byd auto technical monthly_august

BYD AUTO Technical Monthly

AUGUST, 2012


All rights reserved by BYD AUTO 2 / 23

Introduction

The BYD AUTO Technical Monthly is dedicated to providing better technical services and supports

for BYD service centers and/ or service shops. This monthly contains „TECHNOLOGY NOTICE‟

„TROUBLESHOOTING‟ AND „SPARE PARTS‟. It can help distributors, service centers and/or

service shops settle technical problems and order spare parts rightly. All people should

understand it clearly.

If any comments or suggestions about monthly, you can contact BYD AUTO by following ways:

1. Mailbox:[email protected];

2. Tel: +86-755-89888888 ext.64555;

3. Service Engineers for your market.

BYD AUTO CO. LTD.,

2012-8-31

mailto:[email protected]



CATALOG

TECHNOLOGY NOTICE .......................................................................................... 4

BYD vehicles‟ shock absorber oil leakage, abnormal sound determination ..............4

Judging handbook of shock absorber abnormal noise-For all vehicles of BYD .......7

TROUBLESHOOTING............................................................................................ 11

Troubleshooting— False Over-heating in F3 AT ....................................................................11

SPARE PARTS ...................................................................................................... 13

Distinguish—Spare parts of F0 2012 Model Type .................................................................13



TECHNOLOGY NOTICE

BYD vehicles’ shock absorber oil leakage, abnormal sound

determination

1. Purpose and applicable range：

For uniform shock absorber oil leakage, abnormal sound fault determination and acceptance in

warranty, the technology notice is hereby formulated.

This notice is suitable for BYD auto co., LTD., and 4S shop fault parts‟ inspection in warranty.

This notice is suitable for the hydraulic shock absorber produced be BYD automobile co., LTD.

2. Shock absorber oil leakage fault determination

1) Attention

i. Shock absorber oil seepage is a kind of normal phenomenon. In order to achieve the function

of the shock absorber and use requirements, micro cracks exist on the shock absorber

connecting rod surface (below), which can store a certain amount of oil forming oil film on the

surface, thus wetting rod, wet friction is made between connecting rod and oil seal, in order to

protect oil seal and prevent abnormal sound caused by dry friction, overall improve the use of

shock absorber performance, and prolong service life, therefore, oil seepage oil is allowed,

which does not affect the use of shock absorber.

Connecting rod surface microcrack



ii. During the oil leakage criterion of shock absorber, please pay special attention to judge

whether water stain or not, because the rain, snow and ice melt or after washing the car would

affect your test results.

2) Shock absorber oil leakage appearance determination method:

i. There‟s no obvious failure occurs on shock absorber, and oil pollution exists on the surface,

but no oil droplets and no lots of sludge formatted. And the oil pollution stain leaking from oil

cylinder seal doesn‟t reach the spring tray place (not reach 50 mm if no spring tray), hence

define it as oil seepage, see illustrations below:

ii. The oil pollution stain leaking from oil cylinder seal does reach even over the spring tray place

(reach or over 50 mm if no spring tray), hence define it as oil leakage, see illustrations below:

Seal

cage

Spring

tray

Bottom mounting

bracket 50 mm

Oil seepage, not

replace 50 mm

Oil seal to spring tray

Spring tray Seal

cage

50 mm

Oil seepage, not

replace

Oil leakage, replace Oil leakage, replace



iii. The scope from the oil cylinder seal to the spring tray (50 mm from the seal downward if no

spring tray), peak-shaped oil drip trace can‟t be existed, otherwise, define it as oil leakage,

see illustrations below:

iv. All welding and static sealing parts located on the edge of oil cylinder seal are not allowed to

appear oil leakage, otherwise they must be replaced.

Note: Regard rear shock absorber of series 3 auto models as no spring tray ones to

determine.

3. shock absorber abnormal sound fault determination method

1) Check the tire pressure: Automobile suspension overall damping performance would be

reduced if the tire pressure is too high, check the tires using condition and keep the tire

pressure standard;

2) Check shock absorber connecting joints: Looseness of transverse stabilizer bar rod & ball

head assembly, the oscillating arm next ball head, bolt between the horizontal stabilizer bar

rod & ball head assembly and the former damping connection parts, bolt between the upper

part and lower part of shock absorber and etc all will lead to vehicles‟ abnormal noise during

driving, such as a looseness, the bolt with the moment requirements need to be fastened;

3) Check shock absorber spiral spring: If there‟s gap between the shock absorber spiral spring

with the upper and lower spring seat, or contact between the spiral spring bracket ring with

the first working ring car while the car is derived on the concave road with holes, may have

collision sound, then replace shock absorber spiral spring;

4) Check the connecting bracket assembly of front shock absorber: Check the connecting

bracket assembly if there‟s the "click, click" or other noise while the vehicle is steering.

50 mm Oil leakage, replace Oil leakage, replace



Replace the upper connecting bracket, if the shock absorber upper part sends out "click,

click" sound, while shaking the connecting bracket assembly top of shock absorber.

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

Abnormal noise of shock absorber-judgment of the vehicle: before judging, check all the related chassis parts and find the source.

NO. Possible causes of

abnormal sound

Checking methods solution

1

No previous collision,

damage, deformation. The

appearance of the wheels and

hubs is normal.

By sight

replace the damaged

spare parts

2

Tire pressure is too high or

too low

Check if the tire pressure is

normal

Adjust tire pressure

Abnormal sound “kaka”

caused by the friction of

wheel trim cover and the side

of tires

Press the trim board, check if

there is fit clearance and friction

between the trim board and the

side of tires

Increase the gasket

3

Fastening nuts and bolts on

the chassis loosen

Fasten the nuts and bolts to

check if their torque has

decreased. If their torque is

lower than the standard or there

is no torque, it means that nuts

and bolts loosen

Fasten nuts and bolts

Bolts on the front/rear axle

loosen, driving abnormal

sound, metal impact sound

Abnormal noise generates

when shaking the car body

transversely. No abnormal

noise when shaking the car

body perpendicularly.

Fastening torque

4

Ball head of swing arm loosen

or friction noise

Lift the car, hold the wheel and

then rock it, check if the ball

head of front swing arm has

loosened or there is friction

noise

replace the swing

arm

5

All bushings assembly and

other rubber parts damaged

or loosened

Check all the rubber parts if

they have damaged or

loosened

replace the damaged

parts



6

Ball pins of stabilizer bar and

steering link loosen or

damage

1.whether the steering wheel

vibrates when controlling it

2.remove the connecting nuts,

shake the ball pin and check the

ball head

replace relative spare

parts

Stabilizer bar bushings creak Press the engine hood heavily Replace rubber

bushings

7

Steering with sudden

abnormal noise, hub bearing

with abnormal noise

Shake the car body when it is in

stationary state

Replace hub

bearings

Continuous abnormal noise

when steering, steering gear

with noise

Steering in situ in stationary

state

Fasten the steering

connecting bolts.

Other treatment if the

bearings loosen

Steering abnormal noise

No abnormal noise with cold

start. “Tweets” generates after

10 minutes driving. Steering in

situ with abnormal noise after

stopping

8

Heat insulation sheet with

abnormal noise

Check if the heat insulation

sheet has deformed and related

with brake disc

Adjust the clearance

between heat

insulation sheet and

brake disc

Main pin of brake loosens, its

abnormal noise is similar to

that of chassis torque loosen

Clear metal clicking noise

appears in low-speed driving

and backing a car. No abnormal

noise when pressing the car in

vertical stationary state

Coat lubricating oil

and then tighten the

torque

Braking with abnormal noise Harsh noise Polish the brake disc

9 The fuel in the tank vibrates Full up the tank, and check if

there is still abnormal noise

Normal sound

Metal clicking noise generates

because of the loosening of

tank rivet

Check the rivet joint of fuel tank

Coat glue on the rivet

joint

11 Connecting bolts of shock

absorber and steering

knuckle loose

Tighten it and check

Tighten the nuts

(bolts)

12 Connecting bolts of shock

absorber and car body loose

Tighten it and check Tighten the nuts

13 fault mounting place of helical

spring

Check the spring if it is mounted

on the spring seat or side frame

Adjust the spring

14 Steering

knuckle with abnormal noise

Shake the steering knuckle

when driving with abnormal

noise (F6 only)

Replace

steering knuckle



15 Stabilizer bar, rear side frame

with abnormal noise

Check the bolts of two sides of

frame

Tighten the nuts

16

Supporting cushion, buffer

block and dust cover damage

Remove the absorber, and

check if the supporting cushion,

buffer block and dust cover has

damaged

Replace supporting

cushion, buffer block

and dust cover

17 Front (left or lower right) car

body with abnormal noise

when steering in stationary

state

Check if the connecting bolts of

steering gear loose

Adjust bolts of

steering gear

18 Improper torque of tighten

nuts of shock absorber

causes abnormal noise

Test the torque according to the

requirement with a wrench

Reassemble it,

tighten the nuts

according to the

standard torque

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

Noise

Type Phenomenon

Description

Judging Method conclusion

Abnormal

noise in

driving

Sound “chichichi…”

We can hear the sound in

normal circumstance when the

vehicle is driving on gentle slope

at a low speed.

The sound similar to that

of airflow is caused by the

air working inside the

shock absorber. It‟s

normal.

Sound

“dongdongdong…”




at a low speed.(not impact sound)

Continuous clear sound

“Dong…Dong” may be

abnormal noise of the

shock absorber.

Sound ”jijiji…”




at a low speed.

Abnormal noise still exists

after 5-8 minutes‟ driving.

Sound “sisisi…”



vehicle is driving on large slope at

a low speed.

Normal sound caused by

rapid flow of fluid inside

the shock absorber.

Check if the springs

collide obviously

Replace the helical spring Running-on and collision

of helical spring.

The Sound is similar to

that of the friction



Creak

We can hear the sound when the

vehicle is driving on large slope at

a low speed, especially in cold

day, more seriously so long as the

vehicle knocks down, such as

sudden brake.

between metal and

rubber. Check all the

rubber-metal hinged part

on the chassis, especially

the position of stabilizer

bar layering bushings.

Metal crash won‟t exist

except the shock

absorber is destructively

damaged.

Dust

cover

with

abnormal

noise

Scrape forms because

of the friction between

the plastic dust cover

and the wall of oil

reservoir

Keep the car stationary on level

ground. Press the rear of the car

and observe if the dust cover

collides with the oil reservoir

Remove the dust cover

and observe it after it

rotates at an angle if

obvious noise forms by

the friction of the dust

cover and the wall of oil

reservoir. If friction places

are the same, it means

bad tolerance of the car

body and rear torque

beam. If the friction

places are change as the

angle does, it means that

we need to replace the

dust cover.

Springs

collide

with

abnormal

noise

Helical spring collide

Check if the springs collide (little

possibility)

Replace helical springs.

More than 1.5 parallel

circles means that the

vehicle overloaded

heavily



TROUBLESHOOTING

Troubleshooting— False Over-heating in F3 AT

Malfunction Description:

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

Malfunction Analysis:

Checking the whole cooling system, no problems found. Using BYD Diagnostic (ED300/ED400) to

read the data when the malfunction appeared shows that it‟s normal, it is not real over-heating.

Then check the water temperature sensor it‟s OK too.

At last, we analyzed and found that it‟s the poor ground wire that finally leads the dashboard water

temperature gauge in disorder.

Maintenance Process:



1 Please kindly confirm that there is no additional electronics in this vehicle.

2 Please check the ground wiring between power train (Engine & Transmission) and Body. But the

simplest way to solve this malfunction is connecting a new ground wiring between Engine and

Car Body.

3 Check the dashboard ground wiring.

4 Replace the dashboard.

5 Replace the wire harness of dashboard.

Applicable Model: F3 AT



SPARE PARTS

Distinguish—Spare parts of F0 2012 Model Type

No SAP Part Name Suitable Model

1 10136857-00 TRANSMISSION

ASSY

Former Model

2 10782063-00 TRANSMISSION

ASSY

2012 Model

No neutral gear switch Add neutral gear switch

Former Model 2012 Model


1 10124735-00 BRAKE CLUTCH PEDAL ASSY Former Model

2 10739854-00 BRAKE CLUTCH PEDAL ASSY 2012 Model

No clutch switch Add clutch switch





1 10150232-00 LOCK ASSY.,BACK DOOR Former Model

2 10756202-00 LOCK ASSY.,BACK DOOR 2012 Model

No induction switch Add induction switch



1 10209168-00 START BUTTON 2012 Model

2 10763200-00 CONTROLLER ASSY., SMART KEY

SYSTEM

2012 Model

CONTROLLER ASSY., SMART KEY SYSTEM

2012 Model




1 10007906-00 CENTRAL CONTROL MODULE WITH

TELECONTROL

Former Model

2 10763201-00 BODY CONTROL MODULE ASSY 2012 Model



1 10274341-00 CENTRAL DETECTING ANTENNA ASSY. 2012 Model

2 10209162-00 INNER DETECTING ANTENNA ASSY 2012 Model

3 10763398-00 OUTER DETECTING ANTENNA ASSY 2012 Model

4 10763399-00 OUTER JIGGLE SWITCH ASSY 2012 Model

5 10834835-00 REMOTE KEY 2012 Model

6 10303138-00 CARD ELECTRONIC KEY 2012 Model

7 10295381-00 KEY HIGH-FREQUENCY RECEIVER

MODULE

2012 Model

8 10031059-00 ELECTRIC STEERING COMULN LOCK

ASSY.

2012 Model

CENTRAL DETECTING ANTENNA ASSY. INNER DETECTING ANTENNA ASSY



Location: Left front door assy. Location: Left front door assy.

OUTER DETECTING ANTENNA ASS OUTER JIGGLE SWITCH ASSY

REMOTE KEY CARD ELECTRONIC KEY

KEY HIGH-FREQUENCY RECEIVER MODULE ELECTRIC STEERING COMULN LOCK ASSY.




1 10762066-00 REAR LOGO ASSY MOUNTING SEAT, LED 2012 Model

2 10762063-00 REAR LOGO ASSY MOUNTING SEAT, LED 2012 Model

Suitable Type: G-I & GL-I Suitable Type: GLX-I


1 10238197-00 REAR LOGO Former Model

2 10776088-00 REAR LOGO ASSY, LED 2012 Model





1 10402937-00 LOWER SHIELD ASSY.,COMBINATION

SWITCH

Former Model

2 10782864-00 LOWER GUARD BOARD ASSY.,

COMBINATION SWITCH

2012 Model

Suit for Mechanical Ignition Key Suit for Start Button



1 10314599-00 DECORATING COVER,WHEEL Former Model

2 10782064-00 WHEEL HUB CAP ASSY 2012 Model





1 10143840-00 UPPER SHIELD ASSY.,INSTRUMENT

PANEL

Former Model

2 10070157-00 UPPER SHIELD ASSY.,INSTRUMENT

PANEL

2012 Model



1 10143862-00 CENTRAL CONTROL PANEL ASSY. Former Model

2 10725182-00 MIDDLE COVER BOARD ASSY,

INSTRUMENT PANEL

2012 Model

No vent New design vent





1 10048003-00 DRIVER SEAT ASSY Former Model

2 10772865-00 DRIVER SEAT ASSY 2012 Model

No bracket and key bag Add bracket and key bag



1 10048004-00 PASSENGER SEAT ASSY Former Model

2 10772866-00 PASSENGER SEAT ASSY 2012 Model

No bracket and key bag Add bracket and key bag





1 10249838-00 GLASS,BACK DOOR

(WITHOUT ELECTRICALLY HEATED WIRE

AND WIPER HOLE)

Former Model

2 10774237-00 BACK DOOR GLASS 2012 Model

No mounting hole for LED LOGO Mounting hole for LED LOGO



1 10249839-00 GLASS,BACK DOOR(WITH

ELECTRICALLY HEATED WIRE AND

WIPER HOLE)

Former Model

2 10774236-00 BACK DOOR GLASS 2012 Model

No mounting hole for LED LOGO Mounting hole for LED LOGO





1 10141832-00 FRONT DOOR ASSY.,L Former Model

2 10851763-00 FRONT DOOR ASSY.,L 2012 Model

No mounting hole for micro switch Mounting hole for micro switch



1 10782012-00 SPEEDOMETER AND INSTRUMENT

PANEL JUNCTION BOX ASSY

2012 Model/G-I

2 10782013-00 COMBINATION INSTRUMENT ASSY 2012Model/GLX-I

Add key indicator, without SRS and ABS Add key indicator, with SRS and ABS





1 10781782-00 ENGINE WIRE 2012 Model/UAES

2 10781788-00 FRONT DOOR WIRE, L 2012 Model

3 10782893-00 INSTRUMENT PANEL WIRE 2012 Model/G-I

4 10782895-00 INSTRUMENT PANEL WIRE 2012 Model/GL-I

5 10782894-00 INSTRUMENT PANEL WIRIE 2012 Model/GLX-I

6 10781783-00 FLOOR WIRE 2012 Model G-I/GL-I

7 10781779-00 FLOOR WIRE 2012 Model/GLX-I

8 10781781-00 WIRING HARNESS, ENGINE

CABIN

2012 Model/G-I


CABIN

2012 Model/GL-I


CABIN

2012 Model/GLX-I

11 10775870-00 REAR BACK DOOR WIRE, L 2012 Model/GLX-I

12 10775874-00 REAR BACK DOOR WIRE, L 2012 Model G-I/GL-I

byd auto technical monthly_august

Documents

heat insulation sheet

electrically heated wire

add key indicator

front door assy

oil cylinder seal

ball head assembly

spring tray place

connecting bracket assembly