GEELY FC 2008 Workshop Manual

Supplemental restraint system--Note
Special tools and measurers which any safety airbag repairing position should have:
Changeable subassembly which safety airbag repairing position should have:
a. Safety airbag assembly at the side of driver;
b. Safety airbag assembly at the side of passanger;
c. Helix cable assembly.
d. ECU assembly;
e. Steering wheel.
I. Safety airbag joint
No. ItemApplicable
(1) Terminal dual-locking organization
(2) Airbag anti-explosive organizationJoint 3, 4, 7, 8
(3) Checking organization of electric circuit connection
(4) Inadequacy connection protection organization Joint 4
(5) Joint dual-locking organization Joint 2
(6) Joint dual-locking organizationJoint 6, 7, 10
Safety airbag at the
side of passengerSafety airbag at
the side of driver
Helix
cable
Airbag controller
1. All safety airbag joints should be yellow to be easy to distinguish the joints on other automobile parts,
this could guarantee the safety performance and reliability of safety airbag joint, each kind of joint has
special function and design.
 240 
Number
a
b
c
d
eFunction
Disassemble airbag subassembly on steering wheel
Assemble and disassemble big nut on steering column
Assemble and disassemble ECU and safety airbag assembly
at the side of passenger on automobile body.
Used for electric measurement on wiring harness
Used for resistance measurement of electric ignition device
of airbag subassembly. Name and type of tool
5S hexagon wrench
Socket wrench 18S
14S socket wrench
Numeric multi-meter DT 992 type
Electric detonator tester
QJ992 type
Short
wiring
harness

(3) Joint dual-locking organization:
The joint equipping with this organization (male joint and female joint) is locked by dual-locking device
to increase the reliability of connection.
If one time lock is not firm, convex block will interrupt and stop the locking of twice lock. (1) Terminal dual-locking organization:
Each joint should be dual-locking organization and combines
with joint body and locking block. This design is caused by
the reason that dual-locking device (locking block and fixed
sheet) could fix the terminal to prevent it from releasing.
(2) Airbag anti-explosive organization
Each joint has a short circuit sheet, when the joint is
disassembled, short circuit sheet will connect the terminal
of device power supply with that terminal of igniter.
Mother
jointFather
joint Supplemental restraint system--Note
 241 
Body
Body
Body When connecting the joint
When disconnecting the joint
Short circuit spring sheet
Short circuit spring sheet
Terminal
Detonator
Short circuit spring sheetShort circuit spring sheet ON
Detonator
Closed circuitContact with father terminal
Joint
locklock Twice lock
Convex block
One time lock
One time lock is not firm
(twice lock is stopped)Twice lock is firm
(Twice lock could lock)Dual-lock could lock
completelyLocking block

(4) Joint locking organization:
Lock the locking clasp of joint to fasten the connection of joint.
2. When the automobile front face is impacted, and generated force is bigger than the standard pre-set,
airbag will work automatically. The sensor in safety airbag controller will feel the impact, at the same
time, it will judge the generation of impact by inner arithmetic to make ignition electric current. Electric
current will flow in gas generator to make explosive function, then two gas generators in airbag at the
side of driver and passenger will make gas to increase quickly inner pressure of airbag and rush out
the trim cover of steering wheel and instrument panel. After airbag charging is closed, the gas ejects
from the gas outlet at the side or at the back of airbag.
II. Disassemble the connecting joint of lower helix cable and wiring harness of steer-
ing wheel.
1. Put your finger on sliding block.
2. Move the sliding block to release the clasp.
3. Pull out the male joint.
Liking that shown in figure: some joints of wiring harness use the female joints in the right part of figure,
some designs of helix cable is similar with the joints in the left part.
III.Connect the connecting joint of lower helix cable and wiring harness of steering wheel.
1. Liking that shown in figure, align locking part of male joint and sliding block of female joint in same
direction to avoid mutual friction.
Supplemental restraint system--Note
 242 
Sliding block
Sliding block
Disconnect completely

IV. Assemble ECU joint
Figure 1 Figure 2 Figure 3
1. Press down limit switch in figure 1.
2. Dial white switch along the black line in figure 2, dial it to bottom liking that shown in figure3.
Hint: you will hear the assembling sound that shows it is put to position when white switch is
put into position.
V. Connect airbag wiring harness and short wiring harness at the side of passenger.
2. Confirm inserting it until locking, after assemble, pull it to check whether it is locked (when locking,
confirm exterior joint returns to former position, at the same time, assembling sound could hear).
Hint:
zWhen moving the sliding block, do not contact it.
zPay attention to do not distort the release board, if release board is distorted, it is neces-
sary to change it with new helix cable.
Figure 3 Figure 4
1. Insert the connector in figure 3 in the part in figure, after assemble it into its position, you will hear hint
sound.
Supplemental restraint system--Note
 243 
Sliding blockSliding block
Limit switch

2. Inspection for indicating light of safety airbag
(1) When set the ignition switch at ON position, confirm whether the indicating light illuminates.
(2) After illuminating for five seconds, confirm whether indicating light extinguishes forever.
(3) If starting ignition switch for five seconds, indicating light does not extinguish (flash or illuminate for long
time), confirm the position of system malfunction with special diagnostic tool according to the flash
situation of indicating light.
3. System diagnosis
Safety airbag controller (KD4.1) will implement a series of cycle diagnostic testing to check whether the
function of airbag system has been prepared completely. This test will prevent restraint system from
exploding wrongly and insure the necessary explosion in impact. If finding any malfunction, safety airbag
controller (KD4.1) will store a applicable malfunction code and turn on indicating light to indicate a mal-
function state to be easy to maintain.
4. Malfunction judgment
(1) Malfunction category
System malfunction could be divided into three categories: power supply malfunction, subassembly
assembling malfunction and ECU inner malfunction.
a. Power supply malfunction
Normal working voltage of ECU is 9-18 V, related working voltage is 12 V. When automobile key is
turned to ACC gear, ECU connects power and begins to self-check, indicating light extinguishes
after illuminating for five seconds, this shows there is not any malfunction in ECU and exterior
subassembly, they could work normally. When automobile power voltage is less than 9V or higher
than 18V, ECU will self-check again. If self-checking could pass, ECU works normally, and indicat-
ing light extinguishes; if self-checking could not pass, it is necessary to self-check again, this self-
checking could be made six times, if indicating light illuminates all the time after six times, there is
some malfunction in power supply.
b. Assembling malfunction of airbag subassembly
Assembling malfunction of airbag subassembly is that malfunction which only needs to change or
repair airbag subassembly without needing to change ECU, including the situation that airbag
subassembly is not connected completely. If happening this malfunction when connecting power
supply, indicating light will flash N times at first, then it will illuminate all the time until malfunction is
removed. If happening impact in malfunction term, ECU could explode the channel of good part
and record every malfunction when exploding.
c. Inner malfunction of controller
Inner malfunction is the malfunction happening in ECU body, when happening this malfunction,
ECU could not explode airbag, and will record the impacting acceleration.
Note: common repairer could not repair this inner malfunction, if happening this malfunction,
it is necessary to change ECU.
(2) Malfunction state display
Malfunction treatment
1. Basic procedure of malfunction diagnosis
zAfter assembling new electronic control unit of safety airbag system, indicating light of safety airbag
system will extinguish forever after flashing for 5 seconds when ignition switch is at state of ON, this
shows airbag system works normally. At this time, the system does not need to repair, it is necessary
to make system diagnosis and repair when showing any situation except this.
zIf indicating light of safety airbag system does not illuminate when ignition switch is at the state of ON,
check the related circuits of indicating light, then operate it to make it enter working state.
Supplemental restraint system--Malfunction treatment
 244 
Warning light illuminate Scanning ECU by connecting Find the malfunction Deal with Clean the code
and does not extinguish diagnostic instrument malfunction

Malfunction display of SRS could confirm originally by the flash of indicating light, detailed information
could be gained by malfunction diagnostic tool.
a. Safety airbag indicating light is driven by ECU, all malfunction displays are finished by ECU. After
working voltage is supplied for safety airbag controller (KD4.1) by battery, safety airbag controller
(KD4.1) illuminates indicating light to check SRS. To notify driver that there are some malfunctions
in system, indicating light will illuminate for long time after working voltage is supplied. If existing
SRS does not have any malfunction, indicating light will close after illuminating for five seconds
after ignition on. In original phase, safety airbag controller (KD4.1) does not prepare to check the
impact and stop the unfold until the wire of safety airbag controller (KD4.1) is reliable.
After ignition switch is turned to “ON” gear, the display type of indicating light when there is no any
malfunction in SRS is:
Assembling malfunction information of subassembly could see follow table 1.
Table1: Assembling malfunction information indicating table for airbag subassembly
Schematic drawing for slow flash indicating light
Supplemental restraint system--Malfunction treatment
 245 
Ignition switch “ON”
Illuminate
Extinguish NumberMalfunction type
Slow flash times (N times)Remark
1Igniter at the side of driver happens short circuit3
2Igniter at the side of driver happens open circuit4
3Igniter at the side of driver connects grounding5
4Igniter at the side of driver connects battery6
5
Igniter at the side of passenger happens short circuit7
6
Igniter at the side of passenger happens open circuit8
7
Igniter at the side of passenger connects grounding9
8Igniter at the side of passenger connects battery10
9
Safety belt at the side of driver happens pre-tightening malfunction11
10
Safety belt at the side of passenger happens pre-tightening malfunction12
12Impact output interface happens malfunction
or wrong explosion
of airbag subas-
sembly will make
big hurt for human,
its warning rea-
sons should be di-
vided detailedly.

Inner malfunction information could see following table 2.
Table 2: ECU inner malfunction information indicating table
Schematic drawing for fast flash indicating light
Schematic drawing for “short, short, long and short” malfunction
If happening the situations above, it is necessary to turn off key switch of automobile at first, then turn on key
switch and start it again, if information hint could not be removed, it is necessary to change ECU.Supplemental restraint system--Malfunction treatment 246 NumberMalfunction typeFast flash typeRemark
1Electronic acceleration offset malfunctionShort, short, short and long0001
2Electronic acceleration self-checking malfunctionShort, short, long and short0010
3SCM inner RAM is wrongShort, short, long and long0011
4Inner parameter is wrongShort, long, short and short0100
5Inner malfunction or acceleration storage space is full and ignition record has been made. Short, long, short and long0101
6Mechanical safety sensor happens malfunctionShort, long, long and short0110
7Increased pressure is wrongShort, long, long and long0111
8Ignition driving function is wrongLong, short, short and short1000
9Voltage of ignition voltage F12 and F13 is wrongLong, short, short and long1001
10Other parts are wrongLong, short, long and short1010

Supplemental restraint system--Repair
Repair
a. In using process, if happening any malfunction of power supply, it shows the voltage of power supply
is less than 9V or higher than 18V, or the battery is damaged, at this time, it only needs to charge or
change the battery.
b. Use special malfunction diagnostic tool to test.
Malfunction codes approved by safety airbag controller (KD4.1)
Number Malfunction specification Remove
1Ignition circuit 1 (safety airbag at the side of driver), the resistance is too high or open circuit.OK
2
Ignition circuit 1 (safety airbag at the side of driver), the resistance is too low or short circuit.OK
3
Ignition circuit 1 (safety airbag at the side of driver), connects with the groundingOK
4
Ignition circuit 1 (safety airbag at the side of driver), connects with power supplyOK
5
Ignition circuit 2 (safety airbag at the side of passenger), the resistance is too high or open circuit.OK
6
Ignition circuit 2 (safety airbag at the side of passenger), the resistance is too low or short circuit.OK
7
Ignition circuit 2 (safety airbag at the side of passenger), connects with the groundingOK
8
Ignition circuit 2 (safety airbag at the side of passenger), connects with power supply.OK
9
Ignition circuit 3 (pre-tension safety belt at the side of driver), the resistance is too high or open circuit.OK
10
Ignition circuit 3 (pre-tension safety belt at the side of driver), the resistance is too low or short circuit.OK
11
Ignition circuit 3 (pre-tension safety belt at the side of driver), connects with the groundingOK
12
Ignition circuit 3 (pre-tension safety belt at the side of driver), connects with the power supplyOK
13
Ignition circuit 4 (pre-tension safety belt at the side of passenger), the resistance is too high or open circuit.OK
14 Ignition circuit 4 (pre-tension safety belt at the side of passenger), the resistance is too low or short circuit. OK
15
Ignition circuit 4 (pre-tension safety belt at the side of passenger), connects with the groundingOK
16
Ignition circuit 4 (pre-tension safety belt at the side of passenger), connects with power supplyOK
17
Voltage of power supply is too highOK
18
Voltage of power supply is too lowOK
19
Malfunction of indicating light connects with power supply or bulb is short circuit.OK
20 Malfunction of indicating light connects with the grounding or filament is open circuit. OK
21
Lack/wrong calculation rule parametersNo (change safety airbag
controller (KD4.1))
22Front impact has been recordedNo (change safety airbag
controller (KD4.1))
23
Communication malfunctionOK
24
Inner malfunctionNo (change safety airbag
controller (KD4.1))
25
Impact output (oil pump) pin connects with the groundingOK
26
Impact output (oil pump) pin short connects with power supplyOK
27
Impact output (central control door lock) pin connects with the groundingOK
28
Impact output (central control door lock) pin connects with power supplyOK
29
Pre-tension safety belt ignites independentlyOK, but most is five times
30
Pre-tension safety belt ignites six times independentlyNo (change safety airbag
controller (KD4.1))
 247 

cthere are some malfunctions, indicating light will indicate them. If exterior malfunctions are historical,
after they are removed, indicate will disappear.
done displayed or historical malfunction is only set up again by server. Inner malfunction or “impact
record” of safety airbag controller (KD4.1) could not be set up again, in this situation, it is necessary to
change safety airbag controller (KD4.1).
(3) micro controller, independent indicating light illuminates.
Microprocessor having obvious malfunction state could not work, so it could not control the work of indicat-
ing light. In this situation, indicating light will illuminate directly by applicable circuit without considering the
micro-processor, liking that shown in following:
zThe battery providing electricity for safety airbag controller (KD4.1) disables: indicating light illumi-
nates by the automatic light driving function.
zInner working voltage loses: indicating light illuminates usually.
zNew setup caused by the unsuccessful watchdog trigger: indicating light flashes
zMicro-processor does not work: indicating light illuminates usually
zInsert of connecter of safety airbag controller (KD4.1) is wrong: indicating light illuminates usually by
short circuit stick.
Take example to specify diagnostic step:
If finding indicating light of safety airbag illuminates usually, even if it extinguishes at last, you could check
by follow step. First is to check the part happening malfunction with diagnostic tool.
Then make by the checking step for corresponding position.
a. If scan result is inner malfunction or safety airbag has exploded, at this time, change the ECU directly.
b. Malfunction has been removed.
Supplemental restraint system--Repair
 248 

Inspection
I. The inspection for airbag module at the side of
driver could be divided into three situations:
Automobile is not impacted, automobile is impacted but
airbag does not explode, and automobile is impacted and
airbag explodes.
1. Automobile is not impacted:
a. Make malfunction diagnostic inspection,
b. Check the safety airbag assembled on steering wheel
with your eyes,
including following items mainly:
Check whether the airbag has any cut, small crack or the surface and concave slot of airbag has
obvious changed color.
2. Automobile is impacted but airbag does not explode:
a. Make malfunction diagnostic inspection,
b. Check the disassembled safety airbag with your eyes, including following items mainly:
Check whether the airbag has any cut, small crack or the surface and concave slot of airbag has
obvious changed color.
Check whether wiring harness has any cut, crack or joint has any flaw,
Check whether steering wheel has distorted,
Check whether the plug and wiring harness of helix cable has been damaged, the loudspeaker wiring
harness plug and wiring harness has been damaged or distorted,
Check whether contacting board of steering wheel loudspeaker button has been distorted (if it has
been distorted, it is necessary to change with new safety airbag module, forbid repairing it),
Interruption situation could happen between safety airbag module and steering wheel lower defend-
ing cover, and when new airbag module is assembled on steering wheel, its surrounding clearance
must be even (Assemble and disassemble of driver airbag module should accord with correct step to
work).
3. Automobile is impacted and airbag explodes:
a. Make malfunction diagnostic inspection,
b. Check the disassembled safety airbag with your eyes, including following items mainly:
Check whether the plug and wiring harness of helix cable has been damaged, the loudspeaker wiring
harness plug and wiring harness has been damaged or distorted,
Check whether wiring harness has any cut, crack or joint has any flaw,
Check whether steering wheel has distorted,
Interruption situation could happen between safety airbag
module and steering wheel lower defending cover, and
when new airbag module is assembled on steering wheel,
its surrounding clearance must be even (Assemble and
disassemble of driver airbag module should accord with
correct step to work)
II. The inspection for airbag module at the side of
passenger could be divided into three situations:
Automobile is not impacted, automobile is impacted but
airbag does not explode, and automobile is impacted and
airbag explodes.
Supplemental restraint system--Inspection
Safety airbag module at
the side of passengerChange the
wiring harness
of airbag
 249