Haima S5 1.5t Service Manual-1

Table of Contents

General Contents Volume I Chapter I

Engine Body ····················································································· 1A-1

Chapter 2

Electronic Fuel Injection Control System ··················································· 1B-1

Chapter 3

Fuel System ······················································································ 1C-1

Chapter 4

Intake and Exhaust System ···································································· 1D-1

Chapter 5

Cooling System·················································································· 1E-1

Chapter 6

Engine Accessory-Belt ········································································· 1F-1

Chapter 7

Engine Suspension ·············································································· 1G-1

Chapter 8

MF515M Transmission ········································································ 1H-1

Chapter 9

Gearshift Mechanism ··········································································· 1J-1

Volume II Chapter 10

Clutch System ··················································································· 2A-1

Chapter 11

List of tires and drive shafts ··································································· 2B-1

Chapter 12

Wheels and tires ················································································· 2C-1

Chapter 13

Suspension system ·············································································· 2D-1

Chapter 14

Steering system ·················································································· 2E-1

Chapter 15

Brake system····················································································· 2F-1

Volume III Chapter 16

A/C System ······················································································ 3A-1

Chapter 17

Airbags and Restraint System ································································· 3B-1

Chapter 18

Body and Accessories ·········································································· 3C-1

Chapter 19

Electrical System················································································ 3D-1

Table of Contents

Chapter 1 Engine Body Table of Contents 1.1 How to use this manual ················································································ 1A-0 1.1.1Technical Parameters ················································································· 1A-1 1.1.2 Special tools··························································································· 1A-10 1.2 Inspection and Maintenance of Complete Vehicle ················································· 1A-11 1.2.1 Inspection of Compression Pressure .............................................................................. 1A-11 1.2.2 Inspection of the Engine Oil........................................................................................... 1A-11 1.2.3 Inspection of Oil Pressure ..............................................................................................1A-12 1.2.4 Replacement of Engine Oil ............................................................................................1A-12 1.2.5 Replacement of Oil Filter ...............................................................................................1A-13 1.3 Application of Engine Maintenance Platform ······················································ 1A-13 1.3.1 Mount the Engine onto Maintenance Platform...............................................................1A-13 1.3.2 Dismantle the Engine from Maintenance Platform ........................................................1A-14 1.4 Power Generator and Starter ·········································································· 1A-14 1.4.1 Power Generator’s Dismantling/Mounting ....................................................................1A-14 1.4.2 Explanations on Inspection of Power Generator Belt.....................................................1A-14 1.4.3 Explanations on adjustment to tension of power generator and air conditioning drive belts .................................................................................................................................................1A-14 1.4.4 Explanations on inspection of power generator .............................................................1A-15 1.4.5 Starter Dismantling/Mounting........................................................................................1A-15 1.4.6 Explanations on inspection of starter .............................................................................1A-15 1.5 Ignition, Control System··············································································· 1A-16 1.5.1 Spark Plug Dismantling/Mounting.................................................................................1A-16 1.5.2 Control System Parts Dismantling/Mounting.................................................................1A-16 1.5.3 Crankshaft position sensor’s dismantling/mounting explanations .................................1A-17 1.5.4 Explanations to inspection of crankshaft position sensor...............................................1A-17 1.5.5 Explanations on water temperature sensor dismantling/mounting .................................1A-17 1.6 Intake and Exhaust System············································································ 1A-18 1.6.1 Intake and Exhaust System Dismantling/Mounting .......................................................1A-18 1.6.2Explanations on intake manifold dismantling .................................................................1A-19 1.6.3 Explanations on the intake manifold seal ring mounting ...............................................1A-19 1.6.4 Explanations on the throttle body seal ring mounting ....................................................1A-19 1.6.5 Explanations on the exhaust manifold dismantling ........................................................1A-19 1.6.6 Explanations on the turbocharger mounting...................................................................1A-19 1.7 Timing System ·························································································· 1A-19 1.7.1 Timing system dismantling/mounting ............................................................................1A-19 1.7.2 Explanations on timing chain tensioner assembly dismantling ....................................1A-209 1.7.3 Explanations on crankshaft pulley dismantling..............................................................1A-20

Table of Contents 1.7.4 Explanations on cylinder head hood dismantling...........................................................1A-20 1.7.5 Explanations on the timing chain dismantling ...............................................................1A-20 1.7.6 Explanations on the timing chain’s tensioner assembly mounting .................................1A-20 1.7.7 Explanations on the tensioner arm assembly mounting .................................................1A-21 1.7.8 Explanations on timing chain mounting.........................................................................1A-19 1.7.9 Explanations on the cylinder head hood mounting ........................................................1A-21 1.7.10 Explanations on the crankshaft pulley mounting .........................................................1A-22 1.7.11 Explanations on water pump pulley mounting .............................................................1A-22 1.8 Lubricating System ····················································································· 1A-22 1.8.1 Oil Sump Dismantling/Mounting ...................................................................................1A-22 1.8.2 Explanations on the oil sump dismantling......................................................................1A-22 1.8.3 Explanations on the oil sump mounting .........................................................................1A-22 1.8.4 Oil Pump and Timing Chain Case Assembly Dismantling/Mounting............................1A-23 1.8.5 Explanations on oil pump’s oil seal dismantling ............................................................1A-23 1.8.6 Explanations on oil pump’s oil seal mounting................................................................1A-23 1.8.7 Explanations on the oil filter mounting ..........................................................................1A-24 1.8.8 Explanations on oil pump disassembling/ mounting ......................................................1A-24 1.8.9 Inspection of Oil Pump...................................................................................................1A-24 1.9 Cooling System ························································································· 1A-25 1.9.1 Thermostat Dismantling/Mounting ................................................................................1A-25 1.9.2 Explanations on thermostat inspection and mounting ....................................................1A-25 1.9.3 Cooling water pipeline dismantling/mounting ...............................................................1A-26 1.9.4 Explanations on heater water pipe /O-ring mounting.....................................................1A-26 1.9.5 Water Pump Dismantling/Mounting...............................................................................1A-26 1.10 Cylinder Cover and Valve Mechanism ····························································· 1A-27 1.10.1 Cylinder Head Mechanism Dismantling/ Mounting.....................................................1A-28 1.10.2 Valve Mechanism Dismantling/ Mounting...................................................................1A-30 1.10.3 Cylinder Head Inspection /Repair ................................................................................1A-30 1.10.4 Inspection of Valve and Valve Guide ...........................................................................1A-32 1.10.5 Explanations on inspection of valve seat......................................................................1A-32 1.10.6 Explanations on inspection of valve spring..................................................................1A-33 1.10.7 Explanations on the inspection of camshaft .................................................................1A-33 1.10.8 Explanations on inspection of tappet hole and tappet ..................................................1A-35 1.11 Flywheel, clutch ······················································································· 1A-36 1.11.1 Flywheel and Clutch Dismantling/Mounting ...............................................................1A-35 1.11.2 Explanations on Clutch Pressure Plate/Friction Disc Dismantling...............................1A-37 1,11.3 Explanations on the clutch friction disc inspection /mounting.....................................1A-38 1.11.4 Explanations on the clutch pressure plate inspection/mounting ...................................1A-38 1.12 Cylinder body, Crank Connecting Rod Mechanism·············································· 1A-39 1.12.1 Cylinder Body, Crank Connecting Rod Mechanism Dismantling/Mounting...............1A-39 1.12.2 Cylinder Body Inspection /Repair ................................................................................1A-42 1.12.3 Connecting Rod Inspection ..........................................................................................1A-43 1.12.4 Inspection of Piston Connecting Rod Assembly ..........................................................1A-44 1.12.5 Crankshaft Inspection /Repair ......................................................................................1A-44

Table of Contents

Engine block 1A-0 tools

How to use this manual

Prompt signals

Subject Scope 

This manual comprises procedures on engine maintenance, and specific procedures fall into 5 basic operation steps:

I: dismantling/mounting; /mounting; III: resetting; adjustment. 

II IV

disassembling inspection; V

Simple operation may be completed by inspecting the engine appearance, such as dismantling/mounting of periphery parts, parts cleaning, and appearance inspection etc.

Overhaul Steps: 1.

2.

On illustrations there are symbols of wearing parts, tightening torque, lubricating oil, and sealant, and also corresponding explanations and marks are made to special tools or equipments for dismantling or mounting.

3.

Corresponding numbers are marked on pictures for the operation sequence and parts’ major operation process. In general, information of this kind serves as key and core content of the diagnosis procedure. Due to this, please refer to these materials during the overhauling process.

Symbol Four kinds of symbols are used in this manual to indicate application of lubricating oil, sealant, and special tools etc., and they imply occasions where foresaid materials shall be applied during the maintenance period. Connotation

In this manual there are such signals as “Warning”, “Caution”, “Attention”, “Explanation”, and “Limit”. Warning 

Remark

Inject Inject new engine oil lubricating oil Inject sealant

Inject appropriate sealant

Replace parts

wearing parts like O-ring and gasket

Use special

Appropriate special

Warning is used to prompt that personal injury may be caused due to negligence.

Caution 

Caution is used to prompt that engine damage may be caused due to negligence.

Notice 

Prior to most overhaul work, illustrative pictures shall be observed because they will help distinguish parts & components, illustrate the parts fastening way, and the way of inspecting parts appearance. In addition, illustration explanations are attached to dismantling/mounting procedures in need of systematic demonstration.

Symbol

tools or equipments

Notice is used to provide additional information for completion of given procedures.

Explanation 

Explanation is used to prompt the permissible range for inspection or adjustment.

Limit Limit is used to prompt the upper and lower limit for the inspection or adjustment.

Engine block 1A-1

1.1.1 Technical Parameters Technical Parameters of Complete Equipment Item

Parameter

Engine Model

HMA GN15-TF

Code

N01G

N02G

N16G

Remark

N17G

N18G

Cylinder quantity and arrangement

In-line 4-cylinder

Combustion chamber

Roof shape

Ignition sequence

1-3-4-2

Rotation direction

Counterclockwise

Valve timing mechanism

dual overhead camshaft, timing chain drive (silent chain), intake VVT

Valve quantity

16

Displacement (cc)

1497

Bore× stroke (mm)

74.8×85.2

Compression ratio

9.5

ON Valve Intake OFF timing ON (°) Exhaust OFF

By cylinder number From back to front (flywheel side taken as the back end)

4～44

BTDC

48～8

ABDC

36

BBDC

4

ATDC

Max. power(kW/rpm)

113/5500

Net power

Max. torque(N·m/rpm)

210/1800～4000 Air conditioning idle speed:800±50

Heat Engine

Target idle speed:750±50

Heat Engine

Ignition advance angle(°)

0～10

Idle state

Starting mode

Electrical starter

Cooling mode

Water cooling forced circulation

Lubricating mode

Pressure, Split, Complex

Flywheel Type

Dual Single-ma Dual Single-m Flexible Mass ss Mass ass flywheel Flywheel flywheel Flywheel flywheel

Idle speed (rpm)

Clutch Type

No

Dry

No

No

Overall dimension (mm)

554.2×621.7×619.3

Net weight (kg)

No more than 115kg

Dry According to the exhaust side 15 degrees angle measurement

Engine block 1A-2

Technical Parameters of Maintenance Item

Parameter

Cylinder head Height (mm) Deformation at cylinder gasket’s abutment surface (mm) Deformation at manifold’s abutment surface (mm) valve clearance(engine in cold condition)(mm)

Standard

112.9～113.1

Max. grinding

0.2

Max.

0.03

Max.

0.15

Max. grinding

0.20

Intake

0.18～0.26

Exhaust

0.26～0.34

Standard

1.35

Min.

0.85

Standard

1.85

Min.

1.35

Standard

89.51～90.01

Min.

89.31

Standard

90.69～91.19

Min.

90.49

Standard

4.965～4.980

Min.

4.915

Standard

4.955～4.970

Min.

4.905

Standard

5.0～5.012

Intake

12.7～13.3

Exhaust

12.7～13.3

Valve and valve guide Intake Width of valve seal tape (mm) Exhaust Intake Valve length (mm) Exhaust Intake Valve stem diameter(mm) Exhaust valve guide’s inside diameter (mm) valve guide’s protrusion height (mm) Valve seat Width of valve seat’s contact surface (mm)

1.1～1.5 Intake

43.5～44

Exhaust

43.5～44

Intake

38.46

Exhaust

38.46

Intake

H1: 33.4mm

142.2～161.8{14.51～ 16.51kgf}

Exhaust

H2: 24.9mm

293.4～324.4{29.94～ 33.10kgf}

Angle of valve seat (°) Valve seat sinking (valve protrusion height)(mm) Valve spring

valve spring height H pressure (N{kgf})

Verticality(mm) Valve oil seal

1.50mm

Engine block 1A-3 Intake

15.7～16.3

Exhaust

15.7～16.3

Tappet hole’s diameter(mm)

Standard

31.000～31.025

Tappet diameter(mm)

Standard

30.964～30.980

Standard

0.020～0.061

Max.

0.180

Max.

0.03

Standard

44.5

Min.

43.4

Standard

43. 8

Min.

42.7

Standard

25.945～25.960

Min.

25.915

Standard

0.040～0.076

Standard

0.08～0.20

Max.

0.21

Height (division surface between upper surface and main cover)(mm)

Standard

205

Max. grinding

0.20

Deformation of upper surface (mm)

Standard

0.1

Standard

74.8～74.815

Depth L(mm) Tappet

Clearance between tappet and tappet hole (mm) Camshaft Camshaft’s radial run-out(mm) Intake Cam’s protrusion height (mm) Exhaust

Journal diameter(mm) Journal clearance(mm) End gap(mm) Cylinder body

Cylinder bore’s inside diameter [measure inside diameter at the place 37mm below the top surface] (mm) Wearing limit (mm)

0.135

Piston diameter(mm) [Measure the piston diameter at the place19.38mm below the lower rim of oil control ring slot along the vertical direction of the piston pin hole’s axial line.]

Standard

74.76～74.78

Standard

0.013～0.042

Max.

0.10

Top ring

Standard

0.040～0.085

Second Ring

Standard

0.030～0.070

Oil Ring

Standard

0.020～0.060

Top ring / Second Ring

Max.

0.15

Oil Ring

Max.

0.15

Clearance between piston and cylinder bore (mm) Piston ring

Clearance between piston ring and ring slot (mm)

Engine block 1A-4 Top ring

0.20～0.35

Second Ring

0.40～0.60

Oil Ring

0.20～0.40

Max.

1.0

Piston pin’s diameter(mm)

Standard

17.996～18.000

Piston pin hole’s inside diameter (mm)

Standard

18.004～18.010

Standard

0.010～-0.027

Standard

0.004～0.014

Length [center to center](mm)

Standard

133.32～133.40

Inside diameter of connecting rod’s small end (mm)

Standard

18.010～18.023

Standard

0.10～0.30

Max.

0.40

Standard

1.483～1.494

Standard

0.024～0.056mm

Max.

0.10

Opening clearance [measure inside cylinder](mm)

Piston pin

Clearance between connecting rod’s small end hole and piston pin (mm) Clearance between piston pin hole and piston pin (mm) Connecting rod

Connecting rod’s end gap(mm) Connecting rod bearing Connecting rod bush size (mm) Connecting rod bearing clearance (mm) Crankshaft Crankshaft radial run-out(mm) Main journal diameter(mm)

0.03 Standard

45.982～46.000

Standard

0.018～0.036

Max.

0.1

Main bearing bush size (mm)

Standard

1.988～2.003

Crank pin diameter(mm)

Standard

43.979～44.000

Thrust bearing size (mm)

Standard

3.205～3.255

Standard

0.09～0.273mm

Max.

0.30

Standard value

1200{12.2}[300]

Compression pressure

Minimum limit

980{10.0}[300]

kPa{kgf/cm2}[rpm]

Max. limit of pressure difference between cylinders

100{1.0}

Main journal clearance (mm)

Crankshaft end gap(mm) Inspection to complete vehicle

Oil pressure (kPa{kfg/cm2}[rpm]) Oil adding volume L

375～450{4.1～6.0}[2500] Oil replacement

4.6

Engine block 1A-5 Oil and oil filter replacement

4.9 API engine oil grade higher than SJ

Oil grade

Oil viscosity level

Higher than –25 ℃

SAE 10W–30

-30 ℃～37 ℃

SAE 5W–30

Voltage (V)

11

Current (A)

＜95

Starter Zero-load test Timing chain disassembling part Automatic tensioner push rod’s extension strength (mm)

3

Crankshaft rotating speed sensor Clearance between signal wheel and sensor (mm)

0.5～1.5

Thermostat Opening temperature (℃)

80～84

Full-opening temperature (℃)

95

Full-opening stroke (mm)

Min.

8.5

Diaphragn spring’s wearing depth (mm)

Max.

0.6

Diaphragn spring’s radial circle run-out (mm)

Max.

0.6

Clutch pressure plate

Pressure plate’s flatness (mm)

0.05

Clutch friction disc Thickness of protrusion rivet (mm)

Min.

0.3

End-on circle run-out(mm)

Max.

0.7

Max.

0.10

Flywheel End-on circle run-out(mm) Oil pump Clearance between inner rotor’s prong Standard and outer rotor (mm) Max.

0.06～0.18 0.22

Clearance between outer rotor and pump Standard body (mm) Max.

0.250～0.325

Standard

0.030～0.090

Max.

0.14

Backlash (mm)

0.35

Compression spring’s length (mm)[pressure:97.7～107.4N{9.96～10.96kgf}]

34.50

Front-end oil seal’s driving distance (mm)[from oil pump body’s rim]

0～0.5

Rear oil seal

Engine block 1A-6 Rear oil seal’s driving distance (mm)[from crankshaft back cover’s rim]

0～0.5

Plastic fixing bolt’s length Cylinder head bolt(mm) Main bearing cover bolt(mm)

Standard

136.8～144.2

Standard

74.15～74.85

Max.

75.3

Engine block 1A-7

Tightening torque Mounting place

Torque value

Remark

N•m

kgf•m

Bracket

45

4.6

Adjusting arm

45

4.6

Adjusting slider

21.6

2.2

Power generator pivot’s bolt and nut

55

5.6

Ignition coil

8.8

0.9

8～10

Spark plug

25

2.6

20～30

Fuel rail

21.6

2.2

Camshaft position sensor

8.8

0.9

8～10

Water temperature sensor

15

1.53

13～15

Knock sensor

21.6

2.2

Knock sensor bracket

16.8

1.7

Crankshaft position sensor

8.8

0.9

8～10

OCV valve

8.8

0.9

8～10

Throttle body

8.8

0.9

Intake manifold

21.6

2.2

Intake manifold bracket (manifold side) 21.6

2.2

Exhaust manifold

21.6

2.2

Exhaust manifold bracket (cylinder body side)

21.6

2.2

Exhaust manifold bracket (manifold side)

45.1

4.6

Exhaust manifold heat shield

8.8

0.9

Turbocharger

25

2.55

23.6

2.4

29

3.0

Turbocharger oil inlet pipe

25

2.55

25～28

Turbocharger oil return pipe

8.8

0.9

8～10

Turbocharger water inlet pipe

32

3.26

32～35

Turbocharger water return pipe

32

3.26

32～35

Turbocharger heat shield

8.8

0.9

8～10

14.7

1.5

Power generator

Ignition, control system

Intake and exhaust system

Turbocharger bracket

Lubricating system Oil switch

25～28

Engine block 1A-8 Oil filter

14.0

1.43

Oil filter adapter

21.6

2.2

Oil filter

8.8

0.9

Oil sump

8.8

0.9

Cylinder body, crank connecting rod mechanism Mounting place Crankshaft pulley Flywheel

Torque value N•m

kgf•m

50±2

16.7 60±2°

30±2

3.1 45±2°

Remark First set the pretension torque and then tighten the angle. First set the pretension torque and then tighten the angle.

Transmission baffle plate

8.8

0.9

6.9～9.8

Clutch

21.5

2.2

17.6～26.5

Crankshaft’s rear cover

8.8

0.9

8～11

35±2

3.5

Main bearing cover

Tightening 60°(0～ -4°) 20±2N·m

Connecting rod cover

2.0kgf·m

90°(0～4°)

First set the pretension torque and then tighten the angle. Pay attention to the bolt’s length, which has limit value (see corresponding part) First set the pretension torque for two times, and then tighten the angle. Pay attention to the bolt’s length, which has limit value (see corresponding part)

Cylinder head, valve train and others 29

2.96

Cylinder head

First set the pretension torque, and tighten the angle two times. Pay attention to the bolt’s length, which Tighten 90°+ 90°(0～4°) has limit value (see corresponding part)

Camshaft’s front cover

20

2.04

Camshaft cover

11

1.12

Cylinder head hood

8.35

0.85

Oil pump and timing chain case assembly

10

1.02

See corresponding part

39.5

4.03

See corresponding part

Timing chain guide rail

10

1.02

Tensioner arm

23.5

2.4

Timing chain tensioner

9.8

1.0

VVT fixing bolt

60

6.12

Front and rear hook

18.4

1.88

Cooling system

Engine block 1A-9 9.8

1.0

See corresponding part

45

4.6

See corresponding part

Water pump pulley

9.35

0.95

Water inlet pipe seat

9.35

0.95

Heater water pipe assembly

9.35

0.95

Water pump

Engine block 1A-10

1.1.2 Special tools Oil pressure gauge

Oil seal erector

Valve spring ejector

Oil sump ejector

Belt tensiometer

Gear ring stop device

Valve oil seal ejector

Oil filter sleeve

Valve guide ejector / erector

Valve oil seal erector

Flywheel brake

Clutch guider

Engine block 1A-11 8.

1.2 Inspection and Maintenance of Complete Vehicle 1.2.1 Inspection of Compression Pressure

Measure all cylinders’ compression pressures according to preceding method, and inspect if the pressure difference between cylinders is lower than the limit value.

Limit value (maximum): 1300 (kPa)

Warning 

When the engine is running, the oil temperature is extremely high. Therefore, keep cautious during dismantling and mounting process since there is a danger of burn.

1.

Set the vehicle into the normal pre-inspection state: warm up the engine to a normal running temperature; then stop the running and cool it for 10 minutes.

2.

Dismantle the fuel pump relay (see corresponding complete vehicle maintenance manual).

3.

Disconnect ignition coil’s wiring harness joint (see corresponding complete vehicle maintenance manual).

4.

Dismantle Cylinder 1’s ignition coil and spark plug(see Ignition, Control System part).

Injector

Item

Standard value

compression pressure kPa{kgf/cm 2}[rpm]

1170 {12.0} [300]

Maximum pressure Minimum difference limit between cylinders 980 {10.0} [300]

100 {1.0 kgf/cm2}

Note: If one cylinder or several cylinders encounter excessively low pressure, or pressure difference between cylinders goes beyond the limit value specified, some drops of engine oil shall be added for repeated operation. Repeat the inspection following Step5-7. ■ If the compression pressure increases, the fault cause should be attributed to piston, piston ring, or cylinder inner surface’s wearing or damage, and in turn an overhaul is needed. ■ If the adjacent cylinder encounters low pressure, the cylinder gasket may be damaged, or the cylinder head likely suffers deformation, and in turn an overhaul is needed. ■ If the compression pressure is still low, the valve seat is burnt or in poor quality, and the valve’s sealing face has poor contact. Thus, an overhaul is needed. 9.

Compression Gauge

Take off the gauge

10. Mount the spark plug tightening torque:20～ 30N·m{2.1～3.1kgf·m } 11. Connect the ignition coil wiring.

1.2.2 Inspection of the Engine Oil

5.

Mount the gauge into Cylinder 1’s spark plug hole.

6.

Floor the accelerator pedal and start the engine.

7.

Record the gauge’s maximum reading.

1.

Park the automobile on the level ground.

2.

Warm up the engine to a normal running temperature and stop the running.

3.

Wait for 5 minutes.

4.

Pull out the dipstick and observe the oil level and oil state, inspect if the oil level ranges between Scale F and Scale L.

5.

Add or replace oil according to needs.

Engine block 1A-12 6.

Confirm the dipstick O-ring’s installation (see right figure).

7.

Insert the dipstick again. O-ring

figure).

Smearing Sealant is needed when the bolt is reused.

1.2.3 Inspection of Oil Pressure 9.

Warning 

Mount the oil pressure switch. Tightening torque:14.7N·m{1.5kgf·m}.

Wasted and used oil is cancer-causing substance, and so skin shall be cleaned with soap and tap water immediately after the work.

10. Start the engine and inspect if the engine oil suffers leakage.

1.

Dismantle the oil pressure switch.

1.

Dismantle the oil cover and oil drain plug.

2.

Mount the special tools onto oil pressure switch’s mounting hole.

2.

Pour the oil into appropriate vessel.

3.

3.

Warm up the engine to a normal running temperature.

Mount the new oil drain plug. Tightening torque: 30～41N·m{3.1～4.2kgf·m}.

4.

4.

Run the engine to a fixed rotating speed, and cast attention to the oil pressure gauge’s reading.

Add engine oil of specified model and volume into the engine.

5.

Remount the oil cover.

6.

Inspect the dipstick’s scale value.

7.

Start the engine and inspect if there is leakage.

8.

Inspect the engine oil level and add the oil if necessary (see Inspection of Engine Oil).

5.

Stop the running and cool the engine.

6.

Dismantle special tools.

1.2.4 Replacement of Engine Oil

Notice  In some occasions, actual oil volume that is added according to the oil scale may differ from the oil volume specified.

Oil pressure gauge ★ Note: if the pressure goes beyond the specified range, inspect the cause, and repair the engine and replace the oil according to needs. Notice 

Oil with different viscosities and temperatures may vary in pressure

7. Oil pressure:375 6.0kgf/cm2}[2500rpm] 8.

～

450kPa{4.1

～

Smear evenly the thread sealant (A6F011) onto the oil pressure switch thread (see the

Item

Oil capacity (L)

Oil replacement

4.6

Oil and oil filter replacement

4.9



Engine Oil Grade: API Engine Oil Grade: above SJ Oil viscosity standard

Oil viscosity level

Higher than–25℃

SAE10W–30

–30℃～37℃

SAE5W–30

Engine block 1A-13

1.2.5 Replacement of Oil Filter 1.

Dismantle the oil filter with special tools.

2.

Rub and clean the new oil filter with a clean cloth.

3.

Smear clean oil onto the new oil filter’s O-ring.

1.3 Application of Maintenance Platform

1.3.1 Mount the Engine Maintenance Platform 1.

Smear clean oil onto the new oil filter’s O-ring.

4.

Engine onto

Lift the engine, and align the cylinder body’s pin hole to the maintenance platform’s mounting dowel pin to mount the engine(see the figure).

Mount the oil filter with special tools Tightening torque:14.0～16.0N·m{1.42～ 1.63kgf·m}.

2. Mount the work fixture according to the figure and lock it. Fixing bolt

5. Start the engine and inspect if there is leakage. Inspect the oil level and check if oil adding is needed (see Inspection of Engine Oil).

Others Other inspection and maintenance like power generator inspection and starter inspection etc can be conducted on the complete vehicle. See this manual and corresponding complete vehicle maintenance manual for processing procedures.

3.

Adjust the fixing bolt to appropriate place and prevent the engine mounting from getting loose.

4.

Pour the engine oil into specified vessel.

Engine block 1A-14 5.

Mount the new oil drain plug, and tighten the oil drain plug. tightening torque: 30 ～ 41N·m{3.1～4.2kgf·m}

1.3.2 Dismantle the Maintenance Platform

Engine

②Power Generator Belt

from

Dismantle the engine from the maintenance platform according to steps reverse to “Mount the Engine onto Maintenance Platform”.

④Power Generator

Notice 

The engine maintenance platform’s self-locking brake system may lose efficacy in an unbalanced state, for instance, the engine maintenance platform suffers unbalance due to sudden and rapid action resulting from the engine mounting onto and dismantling from the platform, which will result in danger. Due to this, to ensure the engine and the entire maintenance platform’s balance during the operation process, the maintenance platform’s rotary handle shall be held tightly in hands during the engine tilting process.

1.4 Power Generator and Starter 1.4.1 Power Dismantling/Mounting

Generator’s

1

Generator adjusting arm

2

Generator belt

3

Generator bolt

4

Generator

1.4.2 Explanations on Inspection of Power Generator Belt If necessary, inspect the power generator belt’s deflection and tension: see complete vehicle maintenance manual’s corresponding part.

1.4.3 Explanations on adjustment to tension of power generator and air conditioning drive belts 1.

Loosen the power generator’s bolt nut ①.

Warning

2.

Loosen the power generator’s fixing nut ②.



Use the adjusting bolt ③, and adjust the belt tension and belt difference to the specified value.

When dismantling /mounting the power generator on the complete vehicle, the accumulator cable shall be dismantled firstly, or the power generator’s Terminal B will contact the vehicle body, which will lead to sparks and further result in personal injury and electric element damage.

1.

Dismantle the power generator according to the sequence illustrated in the figure.

2.

Mount the power generator according to the sequence reverse to the dismantling process.

3.

3.

Tighten the power generator pivot bolt’s nut ①: tightening torque:53～60N·m

4.

Tighten the power generator’s fixing nut ②: tightening torque:19～25N·m

③Adjust the bolt ②power generator’s fixing nut power

Inspect the belt’s deflection /tension (see Inspection of the Power Generator Belt).

①generator’s bolt nut

Notice 

If mounting the new power generator belt or running power generator belt for less than 5 minutes, adjustment shall be made according

Engine block 1A-15 to the new part’s standard value.

If it fails to stay within the standard value, readjustment shall be made from Step 1 on.

1.4.4 Explanations on inspection of power generator 1.

Confirm if the accumulator has been charged.

2.

Confirm if the belt’s deflection /tension stays within the specified range (See power generator part: Inspection of Power Generator Belt).

3.

Turn the ignition switch to the “ON” position, and the charge warning lamp will turn on.

4.

Confirm if the charge warning lamp is off after the engine has been put into running.

★ Note: If there is abnormal situation, see corresponding “Complete Vehicle Fault Diagnosis and Handling”.

1.4.5 Starter Dismantling/Mounting Warning 

When dismantling/mounting the starter on the complete vehicle, if the accumulator’s positive cable fails to be loosened, the starter’s Terminal B will connect with or contact the body, which will lead to sparks and further result in personal injury and electric element damage. Due to this, accumulator’s positive cable shall be dismantled firstly when the following operations are conducted:

1.

Dismantle the accumulator’s positive cable.

2.

Dismantle the starter according to the sequence illustrated in the figure.

3.

Mount the starter according to the sequence reverse to the dismantling process.

2

Binding post S cable

3

Starter

1.4.6 Explanations on inspection of starter Accompanying inspection: 1.

Confirm if the accumulator is charged.

2.

Start the starter to Confirm if the starter runs stably and has no running noise.

★

Note: If there is abnormal situation, turn the ignition switch to the “START” position, and measure the voltage between Terminal S and Terminal B, and the standard voltage shall be greater than 8(V)

—If the voltage stays beyond the specified range, overhaul the wiring harness and ignition switch. —If the voltage stays within the specified range, dismantle the starter and inspect the solenoid switch and starter. Zero-load test 1.

Confirm if the accumulator is charged.

2.

Connect the starter, accumulator, voltmeter and ammeter (see right figure).

3.

Run the starter and Confirm if its running is stable.

4.

During the starter running process, measure the voltage and current.

Starter

Accumulator



If running power generator belt for more than 5 minutes, adjustment shall be made according to old part’s standard value.

Binding post B cable

Ignition switch



1

Terminal S Note: If there is abnormal situation, conduct repair or replacement. Standard voltage:11(V), standard current:＜95(A)

Engine block 1A-16

1.5 Ignition, Control System Ignition Coil and Dismantling/Mounting

PCV

Valve

Notice 

When dismantling the ignition coil and spark plug, shield sleeve at the connecting rod can be easily torn. Due to this, they should be dismantled only when the replacement is necessary and tearing and damage shall be avoided during the dismantling process.

1.

Dismantle parts according to sequence illustrated in the figure.

1

Air Ventilation Condition Table Test Condition Blow to A Blow to B

Test Result There is air outflow from Interface B There is no air outflow from Interface A

1.5.2 Control System Dismantling/Mounting to

Parts

1.

Dismantle parts according illustrated in the figure.

sequence

2.

Mount parts according to sequence reverse to the dismantling process.

Ignition coil

2 3

Spark plug PCV valve

2. Mantle parts according to sequence reverse to the dismantling process.

1.51 Spark Plug Dismantling/Mounting

1

Fuel distribution pipe assembly

Notice

2

Oil control valve



3

Throttle body

4

Crankshaft position sensor (see Inspection of Crankshaft Position Sensor)

Mount the spark plug cautiously because strong impact will result in spark plug damage.

PCV Valve Dismantling /Inspection 1.

Dismantle the PCV valve.

5

Knock sensor

2.

Confirm if the air ventilation in PCV valve is as the following table. If there is abnormal situation, replacement shall be conducted.

6

Oil pressure sensor

7

Camshaft position sensor

8

Carbon tank solenoid valve assembly

9

Water temperature sensor (see dismantling/mounting explanations)

Engine block 1A-17

Note: this part only lists different parts of the control system’s mounting conditions on the engine. See the complete vehicle’s corresponding part for relevant fault diagnosis and inspection. 1.5.3 Crankshaft position sensor’s dismantling/mounting explanations

Clearance

Crankshaft position sensor Crankshaft signal panel

1.

When mounting the crankshaft position sensor, smear “LOCTITE5971” onto the cylinder body (shade line zone).

2.

When smearing the sealant, keep clean the unit surface’s bonding part.

1.5.5 Explanations on water temperature sensor dismantling/mounting

3.

After smearing the sealant, mount the crankshaft position sensor within 3 minutes.

Use the sleeve to dismantle the water temperature sensor.

1.5.4 Explanations to inspection crankshaft position sensor

of

Clearance inspection Attentions

Zone for smearing the sealant



Under-mentioned inspection conducted if necessary.

1.

Confirm if the crankshaft rotating speed sensor is correctly mounted.

2.

Use the plug gauge to measure the clearance between signal wheel protrusion platform and crankshaft rotating speed sensor.

shall

be

Notice 

If the clearance is incorrect, adjust the crankshaft rotating speed sensor or inspect if there is torsion and indentation in the signal wheel’s protrusion part. (If have, replace the crankshaft signal panel). Standard clearance value:0.5～1.5mm

Engine block 1A-18

1.6 Intake and Exhaust System 1.6.1 Intake and Exhaust System Dismantling/Mounting 1.

Dismantle parts according to sequence illustrated in the figure.

2.

Mount the parts according to the sequence reverse to the dismantling process.

1

5

Throttle body Throttle body seal ring(see Mounting Instruction) Intake manifold Intake manifold seal ring(see Mounting Instruction) Exhaust pipe gasket

10

Turbocharger oil return pipe

11

Turbocharger

12

Turbocharger gasket

13

Heat shield bracket

14

Turbocharger bracket

6

Turbocharger heat shield

15

Exhaust manifold’s upper heat shield

7

Turbocharger oil inlet pipe

16

Exhaust manifold

8

Turbocharger water return pipe

17

Exhaust manifold’s sealing gasket

9

Turbocharger water inlet pipe

2 3 4

Engine block 1A-19 damage on seal ring. If there is, replacement shall be made.

1.6.2 Explanations on intake manifold dismantling 1.

Dismantle parts according to the sequence illustrated in the figure.

1.6.5 Explanations on manifold dismantling

2.

Mount parts according to the sequence reverse to the dismantling process.

1.

Dismantle parts according to the sequence illustrated in the figure.

2.

Mount parts according to the sequence reverse to the dismantling process.

1.6.3 Explanations on the intake manifold seal ring mounting During the mounting process, mount the seal ring into the intake manifold’s slot, and wedge the seal ring’s anti-mistake mark into the intake manifold’s locating slot.

Prior to the mounting, inspect if there is damage on seal ring. If there is, replacement shall be made.

exhaust

1.6.6 Explanations on the turbocharger mounting Notice 

Check turbocharger installed in the front without foreign body, impeller rotation is normal.



Installation turbocharger gaskets should be checked, avoid installing dislocation.



Turbocharger inlet and outlet water pipe position do not reversed.

Caution 

the

1.7 Timing System 1.7.1Timing system dismantling/mounting 1.6.4 Explanations on the throttle body seal ring mounting During the mounting process, mount the seal ring into the intake manifold’s slot, and wedge the seal ring’s mark into the intake Seal ring anti-mistake manifold’s locating slot. Locating

1.

Dismantle power generator belt (see power generator part).

2.

Dismantle ignition coil (see the ignition part).

3.

Dismantle cylinder head hood (see cylinder head hood part).

4.

Dismantle oil sump.

5.

Dismantle oil pump and timing chain case assembly (see oil pump and timing chain case assembly part).

6.

Dismantle parts according to the sequence illustrated in the figure

7.

Mount the parts according to the sequence reverse to the dismantling process.

8.

Adjust the power generator belt deflection /tension (see power generator part).

Seal ring

Notice 

Prior to the mounting, inspect if there is

Engine block 1A-20

1.7.5 Explanations on the timing chain dismantling 1

Timing chain tensioner assembly

2

Tensioner arm assembly

3 4

Timing chain guide assembly Timing chain

5

Camshaft sprocket

6

Intake VVT assembly

1.7.2 Explanations on timing tensioner assembly dismantling

Mount the crankshaft pulley locking bolt.

2.

Rotate crankshaft along the clockwise direction, and align the gas distribution inspection mark.

Notice

chain

1.

Dismantle parts according to the sequence illustrated in the figure.

2.

Mount the parts according to the sequence reverse to the dismantling process.

Notice 

1.

Loosen the timing chain tensioner assembly bolt, and slowly take off the timing chain tensioner assembly (prevent the plunger from popping suddenly).

1.7.3 Explanations on crankshaft pulley dismantling



Keep the timing chain pulley’s key slot upward.



Align the gas distribution inspection mark at the timing chain pulley on the exhaust side of intake VVT.

3.

Dismantle timing chain tensioner assembly (see Timing Chain Tensioner Assembly Dismantling).

4.

Dismantle the tensioner arm assembly.

5.

Dismantle the timing chain’s guide rail assembly.

6.

Dismantle the timing chain.

1.7.6 Explanations on the timing chain’s tensioner assembly mounting 1.

Compress the pallet with bench clamp(see the figure), and insert one hard steel wire into the locking hole to lock the timing chain’s tensioner assembly.

2.

Mount the timing chain’s tensioner assembly onto the cylinder body, and tighten the bolt.

Use the special tools to secure the crankshaft for dismantling. Bolt unit Fixture unit

Double-ended jointing fixture

1.7.4 Explanations on cylinder head hood dismantling Loosen the bolt according to the sequence illustrated in the figure.

Pallet compression Locking hole direction Pallet

Engine block 1A-21

1.7.7 Explanations on the tensioner arm assembly mounting After the mounting, tensioner arm assembly shall not be excessively tightened, and sway the tensioner arm assembly to inspect if it can fall down freely.

6.

Notice 

Rotate the intake & exhaust camshaft to make two timing marks at the timing chain pulley on exhaust side of the intake VVT face toward specific angle.

Camshaft timing chain pulley and VVT assembly timing marks are “△”, gas distribution inspection mark is “○”; and crankshaft timing chain pulley timing mark is semicircular groove



In the event of failure in aligning, dismantle the timing chain, and repeat the operation from Step 1

7.

Rotate the crankshaft for two circles along the clockwise direction, and then rotate the crankshaft to make the intake VVT assembly (timing chain pulley on the intake side) align with two gas distribution inspection marks at the camshaft chain on the exhaust side.

on

timing

2.

Mount the timing chain’s guide rail assembly.

3.

Mount the timing chain.

Notice 

Confirm if all timing marks (4) and valve timing mechanism have been inspected Align the mark (1) accurately.

chain

1.7.8 Explanations mounting 1.

tensioner arm assembly and timing chain guide rail assembly’s guiding slot.

Align the timing mark at the timing chain pulley on the exhaust side of the intake VVT

Notice 

In the event of failure in aligning, repeat the operation from Step 1

1.7.9 Explanations on the cylinder head hood mounting

4.

Mount the tensioner arm assembly (see tensioner arm assembly mounting explanations).

Notice 

5.

Confirm if the timing chain is located in the timing chain guide rail assembly and tensioner arm assembly’s slot. Pull out the timing chain tensioner assembly’s locking pin, when the push rod is popped to push the tensioner arm assembly to compress the timing chain.

Notice 

Confirm if the timing chain is located in the

1.

Confirm if the cylinder head hood groove is free from oil, water, and other foreign objects.

2.

Confirm if the cylinder head hood’s sealing gasket has been completely attached to the cylinder head hood’s groove.

3.

Smear the sealant onto the joint between cylinder head and oil pump and timing chain case assembly according to the illustration.

4.

Mount the cylinder head hood bolt according to the sequence reverse to the dismantling process of cylinder head hood (see the cylinder head hood dismantling part), and tighten the cylinder head hood bolt by step. tightening torque:8～10N·m

Engine block 1A-22

1.8 Lubricating System Sealant-smearing zone

1.8.1 Oil Sump Dismantling/Mounting

Sealant-smearing zone

1.

Discharge the oil (see the complete vehicle’s upper inspection part: Replacement of Engine Oil).

2.

Dismantle parts according to the sequence illustrated in the figure.

3.

Mount the parts according to the sequence reverse to the dismantling process.

1.7.10 Explanations on the crankshaft pulley mounting Use special tools to fasten the crankshaft for mounting. Bolt unit Fixture unit

Double-ended jointing fixture

Dowel hole

1.7.11 Explanations on water pump pulley mounting Mount water pump pulley, and tighten the bolt.

1

Oil drain plug

2

Combination washer

3

Bolt

4

Oil pan

1.8.2 Explanations on the oil sump dismantling 1.

Dismantle the oil drain plug, and discharge the oil in the oil sump.

2.

Dismantle oil sump bolt step by step along the clockwise direction.

3. Use the oil sump dismantling tool to dismantle the oil sump from the engine.

1.8.3 Explanations on the oil sump mounting Notice 

If the bolt will be reused, eliminate the sealant on original thread because bolt with old sealant may lead to damage of the screw hole.



When mounting the reused oil sump, remove the residual sealant at the oil sump and corresponding mounting place.

1.

Add continuous sealant on the internal side of the oil sump bolt hole sealant, and overlap the front ends, with sealant diameter ranging between Φ2.0 and Φ3.0mm

Engine block 1A-23 2.

Mount the soil sump according to the sequence reverse to the dismantling process.

1.8.5 Explanations on oil pump’s oil seal dismantling If necessary, use clean cloth to wrap the screwdriver, and dismantle the oil seal lightly. Dismantled oil seal should be replaced, and further application is prohibited.

Oil sump Smear sealant prior to mounting

1.8.6 Explanations on oil pump’s oil seal mounting Cleft

Old sealant

1.

Smear clean oil onto the oil seal’s peripheral parts.

2.

Mount the oil seal with hands.

3.

Use the special tools to evenly compress the oil seal.

Compression depth:0～0.5mm

1.8.4 Oil Pump and Timing Chain Case Assembly Dismantling/Mounting 1.

Dismantle crankshaft pulley (see crankshaft pulley part).

2.

Dismantle cylinder head explanations on cylinder dismantling).

3.

Dismantle oil sump (see oil sump, oil sump dismantling/mounting).

4.

Dismantle water pump (see water pump dismantling/mounting).

5.

Dismantle parts according to the sequence illustrated in the figure.

6.

Mount the parts according to the sequence reverse to the dismantling process.

hood head

Oil seal erector

oil pump oil seal

(see hood

1

Oil filter(see Mounting Instruction)

2

Dipstick guide

3

Oil pump and timing chain case assembly (see Dismantling Explanations /see Mounting Explanations)

Compress

4.

oil pump

Continuously smear the sealant onto the oil pump and timing chain case assembly’s rims, see the figure. Sealant diameter:Φ2±0.5mm

Notice 

If the bolt will be reused, eliminate the sealant on original thread because bolt with old sealant may lead to damage of the screw hole.



When reusing the oil pump and timing chain case assembly, remove the sealant on the timing chain case and corresponding mounting place.

Engine block 1A-24

5. When mounting the oil pump and timing chain case assembly, tighten bolts by steps according to the sequence illustrated in the figure..

1.8.8 Explanations on disassembling/ mounting

oil

pump

1.

Dismantle oil pump and timing chain case assembly (see oil pump and timing chain case assembly dismantling/mounting).

2.

Disassemble parts according to the sequence illustrated in the figure.

3.

Mount parts according to the sequence reverse to the disassembling process.

Bolt Specifications and Mounting Torque No. 1a, 3a, 4a, 5a 6a, 7a, 8a,

Bolt rod Specification length (mm)

M6

Mounting torque (N·m)

25

8～12

2b, 10b

M6

30

8～12

12c

M6

45

8～12

M10

90

13d, 14d

36.5～42.5

1.8.7 Explanations on the oil filter mounting Tighten bolts by steps according to the sequence illustrated in the figure

1 2 3 4 5 6 7

Bolt Oil pump cover Screw plug Pressure spring Control piston Inner rotor (Smear oil before mounting) Outer rotor (Smear oil before mounting)

1.8.9 Inspection of Oil Pump Explanations on inspection of rotor clearance 1.

Measure the following clearance, and replace

Engine block 1A-25 the rotor or pump body if necessary. Standard gear tip clearance: 0.06～0.20mm Maximum gear tip clearance: 0.22mm

Standard pump body clearance: 0.250～ 0.325mm Maximum pump body clearance: 0.35mm

1.9 Cooling System 1.9.1 Thermostat Dismantling/Mounting 1.

Dismantle parts according illustrated in the figure.

to

sequence

2.

Mount the parts according to the sequence reverse to the dismantling process.

Standard backlash: 0.03～0.09mm Maximum backlash: 0.14mm

1 Thermostat cover Thermostat 2 see explanations on thermostat mounting

1.9.2 Explanations on inspection and mounting

Explanations on inspection of pressure spring Exert pressure on the spring and inspect the spring height. If necessary, replace the pressure spring. Pressure range:97.7～107.4N{9.96～10.96kgf} Standard height: 34.50mm

thermostat

1. Put the thermostat into a vessel with hot water, in which a thermometer is inserted. Then heat the thermostat to raise the temperature, and inspect the thermostat. If it does not comply with regulations, replace the thermostat. —Valve is closed at the room temperature. —Valve is opened after the temperature rise. Opening temperature (℃):80～84 Full-opening temperature (℃):95 Full-opening stroke (mm):≥8.5 2.

Confirm if the thermostat’s movable pin is upward, see the figure.

Engine block 1A-26 3.

Align the cylinder body thermostat’s mounting place, and mount the thermostat onto the cylinder body.

illustrated in the figure. 3.

Mount the parts according to the sequence reverse to the dismantling process.

Movable pin

Replace parts after the dismantling

1.9.3 Cooling water dismantling/mounting

pipeline

1.

Dismantle thermostat dismantling /mounting).

(see

thermostat

2.

Dismantle parts according illustrated in the figure.

3.

Mount the parts according to the sequence reverse to the dismantling process.

to

sequence

Replace parts after the dismantling

3 4 5

bolt(heater water pipe assembly) bolt(heater water pipe assembly) heater water pipe assembly

1.9.4 Explanations on heater water pipe /O-ring mounting When replacing the O-ring, smear the water onto the O-ring, in order to facilitate its mounting and avoid damage. Notice 

Do not smear engine oil or other greasy substances onto the O-ring.

1.9.5 Water Pump Dismantling/Mounting 1.

Dismantle power generator belt (see power generator belt part).

2.

Dismantle

parts

according

to

sequence

1

Bolt (water pump pulley)

2

Water pump pulley

3

Bolt (water pump assembly)

4

Bolt (water pump assembly)

5

Water pump assembly

Engine block 1A-27

1.10 Cylinder Cover and Valve Mechanism

Smear oil before the mounting

Smear oil before the mounting Smear Smear oiloil before before thethe mounting mounting Smear sealant before mounting the cylinder head hood

, 1

Intake VVT (see the dismantling /mounting explanations)

2

Camshaft sprocket (see the dismantling /mounting explanations)

3

Camshaft (see the dismantling /mounting explanations)

4

Tappet

5

Cylinder head (see the dismantling /mounting explanations)

6

Cylinder head gasket

Replace parts after the dismantling

Engine block 1A-28

1.10.1 Cylinder Head Dismantling/ Mounting

Mechanism

1.

Dismantle the intake and exhaust manifold (see the intake/exhaust system part).

2.

Dismantle the timing chain(see the timing chain part).

3.

Dismantle parts according illustrated in the figure.

4.

Mount the parts according to the sequence reverse to the dismantling process.

to

3.

Inspect the camshaft journal clearance (see the camshaft inspection part).

4.

Loosen the camshaft bearing seat bolts by steps according to the sequence illustrated in the figure. First, loosen the front camshaft bearing cover bolt, and then loosen other camshaft bearing cover bolts.

sequence

Explanations on intake VVT dismantling 1.

Lock the camshaft’s hexagon part with a wrench (see the figure), so as to dismantle the VVT and camshaft sprocket’s fixing bolts.

2.

Dismantle the VVT’s fixing bolts.

3.

Shake the VVT slightly, and take off it from camshaft with caution.

Explanations dismantling

1.

1.

If necessary, inspect and adjust the valve clearance (see the valve clearance inspection part).

2.

Inspect the camshaft end gap (see the camshaft inspection part).

head

on

the

cylinder

head

Measure every cylinder head bolt’s outer diameter differential (d1-d2). If the differential exceeds 0.15mm, the cylinder head bolt shall be replaced.

Note: d2 refers to the minimum outer diameter within the ※ mark’s range. 2.

Explanations on camshaft dismantling

cylinder

Loosen the cylinder head bolt by step according to the sequence illustrated in the figure.

Explanations mounting

VVT fixing bolt

on

Tighten the cylinder head bolt to specified torque by steps according to the sequence illustrated in the figure.

Tightening torque: 29N·m{2.96kgf·m}

Engine block 1A-29 3.

Mount the camshaft bearing cover onto corresponding journal according to the sequence.

4.

Tighten the bolts according to the sequence illustrated in the figure: first, tighten every camshaft cover bolt, and then tighten the front camshaft bearing cover bolt.

Explanations on the VVT mounting 3.

Mark every bolt head.

4.

According to the bolt-tightening sequence (Step 2) illustrated in the figure, Each bolt with a reference mark, rotated by 90 °, then rotated 90 °. (see the figure).

1.

Rotate the camshaft to make the dowel pin keep upward.

2.

Smear some oil onto the VVT assembly’s inserting part, align the VVT assembly location hole to the camshaft dowel pin, and mount the VVT assembly slowly.

3.

Lock the camshaft’s hexagon part with a wrench (see the figure), so as to tighten VVT’s fixing bolts. VVT assembly location hole (align camshaft dowel pin)

Paint mark place after Step 4

Initial paint mark

Explanations on the camshaft mounting Notice 

Since the camshaft’s mounting clearance is small, make sure that the camshaft journal is closely attached to the bearing seat during the mounting process, or the contact surface between the shaft and bearing will incur excessive pressure and in turn suffer damage. To avoid foresaid situation, regulations below shall be observed:

1.

Smear some oil onto the camshaft journal and bearing seat.

2.

Mount the camshaft into camshaft bearing seat, making camshaft journal closely attached to the bearing seat.

VVT assembly inserting part (smear some oil around)

Engine block 1A-30

1.10.2 Valve Mechanism Dismantling/ Mounting 1.

Dismantle cylinder head(see the cylinder head dismantling).

2.

Dismantle parts according illustrated in the figure. .

3.

Mount the parts according to the sequence reverse to the dismantling process.

to

sequence

Explanations on inspection of valve clearance 1.

Dismantle the cylinder head hood (see cylinder head hood dismantling part).

2.

Confirm if the engine has been cooled.

3.

Measure valve clearance.

(1) Rotate the crankshaft along the clockwise direction, making the piston located at the stopping place on No.1 Cylinder, namely, gas distribution mark shall be adjusted to the position indicated in the right figure.

1

Valve Half (see dismantling/mounting explanations)

2

Valve spring upper seat

3

Valve spring (see the mounting explanations)

4

Valve spring lower seat

5

Valve (see the mounting explanations)

6

Valve oil seal

(2) Use plug gauge to measure valve clearances of all cylinders at Mark A indicated in the figure.

Explanations on dismantling of valve keeper Use special tool valve spring pressure, remove the valve keeper.

★

Note:If the valve clearance exceeds the standard value, replace the tappet(see the valve clearance’s adjustment)valve clearance’s standard value (when engine is in cooling state):

Engine block 1A-31 Notice:

Intake:0.18～0.26mm Exhaust:0.26～0.34mm (3) Rotate the crankshaft for 360 degrees along the clockwise direction, making the piston located at the stopping place on No.4 Cylinder, namely, gas distribution mark shall be adjusted to the position indicated in the figure below.



If the valve clearance will be adjusted when there is not timing chain, make the crankshaft dowel pin towards side face, in order to prevent the valve from colliding with the piston top during the valve clearance adjustment process.



Mark the tappet thickness inside the tapper with 3 digits, see figure below: Thickness mark

(4) Use plug gauge to measure valve clearances of all cylinders at Mark B indicated in the figure above. ★

Note:If the clearance exceeds standard value, tappet shall be replaced(see the valve clearance’s adjustment)

Valve clearance’s standard value (when the engine is in cooling state): ON:0.18～0.26mm OFF:0.26～0.34mm 4.

Mount cylinder head hood (see the timing chain, cylinder head hood mounting part).

1.10.3 Cylinder Head Inspection /Repair

Explanations on the valve clearance’s adjustment To adjust the valve clearance, operation steps below shall be observed: 1.

Dismantle camshaft dismantling part).

(see

the

camshaft

2.

Take out the tappet at the place where the valve clearance shall be adjusted.

3.

Select an apposite tappet. New tappet’s thickness =old tappet’s thickness + measured valve clearance － standard valve clearance. (standard valve clearance: ON, 0.22mm; OFF, 0.30mm)

4.

Mount the selected tappet into the tappet hole.

5.

Confirm the valve clearance again (see valve clearance, valve clearance inspection). 1.

Inspect

the

cylinder

head’s

defect.

If

Engine block 1A-32 necessary, replace the cylinder head. 2.

7.

Inspect the following items, repair and replacement shall be conducted if necessary.

(1). If there is indentation at the valve seat.

If the distortion measured in Step 6 exceeds the maximum value, grind the surface or replace the cylinder head.

Maximum grinding volume: 0.20mm

(2). If the camshaft journal clearance and end gap is excessive.

1.10.4 Inspection of Valve and Valve Guide

3.

1.

Use the Straight Edge Ruler and plug gauge to inspect if the cylinder head is distorted along six directions, see the figure.

Maximum distortion: 0.03mm 4.

If the cylinder head’s distortion exceeds the maximum value, inspect the cylinder head’s height. If the height stays beyond the standard value, replace the cylinder head.

Measure thickness of every valve’s head rim. If necessary, replace the valve.

Standard thickness: intake valve: 1.35mm; exhaust valve: 1.85mm. Minimum thickness: intake valve: 0.85mm; exhaust valve: 1.35mm.

Brim thickness

Standard height:112.9-113.1mm

2.

Measure every valve’s length. If necessary, replace the valve.

Standard length 5.

If the cylinder head’s distortion exceeds the maximum value, and the height stays within the standard value, grind the height or replace the cylinder head.

Intake valve:89.51～90.01mm Exhaust valve:90.69～91.19mm Minimum length

Maximum grinding volume:0.20mm 6.

Intake valve: 89.31mm

Use the Straight Edge Ruler and plug gauge to measure the cylinder head intake/ exhaust manifold flange’s distortions along different directions, see the figure.

Exhaust valve: 90.49mm

Maximum distortion: 0.15mm

3.

Measure every valve’s rod diameter respectively at A, B, C point (see the figure)

Engine block 1A-33 along X and Y direction. If necessary, replace the valve.

valve seat contact width. If necessary, use a 44 ° valve seat cutter reworked valve or valve seat surface. Standard width: 1.1 ~ 1.5mm

Standard diameter Intake valve: 4.965～4.980mm Exhaust valve: 4.955～4.970mm Minimum diameter Intake valve: 4.915mm Exhaust valve: 4.905mm 4.

Measure every valve guide’s inner diameter respectively at A, B, and C point along X and Y direction (see the figure). If necessary, replace the valve guide.

Standard inner diameter Standard:5.0～5.012mm

5.

2. Check valve seat depression. Measure the valve stem projecting length (size L). If necessary, replace the cylinder head. Standard size L Intake: 38.16 ~ 38.76mm Exhaust: 38.16 ~ 38.76mm

When there is not valve spring’s lower seat, measure every valve guide’s extrusion height (Size A). If necessary, replace the valve guide.

Standard height:12.7～13.3mm Valve guide

1.10.6 Explanations on inspection of valve spring 1.

Cylinder head

1.10.5 Explanations on inspection of valve seat 1. Surface painted with a method to measure the

Use the special tools to exert pressure on the valve spring, and inspect the spring height. If necessary, replace the valve spring. Exert pressure on the valve spring, and compress the spring to a given height, when the pressure value exceeds the specified range, the valve spring shall be replaced.

When the height is 33.4mm, the pressure is 142.2～ 161.8N{14.51～16.51kgf}; When the height is 24.9mm, the pressure is 293.4～324.4N{29.94～33.10kgf}. 2.

Measure the valve spring verticality, and if the verticality goes beyond the standard, the

Engine block 1A-34 valve spring shall be replaced. Valve spring’s maximum verticality:1.50mm

3.

Measure the journal diameter respectively at A and B point along X and Y direction. If necessary, replace the camshaft.

Standard diameter:25.945～25.96mm Minimum diameter: 25.915mm

1.10.7 Explanations on the inspection of camshaft 1.

Point A

Place the camshaft’s No. 1 and No. 5 journals onto the V-shaped block to measure the camshaft’s radial run-out. If necessary, replace the camshaft.

Point B

Radial run-out: 0.03mm 4.

Dismantle the tappet, and measure camshaft journal clearance according to steps below:

(1). Remove all oil on the journal and bearing seat’s internal surface. (2). Put the camshaft into the bearing seat. (3). Make the plastic gauge match the bearing width (see the figure), and then put it on the top of journal along the axial direction.

2.

Measure heights of the two convex parts (see the figure). If necessary, replace the camshaft.

(4). Mount the camshaft cover (see cylinder head dismantling/mounting, camshaft mounting attentions). Axial direction

Standard height Intake side: 44.5mm Exhaust side: 43.8mm Minimum height Intake side: 44.2mm Exhaust side: 43.5mm

Plastic gauge Notice

Engine block 1A-35 

When measuring the clearance, do not rotate the camshaft

1.10.8 Explanations on inspection of tappet hole and tappet

(5). Dismantle camshaft cover (see cylinder head dismantling/mounting, camshaft dismantling attentions).

1.

(6). Use the scale on the plastic gauge bag to measure the widest point on the plastic gauge’s extruded part, and then calculate out the journal clearance.

Standard inner diameter:31.000～31.025mm

Measure every tappet mounting hole’s inner diameter respectively at A and B Point (see the figure) along X and Y direction.

If necessary, replace the cylinder head and camshaft cover. Standard journal clearance:0.040～0.076mm

2.

5.

Mount the camshaft cover (see cylinder head dismantling/mounting, camshaft mounting attentions).

6.

Mount the dial gauge, push camshaft forward or backward at the end of camshaft (see the figure), and measure the camshaft end gap. If necessary, replace the cylinder head or camshaft.

Measure every tappet’s diameter respectively at the A and B point (see the figure) along X and Y direction.

Standard diameter:30.964～30.980mm

Caution 

Do not push the camshaft at the cam part, so as to prevent the cam from being damaged.

Standard end gap:0.08～0.20mm Maximum end gap:0.21mm

3. Calculate the clearance between tappet and corresponding tappet hole. If necessary, replace the tappet or cylinder head. Standard clearance:0.020～0.061mm Maximum clearance:0.180mm

Engine block 1A-36

1.11 Flywheel, clutch 1.11.1 Flywheel and Clutch Dismantling/Mounting 1. If the crankshaft’s back cover needs to be dismantled, oil sump body shall be dismantled at first (see lubricating system, oil sump body dismantling and mounting). 2. Dismantle parts according to sequence illustrated in the figure. . 3. Mount the parts according to the sequence reverse to the dismantling process.

1

clutch pressure disc

(see dismantling explanations/see mounting explanations)

2

Clutch friction disc (see dismantling explanations/see mounting explanations)

3

flywheel

4

Crankshaft’s back cover (see the rear oil seal dismantling explanations /see rear oil seal mounting explanations /see mounting explanations)

5

Transmission’s baffle plate

(see dismantling explanations/see mounting explanations)

Engine block 1A-37

1.11.2 Explanations on Clutch Pressure Disc/Friction Disc Dismantling 1.

Use the special tools to lock the flywheel, and locate the clutch(see the figure).

2.

Loosen the bolt in a disposable manner according to the sequence of right-angled intersection till the diaphragm spring’s pressure is released.

3.

Dismantle the clutch pressure disc and friction disc.

Protective cloth

Explanations on the crankshaft’s back cover mounting 1.

Smear evenly sealant onto indentation of the crankshaft’s back cover (see the figure).

Sealant diameter:Φ1.5～Φ2.5mm Smear sealant

Clutch plate setting tool

Gear ring fixture unit

Explanations on flywheel dismantling 1.

Use the special tools (see the figure) to lock the flywheel.

2.

Follow the right-angled intersection sequence to evenly dismantle the mounting bolt (see the figure), and dismantle the flywheel.

Explanations on the flywheel mounting /inspection 1.

Mount the flywheel onto the crankshaft.

2.

Clean the thread and hole before mounting the bolt.

3.

Smear evenly the sealant onto the thread.

Notice Gear ring fixture unit

Explanations on Rear Dismantling/Mounting 1.

Oil



There is no need to smear the sealant when using new bolt

4.

Tighten the flywheel bolt with hands.

5.

Mount special tools onto the flywheel (see the figure).

6.

Follow

Seal

Use the screwdriver, wrapped with protective cloth, to dismantle the oil seal(see the figure)

Notice 

Normally, there is no need to dismantle the oil seal, unless being replaced.

2.

Add clean oil onto the oil seal opening.

3.

Mount the oil seal with hands.

4.

Use the special tools and hammer to compress the oil seal.

Compression depth:0～0.5mm

the

sequence

of

right-angled

Engine block 1A-38 intersection to tighten the flywheel bolt little by little.

Gear ring fixture unit

7. Mount the dial gauge onto the cylinder body. 8.

Use the special tools to secure the clutch friction disc’s position (see the figure). Clutch disc locator

Rotate the flywheel and measure the flywheel’s end-on circle run-out. If it exceeds the standard, replace the flywheel.

Maximum end-on circle run-out:0.13mm

1.11.4 Explanations on the clutch pressure disc inspection/mounting 1.

Measure the diaphragm spring’s abrasion.

1.11.3 Explanations on the clutch friction disc inspection /mounting

If it exceeds standard, replace the clutch pressure disc

Use the vernier caliper to measure rivets on both sides and the friction disc surface’s depth.

Maximum height: 0.6mm

If it exceeds the standard, replace the clutch friction disc Minimum depth:0.3mm

2.

Use the dial gauge to measure the clutch friction disc’s end-on circle run-out. If it exceeds standard, replace the clutch friction disc Maximum end-on circle run-out:0.7mm

Use the Straight Edge Ruler and plug gauge to measure the pressure disc’s flatness.

If it exceeds standard, replace the clutch assembly. Maximum clearance: 0.05mm

Engine block 1A-39 head part), oil sump, oil pump, and timing chain case assembly (see lubricating system part) and crankshaft’s back cover (see flywheel, clutch part).

3.

2.

Dismantle parts according illustrated in the figure. .

3.

Mount parts according to the sequence reverse to the dismantling process.

sequence

Smear oil before mounting

Use the special tools to lock the flywheel, and locate the clutch(see the figure).

Clutch disc setting tool

to

Gear ring fixture unit

4.

Follow the right-angled intersection sequence to evenly tighten bolts.

5.

Mount the dial gauge onto the cylinder body, and rotate the flywheel to inspect the diaphragm spring’s radial run-out.

If it exceeds standard, replace the clutch pressure plate

⑩Smear oil before mounting

Maximum radial circle run-out:0.6mm

②Smear oil before mounting

1

1.12 Cylinder body, Crank Connecting Rod Mechanism 1.12.1 Cylinder Body, Crank Connecting Rod Mechanism Dismantling/Mounting 1.

Dismantle the cylinder head (see the cylinder

2 3

connecting rod cover (see the mounting explanations) connecting rod bearing piston ring(see the mounting explanations)

connecting rod 7

8

Main bearing cover (see the mounting explanations)

9

thrust bearing

Engine block 1A-40 4 5 6

Piston pin retainer Piston pin (see the mounting explanations) piston

10 Crankshaft bearing Crankshaft 11 12 Cylinder body

Explanations on connecting rod cover dismantling

2.

Tighten main bearing cover’s bolt to specified torque by steps according to the sequence illustrated in the figure, as well as mark every bolt head. Tightening torque:33 ～ 37N·m{3.357～3.784kgf·m}

3.

according to the bolt-tightening sequence (Step 2) illustrated in the figure, rotate every bolt for 60°～64° from the mark.

Inspect the connecting rod end gap (see connecting rod inspection part).

Explanations on piston pin dismantling 1. The piston pin retainer with the tool removed. 2.Hand push the piston pin, which was pushed out.

Explanations on main bearing cover dismantling 1.

Inspect the crankshaft end gap (see the crankshaft inspection /repair part).

2.

Loosen the main bearing cover’s bolt according to steps illustrated in the figure.

Explanations on the piston pin mounting 1. Removing the piston, piston pin into the ring at one end. 2. The clean oil applied to the piston pin.

Explanations dismantling

on

the

crankshaft

Inspect the main journal clearance (see the crankshaft inspection /repair part).

Explanations on the main bearing cover mounting 1.

Measure every bolt’s length. If the length exceeds the standard value, replace the bolt.

Standard length: 74.15～74.85mm Maximum length: 75.05mm

3. Place the piston and connecting rod to press-fit the stage, piston "→" on the mark side and the link "HMA" or logo side, as shown. 4. The piston pin into the piston, connecting rod assembly, to be assembled in place, on the other side of the piston pin into the piston rings.

Explanations on the piston ring mounting 1. The following figure, the first spiral spring loaded oil ring body support groove Connect with the latch pin connector. 2. The oil ring was placed in an oil ring groove. 3. The support spring connectors and oil ring body openings staggered 180 °.

Engine block 1A-41

Explanations on the connecting rod cover mounting 1.

The bolt can be reused, but when the outer diameter difference at the two points illustrated below exceeds 0.1mm, the bolt shall not be further used.

Use the piston ring dilator to mount the No. 2 and No.1 piston ring.

5. Keep the marker side upward during the mounting process. 6.

Align all rings’ opening locations (see the figure).

2.

Outer diameter

4.

Outer diameter

Piston ring dilator

Tigthen the connecting rod bolt to specified torque by steps according to the sequence illustrated in the figure.

Tightening 2.45kgf·m}

torque:18.0 ～ 22.0N·m{1.84 ～

Row

Front

In

Explanations on piston connecting rod assembly mounting 1.

Pistons forward flag " the engine.

" for the front of

3.

Mark every bolt head.

4.

According to the bolt-tightening sequence (Step 2) illustrated in the figure, rotate every bolt for 90°～94° from its marker.

1.12.2 Cylinder Body Inspection /Repair 1.

Use the Straight Edge Ruler and plug gauge

Engine block 1A-42 to measure the distortion on the cylinder body’s upper surface along six directions illustrated in the figure.

Maximum grinding volume: 0.20mm 4.

Cylinder body’s maximum distortion:0.1mm

Use the inside dial indicator to measure the cylinder’s inner diameter at the place 60mm away from upper surface along the X and Y direction (see the figure). Cylinder body’s upper surface

2.

If the distortion on the cylinder body’s upper surface exceeds the maximum value, inspect the cylinder body’s height. If the height stays beyond the standard value, replace the cylinder body.

5.

If the cylinder’s inner diameter goes beyond the abrasion limit, replace the cylinder body, and install the corresponding piston, in order to make it accord with the standard clearance between piston and cylinder. Abrasion limit: 0.135mm Size

Diameter

Standard

74.8～74.815

1.12.3 Piston, Piston Ring, and Piston Pin Inspection

Cylinder body

1. Along the vertical direction of piston pin hole’s axial line, measure the piston’s diameter at the place that is 19.38mm below the lower rim of the oil control ring groove

Standard height:204.95～205.05mm 3.

If the cylinder body’s distortion goes beyond the maximum value and the height stays within the standard value, grind the height or replace the cylinder body. Piston diameter (mm) Size Diameter Standard

74.7625～74.7775

Calculate the clearance between piston and cylinder. If necessary, replace the piston. Standard clearance:0.0225～0.0525mm Maximum clearance: 0.10mm 2.

If replacing the piston, piston ring shall be replaced as well.

Engine block 1A-43 3.

Use the plug gauge to measure the clearance between piston ring and ring slot along the entire perimeter (see the figure). If necessary, replace the piston and piston ring.

Maximum opening clearance:1.0mm 6. Respectively at A, B, C, and D point along X and Y direction, measure every piston pin hole’s diameter. Standard diameter:17.996～18.000mm

Standard clearance Ring 1:

0.040～0.085mm

Ring 2:

0.030～0.070mm

Oil ring: 0.020～0.060mm

Standard diameter:18.004～18.010mm

Maximum clearance Ring 1, Ring2:

7. Respectively at A, B, C, and D point along X and Y direction, measure every piston pin’s diameter

0.15mm

Oil ring: 0.15mm. 4.

Put the piston ring into cylinder with hands, and use the piston to push the piston ring to the bottom of the cylinder bore stroke.

8. Calculate out the clearance between piston pin and piston pin hole. If necessary, replace the piston or piston pin. Standard clearance:0.004～0.014mm 9.

5.

Use the plug gauge to measure every piston ring’s opening clearance. If necessary, replace the piston ring.

Standard opening clearance: Ring 1:

0.20～0.35mm

Ring 2:

0.40～0.60mm

Oil Ring: 0.20～0.40mm

Measure the connecting rod’s small head diameter (see connecting rod inspection), and calculate the clearance between connecting rod’s small head and piston pin. If necessary, replace the connecting rod or piston pin. Standard clearance:-0.010～-0.027mm.

1.12.4 Connecting Rod Inspection 1.

Use the plug gauge to measure the connecting rod’s end gap. If necessary, replace the connecting rod and connecting rod cover.

Engine block 1A-44 φ43.979～φ43.986

blue 1.489～1.494

φ43.986～φ43.993

yellow 1.486～1.491

43.993～φ44.000

red 1.483～1.488

3. As shown in X and Y direction of each of the connecting rod small end diameter measurement.

Standard clearance:0.10～0.30mm Maximum clearance:0.40mm 2.

Standard diameter: 18.010～18.023mm

Measure the crank pin journal clearance according to steps below.

(1). Remove all oil on the journal and bearing seat’s internal surface. (2). Make the plastic gauge match the bearing width and then put it on the top of journal, keeping parallel with the axial line. (3). Mount the connecting rod cover (see piston and connecting rod mounting part). (4). Dismantle the connecting rod cover’s bolt, and slowly take off the connecting rod cover. (5). Use the plastic gauge scale to measure the widest point on the plastic gauge’s extruded part, and then calculate out the journal clearance. If the clearance exceeds the maximum value, replace the crankshaft and corresponding connecting rod bearing to ensure the standard clearance.

1.12.5 Inspection of Piston Connecting Rod Assembly Inspect the swaying torque (see the figure). If the big head fails to drop down by virtue of its own weight, replace the piston or piston pin.

Standard clearance:0.024～0.056mm Drop down by virtue of its own weight

1.12.6 Crankshaft Inspection /Repair Maximum clearance:0.10mm Rod bearing matching table Crank pin diameter

1. mm

Rod bearing thickness

Mount the dial gauge, use the screwdriver to push the crankshaft frontward and backward, and measure the crankshaft end gap (see the figure). If the end gap surpasses the maximum value, replace the thrust bearing or crankshaft to fit the standard end gap.

Engine block 1A-45 Standard end gap:0.09～0.273mm Maximum end gap:0.30mm

(1). Remove all oil on the crankshaft journal and bearing seat’s internal surface.

Thrust bearing’s size Thrust bearing’s thickness

(2). Make the plastic gauge match the bearing width and then put it on the top of journal, keeping parallel with the axial line.

Standard

3.205～3.255

(3). Mount the main bearing cover (see the main bearing cover mounting part). (4). Dismantle the main bearing cover bolt, and slowly take off the main bearing cover (see main bearing cover mounting part).

2.

Measure the crankshaft’s radial run-out. If necessary, replace the crankshaft.

Maximum radial circle run-out:0.03mm

(5). Use the plastic gauge scale to measure the widest point on the plastic gauge’s extruded part, and then calculate out the journal clearance. If the clearance exceeds the maximum value, replace the crankshaft and corresponding bearing bush to ensure the standard clearance. Standard clearance: 0.018～0.036mm Maximum clearance: 0.1mm Crankshaft bearing matching table

3.

Respectively at A and B point along X and Y direction, measure the journal diameter. If necessary, replace the crankshaft.

Main journal Standard Crank pin Standard 4.

Diameter(mm) 45.982～46.000 Diameter(mm) 43.979～44.000

Measure the main journal’s according to method below.

clearance

mm

Crankshaft Crankshaft main journal diameter 1:φ 2:φ 3:φ bearing thickness 45.994 45.988 45.982 ～φ ～φ ～φ 46.000 45.994 45.988 Cylinder Cy lin de r m ai n be ari ng ho le di a m ete r

1:φ 50.000 ～φ 50.006

1# 2# 3# 1.988～ 1.991～ 1.994 1.991 1.994 ～ 1.997

2:φ 50.006 ～φ 50.012

2# 3# 4# 1.991～ 1.994 1.997 1.994 ～ ～ 1.997 2.000

3:φ 50.012 ～φ 50.018

3# 4# 5# 1.994～ 1.997 2.000 1.997 ～ ～ 2.000 2.003

Electronic Fuel Injection Control System 1B-1

Chapter 2 Electronic Fuel Injection Control System 1. Notices for Maintenance of Electronic Fuel Injection System······································1B-2 1.1 General Maintenance Notices······································································ 1B-2 1.2 Maintenance Attentions············································································· 1B-2 1.3 List of Maintenance Tools ···········································································1B-3 1.4 Manual annotation abbreviations in································································1B-5 2. Briefings of ME7 System ················································································1B-6 2.1 Basic Principle························································································· 1B-6 2.1.1 System Profile ME788-Motronic ·································································· 1B-6 2.1.2 Torque-based ME7 System·········································································· 1B-7 2.2 Control signal: ME7 system’s input /output signals·············································· 1B-9 2.3 Introduction of System Functions····································································1B-9 2.3.1 Start Control ······················································································ 1B-9 2.3.2 Warm-up and Three-way Catalyst Converter Heating Control ···························· 1B-10 2.3.3 Acceleration /Deceleration and Towing Astern Oil Cutoff Control······················· 1B-10 2.3.4 Idle Control ······················································································· 1B-10 2.3.5 Close-loop Control··············································································· 1B-11 2.3.6 Evaporation Emission Control ································································· 1B-11 2.3.7 Knock Control ····················································································· 1B-11 2.3.8 VVT Control······················································································ 1B-11 2.3.9Idle Start/Stop Control················································································ 1B-11 2.4 Introduction of System Troubleshooting Function ················································1B-11 2.4.1 Fault Information Record ······································································· 1B-11 2.4.2 Classification of Fault Types ··································································· 1B-12 2.4.3 Connection with Diagnostic Unit······························································ 1B-14 3.ME7’s Overhaul and Diagnosis Flow by Fault Code ················································ 1B-14 4.ME7’s Overhaul and Diagnosis Flow by Fault Phenomenon······································· 1B-21 5. Functional Requirements on ME7 System’s Diagnostic Unit ······································1B-334 5.1 Parts Mounting Torque Specification Table ························································1B-334 5.2 Electronic Fuel Injection System Maintenance Specification ···································1B-34 5.2.1 Family Vehicle ·················································································· 1B-35 5.2.2 Vehicle for Lease ··············································································· 1B-35

4.

1. Notices for Maintenance of Electronic Fuel Injection System 1.1 General Maintenance Notices 

Only the digital multimeter can be used to inspect the electronic fuel injection system.



Original parts and components shall be used in maintenance work, or electronic fuel injection system’s normal running cannot be ensured.



Only the lead-free gasoline can be used during the maintenance process.



Observe standard maintenance and diagnosis flow to conduct maintenance.



Disassembly and dismantling to electronic fuel injection system’s components shall be prohibited during the maintenance process.





Handle the electronic elements (like electronic control unit and sensor etc) with caution during the maintenance process, and do not let them drop on the floor. Cultivate the consciousness of environmental protection, and handle efficiently wastes resulting from the maintenance.

5.

2.

3.

Do not dismantle any of the electronic fuel injection system’s components or connectors from its mounting place without approval, in order to guard against accidental damage and prevent foreign objects like water and oil stain from entering the connector, which may affect the electronic fuel injection system’s normal running. When disconnecting and connecting the connector, place the ignition switch to the “OFF” position, or the electric elements will incur damage. When conducting the fault heating condition simulation or other maintenance jobs that may lead to temperature rise, make the temperature of electronic control unit stay below 80℃.

When dismantling the electric fuel pump from the fuel tank, do not power on the oil pump, in order to avoid electric sparks and fire disaster.

6. Running experiment to fuel pump shall not be conducted in a dry state or in water, or its service life will be shortened. In addition, do not mistake the fuel pump’s negative and positive electrodes. 7.

When inspecting the ignition system, spark test shall not be conducted until it is necessary, and also the spark test time shall be as short as possible. During the testing process do not turn on the throttle or much unburned gasoline will flow into the exhaust pipe, which will in turn result in damage to the three-way catalyst converter.

8.

Since the idle adjustment is completed totally by the electronic fuel injection system, there is no need to conduct manual adjustment. When leaving the factory, throttle’s accelerator stop bolt has been adjusted by the manufacturer, and users’ adjustment to its original location is prohibited.

9.

When connecting with the accumulator, do no mistake the accumulator’s negative and positive electrodes, or the electronic elements will incur damage. In this system, minus earth is adopted.

1.2 Maintenance Attentions 1.

Electronic Fuel Injection Control System 1B-2 The electronic fuel injection system’s oil supply pressure is relatively high (350kPa or so), and all fuel pipelines adopt the fuel pipe resisting high pressure. Even if the engine does not run, the oil pipeline will keep a relatively high fuel pressure. Due to this, do not dismantle the oil pipe at discretion during the maintenance process. In the occasion where the fuel system shall be maintained, pressure discharge treatment is needed before the oil pipe is dismantled, with pressure discharge method as follows: start the engine and make it run at idle speed, connect it with the diagnosis instrument, enter the “Actuator Test”, and turn off the fuel pump till the engine stops automatically. Dismantling of oil pipe and replacement of fuel filter shall be completed by maintenance professionals in the place with sound ventilation condition.

10. During the engine running process, do not dismantle the accumulator cable. 11. Before executing the electric welding in the vehicle, dismantle the accumulator’s negative/positive cables and electronic control unit. 12. Do not test the parts’ electric signal input/output by penetrating the cable sheath.

Electronic Fuel Injection Control System 1B-3

1.3 List of Maintenance Tools

Tool name: Electronic fuel injection system diagnosis instrument Function: Read/clear electronic fuel injection system’s faults, read/clear electronic fuel injection system’s fault code, observe the dataflow and parts action test etc. (Picture here is only for your reference)

Tool name: Electronic fuel injection system commutator Function: Inspect the electric signal at the electronic control unit’s every pin, and inspect the cable condition etc.

Tool name: Ignition Timing Lamp Function: Inspect the engine’s ignition timing etc.

Tool name: Digital Multimeter Function: Inspect the electronic fuel injection system’s characteristic parameters like voltage, current, and resistance etc.

Electronic Fuel Injection Control System 1B-4

Tool name: Vacuum Meter Function: Inspect the pressure in the intake manifold.

Tool name: Cylinder Pressure Gauge Function: Inspect every cylinder’s pressure.

Tool name: Fuel Pressure Gauge Function: Inspect the fuel system’s pressure, and judge the fuel system’s fuel pump extrusion as well as the pressure regulator’s working condition.

Tool name: Tail gas analyzer Function: Inspect the vehicle’s tail gas emission, which helps locate the electronic fuel injection system’s faults.

Electronic Fuel Injection Control System 1B-5

Tool name: Fuel Injector Cleaning Analyzer Function: Make cleaning analysis on the fuel injector

1.4 Manual annotation abbreviations in DG DS-S-TF

Speed sensor; DVE Electronic throttle body; FPM Accelerator pedal; Air intake pressure and temperature sensor

ECU

Electronic control unit

EKP

Fuel pump

EMS

Engine management system

EV

Injector

LSF

Oxgen sensor(Heating type)

KS

Knock sensor

KSZ

Fuel distribution pipe assembly

KVS

Fuel distribution pipe

PG ROV

Phase sensor Ignition system with the distributor; RUV Ignition system without the distributor; TEE Fuel pump bracket assembly

TEV

Carbon canister control valve

TF-W

Coolant temperature sensor

ZSK

Ignition coil

VVT

Variable valve timing system

DS-D2 HFM DV WGV

DR Fuel pressure regulator

Brake vacuum sensor Air Flow Meter Turbocharger pressure relief valve Turbocharger exhaust valve

Electronic Fuel Injection Control System 1B-6

2. Briefings of ME7 System 2.1 Basic Principle 2.1.1 System Profile ME7-Motronic Engine management system usually consists of sensor, microprocessor (ECU), and actuator, which is used to control the air absorption, oil injection volume, and ignition advance angle during the engine running process. See Fig. 2.1 for its basic structure. Diagnosis Sensor

Diagnosis EUC

Actuator

Engine Fig. 2.1 Components of Engine Electric Control System confirmed, the fault diagnosis system will save the In the engine’s electric control system, sensor fault code, and invoke the “Limp Home” function. serves as the input part, which is used to measure When detecting that the fault has been eliminated, different physical signals (like temperature and the fault diagnosis system will resume the normal pressure) and convert them into corresponding value. electric signals. In addition, ECU is used to receive the sensor’s input signal, and conduct computation ME7 engine electronic control management processing according to preset program, during system is characterized by adoption of which control signals produced will be outputted to torque-based control strategy, which aims to link the power drive circuit. By driving different different control objectives. That is the only actuators to execute different actions, the power method in which different functions can be drive circuit enables the engine to run according to integrated into the ECU’s different models scheduled control strategy. In the meantime, according to the engine and vehicle model. See Fig. ECU’s fault diagnosis system monitors all 2.2 for structure of the ME7 Engine Electronic components of the system or their control Control System functions. Once the fault has been detected and

Fig. 2.2: Structure of ME7 Engine Electronic Control System

ME7 Engine Electronic Control System’s basic components include:

Electronic Fuel Injection Control System 1B-7  Catalyst heating 

Carbon canister control

Electronic control unit (ECU)



Idle control

Electronic accelerator pedal



Limp home

Air quality flowmeter (depending on project)



Speed sensing by the incremental system

Fuel injector intake pressure /temperature sensor(depending on project)



VVT control

Electronic fuel pump



Idle start/stop

Coolant temperature sensor

2)

Additional functions

Fuel pressure regulator



Burglar alarm

Electronic throttle body



Connection between the torque and external systems (like driving mechanism or vehicle dynamic control)



Control over several engine parts and components



Provision of interface on EOL-programming tools and maintenance tools

Knock sensor

3)

Online OBD Diagnosis

Ignition coil



Complete a series of OBD functions

VVT controller



Management system used in diagnosis

Oil pump bracket Phase sensor Fuel distribution pipe Rotating speed sensor Carbon canister control valve

Oxygen sensor Brake vacuum sensor (idle start/stop) ME7-Motronicengine Management System is a gasoline engine control system subject to electronic operation, and it provides lots of control features relating to operators and vehicles/equipments. It is worth pointing out that the system adopts open-loop and close-loop (feedback) control mode, which can provide different control signals for the engine’s running. Major functions of the system include: 1) Basic management functions of the engine in physical model: 

Torque-based system structure



Cylinder load determined by the intake pressure sensor/air flow rate sensor



Gas mixture control function improved in static and dynamic state.



Close-loop control



Sequential fuel injection cylinder by cylinder



Ignition timing, including knock control cylinder by cylinder



Emission control function

2.1.2 Torque-based ME7 System In the ME7’s torque-based engine management system, all of the engine’s internal and external demands shall be defined according to the engine’s torque or efficiency requirements (see Fig. 2.3). Different engine demands will be converted into the torque or efficiency’s control variables, and then these variables will be firstly processed in the central torque demanding coordinator module. By sequencing these contradictory requirements by priority, ME7 system will execute the most important requirement, and then it takes advantage of torque conversion module to acquire needed engine control parameters like fuel injection time and ignition timing etc. Meanwhile, execution to such control variable will not affect other variables, which is right the strong point of the torque-based control system. Likewise, during the engine matching process, the torque-based control system has independent variables, and so only the engine data is required when matching the engine characteristic curve and map, and there is no interference with other functions and variables. That in turn avoids repetitive marking, simplifies the matching process, and reduces the matching cost.

Electronic Fuel Injection Control System 1B-8

Fig. 2.3: Structure of ME7’s Torque-based System

In comparison with previous Collection M engine electronic fuel injection management system, ME7 system has the following characteristics:

Electronic Fuel Injection Control System 1B-9 start/stop) 

Neutral position start/stop)

signal

(dedicated

to



All-new engine function structure with torque being the variable, which is easily compatible with other systems and has strong scalability;

Clutch top switch signal (dedicated to start/stop)



Clutch bottom switch signal (dedicated to start/stop)



All-new modularized software and hardware structure that is highly transplantable;



Accumulator sensor signal (dedicated to start/stop)



Model-based engine characteristics maps independent to one another, which helps simplify the marking process;



Engine compartment cover signal (dedicated to start/stop)



Sensor with phase, and sequential fuel injection facilitates the improvement of emission;



Door signal (dedicated to start/stop)





System’s integration with anti-theft function;



Coordinate different torque requirements in a centralized manner to improve the driving performance;

After entering the ECU, above information will be processed to produce the needed actuator control signals, which will be amplified in the output drive circuit and transmitted to corresponding actuators. These control signals include: 

Opening of electronic throttle



16-bit CPU, 40MHz clock frequency, and 768k cache;



Fuel injection timing and oil injection’s duration



The system is scalable according to future demands like emission standard OBDII.



Fuel pump relay



Opening of carbon canister control valve

2.2 Control signal: ME7 system’s input /output signals



Ignition coil’s angle of attachment and ignition advance angle

In the ME7 system, ECU’s major sensor input signals include:



A/C compressor relay



Cooling fan relay



Starter relay



VVT angle



Turbocharger pressure relief valve



Turbocharger exhaust valve



Air flow signal



Intake pressure signal



Accelerator pedal signal



Intake temperature signal



Throttle angle signal



Coolant temperature signal



Engine rotating speed signal



Phase signal



Knock sensor signal



Oxygen sensor signal



Vehicle speed signal



A/C pressure signal



Brake signal



Brake vacuum degree signal (dedicated to

2.3 Introduction Functions

of

System

2.3.1 Start Control During the starting process, special calculation method will be adopted to control the charge, fuel injection, and ignition timing. At the initial phase of this process, air in the intake manifold keeps still, and intake manifold’s internal pressure reading is equal to the ambient atmosphere pressure. When the throttle is closed, the idle speed regulator is assigned a fixed parameter according to the starting temperature.

In the similar process, the given “Fuel Injection Timing” is assigned the initial injection pulse. Fuel injection volume varies according to the engine temperature, in order to facilitate the formation of oil film on the intake manifold and cylinder’s walls. Therefore, when the engine reaches a given rotating speed, thick gas mixture shall be added. Once the engine starts running, the system will immediately reduce the starting excess fuel. When the starting process ends (600…700min-1), the starting excess fuel is completely cancelled. During the engine starting process, the ignition angle is being adjusted constantly, and it varies according to engine temperature, intake temperature, and engine’s rotating speed. Note: As for vehicles with start/stop function, vehicle starting can be determined according to the vehicle gear and clutch information. If the transmission is in gear and engages with the clutch, starter running shall be prohibited.

2.3.2 Warm-up and Three-way Catalyst Converter Heating Control When the engine has been started at low temperature, cylinder charge, fuel injection, and electronic ignition will be adjusted to offset the engine’s higher torque requirements. Such a process will continue till appropriate temperature threshold has been hit. Meanwhile, speedy heating to three-way catalyst converter is most important, because speedy transformation into three-way catalyst converter running will help reduce emission of waste gas considerably. In such a working condition, ignition advance angle should be postponed, in order to heat the three-way catalyst converter by waste gas.

2.3.3 Acceleration /Deceleration Towing Astern Oil Cutoff Control

and

Some of the fuel that has been injected into the intake manifold will not duly flow into the cylinder to partake into the subsequent combustion. On the contrary, it will produce a layer of oil film on the wall of the intake manifold. With improvement of the load and extension of the fuel injection duration, fuel deposited in the oil film will increase sharply. When the throttle opening increases, some injected fuel will be absorbed by the oil film. Due to this, supplementary fuel shall be injected to prevent the gas mixture from getting thin during the acceleration process. Once the load coefficient

Electronic Fuel Injection Control System 1B-10 decreases, additional fuel included in the fuel film on the intake manifold wall will be released again. Then, injection duration must decrease during the deceleration process. Towing astern or traction condition refers to the situation in which the power at the flywheel from the engine is negative. In this case, engine friction and pump gas loss can be used to make the vehicle decelerate. When the engine stays in the towing astern or traction condition, the oil injection will be cut off to reduce the fuel consumption and waste gas emission. More importantly, the process will help protect the three-way catalyst converter. Once the rotating speed declines to the given rotating speed (above idle speed) for recovery of oil supply, the oil injection system will resume the oil supply. As a matter of fact, among the ECU’s programs there is a range for recovery of rotating speed, and it varies with change of parameters like engine temperature and engine rotating speed’s dynamic change. Also, it calculates the rotating speed to prevent it from declining to specified minimum threshold. Once the injection system resumes the oil supply, the system will begin using the initial injection pulse to supply the additional fuel, in addition to reconstructing the oil film on the intake manifold’s wall. After recovery of the fuel injection, torque-based control system will slow and stabilize the engine torque’s increase (smooth transition).

2.3.4 Idle Control At the idle speed, engine will not offer torque to the flywheel. To make sure that the engine can run stably at a low idle speed, the close-loop idle control system must maintain the balance between the torque and the engine’s “Power Consumption”, and it will generate a given power during the idling process, in order to meet different load requirements, which arise from engine crankshaft, gas distribution mechanism, and auxiliary components (like friction in the water pump). ME788 System adopts the torque-based control strategy, which, based on close-loop idle control, determines the engine torque output that is required to maintain the idling speed in any working condition. Such torque output increases with decline of the engine’s rotating speed, or vice versa. By requiring higher torque, the system makes response to the new “Interference Factor”, such as the air conditioning compressor’s start/stop or automatic transmission shift. When the engine temperature is relatively low, torque should be increased to offset more internal friction loss and/or maintain higher idling speed. All these torque output requirements are

transmitted to the torque coordinator, which will make processing calculation and obtain corresponding charge concentration, components of gas mixture, and ignition timing.

2.3 5 Close-loop Control Exhaust post-treatment in the three-way catalyst converter is an effective way to reduce density of harmful substances in the waste gas. Normally, the three-way catalyst converter is able to reduce HC, CO, and NOx by 98% ore more, and turn them into H2O, CO2, and N2. However, above-mentioned high efficiency can be realized only when the engine’s excess air factor is equal to 1 or so. In fact, the close-loop control aims to ensure that concentration of the gas mixture stays within such a range. Close-loop control system takes effect only when the oxygen sensor is installed. Oxygen sensor is used to monitor the oxygen content in the waste gas on the three-way catalyst converter’s side: thin gas mixture (λ>1) produces sensor voltage of about 100mV, and thick gas mixture (λ<1) produces sensor voltage of about 900mV. When λ is 1, the sensor voltage will incur a jumping. To the input signal, the close-loop control will make response (λ>1: too thin gas mixture, λ<1: too thick gas mixture) to modify the control variable, and modifying factor therein will serve as the multiplier to modify the fuel injection duration.

2.3.6 Evaporation Emission Control Due to transmission of external radiation heat and oil return radiation, fuel in the oil tank is heated to produce the fuel steam. Subject to the limitation of evaporation emission laws and regulations, steam brimming with lots of HC shall not be discharged into the air directly. In the system, fuel steam will be collected into the active carbon canister through the duct. When condition permits, fuel steam will be flushed and discharged into the engine to partake in the combustion process. Meanwhile, the flow rate of the flushing air current is realized by ECU that controls the carbon canister’s control valve. Only when the close-loop control system works in the close-loop condition can such a control run.

2.3.7 Knock Control By virtue of the knock sensor that is mounted at the appropriate place of the engine, the system tests the characteristic vibration resulting from the knock, and then converts the vibration into electronic signal, in order to transmit it in the ECU for handling. By adoption of special processing algorithm, ECU tests if there is knock phenomenon at every cylinder’s combustion

Electronic Fuel Injection Control System 1B-11 cycle. Once there is knock, ECU will trigger the knock close-loop control. After the knock danger is eliminated, the affected cylinder’s ignition will be gradually advanced to the preset ignition advance angle again. Knock control’s threshold is applicable to fuel of different working conditions and different grades.

2.3.8 VVT Control By controlling the intake/exhaust camshaft phase, the system can efficiently reduce the engine’s emission at low speed and improve its torque at high speed. According to the vehicle’s running condition and the driver’s driving intention, the ECU can calculate out the intake/exhaust camshaft’s target phase, as well as realize the close-loop control to the camshaft phase according to the phase information acquired from the phase sensor. Compared with the engine without VVT system, the engine with VVT system can efficiently reduce oil consumption and emission as well as raise the maximum power.

2.3.9 Idle Start/Stop Control By analyzing the driver’s driving intention, the system will realize the automatic idle stop/start at a proper time. By analyzing such information as clutch pedal, neutral gear, driving speed, brake vacuum degree, accumulator state, door, and engine compartment cover etc., idle start/stop control will determine if the automatic stop/start conditions have been met. During the normal driving process, drivers need to conduct any additional operation to realize the automatic idle stop/start. Since the idle start/stop control provides the complete vehicle with starter relay, there will be two additional functions like automatic start after stalling and starter’s failure in running when gearing chain engages (transmission is in gear and engages with clutch), which will do good to fresh drivers. In addition, the idle start/stop control can help reduce the complete vehicle’s oil consumption and gas emission.

2.4 Introduction of Troubleshooting Function

System

2.4.1 Fault Information Record Electronic control unit constantly monitors the sensor, actuator, relevant circuits, fault indicators, and accumulator voltage etc., and even the electronic control unit itself, in addition to conducting the reliability test to the sensor output signal, actuator drive signal, and internal signals

(like close-loop control, coolant temperature, knock control, idling speed control, and accumulator voltage control etc). Once there is fault at certain link or a given signal is unreliable, the electronic control unit will immediately set the fault information record in RAM fault memory, and save it in the form of fault code, which will be

Electronic Fuel Injection Control System 1B-12 displayed according to the fault occurrence sequence. According to the fault frequency, faults can be classified into “Steady-state Faults” and “Sporadic Faults” (like the faults resulting from short-lived open circuit or poor contact between connectors)

Fig. 2.4 Electronic Fuel Injection System’s Troubleshooting Principle Class6, Class7, Class11, Class12, and Class13 2.4.2 Classification of Fault Types belong to those fault types that have been defined Diagnostic Fault Path and Fault Categories by the system in a uniform manner. Diagnostic fault path (DFP) is, in fact, a sub-function for fault diagnosis that is used to inspect functions of a given sensor, actuator, or others in the EMS system. By respective diagnostic path, the fault information will be transmitted to the fault diagnosis management module, which will take corresponding actions and determine if the fault lamp should be activated or the fault should be displayed on the diagnostic unit. When a fault is detected at a given DFP, the fault diagnosis management module will make definite the fault type. Usually, the fault types include:

Definitions of Fault Types

Class2: fault is inputted into the fault memory upon taking place; DFP fault types relating to misfire are usually defined as Class 2. As for the misfire fault resulting in damage of catalyst, the MIL lamp will flash in no time to prompt the driver. As for the misfire fault resulting in deterioration of emission, if the misfire fault of corresponding extent has been fully detected in three consecutive driving cycles, the MIL lamp will be activated, and also the fault will be displayed on the diagnostic unit. If the fault fails to be confirmed or eliminated in 40 driving cycles (namely, in a warm-up cycle, E_xxx＝1, but Z_xxx ＝0), the fault information will be deleted from the fault memory. if the fault disappears before the fault confirmation and never occurs within 40 driving cycles, the fault information will be deleted from the fault memory; If the fault disappears after being confirmed, the fault information cannot be deleted from the fault memory until it does not occur within 40 warm-up cycles, and the fault priority is defined as 20. After the fault confirmation, SVS lamp is off. If the fault disappears after the fault confirmation and never occurs within three driving cycles, it means that the fault has been corrected.

In this project there are 10 fault types. Closed fault path is defined as “Class0”, namely, the fault information will not enter the fault memory, and also the diagnostic unit will not read the fault. In addition, faults of Class2, Class3, Class4, Class5,

Class3: fault is inputted into the fault memory upon taking place. After the fault confirmation, the MIL lamp is activated, and the fault confirmation needs three driving cycles, with fault being displayed on the diagnostic unit. If the fault fails to be confirmed or

B_mxdfp Maximum fault, signal goes beyond the upper limit of the normal range. B_mndfp Minimum Fault, the signal goes beyond the lower limit of the normal range. B_sidfp signal fault, without signal. B_npdfp unreasonable signal, with signal, but the signal is unreasonable.

eliminated within 40 warm-up cycles(namely, in a warm-up cycle, E_xxx＝1, but Z_xxx＝0), the fault information will be deleted from the fault memory; if the fault disappears before the fault confirmation and never occurs within 40 warm-up cycles, the fault information will be deleted from the fault memory; If the fault disappears after being confirmed, the fault information cannot be deleted from the fault memory until it does not occur within 40 warm-up cycles; and the fault priority is defined as 30; after the fault confirmation, SVS lamp is off; If the fault disappears after fault confirmation and never occurs within three driving cycles, it means the fault has been corrected.. Class4:fault is inputted into the fault memory upon taking place. After 2.5s since the fault occurs, the MIL lamp will be activated, and also the fault is displayed on diagnostic unit; If the fault fails to be confirmed or eliminated within 40 warm-up cycles(namely, in a warm-up cycle, E_xxx＝1, but Z_xxx＝0), the fault information will be deleted from the fault memory; if the fault disappears before the fault confirmation and never occurs within 40 warm-up cycles, the fault information will be deleted from the fault memory; If the fault disappears after being confirmed, the fault information cannot be deleted from the fault memory until it does not occur within 40 warm-up cycles; and the fault priority is defined as 30; after the fault confirmation, SVS lamp is off; If the fault disappears after fault confirmation and never occurs within three driving cycles, it means the fault has been corrected.. Class5:fault is inputted into the fault memory upon taking place; after the fault confirmation, MIL lamp is off; fault confirmation needs 3 driving cycles; the fault is displayed on diagnostic unit; If the fault fails to be confirmed or eliminated within 40 warm-up cycles(namely, in a warm-up cycle, E_xxx＝1, but Z_xxx＝0), the fault information will be deleted from the fault memory; if the fault disappears before the fault confirmation and never occurs within 40 warm-up cycles, the fault information will be deleted from the fault memory; If the fault disappears after being confirmed, the fault information cannot be deleted from the fault memory until it does not occur within 40 warm-up cycles; and the fault priority is defined as 40; after the fault confirmation, SVS lamp is off; If the fault disappears after fault confirmation and never occurs within three driving cycles, it means the fault has been corrected.. Class6: fault is inputted into the fault memory upon taking place; after the fault confirmation, MIL lamp is off; fault will be confirmed upon taking place; the fault is not displayed on the diagnostic unit;If the fault fails to be confirmed or eliminated within 40 warm-up cycles(namely, in a warm-up cycle, E_xxx

Electronic Fuel Injection Control System 1B-13 ＝1, but Z_xxx＝0), the fault information will be deleted from the fault memory; If the fault disappears after being confirmed, the fault information cannot be deleted from the fault memory until it does not occur within 40 warm-up cycles; and the fault priority is defined as 50; after the fault confirmation, SVS lamp is off; If the fault disappears after the fault confirmation and never occurs within 1.2s, it means the fault has been corrected. Class7:fault is inputted into the fault memory upon taking place; after the fault confirmation, MIL lamp is off; fault will be confirmed upon taking place; the fault is not displayed on the diagnostic unit;If the fault fails to be confirmed or eliminated within 40 warm-up cycles(namely, in a warm-up cycle, E_xxx ＝ 1, but Z_xxx ＝ 0), the fault information will be deleted from the fault memory; If the fault disappears after the fault confirmation, the fault information cannot be deleted from the fault memory until it does not occur within five warm-up cycles, and the fault priority is defined as 50; after the fault confirmation, SVS lamp is off; If the fault disappears after the fault confirmation and never occurs within 120ms, it means the fault has been corrected. Class11:fault is inputted into the fault memory upon taking place; after the fault confirmation, MIL lamp is activated; fault confirmation needs 3 driving cycles; the fault is displayed on diagnostic unit; If the fault fails to be confirmed or eliminated within 40 warm-up cycles(namely, in a warm-up cycle, E_xxx ＝1, but Z_xxx＝0), the fault information will be deleted from the fault memory; if the fault disappears before the fault confirmation and never occurs within 40 warm-up cycles, the fault information will be deleted from the fault memory; If the fault disappears after being confirmed, the fault information cannot be deleted from the fault memory until it does not occur within 40 warm-up cycles; and the fault priority is defined as 20; after the fault confirmation, SVS lamp is off; If the fault disappears after the fault confirmation and never occurs within 4 driving cycles, it means the fault has been corrected. Class12:fault is inputted into the fault memory upon taking place; after the fault confirmation, MIL lamp is off; fault is confirmed upon taking place, and it is not displayed on the diagnostic unit; If the fault fails to be confirmed or eliminated within 40 warm-up cycles (namely, in a warm-up cycle, E_xxx ＝ 1, but Z_xxx ＝ 0), the fault information will be deleted from the fault memory; if the fault disappears before the fault confirmation and never occurs within 40 warm-up cycles, the fault information will be deleted from the fault memory; If the fault disappears after being

confirmed, the fault information cannot be deleted from the fault memory until it does not occur within 40 warm-up cycles; and the fault priority is defined as 50; after fault confirmation, SVS lamp is activated; If the fault disappears after the fault confirmation and never occurs within 120, it means the fault has been corrected, and also the SVS is off.

Electronic Fuel Injection Control System 1B-14 pedal’s opening greater than 75%, and stepping down the brake pedal), SVS will work in blink code mode. Since the ignition switch has been turned on and the ECU embarks on initialization, SVS lamp will remain “ON” state for 4s. Then, after one second of interval, SVS will blink at the frequency of 2HZ, in order to indicate “No Fault” till the blink code request condition cannot be met.

Class13:fault is inputted into the fault memory upon taking place; after the fault confirmation, MIL lamp is activated; fault confirmation needs 3 driving cycles; the fault is displayed on diagnostic unit; If the fault fails to be confirmed or eliminated within 40 warm-up cycles(namely, in a warm-up cycle, E_xxx ＝1, but Z_xxx＝0), the fault information will be deleted from the fault memory; If the fault disappears before the fault confirmation and never occurs within 40 warm-up cycles, the fault information will be deleted from the fault memory; If the fault disappears after the fault confirmation, the fault information cannot be deleted from the fault memory until it never occurs within 40 warm-up cycles; and the fault priority is defined as 30; after fault confirmation, SVS lamp is activated; If the fault disappears after the fault confirmation and never occurs within 4 driving cycles, it means the fault has been corrected, and also the SVS lamp is off.

4) Blink code request, and there is fault in fault memory

SVS Lamp Control Strategy

2.4.3 Connection with Diagnostic Unit

In different working conditions, SVS lamps vary in working condition:

This system adopts CAN communication protocol and ISO 15031-3 standard diagnosis connector (see Fig.2.5). Such a standard diagnosis connector, in the form of bus connector, is fixed at the position between the cab’s steering shaft and the vehicle’s medial axis. Pin 4, 6, 14, and 16 of the standard diagnosis connector are used in the engine’s management system EMS. Of which, the standard diagnosis connector’s Pin 4 links with the earth wire in vehicle, Pin 6 serves as the engine data cable CAN_H’s lead, Pin 14 serves as the engine data cable CAN_L’s lead, and Pin 16 connects with the accumulator’s positive electrode.

1) No blink code request, and empty fault memory When the ignition switch is turned on, ECU will start initialization in no time. Since the initialization, SVS lamp will be turned on for 4s. If the engine is started within 4s, SVS will immediately go out if the engine’s rotating speed (B_nmot=true) has been located. 2) No blink code request, there is fault in the fault memory Since the ignition switch has been turned on and the ECU embarks on the initialization, SVS lamp will remain “ON” state until the engine’s rotating speed has been located. If the fault manager requires that SVS lamp shall be turned on in the fault mode, the SVS lamp will remain “ON” state in the subsequent driving cycle. 3)

Blink code request and empty fault memory

If the ECU blink code request condition has been met (blink code request condition: ignition switch is turned on under the precondition of no vehicle speed, no engine’s rotating speed, accelerator

If the ECU blink code request condition has been met (blink code request condition: ignition switch is turned on under the precondition of no vehicle speed, no engine’s rotating speed, accelerator pedal’s opening greater than 75%, and stepping down the brake pedal), SVS will work in blink code mode. Since the ignition switch has been turned on and the ECU embarks on initialization, SVS lamp will remain “ON” state for 4s. Then, after one second of interval, SVS will indicate the fault code (P-code) in the memory with a blink code. If all faults in the memory have been indicated by SVS lamp in the form blink codes, and blink code request condition is still met, the SVS lamp will go out till blink code request condition cannot be met.

Fig. 2.5: ISO15031-3 Standard Diagnosis Connector Through “CAN” cable, ECU can communicate with the external diagnostic unit. See GEELY Instruction on Diagnostic Unit for detailed operations of the diagnostic unit.

3 ME7’s Overhaul and Diagnosis Flow by Fault Code Explanations: 1. The overhaul cannot be executed only when current fault has been confirmed as “Steady-state” fault, or the diagnosis error will take place. 2. Multimeter required refers to the digital multimeter, and analogue multimeter shall not be used to inspect the electronic fuel injection system’s lines.

Electronic Fuel Injection Control System 1B-15 there is fault at a given circuit, it means that there likely exists open circuit or several types of faults in the circuit. Diagnosis help: 1. If the fault code cannot be cleared, the fault belongs to “Steady-state” fault. If the fault belongs to sporadic fault, emphasis should be put on the inspection to wiring connector’s looseness. 2. No abnormal inspection;

situation

after

preceding

3. In the case of overhauling the vehicle with anti-theft system, if the ECU will be replaced, programming to ECU shall be done after the replacement.

3. During the overhaul process, do not overlook other factors’ influence on the system, such as automobile maintenance, cylinder pressure, and mechanical ignition timing etc.

4. If the fault code indicates that a given circuit has too low voltage, it means that there likely exists short circuit to the earth in the circuit. If the fault code indicates that a given circuit has too high voltage, it means that there likely exists short circuit to the battery in the circuit. If the fault code indicates that

4.

INDEX PCODES

Replace ECU for further test.

If the fault code can be cleared, the fault cause should be attributed to ECU. However if the fault code cannot be cleared, remount original ECU and repeat the workflow for further overhaul work.

UAES Explanations

CLASS

MIL

SVS

1

P000A

Slow intake VVT response

5

×

×

2

P0010

VVT intake control valve circuit, open

3

√

×

3

P0012

Intake VVT fails to stay at defaulted position when starting

5

×

×

4

P0016

Improper relative position between crankshaft and camshaft

3

√

×

5

P0030

Upstream oxygen sensor heater control circuit, fault

3

√

×

6

P0031

Upstream oxygen sensor heater control circuit, low voltage

3

√

×

7

P0032

Upstream oxygen sensor heater control circuit, high voltage

3

√

×

8

P0033

Discharge control valve control circuit.

3

√

×

9

P0034

Discharge control valve control circuit voltage is too low.

3

√

×

10

P0035

Discharge control valve control circuit voltage is too high.

3

√

×

11

P0036

Downstream oxygen sensor heater control circuit, fault

3

√

×

12

P0037

Downstream oxygen sensor heater control circuit, low voltage,

3

√

×

13

P0038

Downstream oxygen sensor heater control circuit, high voltage

3

√

×

14

P0053

Upstream oxygen sensor heater resistance, improper

3

√

×

15

P0054

Downstream oxygen sensor heater resistance, improper

3

√

×

Electronic Fuel Injection Control System 1B-16 16

P006D

Environmental pressure sensor signal circuit.

3

√

×

17

P0101

Air flow meter sensor signal unreasonable.

3

√

×

18

P0102

Air flow meter sensor signal voltage is too low.

3

√

×

19

P0103

Air flow meter sensor signal voltage is too high.

3

√

×

20

P0112

Intake temperature sensor signal circuit, low voltage

3

√

×

21

P0113

Intake temperature sensor signal circuit, high voltage

3

√

×

22

P0117

Engine coolant temperature sensor circuit, low voltage

3

√

×

23

P0118

Engine coolant temperature sensor circuit, high voltage

3

√

×

24

P0121

Electronic throttle position sensor1 signal, improper

3

√

×

25

P0122

Electronic throttle position sensor1 signal circuit, low voltage

3

√

×

26

P0123

electronic throttle position sensor1 signal circuit, high voltage

3

√

×

27

P0130

Upstream oxygen sensor signal, improper

3

√

×

28

P0131

Upstream oxygen sensor signal, low voltage

3

√

×

29

P0132

Upstream oxygen sensor signal circuit, high voltage

3

√

×

30

P0133

Upstream oxygen sensor, aging

3

√

×

31

P0134

Upstream oxygen sensor circuit, signal circuit fault

3

√

×

32

P0136

Downstream oxygen sensor signal, improper

3

√

×

33

P0137

Downstream oxygen sensor signal, low voltage

3

√

×

34

P0138

Downstream oxygen sensor signal circuit, high voltage

3

√

×

35

P0140

Downstream oxygen sensor circuit, signal fault

3

√

×

36

P0170

Offline detection A/F ratio close-loop control self-learning, improper

7

×

×

37

P0171

Offline detection A/F ratio close-loop control self-learning, too lean

7

×

×

38

P0172

Offline detection A/F ratio close-loop control self-learning, too thick

7

×

×

39

P0201

Cylinder 1 fuel injector control circuit, open

3

√

×

40

P0202

Cylinder 2 fuel injector control circuit, open

3

√

×

41

P0203

Cylinder 3 fuel injector control circuit, open

3

√

×

42

P0204

Cylinder 4 fuel injector control circuit, open

3

√

×

43

P0219

Engine rotating speed exceeds the upper limitation

6

×

×

44

P0221

Electronic throttle position sensor2 signal, improper

3

√

×

45

P0222

Electronic throttle position sensor2 signal circuit, low voltage

3

√

×

46

P0223

Electronic throttle position sensor2 signal circuit, high voltage

3

√

×

47

P0234

Turbo boost control over.

3

√

×

48

P0237

Turbocharger pressure sensor signal voltage is too low.

3

√

×

Electronic Fuel Injection Control System 1B-17 49

P0238

Turbocharger pressure sensor signal voltage is too high.

3

√

×

50

P0243

Exhaust gas control valve drive circuit.

3

√

×

51

P0245

Exhaust gas control valve drive circuit voltage is too low.

3

√

×

52

P0246

Exhaust gas control valve drive circuit voltage is too high.

3

√

×

53

P0261

Cylinder 1 fuel injector control circuit’s short circuit to ground

3

√

×

54

P0262

Cylinder 1 fuel injector control circuit’s short circuit to the battery

3

√

×

55

P0264

Cylinder 2 fuel injector control circuit’s short circuit to the ground

3

√

×

56

P0265

Cylinder 2 fuel injector control circuit’s short circuit to the battery

3

√

×

57

P0267

Cylinder 3 fuel injector control circuit’s short circuit to the ground

3

√

×

58

P0268

Cylinder 3 fuel injector control circuit’s short circuit to the battery

3

√

×

59

P0270

Cylinder 4 fuel injector control circuit’s short circuit to the ground

3

√

×

60

P0271

Cylinder 4 fuel injector control circuit’s short circuit to the battery

3

√

×

61

P0299

Turbo boost control deficiencies.

3

√

×

62

P0300

Multiple Cylinders Misfire Detected

2

√or Blink

×

63

P0301

Cylinder 1 Misfire Detected

2

√or Blink

×

64

P0302

Cylinder 2 Misfire Detected

2

√or Blink

×

65

P0303

Cylinder 3 Misfire Detected

2

√or Blink

×

66

P0304

Cylinder 4 Misfire Detected

2

√or Blink

×

67

P0321

Crankshaft TDC shortage signal, improper

3

√

×

68

P0322

Rotating sensor signal, fault

3

√

×

69

P0327

Knock sensor signal circuit, low voltage

3

√

×

70

P0328

Knock sensor signal circuit high voltage

3

√

×

71

P0340

Phase sensor mounting position, improper

3

√

×

72

P0341

Phase sensor signal, improper

3

√

×

73

P0342

Phase sensor signal circuit’s short circuit to the ground

3

√

×

74

P0343

Phase sensor signal circuit’s short circuit to the battery

3

√

×

75

P0420

Three-way catalyst oxygen storage capacity, aging (excessive emission)

3

√

×

76

P0444

Canister control valve control circuit, open

3

√

×

77

P0458

Canister control valve control circuit, low voltage

3

√

×

78

P0459

Canister control valve control circuit high voltage

3

√

×

79

P0480

Cooling fan relay control circuit, open (low speed)

5

×

×

Electronic Fuel Injection Control System 1B-18 80

P0481

Cooling fan relay control circuit, open (high speed)

5

×

×

81

P0501

Vehicle speed sensor signal, fault

3

√

×

82

P0506

Idling control rotating speed, lower than target idling speed

3

√

×

83

P0507

Idling control rotating speed, higher than target idling speed

3

√

×

84

P0560

System accumulator voltage signal, improper

5

×

×

85

P0562

System accumulator, low voltage

5

×

×

86

P0563

System accumulator, high voltage

5

×

×

87

P0571

Brake switch signal circuit, fault or out-of-step correlation

5

×

×

88

P0602

Electronic control unit encoding, fault

3

√

×

89

P0604

Electronic control unit RAM, fault

3

√

×

90

P0605

Electronic control unit ROM, fault

3

√

×

91

P0606

Electronic throttle safety monitoring function, fault

3

√

×

92

P0627

Oil pump relay control circuit, open

3

√

×

93

P0629

Oil pump relay control circuit, high voltage

3

√

×

94

P0645

A/C compressor relay control circuit, open

5

×

×

95

P0647

A/C compressor relay control circuit, high voltage

5

×

×

96

P0688

Main relay’s output voltage, improper

5

×

×

97

P0692

Cooling fan relay control circuit, high voltage(low speed)

5

×

×

98

P0694

Cooling fan relay control circuit, high voltage(high speed)

5

×

×

99

P0704

Clutch pedal switch signal, improper

5

×

×

100

P1297

Throttle forward gas leak

3

√

×

101

P1336

Electronic throttle safety monitoring torque, restriction

6

×

×

102

P1427

Brake vacuum booster pump control circuit high voltage

5

×

×

103

P1429

Brake vacuum booster pump control circuit voltage Open

5

×

×

104

P1479

Brake vacuum booster pump failure

5

×

×

105

P1523

Airbag ECM sends a signal to interrupt or incorrect.

5

×

×

106

P1545

Deflection between electronic throttle’s actual location and target location exceeds limit

3

√

×

107

P1558

Electronic throttle’s starting resistance, too high

3

√

×

108

P1559

Electronic throttle’s self-learning process, fault

6

×

×

109

P1564

System voltage fails to meet electronic throttle’s self-learning condition

6

×

×

110

P1565

Electronic throttle lower position limit initialization self-learning, fault

3

√

×

111

P1568

Electronic throttle return resistance, too high

3

√

×

112

P1579

Electronic throttle self-learning condition, unsatisfied

6

×

×

Electronic Fuel Injection Control System 1B-19 113

P1604

Electronic throttle gain regulation self-learning, fault

6

×

×

114

P1615

ECM eeprom state error

35

×

Blink

115

P1616

False alarms received certification reply.

35

×

Blink

116

P1617

Did not receive anti-theft device authentication reply.(immo code resp)

35

×

Blink

117

P1618

Theft match Security Code (PIN code) entry errors

38

×

Blink

118

P1619

ECM not be burglar match

38

×

Blink

119

P1683

Airbag Communication Information unreasonable

5

×

×

120

P1912

Brake vacuum degree sensor voltage signal, higher than upper limit

5

×

×

121

P1913

Brake vacuum degree sensor voltage signal, lower than lower limit

5

×

×

122

P2088

VVT intake control valve’s short circuit to the ground

3

√

×

123

P2089

VVT intake control valve circuit’s short circuit to the battery

3

√

×

124

P2106

Electronic throttle driving stage, fault

3

√

×

125

P2122

Electronic throttle pedal position sensor1 signal, low voltage

3

√

×

126

P2123

Electronic throttle pedal position sensor1 signal, high voltage

3

√

×

127

P2127

Electronic throttle pedal position sensor2 signal, low voltage

3

√

×

128

P2128

Electronic throttle pedal position sensor2 signal, high voltage

3

√

×

129

P2138

Electronic throttle pedal position sensor signal, improper

3

√

×

130

P2177

A/F ratio close-loop control self-learning value goes beyond upper limit (middle load zone)

11

√

×

131

P2178

A/F ratio close-loop control self-learning value goes beyond lower limit (middle load zone)

11

√

×

132

P2187

A/F ratio close-loop control self-learning value goes beyond upper limit (low load zone)

3

√

×

133

P2188

A/F ratio close-loop control self-learning value goes beyond lower limit (low load zone)

3

√

×

134

P2195

Upstream oxygen sensor, aging

3

√

×

135

P2196

Upstream oxygen sensor, aging

3

√

×

136

P2261

Pressure relief valve mechanical failure

3

√

×

1137

P2270

Downstream oxygen sensor, aging

3

√

×

138

P2271

Downstream oxygen sensor, aging

3

√

×

139

U0001

CAN communication’s relevant diagnosis

3

√

×

Electronic Fuel Injection Control System 1B-20

4

ME7’s Overhaul and Diagnosis Flow by Fault Phenomenon

Preliminary inspection shall be conducted before troubleshooting by the engine’s fault phenomenon: 1. Confirm if the engine’s fault indicator runs normally; 2. Inspect the fault with fault diagnostic unit, and Confirm if there is no fault information record; 3. Confirm existence of the fault phenomenon complained by the car owner, and confirm conditions for the fault occurrence. Then, inspect the appearance: (1) Inspect if the fuel pipeline suffers leakage; (2) Inspect if the vacuum pipeline incurs rupture and distortion, and if the connection is correct; (3) Inspect if the intake pipeline suffers blockage, air leakage, compression to flat, or damage; (4) Inspect if the ignition system’s HV cable suffers breakage and aging, and if the ignition sequence is correct; (5) Inspect if the wire grounding place is clean and secure; (6) Inspect if the sensor and actuator connectors are loosed or poorly contacted. Important Reminder: If foresaid phenomenon does exist, maintenance and repair work shall be done according to the fault condition at first, or subsequent fault diagnosis and repair work will be affected. Diagnosis Help: 1.

Confirm the engine has not any fault record;

2.

Confirm existence of the complained fault phenomenon;

3.

No abnormal situation is found after preceding inspection steps have been done;

4. During the overhaul process, do not overlook other factors’ influence on the system, such as automobile maintenance, cylinder pressure, and mechanical ignition timing and fuel etc. 5.

Replace ECU for further test.

If the fault phenomenon can be cleared, the fault cause should be attributed to ECU. However if the fault phenomenon still exists, remount original ECU and repeat the workflow for further overhaul work.

Analysis of Typical Faults 1. When starting, engine fails to run or runs slowly 2. When starting, engine can run in a dragging manner but fails to start successfully 3. Difficulty in heat starting 4. Difficulty in cold starting 5. Normal rotating speed and difficulty in starting at any time; 6. Normal starting but unstable idling speed at any time; 7. Normal starting but unstable idling speed during the warm-up process 8. Normal starting but unstable idling speed after the warm-up 9. Normal starting but unstable idling speed or stalling when there is partial load (like running of air conditioning)

Electronic Fuel Injection Control System 1B-21 10. Normal starting but over high idling speed; 11. Rotating speed fails to increase or engine is stalled when being accelerated; 12. Slow response when being accelerated 13. Poor performance or lack of power when being accelerated 14. Idle start/stop function ineffective

1.

When starting, engine fails to run or runs slowly

Ordinary faulted parts: 1. Accumulator; 2. Starting motor; 3. Wiring harness or ignition switch; 4 Engine’s mechanical parts; 5 Neutral position switch; Ordinary Troubleshooting Flow: No.

Operation Steps

1

If the engine does not run, floor the clutch pedal, and make another attempt to observe if the engine can be started

Test Results

Follow-up Steps

Yes

Repair neutral position switch

No

Next step

Yes

Next step

2

Use the multimeter to inspect the voltage between the accumulator’s two wiring terminals, and inspect if the voltage ranges between 8V and 12V when the engine is starting.

No

Replace accumulator

Yes

Next step

3

Maintain the ignition switch at the start position, and use the multimeter to inspect if at the starting motor’s positive wiring terminal there is a voltage of more than 8V.

No

Repair or replace wiring harness

Yes

4

Dismantle the starting motor, inspect the starting motor’s working condition, and focus on inspecting if it suffers open circuit or gets stuck due to poor lubrication.

Repair or replace starting motor

No

Next step

Yes

Make use of lubricating oil of appropriate grade.

No

Next step

Yes

Overhaul the engine’s internal resistance

No

Diagnosis Help

5

6

If the fault only occurs in winter, inspect if the starting motor suffers excessive resistance due to inappropriate application of the engine lubricating oil and gearbox oil. Inspect if the starting motor’s running failure or slow running results from excessive mechanical resistance inside the engine.

Electronic Fuel Injection Control System 1B-22

2.

When starting, engine can run in a dragging manner but fails to start successfully

Ordinary faulted parts: 1. No oil in cylinder;2. Fuel pump;3 Rotating speed sensor;4. Ignition coil; 5. Engine’s mechanical parts. Ordinary Troubleshooting Flow: No.

Operation Steps

1

Connect with the fuel pressure gauge (front end of fuel distribution pipe assembly’s inlet tube serves as the connection point), start the engine, and inspect if the fuel pressure hovers around 350kPa.

2

Connect with the electronic fuel injection system’s diagnostic unit, and observe the “Engine Rotating Speed” data. After that, start the engine and observe if there is output of rotating signal.

3

Pull out one cylinder’s spark plug wire, and connect with the spark plug, during which make the spark plug’s electrode keep a distance of 5mm away from the engine body. Then start the engine, and inspect if there is blue/white HV spark.

4

3.

Inspect the engine cylinders’ pressure, and observe if the engine cylinders incur insufficient pressure.

Test Results

Follow-up Steps

Yes

Next step

No

Overhaul the oil supply system

Yes

Next step

No

Overhaul the rotating speed sensor’s circuit

Yes

Next step

No

Overhaul the ignition system

Yes

Rule out the engine’s mechanical faults

No

Next step

Difficulty in heat starting

Ordinary faulted parts: 1. Water in fuel;2. Fuel pump;3. Coolant temperature sensor;4. Fuel pressure regulator vacuum tube;5. Ignition coil. Ordinary Troubleshooting Flow: Test Results

No.

Operation Steps

Yes

Next step

1

Connect with the fuel pressure gauge (front end of fuel distribution pipe assembly’s inlet tube serves as the connection point), start the engine, and inspect if the fuel pressure hovers around 350kPa.

No

Overhaul the oil supply system

Yes

Next step

2

Pull out one cylinder’s spark plug wire, and connect with the spark plug, during which make the spark plug’s electrode keep a distance of 5mm away from the engine body. Then start the engine, and inspect if there is blue/white HV spark.

No

Overhaul the ignition system

Yes

3

Pull out the coolant temperature sensor’s joint, and start the engine to observe if the engine can start successfully. (or connect in series with a 300ohm resistance to replace the coolant temperature sensor at the coolant temperature sensor’s joint to observe if the engine can start successfully )

Overhaul the line or replace the sensor

No

Next step

Yes

Overhaul or

4

Inspect if the fuel pressure regulator vacuum tube gets loosened or

Follow-up Steps

Electronic Fuel Injection Control System 1B-23 replace

suffers air leakage 5

4.

Inspect the fuel condition, and observe if the fault occurs right after the oil is injected.

No

Next step

Yes

Replace fuel

No

Next step

Difficulty in cold starting

Ordinary faulted parts: 1. Water in fuel;2. Fuel pump;3. Coolant temperature sensor;4. Fuel injector;5. Ignition coil;6. Throttle body ;7. Engine’s mechanical parts. Ordinary Troubleshooting Flow: Test Results

No.

Operation Steps

Yes

Next step

1

Connect with the fuel pressure gauge (front end of fuel distribution pipe assembly’s inlet tube serves as the connection point), start the engine, and inspect if the fuel pressure hovers around 350kPa.

No

Overhaul the oil supply system

Yes

Next step

2

Pull out one cylinder’s spark plug wire, and connect with the spark plug, during which make the spark plug’s electrode keep a distance of 5mm away from the engine body. Then start the engine, and inspect if there is blue/white HV spark.

No

Overhaul the ignition system

Yes

3

Pull out the coolant temperature sensor’s joint, and start the engine to observe if the engine can start successfully. (or connect in series with a 2500ohm resistance to replace the coolant temperature sensor at the coolant temperature sensor’s joint to observe if the engine can start successfully

Overhaul the line or replace the sensor

No

Next step

Step on the accelerator lightly and observe if the engine can be easily started.

Yes

Clean throttle and idling air path

No

Next step

Dismantle the fuel injector, and use the dedicated fuel injector cleaning analyzer to inspect if the fuel injector suffers leakage or blockage.

Yes

Fault replacement

No

Next step

Inspect the fuel condition, and observe if the fault occurs right after the oil is injected.

Yes

Replace fuel

No

Next step

Yes

Rule out the engine’s mechanical fault

No

Next step

Yes

Diagnosis Help

No

Overhaul corresponding lines

4

5

6

7

8

Inspect the engine cylinders’ pressure, and observe if the engine cylinders incur insufficient pressure. Connect with the electronic fuel injection system adapter and turn on the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, 61#, and 80# pin is normal.

Follow-up Steps

Electronic Fuel Injection Control System 1B-24

5.

Normal rotating speed and difficulty in starting at any time;

Ordinary faulted parts: 1. Water in fuel;2. Fuel pump;3. Coolant temperature sensor;4. Fuel injector;5. Ignition coil;6. Electronic throttle body;7. Intake port;8. Ignition timing;9. Spark plug;10. Engine’s mechanical parts. Ordinary Troubleshooting Flow: Test Results

No.

Operation Steps

1

Inspect if the air filter suffers blockage and if the intake port suffers air leakage.

Yes

Repair intake system

No

Next step

Yes

Next step

2

Connect with the fuel pressure gauge (front end of fuel distribution pipe assembly’s inlet tube serves as the connection point), start the engine, and inspect if the fuel pressure hovers around 350kPa.

No

Overhaul the oil supply system

Yes

Next step

3

Pull out one cylinder’s spark plug wire, and connect with the spark plug, during which make the spark plug’s electrode keep a distance of 5mm away from the engine body. Then start the engine, and inspect if there is blue/white HV spark.

No

Overhaul the ignition system

Yes

Next step

4

Inspect every cylinder’s spark plug and observe if the model and clearance accord with specification.

No

Adjustment or replacement

Yes

Overhaul the line or replace the sensor

No

Next step

Step on the accelerator lightly and observe if the engine can be easily started.

Yes

Clean throttle and idling air path

No

Next step

Yes

Fault replacement

7

Dismantle the fuel injector, and use the dedicated fuel injector cleaning analyzer to inspect if the fuel injector suffers leakage or blockage.

No

Next step

8

Inspect the fuel condition, and observe if the fault occurs right after the oil is injected.

Yes

Fault replacement

No

Next step

Yes

Rule out the engine’s mechanical faults

No

Next step

Yes

Next step

No

Overhaul ignition timing

Yes

Diagnosis Help

5

6

9

Pull out the coolant temperature sensor’s joint, and start the engine to observe if the engine can start successfully.

Inspect the engine cylinders’ pressure, and observe if the engine cylinders incur insufficient pressure.

10

Inspect if the engine’s ignition sequence and ignition timing accord with specification

11

Connect with the electronic fuel injection system’s adapter, and

Follow-up Steps

Electronic Fuel Injection Control System 1B-25 turn on the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, 61#, and 80# pin is normal.

6.

No

Overhaul corresponding lines

Normal starting but unstable idling speed at any time;

Ordinary faulted parts: 1. Water in fuel;2. Fuel injector;3. Spark plug;4. Throttle body and idling bypass air path; 5. Intake port; 6. Electronic throttle body;7. Ignition timing;8. Spark plug;9. Engine’s mechanical parts. Ordinary Troubleshooting Flow: No.

Operation Steps

1

Inspect if the air filter suffers blockage and if the intake port suffers air leakage.

Test Results

Follow-up Steps

Yes

Overhaul the intake system

No

Next step

Yes

Clean or replace

No

Next step

Yes

Next step

No

Adjustment or replacement

2

Inspect if the idling regulator gets stuck.

3

Inspect every cylinder’s spark plug and observe if the model and clearance accord with specification.

4

Inspect if the throttle and idling bypass air path suffers carbon deposition.

Yes

Clean

No

Next step

Yes

Fault replacement

5

Dismantle the fuel injector, and use the dedicated fuel injector cleaning analyzer to inspect if the fuel injector suffers leakage, blockage, or excessive flow difference.

No

Next step

6

Inspect the fuel condition, and observe if the fault occurs right after the oil is injected.

Yes

Fault replacement

No

Next step

Yes

Rule out the engine’s mechanical faults

No

Next step

Yes

Next step

No

Overhaul corresponding lines

Yes

Diagnosis Help

No

Overhaul corresponding lines

7

Inspect all engine cylinders’ pressure, and observe if engine cylinders differ greatly in pressure.

8

Inspect if the engine’s ignition sequence and ignition timing accord with specification.

9

Connect with the electronic fuel injection system adapter and turn on the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, 61#, and 80# pin is normal.

Electronic Fuel Injection Control System 1B-26

7.

Normal starting but unstable idling speed during the warm-up process

Ordinary faulted parts: 1. Water in fuel;2. Coolant temperature sensor;3. Spark plug;4. throttle body’s carbon deposition; 5. Intake port;6. Engine’s mechanical parts. Ordinary Troubleshooting Flow: No.

Operation Steps

1

Inspect if the air filter suffers blockage and if the intake port suffers air leakage.

2

3

4

Inspect every cylinder’s spark plug and observe if the model and clearance accord with specification.

Inspect if the throttle body suffers carbon deposition.

Pull out the coolant temperature sensor’s joint, start the engine, and observe if the engine’s idling speed is unstable during the warm-up process.

Test Results

Follow-up Steps

Yes

Overhaul the intake system

No

Next step

Yes

Next step

No

Adjustment or replacement

Yes

Clean relevant parts and components

No

Next step

Yes

Overhaul the line or replace the sensor

No

Next step

Dismantle the fuel injector, and use the dedicated fuel injector cleaning analyzer to inspect if the fuel injector suffers leakage, blockage, or excessive flow difference.

Yes

Fault replacement

5

No

Next step

6

Step on the accelerator lightly and observe if the engine can be easily started.

Yes

Fault replacement

No

Next step

Yes

Rule out the engine’s mechanical faults

No

Next step

Yes

Diagnosis Help

No

Overhaul corresponding lines

7

8

Inspect all engine cylinders’ pressure, and observe if engine cylinders differ greatly in pressure. Connect with the electronic fuel injection system adapter and turn on the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, 61#, and 80# pin is normal.

Electronic Fuel Injection Control System 1B-27

8.

Normal starting but unstable idling speed after the warm-up

Ordinary faulted parts: 1. Water in fuel;2. Coolant temperature sensor;3. Spark plug;4、Electronic throttle body;5. Intake port;6. Engine’s mechanical parts. Ordinary Troubleshooting Flow: No.

Operation Steps

1

Inspect if the air filter suffers blockage and if the intake port suffers air leakage.

Test Results

Follow-up Steps

Yes

Overhaul the intake system

No

Next step

Yes

Next step

No

Adjustment or replacement

Yes

Clean relevant parts and components

No

Next step

Yes

Overhaul the line or replace the sensor

No

Next step

Yes

Fault replacement

5

Dismantle the fuel injector, and use the dedicated fuel injector cleaning analyzer to inspect if the fuel injector suffers leakage, blockage, or excessive flow difference.

No

Next step

6

Step on the accelerator lightly and observe if the engine can be easily started.

Yes

Fault replacement

No

Next step

Yes

Rule out the engine’s mechanical faults

No

Next step

Yes

Diagnosis Help

No

Overhaul corresponding lines

2

3

4

7

8

Inspect every cylinder’s spark plug and observe if the model and clearance accord with specification.

Inspect if the throttle body suffers carbon deposition.

Pull out the coolant temperature sensor’s joint, start the engine, and observe if the engine’s idling speed is unstable during the warm-up process.

Inspect all engine cylinders’ pressure, and observe if engine cylinders differ greatly in pressure. Connect with the electronic fuel injection system adapter and turn on the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, 61#, and 80# pin is normal.

Electronic Fuel Injection Control System 1B-28

9. Normal starting but unstable idling speed or stalling when there is partial load (like running of air conditioning) Ordinary faulted parts: 1. Air conditioning system;2. Idling speed regulator;3. Fuel injector. Ordinary Troubleshooting Flow: Test Results

No.

Operation Steps

1

Inspect if the air filter suffers blockage and if the intake port suffers air leakage.

Yes

Overhaul the intake system

No

Next step

Observe if the engine’s output power is increased when the air conditioning is turned on, namely, use the electronic fuel injection system’s diagnostic unit to observe the ignition advance angle, fuel injection pulse width and intake volume.

Yes

To step 4

No

Next step

Connect with the electronic fuel injection system’s adapter, disconnect the ECU 75# pin’s connecting line, and inspect if there is high-level signal at the wiring harness end after the air conditioning has been turned on.

Yes

Next step

No

Overhaul A/C system

Yes

Next step

No

Overhaul A/C system

Yes

Fault replacement

No

Next step

Yes

Diagnosis Help

No

Overhaul corresponding lines

2

4

Inspect if the A/C system pressure, compressor’s magnetic clutch, and A/C pressure pump are normal.

5

Dismantle the fuel injector, and use the dedicated fuel injector cleaning analyzer to inspect if the fuel injector suffers leakage, blockage, or excessive flow difference.

6

Connect with the electronic fuel injection system adapter and turn on the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, 61#, and 80# pin is normal.

Follow-up Steps

10. Normal starting but over high idling speed; Ordinary faulted parts: 1. Throttle body and idling bypass air path;2. Vacuum tube;3. Idling speed regulator;4. Coolant temperature sensor;5. Ignition timing. Ordinary Troubleshooting Flow: No.

Operation Steps

1

Inspect if the throttle cable gets stuck or over-tightened.

2

Inspect if the intake system and connected vacuum tube suffer air leakage.

Test Results

Follow-up Steps

Yes

Adjust

No

Next step

Yes

Overhaul intake system

No

Next step

Electronic Fuel Injection Control System 1B-29 3

4

Dismantle the idling speed regulator, and inspect if the throttle body, idling speed regulator, and idling bypass air path suffer carbon deposition. Pull out the coolant temperature sensor’s joint, and start the engine, and observe if the engine has over high idling speed.

5

Inspect if the engine’s ignition timing accords with specification.

6

Connect with the electronic fuel injection system adapter and turn on the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, 61#, and 80# pin is normal.

Yes

Overhaul the intake system

No

Next step

Yes

Overhaul the line or replace the sensor

No

Next step

Yes

Next step

No

Overhaul corresponding lines

Yes

Diagnosis Help

No

Overhaul corresponding lines

11. Rotating speed fails to increase or engine is stalled when being accelerated; Ordinary faulted parts: 1. Water in fuel;2. Intake pressure sensor and throttle position sensor;3. Spark plug;4. Throttle body and idling bypass air path;5. Intake port;6. Idling speed regulator;7. Fuel injector;8. Ignition timing;9. Exhaust pipe. Ordinary Troubleshooting Flow: No.

1

Operation Steps

Inspect if the air filter suffers blockage.

2

Connect with the fuel pressure gauge (front end of fuel distribution pipe assembly’s inlet tube serves as the connection point), start the engine, and inspect if the fuel pressure hovers around 350kPa when being accelerated.

3

Inspect every cylinder’s spark plug and observe if the model and clearance accord with specification.

4

Dismantle the idling speed regulator, and inspect if the throttle body, idling speed regulator, and idling bypass air path suffer carbon deposition.

5

Inspect if the intake pressure sensor, throttle position sensor, and the line are normal.

6

Dismantle the fuel injector, and use the dedicated fuel injector cleaning analyzer to inspect if the fuel injector suffers leakage or

Test Results

Follow-up Steps

Yes

Overhaul intake system

No

Next step

Yes

Next step

No

Overhaul the oil supply system

Yes

Next step

No

Adjustment or replacement

Yes

Overhaul the intake system

No

Next step

Yes

Next step

No

Overhaul the line or replace the sensor

Yes

Fault replacement

No

Next step

Electronic Fuel Injection Control System 1B-30 blockage. 7

8

Step on the accelerator lightly and observe if the engine can be easily started. Inspect if the engine’s ignition sequence and ignition timing accord with specification.

9

Inspect if the exhaust pipe can efficiently exhaust the air.

10

Connect with the electronic fuel injection system adapter and turn on the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, 61#, and 80# pin is normal.

Yes

Fault replacement

No

Next step

Yes

Next step

No

Overhaul corresponding lines

Yes

Next step

No

Repair or replace the exhaust pipe

Yes

Diagnosis Help

No

Overhaul corresponding lines

12. Slow response when being accelerated Ordinary faulted parts: 1. Water in fuel;2. Intake pressure sensor and throttle position sensor;3. Spark plug;4. Throttle body and idling bypass air path;5. Intake port; 6. Idling speed regulator;7. Fuel injector;8. Ignition timing;9. Exhaust pipe. Ordinary Troubleshooting Flow: No.

1

Operation Steps

Inspect if the air filter suffers blockage.

2

Connect with the fuel pressure gauge (front end of fuel distribution pipe assembly’s inlet tube serves as the connection point), start the engine, and inspect if the fuel pressure hovers around 350kPa when being accelerated.

3

Inspect every cylinder’s spark plug and observe if the model and clearance accord with specification.

4

Dismantle the idling speed regulator, and inspect if the throttle body, idling speed regulator, and idling bypass air path suffer carbon deposition.

5

Inspect if the intake pressure sensor, throttle position sensor, and the line are normal.

6

Dismantle the fuel injector, and use the dedicated fuel injector cleaning analyzer to inspect if the fuel injector suffers leakage or blockage.

Test Results

Follow-up Steps

Yes

Overhaul intake system

No

Next step

Yes

Next step

No

Overhaul the oil supply system

Yes

Next step

No

Adjustment or replacement

Yes

Overhaul the intake system

No

Next step

Yes

Next step

No

Overhaul the line or replace the sensor

Yes

Fault replacement

No

Next step

Electronic Fuel Injection Control System 1B-31 7

Step on the accelerator lightly and observe if the engine can be easily started.

8

Inspect if the engine’s ignition sequence and ignition timing accord with specification.

9

Inspect if the exhaust pipe can efficiently exhaust the air.

10

Connect with the electronic fuel injection system adapter and turn on the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, 61#, and 80# pin is normal.

Yes

Fault replacement

No

Next step

Yes

Next step

No

Overhaul the ignition system

Yes

Next step

No

Repair or replace the exhaust pipe

Yes

Diagnosis Help

No

Overhaul corresponding lines

13. Poor performance or lack of power when being accelerated Ordinary faulted parts: 1. Water in fuel;2. Intake pressure sensor;3. Spark plug;4. Ignition coil;5. Throttle body ;6. Intake port;7. Fuel injector;8. Ignition timing;19. Exhaust pipe. Ordinary Troubleshooting Flow: No.

Operation Steps

1

Inspect if there are faults like clutch slippage, low tire pressure, incorrect size of brake dragging tire, and incorrect four-wheel positioning etc.

Test Results

Follow-up Steps

Yes

Repair

No

Next step

Yes

Overhaul the oil supply system

No

Next step

Yes

Next step

3

Connect with the fuel pressure gauge (front end of fuel distribution pipe assembly’s inlet tube serves as the connection point), start the engine, and inspect if the fuel pressure hovers around 350kPa when being accelerated.

No

Overhaul the oil supply system

Yes

Next step

4

Pull out one cylinder’s spark plug wire, and connect with the spark plug, during which make the spark plug’s electrode keep a distance of 5mm away from the engine body. Then start the engine, and inspect if the HV spark’s intensity is normal.

No

Overhaul the ignition system

Yes

Next step

5

Inspect every cylinder’s spark plug and observe if the model and clearance accord with specification.

No

Adjustment or replacement

Yes

Overhaul the intake system

No

Next step

Yes

Next step

No

Overhaul the line or replace the

2

6

7

Inspect if the air filter suffers blockage.

Inspect if the throttle body and air path suffer carbon deposition.

Inspect if the intake pressure sensor and throttle line are normal.

Electronic Fuel Injection Control System 1B-32 sensor Yes

Fault replacement

8

Dismantle the fuel injector, and use the dedicated fuel injector cleaning analyzer to inspect if the fuel injector suffers leakage or blockage.

No

Next step

9

Step on the accelerator lightly and observe if the engine can be easily started.

Yes

Fault replacement

No

Next step

Yes

Next step

10

Inspect if the engine’s ignition sequence and ignition timing accord with specification.

No

Overhaul the ignition system

Yes

Next step

No

Repair or replace the exhaust pipe

11

Inspect if the exhaust pipe can efficiently exhaust the air.

14. Idle start/stop function ineffective Ordinary faulted parts: 1. Engine compartment cover signal;2. Driver door signal;3. Clutch switch signal;4.Neutral position signal;5. Accelerator pedal;6. Brake vacuum degree signal;7. Accumulator sensor. Note: If the engine has been started, start/stop indicator blinks in yellow color and turns into yellow, indicating the system has located relevant part faults, and the faults shall be diagnosed and repaired in the repair factory. Ordinary Troubleshooting Flow: 1.

Start/stop indicator is green, but the engine cannot stop automatically

No.

Operation Steps

Test Results

Follow-up Steps

Yes

System is right staying in the normal “Automatic Stop Prohibited” condition.

No

Next step

Yes

Inspect the accelerator pedal

2

Inspect if the idling speed is a little bit high after the accelerator has been released, and the normal idling speed should be 700 rpm(depending on specific project).

No

Next step

After the engine stops, the gearbox stays in the gear-engaging state, and then floor the clutch and turn the key to observe if the engine can be started.

Yes

Next step

3

No

Overhaul the clutch switch

1

If it is in green indicator blinking state or turns into yellow lamp now and then.

2. After a period of driving (coolant temperature surpasses 75℃), start/stop indicator remains yellow, and inspect if the accumulator temperature (ambient temperature) is excessively low (below 0℃, specific temperature)

Electronic Fuel Injection Control System 1B-33

5 Functional Requirements on ME7 System’s Diagnostic Unit Functions required: I.

Self-diagnosis

Mostly including: read fault code, and clear fault code; II.

System Parameter Display

Mostly including: including: water temperature, air intake temperature, throttle opening, engine rotating speed, ignition angle, A/F ratio short-term modification, A/F ratio long-term plus and multiplication modification, intake pressure, intake flow, oxygen sensor signal, system voltage, and torque demand value etc; III. System Modes Mostly including: display of 10 modes like programming, cooling system, stable working condition, dynamic working condition, emission control, oxygen sensor, idling speed, fault indicator, emergency operation, and air conditioning etc. IV. Actuator Test Mostly including: six function tests on fault indicator, fuel pump, air conditioning relay, fan control, ignition test, and single-cylinder oil interruption; V.

System Initialization Resetting (self-adaption stop resetting)

After being stalled, engine will send the initialization directive, and the system will stop resetting previous self-adaption. VI. Speedometer Mostly including: display of vehicle driving mileage and driving time; VII. Version Information Mainly including: display of car frame number (optional), ECU hardware number, and ECU software number

5.1 Parts Mounting Torque Specification Table No.

Part Name

Mounting Torque (N·m)

1

Intake air pressure and temperature sensor

3.3

2

Coolant temperature sensor

20 (Max)

3

Knock sensor

20±5

4

Oxygen sensor

50±10

5

Rotating speed sensor

8±2

6

Phase sensor

8±0.5

7

Magnetic fuel injector

6

Electronic Fuel Injection Control System 1B-34

5.2 Electronic Fuel Injection System Maintenance Specification 5.2.1 Family Vehicle Note: 1. This maintenance specification is only tailored to family vehicles; 2. Maintenance interval depends on the speedometer reading or time interval, and the one that expires first shall prevail. 3. Maintenance specification is based on the presumption that the automobile is used according to the normal design, and so it shall be strictly observed. Mileage x1000km

10

20

30

40

50

60

70

80

Month

3

6

9

12

15

18

21

24

Items

Ignition Coil

I

I

I

I

Ignition Cam

I

I

I

I

Ignition Cap

I

I

I

I

Ignition Wire

I

I

I

I

Spark Plug

I

I

I

R

Ignition Timing

I

I

I

I

Engine Idling Speed

I

I

I

I

Fuel Tank

I

C

Fuel Filter

R

R

R

R

Fuel Injector

C*

C*

C*

C*

Air Filter

I

R

I

R

EWD or Stepper Air Bypass

C

C

C

C

Throttle Body

C

C

C

C

Emission Check

I

I

I

I

Check by Diagnostic Tool

I

I

I

I

Electronic Fuel Injection Control System 1B-35

5.2.2 Vehicle for Lease Explanation: 1.

This maintenance specification is applicable to the vehicle for lease;

2.

Maintenance interval depends on the speedometer reading or time interval, and the one that expires first shall prevail.

3.

Maintenance specification is based on the presumption that the automobile is used according to the normal design, and so it shall be strictly observed. Mileage x1000km

20

40

60

80

100

120

140

160

Month

3

6

9

12

15

18

21

24

Ignition Coil

I

I

I

I

I

I

I

I

Ignition Cam

I

I

I

I

I

I

I

I

Ignition Cap

I

I

I

I

I

I

I

I

Ignition Wire

I

I

I

I

I

I

I

I

Items

Spark Plug

I

R

I

R

Ignition Timing

I

I

I

I

Engine Idling Speed

I

I

I

I

Fuel Tank

C

C

Fuel Filter

R

R

R

R

R

R

R

R

Fuel Injector

C*

C*

C*

C*

C*

C*

C*

C*

Air Filter

I

R

I

R

I

R

I

R

EWD or Stepper Air Bypass

I

C

I

C

I

C

I

C

Throttle Body

I

C

I

C

I

C

I

C

Emission Check

I

I

I

I

Check by Diagnostic Tool

I

I

I

I

Note:

R-Replace C-Clean I- Inspect (Replace the spare parts when find out failure in inspection.) C- The maintenance of fuel injector had better clean by a special tool -- fuel injector cleaner

Fuel System 1C-1

Chapter 3 Fuel System Table of Contents 1. Fuel System ································································································1C-2 1.1 Preparatory Work before Repair ··································································· 1C-2 1.1.1 Work Safety Steps ············································································ 1C-2 1.2 Inspection to Fuel Leakage········································································· 1C-2 1.2.1Fuel Hose Mounting··········································································· 1C-2 1.3 Cylinder Dismantling /Mounting ·································································· 1C-3 1.3.1Cylinder Air Tightness Test ·································································· 1C-4 1.3.2 Inspection of Check Valve ··································································· 1C-5 1.3.3 Inspection of Fuel Cylinder Pipeline Pressure ············································ 1C-5 1.3.4 Inspection of Fuel Pressure Maintenance·················································· 1C-6 1.4 Fuel Pump Assembly Dismantling /Mounting··················································· 1C-8 1.4.1 Fuel pump cover removal instructions ····················································· 1C-8 1.4.2 Fuel pump cover installation instructions ················································· 1C-8 1.4.3 Split fuel pump parts / assembly···························································· 1C-8 1.5 Spray Nozzle Dismantling /Mounting ···························································· 1C-11 1.5.1 Inspection of Spray Nozzle ·································································· 1C-11 2. Fuel Vaporation and Absorption System ·······························································1C-11 2.1 Inspection of Carbon Canister Assembly························································· 1C-11 2.1.1 Inspection of Carbon Canister’s Electromagnetic Valve ································ 1C-11 2.2 Inspection of Ventilation Condition ······························································· 1C-12 2.3 Inspection of Open/Short Circuit·································································· 1C-12 3. Dismantling the fuel pump assembly diagram ····················································1C-12 3.1 Demolition relief valve assembly ································································· 1C-12 3.2 Demolition Fuel quantity sensor ·································································· 1C-13 3.3 Demolition pump plug ·············································································· 1C-13 3.4 Demolition of the fuel hose fixed widget ······················································· 1C-13 3.5 Demolition fuel pump at the bottom case ························································ 1C-14 3.6 Demolition prefilter, pump core, fine filter ······················································ 1C-14

Fuel System 1C-2 Caution

1. Fuel System 1.1 Preparatory Work before Repair

 Wrong connection with other wiring terminals may lead to fault, and so caution is needed during the connection process.

Warning

1.

 Fuel vapor is dangerous and combustible, which may lead to personnel injury and property loss. Due to this, avoid spark or naked flame at the place where there is fuel.  Fuel overflow or leakage is dangerous, and the fuel is combustible, which may lead to personnel injury and property loss. In addition, the fuel has side effect on the skin and eye. Due to this, work safety rules shall be observed during the working process. Notice:  Even if the engine does not run, fuel in the fuel system still stays within the high pressure state. 1.1.1 Work Safety Steps 1. 2.

Dismantle the oil cylinder head, and release the pressure from the oil cylinder. Pull out the fuel pump relay (located in the electrical box at the centre of the engine compartment).

3.

Start the engine.

4.

Restart the engine several times after the engine stalls.

5.

Turn the ignition switch to the “OFF” position.

6.

Reload the fuel pump relay.

Connect the DLC’s wiring terminal F/P with the vehicle body (as the ground) with a jumper wire.

Jumper Wire

2.

Turn the ignition switch to the “ON” position to run the oil pump.

3.

Pressurize the oil circuit for at least five minutes according to preceding method, so as to inspect if there is leakage.

4.

In the event that there is fuel leakage, inspect if fuel hose and fuel pipe’s sealing faces suffer damage. If necessary, replace them.

5.

After the overhaul and remounting, repeat Step 1 to Step 3.

1.2.1 Fuel Hose Mounting 1.

Replace the damaged and distorted fuel hose, fuel pipe, and pipe clamp.

2.

Fuel hose shall be mounted 25mm {0.98in} above the fuel pipe, and if the fuel pipe has limit device, mount the hose till it contacts the limit device.

1.2 Inspection Work after Maintenance Warning Fuel Pipe

 Fuel overflow or leakage is dangerous, and also the fuel is combustible, which may lead to personnel injury and property loss. Due to this, follow the under-mentioned “Fuel Leakage Inspection” to conduct inspection after remounting the fuel hose.

Inspection to Fuel Leakage Warning  Fuel overflow or leakage is dangerous, and also the fuel is combustible, which may lead to personnel injury and property loss. Due to this, fuel leakage shall be inspected frequently after the engine stops.

3.

Fuel Hose Limit Device

Use the pipe clamp to clamp the hose within the mounting range (see the figure below), and prevent the clamp from nipping previous nipping place.

Fuel System 1C-3 1.

Inspect the fuel pipeline and supporting pipeline joint’s sealing faces and avoid their damage and distortion. If necessary, replace them.

2.

If the quick plug O-ring is damaged or disengaged, mount the new fuel pipeline.

3.

Push the fuel pipeline quick plug into the loading part till the pipe joint makes the “click” sound.

4.

If the fuel pipeline quick plug is equipped with double-lock mechanism, mount the double locks till there is “click” sound.

5.

Pull the quick plug with hands to confirm if it has been secured mounted.

Avoid nipping previous nipping place

Warning on Plastic Fuel Pipe (fuel supply pipe assembly, fuel supply pipe, and fuel return pipe assembly) Dismantling  When dismantling the fuel pipe, pressure in the fuel system will lead to ejection of fuel from the fuel pipeline, and so oil cylinder head shall be dismantled in advance according to requirements while dismantling the fuel pipeline, in order to release the pressure in the oil cylinder and avoid personnel injury and property loss.

Explanations on fuel filter dismantling /mounting Warning :

Caution

The fuel filter is integrated in the fuel pump assembly, disassembly, repair shop to replace HAIMA.

 While dismantling the fuel pipeline, necessary sheltering measures shall be adopted, in order to avoid the fuel’s ejection onto your body. 1.

2. 3.

If the quick plug assembly is equipped with double-lock mechanism, loosen the quick plug assembly’s double locks along the direction illustrated in the figure.

Pinch locking devices on both sides of the quick plug with fingers to remove the quick plug. Repeat Step 1 and Step 2, and dismantle the quick plug at the other end of the fuel pipeline from the supporting pipeline.

1.3 Cylinder Dismantling /Mounting Warning  Unwashed cylinder is dangerous and may lead to combustion or explosion, which will further result in serious casualties. Due to this, cylinder shall be cleaned with vapor before the overhaul.  Fuel overflow or leakage is dangerous, and the fuel is combustible, which may lead to personnel injury and property loss. Due to this, do not damage the sealing face while dismantling/ mounting the oil pump assembly. Caution

Explanations on Plastic Fuel Pipe (Fuel Supply Pipe Assembly, Fuel Supply Pipe, and Fuel Return Pipe) Mounting

 Dismantling/mounting quick connector before cleaning will lead to damage of the fuel pipe and quick connector. Due to this, cleaning is a must before dismantling /mounting, in order to make sure that no foreign objects enter the fuel pipe and connector.

Notice

1.

Park the vehicle stably on the lifting machine.

When mounting the new fuel supply pipe assembly, assemble properly double locks on the quick plug assembly.

2.

Complete preparatory work before repair (see Preparatory Work before Repair).

3.

Loosen the accumulator’s negative cable.

4.

Dismantle the second-row seats (see Part S,

Fuel System 1C-4 Seat, Second-row /Mounting).

Seats

Dismantling

5

Fuel pump cover

SA12-42-161

5.

Dismantle the cylinder repair cover plate.

6

Hose clamp

S05B-42-239L1

6.

Dismantle all fuel pipes that connect with the oil pump.

7

Refueling hose

SA12-42-231

8

Fuel tank straps (R)

SA12-42-720

9

Refueling pipe

SA12-42-211

11

Dust cover

SA12-42-240

10

Cap-filler

FA1A-42-250

12

Bolt

HQ99786-0816

13

Elastical clamp

HQ99283-1900

14

Breather hose

SA12-42-232

15

Canister bracket

SA12-13-960

16

Canister

SA12-13-96Z

17

Bolt

HQ99786-0820

18

Elastical clamp

HQ99283-1100

19

Snorkel

SA12-13-963

20

Desorption canister hose

SA12-20-374

21

Pipe clip

SA12-45-914

22

Fuel tank

SA12-42-111

23

Fuel tank tie (left)

SA12-42-710

24

Fuel tank insulation panels

SA12-42-741

25

Screw

HQ99845-0510

26

Hose

SA12-20-377

27

Fuel supply pipe assembly

SA12-13-49X

28

Hose

SA12-20-376

29

Clip

SA12-45-911

30

Fuel hard tube

SA12-45-110

31

Hard tube evaporator

SA12-45-711

32

Elastical clamp

HQ99283-1300

7.

Drain fuel in the cylinder.

8.

Life the vehicle with lifting machine and dismantle parts according to sequence illustrated in the figure.

9.

Mount parts according to the sequence reverse to the dismantling process.

10. Complete inspection work after the repair (see Inspection Work after Repair)

No.

Part name

Part No.

1

Bolt

HQ90786-1030

2

Fuelsupply pipe

SA12-42-61X

3

Fuel pump gasket

SA12-42-166

4

Fuel pump

SA12-13-35Z

Torq ue

36.353.9

R e m ar k

20.032.0

Fuel System 1C-5

1.3.1 Cylinder Air Tightness Test Notice  Cylinder air tightness test is used to test the welding quality between parts (like the upper oil filling port, exhaust port, and gravity valve) and the cylinder body. 1.

Dismantle the cylinder mounting assembly (see the Cylinder Dismantling/Mounting).

2.

Block the special blanking plug (dedicated to main fuel pipe) on the fuel pump assembly.

3.

Use special blanking plug to block the gravity valve vapor hose’s joint on the cylinder body.

4.

Connect the special air pressure test tool with the cylinder’s oil filling port and exhaust port.

5.

Put the cylinder horizontally into the special water tank dedicated to cylinder test (the total cylinder shall be immersed 100mm below the water surface).

6.

Charge compressed air into the cylinder’s oil filling port, and pressurize the cylinder to (30～50)kPa. Then, maintain the pressure for 1min.

7.

Inspect if there is air bubble between the parts (like oil filling port, exhaust port, and gravity valve) and the cylinder’s welding face.



If there is air bubble on the welding face, replace the cylinder (see Cylinder Dismantling/Mounting)

1.3.2 Inspection of Check Valve 1. Check the direction of welding welding direction ICV logo on the body with the fuel tank logo are aligned, if not aligned, then weld failed. 2.

The role of the baffle is to prevent anti-jet fuel, while the pressure drop is not too large, to avoid early to jump the gun, and therefore whether the rebound pressure baffle is designed to reflect the performance by refueling. ICV welded to the tank, can not repair.

1.3.3 Inspection of Fuel Cylinder Pipeline Pressure Warning  Fuel overflow or leakage is dangerous, and the fuel is combustible, which may lead to personnel injury and property loss. In addition, the fuel has side effect on the skin and eye. Caution  Dismantling/mounting quick connector before cleaning will lead to damage of the fuel pipe and quick connector. Due to this, cleaning to the quick connector’s contacting zone is a must before dismantling /mounting, in order to make sure that no foreign objects enter the fuel pipe and connector. Notice:  The following tests can be conducted if necessary 1.

Complete preparatory work before repair (see Preparatory Work before Repair)

2.

Loosen the accumulator’s negative cable.

Caution  To avoid the quick connector’s damage or oil leakage, follow the “Explanations on plastic

Fuel System 1C-6 fuel pipe dismantling” to complete the under-mentioned work (see the Fuel System, Explanations on Plastic Fuel Pipe Dismantling) 3.

Dismantle the main fuel hose (fuel supply pipe assembly) from the main pipe (fuel rigid pipe).

4.

Connect the special tool’s quick connector with the fuel distributor(fuel rail), and insert the fuel supply pipe assembly onto the special tool’s interface.



If the pressure is higher than the standard value, inspect the fuel pump’s maximum pressure



If the pressure is normal, inspect if the oil return pipe and pressure regulator suffer blockage.

 If the pressure is lower than standard value, turn the switch handle and measure the oil pressure’s variation (see the figure). —If the oil pressure rises speedily, inspect the pressure regulator. —If the oil pressure rises slowly, inspect the oil pressure’s maximum value.

Switch handle

To main pipe Fuel distributor

 If the oil pump’s maximum pressure is normal, inspect if the oil circuit between the oil pump and pressure regulator suffers blockage.

Switch handle

To main pipe Fuel distributor

5.

Remount the accumulator’s negative cable.

Caution  Wrong connection with other wiring terminals may lead to fault, and so caution is needed during the connection process. 6.

Connect the DLC’s wiring terminal F/P with the Vehicle body’s earthing point GND with a jumper wire.

9.

Dismantle the special tool unit.

Caution 

Earthing jumper

To avoid the quick connector’s damage or oil leakage, follow the “Explanations on plastic fuel pipe dismantling” to complete the under-mentioned work (see the Cylinder Dismantling/Mounting, Explanations on Plastic Fuel Pipe Dismantling)

10. Connect the main fuel hose (fuel supply pipe assembly) and the main pipe (fuel rigid pipe) 7.

Turn the ignition switch to “ON” position to make fuel pump run, and measure the pipeline’s maximum oil pressure. Standard value 390～410kpa

8.

Turn the ignition switch to the “OFF” position and loosen the jumper wire.

11. Complete the inspection work after repair (see Inspection Work after Repair).

1.3.4 Inspection Maintenance

of

Fuel

Pressure

Warning 

Fuel overflow or leakage is dangerous, and the fuel is combustible, which may lead to personnel injury. In addition, the fuel has side effect on the skin and eye.

Fuel System 1C-7 Caution 

7.

Dismantling/mounting quick connector before cleaning will lead to damage of the fuel pipe and quick connector. Due to this, cleaning to the quick connector’s contacting zone is a must before dismantling /mounting, in order to make sure that no foreign objects enter the fuel pipe and connector.

Connect the DLC’s wiring terminal F/P with the Vehicle body’s earthing point GND with a jumper wire.

Earthing jumper

Notice: 

The following tests can be conducted if necessary

1.

Complete preparatory work before repair (see Preparatory Work before Repair)

2.

Loosen the accumulator’s negative cable.

Caution 

To avoid the quick connector’s damage or oil leakage, follow the “Explanations on plastic fuel pipe dismantling” to complete the under-mentioned work (see the Fuel System, Explanations on Plastic Fuel Pipe Dismantling)

8.

Turn the ignition switch to the “ON” position for about 10s, in order to make the fuel pump run.

9.

Turn the ignition switch to the “OFF” position and loosen the jumper wire.

10. Observe the oil pressure after 60 minutes. 

If the oil pressure is lower than the standard value, observe the oil pressure’s variation while rotating the switch handle

3.

Dismantle the main fuel hose (fuel supply pipe assembly) from the main pipe (fuel rigid pipe).

—If the oil pressure maintains unchanged, replace the pressure regulator (see Pressure Regulator Dismantling/Mounting)

4.

Connect the special tool’s quick connector with the fuel distributor (fuel rail), and insert the main fuel hose (fuel supply pipe assembly) onto the special tool’s interface.

—If the oil pressure is changed, inspect if the oil circuit and spray nozzle suffer oil leakage.

Rotate the switch handle along the direction illustrated in the figure.

≥250kpa(2.5kgf/cm2, 36psi)

5.

Standard value:

Switch handle

To main pipe Fuel distributor

6.

Remount the accumulator’s negative cable.

To main pipe

Switch handle

Fuel distributor

11. Loosen the special tool unit.

Caution

12. Connect the main fuel hose with main fuel pipe.

 Wrong connection with other wiring terminals may lead to fault, and so caution is needed during the connection process.

13. Complete the inspection work after repair (see Inspection Work after Repair).

Fuel System 1C-8

1.4 Fuel Pump Assembly Dismantling /Mounting Warning Fuel is a combustible liquid is very strong, and if the fuel spilled from the pressurized fuel system will result in serious injury or death, while also causing facilities were destroyed, oil can irritate the skin and eyes, in order to avoid this case, be sure to perform "Fuel pipeline safety program," while referring to "maintenance precautions." Fuel is a very strong combustible liquids, if spilled or leaked from the fuel pressure in the fuel system, it will cause serious injury or death, while also causing facilities were destroyed, oil can irritate the skin and eyes, in order to To avoid this situation, the fuel pump components prior removal / installation, be sure to perform "After the installation of the fuel pump assembly fuel leak check." 1. Before performing any operations, comply with "maintenance before precautions" to avoid spilling fuel from the fuel system. 2. Disconnect the negative battery cable. 3. Remove the fuel tank. 4. In the order shown in the table to be demolished.

1.4.2 Fuel pump cover installation instructions 1. Fuel tank and the fuel pump so that the alignment marks in the alignment member, as shown in Fig.

1

Quick release connectors

2. As shown in FIG. Fixed SST.

2

Fuel pump cover

3

Fuel pump parts

Using SST accordance with the provisions of the tightening torque to tighten the fuel pump cover, but can not move the alignment mark.

5. According to the order the demolition phase side installation.

4 . If you can not achieve the required tightening torque, replace the fuel pump cover. 5 . If after replacing the fuel pump cover can not achieve the required tightening torque, replace the tank.

6. Through the implementation of "post-maintenance considerations" to check all relevant components. 1.4.3 Split fuel pump parts / assembly

1.4.1 Fuel pump cover removal instructions Notice: In using the SST time, if there is a gap between the fuel pump cover and SST, then the fuel pump cover may be damaged, the SST fixed so that the SST tabs with no gap between the fuel pump side cover. Removing the fuel pump cover using the SST.

Explanation： Can not be split fuel pump components.

Inspection of Fuel Pump Assembly Simulation Test Inspect the fuel pump’s working condition (see Fault Diagnosis, Inspection of Engine Control System’s Working Condition, Inspection of Fuel Pump’s Working Condition).

Fuel System 1C-9 

If the condition is abnormal, conduct further inspection to the fuel pump assembly.

Inspection of Conducting/Non-conducting State Notice

Short Circuit  The circuit between the fuel pump assembly connector B and fuel pump relay connector E, in which there is public connector and ground short circuit (electrical ground) 2.

Remount the fuel pump assembly connector.

3.

Remount the oil tank’s repair cover plate.

Loosen the accumulator’s negative cable.

4.

2.

Remove the second-row seats (see Seats, Second-row Seats Dismantling /Mounting).

Remount the second-row seats (see Seats, Second-row Seats Dismantling /Mounting).

5.

Remount the accumulator’s negative cable.

3.

Dismantle the oil tank’s repair cover plate.

4.

Loosen the fuel pump assembly’s connector.

Inspection of Fuel Pump’s Maximum Pressure

5.

Inspect the conducting/non-conducting state between fuel pump or connector’s wiring terminal B and wiring terminal D. If it is in conducting state but the simulation test is abnormal, inspect if the circuit suffers short/open circuit. If it is in non-conducting state, replace the fuel pump assembly.



Inspection necessary

1.

below

can

be

conducted

if

Warning  Fuel overflow or leakage is dangerous, and the fuel is combustible, which may lead to personnel injury and property loss. Due to this, under-mentioned operations shall not be started until the engine stops. Caution  Dismantling/mounting quick connector before cleaning will lead to damage of the fuel pipe and quick connector. Due to this, cleaning to the quick connector’s contacting zone is a must before dismantling /mounting, in order to make sure that no foreign objects enter the oil pipe and connector.

Inspection of Open/Short Circuit 1.

Inspect if there is open/short circuit on the following wiring harnesses. If there is, repair or replace corresponding wiring harness:

Open Circuit  Earting circuit (between fuel pump assembly’s connector D and the vehicle body GND)  Power circuit (between the fuel pump relay connector A and fuel pump assembly connector B, and there is public connector) Fuel pump relay

Notice  The following tests can be conducted if necessary 1.

Complete preparatory work before repair (see Preparatory Work before Repair)

2.

Loosen the accumulator’s negative cable.

Caution  To avoid the quick connector’s damage or oil leakage, follow the “Explanations on plastic fuel pipe dismantling/ mounting” to complete the under-mentioned work (see the Fuel System, Explanations on Plastic Fuel Pipe Dismantling) 3.

Dismantle the main fuel hose (fuel supply pipe assembly) from the main pipe (vaporation rigid pipe).

4.

Turn the switch handle to the position illustrated in the figure to block the special tool’s port.

Fuel System 1C-10 5.

Push the special tool’s quick connector into the main pipe (fuel rigid pipe) till there is a “click” sound.

6.

Put the hose into a vessel in order to avoid the fuel overflow.

 To avoid the quick connector’s damage or oil leakage, follow the “Explanations on plastic fuel pipe dismantling” to complete the under-mentioned work (see the Fuel System, Explanations on Plastic Fuel Pipe Dismantling) 12. Remount the main fuel hose (fuel supply pipe assembly). 13. Complete the inspection work after repair (see Inspection Work after Repair)

Inspection of Fuel Pump Oil Pressure Maintenance Warning

7.

Remount the accumulator’s negative cable.

Caution  Wrong connection with other wiring terminals may lead to fault, and so caution is needed during the connection process. 8.

Connect the DLC’s wiring terminal F/P with the vehicle body’s earthing point GND with a jumper wire. Jumper wire

 Fuel overflow or leakage is dangerous, and the fuel is combustible, which may lead to personnel injury and property loss. Due to this, under-mentioned operations shall not be started until the engine stops. Caution  Dismantling/mounting quick connector before cleaning will lead to damage of the fuel pipe and quick connector. Due to this, cleaning to the quick connector’s contacting zone is a must before dismantling /mounting, in order to make sure that no foreign objects enter the oil pipe and connector. Notice  The following tests can be conducted if necessary

9.

Turn the ignition switch to the “ON” position to make the fuel pump run, and measure the fuel pump’s maximum output oil pressure.

Fuel pump’s maximum output oil pressure: 650～ 900kpa 10. Turn the ignition switch to the “OFF” position and loosen the jumper wire. If the maximum output oil pressure goes beyond the specified range, inspect items below: —Fuel pump relay (see Inspection of Fuel Pump Relay) —If the fuel filter (LV, HV) suffers blockage.

1.

Complete preparatory work before repair (see Preparatory Work before Repair).

2.

Loosen the accumulator’s negative cable.

Caution  To avoid the quick connector’s damage or oil leakage, follow the “Explanations on plastic fuel pipe dismantling” to complete the under-mentioned work (see the Fuel System, Explanations on Plastic Fuel Pipe Dismantling) 3.

Dismantle the main fuel hose (fuel supply pipe assembly) from the main pipe (fuel rigid pipe).

4.

Turn the switch handle along the direction illustrated in the figure to block the special tool’s port.

5.

Push the special tool’s quick connector into the main pipe (fuel rigid pipe) till there is a “click” sound.

—If the fuel pipeline suffers blockage or leakage. 11. Dismantle the special tool. Caution

Fuel System 1C-11 6.

Put the hose into a vessel in order to avoid the fuel overflow. Air hose

Main fuel pipe

1.5 Spray Nozzle Dismantling /Mounting (see the Control System)

1.5.1 Inspection of Spray Nozzle (see the Control System)

Switch handle

7.

2 Fuel Vaporation and Absorption System Location of Combustion Vaporation & Absorption System’s Components (in Engine Compartment)

Remount the accumulator’s negative cable.

Caution  Wrong connection with other wiring terminals may lead to fault, and so caution is needed during the connection process. 8.

Connect the DLC’s wiring terminal F/P with the vehicle body’s earthing point GND with a jumper wire.

Earthing jumper

2.1 Inspection Assembly

of

Carbon

Canister

1.

Remove the carbon canister.

2.

Block the interface on the carbon canister’s ventilation side and the interface on the carbon canister’s electromagnetic valve side.

3.

10. Turn the ignition switch to the “OFF” position. After 5 minutes, inspect the fuel pump’s oil pressure maintenance.

Blow air into the carbon canister’s oil tank interface, and Confirm if there is no air leakage (If there is air leakage, replace carbon canister).

Fuel pump’s oil pressure maintenance: ＞ 410kpa(4.1kgf/cm2, 59psi)

2.1.1 Inspection of Carbon Canister’s Electromagnetic Valve

11. Loosen the jumper wire.

Conduct simulation test

12. Remove the special tool.

Inspect the carbon canister’s electromagnetic valve (see Fault Diagnosis, Inspection of Engine Control System’s Working Condition, Inspection of Carbon Canister’s Electromagnetic Valve); if it is abnormal, conduct further inspection to the carbon canister’s electromagnetic valve.

9.

Turn the ignition switch to the “ON” position to make fuel pump run for 10s or so.

13. Connect the main fuel hose (fuel supply pipe assembly) with the main pipe(fuel rigid pipe). If the oil pressure maintenance fails to accord with standard, replace the fuel pump assembly (see Fuel Pump Assembly Dismantling/Mounting) 14. Confirm if around the quick plug’s bonding zone there is not oil leakage. 15. Complete the inspection work after repair(see Inspection Work after Repair)

Fuel System 1C-12  Power circuit (the circuit between the carbon canister’s electromagnetic valve connector terminal 2 and main circuit breaker connector terminal D, in which there is public connector) Main relay

Connector on wiring harness’s side (viewing from the electrode terminal side) Short Circuit

2.2 Inspection of Ventilation Condition Notice

 Electrical ground between carbon canister’s electromagnetic valve connector terminal 2 and ECU connector terminal 46, in which there is public connector.

 The following tests can be conducted if necessary

2.

Remount the carbon electromagnetic valve.

1.

Loosen the accumulator’s negative cable.

3.

Remount the accumulator’s negative cable.

2.

Dismantle the carbon electromagnetic valve .

3.

Inspect ventilation condition of the carbon canister’s electromagnetic valve

3

Dismantling the fuel assembly diagram

canister’s

(If normal, inspect if there is open /short circuit, and if the vacuum hose is correctly arranged or suffers distortion and air leakage. If abnormal, replace the carbon canister’s electromagnetic valve ).

2.3 Inspection of Open/Short Circuit 1.

canister’s

Inspect if there is open/short circuit on the following wiring harnesses (If there is, overhaul or replace corresponding wiring harness).

Open Circuit  Earthing circuit (the circuit between the carbon canister’s electromagnetic valve connector 1 and ECU connector terminal 46, in which there is public connector)

pump

3.1 Demolition relief valve assembly

With a screwdriver inserted from here..

Fuel System 1C-13 Use a screwdriver or a special tool to open end of the buckle.

Demolition ends snap.

3.3 Demolition pump plug

Inwards, and then pull up.

Demolition pressure relief valve.

3.2 Demolition Fuel quantity sensor Inwards, and then pull up.

Remove the bracket spring, pull out the fuel pump gland.

3.4 Demolition of the fuel hose fixed widget

Fuel System 1C-14

Fuel pump prefilter.

Use a screwdriver to open the plug-in.

Fuel pump core

Remove the pump

Fuel pump fine filter

core and fine filter.

3.5 Demolition fuel pump at the bottom case.

After all the components apart..

Note:

Bottom snaps open.

3.6 Demolition prefilter, pump core, fine filter. Bottom snaps open.

1. the fuel filter assembly refers to the fine filter, fine filter assembly UMC's part number F 01R 02S9B6. I only fuel pump assembly part number for SA12-13-35Z. 2. the use of fine filter fuel pump assembly time of 2 years or 20,000 kilometers.

Intake and Exhaust System 1D-1

Chapter 4 Intake and Exhaust System Table of Contents 1. Intake system ······························································································1D-2 1.1 Intake System Dismantling/Mounting ·····························································1D-2 2. Exhaust System····························································································1D-3 2.1 Inspection of Exhaust System ·····································································1D-3

Intake and Exhaust System 1D-2

1. Intake system 1.1 Intake System Dismantling/Mounting Warning  When the engine and intake system stay at high temperature, they can easily lead to personnel injury. Before mounting or dismantling the intake system, operation shall not be conducted until the engine has stopped and cooled down.  Fuel vapor is dangerous and combustible, which may lead to serious injury and damage. Due to this, avoid spark or naked flame at the place where there is fuel.  Fuel overflow or leakage is dangerous, which may lead to personnel injury and property loss. In addition, the fuel can irritate the skin and eye. Due to this, Oil Circuit Safety Procedure shall be always observed during the operation process. 1.

Disconnect the accumulator’s negative cable.

2.

Dismantle parts according to the sequence illustrated in the table.

3.

Mount parts according to the sequence reverse to the dismantling process.

1

Intake duct

7

Intake hose bracket

2 3

Intake hose Muffler tubes

8 9

Intercooler intake hose Intercooler outlet hose

4 5

Air flow sensor O-ring

10 11

Intercooler assembly Turbocharger outlet rigid pipe

6

Air filter

12

Turbocharger outlet hose

Intake and Exhaust System 1D-3

2. Exhaust System 2.1 Inspection of Exhaust System 1.

Start the engine, and inspect if the exhaust pipeline suffers air leakage (If there is air leakage, overhaul the exhaust pipeline, or replace it if necessary).

Exhaust System Dismantling/Mounting Warning  When the engine and exhaust system have yet to cool down, they may scald the skin. Due to this, dismantling work shall not be started until the engine has stopped and cooled down. 1.

Loosen the accumulator’s negative cable.

2.

Dismantle parts according to the sequence illustrated in the figure.

3.

Mount parts according to sequence reverse to the dismantling process.

1

Front oxygen sensor

2

Front three-way catalyst converter

3 4

Front hanging bracket Rear three-way catalyst converter

5 6

Rear oxygen sensor Front muffler assembly

Cooling System 1E-1

Chapter 5 Cooling System Table of Contents 1. Cooling System ··························································································1E-2 1.1 Engine Coolant ·························································································1E-2 1.1.1 Inspection of Engine Coolant’s Liquid Level·············································· 1E-2 1.1.2 Replace Engine Coolant ······································································ 1E-2 1.2 Vice radiator cap ···················································································· 1E-3 1.2. 1 Inspection of vice radiator cap ···························································· 1E-3 1.3 Radiator ·······························································································1E-4 1.4 Vice water tank ······················································································ 1E-4 1.5 Thermostat ··························································································· 1E-4 1.5.1

Thermostat Dismantling/Mounting …………………………………………………. 1E-4

1.5.2

Instructions for installing the thermostat······················································1E-5

1.6 Water Pump ····························································································1E-5 1.6.1

Water Pump Dismantling/Mounting ·························································1E-5

1.6.2 Fan Motor························································································1E-5 1.7 Fan Relay································································································1E-6 1.7.1 Inspection of Fan Relay ··········································································1E-6

Cooling System 1E-2 no longer have to re-set in under the water in the radiator outlet, and assembled in place and re-fix the elastic hose clamp in its original location.

1. Cooling System Warning on Cooling System Maintenance When the engine is running or the engine and heat sink are hot, do not dismantle the heat sink lid or loosen the heat sink’s drain valve because hot coolant and vapor may spout, which will result in serious casualties and damage to the engine and cooling system Turn off the engine, and conduct further operation after the engine cools down. Then, keep mindful when removing the heat sink’s filler lid, and wrap the filler lid with thick cloth and slowly turn it to the first stop position along the anticlockwise direction. When the pressure declines, turn it along the reverse direction;

◆After the assembly ended, the reserve tank filler injected into the designated coolant, when manually add, after the filling is completed, the idling operation of the engine a few minutes, after the coolant level in the tank drops to be deputy, no further exhaust gas cooling system, continue to inject cooling fluid, the sub-coolant level in the tank to the vicinity of the following MAX.

If there is not pressure, press the heat sink lid with cloth and dismantle it.

1.1 Engine Coolant 1.1.1 Inspection of Engine Coolant’s Liquid Level 1. Confirm if the coolant’s liquid level in subsidiary water tank ranges between MAX and MIN. If the engine coolant’s liquid level stays below MIN, open the subsidiary water tank’s lid and add the coolant near to the MAX mark. If there is no coolant in the subsidiary water tank, wait till the engine cools down, and open the heat sink’s filler lid to add coolant from the heat sink filler port till the coolant’s liquid level can be seen from the filler port. Then, mount the heat sink’s filler lid, and continue adding the coolant near to the MAX mark.

1.1.2 Replace Engine Coolant ◆ Turn off the engine, and wait for the engine coolant completely cool down, removed fixed the plumbing and radiator assembly of elastic tube outlet folder under the water from the radiator assembly out of the outlet to unplug, let go of the engine and radiator the coolant assembly. When unplug the pipes, be careful not to let the coolant splash to humans. ◆ Wait outlet pipes and radiator coolant outflow

Warning Alcohol or methanol antifreeze may damage aluminum parts on the engine, and so alcohol or methanol shall not be used in the cooling system, and only the glycol-based coolant can be used. Only the softening (demineralization) water can be used to mix with the coolant, and water containing minerals will compromise the coolant’s effect. Engine coolant will result in damage to the lacquer surface, and so the engine coolant shall be rinsed out in no time when it touches the lacquer surface. ◆

Refer to table below to select appropriate volume percentage for mixture of water and coolant. Add slowly the coolant into the water tank till the coolant reaches the filler port.

Filling speed:1.0L(1.1USqt 、 0.9impqt)/min. [Maximum Value] Coolant protective agent Higher than -16℃{3ºF}

Volume percentage Water Coolant 65

35

Proportion at 20℃{68ºF} 1.054

Cooling System 1E-3 Higher than -26℃{-15ºF}

55

45

1.066

Higher than -40℃{-40ºF}

45

55

1.078

1.1.3 Inspection Leakage

of

Engine

Coolant

1.

Inspect the coolant’s liquid level.

2.

Take off the heat sink lid.

3.

Connect the heat sink lid tester and SST special maintenance tool with the heat sink’s filler port.

Notice  If the pressure surpasses 123kPa {1.25kgf/cm2, 17.8psi}, hose joint and other parts will be damaged, which will in turn lead to leakage. 4.

Make the heat sink reach specified pressure:

Pressure:123kPa{1.25kgf/cm2, 17.8psi}

◆

Start the engine and maintain the idling speed till the cooling fan begins to work.

Notice  If the coolant temperature is over high, stop the engine to prevent the coolant from being overheated. ◆

Conduct the following operations after the engine temperature rises:

(1) Make the engine run for one minute at the rotating speed of 4000rpm; (2) Make the engine run for one minute at the idling speed; (3) Repeat Step 1 and Step 2 for several times; (4) Turn on the front/rear heater unit (if has), and confirm if there is hot air exhausted from the heater unit’s ventilation opening. 11. Stop the engine and wait till it cools down. 12. Confirm if there is coolant leakage. 13. Inspect the coolant’s liquid level. If the level is relatively low, add the coolant into the subsidiary water tank till it reaches the MAX mark.

4.

1.2

Inspect if the pressure can be maintained. If cannot, inspect if the system suffers coolant leakage.

Vice radiator cap

1.2.1 Inspection of vice radiator cap Warning  When the engine is running or the engine and heat sink are hot, do not dismantle the heat sink lid because hot coolant and vapor may spout, which will result in serious casualties and damage to the engine and cooling system  Turn off the engine, and conduct further operation after the engine cools down. Then, wrap the vice radiator cap with thick cloth carefully, and slowly turn it to the first stop position along the anticlockwise direction. When the pressure declines, turn it along the reverse direction;  If there is not pressure, press the heat sink lid with cloth and dismantle it. 1.

Use the SST special service tool to connect the vice radiator cap with the tester.

2.

Increase the pressure little by little.

Cooling System 1E-4 3.

Inspect if the pressure stays within the specified range. If the pressure can keep for 10s, it indicates that the vice radiator cap is normal.

3

Fan wiring harness connector

4

Fan assembly

5

Vice-water tank hose I

Pressure range:94-122kPa{0.95-1.25kgf/cm2, 13.5-17.7psi}

6

Vice-water tank hose II

7

Radiator mounting bracket

1.4 Vice water tank ◆ Vice water tank removal / installation 1. Vice water tank drained coolant. 2. Dismantle parts according to the sequence illustrated in the table; 3. Mount parts according to the sequence reverse to the dismantling process.

1.3 Radiator Radiator Dismantling/Mounting Fan Parts Dismantling/Mounting 1.

Disconnect the accumulator’s negative cable;

2.

Drain the engine coolant;

3.

Dismantle the front grille and air intake duct.;

4.

Remove the radiator and condenser mounting bracket bolts bolts; remove the fan mounting bolts;

5.

Remove the engine Water pipe, remove the expansion tank hose. (connect with the heat sink end);

6.

Dismantle parts according to the sequence illustrated in the table;

7.

Mount parts according to the sequence reverse to the dismantling process.

1

Vice-water tank hose I

2

Vice-water tank hose III

3

Vice-water tank hose II

4

Vice-water tank bolt 1

5

Vice-water tank bolt 2

1.5 Thermostat 1.5.1 Thermostat Dismantling/Mounting

1

Lower water pipe

2

Upper water pipe

1.

Drain the engine coolant.

2.

Dismantle parts according to the sequence illustrated in the table.

3.

Mount parts according to the sequence reverse to the dismantling process.

Cooling System 1E-5

1.6 Water pump 1.6.1

Water Dismantling/Mounting

Pump

See Engine Water Pump Dismantling/ Mounting for the water pump dismantling/ mounting. ① Upper heat sink hose

1.6.2 Fan Motor

② Thermostat lid ③ O-ring

◆ Fan Motor Inspection

④ Thermostat Mounting Attentions

1.

Confirm if the accumulator has been fully charged.

2.

Connect the accumulator’s positive electrode and amperemeter with the fan motor plug.

3.

Confirm if the fan motor runs stably while being driven by standard current. Replace fan motor if it fails to meet technical requirements.

1.5.2 Instructions for installing the thermostat 1.

Mount the thermostat onto the thermostat housing, pay attention to the thermostat’s direction, with clamping pin facing upward. Clamping pin

①

Thermostat Inspection 1.

Inspect thermostat according to items below.

—Valve temperature when being turned on or off.

Standard Current:

—Valve’s critical temperature in full opening or full closing state. If technical requirements cannot be met, replace the thermostat.

①Connected, High-speed Action 11-12.5A [12V] ①Disconnected, Low-speed Action 9-10.5A [12V] ◆ Fan Motor Dismantling/Mounting

Condition Temperature rising process

Temperature decline process

Action

Temperature℃

Initial opening

1.

Dismantle the cooling fan.

81

2.

Full opening

Dismantle parts according to the sequence illustrated in the table.

93

3.

Start closing

Mount parts according to the sequence reverse to the dismantling process.

90

Full closing

79

Cooling System 1E-6 Step

1

Cooling fan heat shielding cover

2

Cooling fan blade

3

Fan motor assembly

1.7 Fan Relay 1.7.1 Inspection of Fan Relay 1.

Disconnect the accumulator’s negative cable

2.

Dismantle the fan relay from the relay box.

Use the ohmmeter and 12V power supply to inspect the fan relay’s quality. If the relay is unable to run normally or meet technical requirements, replace the fan relay. See table below for the relay inspection:

Port

Compliance standard

1

Ohmmeter tests Infinite resistance at both ends of resistance Pin 30 and Pin 87

2

Hear the Both ends of Pin 85 and relay’s Pin 86 directly link with actuation 12V power supply voice

3

Keep the relay’s actuation state, and again Resistance is use the ohmmeter to test zero resistance at both ends of Pin 30 and Pin 87

Remark

High/low-speed relay pins have the same definition

Relay Diagram

Accessory-Belt 1F-1

Chapter 6 Engine Accessory-Belt Table of Contents 1. Driving Belt ································································································1F-2 1.1 Inspection of Driving Belt ············································································1F-2 1.1.1 Inspection of Driving Belt’s Distortion ························································1F-2 1.1.2 Inspection of Driving Belt Tension·····························································1F-2 1.2 Adjusting the drive belt ···············································································1F-2 1.2.1 A/C Compressor Multi-wedge V Belt Adjustment ···········································1F-2 1.2.2 Power Steering Pump Belt Adjustment ························································1F-3

Accessory-Belt 1F-2

1. Driving Belt

Use SST to inspect the tension of belt between two driving wheels. 

1.1 Inspection of Driving Belt If necessary, inspect the driving belt’s distortion and tension.

If the tension goes beyond the specified range, make adjustment (see Adjustment of Driving Belt)

1.1.1 Inspection of Driving Belt’s Distortion Notice: 



After 30 minutes since the automobile engine stops, inspect the belt distortion with a belt tensiometer, in order to confirm if the belt tension stays within the standard value. If the belt tension goes beyond the specified range, adjust the driving belt (see Adjustment of Driving Belt)

When measuring When mounting

1.2 Adjusting the drive belt 1.2.1 A/C Compressor Multi-wedge V Belt Adjustment 1.

Loosen appropriately the nut on the power generator’s pivot bolt.

2.

Loosen the power generator’s fixing bolt, and then tighten it for about 5N.m, in order to avoid the pulley’s deflection. Adjust bolt Fix power generator bolt

Power generator pivot nut

3.

Use the adjusting bolt to adjust the belt tension and belt deflection to the standard value.

4.

Tighten the power generator’s pivot nut.

Tightening torque: 5. 1.1.2 Inspection of Driving Belt Tension Notice 

The inspection shall be conducted after the engine cools down

43 ±4N·m

Tighten the power generator’s fixing bolt.

Tightening torque: 20±2N·m

Accessory-Belt 1F-3 torque:40～48N.m Notice

1.2.2 Power Adjustment 1.

Steering

Pump



If mounting new driving belt or running driving belt for not greater than 5minutes, adjustment shall be made according to the new part’s standard value.



If running the driving belt for more than 5 minutes, adjustment shall be made according to the old part’s standard value.

Belt

First, loosen the tension pulley’s nut B, and then tighten it for about 5N.m, in order to avoid the pulley deflection.

Distortion (mm/98N) Driving Belt

2.

3.

Adjust the stud bolt A to drive the tension pulley’s location change in the tension pulley bracket’s slot, so as to adjust the belt tension. After the tension meets requirements, tighten the tension pulley nut B, Tightening

New

Old

A/C Compressor Belt

900N-950N 500N-600N (1.5T 600N-700N)

Power Steering Pump Belt (With Tensioner pulley)

400N-500N 300N-350N

Power Steering Pump Belt (Without Tensioner pulley)

300N-500N

Engine Suspension 1G-1

Chapter 7 Engine Suspension Table of Contents 1.Engine Dismantling/Mounting ·········································································· 1G-2 1.1 Complete the dismantling work ····································································· 1G-2 1.1.1 Engine1# Suspension Bracket Dismantling/ Mounting ··································· 1G-3 1.1.2 Engine3# Suspension Bracket Dismantling/ Mounting ····································1G-4 1.1.3 Engine4# Suspension Bracket Dismantling/ Mounting ····································1G-4

Engine Suspension 1G-2

1. Engine Dismantling/Mounting Warning 

Fuel vapor is combustible, and keep away the spark and naked flame.

Fuel leakage and splash are dangerous, which will irritate the skin and eye. Due to this, follow the “Oil Circuit Safety Inspection Procedure” (see Fuel System, Preparatory Work before Repair). 1.1 Complete the dismantling work Respectively discharge A/C refrigerant, power steering liquid, gearbox oil, and engine coolant: 1.

Disconnect the accumulator’s negative cable.

2.

Dismantle the engine under the fender (see the engine under the fender removal / installation).

3.

Dismantle the left/right driving axles (see Driving Axle Dismantling/Mounting).

4.

Dismantle the engine trim cover (see engine trim cover removal / installation).

5.

Dismantle the front suspension cross member assembly (see the front subframe of removal / installation).

6.

Dismantle heat sink(see Heat Sink, Heat Sink Dismantling/Mounting).

7.

Dismantle three-way catalyst converter assembly (see Exhaust System, Exhaust System Mounting/Dismantling).

8.

Dismantle the accumulator and accumulator tray (see Engine Electrical System, Accumulator Dismantling/Mounting).

9.

Dismantle PM wiring Dismantling/Mounting).

harness

and

engine’s

connector

(see

PM

Wiring

Harness

10. Dismantle the reverse switch joint and gear shift cable that are connected with the gearbox. 11. Dismantle the power steering pump hose on the engine, the intake hose connection. 12. Dismantle A/C compressor’s pipeline connection. 13. Dismantle the engine and engine suspension according to the sequence illustrated in the figure. 14. Mount parts according to the sequence reverse to the dismantling process. 15. Inject A/C refrigerant and discharge the power steering liquid, gearbox oil, and engine coolant. 16. Correct the driving belt’s tension (see Driving Belt, Driving Belt Dismantling/Mounting). 17. Star the engine and conduct the following inspection work: (1) Inspect the belt pulley and driving belt’s deflection and interference. (2) Inspect if there is engine oil, engine coolant, gearbox oil, and fuel leakage. (3) Inspect the idling speed (see Engine Running, Idling Speed Inspection). 18. Confirm the road test. 19. Inspect the engine oil, engine coolant, gearbox oil and power steering liquid’s level again.

Engine Suspension 1G-3

1

Engine1# suspension

3

Engine3# suspension

4

Engine4# suspension

1.1.1 Engine1# Suspension Bracket Dismantling/ Mounting 1. Dismantle the engine # 1 bracket bolts 1 and 2 (transmission side) ; 2. Remove the engine mounts bolt # 1 flat washer 5 ,3, 4 flat washers and bolts to remove the engine 1# 6; 3. Check rubber mounts broken, hardening or damage. 4. Mount parts according to the sequence reverse to the dismantling process.

Engine Suspension 1G-4 1.1.2 Engine3# Suspension Bracket Dismantling/ Mounting 1. Dismantle the engine mounts bolt 3 # 3 and nuts 1 and 2 (engine side); 2. Dismantle the engine mounts bolt 3 # 4, 5 and 6 (body side) ; 3. Whether to remove the engine mounts Check rubber damaged # 3 check 3 # suspended base oil leaks or damage. 4. Mount parts according to the sequence reverse to the dismantling process.

1.1.3 Engine4# Suspension Bracket Dismantling/Mounting 1. Dismantle 4 # 3 and 4-- suspension nut; 2. Dismantle 4 # suspension bolts 1 and 2 (body side); 3. Dismantle the four # mount bracket nut 6 and 7; 4. Dismantle the four # suspended inspection rubber is broken, hardening or damaged. 5. Mount parts according to the sequence reverse to the dismantling process.

MF515L Transmission 1H-1

Chapter 8 6MT Transmission Table of Contents MF515L Transmission·······················································································1H-2 1. Overview ·································································································· 1H-2 2. Transmission Troubleshooting and Maintenance ···················································· 1H-3 2.1 Troubleshooting······················································································ 1H-3 2.2 On-spot Maintenance ··············································································· 1H-4 2.3 Transmission Assembly Dismantling ····························································· 1H-5 2.4 Transmission Components Dismantling, Overhaul, and Remounting ······················· 1H-7

MF515L Transmission 1H-2

6MT Transmission 1. Overview The transmission, through 4 synchronizers and three transmission shafts (input shaft, intermediate shaft, and reverse gear shaft), can provide 6 forward gears and 1 reverse gear, of which all forward gears belong to constant-mesh type, but the reverse gear is a sliding idle gear. 1-2-gear synchronizer is mounted onto the intermediate shaft, and coupled with the intermediate shaft’s first gear and second gear. 3-4-gear synchronizer is mounted onto the input shaft, and coupled with the input shaft’s third gear and fourth gear.

Fig. 1-2

Gear Mechanism

Five or six gear synchronizer assembly is mounted on the input shaft, and with the input shaft 5th gear and six-gear linked in. Reverse synchronizer assembly is mounted in the reverse gear shaft associated with the reverse gear. Intermediate shaft drives the main reduction gear and differential device, so as to rotate the front driving axle that is connected with the front wheel. As for the maintenance work, sealant or equivalent products shall be smeared on gearbox housing surface’s corresponding parts, and the gearbox housing is made of aluminum. On the housing, the fixing bolt shall be tightened to specific torque with the torque wrench. Before remounting, all parts shall be cleaned thoroughly with cleaning agent or liquid and dry air, which is very important.

Fig. 1-1

Transmission assembly

Fig. 1-3

Internal gear shift mechanism

Fig. 1-4

Gearshift Actuator

MF515L Transmission 1H-3 the adjusting mechanism is loosened.

1.1 Shifting mechanism Gear shift lever movement transmitted by the shift power to the shift shaft rotating arm, the pendulum is transmitted to the shift by shift shaft, then through the shift rocker pin to transmit the power to shift head, and finally delivered to the fork assembly. With a transmission gear interlock plate to prevent double engagement.

Solution: Place it to the “Neutral Gear”’ position again, and adjust the clearance.

When put up a gear shift interlock plate to lock the other, it can not be linked to other gear shift operation between each gear interlock avoid while hang two or more file archives.

◆ Transmission Emits High Noise Abnormal Sound Reasons and Solutions

2. Transmission Troubleshooting and Maintenance 2.1 Troubleshooting Transmission’s main faults and troubleshooting methods: ◆ Out of Gear Reasons and Solutions: a.

Reason: shift rod suffers serious abrasion and distortion

Solution: calibrate the shift rod manually. If the shift rod bends or suffers serious abrasion, replace it in time. b. Reason: shift rocker suffers serious abrasion and distortion Solution: replace the shift rocker in time. c.

Reason: Self-locking spring’s elasticity is weakened

Solution: Replace the self-locking spring in time. d. Reason: Gear’s axial clearance is too large, which should be mainly attributed to the gear check ring’s serious abrasion

h. Reason: the engine’s connection with the transmission and complete vehicle is too loose, or the clearance adjustment is inappropriate. Solution: Adjust the clearance

a.

Reason: shift fork’s abrasion and distortion

Solution: Calibrate the shift fork manually when it suffers distortion. Replace it when suffering serious abrasion. f.

Reason: Synchronizer gear housing, gear sleeve, or gear ring suffer abrasion

Solution: If there is out of gear, replace the wear-out parts. g. Reason: After being adjusted, transmission fails to reach the “Neutral Gear” position, or

Reason:Transmission has insufficient oil or the oil is not clean

Solution: Inject sufficient oil or replace the oil. b.

Reason: Gear’s axial clearance is too large

Solution: Replace gear or gear check ring. c.

Reason: Gear suffers abrasion or gear teeth is broken

Solution: If the gear backlash exceeds the specified range, replace the gear. Standard backlash of the five-gear transmission is 0.1mm, and the operating limit is 0.3mm. d. Reason: synchronizer’s gear ring suffers abrasion or the gear is broken Solution: Replace the gear ring. e.

Bearing suffers damage or abrasion

Solution:Replace bearing. f.

Bearing press abrasion.

plate

suffers

damage

or

Solution: Replace the gear check ring. ◆ Shifting Difficulty Reasons and Solutions a.

Solution: Replace the gear check ring. e.

or

Shift rod or shift fork incurs distortion or uneven abrasion

Solution: Replace parts. b. Self-locking steel ball and shift fork shaft’s groove suffer abrasion Solution: Replace parts. c.

Synchronizer’s gear ring gets stuck on the gear’s conic section

Solution: Replace the gear ring. d. Synchronizer spring is damaged

MF515L Transmission 1H-4 Solution: Replace the synchronizer spring.

oil (GL-4) grade:75W-90.

e.

Oil filling volume:1.8～2.0L

Gear sleeve and gear end suffer abrasion or abrasion of gear ring’s key groove becomes wider.

Solution: Replace corresponding parts.

Notice 

◆ Oil Leakage a.

Oil leakage at the drain plug

Solution: first, the plug’s tightening torque is less than the specified value, and so inspect the tightening torque. If the tightening torque does not comply with requirements, tighten the plug. Second, there is deflection in engagement or thread teeth damage, replace corresponding parts. b. Oil Leakage at Sealing Parts

2.2.2 Differential Replacement

d. Oil Leakage at the Input Shaft’s Seal Ring Solution: first, inspect if the seal ring is damaged. If damaged, replace the sealing parts. Second, inspect if the right tank body’s supporting port suffers excessive abrasion. If it suffers, replace right tank body.

Oil

Seal

Jack the automobile and transmission lubricating oil.

2)

Dismantle the differential.

3)

Use the special tool and hammer to dismantle the oil seal and mount a new part. special tools(A): oil seal erector1(right); oil seal erector2(left)

Oil Leakage at the Bonding Surface

Solution: Conduct inspection and make all connection bolt’s tightening torques accord with specifications.

Right/Left

1)

Solution: Replace sealing parts while abiding by operation specifications. c.

When the automobile is jacked for other maintenance work besides the lubricating oil replacement, inspection to leakage of lubricating oil shall be conducted as well.

driving

shaft

drain

the

from

the

Differential limit end face seal in place. 4) Smear lubricating grease on the oil seal’s rim, in addition to inspecting the contacting part between the driving shaft and oil seal, as well as ensure the smoothness. “A”: Suzuki Lubricating Grease A.

2.2 On-spot Maintenance 2.2.1 Replace Oil 1)

2)

While replacing and inspecting the lubricating oil, be sure to stop the engine and lift the automobile steadily. Oil level and leakage cannot be inspected until the automobile has been lifted. If there is leakage, remedial actions shall be taken in time.

3)

Drain original lubricating oil and inject new and specified lubricating oil.

4)

Drain plug and oil filler plug’s torque specifications are as follows, before installing the application on a certain amount of drain plug thread sealant.

Sealant: Suzuki 1215 Tightening torque:12～18N·m Gear oil:GB13895-1992 heavy-load vehicle gear

Fig. 2-1 Differential oil seal replacement 5)

Mount driving shaft into the differential.

Caution 

When inserting the driving shaft’s bolt, do not scratch the oil seal’s rim. Make sure the driving shaft’s bolt has been inserted sufficiently, and the elastic check ring is fixed as original.

6)

Inject transmission oil according to the requirements, and make sure the oil has been sealed tightly by the oil seal.

2.3 Transmission Assembly Dismantling 2.3.1 Dismantle Gearshift Actuator

MF515L Transmission 1H-5 Dismantle the locking bolt assembly and shift the stop pin and the gearshift box’s assembling bolt, in addition to taking off the gearshift box’s components.

1

Fig. 3-2-b Dismantle assembling bolt Assembling bolt M8×40(twelve)

2

Left bearing plate bolt M8×25(six)

3

Left case

Fig.3-1 Dismantle Gearshift Actuator 1 Gearshift box components 2

Gearshift box bolt M8×25(five)

Notice 

Make sure the gearshift box’s components are dismantled when the transmission stays at the “Neutral Gear” position

2.3.2 Dismantle the assembling bolt to split the box 1)

Dismantle the assembling bolt from internal and external sides of the transmission;

2)

Dismantle the Left bearing plate bolt from lateral side of transmission;

3)

Use the soft hammer to knock the left box’s rim and dismantle the left box.

Fig. 3-2-c Split the Box 2.3.3 Dismantle the input shaft assembly, the intermediate shaft assembly and into the gear shift mechanism. 1)

Use the soft hammer to knock input shaft lightly;

2) Take out the input shaft components, intermediate shaft components, first /second gear shift components, third/fourth gear shift components, fifth/sixth gear shift components from the box once for all.

Special tool: Box splitter (A).

1

Fig. 3-2-a Dismantle assembling bolt Assembling bolt M8×40(five)

Fig. 3-3-b

Dismantle Gear Mechanism and Gear Shift Mechanism

MF515L Transmission 1H-6 1

Input shaft components

2

Intermediate shaft components

3

into the gear shift mechanism

3) The reverse shaft assembly, reverse fork assembly and differential assembly box in the right time overall removal;

Fig. 3-3-c

Take off the gear mechanism and gear shift mechanism

2.3.4 Dismantle left box’s other components

(B): Oil seal ejector 5)

Use special tools to dismantle the intermediate shaft’s ring bearing outer ring.

Special tools: (A): slide shaft; (B):Bearing ejector 6)

Dismantle the differential’s right oil seal from right box.

Fig. 3-4-b Dismantle the input shaft’s oil seal 1 Input shaft oil seal Intermediate shaft’s right bearing outer ring

2

2.4 Transmission Components Dismantling, Overhaul, and Remounting 2.4.1 Dismantle input shaft’s components ◆ Disassembly 1) Use the bearing puller and extrusion device to dismantle the input shaft’s right bearing. 2) 1

Fig. 3-4-a Take off other components Intermediate shaft oil tray

Use the puller and extrusion device to extrude left bearing, fifth gear synchronizer unit, and fifth gear, fourth gear, third gear speed synchronizer and together with the sleeve out together.

2

Intermediate shaft’s right bearing outer ring

Notice:

3

Magnet



4

Close box pin（two）

To prevent the gear teeth from being damaged, make the teeth lean against the smooth and straight side of the bearing puller. 1.Input shaft

1)

Take off other components

2.Right bearing

2)

Dismantle differential unit from the right box

3.Bearing puller

3)

Dismantle bolt,

4)

Use special tools to dismantle the input shaft’s oil seal

Special tools: (A): Slide shaft;

MF515L Transmission 1H-7 Fig.4-1-a Dismantle the input shaft’s right bearing

1

Input shaft bearing left

5

High-speed synchronous

2

Five-speed synchronous 5th gear gear assembly 4th gear gear assembly

6 7

Third gear gear assembly Input shaft

8

Bearing puller

3 4

Fig.4-1-b Dismantle the input shaft’s left bearing, each gear synchronizer unit ◆ Assembly

9

3th/4th gear synchronizer gear ring

10

3th/4th gear synchronizer components

11

Input shaft third gear assembly

12

Input shaft

13

Input shaft right bearing

14

Right gear input shaft bearing ring

1)

Clean all parts thoroughly and inspect if there is abnormal situation. Then mount the new one according to demands.



Notice Before assembling, clean every component and smear designated gear oil to slide the gear and the bearing surface. During the remounting process, use new gear ring on the shaft, and application of used gear ring is prohibited.

2)

If the synchronizer’s components will be repaired, inspect the clearance “a” between the gear ring and the gear ring, and then inspect every gear’s crowned teeth, ring, and sleeve. After that, determine if the replacement shall be conducted.

Clearance a: Theoretical value: 1.0- 1.2mm Ultimate value: 0.5mm 3)

Ensure the lubrication, and blow air to every oil port to make sure that there is not blockage.

Assemble Input Shaft Components

1

Fig.4-1-d Input Shaft Components Left input shaft bearing lock nut

2

Input shaft left bearing

3

Input shaft 6th gear assembly

4

5th/6th gear synchronizer gear ring

5

Shaft snap ring

6

5th/6th gear synchronizer components

7

Input shaft 5th gear assembly

8

Input shaft 4th gear assembly

1 2

Fig.4-1-e Gear wheel Gear ring

Fig.4-1-f

MF515L Transmission 1H-8 4)

Mount the high-speed synchronizer onto the hub, insert three slide blocks, and then mount the spring according to the illustration.

After pressing and mounting the synchronizer unit, inspect the third gear’s free rotation. Special tools(B):bearing erector1

Fig.4-1-i

1

Fig.4-1-g High-speed synchronizer spring

2

Slide block

3

High-speed synchronizer gear hub High-speed synchronizer gear sleeve

Notice

3rd gear input shaft



4 5 5)

7)

Use special tool and hammer to mount the right bearing.

1

Input shaft

2

Third gear

3

Gear ring

4

Synchronizer unit

Mount the four gear shaft sleeve and needle bearing, smear lubricating grease on the bearing, and then mount synchronizer gear ring and fourth gear.

Make sure the four gear shaft sleeve is properly mounted.

Special tools(A):bearing erector

Fig.4-1-j

Fig.4-1-h 1 2 6)

7)

Right bearing Input shaft

Mount the third gear needle bearing, smear the lubricating grease, and mount the third gear and synchronizer gear ring. Use special tool and hammer to drive in the high-speed synchronizer assembly.

Note: when pressing and mounting the gear hub and gear sleeve, make sure the synchronizer gear ring’s teeth groove aligns with the synchronizer unit’s slide block.

9)

1

Shaft sleeve

2

Needle bearing

3

Gear ring

4

Fourth gear

5

Input shaft

Mount the fifth gear shaft sleeve and needle bearing, smear lubricating grease on the bearing, and the mount the synchronizer gear ring and fifth gear synchronizer.

10) Press and mount the left bearing with special tool and hammer. special tools(C):bearing erector4 2.4.2 Intermediate Shaft Components ◆ Disassembly 1)

Use the puller and holding-down device to

MF515L Transmission 1H-9 pull out the left conical bearing. Caution Use the puller and holding-down device that can support at least 5t load.

Fig.4-2-a

2)

1

Holding-down device

2

Intermediate shaft’s left bearing

3

Puller

1

Fig.4-2-c Intermediate shaft 5 3rd gear

2

5th gear

3

4th gear

4

3rd/4th gear spacer bush

6

2nd gear

7

Low-speed synchronizer unit

8

1st gear

4)

Dismantle the synchronizer unit.

5)

Take out needle bearing from the shaft.

6)

Use the puller to dismantle right conical bearing.

Use special tool to dismantle the fifth gear snap ring

Special tools(A):snap ring plier 3） Take the pressure with a pull and pull out together with all gear and low speed synchronous assembly. Notice 

To prevent the gear teeth from being damaged, make the teeth lean against the smooth and straight side of the bearing puller.

Fig.4-2-d 1

Metal rod

2

Intermediate shaft’s right conical bearing puller

◆ Assembly Mount Intermediate Shaft Components 1)

1

Fig.4-2-b Intermediate shaft 5th gear

2

Intermediate shaft 5th gear ring

Clean all parts thoroughly, inspect if there is abnormal situation, and mount new parts according to demands.

Fig.4-2-e 1.Left intermediate shaft bearing lock nut 2. Intermediate shaft’s left bearing assembly 3. Intermediate shaft 6th gear 4. 5th/6th gear spacer bush 5. Intermediate shaft 5th gear 6. Intermediate shaft 4th gear 7. 3rd/4th gear spacer bush 8. Intermediate shaft 3rd gear 9. Intermediate shaft 2nd gear 10. 1st/2nd gear synchronizer gear ring 11. Shaft snap ring 12. 1st/2nd gear

MF515L Transmission 1H-10 synchronizer 13. needle bearing 14. Intermediate shaft first gear spacer bush 15. Intermediate shaft first gear assembly 16. Intermediate shaft 17. Intermediate shaft right bearing assembly 18. Intermediate shaft right bearing ring 2)

If the synchronizer’s components will be repaired, inspect the clearance “a” between the ring and the gear, and then inspect every gear’s crowned teeth, ring, and gear ring. After that, determine if the replacement shall be conducted.

Fig.4-2-h

Clearance “a”: standard value:1.0-1.2mm

1

Low-speed synchronizer snap ring

Ultimate value:0.5mm

2

Slide block

3

Low-speed synchronizer gear hub

4

Low-speed synchronizer gear sleeve

5)

Use special tool and hammer to tighten the right conical bearing.

Special tools(A):bearing erector3 Fig.4-2-f 1

Gear

2

Synchronizer ring

3)

Ensure the lubrication, and blow air into every oil port to inspect if there is blockage.

Fig.4-2-g 1

intermediate shaft

2

Oil port

4) Mount the low-speed synchronizer onto the gear sleeve, insert three slide blocks, and the mount the spring according to the illustration.

1. Right conical bearing 2. Intermediate shaft

1

Fig.4-2-i Right conical bearing

2

Intemrmediate shaft

6)

Mount the needle bearing, smear the lubricating grease, and then mount the first gear and first gear synchronizer’s gear ring components.

7)

Use special tool and hydraulic pressure to drive in the low-speed synchronizer unit.

Notice

Notice:



Not to slow-sync the tooth shell or each slide in a predetermined direction , but slide blocks are defined as an assembled unit.

Lean the shaft against special tool according to the illustration, in order to prevent the conical bearing retainer from being extruded.



When pressing and mounting the synchronizer assembly, make sure the synchronizer slide block groove is aligned with the slide block



After pressing and mounting the synchronizer assembly, inspect the first gear’s free rotation.

Caution 

If the extrusion force exceeds 5t, release the extrusion immediately, and remount the puller bracket. Then, continue the push and compression.

Special tools(A):bearing erector3;

MF515L Transmission 1H-11 (B):bearing erector2;

Notice

(C):bearing erector5



It is recommended that bush and third gear shall be firstly pressed and mounted before the fourth gear pressing and mounting, which can prevent the intermediate shaft from being excessively extruded.

Special tools (A):bearing erector3 (D): bearing erector

Fig.4-2-j 1

Low-speed synchronizer unit

2

First-gear synchronizer gear ring components

3

Intermediate shaft first gear

4

Intermediate shaft right bearing

A

Key groove aligned with slide block

8)

Mount shaft sleeve and needle bearing, smear lubricating grease on the bearing, and then mount second gear synchronizer ring and second gear.

Caution 

Make sure the shaft sleeve is properly mounted

1. Third/fourth gear spacer bushes 2. Third gear 3. Second gear

Fig.4-2-l 1

Third/fourth gear spacer bushes

2

Third gear

3

Second gear

10) Press and mount the fourth gear and fifth gear ditto. 11) Installation 5th gear collar with a special tool (collar clamp). 12) Installation left intermediate shaft bearing with special tools and hammers. Notice 

To protect the conical bearing, make the shaft lean against the special tool according to the illustration.

Special tools (A):bearing erector3 Fig.4-2-k 1

Intermediate shaft first gear

2 3

1st gear synchronizer gear ring Low-speed synchronizer unit

4

2nd gear bushings

5

Needle bearing 2nd gear synchronizer gear ring components

6 7 9)

(E):bearing erector4

Intermediate shaft second gear Use special tool and holding-down device to press and mount the third gear and spacer bush.

Fig.4-2-m

MF515L Transmission 1H-12 1

Intermediate shaft left bearing

2 3

5th gear 4th gear

4 5

Third/fourth gear spacer bushes Intermediate shaft right bearing

2.4.3 Reverse gear shaft assembly (1) Installation

Fig.4-3-2 1

Fig.4-3-1 1

Reverse gear shaft left bearing 6207P53

2

Reverse gear synchronizer snap ring

3 4 5

Reverse gear synchronizer components Reverse gear synchronizer gear ring Reverse gear gearwheel

6 7

Needle bearing Reverse gear shaft sleeve

8

Reverse gear shaft

9

Shift fork

2 Synchronizer sleeve Clearance “a”: standard value:1.0mm 2) Use special tools and a hammer to remove parts. Special tool (A): the spring pin puller (5mm) 3) The shift shaft inserted into each shell and check the smoothness of movement, if the movement is not flexible, be corrected on the reamer or similar tool. 4) Replace or correct as needed and installed shaft parts to ensure the correct order of parts, as shown in FIG.

Reverse gear shaft right bearing 6306E st

nd

(2) 1 /2 gear shift assembly, 3rd/4th gear shift components and 5th reverse gear components. 1) Using the gap between the plug, check the fork and synchronizer sets, if it exceeds the limit 1.0mm, the need to replace such parts. Note: To achieve the right to judge whether the parts need to be replaced, it is necessary to carefully check the contact position of the fork and the ring gear.

Fig.4-3-3 st

1

1 /2nd gear shift fork assembly

2 3

3rd/4th gear shift fork assembly 5th/6th gear shift fork assembly

4 5

Reverse gear shift fork assembly Ball gear lock assembly

MF515L Transmission 1H-13

2.4.4 Differential Unit ◆ Differential Unit Dismantling 1)

Use special tool to dismantle the right bearing.

Special tools(A)bearing puller;(B) bearing puller accessories Notice  As for the bearing dismantling, if semilune puller is used together with holding-down device, the main reduction gear shall be dismantled in advance. 2)

Use the puller to dismantle the left bearing, during which protect well the bearing.

3)

Use the soft bench clamp to clamp the differential housing, and dismantle eight differential bolts. After that, take off the main reduction gear.

4)

Use the snap ring plier to dismantle the differential planet gear shaft check ring, and then dismantle components and parts.

Fig.4-4-2 1. Tapered Roller Bearings 2.Differential housing 3. Planet gear 4. Differential spacer 5.Planet gear shaft 6. A type shaft circlip 7. Main reduction gear 8.Differential bolt 9. Induction ring gear 10.Differential half shaft 11. Differential Adjusting washer 1)

Mount the differential gear according to the illustration and follow method below to measure the differential’s pushing clearance.

Special tools(A): dial gauge;(B): magnet base differential gear pushing clearance: 0.03-0.40mm Left side: use the soft bench clamp to clamp the differential assembly, and also insert the dial feeler gauge’s measuring terminal onto the gear’s upper surface. Use two screwdrivers to move the gear upwards and downwards, in addition to reading the gauge feeler gauge’s pointer travel. Fig.4-4-1 ◆ Differential Unit Adjustment and Remounting

Right side: use similar method and insert the dial feeler gauge’s measuring terminal onto the gear’s shoulder. Use the hand to move the gear upwards and downwards and read the feeler gauge’s reading.

Dismantling shall be determined according to the fault denoted in preceding content. After the dismantling, use naked eyes to inspect if the parts have problems, and prepare spare parts for the replacement and remount these parts, during which make sure all parts are clean.

Fig.4-4-3

MF515L Transmission 1H-14 1 2

Screwdriver Half axle gear

2) If the pushing clearance exceeds the specified value, select appropriate thrust washer from the following sizes for mounting, and inspect again if specified gear clearance range has been met. Thickness of thrust washers:0.9, 0.95, 1.0, 1.05, 1.15, and 1.2mm 3) Drive in the spring from right side till the pin keeps even with differential housing surface.

1

Intermediate shaft’s right bearing outer ring

2

Input shaft oil seal

4) Use special tool and hydraulic pressure to press and mount the left bearing. Special tool: bearing erector 6

2)

5) Follow the Step 4, to press and mount the right bearing.

Special tools (B): Mounting connection rod

6) Use soft bench clamp to clamp the differential assembly, mount main reduction gear, and then use eight bolts to tighten the differential assembly according to required torque.

(C): Bearing outer ring erector Special tools (D):Seal ring erector 3)

Notice 

Other bolts beyond requirements shall not be used.

(a):80-100N·m

Use special tool and hammer to mount the differential’s right oil seal till it keeps even with the housing surface.

Notice 

Tightening torque

Use special tool and hammer to mount the intermediate shaft’s right bearing outer ring and intermediate shaft’s oil tray.

Make differential oil seal’s spring side face inward

Special tools (E): Oil seal erector1 Differential gear oil seal’s mounting depth: “a”:1.0-1.5mm 2.4.5 Left Box Body 1. Main reducer gear bolt 2. Final reduction gear 3. Torque wrench 4. Soft bench clamp

1

Fig.4-4-4 Differential bolt

2

Final reduction gear

3

Torque wrench

4

Soft bench clamp

1)

With a special tool with a hammer on the differential left side oil package, until the surface is flush with the housing.

Notice 

Make the oil seal’s spring side face inward

Special tools(A):Oil seal erector2: differential oil seal’s mounting depth: “a”: 1.0-1.5mm

2.4.4 Right box body 1)

Mount the input shaft’s oil seal and keep the spring side upward. During the mounting process, use special tool and hammer.

Special tool(A):bearing erector6

Oil seal

2)

Intermediate shaft with a plastic hammer, gently knock on the left side of the bearing outer ring into the housing chamber.

Gearshift Mechanism 1J-1

Attached Table 1: Special Tools

Snap ring plier

Dial gauge

Box splitter

Bearing puller

Oil seal erector2

Bearing erector1

Bearing erector2

Bearing erector2

Spring pin ejector(4.5mm)

Oil seal ejector

Bearing erector3

Magnet base

Oil seal

erector1

Mounting connection Seal ring erector rod

Bearing outer ring erector

Spring pin ejector (6.0mm)

Bearing puller accessories

Bearing erector4

Gear fixer

Slide shaft

Bearing erector5

Bearing ejector

Bush ejector

Bearing erector6

Bearing erector7

Gearshift Mechanism 1J-2

Chapter 9 Gearshift Mechanism Table of Contents Gearshift Mechanism ························································································1J-2 Manual Gearshift Mechanism Dismantling/Mounting················································· 1J-2 CVT Automatic Gearshift Mechanism Dismantling/Mounting······································· 1J-2

Gearshift Mechanism 1J-3

1.2 CVT Automatic Gearshift Mechanism Dismantling/Mounting

1. Gearshift Mechanism 1.1 Manual Gearshift Dismantling/Mounting

1.

Firstly, dismantle the assistant instrument platform assembly;

2.

Then remove them as illustrated shift mechanism, contrary installation and removal order.

3.

After the mounting, confirm if the mechanism is fixed and can run stably.

Mechanism

1.

Firstly, dismantle the assistant instrument platform assembly;

2.

Then remove them as illustrated shift mechanism, contrary installation and removal order.

3.

After the mounting, confirm if the mechanism is fixed and can run stably.

1

Gearshift handle

2

Flange bolt

3

Flat washer

4

Manual gearshift lever assembly

5

Cable assembly

6

Cable bracket

7

Flange nut

Notice 1. Control the cable and connect it with the transmission correctly (no reverse mounting in gear selection and shift) 2. During the dismantling process, keep cautious and do not injure the cable buckle. After the assembly be sure to check whether the card slot into place.

1

Gearshift handle

2

Gear display cover

3

Flange bolt

4 5

Automatic gearshift lever assembly Flat washer

6

Cable assembly

7

Flange nut

8

Cable bracket

9 Spring clamp 10 Shift cable mounting bracket 11 Flange bolt 12 Flange nut Notice 1. Control the cable and connect it with the transmission correctly. 2. During the dismantling process, keep cautious and do not injure the cable buckle. After the assembly be sure to check whether the card slot into place.