Manual de servicio series a5＆a1

Technical training of the newly established shop
11/2013
BAIC international after-sale service centre
1
<BAIC international>,<training team>

Course schedule
Day 1
Day 2
Day 3
Day 4
Day 5
Day 6
Class I
BAIC brand culture
BAIC Vehicle
Maintenance tool
BAIC manual transmission
BAIC auto transmission
BAIC vehicle chassis
MZ40 model and body introduction
Theoretical examination
Tourism and shopping
Class II
Maintenance tool
Maintenance manual
BAIC vehicle electric
BAIC vehicle chassis
MA40 engine and transmission introduction
Graduation ceremony
Class III
BAIC engine
BAIC vehicle electric
Special maintenance tools
Quality warranty and claim procedure
MZ40 air conditioning and chassis introduction
BAIC group visit
Class IV
Workshop operation
Workshop operation
Workshop operation
Workshop operation
BAIC group visit
2

Course objective
After finishing the course, the trainees will be able to:
Capable of narrating development history of BAIC brand
Capable of using BAIC maintenance tool in a standard manner
Capable of narrating characteristics of BAIC vehicle power train and conducting maintenance on it
Capable of narrating characteristics of BAIC vehicle chassis and conducting maintenance on it
Capable of narrating characteristics of BAIC vehicle electric and conducting maintenance on it
3

Chapter I: BAIC brand culture
Chapter II: BAIC maintenance tool
Chapter III: BAIC engine
Chapter IV: BAIC transmission
Chapter V: BAIC electric system
Chapter VI: BAIC chassis system
4

Chapter objective
After finishing this chapter, the trainees will be able to:
Capable of narrating BAIC brand history
Capable of narrating brand development status quo
Capable of narrating BAIC corporate culture
Capable of narrating BAIC existing model characteristics
5

Development history of BAIC brand—brand birth
6

Development history of BAIC brand—brand exploration
7

Development history of BAIC brand—brand exploration
8

Development history of BAIC brand—chronological events
9
BAIC motor
Beijing Benz
Beijing Hyundai
Foton Automotive
Beijing Jeep
Jinggangshan brand sedan

BAIC brand development status quo—corporate businesses
Independent brand passenger vehicle business
Independent brand off-road vehicle business
Joint venture brand passenger vehicle business
New energy vehicle business
Product development business
Power train business
10

BAIC corporate culture—passenger vehicle
11
Grand
International horizon
Group-based integration
Medium and high end independent brand
Enterprising
Technological development innovation
Management mode innovation
Quality
Excellent product quality
Exquisite manufacture workmanship
Integration
International team
Integrate advanced international technology
Inclusive corporate culture

BAIC model introduction—Class A1 sedan
Vehicle exterior
12

Style
1.3L
1.5L
Comfort version/5MT
Comfort version/4AT
Fashion version/5MT
Fashion version/4AT
Adjustable angle of steering wheel




Electric heating defrosting for rear windshield




Electric exterior rearview mirror +folding +electric heating
Without folding and electric heating
Without folding and electric heating


Deepfreeze




Drive lamp not close alarm




Auto wiper of front windshield
—
—


Auto lighting of headlamp
—
—


Speed induction door lock




Adjustable height of headlamp beam




Intelligent rear wiper




Parking radar
—
—


•Fashion version/4AT optional package: cruise control, side airbag, side air curtain, leather seat, leather steering wheel, reverse image, pre-tensioning force limited front safety belt, engine trim hood.
Vehicle configuration parameter
13

Vehicle interior
14

Rear seat
15

Interior diagram of glove box
Glasses box
Glasses box and deepfreeze
16

Rear tailgate emergency opening
•Remark: when the electric tail door lock fails, dissemble the small trim cover and pull the wrench to open the tail gate
Emergency wrench
Emergency trim cover
17

Vehicle exterior
18

Image promotion
Inheritance of Saab genes
Power control Safety
The model ensures comfortability and scientific features
19

Configuration parameters
Configuration
2.0T5AT Standard version
2.0T5AT Comfortable version
2.0T5AT Luxury version
Drive method
Front-engine, front wheel drive
Type of front/rear brake
Disc type
Disc type
Disc type
Disc type
Disc type
The 9th generation of Bosch ESP
●
●
●
●
●
Tire pressure monitoring system
●
●
●
●
●
Parking braking alarm
●
●
●
●
●
Side view assist (SVA)
●
●
●
●
●
Reversing and front parking radar
●
●
●
●
●
Side air curtain
-
●
●
●
●
Alarm for nonfastened safety belt at driver's side
●
●
●
●
●
Alarm for nonfastened safety belt at passenger's side
●
●
●
●
●
Speed limit alarm
●
●
●
●
●
Smart key and one-key start
●
●
●
●
●
Automatic air conditioning at both areas
●
●
●
●
●
AQS air quality control
●
●
●
●
●
20

Configuration
2.0T5AT Standard version
GPS navigation system
-
-
●
-
●
Prompt for fatigue driving
●
●
●
●
●
Anti-pinch power sunroof
-
●
●
●
●
Heating of outside rearview mirror+folding+memory+Automatic adjustment of R gear
-
●
●
●
●
Gear shift on steering wheel
●
●
●
●
●
Single touch anti-pinch power window
●
●
●
●
●
Powered rear sunblind on the rear wind shield
-
-
●
-
●
220V power source
-
-
●
-
●
Adjustment method of driver's seat
6-way power-driven
8-way power-driven
8-way power-driven
8-way power-driven
8-way power-driven
Adjustment method of front passenger's seat
4 positions, manual
6-way power-driven
6-way power-driven
6-way power-driven
6-way power-driven
Front seat ventilation
-
-
●Front backrest
-
●Front backrest
Auto lighting of headlamp
-
●
●
●
●
Headlamp height adjustment
●Electrical control
●Automatic adjustment
●Automatic adjustment
Headlamp cleaning device
-
-
●
-
●
NIGHT PANEL
●
●
●
●
●
Configuration parameters
21

 Front and rear of the car
22

Headlamp and tail lamp
23

Shift lever and ignition switch
24

Navigation
25

Side view assist
26

Night panel
27

Safety cage body in the form of caribou horn
Yellow: Common steel plate
Brown: High strength steel
Red: Super strength steel
28

Shift gear through paddle shift and sports mode
29

ESP canceling and clearing the total distance
30
Clearing switch of the total distance

Unlocking the shift lever and emergency switch of the trunk
31

Mechanical unlocking and emergency start
32

Switch of night panel and memory of rearview mirror
33

Fatigue driving and exterior rearview mirror downward scroll set
34

35

Chapter objective
Capable of using VDS diagnostic apparatus in a standard manner
Capable of using maintenance manual in a standard manner
36

VDS diagnostic apparatus—system composition
VCI Diagnostic box
Test
Vehicle
Main wire
USB connecting wire
Bluetooth adapter
37

VDS diagnostic apparutus—basic set
Connection set
38
Homepage
Fault code
Real-time data
Actuator test
ECU refresh and write
ECU configuration
ECU information
Log data
Connection set
Language set
Software upgrade
Software validation
Confirmation
Cancel
Connection state

VDS diagnostic apparutus—basic set
Language set
39
Electronic control unit of engine
Homepage
Fault code
Real-time data
Actuator test
ECU configuration
ECU information
Log data
Connection set
Language set
Software upgrade
Software validation
Confirmation
Cancel
Connection state

VDS diagnostic apparatus—system diagnosis
Vehicle identity and system selection
40
Electronic control unit of engine
Homepage
Fault code
Real-time data
Actuator test
ECU configuration
ECU information
Log data
Connection state
Read VIN code

VDS diagnostic apparatus—vehicle diagnosis
System diagnosis
41

Maintenance manual
42

Maintenance manual introduction
The maintenance manual is described by "section" and "chapter"; BAIC Class A1 maintenance manual is divided into seven sections; each section briefly introduces one special part of the vehicle:
−Overviewsection
−Enginesection
−Manual transmissionsection
−Auto transmissionsection
−Chassissection
−Electricsection
−Body and paintingsection
43

Maintenance manual—structure
44
Engine section
Bookmark
Contents
Engine assembly
System summary
DTC fault code diagnosis
Inspection and diagnosis
Technical parameter
Engine assembly
Multiple wedge belt
Crankshaft belt pulley disassembly
Water pump belt pulley disassembly
List of auxiliary set bracket
Cylinder head, valve mechanism and timing device
Crankshaft and connecting rod mechanism
Intake and emission system
Lubricating system
Cooling system
Electronic control and emission system of engine
Fuel supply system
Fuel preparation and injection system
Charging, start, ignition and navigation control system
Describe the system operation principle and relations between components
1-9 operation method procedure and relevant data

Maintenance manual—vehicle component disassembly procedure enquiry:
Disassemble timing chain (make descriptions by taking it as an example)
45
Item number 11 corresponding to the timing device
Timing device, timing chain disassembly
Note: 1.2.3 represents the procedure sequence; get to know the sequence logic to avoid the corresponding error.
Timing chain disassembly
Engine assembly
Cylinder head, valve mechanism and timing device
Contents
Overview
Inspection and diagnosis
Technical parameter
Cylinder head
Valve
Timing device
Timing device list
Timing sprocket shell disassembly
Timing chain and sprocket
Timing chain disassembly
Camshaft timing chain
Timing chain tensioner disassembly
Bolt specification
Check timing
Adjustment timing

Maintenance manual—other enquiries:
Diagnosis index enquiry
Vehicle parameter enquiry
Bolt torque enquiry
Fuel fluid filling volume enquiry
46
Level I catalog
Second- level catalog
Contents
Suspension system
System summary
Technical parameter
Front suspension
Rear suspension
Wheel, tire
Steering system

Maintenance manual-circuit diagram identification
Wire color
47
Black
Green
Blue
Orange
Red
White
Brown
Grey
Light green
Pink
Purple
Yellow
Ex. stripe
L-Y indications L is main color Y is assisting color

The conductor has not only color code but also conductor cross section data, e.g. 0.5 in the diagram below represents the cross section area of the conductor
48
Represent the conductor cross section area 0.5mm

Power supply line and earthing wire
49
Power supply line and earthing wire

Fuse
50

Relay
51
Indicates FB fuse box No.22 30A fuse
J110 represents starting relay

Continued with the neighboring pages
52
Continued with the previous page
5 continued with the next page

Conductor address code enquiry
53
The conductor and address code represents 138 conductor connection
The address code for T20/18 is 138; the 137 in box represents connection with conductor with address code 137

Grounding point
• Connection representation mode (spot connection, bolt connection, etc) “●”：welding point connection “○”：bolt connection
54
Grounding point

55

Chapter objective
Narrate the mechanical characteristics of Class A5 engine
Narrate electronic control characteristics of BAIC engine
56

Class A1 engine
57
Alloy fuel conduit
Resin intake manifold
Throttle body
Overhead ignition coil
Resin rocker chamber cover
Body front
A/C compressor
Water pump
Generator
Oil filter element
Stainless steel exhaust pipe
Aluminum cylinder block
Aluminum sprocket chamber cover

4A9
1.3L(4A90)
1.5L(4A91)
Engine displacement (L)
1.299
1.499
Cylinder diameter/stroke (mm)
75.0/75.4
75.0/84.8
Compression ratio
10.5
10.5
Cylinder block material
Aluminum die casting
Combustion chamber
Single slope roof type
Intake valve open
BTDC 31°—ATDC19°
Intake valve close
ABDC 13°—ABDC63°
ABDC 21°—ABDC 71°
Exhaust valve open
BBDC 35
BBDC 39
Exhaust valve close
ATDC 5
Valve mechanism
Direct drive DOHC16 valve MIVEC
Timing drive
Chain type
Crankshaft material
4 balance blocks (cast iron)
8 balance blocks (cast iron)
Engine mounting mode
Rear exhaust
Maximum power [KW/rpm]
73/6000
83/6000
Maximum torque [Nm/rpm]
124/4000
147/4000
Corresponding emission regulation
National IV
National IV
Whole length of engine (mm)
440
440
Dry weight of engine (kg)
79
82
A1 engine—configuration parameter
58

Class A1 engine—mechanical characteristics of engine
Exhaust manifold
59
(1) Stainless steel tube
(2) Long airway at equal length
(1) Stainless steel plate flange

Connecting rod
60

Camshaft and tappet
61

MIVEC
62
Cam sprocket
Camshaft angle sensor
VVT sprocket component
From the engine oil pump
Crankshaft angle sensor

Timing chain and tensioner
63

Class A5 engine-overview
64

Engine
Engine Model
B185R
B205R
B235R
Emission
National IV
National IV
National IV/
Displacement (L)
1.799
1.992
2.29
Power (KW)
130
150
184
Rotation speed at max. power (rpm)
5500
5500
5300
Torque (N·m)
240
290
350
Rotation speed at max. torque (rpm)
1800-4500
1800-4500
1900-4500
Compression ratio
9.2：1
9.0：1
9.3：1
Cylinder bore*stroke (mm)
*
90*78
90*90
Class A5 engine-configuration parameter
65

Class A5 engine-engine mechanical characteristics
Balance shaft and engine number
66

Cylinder head
67

Crankshaft and tappet
68

Intake and exhaust manifold
69

Balance shaft
70

The timing of balance shaft
71

Timing cover
72

Turbocharged
73

Lubricating system
74

Technical training of the
newly established shop
BAIC engine—engine electric control system
75 <BAIC international>,<training team>

MIVEC structure
76
Phase angle 25°
Lead angle chamber
Lag angle chamber
At maximum lag angle
At maximum lead angle
Middle position
Fixation pin
Hydraulic circuit for lag angle
System for lag angle
Hydraulic circuit for lead angle
Hydraulic pump
System for lead angle

MIVEC control
77

 Turbo charger control
Waste gate of
supercharger
Pressure sensor at
intake manifold
Turbocharger air pressure
relief solenoid valve
Solenoid valve for
waste gate control
Atmospheric pressure
and temperature sensor
Pressure relief by-pass
valve for supercharged
air
Pressure and temperature
sensor for supercharged air

 Cylinder pressure detection with secondary ion
The voltage change in the primary coil
when engine ignition starts
Magnetizing
Electric discharge

Electronic control element of engine
−Pressure sensor at intake manifold
−Boost pressure and temperature sensor
−Crankshaft position sensor
−Coolant temperature signal
−Throttle motor and position sensor
−Accelerator pedal assembly
−Knock sensor
−Oxygen sensor
−EMS
−Fuel rail and injectors
−Ignition coil
80

Engine electronic control element—intake pressure sensor
81

Class A5 vehicle
Class A1 vehicle
Engine electronic control element—crankshaft position sensor
82

Engine electronic control element—throttle valve and accelerator pedal sensor
83

Engine electronic control element—shock adsorption sensor
84

Engine electronic control element—oxygen sensor
85

Engine electronic control element—ECU module
86

Engine electronic control element—fuel nozzle and track
87

Engine electronic control element—ignition coil
88

89

Chapter objective
Narrate characteristics of BAIC manual transmission
Narrate characteristics of BAIC auto transmission
90

Manual transmission—overview
91

Manual transmission—clutch
92

Manual transmission—shift mechanism
93

Manual transmission—gear mechanism
94

Manual transmission—shift shaft
Five reverse selector shaft
One, two selector shaft
Three, four selector shaft
95

Manual transmission—synchronizer
Gear 1, 2 synchronizer
Gear 5 synchronizer
Gear 3, 4 synchronizer
Input shaft
Output shaft
Reverse shaft
96

55-51SN auto transmission—overview
97

55-51SN auto transmission—configuration parameters
Transmission model
55-51SN
Vehicle
BAIC Senova Class A5
Engine
B235R
Stall speed (rpm)
2500 +150rpm
Gear speed ratio
Speed 1
4.576
Speed 2
2.98
Speed 3
1.948
Speed 4
1.318
Speed 5
1
Reverse gear
5.024
Auxiliary shaft
1.018
Differential
2.44
Clutch/brake/one- way clutch
Clutch
C1
Clutch of forward gears
Steel disc:4 fiction discs:4 flanges:1
C2
Clutch of direct gears
Steel disc:4 fiction discs:4 flanges:1 buffer discs:1
C3
Clutch of U/D gear
Brake
B1
Brake for gliding at gear 2
B2
2nd brake
B3
Brake of 1 gear/reverse gear
B4
Brake of low speed gears U/D
Brake band:1
B5
B5 Brake
Steel disc:6 fiction discs:6 flanges:1 buffer discs:1
One-way clutch
F1
One-way clutch No.1
Wedge block: 18
F2
One-way clutch No.2
Roller: 15
Solenoid valve
Gearshift solenoid valve
5 solenoid valves S1, S2, S3, S4, S5
Linear solenoid valve
3 linear solenoid valves SLT, SLU, SLS
ATF
AW
JWS-3309(JAPAN ESSO T-IV)
BAIC
JWS-3309G(GERMANY ESSO T-IV)
Added volume
7.8L
98

55-51SN auto transmission—mechanical structure
99

55-51SN auto transmission—electronic control composition
100
Speed sensor
Input shaft speed sensor
Gear switch
Oil temperature sensor
Manual gear switch
Switch for gear shift mode
Ignition switch
Shift solenoid valve
Locking solenoid valve
Oil pressure solenoid valve of line
Pressure solenoid valve of clutch
CAN cable

55-51SN auto transmission—electronic control element
Input shaft speed sensor
101

Speed sensor
102

Gear switch
103

Gearshift solenoid valve
104

Line pressure solenoid valve
105
Oil pressure
Higher current

Locking solenoid valve
106
Oil pressure
Current

Solenoid valve for controlling gearshift pressure
107
Oil pressure
Higher current

Oil temperature sensor
108

81-40LE auto transmission—overview
109

Actuator
Function
Clutch of forward gears (C1)
Transmit power to the small sun wheel
Clutch of direct gears (C2)
Transmit power to the planetary frame
Reverse clutch (C3)
Transmit power to the big sun wheel
Gear 2-4 brake (B1)
Fastening big sun wheel
Gear 4 brake (B2)
Fastening 2 gear single direction clutch
Low/reverse brake (B3)
Fastening planetary frame
Low gear single direction clutch (F2)
Fastening planetary frame (clockwise rotation of planetary frame allowed)
2 gear single direction clutch (F1)
Fastening big sun wheel (clockwise rotation of big sun wheel allowed)
81-40LE auto transmission—mechanical structure
110
Input shaft
Main drive gear
Main drive gear
Differential

Gear position
Fuel
temperature
Winter mode
Motion mode
S1
S2
SL
ST
SLT
Input speed
Vehicle speed
signal
55-51SN auto transmission—electronic control system

81-40LE auto transmission—electronic control element
Output axis speed sensor
112
Differential
Output axis speed sensor

Input speed sensor
113
Input axis speed sensor
C2 clutch hub

 Oil temperature sensor

 Shift solenoid valve S1 and S2

 ST (timing) solenoid valve

 SL (Locking) solenoid valve

SLT Line pressure solenoid valve
118
Low（current）High
High-Oil pressure-Low

Auto transmission check—stall test
119

Auto transmission check—stray wire regulation
120

Auto transmission check—fuel fluid check
121

Auto transmission check—pressure test
55-51SN transmission 81-40LE transmission

Auto transmission inspection-adaptive study
123
Repeat 5 times

124

Chapter objective
Master the functions of the electrical systems and the mounting positions of the components
Conduct ordinary inspections and repairs to the components in the systems
125

Chapter V: BAIC body electric system
Body electric—vehicle power distribution
Fuse box
126

Body electric—vehicle power distribution
Grounding point
Class A5 vehicle
Class A1 vehicle
127

Body electric—lighting system
Composition
128

Body electric—lighting system component
Module
BCM
AHL
129

Height sensor
130

Class A5 Daytime running lamp
131

Class A5 high/low beam control
For Class A1 vehicle, it's the bonding signal that the light switch transmits to the BCM
132

Class A5 turn signal lamp control
For Class A1 vehicle, it's the bonding signal that the light switch transmits to the BCM
133

Class A5 Fog lamp control
134

Class A1 Fog lamp control
135
Front fog lamp
Rear fog lamp
Lighting combination switch (part)
Relay of front fog lamp
Relay of rear fog lamp
Other width lamp

Class A5 Manual control of light height
136

Class A5 Automatic control of light height
137

Body electric—Class A5 wiper system
Composition
138

Water spray and wiping rainwater
139

140
Rain sensor
Wiper switch
Front washing
Rear washing
Rear wiper
Front wiper motor
Front wiper relay
Rear water spraying relay
Front water spraying motor
Rear wiper motor
Rear wiper relay

Headlamp cleaning
141

Adjustment of headlamp cleaning
142

Body electric—Class A5 electric window
Control modes
143

- Window initialization
144

Control modes
145
To backlit adjustment switch
Left front glass lifting switch
Left front motor
Right front motor
Right rear motor
Right front switch
Left rear switch
Right rear switch

Body electric—Class A5 sun roof
Sun roof initializing
146

Body electric—Class A5 central control lock
Control modes
147

Body electric—Class A1 central control lock
- Control modes
148
To top lamp
Anti-theft coil
Central control switch
Driver door key switch
Left front door state switch
Right front door state switch
Left rear door state switch
Right rear door state switch
To the horn
To left steering signal lamp
To right steering signal lamp
To instrument
Trunk lock motor and switch
Central door locking

Body electric—Class A5 air conditioning
Functional composition
149

Body electric—air conditioning compressor control
Control modes
150

Body electric—Class A5 air conditioning
Airway control
151

Body electric—airbag
Composition
152

Body electric—Class A5 airbag
Control modes
153

Body electric—reverse assist system
Composition
154

Reverse radar system
155
Detection scope
Indicator bar of front right radar
No distance indication
Rear right radar indicator bar
Zone 4
Zone 3
Zone 2
Zone 1
Area
Distance (CM)
Signal
Intermittent buzzer at low speed
Intermittent buzzer at middle speed
Intermittent buzzer at high speed
Continuous buzzer

Control modes
156

Reversing image
157

Body electric—instrument
Control modes
158

Body electric—onboard network
Function and advantages
159

Body electric—Class A5 onboard network
 High speed CAN

 Low speed CAN

LIN network
162

Composition
163
K line
Airbag module
LIN bus
Rainfall optical sensor
CAN bus
Body control module
Engine control module
Auto gearbox module
ABS control module
Instrument cluster

Body electric—Class A5 intelligent access and start
Function and structure
164

Smart access and lock
165

Power source management
166

Control modes
167

Heating/ventilation module
Seat control module
Body electric—Class A5 electric seat
System components
168

Control modes
169

Heating and ventilation control
170

Body electric—tire pressure monitor
Function and structure
171

Set
172
Multifunction display
Tire temperature
Multifunction display
Tire pressure

Replacement of sensors
173

Control modes
174

175

Chapter objective:
Narrate BAIC suspension system characteristics
Narrate BAIC steering system characteristics
Narrate BAIC brake system characteristics
176

Chassis system—suspension overview
177

Front suspension
178

Rear suspension
179

Chassis system—rear wheel slave steering
Structural characteristics
180

Chassis system—steering system
System composition
181

Steering column
182

Belt disassembly
183

Chassis system—brake system characteristics
System components
184

Chassis system—brake system
Electronic control component
Control Unit
Wheel speed sensor
185

Chassis system—brake system
Electronic control component
YAW
SAS sensor
186

Chassis system—brake system function
EBD function
187
The front end will go down
The rear end will go up

CBC function
188

EBA function
189
Pressure increased
Actuator
Brake lamp switch
Master cylinder pressure sensor

Chassis system—brake system function
−—BOS function
Activation condition
−Engine speed is above 1200rpm
−Vehicle speed is above 10 km/h
−The opening of the Accelerator pedal is bigger than 0 and the change of this opening should not be abrupt--that is there is no driver intention to accelerate abruptly.
−Step on the accelerator pedal first and then the braking pedal
Exit conditions
−Release the accelerator pedal and step the braking pedal
−The opening of the Accelerator pedal changes very quickly, which means there is driver intention to accelerate.
−Release the braking pedal
190

TCS function
191
Slipping
Without TCS
With TCS
Under control

EDS function
192
With EDS
Without EDS

HHC function
193
Brake control

ESP function
194
When controlling oversteering
When controlling understeering

Chassis system—brake system maintenance
 Adjustment of parking brake
Class A5 vehicle Class A1 vehicle

Thank you!
196
12/2012 BAIC international after-sale service centre

Manual de servicio series a5＆a1

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