Lifan 630 User manual

Contents
LIFAN 630
2. Introduction········································································································
3. Symbol················································································································3
1
4. Circuit Diagnosis·······························································································
Circuit Diagnosis Procedure················································································4
4
Circuit Diagnosis Device·····················································································5
Repair Tools········································································································6
Terminal Repair···································································································7
Poor Ground Connection Repair·········································································8
5. Wiring Diagram··································································································
Charging/Clock/Power/Starting System·······························································
9
9
Ignition System Fuel System(UE)·······································································10
Ignition System Fuel System(Delphi)··································································11
Cooling System Air Condition System(UE)··························································
14
Electronic Control System(Delphi)·······································································
13
Cooling System Air Condition System(Delphi)····················································
15
16
TCU System········································································································
Headlamps and Rear Fog Lamp and Daytime Running Lamp····························
17
Air Condition Rear Defroster···············································································
18
19
Cigarette Lighter Horn·························································································
21
Dome Lamp Sunroof···························································································
22
Door Lamps········································································································23
Width Lamp Interior Lighting···············································································24
25
Instrument Cluster(I)···························································································
Instrument Cluster(Ⅱ)·························································································
26
CD System··········································································································
27
Power Window····································································································
34
6. Fuse and Relay··································································································
Engine Compartment Fuse and Relay Box·························································
Brake Lamp and Reverse Lamp and ABS System·············································32
34
7. Ground Distribution··························································································
G01-G03-G04-G011-G12-G13············································································
G21-G23·············································································································40
41
G22-G25-G26-G27-G31·····················································································42
42
39
39
8. Harness Connector Location View·································································
Engine Harness Connector Location View(UE)··················································
Engine Harness Connector Location View(Delphi)·············································
Engine Compartment Harness Connector Location View···································
45
43
Body Harness Connector Location View····························································47
44
IP Harness Connector Location View································································
58
10. Connector View································································································
Engine Harness Connector View·····································································
E1a·····················································································································59
E1b·····················································································································
51
51
52
53
9. Ground Point Location View···········································································
Ground Point Location View-engine(UE)···························································
Ground Point Location View-engine(Delphi)······················································
Ground Point Location View-engine compartment·············································
1. Contact
58
58
28
Power Rearview Mirror·······················································································29
Wiper and Washer System·················································································
Door and Back Door Harness Connector Location View···································48
Electronic Control System(UE)············································································
12
20
Left and Right Turn Lamp Hazard Wiring Lamp··················································
Roof Harness Connector Location View·····························································49
54
55
Ground Point Location View-IP···········································································
Ground Point Location View-body······································································
30
Central Lock and Theft-Deterrent System and Reverse Radar System·············31
Supplemental Restraint System··········································································
Driver Seat Heating System and EPS System····················································
33
35
IP Fuse and Relay Box·······················································································36
IP Fuse and Relay Box·······················································································37
Engine Compartment Fuse and Relay Box Power Distribution··························
IP Fuse and Relay Box Power Distribution··························································
38
Airbag Harness Connector Location View··························································50
56
57
Ground Point Location View-SRS·······································································
Ground Point Location View-Roof······································································

Contents
LIFAN 630
E10-E11-E12-E13······························································································63
E14-E16-E17······································································································64
E19-E20-E21······································································································65
E22-E23-E24-E25·······························································································
66
E26-E27-E28-E29·······························································································
67
EU2-EI1··············································································································68
69
EI2·······················································································································
70
Engine Compartment Harness Connector View·················································71
U08-U09-U10-U11······························································································73
U04-U05-U06-U07······························································································72
U12-U13-U14-U15······························································································74
75
U17-U18-U19-U20-U21······················································································
UI1-UI2-UI3·········································································································
76
U22-U23-U24(CVT)····························································································77
78
U25-U26(CVT)····································································································
80
UE1-UE2············································································································81
Instrument Harness Connector View··································································81
I01-I02·················································································································
82
83
I03-I04-I05··········································································································
I06-I07-I08-I09····································································································84
I10-I11-I12-I13····································································································85
I14-I15················································································································
88
I26-I27················································································································
I28·······················································································································90
89
I31-I32-I33-I34····································································································
I35-I37-I38-I39····································································································93
94
I40-I41-I42··········································································································
97
98
92
91
I51-IE1···············································································································
IE2-IU1···············································································································
IU2-IU3-IU4-IU5·································································································
101
99
IB3-IR1-IR2-IS···································································································102
100
IB1-IB2··············································································································
112
BI1-BI2··············································································································
BI3-BU-BV··········································································································
113
BH5····················································································································
114
Door Harness Connector View··········································································114
D01-D02-D03-D04·····························································································
105
106
106
107
IH3-IH4···············································································································
Body Harness Connector View·········································································
B01-B02-B03-B04······························································································
110
111
86
I16-I17-I18-I19····································································································87
I20-I21-I22··········································································································
IA1-IA2···············································································································
103
115
D05-D06-D07·····································································································
U01-U02-U03······································································································
71
79
UI4-UI5-UB··········································································································
I43-I44·················································································································
95
96
I45-I46················································································································
104
108
109
B05-B06-B07-B08-B09······················································································
B10-B11-B12-B13······························································································
116
D11-D12-D13-D14·····························································································
117
D15-D16-D17·····································································································
60
E1b·····················································································································61
E02-E03-E04-E05······························································································62
E06-E07-E08-E09······························································································
E30-E31-EU1······································································································
I23-I24-I25··········································································································
I29-I30·················································································································
I47-I48-I49-T50···································································································
IH1-IH2···············································································································
B14-B15-B16-B17······························································································
B18-B19-B20-B21······························································································
118
D21-D22-D23-D24······························································································
119
D31-D32-D33-D34·····························································································
120
DH1-DH2············································································································
121
DH3-DH4············································································································
122
DH5····················································································································

Contents
LIFAN 630
SRS Harness Connector View············································································
125
S01-S02-S03-SI··································································································
125
S04-S05-S06·····································································································126
Rear bump Harness Connector View·································································127
V01-V02-V03-V04······························································································127
Air Conditioning Harness Connector View··························································
128
129
A01-A02-A03-A04·······························································································
129
A05-A06-A07·······································································································
130
A08-AI1················································································································
131
123
Sunroof Harness Connector View······································································123
R01-R02-R03······································································································
124
RI1-RI2···············································································································
VB·······················································································································
11. Abbreviations·····································································································
132
Abbreviations 1····································································································
Abbreviations 2····································································································
133
132

4
Circuit Diagnosis
LIFAN 630
2. Test Light with Self-supply and Ohmmeter
Use test light with own 12V power supply or
ohmmeter to test the circuit continuity. Test
light comprises a bulb, battery and a pair of
wires. The bulb will be lit when the two wires
contacted. Before test, disconnect the battery
negative and pull out the fuse of the circuit to
be tested. To test the circuit continuity,
contact two wires to the two measurement
points. If the bulb is lit, it means the circuit is
continuous.
Warning
：
DO NOT use test light with self-
supply to test the control module. To do
so, it could damage the circuit inside the
control module. Please use a ohmmeter
with 10M Ωor higher internal impedance.
Ohmmeter has the same usage method as
voltmeter, but ohmmeter can show the
impedance value. The lower impedance, the
better continuity.
3. Jumper with Fuse
Use jumper to test a broken point for open
loop circuit (circuit broken). The jumper
should be in tandem with the circuit to be
tested.
Warning
：
To protect the circuit, DO NOT
use the fuse with higher rated capacity
than the circuit to be tested. DO NOT use
the jumper as the input or output signal
when a control module like ECM, TCM is in
the circuit. To do so, it could damage the
circuit inside the control module.
Fault Test
1. Voltage Test
Voltage test process is to test the voltage at a
certain point. When testing the connector
terminals, insert the positive probe into the
wire instead of breaking the harness.
1 When testing the voltage with test light or
voltmeter, connect the negative wire of
the test light or the negative probe of the
voltmeter to the ground.
2 Connect the other wire of the test light or
the positive probe of the voltmeter to the
place to be tested.
a1105002
5A
a1105003
I/P Fuse and Relay Box
Switch
Solenoid
Test Light
Voltmeter
5A
+B
0.5RD0.5G
2 E00
1E00
1C00
a1105022
Circuit Diagnostic Procedure
Refer to the following procedure for the circuit
diagnosis:
1. Confirm the Fault
To do the proper repair, confirm the fault
descibed by the customer firstly. Inspect the
relevant component carefully and make
record. DO NOT disassemble the component
before confirmation of the fault scope and
causes.
2. Read the Wiring Diagram and Analyze the
Causes.
Make a complete analysis on the faulty
components from power supply to ground
according to the sub-system wiring diagram
and determine the repair solution. If can not
determine the repair solution, please read the
system description in the “Description and
Operation” in the workshop manual to clear
the working principle. And inspect other
circuits that has common part with the faulty
circuit, for example, the fuse, ground, switch,
etc. Inspect the circuit not covered in step 1. If
other components on the common circuit
work properly, it means the fault exists in its
own circuit. Otherwise, the fuse or ground
might has faults.
3. Inspect the Circuits and Components.
Always use the wiring diagram together with
workshop manual and refer to the diagnostic
procedure for the relevant circuits or
components in the workshop manual. For the
circuit with a control module, fully use
diagnostic tools to do the test. Effective
diagnosis should be a logical and reasonable
operation. Fully use the diagnoistic
procedures in the workshop manual and start
the inspection from the most likely causes
and the compents be easiest to inspect.
4. Repair
Repair the faulty circuit. Refer to the wiring
diagram and workshop manual for fault
treatment. For example, the treatment on bad
connection to ground and the harness
connector.
5. Confirm the Fault Removed.
After repair, confirm the fault removed and all
functions work properly. For the fuse blown
fault, check all the relevant circuits.
Circuit Diagnostic Device
1. Voltmeter and Test Light
Use test light or voltmeter to check the circuit
status.
Test light comprises a pair of wires and a 12V
bulb. When inspecting, connect one wire to
the ground and the other one to the
measurement point. If the bulb is lit, it means
the measurement point has power supply.
Warning
：
DO NOT use test light to test the
control module voltage. To do so, it could
damage the circuit inside the control
module. Please use a voltmeter with 10M Ω
or higher internal impedance (e.g. to test
the ECM voltage.).
Voltmeter has the same connection method
as the test light, but voltmeter can display the
voltage value of the circuit. Use a voltmeter
with high impedance to test the voltage. If the
circuit has poor connection, the voltmeter
may show the normal value, but the voltage
can not drive the load successfully.
a1105001

5
Circuit Diagnosis
LIFAN 630
3 It means circuit fualt if light is not lit. If
using voltmeter and voltage display is
lower than the rated value with more than
1V, it means the circuit fault.
2. Power Test
1 Disconnect the battery negative.
2 Connect one of the wire of the test light
with self-supply or the probe of the
ohmmeter to the component to be tested.
If using ohmmeter, please contact the two
probes each other and use reset button
to adjust the ohometer to zero.
3 Connect the other wire of the test light or
probe of the ohmmeter to the other side
of the load to be tested.
4 If the bulb is lit, it means the circuit is
continuous. If using ohmmeter, the
impedance value should be very small or
close to 0Ω..
3. Short Circuit Test
1 Disconnect battery negative.
2 Connect one of the wire of the test light
with self-supply or the probe of the
ohmmeter to the outlet terminal of the
fuse.
3 Connect the other wire of the test light or
probe of the ohmmeter to the ground.
4 Disconnect all the loads to the fuse.
Note
：
If not disconnect all the loads to the
fuse, when testing the low impedance
circuit like lights, the ohmmeter will
always display the low impedance value.
This will cause wrong judgement.
5 Do the careful test from the place closest
to the fuse.
6 If the bulb is lit or ohmmeter has value
display less than 5 Ω., it means the short
circuit to the ground.
3
Switch
a1105005
5A
+B
0.5RD0.5G
2 E00
1E00
1C00
I/P Fuse and Relay Box
Switch
Solenoid
Test Light
Voltmeter
a1105004
4. Voltage Drop Test
This is to test the voltage drop along the wire,
connector or switch.
1 Connect the positive probe of the
voltmeter to the end of the circuit close to
the battery (connector or switch side).
2 Connect the negative probe to the other
end of the circuit (the other side of the
connector or switch ).
3 Disconnect switch or connect it.
4 The voltmeter will display the voltage
drop between the two test points.
5 If the drop is more than 0.1 V (less than
50 mV for 5 V voltage circuit), it means
the circuit fault. Check loose, oxidation or
corrosion circuit.
Repair Tools
1. 5 KΩRheostat
It can simulate ohm-type sensor sginals, like
coolant temperature sensor, air intake
temperature sensor, etc. And help to make
quick adjustment on the performance of the
component.
2. LED Test Light
I/P Fuse and Relay Box
Switch
Selonoid
Voltmeter
5A
+B
0.5RD0.5G
2 E00
1E00
1C00
a1105007
a1105008
a1105009
a1105010

6
Circuit Diagnosis
LIFAN 630
3
Bi-direction two-color LED light can change
its color when exchanging the positive and
negative. This feature can be used to test the
PWM control signals of Hall sensor.
3. Airbag Test Tool
Before installing a new airbag, plug this tool
to the airbag system, and use diagnostic tools
to test the airbag system to confirm it works
properly. After that, remove the airbag test
tool and install the new airbag. This process
can guarantee a safe airbag operation.
4. Probe
When testing a system component, insert this
tool into the connector from the back and do
not need to break the harness.
5. Terminal Repair Tool
When repairing the terminals, use this tool to
separate them from the connector.
a1105011
a1105012
a1105013
Terminal Repair
1. Remove the terminal pin.
2. Fix the clip with terminal repair tool.
3. Pull out the terminal from the rear of
connector.
a1105021
Terminal
Clip
Tool
a1105015
a1105014

7
Circuit Diagnosis
LIFAN 630
3
4. Clean and repair the terminals.
a1105016
Poor Ground Connection Repair
1. Remove the ground bolt.
2. Clean the two surfaces (both bolt side and
car contact side) of the copper ring with grit
cloth until the oxide completely cleared.
3. Clean the ground surface on the car with grit
cloth until it completely clean.
a1105017
a1105018
a1105019

8
Circuit Diagnosis
LIFAN 630
3
4. Install the harness and the bolt. Tighten to
specified torque.
Torque：M6 Bolts 8 Nm
M8 Bolts 20 Nm
a1105020

Charging System/Clock /Power /Starting System
2318171512
LIFAN 630 9
I45
I47 6
117
13
12 I44
18
FS 36
10A
IU1
12
12
UE1
EU1
10
10
FS 03
10A
3.00 W
BCM
2I17
1I17
2
5I29
Clock
2
I131
k
14 I02 I02
18
I02
3
I034
17 I02
EI1
6
6
EI2
IE2
8
8
I20
2
G21
0.50 B
3.00 B
G11
13
I20
1
2.00 B/W
I/P Fuse and Relay Box
Engine Compartment Fuse and Relay Box
IE1
SB 06
30A
I44 I44
I45
I45
Breaker
15.00 R
0.85 R
0.50 V/B 0.50 G/Y 0.50 W
Ignition Switch Coil Lamp
0.50 Y/G
Key Insert Switch
I13
0.50 B/W
I29
Battery
2.00 B
2.00
B/W
0.85 V/G
Charging Indicator
0.50 B
I12
ACC
ON
START
23156
LOCK
Ignition switch
4
SB 01
60A
0.50 G/Y 0.50 V/B
0.50 V/B
8
8EI1
2E23
3
B+
Alternater
1E23
B+
M
Starter Motor
1E21
E23
15.00 R
15.00 R
IE1
3.00
B/Y
FS 01
25A
FS 37
5A
SB 07
30A
14 I46
3.00 W/Bl
G21 G23
2.00
B/W
UI1
0.50 W
I27
4
I27
2
Capacitor
3.00 Y/B
3.00 Bl
3.00 Y/W
3.00 B/Y
3.00 B/Y
0.85 R
2.00
B/W
2.00 B/W
0.85 V
0.85 V
Refer to Ignition
System/Fuel System
Refor to
TCU System
SB 02
100A
Refer to EPS System
FS 17
10A
12 I44
3.00 Y
14
3.00 W/G
Refor to IP Fuse
and Relay Box
Power Distribution
I44
CVT

Electronic Control System(Delphi)
LIFAN 630 13
6
61
18 58
0.50 G
0.50 V/B 0.50 Gr
0.85 Bl/R
IE1
5
EI1
5
17
17
15
15
0.50 Gr
64 38
0.50 G
P
E26
36
0.50 Bl/G
E14b
2E14b 3
28
0.50 V
12
0.50 Bl
E19b
1E19b 2
0.50 W
0.50 B
0.50 W/Y
IE2
3
EI2
3
0.50 W/Y
45
0.50 G/W
0.50 G
0.50 O/G
12
E22
1
29 31
0.50 W/B
CKP
11
EI1
IE1
9
0.50 V
33
0.50 V
4
4
27
0.50 O
0.50 Br/Y
0.50 Bl
324
1
35
20
0.50 Bl
E30 3 2
7
7
0.50 B/Bl
0.50 V/Y
UE1
8EU1
8
0.50 V/Y
21
ECT
43
0.50 Y/B
0.50 B
21
24
5
69
BA
B
A
BA
C
ECU(Delphi)
E14b
1
9
13
I1124
1
2
Front Oxygrn Sensor
17
12
A
C
B
14 15
23
E29
1
1
2
U06 13
53
34
EI1
IE1
10
10
EI2
IE2
22
22
42
G12
0.50 G/R
0.50 Bl/W
0.50 Br/R
0.50 G/R
0.50 O/Bl
s
E1b
E1b
E1b
E1b
E1b E1b
E1b
E1b
E1b E1b
E1b
E1b
E1b
E1b
E1b
E1b
E1b
E1b
E1b
E1b E1b E1b
E1b
E1b E1b E1b
E1b E1b E1b E1b
E12
3
3
S
12
0.50 O/G
0.50 B
E1b
3
E274
49
49
0.50 W/Bl
0.50 R/Y
E20bE20bE20bE20b
E15b E15b
CAN H
CAN L
3E15b
KS TPS Weak Acceleration Sensor IAT/MAP IAC
Refer to Instrument
Cluster(Ⅱ)
E30 E30
UE1
EU1
U06 U06 E29
E29 E29
0.50 W
0.50 B
0.50 Br 0.50 B
0.50 B
0.50 V
0.50 O
0.50 Br/Y
0.50 Bl
0.50 G/R
0.50 Bl/W
0.50 Br/R
0.50 G/R
0.50 V
0.85 R 0.85 R 0.50 Y
0.50 V/B
0.50 V/W
E27
E27 E27
IE2
2
EI2
2
IE2
EI2
IE2
EI2
I11
I11
I11
E12 E12
0.50 B
HPS
IE2
EI2
IE2
EI2
IE2
EI2
0.50 Bl/G
0.50 V 0.50 Bl
0.50 W/Y
Rear Oxygrn Sensor
Vehicle Speed Sensor
MT
19
19 IE2
EI2
Refer to
EPS System
EPS
UE1
10
EU1
10
K11
4
4
1
1
FS 03
10A
1
3
2
5
Engine Compartment Fuse and Relay Box
0.50 R
2.00 Bl/R 0.50 R/W
UE1
EU1
UE1
EU1
0.85 R
2.00 Bl/R
0.85 Y
FS 04
25A
B+ B+
8
8
UE2
EU2
Refer to Charging
System/Clock/
Power/Starting
/System
Refer to Instrument Cluster
54
62 E1b
0.50 O/Y
1
0.50 W/Bl
0.50 R/Y
Engine
Speed
Output
SVS
Fault
Indicator
OBD
Fault
Indicator
Refer to Diagnose Interface System
G12
K-line

Cooling System/Air Condition System(UE)
LIFAN 630 14
2C
E2C
6
6
2C
E2C
3
3
5
5
9
9
ECU(UE)
70 50 68
22 60
1
U15
2
2
U14
1
G12
EU1
UE1
3
3
EU2
UE2
7
7
P
1U04
3
P
U04
U04
2
G12
U04
4
IU2
UI2
6
6
AI2
IA2
8
8
A07
12
1E24
LH
E1a
1
25
3
K06
25
13
4
K05
1
25
3
K04
Engine Compartment Fuse and Relay Box
UE1
EU1
UE1
EU1
UE1
EU1
UE1
EU1
U15 U14
A/C Compressor
HAVC
Fan
A/C Pressure Switch
Fan
E1a
E1a
E1a
E1a
0.85 Y/W
0.50 B/O 0.85 Bl/Y 0.85 O/Bl
0.50 W
2.00 B/Y
2.00 B/R
2.00 B
2.00 B/W
35A
FS 10
B+
FS 09
35A
B+
1
25
3
K03
10A
FS 08
B+
0.50 R/G
0.50 R/G 0.50 R/G 0.50 R/G
FS 07
5A
B+

Cooling System/Air Condition System(Delphi)
LIFAN 630 15
Engine Compartment Fuse and Relay Box
5
5
9
9
ECU(Delphi)
46 67 50
1
U15
2
2
U14
1
G12
1E24
LH
1
25
3
K06
25
13
4
K05
1
25
3
K04
UE1
EU1
UE1
EU1
U15 U14
A/C Compressor
Fan
Fan
E1b
E1b
E1b
0.85 Y/W
0.50 W 0.85 Bl/Y 0.85 R/Bl
0.50 W
2.00 B/Y
2.00 B/R
2.00 B
2.00 B/W
35A
FS 10
B+
B+
FS 09
35A
B+
1
25
3
K03
35A
FS 10
B+
39
EU1
UE1
2
2
1
P
U04
U04
4
IU2
UI2
6
6
AI1
IA1
8
8
A07
12
HAVC
A/C Pressure Switch
E1b
0.50 R/G
0.50 R/G
2C
E2C
6
6
2C
E2C
3
3
UE1
EU1
UE1
EU1
FS 07
5A