– 

Avoid the following actions unless required by the diagnostic procedure: 

– 

Make connector jumper and ground 

– 

Connecting test equipment probes to components or connectors. Connect the ground lead 
first when using test probes. 

Ground the protective packaging of any component before opening it. Do not rest solid-state 
components on metal workbenches, or on top of TVs, radios, or other electrical equipments. 

Important precaution for heat-type oxygen sensor and oxygen sensor   

Important precaution: Do not remove the leading line from either the oxygen sensor (HO2S). 
Removing the leading line or the connector will affect sensor operation. 

Important precaution: Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the 
in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. 

Do not use cleaning agent of any type. 

Important precaution: Do not repair the wiring, connector or terminals. 

Replace the oxygen sensor if the leading line, connector, or terminal is damaged. 

Important precaution: This external clean air reference is obtained by way of the oxygen sensor 
signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in 
the obstruction of the air reference and degraded sensor performance. 

Important precaution: The following guidelines should be used when servicing the oxygen sensor: 

– 

Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. 
These materials may get into the sensor to cause poor performance. 

– 

Do not damage the sensor leading line and harness wires in such a way that the wires inside 
are exposed. This could provide a path for foreign materials to enter the sensor and cause 
performance problems. 

– 

Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks 
could block the reference air path through the lead wire. 

– 

Ensure that the peripheral seal remains intact on the vehicle harness connector in order to 
prevent damage due to water intrusion 

Important precaution for ignition OFF when disconnecting battery 

Important precaution: when connecting or disconnecting the battery cable and the battery charger 
or crossover cable, be sure to turn the ignition switch to the position OFF. Failing to do so may 
damage the control module or other electronic components. 

Important precaution for installing hoses without twists or bends 

Important precaution: The inlet and outlet hoses must not be twisted during installation. Do not 
bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these 
procedures could result in component damage. 

Important precaution for machined surface damage 

Important precaution: Do not carve, scratch or damage the sealing surface. The sealing surface is 
machining surface; and leakage may be caused by the damage to the machining surface. 

Important precaution for power system control module and electrostatic discharge 

Important precaution: Do not touch the connector pins or soldered components on the circuit 
board in order to prevent possible electrostatic discharge (ESD) damage to the PCM. 

Important precaution for power steering system hose disconnection 

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Important precaution: Do not start the vehicle with any power steering gear inlet or outlet hoses 
disconnected. When disconnected, plug or cap all openings of components. Failure to do so could 
result in contamination or loss of power steering fluid and damage to the system. 

Important precaution for ring gear dismantle   

Important precaution: Do not pry the gear ring from the differential housing. The gear ring and/or 
the differential housing may be damaged by prying the gear ring from the differential housing. 

Important precaution for sealant 

Important precaution: Do not let the room temperature hardening sealant into the threaded blind 
hole; if the room temperature hardening sealant enters into the threaded blind hole, the fastener 
produces hydraulic lock-up effect when fastening; the fastener and/or the other compartments may 
be damaged due to hydraulic lock-up of the fastener; moreover, the fastener will not obtain a 
correct clamping force when fastening; the part is unable to seal correctly due to wrong clamping 
force, thereby resulting in leakage; and the fastened can not be properly tightened, so that the part 
is loose or separates, thereby resulting in serious damage to the engine. 

Important precaution for fault diagnosis tester usage 

Important precaution: Before perform vehicle diagnostic, pay attention to the following,otherwise 
it may cause damage to the engine control module. 

– 

The fault diagnosis tester and the software must be up to date. 

– 

Vehicle battery must be fully charged and battery voltage should be 12-14V. 

– 

Fault diagnosis and tester terminals must be firmly connected. 

– 

When programming the engine control module, do not connect the battery to the charger. 

Important precaution on steering wheel in the Steering limiting position   

Important precaution : do not hold the steering wheel in the steering limiting position    longer 
than 5ｓ, as damage to the steering pump may result. 

Important precaution for test probe 

Important precaution: Do not insert test equipment probes (DMM etc.) into any connector or fuse 
block terminal. The diameter of the test probes will deform most terminals. A deformed terminal 
will cause a poor connection, which will result in a system failure.  Always use approved 
terminal test kit in order to front probe terminals. Do not use paper clips or other substitutes to 
probe terminals. 

Important precaution: When using the approved terminal test the components, ensure the terminal 
test adapter choice is the correct dimension for the connector terminal. Do not visually choose the 
terminal test adapter because some connector terminal cavities may appear larger than the actual 
terminal in the cavity. Using a larger terminal test adapter will damage the terminal. 

Important precaution for using proper power steering fluid 

Important precaution: When filling fluid or making a complete fluid change, always use 
DEXRONⅢ power steering fluid. Failure to use the proper fluid will cause hose and seal damage 
and fluid leaks. 

Important precaution for window edge damage 

Important precautions: the window is damaged by bumper due to exposed edge and must be lower 
1mm (0.025 in) than the metal plate surface in order to avoid the damage to the window. 

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1.2 Vehicle inspection 

1.2.1 Description and operation 

1.2.1.1 When drive vehicle, first shall be check items 

Horn operation 

Occasionally press the horn to ensure the speaker is working properly, inspect all the button 
positions. 

Brake system operation 

Be aware of any abnormal noise when braking, brake pedal travel increase and repeatedly 
occurred wheel slip when braking. In addition, if the brake warning light illuminates or flashes, it 
indicates a fault in the brake system. 

Operation of exhaust system 

Be aware of the sound change in the exhaust system and odors. These indicate that the system may 
be leaking or overheating. Inspect the system immediately and repair if necessary. 

Tire, vehicle and positioning operation 

Be aware of the steering wheel and seats vibration when traveling under normal conditions. It 
indicates that there may be a need to balance the wheels. In addition, the wheel slip on even roads 
indicates that there may be a need for tire pressure adjustment or wheel alignment. 

Steering system operation 

Be on guard against the steering change; when the steering wheel is difficultly revolved, or the 
free stroke is too long, or there is abnormal sound in steering or parking, need to check. The light 
pattern shall be observed occasionally for headlamp focusing; if the headlamp focuses wrongly, 
adjust. 

1.2.1.2 Items to be checked during each oil filling. 

Any system fluid leak (except the windshield washer) indicates that the system may be faulty. 
Inspect the system immediately and repair it if necessary. 

Inspect engine oil level 

Inspect the engine oil level and add the engine oil if necessary. It would be best to inspect when 
the engine oil is hot. 

1.  When the engine is shut down, engine oil will flow back to the bottom of the oil pan after a 

few minutes. 

2.  Pull out the dipstick. 

3.  Wipe clean the dipstick and then insert it back. 

4.  Pull out the dipstick and inspect the oil level. 

5.  If necessary, add engine oil, so that the oil level maintained between MIN (minimum) line 

and the MAX (maximum) line. Do not fill an excessive amount of engine oil; otherwise it 
may cause damage to the engine. 

6.  After reading the engine oil level, reinstall the dipstick to the engine. If inspecting the engine 

oil level when the engine is cold; do not start the cold engine. The cold engine oil will not 
quickly return to the oil pan, thus the correct oil level reading will not be obtained. 

Check engine coolant level and conditions 

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Check the level of expansion tank and add engine coolant if necessary. Check the engine coolant, 
replace the dirty engine coolant. 

Check the front windshield washer fluid level. 

Check the washer fluid level and add fluid if necessary. 

1.2.1.3 Check items one time every months at least 

Tire, wheel and tire Pressure Inspection 

Inspect for abnormal tire wear or damage. Inspect the wheels for damage. Inspect the tire pressure 
when cold, also inspect the spare tire. Maintain tire pressure as recommended on the label. 

Vehicle lamp operation 

Inspect the operation of license lamps, headlamps (including the high/low beam lamps), parking 
lamps, fog lamps, tail lamps, brake lamps, steering lamps, reversing lamps and hazard warning 
flasher. 

Oil and fluid leaks 

When the vehicle is parked, regularly inspect whether there is water, engine oil, fuel or other 
liquids on the ground underneath the vehicle. Water dripping from A/C system after use is normal. 
If oil leaks or smoke is found, identify the reason and repair if necessary. 

1.2.1.4 Check items two times every year at least 

Power steering system fluid level 

Inspect power steering fluid surface to maintain the correct power steering fluid level. 

Brake master cylinder fluid level 

Inspect the brake fluid level and maintain the correct fluid level. If the fluid level is too low, it 
indicates that the disc brake has been worn and needs repairing. Inspect the vent lid to ensure that 
no dirt and air path blockage. 

Clutch pedal free travel 

Inspect the free clutch pedal stroke; and adjust if necessary. Measure the distance from the center 
of the clutch pedal to the floor when not stepping on the clutch pedal. Then, step on the clutch 
pedal in the end and measure the distance from the center of the clutch pedal to the floor, wherein 
the difference between the center of the clutch pedal and the floor must be more than 127mm 
(5.07 in). 

Doors and windows seals lubrication 

With a clean cloth to apply a layer of silicon lubrication grease coated film. 

1.2.1.5 Check items at least once a year 

The condition and operation of seat belts 

Inspect seat belt system, including the woven belt, buckle, drainbutton, retractor, guide ring and 
fixtures. 

Spare tire and jack storage 

Be on guard against quack at the rear of the vehicle; spare tire, all lifting equipment and tools must 
be always fixed; and the jack ratchet or helical mechanism is lubricated by engine oil after each 
use. 

Key lock maintenance 

Lubrication key cylinder 

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