole to hold the brush.
Metal wire
NOTICE
Insert metal wire to hold the brush and
replace rotor easily.
Rear bracket
Brush
Line
Metal wire
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Check:
Rotor
Stator
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5HFWL¿HUDVVHPEO\
Brush
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BYD S6, S6A, S6K Service Manual
4 Starting System
4.1 Overview
If the ignition switch is turned to “START” position, current Àows in the coil inside magnetic switch
to attract iron core. When the iron core is attracted, the lever connected to the iron core is actu-
ated to engage the starter clutch. On the other hand, attracted iron core will turn on the magnetic
switch, and allow the B and M terminal to conduct. Thus, current Àows engage the starting motor.
When the ignition switch is returned to “ON” position after starting the engine, the starter clutch is
disengaged from the ring gear.
An overrunning clutch is provided between pinion and armature shaft to prevent damage to the
starter.
6WDUWHU6SHFL¿FDWLRQ
Item Speci¿cation
Type Reduction drive with planetary gear
Rated output power kW/V 1.4/12
Number of teeth 8
0DLQWHQDQFH6SHFL¿FDWLRQ
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Disassemble proce-
dure
1. Oil pipe
2. O-ring
3. Radiator pipe clamp
4. Water supply pipe
5. Water return pipe
6. ATF heater
7. Starter cover
8. Wire harness clamp
9. Starter connector
10. Starter terminal
11. Starter
12. Starter cover bracket
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'LVFRQQHFWWKH¿HOGFRLOIURPWKH0WHU-
minal of magnetic switch.
Switch
2. Connect 12V battery between S terminal
and M terminal.
Battery
3. Turn the ignition switch to “ON” and
Starting make pinion disconnect.
motor Line
NOTICE
The test must be conducted quickly (
less than 10 seconds) to prevent coil be-
ing burnt.
Pinion
Pinion gap
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,ISLQLRQJDSLVRXWRIVSHFL¿FDWLRQDG-
just it by adding or removing gaskets
between magnetic switch and front
bracket.
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Ammeter
1. Connect starting motor to fully-charged
12V battery as shown in the ¿gure.
Variable resistance 2. Connect ammeter and variable resis-
tance to battery positive terminal and
starting motor terminal.
Battery
Starting 3. Connect voltmeter across the starting
motor Voltmeter motor.
CAUTION
%HFDUHIXORI\RXU¿QJHUVZKHQSXVKLQJ
the pinion.
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Disassembly Procedure
12. Plate 13. Planet gear 14. Rod 15. Snap spring 16. Thrust ring 17.Overrunning Clutch
18. Internal gear 19. Planet gear shaft 20. Front bracket
Magnetic
S terminal <<1>> Solenoid Valve Disassemblyl
switch
B terminal
NOTICE
Do not clamp magnetic assembly with
pliers.
M terminal
Field coil head
Disassemble lead from M terminal of mag-
netic switch.
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Overrunning Clutch
1. Do not immerse parts in cleaning sol- 2. Do not immerse drive parts in cleaning
vent to clean them, and the insulation of solvent. Overrunning clutch is lubricated
magnet yoke, ¿eld coil assembly or rotor before delivery and solvent will wash
will be damaged. off lubrication on the clutch when it is
cleaned in cleaning solvent.
Snap spring
Rotor
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Brush Holder
Overrunning Clutch
&RQ¿UPLISLQLRQURWDWHVVPRRWKO\WRWKH
right but not to the left.
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Brush
Armature Coil
NOTICE
Clean the rotor surface completely and
then check it.
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Preface
With the development of national economy, the car ownership is increasing, and the environ-
mental regulations are constantly stricter. From July 1, 2000, the Euro-I emission regulations had
been implemented for newly produced cars. Recently, the Ministry of Environmental Protection
informed that the cars and light vehicles with carburetor engines wouldn’t be allowed for licens-
ing from September 1, 2001. At the same time, the Euro-I emission regulations would also be
implemented for the trucks lower than 3.5t. In fact, many automobile manufacturers develop new
products basing on Euro-II instead of Euro-I. The successful organization of 2008 Beijing Olympic
Games had further promoted China’s automobile emission control.
Since the combination of closed-loop control of petrol rationing and three-way catalytic converter
may reduce emission of toxic substances by more than 92%, replacing the carburetor with elec-
tronically controlled gasoline injection technology has become an irreversible trend. This suggests
that, the carburetor engine era has ended in the Chinese automotive industry, and electronically
controlled gasoline injection engine era had begun.
As the No.1 supplier of auto engine electronic control fuel injection system in China, United Auto-
motive Electronic Systems Co., Ltd. started to supply MOTRONIC series electronic fuel injection
system introduced from Germany BOSCH in china from 1996. As a trademark, MOTRONIC does
not have speci¿c meaning, but MOTRONIC system indeed has certain unique technology char-
acteristics, that is the two systems of fuel quantitative electronic control system and ignition timing
electronic control system are integrated to share a set of sensors, electronic control unit and pow-
er device. MOTRONIC systems all have the ignition timing electronic control function, obviously
improving the engine performance.
Like other electronic control fuel injection system, MOTRONIC system on the one hand can de-
crease the vehicle emission largely; on the other hand, it also presents dif¿culties to the repairer
who is only familiar with the engines equipped with a traditional carburetor. There are no familiar
mechanical components in electronic control fuel injection engine, which is replaced with a va-
riety of electronic components. Formerly, the repairer even driver can adjust the carburetor or
distributor; however, now with the data stored in the computer chips, the common repairer can
not eliminate malfunction through using electronic instrument to modify data. When the electronic
components have malfunction, it can not be identi¿ed from the external without using instruments
for test. So when repairing the electronic control fuel injection engine, the repairer often feels at
limit. In light of this realistic condition, we write this repair manual to offer help in two sides: help
the engineers of engine factory or whole vehicle factory to know more about the engine electronic
control system; and help the repairers in repairing the electronic control fuel injection engine.
The manual ¿rstly introduces the composition and working principle of electronic control fuel injec-
tion system. And then introduce the structure and performance of every part in detail.
Generally speaking, fault diagnosis instrument, which can read the fault information record stored
in the ECU, is an essential tool in the process of repairing the electronic control fuel injection sys-
tem. To help reader understand real meaning of every kind of fault codes, this manual lists all fault
conditions for ECU to set a fault code. However, many faults can not be con¿rmed directly ac-
cording to fault information record, and it may sometimes take a series of analysis to ¿nd out the
real cause of a fault. So, this manual uses many pages to describe how to ¿nd out the real fault
according to fault information record.
Electronic control unit’s existence itself brings up many new fault causes of engines. In other
word, the same kind of engine fault may be caused by mechanical reason, also may be by elec-
tronic reason. And use of fault diagnosis instrument may not always be able to pinpoint the fault.
So, this manual combines engine symptom with the electronic control system to locate fault.
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BYD S6, S6A, S6K Service Manual
1) Only allow using digital multimeter to check the electronic fuel injection system.
2) Only use genuine product parts when repairing, or it can not ensure the electronic fuel injec-
tion system to work normally.
5) In the maintenance process, never disassemble parts of electronic fuel injection system.
6) In the maintenance process, take care when holding electronic component (such as elec-
tronic control unit, sensor) to avoid dropping them on the ground.
7) Build up the environmental protection consciousness, properly deal with the castoff produced
in the maintenance.
1.2 Precautions in Maintenance Process
1) Do not disassemble any parts of electronic fuel injection system or its connector from its in-
stallation position randomly to avoid accidental damaging or entering of water, oil pollution,
which may inÀuence the normal working of electronic fuel injection system.
2) When disconnecting or connecting the connector, always turn the ignition switch to OFF po-
sition, or it can damage electric component.
3) When doing the fault’s heat states condition simulation and other maintenance working
which can make the temperature rise, always keep the temperature of electronic control unit
below 80°C.
4) The supply pressure of electronic fuel injection system is high (about 350kPa), so all fuel
pipes adopt the high pressure fuel pipes. Even if the engine is not running, there is also high
fuel pressure in the fuel circuit. Do not disassemble the fuel pipes in maintenance process
unless necessary. When it is needed to maintain fuel pipes, you should do pressure relief
treatment to fuel system before disassembling the fuel pipes as following: start the engine
and make it running idle, connect the diagnosis instrument, enter “Actuator Test” and shut off
the fuel pump, till the engine going out by itself. The disassembly of fuel pipes and replace-
ment of fuel ¿lter should be done at the draughty place by quali¿ed repairer.
5) When getting down the electric fuel pump from fuel tank, do not electrify the fuel pump to
avoid generating electric spark and causing the ¿re.
6) It is not allowed to test fuel pump under dry state or in the water, or it may decrease the ser-
vice life, in addition the anode and cathode of fuel pump can not be connected reversely.
7) When checking the ignition system, do sparking test only when necessary, and time duration
shall be as short as possible. Do not open the throttle when testing, or it may cause a lot of
unburnt gasoline entering into exhaust pipe and damage the three way catalyst.
8) Because the idle regulation is accomplished completely by the electronic fuel injection sys-
tem, it does not need manual regulation. The throttle stop screw of throttle body has been
regulated when leaving factory, the user is not allowed to change its position.
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BYD S6, S6A, S6K Service Manual
9) When connecting the battery, the anode and cathode of battery can not be connected re-
versely or electronic component may be damaged. The system adopts cathode ground.
11) Before welding on the vehicle, cable of battery anode, cathode and electronic control unit
shall be removed.
12) Do not pierce insulation layers of the cable to test the input and output electronic signal of
parts.
1.3 Maintenance Tool Summary
Tool name:
Function:
Tool name:
Function:
Tool name:
Function:
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BYD S6, S6A, S6K Service Manual
Tool name:
Digital multimeter
Function:
Tool name:
Vacuum meter
Function:
Tool name:
Function:
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Tool name:
Function:
Tool name:
Exhaust analyzer
Function:
Tool name:
Function:
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DG Speed sensor
DKG Throttle position sensor
DLA Idle regulator/step motor
DR Fuel pressure regulator
DS-S-TF Intake pressure temperature sensor
ECU Electronic control unit (computer)
EKP Fuel pump
EMS Engine management system
EWD Idle regulator/rotating pilot valve
EV Fuel injector
LSH Heating type oxygen sensor
KS Knock sensor
KSZ Fuel distributor assembly
KVS Fuel distributor
PG Phase sensor
ROV Ignition system with distributor
RUV Ignition system without distributor
TEE Fuel pump bracket assembly
TEV Canister control valve
TF-W Coolant temperature sensor
ZSK Ignition coil
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2. M7 System Introduction
2.1 System Basic Principle
Engine management system, usually consisted of sensor, microprocessor (ECU) and actuator,
controls the intake air quantity, fuel injection quantity and ignition advance angle. Basic structure
is shown in the ¿gure 2.1.
Diagnosis Diagnos is
Sensor ECU Actuator
Engine
In engine electronic control system, sensor acts as input part to measure every kind of physics
signals (temperature, pressure etc.) and then convert it into corresponding electrical signal; ECU
receives the input signal of sensor, makes calculation according to setting program and generate
corresponding control signal and output to power driving circuit; the power driving circuit makes
the engine running according to vested control strategy through driving every actuator to execute
different actions; fault diagnosis system of ECU can monitor every parts in system or control func-
tion, and, once any fault is detected and af¿rmed, save the fault code and activate “limp home”
function. When ECU detects that the fault is eliminated, the normal value will resume in use.
The most important feature of M7 engine electronic control management system is torque-based
control strategy. The main purpose of torque-based control strategy is to interlink different control
targets together. M7 engine electronic control system structure is shown in ¿gure 2.2.
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BYD S6, S6A, S6K Service Manual
M7-Motronic system is an electronic controlled gasoline engine control system. It supplies many
control features about operator and vehicle or equipment, and combines open loop and closed
loop (feedback) control together, providing a variety types of control signals for engine running.
The main functions of system are:
Improve the mixture gas control function under both static and dynamic status
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BYD S6, S6A, S6K Service Manual
Catalyst heating
Canister control
Idle control
Limp home
2) Additional function
Anti-thief function
Connection of torque and external function (such as transmission mechanism or vehicle dy-
namic control)
In the M7 engine management system, all interior requirements and exterior requirements of
engine are de¿ned with the engine’s torque or ef¿ciency requirement, as shown in ¿gure 2.3. Dif-
ferent requirements of the engine are converted into control variables of torque or ef¿ciency, and
then these variables are processed in center torque demand coordinator module ¿rstly. M7 sys-
tem can arrange these mutual conÀicting requirements according to priority order and execute the
most important requirement. It obtains engine control parameters such as fuel injection time, igni-
tion timing through torque converter module. In this process, the control variable’s execution has
no inÀuence on other variables, which is the advantage offered by torque-based control system.
As for matching the engine, the control system based on torque only depends on engine data
when matching engine characteristic curve and pulse spectra as it has variable independence,
eliminating interference with other performance functions and variables. It avoids repeated de-
marcating, simpli¿es the matching process and reduces the matching cost.
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Compared with the conventional M series engine electronic fuel injection management system,
the main characteristics of M7 system are:
New engine function structure which treats the torque as variable, allowing easiest compat-
ibility with other systems and strong expandability;
New modular software structure and hardware structure, powerful transplantable capability;
Basic engine characteristic graphs based on model, which are independent and simplify the
calibration process;
Improve the drive performance through coordinating every kind of torque requirements;
The system makes room for requirements in the future, for example: emission regulation,
OBD II, electronic throttle, etc.
2.2 Control signal: M7 system input/output signal
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Phase signal
Speed signal
After the signals above enter into ECU, they will be processed to generate the needed actuator
control signals. These signals are ampli¿ed in the output driving circuit and transferred into every
corresponding actuator. These control signals include:
In the starting process, special calculation method is used to control the intake quantity, fuel in-
jecting and ignition timing. In the beginning stage of the process, the air in the intake manifold is
static; the interior pressure of intake manifold is displayed as the atmospheric pressure around.
When closing the throttle, the idle regulator will be appointed with a ¿xed parameter which is de-
cided according to starting temperature.
In the similar process, speci¿c “fuel injection timing” is appointed as primary injection pulse.
The fuel injection quantity is vary with the engine temperature to facilitate the fuel ¿lm forming in
the intake manifold and on the cylinder wall, therefore, before the engine speed reaches certain
speed, mixture of gas and air shall be enriched.
Once the engine starts to run, system immediately begins to decrease the starting enriching till
completely canceling the starting enriching when the starting condition is over (600…700min-1).
The ignition angle is adjusted continuously under starting condition along with engine tempera-
ture, intake temperature and engine speed.
After the engine is starting at low temperature, the cylinder intake quantity, fuel injection and elec-
tronic ignition are all adjusted to compensate the higher torque requirement of engine; the pro-
cess is continued until the engine reaches proper temperature threshold.
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In this stage, the most important is quick heating of three-way catalyst, because quickly transit-
ing to working status of three-way catalyst can decrease the emission greatly. Under this working
condition, the ignition advance angle is delayed moderately so that exhaust gas can be used to
heat up three-way catalyst.
Part of the fuel injecting into intake manifold can not arrive at the cylinder in time to joint the fol-
lowing burning process. Contrarily, it will form a layer of fuel film on the intake manifold wall.
When the load improves and fuel injection duration prolongs, the fuel quantity in the fuel ¿lm can
increase rapidly.
When the throttle opening is increasing, part of the injection fuel is absorbed by fuel ¿lm. So sup-
plement fuel quantity must be injected correspondingly to compensate it and prevent the mixture
gas get less dense when accelerating. Once the load factor is decreasing, the additional fuel in-
cluded in fuel ¿lm on the intake manifold wall will be released again, as a result, in the decelerat-
ing process, fuel injection duration must be decreased correspondingly.
Inverted haul or towed condition is referred to the situation that the power supplied by engine on
Àywheel is negative. Under this situation, engine friction and pumping loss can be used to make
the vehicle decelerate. When the engine is in the condition of inverted haul or towed, the injection
fuel is cut off to decrease the fuel consumption and the exhaust emission, and, the more impor-
tant, to protect the three-way catalyst.
Once when the speed is decreasing to a certain speed where fuel supply is recovered over the
idle speed, the fuel injection system will resume supply fuel. In fact, there is a range of recovery
speed in ECU program. Recovery speed varies with parameters such as engine temperature,
engine speed dynamic change, and prevents the speed decreasing to stated lowest threshold
through calculating.
Once the fuel injection system is supplying fuel anew, system begins to use primary fuel injection
pulse to supply supplement fuel, and build the fuel ¿lm again on the intake manifold wall. After
recovering fuel injection, the control system based on torque makes the engine torque increase
slowly and stably.
In idle speed, the engine does not supply torque to the Àywheel. To ensure the engine to run sta-
bly in the idle speed as low as possible, the closed loop idle control system must keep the bal-
ance between the torque generated and engine “power consumption”. It needs to generate cer-
tain power in idle speed to satisfy the load requirement of different aspects, including crankshaft
and valve mechanism from engine and auxiliary components, such as the interior friction of water
pump.
Torque-based control strategy of M7 system uses closed loop idle control to determine the
needed engine output torque to keep the required idle speed under every working condition. The
output torque is increased as the engine speed decreases, and decreased as the engine speed
increases. The system requests larger torque to answer new “interference factors”, such as the
opening and closing of A/C compressor or shifting gear of AT. When the engine temperature is
low, it also needs to increase the torque to compensate larger interior friction loss and/or keep
higher idle speed. The total of all these output torque demands is passed to torque coordinator,
which processes such demands to obtain the corresponding density, mixture component and igni-
tion timing.
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ȜFORVHULQJFRQWURO
Post-exhausting treatment in the three-way catalyst is an effective method to decrease the con-
centration of harmful substance in exhaust gas. The three-way catalyst can decrease the HC,
CO, NOx by 98% or more, converting them into H2O, CO2 and N2. But it can reach the high ef-
¿ciency only when the engine excess air ratio ¬ falls in a narrow range around 1, and the aim of
¬ closed loop control is to ensure the mixture concentration is in this range.
¬ close loop control can work only when equipping oxygen sensor. The oxygen sensor on the
side of three-way catalyst inspects the oxygen content in exhaust gas, lean mixture (¬>1) gen-
erates the sensor voltage about 100mV; rich mixture (¬1) generates the sensor voltage about
900mV. When the ¬=1, the sensor voltage has a jumping. ¬ closed loop control answers the
input signal (¬!1=lean mixture, ¬!1=rich mixture) and then modi¿es the control variable, and
generates the correction factor to act as multiplier to correct the fuel injection duration.
Because of the exterior radiation heat and return fuel heat transfer, the fuel in the tank is heated,
and form fuel steam. Because limited by evaporation emission code, the steam which contains a
lot of HC is not allowed to exhaust into air directly. The fuel steam in the system is collected in the
carbon canister though canal, and entered into engine and jointed in burning processes by blow-
ing and washing at the proper time. The airÀow which is used to blow and wash the gas is real-
ized through control valve of ECU controls canister. This control only works when ¬ closed loop
control system works in closed loop status.
System detects the characteristic vibration when the knock is happening through the knock sen-
sors installed on the proper positions of engine, translates the vibration into electronic signals,
which is transferred into ECU for processing. ECU detect whether the knock happens in the every
burning circle of every cylinder using the special arithmetic. Once the knock is detected, it will trig-
ger knock closed loop control. After the knock danger is eliminated, the ignition advance angle of
inÀuenced cylinders is reset to scheduled value gradually.
The threshold valve has good adaptability to different working condition and different grade of
fuel.
2.4 System fault diagnosis function introduction
Electronic control unit constantly detects the sensor, actuator, correlative circuit, fault indicator
and battery voltage, even electronic control unit itself, and make reliability test to sensor output
signal, actuator driving signal and interior signals (such as ¬ closed loop control, coolant tem-
perature, knock control, idle speed control and battery voltage control, etc.). Once it ¿nds that any
link appears fault, or some signal value is not reliable, the electronic control unit immediately sets
the fault information record in fault memory of RAM. The fault information records are stored in
the form of fault code and displayed in order of appearance.
The fault can be divided into “random failure” and “stable failure” (for example, faults caused by
transient open harness circuit or poor connector contact) according to the frequency of its appear-
ance.
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Figure 2-4 Electronic fuel injection system fault diagnosis principle diagram
CLASS 5
Once the fault appears, corresponding fault code, as well as correlative fault information is
saved in fault code memory.
If the fault appears in 3 continuous driving cycles, the fault is af¿rmed, but ECU does not turn
on fault indicator.
After the fault is af¿rmed, it is deemed to have been repaired if the engine runs for 3 continu-
ous driving cycles without fault.
For an af¿rmed fault, if the engine runs for 40 continuous preheating cycles without fault after
the fault is repaired, the fault code is cleared.
For a random failure, if the engine runs for 40 continuous preheating cycles without fault, the
fault code is cleared.
CLASS 31
Once the fault appears, corresponding fault code, as well as correlative fault information is
saved in fault code memory.
If the fault appears in 3 continuous driving cycles, the fault is af¿rmed, but ECU does not turn
on fault indicator.
After the fault indicator turns on, the engine runs for 1 second without detecting fault, the
fault is deemed to have been repaired. the fault indicator turn soff..
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BYD S6, S6A, S6K Service Manual
For an af¿rmed fault, after 40 continuous preheating cycle without fault after the fault is re-
paired, the fault code is cleared
For a random failure, after 20 continuous preheating cycle without fault, the fault code is
cleared.
CLASS 33
Once the fault appears, corresponding fault code, as well as correlative fault information is
saved in fault code memory.
If the fault last for 2second, the fault is af¿rmed and ECU doesn’t turn on fault indicator.
After the fault is af¿rmed, if the engine runs for 1 second without detecting fault, the fault is
deemed to have been repaired.
For an af¿rmed fault, after 40 continuous preheating cycle without fault after the fault is re-
paired, the fault code is cleared
For a random failure, after 20 continuous preheating cycle without fault, the fault code is
cleared.
When no fault
After the ignition switch is turned to ON, the fault indicator turns on and goes out after 4 sec-
onds;
Start in 4 seconds, the fault indicator turns off after ¿nding the speed signal;
After K line grounds over 2.5 seconds, the fault indicator Àashes at 2Hz.
After the ignition switch is turned to ON, the fault indicator is always on;
Start, the fault indicator turns off after ¿nding the speed signal; if the fault indicator is de¿ned
to On mode in the fault class, the fault indicator remains on if corresponding con¿rmation
condition is satis¿ed;
After K line grounds over 2.5 seconds, it outputs Àashing code (P-CODE value). For exam-
ple: the Àashing mode of P0203 is: continuously Àash 10 times- intermission- continuously
Àash 2 times -intermission- continuously Àash 10 times- intermission- continuously Àash 3
times.
B_mxdfp Max fault, the signal exceeds the upper limit of normal range.
B_mndfp Min fault, the signal exceeds the lower limit of normal signal.
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The system adopts “K” line communication agreement and ISO 9141-2 standard diagnosis joint
(see ¿gure 2.5). This standard diagnosis joint is ¿xed and connected on engine harness. 4#, 7#
and 16# stitches are used to connect with the engine management system (EMS), in which the 4#
stitch is connected with ground line on vehicle, 7# stitch is connected with 71# stitch of ECU, that
is, the “K” line of engine data, and 16# stitch is connected with battery anode.
ECU can communicate with external diagnosis instrument through “K” line, and make the
following operations:
(See Using Introduction of M7 Diagnosis Instrument for description of functions and diagnosis in-
strument operations)
1.1 Engine speed, coolant temperature, throttle opening, ignition advance angle, fuel injection
pulse width, intake pressure, intake temperature, vehicle speed, system voltage, fuel injec-
tion correction, carbon canister scouring rate, idle speed air control, oxygen sensor wave-
form;
1.2. Engine speed objective, engine relative load, environment temperature, ignition closed time,
evaporator temperature, intake Àowrate, fuel consumption;
1.3. Throttle position sensor signal voltage, coolant temperature sensor signal voltage, intake
temperature sensor signal voltage, intake pressure sensor signal voltage, knock sensor1#
stitch signal voltage, knock sensor 2# stitch signal voltage.
Anti-thief system status, safety status, program status, cooling system status, stable working
condition status, dynamic working condition status, emission control status, oxygen sensor sta-
tus, idle status, fault indicator status, emergency working condition status, A/C system status, AT/
torque request status.
Fault indicator, fuel pump, A/C relay, fan, ignition, fuel injection (single cylinder fuel cut-off).
4. Milemeter display
Vehicle frame No. (VIN), ECU hardware No., ECU software No.
6. Fault display
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Intake pressure sensor, intake temperature sensor, engine coolant temperature sensor, throttle
position sensor, oxygen sensor, oxygen sensor heating line, air-fuel ratio correction, every cylin-
der injector, fuel pump, knock sensor, engine speed sensor, phase sensor, carbon canister control
valve, cooling fan relay, vehicle speed signal, idle speed, idle regulator, system voltage, ECU, A/C
compressor relay, evaporator temperature sensor, fault indicator.
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Turn on the ignition switch and ground engine data K line (standard diagnosis joint 7#) over 2.5
seconds. If there is fault code in ECU fault memory, Àashing code sent out by engine fault indica-
tor is the value of P-CODE. For example, P0203 Àashing mode is: continuously Àash 10 times-
intermission- continuously Àash 2 times -intermission- continuously Àash 10 times- intermission-
continuously Àash 3 times.
2.5 Explanation Related to Items
System characteristic:
New engine function structure using the torque as variable, compatible with other systems and
with strong expansibility;
New modular software structure and hardware structure, with strong expansibility;
Adopting signal panel of 60-2 gear to identify engine speed signal (engine speed sensor DG6);
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BYD S6, S6A, S6K Service Manual
Stitch: 1# grounding;
The sensor is made up by two sensors— intake manifold absolute pressure sensor and intake
temperature sensor, and installed on the intake manifold.
Intake manifold absolute pressure sensing element is made by a silicon chip, on which a piece
of pressure diaphragm is etched. There are four piezoresistances on the pressure diaphragm,
and they are used as strain elements to form a Wheatstone bridge. A signal processing circuit is
also integrated on the silicon chip. The silicon chip together with a metal shell composes a closed
reference space, in which the air absolute pressure is close to zero. This just forms a Microelec-
tromechanical systems (MEMS). There is a pressure close to zero acting on the activity surface
of silicon chip, and there is the intake manifold absolute pressure acting on the back surface of
it. The thickness of silicon chip is only several microns (m), so the changing of intake manifold
absolute pressure can make mechanical deformation on the silicon chip, and the four piezoresis-
tances will deform in turn, resulting in resistance change. After processing by the signal process-
ing circuit of silicon chip, it forms the voltage signal in linear relationship with the pressure.
The intake temperature sensing element is a resistance of negative temperature coef¿cient (NTC),
where the resistance value is changing along with intake temperature. The sensor transmits a
voltage which can express the intake temperature changing to controller.
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Figure 2-6 Pro¿le of intake manifold absolute pressure and intake temperature sensor
1) Limit date
Value
Quantity Unit
Min Typical Max
Tolerance power supply voltage 16 V
Tolerance pressure 500 kPa
Tolerance storage temperature -40 +130 °C
2) Characteristic data
Value
Quantity Unit
Min Typical Max
Pressure test range 20 115 kPa
Running temperature -40 125 °C
Running power supply voltage 4.5 5.0 5.5 V
Current when US=5.0V 6.0 9.0 12.5 mA
Load current of output circuit -0.1 0.1 mA
Load resistance to ground or battery 50 k¡
Response time 0.2 ms
Weight 27 g
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c0=-9.4/95
c1=0.85/95 (1/kPa)
The formula above indicates that under the atmospheric pressure, the signal output voltage of
pressure sensor is close to power supply voltage.
If the power supply voltage is 5V, the signal output voltage of pressure sensor is about 4V when
the throttle is widely opening.
Rating voltage: running with 1k¡ front end resistance under 5V, or running with test current
1mA
The sensor is designed to be installed on the intake manifold plane of engine. Pressure nozzle and tem-
perature sensor both extrude in the intake manifold, using an O ring to realize seal to the atmosphere.
If it is installed on the vehicle in proper manner (extracting pressure on intake manifold, and pres-
sure nozzle is slant downwards), it can ensure that condensed water will not form on the pressure
sensitive elements.
Drilling and ¿xing on intake manifold must be done according to drawing supplied on delivery, so
as to ensure long-term seal and also tolerate the erosion of medium.
The reliable contact of joint electric connection is not only affected by joint of main parts, but also
by the material quality and dimensional accuracy of joint on the harness which matches with it.
General fault cause: 1. there is abnormal high voltage or reverse large current in using pro-
cess; 2. the vacuum element is damaged in repairing process.
Repair precaution: Forbid using high pressure gas to strike the vacuum element; notice to
check whether the output voltage and current of dynamotor are normal when ¿nding the fault
and replacing the sensor.
Temperature sensor part: (Disassemble the joint) Turn the digital multimeter to ohm range, and
connect the two meter pens respectively to 1#, 2# stitch of sensor. The rating resistance is 2.5k¡
± 5% at 20°C, and refer to the characteristic curve of following ¿gure for other corresponding re-
sistance value. You can use the simulation method when measuring: blow wind to sensor with
electric hair dryer (do not place the hair dryer too close to sensor) and observe the change of re-
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Figure 2-8 Throttle position sensor Figure 2-9 Throttle position sensor circuit dia-
gram
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Stitch: For the throttle valve rotating anticlockwise (look at the throttle valve from one side of sen-
sor in the direction of throttle valve shaft) open form:1# grounds; 2# connects to 5V power supply;
For the throttle valve rotating clockwise (look at the throttle valve from one side of sensor in the
direction of throttle valve shaft) open form: 1# connects to 5V power supply;2# grounds;
The sensor is an angle sensor with linearity output, and is made of two arc slip touch resistances
and two slip touch arms. The rotating shaft of slip touch arm connects with throttle shaft on the
same axis. Add 5V power supply voltage US on the two ends of clip touch resistance. When the
throttle is rotating, the slip touch arm rotates along with it, and moves on the slip touch resistance
at the same time, exporting the potential UP of contact as output voltage. So actually it is an angle
potentiometer outputting voltage signal in pro rata relationship with throttle position.
Value
Quantity Unit
Min Typical Max
Total resistance (Stitch 1-2) 1.6 2.0 2.4 k¡
Slip arm protection resistance
710 1380 ¡
(Slip arm is on zero position, stitch 2-3)
Running temperature -40 130 °C
Power supply voltage 5 V
Considering about the leakage of the throttle valve shaft seal after long running, it’s suggested
that the throttle valve shaft is equipped at least 30 degrees deÀection for vertical direction.
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(Disassemble the joint) Turn the digital multimeter to ohm range, and connect the two meter pens
to the 1#, 2# stitch of sensor respectively. The resistance is 2k¡ ± 20% under normal tempera-
ture. Connect the two meter pens respectively to the 1#, 3# stitch, rotate the throttle, the resis-
tance between the two stitches is in linear change along with the throttle opening, but resistance
between 2#, 3# stitches is in the opposite situation.
NOTICE
When observing the resistance value
change, notice whether it has larger
jump.
Stitch: There are two stitches on the sensor and they can exchange.
The sensor is a thermal resistance of negative temperature coef¿cient (NTC), where the resis-
tance value decreases when coolant temperature increases, but not in linear relationship. The
NTC thermal resistance is installed on a copper surface (see ¿gure 2-11).
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BYD S6, S6A, S6K Service Manual
Figure 2-11 coolant temperature sensor char- Figure 2-12 coolant temperature sensor sec-
acteristic curve tional view
Resistance valve(kˮ)
Tempera-
Num-
Temperature tolerance 1°C Temperature tolerance 0°C ture
ber
(°C)
Minimum Maximum Minimum Maximum
1 8.16 10.74 8.62 10.28 -10
2 2.27 2.73 2.37 2.63 +20
3 0.290 0.354 0.299 0.345 +80
The coolant temperature sensors are installed on the cylinder body, and the copper heat conduc-
tion sleeve shall be inserted into coolant. There is screw thread on the sleeve, and the hexagon
head on sleeve is used to easily screw the coolant temperature sensor into the screw bore on cyl-
inder body. Max. allowable tightening torque is 20N.m.
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(Disassemble the joint) Turn the digital multimeter to ohm range, and connect the two meter pens
respectively to the 1#, 3# stitch of sensor. The rating resistance is 2.5k¡ ± 5% at 20°C, and resis-
tance value at other temperature can be measured from the characteristic curve. You can use the
similar method when measuring: dip the operating part of the sensor in boiled water for suf¿cient
time and observe the change in resistance value. It shall drop to 300¡-400¡ (depending on boil-
ing point of water).
3.4 Knock sensor
Figure 2-13 Knock sensor without cable Figure 2-14Knock sensor with cable
1. Vibration shock
2. Shell
4. Contactor
5. Electric joint
3rd cylinder engine is installed in the middle of 2nd cylinder. 4thcylinder engine is installed be-
tween 2nd and 3rd cylinder.
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Knock sensor is a vibration acceleration sensor installed on engine cylinder body. You can install
one or more sensors. The sensitive part of the sensor is a piezoelectric element. The vibration of
engine cylinder body is transferred to piezoelectric crystal through mass block in the sensor. The
piezoelectric crystal generates voltage on two polar planes as a result of the pressure generated
by mass block vibration, in this way the vibration signal is converted into alternate voltage signal
output. See the following figure for frequency-response characteristic curve. Vibration signals
caused by engine knock has a frequency much higher than that of normal vibration signals, so af-
ter processing of the signals ECU can distinguish knock signals and non-knock signals.
The construction of knock sensor is divided into two types for custom use, one with the cable and
another without cable.
Sensitivity
Frequency
Value
Quantity Unit
Min Typical Max
Working temperature -40 +130 °C
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Knock sensor is fastened on the cylinder body with a M8 bolt through a hole in the middle of the
sensor. For the aluminum alloy cylinder, adopt 30mm bolt. For the cast iron cylinder, adopt 25mm
bolt. The tightening torque is 20 ± 5N.m. The installation position should make the sensor receive
the vibration signal from all cylinders easily. You should con¿rm the best installation position of
knock sensor through modal analysis to engine body. Do not let any kind of liquid, such as oil,
coolant, braking Àuid and water, contact the sensor for a long time. The sensor must cling on the
cylinder body with its metal surface. Make good arrangement of wire harness of the sensor to pre-
vent the harness from resonance or it may break. Do not connect high voltage between 1# and 2#
stitch of the sensor as it may damage piezoelectric element.
General fault cause: any liquid such as oil, coolant, braking Àuid, water etc contacting the
sensor for a long time may make the sensor corrode.
(Disassemble the joint) Turn the digital multimeter to ohm range, and connect the two meter pens
respectively to 1# and 2# stitch. The resistance value should be more than 1M¡ under normal
temperature. Turn the digital multimeter to millivolt range and knock slightly near the knock sensor
with small hammer, there should be voltage signal output.
3.5 Oxygen sensor
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5. Clamp joint of
1. Cable line 2. Dish washer 3. Insulation sleeve 4. Protection sleeve
heating element
6. Heating stick 7. Contact gasket 8. Senor seat 9. Ceramic probe 10. Protection tube
All the sensors have cable. The other end of cable is electric joint. The electric joints of oxygen
sensors which are produced by our company all have four stitches:
Stitch de¿nition:
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The sense element of oxygen sensor is a porous ceramic tube, the external tube wall is surround-
ed by engine exhaust, and the internal tube wall is open to atmosphere. Sensing ceramic tube
wall is solid electrolyte with electric heating tube in it (see ¿gure 2-20).
The working of oxygen sensor is realized by translating the oxygen ion concentration difference
between external and internal of sensing ceramic tube into voltage signal output. When the tem-
perature of sensing ceramic tube reaches 350°C, it has solid electrolytes characteristic. Its special
material allows the oxygen ion to pass the ceramic tube freely.
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This characteristic makes it possible to convert the concentration difference into electric poten-
tial difference, accordingly forming the electric signal output. If the mixed gas is thick, the oxygen
ion concentration difference between internal and external of ceramic tube is high, resulting in
high electric potential difference and a mass of oxygen ion moving from internal to external. In
this case the output voltage is high (near 800mV-1000mV). If the mixed gas is thin, the oxygen
ion concentration difference between internal and external of ceramic tube is low, resulting in low
electric potential difference and only a little oxygen ion moving from internal to external. In this
case the output voltage is low (near100mV). The signal voltage has sudden change when ¬=1
(see ¿gure 2-20).
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Value
Quantity Unit
Min Typical Max
Storage temperature -40 +100 °C
Ceramic tube end 200 850 °C
Shell hexagon head İ 570 °C
Working temperature Cable metal retaining ring
İ 250 °C
and connection cable
Connection plug İ 120 °C
Max allowable temperature when Exhaust of ceramic tube
930 °C
the heating element make connec- end
tion (duration shall be no more than Shell hexagon head 630 °C
10 minutes for each time and ac-
cumulated duration no more than 40 Cable metal retaining ring
280 °C
hours) and connection cable
Max allowable temperature change speed of ceramic tube end İ 100 K/s
Ceramic element allowable temperature when exhaust side has
İ 350 °C
condensate
Random vibration
İ 800 m/s2
(peak value)
Harmonic vibration
Shell allowable vibration İ 0.3 mm
(vibration displacement)
Harmonic vibration
İ 300 m/s2
(vibration acceleration)
Absolute
Continuous DC under 350°C A
value İ 10
Max continuous AC when Exhaust temperature 350°C, f ı 1Hz ± 20 A
Unleaded fuel, or allow the lead content to
Allowable fuel additive
reach 0.15g/L
The allowable value and data must be con-
¿rmed by the customer through the proper
Oil consumption and oil burning
scale test.
Guide value: İ 0.7L/1000km
2) Characteristic data
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BYD S6, S6A, S6K Service Manual
The service life of oxygen sensor is relative to the lead content of fuel, refer to following table
Oxygen should be installed on the exhaust pipe which can ensure the exhaust element and meet
the set temperature limit valve. The installation position should be as closed as possible to the
engine. The thread should be set on the exhaust pipe for ¿xing oxygen sensor. See the following
¿gure:
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BYD S6, S6A, S6K Service Manual
Oxygen sensor should be installed with the horizontal plane angle 30°, and the sensor tip down-
ward, in order to avoid that condensate accumulates in the sensor housing and sensing ceramic
tube when cooling starting.
Do no t heat up the cable metal retaining ring improperly, especially after stopping the ve-
hicle.
Do not use the cleaning liquid or volatility solid on the oxygen sensor plug.
Fault phenomenon: idle bad, acceleration bad, harmful exhaust, fuel consumption big etc.
General fault cause: 1. Wet vapor enters into sensor internal, temperature changes rapidly,
probe fractures; 2. Oxygen sensor “poisoning” (Pb, S, Br, Si).
Repair precaution: forbid using the cleaning liquid, oiliness liquid or volatility solid on oxygen
sensor when repairing.
Simple measuring method:(Disassemble the joint) Turn the digital multimeter to ohm range, and
connect the two meter pens respectively to 1#(white) , 2# (white) stitch of the sensor, the resis-
tance value is 1~6¡ in normal temperature.
(Assemble the joint) Under idle state, when oxygen sensor is reaching to the working temperature
350°C, turn the digital multimeter to DC volt range, and connect the two meter pens respectively
to the 3#(gray), 4# (black)stitch of the sensor, the voltage should quickly Àuctuate between 0.1-
0.9V at this time.
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BYD S6, S6A, S6K Service Manual
Stitch: There are two types of speed sensor connector produced by our company used on M7.9.7
electric control system. See following ¿gure. Accordingly there are two stitch de¿nitions. The sys-
tem adopts connectors as shown in Figure 2-25joint.
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Working together with the pulse plate, Speed sensor is used to supply engine speed information
and crankshaft TDC information in ignition system without distributor. The speed sensor is made
of a permanent magnet with a coil around it outside. The pulse plate is a gear plate with 60 teeth
originally, but two teeth are blank. The pulse plate is installed on the crankshaft, and rotates along
with crankshaft. When the speed sensor’s end which is closed to gear tip is passing, the pulse
plate made of iron magnet material cuts the magnetic line of permanent magnet in speed sensor,
generating induced voltage, and outputting the voltage as speed signal.
Value
Quantity Unit
Min Typical Max
Loop area -40 +150 °C
Transition area Mixed Mixed °C
Lead area -40 +120 °C
Storage temperature -20 +50 °C
Allowable
Temperature when not running -40 +120 °C
temperature of
PUR lead speed Long-term temperature when running -40 +120 °C
sensor (refer to
Short-term temperature 150 hours +150 °C
following ¿gure)
when running 380 hours +140 °C
150 hours +150 °C
Lead area in whole service
380 hours +140 °C
life
1130 hours +130 °C
Loop area -40 +150 °C
Transition area Mixed Mixed °C
Lead area -40 +130 °C
Allowable
Storage temperature -20 +50 °C
temperature of
H&S lead speed Temperature when not running -40 +130 °C
sensor (refer to
Long-term temperature when running -40 +130 °C
following ¿gure)
Short-term temperature when running +150 °C
Lead area in whole ser- 500 hours +150 °C
vice life 200 hours +160 °C
Anti vibration ability in each 20 to71Hz Acceleration 40 m/s2
plane in 168 hours 71 to 220Hz Swing 0.2 mm
Allowable magnetic ¿eld intensity of rightabout outside
İ2 kA/m
magnetic ¿eld
Insulation resistance (10s,test New state 1 M¡
voltage 100V) Using time end 100 k¡
Withstand voltage (1 to3 seconds, 1200V AC) Can not breakdown
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2) Characteristic data
Value
Quantity Unit
Min Typical Max
Resistance under 20°C 731 860 989 ¡
Inductance 310 370 430 mH
Output voltage when crankshaft at 416 r/m !1650 mV
Only take out speed sensor from packaging material before installation on vehicle or test
equipment.
Recommend to adopt M6×12 bolt with partial micro seal to ¿x speed sensor.
Gas clearance between speed sensor and pulse plate tooth tip: 0.8 to 1.2mm.
size
Repair precaution: make installation by pressing the sensor in place, rather than using ham-
mered.
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(Disassemble the joint) Turn the digital multimeter to ohm range, and connect the two meter pens
respectively to 2#, 3 stitch of sensor. The rating resistance is 860¡ ± 10% at 20°C.
(Assemble the joint) Turn the digital multimeter to DC volt range, connect the two meter pens re-
spectively to 2#, 3# stitch, start the engine, there should be voltage output at this time.(it is sug-
gested to use vehicle special oscillograph to inspect)
The sensor is used to work together with induction sensor of pulse plate without distributor to sup-
ply crankshaft phase information to ECU, that is, distinguishing the crankshaft compress TDC and
exhaust TDC.
The sensor is designed by the Hall Principle: Hall voltage is inÀuenced by changing magnetic ¿eld
induction intensity.
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Figure 2-32 Phase sensor working diagram Figure 2-33 Phase sensor working diagram
(1) (2)
Limit data
Value
Quantity Unit
Min Typical Max
Environmental temperature -30 +130 °C
Installation clearance 0.5 1.5 mm
Supply voltage 4.5 24 V
This sensor only has one hole on its shell for fastening.
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BYD S6, S6A, S6K Service Manual
(Connect joint) Open the ignition switch but do not start engine, turn the digital multimeter to DC
volt range, connect the two meter pens respectively to 1#, 3# stitch of sensor, and ensure that
there is 12V reference voltage. Start the engine, use oscillograph to check whether 2# stitch sig-
nal is normal.
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(1) Function
MPI
Control ignition
Idle control
Knock control
A/C switch
Fault self-diagnosis
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BYD S6, S6A, S6K Service Manual
Limit data
Value
Quantity Unit
Min Typical Max
Running nor-
9.0 16.0 V
Battery voltage mally
Limited function 6.0 to 9.0 16.0 to 18.0 V
Limit value and time of tolerable Part of function available, can
26.0V 60 s
battery over voltage execute fault diagnosis
Working temperature -40 +70 °C
Storage temperature -40 +90 °C
Fault phenomenon: idle unstable, accelerating bad, can not start, idle too high, harmful emis-
sion, starting hard, A/C failure, fuel injector control failure, Àameout etc.
General fault cause: 1. because the external device electric overloads, it causes the ECU
internal parts burning and failure; 2. because water enter into ECU, it causes circuit board
rusting.
Repair precaution: 1. do not disassemble the ECU randomly in repair process; 2. please
¿rstly disassemble the battery jar end and wait for over 1 minute before disassembling the
ECU; 3. do disassemble ECU before doing welding, and keep ECU properly after disassem-
bling; 4. never install any circuit on ECU connection line.
3. Check whether the external sensor works normally, whether output signal is credible, and
whether its circuit is good;
4. Check whether the actuator works normally, whether its circuit is good;
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Main relay
Figure 2-36 Electric fuel pump Figure 2-36 Electric fuel pump circuit diagram
Stitch: There are two stitches on the electric oil pump and they connects oil pump relay. Oil pump shell
near the two stitches is marked with “+“ ”-”, which means positive electrode and negative electrode.
In fuel tank
Electric fuel pump is made up of DC motor, van pump and end cover (integrating check valve, re-
lief valve and anti-electromagnetic interference element), see ¿gure 2-37.
The pump and motor are installed on same shaft and closed in the same shell. Gasoline is ¿lled
up around the pump and motor within the shell for cooling and lubrication. The battery supplies
power to electric fuel pump through fuel pump relay, which switch on the electric fuel pump’s cir-
cuit only in starting and when engine is running. When the engine stops running because of acci-
dent, the fuel pump will automatically stop running.
1. End cover
2. Motor
3. Fuel path
4. Van pump
The max pressure of electric fuel pump outlet is decided by relief valve (between 450 and
650kPa). As the system has no fuel return, the pressure of whole system is decided by fuel pres-
sure regulator (the general value is 350kPa).
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BYD S6, S6A, S6K Service Manual
According to the demand of engine, electric fuel pumps can have different Àow rate. For produc-
ing, electric fuel pump of EKP13 series with the same structure adjusts electromotor rotating
speed by adjusting coil turns and therefore adjusts Àow rate .So do not use the electric fuel pump
of one vehicle on another vehicle randomly.
Value
Quantity Unit
Min Typical Max
Working voltage 8 14 V (DC)
System pressure 350 kPa
Outlet pressure 450 650 kPa
Environmental temperature
-40 +80 °C
(for storing and transporting)
Allowable fuel temperature -30 +70 °C
Allowable vibration acceleration 20 m/s2
The Àow rate of electric fuel pump is in direct proportion with voltage under certain supply fuel
pressure. Oil pump is different in different vehicle factories.
The electric fuel pump should store in closed original packing box. The maximum allowable stor-
age time is six months after installed on vehicle. As spare part, its max storing time is 4 years.
When the allowable storage time expires, the performance of pump should be checked again by
manufacturer. At storage place, the pump shall be kept away from inÀuence of atmosphere pres-
sure and the original packing can not be damaged.
Electric fuel pump of EKP13 series is only applied in oil tank. When installing the fuel pump, you
must install the mesh whose dimension is less than 60 or the fuel inlet port ¿lter screen agreed
with customer. Notice not to make the fuel spray injecting from vent hole inject on fuel inlet port ¿l-
ter screen, fuel pump bracket or fuel tank wall. Be careful when carrying the fuel pump to protect
the fuel inlet port ¿lter screen from load and impact. The fuel pump should be taken from plas-
tic packing material carefully only when installing. The protection cover can only be taken away
when the fuel pump will be installed at once. Never take away the fuel inlet port ¿lter screen. Any
foreign matter entering into fuel pump fuel inlet port or ¿lter screen can cause damage to the fuel
pump.
Pay attention to cleaning when installing the fuel pipe. You must clean the inside of fuel pipe.
Please only use new fuel pipe clamp. Make sure the clamp is at the right position and follow man-
ufacturer’s instruction.
Do not hold the pump at the fuel inlet port or ¿lter screen.
To prevent damage to the fuel pump, do not run the pump under dry condition. Do not use any
damaged pump. After the fuel tank drops to the ground, the fuel pump in the fuel tank must be re-
placed.
It’s prohibited to impose pressure on the oil inlet plate and mechanical stress can’t be imposed at
the caulking. Oil pump clamp must fall within the prescribed limits, see below.
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BYD S6, S6A, S6K Service Manual
Mechanical stress
can’t be imposed
at the caulking
In case of return to factory, please attach delivery document, inspection document and package
label together to the pump in speci¿ed package. If the pump has been used, Àush it with test Àuid
and let it dry in air. It is not allowed to blow it dry. Considering about the safty,we don’t accept the
oil pump with fuel.
Fault phenomenon: running noise big, accelerating bad, starting hard etc.
General fault cause: using poor quality fuel, leading to: 1. colloid accumulating forms insulat-
ing layer; 2. fuel pump bushing and armature are locked up; 3. fuel surface sensor compo-
nents corrodes.
Repair precaution:
1. Only replace with a pump with the same part number as the original, as fuel pumps which
have same appearance and can be installed in place may have different Àow rate;
3. Pay attention to cleaning the fuel tank and pipe as well as replacing the fuel ¿lter when re-
placing the fuel pump.
(Disassemble the joint) Turn the digital multimeter to ohm range, connect the two meter pens re-
spectively with the 1# and 4# stitch of fuel pump and measure the resistance. It shall be near to
1¡.
(Connect the joint) Connect the fuel press gauge on fuel inlet pipe, start the engine, check wheth-
er the fuel pump is running; if not running, check whether there is power supply voltage at “4#”
stitch; if running, check whether the fuel pressure is about 350kPa under idle condition; depress
the acceleration pedal to the engine speed 2500rpm, check whether the fuel pressure is about
350kPa at this time.
3.10 Electromagnetic Fuel injector
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BYD S6, S6A, S6K Service Manual
Two stitches. One is the 87#stitch which is on one side of the shell with the plus sign and con-
nects with main relay output end. The other one separately connects ECU 27#, 6#, 73#, 47#
stitch.
Figure 2-41 Fuel injector on fuel rail Figure 2-42 Fuel injector sectional view
1. O-shape ring 2. Filter screen 3. Fuel injector body with power plug 4. Coil
6. Valve needle with coil arma-
5. Spring 7. Valve seat with ori¿ce plate
ture
ECU sends electronic pulses to the coil of fuel injector, and forms magnetic force. When the mag-
netic force rises enough to overcome the resultant force formed with return spring pressure, nee-
dle valve gravity and friction force, the needle valve begins to rise, and the fuel injection starts.
When the fuel injection pulses stop, the return spring pressure will make the needle valve closed
again.
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BYD S6, S6A, S6K Service Manual
- It can be divided into long type and standard type according to length;
Value
Quantity Unit
Min Typical Max
Storage temperature (original packing) -40 +70 °C
Allowable temperature of fuel injector in vehicle
+140 °C
(when not working)
Continuous -40 +110 °C
Working temperature of Short time after hot
fuel injector starting (about 3 min- +130 °C
utes)
Allowable fuel tempera- Continuous +70 °C
ture in the fuel injector
Short time (about 3
inlet opening +100 °C
minutes)
The temperature when the fuel flow deviation
-40 +45 °C
reaches 5% compared with that at 20°C
Fuel wetness is allowed in O-shape area, but no leak is al-
O-shape ring leakage allowance at -35 to -40°C
lowed.
Max allowable vibration acceleration (peak value) 400 m/s2
Power supply voltage 6 16 V
Insulation resistance 1 M¡
Tolerable internal fuel pressure 1100 kPa
Tolerable bending stress 6 Nm
Tolerable axial stress 600 N
Value
Quantity Unit
Min Typical Max
Working pressure (pressure difference) 350 kPa
Fuel injector resistance at 20°C 11 17 ¡
The fuel injector can only use the fuel stipulated in Vehicle-use Gasoline, the National Standards
of Peoples Republic of China GB 17930-1999, and Hazardous Materials Control Standard for
Motor Vehicle Gasoline, the National Environmental Protection Standard GWKB 1-1999. It would
be specially mentioned that gasoline will deteriorate as a result of being kept for too long, in par-
ticular, the gasoline used by the taxi with engine using both LPG and gasoline. As LPG is used
for fuel for a long term while gasoline is just for starting, the car consumes very little gasoline, so
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BYD S6, S6A, S6K Service Manual
the gasoline left in the fuel tank can easily get oxidized at a rather high temperature caused by
long-term operation of the fuel pump. What’s worse, the fuel injector will be blocked, or even to be
damaged.
Make sure that speci¿ed plug is used for speci¿ed fuel injector. Don’t mixed it .
To make it easier to install, you are suggested to lay on a coat of silicon-free engine oil on
the upper O-shape ring connected to the fuel rail. Be careful not to contaminate inside the
fuel injector and the ori¿ce.
Put the fuel injector into the fuel injector seat perpendicularly, and then ¿x it on the seat by
clamps.
Notes:
1. Fuel injector clamp is classi¿ed to axial location clamp and radial location clamp ac-
cording to its location mode, so do not use the wrong one.
2. For the installation of the axial-location fuel injector, make sure the bayonet in the
middle of clamp is completely inserted into the groove and the groove on both sides
of the clamp is completely locked the Àanging of fuel injector seat.
3. When installing the fuel injector in need of both axial location and radial location, the
axial location clamp shall be used to make the located block of the fuel injector and
the location pin of the fuel injector seat well placed in the groove corresponding to the
clamps respectively.
4. In case of two grooves in the fuel injector, be careful not to clamp it wrong. You can
refer to the installation location of the original.
The fuel injector shall be installed with hands. Do not strike the fuel injector by using tools
such as hammer.
When removing or reinstalling the fuel injector, the O-shape ring must be replaced. Now do
not damage the sealing face of the fuel injector.
Do not pull out the supporting bead of the O-shape ring from the fuel injector. Be careful to
install and avoid damaging the pipe head of the fuel injector, O-shape ring, supporting bead,
ori¿ce plate and plug. Do not use it if any damage incurs.
After the installation of fuel injector, test the fuel rail assembly for tightness. If no leakage, it
is considered to be quali¿ed.
The failure components shall be removed manually: ¿rst, remove the clamp of fuel injector;
then, pull out the fuel injector from the fuel injector seat. Make sure the fuel injector clean af-
ter installation to avoid contamination.
Fault phenomenon: idle speed, bad acceleration, start failure (hard starting) etc.
General fault cause: for lack of maintenance, colloid accumulates inside the fuel injector and
thus the fuel injector fails.
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BYD S6, S6A, S6K Service Manual
(Remove the adapter) Turn the digital multimeter to ohm range, and contact the two probes to two
stitches of fuel injector respectively. The rated resistance is 11-17¡ at 20°C.
Recommendation: use special cleaner & analyzer to clean the fuel injector thoroughly per
20,000kM
3.11 Idle actuator stepper motor
Stepper motor, a mini-size motor, is made of several steel stators in a circle and a rotor (refer to
¿gure 2-45). Each steel stator winds a coil on it; rotor is a permanent magnet with a nut in the
center. All stator coils are electri¿ed all the time. As long as you change the current direction of its
certain coil, the rotor will turn at an angle. When the current direction of each stator is changed
in proper order, a rotating magnetic ¿eld will form to make the rotor made by permanent magnet
rotate in certain direction. If reversing the order, the rotation direction of rotor will be reversed too.
The nut connected in the center of the rotor will drive a screw rod. As the screw rod is designed
not to rotate, it can only move in the axial direction, also called linear axis. There is a choke plug
at the end of the screw rod, so the choke plug can retract or extend so as to increase or reduce
the sectional area of the by-pass air channel of idle speed actuator, until it is blocked. The step
width is equal to the value that 360 ° is divided by the number of stator or coil and that of this
stepper motor is 15° . Accordingly every step distance moved by the screw rod is ¿xed. ECU can
control the step number of the stepper motor through controlling the times of changing the current
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BYD S6, S6A, S6K Service Manual
direction of the coil so as to regulate the sectional area of the by-pass channel and the air Àow
running through. In general, the air Àow has a linear relation with step width. Once the current di-
rection of certain coil is changed, the rotor will turn in a certain angle, called step width. There is a
spring behind the plug at the end of screw rod, referred as below. The available force in the direc-
tion of plug extension is equal to the force of stepper motor plus spring force; while in the direction
of plug retraction it is equal to the force of stepper motor minus spring force.
The axis of idle actuator with stepper motor shall not be installed horizontally or below the
level, to avoid the condensed water entering.
Do not force in any type in the axial direction to try to press or pull out the axis.
Before placing the idle actuator with stepper motor into throttle body, its axis should be placed at
a fully retracted position.
General fault cause: accumulation of dust, fuel gas, etc causes the by-pass air channel par-
tially blocked and thus, the stepper motor cannot perform normal idle regulation.
Maintenance cautions: 1. Do not force in any type in the axial direction to try to press or pull
out the axis. 2. Before placing the idle actuator with stepper motor into throttle body, its axis
should be placed at a fully retracted position. 3. Attention should be paid to cleaning and
maintaining the by-pass air channel; 4. After disassembling the battery jar or ECU, do auto
tuning to step motor in time.
The auto tuning method of M7 system is: open the ignition switch but do not start the engine im-
mediately, and then start the engine after 5 seconds,. If the engine is found at idle speed this mo-
ment, repeat the steps above.
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Simple measuring method: (remove the adapter) Turn the digital multimeter to ohm range, and
contact the two probes to AD stitch and BC stitch of regulator respectively. The rated resistance is
53 ± 5.3¡ at 25°C.
3.12 Double spark ignition coil (for 4-cylinder engine without distributor system)
NOTICE
the system has two ignition coils, of
which the secondary connects to two
cylinders, that is, to ignite 1# cylinder
and 4# cylinder at the same time, and 2#
cylinder and 3# cylinder simultaneously.
Stitch de¿nition:
High pressure side: two secondary winding terminals connect to the spark plug of homonymy en-
gine cylinder through live line respectively;
Low pressure side: primary winding stitch of 1# coil connects to the main relay 87#;
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BYD S6, S6A, S6K Service Manual
High pressure side: two secondary winding terminals connect to the spark plug of homonymy en-
gine cylinder through live line respectively;
On the engine
The ignition coil is made up of primary winding, secondary winding, iron core, shell, and so on.
When the grounding channel of certain primary winding is connected, the primary winding starts
to charge. Once it is cut off by ECU, charging will be disabled. In the meantime the secondary
winding induces high-voltage electricity, and makes the spark plug discharge. What’s different
with the ignition coil with distributor is that each end of the ignition coil secondary winding con-
nects to a spark plug, so the two spark plugs will ignite simultaneously. The two primary windings
will power on and off alternately. Accordingly, the two secondary windings will discharge alternate-
ly.
Characteristic data
Value
Quantity Unit
Min Typical Max
Working voltage 6 14 16.5 V
General fault cause: too large current causes burning, damaging etc.
Maintenance cautions: do not use “short-circuit testing ¿re” to test the ignition function, to
avoid damaging electronic controller.
Simple measuring method: (remove the adapter) turn the digital multimeter to ohm range,
and contact the two probes to the two stitches of primary winding respectively, the rated re-
sistance is 0.70-0.90¡ at 20°C; secondary winding resistance is 9.68-12.32k¡.
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BYD S6, S6A, S6K Service Manual
To main relay
Carbon canister
control valve
Figure 2-49 Carbon canister control valve Figure 2-50 Carbon canister control valve
TEV-2 TEV-2 circuit diagram
Stitch: Carbon control valve only has two stitches. One connects to 87#stitch of main relay output,
and the other one connects to 46#stitch of ECU.
Figure 2-51 Carbon canister control valve Figure 2-52 Carbon canister control valve
sectional view installation diagram
The carbon canister control valve is made of electromagnetic coil, keeper and valve. There is a ¿l-
ter screen on the intake position. On the one hand the air current Àowrate Àowing through the car-
bon canister is depending on the duty cycle of electric pulse which is output from ECU to carbon
canister control valve; on the other hand it is also relative with the pressure difference between in-
let and outlet of carbon canister control valve. When there is no electric pulse, the carbon canister
control valve is closed.
The Àowrate of different type carbon canister control valve is different under full opening condition,
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BYD S6, S6A, S6K Service Manual
namely 100% duty cycle. The following ¿gure shows two kinds of typical Àowrate curve. From the
¿gure, under the same pressure difference of 200mbar, the Àowrate is 3.0m3/h when A type car-
bon canister control valve is full opening, while the Àowrate of B type is 2.0m3/h. (this item is B
type)
Value
Quantity Unit
Min Typical Max
Working voltage 9 16 V
One minute overvoltage 22 V
Min starting voltage 7 V
Min voltage drop 1.0 V
Allowable working temperature -30 +120 °C
Short time allowable working temperature +130 °C
Allowable storage temperature -40 +130 °C
Allowable pressure difference between inlet and outlet 800 mbar
8
Allowable on-off times 10
Allowable vibration acceleration on product 300 m/s2
Leakage quantity when pressure difference is 400mbar 0.002 m3/h
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BYD S6, S6A, S6K Service Manual
Value
Quantity Unit
Min Typical Max
Rating voltage 13.5 V
Resistance when +20°C 26 ¡
Current under rating voltage 0.5 A
Control pulse frequency 30 Hz
A type 7 ms
Typical control pulse width
B type 6 ms
The connection of carbon canister control valve and carbon canister, intake manifold refers to ¿g-
ure 2-54.
To avoid solid sound passing, commend to hanging install the carbon canister control valve
on the tube.
Must make the air current direction accord with the regulation.
Must prevent the foreign body entering as particulate from carbon canister or tube to carbon
canister control valve according to proper measure as ¿ltrating, cleaning.
General fault cause: because the foreign body enters into internal, it causes corrosion or bad
sealing.
Repair precaution: 1, Must make the air current direction accord with the regulation when
installing; 2, When ¿nding the control valve failure because of black grain inside the valve
body, and need to replace the control valve, please check the carbon canister condition; 3,
Try best to avoid the water, oil etc liquid entering into valve in repair process; 4, To avoid sol-
id sound passing, commend to hanging install the carbon canister control valve on the tube.
(Disassemble the joint) Turn the digital multimeter to ohm range, and connect the two meter pens
respectively with two stitches of carbon canister control valve, the rating resistance is 22~30¡ at
20°C.
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Diagram
Figure 2-54 Fuel pressure regulator Figure 2-55 Fuel pressure regulator sectional
view
Showing as the ¿gure 2-66, a sheet of ¿xable ¿lm which is made by rubber-¿ber divides the fuel
pressure regulator into two chambers. The upper chamber with a spring in it is open to atmo-
sphere. The lower chamber is full of fuel. The underside of ¿lm gets the fuel pressure, and the
upside gets the atmosphere pressure and spring pressure. The ¿lm can deform to drive the valve
seat, making the valve open or close, but because the deformation is too small, the spring force
can be considered to keep invariant. So the on-off of valve is mainly decided by the pressure dif-
ference between fuel pressure in lower chamber and atmosphere pressure in upper chamber. As-
sume that the valve is closed in the beginning, later because the fuel pressure rises, it causes the
pressure difference between upper and lower chamber increasing, ¿nally the ¿lm is pushed up by
fuel pressure, the valve turns on, the fuel releases to fuel tank through the fuel back port in the
center of pressure regulator, the fuel pressure drops till the valve turns off. So when changing the
engine working condition, the difference between fuel system pressure and atmosphere pressure
keeps invariant in the main.
Value
Quantity Unit
Min Typical Max
Leakage Àowrate when pressure difference is 280kPa 9 cm3/min
Continuous working allowable temperature -40 +80 °C
Fuel max allowable temperature +80 °C
Max allowable pressure drifting at -30°C (reversible) -2% +5%
Max allowable pressure drifting at +80°C(reversible) -5% +2%
Max allowable acceleration peak value 100 m/s2
Max allowable pressure pulse value at inlet position 100 kPa
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BYD S6, S6A, S6K Service Manual
Value
Quantity Unit
Min Typical Max
Rating pressure difference when the Àowrate Q is 80 l/h 350 kPa
The working pressure changing value when the flowrate is
17.5 kPa
changing in the range from 15 to 140 l/h
Flowrate range 10 220 L/h
Slope of characteristic curve 0.14 kPa/ L/h
The fuel pressure regulator can be used to the stated fuel which is in compliance with the country
standard.
Fuel pressure regulator also can be used to the fuel which contains carbinol or ethanol below
15% volume.
Lubricate the O type ring lightly with clean, silicone-free engine oil or other lubrication oil au-
thorized by BOSCH.
Do not make the deformation of pressure regulating valve when assembling and disassem-
bling.
Must replace new O type ring when disassembling and reusing the pressure regulating
valve, if the pressure regulating valve bears the pressure more than 1500kPa, replace it.
The pressure regulating valve which has experienced rupture test or durability test can not
be used on the vehicle.
Fault phenomenon: Too low or too high fuel pressure causes starting hard etc.
General fault cause: Because of long-term using and being short of maintenance, it causes: 1,
¿lter screen blocks; 2, grain impurity causes big leakage; 3, manmade mechanical damage.
Repair precaution: In repair process: 1, forbid impacting the diaphragm element with high
pressure gas; 2, forbid cleaning it with strong corrosion liquid; 3, forbid making deformation
with external force. Simple measuring method: Connect the fuel pressure gauge on fuel inlet
pipe, start the engine, make the engine run idle, check whether the fuel pressure is about
350kPa; depress the accelerating pedal till the engine speed is 2500rpm, and check whether
the fuel pressure is about 350kPa at this time.
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Diagram
On intake manifold
Fuel distributor assembly is made of fuel distributor (KVS) and fuel injector (EV). And it is used to
store and distribute the fuel.
Limit data
Value
Quantity Unit
Min Typical Max
Working temperature when fuel distributor and O type ring is
-40 +120 °C
properly connected
Highest working temperature at 15 minutes under wet state +130 °C
Max allowable vibration acceleration peak value 300 m/s2
The system pressure refers to characteristic parameter of pressure regulating valve, the fuel de-
mand refers to characteristic parameter of fuel injector, the sealing requests no fuel leakage un-
der working pressure.
Clamp the joint of fuel intake pipe and rubber pipe closely with clamp hoop, the using clamp
hoop type must match with rubber pipe, and protect the sealing of connection between fuel
inlet pipe and rubber pipe.
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BYD S6, S6A, S6K Service Manual
There is no crack, scaur, groove, burr and corrosion on fuel inlet pipe wall.
Before assembling the fuel distributor assembly, lubricate the lower O type ring of fuel injec-
tor with cleaning lubrication oil.
The sealing of fuel distributor can test with pressure drop method: do the test to the O type ring of
fuel distributor’s injector. At 4.5 bar, the test leakage limit value 1.5cm3/min.
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BYD S6, S6A, S6K Service Manual
1. Ensure the fault is stable malfunction before inspecting, otherwise it will cause the false diag-
nosis.
2. The multimeter mentioned hereunder refers to digital multimeter. It is not allowed to use the
¿nger multimeter to check the injector system circuit.
3. When inspect the vehicle equipped with self-theft system, if the “replace the ECU” is listed in
the “Next steps” items, pay attention to programming ECU after replacement.
4. In this item: when P0171, P0172, P0335, P0336, P1651 occurs, the engine warning lamp
goes out.
5. If the DTC indicates one circuit has over low voltage, it means this circuit may be in short
circuit with the ground; if the DTC indicates one circuit has over high voltage, it means this
circuit may be in short circuit with the power; if the DTC indicates one circuit has circuit fault,
it means this circuit may be in open circuit or multiple faults may exist at the same time.
Diagnostic help:
1. If the DTC can not be erased, it means the malfunction is stable malfunction; check if the
connector is loosed if the malfunction is accidental malfunction.
3. Do not neglect the inÀuence of the vehicle maintenance, cylinder pressure, mechanism igni-
tion timing etc. during the inspection;
4. Do the test after replaced the ECU. If then the DTC can be erased, the malfunction exist in
ECU; if the DTC still existed, change back to use the original ECU and repeat the procedure
to make inspection again.\
4.1 DTC P0107: Intake air pressure sensor circuit voltage over low
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BYD S6, S6A, S6K Service Manual
4.2 DTC P0108: Intake air pressure sensor circuit voltage over high
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Observe if the “intake air pressure” item of the data stream Yes Go to step 5
2 is about 101kpa (idiographic value according the actual air
No Go to next step
pressure).
Disconnect the intake air pressure sensor connector, use Yes Go to step 5
3 the multimeter to inspect if the voltage between connector
No Go to next step
3# and 1# is about 5V.
Check the harness wire between ECU terminal 40#, 19#, Repair or replace the har-
Yes
4 59# and sensor connector 1#, 3#, 4# are open or short cir- ness wires
cuit with the power. No Go to next step
Start the engine, run at idle speed. Slow step the accel- Yes Diagnostic help
erator pedal close to fully opening, observe the change of
“intake air pressure” item of diagnostic test, then the display
5
value should is not change a lot; quickly step the accel- No Replace sensor
erator pedal close to fully opening, then the display value
should immediately to over then 90kpa.
4.3 DTC P0112: Intake air temperature sensor indication temperature is over low
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Observe if the “intake air pressure” item of the data stream Yes Go to step 5
is same as the intake pipe temperature (idiographic value
2 according the actual engine temperature).
Notice: If the indication value is always -40°C, which No Go to next step
means maybe the open harness circuit occurred.
Disconnect the intake temperature sensor connector, use Yes Go to next step
the multimeter to inspect if the resistance between termi-
3
nal 3# and 1# is assort with the temperature(detail refer to No Replace sensor
the correlative parts of the repair manual).
Disconnect the intake temperature sensor connector, use Yes Go to step 5
4 the multimeter to check if the voltage between connecter
terminal 1# and 2# is about 5V. No Go to next step
Check if the harness wire between ECU (terminal 40#, Repair or replace the har-
Yes
5 19#) and the sensor connector (terminal 1#, 2#) is open or ness wires
short circuit with the power. No Go to next step
Start the engine, run at the idle speed. Observe the Yes Diagnostic help
change of “intake temperature” item, then the indication
6
value should increase with the raise of the engine intake No Replace sensor
temperature.
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BYD S6, S6A, S6K Service Manual
4.4 DTC P0113: Intake temperature sensor indication temperature is over high
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Observe if the “intake air pressure” item of the data stream is Yes Go to step 5
same as the intake pipe temperature (idiographic value ac-
2 cording the actual engine temperature).
Notice: If the indication value is always -40°C, which means No Go to next step
maybe the open harness circuit occurred.
Disconnect the intake temperature sensor connector, use the Yes Go to next step
multimeter to inspect if the resistance between terminal 1#
3
and 2# is assort with the temperature(detail refer to the cor- No Replace sensor
relative parts of the repair manual).
Disconnect the intake temperature sensor connector, use the Yes Go to step 5
4 multimeter to check if the voltage between connecter termi-
nal 1# and 2# is about 5V. No Go to next step
Check if the harness wire between ECU (terminal 17#, 40#) Repair or replace the
Yes
5 and the sensor connector (terminal 1#, 2#) is open or short harness wires
circuit with the power. No Go to next step
Start the engine, run at the idle speed. Observe the change Yes Diagnostic help
of “intake temperature” item, and then the indication value
6
should increase with the raise of the engine intake tempera- No Replace sensor
ture.
4.5 DTC P0117: Engine coolant temperature sensor indication is over low
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Observe if the “coolant temperature” item of the data stream Yes Go to step 6
is same as the intake pipe temperature (idiographic value
2 according the actual engine temperature).
Notice: If the indication value is always -40°C, which means No Go to next step
maybe the open harness circuit occurred.
Disconnect the coolant temperature sensor connector, use Yes Go to next step
the multimeter to inspect if the resistance between terminal
3
1# and 3# is assort with the temperature(detail refer to the No Replace sensor
correlative parts of the repair manual).
Disconnect the coolant temperature sensor connector, use Yes Go to step 6
4 the multimeter to check if the voltage between connecter ter-
minal 1# and 3# is about 5V. No Go to next step
Check if the harness wire between ECU (terminal 40#, 41#) Repair or replace the
Yes
5 and the sensor connector (terminal1#, 3#) is open or short harness wires
circuit with the power. No Go to next step
Start the engine, run at the idle speed. Observe the change Yes Diagnostic help
of “coolant temperature” item, then the indication value
6
should increase with the raise of the engine intake tempera- No Replace sensor
ture.
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BYD S6, S6A, S6K Service Manual
4.6 DTC P0118: Engine coolant temperature sensor indication is over high
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Observe if the “coolant temperature” item of the data stream Yes Go to step 6
is same as the intake pipe temperature (idiographic value ac-
2 cording the actual engine temperature).
Notice: If the indication value is always -40°C, which means No Go to next step
maybe the open harness circuit occurred.
Disconnect the coolant temperature sensor connector, use Yes Go to next step
the multimeter to inspect if the resistance between terminal
3
1# and 3# is assort with the temperature(detail refer to the No Replace sensor
correlative parts of the repair manual).
Disconnect the coolant temperature sensor connector, use Yes Go to step 6
4 the multimeter to check if the voltage between connecter ter-
minal 1# and 3# is about 5V. No Go to next step
Check if the harness wire between ECU (terminal 40#, 41#) Repair or replace the
Yes
5 and the sensor connector (terminal 1#, 3#) is open or short harness wires
circuit with the power. No Go to next step
Start the engine, run at the idle speed. Observe the change of Yes Diagnostic help
6 “coolant temperature” item, then the indication value should
increase with the raise of the engine intake temperature. No Replace sensor
4.7 DTC P0122: Throttle position sensor circuit voltage is over low
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Observe if the “throttle absolute opening” item of the data Yes Go to next step
2 stream is between 4%-10% (Detail value is different accord-
ing to the vehicle type) No Go to step 5
Step the accelerator pedal to fully opening slowly, observe Yes Go to next step
the value of the data stream “throttle absolute opening” item
3 is increase to between 85-95% with the throttle opening in-
creasing. (detail value is different according to the vehicle No Go to step 5
type)
Repeat the step 3, observe if the value of the data steam Yes Replace sensor
4
“throttle absolute opening” item is jumping changed. No Go to next step
Disconnect the throttle position sensor connector, check if the Repair or replace the
Yes
harness wire between ECU (terminal 18#, 39#, 26# )and the harness wires
5
sensor connector (terminal 1#, 2#, 3#) is short circuit with the
No Go to next step
ground
Use multimeter to check if the voltage between this connec- Yes Replace sensor
6
tor terminal 1# and 2# is about 5V. No Diagnostic help
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BYD S6, S6A, S6K Service Manual
4.8 DTC P0123: Throttle position sensor circuit voltage is over high
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Observe if the value of data steam “throttle absolute open- Yes Go to next step
2 ing” is between 4%-10% (detail value is according to the
vehicle type). No Go to step 5
Step the accelerator pedal to fully opening slowly, observe Yes Go to next step
the value of the data stream “throttle absolute opening”
3 item is increase to between 85-95% with the throttle open-
ing increasing. (detail value is different according to the No Go to step 5
vehicle type)
Repeat the step 3, observe if the value of the data steam Yes Replace sensor
4
“throttle absolute opening” item is jumping changed. No Go to next step
Disconnect the throttle position sensor connector, check Repair or replace the
Yes
if the harness wire between ECU (terminal 17#, 32#, 16#) harness wires
5
and the sensor connector (terminal 1#, 2#, 3#) is open or
short circuit with the ground. No Go to next step
Use multimeter to check if the voltage between this con- Yes Replace sensor
6
nector terminal 1# and 2# is about 5V. No Diagnostic help
(Remark: The procedure is accord with the no DTC P0135, if the DTC P0135 existed at the same
time, should ¿rst deal with the malfunction P0135, then check as the follow procedure.)
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Start the engine, run at idle speed until the coolant tem- Yes Diagnostic help
perature to the normal value. Observe the value change
2
of diagnostic test “oxygen sensor voltage” item, the value No Go to next step
should change quickly between 100mV~900mV.
Check if the harness wire between ECU (terminal 2#, Repair or replace the
Yes
3 39#, 45#) and the sensor connector (terminal2#, 3#, 4#) harness wires
is short circuit with the ground. No Go to next step
(A) Check if the serious air leakage in the intake air sys- Check and repair based
Yes
tem; on the diagnosis
(B) If the injector is blocked;
4 (C) If the spark plug clearance is too large;
(D) If the high tension line resistance is too high; No Diagnostic help
(E) The abrasion of intake valve guide pipe;
Etc.
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BYD S6, S6A, S6K Service Manual
4.10 DTC P0132: Front oxygen sensor circuit voltage over high
(Remark: The procedure is accord with the no DTC P0135, if the DTC P0135 existed at the same
time, should ¿rst deal with the malfunction P0135, then check as the follow procedure.)
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “ON”.
Start the engine, run at idle speed until the coolant temperature Yes Diagnostic help
to the normal value. Observe the value change of diagnostic test
2
“oxygen sensor voltage” item, the value should change quickly No Go to next step
between 100mV~900mV.
Check if the harness wire between ECU (terminal 2#, 39#, 45#) Repair or replace
Yes
3 and the sensor connector (terminal2#, 3#, 4#) is short circuit with the harness wires
the ground. No Diagnostic help
(Remark: The procedure is accord with the no DTC P0135, if the DTC P0135 existed at the same
time, should ¿rst deal with the malfunction P0135, then check as the follow procedure.)
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “ON”.
Start the engine, run at idle speed until the coolant temperature
Yes Diagnostic help
to the normal value. Observe the value change of diagnostic test
2
“oxygen sensor voltage” item, the value should change quickly
between 100mV~900mV. No Go to next step
Check if the harness wire between ECU (terminal 2#, 39#, 45#) Repair or replace
Yes
3 and the sensor connector (terminal2#, 3#, 4#) is short circuit with the harness wires
the ground. No Diagnostic help
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “ON”.
Remove the front oxygen sensor connector, use multimeter to Yes Go to next step
check if the voltage between the connector C# (correspond to
2
the white line of oxygen sensor) and D# (correspond to the white No Go to step 4
line of oxygen sensor) is about 12V.
Use multimeter to check if the resistance between oxygen sen- Yes Go to next step
3
sor pin C# (white) and D# (white) is between 2~5¡ under 20°C. No Replace sensor
Check if the 8A fuse of oxygen sensor heat circuit has been fus- Yes Replace fuse
4
ing. No Go to next step
Check if the harness wire between ECU (terminal 1#), main re- Repair or replace
Yes
lay (pin 87#) and oxygen sensor connector pin C# (correspond the harness wires
5 to the white line of oxygen sensor), D# (correspond to the white
line of oxygen sensor) is open circuit or short circuit with the No Diagnostic help
power or the ground.
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BYD S6, S6A, S6K Service Manual
4.13 DTC P0171: Air/fuel ratio closed-loop control self-adaptive over upper limit
(Remark: The procedure is accord with the no DTC for intake air pressure sensor, canister control
valve, oxygen sensor etc. if the DTCs existed at the same time, should ¿rst deal with these mal-
function, then check as the follow procedure.)
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch to
1 Go to next step
“ON”.
Start the engine, run at idle speed until the coolant temperature to Yes Go to next step
the normal temperature.
2 With fully load, Observe the change value of diagnostic test “oxygen
sensor voltage” item, then if the value maintain near the 100mV for No Diagnostic help
a long time at the certain load.
Yes Go to next step
Connect the fuel pressure gauge at the fuel inlet pipe, Observe if
3 Check the fuel
the fuel pressure maintain at about 350kPa with fully load. No
system
Check if the harness wire between ECU (terminal 2#, 39#, 45#) and Repair or replace
Yes
4 the sensor connector (terminal 2#, 3#, 4#) is short circuit with the the harness wires
ground. No Go to next step
A. Check if the serious air leakage in the intake air system; Repair based
Yes
B. If the injector is blocked; on the diagnostic
C. If the spark plug clearance is too large;
5
D. If the high tension line resistance is too high;
No Diagnostic help
E. The abrasion of intake valve guide pipe;
Etc.
4.14 DTC P0172: Air/fuel ratio closed-loop control self-adaptive over lower limit
(Remark: The procedure is accord with the no DTC for intake air pressure sensor, canister control
valve, oxygen sensor etc. if the DTCs existed at the same time, should ¿rst deal with these mal-
function, then check as the follow procedure.)
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch to
1 Go to next step
“ON”.
Start the engine, run at idle speed until the coolant temperature to Yes Go to next step
the normal temperature.
2 With fully load, Observe the change value of diagnostic test “oxygen
sensor voltage” item, then if the value maintain near the 100mV for No Diagnostic help
a long time at the certain load.
Yes Go to next step
Connect the fuel pressure gauge at the fuel inlet pipe, Observe if
3 Check the fuel
the fuel pressure maintain at about 350kPa with fully load. No
system
Check if the harness wire between ECU (terminal 2#, 39#, 45#) Repair or replace
Yes
4 and the sensor connector (terminal2#, 3#, 4#) is short circuit with the harness wires
the ground. No Go to next step
A. If the injector leaked; Repair based
Yes
B. The exhaust pipe leakage; on the diagnostic
5
C. The improper ignition timing;
No Diagnostic help
Etc.
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BYD S6, S6A, S6K Service Manual
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Remove the cylinder 1 injector connector, use multimeter to Yes Go to step 4
2 check if the voltage between this connector (terminal 1#) and
the power negative pole is about 12V. No Go to next step
Check if the harness wire between cylinder 1 injector (termi- Repair or replace
Yes
3 nal 1#) and main relay is open circuit or short circuit with the the harness wires
ground No Go to next step
Use multimeter to check if the resistance between cylinder 1 Yes Go to next step
4
injector terminal 1# and 2# is between 11~13¡ under 20°C. No Replace injector
Use multimeter to check the voltage between cylinder 1 in- Yes Diagnostic help
5 jector connector terminal 2# and the power negative pole is
about 3.7V. No Go to next step
Check if the harness wire between cylinder 1 injector terminal Repair or replace
Yes
6 2# and ECU terminal 50# is open circuit or short circuit with the harness wires
the power or the ground No Diagnostic help
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Remove the cylinder 2 injector connector, use multimeter to Yes Go to step 4
2 check if the voltage between this connector (terminal 1#) and
the power negative pole is about 12V. No Go to next step
Check if the harness wire between cylinder 2 injector (termi- Repair or replace
Yes
3 nal 1#) and main relay is open circuit or short circuit with the the harness wires
ground No Go to next step
Use multimeter to check if the resistance between cylinder 2 Yes Go to next step
4
injector terminal 1# and 2# is between 11~13¡ under 20°C. No Replace injector
Use multimeter to check the voltage between cylinder 2 in- Yes Diagnostic help
5 jector connector terminal 2# and the power negative pole is
about 3.7V. No Go to next step
Check if the harness wire between cylinder 2 injector termi- Repair or replace
Yes
6 nal 2# and ECU terminal 63# is open circuit or short circuit the harness wires
with the power or the ground No Diagnostic help
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BYD S6, S6A, S6K Service Manual
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “ON”.
Remove the cylinder 3 injector connector, use multimeter to Yes Go to step 4
2 check if the voltage between this connector (terminal 1#) and the
power negative pole is about 12V. No Go to next step
Check if the harness wire between cylinder 3 injector connector Repair or replace
Yes
3 (terminal 1#) and main relay is open circuit or short circuit with the harness wires
the ground No Go to next step
Use multimeter to check if the resistance between cylinder 3 in- Yes Go to next step
4
jector terminal 1# and 2# is between 11~13¡ under 20°C. No Replace injector
Use multimeter to check the voltage between cylinder 3 injector Yes Diagnostic help
5
connector terminal 2# and the power negative pole is about 3.7V. No Go to next step
Check if the harness wire between cylinder 3 injector terminal Repair or replace
Yes
6 2# and ECU terminal 49# is open circuit or short circuit with the the harness wires
power or the ground No Diagnostic help
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “ON”.
Remove the cylinder 4 injector connector, use multimeter to Yes Go to step 4
2 check if the voltage between this connector (terminal 1#) and
the power negative pole is about 12V. No Go to next step
Check if the harness wire between cylinder 4 injector connector Repair or replace
Yes
3 (terminal 1#) and main relay is open circuit or short circuit with the harness wires
the ground No Go to next step
Use multimeter to check if the resistance between cylinder 4 in- Yes Go to next step
4
jector terminal 1# and 2# is between 11~13¡ under 20°C. No Replace injector
Use multimeter to check the voltage between cylinder 4 injector Yes Diagnostic help
5
connector terminal 2# and the power negative pole is about 3.7V. No Go to next step
Check if the harness wire between cylinder 3 injector terminal
Repair or replace
6 2# and ECU terminal 64# is open circuit or short circuit with the Yes
the harness wires
power or the ground
275
BYD S6, S6A, S6K Service Manual
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “OFF”.
Remove the fuel pump relay, turn the ignition switch to Yes Go to step 4
”ON”, check if the voltage between fuel pump relay power
2
terminal (terminal 30#, 86#) and the power negative pole is No Go to next step
about 12V.
Repair or replace the
Check if the relay power terminal harness circuit is open or Yes
3 harness wires
short circuit with the ground
No Go to step 2
Use multimeter to check if the voltage between fuel pump Yes Replace the fuel relay
4 relay control terminal (terminal 85#) and the power nega-
tive pole is about 3.7V. No Go to next step
Check if the harness wire between relay control terminal Repair or replace the
Yes
5 (terminal 85#) and the ECU terminal 60# is open or short harness wires
circuit with the power or the ground. No Diagnostic help
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “OFF”.
Remove the knock sensor connector, use multimeter to Yes Go to next step
2 check if the voltage between the knock sensor terminal 1#
No Replace sensor
and 2# is more than 1M¡.
Check if the harness wire between knock sensor connector Repair or replace the
Yes
3 (terminal 1#, 2#) and ECU (terminal 30#, 31#) is open or harness wires
short circuit with the power or the ground No Go to next step
Replace the knock sensor according the speci¿cation, start Yes Diagnostic help
4 the engine and accelerate to 2200 r/min. check if the DTC
P0325 occurs again. No Check if accidental
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “OFF”.
Remove the Rotating Speed Sensor connector, use multi- Yes Go to next step
2 meter to check if the voltage between rotating speed sensor
terminal 2# and 3# is between 770~950¡ under 20°C. No Replace sensor
Check if the harness wire between rotating speed sensor Repair or replace the
Yes
3 connector (terminal 2#, 3#) and the ECU (terminal 47#, 46#) harness wires
is open or short circuit with the power or the ground No Go to next step
Yes Diagnostic help
4 Check if the Àywheel signal disc is right.
No Replace the signal disc
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BYD S6, S6A, S6K Service Manual
4.22 DTC P0336: Malfunction of the crankshaft position sensor signal illogicality
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “OFF”.
Remove the Rotating Speed Sensor connector, use multimeter Yes Go to next step
2 to check if the voltage between rotating speed sensor terminal
2# and 3# is between 770~950¡ under 20°C. No Replace sensor
Check if the harness wire between rotating speed sensor con- Repair or replace
Yes
3 nector (terminal 1#, 2#) and the ECU (terminal 39#, 42#) is the harness wires
open or short circuit with the power or the ground No Go to next step
Yes Diagnostic help
4 Check if the Àywheel signal disc is right. Replace the signal
No
disc
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Remove the phase sensor connector, use multimeter to check Yes Go to step 4
2 if the voltage between phase sensor terminal 1# and 3# is
about 12V No Go to next step
Check if the harness wire between the phase sensor 3# Repair or replace the
Yes
and main relay terminal 87# is open or short circuit with the harness wires
3 ground.
Check if the phase sensor terminal 1# is poor contact with the No Go to next step
ground
Check if the voltage between phase sensor 2# and the power Yes Go to step 6
4
negative pole is about 9.9V. No Go to next step
Check if the harness wire between phase sensor connector Repair or replace the
Yes
5 terminal 2# and the ECU terminal 42# is open or short circuit harness wires
with the power or the ground No Go to next step
Yes Diagnostic help
6 Check if the camshaft signal disc is right Replace the signal
No
disc
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Remove the phase sensor connector, use multimeter to check Yes Go to step 4
2 if the voltage between phase sensor terminal 1# and 3# is
about 12V No Go to next step
Check if the harness wire between the phase sensor 3# Repair or replace the
Yes
and main relay terminal 87# is open or short circuit with the harness wires
3 ground.
Check if the phase sensor terminal 1# is poor contact with the No Go to next step
ground
Check if the voltage between phase sensor 2# and the power Yes Go to step 6
4
negative pole is about 9.9V. No Go to next step
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BYD S6, S6A, S6K Service Manual
Detection
No. Operation step Next step
results
Check if the harness wire between phase sensor connector Repair or replace the
Yes
5 terminal 2# and the ECU terminal 42# is open or short circuit harness wires
with the power or the ground No Go to next step
Yes Diagnostic help
6 Check if the camshaft signal disc is right Replace the signal
No
disc
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “ON”.
Remove the phase sensor connector, use multimeter to check Yes Go to step 4
2 if the voltage between phase sensor terminal 1# and 3# is
about 12V No Go to next step
Check if the harness wire between the phase sensor 3# and Repair or replace the
Yes
main relay terminal 87# is open or short circuit with the ground. harness wires
3
Check if the phase sensor terminal 1# is poor contact with the
No Go to next step
ground
Check if the voltage between phase sensor 2# and the power Yes Go to step 6
4
negative pole is about 9.9V. No Go to next step
Check if the harness wire between phase sensor connector Repair or replace the
Yes
terminal 2# and the ECU terminal 42# is open or short circuit harness wires
5
with th
No Go to next step
e power or the ground
Yes Diagnostic help
6 Check if the camshaft signal disc is right Replace the signal
No
disc
4.26 DTC P0443: Canister control valve driving control circuit malfunction
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “ON”.
Remove the canister control valve connector, use multimeter Yes Go to step 4
2 to check if the voltage between this connector terminal 1# and
the power negative pole is about 12V No Go to next step
Repair or replace the
Check if the canister control valve power terminal circuit is Yes
3 harness wires
open or short circuit with the ground
No Go to step 2
Use multimeter to check if the resistance between canister Yes Go to next step
4 control valve terminal 1# and 2# is between 22~30¡ under Replace the
20°C. No
control valve
Use multimeter to check if the voltage between canister control Yes Diagnostic help
5 valve connector terminal 1# and the power negative pole is
about 3.7V. No Go to next step
Repair or replace the
Check if the harness wire between canister control valve con- Yes
6 harness wires
nector terminal 2# and the ECU terminal 37# is open circuit.
No Diagnostic help
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BYD S6, S6A, S6K Service Manual
4.27 DTC P0444: Canister control valve driving control circuit voltage over low
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “ON”.
Remove the canister control valve connector, use multimeter to Yes Go to step 4
2 check if the voltage between this connector terminal 1# and the
power negative pole is about 12V No Go to next step
Repair or replace the
Check if the canister control valve power terminal circuit is Yes
3 harness wires
open or short circuit with the ground
No Go to step 2
Yes Go to next step
Use multimeter to check if the resistance between canister con-
4 Replace the
trol valve terminal 1# and 2# is between 22~30¡ under 20°C. No
control valve
Use multimeter to check if the voltage between canister control Yes Diagnostic help
5 valve connector terminal 1# and the power negative pole is
about 3.7V. No Go to next step
Check if the harness wire between canister control valve con- Repair or replace the
Yes
6 nector terminal 2# and the ECU terminal 37# is short circuit harness wires
with the ground No Diagnostic help
4.28 DTC P0445: Canister control valve driving control circuit voltage over high
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “ON”.
Remove the canister control valve connector, use multimeter to Yes Go to step 4
2 check if the voltage between this connector terminal 1# and the
power negative pole is about 12V No Go to next step
Repair or replace the
Check if the canister control valve power terminal circuit is open Yes
3 harness wires
or short circuit with the ground
No Go to step 2
Yes Go to next step
Use multimeter to check if the resistance between canister con-
4 Replace the
trol valve terminal 1# and 2# is between 22~30¡ under 20°C. No
control valve
Use multimeter to check if the voltage between canister control Yes Diagnostic help
5 valve connector terminal 1# and the power negative pole is
about 3.7V. No Go to next step
Check if the harness wire between canister control valve con- Repair or replace the
Yes
6 nector terminal 2# and the ECU terminal 37# is short circuit with harness wires
the power No Diagnostic help
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BYD S6, S6A, S6K Service Manual
4.29 DTC P0480: Malfunction of the A/C condenser cooling fan relay control circuit
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “OFF”.
Remove the A/C condensator cooling fan relay, turn the Yes Go to step 4
2 ignition switch to “ON”, check if the voltage between this
relay power terminal 30# and 85# is about 12V. No Go to next step
Check if the harness wire of A/C condensator cooling Repair or replace the
Yes
3 fan relay power terminal is open or short circuit with the harness wires
ground. No Go to step 2
Use multimeter to check if the voltage between A/C con- Replace the
Yes
4 densator cooling fan relay control terminal 86# and the relay
power negative pole is about 3.7V. No Go to next step
Check if the harness wire between relay control terminal Repair or replace the
Yes
5 86# and ECU terminal 62# is open circuit or short circuit harness wires
with the power or the ground No Diagnostic help
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “OFF”.
Check and repair the
If the vehicle required with ABS system, check if the DTC Yes
2 ABS system
exists at the ABS system.
No Go to next step
Yes Go to next step
3 Check if the work of the speedometer ¿nger is normal. Check the speedometer
No
circuit
Yes Go to next step
4 Check if the work of the vehicle speed sensor is normal. Replace the speed sen-
No
sor
Check if the harness wire between vehicle speed sensor Repair or replace the
Yes
4 signal wire and the ECU terminal 11# is open circuit or harness wires
short circuit for the power or the ground. No Diagnostic help
4.31 DTC P0506: Idle speed lower than target idle speed
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “OFF”.
Yes Go to next step
Check if the throttle adjusting bolt, throttle valve cable,
2 Make necessary check
and throttle work well. No
and repair, maintenance
Yes Go to next step
3 Check if the idle speed adjustor work well Make necessary check
No
and repair, maintenance
A. Check if the pressure of fuel supply system is too low; Make necessary check
Yes
4 B. Check if the injector is blocked; and repair
C. Check if the exhaust is not smooth No Diagnostic help
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BYD S6, S6A, S6K Service Manual
4.32 DTC P0507: Idle speed higher than target idle speed
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the
1 Go to next step
ignition switch to “OFF”.
Yes Go to next step
Check if the throttle adjusting bolt, throttle valve
2 Make necessary check and repair,
cable, throttle work well. No
maintenance
Yes Go to next step
3 Check if the idle speed adjustor work well Make necessary check and repair,
No
maintenance
A. Check if the pressure of fuel supply system is Yes Make necessary check and repair
too low;
4
B. Check if the injector is blocked; No Diagnostic help
C. Check if the exhaust is not smooth
4.33 DTC P0508: Idle adjustor control circuit voltage over low
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn
1 Go to next step
the ignition switch to “ON”.
Remove the idle adjustor connector, use multi- Yes Go to next step
meter to check if the resistance between termi-
2
nal 1 and 4, 2 and 3 of the idle adjustor is about No Replace the step motor
53 ± 5.3¡ under 20°C.
Separately check if the harness wire between Repair or replace the harness
Yes
idle speed adjustor connector (terminal 1, 2, wires
3
3, 4) and ECU (terminal 36#, 35#, 21#, 22#) is
No Diagnostic help
short circuit with the ground.
4.34 DTC P0509: Idle speed adjustor control circuit voltage over high
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn
1 Go to next step
the ignition switch to “ON”.
Remove the idle adjustor connector, use mul- Yes Go to next step
timeter to check if the resistance between
2
terminal1 and 4, 2 and 3 of the idle adjustor is No Replace the step motor
about 53 ± 5.3¡ under 20°C.
Separately check if the harness wire between Repair or replace the harness
Yes
idle speed adjustor connector (terminal 1, 2, wires
3
3, 4) and ECU (terminal36#, 35#, 21#, 22#) is
No Diagnostic help
short circuit with the ground.
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BYD S6, S6A, S6K Service Manual
4.35 DTC P0511: Malfunction of the idle speed adjustor control circuit
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “ON”.
Remove the idle adjustor connector, use multimeter to check if Yes Go to next step
2 the resistance between terminal 1 and 4, 2 and 3 of the idle ad- Replace the step
justor is about 53 ± 5.3¡ under 20°C. No
motor
Separately check if the harness wire between idle speed adjus- Repair or replace the
Yes
3 tor connector (terminal A, B, C, D) and ECU (terminal 36#, 35#, harness wires
21#, 22#) is open circuit with the ground. No Diagnostic help
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “OFF”.
Yes Go to next step
2 Use multimeter to check if the battery voltage is about 12V.
No Replace the battery
Check if the harness wire between ECU (terminal 16#, 32#) Repair or replace the
Yes
3 and main relay terminal 87# is open circuit or short circuit with harness wires
the ground. No Go to next step
Yes Go to next step
Start the engine, check if the charging voltage of generator is
4 Replace the genera-
always between 9-16V during different rotating speed. No
tor
Yes Diagnostic help
5 Check if the ground wire of engine harness is ¿ne. Repair or replace the
No
harness wires
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition switch
1 Go to next step
to “OFF”.
Yes Go to next step
2 Use multimeter to check if the battery voltage is about 12V.
No Replace the battery
Repair or replace the
Check if the harness wire resistance between ECU (terminal Yes
3 harness wires
16#, 32#) and main relay terminal 87# is too high.
No Go to next step
Yes Go to next step
Start the engine, check if the charging voltage of generator is
4 Replace the genera-
always between 9-16V during different rotating speed. No
tor
Yes Diagnostic help
5 Check if the ground wire of engine harness is ¿ne. Repair or replace the
No
harness wires
282
BYD S6, S6A, S6K Service Manual
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “OFF”.
Yes Go to next step
2 Use multimeter to check if the battery voltage is about 12V.
No Replace the battery
Start the engine, check if the charging voltage of generator is Yes Go to next step
3
always between 9-16V during different rotating speed. No Replace the generator
Yes Diagnostic help
4 Check if the ground wire of engine harness is ¿ne. Repair or replace the
No
harness wires
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Erase the DTC, ensure if the malfunction is stable malfunc- Yes Go to next step
2
tion. No System is normal
3 Replace the ECU. End
Detection
No. Operation step Next step
results
Connect the diagnostic and the adapter, turn the ignition
1 Go to next step
switch to “ON”.
Erase the DTC, ensure if the malfunction is stable malfunc- Yes Go to next step
2
tion. No System is normal
3 Replace the ECU. End
Detection
No. Operation Steps Next step
results
Connect the diagnosis tester and the adapter, turn the igni-
1 Go to next step
tion switch to ‘ON”.
Remove air conditioner compressor relay, turn the ignition Yes Go to step 4
switch to “ON”, and check relay supply end. Check if the
2
voltage between the relay30#and 85#plug and power nega-
tive electrode is about 12V. No Go to next step
283
BYD S6, S6A, S6K Service Manual
Detection
No. Operation Steps Next step
results
Check air conditioner compressor relay control end. Check Repair or replace the
Yes
5 if the harness wire between the relay terminal 86#and ECU harness wires
terminal 70# is open circuit. No Diagnosis help
4.42 DTC: P0646 Air conditioner compressor relay control circuit voltage over low
Detection
No. Operation Steps Next step
results
Connect the diagnosis tester and the adapter, turn the igni-
1 Go to next step
tion switch to “OFF”.
Remove air conditioner compressor relay, turn the ignition Yes Go to step 4
switch to “ON”, and check relay supply end. Check if the
2
voltage value between the relay pin 30#and 85# and power
negative electrode is about 12V No Go to next step
4.43 DTC: P0647 Air conditioner compressor relay control circuit voltage over high
Detection
No. Operation Steps Next step
results
Connect the diagnosis tester and the adapter, turn the igni-
1 Go to next step
tion switch to “OFF”.
Remove air conditioner compressor relay, turn the ignition Yes Go to step 4
switch to “ON”, and check relay supply end. Check if the
2
voltage value between the relay pin 30#and 85# and power No Go to next step
negative electrode is about 12V
Repair or replace the
Check relay supply end harness wire is open circuit or short Yes
3 harness wires
circuit with the ground.
No Go to step 2
Check air conditioner compressor relay control end with the Yes Replace relay
multimeter. Check if the voltage value between the harness
4
wire between the relay 86 pin and power negative electrode No Go to next step
is about 3.7V.
Check air conditioner compressor relay contrail end. Check Repair or replace the
Yes
5 if the harness wire between the relay pin 86#and ECU ter- harness wires
minal 70# is short circuit with the ground. No Go to next step
Yes Diagnosis help
Check if air conditioner compressor electromagnetic clutch
6 Repair or replace the
is ¿ne. No
electromagnetic clutch
284
BYD S6, S6A, S6K Service Manual
Detection
No. Operation Steps Next step
results
Connect the diagnosis tester and the adapter, turn the igni-
1 Go to next step
tion switch to “ON”.
Remove idle adjustor EWD connector on the harness wire, Yes Go to step 4
and check if the voltage value between the connector termi-
2
nal 2# and the power negative electrode is about 12V with No Go to next step
the multimeter.
Repair or replace the
Check if the harness wire of the idle adjustor EWD supply Yes
3 harness wires
end is open or short circuit with the ground.
No Go to next step
Check if the resistance between the terminal 3#and 2# of Yes Go to next step
4 idle adjustor EWD is about 15.5¡ under 20°C with the mul-
timeter No Replace EWD
Check if the harness wire between the idle adjustor EWD Repair or replace the
Yes
5 connector terminal 3# and ECU terminal 29# is short circuit harness wires
with the ground. No Diagnosis help
Detection
No. Operation Steps Next step
results
Connect the diagnosis tester and the adapter, turn the igni-
1 Go to next step
tion switch to ‘ON”.
Remove idle adjustor EWD connector on the harness wire, Yes Go to step 4
and check if the voltage value between the connector termi-
2
nal 2# and the power negative electrode is about 12V with No Go to next step
the multimeter.
Repair or replace the
Check if the harness wire of the idle adjustor EWD supply Yes
3 harness wires
end is open or short circuit with the ground.
No Go to next step
Check if the resistance between the terminal 1#and 2# of Yes Go to next step
4 idle adjustor EWD is about 17.6¡under 20°C with the multi-
meter. No Replace EWD
Check if the harness wire between the idle adjustor EWD Repair or replace the
Yes
5 connector terminal 1# and ECU terminal 26# is open circuit harness wires
or short circuit with the ground. No Diagnosis help
4.46 DTC: P0509 Idle adjustor control circuit voltage over high
Detection
No. Operation Steps Next step
results
Connect the diagnosis tester and the adapter, turn the igni-
1 Go to next step
tion switch to “ON”.
Remove idle adjustor EWD connector on the harness wire, Yes Go to step 4
and check if the voltage value between the connector termi-
2
nal 2# and the power negative electrode is about 12V with No Go to next step
the multimeter.
Repair or replace the
Check if the harness wire of the idle adjustor EWD supply Yes
3 harness wires
end is open circuit or short circuit with the ground.
No Go to next step
Check if the resistance between the terminal 1#and 2# of Yes Go to next step
4 idle adjustor EWD is about 17.6¡under 20°C with the multi-
meter. No Replace EWD
285
BYD S6, S6A, S6K Service Manual
Detection
No. Operation Steps Next step
results
Check if the harness wire between the idle adjustor EWD Repair or replace the
Yes
5 connector terminal 1# and ECU terminal 26# is short circuit harness wires
with the power. No Diagnosis help
Detection
No. Operation Steps Next step
results
Connect the diagnosis tester and the adapter, turn the igni-
1 Go to next step
tion switch to “ON”.
Use the “actuator action test” item of diagnostic test to make Yes Go to next step
2 the action test for the SVS, detect that if it always is OFF or
ON.. No System is normal
Repair or replace the
Check the SVS power terminal harness wire is open circuit Yes
3 harness wires
or short circuit with the ground.
No Go to next step
Check if the harness wire between SVS control terminal and Repair or replace the
Yes
4 the ECU (terminal 28#) is open or short circuit for the power harness wires
supply or the ground. No Go to next step
Yes Diagnosis help
5 Check if the SVS bulb is normal.
No Replace the bulb
286
BYD S6, S6A, S6K Service Manual
3. Ensure the symptom that host complaints exists, and ensure the condition that cause the
malfunction.
Appearance inspection:
(1) Check whether the fuel pipeline has the symptom of leakage;
(2) Check whether vacuum pipeline has the symptom of rupture, twist and bad connection;
(3) Check whether the intake pipeline has the symptom of jam, leakage, staved or hurt;
(4) Check whether high tension cable of ignition system has the symptom of rupture, aging and
wrong ignition sequence;
(5) Check whether the position of wire harness grounding is clean and reliable;
(6) Check whether the sensors and actuator connector has the symptom of loose or bad con-
tact.
NOTICE
,IWKHDERYHV\PSWRPH[LVWV¿UVWPDNH
maintenance in accordance with the
malfunction, or the repair and diagnosis
will be affected.
Diagnosis:
1. ensure there is no malfunction record;
3. has ¿nished the above inspection, and don’t ¿nd abnormal condition;
4. don’t overlook the inÀuence that is caused by the condition such as vehicle mainte-
nance condition, cylinder pressure, mechanism ignition timing and fuel condition in
the repair process;
If the malfunction symptom can be cleared, malfunction exists in ECU. If malfunction symptom
still exists, replace back the original ECU, and repeat inspection procedure again.
287
BYD S6, S6A, S6K Service Manual
H. Starting is normal but idle speed is not stable after warming up;
I. Starting is normal but under partial load (for example, A/C is on) idle speed is not stable or
engine stalls;
Common position for malfunction: 1. battery; 2. starter; 3. wire harness or ignition switch; 4. en-
gine mechanism part
Serial Test
Operation step Continuous step
NO. result
Check the voltage between both electrode with multi- Yes Next step
1 meter, when engine starts, whether the voltage is about
8-12V. No Replace battery
Keep the ignition switch on starting position, check Yes Next step
2 whether the anode of starter is over 8V with multi- Repair or replace wire har-
meter. No
ness
Remove starter, and check its work condition. the point Yes Repair or replace starter
3 is to check whether there is the symptom of open cir-
cuit or locked for bad lubrication. No Next step
If the malfunction happens only in winter. Check wheth- Yes Replace proper lubrication oil
4
er the engine lubrication oil and gear oil is proper. No Next step
Check whether the reason that starter doesn’t work or Repair engine inner resis-
Yes
5 rotate slowly is the over-high engine inner mechanical tance
resistance. No Diagnosis
Common diagnostic position: 1. no fuel in fuel tank; 2. fuel pump; 3. rotate speed sensor; 4. igni-
tion coil; 5. engine mechanical part
288
BYD S6, S6A, S6K Service Manual
Serial
Operation step Test result Continuous step
NO.
Connect fuel pressure meter (connecting position is front Yes Next step
1 end of inlet pipe of fuel distribution pipe assembly), start Repair supply fuel sys-
engine, check whether fuel pressure is about 350kPa. No
tem
Connect diagnostic tester of electronic injection system, Yes Next step
2 observe the data of “engine rotate speed”, start engine Repair circuitry of rotate
and observe whether there is rotation speed signal output. No
speed sensor
Pull out high tension cable of a cylinder, connect spark Yes Next step
plug, make the distance from spark plug electrode to en-
3
gine body is about 5mm, start engine and check whether No Repair ignition system
there is the white-blue high tension ¿re.
Exclude engine me-
Check the pressure condition of each cylinder and ob- Yes
4 chanical malfunction
serve whether there is the symptom of pressure shortage.
No Next step
Connect adapter of electronic injection system, open igni- Yes Diagnosis
tion switch, check whether power supply of 64#, 49#, 50#,
5
63# pin is normal; check whether grounding of 43#, 48#, No Repair related circuitry
5# pin is normal.
Common malfunction position: 1. there is water in fuel; 2. fuel pump; 3. coolant temperature sen-
sor; 4. fuel pressure adjuster vacuum pipe; 5. ignition coil
Serial
Operation step Test result Continuous step
NO.
Connect fuel pressure meter (connecting position is
Yes Next step
front end of inlet pipe of fuel distribution pipe assembly),
1
start engine, and check whether fuel pressure is about Repair supply fuel sys-
No
350kPa. tem
Pull out high tension cable of a cylinder, connect spark Yes Next step
plug, make the distance from spark plug electrode to en-
2
gine body is about 5mm, start engine and check whether
No Repair ignition system
there is the white-blue high tension ¿re.
Pull out connector of coolant temperature sensor, start Repair circuit or replace
Yes
engine, and observe whether engine can start. (serially sensor
3 connect a 300 resistance instead of coolant temperature
sensor to connector of coolant temperature sensor, ob- No Next
serve whether engine can start)
Check whether fuel pressure adjuster vacuum pipe has Yes Repair or replace
4
the symptom of loose or leakage. No Next step
Check fuel condition, observe whether appearance of Yes Replace fuel
5
malfunction symptom is after just adding fuel. No Next step
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BYD S6, S6A, S6K Service Manual
Common malfunction position: 1. there is water in fuel; 2. fuel pump; 3. coolant temperature sen-
sor; 4. fuel injector; 5. ignition coil; 6. throttle body and idle bypass passage; 7. engine mechanical
part
Serial Continuous
Operation step Test result
NO. step
Connect fuel pressure meter (connecting position is front Yes Next step
1 end of inlet pipe of fuel distribution pipe assembly), start en- Repair supply fuel
gine, check whether fuel pressure is about 350kPa. No
system
Pull out high tension cable of a cylinder, connect spark plug, Yes Next step
make the distance from spark plug electrode to engine body
2 Repair ignition
is about 5mm, start engine and check whether there is the No
white-blue high tension ¿re. system
Pull out connector of coolant temperature sensor, start Repair circuitry or
Yes
engine, and observe whether engine can start. (serially replace sensor
3 connect a 2500 resistance instead of coolant temperature
sensor to connector of coolant temperature sensor, observe No Next step
whether engine can start)
Wash throttle and
Lightly step accelerating pedal, observe whether the start is Yes
4 idle passage
easy.
No Next step
Remove fuel injector, check whether the fuel injector has the Malfunction chan-
Yes
5 symptom of leakage or jam with fuel injector special wash- ged
ing analysis tester. No Next step
Check fuel condition, observe whether the appearance of Yes Replace fuel
6
malfunction symptom is after just adding fuel No Next step
Remove the en-
Check pressure condition of each cylinder, observe whether Yes gine mechanical
7 malfunction
there is the symptom of pressure shortage
No Next step
Connect adapter of electronic injection system, open ignition Yes Diagnosis
switch, check whether power supply of 12#, 13#, 44#, 45#,
8 Repair related
63# pin is normal; check whether grounding of 3#, 51#, 53#, No
61#, 80# pin is normal. circuitry
Common malfunction position: 1. there is water in fuel; 2. fuel pump; 3. coolant temperature sen-
sor; 4. fuel injector; 5. ignition coil; 6. throttle body and idle bypass passage; 7. intake passage; 8.
ignition timing; 9. spark plug; 10. engine mechanical part
290
BYD S6, S6A, S6K Service Manual
Check fuel condition, observe whether the appearance of Yes Replace fuel
8
malfunction symptom is after just adding fuel. No Next step
Remove engine me-
Check pressure condition of each cylinder, observe wheth- Yes
9 chanical malfunction
er there is the symptom of pressure shortage
No Next step
Yes Next step
Check whether the ignition sequence and ignition timing
10
match criterion. No Repair ignition timing
Common malfunction position: 1. there is water in fuel; 2. fuel injector; 3. spark plug; 4. throttle
and idle bypass passage; 5. intake passage; 6. idle adjuster; 7. ignition timing; 8. spark plug; 9.
engine mechanical part
291
BYD S6, S6A, S6K Service Manual
Serial Continuous
Operation step Test result
NO. step
Repair intake sys-
Check whether air ¿lter has the symptom of jam, and in- Yes
1 tem
take passage has the symptom of leakage.
No Next step
Check whether the idle adjuster has the symptom of Yes Clean or replace
2
blocking. No Next step
Check spark plug of each cylinder, observe whether its Yes Next step
3
style NO. And the clearance obeys the criterion. No Adjust or replace
Check whether the throttle and idle bypass passage has Yes Wash
4
accumulated carbon. No Next step
Remove fuel injector, check if the fuel injector has the Malfunction
Yes
5 symptom of leakage, jam or flux over-bad with special changed
washing analysis tester. No Next step
Check fuel condition, observe whether the appearance of Yes Replace fuel
6
malfunction symptom is after just adding fuel. No Next step
Remove engine me-
Check pressure condition of each cylinder, observe if the Yes chanical malfunc-
7 tion
difference between cylinder pressure is great.
No Next step
Yes Next step
Check whether engine ignition sequence and ignition tim-
8 Repair ignition tim-
ing obey criterion. No
ing
Connect electronic injection adapter, open ignition switch, Yes Diagnosis
check whether power supply of 64#, 49#, 50#, 63# pin is
9 Repair related cir-
normal; check whether grounding of 43#, 48#, 5#pin is No
normal. cuitry
Common malfunction position: 1, there is water in fuel; 2, coolant temperature sensor; 3, spark
plug; 4, throttle and idle bypass passage; 5, intake passage; 6, idle adjuster; 7, engine mechani-
cal part.
Serial
Operation step Test result Continuous step
NO.
Check whether air ¿lter has the symptom of jam, and Yes Repair intake system
1
intake passage has the symptom of leakage. No Next step
Check spark plug of each cylinder, observe whether Yes Next step
2
its style NO. And the clearance obeys the criterion. No Adjust or replace
Remove idle adjuster, check if accumulated carbon Wash related spare
Yes
3 exists in throttle body, idle adjuster and idle bypass parts
passage. No Next step
292
BYD S6, S6A, S6K Service Manual
Serial
Operation step Test result Continuous step
NO.
Pull out coolant temperature sensor connector, start Repair circuitry or re-
Yes
4 engine, observe whether when warming up engine, place sensor
the unstable idle exists. No Next step
Remove fuel injector, check if the fuel injector has the Yes Malfunction changed
5 symptom of leakage, jam or Àux over-bad with special
washing analysis tester. No Next step
Check fuel condition, observe whether the appear- Yes Replace fuel
6
ance of malfunction symptom is after just adding fuel. No Next step
Remove engine me-
Check pressure condition of each cylinder, observe if Yes
7 chanical malfunction
the difference between cylinder pressure is great.
No Next step
Connect electronic injection adapter, open ignition Yes Diagnosis
switch, check whether power supply of 64#, 49#, 50#,
8
63# pin is normal; check whether grounding of 43#, No Repair related circuitry
48#, 5# pin is normal.
Common malfunction position: 1, there is water in fuel; 2, coolant temperature sensor; 3, spark
plug; 4, throttle body and idle bypass passage; 5, intake passage; 6, idle adjuster; 7, engine me-
chanical part.
Serial
Operation step Test result Continuous step
NO.
Check whether air ¿lter has the symptom of jam, and Yes Repair intake system
1
intake passage has the symptom of leakage.
No Next step
Check spark plug of each cylinder, observe whether Yes Next step
2
its style NO. and clearance obey the criterion. No Adjust or replace
Remove idle adjuster, check if accumulated carbon Wash related spare
Yes
3 exists in throttle body, idle adjuster and idle bypass parts
passage. No Next step
Pull out coolant temperature sensor connector, start Repair circuitry or re-
Yes
4 engine, observe whether when warming up engine, place sensor
the unstable idle exists. No Next step
Remove fuel injector, check if the fuel injector has the Yes Malfunction changed
5 symptom of leakage, jam or Àux over-bad with special
No Next step
washing analysis tester.
Check fuel condition, observe whether the appear- Yes Replace fuel
6
ance of malfunction symptom is after just adding fuel. No Next step
Remove engine me-
Check pressure condition of each cylinder, observe if Yes
7 chanical malfunction
the difference between cylinder pressure is great.
No Next step
293
BYD S6, S6A, S6K Service Manual
5.9 Normally start, unstable idle or mis¿re when there is part load. (for example: open A/C)
Continuous
Serial NO. Operation step Test result
step
Remove idle adjuster, check if accumulated carbon ex- Wash related spare
Yes
1 ists in throttle body, idle adjuster and idle bypass pas- part
sage. No Next step
Observe when A/C is on, whether the output power of Yes To the fourth step
engine increases, that is, observe the change of igni-
2
tion advance angle, injecting fuel pulse width and intake No Next step
amount.
Connect electronic injection adapter, disconnect con- Yes Next step
nective wire of 75# pin of electronic control unit, check
3
when A/C is open, whether there is high level signal in No Repair A/C system
wire harness end.
Check whether A/C system pressure, electromagnetic Yes Next step
4
clutch of compressor is normal. No Repair A/C system
Remove fuel injector, check if the fuel injector has the Malfunction
Yes
5 symptom of leakage, jam or Àux over-bad with special changed
washing analysis tester. No Next step
Connect electronic injection adapter, open ignition Yes Diagnosis
switch, check whether power supply of 64#, 49#, 50#,
6 Repair related cir-
63#pin is normal; check whether grounding of 43#, 48#, No
5#pin is normal. cuitry
Common malfunction part: 1, throttle body and idle bypass passage; 2, vacuum pipe; 3, idle ad-
juster; 4, coolant temperature sensor; 5, ignition timing.
Serial
Operation step Test result Continuous step
NO.
Check whether the accelerating pedal cable is too tight or Yes Adjust
1
blocked. No Next step
Check whether leakage exists in the intake system and re- Yes Repair intake system
2
lated vacuum pipeline. No Next step
Wash related spare
Remove idle adjuster, check if accumulated carbon exists in Yes
3 parts
throttle body, idle adjuster and idle bypass passage.
No Next step
Repair circuitry or
Pull out coolant temperature sensor connector, start engine. Yes
4 replace sensor
Observe whether the over-high idle exists.
No Next step
Yes Next step
5 Check whether the ignition timing of engine obey criterion.
No Repair ignition timing
294
BYD S6, S6A, S6K Service Manual
Serial
Operation step Test result Continuous step
NO.
Connect electronic injection adapter, open ignition switch, Yes Diagnosis
6 check whether power supply of 64#, 49#, 50#, 63#pin is nor- Repair related cir-
mal; check whether grounding of 43#, 48#, 5# pin is normal. No
cuitry
Common malfunction position: 1, fuel including water; 2, intake pressure sensor and throttle posi-
tion sensor; 3, spark plug; 4, throttle body and idle bypass passage; 5, intake passage; 6, idle ad-
juster; 7, fuel injector; 8, ignition timing; 9, exhaust pipe
Serial
Operation step Test result Continuous step
NO.
Yes Repair intake system
1 Check if the jam exists in air ¿lter.
No Next step
Connect fuel pressure meter (connecting position is front Yes Next step
end of inlet pipe of fuel distribution pipe assembly), start
2 Repair supply fuel
engine, check whether the fuel pressure is about 350kPa No
when accelerating. system
Check spark plug of each cylinder, observe whether its style Yes Next step
3
NO. and clearance obey the criterion. No Adjust or replace
Wash related spare
Remove idle adjuster, check if accumulated carbon exists in Yes
4 part
throttle body, idle adjuster and idle bypass passage.
No Next step
Yes Next step
Check whether the intake pressure sensor, throttle position
5 Repair circuitry or
sensor and circuitry are normal. No
replace sensor
Remove fuel injector, check if the fuel injector has the symp- Yes Malfunction changed
6
tom of leakage, jam with special washing analysis tester. No Next step
Check fuel condition, observe whether the appearance of Yes Replace fuel
7
malfunction symptom is after just adding fuel No Next step
Check whether ignition sequence and ignition timing obey Yes Next step
8
criterion. No Repair ignition timing
Yes Next step
9 Check if the exhaust pipe is smooth. Repair or replace
No
exhaust pipe
Connect electronic injection adapter, open ignition switch,
check whether power supply of 64#, 49#, 50#, 63# pin is
10 Yes Diagnosis
normal; check whether grounding of 43#, 48#, 5# pin is nor-
mal.
Common malfunction position: 1. fuel including water; 2. intake pressure sensor and throttle posi-
tion sensor; 3. spark plug; 4. throttle body and idle bypass passage; 5. intake passage; 6. idle ad-
juster; 7. fuel injector; 8. ignition timing; 9. exhaust pipe
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Check spark plug of each cylinder, observe whether Yes Next step
3
its style NO. and clearance obey the criterion. No Adjust or replace
Remove idle adjuster, check if accumulated carbon Wash related spare
Yes
4 exists in throttle body, idle adjuster and idle bypass parts
passage. No Next step
Yes Next step
Check whether the intake pressure sensor, throttle
5 Repair circuitry or re-
position sensor and circuitry are normal. No
place sensor
Remove fuel injector, check if the fuel injector has Yes Malfunction changed
6 the symptom of leakage, jam with special washing
analysis tester. No Next step
Check fuel condition, observe whether the appear- Yes Replace fuel
7 ance of malfunction symptom is after just adding
fuel. No Next step
Check whether ignition sequence and ignition tim- Yes Next step
8
ing obey criterion. No Repair ignition timing
Yes Next step
9 Check if the exhaust pipe is smooth.. Repair or replace
No
exhaust pipe
Connect electronic injection adapter, open ignition Yes Diagnosis
switch, check whether power supply of 64#, 49#,
10
50#, 63#pin is normal; check whether grounding of No Repair related circuitry
43#, 48#, 5# pin is normal
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Common malfunction position: 1. fuel including water; 2. intake pressure sensor and throttle posi-
tion sensor; 3. spark plug; 4. ignition coil; 5. throttle body and idle bypass passage; 6. intake pas-
sage; 7. idle adjuster; 8. fuel injector; 9. ignition timing; 10. exhaust pipe.
Check spark plug of each cylinder, observe whether Yes Next step
5
its style NO. and clearance obey the criterion. No Adjust or replace
Remove idle adjuster, check if accumulated carbon Yes Washing related parts
6 exists in throttle body, idle adjuster and idle bypass
passage. No Next step
Check whether ignition sequence and ignition tim- Yes Next step
10
ing obey criterion. No Repair ignition timing
Yes Next step
11 Check if the exhaust pipe is smooth. Repair or replace ex-
No
haust pipe
Connect electronic injection adapter, open ignition Yes Diagnosis
switch, check whether power supply of 64#, 49#,
12
50#, 63# pin is normal; check whether grounding of No Repair related circuitry
43#, 48#, 5# pin is normal
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The value and related content in this chapter is for reference only.
6.1 Diagnosis appearance is shown as follow
(1) On the left of the panel is a liquid crystal display, displaying various Chinese information.
(1) Self-diagnosis
Mainly Including: The display of main parameter, parameter, and sensor signal voltage;
Mainly Including: The display of program condition, cooling system, steady working condition, dy-
namic driving mode, exhaust control, oxygen sensor, idling, fault light, emergency operation, air
conditioner.
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Mainly including: The function test of fault light, fuel pump, air conditioner relay, fan control, igni-
tion test, and single cylinder fault block oil.
(5) Odometer
Mainly including: The display of Vehicle frame number (optional), ECU hardware, ECU software.
6.4 The diagnosis instrument use introduction
Online operation
1. BOSCH
ConnectM797
the online line 1. Connect the online wire
BOSCH M154 2. Turn on the ignition switch
BOSCH M382
3. Select the right system, press the “con-
¿rm” key.
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Self-diagnosis function
+ Self-diagnosis
+ System parameter display
+System condition After selecting the function with 4 key(upward
select key)and 8 key(downward select
key),press “con¿rm”key;Press “exit” key to go
+Actuation test
back to main function layout.
+Odometer
+ Version information
Self-diagnosis RB
- Read DTC
It can read DTC in the ECU malfunction
- Clear DTC memory with “read DTC”function,including
steady state and the incident malfunction..
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Self-diagnosis-clear DTC
Self-diagnosis RB
- Read DTC
Clear DTC RB
+ Self-diagnosis
+ Actuator tester
+ Odometer
+ Version information
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CAUTION
Injection pulse width 3.5 ms Caution: Turn on the ignition switch. Do
Intake pressure 34.0 kpa not start the engine. At this time, “intake
pressure “display about101.0kPa, that is
Intake temperature 54 c
air pressure
Speed 0 km/h
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+ Voltage
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Evaporator temperature 26 c
Intake flow 7.4 kg/h
Oil consumption 0.5 L/h
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System state RB
+ Program stage
+ Cooling system
+ Stable work condition
+ Dynamic work condition Press “Con¿rm” key or press “exit” key to re-
turn to main function layout after selecting the
+ Exhaust control
required function with key 4 (upward select
+ Oxygen sensor key)and key 8(downward select key)
+ Idle
+ Indicator
+ Emergency operation
+ Air conditioner
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Safe system N
VIN Programmed N Displaying “N” Indicates state No
Fan3 N
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Idle run N
Phase signal N
Coolant temperature N Displaying “N” Indicates state No.
Speed signal N Related condition is not met
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Idle 00000001
Emergency 00000000
The layout is applied to the system with the
electronic throttle valve.
Throttle valve position N
Electronic accelerator power-down N Displaying “N” Indicates state No.
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+ Self-diagnosis
+ System display parameter
+ System condition
Press “Confirm” key after selecting required
function with key 4 (upward select key) and
key 8(downward select key)
+ Actuat or test
+ Odometer
+ Version information
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Actuator test RB
- Maintain light
- Fuel pump
- Air conditioner relay Press “Con¿rm” key or press “exit” key to re-
turn to main function layout after selecting the
required function with key 4 (upward select
key)and key 8(downward select key)
- Fan
- Ignition
- Injection
Malfunction light RB
- Turn on
Please observe Turn on ignition switch, but don’t start engine.
- Turn off
Press “Con¿rm” key and observe if the asso-
ciated state changes of fault light is normal or
not after selecting the required function with
key 4 (upward select key) and key 8(down-
ward select key)
- Fan
- Ignition
- Injection
Fuel pump RB
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Fan RB
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Fuel injection RB
+ Self-diagnosis
+ System parameter display
+ System state Press “Confirm” key after selecting the re-
quired function with key 4 (upward select key)
and key 8(downward select key)
+ Actuator display
+Odometer
+ Version information
Odometer RB
Drive mileage
0 0 0 0 5 5 8 1 km It’s used to know the vehicle information in
the after-sales. Press “exit” key to return to
Drive time
main function layout.
0 0 0 6 5 7 9 3 min
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+ Self-diagnosis
+ System parameter display
+ System state Press “Confirm” key after selecting the re-
quired function with key 4 (upward select key)
and key 8(downward select key)
+ Actuator display
+Odometer
+ Version information
Version information RB
VIN ˖**************
It’s used to know the information of engine
******************* ECU hardware number, software number and
VIN (optional) .Press “exit” to return to main
Hardware ˖********* function layout.
Software ˖**********
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7. Accessory
7.1 Table on installation force/torque standard of spare parts
Speci¿cation:
2. The interval of maintenance is decided by mileage or interval, which ¿rst get to target;
3. The criterion is based on the premise that the vehicle is used normally as the design, so we
must strictly conform it.
Mileage
10 20 30 40 50 60 70 80
Items x1000km
Month 3 6 9 12 15 18 21 24
Ignition Coil I I I I
Ignition Cam I I I I
Ignition Cap I I I I
Ignition Wire I I I I
Spark Plug I I I R
Ignition Timing I I I I
Engine Idling
I I I I
Speed
Fuel Tank I C
Fuel Filter R R R R
Fuel Injector C* C* C* C*
Air Filter I R I R
EWD or Stepper
C C C C
Air Bypass
Throttle Body C C C C
Emission Check I I I I
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Mileage
10 20 30 40 50 60 70 80
Items x1000km
Month 3 6 9 12 15 18 21 24
Check by Diag-
I I I I
nostic Tool
7.2.2 Taxi
Speci¿cation:
3. The criterion is based on the premise that the vehicle is used normally as the design, so we
must strictly abide to it.
Mileage
20 40 60 80 100 120 140 160
Items x1000km
Month 3 6 9 12 15 18 21 24
Ignition Coil I I I I I I I I
Ignition Cam I I I I I I I I
Ignition Cap I I I I I I I I
Ignition Wire I I I I I I I I
Spark Plug I R I R
Ignition Timing I I I I
Engine Idling
I I I I
Speed
Fuel Tank C C
Fuel Filter R R R R R R R R
Fuel Injector C* C* C* C* C* C* C* C*
Air Filter I R I R I R I R
EWD or Stepper
I C I C I C I C
Air Bypass
Throttle Body I C I C I C I C
Emission Check I I I I
Check by Diag-
I I I I
nostic Tool
Note: R-Replace
C-Clean
I - Inspect (Replace the spare parts when ¿nd out failure in inspection.)
C*- The maintenance of fuel injector had better clean by a special tool --- fuel injector
cleaner.
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DTC
Identi¿cation Description Fault
Max Min Signal Abnormal
Crankshaft position sensor
bm P0335 P0335 P0335 P033m6 33
signal fault
Throttle valve position sensor
dk P0123 P0122 P0120 P0120 31
circuit fault
ev1 Injector 1control circuit fault P0201 P0201 P0201 P0201 31
ev2 Injector 2control circuit fault P0203 P0203 P0203 P0203 31
ev3 Injector 3control circuit fault P0204 P0204 P0204 P0204 31
ev4 Injector 4control circuit fault P0202 P0202 P0202 P0202 31
¬ closed-loop control self-
frao study threshold Multiplication P0171 P0172 P0170 P0170 5
part overrun
¬ closed-loop control self-
frau study threshold Multiplication P0171 P0172 P0170 P0170 5
part overrun
hsv Oxygen sensor heating fault P0135 P0135 P0135 P0135 31
Air compressor relay control
Kose P0647 P0646 P0645 P0645 31
circuit fault
Kpe Fuel pump control circuit fault P0230 P0230 P0230 P0230 31
krnt Knock zero test diagnosis P0324 P0324 P0324 P0324 5
krof Knock offset diagnosis P0324 P0324 P0324 P0324 5
krtp Knock test pulse diagnosis P0324 P0324 P0324 P0324 5
ks1 Knock sensor circuit fault P0325 P0325 P0325 P0325 31
Idle speed control deviated a
llr P0507 P0506 P0505 P0505 31
set speed fault
Lm Intake pressure sensor fault P0108 P0107 P0105 P0106 31
Lsv Oxygen sensor fault P0132 P0131 P0134 P0130 31
Luea Fan A control circuit fault P0480 P0480 P0480 P0480 31
N Rotating sensor fault P0335 P0335 P0335 P0336 33
Ph Phase sensor fault P0343 P0342 P0340 P0340 31
¬ closed-loop control self-
rkaz study threshold addition part P0171 P0172 P0170 P0170 5
overrun
stpe Stepper control circuit fault P0509 P0508 P0511 P0511 31
Svse SVS light control circuit fault P1651 P1651 P1651 P01651 5
Intake temperature sensor
Ta P0113 P0112 P0110 P0111 31
fault
Canister control valve control
teve P0445 P0444 P0443 P0443 31
circuit fault
Water temperature sensor
Tm P0118 P0117 P0115 P0116 31
fault
Air conditioner evaporator
Tevrd P1530 P1530 P1530 P1530 5
temperature sensor fault
ub Power supply fault P0563 P0562 P0560 P0560 31
vfz Vehicle speed sensor fault P0500 P0500 P0500 P0500 31
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Foreword
With the development of national economy in China, car ownership is increasing gradually and
environment protection regulations become much stricter. Since July 1, 2007, State III Emission
Regulation has been implemented for new cars. Recently, the National Environment Protection
Bureau has given a notice that a license plate is forbidden to be given to the car with carburetor
engine and light vehicle since September 1, 2001. Since July, 2007, State III Emission Regulation
has also been implemented for the trucks below 3.5 tons. In fact, many automobile companies
develop products based on State IV instead of State III. Beijing 2008 Olympic Game pushes for-
wards vehicle emission control cause.
Closed-loop control gasoline quantitation technology and three-way catalytic converter will reduce
toxic substance in vehicle emissions by more than 92%. It is an irreversible development tenden-
cy that electronic control gasoline injection technology replaces the carburetor. This shows that
carburetor engine era is over and electronic control gasoline injection engine era starts.
United Automotive Electronic Systems Co. Ltd is the biggest and the most inÀuential supplier of
vehicle engine electronic control gasoline injection system. Since 1996, it has supplied MOTRON-
IC series electronic fuel injection system and parts imported from Germany BOSCH company to
each automobile company in China. So-called MOTRONIC is a trade name, which does not con-
tain speci¿c meaning. However, MOTRONIC system has a certain technical feature, i.e., engine
fuel quantitation electronic control and ignition timing electronic system is combined. Two systems
that are originally separate share one set of sensor, electronic control unit and power supply. It is
self-evident that MOTRONIC system has ignition timing electronic control function. This improves
engine performance greatly.
Like other electronic control gasoline fuel systems, MOTRONIC system can reduce vehicle emis-
sion greatly, but it brings dif¿cult to the engine maintainer who is only familiar with the traditional
carburetor engine. Vehicle maintainer thinks carburetor engine is visible and tangible. But, there
are no mechanical components in electronic control gasoline injection engine, which are replaced
by various electronic components. Originally, the maintainer even the driver can adjust the carbu-
retor or distributor by himself; but now, the data is stored in computer chip. Ordinary maintainer
cannot modify data through electronic instrument to make troubleshooting. If one electronic com-
ponent in the system is faulty, it cannot be seen from the appearance. Normally, an instrument is
required to test and recognize it. Therefore,the maintainer does not know how to maintain elec-
tronic control gasoline injection engine. According to this condition, we compile this maintenance
manual. We hope it can play a role in the following two aspects: one on hand, it helps engineers
from engine works or vehicle manufacturer understand engine electronic control system deeply;
on the other hand, it helps maintainers in various regions to repair electronic control gasoline in-
jection engine.
This manual ¿rst introduces composition and working principle of electronic control gasoline injec-
tion system. Next, it introduces structure and performance of all parts in the system.
Generally, during the course of maintaining electronic control gasoline injection system, fault di-
agnosis tester is an essential tool. Fault diagnosis tester can call fault information record stored
in ECU. In order to help the reader to understand true meaning of each fault deeply, this manual
lists fault information recording conditions set by ECU. But many faults are not directly determined
only according to fault information record. However, it is necessary to go through a series of anal-
ysis to ¿nd out the faults. Therefore, this manual mainly describes how to ¿nd the fault according
to fault information record.
Because electronic control component exists, this is new content for engine fault reason. In other
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BYD S6, S6A, S6K Service Manual
words, the same engine fault may arise from mechanical reason or electronic component. In ad-
dition, the engine fault cannot be diagnosed only by fault diagnosis tester. Therefore, this manual
describes how to ¿nd a fault based on engine symptom and electronic control system.
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BYD S6, S6A, S6K Service Manual
Only digital multimeter can be used to conduct inspection for the Electronic Fuel Injection
System.
Please use original parts for repair. Otherwise the Electronic Fuel Injection System will not
work normally.
Do not decompose or dismantle the components of the Electronic Fuel Injection System in
the process of repair.
During the course of maintenance, when holding electronic components (electronic control
unit, sensor), be careful and do not let them fall down to the ground.
Establish the awareness of environmental protection, and dispose effectively waste gener-
ated in the process of repair.
1.2 Notes for maintenance
1) Do not remove any parts in the Electronic Fuel Injection System or other connectors from the
installation position without careful thinking. Otherwise, accidental damage, or water, oil stain
might enter the connectors to impact the Electronic Fuel Injection System.
3) When simulating heat state of the fault and making maintenance work that leads to tempera-
ture rise, electronic control unit temperature never exceeds 80°C.
4) All fuel lines use high pressure resistant fuel pipes as the fuel supply pressure in the Elec-
tronic Fuel Injection System is rather high (about 350kPa). Even when the engine does not
run, fuel pressure in the fuel line is rather high. During the course of maintenance, do not
remove fuel pipe at random. Before removing fuel pipe, fuel system shall be discharged.
Discharging method as follows: Start the engine to run idly, connect the diagnosis tester and
go into “actuator test”, turn off fuel pump until the engine goes out. Remove the oil pipes and
replace the fuel ¿lter by quali¿ed technicians in a well-ventilated place.
5) Do not electrify the oil pump when removing the electric fuel pump from the fuel tank. Other-
wise electric spark might be generated to cause ¿re.
6) It is not allowed to conduct running test of fuel pump in the dry state or under water. Other-
wise the life will be shortened. In addition, do not conduct a wrong connection of anode and
cathode of the fuel pump.
7) Just conduct jump spark test when necessary if the ignition system is being checked. Try to
keep the test duration as short as possible. Do not open the throttle during the inspection
and examination. Otherwise lots of unburned gas might enter the exhaust pipe, leading to
damage of catalytic converters.
8) As adjustment of idling speed is controlled completely by the Electronic Fuel Injection Sys-
tem, there is no need of manual adjustment. The throttle limit screw of the throttle body has
been adjusted well in the factory of the manufacturer. Any user is not allowed to arbitrarily
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9) When connecting the battery, do not reverse the positive and negative electrodes of the bat-
tery to avoid damaging electronic components. This system adopts negative earth.
10) Do not remove the battery cables when the engine is running.
11) Anode cable, cathode cable of the battery and the electronic control units must be removed
before welding on the vehicle.
12) Do not check input/output electrical signal of the parts through a method of piercing the cable
warpage.
1.3 Maintenance tool list
Tool name:
Functions:
Tool name:
Functions:
Tool name:
Functions:
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Tool name:
Digital multimeter
Functions:
Tool name:
Vacuum gauge
Functions:
Tool name:
Functions:
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Tool name:
Functions:
Tool name:
Functions:
Tool name:
Functions:
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DG Speed sensor
DVE Electronic throttle body
FPM Electronic accelerator pedal
DR Fuel pressure regulator
DS-S-TF Intake pressure temperature sensor
ECU Electronic control unit (commonly known as: computer)
EKP Fuel pump
EMS Engine management system
EV Fuel injector
LSF Heated oxygen sensor
KS Knock sensor
KSZ Fuel distribution pipe assembly
KVS Fuel distribution pipe
PG Phase sensor
ROV Ignition system with distributor block
RUV Ignition system without distributor block
TEE Oil pump bracket assembly
TEV Canister control valve
TF-W Coolant Temp Sensor
ZSK Ignition coil
The engine management system generally consists of three components - sensor, microproces-
sor (ECU) and actuator. The system may control intake air amount, fuel injection amount and igni-
tion advance angle. For basic structure, see Fig. 3-1.
Diagnosis Diagnosis
Sen ECU Actuator
Engine
In the engine electrical control system, sensors as input components are used to measure various
physical signals (such as temperature and pressure) and then convert them into corresponding
electrical signal; functions of ECU is receive input signal of sensors, and then process signals ac-
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cording to speci¿ed programs and generate corresponding control signal outputting to the power
drive circuit which can drive various actuators to carry out different actions so that the engine may
run according to control strategies preset; at the same time, the fault diagnosis system of ECU
monitors the various components or control functions in the system. Once fault is detected and
con¿rmed, the system will save trouble code and then activate function “limp home”. When that
the fault is eliminated is detected, the normal value is restored.
ME7 engine electronic control management system is characterized by the use of a torque-based
control strategy. Main purpose of the torque-based control strategy is link lots of different control
targets. This is only way to integrate various functions in the different ECU variants according to
engine and vehicle models. For ME7 engine electronic control system structure, see Fig. 3-2.
Phase sensor
Ignition coil
Fuel distribution pipe
Canister control valve assembly
Phase sensor
Intake air temperature
sensor
Oxygen sensor
Accelerat
CAN
MIL
Diagnosis
interface
Electric fuel pump
Anti-theft
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¬Closed-loop control
Canister control
Limp home
Connection between torque and external system (such as drive mechanism or vehicle dy-
namic control)
Likewise, during the engine matching, the torque-dependent control system is variable-inde-
pendent. Only engine data are used in matching the engine characteristics and pulse spectrum
and other power functions and variables did not interfere. Therefore, repeated calibration can be
avoided, simplifying the matching process and reducing the matching cost.
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Efficiency
requirements
y Engine startup
y Catalytic heating
y Idle control
Efficiency
Compared to the former M-series engine EFI management system, ME7 system has following
main features:
New engine function structure using torque as variable; it is the most compatible with other
systems and so it is very expandable;
Basic characteristics of the engine is based on modules and mutually independent, simplify-
ing the calibration process;
Improve driving performance through centralized coordination of the various torque require-
ments;
16-bit central processing unit, 24 MHz clock frequency, 512k buffer memory;
The system can be expanded according to future needs, such as, future emissions regula-
tions, OBDII and electronic throttle feature.
2.2 control signal: ME7 system input/output signal
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Phase signal
After processing the information entering the ECU, generate required actuator control signals.
These signals are ampli¿ed in the output drive circuit and then transferred to various correspond-
ing actuator. These signals include:
During starting, it is necessary to adopt a special calculation method to control charging amount,
fuel injection and ignition timing. In the beginning stage of this process, air in the intake manifold
is stationary, and the intake manifold internal pressure is displayed as surrounding atmosphere
pressure. Throttle is closed. Idle speed regulator speci¿es a ¿xed parameter based on start tem-
perature.
In a similar process, speci¿c “Injection timing” is designated as the initial injection pulse.
Fuel injection amount varies with temperature of the engine in order to facilitate forming of oil ¿lm
in the intake manifold and the cylinder wall. Therefore, when the engine reaches a certain engine
speed, the fuel/gas mixture should be enriched.
Once the engine starts running, the system immediately begin to reduce the start enriching until
starting condition (600…700min-1) is ¿nished.
Ignition angle is also constantly adjusted in the starting conditions. Vary with engine temperature,
intake air temperature and engine speed.
2.3.2 Warming up and three-way catalytic converter heating control
After the engine starts at low temperature, cylinder charging capacity, fuel injection and electronic
ignition are adjusted to compensate higher torque of the engine; this process proceeds until the
proper temperature threshold value is obtained.
In this stage, the most important is the quick heating of the catalytic converter because quick
transfer to the catalytic converter may start working and greatly reduce emission. In this working
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condition, moderately delayed ignition timing may use exhaust gas for “heating of catalytic con-
verter”.
2.3.3 Acceleration/deceleration and reversed towing fuel cut-off control
Some fuel injected to the intake manifold can not enter the cylinder in time to join the subsequent
combustion process. On the contrary, the fuel may form a layer of oil ¿lm in the wall of the intake
manifold. If the load increases and the fuel injection duration is prolonged, fuel amount stored in
the oil ¿lm may increase dramatically.
When the throttle opening increases, the fuel partially ejected is absorbed by the ¿lm. Therefore,
the corresponding additional amount of fuel must be injected to compensate and prevent the fuel/
air mixture from becoming thin during acceleration. Once the load factor reduces, additional fuel
containing in the fuel ¿lm of the intake manifold wall may release again. During deceleration, it is
required to reduce corresponding injection duration.
Motoring or traction operation condition means that power provided by engine in the Àywheel is
negative. In this case, the engine friction and pumping losses can be used to decelerate the ve-
hicle. When the engine is in motoring or traction operation condition, the fuel supply is stopped
to reduce fuel consumption and exhaust emission. The more important function is to protect the
catalytic converter.
Once the engine speed reduces to certain fuel-supply-restore engine speed above idling speed,
the fuel system supplies fuel again. Actually, the program in ECU has a range of engine speed re-
storing. They can vary with dynamic parameters such as engine temperature and engine speed.
Through calculation, drop to speci¿ed minimum threshold value can be avoided.
Once the injection system supplies fuel again, the system starts using the initial injection pulse for
fuel supply, and then rebuilds oil ¿lm in the wall of the intake manifold. After fuel supply restarts,
the torque-dependent control system may increase engine torque slowly and stably (smooth tran-
sition).
2.3.4 Idle control
The engine does not provide torque to the Àywheel at idling speed. In order to ensure that the
engine may run stably in as low idling speed as possible. Closed loop idling control system must
maintain balance between generated torque and engine “power loss”. A certain power should be
generated at idling speed to meet load requirement. They include engine crankshaft, valve train
and supportive accessories, such as internal friction of water pump.
ME7 system uses torque value as main control strategy and consider close loop idling speed to
con¿rm how much output torque of engine is required to keep the desired idling speed at any op-
erating conditions. The output torque may increase with engine speed decreasing and decrease
with engine speed increasing. The system responds new “interference factors” (such as opera-
tion of A/C compressor, or shifting mechanism of automatic transmission) through greater torque.
When engine temperature is low, it is also required to increase torque in order to compensate
greater internal friction losses and/or maintain a higher idle speed. Sum of the output torque re-
quirements is transferred to the torque coordinator which processes and calculates the sum, then
getting corresponding charging density, composition of fuel/air mixture and ignition timing.
2.3.5 lClosed-loop control
Exhaust post treatment in the catalytic converter is an effective method to reduce concentration of
harmful substances in the exhaust. Three-way catalytic converter can reduce hydrocarbon (HC),
carbon monoxide (CO) and nitrogen oxides (NOx) by 98% or more and convert them into water
(H2O), carbon dioxide (CO2) and nitrogen (N2). Such a high ef¿ciency can be achieved only within
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the very narrow ambient range, when the engine excess air coef¿cient Ȝ=1, lclosed-loop control
target is to ensure gas mixture concentration is within this range.
lThe closed-loop control system can work only when it is equipped with an oxygen sensor. The
oxygen sensor position on the side of three-way catalytic converter monitors oxygen content in
the exhaust. Thin gas mixture Ȝ>(1) generates about 100mzV sensor voltage and strong gas mix-
ture Ȝ<(1) generates about 900mV sensor voltage. When Ȝ=1, the sensor voltage has a transition.
lThe closed-loop control responds the input signal (Ȝ>1 = excessively lean mixture, Ȝ<1 = exces-
sively rich mixture) and then modi¿es the control variable. Correction factor generated is used as
a multiplier to correct the fuel injection duration.
2.3.6 Evaporative emission control
Because of external radiation heat and oil return heat transferring, the fuel in the fuel tank is heat-
ed to form fuel vapor. Due to limitations by the evaporative emission regulations, vapor containing
large amounts of HC is not allowed to be directly exhausted to the air. In the system, the fuel va-
por is collected in the charcoal canister through guide tubes and blew and washed into the engine
to participate in the combustion process in the proper time. Flow of blew and washed air is gener-
ated through the ECU controlling the canister control valve. The control can work only lwhen the
closed-loop control system is working in closed-loop.
2.3.7 Knock control
Through the knock sensor mounted in a proper position of the engine, the system may detect
characteristic oscillation generated in knock, and transfer it into the electronic signal and then
send it to the ECU for processing. The ECU uses a special processing algorithms and may detect
whether knocking phenomenon in each combustion cycle in each cylinder. Once any knocking is
detected, the knocking closed-loop control will be activated. When risk of knocking disappears,
ignition in the impacted cylinder may gradually restore the preset ignition advance angle.
The knock control threshold good adaptability to different conditions and fuels of different grades.
2.4 System fault diagnosis function introduction
The electronic control unit continuously monitors the sensor, the actuator, related circuit fault in-
dicator and battery voltage etc., and even the electronic control unit itself, and conduct reliability
inspection and examination for the sensor output signal, the actuator drive signal and internal
signals (such as closed-loop control, coolant temperature, knocking control idling speed control
and battery voltage control etc.) Once it is found that one link has fault or a certain signal is not
reliable, the electronic control unit may set the fault information record in the RAM fault memory.
Fault information record is saved in form of trouble code and then displayed in sequence of fault
occurrence.
The faults can be divided into “stable faults” and “occasional faults” according to occurrence rate
(such as faults caused by open circuit of wire harness or poor contact of connectors).
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Sensor Actuator
Engine
B_mxdfp, the maximum fault, signal exceeds upper limit of normal range.
B_mndfp, the minimum fault, signal exceeds lower limit of normal range.
This system adopts “K” line communication protocol, and ISO 9141-2 standard diagnosis connec-
tor, see the following Fig. 3-5. The standard diagnostic connector is ¿rmly connected to the engine
wiring harness. #4, #7 and #16 pins are used for standard diagnosis of EMS. Standard diagnostic
connector #4 pin connects the vehicle ground wire; # 7 pin connects # 71 pins, i.e., engine data “K”
Line; # 16 pin connects to the battery anode.
ECU can communicate with external diagnosis tester through “K” line and operate as fol-
lows:
(for each function and diagnosis tester operation, see “ME7 Diagnosis Tester Operation Manual”)
1. Speed, coolant temperature, throttle openness, ignition advance angle, fuel injection
pulse width, intake pressure, intake temperature, speed, system voltage, fuel injection
correction, canister washing rate, idle air control and oxygen sensor wave form;
2. Target speed, engine relative load, ambient temperature, ignition closing time, evapora-
tor temperature, intake air Àow and fuel consumption;
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3. Throttle position sensor signal voltage, coolant temperature sensor signal voltage,
intake air temperature sensor signal voltage, intake pressure sensor signal voltage,
knock sensor 1# pin signal voltage, and knock sensor 2# pin signal voltage.
Anti-theft system state, safety state, programming state, cooling system state, steady working
condition state, dynamic working condition state, emission control state, oxygen sensor state,
idle speed state, MIL state, emergent working condition state, air conditioner state and automatic
transmission/torque request state.
MIL, fuel pump, air conditioner relay, fan, ignition, fuel injection (single cylinder fuel cut-off).
Vehicle identi¿cation number (VIN), ECU hardware number, ECU software number.
intake pressure sensor, intake temperature sensor, engine coolant temperature sensor, throttle
position sensor, oxygen sensor, oxygen sensor heating circuit, air-fuel ratio correction, each cyl-
inder fuel injector, fuel pump, knock sensor, speed sensor, phase sensor, canister control valve,
cooling fan relay, speed signal, idle speed, idle speed regulator, system voltage, ECU, air condi-
tioner relay, evaporator temperature sensor, MIL.
2.5 Problems related to the project
System features:
New engine function structure using torque as variable; it is the most compatible with other sys-
tems and so it is very expandable;
Adopt 60-2 tooth signal panel to identify speed signal (speed sensor DG6);
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PIN definition
Signal outout 1
Input voltage +
Motor driving +
Signal outout 2
Motor driving -
Input voltage -
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Fig. 3-6 Intake pressure and temperature Fig. 3-7 Intake pressure and temperature
sensors sensor circuit diagram
This sensor consists of two sensors, i.e. the intake manifold absolute pressure sensor and the in-
take air temperature sensor, mounted on the intake manifold.
3.2.2 Working principle
The intake manifold absolute pressure sensor subassembly consists of a silicon chip. A piece
of pressure diaphragm is etched in the silicon chip. The pressure diaphragm has 4 piezoelectric
resistors; 4 piezoelectric resistors as strain subassembly form a Wheatstone bridge. In addi-
tion to pressure diagram, the silicon chip is integrated with signal processing circuit. The silicon
chip forms a closed reference space with a metal housing. Air absolute pressure in the reference
space is close to zero. Thus one micro-electro-mechanical system forms. Active surface of the sil-
icon chip is subjected to pressure of almost equal to zero. Its back surface is subjected to intake
manifold absolute pressure which is to be measured and can be introduced by a connection pipe.
Silicon chip thickness is only several microns (mm). Therefore, if the absolute pressure of intake
manifold changes, silicon chip will deform mechanically. 4 piezoresistances also deform and the
resistance values change. After the silicon chip signal processing circuit conducts the process,
voltage signal having linear relationship with pressure is formed.
The intake air temperature sensor subassembly is a negative temperature coef¿cient (NTC) re-
sistor. Resistance varies with the intake air temperature. Now this sensor sends a voltage value
which may indicate intake air temperature change.
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Fig. 3-8 Section drawing of intake manifold absolute pressure and intake temperature
1. Seal ring, 2. Stainless steel bushing, 3PCB plate, 4 sensing element, 5.Case, 6.Pressure
bracket, 7.Welding connection, 8.adhesive connection
3.2.3 Technical characteristic parameter
Value
Amount Unit
Minimum Typical Maximum
Withstand supply voltage 16 V
Withstand pressure 500 kPa
Withstand storage temperature -40 +130 °C
Value
Amount Unit
Minimum Typical Maximum
Range of stress test 20 115 kPa
Operating temperature -40 125 °C
Operating power supply 4.5 5.0 5.5 V
Current when US=5.0V 6.0 9.0 12.5 mA
Load current of output circuit -0.1 0.1 mA
Load resistance to ground or battery 50 k:
Response time 0.2 ms
Weight 27 g
UA=(c1 pabs+c0)Us
c0=-9.4/95
c1=0.85/95(1/kPa)
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From the formula, we can tell that at atmospheric pressure, signal output voltage of pressure sen-
sor is close to power supply voltage.
If supply voltage is 5V, the output voltage of signal from the pressure sensor is equal to about 4V
when the throttle is fully open.
Rated voltage: Front resistor 1kW runs at 5V or runs at test current of 1mA
The sensor is designed to be installed in the plane of the engine intake manifold. The pressure
connection pipe and the temperature sensor are protruded to the intake manifold and sealed
against the atmosphere through an O-ring.
If it is mounted on vehicle in a proper manner (taking pressure from the intake manifold; pressure
pipe tilts downward etc), no condensation water will form in the pressure-sensitive elements.
When drilling or fastening the intake manifold, you must comply with instructions provided in the
supplier ¿gure to ensure that the intake manifold can be sealed for a long time and withstand the
erosion of media.
Whether contacting of connector electrical connection is reliable or not is depending on both com-
ponents connectors and quality/size accuracy of the wiring harness and the connector material.
3.2.5 Fault phenomenon and judgment method
General causes: 1. Abnormally high pressure or large reverse current exists in the process of
use; 2. Vacuum components are damaged in the process of repair.
Repair instructions: Do not punch the vacuum subassemblies by high pressure gas in the
process of repair; When replacing the sensor after finding fault, it is required to carefully
check that the generator output voltage and current is normal.
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4 pins. At idling, #3 pin should have 5V reference voltage and #4 pin about 1.3V voltage (speci¿c
value is related to vehicle model); at no-load state, slowly open the throttle, and voltage change in
#4 pin does not change much; quickly open the throttle, and voltage of #4 pin can reach approxi-
mately 4V instantaneously (speci¿c value is related to vehicle model), and the drop to approxi-
mately 1.5V (speci¿c value is related to vehicle model).
Fig. 3-9 resistance characteristic curve of intake air temperature sensor NTC
3.3 Coolant temperature sensor
Coolant Temp
Sensor
Fig. 3-10 Coolant temperature sensor Fig. 3-11 Coolant temperature sensor circuit
diagram
The sensor is a negative temperature coef¿cient (NTC) resistor. Resistance decreases with cool-
ant temperature increasing, not in linear relationship. Negative temperature coef¿cient thermistor
is installed on a copper surface, see the following Fig.
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Fig. 3-12 Coolant temperature sensor cross- Fig. 3-13 Coolant temperature sensor char-
sectional view acteristic curve
The coolant temperature sensor is mounted on the cylinder body, and the copper heat sleeve
is inserted into the coolant. The sleeve is threaded. Hexagon head in the sleeve can be used to
easily screw the coolant temperature sensor into the threaded hole in the cylinder body. The max-
imum allowed tightening torque is 20Nm.
3.3.5 Fault phenomenon and judgment method
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(Remove the connector) Turn a digital multimeter to ohm position; connect two probes with pins
1# and 2# of the sensor. At 20°C, rated resistance is 2.5k¡ ± 5%. For other corresponding resis-
tance values, see the above characteristic curve. Simulation method can be used for measure-
ment. Speci¿c operation is to place the working part of the sensor into the boiled water (careful
to keep immersion enough long) . Observe change of sensor resistance. Now resistance should
drop to 300¡-400¡ (speci¿c value depending on water temperature).
3.4 Knock sensor
Fig. 3-14 Knock sensor without cables Fig. 3-15 Knock sensor with cables
Fig. 3-16 Knock sensor circuit diagram Fig. 3-17 Knock sensor cross-sectional view
Pin: No. 1 and 2 connect with ECU; No. 3 connects with the shield.
3-cylinder engine is installed between two cylinders; 4-cylinder engine is installed between 2~3
cylinder.
3.4.2 Working principle
The knock sensor is a vibration acceleration sensor, mounted in the engine cylinder block. One
or more knock sensors can be installed. Sensitive element of the sensor is piezoelectric element.
Vibration of the engine block is passed through the mass in the sensor to the piezoelectric crystal.
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Piezoelectric crystal generates voltage in two polar faces due to pressure generated by the vibra-
tion of the mass. Vibration signal is converted into alternative voltage signal before outputting. The
frequency response curve is as shown in the ¿gure below. Since the frequency of vibration signal
caused by the engine knock is much higher than the normal engine vibration signal frequency,
whether it is knock signal or no knock signal can be distinguished after processing the knock sen-
sor signal.
Frequency
Value
Amount Unit
Minimum Typical Maximum
Working temperature -40 +130 °C
There is a hole in the middle of knock sensor. It is fastened on cylinder block with a M8 bolt. Alu-
minum cylinder block is fastened by 30mm - long bolt. Cast-iron cylinder block is fastened by
25mm - long bolt. Tightening torque 20 ± 5Nm. Installation position shall make the sensor receive
vibration signals from all cylinders easily. The best installation position of the knock sensor should
be determined by modal analysis of the engine block. Be careful not to allow a variety of liquids,
such as engine oil, coolant, brake Àuid and water, have a long time of contact with sensor. Do
not use any type of washer during installation. The metal surface of the sensor must be closely
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against to the cylinder block. When wiring the signal cables of sensors, do not cause resonance
of signal cables in order to avoid breaking. High voltage shall be avoided between pin 1# and 2#
because piezoelectric elements may be damaged.
3.4.5 Fault phenomenon and judgment method
General cause: A variety of liquids, such as engine oil, coolant, brake Àuid and water, have a
long time of contact with sensor, causing corrosion.
(Remove the connector) turn a digital multimeter to ohm position, connect two probes with 1#
and 2#, 1# and 3# pins of the sensor. At room temperature, the resistance value shall be higher
than 1M¡. Switch the digital multimeter to position "millivolt" and then gently hit the vicinity of the
knock sensor with a small hammer. Now voltage signal should output.
3.5 Oxygen sensor
Main
relay
Oxygen sensor
Fig. 3-20 oxygen sensor Fig. 3-21 oxygen sensor circuit diagram
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Oxygen sensor is provided with cable. The other end of cable is electric terminal. Electrical termi-
nals of oxygen sensor manufactured by our company have four pins:
No. 1 connects with the positive electrode of heating power source (white);
No. 2 connects with the negative electrode of heating power source (white);
Oxygen sensor sensing subassembly is a porous ceramic tube. External side of the tube wall is
surrounded by the engine exhaust and internal side connects with air. The sensor ceramic wall is
a solid electrolyte, containing electric heating tube. See ¿gure 3-17.
The oxygen sensor works through converting the ion concentration difference between inside and
outside of the sensing ceramic tube into the voltage signal output. When sensing ceramic tube
temperature reaches 350°C, it has solid electrolyte characteristics. Because of its special mate-
rial, oxygen ions can freely pass through the ceramic tube. Through this characteristics,
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BYD S6, S6A, S6K Service Manual
Value
Amount Mini- Maxi- Unit
Typical
mum mum
Storage temperature -40 +100 °C
Ceramic tube end 200 850 °C
Hexagon head of housing 570 °C
Working
Temperature Cable metal buckles and connection
250 °C
cable
Connector 120 °C
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Life of the oxygen sensor is related with content of lead in gasoline; see the table below for de-
tails.
Oxygen sensor shall be installed on exhaust pipe and represent exhaust gas and meet
speci¿ed temperature value. Installation site is close to the engine. Threads are provided on
exhaust pipe to screw in oxygen sensor, see the following Fig.
Oxygen sensor shall be installed with an included angle10° to horizontal plane. The sensor tip
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is downwards to avoid accumulating condensate water between the sensor housing and sensing
ceramic tube, see the following Fig..
Exhaust pipe requirements: heat exhaust pipe in the area in front of oxygen sensor immedi-
ately. If possible, exhaust pipe shall be designed to be inclined downwards to avoid conden-
sate water from accumulating in front of the sensor.
Do not make metal ring of the cable on the side of oxygen sensor heat inappropriately, espe-
cially after the engine stops.
Do not use washing Àuid, oily liquid or volatile solid on oxygen sensor plug.
Fault symptom: improper idling and acceleration; emission exceeds standard value, fuel con-
sumption is too large.
General cause: 1. Moisture enters inside of the sensor; temperature changes suddenly;
probe is broken; 2. oxygen sensor "poisoning". (Pb,S,Br,Si)
Repair instructions: Do not use cleaning Àuid, oily liquid and volatile solids on the oxygen
sensor during repair.
(Remove the connector) Turn a digital multimeter to ohm position; connect two probes with
1# (white) and 2# (white) pins of the sensor. The resistance value is 1~6 Wat room tempera-
ture.
(connect the connector) At idle speed, when oxygen sensor reaches to working temperature
350°C, turn a digital multimeter to DC voltage position; connect two probes with 3# (grey)
and 4# (black) pins of the sensor. Now, the voltage Àuctuates between 0.1-0.9V quickly.
3. 6 Speed sensor (only for the system without distributor block)
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Speed sensor
Fig. 3-25 Speed sensor Fig. 3-26 Circuit diagram of speed sensor
Speed sensor and pulse wheel are used in ignition system without distributor block to provide en-
gine speed information and crankshaft TDC information. Speed sensor consists of one permanent
magnet and coils outside the magnet. Pulse wheel is a Àuted disc. Originally, it has 60 teeth, but
two teeth are vacant. Pulse disc is mounted on the crankshaft, rotating with crankshaft rotation.
When teeth top is passing near the end of speed sensor, pulse wheel made of ferromagnetic ma-
terial cuts magnetic line of force in permanent magnet. Induced voltage is generated in the coil,
which is output as speed signal.
3.6.3 Technical characteristic parameter
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BYD S6, S6A, S6K Service Manual
Value
Amount Unit
Minimum Typical Maximum
Coil area -40 +150 °C
Transition area Mixed Mixed °C
Conducting wire area -40 +120 °C
Storage temperature -20 +50 °C
The tempera- Ambient temperature when it does
-40 +120 °C
ture endured not run
by PUR wire Long-term environmental tempera-
speed sensor -40 +120 °C
ture when it is running
(see the fol- Short-term environ- 150 hours +150 °C
lowing Fig.) mental temperature
when it is running 380 hours +140 °C
150 hours +150 °C
Within use life in
380 hours +140 °C
conducting wire area
1130 hours +130 °C
Coil area -40 +150 °C
Transition area Mixed Mixed °C
Conducting wire area -40 +130 °C
Storage temperature -20 +50 °C
H&S wire Ambient temperature when it does
speed sensor -40 +130 °C
not run
endured by
(see the fol- Long-term environmental tempera-
-40 +130 °C
lowing Fig.) ture when it is running
Short-term environmental tempera-
+150 °C
ture when it is running
Within use life in 500 hours +150 °C
conducting wire area 200 hours +160 °C
Vibration resistant ability in 20 to 71Hz Acceleration 40 m/s2
each plane in 168 hours 71 to 220Hz Amplitude 0.2 mm
Permissible magnetic ¿eld strength in opposite direc-
2 kA/m
tion of external magnetic ¿eld
Insulation resistance (10s, New state 1 MW
test voltage 100V) End of use life 100 kW
Withstand voltage (1-3 seconds, 1200V AC) No breakdown
Conducting
wire area
Transition area
Coil area
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Value
Amount Unit
Minimum Typical Maximum
Resistance at room temperature 20°C 731 860 989 :
Inductance 310 370 430 mH
Output voltage when the crankshaft is
>1650 mV
at 416 rpm
Air gap between speed sensor and pulse wheel tooth top: 0.8~1.2mm.
Repair instructions: Install it in pressing instead of knocking by hammer in the process of re-
pair.
(Remove the connector) turn a digital multimeter to ohm position; connect two probes with 2# and
3# pins of the sensor. At 20°C, rated resistance is 860¡ ± 10%.
(Connect the connector)Turn a digital multimeter to AC voltage position; connect two probes with
2# and 3# pins of the sensor. Start the engine, and voltage shall be output. (recommended to
check it using a vehicular oscilloscope)
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Ground point
Phase sensor
Main relay
Fig. 3-31 Phase sensor Fig. 3-32 Phase sensor circuit diagram
Camshaft cover.
3.7.2 Working principle
This sensor is used for distributorless electrical devices and works with the pulse disc sensor to
provide ECU with crankshaft phase information, i.e., compression top dead point and exhaust
bottom dead point.
This sensor applies Hall principle. The sensor is made according to a fact that Hall voltage is im-
pacted by changed magnetic ¿eld induction intensity.
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I
UH
Rotation direction
Output signal
Fig. 3-34 Operation schematic diagram for Fig. 3-35 Operation schematic diagram for
phase sensor (I) phase sensor (II)
Limit data
Value
Amount Maxi- Unit
Minimum Typical
mum
Ambient temperature -30 +130 °C
Installation clearance 0.5 1.5 mm
Supply voltage 4.5 24 V
The sensor housing has only one hole used for fastening.
3.7.5 Fault phenomenon and judgment method
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(Connect the connector) press start button, and do not start the engine, turn a digital multimeter to
DC voltage position, connect two probes with 3#, 1# pins of the sensor, make sure 12V reference
voltage exists. Start the engine, and now check if 2# pin signal is normal with a vehicle oscillo-
scope.
3.8 Electronic controller unit
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BYD S6, S6A, S6K Service Manual
Fuel pump > Analog signal input 45V > Exhaust phase variable
Reserved >
> Reserved
Air conditioner request signal > Ign. Driver > Ignition coil
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(1) Function
Control ignition
Knock control
Fault self-diagnosis
And so on.
Limit data
Value
Amount Unit
Minimum Typical Maximum
Normal operation 9.0 16.0 V
Battery voltage
Limited function 6.0 to 9.0 16.0 to 18.0 V
Limit and time withstand- Maintain some functions,
26.0V 60 s
ing battery overvoltage and perform fault diagnosis
Working temperature -40 +70 °C
Storage temperature -40 +90 °C
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Fault symptom: unstable idle, improper acceleration, fail to start, too high idle, excessive ex-
haust, dif¿cult start, A/C failure, injector control failure, and stalling.
General cause: 1. Electrical overload caused by the external devices made the internal parts
in ECU burn, and consequently leading to failure; 2. Water ingress into ECU cause corrosion
of circuit board.
Repair instructions: 1. Do not arbitrarily remove the ECU in the process of repair; 2. Remove
the battery terminal posts and wait more than 1 minute before removal of ECU; 3. Before
welding, ECU must be removed, and then place the ECU in a proper position after removal; 4.
Do not additionally mount any line on the connection line of the ECU.
1. (Connect the connector) Read engine fault record through engine data line K;
2. (Remove the connector) Check that the ECU connection cables are in good condition. Pay
attention to check that ECU power supply cable and grounding line are in good condition;
3. Check that the external sensors work normally, and that the output signal is reliable and that
the line is in good condition;
4. Check that the actuator works normally, and that the line is in good condition;
Fuel Pump
Main relay
Battery
Fig. 3-37 Electric fuel pump Fig. 3-38 Electric fuel pump circuit diagram
Pin: electric fuel pump has two pins, which connect with fuel pump relay. There are “+” and “-”
marks on fuel pump cases near two pins, which represent connecting positive and negative elec-
trodes, respectively.
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Electric fuel pump consists of DC motor, vane pump and end cover (integrated with check valve,
relief valve and anti-electromagnetic interference elements). See the following Fig..
The pump and the electric motor are coaxially mounted, and closed in the same housing. Gaso-
line is full in the surrounding of the pump and electric motor in the housing. Use fuel for cooling
and lubrication. The battery supplies power to the electric fuel pump through the fuel pump relay
which just can have the electric fuel pump turn on only when in starting or the engine is running.
When the engine stops running due to an accident, the fuel pump may automatically stop.
The maximum pressure at the outlet of electric fuel pump is determined by relief valve, between
450~650kPa. This system adopts no fuel return system. The pressure of the whole fuel system is
determined by fuel pressure regulator. Normally, it is 350kPa.
According to the requirements of the engine, electric fuel pump can have different Àow rate. In or-
der to facilitate production, EKP13 series of electric fuel pump of the same structure adjusts motor
speed by adjusting turns of coil to adjust Àow rate. Therefore, do not install electric fuel pump of
one vehicle onto the other vehicle.
3.9.3 Technical characteristic parameter
Value
Amount Maxi- Unit
Minimum Typical
mum
Working voltage 8 14 V (DC)
System pressure 350 kPa
Outlet pressure 450 650 kPa
Ambient temperature
-40 +80 °C
(Suitable for storage and transport)
Permissible fuel temperature -30 +70 °C
Permissible vibration acceleration 20 m/s2
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BYD S6, S6A, S6K Service Manual
Flow rate of electric fuel pump in a given fuel supply pressure is proportional to voltage. Vehicle
plant adopts different fuel pumps.
3.9.4 Installation notes
The electric fuel pump should be stored in sealed original packing box. After being mounted in the
vehicle, the maximum permissible storage time is 6-months; as spare part, it can be stored for 4
years at most. If exceed this storage period, have the manufacturer re-check performance data of
fuel pump. Measures should be taken in the storage place to protect the fuel pump against atmo-
sphere. Original packaging should not be damaged during the storage.
EKP13 series electric fuel pump is used for fuel tank. When installing fuel pump, ¿lter screen with
less than 60m meshes or agreed by the customer shall be installed at ¿ller opening. Please pay
attention to prevent fuel ejected from the vent oil from spraying over the oil inlet ¿lter screen, the
pump holder or the fuel tank wall. To be careful when handling the oil pump. Firstly, it is necessary
to protect the oil inlet ¿lter from loading and impacting. The oil pump should be carefully removed
from the plastic packaging material only when it is ready for installation. Before installing fuel
pump, protection cover can be taken away. Never take away the inlet ¿lter screen. Foreign matter
entering the fuel pump inlet or ¿lter screen may cause damage of the fuel pump.
Pay attention to keep oil pipes clean when mounting them. Always keep inside of oil pipe clean.
Please use new oil pipe clips. Make sure that the oil pipe clips are in correct position; please com-
ply with methods recommended by the manufacturer.
Do not hold the oil pump in the oil pipe or the inlet ¿lter screen.
Do not run the fuel pump in dry state in order to avoid damage of fuel pump. Do not use damaged
fuel pump or any fuel pump which was fallen to the ground. After the fuel tank falls to the ground,
you should replace the fuel pump in the fuel tank.
Do not apply any force on fuel inlet plate. No mechanical stress at ¿lleting is allowed. Clamp fuel
pump according to speci¿ed range, see the following Fig.
No mechanical stress at
filleting is allowed.
If product needs to be returned to the manufacturer, please return supply order, check sheet and
packaging label together. Fuel pump returned must be packaged in accordance with methods
speci¿ed. If fuel pump has been used, please clean it by test solution and dry it in the air. Do not
blow-dry fuel pump. In consideration of safety, we do not receive fuel pump containing fuel.
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Fault symptom: Big operation noise, poor acceleration, failure in starting (hard to start) etc.
General cause: Use of poor quality fuel results in: 1. Glial accumulation formed an insulating
layer; 2. Oil pump bushing locks up the armature; 3 Oil level sensor subassembly is corrod-
ed.
Maintenance notes: 1. According to the requirements of the engine, electric fuel pump can
have different Àow rates. Although the outline is the same, fuel pump that is installed may be
not appropriate. Part number for fuel pump used during the course of maintenance shall be
the same as original one. Do not confuse them; 2. In order to avoid damaging fuel pump, do
not run it in a dry state for a long time. 3. If it is necessary to replace fuel pump, please wash
fuel tank and pipe, and replace fuel ¿lter at the same time.
(Remove the connector) Turn a digital multimeter to ohm position; connect two probes with two
pins of fuel pump, measure internal resistance. It is not zero or in¿nite (i.e., not short circuit and
open circuit).
(Connect the connector) connect fuel pressure gauge with fuel inlet pipe, start the engine, check
if fuel pump works; if it does not run, check if “+” pin has power voltage; if it runs, at idle speed,
check if fuel pressure is about 350kPa; step on the accelerator until the engine speed reaches
2500rpm, and check if fuel pressure is about 350kPa.
3. 10 Electromagnetic fuel injector
Pin: each fuel injector has two pins. “+” on the side of case is connected with pin 87# on output
end of main relay; the other is connected with pins 27, 6, 7 and 47 of ECU.
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BYD S6, S6A, S6K Service Manual
ECU sends electrical pulse to the injector coil, forming magnetic force. When the magnetic force
raises to overcome joint resultant of return spring pressure, needle valve gravity and friction force,
the needle valve starts to raise and the injection process begins. When the fuel injection pulse is
cut off, the pressure of the return spring makes the valve close again.
According to spraying shapes, B type (single hole and single beam), C type (four-hole
taper) and E type (four holes and double beam)
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BYD S6, S6A, S6K Service Manual
Value
Amount Maxi- Unit
Minimum Typical
mum
Storage temperature (original packaging) -40 +70 °C
Permissible temperature of injector in the car
+140 °C
(when it is not at work)
Continuous -40 +110 °C
Working temperature of Short time (approxi-
injector mately 3 minutes) after +130 °C
hot start
Injector inlet Continuous +70 °C
Fuel permissive tem- Short time (approximate-
perature +100 °C
ly 3 minutes)
&RPSDUHGZLWKGHYLDWLRQDW&IXHOÀRZFDQ
-40 +45 °C
reach 5% of the temperature.
Permissible leakage of O-ring at range of -35 to Fuel is allowable to be wet in the area of O-ring, but
-40°C dripping is not allowed.
Maximum permissible vibration acceleration (peak) 400 m/s2
Supply voltage 6 16 V
Insulation resistance 1 M:
Bearable internal fuel pressure 1100 kPa
Bearable bending stress 6 Nm
Bearable axial stress 600 N
Value
Amount Maxi- Unit
Minimum Typical
mum
Working pressure (pressure difference) 350 kPa
Injector resistance at 20q 11 17 :
The Injector can only use fuel speci¿ed in national standard of the People’s Republic of China GB
17930-1999 Unleaded Gasoline for Vehicle Use and national environmental standards GWKB
1-1999 Hazardous Materials Control Standard for Motor Vehicle Gasoline. What needs to be
noted is that gasoline will be degraded after a long time of storage. Especially in case of taxi
equipped with dual-fuel engine (LPG and gasoline), LPG is used as fuel for a long time and gaso-
line is used for starting so that the daily consumption of gasoline is very little. But fuel pump runs
a long time, therefore the fuel tank temperature is rather high. If gasoline is stored in the car fuel
tank, gasoline is easily oxidized and degraded, even leading to block or damage of injector
3.10.4 Installation notes
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BYD S6, S6A, S6K Service Manual
For easy installation, it is recommended to smear clean Silicon-free engine oil on the surface
of the upper O-ring which connects with the fuel distributing pipes. Be careful not to let the
engine oil contaminate inside of the injector or the injector nozzle ori¿ce.
Mount the injector in direction perpendicular to the injector seat and then fasten the fuel in-
jector on the injector seat by clips. Note:
1. The injector clips are grouped in locating manner by axially locating clip and radially lo-
cating clip. Do not confuse them.
2. For installation of injector which requires axial locating, it is required to ensure that
the clipping mouth in the middle of clip is completely buckled into the groove and the
groove in the both side of the clip should be buckled into the edge of the injector seat.
3. When installing the fuel injector with axial and radial locating requirements, both axial
and radial locating clips should be used to locate the locating block of the fuel injector
and the fuel injector seat locating pin respectively in the corresponding groove in the
locating clips.
4. If the fuel injector has two grooves, do not make a mistake in buckling. Refer to the
mounting position of original parts.
Installation of fuel injector can be carried out by hands. Do not knock the fuel injector by
hammer.
O-ring should be replaced in removing and re-mounting the fuel injector. Do not damage the
sealing surface of the injector now.
Do not pull out the supporting washer of O-ring from the fuel injector. Be careful to avoid
damage of fuel ingress end of the fuel injector, O-ring, supporting ring, the nozzle orifice
plate and the electrical plug during installation. Do not use it any more if damaged.
Inspect and test air tightness of the fuel distribution pipe after the injector is installed. It is ac-
ceptable if no leakage is found.
Faulty parts should be removed by hands. Firstly remove the injector clips and then pull out
the injector from the injector seat. After removal, make sure that the fuel injector seat is clean
and no contamination is caused.
3.10.5 Fault phenomenon and judgment method
Fault symptom: Improper idling, poor acceleration, failure in starting (hard to start) etc.
General cause: lack of maintenance, lead to occurrence of the glial accumulation inside the
injector, consequently resulting in failure.
(Remove the connector) Turn a digital multimeter to ohm position; connect two probes with two
pins of fuel injector. At 20°C, rated resistance is 11-17¡.
Recommendation: Clean the fuel injector cleaning thoroughly by special cleaning analyzer
each 20,000 km.
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BYD S6, S6A, S6K Service Manual
Engine
Battery
cathode Primary
Secondary
Control
signal
Fig. 3-45 Independent live wire coil Fig. 3-46 Independent coil circuit diagram
De¿nition of pins:
Low voltage side: Primary winding pin of coil #1 connects with main relay 87#;
High voltage side: terminal posts of two secondary windings connect with spark plugs of engine
cylinders of the same name through distributed live wire.
Low voltage side: Primary winding pin of coil #1 connects with main relay 87#;
High voltage side: terminal posts of two secondary windings connect with spark plugs of engine
cylinders of the same name through distributed live wire.
3.11.1 Installation position
On the engine.
3.11.2 Working principle
Ignition coil consists of primary winding, secondary winding and housing. When grounding chan-
nel of one primary winding is connected through, the primary winding is charging. Once the ECU
cuts off the primary winding circuit, the charging stops and simultaneously senses high voltage in
the secondary winding to make the spark plug discharge electricity.
3.11.3 Fault phenomenon and judgment method
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BYD S6, S6A, S6K Service Manual
General cause: Excessively high current cause burning; or damage is resulted from external
force.
Repair instructions: Do not test ignition function by "short-circuit ¿re test" method. Otherwise
the electronic controller will be damaged.
(Remove the connector) switch the digital multimeter to "Ohm" position; have two probe pens
connect two pins of secondary winding. At 20 °C, the resistance value should be approximately
0.70~ 0.90¡; resistance of the secondary winding should be 9.68-12.32k¡.
3.12 Canister control valve
Mainr
Pin: canister control valve has two pins. One pin is connected with 87# pin of main relay output
end, and the other pin is connected with pin 46# of ECU.
3.12.1 Installation position
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BYD S6, S6A, S6K Service Manual
Fig. 3-49 Canister control valve cross-sec- Fig. 3-50 Canister control valve installation
tional view diagram
Canister control valve consists of magnetic coil, armature and valve. The inlet is ¿tted with a ¿lter
screen. On the one hand, airÀow going through the canister control valve is related to the duty
ratio which is output to the canister control valve electric pulse by ECU; on the other hand, it is re-
lated to pressure difference between the canister control valve inlet and outlet. When no electrical
pulse is detected, the canister control valve is closed.
Different types of canister control valves have different Àowrate at 100% duty ratio, i.e., at fully
open. The following Fig. shows two typical Àow curves. As shown in ¿gure, at the same pressure
difference of 200mbar, Àowrate of A type and B type canister control valve is 3.0m3/h and 2.0m3/
h respectively when they are at full open. (B type is used in this project)
A Type
B Type
Flowrate
Pressure difference
363
BYD S6, S6A, S6K Service Manual
Value
Amount Maxi- Unit
Minimum Typical
mum
Working voltage 9 16 V
1 minute overvoltage 22 V
Minimum start-up voltage 7 V
Minimum voltage drop 1.0 V
Permissible operating temperature -30 +120 °C
Short-term permissible operating temperature +130 °C
Permissible storage temperature -40 +130 °C
Bearable pressure difference between inlet and
800 mbar
outlet
Permissible switching times 108
Permissible vibration acceleration speci¿ed in the
300 m/s2
product label
Leakage amount when pressure difference is
0.002 m3/h
400mbar
Value
Amount Maxi- Unit
Minimum Typical
mum
Rated voltage 13.5 V
+20°C resistance 26 :
Current under rated voltage 0.5 A
Frequency of control pulse 30 Hz
Typical A type 7 ms
Controlling pulse width B Type 6 ms
Flowrate when differential pres- A type 2.7 3.0 3.3 m3/h
sure = 200mbar and duty ratio
=100% B Type 1.7 2.0 2.3 m3/h
See ¿gure 3-53 for connection of canister control valve, canister and intake manifold.
In order to avoid passing solid sound, it is recommended to have the canister control valve
mount on the hose, hanging in the air.
Proper measures such as ¿ltering and puri¿cation must be taken to prevent foreign matters
(such as particles) from entering the canister or hose from going into the canister control
valve.
It is recommended to mount appropriate protective ¿lter (mesh size <50mm) on the canister
outlet.
364
BYD S6, S6A, S6K Service Manual
General cause: poor Foreign matter ingress into the valve cause corrosion or poor sealing.
Repair instructions: 1. Air Àowing direction must be consistent with rules during installation;
2. Please check canister can condition if it is required to replace the control valve because it
is found that the black particles in the valve body cause failure of control valve; 3. Try to pre-
vent water or oil from entering the valve in the process of repair; 4. In order to avoid passing
solid sound, it is recommended to have the canister control valve mount on the hose, hang-
ing in the air.
(Remove the connector) Switch the digital multimeter to "Ohm" position; have two probe pens
connect two pins of the canister control valve. At 20 °C, rated resistance value should be approxi-
mately 22~30¡.
3.13 Fuel pressure regulator
Simple diagram
As shown in 3-56, a Àexible ¿lm made of rubber-¿ber separates fuel pressure regulator into up-
per and lower chambers. Upper chamber goes to atmosphere. There is a spring in upper cham-
ber. Lower chamber is full of fuel that comes from fuel openings around the bottom of pressure
regulator. Fuel pressure is applied below the ¿lm, and atmosphere pressure and spring force are
applied above the ¿lm. The ¿lm can be deformed to drive valve seat to open or close the valve.
But, because the deformation is very small, applied force of the spring remains. Therefore, the
365
BYD S6, S6A, S6K Service Manual
valve ON/OFF is determined by the difference between fuel pressure in lower chamber and at-
mosphere pressure. Supposing the valve is closed, fuel pressure rises, leading to pressure dif-
ference increase in upper and lower chambers. Finally, the ¿lm is ejected by fuel pressure and
the valve is opened. Fuel returns to fuel tank through fuel return opening in the center of pressure
regulator. Fuel pressure decreases until the valve is closed. So, when working conditions of the
engine changes, the difference between fuel system pressure and atmosphere pressure remains
unchanged.
3.13.3 Technical characteristic parameter
Value
Amount Mini- Maxi- Unit
Typical
mum mum
Leaking Àow rate at pressure difference 280kPa 9 cm3/min
Permissible temperature of continuous working -40 +80 °C
Maximum permissible temperature of fuel +80 °C
At -30°C, maximum permissible pressure drifting (re-
-2% +5%
versible)
At +80°C, maximum permissible pressure drifting (re-
-5% +2%
versible)
Maximum permissible acceleration peak 100 m/s2
Maximum permissible pressure pulse value 100 kPa
Value
Amount Maxi- Unit
Minimum Typical
mum
Rated pressure difference when Q=80 l/h 350 kPa
Working pressure change when Àow rate is between
17.5 kPa
15 and 140 l/h
Flow range 10 220 L/h
Gradient of characteristics curve 0.14 kPa/ L/h
Fuel pressure regulator is applicable to the fuel speci¿ed by China National Standard GB 17930-
1999
Lead-free Gasoline for Vehicles and National Environment Protection Standard GWKB 1-1999
Hazardous Substance Control Standard for Vehicle Gasoline.
Fuel pressure regulator is also applicable to gasoline containing less than 15% carbinol or etha-
nol.
366
BYD S6, S6A, S6K Service Manual
Immerse O ring in clean and free-ketonic engine oil or other lubricating oil approved by
BOSCH.
When dismantling or reinstalling pressure regulating valve, a new O ring shall be used. If
pressure regulating valve bears more than 1500kPa, this regulating valve shall be replaced.
Pressure regulating valve that goes through burst test or durability test shall not be used on
the vehicle.
3.13.5 Fault phenomenon and judgment method
General fault reason: lack of maintenance for a long time leads to: 1. ¿lter screen clogged; 2.
particle impurity causes heavy leakage; 3. mechanical damage caused by human error etc.
Maintenance notes: during the course of maintenance: 1. High pressure gas is forbidden to
impact diaphragm elements; 2. Strong corrosive liquid is forbidden to wash it; 3. No external
force is applied.
Simple measuring method: connect fuel pressure gauge with fuel inlet pipe, start the engine
to run it idly, check if fuel pressure is about 350kPa; step on the accelerator until engine
speed reaches 2500rpm, and check if fuel pressure is about 350kPa.
3.14 Steel fuel distribution pipe assembly
Simple diagram
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BYD S6, S6A, S6K Service Manual
Fuel distribution pipe assembly consists of fuel distribution pipe (KVS) and fuel injector (EV).
Used to store and distribute fuel.
3.14.3 Technical characteristic parameter
Limit data
Value
Amount Maxi- Unit
Minimum Typical
mum
Working temperature when fuel distribution pipes
-40 +120 °C
and O-ring are connected correctly
Maximum working temperature after immersion of
+130 °C
15 minutes
Maximum permissible vibration acceleration (peak) 300 m/s2
Refer to characteristic parameters of the pressure regulator for system pressure; refer to charac-
teristic parameters of the fuel injector for fuel requirements; the sealing requirement is that no fuel
leakage occurs at working pressure.
Fuel inlet pipe and rubber hose are tightened by clamps. The clamps shall match with rubber
hose to ensure fuel inlet pipe and rubber pipe are tightly connected.
No cracks, scratches, groove, burrs and corrosion should be found in the inlet tube wall.
Before assembling the fuel distribution pipe assembly, lubricate the O-ring under the lubrica-
tion injector using clean lubricant.
3.14.5 Fault phenomenon and judgment method
Sealing ability for fuel distribution pipe can be tested by pressure difference: test O ring of fuel
distribution pipe fuel injector; at 4.5bar, leakage limit value tested 1.5cm3/min.
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BYD S6, S6A, S6K Service Manual
1. Check the current steady-state fault that has been con¿rmed. Otherwise, diagnosis mistake
may occur.
3. Check a vehicle with anti-theft system. If it is required to replace ECU, please program ECU
after replacement.
4. If description of diagnostic trouble code is “too low circuit voltage”, it indicates that short cir-
cuit to ground might exist in this circuit; if description of diagnostic trouble code is “too high
circuit voltage”, it indicates that short circuit to power supply might exist in this circuit; if de-
scription of diagnostic trouble code is line failure, it indicates that open circuit might exist in
this circuit or many line faults exist.
Diagnosis help:
1. Fault code cannot be cleared and the fault is steady-state fault.
3. Do not ignore impact of vehicle maintenance conditions, cylinder pressure and mech-
anical ignition timing on the system during the inspection and repair.
If the trouble code can be cleared now, the fault position is in ECU; if the trouble code
is still not cleared, replace the original ECU and repeat the procedures and then con-
duct the inspection and test job again.
369
BYD S6, S6A, S6K Service Manual
2. Conduct the inspection by the fault diagnostic instrument and con¿rm that no fault informa-
tion record is found;
3. Con¿rm that fault symptom described by the car owner in the complaint exists and con¿rm
conditions where the fault occurs.
(2) 2. Check that vacuum pipeline is broken, twisted and connected correctly;
(3) 3. Check that the intake pipeline is clogged, leaks, or crushed to become Àat or damaged;
(4) 4. Check that high pressure line in the ignition system is broken, degraded and that the igni-
tion sequence is correct;
(6) 6. Check that various sensors and actuator connectors are loose or in poor contact.
Important note: If symptoms above exist, conduct maintenance and repair jobs corre-
sponding to the fault symptom. Otherwise subsequent fault diagnosis and repair jobs will
be impacted.
Diagnosis help:
1. Con¿rm the engine has no fault record;
2. Con¿rm that fault symptoms described by the car own in complaint do exist;
If the fault symptom can be eliminated now, the fault position is in ECU; if the fault
symptom still exists, replace the original ECU and repeat the procedures and then
conduct the inspection and test job again.
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BYD S6, S6A, S6K Service Manual
6. Idling speed is not stable at any time when the starting is normal.
8. Starting is normal, but idling speed is not stable after warming up.
9. Starting is normal; idling speed is not stable or the engine stops with some load (such as,
turn on A/C).
General fault location: 1. Battery; 2. Start motor; 3. wire harness or start button; 4. Mechanical
parts of the engine.
Test re-
S/N Operation steps: Next steps
sults
Use a multimeter to check voltage between two terminal Yes Next
1 posts of the battery. Check that voltage is approximately 8
~ -12V when the engine is starting. No Replace the battery
Yes Next
Press start button to start the engine and keep start button
2 pressed, check if positive electrode terminal post of start Repair or replace
motor has the voltage of 8V above. No
the harness.
Dismantle the starter electric motor, and check working Repair or replace the
conditions of the starter electric motor. Focus on checking Yes
3 starter electric motor
that open circuit exists or seizure occurs due to poor lubri-
cation. No Next
If the fault occurs only in winter, check that the reason why Use lubricants with
the starter electric motor resistance is too large is because Yes proper grade and
4 brand.
of the improper selection of engine lubricating oil and gear-
box oil. No Next
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BYD S6, S6A, S6K Service Manual
General fault location: 1. fuel tank is empty; 2. fuel pump; 3. speed sensor; 4. ignition coil; 5. Me-
chanical parts of the engine.
Test
S/N Operation steps: Next steps
results
Connect the fuel pressure gauge (connection point is the in- Yes Next
let pipe front end of the fuel distribution pipe assembly). Start
1
the engine and check that the fuel pressure is approximately Check and inspect
350kPa. No
the fuel system
Connect up the diagnostic instrument of electronic fuel injec- Next
tion system. Observe “engine speed” item among data stream
2 Check speed sen-
and start the engine. Observe whether the rotating speed sig- No
nal is outputted.Yes sor circuit
Pull out the ignition coil of one cylinder and connect up the Yes Next
spark plug. Keep spark plug electrode 5mm away from the
3
engine body. Start the engine and check that blue and white
Check and inspect
high-pressure ¿re exists. No
the ignition system
Eliminate the en-
Check pressure of reach engine cylinder; observe whether the Yes gine mechanical
4 fault
engine cylinder is in the lack of pressure or not.
No Next
General faulty parts: 1. Fuel containing water; 2. Fuel pump; 3. Coolant temperature sensor; 4.
Fuel pressure regulator vacuum tube;5. Ignition coil.
Test
S/N Operation steps: Next steps
results
Connect the fuel pressure gauge (connection point is the in- Yes Next
let pipe front end of the fuel distribution pipe assembly). Start
1 Check and inspect
the engine and check that the fuel pressure is approximately No
350kPa. the fuel system
Pull out the ignition coil of one cylinder and connect up the Yes Next
spark plug. Keep spark plug electrode 5mm away from the en-
2 Check and inspect
gine body. Start the engine and check that blue and white high- No
pressure ¿re exists. the ignition system
Remove the coolant temperature sensor connector, start the Check circuit or
Yes
engine, and observe whether the engine can be success- replace the sensor
fully started or not. (Or Connect one 300 ohms resistor in the
3
coolant temperature sensor connector to replace the coolant
temperature sensor. Now observe whether the engine can be No Next
successfully started or not.)
Yes Repair or replace it
4 Check if fuel pressure regulator vacuum pipe is loose or leaks.
No Next
Check fuel conditions. Observe that fault symptom is resulted Yes Replace fuel
5
from due to fuel added just a moment ago. No Next
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BYD S6, S6A, S6K Service Manual
General fault location: 1. Fuel containing water; 2. Fuel pump; 3. Coolant temperature sensor; 4.
Fuel injector; 5. Ignition coil; 6. Throttle body; 7. Mechanical parts of the engine.
Test
S/N Operation steps: Next steps
results
Connect the fuel pressure gauge (connection point is the in- Yes Next
let pipe front end of the fuel distribution pipe assembly). Start
1 Check and inspect
the engine and check that the fuel pressure is approximately No
350kPa. the fuel system
Pull out the ignition coil of one cylinder and connect up the Yes Next
spark plug. Keep spark plug electrode 5mm away from the en-
2 Check and inspect
gine body. Start the engine and check that blue and white high- No
pressure ¿re exists. the ignition system
Remove the coolant temperature sensor connector, start the Check circuit or re-
Yes
engine, and observe whether the engine can be successfully place the sensor
started or not. (Or Connect one 2500 ohms resistor in the
3
coolant temperature sensor connector to replace the coolant
temperature sensor. Now observe whether the engine can be No Next
successfully started or not.)
Clean the throttle
Gently depress the accelerator, and observe whether it can be Yes
4 and idling airway
easily started.
No Next
Remove the fuel injector. Use the special cleaning analyzer for Yes Replacement of fault
5
fuel injector to check the fuel injector for leakage or clogging. No Next
Check fuel conditions. Observe that fault symptom is resulted Yes Replace fuel
6
from due to fuel added just a moment ago. No Next
Eliminate the engine
Check pressure of reach engine cylinder; observe whether the Yes
7 mechanical fault
engine cylinder is in the lack of pressure or not.
No Next
Instructions for diag-
Yes
Connect EFI system adapter, start the engine, check if power nosis
8 supply for pins12#, 13#, 44#, 45# and 63# is normal; check if Check and repair
grounding for pins 3#, 51#, 53#, 61# and 80# are normal. No corresponding cir-
cuits
373
BYD S6, S6A, S6K Service Manual
General fault location: 1. Fuel containing water; 2. fuel pump; 3. Coolant temperature sensor; 4.
Fuel injector; 5. Ignition coil;6. Electronic throttle body; 7.Air inlet; 8.Ignition timing; 9.Spark plug;
10.Mechanical parts of the engine.
Test
S/N Operation steps: Next steps
results
Check and inspect
Check that the air ¿lter is clogged, and the air intake channel Yes
1 the intake system
has air leakage.
No Next
Connect the fuel pressure gauge (connection point is the inlet Yes Next
pipe front end of the fuel distribution pipe assembly). Start
2
the engine and check that the fuel pressure is approximately Check and inspect
350kPa. No
the fuel system
Pull out the ignition coil of one cylinder and connect up the Yes Next
spark plug. Keep spark plug electrode 5mm away from the
3
engine body. Start the engine and check that blue and white
Check and inspect
high-pressure ¿re exists. No
the ignition system
Check spark plug for each cylinder. Observe that model and Yes Next
4
clearance are consistent with speci¿cations. No Adjust or replace it
Remove the coolant temperature sensor connector, start the Check circuit or re-
Yes
5 engine, and observe whether the engine can be successfully place the sensor
started or not.
No Next
Clean the throttle
Gently depress the accelerator, and observe whether it can Yes
6 and idling airway
be easily started.
No Next
Remove the fuel injector. Use the special cleaning analyzer Replacement of
Yes
7 for fuel injector to check the fuel injector for leakage or clog- fault
ging. No Next
Check fuel conditions. Observe that fault symptom is resulted Yes Replace fuel
8
from due to fuel added just a moment ago. No Next
Eliminate the en-
Check pressure of reach engine cylinder; observe whether Yes gine mechanical
9 fault
the engine cylinder is in the lack of pressure or not.
No Next
Yes Next
10 Check that engine ¿ring order and ignition timing is correct. Check ignition tim-
No
ing
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BYD S6, S6A, S6K Service Manual
6. Idling speed is not stable at any time when the starting is normal.
General fault location: 1. Fuel containing water; 2. Fuel injector; 3. Spark plug; 4. Throttle body
and idle speed bypass air duct; 5. Air inlet; 6. Electronic throttle body; 7. Ignition timing;8. Spark
plug; 9.Mechanical parts of the engine.
Test re-
S/N Operation steps: Next steps
sults
Check and in-
Check that the air ¿lter is clogged, and the air intake channel Yes spect the intake
1 system
has air leakage.
No Next
Clean or replace
Yes
2 Check if idle speed regulator is not smooth. it
No Next
Yes Next
Check spark plug for each cylinder. Observe that model and
3 Adjust or replace
clearance are consistent with speci¿cations. No
it
Check the throttle body and idling speed bypass air channel Yes Clean it
4
for coke formation. No Next
Remove the fuel injector. Use the special cleaning analyzer for Replacement of
Yes
5 fuel injector to check the fuel injector for leakage, or clogging fault
or Àowrate out-of-tolerance. No Next
Check fuel conditions. Observe that fault symptom is resulted Yes Replace fuel
6
from due to fuel added just a moment ago. No Next
Eliminate the en-
Check pressure of reach engine cylinder; observe whether the Yes gine mechanical
7 fault
engine cylinder pressure is in big difference or not.
No Next
Yes Next
8 Check that engine ¿ring order and ignition timing is correct. Check ignition
No
timing
Instructions for
Yes
Connect EFI system adapter, start the engine, check if power diagnosis
9 supply for pins12#, 13#, 44#, 45# and 63# is normal; check if
Check and repair
grounding for pins 3#, 51#, 53#, 61# and 80# are normal.
No corresponding
circuits
375
BYD S6, S6A, S6K Service Manual
General fault location: 1. Fuel containing water; 2. Coolant temperature sensor; 3. Spark plug; 4.
Throttle body carbon deposition; 5. Air inlet; 6. Mechanical parts of the engine.
Test
S/N Operation steps: Next steps
results
Check and inspect
Check that the air ¿lter is clogged, and the air intake channel Yes
1 the intake system
has air leakage.
No Next
Check spark plug for each cylinder. Observe that model and Yes Next
2
clearance are consistent with speci¿cations. No Adjust or replace it
Clean related
Yes
3 Check if throttle body has carbon deposition. parts
No Next
Remove the coolant temperature sensor connector, start the Check circuit or
Yes
4 engine, and observe whether the engine can run unstably in replace the sensor
warm-up process. No Next
Remove the fuel injector. Use the special cleaning analyzer for Replacement of
Yes
5 fuel injector to check the fuel injector for leakage, or clogging fault
or Àowrate out-of-tolerance. No Next
Check fuel conditions. Observe that fault symptom is resulted Yes Replace fuel
6
from due to fuel added just a moment ago. No Next
Eliminate the en-
Check pressure of reach engine cylinder; observe whether the Yes gine mechanical
7 fault
engine cylinder pressure is in big difference or not.
No Next
Instructions for di-
Yes
Connect EFI system adapter, start the engine, check if power agnosis
8 supply for pins12#, 13#, 44#, 45# and 63# is normal; check if Check and repair
grounding for pins 3#, 51#, 53#, 61# and 80# are normal. No corresponding cir-
cuits
376
BYD S6, S6A, S6K Service Manual
8. Starting is normal, but idling speed is not stable after warming up.
General fault location: 1. Fuel containing water; 2. coolant temperature sensor; 3. Spark plug; 4.
Electronic throttle body; 5. Air inlet; 6. Mechanical parts of the engine.
Test
S/N Operation steps: Next steps
results
Check and inspect
Check that the air ¿lter is clogged, and the air intake channel Yes
1 the intake system
has air leakage.
No Next
Check spark plug for each cylinder. Observe that model and Yes Next
2
clearance are consistent with speci¿cations. No Adjust or replace it
Yes Clean related parts
3 Check if throttle body has carbon deposition.
No Next
Remove the coolant temperature sensor connector, start the Check circuit or re-
Yes
4 engine, and observe whether the engine can run unstably in place the sensor
warm-up process. No Next
Remove the fuel injector. Use the special cleaning analyzer for Replacement of
Yes
5 fuel injector to check the fuel injector for leakage, or clogging fault
or Àowrate out-of-tolerance. No Next
Check fuel conditions. Observe that fault symptom is resulted Yes Replace fuel
6
from due to fuel added just a moment ago. No Next
Eliminate the en-
Check pressure of reach engine cylinder; observe whether the Yes gine mechanical
7 fault
engine cylinder pressure is in big difference or not.
No Next
377
BYD S6, S6A, S6K Service Manual
9. Starting is normal; idling speed is not stable or the engine stops with some load (such as,
turn on A/C).
General fault location: 1. Air conditioner system; 2. Idle speed regulator; 3. Fuel injector
Test re-
S/N Operation steps: Next steps
sults
Clean related
Yes
1 Check if throttle body has carbon deposition. parts
No Next
Observe whether the engine output power increases with A/C Yes To step 4
on or not; use the EFI system diagnostic instrument to observe
2
change of ignition advance angle, fuel injection pulse width
and air input. No Next
Yes Next
Connect up the EFI system and disconnect connection line of
3 the electronic control unit 75 # pin. Check that with A/C on, wir- Check and in-
ing harness end has high level signal. No spect the A/C
system
Yes Next
Check that A/C system pressure, compressor electromagnetic Check and in-
4
clutch and A/C compressor pump are in normal condition. No spect the A/C
system
Remove the fuel injector. Use the special cleaning analyzer for Replacement of
Yes
5 fuel injector to check the fuel injector for leakage, or clogging fault
or Àowrate out-of-tolerance. No Next
Instructions for
Yes
Connect EFI system adapter, start the engine, check if power diagnosis
6 supply for pins12#, 13#, 44#, 45# and 63# is normal; check if
Check and repair
grounding for pins 3#, 51#, 53#, 61# and 80# are normal.
No corresponding
circuits
378
BYD S6, S6A, S6K Service Manual
General fault location: 1. Throttle body and idle speed bypass air duct; 2. Vacuum pipe; 3. Idle
speed regulator; 4. coolant temperature sensor; 5. ignition timing.
Test
S/N Operation steps: Next steps
results
Yes Adjust it
1 Check that accelerator cable is stuck or too tight.
No Next
Check and inspect
Check that the intake system or the connected vacuum pipe- Yes
2 the intake system
line has air leakage.
No Next
Dismantle idle speed regulator, check if throttle body, idle Yes Clean related parts
3 speed regulator and idling bypass air duct have carbon depo-
sition. No Next
379
BYD S6, S6A, S6K Service Manual
General faulty parts: 1. Fuel containing water; 2. Intake combustion analyzer or throttle position
sensor 3. Spark plug; 4. Throttle body and idling speed bypass air channel; 5. Air intake channel;
6.Idle stepper motor; 7.Fuel injector; 8.Ignition timing; 9.Exhaust pipe.
Test re-
S/N Operation steps: Next steps
sults
Check and
Yes inspect the
1 Check that the air ¿lter is clogged intake system
No Next
Connect the fuel pressure gauge (connection point is the inlet Yes Next
pipe front end of the fuel distribution pipe assembly) . Start
2 Check and
the engine and check that the fuel pressure is approximately
350kPa during acceleration. No inspect the fuel
system
Yes Next
Check spark plug for each cylinder. Observe that model and
3 Adjust or re-
clearance are consistent with speci¿cations. No
place it
Dismantle idle speed regulator, check if throttle body, idle Clean related
Yes
4 speed regulator and idling bypass air duct have carbon deposi- parts
tion. No Next
Yes Next
Check that the intake air pressure sensor, the throttle position Check circuit
5
sensor and their circuit are in normal condition. No or replace the
sensor
Replacement
Remove the fuel injector. Use the special cleaning analyzer for Yes
6 of fault
fuel injector to check the fuel injector for leakage or clogging.
No Next
Check fuel conditions. Observe that fault symptom is resulted Yes Replace fuel
7
from due to fuel added just a moment ago. No Next
Yes Next
8 Check that engine ¿ring order and ignition timing is correct. Check ignition
No
timing
Yes Next
Instructions for
Yes
diagnosis
Connect EFI system adapter, start the engine, check if power
10 supply for pins12#, 13#, 44#, 45# and 63# is normal; check if Check and
grounding for pins 3#, 51#, 53#, 61# and 80# are normal. repair cor-
No
responding
circuits
380
BYD S6, S6A, S6K Service Manual
General faulty parts: 1. Fuel containing water; 2. Intake combustion analyzer or throttle position
sensor 3. Spark plug; 4. Throttle body and idling speed bypass air channel; 5. Air intake channel;
6.Idle stepper motor; 7.Fuel injector; 8.Ignition timing; 9.Exhaust pipe.
Test
S/N Operation steps: Next steps
results
Check and inspect
Yes
1 Check that the air ¿lter is clogged the intake system
No Next
Connect the fuel pressure gauge (connection point is the inlet Yes Next
pipe front end of the fuel distribution pipe assembly) . Start
2
the engine and check that the fuel pressure is approximately Check and inspect
350kPa during acceleration. No
the fuel system
Check spark plug for each cylinder. Observe that model and Yes Next
3
clearance are consistent with speci¿cations. No Adjust or replace it
Dismantle idle speed regulator, check if throttle body, idle Clean related
Yes
4 speed regulator and idling bypass air duct have carbon deposi- parts
tion. No Next
Yes Next
Check that the intake air pressure sensor, the throttle position
5 Check circuit or
sensor and their circuit are in normal condition. No
replace the sensor
Replacement of
Remove the fuel injector. Use the special cleaning analyzer for Yes
6 fault
fuel injector to check the fuel injector for leakage or clogging.
No Next
Check fuel conditions. Observe that fault symptom is resulted Yes Replace fuel
7
from due to fuel added just a moment ago. No Next
Yes Next
8 Check that engine ¿ring order and ignition timing is correct. Check ignition tim-
No
ing
Yes Next
9 Check that air in exhaust pipe can Àow smoothly. Repair or replace
No
the exhaust pipe
Instructions for
Yes
Connect EFI system adapter, start the engine, check if power diagnosis
10 supply for pins12#, 13#, 44#, 45# and 63# is normal; check if
Check and repair
grounding for pins 3#, 51#, 53#, 61# and 80# are normal.
No corresponding
circuits
381
BYD S6, S6A, S6K Service Manual
General fault location: 1. Fuel containing water; 2. intake pressure sensor; 3. Spark plug; 4. Igni-
tion coil; 5. Throttle body; 6. Air inlet; 7. Fuel injector; 8. Ignition timing; 19. Exhaust pipe.
Test re-
S/N Operation steps: Next steps
sults
Check that the clutch is slipping, the tire pressure is low, the Yes Repair
1 brake operation is dragging, the tire size is wrong and the
wheel alignment is conducted in a wrong manner. No Next
Connect the fuel pressure gauge (connection point is the inlet Yes Next
pipe front end of the fuel distribution pipe assembly) . Start
3 Check and
the engine and check that the fuel pressure is approximately
350kPa during acceleration. No inspect the fuel
system
Pull out the ignition coil of one cylinder and connect up the Yes Next
spark plug. Keep spark plug electrode 5mm away from the
4
engine body. Start the engine and check that high pressure ¿re Check and
strength is normal. No inspect the igni-
tion system
Yes Next
Check spark plug for each cylinder. Observe that model and
5 Adjust or re-
clearance are consistent with speci¿cations. No
place it
Clean related
Yes
6 Check if carbon deposits on throttle body and air inlet. parts
No Next
Yes Next
7 Check if intake pressure sensor and throttle wire are normal. Check circuit or
No replace the sen-
sor
Replacement of
Remove the fuel injector. Use the special cleaning analyzer for Yes
8 fault
fuel injector to check the fuel injector for leakage or clogging.
No Next
Check fuel conditions. Observe that fault symptom is resulted Yes Replace fuel
9
from due to fuel added just a moment ago. No Next
Yes Next
10 Check that engine ¿ring order and ignition timing is correct. Check ignition
No
timing
Yes Next
11 Check that air in exhaust pipe can Àow smoothly. Repair or re-
No place the ex-
haust pipe
382
BYD S6, S6A, S6K Service Manual
I. Self-diagnosis
Mainly include: Water temperature, intake temperature, throttle opening, engine speed, ignition
angle, short-time correction of air-fuel ratio, long-time addition and multiplication correction of air-
fuel ratio, intake pressure, intake Àow rate, oxygen sensor signal, system voltage and torque de-
mand value;
Mainly include: display programming state, cooling system, stable working conditions, dynamic
working conditions, emission control, oxygen sensor, idle speed, MIL, emergent operation and air
conditioner;
Mainly include: MIL, fuel pump, A/C relay, fan control, ignition test, single cylinder fuel cut-off;
After the engine Àames out, initialization command is sent. The system will reset the previous self-
adaption.
VI. Speedometer
Mainly include: vehicle identi¿cation code (optional), ECU hardware number, ECU software num-
ber.
383
BYD S6, S6A, S6K Service Manual
7. Accessories:
7.1 Installation force of parts/ torque speci¿cation table
Explanation:
3. Maintenance procedures are prepared based on the normal use, and must be strictly ob-
served.
Mileage
10 20 30 40 50 60 70 80
x1000km
Items
Months
3 6 9 12 15 18 21 24
Month
Ignition Coil I I I I
Ignition Cam I I I I
Ignition Cap I I I I
Ignition Wire I I I I
Spark Plug I I I R
Ignition Timing I I I I
Engine Idling Speed I I I I
Fuel Tank I C
Fuel Filter R R R R
Fuel Injector C C C C
Air Filter I R I R
EWD or Stepper Air Bypass C C C C
Throttle Body C C C C
Emission Check I I I I
Check by Diagnostic Tool I I I I
7.2.2 Taxi
384
BYD S6, S6A, S6K Service Manual
Explanation:
3. Maintenance procedures are prepared based on the normal use, and must be strictly ob-
served.
Mileage
20 40 60 80 100 120 140 160
x1000km
Items
Months
3 6 9 12 15 18 21 24
Month
Ignition Coil I I I I I I I I
Ignition Cam I I I I I I I I
Ignition Cap I I I I I I I I
Ignition Wire I I I I I I I I
Spark Plug I R I R
Ignition Timing I I I I
Engine Idling Speed I I I I
Fuel Tank C C
Fuel Filter R R R R R R R R
Fuel Injector C C C C C C C C
Air Filter I R I R I R I R
EWD or Stepper Air Bypass I C I C I C I C
Throttle Body I C I C I C I C
Emission Check I I I I
Check by Diagnostic Tool I I I I
Note: R-Replace
C-Clean
I -Inspect (Replace the spare parts when ¿nd out failure in inspection.)
C*-The maintenance of fuel injector had better clean by a special tool --- fuel injector
cleaner.
385
BYD S6, S6A, S6K Service Manual
386
BYD S6, S6A, S6K Service Manual
387
BYD S6, S6A, S6K Service Manual
388
BYD S6, S6A, S6K Service Manual
Please follow Operation Manual strictly to ¿nd out faults and make maintenance.
389
Body
BYD S6, S6A, S6K Service Manual
Body
Contents
I
BYD S6, S6A, S6K Service Manual
Contents
1-I
BYD S6, S6A, S6K Service Manual
1-II
BYD S6, S6A, S6K Service Manual
(1) Remove the front bumper grille cover sides in the center by two persons to re-
board move the front bumper.
(2) Remove the front bumper griller rubber (4) Install the front bumper in reverse order
head bolts (E) (two) with a cross screw- of disassembly, and pay attention to
driver, and then remove the embedded the following:
plastic nuts (A) and mounting screws
(two) on both sides of the front bumper, Before taking out the front bumper, dis-
and then remove the four self-taping FRQQHFWWKHIURQWIRJODPSFRQQHFWRU¿UVW
screws (C) and two mounting bolts in the to avoid damaging the connector.
bottom of the front bumper in sequence. Make sure that the front bumper, left and
(3) Pull out the mating part of both ends right connecting bracket of front bumper
of the bumper and left/right connecting DQGKHDGODPSEUDFNHWDUH¿WWHGUHOLDEO\
bracket of the front bumper, and then Replace the damaged snap button, screw
push forward the bumper from both and bolt.
1-1
BYD S6, S6A, S6K Service Manual
Push inward
(1) Remove the front bumper (B). (3) Install the front grille in reverse order of
disassembly, and pay attention to the
(2) As shown in the picture, pull the clamp following:
pins of the front bumper and front grille
one by one to remove the front griller; do Do not apply too much force when install-
not pull by force to avoid deforming or ing and removing the front grille to avoid
scratching the bumper. scratching or damaging the grille.
1-2
BYD S6, S6A, S6K Service Manual
Snap button B
1. Remove the snap buttons (B) (five) on 2. Lift one side of the ventilating cover (left
the upper cover board of the griller with a or right), and remove the clamp pins (six)
flat headed screwdriver, and then press shown in the picture. Note: Do not ap-
the circle in the center of the snap button ply too much force to avoid damaging
(A) with fingers to remove the snap but- the clamp pins.
tons (A) from the engine room left/right
trim panel and engine trim panel; 3. Pull out the ventilating panel along the
front windshield. The installation se-
2. Take out the engine room trim panel quence is reverse to removing.
from the engine room;
Removing/installing left/right manhole cover
3. Then, remove the corresponding plug in of the ventilating cover:
left/right trim panel and the small decou-
pler of the engine room trim panel.
Ventilating cover
1-3
BYD S6, S6A, S6K Service Manual
㝊
Clamp pin
1. Remove the manhole cover at the gap shown in the picture with a flatheaded screwdriver;
The installation is reverse to removing. The left and right manhole covers have same installation
and removing method.
1-4
BYD S6, S6A, S6K Service Manual
Section 3 Side Wall Outer Trim (2) Remove snap button B (five; one larger
in the front, and four smaller in the rear)
with a screwdriver.
3.1 Installing/removing side wall
apron (3) Remove the side wall apron
Note: The installation and removal of (4) Remove clips A (six) with a screwdriver
apron require an assistant.
The installation sequence is reverse to re-
Do not scratch the body, and wear gloves to moving
protect your hands.
Please note the following:
(1) Open the door, remove the front mud-
Ɨ The fasteners must be installed in
guard, and remove the self-taping C
place.
(four) and through-hole embedded plas-
tic nut D (two) and E (two) with a screw- Ƙ Replace all damaged clips and snap
driver. buttons.
㸈Ხ
APRON
Do not scratch the body and door glasses, Do not tear off the tape while installing.
and wear gloves to protect your hands. Clamp the outer trim into the mounting
slot, align the top stud hole to the sheet
(1) Open the door, and remove the self- metal hole, adjust the position, and then
taping screw at the position shown in the tear off the tape from the seam between
picture with a screwdriver outer trim and door sheet metal. Then,
press the outer trim tape to make it stick
(2) Push up the outer door trim (tape has tightly. The installation should be in place,
been stuck to the body, and should be and the self-taping screw should be tight-
pulled up with force) ened. Use appropriate screw to avoid ejec-
WRUPDUNVDYRLGVFUDWFKLQJWKHSDLQW¿OP
while removing and installing.
1-5
BYD S6, S6A, S6K Service Manual
㔫ၿᲮ ធ Clip
ធ
Fender Clip
㷴 亟 Ხtrim
panel
1-6
BYD S6, S6A, S6K Service Manual
Section 4 Back Door Outer Trim Note the following in the process of in-
stalling:
4.1 Spoiler Do not scratch the body;
1) Installing/removing spoiler Find an assistant if necessary;
Plate clip
Bolt Bolt
Plate clip Plate clip Stud
Figure 1-4
Figure 1-6
(2) Installing the spoiler
1-7
BYD S6, S6A, S6K Service Manual
Figure 1-7
1-8
BYD S6, S6A, S6K Service Manual
Bolt 4 Nut 4
Rear bumper Body
left front
sheet
bracket metal
Rear bumper
Snap left rear Rear bumper right rear bracket
bracket
button 2
Bolt 2 Rear
bumper
Screw 12
Screw 12
1) Removing the rear bumper 5. Remove the bumper in the arrow direc-
tion shown in the picture. Before remov-
Remove the rear bumper as shown in the ing the bumper, remove the patch cord
picture of the rear fog lamp first (remove the
patch cord of back-up radar for higher
1. Remove the four nuts at position A with
configuration) to avoid damage.
8# socket wrench in the luggage com-
partment, and take out the four bolts af- To remove the bracket, unscrew the
ter the rear bumper is removed; screw at position D.
2. Remove the two snap buttons at position 2) Installing the rear bumper
B of rear bumper hinge with a flatheaded
screwdriver; Install in the reverse order of removal
3. Remove the two bolts at position C re- 1. Install the left and right front/rear brack-
spectively with a cross screwdriver ets of the rear bumper first, and then
tighten the screws (ten) at position D;
4. Remove the screw at position E and the
two self-taping screws at position D of 2. Install the bolt A at rear wall on the rear
the bottom connected to the mudguard bumper;
with a cross screwdriver.
3. Lift the rear bumper, and align the four
mounting bolts to the rear wall of the
body;
1-9
BYD S6, S6A, S6K Service Manual
1-10
BYD S6, S6A, S6K Service Manual
(3) Remove the bolt (B) (four), snap button Ƙ Replace all damaged fasteners.
(C) (seven) and screw (D) (two) in the
˄2˅
Engine mudguard I
Snap
button Engine mudguard II
(7)
Left front
Engine mudguard
mudguard III
III
(2 sets)
1-11
BYD S6, S6A, S6K Service Manual
Engine mudguard I
Snap
button
Engine mudguard II
Lift front
mudguard III
Engine mudguard III
Screw and
clip
(2 sets)
1-12
BYD S6, S6A, S6K Service Manual
6.2 Removal and Installation of (3) Remove the remaining five snap buttons
Front/Rear Mudguard (E) that connects to fender and wheel-
house sheet metal;
Note:
(4) Remove front wheelhouse mudguard I, II
Wear gloves to protect your hands. and III.
Do not scratch the body. 2) Installing front mudguard
1) Removing front mudguard The installation sequence is reverse to re-
moving. Front mudguard I, II and III are con-
(1) Remove the screw connected to front nected through six rivets (F).
bumper, the screw (A) connected to front
bumper and engine mudguard, the bolt Please note the following:
(B) connected to engine mudguard I and
II, and the snap button (C) connected to Ɨ The fasteners must be installed in
engine mudguard II; place.
(2) Remove the six screws (D) connected to Ƙ Replace all damaged fasteners.
body wheelhouse sheet metal;
Front mudguard II
Figure 1-11 Front mudguard I, II, III and rear mudguard I removing
1-13
BYD S6, S6A, S6K Service Manual
1) Remove the snap button, two hex bolts 1) The left and right front inner mud-
and flat washer assembly connected guards have different shapes, but the
with the front sheet metal. installation position and fasteners are
same.
2) Remove the front mudguard.
2) The fasteners must be installed in
4) Installing front inner mudguard place.
Left front
mudguard
Snap
button
1-14
BYD S6, S6A, S6K Service Manual
Plastic nut: 4
Self-taping screw: 1
Plastic nut: 1
1-15
BYD S6, S6A, S6K Service Manual
Left speaker Front left defroster Center speaker Front right Right speaker
cover nozzle cover defroster nozzle cover
Right
Left defroster defroster
nozzle nozzle
Combination Center
instrument Combination Center left cover Center right
cover switch cover vent board vent
1-16
BYD S6, S6A, S6K Service Manual
Before removing instrument panel assembly, remove left/right front door case sealing strips, left/
right front door running boards, and left/right “A” pillar upper/lower panel.
Note:
(1) Wear gloves to protect hands before removing and installing;
(2) Before removing and installing, be familiar with the structure of the part to be removed
or installed to avoid damage in the process;
(3) The tip of the flatheaded screwdriver must be wrapped with flexible tape to avoid dam-
aging the product surface;
(4) After installing, the fit clearance and surface difference of all parts should comply with
the requirement of appearance tolerance.
The removal and installation method of instrument panel assembly parts is described as below:
1-17
BYD S6, S6A, S6K Service Manual
Mounting
buckle
1-18
BYD S6, S6A, S6K Service Manual
When removing,
1-19
BYD S6, S6A, S6K Service Manual
Self-taping screw
decorative cap in lower
right of the panel, which
can be opened by prying
along top edge with a
flatheaded screwdriver Figure 1-21 Combination Switch Cover
Mounting Points
1-20
BYD S6, S6A, S6K Service Manual
Is clamp pin mounting point (one) Is clamp pin mounting point (one)
Figure 1-22 Center Left Lower Panel Mount- Figure 1-23 Gearshift Cover Plate Mounting
ing Points Point Location Diagram
Pry up the two snap buttons shown in the fig- Pry up the buckle and clamp pin mounting
ure with a flatheaded screwdriver, pry up the points shown in the figure with a flatheaded
clamp pin between center left lower panel and screwdriver, and take out gearshift cover
lower body along the gap, and take out the plate when all mounting points are released.
center left lower panel when the clamp pin is
released. The installation sequence of center When install gearshift cover plate component,
left lower panel is reverse to removal. align the installation location points shown in
the figure, and push in the buckle and clamp
The removal of center left lower panel is simi- pin.
lar to center left panel.
1-21
BYD S6, S6A, S6K Service Manual
Screw
Screw
Pull out along
the bottom
edge with
hands
1-22
BYD S6, S6A, S6K Service Manual
Note:
(1) The personnel must be clear of the
product structure before removing to
avoid accidents;
1-23
BYD S6, S6A, S6K Service Manual
Clamp pin
mounting point
Figure 1-28 Combination Instrument Cover Figure 1-29 Left Speaker Cover Body Mount-
Mounting Structure Diagram ing Point Diagram
Pry up the connections of combination instru- When removing, pry up the two buckle mount-
ment cover panel and instrument panel upper ing points of left speaker cover body with a
body with a flatheaded screwdriver: remove flatheaded screwdriver, and then take out left
the four clamp pins in the top, and then re- speaker cover component.
move the two buckle mounting points on the
left and right; take out combination instru- When install left speaker cover, insert the two
ment cover component when all the mounting installation location points in the front into in-
points are released. strument panel mounting hole, and then push
in the two buckles in the rear.
The installation of combination instrument
cover component is reverse to removal: install The removal of right speaker cover compo-
the left and right buckles, and push the four nent and center speaker cover component is
clamp pins into the mounting hole. similar to left speaker cover.
1-24
BYD S6, S6A, S6K Service Manual
Is installation location point (one) Figure 1-31 Left Nozzle Assembly Mounting
Points
Removing:
1-25
BYD S6, S6A, S6K Service Manual
Note:
(1) The personnel must be clear of the
product structure before removing to
avoid accidents;
Figure 1-32 Right Nozzle Assembly Mounting (2) The tip of the flatheaded screwdriver
Points must be wrapped with flexible tape to
Removing: avoid damaging the product surface;
1. First, refer to section 8.4 of the Main- (3) Before removing, please make sure
tenance Manual (Removing/installing that all instrument panel wires have
glove box assembly) to remove the glove been disconnected.
box assembly; Removing:
2. Push the two elastic mounting buckles 1. First, remove lower left panel compo-
at the position of imaginary circle into nent, lower right knee board component,
the square hole reserved in the nozzle glove box assembly, center left/right
(ensure that buckle surface has been lower panel component, cigar lighter
separated from instrument panel body panel component, gearshift cover plate
1-26
BYD S6, S6A, S6K Service Manual
component and instrument panel lower 3. Remove the four mounting bolts and two
body component in sequence (refer to mounting nuts shown in the figure (Fig.
removal instructions above); 17) with 10# socket wrench, and take out
the instrument panel upper body compo-
2. Then, remove the 7Ǝ screen and air nent from the vehicle.
conditioner control panel assembly,
DVD&GPS host and radio assembly and Installation:
combination instrument, and disconnect
respective connector, and remove assis- Insert the three clamp pins in front of the in-
tant driver’s airbag mounting bolts (see strument panel upper body component into
removal instructions of electrical part). the three clamp pin mounting holes, and then
tighten all fastening points according to step 3.
(2) Before removing, please make sure that all tubular beam wires have been disconnect-
ed.
Removing:
1. Remove the instrument panel upper body component first (refer to section 8.17);
2. Then, remove the fastening points of steering column, clutch pedal (MT) and brake pedal on
tubular pedal (refer to removal instructions of chassis part);
1-27
BYD S6, S6A, S6K Service Manual
3. Disconnect all electrical connectors, and remove the fastening points of respective air condi-
tioner cabinet (refer to removal method of electrical part);
4. Remove the ten bolts and one nut shown in the figure with a socket wrench, and then re-
move the tubular beam assembly from the vehicle.
Installation:
Lift the tubular assembly into the cab and hang on the pin, and tighten all fastening points accord-
ing to step 3. (Pay attention to the requirement on tightening torque of each fixed position)
1-28
BYD S6, S6A, S6K Service Manual
1-29
BYD S6, S6A, S6K Service Manual
1-30
BYD S6, S6A, S6K Service Manual
1-31
BYD S6, S6A, S6K Service Manual
1-32
BYD S6, S6A, S6K Service Manual
ĸ The installation of auxiliary facia (4) Removing and installing auxiliary facia
console glove box cover assembly console glove box
is reverse to removal.
1-33
BYD S6, S6A, S6K Service Manual
1-34
BYD S6, S6A, S6K Service Manual
Section 9 Roof & Heat Protector (3) Installing safety handle assembly
1-35
BYD S6, S6A, S6K Service Manual
(1) Turn over the sun visor, and take out the 1) Removing and installing hood inner
sun visor from the mounting support in heat insulator
the arrow direction.
Press-in type plastic buckle
(BYDQ835A0703)
(2) Loosen the two cross recessed screws (1) Removing hood inner heat protector
(Q2140516T23F3) with a cross screw-
driver. Now, the sun visor is released, Remove the ten press-in type plastic
and you can take it out. buckles (BYDQ835A0703) with a flat-
headed screwdriver to remove the hood
inner heat protector.
Ɨ The personnel must be clear of the Remove the heat protector only when the
product structure before removing to main instrument platform, auxiliary instrument
avoid accidents; platform, carpet assembly and cabin engine
covered on the heat protector are removed.
Ƙ The tip of the flatheaded screwdriver
Remove in the following sequence:
must be wrapped with flexible tape to
avoid damaging the product surface. (1) Removing front wall inner heat insulation
pad
1-36
BYD S6, S6A, S6K Service Manual
(2) Removing engine cabin insulation sand- 2) Removing and installing roof assembly
wich
Remove the roof only when the front door
Take out the engine cabin insulation case inner door sealing strips, rear door case
sandwich directly. inner door sealing strips, “A” pillar inner pan-
el, “B” pillar inner panel, “C” pillar inner panel,
interior rear-view mirror, front roof lamp, rear
roof lamp, sun visor, and safety handles have
been removed (see respective chapter for de-
tails of removal).
Note:
Ɨ The personnel must be clear of the
9.4 Removing and installing roof product structure before removing to
avoid accidents;
1) Roof assembly index
Ƙ The tip of the flatheaded screwdriver
must be wrapped with flexible tape to
avoid damaging the product surface.
(2) Lift the rear end of the roof, find the posi-
tion of the three buckles (BYDQ83301)
Installation (see roof index figure), and pry it up from
structure here the roof with a flatheaded screwdriver.
Plate buckle
(BYDQ833C01)
(3) Remove sun visor support base
Plate buckle
(BYDQ833C01)
1-37
BYD S6, S6A, S6K Service Manual
ͪ is clamp pin
mounting point
Note:
Ɨ The personnel must be clear of the
product structure before removing to
avoid accidents;
1-38
BYD S6, S6A, S6K Service Manual
Note:
(1) Please wear protective gloves before
removing
Note:
(1) Please wear protective gloves before
removing
Note:
(1) Please wear protective gloves before
removing
1-39
BYD S6, S6A, S6K Service Manual
Note:
:
(1) Please wear protective gloves before
Clamp pin matching
व㾦䜡ড়
removing
1-40
BYD S6, S6A, S6K Service Manual
1-41
BYD S6, S6A, S6K Service Manual
F
Screw (1)
ĸ
ķ
Plastic
Figure 1-39 Armrest, Handle and Cover Plate buckle (11)
Removal Diagram
3) Lift the inner buckle, pry out the inner Figure 1-41 Front Door Inner Panel Buckle
buckle cover plate along the edge of Removal Diagram
inner buckle cover plate with a small
flatheaded screwdriver, and then
remove the screw behind the cover
plate with a cross screwdriver;
1-42
BYD S6, S6A, S6K Service Manual
5) Make sure that all mounting points After above steps, remove the front door
are released, and push out the panel from door sheet metal, and put it on
front door guard board in direction flat place to avoid scratching the panel. In the
3 shown in figure 1-7; process of removing, do not bend, to avoid
wrinkle and fracture.
6) Loosen inner buckle wires in 1-2,
3-4 sequence shown in figure 11- 4. Install in reverse order of removing, and
8: 1, 3: separate the wires from in- pay attention to the following:
ner handle seat; 2, 4: pull out wires
from the mounting holes in the lock 1) Replace any damaged plastic
button and inner handle; buckles;
1-43
BYD S6, S6A, S6K Service Manual
2) Disconnect switch panel connector 1) Pry out the inner handle cover plate
along the gap in the edge of inner
Pry out the switch panel, press the clamp handle cover plate with a small
pin of connector in direction 1 shown flatheaded screwdriver, and then
in figure 1-45, pull out the connector in remove the screw under the cover
direction 2 and then remove the switch plate with a cross screwdriver;
panel.
Screw (1)
Rear door handle
cover plate is
fixed with three
clamp pins
Screw (1)
1-44
BYD S6, S6A, S6K Service Manual
1-45
BYD S6, S6A, S6K Service Manual
Section 12 Side Wall Inner Trim with instrument panel is installed in place,
and make sure that the position connect-
ing with the roof is compressed and the
12.1 Removing and installing side
buckle is installed in place;
wall guard board
Make sure that the door case sealing
Note: Wear gloves to protect your hands. strips are installed properly.
In the process of removing, do not bend,
to avoid wrinkle and fracture. Be careful 2. Removing and installing front door
and avoid damaging windshield and sur- running boards
rounding parts.
2.1 Removing front door running boards
1. Removing and installing “A” pillar up-
per panel Break out the clamp pins connecting to the
instrument panel with hands, and then sepa-
1.1 Release the door case sealing strips of rate the clamp pins connecting to “A”/”B” pil-
“A” pillar connecting belt lar lower panel to separate it from instrument
panel and “A”/”B” pillar lower panel, and then
1.2 Removing “A” pillar upper panel slide forward/backward along the running
Pry out front bottom edge along arrow 1 di- board to separate the jaw from the buckle
rection in ¿JXUH with a flatheaded screw- fixed on the carpet and sealing strips and re-
driver wrapped with protective tape, and move front door running board (pedal lamp
break out with both hands. connector should be removed for high trim
models).
Separate the plastic buckle fastening points
(two) from the sheet metal, and then take out
“A” pillar upper panel along arrow 2 direction
in ¿JXUH.
: Two plastic
buckles
“A” pillar Instrument
upper panel
Front windshield
panel
“B” pillar lower panel “A” pillar
lower panel
2
1-46
BYD S6, S6A, S6K Service Manual
3. Removing and installing rear door run- 4. Removing and installing doorsill shield
ning boards of luggage compartment
3.2 Install in reverse order of removing, and Ɨ Replace any damaged plastic
pay attention to the following: buckles;
Ɨ If the clamp pin is damaged, re- Ƙ Make sure that the position con-
place new running board; necting with the back doorsill
shield is compressed and the
Ƙ Make sure that the clamp pins clamp pin is installed in place;
of “C” pillar lower panel are in-
stalled in place, and connected ƙ Make sure that the back door
to “B” pillar lower panel properly; case sealing strips are installed
properly.
ƙ Replace the damaged metal
buckles.
1-47
BYD S6, S6A, S6K Service Manual
5. Removal and installation of back door- 6. Removing and installing “A” pillar low-
sill shield er panel
: Two plastic
buckles
Distributor
box
Ɨ Replace any damaged plastic Make sure that the position connecting
buckles; with the doorsill shield is compressed and
the buckle is installed in place;
Ƙ Make sure that it is connected to
“C” pillar upper panel properly. Make sure that the door case sealing
strips are installed properly.
1-48
BYD S6, S6A, S6K Service Manual
7. Removing and installing “ B ” pillar Make sure that it is connected with the
panel height adjuster properly and operated nor-
mally;
“C”Cḡлᣔᶯ
pillar lower panel
Running board
䗾ᇮ䐿ᶯ
Figure 1-58 “B” Pillar Panel Diagram
7.4 Remove “B” pillar lower panel, break out Figure 1-59 “C” Pillar Panel Diagram
along the sheet metal connections with
8.1 Remove rear door running boards
both hands (as direction 1 in ¿JXUH41),
separate the plastic buckle fastening 8.2 Remove rear wall guard boards
points (two) from the sheet metal and
take out “B” pillar lower panel. Note: The 8.3 Release the door case sealing strips of
omega clamp and two wedge clamp pins “C” pillar matching belt
between “B” pillar upper panel and lower
8.4 Remove the seats
panel also should be removed.
8.5 Remove “C” pillar lower panel
7.5 Removing “B” pillar upper panel
As shown in ¿JXUH59, remove the two leaf
Unscrew the hex bolt and flat washer as-
buckles with a flatheaded screwdriver, and
sembly (two), and then break out along sheet
then break out along the sheet metal con-
metal connection with both hands, separate
nection with both hands, separate the plastic
the plastic buckle fastening point (one) from
buckle fastening points (two) from the sheet
the sheet metal and take out “B” pillar upper
metal and take out “C” pillar lower panel.
panel.
Note:
7.6 Install in reverse order of removing, and
pay attention to the following: Ɨ The two installing buckles between “C”
pillar lower panel and upper panel also
Replace any damaged plastic buckles;
should be removed.
Make sure that the positions connecting with
Ƙ When “C” pillar lower panel is removed,
front/rear running boards and roof are com-
the luggage compartment guard board
pressed and the buckle is installed in place;
1-49
BYD S6, S6A, S6K Service Manual
should be removed together because As shown in figure 1-61, pry up the buckles
it is connected to the lower panel with with a flatheaded screwdriver to separate the
pins. plastic buckles (four) from the sheet metal
and take out rear doorsill pedal.
8.7 Remove rear seat belts
1-50
BYD S6, S6A, S6K Service Manual
Mat
clips Foot pad
back
Right front Nylon buckle
foot pad
2) Take out the foot pad from the two Foot pad
mat clips with hands. back
Nylon buckle
Foot pad
back
Nylon buckle
1-51
BYD S6, S6A, S6K Service Manual
Shaped buckle
(BYDQ840B03) Figure 1-63 Coding cover board
Leaf buckle
(2) Removing carpet assembly
(BYDQ832B0515)
1) Peel off the six nylon buckles in
front edge of the carpet from front
Figure 1-62 Carpet assembly index wall heat protector with hands;
2. Removal and installation of carpet 2) Remove the six shaped buckles
(BYDQ840B03) installed on left
Remove the carpet only after removing the
and right side of the carpet with
lower instrument panel, left/right lower guard
wrench;
board of the instrument panel, auxiliary facia
console, transmission gearshift controller, 3) Remove the four leaf buckles (BY-
parking brake handle, front seats, rear seats, DQ832B0515) from the rear edge
seat belt lower fixing bolt, left/right A pillar of the carpet;
lower panel, left/right B pillar lower panel, left/
right C pillar lower panel, left/right front door- 4) Then, remove the carpet assembly.
sill shield, and left/right rear doorsill shield
(3) Installing carpet assembly
(see respective chapter for details of remov-
ing). The installation sequence of carpet assembly
is reverse to removing.
Note:
Ɨ The personnel must be clear of the
13.3 Removal and installation of
product structure before removing to foam carpet
avoid accidents;
Remove the foam carpet after the carpet as-
Ƙ The tip of the flatheaded screwdriver sembly has been removed
must be wrapped with flexible tape to
(1) Removing foam carpet
avoid damaging the product surface.
Unplug the left and right foam carpets from
(1) Removing coding cover board
the welding studs of sheet metal directly.
Pry up the slot with a screwdriver along the
(2) Installing foam carpet
top, reach into and push out the clamp pin,
pull out from the pried side and take out the The installation sequence of foam carpet is
coding cover board (BYDS6-5109092). reverse to removing.
1-52
BYD S6, S6A, S6K Service Manual
1-53
BYD S6, S6A, S6K Service Manual
5 6 7
4
8
3
9
2
2) Removing/installing luggage
compartment system
1. Pieces that can be taken out directly
(not fixed with fasteners) Figure 1-66 Luggage compartment front tool
box removal diagram
Trunk lid panel component can be removed
directly, and then you can find the left tool 1. The front tool box of the luggage com-
box, center tool box and right tool box in the partment is fixed with four buckles (BY-
luggage compartment; front cover plate of DQ840B01); remove the four buckles, lift
luggage compartment also can be removed and take out the front tool box.
directly, and then you can find the front tool
1-54
BYD S6, S6A, S6K Service Manual
2. The installation process is reverse to re- Figure 1-51 Luggage compartment left/right
moval. wheelhouse cover plate removal diagram
4. Removing/installing left/right tool box 1. Left/right wheelhouse cover plate doesn’t
of luggage compartment have fastener; pry up the wheelhouse
cover plate with a flatheaded screwdriver
to separate the clamp pin of the wheel-
house cover plate from left/right guard
board. Then, pull outward to separate
the clamp pin of wheelhouse cover plate
from C pillar upper panel, and remove
the left/right wheelhouse upper cover
plate.
2. The installation process is reverse to re- Figure 1-68 Luggage compartment cord hook
moval. component removal diagram
5. Removing/installing left/right wheel- 1. The four cord hook components are
house upper cover plate of luggage fixed on the sheet metal with a bolt
compartment (Q1400616) respectively, and you can
remove the cord hook component by re-
moving this bolt.
1-55
BYD S6, S6A, S6K Service Manual
1-56
BYD S6, S6A, S6K Service Manual
Contents
2-I
BYD S6, S6A, S6K Service Manual
2-II
BYD S6, S6A, S6K Service Manual
(3) Check whether the drainage pipe and (6) Check whether the relay has failure.
outlet are connected tightly, and whether
the clamp is loose; 1.2 Replacing sunroof glass
(4) Check whether the fastening bolt and Replace sunroof glass in the following steps:
body side wall are loose.
(1) Close the sunroof.
2. Motor noise
(2) Pull back the sun visor.
(1) Check whether the motor is loose;
(3) Remove the sleeve, and take out the nut
(2) Check whether the gear or bearing is and gasket from the cam mounting point,
worn; as shown in the figure below.
(3) Check whether the timing belt assembly (4) Lift and take out the sunroof glass, as
is deformed. shown in figure 2-2 below; do not dam-
age the body roof.
3. Motor is running, and sunroof doesn’t
move (5) Install the sunroof glass in the reverse
order of removal.
(1) Check whether the gear or internal tim-
ing belt are installed properly;
2-1
BYD S6, S6A, S6K Service Manual
Nut location
Cam
Sunroof
glass
2-2
BYD S6, S6A, S6K Service Manual
If the deviation exceeds this standard, adjust the sunroof glass height in the following steps:
(1) Open the sunroof glass, and remove the glass bracket cover.
(2) Loosen the nut, and insert gasket between glass window frame and bracket (as shown in fig-
ure 2-2), and the maximum thickness of front and rear gasket is 2mm.
1
2
(3) If necessary, repeat this operation on the damaged, remove the frame and
other side until the height is appropriate. replace the cable assembly.
1. Checking closing force and opening ĸ Check the sunroof motor; if it
force of sunroof glass doesn’t work or the running isn’t
smooth, replace the motor.
2. Check the closing force of sunroof
glass in the following method: Ĺ Check the opening force.
2-3
BYD S6, S6A, S6K Service Manual
(2) As shown in figure 2-5, disconnect and take out the plug, and remove the bolt.
(4) Install the motor in the reverse order of removal. After installation, connect the plug, and
check the motor running.
M6 nut
(2) Adjust the cam to make the sunroof at the position that allows closing downwards, and then
remove the fastening screws of the drainage tank, as shown below.
(3) Move the drainage tank forward to separate the drainage tank from the hook.
Hook
Screw
Drainage tank
Left/right cam
2-4
BYD S6, S6A, S6K Service Manual
(5) Install the drainage tank in reverse order of removal. However, note the following:
1) When the drainage tank is reinstalled, it should be hooked and there is a click sound.
3) Check whether it leaks water, and do not use high pressure water jets for test.
(2) Slide the sun visor until two sliders of the sun visor are visible, as shown in the figure below:
Sun visor
Slider
2-5
BYD S6, S6A, S6K Service Manual
(4) Lift the rear side of sun visor and move backwards.
(6) Separate the two rear sleeves of the sun visor and frame rail, and remove the sun visor, as
shown below.
Sun visor
Sun visor rear
sleeve
(8) After replacing the sun visor, check whether the glass height is flush; check whether it leaks,
and do not use high pressure water jet.
2-6
BYD S6, S6A, S6K Service Manual
Forward
Cam
2-7
BYD S6, S6A, S6K Service Manual
(2) Slide cam assembly backward, and then remove it from the frame, as shown below
2) Install the cam and timing belt assembly in reverse order of removal. Note the following
while installing:
2) Apply multi-purpose grease on relative running position and rail sliding position
of cam and slider.
3) Before reinstalling the motor, install the frame and glass, and check the opening
force.
Before reinstalling the motor, make sure that the two cam assemblies are parallel and in closed
position.
2-8
BYD S6, S6A, S6K Service Manual
Figure 2-14
2.2 As shown in figure 2-15, release wire connector B, push the bracket in arrow direction, and
remove the interior rearview mirror;
Figure 2-15
Note: Do not apply too much force while removing to avoid damaging wire connectors.
2-9
BYD S6, S6A, S6K Service Manual
3. Removing and Installing Front Windshield and Left/Right Rear Side Wall
Quarter Window
3.1 Removing and installing front windshield
Windshield is installed with single component polyurethane adhesive sealant. To replace the
windshield, use adhesives of sufficient surface adhesion strength and with appropriate procedure.
3.1.1 Removing
Front windshield
buckle Front windshield
trim strip
Front
windshield
Front windshield
lower limiter block
Front windshield
weather strip
2-10
BYD S6, S6A, S6K Service Manual
1. The installation step follows: Do not scratch the body paint, or else the
adhesion will be affected.
1. Strike the adhesives on the body con-
nection to 2mm thick with tool knife. Before re-installing the glass, remove the
old sealing strips and adhesives from the
glass.
2-11
BYD S6, S6A, S6K Service Manual
Do not damage the primer, glass sur- Each adhesive has its curing time.
face or body. Refer to manufacturer’s instruc-
tions, check the curing time of the
After coating, press the glass on the adhesives, and take appropriate
body as soon as possible. measures before the adhesives are
completely bonded.
After coating, use rubber suction cup
gripper to install and transport the Do not drive before the adhesives
glass. are completely bonded to ensure
that it is thoroughly and fully cured.
Finish step 5-6 in ten minutes to en-
sure sufficient adhesion. 3.2 Removing and installing left/
Refer to the instructions of adhesive
right side wall windshield
manufacturer for proper operation and 3.2.1 Removing
drying time.
1. The following tools are required to
6. Install the roof batten, ventilating cover, remove the left/right side wall wind-
and windshield wiper arm. shield:
7. When the adhesive is cured, spray water
Awl
to window from the hose to check wheth-
er it leaks. If yes, wipe the glass, and fill Steel wire
the leaking position with adhesives. If it
still leaks after filling, remove the glass Primer brush
and reinstall in above steps.
Cutter
8. Install the interior rearview mirror and
Rubber suction cup gripper
connector when the adhesives are fully
cured. Sealant gun (to fill adhesives)
2-12
BYD S6, S6A, S6K Service Manual
Putty spatula (to trim adhesives) If the coated surface is scratched or dam-
aged, repair the damage, or else it will
Note: erode from the damage.
Refer to the manufacturer’s instructions if Removing front quarter glass and rear
other primer and glass cement are used. If side wall glass (left side and right side are
the glass cement isn’t used properly, the symmetrical, and the example describes
original adhesion property will be affected. right side)
Therefore, read the manual and grade of
the glass cement carefully; it is important 2. Right front quarter glass assembly dia-
to take this procedure throughout the en- gram follow
tire exercise and comply with each notice.
3. The right front quarter glass is re- 4. With one assistant standing out of the
moved in the following steps: vehicle, pull the steel wire fore-and-aft,
and saw the sealants and weather strips
1. First, paste protective strips on the outer of the entire glass.
surface of the glass
5. Release the three locating buckles and
2. Remove the glass sealing ring, and cut remove the glass carefully.
off if necessary
Note:
3. Drill a hole through the adhesives in ve-
hicle inside from the glass corner with an Leave more adhesives on the body when
awl, thread through the steel wire and removing the glass.
wrap the steel wire on the wood block.
2-13
BYD S6, S6A, S6K Service Manual
2-14
BYD S6, S6A, S6K Service Manual
Retractor lower
mounting bolt
Figure 2-19
Adjuster
connecting Figure 2-20
nut
8. Refer to front seat removal and remove
the front seat.
2-15
BYD S6, S6A, S6K Service Manual
10. Remove the buckle nut, and then re- 4. Refer to side wall inner trim panel re-
move the seat belt buckle. The bolt tight- moval to remove doorsill pedal, “C” pillar
ening torque is 42N.m (figure 2-21). lower panel and “C” pillar upper panel.
Figure 2-24
Figure 2-22
2-16
BYD S6, S6A, S6K Service Manual
8. For the left/right buckles of 60-40 fold- 4.3 Replacing front seat belt (if in-
down split seat: turn over the seat, re- stalled):
move the buckle fastening nut, take out
buckle fastening bolt and bolt sleeve, Note:
and then remove seat belt buckle. The
bolt tightening torque is 42N.m (figure Check whether the seat belt is damaged,
2-22). and replace if necessary. Be careful while
removing and installing to avoid damage.
Figure 2-22
9. For the center position of 60-40 fold- Lap belt mounting bolt
down split seat: remove the seat, re-
move the connector combination bolts of
center buckle and seat lap belt, and then
remove the seat belt buckle and seat lap Figure 2-25
belt. The tightening torque for bolts is 3. Install in the reverse order of removal,
42N.m and tighten the bolts with specified
torque; before installing the mounting
bolts, make sure that seat belt isn’t dis-
torted or knotted.
10. Install in the reverse order of removal; Keep sharp and destructive objects
before reinstalling, coat liquid thread away from the seat belt.
sealant on the bolts of fixing point and Do not bend or damage the buckle lock
tighten the bolts with specified torque; or any part.
make sure that the seat belt connector is
connected properly; before mounting the Do not bleach or dye the belt (wash
bolts of upper/lower fixing points, make with neutral soap and warm water
sure that the seat belt isn’t distorted or only).
knotted; check the function of retractor
locking mechanism (see test section). When installing the seat belt, pre-tight-
2-17
BYD S6, S6A, S6K Service Manual
2-18
BYD S6, S6A, S6K Service Manual
Assistant driver’s seat Middle row 40-split seat Rear seats (optional)
2-19
BYD S6, S6A, S6K Service Manual
2. Adjust the seat to the rear end, remove 3. Install in the reverse order of removal,
the front nut cover plate of the seat, and and tighten the bolts with 40N.m torque.
then remove the mounting bolt. Before
removing the power seats from the ve-
hicle, release the power wires, seat belt
buckle alarm wires and side airbag wires
(if installed); for manual driver’s seat,
release the seat belt buckle alarm wires;
for assistant driver’s seat, release the
seat belt buckle alarm wires, safety belt
unwear warning sensor wires and side
airbag wires (if installed).
2-20
BYD S6, S6A, S6K Service Manual
Six-way
adjustment
button
Two-way
adjustment
button
2-21
BYD S6, S6A, S6K Service Manual
(5) Unplug the lumbar support handwheel in er inner guard board of driver’s (power)
arrow direction seat, and then remove the left and right
upper/lower inner guard board of driver’s
(power) seat. The structure is shown be-
low.
Driver’s
(power)
seat right
upper inner
guard board
Seat backrest
regulator motor
assembly
2-22
BYD S6, S6A, S6K Service Manual
(11) Install the parts in the reverse order of (3) Push in the handwheel retainer in the
removal. thin arrow direction shown in the figure,
and then pull out seat pan angular ad-
Note: juster handwheel in thick arrow direction.
Replace the guard board in time if it is
damaged while removing.
2. Driver’s (manual) seat
Jaw
Jaw
2-23
BYD S6, S6A, S6K Service Manual
(5) As shown in the figure, clamp the head ant driver ’ s sear is same to driver ’ s
restraint sleeve with pliers, pull out and (manual) seat.
remove the head restraint sleeve.
5.2 Middle seats
5.2.1 Removing and installing 60-40 fold-
down split seats
Note:
Clamping
Replace the guard board in time if it is mode of front
guard board
damaged while removing.
3. The removal and installation of assist-
2-24
BYD S6, S6A, S6K Service Manual
(3) Install in the reverse order of removal, (3) Remove the front mounting bolts and
and tighten the bolts with 40N.m torque. then remove the armrest seat.
Jaw A
Jaw
Jaw B
Buckle
Self-taping
screw
2-25
BYD S6, S6A, S6K Service Manual
(6) Remove the mounting screws for right (8) Remove the middle head restraint sleeve
inner guard board of the armrest to re- and the guard board of armrest and
move the board. The removal of left in- backrest.
ner guard board is same to right.
Self-taping
screw
(7) Remove the mounting bolt and then re- (9) Remove the jaws and three mounting
move the middle armrest. bolts, and remove the panelling of arm-
rest and backrest guard board.
Jaw
Handle
mounting bolt
2-26
BYD S6, S6A, S6K Service Manual
Middle row
seat unlocking
60-split seat left mechanism
outer guard board
Jaw
Backrest cable
(3) As shown in the figure, remove backrest (5) Clamp the head restraint sleeve device,
unlocking device; the cable of 60-split pull out, and remove the head restraint
seat is on the left of backrest and the sleeve, as shown in the figure. The
cable of 40-split seat is on the right. method is same to front seats.
2-27
BYD S6, S6A, S6K Service Manual
Mo
u
Lo pin
Q1 ntin
ca
86 g b
tin
10 ol
20 t
g
(6) Install in the reverse order of removal,
and tighten the bolts with specified
torque. (3) Remove the three rear mounting bolt of
5.2.3 Removing and installing middle row middle row integrated seat, and the bolt
integrated seat tightening torque is 40N.m
Plastic buckle
2-28
BYD S6, S6A, S6K Service Manual
Jaw
Jaw
Middle seat
unlocking
mechanism
2-29
BYD S6, S6A, S6K Service Manual
5.3 Removing and installing rear (4) Remove the rear mounting nuts of rear
seats seat cushion
Jaw
Cushion
Floor cross
member
2-30
BYD S6, S6A, S6K Service Manual
㜦㇑ᢓ
Hose buckle IV (single pipe) Roof
亦Ἂ
˄অ㇑˅
Washer hose
⍇⏔㜦㇑
Front auxiliary
ࡽ䴘࡞࢟࡞ windshield wiper
ࡽ䴘࡞ѫ࡞
Front main windshield wiper
ৢᣵ亢⦏⩗
Rear windshield
ࠡ⋫⍸⬉ᴎ
Front washer moto
r
ৢ⋫⍸⬉ᴎ
Rear windshield wiper motor
ৢ䲼ࠂ⬉ᴎ
Rear washer motor
2-31
BYD S6, S6A, S6K Service Manual
6.1 Replacing front/rear windshield 5. Install the windshield wiper motor in re-
wiper motor verse order of removal.
1. Remove the left/right windshield wiper Coat grease on all moving parts.
arm and ventilating cover. Replace damaged buckle if necessary.
2. Remove the connector wires of wind- Adjust the linkage to mark position and
shield wiper motor with a flatheaded then install the driver rocker.
screwdriver, as shown in the figure:
After installation, connect the power and
turn on the wiper to return to the dock po-
sition automatically.
3. Remove the five mounting bolts, and 2. Unplug the connector of washer mo-
then remove the windshield wiper lever tor, take out the washer motor from the
assembly. washer fluid pot, and remove the hose
from the motor.
4. Mark the crank position on the base of
windshield wiper drive shaft, and remove Note:
the crank. When removing hose from the washer
5. Remove the three mounting bolts of motor, remove the side of the check valve
windshield wiper motor, and then remove close to the motor, keep the check valve
the motor. RQWKHKRVHWRDYRLGZDVKHUÀXLGOHDNLQJ
from the hose.
6. Install the windshield wiper motor in re-
verse order of removal. 3. Install the washer motor in reverse order
of removing, and pay attention to the
Replacing rear windshield wiper motor following:
1. Remove the rear windshield wiper arm All positions connected to the hose and
and back door guard board. the inner wall of pipes should be cleaned
and coated with adhesive before install-
2. Remove the connector wires of rear ing.
windshield wiper motor with a flatheaded
screwdriver. Connect the power and check the running
of motor when the adhesive is dry, and
3. Remove the three mounting bolts, and make sure that it allows water spraying.
then remove the windshield wiper lever
assembly. 6.3 Replacing wash fluid pot
4. Remove the four cross recessed pan 1. The following parts should be removed
head screws of the windshield wiper with
a cross screwdriver, and then remove Front bumper, right mudguard and right fender
the windshield wiper motor.
2-32
BYD S6, S6A, S6K Service Manual
2-33
BYD S6, S6A, S6K Service Manual
3. Cross bar is difficult to move 1) Remove the rubber plugs shown in the
figure below, one on each side
(1) Check whether the chute of vertical bar
is distorted or rusts;
2-34
BYD S6, S6A, S6K Service Manual
3) Slide the first cross member forward to 2) Remove the lower bracket of the lug-
slide out from the longeron rail chute, gage rack.
and then slide out the second cross
member in the same method. Remove the retainer, and then remove the
lower bracket.
2-35
BYD S6, S6A, S6K Service Manual
No.
(File name, font size: 3, Times New
Total pages: Page:
Roman, bold) Version/Revision No.
Prepared by:
Proofread by:
Audited by:
Countersigned by:
Standard review:
Approved by:
Mark Number Rev. No. Signature Date Mark Number Rev. No. Signature Date
2-36
BYD S6, S6A, S6K Service Manual
Contents
3-I
BYD S6, S6A, S6K Service Manual
3-II
BYD S6, S6A, S6K Service Manual
Section 1 Door System - Main- the engine cover stay into the seat.
Then, lower the engine cover and
tenance Manual check whether it is locked in place.
1. Hood Tap the front edge to lock if neces-
sary.
1.1 Hood adjustment
Cushion
1.3.2 Hood lock adjustment
3-1
BYD S6, S6A, S6K Service Manual
3-2
BYD S6, S6A, S6K Service Manual
Same to 1.2.1
Same to 1.2.1
3-3
BYD S6, S6A, S6K Service Manual
2. Front doors
2.1 Front door component exploded view
4 5 6
5) BYDS6-5105211 cushion
3-4
BYD S6, S6A, S6K Service Manual
9
15
14
10
11
12
13
3-5
BYD S6, S6A, S6K Service Manual
2.2 Front door glass 4) Remove the front door trim panel. Re-
move the two fastening screws shown in
2.2.1 Removing: the figure with a cross screwdriver, pry
up the buckle of the inner panel and take
1) Remove front power window regulator
it out.
switch assembly.
Buckle A
Screwdriver Jaw
Buckle
Buckle
2) Remove the inner trim panel of exterior 5) Remove the door courtesy in the arrow
rearview mirror. direction shown in the figure.
Courtesy lamp
Inside handle
Jaw
Buckle Jaw
3) Remove the inner trim panel of inside 6) Remove the outer belt line moulding in
opening handle. the direction shown in the figure.
Screwdriver
Jaw
3-6
BYD S6, S6A, S6K Service Manual
7) Loosen the three fastening bolts shown 10) Remove the regulator. Loosen the six
in the figure, and remove the exterior mounting bolts shown in the figure and
rearview mirror. remove the regulator (do not impact and
deform the regulator while removing).
2.2.2 Installing:
8) Remove the front door waterproof thin
film. Install the door glass in the reverse order of
removal, and note the following:
9) Remove the glass. Lower the regulator
to the position shown in the figure, loos- 1) Check whether the positions of the regu-
en the two mounting bolts of the glass, lator shown in the picture are lubricated.
and take out the glass. Install the regulator.
3-7
BYD S6, S6A, S6K Service Manual
Locating
point
3-8
BYD S6, S6A, S6K Service Manual
2.4 Front door lock 2.5.1.2 Left front door sealing strips
2.4.1 Removing and installing front door Remove the connectors of upper case (buck-
lock les can be pried out with a screwdriver), pull
out the sealing strip of the case from the slot,
Lift the front door glass to the top, remove the pry up the buckle, pull out slowly and remove
rail on the side of the lock, unscrew the three the sealing strips.
mounting bolts and remove the lock. Install in
reverse order. The tightening torque for instal-
lation is 5N.m.
3-9
BYD S6, S6A, S6K Service Manual
2.5.1.4 Left front door external batten of sealing strip is sufficient, enroll the section
that isn’t installed if it is too long, and pull out
ķ Lower the glass to the bottom slightly if it is too short.
ĸ Clamp both sides of the punching end with 2.5.2.2 Left front door sealing strips
hand, tilt inward slightly while pulling up, and
pull back to take out the external batten. First, install the two connectors of the door bar,
clamp the sealing strips of the window frame
into the slot, and then clamp the remaining
buckle into the hole and straighten out.
Note:
3-10
BYD S6, S6A, S6K Service Manual
3) Coat glue on the mounting bolts; er, and tap with plastic hammer;
4) Install the bolts on the body; 6) Tighten the screws after adjusting.
Torque: 26N.m
Torque: 26N.m
3-11
BYD S6, S6A, S6K Service Manual
3. Rear doors
3.1 Rear door component exploded view
1
2
3
7
4 5
3-12
BYD S6, S6A, S6K Service Manual
3-13
BYD S6, S6A, S6K Service Manual
3.2 Rear door glass and regulator 4) Remove the rear door waterproof thin
film.
3.2.1 Removing
Jaw
Buckle
Screwdriver
Buckle
Buckle
3-14
BYD S6, S6A, S6K Service Manual
3.2.2 Installing:
3-15
BYD S6, S6A, S6K Service Manual
Same to 2.5.1.4
Same to 2.5.1.5
3.5.2 Installing
Same to 2.5.2.1
When installing glass, check whether the
glass top and upper case run channel con- 3.5.2.2 Right rear door sealing strips
tact uniformly, and whether the movement is Same to 2.5.2.2
smooth.
3.5.2.3 Left rear door run channel
3) Paste waterproof thin film.
Same to 2.5.2.3
Locating point
3.5.2.4 Left rear door external batten
Same to 2.5.2.4
Same to 2.5.2.5
3-16
BYD S6, S6A, S6K Service Manual
Torque: 27N.m
Torque: 27N.m
Torque: 26N.m
Torque: 23N.m
3-17
BYD S6, S6A, S6K Service Manual
4. Back doors
4.1 Back door component exploded view
16
2
3
15
4
14
10 11
3
3) BYDS6-5105214 cushion IV
3-18
BYD S6, S6A, S6K Service Manual
4.2.1 Removing:
3-19
BYD S6, S6A, S6K Service Manual
4.3.1.2 Back door glass glue guard lower Clean the glass, peel off the double-sided
sealing strips adhesive tape on the sealing strip, and stick
the sealing strip to the side edge and bottom
Same to 4.3.1.1 edge of the glass; the outer end of the sealing
strip is 1.3mm from the upper edge of glass;
please paste from one end to the other, and
finally straighten out the folds or bulge.
Braket Lover
Braket Upper
4.3.2 Installing
3-20
BYD S6, S6A, S6K Service Manual
4.4.2 Installing
Torque: 8N.m
Torque: 11.5N.m
Torque: 8N.m
3-21
BYD S6, S6A, S6K Service Manual
5.1 Removing back door glass Before trimming the body with tools, clean
the connections with alcohol or similar
5.1.1 Clear the inside and outside of glass stuff to clear the grease.
and surrounding parts.
5.1.9 Before re-installing the glass, remove
5.1.2 Disconnect the connector with rear the old sealing strips and adhesives
windshield. from the glass.
Note: 5.2 Installing back door glass
When disconnecting the connector, do not 5.2.1 Clean the surface of the body (or wind-
pull the cable; instead, release the lock of shield edge) that will be bonded with
the connector, hold the connector and pull the windshield with cleaning agent. (Let
it out. it dry for at least ten minutes)
5.1.3 Remove the sealing strips of the roof. 5.2.2 Clean the old strips, paint or contact
surface of exposed metal thoroughly. If
5.1.4 Cover the body around the glass with
the paint and metal contact surface are
adhesive tape to avoid damaging the
exposed completely, do not paint the
body.
primer on the surface of the adhesives
5.1.5 Remove (or cut) the sealing strips on the body.
around rear windshield until the edge of
Note:
the rear windshield is exposed.
Refer to the instructions of primer
5.1.6 Drill a hole through the adhesives
manufacturer for proper operation and
with an awl, and thread the steel wire
drying time.
through.
Do not touch the body that will be
5.1.7 Decompose the adhesives around the
bonded to the glass and the surface of
glass with steel wire, pay attention to
old adhesives.
the two fixed points on the front wind-
shield, and the distance between fixed 5.2.3 Install the new strips on the glass. For
points and glass edge is 176mm. easy installation, please heat the strips
at 35°C for 1.5 hours.
Note:
3-22
BYD S6, S6A, S6K Service Manual
Note:
Note:
3-23
Chassis
BYD S6, S6A, S6K Service Manual
Chassis
Contents
I
BYD S6, S6A, S6K Service Manual
II
BYD S6, S6A, S6K Service Manual
1
BYD S6, S6A, S6K Service Manual
1) Prepare the tote box and part shelf, which are used to place the disassembled parts; the
parts should be in order, and mark to avoid confusion if necessary.
2) Be careful when inspect the aluminum alloy to avoid damaging the surface.
4) For the bolts and other fasteners that have standard torque requirement, tighten according to
specified value with dedicated tool.
5) After maintenance, scrap the disposable supplies and replace with new products.
8) If there is any technical problem during maintenance, please consult our after-service center.
1.3 Maintenance materials
The materials listed in the table below are indispensable in the maintenance of the transmission
of this model. Therefore, it should be ready for use. In addition, the washing liquid and lubricant
should also be specified model.
No. Material & model Current material & model Position of application
1 Lubricant Release arm
2 Lubricant Release bearing
Esso Ronex MP, Esso Beacon
3 Lubricant EP2 or Ronex EXTAR Duty Spindle oil seal
Moly2
4 Lubricant Speed sensor assembly
5 Lubricant Gear selector shifting block
2
BYD S6, S6A, S6K Service Manual
To install synchronizer
gear hub of fifth gear and
MD998819 Installation tool joint (40)
reverse gear, differential
bearing and fourth gear
To install synchronizer
MD998820 Installation tool joint (42) gear sleeve of fifth gear
and second gear
3
BYD S6, S6A, S6K Service Manual
To install synchronizer
gear sleeve of first gear,
MD998822 Installation tool joint (46) synchronizer gear hub
of fifth gear and reverse
gear
4
BYD S6, S6A, S6K Service Manual
To install the
MD998826 Installation tool joint synchronizer gear hub of
third and fourth gear
5
BYD S6, S6A, S6K Service Manual
2. Assembly Maintenance
2.1 Release system
2.1.1 Specifications:
Item Specifications
Clutch working mode Hydraulic remote
Clutch plate type Dry single disc
Clutch place size (outer diameter × inner diameter) ĭ215×ĭ140
Clutch cover type Diaphragm spring
Clutch surface rivet sunken depth 0.3
Height difference of diaphragm spring 0.5
Clearance between inner circle of release cylinder
0.15
and outer circle of piston
Clutch hydraulic pipe connecting nut 15 (1.5)
Clutch hydraulic pipe bracket 18 (1.9)
Clutch release cylinder pipe fitting 22 (2.3)
Clutch release cylinder bleed screw 11 (1.1)
Clutch release cylinder mounting bolt 18 (1.9)
Ball screw 35 (3.6)
6
BYD S6, S6A, S6K Service Manual
Disassembly step:
1. Release pump pipe mounting bracket 8. Clutch slave cylinder assembly
assembly
2. Release pump pipe mounting bracket 9. Return spring
rubber pad
3. Washer 10. Release bearing
5. M8X25 hex head bolt (GB/T9074.17 12. Release arm dust cover
M8X25)
6. Hydraulic pipe connector 13. Release arm screws
7. Gasket
Release arm
(Fill)
7
BYD S6, S6A, S6K Service Manual
Disassembly step:
1. Cap 5. Piston cup
2. Bleed screw 6. Piston
3. Push rod 7. Conical spring
4. Clutch slave cylinder dust cover 8. Clutch slave cylinder pump
8
BYD S6, S6A, S6K Service Manual
Note:
The release bearing is filled with grease, and thus do not clean with oil.
(1) Check whether the bearing is burnt, and whether has damage, noise, unsmooth rotation and
other problem.
(2) Check whether the contact surface of release bearing and diaphragm spring is worn.
Replace the release arm if the bearing contact surface is worn abnormally.
2.1.3.2 Clutch slave cylinder assembly
(1) Check whether the inner surface of the release hydraulic cylinder is damaged or rusts.
(2) Use bore gauge to measure the inner diameter of the release hydraulic cylinder at three
positions (bottom, center and top), and replace the release hydraulic cylinder assembly if the
clearance with outer circle of piston exceeds the limit. Limit: 0.15mm
2.2 Transmission
2.2.1 Specifications
Basic
9
BYD S6, S6A, S6K Service Manual
Maintenance specifications
Adjustment of circlip, differential adjusting shim and axle shaft gear adjusting shim
2.25
BYD5T19-1701112
2.35
Counter shaft rear retainer (for adjustment of spindle rear bearing clearance)
į=2.3
į=2.4
į=2.5
BYD5T19-1701221
į=2.6
į=2.7
į=2.8
10
BYD S6, S6A, S6K Service Manual
Counter shaft front retainer (for adjustment of counter shaft front bearing clearance)
į=1.40
į=1.48 BYD5T19-1701218
į=1.56
Counter shaft rear retainer (for adjustment of counter shaft rear bearing clearance)
į=2.3
į=2.4
į=2.5
BYD5T19-1701221
į=2.6
į=2.7
į=2.8
Counter shaft middle retainer (for adjustment of counter shaft third gear axial clearance)
į=2.4
į=2.5
į=2.6
į=2.7 BYD5T19-1701219
į=2.8
į=2.9
į=3.0
11
BYD S6, S6A, S6K Service Manual
į=0.80
į=0.85
į=0.90
į=0.95
į=1.00
į=1.05
į=1.10
į=1.15
į=1.20
į=1.25
į=1.30 BYD5T19-1701432
į=1.35
į=1.40
į=1.45
į=1.50
į=1.55
į=1.60
į=1.65
į=1.70
į=1.75
į=1.80
12
BYD S6, S6A, S6K Service Manual
Axle gear adjusting shim (for adjustment of differential body radial clearance)
į=0.6
į=0.7
į=0.8
į=0.9 BYD5T19-1701312
į=1.0
į=1.1
į=1.2
Item Nm3
Stud bolt 35
Crankcase bolt 44
Speed sensor 9
13
BYD S6, S6A, S6K Service Manual
1) Transmission assembly
Disassembly & assembly steps
Disassembly step:
14
BYD S6, S6A, S6K Service Manual
Disassembly step:
16. Return spring assembly 24. Reverse gear shift fork board assembly
15
BYD S6, S6A, S6K Service Manual
Disassembly step:
31. First/second gear fork 40. Third/fourth gear shift fork sub-assembly
16
BYD S6, S6A, S6K Service Manual
Sealing cover
Countershaft retainer
Third/fourth
synchronizer
gear hub
17
BYD S6, S6A, S6K Service Manual
Solder
(1) At the position of transmission housing
shown in the picture, place the solder
(about 10mm long, 1.6mm diameter),
and then install the differential.
(T+0.05mm) to (T+0.10mm)
18
BYD S6, S6A, S6K Service Manual
Spindle
Counter shaft assembly
19
BYD S6, S6A, S6K Service Manual
Reverse gear
Reverse gear
shifting arm
interlocking
shaft
Reverse gear
shifting arm
Fifth/rever Fifth/reverse
Spring pin/washer assembly
se gear gear shift fork
shift lever
Install the washer selected in the step “Ad-
justment before reassembly”
Spring pin
Opening
Drainage groove
board
Third/fourth
Synchronizer
sliding sleeve
20
BYD S6, S6A, S6K Service Manual
Note:
Sealing cover
21
BYD S6, S6A, S6K Service Manual
Note:
Transmission oil:
22
BYD S6, S6A, S6K Service Manual
2) Spindle
Disassembly and reassembly
Disassembly step:
1. Spindle rear retainer 10. Spindle fifth gear distance 19. Synchronizer spring
ring
2. Spindle rear bearings 11. Spindle fourth gear 20. Middle steel ring
connecting piece
3. Spindle distance ring 12. Fourth gear needle bearing 21. Double cone inner ring
4. Fifth gear synchronizer 13. Spindle fourth gear 22. Spindle third gear
gear sleeve distance ring connecting piece
5. Fifth gear synchronizer 14. Fourth gear synchronizer 23. Second/third/fifth gear
gear hub ring needle bearing
6. Fifth gear synchronizer 15. Synchronizer spring 24. Spindle front retainer
ring
7. Synchronizer lever 16. Third/fourth synchronizer 25. Spindle front bearing
gear sleeve
8. Spindle fifth gear 17. Third/fourth gear 26. Oil seal
connecting piece synchronizer gear hub
9. Second/third gear needle 18. Double cone outer ring 27. Spindle
bearing
23
BYD S6, S6A, S6K Service Manual
24
BYD S6, S6A, S6K Service Manual
Circlip
25
BYD S6, S6A, S6K Service Manual
Synchronizer spring
Identification mark
26
BYD S6, S6A, S6K Service Manual
Installation direction
27
BYD S6, S6A, S6K Service Manual
28
BYD S6, S6A, S6K Service Manual
3) Counter shaft
Disassembly and reassembly:
Disassembly step:
1. Counter shaft rear retainer 10. Counter shaft second gear 19. Middle steel ring
distance ring
2. Counter shaft rear bearings 11. Double cone inner ring 20. Double cone inner ring
3. Counter shaft distance ring 12. Middle steel ring 21. Counter shaft first gear
connecting piece
4. Counter shaft fifth gear 13. Double cone outer ring 22. First gear needle bearing
synchronizer gear sleeve
5. Counter shaft fourth gear 14. Synchronizer spring 23. Counter shaft first gear
distance ring
6. Counter shaft middle 15. Synchronizer gear sleeve 24. Counter shaft front retainer
retainer
7. Counter shaft third gear 16. First/second gear 25. Cylindrical roller bearing
synchronizer gear hub
8. Counter shaft second gear 17. Synchronizer spring 26. Counter shaft
connecting piece
9. Second/third/fifth gear 18. Synchronizer ring
needle bearing
29
BYD S6, S6A, S6K Service Manual
30
BYD S6, S6A, S6K Service Manual
Roller
bearing
inner ring
Synchronizer spring
31
BYD S6, S6A, S6K Service Manual
32
BYD S6, S6A, S6K Service Manual
Circlip
33
BYD S6, S6A, S6K Service Manual
4) Speed sensor
Disassembly and reassembly
Disassembly step:
34
BYD S6, S6A, S6K Service Manual
Disassembly step:
35
BYD S6, S6A, S6K Service Manual
Disassembly step:
1. 5x22 groove pin 8. Spring pin 15. Gear shift/selector lever oil
seal
2. Gear interlocking rack 9. Shift lever mounting sleeve 16. Linear bearing
4. Pin 11. Return spring baffle 18. Reverse lock limit board
36
BYD S6, S6A, S6K Service Manual
37
BYD S6, S6A, S6K Service Manual
Fifth/reverse Fifth/reverse
Spring pin assembly
gear shift gear shift fork
lever
Spring pin
Opening
(2) Install, and keep the convex part face to the direction shown in the picture.
38
BYD S6, S6A, S6K Service Manual
Disassembly step:
* Refer to the assembly operation essentials only when replacing the clutch housing.
39
BYD S6, S6A, S6K Service Manual
Bushing assembly
Press the bushing into the position shown in the picture, and do not let the slotted surface contact
the air bleed slot.
Press in the outer ring of cylindrical roller bearing and keep the side printed with model face to the
direction shown in the picture
40
BYD S6, S6A, S6K Service Manual
Disassembly step:
41
BYD S6, S6A, S6K Service Manual
Bushing assembly
Press the bushing into the position shown in the picture, and do not let the slotted surface contact
the air bleed slot.
Slotted end
Air bleed
slot
42
BYD S6, S6A, S6K Service Manual
9) Differential assembly
Disassembly and reassembly
Disassembly step:
43
BYD S6, S6A, S6K Service Manual
44
BYD S6, S6A, S6K Service Manual
Differential
bearing
Item Conductivity
Press the switch No
Release the switch Yes
45
BYD S6, S6A, S6K Service Manual
1. Spindle
(2) C h e c k w h e t h e r t h e s p l i n e h u b i s
damaged or worn.
2. Roller bearing
2) Spindle
3. Synchronizer ring
46
BYD S6, S6A, S6K Service Manual
5. Synchronizer spring
3) Counter shaft
1. Counter shaft
2. Roller bearing
3. Synchronizer ring
47
BYD S6, S6A, S6K Service Manual
5. Synchronizer spring
4) Speed sensor
7) Clutch housing
8) Transmission housing
9) Differential
48
BYD S6, S6A, S6K Service Manual
Transmission
BYD6T25
model
4th
Gears 1st gear 2nd gear 3rd gear 5th gear 6th gear Reverse
gear
Gear ratio 47/13 48/22 47/32 46/40 43/36 39/40 34/13×23/14
Total drive ratio: 14.258 8.606 5.794 4.536 3.686 3.01 13.265
49
BYD S6, S6A, S6K Service Manual
1. Prepare part box and part rack for dismantled and disassembled parts. Place them in order
and make marks if necessary to avoid confusing and misplacing.
2. Place aluminum alloy parts with care to avoid damaging machining surface.
3. Prepare sufficient auxiliary materials for using when repairing at any time.
4. For bolts and other tightening parts with standard tightening torque requirement, tighten them
with special tools according to the specified value.
5. After overhauling, disposable parts shall be waste and replaced by new ones.
9. When maintaining, if you have any technical problem, please consult after-sales technical
service department of our company.
1.3 General Requirements
Before installing, mounting surface for oil seal shall be cleaned thoroughly.
Before installing, check if oil seal is cracked, scratched or notched thoroughly. If it is defective,
it shall not be used.
New oil seal lip has lubricating grease, it is not necessary to apply lubricating grease on it.
Before dismantling parts with seal ring, it is necessary to check if seal ring is valid. If
necessary, replace it.
2. Sealant
Sealant shall be applied on the surface uniformly and continuously to be full of sealing tape
after tightening. It is suggested to use sealant line with a diameter 2mm~3mm.
3. Snap spring
When selecting snap ring, it is based on the maximum thickness in snap ring slot.
50
BYD S6, S6A, S6K Service Manual
Thread holes applied by thread sealant shall be cleaned with thread tap before applying
again.
5. Bearing
Install the bearing matched with the vehicle. New bearing does not require new lubrication.
Several bearings installed on the same shaft shall be replaced together. Bearings shall come
from the same supplier.
Taper bearing inner and outer rings shall be matched and used. Do not interchange them.
6. Adjusting shims
Measure adjusting shim on several positions with a micrometer, take the average value as the
thickness of adjusting shims.
7. Synchronous loop
Place dismantled synchronous loop assembly together, install them on original synchronizer
gear.
Before installing, lubricate synchronous loop conical surface with gear oil.
8. Gear
51
BYD S6, S6A, S6K Service Manual
9. Auxiliary materials
Model or
Assembling position Position applied by grease
specification
Main shaft oil seal inner lip and outer ring
52
BYD S6, S6A, S6K Service Manual
10. When installing the transmission fasteners, please tighten it according to the following
requirements.
Tightening
Bolt Part number/national Usage for
Part torque
specification standard number unit set
(N·m)
Hex flange bolt M8×25 Q1840825T1F6 2 20
53
BYD S6, S6A, S6K Service Manual
54
BYD S6, S6A, S6K Service Manual
55
BYD S6, S6A, S6K Service Manual
56
BYD S6, S6A, S6K Service Manual
57
BYD S6, S6A, S6K Service Manual
Each gear shifting fork shaft and installation site of the shaft as shown in the Fig.:
2. gear shifting fork shaft for 1st and 2nd gear 8. Reverse gear shaft assembly
3. gear shifting fork shaft for 3rd and 4th gear 9. End face bearing baffle
5. Gear shifting fork shaft for 5th and 6th gear 11. Front box
58
BYD S6, S6A, S6K Service Manual
1. Shock absorber
2. Linear bearing
Note: each gear shifting fork shaft assembly shall not be disassembled.
59
BYD S6, S6A, S6K Service Manual
3. Transmission Mechanism
3.1 Drive Schematic Diagram
60
BYD S6, S6A, S6K Service Manual
1. Main shaft rear bearing outer snap ring 5. Main shaft 5th gear
61
BYD S6, S6A, S6K Service Manual
62
BYD S6, S6A, S6K Service Manual
63
BYD S6, S6A, S6K Service Manual
64
BYD S6, S6A, S6K Service Manual
7. Ta k e d o w n c o u n t e r s h a f t 1 s t g e a r
assembly.
65
BYD S6, S6A, S6K Service Manual
Standard Maintenance
Clearance a
dimension limit
1st/2nd
synchronous 0.75 ~ 1.25mm 0.5mm
ring assembly
3rd
synchronous 0.75 ~ 1.25mm 0.5mm
ring assembly
4th
synchronous 1.0 ~ 1.7mm 0.5mm
ring
5. I f n e c e s s a r y, d i s a s s e m b l e e a c h
synchronizer assembly and check if
each part is abnormally worn.
1) Synchronous spring
2) Slide
4) Synchronous hub
66
BYD S6, S6A, S6K Service Manual
67
BYD S6, S6A, S6K Service Manual
11. S e l e c t a p p r o p r i a t e c o u n t e r s h a f t
rear bearing snap spring and finish
assembling countershaft I assembly.
68
BYD S6, S6A, S6K Service Manual
Front box
Rear box
Countershaft I
h = a’-a+(0.05 ~ 0.1)mm
For example:
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2. Countershaft II front bearing outer ring 15. 5th/6th synchronous hub snap spring
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3. Ta k e d o w n c o u n t e r s h a f t 5 t h g e a r
assembly, 5th gear needle bearing and
5th/6th gear synchronous ring.
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Standard Maintenance
Clearance a
dimension limit
5th gear
synchronous 1.0 ~ 1.7mm 0.5mm
ring
6th gear
synchronous 1.0 ~ 1.7mm 0.5mm
ring
5. I f n e c e s s a r y, d i s a s s e m b l e e a c h
synchronizer assembly and check if
each part is abnormally worn.
1) Synchronous spring
2) Slide
4) Synchronous hub
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Front box
Rear box
Countershaft II
h = a’-a+(0.05 ~ 0.1)mm
For example:
h = a ’ - a + ( 0 . 0 5 ~ 0 . 1 ) m m = 1 . 4 8 + 0 . 0 5 §
1.55mm;
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2. differential adjusting shim 7. differential bearing outer 12. differential planet gear
ring shaft
3. differential bearing outer
ring 8. differential bearing baffle 13. 5X35 carbon steel roll pin
5. Main reducer driven gear 10. differential oil seal 15. differential spherical wash-
(with differential case) er
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Front box
Rear box
Differential case
Differential bearing
h = a’-a+(0.05 ~ 0.1)mm
For example:
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4. Transmission assembly
4.1 Transmission assembly structure
2. gear shifting fork shaft for 1st and 2nd gear 10. T pipe assembly
3. gear shifting fork shaft for 3rd and 4th gear 11. Front box
5. Gear shifting fork shaft for 5th and 6th gear 13. Release bearing unit seal ring
6. Shifting fork assembly for reverse gear 14. Release bearing unit
shaft
15. Mounting bolt of release bearing assem-
7. Main shaft assembly bly
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7. Main shaft rear bearing outer snap ring 14. Mounting bolt of release bearing assembly
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1. Check the magnet. After taking out the magnet, check if there is large iron particle on the
magnet. Attachments on the magnet and particle size are main basis to determine if the
transmission is damaged first time. Before reusing, wipe off the magnet.
2. Replace parts in main shaft assembly. (See 3.2 Disassembling and assembling main shaft
assembly in details)
5. Replace parts in differential components. (See 3.5 Disassembling and assembling differential
assembly)
6. Reverse gear idling gear shaft assembly is not allowed to be disassembled. If maintenance
is required, replace it completely.
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When selecting countershaft I rear bearing adjusting shim, refer to 3.3.5 Countershaft I rear
bearing adjusting shim selection
When selecting countershaft II rear bearing adjusting shim, refer to 3.4.5 countershaft II rear
bearing adjusting shim selection
When selecting differential bearing adjusting shim, refer to 3.5.4 Differential bearing adjusting
shim selection.
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O-ring
Replace Lock pin
Clutch pedal
Adjust
Replace
Pedal in
Clamping ring stop
Replace Main clutch cylinder
Replace
Clutch hose
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3. Adjustment of Clutch Pedal and 1. Tighten the lock nut (D) of the clutch
Bolts push rod.
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4. Pry out the lock pin (A), and then pull out
the pedal pin (B) from the clutch release
fork. Remove the mounting nut (C) of
master cylinder.
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5. Remove the mounting bolt (A) of storage 9. Remove the O-ring (E) and clutch master
tank. cylinder seal (F) from the clutch master
cylinder.
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Pipe fitting
Make sure that the clutch master cylinder
has sufficient brake fluid, and then boost
the clutch pedal slowly until there is no
bubble in the hose.
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7. Replacing Clutch
7.1 Clutch specifications
Basic
Item Specification
Maintenance
Tightening torque
Item Specification
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1. Clutch
Limit: 0.5mm
7.3 Clutch device assembly
2). Check whether the surface of pressure
1. Use dedicated tool (as shown in the pic- plate is worn, and whether there is crack
ture) to keep the clutch friction plate at or discoloration.
appropriate position.
3). Check whether the rivet of the cover
plate is loose, and replace the clutch
cover if yes.
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Limit: 0.15mm
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1. Clamp the flywheel with dedicated tool 2. Measure the axial run-out of the flywheel,
(as shown in the picture). and replace if it exceeds the limit.
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Note:
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1.2.1 Pre-alignment checking (3) Rotate the rack end until the toe is
appropriate.
To check and adjust the wheel alignment
properly, please check the following: Note: Adjust left and right wheels in op-
posite direction with same amplitude to
(1) Release the parking brake to avoid get the appropriate toe and also keep the
improper measurement. steering wheel straight.
(2) Make sure that the suspension isn’t (4) After adjusting, clamp the steering tie
changed. rod, and tighten the lock nut. Make sure
(3) C h e c k t h e t i r e s i z e a n d p r e s s u r e that the toe setting won’t be changed.
according to tire information. 1.2.3 Rear wheel toe adjustment
(4) Check the wheel runout and tire. (1) Use a wrench to loosen the mounting nut
(5) Check ball ends of the suspension. of rear control arm and auxiliary frame.
(Hole wheel with hands, move up and (2) Rotate the eccentric bolt and adjust the
down, left and right, and check its gasket as shown in the picture, and
swing) adjust the tire to get appropriate toe.
Rack end
Lock nut
Pull rod
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Limit: 2.0mm
Rear:
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2. Suspension System
2.1 Replacing front shock absorber column assembly
Torque 50N.m
Bearing
Spring upper
support
Front shock
absorber dust
cover
Torque 80N.m
Torque 230N.m
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Unless the coil spring will be disassem- (4) Unscrew the three nuts in the top of the
bled from the shock absorber assembly, front shock absorber column assembly.
do not loosen or unscrew the spiral nut.
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As shown in the picture, clamp through the 2.1.7 Installing left front shock absorber
double mark bolts of the front shock absorber assembly
column assembly in the bottom bracket.
(1) Install the front shock absorber spring
dust cover on the left front shock
absorber assembly.
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(6) Position with the mark facing to outside 2.1.8 Installing shock absorber assembly
of the vehicle, and install the upper
mounting bracket of the left front shock (1) Position the shock absorber column
absorber spring. assembly on the body.
Torque: 80 N.m
Note:
(7) I n s t a l l a n e w s u s p e n s i o n s u p p o r t
bearing.
Outside Outside
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Front
(5) Tighten the lock nut. Note: If the toe isn’t in specified range, ad-
just the rod end.
Torque: 50 N.m
(3) Adjust the toe; see 1.2.2.
2.1.9 Installing stabilizer bar
(4) Check wheel rotation angle.
Install stabilizer bar with nuts
Torque: 80 N.m
Prompt:
Front
If the ball end hinge follows bolt rotation,
fix it with hex wrench.
A: Inside
B: Outside
Toe: Detector
Locator
A+B (mm)
0±2
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Note:
Keep the vehicle in no-load state while
checking (spare tire and tool box in the
vehicle).
The error of left and right wheel
camber angle and caster angle is not
higher than 30ƍ.
Prompt:
The kingpin caster angle and inclina-
tion can’t be adjusted.
If the measured value isn’WLQVSHFL¿HG
range, please recheck the suspension,
and replace the parts if necessary.
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Torque 50N.m
Steel bushing
Torque 65N.m
Torque
Stabilizer bar 50N.m
Torque 180N.m
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2.2.5 Fixing rear shock absorber column 2.2.7 Checking left rear shock absorber
assembly assembly
Do not damage the stud. (1) Install the buffer on the piston rod.
(2) Compress the coil spring with a spring (2) Install the dust cover as shown in the
clamping device. picture, and pay attention to the groove
mating in the bottom.
Note:
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Lower bracket
Front
Outside
(2) Install the two sets of bolts and nuts in
the bottom of the shock absorber column
(6) Install the steel sleeve to the piston rod. assembly.
After the spring clamping device is re- (3) Install the hose and speed sensor as
moved, check whether the direction of left shown in the picture, and fix with three
rear shock absorber upper support as- bolts.
sembly is appropriate.
Torque: tighten manually
(9) Do not damage the stud, fix the upper
support assembly with a stick, and tight-
en the lock nut.
Torque: 50 N.m
Note:
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Camber angle:
Camber angle
-0°45ƍ45ƍ
Note:
2.2.11 Installing rear wheels
Keep the vehicle in no-load state while
Torque: 120 N.m checking (spare tire and tool box in the
vehicle).
2.2.12 Checking rear wheel positioning
The error of left and right wheel
(1) Shake the vehicle with hands for several camber angle is not higher than 30ƍ.
times to stabilize the suspension. Prompt:
(2) Check the toe Camber angle can’t be adjusted.
If the measured value isn’WLQVSHFL¿HG
Toe:
range, please recheck the suspension,
and replace the parts if necessary.
A+B (mm)
3±2
Front
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Shock absorber
column assembly
Brake assembly
Note: Left/right lower arm should be oper- (3) Remove the front and rear mounting
ated as follows bolts of lower arm and auxiliary frame.
2.3.2 Disassembly 1). Remove front mounting bolt of lower
arm.
(1) Remove the front wheels.
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2.3.3 Assembly
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Brake
assembly
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(3) Remove the brake caliper. 1). Remove the split pin and slotted nut.
Special tool
Remove the two bolts from the brake calipers,
and move the brake caliper away from the
brake disc. (7) Remove the mounting bolts and nuts of
shock absorber and steering knuckle.
Note: Separate the brake caliper, and hang
with a piece of rope or corresponding de-
vice.
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(9) Remove the ball end. Note: If the slot of the slotted nut isn ’ t
aligned to the hole in the ball end, rotate
1). Remove the bolts and nuts. the slotted nut for 60° further.
2). Separate the ball end from steering (2) Install the steering knuckle and ball end
knuckle with special tool. to the axle together.
Note: Do not damage the ball end dust
cover while installing.
Special (3) Install the connecting bolt and nut of
shock absorber and steering knuckle,
and tighten with 180N.m torque.
2.4.2 Checking
2.4.3 Assembly
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(6) Fix the axle on the wheel hub. Note: Avoid foreign substances adhering
to the sensor.
1). Use sleeve to install a new axle nut, and
tighten with 220N.m torque. (9) Install the front wheels, and tighten with
120N.m torque.
2). Use a new bolt
2.4.5 Checking front wheel positioning
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Rear control
Eccentric arm assembly
Hex flange bolt
bolt 115N.m 115N.m
Brake assembl
y
Rear auxiliary
frame assembly
Left/right traction arm
assembly
Hex flange bolt 90N.m
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2.5.2.3 Front control arm disassembly (2) Remove the mounting bolt and nut of
rear control arm and auxiliary frame.
(1) Remove the mounting bolt of front con-
trol arm and steering knuckle.
2.5.3 Assembly
Note: When remove the hex bolt and Note: While installing, fix the eccentric
flat washer combination, fix the nut with bolt with wrench, rotate the eccentric nut
wrench to prevent the nut from rotating and prevent the bolt rotating along with
with the bolt. the nut. The eccentric bolt and eccentric
nut should be on the same side.
2.5.2.4 Rear control arm disassembly
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(2) Install the mounting bolt and lock nut of 2.5.3.3 Traction arm assembly
rear control arm and steering knuckle,
and tighten with 115N.m torque. (1) Install the connecting bolt and nut of the
traction arm and body, and tighten with
115N.m torque.
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Shock absorber
column assembly
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(4) Lower the front auxiliary frame; see (3) Install the upper and lower bracket of
Front Auxiliary Frame Disassembly for front stabilizer bar, and tighten with
details. 20N*m torque.
Front
Inside
Limit ring
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2.7.2 Disassembly
Torque: 1.0N*m
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(4) Remove the right fixation bracket I (7) Remove the left fixation bracket I
assembly of the rear stabilizer bar assembly of the rear stabilizer bar
(6) Remove the left fixation bracket II of the (9) Take out the rear stabilizer bar from the
rear stabilizer bar bush
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2.7.3 Assembly
Front
Outside
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Nut
Left front mounting Right front
bracket mounting bracket
Bolt
Bolt
Front Bolt
Bolt auxiliary
frame
Left arm
Right arm
Nut
Bolt
2.8.2 Disassembly
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(1) Remove the split pin Fig. 5-1 Front Mounting Bolt
(2) Remove the slotted nuts
(3) Separate the steering tie rod ball end Fig. 5-2 Rear Mounting Bolt
and knuckle with special tool (if not
10. Remove the auxiliary frame mounting
available, knock at the knuckle with a
bracket and body connecting bolt
hammer to pull out the ball end)
(1) Hold the auxiliary frame with a small
8. Remove the mudguard
hoisting gear
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11. Remove the front/rear mounting bolt of 16. Remove the steering gear
auxiliary frame
2.8.3 Checking
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2. Install the stabilizer bar and bushing 5. Install the limit bushing (press down
on the opposite position of the auxiliary and rotate the limit bushing until the
frame. limit bushing and auxiliary frame fit
completely)
3. Install the stabilizer bar and bracket
bolts, and tighten with 20N.m torque.
(2) I n s t a l l a u x i l i a r y f r a m e a n d b o d y
connecting bolt, and tighten with 150 N.m
torque
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2.9.1 Composition
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ABS system is related to personal safety.So when repairing and diagnosing ABS system, you
shall follow the precautions below in addition to general safety and precaution procedures.
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(6) A B S h y d r a u l i c a d j u s t o r w i t h E C U
4 Fixing includes components as following:
ABS Control Unit
(with reflux pump ķ ABS ECU: with reflux pump motor relay
motor and solenoid and solenoid valve relay
valve relay)
8 Solenoid
Valves (4
ĸ Solenoid valves (8) : 4 oil inlet valves
filling valves and 4 oil outlet valves
and 4 outlet
values) Hydraulic
Pressure Ĺ Reflux pump and pressure accumulator.
Reflux Pump Controller
ĺ Others: motor, bolts, etc.
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2. Diagnosing Procedures
2.1 ABS with EBD
Diagnosing procedures
No DTC Go to step 9
5 Confirm and make fault reappear: simulate state of fault. Reread DTC.
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Inspector_________
Telephone
Chassis number
number
Occurrence
/ /
Date
Fault details
Frequency Ƒ Often Ƒ Occasionally ( Times / day)
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It means check of components which are easy to access and may cause faults in ABS.
Visual check and appearance check is helpful to locate faults quickly, so further diagnosis is not
needed sometimes.
Fuse
Blown Fuse
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Please refer to “Set up / Cancel Speed Limit of Diagnostic Communication” if you want to cancel
speed limit.
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Value/Range
Type Item Normal State Notes:
Displayed
Left front wheel speed 0 ~ 350 km/h Actual wheel speed
Wheel Left rear wheel speed 0 ~ 350 km/h Actual wheel speed
speed
signal Right front wheel speed 0 ~ 350 km/h Actual wheel speed
γ : When speed is less than 2.6 km/h or when vehicle is still, 0 km/h will be displayed on
diagnosis instrument.
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Read the data stream Wheel speed signal Read the data of wheel speed
sensor signal.
Ĝ 1. Wheel speed signal Left front wheel speed: 8.2 km/h Notes:
Ƒ 2. Analog quantity state Right front wheel speed: 8.2 km/h 1. Please refer to page 34 for “Set
Ƒ 3. Digital quantity state Left rear wheel speed: 8.2 km/h / Cancel Speed Limit on Diag-
Ƒ 4. Filling state of hydraulic unit Right rear wheel speed: 8.2 km/h nostic Communication”
Press [ Ĺ ] button to move up 2. *When speed is less than 2.6
Press [F2] button to print current km/h or when vehicle is still,
Press [ Ļ ] button to move down
page 0 km/h will be displayed on
Press [OK] button to perform
Press [ESC] button to back diagnosis instrument.
Press [ESC] button to quit
Read the data stream Analog quantity state
Ƒ 1. Wheel speed signal
Read the data of analog quantity
Ĝ 2. Analog quantity state
Battery voltage: 12.2 V state.
Ƒ 3. Digital quantity state
Normal value: 9.3 V ~ 17.5 V.
Ƒ 4. Filling state of hydraulic unit
Please refer to system fault ˖
Press [ Ĺ ] button to move up Voltage is out of range.
Press [F2] button to print current
Press [ Ļ ] button to move down
page
Press [OK] button to perform
Press [ESC] button to back
Press [ESC] button to quit
Read the data stream Digital quantity state
Left front oil inlet valve: Off
Left front oil outlet valve: Off
Right front oil inlet valve: Off
Right front oil outlet valve: Off
Ƒ 1. Wheel speed signal
Left rear oil inlet valve: Off
Ƒ 2. Analogue state
Left rear oil outlet valve: Off Read data of digital state.
Ĝ 3. Digital state
Right rear oil inlet valve: Off Normal value: please refer to page
Ƒ 4. Filling state of hydraulic unit
Right rear oil outlet valve: Off 11.
Brake light state: On
Reflux pump motor state: On
Solenoid valve relay state: On
Press [ Ĺ ] button to move up
Press [F2] button to print current
Press [ Ļ ] button to move down
page
Press [OK] button to perform
Press [ESC] button to back
Press [ESC] button to quit
Read data on filling state of
Read data stream Filling state of hydraulic unit
hydraulic unit.
Ƒ 1. Wheel speed signal Now 5 states may be displayed:
Ƒ 2. Analogue state Filling state of hydraulic unit: filling ķ Filling has not completed;
Ƒ 3. Digital state completed normally. ĸ Invalid value – value with wrong
Ĝ 4. Filling state of hydraulic unit memory;
Ĺ New ABS hydraulic unit;
ĺ Filling completed normally;
Ļ Filling completed abnormally.
“New ABS Hydraulic Unit” will be
Press [ Ĺ ] button to move up displayed for new ABS hydraulic
Press [F2] button to print current
Press [ Ļ ] button to move down unit with ECU.
page
Press [OK] button to perform If “Invalid Value – Incorrect Value in
Press [ESC] button to back
Press [ESC] button to quit Memory” is displayed, ABS memory
has been damaged.
Please refer to page 35 to alter
filling state.
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Notes:
BOSCH ABS8 system Release test routines
When hydraulic brake pipe
1 Read computer version has been opened or dry ABS
hydraulic adjustor with ECU has
2 Read system fault
been replaced, exhausting is
3 Clear DTC required.
4 Read data stream
During brake exhausting, brake
5 Release test routines fluid in fluid reservoir may
6 Set up / cancel speed Ĝ 1. Evacuation and filling test reduce fue to outflow of brake
limit on diagnostic Ƒ 2. Brake exhaust ÀXLG0DNHVXUHWKHUHLVHQRXJK
communication Ƒ 3. Dynamic test brake fluid during the whole
7 Alter filling state Ƒ 4. Action test process.
Notes: Ƒ 5. Wheel speed sensor test At least two service men are
Communication between needed in this process. One
diagnosis instrument and ABS supplement brake fluid to
ECU will be cut off forcibly for break fluid reservoir on the
safety when speed exceeds ground, the other processes
a certain value under normal the diagnosis instrument
state. communication and depresses
the brake pedal on the lifted
vehicle.
Change the gear to P (AMT
model) or N (MT model) and
apply parking braking before
exhausting.
Brake fluid is poisonous. If
brake fluid spills on your skin
accidentally, you must wash it
immediately.
Regular exhausting method
Press [ Ĺ ] button to move up Press [ Ĺ ] button to move up is adopted usually. Automatic
Press [ Ļ ] button to move down Press [ Ļ ] button to move down exhausting procedure is
Press [OK] button to perform Press [OK] button to perform recommended when any of
Press [ESC] button to quit Press [ESC] button to quit the following circumstances
happens:
ķ Regular brake system exhausting
has not reach the best pedal height
and foot feeling;
ĸ Severe shortage of brake fluid;
Ĺ Auxiliary oil passage of hydraulic
adjustor assembly may have air
lock. Diagnosis instrument is
adopted to evacuate only when air
in brake pipe can not be evacuated
completely by regular method.
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4.3.5.2.1 Preparation
(3) C o n n e c t d i a g n o s i s i n s t r u m e n t t o
diagnostic communications link.
Normal
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Next Step
4.3.5.2.3 Exhausting of the first loop using left rear wheel exhaust screw
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Next Step
4.3.5.2.4 Exhausting of the first loop using left front wheel exhaust screw
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Next Step
4.3.5.2.5 Exhausting of the first / second loop using right front wheel exhaust screw
(1)S e r v i c e m a n i n t h e
Right front wheel brake exhausting vehicle presses [OK]
button:
Press [OK] button and at the same time loosen left front wheel cylinder exhaust The repairman outside the
screw. vehicle shall loosen the
Notes: Brake pedal may vibrate violently in this process, which is normal. right front wheel cylinder
Please continue to depress and then release the brake pedal. exhaust screw immediately.
Press [OK] button to perform
Press [ESC] button to quit
(2)N o w b e g i n t h e t h i r d
Right front wheel brake exhausting stage:
Exhausting of the first /
Right front wheel is exhausting… second loop using right
Please wait for 99 S front wheel exhaust screw
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Next Step
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4.3.5.2.6 Exhaustiasang first / second loop by right rear wheel exhaust screwa
(1)S e r v i c e m a n i n t h e
Right rear wheel brake exhausting vehicle presses [OK]
button:
Press [OK] button and at the same time loosen left front wheel cylinder exhaust The repairman outside the
screw. vehicle shall loosen the
Notes: Brake pedal may vibrate violently in this process, which is normal. right front wheel cylinder
Please continue to depress and then release the brake pedal. exhaust screw immediately.
Press [OK] button to perform
Press [ESC] button to quit
(2)N o w b e g i n t h e t h i r d
Right rear wheel brake exhausting stage:
Exhausting of the first /
Right front wheel is exhausting… second loop using right
Please wait for 79 S rear wheel exhaust screw
Next Step
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Next Step
Left-front Left-rear
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Check:
ķ Wheel speed sensor body
ĸ Wheel speed sensor is wrongly connected
Ĺ Interference on signal of wheel speed sensor
Press [F2] button to print current page ĺ The clearance between wheel speed sensor and
Press [OK] button to the next step. gear ring is too big (caused by vibration)
Press [ESC] button to quit Ļ Corrosion on wheel speed sensor and support
ļ Fault on gear ring (it is dirty or gear teeth were
damaged)
Ľ Tyre: size, air pressure, tread patterns and depths.
ľ Brake testbed: drive mechanism, roller state, etc
Press [OK] to perform Left rear wheel: 1000 N < F < 1500 N
Press [ESC] to exit
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Brake Pedal:
rear wheels in ABS works normally.
Push down harder
ABS Hydraulic Unit Status: Press [OK] button to the next
Left-rear Wheel: pressure increase Normal
Right-rear Wheel: pressure increase step
Observe the indicating value of brake force
Left-rear Wheel: 1000N<F<1500N
Right-rear Wheel:1000N<F<1500N
Abnormal Press [ESC] button to quit
Check:
Press [OK] to take the next step
Press [ESC] to exit
(1) ABS hydraulic unit with ECU
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BYD S6, S6A, S6K Service Manual
Check:
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BYD S6, S6A, S6K Service Manual
3UHVV>Ĺ@WRPRYHXS 3UHVV>Ĺ@WRPRYHXS
3UHVV>Ļ@WRPRYHGRZQ 3UHVV>Ļ@WRPRYHGRZQ
3UHVV>2.@WRSHUIRUP 3UHVV>2.@WRSHUIRUP
3UHVV>(6&@WRH[LW 3UHVV>(6&@WRH[LW
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BYD S6, S6A, S6K Service Manual
Preconditions:
Components Motion Test ABS Warning Light
Normal:
Abnormal:
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BYD S6, S6A, S6K Service Manual
Normal:
Abnormal:
Normal:
Abnormal:
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BYD S6, S6A, S6K Service Manual
Normal:
Abnormal:
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BYD S6, S6A, S6K Service Manual
Functions:
Bosch ABS8 System Release Test Routines
1. Read computer versio n
2. Read system fault
Ƒ
Ƒ
1. Evacuation and filling test
2. Brake exhaust
The test can detect mechanical faults of
3. Clear DTC
4. Read data stream
ĺ5. Release test routines
Ƒ 3. Dynamic test gear ring, such as gear clearance fault, gear
Ƒ 4. Motion test
6. Set/cancel the speed restriction
of diagnostic communication
¥ 5. Wheel speed sensor test fault, by changes in each signal produced by
7. Alter filling status
Notes: under normal conditions the
calculation.
communication between diagnostic
scanner and ABS ECU will be forced to
cut off for safety when the car spee d (1) C o n n e c t d i a g n o s i s i n s t r u m e n t t o
exceeds a certain speed.
diagnostic communications link.
Press [Ĺ] to move up Press [Ĺ] to move up
Press [Ļ] to move down Press [Ļ] to move down
Press [OK] to perform
Press[ESC] to exit
Press [OK] to perform
Press[ESC] to exit (2) Turn on ignition switch, and ECU begins
to initialize. Read the DTC
Brake Testbed
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Brake Testbed
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Tyre diameter
Press [F2] to print the current page
Press[ESC] to return Wheel hub bearing clearance
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Functions:
Bosch ABS8 System Set/Cancel the Speed Restriction of
Diagnostic Communication
1. Read computer version Notes: under normal conditions the
When speed is over 10 km/h, diagnosing
2. Read system fault communication between diagnostic scanner and
3. Clear DTC ABS ECU will be forced to cut off for safety on ABS ECU is not allowed for the sake of
4. Read data stream when the car speed exceeds a certain speed.
5. Release test routines This function can not only achieve to cancel this safety.
ĺ6. Set/cancel the speed restriction of restriction but also read the wheel speed signal
diagnostic communication after the speed exceeds its limits. But, ABS will
stop running. Then the safety performance will
7. Alter filling status
Notes: under normal conditions the
be lowered. If some special repair or diagnosis is needed,
Are you sure to continue this test?
communication between diagnostic
scanner and ABS ECU will be forced to
Notes: when it exits from the diagnosis, the the
speed restriction of diagnostic communication
you can cancel this limit.
cut off for safety when the car speed will be restored automatically DŽ
exceeds a certain speed.
Special notes: improper operation may
Press Ĺ]
[ to move up
Press Ļ]
[ to move down
Press [OK] to cancel the speed restiction of
diagnostic communication result in severe accidents after this limit is
Press [OK] to perform Press [ESC] to restore the speed restiction of
Press[ESC] to exit diagnostic communication canceled. Therefore, enough safety mea-
sures and open test area are indispens-
able.
Setting:
Set/Cancel the Speed Restriction of
Press [OK] button to cancel speed limit on
diagnostic communication
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BYD S6, S6A, S6K Service Manual
Notes:
BOSCH ABS8 system Modify filling state
1. Read computer version ĺ New ABS hydraulic unit Ɨ This job must be done after replacing ABS
2. Read system fault Already filling complete and normal
3. Clear DTC Already filling complete but abnormal hydraulic adjustor with ECU, otherwise it’ll
4. Read data stream
5. Release test routines result to unexcepted fault.
6. Set up / cancel speed limit on
diagnostic communication
ĺ7. Alter filling state
Ƙ It’s only allowed to be rewrited from “New
Notes:
Communication between diagnosis
ECU”to “Already filling complete and normal”,
instrument and ABS ECU will be cut off
forcibly for safety when speed exceeds a
but can’t reverse rewrite.
certain value under normal state.
3UHVV>Ĺ@WRPRYHXS
3UHVV>Ļ@WRPRYHGRZQ
3UHVV>2.@WRSHUIRUP Press any bottom to go on
3UHVV>(6&@WRH[LW
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3UHVV>Ĺ@WRPRYHXS
3UHVV>Ļ@WRPRYHGRZQ
3UHVV>2.@WRSHUIRUP Press any bottom to go back
3UHVV>(6&@WRH[LW
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BYD S6, S6A, S6K Service Manual
5. DTC Table
Note:
Notes:
If no fault is diagnosed on components, you need to check ABS hydraulic adjustor with
ECU and its grounding places or power wires.
If DTC is memorized, check the circuit indicated by it. Please refer to corresponding sec-
tion for detailed repair steps of each DTC.
If more than two DTC are memorized, check the one and its circuit relating to fault appear-
ance first.
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6. Components Location
Illustration
(5) ABS control unit (fastened on hydraulic (11) Diagnostic communications link
adjustor)
(6) Brake hose
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ECU side K2
Wire side
JC24
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Turn on
ignition 0.5V or 1V
switch, static
R.L wheel Turn on
20 WS_RL DSHL speed sensor Y/R GND(38) ignition
- signal switch, Turn 0.5V to 1V
a circle per leap
second by
hand
Turn on
ignition 0.5V or 1V
switch, static
F.R wheel Turn on
22 WS_FL DSVL speed sensor Br/W GND(38) ignition
-signal switch, turn 0.5V to 1V
a circle per leap
second by
hand
12V
continuous
25 UBVR UBVR W MGND(13) All 9.3~16.9V
power supply
- 25A fuse
Wheel speed
27 DFAVR DFAVR sensor signal W/L
output-F.R
Turn on
ignition
switch, step 9.3~16.9V
down brake
Brake light pedal
30 BLS BLS W/B GND(38)
switch (+) Turn on
ignition
switch, § 0V
loosen brake
pedal
Turn on
ignition 0.5V or 1V
switch, static
R.R wheel Turn on
WS_
31 DSHR speed sensor Lg/Y GND(38) ignition
RR
- signal switch, turn 0.5V to 1V
a circle per leap
second by
hand
Ignition Turn on
32 VIGN UZ switch battery B/R GND(38) ignition 9.3~16.9V
- DIN 15 switch
R.L wheel Turn on
33 WP_RL DPHL speed sensor R GND(38) ignition 4.5V~20V
- battery switch
F.L wheel Turn on
34 WP_FL DPVL speed sensor L/W GND(38) ignition 4.5V~20V
- battery switch
Battery
Grounding -
38 GND GDN B negative All <0.5V
ABS ECU
electrode
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Oil Inlet
Oil Inlet Valve EV Oil Inlet Valve EV Oil Inlet Valve EV
Wheel
Wheel Cylinder RZ Wheel Cylinder RZ Wheel Cylinder RZ Cylinder RZ
Rear-left Wheel Cylinder RL Front-right Wheel Cylinder FR Front-left Wheel Cylinder FL Rear-right Wheel Cylinder RR
Brake Pedal
Vacuum Booster
Brake Fluid Container
Wheel Speed
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8. Symptom of Fault
8.1 Table of Fault Symptom
If fault appears even if there is no fault memory, please check the circuit associated with each
fault symptom in the sequence in the following table and refer to corresponding diagnosing sec-
tion.
Note:
Make sure regular braking system is in normal work before repairing ABS.
Ignition switch should be turned off before replacing ABS hydraulic adjustor with ECU,
sensor or other components.
Symptom of
Checking area
fault
If fault remains even if the following items 1 - 4 are normal, ABS hydraulic adjustor with
ECU shall be replaced:
1. Read DTC and confirm fault memory
ABS dose not 2. Circuit of ignition switch power supply UZ (Pin 32)
work
3. Circuit of wheel speed sensor
4. Test ABS with diagnosis instrument. If it is abnormal, test whether there is leakage in
brake pipe
If fault remains even if the following items 1 - 4 are normal, ABS hydraulic adjustor with
ECU shall be replaced:
1. Read DTC and confirm there is no fault memory
2. Circuit of wheel speed sensor
ABS works poorly 3. Test ABS with diagnosis instrument. If it is abnormal, test whether there is leakage in
brake pipe
4. Read “Filling state of hydraulic adjustor” by diagnosis instrument
5. Make sure installing support is fixed properly (now the driving comfort decreases)
3. Diagnosis instrument
Notes:
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BYD S6, S6A, S6K Service Manual
Check Operation
Firstly make primary check
Collect the information about intermittent fault from the customers, for example:
- What’s the speed range when fault appears?
- Whether fault appears when using electrical devices added after sale?
- Whether fault appears on rugged or wet road?
- If fault on wheel speed sensor appears only on wet road, then check whether water
Primary
penetrates the circuit of wheel speed sensor. If DTC does not appear, make following
check
operations to simulate wet road condition:
1. Mix two teaspoons of salt with 35 ml water.
2. Spray the salty water onto the suspected part.
3. Test the vehicle on road under different road conditions.
4. Keep the speed over 40 km/h for at least 30 minutes.
5. If the suspected wheel speed sensor has set the current DTC, refer to the corresponding
DTC diagnosing table.
Test on intermittent fault with diagnosis instrument as following:
Shake the wire harness and connector of suspected ABS components by your hands, and
observe the data stream of the tested circuit displayed on the diagnosis instrument. If there
is fluctuation in reading on diagnosis instrument, check whether the circuit connection is
loose.
Test with
Test the vehicle on road in the condition when there is intermittent fault, and let the assistant
diagnosis
observe the suspected data displayed on diagnosis instrument.
instrument
When fault appears, capture it in snapshoot mode and store the data. The stored data
cab is played at a lower speed to assist diagnosing. You can also test the signal with
oscillograph.
Test the action of the suspected ABS components by the component test function of
diagnosis instrument.
The following circumstances may result in intermittent lighting of warning light without DTC.
Electromagnetic Interference (EMI) caused by component with fault (eg: relay).
Abnormality or wrong location of electrical devices added after sale, for example:
- Mobile phone
- Anti-theft warning device
Warning light - Light
- Wireless device
- Audio amplifier
The circuit of warning light is short to ground intermittently.
The grounding point of ABS hydraulic adjustor with ECU or instrument is loose.
The rotating speed is low.
Make a visual check on wheel speed sensor and magnetic ring to find whether they
are loose, damaged, having foreign matters, or installed improperly. Replace damaged
components, clear all the foreign matters and fix the loose components, if any.
Wheel speed Check whether the wring of front wheel speed sensor is proper. Make sure the wire harness
sensor of front wheel speed sensor is not very close to distributor.
Observe the data of wheel speed sensor displayed on the diagnosis instrument and road
test the vehicle with the help of assistant. Test whether there is any wheel speed sensor
displaying abnormal speed range.
Test whether electrical devices added after sale is properly installed. For example:
- Mobile phone
- Anti-theft warning device
- Light
- Wireless device
- Stereo amplifier
Additional
Test whether there is electromagnetic Interference (EMI) caused by components with faults
test
(eg: when the power of relay or solenoid coil is on).
Test the air condition compressor clutch and relays including catching diode or resistor
when the power of relay or solenoid coil is on.
Test whether there is fault on rectifier bridge of generator when the power of relay or
solenoid coil is on. Such fault will make the noise of air conditioner enter the circuit of
electronic control unit.
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9. DTC Diagnosing
Circuit notes:
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BYD S6, S6A, S6K Service Manual
Test
DTC Setting conditions Possible fault section
conditions
ķ Monitor whether the power supply voltage of
sensor is too low
All the working
ĸ Monitor whether the signal wire of sensor is
conditions after
normal
ignition switch is
Ĺ When the vehicle speed is over 2km/h, the
turned on
speed signal of wheel with fault can not be
detected
ķ At least one wheel has a speed exceeding
reference speed by 5 km/h for more than 18s
ĸ Speed difference between wheels on the
Wheel speed
same side (for example: left front and left
monitoring
rear) is over 6 km/h, speed difference
1. Reference
between wheels on the same shaft (for
speed: 2~100 ķ Wheel speed sensor
example: left front and right front) is over 10
km/h body
km/h, or speed difference between diagonal
wheels (for example: left front and right rear) ĸ Wheel speed sensor is
is over 14 km/h wrongly connected
ķ Speed difference between wheels on the Ĺ Interference on signal of
C0031 same side exceeds reference speed by 6 %, wheel speed sensor
C0032 2. Speed or speed difference between wheels on the ĺ The clearance between
CO034 reference > same shaft exceeds reference speed by 6% + 4 wheel speed sensor
C0035 100 km/h km/h, and gear ring is too big
C0037 or speed difference between diagonal wheels (caused by vibration)
C0038 exceeds reference speed by 6% + 8km/h. Ļ Corrosion on wheel
C003A speed sensor and
ķ If there is fault signal on one or two wheel
C003B support
speed sensors, the fault is detected after 20s
CO245 ļ Fault on gear ring (it is
(when brake pedal is depressed) or 5s (when
Long-term dirty or gear teeth were
brake pedal is not depressed)
monitoring damaged)
ĸ If there is fault signal on three or four wheel
Ľ Tyre: size, air pressure,
speed sensors at the same time, the fault is
tread patterns and
detected after 1s
depths.
Wheel slip
monitoring The absolute speed difference between the
1. Speed < 50 fastest and the slowest wheel is over 3 km/h
km/h The absolute speed difference between the
2. Speed > 50 fastest and the slowest wheels is over 6%
km/h
Gear ring When speed is 10~80 km/h and ABS dose not
monitoring work, the connecting wire of wheel speed sensor
For example: is indicated to be broken for each revolution and
missing teeth it continues for over 6 rounds
If speed > 43 km/h, no wheel speed signal has
Dynamic
been received for 10 ~ 20 ms within a time
monitoring
period of 60 ms
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Test
DTC Setting conditions Possible fault section
conditions
When any of the following faults exists
C0031 ķ Socket connector is defective, dirty, or
more than 200 ms:
C0032 damp
All the ķ The connecting wire between
CO034 ĸ Connecting wire and socket connector
working sensor and ground or power supply
C0035 of wheel speed sensor is loose or
conditions is in broken or short circuit
C0037 broken.
after ignition ĸ The socket connector of sensor is
C0038 Ĺ Connecting wire between sensor and
switch is loose
C003A ground is in short circuit
turned on Now the wheel speed sensor current is
C003B ĺ Insulation layer of connecting wire of
out of range:
CO245 the sensor has been damaged
Current < 1.1 mA or > 39 mA
Ground
Battery
Fuse 25A
Ground
Wiring Terminal 15
Fuse 15A
Right-front
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Notes:
If you turn on ignition switch again after fault has been cleared but DTC has not been
cleared, the warning light will be off only when the speed is over 12 km/h.
If more than one fault has been detected, the TDC having the highest priority level
ZLOOEHGLVSOD\HG¿UVWO\7KHQH[W7'&KDYLQJWKHVHFRQGKLJKHVWSULRULW\OHYHOZLOOEH
GLVSOD\HGDIWHUWKH¿UVWIDXOWKDVEHHQVROYHG
If power supply voltage is lower than 7.1 V or more than 17.4 V, system would stop
monitoring wheel speed sensor.
1 Fault confirming
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Yes Go to step 11
No Go to step 4
3 Appearance checking
Normal value:
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Yes Go to step 10
Normal Go to step 8
Normal: 3 Mȍ ~ 5 Mȍ
Normal
Replace wheel speed sensor
Abormal
and reconfirm fault
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6 Make sure the connecting wire of wheel speed sensor is properly connected
Normal: § 0ȍ
Pin of
Wheel
ABS
speed
Location Function hydraulic
sensor
adjustor
pin
with ECU
Signal 22 1
Left front
wheel Power
34 2
supply
Signal 6 1
Power 18 2
Signal 20 1
Power
33 2
supply
Signal 31 1
Right rear
wheel Power
19 2
supply
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BYD S6, S6A, S6K Service Manual
Output Signal: low voltage 0.44V-0.63V, high voltage 0.89V-1.26V Waveform introduction:
Low
Speed
Lift the vehicle, turn the wheel by hand at
Driving
some 1 round/second (around 2 km wheel
Output Signal: low voltage 0.44V-0.63V, high voltage 0.89V-1.26V
High speed), the waveform displayed is as shown
Speed
in the figure.
cell Per cell Waveform displayed when speed is 30 km/h.
The quicker speed, the higher frequency
Normal
Waveform
Notes:
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Normal
Normal
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BYD S6, S6A, S6K Service Manual
Normal
Normal
(2) (Except DTC C0245) driving the vehicle on a straight road at the speed over 30 km for at
least 10 s after the ignition switch is on for 30 s.
(DTC C0245) Drive the vehicle from still to 60 km/h, or drive it at the speed of over 30 km/h for at
least 7s.
After the normal driving, turn off the ignition switch and turn on it again to make sure there is no
DTC memorized by ABS after 30 s.
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DTC CO010 Fault on circuit of left front oil outlet valve of hydraulic adjustor
DTC CO011 Fault on circuit of left front oil inlet valve of hydraulic adjustor
DTC CO014 Fault on circuit of right front oil outlet valve of hydraulic adjustor
DTC CO015 Fault on circuit of right front oil inlet valve of hydraulic adjustor
DTC CO018 Fault on circuit of left rear oil outlet valve of hydraulic adjustor
DTC CO019 Fault on circuit of left rear oil inlet valve of hydraulic adjustor
DTC CO01C Fault on circuit of right rear oil outlet valve of hydraulic adjustor
DTC CO01D Fault on circuit of right rear oil inlet valve of hydraulic adjustor
Notes on circuit:
After the ignition switch is turned on, solenoid valve relay of ABS hydraulic unit with ECU
will be connected power to provide battery voltage to one end of hydraulic adjustor so-
lenoid valve. The power of solenoid valve relay remains on unless the ignition switch is
turned off and ABS is disabled.
Functions:
ABS ECU controls the working of solenoid valves through controlling their grounding to adjust the
braking pressure of each brake circuit.
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Circuit
ABS Hydraulic Pressure Regulator with ECU
Diagram:
Ground
Battery
Fuse 25A
Solenoid Valve
Relay Control
Solenoid Valve
Voltage Oil Inlet Valve
Left Front
Oil Outlet Valve
Right Front
Oil Outlet Valve
Left Rear
Oil Outlet Valve
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BYD S6, S6A, S6K Service Manual
1 Check vehicle with ABS hydraulic adjustor with ECU when it is still
Abormal Go to step 3
Normal
2 Test the solenoid valve components of ABS hydraulic adjustor with ECU by diagnosis
instrument
Next Step
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3 Check the voltage of pin of ABS hydraulic adjustor with ECU (voltage of pin 25)
If multimeter is used:
Connection
(1) Turn off the ignition switch
Abnormal
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(2) Check charging system: generator / battery and the connecting wires
Normal
5 Final check
(2) Warning lights of ABS and braking system will be off within a short time after the ignition
switch is turned on
(4) Go to step 2 of this diagnosing procedure and the test result shall be normal
DTC CO020 Fault on reflux pump motor: can not work or can not stop working
Notes on circuit:
ABS hydraulic unit with ECU integrates reflux pump and its motor. When ABS is not in ad-
justment, reflux pump relay would stop working and reflux pump would be still. When ABS
is in pressure-reducing adjustment, ABS ECU controls the working of reflux pump motor
through controlling the grounding of reflux pump relay.
Functions:
ABS pressure reducing stage: reflux pump pumps the brake fluid in the brake wheel cylinder of
locked wheels to the pipe of brake master cylinder, reducing the pressure in brake wheel cylinder.
EBD pressure reducing stage: pressure accumulator stores the brake fluid from rear wheels. But
if pressure accumulator is full of brake fluid and the deceleration of rear wheels is larger than that
of front wheels, ABS ECU will controls the reflux pump action to pump extra brake fluid into the
pipe of brake master cylinder.
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Notes:
When the faults have been solved, turn on ignition switch again and drive the vehicle at a
speed over 12 km/h, warning lights of ABS and braking system will be off automatically.
Circuit diagram
Ground
Battery Fuse 40A
Reflux Pump Motor Relay
Ground
Reflux Pump Motor
Wiring Terminal 15 Relay Voltage
(ignition switch power) Fuse 15A
Solenoid Valve
Relay Control
Reflux Pump
Motor Control
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BYD S6, S6A, S6K Service Manual
1 Check vehicle with ABS hydraulic adjustor with ECU when it is still
Abormal Go to step 4
Normal
2 Procedure check for initializing self examination on ABS hydraulic adjustor with ECU
Abnormal
No Go to step 4
Normal
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3 Test the components of ABS hydraulic adjustor with ECU by diagnosis instrument
4 Check the voltage of pin of ABS hydraulic adjustor with ECU (voltage of pin 1)
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4 Check the voltage of pin of ABS hydraulic adjustor with ECU (voltage of pin 1)
If multimeter is used:
Connection side
Abnormal
(2) Check charging system: generator / battery and the connecting wires
Normal
6 Final check
(2) Warning lights of ABS and braking system will be off within a short time after the ignition
switch is turned on
(3) DTC C0110 will not appear after ignition switch is turned on for 30s.
(4) Drive at the speed of 10 ~ 15 km/h, and do not depress brake pedal. C0110 DTC does not
appear
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Notes on circuit:
When ignition switch is turned on, solenoid valve relay of ABS with hydraulic adjustor will
be connected to power, providing battery voltage to one end of hydraulic adjustor solenoid
valve.
The power of solenoid valve relay remains on unless the ignition switch is turned off or
ABS is disabled.
Functions:
ABS ECU controls the working of solenoid valves through controlling their grounding to adjust the
braking pressure of each brake circuit.
Test
DTC Setting conditions Possible fault section
conditions
“Solenoid voltage” detected short circuit to
Turn on ķ “Circuit of solenoid valve relay”
Uz or ground, or broken circuit, or fuse is
ignition switch in ABS
burned.
C0121 and test fault ĸ Power supply is not normal
“Solenoid valve voltage” detected the sole-
when ABS is Ĺ Short circuit
noid voltage is less than <0.8*Uz( § 8.0V)
working ĺ Circuit
for over 0.8 s
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Ground
Battery
Fuse 25A
Solenoid Valve
Relay Control
Solenoid Valve
Voltage Oil Inlet Valve
Left Front
Oil Outlet Valve
Right Front
Oil Outlet Valve
Left Rear
Oil Outlet Valve
Right Rear
Oil Outlet Valve
1 Check vehicle with ABS hydraulic adjustor with ECU when it is still
Abormal Go to step 3
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BYD S6, S6A, S6K Service Manual
Normal
2 Test the solenoid valve components of ABS hydraulic adjustor with ECU by diagnosis
instrument
Next Step
3 Check the voltage of pin of ABS hydraulic adjustor with ECU (voltage of pin 25)
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If multimeter is used:
Connection
side (1) Turn off the ignition switch
Abnormal
(2) Check charging system: generator / battery and the connecting wires
Abnormal
5 Final check
(2) Warning lights of ABS and braking system will be off within a short time after the ignition
switch is turned on
(3) DTC C0121 will not appear after ignition switch is turned on for 30s.
(4) Go to step 2 of this diagnosing procedure and the test result shall be normal
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Circuit Description :
When brake pedal is stepped down, the switch is closed. Brake light switch provides +12V for
brake light signal circuit BLS.
Signal VoltageDŽ
ABS ECU monitors brake light switch signal voltage to make sure brake engaging time, and
monitors brake light switch circuit.
Circuit Diagram:
Grounding
Grounding
Terminal 15
(Ignition switch
power) Fuse 15A
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BYD S6, S6A, S6K Service Manual
Normal
2 Check ABS hydraulic pressure adjustor stitching voltage with ECU (voltage of stitching 30 vs
stitching 38 )
(4) M e a s u r e b r a k e l i g h t s w i t c h w i t h
multimeter to mesure the voltage
between brake light switch terminal and
grounding terminal (38).
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Normal
Relace ABS with hydraulic
pressure adjustor
Abnormal
3 Check connecting line and connector (Brake light switch to ABS hydraulic pressure adjustor with
ECU)
(1) Check brake light switch to connecting line and connector of ABS with hydraulic pressure
adjustor, and whether there exists short circuit or open circuit.
Normal
Abnormal
5 Final check
(2) Confirm fault is no longer appeared when speed is less than >20km/h.
Notes on circuit:
ABS ECU, which is installed in ABS hydraulic adjustor with ECU, is the control center of
the whole ABS.ABS
Program and calibration data needed by operation are stored in ROM of ABS ECU. ABS
ECU makes self examinations continuously to test and monitor whether there is fault on
ABS
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Circuit diagram:
Ground
Battery
Fuse 25A
Ground
Right Rear
Right-rear Wheel Sensor
Signal
Power
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1 Check vehicle with ABS hydraulic adjustor with ECU when it is still
C0550 remains
(5) C h e c k w h e t h e r e l e c t r o m a g n e t i c
interference exists.
Yes Go to step 4
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No
(2) No DTC in ABS memory after ignition switch is turned on for 30s.
Notes on circuit:
ABS ECU monitors battery voltage supplied to ABS ECU through Uz (pin 32). The following
faults would appear if the voltage provided to ABS ECU is out of specified range.
Too low voltage provided to ABS ECU would result in abnormal working of ABS.
Too high voltage provided to ABS ECU would result in damage to components of ABS.
Normal voltage for system working: 9.3 V ~ 16.9V when reflux pump motor is running
Test
DTC Setting conditions Possible fault section
conditions
ķ When ABS has no action, voltage < 9.6
V; or when ABS is in action, voltage < 9.3
V, memorize this DTC and turn off ABS
through software. ķ Battery is over discharged or
ĸ If voltage < 7.6 V or > 16.9 V are detected damaged
Turn on continually ĸ Fault on voltage regulator
C0800 ignition memorize this DTC and turn off ABS through (charging system )
switch hardware. Ĺ Fuse, socket connector and
Ĺ If the voltage provided to wheel speed body is in poor grounding, or
sensor < 7.1V, or <7.8 V continually, has contact resistance
memorize this DTC.
ĺ If power supply voltage > 17.5 V, system
would stop working to avoid overloading.
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Circuit diagram
Ground
Fuse40A
Battery
Fuse25A
Reflux Pump
Motor Control
Reflux Pump Motor Relay
Reflux Pump
Motor Control
Solenoid Valve
Voltage Oil Inlet Valve
Left Front
Oil Outlet Valve
Right Front
Oil Outlet Valve
Wheel Speed
Left Front Left-front Wheel Sensor
Signal Oil Inlet Valve
Power
Right Front Right-front Wheel Sensor Oil Outlet Valve Left Rear
Signal
Power
Oil Inlet Valve
Left Rear Left-rear Wheel Sensor
Signal
Power Oil Outlet Valve Right Rear
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1 Check fuses
Normal: conductive
Yes
Ĺ Braking in driving;
Normal: 10 ~ 16.9 v
Yes
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Ĺ Braking in driving;
Normal: 10 ~ 16.9 v
Yes
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Red Probe
Black Probe Connecting
Connecting to Signal
to Signal Wire Working Normal
Wire
Condition Value
Measurement Pin Measurement Pin
Working
Reflux
Condition of
Pump Motor UBMR 1 MGND 13 9.3~16.9V
Reflux Pump
Voltage
Motor
Soleniod
Each Working
Valve UBVR 25 GND 38 9.3~16.9V
Condition
Voltage
ECU Power
Each Working
Supply UZ 32 GDN 38 9.3~16.9V
Condition
Voltage
Reflux
Each Working
Pump Motor MGND 13 Negative Pole of Battery <0.5V
Condition
Ground
Each Working
ECU Ground GND 38 Negative Pole of Battery <0.5V
Condition
Notes: when controlling the actuating of reflux pump motor and measuring the UZ voltage,
electric appliances with high power consumption may be turned on and then off (eg: air
conditioner, headlight, etc) to observe the change of voltage
Notes: when measuring the UZ voltage, electric appliances with high power consumption
may be turned on and then off (eg: air conditioner, headlight, etc) to observe the change of
voltage
Normal
Abormal Check and repair circuit
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5 Fault reconfirming
Normal
6 Intermittent fault
Etc.
Notes on circuit:
ABS ECU contacts the other modules of vehicle via the CAN bus.ABS ECU still test the
CAN network and itself CAN system, in order to monitor the faults.Also, ABS ECU can
monitor the whole contact information, operating information and the orders converted
from one module to another, while the vehicle is driven normally.Each module of CAN bus
would transmit and obtain the error count, and the counter will increase while it senses the
fault, decrease while it obtain the releasing signal. The count will be cleared by ABS itself ,
if it is over 255, and then set the DTC C1001, U1000
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Circuit diagram:
Ground
Battery
Fuse 25A
Ground
CAN-H
Right Rear
Right-rear Wheel Sensor
Signal
Power
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1 Check vehicle with ABS hydraulic adjustor with ECU when it is stop
C1001ǃU1000 remians
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Yes Go to step 3
(2) No DTC in ABS memory after ignition switch is turned on for 30s.
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Model BYD S6
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ABS hydraulic
control unit
Rear brake
Parking lever
Brake line
Brakepedal
Front brake
ABS hydraulic
control unit
Rear brake
Parking lever
Brake line Brakepedal
Front brake
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1.2 Inspection and testing of brake sys- (3) Step on the brake pedal gently and keep
tem this sate (about the pressure required
to keep A/T vehicle amble), and then
1 Component inspection release the parking brake.
Inspection Other (4) While stepping on the brake pedal, pinch
Component
procedure items on the rear of the tape end. Then, pull up
Check for the tape to the steering wheel, and note
damage and
The seal the position where the tape will align to
leakage:
on the oil the reference line drawn on the masking
Oil cup or oil
cup cover tape.
cup seal
Brake master plumps,
Pipe joint
cylinder indicating (5) Apply stable pressure on the brake pedal
Between
that it is
brake master and hold for three minutes.
polluted by
cylinder and
mineral oil (6) Observe the tape.
vacuum
booster
Check for If the displacement is less than 10mm, the
damage and brake master cylinder is conforming.
leakage:
Pipe joint and If the displacement exceeds 10mm,
Pipe
flat connector
plumps,
replace the brake master cylinder.
Brake hose with brake
twisted or
Check The brake pad wears quickly, vehicle vi-
bent
whether the brates (after driving for a long time), or
hose and pipe brake pedal is high and difficult to step
are twisted or
on.
damaged
Check for (1) Drive the vehicle until the brake drags, or
damage and
until the pedal becomes high and difficult
leakage: Brake
Piston seal caliper pin to step on. In the long testing process, it
Brake caliper may be necessary to step on the brake
Flat connector is stuck or
of brake hose bonded pedal for 20 times or more.
Exhaust valve
screw (2) Connect the vehicle power, lift the
Check for vehicle with lifting gear, and turn the four
damage and wheels with hands.
ABS hydraulic
leakage:
unit
Pipe joint Whether the wheels have brake drag?
Hydraulic unit
Yes Go to step 3
2 Brake system testing
No Find other reasons that may cause brake
When braking, brake pedal sinks/gradually pad wear, pedal too high or vehicle
malfunctions vibration.
(1) Connect the vehicle power, and start the (3) Cut off the vehicle power, step on the
engine, so that there is enough time to brake pedal repeatedly to vacuum the
vacuum the booster. brake booster, and then turn the wheels
to check whether the brake drags.
(2) Stick a piece of 2-inch masking tape on
the bottom of the steering wheel, and Whether the wheels have brake drag?
draw a horizontal reference line on the
tape. Yes Go to step 4
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Yes Go to step 5
Yes Go to step 6
No Check whether the sealing ring of brake (2) Roll up the carpet and other coverings,
master cylinder cover expands, whether and measure the pedal height (C) to the
the brake fluid in the brake master left side of the pedal pad (B) at the cut of
cylinder is discolored or polluted, and insulating parts.
whether the braking line is damaged. Standard pedal height (excluding carpet): MT:
Replace if any of above items is damaged. 155mm
If above items are in good condition, please AT: 160mm
replace the ABS hydraulic unit.
(3) Loosen the lock nut (A) of the push
1.3 Brake pedal and brake pedal lamp pole, and screw in or screw out the push
switch adjustment pole with pliers to achieve the standard
1 Pedal height pedal height relative to the floor. After
adjustment, tighten the lock nut.
(1) Rotate the brake pedal lamp switch (A)
counterclockwise until it doesn’t contact Note: Do not adjust the pedal height when
the brake pedal. the push pole is depressed.
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(2) Take out the lock pin (A) and pin roll (B).
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(3) Remove the bolt (C) and nut (D) on the (1) Lift the rear part of the vehicle and make
brake pedal bracket that connects to the sure that the vehicle is supported firmly.
tubular beam.
(2) Remove the rear cover of the auxiliary
(4) Disconnect the position switch connector facia console (refer to Auxiliary Facia
(E) of the brake pedal. Console Disassembly and Assembly).
(5) Remove the brake pedal and bracket (F) (3) Pull p the parking brake lever one tooth (a
together. “click” sound is audible).
1 Checking
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1.6 Replacing parking cable (1) Insert the parking cable through the
body, arrange the position properly, and
1 Parking cable disassembly install the rear end to the rear brake
(1) Remove the auxiliary facia console. calipers.
(2) Loosen the cable adjusting nut, and take (2) Tighten the fastener and fix the parking
out the cable from the balancer. brake cable.
(3) Lift the vehicle, and remove the parking (3) Lower the vehicle, and connect the
cable from the brake calipers. parking cable and parking brake handle.
(4) Remove the fastener and take out the (4) Adjust the parking in the method of
parking brake cable. parking brake adjustment.
Exploded View
Connection calipers
Balancer
Adjusting
nut
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(1) Make sure that the brake fluid in the res- Front
ervoir is at the highest level (“MAX”).
Instrument assembly
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BYD S6, S6A, S6K Service Manual
(2) C h e c k w h e t h e r t h e b r a k e l i n e i s
damaged, rusts or leaks. And also check
whether the brake line is bent.
(3) C h e c k w h e t h e r t h e h o s e a n d l i n e
connections leak, and re-tighten if
(2) Check the conductivity between positive
necessary.
terminal and body grounding.
(4) Check whether the brake master cylinder
Connect when the brake lever is lifted.
and ABS modulator device are damaged
Disconnect when the brake lever is or leak.
depressed. Note: Once the brake line is repaired, the
1.10 Checking brake fluid level switch brake line clamp should be replaced.
When the buoy is in lower position and upper 1.12 Replacing brake hose
position, check the conductivity with terminal Note:
(1).
Before reinstalling, check all parts and
Drain the brake fluid from the reservoir, make sure that there is no dust or oth-
buoy sinks and the terminals should be er impurities.
connected. Replace new parts as required.
Fill the reservoir with brake fluid to make Do not splash the brake fluid on the
the level reach “MAX” marking, the buoy vehicle, or else it may damage the
floats and the terminals should be discon- paint; wash with water immediately if it
nected. splashes.
(1) If the brake hose is twisted, cracks or
leaks, please replace the brake hose (A),
or else it will leak.
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(6) Use mounting bolt (B) to install the Check whether the brake hoses interfere
brake hose (A) on the cantilever, and with each other and whether are twisted.
then connect the brake hose and brake
caliper with mounting bolts (C) and new Required torque:
sealing washer (D) (as shown below). Brake pipe to brake hose: 17.5N.m
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Special attention
The ingredients of brake pad are toxic,
and it is harmful to your health if the dust
is inhaled.
Avoid inhaling dust of friction plate.
C l e a n t h e b r a k e a s s e m b l y w i t h
vacuum cleaner instead of inhalation
hose or brush.
(3) If the friction plate thickness is lower
1 Checking than the maintenance limit, replace the
whole set of friction plate.
(1) Lift front part of the vehicle, support at
appropriate position, and remove the 2 Replacing
front wheels.
(1) Lift front part of the wheel, support at
(2) Check the thickness of inner and outer appropriate position, and remove the
friction plate, excluding gasket thickness. front wheels.
Friction plate thickness: (2) Remove the mounting bolts of brake
hose.
Standard: 17.5-18.5mm
(3) Clamp the pin with wrench and remove
Maintenance limit: 1.6mm
the flange bolt (A). Be careful and avoid
Inner friction plate checking damaging the pin sleeve. Screw out the
brake caliper (B). Check whether the
hose and pin sleeve are damaged or
aged.
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(7) C h e c k w h e t h e r t h e b r a k e d i s c i s
damaged or cracks.
(8) C l e a n a n d i n s t a l l t h e b r a k e p l a t e
(11) Turn the brake caliper (B) downwards
retaining seat.
to make it in place. Install the flange
bolt (C), clamp the pin with wrench and
tighten the flange bolt with specified
torque. Do not damage the small sleeve.
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(13) Step on the brake pedal several times, (6) If the brake disc runout exceeds the
make sure that the brake works normally, maintenance limit (0.10mm), adjust the
and then perform trial operation. brake disc with onboard brake lathe.
Maximum adjusting limit: 26mm.
Note: When the whole set of brake pads
are replaced, the brake may require larger (7) Replace the brake disc if it exceeds the
pedal travel. Step on the brake pedal sev- adjusting limit.
eral times to resume normal pedal travel.
2 Thickness and parallelism
(14) After installation, check whether the
hose and line connector or connecting (1) Lift front part of the wheel, support at
mechanism leaks, and re-tighten if nec- appropriate position, and remove the
essary. front wheels.
1.14 Front brake disc checking and re- (2) Remove the brake pad.
placing (3) Use a micrometer to measure the
1 Runout thickness of the brake disc at eight
points which are 10mm from the outer
(1) Lift front part of the wheel, support at edge of the brake disc and space about
appropriate position, and remove the 45°; if the measured minimum value is
front wheels. lower than the maximum adjusting limit,
please replace the brake disc.
(2) Remove the brake pad.
Brake disc thickness:
(3) Check whether the surface of brake disc
is damaged or cracks, clean the brake Standard: 27.9-28.1mm
disc and clear the rust.
Maximum adjusting limit: 26mm
(4) Install appropriate flat washer (A) and
wheel nut, and tighten the nut with Brake disc parallelism: <0.015mm
specified torque to make the brake disc Note: This is the maximum allowable de-
affix to the wheel hub. viation of the thickness value.
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1.15 Front wheel hub assembly replacing (7) Depress the bearing with a 41mm
diameter push pole (as shown below).
1 Front wheel hub and bearing disassem-
bly:
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(2) Install the snap ring onto the steering 1.16 Replacing brake master cylinder
knuckle reliably (as shown below)
Note: Do not splash the brake fluid on the
vehicle, or else it may damage the paint;
wash with water immediately if it splashes.
(7) Lower the vehicle. (5) Open the reservoir cap, and drain
Note: Before installing the wheel hub and the brake fluid from the brake master
wheel hub bearing, check whether the cylinder reservoir.
speed sensor bracket is damaged or sen- (6) Remove the brake fluid level alarm
sor bracket shifts in the process of disas- switch connector (A).
sembly, to ensure that the speed sensor
works normally, and the sensor bracket (7) Remove the flow sink assembly.
won’t scrub the drive shaft.
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Vacuum gauge
Pipe fitting
(8) Disconnect the brake line (B) from the (2) Start the engine, adjust the engine
brake master cylinder (C). To avoid speed through the accelerator pedal to
splashing, please wrap the hose joints make the reading of vacuum gauge in
with cloth or maintenance towel. the range of 40.0-66.7Kpa, and then
shut down the engine.
(9) Remove the mounting nut (O) and
washer of brake master cylinder. (3) Read the vacuum gauge; if the reading
drops 2.7kPa or more after 30 seconds,
(10) Remove the brake master cylinder from check whether the following component
the brake booster (E). When removing leak.
the brake master cylinder, do not bend
or damage the brake line. 1) Vacuum hose and line
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(5) Remove the assembly bolt (C) of fuse/ (10) Remove the fixing pin and lock pin (A),
relay box under the engine hood, and and loosen the mounting nut (B) of
then take out the fuse/relay box from the vacuum booster and brake pedal.
vehicle.
(6) Remove the air filter assembly (A). Be careful and avoid damaging the
threads of the front and rear studs of the
booster.
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1 Checking
Standard: 16.0-17mm
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(6) C h e c k w h e t h e r t h e b r a k e d i s c i s
damaged or cracks.
(7) C l e a n a n d i n s t a l l t h e b r a k e p l a t e
retaining seat. (10) Install the brake caliper in place. Install
the flange bolt (B), clamp the pin (C) with
(8) Install the brake disc properly, and wrench and tighten the flange bolt with
install the brake disc with wear alarm (B) specified torque. Do not damage the
inside. small sleeve.
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(6) If the brake disc runout exceeds the Note: Replace the brake disc if the paral-
maintenance limit, adjust the brake disc lelism exceeds the re-maintenance limit.
with onboard brake lathe.
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1) Stop the vehicle and keep the front 3) Make sure that the front wheels face
wheels forward forward
2) Jiggle the steering wheel and check the 4) Remove DAB module assembly
free travel (1) Align the small holes in both sides of the
As shown in the picture, the maximum free steering wheel, and loosen the two hex
travel of the steering wheel is 30mm screws with socket wrench or T30, as
shown below.
30mm
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Remove
(1) Note:
Steering wheel
locking bolt
ķ Do not use airbag parts removed from
another vehicle; only replace with
new parts.
2.2 Assembly
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3. Steering Column and Dust Cov- 6. Disconnect the wire connector from the
er Disassembly/Assembly combination switch assembly.
SRS parts are installed in this area. Before 7. Remove the screw, and then remove
maintenance or service, review SRS part lo- the combination switch assembly and
cation, notice and step in this chapter combination switch cover assembly from
the steering column.
3.1 Disassembly
8. Disconnect the connector from the axis
1. Make sure that you know the acoustics lock, and loosen the wire clip from the
password, and record the preset fre- steering column.
quency of the radio channel.
9. Remove the universal joint mounting
2. Disconnect the cathode cable of the bolt, and then disconnect the universal
battery. joint from the steering gear pinion.
3. Remove driver’s airbag assembly and
steering wheel.
Mounting bolt
Steering gear shaft
Mark properly
Q67590
Upper mounting
points
QQ32008T13F3
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Upper mounting
points
Q32008T13F3
Mounting torque
Mounting bolt
Lower mounting points BYD150A0835TF6
BYD1401080TF3 Mounting torque
Mounting torque 30N.m
35N.m
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BYD S6, S6A, S6K Service Manual
Check the operation of cruise control, Check the oil pressure in the following steps
acoustics remote and steering signal and identify whether the oil pump or steering
switch. gear has fault.
Make sure that the steering wheel is 1. Check the level of power steering fluid.
aligned.
2. Disconnect the steering pump inlet
3.3 Dust Cover I Disassembly/Assembly hose (A) from the oil pump outlet, and
avoid power steering fluid splashing on
1. Separate dust cover I and dust cover II the chassis and other parts. Install P/S
assembly (refer to the steps of column adapter (pump) onto the oil pump outlet,
disassembly/assembly). as shown in Fig. 8-1.
2. Remove the mounting bolts and nuts of 3. Connect P/S adapter (hose) to P/S
dust cover I. pressure gauge, and then connect the
3. Remove dust cover I and mounting steering pump inlet hose (A) to P/S
bracket. adapter (hose), as shown in Fig. 8-1.
Dust cover
mounting bolt
Dust cover
mounting nut
Fig. 8-1
Mounting
torque 10N.m
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Pipeline
Check whether the hose is damaged,
twisted, leaks, or interferes with
each other
Check whether the oil line i
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BYD S6, S6A, S6K Service Manual
Pipeline
Check whether the hose is damaged,
twisted, leaks, or interferes with each other
Check whether the oil line is damaged,
rusts or leaks
Check whether the oil line and pipe
connector leak
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Fig. 8-3
Fig. 8-4
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Steering pump
inlet hose
Hollow bolt
Steering Oil return pipe 50N.m Oil return pipe connecting
bolt 30N.m
High pressure pipe
Pipe fixing bracket connecting bolt 45N.m
on the cylinder
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4. Remove the pump mounting bolt (B). 10. Tighten the oil pump mounting bolt to
specified torque.
5. Cover the automatic tension device,
AC generator and A/C compressor with 11. Fill oil to the tank to the upper level.
several pieces of maintenance cloth to
avoid splashing the power steering fluid. 7.2 488QA Engine Model
Disconnect steering pump inlet hose (C) 1. Place an appropriate container under the
and high pressure pipe (D) from the oil vehicle.
pump (E), and then plug the port. Do not
splash oil on the vehicle or parts. Wipe 2. Drain the steering fluid from the steering
the splashed oil immediately. When the tank.
oil pump is removed, do not turn the
steering wheel, as shown in Fig. 8-7. 3. Remove the drive belt (A) from the pump
pulley.
6. Cover the pump opening with tape to
prevent foreign objects falling into the
pump.
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5. Install large ratchet on 14# sleeve and 9. Connect the inlet hose and high pressure
place in a pulley hole in the pump, pipe of the steering pump.
remove the mounting bolt below the
oil pump and screw out the thread 10. Use mounting bolt to install the oil pump
completely. on the engine loosely, and then fasten
the oil pump.
6. Keep the ratchet in the pulley hole and
rotate to the top mounting point, as 11. Install the drive belt (A), as shown in Fig.
shown in Fig. 8-10: 8-12.
Note the Following in the Process of In-
stalling Belt:
Fig. 8-10
Fig. 8-12
Ratchet
Fig. 8-11
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7.3 Structure of Power Steering Gear 4. If the measured value is lower than the
standard value, check whether the ball
The structure of power steering gear is shown joint is loose and creaks. If the swing is
in the picture below: smooth, the tie rod can be used; if it is
loose or creaks, replace the steering tie
rod.
2) Checking dust cover of steering tie
rod
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7.5 Power Steering Gear Disassembly 3) Separate the steering tie rod ball end
and knuckle with special tool (if not
Special tool required: ball puller available, knock at the knuckle with a
Note the following in the process of disas- hammer to pull out the ball end; do not
sembly: impact the thread of the ball stud).
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So far, the steering gear disassembly 2. Insert the mounting bolt and nut of the
completes. steering gear into the mounting hole of
the steering gear and auxiliary frame,
7.6 Steering Gear Checking as shown below; install the pinion first
and then install the cylinder, and finally
For removed steering gear, check the reason tighten the torque when the nuts are
of fault preliminarily and determine whether screwed in both ends. The tightening
it should be replaced. If there is no problem, torque on bolt head is 100N.m.
check other aspects. Replace the steering
gear if it has problem.
Note: Except the outer link and dust cover,
the steering gear can’t be repaired or dis-
assembled; please return to the manufac-
turer for maintenance or replacement.
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Gearshift lever
3). L o o s e n t h e m o u n t i n g s c r e w o f
transmission gear switch, and then
rotate the gear switch to the flange of
the manual control lever and align to the
flange on the gear switch.
Adjusting nut
Transmission
A-A hole’s end
control line Manual
control lever
Hole in
Manual flange
control lever Suppress
switch
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BYD S6, S6A, S6K Service Manual
5). Tighten the transmission control line in 3). Start the engine, and check whether the
the arrow direction, and then tighten the vehicle moves forward when the lever
adjusting nut. is turned from N to D, and whether the
vehicle moves backward when the lever
is turned to R.
Adjusting bolt
Manual
control lever
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1.3 Axle Shaft Assembly 4 Align and insert the inner CV joint (A) of
right axle shaft and intermediate shaft,
1 Install the new positioning ring in the and make sure that the spring clamp (B)
groove of the axle shaft. on the intermediate shaft is assembled
in place.
3 Insert the intermediate shaft into the 6 Connect the ball stud assembly (C) and
differential from the right, ensure that arm welding assembly (D), install the
the bracket mounting hole aligns to the hex flange nut (A) and hex flange bolt (B)
engine mounting hole, and tighten the at the connection, and tighten the torque
hex flange bolt (A) and intermediate to specified value.
support mounting bolts (B) of the
mounting bracket to specified torque.
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7 Install new axle shaft nut (B) and washer 2. Automatic Transmission Shaft
(A), and tighten the axle shaft nut (B) to
specified torque. Insert the new split pin 2.1 Axle Shaft Inspection
(C) into the hole, and then bend the split
1 Check whether the inner guard (A) and
pin as shown in the picture. If the split
outer guard (B) on the axle shaft (C)
pin can’t be inserted into the slot and pin
have crack, damage or grease leakage,
hole, please tighten the nut appropriately
and whether the guard clasp (D) is loose.
to align the slot and pin hole; do not align
If there is any defect, please replace the
by loosening the nut.
guard and guard clamp.
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276
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Locking pin
Spring washer
Gearshift
control cable
Locking pin
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278
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Gearshift base
Pressurize mat
Retainer
279
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280
Electric Equipment Ư
BYD S6, S6A, S6K Service Manual
Electric Equipment Ư
Contents
I
BYD S6, S6A, S6K Service Manual
II
BYD S6, S6A, S6K Service Manual
Section 1 SRS
1. Component Location
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2
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INTEGRATED
*4:for flagship
3
BYD S6, S6A, S6K Service Manual
3. System Introduction
Vehicle safety includes active safety system
and passive safety system. Active safety re-
fers to the ability of discovering hazards in
advance, e.g. windshield vision, lighting sys-
tem, mirror, etc.; the ability of avoiding haz-
ards in advance, e.g. steering system, brak-
ing system, anti-slip, smooth driving control
system. Passive safety refers to preventing
or reducing injuries to driver and passengers,
e.g. seat belt, air bag, etc. The airbag system
described in this section is Supplemental Re-
straint System (SRS). The vehicles equipped
with this system can be identified quickly
through the “SRS-AIR-BAG” mark.
2. SRS ECU
4. Clock spring
Airbag ECU is installed on the vehicle axis, below the central control panel. If the battery
voltage is too low or power supply is cut off due to crash, the airbag ECU still can work for
at least 100ms.
Driver’s airbag (DAB) is installed on the trim cover in the center of the steering wheel, and
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BYD S6, S6A, S6K Service Manual
can’t be separated. DAB consists of gas generator, air bag, trim cover and bracket. The
function of DAB is to receive ignition signal from airbag ECU to ignite the gas generator,
and produce large amount of gas to inflate the airbag and form air cushion to protect the
driver and passengers.
Clock spring is installed on the combination switch, and consists of spiral cable, rotor, hous-
ing, wiring harness, and auxiliary structure. When the steering wheel is turned, the rotator
and the steering wheel form an overall rotation. Sufficient length of spiral cable is coiled in
the housing, and thus the reliable connection of the cable won’t be affected when the rota-
tor rotates for 3.5 cycles in the center clockwise or counterclockwise.
Passenger’s airbag (PAB) is installed above the glove box of the instrument panel. Its com-
position and function are same to DAB.
The front seat airbag module is installed by the doors on driver’s side and front passenger’s
side. The seats equipped with this airbag module are sewn with the “SIDE AIR BAG” mark
on the sideline of the backrest skin. The function of seat side airbag is same to DAB.
The side curtain airbags are installed on the side sheet metal on the boundaries on both
sides of the roof. The inflation device is installed on the sheet metal in C pillar trim panel
and the air bag is installed in the roof boundary, extending from D pillar to A pillar. The ve-
hicles equipped with side curtain airbags have the “SRS CURTAIN AIR BAG” mark on the
interior surface of C pillar trim panel and A pillar trim panel. The function of side curtain air-
bag is same to DAB.
The left front crash sensor is installed in inside of the left longeron in engine room, and the
right front crash sensor is installed in inside of the right longeron in engine room. The func-
tion of front crash sensor is to send the crash signal to airbag ECU, which will use the sig-
nal as the basis to determine whether sends ignition signal and crash unlocking signal.
The left side crash sensor is installed on the body sheet metal in B trim panel on the left of
the interior trim, close to seat belt retractor; the right side crash sensor is installed on the
body sheet metal in B trim panel on the right of the interior trim, close to seat belt retractor;
the function of left and right side crash sensors is to send the crash signal from body center
to airbag ECU, which will use the signal as the basis to determine whether sends ignition
signal and crash unlocking signal.
The left rear side crash sensor is installed on the body sheet metal above the left rear
wheel arch, and the right rear side crash sensor is installed on the body sheet metal above
the right rear wheel arch. The function of left and right side crash sensors is to send the
crash signal from middle and rear part of the body to airbag ECU, which will use the signal
as the basis to determine whether sends ignition signal and crash unlocking signal.
Airbag wires are used to connect airbag ECU, DAB, PAB, SAB, CAB, clock spring, instrument
panel wiring harness, etc. Airbag wires include airbag module drive line, emergency warning
lamp line, crash unlocking line and vehicle communication bus. The function of airbag wires is
to transmit signals between airbag ECU and airbag module, as well as vehicle to ensure reliable
communication. Airbag circuit wires can be identified with the yellow cable or plug.
Airbag fault indicator is located on the combination instrument. If the self diagnosis circuit of
the airbag ECU has fault, the airbag fault indicator will be lit, informing the driver that airbag
system has fault. Under normal condition, when the power is turned to ON position, the in-
dicator will light for five seconds and then go out.
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BYD S6, S6A, S6K Service Manual
Steering wheel lower panel: it is a molded structure located in the rear of steering column
opening and integrated with the instrument panel to protect driver’s knees.
Right bin assembly: it is a reinforced structure, which is concealed in the glove box and in-
tegrated with the door of glove box to protect front passenger’s knees.
Seat belt: the main protection for passengers is seat belts. When emergency brake, crash
or rollover occurs, the seat belts will firmly bind the driver and passengers on their seats,
restrict the positions of driver and passengers, and avoid or reduce the injuries caused by
secondary impact due to the effect of inertia. To ensure the highest security, the driver and
passengers must wear the seat belts.
Airbag system:
The working of airbag depends on the angle and severity of vehicle crash. The crash angle of the
airbag system is 30° in front of the body centerline. The expansion of airbag depends on the de-
celeration ratio measured with gravity (G) instead of speed. The force is measured with the crash
sensor in airbag ECU. If the crash is severe enough, the microprocessor in airbag ECU will send
a signal to the expansion device of the six airbag modules to expand the airbag. The clock spring
in the top of the steering column allows maintaining a continuous circuit between steering column
and driver’s airbag (DAB), and also allows rotating with the steering wheel. When front crash oc-
curs and airbag expands, the knee board and seat belt work together to constrain the driver and
front passenger in place. The knee board also can absorb and disperse the collision energy of
driver and front passenger on instrument panel. When the airbag ECU monitors a problem in
airbag component or airbag system circuit, it will save the DTC in its memory, and send the infor-
mation to combination instrument to light the airbag fault indicator. The diagnostic apparatus is
required to properly test the airbag system component, read or clear DTC and repair.
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BYD S6, S6A, S6K Service Manual
During maintenance of airbag system, if the operating process isn’t executed properly, the airbag
may expand unexpectedly, resulting in serious accidents. In addition, if the maintenance opera-
tion has any error, the airbag may fail to expand when it needs to expand. Therefore, please read
the following notice carefully before maintenance, and follow the operation procedures.
2. Notice:
Except the operations described in this manual, it is prohibited to use electrical test equip-
ment to perform any circuit test for the airbag system.
When install airbag ECU, maintain proper installation direction to ensure that it works nor-
mally. Before installation, check for any crack, deformation or corrosion.
It is prohibited to use airbag system components removed from other vehicles. Replace
with new parts.
It is prohibited to break down and repair DAB, PAB, SAB, CAB and install airbag ECU for
repeated using or any other reasons.
It is prohibited to put DAB, PAB, SAB, CAB and airbag ECU in hot air or flame directly.
After a minor crash, check the airbag system even if the airbag didn’t expand.
If DAB, PAB, SAB, CAB or airbag ECU falls to the ground, is vibrated or impacted, or the
shell, bracket or connector has crack, indentation or other damage, replace with new parts.
The parts of airbag system and related positions in the vehicle are pasted with warning la-
bels. Please follow the instructions on the labels while operating.
If the vehicle might be vibrated while repairing other systems or components of the vehicle,
remove the airbag ECU first.
If thee vehicle is affected by overheating (>93°C) while painting, please remove airbag
ECU, DAB, PAB, SAB, CAB and clock spring and put aside.
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BYD S6, S6A, S6K Service Manual
Correct Wrong
Before removing battery cathode ground wire, please record the state of other systems, because
the DTC of other system will be lost when the battery cathode ground wire is removed.
Before welding any part, disconnect the airbag system to avoid mistaken explosion.
Do not use detection light, common voltmeter or ohmmeter for testing, and do not use ohm-
meter on DAB, PAB, SAB or CAB.
Before and after replacing any component, perform self diagnosis and check whether the
system function is normal.
Airbag ECU connector, clock spring connector, DAB connector, PAB connector, SAB con-
nector and CAB connector are equipped with protection mechanism that can prevent the
airbag from unexpected expansion.
After maintenance of the airbag system, make sure that the electrical connection is proper
before connecting the airbag module to the circuit.
The life expectancy of the airbag is ten years; replace the airbag and label after that period.
Airbag expansion device contains sodium azide and potassium nitrate, which are toxic and
highly flammable. If contacting acid, water, or heavy metals, it will generate harmful and ir-
ritant gases (easy to form sodium hydroxide in wet areas) or flammable compounds. Airbag
device contains pressurized argon gas; do not try to disintegrate the airbag device or dam-
age the expansion device of the airbag, do not pierce, burn the airbag, do not let the airbag
to contact with electrical, and do not store in the environment higher than 93°C.
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BYD S6, S6A, S6K Service Manual
5. Diagnostic Process
Follow this process for troubleshooting
NEXT
Standard voltage:
11V~14V
NEXT
3 Vehicle inspection
Result Perform
Go out after 5s OK
Constantly lit NG
B System is normal
9
BYD S6, S6A, S6K Service Manual
Result Perform
Have DTC output A
No DTC output B
B Go to step 6
5 Compare with the DTC list and enter Comprehensive Diagnostic Process
NEXT
NEXT
7 Finish
10
BYD S6, S6A, S6K Service Manual
6. DTC List
DTC Fault
11
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7. Fault Table
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8. Terminal Diagnosis
1. Check the ECU terminal of SRS system (board side connector)
(1) Unplug connector M34 and M15 from ECU, and measure the voltage and resistance be-
tween terminals of the wire connector
Terminal No. Wire color Terminal description Test condition Normal value
M34-1 body ground R Power signal ON position 11-14V
M34-2-M34-13 —— Left front crash sensor —— ——
M34-3-M34-14 —— Right front crash sensor —— ——
M34-8 body ground V B-CAN-L signal Constant About 2.5V
M34-9 body ground P B-CAN-H signal Constant About 2.5V
Crash unlocking signal
M34-10 body ground Y/G Constant 11-14V
output
Ground (crash unlocking
M34-11 body ground W/B Constant <1ȍ
signal grounding)
M34-12 body ground W/B Grounding Constant <1ȍ
M34-17-M34-18 —— Left airbag —— ——
M34-19-M34-20 —— Right airbag —— ——
M34-21- M34-22 G/R Front passenger airbag —— ——
M34-23- M34-24 Y/R Clock spring —— ——
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BYD S6, S6A, S6K Service Manual
(2) Lead wire from rear side of connector M15 of ECU, and measure the voltage and resis-
tance between terminals of the wire connector
Terminal No. Wire color Terminal description Test condition Normal value
M15-14-M15-13 —— Right curtain airbag —— ——
M15-15-M15-16 —— Left curtain airbag —— ——
M15-17-M15-18 —— Right side crash sensor —— ——
M15-19-M15-20 —— Left side crash sensor —— ——
Left rear side crash sen-
M15-24-M15-25 —— —— ——
sor
Right rear side crash
M15-26-M15-27 —— —— ——
sensor
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
IG POWER
15
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
OK
16
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Circuit diagram:
COMBINATION
INSTRUMENT
F1/12 AJ32-22
COMPRESS
OR 7.5A
F1/23-2
IGNITION
SWITCH 50A
VOLTAGE REGULATOR
RECTIFIE
EXCITATION COIL
IG1
RELAY
SRS SYSTEM
BATTERY
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BYD S6, S6A, S6K Service Manual
Inspection steps
OK
Normal
Terminal Condition
value
Apply battery voltage
3-5 <1ȍ
to pin1 and pin2
3-5 Pin1 and pin2 floating >10Kȍ
OK
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
IG POWER
19
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
20
BYD S6, S6A, S6K Service Manual
Circuit diagram:
CLOCK SPRING
OF DRIVER
AIRBAG IN FRONT
21
BYD S6, S6A, S6K Service Manual
Inspection steps
1 Check whether the connector between clock spring wire and SRS ECU is proper
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
DTC is cleared A
DTC still exists B
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BYD S6, S6A, S6K Service Manual
Check whether driver’s airbag wire is short circuited to ground and power supply (report
3
this fault in this case)
OK
Result Perform
DTC is cleared A
DTC still exists B
23
BYD S6, S6A, S6K Service Manual
OK
OK
5 Check whether the wires between clock and airbag are connected properly
Result Perform
DTC is cleared A
DTC still exists B
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25
BYD S6, S6A, S6K Service Manual
Circuit diagram:
CLOCK SPRING
DRIVER
FRONT OF
AIRBAG IN
26
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
2 Check whether the connector between clock spring wire and SRS ECU is proper
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
Connected A
Not connected B
B Go to step 9
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OK
5 Check whether the short circuit piece between airbag ECU and airbag wire is pushed out
Result Perform
Connected C
Not connected D
C Go to step 11
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Result Perform
DTC is cleared OK
DTC still exists NG
NG Finish
NG
Result Perform
DTC is cleared OK
DTC still exists NG
29
BYD S6, S6A, S6K Service Manual
NG
Result Perform
DTC is cleared OK
DTC still exists NG
NG
NG: Connected
OK
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Circuit diagram:
31
BYD S6, S6A, S6K Service Manual
Inspection steps
Check whether the connector between front passenger airbag module wire and airbag
1
wire is connected properly
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
DTC is cleared A
DTC still exists B
32
BYD S6, S6A, S6K Service Manual
Check whether front passenger’s airbag wire is short circuited to ground and power supply
3
(report this fault in this case)
OK
33
BYD S6, S6A, S6K Service Manual
OK
Result Perform
DTC is cleared A
DTC still exists B
34
BYD S6, S6A, S6K Service Manual
Circuit diagram:
OF FRONT PASSENGER
AIRBAG IN THE FRONT
35
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
Check whether the connector between front passenger airbag module wire and airbag
2
wire is connected properly
Result Perform
DTC is cleared A
DTC still exists B
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BYD S6, S6A, S6K Service Manual
Result Perform
DTC is cleared OK
DTC still exists NG
NG
Result Perform
Connected A
Not connected B
37
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Result Perform
DTC is cleared A
DTC still exists B
38
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Circuit diagram:
39
BYD S6, S6A, S6K Service Manual
Inspection steps
Check whether the connector between left side airbag module wire and airbag wire is con-
1
nected properly
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
DTC is cleared A
DTC still exists B
40
BYD S6, S6A, S6K Service Manual
Check whether left side airbag wire is short circuited to ground and power supply (report
3
this fault in this case)
OK
41
BYD S6, S6A, S6K Service Manual
OK
Result Perform
DTC is cleared A
DTC still exists B
42
BYD S6, S6A, S6K Service Manual
Circuit diagram:
43
BYD S6, S6A, S6K Service Manual
Inspection steps
1 Check whether the locking piece on left side airbag connector is installed in place
OK
Check whether the connector between left side airbag module wire and airbag wire is con-
2
nected properly
Result Perform
DTC is cleared A
DTC still exists B
44
BYD S6, S6A, S6K Service Manual
Result Perform
DTC is cleared OK
DTC still exists NG
NG
Result Perform
Connected A
Not connected B
45
BYD S6, S6A, S6K Service Manual
Result Perform
DTC is cleared A
DTC still exists B
46
BYD S6, S6A, S6K Service Manual
Circuit diagram:
47
BYD S6, S6A, S6K Service Manual
Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
Check whether right side airbag wire is short circuited to ground and power supply (report
2
this fault in this case)
48
BYD S6, S6A, S6K Service Manual
OK
49
BYD S6, S6A, S6K Service Manual
OK
Result Perform
DTC is cleared A
DTC still exists B
50
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Circuit diagram:
51
BYD S6, S6A, S6K Service Manual
Inspection steps
1 Check whether the locking piece on right side airbag connector is installed in place
OK
Result Perform
DTC is cleared OK
DTC still exists NG
NG
Result Perform
Connected A
Not connected B
52
BYD S6, S6A, S6K Service Manual
Result Perform
DTC is cleared A
DTC still exists B
53
BYD S6, S6A, S6K Service Manual
Circuit diagram:
54
BYD S6, S6A, S6K Service Manual
Inspection steps
Check whether the connector between left side curtain airbag module wire and airbag wire
1
is connected properly
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
DTC is cleared A
DTC still exists B
55
BYD S6, S6A, S6K Service Manual
Check whether left side curtain airbag wire is short circuited to ground and power supply
3
(report this fault in this case)
OK
56
BYD S6, S6A, S6K Service Manual
Result Perform
DTC is cleared A
DTC still exists B
57
BYD S6, S6A, S6K Service Manual
Circuit diagram:
58
BYD S6, S6A, S6K Service Manual
Inspection steps
1 Check whether the locking piece on left side curtain airbag connector is installed in place
OK
2 Check whether the short circuit piece between airbag ECU and airbag wire is pushed out
Result Perform
Connected A
Not connected B
B Go to step 5
OK
59
BYD S6, S6A, S6K Service Manual
Result Perform
DTC is cleared OK
DTC still exists NG
NG
60
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Circuit diagram:
61
BYD S6, S6A, S6K Service Manual
Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
Check whether right side curtain airbag wire is short circuited to ground and power supply
2
(report this fault in this case)
62
BYD S6, S6A, S6K Service Manual
OK
Result Perform
DTC is cleared A
DTC still exists B
63
BYD S6, S6A, S6K Service Manual
Circuit diagram:
64
BYD S6, S6A, S6K Service Manual
Inspection steps
1 Check whether the locking piece on right side curtain airbag connector is installed in place
OK
2 Check whether the short circuit piece between airbag ECU and airbag wire is pushed out
Result Perform
Connected A
Not connected B
B Go to step 5
OK: connected
OK
65
BYD S6, S6A, S6K Service Manual
Result Perform
DTC is cleared OK
DTC still exists NG
NG
66
BYD S6, S6A, S6K Service Manual
Circuit diagram:
CRASH SENSOR
LEFT FRONT
67
BYD S6, S6A, S6K Service Manual
Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
DTC is cleared A
DTC still exists B
68
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OK
4 Finish
69
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Circuit diagram:
SENSOR
CRASH
LEFT FRONT
70
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Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
3 Finish
71
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Circuit diagram:
SENSOR
CRASH
LEFT FRONT
72
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Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
DTC is cleared A
DTC still exists B
73
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OK
4 Finish
74
BYD S6, S6A, S6K Service Manual
Circuit diagram:
SENSOR
CRASH
RIGHT FRONT
75
BYD S6, S6A, S6K Service Manual
Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
3 Finish
76
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Circuit diagram:
77
BYD S6, S6A, S6K Service Manual
Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
DTC is cleared A
DTC still exists B
78
BYD S6, S6A, S6K Service Manual
OK
4 Finish
79
BYD S6, S6A, S6K Service Manual
Circuit diagram:
80
BYD S6, S6A, S6K Service Manual
Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
3 Finish
81
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Circuit diagram:
82
BYD S6, S6A, S6K Service Manual
Inspection steps
1 Check whether the left rear side crash sensor is connected properly
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
DTC is cleared A
DTC still exists B
83
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OK
4 Finish
84
BYD S6, S6A, S6K Service Manual
DTC B1677 Left rear side crash sensor short circuit to ground
Circuit diagram:
85
BYD S6, S6A, S6K Service Manual
Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
3 Finish
86
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Circuit diagram:
87
BYD S6, S6A, S6K Service Manual
Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
DTC is cleared A
DTC still exists B
88
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OK
4 Finish
89
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Circuit diagram:
90
BYD S6, S6A, S6K Service Manual
Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
3 Finish
91
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Circuit diagram:
92
BYD S6, S6A, S6K Service Manual
Inspection steps
1 Check whether the right rear side crash sensor is connected properly
Result Perform
DTC is cleared A
DTC still exists B
Result Perform
DTC is cleared A
DTC still exists B
93
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OK
4 Finish
94
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DTC B167B Right rear side crash sensor short circuit to ground
Circuit diagram:
95
BYD S6, S6A, S6K Service Manual
Inspection steps
Result Perform
DTC is cleared A
DTC still exists B
OK
3 Finish
96
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2. Remove the cathode ground wire from the battery, and wait at least 90 seconds
Warning label:
Before disassembling or assembling the airbag system, pay attention to the warning label (yellow)
of airbag system in the vehicle, and operate according to the label. In addition, replace the label if
it is damaged or dirty.
DAB surface:
PAB module:
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BYD S6, S6A, S6K Service Manual
SAB module:
CAB module:
Clock spring:
Airbag ECU:
99
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Note: Do not open the casing of the airbag ECU unless necessary. The integrated circuit
may be damaged if you touch the terminal.
Note:
Note:
Note:
100
BYD S6, S6A, S6K Service Manual
Note:
When the airbag is expanded, please wear the maintenance goggles and rubber gloves
Prompt:
Note:
Note:
(1) Unplug the horn connector, and remove the mounting nut in the center of the steering
wheel
(2) Remove the steering wheel with a dedicated tool (steering wheel puller)
Note:
Record the alignment mark on the steering wheel and steering wheel spindle
101
BYD S6, S6A, S6K Service Manual
5. Remove the upper and lower cover of the steering column (i.e. combination switch cover)
(1) Loosen the wire connector from the clock spring and avoid damaging the wires
(2) Separate the three jaws, and remove the clock spring
Note:
,WLVSURKLELWHGWRGLVDVVHPEOHFORFNVSULQJFRPSRQHQWGRQRW¿OOLQOXEULFDQW
(1) Remove the locking pin first (when replace new parts)
(2) Confirm the center position of clock spring, check whether the front wheels are going
straight, turn the clock spring counterclockwise with hands until tightened, and then turn
for 2.5~3 circles clockwise, align the mark, and lock the clock spring with the locking pin.
Align the steering wheel and the mark on the steering wheel spindle, adjust the direction of new
steering wheel, and use 50N.m torque to install the mounting bolts of steering wheel.
Use 10N.m torque to install the mounting screws of driver’s airbag module (DAB)
After installation, turn the steering wheel slightly to left/right, and check whether there is fault or
noise
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BYD S6, S6A, S6K Service Manual
When the airbag is expanded, please wear the maintenance goggles and rubber gloves
Prompt:
Note:
Be careful when operate the airbag connector to avoid damaging the airbag wires.
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BYD S6, S6A, S6K Service Manual
4. Crash sensor
Prompt:
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BYD S6, S6A, S6K Service Manual
To scrap the airbag module, remove it first. To scrap the vehicles equipped with airbag system
or scrap the airbag module, always follow the operating procedures below to expand the airbag
module. If the airbag can’t expand, please contact the service center of BYD.
It will produce a great sound when the airbag expands. Therefore, the airbag should be ex-
panded in open area outdoor and won’t cause public nuisance.
When expand the airbag, always use dedicated maintenance tools (expansion tool SST,
airbag module bracket, detonation wiring). Always perform at the place without electrical
noise.
When expand the airbag, keep at least 10m away from the airbag module.
When the airbag is expanded, the airbag module is very hot; do not touch in 30min.
When dealing with expanded airbag module, wear maintenance goggles and rubber gloves,
and wash hands after operation.
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1. Component Location
REGULATOR SWITCH
SET, FRONT POWER
REGULATOR SWITCH, REAR
WINDOW, R
POWER WINDOW, R
-REGULATOR SWITCH,
FRONT POWER WINDOW,
R
-CENTRAL LOCKING,
FRONT DOOR, R
REGULATOR
SWITCH, REAR
POWER WINDOW, L
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
MOTOR, FRONT
FRONT WINDOW, LH
WINDOW, LH
SWITCH, FRONT WINDOW, LH
FRONT
WINDOW, RH
SWITCH, FRONT MOTOR, FRONT
WINDOW, RH WINDOW, RH
REAR WINDOW,
LH
MASTER
SWITCH
SWITCH, REAR MOTOR, REAR
WINDOW, RH WINDOW, RH
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BYD S6, S6A, S6K Service Manual
3 System Introduction
Power window system controls the ascending and descending of windows by operating the switch
on the door trim panel, and the driver can control the ascending and descending of windows
through the master switch on the front door trim panel. The locking switch of power windows is
located on the front door trim panel on driver’s side. It allows the driver disabling the opening/clos-
ing of all passenger windows (power window system works only when the ignition switch is turned
to ON). The AUTO feature allows the window on driver’s side descending to the bottom automati-
cally. For operation, press the window switch on driver’s side in the descending direction and the
window starts descending automatically at a fixed position; press the switch again in any direc-
tion, the window stops and cancels auto operation. Certain functions and features of the power
window system depend on the control of electronic modules, which are integrated in the compo-
nents of front left power window regulator switch.
Power window motor uses the latest process, technology and materials. On waterproof, we use
seal design and breathable film technology (when the motor is running and temperature rise, it
will cause pressure difference inside and outside of the motor, and break through the most vulner-
able part. Therefore, the motor requires a breathing apparatus to balance the pressure difference
and avoid impacting the vulnerable seal. The breathable film plays this role. It allows air passing
to balance the pressure difference and prevent liquid entering into the motor, making the motor
comply with sealing and waterproofing requirement); On overheating protection of motor, we use
PTC over-current protector, which can prevent the motor from burning out due to external fault
(e.g. switch failure); On noise reduction, we adopt special design, highly wear-resistant and shock
absorption materials for the motor axis to prevent metal impact and friction noise when the mo-
tor is running at high speed. On power wiring, we use terminal interface directly, which removes
power wires and avoids poor contact and other faults caused by wires; The motor is in DC bipolar
permanent magnet structure, bi-directional rotation, integrates overheating protection device, and
there is no need for external circuit protection. When the motor is electrified, it generates a rotary
motion under the effect of magnetic field force, decelerates through a larger turbine reduction
gear, and obtains low speed high torque on output gear. When the motor is stuck or circuit failure
occurs, the overheating device will cut off the power in time to protect the motor.
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BYD S6, S6A, S6K Service Manual
4. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
B Go to step 5
4 Comprehensive diagnosis
NEXT
NEXT
NEXT
7 Finish
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BYD S6, S6A, S6K Service Manual
5. Fault Table
Left front window can’t control right 1. Right front window switch
front window, but right front window 2. Left front window switch
controls normally 3. Wiring harness
Left front window can’t control left rear 1. Left rear window switch
window, but left rear window controls 2. Left front window switch
normally 3. Wiring harness
Left front window can’t control right 1. Right rear window switch
rear window, but right rear window con- 2. Left front window switch
trols normally 3. Wiring harness
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BYD S6, S6A, S6K Service Manual
6. Terminal Diagnosis
Check the left front window switch
(2) Measure the voltage or resistance between terminals of the wire connectors.
115
BYD S6, S6A, S6K Service Manual
Normal:
Prompt:
If the test result doesn’t match the normal value, the respective wires may have fault.
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BYD S6, S6A, S6K Service Manual
Description:
The power supply of power window is lead from the instrument panel fuse and relay box.
Circuit diagram:
Mains electricity
Mains electricity
K2 -5
POWER
WINDOW
RELAY
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BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
OK
118
BYD S6, S6A, S6K Service Manual
Normal con-
Terminal Condition
dition
T09-1 body
Constant 11-14V
ground
T09-9 body
Constant <1V
ground
T09-10 body
Constant <1V
ground
T09-14 body
ON position 11-14V
ground
T09-19 body
Constant 11-14V
ground
Normal con-
Terminal Wire color
dition
T09-8-T2J-2 R <1ȍ
OK
Normal con-
Terminal Condition
dition
T09-8 body
ON position <1V
ground
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BYD S6, S6A, S6K Service Manual
OK
5 Finish
Left front window switch can’t control the left front window
Description:
When the engine is working or the start switch is turned to ON position, the left front power win-
dow regulator switch set (referred to as left front window switch) controls the ascending/descend-
ing of left front, right front, left rear and right rear window, and the priority is higher than right front,
left rear and right rear window switch. The left front power window has five positions in ascending/
descending: ķ Stop; ĸ Ascend I; Ĺ Descend I; ĺ Descend II (AUTO)
Note:
When the left front power window assembly is reinstalled or replaced, the window control
system must be initialized.
1. Press the left front window switch (AUTO) until the window open fully.
Circuit diagram:
WINDOW MOTOR
LEFT FRONT
DETECTION
CIRCUIT
120
BYD S6, S6A, S6K Service Manual
Inspection steps:
Terminal Normal
Battery anode-T11-1
Motor runs normally
Battery cathode -T11-2
OK
OK
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BYD S6, S6A, S6K Service Manual
Right front window switch can’t control the right front window
Description:
When the engine is working or start switch is turned to ON position and the master switch pops
up, the right front window switch can control its ascending/descending. Right front window switch
has three positions: ķ Stop; ĸ Ascend; Ĺ Descend
Circuit diagram:
POWER WINDOW
RELAY
LEFT FRONT WINDOW SWITCH
122
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Terminal Normal
Battery anode-U10-1
Motor runs normally
Battery cathode -U10-2
OK
123
BYD S6, S6A, S6K Service Manual
Normal
Terminal Condition
value
U08-6 - (body ground) Constant <1V
U08-9 - (body ground) ON position 11-14V
U08-10 - (body ground) ON position 11-14V
OK
4 Check the wires (right front window switch – right front window motor)
Normal
Terminal Wire color
value
U08-5-U10-2 Y/B <1ȍ
U08-7-U10-1 R/L <1ȍ
OK
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BYD S6, S6A, S6K Service Manual
Left rear window switch can’t control the left rear window
Description:
When the engine is working or start switch is turned to ON position and the master switch pops
up, the left rear window switch can control its ascending/descending. Left rear window switch has
three positions: ķ Stop; ĸ Ascend; Ĺ Descend
Circuit diagram:
125
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Terminal Normal
Battery anode-V02-1
Motor runs normally
Battery cathode -V02-2
OK
126
BYD S6, S6A, S6K Service Manual
OK
4 Check the wires (left rear window switch – left rear window motor)
OK
127
BYD S6, S6A, S6K Service Manual
Right rear window switch can’t control the right rear window
Description:
When the engine is working or start switch is turned to ON position and the master switch pops
up, the right rear window switch can control its ascending/descending. Right rear window switch
has three positions: ķ Stop; ĸ Ascend; Ĺ Descend
Circuit diagram:
128
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Terminal Normal
Battery anode-W02-1
Motor runs normally
Battery cathode -W02-2
OK
129
BYD S6, S6A, S6K Service Manual
OK
4 Check the wires (right rear window switch – right rear window motor)
OK
130
BYD S6, S6A, S6K Service Manual
Left front window switch can’t control the right front window
Description:
When the engine is working or start switch is turned to ON position and the master switch pops
up, the left front window switch can control the ascending/descending of right front window.
Circuit diagram:
POWER WINDOW
RELAY
131
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
value
U08-1 - (body Controls the
11-14V
ground) right front win-
dow to ascend
U08-2 - (body
with left front <1V
ground)
window switch
U08-1 - (body Controls the
<1V
ground) right front win-
dow to descend
U08-2 - (body
with left front 11-14V
ground)
window switch
NG
3 Check the wires (left front window switch – right front window switch)
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BYD S6, S6A, S6K Service Manual
OK
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BYD S6, S6A, S6K Service Manual
Left front window switch can’t control the left rear window
Description:
When the engine is working or start switch is turned to ON position and the master switch pops
up, the left front window switch can control the ascending/descending of left rear window.
Circuit diagram:
134
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
value
V04-1 body Controls the left
11-14V
ground rear window to
descend with
V04-2 body
left front win- <1V
ground
dow switch
V04-1 body Controls the left
<1V
ground rear window to
ascend with left
V04-2 body
front window 11-14V
ground
switch
NG
3 Check the wires (left front window switch – left rear window switch)
135
BYD S6, S6A, S6K Service Manual
OK
136
BYD S6, S6A, S6K Service Manual
Left front window switch can’t control the right rear window
Description:
When the engine is working or start switch is turned to ON position and the master switch pops
up, the left front window switch can control the ascending/descending of right rear window.
137
BYD S6, S6A, S6K Service Manual
Circuit diagram:
138
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
value
W04-1 body Controls the
11-14V
ground right rear win-
dow to descend
W04-2 body
with left front <1V
ground
window switch
W04-1 body Controls the
<1V
ground right rear win-
dow to ascend
W04-2 body
with left front 11-14V
ground
window switch
NG
3 Check the wires (left front window switch – right rear window switch)
139
BYD S6, S6A, S6K Service Manual
OK
140
BYD S6, S6A, S6K Service Manual
Can’t control the ascending/descending of right front, left rear and right rear
window with the left front window switch
Description:
When the engine is working or start switch is turned to ON position and the master switch pops
up, the left front window switch can control the ascending/descending of right front, left rear and
right rear window. The button on the left front window switch that controls right front, left rear and
right rear window has three positions: ķ Stop; ĸ Ascend; Ĺ Descend.
Inspection steps:
1 Vehicle inspection
OK
141
BYD S6, S6A, S6K Service Manual
Jog ascending/descending of left front window switch is normal, but the auto
function doesn’t work
Description:
When the engine is working or the start button is turned to ON position, the left front power win-
dow regulator switch set (referred to as left front window switch) controls the ascending/descend-
ing of left front, right front, left rear and right rear window, and the priority is higher than right front,
left rear and right rear window switch. The left front power window has five positions in ascending/
descending: ķ Stop; ĸ Ascend I; Ĺ Descend I; ĺ Descend II (AUTO)
Note:
When the left front power window assembly is reinstalled or replaced, the window control
system must be initialized.
Inspection steps:
OK Finish
NG
OK
142
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
143
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
144
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
145
BYD S6, S6A, S6K Service Manual
Prompt: The right front window regulator assembly is disassembled and assembled in the same
way as the left front window regulator assembly. The example is left front window regulator as-
sembly.
Disassembly
(1) Lower the glass to certain position, and remove the two bolts that fix the glass from the
sheet metal holes in the door with 10# socket wrench.
Assembly
146
BYD S6, S6A, S6K Service Manual
Prompt: The right rear window regulator assembly is disassembled and assembled in the same
way as the left rear window regulator assembly. The example is left rear window regulator assem-
bly.
Disassembly
Assembly
147
BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
1. Component Location
FRONT DOOR
COURTESY, RH
FRONT COURTESY
LAMP ASSY., RH
SWITCH, REAR
DOOR
COURTESY, LH
REAR COURTESY LAMP
FRONT COURTESY LAMP ASSY., LH
ASSY., LH
149
BYD S6, S6A, S6K Service Manual
Light, footwell
Clutch start switch (Assistant
Driver's side)
Headlamp adjusting switch
150
BYD S6, S6A, S6K Service Manual
FRONT FOG
LAMP, RH
FRONT FOG LAMP, LH
COMBINATION, HEADLAMP (&
COMBINATION, HEADLAMP BRACKET) ASSY., LH
(& BRACKET) ASSY., RH
- DIPPED HEADLIGHT
- DIPPED HEADLIGHT
- HEADLIGHT ON FULL BEAM
- HEADLIGHT ON FULL BEAM
- SIDELIGHT
- SIDELIGHT
- LAMP, SIDE TURN SIGNAL
- LAMP, SIDE TURN SIGNAL
151
BYD S6, S6A, S6K Service Manual
TAIL LAMP, RH
LAMP, REAR
COMBINATION,
RH
152
BYD S6, S6A, S6K Service Manual
HEADLIGHT ON RELAY,
FULL BEAM, LH HEADLIGH
T ON FULL
HEADLIGHT ON BEAM
FULL BEAM, RH
DIPPED
HEADLIGHT, LH
FRONTEYEBROW
LAMP, LH
FRONTEYEBROW
LAMP, RH
REAR SIDELIGHT, LH
REAR SIDELIGHT, RH
PORCH LAMP,
BACK DOOR, LH
PORCH LAMP,
BACK DOOR, RH
LAMP, LICENSE
PLATE, LH
LAMP, LICENSE
PLATE, RH
LIGHT, GLOVE
BOX
153
BYD S6, S6A, S6K Service Manual
FOOTWELL LIGHT, LH
FOOTWELL LIGHT, RH
ALL BACKLIGHTS
RELAY
FRONT FOG LAMP, LH CONTROL
RELAY, MODULE
FRONT FOG
FRONT LAMP
FRONT
FOGLAMP,RH
FOG LAMP, RH
COMBINAT
ION
SWITCH
SWITCH, FRONT
DOOR COURTESY, LH
FRONT DOOR
INTEGRATED CONTROL MODULE
COURTESY, LH
FRONT DOOR
COURTESY, RH
154
BYD S6, S6A, S6K Service Manual
LUGGAGE
COMPARTMENT LAMP
SWITCH,
BRAKE LAMP
BRAKE LAMP, LH
LAMP, HIGH-MOUNTED
BRAKE
LAMP, BACK-UP, LH
LAMP, BACK-UP, RH
FOOTWELL LIGHT,
REAR VIEW MIRROR,
OUTWARD, LH
FOOTWELL LIGHT,
REAR VIEW MIRROR,
OUTWARD, RH
155
BYD S6, S6A, S6K Service Manual
RELAY,
LAMP, FRONT
LAMP, TURN
TURN SIGNAL, LH
SIGNAL, LH
SWITCH, HAZARD
WARNING SIGNAL
156
BYD S6, S6A, S6K Service Manual
3. System Introduction
The lighting system provides lighting for driving at night. Exterior lighting fixtures consist of head-
lamp combination, rear lamp combination, tail lamp, license plate lamp, front fog lamp, rear fog
lamp, etc. The interior lighting fixtures consist of footwell lamp, roof lamp, luggage compartment
lamp, door courtesy, backlights, etc. The lamps are installed on required positions respectively,
and are equipped with control switches, wiring and fuses, forming the lighting system. The lighting
system also integrates signal alerts, which will warn the drivers of other vehicles and the pedes-
trians through audible and visible signals, including turn signals, brake signals, hazard warning
signals, marker signal, and reversing signals, to call their attention.
157
BYD S6, S6A, S6K Service Manual
4. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
B Go to step 5
4 Comprehensive Diagnosis
NEXT
NEXT
NEXT
7 Finish
158
BYD S6, S6A, S6K Service Manual
5. Fault Table
Head lamp
Fog lamp
Turn lamp
159
BYD S6, S6A, S6K Service Manual
Reversing lamp
Roof lamp
Brake lamp
Small light
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BYD S6, S6A, S6K Service Manual
One rear side light isn’t lit, and other small 1. Left (right) rear side light
lights are normal 2. Wire or connector
Marker lamp and license plate lamp aren’t
1. Left floor wire
lit, while other small lights are normal
Certain marker lamp or license plate lamp 1. Marker lamps and license plate lamps that aren’t lit
isn’t lit, while other small lights are normal 2. Wire or connector
1. Combination instrument
All backlights aren’t lit, while other small
2. Instrument panel fuse and relay box
lights are normal
3. Wire or connector
Backlight brightness can’t be adjusted 1. Combination instrument
161
BYD S6, S6A, S6K Service Manual
6. Terminal Diagnosis
1. Check the engine room fuse and relay box
(1) Lead wires from rear end of engine room fuse and relay box
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BYD S6, S6A, S6K Service Manual
(3) Lead wire from rear end of instrument panel fuse and relay box
163
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Mains electricity
Dimming signal switch
Switch
Turn signal
Switch
Fog lamp signal
164
BYD S6, S6A, S6K Service Manual
Inspection steps
1 Vehicle inspection
Result Perform
No light responds A
Certain lights do not respond B
B Go to Lighting Check
2 Check DTC
DTC Meaning
Master lighting switch OFF
B24A0-00
position circuit fault
Master lighting switch TAIL
B24A1-00
position circuit fault
Master lighting switch AUTO
B24A2-00
position circuit fault
B24A4-00 Dimmer switch circuit fault
B24A5-00 Turn signal switch circuit fault
Internal error or combination
B24AA-00
switch control device
Master lighting switch ON po-
B24AC-00
sition circuit fault
Rear fog lamp switch ON po-
B24AE-00
sition fault
165
BYD S6, S6A, S6K Service Manual
OK
OK
Normal
Terminal Condition
value
G11-5-G11-3 Constant 11~14V
G11-6-G11-3 ON position 11~14V
G11-3 body ground Constant <1V
OK
Normal
Terminal Condition
value
Turn on the
G11-4 body ground <1V
head lamp
166
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Wire color
value
G11-5-G2X-22 W/R <1ȍ
G11-6-G2X-12 L/Y <1ȍ
G11-1-G2X-13 P <1ȍ
G11-2-G2X-14 V <1ȍ
G11-4-B1I-7 R/L <1ȍ
G11-3 body ground W/L <1ȍ
OK
167
Right front dipped
Light
F1/4 right
Dipped
BYD S6, S6A, S6K Service Manual
168
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
OK
169
BYD S6, S6A, S6K Service Manual
Normal
Terminal Wire color
value
C02-1-C1H-13 W/R <1ȍ
C02-2 body ground B <1ȍ
C17-1-C1H-11 W/G <1ȍ
C17-2 body ground B <1ȍ
OK
170
171
Right front
Headlight on
Full bea
F1/1 right
Headlight on
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
OK
172
BYD S6, S6A, S6K Service Manual
Normal
Terminal Wire color
value
C07-1-C1H-14 L/Y <1ȍ
C07-2 body ground B <1ȍ
C14-1-C1H-5 L/R <1ȍ
C14-2 body ground B <1ȍ
OK
173
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Lamp
Right front fog
Lamp
Left front fog
174
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
Normal
Terminal Condition
value
Apply battery voltage
3-5 <1ȍ
to pin1 and pin2
3-5 Pin1 and pin2 floating >10Kȍ
OK
Normal
Terminal Condition
value
C20-3 body ground Constant 11~14V
C20-2 body ground Constant 11~14V
175
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
value
C1H-3 body Turn on the front fog
<1V
ground lamp
OK
OK
176
BYD S6, S6A, S6K Service Manual
Circuit diagram:
177
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
Normal
Terminal Wire color
value
G2Q-3-R05-1 V <1ȍ
G2Q-3-M29-1 V <1ȍ
R05-2 body ground B <1ȍ
M29-2 body ground B <1ȍ
OK
178
BYD S6, S6A, S6K Service Manual
Normal
Terminal Condition
value
Turn on the
G2Q-3 body ground 11~14V
rear fog lamp
OK
179
COMBINATION
INSTRUMENT
G14 -22
TURN LAMP
K5 RIGHT
RELAY
TURN/WARNIN
FLASH
RELAY
K2 -8
LEFT REAR TURN LAMP
F1/13 K6 LEFT TURN ENGINE ROOM FUSE AND
LEFT FRONT
COMBINATION
LAMP RELAY
INSTRUMENT
RELAY BOX
TURN LAMP
G14 -33
LEFT FRONT TURN LAMP
Circuit diagram:
HAZARD WARNING LEFT TURN INDICATOR
180
SWITCH
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
Normal
Terminal Condition
value
Press the
G25-5-G25-4 <1ȍ
switch
G25-5-G25-4 Switch pops up >10Kȍ
OK
181
BYD S6, S6A, S6K Service Manual
Normal
Terminal Wire color
value
B2D-1 body ground Y/R 11~14V
G25-5 body ground W/B 11~14V
G39-6 body ground W/B 11~14V
G39-8 body ground W/B 11~14V
G39-1 body ground W/B 11~14V
G39-3 body ground W/B 11~14V
G25-4-G2P-12 G <1V
G2Q-4-G39-5 W/G <1ȍ
G2Q-4-G39-10 W/G <1ȍ
OK
2. Press the hazard warning lamp and certain turn lamps aren’t lit
182
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
Normal
Terminal Wire color
value
C01-1-B2D-5 Y <1ȍ
C01-1 body ground Y >10Kȍ
C01-2 body ground B <1ȍ
OK
183
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
NG
184
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Ig1 power
Resversing lamp
185
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
Normal
Terminal Condition
value
A21-1-A21-2 Reverse gear <1ȍ
A21-1- A21-2 Exit reverse gear >10Kȍ
C01-2 body
B <1ȍ
ground
OK
186
BYD S6, S6A, S6K Service Manual
Normal
Terminal Condition
value
G2X-16-G2P-27 Reverse gear <1ȍ
OK
OK
187
BYD S6, S6A, S6K Service Manual
Normal
Terminal Wire color
value
G2P-14-Y15-2 G <1ȍ
G2P-14-Y10-2 G <1ȍ
Y15-1 body ground B <1ȍ
Y10-1 body ground B <1ȍ
OK
188
189
BACK DOOR COURTESY SWITCH (CLOSE: DOOR OPENS)
BYD S6, S6A, S6K Service Manual
F2/2 ROOF
LAMP 7.5A RI GHT LUGGAGE
COMPARTMENT LAMP
Circuit diagram:
LEFT LUGGAGE BACK DOOR
COMPARTMENT LAMP COURTESY SWITCH
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
OK
Normal
Terminal Condition
value
Open left
K16-1 body ground <1ȍ
front door
Close left
K16-1 body ground >10Kȍ
front door
190
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Wire color
value
Open left
G2N-22-U05-1 <1ȍ
front door
Y <1ȍ >10Kȍ
T2J-7-T06-2 B/Y <1ȍ
T2K-9-T06-1 O <1ȍ
K2E-13-K16-1 W <1ȍ
OK
191
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
OK
Normal
Terminal Condition
value
Open right
M10-1 body ground <1ȍ
front door
Close right
M10-1 body ground >10Kȍ
front door
192
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Wire color
value
G2N-22-U05-1 Y <1ȍ
G2Q-9-U05-2 Lg <1ȍ
K2H-14-M10-1 W <1ȍ
T2K-9-T06-1 O <1ȍ
K2E-13-K16-1 W <1ȍ
OK
193
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
OK
194
BYD S6, S6A, S6K Service Manual
Normal
Terminal Condition
value
Press the
Y14-1 body ground door courtesy >10Kȍ
switch
Door cour-
Y14-1 body ground <1ȍ
tesy pops up
OK
Normal
Terminal Wire color
value
Press the door
K2F-6-Y08-1 >10Kȍ
courtesy switch
Br <1ȍ <1ȍ
K2F-6-Y13-1 Br <1ȍ
Y13-2-Y14-1 L/Y <1ȍ
Y08-2-Y14-1 L/Y <1ȍ
OK
195
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Mains electricity
F2/2 roof
Lamp 7.5a
Front roof lamp
196
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
condition
Turn to ON
Lamp is lit
position
P03-9- battery (+)
Turn to DOOR
P03-4- battery (-) Lamp is lit
position
P03-2- battery (-)
Turn to OFF
Lamp is off
position
OK
197
BYD S6, S6A, S6K Service Manual
Normal
Terminal Wire color
value
P2I-4-P03-9 R/B <1ȍ
P03-4-P2I-1 B <1ȍ
G2N-23 body
B <1ȍ
ground
P03-2-P2I-3 O <1ȍ
P2I-4 body
R/B >10Kȍ
ground
P03-4 body
B >10Kȍ
ground
P03-2 body
O >10Kȍ
ground
OK
198
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
condition
Turn to ON
Lamp is lit
position
P04-2- battery (+)
Turn to DOOR
P04-3- battery (-) Lamp is lit
position
P04-1- battery (-)
Turn to OFF
Lamp is off
position
OK
199
BYD S6, S6A, S6K Service Manual
Normal
Terminal Wire color
value
P2I-4-P04-2 R/B <1ȍ
P04-3-P2I-1 B <1ȍ
G2N-23 body ground
B <1ȍ
P04-1-P2I-3 O <1ȍ
P2I-4 body ground R/B >10Kȍ
P04-3 body ground B >10Kȍ
P04-1 body ground O >10Kȍ
OK
200
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Mains electricity
F2/2 roof
Lamp 7.5a
Left footlight
Right footlight
201
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
OK
202
BYD S6, S6A, S6K Service Manual
Normal
Terminal Wire color
value
T2K-9-T05-6 O <1ȍ
G2N-22-U04-6 Y <1ȍ
T05-11-G2Q-5 Br/W-O <1ȍ
U04-11-G2Q-5 O <1ȍ
T2K-9 body ground O >10Kȍ
G2N-22 body ground Y >10Kȍ
T05-11 body ground Br/W-O >10Kȍ
U04-11 - body ground O >10Kȍ
OK
203
BYD S6, S6A, S6K Service Manual
Circuit diagram:
MAINS
ELECTRICITY
INSTRUMENT
PANEL FUSE
AND RELAY
BOX
PANEL FUSE AND
INSTRUMENT
HIGH-MOUNTED BRAKE LAMP
LEFT BRAKE LAMP
204
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
value
B1D-10 body ground Constant 11~14V
OK
205
BYD S6, S6A, S6K Service Manual
Normal
Terminal Condition
value
Step on the
<1ȍ
brake pedal
G13-2-G13-1
Brake pedal
>10Kȍ
pops up
Step on the
>10Kȍ
brake pedal
G13-4-G13-3
Brake pedal
<1ȍ
pops up
OK
Normal
Terminal Condition
value
B1D-10-G2N-21 R <1ȍ
G2X-34-G13-1 R <1ȍ
G13-2-G2N-11 W/B <1ȍ
B1D-10 body ground R >10Kȍ
G2X-34 body ground R >10Kȍ
G13-2 body ground W/B >10Kȍ
206
BYD S6, S6A, S6K Service Manual
OK
2. Certain brake lamps aren’t lit (left brake lamp for example)
207
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
208
BYD S6, S6A, S6K Service Manual
MAINS
F1/6
SMALL
LIGHT 15A
LIGHT
FRONT SIDE
RIGHT
MARKER
LICENSE
SIDE LIGHT
209
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
OK
2. Left front side light isn’t lit, and other small lights are normal
210
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Mains
F1/6
Small
Light
15a
Km5
Inner
Small
Light
Relay
Left front side light
211
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Wire color
value
C1H-10-C08-1 B/Y <1ȍ
C08-2 body ground B <1ȍ
C08-1 body ground B/Y >10Kȍ
OK
3. Right front side light isn’t lit, and other small lights are normal
212
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Mains
F1/6 small
Light 15a
Km5 inner
Small light
Relay
Right front side light
213
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Wire color
value
C1H-9-C13-1 Br <1ȍ
C13-2 body ground B <1ȍ
C13-1 body ground Br >10Kȍ
OK
5. One rear side light isn’t lit, and other small lights are normal (left rear side light)
214
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Light
Left Rear Side
215
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Wire color
value
K38-3-K2F-12 V <1ȍ
K38-1 body ground B <1ȍ
K38-3 body ground V >10Kȍ
OK
6. One rear side light isn’t lit, and other small lights are normal (right rear side light)
216
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Instrument panel
Fuse a Nd relay box
Light
Right rear side
217
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Wire color
value
M30-3-K2F-12 V <1ȍ
M30-1 body ground B <1ȍ
M30-3 body ground V >10Kȍ
OK
7. Certain marker lamp or license plate lamp isn’t lit, while other small lights are normal
218
219
BYD S6, S6A, S6K Service Manual
RIGHT REAR
INSTRUMENT PANEL FUSE AND
LICENSE PLATE
LEFT REAR
LICENSE PLATE
RELAY BOX
BACK DOOR
RIGHT MARKER
BACK DOOR LEFT
MARKER LAMP
Circuit diagram:
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
220
BYD S6, S6A, S6K Service Manual
Normal
Terminal Wire color
value
Y15-3-K2F-12 V <1ȍ
Y10-3-K2F-12 V <1ȍ
Y06-1-K2F-12 V <1ȍ
Y12-1-K2F-12 V <1ȍ
Y15-1 body ground B <1ȍ
Y10-1 body ground B <1ȍ
Y06-2 body ground B <1ȍ
Y12-2 body ground B <1ȍ
OK
8. All backlights aren’t lit, while other small lights are normal
221
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Backlight
Vehicle backlight power supply
222
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
OK
223
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Roof lighting
Inner small
Light relay
B1i-10
Supply
T power
Backligh
Headlamp adjustment
Switch
Adjustment motor
Left headlamp
Adjustment motor
Right headlamp
224
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
225
BYD S6, S6A, S6K Service Manual
OK
OK
226
BYD S6, S6A, S6K Service Manual
OK
227
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
228
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
229
BYD S6, S6A, S6K Service Manual
Tail lamp
Disassembly
Assembly
Disassembly
Assembly
230
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
Disassembly
Assembly
231
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
Disassembly
Assembly
232
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
233
BYD S6, S6A, S6K Service Manual
Disassembly
234
BYD S6, S6A, S6K Service Manual
Assembly
235
BYD S6, S6A, S6K Service Manual
1. Component Location
236
BYD S6, S6A, S6K Service Manual
237
BYD S6, S6A, S6K Service Manual
3. System Introduction
The electric rearview mirror system allows operations of rearview mirror and assembly on the
driver’s seat through the electrical switch on left instrument panel. If the rearview mirror is impact-
ed by an object from the behind, the shell will fold out certain angle to avoid damage; if the glass
is broken due to impact, the small pieces won’t fall off from the mirror pallet, which will improve
the security.
Main functions:
Mirror adjusting: the driver can adjust the mirror up and down, left and right to get the best
rear view.
Folding function: control the folding and expanding of rearview mirror through the switch
to improve the passability of vehicle and protect the rearview mirror; meanwhile, when the
security system of the vehicle is activated, the rearview mirror folds automatically to avoid
scratching.
Main components:
238
BYD S6, S6A, S6K Service Manual
4. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
B Go to step 5
4 Comprehensive Diagnosis
NEXT
NEXT
NEXT
7 Finish
239
BYD S6, S6A, S6K Service Manual
5. Fault Table
240
BYD S6, S6A, S6K Service Manual
Description:
If the electric rearview mirror doesn’t work at all, it may be caused by the power problem of con-
troller.
mains electricity
F1/16
F2/5 mains
cigar electricity
lighter 40A
15A
K2-3 cigar
lighter relay
241
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
OK
242
BYD S6, S6A, S6K Service Manual
Normal con-
Terminal Condition
dition
G02-7 body
Constant <1V
ground
G02-8 body
ACC 11-14V
ground
OK
3 Finish
243
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Left Up
Right Dow
244
BYD S6, S6A, S6K Service Manual
Inspection steps
Normal con-
Terminal Condition
dition
G02-8-G02-5 Adjust switch <1ȍ
G02-6-G02-7 to left <1ȍ
G02-6-G02-8 Adjust switch <1ȍ
G02-5-G02-7 to right <1ȍ
G02-8-G02-4 Adjust switch <1ȍ
G02-6-G02-7 up <1ȍ
G02-8-G02-6 Adjust switch <1ȍ
G02-4-G02-7 down <1ȍ
OK
245
BYD S6, S6A, S6K Service Manual
OK
3 Check wires (electric rearview mirror switch – left electric rearview mirror motor)
Normal value
Normal
Terminal Wire color
value
G02-4-T05-3 G/R <1ȍ
G02-5-T05-9 L/B <1ȍ
G02-6-T05-4 Y/B <1ȍ
NG Replace wires
OK
4 Finish
246
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Lef Up
247
BYD S6, S6A, S6K Service Manual
Inspection steps
Normal con-
Terminal Condition
dition
G02-8-G02-2 Adjust switch <1ȍ
G02-6-G02-7 to left <1ȍ
G02-7-G02-2 Adjust switch <1ȍ
G02-8-G02-6 to right <1ȍ
G02-8-G02-3 Adjust switch <1ȍ
G02-6-G02-7 up <1ȍ
G02-8-G02-6 Adjust switch <1ȍ
G02-3-G02-7 down
OK
248
BYD S6, S6A, S6K Service Manual
OK
3 Check wires (electric rearview mirror switch – right electric rearview mirror motor)
Normal value
Normal
Terminal Wire color
value
G02-2-U04-4 G/B <1ȍ
G02-3-U04-3 Y/R <1ȍ
G02-6-U04-9 Y/B <1ȍ
NG Replace wires
OK
4 Finish
249
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Retur Retur
Fold Fold
Left electric rearview mirror motor Right electric rearview mirror motor
250
BYD S6, S6A, S6K Service Manual
Inspection steps
Normal con-
Terminal Condition
dition
G02-9 body
Fold/expand 11-14V
ground
button is
G02-10 body
pressed down <1V
ground
G02-9 body
<1V
ground Fold/expand
G02-10 body button bounces
11-14V
ground
OK
OK
251
BYD S6, S6A, S6K Service Manual
OK
Normal value
Normal
Terminal Wire color
value
G02-9-G2P-17 W <1ȍ
G02-10-G2P-16 Gr <1ȍ
NG Replace wires
OK
252
BYD S6, S6A, S6K Service Manual
Normal value
Normal
Terminal Wire color
value
U04-2-G2X-37 P <1ȍ
U04-8-G2Q-11 Gr <1ȍ
Y/L <1ȍ
NG Replace wires
OK
253
BYD S6, S6A, S6K Service Manual
Normal value
Normal
Terminal Wire color
value
T05-2-G2X-37 G/B <1ȍ
T05-8-G2Q-11 Y/L <1ȍ
NG Replace wires
OK
7 Replace MICU
254
BYD S6, S6A, S6K Service Manual
7. Tool Preparations
255
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
256
BYD S6, S6A, S6K Service Manual
1. Component Location
MOTOR, VERTICAL
ADJUSTER, SEAT
FRONT SEAT
HEATER SWITCH, L
MOTOR, LEVELING SEAT BACKREST
ADJUSTER, SEAT ADJUSTER
ADJUSTER SWITCH, LUMBAR
MOTOR
SUPPORT, POWER SEAT
ADJUSTER SWITCH,
POWER SEAT, LH
257
BYD S6, S6A, S6K Service Manual
MOTOR, LUMBAR
SUPPORT ADJUSTER
FRONT VERTICAL
ADJUSTING MOTOR
ADJUSTER
SWITCH, LEVEL
POWER SEAT SLIDINGMOTOR
ON DRIVER’S
SIDE
REAR VERTICAL
ADJUSTING MOTOR
BACKREST
INCLINATION ANGLE
ADJUSTING MOTOR
258
BYD S6, S6A, S6K Service Manual
3. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
B Go to step 5
4 Comprehensive Diagnosis
NEXT
NEXT
NEXT
7 Finish
259
BYD S6, S6A, S6K Service Manual
4. Fault Table
260
BYD S6, S6A, S6K Service Manual
Only lumbar support adjuster is invalid, while other electric adjusting function
of the seat are normal
Circuit diagram:
MAINS
UP DOWN
261
BYD S6, S6A, S6K Service Manual
Inspection steps
NG Replace fuse
OK
Normal
Terminal Condition
value
Adjust lumbar
Nc03-2- <1ȍ
support up
Nc03-10
Other position >10Kȍ
Adjust lumbar
Nc03-14- <1ȍ
support up
Nc03-13
Other position >10Kȍ
Adjust lumbar
Nc03-10- <1ȍ
support down
Nc03-13
Other position >10Kȍ
Adjust lumbar
Nc03-2- <1ȍ
support down
Nc03-14
Other position >10Kȍ
OK
262
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
value
K2F-11-Nc03-2 G/B-R <1ȍ
Nc03-10-Nc08-2 Y <1ȍ
Nc03-14-Nc08-1 L <1ȍ
Nc03-13 body
B <1ȍ
ground
OK
4 Finish
263
BYD S6, S6A, S6K Service Manual
Circuit diagram:
MAINS
F2/8 FRONT
SEAT, LH
20A
DRIVER’S SIDE
POWER SEAT ON
ADJUSTER SWITCH,
UP DOWN
ADJUSTER
VERTICAL
MOTOR, FRONT
264
BYD S6, S6A, S6K Service Manual
Inspection steps
Normal
Terminal Condition
value
Increase front
Nc03-4- <1ȍ
vertical adjuster
Nc03-3
Other position >10Kȍ
Increase front
Nc03-9- <1ȍ
vertical adjuster
Nc03-8
Other position >10Kȍ
Reduce front
Nc03-4- <1ȍ
vertical adjuster
Nc03-9
Other position >10Kȍ
Reduce front
Nc03-3- <1ȍ
vertical adjuster
Nc03-8
Other position >10Kȍ
OK
265
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
value
K2F-7-Nc03-4 L/Y-R <1ȍ
Nc03-3-
V <1ȍ
Nc04-2
Nc03-9-
L <1ȍ
Nc04-1
Nc03-8 body
B <1ȍ
ground
OK
4 Finish
266
BYD S6, S6A, S6K Service Manual
Circuit diagram:
MAINS
F2/8 FRONT
SEAT, LH
20A
DRIVER’S SIDE
POWER SEAT ON
ADJUSTER SWITCH,
UP DOWN
VERTICAL ADJUSTER
MOTOR, REAR
267
BYD S6, S6A, S6K Service Manual
Inspection steps
Normal
Terminal Condition
value
Increase rear ver-
Nc03-4- <1ȍ
tical adjuster
Nc03-5
Other position >10Kȍ
Increase rear ver-
Nc03-1- <1ȍ
tical adjuster
Nc03-8
Other position >10Kȍ
Reduce rear ver-
Nc03-4- <1ȍ
tical adjuster
Nc03-1
Other position >10Kȍ
Reduce rear ver-
Nc03-5- <1ȍ
tical adjuster
Nc03-8
Other position >10Kȍ
OK
268
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
value
K2F-7-Nc03-4 L/Y-R <1ȍ
Nc03-5-Nc05-1 L/O <1ȍ
Nc03-1-Nc05-2 O <1ȍ
Nc03-8 body
B <1ȍ
ground
OK
4 Finish
269
BYD S6, S6A, S6K Service Manual
Circuit diagram:
MAINS
F2/8 FRONT
SEAT, LH
20A
DRIVER’S SIDE
POWER SEAT ON
ADJUSTER SWITCH,
FORWARD BACKWAR
MOTOR
LEVEL SLIDING
270
BYD S6, S6A, S6K Service Manual
Inspection steps
Normal
Terminal Condition
value
Forward adjust-
Nc03-4- ing in horizontal <1ȍ
Nc03-11 direction
Other position >10Kȍ
Forward adjust-
Nc03-7- ing in horizontal <1ȍ
Nc03-8 direction
Other position >10Kȍ
Backward adjust-
Nc03-4- ing in horizontal <1ȍ
Nc03-7 direction
Other position >10Kȍ
Backward adjust-
Nc03-11- ing in horizontal <1ȍ
Nc03-8 direction
Other position >10Kȍ
OK
271
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
value
K2F-7-Nc03-4 L/Y-R <1ȍ
Nc03-11-Nc06-1 B/R <1ȍ
Nc03-7-Nc06-2 Y/R <1ȍ
Nc03-8 body
B <1ȍ
ground
OK
4 Finish
272
BYD S6, S6A, S6K Service Manual
Circuit diagram:
MAINS
F2/8 FRONT
SEAT, LH
20A
DRIVER’S SIDE
POWER SEAT ON
ADJUSTER SWITCH,
LEAN LEAN
FORWARD BACKWARD
ANGLE ADJUSTER
INCLINATION
BACKREST
MOTOR,
273
BYD S6, S6A, S6K Service Manual
Inspection steps
Normal
Terminal Condition
value
Forward adjust-
Nc03-4- ing in horizontal <1ȍ
Nc03-12 direction
Other position >10Kȍ
Forward adjust-
Nc03-6- ing in horizontal <1ȍ
Nc03-8 direction
Other position >10Kȍ
Backward adjust-
Nc03-4- ing in horizontal <1ȍ
Nc03-6 direction
Other position >10Kȍ
Backward adjust-
Nc03-12- ing in horizontal <1ȍ
Nc03-8 direction
Other position >10Kȍ
OK
274
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
value
K2F-7-Nc03-4 L/Y-R <1ȍ
Nc03-12-Nc07-2 W <1ȍ
Nc03-6-Nc07-1 Y <1ȍ
Nc03-8 body
B <1ȍ
ground
OK
4 Finish
275
BYD S6, S6A, S6K Service Manual
1. Component Location
HIGH MOUNTED
MULTIFUNCTION DISPLAY
SCREEN ASSEMBLY
276
BYD S6, S6A, S6K Service Manual
POWER
DISPLAY SCREEN
MULTIFUNCTION
DISTRIBUTOR
277
BYD S6, S6A, S6K Service Manual
3. System Introduction
The vehicle is equipped with multifunction display screen, which is installed in the center of the in-
strument panel shield. It won’t affect the driver’s vision, and the driver also can easily get the cur-
rent basic information of the vehicle, in order to take measured in time.
Time display
278
BYD S6, S6A, S6K Service Manual
4. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
4 Comprehensive diagnosis
NEXT
NEXT
NEXT
7 Finish
279
BYD S6, S6A, S6K Service Manual
5. Fault Table
280
BYD S6, S6A, S6K Service Manual
281
BYD S6, S6A, S6K Service Manual
7. Terminal diagnosis
1. Check the pin of the multifunction display screen
(1) Lead wire from the rear end of multifunction display screen Gb07 connector
282
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Combination instrument
Mains
Multifunction Display Screen
Combination instrument
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Inspection steps
Normal
Terminal Condition
value
Gb07-5 body
ACC power 11~14V
ground
Gb07-6 body
Constant 11~14V
ground
Gb07-4 body
Constant <1ȍ
ground
Gb07-1 body
Constant <1ȍ
ground
OK
OK
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Disassembly
Assembly
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BYD S6, S6A, S6K Service Manual
1. Component Location
TREBLE FREQUENCY
MIDRANGE SPEAKER (M) SPEAKER (R)
MIDRANGE SPEAKER (L)
TREBLE
FREQUENCY
USB&AUX INTERFACE
SPEAKER (L)
ASSEMBLY
LEFT SWITCHES
GROUP, STEERING
WHEEL
ON-BOARD PHONE SWITCH
ACOUSTICS SWITCH
CLOCK SPRING
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BYD S6, S6A, S6K Service Manual
287
BYD S6, S6A, S6K Service Manual
OUTBOARD ANTENNA
ON-BOARD TV MODULE
ANTENNA AMPLIFIER
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ANTENNA
ANTENNA SPEAKER
AMPLIFIER
USB&AUX
EXTERNAL
AMPLIFIER
STEERING DVD/CD
WHEEL HOST
SWITCH
TV
CAMERA
7” LCD
*1. CD SYSTEM
CAN CABLE *2. DVD SYSTEM
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BYD S6, S6A, S6K Service Manual
The multimedia system is an all-in-one (2) Compatible disc: DVD, VCD, MP3,
player that integrates digital imaging, CD, WMA
which will make your car become a small
(3) Disc cleaning
mobile audio-visual theater. It will meet
your different needs, including playing Prompt:
disc, watching TV, listening to radio, in-
telligent GPS navigation. Do not wash the disc with lens cleaning liq-
uid, which may damage the DVD host
Main components:
(1) If the disc is stained with dust, please
Multimedia host (DVD, radio, TV) wipe with soft cloth (e.g. glasses cloth)
from the center to edge.
Central control panel
Prompt:
Multifunction steering wheel
The disc may be scratched if you press the
External amplifier disc with hands or wipe with hard cloth.
Speakers (two treble frequency speak- 2. MP3/WMA files playing
ers, two front door speakers, and two
rear door speakers) (1) Allow playing MP3 and WMA files
AM: 522KHz~1620KHz
FM: 87.5MHz~108.0MHz
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SIGNAL ATTENUATION
(2) Multi-channel interference
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4. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
B Go to step 5
4 Comprehensive diagnosis
NEXT
NEXT
NEXT
7 Finish
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5. Fault Table
1. Speakers
2. External amplifier
Speakers have no sound
3. Multimedia host
4. Wiring harness
1. Speakers
Noise or poor audio 2. Multimedia host
3. External amplifier
1. Multimedia host
No sound in DVD mode 2. External amplifier
2. Wiring harness
Can’t receive radio signal (or weak signal) 1. Go to “Can’t receive radio signal (or weak signal)”
1. Disc
Can’t insert or eject disc 2. Multimedia host
3. Wiring harness
1. Multimedia host
Black screen 2. Central control panel
3. Wiring harness
1. Multimedia host
Touch screen is unavailable 2. Central control panel
3. Wiring harness
1. Multimedia host
Fails to connect to mobile phone
2. Wiring harness
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BYD S6, S6A, S6K Service Manual
1. Mobile phone
2. Microphone
The other party can’t hear your speech
3. Wiring harness
4. Multimedia host
1. Mobile phone
Can’t hear the speech of the other party 2. Wiring harness
3. Multimedia host
1. SD card of map
2. Multimedia host
GPS screen shakes or image isn’t clear
3. GPS antenna
4. Wiring harness
1. SD card of map
GPS position on the screen isn’t correct
2. Multimedia host
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BYD S6, S6A, S6K Service Manual
6. Terminal diagnosis
1. Check the terminals of DVD host.
(1) Lead wire from the rear side of connector G16, and check the voltage of each terminal.
Terminal descrip-
Terminal No. Wire color Test condition Normal value
tion
G16-1 body ground V LCD_R —— ——
G16-2 body ground W/R LCD_G —— ——
G16-3 body ground W/L LCD_B —— ——
G16-4 body ground W LCD_VSY —— ——
G16-5 body ground W/L LCD_HSY —— ——
G16-6 body ground G TSXM —— ——
G16-7 body ground W TSYP —— ——
G16-8 body ground G/B GND Constant <1V
G16-9 body ground Y/R LCD_PWR —— ——
G16-10 body ground G/Y LAMP_PWR —— ——
Shielding layer
G16-11 body ground B Constant <1V
grounding
Shielding layer
G16-12 body ground B Constant <1V
grounding
Shielding layer
G16-13 body ground B Constant <1V
grounding
Shielding layer
G16-14 body ground B Constant <1V
grounding
Shielding layer
G16-15 body ground B Constant <1V
grounding
G16-16 body ground R AGND Constant <1V
Shielding layer
G16-17 body ground B Constant <1V
grounding
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BYD S6, S6A, S6K Service Manual
Terminal descrip-
Terminal No. Wire color Test condition Normal value
tion
G16-18 body ground R TSYM —— ——
G16-19 body ground L TSYP —— ——
G16-20 body ground W CAN_MH —— ——
G16-21 body ground Y CAN_ML —— ——
G16-22 body ground O LAMP_GND Constant <1V
(2) Lead wire from the rear side of connector G19, and check the voltage of each terminal.
Terminal descrip-
Terminal No. Wire color Test condition Normal value
tion
G19-1 body ground V/W LCD_CTL —— ——
G19-2 body ground W/R LCD_G —— ——
G19-3 body ground W/L LCD_B —— ——
G19-4 body ground W LCD_VSY —— ——
G19-5 body ground W/L LCD_HSY —— ——
G19-6 body ground G TSXM —— ——
G19-7 body ground W TSXP —— ——
G19-8 body ground G/B GND Constant <1V
G19-9 body ground Y/R LCD_PWR —— ——
G19-10 body ground G/Y —— —— ——
G19-11 body ground B —— —— ——
G19-12 body ground B —— —— ——
G19-13 body ground B —— —— ——
G19-14 body ground B —— —— ——
G19-15 body ground B —— —— ——
G19-16 body ground R AGND Constant <1V
G19-17 body ground B —— —— ——
G19-18 body ground R TSYM —— ——
G19-19 body ground L TSYP —— ——
G19-20 body ground W CAN_MH —— ——
G19-21 body ground Y CAN_ML —— ——
G19-22 body ground O LAMP_GND Constant <1V
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BYD S6, S6A, S6K Service Manual
(3) Lead wire from the rear side of connector G20, and check the voltage of each terminal.
Terminal descrip-
Terminal No. Wire color Test condition Normal value
tion
G20-1 body ground B GND Constant <1V
G20-2 body ground Y AUX_L —— ——
G20-3 body ground Gr AUX_R —— ——
G20-4 body ground Br AUX_DEC —— ——
G20-5 body ground —— —— —— ——
G20-6 body ground —— —— —— ——
G20-7 body ground —— —— —— ——
G20-8 body ground V BCAN_L —— ——
G20-9 body ground P BCAN_H —— ——
G20-10 body ground Sb KEY_AD3 —— ——
G20-11 body ground —— —— —— ——
G20-12 body ground L/O AGND_IN —— ——
G20-13 body ground Gr SW_IN —— ——
G20-14 body ground Y/G CT_IN —— ——
G20-15 body ground R GND Constant <1V
G20-16 body ground G AUX_USBN —— ——
G20-17 body ground L AUX_USBP —— ——
G20-18 body ground W AUX_PWR —— ——
G20-19 body ground W AGND Constant <1V
G20-20 body ground Gr TV_R —— ——
G20-21 body ground G TV_L —— ——
Shielding layer
G20-22 body ground B/W Constant <1V
grounding
G20-23 body ground —— —— —— ——
G20-24 body ground —— —— —— ——
G20-25 body ground —— —— —— ——
G20-26 body ground —— —— —— ——
G20-27 body ground —— —— —— ——
G20-28 body ground B GND Constant <1V
G20-29 body ground —— —— —— ——
G20-30 body ground —— —— —— ——
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BYD S6, S6A, S6K Service Manual
(4) Lead wire from the rear side of connector G21, and check the voltage of each terminal.
Terminal descrip-
Terminal No. Wire color Test condition Normal value
tion
G21-1 body ground R/B LAMP_IN —— ——
G21-2 body ground R/B B_C_PWR —— ——
G21-3 body ground V/W R_C_PWR —— ——
G21-4 body ground —— —— —— ——
G21-5 body ground Y PAK_IN —— ——
G21-6 body ground G BACK_IN —— ——
G21-7 body ground L LEMP_GND Constant <1V
G21-8 body ground L/B GND Constant <1V
G21-9 body ground Sb GND Constant <1V
G21-10 body ground —— —— —— ——
G21-11 body ground —— —— —— ——
G21-12 body ground —— —— —— ——
G21-13 body ground —— —— —— ——
G21-14 body ground —— —— —— ——
(5) Lead wire from the rear side of connector G22, and check the voltage of each terminal.
Terminal descrip-
Terminal No. Wire color Test condition Normal value
tion
G22-1 body ground —— —— —— ——
G22-2 body ground —— —— —— ——
G22-3 body ground —— —— —— ——
G22-4 body ground —— —— —— ——
Shielding layer
G22-5 body ground B Constant <1V
grounding
G22-6 body ground R AGND Constant <1V
G22-7 body ground L TV_C —— ——
G22-8 body ground Y TV_Y —— ——
G22-9 body ground —— —— —— ——
G22-10 body ground —— —— —— ——
G22-11 body ground —— —— —— ——
G22-12 body ground —— —— —— ——
G22-13 body ground —— —— —— ——
Shielding layer
G22-14 body ground B/L Constant <1V
grounding
G22-15 body ground W R_C_CVBS —— ——
G22-16 body ground W/L B_C_CVBS —— ——
Shielding layer
G22-17 body ground W/B Constant <1V
grounding
G22-18 body ground —— —— —— ——
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BYD S6, S6A, S6K Service Manual
(6) Lead wire from the rear side of connector G23, and check the voltage of each terminal.
Terminal descrip-
Terminal No. Wire color Test condition Normal value
tion
G23-1 body ground L FR_IN —— ——
G23-2 body ground Y/O FL_IN —— ——
G23-3 body ground G ACC ACC position power 11~14V
Mains electricity
G23-4 body ground W/G Constant 11~14V
supply
G23-5 body ground —— —— —— ——
G23-6 body ground —— —— —— ——
G23-7 body ground B GND Constant <1V
G23-8 body ground L/Y Antenna wire —— ——
G23-9 body ground —— —— —— ——
G23-10 body ground —— —— —— ——
(7) Lead wire from the rear side of connector G24, and check the voltage of each terminal.
Terminal descrip-
Terminal No. Wire color Test condition Normal value
tion
G24-1 body ground L/W RR_IN —— ——
G24-2 body ground Y/L RL_IN —— ——
G24-3 body ground —— —— —— ——
G24-4 body ground R/G KEY_AD2 —— ——
G24-5 body ground Br GND Constant <1V
G24-6 body ground —— —— —— ——
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BYD S6, S6A, S6K Service Manual
Inspection steps:
1 Vehicle inspection
OK System is normal
NG
NG
NG
300
BYD S6, S6A, S6K Service Manual
Inspection steps:
NG
NG
301
BYD S6, S6A, S6K Service Manual
Inspection steps:
NEXT
Result Perform
Certain speakers have no sound A
No speaker has sound B
OK
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BYD S6, S6A, S6K Service Manual
NG
NG
303
BYD S6, S6A, S6K Service Manual
Inspection steps:
1 Vehicle inspection
OK System is normal
NG
Result Perform
Certain speakers do not
A
have normal audio effect
No speaker has normal
B
audio effect
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BYD S6, S6A, S6K Service Manual
NG
NG
305
BYD S6, S6A, S6K Service Manual
Inspection steps:
1 Vehicle inspection
Result Perform
No sound in DVD mode, while
A
other modes have sound
No sound in DVD mode and
B
other modes
Go to “Speakers have no
B
sound in any mode”
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BYD S6, S6A, S6K Service Manual
Inspection steps:
1 Vehicle inspection
OK System is normal
NG
OK
3 System is normal
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BYD S6, S6A, S6K Service Manual
Inspection steps:
NG Disc is damaged
OK
NG
OK Disc is damaged
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BYD S6, S6A, S6K Service Manual
NG
OK
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BYD S6, S6A, S6K Service Manual
Inspection steps:
1 Vehicle inspection
OK System is normal
NG
OK System is normal
OK
NG
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BYD S6, S6A, S6K Service Manual
OK
311
BYD S6, S6A, S6K Service Manual
Inspection steps:
NG
OK Disc is damaged
NG
Result Perform
Road is bumpy NG
Road condition is good OK
OK Go to step 5
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BYD S6, S6A, S6K Service Manual
NG
OK
OK
6 The fault is caused by temperature change (place for a while before using again)
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BYD S6, S6A, S6K Service Manual
Inspection steps:
1 Vehicle inspection
OK System is normal
NG
NG
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BYD S6, S6A, S6K Service Manual
Prompt: Check the radio receiving at a place away from tall buildings. The signal is weak if it is far
away from the radio station or near mountain or tall buildings.
Inspection steps:
NG
OK
315
BYD S6, S6A, S6K Service Manual
NG
316
BYD S6, S6A, S6K Service Manual
Circuit diagram
MAINS
F1/16MAINS
ELECTRICIT
Y 40A
F2/4 ACOUSTICS 20A
MAINS
DVD HOST
Inspection steps:
317
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
value
G23-3 body
ACC power 11-14V
ground
G23-4 body Mains electric-
11-14V
ground ity supply
G23-7 body
Constant <1V
ground
OK
3 Finish
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BYD S6, S6A, S6K Service Manual
Circuit diagram
MAINS
ELECT
RICITY
EXTERNAL AMPLIFIER
319
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
value
K39-1 body Mains electric-
11-14V
ground ity supply
K39-2 body Mains electric-
11-14V
ground ity supply
K39-3 body
ACC power 11-14V
ground
K39-6 body Mains electric-
11-14V
ground ity supply
K39-7 body Mains electric-
11-14V
ground ity supply
K39-4 body
Constant <1V
ground
K39-5 body
Constant <1V
ground
K39-11 body
Constant <1V
ground
K39-12 body
Constant <1V
ground
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BYD S6, S6A, S6K Service Manual
OK
3 Finish
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Circuit diagram
DVD HOST
EXTERNALAMPLIFIER
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BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Wire color
value
K30-1-G23-2 Y/O <1ȍ
K30-2-G23-1 L <1ȍ
K30-3-G24-1 L/W <1ȍ
K30-4-G24-2 Y/L <1ȍ
K30-5-G20-14 Y/G <1ȍ
K30-6-G20-13 Gr <1ȍ
K30-7-G20-12 L/O <1ȍ
K30-8-G20-28-
B <1ȍ
body ground
OK
3 Finish
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Speaker circuit
Circuit diagram
EXTERNAL AMPLIFIER
324
325
BYD S6, S6A, S6K Service Manual
SPEAKER, LEFT
REAR DOOR
EXTERNAL AMPLIFIER
SPEAKER, RIGHT
REAR DOOR
CENTRAL SPEAKER
BYD S6, S6A, S6K Service Manual
EXTERNAL AMPLIFIER
RIGHT SPEAKER,
INSTRUMENT
PANEL
RIGHT SPEAKER,
A PILLAR
SPEAKER, RIGHT
REAR DOOR
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Inspection steps
1 Vehicle inspection
Result Go to
No speaker has sound A
One or several speaker
B
don’t have sound
OK
3 Finish
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BYD S6, S6A, S6K Service Manual
Normal
OK
OK
OK
328
BYD S6, S6A, S6K Service Manual
Normal
OK
OK
329
BYD S6, S6A, S6K Service Manual
Normal
Normal
Terminal Wire color
value
K32-1-T10-1 Gb <1ȍ
K32-2-T10-2 L/G <1ȍ
OK
OK
330
BYD S6, S6A, S6K Service Manual
Normal
OK
OK
331
BYD S6, S6A, S6K Service Manual
Normal
Normal
Terminal Wire color
value
K31-5-V03-1 L <1ȍ
K31-6-V03-2 Lg <1ȍ
OK
OK
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BYD S6, S6A, S6K Service Manual
Normal
Normal
Terminal Wire color
value
K31-3-W03-1 W <1ȍ
K31-4-W03-2 R <1ȍ
OK
OK
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BYD S6, S6A, S6K Service Manual
Normal
Normal
Terminal Wire color
value
K32-1-Gb14-1 G/B <1ȍ
K32-2-Gb14-2 LG <1ȍ
OK
OK
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BYD S6, S6A, S6K Service Manual
Normal
Normal
Terminal Wire color
value
K31-1-Gb05-1 G/Y <1ȍ
K31-2-Gb05-2 Gr <1ȍ
OK
OK
335
BYD S6, S6A, S6K Service Manual
Normal
Normal
Terminal Wire color
value
K32-3-Gb03-1 L <1ȍ
K32-4-Gb03-2 L/R <1ȍ
OK
336
BYD S6, S6A, S6K Service Manual
Circuit diagram
GROUND
BRACKET
ANTENNA LEAD
ANTENNA
ANTENNA
ANTENNA
DVD HOST
337
BYD S6, S6A, S6K Service Manual
Inspection steps
NG
Normal
Normal
Terminal Wire color
value
GJ73-1-G23-8 L <1ȍ
OK
338
BYD S6, S6A, S6K Service Manual
Circuit diagram
SWITCH
ACOUSTICS
STEERING WHEEL
STEERING WHEEL
CLOCK SPRING ONBOARD PHONE SWITCH
CLOCK SPRING
SPRING
CLOCK
DVD HOST
339
BYD S6, S6A, S6K Service Manual
Inspection steps
Normal
OK
Normal
340
BYD S6, S6A, S6K Service Manual
OK
Normal
Normal
Terminal Condition
value
HJ01-7-GJ59-7 Constant <1ȍ
HJ01-8-GJ59-8 Constant <1ȍ
HJ01-13-
Constant <1ȍ
GJ59-13
HJ01-15-
Constant <1ȍ
GJ59-15
HJ01-16-
Constant <1ȍ
GJ59-16
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BYD S6, S6A, S6K Service Manual
OK
Normal
Normal
Terminal Wire color
value
G24-4-GJ59-7 G/R <1ȍ
G24-5-GJ59-8 Br <1ȍ
G20-10-
Sb <1ȍ
GJ59-13
G20-10-
Sb <1ȍ
GJ59-15
G24-5-
Br <1ȍ
GJ59-16
OK
342
BYD S6, S6A, S6K Service Manual
USB&AUX circuit
Circuit diagram
DVD HOST
343
BYD S6, S6A, S6K Service Manual
Inspection steps
OK SUB&AUX fault
OK
Normal
Normal
Terminal Wire color
value
G20-1-G15-8 B <1ȍ
G20-2-G15-4 Y <1ȍ
G20-3-G15-9 Gr <1ȍ
G20-4-G15-10 Br <1ȍ
G20-15-G15-7 R <1ȍ
G20-16-G15-2 G <1ȍ
G20-17-G15-6 L <1ȍ
G20-18-G15-1 W <1ȍ
G15-3 body
—— <1ȍ
ground
G15-5 body
—— <1ȍ
ground
OK
344
BYD S6, S6A, S6K Service Manual
Circuit diagram
DVD HOST
SHIELD GROUNDING
RIGHT FRONT
345
BYD S6, S6A, S6K Service Manual
Inspection steps
OK
Normal
OK
346
BYD S6, S6A, S6K Service Manual
Circuit diagram
DVD HOST
SHIELD GROUNDING
REAR CAMERA
347
BYD S6, S6A, S6K Service Manual
Inspection steps
1 Vehicle inspection
OK
Normal
Terminal Condition
value
G21-2 body Reverse gear posi-
11-14V
ground tion
OK
348
BYD S6, S6A, S6K Service Manual
OK
Normal
OK
349
BYD S6, S6A, S6K Service Manual
TV module circuit
Circuit diagram
ACOUSTIC
S SYSTEM
SIGNAL FEEDER
ANTENNA AMPLIFIER
POWER SUPPLY
ANTENNA AMPLIFIER
TV MODULE
SHIELD LAYER
SHIELD LAYER
DVD HOST
350
BYD S6, S6A, S6K Service Manual
Inspection steps
NG Replace TV module
OK
Normal
Normal
Terminal Wire color
value
M14-8-G22-6 R <1ȍ
M14-9-G22-8 Y <1ȍ
M14-10-G22-7 L <1ȍ
M14-20-G20-19 W <1ȍ
M14-21-G20-20 Gr <1ȍ
M14-22-G20-21 G <1ȍ
NG Replace TV module
OK
3 Replace TV module
351
BYD S6, S6A, S6K Service Manual
7” screen circuit
Circuit diagram
7” LCD
DVD HOST
7” LCD
SHIELD LAYER
SHIELD LAYER
SHIELD LAYER
SHIELD LAYER
SHIELD LAYER
SHIELD LAYER
DVD HOST
352
BYD S6, S6A, S6K Service Manual
Inspection steps
OK 5HSODFHWKHƎ/&'
OK
OK
353
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
354
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
355
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
356
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Disassembly
Assembly
357
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Disassembly
Assembly
358
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Disassembly
Assembly
359
BYD S6, S6A, S6K Service Manual
Disassembly
360
Electric Equipment ư
BYD S6, S6A, S6K Service Manual
Electric Equipment ư
Contents
I
BYD S6, S6A, S6K Service Manual
II
BYD S6, S6A, S6K Service Manual
III
BYD S6, S6A, S6K Service Manual
IV
BYD S6, S6A, S6K Service Manual
1. System Introduction
The rear LOGO assembly is installed at the rear of the car; when driving in dark environment and
only small lights are lit, the vehicle LOGO still can be highlighted.
1
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Small Light
Inspection steps:
OK
2
BYD S6, S6A, S6K Service Manual
Connection Normal
Condition
terminal value
K2F-12 body Turn on the small
11~14V
ground lights
OK
OK
3
BYD S6, S6A, S6K Service Manual
Disassembly
4
BYD S6, S6A, S6K Service Manual
Section 2 Accessories
1. Component Location
ANNUNCIATOR
STANDBY POWER
5
BYD S6, S6A, S6K Service Manual
INSIDE MIRROR
6
BYD S6, S6A, S6K Service Manual
2. System Introduction
The accessory system mainly consists of:
Cigar lighter
Electric horn
Annunciator
Standby power
7
BYD S6, S6A, S6K Service Manual
NEXT
Standard voltage:
11V~14V
NEXT
NEXT
NEXT
NEXT
6 Finish
8
BYD S6, S6A, S6K Service Manual
4. Fault Table
Cigar lighter
1. Fuse
2. Cigar lighter
Cigar lighter doesn’t work
3. Cigar lighter relay
4. Wire
Electric horn
1. Horn
Only one horn doesn’t work
2. Wire
3. Horn switch
4. Clock spring
5. MCU
All electric horns do not work
6. Internal horn relay
7. Electric horn
8. Wire
1. Horn switch
Horns continuously hoot 2. Horn relay
3. Wire
Annunciator
1. Annunciator
2. Internal annunciator relay
Annunciator doesn’t work
3. MCU
4. Wire
Inside mirror
Vehicle power
1. Fuse
2. Cigar lighter relay
Vehicle doesn’t have output
3. Vehicle power interface
4. Wire
9
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Roof lamp
F1/16
mains
electricity
F2/5 40A
cigar
lighter
15A
K2-3 cigar
lighter
relay
Cigar lighter
10
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
OK Go to step 5
NG
OK
11
BYD S6, S6A, S6K Service Manual
NG Replace wires
OK
OK
6 Finish
12
BYD S6, S6A, S6K Service Manual
Circuit diagram:
F1/14 mains
KM4
internal
electric horn
relay
Horn switch
Clock spring
Low-sounding snail horn, LH
13
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK Go to step 3
NG
OK
14
BYD S6, S6A, S6K Service Manual
OK
OK
5 Finish
OK
15
BYD S6, S6A, S6K Service Manual
OK
OK
NG Replace wires
OK
5 Check MCU
NG Replace MCU
OK
6 Check speaker and wires; refer to “Only one electric horn works”
16
BYD S6, S6A, S6K Service Manual
Circuit diagram:
Electronic compass
17
BYD S6, S6A, S6K Service Manual
Inspection steps:
NG Go to step 4
NG
NG
18
BYD S6, S6A, S6K Service Manual
NG Replace wires
NG
19
BYD S6, S6A, S6K Service Manual
Circuit diagram:
KM8 internal
annunciator
relay
Annunciator
20
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
OK
21
BYD S6, S6A, S6K Service Manual
OK
22
BYD S6, S6A, S6K Service Manual
Circuit diagram:
F2/3 mains
electricity 10A
Filler inlet
cap opening
switch
Filler inlet
cap actuator
motor
23
BYD S6, S6A, S6K Service Manual
Inspection steps:
` OK Go to step 4
NG
OK
Normal
Connection terminal Condition
value
Open Filler inlet
G04-6-G04-9 <1ȍ
cap switch
G04-6-G04-9 Normal >10Kȍ
OK
24
BYD S6, S6A, S6K Service Manual
NG
NG
6 Finish
25
BYD S6, S6A, S6K Service Manual
Circuit diagram:
F2/5 F1/16
cigar mains
lighter electricity
15A 40A
K2-3 cigar
lighter
relay
Vehicle
power
26
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Connection terminal Test condition
value
K28-2 body ground ACC power 11-14V
OK Go to step 5
NG
Normal
Terminal Condition
value
Apply battery voltage to
3-5 <1ȍ
pin1 and pin2
3-5 Pin1 and pin2 floating >10Kȍ
27
BYD S6, S6A, S6K Service Manual
OK
Normal
Connection terminal Wire color
value
B1D-8-B2B-5 Y <1ȍ
G2N-12-K28-2 W/R <1ȍ
NG
Connection Normal
Wire color
terminal value
K28-1 body
B <1ȍ
ground
NG
6 Finish
28
BYD S6, S6A, S6K Service Manual
6. Tool Preparations
Flatheaded screwdriver
Cross screwdriver
10# socket wrench
29
BYD S6, S6A, S6K Service Manual
Snail horn
Disassembly
Disassembly
1. Remove the upper guard panel of right
pillar C
Assembly
30
BYD S6, S6A, S6K Service Manual
)XHO¿OOHUFDSDFWXDWRU
Disassembly
Assembly
Cigar lighter
Disassembly
31
BYD S6, S6A, S6K Service Manual
Assembly
32
BYD S6, S6A, S6K Service Manual
Inside mirror
Disassembly
South
South
33
BYD S6, S6A, S6K Service Manual
Assembly
6ZLWFKIXHO¿OOHUFDS
Disassembly
34
BYD S6, S6A, S6K Service Manual
Assembly
35
BYD S6, S6A, S6K Service Manual
1. Component Location
CONDENSER &
BRACKET ASSEMBLY
36
BYD S6, S6A, S6K Service Manual
SOLAR SENSOR
AIR CONDITIONING PANEL &
MULTIFUNCTIONAL SCREEN
ASSEMBLY
37
BYD S6, S6A, S6K Service Manual
AIR BLOWER
38
BYD S6, S6A, S6K Service Manual
EVAPORATOR
TEMPERATURE
SENSOR LOOP CONTROL MOTOR
ROOM TEMPERATURE
AMBIENT TEMPERATURE
SENSOR OUTPUT MODE AIR
THROTTLE MOTOR
SOLAR SENSOR
AIR MIX CONTROL SERVO
MOTOR (DRIVER’S SIDE)
483EMS
AC COMPRESSOR
INTEGRATED
CONTROL MODULE REAR DEFROSTER
ELECTRIC HEATING
WIRE
PANEL KEY
CAN COMMUNICATION
CABLE
39
BYD S6, S6A, S6K Service Manual
3. System Introduction
The air conditioning system of the vehicle uses double-distilled independent control automatic
constant temperature air conditioner, which applies to high-grade cars. The system consists of
compressor, condenser, expansion valve, evaporator, pipeline, heater core, air blower, and air
duct, featuring cooling, heating, defrosting/defogging, and ventilation function. The system uses
waste heat of engine cooling water for heating, uses vapor compression refrigeration for cycle
refrigerating (refrigerant: R134a), and uses independent temperature partition automatic control
mode. The air circulation throttle, mixing throttle, air supply mode throttle and independent parti-
tion throttle in the enclosure of the air conditioner are driven by motor. The wind speed of the air
blower has seven levels, the air supply direction has five options, and fresh air supply modes in-
clude internal circulation and external circulation.
The integrated compressor driven by the air conditioner driver extracts the gaseous refrigerant
from the evaporator and compresses into the condenser. The high pressure gaseous refrigerant
is liquefied in the condenser for heat exchange (releasing heat), and the heat is carried away by
the air outside the car. High-pressure liquid refrigerant decompresses under the throttling effect
of the expansion valve, the low pressure liquid refrigerant gasifies in the evaporator for heat ex-
change (absorbing heat), and the cooled air near the evaporator is blown into the compartment
through the blower. The gaseous refrigerant is extracted by the compressor and pumped into the
condenser, so that the refrigerant enters closed circulation, discharges the heat from the compart-
ment to outside, making the room temperature drop to a suitable level.
LOW TEMPERATURE
MEDIUM LOW PRESSURE LIQUID
TEMPERATURE DRYING EXPANSION
VALVE 200-500kpa
HIGH PRESSURE BOTTLE
10-20ć
LIQUID
HIGH TEMPERATURE
HIGH PRESSURE MEDIUM TEMPERATURE
LIQUID LOW PRESSURE LIQUID
1500-1700kpa COMPRESSURE
200-300kpa
80-90ć 5-10ć
The heating system is in water heating type, and the heat source is the coolant of the heat source.
The heating system consists of heat exchanger, coolant pipeline, air blower, air duct, bottom air
channel and control mechanism. The heater unit is integrated with the evaporator enclosure, and
shares air blower and ducts with the refrigeration system.
When the engine is working, the coolant heated by the engine cylinder enters heat exchange
through water pipe under the effect of the water pump of the engine cooling system, and delivers
the heat emitted by the coolant to the compartment or windshield through the air blown by the air
blower to increase the temperature in the compartment and defrost. The coolant after cooling in
the heat exchange is extracted by the water pump through the return pipe, thus achieving warm-
ing and heating.
40
BYD S6, S6A, S6K Service Manual
HIGH
ENGINE TEMPERATUR
E COOLANT
Only use dedicated refrigerant oil. Do not use other lubricants or mix with different grades.
The total amount of refrigerant oil in S6 air conditioning system is 150ml; if the amount is
lower than 140ml due to leakage, it may cause excessive wear of the compressor, and thus
the maintenance center should refill the refrigerant oil accordingly.
Please note that the O-ring of opened pipeline must be replaced, coat refrigerant oil on the
O-ring before assembly and tighten in specified torque.
Follow the technical requirement strictly (filling amount, refrigerant oil model, torque require-
ment, etc.), and inspect the air conditioner according to the requirement to ensure normal
working and service life of the air conditioning system.
Since the refrigerant oil has strong water absorption, please block the nozzle immediately
41
BYD S6, S6A, S6K Service Manual
when pipeline is removed, and avoid moisture or dust entering into the refrigeration system.
Do not discharge the excessive refrigerant in the system too fast to avoid extracting the
compressor oil in the system.
Check whether the surface of the condenser heat sink is dirty; scrub with soft brush instead
of washing with steam or high pressure water jet to avoid damaging the heat sink.
42
BYD S6, S6A, S6K Service Manual
4. Diagnostic Process
NEXT
Standard voltage:
11~14V
If the voltage is lower than 11V, please charge
or replace the battery before next step.
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
B Go to step 5
4 Comprehensive diagnosis
NEXT
NEXT
6 &RQ¿UPWKHWHVW
NEXT
7 )LQLVK
43
BYD S6, S6A, S6K Service Manual
5. Fault Table
44
BYD S6, S6A, S6K Service Manual
Diagnostic Trou-
Fault Possible position
ble Code (DTC)
B2A20 Room temperature sensor open circuit
Room sensor circuit
B2A21 Room temperature sensor short circuit
B2A22 Ambient temperature sensor open circuit
Ambient sensor circuit
B2A23 Ambient temperature sensor short circuit
B2A24 Evaporator temperature sensor open circuit
Evaporator sensor circuit
B2A25 Evaporator temperature sensor short circuit
Air outlet control servo motor fault (can’t
B2A2A Air outlet control servo motor circuit
save)
Air mix control servo motor (driver’s side) Air mix control servo motor (driver’s
B2A2B
fault (can’t save) side) circuit
Air mix control servo motor (front passenger Air mix control servo motor (front
B2A2C
side) fault (can’t save) passenger side) circuit
Air conditioner line is in high pressure or low
B2A2F High/low pressure fault
pressure state
Main controller doesn’t receive CAN signal
B2A31 CAN cable fault
from the control panel
B2A33-00 Air blower fault Air blower circuit
7. Terminal Diagnosis
1. Check the air conditioner control module
45
BYD S6, S6A, S6K Service Manual
Normal
Terminal No. Terminal description Condition
value
Mains electricity supply of air con-
G18-1 body ground Constant 11-14V
ditioner panel
ACC power supply of air condi-
G18-2 body ground ACC position power 11-14V
tioner panel
G18-3 body ground IG2 power of air conditioner panel ON position power 11-14V
ON position power; press
G18-4 body ground Parking assistant switch signal the parking assistant 11-14V
switch
G18-5 body ground Body ground Constant <1V
G18-6 body ground Body ground Constant <1V
Rear defroster compensation re-
G18-7 body ground Turn on rear defroster 11-14V
quest signal
Grounding signal of parking assis-
G18-8 body ground Constant <1V
tant buzzer
G18-9 body ground Air conditioner panel backlight Turn on small light 11-14V
G18-10 body ground Body ground Constant <1V
G18-11 body ground Anion generator —— ——
G18-12 body ground Anion generator —— ——
G18-13 body ground CANH Constant 2.5-3.5V
G18-15 body ground CANL Constant 2.5-3.5V
G18-16 body ground Body ground Constant <1V
46
BYD S6, S6A, S6K Service Manual
47
BYD S6, S6A, S6K Service Manual
8. Vehicle inspection
1 Direct observation
OK
48
BYD S6, S6A, S6K Service Manual
49
BYD S6, S6A, S6K Service Manual
OK
OK
50
BYD S6, S6A, S6K Service Manual
Circuit diagram:
IG2 POWER
F2/2
MAINS
ELECT
RICITY
7.5A
51
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Wire Normal
Terminal Condition
color value
G18-1 body Mains elec-
R 11~14V
ground tricity supply
G18-2 body
Sb ACC power 11-14V
ground
G18-3 body
L/Y ON position 11-14V
ground
OK Go to step 4
OK
52
BYD S6, S6A, S6K Service Manual
Wire Normal
Terminal
color value
G2N-25-G45-20 W/R <1ȍ
G2N-25-G18-3 L/Y <1ȍ
Wire Normal
Terminal
color value
G2N-25-G18-3 L/Y <1ȍ
G2X-26-G18-1 R <1ȍ
G2N-27-G18-2 Sb <1ȍ
OK
Wire Normal
Terminal
color value
G45-7-G48 (body
B <1ȍ
ground)
G45-21-G48 (body
B <1ȍ
ground)
G45-40 G48 (body
B <1ȍ
ground)
53
BYD S6, S6A, S6K Service Manual
Wire Normal
Terminal
color value
G18-6-G49 (body
B <1ȍ
ground)
G18-10-G49 (body
B <1ȍ
ground)
G18-16-G49 (body
B <1ȍ
ground)
OK
5 Finish
54
BYD S6, S6A, S6K Service Manual
Circuit diagram:
AMBIENT TEMPERATURE
CONTROLLER
55
BYD S6, S6A, S6K Service Manual
Inspection steps:
Normal value:
Termi- Condi-
Normal value
nal tion
1-2 0°C 32.25~33.69 Kȍ
1-2 15°C 15.77~16.00Kȍ
1-2 25°C 9.90~10.10Kȍ
1-2 35°C 6.424-6.610 Kȍ
1-2 90°C 0.8810-0.9429 Kȍ
Note:
The resistance will change even if
you touch the temperature sensor
lightly, and thus please hold the
connector of the sensor.
When measuring resistance, the
temperature of the sensor must
be consistent with the ambient
temperature.
OK
56
BYD S6, S6A, S6K Service Manual
Wire Normal
Terminal
color value
C05-1-G45-24 V-Sb <1ȍ
C05-2-G46
O-B <1ȍ
(body ground)
OK
57
BYD S6, S6A, S6K Service Manual
Circuit diagram:
TEMPERATURE SENSOR
EVAPORATOR
58
BYD S6, S6A, S6K Service Manual
Inspection steps:
Normal value:
Condi-
Terminal Normal value
tion
1-2 0°C 14.820~16.380 Kȍ
1-2 25°C 1.581~1.679Kȍ
1-2 35°C 1.031~1.095Kȍ
1-2 80°C 0.209~0.215 Kȍ
Note:
OK
59
BYD S6, S6A, S6K Service Manual
Wire Normal
Terminal
color value
G45-23-Hg01-2 Br <1ȍ
Hg01-1-G49 (body
B <1ȍ
ground)
OK
60
BYD S6, S6A, S6K Service Manual
Circuit diagram:
SENSOR
ROOM TEMPERATURE
61
BYD S6, S6A, S6K Service Manual
Inspection steps:
Normal value:
Note:
OK
62
BYD S6, S6A, S6K Service Manual
Wire Normal
Terminal
color value
G45-25-G08-2 R <1ȍ
G08-1-G48
B <1ȍ
(body ground)
OK
63
BYD S6, S6A, S6K Service Manual
Circuit diagram:
THROTTLE MOTOR
OUTPUT MODE
64
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
value
G45-35 Turn on the air
About 5V
body ground conditioner
Turn on air condi-
G45-8 body tioner, and adjust
11-14V
ground temperature (de-
crease)
Turn on air condi-
G45-9 body tioner, and adjust
<1V
ground temperature (de-
crease)
Turn on air condi-
G45-9 body tioner, and ad-
11-14V
ground just temperature
(increase)
Turn on air condi-
G45-8 body tioner, and ad-
<1V
ground just temperature
(increase)
65
BYD S6, S6A, S6K Service Manual
OK
Wire Normal
Terminal
color value
G45-2-Hg02-3 P/B <1ȍ
G45-9-Hg02-4 P/L <1ȍ
G45-8-Hg02-5 G <1ȍ
G45-35-Hg02-2 G/L <1ȍ
Hg02-1-G49 (body
B <1ȍ
ground)
OK
Normal
Terminal Condition
value
Turn on air
G45-
conditioner, and Voltage
2 body
adjust tempera- signal
ground
ture
OK
5 Finish
66
BYD S6, S6A, S6K Service Manual
Circuit diagram:
67
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
value
G45-36 Turn on the air About
body ground conditioner 5V
Turn on air condi-
G45-12 tioner, and adjust
11-14V
body ground temperature (de-
crease)
Turn on air condi-
G45-13 tioner, and adjust
<1V
body ground temperature (de-
crease)
Turn on air condi-
G45-13 tioner, and ad-
11-14V
body ground just temperature
(increase)
Turn on air condi-
G45-12 tioner, and ad-
<1V
body ground just temperature
(increase)
68
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Wire color
value
G45-3-Hg03-3 P/B <1ȍ
G45-13-Hg03-4 P/L <1ȍ
G45-12-Hg03-5 G <1ȍ
G45-34-Hg03-2 G/L <1ȍ
Hg03-1-G49
B <1ȍ
(body ground)
OK
4 Check the position feedback signal of air mix control servo motor (driver’s side)
Normal
Terminal Condition
value
Tu r n o n a i r
G45-3 body conditioner, Vo l t a g e
ground and adjust signal
temperature
OK
5 Finish
69
BYD S6, S6A, S6K Service Manual
Circuit diagram:
70
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
2 &KHFNWKHDLUFRQGLWLRQHUFRQWUROOHU
Normal
Terminal Condition
value
G45-37 body Turn on the air
About 5V
ground conditioner
Turn on air
G45-14 body conditioner, and
11-14V
ground adjust tempera-
ture (decrease)
Turn on air
G45-15 body conditioner, and
<1V
ground adjust tempera-
ture (decrease)
Turn on air
G45-15 body conditioner, and
11-14V
ground adjust tempera-
ture (increase)
Turn on air
G45-14 body conditioner, and
<1V
ground adjust tempera-
ture (increase)
71
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Wire color
value
G45-4-Hg04-3 Y <1ȍ
G45-15-Hg04-4 Lg <1ȍ
G45-14-Hg04-5 Y/B <1ȍ
G45-37-Hg04-2 Y/R <1ȍ
Hg04-1-G49 (body
B <1ȍ
ground)
OK
4 Check the position feedback signal of air mix control servo motor (front passenger side)
OK
5 Finish
72
BYD S6, S6A, S6K Service Manual
Circuit diagram:
MAINS ELECTRICITY
AIR CONDITIONER
PRESSURE SWITCH
(DISCONNECT:
F1/12 0.196Mpa, 3.14Mpa)
COMPRESS
OR 7.5A
73
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
value
G45-4 body Turn on the air
11-14V
ground conditioner
NG Finish
NG
74
BYD S6, S6A, S6K Service Manual
Wire Normal
Terminal
color value
C1F-3-C15-1 R <1ȍ
C15-4-C1F-13 Sb <1ȍ
B1E-G45-26 P <1ȍ
OK
75
BYD S6, S6A, S6K Service Manual
Circuit diagram:
IG2 POWER
76
BYD S6, S6A, S6K Service Manual
Inspection steps:
Wire Normal
Terminal
color value
Hg05-5 body
W/R 11-14V
ground
OK Go to step 3
NG
Wire Normal
Terminal
color value
Hg05-5-G2N-25 W/R <1ȍ
OK
77
BYD S6, S6A, S6K Service Manual
OK
Wire Normal
Terminal
color value
G45-10-Hg05-1 G/R <1ȍ
G45-11-Hg05-2 G/W <1ȍ
OK
78
BYD S6, S6A, S6K Service Manual
Circuit diagram:
F1/21 AIR
BLOWER 40A
BLOWER
AC AIR
K1-1 A/C AIR
BLOWER
RELAY
SPEED SETTING
MODULE
79
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
value
ON position
G34-2 body
power; press A/ 11~14V
ground
C switch
OK Go to step 5
NG
3 Check the power output of instrument panel fuse and relay box
Condi- Normal
Terminal
tion value
B2D-14 body ON posi-
11~14V
ground tion
Relay pin88 –
Constant 11~14V
body ground
80
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
value
Apply battery
3-5 voltage to pin1 <1ȍ
and pin2
Pin1 and pin2
3-5 >10Kȍ
floating
OK
Wire Normal
Terminal
color value
B1E-15-B2D-14 Br <1ȍ
B1E-10-B11 (body
B <1ȍ
ground)
B1D-4-G34-2 W/L <1ȍ
OK
81
BYD S6, S6A, S6K Service Manual
OK
Wire Normal
Terminal
color value
B1D-4-G34-2 W/L <1ȍ
G34-2-G32-2 W/L <1ȍ
G34-1-G32-4 B/Y <1ȍ
G34-1-G45-1 B/Y <1ȍ
G32-3-G45-34 G/B <1ȍ
OK
82
BYD S6, S6A, S6K Service Manual
Normal
Terminal Condition
value
G45-34 body Turn on the Analog
ground air blower signal
OK
Normal
Terminal Condition
value
G32-4 body Turn on the
Analog signal
ground air blower
OK
83
BYD S6, S6A, S6K Service Manual
Compressor circuit
Circuit diagram:
F1/12
COMPRESSOR
7.5A
K1-3 A/C
COMPRESSOR
CLUTCH
RELAY
AND RELAY BOX
INSTRUMENT PANEL FUSE
AC COMPRESSOR
84
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Normal
Terminal Condition
value
C11-1 body Press A/C
11-14V
ground switch
NG
Normal
Terminal Condition
value
Apply battery voltage
3-5 <1ȍ
to pin1 and pin2
3-5 Pin1 and pin2 floating >10Kȍ
85
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
value
G45-33 body Press A/C
<1V
ground switch
OK
Wire Normal
Terminal
color value
C1F-2-C11-1 Br <1ȍ
B1E-11-G45-33 L/R <1ȍ
OK
6 Finish
86
BYD S6, S6A, S6K Service Manual
Circuit diagram:
F1/15 REAR
DEFROSTER
40A
K1-2 REAR
DEFROSTER
RELAY
HEATING WIRE
REAR DEFROSTER ELECTRIC
REAR DEFROSTER
COMPENSATION
REQUEST SIGNAL
87
BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
2 Check the power supply signal of rear defroster electric heating wire
Normal
Terminal Condition
value
Y04-1 body Press the rear
11-14V
ground defroster switch
Y17-1 body
Constant <1V
ground
NG Go to step 5
OK
Termi- Normal
Condition
nal value
Apply battery voltage
3-5 <1ȍ
to pin1 and pin2
3-5 Pin1 and pin2 floating >10Kȍ
88
BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Wire color
value
B2D-14-B1E-15 Br <1ȍ
B1D-2-Y04-1 B/Y <1ȍ
OK
OK
89
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
90
BYD S6, S6A, S6K Service Manual
Disassembly
Assembly
Assembly
91
BYD S6, S6A, S6K Service Manual
Solar sensor
Assembly
Assembly
92
BYD S6, S6A, S6K Service Manual
HVAC assembly
Disassembly
Assembly
93
BYD S6, S6A, S6K Service Manual
Relay box
Relay control module
NC
NC Relay, accessory power outlet
Integrated electronic
control unit
Relay, oil pump Starter trip relay Instrument panel lower fuse/Relay box
94
BYD S6, S6A, S6K Service Manual
95
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96
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K2-8 flash
relay
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1. Component Location
Sunroof Assembly
Motor Assembly
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CAN cable
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4. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
NG Go to step 5
4 Comprehensive diagnosis
NEXT
NEXT
NEXT
7 Finish
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5. Fault Table
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6. Terminal diagnosis
1. Disconnect sunroof control motor assembly P02 connector.
Normal:
Wire
Terminal Terminal description Condition Normal value
color
P02-1 body ground Grounding B Constant <1V
P02-2 body ground Mains electricity supply G Constant 11-14V
P02-4 body ground Sunroof opening control L Press open switch <1V
P02-5 body ground Sunroof close control Y Press close switch <1V
P02-6 body ground Sunroof incline+ control Gr Press Incline+ switch <1V
P02-7 body ground CAN-L V Constant About 2.5V
P02-8 body ground ON position Br ON position 11-14V
P02-9 body ground CAN-H P Constant About 2.5V
P02-10 body ground Sunroof incline- control Sb Press Incline- switch <1V
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BYD S6, S6A, S6K Service Manual
Description:
If the sunroof doesn’t work at all, it may be caused by the problem of controller power or sunroof
control motor assembly.
Mains
electricity from
F1/13 IG1 from
G40-6
F2/15 sunroof
25A
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BYD S6, S6A, S6K Service Manual
Inspection steps
NG
OK
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Circuit diagram:
Switch ground
Lamp, front roof
Close
Open
Incline+
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VInspection steps
Normal
Terminal Condition
condition
P03- Press close
<1ȍ
11-P03-1 button
P03- Press open
<1ȍ
13-P03-1 button
P03- Press in-
<1ȍ
14-P03-1 cline+ button
P03- Press incline- <1ȍ
16-P03-1 button
OK
Normal
Terminal Condition
value
P03-1 body
Constant <1V
ground
OK
3 Check the wire (front roof lamp – sunroof control motor assembly)
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BYD S6, S6A, S6K Service Manual
Normal value
Wire Normal
Terminal
color value
P02-4—P03-13 L <1ȍ
P02-5—P03-11 Y <1ȍ
P02-6—P03-14 Gr <1ȍ
P02-10—P03-16 Sb <1ȍ
OK
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BYD S6, S6A, S6K Service Manual
Description:
The sunroof features one-key-open and one-key-incline function, i.e. press and hold open or in-
cline switch for 300ms, and the sunroof will open or incline to memory position automatically
Inspection steps
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BYD S6, S6A, S6K Service Manual
Description:
When the sunroof returns to close position from open or incline position, it returns to the memory
position of sunroof control motor assembly under the action of motor, and also plays a role of
sealing and waterproofing.
Inspection steps
Result Go to
Clear the impurities and
Has impurities
go to next step
Replace sunroof control
Seriously distorted
motor
OK
OK
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BYD S6, S6A, S6K Service Manual
Sunroof motor
Disassembly
Assembly
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OK
Terminal Resistance
G11-1-G11-2 56-64ȍ
OK
Normal
Terminal Wire color
condition
G11-4-B1I-7 R/L <1ȍ
G11-8- B1I-8 G/W <1ȍ
OK
7 Go to next step, or replace relay control module, or check relay control module
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
MOTOR
FRONT WASHER
MOTOR RELAY
WASHER
KM3 INNER
114
ACC relay IG2 relay
Relay, side
turn signal, RH Relay, side turn
signal, LH
IG1 relay
BYD S6, S6A, S6K Service Manual
115
116
Relay, front fog lamp Relay, low speed fan
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BYD S6, S6A, S6K Service Manual
Section 7 Gateway
1. Component Location
Gateway Controller
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2. System Introduction
Since the vehicle bus has several networks, which require communication, and the gateway is an
intermediate to maintain networking.
Message routing:
The gateway features message forwarding and diagnosis of bus message status;
Signal routing:
Network management:
Network status monitoring and statistics, error handling, sleep, wake up, etc.;
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BYD S6, S6A, S6K Service Manual
3. Diagnostic Process
NEXT
Standard voltage:
11V~14V
NEXT
NEXT
NEXT
NEXT
6 Finish
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4. Terminal Diagnosis
1. Check gateway controller
Terminal de-
Terminal No. Wire color Condition Normal value
scription
G60-1 body ground B Signal grounding Constant <1ȍ
G60-2 body ground V/W Speed signal * 3 When there is speed Speed signal
G60-5 body ground W/R Battery anode Constant 11~14V
G60-7 body ground L/Y IG1 power supply ON position 11~14V
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
Independent gateway
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BYD S6, S6A, S6K Service Manual
Inspection steps:
Condi- Normal
Terminal
tion condition
G60-5 body ground Constant 11-14V
ON posi-
G60-7 body ground 11-14V
tion
G60-1 body ground Constant <1ȍ
OK Go to step 3
NG
Normal
Terminal Condition
condition
G2X-12 body
ON position 11-14V
ground
G2X-22 body
Constant 11-14V
ground
NG
Wire fault (instrument panel fuse and relay box – gateway controller)
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Normal
Terminal Condition
condition
G60-2 body ON position, Speed signal
ground with speed waveform
NG
Condi- Normal
Terminal
tion condition
G60-6-Ac01-33 Constant <1ȍ
G60-12-Ac01-34 Constant <1ȍ
G60-6-G60-12 Constant >10kȍ
Condi- Normal
Terminal
tion condition
B1I-2-G60-4 Constant <1ȍ
B1I-1-G60-10 Constant <1ȍ
G60-4-G60-10 Constant >10kȍ
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Condi- Normal
Terminal
tion condition
G60-8-K35-12 Constant <1ȍ
G60-9-K35-6 Constant <1ȍ
G60-8-G60-9 Constant >10kȍ
OK
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Circuit diagram:
Gateway controller
Instrument panel fuse and relay box
Inspection steps:
Condi- Normal
Terminal
tion condition
4 - 10 Constant About 120ȍ
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BYD S6, S6A, S6K Service Manual
OK
Condi- Normal
Terminal
tion condition
1-2 Constant About 120ȍ
OK
Condi- Normal
Terminal
tion condition
B2D-11-G2X-23 Constant <1ȍ
B2D-12-G2X-24 Constant <1ȍ
B2D-11-B2D-12 Constant >1Mȍ
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OK
Normal
Terminal Condition
condition
G60-10-B1I-1 V <1ȍ
G60-4-B1I-2 P <1ȍ
G60-10-G60-4 V-P >1Mȍ
OK
5 Finish
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Circuit diagram:
Gateway controller
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BYD S6, S6A, S6K Service Manual
Inspection steps:
Condi- Normal
Terminal
tion condition
8-9 Constant About 120ȍ
OK
Condi- Normal
Terminal
tion condition
6 - 12 Constant About 120ȍ
OK
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Condi- Normal
Terminal
tion condition
G60-8-K35-12 P <1ȍ
G60-9-K35-6 V <1ȍ
G60-8-G60-9 P-V >1Mȍ
OK
4 Finish
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Circuit diagram:
Gateway controller
Inspection steps:
OK
Condi- Normal
Terminal
tion condition
12 - 6 Constant About 120ȍ
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OK
Condi- Normal
Terminal
tion condition
3- 4 Constant About 120ȍ
NG Replace ECM
OK
Condi- Normal
Terminal
tion condition
G60-12-Ab48-3 V <1ȍ
G60-6-Ab48-4 P <1ȍ
G60-12-G60-6 V-P >1Mȍ
OK
4 Finish
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Assembly
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Section 8 Battery
1. Component Location
Battery
2. Battery Introduction
Battery is device that converts chemical energy into electrical energy, which is reversible DC power.
Automobile battery is mainly used to supply power for the starter and ignition device when the en-
gine is being started.
The vehicle uses 80D26 maintenance-free lead-acid battery.
Warning:
If you don’t operate in correct steps, the battery may explode and cause serious injury to people
nearby.
Follow all steps strictly and keep the battery away from sparks and open flame.
Note:
To get accurate result, the temperature of the battery electrolyte must be 21~38°C
(70~100 ̧ ) before testing.
134
3. Preparation
Tools
Multimeter
0-300W carbon rod
12V battery charger 50A quick charging and 5A slow charging
NG Replace fuse
OK
NEXT
Voltage Result
>9.6V Normal
6.5~9.6V Go to step 4
<6.5V Go to step 5
BYD S6, S6A, S6K Service Manual
NEXT
Note:
NEXT
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Disassembly
Before disassembling:
Assembly
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1. Component Location
COMBINATION SWITCH, R
FRONT NOZZLE
FRONT NOZZLE
WASHING POT
- WASHER MOTOR
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WIPER RELAY 1
FRONT
WINDSHIELD
REAR WINDSHIELD
WIPER MOTOR
COMBINATION
CAN CABLE
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3. System Introduction
The wiper and washer system consists of wiper arm assembly, wiper connecting rod mechanism,
wiper, wiper motor, washer bump, fluid reservoir, filling pipe and nozzle, featuring single-step wip-
ing, intermittent wiping, slow wiping and quick wiping. The wiper and washer system is intended
to provide convenient, safe and reliable means for the driver to ensure the vision of windshield.
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4. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
B Replace ECM
4 Comprehensive Diagnosis
NEXT
NEXT
NEXT
7 Finish
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5. Fault Table
Front wiper and washer system
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6. Terminal Diagnosis
1. Check the engine room fuse and relay box
(1) Lead wires from rear end of engine room fuse and relay box B1I and B1J
Wire Normal
Terminal No. Terminal description Condition
color value
Turn on high speed wip-
B1I-1 body ground G/W HI position wiper hard wire 11-14V
er
Front wiper at resetting
B1J-1 body ground W Wiper reset <1V
position
Power supply of high speed Turn on high speed front
B1J-5 body ground Y 11-14V
wiper wiper
Power supply of low speed Turn on low speed front
B1J-4 body ground B 11-14V
wiper wiper
C1F-20 Y/B Power supply of front washer Turn on front washer 11~14V
Control pin of rear washer re-
C1H-1 body ground L/W Turn on rear washer <1V
lay
C1H-4 body ground G/Y Rear wiper motor control Turn on rear wiper <1V
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Circuit diagram:
MAINS
SWITCH
WASHER SIGNAL
THIRD SECOND
GEAR
FIRST
FOURTH
GEAR
GEAR
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Inspection steps:
DTC Meaning
General lighting switch OFF
B24A0-00
position circuit fault
General lighting switch TAIL
B24A1-00
position circuit fault
General lighting switch AUTO
B24A2-00
position circuit fault
B24A4-00 Dimmer switch circuit fault
B24A5-00 Turn signal switch circuit fault
Internal error or combination
B24AA-00
switch control device
General lighting switch ON
B24AC-00
position circuit fault
Rear fog lamp switch ON posi-
B24AE-00
tion fault
OK
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BYD S6, S6A, S6K Service Manual
OK
Wire Normal
Terminal
color condition
G11-5 body ground W/R 11-14V
G11-6 body ground L/Y 11-14V
G11-3 body ground W/L <1V
OK
Normal
Termi- Wire
Condition condi-
nal color
tion
Turn the
G11- combina-
4 body R/L tion switch <1V
ground to headlamp
position
G11-
1 body R Constant 2.5-3.5V
ground
G11-
2 body L Constant 1.5-2.5V
ground
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BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Termi- Normal
Condition
nal value
Apply battery voltage to
3-5 <1ȍ
pin1 and pin2
Apply battery voltage to
3-4 >10Kȍ
pin1 and pin2
3-5 Pin1 and pin2 floating >10Kȍ
3-4 Pin1 and pin2 floating <1ȍ
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OK
Wire Normal
Terminal
color value
B1E-8 body ground Y/G 11~14V
C1F-20-C16-1 Y/B <1ȍ
C16-2 body ground B <1ȍ
OK
OK
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
F2/33
FRONT
WIPER
30A
FRONT WIPER MOTOR
MOTOR RELAY
KM1 INNER WIPER
SWITCH RELAY
KM2 INNER WIPER
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BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Termi- Normal
Condition
nal value
Apply battery voltage to
3-5 <1ȍ
pin1 and pin2
Apply battery voltage to
3-4 >10Kȍ
pin1 and pin2
3-5 Pin1 and pin2 floating >10Kȍ
3-4 Pin1 and pin2 floating <1ȍ
OK
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Wire Normal
Terminal
color value
B1J-3 body ground Gr 11~14V
B1J-2 body ground B <1ȍ
B1J-4-BJ20-2 L <1ȍ
B1J-5-BJ20-1 Y <1ȍ
B1J-1-BJ20-3 W <1ȍ
BJ20-4 body ground B <1ȍ
OK
Condi- Normal
Terminal
tion condition
BJ20-1- battery (+)
Motor running
BJ20-4- battery (-) ——
at high speed
BJ20-2- battery (+)
Motor running
BJ20-4- battery (-) ——
at low speed
Wiper ro-
BJ20-3-BJ20-4 tates to the >10Kȍ
bottom
Wiper stays
BJ20-3-BJ20-4 <1ȍ
in the middle
OK
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
MOTOR RELAY
REAR WASHER
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BYD S6, S6A, S6K Service Manual
Inspection steps:
OK
Ter- Normal
Wire color
minal condition
Apply battery voltage
3-5 <1ȍ
to pin1 and pin2
3-5 Pin1 and pin2 floating >10Kȍ
OK
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BYD S6, S6A, S6K Service Manual
OK
Wire Normal
Terminal
color condition
C25-1-G38-12 L/R <1ȍ
C25-2 body ground B >10Kȍ
OK
Normal
Terminal Wire color
condition
C1H-1-G38-15 L/W <1ȍ
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BYD S6, S6A, S6K Service Manual
OK
6 Check the wires (rear washer relay – instrument panel fuse and relay box)
Normal
Terminal Wire color
condition
B2D-7-G38-11 Br/Y <1ȍ
B2D-7-G38-13 Br/Y <1ȍ
OK
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
IG1 POWER
F2/20
REAR
WIPER
15A
RESETTING
SIGNAL
ACQISITION
MOTOR
REAR WIPER
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Inspection steps:
OK
Wire Normal
Terminal
color condition
Y07-1 body ground G 11-14V
OK
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BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Wire color
condition
Y07-3-C1H-4 G/Y <1ȍ
NG Replace wires
OK
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Disassembly
Assembly
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Disassembly
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Assembly
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Disassembly
Assembly
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1. Component Location
OUTER GRIP
ASSEMBLY,
FRONT DOOR, LH
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MOTOR DOOR
OUTER MAGCARD LOCK MOTOR
DETECTING
ANTENNA &
MICRO SWITCH
ASSY.
START SWITCH
INTELLIGENCE
KEY
ACC, IG1, IG2
RELAY
HIGH
FREQUENCY
RECEIVER START RELAY
INNER
MAGCARD
CLUTCH SWITCH
DETECTING
OR BRAKE
ANTENNA
SWITCH, N
POSITION
SWITCH
STEERING LOCK
CAN CABLE
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BYD S6, S6A, S6K Service Manual
The system is controlled through I-Key ECU. When it detects a key in its detection range, it will
validate the key, and send running signal to related ECU to complete the work of the system.
The detection system consists of five detection antenna (three inner and two outer) and one high
frequency receiver, which will detect the effective range in the vehicle and certain range out of the
vehicle.
FRONT
KEY
DETECTING
FRONT DETECTING ANTENNA,
ANTENNA FRONT DOOR,
RH
MIDDLE DETECTING
ANTENNA
DETECTING
ANTENNA, FRONT
DOOR, LH
REAR DETECTING
ANTENNA
REAR
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Prompt:
If you won’t use the vehicle when the door is locked and security state is activated, please keep
the key away from the vehicle, because the automatic scanning of the vehicle will consume the
battery.
Note: The keyless entry system may be invalid in the following cases
Detection system is near a strong magnetic field or electric field, e.g. TV signal tower.
If the key can’t be detected even in effective range, please approach the key to the mag-
card antenna.
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BYD S6, S6A, S6K Service Manual
4. Diagnostic Process
Prompt:
Analyze with diagnostic apparatus in the step 4
NEXT
Normal voltage:
11V~14V
NEXT
Result Go to
The result is in the Fault Table A
The result isn’t in the Fault Table B
A Go to step 5
NEXT
NEXT
NEXT
7 Finish
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5. Fault Table
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BYD S6, S6A, S6K Service Manual
6. Terminal Diagnosis
1. Check I-Key ECU
(2) Measure the voltage or resistance between terminals of the wire connectors.
Prompt:
If the test result doesn’t match the normal value, the respective wires may have fault.
(2) Lead wires from the rear end and measure the voltage of each terminal
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BYD S6, S6A, S6K Service Manual
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BYD S6, S6A, S6K Service Manual
7. Vehicle inspection
OK
NG
Result Go to
Work normally A
Can’t work normally B
4 Go to next loop
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Circuit diagram
MAINS
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BYD S6, S6A, S6K Service Manual
Inspection steps
OK
Normal
Condition Condition
value
K36-1 body Mains electricity
11-14V
ground supply
K36-9 body
Constant <1V
ground
K36-10 body
Constant <1V
ground
OK
3 Finish
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BYD S6, S6A, S6K Service Manual
Circuit diagram
INTELLIGENCE KEY
Inspection steps
Condi- Normal
Condition
tion value
K34-5 body ground Constant 11-14V
K34-1 body ground Constant <1V
NG Go to step 3
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BYD S6, S6A, S6K Service Manual
OK
Condi- Normal
Condition
tion value
K36-12 body ground Constant 11-14V
K36-7 body ground Constant <1V
OK
Wire Normal
Condition
color resistance:
K34-1-K36-7 B <1ȍ
K34-2-K36-11 G/Y <1ȍ
K34-3-K36-5 L <1ȍ
K34-5-K36-12 R/Y <1ȍ
K34-3 body ground L <1ȍ
K34-5 body ground R/Y >10kȍ
OK
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Circuit diagram
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BYD S6, S6A, S6K Service Manual
Inspection steps
OK: flash
OK
Normal resistance:
Normal re-
Terminal Condition
sistance:
Press the
Terminal 1, 2 <1ȍ
micro switch
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BYD S6, S6A, S6K Service Manual
OK
Check wires (front left outer magcard detecting antenna and micro switch assembly - I-Key
3
ECU wire)
Normal resistance:
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BYD S6, S6A, S6K Service Manual
OK
Check wires (front right outer magcard detecting antenna and micro switch assembly - I-Key
4
ECU wire)
Normal resistance:
NG Replace wires
OK
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BYD S6, S6A, S6K Service Manual
Circuit diagram
ANTENNA – FRONT
INNER MAGCARD DETECTING
ANTENNA – REAR
INNER
ANTENNA – MIDDLE
INNER MAGCARD DETECTING
MAGCARD
DETECTING
Inspection steps
Result Perform
None of the LED flashes A
One or two do not flash B
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BYD S6, S6A, S6K Service Manual
Normal resistance:
Normal
Condition Wire color
resistance
K27-1-K36-15 Sb <1ȍ
K27-2-K36-5 G <1ȍ
OK
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BYD S6, S6A, S6K Service Manual
Normal resistance:
Normal re-
Condition Wire color
sistance
G35-1-K36-14 Y/L <1ȍ
G35-2-K36-4 W/L <1ȍ
OK
Normal resistance:
OK
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Circuit diagram
START SWITCH
ADAPTER A
TUBULAR BEAM
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Inspection steps
Normal resistance:
OK
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BYD S6, S6A, S6K Service Manual
OK
Preparation
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Disassembly
Assembly
Disassembly
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Assembly
Disassembly
Assembly
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Disassembly
Assembly
Disassembly
Assembly
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Prompt:
Outer detecting antenna is damaged and outer grip assembly should be replaced. The example is
front left door outer grip.
Disassembly
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Start switch
Disassembly
Assembly
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1. Component Location
LOCK ASSEMBLY,
BACK DOOR
LOCK ASSEMBLY,
FRONT DOOR, RH LOCK ASSEMBLY,
REAR DOOR, RH
REGULATOR SWITCH
SET, FRONT POWER
WINDOW, R
CENTRAL LOCK
SWITCH, FRONT
DOOR, RH
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FRONT DOOR
LOCK MOTOR,
LH
- DOOR LOCK
MOTOR
CAN CABLE
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FRONT DOOR
LOCK MOTOR,
LH
- DOOR LOCK
MOTOR
SWITCH, FRONT
WINDOW CONTROL,
LH
CAN CABLE
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3. System Introduction
Central door lock system controls locking/unlocking of electric door lock with body control module
(BCM) in the following two modes:
Press the door lock switch or central lock switch of right front door on the regulator switch set, left
front power window to send unlocking/locking request signal to BCM, which receives and pro-
cesses switching signal, and drive corresponding door lock motor to unlock/lock.
When open the door with mechanical key, the key cylinder switch sends unlocking/locking request
signal to BCM, which receives and processes switching signal, and drive corresponding door lock
motor to unlock/lock.
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4. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
B Go to step 5
4 Comprehensive Diagnosis
NEXT
NEXT
NEXT
7 Finish
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5. Fault Table
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BYD S6, S6A, S6K Service Manual
6. Terminal Diagnosis
1. Check BCM
(1) Lead wires from back end of BCM G2P, T2K, K2G, K2E, G2N, K2H, K2F and G2Q.
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Circuit diagram:
SWITCH, FRONT
WINDOW, LH
DOOR LOCK
GENERAL
SWITCH
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Inspection steps:
DTC Meaning
Door lock key cylinder switch on
B2240-00
driver’s side has failure
General door lock switch on driv-
B2241-00
er’s side has failure
Door lock switch on driver’s side
B2242-00
has failure
OK
Normal
Terminal Wire color
condition
T09-17 body
P About 2.5V
ground
T09-18 body
V About 2.5V
ground
OK
3 Replace BCM
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Circuit diagram:
Inspection steps:
Normal
Terminal Condition
value
U08-6-G50
Constant <1ȍ
(body ground)
Turn the switch to
U08-6-U08-3 <1ȍ
LOCK
U08-6-U08-3 Reset switch >10Kȍ
Turn the switch to
U08-6-U08-4 <1ȍ
UNLOCK
U08-6-U08-4 Reset switch >10Kȍ
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OK
OK
3 Check BCM
Normal
Terminal Condition
value
G2P-18 body Turn central lock
0~11-14V
ground switch to LOCK
G2P-19 body Turn central lock
0~11-14V
ground switch to UNLOCK
OK
4 Finish
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Circuit diagram:
general switch
Door lock
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BYD S6, S6A, S6K Service Manual
Inspection steps:
Normal
Terminal Condition
value
T07-1- battery (+)
T07-8-T07-7 <1ȍ
T07-4- battery (-)
T07-4- battery (+)
T07-8-T07-7 >10Kȍ
T07-1- battery (-)
OK
Normal
Terminal Wire color
value
T07-1-T2K-2 LG <1ȍ
T2K-8-T07-4 Gr <1ȍ
T07-8-T09-4 Y/L <1ȍ
T07-7-T2K-6 B <1ȍ
OK
3 Check BCM
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BYD S6, S6A, S6K Service Manual
Normal
Terminal Condition
value
T2K-2 body Turn door lock con-
0~11-14V
ground trol switch to LOCK
Turn door lock
T2K-8 body
control switch to 0~11-14V
ground
UNLOCK
NG Replace BCM
OK
4 Finish
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Circuit diagram:
Inspection steps:
Normal
Terminal Condition
value
U06-1- battery (+)
U06-7-U06-8 <1ȍ
U06-4- battery (-)
U06-4- battery (+)
U06-7-U06-8 >10Kȍ
U06-1- battery (-)
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BYD S6, S6A, S6K Service Manual
OK
Wire Normal
Terminal
color value
G2N-8-U06-1 B/Y <1ȍ
G2N-7-U06-4 G/W <1ȍ
G2Q-14-U06-8 R/B <1ȍ
U06-7-G50 (body
B <1ȍ
ground)
OK
3 Check BCM
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Normal
Terminal Condition
value
Turn door lock
G2N-8 body
control switch 0~11-14V
ground
to LOCK
Turn door lock
G2N-7 body
control switch 0~11-14V
ground
to UNLOCK
NG Replace BCM
OK
4 Finish
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Circuit diagram:
Inspection steps:
Normal
Terminal Condition
value
V05-1- battery (+)
V05-9-V05-10 <1ȍ
V05-2- battery (-)
V05-2- battery (+)
V05-9-V05-10 >10Kȍ
V05-1- battery (-)
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BYD S6, S6A, S6K Service Manual
OK
Wire Normal
Terminal
color value
K2E-8-V05-1 O <1ȍ
K2E-1-V05-2 G <1ȍ
G2P-3-V05-8 G/B <1ȍ
V05-7-K26 (body
B <1ȍ
ground)
OK
3 Check BCM
Normal
Terminal Condition
value
Turn door lock
K2E-8 body
control switch 0~11-14V
ground
to LOCK
Turn door lock
K2E-1 body
control switch 0~11-14V
ground
to UNLOCK
NG Replace BCM
OK
4 Finish
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Circuit diagram:
Inspection steps:
Normal
Terminal Condition
value
W05-3- battery (+)
W05-6-W05-5 <1ȍ
W05-4- battery (-)
W05-4- battery (+)
W05-6-W05-5 >10Kȍ
W05-3- battery (-)
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BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Wire color
value
K2H-11-W05-3 O <1ȍ
K2H-4-W05-4 G <1ȍ
G2P-2-W05-6 Br <1ȍ
W05-5-M17 (body
B <1ȍ
ground)
OK
3 Check BCM
Normal
Terminal Condition
value
Turn door lock
K2H-11 body
control switch 0~11-14V
floor
to LOCK
Turn door lock
K2H-4 body
control switch 0~11-14V
floor
to UNLOCK
NG Replace BCM
OK
4 Finish
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Circuit diagram:
Roof lamp
unlocking power
Back door
Inspection steps:
Normal
Terminal Condition
value
Y05-1- battery (+)
Y05-4-Y05-2 <1ȍ
Y05-3- battery (-)
Y05-3- battery (+)
Y05-4-Y05-2 >10Kȍ
Y05-1- battery (-)
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OK
Wire Normal
Terminal
color value
Y05-1-K2F-13 Y/G <1ȍ
K2G-4-Y05-3 Y <1ȍ
G2P-15-Y05-2 Gr <1ȍ
Y05-4-Y16 (body
B <1ȍ
ground)
OK
3 Check BCM
Normal
Terminal Condition
value
Turn door lock
K2F-13 body
control switch 0~11-14V
floor
to LOCK
Turn door lock
K2G-4 body
control switch 0~11-14V
floor
to UNLOCK
NG Replace BCM
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OK
4 Finish
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Disassembly
Assembly
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Disassembly
Assembly
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1. Component Location
FRONT
ANGLESENSO ˈRH
FRONT
ANGLESENSO ˈLH
BACK-UP RADAR ECU
SWITCH, BACK-UP
RADAR
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BYD S6, S6A, S6K Service Manual
CAN CABLE
PARKING ASSISTANT MODULE
REAR ANGLE
SENSOR, LH
REAR ANGLE
SENSOR, RH
REAR BACK-UP
SENSOR, LH
REAR BACK-UP
SENSOR, RH
FRONT ANGLE
SENSOR, RH
FRONT ANGLE
SENSOR, LH
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BYD S6, S6A, S6K Service Manual
The parking assistant is a vehicle monitoring 1. The detection function of the sensor
system developed by imitating the bat flying doesn’t work normally in the following
and detection principle. Several ultrasonic ra- cases
dar probes are installed in the rear and front
Mud or snow is attached to the sen-
of the vehicle to transmit and receive signals
sor (wash the foreign matters with
and feed back to the controller, which will cal-
water to resume the normal func-
culate the distance from obstacle according
tion)
to the return time of the signal, and trigger dif-
ferent audible and indicator alarms according When the sensor is covered by the
to the distance to prompt driver the distance hand
between obstacle and the vehicle, and thus
increase the convenience and security of re- When the ambient temperature is
versing and parking. low, the sensor has failure due to
freezing
The alarm mode of parking assistant:
2. The detection range of the sensor
Distance be- changes in the following cases
tween probe and Display
obstacle Mud or snow is attached to the sen-
The light isn’t on if the sor (wash the foreign matters with
Left rear angle sen- distance from obstacle is water to resume the normal func-
sor longer than 0.6m tion)
Right rear angle Flash in the same fre-
sensor quency (4Hz) as the an- The vehicle is exposed to sunlight
Left front angle sen- nunciator of the distance or ultra low temperature
sor is 0.5m-0.6m;
Right front angle Constantly on if the 3. The detection of sensor may have error
sensor distance is shorter than
in the following cases
0.5m
The light isn’t on if the The vehicle is running on bumpy,
distance from obstacle is
gravel road or grass
longer than 1.2m
Flash in the same fre- Interference from other vehicle horn,
quency (2Hz) as the an-
nunciator of the distance
the sound of motorcycle engine, the
Left back-up sensor air brake sound of large vehicles or
is 0.8m-1.2m;
Right back-up sen- sound waves from other vehicles
Flash in the same fre-
sor
quency (4Hz) as the an- equipped with sensor
nunciator of the distance
is 0.5m-0.8m; The vehicle is in rain or splashed
Constantly on if the with water
distance is shorter than
0.5m The vehicle is inclined
The parking assistant mainly consists of: Mud or snow is attached to the sen-
sor
Parking assistant module
The vehicle has towing hook
Sensor (six: two on front bumper
and four on rear bumper) Close to another vehicle equipped
with sensors
Parking assistant switch (integrated
on air conditioning panel) The vehicle is running to higher or
right angle curb
Alarm buzzer
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4. System Introduction
Diagnostic Process
Prompt:
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
No DTC output A
Have DTC output B
B Go to step 5
NEXT
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Vehicle inspection
Check ECU terminal
NEXT
NEXT
NEXT
7 Finish
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5. DTC list
DTC Fault
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6. Terminal Diagnosis
1. Disconnect parking assistant module connector.
Normal value:
Normal value:
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Power circuit
Circuit diagram:
AIR CONDITIONING
G18-4
Inspection steps:
Con- Nor-
Wire
nection Condition mal
color
terminal value
IG1 power
K19-19 Press the
R/L 11-14V
body floor parking as-
sistant switch
OK Go to step 4
NG
2 Check wires (between parking assistant switch and module on the air conditioning panel)
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BYD S6, S6A, S6K Service Manual
OK
OK
OK
5 Finish
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Circuit diagram:
Inspection steps:
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Connection Normal
Test condition
terminal value
ON position
K19-13 body Reverse gear
4-6V
floor Press the parking
assistant switch
ON position
K19-11 body Reverse gear
<1V
floor Press the parking
assistant switch
Connection Normal
Test condition
terminal value
ON position
K19-28 body Reverse gear
4-6V
floor Press the parking
assistant switch
ON position
K19-11 body Reverse gear
<1V
floor Press the parking
assistant switch
Connection Normal
Test condition
terminal value
ON position
K19-12 body Reverse gear
4-6V
floor Press the parking
assistant switch
ON position
K19-11 body Reverse gear
<1V
floor Press the parking
assistant switch
Connection Normal
Test condition
terminal value
ON position
K19-12 body Reverse gear
4-6V
floor Press the parking
assistant switch
ON position
K19-11 body Reverse gear
<1V
floor Press the parking
assistant switch
OK
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BYD S6, S6A, S6K Service Manual
NG Replace wires
OK
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Circuit diagram:
Inspection steps:
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BYD S6, S6A, S6K Service Manual
Connection Normal
Test condition
terminal value
ON position
K19-31 body Reverse gear
Press the parking 4-6V
floor
assistant switch
ON position
K19-16 body Reverse gear
Press the parking <1V
floor
assistant switch
Connection Normal
Test condition
terminal value
ON position
K19-29 body Reverse gear
Press the parking 4-6V
floor
assistant switch
ON position
K19-14 body Reverse gear
Press the parking <1V
floor
assistant switch
OK
OK
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
ON POSITION
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BYD S6, S6A, S6K Service Manual
Con-
Wire Test con- Normal
nection
color dition value
terminal
Reverse
K19-5 G 11-14V
gear
NG Finish
NG
NG Replace wires
OK
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BYD S6, S6A, S6K Service Manual
OK
NG Go to step 6
NG
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BYD S6, S6A, S6K Service Manual
OK
OK
7 Finish
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8. Tool Preparations
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BYD S6, S6A, S6K Service Manual
Note: The two sensors on front bumper and the four sensors on the rear bumper are as-
sembled and disassembled in the same way. Following example is rear left angle sensor.
Disassembly
Assembly
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Disassembly
Assembly
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1. Component Location
Steering lock
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BYD S6, S6A, S6K Service Manual
The steering lock is an important part of the security system. If the steering lock is engaged, the
mounting bolts can’t be removed, and the steering lock still can’t be unlocked even if the steering
lock is destroyed. The bracket of the steering lock should be destroyed to remove the steering
lock; the bracket is welded on the steering column.
Working principle:
The steering lock sends unlocking or locking signal to steering lock controller through keyless
ECU and BCM, the motor executes unlocking and locking action, the steering lock control mod-
ule checks whether unlocking or locking is successful through the signal obtained by Hall sensor,
and sends the information back to keyless system and vehicle control module ECU to finish other
commands.
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BYD S6, S6A, S6K Service Manual
4. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
B Go to step 5
4 Comprehensive diagnosis
NEXT
NEXT
NEXT
7 Finish
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5. Fault Table
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6. Terminal diagnosis
(1) Disconnect G12 connector
(2) Measure the voltage or resistance between terminals of the wire connectors.
Normal:
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BYD S6, S6A, S6K Service Manual
Circuit diagram
Steering lock
Inspection steps
Normal
Terminal Condition
value
Mains electric-
G12-5 body ground <1V
ity supply
Mains electric-
G12-1 body ground <1V
ity supply
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BYD S6, S6A, S6K Service Manual
Normal
Terminal Condition
value
G12-4~G2P-29 Y <1ȍ
G12-2~G2P-30 L <1ȍ
G12-3~G2X-24 P <1ȍ
G12-6~G2X-23 V <1ȍ
OK
2 Check MICU
Normal
Terminal Condition
value
G2P-30 body ground Unlock/lock 11-14V
NG Replace MICU
OK
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1. Component Location
Combination
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BYD S6, S6A, S6K Service Manual
AIRBAG SYSTEM
LIGHTING SYSTEM
COMBINATION INSTRUMENT
MULTIMEDIA
OIL LEVEL SENSOR
SYSTEM
GENERATOR
MULTIFUNCTIONAL
SCREEN
PARKING SWITCH
COMBINATION
ENGINE OIL SWITCH
PRESSURE SWITCH
START CAN
Information List
Receiving
Sending node Information Transfer type
node
1. Left front door state
2. Right front door state
3. Left rear door state
4. Right rear door state
5. Driver’s seat belt switching signal
Combination in-
BCM 6. Vehicle state CAN
strument
7. Luggage compartment signal
8. Keyless system emergency warning lamp
signal
9. Buzzer control signal
10. Power position signal
Combination in- 1. SRS fault LED drive signal
SRS CAN
strument 2. PAB_SW signal
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BYD S6, S6A, S6K Service Manual
Receiving
Sending node Information Transfer type
node
1. Tail lamp switch signal
2. Dipped headlight switch signal
Combination Combination in-
3. Headlight on full beam switch signal CAN
switch strument
4. Front fog lamp switch signal
5. Rear fog lamp switch signal
Multifunctional
1. Dimming position signal CAN
screen
BCM 1. Overspeed locking signal CAN
Combination in- SRS 1. Assistant driver’s seat belt signal CAN
strument
Multimedia sys-
1. Parking brake switch signal CAN
tem
Multimedia sys-
1. Oil level signal CAN
tem, ECM
1. Can’t detect key
Combination in- 2. The key is in the vehicle
Keyless CAN
strument 3. The key is in card reader area
4. Battery status of the key
1. Fault signal related to engine fault MIL
2. Coolant temperature error signal
3. Speed signal error
4. Engine speed error signal
5. EBD fault signal
6. ABS fault signal
Combination in- 7. Engine speed signal
Gateway CAN
strument 8. Speed signal
9. Engine state signal
10. Coolant temperature signal
11. Service alarm light
12. Gear position signal
13. Instantaneous fuel signal
14. Total fuel consumption signal
Combination in-
Generator system 1. Charging system lamp Hard wire
strument
Combination in- 1. Left turn signal indicator
Lighting system Hard wire
strument 2. Right turn signal indicator
Combination in-
Roof lamp system 1. Backlight drive signal Hard wire
strument
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BYD S6, S6A, S6K Service Manual
3. System Introduction
This is an electromechanical combination instrument located in front of the driver and in upper
part of the steering column, including mountings and electrical connections. All the circuits of the
combination instrument form a single wiring harness and are connected to the rear of the com-
bination instrument shell. The combination instrument panel and indicator are protected in a full
piece of transparent mask. The transparent mask uses a shielding plate to protect the instrument
from ambient light and reflection and reduce glare.
Meters:
Speedometer
Fuel gauge
Engine tachometer
Mileage information
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BYD S6, S6A, S6K Service Manual
SVS indicator
The lighting of the combination instrument is realized through the adjustable LED in the back,
which can illuminate the instrument and provide necessary visibility. Each indicator of the combi-
nation instrument is also lit through dedicated LED. Each LED is welded to the circuit board be-
hind the combination instrument shell integrally. The connecting circuits connect the combination
instrument to the electrical system of the vehicle. These circuits are integrated in the vehicle wir-
ing harness, and are fixed in different directions and modes.
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BYD S6, S6A, S6K Service Manual
4. Diagnostic Process
NEXT
Standard voltage:
11~14V
NEXT
Result Perform
The fault isn’t in the table A
The fault is in the table B
B Go to step 5
4 Comprehensive diagnosis
NEXT
NEXT
NEXT
7 Finish
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BYD S6, S6A, S6K Service Manual
5. DTC List
DTC Fault
6. Fault Table
1. Instrument
Vehicle backlight can’t be adjusted 2. Wiring harness
3. Other module
1. Wheel speed sensor
2. ABS
Speedometer is abnormal 3. Gateway
4. Combination instrument
5. CAN communication
1. Crankshaft position sensor
2. ECM
Tachometer is abnormal 3. Gateway
4. Combination instrument
5. CAN communication
1. Oil level sensor
Fuel gauge is abnormal 2. Instrument
3. Wire or connector
1. Coolant temperature sensor
2. ECM
Coolant temperature gauge is abnormal 3. Gateway
4. Combination instrument
5. CAN communication
1. Combination switch
Instrument turn signal indicator isn’t lit 2. Combination instrument
3. Wire or connector
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7. Terminal Diagnosis
1. Check the pin of combination instrument
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Circuit diagram:
IG1
MAINS POWER
COMBINATION INSTRUMENT
Inspection steps:
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BYD S6, S6A, S6K Service Manual
OK
Normal
Wire Condi-
Terminal condi-
color tion
tion
G14-39 body
W/R Constant 11~14V
ground
G14-38 body ON posi-
Y/L 11~14V
ground tion
G14-11 body
B Constant <1ȍ
ground
G14-12 body
B Constant <1ȍ
ground
OK
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Circuit diagram:
COMBINATION
INSTRUMENT
ABS SYSTEM
GATEWAY
Inspection steps:
Combination instrument
Result Go to
Have DTC output A
No DTC output NEXT
ABS system
Result Go to
Have DTC output B
No DTC output NEXT
NEXT
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BYD S6, S6A, S6K Service Manual
Tachometer is abnormal
Circuit diagram:
COMBINATION
INSTRUMENT
ECM SYSTEM
GATEWAY
Inspection steps:
Combination instrument
Result Go to
Have DTC output A
No DTC output NEXT
ECM system
Result Go to
Have DTC output B
No DTC output NEXT
NEXT
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Circuit diagram:
COMBINATION
INSTRUMENT
OILLEVELSE
NSOR
Inspection steps:
OK
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BYD S6, S6A, S6K Service Manual
Normal
Wire Condi-
Terminal condi-
color tion
tion
G14-
B/W Constant <1ȍ
8-K43-3
G14-
B/Y Constant <1ȍ
9-K43-2
G14-11 body
B Constant <1ȍ
ground
G14-12
B Constant <1ȍ
body ground
OK
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Circuit diagram:
TEMPERATURE SENSOR
COMBINATION
COOLANT
INSTRUMENT
GATEWAY
CONTROLLER
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Inspection steps:
Combination instrument
Result Go to
Have DTC output A
No DTC output NEXT
ECM
Result Go to
Have DTC output B
No DTC output NEXT
A Go to “CAN Diagnosis”
B Go to “Engine System”
NEXT
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Circuit diagram:
COMBINATION
INSTRUMENT
COMBINATION SWITCH
Inspection steps:
NG Go to “Lighting System”
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BYD S6, S6A, S6K Service Manual
OK
Result Go to
Have DTC output A
No DTC output B
A Go to “CAN Diagnosis”
271
Open the front door and check whether
Go to “Lighting System”
COMBINATION
INSTRUMENT
NG
Check whether the door courtesy works normally.
(1)
Backdoor courtesy switch(dooropenswhenitisclosed)
Door opening indicator is abnormal
Inspection steps:
Circuit diagram:
Left front door courtesy switch
(door opens when it is closed)
272
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BYD S6, S6A, S6K Service Manual
OK
Result Go to
Have DTC output A
No DTC output B
A Go to “CAN Diagnosis”
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Circuit diagram:
COMBINATION
INSTRUMENT
COMBINATION SWITCH
Inspection steps:
NG Go to “Lighting System”
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OK
Result Go to
Have DTC output A
No DTC output B
A Go to “CAN Diagnosis”
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Circuit diagram:
COMBINATION
INSTRUMENT
COMBINATION SWITCH
Inspection steps:
NG Go to “Lighting System”
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OK
Result Go to
Have DTC output A
No DTC output B
A Go to “CAN Diagnosis”
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Circuit diagram:
COMBINATION
INSTRUMENT
COMBINATION SWITCH
Inspection steps:
NG Go to “Lighting System”
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OK
Result Go to
Have DTC output A
No DTC output B
A Go to “CAN Diagnosis”
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Circuit diagram:
COMBINATION INSTRUMENT
Engine oil
pressure switch
(close: engine
stops; open:
engine starts
running)
Inspection steps:
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BYD S6, S6A, S6K Service Manual
OK
Normal
Wire Con-
Terminal condi-
color dition
tion
G14-34-A24-1 Y/R Constant <1ȍ
G14-34 body
Y/R Constant >10Kȍ
ground
OK
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Circuit diagram:
MAINS
F2/13 TURN
SIGNAL/W
ARNING
LAMP 15A
SIGNAL LAMP RELAY
K6 LEFT TURN
K5 RIGHT TURN
SIGNAL LAMP
LEFT TURN LEFT TURN
SIGNAL LAMP SIGNAL RELAY
COMBINATION INSTRUMENT
INTEGRATED
CONTROL
MODULE G2Q-4
Inspection steps:
NG Go to “Lighting System”
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OK
OK
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
COMBINATION
SWITCH
GENERATOR
Inspection steps:
Normal
Terminal Condition
condition
A25-2 body
Engine is running 11-14V
ground
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BYD S6, S6A, S6K Service Manual
OK
Normal
Wire Con-
Terminal condi-
color dition
tion
G14-35- A25-2 Y/L Constant <1ȍ
OK
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
COMBINATION
INSTRUMENT
(close: pull up)
HANDBRAKE
Inspection steps:
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BYD S6, S6A, S6K Service Manual
OK
Normal
Terminal Condition
condition
M28-1 body Pull up the
<1V
ground handbrake
OK
Normal
Termi- Wire Condi-
condi-
nal color tion
tion
M28-
Br/G-G/P Constant <1ȍ
1-G14-23
OK
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BYD S6, S6A, S6K Service Manual
Circuit diagram:
COMBINATION
SWITCH
Inspection steps:
Result Go to
Have DTC output A
No DTC output B
A Go to “CAN Diagnosis”
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BYD S6, S6A, S6K Service Manual
Normal
Terminal Condition
condition
Fasten the seat
KJ08-1-KJ08-2 >10Kȍ
belt switch
Do not fasten
KJ08-1-KJ08-2 the seat belt <1ȍ
switch
OK
Normal
Wire Condi-
Terminal condi-
color tion
tion
K2F-14-KJ08-1 L/R Constant <1ȍ
KJ08-1-KJ08-2 B Constant <1ȍ
OK
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BYD S6, S6A, S6K Service Manual
Inspection steps:
Disassembling/assembling combination
instrument
Disassembly
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BYD S6, S6A, S6K Service Manual
291
Section15 Distribution Fuse
292
Configuration Table
Code B L Br G Gr Lg O P R V W Y
Light
Color Black Blue Brown Green Grey Orange Pink Red Purple White Yellow
green
Relay
No. KC-1 KC-2 KG-5 KG-4 KC-4 KC-3 KG-6 KG-7 KG-1 KG-2 KG-3
Specification 20A 20A 20A 20A 20A 20A 20A 30A 20A 50A 20A
Lamp, side Lamp, side
Front Low speed Rear Seat Rear air
Description turn signal, turn signal, Reserved ACC IG1 IG3
fog lamp fan washer heater blower
LH RH
Fuse
No. F1/1 F1/2 F1/3 F1/4 F1/5 F1/6 F1/7 F1/8 F1/9 F1/10 F1/11
Specification 10A 10A 10A 10A 30A 15A 7.5A 20A 15A 30A 20A
Headlight Headlight Dipped Dipped
Front fog Low speed High
Description on full on full head- headlight, Reserved Side light MCU EMS
lamp fan speed fan
beam, RH beam, LH light, LH RH
No. F1/12 F1/13 F1/14 F1/15 F1/16 F1/17 F1/18 F1/19 F1/20 F1/21 F1/22-1
Specification 7.5A 15A 15A 40A 40A 25A 40A 40A 40A 40A 120A
Lamp,
side Brake Rear F2/1 ~ F2/7 ~ Front air
Description Compressor ABS EMS ABS Main fuse
turn lamp defroster F2/6 F2/11 blower
signal
No. F2/1 F2/2 F2/3 F2/4 F2/5 F2/6 F2/7 F2/8 F2/9 F2/10 F2/11
Specification 20A 7.5A 10A 15A 15A 7.5A 20A 20A 20A 20A 20A
Door Front
Cigar Rear fog Seat Front seat,
Description lock Roof lamp MICU Acoustics Reserved Reserved cushion,
lighter lamp heater LH
motor LH
BYD S6, S6A, S6K Service Manual
No. F2/12 F2/13 F2/14 F2/15 F2/16 F2/17 F2/18 F2/19 F2/20 F2/21
Specification 7.5A 7.5A 10A 25A 20A 20A 20A 20A 7.5A 15A
Front
Steering Rear power Front power Rear power
Description Reserved IG2 Sunroof window ACC Ignition coil
lock window, RH window, RH window, LH
motor, LH
No. F2/22 F2/23 F2/24 F2/25 F2/26 F2/27 F2/28 F2/29 F2/30 F2/31 F2/32 F2/33
Specification 15A 15A 15A 15A 15A 15A 10A 15A 7.5A 15A 30A
Rear Second Front
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Main Oil Rear Mirror
Description Reserved ETV EMS Reserved windshield gear SRS windshield
relay pump washer heater
wiper switch wiper
BYD S6, S6A, S6K Service Manual
ķ Position code: expressed with A, B, C, K, M…… (I, J, O, X, i and j aren’t used); this digit de-
pends on the position of the wiring harness. See Table 1 for the relationship.
ĸ Category code: expressed with 1, 2 …… or capitalized letter J, including the following three
conditions:
If the circuit element is a connector on the distributor box, this code will be expressed with
number 1, 2, 3……; see Table 2 for distributor box coding.
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BYD S6, S6A, S6K Service Manual
If this circuit element is a docking connector between wires, this digit will be expressed with
letter J;
If this circuit element is a connector, relay seat, external insurance, or wire ground terminal
connected to vehicle electrical module, this digit is null;
Ĺ Sorting code: expressed with capitalized letters A, B, C, D, E, F…… or 01, 02, 03, 04,
05……, including the following two conditions.
If the circuit element is a connector on the distributor box, the code will be expressed with
A, B, C, D, E, F……; this digit is consistent with the socket location coding of the distributor
box in which the connector is inserted.
For other circuit elements, assign number 01, 02, 03, 04, 05 …… in sequence according to
the space position.
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