Shineray Auto Repair Manual

Contents
CHAPTER FINISHED VEHICLE APPLICATION AND MAINTENANCE ........................................................ 5

SECTION MAJOR TECHNICAL PARAMETER ................................................................................................................ 5
. Basic parameter ..................................................................................................................................................... 5

. Structure parameter ............................................................................................................................................... 7
. Other parameters (table 1-6) ................................................................................................................................. 7
SECTION APPLICATION OF FINISHED AUTO AND NOTICES ............................................................................................. 8
I. Elementary Knowledge for Application of New Auto ................................................................................................ 8
1. Inspection for New Auto ........................................................................................................................................... 8
II. Driving of Auto ...................................................................................................................................................... 10
III. Proper use of the fuel, lubricants and fluids ......................................................................................................... 13
IV. Use of the body facilities and accessories ............................................................................................................. 17
SECTION III FULL AUTO MAINTENANCE ........................................................................................................................... 18
I. Maintenance table ................................................................................................................................................... 18
II. Repair and maintenance ........................................................................................................................................ 23
CHAPTER II ENGINE MECHANICAL PART ............................................................................................................ 41
SECTION I OVERALL STRUCTURE OF ENGINE ................................................................................................................... 41
I. Composition of engine............................................................................................................................................. 42
II. Main features of the engine .................................................................................................................................... 43
I. Cleaning and protection .......................................................................................................................................... 43
II. Engine maintenance overview ............................................................................................................................... 44
III. Engine maintenance without disassembly ............................................................................................................ 46
Engine removal ...................................................................................................................................................... 46

SECTION CRANKSHAFT CONNECTING ROD .................................................................................................................. 47
I. Composition ............................................................................................................................................................ 48
II. Common faults diagnosis of crankshaft connecting rod ........................................................................................ 48
III. Maintenance of the crankshaft connection rod ..................................................................................................... 50
SECTION VALVE TRAIN ............................................................................................................................................... 61
. Composition of valve train ................................................................................................................................... 62

. Common fault diagnosis of cam valve train ......................................................................................................... 64
. Maintenance of cam valve train ........................................................................................................................... 65
SECTION LUBRICATING SYSTEM ................................................................................................................................. 71
. Composition of engines lubricating system ......................................................................................................... 72

. Common fault diagnosis of lubricating system ..................................................................................................... 73
. Maintenance of lubricating system ....................................................................................................................... 74
. Positive crankcase ventilation system (PCV system) ............................................................................................ 74
SECTION ENGINE COOLING SYSTEM ............................................................................................................................ 75
. Major component of cooling system ..................................................................................................................... 76

. Common fault of cooling system ........................................................................................................................... 77
. Repair and maintenance ....................................................................................................................................... 78
. In-car maintenance............................................................................................................................................... 82
. Composition of starting system............................................................................................................................. 86
. Common fault diagnosis of starting system .......................................................................................................... 87
. Repair and maintenance of starter ....................................................................................................................... 90
SECTION ENGINE ASSEMBLY ....................................................................................................................................... 95
. Assembly of internal parts of engines ................................................................................................................... 96

. Installation method of engines............................................................................................................................ 106
. Check .................................................................................................................................................................. 107
. Engine vacuum test ............................................................................................................................................. 108
. Oil pressure check .............................................................................................................................................. 109
SECTION MAJOR TROUBLES AND TROUBLESHOOTING METHOD OF MECHANICAL ENGINE PARTS ............................... 111
CHAPTER DRIVE SYSTEM ................................................................................................................................... 125
SECTION FIVE SPEED TRANSMISSION ........................................................................................................................ 125
. Composition........................................................................................................................................................ 125
. Fault diagnosis ................................................................................................................................................... 125
.In-car maintenance.............................................................................................................................................. 129
. Transmission repair ............................................................................................................................................ 134
. Required servicing materials .............................................................................................................................. 152
. Special tools ....................................................................................................................................................... 154
SECTION CLUTCH ..................................................................................................................................................... 155
. Composition........................................................................................................................................................ 155
. Trouble diagnosis ............................................................................................................................................... 156
. In-car maintenance............................................................................................................................................. 157
. Parts repair ........................................................................................................................................................ 158
. Servicing materials ............................................................................................................................................. 162
. Special tool ......................................................................................................................................................... 162
SECTION DRIVE SHAFT ............................................................................................................................................. 162
. Composition........................................................................................................................................................ 162
. Special tools ....................................................................................................................................................... 167
SECTION DIFFERENTIAL............................................................................................................................................ 167
. Composition........................................................................................................................................................ 167
. Trouble diagnosis ............................................................................................................................................... 168
. Disassembly and repair ...................................................................................................................................... 170
. Special tools ....................................................................................................................................................... 179
DRIVE SYSTEM ....................................................................................................................................................... 180
SECTION FRONT SUSPENSION .................................................................................................................................... 180
. Composition........................................................................................................................................................ 180
. Check and Adjustment ........................................................................................................................................ 182
.Special tools ........................................................................................................................................................ 194

SECTION REAR SUSPENSION...................................................................................................................................... 195
. Composition........................................................................................................................................................ 195
. Disassembly and assembly ................................................................................................................................. 196
. Tightening torque of fastener ............................................................................................................................. 205
SECTION WHEEL AND TIRE........................................................................................................................................ 206
. Composition........................................................................................................................................................ 206
. Trouble diagnosis .......................................................................................................................................... 208
. Maintenance and slight adjustment .................................................................................................................... 209
CHAPTER STEERING SYSTEM ........................................................................................................................... 213
SECTION TROUBLE DIAGNOSIS.................................................................................................................................. 213
. Diagnosis of common troubles ........................................................................................................................... 213

. Diagnosis of tire troubles ................................................................................................................................... 218
. Vibration fault diagnosis .................................................................................................................................... 220
SECTION FRONT WHEEL ALIGNMENT......................................................................................................................... 221
. Composition........................................................................................................................................................ 221
. Technical requirement of tightening torque ........................................................................................................ 224
SECTION RACK AND PINION ...................................................................................................................................... 224
. Composition........................................................................................................................................................ 224
. Fault diagnosis ................................................................................................................................................... 225
. Special tools ....................................................................................................................................................... 234
SECTION 3 STEERING WHEEL AND STEERING COLUMN ................................................................................................... 234
. Composition........................................................................................................................................................ 234
. Fault diagnosis ................................................................................................................................................... 235
. Special tool ......................................................................................................................................................... 240
CHAPTER BRAKING SYSTEM.............................................................................................................................. 241
SECTION SYSTEM COMPOSITION AND OPERATING PRINCIPLE .................................................................................... 241
. Booster assembly ................................................................................................................................................ 241

. Master cylinder assembly ................................................................................................................................... 242
. Load sensing proportioning valve ...................................................................................................................... 243
. Front wheel disc brake ....................................................................................................................................... 244
. Rear drum brake assembly ................................................................................................................................. 245
. Parking braking system ...................................................................................................................................... 246
SECTION FAULT DIAGNOSIS....................................................................................................................................... 247
. Check on brake fluid........................................................................................................................................... 247

. Brake road test ................................................................................................................................................... 247
. Braking system fault diagnosis table .................................................................................................................. 247
SECTION CHECK AND ADJUSTMENT .......................................................................................................................... 252

SECTION IN-CAR MAINTENANCE ............................................................................................................................... 260
SECTION SERVICING MATERIALS, TIGHTENING TORQUE AND SPECIAL TOOLS ............................................................ 289

. Tightening torque ................................................................................................................................................ 289
. Special tools ....................................................................................................................................................... 290
CHAPTER CAR BODY MAINTENANCE ................................................................................................................. 291
SECTION STRUCTURE AND MAINTENANCE OF SY1020 FRONT DOOR ........................................................................ 291
. Structure of front door ........................................................................................................................................ 291

. Maintenance of front door .................................................................................................................................. 291
SECTION WINDSCREEN ............................................................................................................................................. 296
SECTION SEAT STRUCTURE AND ITS DISASSEMBLY AND ASSEMBLY ........................................................................... 301
SECTION DISASSEMBLY AND ASSEMBLY OF SEAT BELT .............................................................................................. 303
SECTION FRAME SIZE ................................................................................................................................................ 305
CHAPTER AIR CONDITIONING, HEATING, VENTILATION SYSTEM ....................................................... 306
SECTION HEATING AND VENTILATION EQUIPMENT .................................................................................................... 306
1. Composition ......................................................................................................................................................... 306
. Fault diagnosis ................................................................................................................................................... 308

. In-car service ...................................................................................................................................................... 308
SECTION AIR CONDITIONER ...................................................................................................................................... 313
. Composition........................................................................................................................................................ 313
. Assembly of air conditioner parts ....................................................................................................................... 315
. Fault diagnosis ................................................................................................................................................... 319
. Performance test................................................................................................................................................. 331
CHAPTER ELECTRICAL SYSTEM ..................................................................................................................... 332
SECTION POWER SUPPLY SYSTEM ............................................................................................................................. 332
. General ............................................................................................................................................................... 332

SECTION CAR BODY ELECTRICAL SYSTEM ................................................................................................................ 351
. General ............................................................................................................................................................... 351

. Fault diagnosis ................................................................................................................................................... 359
. Circuit diagram .................................................................................................................................................. 383
Chapter Finished vehicle application and maintenance

Section Major technical parameter
. Basic parameter
1. Vehicle basic dimension and mass parameter (Table 1-1)
Table 1-1 Vehicle basic dimension (mm) and mass parameter (Kg)
Item
Parameter
Model
SY6370
SY6390
SY1020
Overall length
3730
3900
4590/4360
Overall width
1510
1510
1510
1823
1823
1823
Wheel base
2350
2430
2760
Front wheel tread
1300
1300
1300
Rear wheel tread
1310
1310
1310
Front suspension
690
510
690
Rear suspension
690
960
960
Front wheel toe-in
05
05
05
SY6370
SY6390
SY1020
Curb weight
985
1000
890
Fully loaded weight
1610
1650
1820
Overall height (no

load)
2. Vehicle service performance parameter (Table 1-2)

Table 1-2 Vehicle service performance parameter
Item
Parameter
SY6370
Type
of
engine
Max.
SY6390
SY1020
XC4
XC4F18-T
DL465Q5
XC4F18-T
F18T
speed
(km/h)
DL465Q
5
XC4F18-T
105
105
105
105
105
105
30
30
30
30
30
30
50
48
50
50
48
Max.
gradability
()
0-90km/hs
sequential
shift
acceleration
time (s)
Integrated
cycling value
of
fuel
5.5
5.5
5.5
5.5
consumption
L/100km
Braking
distance (m)
20 ( when the speed is 50 /h under full load)
noise emitted
by
accelerating
motor vehicle
(dB)
74
5.5
. Structure parameter
1. Major technical parameter of engine ( table 1-3
Table 1-3 Major parameter of engine
Item
Type
Type
XC4F18-T
DL465Q5
four-stroke, water cooling, single
four-stroke,
overhead
overhead camshaft, multi-point electronic
camshaft,
multi-point
water
cooling,
electronic control fuel injection
control fuel injection
Cylinder diameter (mm)
65.5
65.5
Piston travel (mm)
74
74
Displacement (mL)
997
998
compression ratio
9.31
9.51
Rated power /speed
45Kw/5200 r/min
45Kw/520050 r/min
Max. torque/speed
78Nm/2800~3200 r/min
85Nm/35004000 r/min
Mass (kg)
98
97
Fuel
93# superior nonleaded gasoline
93# or above nonleaded gasoline
Idle speedr/min
850 50
800 50
Max./Min speed (r/min)
5300/850 50
5600/800 50
2. Technical parameter of transmission (table 1-4)

Table 1-4
Technical parameter of transmission

XC4F18-T
DL465Q5
Gear 1
3.652
3.652
Gear 2
1.948
1.947
transmission
Gear 3
1.424
1.423
ratio
Gear 4
Gear 5
0.795
0.795
Reverse
3.466
3.466
Item
Type
3. Wheel parameter (table 1-5)

Table 1-5 Wheel parameter
Item
Parameter
Tire size
165/70R13165/70R14
Front wheel tire pressure (kPa)
(half load and fully load ) 200/240
Rear wheel tire pressure (kPa)
(half load and fully load ) 240/280
. Other parameters (table 1-6)
single
Table 1-6
Volume data
Jinbei Haixing
Item
Unit
XC4F18-T
DL465Q5
Engine cooling system
5.5
5.5
Engine lubricating system
3.5
3.5
Fuel tank
40
Transmission lubricating oil
1.2
Rear axle lubricating oil
1.3
Brake fluid
0.36
1.2
Section Application of Finished Auto and Notices

I. Elementary Knowledge for Application of New Auto
1. Inspection for New Auto

To ensure safe and reliable operation of auto, before putting into use, the new auto shall be conducted the following
inspections:
(1) Inspect from the outlook on whether the connection and tighten situation between key and crucial parts satisfy
requirements, particularly on steering and brake devices such as universal joint sheath, brake bottom plate, brake
piping, wheels, steering tension rod sheath, steering sheath and gearbox etc.
(2)Inspect whether the specification, type and quantity of all oils and liquids satisfy requirements, including
gasoline, oil and cooling fluid, electrolyte, window washer tank, brake fluid, gearbox oils and oils for brake and
steering etc., and inspect whether there occurs the situations such as oil spills and leaking in the auto.
3Inspect the working status of voltage of storage battery, electrical equipment, lamplight, horn, instrument and
indicator light, etc. Inspect the installation of fuse wire within driving cab.
4Inspect whether the type, specification and pattern of wheels satisfy requirements, whether the bolt tightening
moment of wheels(10010N.m)satisfies specified requirements and whether the inflation pressure of each wheel is
normal(including spare wheel) as well as the installations of valve core of wheels and wheel cowl.
(5) Inspect the connection and tightening status of all spare parts, especially the spare parts such as transmission,
steering, brake, suspension and wheel etc.
6Inspect whether the clutch and free pedal travel satisfy specified value and inspect braking system and free
pedal travel of braking, ensuring to remove the air within piping.
7Inspect external cleanness of auto, including painting, trimming and glass; Inspect internal cleanness of auto,
including saddle and internal trimming; Inspect status of windshield washing unit.
(8) Until normal work temperature after starting engine, heating of turbine, observe whether there exist
phenomena such as oil spills, gas spills, leaking and leakage of electricity.
9After putting into gear and starting to move, inspect the work situations of road tests for clutch, gearbox, hand
braking, foot braking and steering system.
1) Clutch: whether there occurs clickety-clacking and abnormal noise during operation.
2) Accelerator Pedal: shall be shown the phenomena with flexibility and no loose.
3) Gearbox: free shift, without the phenomena such as out of nimbleness, abnormal noise and out of gear.
4) Speedometer: During driving of auto, the pointer of speedometer shall be without sheering, when the auto speed
changes, the pointer runs stably.
5) Steering operational setting: whether the free play of steering wheel is normal, whether the control force is
appropriate and whether the automatic return ability could be realized after steering.
6) Foot braking: When braking at the auto speed of 40 km/h, the braking effect can be experienced, no derivation
during braking.
7) Hand braking: When lifting the handle of hand braking and when the auto is traveling at low speed 20 km/h, the
gearbox will be put into neutral, and the braking effect can be experienced.
8) Air conditioner: operate the buttons to inspect whether all the functions are normal.
9) Judge whether the noise of all parts is normal: during traveling of auto, especially at accelerating and
decelerating, please Notice whether there occurs obvious abnormal noise in all parts.
10) Inspect whether the technical materials of tool box and essential tool technology are comprehensive.
2. Running-in of New Auto
On account of processing and assembling errors, the frictional resistance of all the motional parts of new auto at
the time when it starts operation is much greater than that in normal situations. The running-in effect of initial
application period for auto produces enormous impact on service life, reliability of operation, economical
efficiency of the auto. Thereupon, the running-in regulations shall be strictly executed when the new auto is put
into use.
(1) Running-in regulations within 1000km that the auto travels:
1) Driving at full speed is absolutely prohibited.
2) In general, the driving speed is prohibited to excess 65km/h.
3) Driving at high speed within each bumping block shall be avoided.
(2) Running-in regulations between driving within 1000km to 15000km: could gradually accelerate to the highest
speed or at highest steering driving by permission of the engine.
(3) After running-in periods, please Notice:
1) When driving the auto with steering meter, the neighboring bumping block with high speed will be changed into
and the permitted highest steering speed of engine within short time is 5500r/min. The permitted highest speed of
each bumping block is: below 20km/h for the bumping block 1; 30km/h for bumping block 2; 50km/h for bumping
block 2; 70km/h for bumping block 4; above 80km/h for bumping block 5.
2) Avoid making the engine runs at unnecessary high speed, converting into the bumping blocking with high speed
as early as possible brings benefits to saving fuel oil and reducing operation noise.
3) The steering speed of engine during driving is prohibited to be too slow, only when the engine runs strenuously,
will the low bumping block be converted into.
4) The speed and revolving speed listed in the specification are only suitable for the engine with normal
temperature. When the engine is cold, no matter at neutral or at each bumping block, the engine is prohibited to
runs at the highest revolving speed.
5) The new wheels are without best adhesive force at initial application, thus, the new wheels also requires for
running-in. During driving with the first 100km, the speed shall be kept slow and the driving methods also shall be
cautious.
6) The new braking friction plate also requires for running-in. During driving within the first 200km, it still has no
ideal frictional force, during this stage, if the braking effect is a litter bit weak, the pressure of the pedal could be
increased appropriately. This situation also applies to changing braking friction plate each time later on.
II. Driving of Auto

Correct driving of auto not only could give full play to good technical performance of the auto, but above all could
ensure the safety of driving. Therefore, as a driver, the operation of auto maintenance must be conducted well
before utilization of vehicles. And during the process of driving, the vehicle shall be used correctly according to
different road situations.
1. Inspection and Preparation before Utilization of Auto
(1) Inspect fuel oil meter, to judge whether the fuel oil is needed to add.
(2) Inspect the oil level, to see whether the imprint of oil scale is within the mark of top and bottom limitation. Any
insufficiency, it shall be added promptly. When there occurs stoppage in lubrication system of the autos engine or
the mechanical oil alarm lamp is lit up during the operation of engine, the operation of engine shall be stopped
immediately and the reasons shall be analyzed to remove promptly.
(3) Inspect whether the height of coolant level satisfies requirements, any insufficiency, it shall be added promptly.
(4) Inspect whether the braking level satisfies requirements, any insufficiency, it shall be added promptly.
(5) Inspect whether the electrolyte level of storage battery satisfies requirements, any insufficiency, the distilled
water shall be supplemented.
(6) Inspect whether the air pressure of the wheels satisfies requirements and whether the spare wheels are
comprehensive.
(7) Inspect whether the lamplight, direction indicator light and braking indicator light function well.
(8) Inspect whether the front and rear windshield glass are clean, whether the degree of rearview mirrors in and out
of the auto is appropriate and whether the wiper functions well.
(9)Whether the seats and belts have been adjusted to the appropriate position;
(10)Inspect whether the operation of performance of wheel braking is reliable.
(11) Inspect whether the moving of each pedal is flexible, whether the free play is within specified scope, whether
the transposition is free and whether there exist jammed phenomena.
(12) Inspect whether the tool box is comprehensive and whether a proper amount of melt silk and bulb have been
prepared well.
(13) During long-distance driving, a proper amount of oils and coolant liquid are still needed to prepare.
Crucial Notices for safe driving:
(1) The safety belt shall be fastened well before utilization of vehicles each time and the headrest shall be adjusted
well according to figure.
(2) Be bound to Notice no object could exist to impede the operation of the pedal.
(3) No driving when tired. In general, a break shall be taken after driving for two hours.
(4) The reaction ability of the drivers will be influenced by alcohol, drugs and medicines. Therefore, driving is
prohibited after drinking wine or at absence of mind. The latest research achievements show: when the drivers use
mobile communication devices during driving, the descending degree of their reaction ability is even severer than
that after drinking wine. Thus, during the process of driving, the mobile communication devices shall be strictly
prohibited.
(5) In any case, the auto speed shall be suitable for the status of road and traffic. For example, it shall be
decelerated at the road with snow and ice, or at wet road or when it is trapped into traffic jam.
(6)For the sake of safety of drivers and others, please be sure to obey the traffic rules.
2. Starting engine
(1) Manual transmission auto
1) Before start the auto, move the gear selector to the neutral position, and pull the parking brake.
2) When start the auto with the manual transmission, step the clutch pedal to the end, and this needs drive the
engine only when engine is working,
3) Open the ignition switch, start the engine, but do not need to step the accelerator pedal.
Notice: Once start the engine, release the ignition switch immediately to prevent the starter from operating
passively.
4) After starting the engine, it not necessary to park the auto for preheating of the engine, and drive the auto after
starting.
Notice: Before the temperature of the engine reaches the normal temperature, do not make the engine
operate at high speed or step the accelerator pedal to the end.
(2) Notices when start the engine:
1) When start the engine in cold condition, because the engine used in this auto is equipped with the continuous
fuel injection device, it can provide the suitable the fuel mixed by the oil and gas in any condition. This starting
process is not affected by the external temperature, and do not step the accelerator pedal before start and when start
the auto. If the engine is not started immediately, you should turn off the ignition switch and repeat it after about
half a minute.
2) If the engine fails to be started, it is possible that the fuse of the electrical or the fuse of the engine control system
is fusing.
3. Notice in driving
In order to play the technical performances of the vehicle, reduce the fuel consumption, reduce the adverse impacts
for the environment by the exhaust gas and noise, you should pay attention to the following matters in driving:
(1) Avoid to step the accelerator pedal suddenly, and should step the accelerator by the gentle way, this shall not
only reduce the fuel consumption, but also reduce the abnormal wear between the pollution and automobile internal
motion.
(2) Exchange the shift according to the need to make the auto drive in the economy shift to avoid the engine to
operate at the high or low speed.
(3) Drive the auto as stable as possible, the operation should be predictable, and the unnecessary acceleration,
braking, starting and parking make the fuel consumption increase. Avoid the sharp turns and emergency braking.
(4) In the case of traffic jam, turn off the engine.
(5) Check the tire pressure regularly, and the lower pressure of the tire may increase the rolling resistance,
accelerate the tire wear and make the steel ring deformed.
(6) Clean out the unnecessary things in the trunk timely.
(7) Use the heating, air conditioner, rear window heating device, headlamp and other ancillary electrical
equipments only when necessary.
(8) After driving at high speed for a long time, do not turn off the engine immediately, and make the engine operate
at the idling speed for two minutes to make the temperature reduce gradually.
(9) Before drive the auto for long distance, should check and make the driving preparation according to the safety
driving precautions.
If you have known this long-distance driving, the oil changing or other maintenance items will be expired, and need
to implement these work in advance. Especially, the changing of the brake fluid has the significance for the safety
of the vehicle driving.
(10) When drive the automotive under full load, the external temperature is too high or too low, the sand is serious,
the fuel quality is poor and other conditions, should take some special technical measures, such as: use the
lubricants with the viscosity which meets the requirements of the external temperature (select the viscosity grade of
the lubricants according to the appropriate external temperature scope), install the air filter with the special
efficiency, and the maintenance cycle shall be changed correspondingly. If the engine load is large, the replacement
cycle of the lubricant should be shortened.
(11) Need to observe all instruments and indicators in driving. In order to facilitate the driver, in addition to the
common instruments, increase various indicator warning devices and engine failure diagnosis indicator. They can
reflect the working conditions of all systems accurately, if there is the hidden fault, it shall issue the warning and
request the driver to pay attention it immediately to avoid the traffic accidents caused by the serious mechanical
failure, and the warning device needed to be paid attention to include:
1) Alarm light of low oil level or pressure;
2) Alarm light of hand-brake system;
3) Alarm light of engine;
4Alarm light of no power of the engine;
(12) When drive the auto in the water, must reduce the speed and operate the auto carefully to prevent that the
water is sucked in the engine or wet the electrical equipment and cause the failures. After entering the water, restore
the brake performance immediately. When the surface water is more, do not pass through it forced.
(13) Do not attempt to change the vehicle as not to affect the normal technical condition of the vehicle and enjoy
the quality warranty.
(14) Maintain the repair the vehicles according to the regulations of the manufacturer strictly.
4. Proper use of the tractive device
There is a tractive hook at the end of the bumper, and it is used to be towed by other vehicles.
(1) When tow or be towed, the connect the towline and tow bar. It should be Noticed to avoid the forcible traction
or sudden tug, otherwise, it may damage the tow line and happen the danger.
(2) Comply with the traffic laws and regulations related to the traction, and the alarm lights of the towing and
towed vehicles must be flashing.
(3) The driver of the towed auto should pay attention to that the tow line must be kept taut state.
(4) The towed auto must be turned on the ignition switch to facilitate the steering gear to rotate freely, and the turn
signal, horn, windscreen wiper can work properly.
III. Proper use of the fuel, lubricants and fluids
1. Refueling properly
The quality of the fuel shall impact on the driving performance of the auto, performance of the engine and the
service life, and the fuel additives can improve the above performance, thus it is required to use the high-quality
fuel including the additives. If you can not buy the high-quality fuel including the additives, or if the engine occurs
the problems, such as difficult starting, unstable idle speed, descend power and other faults, you should add the
proper additives in refueling.
Pay attention to that the refueling mouth should be located in the small cover surface of the lower side panel
Behind the front door, the standard fuel tank capacity is 40L, after unscrewing the fuel tank cap, hang it on the
cover, and must use the refueling gun properly in refueling.
Description:
1) For safety reasons, do not carry the canned backup fuel to avoid to damage the oil reservoir in accident and the
overflowed gasoline may cause the fire.

2) When carry the fuel with the auto, please be sure to comply with the local traffic and safety regulations.
2. Proper use of engine lubricant
The auto has been added the high-quality engine lubricant before leaving the factory, in addition to the particularly
cold climate region, it can be as the full-year general-purpose lubricant. The high-quality lubricant is the
prerequisite which ensure the engine operation without faults and maintain the long life. Therefore, only use the
corresponding high-quality lubricant when add the lubricant or replace the lubricant.
(1) Check the lubricant level surface. When the engine is working, the consumption of the lubricant is very normal,
and the consumption of the lubricant can reach 0.138Ll000km. Therefore, must check the lubricant level surface
regularly, and it is better to check the auto in refueling every time.
When check the lubricant level, the auto should be maintained in a horizontal position. After stopping the engine
for a few minutes, so that the lubricant can be back to the lubricant tray. And then take out the dipstick wiping by
the clean cloth, and insert the dipstick into it to the place, and then take out the dipstick for reading, and the oil
level must be between the upper mark
and the lower mark X.
The difference of the maximum oil level and the minimum oil level of the engine is about 1.OL.
(2) Make up the engine lubricant. Unscrew the refueling cover on the cylinder head , and use the dipstick to check
the oil height after adding the lubricant.
Notice: The oil level should not exceed the maximum mark, otherwise the lubricant may be sucked by the
crankcase breather. When make up the engine lubricant, do not allow the lubricant to drip on to the
high-temperature parts of the engine, otherwise, it may be burning.
After making up the lubricant, cover the fueling mouth. Insert the dipstick until it is locked, otherwise the
engine may flow out some lubricant in operating.
(3) Replace the engine lubricant. The load of the lubricant and the oxidation of the lubricant in working make the
nature of the engine lubricant change. Therefore, replacing time of the lubricant depends on the used load and the
used time. In the case of using SF Grade engine oil commonly, when the auto drives for 5000km, replace the engine
lubricant.
If the vehicle is driving in the special road sections or the region with the larger temperature range, you should
shorten the driving mileage of replacing the lubricant to ensure the reliable operation and safe driving.
Notice: The engine lubricant should not be added other things for mixture. The used lubricant must be
processed by the regulations strictly, and prohibit the children from contacting. In any case, do not allow the
lubricant flow into the drainage pipeline or the land.
3. Proper use of cooling liquid
The cooling system should be checked and maintained regularly.
The cooling system has been added the cooling liquid when the auto leaves the factory.
The cooling liquid is mixed by ethylene glycol and water at the rate of 5:5, the antifreezing capacity is -35, and it
has the excellent corrosion resistance performance. In addition, the additives can prevent the system to produce the
scale and improve the boiling point of the cooling liquid.

Based on the above excellent performance, the cooling system should use this kind of cooing liquid all year round,
and do not add the pure water at any time (especially in the summer or hot regions) so as not to reduce the
density of the cooling liquid. In order to ensure the normal function of the cooling liquid, the density of the cooling
liquid should not be less than 40% (volume ratio).
If need to improve the antifreezing capacity of the cooling liquid, you can increase the ratio of ethylene glycol, but
the density of the cooling liquid should not exceed 60% (volume ratio).
In the cold region (below -40), prepare the cold protection and replace -40ethylene glycol engine antifreezing
liquid.
(1) Check the height of the cooling liquid level: the cooling liquid reservoir is located in the front bulkhead. The
cooling liquid level must comply with the regulations to meet the work requirements of the cooling system.
Therefore, check the level height regularly.
In order to check the cooling liquid level correctly, turn off the engine before inspection, and check the engine after
stopping operation. The cooling liquid reservoir should be transparent plastic container with the maximum (max or
H) and minimum (min or L) mark, and you can check the level without opening the reservoir.
Notice: When the engine is in the cold state, the cooling liquid level must be between the maximum and minimum
mark, once reaching the hot state, the level may be higher than the maximum mark.
Notice: If the cooling liquid is lost abnormally, it indicates that the cooling system may have the leakage fault,
at this time, adding the cooling liquid can not resolve the problem completely. Therefore, do not delay and go
to the authorized service station to check the cooling system immediately.
(2) When add the cooling liquid, turn off the engine, use the both to cover the cooling tank lid after cooling, rotate
it by the clockwise, remove the tank lid after reducing the pressure, and add the cooling liquid.
Notice: When the engine is in the hot state, the cooling system is still in the high-temperature and
high-pressure state, at this time, do not open the tack lid to avoid burn!
In the emergency case, if you add the pure water, must add the cooling liquid additives according to the regulations
to make the density of the cooling liquid restore to the normal state.
If the cooling liquid is consumed substantially, must add the cooling liquid for the engine in the cold state to avoid
to damage the engine.
When add the cooling liquid, do not make the level exceed the maximum mark of the tank. Because once the
engine reaches the hot state, the excessed cooling liquid shall overflow the cooling system by the pressure limiting
valve of the tank. After adding the cooling liquid, must tighten the tank cap.
Notice: The cooling liquid and the cooling liquid additives are the toxic substances! Thus, the additives must
be stored in the original container to prevent the children from contacting it, if must let out the cooling liquid
in the system, collect it and store it in the safe area. The released cooling liquid should not be used again, and
process the disposal cooling liquid according to the regulations of the environment protection law strictly.
4. Proper use of brake fluid

(1) Check the brake liquid level. The brake liquid tank is located on the left side of the front bottom. The brake
liquid level should comply with the regulations to meet the work requirements of the brake system.
The level should be between the liquid tank maximum (max or H) and minimum (min or L) mark.
The brake system of this vehicle is equipped with the friction lining to adjust the gap. Therefore, in the using
process, the brake liquid level may be declined slightly, this situation is normal without worry, however, the level is
declined or declined below the lowest mark in the short period, it indicates that the brake system is leaked, at this
time, you should drive your auto to the authorized service station for maintenance of the brake system.
(2) Replace the brake liquid. The brake liquid has the hygroscopicity, and it can absorb the moisture in ambient
air in the using process. If the moisture content of the brake liquid is excessive, it may corrode the brake system,
and the boiling point of the brake liquid can be reduced significantly, and this shall affect the brake effect and
safety, based on the above reasons, replace the brake liquid once a year.
Notice: If the brake liquid is used for a long time or frequent braking, the brake system can produce the
steam bubbles, and this shall impact the brake effect and driving safety.
In order to ensure the brake effect and driving safety, please must use the original brake liquid equipped by
the company and used the unused brake fluid.
Notice: The brake liquid is the toxic liquid! Therefore, it must be stored in the original sealed container to
prevent the children from contacting it! The brake liquid can corrode the paint of the auto body!
The treatment of the waste brake liquid is a highly professional work, must use the special tool, therefore it
should be replaced by the authorized service station.
5. Proper use of the transmission gear oil
In order to ensure the normal work performance of the transmission, please pay attention to filling the gear oil
regulated by the manufacturer, if the quality of the gear oil is not proper, it can accelerate the abnormal wear of the
gears and impact the use performance of the vehicle.
(1) The specification model of the gear unused by the transmission is 85W-90 GL-5 GB13895-1999, in order to
maintain the transmission better, please replace the gear oil once a year or traveling 50000km.
Notice: After the vehicle is driving at high speed or full load for a long time, if the oil level can not meet the
requirements, fuel it or discharge the oil timely (the drain plug is located lower of the bottom of the transmission oil
tank ). The transmission oil should be red, if the oil is brown or black, it indicates that it contains the friction
materials and a large amount of impurities. If the oil fluid is pink or white, replace it. Under the normal
circumstances, replace the transmission gear oil once a year or driving 50000km. If the traveling road surface
condition is poor, you should shorten the driving mileage of replacing the transmission gear oil to ensure the
reliability and safety of driving.
IV. Use of the body facilities and accessories

1. Opening and closing of the door
(1) If you are outside of the car, pull the door handle outward when open the door. Lock or unlock the front two
doors by the key, when open the door, the safety lock button is popped up, when lock the door, it will be back to the
original position.
(2) In the car, all doors (the lock of the front left door must be in the engagement state) can be locked by pressing
the safety lock button rod. As long as press the safety lock rod, you can not open the door whether from outside or
inside of the car.
Notice: Do not press the safety lock button to lock the door when the car is driving. So that the door can be
opened from the outside of the car under the emergency circumstances.
2. Close the windows
(1) Window lifter. The windows in the car can be opened and closed by hand operating crank of the door. When
rotate the glass lifting device handle clockwise from the left side, the glass of the door shall be dropped. Rotate the
handle counterclockwise, the glass shall rise; in the right side, it is converse. Notice: some configured middle door
window lifter is the Grade 2 window lifter, when the glass of the middle door is dropped to half, need to rotate
1/41/2 cycles, and then continue to rotate the glass of all middle doors.
3. Adjustment of the rear view mirror
In order ensure the best visual effect at any time, you should adjust the rear view mirror in driving.
Adjust the rear view mirror outside of the car manually. The outside rear view mirror should be adjusted to the
position where you can see the upside of your car. This position can ensure the maximum field of vision.
4. Use and adjustment of the safety belt
A large number of facts prove that the safety belt may provide the very good protection in the accident. Thus, you
should wear the safety belt before drive the car.
Use of the safety belt rolling wheel safety belt.
1) Three-point inertia. In the normal driving state, the safety belt can be expanded freely according to the need of
the passengers, however, the speed of the auto or other factors (such fast pulling or emergency brake) are changed,
the safety lockup mechanism shall lock it and maintain a certain tightening force.
Notice: Correct use of the safety belt is very important for playing its role.
2) Fasten the safety belt to the pelvic. Pull one end of the lock tongue of the safety belt from the front of the pelvis
slowly by hand, insert the lock tongue and connect it to the other side of the lock until hear the sound of loc, and
then pull it outside to check whether it is locked really or not.
3) Fasten the safety belt to the shoulder. The safety belt should be across the middle of the shoulder and then be
across the chest to close to the body.
5. Adjustment of the seat

(1) Forward and backward adjustment of the front seats: in order to ensure the safety, adjust the driving set whether
auto is static. The forward and backward adjustment method of the front seat is to pull the rod in the font of the seat
to move the seat forward and backward.
(2) The adjustment of the seat backrest angle is to toggle the rod next to the backrest by leaning forward of the
body. The backrest should not be tilted to the back excessively in driving, otherwise, it may affect the effect of the
safety belt.
(3) Seat of the rear two rows. The backrest and the cushion of the rear seats of some models are separated, and it
has the tilt forward function to increase the volume of the trunk. The method of tilting the backrest: Move the
front seat to the appropriate position to prevent from collision with the rear seat. And then pull the plastic rod on
the top of the backrest of the rear seat to title the backrest forward.
Section III Full auto maintenance
I. Maintenance table
1. Maintenance table under the normal condition
Maintenance
interval:
Determine
the
interval according to
the mileage reading
or month, and it
subject to the firs
arrival.
This table lists the maintenance requirements of the vehicles with the driving mileage of
80,000km, for the vehicle driving more than 80,000km, implement the same maintenance
by the same interval.
Km (1000)
10
20
30
40
50
60
70
80
Miles (1000)
12
18
24
30
36
42
48
Month
12
18
24
30
36
42
48
1. Engine
J.T
J.T
1-2Camshaft timing belt
Replace it every 100,00km.
l-3Valve clearance
l-4Engine oil (Grade SF engine oil) and

engine oil filter
After first maintenance, replace it every 5000 km or every six

months.
l-5Engine oil (Grade SJ engine oil) and

engine oil filter
After first maintenance, replace it every 10000 km or every six

months.
1-6Cooling system hoses and fittings
J.T
l-1Drive belt
J.T
I&(R)
2-1Crankcase breather and connectors
2-2Crankcase ventilation capacity control

valve
2-3Fuel evaporative exhaust control system
1-7Engine cooling liquid

l-8 Exhaust pipe and installation parts
(excluding the exhaust filter)
2. exhaust gas control system
3. Electrical system
3-1Harness and fittings
4. Ignition system
If use the unleaded
gasoline.
4-1Spark plug
If use the unleaded gasoline, please refer to the table of Driving Under the Harsh
Conditions.
4-3Ignition system line
()
JT
5. Fuel
5-1Mixture ratio of the engine speed (idling
speed) and idling speed
5-2Fuel tank head
5-3Air filter element
5-4Oil filter
Replace it every 10000 km.
5-5Fuel pipe and fittings/tank
JT
JT
JT
Maintenance
interval:
Determine
the
interval according to
the mileage reading
or month, and it
subject to the firs
arrival.
This table lists the maintenance requirements of the vehicles with the driving mileage of
80,000km, for the vehicle driving more than 80,000km, implement the same maintenance
by the same interval.
Km (1000)
10
20
30
40
50
60
70
80
Miles (1000)
12
18
24
30
36
42
48
Month
12
18
24
30
36
42
48
Brake disc and pad (front)
Brake drum and brake shoe
6-2Brake hoses and pipes
6-3Brake liquid
6-4 Brake pedal
6-5Bbrake lever and link
7-1Clutch
7-2Tire
7-3Wheel roulette
7-4Suspension devices
7-5Drive shaft
7-6Manual transmission oil
7-7Differential oil
7-8Steering system
6. Brake
6-1
7Chassis and body
7-9All latches, hinges and locks

7-10Transmission shift fork and shaft
Notice:
RReplacement, JInspection,TAdjustment
Check and repair, and replace it if necessary.
1-7Ris only suitable to the discharge device installation rubber parts.
Maintenance recommendations driving under the harsh conditions

If the auto is driving under the harsh conditions, it is recommended to perform the special maintenance
interval in the following table.
2. Code of harsh conditions
A-Repeated short trips
B-Driving on the uneven/or slimy road
C-Driving on the dusty road
D-Driving in the very cold weather conditions and /or on the salt road
E-Repeated short trip in the very cold weather conditions
F-Full load for long timer or driving on the mountain road
Code of harsh
conditions
Maintenance
M
ain
ten
an
ce
op
era
tio
n
Maintenance interval
Every 20,000km or 12 months
-BC---
Drive belt
R
A-CDEF
Engine oil and oil filter

R
AB-D--
Discharge
fittings
pipes
and
Every 2,500km
R
--C---
Air filter element *1

ABC-E
Spark plug

R
AB-D--
Drive shaft
-B--EF-
-B----
Transmission (manual)
and differential oil

R
Chassis bolts and nuts

T
Brake disc
(front)
and
pad
ABC---
Every lO,000km or 6 months

Brake drum and brake
shoe (rear)
Notice:
RReplacement
Check and repair, and replace it if necessary.
TTighten it according to the regulated torque.
*
1If the auto is driving on the dusty road, the inspection and replacement should be more frequent.
II. Repair and maintenance

1. Engine
Drive belt
Warning: Before check and adjust the tension of the belt, disconnect the negative post of the battery.
Water pump belt inspection
1. 10kg (22 Ibs)

2. Adjust the bolts
1) Check whether the belt has the cracks, incision, deformation, wear and cleanliness or not. If necessary, replace it.
2) Check the tension of the belt, press the middle of the belt by the force of about 10kg, it shall sink about 7
10mm.
The belt tension a: the subsidence value is 710mm.
Notice:
After replacing the belt, the tension shall be adjusted to: press the middle of the belt by the force of about
10kg, the subsidence value is 56mm.
Replacement of the water pump belt
1) Disconnect the negative pole of the battery.
2) If equipped with the air conditioning, remove the air conditioning compressor drive belt (refer to the air
conditioning compressor drive belt).
3) Replace the water pump belt by the new belt.
4) Adjust the belt tension according to the technical requirements.
5) Connect to the negative pole of the battery.
Check the air conditioning compressor drive belt (optional)
Check the wear, damage and tension of the belt. If necessary, replace
or adjust it in time.
Tension of the air conditioning compressor drive belt:
When press the middle of the belt by the force about 10kg, the
1. Drive belt
2. Crankshafte pulley
3. Air conditioning compressor
subsidence vaue is 811mm.

Replacement of the air conditioning compressor drive belt:
1) Disconnect the negative pole of the battery.
2) Release the belt tension, and replace the old belt by the new belt.
3) Adjust the belt tension according to the technical requirements.
4) Connect to the negative pole of the battery.
Notice:
When replace the new belt, the tension is adjusted to: Press the middle of the belt by the force of 10kg, and
the subsidence value is 89mm.
Camshaft timing belt inspection
1) Remove the hole plug from the belt
2) Use the light and special mirror to check the timing belt wear, cracks, damage, oil and other conditions. If
necessary, replace it.
3) Install the inspection hole plug.
1. Crankshaft belt wheel

2. Adjustment of bolts
3. Valve rod
4. Adjust the screw and lock the
nuts
1. Crankshaft belt wheel

2. Adjustment of bolts
3. Valve rod
4. Adjust the screw and lock
the nuts
Valve clearance inspection:
1) Remove the crankcase ventilating horse on the valve
mechanism cover.
Engine oil viscosity table
2) Remove the valve mechanism cover.

3) Check the clearance of the intake and exhaust valve, if necessary, adjust it.
4) Install the valve mechanism cover, and tighten the bolts according to the technical requirements.
5) Connect the crankcase ventilating horse.
Inspection and adjustment of valve clearance steps refer to Chapter II.
Technical
requiremen
ts of the
valve
clearance
(clearance
a)
Cold
state the
cooling
temperatureis 1525
Hot state the cooling

temperature is 6068
XC4F18-T
DL465Q5
XC4F18-T
DL465Q5
0.150.19mm
0.230.28mm
0.230.28mm
0.150.19mm
0.230.28mm
0.230.28mm
Intake
0.15
0.19mm
Exhau
st
0.15
0.19mm
liquid
Engine oil and engine oil filter

Fill the engine oil:
If the temperature is more than 15 in summer, use SF15W-40, if the temperature is less than 15 in winter, use
1. Oil bottom shell
SF10W-30, and in winter, the northeast, Inner Mongolia and Xinjiang shall use SF5W-30.
2. Plug of oil discharge
Notice: Replace the corresponding engine oil according to the different temperature.
Before discharge the engine oil, you should check whether the engine oil is leaked. If it is leaked, please replace
the damaged parts before perform the following work.
1) Remove the plug of discharging the oil to discharge the engine oil.
2) After discharging the engine oil, clean the plug of oil discharge. And then install the plug of oil discharge and
tighten it according to the following requirements.
Tightening torque: (a): 35 Nm
3) Use the engine filter spanner (special tool) to release the oil filter.
Special tool (A):09915-47340
4) Smear the engine oil on the O ring of the new engine oil filter.
5) Tighten the new engine oil filter on the filter base, until the filter O ring
contacts with the installation surface.
Caution:
1. Oil filter
In order to tighten the engine oil filter appropriately, please pay attention to identifying the accurate position
of the filter o ring and the installation surface.
6) After contacting with the installation surface, use the engine oil filter spanner twist the filter 34 rings.
Special tool (A):09915-47340
Pressing torque(a35Nm
7) Fill the engine oil until it reaches the sign of full oil on the
dipstick, and the filling hole is located in the tope of the cylinder
head.
8) Before check the oil level, start the engine for 3 minutes no load.
After stopping, check the oil level after 5 minutes. If necessary, fill
the oil, until it reaches the sign of full oil on the dipstick.
1. Sign of low oil level

2. Sign of high oil level
Refer to Section 1 of this chapter Filling amount of engine oil

9) Check whether the engine filter and the plug of oil discharge are leaked.
Cooling system horses and fittings
Inspection
1) Visual inspection of the cooling system, check whether the horses of the
cooling system have the obvious leaks and cracks, check whether the horses are
damaged and check the tension of the pipe clamp.
2) Replace the horses with the leak, cracks and other damages. Replace all pipe
clamps without the appropriate tension.
3) Clean the front part of the radiator core.
4) The test pressure of the cooling system and the radiator cover is 108kPa. If
necessary, replace the radiator cover designed for the cooling system of this
vehicle.
1.
2.
3.
4.
Full liquid level mark

Low liquid level mark
Tank cover
Matching mark
5) Check the cooling liquid level and density. Refer to the inspection steps of Cooling Liquid Level in Section 6 of
Chapter II.
Engine cooling liquid
Warning:
When the engine and the radiator are still hot, do not remove the radiator cover to avoid the burn. If you
remove the radiator cover immediately, the steam and the hot water shall spray under the pressure.
Replacement
Model of filled cooling liquid: Fill No. -20 ethylene glycol engine
cooling liquid, in winter, in the regions of northeast, Inner Mongolia,
Xinjiang and the regions with the temperature less than -20, fill No.
1. Radiator
2. Radiator discharge plug
-4 ethylene glycol engine cooling liquid.

1) When the engine is cooling, remove the radiator cover.
2) Release the radiator discharge plug to discharge the cooling liquid.
3) Remove the liquid tank, and discharge the cooling liquid completely.
4) Tighten the discharge plug, and install the liquid tank.
5) Fill the quantitive cooling liquid for the radiator (refer to Section 6 of Chapter II), exhaust the air in the cooling
system, and then make the engine operate for 2-3 minutes at the idle speed, after stopping the operation, fill the
cooling liquid until the liquid level reaches the filling mouth of the radiator. Install and tighten the radiator cover.
6) Fill the cooling liquid to the liquid tank, until the liquid level reaches the sign of Full, and then cover the tank
head to make the matching signs on the tank and cover aligning.
Caution:
When replace the engine cooling liquid, and the temperature is less than -16 in winter, use the mixture
cooling liquid at the ratio of water of 50% and the ethylene glycol of 50%. When the temperature is more
than -16, use the cooling antifreezing liquid at the ratio of water of 70% and the ethylene glycol of 30%.
Even under the condition higher the freezing temperature, for the purpose of anticorrosion and lubrication,
use the mixed cooling antifreezing liquid at the ration of water of 70% and ethylene glycol of 30%.
Muffler and installation accessories
Warning:
When the discharging system is still hot, do not contact with it to avoid burn. Any maintenance work of the
discharging system shall be performed after cooling.
Inspection
When implement the regular maintenance or repairs according to the
following steps, you should check the discharging system.
Check whether the rubber installation parts are damaged and worn.
Check whether the discharging system is leaked, the connector is
loosened, has the impression and damages or not.
If the bots or the nuts are loosened, tighten them according to the
technical requirements. Refer to Chapter II.
Check whether there are the damaged, poor matching or misplaced components, or the slotting, hole, loosened
joints which may lead the discharged smoke to penetrate the vehicle or other damages.
Ensure the sufficient clearance between the discharge system components and bottom plate of the body to avoid
that the overheating may damage the floor carpet.
If all parts are damaged, please repair it immediately.
2. Exhaust pollution control system

Crankcase breather horses and fittings
Inspection
Check whether the crankcase breather has the leaks and cracks, if it is
damaged, you should repair or replace it, check and ensure that the horse
joints are fastened.
Crankcase ventilating volume control valve
1. Crankcase ventilating volume

control valve
1) Disconnect the crankcase ventilating volume control valve on the

valve mechanism cover, and then use the plug to plug the hole on the valve mechanism cover.
2) Operate the engine by the idling speed.
3) Put the hand on the end of the crankcase ventilating volume control valve, and check whether it is vacuum. If it
is not vacuum, check whether the valve is blocked or not. If necessary, replace it.
4) After checking the vacuum, stop to operate the engine, and remove the
crankcase ventilating volume control valve. Shake this valve, listen
whether there is the click sound, if there is the click sound, and replace this
valve.
5) After inspection, remove the plug. And install the crankcase ventilating
volume control valve.
Fuel evaporative pollution discharge control system
1) Check whether the horse is damaged, cracked or excessive bending by visual. Check whether all pipe clamps are
damaged and positioned properly or not.
2) In case of any damage, repair or replace it.
3) Check the evaporator, and refer to Section 6 of Chapter II. (Inspection
procedures of evaporator)
3. Electrical system
Harness and fittings
Inspection
1. Pressure resistance 2. Cover
Check al wires of the engine components are damaged or not visually.
Check the insulation (cracks) conditions, and all wire clips should be fastened.
Replace all damaged or poor harness.
4. Ignition system
Spark plug
Replacement
1) Remove the dust on the cylinder head around the spark plug.
2 ) Disconnect the high-pressure damping line on the spark plug. Pay attention to pulling the protective shield of
the high-pressure damping line.
3) Use the spark plug wrench to loosen the spark plug and remove the spark plug.
4) Re-install the new spark plug.
Notice:
Ensure to use the new spark plug with the regulated heating degree and si ze.
5) Tighten the spark plug by the regulated torque.
Tightening torque: 2528Nm465
6) Connect to the spark plug high-pressure damping line, do not push the high-voltage line in connecting, and you
can only push the protection cover.
Ignition system circuit (high resistance cable)
Inspection
Check whether the high resistance cable has the cracks or joints, the resistance data and the measurement procedure
should refer to Section 7 of Chapter III.
If it is damaged and the resistance value does not meet the requirements, replace it.
Notice:
Check and ensure that each high resistance cable terminal and joint have been fastened, and they have been
inserted in the corresponding components. Must replace all burned-out joints.
1) Disconnect the high resistance cable and ignition coil.
2) Connect to the new high resistance cable and clamp it by the clip firmly. Do
not push the high resistance cable joint in connecting, and you should push the
protective boot.
Ignition timing
Inspection
1. Air filter shell cover

2. Clamp
Inspection: Use the failure decoding to check it in the idling speed, and ensure
whether the setting of the ignition timing is appropriate. If it does not meet the
technical requirements, check the corresponding components or electrical control system.
5. Fuel
The fuel is 93 high-quality unleaded gasoline used by the auto.
Engine idling speed and idling speed mixture
Inspection
Check the idling speed by the engine speed or special instrument, and use the special instrument to check the ration
of the air and fuel.
Fuel tank cover

Inspection
Check the fuel pad by visual, if it is damaged, replace it timely.
Caution:
1. Fuel filling port cover

2. Pad
Replace the new fuel tank cover by the same specification,

otherwise, it shall cause poor work.
Replacement of the air filter element

Check and replace the air filter element regularly.
Notice: Replace it in the dusty conditions frequently.
Replace the air filter element according to the procedures of Section 5 of

Chapter III.
Inspection and cleaning
1) Check whether the air filter is too dirty, damaged or has the oil by visual, if there are the above situations, please
replace the air filter timely.
2) Use the compressed air to clean the element by the exhaust hole of the filter element.
Notice:
If the auto is driving on the dusty road, clean or replace it every 2,500km.
Fuel pump filter
1. Fuel pump
5. Drain valve
2. Fuel pump filter 6. Dual way check valve
3. Fuel filter
7. Fuel shut-off valve
4. Fuel ruler
8. Fuel pump assemblies
Fuel flow direction
Replacement warning:
Must replace the fuel filter in the ventilating area, and be away from the source of fire.
The fuel filter is located in the fuel tank, including the fuel pump
assemblies.
Clean or replace the fuel pump filter regularly.
Fuel pipe and fittings/tank

Inspection
Check whether the fuel tank, fuel pipe and joints have the leaks, horse cracks, damages or not, and ensure fasten all
pipe clamps.
If the fittings are leaked, repair them. If the horse is cracked, replace it.
6. Brake
Brake disc and pad (front)

Inspection
1) Remove the wheel and calipers, but do not remove the brake horse from the caliper.
2) Check whether the disc brake pad and the brake disc have the
excessive wear, damages, if necessary, replace it. Refer to Chapter VII.
The tightening torque of the caliper pin bolt should meet the technical
requirements.
Notice:
When step the brake pedal, if the front brake has the noise, check
whether the brake pad friction lining is worn seriously or not. If it is worn seriously, the right and left brake
pads should be replaced together.
Brake drum and brake shoe pad (rear)

Inspection
1) Remove the wheel and brake drum.
2) Check whether the brake drum and the brake friction lining are worn
and damaged or not. When remove the wheel and brake drum, check
whether the brake sub-pump is leaked or not. If necessary, replace it. Refer
to Chapter VII.
Brake horse and oil pipe
Inspection
When perform the inspection, the light intensity should be sufficient, if necessary, use the inspection mirror.
Check whether the brake horses and the oil pipe clamps are appropriate or not, whether have the leaks, cracks, jam,
wear, corrosion, bending, twisting and other damages. If necessary, replace it.
Check whether all pipe clamps are fastened, and the joints are leaked or
not.
Check the oil pipes and horses to avoid contacting with the sharp edges
and moving parts.
Caution:
After replacing any brake oil pipe and horse, must implement the
exhaust operation.
Brake liquid inspection
1. Fluid tank
2. Fluid tank cover
1. Fluid tank
2. Fluid
tank
cover
Check whether the brake master pump and liquid tank are leaked or not.
If it is leaked, repair it immediately.
Check the liquid level.
If the liquid level is below the minimum liquid level of the liquid tank, make up it by the regulated brake liquid.
Brake liquid:
The brake liquid brand No. is HZY3
GB12981-2003
Refer to Chapter VII Vehicle Maintenance.

Caution:
As the auto has been filled the brake liquid before leave the factory, if need to fill or make up it, you should
use the same brake liquid, otherwise it may cause the serious damages.
Do not use the expired and used brake liquid, or the brake which is not stored in the sealed container.
Replacement
Replace the brake liquid according to the following requirements.
Drain the brake liquid in the brake system completely. Fill it by the above recommended brake liquid, and exhaust
the air.
The exhaust procedures refer to Chapter VII.
Brake pedal
Inspection
Check the travel of the brake pedal.
The inspection procedures refer to Chapter VII Inspection of Brake Pedal
Travel.
Brake handle and link

Inspection
Check whether the brake handle tooth tip is worn or damaged. If it is worn or damaged, replace the parking brake
handle.
Check whether the operation and travel of the parking brake handle are correct. If necessary, adjust it.
Inspection and adjustment procedures refer to Chapter 5 Inspection and Adjustment of Parking Brake.
aParking brake handle travel.
47 teeth (apply the pulling force of 25kg).
1. Clutch pedal
7. Chassis and body

Clutch inspection
Check the free travel of the clutch pedal. The inspection adjustment procedures refer to Section 2 of Chapter 6.
a free travel of the pedal is 1525mm
Tie
Inspection
Check whether the tire is worn or damaged excessively. If it is poor, replace it.
Check the pressure of each tire, if it does not comply with the technical
requirements, adjust the pressure value.
Notice:
Check the tire pressure after cooling.
Find out the regulated tire pressure from the tire pressure plate or manual
equipped with the vehicle.
1. Wear indication pattern
Rotation of the tire: Rotate the tire after a certain period.

The detailed procedures refer to Section 3 of Chapter IV.
Wheel
Inspection of wheel rim
Check whether the wheel rim has the indentation, deformation and cracks. If the wheel rim is damaged seriously,
must replace it.
Inspection of wheel bearing
Check whether the bearing of the front wheel is worn and damaged, and has the noise or clicks. Refer to Section 1
of Chapter V Inspection of Front Suspension.
Check whether the bearing of the rear wheel is worn and damaged, and has the noise or clicks. Refer to Section 1 of
Chapter V Inspection of Rear Suspension.
Wheel nuts
Check whether the wheel nuts are fastened, if it is not fastened, fasten it by the regulations again.
1. Front tie
2. Rear tie
3. Reserved tire
Suspension device
Inspection
Check whether the front/rear shock absorber has the oil leak, indentation or other damages on the bushing, and
check whether the end of the base is damaged, if it is damaged, replace it.
Check whether the front/rear suspension device is damaged and loosened, and check whether the components are
worn or lubricated.
If the component is damaged, repair or replace it.
Check whether the dustproof sealed cover of the front cantilever ball head pin is leaked, released, torn or damaged.
If it is damaged, replace it.
Check whether the suspension bolts and nuts are fastened or not, if necessary, fasten it again, if the component is
damaged, repair or replace it.
1. Ball joint bolt dustproof sealed pad

2. Suspension cantilever
1. Pillar
Drive shaft
Inspection
Check whether the universal joint and spline of the drive shaft has the clicks, if there is the click, replace the
damaged components.
Check whether the collar-head fork bolts and nuts of the drive shaft are fastened or not, if necessary, fasten it again.
Tightening torque
(a)235Nm
Manual transmission oil

Inspection
Check whether the transmission gear has the oil leak, if have, repair the leaking position.
When check the oil level, ensure the auto flat.

Remove the oil level plug of the transmission. Check the oil level by the oil filling
hole/oil level plug hole.
1. Oil filling hole/oil level plug

2. Oil discharge plug
When remove the oil level plug, the oil outflow from the oil level hole, it indicates that it has been filled to the
position.
If it is found that the lack of the fuel, fuel it by the regulated oil and make the oil level reach the oil level hole.
The regulated oil refer to the instruction of the oil replacement of Drive System of Chapter IV.
Tighten the oil level plug according to the regulated torque.
Replacement
1) Make the auto flat. Put the oil container under the body, and remove the oil discharge plug for discharging the
oil.
2) Smear the sealant on the oil discharge plug, and then tighten the oil discharge plug by the regulated torque.
3) Fill it by the regulated oil and make the oil level reach the oil level hole.
4) The recommended oil, oil volume and tightening torque data refer to Chapter Iv.
Specification
Location
Winter
Filling volumeL
Summer
Transmission
Rear
differential
axle
75W/90 GL-5
GB13895-1999
85W/90 GL-5
GB13895-1999
XC4F18 engine
DL465Q5
engine
1.3
1.3
1.3
Inspection of differential oil

Check whether the differential case is leaked, if it is leaked, repair it.
When check the oil level, make the auto flat.
Remove the oil level plug of the differential. Check the oil through the oil
level plug hole roughly.
1. Oil discharge plug
2. Oil filter/oil level plug
When remove the oil level plug, the oil shall outflow from the hole, and it indicates that the oil has been filled to
the place.
If it is found that the lack of the oil volume, fill the regulated oil and make the oil level to the oil level hole.
The regulated oil refer to the replacement instruction of Vehicle Maintenance of Section 5 of Chapter III.
Tighten the oil level plug according to the regulated torque.
Replacement
1) Make the auto flat. Put the oil container under the body, and remove the oil discharge plug for discharging the
oil.
2) Smear the sealant on the oil discharge plug, and then tighten the oil discharge plug by the regulated torque.
3) Fill it by the regulated oil and make the oil level reach the oil level hole.
4) Tighten the oil filling plug according to the regulated torque, and the recommended oil, oil volume and
tightening torque data refer to Chapter IV.
Steering system
Inspection
Make the auto drive straightly, check whether the clearance of the steering wheel is appropriate, and check whether
the is there clicks or not.
Free travel of peripheral flange of the steering wheel a030mm
Check whether the bolts and nuts have been tightened or not, if necessary, tighten it again. If the component is
damaged, repair or replace it.
Check whether the steering rod is loosened or damaged. If it is loosened or damaged, repair or replace it.
Check whether the steering rod protective boot and the steering pinion case are damaged or not (leak, tear, loosen,
etc.). If it is damaged, replace it by the new case.
Check whether the universal joint of the steering shaft has the clicks and is damaged, if it has the clicks and is
damaged, replace it by the new components.
Check whether the steering wheel is steering around. If the steering is bad, repair or replace it.
Check whether the bolts and nuts are tightened or not, if necessary, tighten it again. If it is damaged, repair or
replace it.
Refer to Chapter VI Tightening Torque Technical Requirements.
Check whether the steering wheel is calibrated or not.
Notice:
Detail description of the steering wheel calibration. Refer to Chapter V Steering Wheel Calibration.
1. Tie rod end boot

2. Steering gear case
3. Universal joint
All door latches, hinges and locks

Inspection
Check whether the switch of the front door, rear door and back door are flexible and fastened or not. Refer to
Chapter IX.
Example: front door
Shift fork and shaft

Inspection
Check whether the shift form is flexible, has the abnormal noise or not.
If the operation is badly, lubricate it by the following requirements:
Use the chassis waterproof grease to lubricate the control rod base and shaft bushing.
8. Final inspection
Warning: When implement the road test, in order to avoid any accident, implement it in the safe area.
Door
Check whether the opening and closing of each door are flexible, and the door is fastened or not.
Seat
Check whether the front seat backrest governor mechanism is locked firmly in the allowed angle.
Seat belt
Check whether the seat belt device (including the reinforcing plate, buckle, pinch plate telescopic device and
fasteners) is damaged or worn or not.
Check whether the seat belt is locked firmly or not.
Inspection of battery electrolyte level

Check the electrolyte level of all battery is located between the up and below liquid level on the battery case.
maintenance free battery
Accelerator pedal operation

Check whether the accelerator pedal operation is flexible or not, and it should not be interfered or locked.
Check whether accelerator pedal clearance is appropriate or not.
Starting the engine

Check the starting conditions of the engine.
Warning:
Before inspection, there must be the enough space around the auto. Ensure the parking brake and foot brake
reliable, and do not step the accelerator pedal. If start the engine, turn off the ignition device immediately.
These preventive measures are to avoid that the carelessness cause the personal injury or property damages.
Put the stick shift in N neutral position, when step the clutch completely, start the engine.
Exhaust system inspection

Check whether the exhaust system is leaked, cracked or loosened or not.
Clutch
Check the following conditions:
When step the clutch pedal, the clutch shall be fully released.
When release the pedal to accelerate, the clutch shall not slip.
The clutch does not exist any abnormalities.
Shift or selector (transmission)

Check the shift of the shift or selector in all positions is flexible, the transmission performance in any position is in
good condition or not.
Brake
[Foot brake]
Check whether the brake pedal travel is appropriate or not.
The work performance of the brake is good or not.
Check whether there is the noise.
Check whether the brake force applied to all wheels are even or not.
Check whether the brake can reset or not.
[Parking brake]
Check whether the brake lever travel is appropriate or not.
Warning:
When park the auto on the steep road, ensure that there is nothing in front to avoid the personal injury and
property damages. Even the auto starts to move, it can implement the foot brake immediately.
When park the auto on the road with the gradient of 30%, if the pull up the brake level fully, ensure that the parking
brake is effective completely.
Steering
Check the stability of the steering wheel, and ensure that there is no the unstable and extremely heavy
phenomenon.
Check the auto operating stability and driving stability.
Engine
Check the engine, and it should operate freely in any speed.
Check the engine without abnormal noise and abnormal vibration.
Body, wheel and power transfer system

Check the body, wheel and power transfer system without abnormal noise and abnormal vibration or any other
abnormal circumstance.
Measurement instruments
Check whether the working of the odometer, speedometer, fuel gauge, and thermometer are accurate or not.
Light
Check whether all lights work well or not.
Windscreen defroster
When the heater or air conditioning is working, check the air exhausted from the defroster regularly.
When implement the inspection, turn the fan switch to the position of HI.
Chapter II Engine mechanical part

Section I Overall structure of engine
Up to now, Jinbei Haixing series microcar uses DL465Q5, XC4F18-T, XC4F18-F, LJ465QR1E2 and other
engines according to the needs of the customer; Chongqing Xinyuan Auto Co., Ltd. uses DL465Q5 and XC4F18-F
engine, DL465Q5 and XC4F18-F received the users favor by the excellent quality, therefore, this book is mainly
by the maintenance of DL465Q5 and XC4F18-F engine.
DL465Q5 engine appearance picture
XC4F18-F engine appearance picture

I. Composition of engine
The engine is composed of two mechanisms and four systems: connecting rod, valve gear, fuel injection electronic
control system, lubrication system, cooling system, starting system.
1. Connecting rod, includes:
(1) Organism group includes: cylinder block, cylinder head, cylinder gasket, cylinder head fastening bolts, oil
bottom shell, etc.
(2) Piston connecting rod group includes: piston, piston ring, piston pin, connecting rod, connecting rod bearing,
connecting rod bolts, etc.
(3) Crankshaft flywheel includes: crankshaft, flywheel, crankshaft bearing, timing gear, etc.
2. Valve mechanism includes:
(1) Valve group includes: intake and exhaust valve, valve guide pipe, valve spring, valve race, valve lock, etc.
(2) Valve drive group includes: camshaft, timing gear, synchronous tooth drive belt, tension pulley and adjustment
device, rocker arm, rocker arm shaft, valve clearance adjustment device.
3. Fuel injection and electronic control system, includes:

(1) Fuel injection input, output device and various sensors, mainly include: engine speed and crankshaft position
sensor, intake pressure temperature sensor, joint valve position sensor, speed sensor, oxygen sensor, etc.
(2) Fuel supply and injection device, mainly include: fuel tank, fuel pump, fuel filter, pressure regulator, fuel
injector, etc.
(3) Intake device, mainly includes: air filter, joint valve body, idling speed control valve, intake manifold.
(4) Gasoline vapor collection device: active carbon filter, carbon canister control valve.
(5) Ignition device includes: 1. ignition coil, 2. spark plug, 3. phase sensor, 4. ECU.
(6) Exhaust device includes exhaust manifold, exhaust pipe, muffler, catalytic converter.
(7) The computer and its control devices include the fuel injection control, fuel injection timing control, ignition
control, idling speed control, etc.
(8) Fault self-diagnosis, storage device.
4. The lubrication system includes:
Oil bottom shell, oil pump, oil filter, oil passage, instrument, sensor, etc.
5. The cooling system includes: radiator, water pump, electric fan, thermostat, water
thermometer, sensor, heater exchanger, etc.
6. Power supply and starting system include: battery, starter, generator (belt regulator), etc.
II. Main features of the engine
The engine is the water-cooled, 4-cylinder and 4-stroke gasoline engine, and uses SOHC (single overhead
camshaft) mechanism. SOHC should be installed on the cylinder head, and it is driven by the timing belt and a
pair of timing gear crankshaft.
Section 2 Notices of engine mechanical part maintenance
I. Cleaning and protection
The auto engine is composed of many precisely machined parts, the surface accuracy of these parts is high, and
must use the spiral micrometer, cylinder bore instrument to measure.
Therefore, when maintain any part in the engine; the care and cleaning are very important.
After reading this section, the maintenance procedure of cleaning and protecting the machine surface and friction
surface are the important parts. Even there is no the special provisions, you should also develop the good work
habit.
In assembly, smear the enough engine oil on the friction surface to facilitate to protect and lubricate the internal
work surface.
When remove the valve, piston, piston ring, connecting rod, connecting rod bearing, crankshaft bearing for
maintenance, implement it according to the regulations. In assembly, install then in place according to the same
position and matching surface of disassembly.
Before maintain the engine, remove the battery cable.

If the cable is not removed, it may damage the harness or other electronic components.
According to the regulations of this manual, the part number of 4 cylinders of the engine from the front crankshaft
pulley to the flywheel is No.1, 2, 3 and 4. Such as the left picture in this page.
II. Engine maintenance overview
Please read the following knowledge related to the engine maintenance carefully. This is very important to prevent
the failures, and shall help improve the reliability of the engine.
When lift the engine, place the jack on the ground and under the oil bottom shell. As there is the small clearance
between the oil bottom shell and oil pump filter, incorrect operation method may cause the deformation of the oil
bottom shell and damage the oil sensing devices.
Notice: When the engine is working, the electrical system may be damaged by the serious short circuit.
When implement the maintenance work, be sure to remove the negative connecting wires of the battery.
At any time, after removing the air filter, air throttle, intake manifold, cover the inlet to prevent the extraneous
matter from entering accidentally, if you do not start the engine by this way, the impurities may enter the cylinder
along the intake channel to cause a wider range of failures.
When remove the cable plug connectors, you only pull the connector and do not pull the harness, for the connector
with the lock, be sure remove it after pressing the lock. If you remove it without pressing the lock, it may damage
the plug connectors. When connect the lock connector, insert it until hear the sound of click, and it indicates that
it has been connected reliably. As shown in the following right picture.
No. 1-1 cylinder

No. 2-2 cylinder
No. 3-3 cylinder
No. 4-4 cylinder
Part number principle of the cylinder
Correct connecting method of wire lock
Parts
Maintenance property
Spark plug
Replacement or inspection
Ignition coil
Replacement, inspection or adjustment
Exhaust manifold
Oil filter
Oil pressure alarm
Cylinder head cover
Replacement
Replacement
Replacement
Cylinder head
Radiator
Cooling fan
Replacement
Camshaft timing pulley
Crankshaft timing pulley
Timing belt
Fuel pump
Intake manifold
Replacement
Replacement
Generator
Start the motor
Water pump belt
Replacement, inspection or tension adjustment
Water pump
Pulley (crank, water pump)
Timing belt cover
Replacement
Replacement
Replacement
Water pipe
Oil pan and oil filter
Oil pump
III. Engine maintenance without disassembly

When repair the above parts and components (replacement, inspection or adjustment), it is not necessary to
disassemble the engine.
Engine removal
The repair to some parts of the engine needs to remove it. The
procedures for such removal are as follows:
(1) Loosen the fuel tank cap to release the fuel pressure.
(2) Remove the front seats, and then dismantle the central elements in
the engine compartment together with the gear lever and brake bar.
(3) Remove the accumulator and its base plate.
1. Radiator
2. Drain plug
(4) Let the coolant and transmission oil out.

(5) Tear the wire harness tube clamp of the engine down from the car body or the intake manifold.
(6) Remove the switch lead of the cooling fan.
(7) Remove the minus earth wire of the accumulator form the intake
manifold.
(8) Dismantle fuel cutoff solenoid wires and water temperature sensor
leads.
(9) Remove the vacuum solenoid leads and ECT sensor connector of air
conditioner (if any).
(10) Remove the wire terminals and outlet terminals of the generator.
2. A/C vacuum solenoid

4. A/C ECT sensor
3. ECT sensor
(11) Remove the air filter.

(12) Remove the inlet hose.
(13) Remove the throttle cables.
(14) Remove the oil inlet pipes and oil return pipes.
(15) Remove the heating and ventilation pipes from the inlet manifold.
(16) Remove the inlet pipe of the radiator of the fluid reservoir hose from
the inlet manifold.
(17) Remove the water inlet hose of the heating ventilator from the inlet manifold and then remove the outlet hose
of the radiator from the water inlet pipe.
(18) Remove the vacuum hose from the carbon tank.
(19) Remove the brake booster hose from the inlet manifold.
(20) Remove the switch leads of the compressor from the compressor of air conditioner (if an air conditioner is
equipped).
(21) Discharge the refrigerant from the air conditioning system,
and then remove the hose from the compressor.
(22) Lift the car body and place it at a proper height.
(23) If necessary, let the engine oil out.
(24) Remove the nut of the central pipe of the exhaust.
(25) Remove the terminals from the starting dynamo, and the
positive electrode wire from the accumulator.
(26) Remove the minus earth wire of accumulator from the
transmission.
(27) Remove the switch lead terminations from the reversing lights.
(28) Remove the speedometer cable from the transmission.
(29) Remove the high voltage cable from the ignition coil.
(30) Remove the leads from the oil pressure alarm.
(31) Remove the exhaust manifold cover and then remove the engine earth lead from exhaust manifold.
(32) Remove the clutch cable from the clutch release arm and transmission housing.
(33) Remove the drive shaft.
(34) Remove the lower cover and stays.
(35) Put the transmission special lifter under the engine with the transmission. When use the lifter, ensure that it
plane can support the whole oil pan evenly, even removing the bracket bolts of the rear suspension, the engine
with
the transmission can maintain the level support.
(36) Remove the engine suspension bracket bolts.
(37) Before drop, check again and determine whether all pipelines and links have been removed from the engine
and transmission.
(38) Remove the engine with the transmission.
(39) Remove the reinforcing plate of the transmission to make the engine and transmission separate.
(40) Remove the engine bracket, if necessary, replace the suspension cushion.
(41) Decomposition and maintenance of all parts of the engine.
Section Crankshaft connecting rod
The crankshaft connecting rod is the core and base of the engine, and is the place where convert the gasoline to
the mechanical work. Its main role is: convert the expansion pressure acting on the top of the piston in combustion
of gasoline to the external output power in rotary motion of the crankshaft (torque), and all components of the
engine shall be mounted on top directly or indirectly.
Cylinder
I. Composition
head cover
Cylinde
Piston
r head
Cylinde
r pad
Connecting rod
Cylinder
body
Flywheel
Body group
Crankshaft
II. Common faults diagnosis of crankshaft connecting rod

The crankshaft connecting rod bear great heat load and mechanical load, the wear is seriously and is higher than the
failure rate of the assembly, the common faults include:
1. Detonation
Detonation is a kind of abnormal combustion noise, and the main reasons for this failure include:
(1) The used gasoline brand is lower.
(2) The compression ratio of the engine is larger, and there are too much carbon in the burning room or there is the
hot point.
(3) Work under the large load for a long time, or the cooling system is abnormal to make the engine overheating.
(4) The spark advance angle is too small (the ignition time is too late).
It is worth noting that: for the electrostatic spray engine equipped with the detonation sensor, the sensitivity
of the detonation caused by the above reasons is lower, even avoid it.
2. Knock
The knock is a kind of abnormal sound by knocking the cylinder wall in the reversing movement of the piston, the
reasons caused this failure include:
(1) The wear of the piston skirt and the cylinder wall can cause the larger gap of the cylinder wall.
(2) Deformation of the connection rod.
(3) The piston pin is declined, and the piston direct in is reverse.
(4) The cylinder gap is larger in assembly, especially knock is more obvious in the cooling state, and there is
Dangdang sound.
3. Water and air leakage
The water leakage is that the cooling water flow from the cooling system to the cylinder, oil bottom shell and
outside of the engine, and air leakage is that the air in the cylinder leak into the crankshaft case and outside of the
engine in the compression and working process. The main reasons caused this failure include:
(1) The joint surface of the cylinder block and head is warping, and the roughness exceeds the required value.
(2) The cylinder pad is damaged or burned.
(3) The tightening sequence of the fastening bolts of the cylinder head does not comply with the requirements, or
the tightening torque value does not meet the requirements.
(4) There are other foreign body in addition to the cylinder pad on the joint surface of the cylinder body and head.
(5) The cylinder block and head have the cranks, and the joints of the cooling system pipeline are leaked.
4. Cylinder score
The cylinder score is that there is the grooves along the direction of the piston movement on the smooth cylinder
wall, and the main reasons include:
(1) The air filter is useless, so that make the mixed air, dust and impurities entering the cylinder exceed the
standard.
(2) The impurities in the lubricant exceed the standard.
(3) The piston ring is broken, or the carbon in the cylinder is too much.
(4) The various reasons cause that the piston skirt is expanded excessively to cause the cylinder locking
phenomenon.
5. Excessive oil consumption (generally, after driving 100 km, the pump oil should not exceed 10% of
consumption)
The oil consumption exceeds the normal value too much, and the reasons cause this phenomenon include:
(1) The gap between the piston and cylinder wall is too large, and more lubricant entering the combustion chamber:
(2) The piston ring lost its elasticity or is stuck in the ring slot, the direction of the distorted ring (non-rectangular
cross-section gas ring) is reverse to make more lubricant enter the combustion chamber.
(3) The oil is deteriorated, or the viscosity is too thin.
(4) The mouth of the gas ring and oil ring are matching.
6. Main bearing, connecting rod bearing (commonly known as big and small shell) abnormal sound. The
main reasons include:
(1) Gap between the bearing and journal is too large.
(2) The tightening force of the fastening bolts of the bearing is not enough, or the crankshaft diameter is worn.
(3) The bearing damage due to poor lubrication.
(4) The thrust tile is damaged and exceeds the standard.
III. Maintenance of the crankshaft connection rod

1. Cylinder head
Remove all carbon in the combustion chamber.
Notice:
Do not use any tool with the sharpening edge scrape the carbon deposit, when scrap the carbon deposit,
please do not scratch the metal surface. The valve and valve seat are the same.
Check whether the intake and exhaust port of the cylinder head, combustion chamber
and cylinder head surface have the cracks or not.
Check the flatness of the cylinder block connection surface:
Item
Standard
Limiting value
Flatness
0.03mm
0.05mm
Use the straightedge and thickness gauge to check the flatness of 6 parts, if exceed the
following given limiting value, use the flat plate and about 400# sandpaper to grind the
sealing surface. Put the sandpaper on the flat plate, grind the flat, and grind the convex parts, if this fails to meet
the requirements, please replace the cylinder head. (water grinding diamond sandpaper)
Due to the deformation of the sealing surface, the air in the combustion chamber is often leaked from this sealing
surface. This leakage shall cause that the output power is decreased.
Flatness limiting value: 0.05mm
The flatness of the combining surface of the intake (exhaust) manifold:
Use the straightedge and thickness gauge to check the combining surface of the cylinder intake (exhaust) manifold
to determine whether these surfaces must be grinding, or the must replace the cylinder head or not.
Inspection of cylinder flatness
Flatness limiting value: 0.10mm.
2. Cylinder
Check the cylinder wall scratches, roughness or convex parts with excessive wear, if the cylinder wall has the
roughness, scratches or convex parts, bore the cylinder again and use the oversize piston.
Use the inside micrometer to measure the diameter of two locations of the cylinder as shown in the picture, if
there are the following phenomenon, bore the cylinder again.
The cylinder diameter exceeds the limiting value.
The measurement of two positions exceed the roundness limiting value.
The differences of the measurement of two positions as shown in the picture exceed the roundness limiting value
(conical degree).
Cylinder wear limiting value: 0.05mm
Conical degree and loss of roundness limiting value: 0.10mm
Size (specification)
Standard
Oversize 0.25mm
Oversize 0.50mm
Piston diameter
65.45065.475mm465
73.9773.99mm474
65.70065.725mm465
74.0074.01mm474
65.95065.975mm465
74.0174.02mm474
Notice: in four cylinder holes, if need to increase the size of any hole, increase the size for 4 cylinder holes at
the same time, and the size of 4 holes should be consistent.
Cylinder boring
1When any cylinder is needed to bore again, all other cylinders must be boring at the same time.
2Select the corresponding piston of increasing the size according to the cylinder wear volume.
3) Use the micrometer to measure the piston diameter of the position
as shown in the picture. As shown in the right picture.
4) Calculate the cylinder diameter by boring again.
DA+BC
DRe-boring cylinder diameter.
AMeasured piston diameter.
BGap between the piston and cylinder wall.
CHoning margin0.02mm
5) Re-boring and honing cylinder to calculate the size.
Notice: Before re-boring cylinder, install all main bearing heads in place, and tighten it by the
regulated torque to avoid the deformation of the bearing hole.
6) After honing, measure the piston clearance.
Use the straightedge and thickness gauge to check the deformation conditions of the top surface, if the
flatness exceeds the regulated value, correct it.
3. Piston, piston pin, piston ring and connecting rod
Piston
Check whether the piston has the abnormal wear and cracks, if have, replace it.
As shown in right picture, must measure the piston diameter in the vertical direction with the piston pin
hole at the position 15mm away from the piston skirt.
Piston clearance:
Piston clearance
0.020.04mm
In order to determine the piston clearance, must measure the cylinder diameter and piston diameter. The
piston clearance the difference between the cylinder diameter and piston diameter, and it must be in the
following given regulated scope.
If exceed the regulated scope, must implement re -boring cylinder and use the piston of increasing the
size.
Notice: Calculate the piston clearance by the cylinder diameter measured at the stop position (2).
Piston ring slot clearance:
before inspection, be sure to clean and dry the piston ring slot, and remove the carbon deposits. Install the new
piston ring into the piston ring slot, and use the thickness gauge to measure the clearance between the piston ring
and piston ring slot. If the clearance exceeds the regulations, replace the piston.
Piston ring slot

clearance
One ring
0.030.07mm
Two rings
0.020.06mm
1. Piston ring
2. Thickness gauge
Piston pin
Smear the oil on the piston pin, push it by the finger at the room temperature, the
piston pin should be installed in the piston pin hole easily.
Check the piston pin, the wear and damage conditions of the connecting rod
small end pin hole and piston pin hole, pay special attention to the small end hole
bushing, if the piston pin, connecting small end pin hole, piston pin hole are worn
or damaged seriously, please replace the piston pin, connection rod or piston.
Piston pin clearance:
Check the piston clearance in the small end. If the small end is worn or damaged
seriously, if the clearance exceeds the limiting value, please replace the
connection rod.
Piston pin clearance in small end:
Standard: 0.0030.016mm
Limiting value: 0.05mm
Small end pin hole: 16.00316.011mm
1. Cylinder block
2. Side feeler gauge
4. Piston ring
3. Piston ring
4. 120mm
As shown in the right picture, measure the open clearance, insert the piston ring into the cylinder hole firstly, and
then use the thickness gauge to measure the clearance. If the measured open clearance does not meet the
specification, replace the piston
Item
Standard
Limiting value
ring.
Piston pin diameter: 15.99516.000mm
One
ring
Piston ring
Two
open
rings
clearance
Oil
ring
0.150.30mm
0.6mm
0.150.30mm
0.6mm
0.200.70mm
1.8mm
Notice: Before put it in the plug ring, remove the deposited carbon, and then
Clean the cylinder top.
item
Connecting
rod big end
side
clearance
Standard
0.100.20mm
Limiting value
0.30mm
Parallelism
bending
limiting value
0.05mm
Parallelism distorting
limiting value
0.10mm
Connecting rod
Big end side clearance:
After installing the connecting rod according to the correct assembly process, check the connecting rod big end side
clearance, if the side clearance exceeds the regulated limiting value, replace the connecting rod.
Parallelism of small and big ends of the connecting rod.
Use the straightening devise to check the parallelism of the small and big axis, if it exceeds the regulated limiting
value, replace it.
5. Crankshaft connecting rod journal and connecting rod shell
Check the uneven wear or damage conditions of the connecting rod journal.
Use the micrometer to check the crankshaft connecting rod journal diameter, if the crankshaft connecting rod
journal is damaged or the roughness exceeds the limiting value, replace the crankshaft or refer to Step 6 connecting
bearing clearance lapping journal.
Connecting rod shell:
Check whether the connecting rod has the pits, ablation or surface spelling conditions, and observe the contacting
graphics, if it is found that the shaft shell quality is unqualified, replace it. Equip with two connecting rod shaft
shells:
Bearing shell with the standard size and bearing shell reducing 0.25mm. In order to distinguish
Their sizes, print 0.25 on the back of the bearing shell, but the bearing shell with the standard
Size has no the part number.
1.
Connecting rod bearing head
Connecting rod bearing shell clearance:
2.
Arrow mark
1) Before check the clearance, clean the bearing shell and connecting rod journal.
3.
Crankshaft pulley side
4.
Connecting rod head nut
2) Install the bearing shell on the connecting rod big end and connecting rod cover correctly.
3Put a plastic gauge with the same width with the crankshaft connecting rod journal on the connecting rod journal
in parallel, and pay attention to avoid the oil hole.
4) Install the connecting rod to the connecting rod.
When install the connecting rod head, make the arrow mark on the connecting rod cap point to one side of the
crankshaft pulley according to the instruction of the picture, after smearing the oil for the connecting bolts, tighten
the connecting rod nuts to the regulated torque. After placing the plastic gauge, pay attention to that do not rotate
the crankshaft.
Tightening torque
(a)2832Nm
5) Remove the connecting rod, and then use the straightedge to measure the width of the plastic gauge at the widest
point on the plastic gauge cover and read the corresponding clearance value, if the clearance exceeds the limiting
vale, use the new bearing shell with the standard size, and then measure the clearance.
Item
Standard
Limiting value
Bearing clearance
0.0200.040mm
0.080mm
6) If use the new bearing shell with the standard size, the clearance still not reaches the limiting value, grind the
crankshaft connecting rod journal by the following procedures.
Install the bearing shell with the size of 0.25mm to the connection
big end.
Measure the hole diameter of the connecting rod big end (install the
bearing shell with the reduced size)
The lapping journal make it to the following dimensions.
Finishing connecting rod journal diameter = connecting rod big end
hole diameter (include the bearing shell with the reduced size)
0.048mm
Confirm whether the bearing shell clearance is within the above standard value or not.
6. Crankshaft
Crankshaft straightness
Use the micrometer to measure the offset of the central journal. Rotate the crankshaft slowly, if the straightness
exceeds the limiting value, replace the crankshaft.
Straightness limiting value
0.06mm
Crankshaft thrust clearance

After assembling the main bearing shell and main bearing head as well as
the thrust plate, tighten it by the regulated torque, and then use the axis
direction to push the crankshaft to measure the crankshaft thrust clearance.
Item
Standard
Limiting value
Crankshaft
0.130.28mm
0.35mm
thrust
clearance.
Tightening torque
(a)4348Nm
Use the dialgauge to read the crankshaft axial displacement.
If it exceeds the limiting value, replace the new thrust plate with the standard size or oversize to reach the thrust
1. Thrust plate
clearance requirements.
7.
Cylindricity
of
main
journal
requirements
The difference of the diameter of different points at the same profile location in the diameter and length direction
measured by the micrometer can reflect the uneven wear of the crankshaft, if any journal is damaged seriously or
the uneven wear exceed the cylindricity limiting value, grind the journal or replace the crankshaft.
Roundness limiting value of crankshaft and conical degree: 0.01mm
1. Upper bearing
2. Oil slot
8. Main bearing shell

General description
1. One side of crankshaft pulley

The bearing shell with the standard size and reducing 0.25mm are available
from
theofstock,
each kind of them has 5
2. One
side
the flywheel
kinds of tolerance series for available.
The upper bearing shell has the oil slot as shown in the picture. It shall be installed
on the cylinder block.
According to the instruction of the picture, when install the bearing shell head, print
the arrow and number on each main bearing shell, make the arrow mark point to
one side of the crankshaft pulley, and then install each bearing
sequence of 1,2,3,4,5 and tighten the bearing shell head to the
Tightening torque
(a)4348Nm
shell by the
regulated torque.
Inspection
Check whether the bearing shell has the rust spots, scratches, wear or damages or not.
If there are abnormal conditions, replace the upper and lower bearing shell, and do not replace half of the bearing
shell.
Thickness
crankshaft
plate
Standard
2.500mm
Increase the size

of
thrust 0.125mm
2.563mm
Increase the size

2.625mm
0.250mm
Main bearing shell clearance

Use the plastic gauge to check the clearance according to the following procedures.
1) Remove the bearing shell head.
2) Clean the bearing shell and main journal.
1. Straightening plastic strip

3) Place a plastic gauge (parallel to the crankshaft) with the width same with the2.bearing
Ruler shell on the journal, and
avoid the oil hole.
4) Install the main bearing head according to the above method and tighten the bearing head bolts by the
regulations, and the bearing head must be tightened to the regulated torque to ensure the reading is correct.
Notice: Before install the plastic strip, do not allow to rotate the crankshaft.
5) Remove the bearing head, and measure the thickness of the straightening plastic strip at the w idest
point by the scale on the straightening plastic strip. If the clearance exceeds its limiting value, replace
the bearing. When replace the bearing, replace the upper and lower bearing shell together.
The new standard bearing can generate the correct gap. If it cant, must grind the crankshaft journal to
facilitate to use the bearing with small size of
0.25mm. After selection of new bearing, check
Standard
Limiting value
Bearing
the clearance again.
clearance
0.0200.040mm
0.06mm
Selection of main bearing shell
Standard bearing shell:
If the main bearing shell is in the abnormal state, or the clearance of the main bearing shell does not meet the
regulations, select the new standard bearing shell for installation according to the following procedures.
1) Firstly, check the diameter of the journal by the following methods. As shown in the picture, No.1
cylinder crankshaft arm has 5 printing numbers.
2Three number (1, 2 and 3) represent the diameter of the following journal.
Printed number
Journal diameter
No. 1 cylinder crank arm
37.98238.000mm
37.73237.750mm
37.48237.500mm
The first, second, third, fourth and fifth (from left to right) numbers
represent the journal diameter on the bearing head of No.1, 2,
3, 4 and 5.
Such as 465 engine in the above right picture, the first (left-most)
number 3 represents that the journal diameter of No. 1 bearing
head is 37.482-37.500mm, and the second number 1 represents
that the journal diameter on No. 2 bearing head is
37.98238.000mm.
2) And then, before install the main bearing shell, check the diameter
of the bearing head boring hole. On the cylinder block assembly surface, the positions of 4 printed letters are shown
in the picture.
Three letters (A, B and C) represent the diameter of the following bearing head boring holes.
Printed letter
Bearing head boring hole diameter

(without bearing shell)
49.00049.006mm474
49.00649.012mm474
49.01249.18mm474
The first, second, third, fourth and fifth (from left to right) numbers represent the boring hole diameter of No.1,
2, 3, 4 and 5 separately.
such as 474 engine, the first letter (left-most) B represents that the bearing head boring hole diameter of No. 1
is 49.00649.012mm, and the fifth letter (right-most) A represents that the bearing head boring hole diameter
of No. 5 is 49.00049.006mm.
3) There are 5 kinds standard main bearing shell with different thickness. In order to facilitate to distinguish them,
paint the following colors according to the positions in the picture.
Colored point
The colors marked on the bearing hell center indicate the following thickness respectively.
Color
Thickness of bearing shell
Green
1.9861.990mm
Black
1.9891.993mm
None (no color)
1.9921.996mm
Yellow
1.9951.999mm
Blue
1.9982.002mm
4) According to the numbers printed on No. 2 and No.3 cylinder crank arms and the printed letters on the assembly
surface of cylinder block, refer to the following table to make sure that new standard bearing shells are fitted to
journals.
Numbers printed on crank arms
(journal diameter)
Letters printed on
assembly surface
(bearing cap bore
diameter)
Green
Black
None
Black
None
Yellow
None
Yellow
1.Journal
diameter
(number)
2.Bearing
cap
bore
diameter(letter)
Blue
New standard bearing shells that

shall be assembled.
For example, provided that the printed
number on the crank arm is 1, and the printed letter on the assembly surface is B, the new standard bearing
shell painted as Black shall be assembled to the journal.
5) Use aligning plastic strip to inspect the clearance of the newly-selected
standard bearing shell. If the clearance is still larger than its limit, use a
thicker bearing shell and re-inspect the clearance.
6) When a crankshaft or a cylinder block is changed for whatever reasons,
new standard bearing shell shall be the first choice. The method of
choosing it is to refer to the printed number on the new crankshaft or the
printed letter on the assembly surface of the new cylinder block.
Small bearing shell (0.25mm)
Small 0.25mm bearing shells fall into 5 types in terms of thickness.
Painting point
To make distinguishment convenient, all types of bearing shell shall be
painted with the following colors on the positions as shown in the figure. The colors at the bearing shell center
denote the following thickness respectively.
Color
Bearing thickness
Green/red
2.1212.125mm
Black/red
2.1242.128mm
Red only
2.1272.131mm
Yellow/red
2.1302.134mm
Blue/red
2.1342.137mm
If necessary, crank journals shall be grinded, and small bearing shells are chosen by the following method.
1) Grind journals to the following finish sizes.
Finish size
44.732~44.750mm
2) Use a micrometer to measure the diameter of grinded journals. The measurement shall be along two directions
which are perpendicular to each other so as to check whether they are out of circularity.
3) Make use of the journal diameters measured as above and printed letters on the assembly surface of the cylinder
block; refer to the following table to choose small bearing shells.
Measured journal diameter
Printed letters
on the assembly
surface of cylinder
block
44.774~44.750mm
44.738~44.744mm
44.732~44.738mm
Green/red
Black/red
Red only
Black/red
Red only
Yellow/red
Red only
Yellow/red
Blue/red
Small bearing shells shall be assembled.

The clearance of newly-selected small bearing shells shall be checked.
9 Rear oil seal
1. Rear oil seal
A check shall be carefully given to oil seals to make sure whether they are worn or damaged.
If oil seal lips are worn or damaged, the oil seals shall be changed.
10Flywheel
If gear rings have damage such as cracks and wear, the flywheels shall be changed.
If the surface of driven discs in touch with clutches is damaged or badly worn, corresponding parts shall be
changed.
Use a micrometer to check the flywheel end run-out.
Flywheels tightening torque40~50
If its end run-out exceeds the limit, the flywheel shall be changed.
Nm (465)
7
6~80 Nm (474)
Limit of flywheels end run-out: 0.2mm
Radial
clearance
between outer rotor
and oil pump housing
Standard
Limit of radial
clearance
0.045~0.120mm
0.300mm
Standard
Limit
0.045~0.120mm
0.17mm
Lateral clearance
11Oil pump
Check whether oil seal lips have faults or other damage. They shall be
changed if necessary.
Check whether inner and outer rotors, rotor plates and oil pump housing
are badly worn, out of clearance or damaged.
Radial clearance
Use a feeler to inspect the radial clearance between outer rotors and oil
pump housings.
If the clearance exceeds its limit, the outer rotor or oil pump assembly shall be changed.
Lateral clearance
Use a ruler or feeler to inspect lateral clearances.
Section Valve Train

The valve train is, according to requirements of engine working order and cylinders working cycles, to close and
open intake and exhaust valves punctually to supply adequate combustible mixture, and exhaust waste gases in the
combustion chamber at the same time to ensure the engine of continuous run.
. Composition of valve train

Camshaft
Valve mechanisms of DL465Q5 and XC4F18-Fi EFI (electronic fuel

injection) engines are overhead type, with camshaft directly arranged
on cylinder heads, as shown in the right figure.
The advantage of arranging camshafts on cylinder heads is to
dispense with such parts as push rod and tappet, which greatly
reduces the mass of reciprocating motion in valve mechanisms and
thus picks up the engine speed. However, as the camshaft is far away
from the crankshaft center, it is inconvenient to adopt gear drive.
Accordingly, most of them employ synchronous belt transmission.
The cam on the camshaft directly drives rocker arms to control the
switches of intake and exhaust valves.
Valve
assembly
Rocker arm shaft
Rocker arm assembly
Valves of valve trains include valves, valve-seat rings, valve guides,

valve springs and cotter;
The valve drive assembly consists of camshafts, timing gears,
cog belts, tension pulleys, and valve rocker arm shaft and valve rocker arm.
Figure 2-10 Cam valve train
() Valve assembly
Each cylinder of an engine has two valves which are arranged in V shape, and the angle between the intake valve
and the centerline is 330.
1. Valve
An engine has an intake valve and an exhaust valve in each cylinder.
As exhaust valves undergo more serious high-temperature gas impact than intake valves, the material of exhaust
valves is more resistant against high temperature than intake valves, and the head of the former is larger than the
latter in terms of strength and rigidity. To improve intake efficiency, the diameter of intake valve heads is larger
than exhaust valves, while their working face cone angle is smaller than exhaust valves (generally 30 0 for intake
valves and 450 for exhaust valves). Working faces shall undergo finish machining before grinding so as to ensure
good tightness.
2. Valve guide
Valve guides are made of nodular cast iron with finish machining and then pressed in the valve guide holes in the
cylinder heads. Valve guides are mainly to guide the direction. Guide holes exactly fit valve stems to make valve
head cones concentric with valve seat cones, ensuring that the valves correctly adhere to the seal when closed.
Meanwhile, the heat through the valves can be guided to cylinder heads by them. As the requirement of working
accuracy is high, and the wear is severe, valve guides fall into two categories: standard dimension and service
dimension.
3. Valve seat ring
The valve seat ring is to prolong the useful lift of valves and cylinder heads, and ensure valves sealing accuracy
and cut maintenance cost. In fact, it is a wear resistant cast iron ring set in the cylinder head. To ensure it working
reliably and avoid catastrophic failure caused by its falling into the cylinder, it must be set firmly. Valve seat rings
also are divided into standard dimension and maintenance dimension.
4. Valve spring
The valve spring is between the cylinder head and the valve spring seat at the valve stem end. It is to close valves
firmly without air leakage; avoid clearances caused by inertia forces produced among the driving parts; ensure
valves to regularly close and open in accordance with cam contour curve, prevent air leakage resulting from untight
closing of valves which jump when the engine vibrates.
Valve springs are made of quality alloy spring steel wire which is coiled to be spiral shape. To ensure its elastic
force not reduce under high speed alternating shock loads and improve its fatigue strength, the spring steel wire
shall undergo grinding, polishing and shot blasting, as well as bluing or phosphating to meet operational
requirements.
5Cotter
The working cone of valve heads tightly fit the valve seat ring cone. The stem is fixed on the cylinder head under
the action of valve spring force applied by the valve taper cotter on the spring seat. Thus closing and sealing valves
depends on valve springs, and opening intake and exhaust depends on the drive of the cam on the camshaft.
() Valve drive assembly
The valve drive assembly of the engine is composed of such main components as camshafts, camshaft timing gears,
synchronous belt, rocker arm shaft, rocker arms.
The function of valve drive assembly is to utilize crankshaft power to punctually open and close intake and exhaust
valves as required by cylinders working order and valve timing, and minimize noises and wear.
1. Crankshaft
The camshaft is one of the important parts of engines valve train. The camshaft, of full supporting type, is fixed on
the cylinder head with 5 journals supporting it. To make the installation convenient, the dimension of these journals
increases successively from the flywheel end to the timing gear.
The camshaft has 8 (XC4F18-F is 16) cams in total, of which each is responsible for opening and closing 8
(XC4F18-F is 16) valves. The cam contour curve is designed in accordance with the requirements of valve timing.
The spatial location of the 8 (XC4F18-F is 16) cams is determined by both the working order and valve timing.
To ensure normal work of the camshaft, the camshaft journals shall have adequate pressure lubrication and shall be
furnished with plain bearings that make service convenient.
2. Timing gear
A timing gear is fitted into the crankshaft and camshaft respectively. In a working cycle of an engine, the crankshaft
makes two turns, and the camshaft made one, so the number of teeth of the camshaft timing gear is as many again
as the crankshaft timing gear.
As the opening and closing time of intake and exhaust valves is exactly fit into the crankshaft position, it is quite
crucial to ensure the two timing gears of proper installation.
3. Synchronous belt
As the camshaft is fixed on the cylinder head, the center distance of these two timing gears is increased. If
traditional gears are still employed to drive, it will be structurally unreasonable. Thus synchronous belts are
employed, which is both accurate and noiseless. Special-purpose synchronous belts are dedicated oil-resistance
internal tooth flexible belt.
4. Rocker arm, rocker arm shaft
Taking the rocker arm shaft as pivot, the rocker arm has its one end directly touch the cam on the camshaft, and the
other end touch the valve stem top though a valve clearance adjusting bolt (there is a certain clearance when the
valve is closed).
The rocker arm shaft, a type of long axis part which has an oil passage at the middle, is fixed on the cylinder head
with cylinder head bolts by 5 rocker arm seats. The rocker arm shaft has 8 rocker arm assemblies in total, of which
each drives one valve.
() Valve timing
The indication of switching time of intake and exhaust valves by the turn angle of crankshaft position is called
valve timing. To make full use of gas flow inertia to improve gas filling and thorough exhaust, engines open intake
valves before top dead canter and close them after bottom dead center, and open exhaust valve before bottom dead
center and open them after top dead center. The angle size of lag closing and engine speed, the arrangement of
intake and exhaust valves and other structural parameters, all have relations.
. Common fault diagnosis of cam valve train

1. Valve knock
The valve knock is practically the metal impact sound produced between the valve stem top and the valve clearance
adjusting bolt bottom. Normally, there is also such sound, but it is low, only ticktacks. It will be obvious in cold
starting, and will get lower when reaching the normal working temperature. However, when the ticktack becomes
bang, it will be noise pollution, which is a fault. The major causes for such loud noise are as follows:
(1) The valve clearance is large.
(2) The cam of camshaft is so badly worn that the valve clearance becomes large finally.
(3) Valve stems and valve guides are badly worn, exceeding the allowable value.
(4) The valve clearance adjusting screws become flexible.
2. Inaccurate valve timing
If the engines dynamic property and economic efficiency reduce in normal working conditions, it may be caused
by inaccurate valve timing. For example, a Dongfeng Xiaokang that runs normally in coastal and plain areas at
lower altitudes may encounter such phenomenon when it runs plateau areas, because the valve timing in lower
altitudes is substantially different from that in plateau areas. A comprehensive study shows that if the advance angle
and lag angle of intakes differ by 10 from the standard value in valve timing, the power drops 4% and oil
consumption rises 5%; and if they differ by 20, the power drops 8% and the oil consumption rises 12%. Apart from
the altitude, there may be the following causes that lead to changes in valve timing:
(1) The valve clearance is too large.
(2) The cam tip of camshaft is so badly worn that the cam lift reduces.
(3) The timing belt is worn.
(4) The tensile force of timing belt is inadequate, and too slack.
3. Valve spring knock
It is an omen of serious accidents. It shall be eliminated immediately after discovered, or valve springs will be
broken, and valves will fall into the cylinder. They then will accordingly scratch the cylinder, bend connecting rods
and crankshafts. The chief causes for such fault are as follows:
(1) The rigidity of valve springs is small.
(2) The valve springs are broken.
4. Valve leakage
It is caused by bad seal of valve working cones and valve seats. The chief causes are as follows:
(1) The valve and working cone of valve seat rings are badly worn.
(2) Valve stems and valve guides are badly worn so that the clearance is too large.
(3) There is carbon or impurities accumulated on the valve working cone.
. Maintenance of cam valve train

1. Valve adjusting screw
2. Lock nut
3. Rocker arm
Screwdriver
1. Cylinder head 2. Intake manifold
A. Transmission side
1. Valve cotter
1. Valve stem oil seal

2. Screwdriver
3. Valve spring seat
1. Removal of mechanisms
1) Remove the distributor assembly and its bracket (if any).
2) Remove the exhaust manifold cover, exhaust manifold and its seal gasket.
3) Strip the intake manifold bolt, nut and reinforced plate bolt, and remove the intake manifold.
4) Remove the cylinder head cover as shown in figure 1.

5) Undo all valve adjusting screws and then rotate them reversely to close all valves, as shown in figure 2.
6) Remove the cylinder head bolt.
7) Tear down other connecting parts, hoses and wires, if any.
8) Remove the cylinder head.
9) Remove rocker arm shaft screws as shown in figure 3.
10) Remove the rocker arm shafts of intake and exhaust valves, and then strip
rocker arms and rocker arm springs, as shown in figure 4.
11) Strip the camshaft off the cylinder head, as shown in figure 5.
12) Use special tools (valve lifter) to compress valve springs and then use dedicated tools (forceps) to remove valve
taper cotter, as shown in figure 6.
Special tools:
(A): 0991614510
(B): 0991648210
Dedicated tool:
(C): 0991684510
13) Undo the valve lifter to remove the valve spring seat and valve
spring, as shown in figure 8.
14) Remove the valve from the combustion chamber side.
15) Remove the valve oil seal and valve spring pedestal.
Notice:
The oil seal shall, once removed, not be used again. New oil seals must be used for re-assembly.
16) Use dedicated tools (valve guide puller) to remove valve guides, as shown in figure 9.
Notice:
The valve guides shall, once removed, not be used again. New valve
guides (oversize) must be used for re-assembly.
Special tool:
(a): 09913-48010
2. Rocker arm, rocker arm shaft and camshaft
Adjusting screw and rocker arm
If the adjusting screw is worn, replace it.
If the arc surface is worn, the rocker arm must be changed.
Straightness limit
0.02mm
Rocker arm shaft straightness

Use a V-shaped block and dial indicator to inspect the straightness.
If the straightness is beyond the limit, the rocker arm shaft shall be changed.
Rocker arm-rocker arm shaft clearance
Use a micrometer and inside dial indicator to measure rocker arm shaft diameter and rocker arm bore diameter.
The difference value of two readings is rocker arm-shaft clearance, which must be within the specified range.
If the clearance is beyond the limit, please change the shaft or the arm or both.
Item
Standard
Inside
diameter
of
rocker
arm
shaft bore
Limit
14.98515.005mm465
15.98516.005mm474
Rocker
arm
shaft diameter
14.96514.980mm465
Arm-shaft
clearance
0.0050.040mm465
0.07mm465
0.0010.036mm474
0.09mm474
15.96915.984mm474
Wear cam
Use a micrometer to measure the cam height; if the height to be measured is lower than the specified limit, please
change the camshaft.
Cam
height
Intake cam
Exhaust
cam
Standard
Limit
36.152mm465
36.100mm465
36.14836.344mm474
36.084mm474
36.152mm465
36.100mm465
35.90036.060mm474
35.800mm474
Camshaft straightness
0.10mm465
Straightness limit
0.12mm474
Keep the camshaft at between two V blocks, and then use a dial indicator to
measure the straightness.
If the measured straightness exceeds the limit, change the camshaft.

Camshaft journal wear
Measure the diameter of the journals at the four positions to gain four readings, and then use an inside dial
indicator to measure the camshaft hole inside diameter of the cylinder head to gain four readings.
The camshaft hole inside diameter of the cylinder head Seven minus camshaft journal diameter is journal clearance.
If the journal clearance exceeds the limit, the camshaft shall be changed, and so shall the cylinder head if necessary.
Item
Journal
clearance
Camshaft
diameter
Standard
Limit
0.0500.091mm
journal
Camshaft
diameter
0.15mm
hole
a43.42543.450mm
43.50043.516mm
b43.62543.650mm
43.70043.716mm
c43.82543.850mm
43.90043.916mm
d44.02544.050mm
44.10044.116mm
e44.22544.250mm
44.30044.316mm
inside
3. Valve guide, valve and valve spring

Valve guide
Use a micrometer and inside dial indicator to inspect valve stems and guide clearances and read the readings of
valve stem diameter and guide inside diameter. Be sure that there is more than one measuring points. If the
clearance exceeds the limit, change the valve and valve guide.
Item
Standard
Intake
Valve
stem
diameter
Exhaust
Intake
Valve
guide
inside diameter
Exhaust
Intake
Stem-guide
clearance
Exhaust
Limit
6.9656.980mm465
5.4655.480mm474
6.9506.970mm465
5.4405.455mm474
7.0007.015mm465
5.5005.512mm474
7.0007.015mm465
5.5005.512mm474
0.0200.050mm465
0.0200.047mm474
0.0200.050mm465
0.0450.072mm474
1. Valve seat
0.07mm
contact
width
0.09mm
If there is no inside dial indicator, a dial indicator with a stand may be used to inspect the deviation of valve tips.
Shake the valve tip in A and B directions to measure the end offset. If the end offset exceeds the limit, change the
valve stem and valve guide.
Valve
Eliminate all carbon deposits from the valves.
Inspect the wear and ablation or deformation of each valve. If necessary, change them.
1. Valve seat thickness
Measure the thickness of valve tips; if the thickness fails to reach the specified limit, the valve must
be changed.
2. 45
Intake
0.12mm
Valve stem end offset limit

Exhaust
0.16mm
Inspect the end wear of each valve tip. The end contacts the rocker arm intermittently in running, and will become
concave or irregular shape. If necessary, use an oil stone to grind it to be smooth. If it is not smooth until grinding
to the chamfer, the valve shall be changed.
Contact zone width of the cone and valve seat:
Common grinding methods are employed to produce a contact pattern, that is, spread a layer of compound (red lead
for instance) over the valve cone and then turn it. The valve must be grinded with a valve grinding machine. The
pattern generated on the valve cone after grinded must be a continuous ribbon, whose width must be within the
specified range.
Ribbon
width
Intake
1.31.5mm465
1.11.3mm474
Exhaust
Valve tip thickness

Standard
Limit
Intake
0.6mm
Exhaust
0.7mm
1. Valve seat tool
0.8~1.2mm
Repair of valve seat:

If the contact between the valve seat and the valve is uneven, or the valve seat contact width exceeds the specified
range, it must be grinded again or must be cut for finish grinding and lapping.
1) Exhaust valve seat: use a valve seat reamer to make three cuttings as shown in the right figure. The first make a
150 cutting, the second a 600 cutting and the third a 450 cutting. The third cutting must produce a cone contact width
satisfactory to requirements.
2) Intake valve seat: the cutting order is the same as the exhaust valve seat.
3Valve grinding: Grinding valves falls into two steps: first, use coarse abrasive to grind the valve surface; second,
use fine abrasive. The grinding takes conventional means, but must use valve grinding machines every time.
Item
Free length of
valve spring
Valve spring
preload
Standard
Limit
48.9mm465
47.6mm465
36.83mm474
35.67mm474
At 23.6~27.6kg, the length is 40mm (465)
At 22.0kg, the length is 40 mm (465)
At 10.7~12.5kg, the length is 31.5mm (474)
At 9.3kg, the length is 31.5mm (474)
Valve spring
Refer to the given data below and inspect the springs to make sure that every spring is in good condition and has no
signs of damage or elasticity weakening; the valve springs whose elasticity
weakens may cause vibration, but it will not cause drops in output power due
to mixture leakage resulting from reduction in valve spring elasticity.
Exhaust valve seat

width
1.31.5mm4651.11.3mm474
Intake valve seat

width
1.31.5mm4651.11.3mm474
Spring verticality:
Use a square and plate to inspect the verticality of every spring, namely, measure the gap
between the valve spring end face and the square. If the valve spring verticality exceeds
the limit, it must be change.
Valve spring verticality limit
2.0mm
Section Lubricating System

The engine adopts a lubricating system which combines forced lubrication and splash lubrication. The oil pump, of
rotor type, is fixed to a crankshaft, adjacent to the crankshaft
pulley. The oil is pumped out by an oil strainer and delivered to
the oil filter by the oil pump.
The filtered oil flows into the two oil lines in the crankcase. In
one oil line, the oil will reach the crankshafts main bearing shell.
The oil from the crankshafts main bearing shell flows through the
oil lines that run through to each other to the connecting rods
bearing shell. The connecting rod big end has a small hole in it,
through which the oil sprays out to lubricate pistons, piston rings
and cylinder walls. In the other oil line, the oil runs through the oil
lines in the rocker arm shaft to the cylinder head to lubricate the rocker arm, valves and camshafts. On the oil pump
is fixed a relieve valve, which will release the pressure when the oil pressure exceeds about 400kPa. The
overflowed oil returns to the oil pan.
The functions of lubricating systems are summarized as follows:
Anti-attrition: they deliver the lubricating oil to the parts surface in relative motion, reducing friction loss and
wear.
Cleaning: the lubricating oil, at a pressure, circulates on friction surfaces to clean away abrasive dust.
Cooling: the lubricating oil circulates continuously, taking away friction surface heat and having a cooling effect.
Sealing: the lubricating film takes up partial fit clearances, thus enhancing the tightness.
Anti- corrosion: the lubricating film can separate the parts from the oxygen and corrosive substances in the air,
preventing corrosion.
Vibration reduction: the oil film between friction surfaces can absorb vibration and alleviate impacts, so as to play a
role in vibration reduction.
. Composition of engines lubricating system

1. Major component
The lubricating system of an engine is mainly composed of oil pan, oil strainer, oil pump, oil filter, oil pressure
sensor, instrument and pipeline.
Camshaft central
Piston and cylinder wall
journal, #3
2. Lubricating oil flow chart
Connecting rod small end
Rocker arm shaft
The lubricating oil is drawn by a strainer into the oil pump, from which
the oil pressure is specified
as 400kPa by a
Connecting rod big end
Rocker arm
pressure limiting valve. The pressure oil from the oil pump then flows into the oil filter to clear away dust,
Camshaft journal, #5
Crankshaft
main journal
impurities and colloids, and finally to the friction surfaces through several
lines.
Camshaft journal,
#1,2,4
Distributor gear case
Cylinder saddle
block oil hole
(1) One line leads to the main oil passage of, and then to the main bearing
of the cylinder block to provide
Camshaft
lubrication in the main journal bearing. The main journals of crankshaft
2 and 4Bypass
havevalveoil passaged to everycenter
oil hole
Oil filter
connecting rod journal for lubrication of connecting rod journals. The spare lubricating oil is thrown
away and
Cylinder wall
Oil pump
Safety valve
splashed from the clearance with the connecting rods run to cylinder walls, piston pin boss holes to make
Oil filter screen
lubrication. Finally, the superfluous lubricating oil returns to the oil pan by gravity.
Oil pan
(2) Another line leads to the rocker arm shaft to make lubrication for rocker arms and camshaft journals. The spare
oil flows out from the clearance and then returns to the oil pan through oil passages by gravity. The oil passage
diagram is as shown in the right figure.
3. Major components of lubricating system
(1) Oil strainer: the oil strainer is fixed on the oil pump to preliminarily filter large impurities in the oil. A 150~200
mesh screen is furnished at the inlet. The oil strainer shall keep contacting the liquid level all the time so as not to
interrupt oil suction.
(2) Oil pump
The oil pump is fitted to the camshaft and is directly driven by the camshaft. The oil pump is furnished with a
plunger-type pressure limiting valve. Adjusting the spring preloaded force can get different oil pressures. The
maintenance parameters of oil pumps can be referred to the section of this chapter.
(3) Oil filter
The function of oil filters is to clear away metal abrasive dust, dust, moisture and colloids so as to ensure that the
quality of the oil entering the friction surfaces meets requirements. The characteristics of engines oil filters are as
follows:
1) Only one oil filter plays a role in fine filtering.
2) The filter case is integrated with the filter element. Both of them are spun on the oil pumps oil outlet circuit at a
time. The oil will, after filtered, flows into the oil passage.
3) Oil filters are disposable wearing and Consumable parts, so that they need not maintenance, only need regular
replacement.
. Common fault diagnosis of lubricating system

Though the engine bears high pressure, high temperature, high speed and alternating shock load, it will not have
major failure if carefully maintained in accordance with maintenance regulations. Generally, common faults are as
follows:
() Low oil pressure
When engines run normally, the oil pressure shall stay at 200~400kPa, and shall not less than 100kPa in idle run. If
it is lower than the value, it is a failure. The main causes are:
(1) Low oil level (inadequate oil)
(2) Improper selection of oil brand and grade
(3) Distortion of oil pressure sensor or oil pressure indicator
(4) Bad wear of oil pump; uneasy stabilization of oil pressure due to large clearance
(5) Improper adjustment of pressure limiting valve of oil pumps
(6) Poor through capacity of oil filters
(7) Oil leak of lubrication line or lubricating system
() High oil pressure
In any case, the oil pressure shall not exceed 400kPa, or the pressure is too high. Low pressure makes the
lubrication unreliable, but high pressure is not only unnecessary but also wastes drive energy, which may be easy to
cause oil lead of pipelines and accelerate oxidative deterioration of lubricating oil. The principal causes for high oil
pressure include:
(1) Great viscosity of lubricating oil (improper selection of brand)
(2) Distortion of oil pressure sensors
(3) Improper adjustment of pressure limiting valve
(4) Blockage of oil filter elements or oil passages
() High oil consumption
The normal oil consumption shall be 0.1~0.25 of the fuel consumption, that is, a 1,000km drive consumes
0.1-0.5L oil. If it exceeds the value, the oil consumption is too high. The chief causes for such phenomenon are as
follows:
(1) Bad wear of cylinders and pistons; large clearance of cylinder walls or cylinder score
(2) Deterioration of the seal of piston rings; severe oil leak, reverse installation of twist rings
(3) High temperature in the crankcase; ingress of oil vapor though crankcase ventilating system into the cylinder for
combustion
(4)Long high-load run of engines
() Fast deterioration of oil

Replace for deteriorated oil requires a certain mileage. If the oil deteriorates before reaching the specified mileage,
it is fast deterioration. The major causes for it are as follows:
(1) Large gap of cylinder walls and severe leakage cause the fresh mixture and high-temperature burnt gas to
aggravate their dilution and oxidization of the oil.
(2) Inadequate ventilation of crankcase causes the pressure and
temperature in it high.
(3) The oil filter fails.
(4) The engine leaks water.
. Maintenance of lubricating system

Maintain and change the oil and corresponding parts according
to the failure symptoms above.
. Positive crankcase ventilation system (PCV

system)
Flow direction of fresh air

Flow direction of mixture
1. Throttle valve 2. Intake manifold 3. PCV

When the engine is running, the mixture in the cylinder will
valve 4. Cylinder head cover 5. Cylinder head
scurry through the clearance between the cylinder and the
6. Cylinder block 7. Oil pan
piston into the crankcase. The mixture contains a great deal of
unburned gas such as carbon monoxide and hydrocarbon. The role of positive crankcase ventilation system is to
prevent such mixture discharging in the atmosphere. The operating principle of it is as follows:
When the vacuum in the intake manifold reduces (throttle valve is opened), the PCV valve is fully opened under
the spring pressure. Thus, large quantity of mixture in the crankcase is sucked into the intake manifold. Additionally,
when the throttle valve is turned down and the vacuum in the intake manifold increases, the openness of the
crankcase volume control damper is limited by the strong vacuum. Thus the mixture sucked into the intake
manifold will be less.
PCV hose inspection
Check to make sure whether the PCV hoses are well connected and whether there is leakage, blockage
and
1.PCV valve
deformation. Replace them if necessary.
PCV volume control damper inspection
1) Remove the PCV volume control damper on the cylinder head cover to fit the plug into the hole.
2) Let the engine run at idle speed.
3) Put the hands before the PCV volume control valve to check if there is vacuum; if there is no vacuum, check it to
make sure whether it is blocked. If necessary, replace it.
4) After the check on vacuum, stop the engine immediately to remove the PCV volume control damper. Shake the
damper to listen to whether the inspection probe has clicking sound, and change it if there is no such sound.
5) If it passes the check, fit the plug into the PCV volume control damper again.
1. PCV valve
Notice:
Before adjusting the engine to idle running, make sure that the PCV valve or the hose is not clogged, or it
will affect the adjusting accuracy. After the exhaust control hose is removed and the system components are
maintained, the components shall be properly re-assembled when they are checked to meet the requirements,
and then the lines and hoses shall be connected properly.
Section Engine cooling system

The cooling system is to
maintain the engine to work
within an optimum temperature
range. When the engine is
working,
the
maximum
temperature in the cylinder can
be as high as 1,900~2,500.
Especially the parts in direct
touch with high-temperature
gases will not work normally if
not cooled down timely. The
Jinbei Haixing engines adopt
forced water cooling, whose
structural
arrangement
is
shown as the figure below.
1. Radiator inlet pipe

2. Radiator outlet pipe
3. Inlet pipe
4. Thermostat
5. Water pump
6. Water pump belt

7. Cylinder block
8. Cylinder head
9. HVAC inlet hose
10. HVAC outlet hose

11. Radiator
12. Liquid storage tank
13. Radiator cap
1) As the engine gradually heats up

(the thermostat is closed), the
circulation of cooling liquid is shown
as the figure (note: do not pass the
radiator)
Water pump
pump
Water
Cylinder block
Cylinder head
Intake manifold
When thermostat closed

Inlet pipe
Temperature sensor
Thermostat
2) When the cooling liquid heats to the

Radiator
normal temperature and the thermostat
is opened, the cooling liquid still circulate as the above figure, and it will cool down through the radiator.
. Major component of cooling system

The major components of the cooling system include: radiator, water pump, electric fan, thermostat, cooling water
flume (pipeline), water temperature sensor, water thermometer, etc.
1. Radiator
EFI engine radiators, structurally identical to the average engine radiators, are composed of aluminum tubes or
copper tubes and cooling fins. The difference is that this radiator employs a two-gear rotary switch as its cap
instead of the air-valve cap, which makes the cooling system change from average open cycle to closed cycle. It is
because the change in caps that special attention shall be paid to removing them.
Opening radiator caps falls into two steps: first, loosen the cap to the safety tongue lock, and then open it entirely
when the systems working pressure drops, or the hot coolant will splash out to cause personal injury.
2. Water pump
The water pump is to circulate the coolant in the cooling system to take away the heat of cylinder block and head
and radiate it through radiators.
EFI engines adopt a type of centrifugal impeller pump, whose housing is cast together with the cylinder block. The
impeller is driven by drive belt through crankshaft driving wheel so as to put the coolant into forced circulation.
3. Electric fan
The electric fan is to improve the velocity and flow of the air flowing through the radiator to enhance the radiators
heat-sinking capability.
The fan of EFI engines is driven by a motor, which is fixed behind the radiator, and borne by a holder made of
metal. The holder is furnished with a wind-guide ring and air flow reverse prevention device. Its operation is
controlled by ECU based on the coolant temperature.
4. Thermostat
The thermostat is to adjust the coolants circulation line to meet the purpose of adjusting the temperature of cooling
liquid.
This model employs wax-type thermostat, which is unrepairable. If it is sure of a thermostat failure, please replace
a new one.
. Common fault of cooling system

1. Engine overheat
As the DL465Q5 EFI engine run normally, the coolant temperature ranges within 85~98oC; if it exceeds 118oC, the
engine is overheated. The main causes for overheat are as follows:
(1) The coolant in the cooling system is inadequate.
(2) The thermostat works abnormally.
(3) The tank cap is not twisted to the specified position, causing coolant overflow.
(4) The air is not be drained in according with requirements when coolant is filled.
(5) The water flumes of radiators and cylinder blocks are clogged.
(6) The water thermometer and water temperature sensor work abnormally.
(7) The cooling fan works abnormally.
(8) The internal pressure of the cooling system is too high.
(9) The engine runs at a high speed long.
(10) The water pump belt gets slack or damaged.
(11) The water property is poor.
(12) The cooling system has leakage.
(13) The radiator is blocked.
(14) The ignition timing is subject to maladjustment.
(15) The brake drags.
(16) The clutch slips.
2. Engine overcooling
If the cooling temperature of engines is below 80oC, it is too cold.
The causes for this are as follows:
(1) The thermostat valves are all opened long to be in a state of
major cycle all the time.
(2) The cooling fan works abnormally.
1. Water temperature sensor
(3) The water thermometer and temperature sensor work abnormally.
(4) The temperature of the work environment is too low.
3. Coolant outleakage
If there is water below the car when parked in a place, it may be water leakage, for which the causes are as follows:
(1) The connecting water pipe is damaged or get slack.

(2) The radiator has cracks.
(3) The tank cap is not twisted to the required position.
(4) The water pump gasket is damaged.
(5) The overheat of the engine cause boiling.
4. Inner leakage of coolant
If the quality of lubricating oil is found to deteriorate after a check, it may be caused by inner leakage of coolant.
The main causes may be as follows:
(1) The gasket of cylinder head is damaged.
(2) The junction surface of cylinder head and cylinder block is not level.
(3) The cylinder block has cracks.
5. Corrosion of cooling system
The major causes for cooling system corrosion are as follows:
(1) The cooling system is not maintained according to requirements, and the coolant is not changed according to
requirements either.
(2) The mixture ratio of coolant is wrong, so is the cooling liquid type.
Make checks, adjustment or repairs to the faults or change corresponding parts.
. Repair and maintenance

1. Cooling fan
The cooling fan automatically starts under the control of ECU. The technical parameters of its opening and closing
are as follows.
Main technical parameters of cooling fan switch (5)

Opening temperature
Above 93.5
Closing temperature
Below 87
Notice:
Hands, tools and clothes shall always keep away from the engines cooling fan to avoid personal injury.
The water temperature sensor is fixed on the intake manifold. It transmits the water temperature signals to the water
thermometer on the dashboard.
3. Maintenance of cooling liquid

The quantity of cooling liquid poured in the cooling system is standard. The cooling liquid in the radiator expands
when heated and overflows in the liquid storage tank. When the system cools down, the cooling liquid will return to
the radiator.
The anti-freeze liquid has a so fine anti-corrosive property that it can prevent the system producing scale and
improve the boiling point. Additionally, anti-freeze liquid can reduce evaporation loss. With the premium properties
above, the cooling system shall use cooling liquid all the year round, and shall be not added with pure water at any
time so as not to reduce the density of cooling liquid.
-20# ethylene glycol anti-freeze liquid is used in most areas or in winters where the minimum temperature is
above -20; and -40# ethylene glycol anti-freeze liquid is used in winter in North East, Xinjiang and Inner
Mongol and other areas where the minimum temperature is below -20.
When the cooling liquid is reduced by consumption, the anti-freeze liquid of the same sort shall be added.
Notice:
In any case, neither alcohol or methanol cooling liquid, nor ordinary water can be poured into the cooling
system, or it will be damaged.
Even if there is no desired cooling liquid on market, the cooling liquid of 70% water and 30% ethylene glycol
would be used to realize corrosion prevention and lubrication. The following is the table of anti-freeze
liquids proportion and volume:
o
16
-36
30
50
Volumetric ratio
30/70
50/50
Freezing temperature
Anti-free
ze
protector
Concentration of
anti-freeze/anticorrosive
cooling liquid
Mixing proportion with cooling
water
(ethylene glycol/water)
Cooling
liquid
volume
(L)
Cooling liquid level
Engine radiator and HVAC
1.3
Liquid storage tank
0.6
Others
2.9
Total
4.8
Check on liquid level: open the engine hood to check the level of the liquid in the tank; the check on cooling liquid
level does not require removing the radiator cap.
Warning:
To avoid scald:
Do not open the liquid storage tank cap when the cooling liquid is boiling.
Do not open the radiator cap when the engine and radiator do not cool down.
If the caps of the liquid storage tank and radiator are opened too early, the
boiling liquid and steam will puff up suddenly under pressure.
When the engine cools down, check the level of the liquid in the liquid storage
tank. Normally, the cooling liquid level shall stat between the FULL and LOW (L)
mark lines.
If the level is below the LOW (L) mark, the liquid storage tank cap shall be
removed to add cooling liquid of the same proportion to raise it to the FULL (F)
mark; then cover the cap and align the mark on the liquid storage tank to that on
the cap.
1. Liquid storage tank

2. Maximum level mark
3. Minimum level mark
4. Liquid storage tank cap
5. Alignment mark
6. Hose to water
Notice:
If the anti-freeze liquid of the same quality is use, it is unnecessary to add other aseptic or protective agent
to provide further protection of the system.
In covering the liquid storage tank cap, the arrow marks on both the tank and the cap shall be aligned.
4. Maintenance of cooling system
Warning:
To prevent scald, do not open the radiator cap when the engine
and radiator do not cool down.
If the caps of the liquid storage tank and radiator are opened
too early, the boiling liquid and steam will puff up suddenly
under pressure.
The cooling system shall be maintained according to the following
method:
1) Check the cooling system to make sure whether it has leakage or
damage.
2) When the engine cools down, remove the radiator cap and use
pure water to clean the cap and the filling orifice.
3) Check the cooling liquid level to see if it is proper.
4) Use a pressure tester to check the tightness of the cooling system
and radiator cap. If the radiator cap is necessary to change, choose
1. Thermostat cap drain bolt

2. Thermostat cap
3. Radiator water service hose
the dedicated ones.

Notice:
When the radiator cap is fitted into the radiator, be sure the pipe fittings are parallel to the radiator.
5) Tighten the hose clamp to check all hoses; in case the hoses have
cracking, expanding or other damage, they shall be changed.
6) Clean the front of radiators.
7) Use a pressure tester to check whether the radiator cap is able to
maintain a 90kPa pressure. If the radiator cap is necessary to change,
choose the dedicated ones.
Cleaning and refilling of cooling system
1) Remove the radiator cap after the engine cools down
Slowly turn the cap counterclockwise to the stop (stop sign). (Do
not press down it in turning) press it down and continue turning it
counterclockwise when the pressure releases (fizzing).
1. Pressure tester
2. Radiator
3. Radiator cap/cap (including
thermostat cover)
2) After the radiator cap is removed, the engine shall continue

running till the radiators upper end hose gets hot (which means that
the thermostat is opened and the cooling liquid flows through the system).
3) Stop the engine and discharge the cooling liquid.
4) Tighten the water drain plug to fill soft water till the system is filled; then start the engine again until the
radiators upper end rubber hose get hot.
5) Repeat the step 3) and 4) till the discharged liquid becomes nearly
colorless.
6) Drain the cooling system and screw up the water drain plug.
7) Remove the liquid storage tank and open its cap to pour out all the liquid;
then use soap and water to scrub its interior; finally rinse it with clear water
before fitting the liquid storage tank.
1. Radiator
2. Water drain bolt
8) Fill the quality anti-freeze liquid into the radiator and liquid storage tank.
Fill the liquid first to the full level mark FULL (F) on the lower part of radiator filling orifice and the liquid
storage tank, and cover the liquid storage tank cap; remove the HVAC hose and loosen the venting plug of the
thermostat to exhaust the air in the cooling system; then fill the cooling liquid till the level rises to the filling
orifices of the radiator and liquid storage tank.
9) Remove the radiator cap to run the engine till the radiators upper end hose gets hot.
10) Stop the engine to cool down, and then fill the cooling liquid into the liquid storage tank; then cover the
radiator cap, making sure the pipe joint on the cap are parallel to the radiator.
Tension of water pump belt
Warning:
The battery negative wire shall be first removed before
checking and adjusting the tension of the belt.
Refer to the warning in the Maintenance of cooling system.
1) Check the belt to make sure whether there are cracks, ruptures,
deformation, wear and cleaning; change it if necessary; the step of
replacing it can be referred to the Water pump belt in this section.
2) Check the belt tension. If the belt sinks 6-9mm when pressed by
a thumb (about 980N), it means that the tension is proper.
1. 10kg (22 lbs)

2. Adjusting bolt
Belt tension: a: 6~9mm sinkage

Notice:
In replacing new belts, the tension shall be adjusted to 5~6mm.
3) If the belt is too tight or too slack, it can be adjusted to be
suitable by moving the engines position.
4) Tighten the adjusting bolt of the belt and the fixed bolt of the
generator.
5) Connect the battery negative wire.
. In-car maintenance
Warning:
Give a check to make sure the cooling liquid cools down before
all the components of the cooling system are removed.
Make sure that the battery negative ground wire has be removed
before stripping the components.
1. Discharge of cooling liquid
1. Radiator
2. Water drain bolt
1) Remove the radiator cap.

2) Slowly slacken the water drain bolt to discharge cooling liquid.
3) After the cooling liquid is discharged, the water drain bolt must be
tightened before refilling it.
4) Fill cooling liquid (refer to Maintenance of Cooling Liquid)
Removal:
1) Drain the cooling system
1. Thermostat cap 2. Thermostat bolt
2) Loosen the pipe clamps of the cooling system, and then remove all the pipes of the system.
Installation:
Assemble all the removed clamps and pipes in the reverse order of their disassembly, while pay attention to the
following aspects:
Fasten all the pipe clamps.
Refill the cooling liquid of proper proportion into the cooling system; refer to the Maintenance of Cooling
Liquid in the above section.
While the water pipes are fitted into the pump, a new O seal ring shall be used.
2. Thermostat
Caution:
Do not remove the thermostat cover.
Removal
1) Discharge the cooling liquid and tighten the drain bolt.
2) Remove the thermostat cap from the intake manifold.
1. Air release valve 2. Thermostat seal block
3) Detach the thermostat. air release valve

Check
1) Make sure the air release valve of the thermostat is clean; if it is clogged, the engine will overheat.
2) Make a check to make sure that there are no foreign bodies, which will impair valve seats tightness.
3) Check to figure out whether the thermostat gasket is damaged, aged or otherwise impaired.
4) Check the flexibility of the thermostat wax cylinder by the following
methods:
a) Immerse the thermostat in water and heat it up.
b) Check whether the valve opens at the specified temperature.
c) If the valve opens below or above the specified temperature range, it means
the thermostat is damaged, and it will cause the engine to get supercooled or
overheated if remaining in use.
Installation
Thermostat working parameter
Temperature when the valve
starts opening
82oC
Temperature when the valve

fully opens
95oC
1. Thermostat
2. Thermometer
3. Heating furnace
1) Fix the thermostat on the correct position.

2) Fit the thermostat into the intake manifold, and tighten
the bolt according to the specified moment.
3) Fill the cooling liquid of proper proportion.
4) Check all parts for leakage after they are assembled.
3. Water pump belt
1. Thermostat 2. Inlet manifold
1) Remove the battery negative wire.
2) Unscrew the drive belts adjusting screw and the generators set screw.
Note: in maintaining cars equipped with air conditioners, the compressor drive belt shall be first removed, and then
the water pump belt.
3) Move the generator to slacken the belt and take it down.
Installation
1) Fit the belt to the water pump pulley, crank pulley and generator pulley. (in repairing cars with air conditioners,
compressor belt shall be installed as well).
1. Water pump belt
2) Adjust the belt tension.
2. Adjusting screw
3. Set screw
Adjust the tension of the compressor drive belt. Refer to the above
section for the adjustment method.
3) Tighten the water pump belts adjusting screw and set screw.
4) Connect the batter negative wire.
Installation and adjustment
Refer to the section of Water Pump Belt Tension for check and
adjustment of water pump belts.
4. Radiator
Removal
2) Unscrew and pluck the water drain bolt to discharge the cooling liquid
in the cooling system.
1. Radiator
2. Water drain bolt
3) Remove the plug connectors of the cooling fan motor.

4) Remove the front bumper.
5) Remove the radiator support.
6) Remove the radiators inlet and outlet hoses, as well as the hoses of the liquid storage tank on the radiator.
7) Remove the radiator of the fan motor.
Check:
Check if the radiator has leakage or damage.
Straighten the bent radiator fins.
Cleaning
Clean the external surface of the radiator core to keep good ventilation.
Installation
Assemble them in the reverse order of disassembly.
Notice:
1. Bolt
2. Air-conditioning condenser (if any)
Refill proper cooling liquid into the cooling system; refer to the section Maintenance of Cooling Liquid.
Check all connectors for leakage after installed.
5. Water pump
Removal
2) Drain the cooling system.
3) Remove the front seat.
4) Remove the gear lever and brake handle, as well as the central
components in the engine compartment.
Water pump
5) Slacken the water pump drive belt, and then remove the water pump pulley and the belt. In repairing cars with
air conditioners, the compressor belt shall be first removed and then the water pump belt.
6) Remove the timing belt and tension pulley.
7) Take down the water pump assembly
Check:
Rotate the water pump manually to check whether it runs steadily; if it fails to turn flexibly or makes noises, if
shall be changed.
Check the water pump impellers to see whether they
are damaged; change the assembly if necessary.
Notice:
Do not disassemble the water pump to check the
impellers.
Installation:
1) Apply sealant to the new pump gasket before fitted
to the cylinder block.

2) Fix a rubber seal between the water pump and the oil pump, as well as between the water pump and the cylinder
head.
3) Install bolts and tighten them, with the torque value as specified.
4) Install the timing tension pulley wheel, tension pulley, tension pulley spring, timing belt and timing belt cover.
5) Install the crank pulley, water pump pulley and water pump belt.
6) Adjust the water pump belt tension according to the former figure; as
for the cars with air conditions, the air conditioner drive belt shall be
adjusted.
1. Rubber seal

8) Fill cooling liquid into the cooling system.
9) Install the central components in the engine compartment, and then
adjust the parking brake and install the gear lever.
10) Refer to the section Installation of Front Seat to install the front seat.
11) Check all parts for leakage after assembly.
12) Adjust the tension of the water pump belt and air conditioner belt (if an air conditioner is equipped).
Tightening torque: (a) 9-12Nm
Section Engine starting system

To make a static engine start operating, an external force must be exercised to turn the engines crankshaft so as to
let the cylinder suck in inflammable mixtures, which are compressed and ignited to produce a strong power to push
down the piston and thus to drive the crankshaft to turn. In this way, the engine automatically begins working cycle.
The system from turning the engines crankshaft by an external force to the engine beginning idling automatically
is called starting system.
. Composition of starting system

The starting system circuit is composed of battery, ignition switch, starting motor, solenoid switch, one-way clutch,
flywheel ring gear and relevant wires. This section deals with the starting motor alone.
1.
Starting motor circuit
As the ignition switch closes, the solenoid switch coil produces a magnetic field.
When the plunger and the gear drive cable move to make the pinion and the engines flywheel gear in mesh, and
the solenoid switch contacts close, the starting begins.
When the engine is starting, the pinion overdrive clutch protects the armature to prevent the starter overrunning till
the switch is opened. Then the return spring disengages the pinion. The circuit diagram is as shown below.
Solenoid switch
Pull-in coil
Holding coil
Solenoid switch contact
Plunger
Pinion
drive
Ignition and starter switch
cable
Pinion
drive
cable
Pinion and overdrive clutch
Starting motor
Battery
2. Starting motor
It consists of stator assembly, armature assembly, overdrive clutch assembly, solenoid switch assembly, front shell,
rear shell, brush support and drive cable (see the figure below). The solenoid switch assembly and parts on the
starting motor are enclosed in the shell so as to avoid damage from dirt and splash.
Annotation:
The positions marked with A in the figure below shall be applied with grease before installation.
. Common fault diagnosis of starting system

The conditions due to starting system faults are as follows:
The starting motor fails to operate (or operate at a slow speed).
The starting motor operates but fails to start the engine.
Abnormal noise
Proper diagnoses must be made to confirm where the fault occurs, for instance battery, wiring harness (including
starting motor switch), starting motor or engine.
Do not disassemble the starting motor only because it fails to operate. Check the items listed in the below table to
examine the failure causes (examine one item after another according to the table below).
1) Fault conditions
2) Battery terminals (including ground wire terminal at the engine side) and starting motor terminals
3) Battery discharge
4) Installation of starting motor
1. Starting motor assembly
2. Solenoid switch block
3. Gasket
4, 5. Nut
6. Gasket
7. Drive fork block
8. Starting engine bolt
9. Nut
10. Drive end shield
11. Starting engine bolt
12. Lock ring
13. Front support bearing
14. Stator
15. Brush
16. One-way clutch component
17. Armature
18. Rear end cap
19. Brush pressure spring
20. Stay bolt
21. Sealing gasket
22. Tripping spring
23. Positioning chuck plate
24. Rear cover
25. Screw
1. Armature
4. Snap ring
2.Overdrive clutch
3. Pinion upper snap ring A: apply
grease
Problems
Causes
Troubleshooting method
Solenoid switches have no operation sound:

The battery runs out or low.
The battery voltage is too low due to
deterioration.
Recharge
The battery terminals are in poor contact.
Change the battery
The ground wire terminal gets slack.
Tighten it up or change it
The fuse gets slack or blown.
Tighten it up
The ignition switch and solenoid switch are

in poor contact.
Tighten it up or change it
The lead connection becomes flexible.

The circuit between the ignition switch and
solenoid switch are opened.
The motor fails to
operate.
The pull-in coil circuit is opened.

The brush holder is slackened or worn.
The plunger and pinion do not rotate
smoothly.
Change
Tighten it up
Repair or change
Change the solenoid switch
Repair or change
Repair
Solenoid switches have no operation sound:
The power supply contact is burnt out or the

solenoid switch is in poor contact.
Repair or change
The brush holder is not firm or worn

The elasticity of the brush spring declines.
The rectifier is burnt out.
The coil is badly earthed.
Change
Change the armature
Repair
Repair
Repair
The armature isolated layer is short circuited.

The crank rotation is hindered.
If the battery and wires have no problem,
please check the starting motor
The solenoid switch is in poor contact.
The armature isolated layer is opened.
The starting motor
does operate but
the speed is slow
and torque is small.
The rectifier is disconnected, burnt out or

worn.
The coil is badly earthed.
The brush is worn.
The elasticity of the brush spring declines.
The end bushing is burnt out or abnormally
worn.

Change
Repair or change the armature
Repair
Change the brush
Change the spring
Change the bushing
The starting motor

operates but the
engine fails to start.
The pinion tip is worn.
Change the overdrive clutch
The overdrive clutch does not rotate smoothly.
Repair
The overdrive clutch slips.
Repair, change
The pinion teeth are worn.
Repair the flywheel
The brush is abnormally worn
Change
The pinion teeth or pinion drive teeth are

worn.
Change the pinion or the flywheel

Repair or change
Noise
The pinion does not rotate smoothly (cannot
return).
Lubricate
The parts lack lubricating oil.
The starting motor

fails to stop.
The solenoid switch contacts are melted.
Short circuit occurs between the solenoid

switch coils (isolated layer short circuited).

Change
The ignition switch fails to return.
. Repair and maintenance of starter

1. Removal and reassembly
2) Remove the solenoid switch wire and battery wire from the
starting motor terminals.
3) Unscrew the two mounting screws.
4) Remove the starting motor.
1. Wire 4. Nut
2. Nut
A: pull to disengage the internal hook
3. Solenoid switch
5) Remove the nuts from the solenoid switch and disconnect the
wires.
6) Remove the two nuts, and take out the solenoid switch by
pulling the solenoid switch tail so as to detach the internal hook
from the drive cable.
7) Remove the shell bolts and then pull out the rectifier end cap.
8) Remove the insulator and brush spring, and then dismantle
1. Brush
2. Brush spring
3. Brush holder
the brush holder.

9) Remove the stator, armature and drive cable.
10) Use a snap ring plier and driver to remove the armature and then pull out the pinion snap ring and overdrive
clutch.
Note:
Do not remove the solenoid switch; if necessary, replace it in assembly.
11) The reassembly shall be performed in the reverse order.
Special tool
(A): 0990006107
1. Armature
2. Chuck ring
3. Pinion snap ring
4. Overdrive clutch
Reassembly
1. Armature
2. Drive cable
shield
3. Drive end
1) Check the parts (seen the section of check), which shall be

changed if necessary
2) Apply grease as shown in the figure before installing the
overdrive clutch, and then fix the locating snap ring with a snap
ring
A: grease 9900-25010
3) The drive cable shall, after applied with grease, be fitted to the
armature, and then they are installed with the drive end shield.
1. Armature
2. Drive cable
3. Drive end shield
A: apply grease
A: grease 99000-25010
4) Install the stator and brush holder, and then fix the brush with four springs, and finally install the insulator.
Notice:
In installing brushes, be sure that the grease on the brushes and
rectifiers is wiped off.
Make sure the brush parts have no unnecessary contact with
other parts.
5) Posterior to apply grease inside the bushing, install the back cover.
1. Brush
2. Brush spring
3. Brush holder
A: grease 99000-25010
6) Replace the solenoid switch and its cover; if necessary,
apply grease to the plunger.
A: grease 99000-25010
7) Clasp the drive cable with the solenoid switch plunger,
and then fasten the solenoid switch assembly with nuts.
8) Connect the wires in place, and then check the operation
of the solenoid switch.
Notice:
Before screwing the nuts, make sure the plunger is
well connected with the drive cable.
1. Solenoid switch
2. Bushing
A: apply grease
3. Plunger
Make sure the bushing air holes are downward.

Performance tests shall be conducted when the assembly is completed.
2. Check
Plunger
Check the plunger for wear, and change it if necessary.
Solenoid switch
Push in the plunger and let it go, then the plunger shall
quickly return to its original position. Change it if necessary.
Disconnection test of pull-in coil
Check the solenoid switch to make sure whether its S terminal and
M terminal are connected; if not, it means the coil is disconnected,
and it shall be changed.
Brush
Measure the brushs length, and change it if necessary.
Brush length limit: 12.0mm
1. Terminal S
2. Terminal M
Brush holder
Check the brush to see if it is corroded or ruptured; check the
brush holder to figure out whether is corroded or insulated; if
necessary, change them in assembly.
Armature
1. Terminal S
Earth test
Insulation shall be provided between the rectifier plate and the armature core, which can be tested with an
ohmmeter.
Disconnection test
Check the continuity between rectifier plates; if there is no continuity at any test point, it means the circuit is
disconnected, and then the armature must be change.
Support the armature on a V-shaped block to check if the rectifier is eccentric; if it has problems, cut it by a lathe.
Rectifier roundness limit (maximum): 0.4mm
1. Armature
2. V-shaped block
3. Magnetic gauge stand
4. Micrometer
Use a micrometer to measure the rectifiers outside diameter; if the

diameter is below the limit, change the rectifier or the armature.
Rectifier outside diameter limit (minimum): 27mm
Polish the surface with emery cloth and check the mica depth.
Rectifier insulators depth a limit (minimum): 0.2mm
(0.008in.)
Stator
Check if the exciting coils conduct. There shall be continuity
between the following terminals.
1) Between terminals
2) Between terminals
3) Between the terminal and C terminal (the surface of metal pieces
of the stator)
Overdrive clutch
Check the pinion to make sure whether it has wear, damage or other
abnormalities. Turn the clutch in the driving direction to check whether
the clutch is locked and can turn smoothly in a reverse direction; if
necessary, change it.
A: Free rotation
1. Mica insulator
2. Rectifier plate
Material
Recommended Suzuki
product
Use
Armature shaft
Super grease A
Overdrive clutch
(99,000-25,010)
Rectifier end shield
Lithium grease
Drive cable
Performance test
Warning:
Every time the test must be
completed within 3-5 seconds
to avoid burning out the coils.
Pull-in test
Connect the wires as shown in
the figure and check if the
pinion (overdrive clutch) turns
outwards; if it fails to move,
change the solenoid switch.
Notice:
1. Terminal S
2. Terminal M
3. Wire
(motor switch)
The exciting coil must be

disconnected with the terminal M before the test.
Holding test
Connect the wire as shown in the figure above when the iron core
extends out, and then remove the negative wire from the terminal
M. The check if the iron core still extends out; if it contracts
inwards, the solenoid switch shall be changed.
Pinion (plunger) return test
Follow the last step to remove the
negative wire and give a check to
make sure the pinion quick return
inwards, as shown in the right figure.
No-load performance test
Connect the test leads as shown in the right figure and check if the motor has
operational failure and make sure the pinion rotate outwards; additionally, check if the
armature indicates the specified current.

Specified current: 50A at 11V.
Technical requirement
Servicing materials
Special tool
09900-06107
clasp forceps
(open mouth type)
Voltage
12V
Output power
0.8KW
Rated operating time
30s
Rotation direction
Counterclockwise (see from the pinion

side)
Brush length
16.0mm
Teeth number of pinion
Performance
At about
20oC
Conditions
Rated load
No-load
characteristic
11V
Below 50A (above 5,000 r/min )
Load characteristic
9.5V
Below 5.0Nm (
Braking current
5.5V
Below 430A (above 6.5 Nm)
working voltage of solenoid switch
above 1,200 r/min)
Below 8V
Section Engine assembly

The assembly steps of engines are reverse to their disassembly steps, but some necessary measures must be taken to
make sure that the assembled engines meet the factory requirements.
Notice:
All parts must be cleaned.

Make sure to apply oil to main crankshaft journals, main
journal bearings, thrust bearings, journal pins, connecting rod
bearings, pistons, piston rings and cylinder, oil passages and
surfaces for lubrication.
Main bearings, bearing caps, connecting rods, connecting rod
bushes, connecting rod caps, pistons and piston rings are
combined parts, so they shall be not disrupted, but be fitted to
their original position.
1. Cylinder block
2. Upper part of bearing
3. Sump
. Assembly of internal parts of engines
1. Crankshaft
Thrust bearing
1) Fix the main bearing shell on the cylinder block.

Of the two main bearing shells, one has a sump. The one with a sump
is fixed on the cylinder block, and the other one without a sump on
the main bearing cap. Make sure the color of the both shells are the
same.
Sump
2) A thrust bearing shall be mounted between No. 2 and No.3
cylinders. The side with a sump shall face the crank arm.
3) Place the crank on the cylinder block.
4) Assemble the bearing caps from the belt pulley side in the
increasing order from 1, 2, 3, 4, and 5. Make sure the arrow marks (on
every bearing cap) aim at the crankshaft pulley side. For bearing cap
bolts, tightening them gradually and evenly is of importance. Make
sure the 5 bearing caps are tightened evenly and gradually as required
to the specified torque.
Tightening torque
(a): 43~48Nm (465), 52~56Nm (474)
Notice:
After the bearing cap bolts are tightened up, manually
turn the crankshaft to give a check, making sure the
crankshaft rotates smoothly.
1. Outer rotor
2. Inner rotor
1. Crankshaft pulley side

2. Arrow mark
2. Oil pump and rear cover

1) All assembly parts shall be cleaned and dried.
2) Apply a thin layer of engine oil to the internal surfaces of
the inner/outer rotors, oil seal lip, oil pump casing and
header.
3) Fix the outer/inner rotors on the pump casing.
4) Mount the rotor header, and tighten the five screws. When
the rotor header is well mounted, check and make sure the rotor rotate smoothly.
Tightening torque
(a): 9~12Nm
5) Fit the two oil pump pins and oil pump seal gasket to the
cylinder block; the seal gasket shall a new one.
6) To avoid the seal lip being upturned or damaged, when the
oil pump is fixed on the crankshaft, a special tool (oil seal
guide bush) shall be fit to the crankshaft and it shall be
applied with engine lubricating oil.
7) Mount the oil pump on the crankshaft and cylinder block.
1. Crankshaft
Of the 7 oil pump bolts, the four 1# bolts shall be shorter than
the three 2# bolts. As shown in the figure, fit the 1# and 2#
bolts in place, and tighten them to the specified torque.
After the oil pump is installed, check and make sure the oil seal
lip does not upturn, and then remove the special tool.
Tightening torque
(a): 9~12Nm
1. 1# bolt (short)
2. 2# bolt (long)
8) The edge of the oil seal gasket may bulge.
In this case, cut it off with a sharp cutter so as to make the
edge smooth and flush with the pump casing and cylinder
block.
Use a new seal gasket. Do not use the removed old

seal gasket. Before installing it, the seal lip shall be
applied with engine oil. Tighten the rear cover
bolts up in accordance with the specified technical
conditions. After installing the rear cover, the edge
of the seal gasket may bulge; in this case, cut it off
so as to make it flush with the cylinder block and
the rear cover.
Tightening torque
(a): 9~12Nm
Arrow mark
Piston
9) Install the rear cover and the seal gasket
mounted position of
piston pins snap spring
Snap spring
Connecting rod
Crankshaft pulley side
The installation shall locate the

snap spring end clearance within
the range pointed by the arrow
points
3. Piston
1) Fix the piston pin on the piston and the connecting rod.
After applying engine oil to the piston pins and piston pin holes in
the piston and connecting rod, assemble them according to the
following method, and insert the piton pins into the piston and
connecting rod, and finally fit the piston pin snap spring.
Note: the installation shall locate the snap spring end
1. No. 1 piston ring

2. No. 2 piston ring
3. Scrapper ring
clearance within the range pointed by the arrow.

2) Fix the piston ring on the piston.
In installing, notice that No. 1 piston ring has
different marks from No. 2 piston ring. In fixing them
on the piston, the mark side of them shall align with
the top of the piston.
No. 1 piston ring is different from No. 2 in thickness,
shape and the color in contact with the cylinder wall
surface. Please notice to distinguish both of them in
disassembly.
In mounting scrapper rings, the gasket shall be first
mounted before the two scrapper rings.
1. Arrow mark
2. No.1 piston ring end clearance
3. No.2 piston ring end clearance and
scrapper ring gasket clearance
4. Scrapper ring upper guide clearance
5. Scrapper ring lower guide clearance
6. Intake side
7. Exhaust side
3) Once No. 1 and No. 2 piston rings and the scrapper rings are
mounted, arrange
their clearances
as shown in the
figure.
1. Crank pulley side

2. Flywheel side
1. Connecting rod bearing cap

2. Arrow mark
3. Crank pulley side
4. Bearing cap nut
4) Apply engine oil to the piston, piston ring, cylinder wall, connecting
rod and piston pin before installation.
5) Attach a hose to the connecting rod bot.
In installing connecting rods and piston assembly, these hoses can
protect piston pins and connecting rod bolts against damage.
6) When the piston and connecting rod assembly are installed in the
cylinder, the arrow mark on the piston top shall point to the crank
pulley side.
7) In installing the piston and connecting rod assembly in the cylinder, a special tool (piston ring compressor) shall
be employed to squeeze the piston ring to install the crankshaft in place; use a
hammers wooden handle to tap the piston top so as to fit it to the cylinder
hole; hold the piston ring compressor firmly to make it abut against the
cylinder block till the piston ring totally enters the cylinder.
Special tool:
A: 09916-7310
8) Install connecting rod bearing cap:
The arrow mark on the bearing cap shall be aimed at the crank pulley side, and
then tighten bearing cap nuts according to specified technical conditions.
Tightening torque
(a): 28-32Nm (465), 33-37Nm (474)
4. Oil pump strainer and oil pan
1) Install oil pump strainer:
Install sealing member on the position as shown in the figure.
First tighten up the strainer bolt, and then screw the bracket bolt according to the specified torque.
Tightening torque:
(a): 9~12Nm
2) Clean up the upper and lower oil pans and cylinder
assembly surface. Eliminate the old sealant and dirt on the
assembly surface; after this, apply silicone sealant to the oil
pans assembly surface repeatedly as shown in the figure.
A: sealant 99000-31150
3) Fix the upper oil pan on the cylinder block, and then fit the
lower oil pan to the upper oil pan; once both oil pans are well
1. Sealing member
2. Strainer
3. Bracket
fitted, fix the fixing bolts on the middle part and tighten them up: move the wrench outward to tighten one bolt at a
time. Tighten up the bolts and nuts according to the specified tightening torque.
Tightening torque
(a): 6~8Nm (465), 9~12Nm (474)
Fit the seal ring and oil drain plug on the oil pan.
Tightening torque
(b)35~40Nm (465), 30~37Nm (474)
5. Flywheel
Install flywheels
1. Flywheel bolt
Use special tools to fix the flywheel and tighten its bolts up according to the specified tightening torque.
Special tool:
(A): 09924-17810
Tightening torque
(a): 40~45Nm (465), 76~78 Nm (474)
1. Valve guide projection

(14mm 10.55in)
6. Cylinder head
1) Before the cylinder guide is fit to the cylinder head, special tools
shall be used (12mm reamer) to trim it so as to eliminate burs.
Special tool:
(A): 09916-37310
2) Fix the valve guide on the cylinder head. Heat the cylinder head
evenly to a temperature of 80~100 (176~212), at which the
cylinder is hard to deform. Then use a special tool to press the valve guide in the holes till the special tool (valve
guide installer) touches the cylinder head. After mounted in place, the valve guide shall project 14mm out of the
cylinder head.
Special tools:
(B): 09916-57321
(C): 09917-88210
Notice:
Do no reuse the removed old valve guides, but use the new ones (oversize).
Valve guide hole diameter (intake and exhaust)
12.030~12.048mm
Oversize valve guide
0.03mm
Projecting distance of valve guides (intake and exhaust)
14mm
The intake guide is identical to the exhaust guide.

3) Use special tools (1mm reamer) to trim the valve guide hole; after this, clean
the hole.
Special tool:
(D)09916-34520
4) Fix the valve spring support on the cylinder head.
1. Valve guide
5) Fit the new valve oil seat on the valve guide.

After applying engine oil to the valve oil seals and the main shaft of the special tool (valve oil seal installer), mount
the oil seal on the main shaft; and then manually press the special tool to fit the valve oil seal on the valve guide.
After it is installed, check and make sure the valve oil seal is
properly mounted on the valve guide.
Special tool:
(E): 09917-98210
Notice:
Do not reuse the removed valve oil seal, and make sure the
valve is sealed.
Install new valve oil seals
In installing, do not use hand hammers or other things to
knock or strike the special tool ever, but press the special
tool by hands alone to fix the valve oil seal on the guide.
Knocking or striking special tools may cause damage to oil
seals, resulting to oil burning.
6) Fix the valve on the guide.
Before fixing the valve on the guide, apply engine oil to the
1. Valve stem oil seal
valve stem oil seal, valve guide holes and valve stem.
7) Valve spring and spring retainer
Every valve spring has a top (large pitch end) and a bottom (small pitch end). To make sure the spring is in place,
its bottom (small pitch end) shall touch the base (valve spring seat end side)
8) Use a special tool (lift valve) to compress the valve spring and fit the two valve cotters in the valve stem groove.
Special tools:
(A): 09916-14510
1. Large pitch
2. Small pitch
3. Valve spring retainer side
4. Valve spring seat end side
(B): 09916-48210
(C): 09916-84510
9) Install intake manifold
and exhaust manifold.
Tightening torque
1. Valve cotter
18~23Nm (465)
23~28Nm (474)
10) Install cylinder head seal gasket
Mount new cylinder gaskets as shown in the figure, that is, the TOP
mark on the seal gasket lies on the cylinder head gasket at the shaft
pulley side, with right side up (to the cylinder head)
11) Fix the cylinder head on the cylinder block.
1. Cylinder head seal gasket

2. Shaft pulley side
3. Transmission side
After applying engine oil to the cylinder head bolts, tighten them up
one after another by a wrench in the order as shown in the figure,
and then screw the bolts according to the specified torque.
Tightening torque: (a)55~60Nm (465) 58~71Nm (474)
1 : Camshaft pulley side

2 : Distributor side
12) Apply engine oil to the cam and journal on the camshaft as well as the oil seal on the cylinder head.
13) Fix the camshaft on the cylinder head from the transmission housing side.
14) Apply engine oil to the rocker arm and rocker arm shaft.
15) Fit on the rocker arm, spring and rocker arm shaft. the two types of rocker arm shaft are different. To identify
them, the dimension shall be marked at the echelon end as shown in

the right figure. Install intake rocker arm shaft, with tis echelon end
pointing to the camshaft pulley side. Install exhaust rocker arm shaft,
with its direction reverse to the intake rocker arm shaft.
Intake rocker arm shaft
Camshaft pulley side

16) As shown in the figure, when the rocker arm, spring and rocker
arm shaft are installed, the rocker arm shaft bolts shall be tightened
Tightening torque
Exhaust rocker arm shaft

1. 14mm (0.55in.)
2. 15mm (0.59in.)
(b): 9~12Nm
Notice:
Valve adjusting bolts and nuts shall be preassembled before
installing rocker arms.
7. Camshaft and crankshaft timing belt pulley
1) First, fix the rear case seals and grommets on the timing belt rear
case, and then fit the gasket to the grommet.
1. Intake side
2. Exhaust side
2) Install camshaft timing belt pulley

Lock the camshaft by a special toll, and tighten the belt pulley bolts to a specified torque.
Tightening torque
(a): 55~60Nm (465)
57~61Nm (474)
Special tool:
1. Timing belt pulley rear case

2. Camshaft belt pulley
3. Belt pulley locating pin
4. Belt pulley bolt
(A): 09917-68227
3) Fix the tension pulley bottom plate on the tension pulley.
Insert the lock pawl of the tension pulley bottom plate into the holes.
4) Install the tension pulley, tension pulley bottom plate, spring
and spring buffer.
Still, do no use wrenches to tighten the tension pulley bolts and
stud bolts, but use hands alone. Check and make sure the tension
pulley bottom plate to move along the arrow direction as shown
in the figure so as to allow the tension pulley to move in the
same direction. If the bottom plate fails to move with the tension
pulley, both of them shall be removed again, and once more
insert the bottom plates lock pawl in the holes in the tension
pulley.
5) Before fixing the timing belt on the camshaft belt pulley and
crankshaft timing belt pulley, the cylinder head cap shall be
Valve adjusting nut

Valve adjusting screw
Tension pulley
Tension
pulley
bottom plate
Lock pawl
locking hole
removed.
When the cylinder head cap is removed, unscrew the valve adjusting
nuts first, and then the valve adjusting nuts in intake and exhaust
rocker arms. Turn the camshaft freely. In fixing the timing belt on
the (two) belt pulleys, tense the belt correctly by the elasticity of the
tension pulley.
Adjusting screw torque of intake and exhaust rocker arm:
18~20Nm465
1. Tension pulley belt

4. Tension pulley
2. Tension pulley stud bolt 5. Spring
3. Tension pulley bottom plate 6. Spring buffer
10~13Nm474
6) In case the camshaft fails to rotate freely, and the belt cannot be
correctly tensed the tension pulley, the camshaft belt pulley shall be
turned clockwise after all valve adjusting screws are slackened, as
shown in the figure. All the timing marks on the camshaft belt pulley
shall aim at the V sign at the belt side cover.
7) The method of installing timing belt locating slot is as follows:
aiming the concave side at the oil pump, and then install the slider
and timing belt pulley. The correct positions where these parts are
installed are as shown in the figure. After the crankshaft is locked,
tighten the belt pulley bolt.
1. Camshaft timing pulley 3. V sign

2. Timing mark
4. Belt side cap
Tightening torque of crankshaft timing belt pulley

(a): 55~60Nm (465) 120~130 Nm (474)
8) Turn the crankshaft clockwise to mate the 17mm wrench with the crank timing belt pulley bolt. Aim the punch
mark on the timing belt pulley to the arrow mark on the oil pump as shown in the
1. Timing belt
figure.
1. Timing pulley locating slot
2. Slider
3. Camshaft timing belt pulley
4. Belt pulley bolt
1. Crankshaft timing belt pulley bolt 3. Arrow mark

2. Punch mark
4. Crankshaft timing belt pulley
9) Once the two marks are aligned, fit the timing belt to the two belt pulleys,
with no looseness at the drive side. Push the tension pulley bottom plat upward
by hands.
Crankshaft direction
Notice:
In fitting on the timing belt, the arrow mark
on it shall be consistent with the rotation direction of the
crankshaft.
In this state, 4# piston shall be at the top dead center of the
compression stroke.
10) To eliminate the slackness, rotate the crankshaft two turns
clockwise when the belt is installed. Make sure the belt is not
slack, and then tighten the tension pulley adjusting plate bolt,
and then screw up the tension pulley bolt to the specified torque.
Finally confirm whether the two marks align with each other.
Tightening torque:
1. Tension pulley bottom adjusting plate bolt

2. Tension pulley bolt
(a): 15`23Nm (465) 23~28 Nm (474)

11) Install timing belts front case
Before installing it, be sure there is a seal between the water
pump and the oil pump housing, and another seal between the
water pump and the cylinder head (see the left figure); then make
sure the front case seal is fixed on the front case, with the seal
joint aiming at the front case step.
12) Install crankshaft bell pulley
1. Water pump
2. Cylinder head
3.Rubber seal
Install the locating pin of the crankshaft timing belt pulley in the
belt pulley pin hole, and tighten the belt pulley bolts
according to the specified torque.
Tightening torque
(a): 55~60Nm (465)
120~130 Nm (474)
8. Generator
Mount the generator and adjust the drive belts tension
according to the technical requirement.
For the technical requirement of the belt tension, see Water
Pump Belt Tension in this chapter.
1. Crankshaft belt pulley locating pin

2. Crankshaft belt pulley
Clutch plate and clutch housing

Install clutches and their housings.
As for the installation method, see Clutches in this chapter. All the bolts shall be tightened up according to
specified torque.
Notice:
On installing and connecting all the parts (components) and making sure they are well connected, check and
adjust the ignition timing. As for the steps of such checks and adjustment, see the Ignition System in the
following chapter.
Air-conditioner Compressor
Install the air-conditioner compressor and adjust the drive belts tension according to the specified technical
requirement. See the Check on Drive Belts in this chapter.
Valve clearance adjustment
Adjust the clearances of intake valves and exhaust valves; as for the adjusting steps, see the first chapter of this
manual.
. Installation method of engines

1) Lift the engine with a transmission to its mounting position, but the lifting device shall not detached.
2) Install the right engine support bolts.
3) Install the left engine support bolts.
4) Install the transmissions mounting bolts and nuts.
5) Tighten the bolts and nuts mentioned in the steps 2), 3) and 4) above to the specified torque.
Tightening torque
Mounting beam bolt of engines: 30~40Nm
Engine side bolts of the engine mounting bracket: 18~23Nm
Engine mounting nut: 23~28Nm
6) Detach the lifting device.
7) Install the rest parts in the reverse order of disassembly.
8) Tighten the gearshift lever bolts to the specified torque. Refer to the Installation of Gearshift Control
Mechanisms of the transmission system of chassis in this manual.
9) Adjust parking brake, which can be referred to Check and
Adjustment of Parking Brake of the chassis braking system in
the manual.
10) Tighten the front seat bolts to the specified torque.
11) Adjust the free stroke of the clutch pedal.
12) Adjust the clearance of the accelerator pedal cable .
13) Refill the engine with engine oil, and fill the transmission
with transmission oil.
14) Refill the cooling system.
15) Fill the refrigerant into the air conditioning system.
16) Check and adjust the air compressor (if equipped) and generator belts (water pump belt)
17) Check and adjust the ignition timing.
18) While finishing all work, check and make sure all joints have no leakage of fuel, cooling liquid and waste gas.
. Check
Compressors
Check the compression pressure of the four cylinders according to
the following requirements:
1) Heat the engine
2) Stop the engine after heated up.
3) Remove all the spark plugs.
4) Disconnect the wire harness connector of the ignition coil.
Warning:
Error in disconnecting the ignition coils wire harness connector
will produce sparks in the engine compartment, which may give rise to risks of explosion.
5) Fit the special tool (cylinder compression gauge) into the spark plug hole.
Special tools:
(A): 09915-64510-001
(B): 09915-64510-002
(C): 09915-64530
(D): 09915-64540
6) Separate the clutch (to lighten the engines starting load), and then press on the accelerator pedal till the throttle
opens totally.
7) Start the engine with a fully charged battery, and read the maximum pressure indicated on the cylinder pressure
gauge.
8) Repeat the steps from 5) to 7) for every cylinder to gain the readings of the 4 cylinders.
9) Upon checking, connect the ignition coils wire harness connector and install the spark plug.
Compression pressure
Model
EQ474i
Standard
1400kpa
EQ465i-21
9301340 kpa
Minimum limit
1200kpa
Maximum differential pressure

between any two cylinders
90kpa
Remarks
. Engine vacuum test

The engine vacuum formed in the intake manifold is a good
indicator value that reflects the engines state. The check of
vacuum shall be made according to the follow procedures.
1) Heat the engine to the normal working temperature.
2)While stopping the engine, remove the VSV (vacuum
switch valve) hose from the intake manifold, and then connect
the hose and the special tools (vacuum gauge and connector)
as shown in the figure.
Special tools:
(A): 09915-67310
(B): 09918-08210
3) Run the engine at a specified idle speed, and then read the
vacuum gauge reading.
The vacuum must be within the following specifications.
vacuum range: 53.3~66.7kPa (made at the specified idle
speed)
Engine speed: 300r/min or more
Intake manifold
Vacuum hose
. Oil pressure check

Notice:
Check the following aspects first before checking the oil pressure:
Oil level of the oil pan
If the oil level is too low, fill oil to the position specified by the dip stick.
Engine oil quality
If the engine discolors or deteriorate, change it.
Engine oil leakage
If there is leakage discovered, repair and remove it.
1) Clean the surrounding of the oil pressure switch.
2) Remove the oil
pressure alarm from the cylinder block.
3) Install special tools (engine oil pressure gauge)

Special tools:
(A): 09915-77310
(B): 09915-78211
1. Engine oil filter
4) Mount the engine speed recorder.

5) Start the engine and heat it up to the normal working temperature.
6) Once heated up, raise the engines speed to 3,000r/min, and then measure the oil pressure.
Oil pressure reading: 300~450.kpa, measured at 3,000r/min.
7) When the check on oil pressure is finished, shut down the engine and remove the oil pressure gauge.
8) Before re-assembling the engine oil pressure alarm, the threads of it must be wrapped by sealing tape. Tighten it
Notice: cut off the stretching part of the sealing tap from the engine oil pressure alarm threads.
Tightening torque: (a): 14Nm (465) 12~25Nm (474)
Special tools
1. 09915-64510-001 cylinder
pressure gauge
2. 09915-64510-002 adaptor
09915-47310
09915-67310 vacuum
pressure gauge
3. 09915-64530 hose
Engine oil filter wrench
1. 09915-77310
pressure gauge
engine
2. 09915-78211 engine oil

pressure gauge fitting
4. 09915-645430 accessory
1. 09916-14510 valve lifter

2.
09916-48210
remover fitting
valve
09916-34520
09916-34542
Reamer (7mm)
Reamer shank
09916-37310
Reamer (12mm
09916-57321
09916-46010
Valve guide installer handle
Valve guide remover
09916-84510
09916-77310
Forceps
piston ring compressor
09917-68221
09917-88210
09917-98210
09918-08210
Camshaft belt pulley holder
Valve guide installer
Valve stem seal installer
Vacuum pressure
hose coupling
gauge
Section Major troubles and troubleshooting method of mechanical engine

parts
Notice: see the steps given for corresponding positions in the Section for the adjustment, removal and
change of fault location in the table.
Troubles
Causes
Troubleshooting
The engine fails to start (fails to operate)
Poor starting (difficult

starting)
1.
Fuses are blown out.
Change
2.
Batteries run out of their energy.
Recharge
3.
The connection of battery terminals is

loose.
Wipe clean and tighten

Tighten
4.
Battery wire connection gets loose.
5.
The contacts in starting switches fail

to close, or starting switches suffer an
open circuit.
Change
6.
Starters solenoid switches are worn.
Change
7.
Starters brushes are worn.
Repair or change
8.
The magnetic field or armature

circuits of the starter disconnect.
Repair or change
Tighten or change
No spark
Adjust the clearance or change
1.
Fuses get loose or blown out.
2.
Spark plugs have failures.
3.
High voltage cables are short circuited

(ground wire).
4.
Ignition coils are damaged.
5.
Crankshaft position sensors

damaged or suffer poor contact.
6.
Repair or change
Change
Change
Repair or change
are
ECU is damaged or the circuits open.
Change
Change
Failures in intake and oil supply systems
Check or change
1.
Fueling
The idle adjuster (stepper motor) is
2.
damaged.
Change
Water temperature sensors are

damaged.
Clean or change
3.
Oil pump relays or fuses face failures.
4.
The fuel in the tank is inadequate.
5.
The Electric fuel pump fails to

operate.
6.
Fuel filters are clogged.
7.
Fuel pipes have air.
8.
The oil nozzle is clogged.
9.
The fuel pressure is inadequate.
10. Fuel hoses or pipes are clogged.
Start repeatedly
Change or clean
Check, adjust
Clean or change
Check, adjust
Check or change
Tighten
Change
Change
11. The oil inlet and return pipes are

connected reversely.
Change
12. ECU encounters failures.
Adjust
13. Intake manifolds get loose.
Change
14. Intake pressure sensors are damaged.
Change
15. Intake temperature sensors are

damaged.
Repair or Change
Abnormal internal state of the gasoline

engine
1.
The sealing gasket of the cylinder

head ruptures.
2.
The valve clearance is incorrect.
3.
Valve springs get weak or damaged.
4.
Timing belts are damaged.
5.
Valves fail to be tightly fitted.
6.
Valves are burnt.
7.
Valve guides are jammed.
8.
Intake manifolds get loose and leak

air.
9.
Pistons, piston rings or cylinders are
Change
Adjust or change the valve and
guide
Tighten; if necessary, change
the gaskets
Change the worn piston rings
and pistons; drill cylinder holes
if necessary
Change
worn.
10. The fuel brand is inconsistent.
Inadequate compression pressure
Adjust and repair
1.
Change
2.
Valves fail to be tightly fitted.
Change
3.
Valve stems are jammed.
Change
4.
Valve springs get weak or damaged
Change
5.
Piston rings leak air.
6.
Pistons, piston rings or cylinders are

worn.
Change worn parts, and drill

cylinder holes if necessary
Change
7.
Cylinder head gaskets suffer leakage.
Change
8.
Intake pressure sensors are damaged.
Change
9.
Intake temperature
damaged.
Change
sensors
are
10. Fuel pressure adjustors are damaged.

Ignition system failures
Underpower
1.
Spark plugs have failures.
2.
ECU has failures.
3.
High voltage cables have electric

leakage or get loose or ruptured.
4.
Crankshaft position sensors have

failures.
Adjust the clearance or change

Change
Connect or change if necessary
Repair or change
Change or clean
Repair or Change
Fuel system failures
Change
1.
Check, change
2.
The Electric fuel pump has failures.
Repair or Change
3.
Gas filters are clogged.
Change
4.
Fuel pressure adjustor is abnormal,

and the fuel pressure is inadequate.
Check, change
5.
Fuel tanks outlet pipes are clogged.
6.
Fuel tanks inlet pipes are clogged.
Adjust
Clean or change
Repair, adjust or change
7.
Fuel system connectors get loose.
8.
Accelerator cables are abnormal.
Abnormal intake system
Repair or Change
1.
The air filter gets dirty or clogged.
Adjust or change
2.
The idle adjuster is damaged.
Tendency of gasoline engine to overheat

1.
(See overheat)
Others
Troubles
1.
The brake drags.
2.
The clutch slips.
Causes
Troubleshooting
Electrical system failures

1.
Gasoline engine panting

(when the accelerator pedal
is pressed, the engine fails
to react temporarily; this
happens at any speed, and
is most serious when the
car
is
started
from
stopping).
The park plug is damaged or the

spark plug clearance is out of tune.
2.
Ignition coils deteriorate or crack to

cause leakage of electricity.
3.
High voltage wires leak current.
4.
ECU has faults.
5.
The throttle body has failures.
6.
Idle adjuster is damaged.
7.
The throttle
damaged.
Change or adjust the clearance

Change
Change
Change
Repair or change
position
Change
Change
sensor
is
Clean or change
Change
1.
Change
2.
The fuel pressure adjuster is out of

order.
3.
The electric fuel pump fails to

operate.
Gasoline engine failures

1.
The cylinder head gasket is damaged.
2.
The pistons, piston rings or cylinder

holes are worn, or the valves are
burnt.
3.
The water temperature sensor is

damaged.
4.
The water pump performance is poor.
5.
The radiator suffers leakage.
Lubricating system failures

1.
The oil filter is clogged.
2.
The oil filter screen is blocked.
3.
The oil pumps performance is poor.
4.
The oil pan or oil pump has leakage.
5.
The oil brand is inconsistent.
The oil in the oil pan is inadequate.

The brake drags.
The clutch slips.
Change
Change, and drill cylinder
holes if necessary
Change
Repair or change
Repair or change
Clean or change
Clean
Change
Repair
Change
Add
Repair or change
Adjust or change
Gasoline engine noise

Note: make a check to
make sure whether the
ignition timing is correct;
whether the specified spark
plug is used; whether the
specified fuel is used before
testing the mechanical
noise.
Noises caused by crankshaft
Change
1.
Change
The bearing shell is worn, or the

clearance is wide.
2.
The connecting rod bearing shell is

worn.
3.
The connecting rod is deformed.
4.
The main crankshaft journals are

worn.
5.
The crank pin is worn.
Noises caused by pistons, piston rings,

piston pins or cylinders
1.
Cylinder holes are abnormally worn.
2.
Pistons, piston rings and piston pins

are worn.
3.
The pistons are jammed.
4.
The piston rings are damaged.
Repair or change
Repair by grinding or change
the crankshaft
Repair by grinding or change
the crankshaft
Drill the cylinder hole to the
next reconditioning dimension
Change
Change
Change
Adjust
Others
1.
Troubles
The camshaft thrust clearance is too

wide.
Causes
Troubleshooting
Gasoline engine noise

Note: make a check to
make sure whether the
ignition timing is correct;
whether the specified spark
plug is used; whether the
specified fuel is used before
testing the mechanical
noise.
2.
The camshaft thrust clearance is too

wide.
3.
The valve clearance is great
4.
The gas in the gasoline engine is

inadequate.
Adjust
according
specification
to
Adjust according specification

Add

1.
2.
High fuel consumption
The connection of high voltage cables

has electric leakage or gets loose.
Repair or change
Clean, adjust or change
Spark plugs have failures (incorrect

clearance, much deposited carbon,
burnt electrode, etc.)
Change
1.
Repair or change
2.
The fuel pipe of the fuel tank has

leakage.
Repair or change
3.
4.
The oil nozzle cannot be closed

tightly.
5.
The air filter element is clogged.
6.
The intake
failures.
pressure
sensor
Clean or change
Clean or change
has
Change
See the above

Repair or change
Adjust
1.
The compression pressure is low.
Check and repair
2.
The valve fails to fit tightly.
3.
Repair or change
Adjust or change
Others
Adjust
1.
The brake drags.
Change
2.
The clutch slips.
3.
The tire pressure is incorrect.
4.
ECU is damaged.
oil leak
High fuel consumption
1.
The oil drain plug gets loose.
Tighten
2.
The fixing bolt of the oil pan gets

slack.
Tighten
3.
The oil pan sealing gasket is damaged.
4.
The oil seal leaks oil.
5.
The cylinder head cap has leakage.
6.
The oil filter is not tightly screwed.
7.
The oil pressure switch gets loose to

make oil flee.
Tighten
Tighten
Remove the deposited carbon

or change the piston ring
Oil flees
1.
The piston ring is jammed.
2.
The piston ring and ring groove are

worn.
3.
The opening position of the piston

ring is incorrect.
4.
The piston or cylinder is worn.
Change the piston and piston

ring
Adjust the opening position
Change the piston, and drill
cylinder holes if necessary
Change
1.
The valve oil seal is worn.
2.
The valve or valve guide is badly

worn.
Causes
Change
Change
oil leak around valve stems
Troubles
Change the seal gasket
Change
Troubleshooting
Surge (in driving at a

steady speed or normal
speed, changes take place
in the gasoline engine
power.
While
the
accelerator pedal is not
changed, the car is felt to
slow down).
1.
The gas filer is clogged.
Change
2.
The fuel pipe is bent, damaged

or has leakage.
Check, and change if necessary
3.
The electric fuel pump is out of

order.
4.
The intake manifold and throttle

body have leakage.

Change
Clean or change
5.
Change
6.
Change
7.
The intake pressure sensor is

damage.
Change
8.
The intake temperature sensor is

damaged.
9.
The fuel pressure adjuster is out

of order.
Repair or change
Test and repair, or change
Change
1.
The connection of high voltage

damper is loose or subject to
current leakage.
Change
2.
The spark plug breaks down

(too much deposited carbon,
incorrect clearance and burnt
electrode) .
3.
The crankshaft position sensor

breaks down.
4.
ECU goes wrong.

1.
The park plug goes wrong.
Adjust or change
2.
The connection of high voltage

cables leak current or is
disconnected.
Connect or change
3.
The crankshaft position sensor

breaks down.
4.
ECU goes wrong.
Change
Clean or change
Change
1.
Clean or change
2.
Change
3.
The air
clogged.
4.
5.
Unsteady
idling
(the
adjustment in the gasoline
engine idle speed is
incorrect.)
Change
6.
7.
8.
filter
element
is
Test or change
The intake manifold and

cylinder head gasket suffer
leakage.
The fuel pressure adjuster goes
wrong.
The intake
temperature
damaged.
Change
pressure
sensors
and
are
Adjust
Connect
Change
See the above
The throttle position sensor is

damaged.
The accelerator
incorrect.
Adjust
cable
is
Screw the bolts or nuts

Change
Check, repair
Change
Others
1.
The connection of vacuum hose

is loose or detached.
2.
The cylinder head

gasket suffer leakage.
3.
The cylinder
inadequate.
4.
The intake manifold bolts and

nuts get loosened.
5.
The intake manifold sealing

gasket has leakage.
6.
The signal lines of the air

conditioner are damaged.7
sealing
pressure
is
Abnormal detonation
1.
The spark plug is overheated.
2.
The ignition advance angle is

too large.
3.
ECU goes wrong.
Replace with a new one with a suitable heat

value
Adjust
Change

1.
The fuel pressure adjuster goes

wrong.
2.
The gas brand fails to meet the

requirements.
Abnormal detonation

1.
Too much carbon is deposited

on the piston top or the cylinder
head.
Adjust
Change
Clean

2.
ECU goes wrong.
Change
3.
The heat valve of the spark

plug is not right
Replace with a new one with a suitable heat

value
4.
The ignition advance angle is

too small.
Adjust
Overheat
Clean or change
1.
2.
3.
The intake
loosened.
manifold
Adjust
gets
Add cooling liquid
Cooling system failures

1.
2.
The
cooling
inadequate.
Tighten
liquid
is
Adjust or change
Change
The water pump belt gets slack

or damaged.
3.
The temperature regulator fails

to work normally.
4.

damaged
5.
The radiator fan fails to work

normally.
6.
The
air
mismatches.
conditioner
Change
Repair or change
Check or change
Emission influence factor and elimination method

Troubles
Causes
Troubleshooting
Gasoline engine
1.
The water temperature of the

gasoline engine fails to reach
the normal temperature.
The air filter is clogged.
3.
Air leakage
4.
Low cylinder pressure
5.
The fuel is not up to the mark.
Check, repair
Replace with qualified fuel
Check, repair
Fuel system
2.
3.
The oil tank evaporation control

system is out of order.
The fuel pressure
breaks down.
Change
Clean or change
adjuster
The fuel injector is clogged.
Intake and exhaust systems

1.
The
three-way
catalytic
converter is damaged.
Excessive emission of HC 2.
CONOx
3.
The oxygen sensor goes wrong.

The throttle position sensor is
damaged.
4.
The intake pressure sensor is

damaged.
5.

damaged.
6.
The thermostat is damaged.
7.
The vacuum tube leaks and is

blocked.
8.
Clean or change
Check, adjust
2.
1.
Check
The exhaust system leaks air.

1.
The spark plug breaks down.
2.
Cylinder
misfire
(some
cylinders fails to operate) High
voltage cables are subject to
poor contact or leakage
3.
ECU goes wrong.
Change
Check, change
Check, change
Check, change
Check, change
Check, change
Check, repair
Check, repair
Clean or change
Check, repair
Check, repair
Check, repair
Chapter Drive system

Section Five speed transmission
. Composition
The five speed transmission, a fully synchronized transmission, has five forward gears and one reverse gear. It
changes speed by three synchronizers and four shafts (input shaft, main shaft, intermediate shaft and reverse gear
shaft). All the forward gears are in constant mesh, and the reverse gear is of slide construction or setting wheel
structure.
The low speed synchronizer is fixed on the intermediate shaft, and is engaged with the first gear or the second gear
of the intermediate shaft, while the high speed synchronizer is mounted on the input shaft, and is engaged with the
third gear or the fourth gear of the input shaft.
The fifth gear synchronizer fixed on the input shaft meshes with the fifth gear on the main shaft.
The gear shift mechanism and the selector shaft are fixed on the top of the transmission housing, and are equipped
with cams to avoid direct reverse gear from the fifth gear.
For maintenance, the original sealant or an equivalent shall be used on the transmission case bonding surface. A
torque spanner may be used to tighten the bolts to the specified torque. All the parts shall be thoroughly cleaned
with cleaning agent and dried before assembly.
See page 162 for the structural drawing.
. Fault diagnosis
Trouble
Cause
Troubleshooting
The shift fork shaft is worn.

The shift fork or the synchronizer gear sleeve is
worn.
The guide spring suffers a loss in elasticity or
damage.
Out of gear
The bearings on the input shaft or the main shaft
are worn.
The chamfering teeth of gear sleeves and gears
are worn.
The split ring dislocates or falls off.
Change
Change
Change
Change
Change the sleeves and
gears
Install
Impossible to shift the

gears or disengage the
gears
The synchronizer spring suffers a loss in

elasticity or rupture.
The shift shaft or shift fork deforms.
The clutch pedal travel is not correct.

The friction plate deforms or fractures.
The Clutch pressure plate is damaged.
Difficult to shift gears
The synchronizer gear ring is worn.

are worn.
The shift shaft deforms.
Noises
Change
Change
Adjust
Change
Change
the
pressure plate
clutch
Change
Change the sleeves and
gears
Change
The lubricating oil is inadequate in quantity of

unsuitable in variety.
Add or change
Bearings are damaged or worn.
Change
Gears are damaged or worn.
Change
The synchronizer gear ring is damaged or worn.
Change

are damaged or worn.
Change
1. Input shaft
9. High speed synchronizer gear sleeve
17. Oil filler plug
2. Input shaft oil seal
10. The 4 gear of input shaft
18. The 5th synchronizer gear hub
3. Front housing
11. Extension shaft
19. The 5th synchronizer gear sleeve
4. Reverse gear shaft
12. Oil filler plug
20. Intermediate shaft
5. Reverse gear oil
13. Odometer driven gear
21. The 2nd gear of intermediate shaft
6. Rear housing
14. Main shaft
22. Low speed synchronizer gear
15. transmission extension case oil seal
23. Low speed synchronizer gear hub
8. High speed synchronizer gear hub
16. Odometer drive gear
24. The 1st gear of intermediate shaft
rd
th
1. Input shaft
16. Conical snap ring
30. Drive gear of intermediate shaft
2. Oil seal
17. Synchronizer gear ring (reverse gear)

th
3. Spring snap ring
18. Speed synchronizer gear hub of the 5 gear
4. Front shaft oil seal of input shaft
th
19. Synchronizer gear ring (5 gear)

th
31. Inner spacing collar

32. Intermediate shaft nut
33. Main shaft
5. Snap ring
20.The 5 gear/reverse gear sleeve
34. Bearing plate
6. Needle bearing
35. Front bearing of main shaft
22. Intermediate shaft front bearing
rd
7. The 3 gear bearing of input shaft
st
8. High speed gear sleeve
23. The 1 gear of intermediate shaft

rd
st
37. Rear bearing of main shaft
9. Synchronizer gear ring (3 )
24. Synchronizer gear ring (1 gear)
38. Steel ball
10. Synchronizer spring
25. Low speed synchronizer gear hub
39. reverse gear slide/setting wheel
nd
11. High speed synchronizer gear hub
26. Synchronizer gear hub (2 gear)
40. Gasket
12. Synchronizer slide
27. Low speed gear sleeve
13. Synchronizer gear ring

th

15. Rear bearing of input shaft
nd
28. The 2 gear of intermediate shaft
42. O seal ring
29. Intermediate bearing of intermediate shaft
43. Odometer driven gear assembly
.In-car maintenance
SAE viscosity number
Temperature
1. Change of engine oil
1) Before changing or checking the oil, stop the engine first and lift the car horizontally.
2) Once the car is lifted, check the oil level and make sure whether there is oil leak. If there is, repair it.
3) When the waste oil is drained, apply the sealant to the threads of the oil drain plug, and tighten it to the torque
specified in the following.
4) Fill new oil of given brand according to the specified quantity (till the level reaches the oil level hole)
5) Tighten the oil drain plug and oil filler plug to the specified torque below.
A: sealant 99000-31110
Tightening torque
(a): 36~54Nm (465), 30~37Nm (474)
Notice:
It is recommended to use API GL-5 85W- 90 GB13895-1999 gear oil.
When the car is lifted up for maintenance without changing the oil, it is still necessary to make checks for
the oil leak.
Engine oil specification: winter: 75W/90 GL-5 or 80 W/90 GL-5
Summer: 85W/90 GL-5, see the viscosity table on the above figure.
Oil volume: 1.3

2. Change of extension tank oil seal
1) Lift the car horizontally.
2) Make assembly marks on the joint flanges and the transmission shaft as shown in the figure.
3) Remove the 4 bolts in the rear transmission shaft flange, and then the transmission shaft.
4) Remove the oil seal with a screw driver.
5) Press the new oil seal in the extension tank with special tools and plastic hammers; the grease must be applied to
the oil seal lip.
A: grease 99000-25010
Special tool:
(A): 09940-51710
1. Assembly mark
1. Extension tank oil seal
6) Clean and check the front worn part (which is to contact the oil seal) of the transmission shaft; if there are
indents or scratches, treat and re-clean it, and then apply grease to the interior splines of the transmission shaft.
A: grease 99000-25010
7) Assemble the transmission shaft according to the assembly marks, and tighten the flange bolts of the universal
joint to the specified torque.
Notice:
Only given lock washers of bolts, nuts and universal joint flanges can be used.
Tightening torque
(a): 18~28Nm
8) Check the oil level, and add it to the specified level if necessary (the oil level should reach the oil level hole).
3. Gear shift lever and cable
1. Shift lever ball

2. Gear shift lever boot
3. Spacer
4. Elastic cushion
5. Shift cable assembly
6. Gear selector cable
7. Cable support
8. Cushion
9. Cushion plate
10. Gasket
11. E snap ring
12. Cable clamp
Disassembly
1) Remove the cable clamp and gasket at the transmission control end.
2) Unscrew the two bolts and remove the cable support from the rear transmission cap.
3) Remove the control box, and then remove the cushion plate the of the gear control cable.
4) Remove the shift and selector control cables from the shift lever assembly.
5) Unscrew the four bolts, and take out the shift lever assembly.
Installation
1) Apply the grease to the moving or sliding parts.
2) The lever ball, if removed from the lever, shall be applied with thread-locking glue before fixed on the lever.
Make sure the lever ball is aligned with the lever.
3) Install the lever assembly and relevant parts.
Notice:

2. Gear hub
3. Spring pin
Make sure the boot is correctly mounted.

Check if the lever can smoothly move after assembly.
Disassembly
1) Lift the car horizontally to a safe position.
2) Remove the odometer hose from the transmission.
3) Unscrew the bolts and take off the flexible shaft gear from the transmission.
Notice:
The a little transmission oil may flow out, so an oil reservoir
shall be placed under the odometer drive gear hole.
4) Take out the spring pin and remove the odometer driven gear.
Notice:
Use a pin remover of a diameter of 2.8~3.0mm to pull out the
spring pin.
1. Gear hub
2. Oil seal
In removing the spring pin, do not press or beat the driven gear.
5) Remove the oil seal from the hub.
Notice:
Use a L-type hand pushing device to take off the oil seal.
Assembly
1) Be sure that the O ring and the case are not damaged, and apply
grease to the O ring.
2) Apply grease to the driven gear, as shown in the figure.
3) Apply grease to the lip of the new oil seal; fix it on the bottom, with
the lip facing inward. A special tool shall be used for its assembly.
1. Driven gear
2. Gear hub
3. O ring
4. Spring pin
5. Oil seal
6. Bolt
A: grease 99000-25010
Special tool:
(A): 09916-46010
4) Check to make sure whether the odometer driven gear has abnormal wear or whether the gear shaft is bent; if
necessary, change them.
5)Insert the driven gear into the hub and fix it with a spring pin, making sure it can rotate smoothly.
6) Fix the gear hub assembly on the transmission and connect the odometer hose.
Tightening torque
(a): 10Nm (465), 9~12Nm (474)
7) Make sure the oil level complies with requirements.
5. Removal of transmission assembly
1) Remove the negative (-) and positive (+) lines from the battery terminals and lift up the car.
2) Remove the reversing light switchs plug connectors from the detachable joints.
3) Remove the black/yellow wire and positive line (+) from the starting motor.
4) Remove the battery negative (-) line from the transmission case and the remove the starting motor.
5) Undo the reversing light switch wires from the wire clip.
6) Detach the odometer hose from the transmission case.
7) Remove the oil drain plug, and discharge the transmission oil.
8) Remove the front transmission case, and detach the clutch cable from the clutch throw-out fork.
1. Clutch cable assembly

2. Clutch release rocking lever
3. Front transmission case
1. Reversing light switch plug connector

2. Odometer fitting
9) Remove the clip and gasket at the control cable end, and then strip off the shift cable and selector cable from the
levers.
10) Strip off the cable support.
11) Remove the transmission shaft.
12) Detach the right reinforcement and then remove the lower clutch separator from the transmission case.
1. Left reinforcement
2. Lower separator of clutch housing
3. Clutch housing
1. Clip at the control cable end

2. Rear gasket of control cable
3. Shift cable assembly
4. Shift selecting cable assembly
5. Control cable support
13) Unscrew the bolts that fix the engine cylinder and transmission case.
Notice:
Check again to make sure all connections are detached before removing the transmission.
14) Unscrew the transmission from the chassis and then fit the bolts and nuts.
15) Remove the transmission.
Transmission assembly
The assembly shall be in the reverse order of the
disassembly.
the specified torque is as follows.
Tightening torque
(a): 50Nm
(b): 55Nm
1. Bolt installed later

2. Cylinder block and
transmission case nut
3. Cylinder block and
transmission case bolt
4. Control cable support
bolt
(c): 61Nm
(d): 23Nm
Notice:
For easy assembly, after the input shaft is inserted
into the clutch disc, the fittings to be assembled later
then shall be fitted to the transmission.
For the tightening torque of the starting motor bolts, see Section , Chapter .
According to the stipulation above, fill a certain amount of gear oil.
Once the clutch cable is connected, adjust its clearance.
. Transmission repair
1. Transmission disassembly
Main shaft
1) Unscrew the transmission bolts to remove the transmission mounting elements, and the remove the extension
tank.
2) Remove the main shafts front limiting plate, and then take out the main shaft assembly with a metal bar and
hammer.
Notice:
Be careful not to damage the oil seal.
3) Remove
4) Unscrew
fork of the 5th gear.
bar
the 51.th Metal
reverse
gear rod.
2. Main shaft
Extension
tanktake out the selector shaft and shift
the 3.
bolts,
and then
5) Remove the split ring, and then take out the 5th gear speed synchronizer sleeve and gear hub assembly, the
reverse gear stop ring and cone
6) Remove the sleeve and the gear hub assembly.
1. The 5th reverse rod

2. The 5th gear shift shaft
3. The 5th gear shift fork
1. Input shaft
2. The 5th gear speed synchronizer gear hub
and sleeve assembly
3. Snap ring
7) Use the 5th gear shift shaft to push the low speed shift shaft so as to mesh the intermediate shaft with the input
shaft.
8)Undo the filling ring of the intermediate shaft, and then use the special tool to fix the 5 th gear speed synchronizer
gear hub, and finally remove the intermediate shaft nuts.
Special tool:
(A): 09927-25411
9) Remove the 5th gear shift shaft, synchronizer gear hub and special tool.
10) unscrew the 5 bolts and the take down the rear cover plate.
1. The 5th gear shift shaft 4 Intermediate shaft

2. Input shaft
3. The 5th gear speed synchronizer hub
1. Rear cover plate

2. Bolt
Shift fork, input shaft and intermediate shaft

1) Remove the intermediate shaft, intermediate bearing and spring snap ring.
2) Unscrew the 3 bolts, and take out the selector cable strut.
1. Spring snap ring
1. Selector cable strut

2. Selector cable strut bolt
3) Remove the shift stop bolt and the interlock bolt.

4) Remove the reversing light switch.
5) Remove the 3 bolts under the shift guide sleeve, and then pull out the shift and selector shaft assembly.
6) Remove the reverse gear bolt with gasket.
7) Remove the 5 bolts from the outside of the case, and the other 3 bolts from the front case.
8) Separate the front case and the rear case, and remove them.
1. Shift stop bolt

2. Interlock bolt from the 5th gear to
the reverse gear
3. Backup switch
4. Shift and selector shaft assembly
5. Shift guide sleeve case (box)
6. Shift guide sleeve case bolt
1. Front case
2. Rear case
3. Case bolt
bolt
9) Remove the shift fixed bolt, and take out the low speed fixed spring, high speed fixed spring and the 5 th gear
fixed spring and the 3 steel balls.
10) Remove the front bearing snap ring of the input shaft.
1. Shift fixed bolt

2. The 5th and
reverse gear fixed
spring (short)
3. High speed fixed
spring (short)
4. Low speed fixed
spring (long)
5. Steel ball
1. Input shaft
2. Input shaft front
bearing
3. Snap ring
11) Unscrew the two bolts, and remove the reverse shift lever.
12) Pull out the reverse gear shaft with a gasket, and then take out the reverse slide setting wheel.
13) Beat the input shaft end with a plastic hammer to push it out from the case, and then take out he input shaft
assembly and the intermediate shaft assembly, high speed shift shaft, low speed shaft and the 5the gear shaft and
reverse gear shaft.
14) Remove the input shaft oil seal from the front case if necessary.

2. Gasket
3. Reverse gear slide
setting wheel
4. Reverse rod
5. Bolt
2. Main shaft assembly
1. Front case
2. Input shaft
4. Low speed shift shaft
5. High speed shift shaft
Disassembly
1) Remove the spring snap ring as shown in the figure.
2) Stretch out from the rear bearing with a special tool.
Special tool:
(A): 09913-65135
1. Main shaft
2. Snap ring
1. Main shaft
2. Rear bearing
3) Remove the snap ring, and then take out the odometer drive gear and steel balls.
4) Remove the snap ring, and then pull out the front bearing with the remover and press.

2. Snap ring
3. Steel ball
1. Main shaft
front bearing
2. Remover
Check and assembly

1) Clean thoroughly all the parts and check whether they are abnormal, and change them if necessary.
2) If the synchronizer parts need a repair, check the clearances a between gears, between gears and chamfering
gear, and between gears and gear sleeves before determine the part to be changed.
Clearance a: standard 1.0~1.4mm
Maintenance limit: 0.5mm
1. Main shaft
2. The 5th gear speed
synchronizer gear ring
3) Apply gear oil to the front gear, and use a special tool and press to install it, and then fit the spring snap ring.
Special tool:
(A): 09940-51770
4) Mount the steel balls, odometer drive gear and the snap ring.
5) Apply gear oil for transmission case to the rear gear, and then install it with a special tool and press, and finally
mount the spring snap ring.
Special tool
(B): 09940-51770
1. Main shaft front bearing
1. Main shaft rear bearing
3. Input shaft assembly

Disassembly
1) Strip off the spring snap ring, and then use the bearing puller and press to take down the front bearing rom the
input shaft.
2) Remove the spring snap ring, and use the remover and press to pull out the rear bearing.
1. Input shaft
2. Front bearing
3. Bearing remover
3) Take out the 4th gear, needle bearing and high speed
synchronizer gear ring.
1. Input shaft
2. Rear bearing
3. Remover
4) Use a special tool to remove the snap ring.

Notice:
To remove the snap ring successfully, it is recommended to flatten the tool tip.
Special tool:
(A): 09900-06107
5) Use a remover to take down the high speed synchronizer gear sleeve, gear hub assembly and the 3rd gear.
Notice:
Make sure to use the flat side of the remover to avoid damaging the 3rd gear teeth.
6) Take out the needle bearing of the 3rd gear.
7) Remove the synchronizer gear sleeve and gear hub assembly.
1. Input shaft
2.
High
speed
synchronizer gear sleeve
and gear hub assembly
3. The 3rd gear
4. Remover (the flat
side upwards)
1. Snap ring
2. High speed synchronizer gear
sleeve
Check and reassembly

1) Clean thoroughly all the parts, and check if they are abnormal, and replace them with the new ones if necessary.
2) If the synchronizer parts need a repair, check the clearances between gears, between gears and chamfering gears,
and between gears and gear sleeves before determine the part to be changed.
Clearance a: standard valve 1.0~1.4mm
Maintenance limit 0.5mm
3)To make sure of lubrication, sweep the oil holes to ensure they are not blocked.
1. Gear
2. Synchronizer
gear ring
1. Input shaft
2. Oil hole
4) Apply grease to the front gear, and then use special tools and
press to fix them, and then fit the snap spring
Special tools:
(A): 09951-76080
1. Input shaft
2. front bearing
(B): 09940-54950
5) Fit the high speed synchronizer gear sleeve into the gear hub, and then
insert the three sliders into the gear sleeve, and finally mount the spring as
shown in the right figure.
Notice:
There is no specified direction for the sliders, but they shall be given
one in assembly.
The specification (dimension) of high speed synchronizer gear sleeves,
hubs, sliders, springs is between that of the low speed synchronizer
and the 5th gear synchronizer.
6) Fit on the 3rd gear needle bearing and apply grease to it.
7) Apply gear oil to the 3rd gear and synchronizer gear ring before installed.
1. Input shaft
2. The 3rd gear
3. Synchronizer gear ring
4. Gear sleeve and gear hub assembly
A. Slider groove
8) Use special tools and hammer to beat the high speed shift sleeve and gear hub parts.
Notice:
High speed synchronizer gear sleeve and gear hub
assembly do have specified mounting direction, which can
be referred to the figure in the step 5).
In pressing to assemble the shift sleeve and gear hub, make
sure the synchronizer slider groove aligns with the sliders of
the gear sleeve and gear hub assembly.
After the gear sleeve and gear hub assembly are installed
by pressing, check if the 3rd gear can rotate flexibly.
The synchronizer gear rings of the third gear and the
fourth gear are the same.
1.
High
speed
synchronizer spring
2. Slider
3. Gear hub
4. Gear sleeve
5. The 3rd gear
Clutch side
(The 3rd gear side)
A=B
C: Long flange (clutch side)
D: Slider groove
Special tool:
(C): 09913-84510
Clutch side
9) Mount the snap ring in a proper direction, as shown in the

figure; apply gear oil to the needle bearing before installed.
1. Rear bearing
1. Snap ring
4. The 4th gear
2. Needle bearing 5. Input shaft
3. Synchronizer gear ring 6. Synchronizer gear hub
Notice:
Make sure the snap ring is firmly fitted to the groove.
10) Install the synchronizer gear ring. The sliding part of the 4th gear shall be applied with gear oil before assembly.
11) Install the bearings by pressing them with a special tool and hammer, and then mount the spring snap ring.
Special tool
(D): 09925-98221
4. Intermediate shaft assembly
Disassembly
1) Remove the snap ring, and then use the special tool, remover and press to push out the front bearing.
Special tool:
(A): 09913-85230
2) Take out the first gear, the first gear needle bearing and synchronizer gear ring.
3) Make use of a special tool to take down the spring ring.
Notice:
The tool tip shall be flat so as to make the removal of snap spring easy.
Special tool:
(B): 09900-06107
2. Bearing remover
2. Snap ring
4) Press the remover in the 2nd gear, and then use the press to
pull out the low speed synchronizer gear sleeve and gear hub
assembly with gears
5) Remove the synchronizer gear sleeve and gear hub assembly.
6) Strip off the needle spring from the shaft.
7) Set the remover on the drive gear, and pull out the rear
bearing inner spacer and gear with help of the remover and metal
bars squeezing as well as the press.
1. Metal bar
2. Rear bearing inner spacer
3. Intermediate shaft drive gear
4. Remover (the flat side upwards)
Notice:
Make sure the flat side of the remover is used to avoid damage to the drive gear teeth.
1. Low speed synchronizer gear
sleeve and gear hub assembly
2. The 2nd gear
3. Remover
1. Intermediate shaft intermediate bearing
8) Remove the snap ring, and then use the remover and press to take out the intermediate bearing
Check and reassembly
1) Clean thoroughly all the parts, and check if they are abnormal, and replace them with the new ones if necessary.
2) If the synchronizer parts need a repair, check the clearances a between gears, between gears and chamfering
gears, and between gears and gear sleeves before determine the part to be changed.
Clearance a: standard value 1.0~1.4mm
Maintenance limit 0.5mm
3) Mount the 2nd gears needle bearing, and apply gear oil to it.
4) Apply gear oil to the 2nd gears sliding part before fixing the 2nd gear and the 2nd gear synchronizer gear ring.
Notice:
The slider groove width of the 1st gear synchronizer gear ring is smaller than the 2nd synchronizer gear
rings.
Width difference: width b: 8.2mm c: 8.8mm
1. Gear
2. Synchronizer
gear ring
1. The 1st synchronizer gear ring

2. The 2nd synchronizer gear ring
1. Low speed synchronizer

spring
2. Slider
3. Gear
4) Fit the low speed synchronizer gear sleeve into the gear hub,
and hub
insert three sliders, and finally mount the
4. Gear sleeve
spring as shown in the right figure.
Clutch side
Notice:
A=B
C: slider groove
There is no specified direction for the low speed synchronizer gear hub and sliders, but they shall be given
one in assembly.
The dimension of low speed synchronizer sliders and springs shall be larger than that of the high speed
synchronizer and the 5th gear synchronizer.

6) Use a special tool and hammer to tap into the low speed
synchronizer gear sleeve and gear hub assembly.
1. Low speed synchronizer sleeve and gear hub assembly
Notice:
2. The 2nd gear synchronizer ring
3. Intermediate shaft low speed synchronizer
In pressing to assemble the gear sleeve and gear hub assembly,
A: sliding chute aligns with the slider
make sure the synchronizer gear rings slider groove aligns
with the sliders.
Check if the 1st gear and the 2nd gear can rotate flexibly after
the gear sleeve and gear hub assembly are mounted by
pressing.
Special tool:
(A): 09940-53111
(B): 09913-85210
7) Install the snap ring in proper direction as shown
in the right figure.
Notice:
Make sure the snap ring is firmed fitted to the
groove.
8) Install the needle bearing and apply gear oil to it,
and finally mount the 1st gear synchronizer gear
ring.
Apply gear oil to the 1st gears sliding part before
installed.
9) Apply gear oil to the front bearing, and install
them with a special tool and press, and finally
mount the spring snap ring.
4. Needle bearing
2. The 2nd gear
5. The 1 st gear ring
3. Low speed synchronizer gear sleeve and gear hub assembly 6 The 1st gear
Special tool:
(A): 09913-85210
10) Apply gear oil to the intermediate bearing and install it with a special tool and hammer, and finally mount the
spring snap ring.
Special tool:
(B): 09941-74910
2. The 1st gear

11) Use the same special tool to knock in the intermediate shaft drive gear.

2. The 1st gear
12)Use a special tool and hammer to assemble the rear

bearing inner spacer by pressing it.

1. Rear bearing inner spacer

Special tool:
(C): 09925-98221
13) The outer surface of the spacer shall be applied with
gear oil.
5. Shift fork
Shift and selector shaft assembly
1) To remove parts, the special tools and 2.8-3.0mm pin remover shall be made use of.
Special tools:
(A): 09922-85817(4.5mm)
(B): 09925-78270(6.0mm)
2) Clean thoroughly all the parts,
and replace them with new parts if
necessary.
3) Assemble the parts in the reverse
order of the disassembly.
4) Apply lubricating oil to the oil
seal lip when it is changed.
A: grease 99000-25010
Notice:
In knocking in the spring pin, a
wooden block shall be support it
to avoid the shaft bending.
1. C ring
11. Cam guide gear return spring
2. Gasket
12. Cams of the 5th gear and the reverse

gear
Assemble the cams of the 5 the

gear and the reverse gear by
rolling the cam guide sleeve
return spring, and then knock in
the spring pin.
3. Low selector spring
13. Shift and selector shafts
4. Interlock plate
14. Reverse selector spring
5. Shift lever and selector lever
15. Guide sleeve case
6. External pins of shift and selector levers
16. Oil seal
7. Internal pins of shift and selector levers
17. Oil rubber sleeve (check ring)
th
Fix the positions of the low

speed selector spring (green) and
the reverse gear selector spring
(yellow) correctly.
8. Cam guide sleeves of the 5 gear and the reverse
18. Shift cable rod
gear
9. Cam guide pin
19. External pin of shift cable rod
10. Reverse gear interlock shaft pin
20. Internal pin of shift cable rod
Check
Shift shafts of high gear, low gear, the 5th gear and the reverse
gear:
1) Use a feeler to check the clearance between the fork and the gear
sleeve; if the clearance exceeds 1.0mm, the limit, these parts shall be
changed.
Notice:
To make a correct judgment of whether the parts need to be
changed, a careful check shall be paid to the contact site of the
fork and the gear sleeve.
Clearance a: maintenance limit 1.0mm
2) Install the shift shafts in the tank, and check if they rotate flexibly.
If they fail to rotate flexibly, use such tools as oil stone, reamer or
like to trim them.
1. Shift fork
2. Synchronizer gear sleeve
6. Transmission assembly
Front and rear cases
1) Mount the oil seal facing the input shaft spring side to the clutch side with a special tool and hammer. Apply
grease to the oil seal lip.
A: Suzuki super grease A 99000-25010
Special tool
(A): 009941-74910
2) The oil groove, if removed already, shall be installed with
bolts applied with thread lock cement.
B: thread lock cement: 1322, 99000-32110
Tightening torque
(a): 18~28Nm
3) Connect the input shaft, intermediate shaft, low speed
gear shift shaft, high speed shift shaft and the 5th gear and
reverse gear shaft assembly, and then fit them into the front case.
Notice:
Tap the shaft with a plastic hammer to install the input
shafts front bearing in the front case.
Notice:
To avoid damage to the oil seal, wrap the spline groove of
the input shaft by nylon tapes in assembly.
4) Mount the reverse gear lever, and fix it with 2 bolts with
thread lock cement.
B: thread lock cement 1322, 99000-52110
Tightening torque
(a): 18~28Nm
5) Fit the reverse gear slide setting wheel to the reverse lever,
and then insert the reverse shaft with gear oil in the case
through the slide setting wheel, and finally align the A on the
shaft with the B on the case.
1. Front case
2. Input shaft
4. Low speed shift shaft
5. High speed shift shaft
6. The 5th gear and reverse shift shaft
1. Reverse lever
2. Reverse lever bolt
4. Gasket
5. Reverse slide setting wheel
6. Front case
Notice:
Make
mentioned
sure the gasket is fitted into the gear shafts

above.
6) Clean the
and
then
evenly.
two fitting surfaces of the front and rear cases

apply sealant on the front case fitting surface
Sealant:
7) Tighten the
torque.
1. Front case
2. Oil groove
plate
3. Bolt
Suzuki Bond NO.1215, 99000-31110

case bolts from the outside to the specified
Tightening torque
(a): 18~28Nm
8) Fit the reverse shift shaft bolts with aluminum gasket, and tighten them up.
1. Input shaft oil

seal
Tightening torque
1. Rear case
2. Front case
3. Case bolt
4.
Reverse
shaft bolt
(b): 18~28Nm
9) Fit the other 3 bolts from the front case, and tighten them up to the same torque.
10) Check if the fixed spring are aged, and change the if necessary.
11) Install the steel balls and fixed spring in the shaft
respectively, and tighten them up with bolts applied with thread
lock cement.
A: thread lock cement 1322, 99000-32110
Tightening torque
(a): 13~20Nm
Main shaft
1) Mount the intermediate shaft, intermediate bearing spring
snap ring and rear case plate, and secure them with 5 bolts
1. Shift fixed bolt
2. The 5th gear and reverse gear fixed bolts
3. High speed setting spring
4 Low speed setting spring
5. Steel ball
applied with thread lock cement.

A: thread lock cement 1522, 99000-32110
Tightening torque
(a): 23Nm
2) Push the low speed gear shift shaft by the 5th gear shift shaft to mesh the intermediate shaft with the input shaft,
as shown in the figure.
3) Install the 5th speed synchronizer gear hub with special tools to make the shaft not rotate.
Special tool
Free length of setting
spring
Standard
Maintenance
limit
High gear, 5th gear

and reverse gear
36.7mm
35.6mm
Low gear
46.7mm
45.6mm
(A): 09927-25411
4) Screw the nut of the intermediate shaft, and
tighten it to the specified torque.
1. Input shaft
2.
Intermediate
shaft
3. Rear case plate
4. Bolt
5. Rear case
1. Reverse gear brake cone

2. Reverse gear brake ring
Tightening torque
(a): 68Nm
5) Take down the special tool, and stuff the nuts at A with a
caulking tools and a hammer.
6) Put the reverse gear brake cone in place, and apply gear oil to
the cone, and then fit on the reverse gear brake ring.
1. The
2. Inp
3. T
synch
4. Inte
5. Inte
7) Assemble the 5th gear speed synchronizer gear sleeve and

the gear hub with sliders and springs.
Notice:
The long flange C in the gear hub and the chamfers tooth
space E in the gear sleeve shall be matched inwardly (rear
case side)
8) Install the 5th gear synchronizer gear sleeve, gear hub
assembly and the long flange facing the rear case side.
9) Mount the snap ring in the correct direction, as shown in the

figure.
Notice:
Be sure the snap ring is firmly fixed in the groove.
1. The 5th gear shift fork

2. The 5th gear shift shaft
3. The 5th gear reverse lever
4. The 5th gear shift fork bolt
5. Reverse gear lever bolt
1. Input shaft
2. The 5th gear speed synchronizer gear hub and sleeve assembly
3. Spring ring
10) Fit on the 5th gear shift fork gear sleeve

and gear hub assembly, and then the 5th gear
shift shaft.
11) Tighten up the 5th gear shift fork bolts
with thread lock cement.
A:
thread
99000-52110
lock
cement
1322,
Tightening torque
(a): 10Nm
A=B
C: clamping flange
D: Slider groove
E: Chamfer tooth space
12) Fit on the 5th reverse lever, and screw the bolts with thread lock cement.
B: three lock cement 1322, 99000-32110
Tightening torque
(b): 8~14Nm
1. The 5th gear speed

synchronizer spring
2. Slider
3. Gear hub
4. Gear sleeve
Extension tank
1) Refer to section to install oil seal if it has been removed.
2) Install the main shaft assembly in the extension tank with a special tool and hammer, and then tighten the front
bearing plate bolt to the specified torque.
Special tool:
(A): 09925-98210
Tightening torque
(a): 18~28Nm
3) Clean up the dirt on the two fitting surfaces of the extension tank and the rear case. Apply sealant to the fitting
surface of the rear cast evenly before assembling the rear case and the extension tank. Finally tighten them up with
7 bolts.
A: sealant 99000-31110
Tightening torque
(a): 18~28Nm
1. Main shaft assembly

2. Front bearing plate
3. Front bearing plate bolt
4. Extension tank
Gear shift and selector shaft assembly

1) Clean the fitting surfaces of the rear case and the
shift guide sleeve case. Apply evenly a layer of
sealant to the rear cases fitting surface, and then
install the shift and selector shaft assembly.
A: sealant 99000-31110
Notice:
In fitting shift and selector shaft assembly, put the gear in the neutral position so as to move the gear shift
lever smoothly.
2) Tighten the 3 bolts to the specified torque.
Tightening torque
(a): 13~20Nm
3) Fit on the interlock guide sleeve bolts from
the 5th gear to the reverse gear (applied with
thread lock cement), and shift catch bolts
(applied with thread lock cement) and reversing
light switch.
B: thread lock cement 7322, 99000-32110
Tightening torque
1. Extension tank
2. Rear case
3. Extension tank bolt
(b): 23Nm
(c): 20Nm
4) Install the selector cable rod and fasten them with 2 bolts
Tightening torque
(a): 23Nm
5) Check if the input shafts of all gears can rotate. Use a ohmmeter to determine whether the reversing light switch
at the reverse gear can function normally. They shall be subject to conduction when at the reverse gear.
1. Selector cable rod
. Required servicing materials

Materials
Recommended Suzuki
product
Use
Control cable rear gasket

Odometer driven gear
Suzuki super grease A
lithium lubricating oil (grease)
(99000-25010)
Odometer driven gear case O seal

ring
Odometer driven gear case oil seal
Extension tank oil seal
Front end of drive shaft
Gear shift shaft oil seal

Input shaft oil seal
Fuel drain and fuel level plug

Suzuki BONDNO.1215
Sealant
(99000-3lll0)
Fitting surface of transmission case

Fitting surface of gear shift guide
sleeve case
Lever ball handle
Reverse lever bolt
Sump bolt
Thread lock cement
Thread lock cement

1322
(99000-32110)
Rear case plate bolt

Interlock guide sleeve bolt from the
5th gear to the reverse gear
The 5th gear shift fork bolt
Gear shift catch bolt
Gear shift fixed bolt
. Special tools
Spring snap ring pliers

(open type)
Bearing installer
Gear hub clamp
Bearing puller
Bearing installer
Bearing installer
Bearing installing
attachment
Bearing installer
attachment
Bearing installer
4.5mm spring pin

remover
Valve guide installer
Bearing puller
attachment
6mm spring pin

remover
Bearing installer
Bearing installer
Bearing installer
Input shaft
bearing installer
Section Clutch
. Composition
The clutch is single-plate dry diaphragm spring clutch. The diaphragm spring is a conical diaphragm spring, which
is composed of a ring outside and a group of inner conical pointer. The clutch plate is furnished with three tension
coil springs which is connected to the transmission input shaft by splines and can slip axially.
The clutch case assembly is fixed on the flywheel, while the diaphragm shall be such installed that the fixed part of
the diaphragm spring is able to push the pressure plate to the flywheel (equipped with clutch discs ) when the
release bearing withdraws. This is the clutch engagement.
When the clutch is treaded, the release bearing will move forwards to push the spring conical pointer. Then the
diaphragm will push the pressure plate to divorce from the flywheel, and thus the driving force transferred by the
flywheel to the transmission input shaft through clutch plate is cut.
1. Clutch case
2. Pressure plate
3. Diaphragm spring
4. Release bearing
5. Release fork
6. Upper transmission case
7. Clutch plate
8. Release fork return spring
9. Input shaft bearing
10. Input shaft
11. crankshaft
12. Flywheel
. Trouble diagnosis
Troubles
clutch slipping
Causes
Troubleshooting
The free pedal travel of clutches is improper.
Adjust the free travel
Clutch discs are worn or smeary..
Change clutch discs
Clutch plates pressure plates or flywheel

surfaces deform.
Change clutch discs, clutch

pressure plates or flywheels
The elasticity of diaphragm spring becomes

weak.
Change clutch cases

Change the cable
The clutch cable is corroded.
Difficult clutch
release
The free pedal travel of clutches is improper
Adjust the free travel
The diaphragm spring becomes weak in

elasticity or gets worn.
Change clutch cases
The spindles of input shaft are corroded.

The spindles of transmission input shaft are
damaged or worn.
The clutch discs swing seriously.
Lubricate
Change the input shaft
Change clutch discs
Change clutch discs
The clutch disc is worn or smeary.
Clutch vibrating
Clutch discs are burnished (like glass)
Repair or change clutch discs
Clutch discs are greasy.
Change clutch discs
Release bearings fail to slide smoothly on the

input shaft bearing retainer.
Lubricate or change input shaft

bearing retainer
Clutch discs swing or have poor contact.
Change clutch discs
The torsion spring in the clutch plate get

weak.
Change clutch discs
The rivets of clutch discs get slack.
Change clutch discs
The pressure plate or flywheel surface

deforms.
Change clutch cases or flywheels
The mounting cushion of engines gets weak,

or mounting bolts or nuts get loose.
Clutch noise
Re-tighten or change the mounting

cushion
The release bearing is worn or damaged.
Change the release bearing
The front bearing of input shaft is worn.
Change the input shaft bearing
Clutch disc hubs are too loose.
Change clutch discs
Clutch discs have cracks.
Change clutch discs
Pressure plates or diaphragm spring get

loosened.
Change clutch cases
Clutch discs are greasy.
Change clutch discs
Clutch discs are badly worn.
Change clutch discs
The rivets project over the disc surface.
Change clutch discs
Tension springs get weak.
Change clutch discs
Clutch drag
1. Free pedal travel of clutches
1) Tread the clutch pedal till a resistance is felt, and then measure the distance (free pedal travel of the clutch). The
free pedal travel shall be with the specified range.
Free pedal travel a: 10~15mm
2) If the free travel is not within the specified range, it can
be adjusted by the turning the cable adjusting nut.
1. Cable adjusting nut
2. Oil pan
1. Clutch pedal
3) Upon checking the freed pedal travel of the clutch, check if the clutch functions normally when the engine is
started.
2. Cable alignment chart
A view
B view
C view
1. Bottom plate
2. Sleeve
3. Compression rod mounting bracket
4. Cross bar
5. Water pipe
6. Brake pipe
In fitting the clutch pedal shaft arm to the clutch pedal shaft, the punch mark shall be aligned, as shown in the
7. Air conditioner hose (if equipped)
8.figure.
Cable adjusting nut
Before installing cables, apply grease to the pins, rivets and shaft arms.
A: grease 99000-25010
. Parts repair

2. Flywheel
3. Clutch disc
4. Clutch case
5. Clutch bolt cover
6. Release bearing
7. Release fork
8. Release fork clamp
9. Release bearing clamp
10. Return spring
1. Clutch cable
2. Rivet
3. Pin
4. Clutch pedal shaft arm
5. Punch mark
6. Clutch pedal shaft
Disassembly/ assembly
See the Disassembly/Assembly of Manual Transmission in the Section for disassembly/assembly.
1. Clutch pressure plate, clutch disc and flywheel
Disassembly
1) Clamp the flywheel with a special tool (A) to remove the clutch pressure plate bolt, clutch case and clutch disc.
Special tool
(A): 09924-17810
2) Draw the input shaft bearing with a special tool (B) and wrench.
Special tool
(B)0991758010
1. Bolt
2. Clutch case

2. Flywheel
Check
Input shaft bearing
Check if the bearing can rotate smoothly, and change it if there are
abnormalities.
Clutch disc
Measure the sinkage of the rivet head, that is, the distance from the Revit head to the clutch disc surface. If the
depth of any hole exceeds the operating limit, the clutch assembly shall be changed.
Rivet head depth
Standard: 1.2mm
Operating limit: 0.5mm
Clutch case
1) Check if the diaphragm spring is abnormally worn or damaged
2) Check if the pressure plate is worn or has partial ablation.
3) If any abnormality is found, change the assembly, while the diaphragm and pressure plate shall not be
disassembled.
Flywheel
Check if the contact surfaces of clutch discs are abnormally worn or
have partial ablation, and change them if necessary.
Assembly
Notice:
Make sure the surfaces of the flywheel and the
pressure plate are clean and dry before assembly.
1) Fit the flywheel to the crankshaft, and tighten it to the
specified torque.
Special tool
(A): 09924-77810
1. Diaphragm spring
2. Pressure plate
Tightening torque
(a): 40~45 Nm
2) Fit the input shaft bearing to the flywheel with a special tool.
Special tool
(B): 09925-98210
1. Flywheel
2. Bolt
3) Align the clutch disc with the flywheel center with a special tool, and then fit on the clutch case and bolts, and
tighten them to the specified torque.
Notice:
In tightening the clutch case bolts, press the clutch discs down firmly with a special tool (c) and make sure
the clutch discs align with the center.
Screw up the pressure plate bolts evenly in the diagonal order.
Special tool
(A): 09924-17810
1. Clutch case
(C): 09923-35550
Tightening torque
(a): 18~28 Nm
4) Apply a little grease to the input shaft, and then connect the transmission assemble with the engine. Refer to
Section for the installation steps.
1. Release bearing
2. Clutch release fork
3. Input shaft
A: grease 99000-25210
Notice:
While inserting the transmission into the clutch disc, turn
the crankshaft with a wrench from the front side till it
meshes with the splines.
2. Clutch release fork
Disassembly
1) Remove the release fork return spring and release fork
clamp.
2) Remove the release fork and release bearing together.
1. Release fork
2. Release bearing
3. Return spring
Check
Clutch release bearing
Check if the clutch release bearing can rotate smoothly, and change it if
there is any abnormality.
Caution:
Do not wash the release bearing, or it will wash off the grease and
thus damage the bearing.
Clutch release fork
Check to make sure whether the clutch release fork and its clamp are damaged or deformed. The clutch fork return
spring shall be checked as well. If there is any abnormality or deformation, change them.
Assembly
1. Release fork
2. Release bearing
3. Bearing clamp
4. Fork clamp
5. Return spring
Assemble them in the reverse order of disassembly, and pay attention to the following requirements in assembly:
Apply grease as shown in the figure.
A: grease 99000-25010
B: grease 99000-25210
Fit the release bearing, return spring and clamps to the release fork, as shown in the figure.
. Servicing materials
Materials
Recommended Suzuki products
Use
Clutch pedal shaft arm
Suzuki superior grease A

Clutch release fork
Lithium grease
Suzuki superior grease 1
(99000-25210)
Front end of the input

shaft spline
. Special tool
Bearing puller
Clutch center guide device
Flywheel localizer
Input shaft bearing installer
Section Drive shaft

. Composition
The drive shaft assembly is composed of a drive shaft, front and rear universal joints. The drive shaft connects the
cone drive gear shaft wheel by a flange joint and connects transmission output shaft by a sliding spline.
The front universal joint has an inner spline sleeve, in which the spline of transmission input shaft is installed. The
rear universal joint, a flange joint, is connected with the flange fixed on the differential front end by bolts.
The cross of every universal joint is equipped with 4 needle bearings.
1. Drive shaft
2. York
3. Front universal joint
4. Rear universal joint
1. Drive shaft
Maintenance
Universal joint noise
If there is doubt about clatter or vibrating sound in the universal
joints, check them to make sure whether they are worn, whether the
crosses are worn or whether the splines are worn. Replace the drive shafts that have noises with the new ones. The
universal joint noises are easy to be distinguished from other noises, or the rhythm of the clatter or vibrating sound
is consistent with the driving pace at constant speed. Especially in starting from the state at rest or in free wheeling
(when the engine is found to disengage in power transmission), the noises are particularly noticeable.
Disassembly
1) Lift up the car and place it safely.
2) Make an assembly mark on every joints flange and drive shaft before the drive shaft is removed, as shown in the
figure.
3) Remove the drive shaft bolts.
4) Remove the drive shaft.
Notice: there will be some transmission oil flowing out then.
1. Assembly mark
2. Drive shaft
3. Universal joint flange
Disassembly
Disassembly of drive shaft yoke
1) Use a special tool (A) to remove 2 snap rings
Special tool
(A): 09900-06108
2) Use a special tool (B) to pull the cross bearing race out 3~4mm
from the yoke race
Notice:
Apply permeable lubricant between the bearing race and the yoke race before pulling out the cross bearing
race.
Special tool:
(B): 09926-48010
Length a: 3~4mm
3) Hit the drive shaft yoke with a hammer to remove the bearing
race thoroughly.
4) Remove the bearing race at the other side with the same
method as 2) and 3).

Disassembly of flange yoke
Pull out the bearing race at the flange yoke side with the same method as 1) and 2). Then hold the bearing race with
a vice, and hammer the flange yoke to take out the race (see figure). Remove the bearing race at the opposite side
with the same method.
Notice:
Fit the removed bearings to the cross temporarily so as to remount
them on their original positions.
Check
Check if the drive shaft and flange yoke are damaged, and give a check to
the radial run-out of the drive shaft as well. If there is damage or the radial
run-out exceeds the limit, change the drive shaft or the flange yoke.
Drive shaft
limit:0.7mm
radial
run-out
Assembly
1. Vice
Notice
Make sure the needles in the
cross bearing race are evenly
installed in place.
Be sure to apply grease to the cross bearing race.
A: grease 99000-25030
Notice:
In reassembly, be sure to use new snap rings, crosses and bearings. The
old removed snap springs, crosses and bearing are not permitted to
reuse.
1) Insert the bearing race into the yoke and hammer it to be flush with the
yoke surface. Meanwhile, insert the cross into the bearing race to avoid the
needles in the bearing race rolling out.
1. Cross
2. Bearing
2) Insert the bearing race at the opposite side into the yoke and hammer it to be flush with the yoke surface.
3) Insert the bearing race into the flange yoke at the other side with the same methods as 1) and 2).
4) In knocking in the bearing race, a metal plate shall be placed
on the bearing race to avoid damage to the yoke.
5) Fix the shaft and flange yoke of universal joint with 4 snap
rings.
1. Copper hammer
2. Bearing race
3. Yoke
4. Cross
Notice:
Check and make sure the shaft yoke and flange yoke can rotate flexibly after assembly.
Make sure every snap ring is firmly fitted into the groove.
Assembly
Assemble the drive shaft in the reverse order of disassembly, and pay attention to the following main points:
In assembling the drive shaft, the assembly marks shall be aligned, or there will be vibrating in driving.
Tighten the universal joint flange to the specified torque below.
Tightening torque
(a): 18~28Nm
Notice:
If the transmission oil flows away in removing the drive shaft, the specified gear oil shall be filled in the
transmission case to the specified level.
Material
Recommended Suzuki products
Use
Lithium grease
Super grease C (99000-25030)
Apply to cross bearing race
. Special tools
Spring snap ring

forceps
(clamped type)
Universal joint puller
Section Differential
. Composition
The differential is made up of the parts as shown in the figure. The gear drive mechanism of this differential is of
hypoid design, and its drive gear and driven gear are hypoid gears. This means the driven gear is installed slightly
below the drive gear centerline. Thus, the height of the car body can be reduced in design. Gear engagement will
result to frictional contact and slippage. This is why the differential shall use the specified hypoid gear oil.
1. Bevel drive/driven gear
2. Differential case
3. Differential bearing
4. Differential adjusting screw
5. Side gear
6. Planetary gear
7. Side gear adjusting shim
8. Planetary gear shaft
9 Planetary gear adjusting shim
10, 14. Drive gear shaft bearing
11. Drive gear shaft adjusting shim
12. Drive gear sleeve
13. Differential oil seal
15. Mounting bolt
. Trouble diagnosis
Troubles
Causes
The gear oil deteriorates or contains water.
The gear oil is inadequate or the brand is wrong.
The clearance between the bevel drive gear and the
bevel driven gear is incorrect.
Gear noises
The meshing contact of the bevel drive gear and the
bevel driven gear is improper.
Troubleshooting
Change and refill the
oil
Change or refill the
oil
Adjust
Adjust or change
The fixed bolts of the bevel driven gear get loose.
Change or re-tighten
The differential side gear or the drive gear is damaged.
Change
(Unchanged noise) the gear oil deteriorates or contains

water.

oil
(Unchanged noise) the gear oil is inadequate or the

brand is wrong.

oil
(Noises produced in sliding) the bevel drive gear

bearing is damaged.
Change
Bearing noises
Change
(Noises produced in turning) the differential side gear

bearing or the rear axle bearing is damaged.
Oil leak
The air plug is clogged.
Clean up
The oil seal is worn or damaged.
Change
The oil is too much.
Adjust the oil level
1. Change of gear oil

1) Remove the oil drain plug to discharge gear oil.
2) Re-install the oil drain plug and tighten it to the specified torque.
Tightening torque
(a): 35~50Nm
3) Remove the sealing gasket and oil filler plug, and fill the new oil
that meet requirements into the differential case.
About 1.3L gear oil shall be filled.
Oil volume
1.3L
Gear oil
SAE90 or SAE80W or 75W/80~85
Notice:
As for the cars travelling in the areas where the temperature is
below-15 in cold seasons, it is recommended to use 75W/90 GL-5
or 80 W/90 GL-5 for periodic maintenance.
4) Fit on the sealing gasket and oil filler plug, and tighten them to the
specified torque.
Tightening torque
(b): 35~50Nm
2. Disassembly
1) Stop the car on a safety platform, and then pull out the left/right axle shaft. See Disassembly of Rear Axle in
Chapter 5 in the manual for the method.
2) Unscrew the bolts connecting the final drive, flange and drive shaft flange from the deferential case to strip off
the drive shaft. Unscrew the 8 bolts connecting the final drive and axle housing to take down the final drive and
differential.
3. Assembly
The assembly shall be in the reverse order of disassembly, and pay attention to the following requirements:
Clean the joint face of the differential and axle housing first before inserting the differential into the axle housing,
and apply sealant to it. After assembly, tighten the bolts to the specified torque.
A: sealant 99000-31110
Tightening torque
(a): 18-28Nm
For the assembly of rear suspension, please see the Assembly of Rear Axle the Chapter 4 in the manual.
For filling gear oil, see the chapter of Change of Oil.
To make sure the air in the brake oil pipe circuit is expelled, see the Exhaust operation of brake in chapter 6.
Finally check and make sure the oil pipe joint has no oil leak.
. Disassembly and repair

1. Disassembly
1) Clamp down the flange, and unscrew the adjusting nuts at the bevel drive gear shaft side.
2) Make a mark on every bearing cap of the differential. The bearing cap is to fasten axle bearings, and the mark is
to identify bearings. As some bearings are left bearing, and some are right bearing, they shall be marked to make it
easy to identify and install in reassembly.
A: Assembly mark
3) Unscrew the lock bolts and bearing cap bolts and remove the left and ring bearing caps, and then take out the
differential assembly from the final drive housing.
4) Use a special tool to remove the right axle bearing from the differential case.
Special tools
(A): 09913-60910
(B): 09913-85230
1. Lock bolt
1. Right axle bearing
5) Unscrew the bolts fixing the bevel driven gear on differential case, and then remove the gear.
6) As shown in the figure, pull out the planetary gear shaft, side gear and thrust washer.
Special tool
(C): 09922-85811
7) Use a special tool to remove the left axle bearing from the differential case.
Special tools
(A): 09913-60910
(B): 09915-85250
2. Adjustment
1. Left axle shaft

bearing
Differential side gear clearance

Check the gear clearance with soft fuses.
According to the clearance check standard, squash the fuse and measure its thickness, and compare it with the
specified clearance in the following table.
If necessary, change the thickness of thrust washers to adjust the clearance.
Side gear clearance
0.05~0.15mm
Thrust washer thickness
0.9, 1.0, 1.1&1.2mm
Notice:
1. Gasket or plate
If the fuse fails to measure the differential side gear clearance, the side gear thrust clearance shall be
measured. If the maximum thrust clearance is 0.37mm, the side gear clearance is considered acceptable. To
measure the thrust clearance, a suitable flat washer or gasket shall be placed on the side gear.
Special tool:
(A): 09900-20606
Determine the thickness of the bevel drive gear adjusting shim.
1. Nut 2. Spring rod (range: 1-5 or 1-19kg)

3.Torque wrench
4. Coupling sleeve
To correctly mesh the bevel drive gear with the driven gear, it is required to use the adjusting shim below to fit the
drive gear to the final drive housing beforehand. The following is the relevant position of the drive gear, final drive
housing and installation copying machine.
1) Fit the bevel drive gear installation copying machine with bearings into the differential final drive housing and
tighten the flange nuts so as to make the bearing pre-load meet the specification.
Notice:
Gaskets or oil seals are unnecessary for the assembly.

Manually check the bearing to make sure whether it can rotate, and apply a little lubricating oil to it before
measuring it with a spring balance or torque wrench.
Special tools
(A): 09922-75222
(B): 09924-36320
Drive gear bearing pre-load
(a): 5.0~13.010 3Nm

Initial torque:1.0~2.610
Nm
2) Considering the machining and assembling factors, the number of

gaskets used for the bevel drive gear is different. Thus, to every car, a
different number of gaskets shall be used to correctly locate the planetary
gears. (As there is a suitable clearance between the bevel drive gear and the
driven gear) the gasket thickness shall be determined again for every
assembly. To make it easy to determine, two special tools shall be put in
use. The following method is determined according to this special tool.
Then one of the two planetary gear copying tools is placed in the deferential case, with no gasket installed, as
shown in the figure.
Special tool
(A): 09924-36320
(B): 09900-20606
3) Place a dial indicator on the copying tool, with its probe stretching 5~6mm out the copying tool bottom. Place
the copying tool on a plate to return the dial indicator to zero.
Special tools
(A): 0992436320
(B): 0990020606
4) Fit a copying planetary gear into the final drive housing, as shown
in the figure, and locate it properly.
Tightening torque
See the figure, and pay attention to the three dimensions: a, b and
c. b value is unknown, and is the gasket thickness to be calculated.
a + c equals 85mm.
1. Plate
2. Screw
5) In case the copying machine is firmly fixed, dial indicator finger

has deflected from 0 to indicate a valve, which is b. This value
adds 85mm (a + c) and then subtracts the value marked on the
bevel drive gear is the desired gasket thickness.
Equation of gasket thickness: (85 + b) marked value = desired
gasket thickness.
1. Stated value
6) The are four gaskets of different thickness for option. In selecting and
combining the gaskets, be sure that the total thickness shall be consistent
with the desired thickness as much as possible. Then insert the selected
gasket into the clearance d, as shown in the figure.
d clearance
Bevel drive
gear gasket
dimension
0.05, 0.1, 0.2, 0.3, & 0.5mm
Adjustment of bevel drive gear bearing pre-load
1. Electric wrench
2. Socket spanner
3. Spring balance
4. Torque wrench
Pay attention to setting the drive gear pre-load to the specified value when using a flange localizer (special tool)
and electric wrench to tighten up the flange nuts
Notice:
Manually check the bearing to make sure whether it
can rotate smoothly before measuring it with spring
balance or torque wrench.
The method of adjusting bevel drive gear bearing
pre-load is to tighten the drive gear nuts and
compression pad. Thus new pads must be used in
adjusting and the nuts shall be gradually tightened up.
1. Bearing case bolt
In tightening it up, check the initial torque at any time to avoid crushing the pad.
In adjusting, if the following given specification is exceeded, change the pad and repeat the pre-load
adjusting procedures. Do not unscrew the gear nuts to reduce the initial torque (pre-load).
Bevel drive gear bearing pre-load: 5.0~13.010
Initial torque: 1.0~2.610
Nm
Nm
Special tools
(A): 09922-75222
(B): 09922-66020
Bevel driven gear clearance adjustment
1) Check the clearance between the bevel driven gear and the drive gear by the method as shown in the figure.
Notice that the final drive housing assemble shall be installed by common methods, and the axle bearing bolts shall
be tightened up to fix the differential case assembly downwards. Align the dial indicator with the tooth root at the
gear drive side (convex side). Then grasp the bevel drive gear to move the bevel driven gear to and fro.
The reading of the dial indicator is the clearance, which shall be
within the specified range.
Tightening torque
(a):
15N.m
Special tool
(A): 09900-20606
1. Bearing cap bolt

2. Bearing adjuster
(B): 09900-20701
Bevel gear clearance: 0.10~0.20mm
Special tool
(C): 09930-40113
Caution:
In adjusting the clearance, regulate the pre-load value
of the axle bearing: fit the torsion pulley (with a special
tool) to the bevel drive gear and use a spring g to make
measurement. If the torque reading is within the
following specified range when the bevel driven gear
Spring gauge
tester
Bevel drive gear bearing pre-load + axle
shaft bearing preload
2) In adjusting the gear clearance, the two adjustors shall

be used, which shall be equally turned inwards or
outwards (slightly unscrew the axle bearing cap nut at the
same time). Turning one hole site of the adjustor may
cause the clearance to change 0.1mm.
Bevel drive gear bearing pre-load
starts turning, the axle bearing pre-load can be considered acceptable. See the figure: for example, when the
bevel drive gear bearing pre-load is 2.0kg, the bevel drive gear pre-load value (kg) plus axle bearing pre-load
valve shall be 2.2~2.6kg. After adjusting, tighten the bearing cap bolts to the specified torque.
Special tool
(D): 09922-75222
The tightening torque of bearing cap bolts after adjusted shall be: 30~37Nm
Check and adjustment of the engagement of bevel drive gear and bevel driven gear
Engagement system
Diagnosis and treatment
Outer end
Driven surface
Drive surface
Front differential
fails to operate
Engagement system
Diagnosis and treatment

Change the differential
case
Front differential
drives
Inner end
Normal
Low contact
The bevel drive gear is
further back, so that the
adjusting shim it shall be
thickened.
1.Check the bevel driven

gear stand or differential
case.
2. Change the bevel
drive gear or bevel
driven gear.
3. Change the deferential
case.
High contact
The bevel drive gear is

further forward, so the
adjusting shim it shall be
thinned.
1. Change the drive gear

or driven gear.
2. Change the deferential
case.
Check the engagement of the gear teeth by the following method.

1) After the tooth surface of the 10 bevel driven gears are cleaned, use a
brush or a sponge to apply coloring materials to the gears (red lead
powder for instance).
2) Turn the driven gear to mesh the colored part with the bevel drive gear;
manually turn the gear to and fro the mesh them repeatedly.
3) Check the engagement system (see the above table). If the engagement
system is not correct, adjust them as indicated in the table or change them.
1. Brush A: apply gear mark

compound evenly
Notice:
The bevel driven gear shall not make a complete turn, for it will hinder making accurate checks.
3. Assembly
The assembly shall be carried out in the reverse order of the disassembly, and pay attention to the following
requirements:
Notice:
The bevel drive gear and the bevel driven gear are supplied in pairs. Even only the bevel drive gear or the
bevel driven gear needs to be changed, they shall be changed
simultaneously in pairs.
Drive bolts of bevel driven gear
The bolts that fasten the bevel driven gear to the differential case will
undertake a shear stress, for it is through the bolts that the force is
transferred from the driven gear to the differential case. Thus, these bolts
shall be special purpose bolts made of chrome steel, and shall not be
replaced with plain bolts.
A: adhesive 99000-32020
Tightening torque
(a): 80~90 Nm
Bevel drive gear bearing
The 2 tapered roller bearings must be fitted on the drive gear shaft by
pressing, with the outer race fitted into the final drive housing and the inner
race fitted to the bevel drive gear shaft.
1) The outer race of the front bearing (at the yoke side) shall be installed with
a special tool:
Special tool
(A): 09913-75520
2) The installer for the outer race of the rear bearing (at the gear side) is:
Special tool
(B): 09915-75510
3) The special tool used for fitting inner race is:
Special tool
(C): 09940-51710
Differential axle bearing
Use a special tool to correctly fit the bearing into the differential case
by pressing. Do not hit them into the case.
Special tool
(A): 09940-53111
Materials
Recommended Suzuki product
Use
Thread sealant
Superthread sealant 1333B(9000-32020)
Bevel driven gear bolt
Lithium grease
Suzuki super grease A (99000-25010)
Oil seal cover lip

Oil drain plug
Sealant
Suzuki 1215 (99000-31110)
Fitting surface of final drive and

axle housing
. Special tools
Bearing removal clip
Dial indicator
Bearing installer
Spring platinum puller
Bearing installer
Rotor spacer
Bearing installer
Magnetic stand
Bevel drive gear installation

Preload adjuster
copying machine
Bearing/gear puller
Chapter Drive system

Section Front suspension
. Composition
The front suspension is an independent strut-and-link type suspension, as shown in the following figure. The strut
upper end connects the car body through a strut member. The strut and the strut member are separated by a rubber
mounting member, under which a strut bearing is fitted.
The lower end of the strut connects the steering knuckles upper end, which links the ball stud. The ball stud
integrates the swing arm to form a device. The tie rod connects the steering knuckle.
Thus the action of the steering wheel is transferred to the tie rod and then to the steering knuckle so as to turn the
wheels. During the operating procedure, with the motion of the steering knuckle, the strut will move through strut
bearing and lower ball stud.
Top view
Front view
: Direction of forward motion 1. Front strut assemble 2. Steering knuckle 3. Suspension swing arm
4. Ball stud 5. Wheel bearing 6. Front hub 7. Front wheel 8. Stabilizer bar 9. Strut bar 10. Steering tie rod
Front suspension assembly drawing
1. Front strut boot 2. Strut nut 3. Strut lock washer 4. Strut rebound
stroke limiting stopper 5. Strut member 6. Strut inner support 7. Strut
bearing saddle 8. Strut bearing
9. spring upper support
10. Strut spring rubber support 11. shock absorber limiting stopper 12. Coil
spring 13. Front strut assembly
Front strut assembly drawing
. Check and Adjustment

1. Checks on stabilizer bar and bushing
Stabilizer bar
Check to make sure whether there is damage or deformation; if there are defects, change them.
Bushing
Check to make sure whether there is damage, wear or deterioration; if there are defects, change them.
2. Strut bar and bushing

Strut bar
Check to make sure whether there is damage or deformation; if there are defects, change them.
Bushing
Check to make sure whether there is damage, wear or deterioration; if there are defects, change them.
3. Check on front strut assembly

1) Check if the shock absorber leaks oil. If it does leak oil, it shall be
changed entirely, for it is impossible to be disassembled.
2) Check and adjust the tire pressure according to requirements. In
checking the shock absorber, push hard the lateral front car body to
swing the car for three to four times. Exercise the same force every
time and notice the damping property of the shock absorber. Additionally, pay attention to how many times the car
swings after the hands leave the car. Do the same thing to the other side of the car. Then compare the damping
properties and rebound times of the left and right shock absorber, which must be consistent. If the shock absorbers
are normal, the car shall stop swinging immediately after the hands leave it, or slightly swing one to two times. This
can be compared with other cars with normal shock absorbers or shock absorbers.
3) Check if there is damage or deformation.
4) Check if the bearings has wear, abnormal noise or clamping.
5) Check if the spring saddles have cracks or deformation.
6) Check if the damping limiting stoppers are damaged.
7) Check if the rebound limiting stoppers and strut mounting
members have wear, cracks or deformation.
If there are parts found to be flawed in the steps 2) -7), change
them.
4. Checks on swing arm/steering knuckle
Check if there are cracks, deformation or damage.
5. Check on swing arm bushing
Check if there is damage or wear.
6. Checks on swing arm ball stud
1) Check if it can rotate smoothly.
2) Check if the ball stud is damaged.
3) Check if the boot is damaged.
4) Check the ball stud clearance. If there are defects, change it.
Notice:
The swing is and ball stud cannot be separated from each other.
Either of them is damaged, the swing is assembly shall be changed as
a whole.
7. Checks on wheel discs, nuts and bearings
1) Check if the wheel discs have dents, deformation and cracks. The
wheels that are badly damaged must be changed.
2) Check if the wheel nuts are firm. If necessary, tighten them up
again as required.
Tightening torque
Forward
1. Stabilizer bar
6. Stabilizer bar joint nut
2. Mounting bushing
7. Washer
3. Mounting bushing support 8. Cushion
4. Mounting frame bolt
9. Stabilizer bar joint nut
5. Stabilizer bar joint
10. Strut bar
(a): 85Nm
3) Check the wear of wheel bearings. In measuring the thrust clearance, remove the wheel axle cover from the
wheel disc first and then use a dial indicator to measure at the hub.
Thrust clearance limit: a: 0.1mm
If the measured value exceeds the limit, change the hub assembly.
4) Check if the wheel axles have noises by turning the wheels and if they can turn smoothly. If there are defects,
change the hub assembly.
1. Stabilizer bar
2. Painting point
3. Stabilizer bar joint
4. Strut bar
1.Stablizer bar and bushing

Disassembly
1) Jack up the car to hang the front swing arm in the air.
2) Remove the stabilizer bar connecting nut, washer and cushion.
3) Remove the stabilizer bar mounting bush bracket bolts.
4) Remove the stabilizer bar and its joints.
5) Remove the joints from the stabilizer bar. When the joint nuts are
unscrewed, the bolts shall be held by a wrench.
Assembly
In assembling the stabilizer bar, all the parts shall be fitted together in order and make sure that the stabilizer bar
is at the center.
Notice:
To correctly install the stabilizer bar, the colored paint on it shall be aligned with the left and right mounting
bushings, as shown in the figure.

Tighten the bolts and nuts to the specified torque.
Caution:
Be careful to tighten the stabilizer connecting nuts so as to coincide the cushion with the washer.
Tightening torque:
(a): 25 Nm
(b): 55 Nm
(c): 23Nm
2. Strut bar and bushing
1. Strut bar mounting bolt 5. Strut bar rear nut

2. Strut bar support
6. Strut bar front nut
3. Strut bar bushing
7. Strut bar
4. Strut bar rear washer 8. Suspension swing arm
9. Strut bar front washer
Disassembly
1) Jack up the car to hang the front suspension in the air.
2) Remove the stabilizer bar. Please refer to the steps 2) -4) Removal of Stabilizer Bar Bushing.
3) Remove the front and rear strut bar nuts.
4) Remove the strut bar.
5) Remove the strut bar support from the car body.
1. Strut bar front nut 3.Strut bar

2. Strut bar rear nut 4. Swing arm
1. Strut bar support mounting bolt

2. Strut bar support
Assembly
The assembly shall be made in the reverse order of disassembly,
while attention shall be paid to the following points:
See the right figure to correctly install the strut bar bushing and
its rear washer.
Use new strut bar rear nuts.
Every bolt and nut shall be tightened to the specified torque.
Tightening torque
(a): 55 Nm
E shaped ring
(b): 65 Nm
(c): 95Nm
3. Front strut assembly
If there are parts in the front strut assembly damaged, please change the strut assembly, which is removed by the
flowing procedures.
Disassembly
1) Remove the battery negative wires.
2) Jack up the car to hang the front suspension in the air.
3) Take down the wheels.
4) As shown in the figure, remove the E-shaped ring used to fix brake hoses and remove the brake hoses from the
strut support.
5) As shown in the figure, remove the caliper pin bolts and incline the caliper.
Caution:
When the caliper is inclining, be careful not pull hard the brake hose so
as to avoid damage.
6) Remove the wire harness retainer bolt of wheel speed sensor from the strut
(if equipped).
1. Caliper pin bolt

2. Brake hose
3. Caliper
7) Remove the strut support bolts.

8) Remove the strut member nuts and hold them by hand to avoid falling down.
9) Remove the strut assembly.
1. Nut
1. Strut bracket nut 4. Bracket end face

2. Strut support nut 5. Caliper pin bolt
3. E-shaped ring A: Apply rubber grease
Assembly
1) Assemble them in the reverse order of the disassembly procedures from 1) to 9), and fit the bolts on the positions
as shown in the right figure.
2) Tighten all the fasteners to the specified torque.
Tightening torque
(a): 73 Nm
(b): 95 Nm
(c): 35 Nm
Notice:
Do not bend the brake hoses in assembly.
Fit the E-shaped ring to the bracket as shown in the figure.
4. Hub/wheel stud
Disassembly
1) Jack up the car and remove the wheels.
2) Remove the axle cover as shown in the figure (tap the three points around the cover with a hammer, and be
careful not to deform or damage the axle cover seat).
3) Unscrew the wheel axle nuts.
4) Remove the wheel axle nuts.
1. Axle cover
1. Wheel axle nut
5) Remove the caliper bracket bolts.

6) Remove the caliper and the bracket together.
Note:
Lift the caliper with a crampon and alike to avoid the brake hoses being excessively bent or pulled out.
Do not press the brake pedal after brake discs are removed.
7) Remove the brake discs with two 8mm bolts.
8) Remove the hub with a special tool

Special tools
(A): 0994317912
(B): 0994215510
9) Remove the hub bolts

Notice:
Do not remove the bolts unless it is necessary to change parts. New
bolts shall be used when the parts are changed.
Assembly
Assembly of hub bolt
1) Insert the new bolts into the hub holes, and turn them slowly to
make their serration consistent with that before.
1. Hammer
2. Hub bolt
Fit the hub to the wheel axle, and tighten the new wheel axle nuts to the specified torque.
Tightening torque
(a): 175 Nm
2) Install the brake discs.
3) Install the brake caliper/ caliper bracket
4) Tighten the caliper bracket bolts to the specified torque.
Tightening torque
(b): 95Nm
1. Oil pressure unit

2. Rod
3. Hub bolt
5) Screw up the wheel axle nuts as shown in the figure.

Warning:
Be careful to screw up the nuts so as not to let the lock groove of the nuts have cracks. The cracked nuts
must be changed.
6) Fit the hub to the axle cover.
7) Fit on the wheels and lower the lift platform.
1. Strut front nut

3. Ball stud nut
5. Swing arm nut
2. Ball stud
4. Swing arm bolt
6. Swing arm
5. Swing arm/bushing
Disassembly
2) Remove the strut bar front nuts from the swing arm.
3) Remove the ball stud and nuts.
4) Remove the swing arm bolts and nuts.
1. Hydraulic equipment
5) Remove the swing arm.

6) Remove the bushing.
Use a special tool and the hydraulic equipment to pull out the bushing, as shown in the figure.
Special tool
(A): 09943-77910
Assembly
1) Bushing installation
Special tool
(A): 09943-77910
Notice:
Before installing the busing, dip it in soapy water to make it easier to be installed.
As shown in the figure, the dimension of left and right sides of the bushing shall be equal after installed.
1. Hydraulic equipment
2) Fit the swing arm to the suspension. The bolts and nuts shall be
fit on the correct position, as shown in the right figure.
1. Swing arm
Forward
Notice:
The nuts shall not be tightened.
3) Fit the ball stud to the steering knuckle, aligning the ball stud
groove with the steering knuckle bolt holes as shown in the figure.
Then screw in the ball stud bolts in the direction as shown in the
figure and tighten them to the required torque.
Tightening torque
(a): 55 Nm
1. Steering knuckle
2. Ball stud
4) Tighten the strut bar front bolts to the specified torque.

Tightening torque
(b): 100Nm
1. Strut bar
2. Strut bar front nuts
3. Swing arm
5) Fit on the wheels and tighten the wheel nuts to the specified torque. See Technical Requirement of
Tightening Torque in this section.
6) Let down the jack and tighten the swing arm nuts to the
specified torque under the condition of no load.
Tightening torque
(c)73Nm
7) Check the tie-in and adjust it according to requirements.
6.Steering knuckle
1. Strut
2. Steering knuckle
3. Ball stud
3. Swing arm
Disassembly
2) Remove the hubs. See the procedures 2) -8) in Hub/Wheel
Bolt in this section.
1. Steering knuckle
2. Tie rod end
3. Puller
3) Use a puller to remove the tie rod end from the steering knuckle.
4) Remove the wheel speed sensor (if equipped) from the steering knuckle.
5) Remove the ball stud from the steering knuckle, and then remove the strut bracket bolts from the strut
bracket.
6) Remove the steering knuckle.

Assembly
1) Fit the steering knuckle to the ball stud and strut bracket
on the swing arm, with the installation position as shown in
the figure. Align the steering knuckle bolt holes with the ball
stud groove to fit on the ball stud bolts. Tighten the bolts and
nuts to the specified torque.
Tightening torque
(a): 95Nm
1. Strut
3. Ball stud arm
2. Steering knuckle 4. Swing arm
1. Tie rod end

2. Steering knuckle
3. Nut
(b): 55Nm
2) Fit on the wheel speed sensor (if equipped)
3) Connect the tie rod end with the steering knuckle,
and tighten the new nuts at the tie rod end to the
specified torque.
Tightening torque
(c): 45 Nm
Notice
In tightening the nuts at the tie rod end, jack up the tie rod end so as not to move the ball stud.
4) The procedures of assembly are as mentioned above. See the steps 1) -7) in Hub/Wheel Bolt in this
section.
7. Suspension bracket
1. Suspension bracket
2. Steering gearbox housing mounting bolt
Disassembly
1) Jack up the car and remove the wheels
2) Remove the swing arms (left and right). See the steps
from 2) to 5) in Removal of Swing Arms in this section.
3) Remove the steering gearbox housing mounting bolts.
1. Wheel speed sensor wire harness clamp

2. Wheel speed sensor wire harness clamp
3. Suspension bracket bolt
Wheel side
4) Remove the wheel speed sensor wire harness clamp bolts and clamps (if equipped) from the suspension
bracket.
5) Remove the suspension bolts and its bracket.
Assembly
1) Fit on the suspension bracket and tighten its bolts to the specified torque.
Tightening torque
(a): 100Nm
2) Fit the wheel speed sensor wire harness clamp bolts and clamps to the suspension bracket (if equipped).
3) Fit on the steering gearbox housing mounting bolts and tighten them to the specified torque.
Tightening torque
(b): 25 Nm
4) Fit on the swing arms (left and right). See the steps from 2) to 6) in Removal of Swing Arms in this
section.
5) Make sure whether the (wheel) front end is aligned.
.Special tools
1. 09900-0041
Hexagon wrench socket
2. 09900-00414
Hexagon wrench head
09943-77910
Adjusting
puller
09945-26010
Socket wrench
09942-15510
Sliding weight
bushing
1. Suspension bracket bolt

2. Steering gearbox bolt
09943-17912
Front hub puller
(brake drum puller)
Section Rear suspension

. Composition
The rear suspension system is of integral axle type which makes use of leaf springs, as shown in the figure below.
1. Leaf spring
2. Limiting stopper
3. telescopic shock absorber 4. buffer stopper
Rear suspension assembly drawing
. Disassembly and assembly
1. Lock washer 2. Nut (upper support) 3. Washer 4. Shock absorber bushing

5. Shock absorber 6. Washer 7. Lock washer 8. Nuts (lower support)
9. Upper support screw (fixed on bracket) 10. Lower support screw (fixed on leas spring assembly)
1. Shock absorber
Disassembly
1) Crane up the car.
2) Remove the lower support nuts.
3) Remove the upper support nuts and then remove the shock absorber.
Assembly
1) Refer to the figure below to install the shock absorber.
2) Screw up the nuts.
3) Let down the crane.
2. Leaf spring
Disassembly
Leaf spring
1) Lift up the car. In doing so, the jack or crane shall not prop the rear suspension parts to jack or lift up the car. If a
jack is made use of, a safety platform must be placed under the car chassis to support the jacked car.
Notice:
Do not let the rear axle housing hang on the brake hoses or pipes. If so, the hoses or pipes may be ripped. To avoid
such case, a safety platform shall be used to support the rear axle housing of the jacked car any time.
2) Remove the rear wheel and release the parking brake cable from the clip.
3) Remove the U-shaped bolts and nuts.
4) Remove the lug nuts and leaf spring front nuts.
5) Pull out the leaf spring front bolts and tear down the leaf spring from the lug pin.
Assembly
Lug pin bushing
Make press fit for lug pin bushing. Dip the bushing in water or soapy water to make it easy.
Notice:
Any oil shall not be applied to the bushing.
1. Leaf spring
2. Leaf spring bushing
Leaf spring
1) Install the lug pins from the car center to the outside.
2) Fit on the leaf spring front bolts from the car outside to the inside.
3) Fit the leaf spring center bolts and nuts into the spring seat holes, and the tighten the U-shaped bolts and nuts to
the specified torque.
4) Tighten the lug pin nuts and spring front nuts to the specified torque under no-load conditions.
5) Link the parking brake cable with cable clips.
6) Fit on the rear wheels and tighten them to the specified torque.
7) Let down the crane.
U-shaped bots and nuts of Leaf spring
Leaf spring front busing

When the front bushing is pressed into the leaf
spring, its narrow notch shall point forward.
Upside
Notch (wide)
Forward
Rear
Notch
(narrow)
Tighten up the 4 U-shaped bolts and nuts evenly so as to let
their B measurement equal.
Leaf spring
Every piece of leaf spring shall be
aligned at the edge.
1. Leaf spring
2. Leaf spring bushing
Forward
Rear
Spring upper seat
Nut
Spring lower seat

Center bolt and nut
bolt
Car body center
3. Wheel bearing and axle shaft

Disassembly
1) Check if the brake parking lever is not pulled up.
2) Jack up the car and remove the rear wheels.
3) Unscrew the oil drain plug to discharge the differential oil
from the axle housing.
Leaf spring
4) Release the brake parking lever.

5) Pull out the brake drum with 8mm bolts.
6)Rotate the brake shoe pressure pin to remove the brake shoe
pressure spring.
8mm bolt
1. parking brake shoe lever

2. parking brake cable
3. Brake shoe
7) Take apart the parking brake cable from the parking brake shoe lever
and remove the brake shoe.
8) Remove the parking brake cable clip and disassemble the brake
cable from the brake bottom plate.
1. Parking brake cable

2. Clip
Intake plug cover
9) Draw out the brake fluid by pumps or alike, and then remove the brake pipes from the car brake cylinder, and
meanwhile use a intake plug cover or alike to cover the
pipe end to avoid the brake fluid flowing out.
10) Remove the brake bottom plate nut from the rear axle
housing.
11) Use the special tools (A and B) to pull out the axle
shaft connecting with the brake bottom plate.
12) Pull out the axle shaft.
Sliding weight
Brake drum puller

Rear axle shaft
Graded out by lapping machine
Rear wheel bearing retainer

13) To remove the retainer form the axle shaft, use a lapping machine to grind the two parts of the bearing retainer
till they get thin, as shown in the figure.
Caution:
Be careful not grind over the head surface to damage the axle shaft.
Universal puller
Use a chisel to unclench the thinned part of the retainer and remove it.
Bearing puller
14) Use the special tools (C and D) to remove the bearing from the axle shaft and then remove the brake bottom
plate.
Assembly
1) Fit the parts shown in the figure below to the axle
shaft.
Retainer
Notice:
Fit on the wheel bearing spacer with its inside
diameter beveled side orientated to the brake drum
side.
Differential side
Spacer
Fit on the wheel bearing with tis seal side

orientated to the brake drum side.
Bearing
Beveled side
Hub bolt
Seal side
When fitting the hub bolts to the axle shaft, make sure the
bolt head firmly fits into the cascading part of the axle
shaft.
2) Press into the new bearings and retainers in order by an oil
press.
Notice:
The exterior surface of the retainer shall be protected
against damage then. If it is damaged, the rear of the oil
seal will be worn, and the differential oil will leak to the brake shoe side.
Pressing into the retainer needs a 3t to 5t pressure.
3) If it is sure that the retainer contacts the bearing, clean up the retainer and apply adequate wheel bearing grease
to the it.
4) Check to make sure that the oil seal seat and the oil seal are both correctly fitted to the rear axle.
Notice:
Oil
No matter whether there is oil leak, the oil seal, if removed, shall be a new oneseal
for reassembly.
Spring
Refer to the right figure for the installation direction of oil seal. Be sure to apply superior grease A
(99000-25010) to the oil seal lip.
Apply grease
Wheel side
Differential side
1. Axle shaft oil

seal
2. Protector
3. Rear axle
5) Apply a type of waterproof sealant to the joints of rear axle and brake bottom plate.
Apply waterproof sealant

(Sealant 366E) (99000-310990)
6) Fit the axle shaft into the rear axle housing and tighten the brake
bottom plate firmly to the specified torque.
7) Remove the intake plug cover from the pipe end, and then
connect the brake pipe to the wheel brake cylinder and tighten
the coupling nuts to the specified torque.
8) Apply waterproof sealant to the contact of the plate and the wire cable, and then thread the parking brake cable
through the brake bottom plate and buckle it up tightly with a clip.
Apply waterproof sealant (99000-31090)
9) Connect the brake shoe lever to the brake parking lever and fit on
the brake shoe.
2. Clamp
10) Before installing the brake drum, to let the clearance between the brake shoe and the brake drum to maximum,
put a screwdriver between the support bar and the ratchet to remove the ratchet as shown in the figure.
Support bar
Ratchet
The position of the ratchet shown in the left

figure is that when the clearance between the
brake shoe and the brake drum.is maximum.
The position of the ratchet shown in the left

figure is that when the clearance between the
brake shoe and the brake drum.is maximum.
Support bar
Ratchet
11) Fit on the brake drum.

12) Fill a given amount of specified gear oil into the rear axle housing (differential gearbox), and tighten the plugs
of the oil filler and oil drain hole to the specified torque.
13) Exhaust the air in the brake pipe, and refill the brake fluid into the fluid reservoir.
14) Fit on the rear wheel and tighten the wheel nuts to the specified torque.
Wheel nut tightening torque: 50~80Nm
15) While completing all the operation, press the brake pedal three to five times with a 400N loads so as to allow a
suitable clearance between the brake shoe and the brake drum.
16) Check the brake drum to make sure it can rotate freely and play a proper role in braking, and then let down the
jacked car to carry out brake test.
17) Check whether there is leakage of differential oil and brake
fluid.
Rear shock absorber
1) Check if it is deformed or damaged.
2) Check if the bushing is worn or damaged.
3) Check if there is oil leak.
If there are defective parts, change them.
Leaf spring and buffer stopper
Check if they have cracks or damage. If they are defective, change them. Check if the buffer stopper is fixed on the
correct position. If it deviates, change it.
Leaf spring bushing
Check if it is worn or damaged. If it is found defective, change it.
If there are abnormal noises in driving where the lug pin bushing is not worn, remove the bushing and apply grease
to the parts shown in the figure.
Spread a thin layer of silicone grease and let it harden on the

surface.
(Be sure to use the silicone grease that will not affect the
rubber)
Silicone grease: 99000-25190
Wheel disc, nut and bearing
1) Check if the wheel discs have dents, deformation and cracks.
The wheel discs that are badly damaged shall be changed.
2) Check if the wheel nuts are tightened up, and tighten the to the
specified torque as necessary.
3) Check if the wheel bearings are worn. In measuring the axial clearance, set a dial indicator on the hub when the
wheel center cap is removed from the wheel disc. If the measured value exceeds the limit, change the bearings.
4) Jack up the car frame and turn the wheels to check whether the wheel bearings have noises and whether they can
rotate smoothly. If there are undesirable phenomena, change the bearings.
Tightening torque of wheel nuts: 70~100Nm
Axial clearance limit: rear wheel
0.8mm
. Tightening torque of fastener

Fasteners
Tightening torque (Nm)
1. Upper and lower nuts of shock absorber
35~45
2. Upper nut of shock absorber (only limited to van-body

trucks)
22~35
3. U-shaped bolt and nut (or U-shaped bolt locknut)
53~60
4. Lug nut
30~55
5. Rear leaf spring front nut
60~85
6. Rea wheel brake nut
18~28
7. Coupling nut of brake pipe
14~18
8. Rear wheel nut
70~100
9. Rear axle housing drain hole plug
40~70
10. Rear axle housing oil filler plug
35~50
Section Wheel and tire

. Composition
Notice: all wheel fasteners are an integral part of the car, so they may even have impacts on the performance
of critical components and systems, and bring about huge maintenance costs accordingly. If necessary to be
changed, they must be replaced with those of the same brand or equivalence, and not with the inferior
substitutes ever. They must, when reassembled, be tightened to the specified torque to ensure all parts of
suitable tightness.
Do not weld these fasteners so as to avoid excess damage or weakness in mental strength.
1. Tire
This car is equipped with the following tires: 165/70R14
This type of tire is tubeless. The tire, when reaching to a certain pressure as specified, is such designed that it can
still work normally when borne a maximum load.
Appropriate tire pressure and driving habits have a major influence on tire life . Sharp turns, fast acceleration and
unnecessary hard braking will aggravate tear wear.
2. Tire
There are two standard configuration for wheel: steel rim and aluminum rim: 145J (135J)
3. Tires for changes
If it is necessary to change tires, it is recommended to use those the same as the original. See the tire schedule. The
substitute tires shall be consistent with the original ones in terms of size, load range and structure. The tires of other
types will result to influences on the travelling, driving, speedometer/ odometer readings, ground clearance, and the
clearance between the tire or tire chain and the car body and chassis.
Warning:
Do not use tires of different types to the same car unless in
emergency, for example radial ply tire or bias tire, or it will
have a strong impact on the driving and even cause the care to
go out of control.
It is recommended to install new tires in pairs to the same axle. If
only one tire needs to be changed, it must make a pair with the one
which has the most tread patterns so as to ensure a consistent
traction of the wheels in braking. The metric unit of tire pressure is kilopascal (kPa).
Metric tire gauges can be available from the suppler. The right table lists the conversion of the three units: kPa,
kgf/cm2 and psi for reference.
4Change of tire
If the wheels have bending, dents, great lateral or radial run-outs, air
leakage in welding lines, prolonged bolt hole, untight lug bolt nuts or
excessive rustiness, they must be changed. If the radial or lateral run-outs
of the wheel exceed the limits in the table below, harmful vibration will be
resulted from.
The changed tires must be consistent with the original in terms of load
capacity, diameter, rim deviation and assembly structure. The wheels of
inappropriate size or type will have an impact on the life of wheels and
bearings, cooling of brake, speedometer/odometer readings, ground
clearance and the clearance between the tire and car body and chassis.
To measure the run-out value of wheels, it is necessary to use a precise dial
indicator. The tire can be fitted on the wheel or removed. For correct
measurement, the wheel shall be fixed on wheel balancer alike.
1. Radial run-out
2. Lateral run-out
Measure the radial and lateral run-outs at the inner and outer sides of the rim flange. Put the dial indicator in place,
and turn the wheel slowly to write down the reading on the dial indicator.
When the measured run-out exceeds the specified value and cannot be adjusted by a balancing machine, the wheels
shall be changed. The readings resulted from welding lines, baking varnish or scratching shall be ignored.
Steel wheel
Radial run-out limit
Lateral
limit
1.14mm
1.40mm
run-out
5. Metric nut with lug and wheel bolt

All types of wheel use the metric nuts with lug and wheel bolts (specification: M1212.5).
. Trouble diagnosis
[A]: Before balancing 1. Wheel run-out caused by serious defects

[B]: After balancing 2. Place where balance weights are installed
3. Axle centerline
1. Trouble diagnosis table

See Section , Chapter .
2. Wheel balance
The balance of wheels and tires is divided into two types: static and dynamic balances.
Static balance, as shown in the right figure, is to distribute the weight evenly around the wheel. Non-static balance
will bring about wheel run-out, so it is called pitch, which will cause uneven tire wear.
Dynamic balance, as shown in the right figure, is
to equally distribute the weight along the two
sides of the wheel centerline so as to avoid the
wheel assembly swaying side to side. The wheels
of dynamic imbalance will cause the car to yaw.
The wheel of static balance is not always subject
to dynamic balance.
Steps of balance test

Mud deposit and alike must be removed from the rim.
[C]: Before balancing 1. Wheel run-out caused by serious defects

[D]: After balancing 2. Place where balance weights are installed
3. Axle centerline
Warning:
The stones in the tread pattern shall be eliminated so as to avoid hurting the operators when the wheel is
turned and get good balance.
The tires shall be checked for damage and then undergo the balance test as required by the equipment manufacturer.
Balance adjustment on dynamic wheel balancer
Most dynamic balancers are better than the built-in rotary balancers in terms of accuracy. They are easy to use and
are able to provide dynamic (two surfaces) balance. Though they cannot rectify brake drum or brake disc
imbalances, their accuracy suffices to overcome the defect. Their accuracy is always under 0.044kg.
The method of aboard balancing varies with the equipment and tool manufacturers. In carrying out the balancing,
please follow the manufacturers recommendations.
Warning:
The wheel speed shall be limited to 55km/h. It is necessary to set the limit because of the action of differential
planetary gear. When the driving wheel at one side turns and the one at the other side stop turning, the
speedometer can only indicate half of the actual maximum wheel speed.
Be careful in setting the driving wheels limit speed, or the wheel
speed may be too high, which will cause tire fracture or
differential faults, and even serious personal injury or further
damage to the car.
. Maintenance and slight adjustment

1. Wheel and tire
Do not repair the wheels by welding, heating or sand blasting. All
damaged wheels shall be changed.
Bolts
1. Paint point
If bolts are found to be damaged, change them timely.

Auxiliary tire and wheel
The tires are installed in combination with the wheels at assembly plants. The tires and wheels are fitted together to
undergo dynamic balance test. The tires and wheels are marked with paint so as not to damage the tires dynamic
balance, so pay attention to aligning the paint points on the tires and wheel in assembly.
If it is impossible to confirm the paint points on the tire, please draw a line on the tire and wheel before removed to
ensure their position are identical in reassembly.
Tire pressure
The tire pressure of any type of tires are carefully calculated to get desired travelling, stability and steering, reduce
tire wear and prolong tire life.
The tire pressure shall be checked once a month before long-distance driving when the tire is in a cooling state (the
car is parked for more than 3 hours, or travels less than 1.6km). The tire pressure shall be adjusted to the specified
value as indicated by the labels on the door (right door if it is right hand steering)lock support bar.
Traveling may cause the tire to heat, so it is normal when the tire pressure rises to 28kPa accordingly.
Be careful not to exhaust the air or reduce the tire pressure immediately after a long-distance travel, for the air
exhaust will reduce the cold tire pressure.
If the tire pressure oversteps the recommended value, it will cause:
1. Difficult driving and reduction in riding comfort.
2.Tire cracks or tire damage, even tire burst.
3. Accelerating wear of central tire tread.
Unequal tire pressure at the same axle will cause:
1. Uneven braking
2. Steering wheel deviation
3. Reduction in operability
4. deflection in accelerating
The valve covers shall cover the valves to avoid ingress of dust and water.
If the tire pressure is less than the recommended value, it will cause:
1. Tire squeal in turning.
2. Difficult steering
3. Accelerating and uneven heel-and-toe wear
4. cracks and ruptures in tire rim
5. Tire cord damage
6.Tire overheat
7. Reduction in operability
8. Fuel consumption increase
Tire specification
It is on the right door (the left door if it is a car with the steering wheel on
the right-hand side) lock support bar. See this specification for the tire
information.
This specification gives the maximum load, tire size and applicable cold
tire pressure.
1. Front tire
2. Rear tire
3. Spare tire
Tire rotation:
To ensure the tires to be worn equally, they shall be rotated according to the right figure. When the car first travels
10,000km the tires shall be rotated. Then it is recommended to rotate the tires every 10,000km and adjust the tire
pressure.
1. Wheel
Disassembly
1) Unscrew the wheel nuts about 180(half a turn).
2) Lift up the car.
3) Remove the wheels
Tightening torque of wheel nuts: 50~80Nm
Notice:
Do not unscrew the tight wheels by heating, for the heating will reduce the
wheel life and damage the wheel bearings.
Assembly
The wheel nuts must be tightened to a suitable torque one after another to avoid
bending the wheel and brake disc, as shown in the right figure.
Additionally, the wheel nuts must be tightened to a suitable torque one after another
to avoid bending the wheel and brake disc.
Notice:
Prior to wheel assembly, the rust set on the mounting surfaces of both the wheel and brake disc shall be
scraped or brushed by a wire brush.
In fitting on wheels, if the metal on the mounting surfaces fails to joint well, it may cause the wheel nuts to get
loose, and even cause the wheel to come off the car in driving.
2. Tire
Assembly and disassembly
Installing or removing tires with tire changers shall follow the manufacturers recommendations. Do not use the
hand tool or the tire iron alone to change the tires, for they may damage the tire bead or the rim.
A steel brush may be used to clean up the bead of rim, or heavy steel wool may be employed to eliminate the
lubricant, old rubber and some rust. Before the tire is installed or removed, appropriate tire lubricant shall be
properly applied to the tire bead.
After the assembly, the tire shall be inflated to the specified tire pressure (as indicated in the tire specification) to let
the bead completely sit on the ground.
Notice:
Do not stand on the tire when it is inflated, or the bead may break and cause serious personal injuries.
The tire shall not be inflated to exceed the specified tire pressure. If the bead fails to sit on the ground, it
shall be deflated to lubricate and inflate it again.
Over-inflation will cause bead rupture and serious personal injuries.
Tire repair
There are many different materials and methods for tire repair on the market. As these materials and methods are
not all applicable to all the types of tires, tire manufacturers publish detailed descriptions about how and when to
repair tires. These descriptions are available from tire manufacturers.
Chapter Steering system

Section Trouble diagnosis
. Diagnosis of common troubles
As the troubles in steering involve such systems as steering system, suspension, wheels and tires, the factors of
such aspects shall be considered in analyzing a trouble cause. Do not be confused by the symptoms of failure, and
make a road test for the cars first to confirm them. Then do checks according to the following methods and
eliminate the troubles that are found out.
1) Check whether the tire pressure is normal and whether the tire is evenly worn.
2) Jack up the car to check if there front and rear suspensions, steering gear racks and pinions get loose or have
worn parts.
3) Turn the front wheels rapidly to check if the tire is out of circularity or unbalanced, if the rim is deformed or if
the wheel bearing is loose or tight.
Troubles
Wheel deviation
Causes
The tires are unmatched or uneven.
Change
The tire pressure is not appropriate.
Adjust the tire pressure
The front suspension springs are broken or

sagging.
Change the springs
The radial ply tire gets wrapped under cross

force.
The front wheel is misaligned.
One running wheel drags (not disengaged).
The front or rear suspension parts get loose,
bent or damaged.
The front suspension springs are broken or
sagging.
The tire is unbalanced.
Abnormal or
excessive wear of
tires
Troubleshooting
Change the tire

Check and adjust the front wheel
alignment
Repair the front brake
Tighten or change the suspension
parts (components)
Change the springs

Adjust the balance or changed the tire

alignment
The strut (shock absorber) goes wrong.
Change the strut
The road conditions are poor.
Change the tire
The car is overloaded.
Change the tire
The tires fail to be rotated timely.
Change or rotate the tire
The wheel bearings are worn or loosened.
Change the wheel bearings
The wheel or tire swings.
Change the wheel or tire
The tire pressure is inadequate.
The tire has bulges or damage.
Change the tire
The strut (shock absorber) is inappropriate.
Change the strut
The tire or wheel is unbalanced.
Balance the wheel or change the tire

or wheel
Wheel bounce
The wheel bearings are damaged or worn.
The ball stud of steering tie rod is worn.
Change the steering tie rod end
The left and right ball studs of the front

cantilever are worn.
Front
wheel
shimmy, vibration
and hop
Change the front cantilever
The he radial runout of wheels is excessive.

The tire has bulges or damage.
The wheel assembly has overloaded radial
runout.
The mounting bolts of steering gear box get

loose.
Difficult
steering
Causes
Change the tire

Change the tire or wheel
Check and change the front wheel
alignment
The steering link gets loosened or worn.
Troubles
Repair or change the wheel or change

the tire
Tighten or change the steering link

Tighten or change the gear box bolts
Troubleshooting
The tire pressure is inappropriate.
Inflate the tire to a suitable pressure.
The ball joints of the steering tie rod or

of the left and right front suspension arms
are jammed.
Change the ball joints of the steering tie rod

or the front suspension arm

The rack and pinion is improperly
adjusted.
Check and adjust the front wheels

alignment.
Check and adjust the torque of racks and
The steering column.
pinions
Repair or change
Great steering
wheel
clearance
The wheel bearings are worn.
The steering gear box bolts get loose.
Tighten up
The rack and pinion is not adjusted

correctly.

pinions
The steering shaft universal joint is

worn.
Change the universal joint
The end of the steering tie rod or the ball

joint at the inner side of the steering tie
rod is worn.
The ball joints of left and right
suspension arms are worn.
The ball joint at the steering tie rod end
is jammed.
The ball joints are jammed.
The steering column is jammed.
Bad
Returnability of
steering wheel
The racks and pinions are badly

lubricated.

The racks and pinions are
inappropriately adjusted.
Change the steering tie rod end or the

steering tie rod
Change the front suspension arm
Change the steering tie rod end.

Repair or change
Check, repair or apply lubricating oil to the
racks or pinions
Check and adjust the front wheel alignment
pinions.
The tire inflation pressure is inadequate.
Steering noise
(clatter or chug)
The steering gear box bolts are loose.
Tighten
The wheel bearings are damaged or

encounter with other failures.
Change
The end of the steering tie rod is worn or

cannot rotate freely.
The racks and pinions are inappropriately
Change
Check or adjust the torque of racks and
pinions
adjusted.
The steering tie rod end, (left and right

front suspension arms) ball joints, ball
joints at the inner side of the steering tie
rod or transmission shaft joints are worn,
loose or fail to rotate freely.
The strut or mounting members are
damaged.
Abnormal
knocking
front wheel
of
Change the steering tie rod end, front

suspension arm, steering tie rod or
transmission shaft joint
Repair or change
Change
The cantilever bushing is worn.
Tighten the bolts and change the bushing
The stabilizer bar gets loosened.
Tighten the wheel bolts
The wheel bolts are loose.
Tighten suspension bolts or nuts
The suspension bolts or nuts get

loosened.
The wheel bearings are damaged or have

other faults.
he suspension springs are damaged.
Change the springs

Apply lubricating oil or change the strut
bearings
Change
The strut bearings are insufficiently

lubricated or worn.
The connecting ball joints of the
stabilizer bar are worn or are not flexible.
Troubles
Steering swing or
poor
steering
stability
Causes
Troubleshooting
The tires are unmatched or the inflation

pressure is uneven.
Change the tires or inflate the tires to

a suitable pressure
The front cantilever ball joints and steering

tie rod end get loosened.
Change the suspension arm or

steering tie rod end
The shock absorber/strut or mounting

members are out of order.
Change the strut or repair mounting

members
The stabilizer bar gets loosened.
Tighten or repair the stabilizer bar or

bushing
The springs are damaged or hang down.
The racks and pinions are inappropriately

adjusted.
Instable steering in
braking
Change the springs

Check and adjust the racks and
pinions
The connecting ball joints of the stabilizer

bar are loose.
Check and adjust the front alignment
Change the springs
The tire is under-inflation.
Inflate the tires to a suitable pressure

alignment
The brake works inconsistently.
Change the connecting ball joints of

the stabilizer bar
See chapter 7
Car height is low or

inclined.
The suspension is
pressed down to the
bottom.
The car deflects or

shakes in turning.
The springs are broken or hang down.
Change the spring
Overloaded.
Check the loads
The springs are misused.
Change the spring
The shock absorber or strut breaks down.
Change the shock absorber or strut
Overloaded.
Check the loads
The shock absorber or strut is out of order.
Check the shock absorber or strut
The springs are out of order or hang down.
Change the springs
The stabilizer bar is loosened or damaged.
Tighten the stabilizer bar bolts or

nuts, or change the bushing or joints
The shock absorber, strut or mounting

member is out of order.
Overloaded
The
tire
concave.
gets
Change the strut or mounting

members
Change the springs
Check the loads
The front strut is defective.
Change
The runout of tires and wheels are great.
Change the tires or rims
The ball joints of the front cantilever are
worn.
Adjust the tires
The tires are not balanced.
. Diagnosis of tire troubles

1Irregularity or premature wear
There are many causes for irregularity or premature wear. Some of them are incorrect inflation pressure, no tire
rotation, bad driving habits and inappropriate alignment of front wheel.
The tires must be rotated if any of the following cases happens:
1) The wear of front tires is different from that of the rear tires.
2) The lateral ground contact surface has uneven wear.
3) The wear of the left and right front tires is different.
4) The wear of the left and right rear tires is different.
5) There are dents in the tires or the tires get bald.
The wheels must undergo an alignment check if any of the following cases happens:
1) The wear of the left and right front wheels are not equal.
2) The lateral ground contact surface of the front tires has uneven wear.
3) There is pinnate wear at the side of tread ribs or tread blocks.
Difficult
turning
due
to
under-inflation or failure to rotate
tires
Incorrect tire alignment, uneven tire

structure or difficult acceleration
2. Wear indicator
The original tires are equipped with built-in tread wear indicators to examine whether
there is need for change. When the groove of the tread patterns is 1.6mm deep, the
indicating patterns are 12mm wide. There are 6 indicating patterns in the same direction
as the tire tread. When 3 or above of them come out from the groove, the tire shall be
changed.
1. Indicator
3. Radial ply tire swing

Swing means the front/rear part of the car swings from side to side, which is resulted from the out-of-straight steel
belt of the tire. Such kind of swing will be obvious when the
speed is at 8~48km/h.
A road test may ascertain the faulty tires.
If there is something wrong with the rear wheels, the rear part
of the car will swing. Then the driver at the seat will feel that
there is someone pushing the car from one side.
If there is something wrong with the front wheels the swing
will be even more obvious. Then the front panels will move
forwards or backwards, and the driver will feel that the car is
swinging.
Swing can be diagnosed by wheel fault diagnosis equipment and can be quickly ascertained by the manufacturers
recommendations.
If there is no wheel fault diagnosis equipment available, only the time-consuming methods can be adopted, that is,
substitution with good tire/wheel assembly.
1) Ascertain whether the front part or the rear part is swinging.
2) Fit the good tire or wheel (of the same type of cars) to the car. If the swinging part is still impossible to ascertain,
substitute the rear tires.
3) Make a road test again. If it gets better, then fit on an old tire till the swinging tire is found. If it still does not get
better, replace the 4 old tires with the new ones. Then fit on one old tire by the same method as mentioned above to
make check one by one.
4. Radial ply tire deviation
Deviation means that the car deviates from a straight course on a level road even the steering wheel is not turned.
Generally, the causes for deviation are:
Incorrect alignment of front wheel.
Uneven brake adjustment
Tire structure
The way the tires are made may cause the care to deviate. This example involves the tire of belt. Belt eccentricity
will produce a lateral force in the car to swing in on straight roads. If the diameter of the tire is larger at one side
than the other side, the tire is liable to swing to one side, which will increase the lateral force of car deviation.
The procedures in the following diagram shall be adopted (deviation fault diagnosis flow chart) to ensure the front
wheels are correctly aligned and avoid tire deviation.
1) The deviation diagnosis procedure is different from the correction tire rotation diagram commonly shown in the
users manual and maintenance guide.
2) The rear tires will not cause deviation.

Deviation fault diagnosis flow chart
Inflate the tire to the recommended pressure.
Make a bidirectional road test on flat roads.
Interchanged
The tires shall
the be
tires
interchanged
from the leftfrom
to the
theright
left before
to the
right before
another
roadanother
test. road test.
Deviate in the same direction.
Change the tire if the interchange

of tires improves the deviation
Re-install the tire and check

tis alignment.
Deviate in the reverse direction.
Fit a good tire on the front wheel
Change the tires if the deviation

is improved.
If the deviation still exists, fit a

good tire to the other front wheel
Change the tires if the deviation

is improved.
If the deviation still exists, the

good tire is not a qualified
product.
. Vibration fault diagnosis

Most vibration problems of cars running on expressways result from wheel imbalance. If there is still vibration
after dynamic balancing, the causes may be:
Tire runout.
Wheel runout
Changes in tire rigidity.
Measuring the runout of tires and wheels can only reveal partial problems, so the tire problem detector (TPD) must
be used to check these three causes, for example, loading runout. If there is no tire problem detector available, the
only way is to replace with new tire assembly, which is time-consuming.
Suspension action (loading runout)
Flat road
Causes
Section Front wheel alignment

Tire out of circularity
Deterioration of tire rigidity
Rim bending or out of circularity
. Composition
Top view front wheel toe-in
Positive camber
Alignment maintenance data:

Toe-in (B-A):05mm
1. Forward
2. Center side of car body
Wheel side camber: 13030, left and right difference 30

Kingpin caster: 330, left and right difference30
Kingpin inclination: 93030, left and right difference30
Notice:
3. Wheel central perpendicular

4. Camber
The front wheel toe-in value is measured by front wheel toe-in gauge.
The front wheel alignment shall refer to the angular dependence between the front wheels, and between front wheel
suspension accessories and the ground. Generally, the adjustment to front wheel alignment is only made to the
wheel toe-in, not to the camber and kingpin inclination. Thus the camber and kingpins inclination have no technical
requirements for adjustment to the damage caused by hazardous road condition or collision. Accordingly, it shall be
sure whether the damage exists at the car body or suspension. If the car body is damaged, the car body shall be
repaired, and if the suspension is damaged, the suspension shall be repaired. After repair and change, the front
wheel alignment shall be also checked or rectified.
1. Setting of wheel toe-in
Wheel toe-in is a type of wheel constraint which is used to avoid the motion trend of wheels at both sides rolling
outwards due to wheel toe-out from causing the centerlines of the wheels at both sides to be not parallel. (As shown
in the figure above) The technical requirement of wheel toe-in is to ensure the front wheels parallel motion (excess
toe-in or toe-out may increase tire wear). The value of wheel toe-in can be obtained from B minus A, with the
units as mm.
2. Wheel camber
The camber is the inclination between the front wheel and the perpendicular (seen from the front of the car). If the
wheels incline outwards at the top, the inclination is positive, or is negative. The size of inclination is calculated by
degree.
3. Pre-check before front wheel alignment adjustment
Not all the steering and vibration faults result from the tire misalignment. Wear or unqualified tires are also
impossible to give rise to lateral deviation, so that it is a must to add inspection items. Lead is that the car
deviates from the straight course when there is no manual force excised on the steering wheel. Before any work that
may have impact on the adjustment of front wheel alignment, the following check and service shall be made to
ensure the alignment sample value and alignment adjustment methods are correct.
1. Steering tie rod

2. Steering tie rod end
3. Steering tie rod clamp nut
4. Rack housing
1) Check if the inflation pressure of all the tires is suitable or if the tread wear are approximately equal.
2) Check if the ball head connections are loose. Check the tie rod end: if it gets loosened, rectify it before
adjustment.
3) Check if the wheels and tires have radial runout.
4) Check the cars balance height: if it exceeds the limit, rectify it. This job must be well done before adjusting the
toe-in.
5)Check if the swing war is loose.
6) Check if the stabilizer bar gets loosened or leaked.
7) Additional load must be taken into consideration, for example tool kit. If such sort of additional load is always
carried in the car, leave it in the car when the alignment check is made.
8) Consideration shall be made to make sure whether the equipment used for check is in good condition, and they
shall be operated based on the manufacturers manual.
9) To do setting work, the car shall be laterally on a level surface from the front to the rear.
4. Toe-in adjustment
Adjust the toe-in by changing the steering tie rod length. First, unscrew the clamp nuts at the ends of the right and
left steering tie rods, and then turn the tie rod to the right and left (same torque). In adjusting, the length of the left
and right tie rods shall be equal (see figure A). Before turning the steering tie rods, apply grease between the
steering tie rod and rack housing to avoid the boot being distorted.
After adjustment, tighten the clamp nuts to the specified torque.
Tightening torque
(a)40~72 Nm
5. Adjustment of camber and kingpin caster
If the camber and kingpin caster fail to meet the technical requirement, the reasons shall be first ascertained. If it is
due to damage, looseness, bending, dents or suspension part wear, change them; if it is due to the care itself, repair
it to meet the technical requirements. To avoid error in the measured value of camber and kingpin caster, move the
front part of the car up and down several times before the check.
6. Steering angle
In changing the steering tie rod or the steering tie rod end, Check the wheel toe-in first, and then use a steering
radius analyzer to examine the steering angle. If the steering angle is not correct, check if the length A of the left
and right steering tie rods is equal.
Notice:
If the length of steering tie rods is changed to adjust the steering angle, the wheel toe-in shall be re-checked.
1. Steering radius analyzer

2. Steering tie rod
4. Steering tie rod end nut
Inside of steering angle: 383

Outside:344
Reference data:
Wheel sideslip:
Test the front sideslip by a wheel sideslip tester
Wheel sideslip range:0~5m/Km
If the wheel sideslip exceed the range, the wheel toe-in of the front wheel alignment may be not correct.
. Technical requirement of tightening torque

Tightening torque
Fastener
Nm
Clamp nut of tie-rod end
40~72
Section Rack and pinion

Notice:
All steering gear fasteners may have impacts on important fastening parts of key performance. If it is
necessary to change parts, they shall be of the same piece number or the equivalent. Do not use the substitute
parts of inferior quality or under the design requirement. Reassembly of them must use the specified torque
to ensure that the parts can be well fixed.
. Composition
The rack and pinion steering system consists of two major parts: rack and pinion. In turning the steering wheel, the
power is transferred to the steering shaft, universal joint and then to the pinions. The pinions mesh with the racks
accordingly so that the power is further transferred to the racks to make motion in a straight line. Finally the power
is transferred to the steering knuckle of the steering wheel through the steering tie rod.
. Fault diagnosis
1. Check on the steering wheel clearance
Check the steering wheel clearance when driving a car forwards in a straight line.
Steering steel clearance a: the free travel of steering wheel outer rim is within 0~30mm.
If the steering wheels clearance is beyond the specified technical scope, it shall be check according to the
following procedures. If it is damaged, change it.
Whether the steering tie rod ball stud is worn (The ball stud, when is exercised on a 2kgcm torque, shall move).
Whether the lower ball stud is worn.
Whether the steering shaft joints are worn.
Whether the pinion or racks are worn or broken.
Whether there are part getting loose.
1. Lubrication
The parts in the steering gear box, after removed, shall be cleaned up before reassembly. The following grease is
recommended.
Grease: super grease E (99000~25050) or lithium grease (suitable for -40~130)
1. Steering rack
2. Steering tie rod lock washer
3. Steering tie rod
5. Boot
6. Steering pinion
7. Steering gear oil seal
8. Pinion bearing oil seal
9. O ring
10. Steering pinion side-entry piece
11. Rack shock pad screw
12. Rack plunger spring
13. Steering rack plunger
14. Steering rack housing and gear box assembly
15. Steering rack side-entry piece
16. Steering tie rod upper end lock nut
17. Rack boot snap ring
18. Wire
2. Steering gear box

Disassembly
1) Unscrew the joint bolts on the steering lower shaft
2) Remove the steering shaft sealing members from the front panel, and then remove the lower joint of the steering
lower shaft.
3) Jack up the car to remove the wheel.
4) Remove the steering tie rod end nuts.
5) Use a puller to take apart the steering tie rod end from
the steering knuckle.
6) Remove the steering gear box

2. Mounting bolt
1. Steering lower shaft

2. Upper joint bolt
3. Lower joint bolt
4. Steering shaft sealing member

2. Joint
3. Puller
Check
Steering rack boot
Check every boot to make sure whether they are damaged. Damaged
boots will allow dust and water enter, which may cause steering racks
and pinions to suffer wear, rust, noise, and thus give rise to system
operating troubles.
Even if there is a tiny damage, they shall be replaced with the new one.
A visual inspection shall be made to make sure whether the boot has damage or breakage when regular inspections
are made at specified intervals or the car is jacked up for other reasons.
Steering tie rod end boot
Check every boot to make sure whether they are damaged. Even if there is
a tiny damage, they shall be replaced with the new one.
Steering shaft joint

Check if the steering shaft joint has wear, breakage and other damage. They shall be changed if there is any sign of
damage.
Steering tie rod end joint

Check if it moves about in the ball joint.
Check if it moves about in ball joint at the rack end.
If any one of the above fails to meet the requirement, it shall be
changed.
Assembly

2. Mounting bolts
The reassembly shall be made in the reverse order of disassembly by the following according to the following
instructions.
After reassembly, refer to the relevant contents in Section of this
chapter to check the wheel alignment.
Tighten the gear box mounting bolts and nuts to the specified
torque.

2. Upper joint bolt
3. Lower joint bolt
4. Steering shaft sealing member
Tightening torque
(a): 253Nm
Fit the steering lower shaft on the pinion and tighten the lower joint bolts, and then tighten the joint bolts.
Tightening torque
(b): 253Nm
Fit the steering shaft sealing members on the front panel.
Fit the steering tie rod end to the steering knuckle, and then tighten the steering tie rod end nuts to the specified
torque.
Tightening torque
2. Steering knuckle
3. Steering tie rod end nut
4. Steering tie rod end clamp nut
(c): 505Nm
Notice:
The clamp nuts removed from the steering tie rod end shall be not reused, and shall be replaced with new ones.
Tighten the steering tie rod end clamp nuts to the specified torque.
Tightening torque
(d): 40~72Nm
Tighten the wheel nuts to a specified torque.
Tightening torque
(e): 1005Nm
After the assembly, check the wheel alignment and wheel tie-in setting and change them as required. (see Front
Wheel Alignment in Section of this chapter.)
Disassembly
1) Remove the steering gear box according to the Disassembly methods in the Steering Gear Box of the
chapter.
2) To make appropriate adjustment after assembly, a mark shall be made on the steering/tie rod end clamp nut of
the steering tie rod thread.
3) Unscrew the steering tie rod clamp nuts, and disconnect the steering tie rod end from the tie rod end clamp nuts.
4) Remove the boot wires and clamp.
1. Clamp nut
2. Steering tie rod
4. Marking place
1. Clamp; 2. Clip
5) Remove the boot from the steering tie rod.
6) Remove the steering tie rod lock washer bending members, and then remove the steering tie rod from the rack.
1. Lock washer
2. Steering tie rod
3. Steering rack
7) Remove the parts as shown in the figure.
8) Remove the steering gear box cover.
9)Remove the bearing plug with a special tool.
Special tool (43mm socket wrench)
(A)0994426011

3. Rack plunger
10) Tap the place as shown in the right figure with a plastic hammer so as to pull out the pinion assembly from the
case.
11) Remove the pinion assembly.
12) Remove the rack from the gear box. The direction shown in the figure
is the direction in which the rack is removed.
Caution:
The interior of the steering gear sleeve is treated with special coating.
As it is a wearing part, please be careful not to damage it when
remove the racks from the steering gear box.
13) Remove the oil seal with a special tool.
Special tool:
1. Pinion assembly
2. Plastic hammer
(B): 09913-50121
1. Pinion bearing plug

2. Oil seal
1. Rack
2. Gear box

3. Rack plunger
Check
Rack plunger
Check if the rack plunger is worn or damaged.
Check if the rack plunger spring is deformed or damage.
If any one of the above occurs, it shall be changed.
Steering pinion
Check if the tooth surface of the pinion is worn or damaged.
Check if the oil seal is damaged.
Check if the gear box O seal is damaged.
Change the damaged parts.
Steering pinion bearing
Check the bearing rotation to make sure whether it is worn.
If there is damage, change the gear box assembly.
Steering rack
Check if the rack has straightness deviation, wear or damage, and check
if the back is worn or damaged.
1. Gear box oil seal

2. O ring
3. Steering pinion
Rack deviation range: 0.1 mm

If the deviation goes beyond the range, change the rack.
Caution:
Do not use metal bush to clean it.
Reassembly
The reassembly shall be made in the reverse order of the disassembly,
with attention paid to the following aspects:
1. Pinion bearing plunger.
1) Use a special tool to fit the pinion bearing oil seal to the pinion bearing plunger.
Special tool
(A): 09925-98210
2) Apply grease to the oil seal clamp.
Grease:(99000-25050)(Suzuki super grease E)
3) Apply grease to the central tooth surface of the rack and around it.
Grease: (99000-25050) (Suzuki super grease E)
1. Rack
4) Slip the rack into the steering gear box in the direction as shown in the figure.
Caution:
The interior of the steering gear sleeve is treated with special coating. As it is a wearing part, please be
careful not to damage it when fit the rack into the
steering gear box.
5) Apply grease around the pinion teeth, and to the
pinion bearing and gear box oil seal lip.
A:
grease
(SUZUKI
E(99000-25050))
SUPER
GREASE
6) Apply fastening adhesive to the pinion bearing plug

thread.
B: fastening adhesive(THREAD LOCK CEMENT 1401 99000-32040)
7) Install the pinion assembly and tighten the pinion bearing plug to the specified torque.
Special tool (43mm wrench)
(B): 09944-20011
Tightening torque of bearing plug: 95Nm
8) Apply a little lubricating oil to the plunger sliding part close to the rack.
1. Gear box oil seal

2. Pinion tooth
3. Fill the pinion bearing
sleeve
interior
with
grease
4. O ring
5. Pinion bearing plug
6. Pinion bearing
9) Fit on the parts as shown in the figure.

10) Apply sealant around the thread of the rack shock pad screws, and tighten
them to the specified torque.
C: sealant (SUZUKI BOND No. 1215 (99000-31110))(Suzuki adhesive)
Tightening torque (a): 15Nm
1. Rack shock pad bolt

3. Rack plunger
11) After tightening the rack shock pad screw to the specified torque as
stipulated above, adjust it to incline backwards about 0~9 and check the
rotating torque of the pinion. If it fails to reach the specified valve below, adjust it to be within the specified torque
range. Meanwhile, check if the rack can move smoothly within its range of movement.
Special tool
(C): 09944-18211
Rotating torque of pinion: 8-13Nm
12) Install the steering gear box cover
13) As shown in the figure, fit the new steering tie rod lock washer and steering tie rod to the rack, with the D
part of the washer aligned with E of the rack platform.
14) Tighten the tie rod interior ball nut to the specified torque.
Tightening torque
(b): 85Nm
1. Torque wrench
15) As shown in the figure, bend the lock washer towards the steering tie rod.
1. Steering rack
2. Steering tie rod lock washer
3. Steering tie rod
4. Rack side
1. Steering rack case

2. Mounting member at rack side
16) Make sure the rack side is mounted in place as shown in the figure before a boot is fitted on the steering rack
case.
a: 0.51.3mm
1. New wire 2. Rack side-mounted member

3. Snap spring 4. Steering tie rod
17) Apply grease to the parts at the side F of the boot steering tie rod.
Caution:
Do not apply grease to the parts at the side G that contact the boot steering gear box.
18) Fit the boot correctly into the groove of the gear box and steering tie rod, and fasten it with new wires or
clamps.
The wire shall be new and wound twice. Both of its ends shall be twisted together and the twisted ends shall bend
to the twisting direction. Then check to make sure the boot has not twisting and bending.
19) Fit the steering tie rod clamp nuts and steering tie rod end to the steering tie rod, and fit the clamp nuts on the
marks made in disassembly.
1. Mark
Notice:
The length b of the original steering tie rod shall measure as a basis for changing for new steering tie rod
when the steering tie rod is changed so as to set the clamp nuts appropriately.
Materials
Recommended Suzuki
product
Use
Sliding parts close to the steering gear

case (apply grease to rack plunger, rack
bushing and rack)
Lithium grease (applicable
to-40~130)
SUZUKI super grease

(99000-25050)
Sliding parts close to the steering pinion

(apply grease to oil seal, needle bearing)
Contact part of the steering rack and
pinion teeth steering tie rods and rack
boot
Rack end ball joints
Lock cement
Thread lock cement

140(99000-32040)
Sealant
SUZUKI adhesive No.

1215 (99000-31110)
Pinion housing
The tread of rack shock pad screw
. Special tools
Oil seal puller
Bearing installer
Pinion torque testing

bushing
Pinion bearing plug

bushing (43mm)
Section 3 Steering wheel and steering column

. Composition
This set of tube type steering column has the following three important characteristics apart from the steering
function.
The steering column adopts an energy-absorbing design so that it can alleviate the front impact.
This column is equipped with an ignition switch and security lock.
As the steering column is furnished with a security lock, it can lock the ignition and steering wheel to prevent the
car being stolen.
To ensure the function of energy absorbing, the key parts employ specified screws, bolts and nuts as required by the
design, and they all shall be tightened to the specified torque.
Be careful in removing the steering column assembly from the car. It is necessary to use the removers
recommended in the manual and they shall not lean against the assembly. Do not impose violent impact on the
steering shaft end, and do not let the assembly fall down, or it will cut off the shear lockpin that maintain the length
of the steering column.
1. Steering wheel
2. Multi-function switch
3. Steering column upper cap
4. Steering column lower cap
5. Steering column assembly
. Fault diagnosis
See Section for the fault diagnosis of steering wheel and steering column
Check and maintenance after accident
In case of accident, it is bound to make check, test and repair based on Check on Fault and Damage of Steering
Column in this chapter.
1. Steering wheel
1. Steering wheel top cover

2. Steering wheel shock
absorber
3. Steering wheel bottom
cover
4. Steering wheel
Disassembly
1) Remove the
negative wire.
battery
2) Remove the steering

wheel top cover.
3) Remove the steering
wheel shock absorber.
4) Unscrew the steering
shaft nut.
5) Disassemble the steering wheel with a special tool.
Special tool
(A): 09944-36011
Caution:
Do not knock the shaft end. If so, the shear lockpin that maintain
the length of the steering column will get loosened, and the
particular shock-absorbing capacity of the steering column will be
damaged as well.
1. Alignment mark
Installation
1) Fit the steering wheel to the steering column, with the marks aligned.
2) Tighten the steering shaft nut to the specified torque.
Tightening torque of steering shaft nut: 755Nm
3) Fit on the shock absorber and top cover.
2. Multi-function switch, steering column and steering lower shaft
Caution:
1. Steering wheel
3. Steering column cap
4. Steering column
The steering column, once removed from the car, will be liable to be damaged. If the steering column
assembly sides off, its end will crack up the steering column or loosen the plastic shear lockpin that maintain
the length of the steering column. Inclining against the assemble may cause it to be bent or deformed. Any
damage of the above will affect the shock-absorbing capacity of the steering column.
The steering column mounting bolts shall not be loose, and the steering lower shaft bolts shall be tightened
up, or the bearing of steering shaft joint will be damaged.
Notice:
In maintaining the steering column or other parts fitted on the steering column, the steering wheel shall be
first removed. But if the parts to be repaired can be touched only by unscrewing the steering column, the
steering wheel shall be stay on the steering column.
Disassembly
1) Turn the steering wheel to let the front wheels straight ahead.
3) If necessary, remove the steering wheel. See the section Steering Wheel in this chapter.
4) Remove the upper and lower caps of the steering column.
5) Remove the plug connectors of the multi-function switch and ignition switch wiring harness
6) If necessary, remove the multi-function switch
1. Steering shaft top cover

2. Steering shaft bottom cover
2. Screw
1. Steering pinion shaft

3. Steering lower shaft upper joint bolt
4. Steering lower shaft lower joint bolt
5. Steering column
6. Steering column mounting bolt
7) Unscrew the steering lower shaft joint bolts.

8) Unscrew the steering column mounting bolts and remove the steering column.
9) Remove the steering shaft seals from the front panel.
10) Unscrew the steering lower shafts lower joint bolts and remove the steering shaft lower joints if necessary.
1. Steering lower shaft lower joint bolt

3. Steering pinion shaft
4. Steering shaft seal
1. Steering column mounting bolt

2. Steering lower shaft upper joint bolt
Assembly:
1) Make sure that the front wheels and steering wheel are traveling in a straight line. Insert the lower joints into the
steering pinion shaft.
2) Tighten the lower joint bolts of the steering lower shaft to the specified torque.
Tightening torque
(a): 253Nm
3) Apply lubricating oil to the steering shaft seal A, and then fit the steering shaft seal to the front panel, as
shown in the figure.
4)Align the flat part B of the steering lower shaft with the steering column joint bolt hole C, as shown in the
figure, and then insert the steering lower shaft into the steering column joint.
5) Tighten the steering column mounting bolt to the specified torque.
Tightening torque
(b): 253Nm
6) Tighten the steering lower shafts upper joint bolts to the
specified torque.
Tightening torque
(c): 253Nm
1. Steering column
2. Steering wheel security lock
7) If necessary, fit on the multi-function switch.

8) Connect the wire harness of the ignition switch and multi-function switch to the plug connector.
9) If necessary, fit on the top and bottom covers of the steering column.
10) If necessary, fit on the steering wheel. See the section

Steering Wheel in this chapter.
3. Steering wheel security lock (ignition switch)
Disassembly
2) Remove the steering column. See the section Multi-function
switch, steering column and steering lower shaft in this chapter.
1. Center punch
2. Security lock mounting bolt
3) As shown in the figure, use a center punch to unscrew and

remove the mounting bolts of the steering wheel security lock
Notice:
Be careful to use the center punch so as not to damage the
aluminum parts of the steering wheel security lock.
4) Rotate the ignition key to ACC or On, and remove the
steering wheel security lock assembly from the steering
column.
1. Steering column
2. Steering shaft
Assembly
1) Align the rectangular holes of steering shaft with the center of steering column inner holes.
2) Rotate the ignition key to ACC or On, and fit the steering wheel security lock assembly to the steering
column.
3) Rotate the ignition key further to LOCK position, and pull it out.
4) Align the lock sleeve with the rectangular holes of the steering shaft, and then turn the shaft to lock the steering
shaft.
5) Tighten the two new bolts till their heads fall off, as shown in the
right figure.
6) Rotate the ignition key to ACC or On, and check if the
steering shaft can rotate smoothly. Then check the service
conditions of the security lock.
7) Fit on the steering column. See the section Multi-function switch, steering column and steering lower shaft in
this chapter.
4. Check the safety equipment of steering column after accident
Notice:
In case of car accident, the car body may be damaged; once the
1. Packaging clip
steering column is impacted, it will be damaged or misaligned.

Check order
1) Check if the two packaging clips are fixed on the steering column support.
Check the clearance between the packaging clip and the steering column support, as shown in the figure. Check if
the clearance a at both sides has cracks, looseness. If there is damage,
change it.
2) Measure b, as shown in the figure.
If it is shorter than the specified length, replace it with a new steering
column.
Length b: 449.51mm
3) Check if the steering shaft joints and shaft are damaged, for example cracks, rupture, malfunction or large
clearance, and etc.
4) Check if the steering shaft can rotate smoothly. If there is damage, change the steering column assembly.
5) Check if the steering shaft or steering column are bent, cracked or
damaged. If there is damage, change the steering column assembly.
Materials
Recommended Suzuki product
Use
Lithium lubricating oil
Grad A grease (99000-25010)
Steering shaft seal
. Special tool
Steering wheel remover
Chapter Braking system

Section System composition and operating principle
When the brake pedal is pressed down, the master cylinder will produce a hydraulic pressure inside, which impels
the wheel braking cylinder pistons (two at front and rear respectively) to act.
The master cylinder is a series dual-chamber master cylinder, with the brake pipe connected with the master
cylinder. It has two independent circuits, one connecting the front brake (left and right), and the other connecting
the rear brake (left and right).
The brake proportioning valve (BP valve) or load sensing proportioning valve is located in the circuits between the
master cylinder and the rear wheel. In the braking system of this sort, the disc brake is used for the front wheel
braking, and the drum brake is used for the rear wheel braking. The parking braking system, which is mechanical,
exercise braking force on rear wheels alone by cable and mechanical link.
The parking brake and service brake use the same brake shoe.
Direction
of advance
1. Booster 2. Brake master cylinder 3. Four-way 1 4. Four-way 2 5. load sensing valve

6. Front wheel disc brake 7. Rear wheel drum brake 8. Hand brake lever
9. Hydraulic braking pipe 10. Hand brake cable
Braking system schematic diagram
. Booster assembly
The booster sits between the master cylinder and the brake pedal. The advantage of such design is that the engine
vacuum negative pressure can be made use of to increase mechanical braking force as the brake pedal is pressed
down.
Caution:
When and after the booster is removed, never let it fall off or deform ever.
Warning:
Never take apart the brake booster assembly. If it is found to have fault, replace with a new booster
assembly.
Caution:
Tighten the fasteners not lubricated to the specified torque. The brake fluid shall be discharged first when
any hydraulic element is removed or the brake pipe is disconnected.
Operating principle
When the brake pedal is pressed down, the brake force is transferred to the master cylinder piston through the valve
lever, booster air valve, reaction disc and piston rod. Meanwhile, the pressure difference between the piston
chambers A and B (see the figure below) acts on the booster piston to generate boosts. Therefore, a little force
on the brake pedal will form a strong thrust to the master cylinder rod, and thus produce a high hydraulic pressure.
Any part relating to the vacuum in the booster once breaks down, the brake force will not increase any more.
However, the brake force generated from pressing down the brake pedal can be still transferred to the valve lever,
booster air valve, valve stop pin and booster piston, and thus impelling the master cylinder rod. Accordingly, the
booster itself will not encounter failure.
. Master cylinder assembly
A: Brake pedal
B: Master cylinder
1. Booster 1
2. Booster 2
3. Valve lever
4. Air filter element
5. Air filter separator
6. Air valve return spring
7. Air valve return spring
8. Control valve spring space
9. Control valve spring
10. Booster control valve
11. Booster air valve
12. Booster piston
13. Valve stop
14. Booster diaphragm
15. Reaction disc
16. Booster piston return spring
17. Booster piston rod
18. Booster rod adjusting screw
The master cylinder has two pistons and three piston cups. The hydraulic pressure is generated in the first piston
chamber (a in the figure below) and the second piston chamber (b). The hydraulic pressure generated in the
first piston chamber (a) acts on the rear wheel brake (front wheel brake for the cars equipped with anti-lock
braking system). Similarly, the hydraulic pressure generated in the second piston chamber (b) acts on the front
wheel brake (rear wheel brake for the cars equipped with anti-lock braking system).
Notice:
To repair the master cylinder, the original spare parts in the service kit shall be used. New rubber articles
lubricated with clean brake fluid shall be employed to make the assembly easy. The compressed air with oil
shall be not used to blow the braking components, for it will damage the rubber articles. If it is necessary to
remove the hydraulic components or disconnect the brake pipe, the brake fluid shall be discharged first. The
dry fasteners that have no lubrication shall be tightened to the specified torque.
1. Piston stop snap ring

2. Piston stop
3. Cylinder head
4. Plate
5. The first piston
6. Piston cup
7. Piston 1 return spring
8. Piston 1 spring space
9. Piston 2 pressure cup
10. Piston 2
11. Return spring seat
12. Piston 2 return spring
13. Piston 2 stop bolt
14. Master cylinder block
A piston 1
B piston 2
. Load sensing proportioning valve
As shown in the figure below, the load sensing proportioning valve (LSPV) is located in the brake circuit
connecting the master cylinder and the rear wheel brake. It can control the hydraulic pressure supplied to the rear
wheel brake according to the load on the car (or load weight) to prevent the rear wheel locking too early, and it can
release the high hydraulic pressure supplied to the rear wheel brake as well. If there are troubles in the front wheel
brake hydraulic circuit, the hydraulic pressure generated in the master cylinder will be directly supplied to the rear
wheel brake to carry out rear wheel brake control.
Caution:
Never take apart the load sensing proportioning valve, or the original functions will be impaired. If it has
failures, replace it with a new one.
1. LSPV spring holder (connected to the rear axle housing)

2. LSPV (load sensing proportioning valve) assembly
3. Connected to the master cylinder
4. To the rear wheel brake
Load sensing valve assembly

Structure
LSPV component is mainly composed of:
A: sensor part
The sensor part is mainly composed of lever and spring. The spring can, when impacted by load, sense the cars
changes in height, and can convert the changes into load signals.
B: hydraulic pressure control part
The hydraulic pressure control part is mainly composed of plunger and valve system that exercises proportioning
control.
C: fail-safe part
The fail-safe part is mainly composed of piston chamber and fail-safe piston. The piston chamber sucks hydraulic
pressure through the front wheel brake. The fail-safe piston will release valve system pressure when the front wheel
braking system brakes down. This system is connected with the rear wheel brake.
1. Plunger
2. LSPV lever
3. Sensor spring
4. From the master cylinder
Piston chamber 1
Front wheel brake
5. To the rear wheel brake
6. From the master cylinder
Piston chamber 2
Rear wheel brake
7. Bleeder plug
. Front wheel disc brake

The disc brake caliper has only one single piston cylinder. The hydraulic pressure generated by applying force to
the brake pedal is transferred through the caliper to the shoes to produce friction. The hydraulic pressure acts
evenly on the piston and caliper cylinder bottom to move the piston outwards, and the caliper inwards (slide) to
clamp the brake disc. The clamping action forces the brake pad (friction facing) to exercise a pressure on the brake
disc to produce friction, and thus to stop the car.
Notice:
Components shall be lubricated as stipulated. Do not use compressed air with oil to blow the brake parts, for it will
damage the rubber elements. The brake fluid shall be first discharged when it is necessary to remove the parts or
the pipes. The dry fasteners that need no lubrication shall be tightened to the specified torque.
1. Brake caliper spacer

2. Boot
3. Caliper
4. Disc brake piston
5. Piston seal
6. Cylinder bushing
7. Brake pad
8. Bleeder plug
9. Bleeder plug lid
10. Block (gasket)
11. Boot retaining ring
. Rear drum brake assembly

The drum brake is structured as shown in the figure below. Drum brake assembly has a device which can
automatically adjust the brake shoe clearance, so that it can always keep a suitable clearance between the brake
drum and brake shoe.
Notice:
To repair this type of drum brake, the whole set of parts in the service kit shall be used. The parts shall be
lubricated as required.
Warning:
The brake fluid shall be discharged first when any hydraulic element is removed or the brake pipe is
disconnected. The dry fasteners that need no lubricating shall be tightened to the specified torque.
When the brake pedal is press down, the piston impels the brake shoes to move towards the brake drum. When the
pedal effort increases, the brake shoes continue moving close to the brake drum. When the brake shoes press the
brake drum, the brake force is produced.
The migration length of tie rod arm is consistent with the wear. As the tie rod arm moves, the sector ratchet moves,
too, for they are assembled together. Until the clearance between the brake shoes and the brake drum is larger than
the migration length, the tie rod arm and ratchet are moved in place and stay where they are.
In this way, the clearance between the brake shoes and brake drum will be automatically adjusted to be consistent at
every time when the brake pedal is pressed.
1. Brake bottom plate

2. Brake shoe
3. Parking brake rod
4. Brake anchor plate
5. Segmented spring
6. Shoe return spring

7. Shock absorbing spring
8. Brake shoe pressure spring
9. Shoe pressure pin
10. Parking tie rod arm spacer
11. Wheel cylinder

12. Bleeder plug lid
13. Rubber stopper
. Parking braking system

The car employs mechanical parking braking system, whose control and driving devices are mainly composed of
machine parts such as lever, rod and cable. The schematic diagram of the mechanical parking braking system of
this car is as follows.
The parking braking system must ensure that the car can park where it is and will never slide in any case.
1. Parking brake handle 2. Parking control mechanism assembly 3. Cable 1

4. Cable spring 1
5. Cable 2 (right)
6. Cable 2 (left) 7. Rear wheel
Mechanical parking braking system
Section Fault diagnosis

. Check on brake fluid
Brake fluid leakage
Give a check to the brake fluid level of the master cylinder. If the level of fluid reservoir drops a little, it is caused
by normal pad wear. If there is abnormal drop in the fluid level, it means that the system has a leakage. Even if the
leakage sign is slight, the damaged part shall be repaired or changed timely.
Unacceptable or polluted brake fluid
Unsuitable brake fluid and content of mineral oil or water in the brake fluid will cause the brake fluid to boil to
form bubbles or the rubber elements in the hydraulic system to be damaged.
If the first piston cup swells, it means the rubber element is damaged, which will also cause the wheel brake pump
piston cup of the drum brake to swell.
If the rubber elements are damaged, all hydraulic elements shall be removed and cleaned with ethanol (for instance
alcohol). Before assembly, these elements shall be blown dry by compressed air so as to leave no ethanol in the
system. All rubber elements are changed in the system, including hoses. When the braking device is working, a
check shall be given to the friction facing to make sure whether it has brake fluid. If there is excess brake fluid
found, the brake pad shall be changed.
If the piston seal ring of the master cylinder has no problem, check if there is leakage or overheat. If there is no
leakage or overheat found, discharge the brake fluid, and clean it with the brake fluid, and finally refill the brake
fluid and exhaust the air in the system.
If you have a doubt about the grade of the brake fluid used for the system, or a polluted brake fluid is used, the
system must be rinsed with a brake fluid that meets requirements.
. Brake road test

Tests on brakes shall be carried out on dry, clean and plat roads, not the rugged roads. In carrying out the brake road
test, the brake pedal shall be pressed gently or heavily at different speeds according to brake uses to check if the car
can stop quickly or effectively.
Another check shall be made to make sure whether the car pulls to one side when the brake is not applied. If yes,
check the tire pressure and make sure whether the front wheel alignment is proper and whether the front suspension
connecting pieces are loose. See the fault diagnosis table for other reasons.
. Braking system fault diagnosis table

Notice:
All the fasteners of the brake connecting pieces are of great importance, for they will affect the
performance of major parts and systems and increase the maintenance cost. If they are necessary to change,
they shall not be replaced by inferior product or substitute. When they are reassembled, all the parts shall be
tightened to the specified torque instead of welding, which may cause the metal to be extensively damaged or
softened.
Troubles
Causes
The brake pipe leaks oil.
Ascertain where oil leaks and repair it
The brake disc or brake pad (block) is

contaminated by oil.
Clean or change
The brake is overheated.

The contact of the brake drum and brake
shoe is poor.
The brake shoe friction facing has oil stain
or water.
Inadequate
brake force
Troubleshooting
Find out the causes and repair it

Repair it to let them contact correctly
Change
Change
Repair or change
The brake pad (block) gasket is worn.
Repair or change
The wheel cylinder is damaged.
Check or adjust
The brake caliper assembly breaks down.
Exhaust
(If equipped) LSPV sensor spring length is

improperly adjusted.
Change
There is air in the system.

LSPV sensor spring is damaged.
LSPV collar is damage (if equipped)
Anti-lock braking system (ABS) has failures
(if equipped)
Change
See other relevant materials, for it is not
covered in this manual.
Change
The brake pad (block) friction facing or
brake shoe friction facing has water or oil
stain.
The clearance between the brake drum
and brake shoe is subject to
maladjustment (failure of automatic
adjusting mechanism).
The brake disc and/or brake drum of the
brake is out of circularity.
Uneven brake (the

brake fails to work
in harmony)
Repair or change
The wheel brake pump breaks down.
Fit tires of the same tread to the same

shaft
The brake caliper assembly goes wrong.
The suspension elements get loose.
The brake locks

(cars
equipped
with ABS)
Inflate evenly
Adjust as required.
The fluid in the brake oil pipe or hose

fails to flow smoothly.
The rear brake

locks too early
(for cars equipped
with LSPV)
Change
The wheel pressure is not uniform.
The tires of the axles are unmatched.
Noise (there is
squeak when the
brake
is
not
applied)
Check the ineffective automatic adjusting

mechanism.
Check if the hose is softened and if the oil

pipe is damaged; replace with the new
hose and new double wall brake steel tube
Check if the piston is jammed or act
slowly. The calipers sliding bushing shall
be properly lubricated. The caliper shall
slide.
Check all the suspension mounting
members.
The caliper is loosened.
Check and tighten the bolts to the

specified torque.
The front brake friction facing is worn.
Change the friction facing
LSPV sensor spring length is improperly

adjusted.
Check or adjust
LSPV assembly goes wrong.
ABS
system
goes
wrong.
(ABS-Anti-lock Braking System)
Change the assembly
See other relevant materials, for it is not

covered in this manual.
The braking
partially.
system
breaks
down
the brake fluid in the master cylinders

reservoir is inadequate.
Check the braking system, and repair it if

necessary.
Fill acceptable brake fluid
Check if the braking system has leakage
or air.
Check the warning light, and exhaust the
system if necessary.
Too great pedal

travel
here is air in the braking system (the

pedal is so weak like pressing a sponge)
The rear braking system cannot be
adjusted (automatic adjusting mechanism
failure)
The brake shoe is bent.
The rear brake shoe is worn.
Exhaust
Repair
the
mechanism
automatic
adjusting
Adjust the rear brake

Change the brake shoe
Change the brake shoe
The master cylinder piston cannot

return correctly.
The brake oil pipe hose is clogged that
the flow diminishes.
Repair the master cylinder

Check if the hose is softened and if the oil
pipe is damaged; replace with the new
hose and new double wall brake steel tube
Brake return is
hindered
(when
the
pedal
is
released, the brake
cannot
return
timely)
The parking brake of the rear brake is

improperly adjusted.
The return spring in the brake cannot
return or is damaged.
The parking brake cable or rod reacts
slowly.
Check and adjust according to technical

requirements
Change
Repair or change
Repair if necessary
The wheel brake pump or caliper piston

is jammed.
The piston seal in the caliper is severely
worn.
Change the piston seal
Pedal
pulsation
(the pedal pulsates
when
pressed
down)
The wheel bearing is damaged or

loosened.
Change the wheel bearing
The steering knuckle or rear wheel axle

is deformed.
Change the steering knuckle and rear

wheel axle
The radial runout of brake disc is too

great.
Follow the instructions to make checks.

Change or fit brake disc if it fails to meet
the technical requirements.
The parallelism fails to comply with the

technical requirement.
The rear brake drum is out of out of

circularity.
follow the instructions to make checks.

Change or fit brake disc if it fails to meet
the technical requirements.
Check the radial runout, and repair or
change the brake drum if necessary.
The brake shoe is rubbed to be shiny or

stained with impurities.
Repair or change
The brake shoe is worn or deformed.
Change
The front wheel bearing gets loose.
Change
The bottom plate or mounting bolt gets

loose.
change or tighten the fixed bolts
Brake noise
The parking brake is not released.

The
brake
warning light is
on after the engine
starts.
The
brake
warning light is
on when the brake
is applied.
The
brake
warning
light
cannot be on
when
parking
brake is applied.
The brake fluid is inadequate.

The brake pipe leaks fluid.
The brake warning light circuit is out of
order.
The brake pipe leaks fluid.

The brake fluid is inadequate.
The brake warning light circuit is out of

order.
Release the parking brake, and check and

turn off the brake warning light.
Fill brake fluid
Check the leaking position and repair it,
and then refill brake fluid
Repair
Check the leaking position and repair it,

and then refill brake fluid
Change the bulb or repair the circuit
Section Check and adjustment

1. Adjustment of brake pedal free height
Check the brake pedal free height a. if the free height fails to meet
the technical requirements, check and adjust it according to its 1) and
2).
1) Check the distance from the booster mounting surface to the U pin
hole center. In reassembling the tie rod U pin, pay attention to
adjusting the distance.
Length
b: 99.5~100.5mm
Tightening torque
(a): 25Nm
1. Tie rod U pin
2) Check the position of the stop light switch. If it fails to comply with the technical requirements, please adjust it.
2. Adjustment of stop light switch
Fitting on switches shall make adjustment according to the following requirements:
pull up the brake pedal to yourself to adjust the switch position so as to enable the
clearance between the thread end and the brake pedal to comply with the technical
requirement; then tighten the lock nuts to the specified torque.
Clearance
a: 1.5~2.0mm
Tightening torque
(a): 7.5Nm
3. Check on pedal travel
1) Starting engine
2) Press down the brake pedal several times.
3) Press down the brake pedal with a force no more than 400N to measure
the clearance a between the brake pedal and the front panel inner wall.
Clearance
a: more than 155mm
4) If the clearance a is less than the specified size, it may be caused by rear
brake shoe wear or existence of air in the pipe.

If the clearance a is always less than the specified size, and remains so even if the brake shoe is replaced and the
system is exhausted, it may be such case that the rear brake shoe adjuster breaks down or the booster rod length is
improperly adjusted. But this possibility is somehow little.
Refer to the section of brake exhaust to exhaust the system.
In checking the adjuster, the brake drum shall be removed (refer to brake drum check). If it is damaged, repair or
change it.
4. Check on front brake disc
As for the check points and check method of the front brake disc, see Check on Brake Pad in this chapter.
Check on front brake pad lining
Whenever the tire is removed (tire rotation or other reasons), the brake lining shall be periodically checked
according to the maintenance schedule. Check the lining thickness inside and outside the brake pad through the
caliper end (or hole).
If the lining is worn, the thickness (d in the figure will be less than specified value, all the brake pads shall be
change.
Thickness d
Limit size: 1.0mm
5. Check on rear brake shoe
Thickness e
1. Backing ring
2. Brake disc
3. Lining
Limit size: 1.0mm

The check on this item shall follow the check on brake pedal travel. Even if the pedal travel is normal, the check
shall be made according to the following requirements.
The check on the brake shoe wear is as follows:
1) Jack up the car.
2) Remove the rubber stopper from the brake bottom plate.
3) Observe the brake shoe linings thickness visually through the bottom plate holes. If the lining thickness e is
less than the limit size, change all the brake shoes at the same time.
1. Rubber stopper
2. Brake lining
3. Brake shoe backing ring
6. Check on brake pedal clearance

The pedal clearance shall be within the following technical range, or a check shall be given to the stop light switch
to make sure whether its mounting position is suitable. If necessary, adjust it. Checks shall also be made to pedal
shaft bolts and the tightness of master cylinder pins. They shall, if damaged, be changed.
Pedal clearance f: 1~8mm
7. Master cylinder check
Check if the master cylinder casting has cracks or whether there is brake
fluid around the master cylinder. If there is a little liquid drops, it means
there is a leakage. Moisture regain is also abnormal.
8. Adjustment of rear drum brake shoe
The rear brake is equipped with an auto mechanical adjusting device. But
after the brake shoes have been changed or the brake drum has been removed to make other maintenance, it is
necessary to adjust the clearance between the brake drum and brake shoe. When all the parts are assembled, the
adjustment shall be carried out by pressing the pedal 3-5 times with a force of about 400N after the engine is
started.
Then check if the brake drum is jammed and whether the braking system has
good performance. And finally let down the car to conduct brake tests.
9. Check and adjustment of parking brake
Check
Hold the parking brake lever and pull it up with a force of 25kg. Pull up the
parking brake lever as required above (see the figure), and count the number
of teeth of the ratchet at A.
The number of the ratchet teeth is 5~8.
It is still necessary to check if the left and right rear wheels are locked.
Another method of counting the number of teeth is to pull up the parking
brake instead of pressing the button on the lever to listen to the click of
the ratchet.
A click means a tooth.
If the number of teeth fails to meet the technical requirements, refer to
the following step b) to adjust the cable to gain the specified parking
braking distance.
Notice:
Check if the tip of every tooth is worn or damaged. If yes, change
the parking brake lever.
Adjustment
1. Parking brake lever

2. Brake cable
3. Nut
Notice:
Ensure the following conditions before the cable is adjusted:
There shall be no residual air in the braking system.
The brake pedal travel shall be appropriate.
Press the brake pedal several times with a force of about 400N.
Pull up the parking brake lever several times with a force about 25kg.
The wear of the rear brake shoe shall not go beyond the limit.
Provided the five conditions above are met, adjust the parking brake lever travel by unscrewing or screwing the
parking brake nuts (right figure).
Tightening torque
(a): 20Nm
(b): 11Nm
Notice:
Check if the brake drum is jammed after the adjustment.
Parking brake lever travel:
Pull up the parking brake lever with a force of 20kg; it has 4~7 teeth.
10. Rinse of brake hydraulic system
It is recommended that the whole hydraulic system shall be thoroughly rinsed with clean brake fluid when new
elements are installed in it.
It is recommended to change the brake fluid periodically.
11. Brake air exhaust
Caution:
The brake fluid is very harmful to the paint, so that it shall be wiped up immediately when the brake fluid
accidentally touches the lacquered surface.
As soon as the air enters the hydraulic system, it shall be exhausted from the brake fluid.
The hydraulic tube of the braking system is composed of two independent pipelines, one connected to the front
wheel brake, and the other one connected to the rear wheel brake. When one brake tube or hose is removed from
the wheel, a discharge must be given to the two ends of the removed pipeline or hose. When a joint element
between the master cylinder and the brakes (wheels) is removed, the hydraulic system must give a discharge to the
left and right brake calipers, left and right wheel cylinders of the rear wheel and LSPV (if equipped).
1. Plunger
2.Vinyl resins
3. Vessel
1. Master cylinder
4. LSPV
2. 4-way connector 1 5. Front wheel brake
3. 4-way connector 2 6. Rear wheel brake
1) Fill the master cylinder reservoir with brake fluid. The reservoir
shall have at least half of the brake fluid when the air is exhausted.
2) Remove the drain plug cover.
Insert the vinyl resins into the drain plug, with the other end into the
vessel.
Press the brake pedal several times

Unscrew the drain plug when it pressed
3) Press the brake pedal several times, and then unscrew the drain
plug about 1/3 turn to 1/2 turn when it is pressed.
4) When the hydraulic pressure is almost released, screw the drain plug.
5) Repeat the operation till there are no bubbles puffing out from the
hydraulic tube.
6) If there are no bubbles puffing out, press down the brake pedal to screw
up the drain plug.
Tightening torque
(b): 8Nm for rear brake, and LSPV
11Nm for front brake
7) Close the drain plug cover.
8) Once the air exhaust is finished, apply hydraulic pressure to the
pipeline to check if there is leakage.
9) Refill the reservoir with brake fluid to the specified level.
10) Check if the pedal is pressed like a sponge. If it is weak, please
repeat the step of air exhaust.
Press the brake pedal

Screw the drain plug again
12. Brake hose and oil pipe

Check if the brake hose assembly has damage, cracks and external wear or leakage. If necessary, make the thorough
check with the help of light and minor. If there is faults as mentioned above,
change the brake hose.
Check if the oil pipe has damage, cracks, bending and corrosion. If has,
change it.
13. Check on brake fluid level
The car must use the brake fluid marked on the reservoir or recommend in
the manual.
Any other brake fluid is prohibited to use.
The brake fluid level shall be between the minimum level and the maximum level
marked in the reservoir. When the warning light turns on, fill brake fluid to the
maximum level.
When the brake fluid declines rapidly, a check shall be made to make sure whether the
system has a leakage. If there is, repair it and refill the brake fluid to the specified
level.
Caution:
1. Maximum level
2. Minimum level
Do not use shock absorber fluid or other fluid with mineral oil; do not use damp
vessels or the vessels that have held mineral oil. Mineral oil will cause the rubber elements in the hydraulic
braking system to swell or deform. Moisture in the brake fluid will lower the boiling point of the brake fluid.
All the brake fluid vessels shall be covered to prevent from pollution.
14. Check on boosters service conditions

The methods of check on boosters service are divided into two classes: use of testing equipment and no use of
testing equipment. If no testing equipment is made use of, it can only check the boosters service approximately.
Notice:
Check if there is air in the hydraulic pipes.
Check the gas seal
1) Start the engine.
2) Stop the engine after it runs 1-2 minutes.
3) Press the brake pedal continuously several times with the same common braking force and observe the pedal
travel. If the pedal sinks deeply at the first time, and its travel diminishes at the second and third time, it means the
airtight seal is formed.
4) If the pedal travel remains the same, it means the gas seal is not formed.
Notice:
If the check finds out damage in the vacuum tubes and seals, the damaged members shall be changed.
Repeat the test after all operation.
The third time

Gas seal not formed
Good gas seal

The first, second and third time
The second time

The first time
Check on service conditions

1) When the engine stops, press the brake pedal several times intermittently with the same force to confirm that the
pedal travel does not change.
2) While starting the engine, press the brake pedal with the same force (as the pedal effort mentioned in 1)). If the
pedal travel increases slightly, it means the operation is good, but if the pedal travel has no changes, it means there
is a failure.
Check on gas seal under loads

1) While the engine is running, press down the brake pedal and then stop the engine, leaving the brake pedal
pressed down.
2) Let the brake pedal keep pressed for 30s. If the pedal height has no changes, it means it is in good condition; if
the pedal rises, it means a failure.
30s
Keep pressed
Keep pressed for 30s
15. Hydraulic test ( if equipped with LSPV (load sensing

proportioning load)
The test procedure of LSPV assembly is as follows:
The following requirements shall be met before the test:
Fill the fuel tank
The car is equipped with spare tire, tools, jack and jack handle.
1) Park the car as shown in the figure, putting the weight slowly
on the center of the rear axle housing to let the rear axle carry a
load of up to 660kg.
2) Fit the pressure gauges to the front and rear brakes.
Notice:
The pressure gauge shall be connected to the left exhaust
plugs of the front and rear brakes.
1. Weight
Special tool
Front brake
(A): 3509110-01
Rear brake
(A): 3509110-01
(B): 3509120-01(hydraulic pressure gauge accessories)
(C): 3509130-01(exhaust plug of spare parts (10mm)
Notice:
The thread attachment of the special tool (B) can be substituted by that (10mm diameter) of the special tool
(A). Thus it is possible to remove the attachment from the
special tool (A) to fit to the special tool (B).
3) Slowly press down the brake pedal till the hydraulic
pressure of the front brake reach the pressure range listed in
the table below. Then check if the hydraulic pressure of the
rear brake falls into the range specified as below.
Front brake pressure
Rear brake pressure
8000kPa
4200-5600kPa
Provided the requirements above are met, exercise a 10,000kPa pressure to the front brake and then check if the
rear brake pressure is within the specified range as below.
Front brake P1
Rear brake P2
10000kPa
4800-6200kPa
4) If the rear brake pressure is beyond the specified range, adjust it by

changing the tightening position of the bolt (a) according to the
following method.
If the rear brake pressure is higher than the specified technical
requirement, screw the bolt (a) downwards; if lower than the specified
requirement, screw the bolt (a) upwards.
Repeat the procedures 3) and 4) until the rear brake pressure complies
with the technical requirements.
Tighten the nuts to the specified torque after the adjustment.
1. LSPV rod 3. LSPV stay

2. LSPV spring
Tightening torque
(a): 23Nm
5) Disconnect the brake pipe on the master cylinder to the front
wheel brake (connecting pipe between the master cylinder and the
four-way box)
Special too
(A): 3509140-01
1. Master cylinder
Screw the bolts (special tool)to the master cylinder, as shown in the
figure.
In pressing down the brake pedal, if the pressure to the front wheel brake is 10,000kPa and is 9,500-10,000kPa to the
rear brake, it means the fail-safe system is good in performance.
Front brake
10000kPa
Rear brake
9500~10000kPa
100kg/cm2
95~100kg/cm2
1422psi
1350~1422psi
6) After the hydraulic test finishes, exhaust the braking system to carry out brake tests.
Section In-car maintenance

1. Front brake hose/pipe
1) The car shall be jacked up and supported properly to remove the tires and wheels. This is not necessary when the
pipe connecting the master cylinder and the proportioning valves is removed.
2) Dirt and impurities in the hoses and end mounting pieces shall be eliminated so as to remove the brake hose or
pipe.
3) The brake hose shall be assembled in the reverse order of its disassembly. In installing, make sure the steering
wheel is in the proper position and the hose is not twisted. Check to make sure that the hose will not contact any
suspension element in turning left and right. If it does contact them, remove it to rectify. Fill the reservoir with
brake fluid to the specified level, and then exhaust the braking system.
4) Carry out brake test to check if the
mounting pieces have leakage.
1. Parallel four-way
2. Brake proportioning valve (BP
valve)
3. Four-way box
4. Dual pipe clip
7. From master cylinder (first) to
parallel four-way.
8. From master cylinder (second) to
parallel four-way.
11. To front brake (right)
12. To front brake (left)
13. To rear brake or LSPV (load sensing proportioning valve)
14. From four-way box to LSPV
Tightening torque
(a)16Nm
(b)llNm
(c)10Nm
2. Rear brake hose/pipe
1) The car shall be jacked up and supported properly to remove the tires and wheels.
2) Dirt and impurities in the hoses and end mounting pieces shall be eliminated so as to remove the brake hose or
pipe.
3) The brake hose shall be assembled in

the reverse order of its disassembly. Fill
the reservoir with brake fluid to the
specified level, and then exhaust the
braking system.
4) Carry out brake test to check if the
mounting pieces have leakage.
Notice of installation:
The removed protector nuts shall not
be reused, and shall be replaced with
new ones.
The clip shall be fixed on the proper position as shown in the right figure. Screw up the bolts.
Make sure the hoses are not twisted when they are installed.
1. Hose
2. E-shaped clip
3. LSPV(load sensing proportioning valve)
4. LSPV bolt
5. Dual pipe clip
6. Tapping screw
7. Wheel
(right)
cylinder
8. Wheel
(left)
cylinder
10. From the master

cylinder (first)
11. From the master cylinder (second)
12. To wheel brake cylinder
13. Exhaust switch plug
14. Rear axle
15. Upside
16. Front side
17. Left side
Tightening torque
(a): 16Nm
(b): 8Nm
(c): 23Nm
(d): 11Nm

2. Parking brake lock nut
3. Parking brake adjusting nut
4. Brake parking lever bolt
5. Brake parking lever assembly
6. Center member
3. Brake parking lever

Disassembly
1) Remove the control box
2) Disconnect parking brake switch wire to unplug the plug connector.
Notice:
Do not remove the brake parking lever switch. The switch assembly shall be removed and fitted on
simultaneously.
3) Remove the parking brake cable nuts.
4) Remove the brake parking lever bolts
Assembly
1) The assembly shall be made in the reverse order of the
disassembly procedures from 2) to 4).
1. Parking brake shoe rod

Tightening torque
(a): 20 Nm
2) Adjust the brake parking lever, with reference to the
check and adjustment of parking brake in this chapter.
3) Check if the rear brake is jammed and if the braking system is good in performance.
4) Fit on the control box.
4.
Parking brake cable
Disassembly
1) Remove the cable from the brake parking lever (see the brake parking lever disassembly procedures 1)~3) in this
chapter).
2) Remove the brake drum (see the brake drum disassembly procedures 1)~5) in the chapter).
3) Separate the parking brake cable from the brake shoe rod (see the brake shoe disassembly procedure 2)~4) in the
chapter).
4) Remove the brake cable from the brake bottom plate (see the brake bottom plate disassembly procedure 4)).
Notice:
If it is necessary to remove the left/right parking brake cable, repeat the steps 2)~4) for the left/ right wheel.
5) Remove the cable from the car body.
B-1: Clip
B-2: Stud bolt insert direction
B-3: Cable
A-1: Brake parking lever
A-2: Brake parking lever bolt
A-3: Cable lock nut
A-4: Cable not disconnected, reed bent
A-5: Cable locating ring (cable is inserted
D-1: Balancer
into the center member till the cable

locating ring is installed in place.
F-1: Parking brake shoe rod

F-2: threaded end
F-3: Guide
1. Center member
2. #1 parking brake cable (right)
3. #2 parking brake cable (right)
4. #2 parking brake cable (left)
5. Cross piece
a angle: within 20
C-1: Cable end cap
Distance b: 20-30mm
E-1: Clip
Tightening torque
(a): 20Nm
(b) 11Nm
Assembly
1) Apply waterproof sealant A along the cable to the point marked as
shown in the figure and connect the cable with the bottom plate by clips.
Sealant
A: 6100997-01
2) Connect the cable and the brake shoe rod, and fit the brake shoe on
the brake bottom plate (see the brake shoe assembly procedure 1)~2) in
the chapter).

2. Cable
3. Clip
3) Fit on the brake drum (see the brake drum assembly procedure 1)~2) in the chapter).
4) Connect the cable and the brake parking lever (see the brake lever assembly procedure 1) in the chapter). Then
the brake lever cannot be adjusted.
Notice: the assembly of the left/right wheel parking brake must follow the steps 1)~3) mentioned above.
5) Firmly clamp the cable with reference to the figure.
6) After assembly, adjust the cable (see the check and adjustment of parking brake in the chapter). Then check if the
brake drum is jammed and if the braking system is in good performance.
Put down the car from the lifting equipment to carry out brake test.
5. Brake pad
Disassembly
1) Jack up the car to remove the wheels.
2) Take apart the E-shaped clip that is used to fix the brake hose and remove the hose from the support.
3) Remove the caliper pin bolts.
4) Remove the caliper from the bracket.
Notice:
Hoist the removed caliper by a steel wire hook to avoid brake hose being excessively bent, twisted or pulled.
Do not press the brake pedal after the brake pad is removed.
5) Remove the brake pad.
1. Caliper
Check
2. Steel wire hook
3. Brake pad
1. Caliper
2. Caliper pin bolt
3. Brake disc
Brake pad
Check if the brake pad lining is worn. If it is excessively worn, replace it with the a new one.
Caution:
Never use abrasive paper to polish the brake pad lining, or the hard particles will penetrate into the lining to
damage the brake disc. When the brake lining needs to be changed, use a new one.
Pad thickness (lining + brake pad)
Standard: 15mm
Limit: 7mm
Notice:
In removing the brake pad, observe whether there is brake
fluid leak on the caliper. If there is, repair it.
Wheel cylinder sliding pin/caliper pin bolt
Check if the sliding pin can slide smoothly as shown in the figure below.
A applied with rubber grease
If there is damage in it, repair or change it. Apply rubber grease to the outer surface of the sliding pin and caliper
pin bolt. The viscosity of rubber grease is basically not affected at low temperature of -40.
Sliding bushing of boot and pin
Check if the boot and bushing have cracks and damage. If they are
damaged, change them.
Brake disc
Check the scrape on the brake disc surface and worn parts.
Check or change periodically, and notice that it is normal to have
scrapes on the brake disc surface.
The brake disc is not damaged, unless the scrape is serious.
But if the scrape on the brake disc surface is too deep or high, the brake
disc shall be changed. If there are scrapes on only one side, it shall be polished and repaired.
Change he brake disc when it is worn to a certain degree.
Brake disc thickness:
Standard: 12.0mm
Limit: 10.0mm
Secure the brake disc against the hub with wheel nuts and then fit on a dial indicator, as shown in the figure. To
measure the deviation of brake disc, take two points from the circumference of the brake disc to measure with a dial
indicator when the brake disc is turned.
Brake disc deviation limit: 0.15mm
Special tools
(A): 3509150-01
(B): 3509160-01
Notice:
Check if the front wheel bearing gets loosened before measurement.
Assembly
1) Fit the gasket to the friction block, and then fit on the block clip, and
finally fit the friction block to the caliper bracket.
2) Fit on the caliper and tighten the caliper pin bolts to the specified torque.
Notice:
Make sure the boot is firmly fitted into the groove.
Tightening torque
(a): 85 Nm
3) Fit the E-shaped clip firmly to the stud.
4) Tighten the front wheel nuts to the specified torque.
Tightening torque
(a): 85 Nm
5) Carry out the brake test after the assembly finishes.
1. Clip
2. Pad
3. Brake disc
4. Caliper bracket
1. Caliper pin bolt
6. Caliper assembly
Disassembly
1) Jack up the car to remove the wheels.
2) Remove the E-shaped clip.
3) Unscrew the hose joint bolt slightly at the caliper.
Caution:
Be careful not to twist and knot the hose in unscrewing the bolt.
4) Remove the caliper pin bolt.
5) Remove the caliper from the bracket.
6) Disconnect the hose from the caliper. Be careful not to twist the hose, as it will cause the brake fluid to flow out
of the hose. Accordingly, there shall be a vessel prepared ahead.
1. E-shaped ring
1. Caliper
2. Caliper pin bolt
3. Brake disc
Disassembly
Clean the caliper all around with brake fluid before disassembly.
1) Remove the piston cover locating ring and boot from the caliper. They shall be pried out by a chip tool. Be
careful not to damage the boot.
2) Inject the compressed air to the cylinder through the bolt holes of the assembly hose, and then the piston can be
pushed out from the cylinder under the action of the compressed air, as shown in the figure on the next page.
Warning:
The pressure of the compressed air shall not be too high, or it will separate the piston from the cylinder. The
compressed air shall be of moderate pressure which can be slowly blown in to pull out the piston. Do not
place your fingers before the piston when the compressed air is applied.
1. Boot locating ring
1. Cloth
3) Remove the piston seals by bladed tools like feeler.
Caution:
Be careful not to damage the cylinder inner wall (boring inside).
Check
Cylinder boot
Check if the boot has rupture, cracks and damage. If yes, change them
immediately.
Piston sealing
Excessive wear or uneven wear of brake pad lining are possibly the
manifestation of unsmooth piston return. In this case, the rubber seal shall be changed.
Assembly:
The front brake shall be reassembled in the reverse order of the disassembly. In doing so, pay attention to the
following aspects.
Caution:
Use the same fluid in the master cylinder reservoir to clean up every elements before assembly.
Never use other fluid or diluent.
Apply brake fluid to the piston and piston seals before they are fitted to the cylinder.
Exhaust the air after the brake pipe is reassembled.
Piston seals
The piston seals are used to seal pistons and cylinders, and to adjust the clearance between the friction block and
brake disc as well. They shall be replaced with the new ones in every overhaul. The piston seals shall be fitted into
the cylinder groove and be careful not to distort them.
Piston and boot
1) Fit the boot on the piston before it is inserted into the cylinder, as shown in the figure.
2) Fit on the boot, and press the boot into the cylinder groove by hand.
3-Groove
side
faces the brake
pad side
2-Groove side faces

the pump side
1. Boot
2. Piston
3) Insert the piston to the cylinder by hand, and fit the boot into the piston boot groove.
4) To ensure that the boot is properly fitted into the cylinder groove, the piston shall be pulled out a little, not
wholly, from the cylinder.
Notice:
The face B of the boot shall be at the same height as the face A of the cylinder.
5) Insert the piston into the cylinder by hand.
6) Fit on the boot locating ring.
Caliper
Check to make sure the caliper can move smoothly in the insert direction
before it (cylinder block) is fitted to the bracket.
Notice:
The rubber grease shall be used under in the cold condition where the
temperature is as low as -30, for the change of its viscosity is very
small, even so at -40.
Assembly
1) Connect the caliper and the hose.
2) Apply grease to the caliper pin belts and sliding pins, and then fit the
caliper to the bracket.
A Apply rubber grease
3) Tighten the caliper pin bolts to the specified torque.

Notice:
Make sure that the boot is firmly fitted into the groove.
Tightening torque
(a): 85Nm
4) Tighten the hose joint bolts to the specified torque.
Tightening torque
(b): 16 Nm
Warning:
Make sure that the hose is not distorted when the joint bolts are tightened up, or they shall be connected
again, in which they shall never be distorted.
5) Fit the E-shaped clip into the strut firmly.
6) Lower the lifting jack.
7) Tighten the wheel nuts to the specified torque.

8) After assembly, fill the reservoir with brake fluid and exhaust the air in the braking system. After this, carry out
brake tests to check if the mounting members leak oil.
1. Caliper pin bolt
7. Brake disc
Disassembly
2) Unscrew the bracket bolts (2), and remove the caliper assembly.
Caution:
During the disassembly, be careful not to damage the brake hose and press the brake pedal.
3) Pull apart the brake disc with 8mm bolts (2)
Check
See the contents of the check on brake pad.
1. 8mm bolt
Assembly
1) Fit the brake disc to the hub
2) Fit the caliper assembly to the steering knuckle.
3) Tighten the caliper bracket bolt to the specified torque.
Tightening torque
(a): 95 Nm
4) Tighten the front wheel nuts to the specified torque.
5) Carry out the brake test after assembly.

8. Disassembly of brake drum
1) Jack up the car and remove the wheel
2) Remove the bracket case.
3) Release the bake parking lever (hand brake)
4) Unscrew the parking brake cable nuts.
5) Unscrew the 8mm bolts and pull out the brake drum.
Check
1. Brake parking lever

2. Brake cable
3. Nut
1. 8mm bolt
Brake drum
Check if the brake drum is clean. Check if the brake surface is worn by measuring its
inside diameter.
Brake drum inside diameter
Standard: 220mm
Operating limit: 222mm
Whenever the brake drum is removed, it shall be thoroughly cleaned, and checked to
make sure whether there are cracks, scrape and deep scratches. It is not safe to
continue using the cracked brake drum, so it shall be changed timely. The cracks in the brake drum shall never be
welded.
Slight scrape has little impact on the smoothness, but too many or severe scrapes will cause excessive wear to the
brake lining. In this case, the brake surface of the brake drum shall be repaired.
If the brake lining has slight wear, and the brake drum has scratches, the brake drum shall be polished with good
emery cloth, not turned.
Brake shoe
If the wear of brake friction facing exceeds the operating limit, it shall
be changed.
Brake friction facing thickness (facing + brake shoe rim)
Standard: 6.9mm
Operating limit: 3.5mm

If the wear of one brake friction facing reaches the maximum operating limit, all the facings shall be changed.
Caution:
Never use abrasive paper to polish the facing. If so, the hard particles of the abrasive paper will penetrate in
it to damage the brake drum. If necessary, replace it with a new one.
Assembly
Notice of assembly: see the annotation at the beginning of Section in the chapter.
1) Before the brake drum is installed, to ensure a maximum clearance between the brake shoe and the brake drum, a
screwdriver shall be placed between the rod and ratchet to push down the ratchet, as shown in the figure.
Notice:
The right figures indicates that the position at which the ratchet is when the clearance between the brake
shoe and the brake drum is maximum.
2) The brake drum cannot be installed until it is sure that there are no dirt or oil stain on the brake drum inside and
brake shoe.
3) After installation, press down the brake pedal for 3 to 5 times with an load of about 400N to gain a suitable
clearance between the brake drum and brake shoe.
Adjust the parking brake cable (see Check and Adjustment of Parking Brake for the adjustment method).
4) Install the bracket case
1. Lever
2. Ratchet
1. Lever
2. Ratchet
3. Screwdriver
5) Fit on the wheels, and tighten the wheel nuts to the specified torque.
Tightening torque
(a): 70~100Nm
6) Check to make sure the brake drum is not jammed, and can apply the brake appropriately. Then let down the car
from the lifting jack to carry out parking brake test
(service brake and parking
brake).
9. Brake shoe
Disassembly
1) Carry out the brake drum disassembly procedure 1)~5).
2) urn the brake shoe clamp pin to remove the shoe clamp spring.
3) Remove the brake shoe.
4) Disconnect the parking brake shoe rod from the parking brake cable.
5) Remove the strut and spring.
1. Brake shoe clamp pin 2. Brake shoe clamp spring

6) Remove the locating ring and disconnect the parking brake rod from the brake shoe rim.
Check
Brake strut
1. Locating ring
Check if the strut ratchet is worn or damaged.

Spring
check if the spring is damage, rusted, or the elasticity gets weak. If year,
change its
Parking brake shoe rod
Check if the brake shoe rod can smoothly move around the shoe rim. If
damaged, repair or change it.
Assembly
1) As shown in the figure, assemble the elements in the reverse order of the disassembly.
Notice:
The removed locating ring shall be changed instead of being reused.
2) Install the shoe clamp spring by compressing the spring in place and turning the clamp pin.
3) The procedure hereafter can refer to the brake drum assembly procedures 1)~6).
1. Shoe clamp pin
2. Shoe clamp spring
10. Wheel brake pump

Disassembly
1) Carry out the brake drum disassembly procedures 1)~5)
2) Carry out the brake shoe disassembly procedures 2)~4)
3) Unscrew the brake pipe joint bolts, and do not let the brake fluid leak.
4) Remove the wheel brake cylinders mounting bolts; disconnect the brake pipe from the wheel brake cylinder and
put the drain plug cover on the brake pipe to avoid overflow of brake fluid.
1. Drain plug cover

1. Brake pipe bolt
Check
Check if the removed elements of the wheel brake cylinder has
wear, cracks, corrosion or damage.
Notice
Clean the wheel cylinder elements with brake fluid.
Assembly
1) Fit the cylinder seat to the wheel brake cylinder; then remove the drain plug cover from the brake pipe which
shall be correctly connected to the wheel brake cylinder to avoid leakage.
2) Tighten the wheel brake cylinder to the brake bottom plate to the specified torque.
Tightening torque
(a): 72 Nm
3) Tighten the brake pipe joint nut to the specified torque, and the brake pipe shall be connected as required by the
step 1).
Tightening torque
(b): 16 Nm
4) Fit the plug cover removed from the brake pipe to the original drain plug.
1. Wheel brake cylinder

2. Cylinder seat
5) See the brake shoe assembly procedures 1) and 2) to fit on the brake shoe.

2. Brake pipe nut
3. Brake pipe
4. Wheel brake cylinder bolt
6) See the brake drum assembly procedures 1) and 2) to fit on the brake drum..
7) Fill the reservoir with brake fluid and exhaust the air in the braking system. (see Air Exhaust of Brake for the
exhaust operation.)
8)After installation, press down the brake pedal for 3 to 5 times with a force of about 30kg to gain a suitable
clearance between the brake drum and brake shoe. Adjust the parking brake cable (see Check and Adjustment of
Parking Brake for the adjustment method).
9) Install the bracket case.
10) Fit on the wheels, and tighten the wheel nuts to the specified torque. (see Technical Requirement of Tightening
Torque).
11) Check and make sure that the brake drum is not jammed and has a suitable brake. Then let down the car from
the lifting jack to carry out brake test (service brake and parking brake).
12) Check if the mounting pieces leak oil.
11. Disassembly of brake bottom plate
1) Carry out the brake drum disassembly procedures 1)~5).
2) Carry out the brake shoe disassembly procedures 2)~4).
3) Carry out the wheel brake cylinder disassembly procedures 3)~4).
4) Remove the parking brake cable clip and tear down the parking brake cable from the brake bottom plate.
5) Unscrew the brake bottom bolts.
6) Pull out the brake bottom plate and the rear axle. See Section in Chapter .
7) Remove the wheel bearing. See Section in Chapter .
8) Remove the brake bottom plate from the rear axle shaft.
Assembly

3. Clip
1) Fit the brake bottom plate to the rear axle shaft.

2) Fit on the wheel bearing and locating ring by pressing.
3) Apply grease to axle shaft oil seal cover as shown in the figure.
A: grease 6206999-01
4) Apply sealant to the fitting surface of the axle housing with brake bottom plate.
Notice:
Eliminate the old sealant before applying new sealant.

2. Bottom plate bolt
B: sealant 6100997-01
5) Fit the rear axle shaft to the rear axle housing.
6) Tighten the brake bottom plate bolts to the specified torque.
Tightening torque
(a): 25Nm
7) Fit on the wheel brake cylinder and tighten the wheel brake cylinder bolts and brake pipe joint nuts to the
specified torque. (see the wheel brake cylinder assembly procedure 1)~4)).
1. Oil seal
2. Axle housing
8) Apply waterproof sealant to the contact of the bottom plate and the
cable. Turn the parking brake cable and secure it with a clip through the
brake bottom plate.
A: sealant 6100997-01
9) Fit on the brake shoe. See the brake shoe assembly procedures 1) and
2).
1O) Fit on the brake drum. See the brake drum assembly procedures 1)
and 2).
11) Refill the differential case with new gear oil complying with the
specified requirements.

3. Clip
12) Fill the reservoir with brake fluid, and exhaust the air in the braking system (see Exhaust Operation of
Brake).
13) Fit on the wheel and tighten the wheel nuts to the specified torque.
14) After installation, press down the brake pedal for 3 to 5 times with a force of about 400N to gain a suitable
clearance between the brake drum and brake shoe. Adjust the parking brake cable (see Check and Adjustment of
Parking Brake for the adjustment method).
1. Reservoir cap
2. Reservoir
3. Reservoir hose
4. Reservoir bracket
5. Nut
15) Install the bracket case.

16) Check and make sure that the brake drum is not jammed and has a suitable brake. Then let down the car from
the lifting jack to carry out brake test (service brake and parking brake).
17) Check all the fitted element to make sure whether they have leakage.
12. Master cylinder reservoir
Disassembly
1) Disconnect the reservoir wires.
2) Clean up the reservoir outside.
3) Eliminate the fluid by a syringe.
4) Disconnect the main brake hose from the reservoir.
5) Remove the nuts of the reservoir bracket.
6) Remove the reservoir.
Assembly
1) Fit on the reservoir and tighten the nut to the specified torque.
Tightening torque
(a): 11Nm
2) Connect the reservoir hose with the reservoir.
3) Fit on the reservoir wire grip.
4) Fill the brake fluid to the maximum level.
5) Carry out the exhaust operation. See brake exhaust and check for leakage.
13. Master cylinder assembly
1. Reservoir
2. Wire jointer
3. Main brake hose
4. Nut
1. Piston locating circlip

2. Piston locating block
3. Cylinder head and bottom plate
4. #1 piston
5. Piston cup
6. #2 piston pressure cup
7. #1 piston assembly
8. #2 piston
9. #2 piston assembly
10. #2 piston locating block bolt
11. Master cylinder
12. O ring
1. Master cylinder
2. Coupling nut
3. Fixing nut
Disassembly
1) Clean the reservoir cap and eliminate the fluid by a syringe.
2) Disconnect the reservoir hose.
3) Disconnect the brake hose from the master cylinder.
Caution:
Do not stain the painted surface with brake fluid.
4) Unscrew the two fixing nuts.
5) Remove the master cylinder.
Disassembly
1) unscrew the pin and joint that are used to fix the cylinder block with a special tool.
1. Joint
2. Pin
3. Rubber gasket
Special tool
(A): 3509170-01
2) Remove the joint and the 2 rubber gaskets.
3) Remove the circlip.
4) Remove the #1 piston
Remove the piston locating bolt. Then blow in the compressed air
1. Circlip
2. Master cylinder
through the piston locating bolt hole to remove the #2 piston. Be careful when the #2 piston is removed, for it may
jump out.
Check
Check if the removed part are worn or damaged, and change them if
necessary.
Notice:
Clean the removed parts with the brake fluid.
1. Locating bolt
2. Compressed air
The piston assembly shall not be reused.
Check if the master cylinder block has scratches or corrosion, and change the corroded cylinder. If the cylinder
block is pitted or is too rough, it means the cylinder block has been corroded.
Notice:
It is prohibited to use any abrasive to polish the master cylinders with
cast aluminum seat, for it will damage the cylinder block.
Rinse the master cylinder in the clean brake fluid, and then shake off the
brake fluid. Do no use the cloth to wipe the cylinder, for the fluff will
adhere to the master cylinder surface.
Assembly
Caution:
Do not use any mineral oil in cleaning and assembling the parts, for example coal oil and gasoline.
Check to make sure that there is not impurities like dust and dirt on the cylinder inner wall, piston and cup
seals. Be careful to use tools to assemble them, or they will be damaged.
Any parts shall not fall off, and any part that has fallen off shall not be reused.
1)Apply brake fluid to the contact surface of the cylinder inside and the piston assembly, and then insert the #2
piston into the cylinder block.
Make sure the piston cup is fitted to the correct direction so that it
cannot be jammed when inserted into the cylinder.
2) Fit the 1# piston into the cylinder .
3) Push down to fit on the circlip.
4) Fit on the piston locating piston and then push the piston in entirely.
1. Locating bolt
Tighten it up to the specified torque.

Tightening torque: (a): 10Nm
5) Apply a thin layer of brake fluid around the two new rubber
gaskets before fitted to the cylinder, and then install the reservoir.
1. Rod
2. Circlip
6) Fit the new pin to the joint hole and screw it into, and at the same time, align the pin end with the spare end
surface of the joint (equal length).
Assembly
Notice:
1. Pin
2. Joint
3. Master cylinder
See the annotation at the beginning of the chapter.
Check the clearance between the booster piston rod and the master cylinder piston (See Check and
Adjustment of Brake Booster ).
Use a special tool to adjust the length of the booster piston rod (see Check and Adjustment of Brake
Booster ).
1) Fit on the master cylinder as shown in the figure, and tighten the fixing nut
Tightening torque
(a): 15 Nm
2) Fit on the hydraulic tube, and tighten up the oil pipe joint nut to the specified
torque.
Tightening torque
1. Reservoir hose
2. Clip
3. Joint
(b) 16Nm
3) Connect the reservoir hose.
Distance
a: less than 5mm
b: 4-10mm
4) Fill the reservoir with the brake fluid that complies with the requirements.
5) After assembly, check the brake pedal clearance and exhaust the air in the system (see Check on Brake Pedal
Clearance and Brake Exhaust).
6) Carry out the brake test and check if the mounting pieces leak oil.
14. Brake booster
1. Brake booster assembly

2. Push rod U clamp
3. Nut
4. U clamp pin
5. Clip
6. Nut
Disassembly:
1) Disassemble the master cylinder assembly. See the master cylinder disassembly procedures 1)~5).
2) Disconnect the stop light switch wire at the coupling.
3) Remove the pedal bracket extension (cars equipped with anti-lock braking system)
4) Remove the nuts of the 4-way joint oil pipe and remove the brake pipe.
5) Disconnect the #1 vacuum hose from the booster, and the #2 vacuum hose from the panel, and then remove the
oil pipe and hose.
6) Disconnect the clutch cable from the clutch pedal arm.
7 ) Remove the steering lower shaft.

8) Unscrew the pedal bracket mounting bolts and nuts from the panel.
9) Remove the pedal bracket with a brake booster.
1. Stop light switch coupling 4. Brake

2. Pedal bracket extension
5. #1 vacuum hose
3. 4-way joint
1. Pedal bracket mounting bolt

2. Pedal bracket mounting nut
10) Detach the push rod U clamp from the brake pedal arm.
11) Unscrew the fixing nuts from the brake booster and remove the brake booster from the pedal bracket.
1. Pedal bracket
4. U clamp pin
2. Brake pedal arm 5. Pin
3. Push rod U clamp 6. Booster nut
Caution:
Do not tear down the brake booster, or its original functions will be damaged. If there is failure in it, replace
it with the new one.
Check and adjustment
Length of push rod U clamp
Check the lengthen of the push rod U clamp, whose size a shall be is
within 99.5~100.5, as shown in the figure. Tighten the nut to the
specified torque.
Size: a: 99.5-100.5mm
Tightening torque
(b): 25 Nm
Notice:
Whenever the booster is removed, make sure that the clearance
between the piston rod and the master cylinder piston shall be
correct (see the following procedures for the detailed specification).
1. Push rod U clamp

2. Nut
Clearance between the booster piston rod and the master cylinder
piston
Apply a negative pressure to the booster and let the engine idle. Then the
clearance a between the piston and the piston rod shall turn to be:
Clearance a: 0.25~0.5mm
Push the piston rod several times to make sure the reaction disc is in
place before the clearance is measured.
Keep a maximum pressure in the booster in measurement.
1) Fit the special tool (A) on the master cylinder till the push pin contacts the piston.
Special tool
(A): 3509180-01

2. Master cylinder piston
2) The special tool shall be inverted on the booster. Adjust the length of the booster piston rod till the rod end touch
the pin cap.
Special tool
(A): 3509180-01
Clearance b: 0mm
1. Master cylinder
2. Piston
3. Pin cap
Notice:
The booster shall be upright in measurement, with the push rod in the middle and the piston rod fixed by a
screwdriver.
3) Adjust the clearance by turning the piston rod adjusting screw.
Special tool
(B): 3509180-01
Reference:
In carrying out the adjustment above, apply a negative pressure to the booster and let the engine idle. Then the
clearance a between the piston and the piston rod shall turn into:
Clearance a: 0.25~0.5mm
Assembly

2. Master cylinder piston
Notice:
See the annotation at the beginning of the chapter.
Use a special tool to adjust the clearance between the booster piston rod and the master cylinder plunger
(see Check and Adjustment).
Check on the length of the push rod U clamp (see Check and Adjustment)
1) Fit the booster to the pedal bracket, and then connect the booster push rod U clamp with the pedal arm by a U
clamp pin and clip.
2) Tighten the booster fixing nut to the specified torque.
Tightening torque
(a): 13Nm
3) Fit the pedal bracket to the front panel, and then tighten the pedal bracket bolts and nuts to the specified torque.
Tightening torque
(b): 25 Nm
4) Connect the clutch cable and the clutch pedal arm. See Clutch Cable Assembly in Chapter .
5) Connect the #1 vacuum hose to the booster, and then connect the vacuum hose to the #2 vacuum hose.
6) Connect the brake pipe and 4-way joint. The oil pipe nut shall not be tightened too tightly.
7) Fit on the steering lower shaft.
8) Fit on the pedal bracket extension (used for the cars with
anti-lock braking system)
9) Connect the stop light switch wire to the coupling.
10) Fit the master cylinder to the booster (see Master Cylinder
Assembly in this chapter).
11) Tighten the brake pipe nut to the specified torque.
Tightening torque
(c): 16 Nm
12) Fill the reservoir with the brake fluid that is up to the
specification.
13) Carry out exhaust operation (see Air Exhaust of Brake).
14) After assembly, check the pedal height and clearance. Refer to
Checks on Excessive Pedal Travel and Brake Pedal Clearance.
15) Carry out the brake test to check if the mounting pieces leak
oil.
1. Brake pedal
9. #1 vacuum hose
2. Brake pedal arm
10. Brake hose
3. Push rod U clamp
11. 4-way joint
4. U clamp pin
12. Pedal bracket extension
5. Clip
13. Stop light switch coupling
6. Booster nut
7. Pedal bracket mounting nut
8. Pedal bracket mounting bolt
15LSPV(load sensing proportioning valve)

Disassembly
1) Clean the reservoir cap and eliminate the fluid (brake fluid) by a
syringe.
2) Jack up the car.
3) Disconnect the brake pipe from the LSPV.
4) Remove the LSPV assembly from the LSPV support.
5) Remove the spring from the LSPV rod.
Caution:
LSPV assembly nut shall not too loose nor too tight.
Do not take apart the LSPV assembly. If it is damaged, replace it with a new one.
Assembly
Caution:
See the Caution above.
1. LSPV assembly
2. LSPV spring
3. LSPV
rod
The assembly shall be made in the reverse order of the disassembly, while pay attention
to the
following aspects:
4. Nut
1) Apply the general-purpose grease to the upper and lower joints of the coil
spring.
2) Tighten the bolt and nut marked in the figure to the specified torque
respectively.
Tightening torque
(a): 23Nm
(b)16 Nm
A Apply grease
(c)8.0 Nm
3) after assembly, fill the reservoir with the brake fluid that meet the requirements and then exhaust the air in the
braking system.
Notice:
Make sure that the air is exhausted from the LSPV drain hole without fail.
4) After the exhaust, check if the LSPV is properly fitted. See the Check and Adjustment below.
1. Bottom plate
2. Shaft cap
Check and adjustment

The check and adjustment shall meet the following requirements:
The fuel tank is filled with fuel.
The car shall be equipped with spare tire, tools, jack and jack handle.
The car has no other loads.
The check and adjustment shall not be carried out until the conditions above are met:
1) Park the car on the flat ground.
2) Push the LSPV rod up till it cannot move further and then pull out the coil spring to measure the length (L in
the figure)
3) The spring length L shall comply with the following requirements: spring length L: 205mm.
Notice:
1. LSPV rod
2. Nut
Do not press the brake pedal in measuring the spring length.
3. LSPV
4) If the spring length fails to meet the requirements, change the tightening position of the bolt (a) to adjust the
spring to the specified size, as shown in the right figure. After the adjustment, tighten the nut to the specified
torque.
Tightening torque
(a): 23Nm
Notice:
Check to make sure the LSPV seat and brake pipe joints have no leakage. If there is, change the damaged
parts.
Section Servicing materials, tightening torque and special tools

Materials
Recommended Haixing products
Use
Fill the master cylinder reservoir
HZY3
Brake fluid
Clean and apply to the external components of

master cylinder caliper and wheel brake cylinder
3501999-01
Apply to the fitting surface of the brake bottom

plate and rear axle housing.
Sealing composition 366E
Waterproof
sealant
6100997-01
Apply to the fitting surface of the brake

bottom plate and parking brake cable..
. Tightening torque
Tightening torque
Fastener
Nm
Kg m
1bft
Brake caliper pin bolt
85
8.5
61.5
Brake caliper bracket bolt
95
9.5
69.0
Front brake hose joint bolt
16
1.6
12.0
Rear brake bolt
23
2.3
17.0
Master cylinder nut or booster nut
13
1.3
9.5
Brake booster push rod nut
25
2.5
18.5
Brake pipe 4-way joint nut
11
1.1
8.0
Proportioning valve bolt/4-way box bolt
10
1.0
7.5
Brake oil pipe nut
16
1.6
12.0
Brake pedal bracket bolt and nut
25
2.5
18.5
11
1.1
8.0
0.8
6.0
Wheel nut
85
8.5
61.5
Wheel cylinder bolt
12
1.2
9.0
20
2.0
14.5
23
2.3
17.0
Brake drain hole
Brake parking lever bolt
LSPV bolt (nut)
. Special tools
Pin remover
Booster piston rod adjustor
Brake circulation plug
Dial indicator
Oil pipe nut wrench
Magnetic stand
Hydraulic pressure gauge
Hydraulic pressure gauge accessory
Chapter Car body maintenance

Section Structure and maintenance of SY1020 front door
. Structure of front door
1. Front door weld assembly; 2. Front door trim panel; 3. Front door trim panel waterproof membrane; 4. Front
door glass internal weather strip; 5. Front door glass external weather strip; 6. Front door frame sealing strip; 7.
Front door opening stopper; 8. Front door rear channel assembly; 9. Front door glass peripheral strip; 10. Front
door window lifter Assembly; 11. Front door glass clamp strip;12. Front door glass clamp rubber strip;
13.Windown lifter crank;14. Front door hinge; 15. Front door internal handle; 16. Front door external handle; 17.
Front door lock assembly; 18. Front door lock core assembly; 19. Front door lockpin assembly; 20. Front door
check pin; 21. Internal lock-off button; 22. Front door glass; 23. Front door garnish
. Maintenance of front door

Front door glass and glass lifter
Disassembly
1) Remove the window lifter crank, which shall be pulled out by a piece of cloth, as shown in the figure.
2) Roll down the front door glass totally.
3) Unscrew the screw and then remove the internal handle assembly from the door trim panel by sliding it
forwards.
4) Remove the door rearview mirror garnish and clips.
5) Unscrew the screw and then remove the plug connectors and door membrane.
6) Remove the electric window switch plug connectors and clips.
1. Cloth strip
2. Crank
7) Remove the front door trim panel waterproof membrane.

8) Unscrew the mounting bolt in the door front channel.
9) Unscrew the fixing screw in the front door glass clamp strip
1O) Remove the front door glass.
11) Unscrew the fixing screws (6) of the front door window lifter assembly, and then take out the glass lifter from
the hole A.
1. Front door rear channel

2. Front door glass peripheral strip
3. Front door window lifter assembly
4. Front door glass
1. Fixing screw
Check:
Lubricating points of front door window lifter assembly
Check the lubrication of the sliding and revolving parts of the front door window lifer assembly.
Check if the gear is worn or damaged.
Check if the hinge is damaged.
Assembly
The front door glass and front door window lifter assembly shall be installed in the reverse order of their
disassembly, ant the following aspects shall be paid attention
to.
When fitting the glass into the front door glass clamp strip,
dip the clamp strip into the soapy water, and then tap the
glass in lightly with a plastic hammer.
The position where the glass is fitted is as shown in the
figure.
Section: A-A
Length a: 56.5~60.5mm
1. Glass clamp strip
In fitting on the glass, check to make sure whether the
glass top evenly contact the front door glass peripheral strip and whether the glass can slide up and down flexibly.
If the glass fails to be in the strip, adjust it with screws as shown in the figure.
Seal the door trim panel firmly with glue
The window lifter crank shall be such installed that it is 45when the glass is fully lifted
1. Window lifter crank
2. Front door internal handle
3. Screw
1. Fixing screw
1. Front door external handle

2. Front door lock core assembly
3. Front door internal handle
4. Front door lock assembly
5. Front door lockpin assembly
Disassembly of door lock
6. External lock-off button
Disassembly
1) Lift up the front door glass totally.
2) Remove the window lifter crank, door
rearview mirror garnish, door trim panel,
electric window switch, door trim panel and
front door rear channel (see Disassembly of
Front Door Glass and Front Door Window
Lifter Assembly)
3) Remove the joints of the control lever, and
then remove the door external handle and door
lock assembly.
Assembly
The assembly shall be made in the reverse order
of the disassembly, and pay attention to the
following requirements.
Fit on the door lockpin.
Move the door lockpin up and down to align the
lockpin with the center groove A of the door
lock.
Notice:
The lockpin shall place horizontally, and
shall move vertically. The door lock shall be
1. Door lock
2. Front door external handle
3. Sleeve (holder)
4. Front door lock core assembly
not adjusted.
Close the door to adjust the lockpin so as to make the door surface is flush with the car body, with a height
difference of 0mm.
1. Lock
2. Lockpin boss
3. Lockpin
1. Car body
2. Door
3. Lockpin
4: Front side
To correctly get the position of the lockpin hole, adjust it by increasing or reducing the gasket between the car body
and the lockpin. The size b shall be adjusted to the specified value.
Size b: 3.3~5.3mm
Notice:
The lockpin joint shall be applied with grease regularly
Front door assembly
Disassembly
1) Remove the door wire harness connector and remove the
corrugated pipe from the car body.
1. Lockpin boss 2. Gasket 3. Door

4. Front side 5. Car body
2) Tap out the front door check pin with a hammer.
1. Door check
2. pin
1. Corrugated pipe
2. Plug connector
1. Wooden component
3) Place a board between the jack and door skin to support the
door.
4) Unscrew the hinge mounting bolt and remove the door assembly.
Assembly
Assemble the front door in the reverse order of its disassembly
Apply sealant to the hinge mounting surface, as shown in the figure, and apply grease to the revolving part.
If the sealing step is hardened, there will be serious water leakage. In this case, it shall be replaced with a new
sealing strip.
Refer to Front Door Lock Assembly to adjust the door lockpin position to
put the door in a suitable position.
Close the door to adjust the front door cushion rubber to contact the door
with the car body.
Section Windscreen
1. Windscreen seal
2. Windscreen side trim strip
3. Windscreen
Windscreen
Use special-purpose glue to fit on the windscreen (that is, use single-component urethane glue with the primer).
Changing the windscreen must use the glue of strong adhesion and shall be done according to the following
methods.
Caution:
In this chapter, primer and glue (urethane glue used in conjunction with the primer) made by
YOKOHAMA are used to change the windscreen. When primer and glue of other manufacturers are put in
use, the manual they provided shall be followed. Failure to follow the procedures or misuse of other glue will
impair the performance of original glue. Therefore, be careful to read the manual and instruction book
provided by the glue manufacturer before do such work. The whole repair must follow the procedure and
correct method.
The scratched surface and other damage surfaces shall be painted. The damaged part shall be repaired, or
the corrosion will start here.

If the type of glue mentioned above is used, the bonding strength shall meet the following requirement.
Shear strength: 0.4Mpa or above
Glue and tools necessary to remove the windscreen
Single-component urethane glue and primer material. Quantity (of installing one windscreen)
Glue (300g)
Glass primer (15g)
Car body primer (15g)
Awl
Steel wire
Brush for applying primer (2)
Knife
Rubber cupule
Sealant guns (filled with glue)
Putty scraper (scrape mucus)
Disassembly
1) Clean the inside and outside and the circumference of the windscreen
2) Remove the wiper arm.
3) Remove the trimming garnish and fixture block.
4) Cover the car body around the windscreen with tape to avoid damage.
5) Remove the dashboard and roof lining.
6) Remove the rearview mirror, sun visor, front pillar trimming garnish and then remove the windscreen trim strip
from the front pillar (right/left).
7) Remove (or cut off) all the strips around the windscreen to reveal the glass edge.
8) Use a windscreen knife to cut off the glue around the glass. If it is wiped by steel wire, please follow the steps 9)
and 10).
9) Drill through the glue by an awl and thread the steel wire through it.
1. Awl
10) Cut off the glue around the windscreen with steel wire.
Notice:
The steel wire when used shall be close to the windscreen as much as possible to avoid damage to the car
body.
1. Steel wire 2. Tape

3. Windscreen 4. Glue
11) Use a knife to smoothly scrape the glue remained at the car body side, with a penetration depth of 1~2mm.
Notice:
The knife shall, before used, be cleaned in alcohol or alike to get rid of the greasy dirt.
12) When the glass is removed again, the division bar and glue shall be totally removed.
Assembly
1. Knife
2. Glue
3. Car body
1. Glue
2. Primer
1) Use washing liquid (aviation gasoline) to wash the glue remained on the car body (or the windscreen edge) at the
place where the windscreen is glued. (dry it for more than 10
Primer
minutes)
Brush
Primer
2) Clean thoroughly the old glue contact surface, painted surface
or exposed metal. Apply the car body primer carefully to the
Old glue
painted surface or exposed metal. Do not apply the premier to the
No primer
glue surface remained on the car body.
Notice:
Please do follow the instruction book of the primer manufacturer to perform the operation and dry it for
the specified time.

The primer shall not contact the car body and glass glue surface.
3) Wipe off the glue on the glass with clean cloth; if washing liquid is used, dry it for over 10 minutes.
4) Fit the windscreen trim strip to the front pillar, and then install the fixture block.
1. Windscreen seal 4. Windscreen side seal

2. Windscreen
5.Clump
3. Windscreen pad
5) Use a new brush to apply adequate primer along the
windscreen edge.
Notice:
Please be sure to follow the manufacturers instruction
book to perform proper operation and dry it for a specified
time.
1. insertion strip
2. Parting strip
Do not apply the primer to the place where finishing paint

is applied.
Do not touch the primer surface.
Width: a: about 20mm
b: about 20mm
c: about 18mm
6) See the right figure to apply the glue.
Notice:
1. Insertion strip
2. Glue
3. Windscreen
Apply the glue from the bottom of the glass.

Be careful not to damage the primer.
The glue height at the bottom shall be higher than the other three sides: upper side, right side and left side.
Width e: about 8mm
Height f: about 14mm
Press the glass into the car body immediately the glue is applied.
After the glue is applied, use a rubber cupule to grip the glass.
Finish the steps from 7) to 9) within 10 minutes to ensure the glue of adequate viscosity.
The treatment method and drying time must follow the glue manufacturers instruction book.
7) Cut off the residual paper from the insertion strip and parting strip.
8) Use a rubber cupule to press the glass into the car body, and tap the glass surface and the insertion strip around it
to fasten the glass.
Notice:
Be careful not to damage the glass surface or the car body.
9) Fix the top insertion strip.
10) Spray water on the windscreen with a hose to check if it leaks. If yes, dry the windscreen and fill the leakage
point with glues. If it still leaks, remove the glass and re-install it again according to the method above.
Notice:
Do not use the high pressure water.
In drying, do not use the compressed air to directly blow the place dry where glue is applied
Do not use infrared lamp or alike to bake it dry.
1. Rubber cupule
Caution:
Pay attention to the following aspects in assembly:
Sudden closing of door before the glue gets dry will cause the glass to get loosened or fall off. Thus, all the
door glass shall be opened before the glue gets dry regardless of whether the doors are closed or opened. Be
careful to perform the operation.
If the insertion strip cannot be firmly fixed in place, use the tap to fasten it till the glue is fully stuck.
Every type of glue has its own drying time, so that be sure to refer to the manufacturers instruction book to
be aware of the drying time before apply them. Be sure to follow the notices beforehand.
The car is not permitted to be driven until the glue become fully cemented so as to ensure firm cementation.
11) Install the rearview mirror, roof insertion strip, front pillar trimming garnish, sun visor, garnish and wiper.
Section Seat structure and its disassembly and assembly
Front seat
1. Right front seat back assembly

2. Right front seat cushion assembly
3. Left front seat back assembly
4. Left front seat cushion assembly
5. Right front seat internal adjustor
6. Right front seat external adjustor
7. Left front seat internal adjustor
8. Left front seat external adjustor
9. Right front seat floor
10. Left front seat floor
11. Headrest assembly
Folding seat
(three-row seat model)
Passenger double seat

(three-row seat model)
Passenger triple seat (three-row seat model)

Passenger triple seat (two-row seat model)
11. headrest assembly

12. Rear seat cushion assembly
13. Rear seat back assembly
14. Rear seat right leg assembly
15. Rear seat hinge assembly
16. Rear seat floor latch assembly
17. Rear seat floor latch shaft
Disassembly
1) Remove the seat rail mounting bolt, and then remove the seat internal and external adjusters and the floor (front
seat) from the seat assembly.
2) If necessary, remove the seat to adjust, repair or change it.
Assembly
The front seal shall be assembled in the reverse order of the disassembly.
Tighten it to the specified torque as follows:
Tightening torque
a: 55Nm
b: 25Nm
c: 5 Nm
Section Disassembly and assembly of seat belt
1. Buckle
2. Seat belt
3. Seat belt plug connector
4. Fixing bolt
5. Front seat
6. Retractor assembly
Warning:
If it is necessary to change the seat belt, the buckle and emergency locking retractor (or vehicle-sensitive
emergency locking retractor) shall be changed together. Only this, the buckle can lock the bolt plate firmly.
If only these parts are changed dividedly, the lock conditions will produce unsafe factors. Thus we only
provide complete set of spare buckle and emergency locking retractor (or vehicle-sensitive emergency
locking retractor).
Seat belt maintenance:
pay attention to the following notices before repair or change the seat belt:
1) The seat belt shall be normally fitted to the belt retractor and buckle.
2) Do no let sharp edges and objects that are possible to damage the seat belt to approach.
3) Do not bend or damage the belt buckle and bolt plate.
4) Do not bleach or dye the seat belt (which can only be washed by neutral soap and warm water).
5) Manually screw the fixing nuts and bolts of the seat belt to avoid sliding when they are fitted.
6) Do not make any repair to the retractor or retractor cap; they shall be replaced with the new one.
7) Keep the belt dry and clean all the time.
8) Any part that has fault shall be changed.
9) Change the belt which has notches or damage in braid.
10) Do not place any object in the trim panel opening through which the belt passes.
Disassembly and assembly
Assemble and disassemble the rear seat belt in accordance with the figure mentioned above.
Notice:
The seat belt fixing bolt shall be tightened to the specified torque. The fixing bolts and nuts of the seat belt
are of the uniform fine thread (7/6-20UNF). Never use the bolts of different type or of metric thread in any
case.
Tightening torque
(a): 35Nm
Check
Seat belt and accessories are the vital parts and key system of a car, so they shall be carefully inspected and can
only be replaced with certified products.
1) Seat belt
The braid and suture line shall have no damage.
2) Retractor
When it is pulled out quickly, the belt shall be locked.
The retractor of the front seat belt shall not only pass the inspection above, but also lock the belt when it inclines
about 15from head to tail or to the left and right.
3) Bolts
The bolts shall be tightened to the specified torque.
4) Buckle
It shall be firm when locked.
5) Alarm system
Check the driver seat belt switch.
Section Frame size

Frame size
Unit: mm
Chapter Air conditioning, heating, ventilation system

Section Heating and ventilation equipment
1. Composition
1. Heater and ventilator
The heater and ventilator of the car consist of control knob (lever), fan motor, heater core and air duct. The fan
motor feeds the air into the car. The heater core keeps circulating the cooling water heated in the motor. Every
control knob (lever) controls the fan motor speed, temperature and exhausts the air (damper in the heating and
ventilation equipment works) so as to convey the air to the where it is needed.
Windscreen defrosting exhaust valve

Side defrosting vent
Floor vent
2. Heater control operation

A: Wind direction control knob
B: Fresh air control lever
C: Temperature control knob
D: Fan motor speed control knob
Central air vent
3. Wind direction control knob
Ventilator
(1) Ventilate from the central air vent

(2) Ventilate from the central air vent or the lower
air vent
B1-level
(3) Ventilate from the lower air vent

(4)Ventilate from the lower air vent, defrosting vent
and defogging vent
Heating
(5) Ventilate from the defrosting vent and defogging

vent
Heating defroster
Defroster
4. Fresh air control lever
Self-circulation of air in vehicle
Circulation of the air in vehicle and the fresh air outside the vehicle
5. Temperature control knob

Cold
Hot
6. Fan motor speed control knob

Low
High
. Fault diagnosis
Troubles
Causes
The fan fuse is blown.
The fan resistor works
abnormally.
The heater still fails to

work when switched
on.
Troubleshooting
Change the fuse, and check the short
circuit.
Check the continuity
The fan motor works abnormally.
Change the motor
The circuit and ground are out of

order.
Repair if necessary
Change the fan blades or the heater case
Fan blades interfere in the heater

case.
The control cable breaks or
bends.
The
temperature
incorrect.
output
is
The air pipe is blocked.

The heater core leaks or is
blocked.
The heater hose leaks or is
blocked.
. In-car service
1. Circuit diagram
Check the cable

Repair the air pipe
Change the heater core
Change the hose
1. Battery
2. Main fuse
3. Ignition switch
4. Fuse box
5. Fan motor
6. heating resistor
7. Heater switch
2. Heater unit
1. Heater assembly 2. Fan assembly 3. Motor assembly 4. Resistor

5.
Ventilation control lever 6. Ventilation control lever 7. Heater core
8. Heater
case (left) 9. Heater case (right) 10. Bumper block 11. Air filter
12. Heater core
support
Disassembly
2) Drain the engine cooling liquid and remove the heater hose on heater unit.
3) If there is an airbag system, make sure it is inoperative station.
4) Refer to the Dashboard in the chapter to remove it, and remove the wire harness clip from the steering support
element, and the remove the support element.
5) Remove the fan motor and resistor plug connector.
1. Heater unit
2. Nut
3. Heater intake guide
4. Air intake box
6) Remove the heater intake guide

7) Remove the heater unit
8) Pull out the heater core from the unit
1. Heater core
2. Heater case
3. Bracket
4. Gasket
Assembly
1) Assemble the heater unit in the reverse order of its disassembly. Pay attention to the following points:
Be careful not to jam the cable or wire harness in fitting on the parts.
Refer to the Steering Column in Chapter to install the steering column assembly.
2) Adjust the control cable (see Heating and Ventilation Control Cable in the chapter)
3) Fill the engine cooling liquid into the radiator and then exhaust the air in the cooling system.
3. Heater blower resistance
Disassembly
1) Remove the battery negative wire
2) Remove the fan resistor plug connector
3) Remove the heater fan resistor
Check
Measure the resistance between the terminals
Terminal-terminal
Resistance
L-M1
2.8
M1-M2
M2-H
0.6
If the measured resistance is incorrect, change the heater resistor.

Assembly
The assembly shall be made in the reverse order of the disassembly.
4. Heater motor switch
Disassembly
1) Remove the instrument wire harness and took kit.
2) Remove the control cable from the connecting bar.
3) Remove the wire of the plug connectors of the blower resistor switch.
4) Remove the stayed instrument wire harness retainer.
5) Remove the control knob assembly.
Check
Check the continuity between the terminals; if they fail to have continuity, change the control lever assembly.
Assembly
The assembly shall be made in the reverse order of the
disassembly.
Ventilation control lever
5. Heater control cable

Adjustment
Wind direction control cable
1) Set the control lever to the ventilation position
2) Turn the knob in the arrow direction to the end and stay there and then fix the cable, as shown in the figure.
Temperature control cable

1) Set the control lever to the cooling position.
2) Turn the knob in the arrow direction to the end and stay there and then fix the cable, as shown in the left figure.
Ventilation control lever
Temperature
control link rod
Fresh air control cable

1) Set the control lever to the position circulation of fresh air and air in vehicle.
2) Pull the rod to the end in the arrow direction and then fix it as shown in the figure.
1. Fresh air shutter rod

2. Fresh air control cable
Section Air conditioner

Notice:
This type of air conditioning system adopts HFC-134a(R-134a) refrigerant.
Prior to making any test or repair, it is necessary to check which refrigerant is used.
In renewing or changing refrigerant and compressor oil and changing parts, be sure that the material and
parts are suitable to the air conditioner under repair. Even if one part is misused, it will cause refrigerant
leakage, part damage and other failures.
. Composition
As an optional equipment, the air conditioner can supply from stock. This part will describe the function of its main
parts as well as relevant content of installation and maintenance.
1. Main parts air conditioning system and refrigerant flow path
Forward
1. Compressor
2. Magnetic clutch
3. Condenser
4. Reservoir/dryer
5. High- and low-voltage protection switch
6. Expansion valve
7. Evaporator (core)
8. Fan motor
9. Overhead evaporator assembly
10. To front seat
11. To rear seat
2. System parts
Refrigerant state
Liquid
Vapor
Superheated vapor
Cold air
1. Condenser assembly
2. Condenser fan
3. Drying bottle
4. Condenser inflow pipe
5. Front evaporator
6. Overhead evaporator
7. Compressor
3. Air conditioning system circuit

Backlight power supply
Blower
motor
Speed
control
resistor
Air
conditioner
temperature
sensor
Air
conditi
oner
fan
relay
Fan
motor
Comp
ressor
relay
Overhe
ad
evapor
ator
Air
condi
tioner
relay
Air conditioner control panel
A/C
switch
. Assembly of air conditioner parts

1. Preparations before installation
Check and adjustment of the car
Check and adjust the following parts before installing the air conditioner:
Engine ignition timing
Engine cooling system
Battery electrolyte and charging system
Passenger compartment seal
Fuel system
General status of the car
Preparation for the air conditioner parts
Please remove the parts in the order of assembly.
Then make sure that the parts art not missed or damaged. When the air conditioner is installed, the wing and seat
must be covered by a cover.
2. Notice on installation
1) The battery negative wire must be removed.
2) The bolts in the tool kit must be used to install the engines air conditioner parts and they shall be tightened to
3) In installation, the air conditioner pipe and wire harness must be designated with specific lines so as not to
interfere in the surrounding parts.
4) The hose and the pipe must be connected after the flared pipe connecting nut bed is applied with 2-3 drops of
refrigerant oil.
5) The pipe fittings must be tightened or unscrewed by two wrenches so as to let them to be evenly supported in
such tightening or unscrewing.
6) The connecting nut must be tightened to the specified torque.
7) Do not remove the pipe-end plug of the fittings before the parts are connected in place.
Notice:
To let the refrigerant penetrate slowly, it is necessary to remove the plug from the compressor, for the
compressor is allowed to have a little refrigerant in it to avoid seals being corroded when it is delivered.
8) Anyone who begins to treat HFC-134a(R-134a) refrigerant shall wear safety glasses. Be careful not to let the
refrigerant contact with skin.
9) Put the HFC-134a(R-134a) refrigerant tank in the warm water to keep the temperature at 40.
3. Method of installation
Refer to the manual attached to the air conditioner parts for the installation of air conditioner.
Vacuation at a time
50S
Vacuation stopping
8S
Joint check and repair

Abnormal system
Gas seal check
Vacuation at a time
25S
Refrigerant charging
Charging 680k refrigerant
System check
Performance test
. Recovery, vacuum discharge and charging

1. Method of charging refrigerant to air conditioning system
2. Refrigerant recovery
The refrigerant can be recovered by recoverer and recycle unit when it is discharged from the air conditioning
system. If it is discharged into the atmosphere, it will cause damage to the environment.
Notice:
The recovery plant and recycle unit shall be treated in accordance with their manuals
Vacuum-pumping system
Notice:
The air conditioning system shall, whenever it is opened (exposed to the atmosphere), be pumped to be
vacuum by a vacuum pump.
3. Vacuum-pumping system
1) Screw off the cover of the high- and low-pressure tube and clasp the filling machines output tube clamp to the
air conditioners high- and low-pressure tube filler
2) Operate the equipment
3) If there is no leakage, about 35s later, the equipment will display the vacuum below 760mmHg.
4) The vacuum-pumping time must last 50s in total.
5) Continue to pump till the vacuum is below 760mmHg.
4. Check on system leakage
When the vacuum-pumping task is accomplished, the equipment will automatically stop vacuation for 8s to check
if the air conditioning system has leakage.

Notice:
If the equipments displayed valve is largely different from the set value, it means there is a leakage
somewhere. Then check the tube joints and make necessary correction. After this, vacuate the system
again and ensure there is no leakage.
5. Charge refrigerant to the system
The air conditioning system shall be charged with HfC-134a (R-134a) refrigerant.
Here is a method which employs the refrigerant in the refrigerant maintenance vessel to charge the air conditioning
system.
If the refrigerant recovered by the refrigerant recovery and recycle equipment is used to charge the system (when
the refrigerant is recycled), the procedures given in the manufacturers manual shall be followed.
Warning:
Do not expose your eyes to the refrigerant (you must wear safety glasses).
The temperature of any HFC-754a(R-134a) refrigerant leaked due to accident is below the freezing point. If
the HFC-134a(R-734a) refrigerant splashes into your eyes, it will cause serious injury. To protect your eyes
against such accident, it is necessary to wear the protective glasses (safety glasses). If HFC-134a(R-134a)
splashes into your eyes, do not wipe your eyes, and go to see the doctor immediately.
If the refrigerant does harm to a part of your body, wash it with cold water till the skin temperature returns
to normal to minimize the damage. The go to see a doctor or an expert for proper therapy.
If the HFC-134a (R-134a) refrigerant splashes to your skin, the injured part shall be treated with the same
therapy as that for cold injury.
Do not treat the refrigerant at the places close to welding or steam cleaning.
The refrigerant must be kept in a shady place. It must be not placed in high temperature, for example,
being directly exposed to the sun, placed near the fire or in a car ( including trunk).
Try not to inhale the smoke produced in HFc-134a (R-134a) refrigerant burning, which is harmful to health.
Caution:
The refrigerant must be filled from the low-pressure side of the air conditioning system.
The refrigerant must not be filled from the high-pressure side of the air conditioning system.
Do not fill the refrigerant when the compressor heats.
When holes are drilled in the refrigerant vessel to fit it a tap, it must be operated carefully in the direction
specified by the manufacturer.
A pressure gauge must be used before and during the refrigerant is refilled.
When the refrigerant vessel is thrown away, be sure the refrigerant in it have been drained.
The refrigerant vessel shall not be heated to or above 40.
In filling refrigerant, the vessel shall not be reversed, for it will cause the liquid refrigerant to enter the
compressor, which will result in failure, for example liquid hammer.
6. Refrigerant charging
1) When the system is vacuated, the equipment will automatically fill refrigerant to the system;
2) Screw up the filler lid after the refrigerant is filled;
3) When the refrigerant vessel is vacuated, replace it with a new one in accordance with the following procedure.
7. Check on leakage of air conditioning system
Use an electronic leak detector to carefully check the leakage of the system.
Warning:
To avoid explosion and fire, be sure there is no inflammable materials nearby.
The refrigerant, when exposed to the fire, will turn into poisonous gas (toxic gas). Do not inhale the gas (not
put directly over a flame).
1. Electric leak detector
. Fault diagnosis
Troubles
Causes
Troubleshooting
The air conditioner fails to work.

1)No refrigerant
2) Fuse blowout
3) Failure in air conditioner and
fan switches
4) Low idling
5) Failure in air conditioner
thermal resistor
6) Failure in the water
temperature
sensor
of
air
conditioner
7) Failure in highlow-voltage switches
No cold air ( the air
conditioning
system
works
abnormally)
and
Recover, vacuate and charge refrigerant; check the fuse

and heating & ventilation
Change the air conditioner fuse and check if there is
short circuit.
Check the air conditioner and fan switches.
Check and adjust air conditioner idle speed.
Check the air conditioner thermal resistor.
Check the water temperature sensor of air conditioner
Check the high- and low-voltage switches
Repair as required.
8) Circuit or ground fault

The compressor fails to work (or
operate)
1) Failure in compressor thermal
protector
2) Magnetic clutch failure
3) Driving belt slackened or
damaged
Check the compressor thermal protector

Check the magnetic clutch
Tighten or change the driving belt
Check the compressor
4) Compressor failure
Condenser fan fails to work.
1) Fuse blowout
2)Failure in the condenser fan
relay of air conditioner
4) Failure in the condenser fan
motor of air conditioner
Change the fuse and check if there is short circuit.

Check the condenser fan relay
Repair as required.
Check the condenser fan motor
Blower motor fails to work

1) Failure in the blower motor
resistor
2) Failure in the air conditioner
and fan switch
Check the blower motor resistor

Check the conditioner and fan switch
Repair as required
Check the blower motor
4) Blower motor failure

Refrigerant filled inadequately or
excessively
Check the charging of refrigerant
Condenser clogged
Check the system leakage
Evaporator clogged or frozen
Check the condenser

Check the evaporator
Check the air conditioner thermal resistor failure
No or inadequate
cold
air
(air
conditioning system
works normally)
Check the air conditioner controller

Air conditioner thermal resistor
failure
Air conditioner controller failure
Expansion valve failure
Check the air conditioner thermal resistor

Check the air conditioner controller
Check the expansion valve
Check the dryer
Dryer blocked
Check or change the driving belt
Driving belt sliding
Magnetic clutch failure
Troubles
No or inadequate cold air (air

conditioner works normally)
Causes
Troubleshooting
Compressor failure
Existence of air in air conditioning

system
Change the receiver drier and fill refrigerant

after vacuation
Air leak from the

evaporator or air duct
Repair if necessary
overhead
Failure in heater and ventilator
Check the evaporator assembly

Check the heater control lever assembly
Check the heater assembly

Blower motor failure
Existence of excess compressor
oil in air conditioning system
Lin connection failure
Repair if necessary
Expansion valve failure
Intermittent cold air
High humidity in
conditioning system
Check expansion valve

the
air
Magnetic clutch failure

Failure in compressor thermal
protector
Condenser clogged.
Inadequate refrigerant
Producing cold air only at high
speed
Pump out the compressor oil from the air

conditioning system and change the
compressor
Existence of air in air conditioning

system
Change receiver/dryer and vacuate and

charge refrigerant
Check the compressor thermal protector
Check the condenser

Change the dryer and then vacuate it
Fill (refrigerant)
Driving belt sliding

Compressor failure
Check and change the driving belt


Excess charging of refrigerant
No cold air only at high speed

Evaporator frozen
Check the air conditioners thermal resistor
Evaporator clogged or frozen
Inadequate wind force of cold

air
Air leakage of cooling equipment

or air duct
Blower motor failure

Check the air conditioners thermal resistor
Repair if necessary
Circuit or line fault
Repair if necessary
2. Check on driving belt of air conditioner compressor

1) Push the intermediate point between the compressor pulley
and the crank pulley with a force of about 100N to measure its
offset to check the tension of the belt.
a: offset under 100N: 8~11mm
Notice:
When the belt is changed, adjust the tension to b 8~9mm.
2) Check if the belt has wear or cracks, and change it if
necessary.
1. Driving belt
2. Crank pulley
3. Air conditioner compressor
3. Check on the refrigerant quanity through observation hole

Make a quick check by the following procedures to check if the refrigerant filled to
the air conditioning system is suitable.
1) Operate the air conditioner for several minutes according to the following setting.
Air conditioner and fan switches: high position
Motor speed:
1100rpm (high idle speed)
Ari vent window: full open

2) Check the refrigerant in the air conditioning system through the observation hole
and compare the observed results with the following table.
A excess charging or no refrigerant

B suitable
C inadequate refrigerant
1. Observation hole
2. Bubble
No.
Troubles
Causes
Troubleshooting
There are bubbles found in the

observation hole
The system is not adequately

charged with refrigerant.
Use a leak detector to check if

the system leaks.
There are no bubbles found in

the observation hole
The refrigerant in the system

runs out or is inadequately
charged.
Refer to the step 3) and 4).
The temperature change at the

compressor inlet and outlet is
not great.
There is no or almost no
refrigerant in the system.
Vacuate and refill the air

conditioning system, and then
use a leak detector to check the
leakage.
The temperature at the

compressor inlet is obviously
different from that at the
outlet.
Adequate or excess
Refer to the step 5 and 6.
When the air conditioner is

shut down, the refrigerant in
The system is excessively

charged with refrigerant.
Discharge the excess refrigerant

and adjust it to the specified
the observation hole disappear

immediately
and
the
observation hole keeps clear.
When the air conditioner is

closed, there are bubbles
produced in the observation
hole and then disappear.
charging level.
The system is charged with

adequate refrigerant .
It is not necessary to take

treatment, for the refrigerant is
charged normally.
4. Check on air conditioner controller and its circuit

The air conditioner controller and its circuit can be checked by measuring the voltage of the line connector of the
air conditioner controller.
Voltage check
3) Check the voltage of every terminal of the overhead evaporator line and then turn on the ignition switch.
Notice:
As the voltage of every terminal is affected by the battery voltage, verify whether the voltage is 11V or above
when the ignition switch is turned on.
Notice:
If it is necessary to disconnect or connect the refrigerant pipe to remove or reassemble any part of the air
conditioning system, the following instructions shall be followed.
When any pipeline is removed from the system, the pipe end plug or end cap shall be immediately fitted to
the assembly parts of these pipelines.
When the hose and pipe are connected mutually, the connecting nuts and O ring seat shall be applied with
several drops of refrigerant oil ahead.
When the mounting pieces are screwed or unscrewed, two wrenches are needed, one for turning, and the
other for bearing.
According to the following technical requirements, tighten the connecting nut. The tightening torque of the
connecting nut:
8mm pipe: 13Nm
14.5mm pipe: 32Nm
1. Check and adjustment of air conditioner idle
prior to making check to the idle, be sure to following the aspects below:
Wires, fuel hoses and ignition must be firmly connected with the exhaust control system.
If the accelerator cable wobbles, it means that it is not tightened.

The ignition timing shall comply with the specification.
Apart from the ignition system, all the electric loading shall be closed.
Notice:
Prior to starting the engine, put the gear shift operating rod in neutral, and then adjust the parking brake
and stop the driving wheel.
1) Heat the engine to the normal working temperature
2) Calibrate the rev counter
3) Check to make sure the idle complies with the specification.
Engine idle (air conditioner shut down):
100050rpm
If the engine idle value is not within the specified value, refer to the fault repair in Chapter .
4) Turn on the switches of the air conditioner and fan.
5) Check to make sure the idle is up to the specification.
Engine idle (air conditioner opened): 110050rpm
If the engine idle is not within the specified value, check the air conditioner vacuum control valve and relevant
pipes and hoses.
2. Pressure switch
Check
1) When the air conditioning system is filled with adequate refrigerant and the air conditioning system (compressor)
is working, check if the switch can conduct at normal temperature. In these two cases, all the switches shall be
turned on.
2) When pressure is within the specified range below, the switch shall not be turned on.
Pressure at high-pressure side
High- and low-voltage

switch
200kPa or below
Not turned on
3200kPa or above
Not turned on
Tightening torque of pressure switch:

11N.m
1. Air conditioner condenser assembly
2. Air conditioner condenser fan
3. Check on air conditioner condenser

Check the following conditions
Is there leak, stoppage and damage in the condenser radiator shutter?
Is there leak in the condenser assembly parts?
The blocked radiator shutter must be washed with water and then dried by compressed air.
Notice:
Be careful not to damage the condenser radiator shutter. If
the condenser radiator shutter is bent, straighten it with a
screwdriver or pliers; if the fittings or pipes leak, repair them
or change the condenser.
4. Check on air conditioner condenser fan motor
Check if there is continuity between the two terminals.
If they are in continuity, make the next check; if not, change
them.
1. Air conditioner condenser fan motor plug connector
Connect the battery to the air conditioner condenser fan motor, and then check if the condenser fan motor can work
steadily, as shown in the right figure.
reference current: 5.8~7.2A at 12V.
5. Check on air conditioner condenser fan relay
Check the resistance between every two terminals in the following table.
Resistance between terminals A and B: (infinite)
Resistance between terminals C and D: 80~100 at 20(68).
Condenser fan relay
If the inspection result comply with the requirements, make the next check; if not, change it.
Given a voltage of DC 12V between terminals C and D, check if there is continuity between terminals A and
B.
If there are defects founded, change it.
6. Overhead evaporator assembly
Disassembly
2) Recovering the refrigerant by recovery plant and recycle unit shall follow the requirements of the manual. Be
sure to measure the compressor oil that is discharged and then refill the system with equal amount of compressor
oil.
3) Remove the left and right covers of the overhead evaporator.
4) Remove the joint of the overhead evaporator assembly.

5) Remove the compressor intake pipe and dryer exhaust pipe from the overhead evaporator assembly.
Notice:
Remove the pipes mentioned above and cover the opened joints to avoid moisture and dust entering the
evaporator.
6) Remove the mounting bolts and screws and then remove the overhead evaporator assembly.
Assembly
1) The overhead evaporator assembly shall be assembled in the reverse order of its disassembly.
2) Vacuate the air conditioning system according to the steps set forth above and then refill refrigerant in the
system.
Disassembly and reassembly
Refer to the figure below when the overhead evaporator assembly is reassembled after disassembly.
Check
1. Evaporator
2. Fan motor
3. Thermal resistor
4. Air conditioner and fan switches
5. Expansion valve
6. Fan resistor
Fan motor
Check if the terminals are in continuity.
If there are in continuity, make the next check.
If not, change them
Connect the battery to the fan motor as shown in the figure, and then check if the fan motor can work normally.
Reference current: 4.8~6.0A at 12V.
Evaporator
Is there leak, stoppage and damage in the evaporator radiator shutter?
Is there leak in the evaporator fittings.
The blocked evaporator radiator shutter must be washed with water and then
dried by compressed air.
Notice:
Be careful not to damage the evaporator radiator shutter. If the evaporator
radiator shutter is bent, straighten it with a screwdriver or pliers; if the
fittings or pipes leak, repair them or change the condenser.
1. Evaporator
The thermal resistor, if removed, shall be reinstall on the original position.

Air conditioner and fan switches
2) Remove the overhead evaporator assembly case.
3) Remove the air conditioner and fan switch connectors, and the remove the air conditioner and fan switches.
4) Check if every two terminals of the air conditioner and fan switches are in correct continuity by an ohmmeter.
Position
Off
Low
Intermediate
High
If the air conditioner and fan switches are not on, change them.
Fan motor resistance
Check the resistance between every terminals as shown in the table below.
Terminal-terminal
Resistance ()
AB
1.6~1.8
AC
2.8~3.0
1. Resistor plug connector
BC
1.1~1.3
If the inspection result is not within the range as specified in the table, change the fan motor and resistor.
Expansion valve
Refer to the Removal of faults by manifold pressure (procedure) in the chapter.
7. In-car check on air conditioner compressor
Expansion valve
The fault of compressor includes the following three classifications: air leakage,
noise and underpressure. In most cases, compressor air leakage is caused by
the shaft seal. Checking air leakage usually makes use of leak detector. If only
little oil leaks from the shaft seal, it is unnecessary to change the seal, for it is designed to allow little oil leakage for
the purpose of lubrication. Thus the shaft seal shall be changed only when the oil leakage is great or there is air
leakage by gas detector.
Troubles
Noise in compressor
Possible causes
Troubleshooting
Rotary valve failure
Change
Bearing valve failure
Change
Cylinder or shaft failure
Change
Bearing failure
Change
Clutch disc damage
Change
Sealing gasket damage
Change
Leaf spring valve failure
Change
Bearing valve is locked so that the cylinder

and/shaft and leaf spring valve is locked
Change
Magnetic clutch jammed.
Change
Due to inadequate oil, the revolving parts are

jammed.
Change
Shaft seals damage
Change
Noise in magnetic clutch
Inadequate cold air
No rotation
Oil or liquid leakage
O ring damage

Refer to the figure below for disassembly and assembly of air conditioner compressor. After assembly, check and
adjust the tension of the driving belt. Refer or Check on air conditioner compressor driving belt)
Check
Check if the pressure plate and rotor are worn or immersed in
oil. Check if the clutch bearing has noise, wear or grease leak.
Measure the resistance of stator coil at 20.
Standard resistance: 2.9~3.8
If the measured resistance value is not within the specified
range above, change the coil.
8. Charging of Compressor oil
When the air conditioner parts is replaced with the new parts, conjecture the quantity of the oil in every part and
then replenish the oil of the same quantity.
Compressor oil type: RS20
Charging of refrigerant
It may be inevitable to replenish refrigerant even if no part is changed
due to disassembly and assembly of engine or other reasons, and the
charging of engine oil is unnecessary.
When the compressor is changed
As the compressor oil is packaged in every new compressor according
to the air conditioner circulation, it is necessary to discharge the
compressor oil when it is replaced with a new one. The discharge
amount shall be calculated as follows:
C= D-E
C: Discharged oil amount
D: Amount of oil packaged in the new compressor A
E: Amount of oil left in the removed compressor B
When other parts are changed:
Changed parts
Compressor oil amount
Evaporator
25cc
Condenser
15cc
Reservoir/ dryer
20cc
1. New compressor
2. Removed compressor
3. Excess oil
Hose
10cc (each)
Pipe
10cc (each)
. Performance test
After all the repair is done, make sure to follow the procedure below to carry out performance test for the air
conditioning system.
Procedure
1) Connect the high- and low-pressure compensation hoses of the
manifold pressure gauge to the compressor pipe fittings.
2) Let the engine run and remain at the speed of 1,500rpm.
3) Set the air conditioner and fan switch to the high position.
4) Keep all the air conditioner windows and doors open.
5) Insert a dry bulb thermometer into the cold air outlet and fit a
hygrometer (dry bulb thermometer) close to the evaporator air inlet.
1. Thermometer
2. Hygrometer
6) The reading of high pressure gauge shall be within the specified

pressure range.
Reading of high pressure gauge: 1.4~1.6Mpa
7) The reading of the dry bulb thermometer at the air inlet shall be within 25~35. Make adjustment to the air
conditioning system to make its high and low pressure and thermometer in the stable state.
How to read standard performance curve (figure)
1) Read the air humidity reading at the air inlet and get the relative humidity from the air humidity chart (see the
figure below)
2) Measure the dry-bulb temperature at the cold air outlet and then find the temperature difference of the inlet and
outlet.
3) Check the relation between the relative humidity and the temperature difference with the curve chart. The
difference 17(62.5) and 60% relative humidity are the example. If their junction falls within the region
between the two lines, the cooling performance is satisfactory and suitable.
How to read relative humidity ()
Measure the wet-bulb temperature and dry-bulb temperature of the hygrometer at the evaporator air inlet,
and read the relative humidity curve intersecting with it according to the temperature line below.
For example:
If the dry-bulb temperature is 25 and the wet-bulb temperature is 19.5, the relative humidity is
60%.
Temperature difference of the inlet and outlet
Relative humidity (%)
Wet-bulb
temperature ()
Relative humidity (%)
Dry-bulb temperature ()
Chapter Electrical system

Section Power supply system
. General
The cars power supply system is composed of battery, generator
(three-phase AC generator), rectifier (three-phase AC full-wave rectifier),
voltage regulator (built-in type) and charge lamp. The care is equipped with
12V DC power supply for its electrical equipment.
1. Battery
In the electrical system, the battery has three major functions.

It is a power supply for starting the engine.
It can function as voltage stabilizer for the electrical system.
It can provide electrical energy with the generator in a limited timeframe when the electrical load exceeds the
generator output.
The types of battery installed in cars are as follows.
Rated power
Electrolyte specific
gravity
6-QW-45
12V 45Ah
1.28 in full charge at 20oC
Battery
Mounting bracket and pressure plate
The battery mounting bracket shall in good condition so that it can secure the battery and keep it level.
Prior to installing the battery, the battery mounting bracket and pressure clamp shall be clean without corrosion, and
the bracket shall not have any part in it.
To avoid the battering swinging in the bracket, the pressure bolt shall be tightened appropriately, but not too tightly.
Electrolyte freezing
The electrolyte freezing point depends on its specific gravity. As the freezing will damage the battery, it can be
protected against freezing by full charge. If the battery accidentally freezes, it can be charged after thawed.
Sulfation
If the battery is kept a long time in discharge condition, the lead sulfate will become hard crystal, which will be
difficult to translate into active material. Sulfation means the result and process of reaction. The battery of this
sort can restore to the available mode by the charging method of devulcanization, but the volume will be lower than
before.
Battery maintenance
Notice: the charging current value of the maintenance free battery shall be selected according to the factory
requirements
Warning:
Pay attention to safety in using and changing maintenance free battery. It is better to wear glasses in the face of
battery. The battery shall be kept away from flame and spark source to avoid explosion and personal injury
accordingly.
Inspection method of technical condition of maintenance free battery
Method of observing charge indicator
The charge indicator (electrolyte densimeter magic eye) equipped in the maintenance free battery can indicate the
charging condition of the battery. As shown in the figure below, the straight tube under the charge indicator is
inserted into the electrolyte from the battery top. There is a small green ball in the indicator. When the electrolyte
density is higher than 1.265g/cm3, or the state of charge is above 65%, the small ball will float up and the indicator
turns green; when the state of charge is below 65%, the small ball sinks, and the indicator turns black. If the
electrolyte is lower than the limit, the indicator will turn colorless and transparent, which means the electrolyte has
dropped to the limit and the battery shall be scrapped.
Thus, it can judge the technical condition of the battery by observing the indication of the charge indictor.
If the charge indicator is green, it means the battery is in good condition, and voltage measurement can be made
to further judge the technical
Charging degree lower than 65%
condition of the battery.
Charging degree higher than 65%
Electrolyte level lower than limit
If the charge indicator is
green, but the starting appears to
be weak or costs too much time,
the battery shall be charged.
If the charge indicator is
black, it means the battery is in
serious power shortage, and
shall be charged immediately.
If the charge indicator shows
colorless and transparent light
spot (pale yellow for some
battery), it means the electrolyte
level is too low. If the starting is
Charge indicator schematic diagram
weak when it is connected to the
starter, the battery shall be changed, or the causes for the low level shall be figured out. The causes for low level
may be cracks in the case of serious overcharge. If it is overcharge, the charging system shall be checked.
Method of measuring battery terminal voltage
Charge the battery fully; connect the carbon pile tester between the positive and negative electrodes as
adjustable load; adjust the load current to the specified value, and then discharge continuously for 15s.
Measure the batter terminal voltage. If the terminal voltage is above 9.6V, it means the battery is in good
technical condition and can continue using after charged; if the terminal voltage is below 9.6V, it means the
technical condition deteriorates and it cannot be used any more.
The test above is carried out at the ambient temperature of 21oC. The allowable value at different temperatures is
as follows:
The load current shall be as the factory setting when the battery terminal voltage is measured.
Electrolyte
temperature
()
Allowable
voltage (V)
Electrolyte
temperature
()
Allowable
voltage (V)
Electrolyte
temperature
()
Allowable
voltage (V)
21
9.6
-1
9.1
-18
8.5
10
9.4
-9.5
8.8
<-18
8.0
Charging method of maintenance free battery

Charging is necessary when the magic eye becomes black, and the procedure for charging is as follows:
The circuit between the battery and the charger shall be well connected.
Charging shall be not started until the charger voltage is adjusted to 14.4V and the current is adjusted to the
maximum.
In charging, regular check shall be made to make sure whether the battery suffers overflow and leakage, whether
it puffs air or whether its temperature is above 45. Provided any one of them occurs, stop charging immediately
and eliminate the phenomenon.
When the charge indicator turns green, the charging is completed.
2. Generator
The generator is three-phase AC generator, which is equipped with three-group full-wave rectifiers made of three
groups (9 diodes) of diodes, as shown in the following figure.
Charging indicator
Generator characteristics
The regulator is fixed on the inside of the generator.
The voltage regulator is integrated circuit which regulates the voltage produced by the generator to the setting
voltage.
The generator rotor bearing has so adequate lubricant that it needs no periodic lubrication. The two brushes
transfer the current through the two slip rings to the exciting coil around the rotor. Under normal circumstances, it
need no maintenance over a long time.
The stator armature winding is installed in the stacked iron
core, which is the generator frame element.
The capacitor fixed in the rear cover can suppress the radio
interference.
The generator has the following functions:
1) The generator supplies power to the electrical equipment
when it is working normally.
2) The generator supplies power to the battery when the
battery is undervoltage and the car power consumption is low.
1. Belt pulley 2. Belt pulley nut 3. Rotor fan 4. Stator coil 5. Stator coil 6. Exciting coil
7. Regulator 8. Carbon brush 9. Back end cap 10. Drive end cap
B: Generator output (battery terminal)
D: Virtual terminal
E: Earthing
F: Field coil terminal
IG: Ignition terminal
L: Charge indictor terminal
. Fault diagnosis
1. Battery
Visual inspection
Check if there is obvious damage, for example electrolyte leakage. If yes, change or repair the battery.
Hydrometer test
Notice:
The method of directly inspecting the battery charge state is to use precision voltmeter to carry out high
current discharge test.
Provided the battery temperature (electrolyte temperature) is at 20:
When the battery is in fully charged, and the electrolyte specific gravity is 1.280.
When the battery is half charged, and the electrolyte specific gravity is 1.220.
When the battery is close to discharge state, and the electrolyte specific gravity is 1.150, there is risk of freezing.
If the battery temperature is not 20oC, the specific gravity reading (measured by densimeter) shall be corrected in
terms of 20 as the specific gravity varies with the temperature, and the corrected specific gravity shall correspond
with the three values above.
Overcharge
Refer to the coil below that expresses the relation of specific

gravity and temperature for the correction method
Given specific gravity
Use method of diagram
Provided the specific gravity is 1.28, the battery temperature is

Due charge
-5, find out the intersection of -5 line and 1.28 specific
gravity line. The intersection is A region (dashed area), which
means charge state. How is the charging degree of the battery
Temperature
determined? To find the answer, draw a line parallel to the dividing line and extend it to the right to find out the
intersection with the percentage line. The percentage reading at this intersection is the answer. The parallel line in
this example intersects at the point of 85%, so it means the
charge state is 85% of the full charge.
Ignition terminal Light terminal
Virtual terminal
2. Generator
Generator output
Caution:
(Battery
Earth terminal)
Do not mistake the polarity of the ignition terminal and the
indicator light terminal.
There shall be no short circuit between the ignition terminal and
the light terminal. Both of them are always connected through
indicator light.
No electric charge shall be connected between the light
terminals and earthing.
If the car battery is to connect charger or auxiliary battery, refer
to the battery charge in this chapter.
If one or several cases below occur, it means the charging system
breaks down:
1) When the ignition switch is turned on, the charge lamp is on;
when the engine is started to work normally, the lamp is off. If the trouble lamp is still on, it means there is a
trouble.
2) If the starter starts slowly or the indicator light is not bright, it means the battery is undercharged.
3) Too much electrolyte leaks out through the holes; it means the battery is overcharged.
The generator noise may be caused by loose drive pulley, loose mounting bolts, bearing wear or dirt, or damage of
diode and stator.

Trouble lamp operation
Troubles
Provided ignition connected,

the charge light is not on
when the engine does not
start.
Causes
Troubleshooting
The fuse blows out.
Check the fuse
The light blows.
Change the light
The connection of the wires gets

slack.
Tighten the connector
The voltage regulator or the field coil

is out of order.
Check the generator

Repair or change
There is poor contact between the

electrical brush and slip ring.
The driving belt gets loose or worn.
The charge light fails go out
when the engine is operating
(battery needs to be charged
frequently)
The voltage regulator or AC

generator breaks down.
The circuit is out of order.
Adjust or change the

driving belt
Check the charging
system
Repair the circuit
Battery
undercharge
Even if the indicator light is in working order, the case of engines slow
starting is still caused by the following conditions.
Ammeter is between generator (B)

terminal and battery (+) terminal
The following methods are also applicable to the cars with voltmeter
and ammeter.
1) Check if the tension of the driving belt is suitable.
2) If there is doubt about battery damage, refer to the section battery.
Voltmeter is between
generator
(B)
terminal and earth
3) Check if the circuit is damaged; check if the tension and cleanliness

of battery, stator and ignition earth wire or the battery cable are
suitable.
4) Connect the voltmeter and ammeter as shown in the right figure.
Voltmeter
The voltmeter is connected between the generator B terminal and the earth.
Ammeter
1. Generator
2. Ammeter
3. Voltmeter
4. Battery
5. Load
6. Switch
The ammeter is connected between the generator B terminal and the battery (+) terminal.
Notice:
Use fully charged battery
5) Measure the current and voltage.
Regulating voltage
No-load check
1) Let the engine run at the idle speed of 2,000rpm to read the reading.
Notice:
Turn off the auxiliary equipment switch (wiper and HVAC, etc.)
Standard current
Maximum 10A
Standard voltage
14.2~14.8V at 25
Radiating (equipment) temperature
Notice:
The voltage will slightly vary with the change in regulator shell temperature, as shown in the right figure.
Too high voltage
If the voltage is higher than the standard value, a check
shall be given to the brush earthing.
If the brush is correctly earthed, the voltage regulator shall
be changed.
Too low voltage
If the voltage is lower than the standard value, the
following check shall be made.
2) Earth the field coil terminal to start the engine, and then measure the voltage at the generator output terminal as
shown in the right figure.
Provided the voltage is higher than the standard value,
The generator shall be considered good and the voltage regulator damaged, which shall be then changed.
Provided the voltage is lower than the standard value,
It may the problem of the generator itself, so the generator shall be inspected.
Load check
1) Let the engine run at the speed of 2,000 rpm, and open the headlight and HVAC motor.
2) Measure the current; if the current is less than 20A, change or repair the generator.
Battery overcharge
1) Refer to the section of battery in the fault diagnosis in the chapter to determine whether the battery is
overcharged.
2) If there is obvious sign of overcharge like electrolyte seepage, the generator shall be disassembled to check if the
field armature is earthed or short circuited. If there are problems, change the rotor.
3) Measure the voltage when the engine runs at the speed of 2,000rpm.
4) If the measured voltage is beyond the standard range, check the brush earthing and voltage regulator.
1. Battery
Jump staring in emergency
In bridging the wires, be careful to treat the auxiliary battery and discharge battery in accordance with the following
procedures, or spark will be caused.
Warning:
Violation against the following requirements or procedures will result in:
1) Battery explosion, battery acidification or fire, which will thus cause serious personal injury (especially
eyes) or damage to mechanical property.
2) Damage to the electrical elements of the car.
It is necessary to wear protective glasses to detach parts.
Be careful not to let the metal tool or jumper wire to touch the battery positive terminal or other metal of
the car, or short circuit will happens.
1) Set the parking brake and automatic transmission to the stop position (neutral of manual transmission), and then
turn off the ignition equipment, light and other electrical load.
2) Check the electrolyte level. If it is lower than the minimum level, distilled water shall be filled.
3) Connect one end of the jumper wire to the auxiliary battery positive terminal, and the other end to the discharge
battery positive terminal (the 12V battery can only be bridged to the starting engine).
4) Connect one end of the jumper negative wire to the auxiliary battery negative terminal, and the other end to the
engines earthed part (for example exhaust manifold)
Fixing strap
and at least 45cm (18in) away from the car battery.
Battery
Warning:
The negative wire cannot be directly connected to
the negative terminal of the discharged battery.
5) Start the engine of the car with auxiliary battery and
turn off the electric accessories; and then start the
engine of the car with discharge battery.
Negative wire
Positive wire
6) Disconnect the jumper wire in the reverse order.

2. Charging equipment (the battery shall be charged when the engine is shut down)
Caution:
In starting the engine with charging equipment by jumper, make sure the voltage of the used charging
equipment is 12V, and the negative electrode is earthed. Do not use 24V charging equipment, for it will cause
serious damage to the electrical system or electrical element.
Disassembly
1) Open the engine compartment cover at the driver seat side.
2) Disconnect the negative wire.
3) Disconnect the positive wire.
4) Remove the fixing strap.
5) Take out the battery.
Treatment
Pay attention to the following safety precautions in treating battery:
The battery can produce hydrogen, which will be ignited if the battery is close to a flame or spark.
The battery electrolyte is strongly acidic so that it shall be prevented from splashing on clothes or other fibers. If
the electrolyte splashes, clean it with large amount of water immediately.
Assembly
1) The assembly shall be made in the reverse order of the
disassembly.
2) Tighten up the battery wires.
Notice:
Check to make sure there is an adequate clearance
between the earth wire and the engine hood.
The car body shall not interfere with the battery wires.
The positive terminal, after tightened up, shall be
covered with insulation rubber sleeve.
Generator
Disassembly
1) Remove the negative wire from the battery.
2) Remove the reinforcement of compressor bracket.
3) Disconnect B terminal and the coupling from the generator.
1. Generator
4. Base
2. Belt adjusting bolt 5. Generator adjusting stiffener
3. Adjusting bolt
6 Generator belt adjustor
4) After the belt adjusting bolts, generator bolts and pivot bolts are removed, remove the generator generating arm
5) Remove the generator.
Assembly
The assembly shall be made in the reverse order of
disassembly. Adjust the driving belt to the specified
tension.
Notice:
Refer to the chapter of Engine for the belt
tension.
Tightening torque
(a): 23Nm
(b): 50Nm
(c): 8Nm
Generator belt
Check on belt tension
1) Check to make sure whether the belt has cracks,
notches, deformation and wear and whether it is
clean.
1. Adjusting screw
2. Pivot bolt
3. Belt adjusting bolt
4. 10kg (22lbs)
2) Check the belt tension. If the belt sinks 6-8mm when pressed by the thumb (about 10kg), it means the tension is
suitable.
Belt tension a: 6~8mm
Notice:
The belt tension shall be adjusted to 5`6mm when it is replaced with a new one.
3) If the belt is too loose or too tight, the adjusting bolts and pivot bolts shall be unscrewed. The belt tension can be
adjusted by turning the belt adjusting bolt.
4) Screw up the generator adjusting bolts and pivot bolts.
Tightening torque
(a): 23 Nm
(b): 50 Nm
5) Connect the negative wire to the battery terminal.
Change of belt
Refer to Water Pump Belt in the chapter of engine.
. Overhaul
1. Generator
1. Belt pulley
2. Belt pulley bearing
3. Nut
4. Drive end cap assembly
5. Generator front bearing
6. Bearing retaining ring
7. Screw
8. Stud bolt
9. Rotor assembly
10. Generator rear bearing
11. Bearing cap
12. Voltage regulator
13. Brush holder assembly
14. Screw
15. Terminal insulating part
16. Back cover
Disassembly
1) Remove the
bolts and insulating part in the generator output terminal.
2) Remove the back cover.
1. Back cover
2. Nut in B terminal
2. Insulating part
3) Unscrew No. 2 screw to pull out the brush holder

assembly.
4) Unscrew No. 2 screw to remove the voltage regulator.
5) Remove the brush holder cover from the brush holder.
6) Remove the rectifier holder
7) Hold the shaft with an inner hexagon spanner to
unscrew the pulley nut and then pull out the belt pulley.
Caution:
1. IC adjustor bolt and screw 3. Brush holder screw

2. IC regulator
4. Brush holder assembly
To hold the shaft, an inner hexagon spanner shall be

used, for the inner dodecagon spanner skids, which will damage the shaft or the tool.
Do not use vice or pipe wrench to hold the belt pulley, or
the belt pulley will be deformed.
1. Rectifier holder
1. Back end frame
2. Rotor shaft
3. Back end nut

4. Back end bolt
8) Unscrew 2 back end nuts and bolts respectively

9) Tap out the back end frame with rotor threading
shaft with a plastic hammer.
10) Separate the back end cap from the rotor with a
plastic hammer.
Caution:
Do not knock the shaft at the slip ring side in
separating the rotor from the back end cap.
1. End cap bearing

2. Bearing puller
3. Bearing cap
11) If necessary, use the bearing puller to remove the end cap bearing and bearing cap.
Caution:
Be careful to operate the puller so as not to
damage the cooling fan blades.
12) If necessary, remove 4 screws and the locating
plate, and then take out the drive end bearing.
13) If necessary, unscrew the stud bolt and then
pull out the rotor.
Notice:
It will be easy to remove the stator by heating
the drive end cap.
Check on rotor
1. Stud bolt
2. Locating plate
3. Drive end bearing

4. Stator
Broken circuit
Use an ohmmeter to check if the two rotor slip rings
are conductive; if not, change the rotor
Standard resistance is about several ohms.
Ground (short circuit)
Use an ohmmeter to check if the slip ring and the
rotor are conductive between each other. If yes,
change the rotor.
1. Rotor
1. Rotor
Slip ring
Check if the slip ring is not smooth or has scratches; if year, change the rotor
Use a vernier caliper to measure the diameter of the
slip ring.
Standard diameter: 14.4mm (reference)
Minimum diameter: 14.0mm (reference)
If the measure diameter is less than the specified
minimum diameter, the rotor shall be changed.
Stator
Broken circuit
Use an ohmmeter to check if all the wires are conductive; if not, change the stator
Ground
Use an ohmmeter to check if the coil wire and the
stator core is conductive each other. If yes, change
the rotor.
Brush
Length of exposed brush
Check the brush wear by measuring its length. If the
brush wear exceeds the operating limit, it shall be
changed. Refer to Change of Brush in this
chapter.
Length of exposed brush a
Standard value: 10.5mm
Limit value: 4.5mm
Rectifier
Positive rectifier
1) Use the ohmmeter, with its one probe connected to the generator
output terminal and other other probe to the rectifier terminal (P1-P4)
2) Exchange the probes and repeat the step 1).
3) Check if the rectifier is conductive in one direction and not in the
other direction; if yes in both direction, the rectifier holder shall be changed.
B: Positive terminal E: Negative terminal

P2-P1: Rectifier terminal
Bearing
B: Positive terminal
E: Negative terminal
P1-P4: Rectifier terminal
Drive end bearing

Check if the bearing is damaged or worn.
End cap bearing

Check if the bearing is damaged or worn
Change of brush
1) Seal off and then remove the brush and spring.
2) Roll the new brush wire to the brush holder hole, and then insert
the spring and brush into the holder.
3) Solder the brush wire to the holder, with a specified exposed
length.
Exposed length a: 10.5mm
4) Check if the brush can move smoothly in the brush holder.
5) Cut off the redundant wire.
6) Apply insulating varnish to the soldering point
Assembly
Assembly
1) If the end cap bearing is removed, it shall be installed.
2) Check if the end cap bearing can rotate smoothly.

3) If the rotor is removed, it needs to install the rotor and tighten the
stud bolt.
4) If the drive end bearing is removed, it is necessary to install the drive
end bearing.
5) Check if the drive end bearing can rotate smoothly.
Tightening torque
1. End cap bearing 2. Bearing cap

3. Rotor
(a): 8.8 Nm
(b): 2.6 Nm
6) Place the spacer ring and drive end frame on the belt pulley, and then
fit the rotor into the drive end frame.
7) Fit the back end frame to the drive end frame.
8) Tighten the bolt and nut to the specified torque.
Tightening torque
1. Stud bolt 3. Drive end bearing

2. Locating plate 4. Rotor
(a): 4.5 Nm
9) Fit on the belt pulley and tighten the pulley nut to the specified torque.
Tightening torque
(b): 45~60Nm
1. Rotor
2. Drive end cap
10) Install the rectifier holder, and fix the stator wire as shown in the figure.
1. Rectifier holder
2. Bolt
Caution:
3. Stator wire
Check to make sure that there is an adequate clearance between the stator wire and cooling fan blade in
fitting on rectifier.
Tightening torque
(c): 2.0 Nm
11) Fit the brush holder cap to the brush holder.
12) Fit the voltage regulator and brush holder horizontally to the back end frame.
13) Fit on the 5 screws to allow a clearance of about 1mm between the brush holder and the joint.
Tightening torque
(d)2.0 Nm
About 1mm
14) Fit on the back end cap cover

1. IC regulator
2. Brush holder
3. Back end frame
Tightening torque
(a): 4.5 Nm
15) Fit on the insulating parts and tighten the nut in terminal B to
Tightening torque
(b): 8.0 Nm
16) Make sure that the rotor can rotate smoothly.
1. Back end cap

2. Insulating part 3. Nut in terminal B
Technical requirement
Rated voltage
12V
Standard output
60A (at 13.5V)
Allowable
maximum speed
18,000rpm
No-load speed
1,180rpm
Output voltage
Allowable
working temperature
-30~90oC
Polarity
Minus earth
Direction of rotation
Clockwise rotation if seen

from the belt pulley side
14.2~14.8V
Tightening torque
Recommended tightening torque

Fastener
Nm
Kgm
0.8
23
2.3
3. Generator pivot bolt
50
5.0
4. Generator support bolt
23
2.3
5. Nut in generator output

terminal
4.2
0.42
0.8
113
11.3
4.5
0.45
4.0
0.4
1. Machine earth stud

2. Generator
adjusting bolt
drive
6. Nut outside
output terminal
pulley
generator
7. Pulley nut
8.
Back end frame nut
9. Back end cap nut

10. Negative rectifier segment
bolt
Section Car body electrical system

. General
The working power supply of the cars electrical elements is fed by generator and battery, whose voltage is 12V.
The electric system adopts negative ground.
1. Notice of maintenance
When the maintenance involving electric system is carried out, the
following shall be followed to protect the electrical elements and avoid
fire.
When the battery is removed from the car or the wire is disconnected
from the battery terminal to carry out check and maintenance of electrical system, it shall be sure that the ignition
switch and other switches have been disconnected, or the semiconductor components may be damaged.
To disconnect the wire from the battery, the negative (-) terminal shall be first disconnected and then the positive
(+) terminal.
To connect the wire with the battery, it shall in the reverse order as
above.
Forbidden
To disconnect the plug connector, it is not permitted to pull the wire

harness. First, the lock of the plug connector shall be opened and then
hold the connecter by hand to pull them open.
To connect the plug connector, it is also necessary to hold the
connector by hand to push them in till they are locked (sounds
click).
The wire harness, when fitted on, shall be fixed by a clip, without
looseness.
Be careful not to hinder the wire harness or press the wire
harness by parts in fitting car parts.
Click
Acceptable
Forbidden
Forbidden
To avoid damaging wire harness and protect the part contacting the edges and corners against damage, the wire
harness shall be wound by strap, as shown in the figure.
The fuse, when changed, shall be replaced with that complying with the specified fusing current value. If it is
replaced with the fuse of higher fusing value, the electrical part may be easy to be damaged or it may cause a fire. If
it is replaced with the fuse of lower fusing value, it will be often blown out.
Be careful not to treat the electrical parts (ECm, relay, etc.) violently by hand or let them fall off.
Forbidden
Acceptable
Not
allowed
In maintenance, if the temperature close to the electrical part exceeds 80, the electrical parts of poor heat
resistance shall be first removed.
Be careful not to let the plug connector and electrical parts contact water, or a failure will occur.
Make sure the tester probe is inserted from the wire harness side when it is used to check the conductivity and
measure the voltage.
Forbidden
Forbidden
2. Symbol or sign
In the circuit diagram of this manual, all the electrical parts are expressed by the following symbols and signs:
Battery
Earth (ground)
Main power
supply fuse
Fuse
Breaker protector
solenoid valve
coil
Heater
Cigar lighter
Motor
Pump
Horn
Loudspeaker
Buzzer
Music indicator
Capacitor
Thermal element
Reed switch
Bulb
Resistor
Photistor
Piezoelectric
element
Adjustable resistor
Diode
Voltage
stabilizing diode
Triode
Light-emitting
diode
Wire (wire harness)
Relay
(Intersection)
(Connection)
Normally opened relay
Plug connector
Photosensitive
diode
Switch
O terminal
Normally closed relay
3. Code table
1) English codes used in this chapter and their full name in Chinese
Abbreviation
Full name
Abbreviation
Full name
2WD
2 wheel drive vehicle
IG
Ignition
4WD
4 wheel drive vehicle
ILL
Illuminator
AC
Air conditioner
IND
Indicator
ACC
Accessory
JB
Joint/fuse box
CKP
Crankshaft position
JC
Connector
CMP
Camshaft position
LH
Left-hand side
DIC
Data transmission connector
LO
Low
DRL
Daytime running light (if

equipped)
MAP
Manifold absolute pressure
ECT
Engine cooling water temperature
PSP
Power steering pressure
EFE
Engine intake preheating
RH
Right-hand side
EGR
Exhaust gas recirculation
SDM
Sensing & diagnostic module
F/L
Fuse
SEDAM
Double cab saloon car
HATCHBACK
Hatchback
ST
Starter
HI
High
TCC
Hydraulic converter clutch
IAC
Idle air control
VSS
Vehicle speed sensor
IAT
Intake air temperature
2) Wire color mark

The letter code of wires represents single- or double-color wire.
For example: R is single-color red wire; RU is double-color wire, where the R is main red wire, and the U is
auxiliary blue wire.
Code of wire color:
R-Red
B-Black
RG-Red with green

BU-Black with blue
PG-Pink with green
RU-Red with blue

BG-Black with green
PU- Pink with blue
RY-Red with yellow

RB-Red with black
BY-Black with yellow
P-Pink
PB- Pink with black
LgR-Light green with red S-Grey
SY- Grey with yellow
YU-Yellow with blue
W-White
Bl-Blue
O-Orange
Br-Brown
G-Green
PW-Pink with white
Lg-Light green
N-Brown
P-Pink
Lg-Light green
Y-Yellow
V-Violet
Lb1-Light blue
4. Fuse
Fusible link
3) Combination instrument
4) Headlight
5) Radio cassette player
White backlight
Red LED display
Jinbei Haixing
6) Windscreen wiper
1. Wiper blade 2. Wiper arm 3. Wiper motor 4. Front washer pump 5. Rear washer pump
6. Water tank 7. Hose 8. Nozzle
. Fault diagnosis
1. Power supply failure
Troubles
Causes
Fuse is blown out.
When the ignition is switched

on and the engine is shut down,
the charge light fails to be on.
Bulb is damaged.
Wire connection gets loose or the
joint is corroded.
Troubleshooting
Replace it with the fuse of the same
specification
Change the bulb
Tighten the joint after rust removal
The regulator or field coil goes

wrong.
Check the motor

Repair or change
The bush has a poor contact with

the slip ring.
The charge light fails to go out

when the engine is running
(battery needs to be charged
frequently)
The driving belt gets loose or

worn.
The regulator or AC generator
goes wrong.
Adjust or change the driving belt

Check the charging system
Repair the line
Line failure
2. Failure in lights and indicator light systems
Headlight failure
Troubles
All the headlights fail to

work
Only one headlight fails

to work.
Causes
Troubleshooting
Bulbs are damaged.
Change bulbs
The switch of headlights is out

of order.
Check the headlight switch
The fuses of the headlight (left

and right) are both blown out.
Check the left and right fuses and change them if

necessary (if changed, check if it will be short
circuited)
The wire or earth wire is out

of order.
Repair the line
The bulb is damaged.
Change the bulb
The fuse of the headlight (left

or right) is both blown out.
Replace with a fuse of the same specification and

check if there is short circuit before changed
Repair the line
The wire or earth wire of this

headlight is out of order.
Front fog light failure
Troubles
Causes
Troubleshooting
Bulbs are damaged.
Change bulbs
The fuse of front fog lights are

blown out.

Check the switch of front fog lights
Front fog lights fail to

work.
The switch of the front fog light

is out of order.
The relay of front fog lights is
out of order.
Check the relay

Check the switch
Repair the line
The switch of front fog lights is

out of order.
The wire or earth wire is out of
order.
Only one fog light fails

to work.
Change the bulb
The wire or earth wire is out of

order.
Repair the line
Failure in turn signal and emergency warning light

Troubles
Causes
The
flashing
frequency is too
high or only one
side flashes.
The bulb at the side where the flashing

frequency is too high is damaged.
The bulbs are wrongly arranged.
Troubleshooting
Change the bulb
Replace the bulb
Check the relay
The turn signal/emergency warning relay is out

of order.
Repair the line
There is open circuit or large resistance

between the turn signal/emergency warning
switch and the lights.
Repair the line
The wire or the earth is out of order.

No flashing
The fuse of back-up horn and /or back-up
signal light is damaged.
Replace with a fuse of the same

specification and check if there is short
circuit before changed
Check the bulb and the line

There is open circuit or large resistance
between the battery and switch.
Check the relay
The turn signal/warning relay is out of order.
Check the switch
The combination switch and /or warning switch

are out of order.
The flashing
frequency is too
low.
The power supply voltage is too low.

The turn signal/emergency warning relay is out
of order.
Check the battery voltage and charging

system
Check the relay
Failure in width lamp, tail lamp and license plate lamp

Troubles
All are
inoperative.
Causes
Troubleshooting
Bulbs are damaged.
Change the bulbs
The fuses of tail lamp and stop lamp are blown

out.

Repair the line
The wire or earth wire is out of order.

Some are
inoperative.
Bulbs are damaged.
Change the bulbs
The wire or earthing is out of order.
Repair the line
Back-up lamp failure

Troubles
Causes
Troubleshooting
Change the bulb
The fuse of the back-up lamp is blown out.

The back-up lamp

is inoperative.
The switch of the back-up light is out of order.
The wire is out of order.
Check the switch

Repair the line
The back-up lamp

fails to be turned
off.
The switch of the back-up lamp goes wrong.
Check or change the switch
Stop lamp failure

Troubles
The stop lamp is

inoperative
The stop lamp

fails to be turned
off.
Causes
Troubleshooting
Change the bulb
The fuse of the rear stop

lamp is blown out.
Replace with a fuse of the same specification and check if

there is short circuit before changed
The switch of the stop light

is out of order.
Change or replace the switch
The wire or earthing is out of

order.
Repair the line
The switch of the stop light

is out of order.
Check, adjust or change the switch
Rear fog lamp failure

Troubles
The rear fog lamp

is inoperative.
Causes
Troubleshooting
Change the bulb
The fuse of the rear fog lamp

is blown out.

The switch of the rear fog

lamp is out of order.
Change the switch

Repair the line

order.
Fuel gauge and fuel metering units
Troubles
Causes
Troubleshooting
The main fuse of dashboard is blown

out.
The fuel gauge fails to make

accurate indication.
The metering units of the fuel gauge

are out of order.
The fuel gauge goes wrong.
The fuel sensor is out of order.

Change the metering units of the fuel
gauge
Change the fuel gauge
Change the line
Change the sensor
Engine coolant thermometer (ECT) and ECT (water temperature) sensor

Troubles
The engine coolant

thermometer fails to work.
Causes
Troubleshooting
The main fuse of dashboard is

blown out.

The engine coolant thermometer is

out of order.
The ECT sensor is out of order.
Check the engine coolant thermometer

Check the ECT sensor
Repair the line

Oil pressure warning light
Troubles
Causes
When the engine is

not started and the
ignition switch is not
connected, the oil
pressure
warning
light is inoperative.
The bulb of the combination instrument is

damaged.
The main fuse of dashboard is blown out.
The line of the combination instrument is

out of order.
The oil pressure switch is out of order.
Failure in brake and parking brake warning lamp
Troubleshooting
Change the bulb
Check the
instrument
line
of
the
Check the oil pressure switch

Repair the line
combination
Troubles
Causes
damaged.
When the brake fluid

is at the lower level,
the brake fluid level
warning lamp fails to
work
The line of the combination instrument is out

of order.
The switch of the brake fluid level is out of
order.
Troubleshooting
Change the bulb
Check the line of the combination
instrument
Check the brake fluid level switch
Repair the line

In starting (ignition
switch at the starting
position), the brake
fluid level warning
lamp fails to work.
The ignition switch is out of order.
Check the ignition switch

of order.

instrument
Repair the line

damaged.
Change the bulb

Parking brake
warning lamp fails to
work.

of order.
The parking brake switch is out of order.

instrument
Check the parking bake switch
Repair the line
Seat belt warning lamp

Troubles
The seat belt warning

lamp fails to work.
Causes
damaged.
The seat belt switch is out of order.
Troubleshooting
Change the bulb
Check the seat belt switch
4.
Repair the line
Appendix
Rear window defroster (option)

Troubles
Causes
Troubleshooting
The defroster fails

to work.
The fuse of the rear window

defroster is blown out.

The heating wire is damaged.
Check the heating wire
The switch of the rear

window defroster is out of
order.
Check the switch

Repair the line

order.
Front wiper and washer, rear wiper and washer (option)
Troubles
Causes
Troubleshooting
The wiper is out

of order or cannot
return
to
the
original position.
The fuse of the wiper (washer)

defroster is blown out.

Check the wiper motor
Check the wiper switch
The wiper motor breaks down.
Repair the line
The wiper switch (combination

switch) goes wrong.
order.
The washer is out
of order.
The washing hose or nozzle is

clogged.
The washer motor breaks down.
The washer switch (combination
switch) goes wrong.
The washer water kettle has no
water or breaks.
Clean up or repair the clogged hose or nozzle.

Check the washer motor
Check the washer switch
Fill clear water and change the kettle.
Repair the line

order.
Failure in power window control system (option)
Troubles
Causes
Troubleshooting
All
the
power
windows are out of
order.
The power window fuse is blown

out.

Check the ignition (main) switch
The ignition (main) switch goes

wrong.
The power window switch goes
wrong.
order.
Check the power window switch

Repair the line
Only one power

window is out of
order.
The wire or plug connector goes

wrong.
The power window or auxiliary
switch goes wrong.
The window lifter breaks down.
The window locking switch goes
wrong.
Check the wire and /or plug connector

Check the power window switch
Check the window lifter
Check the window locking switch
Repair

order.
Cigar lighting failure
Troubles
Causes
Troubleshooting
Cigar lighter fails to

work.
The fuse of radio/ cigar lighter is

blown out.

Check the ignition switch
The ignition switch goes wrong.
Check the cigar lighter
The cigar lighter goes wrong.
Repair the line

order.
1. Headlight
Headlight switch
Check
1) Remove the negative (-) wire from the battery.
2) Disconnect the combination switch line trap from the interface.
3) Use a multimeter to check if the circuit at every switch position is conductive, as shown in the follow table.
Power supply W
Lamplet KY
Low beam output GB
Low beam GW
Left turn signal GR
Right turn signal GR
Flicker relay G
Switch position
function
High beam R
Wire and color
Left turn signal

Stop
Right turn signal
Overtaking
High beam
Lamplet
Overtaking
High beam
Headlight
Overtaking
Low beam
High beam
If the circuit is not conductive at corresponding switch position, the combination switch shall be repaired or
changed.
See the detailed description of combination switch, steering column and steering lower shaft in the chapter of
Steering System for the disassembly and assembly.
Headlight
Disassembly
2) Unscrew the headlight mounting bolt
3) Remove the headlight assembly from the car.
4) Disconnect the headlight assembly from the plug connector.
5) Take down the headlight assembly.
Assembly
Change of bulb
Warning:
Do not touch the bulb when it is at red heat.
Notice:
1.Bulb
2.Clip
ring
The headlight has three types: detachable (not used any more
now), semi-detachable and non-detachable. The non-detachable
headlight only can be changed wholly.
1) Remove the battery negative (-) wire.
2) Disconnect the wire from the bulb.
3) Remove the lampshade and bulb.
4) Change the bulb and assemble all removed parts.
Test the headlight beam by a screen
Notice:
Adjust the headlight beam by the following method
except local mandatory rules and laws.
White wall
The headlight, after changed, shall be adjusted for
its beam.
Make sure to meet the following requirements before the
adjustment:
a) Stop the car at the flat ground before a white wall,
with the distance between the headlight surface and the
screen as:
Distance a: 10m
b) The pressure of all tires shall be adjusted to the
specified value.
Right headlight
Left headlight
Highlight
X-X: headlight horizontal center beam

A-A: left headlight vertical center beam
B-B: right headlight vertical center beam
c) Shake the car body by hand to make the suspension to

keep stable.
d) It shall be operated by a driver.
Driver weight: 75kg
Adjustment
1) Check to make it clear whether the highlight of the
high beam optic axis is as shown in the figure.
Distance H: about 130mm
1.Screwdriver
2) If the headlight beam is improperly arranged, the beam adjusting beam and adjusting gear shall be adjusted to
meet the requirement.
Notice:
It shall be sent to the safety test line for check and
adjustment by light tester.
2. Froing fog lamp (if equipped)
Front fog lamp switch
Check
Use a multimeter to check if the switch of two terminals is connected.
Terminal
Switch position
(Off)
(On)
Front fog lamp
Disassembly
1) Remove the head light
3) Disconnect the front fog lamp plug connector.

4) Remove the fog lamp assembly.
Assembly
Fog lamp
Change of bulb
Warning:
Do not touch the bulb when it is at red heat.
2) Remove the headlight.
4) Disconnect the front fog lamp plug connector.
5) Remove the lampshade and the wire to the terminal.
6) Unscrew the bolt that fit on the bulb and then remove the bulb from the fog lamp assembly.
7) Change the bulb and re-assemble all removed parts.
Notice:
Be sure the bulb terminal is covered well.
3. Turn signal and emergency warning lamp
Turn signal switch
Lamp socket cover
Check
2) Disconnect the plug connector of the combination switch.
3) Use a multimeter to check if the circuit at every switch position is closed,
as shown by the headlight.
See the detailed description of combination switch, steering column and
steering lower shaft in the chapter of Steering System for the disassembly and assembly.
Emergency warning lamp relay
The relay of turn signal/emergency warning lamp is close to the fuse box.
Connect the battery and mutimeter.
If no continuous clatters sound, change the relay.
1. Emergency warning lamp relay

2. Fuse box
4. Rear fog lamp

Check on rear fog lamp switch
Use a multimeter to check if the switch between the two terminals is closed, as shown in the figure below.
1.Emergency warning lamp relay
Terminal
5
Switch
position
1)
2)
3)
Terminal
Terminal
Gear
Gear
Power
Power (w)
(w)
Constant
current
Starter
Instrument
Key lighting
Key lighting
6. Disassembly and assembly of combination instrument

Disassembly
2) Unscrew the mounting bolt of the steering column.
3) Remove the dashboard components. Make sure to disconnect all
the plug connector of the switch on the instrument component and
cigar lighter wire.
4) Remove the odometer flexible shaft and disconnect the plug
connector of combination instrument and then remove the
combination instrument.
Assembly
1. Battery
2. Fuel gauge
3. Test lamp
Earth

7. Fuel gauge/fuel gauge metering equipment
Check on fuel gauge
1) Take apart the back seat, and lift the back end of the carpet.
2) Detach the yellow grey wire connecting the metering equipment
3) Connect one bulb (12V, 3.4W) to an earth wire, as shown in the figure.
4) Turn the ignition switch to ON, then bulb will light on, and the meter hand will swing several seconds. If it is
out of order, it shall be changed.
8. Fuel level sensor
Check
See this manual for the disassembly of the
fuel pump assembly.
Chip pole
Use an ohmmeter to check if the resistance
of the fuel level sensor varies with the
change of float position.
Power supply anode (+)
If the measured value fails to comply with

the specification, it shall be changed.
Float position H
(mm)
Chip pole
Power supply cathode (-)
Full
Chip resistance ()
Standard value
20 (Empty)
39.5(alarm point)
Empty
210 (Full)
9. Water thermometer and water temperature sensor

Water thermometer
1. Battery
2. Water thermometer
1) Disconnect the yellow white wire fixed on the water temperature sensor.3. Test lamp 12V, 3.4W)
Check
2) Use a bulb here (12V, 3.4W) and earth it, as shown in the right figure.
3) As the main switch is turned to ON, the bulb will light on, and the meter hand will swing several times. If
there is fault, the meter shall be changed.
Water temperature sensor
Disassembly
Warning:
Prior to disassembling any part of the cooling system, make sure
the engine coolant temperature has been dropped and cooled
down.
Prior to disassembly, the negative wire shall be disconnected
from the battery.
1) Discharge the coolant.

2) Remove he air filter assembly.
3) Remove the water temperature sensor.
Check
Heat the water temperature sensor to check if the resistance of the water temperature sensor reduces as the
water temperature rises.
Temperature
Resistance
50
230
90
52
110
25
120
21
130
15.7
Assembly
The assembly shall be made in the reverse order of the assembly, and pay
attention to the following requirements:
The thread of the water temperature sensor shall be applied with sealant.
(A): sealant 99000-31150
Tightening torque
(a): 8 Nm
Oil pressure switch
10. Oil pressure warning lamp (engine oil)

Oil pressure switch
Check
Wiring harness
The engine is running.
Not closed ()
The engine stops.
Closed (0)

See the Oil Pressure Check in the chapter of Engine for
disassembly and assembly.
11. Brake fluid level signal lamp and parking brake signal lamp
Check
Brake fluid level switch
Use an ohmmeter to check if the switch is closed.
If it is damaged, the switch shall be changed.
OFF (closing) position (float
upward)
Not closed
ON(Opening) position (float

downward)
Closed
Parking brake switch

OFF(closing) position
Not closed
(parking brake released)
ON(Opening) position
Closed
(parking brake handle pulled up)
Cylinder block
12. Seat belt signal lamp

Seat belt switch
Check
OFF position
Not closed
(seat belt fastened)
ON position
Closed
(seat belt opened)
13. Rear window defroster (option)

Defroster switch
Check
Use an ohmmeter to check if the defroster switch is closed. If the switch between the two terminals fails to be
closed, the switch shall be changed.
Terminal
Switch position
Defroster wire
Probe
Check
Notice:
Tinfoil
The rear window glass, when cleaned, shall be wiped by cloth along the wire direction.
Heating wire
The glass shall be not cleaned by detergent or washer with abrasive
At center (point)
To measure the wire voltage, use tinfoil to wrap the negative probe of the multimeter and press it to the
Good
wire by hand.
1) Check if the wire is damaged.
Wire damaged
a. Turn the main switch to ON.

Wire damaged
b. Turn the defroster switch to ON.

c. Use a voltmeter to check the voltage at the center of each
wire, as shown in the figure.
Several volts
0 volt
Voltage
Judgment method
About 5V
Good (wire not damaged)
About 10Vor 0V
Wire damaged.
If the measured voltage is 10V, there must be damage between

the center point and the positive terminal.
If the measured voltage is 0V, there must be damage in the wire
between the center point and the earth.
2) Definition of the wire damage position
a. Connect the voltmeter positive pen (+) to the positive terminal
of the heating wire.
b. Connect the voltmeter negative pen (-) wrapped with tinfoil to
1. Gummed paper 2. Wood chip

3. Damaged wire
4. Repairing agent
the positive terminal of the heating wire and then move to the
negative terminal along the wire.
c. If the voltmeter jumps from 0V to several volts, it means
the wire here is damaged.
Notice:
If the heating wire has no damage, the voltage at the
positive terminal of it shall be 12V. As the positive pen
moves to the other terminal (earth), the voltage reduces
gradually to zero.
14. Defroster circuit

Repair
1) Clean with aviation gasoline.
2) Pad the upper and lower ends of the heating wire with
adhesive tape to facilitate maintenance.
Horn UG
Washing RS
Power supply FV
Return UV
Low speed LB
High speed BV
3) Apply the commercially available repairing agent with a

tapering brush.
4) 2~3 minutes later remove the adhesive tape

5) The repaired wire shall be reused after at least 24 hours.
15. Windscreen wiper
Front wiper and washer
Front wiper/washer switch
Check
2) Disconnect the wire plug connector of combination switch
3) Use an ohmmeter to check if the switch position circuits are closed, as shown in the table below.
Washing
Horn
Front wiper return
Washing pump
Front wiper high gear
Front wiper low gear
Power supply
1. Battery
2. Wiper motor
3. Red wire
4. Black wire

See the detailed description of combination switch, steering column and steering lower shaft in the chapter of
Steering System for the disassembly and assembly.
Wiper motor
Check
l) Use a 12V battery, with its (+) terminal connected with the
1. Battery 2. Wiper motor

3. Black wire 4. Red wire 5. Jumper wire
terminal A, as shown in the right figure, and its (-) terminal connected with the bracket (wiper earthed). If the
motor runs at a speed of 44~52 rpm, it means the wiper motor is normal. For high-speed inspection, the battery (+)
terminal shall be connected with terminal D, and the (-) terminal connected with the bracket (wiper earthed).
Then if the motor runs at a high speed of 64~78rpm, it means the wiper motor is normal.
2) Test on automatic stop
a) Connect the (+) terminal of a 12V battery to the wiper motor terminal A, and the (-) terminal to the bracket
(wiper earthed) to run the motor.
b) Remove the terminal A from the battery to stop the motor.
c) Connect terminals A and D by jumper wire, and connect the terminal C to battery (+) terminal. Observe
the motors operation again, and finally stop it at the
given position.
d) Repeat a)-c) several times to check if the motor
stops at the given position every time.
Washer pump
Disassembly
2) Unscrew the mounting bolts of the washer
reservoir.
3) Disconnect the pump wire plug connector and remove the hose.
4) Remove the washer reservoir.
5) Remove the pump from the washer tank.
Check
Connect the battery (+) terminal and (-) terminal with the pump
(+) terminal and (-) terminal respectively to check the pump
displacement.
The displacement of the front window pump shall be within the
following range:
Front window washer pump: 0.6 L/min
Assembly
Wiper intermittent relay circuit
2) Disconnect the combination switch plug connector and remove the hose.
1. Front window washer pump

2. Washer reservoir
3) Turn the wiper switch to the INT (intermittent) position.

4) Connect the battery positive terminal to the terminal power supply, and the battery negative terminal to the
headlight switch terminal GND (Ground).
5) Connect the voltmeter positive pen to the terminal low speed, and the negative pen to the terminal GUN
(ground). Check the battery voltage (10~14V) indicated by the voltmeter.
6) Use the jumper wire to connect the terminals return and power supply, and then connect the terminal power
supply with the terminal GND (ground).
posterior to connecting the jumper wire to the terminals power supply and GUN (ground), observe that the
voltmeter voltage drops to 0V, and then rises to the battery voltage (10V~14V).
1s
Wiper and washer troubleshooting
Common faults in wipers and washer are as follows: wiper failure to actuate; wiper out-of-position stop; wiper
trembling and washer failure to spray.
1. Wiper fails to actuate.
(1) The causes for the failure that the wiper fails to actuate after the switch is closed are as follows:
1) Circuit failure, for example fuses blowout, circuit poor contact or breakage;
2) Time delay relay damage;
3) Transmission mechanism damage;
4) Motor damage
(2) Diagnosis and maintenance of faults
1) Check the fuse and the line; if there is breakage in the circuit, repair or change it; if there is no problem, make
further checks.
2) Check the voltage of switch power supply terminal to ground, which shall be the battery voltage; if none, check
the power supply line before the switch carefully; if the voltage is normal, make further checks.
3) When the switch is closed, measure the voltage of switch output terminal to ground. If there is no voltage, it
means the switch goes wrong, and shall be changed. If the voltage is normal, it means the switch is all right. Then
make a further check.
4) Switch on the intermittent wiping gear to see if the time delay relay acts; if it does not act, check or change the
time delay relay; if it can act normally, make a further check.
5) Touch the motor by hand when the switch is closed. If the motor fails to make response, it may be motor failure,
and the motor shall be repaired or changed. If the motor vibrate slightly and buzzes and heats, it may be such case
that the transmission mechanism is jammed or damaged, so that it shall be repaired.
2. Wiper out-of-position stop
(1) The main causes for the failure are as follows:
1) The parts of transmission mechanism are worn or deformed.
2) The motor stop device is defective.
(2) Fault diagnosis and repair: check the transmission mechanism; if it is not defective, it is necessary to remove
and repair the motor.
3. Wiper trembling
(1) The main causes for wiper trembling are as follows:
1) The wiper is aged, bent or has an improper dip angle with the glass.
2) The transmission mechanism fails to work normally.
3) The windscreen glass is too dirty.
(2) Diagnosis and repair: first check if the windscreen is stained with dirt and if the wiper is normal. If both are
normal, repair the transmission mechanism.
4. Washer failure to spray
(1) The main causes for such failure are as follows:
1) The reservoir has no washing liquid, the liquid tube breaks or the nozzle is clogged.
2) The washer pump has open circuit fault.
3) The washer pump is damaged.
(2) Diagnosis and repair: first, check if the reservoir has washing liquid, if the liquid tube breaks or if the nozzle is
clogged; if not, check if the washer pump circuit is open; if not either, repair the washer pump.
. Circuit diagram
1. Fuse box
Fuse box 1 (label)
Main
relay
Front
Oil
fog
Air
pump
relay
conditioner
relay
relay
compr
essor
relay
Air
Backup 10A
conditioner
Water
relay
electronic
fanrelay
Backup 15A
20A
left
headlight
10A
15A
blower
cigar lighter
Radio
10A Radio lamp
Backup 15A
instrument
20A
50A
left
ignition
headlight
switch
Backup 20A
Fuse box 1 (back wiring diagram)
Backup 10A
Cooling
Backup 15A
fan
Backup 15A
Main relay
Front fog lamp relay
Oil pump relay
Air conditioner
Compressor
Cooling
relay
relay
relay
fan
Backup 20A
relay
tank
fan
2. Fuse box 2
Fuse box 2 (label)
Cooling fan relay

Bushing:DJJ7053A-6.3-21
Terminal: DJ523-AG 3A/D
Fuse box 2 (wiring diagram)
Connect oil pump relay

Connect main relay
Terminal: DJ623-AG 3A/E
Ignition switch fuse

Flasher relay
Bushing:DJJ7021-9.8-11
Terminal: DJ611-9.8

Fuse
Fuse
Ignition switch
10A ignition
10A
generator
signal/backu
turn
15A wiper
15A blower
15A radio
20A
water
tank fan
p lamp
15A
relay
main
10A
20A
electric
horn/
warning
lamp
ECD
instrument
10A
lamp/
dome light
10A
lamp
stop
10A
pump
fuel
15A
headlight
left
15A
right
headlight
3. Combination instrument wiring diagram

A terminal
B terminal
B terminal
A terminal
B1
Turn signal negative wire
A1
Braking system trouble indicator
B2
Left turn signal
A2
Parking brake
B3
Battery +12V
A3
Charge and discharge
B4
A4
Oil pressure alarm
B5
A5
Fuel sensor
B6
Engine trouble indicator
A6
Instrument positive wire
B7
Seat belt
A7
B8
Speed signal input
A8
Water temperature sensor
B9
A9
Braking system trouble indicator
B10
Positive interior light
A10
+8V
B11
Negative interior light
A11
B12
Speed signal input
A12
B13
Speed signal output
A13
High beam+
A14
High beam-
A15
EOBD fault indicator
A16
Right turn signal
2. Electrical diagram
Single-chip microcomputer control

Single-chip microcomputer control

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Contents

CHAPTER FINISHED VEHICLE APPLICATION AND MAINTENANCE ........................................................ 5

. Basic parameter ..................................................................................................................................................... 5

Engine removal ...................................................................................................................................................... 46

. Composition of valve train ................................................................................................................................... 62

. Composition of engines lubricating system ......................................................................................................... 72

. Major component of cooling system ..................................................................................................................... 76

. Assembly of internal parts of engines ................................................................................................................... 96

.Special tools ........................................................................................................................................................ 194

. Diagnosis of common troubles ........................................................................................................................... 213

. Booster assembly ................................................................................................................................................ 241

. Check on brake fluid........................................................................................................................................... 247

SECTION CHECK AND ADJUSTMENT .......................................................................................................................... 252

. Servicing materials ............................................................................................................................................. 289

. Structure of front door ........................................................................................................................................ 291

. Fault diagnosis ................................................................................................................................................... 308

. General ............................................................................................................................................................... 332

. General ............................................................................................................................................................... 351

Chapter Finished vehicle application and maintenance

Front wheel tread

Rear wheel tread

Front wheel toe-in

Fully loaded weight

Overall height (no

2. Vehicle service performance parameter (Table 1-2)

20 ( when the speed is 50 /h under full load)

four-stroke, water cooling, single

overhead camshaft, multi-point electronic

electronic control fuel injection

control fuel injection

Cylinder diameter (mm)

Piston travel (mm)

Rated power /speed

93# superior nonleaded gasoline

93# or above nonleaded gasoline

Max./Min speed (r/min)

2. Technical parameter of transmission (table 1-4)

Technical parameter of transmission

3. Wheel parameter (table 1-5)

Front wheel tire pressure (kPa)

(half load and fully load ) 200/240

Rear wheel tire pressure (kPa)

(half load and fully load ) 240/280

. Other parameters (table 1-6)

Engine cooling system

Engine lubricating system

Transmission lubricating oil

Rear axle lubricating oil

Section Application of Finished Auto and Notices

1. Inspection for New Auto

II. Driving of Auto

overflowed gasoline may cause the fire.

and the lower mark X.

scale and improve the boiling point of the cooling liquid.

4. Proper use of brake fluid

IV. Use of the body facilities and accessories

5. Adjustment of the seat

1-2Camshaft timing belt

Replace it every 100,00km.

l-4Engine oil (Grade SF engine oil) and

After first maintenance, replace it every 5000 km or every six

l-5Engine oil (Grade SJ engine oil) and

After first maintenance, replace it every 10000 km or every six

1-6Cooling system hoses and fittings