3.1 Warnings and precaution ............................. 1082 

3.1.1 Warnings and precaution ............................. 1082 

3.2 Clutch system ................................................ 1084 

3.2.1 Fastener specification .................................. 1084 

3.2.1.1 Fastener Specifications ............................. 1084 

3.2.1.2 General Specifications .............................. 1084 

3.2.2 Description and operation ............................ 1084 

3.2.2.1 Description and operation ......................... 1084 

3.2.3 System operating principle .......................... 1085 

3.2.3.1 System Operating Principle ...................... 1085 

3.2.4 Disassemble drawings ................................. 1086 

3.2.4.1 Clutch control mechanism ........................ 1086 

3.2.4.2 Clutch disengaging mechanism ................ 1087 

3.2.5 Diagnostic information and procedures ....... 1088 

3.2.5.1 Diagnosis descriptions .............................. 1088   

3.2.5.2 Clutch disengaging fault (Gearshift lever 
cannot select gears). .............................................. 1088   

3.2.5.3 Clutch skidding fault................................. 1090   

3.2.5.4 Clutch pedal is hard to push ...................... 1092   

3.2.5.5 Clutch pedal does not return ..................... 1093   

3.2.5.6 Clutch bearing noisy when clutch engaging
 .............................................................................. 1094   

3.2.5.7 Clutch rattle .............................................. 1094   

3.2.6 Dismantle and installation ........................... 1095   

3.2.6.1 Replacement of clutch pedal ..................... 1095   

3.2.6.2 Clutch master pump Replacement ............ 1096   

3.2.6.3 Hydraulic clutch exhaust .......................... 1099   

3.2.6.4 Clutch pedal free travel adjustment .......... 1100   

3.2.6.5 Clutch assembly replacement ................... 1101   

3.2.6.6 Release bearing replacement .................... 1102   

3.2.6.7 Clutch slave pump replacement ................ 1104   

3.2.7 Special tools and equipment  ...................... 1105  

3.2.7.1 Special tools list. ....................................... 1105   

3.3 V5A1C Manual transmission ....................... 1106   

3.3.1 Specifications ............................................... 1106   

3.3.1.1 Fastener specifications .............................. 1106   

3.3.1.2 Manual transmission specifications .......... 1107   

 

3.3.2 Description and operation ........................... 1110   

3.3.2.1 Transmission system operation ................ 1110   

3.3.3 System operating principle ..........................  1111   

3.3.3.1 Gearshift operating principle .................... 1111   

3.3.3.2 Operating principle of odometer sensor   . 1111   

3.3.3.3 Reverse lamp switch operating principle.. 1111   

3.3.4 Component position .................................... 1112   

3.3.4.1 Transmission assembly position ............... 1112   

3.3.4.2 Vehicle speed sensor, reverse switch position
 ..............................................................................  1113   

3.3.5 Diagnostic information and procedures ....... 1114   

3.3.5.1 Diagnosis descriptions .............................. 1114   

3.3.5.2 Visual inspection ...................................... 1114   

3.3.5.3 Hard to shift .............................................. 1116   

3.3.5.4 Out of gear ................................................ 1118   

3.3.5.5 Hard to disengage ..................................... 1120   

3.3.5.6 Abnormal sound when running ................ 1121   

3.3.5.7 engage in gear when driving, there is gear 
collision or grinding sound ................................... 1122   

3.3.5.8 Engage in gear when driving, there is a dull 
metal sound .......................................................... 1122   

3.3.6 Dismantle and installation   ......................... 1123   

3.3.6.1 Transmission oil level inspection ............. 1123   

3.3.6.2 Vehicle speed sensor replacement   .......... 1124   

3.3.6.3 Transmission assembly replacement ........ 1127   

3.3.6.4 Transmission disassemble and assemble .. 1134   

3.3.6.5 Input shaft disassemble and assemble ...... 1140   

3.3.6.6 Input shaft disassemble and assemble ...... 1145   

3.3.6.7 Reverse intermediate gear disassembly and 
assembly ...............................................................  1152   

3.3.6.8 Disassemble and assemble of shift control 
mechanism ............................................................  1153   

3.3.6.9 Shifter replacement ................................... 1155   

3.4 S170BⅡManual transmission   ................... 1157 

3.4.1 Specifications  ............................................ 1157  

3.4.1.1 Fastener tightening specification ..............  1157   

3.4.1.2 Manual transmission specifications ..........  1158   

3.4.1.3 Size parameter specification ..................... 1159   

3.4.2 Description and operation ............................ 1160   

3.4.2.1 Transmission system and operated description
 .............................................................................. 1160   

3.4.3 System operating principle .......................... 1162   

3.4.3.1 System operating principle ....................... 1162   

3.4.4 Component position ..................................... 1169   

3.4.4.1 Transmission assembly position   ............. 1169   

3.4.4.2 Vehicle speed sensor, reverse switch position 
 .............................................................................. 1170   

3.4.5 Disassemble drawings ................................. 1171   

3.4.5.1 Part disassemble drawing of gear module and 
gear box  .............................................................. 1171  

3.4.5.2 Disassembly drawing of control mechanism 
and fork module .................................................... 1174   

3.4.6 Electrical schematic diagram ....................... 1175   

3.4.6.1 Reverse switch, vehicle speed sensor circuit 
schematic  ............................................................ 1175  

3.4.7 Diagnostic information and procedures ....... 1176   

3.4.7.1 Diagnosis descriptions .............................. 1176   

3.4.7.2 Visual inspection ...................................... 1176   

3.4.7.3 Hard to shift. ............................................. 1178   

3.4.7.4 Out of gear ................................................ 1181   

3.4.7.5 Hard to Disengage   ................................. .1183   

3.4.7.6 Abnormal sound when running................. 1184   

3.4.7.7 Engage in gear when driving, there is gear 
collision or grinding sound. .................................. 1185   

3.4.7.8 engage in gear when driving, there is A dull 
metal sound. .......................................................... 1185   

3.4.8 Dismantle and installation ........................... 1186   

3.4.8.1 Transmission oil level inspection ............. 1186   

3.4.8.5 Disassembly and assembly of shift control 
mechanism ............................................................ 1203   

3.4.8.8 Disassembly and assembly of main shaft   1230   

3.4.8.9 Shift control lever replacement ................. 1238   

3.5 DSI Automatic transmission ........................ 1242   

3.5.1 Specifications ............................................... 1242   

3.5.1.1 Fastener specifications. ............................. 1242   

3.5.1.2 Automatic transmission fluid specification.
 .............................................................................. 1242   

3.5.1.3 Relation of temperature sensor resistance and 
temperature for automatic transmission fluid  ..... 1242  

3.5.2 Description and operation ........................... 1244   

3.5.2.1 DSIAutomatic transmission overview ...... 1244   

3.5.2.2 Six forward gear characteristic .................  1245   

3.5.2.3 Transmission cooling system ................... 1246   

3.5.2.4 Shift strategy  ........................................... 1246   

3.5.3 System operating principle ..........................  1249   

3.5.3.1 Automatic transmission structure principle
 ..............................................................................  1249   

3.5.3.2 Shift work principle ..................................  1256   

3.5.3.3 Shift mode  .............................................. 1260  

3.5.3.4 Control system element of transmission ... 1261   

3.5.4 Component position   .................................. 1263   

3.5.4.1 Automatic transmission assembly position
 ..............................................................................  1263   

3.5.4.2 Automatic transmission sensor position   . 1263   

3.5.4.3 Automatic transmission control module 
position .................................................................  1265   

3.5.5 Electrical schematic diagram ....................... 1266   

3.5.5.1 Diagnostic schematic diagram. ................. 1266   

3.5.5.2 Circuit schematic diagram. ....................... 1267   

3.5.6 Diagnostic Information and Procedures   .... 1268   

3.5.6.1 Diagnosis descriptions ............................. .1268   

3.5.7.4 Automatic transmission refresh process ... 1270   

3.5.7.5 Automatic transmission terminal definition list 
 .............................................................................  .1273   

3.5.7.6 Fault diagnosis code (DTC) chapter index 1277   

3.5.7.7 Data glow table ......................................... 1281   

3.5.7.8 P0603 P0604 P1604 P1701 P1703 ........... 1283   

3.5.7.9 P0707 P0708 ............................................ 1288   

3.5.7.10 P0711 ......................................................  1293  

3.5.7.11 P0712 P0713 ............................................ 295   

3.5.7.12 P1605 P1610 P1611 ............................... 1300   

3.5.7.13 P0716 P0717 .......................................... 1305   

3.5.7.14  P0721 P0722........................................ 1311   

3.5.7.15 P071D P071E P071F .............................. 1317   

3.5.7.16 P0729 P0731 P0732 P0733 P0734 P0735 
P0736 ....................................................................  1323   

3.5.7.17 P0741 P0742 P0744 ............................... 1328   

3.5.7.18 P0962 P0963 .......................................... 1332   

3.5.7.19 P0966 P0967 ........................................... 1337   

3.5.7.20 P0985 P0986 ........................................... 1342   

3.5.7.21 P0998 P0999 ........................................... 1347 

  3.5.7.22 P099B P099C   ..................................... 1352 

  3.5.7.23 P099E P099F   ...................................... 1357 

 3.5.7.24 P0973 P0974. ........................................ 1362   

3.5.7.25 P0976 P0977 ........................................... 1367 

3.5.7.26 P0979 P0980 ........................................... 1372 

3.5.7.27 P0982 P0983 ........................................... 1277 

3.5.7.28U0100U0121 U0146 U0415.....................1382   

3.5.7.29 U1601 U1606 U1607 U1608 U1609 ...... 1385   

3.5.7.30 U160E ..................................................... 1388 

3.5.7 Dismantle and install ................................... 1391 

3.5.7.1 Automatic transmission maintenance 
precaution  ........................................................... 1391  

3.5.7.2 Check process of automatic transmission oil 
level ...................................................................... 1392   

3.5.7.4 Automatic transmission fluid cooling system 
cleaning process ................................................... 1394   

3.5.7.5 Gears switch replacement  ....................... 1395  

3.5.7.6 Automatictransmission assembly replacement 
 ..............................................................................  1396   

3.5.7.7 Shifter replacement. .................................. 1403   

3.5.7.8 replace automatic transmission control module
 ..............................................................................  1406   

 

 

 
 

3.1 Warnings and precaution 

3.1.1 Warnings and precaution 

Warning for battery disconnection 

Warning! 

Unless directed, otherwise, the ignition and start switch must be in OFF or LOCK position, and all electrical loads 
must be OFF before servicing any electrical component. Disconnect the negative battery cable if a tool or any 
equipment easily comes in contact with an exposed electrical terminal. Failure to follow these precautions may 
result in personal injury and/or damage to the vehicle or its components. 

Warning for clutch dust   

Warning! 

When servicing clutch components, do not create dust by grinding or sanding the clutch disc or by cleaning parts 
with a dry brush or with compressed air. A water-dampened cloth - NOT SOAKED - should be used. Clutch disc 
may contain fiber, which can be mixed into air if dust is produced during maintenance. inbreathing dust 
containing fiber can damage your health severely. 

Warning for moving components and hot surfaces 

Warning! 

Avoid contacting with moving components and hot surfaces while working around a running engine in order to 
prevent personal injury. 

Warning for protective goggles and glove warning   

Warning! 

Approved protective goggles and gloves should be worn when dismantling the exhaust system components, or 
else the sharp edge or the iron rust dropped down from the exhaust system components may cause serious 
personal injury. 

Warning for road test 

Warning! 

Test a vehicle on the roads under safe conditions and obey all traffic laws. Do not attempt any operation that could 
jeopardize vehicle control. Failure to obey these precautions will lead to serious personal injury and vehicle 
damage. 

Precaution for lifting engine   

Notes: 

When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the 
crankshaft pulley. Lifting the engine in an unapproved manner may cause damages to component. 

Precaution for fastener   

Notes: 

Use the correct fastener in the correct position. Replacement of fasteners must have the correct part number for 
that application. Fasteners requiring replacement and fasteners requiring the use of thread locking compound or 
sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or 
fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may 
damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to 
avoid damage to parts and systems. 

Precaution for sealant   

Notes: 

1082