Midi Service Manual-091231 PDF

Chapter I Outline of vehicle
Section I Summary
The model MP.Midi is a brand new sedan independently developed and designed by BEIJING FOTON
MOTOR CO.LTD, which is displayed in the world by its sculptural outlook, smooth and robust line and
active visual effect.
It uses the engine, model 4G13S-7L/4G18S-7L, which is characterized by strong power, stable operability,
smooth drivability, reliability, durability and easy maintainability
Product classification of the Foton, MP.Midi Maintenance Manuals:
By the classification of model uses: the model Foton MP.Midi is divided in to dual-purpose type and
passenger type
Section II Technical parameters of main models

1. Size parameters of main model structures
Parameters
Passenger type Duo-purpose type
Size
Outer dimension(LWH)(mm) free
4288/1725/1728 4338/1725/1768
load
Trunk(cargo space)capacity(m3) 6242800 8243000
Axle base(mm) 269 2695
Wheel Front 1420 1420
base(mm) Rear 1440 1440
Front suspension(mm) 830 830
Rear suspension(mm) 763 813
Drive type FF FF
Dynamic displacement and gearbox
1.3.L/1.6L,5MT 1.3.L/1.6L,5MT
pattern
Number of seats 6/7 7
Type of front rear suspension bracket McPherson/vertical arm torsion bar McPherson/vertical arm torsion bar
Drive brake type Front disc/rear drum Front disc/rear drum
Steering system type Power steering by rack/pinion Power steering by rack/pinion
2. Vehicle mass parameters

Mass parameters Passenger type Duo-purpose type
Full mass (kg) 1290 1320
Full mass state
Front/rear shaft load(kg) 748/542 722/598
Number of seats 2 2
Half loaded state Vehicle mass 1440 1470
Number of seats 5 5
Full loaded state Full loaded mass 1665 1695
Max. passengers 7 7
Max. designed load mass(kg) 525 650
Max. designed mass (kg) 1815 1970
Max. designed total mass state
3. Parameters of wheel positioning
Parameters of front wheel positioning Steering angle of
front wheel
Front axle
Type of product Backward Internal External
type Introversion Wheel Toe-in of
tilt of master corner corner
of master pin camber front wheel
pin
BJ6438MC6VA-1
BJ6438MC6VA-2 Steering 13 mm
10830 23030 1530 37 31
BJ6438MC6VA-P1 booster (1510)
BJ6438MC6VA-P2
BJ6438MC6VA-P1 Mechanical 13 mm
10830 130 1530 37 31
BJ6438MC6VA-P2 steering (1510)
Parameters of rear wheel positioning

Type of product Main reduction ratio
Wheel camber Toe-in of rear wheel
BJ6438MC6VA-1 4.052
BJ6438MC6VA-2 4.333 -2010 or
-12530
BJ6438MC6VA-P1 4.052 -1-3mm
BJ6438MC6VA-P2 4.333
4. Mobility and traffic ability

Functional parameters Passenger type Duo-purpose type
Min.turning diameter(m) 5.65 5.65
Min. ground clearance(mm)(free/full load) 156/124 154/121
Approach angle ()(Full load) 16 16
Departure angle()(Full load) 24 22
5. Dynamic and economic parameters

Passenger type Duo-purpose type
Functional parameters
(4G18S) (4G13S) (4G18S) (4G13S)
Power ratio(w.t-1) 57.5 48.4 56.2 47.3
Moment ratio (N.m.t-1) 103.9 83.7 100.7 81.8
Max.speed(Km/h) 161 154 160 152
Max. gradeability (%) 40 30 40 30
Acceleration time:0-100km/h (s) 15.5 19.3 16.36 19.6
Acceleration time of the direct gear:
20.39 24.41 20.39 24.41
80-120Km/h (s)
Min. steady speed of the direct gear (km/h) 21 20 21 20
Fuel consumption: 90 km/h 6.66 6.51 6.66 6.51
Fuel consumption of integrated operating
7.6 7.6 7.6 7.6
mode (L/100km)
Chapter II Engine
The vehicles, Model-MP.Midi have been fitted, on demand, with the engine model
4G13S-7L/4G18S-7L produced by Harbin Andong Automobile Engine Manufacturing
Corp.Litd. The engine, Model-4G13S-7L/4G18S-7L is the ideal dynamic of the family
multi-purpose vehicles and sedans with displacements of 1.3l/1.6l. In comparison with
homologue type, the engine is characterized with the compact construction, large power per
liter, good fuel economy, high speed and less noise etc., By adopting the electronically
controlled fuel injection system, which reduces considerably the harmful constituents in
off-gases, the engine is worth of the Green Earth power fully meeting the III of new National
Emission Regulations III.
Section I Introduction to engine products
1. Engine diagram
Figure 2.1 Engine assembly outlook

Figure 2.2 Engine left-side outlook
Figure 2.3 Engine right-side outlook

Figure 2.4 Engine front-view outlook
Figure 2.5 Engine rear viewoutlook

II. Engine technical performance and structural parameters
Table 2.1 Engine technical performance and structural parameters
Model 4G13S-7L 4G18S-7L
Type L4/16VSOHCMPI
Displacement 1299cm3 1584cm3
Cylinder bore 71.0mm 76.0mm
Stroke 4 4
Compression ratio 9.5

Max.power 62.5Kw /6000r/min 74.2Kw /6000r/min
Max.Torque 108N.m / 4500r/min 134N.m / 4500r/min
Min. fuel consumption 272g/Kw.h

Rated Speed rpm 6000r/min
Idle 75050r/min
Steering Counterclockwise(seen from rear to front)
Ignition sequence 1-3-4-2
Oil pressure 150kpa(750r/min)\54050kpa(2000r/min)
Overall dimension Overall lengthwidthheight=617.8mm613.3mm622.2mm
Net weight 1132kg 1152kg
Fuel Unleaded gasoline over 93#

SAE5W-30(in winter, north);
Use of oil
SAE15W-40(through year, south or in summer, north)
Emissions regulation to meet National 3
Number of cylinders 4 4
Combustion chamber Roof type Roof type
Stroke mm 82 87.3
Valve and drive mechanism SOHC-4 SOHC-4
Cylinder center distance 82 82
Cylinder height 201 201
Central distance between the connecting 131

131
big/small rods
Intake valve 8 8
Number of valves
Exhaust valve 8 8
Emissions regulation to meet National 3 National 3
Lubrication system Oil supply under pressure Oil supply under pressure
Electric fuel pump, non-return oil electric fuel pump non-return oil
Fuel supply mode system
system
Type of oil pump Cycloidal gear pump. Cycloidal gear pump.
Cooling system Forced water cooling cycle Forced water cooling cycle
Type of water pump Centrifugal, impeller Centrifugal, impeller

III. Characteristic curves of engine
Figure 2.6 Characteristic curves of engine, Model 4G13S-7L

Figure 2.7 Characteristic curves of engine, model 4G18S-7L
IV. Position of engine No.and cylinder No.
e.g:
4G13S Engine Model
Engine no. print area 7L 79A0001
79A0001production serial number
72007
9Septermber
A0001Production S/N
Identification sign of the engine model
Section II Use and maintenance of engine

I. Use of engine
1. Coolant
Checks to see whether the engine coolant is sufficient or not, if insufficient, adds the coolant
adequately.
Attention: The cooling system includes the water pump, water pipe and water jacket
etc.,.When the engine runs, the cooling system has to be sufficient of the coolant, to ensure
the normal operation of engine, otherwise the car will be boiling. The gasoline consumed
engine operating under the overheating condition will affect the service life and in serious
case, cause the malignant failure such as cylinder score.
2. Oil
Checks the level of engine oil. In case of oil shortage, the adding should be made in tiem.
Attention: The oil insufficience will cause the oil pressure of gasoline engine very low, poor
lubrication, worsen engine wear and bad cooling, which are easy to come about with the
failures and affect the service life of gasoline engine.
3. Fuel grade
Fuel uses the unleaded gasoline graded higher than RON93# and 93#.
4. Engine startup
When starting the engine, twists the ignition switch key on the Startup position. The engine is
activated by thestarter. Once the engine ignited, the key should be released, and the power
supply of starter cut off.
Attention: Do not let the starter running more than 5s per each duty time. If the gasoline
engine fails to start, try to restart in 10s, otherwise it will damage the starter. If failed to
startup after several attempts, please check the fuel system and electric system, or call on the
automobile manufacturer and our service station for maintenance.
5. Idle
After the engine started, you should keep it run at idle speed for several minutes for engine
preheating.
Attention: The idle emission level of our engine products prior to delivery is strictly limited
within the specified range by the national standard. The idle speeds of gasoline engine,
models 4G13S-7L/4G18S-7L are set at 75050r/min. The idle mechanism of the gasoline
engine delivered with the car has been properly adjusted, there is no need for user to change it.
In case of necessary adjustment, you should call on the special maintenance department for
assistance. When the emission is tested, the engine should be in warm state, i.e. the water
temperature over 80; the oil temperature over6 0 (Idle speed: 75050r/min). The idle
speed and emission level are changeable all time. During the usage, the engine should be
regularly inspected and adjusted at the testing point.
6. Drive
During the drive in the car, the coolant temperature should be kept at 8090. At the
moderate speed, be careful that the oil pressure be 54050kPa.
7. Stopping
When the engine is working, especially running at high speed under heavy duty, do not shut
down the engine, you should shut down the engine after it has run at the low speed for
5mins instead of doing it immediately.
8. Driving in rainy day or wading
When driving on the puddle in rainy day or wading, be sure that the air filter be well sealed,
otherwise it will cause the engine cylinder inflowed and the connecting rod etc. damaged.
Attention: The water can not be compressed liquid. After the cylinder inflowed, the
connecting rod will bear the pressure of several times under the inertia action of car and bend
or break up the connecting rod.
9. Preheating in winter
As the temperature in winter is lower, the viscosity of oil increases. For the time being, the
lubrication effect of engine is worser than in summer. Hence, the engine after started up can
not operate at high speed as well as under heavy duty, instead, you should preheat the engine
at idle speed for 10mins and start driving only after increasing the oil and coolant
temperatures and lubricating the engine sufficiently.
Attention: When the gasoline engine is driving without adequately lubricated in wintergine,
it will cause the parts such as camshaft excessively worn and even, locking.
10. Electric injection system
In case of the engine inspection, do not randomly modify the electrical devices or wiring,
otherwise it will cause the electric devices overloaded, short-circuited and sparking. When the
electric system is inpected, the neg. cable should be disconnected fron the battery terminal.
Prior to connect or disconnect the neg.cable, be sure to turn off the ignition switch and
lighting switch(If not, it will burn up the semiconductor elements).
II. Regular check and maintenance of engine
Table of the regular checkand maintenance of engine
Each item is expressed by the running distance and time (month), and whichever comes first
(distance or time) is taken as the check basis.
Maintenance job code: IInspection; RReplacement; CCleaning;
Interval of maintenance(the odometer reading and month, whichever comes first)
S/C Month - 6 12 18 24 30 36 42 48 54 60
10
Odometer reading 1000km 1 10 20 30 40 50 60 70 80 90
0
Checks the driving belt of A/C generator to see if

1 there is any crackles, flying debris and wears on the I I I I I I I I I I I
driving belt and ajusts its tightening
2 Checks the ignition cable for any damages I I I I I

Replaces the engine General conditions of use I I I R I
3
timing belt Harsh conditions of use R: per 70,000km
Checks to see if the vapor control system of crankcase
4 I I
is normal.
5 Replaces the spark plug I I R I I R I I R I
6 Replaces the engine coolant R R R R R
Checks the air filter General conditions of use I: per 5,000KM
7 elements for any chocks
and damages Harsh conditions of use I: More frequently
Replaces the air filter General conditions of use R R R R R R R R R R
8
elements Harsh conditions of use R: More frequently
API General conditions of use R: per 5000KM
Oil Class.
9
replacement SJ Harsh conditions of use R: per 3001KM
grade
Replaces the General conditions of use R: per 5002KM
10
Oil filter Harsh conditions of use R: per 3003KM
Checks the liquid level in the clutch hydraulic
11 I
reservoir
12 Checks the engine idle and carbon monoxide I I I I I I I I I I
13 Checks the ignition timing I I I I I
14 Checks the crankcase air hoses I I I I I I I I I I
Checks if there is any leakage on the exhaust pipe
15 I I I I I I I I I I
connectors
16 Throttle body C C C C C C C C C C
17 Injector C* C* C* C* C* C* C* C* C* C*
18 Checks the valve clearance I I I I I I
Note:
C* for the cleaning and maintenance of the injection nozzle, it is recommended to use the
special cleaning analyzer of injection nozzlecheck once per 3months or per 5000km. the
failures such as vapor lock on the nozzle and block etc. are not considered as the quality
problems of product, the maintenance of which is charged by the user.
The Use speficiation under the harsh conditions is only applicable to the vehicles used under
the harsh conditions.
The harsh conditions of use include the following subjects:
(1) Driving in the dusty areas, or the car often at exposure to the salty air or seawater.
(2) Driving on the uneven road, puddle or hill road.
(3) Driving in the cold areas.
(4) The engine runs at idle for longtime or drives in short-distance in cold season
(5) Uses frequently the brake and often makes panic stops.
(6) Used as the tractor-trailer.
(7) Used as the taxi or rent car.
(8) At the temperature more than 32, the driving time in the city of heavy traffic exceeds
50% of the total driving time.
(9) At the temperature more than 30, the driving time at speed of 120km/h or higher
exceeds 50% of the total driving time.
(10) Overloaded driving
III. Internal inspection of engine
1. Checks the driving belt of A/C generator to see if there are anycrackles, flying debris and
wears and adjusts its tightening.
The driving belt condition of A/C generator: checks if there are anycrackles, flying debris and
wears while turning the driving belt of A/C generato.
The driving belt tightening of the A/C generator
Mode of bolt structure adjustment
(1) Unscrews the nuts of A/C generator bearing
bolt;
(2) Unscrews the locking nut of belt tensioner;
(3) Turns the adjusting bolt to adjust the belt
tightening
(4) Tightening locking nut.
(5) Tightens the nut of A/C generator bearing
bolt
(6) Checks the deflection of driving belt,
re-adjusts it if necessary.
Regulating bolt
Locking nut
Specifications
Check method
When the new belt is fitted On inspection
Check time
Driving belt deflection of A/C
generator 5.6~6.7(mm) 8.3~10.4(mm)
(under acting force of 100N)
Driving belttension of A/C
785~981(N) 392~588(N)
generator
2. Checks any of damage on the ignition cable
(1) Checks the ignition cable and rubber lid, incl. the installing condition to see if there are
any damages or fragility.
(2) Checks if the ignition cable, spark plugs and ignition coil joints are condaminated by any
filths and dirt deposit etc.
(3) The dirts if any should be cleaned outany damages shoud necesit the replacement.
3. Replaces the timing belt of engine
Under the general conditions of use, one piece
replaced per 80,000km; Under rigorous conditions,
one piece replaced per 70,000km .
4. Checks if the vapor control system of crankcaseis
normal.
(1) Checks if there are any crackles or damages on
the channeling gas hose.
(2) If necessary, the interior of the channeling gas
hose should be cleaned out.
Check of the forced ventilation device of crankcase.
Removes the air hose from the forced ventilation
Forced vent valve of camshaft case
valve of crankcase
Removes the forced ventilation valve of
crankcase under the rocker arm cover.
Refixes the forced ventilation valve of crankcase
on the air hose.
Starts up the engine and keeps it run at idle
speed.
Fingers at the openture of the forced ventilation
valve of crankcase to prove if any vaccum inside the
Forced vent valve of camshaft case
intake manifold can be felt.
Note:
Now, the plunger in the forced ventilation valve
crankcase will move back and forth.
If no vaccum is felt, the forced ventilation valve
of crankcase should be cleaned or replaced.
Drainage valve of cylinder
Check of the PCV valve

Inserts, in general, a thin rod shown as in Figure (mounting side of the rocker chamber
cover) into the forced ventilation valve of crankcase, and moves it around to confirm if the
plunger is moving.
If the plunger is immobile, it means there is a chock inside the forced ventilation valve of
crankcase. In such case, the valve should be cleaned or replaced.
5. Replacement of spark plug
The replacement is to be made each time per 30,000km. In case of replacement, remember
that the model is BKR5E-11 or K7RF-11 with the thread M141.25
6. Replacement of engine coolant
(1) Shuts down the engine after it has been fully preheated.
(2) Adds the detergent for cleaning the cooling system of engine into the engine coolant
trough the radiator filler, then starts up the engine.
(3) Removes the drainage cover of radiator at the cold state of engine, and drains the coolant
out.
(4) Adds the clean water into the cooling system via the filler of radiator, then cleans the
cooling system. After the cooling system cleaned out, tightens the drainage cover of radiator.
(5) Determines, depending on the conditions of use, the amount of coolant of long service life,
antifreeze or antirust agent.
Attention: Uses neither alcohol or methanol antifreezer, nor the engine coolant mixed
with the alcohol or methanol antifreezer. Use of uncorrect antifreezer may cause
thecorrosion of aluminum parts.
(6) Slowly poors the the engine coolant through the filler of radiator into the radiator until it is
fully filled, while filling reserve tank with the engine coolant until the level reaches the mark
lime FULL(alternative dependint the availability of car).
(7) Fixes tightly the radiator lid.
(8) Starts up the engine and lets it run unti the thermostat turns on(touches by hands the
radiator hose to verify if the hot water is flowing).
(9) After the thermostat is turned on, keeps the engine run idle at the high speed for several
times, then shuts down the engine.
(10) After the engine cooled, fills the reserve tank with the engine coolant as long as the level
reaches the FULL line. If the level is still lower, please repeat the procedure from (9).
Attention: Do not open the coolant tank lid or radiator lid when the engine remains in
hot state. The cooling system in the hot state is under a certain pressure. If opening the
lid, the hot coolant will spray out and scald the people around.
Drains the engine coolant through thedrainage plug of cylinder.
1) Removes the drainage plug, then radiator lid, and drains out the coolant from the engine.
2) Removes the drainage plug of cylinder and drains the engine coolant.
3) Removes the reserve tank and drains out the engine coolant (alternative dependint the
availability of car)
4) After the engine coolant drained out, fills in the clean water through the radiator lid to clean
up the pipleline of engine coolant.
5) Applies the specified sealant on the drainage plug thread of cylinder and thghtens as per the
moment as specified.
6) Firmly tightens the drainage plug of radiator.
7) Fits the reserve tank (alternative dependint the availability of car).
8) Removes the bleed bolt and replaces the seal washer (alternative dependint the availability
of engine).
9) Fills the radiator with the engine coolant until it overflows from the bleed bolt. Then closes
the bleed bolt (alternative dependint the availability of engine)
10) Slowly poors the engine coolant through the filler of radiator into the radiator until it is
filled up, while filling the reserve tank with the engine coolant unti the level is up to the
FULL line (alternative dependint the availability of car).
11) Fits tightly the radiator lid.
12) Starts up the engine and lets it run unti the thermostat turns on(touches by hands the
radiator hose to verify if the hot water is flowing).
13) After the thermostat is turned on, keeps the engine run idle at the high speed for several
times, then shuts down the engine
14) After the engine cooled, fills the reserve tank with the engine coolant as long as the level
reaches the FULL line. If the level is still lower, please repeat the procedure from (13).
7. Checks if there are any blocks and damages on the air filter elements.
(1) Checks if there any blocks and damages on the filter elements
(2) Removes the dirt deposit on the filter elements as per the method as below.
Tpas one side of filter elements.
Blows the compressed air from the internal side of filter elements.
(3) Scraps out the dirts in the air filter.
(4) For the gasoline consumed vehicles, places, while installing, the dirty part of filter
elements at intake port of channeling gas (prevent the greasy dirt from spreading) if the old
filter elements are intended to be reused.
8. Replacement of air filter elements.
(1) Removes the air filter cover and filter elements. Scraps the filth in the filter.
(2) Fits the new air filter elements.
Procedure of replacement:
In the process of use, the air filter elements will get dirty and dusty, which significantly
reduces the filtering effect. In such time, they should be replaced by the new ones.
Releases the bucle of the air filler cap.
Removes the air filter elements and fits the new ones.
Be sure to keep the air filler cap fully closed when holding it down.
9. Oil replacement.
(1) Removes the filler lid set on the rocker chamber cover of engine.
(2) Removes the oil drain plug on the engineoil sump and drains out the oil.
(3) Renews the spacer of drainage bolt.
(4) Tightens the drainage bolt.
(5) Poors in the renewed oil through the filler into the crankcase.
(6) Pulls out the dipstick from the engine, and checks if the oil level remains between the
marks MAX and MIN.
(7) Fitss the filler cap.
(8) Checks the oil level after the road test.
Selection of oil:
SAE5W-30(in winter, north), SAE15W-40(through year, south or in summer, north)
Note: The quality class (API): SJ or higher than SJ.
10. Replacement of oil filter
(1) Starts up the engine and lets it preheating until the temperature of engine coolant is up to
80-90.
(2) Removes the filler cap on the rocker chamber cover.
(3) Removes the oil drain plug on the oil sump to drain out the oil. Be careful! The oil
temperature could be very high.
(4) Removes the oil filter of engine with special tools as shonw in Figure.below.
O-ring
Or marketed tools
(5) Cleans out the fitting side of filter bracket.

(6) Applies a few of oil on the O-ring of the oil filter.
(7) Once the O-ring of oil filter touches the flange, please use the special tool shown in Figure
to tighten it up to the specified moment.
(8) Fits the oil drain plug on the oil sump and poors in the oil through the filler on the rocker
chamber cover.
(9) Runs the engine at high speed for 2-3 times, then checks the fitting side of filter and be
sure no oil leakage is allowed.
11. Checks the idle of engine and the content of carbon monoxide.
(1) Prior to the check and adjustment, get the engine ready under the following conditions:
Temperature of engine coolant: 80-95
All car lamps, electric cooling fan and accessories: OFF
Gearbox: N-gear
(2) When making check on the ignition timing, adjusts it if necessary.
(3) Fits the tachometer after the ignition switch turned on the position OFF.
(4) Starts up the engine and let it run at idle speed.
(5) Keeps the engine running at idle for 2 mins.
(6) Checks the idle and accesses the reading of idle according to the tachometer.
Remark: The idle control system (ISC) will adjust the idle automatically.
(7) If there is any deviation from the standard value, please refer to the maintenance manual
for the check of MPI elements.
(8) Fits the tester of carbon monoxide.
(9) Keeps the engine running at 2000-3000r/min for more than 10s.
(10) Checks the mixture of idle.
12. Check of the ignition timing
(1) Prior to the check and adjustment, get the engine ready under the following conditions:
Temperature of engine coolant: 80-90
All car lamps, electric cooling fan and accessories: OFF
Gearbox: N-gear
(2) Inserts a paper clip along the wiring side into the connector between the primary side of
ignition coil and the tachometer.
(3) Connects a tachometer for the primary voltage to the paper clip.
(4) Fits the timing lamp.
(5) Starts up the engine and let it run at idle speed.
(6) Checks if the engine idle is within the range of standard value.
13. Check of the air hose of crankcase
(1) In case of need, checks with reflector the full peripheryand length.
(2) Checks if all clippers are well tightened, whether there are any leakages on the joints.
(3) If there are any clear signs of deterioration or damage, the replacement should be made at
once.
14. Checks the valve clearance.
Timing indication panel
Notch
Side of timing belt
Identification sign
(1) Starts up the engine and preheats the engine until the coolant temperature is up to 80-90.
(2) In order to facilitate inspectio, removes all spark plugs from the cylinder head.
(3) Removes the cover of rocker chamber.
(4) Turns clockwise the crankshaft until the notch of pulley aligns with the markT on the
timing dashboard.
(5) Moves up and down the rocker arms of the 1st and 4th cylinders to be sure that the pistons
of both cylinders are located at the top dead center of compression stroke. If there are the
clearances between the rocker arms of both intake and exhaust valves, the pistons in the
cylinder correspongding to those rocker arms should be positioned in the top dead center of
the compression stroke
(6) When the pistion of the cylinder No.1 is sited at the top dead center of compression stroke,
The valve clearance can be checked and adjusted with the rocker arm indicated by the white
arrowand when the pistion of the cylinder No.4 is sited at the top dead center of compression
stroke, the valve clearance can be checked and adjusted with the rocker arm indicated by the
solid arrow;
(7) Check of valve clearance
If the valve clearance is non-conform to the specified requirements, you may unscrew the
locking nut of rocker arm, and turns the governing screw while measuring with a feeler gauge
the clearance and makes the adjustment.
Standard values:
Ambient temperature(C)
Valve Engine in hot state
0~15 15~25 25~40
Intake valve 0.120.03mm 0.140.03mm 0.160.03mm 0.20mm
Exhaust valve 0.170.03mm 0.190.03mm 0.210.03mm 0.25mm
Note: The variation of the valve clearance against the external temperature: every 1 degree
rise in temperature , the valve clearance is added by 0.0018mm.
(8) Fixes the governing screw with the screwdriver to prevent it from turning, tightens the
locking nut up to the specified moment.
(9) Turn s the crankshaft by 360, and aligns the notches on the crankshaft pulley with the
markTon the timing dashboard.
(10) Repeats the procedures (7) and (8) and adjusts the clearances of other valves.
(11) Fits the cover of rocker chamber.
(12) Fits the spark plugs and tightens them as per the specified moment.
15. Checks if there are any leakage on the exhaust pipe joint.
(1) Be sure that the exhaust pipe cause no interferences on any parts of car.
(2) Checks if the exhaust pipe has been damaged due to the impact by the gravel etc.
(3) Starts up the engine, to check if there is any leakage on the exhaust pipe joint.
16 Cleaning of the throttle assembly
In case where the following cases occur in your car, you should clean the throttle assembly:
(1) After completed the travel of 10,000kms or 6 months, whichever comes the first.
(2) When the following problems occur to your car: insteady idle, throttle valve lock, high
idle and low idle.
The portion to be cleaned as below:
Ball head of stepping motor
Taper hole matching with the ball head
Throttle valve plate
The inner wall of the main chanel in the throttle valve
17. Check of water pump leakage
During the use of water pump, it is normal to see a few of water from the drainage hole of
water pump. When the water pump is mechanically sealed, the mechanical seal needs the
cooling waterto lubricate the sliding surface. Hence, in normal closing state, the coolant will
be drained out in form of steam or mist. In view of the water pump structure, the coolant
drained out needs to be discharged from the drain and steam holes.
Causes of leakage
1) The most cases of leakage are temporary instead of permanent. Such leakage should be
originated from the drain hole of water pump or the cooling water form the steam hole.
2) In addition, in terms of the water pump structure (mechanical seal), the temporary leakage
will not reduce the cooling performance (overheating etc.)(less or more cooling water etc.).
3) The after sales service will judge whether the water pump is qualified according to the
fowling methods and prevent the misjudgment of water pump leakageIn case of true leakage,
replaces the water pump.
Whether the water pump leaks or not will be determined as per the following procedures:
Drain hole
Leakage inspection of
water pump
Identification of water leakage traces.

NON
Visually confirms the leakage traces of drain hole, steam
hole and fitting surface.
YES
Hydraulic pressure testing

YES
Pressure increased with the tester of the radiator
cover
Pressure1000kpa
Pressurizing time20min
Visually confirms whether there is any
water leakage
NON
Turbine driver test YES
Engine heater
Idle turbine driver20min
Visually confirms whether there is any
water leakage
Normal
NON Pump replacement
Continues to use after wiping out the water

traces(normal)
IV. Tightening moment of main bolts of engine

Items Nm
Intake manifold and exhaust manifold
Intake manifold stay bolt (M8) 15~20
Intake manifold stay bolt (M10) 27~34
Intake manifold bolt 15~20
Exhaust manifold stay bolt (M8) 15~20
Exhaust manifold stay bolt (M10) 27~33
Exhaust manifold housing bolt 27~33
Bolts of engine lugs 15~20
Rocker arm, rocker arm shaft and camshaft
Rocker chamber cover bolt 3~4
Items Nm
assembly bolt, rocker arm shaft 28~34
governing screw 8~10
Cylinder head and valves
Tightens up to 49Nm
Releases
Cylinder headbolt 202
90 to 94
90 to 94
Oil pump and oil sump
Gearbox bracket bolt(1020-7T) 42~54
Gearbox bracket bolt(840-7T) 19~27
Oil drain plug 34~44
Oil sump bolt(M6) 6~8
Oil sump bolt(M8) 22~25
Oil filter 12~16
Front cover bolt 12~15
Connecting rod
Connecting rod nut 16.72.090 to 94
Crankshaft and cylinder body
Flywheel bolt 127~137
Backboard bolt 8~12
Flywheel shell bolt 8~12
Rear seal shell bolt 10~12
Bearing cap bolt 34.32.030 to 34
Engine and vehicle interface
Fitting bolts, exhaust manifold and exhaust front tube 40~50
Fitting nuts, engine right bracket and vehicle frame 575
A/C generator and ignition system
Pulley bolt, water pump 7~11
A/C generator stay bolt (side of the A/C generator) 20~25
Master-pin bolt, A/C generator 34~54
Dipstick guided-tube bolt 19~28
crankshaft bolt M141.5 176~186
Spark plug 20~29
A/C generator nut 34~54
Ignition coil 8~12
Camshaft position sensor bolt 7.5~8.5
Camshaft position sensor, bracket bolt 12~15
Camshaft position sensor, tooth plate bolt 17~26
Timing belt
Fitting bolt, timing belt shell, 10~12
Fitting bolt, timing belt tensioner 20~27
Fitting bolt, crankshaft, winkel-sensor (speed sensor) 6~10
Items Nm
Nut and bolt, engine right bracket (M10) 30~42
Fitting bolt, engine right bracket (M8) 17~25
Fuel injection and control system
Sensor bolt, air intake temperature pressure 4~6
Fitting bolt, canister solenoid bracket 8~10
Fitting bolt, throttle assembly 15~22
Fitting bolt, oil rail assembly 10~13
Fitting bolt, , knock sensor 15~25
Water pump and intake pipe
Water thermostat 10~12
Joint, water pipe 17~26
Temperature sensor, cooling water 20~40
thermostat shell bolt 19~28
Intake pipe bolt 10~15
water pump bolt 12~15
V. Main failures of engine and troubleshooting

5.1 Difficult start-up of engine
Failure phenomenon and causes Troubleshooting
1. The terminal connection of Tightens or unscrews
battery loosens or insufficient
power.
The starter doent run
2. Some parts of circuit are Inspection and maintenance
disconnected.
3. The starter is damaged Repair or replace
1. The ignition timing is not Adjustment
well adjusted
2. Poor grounding Repair
3. The ignition coil is damaged. Replacement
The spark plug fails to strike 4. Inappropriate clearance Adjustment or replacement
between the spark plugs or
burnt out.
5. Failures in the electronic Repair or replace
ignition system.
1. Insufficient supply of Repair or replace
The oil supply system fails to gasoline pump
work 2. The gasoline hose and filter Cleaning
are jammed.
1. The cylinder pads are broken Replacement
2. The valve clearance is poorly Adjustment, repair or replace
adjusted or damaged.
The compression pressure of
3. The intake manifold loosens Tightening
cylinder weakens.
and the air flows in.
4. The pistons, piston rings and Repair or replace
cylinder are worn.
5.2 Insufficient power during the running
The throttle pedal and the throttle Adjustment
valve are inappropriately
adjusted.
The compression pressure of 1. Checks the valves, spark plugs
valve decreases and valve pads for any leakages
2. Cylinder grinding
Insufficient rate during the
The ignition timing is inaccurate. Adjustment
running.
Insufficient supply of gasoline Adjustment or reparation
Insufficiency of air intake Checks the intake system
Air exhaust jam Checks the air exhaust system and
cleans out the carbon deposit
Inappropriate clearance between Adjustment or replacement
the spark plugs or damage
5.3 Piston clicks in the engine
Bearing, camshaft cam and rocker Replacement
arm worn
Crankshaft, connecting rod shaft Repair or replace
There are the pistion clicks heard and piston pins seriously worn.
from the engine. Piston ring damaged Replacement
Inappropriate valve clearance Adjustment
Stop clearing of crankshaft too Adjustment
large.
5.4 Engine overheated
Ignition timing not well adjusted Adjustment
Inappropriate clearance between Cleaning or adjustment
the spark plugs or carbon deposit
The intake manifold loosens and Tightening or cleaning
the exhaust manifold blocked
Insufficient tension of fan tape Adjustment
Insufficient coolant or water pipe Adding orcleaning
blocked.
Engine overheated Inappropriate clearance of water Repair or Replace
pump or damaged
Insufficient oil supply Adding
Oil pipeline blocked or oil pump Cleaning or replacement
damaged
Cylinder pad damaged Replacement
Clutch sliding Repair or Replace
The radiator is blocked by scald Cleaning or replacement
deposit.
5.5 Excessive oil consumption
Failure phenomenon and causes Rroubleshooting

Oil seal of valve duct worn or Replacement
damaged
Excessive oil consumption Oil ring worn or damaged Replacement
The interface of piston ring is not Adjustment
staggered as per provision.
Failure phenomenon and causes Rroubleshooting
Cylinder pad damaged Replacement
Valve and valve duct worn Replacement
Engine overheated, internal Checks the relevant parts and
Excessive oil consumption
pressure increased, a part of exclude them therefrom.
lubricant is discharged through
the vent.
5.6 Noise in the clutch
S/N Failure phenomenon and causes Troubleshooting
1 Release bearing worn or damaged Replacement
2 Output shaft bearing damaged Replacement
3 Clutch hub loosened Repair
4 Crackles existing on the clutchplaten Replacement
5 Platen and diaphragm spring loosened Maintenance or replacement
6 Clutch friction plate soaked with greasy stains Cleaning or replacement
7 Glue stick or spring of clutch damping broken Replacement
VI. Engine sealed for safekeeping and seal removal
6.1 Storage of engine oil seal
1. Drains out the coolant of cylinder body.
2. Wipes out the apparent surface with the cleaning gasoline.
3. Wraps or seals, with plugs, the engine inlet port, In/outlet port of water pipes and all
sensors etc.
4. Puts the engine into the packing case.
6.2 Seal removal of engine
1. Cleans out the outer grease of engine.
2. Adds the oil.
3. Adds the coolant.
4. Removes all plugs.
VII. Engine maintenance
7.1 Maintenance rules
1) Prepares the spare parts kit and part rack used for the detached, disassembled parts. They
have to be disposed in order and marked if necessary to prevent the disorder and
misplacement.
2) Be very careful when overhauling the aluminum alloy parts so as to prevent the damage on
the process surface.
3) Gets ready with adequate auxiliary material so that they are readily accessible during the
overhaul.
4) Where there are the standard tightening moments imposed for the bolts and other fasteners,
the tightening has to be made with the special tool as per the specifieid values.
5) After the overhaul, the deposable parts should be rejected and replaced by new ones.
6) Uses the correct disassemble tools for assembly and disassembly.
7) Refers the maintenance manual during the work.
8) In case of any technique problems difficult to resolve encountered during the overhaul, it is
recommended to consult with our Products Sale Department.
7.2 Materials necessary for the overhaul
The materials listed in the table below are indispensable for the overhaul of the engine.
Therefore, gets them prepared for readily accessible all times. In addition, the specified type
of washing liquid and lubricant should be applied as far as possible.
Table of the auxiliary materials for DA Engine:
S/N Name Inteded use Specification and grade
Mobil Super 9900 or Esso Superflo SJ/CF

1 Oil Oil filling, oil for assembly
5W30
2 Silica gel Oil pump, water pump, oil sump LT5699

Oil pressure switch, water drain
3 Sealant LT243
screw plug, flywheel bolt
4 Sealant Water temperature sensor LT648
5 Silica gel Rear seal shell, crankshaft LT5699
6 Gasoline Unleaded gasoline 93# and higher
7 Sealant Stud bolt LT271
Table of the auxiliary materials for gearbox:

AOS materials Actually used materials and
S/N Assembly position
and Model model
1 Lubricant Mobilith SHC220 or Spartan syn Shift fork
2 Lubricant EP 220 Release bearing
3 Lubricant Input shaft oil seal
Mobil HD80W-90 or Esso Gear
4 Gear oil Gearbox assembly
Oil GX 80W-90
5 Lubricant Shifting block
6 Sealant TB1501 LT480 Air respirator
7 Anti-rust oil Mobil Lama LT or Rust-Ban330 Input shaft
8 Gear oil Mobil HD80W-90 or Esso Gear Input shaft needle bearing
9 Gear oil Oil GX 80W-90 Input shaft needle bearing
10 Sealant TB1303 LT243 Differentialbolt
11 Sealant TB1216 LT5699 Gearbox shell joint surface
Mobil HD80W-90 or Esso Gear
12 Gear oil Control shaft and shifting lever
Oil GX 80W-90
13 Sealant TB1216 LT5699 Control box sub-assembly
Table of the auxiliary materials for cylinder head assembly:

S/N Actually used materials and model Assembly position
Mobil Super 9900 or Esso Superflo
1 Oil Valve head
SJ/CF 5W30
2 Oil Camshaft, rocker arm, rocker arm shaft
SJ/CF 5W30
3 Sealant TB1386D LT271 Stud bolt
4 Oil Camshaft oil seal
SJ/CF 5W30
S/N Actually used materials and model Assembly position
Spark plug guide bush, cylinder
5 Sealant LT962T body/cylinder head
Bowled expansion plug, filler neck
7.3 Signs of the lubricant, sealant and binder
-------------------When the lubricant has no trade mark(lable), it means

multi-puropose lubricant
------------------Sealant and adhesive
-----------------Brake fluid, automatic gearbox fluid or air compression oil
--------------------Engine or gear oil
7.4 Engine inspection tools

Tools Number Name Intended use
When unscrewing or
tightening the bolt(clamps
MB990767 Terminal fork clip the sprocket wheel of
camshaft with the tool
MD998715)
Setting tool for the rear oil For fitting of the rear oil
MD998718
seal of crankshaft seal of crankshaft
Removal and fitting of oil

MD998054 Oil pressure switch wrench
pressure switch
Setting tool for the front For fitting of the front oil
MD998304
oil seal of crankshaft seal of crankshaft
Guided installation for the

Front oil seal guide bush
MD998305 fornt oil seal of crankshaft
of crankshaft
Tools Number Name Intended use
Setting tools for the Fitting of the camshaft oil

MD998713
camshaft oil seal seal
When unscrewing or
tightening the bolt(clamps
MD998719
Pins the sprocket wheel of
or MD998754
camshaft with the tool
MD990767)
Disassemble tool for the

MD998727 Removal of the oil sump
oil sump
Valve spring Compression valve

MD998772
compressor spring
Setting tool for the oil seal Fitting for the oil seal of
MD991671
of valve rod valve rod
Positioning tool of the Removal and fitting of the

MD998780
piston pin piston pin
Guide bush for the

MB991659 Guide bushD removal and press-fitting
of the piston pin.
Compressor of Compression of valve

MD998735
valve spring spring
Locks the flywheel on the

MD998781 Flywheel stopper
fixed position
Wrench for the cylinder Removal and fitting for

MB991653
head bolts the cylinder head bolts
Section III Disassembly of engine
I. Specifications of maintenance
Items Standard value Limit values
Camshaft
Air intake 37.298 36.8
Camshaft height in mm
Air exhaust 37.161 36.66
Diameter of the camshaft journal in mm 44.92544.94
Cylinder head and valve
Surface plainness of the cylinder pad in mm Lower than 0.03 0.1
Total thickness of the cylinder head in mm 119.9120.1
Thickness of valve edge in Intake valve 1.35 0.85
mm Exhaust valve 1.85 1.35
Diameter of valve rod in mm 5.5
Clearance between the valve Air intake 0.020~0.036 0.1
rod and valve duct in mm Air exhaust 0.030~0.045 0.15
Coneangle of valve 45~45.5
Proturding of the valve rod in Intake valve 53.21 53.71
Total length of the valve in Intake valve 111.56 111.06
Free height of the valve spring in mm 50.87 50.37
216/44.2
Load/fitting height of the valve spring in N/mm
588/34.7
verticality of the valve spring Less than 2 4
Contact width of the valve seat in mm 0.9~1.3
Valve duct I/D in mm 5.5
Protruding of the valve duct in mm 23
Extra.0.05 10.605~10.615
Aperture of the valve duct for oversized
Extra.0.25 10.805~10.815
cylinder head, in mm
Extra.0.50 11.055~11.065
Extra.0.3 28.425~28.445
Air intake
Extra.0.6 28.725~28.745
4G13S-7L
Extra.0.3 26.425~26.445
Hole diameter of Air exhaust
the housing Extra.0.6 26.725~26.745
washer for the Extra.0.3 30.425~30.445
oversized valve, 4G18S-7L Air intake
Extra.0.6 30.725~30.745
in mm
Extra.0.3 28.425~28.445
Air exhaust
Extra.0.6 28.725~28.745
Oil pump and oil sump
Tooth top clearance of the oil pump, in mm 0.06~0.18
Clearance of the oil pump, inmm 0.04~0.11
Clearance of the oil pump shell, in mm 0.100.18 0.35
Item Standard value Limit value
Pistons and connecting rod
Reference O/D of the pistons, 4G13S-7L 71
in mm 4G18S-7L 76
st
Lateral clearance of the piston 1 ring 0.03~0.07 0.1
ring, in mm nd
2 ring 0.02~0.06 0.1
st
1 ring 0.20~0.35 0.8
nd
Opening clearing of the piston 2 ring 0.35~0.50 0.8
ring, in mm 4G13S-7L 0.20~0.50 1.0
Oil ring
4G18S-7L 0.10~0.40 1.0
O/D of the piston pin, in mm 18.0
Press-fitting load of the piston pin(at the room
4900~14700
temperature) N
Oil clearance of the crank pin(clearance of the connecting
0.02~0.04 0.1
rod journal), in mm
Clearance of the large head of connecting rod, in mm 0.10~0.25 0.4
Crankshaft and cylinder body
Axial clearance of the crankshaft, in mm 0.05~0.18 0.25
Main journal diameter of crankshaft, in mm 48.0
Journal diameter of connecting rod, in mm 42.0
Main journal clearance of crankshaft, in mm 0.02~0.04 0.1
Surface plainness of the cylinder body spacer, in mm Lower than 0.03 0.1
Overall height of cylinder body, in mm 256

Cylindricity of cylinder body, in mm 0.01
Reference I/D of the cylinder 4G13S-7L 71.0
body, in mm 4G18S-7L 76.0
Clearance of the pistons with the cylinder, in mm 0.02~0.04
II. Removal and breakdown procedure for each part

Removes firstly the starter, clutch and gearbox from the engine.The order of breakdown is
shown as below:
2.1 A/C generator and ignition system
Removal and installation procedures
Removal procedure:
1. Dipstick 9. Crankshaftpulley
2. Dipstick duct 10. Spark plug cable assembly No.1
3. O-RING 11. Spark plug cable assembly No.3
4. Timing belt 12. Spark plug
5. Water pumppulley 13. Camshaft position sensor
6. A/C generator bracket A 14. CPS bracket
7. A/C generator 15. CPS tooth plate
AB 8. Pulley bolts of crankshaft 16. Ignition coil asssembly
Essentials of the removal operation:
A Removal of the crankshaft bolts. Uses the special tool shown in Figure to lock up the
flywheel or drive plate on the relevant places, then unscrews the crankshaft bolts.
Essentials for the installation operation
A CPS Bracket installation
Shown as in Figure., applies the field-shaping curl spacer in thickness of 3mm (FIPG).
Special sealant: LT5699
B Installation of the crankshaft bolt. Uses the special tool shown in figure to lock up the
flywheel or drive plate on the relevant position, then tightens the crankshaft bolts
2.2 Timing belt

Removal procedure
1.Timing belt upper cover B A 7.Camshaft timing gear bolt
2. Timing belt lower cover 8.Camshaft timing gear
A C 3. Timing belt 9.Engine bracket
B 4. Tensioner spring
B 5. Timing belt tensioner
6. Crankshaft timing gear assembly
Essentials for the removal operation:
A Removal of the timing belt /tensioner spring/timing belt tensioner:
(1) Clamps the entended end of the tensioner spring with the pliers, removes it from the
stopping block of oil pump shell, then removes the tensioner spring.
(2) Removes the timing belt tensioner.
(3) If the timing belt is intened to be reused, draws an arrow with the chalk on the belt to
show the turning direction prior to the removal. This will ensure the correct installation of
timing belt when it is reused.
B Removal of the timing gear bolt of camshaft
(1) Uses the special tool shown in figure to lock up the timing gear of camshaft on the
relevant position.
(2) Unscrews the timing gear bolts of camshaft.
Essentials for installation operation:

A Installation of the timing gear bolts of camshaft
(1) Uses the special tool shown in Figure to lock up the timing gear of camshaft on the
relevant position.
(2) Tightens the timing gear of camshaft up to the specified moment.
B Installation of the timing belt tensioner /tensioner spring.

(1) Locks up the timing belt tensioner on the position shown in Figure
Tensionner of
the timing belt
(2) Hooks the one extended end of tensioner spring on the clevis part of the timing belt
tensioner and fits the tensioner on the oil pump shell.
(3) Clamps the other extended end of tensioner spring and hooks it on the lug of oil pump
shell shown as in Figure
(4) Removes the timing belt tensioner as shown in figure and tightens the belt in time.
C Installation of the timing belt
(1) Aligs the timing mark on the timing gear of camshaft with that on the cylinder head.
(2) Aligs the timing mark on the timing gear of camshaft with that on the front shell.
(3) Keeps the tension side of timing belt tightened, and fits orderly, the timing belt into the
timing gear of crankshaft and tensioner pulley.
Timing gear of the

camshaft
Belt pulley of
tensionner
Timing gear of
the crankhaft
(4) Unscrews the fitting bolts of tensioner pulley by the turn of 1/41/2, enabling the tension
effect of tensioner springto act on the timing belt.
(5) Turns the crankshaft for two cycles in the normal direction of rotation (clockwise) to
check if the timing marks is properly aligned.
Attention: by this method, the tension effect acts evenly on the timing belt by the driving
moment of the crankshaft. The crankshaft has to be turn as per the above-said direction
instead of turning counterclockwise the crankshaft.
(6) Tightens the fixing bolts of tensioner pulley.
2.3 Fuel control system
1. Engine sub-assembly 2. Throttle body assembly

3. Throttle spacer 4. Bolted spacer
5. Bolted spacer 6. Harness bracket
7. Flange bolt A 8. Oil rail assembly
Essentials for installation operation
A Installation of oil rail assembly
(1) Prior to the injector installation, a layer of the clean oil should be applied on the surface of
the O-rubber ring for easy installation.
(2) Be careful not to damage the O-ring when fitting the injector.
(3) Fixes up the 8 with the bolt 5 on the intake manifold 1.
2.4 Water pump and cooling water hose
1. Cooling waterhose 7. Thermostat shell

2. Cooling waterhose 8. Thermostat spacer
E 3. Water temperaturesensor B 9. Water inlet pipe
D 4. Water thermostat B 10. O-RING
5. Water inlet pipe joint B 11. O-RING
C 6. Thermostat A12. Water pump essentials for installation operation
A Installation of water pump
Applies the 3mm field-shaping space (FIPG) on the mounting surface.
Specified sealant: LT5699
B Installation of O-ring/water inlet pipe
Replaces the O-ring of water inlet pipe with a new one, then applies the coolant on the O-ring,
so that it can be easily inserted in to the shells of water pump and thermostat.
Attention:
1. Be sure not to apply the engine oil or other greasy substances on the O-ring.
2. The water pipe behind the thermostat shell has to be firmly fitted.
C Installation of thermostat.
When fitting up the thermostat, the highest position of the beat vavle should be used.
D Installation of water thermostat.

If the water thermostat is intended to be reused, the specified coolant should be applied on its
threads.

D Installation of water temperature sensor
If the water temperature sensor is intended to be reused, the specified coolant should be
applied on its threads.

2.5 Intake manifold and exhaust manifold
Removal procedure
1. Engine sub-assembly 7. Intake manifold bracket
2. Intake manifold 8. Bolted spacer
3. Intake manifold spacer 9. Bolted spacer
4. Bolted spacer 10. Engine lugs
5. Nut 11. Air intake temperature pressure sensor
6. Spring spacer 12. Bolted spacer
13. Bolted spacer 14. Vacuum booster joint
15. Bolt spacer assembly 16. Canister control valve bracket
17. Canister control valve 18. Exhaust manifold spacer
19. Exhaust manifold 20. Flat spacer
21. Nut 22. Flat spacer
23. Nut 24. Oxygen sensor
25. Thermal shield of air exhaust 26. Flange bolt
27. Bolted spacer
2.6 Rocker arm and camshaft
Removal procedure
1. Air hoses C 11. Rocker arm A
2. Oilfiller cap 12. Rocker arm B
3. PCV VALVE A 13. Rocker arm shaft
4. PCV spacer B 14. Governing screw
5. Rocker chamber cover 15. Adjusting nut
6. Rocker chamber cover pad 16. Rocker arm C
D 7. Oil seal B 17. Rocker arm shaft
8. Oil seal A 18. Governing screw
C 9. Rocker arm and rocker arm shaft assembly(air intake) 19. Adjusting nut
C10. Rocker arm and rocker arm shaft assembly(air exhaust) 20. Camshaft
A Installation of governing screw.
Places the screw into the rocker arm for a while. Puts it inside and keeps the the
bottom of screw in line with falling edge of rocker arm or slightly protruding (less
than 1mm)).
B Installation of rocker arm shaft
(1) Places the large inclined plane toward the side of timing belt.
Note: there are 8 oil holes on the rocker arm shaft of air intake valve.
(2) Faces the oil holes side of rocker arm shaft on the cylinder head.
C Installation of rocker arm/rocker arm shaft assembly
When assembling the rocker arm and rocker arm shaft, attentions should be paid on
the identification sign. Then, fits this assembly on the cylinder head.
Side of the timing belt
Identification sign
D Installation of camshaft oil seal

Drives the oil seal into the cylinder head with the tool shown in Figure
2.7 Cylinder head and valve
Removal procedure
A D 1. Cylinder headbolt 9. Intake valve
2. Cylinder head asssembly 10. Exhaust valve
3.Cylinder pad 11. Cylinder head
B C 4. Lock pin
5. Intake valve spring holder
B 6.Valve spring
C A 7.Valve duct
8.Valve housing washer
Essentials for removal operation:
A Removal of cylinder head bolts
Unscrews the cylinder head bolts with the special tool shown in Figure
B Removal of lock pin

Attaches the labels on the knocked down valves, springs and other parts, and marks out their
cylinder number and position for reassembly. Safekeeps those parts.
C Removal of valve oil seal

A Installation of valveoil seal
(1) Installation of valve spring seat
(2) Fits the new oil seal of valve with the special tool shown in Figure
Attention:
1. The valveoil seal can be reused.
2. The correct special tools has be used for installing the valveoil seal. Incorrect
installation may cause the oil leakage when passing through the valve guide bush.
B Installation of valve spring
When fitting up the valve spring, keeps the end to be painted position at the side of rocker
arm.
Spring seat of valve

Printing side
Oil seal of valve rod
Spring seat of valve

C Installation of lock pin
D Installation of cylinder head bolts

(1) Prior to reuse the cylinder head bolt, checks if its nominal length has exceeded the
specified limit value. If the measuring result is beyond the limit value, the bolt should be
replaced.
Limit values: 103.2mm
(2) Fits up the spacer as shown in Figure
(3) Applies the engine oil on the spacer of bolt thread.

(4) Tightens the bolt as per the order shown in figure until all bolts have reached the moment
49Nm(5kgf.m)
Side of timing belt
(5) Fully unscrews the bolt

(6) Retightens the bolt as per the order shown in figure until all bolts have reached the
moment 202Nm
(7) Marks the plaint signs on the cylinder head bolts and cylinder head(shown in figure )
Print mark
(8) Each bolt is screwed by a plus 90 as per the tightening order.
(9) Each bolt is tightened by 90 to check whether the paint mark on the bolt head is aligned
with that on the cylinder head.
Attention: If the tightening angle of bolts is less than 90, it is impossible for them to have
sufficient power to fasten theif the tightening angle of bolt is larger than 90, they should be
removed down and refixed.
(10) If the old cylinder head bolts have been replaced during the maintenance, the overhaul
should be carried out as per the sequence (2)~(9).
(11) If no used cylinder head bolts have been replaced, the overhaul should be effected
following the order of (2),(3),(6),(7),(8) and(9).
2.8 Oil pump and oil sump
A Removal of oil sump
(1) Removes the fitting bolts of oil sump.
(2) As shown in figure drives the special tool between the oil sump and cylinder body.
(3) Taps the side of special tool and makes it move along the sealing side of oil sump
/cylinder body, than removes the oil sump.
A Installation of front oil seal shell (oilpump shell)
(1) Cleans out the sealant painted surface of cylinder body and front oil seal shell.
(2) Applies the 3mm field shaping curl spacer on the overall periphery of the oil sump fange.

B Installation of front oil seal
(1) Places the special tools in front of the crankshaft, and applies engine oil on its pheripher.
(2) Applies the engine oil on the sealing lips, then pushes by hands the oil seal along the guide
bush until it touches the oil seal shell. Taps the oil seal with the special tool to make it in
position
C Installation of oil sump

(1) Cleans out the fitting surface of the cylinder body and oil sump.
(2) Applies the field-shaping curled pearl spacer on the overall pheriphery of the oil sump
flange.
D Installation of oil drain plug spacer
Uses the new oil drain plug spacer, fits up the spacer as showin in figure
Attention: If the spacer is fitted in a wrong direction, it will cause the oil leakage.
Side of printing shell
E Installation of oil filter

(1) Cleans out the oil filter mounting surface on the oil pump shell.
(2) Applies the engine oil on the O-ring of oil filter.
(3) Tightens the oil filter until the O-ring sets on the mounting surface, then screws again the
oil filter by one cycle to tighten the moment up to 12~20Nm.
Attention: Th oil filter has to be tightened with the filter pliers sold in the market. If the filter
is tightened with hand, the leakage will occur due to the insufficient tightening moment.
2.9 Pistons and connecting rod
Removal procedure
G 1. Connecting rod nut C 7. 2nd piston ring
A F 2. Connecting rod cap B 8. Oil ring
E 3. Connecting rod bush B A 9. Piston pin
D 4. Pistons and connecting rod assembly 10. Pistons
5. Connecting rod bush 11. Connecting rod
st
C 6. 1 piston ring 12. Connecting rodbolt
A Removal of onnecting rod cap
In favor of the re-installation, marks the cylinder number on the large head side of connecting
rod.
Cylinder no.
B Removal of piston pin

(1) Inserts the tappet from the side of the arrow sign in front (special tool), tten fits the guide
bush D.
(2) Puts upward the sing in front of piston, fits the pistons and connecting rod assembly on the
foot mounting of piston pin (special tool).
(3) Presses oug the piston pin with a press.
Push rod
Front sign
Front sign
Guide bush D
Base
Attention: After the piston pins removed, puts the pistons, piston pins and connecting
rod together. Do not put the pistons, piston pins and connecting rod of each cylinder
together.
A Installation of piston pins
(1) Measures the following lenghs (shown in figure )
A: Outer size between the pistons bosses
B: Inner size between the pistons bosses
C: Length of piston pin
D: Thickness of the small head of connecting rod
(2) Fills the measured values into the following formula:
( A C ) ( B D)
L=
2
Link rod
Piston pin
Piston
(3) Inserts the tappet (special tool) into the piston pin, then fits the guide bush A(special tool).
(4) When the pistons and connecting rod are installed, the signs in front of them should be
located in the same side.
(5) Applies the engine oil on the outer circle of piston pin.
(6) Started from the guide bush A, presses theguide bush A, piston pin and tappet into the side
of signs in front of the pistons.
(7) Screws the guide bush B into the guide bush A. the clearance between both guide bushes
is 3mm plus the value L approached from the calculation in Step 2.
Guide Guide
bush B bush A
(8) In case where the sign in front of the piston is down, fits the pistons and connecting rod on
the foot mounting of piston pin.
(9) Fits the piston pin by a press. If the load I overrated, replaces the piston pins, piston
assembly and connecting rod or both replaced.
Standard value: 1000500 kg.f
Push rod
Piston pin
Front sign
Front
sign
Guide-bush A
Base
Guide-bush B
A Installation of oil ring

(1) Fits up the spacing ring of oil ring into the piston ring groove, then fits the upper and
lower steel rings.
Steel
ring
Spacing
ring
Attention:
1. The spacing ring and steel ring may be fitted in any of directions. There is no
difference between the upper and lower steel rings
2. Color codes used for the spacing ring and steel ring sizes are shown as follows:
Sizes Colors
Standard None
Extra, 0.50mm Blue
Extra, 1.00mm Yellow
(2) In order to fit up the steel ring, fits the one end of steel ring into the groove as shown in
figure, then press-fits the other parts into the places.
Side of steel ring
Attention: Do not fit the steel ring with the expander of piston ring, otherwise they are
likelyto be broken.
(1) After the steel ring fitted up, checks whether they are slidable in both directions.
C Installation of the 2nd and 1st piston rings
Fits the 1st and 2nd piston rings with the expander of pistion ring. Their dentification signs
should face upward (top of the piston).
Identification sign:
The 1st piston ring: 1T
The 2nd piston ring: 2T
Expander of
pistion ring
Attention:
The following signs of size are marked on the piston rings:
Sizes Size sign
Standard None
Extra, 0.50mm 50
Extra,1.00mm 100
ID sign of 1T
ID sign of 2T Sign of size
1st ring
2nd ring
D Installation of pistons and connecting rod assembly

(1) Applies the oil on the pistons, piston rings and piston pins.
(2) As shown in figure ains at the apentures of the air ring and oil ring (steel ring andspacing
ring).
Steel ring 1st ring
Piston pin
2nd ring and loop Steel ring
(3) Ains the arrow sign in front of the top of piston at the side of timing belt, from the upper
side of cylinder, press-fits the pistons and connecting rod assembly into the cylinder.
(4) Presses tightly the piston ring with the suitable pressing tool of piston ring, then press-fits
the pistons and connecting rod together into the cylinder. Do not knock forcely the pistons,
otherwise, the piston ring will be broken and the connecting rod journal crackled.
E Installation of connecting rod bearing

Please confirm the identification signs on the crankshaft and connecting rod as shown in
figure selectsthe bearings as per the following table.
Crankshaft identification sign Identification sign of connecting rod Identification sign of bearings
White 1
I.Yellow None 1
Yellow 2
White 1
II.None None 2
Yellow 3
White 2
III.White None 3
Yellow 3
Col.code position Col.code position 1#

4# 1# 4#
3# 3#
2# 2#
ID sign position
ID sign position
2# 4# 2# 4#
1# 3# 3#
1#
4G13S-7L Crankshaft 4G18S-7L Crankshaft
ID color
F Installation of connecting rod cap
(1) Aimiing at the sign made at the time of break-down, fits the connecting rod bearing cap on
the connecting rod. If the connecting rod is a new one, there is no sign, the bearing locking
notches have to be on the same side.
Cylinder No.
Notch locking
(2) Checks whether the lateral clearance of the large head of connecting rod is conform to the
provisions.
Standard value: 0.100.25mm
G Installation of connecting rod nut

Attention: If the cylinder head has been fitted prior to the installation of connecting rod nuts,
the spark plugs have to be removed first.
(1) The connecting rod bolts and nuts are tightened by the tension method of plastic
deformation. Prior to the reinstallation, the bolts have to be checked to see there are any parts
crackled. In order to do such, screws with the hand the nut for a full length of thread. Only
when the nut has been screwed fully down to the end of thread than can prove there are no
scratches on the thread part, otherwise the bolt has to be replaced.
(2) Before the nut is installed, applies the engine oil on their threading part and mounting
surface.
(3) Fits the nuts on the bolts and screws then Tightlu. Afterward, the nuts have to be tightened
alternatively to ensure the correct installation of connecting rod cap.
(4) The tightening moment of nuts: 16.720Nm.
(5) As shown in figure the paint mark has to be made on the top of each nut.
Printing sign
Printing
sign
Bolt
Nut
(6) Starting from the paint mark on the nut, turns clockwise toward the angle 90~94, and
makes the paint mark on the bolt.
(7) Turns the nut until it is aligned with the paint mark on the bolt and that on the nut.
Attention:
1. If the turning angle of nut is less than 90, the fastening power of connecting rod cap will
be insufficient.
2. If the turning angle of nut is more than 94, they should be fully unscrewed, and renews the
tightening steps.
1.10 Crankshaft and cylinder body
1. Flywheelbolt 7. Lower partition B 13. Main bearing (lower)
3. Flywheel D 8. Crankshaft rear oil seal 14. Crankshaft
6. Upper partition 9. Crankshaft rear seal shell B 15. Main bearing (Upper)
C 11. Bearing cap bolt C 12. Main bearing cap AA16. Oil pressure switch
17. Cylinder body
A Removal of oil pressure switch
(1) Disengages the terminal from the oil pressure switch.

(2) Removes the oil pressure switch with special tool
Attention: The sealant is painted on their threads. When the oil pressure switch is removed,
please be careful not to bend it.
Installation operating essentials
A Installation of oil pressure switch
Applies the specified sealant on the threads, then fits up the oil pressure switch with the
special tool as shown in Figure
Pushing direction
Specified sealant
Attention:
1. When the sealant is applied, do not let the sealant beyond the end do thread.
2. Do not overtighten the oil pressure switch. Moment: 15~22Nm.
B Installation of crankshaft bearing
(1) Selects the bearings according to the identification sign or color code of crankshaft (refer
to the following table). If they are not identied, the diameter of the crankshaft should be
measured and the suitable bearing selected to match it.
Aperture of the cylinder
Crankshaft journal Bearing
bearing holes
Color Identification
Range Diameter of journal Identification sign Identification sign
code sign
0 1
1 Yellow 1 47.995~48.000 1 2
2 3
0 2
2 None 2 47.988~47.995 1 3
2 4
0 3
3 White 3 47.982~47.988 1 4
2 5
Class impact print
Axile diameter 1 Axile diameter 2
Class impact print
Axile diameter 3 Axile diameter4

2nd main shaft diameter
3rd main shaft diameter
1st main shaft diameter
4th main shaft diameter

2nd main shaft diameter

Class impact print
3rd main shaft diameter 5th main shaft diameter

Axile diameter 1
Axile diameter 4
Axile diameter 2
Axile diameter 3
4G18S-7L Crankshaft 4G13S-7L Crankshaft

Side of timing belt
Hole dia.of cylinder journal
The shaft diameter level is classified as 5, 4, 3, 2 and 1 counted from front to back.
(2) The identification sign representing the bearing aperture of cylinder is the position
engraved by the number 1 in front of the engine. The selection and installation of bering have
to be made on the basisi of these identification signs have to be.
(3) On the basis of the verification of identification signs according to the steps (1) and (2),
the bearings are to be selected from the above table.
The example is given as below:
1. If the measured result of a journal is 48.000mm, it corresponds the class 1 in the above
table.
2. If the identification sign of the bearing aperture of a cylinder is the number, the bearing
with the identification sign 2 should be choosen.
(4) Except the intermediate bearing, all bearings are grooved. The intermediate bearings are
fitted with spport lugs instead of the grooves. The upper parts of the intermediate bearings are
identical.
(5) All lower bearings are without grooves.
Groove
Grooveless
Upper axle bearing

(1#,2#,4#and 5#)
lower axle bearing
Grooveless
(1#,2#,4#and 5#)
Up/lower axle bearings (intermediate)

C Installation of main bearing cap
(1) There the number and an arrow on the surface of each main bearing cap. Started from the
side of the timing belt, the bearing caps are to be fitted following the number sequence. The
arrow has to aim at the side of the timing belt.
The arrow refers to Axle bearing cap no.
the front of engine
(2) After the bearing fitted up, the axial clearing of crankshaft is to be measured. If the
measured value exceeds the specified limit, the crankshaft bearing should be replaced.
Standard value: 0.05-0.18mm

D Installation of rear oil seal
Press-fits the rear oil seal with the special tool as shown in Figure
Oil seal
Oil seal shell
2.4 Inspection and maintenance operation

1) A/C generator and ignition system
2) Timing belt
1. Timing belt
Checks carfuly the timing belt. In case of the following defections shown, it should be
replaced by a new one:
(1) The vulcanization on the opposite side (the rubber in reverse is smooth and inelastic,
which is hardened to the extent that no traces are left when scratching with nails).
(2) The crackles are shown on the reverse side of rubber.

(3) The canvas is torn and (or) separated with the rubber.
(4) The tooth roots are crackled.
(5) The lateral sides of belt are crackled.
Crack Crack
Separated
Crack side
Tooth root with crack
(6) The belt sides are abnormally worn .
Edged fillet
Abnormal wear
(Exposed core)
Attention: If the belt sides are as sharp as the knif cutting, it should be considered as
normal.
(7) Abnormal wear on the teeth
Initial phase:
(Canvas fibers loosened, rubber destructed, white faded, canvas texture unidenfied)
Final phase:
Canvas worn up, rubber exposed(the tooth width dimished)
Worn cancas and exposed rubber
Toothless
(8) Teeth disappeard

2. Tensioner pulley
Checks if the pulley rotates steadily and there are any clearances and abnormal noise. When
necessary, one or two pulleys should be replaced.
3) Fuel and emissioncontrol system

4) Water pump andcooling water hose
5) Intake manifold and exhaust manifold
6) Rocker arm and camshaft
1. Camshaft
Check of the cam height. If the height is over the limit value, the camshaft should be replaced.
Height limit of Air intake 36.8

camshaft, in mm Air exhaust 36.666
7) Cylinder head and valve
1. Cylinder head
(1) Prior to clean up the cylinder head, check it to see if there are any water/air leakage, any
crackles and other damages.
(2) Eliminates all oil, water scales, sealants and carbon deposits. After the oil rail cleaned,
blows the compressed air to the oil rail to ensure it is free of jam.
(3) Checks with the ruller or clearance gauge to see if there are any deformations on the
surface of cylinder head spacer. If the degree of deformation exceeds the specified limit value,
the surface of spacer has to be ground according to the specification.
Standard value of spacer surface deformation: less than 0.03mm
Height of cylinder head (new): 1200.1mm
Attention: The grinding margin allowable for the fitting surface of cylinder head and
cylinder body is not larger than 0.2mm.
2. Valve
(1) Checks the valve surface to see if it is in correct contact. If the contact is not uniform or
complet, the surface of valve seat should be refixed.
(2) If the edge thickness is less than the fixed value, the valve should be replaced.
Contact
(within the
surface center)
Edge thickness
Standard value: Limit values:

Intake valve: 1.35mm Intake valve: 0.85mm
Exhaust valve: 1.85mm Exhaust valve: 1.35mm
(3) Total length of measured valve. If the measured result is less than fixed value, the valve
should bereplaced.
Standard value: Limit values:
3. Valve spring
(1) Measurement of the free height of valve spring. If the measured result is less than fixed
value, the valve spring should be replaced
Standard value: 50.87 Limit values: 50.37
(2) Measurement of the vertical height of valve spring. If the measured result is less than
fixed value, the valve spring should be replaced
Standard value : 2 Limit values : 4
Verticality
Free height
4. Valve duct
Measurement of the clearance between the valve guide bush and valve rod. If the clearance
exceeds the limit value, one or two parts should be replaced.
Standard value :
Intake valve guide bush: 0.0200.036mm
Exhaust valveguide bush : 0.0300.045mmm
Limit values :
Intake valve guide bush : 0.10mm
Exhaust valveguide bush : 0.15mm
Valce duct
Valce rod O/D

Valce duct I/D
3. Valve seat
Fits up the valve, then measures the protrusion height between the end surface of valve rod
and surface of valve spring seat. If the measured result is less than fixed value, the valve seat
should be replaced.
Standard value: Limit value:
End face of valve rod
Extruding height of valve rod
Face of the valve spring seat
Operating essentials for the valve seat correction

(1) Prior to correct the valve seat, checks the clearance between the valve guide bush and
valve. When necessary, the valve duct should be replaced.
(2) Corrects the valve seat with the suitable special tools or valve seat grindert to reach the
specified width and angle of seat surface.
(3) After the valve seat revised, grinds the valve and valve seat with grinding paste. Afterward,
checks the flange height of valve rod (refer to the previous check procedure of valve seat).
Operating essentials for valve seat replacement
(1) To reduce the wall thickness, cuts out the replaced valve seat from the inner side, then
removes the valve seat.
Cut off
(2) Rebores the hole of valve seat on the cylinder boring head to match it with the
selected extra diameter of valve seat.
Aperture of intake valve seat (Extra. 0.3mm)
Intake valve 4G13S-7L : 28.425-28.445mm
Intake valve 4G18S-7L: 30.425-30.445mm
Aperture of intake valve (Extra. 0.6mm)
Aperture of exhaust valve seat (Extra. 0.3mm)
Exhaust valve 4G13S-7L: 26.425-26.445mm
Aperture of exhaust valve seat (Extra. 0.6mm)
Heigh of the valve

seat
I/D of extra.aperture
(3) Prevents the cylinder head holes from being grazed by the valve seat cooled by liquid
nitrogen prior to assembly.
(4) Corrects the valve seat to match it with the specified width and angle(refer to the operating
essentials of valve seat)
Operating essentials for the valve duct replacement
(1) Pushes out the valve duct with a pressing machine from the side of cylinder body.
(2) Rebores the hole of valve duct on the cylinder boring head to match it with the extra-sized
valve duct .
Attention: Do not fit the valve guide bush of same size
Aperture of the valve duct:
Extra,0.05: 10.605-10.615mm
Extra,0.25: 10.805-10.815mm
Extra,0.50: 11.055-11.065mm
(3) Press-fits the valve duct until its flange height reaches the fixed value.
Standard value: 23.0mm
Extruding heigh
Attention:
1. The valve duct has to be fitted in from the upper side of cylinder head.
2. The duct length on the air intake side is different from that on the air exhaust side.
3. After the duct valve fitted in, inserts the new valve and checks if it slides smoothly.
8) Pump and oil sump
1. Pump
(1) Fits the rotor into the front cover.
(2) Checks the tooth top clearance with the thickness gauge
(3) Checks the lateral clearance with the ruler and clearance gauge.

(4) Checks the shell clearance with the clearance gauge.
Standard value: 0.100.18mm Limit values: 0.35mm
9) Pistons and connecting rod

1. Piston ring
(1) Check of the piston ring clearance. If the clearance exceeds the specified limit, the
ring/pistion or both of them should be replaced.
Standard value: Limit values :
st
The 1 ring: 0.030.07mm The 1st ring: 0.1mm
The 2nd ring: 0.020.06mm The 2nd ring: 0.1mm
(2) Places the piston ring into the cylinder hole, pushes it down with the piston. The top of
piston has to be used to contact the piston ring, so as to form an anle 90 between the ring and
the cylinder. Then measures the open clearance with the clearance gauge. If the open
clearance is too large, the piston ring has to be replaced.
Standard value:
The 1st ring: 0.200.35mm
The 2nd ring: 0.350.50mm
Oil ring 4G13S-7L: 0.200.50mm
Oil ring 4G18S-7L: 0.100.40mm
Limit value: The 1st ring: 0.8mm

The 2nd ring: 0.8mm
Oil rings 4G13S-7L and 4G18S-7L: 1.0mm
Push in with the piston
Pistion ring Opening clearance
2. Clearance of the connecting rod bearing (plastic wire gauge)

(1) Wipes out all oil from the connecting rod journal and connecting rod bearing.
(2) Places on the connecting rod journal, the plastic wire gauge, which is cut in same width
with the bearing. The plastic wire gauge has to be sited in the center of the connecting rod
journal and parallel with its axial line.
(3) Gently places the connecting rod cap on its position and tightens the bolt till its specified
moment.
(4) Removes the bolt andslowly detaches the connecting rod cap.
(5) Measures with the marker printed on plastic wire gauge, the extruded part of the plastic
wire gauge at the widest point.
Standard value : 0.020.04mm
Limit values : 0.1mm
10) Crankshaft and cylinder body

1. The clearance of crankshaft can be easily measured out with the plastic wire gauge. In
order to measure the clearance of crankshaft with the plastic wire gauge, the procedure below
should observed:
(1) Wipes out all oil in or on the surfaces of the crankshaft journal and bearing.
(2) Fits the bearing.
Plastic wire guage
(3) Cuts the length of plastic wire gauge into that matching with the width of bearing.
Then places it on the journal along the axial line of journal.
(4) Softly fits the bearing cap of crankshaft and tightens the bolt till the specified moment.
(5) Removes the bolt and softly detaches the cap form the crankshaft bearing.
(6) Measures the extruding part of the plastic wire gauge with the ruler printed on the plastic
wire gauge bag.
Limit values: 0.1mm
Fillet rolling area
Attention: The connecting rod journal of crankshaft and main journal have
been subject to the rolling process, it is unnecessary to reduce the size by the
machine tool.
2. Cylinder body
(1) Vusually checks the crackles, rust and corrosion, and examins the cylinder body with the
defection tester. Repairs the defections as much as possible or replaces the cylinder body.
(2) No spacer debris and other dyed stuff are allowed on the top surface. Checks the
deformation on the top of cylinder with the ruler and clearance gauge.
Standard value: less than 0.03mm
Limit value: less than 0.1 mm
(3) Checks if there are signs of cylinder crackles or scors on the cylinder wall. If the defection
is distinct, all cylinders should be bored to the extra size or replaced.
(4) Measures the aperture of each cylinder and the cylindricity with the cylinder gauge. If any
of the cylinders is seriously worn, it should be bored to the extra size and the piston and
piston ring replaced accordingly. The measuring points are shown as below.
Standard value:
Cylinderaperture: 71.0mm(4G13S-7L)
76.0mm(4G18S-7L)
Cylindricity: less than 0.01mm
3. Boring hole of cylinder

(1) All extra-sized pistons should be determined as per the cylinder with the max. aperture
(2) Extra pistons with the following extra sizes: 0.25mm, 0.50mm, 0.75mm and 1.00mm.
Piston diameter for measurement. After the cylinder bored, the clearance between the piston
and cylinder has to meet the standard value. The points shown in Figure should be used to
measure the diameter of pistons
Sealant
application
Piston O/D
(3) Calculates the boring size according to the diameter of piston.

[ Boring size]=[Piston O/D][Clearance between the Piston and Cylinder(0.02
0.04)mm][Grinding Marge(0.02mm)]
(4) Bores each cylinder to the calcultated boring size. Attention: In order to prevent the
heating deformation, please proceed with the cylinder boring as per the following order: 2nd
cylinder, 4th cylinder, 1st cylinder, and 3rd cylinder.
(5) Grinds the cylinder to the final process size(piston O/Dclearance between the piston and
cylinder )
(6) Checks the clearance between the piston and the cylinder.
Section III OBD diagnosis and maintenance

The on-board diagnostic system (hereafter refered as to OBD) is referred to a diagnosis
system which is integrated in the engine control system and able to monitor and effect the
failure parts of exhaust emission as well as the engine state of primary performance. It has the
function of identifying, saving and dislaying the failure information through the
self-diagnostic malfunction indication lamps (MIL).
To guarantee the durability of the emission control performance during the use of vehicle, In
China, it is clearly stated in the Contaminant Emission Limits of Light-Duty Vehicles and
Measure Method (Phases III and IV in China)that All vehicles have to be fitted with OBD
system, which is able to ensure the identification of worsen of failure parts during the whole
service life of vehicle.
When the vehicle fitted with the OBD system is maintained, the service men are able to
rapidly and accurately locate the failure parts through the diagnostic set, which largely
increases the maintenance quality and efficiency.
The model Foton MP. Midi is equipped with the Kingtec Failure Diagnostic Set.
The OBD technology is involved with many brandnew concepts. The following pages will be
contributed to the introduction of same basic knowledge relevant to the OBD technology, so
as to facilitate the understanding of the follow-up content.
I Failures
Once the following cases are detected by the OBD system, they are considered as Failures.
The conversion efficiency of catalytic converter decreases, and the emissions exceed the
OBD value.
The engine catches fire, the contaminants of air exhaust will surpass the OBD value, or
cause the catalyst temperature too high or damaged.
The oxygen sensor damaged or aged to the extent that the contaminants of air exhaust
will be higher than OBD value.
The parsts connecting the ECU and relevant to the emission are ineffective, and possibly
cause the contaminants of air exhaust over the OBD value.
The power train parts connecting the computer, including the abnormal circuit
communication of any sensors able to achieve the monitoring functions nitoring
functions.
1. Troubleshooting
After detecting the failure, the OBD system will proceed the following steps according to the
failure conditions:
By matching (lighten, flash or flame out) failure indicator.
In the ECU(Addition, Update and deletion of the relevant failure information), these
information can be accessed by the standard diagnostic set through the standard
diagnosis interface.
(1) Failure conditions
The failure process of the OBDsystem varies depending to the fault conditions. In order to
better understand the failure states,
Two concepts of the failure as Confirmation and Restoration have to be clarified.
The confirmation of failure is referred to the process from the initial discovery by the OBD
system of the failure to the confirmation by system and MI trigger as per the relevant strategy.
A failure prior to be confirmed is known as the Random Failureand then the Identified
Failuresafter it has been confirmed. In general, there are two method of confirmation of
failure:
The failure has been detected by three operating cycles of detection.
The alleged operating cycle refers to the process including the engine startup, relevant
operating duty (the failure of vehicle if any should be detected) and flame out of engine.
the most failures relevant to the emission are to be confirmed by this process.
The time, where the detected failure continues to exit, is more than 2.5s.
For the more reliable diagnosis function, this process will be applied, e.g. speed sensor
diagnosis.
The restoration of failure is referred to the fact, where the OBD system detects no existence
of failure after the failure has been eliminated. The failure restoration is also a process of
confirmation. In terms of the random failure. After the failure detected by the OBD has been
restored, the record of failure will be immediately cleaned upIn terms of the confirmed
failure, Only no such failure has been detected by three consequent operating cycles that the
OBD system can confirm the restoration of the failure, then operates accordingly the failure
indicator and failure according to the failure resolution strategy .
Depending to whether the failure has been confirmed, restored and restored by confirmation
or not, the failures can be devided into the following status:
Confirmed
Confirmed but
Random and Random and Confirmed and with
Fault condition restoration not
non-confirmed confirmed not restored restoration
confirmed
confirmed
Whether found

by detection
Whether

restored
Whether

confirmed
Whether

restored
Whether the
restoration
confirmed
(2) Failure Processing Strategy
The followings are the failure processing strategies by the OBD system of different failure
status, which are established according to the regulation and the characteristics of failure part
and system.
Fault condition MI CONTROL Failure information memory operation
Continuously monitored failure code is output
Random and through the Mode 7.
The MI state is not changed
non-confirmed Non-continuous monitor result is output
through the Mode 6.
Random and Cleans out the failure information stored
The MI state is not changed
restored in the ECU memory.
Fault condition MI CONTROL Failure information memory operation
MI lamp of the failures The information of failure codes and its
relevant to the emission corresponding blocked frames are output
activated. through the Mode 2.
Failure confirmed
Emission not affected, but The failure codes are output through the
but not restored
the failure needed for repair Mode 3.
yet
doesnt activate the MI.
Catch-fire failure of the
damaged catalyst flashes MI.
Failure confirmed
prior to the
The MI state is not changed.
restoration
confirme
If the same failure after delected, doesnt appear
Failure confirmed
for more than 40 cycles of engine preheating
after the
MI deactivated. operations, this failure code is to be cleaned out,
restoration
including the information of travel distance since
confirmed
the failure dislay and blocked frames.
(3) Failure indicator(MI)
MI refers to a failure indicator, which can give hints to the driver when the MI is connected
with any of the parts relevant to the emission of the diagnosis system or when the OBD
system fails per se.
In general, MI are the lamps which can display on the dashboard and whose form is consistent
with the standard.
The activation of MI lamps complies with the following principle:
When the ignition switch is turned on and the engine has not started up or run, MI will
lighten.
If the confirmed failures relevant to the emission (except the catch-fire failures caused
by the catalyst damage) already exist in the system, the OBD system will light up the MI
lamp to remind the driver for check.
Once the engine caught on fire meets the level specifield by the manufacutrer, to the
extent that the catalytic converter risks to be burnt out, MI will immediately flash at the
frequency of 1Hz.
The deactivation of MI lamps(goes out) follows the principles below:
After engine started, MI will go out in 3s if no failures have been detected before.
If the fire rate of engine able to destroy the catalytic converter doent exist anymore or
the fire rate of engine is not to such an extent as to damage the catalytic converter after
the engine speed and load have been changed, MI should be switched to the original
state prior to the activation.
For all of other failures, during three consequent operating cycles, if the monitor system
of the activated MI detects no failures and other MI failures which can be individually
activated, MI will deactivate (go out).
(4) Failure code
According to the regulations, the OBD system has to be possessed of the function for
identifying eventual failure areas, and storing these information into the ECU memory in
manner of failure code. SAE(American Association of Engineers) and ISO(International
Standardization Organization) have standarized the diagnosis failure codes. They are
composed of 5 characters, e.g.: P0112.
The 1st character of the failure codes is a letter, refleting the system, which the failure belongs
to:
Pxxxx Transmission system failure
Bxxxx Body failure
Cxxxx Chassis failure
Uxxxx Netword failure
The failures relevant to the OBD system are mainly expressed with the code P.
The 2nd character of failure codes represents the failure code maker:
P0xxx in conformity with to the SAE definitions and applicable to the diagnosis system
and freely select the failure code, they comprises specific text description of
failures(From the model year 2000: P0xxx and P2xxx)
P1xxx Effect involved in the exhaust emission is provided by the manufacturer, the
additional failure code which may be freely selected. They do not contain the
speciao text description of failure, but has to be registered at the legislator(From
the model year 2000: P1xxx and P3xxx)
The 3rd character of failure codes represents the type of failures, which are defined as follows:
Px0xx Fuel and air metering, emission control
Px1xx Fuel and air metering
Px2xx Fuel and air metering
Px3xx Ignition system or catch-fire
Px4xx Additional emission control
Px5xx Speed, idle control and input signal
Px6xx Computer and output signals
Px7xx Gearbox
Px8xx Gearbox
Px9xx Gearbox
PxAxx Combination propulsion
The 4th and 5th characters of failure codes represent the signs of failure part/system.
The failure code of random failure detected by continuous monitoring will be output in the
Mode 7 of scan tool throught the standard scan tool and diagnosis interface; the failure code
of the identified failure will be output through the Mode 3; the failure code corresponding to
the blocked frames (if any) will be output through the Mode 2.
II. Performance description of failure diagnostic set
The OBD system is able to provide many information relevant to the failure diagonse, which
are of reference value in terms of the maintenance of electric injection system. According to
the definitions of ISO/DIS15031-5, the information relevant to the OBD system may be
acquired in 9 different services/modes through the diagnosis tool meeting the requirements
of ISO/DIS15031-4.
The main functions of each mode are listed as follows:
01 Reads out the current data of dynamic system diagnosis
02 Reads out the blocked data frames
03 Reads out the failure code by the power system diagnosis relevant to the emission.
04 Cleans out and resets the diagnosis information relevant to the emission.
05 Reads out the test result of the oxygen sensor monitoring
06 Reads out the OBD test result by the continuous monitoring system.
07 Reads out the OBD test result by the continuous monitoring system.
08 Recommendation instead of imposed requirements
09 Reads out the ID No. of vehicle and softwares
The output information under each mode is identical, which are described respectively in the
following text. It is worthy of noting that,
The different diagnostic sets vary in design and use, but the it is certain that the content to be
accessed be one of the above modes.
(1) Mode 1
The function of the Mode 1 is to allow the exteriour standard diagnosis set to get access to
some data values relevant to the current basic parameters of the emission according to the
requirements of regulations. These parameters include the information of some
system-simulated input/output, digital input/output and system states etc.
The International Standard ISP/DIS15031-5 has defined all parameters, which can be output
from the Mode 1. The definitions contain the Name, unit, format, text description of
parameters. The parameters between them are recognized by the parameter identifiers(PID).
In the output of the Mode 1, all parameters relevant to the emission of the OBD system,
including the PID, parameter values, unit and text description will be listed one by one.
According to the regulations, the output of the Mode 1 has to comprise at least the following
parameters (If the on-board ECU is fitted with, or determined via the on-board ECU):
PID 01Informaton of the OBD system status
PID 03Fuel control system status(Open/close loop and others)
PID 04Calculated load value
PID 05Temperature of engine coolant
PID 06, 07 Fuel revision of the cylinder 01and 03
PID 08, 09 Fuel revision of the cylinder 02and 03
PID 0A Fuel pressure
PID 0B Air pressure of manifold
PID 0C Engine in rpm
PID 0D Speed
PID 0EIgnition timing advance
PID 0F Air intake temperature
PID 10Airflow
PID 11 Output value of the thottle valve position sensor
PID 12State of secondary air(upstream, downstream or admosphere)
PID 1C Requirement of the OBD system
PID 21Drive mileage after the MIL has been activated.
In addition, the output of the Mode 1 includes in general the information of the oxygen sensor
position (PID 13) and the voltage value of each oxygen sensor output (The oxygen sensors in
different types and positions correspond to different PID). The outcomes from the Mode 1 are
the current true values of the electric control system(In case of some failures, the system may
use the default or alternative value), these results provide important reference values to the
maintenance service.
It is particularly noteworthy that the PID 01 reflects the state of OBD system.
(2) Mode 2
According to the requirements of regulations, once the initial failure has been detected by the
ODB system on any of the parts or systems, the blocked data frame of the engine state has to
be stored into the ECU memory. The function of the Mode 2 is to output the information of
blocked frames of OBD system.
Each information of the blocked frames output by the Mode 2, same as the Mode 1, has to be
conform to the relevant definition of the International Standard ISO/DIS 15031-5. All states
of engine saved, include but not limited to the following parameters:
PID 03 Run under close/open ring state(If available)
PID 04 Calculated load value
PID 05 Coolant temperature
PID 06, 07 Fuel revision of the cylinders 01 and 03(if available)
PID 08, 09 Fuel revision of the cylinders 02 and 04(if available)
PID 0A Fuel pressure(if available)
PID 0B Manifold pressure of air intake(if available)
PID 0C Engine in rpm
PID 0D Speed(if available)
PID 02 The saved failure code of he above initiated data.
It is noteworthy that only one group of the blocked frame information can be saved in the
Mode 2. In case of multiple failures detected by the system, only the failure possessing the
higher priority of blocked frames will display in the output of Mode 2.
Higher priority
Catch-fire and oil supply system failure
Common failures relevant to the emission
Failures not affecting the emission, but necessary for
maintenance, e.g. A/C, fan and evaporator sensor.
Lower priority
(3) Mode 3
The function of the Mode 3 is allow the access of the exterior testing devices to the failure
codes of dynamic system relevant to the emission. Different from the Mode 2, the Mode 3 can
output multiple failure codes.
If the same failure doent show up during more than 40 operating cycles of engine preheating,
it can be delected by the on-board diagnosis system, including the information of travel
distance since the failure dislay and blocked frames.
The alleged the cycle of engine preheating refers to the vehicle fully driven to get the
temperature of engine coolant at least 22 K higher than that at the time of starting, and
achieve up to min.343K (70deg).
(4) Mode 4
The objective of the Mode 4 is to enable the exterior testing devices for deactivating the MIL,
clearing out the diagnosis information relevant to the emission in ECu. Those information
include:
The digital number of diagnosis failure codes(accessible through the PID01 under the
Mode 1)
Codes ready for the failure diagnosis (accessible through the PID01 under the Mode 1)
Failure code confirmed by diagnosis (accessible through the Mode 3)
Random failure code by diagnosis (accessible through the Mode 7)
Data on failure code and blocked frames corresponding to the blocked frames(accessible
through the Mode 2)
Testing data on oxygen sensor(accessible through the Mode 5)
System monitoring state(accessible through the PID 01 of Mode 1)
On-board monitor result(accessible through the Modes 6 and 7)
Drive mileage after the MIL has been activated(accessible through PID 21 of Mode 1)
(5) Mode 5
The objective of the Mode 5 is to access to the monitor result of each oxygen sensor. The
information output includes the constant values predefined and some outcomes of
measurements/calculations. In terms of the results of the measurement /calculation, their
corresponding max./min.values will be output at the same time, the format of which is listed
as follows:
TID Test Value Min Limit Max Limit
Predefined upper/lower boundaries of the

correspongding the index. If the test value is a
constantno result will be output from the
upper/lower boundary.
The test result is the outcome of system measurement/calculation or a

predefined constant used to the quantification and reflect a certain type
index corresponding the oxygen sensor,
The test ID signs reflect the different test projects of the oxygen sensorwhich are
defined as per the corresponding international standards.
ISO/DIS 15031-5 provides the definitions for all accessible information of oxygen sensor.
Each information has a corresponding test identifier (TID)
In terms of the two-point oxygen sensor system, the commonly used TIDs are listed as
follows:
TID 01 Switching voltage from dense to thin (constant)
TID 02 Switching voltage from thin to dense (constant)
TID 07 Min. voltage of oxygen sensor
TID 08 Max. voltage of oxygen sensor
TID 09 Switching time required for two times from dense to thin
TID 30 Index of denser sign
TID 31 Index of thinner sign
TID 32 Average peiord of oxygen sensor
In terms of the widthbanded oxygen sensor at the upstream of catalyst, the output of the
Model 5 include the following TIDs:
TID 81 Ratio of chemical equivalent
TID 82 Control valve value of the front oxygen sensor
TID 83 Indication of dynamic characteristic of the front oxygen sensor
TID 84 Index of Lamda offset
Based on the information from the Mode 5, it is convenient to know the main index of each
oxygen sensor and its corresponding boundary, which enables for judging whether therea are
failures in the oxygen sensor, types of failures and the level of failure.
(6) Mode 6
The objective of the Mode 6 is to access to the result of non-continuous monitoring by the
on-board diagnosis system on a component/system. the alleged non-continuous monitoring
refers commonly to the single diagnosis completed by a cycle of drive, e.g. The diagnosis
result of catalyst and test result of evaporation control system.
The information output by the Mode 6 includes four parts, i.e. TID, CID, test values and
boundary(max. Or min.) values, which format and relevant description are given below:
TID CID Test Value Min Limit Max Limit
Test results and boundary values. Each information only

indicates one boundary. After eliminating the failure
information by the Mode 4they are initiated to zero.
ID number of part is used to identify the different items of the same

diagnosed objectwhich is defined by the automobile manufacturer.
After eliminating the failure information by the Mode 4CID is
initiated to zero.
The test ID number is classified as per the diagnosed objectwhich is definedby the automobile manufacturer.
In the current system, TID is defined as below:

TID $01 Catalyst monitoring
TID $02 Oxygen sensor monitoring(output from the Mode 5)
TID $03 Monitoring of secondary air
TID $04 EGR monitoring
TID $05 Evaporation and emission control monitoring
TID $06 Oxygen sensor heating monitoring
TID $07 Catalyst heating monitoring
TID $08 Camshaft control monitoring
TID $09 cooling system monitoring
The information accessed from the Mode 6 is the last diagnosis result of the OBD system,
which will be saved until the next diagnosis has been finished and will be not disappeared by
turning off the switch key.
According to the test result provided by the Mode 6, it is judgeable wheterh there are any
failures in the index corresponding to the component as well as the failure level.
After the maintenance, the determination on whether the failure has been correctly eliminated
or not can be made according to the test result from the Mode 6.
(7) Mode 7
The mode 7 is able to output the test result by continuous diagnosis , e.g.
Test on the drive class, circuit continuity diagnosis of the actuator.
Sensor voltage(rationality diagnosis )
Oil supply system diagnosis
The Mode 7 only displays the random failure. The random failure has been detected, but it is
not yet finally confirmed. The random failure is unable to activate the MIL.
Once the failure confirned, the record of failure will display in the Mode 3 instead of in the
Mode 7. The recorded result from the Mode 7does not necessarily indicate that the
corresponding failure still existing in the system.
The service men can confirm whether the failure has been truly cleaned out by accessing the
output of the Mode 7 after eliminated the failure and completed a cycle of drive, instead of
driving several cycles unti the failure has been confirmed and the MIL activated.
(8) Mode 8
The regulations in China and Europe do not require the function activation of the Mode 8 by
the OBD system.
(9) Mode 9
The objective of the Mode 9 is to allow the exterior devices for getting access to the
designated information, e.g. the Vehicle Identification Number(VIN), Calibration
Identification Number(CID or CVN) EOBD, which only requires that the Mode 9 outputs the
Calibration Identification Number(CID).
III. Inspection procedure of failure
For the vehicles fitted with the OBD function, the inspection of failures respects in general the
following procedure:
1. Connects the diagnosis device to the diagnosis interface to get through the diagnosis
device.
Position of diagnosis seat
Device connection
Connection method of J1962 joints
2. Gets through with the Ignition switch

3. Accesses the information of failures (failure code and blocked frames etc.)consults with
the maintenance manual to confirm the failure parts and typesEstablishes the maintenance
schedule according to the information and experience relvevant to the failures.
Main interface of the K81 Diagnostic Set
Function interface
Interface of car series

Interface of models
Interface of specific models
Interface of systems
4. Troubleshooting
5. Troubleshooting memoryDriving the car adequately, but in a way meeting the
conditions of failure diagnosisgets accesss to the failure information and confirms the
elimination of failure.
IV. Connection of diagnostic set
The system adopts the KLine Communication Protocol and applies the standard diagnosis
connector ISO 9141-2 as shown below in figure 2.5. This standard diagnosis connector is
perminently connected on the harness of engine. The standard diagnosis connectors used for
the Engine Management System (EMS) are the pins no. 4,7 and 16.
The pin number 4 of the standard diagnosis connector is connected to the grounding of the
vehiclethe pin number 7 to the pin no.71 of the ECU, i.e. the Kline of engine datathe pin
no.16 to the positive of the battery.
ISO9141-2 Standard diagnosis connector

Chapter III Clutch
Section I Outline
I. Structure parameters
Modes of clutch disc Dry-type, single chip diaphragm spring

Distance from BHC to the surface of cover assembly clutch 37.9
Pressing load of assembly(N.m) 4150300
Cover assembly clutch Leverage ratio of diaphragm spring 2.833 ( 51/18 )
Leverage of the diaphragm spring (mm) 31.51.0
O/D I/D( mm ) 200130
Clutch disc Friction materials B8805
Spline size 24/48-30 0 20NT
control mode Operated directly by cable
Leverage ratio of release fork 2.87
Clutch control mechanism
Hydraulic cylinder size( mm ) None
release thrust bearing Self-aligning type
2. Basic specifications
Items Specifications
Operating mode of clutch Operated directly by cable
Mode of clutch disc Dry-typed, single plate
Size of clutch disc 200130
Cap typed clutch Diaphragm spring typed
3. Inspection specifications
Items Specifications(limit value)
Riveting depth of clutch surface in mm 0.3
difference in height of the diaphragm spring, in mm 0.5
Clearance between the inner circle of slave cylinder and the outer circle
0.15
of piston
4. Specifications of tightening torque
Items Specifications(N.m)
Connecting nuts of the hydraulic oil tube of clutch 15 ( 1.5 )
Hydraulic oil bracket of clutch 18 ( 1.9 )
Tube joints of the clutch slave cylinder 22 ( 2.3 )
Deflated plug of the clutch slave cylinder 11 ( 1.1 )
Fitting bolts of the slave cylinder 18 ( 1.9 )
Ball stud bolts 35 ( 3.6 )
Section II Break-down and assembly
Removal and assembly procedures
Removal procedures
1. Clutch cable bracket 6. Reset spring
2. Bolts 7. Release thrust bearing
3. Dust cover 8. Clutch cover assembly clutch
A A 4. Release fork assembly 9. Clutch disc
5. Ball stud bolts
Essentials to the removal operation
A Removal of the release fork
Removes the release fork as per the direction shown in figure .Removes the reset clip from the release
thrust bearing.
Essentials to the assembly operation
A Assembly of the release fork

Applies the grease on the position of release fork as shown in figure and packs with grease.
Specified grease: Esso Ronex, Esso Beacon EP2 or 3# calcium-based grease.
Section III Checks and maintenance
1. Clutch
1.1 Clutch platen
(1) Checks the diaphragm spring end to see if there are any wears and difference in height. If there are
remarkable wears or height difference over the limit valuethe clutch platen should be replaced. Limit
value: 0.5mm
(2) Checks the platen surface to see if there are any wears, fractures and discoloration on the surface.
(3) Checks to see whether the platen rivets are loosening or not. In loosened, the clutch platen should be
replaced.
1.2 Clutch driven disc
Attention:
The clutch driven disc can not be cleaned with the gasoline!
Checks to see if there are any deterioration and greasy contamination on the surface caused by looseness,
single faced contact and burn etc. If such problems detected, the clutch driven disc should be replaced.
Measures the riveting depth. If it exceeds the limit valuethe clutch driven disc should be replaced. Limit
value: 0.3mm
Checks the damping spring to see if there are any looseness and breakage. In such problems occurred,
the clutch driven disc should be replaced.
Fits up the clutch driven disc on the input shaft. Checks if the lubrication state and turning direction are
loosened. If they are sliding in poor state, then you should clean them up. Replacement after the assembly.
If obviously loosenedthe clutch driven disc or input shaft should be replaced or both replaced at the same
time.
1.3 Release thrust bearing of clutch
Attention: As the release thrust bearing is packed with the greasebe sure not to use the grease, Substances
to clean it
(1) Checks the bearing to see if there are burns, damages, abnormal noise and uneven revolution etc
(2) Checks the contact face between the release thrust bearing and diaphragm spring to see if there are any
wears. If any abnormal wears on the contact face, the replacement should be made.
(3) Checks the contact face between the release thrust bearing and release fork to see if there are any
abnormal wears on the contact face. If any abnormal wears on the contact face, the replacement should be
made.
1.4 Clutch release fork
(1) Checks he contact face between the release fork and release thrust bearing to see if there are any wears.
If such case, the replacement should be made.
Chapter IV Gearbox
Section I Summary
1. Baseline profile
Gearbox model F5M41-7L F5M41-71

Applicable engine 4G13 4G18
Mode 5 manual transmission , FWD
Final reduction gear ratio 4.333 (78/18) 4.052 (77:19)
Wheelbase (mm) 78 126 204
Full length(mm) 390
Outline dimension (L x W x H)( mm ) 390543365
st
1 gear 3.583 ( 43:12 )
nd
2 gear 1.947 ( 37:19 )
rd
3 gear 1.343 ( 43:32 )
Gear ratio th
4 gear 0.976 ( 41:42 )
th
5 gear 0.767 ( 33/43 ) 0.804 ( 37:46 )
Reverse gear 3.416 ( 41:42 )
Differential gear size No.4.2
1st gear 0.98
nd
2 gear 0.98
rd
3 gear 0.98
Transmission efficiency th
4 gear 0.98
th
5 gear 0.98
Reverse gear 0.97
1st gear 71 bicone
nd
2 gear 71 bicone
rd
Synchronous ring size (mm) 3 gear 71 bicone
Synchronous ring mode th
4 gear 71 monocone
th
5 gear 71 lever synchronizer
Reverse gear Lever synchronizer
Gearshift lever
55/22.37
ratio
Shift control mechanism
Gear selecting
60/35
lever ratio
Gear ratio 31/36
Speed sensor
mode Electronic
SAE viscosity 80W-90 (summer in north) 75W-90 (winter in north ) 80W-90
classification or 85W-140 (through year in south)
Lubricant oil API
GL4 or higher than GL4
classification
Oil mass(L) 2.1
Net weight (excl. clutch)(kg) 41
2. Table of the auxiliary materials for the gearbox assembly line:
Materials and
S/N Current materials and models Assembly location
models used by AOS
1 Lubricant oil Mobilith SHC220 or Spartan syn EP Shift fork
2 Lubricant oil 220 Clutch Bearing
3 Lubricant oil Input shaft oil seal
MobilHD80W-90 or Esso Gear Oil
4 Gear oil Gearbox assembly
GX 80W-90
5 Lubricant oil Gear selection block
6 Sealant TB1501 LT480 Air respirator
7 Anti-rust oil Mobil LAMA LT or Rust-Ban330 Input shaft
8 Gear oil MobilHD80W-90 or Esso Gear Oil Input shaft needle bearing
9 Gear oil GX 80W-90 Input shaft needle bearing
10 Sealant TB1303 LT243 Differential bolt
11 Sealant TB1216 LT5699 Gearbox shell joint surface
MobilHD80W-90 or Esso Gear Oil
12 Gear oil Control shaft and shift lever
GX 80W-90
13 Sealant TB1216 LT5699 Control box sub-assembly
3. Special tools
Tools Numbers Names Intended uses
Uses together with the

MD998812 Fitting tool caps joiners of fitting tool and
fitting tool

MD998813 Fitting tools100 joiners of fitting tool and
fitting tool

MD998814 Fitting tool200 joiners of fitting tool and
fitting tool
Fitting of the front bearing of

MD998817 Fitting tool joiners
input shaft
Fitting of the rear bearing
of input shaft, roller bearing
inner race and
reverse gear, needle bearing
and reverse gear shaft
bushing
5th gearfitting of the

MD998819 Fitting tool joiners reverse synchronizer, spline
hub, ball bearing and 4th gear
5th gearfitting of the gear

slide sleeve.
2nd gearfitting of the gear
slide sleeve
1st gearfitting of the gear

slide sleeve.
MD998822 Fitting tool joiners 1st and 2nd gearsfitting of
the synchronizer and spline
hub
Fitting of the input shaft oil

MB990926 Fitting tool joiners seal of clutch shell
MB990927 Fitting tool joiners Fitting of the sealing cap
Fitting of the outer ring of

cylindrical roller bearings I
Fitting of the bearing outer

ring of differential case ball
Used together with the fitting

MD990938 Handle
tool joiners
Fitting tool of Fitting of the differential oil

MB998325
differential oil seal seal
Dismantle tool of Removal of the outer ring of

MB998346
bearing outer ring cylindrical roller bearings
Fitting and removal of

Dismantle tool of
MB998801 various gears, bearings and
bearing
sleeves
Fitting of the gear hub of the

3 th-4th gears synchronizer
Dismantle tool of
MD998917 Fitting and removal of
bearing
4. Baseline profile
Model of gearbox F5M41-7L F5M41-71
Applicable engine 4G13 4G18
Final reduction gear ratio 4.333 ( 78/18 ) 4.052 ( 77/19 )
th
mode Cable shift of the 5 gear
1st gear 3.583 3.583
nd
2 gear 1.947 1.947
rd
3 gear 1.343 1.343
Gear ratio
4th gear 0.976 0.976
th
5 gear 0.767 0.804
Reverse gear 3.416 3.416
Gear ratio of the speedometer 31/36
5. Inspection specifications
Items Tolerance range of tightness Limit value
Front bearing clearance of Input shaft in mm 0 0.12
Rear bearing clearance of Input shaft in mm 0 0.09
Axial clearance of the 5th gears, input shaft mm 0 0.09
Items Tolerance range of tightness Limit value
Front bearing clearance of output shaft, in mm 0 0.12
Rear bearing clearance of output shaft, in mm 0 0.09
rd
Axial clearance of the 3 gear, output shaft in mm 0 0.09
Axial clearance of the differential body, in mm 0.05 0.17
Pinion clearance of the differential body, in mm 0 0.150
Clearance between the synchronous ring back and gear, in mm 0.5
Remark: standard clearance: 0mm
6. Regulating of the adjusting shims of snap ring, differential padding and differential gear.
Snap ring (used to the adjustment for the front bearing clearance of input shaft)
Thickness Identifier Mitsubishi-Part No. Localization part No.
2.24 None MD706537 BS15-1701037-1
2.31 Blue MD706538 BS15-1701037-2
2.38 Brown MD706539 BS15-1701037-3
Snap ring(used to regulate the rear bearing of input shaft)

Thickness Identifier Mitsubishi-Part No. Localization part No.
2.31 Black MD747149 BS15-1701038-11
2.35 None MD746561 BS15-1701038-1
2.39 Blue MD746562 BS15-1701038-2
2.43 Brown MD746563 BS15-1701038-3
2.47 Green MD746564 BS15-1701038-4
2.51 White MD746565 BS15-1701038-5
2.55 Yellow MD746566 BS15-1701038-6
2.59 Black MD746567 BS15-1701038-7
2.63 Orange MD746568 BS15-1701038-8
2.67 Blue MD746569 BS15-1701038-9
2.71 Brown MD746570 BS15-1701038-10
7. Tightness torque specifications
Items Nm( kgfm )
Spring group assembly 50 ( 5.1 )
Mounting bolt of the clutchgearbox shell 44 ( 4.5 )
Mounting bolts, Clutch bearing cage retainer 9.8 ( 1.0 )
Mounting bolts, control shaft shell 18 ( 1.9 )
Mounting bolts, shift cable bracket 18 ( 1.9 )
Mounting bolts, speed sensor 3.9 ( 0.4 )
Bracket mounting bolts 18 ( 1.8 )
Mounting bolts, gear selector 18 ( 1.8 )
Mounting nuts, gear selector 11 ( 1.2 )
Mounting bolts, gear, differential drive 132 ( 13.5 )
Switch, backup lamp 32 ( 3.3 )
Mounting bolts, front bearing, cage retainer 18 ( 1.8 )
spring group assembly 32 ( 3.3 )
Items Nm( kgfm )
Limit ball assembly 32 ( 3.3 )
Mounting bolts, reverse gear 48 ( 4.9 )
Mounting bolts, reverse shift lever 18 ( 1.8 )
Mounting bolts, gearbox bracket 69 ( 7.0 )
Section II Break-down and assembly

Gearbox assembly
Break-down procedure:
1. Gearbox bracket 7. Gasket
2. Speedometer sensor 8. Limit ball assembly
3. Shift cable bracket 9. Gasket
M 4. Gear selector assembly 10. Spring group assembly
L 5. Speed sensor assembly 11. Gasket
6. Switch, backup lamp assembly 12. Bracket
In the reassembly, all inner
parts have to be lubricated
with gear lubricant.
13. Booster spring group assembly 21. Reverse intermediate gear assembly
K 14. Control shaft shell 22. Reverse shift lug call block
15. N-gear return spring 23. Reverse shift lug assembly
J 16. Reverse intermediate gear screw F24. Oil guided
17. Gasket 25. Magnet holder
A I 18. Sealing Cap 26. Magnet
B H 19. Gearbox shell E27. Gasket
C G 20. Reverse gear
parts have to be lubricated with
gear lubricant.
D 28. Spring pin D C 37. Reverse interlock rail
29. 1-2 Shift fork shaft D C 38. Steel ball
30. 1-2 Shift fork D C 39. 3-4 Shift fork shaft
D 31. Spring pin D C 40. 3-4 Shift fork
D 32. Spring pin B 41. Cage retainer, front bearing
D C 33. 5- Reverse shift fork shaft E A 42. Input shaft
D C 34. 5- Reverse shift fork E A 43. Output shaft
D C 35. Reverse shift lug 44. Differential assembly
D C 36. Snap ring 45. Clutch shell
Essentials to the break-down procedures:
ARemoval of sealing cap
BRemoval of gearbox shell

Widens the snap ring and removes it from the snap ring of ball bearing.
Attention: If expanding the snap ringthe snap ring groove will deviate with the input shaft under the
effect of dead weight.
CRemoval of reverse gear

Laterally moves the synchronizer sleeve of the3rd 4th gears to the 4th gear.
DRemoval of the 34 shift fork shaft/34 shift rail/5reverse shift rail/elastic ring/reverse shift lug/5-
reverse shift fork shaft/steel ball/reverse interlock rail.
(1) Moves the reverse shift lug to the direction shown in the figure. while dismantling the sub-assembly of
5- reverse shift fork shaft and reverse gear arm snap ring, steel ball and reverse interlock rail.
(2) Moves the reverse shift lug to the direction shown in the figure. and removes it together with the fork.
ERemoval of the input/output shaft

Removes the Input/output shaft at the same time.
Adjustment prior to the reassembly:
Selects the gasket to adjust the axial clearance of differential case.
(1) On the position of gearbox shell as shown in figure., places soldering tin(Length ca. 10mmdiameter, ca.
1.6mm)then fits up the differential.
(2) Fits up the clutch shell and tightens the bolts to the specified moment.
If the soldering tin is not pressed flatuses the thicker soldering tin to repeat the procedure of (1) and (2).
(3) Measures with a micrometer the thickness(T) of flattened soldering tin and selects the gasket according
to the formula shown as below.
To select the thickness of gasket: (T 0.05mm) to (T 0.17mm).
Operating essentials to the reassembly.
AAssembly of the output/input shafts

Removes the Input/output shaft at the same time.
BFitting of the front bearing cage retainer
Applies the sealant on the mounting bolt (only countersunk screw) of front bearing cage retainer.
Specified sealant: LT243 (China)
CFitting of the reverse interlock rail/steel ball/5-reverse shift rail/reverse shift lug/snap ring /5-reverse
shift fork /34 shift fork /34 shift rail.
(1) Fitting of the 3th 4th shift rail and fork.
(2) Fitting of reverse interlock rail, steel ball, 5threverse shift rail. 5-reverse shift fork, reverse shift lug,
snap ring and positions them as shown in figure.
(3) Moves the reverse shift lug to the direction shown in figure. while fitting the 5-reverse shift fork, shift
rail and reverse shift lug, snap ring, steel ball, reverse interlock rail.
DFitting of spring pin
EFitting of gasket
Fits up the gasket selected from the step of the Adjustment prior to the reassembly.
FFitting of the oil guide

GFitting of the reverse gear
(1) Laterally moves the 3th 4th synchronizer sleeve to the 4th gear.
(2) Orients the bolt hole on the reverse gear to the direction shown in figure.
HFitting of the gearbox shell

Applies the sealant on the position of gearbox shell shown in figure.
Attention: Evenly extrudes the sealant without breaking off or over applied.
I Fitting of sealing cap

(1) Fits up the gearbox shell and expands the snap ring.
(2) Tightens the shell connected bolts with the specified moment.
Attention: Be sure of pressing down to the position shown in figure.
J Fitting of the reverse gear bolts

Uses the screwdriver etc (thickness 8mm ) and finds out the screw hole center.
K Fitting of the control shaft shell

Extrudes the sealant to apply on the position of gearbox shell shown in figure.
Attention: Evenly extrudes the sealant without breaking off or over applied.
LFitting of the speed sensor
Applies the gearbox oil on the O-ring of speed sensor.
Gearbox oil: gear oil Esso Gear Oil GX80W-90.
M Fitting of the gear selector

Applies the lubricant grease on the gear selector control shaft.
Specified grease: Esso Ronex . Esso Beacon EP 2 or 3# calcium-based grease.
2) Input shaft
Break-down and reassembly
L1. Snap ring D 15. Synchronizer spring
A K2. ball bearing F 16. Synchronizer gear sleeve
3. Snap ring E 17. 3-4 Gear, synchronizer hub
J4. Synchronizer sleeve
BI5.5- Reverse synchronizer hub 18. Bicone outer ring
6. Synchronous ring D 19. Synchronizer spring
D7. synchronizer lever 20. Intermediate steel ring
8. 5 Gear, drive gear assembly 21. Bicone inner race
C I 9. Needle bearing 22. 3 Gear, drive gear
10. 5 Gear, drive gear sleeve 23. Needle bearing
C H11. 4 Gear. drive gear assembly C 24. Snap ring
12. Needle bearing E B 25. Ball bearing
D G13. 4 Gear, drive gear sleeve A 26. Oil seal
14. Synchronous ring 27. Input shaft
Essentials to the break-down procedures
ARemoval of ball bearing
BRemoval of the 5reverse synchronizer hub

Mounts the special tools on the 5th gear, drive gear and removes the 5th reverse synchronizer hub.
CRemoval of the 5th gear, drive gear sleeve

Mounts the special tools on the 4th gear, drive gear and removes the 5th gear, drive gear sleeve.
DRemoval of the 4th gear, drive gear sleeve
Mounts the special tools on the 3rd gear, drive gear and removes the 4th gear, drive gear sleeve and
the 3th -4th gear synchronizer hubs
ERemoval of the ball bearing

Operating essentials to the reassembly
AFitting of the oil seal

Securely knocks into the position shown in figure.
BFitting of the ball bearing
CFitting of the snap ring

Selects and fits up the snap ringto achieve the standard value of the front bearing clearance of the
input shaft: 00.12mm
DFitting of the synchronizer spring

Securely fits up it to make it on the position shown in figure.
E Fitting of the 3th 4th synchronizer hub
Fits up the synchronizer hub to make it toward the direction shown in figure.
Attention: presses in the gear hub to push the synchronous ring in instead of meshing in.
FFitting of the synchronizer gear sleeve

(1) Fits up the gear sleeve to make it in the direction shown in figure.
(2) Aligns the deep groove of the synchronizer hub with the bump of the gear sleeve and fits up.
G4 Fitting of the drive gear sleeve
HFitting of the 5th gear, drive gear sleeve

IFitting of the 5th reverse synchronizer hub
Fits up the 5th R- synchronizer hub as per the direction shown in figure.
Attention: Pushes the hub in to prevent the synchronous ring from meshing up
JFitting of the synchronizer sleeve

(1) Fits up the gear sleeve to make it in the direction shown in figure.
KFitting of the ball bearing
LFitting of the snap ring

Selects and fits up the snap ring to achieve the standard value of the front bearing clearance of the
input shaft: 00.09mm
3) Output shaft
J 1. Snap ring E 14. Synchronizer spring
A I 2. Ball bearing 15. 1-2nd gear, synchronizer gear sleeve
3. Snap ring D 16. 1-2nd gear, synchronizer hub
4. 5th gear, driven gear 17. Synchronizer spring
th
5. 4 gear, driven gear 18. Bicone outer ring
H 6. Snap ring C C 19. Intermediate steel ring
rd
7. 3 gear, driven gear B 20. Bicone inner race
nd
8. 2 gear, driven gear D A 21.1st gear, driven gear
9. Needle bearing 22. Needle bearing
B G10. 2nd gear, driven gear sleeve 23. 1st gear, driven gear sleeve
11. Bicone inner race 24. Snap ring
D 12. Intermediate steel ring 25. Bearing inner race
F 13. Bicone outer ring 26. Output shaft
ARemoval of the ball bearing
BRemoval of the 2nd gear, driven gear sleeve

Mounts the special tools on the 1st gear, driven gear and removes the 1st -2nd gear synchronizer and
2nd gear, driven gear sleeve.
CRemoval of the 1st gear, driven gear sleeve

DRemoval of the inner race of cylindrical roller bearing
A Fitting of the inner race of roller bearing.
BFitting of the snap ring

Selects and fits up the snap ringto achieve the standard value of the front bearing clearance of the
input shaft: 00.012mm.
CFitting of the 1st gear, driven gear sleeve
DFitting of the synchronizer spring

Securely mounts it on the position of synchronous ring shown in figure.
EFitting of the 1st 2nd gears, synchronizer hubs

Attention: Pushes the gear hub and prevents the synchronous ring from meshing up.
FFitting of the synchronizer gear sleeve
(1) Fits up the synchronizer gear sleeve to make it in the direction shown in figure.
GFits up the 2nd gear, driven gear sleeve
HFitting of the snap ring

Selects and fits up snap ringto achieve the standard value of the axial clearance of the 3rd gear,
output shaft: 00.012mm.
IFitting of the ball bearing

J Fitting of the snap ring
Fits up the snap ringto achieve the standard value of the rear bearing clearance of the output shaft:
00.09mm.
4) Speed sensor

parts have to be lubricated
with gear lubricant.
1. E clip 3. O-race
2. Speedometer driven gear 4. Sleeve
5) Gear selector sub-assembly
A 1. Dust cover 6. Select shaft shoe
2. Nuts 7. Select gear sub-assembly
3. Spring gasket 8. Gear selector sleeve
4. Gasket A 9. Dust cover
5. Gear selector sleeve 10. Gear selector shaft
A Fitting of the dust cover

6) Control shaft sub-assembly
Break-down procedure: :
A F 1. Lock pin 10. N-gear return spring
2. Interlock plate 11. Adjusting padding
3 Control arm 12. Control shaft
4 Pin C 13. Aerator
5 Return spring 14. Dust cover, control shaft
6. Limiting plate B 15. Oil seal
E 7. Spring pin A 16. Needle bearing
D 8. Spring pin 17. Spring gasket
9. Limiting shoe 18. Limit show bracket
19. Control shaft shell
A Fitting of the lock pin

Knocks out the lock pin along the direction shown in figure.
AFitting of the needle bearing

Pushes it in to the size shown in figure. to make the model print in the direction shown in figure.
BFitting of the oil seal

Applies the gearbox on the oil seal lip.
Gearbox oil: gear oil Esso Gear Oil GX80W-90
C Fitting of the aerator
(1) Applies the sealant around the insert part.
Specified sealant: LT480(China)
(2) Start fitting up and making the bump in the direction shown in figure.
D Fitting of the spring pin

E Fitting of the spring pin
F Fitting of the lock pin

7) Clutch shell
Break-down procedure::
1. Cage retainer, clutch bearing 5. Oil guider
D 2. Oil seal A 6. Sleeve
C 3. Oil seal 7. Clutch shell
A B 4. Cylindrical roller bearing
Installation operating essentials only referred when replacing the clutch shell.
A Removal of the cylindrical roller bearing

AFitting of the sleeve
Pushes the sleeve in the position shown in figure. Do not let its split ends touch on the air purge
groove.
BFitting of the cylindrical roller bearing

Pushes in the cylindrical roller bearing to make the model print in the direction shown in figure.
CFitting of the oil seal

Applies the gearbox oil on the oil seal lips.
Gearbox oil: Esso Gear Oil GX80W-90.
D Fitting of the oil seal
Applies the gear oil on the oil seal lips
8) Gearbox shell
C 1. Oil seal l 4. Snap ring
B 2. Needle bearing A 5. Sleeve
3. Oil guider 6. Gearbox shell
Installation operating essentials only referred when replacing the gearbox shell.
A Fitting of the sleeve
Keeps pushing the sleeve in the position shown in figure, and prevent it from touching on the split face.
BFitting of the needle bearing

Pushes it down to the dead end and makes it in the direction shown in figure.
CFitting of the oil seal
Applies the gearbox oil on the oil seal lips.
Gearbox oil: Esso Gear Oil GX80W-90
9) Differential
D 1. Gear, driven gear A 6. Gasket
A C 2. Ball bearing A 7. Differential gear
B 3. Lock pin A 8. Gasket
A 4. Shaft, planet pinion 9. Differential case
A 5. Planet pinion
A Removal of the ball bearing

A Fitting of the gasket/differential gear/gasket/planet pinion/planet pinion.

(1) Fits up the gasket on the back of the differential gearthen the differential gear in the differential case.
Remark: When fitting up the new differential gearplease select the gasket in the medium thickness
(0.931.00mm).
(2) Fits up the gasket on the back of the planet pinion to mesh in with the differential gear when it is in the
position 7, and fits up on the specified position while turning it.
(3) Inserts the planet pinion shaft.
(4) Measures the teeth clearance between the differential gear and the planet pinion. Standard value:
00.150mm.
(5) If the teeth clearance exceeds the standard valueyou should select the suitable gasket and measures the
teeth clearance.
Remark: Adjusts to make even the teeth clearances at both sides.
BFitting of the lock pin
Fits it up to make it in the direction shown in figure.
CFitting of the ball bearing
DFitting of the gear, driven gear

Applies the sealant on the overall threads of the bolt. Specified sealant: LT243(China )
Tightens it up to the specified moment as per the order shown in figure.

2.2.3 Inspection and maintenance
1) Gearbox assembly
Switch, backup lamp:

Checks the conductivity among various terminals.
Items Conductivity
Presses down the switch Non-conductive
Releases the switch Conductive
2) Input shaft
1. Input shaft
(1) There should be no damage on the outer circle of the needle bearing mounting as well as abnormal
wears and scalds.
(2) Checks the splines to see whether there are damages or wears,
2. Needle bearing
(1) Combines the input shaft, sleeve and the gears and let them run to verify if they run smoothly and with
any abnormal noise.
(2) Whether the cage retainer is deformed.
3. Synchronous ring
(1) The teeth face of the synchronous ring should have no damages and breakages
(2) On the conical inner surface, there should be no damages, wears or no breakage on the thread teeth.
(3) Pushes the synchronous ring toward the gear to check the clearance A. When the clearance A is
lower than the limit value, it should be replaced. Limit value: 0.5mm
4. Synchronizer sleeve and hub
(1) When combining the synchronizer sleeve with the synchronizer hub to let them skiddingthey should be
able to skid smoothly with no retardation.
(2) On the front/rear end of the inner surface of gear sleeve, there should be no damages
Attention: In replacementthe synchronizer sleeve and synchronizer hub should be replace as one group.
5. Synchronizer spring
The spring elasticity should not decay and there are no deformation and breakages.
6. Speed gear at each gear
(1) Helical gear and the teeth face of outer gear should have no damages or wears.
(2) On the conical surface of outer gear, there should be no roughness, damages and wears.
(3) On the inside peripheral and front/rear surface of gear, there should be no damages and wears.
3) Output shaft
1. Output shaft
Checks the damage and wear of the spline.
2. Needle bearing
(1) When combining the input shaft sleeve with the gears for running together, checks to see if they run
smoothly and with any of abnormal noise
(2) Whether the cage retainer is deformed.
3. Synchronous ring
(1) The teeth face of the synchronous ring should have no damages and breakages.
(2) On the conical inner surface, there should be no wears or no breakages on the thread teeth.
(3) Pushes the synchronous ring toward the gear to check the clearance A. When the clearance A is
lower than the limit value, it should be replaced. Limit value: 0.5mm.
4. Synchronizer sleeve and hub
(1) When combining the synchronizer sleeve with the synchronizer hub to let them skiddingthey should be
able to skid smoothly with no retardation.
(2) On the front/rear end of the inner surface of gear sleeve, there should be no damages.
Attention: In replacementthe synchronizer sleeve and synchronizer hub should be replace as one group.
5. Synchronizer spring
The spring elasticity should not decay and there are no deformation and breakages.
6. Speed gear at each gear
(1) Helical gear and the teeth face of outer gear should have no damages or wears.
(2) On the conical surface of outer gear, there should be no roughness, damages and wears.
(3) On the inside peripheral and front/rear surface of gear, there should be no damages and wears.
Chapter V Steering system
The models series C2 apply the pinion racked mechanical/booster steering system.
Section I Introduction to the structure of the models series C2
During the drive in the car, you need often to change the direction of drive (i.e. steering). Thus, the driver
will make, through the automotive steering system, the deflection at a certain angle of the wheel (steering
wheel)on the steering axle(front axle) relative to the vertical axis. In addition, when the car drive straight,
the steering wheel will deviate automatically under the effect of lateral disturbance of the road, and change
the original direction. Hence, the driver may also make, through the automotive steering system, the
steering wheel deflect in reverse direction and regain the initial direction.
The automotive steering system mainly includes three basic parts, i.e. the steering control mechanism,
steering gear and steering linkage device.
The steering control mechanism is basically composed of the steering wheel, steering shaft and steering
column. The automotive power system is made up of the power steering, steering oil pump, steering
reservoir and steering pipeline, where the power steering is the hydraulic booster actuator of the steering
system;
The steering oil pump is connected with the engine to build up the hydraulic power supply of system; and
the steering reservoir serves as the roles of storage, cooling, filter and oil supply.
I. Description of the steering system structure, Main technical parameters

1. Mechanical steering
Items Description
Energy-absorbinguniversal joint connection(2 joints) with

Types of the steering column and steering connecting shaft
adjustable inclination of steering column
Type of steering Pinion and rack

Rack trip 148mm
Total circles of steering wheel 4.64 circles
Free path of steering wheel 7
Max. rotating angle of wheel Inner: 37; Outer: 31
2. Electric Power Steering (EPS)
Items Description
Energy-absorbinguniversal joint connection(2 joints) with
Types of the steering column and steering connecting shaft
adjustable inclination of steering column
Type of steering Pinion and rack
Rack trip 143mm
Total circles of steering wheel (3.34 circles)
Free path of steering wheel 7
Max. rotating angle of wheel Inner: 37; Outer: 31
Type of oil pump Vane typed
Theoretical discharge capacity of oil pump 7.5mL/r
open pressure of oil pump pressure valve 1.52.0MPa
Section II Operation principle, maintenance and use of the steering

system
I. Operation principle and structure diagram of the steering System

1. Operation principle of mechanical steering: the steering wheel is turned manually by the driver, Which
deflects the steering wheel through the process of steering column and transfer shaft, pinion and rack
steering.
Steering wheel
Steering column and drive shaft
Meachnical steering
2. Operation principle of steering booster: Under the control of driver, the change of direction of the wheel
is actualized by the hydraulic pressure produced from the power steering pump driven by the engine.
Steering oil
reservoir
Steering Steering oil
wheel pump
Steering coloumn and

drive shaft
Steering oil pipe

Steering
device
3. Maintenance and use of the steering system
3.1 Regularly checks whether the steering hydraulic oil is at shortage. If in such case, you should add in
time. At the same timeregularly cleans out the hydraulic oil cup and filter elements to prevent the
hydraulic oil from contamination or deterioration. It is recommended to replace the hydraulic oil one time
per 30000km,
3.2 During the maintenanceyou should check the tightness of the steering pump belt for any fractures. If in
such case, you should replace it in time. About 1cm pressed down by finger is considered as the appropriate
tightness;
3.3 Regularly checks the pipe joint of hydraulic system to see if there are any oil leakages. The hydraulic
oil pipe should be kept as far as possible away from the friction of other parts to prevent the air leakage. At
the mean timethe hydraulic hose should be replaced regularly to prevent the rubber hose from peeling and
blocking the pipe;
3.4 During the maintenance of steeringthe installation and adjustment should be properly made and the
hydraulic oil distribution valve and piston cavity cleaned out. Chooses the qualified and type matching oil
seal to prevent the hydraulic oil leakage;
3.5 When making the steeringthe time of steering to the dead end can not longer than 5sespecially
when turning in the spota certain margin should be reserved to ensure the normal operation state of the
hydraulic steering system.
Section III Common faults and troubleshooting
Any of the failures in the steering system is possible to affect the drive safety and cause the driving faults.
Hence, the steering System has to be often checked.
Troubles Possible reasons of failures Solutions

The fastening bolts on the universal joint of Tightens the fastening bolt of universal joint
steering column are loosened as per the specified moment.
Too large free path of the The bolts on the fitting part of steering Tightens the fitting bolts of the steering gear
steering wheel gear. as per the specified moment.
Linkage tire rod worn Replaces the ball stud or tie rod.
Too large backlash of the steering Adjusts the backlash of the steering
Charges the tire pressure as per the range of
Lower air pressure in the front wheel
specification.
Ball stud of steering is at oil shortage Fills with the grease.
Too small backlash of the steering Adjusts the backlash of the steering.
Heavy steering(mechanical
Steering mechanically damaged Replaces the steering.
steering)
steering rod bent, deformed or all ball studs
Replaces the tie rod or ball stud.
assembled too tightly
Adjusts the toe-in value of the
Too small toe-in of front wheel
front wheel.
Adjusts or replaces the drive belt of the power
Drive belt loosened
steering pump (A/C compressor belt).
Insufficient hydraulic oil or air leaked into Drives out the air in the oil pipeline and adds
Heavy steering(steering the hydraulic oil the hydraulic oil.
booster) Poor performance of oil pump (insufficient
pump oilunable to supply adequate flow Checks and replaces the power steering pump.
or pressureinner damage)
Oil leakage in the hydraulic system Replaces the oil leakage parts.
Tire pressure inconsistent at the L/R front Checks the tire pressure to keep both sides
wheel or the inconsistent tire sizes consistent
Steering rod deformed Replaces or corrects in time.
Driving deflection
Inaccurate positioning of the front wheel Tests the wheel positioning.
The brake of front wheel at one side biting Adjusts the brake clearance or the reserved
or the hub bearing over tightened tightness of the hub bearing.
Opens the oil cap on the top of the steering
When adding the power steering fluidthe
Abnormal noise after filling reservoir and turns the steering wheel on the
air leaked into the steering system and
with the power steering fluid. spot at engine idle to drive out the air from
caused the abnormal noise. the system.
Chapter VI Transmission shaft
The transmission shaft is also known as the universal driving device. Whose function is mainly to
connect two non-parallel shafts, and transfer the power along with its change of position. The axial line of
the gearbox output shaft intersects with that of the drive gear of rear axle with change in the relative
position. The power transfer between both units have to be made in the application of the universal driving
device. The universal driving device is in general composed of the universal joint, spline shaft, bushing
fork and transmission shaft body, sometimes added with the intermediate mounting parts.
Section I Introduction to the transmission shaft, model C2
I. Inspection and reparation of the transmission shaft

1) Checks the dust cover on the drive shaft to see if there are any fissure, damage, oil leakage and looseness
of dust cover clamp etc. If any damages detected, the dust cover and clamp should be replaced.
2) Checks the ball cage to see if there are any wears and moves.
3) Turns by hand the drive shaft, no looseness is allowed between the axle and ball cage.
4) Checks the shaft splines to see if there are any wears or damages.
5) Be sure of no distortion or fissure on the drive shaft. If in such case, the replacement has to be made.
6) Checks the grease on the universal joints to see whether it is contaminated or not. It is just done by
rubbing it between two fingers. If sand grains felt, it indicates the CS universal joint has been contaminated
and needs to be replaced.
II. Assembly and adjustment of the CS axle shaft

The CS drive shaft assembly, model C2 applies the mode AC+GI, i.e.: the outer ball cage is the AC type,
ball caged universal joint; the ball cage is the GI typed, axle movable three-ball pin universal joint (See
figure 1.1)
CS drive shaft, LH CS drive shaft, RH
4 5
2 3
1 4
Figure 1.1
1) Applies the gear oil on the surfaces of drive shaft splines and gearbox shell.
2) Be sure that the opening of snap spring faces down prior to the assembly of drive shaft.
3) Inserts the sliding end 2 of CS axle shaft, LH into in the left end of differential, and fits the fixing end
1in the front wheel hub LHInserts the sliding end 2 of CS axle shaft, RH into in the right end of
differential, and fits the fixing end 1in the front wheel hub LH (See figure 1.1).
Attention: be sure to insert the ends 2 and 3 of differential on the position until a Click from the snap
spring is heard. There is a clearance in 3-5mm on the outermost face of gearbox in the sections 4 and 5 of
the universal joint at the sliding end (See figure 1.1)
4) Checks by hand the drive shaft after the assembly.
5) Fits up the axle nuts and locks the nut caps and lock pins (See figure 1.2)
6) Fits up the wheel assembly.
Lock pin Locking nut cap Shaft head nut
Figure 1.2
Section II Common faults of transmission shaft and troubleshooting
I. Abnormal noise of front drive shaft

1) If the Click sounds from the front drive shaft when turning off, it indicates that the CS universal joint
at the outer side has been seriously worn
Solution: Replace the CS universal joint at the outer side.
2) When the car accelerates, decelerates or turns off, the abnormal metal knocking sounds from the drive
shaft, then, this indicates the CS universal joint at the inner side has been seriously worn.
Solution: Replace the CS universal joint at the inner side.
3) Whatever you turn off, accelerate or decelerate, there is always the abnormal noise from the drive shaft
at some of sides, this indicates there is defection in the front wheel bearing at the side concerned.
Solution: Replaces the front wheel hub bearing.
II. Vibration of the front drive shaft

If driving by acceleration, the vibration or turning run-out occurs on the drive shaft, it is possibly caused by
the excessive wear on the liquid channel surface of inner sided universal joint.
Solution: Replaces the inner sided CS universal joint.
Chapter VII Suspension
Section I Introduction to the structure of suspension system

The axle is divided into the front axle and rear axle. It is a device between the frame and wheels intended to
load various weights and transfer the forces and moments from every aspect.
The suspension system refers to the generic terms of a device, which joints the resilience and used between
the frame and axles. It absorbs and moderates the impacts and vibrations from all forces and moments on
the road so as to ensure the safety drive.
The model MP Midi is a brand new sedan independently developed and designed by BEIJING FOTON
MOTOR CO.LTD.
The front suspension of the model has adopted the McPherson independent suspension of high technology
maturity and the rear suspension the trailing arm typed, torsion rod independent suspension.
I. Structure of suspension system

1. The front suspension uses the McPherson independent suspension of high technology maturity, which is
characterized by less space occupation, compact structure and Medium load capacity. The front suspension
assembly is shown in figure 1.
L/R sliding column assembly
Lower swing arm assembly LH
Sub-frame assembly
Lower swing arm assembly RH
Front cross stabilizer assembly
2. The rear suspension uses the trailing arm typed, torsion rod independent suspension, which is
characterized by less space occupation, compact structure and strong load capacity. It is fitted with the
torsion bar stabilizer assembly, which is able to control effectively body heeling and increase the safety.
The rear suspension assembly is shown in figure 2.
Rear PU aux. spring
Rear cross stabilizer
Rear axle tube bracket assembly
Rear axle tube bracket assembly
Rear axle support cushion
Rear shock absorber assembly
II. Maintenance of the axles and suspension system

1. Maintenance of the front suspension
(1) Checks to see if the helical spring has any fissure, scratch and damage. Replaces it when necessary.
(2) Checks the stabilizer bushing and slip-pillared cushion to see if there are any ageing and damage.
Replaces it when necessary.
(3) Checks the column linkage ball pin and lower swing arm joint pin see if there are any looseness, and
whether the front/rear bushings of swing arm are aged and cracked. Replaces it when necessary.
(4) Uses a 4W locator to check the front wheel positioning
2. Maintenance of rear suspension
(1) Checks the shock absorber to see whether there are any oil leakages, any ageing and cracking on the
rubber bushing of lifting lug. Replaces it when necessary.
(2) Checks to see if there are any damage and fall-off on the rear PU aux. spring. Replaces it when
necessary.
(3) Checks to see if there are any deformation and damage on the rear axle support cushion. Replaces it
when necessary.
(4) Checks to see if there are any fissures and scratches on the rear torsion rod stabilizer. Replaces the rear
axle assembly when necessary.
III. Failure diagnosis of the axles and suspension system

1. Failure symptom: the rear suspension produces abnormal noise and swing etc., prior to the drive.
Causal analysis: Fitting parts loosenedthe front suspension lower ball joint pin, the stabilizer
column linkage ball hinge, the stabilizer clamp, the upper support cushion of
sliding pole, the rear axle fastening bolts, the support cushion fastening bolts, the
rear shock absorber fastening bolts and the rear backing plate bolts etc. loosened.
Solution: Tightens the loosened bolts
2. Failure symptom: Oil leakage on the front/rear shock absorbers accompanied with abnormal noise.
Causal analysis: Hydraulic oil leakage in the shock absorber due to the failure of shock absorber
gasket, abnormal noise caused by the absorbing performance degradation of the
shock absorber.
Solution: Replaces the shock absorber.
3. Failure symptom: drive-line deflection, eccentric wear on tires.
Causal analysis: Too large deviation of toe-in between the L/R front wheels, difference in the
pressure on the L/R tires, lower ball joint deformation and ball pin loosened.
Solution: Tests the front wheel positioning, adjusts the toe-in, supplements the tire pressure.
Replaces the lower ball joint when necessary.
Positioning parameter of the MIDI wheels

1. Front wheels
Steering angle of
Positioning parameter of front wheels
front wheels
Front axle
Model of product Backward
type Introversion Camber of Toe-in of Internal Outer
tilt of master
of master pin wheels front wheels corner corner
pin
BJ6438MC6VA-1
BJ6438MC6VA-2 Steering 13 mm
10830 23030 1530 37 31
BJ6438MC6VA-P1 booster (1510)
BJ6438MC6VA-P2
BJ6438MC6VA-P1 Mechanical 13 mm
10830 130 1530 37 31
BJ6438MC6VA-P2 steering (1510)
2. Rear wheels
Positioning parameter of rear wheels

Model of product Main deceleration ratio
Camber of wheels Toe-in of rear wheels
BJ6438MC6VA-1 4.052
BJ6438MC6VA-2 4.333 -2010 or

-12530
BJ6438MC6VA-P1 4.052 -1-3mm
BJ6438MC6VA-P2 4.333
Chapter VIII Brake system
Section I Introduction to the brake system structure
I. Structure description:
The brake systems may be divided into the service brake system, parking brake system, emergency brake
system and assistant brake system etc. The brake system intended to decelerating and even parking in the
use process of the car is referred as to the Service Brake System; The brake system intended to park the
stopped car on the place is referred as to the Parking Brake System; The brake system, which can ensure
the car for decelerating or parking in case of the failure of service brake system, is referred as to the
Emergency Brake System; The brake system. Which assists the service brake system to reduce the speed or
maintain the steady speed in the use process, but unable to make an emergency brake, is referred as to the
Assistant Brake System. In terms of the above-describe brake systems, the service brake and parking brake
systems are necessarily required for every vehicle. Their functions are intended to force a car, as per the
requirement of driver, in the running process for deceleration and even stop, steadily park a stopped car on
different road conditions (incl. on the slope) and keep the stable speed of a car driving on down-hill road.
The model MP Midi is fitted with two sets of independent brake systems including the service brake system
action on the front/rear wheels; the hydraulic controlled dual braking system with the vacuum booster; the
front disc and rear drum brake and the rear wheel brake attached with the parking brake.
The service brake system is to be used during the driving in the car. It is food-operated and serves as the
master brake. The parking brake system is used during the parking and moving up on the slope. It is
manually controlled.
In case of emergency brake, the parking brake system is applied together with the service brake systems. In
case of the failure of service brake system, you should drive the car immediately , with the assistance of the
parking brake system, to a safe area or a service station for the inspection and maintenance.
II. Main specifications of the brake system

S/N Items Data
Hydraulic operated with vacuum booster,
1 Service brake system modes double-loop-wheel brake system and front disc and rear
drum brake.
Front wheel Disc brake
2 Brake
Rear wheel Drum brake
+02
3 Brake disc(mm) Standard thickness 22 01
4 Friction plate(mm) Standard thickness 18 0.2

5 Brake drum I/D(mm) Standard value 228.6
Brake shoe friction liner
6 Standard thickness 6
(mm)
Brake master cylinder Cylinder diameter 23.81

7
size(mm)
Stroke 35.68
8 Diameter of rear brake sub-cylinder(mm) 22.22
9 brake liquid HYZ4 rated synthetic brake liquid
10 Parking brake system mode Pull-wired and hand-wheel brake
11 Free stroke of brake pedal(mm) 166
Braking distance for the road test (cement pavement in
12
80Km/h) 50m
III. Inspection and reparation
1. Checks the height of the brake pedal. The ground height of brake pedal should be 140mm. If incorrect,
the adjustment should be made at once.
2. Free stroke of brake pedal. Steps down the brake pedal until the resistance is felt. The free stroke of
brake pedal is to be 10~12mm.
3. The front disc brake clearance is automatically adjusted while the rear drum brake clearance manually
adjusted.
4. Performance test of vacuum booster
1) Steps down several times the brake pedal prior to start up the engine and checks to see that no change
should take place in the stroke margin of brake pedal;
2) Steps down the brake pedal and starts up the engine. If the pedal continues to move slightly down a little
bit, it indicates a sound operation.
3) Shuts down the engine after started up in 1~2mins. Slowly steps down the brake pedal for several times.
If the stroke of pedal for the first step is the largest, but is lifting gradually for the 2nd or the 3rd time, it
shows a proper performance of vacuum booster.
4) Steps down the brake pedal during the running of engine. Foots down the brake pedal and shuts down
the engine while keeping the pedal stepped down. If there is no change in the stroke margin of pedal within
30s, it represents a healthy seal quality of vacuum booster.
5. Inspection of the parts of brake master cylinder;
1) Blows clean with the compressed air the parts of brake master cylinder after break-down and cleaning.
2) Checks the cylinder wall to see whether there are any rusts or scratches.
3) If there are any wears or damages on the cylinder tube, it should be replaced.
4) Checks if there are any scratches on the pistons and sealing rings and replaces them when necessary.
5) After the brake master cylinder fitted up, adjusts the length of tappet before it is mounted on the vacuum
booster(right side)
6. Inspection of the front disc brake
1) The standard thickness of brake disc: 22mm, the wear limit: 19.5mm.
2) Measures the radial bounces within 10mm of the outer edge of brake disc. If the bounces are larger than
0.12mm, it should be replaced by the new part.
3) The max. increment of the cylinder diameter is not allowed to be exceeded by 0.05mm.
7. Inspection of the rear drum brake
1) The standard I/D of the brake drum: 228.6mm, the max I/D: 230mm
2) The wears or scratches of the brake drum may be repaired by the lathe polishing.
3) The contact area of the friction plate of brake shoe with the brake drum should reach more than 85%,
otherwise subject to the grinding process.
4) When the distance from the friction plate surface of brake shoe to the rivet head is lower than 0.8mm, it
has to be replaced.
IV. Reassembly, adjustment and inspection

1. Reassembly of brake lines
1) Proceeds in reverse order of the removal.
2) In reassembly, takes care of the cleanness of each brake connector. The oil pipe has to be securely
clamped with the clip and joints fastened. The oil pipe should be free of obstruction and the joints without
leakage.
2. Exhaust adjustment of the brake lines system
The brake system is fitted with the ABS, type MK60.
In terms of the air exhaust of line, please refer to the specifications of the ABS liquid filling and air exhaust
3. Inspection of the brake performance
The automotive brake performance may be inspected on the brake tester. Drives the car onto the test-bed
and tests respectively the weight of front axle and rear axle. Then drives the tested car on the brake tester
and keeps it in straight position. Operates as per the operating instructions of equipment. Only one
inspector is allowed in the car.
Percentage(%) between the front axle brake power and the shaft load 60%
Ratio between the R/L difference of the front axle and the greater (%) 15%
Brake
Ratio between the R/L difference of the rear axle and the 20%
Greater (%)
performance
testing Ratio (%) between the max. value of the brake power difference and the rear axle load 7%
when the rear axle brake power is 60% lower than the rear axle load.
Ratio (%) between the sum of the parking brake power and the vehicle weight. 20%
Percentage (%) between the total brake power and the vehicle mass. 60%
Section II Common Faults of Brake system and Troubleshooting
1. Common Faults of Brake system and Troubleshooting

(1) Brake failure. When stepping down continuously on the brake pedal, no brake effect is available on the
wheels.
Causes Troubleshooting
None or insufficient brake liquid in the master pump Fills with full brake liquid
Master pump cylinder badly worn or the leather cuff of the
Replacement
master/sub-cylinder worn
Brake pipe broken or joints badly worn Repairs or replaces the brake line
Tappet pin of the master pump fallen off. Reassembly
(2) Ineffective brake. The car is unable to stop immediately when the brake pedal is stepped down, even
with poor effect followed by several steps.
Air or oil leakage in the brake lines Drains out the air and eliminates the oil leakage
failure.
Excessive gap between the brake pedal and the free stroke Adjusts the free stroke of brake pedal
Excessive gap between the brake drum and friction plate clearance Adjusts the clearance
Leather cuff of brake blocked due to expansion Replaces the leather cuff
Friction plate excessively worn, poor contact or oil fouling Polishes or replaces the friction plates
Brake drum out of round, friction coefficient disqualified Repairs the brake drum or replaces it
Brake hose aged and expanded Replaces the hose
(3) Brake deviation. When making the brake, the brake power at both side is unbalanced or asynchronous
which deviates the car during the brake process.
The clearance of the brake shoe plate on the right wheel is inconsistent Adjusts the clearance
Joint of some brake hose jammed. Air leaked into the pipeline Dredges the line and bleeds the line
Some sub-cylinder blocked due to the leather cuff expansion Replaces the leather cuff
Friction plate of brake shoe on a certain wheel is contaminated by oil
Polishes or replaces the shoe plate
stains or the rivet exposure due to severe wear
Unbalanced air pressure between the R/L tires Fills up the pressure
Some of the brake drum out of round Repair
Measures and checks after the assembly of the
Brake drum deformed after assembled with the tires
brake drum with the tire, polishes if necessary.
Replaces with brake drum of consistent friction
Inconsistent friction coefficient between R/L brake drum
coefficient
Time difference in the effects between the R/L brake power Checks the causes and adjusts
The car Frame seriously deformed. The wheelbase is not parallel Measures and adjusts
(4) Brake biting (Brake drum heating)
The brake effect can not be relieved in time after releasing the brake pedal, which overheats the brake drum.
The normal operating temperature of brake drum should not be higher than 70 of the ambient
temperature (the temperature will be even higher when driving on the long slope in the mountain area.).
The detection of cause for the brake drum heating may be carried out by the ways of the free driving path
and non-braking drive.The free loaded vehicle starts free driving on the Plain and dry road from the initial
speed of 30km/h to fully stop. The free-driving distance value (calculated as per the average value of two
round-trips) for the ordinary vehicle should be not less than 220m and for the FWD vehicle not less than
180m. If the slickness occurs between the brake drum and brake friction plate, the free wheel drive will
largely shorten and the brake drum will heat up.
The car drives 3-5km without stepping on the brake pedal.If the brake drum is heating, it is resulted by the
causes such as the brake friction plate rubbed with the brake drum or the looser hub bearing, rear axle
bending etc.To make further adjustment, you may lift the heating axles with the jack and rotate the
wheels.If the brake friction plate does not rub the brake drum, it should be determined that the hub bearing
is too loose the rear axle bent.
1. Biting up between each wheel
Slow return of the master pump Repairs the master pump
Too short free stroke of brake pedal Adjusts the free stroke
Pipeline jammed and difficult oil loop Dredges the oil line
2. Some of individual wheel biting

Too narrow clearance between the brake drum and friction plate Adjusts the clearance
The reset spring of brake shoe weakens or support pin of brake shoe and Replacement spring or adjusts the support pin
eccentric resistances too large and the eccentricity
The leather cuff of sub-cylinder bloated or the pistons locked Replace or repair
Brake hose bloated and jammed Replaces the brake hose
3. Abnormal brake noise. When making the brake, you often hear the squeak noise or discontinuous
friction.
Brake drum out of round or uneven friction Repairs or replaces the brake drum
Friction plate dirty or rivet loosened Polishes or repairs by riveting
Brake shoe impact with the brake drum Repairs and adjusts
Friction plate excessively worn. Brake drum rubbed by the
Replaces the brake shoe with the friction plate assembly
rivet head
4. Gradual depression of brake pedal. When braking during the drive, it suddenly happens to step down
brake pedal to the end or not rebound sufficiently by continuous steps on the brake pedal.
Oil leakage of the brake line or air leaked into the system Reparation and deflation
The leather cuff race of master pump worn
Repairs and replaces the parts
Oil channeling at both ends when braking
Leather cuff of sub-cylinder overturned by stepping Reparation
5. Brake pedal gradually raised up. When braking in the drive, the brake pedal raises up gradually by
several continuous steps
Fill hole of master pump jammed or blocked by
the rubber ring, which keep the redundant brake liquid from Dredges or readjusts the fill hole
returning to the storage cup
The free clearance of the piston tappet of master pump is too
Readjustment
narrow
6. Brake pedal too ponderous. It feels difficult with poor braking effect when stepping down the brake
pedal due to the vacuum booster failure.
Air leakage in the diaphragm of vacuum booster or the spring
Checks and repairs the damaged part of vacuum booster
broken
Oil leakage in the diaphragm of control valve Checks and repairs the damaged part of vacuum booster
Vacuum valve of control valve badly closed Checks and repairs the damaged part of vacuum booster
Air leakage in the vacuum line Replaces the hose or tightens the joints
Failure of the non-return valve Replaces the non-return valve
Appendix: Test method to prove whether the brake drum is in normal heating process or not:
Drives the car on a plain road for 10km and uses the brake properly, then touches the brake drum. If the
temperature is tolerable, it is considered that the brake drum is in normal temperature.
Attention:
1. Under the above state, it is allowable that the temperature difference exists between the front/rear brake
drums or R/L brake drums.
2. In case where the temperature of brake drum is intolerable by hand touch when several emergency
brakes have been tried on the road test path, it is considered that the brake drum is in abnormal temperature.
Chapter IX Electric equipment
The body electric system refers to power supply, powered devices,connection conductors, various
switches and different protective equipment etc., fitted in the body. The system is characterized by a large
variety of parts, complex structure, interconnection, interaction and at the meantime opposition to each
other. The power supply is composed of the battery, charger, fuse group and harness etc,. The vehicle line
is made up primarily with four harness divisions such as chassis, body, front dashboard and door.
During the process of reparation, you may refer to the wiring schematic of the vehicle electric equipment
(See the Wiring Schematic of Electric Equipment in the end of manual).
Section I Battery
I. Introduction to the product structure of battery
z This is afully service-free lead-acid battery.
z The positive/negative grids of battery are made on the lead-calcium alloy. The grid applies the
intermediate plate lugs and radial-grided frame in lesser thickness.
z The battery uses the PE bag-partition.
z The polar group of battery is made in general, through the forge welding.
z The positive/negative plates of battery are made in the application of the active substances in most
rational formular and painted by machine, the substance of positive/negative nature are formulated
through calculation in best ratio.
z The plastic enclosure of battery adopted the seal structure.
z The plastic grooved bottom is designed in fixed structure.
z The plastic cover is in double layers, two covered rooms are designed in the structure of labyrinthed
acid reflux and air exhaust.
z In the host exhaust port are fitted the hydrophobic air filter plates, which, in case of no acid leakage do
not restrict the air overflow, but once the acid exhaust into the system, it will reflow into the battery.
z The air filter plates in the exhaust system also perform the effect of antiflame device, which is able to
prevent
z The battery explosion due to the exterior open fire or the entry of sparks into the battery.
z The battery applies the sulfuric acid of higher purity and strictly controls the quantity of electrolyte in
the battery.
z The battery is fitted with the charge indicator,
z Through the sight hole of indicator, you may keep track of three states such as the adequate charge,
shortage of charge and insufficient electrolyte.
II. Installation of battery:
The battery is located near the gearbox at the left side of the engine compartment. In application of the
following fixing method, it is press-fixd on the battery bracket by the battery platen.
Precautions to the installation: The battery grooves have to match up with the bumps on the battery bracket.
When fixing the platen, Places first the bump into the groove, then, tightens the nut.After the completion of
installation, the battery must be ensured with any shakes.
Operation note of battery
Description of Indicator:
On the top of battery, there is a charge indicator positioned as showin in Figure . below:
Charge
indicator
Green Good
Black Charge required

Liquid insufficient and
None
Color description: necessary for replacement
Description of warning signs:

Keep the children away from the battery and electrolyte
The battery contains the highly corrosive dilute sulfuric acid. Wear the protective gloves and
safety goggle during operation. Care for protecting your eyes and face. Once exposed to the
skin, rinses it with plenty of water for several minutes, then calls on the doctor for medical
treatment.
The battery belongs to the dangerous parts. Reads carefully the operating instruction manual
prior to the operation!
The battery is able to produce flammable and explosive gases. The cigarettes, sparks or sparkle
are possilbe to cause the battery explosion, thus, use of open flame, coverless lamp and
smoking are strictly prohibited near the battery
When operating the battery, it is necessary to wear the safety goggle.
The charge of battery can easily produce flammable and explosive gases, hence the charge
should be carried out in a well ventilated place.
Sing of recycle. The material of value of the battery may be reused. Therefore, it is prefereable
to give the used or damaged battery to the Dealership or service station of Foton Company
The battery also contains the toxic substances e.g. sulfuric acid and lead etc. The are the
special garbage harmful to the environment. Be sure not to handle it as household waste.
Operation notes and cautions:
z Chechs the voltage of battery measuring terminal prior to the loading. If the voltage at terminal is lower
than 12.5V, the charge is necessaire.
z Handls the battery with care during the loading. In the process of handling and use, the battery inclined
should be less than 30. Be careful of the polarity and positive anchoring when loading. Avoid the
mechanical shock during the use.
z De sure not to disconnect the battery when the ignition switch is turned on the engine runs, otherwise it
may damage the electric system or parts.
z When a metal part comes into contact with two polarities of battery electrical wiring, or the
positive of battery with the body, the short-circuit will come about and cause the fire and serious burns
z Prior to operating the electric system, you have to shut down the engine and all powered devices,
disconnect the negative cable of battery.
z When disconnecting the battery with the vehicle electric system, the negative cable has to be cut off,
then the positive. The reverse order is required when encasing.
z Do not keep the battery under direct sunshine for longtime, to avoid the damage of the battery shell by
strong ultraviolet ray.
z It is recommended to disconnect the battery when the car is going to leave unused more than 1 month.
z Provided the car is not used at low temperature for longtime, the proper measures for battery protection
should be taken to prevent the frozen damage.
z Be sure not to charge the frozen or defrost battery, otherwise it is likely to cause explosion. The frozen
battery has to be replaced. The empty battery is likely to freeze at about 0.
z In storage of battery, be sure that no large difference of temperature between the upper and lower parts,
otherwise the free discharge will come about.
Maintenance and testing
z The ambient temperature for battery storage is at 5-40, the heating or cooling measure should be
taken in excess of this rage.
z The environment of battery storage should be kept clean and dry, and the protective measures from
dust, rain and moisture should be available.
z If the storage of battery is longer than 90 days, it should be charged, the charge is to be made by the
ways as follows:
(1) The current at the rate capacity of 0.1 time for 20 hours (e.g. 6-QW-70: the charge current
=0.170=7A): After the battery voltage charged with the constant current reached to 14.40V,
continues to charge it for 1-2hours.
(2) Before the sale of car, the voltage should be measured. If the terminal voltage is lower than 12.50V,
the charge should be supplemented as per the above method.
z Visually checkes the outlook to observe if the battery shell shows any expansions or fractures. In case
of such expansion or fracture, be sure not to use again.
z Checks if there are any corrosions and contaminations on the connections of battery cable and the
cables. If contaminated, loosens them and wipes out.
z Checks through dropping the voltage of battery poles, and judges by the voltage dropout if there are
poor contacts at the joints. If the voltage dropout is higher than 0.1V, it indicates that extra-high
resitance exists at the pole connection, the joints need to be cleaned out.
z Leak detection of battery: connects the negative lead of voltmeter to the negative column of battery;
moves the positive lead to different position of battery shell. If no leakage of battery, there is no votage
display.
z This is the maintenance-free battery. With an interscope, the rough judgment can be made: when the
battery is of adequate charge (over 65%), it displays in green, when the charge is lower than 65%, it
displays in black. If colorless, it means the shortage of electrolyte. For the time being, the battery has to
be replaced.
z The voltage tesing by open circuit may substitutes the gravity testing: Bridges two test leads of
voltmeter over two pole columns of battery to measure the open-circuit voltage. The corresponding
relation between the test value of open-circuit voltage and the power state are shown as below:
Open-circuit voltage/V Power state /%
12.6 100
12.4 75
12.2 50
12.0 25
11.9 Fully discharged
Battery charge:
Additional charge of battery
z Storage period: three months for the storage of battery with liquid. When using in excess of the time
limit, the charge should be supplemented by the ways as follows:
In terms of maintenance-free battery: the charge applies the method of constant voltage: constant
voltage at 16V; max. tolerance current: 0.25C20A, until the charge current approaches the zero, and
keep continuousely steady for 2-3hours without change.
Description: C20 refers to the nominal rate capacity of battery for 20hours, e.g. the nominal rate
capacity for 20hrs of the battery in 54Ah: 54Ah, max. tolerance charge of current: 0.2554=14A
z When charging the battery, the temperature should not be higher than 45, otherwise the measures
such as the water bath should be used to reduce the temperature to temporarily lower the charge current
or voltage.
z During the first 3 hours of the charge process, be sure to observe in time and adjust the charge current,
so as to prevent the burnout of charger due to the overcurrent or other accidents.
Difference of supplementary charges between the fully free-service battery and open battery
z Because of the structural difference of the maintenance-free battery from the open typed battery, the
former one requires no water supplementary supply during the usage, thus the different charge method
is applied for the routine maintenance and application.
z In the maintenance and charge of open typed battery, the actual interior of the battery can be visible
because of the openable stopper, which enables the density measurement of each cell. While testing the
battery, each cell can be individually checked by the methods of constant voltage limit and constant
current charge; the distilled water can be supplemented during the use and maintencance, while the
service-free battery is different instead.
z When charging the maintenance free battery, the constant voltage limit should be applied, the voltage
at each terminal of battery in average should not exceed 16V(12V battery, same as below). If the
voltage is over 16V, large amount of air will exhaust from the air outlet, and cause the loss of
electrolyte. During the use, the battery can not be added with water. The overdissipated air will
premature the failure of battery. Therefore, the charge voltage of the service-free battery has to be
strictly controlled during the use and maintenance.
z In normal cases, the service-free battery doesnt require the charge by constant current, for the
temperature of battery will increase at the later period of the constant-current charge, most electrolyte
water from electric power will cause the loss of electrolyte. The repetition of constant current charge
will loosen too much of electrolyte and affect the starting performance of battery as well as the
premature of service life.
Causes of battery common defects(failures) and solution of testing and determination
Problems due to the customer use. The last two are attributed to the responsibility of manufacturer. The
specific defects are listed as below
Table of causes of battery common defects(failures) and solution of testing and determination
Solution for testing and Responsi
Defects Analysis of cause Handle of defects
determination bility
Battery coupled with dry
1. Overcharged Renew supply
electrolyte.
Battery bulging for customer
2. Air outlet blocked Visual inspection
and deformation
Normal electrolyte, teardown
3. Pole plate seriously bended Company claims
analysisi
1. Mechanical shock Visual inspection
Renew supply
2. Batter explosion due to the Battery coupled with dry
for customer
overcharge. electrolyte.
Battery leakage 3. Fracture at the heat sealing
Air tightness testing
part
Company claims
4. Terminal crept and seepted Quality problem if the terminal
with acid liquid intact
1. The set value of voltage Check and
regulator is lower sited 1. Voltage Ca. 12V. adjustement
Insufficient 2. Pole columns and wires 2. Indicator shows insufficient Supplementary

charge corroded charge charge
3. Hard startup Renew supply
3. Failures of generator or lines.
for customer
1. The set value of voltage 1. Indicator color darkened and Check and
regulator is higher sited. yellowed adjustement
2. Overcharge of current and 2. Electrolyte dried or liquid level
Over charged overtime. lower and muddy
Renew supply
3. After teardown, the active
for customer
substances on the pole plates fall
off
Supplementary
1. Longtime shortage of charge
1. Voltage under 10V charge
2. Short-circuit and electric 2. Indicator shows insufficient Check and
Over discharge
leakage charge adjustement
3. The electrice devices not 3. Unable to startup the vehicle Renew supply
turned off after parking for customer
Terminal voltage lower than 10V,
Short-circuit Partition damaged Company claims
supplementary charge invalid
welding through the partition
sealed-off
Company claims
Pole columns droped and 1. Voltage abnormal and insteady
broken
2. Terminal damaged by solution
Open-circuit Terminal false welded. Basbar 3. Unable to charge and discharge
broken
Bad use condition
Connection of busbar with the Renew supply
plate lug is broken up. The for customer
electrolyte is lower than the
lugs.
Inverse pole of Wrong connection of positivie Inverse charge by
Voltage in negative display
charge pole when charging the battery. customer or renew
1. The state of discharge lasted
1. Discharge capacity lower Repeated charge
overtime.
Carbonatization 2. High charge voltage and battery
2. Insufficient charge for Renew supply
heating
longtime for customer
1. Decreased level of liquid due Electrolyte liquid muddy and Renew supply

Indicator shows to over charge indicator darkened and yellowed for customer
Liquid used out Normal again after the indicator Indicator
2. Failure of indicator
changed replacement
Board drop False welding Teardonw analyisis Company claims
Common battery defects and analysis of causes
z The pole plate sulfitation of battery is one of commonly seen defects. The major cause is the fact that
the battery is short of the charge for longtime or the battery is left unused in state of insufficient power.
The heavy pole plate sulfitation causes the much lower voltage of battery, the concentration of
electrolyte reaches or approaches to that of water, which leads the larger inner resistance of battery and
difficult charge. The worser case may cause the battery discarded.
z Treatment of the pole plate sulfitation of battery:
Charges the battery with the current at 0.1C20A until the terminal voltage reaches to 15V, then
continues to charge by the current at 0.05C20A until the terminal voltage reaches again to 15V,
afterward, keeps charging for 5hours. Discharges the charged battery with the current at 0.05C20A
until the terminal voltage reaches to 10.8V. If the battery suffers from heavy sulfitation, the voltage
will surpass 15V once it is power-supplied, thus, charges the battery with the current at 0.05C20A until
the terminal voltage is lower than 15V. Afterward, follows up the above method for subsequent
treatment.
z The blockout of pole plate is another defect. The major reason thereof is that the battery is kept for
longtime in state of overcharge during the usage, due to higher voltage output from the voltage
regulator of car, which increases the water consumption of battery and furtherly raises the temperature
in the battery. This leads to fast blockout of pole plates as well as much lower capacity.
z This kind of loss of capacity is perminant, there is no alternatives for the battery remedy.
Section II Audio system
I. Audio configuration and operating description

CD player
Cassette player
II. CD player failures in vehicle system and solutions
Division of
Failure Possible reason of
Functions S/N Definition of failure modes Solution Responsibili
modes failures
ties
Poor contact of fuse
Replug-in
tube Not
When turning on the ignition determined
Poor contact of wire
switch by inserting the key and Replug-in
with the host
No power or pressing down the power supply
1 Poor contact of the Lock-pin Spare part
no display switch, neither the radio reacts,
nor the screen lamp lightens and ignition switch replaced supplier
displays Audio
Damage in the Not
replacement and
audio-system determined
retry
Antenna not Pulls out the
Use
pulled out antenna
When you press down the search
Antenna feeder Antenna Spare part
button or tune the station
Bad/few broken/short-circuit replacement supplier
selection knob, the wavebands
2 broadcasting Poor contact of Automobile
of frequency modulation (FM)/ Replug-in
stations antenna with the host manufacturer
amplitude modulation (AM) are
unable to receive any stations Audio
Not
Audio-system failure replacement and
determined
Vehicle retry
function If the balancer is sited
Reset Use
in the middle
Speaker line Re-solding or
When receiving the broadcasting
falloff/poor contact connecting Spare part
Mute in one station or playing the CD, no
3 Speaker supplier
side audio output available on the Speaker damaged
left/right channel. replacement
Audio
Unhealthy in Not
replacement and
audio-system determined
retry
Trial run after
Electricity shortage of
adequately Use
battery
charged
Each time after turning on, the
Lines of B+and ACC readjusts the
No memory timer on the main dashboard
4 power supply in connection
of timer displays
inverse position position Not
12: 00
Audio determined
Unhealthy in
replacement and
audio-system
retry
III. Judgment of CD Player failures per se in the vehicle system and solutions
Failure Definition of failure Possible reason of Division of
Functions S/N Solution
modes modes failures Responsibilities
Replaces the fuse
Main power
tube(due to the
supply/fuse tube
conductor inserted
burnt
into the device)
When turning on the Poor contact of the
Not determined
ignition switch by host connection with Replug-in connector
inserting the key and the body
Partial Unable to turn pressing down the The power supply of
1 radio-cassette players Reconnect
function on power supply switch,
neither the radio reacts, disconnects/falls off
nor the screen lamp Buttons on dashboard
lightens and displays Readjusts the bottons Use
lock up
Contact with the
special service station
Others not determined
of R/C player
manufacturer
Screen is damaged by
No display: when Displayer replacement Use
impact
You turn on the radio
Contact with the
set, the display lamp
Screen has Displayed IC pin is special service station Product
lightens, but no digital
no false welded of R/C player manufacturer
2 display; Insufficient
display/show manufacturer
dislay: On the screen,
insufficiency Contact with the
there are number of
missing strokes or special service station
Others Not determined
overstrokes. of R/C player
manufacturer
All bottons ineffective:
whenn pressing any of Cleans out the wrong
the bottons on the Wrong operation memory by pressing
dashboard, no one is the RESET button.
active; Use
A certain botton
ineffective: if some Buttons on dashboard
Readjusts the bottons
botton can not performs lock up
its function;
Botton
Wrong butoon function:
function Poor contact/false
3 the function of button is Product
lost/wrong welding of dashboard Replug-in/reweld
not consistent with the manufacturer
function wiring
actual performance;
Contact with the
Control panel wiring
damped and with
of R/C player
leakance
manufacturer
Not determined
Contact with the
Partial Other problems
of R/C player
function manufacturer
Poor contact of the
Replug-in the
host connection with Not determined
connecting wire
the body
Cancels the mute
Stay in mute state Use
Under the normal state function
4 Mute speaker of Radio/CD play, the Amplifier IC Product
Rewelds the IC pins
speaker is fully mute. burnt/false welded manufacturer
One speaker Spare part
Speaker replacement
grouding/short-circuit supplier
The balance(BAL) is Retunes to the middle

Use
not set in the middle position
When receiving the
Speaker wire fall Spare part
broadcasting or playing Speaker replacement
Mute speaker off/speaker burnt supplier
5 CD, no audio output
in one side Contact with the
from the left or right
side. special service station
of R/C player
manufacturer
Front/rear
Retunes to the middle
balance(FAD) is not Use
Whatever playing CD position
tuned on the middle
A group of or broadcasting, only
Speaker wire fall Spare part
front or rear one of front/rear group Speaker replacement
6 off/speaker burnt supplier
speakers of speakers has audio
mute. output, the other group Contact with the
mute. special service station
Other problems Not determined
of R/C player
manufacturer
When you press down Radio antenna falls Automobile
Replug-in the antenna
the search button or off manufacturer
tune the station Radio antenna is Spare part
Antenna replacement
No selection knob, the short-circuited supplier
broadcasting wavebands of Broadcast station
7 Normal condition Mis-judgment
stations frequency modulation pause
received (FM)/ amplitude Contact with the
modulation (AM) are special service station
unable to receive any Others Not determined
of R/C player
stations manufacturer
Radio antenna falls Automobile
off(poor contact) manufacturer
Some of the waveband RFH of FM/AM or Product
FM or AM Antenna replacement
normal while another circuit damaged manufacturer
8 receives not
band receives no Contact with the
stations
stations special service station
of R/C player
manufacturer
Radio mute: FM/AM
has no audio output, Antenna falls Automobile
while the audio or CD off(poor contact) manufacturer
play is normal;
FM/AM mute: some of Contact with the
waveband has audio Bad switching of special service station
output while another Receiving/playing of R/C player
Radio or no audio output manufacturer Product
9
FM/AM mute Contact with the manufacturer
RFH of radio or special service station
Radio circuit damaged of R/C player
manufacturer
Contact with the
of R/C player
manufacturer
Radio antenna falls Automobile
off manufacturer
RFH OF FM/AM OR
Product
CIRCUIT Antenna replacement
manufacturer
After you press down DAMAGED
the search button or LO/DX(far/near
Few stations tune the station distance)button
Reset is in DX state Use
10 received or selection button, the setting
with noise FM/AM waveband only inappropriately
receives rare stations or All environmental
with stronger noise. normal condition Mis-judgment
influences
Contact with the
of R/C player
manufacturer
Contact with the
Failure of radio special service station Product
After the radio receives
output circuit of R/C player manufacturer
a staion,
Radio mute at manufacturer
11 the speakers at one side
one side Contact with the
are mute, but
normal in play/CD state Others special service station
Not determined
of R/C player
manufacturer
Heavy taps/scratches on
CD disc replacement
CD disc
Inconsistent CD format
CD disc replacement Use
(MP3/VCD etc)
After you placed CD
Cleans out the laser
No disc disc, the scrren displays Laser head dirty (dusty)
head with swab.
reading/poor no CD timer or only
12 Aged laser head
reading reads out some tracks, Laser head
performance and can not continue to (Tapping disc use for
replacement
play normally. longtime)
Contact with the Not determined
Others
of R/C player
manufacturer
Presses down the
CD disc already in the
Disc Out button to
core
reject the disc.
Use
The press-dish sinks Presses Disc Out
When inserting the CD
down in the playing button and resets the
disc into the tray
Disc unable to state disc dish.
13 mouth, the CD player is
get-in. The core wiring loosens Replugs in the Product
unable to take in
automatically the disc. off pin-socket manufacturer
Contact with the
of R/C player
manufacturer
Multi-discs or disc in
Takes out the disc
wrong format inserted
Use
Disc tray mouth Replaces the core of
deformed by prying CD player
When you press down Contact with the
CD The Disc Out button
the Disc Out button, special service station
14 No disc out ineffective (No EJECT
the CD player is unable of R/C player
to reject the CD disc. display)
manufacturer
Contact with the
Others
of R/C player
manufacturer
Not determined
Contact with the
The core structure special service station
After you inserted the dislocated of R/C player
Disc CD disc, the CD can manufacturer
15
auto-In/Out not play, and reject it Contact with the
after a while. special service station
Others
of R/C player
manufacturer
Driving continuously on
Pauses the CD playing
With the car driving on the uneven road (45S) Use
the plain road, the CD CD track tapping Replaces the CD disc
Lack of
16 disc plays Contact with the
anti-shocking
discontinuously or with special service station
pauses. Others Not determined
of R/C player
manufacturer
Contact with the
When the time of disc The core wiring loosens special service station Product
reading runs off of R/C player manufacturer
CD mute or normall, but without manufacturer
17
L/R mute audio or L/R Contact with the
output or, the audio is special service station
normal. Others Unot determined
of R/C player
manufacturer
IV. Precautions to the use and maintenance of CD player
1. Please be sure to use the correct D/C voltage (1214V) instead of the positive grounding;
2. During the interior cleaning and maintenance of car, do not let water and detergent etc. on the panel of or
into the R/C player, to prevent the the PCB from corrosion and short-circuit.
4. Keeps the product as far as possible away from the dirty, dusty or highly damp and excessively worn
places;
5. Maintains the R/C player panel and disc tray entry clean and wipes them regularly with the wet towel.
6. When driving in the car on bumpy road and passing by the speed limit, try not to change the disc, for it is
easy for the disc to get misplaced.
7. Using the deformed, shaped, too thin or thick, punched and labeled discs are likely to cause the grip
socket failed;
8. Do not use heavily scratched discs. When hearing of the staccato and Clatter from disc knocking
during the disc playing, the laser head is aged and damaged.
9. When inserting the CD disc, please be sure that there is no disc in the player, and do not insert two or
more CD discs at the same time.
10. Do not place the CD disc directly on the dashboard or sun visor, to prevent the disc scratch,
deformation or large dust deposit.
11. Do not expose the CD disc to a heat source or under the sunshine to prevent from deformation.
12. When parking the car under strong light without use for longtime, it is best to take out the CD disc prior
to turn off the audio-system, to prevent the deformation under the high temperature for longtime;
13. Prior to insert the CD disc, please be sure if the surface of CD data recording is clean to prevent the
dust from entering into the CD player, which affects the CD player reading performance;
14. When taking out the CD disc, do not get in touch with the CD data recording surface to prevent the
finger prints left on the disc surface and effect on the reading capability.
15. When cleaning the disc, please use the special cleaning cloth/brush with the wiping direction starting
from the inner ring to the outer, and avoid the wiping on the same position.
16. Forcely inserting or taking out the disc causes the CD player failed;
17. Unauthorized external high power loudspeaker is strictly prohibited to avoid damaging the host;
18. In case of failures, be sure to have it repaired at the designated service station instead of arbitrarily
dismantling, to prevent expanding the scope of failures due to the man-made causes;
V. Judgment of Cassette Players failures per se in the vehicle system and solutions
When turning on the Poor contact of
Replug-in
ignition switch by fuse tube
inserting the key and Poor contact of car Not determined
No power pressing down the connecting wire Replug-in
1 supply or power supply switch, with the host
Vehicle
display neither the radio Poor contact of Spare part
function Lock-pin replaced
reacts, nor the screen ignition switch supplier
lamp lightens and Damage inside Audio replacement
displays Not determined
audio -system and retry
Bad/feu When you press down Antenna not pulled Pulls out again the
2 use
stations the search button or out antenna
received tune the station Antenna feeder spare part
selection knob, the Antenna replacement
broken/short-circuit supplier
Vehicle wavebands of Poor contact of
automobile
function frequency modulation antenna with the Replug-in
manufacturer
(FM)/amplitude host
modulation (AM) are
Audio-system Audio replacement
unable to receive any Not determined
damaged and retry
stations
Whether the
balance R/L is not
Reset Use
set at the middle
When receiving the point
No sound in station or playing CD, Speaker connection
3 re-solding or
one side the L/R audio channel wire falloff/poor Spare part
connecting
mute. contact supplier
Speaker damaged Speaker replacement
Unhealthy in Audio replacement
Not determined
audio-system and retry
Battery short of Trial run after
Use
charge adequately charged
Each time after
Lines of B+and
No memory turning on, the timer readjusts the
4 ACC power supply
of timer on the main dashboard connection position
in inverse position Not determined
displays
Unhealthy in Audio replacement
audio-system and retry
VI. Judgment of the cassette player failures per se and solution

Replaces the fuse
Main power
tube (due to the
supply/fuse tube
conductor inserted
burnt
into the device)
Poor contact of the
When turning on the Replug-in the
host connection Not determined
ignition switch by connecting wire
with the body
inserting the key and
The power supply
Unable to pressing down the
1 of radio-cassette
turn on power supply switch, Reconnect
players
neither the radio reacts,
disconnects/falls off
nor the screen lamp
lightens and displays Buttons on
Readjusts the bottons Use
dashboard lock up
Function Contact with the
of R/C player
manufacturer
Screen is damaged
No display: when you Displaer replacement Use
by impact
turn on the radio set,
Contact with the
the display lamp
Screen has Displayed IC pin is special service station Product
lightens, but no digital
no false welded of R/C player manufacturer
2 display; Insufficient
display/show manufacturer
display: On the screen,
incompletly Contact with the
there are number of
missing strokes or special service station
extra-strokes. of R/C player
manufacturer
All buttons ineffective:
Button
When pressing any of Cleans out the wrong
function
3 the buttons on the Wrong operation memory by pressing Use
lost/wrong
dashboard, no one is the RESET button.
function
active;
Function A certain button
ineffective: if some Buttons on
Readjusts the bottons
button can not performs dashboard lock up
its function;
Wrong button function:
Poor contact/false
the function of button is Product
welding of Replug-in/reweld
not consistent with the manufacturer
dashboard wiring
actual performance;
Contact with the
Control panel
wiring damped and
of R/C player
with leakance
manufacturer
Not determined
Contact with the
Other problems
of R/C player
manufacturer
Poor contact of the
Replug-in the
host connection Not determined
connecting wire
with the body
Cancels the mute
Stay in mute state Use
function
Amplifier IC Product
Under the normal state Rewelds the IC pins
Mute burnt/false welded manufacturer
4 of Radio/CD play, the
speaker One speaker
speaker is fully mute.
grounding/short-circ Speaker replacement spare part supplier
uit
Contact with the
of R/C player
manufacturer
The balance(BAL)
is not set in the Use
position
When receiving the middle
Mute broadcasting or playing Speaker wire fall Spare part
Speaker replacement
5 speaker in CD, no audio output off/speaker burnt supplier
one side from the left or right Contact with the
side. special service station
of R/C player
manufacturer
Front/rear
balance(FAD) is not Use
Whatever playing CD position
tuned on the middle
A group of or broadcasting, only
Speaker wire fall
front or rear one of front/rear group Speaker replacement Sare part supplier
6 off/speaker burnt
speakers of speakers has audio
mute. output, the other group Contact with the
mute. special service station
Other problems Not determined
of R/C player
manufacturer
Silent Available audio output Laser head
7 Laser head cleaning Use
playback in radio state; no dirty(dusty)
speaker in cassette Switch of laser head Product
playback. Adjusts the switch
damaged manufacturer
Playback Mute switch Product
Adjusts the switch
short-circuited manufacturer
Tape in wrong drop Adjusts the tape room
position(deformatio or takes out the Use
n or foreign matters) foreign matter
Motor burnt Motor replacement
Product
Core belt falls off Belt replacement
manufacturer
Core pin-socket Re-inserts the plug
falls off line.
Contact with the
of R/C player
manufacturer
Core magnetic head
Laser head cleaning
(dirty)
Playback Core guide pulley Guide pulley
Use
Playback dirty (dusty) cleaning
In playback state,
sounds Broken tape on the Takes out the broken
8 speaker output smaller
small/tonal guide pulley tape
or tonal modulation
modulation Contact with the
of R/C player
manufacturer
Tape deformed Tape replacement
Tape room Tape room Use
The tape can not get
deformed adjustment
smoothly into the tape
9 No tape -in Contact with the
room, and leads to the
ineffective playback special service station
of R/C player
manufacturer
Tape room
Tape deformed
adjustment
After the tape moved
Tape label locking Takes out the tape
into the
Foreign matters into Takes out foreign Use
tape room, the tape can
the core. matters
not
10 No tape-out Tape eject button Adjusts the tape eject
eject smoothly by
pressing deformed/locked button
the tape-out button, Contact with the
of R/C player
manufacturer
Audio Foreign matters Takes out foreign
locked in the core matters
Use
In state of tape normal Shift button Regulates the shift
No side playback, the playback deformed/locked button.
11
shifting from the side A to B or Contact with the
side B to A smouthly special service station
of R/C player
manufacturer
The chassis pully of
Tape continues to shift Takes out the foreign
core is locked by
No stop of frin the side A to B or matters
12 foreign matters.
side shifting from the side B to A
without stop. Tape too tight due
Tape replacement
to moisture.
Cleans out the pully
Pully in the core Use
dust or
Playback In playback state, dirty or with foreign
takes out foreign
with There are other sounds matters
13 matters
abnormal combined except the
Guide pulley of core Cleanss out the guide
sound soft tape tracking noise.
dirty pulley
Probleme of tape Tape replacement
Radio When you press down Radio antenna falls Replug-in the Automobile
14
available, but the search button or off antenna manufacturer
no stations tune the station Radio antenna is
Radio Antenna replacement spare part supplier
received selection knob, the short-circuited
wavebands of Broadcast station
frequency modulation Normal condition Mis-judgment
pause
(FM)/ amplitude Contact with the
modulation (AM) are special service station
unable to receive any of R/C player
stations manufacturer
Radio antenna falls Replug-in the automobile
off (poor contact) antenna manufacturer
RFH OF FM/AM
FM or AM Some of wavebands Product
OR CIRCUIT Antenna replacement
unable to normal, but another manufacturer
15 DAMAGED
receive waveband unable to
stations receive stations. Contact with the
of R/C player
manufacturer
Radio mute: both
FM/AM hasno audio
Antenna falls off Replug-in the automobile
output, while the
(poor contact) antenna manufacturer
playback or CD audio
outputis normal
FM/AM mute: some of
Contact with the
wavebands has the
Bad switching of special service station
audio output while
Radio mute Receiving/playing of R/C player
another waveband has
16 or FM/AM manufacturer Product
none.
mute manufacturer
Contact with the
RFH OF radio OR
CIRCUIT
of R/C player
DAMAGED
manufacturer
Contact with the
of R/C player
manufacturer
Radio antenna falls Replug-in the automobile
off antenna manufacturer
Rfh of fm/am or Product
Antenna replacement
After you press down circuit damaged manufacturer
the search button or Lo/dx(far/near
tune the station distance)buttons
Few stations Reset is in DX state use
selection button, the setting
17 or with
Radio FM/AM waveband can inappropriately
interference
only receive few All environmental
stations or with larger normal condition Mis-judgment
influences
interference. Contact with the
of R/C player
manufacturer
Contact with the
Failure of radio special service station Product
After the radio received
output circuit of R/C player manufacturer
Radio has no station, the speaker at
manufacturer
18 sound at one side has no sound,
one side and normal in Contact with the
playback/CD. special service station
of R/C player
manufacturer
VII. Precautions to the use and maintenance of cassette player
The car audio-system is the product made by the special design and the optimal process. If you follow the
recommendation shown as below, you may enjoy your car audio-system for long lasting time.
1. Please be sure to use the correct D/C voltage(1214V) instead of the positive grounding;
2. The product should be used or stored under normal temperature. Over high temperature may shorten the
service life of electric elements, and deform or melt the plastic parts;
3. Be sure to handle with cares. Falling from height may damage the circuit board, and cause the
malfunction of product;
4. Keeps the product dried. If drenched inadvertently, drys it at once; If contaminated by the liquid
containing the mineral substance, the electronic circuit is likely to be subject of corrosion;
5. Uses sometime with the wet cloth to clean the product and keep it clean, but do not use the chemical
drugs containing the impurity or the solubable detergent to clean the product;
6. Keeps the product as far as possible away from the dirty, dusty or highly damp and excessively worn
place;
7. The good grounding may eliminate much of electronic noise. Hence, makes good contact between the
grounding terminal of audio-system with the metal chassis of car;
8. Before the speaker has been securely connected, be sure not to turn on the power supply switch, so as to
prevent the speaker line from burning up the elements by the inter-contact and short-circuit.
9. Bad-quality or damaged, deformed, broken and scratched tapes will impact the effect of use and service
life of audio system.
10. During the normal use, the magnetic head of playback will get in direct touch with the tape. The dirts
and filths etc., will deposit on the magnetic head after use for longtime, this will directly affect the playback
effect of R/C player(sound lower and muffle etc.), therefore, Cleans the magnetic head with head cleaning
tape for each 10 hours of tape run, so as to maintain the quality sound.
11. Do not leave the tape in the tape room without use, to prevent the dust from attaching on the head and
guide pulley and affecting the sound effect.
12. Unauthorized external high power loudspeaker is strictly prohibited to avoid damaging the host.
Section III Combination instrument
The instrument includes the engine tachometer(max. speed 7500), speedometer (max. speed 200), water
thermometer, fuel gauge and L/R turn indicators, rear fog lamp, high-beam light as well as indicators such
as the oil charge pressure, safety belt, safety airbag, ABS, engine failures, water temperature alarm, brake
failure, handbrake, door opening indication, coolant level, oil level alarm, process water, backup, vacuum
alarm, failure lamp, SVS, rear defroster etc.
22 Indicators 4 reserved indicator:

S/N Indicator Legends Description
1 L turn indicator Controlled by the combination turn switch
2 R turn indicator Controlled by the combination turn switch
In case of no failures, if the engine fails to startup within 4s, it

will flame out automatically in 4s; If the engine starts up within
3 Service lamp
4s, it will go out automatically; In case of the failures of
conventional engine parts except the EOBD, the lamp lightens.
High-beam
4 Controlled by the combination headlight switch
indicator
Rear fog lamp
5 Controlled by the switch of rear fog lamp
indicator
6 Backup indicator Lights up when back up
Water After the ignition, the indicator lightens for 3s and goes
7 temperature alarm out; when the water temperature exceeds 1052.5,
indicator the lamp lightens and flashes.
After the ignition, the indicator lightens for 3s and goes
Oil level alarm
8 out; when the oil amount is less than 10ls(pointer within the red
indicator
zone), the lamp lightens and flashes.
Brake failure After the ignition, the indicator lightens for 3s and goes; when
9
indicator the brake liquid level is too low, the indicator lightens.
When the ABS starts up, it lights up for 1.6s, then goes out; In
10 ABS indicator
case of ABS failure or disconnection, the lamp lights up
Handbrake Pulls out the handbrake, the lamp lights up; pulls down the
11
indicator handbrake, it goes out.
Preheating Available for the model with preheating function. It
12
indicator lights up when heating.
13 Charge indicator In case of the generator failure, it lights up.
It lights up constantly before the engine startup, and goes
Enginefailure
14 out in 2-3s after the engine started up; In case of EOBD
indicator
failures relevant to the emission es, it lights up.
Safety belt alarm It keeps lightened and goes out after the driver has fastened
15
indicator the safetey belt
Rear defroster It lights up by pressing down the rear defroster switch, and
16
indicator goes out after lasted for 8min2min.
Door opening It lights up when the doors are closed and goes out when
17
indicator the door are opened.
S/N Indicator Legends Description
Safety airbag
18 It lights up in case of the safety airbag failure or disconnection.
indicator
Oil pressure After the ignition, the indicator lightens for 3s. It lights up when
19
indicator the oil pressures is too low.
Coolan level
20 It lights up when the coolanl level is too low.
indicator
Vacuum alarm
21 It lights up when the vacuum degree is too low.
indicator
Process water
22 It lights up when the water-oil ratio is too high.
indicator
Installation of combination instrument:

Section IV Safety airbag
I Outline
1.1 Product profils
When the car is subject to a serious frontal collision, the drivers safety airbag(DAB) is used to mitigate the
possible injury of driver. The safety airbag(DAB) of the passenger in front row is used to reduce the
eventual of the passenger in front row
The present product is a positive single-point electronic airbag system characterized by integration of
sensor and control circuit(in the control box). The gas agent is pyrotechnic.
1.2 Environment of use and operation condition
a. Ambient temperature (-35+85).
b. Operating voltage (123)V.
c. In case of failure in the system self-detection, the system will stop working.
d. Within the time of self-detection (ca. 4s), the system doesnt make analysis on the collision information
and issue the ignition command; Only after the completion of self-detection that the system starts its
normal work.
e. To enable the safety airbag system for realizing the ideal and safe effect, it is imperative for the driver
and passenger in front row to sit right and properly fasten the safety belt.
1.3 Effect on the environment and safety
After the safety airbag system activated, it will not cause any harmful effect to the interior air, environment
and atmosphere, and there is no healty hazard when the passenger gets in touch with the air from the airbag.
II Techique profil
a. When the strength of the front collision is less than that of a car impacting at the speed of (131)km/h, on
a rigid fixed wall perpendicular to the direction of vehicles, the airbag system will not activate.
b. When the strength of the front collision is stronger than that of a car impacting at the speed of
(231)km/h, on a rigid fixed wall perpendicular to the direction of vehicles, the airbag system shoud
activate reliably and in time.
c. When the strength of the front collision is stronger than that of a car impacting at the speed between
(131)km/h and (231)km/h, on a rigid fixed wall perpendicular to the direction of vehicles, the system
remains in a fuzzy control state and the airbag system may either activate or disactivate. Both cases are
normal.
d. In case of occurrence of the collisions as below, the safety airbag provides the driver and passenger in
front row with effective protection and confoms to the relevant regulations:
Equal to a collision by a car at the speed of 23Km/h on a rigid fixed wall perpendicular to the
direction of vehicles;
Equal to a collision by a car at the speed of 30Km/h on a rigid fixed wall at 30(or smaller than
30)perpendicular to the direction of vehicles;
Equal to a collision by a car at the speed of 30Km/h on a rigid fixed column wall of 250mm
perpendicular to the direction of vehicles;
Equal to a collision by a car at the speed of 56Km/h on a 40%bias wall perpendicular to the
direction of vehicles;
III. Structure and operation principle
a System structure
The safety airbags system is made up by the drivers airbag components(to protect the driver. The
drivers airbag components are located in the steering wheel, with which it is connected), the safety
airbag components of the front row passenger(to protect the front row passenger. the safety airbag
components of the front row passenger are sited in the dashboard, to which, it is connected, and
positioned on the right side of the dashboard), spiral cable(continuously connecting the drivers airbag
system with the car system), harness(various parts connecting the airbag system), controler (control
center of airbag system).
b Work schematic. See Figure .1.
Driver safety airbag Front row passengers safety

components airbag components
(fitted in the steering wheel) (fitted on the dashboard)
Indicator light
(fitted on the combination
Spiral cable instrument)
Safety airbage harness
Controller(ECU)
Figure 1 Work schematic

When the switch is turned on the IG by the key, the safety airbag system activates. The ECU performs the
self-diagnosis as per preset program. If the indicator lights up for 4s, then goes out, It indicates that the
self-diagnosis is okey and the system normal. The ECU passes into the monitor state; If the indicator
flashes discontinuously or keeps lighting perminently, it indicates the the self-diagnosis failed and the
system abnormal.
During the normal drive (including on various road conditions and interferences), the ECU will not give
any IG order, the airbag will not activate;
In case of serious frontal collision, the ECU motivates the ignition in time, to stimulate the airbag
components for opening the airbag, and to absorbe the partial collision energy from the driver and front
row passenger, this will mitigate the eventual injury of the passenger and thus play its protective effect.
IV. Precautions
4.1 The assembly, disassembly and maintenance personnel have to receive the special training.
4.2 The safety airbag is relevant to the parameters of delivery car. Do not modify the Front bumper
configuration or add the bumper without permission.
4.3 When removing the steering wheel for maintenance, the wheel has to be in right position, as only such
enables the spiral cable assembly for locking at the proper position, otherwise it will damage the spiral
cable assembly.
4.4 Special danger! If fitted with the safety airbag assembly of passenger, allow the chidren neither for
sitting on the front row seat, nor for using the faceback child seat!
4.5 Prior to fit up the product on the car, it is forbidden for non-professional personnel to power up so as to
prevent the accidents.
4.6 During the drive, it is required to fasten the safety belt. The safety airbag should be used in combination
with the safety belt. In order to obtain the optima protection effect in case of the accident. Do not mistake
that the airbag may replace the airbag.
4.7 The ECUtechnique specification matches with the parameters of airbag components, they should be use
in match-up way. Do not substitute the airbag component or ECU by other types of ECU or airbag
components.
4.8 After turning on the power supply, both permanent lighting or non-lighting of safety airbag indicator
indicates a failure in the safety airbag system. Such a failure means that the ECU per se is damaged or not
powered on (or harness in open circuit)
4.9 The failure of power supply voltage can be repaired by the user, but others failures have to be
maintained at the special service station.
4.10 Disassembly and reparation at the unauthorized service station are strictly prohibited
4.11 In case of failure alarm, the reparation has to be made. If continue to use instead of repair, the damage
due to the collision will be born on own responsibility
4.12 When repairing the car (especially welding), you have to turn off the switch (1st gear), and disconnect
completely the positive of battery.
4.13 In case of the reparation of car, the special tools have to be used to remove the airbag assembly. After
the airbag explosion, the airbag components, spiral cable controller, main and short harnesses should be
completely replaced.
4.14 In case of failure of safety airbag assembly, it is unrepairable and has to be replaced.
4.15 When removing or handling the airbag components, the trim cover should be faced up. The airbag
components can not be piled up so as to prevent the airbag from unintentional explosion and the accident.
4.16 Airbag components should be kept under the ambient temperature lower than 93, relative humidity
75% and far awary from the interference by electric field.
4.17 Be sure not to test the ignition resistance of safety airbag with the analog multimeter, otherwise it will
cause the unintentional airbag explosion.
4.18 Special danger! Disassembly of airbag components and its inside air generator are strictly
prohibited!
4.19 To prevent the damage, it is strictly prohibited for the controller to connect with the A/C or D/C higher
than 20V
4.20 StatementIn case of the following collisions occurred, the safety airbag system stays in the state
between folding and unfolding phases. We do not undertake any responsibility for the personnel injury and
property damage caused therefrom.
The car A is the mode fitted with our safety airbag system.
Re-impact after the airbag has been defolded

Front collision at the angle more than 30
Side-collision Tail -collision
Collision into the bottom of the truck carriage Lateral fall dwon and cross overturn
V Causes of failures and maintenance
The failures of safety airbagsystem are divided into the exterior and interior parts, which may be displayed
through the indicator flashing of combination instrument. The safety airbag indicator is driven by the ECU.
The indication of all information is controlled by the ECU. By flashing of the indicator, the information
output of system may be classified into three types: i.e. Failures of power supply failures, installation of
airbag components and ECU interior, where the failures of power supply and installation of airbag
components belong to the exterior failures.
a. Exterior failures
Power supply failure
ECU normal working voltage: 915V, Rated working voltage:12V.
0V 12 V
In normal cases, the safety airbag system is powered on. The indicator lights up for 4s, then goes
out. It indicates that the system passes by the self-diagnosis.
Indicator lightens up
Indicator goes out

4S
When the battery voltage is lower than 9V, powers on , the indicator flashes 2 times, and keeps
lighting. This indicates that the battery needs the charge of replacement instead of repairing.
Indicator
lightens up 1.5 S
4S
Indicator
Indicator
3S 1.2 S lightens up
goes out
Failure of airbag component installation

Before the airbag component installation is completed, the indicator flashes and gives the
info-tips. Information, codes and failure states hinted by the airbag indicator flashing from the
combination instrument are tabled as follows:
S/N State of failures Codes of information(Flash times/group
number)
1 Low resistance of the drivers side igniter 3
2 High resistance of the drivers side igniter 4
3 The drivers side igniter grounds up 5
4 Low resistance of the front row passengers
7
side igniter
5 High resistance of the front row passengers
8
side igniter
6 The front row passengers side igniter
9
grounds up
To take, for an example, the low resistance of the drivers side igniter and 3times of flashing,
the flash sequence of the indicator is given as below:
Indicator
lightens up Flasing for 3 times
4S
Indicator
Indicator
3S 1.2 S 1.5 S lightens up
goes out
In case where the above state occurs in the safety airbag system, you have to send it to the
special service station for reparation.
b. Failure in the controller
In case of failures in the controller, the indicator keeps flashing, while the ECU interior is locke
up and stops working.
Indicator
lightens up
4S
1.2 S 1.5 S Indicator

Indicator goes 3S flashes out
out
In case where the above state occurs in the safety airbag system, you should turn off the key
switch, then turn it on again to restart. If the information hint can not relieved, then you should
have the ECU replaced by the special service station.
Section V Accessories of electric equipment

I. How to use the cigar-ligher and precautions:
1. Presses down the handle of cigar-lighter to enable the electric pot for mashing up with the bimetallic
strip. For the time being, the circuit is powered on and the cigar-lighter starts working.
2. In 14s 4s, the inner bushing assembly of cigar-lighter will bounce up. Pulls up the inner bushing
assembly to enkindle the cigarette.
Note: In use, takes out the inner bushing assembly within 10s to enkindle the cigarette. If overdelayed, the
heating wire temperature is not powerful enough to enkindle the cigarette.
Precautions:
1. When using the cigar-lighter, the rated voltage is 12V, the max. working current 10A. the cigar-lighter is
of the overheating protection function. The time of overheating is 90S, i.e. when failed to bounce up by
continuous heating for 90s, the cigar-lighter will jump out between the positive and negative poles and burn
out the fuse of the cigar-lighter and break up the power supply in the circuit(hazard of consequence: as the
cigar-lighter, power supply socket, rear electric mirror and power sunruuf are shared with the same fuse. If
it is burnt out, the powered devices in the circuit can not work, thus, it is necessary to replace the
cigar-lighter in time).
2. When using the cigar-lighter, heavy objects loaded on the top are not allowed, for this will hinder the
inner bushing of cigar-lighter to bounce out and burn ou the cigar-lighter by overheating. In severer case, it
may cause the panel catching fire.
3. In the outer bushing assembly of cigar-lighter, no other parts except the inner bushing assembly are
allowed to insert, such as the power supply socket. The cigar-lighter can not be use as the power supply
socket.
4. After powered on, the inner bushing assembly of cigar-lighter is very high in temperature. In usage, the
user must pay attention to the safety. Do not hand directly the metal surface, to prevent from scald.
5. After use, the inner bushing assembly of cigar-lighter should be inserted in time into the outer bushing
assembly instead of other place to prevent the objects from burn out
The The
cigar-ligher cigar-lighter
after pressed boucns out
down
Use method of power supply socket and precautions:

1. In use of the power supply socket, the rated voltage is 12V, the max. current 10A. With the end cap
opened, the around of metal shell is negative and the center positive. If the conductor falls inside, it will
lead to the short-circuit between the positive and negative, and burn out the fuse of power supply socket.
2. In use, inserts the power supply plug into the power supply socket. In the inserting process, Do not insert
the power supply plug obliquely into the outer bushing assembly, and try to make the metal head of power
supply plug fully contact with the positive plate of power supply socket. After completing the charge, it is
necessary to cover the cap of power supply socket, to prevent other parts from enter into the power supply
socket inadvertently.
Power
supply
socket cap
Use method of central lock controller and precautions:

1. Unlocking/locking function(Unlocking/locking by key, unlocking/locking switch)
With the battery has power and the ignition switch is on the OFF position, uses the key or presses down
the concaved unlock mark on the Unlock/Lock switch of door master control switch to completes the
unlocking process. Uses the key or presses down the concaved lock mark on the Unlock/Lock switch of
door master control switch to completes the locking process.
2. Remote-control function (Unavailable if without the remote-control function)
With the battery has power and the ignition switch is on the OFF position, presses down the R/C unlock
switch. For the time being, the R/L turn lamp flashes 2 times to complete the unlock process. Presses
down the R/C lock switch, the R/L turn lamp flashes 1 time to complete the lock process.
3. LH power window lifting (Manual up and down, auto-down)
Manual liftup: With the battery has power and the ignition switch is on the ON position, Pulls up the LH
button of door master control switch, the The LH window lifter raises up; releases the button, The LH
window lifter stops.
Manual down: With the battery has power and the ignition switch is on the ON position, presses
downdoor master control switch the LH button(half-way), the The LH window lifter drops down;
Releases the button, the The LH window lifter stops.
Auto-down: With the battery has power and the ignition switch is on the ON position, presses down the
LH button door master control switch (full way), the The LH window lifter drops down; releases the
button, The LH window lifter continues to drop down until the window lifter reaches the end. The LH
window lifter stops.
4. RH power window lifting(Manual up and down)
Manual up : With the battery has power and the ignition switch is on the ON position, presses down the
RH button of door master control switch or the side window lifting switch of assitant driver, the RH side
window lifter drops down; releases the button, the RH side window lifter stops.
Manual down: With the battery has power and the ignition switch is on the ON position, presses
downdoor master control switchRH button or the side window lifting switch of assitant driver, the RH
side window lifter drops down, releases the button, the RH side window lifter stops.
5. Child lock function
With the battery has power and the ignition switch is on the ON position, by releasing the child lock
button of door master control switch, the side switch of assitant driver possesses the function of the RH
side window lifter. When pressing down the child lock button of door master control switch, the side
switch operation of assitant driver is ineffective.
6. Auto-closing window function
With the battery has power and the ignition switch is on the ON position, the doors are closed up. 2s
after the key locking or R/C locking finished, the power window will complete the auto-closing window
in turn from left to right.
Lifting Lifting
R/L doors button of the button of the
unlocking R/L left power right power
doors window window
locking
Child
lock
Lifting
button of the
right power
window
Use method of door state controller and precautions:
1. Rated load: 21W;
2. Beep tone: 80dB;
3. With the key on the position ACC or ON, the controller alarms when the door is opened or left opened.
4. With the key on the position OFF, the controller alarms when the small light is left turn off.
5. With the dome light switch on the Door position, it lights up when the door is opened and lasts lighting
for 15s 1s after the door is closed up.
Relay and
controller
inspection cap
Cnetro lock
Door controller
state
controller
Bulb replacement
Long bodied car
Headlamp :
1
Low/high-beam lamp
Position lamp
Turn light
Note: In some of use condition, a
thin layer of water vapor will emerge
on the headlamp glass.
2
3
Attention
The replacement of halogen bulb should be made a few minutesafter the headlamp goes outotherwise
there is a serious risk of burns. Do not hand touch the bulband wrap it with lint free cloth.
Signed by:
Low beam/high-beam light
Pulls out the connector;
Takes out the rubber sheath;
Presses the head of steel clip and release
it
Takes out the bulb for replacement.
Bulb typeH4 (55W/60W)
Note: If necessary to adjust the

headlight (it is best to use a chemical
tester): Inserts a special screwdriver
in6, respectively through the hole I
reserved by the sheet metal and the gap
II between the sheet metal and
headlight on the manually adjusting of
headlight for the vertical and R/L
dimming.
Positioning lamp:
Do not pull out the connector. Tuns the lamp
holder by 1/4 circle, then takes it out from the
holder, then pulls out bulb for replacement.
Bulb type: W5W.
Front turn lamp:
holder by 1/4 circle, Then refit it and checks to
see if it is well fitted in place.
Bulb type: P21W.
3
2
Side-turn lamp:
Pushes forward or rearward the side-turn lamp,
pulls it out after releasing it. Turns by 1/4 cicle to
take out the lamp holder, then pulls out bulb for
replacement.
Note: Do not let the lamp and other connectors,
locked in the metal sheet hole, otherwise it is not
convenient for taking it out.
Bulb type: W5W
Front fog lamp:

Turns counterclockwise the black cap behind the
lamp shell to remove it. Presses the press-spring to
take out the bulb for replacement.
Bulb type: H3(55W)
Front dome lamp:
Takes out the front dome lamp from the
trim ring of dome lamp and replace the
bulb
Bulb type: W5W
Side dome lamp:

Takes out the dome lamp from the trim
ring of dome lamp to replace the bulb.
Bulb type: W5W
Rear tail lamp:

Marks the failure bulb.
Bulb:
Rear position/brake lamp: P21/5W
Turn light: P21W
Back light: P21W
Dismantle:
Emoves the screw fixing the lamp;
Oves the lamp outward to take the
buckle locked on the metal plate
from the hole and remove the lamp
Behind lamp shell:

Turns by 1/4 circle the failed bulb
counterclockwise from the lamp holder,
and take out the lamp holder and change
the failed bublt
Assembly:
Fits the lamp buckle on the metal sheet,
then fixe the lamp with the bolt
Rear fog lamp:
Takes out the lamp holder by turning 1/4
cicl and replace the failed bulb.
Bulb type: P21W
License lamp:
Takes out the license lamp from the
guard board of license lamp.
Replaces the failed bulb.
Bulb type: W5W
Bulb replacement
Short bodied car
Headlamp :
Low/high-beam lamp
Position lamp
Turn light
Note: In some of use condition, a
thin layer of water vapor will emerge
on the headlamp glass.
Attention
The replacement of halogen bulb should be made a few minutesafter the headlamp goes outotherwise
there is a serious risk of burns. Do not hand touch the bulband wrap it with lint free cloth.
Signed by:
Low beam/high-beam light
Pulls out the connector;
Takes out the rubber sheath;
Presses the head of steel clip and release
it
Takes out the bulb for replacement.
Bulb typeH4 (55W/60W)
II
I
Note: If necessary to adjust the

headlight (it is best to use a chemical
tester): Inserts a special screwdriver
in6, respectively through the hole I
reserved by the sheet metal and the gap
II between the sheet metal and
headlight on the manually adjusting of
headlight for the vertical and R/L
dimming.
Positioning lamp:
holder by 1/4 circle, then takes it out from the
holder, then pulls out bulb for replacement.
Bulb type: W5W.
Front turn lamp:
holder by 1/4 circle, Then refit it and checks to
see if it is well fitted in place.
Bulb type: P21W.
3
2
Side-turn lamp:
Pushes forward or rearward the side-turn lamp,
pulls it out after releasing it. Turns by 1/4 cicle to
take out the lamp holder, then pulls out bulb for
replacement.
Note: Do not let the lamp and other connectors,
locked in the metal sheet hole, otherwise it is not
convenient for taking it out.
Bulb type: W5W
Front fog lamp:

Turns counterclockwise the black cap behind the
lamp shell to remove it. Presses the press-spring to
take out the bulb for replacement.
Bulb type: H3 (55W)
Front dome lamp:

Takes out the front dome lamp from the
trim ring of dome lamp and replace the
bulb
Bulb type: W5W
Side dome lamp:
Takes out the dome lamp from the trim
ring of dome lamp to replace the bulb.
Bulb type: W5W
Rear tail lamp:

Marks the failure bulb.
Bulb:
Brake lamp: P21W
Turn light: PY21W
Back light: P21W
Positioning lamp: W5W
Dismantle:
Emoves the screw fixing the lamp;
Oves the lamp outward to take the
buckle locked on the metal plate
from the hole and remove the lamp
Behind lamp shell:

Turns by 1/4 circle the failed bulb
counterclockwise from the lamp holder,
and take out the lamp holder and change
the failed bublt
Assembly:
Fits the lamp buckle on the metal sheet,
then fixe the lamp with the bolt
Rear fog lamp:
Takes out the lamp holder by turning 1/4
cicl and replace the failed bulb.
Bulb type: P21W
Third brake lamp:

Opens the back door. Presses 6 buckles,
and remove the cover behind the brake
lamp. Removes 3 bolts with wrench and
takes out the lampholder
Bulb type: LED
License lamp:
Takes out the license lamp from the
guard board of license lamp.
Replaces the failed bulb.
Bulb type: W5W
Section VI A/C system
I. Sound use of A/C system and precautions:
When starting the engine, the A/C switch should be on the OFF position.
After the engine flamed out, sets the A/C airflow switch on the OFF, turns off the A/C switch to save the
battery power.
Try to avoid parking the car directly exposed under sunshine for longtime in summer. After parking for
longtime, the car gets very hot inside. In such case, you should open the windows first and turns on the
blower to max. level(i.e. blower outer circulation mode instead of A/C) to exhaust the hot air inside. Turns
off again and sets the fresh air circulation damper to inner circulation for turning on the A/C.
Adjusts the outlet to orient the airflow to the upper body or face, instead of facing the cool air directly
on the headback or knees. If the airflow is stronger, do not blow it directly to the body.
When overtaking a car, turns off the A/C to ensure the optimal overtaking performance.
When driving on hill road for a long distance, you should turn off the A/C for a while to prevent the
water tank boiled.
When driving at rainy night, do not set the A/C at too much lower temperature and try to lower the
airflow of blower.
The overheating level of expansion valve has been set before the delivery, it is not advisable to adjust it.
Regularly cleans out the condenser (rinse with the compressed air or cool water instead of injecting with
steam).
During non-use period in winter, you should frequently operate the compressor to prevent the
compressor shaft seal from oil dried leakage and axis locking due to the oil dry. En general, the compressor
should run 1-2 times per month, ca. 10mins per time. Try to prevent the compressor shaft seal from oil
dried leakage and axis locking due to the oil dry. When the temperature is too low in winter (ca. 5), the
A/C may fail to start due to the low temperature, thus, turns on the heater first and then the A/C after the
temperature inside raises up.
During the A/C operation, turns off it when hearing the abnormal noise in the A/C device(e.g.
compressor, blower, tube cracks etc.) or any other abnormality and calls on the maintenance personnel for
inspection.
The temperature the most healthy inside temperature differs around 57 from the outside air
temperature.
It is not allowed to add the liquefied coolant from the low pressure end. When filling with the coolant
from the high pressure end, do not turn on the compressure. The charge of coolan should be operated by the
special maintenance personnel.
The temperature inside lower than 25 or inappropriate operation (compressor speed too high or
airflow of blower too low) are very likely to freeze the evaporator. Once the frosted evaporator detected,
one of the following methods may be taken for defrosting: 1. The A/C system will automatically turn off
once frosted. In case of any changes inside the control parts, pauses the A/C switch for a while. 2. Opens
wider the outer circulation vent to introduce fresh aire for defrosting, while the blower is turned on to the
max. speed.
In comparison of the use of the Green World type R134asystem with the R12 system, two types of
coolant media can not Mix with the system and each parts not substitutable. Hence, this model can not
added with the coolant type R12.
In case of the coolant addition by maintenance, the coolant should be added appropriately and the type
of coolant matching with the compressor to be used. The mixed use of coolant will cause it spoiled. E.g.
Chongqing JIANSHE compressor-JSS120 uses the lubricant type RS20.
In case of failures, please contact with the special service station, be sure not to make any disassembly
and adjustmeng individually.
II. Maintenance of automotive A/C
2.1 Routine maintenance of automotive A/C
1. Prior to departure, makes regular check on the A/C system and cleans out the carriage to prevent the
miscellanies, paper scraps from jamping the exchanger port and catching fire. Before the summer comes,
you should more carefully check the A/C system and correctly use it.
2. Checks frequently the operation of oil line system to prevent from leakage.
2.2 Cleaning and maintenance of dual air system
1. Clean condenser. Regularly checks the condenser faade to see if there are any curved fins and foreign
matters. In caseof fins if any, pulls them straight with the nose pliers, If any foreign matters, you should use
the hard brush to remove them.
2. Checks the coolant to see if there are any leakages, for the compressor oil and coolant are conveyed
together through the system. therefore, when the coolant leaks, it will bring out the oil and leave the oil
traces on the leakage place. Checks especially if there are any greasy stains on the joints of various hoses
and connectors. If any greasy stains discovered, it means that there aer leakages in the system and needs to
repare it.
3. Checks the tightness of the compressor belt, and regularly examins the belt tension and its use condition.
In case where the contact surface between the belt and belt pully shimmers, it indicates the belt is skidding.
You should check if the belt is too looser. For the check operation, uses the finger to forcibly press down
the middle part of the belt tensionner, the belt should bend down ca. 1215mm.
4. Regularly runs the A/C at a rate of 5min/week to lubricate the interior of parts and prevent the hosed
from aging.
5. After the new car has been used for a half year, some items of A/C system of new car should be made in
combinatntion the complete vehicle.
6. After the new car has been used for one year, some items of A/C system of new car should be made in
combinatntion the complete vehicle.
Table Regular check subjects
Check schedule
Check subject Subjects and objcets 6 months or mileage 12months or initiao
Routine
of 5, 000km mileage of 10, 000km
Badly fixed and cracks
Piping
Joints and screw cap loosened
Bolts Loosened, cracked and felt off
Loosened and bent
Worsen: worn, scar and cracking
Belt
Glide combined with burning smell

and warm
Heat sinks damaged
Condenser
Blocked by foreign matters
A/C switch. Startup check: airblow, temperature

Temperature control
control Outlet vent shifting etc.
Leakage from the piping joints
Coolant leakage
(incl. oil leakage) Leakage from the parts (compressor,

condenser and evaporator etc.)
Noise Compressor
(In startup state) Idle pulley
Check schedule
Check subject Subjects and objcets 6 months or mileage 12months or initiao
Routine
of 5, 000km mileage of 10, 000km
Airblow motor
Expansion valve
Outer air reversing entry(blower)
Air leakage
Heat invasion from the heater
8. Regular check of the refrigerant leakage

Check schedule
Check subject Subjects and objcets 6 months or
12months or initiao
Routine mileage of 5,
mileage of 10, 000km
000km
Leakage from the piping connection
Coolan media
leakage Leakage from the parts
(incl.oil leakage) connection(compressor, condenser and
evaporator etc..)
2.3 Adds the refrigerant

After the refrigeration system of automobile A/C has been assembled or disassemble for maintenance, the
system can be vacuumized and added with coolant media. To use the coolant meida, the characteristics
should be thouroughly understood. Be careful of the operation environment (rare dust, gabbage, well
ventilated and dry) and the following precautions should be taken to the safety opertion
Refrigerant specification: R-134a
Filling volume of refrigerantR-134a: (45025)g
Use of the refrigerant Oil of A/C system limited to RS20, weight: 20010ml (supplied with compressor )
Adds appropriately the refrigerant oil each time when filling the system or at the time of system
maintenance with the refrigerant
Checks the cleaning states of condenser and
evaporator
Checks the state of compressor belt
Checks if there is any worn damage on the

exterior of A/C system pipeline
Figure 1Maintenance practice
Failures infos
Stationary state check

Checks whether there are any oil stains on
the joints of system pipeline or not
Listens whether the belt pulley has any

Failure car
abnormal sound or not

Vehicle check
User infor-collection
Checks if the blower and condenser work

properly
Maintenance as per table 1

A/C switch OFF
Checks if the compressor picks up(sucking)
A/C use info.
Failure position determined as per table 1

Checks the refrigerant flow and liquid
reservoir
Engine startup check
Tests the pressure state with pressure

gauge(at low pressure send)
A/C switch ON
Listens the compressor sound with the

connecting rod
3.2 Maintenance of system
3.2.1 Diagnosis of A/C failures
For the maintenance of automotive A/C system, it is necessary to adequately understand the objective and
function composing such a system, which include the roles and reactions of the mechanical and electronic
and sub-systems.
The A/C systems vary from the years and models of manufacturing. Thus, there are no standard diagnosis
procedures. All automotive A/C systems share only one part of common knowledge, which include:
1) Determines whether the failure belongs to the electric or mechanical or both parts.
2) Determines if the filling volume of system refrigerant is adequate, whether it is inadequately filled or
over filled.
Maintenance advice: It may be determined by a test phase so-called Fast Check of Insufficient
Refrigeration.
3) Determines the type of system: cycle working clutch or non-cycle working clutch.
4) Makes a function test on the air supply system to determine whether it runs in sound performance or not.
This can be completed prior to the diagnosis process. The air supply sub-system includes the following
parts: fan generator, switch, vacuum tube, airway and status door.
5) Makes a functional test on the system to determine if it is normal depending to the temperature, and
whether the low pressure curve and high- side pressure are regular or not.
Attention: Have the ambient temperature and relative humidity under consideration.
Basic Tools: basic mechanical tools; manifold pressure gauge ;open nut wrench ; spring-lock connector
tool; vacuum motor;
3.2.2 Check of system
If the failure of A/C system is caused by the abnormality of the low/high pressure of system. the following
check subjects should made:
1) Visually tests the condenser to be sure that the airflow is jammed by no filth and debris or others foreign
matters.
2) Checks the space between the condenser and radiator, if there are foreign matters. Eliminates them when
necessary.
3) Visually tests if the pipe and line are blocked or twisted. Checks the hoses and connecting pipe of the
condenser and refrigerant.
4) Uses the suitable leak detector to check the leakage of refrigerant.
It is the best way to make leak check of the insufficient filling of A/C system or suspicious leakage. In case
of the system necessary to open for maintenance, the leak check is also required.
Attention: The leak detector should be used as per special need.
5) Leak test made on the air supply system. Bond inspection of the throttle valve or state door. The
insufficient airflow of blower will be expressed in the jam or throttle of evaporator core.
6) Visually test whether the clutch works properly or not. The clutch skidding is likely originated from the
low voltage of looser belt pulley or controller failure.
7) Uses the belt tension gauge to check the tension of driving belt in reference to the adequate belt tightness
set out in the technique index of the manufacturer. Failures are often discovered by visual checks.
3.2.3 Diagnosis and testing of electric parts
3.2.4 Failures of parts
The followings are the summary on whether the A/C system parts have failures, which the technicians wish
to know.
1. Evaporator
Cool air supply insufficient caused by the evaporator failure due to the center leakage of evaporator. Other
reasons include:
1) The evaporator core has been jammed by the filth or debris which needs to be eliminated.
2) The cracks or fractures on cases. Replaces or repairs the box cracks.
3) Leakage of seals or O-ring. Replaces them.
2. Compressor
The failed compressor will show one or several features as below:
1) The noise indicates the premature of failure.
2) Locking(cylinder sticking)commonly due to the leakage.
3) Leakage due to the failure of sealing, air cushion or O-ring.
4) The low pressure of the in/outlet port is commonly caused by the insufficient filling of refrigerant or the
throttle at the low pressure side.
5) High pressure at the inlet port and low pressure at the outlet port are normally due to the failure of the
compressor valve disc or sealing packing assembly.
Most noises during the operation are considered as normal. The abnormal chocks and noises are caused by
the premature of failure of leakage or part damage. When the refrigeration is required by the A/C system
control, the compressor fails to work. The determination should be done to verify if the voltage on the
clutch joint is normal. Checks if the compressor is jammed.
1) Shuts down the engine
2) Disconnects the power supply of compressor and clutch and adjusts the tension pulley to fall off the belt
3) Manually turns the drive disc
Attention: If the drive disc doesnt run or painfully, it means the compressor is blocked.
The low pressure at the outlet port is originated either from the bad sealing of the compressor, e.g. valve
disc or valve sealing pad group ineffective, or from the throttle at the low pressure side of compressor or
system. the insufficient filling of refrigerant may also result in the low pressure at the outlet. All possible
reasons should be determined through the failure diagnosis.
Checks if there is a leakage of the compressor.
3. Condenser
There are three possible failures of condenser as below:
1) Due to the rust, corrosion or leakage resulted from the impact of sharp object and stones.
2) Throttle due to the pipes bent by the impact of foreign matters. E.g. when the leakage of pipe is caused
by the stone beating in weak force and the pipe bent or broken when the force is sufficiently powerful.
Maintenance advice: the throttle of condenser will induce the overpressure at the compressor outlet. The
partial throttle will lead to the change of temperature and frost or frozen case at the throttle.
3) Air throttled due to the filth, debris or foreign matters through the condenser. When the airflow is
jammed or throttled, it will result in the overpressure at the outlet.
Attention: Although uneasy to detect, but in normal operation, the outlet pipe of condenser is slightly
cooler than the inlet pipe.
To determine the throttle by searching the frosted section.
4. Throttle pipe
The low pressure at the in/outlet port occurs normally due to the throttle failure, which leads to the
insufficient cool air supply in the evaporator.
The common factors of throttle pipe failures are the blockage. The others are the inefficiency of the liquid
reservoir , the filth , corroded grains in the refrigerant system or the inner strainer jammed due to the looser
dryer agent in the refrigerant. For whatever reasons, it is recommended to replace the throttle pipe at the
time of maintenance.
5. Thermal expansion valve (TXV)
The failure feature is same as that of the throttle. The failures of many thermal expansion valves are caused
by the ineffective dynamic elements, which are able in general to shut down the valves and keep the
refrigerant from entry into the evaporator. For whatever reasons of failures, it is suggested to replace it in
time at the time of the maintenance is except the jammed inner strainer.
The blockage of the inner strainer of thermal expansion valve occurs due to the failure the liquid storage
dryer, which loosens the filth and corrosive grain in the system or the refrigerant drying agent.
6. Refrigerant piping
The throttle of the refrigerant piping has one or several features as below:
1) The throttle of the inlet pipe causes the low pressure in the in/outlet ports, insufficient refrigeration or no
refrigeration available. The evaporator is short of refrigerant.
2) The outlet throttle leads to the opening of relief valve. When the pressure drops down to the design value,
the relief valve will sit down automatically.
3) The throttle feature of liquid pipe is same as that of the inlet throttle. The low pressure of in/outlet ports,
insufficient refrigeration or no refrigeration available.
The inlet pipe is normally the largest horse or pipe, while the liquid pipe the smallest horse or pipe
3.2.5 Causes of failures
1) Leakage: Insufficient volume of refrigerant.
2) High pressure: Refrigerant surplus, air entry into the system and oil surplus in the system etc.
3) Poor connection.
4) Throttle
5) Contamination
6) Humidity
7) Failure of parts
3.2.6 Functional testing
The functional testing is able to determine the operating state of the A/C control panel and air supply
system. The functional testing includes the subjects of the knob operating states of the fan, heater, A/C
control components. It also comprises the air supply state of the comparison status knob and switch when
they are in different places.
The fast testing on the system may determine whether the refrigerant volume of A/C system is suitable.
This testing can be effected only when the ambient temperature is higher than 21.
The fast testing is able to simplify the system diagnosis through the determination of the failure of
insufficient refrigerant, and also to eliminate the failure source of the insufficient refrigerant. The fast
testing is to be made as per the following procedures:
1) Starts up the engine and preheat it at idle speed.
2) Opens the engine hood and doors.
3) Selects the standard (NORM) state.
4) Adjusts the knob to the full position COLD.
5) Selects the max. fan speed (4th level)
6) Measures the inlet temperature of evaporator behind the throttle pipe.
7) Measures the temperature of the liquid storage level while the compressor is operating.
Maintenance advice: If the compressor recycles, waits until the clutch meshes up.
Both temperatures [(6) and7)] should be at same level. If different, checks the other failure
If the inlet temperature of evaporator is lower than the inlet level of the storage, or there is frost
accumulation on the inlet, it indicates the shortage of refrigerant.
8) If the volume of refrigerant is at shortage, adds 120ml of refrigerant and repeats the procedures of
(6)and(7).
9) Adds the 120ml of refrigerant until the temperatures on both levels are same.
Maintenance advice: Every time when adding the refrigerant, be sure to allow the time for the system to
be stabilized, e.g. about 5mins.
Warning: By using the method to add the refrigerant, you should know perfectly the system and besides,
the system has no leakage. To fill the leak system with the refrigerant may cause greater damage.
3.3 Maintenance of system parts
3.3.1 Preparations
Prior to any maintenances, some preparations have to be made. Whatever it is practical or not, the
following processes should be taken as the reference during the various maintenance.
1) The ignition switch on the position (OFF).
2) Puts the protective cover to protect the car surface.
3) Pulls out the battery lead. Carries out the operation as per the relevant maintenance manual.
4) Drains out the refrigerant from the system. Uses the suitable recycle equipment and operates as per the
relevant maintenance manual.
5) Finds out the parts to be maintained or replaced .
6) Takes out from the observation panel, the metal parts or others imperative to be detached, so as to get
access to the parts.
Be especially careful when pulling out the battery leads.
3.3.2 Maintenance of refrigerant horse and connectors
There are many types of other pars used to connect the refrigerant hoses and A/C system(this model
classified to the 2nd case).
1) SAE flaring typed connectors
2) Bump flange connectors commonly referred as to O-ring connectors
3) Spring-locking connectors
4) Insert typed connectors.
Checks to verify if there are the following modes of failures and repairs.
1) If the O-ring has any broken damages or serious aging deformation. If in such case, you should replace
then with the same type of O-ring.
2) If there are any signs of leakage at the pressed hoses and hard tubes. If in such case, you should replace
them with one ones.
3) If the threads of connector joints have any tripping disengagement. If in such case, you should replace
them with one ones.
4) If the hoses have any aging damage and leakage. If in such case, you should replace them with one ones.
5) When reconnecting the pipeline, applies the specified brand of refrigerant oil on the connector joints of
pipeline.
Uses the special tools: nut spanner;1/4in socket wrench; torque wrench; hacksaw and saw blade in 32tpi;
pliers; spring lock assembly tools ;single-blade scraper. Keeps them away from your body when they are
used.
3.3.3 Replacement of A/C system parts
The followings are the elementary procedure guide for the replacement of A/C system parts. For the more
detailed operation of replacement, the maintenance manuals relevant to the specific year, model and date of
manufacturing should be referred.
3.3.4 Removal and replacement of thermal expansion valve (TXV)
The maintenance of thermal expansion valve is not recommended.
This practice rules are divided into the maintenance standard TXV and H valve maintenance(H-LOCK)
Special tool: Horn-shaped wrench.
H-valve TXV
1) Carries out the items as per the section Preparation.
2) Takes out the conductor of the pressure stop switch or pressure differential switch.
3) Takes out the seal disc bolt between the inlet pipe and liquid pipe.
5) Covers the pipe opening to prevent the foreign matter from entry.
6) Takes out and rejects the seal padding between the coil and H-valve.
7) Removes two screws from the H-valve.
8) Removes the H-valve from the evaporator bracket.
9) Removes and rejects the seal padding between the H-valve and evaporator bracket.
10) Fits up the new H-valve with new seal padding.
11) Fits up two screws and tightens them to 20~26Nm
12) Replaces the seal padding between the coil and H-valve
13) Fits up the pipe to its original position and tightens the bolts to 20~26N-m.
14) Fits up the observing plate and detached parts.
15) Reconnects the battery as per the requirements of Maintenance Manual.
16) Checks the leakage and the vacuum pumping, and fills the system with refrigerant as per the Chapter19
of the Manual.
17) Makes the functional testing when necessary. Be careful not to scratch the fitting surface.
3.3.5 Removal and replacement of the compressor
1) Completes the Preparation.
2) Removes the in/outlet hoses or service valve of the compressor.
Attention: the in/outlet pipes of many systems use a common manifold to connect the compressor.
3) Removes the lead of the clutch.
4) Loosens and removes the belt.
5) Removes the fixing bolt from the compressor bracket or socket.
6) Removes the compressor from the car.
7) Positions the new or repaired compressor.
8) Fits up the bolts to the compressor bracket and socket.
9) Positions and fits up the belt.
10) Fits up the clutch lead.
11) Fits up the new seal padding or O-ring as per the inverse order of 2) and installs the in/outlet pipes.
12) Checks the system leakage.
13) Vacuum pumping.
14) Fills up the refrigerant.
15) Functional testing.
Attention: contents relevant to 12) and14)
Removes other leads from the compressor, e.g. overheating switch lead etc.
3.3.6 Removal and replacement of the
1) Carries out the items as per the section Preparation.
Attention: To carry out the process, it is unnecessary to pull out the power supply cable.
2) Removes the fixe body of cap and any leads and parts which prevent the removal of condenser.
3) Removes the thermal tube on the top of condenser.
4) Removes and rejects the O-ring.
5) Removes the liquid pipe on the bottom of condenser.
6) Removes and rejects the O-ring.
7) Removes and preserves the connecting bolts or nuts supporting the condenser.
8) Takes out the condenser from the car.
9) Fits up the condenser as per the inverse order of 2).3).5) and 7).
Attention: Fits up the new O-rings on the thermal tube and liquid pipe.
10) Checks the leakage of system.
11) Vacuum-pumping.
12) Fills up the system with refrigerant.
Use of special tools: nut wrench; torque wrench; do not use the removed O-rings
3.3.7 Removal and replacement of evaporator
This process is divided into two parts, i.e. Assemblies by auto-parts market and manufacturer s/ suppliers.
Prior to work on the two parts, the first step is to complete the items set out in the section "Preparation".
After this process, the check of system leakage, vacuum pumping and filling of refrigerant should be
followed.
Special tools: nut wrench, torque wrench.

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Chapter I Outline of vehicle

Section II Technical parameters of main models

2. Vehicle mass parameters

Parameters of rear wheel positioning

4. Mobility and traffic ability

5. Dynamic and economic parameters

Section I Introduction to engine products

Figure 2.1 Engine assembly outlook

Figure 2.3 Engine right-side outlook

Figure 2.5 Engine rear viewoutlook

Cylinder bore 71.0mm 76.0mm

Compression ratio 9.5

Max.Torque 108N.m / 4500r/min 134N.m / 4500r/min

Min. fuel consumption 272g/Kw.h

Fuel Unleaded gasoline over 93#

Combustion chamber Roof type Roof type

Valve and drive mechanism SOHC-4 SOHC-4

Cylinder center distance 82 82

Cylinder height 201 201

Central distance between the connecting 131

Emissions regulation to meet National 3 National 3

Type of oil pump Cycloidal gear pump. Cycloidal gear pump.

Type of water pump Centrifugal, impeller Centrifugal, impeller

Figure 2.6 Characteristic curves of engine, Model 4G13S-7L

Section II Use and maintenance of engine

Checks the driving belt of A/C generator to see if

2 Checks the ignition cable for any damages I I I I I

Check of the PCV valve

(5) Cleans out the fitting side of filter bracket.

Timing indication panel

Side of timing belt

Identification of water leakage traces.

Hydraulic pressure testing

Turbine driver test YES

Continues to use after wiping out the water

IV. Tightening moment of main bolts of engine

V. Main failures of engine and troubleshooting

5.5 Excessive oil consumption

Failure phenomenon and causes Rroubleshooting

Mobil Super 9900 or Esso Superflo SJ/CF

2 Silica gel Oil pump, water pump, oil sump LT5699

Table of the auxiliary materials for gearbox:

Table of the auxiliary materials for cylinder head assembly:

-------------------When the lubricant has no trade mark(lable), it means

------------------Sealant and adhesive

-----------------Brake fluid, automatic gearbox fluid or air compression oil

--------------------Engine or gear oil

7.4 Engine inspection tools

Removal and fitting of oil

Guided installation for the

Setting tools for the Fitting of the camshaft oil

Disassemble tool for the

Valve spring Compression valve

Positioning tool of the Removal and fitting of the

Guide bush for the

Compressor of Compression of valve

Locks the flywheel on the

Wrench for the cylinder Removal and fitting for

Overall height of cylinder body, in mm 256

II. Removal and breakdown procedure for each part

2.2 Timing belt

Essentials for installation operation:

B Installation of the timing belt tensioner /tensioner spring.