U201 Service Manual Volume 1

Edition:July 2014 VOLUME 1
Printing:August 2014 INTRODUCTION 01

Version Number:FTSM-201408 PREPARATION 02
Printed in China MAINTENANCE SPECIFICATION 03
VEHICLE CARE 04
ENGINE CONTROL SYSTEM 11
ENGINE MECHANICAL SYSTEM
(ISF2.8)
12A
ENGINE MECHANICAL(BJ486ZLEQ4) 12B
FUEL 13
INTAKE AIR 14
EXHAUST 15
COOLING 16
LUBRICATION(BJ486ZLEQ4) 17
START AND CHARGING 18
IGNITION(BJ486ZLEQ4) 19
TRANSMISSION 21
CLUTCH 22
TRANSFER CASE 23
VOLUME 2
FRONT SUSPENSION 31
REAR SUSPENSION 32
TIRE AND WHEEL 33
AXLE AND PROPELLER SHAFT 34
BRAKE 35
PARKING BRAKE 36
STEERING MECHANISM 37
POWER STEERING 38
HEATING AND AIR CONDITIONING 41
S U P P L E M E N TA L R E S T R A I N T
SYSTEM
42
© 2014 Beiqi Foton Motor Co., Ltd LIGHTING 43
WIPER AND WASHER 44
All right reserved.No part of this AUDIO SYSTEM 45
service manual may be reproduced PARKING AID 46
or stored in a retrieval system,or
VEHICLE CONTROL SYSTEM 47
transmitted in any form,or by any
HORN AND CIGARETTE LIGHTER 48
means, electronic,mechanical,
WINDOWS AND REARVIEW MIRRORS 51
photocopying,recording or
INSTRUMENT PANEL AND AUXILIARY
otherwise, without the proir written INSTRUMENT PANEL
52
permission of Foton.
SEAT 53
DOOR LOCK 54
DOORS AND ENGINE HOOD 55
INTERIOR/EXTERIOR TRIM 56
VOLUME 3
CIRCUIT 61
DIAGNOSIS 62
INDEX
INTRODUCTION
HOW TO USE THIS MANUAL ............. 01-1 01
GENERAL ......................................... 01-1
IDENTIFICATION INFORMATION ....... 01-5
VEHICLE IDENTIFICATION NUMBER
(VIN).................................................. 01-5
SERIAL NO. (SN) ............................. 01-6
GENERAL RULES OF MAINTENANCE
OPERATION........................................ 01-7
OPERATION PRECAUTIONS .......... 01-7
VEHICLE JACKING AND SUPPORTING
POSITION ....................................... 01-17
HOW TO TROUBLESHOOT THE
VEHICLE ........................................... 01-18
GENERAL ....................................... 01-18
ABOUT USING DIAGNOSTIC DEVICE
........................................................ 01-19
HOW TO PERFORM
TROUBLESHOOTING .................... 01-20
ANALYZING FAULT DESCRIBED BY
CUSTOMER ................................... 01-21
FAULT SYMPTOM CONFIRMATION
AND DTC (AND DATA FLOW)
DETECTION ................................... 01-22
SIMULATING DETECTION FOR
SYMPTOM ...................................... 01-25
DIAGNOSTIC TROUBLE CODES(DTC)
LIST ................................................ 01-27
SYMPTOM TABLE .......................... 01-28
DETECTION PROCEDURE OF
CIRCUITS ....................................... 01-29
INTRODUCTION - HOW TO USE THIS MANUAL 01-1
HOW TO USE THIS MANUAL

GENERAL
1. Introduction 01
(a). This manual offers a general instruction for completing the maintenance service.
The operation in the light of such instruction helps ensure the quality and efficiency
of the maintenance.
(b). In general, the maintenance operations can be divided into the three following main
parts:
• Diagnosis
• Replacement (Removal and installation), disassembly and assembly, (vehicle)
inspection and adjustment
• Final inspection
(c). "Replacement (removal and installation), disassembly and assembly, (vehicle)
inspection and adjustment" is described in this manual, but excluding the final
inspection.
(d). The following important operations essential to the actual maintenance are not
explained in this manual:
• Operation with a jack or lift
• Clean the removed parts, as needed
• Visual inspection
2. Index
(a). "Vocabulary Index Table" is attached at the end of this manual for your easy
reference.
3. Preparation
(a). "Preparation" of Section 2 in this manual lists the special tools, recommended tools
and auxiliary materials required for maintenance service. Please strictly comply with
the operation procedure for the purpose of proper use.
4. Maintenance steps
(a). According to the needs of the sections, insert the component drawing to explain the
system.
01-2 INTRODUCTION - HOW TO USE THIS MANUAL
(b). The component drawing, in the form of exploded view, clearly describes the
assembly relationship between all parts, and it lists the name of all parts following
the drawing.
Example:
INTRODUCTION - HOW TO USE THIS MANUAL 01-3
(c). If the installation steps are opposite to the disassembly step, only the key part shall
be described.
(d). The maintenance steps of this manual only describe the key part and use illustration
to indicate the operation objects and operation content. In the step description, it 01
lists the details, standard values, operation cautions, etc. for the operation method.
(e). In this manual, some similar vehicle types may share with the same illustration. In
this situation, the relevant content may have a little difference with the actual vehicle
type.
(f). The operation steps are shown in the following form:
• Operation step illustration indicates "What to do" and "Where to do".
• Operation step heading indicates "What to do".
• Operation step description indicates "How to do", and provides other information
including such as "Maintenance specification" and "Maintenance warning", etc.
Example:
5. Maintenance specification
(a). In this manual, the maintenance specification shall be marked in bold, without
requiring you to put your current work aside to look up. The relevant content is also
listed in the "Maintenance specification" in Chapter 3, for fast look-up.
01-4 INTRODUCTION - HOW TO USE THIS MANUAL
6. "Danger", "Warning" and "Attention"
Bold expression indicates that it may cause personal injury

Danger
to you or others.
Bold expression indicates that it may damage the parts
Warning
being repaired or equipments being used.
Bold expression indicates that it will provide further
Attention
additional information for maintenance operations.
7. Units - International System of Units

(a). The "units" in this manual use the International System of Units. (SI UNIT)
Example:
Torque:30N•m
INTRODUCTION - IDENTIFICATION INFORMATION 01-5
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
01
1. Vehicle identification number (VIN)
(a). As shown in the figure, the vehicle identification number (VIN) is stamped on
the vehicle identification tag (VIN tag) and vehicle identification nameplate (VIN
nameplate).
• Vehicle identification tag (VIN tag) - at the left corner of instrument board, it can
be seen through the front windshield.
• Vehicle identification nameplate (VIN nameplate) - it can be seen by just opening
the cabin cover of the engine.
China Beiqi Foton motor Co. Ltd. Manufacture

Brand Model
Gross mass Kg Number P
Engine Type Rated power Kw

Discharge Maximum design
capacity ml drawing quality Kg
Date of
manufacture Y T D
VIN
fuwx01003
01-6 INTRODUCTION - IDENTIFICATION INFORMATION
SERIAL NO. (SN)
1. Serial No. of the rear driving axle

(a). Serial No. of the rear driving axle is on the
axle tube.
2. Serial No. of drive shaft

(a). Serial No. of the drive shaft is printed on
the drive shaft tube.
INTRODUCTION - GENERAL RULES OF MAINTENANCE OPERATION 01-7
GENERAL RULES OF MAINTENANCE OPERATION

OPERATION PRECAUTIONS
01
1. Precautions for basic maintenance
(a). Precautions for maintenance operations.
• Be sure to wear uniform clean work clothes.

1 Clothing
• Be sure to wear helmet and work shoes.
• Before performing maintenance operations, get ready the

2 Vehicle protection front grille protective mats, fender protective mats, chair
cover and carpet, etc.
01-8 INTRODUCTION - GENERAL RULES OF MAINTENANCE OPERATION
• When two people or above jointly operate, be sure to pay

attention to the safety of others.
• If performing operation when the engine runs, always make
sure the good ventilation of workshop.
• When operating the high temperature, rotation, movement
3 Safety operation or vibration parts, always wear necessary protective device
to avoid to get burned or damaged.
• When jacking the vehicle, always perform operation in
specified supporting point and make sure the firm support.
• When jacking the vehicle, always use safe and qualified
equipment to perform operation.
• Before performing maintenance operations, always get

Preparation for tools ready tool rack, special tools, measuring instruments,
4
and measuring meter accessories, cleaning cloth and replacement parts used by
vehicle.
• Perform complete analysis and diagnosis for fault symptom,

and take effective solutions
• Before removing parts, check its general situation and
Removal installation and whether there is deformation or damage, etc..
5
disassembly assembly • When parts are very complex, record the operating steps or
make assembly marks to avoid damaging its function.
• Clean the removed parts as required, perform installation
after complete inspection.
• Put the removed parts according to sequence to avoid

being disturbed or contaminated.
• The disposable parts including O-rings and self-locking
6 Removed parts screw
shall obey the guidance of this manual, and new part shall
be replaced after removal.
• Reserve the replaced parts in case the customer checks.
(b). Jacking and supporting the vehicle.

• While jacking and supporting the vehicle, you must be especially careful and
ensure to implement the operation in the correct position. (Refer to "Chapter 01
Introduction - General Rules Of Maintenance Operations, Vehicle Jacking And
Supporting Position")
(c). Glue parts
• Glue parts refer to the parts having being applied with sealant before delivery,
such as bolt, nut, etc.
• If a glue part needs to be loosened, fastened again or moved in any way, it must
be reapplied with the designated sealant.
• When a glue part is reused, be sure to clean up the original sealant, and use the
compressed air to dry it, then apply the designated sealant onto the bolt, nut or
screw thread.
DANGER:
Torque inspection must be carried out according to the lower limiting value of torque
requirements.
• When using the sealant, sometimes it needs to wait for a period of time until the 01
sealant is solidified.
(d). Gasket.
• Add seal ring on the gasket so as to avoid oil leakage, as needed.
(e). Bolts, nuts and screws.
• In strict accordance with the specified tightening moment of force, use the torque
wrench to tighten up.
(f). Fuse.
•When replacing fuse, always conform
whether the rated current of new fuse
meets the requirements, never use the
fuse of which rated current does not
conform to the requirements.
Figure Symbol Part name Abbreviation
Fuse F
Fuse F/L
(g). Buckle
The common dismounting method of buckles used for the body parts is shown in
the following table
WARNING:
If the buckle is damaged in the process of maintenance, always replace it with a new one.
Shape(Example) Removal/Installation
Clip remover Slip-joint pliers
Shape(Example) Removal/Installation
Clip remover Slip-joint pliers
01
(h). Disassembly and assembly of vacuum

hose.
• During the disassembly and assembly of
vacuum hose, always hold the hose end,
never pull the middle part of the hose.
• When disconnecting the vacuum hose

connection, mark up with the tag, in order
to identify when connecting the pipeline.
• After completing the disassembly, always
carefully check if the vacuum hose has
been connected correctly.
• When using the vacuum pressure gage,
if the connection is too large, never
make the vacuum hose to be directly
connected with it, it shall always use the
dedicated adapter for adjustment. Once
the vacuum hose is forced open, it may
lead to air leakage.
(i). Use the torque wrench with a longer handle.

• When using the special maintenance tool
or torque wrench with a longer handle,
if the torque indicated by the torque
reaches the specified value, it means
that the actual torque is too large.
• This manual only describes the torque
value needs to be specified. When using
the special maintenance tool or torque
wrench with a longer handle, please
calculate the torque according to the
following formula.
• Formula: T'=T×L2/(L1 ＋ L2)
Torque wrench
T＇
reading(N•m)
T Actual torque(N•m)
Length of special tool
for service or
L1
lengthened
handle(mm)
Torque wrench
L2
length (mm)
2. Maintenance precautions for the vehicle type configured with the supplemental
restraint system
DANGER:
Part of vehicle types is configured with the supplemental restraint system: Driver airbag. In
case of operation not following the correct steps, it may cause sudden expansion of SRS,
and even result in serious accidents. At the same time, in case of wrong operation for
the supplemental restraint system, it may also lead to the failure to work properly. Before
carrying out the maintenance (including the removal, installation, inspection or replacement
of parts) for the supplemental restraint system, always carefully read all the following,
then carry out the operation following the correct steps as described in the maintenance
manual.
(a). General precautions.
• Because it is hard to identify the fault phenomenon for the supplemental restraint
system, diagnostic trouble code (DTC) will be taken as the most information
source when troubleshooting. Therefore, during troubleshooting for the
supplemental restraint system, always detect the diagnostic trouble code (DTC)
before disconnecting the battery.
• Always confirm to turn off ignition switch to "LOCK" position, and don't carry out
the operation until 90s after disconnecting the battery positive and negative cable.
(The supplemental restraint system is configured with a backup power supply,
therefore if the operation is carried out within 90s after disconnecting the battery 01
positive and negative cable, it may cause the sudden expansion of air bag.
• After disconnecting the battery negative cable, the memory of electronic clock
and audio system will be cleared. All necessary data shall be recorded before
maintenance. At the end of maintenance, reset the audio system and adjust the
electronic clock. Never try to use the backup power supply outside of the vehicle,
so as to avoid the loss of data in each memory of system. The backup power
supply will supply power for the supplemental restraint system, it may cause a
sudden expansion of air bag at the time of maintenance.
• Even if the impact is very small and the air bag is not expanded, the horn
button assembly and air bag ECU shall also be checked. (Refer to "Chapter 42
Supplemental Restraint System - Driver Air Bag, Replacement", "Chapter 42
Supplemental Restraint System - Airbag Control Units, Replacement")
• Never use the supplemental restraint system parts removed from another vehicle.
If the replacement is needed, always use the new parts.
• Never disassemble horn button assembly.
• If the horn button assembly falls to the ground, or cracks, pits, or other defects
appear on the shell, always replace it with the new parts.
• Never make the horn button assembly to be exposed in the hot air or open fire.
• A high- impedance multimeter shall be used for the system circuit fault check.
• The parts of the supplemental restraint system carry the instructions information
labels, always follow the precautions on the label in the process of maintenance.
• Always check the indicator light of air bag after completing the operation of the
supplemental restraint system.
(b). Clock spring.

• Always check if the clock spring is in the
centring state and the steering wheel has
been correctly installed on the steering
column. Otherwise, it may cause the
harness and connector get loose and
other faults. (Refer to "Chapter 37
Steering Mechanism - Steering Wheel,
Overhaul", "Chapter 42 Supplemental
Restraint System - Clock Spring,
Replacement")
(c). Horn button assembly (Configured with air

bag).
• When storing the horn button assembly,
alway place them face up and never
place any items on the horn button.
• Never measure the resistance of
explosive device of air bag, it will cause
the sudden expansion of air bag, this is
very dangerous.
• Never apply any grease or cleaning fluid
on the horn button.
• Store the horn button assembly in the
place where the ambient temperature is
lower than 93 ℃ , the humidity is not high
humidity and there is no electromagnetic
interference.
• Before the use of welding, always
disconnect air bag ECU connector.
• Before throwing away the old parts of the horn button assembly, always use the special
tool to ignite the air bag in the safe place with no electromagnetic interference. (Refer to
"Chapter 42 Supplemental Restraint System - Driver Air Bag, End-of-Live Disposal")
3. Electrical control
(a). Disconnect and connect the battery
negative cable.
• Before electrical maintenance, be sure
to disconnect battery negative cable to
prevent accident caused by reasons
such as short circuit.
• Before disconnecting or connecting the
battery cable, be sure to turn off ignition
switch and all electric appliance switches
and completely loosen the fixed nut of
cable. Do not distort or pry cable.
• Record for clock and radio, etc. will
be reset after disconnecting battery
negative cable. All necessary data shall
be recorded before maintenance.
(b). Operate electrical components.

• If there is no special needs, do not open
control module housing(If the IC pin is
accidentally touched, it may be damaged 01
due to electrostatic interaction).
• When disconnecting harness connector,
do pull the connector, and do not pull the
harness.
• Operate carefully, do not drop out
electrical components (such as sensor,
relay). If the electrical component is
dropped on the solid ground, replace it
with a new one, never reuse it.
• When cleaning engine with vapor, make sure that electrical components, air filter and
relevant parts of emission control system are protected from the effect of vapor.
• Never use impact wrench to disassemble and assemble temperature controlled switch or
temperature sensor.
• When checking the continuity of harness connector, insert the probe carefully to avoid the
pin distortion or damage.
• After replacing electrical element, always perform functional check for electrical element
and make sure its normal function.
4. Remove and install fuel control system parts
(a). Work site instruction for removing and installing fuel control system parts
• Select places with good ventilation, and there is no equipment or object that can
produce flame, including weld, grinder, electric drill, motor and oven.
• Never select a gas station or its surrounding, because vapored fuel may have
already been filled with the whole space.
(b). Remove and install fuel system parts
• Be sure to prepare the fire extinguisher before conducing any operation.
• To prevent static electricity generation, always connect vehicle and fuel tank, etc.
to ground, and maintain the dryness of workshop ground to prevent slip down.
• Never use such electric appliances as motor or work light to avoid the generation
of spark or high temperature.
• Never use hammer to prevent the generation of spark.
• Use fireproof container to collect cleaning cloth with fuel.
5. Remove and install the engine air intake system parts

WARNING:
Any Metal Debris Mixing Into Intake Tube Will Badly Damage The Engine.
(a). After removing air intake system parts, seal the parts opening with clean cleaning
cloth or adhesive tape.
(b). When installing air intake system parts, always confirm that there is no metal debris
enters into air intake system.
6. Operation Of Hose Hoop

(a). Before removing hose, check the depth
of connector insertion and the position of
hoop so as to accurately re-install.
(b). If the hose has deformation or dent,
replace it.
(c). If the hose can be reused, always put
the hoop in the place of print which is left
before.
(d). For spring type hoop, after the completion
of installation, its position can be adjusted
by pressing hardly to the direction of arrow.
7. Three way catalyst

WARNING:
A large amount of unburned fuels filling into three way catalyst will result in the overheating
of three way catalyst and cause fire. To prevent such accidents, always obey the following
matters needing attention when operating.
(a). Only use unleaded gasoline.(gasoline locomotive type)
(b). Engine idle running over 20min shall be avoided.
(c). Avoid unnecessary arcing test.
• Never perform arcing test if there is no special needs. If this experiment is
necessary, be sure to complete it as soon as possible.
• Never step on the accelerator when performing arcing test.
(d). Avoid to perform engine pressure test for a long time, be sure to complete it as soon
as possible.
(e). Never run the engine when the fuel in the fuel tank will be used up, to avoid engine
to flame out and bring additional load to three way catalyst.
VEHICLE JACKING AND SUPPORTING POSITION
1. Pay attention to the vehicle condition when jacking

(a). Principle: Be sure to jack vehicle under no-load condition, never perform this 01
operation under load condition.
(b). The center of gravity of the whole vehicle will be changed after removing heavy
parts such as engine and transmission. Always place balance block to prevent
vehicle overturn, or use jack for support in a position specified for jacking.
2. Precautions for using jack and four-post lift
(a). Always perform safe operation in accordance with the instruction of this manual.
(b). Never try to lift tire by crowbar to avoid the wheel and tire damage.
(c). Park the vehicle in a flat road surface, and tighten the parking brake.
(d). Turn the gear lever to the position of reverse gear.
(e). Always use the limit stop to block the wheel in the diagonal direction to the position
need to be jacked.
(f). Use jack with rubber pads or four-post lift to jack the vehicle.
DANGER:
Be sure to jack the vehicle in the specified jacking position.
01-18 INTRODUCTION - HOW TO TROUBLESHOOT THE VEHICLE
HOW TO TROUBLESHOOT THE VEHICLE

GENERAL
This vehicle model used a large amount of circuits. In general, the maintenance personnel
is required to have rich knowledges and skills to troubleshoot complex circuit fault.owever,
most of faults need checking circuits one by one. Provided a maintenance personnel has
a thorough understanding for each system and has basic knowledge of circuit, it is enough
for him to perform accurate diagnosis and necessary maintenance, thereby troubleshooting
the fault.
This manual is written based on above principles, aiming to provide accurate and effective
fault solution for maintenance personnel.
Please see the detail description in the following for troubleshooting procedure.
system Reference
ABS anti-lock brake system Chapter 62 Diagnosis - ABS anti-lock brake system
Air bag system Chapter 62 Diagnosis -Air bag system
Reversing radar system Chapter 62 Diagnosis – Reversing radar system
Chapter 62 Diagnosis – Power window control

Power window control system
system
Power Mirrors Chapter 62 Diagnosis – Power Mirrors
Chapter 62 Diagnosis – Power door lock control

Power door lock control system
system
Chapter 62 Diagnosis – Gasoline engine control
Engine control system
system
Wiper and washer Chapter 62 Diagnosis – Wiper and washer
Rear window defrosting system – Rear window defrosting system
Horn Chapter 62 Diagnosis – Horn
Heater and air conditioning Chapter 62 Diagnosis – Heater & air conditioning
Audio system Chapter 62 Diagnosis –Audio system
Lighting system Chapter 62 Diagnosis – Lighting system
Combination meter Chapter 62 Diagnosis – Combination meter
Integrated display Chapter 62 Diagnosis – Integrated display
Body controller Chapter 62 Diagnosis – Body controller
Chapter 62 Diagnosis – Tire pressure monitoring

Tire pressure monitoring system
system
Transfer case Chapter 62 Diagnosis – Transfer case

INTRODUCTION - HOW TO TROUBLESHOOT THE VEHICLE 01-19
ABOUT USING DIAGNOSTIC DEVICE
1. Before using diagnostic device, be sure to read the instruction carefully

2. Connect diagnostic device to the diagnostic harness connector of instrument panel, 01
turn ignition switch to "ON". If the diagnostic device cannot establish communication
with control module, it indicates that vehicle or diagnostic device may have fault
(a). If the communication is normal when this diagnostic device is connected to another
vehicle, detect the diagnostic harness of instrument panel or the power circuit of
control module.
(b). If the communication still cannot be established when this diagnostic device is
connected to another vehicle, it indicates that the diagnostic device itself may have
fault. Please perform operation in accordance with the self-diagnostic procedure of
diagnostic device operation instruction.
HOW TO PERFORM TROUBLESHOOTING

NOTICE:
• Only the basest operating procedure is simply listed here.
• Please perform troubleshooting in accordance with the operating procedure described in
the following.
• Before performing any maintenance operation, be sure to determine the troubleshooting
procedure of relevant circuit.
1. Fault vehicle entering factory

2. Analyzing fault described by customer
(a). Inquiry the customer about the conditions and the environment when the incident
occurred.
3. Fault symptom confirmation and dtc (including data flow) detection
(a). Measure the battery voltage.
Voltage: 11-14 V (Engine is in off state)
(b). Visual check whether harness, connector and fuse are open circuit or short circuit.
(c). Start engine and warm it up to normal operating temperature.
(d). Confirm fault symptom and setting conditions, and detect DTC.
Is DTC detected?
Yes> Go to Step 4.
No> Go to Step 5.
4. Inquiry DTC list
(a). Check DTC obtained in Step 3, inquiry DTC list, and formulate checking procedure
for system or parts according to "Fault Position".
Directly go to Step 6.
5. Inquiry fault symptom table
(a). Check fault symptom obtained in Step 3, inquiry Fault Symptom Table, and
formulate checking procedure for system or parts according to "Suspected Position".
6. Circuit and parts detection
(a). Check the system circuit or parts that may have fault which are obtained in Step 4
and Step 5.
(b). Confirm fault circuit or parts.
7. Maintenance
(a). Adjust, repair or replace fault circuit or parts.
8. Confirmatory test
(a). After completing maintenance, always confirm whether fault is eliminated.
(b). If fault does not appear again, you still shall simulate the vehicle and environment
conditions when the fault firstly occurred and perform confirmatory test.
9. Completion
ANALYZING FAULT DESCRIBED BY CUSTOMER

NOTICE:
• In the troubleshooting process, never simply take the first impressions, always do
accurate judgment, and confirm fault symptom. 01
• It is very important to inquiry the customer about the conditions and the environment
when the incident occurred.
• Some seemingly irrelevant fault and maintenance experiences sometimes may also
assist the fault analysis. Therefore, collect fault symptom related information as much as
possible to provide reference for troubleshooting.
• To accurately confirm fault symptom, the following 5 items shall be generally considered
when analyzing fault described by customer.
What's the situation? Model No., system name

When? Date, time and frequency
Where? Road condition
Operating conditions, driving condition,
What's the condition?
climate condition
How happened? Malfunction
FAULT SYMPTOM CONFIRMATION AND DTC (AND DATA FLOW)

DETECTION
NOTICE:
The diagnostic system has many functions.
1. The first function is diagnostic trouble code (DTC) detection The fault signal of
control module circuit will be saved in the memory of control module in the form of
code. The maintenance personnel can check previous DTC when operates.
2. Another function is input signal detection. Check whether each signal from switch
has accurately been sent to control module. Utilizing these functions can help to
rapidly reduce the range of troubleshooting and improve maintenance efficiency.
Detect Signal
System Symptom
system trouble detection streaming
description diagnosis
code(DTC) (sensor)
ABS anti-lock
- ● ● ● ●
Brake system
Engine control
● ● ● ● ●
system
Body control
● ● ● ● ●
system
SRS
Supplemental
- - - - ●
restraint
system
Reversing
- - - - ●
radar system
Power window
- - - - ●
control system
Power rearview
- - - - ●
mirrors
Power door
lock control - - - - ●
system
Wiper and
- - - - ●
washer
Rear window
defroster - - - - ●
system
Horn - - - - ●
Heater and air

- - - - ●
conditioning
Detect Signal
System Symptom
system trouble detection streaming
description diagnosis
code(DTC) (sensor)
Audio system - - - - ● 01
Lighting
- - - - ●
system
Combination
- - - - ●
meter
Integrated
- - - - ●
display
Tire pressure
monitoring - - - - ●
system
Transfer case - - - - ●
1. When detecting DTC, it is very important to judge whether the fault indicated by this
code has been occurred but returns to normal now. In addition, when confirming
fault symptom, you must check whether the fault indicated by DTC has direct
relationship with fault symptom. Therefore, DTC detection must be performed before
and after confirming fault symptom, to judge the current state of vehicle. Otherwise,
it will result in unnecessary fault diagnosis and elimination for normal system,
increase the difficulty of trouble shoot or perform some irrelevant maintenance
operations. Therefore, always obey the operating procedure to perform DTC
detection
2. The procedure about how to use DTC detection to perform troubleshooting is
as shown in the following picture. This flow indicates how to effectively use DTC
detection. Finally, this flow indicates how to use DTC and Fault Symptom Table to
perform troubleshooting
(a). DTC detection.
(b). Record the detected DTC and erase DTC.
WARNING:
If DTC is detected in inital DTC detection, it indicates that circuit harness or connector may
have fault, please check relevant harness or connector.Harness or connector. (Refer to
"Chapter 01 Introduction-How to Eliminate Vehicle Fault, Circuit Detection Procedure")
(c). Fault symptom confirmation.
Does fault symptom still exist?
Yes> Go to Step 4.
No> Go to Step 5.
(d). Fault symptom simulation detection. (Refer to "Chapter 01 Introduction-How to
Eliminate Vehicle Fault, How to Perform Troubleshooting")
(e). Check DTC again.

Is DTC detected?
Yes> Check the fault indicated by DTC.
No > System OK.
(f). Fault symptom confirmation.
Is fault symptom detected?
Yes> Go to Step 7.
No > System OK.
(g). Troubleshooting by Fault Symptom Table
The occurred fault exceeds the detection range of vehicle diagnostic system (The
previously occurred DTC may indicate previous fault, or it is not the key point).
(h). End.
SIMULATING DETECTION FOR SYMPTOM

NOTICE:
• As for troubleshooting, the most difficult is that there is no symptom being found. In this
case, intensively analyze the faults mentioned by clients, and simulate the vehicle and the 01
environmental condition while the faults appear. For a maintenance technician, regardless
of his abundant experience and skillful technique, if he do not identify the symptom in
troubleshooting, he must neglect some important information in maintenance operations
and make wrong guessworks.
• For example, those faults, which only exist when the engine is cold or when the highway
conditions are poor in the process of moving, will never be found when the engine is hot
or when the vehicle stops. Common causes for faults such as vibration, high temperature,
water leakage (dampness), etc., can hardly appear again. Therefore, we introduce the
simulating detection for symptom here, which is an effective method to modulate the
external factors while the vehicle is at parking state.
• Key points on the simulating detection for symptom:
Firstly, the symptom must be identified and the position or part must be detected. To
achieve this goal, before the simulating detection for symptom, connect the diagnostic
device firstly and decrease the checking scope of the malfunctioning circuit according
to the symptom. Then, implement the simulating detection for symptom to decide
whether the circuit tested is out of order or in good condition and meanwhile to ensure
the symptom. Inquire all the system symptom table to decrease the scope of the possible
causes for the symptom.
1. Shake method---is for the faults possibly

caused by vibration
(a). Parts and sensors
• Shake slightly the sensor, which may
have faults, and check whether there are
faults.
WARNING:
Shaking at full tilt may lead to the the short circuit
of the relay.
(b). Connector.
• Shake the connector slightly in vertical
and horizontal directions.
(c). Harness.
• Shake the harness slightly in vertical
and horizontal directions. The main area
for checking is the connection between
harness and connector.
2. Heating method---is for the faults possibly

caused by some positions heated
(a). Heat the part, which possibly causes faults,
with a blower or something similar and
check whether there are faults.
WARNING:
• The heating temperature is not allowed to exceed
60℃ to avoid damaging the part.
• Do not heat the part in control module.
3. Drenching method---is for the faults

possibly caused by rainy days or high
humidity environmental conditions
(a). Sprinkle water on the vehicle and check
whether there are faults.
WARNING:
• Do not sprinkle water directly on the cabin cover
of the engine. Sprinkle water on the radiator to
indirectly change the temperature and humidity
of the engine.
• Do not sprinkle water directly on the electrical
components.
• If the vehicle leaks water, the liquid leaked
may pollute the control module. Much attention
should be paid to this point while implementing
the drenching method on vehicles.
4. High electrical load method---may be for the faults caused by the overhigh electrical
load.
(a). Open all the electric equipments including air condition, headlamp, rear window
heater, etc. and check whether there are faults.
DIAGNOSTIC TROUBLE CODES(DTC)LIST

Take the DTC list of the engine control system as an example, as shown in the table below.
This table shows the DTC and lists the corresponding detection procedure. Check faults
according to this table will improve the efficiency and accuracy greatly. 01
Diagnostic Trouble Code List

Note:
In the process of DTC test in the check mode , check the circuits of codes listed
in the table below if a certain DTC is displayed. Refer to the corresponding page for
the detailed description of every DTC .
Diagnostic Trouble The concrete meaning Circuits or parts

Code of trouble code which may has faults
DTC code Diagnostic Item ( DTC Definition ) Trouble location
·Battery
Under voltage ·Charging system
·System Power Supply
·Fuse
·System power supply
Overhigh voltage
·Airbag Control Module
Driver Front Airbag Short Circuit

to the Grounding ·Driver Airbag Circuit
·Driver Airbag Assembly
· Airbag Control Module
fuwx01033
SYMPTOM TABLE
Symptom table is to show the possible reasons causing every fault (e.g. circuit, part, etc.),
as shown in the table below. If the diagnostic device shows that the system is in good
condition but there still are faults, detect the faults through the symptom table. The serial
numbers of the table mean the checking sequence of circuits or parts.
If the vehicle diagnosis system fails to detect faults but they actually have, it means that
the faults occurred are out of the detection range of the vehicle diagnosis system.
Table of Malfunction Symptoms

You can find the needed fault information quickly using the following table.
Circuits or parts
Fault Symptom need to be Methods of trouble removal
checked
fuwx01034
DETECTION PROCEDURE OF CIRCUITS
1. Basic checkup
(a). The measuring condition of the resistance of electrical components. 01
• If there are no special instruments, all the measuring operations of resistance
should be implemented in the environment with the temperature at 20℃ .
• The operating vehicle will generate high temperature, in which the resistance
value measured may exceed the range required. Therefore, the resistance
measure must be implemented after the engine becomes cool.
(b). Operating notes for connectors

• While removing the connector with a
snap close, press the connector slightly
along the connecting direction, and then
press the agraffe gently to open the snap
close.
• While removing the connector, hold it
and do not pull the harness.
• While connecting the connector, check
whether the connector is distorted,
damaged or in lack of pins.
• While connecting the connector with
a snap close, the sound "clatter" must
be heard to ensure that it is securely
connected.
• While checking the connector with a
multimeter, be sure to check the back of
the connector (the side of harness) with
the microprobe.
NOTICE:
• The waterproof connector cannot be checked in the back, so please check it after
connecting the auxiliary harness.
• Be careful to move the probe and do not damage the pins of the connector.
(c). Key points for checking connectors

While connecting the connector, please
check:
• Hold the connector, check the cut-in and
lock states (i.e. coherent state).
While the connector is disconnected,
please check:
• Pull the harness slightly to check whether
the pin is complete and curved and
whether the center harness is broken.
•Check visually whether the connector is rusted, mixed with metal debris and dipped by
water, or whether the pin is curved, rusted, mixed with foreign matters or distorted.
Check the contact pressure of pins:
• Insert the male plug prepared into the

female plug to check the coherent state
and sliding resistance.
WARNING:
The gilded male plug must be used to check the
gilded female plug.
(d). Maintenance methods of connector pins.

• If the contact is polluted by oil stain, it
must be cleaned with compressed gas or
duster cloth. Do not polish it with emery
cloth, because the galvanized coating
may be destroyed.
• If the contact pressure is abnormal, the
female plug should be replaced. At this
time, if the male plug is gilded, the gilded
female plug must be replaced; if the male
plug is silver-gilt, the silver-gilt female
plug must be replaced.
(e). Operating notes of harness.
• Before removing the harness, check it
and the position of the harness strip to
make sure the exact reassembly.
• Do not distort, pull and suspend the
harness excessively.
• Do not contact the harness with parts
of high temperature, rotation, move,
vibration and tartness (e.g. panel edge,
screw tip, etc. )
• While installing parts, do not press or
clamp the harness.
• Do not cut or damage the insulation
covering of the harness. If it is broken
carelessly, replace the harness or bind
up the breakage with the empire cloth.
2. Checkup of open circuits

(a). The circuit is shown as the fig. on the left.
Check the continuity and voltage in Step
(b) and Step (a) respectively to identify the 01
position of open circuit.
(b). Checkup of continuity.

• Disconnect the connector A and C, and
measure the resistance between them.
Resistance: ＜ 2Ω
NOTICE:
Shake the harness slightly in vertical and
horizontal directions and measure the resistance.
Take this circuit as an example:
If the resistance between connector A and
the No.1 pin of connector C is：≥ 1 MΩ
and the resistance between connector A
and the No.2 pin of connector C is: ＜ 2 Ω
It can be concluded that the open circuit is
between connector A and the No.1 pin of
connector C.
• Disconnect connector B and measure the

resistance between connectors.
If the resistance between connector A and
the No.1 pin of connector B1 is: ＜ 2 Ω
and the resistance between connector B2
and the No.1 pin of connector C is: ≥ 1 MΩ
it can be concluded that the open circuit is
between connector B2 and the No.1 pin of
connector C.
(c). Checkup of voltage.

• In the Power ON condition of the circuit,
identify whether the loop is an open
circuit through checking the voltage.
• Take this circuit as an example, all the
connectors are still connected. Measure
the voltage between the grounding and
the No.1 pin of connector A, the No.1
pin of connector B and the No.1 pin of
connector C respectively in order, which
are located at the position where control
module 5V outputs pins.
If the measuring result is as follows:
the voltage between the No.1 pin of connector A and the grounding: 5 V
the voltage between the No.1 pin of connector B and the grounding: 5 V
the voltage between the No.1 pin of connector C and the grounding: 0 V
it can be concluded that the open circuit is between connector B and the No.1 pin of
connector C.
3. A short circuit inspection

(a). The short circuit of harness grounding is
shown as the fig. on the left.Check the
continuity between it and grounding to
make sure the position of short circuit in
Step (2).
(b). Checkup of continuity.

• Disconnect connector A and C, and
measure the resistance between the
grounding and the No.1 pin and the No.2
pin of connector A respectively.
Resistance：≥ 1 MΩ
NOTICE:
Shake the harness slightly in vertical and
horizontal directions and measure the resistance.
the resistance between the No.1 pin of connector A and the grounding: ＜ 2 Ω
and the resistance between the No.2 pin of connector A and the grounding: ≥ 1 MΩ
it can be concluded that the short circuit is between connector A and the No.1 pin of
connector C.
•Disconnect connector B and measure the

resistance between the grounding and
connector A and the No.1 pin of connector
B2 respectively. 01
If the resistance between the No.1 pin of
connector A and the grounding: ≥ 1 MΩ
and the resistance between the No.1 pin
of connector B2 and the grounding: ＜ 2 Ω
It can be concluded that the short circuit is
between connector B2 and the No.1 pin of
connector C.
- MEMO -
PREPARATION
ENGINE CONTROL SYSTEM ............. 02-1 ILLUMINATIONS ................................ 02-32
PREPARATION ................................. 02-1 PREPARATION ............................... 02-32
ENGINE MECHANICAL ....................... 02-2 WIPER AND WASHER ....................... 02-33 02
FUEL .................................................... 02-6 AUDIO SYSTEM ................................ 02-34
INTAKE ................................................. 02-7 VEHICLE CONTROL SYSTEM .......... 02-35
EXHAUST............................................. 02-8 THE HORN AND THE CIGARETTE
PREPARATION ................................. 02-8 LIGHTER ........................................... 02-36
COOLING ............................................. 02-9 PREPARATION ............................... 02-36
PREPARATION ................................. 02-9 GLASS AND REAR-VIEW MIRROR .. 02-37
LUBRICATION.................................... 02-10 PREPARATION ............................... 02-37
PREPARATION ............................... 02-10 INSTRUMENT DESK AND SECONDARY
STARTING AND CHARGING ............. 02-11 INSTRUMENT DESK ......................... 02-38
PREPARATION ............................... 02-11 PREPARATION ............................... 02-38
TRANSMISSION ................................ 02-12 SEAT .................................................. 02-39
CLUTCH ............................................. 02-17 DOOR LOCKS.................................... 02-40
TRANSFER CASE ............................. 02-18 DOOR OF THE VEHICLE/ENGINE HOOD.
PREPARATION ............................... 02-18 ............................................................ 02-41
FRONT SUSPENSION....................... 02-19 PREPARATION ............................... 02-41
PREPARATION ............................... 02-19 INTERIOR AND EXTERIOR
REAR SUSPENSION ......................... 02-20 DECORATIONS ................................. 02-42
TIRE AND WHEEL ............................. 02-21
PREPARATION ............................... 02-21
AXLE AND TRANSMISSION SHAFT ..........
............................................................ 02-22
PREPARATION ............................... 02-22
SERVICE BRAKE............................... 02-26
PREPARATION ............................... 02-26
PARKING BRAKE .............................. 02-27
PREPARATION ............................... 02-27
STEERING GEAR .............................. 02-28
PREPARATION ............................... 02-28
POWER STEERING........................... 02-29
PREPARATION ............................... 02-29
HEATER & AIR CONDITIONING ....... 02-30
PREPARATION ............................... 02-30
SUPPLEMENTAL SAFEGUARD
SYSTEM ............................................. 02-31
PREPARATION ............................... 02-31
PREPARATION - ENGINE CONTROL SYSTEM 02-1
ENGINE CONTROL SYSTEM

PREPARATION
Recommended tools
Tool Name Function 02
Diagnose the fuel injection system

Diagnose the ignition system
Intelligent diagnostic unit
Diagnose the sensor
Diagnose the actuator
Detect the sensor

Digital multimeter Detect the actuator
Detect the ECM
Detect the sensor

Test the conductor group Detect the actuator
Detect the ECM
Disassemble and assemble the

Torque spanner
fixed bolt
02-2 PREPARATION - ENGINE MECHANICAL
ENGINE MECHANICAL
PREPARATION
Special Tools
Tool Name Function
Installation tool for valve lock

Install the valve lock clamp
clamp
emoval tool for valve lock

Remove the valve lock clamp
clamp
Oil pan pry Remove the oil pan
Flywheel stopper Fix the flywheel and crankshaft
Steering tool for crankshaft

Install the crankshaft rear oil seal
rear oil seal
Installation tool for crankshaft

Install the crankshaft front oil seal
front oil seal
PREPARATION - ENGINE MECHANICAL 02-3
Tool Name Function
Piston installation tool Install the piston

02
Clutch driven plate centring

Install the clutch
tool
Removal tool for intermediate Remove the front bush of

shaft bush intermediate shaft
Installation tool for termediate Install the front bush of intermediate

shaft bush (front) shaft
Installation tool for termediate Install the rear bush of intermediate

shaft bush (rear) shaft
Timing chain brace rod Support and tension timing chain

02-4 PREPARATION - ENGINE MECHANICAL
Recommended tools
Tool Name Function
Detect parts such as crankshaft

Dial indicator
and camshaft
Micrometer Detect the camshaft

Circlip plier
piston pin

Lifting type hydraulic jack
engine
Vernier caliper Detect the piston
Clearance gauge Detect the piston ring gap

PREPARATION - ENGINE MECHANICAL 02-5
Tool Name Function

Nipper plier
water pipe clamp 02

Torque spanner
fixed bolt
Detect the flatness of cylinder block

Precision straight edge and cylinder cover with fit clearance
gauge
02-6 PREPARATION - FUEL
FUEL
PREPARATION
Recommended tools
Tool Name Function

Nipper plier
elastic clamp of oil pipe
Disassemble and assemble the fuel

Lifting type pressure jack
tank assembly
Disassemble and assemble the fuel

Filter wrench
filter assembly
PREPARATION - INTAKE 02-7
INTAKE
PREPARATION
Recommended tools
High pressure air rifle Clean the air intake system

Torque spanner
fixed bolt or nut
02-8 PREPARATION - EXHAUST
EXHAUST
PREPARATION
Recommended tools
Tool Name Function

Torque spanner
fixed bolt or nut
PREPARATION - COOLING 02-9
COOLING
PREPARATION
Recommended tools
Detect the sealing performance of

Radiator cap tester
radiator
High pressure air rifle Clean heat exchanger
Thermometer Detect the thermostat

02-10 PREPARATION - LUBRICATION
LUBRICATION
PREPARATION
Recommended tools
Tool Name Function
Detect the radial clearance of oil

Clearance gauge
pump rotor
Oil pan pry Remove the oil pan

Torque spanner
fixed bolt
Measure the oil pump rotor axial

Precision straight edge
clearance
PREPARATION - STARTING AND CHARGING 02-11
STARTING AND CHARGING

PREPARATION
Recommended tools
Digital multimeter Detect the alternator
Detect the alternatorDetect the

Dial indicator
starter
Vernier caliper Detect the starter
Puller Remove the alternator pulley
Electric soldering iron Overhaul the alternator
Circlip plier Overhaul the starter

02-12 PREPARATION - TRANSMISSION
TRANSMISSION
PREPARATION
Special Tools
Tool Name Function
Installation tool for shaft Install the shaft sleeve of reverse

sleeve of reverse shaft shaft
Removal tool for shaft sleeve Remove the shaft sleeve of reverse
of reverse shaft shaft
Removal tool for front and Remove the front and rear box of
rear box transmission
Chuck
Bearing outer ring puller

Remove the bearing outer ring
Remove
Removal tool (punch)5mm

Remove the differential shaft pin
for differential shaft pin
PREPARATION - TRANSMISSION 02-13
Tool Name Function

for differential shaft pin 02

for differential shaft pin
Selector pin ejection tool Remove the selector pin
Handle for oil seal installation Install oil seal
Installation and removal tool Disassemble and assemble the

for input bearing input shaft bearing
Installation tool for output

Install the output shaft bearing
bearing
Removal tool for output

Remove the output shaft bearing
bearing
Tool Name Function
Installation tool for oil seal of Install the oil seal of input shaft
input shaft front end cover front end cover
Installation tool for output

Install the output shaft oil seal
shaft oil seal
Installation tool for reverse

Install the reverse shaft oil seal
shaft oil seal
Installer cover
Installer 1
Installer 2
Installation tool 1 for Install the bearing of intermediate

intermediate bearing shaft
PREPARATION - TRANSMISSION 02-15
Tool Name Function
Removal tool for bearing Remove the bearing outer ring of

outer ring of second shaft second shaft 02
Recommended tools
Tool Name Function
Detect the clearance of

synchronizer
Clearance gauge
Detect the adjusting gasket of
intermediate shaft

Nipper plier
return spring

Copper rod
reverse idle gear shaft

Hammer
reverse idle gear shaft
Micrometer Detect the transmission shaft

Tool Name Function
Dial indicator Detect the transmission shaft

Circlip plier
circlip
Puller Remove the bearing or gear
Detect the shift fork

Vernier caliper
Detect the synchronizer

Torque spanner
fixed bolt
PREPARATION - CLUTCH 02-17
CLUTCH
PREPARATION
Recommended tools
Dial indicator Detect the friction plate

Circlip plier
clutch master cylinder
Vernier caliper Detect the friction plate

Torque spanner
fixed bolt
Clutch driven plate centring

Install the clutch
tool
02-18 PREPARATION - TRANSFER CASE
TRANSFER CASE
PREPARATION
Recommended tools
Tool Name Function
Puller Remove the bearing and flange

Torque spanner
fixed bolt
PREPARATION - FRONT SUSPENSION 02-19
FRONT SUSPENSION
PREPARATION
Recommended tools

Torque spanner
fixed bolt
Ball head puller Remove the swing arm ball head

Nipper plier
cotter pin of fixed nut
02-20 PREPARATION - REAR SUSPENSION
REAR SUSPENSION
PREPARATION
Recommended tools
Tool Name Function

Torque spanner
fixed bolt

Damper spring compressor
damping spring
Lifting type pressure jack Support rear axle

PREPARATION - TIRE AND WHEEL 02-21
TIRE AND WHEEL

PREPARATION
Recommended tools
Tire pressure gauge Detect the tire pressure

Torque spanner
fixed bolt
Hydraulic jack Support frame

02-22 PREPARATION - AXLE AND TRANSMISSION SHAFT
AXLE AND TRANSMISSION SHAFT

PREPARATION
Special Tools
Tool Name Function
Removal tool for differential

Removing differential side bearing
bearing
Installation tool for differential

Install the differential bearing
bearing

Install the right oil seal of differential
oil seal (right)

Install the left oil seal of differential
oil seal (left)
Installation tool for differential Install the differential left bearing

bearing outer race (left) outer race
Installation tool for differential Install the differential right bearing

bearing outer race (right) outer race
PREPARATION - AXLE AND TRANSMISSION SHAFT 02-23
Recommended tools
Tool Name Function
02
Tire pressure gauge Detect the tire pressure
Remove the universal joint of

transmission shaft
Remove the intermediate bearing
Remove the front hub cover
Hammer
Remove the rear hub cover
Remove the steering knuckle
Remove the differential and planet
gear shaft
Remove the universal joint of

transmission shaft
Remove the intermediate bearing
Remove the front hub cover
Copper rod Remove the rear hub cover
Remove the rear hub bearing
Remove the steering knuckle
Remove the differential and planet
gear shaft
Detect the universal joint crossing

Micrometer
shaft of transmission shaft
Detect the universal joint of

transmission shaft
Detect the front hub bearing
Detect the rear hub bearing
Dial indicator Detect the driving gear
Detect the passive wheel
Detect the half axle gear
Detect the planet gear
Detect the driving gear flange
02-24 PREPARATION - AXLE AND TRANSMISSION SHAFT
Tool Name Function

universal joint of transmission shaft
Circlip plier
output flange of main reducer
Remove the joint fork of transmission

Puller
shaft
Lubricate the front hub bearing

Grease gun Lubricate the rear hub bearing
Lubricate the steering knuckle
Detect the front hub rotary starting

force
Spring balance
Detect the rear hub rotary starting
force

Nipper plier
cotter pin
Measure the total clearance of rear

Tape measure
axle
Disassemble and assemble the oil

filler plug of main reducer
Allen key
Disassemble and assemble the oil
drain plug of main reducer
PREPARATION - AXLE AND TRANSMISSION SHAFT 02-25
Tool Name Function

Lifting type hydraulic jack
main reducer assembly 02
Detect the axle shaft gear thrust

washer
Detect the planet gear thrust
washer
Vernier caliper
Detect the differential bearing
adjustment shim
Detect the driving gear adjusting
shim
Detect the starting torque of driving

gear
Torque spanner
fixed bolt
02-26 PREPARATION - SERVICE BRAKE
SERVICE BRAKE
PREPARATION
Recommended tools
Tool Name Function
Micrometer Detect the brake disc
Dial indicator Detect the brake disc
Detect the rear brake drum

Vernier caliper
Detect the rear brake shoe
Measure the total clearance of rear

Tape measure
axle
Puller Remove the front hub

Torque spanner
fixed bolt
PREPARATION - PARKING BRAKE 02-27
PARKING BRAKE
PREPARATION
Recommended tools
Detect the rear brake drum

Vernier caliper
Detect the rear brake shoe

front cable of parking brake
Disassemble and assemble the left
Nipper plier
rear cable of parking brake
right rear cable of parking brake
02-28 PREPARATION - STEERING GEAR
STEERING GEAR
PREPARATION
Recommended tools
Tool Name Function
Measure the driving wandering

Tape measure
distance

Allen key
driver air bag assembly
Detect the steering wheel turning

Spring balance
force

Torque spanner
fixed bolt
PREPARATION - POWER STEERING 02-29
POWER STEERING
PREPARATION
Recommended tools
Tape measure Driving wandering

Torque spanner
fixed bolt
02-30 PREPARATION - HEATER & AIR CONDITIONING
HEATER & AIR CONDITIONING

PREPARATION
Recommended tools
Tool Name Function
Refrigerant fills the rubber

Add the refrigerant
tube
Gas leak detector Refrigerant leakage detection
Overhaul the heater & air

Digital multimeter
conditioning control system
Detect the belt tightening of

Belt tension meter
compressor
fuwx02030
Refrigerant charging and

recycling device(The device Fill and recycle refrigerant
does not need vacuum Maintain the compressor assembly
pump)
Circlip plier Maintain the compressor assembly

PREPARATION - SUPPLEMENTAL SAFEGUARD SYSTEM 02-31
SUPPLEMENTAL SAFEGUARD SYSTEM

PREPARATION
Recommended tools

Allen key

Torque spanner
fixed bolt
Digital multimeter Detect the seat belt unfasten switch

02-32 PREPARATION - ILLUMINATIONS
ILLUMINATIONS
PREPARATION
Recommended tools
Tool Name Function
Digital multimeter Detect the circuit

Torque spanner
fixed bolt
PREPARATION - WIPER AND WASHER 02-33
WIPER AND WASHER

PREPARATION
Recommended tools
Digital multimeter Detect the wiper and circuit

Torque spanner
fixed bolt
02-34 PREPARATION - AUDIO SYSTEM
AUDIO SYSTEM
PREPARATION
Recommended tools
Tool Name Function
Detect the circuit and components

Digital multimeter
& parts

Torque spanner
fixed bolt
PREPARATION - VEHICLE CONTROL SYSTEM 02-35
VEHICLE CONTROL SYSTEM

PREPARATION
Recommended tools
Remove the anti-theft bolt of

Electric drill
ignition switch

Nipper plier
combination switch

Torque spanner
fixed bolt
02-36 PREPARATION - THE HORN AND THE CIGARETTE LIGHTER
THE HORN AND THE CIGARETTE LIGHTER

PREPARATION
Recommended tools
Tool Name Function

Nipper plier
cigar lighter

Torque spanner
fixed bolt
PREPARATION - GLASS AND REAR-VIEW MIRROR 02-37
GLASS AND REAR-VIEW MIRROR

PREPARATION
Recommended tools
Windshield
Plastic scraper
Rear window
fuwx02033

windshield
Glass sucker
rear window
Art knife Cut the sealant
fuwx02035
Silicone gun Smear the glazing compound
fuwx02036
Install the windshield

Rubber hammer
Install the rear window
Remove the windshield

Small-gauge wire
Remove the rear window
02-38 PREPARATION - INSTRUMENT DESK AND SECONDARY INSTRUMENT DESK
INSTRUMENT DESK AND SECONDARY INSTRUMENT

DESK
PREPARATION
Recommended tools
Tool Name Function
Intelligent diagnostic unit Combination meter

Allen key
Plastic crow plate Remove the trim strip

Torque spanner
fixed bolt
PREPARATION - SEAT 02-39
SEAT
PREPARATION
Recommended tools
Nipper plier Driver/passenger seat back

Torque spanner
fixed bolt
02-40 PREPARATION - DOOR LOCKS
DOOR LOCKS
PREPARATION
Recommended tools
Tool Name Function

Torque spanner
fixed bolt
PREPARATION - DOOR OF THE VEHICLE/ENGINE HOOD 02-41
DOOR OF THE VEHICLE/ENGINE HOOD

PREPARATION
Recommended tools
Grease gun Lubricate the door hinge

Torque spanner
fixed bolt
02-42 PREPARATION - INTERIOR AND EXTERIOR DECORATIONS
INTERIOR AND EXTERIOR DECORATIONS

PREPARATION
Recommended tools
Tool Name Function
Plastic crow plate Remove the interior trim part

Torque spanner
fixed bolt
MAINTENANCE SPECIFICATION
ENGINE CONTROL SYSTEM ............. 03-1 MAINTENANCE DATA .................... 03-25
MAINTENANCE DATA ...................... 03-1 TORQUE REQUIREMENTS........... 03-26
ENGINE MECHANICAL SYSTEM SERVICE BRAKE............................... 03-29
(ISF2.8)................................................ 03-2 MAINTENANCE DATA .................... 03-29 03
TORQUE REQUIREMENTS............. 03-2 TORQUE REQUIREMENTS........... 03-29
ENGINE MECHANICAL SYSTEM PARKING BRAKE .............................. 03-31
(BJ486ZLEQ4)...................................... 03-3 MAINTENANCE DATA .................... 03-31
TORQUE REQUIREMENT ............... 03-5 STEERING GEAR .............................. 03-32
FUEL .................................................... 03-8 MAINTENANCE DATA .................... 03-32
TORQUE REQUIREMENTS............. 03-8 POWER STEERING........................... 03-33
INTAKE ................................................. 03-9 MAINTENANCE DATA .................... 03-33
TORQUE REQUIREMENTS............. 03-9 TORQUE REQUIREMENTS........... 03-33
EXHAUST........................................... 03-10 HEATER & AIR CONDITIONING ....... 03-34
TORQUE REQUIREMENTS........... 03-10 MAINTENANCE DATA .................... 03-34
COOLING ........................................... 03-11 TORQUE REQUIREMENTS........... 03-34
MAINTENANCE DATA .................... 03-11 SUPPLEMENTAL SAFEGUARD SYSTEM .
TORQUE REQUIREMENTS........... 03-11 ............................................................ 03-36
LUBRICATION.................................... 03-12 MAINTENANCE DATA .................... 03-36
MAINTENANCE DATA .................... 03-12 TORQUE REQUIREMENTS........... 03-36
TORQUE REQUIREMENTS........... 03-12 ILLUMINATIONS ................................ 03-37
STARTING AND CHARGING ............. 03-13 TORQUE REQUIREMENTS........... 03-37
MAINTENANCE DATA .................... 03-13 WIPER AND WASHER ....................... 03-38
TORQUE REQUIREMENTS........... 03-13 TORQUE REQUIREMENTS........... 03-38
IGN ..................................................... 03-15 VEHICLE CONTROL SYSTEM .......... 03-39
TORQUE REQUIREMENTS........... 03-15 GLASS AND REAR-VIEW MIRROR ...........
TRANSMISSION ................................ 03-16 ............................................................ 03-40
TORQUE REQUIREMENTS........... 03-18 INSTRUMENT DESK AND SECONDARY
CLUTCH ............................................. 03-19 INSTRUMENT DESK ......................... 03-41
TORQUE REQUIREMENTS........... 03-19 SEAT .................................................. 03-42
TRANSFER ........................................ 03-20 TORQUE REQUIREMENTS........... 03-42
TORQUE REQUIREMENTS........... 03-20 DOOR LOCKS.................................... 03-43
FRONT SUSPENSION....................... 03-21 TORQUE REQUIREMENTS........... 03-43
MAINTENANCE DATA .................... 03-21 DOOR OF THE VEHICLE/ENGINE HOOD.
TORQUE REQUIREMENTS........... 03-21 ............................................................ 03-44
REAR SUSPENSION ......................... 03-23 TORQUE REQUIREMENTS........... 03-44
TORQUE REQUIREMENTS........... 03-23 INTERIOR AND EXTERIOR
TIRE AND WHEEL ............................. 03-24 DECORATIONS ................................. 03-45
TORQUE REQUIREMENTS........... 03-24
AXLE AND TRANSMISSION SHAFT ..........
............................................................ 03-25
03-1
MAINTENANCE SPECIFICATION - ENGINE CONTROL SYSTEM

MAINTENANCE DATA
Working voltage range 9~16V
ECU Operating ambient
-40~70℃
temperature
03
Coolant temperature Working temperature -30~130℃
sensor Thermistor (At 25 ℃ ) 1.825~2.155kΩ
Ambient temperature -40~150℃
Phase sensor Sensor clearance 0.2~1.8mm
Nominal voltage 5V
Coil resistance
731~989Ω
(At 20 ℃ )
Speed sensor Sensor working

0.5~1.5mm
clearance
Working temperature -40~120℃
Intake pressure Working voltage 5±0.25V

temperature sensor Working temperature -40~130℃
Minimum cut-in voltage 7V

Canister solenoid
Coil resistance 26±4Ω
Power supply voltage of

Oxygen sensor the plug (when working 12~14V
continuously)
Working temperature -40~130℃

Knock sensor
Resistance >1MΩ
Assembly Working temperature -40~140℃

Electronic Sensor Supply voltage 5±0.2V
throttle
Voltage range 8~16V
Air valve
DC Motor Terminating resistance 1.1~2.1Ω
Inductance (1k Hz) 1.1±0.3mH

03-2
MAINTENANCE SPECIFICATION - ENGINE MECHANICAL SYSTEM (ISF2.8)
ENGINE MECHANICAL SYSTEM (ISF2.8)

TORQUE REQUIREMENTS
Fasteners N•m
Engine right suspension assembly fixed bolts 95~100
Engine left suspension assembly fixed bolts 95~100
Air conditioning compressor pipeline fixed bolts 21~25
Steering oil pump pipeline hole bolts 40~45
Generator harness fixed nuts 21~25
Starter harness fixed nuts 18~20

03-3
MAINTENANCE SPECIFICATION - ENGINE MECHANICAL SYSTEM (BJ486ZLEQ4)
ENGINE MECHANICAL SYSTEM (BJ486ZLEQ4)

MAINTENANCE DATA
Correct electrode clearance of the spark plug 0.80~0.90mm
Axial clearance of the counter shaft 0.05~0.20mm
Inlet and exhaust camshaft radial circular runout 0.06mm 03

Inlet and exhaust camshaft diameter 23.939~23.960mm
Axial clearance of Standard value 0.05~0.15mm

the inlet and exhaust
Limit value 0.3mm
camshaft
Axial clearance of the Standard value 0.05~0.15mm

exhaust camshaft Limit value 0.3mm
Cylinder head bolt diameter difference limit value 0.15mm
Cylinder head base plane maximum flatness value 0.15mm

Maximum value of the installing surface for the
0.1mm
cylinder head and the intake/exhaust manifold
Maximum height for the cylinder head 113mm
Maximum removal for the cylinder head 0.2mm
Diameter of the tappet hole 31.00~31.02mm
Standard diameter of the tappet 30.946~30.980mm
Standard clearance between the tappet and the

0.020~0.056mm
tappet hole
Perpendicularity of the Standard value <2°

valve spring Limit value 4°
The intake and exhaust Standard value 1.0~1.2mm

door edge thickness Limit value 0.9mm
Standard value 105.7mm

The inlet valve length
Limit value 105.5mm
The exhaust valve Standard value 104.9mm

length Limit value 104.7mm
The intake valve stem diameter 5.468~5.480mm
The exhaust valve stem diameter 5.458~5.470mm
Clearance between the Standard value 0.020~0.050mm

intake valve stem and
Limit value 0.10mm
the conduit
03-4
Clearance between the Standard value 0.030~0.060mm

exhaust valve stem and
Limit value 0.12mm
the conduit
The width of the contact of the valve seat 1.0~1.2mm
Clearance of the intake valves 0.22~0.28mm
Clearance of the exhaust valves 0.27~0.33mm
The axial clearance of Standard value 0.160~0.312mm

the piston connecting
Limit value 0.35mm
rod
Clearance of the connecting rod neck of the

0.020~0.051mm
crankshaft
A 85.95~85.96mm
Piston diameter B 85.96~85.97mm
C 85.97~85.98mm
Clearance between the piston and the cylinder 0.04~0.06mm
Clearance between the The first ring groove 0.04~0.085mm
piston ring and the wall The second ring groove 0.03~0.07mm
of the piston ring Oil ring 0.03~0.13mm
The first ring 0.20~0.40mm
Piston ring end gap The second ring 0.35~0.55mm
Oil ring 0.20~0.90mm
The radial runout of the main journal of the

0.06mm
crankshaft
Crankshaft main journal diameter 57.981~58.000mm
Crankshaft connecting rod diameter 47.981~48.000mm
Ovality of the connecting rod neck of the crankshaft 0.02mm
The radial runout of the crankshaft main journal 0.020~0.051mm
Standard value 0.05~0.22mm

Crankshaft axial gap
Limit value 0.35mm
The maximum value of the flatness for the top

0.04mm
plane of the cylinder block
The first set 86.00~86.01mm

Cylinder bore inner
The second set 86.01~86.02mm
diameter
The third set 86.02~86.03mm
Cylindricity of the cylinder hole 0.007mm

03-5
TORQUE REQUIREMENT
Fasteners N•m
The fixed bolts of the main bearing cap 78
The fixed bolts of the connecting rod cap 49
The fixed bolts of the rear oil seal of the
22 03
crankshaft
The fixed bolts which support the rear cover plate 22
The fixed bolts of the flywheel 95~105
The fixed bolts of the oil pump 22
The fixed bolts of the oil filter 22
The connecting bolt on the flange of the oil filter 22
The fixed bolts of the sprocket chamber cover 23
The fixed bolts of the thrust washer of the counter
23
shaft
The fixed bolts of the oil pan 13
Oil pan drain plug 40
The central fixed bolts 98
The fixed bolts of the
The rear fixed bolts 16
cylinder head
The left fixed bolts 25
The fixed bolts of the exhaust camshaft 10
The fixed bolts of the intake camshaft 10
The fixed bolts of the OCV valve 10
The tightening torque of the spark plug 25~30
The fixed bolts on the sprocket wheel of the
100
counter shaft
The fixed bolts of the No.1 tensioner 30
The fixed bolts of the No.1 orbit determination 22
The fixed bolts on the sprocket wheel of the
50
exhaust camshaft
The fixed bolts of the phase regulator 60
Dynamic orbit pin 23~26
No.2 tensioner 10
The fixed bolts of the No.2 orbit determination 22
03-6
Fasteners N•m
The fixed bolts of the M6 10
sprocket chamber
cover M8 22
The fixed bolts of the front cover plate of the

10
cylinder head
The fixed bolts of the camshaft hood 10
The fixed bolts of the phase sensor of the intake
10
camshaft
The fixed bolts of the ignition coil 10
The fixed bolts on the adapter assembly of the
22
inlet pipe
The fixed bolts of the outlet pipe 61
Water temperature sensor 20
Knock sensor 22
The fixed bolts of the oil injector assembly of the
22
fuel rail
The fixed bolts of the oil filter seat 23
The hollow bolts of the engine oil cooler 23
The fixed bolts on the flange of the heater pipe 22
The fixed bolts on the left side of the heater
22
return pipe
The fixed bolts on the right side of the heater
23
return pipe
The fixed bolts on the rear side of the heater
23
return pipe
The fixed nuts of the intake manifold 25~31
The fixed bolts of the intake manifold bracket 22
Th e fixe d b o l ts o f th e e l e ctro n i c throttle
10
component
The fixed bolts of the exhaust manifold 25~31
The hollow bolts of the turbocharger inlet pipe 50
The hollow bolts of the turbocharger return pipe 50
The fixed bolts of the thermal baffle of the
22
supercharger
Thermal baffle of the tail pipe of the supercharger 10
03-7
Fasteners N•m
The fixed bolts of the exhaust manifold bracket 22~28
The fixed bolts on the tail pipe bracket of the
22~28
supercharger
The fixed bolts on the conduit of the bayonet
22
gauge 03
Fixed bolts on the left side of the inlet/return pipe

22
of the oil cooler
The fixed bolts on the return pipe flange of the
10
turbocharger
The joint of the inlet pipe of the turbocharger 30
The fixed bolts on the right side of the inlet pipe
10
of the turbocharger
The fixed bolts on the rear side of the inlet pipe
10
of the turbocharger
The fixed bolts on the pipe clamp of the inlet pipe
10
of the turbocharger
The fixed bolts on the belt pulley of the crankshaft 180
The fixed bolts of the water pump 23
The fixed bolts on the belt pulley of the water
10
pump
The fixed bolts of the engine 50
The fixed bolts of the generator support 39
The fixed bolts on the tensioning block of the
22
generator
03-8
MAINTENANCE SPECIFICATION - FUEL
FUEL
MAINTENANCE DATA
Fuel tank capacity 75L
The high-quality unleaded gasoline or ethanol

gasoline (GB17930) of No.93 RON and over
(Regions applying the gasoline and diesel used
Fuel standard by vehicles according to the national standard on
the auto-pollution of the fifth stage should use the
high-quality unleaded gasoline of No.92 and over)
TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts on the front and rear drawstring of
41~45
the fuel tank
The fixed bolts and nuts of the oil filter 12~14
Bleed screw of the oil filter 1.5

03-9
MAINTENANCE SPECIFICATION - INTAKE
INTAKE
TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts of the air filter assembly 21~25
The fixed bolts on the top of the intercooler 21~25 03

The fixed bolts on the bottom of the intercooler 21~25
The fixed bolts on the plastic inlet pipe of the air

9~11
filter
The fixed bolts on the rubber inlet hose bracket of

9~11
the intercooler
03-10
MAINTENANCE SPECIFICATION - EXHAUST
EXHAUST
TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts on the bracket of the oxidation
45~55
catalytic converter
The fixed bolts of the oxidation catalytic converter

22~27
assembly
The connecting bolts between the oxidation

45~55
catalytic converter and the bracket
The connecting nuts between the front exhaust

pipe assembly and the oxidation catalytic converter 45~55
assembly
The connecting nuts between the front exhaust pipe

45~55
assembly and the muffler assembly
The connecting nuts between the muffler assembly

45~55
and the rear exhaust pipe assembly
03-11
MAINTENANCE SPECIFICATION - COOLING
COOLING
MAINTENANCE DATA
Type of the coolant 50 % glycol 50% water
The charging up capacity of the coolant 9L
Temperature of the outlet of the cooling system Max 105℃ 03

Temperature of starting the thermostat valve 83~95℃
Lift of the thermostat valve 8mm
TORQUE REQUIREMENTS
Fasteners N•m
The Fixed bolts on the front baffle of the engine 23±2
The fixed bolts on the left and right baffle of the

23±2
engine
The fixed bolts of the radiator assembly 45~55
The fixed nuts of the radiator assembly 45~55
The fixed bolts of the electronic fan assembly 21~25
The fixed bolts on the stock solution tank assembly

21~25
of the coolant
Faucet on the bottom of the radiator 0.78~1.56

03-12
MAINTENANCE SPECIFICATION - LUBRICATION
LUBRICATION
MAINTENANCE DATA
Clearance between the initiative rotor Limit
0.2mm
and the driven rotor of the oil pump value
Clearance between the driven rotor Limit

0.38mm
and the shell of the oil pump value
Clearance between the rotor and the Limit

0.2mm
top of the shell of the oil pump value
TORQUE REQUIREMENTS
Fasteners N•m
Oil drain plug 40
The fixed bolts of the oil pan 10
The fixed bolts of the oil filter 22
The fixed bolts on the flange of the oil filter 22
The fixed bolts of the oil conduit 10
The fixed bolts of the oil pump cap 10

03-13
MAINTENANCE SPECIFICATION - STARTING AND CHARGING
STARTING AND CHARGING

MAINTENANCE DATA
Nominal voltage of the generator 13.5
Nominal voltage 120A
Rated rotating speed 6000rpm 03

Rotation mode Clockwise from the driving termination
Polarity Negative grounding
Voltage 12V
Output power 2.5kW
Coil resistance of the rotor 3~5Ω
Coil resistance of the stator 5~6Ω
Diameter of the rotor Standard value 14.2~14.4mm

shaft Limit value 12.8mm
Clearance of the pinion

Standard value 0.5~2.0mm
on the starter
Out-of-round of the Standard value 0.05mm

armature surface Limit value 0.1mm
Diameter of the Standard value 29.4mm

armature Limit value 28.4mm
Insertion depth of the Standard value 0.5mm

armature slice mica Limit value 0.2mm
Height of the carbon

Limit value 7.0mm
bush of the armature
TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts on the rectifier of the generator 6~8
Generator bracket bolt 20 ~24
Nuts on the binding post of the generator 21~25
The fixed bolts on the external shell of the starter 8~10
The fixed bolts of the electromagnetic switch 8~10
The fixed nuts of the magnetic field coil 14~16
The connecting nuts between the starting motor

18~20
and the connection of the power end
The fixed bolts of the starter 68~72

03-14
MAINTENANCE SPECIFICATION - STARTING AND CHARGING
Fasteners N•m
The fixed bolts of the battery tray 21~25
The fixed bolts on the negative and positive cable

9~11
of the battery
03-15
MAINTENANCE SPECIFICATION - IGN
IGN
MAINTENANCE DATA
Electrode clearance of the spark plug 0.80~0.90mm
TORQUE REQUIREMENTS 03
ITEM N•m
The fixed bolts of the ignition coil 10
Spark plug 28
03-16
MAINTENANCE SPECIFICATION - TRANSMISSION
TRANSMISSION
MAINTENANCE DATA
Transmission oil GL-4 75W/90 gear oil
Transmission ratio of the 1 gear 4.016
Gear ratio of the speedometer (driven/initiative) 16/5
Axial clearance of the adjusting shim of the counter

0~0.06
shaft
Axial clearance of the Standard value 0~0.06

gear bearing of the input
Limit value 0.06
axis

front bearing bracket Limit value 0

side gear shifting shaft
of the control stem
Limit value 0.06
components of the gear
shifting shaft

side gear shifting shaft
of adjusting shim of the Limit value 0.06
gear shifting shaft

reverse shaft Limit value 0306
Runout of the output

Standard value 0~0.2mm
shaft
V. Axial clearance Standard value 0~0.5mm

between the
synchronizer ring of the
Limit value 0.5mm
reverse gear and the
gear
03-17
Axial clearance between Standard value 0~0.5mm

the synchronizer ring of
the forth gear and the Limit value 0.5mm
gear

03
the third gear and the Limit value 0.5mm
gear

the second gear and the Limit value 0.3mm
gear

the synchronizer ring
of the first gear and the Limit value 0.3mm
gear
V. Radial clearance Standard value 0~0.6mm

between the
Limit value 0.6mm
gear

the forth gear and the Limit value 0.6mm
gear

the third gear and the Limit value 0.6mm
gear

the second gear and the Limit value 0.6mm
gear

the synchronizer ring
of the first gear and the Limit value 0.6mm
gear
V. Radial clearance Standard value 0~0.6mm

between the
Limit value 0.6mm
gear
03-18
III. Fit clearance Standard value 0~0.6mm

between the
synchronizer gear
bushing of the third/forth Limit value 0.6mm
gear and the shifting
fork
I. Fit clearance between Standard value 0~0.6mm

the synchronizer gear
bushing of the first/
Limit value 0.6mm
second gear and the
shifting fork
III. Axial clearance of the Standard value 0~0.6mm

synchronizer toothholder
Limit value 0.6mm
of the third/forth gear
TORQUE REQUIREMENTS
Transmission model
Fasteners N•m
Plug of oil draining of the transmission 65~78
Plug of oil filling of the transmission 65~78
Connecting bolt of the transmission and the engine 30~42
The fixed bolts on the body bracket of the

21~25
transmission
The connecting bolt of the transmission and the

46~56
body bracket
The fixed bolts on idler shaft bracket of the reverse

38~49
gear
The fixed bolts of the outspread shell 30~42
The fixed bolts of the front shell 30~42
The fitting bolt of the shifting yoke 38~49
The fixed bolts of the front bearing cap of the

7~11
transmission
The fixed bolts of the clutch housing 30~42
The fixed bolts on the back plate of the back shell 14~21
03-19
MAINTENANCE SPECIFICATION - CLUTCH
CLUTCH
MAINTENANCE DATA
Clutch pedal
Height of the clutch Standard value 155
pedal Limit value ±10mm 03
Standard for the free Standard value 7.5mm

path of the clutch pedal Limit value ±2.5mm
Clutch
Thickness of the friction Standard value 8.4mm
plate for the clutch Limit value ±0.3mm
Height difference of the Standard value 0mm

diaphragm spring of the
Limit value 1mm
clutch
Oscillating quantity of
Limit value ±0.3mm
the friction plate
Abraded quantity of the

Limit value 2.0mm
friction plate
TORQUE REQUIREMENTS
Fasteners N•m
The fixed nuts of the clutch pedal 9~11
The fixed bolts of the clutch pedal 21~25
The connecting nuts of the master cylinder of the

21~25
clutch and the vacuum booster
The fixed bolts on the wheel cylinder of the clutch 21~25
The bolts of the clutch pressure plate 41~51
Collar nuts on the vitta of the master cylinder of the

29~35
clutch
Collar nuts on the vitta of the wheel cylinder of the

19~21
clutch
The fixed nuts of the clutch booster 21~25

03-20
MAINTENANCE SPECIFICATION - TRANSFER
TRANSFER
TORQUE REQUIREMENTS
Fasteners N•m
Plug of oil draining of the power transfer 19~30
Plug of oil filling of the power transfer 19~30
The fixed nuts of the power transfer 41~51
The fixed nuts of the electromagnetic clutch 8~11
The connecting bolts of the power transfer shell 27~40
The fixed nuts of the front flange 203~241
The fixed nuts of the rear flange 305~332
The fixed bolts of the changeover governor

8~11
assembly
The fixed bolts of the odometer sensor 3~6
The fixed nuts on the control unit of the power

6~10
transfer
03-21
MAINTENANCE SPECIFICATION - FRONT SUSPENSION
FRONT SUSPENSION
MAINTENANCE DATA
Front wheel alignment
Toe-in Standard value 2.2±1mm(10'±5')
Camber angle 12.08° ±30' 03

Camber angle of king pin 3.5° ±30'
Radial runout of the

wheel
Axial runout of the wheel Standard value 0.25mm
Specification of the front 265/70R16 220±10kPa

wheel/pressure value 265/65R17 220±10kPa
Specification of the rear 265/70R16 240±10kPa

wheel/pressure value 265/65R17 240±10kPa
Run out tolerance of the wheel ≤ 1.2mm
TORQUE REQUIREMENTS
Fasteners N•m
The blocking nut of the track rod lever 81~99
The mounting nuts on the top of the front vibration

63~77
isolator
The mounting nuts on the bottom of the front

110~130
vibration isolator
The fixed bolts on the button head bracket of the

120~150
lower oscillating arm
The fixed nuts connecting the upper oscillating arm

120~140
shaft and the body frame
The fixed nuts on the fetlock of the upper oscillating

85~145
arm
The connecting bolts and nuts between the lower

150~190
oscillating arm and the body frame
The fixed bolts on the fetlock bracket of the lower

120~150
oscillating arm
The fixed nuts on the fetlock bracket of the lower

130~190
oscillating arm
The connecting bolts between the stock stabilizer

41~51
and the body frame
03-22
MAINTENANCE SPECIFICATION - FRONT SUSPENSION
Fasteners N•m
The fixed bolts on the motherboard bracket of the
20~25
engine
Fasten the fixed bolts on the motherboard bracket

23±2
of the engine
The fixed bolts of the armour plate 23±2
The connecting piece and connecting nuts of the

90~110
stock stabilizer
The connecting piece of the stock stabilizer and the

90~110
connecting nuts of the knuckle
03-23
MAINTENANCE SPECIFICATION - REAR SUSPENSION
REAR SUSPENSION
TORQUE REQUIREMENTS
Fasteners N•m
The mounting bolts on the rear of the rear
188~218
oscillating arm
03
The mounting bolts on the front of the rear
188~218
oscillating arm
The fixed bolts on the right side of the cross tie 113~138
The fixed bolts on the left side of the cross tie 100~120
The fixed bolts on the rear of the longitudinal tie 188~218
The fixed bolts on the front of the longitudinal tie 188~218
The mounting bolts on the top of the rear vibration

41~51
isolator
The mounting bolts on the bottom of the rear

78~96
vibration isolator
03-24
MAINTENANCE SPECIFICATION - TIRE AND WHEEL
TIRE AND WHEEL

MAINTENANCE DATA
Front 265/70R16 220
wheel 265/65R17 220
Rear 265/70R16 240

wheel 265/65R17 240
Spare 265/70R16 220

Wheel 265/65R17 220
TORQUE REQUIREMENTS
Fasteners N•m
The wheel nuts of the Two-wheel drive 95~115
front wheel Four-wheel drive 111~131
The wheel nuts of the Two-wheel drive 95~115

rear wheel Four-wheel drive 111~131
The fixed bolts on the pressure monitoring model of

9~11
the wheel
03-25
MAINTENANCE SPECIFICATION - AXLE AND TRANSMISSION SHAFT
AXLE AND TRANSMISSION SHAFT

MAINTENANCE DATA
Transmission Shaft Assembly
Dynamic unbalance Rotate speed 3200rpm, unbalance quantity
Max
quantity remnants ≤ 15gcm
03
Radial runout of the Standard value 0.7mm
transmission shaft Limit value 1.2mm
Universal joint
Cross journal
Limit value 18.425mm
Clearance between the needle roller bearing and

0 (interference fit)
the universal yoke
Bearing clearance between the cross and the

0.01~0.06mm
needle roller bearing
Axial clearance of the journal 0.1~0.3mm
Wheel Boss
Bearing clearance of the Front wheel boss 0.04~0.11mm
wheel boss Rear wheel hub 0.05~0.125mm
Rear Axle Assembly

Track width of the rear wheels 1580mm
Final Drive Ratio 3.91
Runout of the installation Front axle ≤ 0.2mm

surface of the driven
Rear axle ≤ 0.2mm
gear
Flank clearance Front axle 0.11~0.16mm

between the driving gear
Rear axle 0.127~0.203mm
and the driven gear
Locating at the central section of the tooth flank of

Mesh moulage between Location
the driven gear (forwards the small end)
the driving gear and the
Length ≥ 60% of the gear length
driven gear
Width ≥ 60% of the gear breadth
Flank clearance of the Standard value 0.05~0.1mm

half axle gear and the
Limit value 0.2mm
planet gear
Front axle 0~0.2mm

Half axle gear
Rear axle 0~0.2mm
03-26
Radial clearance of the Front axle <0.06mm

planet gear and the
Rear axle <0.06mm
planet gear shaft
Radial clearance Front axle 0.05~0.1mm

between the half axle
gear and the differential Rear axle 0.05~0.1mm
carrier
Spline clearance Front axle 0~0.076mm

between the half axle
gear and the output Rear axle 0~0.076mm
flange
Thickness of the thrust

washer of the half axle Standard value 1.22~1.28
gear
Thickness of the thrust

washer of the planet Standard value 0.762~0.826
gear
Driving Gear
Runout of the Front axle ≤ 0.1mm
cooperating face of the
Rear axle ≤ 0.2mm
driving gear flange
Runout of the rabbet of Front axle ≤ 0.08mm

the driving gear flange Rear axle ≤ 0.08mm
Starting torque of the Front axle 0.49~0.69

driving gear Rear axle 1.5~2.6
Runout of the driving

gear installing surface of Standard value ≤ 0.2mm
the front differential gear
TORQUE REQUIREMENTS
Fasteners N•m
The connecting bolts between the transmission
65~79
shaft and the driving gear flange of the main retarde
Disassemble and Front axle 59~69

assemble the oil drain
Rear axle 38~45
plug of main reducer
Plug of oil filling of the Front axle 41~51

main retarder Rear axle 27~41
03-27
Fasteners N•m
Nuts of the fixed bracket on the right side of the
78~98
front main retarder
The bolts of the fixed bracket on the left side of the

78~98
front main retarder
The fixed bolts on the fixed bracket of the front 03

113~138
retarder
The connecting nuts between the front main

113~138
retarder and the frame
The fixed bolts of the breather pipe 9~11
The fixed bolts on the gland of the differential gear

54~64
bearing
The connecting bolts between the main retarder

15~22
and the rear cover
The connecting nuts between the half front axle (the

63~77
right side) and the intermediate shaft
The fixed bolts on the fixed bracket of the lower

150~180
oscillating arm
Nuts on the fetlock of the track rod lever 84~100
The fixed bolt on the wheel boss of the front wheel 70~90
Nuts on the axle head of the half axis 350~380
The connecting nuts between the upper oscillating

85~145
arm and the knuckle
Stabilizer connecting rod 90~100

The fixed bolts on the fixed bracket of the brake
24
hose
The fixed bolts on the speed sensor of the front

6~10
wheel
The connecting bolts between the universal joint of

the rear transmission shaft and the flange assembly 65~79
of the power transfer
The connecting bolts between the universal joint

of the front transmission shaft and the flange 65~79
assembly of the power transfer
The connecting bolts between the universal joint

of the front transmission shaft and the flange 65~79
assembly of the main retarder
The fixed nuts of the half rear axle 50~60

03-28
Fasteners N•m
The fixed bolts and nuts of the longitudinal tie 188~218
The fixed bolts and nuts of the cross tie 100~120
The fixed bolts of the retarder 78~96
The fixed bolts of the lower oscillating arm on the

188~218
both sides of the rear suspension
The fixed bolts of the Front axle 78~88

driven gear Rear axle 129~142
The fixed nuts of the driving gear shaft 245
The fixed bolts on the arrester oil duct of the rear

21~25
wheel
03-29
MAINTENANCE SPECIFICATION - SERVICE BRAKE
SERVICE BRAKE
MAINTENANCE DATA
Brake Pedal
The distance between the central plane of the pedal
Brake pedal height Standard value
and the motherboard of the vehicle (192 ＋ 5)mm
03
Free stroke of pedal Standard value （5~10）mm
Front Brake
Thickness of the brake Standard value 11mm
strip Limit value 2mm
Standard value 28mm

brake disc thickness
Limit value 26mm
Oscillating quantity of Standard value 0.08mm

the brake disk Limit value 0.15mm
Rear Brake
Brake shoe plate for Standard value 9mm
thickness Limit value 2mm
Drum inner diameter Standard value Φ190mm
Standard value 20mm

brake disc thickness
Limit value 18.4mm
TORQUE REQUIREMENTS
Fasteners N•m
Vent plug of the brake tongs (the front callipers) 9~11
Vent plug of the brake cylinder (the rear callipers) 9~11
The fixed bolts of the brake pedal assembly 24
The fixed nuts connecting the brake pedal assembly

24
and the vacuum booster
The brake master pump fixing nut 17~23
Fuel pipe fittings of the brake master cylinder 22~24
The fixed nuts connecting the ABS actuator and the

6~11
bracket
The fixed bolts of the ABS actuator 24
The fixed nuts of the ABS actuator 24
Brake fuel pipe union connected with the ABS

19~21
actuator
03-30
MAINTENANCE SPECIFICATION - SERVICE BRAKE
Fasteners N•m
The fixed bolts on the front wheel speed sensor 6~10
The fixed bolts on the rear wheel speed sensor 6~10

03-31
MAINTENANCE SPECIFICATION - PARKING BRAKE
PARKING BRAKE
MAINTENANCE DATA
Thickness of the brake Standard value 9mm
shoe Standard value 2mm
Drum inner diameter Standard value Φ190mm 03
TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts on the control handle of the parking
24
brake
The fixed bolts on the stay wire of the

24
parking brake
Bolts of fixing clamp on the stay wire of the

9
parking brake
Thermal baffle of the rear stay wire on the parking

9
brake
03-32
MAINTENANCE SPECIFICATION - STEERING GEAR
STEERING GEAR
MAINTENANCE DATA
The Vehicle Runs
Turning radius Minimum 12.5mm
Disalignment（30m， Disalignment LH 0.15mm

40km/h） Disalignment RH 0.15mm
Steering Wheel
Diameter Φ385mm
Free play ±5℃
Stroke adjustment (up/down) 4.16℃
Engine OFF 180N

Steering force
Engine idling 30N
Steering Transmission Shaft Assembly

Clearance between the cross and the journal 15'
TORQUE REQUIREMENTS
Fasteners N•m
Nuts of the steering wheel 30.6~37.4
The fixed bolts on the top of the steering column 25~30
The fixed bolts on the bottom of the steering column 25~30
The connecting bolts between the steering column

25~30
and the steering transmission shaft
The fixed bolts on the hood of the steering

9~11
transmission shaft
The connecting bolts between the steering

25~30
transmission shaft and the redirector
03-33
MAINTENANCE SPECIFICATION - POWER STEERING
POWER STEERING
MAINTENANCE DATA
Steering oil ATF-III
Working temperature -40~120 ℃
Engine idling, valve ON 03

Steering oil and the steering wheel 8.5MPa
at the limiting position
TORQUE REQUIREMENTS
Fasteners N•m
The connector lug between the high pressure pipe
33~42
and the redirector
The fixed bolts on the rear of the steering oil pump 20~25
The fixed bolts on the front of the steering oil pump 20~25
The fixed bolts of the belt pulley on the steering oil

20~25
pump
The hole bolts of the the steering oil pump 80~100
The fixed bolts of the redirector 110~130
The fixed bolts of the steering transmission shaft 25~30
The fixed nuts on the fetlock of the redirector

84~100
tension rod
The fixed bolts on the motherboard of the front axle 20~25

03-34
MAINTENANCE SPECIFICATION - HEATER & AIR CONDITIONING
HEATER & AIR CONDITIONING

MAINTENANCE DATA
The charging capacity of the refrigerant oil
The oil mass of the new compressor is equal to that
While replacing the compressor
poured out of the previous compressor.
Supply the 33% of the oil mass required for the

While replacing the evaporator
compressor.
Supply the 20% of the oil mass required for the

While replacing the condenser
compressor.
Supply the 27%~33% of the oil mass required for

While replacing the tube
the compressor.
Pressure value when Low-pressure side 0.2~0.4MPa

the refrigeration system
High-pressure side 1.2~2.0MPa
operates normally
TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts of the pipeline connecting the
21~25
compressor
The fixed bolts of the compressor 40~45
The fixed bolts of the crossbeam 21~28
Bolts of the fixed bracket on the top of the

20~24
condenser
The fixed bolts of the lock on the hatch cover of the

15~18
engine
The fixed bolts on the right side of the HVAV

8~9
assembly
The fixed bolts on the right side of the HVAV

8~9
assembly
The fixed bolts on clamp plate of the air-conditioning

8~9
pipeline
The fixed bolts on the low-pressure line of the air-

8~9
conditioning
The fixed bolts connecting the expansion valve and

21~25
the compressor
The fixed bolts of the pipeline on the pressure

8~9
switch of the expansion valve
03-35
MAINTENANCE SPECIFICATION - HEATER & AIR CONDITIONING
Fasteners N•m
The fixed bolts of the pipeline on the pressure
8~9
switch of the condenser
The fixed bolts of the rear fan 8~9
03
03-36
MAINTENANCE SPECIFICATION - SUPPLEMENTAL SAFEGUARD SYSTEM
SUPPLEMENTAL SAFEGUARD SYSTEM

MAINTENANCE DATA
SIR System
Working temperature -35~85 ℃
Working voltage 12±3V
TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts of the SRS assembly for the driver 6±1
The fixed bolts of the SRS electric control 9±1
The fixed bolts of bonding on the SRS control unit 9±1
The fixed bolts on the emergency locking retractor

10~14
(ELR) of the life belt for the front
The fixed bolts of the life belt (upper) 45~55
The fixed bolts of the life belt (lower) 45~55
The fixed bolts of the seat belt buckle 45~55

03-37
MAINTENANCE SPECIFICATION - ILLUMINATIONS
ILLUMINATIONS
TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts of the front combination lamp
9~12
assembly
03
The fixed bolts of the rear combination lamp 9~12
The fixed bolts of the rear fog lamp assembly 9~12

03-38
MAINTENANCE SPECIFICATION - WIPER AND WASHER
WIPER AND WASHER

TORQUE REQUIREMENTS
Fasteners N•m
Bolts of the front wiper assembly 18~21
03-39
MAINTENANCE SPECIFICATION - VEHICLE CONTROL SYSTEM
VEHICLE CONTROL SYSTEM

TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts of the accelerator pedal 9~11
03
03-40
MAINTENANCE SPECIFICATION - GLASS AND REAR-VIEW MIRROR
GLASS AND REAR-VIEW MIRROR

TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts of the electric riser on the front door 9~12
The fixed bolts of the electric riser on the rear door 9~12
The fixed nuts of the outside rear-view mirror 9~11

03-41
MAINTENANCE SPECIFICATION - INSTRUMENT DESK AND SECONDARY INSTRUMENT DESK
INSTRUMENT DESK AND SECONDARY INSTRUMENT

DESK
TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts connecting the crossbeam of the 03
21~25
instrument desk and the vehicle body
03-42
MAINTENANCE SPECIFICATION - SEAT
SEAT
TORQUE REQUIREMENTS
Fasteners N•m
The fixed bolts of the driver seat 45~55
The fixed bolts of the secondary driver seat 45~55
The fixed bolts on the seats of the middle 45~55
The fixed bolts on the seats of the rear 21~25

03-43
MAINTENANCE SPECIFICATION - DOOR LOCKS
DOOR LOCKS
TORQUE REQUIREMENTS
Fasteners N•m
Bolts of the lock on the engine hood 9~12
The fixed bolts on the door lock of the tailgate 6 03

The fixed screws on the door lock of the front door 6
The fixed screws on the door lock of the rear door 6

03-44
MAINTENANCE SPECIFICATION - DOOR OF THE VEHICLE/ENGINE HOOD
DOOR OF THE VEHICLE/ENGINE HOOD

TORQUE REQUIREMENTS
Fasteners N•m
The hinged bolts of the engine hood 22~28
Bolts of lock body on the engine hood 9~12
The hinged bolts of the front door 22~28
The hinged bolts of the rear door 22~28
The fixed screws of the snap close 23
The hinged bolts of the tailgate 28~32

03-45
MAINTENANCE SPECIFICATION - INTERIOR AND EXTERIOR DECORATIONS
INTERIOR AND EXTERIOR DECORATIONS

TORQUE REQUIREMENTS
Fasteners N•m
The fixed screws on the stopper of the tailgate 6.5~8.5
Bolts on the fixed bracket of the sun-shield 9~11 03

The fixed bolts on the armrest of the pole A 9~11
The fixed bolts on the armrest of the pole B 9~11
The fixed bolts of the life belt for the front 45~55
The fixed screws on the lower armour plate of the

9~11
pole C
The fixed bolts (lower) of the life belt for the middle 45~55
The fixed bolts (lower) of the life belt for the rear 45~55
The fixed bolts of the pedal 22~30
The fixed nuts on the decoration strip of the tailgate 6.5~8.5
The fixed bolts on the decoration strip of the tailgate 6.5~8.5
The fixed nuts of the flow deflector 9~11
The fixed nuts of the high-mounted stop lamp 9~12
The fixed screws of the tool box in the middle

9~11
luggage room
The fixed screws of the tool box in the left luggage

9~11
room
- MEMO -
VEHICLE CARE
VEHICLE CARE ................................... 04-1 REPLACEMENT................................. 04-32
NOTICES ......................................... 04-1 REPLACE THE AIR FILTER ELEMENT ..
INSPECTION........................................ 04-2 ........................................................ 04-32
CHECK THE WORKING CONDITION CHANGE THE AIR FILTER ELEMENT....
OF ELECTRIC SYSTEM .................. 04-2 ........................................................ 04-35
CHECK BATTERY ............................ 04-3 REPLACE THE ENGINE OIL AND OIL 04
CHECK ABRS ................................... 04-4 FILTER(ISF2.8) ............................... 04-38
CHECK SAFETY BELT ..................... 04-5 REPLACE THE ENGINE OIL AND OIL
CHECK PARKING BRAKE AND FILTER(BJ486ZLEQ4) .................... 04-45
BRAKE PEDAL ................................. 04-8 CHANGE SPARK PLUG ................. 04-51
CHECK DOOR CHECK, DOOR LOCK REPLACE FUEL FILTER
AND HINGE ...................................... 04-9 ELEMENT(ISF2.8) .......................... 04-53
CHECK THE DRAIN HOLE OF FRONT REPLACE COOLANT ..................... 04-58
WINDSHIELD DRAIN TANK ........... 04-11 CHANGE BRAKE FLUID ................ 04-62
CHECK ENGINE COMPONENTS ........... REPLACE MANUAL TRANSMISSION
........................................................ 04-12 CASE LUBRICATING OIL (JC538) ..........
CHECK THE ACCESSORY BELT ........... ........................................................ 04-65
........................................................ 04-13 REPLACE THE REAR MAIN REDUCER
CHECK THE HEAD OF STEERING GEAR OIL ....................................... 04-67
ROD BALL JOINT AND THE DUST REPLACE THE FRONT MAIN
COVER ........................................... 04-14 REDUCER GEAR OIL(FOUR-WHEEL
CHECK AND TIGHTEN THE BOLT ON DRIVE ) ........................................... 04-69
THE CHASSIS ACCORDING TO THE REPLACE POWER TRANSFER OIL.......
REGULATED TORQUE .................. 04-15 ........................................................ 04-71
CHECK HEADLAMP....................... 04-16
CHECK THE WINDSHIELD WIPER
AND CLEANING DEVICE............... 04-17
CHECK SUSPENSION MEMBER ...........
........................................................ 04-19
CHECK SUSPENSION BALL JOINT
AND DUST COVER ........................ 04-20
CHECK THE OIL LEVEL OF THE
BRAKE FLUID RESERVOIR OF THE
POWER STEERING ....................... 04-21
CHECK BRAKE SYSTEM .............. 04-22
CHECK THE BRAKING DISC, BRAKE
DRUM AND BRAKE LINING........... 04-23
CHECK TIRE .................................. 04-25
CHECK EXHAUST SYSTEM.......... 04-26
CHECK THE OIL LEVEL OF THE
COOLING BRAKE FLUID RESERVOIR..
........................................................ 04-27
CHECK THE ENGINE OIL
LEVEL(ISF2.8) ................................ 04-28
CHECK THE ENGINE OIL
LEVEL(BJ486ZLEQ4) ..................... 04-30
VEHICLE CARE - VEHICLE CARE 04-1
VEHICLE CARE
NOTICES
1. Preparation before performing maintenance item

(a). If necessary, the operating personnel shall wear safety shoes, work gloves and
safety goggles, etc..".
(b). Make sure the ventilation and cleanness of work site; the arrangement of tools and
instruments shall be tidy; fire extinguisher shall be equipped when necessary. 04
(c). Check safe condition of instrument and equipment use, such as check lift and jack,
etc.."
(d). Check vehicle safety driving and operation condition, make sure the maintenance
can be performed successfully."
2. Precautions in maintenance process
(a). Before the vehicle drives into lifting frame, make sure that there is enough distance
between lifting frame and vehicle bottom & two sides to avoid scratches."
(b). Before lifting vehicle, make sure that vehicle weight does not exceed rated loading
capacity of lift."
(c). When lifting vehicle, must select the right lifting point."
(d). In the process of lifting vehicle, starting engine or putting into gear is not allowed
when the driving wheel is landing, otherwise the operating personnel and vehicle
may be in danger."
(e). In the maintenance process, the operating personnel shall strictly obey each safety
regulation and service regulation, otherwise, major accident and personal injury may
occur."
(f). When replacing parts and consumables, please use the products recognized by
Futian Automobile Co., Ltd. to guarantee vehicle's safety and performance."
3. Precautions after maintenance
(a). After maintenance, you must perform test drive and pay special attention to the
checkup for braking system and supplementary restraint system (SRS)."
(b). Before delivering the vehicle to customer, the fault messages in memory must be
eliminated."
04-2 VEHICLE CARE - INSPECTION
INSPECTION
CHECK THE WORKING CONDITION OF ELECTRIC SYSTEM
1. Check the brightness and working condition of front combination lamp, fog lamp,
turn signal lamp, warning flash, rear combination lamp, rear fog lamp, backup lamp
and brake lamp.
2. Check the working condition of interior lights.
3. Check the working condition of buzzer, control unit, center tunnel, all switches and
horn in instrument panel.
4. Check the working condition of power window, exterior rear view mirror and central
control door lock.
5. Check the radio's receiving condition and anti-interference performance, and check
loudspeaker.
VEHICLE CARE - INSPECTION 04-3
CHECK BATTERY
NOTICE:
• Maintaining the cleanness of battery cable and firmly installing battery cable are favorable
for the usability and life of battery.
• When fixing battery cable, pay attention to the suitable installation of battery cable,
otherwise, it may influence the use of electrical appliances and the service life of battery.
1. Open battery cable cover 04
2. Check battery
(a) . Check whether battery case and cable
is corroded or broken, replace it when
necessary.
(b) . Shake the battery cable to check whether it
is firmly installed.
(c) . If it is founded that the battery positive
cable is not firmly fixed, firstly disconnect
battery negative cable,tighten battery
positive cable, and then re-install and
tighten the bolt of battery positive cable.
3. Check the color of battery power indicator

light
(a) . If the display is blue, it indicates that the
battery power is good.
(b) . If the display is white, it indicates that
the battery power is deficient and needs
charging.
(c) . If the display is red, it indicates that the
battery acid is deficient, and the battery
shall be replaced.
CHECK ABRS
NOTICE:
• It is prohibited to paste or attach articles to air bag housing. You shall remind the user
that articles are prohibited to damage or hinder air bag housing, to make sure the normal
function of air bag.
• Only dry or a little wet cleaning cloth can be used to clean the air bag housing.
1. Check driver air bag module

(a). Driver side air bag is located at the middle
of steering wheel. Check whether the
plastic housing is in good condition by
visual inspection.
2. Check passenger side air bag

(a). Passenger side air bag is located at the
place above glove box. Check whether
the plastic housing is in good condition by
visual inspection.
CHECK SAFETY BELT

NOTICE:
• When checking, completely pull out the safety belt from safety belt automatic rewinding
device.
• Check whether the safety belt is dirty. Clean it with neutral liquid soap if necessary.
1. Check whether the safety belt has the

following damage, replace it if damaged 04
(a). The safety belt is broken, torn or scratched.
(b). The fabric winding on belt edge is torn.
(c). Trace burned by cigarette, etc..

(d). One side of belt edge deforms, or the edge

of safety belt is wavy.
2. Check safety belt lock

(a). Pull down safety belt quickly, check
whether safety belt lock can lock
sensitively. If cannot, you shall replace it.
3. Check leading buckle and lock tongue

(a). Check whether leading buckle housing is
deformed, fell off or cracked. If damaged, it
shall be replaced.
(b). Check whether lock tongue is deformed or

cracked. If damaged, it shall be replaced.
(c). Put lock tongue into leading buckle, check
whether lock tongue can be locked, after
above 5 times of repeated examinations,if
the lock tongue cannot be locked in leading
buckle for one time, it shall be replaced.
04
CHECK PARKING BRAKE AND BRAKE PEDAL
1. Check parking brake and brake pedal

(a). Check whether the parking brake works
flexibly, whether the pull strength of
handle is normal and whether the cable is
worn,perform maintenance if necessary.
(b). Check whether the brake pedal is loosed

and whether the free stroke is normal,
perform maintenance if necessary.
Free stroke:5~10mm
2. Perform road test, check the working condition of parking brake and brake pedal,
perform maintenance again if necessary.
CHECK DOOR CHECK, DOOR LOCK AND HINGE
1. Check door check

(a). Check whether the door check works well,
if lacking lubrication, apply lubricating
grease to moving part.
04
2. Check child safety lock

(a). Turn the child safety lock switch from OFF
position to ON position. After the child
safety lock is started, the door can only be
opened from the outside.
3. Check lock cylinder

(a). Put car key into door lock, rotate the key
left and right, the lock cylinder shall be able
to rotate smoothly.
4. Check engine hood and back door

assembly hinge
(a). Continuously open and close engine
hood, check whether the hinge is out of
nimbleness. If lacking lubrication, apply
lubricating grease to the moving part.
(b). Continuously open and close back door

hinge, check whether the hinge is out of
nimbleness. If lacking lubrication, apply
lubricating grease to the moving part.
CHECK THE DRAIN HOLE OF FRONT WINDSHIELD DRAIN

TANK
1. Open engine hood
2. Check whether there is impurity and

blocking in drain hole of front windshield
drain tank, and clean the drain hole 04
3. Set down engine hood

CHECK ENGINE COMPONENTS
1. Open engine hood

2. Check whether there is any leakage, damage and aging of the following pipes,
hoses and joints, check whether the gap between each pipeline and car body is
reasonable, and adjust or replace if necessary.
(a). Fuel system.
(b). Air conditioning system pipeline and cooling system pipeline.
(c). Braking device and pipeline.
NOTICE:
• The encountered fault shall be eliminated timely.
• Timely supplement fluid loss and eliminate pipeline leakage.
CHECK THE ACCESSORY BELT
1. Turn off ignition switch

2. Open engine hood
3. Check whether the accessory belt has

fracture, is aging or has other defects, and
replace it if necessary 04

NOTICE:
• Belt adhered with water or grease can dramatically reduce the service life of the belt; If
there is oil stains on the belt and it is severely polluted, do not wash, a new one should
be replaced.
• If there is oil on the belt, the engine should be checked whether there is a oil leakage.
CHECK THE HEAD OF STEERING ROD BALL JOINT AND THE

DUST COVER
1. Lift up the vehicle
2. Shake the rod and confirm there is no

clearance
3. Check whether the fixed nut of the head of
steering rod ball joint is strong
4. Check whether the dust cover and rubber

ball head are damaged, and replace them
if damaged
C H E C K A N D T I G H T E N T H E B O LT O N T H E C H A S S I S
ACCORDING TO THE REGULATED TORQUE
1. Turn off all electrical appliances and ignition switches

3. Check the tightness and rust of all fixed bolts and nuts of the chassis
4. Tighten all the fastening bolts and nuts again according to the regulated torque
NOTICE: 04
• Prevent dust, sediment or other foreign materials from falling into eyes when looking up
the chassis.
• Safety measures such as wearing a helmet and gloves should be conducted when
tightening the chassis bolts.
CHECK HEADLAMP
1. Check the preparation of the headlamp

(a). Place the vehicle on a level surface.
(b). Sitting in the vehicle (or with weight of 73kg), and the fuel tank should have more
than half of the fuel.
(c). Confirm the tire pressure is normal.
(d). Confirm the inner structure of the headlamp is normal.
2. Check the lamp
(a). Check whether the headlamp assembly is broken, and replace it if necessary.
(b). Test the function of the headlamp, and replace it if the bulb is burned; and test
whether the adjustment function of the headlamp is normal.
(c). Check whether there is water vapor or other foreign material inside the headlight.
(d). If the headlight illuminate deviating from the normal range, it must be adjusted.(Refer
to "Chapter 43 Lighting-Left Front Combination Lamp Assembly Adjustment")
CHECK THE WINDSHIELD WIPER AND CLEANING DEVICE
1. Check the limit position of the windshield

wiper blade
(a). Driver side.
•The distance between the the wiper blade
rubber and the lower edge of windshield
is 45 mm. 04
•Remove the wiper arm, and perform
adjustment if necessary.
(b). Front passengers side.

•The distance between the the wiper blade
rubber and the lower edge of windshield
is 30mm.
•Remove the wiper arm, and perform
adjustment if necessary.
2. Replace wiper blade

(a). Put the wiper arm in remove position,
press the twist lock of the wiper blade, and
remove the wiper blade downward.
(b). Install the wiper blade, and make the twist
lock in the lock position.
(c). Turn on the ignition switch and operate
the wiper arm in short time, and make the
windshield wiper in the end position again.
3. Check the cleaning fluid of the windshield

(a). The windshield cleaning fluid level should
be about 10 cm from open place, add if
deficient.
NOTICE:
The windshield cleaning fluid is consumable
liquid, please check regularly.
4. Check the windshield wiper spray

(a). The spray area as shown in figure is
normal spray area.
(b). If the spray has deviation, adjust the

nozzle.
CHECK SUSPENSION MEMBER

2. Check the fuel line and the brake fluid pipeline for leakage
3. Check the protective layer of bottom, wheel cover and side beam for damage
4. Visually inspect whether the installation lug of the exhaust pipe is aging, and
whether the installation is firm
04
CHECK SUSPENSION BALL JOINT AND DUST COVER
1. Check whether the dust cover of the lower

arm ball joint is damaged, and replace it if
damaged
2. Check whether the dust cover of the power

steer is damaged, and replace it if damaged
CHECK THE OIL LEVEL OF THE BRAKE FLUID RESERVOIR OF

THE POWER STEERING
1. Place the vehicle on level ground

3. Straighten front wheels
4. Open engine hood
04
5. Unscrew the filler cap of the power steering
6. Check the oil level, which shall be between

the ceiling and the lowest line,If the oil level
is beyond the ceiling or below the lowest
line, it should be drained or filled with
Steering hydraulic oil:ATF- Ⅲ
7. Tighten the filler cap of the power steering

CHECK BRAKE SYSTEM

NOTICE：
• The brake fluid used can only be recognized by Foton Motor Co., Ltd..
• Brake fluid can not be used mixed with other liquid, otherwise it is more likely to damage
the brake system piping and endanger vehicle.
• Deciding whether to add the brake fluid must be based on the wear intensity of the brake
lining.
1. Open engine hood

2. Check the oil level of the brake fluid reservoir
(a). When the wear intensity of the brake lining near the limit, the brake fluid level should
be close to the lowest line.
(b). When the the brake lining wear light, the brake fluid level shall be close to the
ceiling.
3. Check whether there is any damage and fluid leakage to the following components
(a). Brake master pump
(b). Brake booster
(c). Brake caliper
(d). Brake piping
4. Check whether the clearance between car body and brake hose is appropriate,
whether the brake hose is scratched, and whether the brake line interface and the
fixed device is firm.
CHECK THE BRAKING DISC, BRAKE DRUM AND BRAKE LINING

NOTICE：
If the thickness of the braking disc, brake drum and brake lining is up to the wear limit,
customer must be informed for replacement.
1. Check the front braking disc and brake

lining
(a). Disassemble front wheel.(Refer to "Chapter 04
33 Tires and Wheels - Front Tires and
Wheels Replacement")
(b). Measure the thickness of brake lining and
braking disc.
The standard thickness of the brake lining
is: 11mm
The thickness limit is: 2mm
The standard thickness of the braking disc
is: 28mm
(c). Install the front wheel.(Refer to "Chapter 33
Tires and Wheels - Front Tires and Wheels
Replacement")
2. Check the rear braking disc and brake lining
(a). Disassemble the rear wheel.
(b). Measure the thickness of brake lining and
braking disc.
The standard thickness of the brake lining
is: 11mm
The standard thickness of the braking disc
is: 28mm
(c). Install rear wheel. (Refer to"Chapter 33
Tires and Wheels -Rear Tires and Wheels
Replacement")
3. Check the park brake cable

(a). Disassemble the rear wheel.
(b). Check the thickness of the brake shoe and
the inner diameter of the brake drum.
The standard thickness of the brake shoe
is: 9mm
The standard inner diameter of brake drum
is : 190mm
(c). Install rear wheel. (Refer to"Chapter 33
Tires and Wheels - Rear Tires and Wheels
Replacement")
CHECK TIRE
NOTICE:
When finding that the tire wear hits a limit or is damaged so that affects the safe driving,
the customer must be informed for replacement.
1. Check whether the tire rolling surface and wall are damaged and have foreign
material, whether the tire wall is porous, has incision and is pierced by foreign
materials 04
2. Check whether the tire rolling surface wears unilaterally, if one side wear
serious,vehicle four wheels positioning must be conducted for correction
3. Check the tire tread depth (including spare

tire) to guarantee that the tread groove
depth is above the wear tag thickness, and
that the tire triangle wear mark does not
wear out
4. Check and adjust the tire charging pressure (including the spare tire)
Tire specification Front tire(kPa) Rear tire(kPa) Spare tire(kPa)

265/70R16 240 240 220
265/65R17 240 240 220
CHECK EXHAUST SYSTEM

NOTICE:
In the exhaust air system operation, pay attention to preventing from being burned.
1. Lift up the vehicle.

2. Check whether the front and rear exhaust pipe, muffler, and oxidation catalyst shell
is broken.
3. Check whether the connection among all parts of the exhaust air system has any
leakage.
4. Check whether the hanging piece is aging or has any fracture.
CHECK THE OIL LEVEL OF THE COOLING BRAKE FLUID

RESERVOIR
NOTICE：
• In the cooling system operation, pay attention to avoiding scald by hot water and hot
steam.
• The coolant used can only be recognized by Foton Motor Co., Ltd..
2. Wait until engine is cooled down to the normal temperature 04
3. Open engine hood
4. Check the coolant fluid level line, the fluid

level shall be near to the F fluid level line
(when the engine has been cooled)

NOTICE：
• In the cooling system operation, pay attention to avoiding scald by hot water and hot
steam.
• The coolant used can only be recognized by Foton Motor Co., Ltd.
CHECK THE ENGINE OIL LEVEL(ISF2.8)

2. Warm up the engine to the normal operating temperature
4. Wait for about 3 min
5. Open engine hood
6. Pull out the oil level gauge slowly and

clean its head with duster cloth. Insert this
oil level gauge back and pull it out again
7. Check engine oil level, which should be

within the mark range of the oil level gauge
8. Check the oiliness of engine oil. If the oiliness is too dirty or diluent, the trouble
removal should happen ahead of the change of engine oil
9. Insert the oil level gauge back
04

CHECK THE ENGINE OIL LEVEL(BJ486ZLEQ4)

4. Wait for about 3min
5. Open engine hood

7. Check engine oil level, which should be

within the mark range of the oil level gauge
8. Check the oiliness of the oil. If the oiliness is too dirty or diluent, the trouble removal
should happen ahead of the change of oil
04

04-32 VEHICLE CARE - REPLACEMENT
REPLACEMENT
REPLACE THE AIR FILTER ELEMENT
1. Turn off all the electrical appliances and ignition switch

2. Disconnect battery negative cable (Refer to "Chapter 18 Starting and Charging--
Battery, Replacing")
3. Push the lock pin backwards
4. Press down the bayoner lock vertically, and

pull out the sensor connector of the intake
air flow
5. Unscrew the collar clamp and pull out the

inlet air hose
VEHICLE CARE - REPLACEMENT 04-33
6. Unscrew the fixing screw and remove the

air filter assembly
04
7. Take out the air filter element
8. Clean the impurity inside the air filter housing cover
9. Install the air filter element
10. Install the air filter assembly and screw the

fixing screw
11. Install the inlet air hose and screw the

collar clamp
12. Install the sensor connector of the intake

air flow, and push and press the lock pin
forwards after hearing the ringing sound
that the connector is locked
13. Connect battery negative cable (Refer to "Chapter 18 Starting and Charging--
CHANGE THE AIR FILTER ELEMENT
1. Turn off all the electrical appliances and

ignition switch
2. Remove the glove box assembly
(a). Open the glove box.
04
(b). Pull the glove box upwards to separate it

from the fixed shaft.
(c). Take out the glove box in the inclining
direction.
3. Press the buckle clamp and take out the

air ilter element
4. Take out the air filter element
5. Install new air conditioning filter element

NOTICE:
In the process of installation, make the arrow of
the air conditioning filter element upwards.
6. Install the air filter element and lock the

buckle clamp
7. Install the glove box assembly

(a). Load it into the glove box in the inclining
direction.
(b). Make the glove box installation card on a

fixed shaft and press it in downwards.
NOTICE:
After installing, the glove box should switch freely
without shaking and binding.
(c). Close the glove box.
04
REPLACE THE ENGINE OIL AND OIL FILTER(ISF2.8)
1. Put the vehicle on level ground

3. Turn ignition switch off
5. Wipe the engine oil filler cap with duster

cloth and unscrew it
7. Remove the lower baffle of engine

(a). Remove fixed bolts of the baffle on both
sides and take off the baffle.
(b). Remove fixed bolts of the front baffle and

take off the front baffle.
04
(c). Remove fixed bolts of the back baffle and

take off the back baffle.
8. Remove drain plug and then drain engine

oil
NOTICE:
• Be careful not to be burned by engine oil while
draining it.
• The engine oil drained should be collected and
disposed according to the regulations.
9. After the completion of draining engine oil,

replace the drain plug gasket with a new
one,screw the draining plug and clean the
oil stain
Moment of force：45N•m
10. Remove the oil filter with tools and replace

it with a new one
11. Clean the bracket and the contact surface
of the oil filter
12. Top up the oil filter with clean oil and

spread a small amount of engine oil on the
O-type ring of the oil filter
13. Do not stop screwing the oil filter onto its

bracket manually until its O-type ring meets
the oil filter bracket, and then tighten up
its moment of force with tools:14N•mor 3/4
circles
04
14. Lower the vehicle
15. Unscrew the engine oil filler cap
16. Fill up the engine oil

NOTICE:
The engine oil used must be recognized by Foton Motor Co., Ltd..
17. Screw the engine oil filler cap
18. Start engine and let it idle for several minutes

19. Turn ignition switch OFF
20. Wait for several minutes

22. Check the engine oil level. If the oil level is

higher than the minimum rate, drain the
engine oil to the normal range; if the oil
level is lower than the minimum rate, fill the
engine oil to the normal range
04

25. Check whether the oil drain hole and the place screwing the oil filter leaks oil
26. Install the lower baffle of engine

(a). Install the back baffle and tighten up the
fixed bolts.
Torque : 21~25N•m
(b). Install the front baffle and tighten up the

fixed bolts.
Torque : 21~25N•m
(c). Install the baffle on both sides and tighten

up the fixed bolts.
Torque : 21~25N•m

NOTICE:
The engine oil used must be recognized by Foton Motor Co., Ltd.
REPLACE THE ENGINE OIL AND OIL FILTER(BJ486ZLEQ4)
1. Put the vehicle on level ground

5. Remove the engine upper cover
04
6. Wipe the engine oil filler cap with duster
cloth and unscrew it


(c). Remove fixed bolts of the back baffle and

take off the back baffle.
9. Remove drain plug with tools and then drain

engine oil
NOTICE:
• Be careful not to be burned by engine oil while
draining it.
• The engine oil drained should be collected and
disposed according to the regulations.
10. After the completion of draining engine oil,

replace the drain plug gasket with a new
one.After the completion of draining engine
oil, replace the drain plug gasket with a
new one
Torque : 40N•m
04
11. Remove the oil filter with tools and replace

it with a new one
12. Clean the bracket and the contact surface of the oil filter
13. Spread a small amount of engine oil onto

the O-type ring of the new oil filter
14. Screw the oil filter onto its bracket manually

and then tighten up the oil filter with tools
Torque : Screw for 3/4 circles after
tightening up manually
16. Unscrew the engine oil filler cap
17. Fill up the engine oil

NOTICE:
The engine oil used must be recognized by Foton Motor Co., Ltd..
18. Screw the engine oil filler cap
19. Start engine and let it idle for several minutes
21. Wait for several minutes

04
23. Check the engine oil level. If the oil level is

higher than the minimum rate, drain the
engine oil to the normal range; if the oil
level is lower than the minimum rate, fill the
engine oil to the normal range

25. Install the engine upper cover

27. Check whether the oil drain hole and the place screwing the oil filter leaks oil

(a). Install the back baffle and tighten up the
fixed bolts.
Torque : 21~25N•m
(b). Install the front baffle and tighten up the

fixed bolts.
Torque : 21~25N•m
(c). Install the baffle on both sides and tighten

Torque : 21~25N•m

CHANGE SPARK PLUG

2. Disconnect battery negative cable(Refer
to "Chapter 18 Starting and Charging--
3. Pull out the fixing clip of ignition coil
connector 04
4. Press and hold the fixing clip, and then take

ignition coil connector off
5. Remove fixed bolt of ignition coil, and then

take out ignition coil
6. Remove spark plug with a tool

NOTICE:
After unscrewing spark plug, set the ignition coil
in the head of spark plug, and then take out spark
plug.
7. Replace with a new spark plug until air
cylinder is covered and screwed down
Torque : 25~30N•m
NOTICE:
Set ignition coil in the head of spark plug, screw
into spark plug, then use a tool to fasten spark
plug.
8. Install ignition coil, assemble the fixed bolt

and fasten it
Torque : 10N•m
9. Connect ignition coil connector

10. Connect battery negative cable(Refer
to "Chapter 18 Starting and Charging--
REPLACE FUEL FILTER ELEMENT(ISF2.8)

NOTICE:
Before replacing fuel filter, be sure that a fire extinguisher is equipped in the specified
place.

2. Disconnect battery negative cable (Refer to "Chapter 18 Starting and Charging--
Battery, Replacing") 04
3. Pull out fuel filter heater connector
4. Discharge the fuel of fuel filter

(a). Press and hold lockpin, pull out the fuel
pipe at the same time.
(b). Press and hold lockpin, pull out the fuel

pipe at the same time, and use a specified
container to collect the fuel discharged.
5. Counterclockwise unscrew covering cap by

hand, take covering cap off
6. Take out fuel filter element, replace with

the new fuel filter element
7. Replace with the new O-ring, and apply a

little machine oil on the surface of the new
O-ring
04
8. Install covering cap, clockwise screw down

for about 3 and a half circles
9. Plug fuel pipe back, until you can hear a

clear and crisp sound of chucking
10. Plug fuel pipe back, until you can hear a

clear and crisp sound of chucking
11. Plug back fuel filter heater connector, until

you can hear a clear and crisp sound of
chucking
12. Discharge the air of fuel filter

(a). Unscrew bleed screw.
(b). Press and hold the upper cover of manual

fuel pump until there is fuel discharged and
no air in it.
04
(c). Screw down bleed screw.
13. Connect battery negative cable (Refer to "Chapter 18 Starting and Charging--
NOTICE:
Before replacing fuel filter, be sure that a fire extinguisher is equipped in the specified
place.
REPLACE COOLANT

2. Wait until engine is cooled down to the normal temperature
3. Slowly open coolant filler cap

Danger:
Never open coolant filler cap at the time of
warming up of the engine, otherwise,The ejection
of high-temperature coolant or steam might cause
a personal injury.


04
6. Slowly unscrew coolant drain cock and

drain the coolant
NOTICE:
Use a special container to collect the coolant, if
not continues using it, it shall be disposed as the
waste according to the relevant provisions.
7. After all the coolant are drained, screw

down the drain cock

(a). Install the front baffle and tighten up the
fixed bolts.
Torque : 21~25N•m
(b). Install the baffle on both sides and tighten

Torque : 21~25N•m
10. Fill the engine coolant till to the specified

position
11. Screw down coolant filler cap

NOTICE:
Pay attention to screwing the stuck point of filler
cap to the place between the two stuck points of
filler port.
04
12. Start the engine, accelerate to 2500 r/min, until electronic fan runs at high speed,
check if the coolant in the coolant fluid reservoir reaches to the specified position, if
not, continue to add coolant until to the specified position
NOTICE:
• Use a special container to collect the coolant, if not continues using it, it shall be disposed
as the waster according to the provisions.
• Pay attention to screwing the stuck point of filler cap to the place between the two stuck
points of filler port.
CHANGE BRAKE FLUID

NOTICE:
• The brake fluid used must be be recognized by Foton Motor Co., Ltd..
• The mixture of brake fluid with different brands and different types shall not be used,
otherwise it may affect the brake performance.
• Once the brake fluid gets on your skin, it must be cleaned immediately.
• The brake fluid discharge shall be collected and disposed according to the provisions.

2. Open engine hood
3. Drain brake fluid air
(a). Use a transparent plastic hose to connect
air vent screw and collection vessel.
(b). Unscrew brake fluid storage tank filler cap.
(c). According to the condition of brake liquid

storage tank liquid level, filling brake liquid
while draining.
Brake fluid model:7104–1
(d). Let one technician press brake pedal with

all his/her strength for several times and
keep the brake pressed.
04
(e). Let another technician unscrew brake fluid

air vent screw until the brake pedal reaches
the bottom, at this time screw down brake
fluid air vent crew.
(f). Repeat the operation of Step (d) - (e), until
there is no air in the brake fluid drained
from the air vent screw, screw down air
vent screw.
(g). Clean up the oil sludge on the air vent
screw.
4. With the method of the above step, drain

the brake fluid air in order according to the
sequence as shown in the figure
5. After completely draining the air, fill the

fluid in the brake fluid storage tank to the
standard range
6. Screw down brake fluid storage tank filler

cap

REPLACE MANUAL TRANSMISSION CASE LUBRICATING OIL

(JC538)

3. Unscrew transmission case oil filling bolt

04
4. Unscrew transmission case oil draining

bolt, drain transmission case lubricating oil
NOTICE:
The transmission case lubricating oil drained
shall be collected and disposed according to the
provisions.
5. After the transmission case lubricating oil is

completely drained, screw down oi l
draining bolt
Torque : 65~78N•m
6. Use a tool to fill tr ansm ission ca s e

lubricating oil in the transmission
case lubricating oil filler port,until the
transmission case lubricating oil is spilling
out of the filler port
NOTICE:
The transmission case lubricating oil used must be
recognized by Foton Motor Co., Ltd..
7. Screw down oil filling bolt, and clean up the

oil sludge
Torque : 65~78N•m
8. Check if there is oil leakage where the bolt is tightened

REPLACE THE REAR MAIN REDUCER GEAR OIL

3. Unscrew the rear main reducer gear oil

filling plug screw
04
4. Unscrew the rear main reducer gear oil

draining bolt, drain the rear main reducer
Gear oil
NOTICE:
The rear main reducer gear oil drained shall
be collected and disposed according to the
provisions.
5. After the rear main reducer gear oil is fully

drained, screw down oil draining Bolt
Torque : 38~45N•m
6. Use a tool to fill additive and rear main

reducer gear oil in the rear main reducer
gear oil filler port, until the rear main
reducer gear oil is spilling out of filler port
Additive model : Houghton Sturaco 7098
Dosage : about 0.08L
Gear oil type : GL-585W/90
Dosage : (1.27±0.03)L
NOTICE:
The rear main reducer gear oil used must be be
7. Screw down oil filling plug screw, and

clean up the oil sludge
Torque : 27~41N•m

REPLACE THE FRONT MAIN REDUCER GEAR OIL(FOUR-

WHEEL DRIVE )

3. Unscrew the front main reducer gear oil

filling bolt 04
fuwx04089
4. Unscrew the front main reducer gear oil

draining bolt, drain the front main reducer
NOTICE:
The front main reducer gear oil drained shall
be collected and disposed according to the
provisions.
5. After the front main reducer gear oil is fully

drained, replace the oil draining bolt
gasket, screw down oil draining bolt
Torque : 59~69N•m
6. Use a tool to fill front main reducer gear oil

in the front main reducer gear oil filler port,
until the front main reducer gear oil is
spilling out of filler port
NOTICE:
The front main reducer gear oil used must be be
7. Replace bolts gasket in the filler port, screw

down oil filling bolt, and clean up the oil
sludge
Torque : 41~51N•m
fuwx04089

REPLACE POWER TRANSFER OIL

3. Unscrew power transfer oil filling plug

screw
04
4. Unscrew power transfer oil draining plug

screw, drain power transfer oil
NOTICE:
The power transfer oil drained shall be collected
and disposed according to the provisions.
5. After the power transfer oil is fully drained,

screw down power transfer oil draining
plug screw
Torque : 19~30N•m
6. Use a tool to fill power transfer oil in the

power transfer oil filler port, until the power
transfer oil is spilling out of filler port
NOTICE:
The power transfer oil used must be recognized
by Foton Motor Co., Ltd..
7. Screw down power transfer oil filling plug

screw, and clean up the oil sludge
Torque : 19~30N•m
8. Check if there is oil leakage where the plug screw is tightened

ENGINE CONTROL SYSTEM ............. 11-1
SYSTEM DESCRIPTION.................. 11-1
NOTICES .......................................... 11-2
SYSTEM OVERVIEW ....................... 11-3
INTRODUCTION TO SYSTEM
FUNCTION ...................................... 11-7
FUNCTION DESCRIPTION OF
11
SYSTEM COMPONENTS .............. 11-10
ENGINE CONTROL MODULE (ECM) ........
............................................................ 11-12
AIR fLOW METER .............................. 11-13
OVERHAUL .................................... 11-14
ELECTRONIC THROTTLE ................ 11-15
OVERHAUL .................................... 11-16
INTAKE PRESSURE/TEMPERATURE
SENSOR ........................................... 11-18
OVERHAUL .................................... 11-19
COOLANT TEMPERATURE SENSOR .......
............................................................ 11-21
OVERHAUL .................................... 11-22
FRONT OXYGEN SENSOR............... 11-23
OVERHAUL .................................... 11-24
REAR OXYGEN SENSOR ................. 11-25
OVERHAUL .................................... 11-26
SPEED SENSOR ............................... 11-27
OVERHAUL .................................... 11-28
PHASE SENSOR ............................... 11-29
OVERHAUL .................................... 11-30
CANISTER PURGE CONTROL VALVE ......
............................................................ 11-31
OVERHAUL .................................... 11-32
KNOCK SENSOR............................... 11-33
OVERHAUL .................................... 11-34
OCV VALVE ........................................ 11-35
OVERHAUL .................................... 11-36
IGNITION COIL .................................. 11-37
OVERHAUL .................................... 11-38
FUEL INJECTOR................................ 11-39
OVERHAUL .................................... 11-40
ENGINE CONTROL SYSTEM - ENGINE CONTROL SYSTEM 11-1

SYSTEM DESCRIPTION
BJ486ZLEQ4 gasoline engine adopts UAES ME7.8 engine electronic management system,
which takes Engine Control Module (ECM) as the control center, with the corresponding
sensing elements, it inputs the air intake,crankshaft rotating speed and position, camshaft
phase information, oxygen sensor signal and some other auxiliary signals into the ECU
electronic control unit, after handling the signals, ECU controls the executive element to
keep the gas mixture in a reasonable combustible mixture ratio (air-fuel ratio) and make
it ignite at the right moment (ignition timing), so as to obtain the ideal motive power, fuel 11
economy and emission standards. In addition, ECM has the OBD diagnostic function,
which can simplify the troubleshooting.
11-2 ENGINE CONTROL SYSTEM - ENGINE CONTROL SYSTEM
NOTICES
1. To prevent the damage to the persons or vehicles, before removing or installing any
electric units and when the tools or equipments have easy access to the exposed
electrical terminals, the battery negative cable must be firstly disconnected and
connected in the end. Unless otherwise indicated, the ignition switch must be off.
DANGER:
Before connecting or disconnecting the battery negative cable, both ignition switch and
lighting switch must be off. (If not, it may damage the semiconductor component)
2. While implementing the maintenance, the adjustment, disassembly and assembly

and detection shall be conducted according to all the provisions as introduced in
this manual.
3. The components and parts of electronic injection system has a higher reliability,
when entire car or engine arise abnormity, first check the conditions of relevant
mechanical parts, system connector and wiring harness, ground wire, high tension
wire interface of spark plug and vacuum pipe of oil pressure regulator, etc.
4. Before installing the components and parts, clean the installation surface with FIPG
scraper or wire brush and ensure the surface is flat and smooth without oil. Do not
forget to clean the sealant in the assembly holes and bolts holes as well as on the
screw thread.
5. During the installation of components of sensors and actuators, the bolts shall be
screwed down and fixed according to the specified value.
6. Unless otherwise specified during the process, a pointer multimeter shall not be
used to test ECM and sensor;instead, a high impedance digital multimeter shall be
used for testing.
7. When installing and moving sensor, to ensure no damage to it, the sensor must be
handled with care. Any impact and drop may properly cause great damage to its
performance.
8. When battery voltage is low or starting motor goes out of order, it is not allowed to
start engine for a long time, so as to avoid damaging ternary catalytic converter.
9. The method of fine needle punching wiring harness is not allowed to use to check
system electric signal.
10. When removing and replacing the oxygen sensor, the oxygen sensor shall not be
contacted with water or other liquid.
11. The fuel pump shall not be operated for a long time under the condition of no
gasoline.
12. Most of electric injection parts are irreparable, and normally change them if parts
are damaged.
13. The system shall use the anti-jamming spark plug and high tension wire. Non-
resistible spark plug and high tension wire will not only release interference wave,
but also exert an unfavored effect on driver module of ignition coil in ECM.
14. ECM shall not be disassembled.
SYSTEM OVERVIEW
1. Introduction
BJ486ZLEQ4 engine electronic management system is mainly composed of three
parts of sensor, microprocessor (ECU) and actuator. In the engine electronic control
system, as the input part, the sensor is used to measure all kinds of physical signals
(temperature, pressure, etc.), and transform them into the corresponding electric
signals; The role of ECU is to receive the input signal of the sensor and process
it according to the set program so as to generate the corresponding control signal
and output it to the power-driven circuit, by driving each actuator to perform different 11
actions, the power-driven circuit makes the engine to run according to the fixed
control strategy; at the same time, the fault diagnosis system of ECU monitors
each component and control function in the system, once a fault is detected and
confirmed, the fault code shall be stored and "Limp home function" shall be invoked;
when it is detected that the fault is eliminated, it shall be recovered to normal run.
2. Main functions of this system
NO. FUNCTION NO. FUNCTION

Acceleration/Deceleration and
1 Start control 6
reversed towing fuel cut control
2 Idle speed control 7 Steam generation emission control
3 λClosed-loop control 8 Over-voltage protection
4 Knock control 9 A/C Compressor control
Warming up and heat control of ternary

5 10 Fault diagnosis and limp home
catalytic converter
3. The basic working module is as shown in the figure
Injector 1
Continuous power supply Injector
Injector 2
Non-continuous power supply
Injector 3
Ignition switch
Injector 4
Diagnosis K line
Ignition coil 1
Front oxygen sensor
Ignition coil 2
Rear oxygen sensor Ignition coil 3
Coolant temperature sensor Ignition coil 4
Rotate speed sensor Malfunctioning indicator signal
Knock sensor Oxygen sensor heater
Accelerator pedal module
ECU Electronic throttle motor
Throttle position sensor OCV valve
Air flow sensor Supercharger relief valve
Increased pressure temperature sensor Canister solenoid
Break vacuum sensor Rotate speed output
Vehicle speed signal 5V output

Air conditioner compressor relay
Air-conditioning switch
Fuel pump relay
Air-conditioning medium-voltage switch
Fan relay
Power steering control
Electronic vacuum pump relay
Clutch switch
Main relay
fuwx11001
4. Engine control system diagram
1
18
2 17
15
19
21
3 10 16
22
20 23
24
4 11
12
11 28
25
27
5
13
26 29
14
6
7
8 30
9
fuwx11002
NO. Name NO. Name

1 Canister 16 Intake of camshaft phaser
2 Canister solenoid 17 Vacuum tank
3 Intake pressure/Temperature sensor 18 Solenoid valve
4 Ambient pressure sensor 19 Safety valve
5 Electronic control unit 20 Fuel injector
6 CAN 21 Ignition coil/Spark plug
7 Diagnostic indicator lamp 22 Camshaft phase sensor
8 Diagosis socket 23 Waste gate actuator
9 Anti-thief control system 24 Heating charger
10 Air intake cooler 25 Knock sensor
11 Throttle(ETC) 26 Speed sensor
Intake manifold sensor and pressurized

12 27 Coolant temperature sensor
air temperature sensor
13 EGR 28 Waste gate
14 Accelerator pedal 29 Oxygen sensor
15 One-way valve 30 Fuel pump

INTRODUCTION TO SYSTEM FUNCTION
1. Start control
• In the process of starting, it adopts the special method of calculation to control the
charge, injection and ignition timing.
• At the beginning of the process, the air in the intake manifold is still, the internal
pressure of intake manifold is shown as the surrounding atmospheric pressure.
Open the electronic throttle to a certain angle, of which size is a fixed parameter
according to the starting temperature.
• The amount of fuel injection changes according to the temperature of the engine, 11
in order to promote the oil film to be formed on the intake manifold and cylinder
wall. Before the engine reaches a certain speed, the enrichment of mixture shall
be made. Once the engine starts to run, the system shall immediately start to
reduce the start enrichment, until the state of starting operation ends (the engine
speed reaches 600 - 700r/min), it shall completely cancel the start enrichment.
• Under the state of starting operation, the ignition angle shall also be adjusted,
changing with the engine temperature, intake temperature and engine speed.
2. Warming up and heat control of ternary catalytic converter

• After the cold-starting of the engine, all of air charge, fuel injection and ignition
in the air cylinder are adjusted to compensate the higher torque requirement
of the engine. This process is continued until the engine temperature rises to a
certain threshold (the engine temperature is approximate to the engine coolant
temperature).
• The function of ternary catalytic converter is to convert the harmful gas exhausted
from the combustion in the engine into harmless gas and then discharge it into
the atmosphere.
• Due to that the working temperature of ternary catalytic converter is more than
300℃ , the most important thing in the process of warming up is the rapid heating
of ternary catalytic converter. Under such condition, it may adopt the method of
appropriately delaying the advance angle of ignition to conduct the heating of
ternary catalytic converter by using exhaust gas.
3. Idle speed control

• The function of idle speed control refers to the control of the system for the engine
speed when the accelerator pedal is not pressed.
• Idle speed control includes the control of stabilizing the engine speed when the
vehicle runs at the idle speed. It also includes the idle regulator control when the
load is increased, for example, in case of opening the air conditioning, power
steering, opening headlight, etc.
• The system uses a step motor (integrated in the electronic throttle body) to
automatically adjust the throttle opening angle, so as to achieve a high precision
idle speed control.
4. λClosed loop control
5. Knock control
• The system detects the characteristic vibration when the knock occurs by the
knock sensor installed between the NO. 2 cylinder and NO. 3 cylinder of the
engine and converts it to the electronic signal, so as to transmit to ECM for
processing.
• ECM uses a special processing algorithm that it detects if there is a knock
occurring in each combustion cycle of each air cylinder. Once a knock is detected,
the knock closed loop control shall be triggered. After the shock danger is
eliminated, the affected cylinder may be gradually advanced to the predetermined
ignition advance angle again.
6. A/C compressor control
• When the air-conditioning switch is turned on, ECM will receive the signal called
air conditioning request, and make preparations for loading the air conditioning
according to the operating condition of the engine at that time, then connect air-
conditioning compressor.
• ECM will control the connection and disconnection of air-conditioning according to
the needs of self-protection of the air-conditioning. In order to ensure power take
off and protect the engine, the system will disconnect the air-conditioning under
some certain conditions.
7. Steam generation emission control
• Due to the reason of external radiation heat and oil return heat transfer, the fuel
oil in the tank is heated to form the fuel vapor.
• Due to restrictions with evaporative emission regulations, these vapor containing
a large amount of HC content is not allowed to be directly discharged into the
atmosphere. In the system, the fuel vapor is collected in the charcoal canister
through the conduit, and then it enters into the engine to participate in the process
of combustion by flushing at the proper time.
• The flow of flushing the airflow is achieved by ECM controlling canister solenoid.
This control may work only when the λ closed-loop control system is in the
closed loop working mode.
8. Cooling fan control

• The vehicle is equipped with the electric double speed engine cooling fan.
• Electric fan control function: ECM determines whether to turn on each fan
according to the basis that whether the temperature of the coolant temperature
of the engine meets the condition starting the air conditioner, so as to reduce the
internal power consumption of the engine.
9. Self- diagnosis
• Self-diagnosis of system malfunction is an essential function of engine control
system. When one or several parts in the system work abnormally, the system
will remind the vehicle user to perform necessary inspection and maintenance by 11
lighting up MIL in a timely manner. When the malfunction occurs, the system may
use temporary emergency plan to control the operation of the engine, so as to
ensure that the user can drive the vehicle for maintenance.
• When the abnormality of an abnormal certain sensor and actuator is detected, the
engine MIL lights up so as to remind the vehicle user.
• RAM data related to the sensor and actuator in the ECM can be read through
trouble diagnosis device. In addition, in some cases, the actuator can be driven
by force.
FUNCTION DESCRIPTION OF SYSTEM COMPONENTS

NO. Part Number Function
Optimize the control system according to the
Electronic control
1 1 signal provided by sensor, make it suitable
unit(ECM)
for the operating condition of the engine
Detect the rotation position and rotate speed

2 Speed sensor 1
of engine crankshaft
Provide crankshaft and camshaft position

information for ECM, i.e., differentiate the
3 Phase sensor 1
compression top dead center and exhaust
top dead center of crankshaft
Detect intake air temperature and air inflow,

4 Air flow meter 1
determine engine load
Detect the temperature and flow of air entering

Intake pressure/
5 1 into air cylinder, perform pressurize pressure
Temperature sensor
control
Detect the throttle position, adjust the throttle
6 Electronic throttle body 1
percentage
The pedal position signal is transformed to

7 Accelerator pedal 1 electrical signal. The throttle percentage is
adjusted indirectly
8 Ignition coil 4 Ignite gas mixture
9 Fuel pump 1 Transport fuel
10 Fuel injector 4 Eject fuel according to signal from ECM
Coolant temperature Detect the engine coolant temperature,

11 1
sensor confirm the engine operating conditions
Make the fuel vapor enter into canister

Canister purge control
12 1 according to digital pulse square wave of
valve
ECM
Control the oil flow of the engine, which

13 Intake VVT valve 1 flows towards the camshaft position actuator,
change air intake phase
Detect the oxygen concentration of exhaust

14 Front oxygen sensor 1
gas, confirm air-fuel ratio
Detect the oxygen concentration of exhaust
15 Rear oxygen sensor 1 gas, confirm whether the exhaust emission
reaches the standard
NO. Part Number Function

Detect whether the engine is knocked, and
16 Knock sensor 1 corresponding affects the ignition advance
angle
Detect the driving condition and the engine

17 Clutch switch 1
speed in stable shift
Adjust the intake boost pressure according to

18 Air circulation valve 1
the air intake cylinder load
11
Adjust the exhaust gas flow direction in
19 Exhaust gas bypass valve 1
turbocharger according to the engine speed
11-12 ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE(ECM)
ENGINE CONTROL MODULE (ECM)
1. Principle of Work
ECM is an electronic engine control center with the sensor signal input interface and
actuator drive circuit, which is mainly composed of microprocessor as its core. It
receives and processes the engine state signals input by each sensor and send the
control signal to the actuator, so as to make the engine to work in accordance with
the scheduled program, keeping the engine working in the best state and ensuring
good dynamic performance, fuel economy and emission performance.
ECM has the self-protection function. A failure in starting may occur during the
maintenance, however, everything will be working fine after replacing the ECM,
therefore it is possible that ECM goes out of order, in fact, ECM is not damaged,
just because the ECM enters into the self-protection mode and ECM will be back to
normal after a while.
2. Working voltage range:9~16V
3. Working environment temperature:-40℃ ~70℃
4. Removal of ECM
(a). Turn ignition switch off, disconnect battery negative cable.
NOTICE:
Before disconnecting and reconnecting battery negative cable, please firstly turn off ignition
switch and lighting switch, completely loosen the nut tightened on the battery negative
terminal. Do not levering cable terminal in the process of performing these operations.
(b). Disconnect the ECM connectors.
NOTICE:
After removing the connector, ensure the connector's connection part not to be contacted
with the dirt, water and other impurities.
(c). Remove ECM fixed bolt, take ECM down.
NOTICE:
After removing ECM, pay attention to being protected from the water, it is neither allowed
to be stained with water, nor to be immersed in the water. Pay attention to the protection
for the plug pin. Before removing ECM, please firstly remove battery negative cable for
more than 1 min. Do not allow collision, ECM must be removed with care.
5. Install ECM
NOTICE:
Pay attention to the electrostatic protection during installation.
(a). Install ECM, assemble the fixed bolt and fasten it.
(b). Connect the ECM connectors.
(c). Connect the battery negative.
ENGINE CONTROL SYSTEM -AIR FLOW METER 11-13
AIR fLOW METER
The system adopts mass flow measurement method to measure the air quantity
entering into the engine, and then control the injection pulse duration, so as to
accurately control the engine power take off.
2. Function and installation
Air flow meter is installed on the intake air duct between air filter and electronic
throttle valve to measure the air intake and intake temperature signal of the engine 11
in real time, and then feed back to ECU. ECU calculates fuel injection quantity per
cycle according to the intake air temperature, air intake and other parameters, so as
to precisely control air-fuel ratio, ensuring that the engine can meet the demand of
power performance and fuel economy under all working conditions.
3. Fault phenomenon and judgment method
(a). Fault phenomenon: poor acceleration, etc..
(b). General causes for faults:
•Poor-contact connector, short-circuit pin, accumulated dirt on the surface, etc..
•Vacuum unit is damaged in maintenance process.
(c). Precautions for maintenance:
Prevent falling and foreign matters from entering into the case of flow meter, so as
to ensure a good performance of air filter.
11-14 ENGINE CONTROL SYSTEM - AIR FLOW METER
OVERHAUL
1. Visual inspection
Visually inspect if the appearance is complete with no defects of collisions and
scratches.
2. Check with the scan tool
Connect the diagnostic device to check if air flow meter has a relevant fault code
output, and check if the data flow shown by diagnostic device under all working
conditions is correct. In case of a fault code or abnormal data flow, replace air flow
meter after checking the wiring harness is in good condition.
ENGINE CONTROL SYSTEM - ELECTRONIC THROTTLE 11-15
ELECTRONIC THROTTLE
The throttle opening of electronic throttle body assembly is obtained that according
to throttle pedal control input signal controlled by the driver and other various
sensors' input signal, ECM calculates the engine output power required by the
vehicle at this moment and in this state, and then accordingly it controls the fuel
supply (injection) quantity of the engine, so as to ensure the engine works in the
best control condition. Electronic throttle body is added with the components of drive 11
motor, gear drive mechanism, etc. as well as throttle position sensor with stronger
function and reliability.
The electronic throttle body is composed of three parts of DC motor, throttle position
sensor and throttle. It is equipped on the intake manifold to receive the signals from
ECU under all working conditions, comprehensively process and adjust the throttle
opening, meanwhile it measures the throttle opening in real time through throttle
position sensor and feed back to ECU, so as to achieve the goal of meeting air
intake demand of engine under different working conditions.
3. Working temperature range:-40℃ ~140℃
4. Sensor power supply voltage:5±0.2V
5. DC Motor:
Voltage range:8V~16V
Terminating resistor:1.1Ω~2.1Ω
Inductance(1kHz):1.1±0.3mH
(a). Fault phenomenon: unstable idle speed, poor acceleration, etc..
(b). General causes for faults: Man-made fault (such as damage to casing).
(c). Precautions for maintenance: avoid the occurrence of falling or knocking, pay
attention to installation position, in consideration of leakage in the shaft seal
of throttle after long-time running, the throttle body assembly shall be installed
according to the correct position and direction, the maximum allowable moment of
fastening screw is 10N•m.
11-16 ENGINE CONTROL SYSTEM - ELECTRONIC THROTTLE
OVERHAUL
1. Check action sound

When the ignition switch turns to "ON"(do not start engine), check whether the
action sound of throttle motor.
NOTICE:
If there is no action sound of throttle motor, check the control harness of electronic throttle.
If the control harness is normal, it may be the throttle motor or ECM fault.
2. Check throttle percentage

(a). Connect diagnostic device to diagnose
interface.
(b). Turn the ignition switch to "ON" and open
the diagnostic device–to read the data flow
using the latest software version.
(c). Select the menu item of "Read data flow".
fuwx11017
Device display
Detection condition(range) Normal conditions
item
Idle position(Accelerator pedal

10%±2
•Ignition switch not depressed)
Air control shutter ON

Throttle gradually Increase with the increase of
turndown ratio •Engine does not
Open throttle open angle
run
Full open(When the accelerator
93%
pedal is fully depressed)
(d). If the signal value does not conform to provision or there is no signal output, check
electronic throttle, harness and ECM.
ENGINE CONTROL SYSTEM - ELECTRONIC THROTTLE 11-17
3. Check electronic throttle

(a). Turn ignition switch off, disconnect battery negative cable.
(b). Disconnect electronic throttle connector.
(c). Remove intake tube assembly.
(d). Remove fixed bolt of electronic throttle, and take electronic throttle down.
(e). Turn digital multimeter to ohms range,

connect two probes to No.2 and No.3 pin,
respectively, its resistance value at normal
4 5 6
temperature is 1.25kΩ±30%. 11
1 2 3
(f). Use digital multimeter to detect the
resistance between No.2 pin of electronic
throttle body and No.5/6 pin, and the
resistance between No.3 pin and No.5/6
pin. Stir valve by hand, the resistance shall
have slow linear change; if it's the opposite
condition, the change of two resistance will
be the opposite.
fuwx11005 NOTICE:
If the resistance is outside the scope of the
standard, or the resistance changes unsteadily,
the electronic throttle body assembly shall be
replaced.
4. Install electronic throttle
(a). Install electronic throttle to intake manifold.
(b). Install and tighten the fixed bolt of electronic throttle.
Torque: 10N•m
(c). Connect intake tube assembly, connect electronic throttle connector.
(d). Connect the battery negative.
11-18 ENGINE CONTROL SYSTEM - INTAKE PRESSURE/TEMPERATURE SENSOR
INTAKE PRESSURE/TEMPERATURE SENSOR
1. Principle of work
Adopting the speed-density air measurement method, the system detects the air
amount in engine after inter-cooling,to correct the fuel-injection quantity, etc..
The intake air temperature sensing element is a negative temperature coefficient
(NTC) resistance, whose resistance value declines with the increase of intake air
temperature.Engine ECM detects the change of intake air temperature through a
internal comparison circuit.
The sensor is composed by absolute pressure sensor and intake air temperature
sensor, to measure the pressure temperature value after inter-coolingand feed it
back to ECU as the basis for supercharge pressure control. It is installed in the
intake tube after intercooling and before throttle.
(a). Fault phenomenon: Flame out and poor idling, etc..
• Abnormal high pressure or large reverse current in using process.
• Vacuum unit is damaged in maintenance process.
• Impacting vacuum unit by high pressure gas is prohibited in maintenance
process;
• Check whether vacuum hole of sensor is blocked, and dispose it in time;
• Upon replacing sensor after fault detection, check whether the engine output
voltage and current are normal;
• Use press-in method rather than hammering method while install.
ENGINE CONTROL SYSTEM - INTAKE PRESSURE/TEMPERATURE SENSOR 11-19
OVERHAUL
1. Check intake air pressure temperature

sensor
(a). Turn ignition switch to OFF.
(b). Connect diagnostic device to diagnose
interface.
(c). Turn the ignition switch to "ON" and open
the diagnostic device–use the latest
software version. 11
(d). Select the menu item of "Read data flow".
Diagnostic
Detection Normal
device
condition(range) value
display item
fuwx11017
Intake air
0℃
temperature:0℃
Intake air Intake air

20℃
temperature temperature:20℃
•Ignition
switch:ON Intake air
80℃
•Or start temperature:80℃
run Intake air
3.2~3.8V
Intake air temperature:0℃
temperature Intake air

2.3~2.9V
sensor temperature:20℃
voltage Intake air
0.4~1.0V
temperature:80℃
(e). If the results do not conform to provision, check intake air pressure temperature
sensor, harness or ECM.
11-20 ENGINE CONTROL SYSTEM - INTAKE PRESSURE/TEMPERATURE SENSOR
(f). Check intake air temperature sensor

section.
•Turn digital multimeter to ohms range,
4 3 2 1 connect two probes to No.1 and No.3 pin
of sensor, respectively.
Rated resistance(at 20℃ ): 2.5kΩ±5%
•Simulate the air supply to sensor by
electric hair drier (Note: Don't get too
close), observe the change of sensor
Ω resistance, the resistance value shall
decline at this time.
NOTICE:
fuwx11006 Upon checkup, the sensor connector shall be
disconnected, and the resistance at sensor side
shall be detected by multimeter.
(g). Check pressure sensor section

Turn digital multimeter to DCV, connect
4 3 2 1 black probe to ground, and connect red
probe to No.2 and No.4 pin.
Test
Terminal Voltage
conditions
V
2-Grounding 5V
Idle
4-Grounding 1.3V
Open the
throttle 4-Grounding Basically no change
No slowly
fuwx11007
load Open the
Instantly reach4V,
throttle 4-Grounding
thendecline to1.5V
quickly
NOTICE:
If the checkup does not conform to provision, replace the intake air pressure temperature
sensor.
ENGINE CONTROL SYSTEM - COOLANT TEMPERATURE SENSOR 11-21
COOLANT TEMPERATURE SENSOR
Inside the coolant temperature sensor, there is a NTC thermistor which converts
temperature signal to electrical signal and inputs to ECM. The higher the
temperature is, the smaller the resistance value will be.
The water temperature sensor assembly is used to monitor the temperature of
engine coolant so as to correct the oil injection and ignition based on this; Pins: Pin 11
A outputs signal; Pin B connects the temperature display of instrument controller
board; Plate temperature display; Pin C connects the ground.
Install water temperature sensor assembly to discharging tube connector, and
insert copper thermal conductive sleeve to coolant. The sleeve has thread. Applying
243 sealant to thread before installation, you can conveniently screw in the water
temperature sensor assembly to the threaded hole on discharging tube connector.
(a). Fault phenomenon: Starting difficulty, etc..
Man-made fault (such as thread failure).
Removing sensor under warm-up condition is prohibited.
11-22 ENGINE CONTROL SYSTEM - COOLANT TEMPERATURE SENSOR
OVERHAUL
1. Check coolant temperature sensor

(a). Soak temperature sensing part of coolant
2
temperature sensor to hot water,measure
1 3 the resistance between No.1 and No.3
terminal of coolant temperature sensor by
multimeter.
(b). If the measuring result does not conform to
standard, the coolant temperature sensor
shall be replaced.
Ω Measurement Standard
condition resistance(kΩ)
fuwx11008 20℃ 2.1~2.7
100℃ 0.3~0.4
NOTICE:
Put working area of sensor into water, upon
simulating detection, do not let water enter into
binding post. After the checkup, the sensor shall
be wiped dry immediately.
NOTICE:
• Upon checkup, the sensor connector shall be
disconnected, and the resistance at sensor side
shall be detected by multimeter.
• If the checkup does not conform to provision, the
coolant temperature sensor shall be replaced.
ENGINE CONTROL SYSTEM - FRONT OXYGEN SENSOR 11-23
FRONT OXYGEN SENSOR
The sensing element of oxygen sensor is a kind of ceramic tube with hole. The
outside of tube wall is surrounded by engine exhaust emission, while the inner side
connects to the atmosphere. The sensing ceramic wall is a kind of solid electrolyte
with electric heating tube inside. The work of oxygen sensor is realized through
transforming the oxygen ion concentration difference inside and outside the sensing
ceramic tube into the voltage signal output. The sensing ceramic tube will have 11
the property of solid electrolyte when its temperature reaches 350 ℃ . Due to the
particularity of its texture, the oxygen ion can go through the ceramic tube freely.
Utilizing this feature, the concentration difference is transformed into potential
difference, thereby forming electrical signal output. If the mixed fas is thicker, The
oxygen ion concentration difference inside and outside the ceramic tube will be
higher, so is the potential difference, and a large amount of oxygen ions will move
from inside to outside, leading to a higher output voltage (near 800-1000mV). If the
mixed fas is in low concentration, the oxygen ion concentration difference inside
and outside the ceramic tube will be lower, so is the potential difference, and only
a small amount of oxygen ions will move from inside to outside, leading to a lower
output voltage (near 100mV).
It is used in the feedback system of electronic control fuel injection device to realize
the closed-loop control and improve ECU's control accuracy for air-fuel ratio. It is
installed in the exhaust pipe (before three-way catalyst) to determine the oxygen
content in exhaust gas and whether gasoline and air are thoroughly burned, so as
to ensure that three-way catalytic converter has a maximum conversion efficiency to
HC, CO and NOX in exhaust gas.
(a). Fault phenomenon: Poor idling, poor acceleration, tail gas exceeding standard and
too large fuel consumption, etc..
• Wet moisture enters into the sensor. Temperature changes sharply. The probe
breaks;
• Oxygen sensor "poisoning". (such as Pb, S, Br and Si, etc.)
• Using cleaning fluid, oily liquid or volatile solid on the sensor during maintenance
is prohibited.
11-24 ENGINE CONTROL SYSTEM - FRONT OXYGEN SENSOR
OVERHAUL
1. Check oxygen sensor

(a). Disconnect the oxygen sensor connector.
(b). n the Power "OFF" Condition, check the
resistance between No.1 and No.2 pin of
1 2 3 4
oxygen sensor.
Resistance: 2.5Ω-4.5Ω (20℃ )
NOTICE:
While checkup, check the resistance at the sensor
side with digital multimeter.
Ω
fuwx11009
(c). Connect oxygen sensor connector.

(d). Connect diagnostic device, start engine, read the voltage of oxygen sensor on
diagnostic device. When the engine operates above 3min and the oxygen sensor
temperature reaches above 350 ℃ , the oxygen sensor voltage shall continuously
change between 0.1V-0.9V. If there is no change, it indicates that the sensor is
"poisoned", invalid or damaged.
NOTICE:
If the checkup is not in conformity with the regulations, it indicates that the oxygen sensor
is damaged and should be replaced.
ENGINE CONTROL SYSTEM - REAR OXYGEN SENSOR 11-25
REAR OXYGEN SENSOR

The aim of rear oxygen sensor is to detect the oxygen content in exhaust after
three-way catalytic transformation. The sensor transforms this signal to electrical
signal and sends it to ECM. After comparing the signal of front and rear oxygen
sensors, ECM judges whether three-way catalytic works well.
(a). Fault phenomenon: Poor idling, poor acceleration, tail gas exceeding standard and 11
too large fuel consumption.
11-26 ENGINE CONTROL SYSTEM - REAR OXYGEN SENSOR
OVERHAUL
The rear oxygen sensor is only used in electronic fuel injection system with OBD function.
It detects whether the exhaust exceeds standard. The rear oxygen sensor has the same
technical conditions and material object with the front oxygen sensor, but has different
installation site.
ENGINE CONTROL SYSTEM - SPEED SENSOR 11-27
SPEED SENSOR
The speed sensor, i.e., crankshaft position sensor system, adopts the magnetic
induction loop type speed sensor and generates alternating current and voltage
signal by rotatively cutting magnetic line of force. ECM adopts this alternating
signal, turns this signal into digital signal that can be identified by engine ECM
after transformation, which is used for the system control of engine. The flywheel
ring gear and signal wheel are installed together. The signal wheel adopts the form 11
of 58X tooths to provide rotate speed, corner and top dead center for ECM. The
continuous gap is a top dead center of cylinder.
It is used in the electronic control fuel injection device to monitor the crankshaft
speed of engine, output voltage-frequency signal to electronic controller and judge
the working condition of engine. Coordinated with missing tooth position of sensing
signal wheel, it can detect the crankshaft position of engine, thereby judge the
position of top dead center of the first cylinder, which can be regarded as one of
parameters for calculating the ignition advance angle.
The speed sensor is installed on the flywheel platform at the back of engine.
(a). Fault phenomenon: Unable to start, etc..
The sensor will be corroded, if it is connected with various liquids (such as oil,
coolant, brake fluid, etc.) for a long time.
Use press-in method rather than hammering method in maintenance process.
11-28 ENGINE CONTROL SYSTEM - SPEED SENSOR
OVERHAUL
1. Check speed sensor

(a). Disconnect speed sensor connector.
(b). Measure the resistance between No.1 and
1 2 No.2 terminal of speed sensor.
Resistance: 860Ω (20℃ )
(c). Connect speed sensor connector.
(d). Turn digital multimeter to ACV, connect
two probes to No.1 and No.2 pin of sensor,
start engine, and at this time, the voltage
Ω signal should be output.
NOTICE:
If the checkup does not conform to provision, the
fuwx11010 speed sensor shall be replaced.
ENGINE CONTROL SYSTEM - PHASE SENSOR 11-29
PHASE SENSOR
The phase sensor is also the camshaft position sensor. This sensor is composed of
a hall sensor and a rotor made of steel plate. The hall sensor is fixed. The rotor is
installed on camshaft. The rotor is a cylindrical steel blade with the range of 180° .
There is no output signal when the blade covers hall sensor, otherwise, there is an
output signal. Since that two semi-cycles of camshaft are equal to two hole cycles
of crankshaft, the compression top dead center and exhaust top dead center of 11
crankshaft can be identified.
Phase sensor is applied to match with speed sensor to provide crankshaft phase
information for ECU, namely, to identify the compression top dead center and
exhaust top dead center of the first cylinder.
Phase sensor is installed at the camshaft cover.
(a). Fault phenomenon: Emission exceeds standard, and fuel consumption increases,
etc..
Man-made fault.
• Use press-in method rather than hammering method in maintenance process.
• Clean the surface of installation site after removal, and ensure that there is no oil
contamination.
11-30 ENGINE CONTROL SYSTEM - PHASE SENSOR
OVERHAUL
1. Check the position sensor

(a). Disconnect the socket connector of the
position sensor.
(b). In the Power "ON" Condition, check the
voltage between No.1 pin of the position
sensor and grounding with the digital
multimeter.
Voltage: 5V
Check the resistance between No.3 pin of
the position sensor and grounding with the
digital multimeter.
Resistance: 0Ω
fuwx11011 NOTICE:
While checking, check the voltage or resistance of
the camshaft position sensor in the harness side
of the engine with digital multimeter.
(c). Connect the socket connector of the position sensor.
(d). Start the engine and check the voltage waveform of No.2 pin with the automobile
oscilloscope. The voltage waveform should change consistently and regularly.
NOTICE:
If the checkup is not in conformity with the regulations, it means that the position sensor
fails and should be replaced.
ENGINE CONTROL SYSTEM - CANISTER PURGE CONTROL VALVE 11-31
CANISTER PURGE CONTROL VALVE
Canister purge control valve has a solenoid valve system inside and its jaw opening
is controlled by the digitalized pulse square wave output by ECM. With different
operating conditions of the engine, the jaw opening of canister purge control valve
changes. If the load of the engine is huge enough to idle, the canister purge control
valve will not operate in order to protect the output power of the engine.
2. Function and installation 11
The function of the canister purge control valve is to control and adjust the fuel
vapor volume, which is absorbed by activated charcoals in the canister and then
flows into the admission manifold, with ECU electronic control unit. Canister purge
control valve is fixed in its sheath.
(a). Fault phenomenon: function failure, etc..
The rustiness and poor sealing performance caused by foreign matters entering into
the valve, etc..
• The direction of air flow must be in conformity with regulations in the process of
installation.
• Please check the condition of the canister, if the control valve should be replaced
for finding that the control valve fails because of the black granules.
• Try to avoid getting liquid such as water, oil, etc. into the valve in the process of
maintenance.
• Canister purge control valve must be installed with the canister purge control
valve bush in order to avoid the transmission of the solid-borne noise.
11-32 ENGINE CONTROL SYSTEM - CANISTER PURGE CONTROL VALVE
OVERHAUL
1. Check the canister purge control valve

(a). In the Power "OFF" Condition, disconnect
the negative cable of accumulator.
2 1 (b). Disconnect the plug-in of the canister
purge control valve.
(c). Check the resistance of the canister purge
control valve. Turn digital multimeter to
ohm range and connect two probes to
No.1 and No.2 terminals respectively to
Ω measure the resistance between the two
terminals.
Standard resistance: 22Ω~30Ω(20℃ )
fuwx11012 NOTICE:
If the resistance value is not in conformity with
regulations, the canister purge control valve
should be replaced.
ENGINE CONTROL SYSTEM - KNOCK SENSOR 11-33
KNOCK SENSOR
Knock sensor is a vibrated and accelerated speed sensor, installed in the cylinder
block of the engine. The sensitive element of sensor is a piezoelectric element.
The vibration of the engine cylinder block is transmitted to the piezoelectric crystal
through the mass block inside the sensor. Because the piezoelectric crystal is under
the vibration of mass block, it produces voltage in both polefaces, and turned the
vibration signal into the alternating voltage signal outputting. The frequency of the 11
vibration signal caused by engine knocking is much higher than the normal vibration
signal of the engine. Therefore, the knocking and non-knocking signals can be
divided after ECM has disposed the signal of the knock sensor.
Knock sensor is used to monitor the knocking of the engine, making judgment on
the operating condition of the engine by outputting the voltage signal to ECU.
Knock sensor is installed on the dummy club between the No.2 and No.3 cylinders
in the intake side of the engine cylinder block.
(a). Fault phenomenon: poor acceleration, etc..
The sensor will be rusted, if it is connected with various liquids such as oil, coolant,
brake fluid, etc. for a long time.
• Ensure that the surface of installation dummy club is clean without oily foul.
• In the process of installation, any kind of gaskets is not allowed. And it must be
the metal surface of the sensor that clings closely to the cylinder block.
• High voltage should not be connected between the two pins of the sensor, for it
may damage the piezoelectric element.
11-34 ENGINE CONTROL SYSTEM - KNOCK SENSOR
OVERHAUL
1. CHECK KNOCK SENSOR

(a). Disconnect the socket connector of the
knock sensor.
1 2 (b). Check the resistance between the No.1
and No.2 pins of the knock sensor with the
Ω digital multimeter.
Resistance: ＞ 1MΩ
(c). Switch the digital multimeter to mv range,
knock slightly on the place near the knock
sensor with a little hammer, and at this
time, the voltage signal should be output.
NOTICE:
fuwx11013 •While checking, check the voltage or resistance
besides the sensor element with digital
multimeter.
•If the checkup is not in conformity with
regulations, it means that the knock sensor is
damaged and should be replaced.
ENGINE CONTROL SYSTEM - OCV VALVE 11-35
OCV VALVE
The working power supply of the intake VVT solenoid valve is provided by the main
relay and ECM modulates the signal control grounding with pulse width Therefore,
to control the oil flow of the engine flows towards the camshaft position actuator.
Oil pressure is a safe slide valve action inside the camshaft position actuator, which
is fixed in front of the camshaft. In the process of the safe slide valve action, oil is
channeled into the camshaft position actuator to rotate the camshaft. The continual 11
change of the phase between camshaft and crankshaft can control the valve timing.
According to the rotation speed of engine, load, temperature of cooling water, etc.,
ECU confirms the camshaft phase required and sends duty ratio signal to OCV
valve. OCV valve is a solenoid valve of four-access pulse width modulation with the
ability of bidirectional movement. According to the control signal of ECU, it changes
the axial displacement of the slide valve and controls the oil flow and the flowing
direction of the oil towards VVT.
OCV valve is installed on the intake side of cylinder head.
(a). Fault phenomenon: VVT cannot reach the targeted phase angle.
The seal ring on the surface of OCV valve is damaged, which will lead to oil
pumping between oil passages, and the short circuit or open circuit of OCV coils.
• Avoid knocking in the process of installation, and check whether the strainer filter
is clean and intact without obvious granules, whether the O-type ring is in good
condition, and whether the seal ring is scratched seriously, or else the installation
cannot be implemented.
• Check whether the slide valve of OCV is on the fully closed position, or else it
cannot be used.
• Before installation, lubricate the O-type ring with oil, and then push the OCV valve
into the mounting holes of the cylinder head carefully till the mounting surface is
connected with the cylinder head, and at last, tighten the bolt.
• Clean the OCV valve with clean oil rather than oil of powerful solvent (e.g.
gasoline), nor can it be blew by compressed air.If OCV valve is pasted with oils
except for the engine oil, it should be cleaned promptly.
• The slide valve and the head of connectors are not allowed to be dipped by water.
11-36 ENGINE CONTROL SYSTEM - OCV VALVE
OVERHAUL
1. Check OCV valve

(b). Disconnect the connector of OCV valve.
1 2
(c). Remove the fixing bolt on the OCV valve
and take out the OCV valve.
(d). Check the strainer filter of OCV valve,
replace it, if it is blocked or damaged.
(e). Measure the resistance value between
Ω No.1 and No.2 terminals of OCV valve
with the digital multimeter switched on the
resistance range.
fuwx11014 Standard resistance value:
6.9Ω~7.9Ω(20℃ )
NOTICE:
regulations, the OCV valve should be replaced.
ENGINE CONTROL SYSTEM - IGNITION COIL 11-37
IGNITION COIL
Ignition coil is mainly comprised of primary coil, secondary coil, iron core，etc.. The
ignition system turns the low-voltage electricity into the high-voltage electricity by
means of ignition coil, making the spark plug generate electric spark. Each ignition
coil is only for one cylinder. Under the control of computer ECM in automobile,
charge the primary coil to accelerate magnetic energy. The secondary coil winding
will induce high-voltage electricity, making the spark plug connected to the coil 11
flash over. And meanwhile, make ignition coil of every cylinder output high-voltage
electricity to spark plug under the orderly control.
Ignition coil is installed on the engine hood in the form of single cylinder igniting
independently. After receiving the ignition signal of ECU, ignite the high-temperature
and high-pressure gas mixture through the high-voltage spark generated by spark
plug in each cylinder according to the correct timing sequence of ignition, to ensure
the normal operation of engine.
(a). Fault phenomenon: the engine shakes or fails to start, etc..
It is burned as a result of overcurrent, or damaged by outside force, etc..
n the process of maintenance, the ignition function is not allowed to be tested by
means of "short circuit test", to avoid damaging the components of electrical
equipment.
11-38 ENGINE CONTROL SYSTEM - IGNITION COIL
OVERHAUL
1. Check ignition coil

3 2 1
(b). Disconnect the connector of ignition coil.
(c). Check whether the harness of ignition coil
is damaged and has cracks on its surface.
(d). Check the resistance between No.1 and
No.2 pins of ignition coil with digital
multimeter.
Ω Standard resistance value: 0.5~0.6Ω
NOTICE:
• If the resistance is not conformity with
fuwx11015 regulations, it means that the ignition coil is
damaged and should be replaced.
• If the resistance is in conformity with regulations
but there are still faults for the ignition system,
the further diagnosis should be implemented for
ignition coil.
ENGINE CONTROL SYSTEM - FUEL INJECTOR 11-39
FUEL INJECTOR
Nozzle structure is a ball valve device of magnetic switch. The two poles of the coil
goes through engine harness and connects with the power supply and ECM. After
coil’s grounding continuity controlled by ECM, the magnetic force generated by
the coil overcomes spring force, fuel pressure and manifold vacuum suction and
sucks the valve core, so the fuel can go through the valve hole, shot up through the
guiding hole to intake valve; after cutting the power supply, there is not magnetic 11
force and under the spring force and fuel pressure, the nozzle is closed.
Fuel injector, installed at the end of intake manifold, is controlled by ECM and
exactly outputs fuel volume required by system in different operating conditions.
(a). Fault phenomenon: Poor idling, poor acceleration, failure in starting (being difficult
to start), etc..
If there is colloid accumulation inside fuel injector because of the lack of
maintenance, the fuel injector will fail.
11-40 ENGINE CONTROL SYSTEM - FUEL INJECTOR
OVERHAUL
1. CHECK fuel injector

(a). In the "OFF" condition of ignition switch,
press the circlip of fuel injector connector
1 2 to cut off the fuel injector connector.
(b). Check the resistance between the No.1
and No.2 pins of fuel injector with the digital
multimeter.
Standard resistance value:
11Ω~17Ω(20℃ )
Ω
NOTICE:
regulations, the fuel injector should be replaced.
fuwx11016
ENGINE MECHANICAL SYSTEM
ENGINE ASSEMBLY ..........................12A-1
REPLACEMENT .............................12A-1
ENGINE ACCESSORY BELT ...........12A-17
OVERHAUL ..................................12A-17
12A
ENGINE MECHANICAL SYSTEM - ENGINE ASSEMBLY 12A-1
ENGINE ASSEMBLY
REPLACEMENT
NOTICE:
• Before disassembling the engine assembly, drain up all the fluids in the engine and
disconnect the harness, pipe fittings and connections between the engine and the body.
• Before disconnecting all harness and pipes, mark them properly to prevent mismatching
or missing harness and pipes during installation.
• Once a fitting is disconnected, seal the opening to avoid foreign objects from entering.
• All drained fluids must be collected and handled as required. Keep the site clean and
neat.
12A
1. Discharge the pressure in the fuel system (Refer to"Chapter 13 Fuel - Fuel System,
Notices")
2. Disconnect the positive and negative battery cables (Refer to"Chapter 18 Starting &
Charging - Battery, Replacement")
3. Drain the engine oil (Refer to"Chapter 04 Vehicle Maintenance - Replacement,
Engine Oil Replacement And Oil Filter (Isf2.8)")
4. Drain the coolant (Refer to"Chapter 04 Vehicle Maintenance-Coolant, Replacement")
5. Collect the refrigerant (Refer to"Chapter 41 Heating & A/C - Refrigerant,
Replacement")
6. Drain up the hydraulic oil in the power steering tank
7. Disconnect the harness connector and the

grounding harness
(a). Disconnect the ECM connector and the
connection between the harness and the
body.
fuwx12A001
12A-2 ENGINE MECHANICAL SYSTEM - ENGINE ASSEMBLY
(b). Unscrew the retaining nuts and

disconnect the generator connector and
the harness.
fuwx12A002
(c). Unscrew the nuts and disconnect the

starter connector and the harness.
fuwx12A003
(d). Disconnect the A/C compressor connector.
fuwx12A004
(e). Disconnect the high-pressure fuel pump

connector.
fuwx12A005
(f). Press the latch and open the fuse box cover.
12A
fuwx12A006
(g). Pull out the connector.
fuwx12A007
(h). Unscrew the retaining nuts and disconnect

the harness and the body.
fuwx12A008
(i). Disconnect the connector.
fuwx12A009
(j). Unscrew the retaining nuts of the engine

grounding wire and disconnect the harness
and the body.
fuwx12A010
(k). Unscrew the retaining bolts of the grounding

harness and disconnect the harness and
the body.
fuwx12A011
(l). Unscrew the retaining bolts of the grounding

harness.
(m). Disconnect the harness and the body.
12A
fuwx12A012
(n). Unscrew the retaining bolts of the engine

grounding.
fuwx12A014
8. Disconnect the pipe fitting

(a). Press the latch and disconnect the pipe
fitting of the high-pressure oil pump.
fuwx12A015
(b). Unscrew the retaining bolt of the A/C pipe

and remove the pipe.
fuwx12A016
(c). Unscrew the retaining bolts and the clip

screws of the steering fluid pump pipe, and
remove the pipe.
fuwx12A017
(d). Remove the clip and disconnect the

vacuum booster hose.
fuwx12A018
(e). Loose the clip and disconnect the heating

water pipe.
(f). Remove the air filter outlet hose.(Refer
to"Chapter 14 Intake Air - Intake Air Pipe,
Replacement")
(g). Remove the aftercooler rubber intake pipe.
(Refer to"Chapter 14 Intake Air - Intake Air
Pipe, Replacement")
(h). Remove the engine intake rubber pipe.
(Refer to"Chapter 14 Intake Air - Intake Air
Pipe, Replacement")
12A
(i). Remove the oxidation catalyst assembly.
fuwx12A019 (Refer to"Chapter 15 Exhaust Air - Exhaust
Pipe, Replacement")
9. Remove the electronic fan assembly (Refer to "Chapter 16 Cooling - Electronic Fan,
Replacement")
10. Remove the radiator assembly (Refer to "Chapter 16 Cooling - Radiator,
Replacement")
11. Remove the transmission assembly (Refer to "Chapter 21 Transmission -
Transmission Assembly, Replacement")
12. Fix the engine assembly with toolkit
13. Unscrew the retaining bolts and nuts of the

powertrain suspension system
fuwx12A020
14. Slowly lift the engine assembly, while carefully examining whether all the harness
and pipe connections between the engine and the body are all disconnected.
Remove the parts on the way of the engine
15. Steadily place the engine assembly in a clean location
16. Plug the disconnected openings to prevent foreign objects from entering
17. Unscrew the retaining bolts and remove

the right suspension assembly
fuwx12A021
18. Unscrew the retaining bolts and remove

the left suspension assembly
fuwx12A022
19. Remove the starter assembly (Refer to "Chapter 18 Starting & Charging - Starter,
Overhaul")
20. Remove the engine accessory belt
21. Remove the generator assembly (Refer to "Chapter 18 Starting & Charging -
Generator, Overhaul")
22. Remove the steering oil pump assembly (Refere to "Chapter 38 Power Steering -
Steering Oil Pump And Reservoir Assembly, Replacement")
23. Remove the A/C compressor assembly (Refer to "Chapter 41 Heating & A/C - A/C
Compressor, Overhaul")
24. Replacement a new engine assembly
25. Install the right suspension assembly and

tighten the retaining bolts
Torque : 73~89N•m
fuwx12A021
26. Install the left suspension assembly and

tighten the retaining bolts
Torque : 95~100N•m
fuwx12A022
12A
27. Install the A/C compressor assembly (Refer to "Chapter 41 Heating & A/C - A/C
Compressor, Overhaul")
28. Install the steering oil pump assembly (Refere to "Chapter 38 Power Steering -
Steering Oil Pump And Reservoir Assembly, Replacement")
29. Install the generator assembly (Refer to "Chapter 18 Starting & Charging -
Generator, Overhaul")
30. Install the engine accessory belt
31. Install the starter assembly (Refer to "Chapter 18 Starting & Charging - Starter,
Overhaul")
32. Lift the engine assembly, slowly guide it into the engine compartment and remove
the parts in its way
33. Align the powertrain suspension system

and tighten the retaining bolts and nuts
Torque : 73~89N•m
fuwx12A020
34. Install the transmission assembly (Refer to "Chapter 21 Transmission - Transmission

Assembly, Replacement")
35. Install the radiator assembly (Refer to "Chapter 16 Cooling - Radiator,
Replacement")
36. Install the electronic fan assembly (Refer to "Chapter 16 Cooling - Electronic Fan,
Replacement")
37. Connect the pipe fitting

(a). Insert the pipe fitting of the high-pressure
oil pump, until you hear the click.
fuwx12A015
(b). Install the A/C pipe and tighten the

retaining bolts.
Torque : 21~25N•m
fuwx12A016
(c). Install the steering oil pump pipe and

tighten the retaining bolts and clip screws.
Torque : 40~45N•m
fuwx12A017
(d). Install the vacuum booster hose and

tighten the clip.
12A
fuwx12A018
(e). Install the heating water pipe and tighten

the clip.
fuwx12A019
(f). Install the air filter outlet hose (Refer to"Chapter 14 Intake Air - Intake Air Pipe,
Replacement")
(g). Install the aftercooler intake rubber pipe (Refer to"Chapter 14 Intake Air - Intake Air
Pipe, Replacement")
(h). Install the engine intake rubber pipe (Refer to"Chapter 14 Intake Air - Intake Air
Pipe, Replacement")
(i). Install the oxidation catalyst assembly (Refer to "Chapter 15 Exhaust Air - Exhaust
Pipe, Replacement")
38. Install the harness connector and the

grounding harness
(a). Put the ECM connector back and the
connection between the harness and the
body.
fuwx12A001
(b). Install the generator connector and harness

until you hear the click. Tighten the
retaining nuts.
Torque : 21~25N•m
fuwx12A002
(c). Install the starter connector and harness,

and tighten the retaining nuts.
Torque : 18~20N•m
fuwx12A003
(d). Insert the A/C compressor connector back,

until you hear the click.
12A
fuwx12A004
(e). Insert the high-pressure oil pump

connector back , until you hear the click.
fuwx12A005
(f). Insert the connector back , until you hear

the click.
fuwx12A007
(g). Install the harness and tighten the retaining

nuts.
fuwx12A008
(h). Insert the connector back , until you hear

the click.
fuwx12A009
(i). Install the fuse box cover and set the latch.
fuwx12A006
(j). Install the engine grounding harness and

tighten the retaining nuts.
12A
fuwx12A010
(k). Install the grounding harness and tighten

the retaining nuts.
fuwx12A012
(l). Install the grounding harness and tighten

the retaining nuts.
(m). Connect the harness and the body.
fuwx12A011
(n). Install the engine grounding harness and

tighten the retaining bolts.
fuwx12A014
39. Fill up the steering oil (Refer to"Chapter 38 Power Steering - Steering Oil,
Replacement")
40. Fill up the refrigerant (Refer to "Chapter 41 Heating & A/C - Refrigerant,
Replacement")
41. Fill up the coolant (Refer to "Chapter 04 Vehicle Maintenance - Replacement,
Coolant Replacement")
42. Fill up the engine oil (Refer to "Chapter 04 Vehicle Maintenance - Replacement,
Engine Oil Replacement And Oil Filter (ISF2.8)")
43. Drain out the air in the fuel system (Refer to "Chapter 04 Vehicle Maintenance -
Replacement, Fuel Filter Element Replacement (ISF2.8)")
44. Connect the positive and negative battery cables (Refer to "Chapter 18A Starting &
ENGINE MECHANICAL SYSTEM - ENGINE ACCESSORY BELT 12A-17
ENGINE ACCESSORY BELT

OVERHAUL
1. Switch off the ignition

2. Open the engine hood
3. Wait until the engine cools down
4. Drain the coolant (Refer to "Chapter 16 Cooling - Coolant, Replacement")
5. Unscrew the clip screw and pull out the

engine water outlet hose
12A
fuwx12A023
6. With the toolkit, turn the accessory belt

tensioner bolt clockwise, until the
accessory belt is completely loose
fuwx12A024
7. Remove and examine the accessory belt, replace it in case of any of the following
damages
NOTICE:
• Water or grease on the belt will quickly reduce its service life. Therefore, after removal,
protect the belt, the belt pulley and the tensioner from water or grease. Do not wash these
parts. In case of heavy contamination, replace it with a new one.
• If any water or grease is found on these parts, check whether there is fluid leakage in the
engine.
12A-18 ENGINE MECHANICAL SYSTEM - ENGINE ACCESSORY BELT
(a). Aged and shiny rubber on the back,

showing no nail scratch.
fuwx12A025
(b). Cracked or peeled canvas.

(c). Cracked rubber on the back.
(d). Cracked belt tooth at the bottom.
(e). Cracked belt tooth on the side.
fuwx12A026
(f). Unusual tear and wear on the side of the

belt. If the side of the tooth belt is as neat
as cut, it is normal.
fuwx12A027
(g). Unusal tear wear of the belt.

(h). Missing tooth.
fuwx12A028
ENGINE MECHANICAL SYSTEM - ENGINE ACCESSORY BELT 12A-19
8. Put the accessory belt around all the belt

pulley, tensioner and idler, except for the
generator belt pulley. With the toolkit, turn
the tensioner bolts clockwise, so that the
accessory belt wraps around the generator
belt pulley. Loose the tensioner
NOTICE:
After the installation of the accessory belt, check
whether it is properly installed around each
pulleys. If any malposition between the belt and
the pulley, turn the tensioner nuts with the toolkit
12A
and slightely loosen the accessory belt, before
fuwx12A024 further adjustment.
9. Install the engine water outlet hose and

tighten the clip screw
fuwx12A023
10. Fill up the coolant (Refer to "Chapter 16 Cooling - Coolant, Replacement")

11. Restore the engine hood
- MEMO -
ENGINE MECHANICAL
ENGINE MECHANICAL .....................12B-1 CRANKSHAFT OIL SEAL ..............12B-143
NOTICES ........................................12B-1 REPLACEMENT .........................12B-143
TABLE OF MALFUNCTION
SYMPTOMS ...................................12B-2
ENGINE ASSEMBLY ..........................12B-7
DISASSEMBLE ENGINE
ASSEMBLY .....................................12B-7
CLEAN THE ENGINE PARTS ......12B-40
ASSEMBLING ENGINE 12B
ASSEMBLY ...................................12B-41
DRIVING BELT .................................12B-83
PARTS DRAWING ........................12B-83
INSPECTION ................................12B-84
ADJUSTMENT ..............................12B-85
REPLACEMENT ...........................12B-86
TURBOCHARGER ...........................12B-88
INSPECTION ................................12B-88
INTAKE AND EXHAUST
MANIFOLD .......................................12B-90
INSPECTION ................................12B-90
TIMING SPROCKET MECHANISM ............
..........................................................12B-91
PARTS DRAWING ........................12B-91
INSPECTION ................................12B-93
CAMSHAFT ......................................12B-97
PARTS DRAWING ........................12B-97
INSPECTION ................................12B-98
REPLACEMENT .........................12B-100
CYLINDER HEAD .......................... 12B-111
PARTS DRAWING ...................... 12B-111
INSPECTION .............................. 12B-112
VALVE ............................................12B-114
PARTS DRAWING ...................... 12B-114
INSPECTION .............................. 12B-115
ADJUSTMENT ............................12B-120
REPLACEMENT .........................12B-123
PISTON AND CONNECTING ROD.............
........................................................12B-127
PARTS DRAWING ......................12B-127
INSPECTION ..............................12B-128
REPLACEMENT .........................12B-133
CRANKSHAFT AND FLYWHEEL ...12B-136
PARTS DRAWING ......................12B-136
INSPECTION ..............................12B-137
CYLINDER BLOCK ........................12B-141
PARTS DRAWING ......................12B-141
INSPECTION ..............................12B-142
ENGINE MECHANICAL - ENGINE MECHANICAL 12B-1
ENGINE MECHANICAL
NOTICES
1. When draining the engine coolant, it needs wait for the engine cooling down and
then carries out the operation.
2. When carrying out the operation of disconnecting fuel line, the operation
environment shall be away from fire source and other places affecting the safety as
far as possible.
3. After the oil line is removed down, it needs to implement the seal processing
operation for each oil line joint, so as to avoid the oil-line plugging or fuel leakage.
12B
4. When disassembling the engine, it requires special care that the matching surface
and sliding surface shall not be damaged.
5. When carrying out the operation of disassembling the engine, use a tape or
equivalent effective substance as far as possible to seal the opening of the engine,
so as to prevent the foreign matters from entering.
6. In the process of disassembly, it needs to mark and arrange disassembly parts in an
organized way for easy troubleshooting and reassembly.
7. Before repairing or replacing, thoroughly inspect parts.
8. When assembling the engine, the basic principle of tightening nuts and bolts is to
tighten with the same torque in several different steps starting with the nuts and
bolts in the center, then ones on inside and outside diagonally in this order. If the
order of tightening is specified, do exactly as specified.
9. When assembling the engine, please replace with the new gasket, oil seal and
sealing ring.
10. When applying the sealant, it needs to apply evenly, and install the matching
components within a certain time after the sealant is applied in place.
11. When assembling the engine, carefully check if any oil line and vacuum pipe of the
engine is clogged.
12. When connecting each sensor connector, after hearing a clear "click", it means the
connector has been installed in place.
13. After repairing and assembing the engine, start the engine and increase engine
speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.
NOTICE:
If there are specific instructions in this manual, observe them.
12B-2 ENGINE MECHANICAL - ENGINE MECHANICAL
TABLE OF MALFUNCTION SYMPTOMS

Using the following table will help to find the causes of fault, check each component in
order, repair or replace, as needs.
Malfunction
Possible cause Reference
symptom
1.Battery voltage<8V Charge or replace the battery
Clear and fasten the battery wiring, and

2.The battery wiring is rusted or
spread a thin layer of Vaseline oil on the
loosened
terminal post
Check and maintain the starter, and change

3.The starter fails
it if necessary
4.There is no fuel for the oil supply

Refueling
system
Clean the oil supply system and replace the

5.Oil supply system is polluted
fuel filter
6.The reversed connection of the oil

Connect the oil pipes in the correct way
inlet/outlet pipe
Repair the whole car wiring harness, and

7.The fuel pump circuit is opened
connect oil pump plug again
Engine can not
start light fuel flooded engine: Fully open throttle
and startup starter
8.Fuel submerged cylinder Serious fuel flooded engine: Remove spark
plug and startup starter, recovery after the
residual oil of cylinder and spark plug dried
9.Oil nozzle is blocked Replace the fuel injector
10.The connector of the ignition coil is Connect the connector of the ignition coil
connected unstably of incorrectly. correctly
11.The clearance of the park plug is

Readjust the clearance of all the park plugs
incorrect
12.Spark plug is damaged Change spark plug
13.Ignition coil is damaged Change ignition coil
14.The timing of the engine is incorrect Adjust the timing
15.Engine oil viscosity is too high Change engine oil

Malfunction
symptom
The continuous pressure of the oil supply
1.Pressure of sucker<350kPa
system
2.Oil mass in fuel tank is inadequate Refueling
3.Fuel oil filter blockage Replace fuel filter
4.Leakage of oil for the oil inlet pipe of

Change the oil inlet pipe of the engine.
The engine the engine
starts but the 5.The control valve of the oil pressure
Change the fuel pump
vehicle fails to on the fuel pump is damaged 12B
operate
6.The pressure of the fuel pump is
insufficient
Clean the intake duct and replace the air filter

7.Air filter clogging warning
element
8.Ternary catalytic converter is blocked

Change ternary catalytic converter
or damaged
1.The lead wire of the spark plug is not

Reconnect the connector
in good connection
2.The clearance of the park plug is

Engine is idling Readjust the clearance of all the park plugs
incorrect
or unstable
3.The control valve of the oil pressure
on the fuel pump is damaged
4.Several fuel injectors are blocked. Clean or replace the fuel injector
1.Oil mass in fuel tank is inadequate Refueling

The engine 2.Leakage of oil for the oil inlet pipe of
flameouts Change sucker
the engine
suddenly in
3.There is air in the oil supply system Evacuate the oil supply system
the process
of normal 4.The fuel filter or the oil line are
Replace the fuel filter or clean the oil line
operation blocked
5.The fuel is mixed with water Change the fuel

Malfunction
symptom
1.The intake system is not expedite for
Clean inlet channel, air filter element
gas intake
Clean the detecting hole of the temperature

2.The hole of the temperature sensor
sensor for the intake pressure and replace
for the intake pressure is blocked
the sensor is necessary
3.Air control shutter can not be fully Adjust throttle limit screws, ensure the throttle
opened is fully opened
4.The fuel injector is blocked Clean or replace the fuel injector
The engine 5.The spark plug is polluted or is Clean the spark plug and adjust the
accelerates incorrect in its clearance clearance
poorly or dully Clean the oil supply system and replace the
6.Oil supply system is polluted
fuel filter
7.The fuel pump fails Change the fuel pump
8.The cylinder head gasket is not

Replace the cylinder head gasket
sealed fully
9.The valve is burned, distorted or has

Replace the valve
the pezograph
Overhaul exhaust system and ternary

10.Air intake system is blocked
catalytic converter
1.Air intake system is blocked Clean inlet channel, air filter element
2.Air control shutter can not be fully Adjust throttle limit screws, ensure the throttle
opened is fully opened
Overhaul exhaust system and ternary

3.Exhaust system is blocked
Underpowered catalytic converter
of engine 4.Resistance force of the parts on the
Overhaul related parts and components of
motive power transmission system
motive power transmission system
is too large
5.Engine is over heating Overhaul engine cooling system
6.The fuel injector is blocked Clean or replace the fuel injector
1.The electric leakage of the high- Reconnect all the connectors and change the
The vehicle idles
voltage lines damaged parts
while driving
2.The fuel injector is blocked. Clean or replace the fuel injector
Chattering when 1.The electric leakage of the high- Reconnect all the connectors and change the
speed up voltage lines damaged parts
1.Fuel is not meet the standard Change the fuel

Knocking
2.Engine is over heating Overhaul engine cooling system
Malfunction
symptom
Renew the ignition of the cylinder of failure
Postignition(the timely. If it cannot be renewed temporarily,
1.The failure of the cylinder in the
temperature of disconnect the connector of the fuel injector
process of the ignition of engine
the exhaust is on this cylinder to protect the ternary catalytic
extremely high) converter
2.Breakdown of engine exhaust valve Repair the engine
1.The state of engine is abnormal Check and maintain the engine
2.Electronic control fuel injection is Check and maintain the electronic injection 12B
abnormal system
3.The exhaust manifold or the joint of

Fasten related bolts, change spacer if
the ternary catalytic converter leak
necessary
gas
4.Air leakage of the screw thread of

the oxygen sensor for the exhaust Fasten oxygen sensor
system
5.The control valve of the oil supply

system is damaged
Test excess
Replace the ternary catalytic converter and
emission by 6.Use exceeding term for ternary
oxygen sensor (use them under the standard
method of catalytic converter and oxygen
conditions with the life span less than
operating mode sensor
80000km)
7.Damaged caused by heavy metal

poisoning or overheating of ternary Change catalytic converter and oxygen
catalytic converter and oxygen sensor
sensor
8.Sulfur poisoning of ternary catalytic Run 10 minutes at 3- gear shift and 70 km/h
converter and oxygen sensor speed
9.Grounding of ECM or electronic

control fuel injection system is not in Improve the position of system ground wire
good condition
10.Earth of casing of ECM Make the ECM case shell insulated
Check whether
the exhaust
exceeds the
standard with 1.The engine is not warmed-up fully Warm-up engine
the operating
condition
method
Malfunction
symptom
The density of
CO and HC is
1.The engine is not warmed-up fully Warm-up engine, test high idle speed firstly
high when it is
in idle speed
1.Incorrect quantitative method Use reliable quantitative method
2.The vehicle state Overhaul the vehicle
3.Engine status Check and maintain the engine
4.Thermostat damaged Change coolant temperature sensor
5.The temperature sensor of the

Abnormal of fuel Replace coolant temperature sensor
coolant is damaged
consumption
6.The fuel injector leaks oil Replace the fuel injector
7.The control valve of the oil pressure

is damaged
8.The oxygen sensor is damaged Change oxygen sensor
9.ECM is damaged Replace ECM
Trouble light
irregularly on/ 1.The connector of the ignition system Check all the connection terminals of the
off during the is not in good connection ignition system and reconnect the connectors
running time
ENGINE MECHANICAL - ENGINE ASSEMBLY 12B-7
ENGINE ASSEMBLY
DISASSEMBLE ENGINE ASSEMBLY
1. Disassembly preparation
(a). Correctly fix the engine, remove the
draining plug at the left side of cylinder
body, and drain the rest coolant.
NOTICE:
Using a container to recycle coolant, so as to
prevent pollution.
12B
(b). Remove oil filling hole cover.

(c). Remove the oil draining bolt at the bottom
of the oil sump.
NOTICE:
Using a container to recycle engine oil, so as to
prevent pollution.
2. Remove the drive belt

(a). Loosen generator tensioning block fixed
bolt ① .
(b). Loosen generator fixed nut ② .
(c). Loosen the drive belt adjusting bolt ③ .
12B-8 ENGINE MECHANICAL - ENGINE ASSEMBLY
(d). Gently push the generator, take off the

drive belt of the generator.
NOTICE:
If there is water or grease on the belt, the service
life of the belt would be sharply decreased, so
after the removal, pay close attention to not
allowing the water or grease adhering to and
contaminate the belt.
3. Remove generator
(a). Remove generator tensioning block fixed
bolt ① .
(b). Remove generator fixed nut ② , take
out the fixed bolt, take off the generator
assembly.
NOTICE:
When removing the generator assembly, firstly
hold the generator by hand, then carefully take
out the bolt, don't knock against the generator.
(c). Remove generator support fixed bolt, take

out the generator support.
(d). Remove generator bearing fixed bolt, take

out the generator bearing.
12B
4. Remove water pump pulley

(a). Remove the fixed bolt of the water pump
pulley, and remove the water pump pulley.
NOTICE:
When removing the water pump, wrap waste
drive belt on the water pump pulley, and clench by
hand for removing.
5. Remove water pump

(a). Remove the fixed bolt of the water pump,
and remove the water pump.
6. Remove crankshaft pulley

(a). Install the flywheel stop dog, fixed the
flywheel.
(b). Remove the fixed bolt of the crankshaft belt

pulley, and remove the crankshaft belt
pulley.
7. Install the turbocharger inlet and return

pipe assembly
(a). Remove fixed bolts on the pipe clamp of
the inlet pipe of the turbocharger.
(b). Gently pry the pipe clamp, take out the
pipe clamp.
(c). Loosen the oil pipe nut, disconnect the

connection between oil inlet pipe and
supercharger.
12B
(d). Remove the fixed bolt of oil inlet pipe on

the camshaft cover.
(e). Remove the fixed bolts of oil inlet pipe on

the intake manifold.
(f). Take off front oxygen sensor connector.
(g). Disconnect the connection between oil inlet

pipe and engine cylinder body.
(h). Loosen the fixed clamp in the connection

between oil return pipe and oil sump.
(i). Gently turn the hose, disconnect the
connection between supercharger return
pipe and oil sump.
(j). Remove the fixed bolt of turbocharger oil

return pipe, take down turbocharger oil
return pipe.
12B
8. Remove the oil cooler inlet and return pipe

assembly
(a). Remove fixed bolt ① of the inlet/return pipe
of the oil cooler.
NOTICE:
In order to remove conveniently, it needs to firstly
remove the fixed bolt ② on the thermal baffle of
the supercharger here.
(b). Loosen the clamp of oil cooler inlet and

return pipe assembly at the left side,
unplug the hose.
NOTICE:
The removed pipeline connection shall be done
with good sealing processing, preventing the
foreign matter from entering into.
(c). Remove fixed bolt of the inlet/return pipe of

the oil cooler at the left and right side of the
engine.
(d). Loosen the clamp of oil cooler inlet and

return pipe assembly at the left side of the
engine,unplug the hose, take out oil cooler
inlet and return pipe assembly.
NOTICE:
The removed pipeline connection shall be done
with good sealing processing, preventing the
foreign matter from entering into.
9. Remove the exhaust system

(a). Remove the fixed bolt ① on the bracket
of the exhaust manifold, take off exhaust
manifold bracket.
(b). Remove fixed bolt ② on the support of
tail pipe of the supercharger, take off
supercharger tail pipe support.
(c). Remove fixed bolt on the thermal baffle of

tail pipe bracket of the supercharger, take
off supercharger tail pipe thermal baffle.
12B
(d). Remove front oxygen sensor.

NOTICE:
Remove front oxygen sensor and properly kept.
(e). Remove the fixed nut ① of supercharger

tail pipe.
(f). Remove fixed bolt ② on the thermal baffle
of the supercharger, take off supercharger
tail pipe.
NOTICE:
Carefully remove the supercharger tail pipe and
the gasket in its interface.
(g). Remove the fixed bolt of turbocharger

thermal baffle, take down turbocharger
thermal baffle.
(h). Remove hole bolt ① on the inlet pipe of the

turbocharger.
(i). Remove hole bolt ② on the return pipe of
the turbocharger.
NOTICE:
After the completion of removing, each pipeline
interface shall be done with good sealing
processing, preventing the foreign matters from
entering into.
(j). Remove fixed nut of exhaust manifold, take

off exhaust manifold and turbocharger
assembly.
NOTICE:
Carefully take off exhaust manifold and interface
gasket, properly kept.
(k). Remove fixed nut of turbocharger assembly.

(l). Take off turbocharger assembly and
gasket.
12B
10. Remove oil level gauge conduit tube

assembly
(a). Remove fixed bolts on the conduit of the
bayonet gauge.
(b). Gently shake the engine oil level gauge

tube, pull out engine oil level gauge tube.
(c). Take out oil level gauge.
11. Remove the intake manifold assembly

(a). Remove fixed bolt of the electronic throttle
valve.
(b). Take off electronic throttle valve and
gasket.
(c). Loosen fixed clamp at both ends of PCV

valve hose.
(d). Disconnect the connection at both ends of
PCV valve hose, take off PCV valve hose.
(e). Remove fixed bolt of the intake manifold

bracket, take off bracket.
(f). Remove the fixed nut of intake manifold,

take off intake manifold assembly and
gasket.
NOTICE:
Carefully take off intake manifold assembly and
interface gasket, properly kept.
12B
12. Remove the warm wind pipe installation

components
(a). Remove the fixed bolt of pipe components
connected at the right side of camshaft
cover.
(b). Remove the fixed bolt of pipe components

connected at the right side of engine
cylinder body.
(c). Remove the fixed bolt of pipe components

connected at the rear end of cylinder body.
(d). Loosen the clamp of warm wind inlet pipe.

(e). Disconnect warm wind inlet pipe, take off
warm wind inlet pipe at the left side of the
engine.
(f). Loosen the clamp of warm wind water
return pipe.
(g). Disconnect warm wind water return pipe.
(h). Remove fixed nut on the flange plate of the

flange plate.
(i). Take off warm wind pipe at the left side of
the engine.
(j). Loosen clamp of wet return pipe U type

hose.
(k). Unplug U type hose, take off warm wind
pipe at the right side of the engine.
12B
13. Remove oil filter assembly

(a). Use oil filter wrench to remove oil filter.
NOTICE:
Oil filter is the disposable use, shall not be
reused after removal.
(b). Remove hole bolt of the oil cooler, take off

oil cooler.
(c). Remove the oil pressure sensor.

NOTICE:
When removing oil pressure sensor, sealing
processing for the installed hole shall be done
well, keep the oil pressure sensor properly.
(d). Remove fixed bolt of oil filter base, take off
filter base and gasket.
14. Remove the fuel rail injector assembly

(a). Remove the fixed bolts on the oil injector
assembly of the fuel rail.
(b). Gently shake the oil rail injector, pull out oil
injector assembly.
NOTICE:
• When removing the fuel rail injector assembly,
the sealing processing for installed hole shall be
done well, keep the fuel rail injector assembly
properly.
• When removing, don't strike with the tools such
as a hammer, etc., after removing, check if the
seal ring falls off
15. Remove knock sensor

(a). Remove the fixed bolt of knock sensor,
take off knock sensor.
NOTICE:
When removing knock sensor, sealing processing
for the installed hole shall be done well, keep the
knock sensor properly.
16. Remove the engine outlet pipe connector

components
(a). Remove water temperature sensor.
NOTICE:
When removing water temperature sensor,
sealing processing for the installed hole shall be
done well, keep the water temperature sensor
properly.
(b). Remove fixed bolts of the outlet pipe, take
off the outlet pipe.
NOTICE: 12B
When taking off the outlet pipe, pay attention to
taking off the outlet pipe joint gasket.
17. Remove the engine inlet pipe connector

components
(a). Remove the fixed nut of engine inlet pipe
joint, carefully take off gasket and the inlet
pipe joint.
(b). Take down thermostat.

(c). Remove the fixed nut on the dead plate of

thermostat, take down thermostat dead
plate and thermostat mat.
NOTICE:
Sealing processing shall be done well for each
joint, preventing the foreign matters from entering
into.
18. Remove ignition coil

(a). Remove fixed bolt of ignition coil, and then
carefully take out ignition coil and keep it
properly.
19. Remove the camshaft hood

(a). Remove camshaft position sensor.
NOTICE:
The removed camshaft position sensor shall be
kept properly.
(b). As shown in the figure, remove the fixed

bolts of the camshaft hood, gently pry
camshaft hood, and then remove the
camshaft hood.
(c). Take off camshaft hood sealing gasket.
NOTICE:
To avoid the deformation of camshaft hood due to
the uneven stress, destroying the leakproofness,
when removing camshaft hood, firstly all screw
bolt assembly shall be unscrewed, then loosen
and take off them one by one.
12B
20. Remove the timing sprocket mechanism

(a). Remove fixed bolts on the front shroud of
the cylinder head.
(b). Use a stick to gently knock the front shroud
of the cylinder head, take down the front
shroud of the cylinder head.
NOTICE:
When removing, the contact surface of front
shroud of the cylinder head shall not be
scratched.
(c). Remove fixed bolts of the sprocket

chamber cover.
(d). Use a slot type screwdriver to evenly pry
the ① , ② and ③ position as shown in the
figure, pry and take off sprocket chamber
cover.
NOTICE:
When removing, the contact surface of front
shroud shall not be scratched.
(e). Use a tool to remove crankshaft front oil

seal.
NOTICE:
• The removed crankshaft front oil seal shall not
be used repeatedly.
• When removing the front oil seal, do not scratch
the sprocket chamber cover.
(f). Remove the fixed bolts of No.2 fixed rail

component, and then take down No.2 fixed
rail component.
(g). Remove the fixed bolts of No.1 fixed rail

component, and then take down No.1 fixed
rail component.
(h). Remove No.2 tensioner component, then

take down No.2 tensioner component.
12B
(i). Remove fixed pin of slide rail, then take off

the rail.
(j). Stick the upper hexagon section of the

exhaust camshaft with a wrench to remove
the fixed bolts from the sprocket of the
exhaust camshaft.
(k). Use a stick to evenly knock exhaust

camshaft sprocket, at the same time take
off timing chain 2 and exhaust camshaft
sprocket.
(l). Compress tensioner component 1, use a

clean small-gauge wire to go through
locking hole of tensioner component 1 ,
keep it in the state of compression.
(m). Remove No.1 tensioner component, then

take down No. 1 tensioner component.
(n). Remove the fixed bolt of intermediate shaft

sprocket wheel 2, take off intermediate
shaft sprocket wheel 2.
12B
(o). Gently shake the sprocket wheel, take

down timing chain 1, intermediate shaft
sprocket wheel 1 and crankshaft timing
sprocket wheel.
NOTICE:
Overall take out the crankshaft timing sprocket
wheel, timing chain 1 and intermediate shaft
sprocket wheel 1.
(p). Stick the upper hexagon section of the

intake camshaft with a wrench to remove
the fixed bolts from the phase regulator.
(q). Use a stick to evenly knock the phase
regulator, then take phase regulator off.
21. Remove the spark plug

(a). Use spark plug dismounting sleeve to
loosen the spark plug.
(b). Set the removed ignition coil in the head of

spark plug, then rotate and take out spark
plug.
NOTICE:
• Never knock against spark plug, especially for
the electrode.
• After taking spark plug out, it is suggested to
conduct the sealing processing for the mounting
hole of spark plug,preventing the foreign matters
from entering into the air cylinder.
• The spark plug disassembling method for each
cylinder is the same with each other.
22. Remove the intake/exhaust camshaft and

cylinder head
(a). Remove the fixing bolt on the OCV valve
and take out the OCV valve.
(b). Use a wrench to rotate inlet and exhaust
camshaft, making all camshaft convex
point not face down.
• When removing the camshaft, adjust
the position of camshaft convex point,
making the camshaft bear averaged
force.
(c). Remove the fixed bolts from the front gland

of the intake camshaft, then take off the
front gland of the camshaft.
12B
(d). As shown in the figure, remove the fixed

bolts on the gland of intake camshaft in
order, then take off the gland of intake
camshaft.
(e). Take down the intake camshaft assembly.
NOTICE:
Place the intake camshaft bearing caps taken off
in order.
(f). Remove the fixed bolts from the front gland

of the exhaust camshaft, then take off the
(g). As shown in the figure, remove the fixed

bolts on the gland of exhaust camshaft in
order, then take off the gland of exhaust
camshaft.
(h). Remove the exhaust camshaft assembly.
NOTICE:
Place the exhaust camshaft bearing caps taken
off in order.
(i). Remove the fixed bolts of the cylinder

head.
NOTICE:
When removing cylinder head bolt, according
to the order as shown in the figure, loosen and
remove the fixed bolt of cylinder head in proper
order.
(j). Take down the cylinder head assembly.
(k). Remove the cylinder head gasket.
NOTICE:
The cylinder head gasket is disposable part,
which shall not be used again after removal.
23. Remove sprocket chamber

(a). Remove fixed bolts on the transmission
shaft of the oil pump, then take out oil
pump transmission shaft.
(b). Remove fixed bolts on the thrust washer of

the intermediate shaft, then take out thrust
washer.
12B
(c). Carefully take out intermediate shaft.

NOTICE:
When removing the intermediate shaft, the engine
shall be fixed horizontally, avoiding unnecessary
trouble brought by the sliding of intermediate shaft
for the removal.
(d). Remove fixed bolts of sprocket chamber,

evenly pry sprocket chamber.
(e). Take out sprocket chamber and sprocket
chamber mat.
24. Remove the oil pan

(a). Rotate the engine, cornerwise remove
fixed bolts of oil pan in the proper order.
(b). Use a oil pan dismounting tool to remove

the oil pan.
NOTICE:
When using a special tool to remove the oil pan, it
shall gently pry, preventing the deformation of oil
pan.
25. Remove oil pump and oil strainer

(a). Remove fixed bolt ① of oil strainer.
(b). Remove flange coupling bolt ② of oil
strainer, take off oil strainer.
(c). Remove the fixed bolts of oil pump, gently

rotate, then take off oil pump.
12B
26. Remove flywheel

(a). Remove the fixed bolts of the flywheel.
(b). Remove the flywheel stop dog, then take

off flywheel.
NOTICE:
• Keep safe when taking flywheel off.
• In the process of moving the flywheel, avoid
bump against the flywheel signal gear.
(c). Remove the fixed bolts of supporting back

shroud.
(d). Take down supporting back shroud.
27. Remove rear oil seal seat and oil seal of

crankshaft
(a). Remove the fixed bolts on the rear oil seal
of the crankshaft.
(b). Use a stick to evenly loosen rear oil seal
of the crankshaft, take down the rear oil
seal, oil seal seat, rear oil seal seat sealing
strip and rear oil seal seat cushion of the
crankshaft.
(c). Use a tool to take out the rear oil seal.

NOTICE:
• The removed real oil seal and rear oil seal seat
cushion shall not be used again.
• When removing the rear oil seal, don't scratch
the rear oil seal seat.
28. Remove the piston and connecting rod

assembly
(a). Rotate the crankshaft properly to make the
piston to be at the bottom, for easy removal
of fixed bolt of connecting rod cap.
(b). Remove the fixed bolts of the connecting
rod cap, take off the connecting rod cap
and lower bearing shell.
NOTICE:
Place the removed connecting rod cap and
bearing shell in proper order correspondingly,
12B
never mix them up.
(c). Use a stick to push out piston assembly

with caution.
(d). Take out piston assembly and upper
bearing shell from the opposite side.
(e). Rotate the piston to make the piston of the other cylinders to be at the bottom, the
disassembling method is the same with the above.
NOTICE:
• If carbon deposit exits in the bore hole, carbon deposit shall be firstly cleaned up,
avoiding scratch to the piston surface when removing the piston.
• When using a stick to push out piston assembly, never use metal objects, avoiding
damage to the connecting rod end.
• Use a marker to mark well on the piston and connecting rod, place the piston and
connecting rod assembly in the correct order, never mix them up.
29. Remove crankshaft

(a). Remove the fixed bolts of main bearing cap
in pairs and in the order as shown in the
figure.
(b). Take down main bearing cap and bearing

shell.
NOTICE:
• When taking off the third main bearing cap, it
shall pay attention to taking out the lower thrust
washer.
• The main bearing cap and main bearing
shell taken out shall be placed in order
correspondingly, for easy of subsequent
installation.
(c). Take off the crankshaft.

(d). Take out the upper thrust washer of the

crankshaft.
12B
(e). Take out the rest bearing shells and place

them in order correspondingly.
30. Remove cylinder cooling nozzle

(a). Remove pressure limiting valve component
① , cooling nozzle ② in order, take off the
pressure limiting valve component ① and
cooling nozzle ② .
31. Take off engine cylinder body from the support, place it based on the requirement,
complete the disassembly of engine assembly.
CLEAN THE ENGINE PARTS
1. Disassemble the parts need cleaning to the greatest extent, perform human
assistance pretreatment for the soil, heavy oil and carbon deposit on the surface of
parts according to requirements using high-pressure water gun, wire brush, scraper
knife or other tools, to ensure the service life of cleaning fluid and speed & effect of
cleaning.
NOTICE:
• In actual operation process, in order to improve cleaning efficiency, the technological
process of cleaning along with disassembly can be adopted.
• If there is no cleaning machine, the gasoline can be used to clean the part one by one.
2. Add tap water to rinse tank, ensure that the water level is higher or equal to 3/4
height of internal groove of rinsing pool, start the electrical heating, meanwhile
perform degassing by starting ultrasonic wave, add specified amount of cleaning
agent dedicated for ultrasonic wave when the water temperature is about 40 ℃ ,
start to clean the parts when the water temperature reaches 55-60℃ .
3. Put the parts need cleaning to the rinsing pool; the arrangement shall not overlap;
ensure that the parts are completely emerged by cleaning fluid.
NOTICE:
Clean according to requirements. Do not use ultrasonic wave to clean those can not be
cleaned by it.
4. Start the ultrasonic wave, regularly clean for40-60min, close the ultrasonic wave
after completion, take out the parts.
NOTICE:
To improve cleaning effect, you can extend the cleaning time of parts in cleaning fluid if
time permits.
5. Use high-pressure water gun to remove the residue on the surface of parts, use
compressed air gun to remove the residue in duct. Parts that need rust protection
shall be treated separately.
ASSEMBLING ENGINE ASSEMBLY
1. Assembly preparation
(a). Fix the engine cylinder block to roll-over
stand.
(b). Install the water drain plug on the left side
of engine.
NOTICE:
When installing the water drain plug, Loctite 262
glue shall be applied.
12B
2. Install cooling nozzle fitting and pressure-

limiting valve components
(a). Fix the cooling nozzle fitting to the main oil
gallery in cylinder block through pressure-
limiting valve components.
NOTICE:
When installing, check whether the cooling nozzle
is unobstructed.
3. Install crankshaft
(a). Select the upper and lower main bearing
shell according to the identification labels
on the bottom surface of cylinder block.
1 2 or 3
NO.1-NO.5
fuwx12B101
(b). Install the main bearing shell of oil groove

and oil hole to the cylinder block support.
Check whether the oil hole is aligning to
the oil hole of cylinder block, lubricate the
internal surface of main bearing shell by
engine oil.
NOTICE:
• Strictly install the main bearing shell in the
corresponding position when removing.
• When lubricating the bearing shell, the contact
surface of bearing shell and cylinder block can
not be lubricated.
• Ensure that the location tongue of main bearing
shell aligns at the groove-and-tongue on cylinder
block in installation.
(c). Apply a suitable amount of engine oil to

each working surface of crankshaft for
lubrication, gently horizontally put it to the
bearing shell of main shaft.
NOTICE:
Crankshaft can not be turned from installing
crankshaft to the completion of main bearing cap,
to prevent main bearing shell dislocation.
(d). A thrust washer is installed on two sides of

third spindle seat.
NOTICE:
Before installing thrust washer, the surface of
thrust washer which has oil groove shall be
lubricated by engine oil.
WARNING:
The surface of upper thrust washer which has
oil groove shall be installed towards crank arm.
Reverse installation of thrust washer will directly
result in crankshaft and cylinder block scrapping.
(e). Install the lower main bearing shell to the

main bearing cap.
(f). Apply a suitable amount of engine oil to
the surface of lower main bearing shell
and fixed bolt of main bearing cap for
lubrication.
NOTICE:
shell aligns at the groove-and-tongue on main
bearing cap in installation.
• Ensure that reverse side of main bearing shell is
12B
clean and free of any foreign matter. Do not use
engine oil to lubricate the reverse side of bearing
shell.
(g). According to the direction mark,
install1、2、4、5main bearing cap
assembly to the cylinder block, tighten the
bolt with hand.
NOTICE:
• The main bearing cap can not exchange. Install
it with the forward arrow towards the timing
sprocket chamber. Reverse installation is not
permitted.
• Before installing main bearing cap, the side face
of main bearing cap needs to be lubricated by
engine oil.
(h). Install two lower thrust washers to the3rd

main bearing cap, install the main bearing
cap, and tighten the bolt with hand.
NOTICE:
Before installing thrust washer, the surface of
thrust washer which has oil groove shall be
lubricated by engine oil.
NOTICE:
Before installing the main bearing cap, the side
face of main bearing cap needs to be lubricated
by engine oil.
WARNING:
When installing the lower thrust washer, the
surface of upper thrust washer which has oil
groove shall be installed towards the crank arm.
Reverse installation is not permitted.
(i). According to the sequence of bearing

seat3、2、4、1、5、rom middle to sides,
alternately tighten the bolt of each bearing
seat by 3 steps.
Step 1: Tighten with the torque of30N•m
Step 2: Loosen60°
Step 3: Perform a comprehensive retighten
with the anchoring force value of 78N•m
NOTICE:
• After assembly, the crankshaft rotational torque
shall be not more than10N•m.
• After installation, check whether the axial
clearance of the crankshaft fits.
• After installing each main bearing cap, the
crankshaft shall rotate freely when rotated. If
there is an out of nimbleness symptom, you
shall check and re-install it.
4. Install the piston and connecting rod

assembly
(a). Install the upper bearing shell of connecting
rod.
NOTICE:
shell aligns at the groove-and-tongue on
connecting rod in installation.
• Ensure that reverse side of connecting rod and
connecting rod bearing shell is clean and free of
any foreign matter.
• It is prohibited to lubricate the reverse side of
connecting rod bearing shell.
(b). Apply a layer of clean engine oil to cylinder
wall and piston surface.
(c). Rotate crankshaft, make the rod journal of

installed piston in the bottom dead center
to facilitate installation.
(d). Check and adjust the open position of
piston ring.
NOTICE:
The angle between the expander oil rail and
the incision of top & bottom rails shall be
about90° ,the angle between the opening of two
gas rings shall be180 ° , and the opening shall
not be in the piston pin.
12B
(e). Insert the piston and connecting rod

assembly into cylinder, ensure that the
forward mark on the top of piston orients to
camshaft sprocket.
(f). Gently push the piston assembly into

cylinder using the piston installation tools
and sticks.
NOTICE:
• An assistant shall hold the connecting rod from
the other side and install aligning to crankshaft
to prevent knocking the crankshaft.
• Use a stick to push piston assembly, rather than
metal objects.
(g). Push the piston connecting rod set to the
crankshaft connecting rod journal.
(h). Evenly apply a layer of engine oil to the

internal surface of connecting rod lower
bearing shell, install the connecting rod
lower bearing shell to the connecting rod
cap.
NOTICE:
shell aligns at the groove-and-tongue on
connecting rod cap in installation.
• Ensure that reverse side of connecting rod cap
and connecting rod bearing shell is clean and
free of any foreign matter.
• It is prohibited to lubricate the reverse side of
connecting rod bearing shell.
(i). Install the connecting rod and fasten the

fixed bolts of the connecting rod cap
according to the requirements.
Step 1:Tighten with the torque of20N•m
Step 2:Perform a re-tightening with the
torque of49N•m
NOTICE:
• Before installing connecting rod, apply the
engine oil to the side of connecting rod cap for
lubrication.
• The connecting rod cap can not exchange.
Install it with the forward arrow towards the
timing sprocket chamber. Reverse installation is
not permitted.
• When installing fixed bolt, firstly tighten with
hand, then tighten for many times in circulation.
(j). Rotate the crankshaft to a suitable position, and install the rest piston and rod
assembly in the same method.
NOTICE:
After completing the installation of all piston connecting rod components, the crankshaft
shall be flexible in rotation, and the drag torque shall be less than16N•m,the mutual
interference or out of nimbleness phenomenon of parts are not allowed.
5. Install the crankshaft rear oil seal

(a). Put the crankshaft rear oil seal into the
crankshaft rear oil seal seat, press the
crankshaft rear oil seal into the bottom
of rear oil seal seat using crankshaft
installation tools.
NOTICE:
Pay attention to the orientation of oil seal when
installing.
12B
(b). Install the crankshaft rear oil seal seat

cushion aiming at the dowel pin.
(c). Apply the sealant evenly and continuously

on the crankshaft rear oil seal seat.
Glue line requirements:
Width:3mm
Thickness:1mm
(d). Install the the crankshaft rear oil seal seat

assembly, fix the bolts and diagonally
tighten the fixed bolt.
Torque : 22N•m
NOTICE:
When installing, to facilitate installation, you can
apply a suitable amount of lithium base grease to
the lip of oil seal.
(e). Apply sealant to the outside of crankshaft

rear oil seal seat.
(f). Install the sealing strip of rear oil seal seat.
NOTICE:
When installing the sealing strip of rear oil seal
seat, its complete fitness with rear oil seal seat
shall be ensured.
6. Install flywheel
(a). Install the rear cover plate of support,
install and fasten the fixed bolt.
Torque : 22N•m
(b). Evenly apply a suitable amount of Loctite

263 locking sealant to the flywheel
fastening bolt as required.
NOTICE:
Before applying sealant, it shall be ensured that
the surface of bolt is dry, clean without oil stain.
(c). Align the pin hole on flywheel to dowel pin
on crankshaft, tighten the bolt with hand.
(d). Install the flywheel stop dog, tighten the
flywheel fixed bolts for three times in a
diagonal cross order.
12B
Torque : 100 ± 5 N•m
(e). Remove the flywheel stop dog.
7. Install oil pump and oil strainer

(a). Drip a small amount of engine oil to the
transmission shaft cavity of oil pump.
The oil pump shall rotate flexibly without
clamping stagnation when the pump shaft
is rotated by tools.
(b). Gently insert the oil pump into mounting

hole, install the fixed bolt of oil pump.
Torque : 22N•m
(c). Install oil strainer and gasket in flange, fix

and fasten the fixed bolt of oil strainer.
Torque : 22N•m
(d). Fix and fasten the connecting bolt of oil

pump flange plate.
Torque : 22N•m
8. Install sprocket chamber

(a). Align to the dowel pin, install sprocket
chamber mat on the front face of cylinder.
NOTICE:
When installing sprocket chamber mat, clean the
front face of cylinder using tools in advance.
(b). Install sprocket chamber, fix and fasten the

fixed bolt of sprocket chamber.
Torque : 23N•m
12B
(c). Meanwhile, install transmission shaft and

intermediate shaft of oil pump.
NOTICE:
• When installing, the cylinder block shall be put
horizontally.
• Before installation, you can apply a small
amount of engine oil to the internal surface of
intermediate shaft bearing, intermediate shaft
journal, O-ring of oil pump transmission shaft
and the tooth surface of oil pump drive gear, to
facilitate installation.
• If it is hard to install, you can slightly rotate the
intermediate shaft and oil pump transmission
shaft to make them fully engaged, then rotate
the intermediate shaft to confirm its rotating
flexibility.
(d). Install the thrust washer of intermediate

shaft.
NOTICE:
When installing the thrust washer, make the thrust
washer surface with pit orient to the sprocket
wheel.
(e). Fix and fasten the fixed bolt of thrust
washer.
Torque : 23N•m
(f). Fix and fasten the fixed bolt of oil pump

transmission shaft.
Torque : 23N•m
9. Install oil pan

(a). As shown in the figure, evenly apply the
Loctite5999sealant to the junction surface
of oil pan.
Width:3~4mm
Thickness:2mm
(b). Install the oil pan, install the fixed bolt, and
fasten in diagonal direction.
Torque : 13N•m
NOTICE:
Before installing the oil pan, the sealing strip of
rear oil seal seat shall be made flat by tools.
(c). Install the oil pan and drain bolt.

Torque : 40N•m
12B
10. Install the intake/exhaust camshaft and

cylinder head
(a). Align the cylinder head gasket to the dowel
sleeve, install the cylinder head gasket.
(b). Align to the dowel of cylinder head, install

the cylinder head, install the fixed bolt and
fasten it with hand.
NOTICE:
When installing the cylinder head bolt, apply a
small amount of engine oil to the bolt & screw
thread.
(c). Fasten the cylinder head bolt according to
the following steps.
Step 1: Tighten the bolts1~10according to
the sequence in the figure in 3 times, and
the final tightening torque is 98N•m
Step 2: Tighten the bolts11,12in two times
to16N•m
Step 3: Tighten the bolts13,14in two times
to25N•m
(d). Apply a small amount of engine oil to the

journal, the bearing hole and the protruding
point of the intake/exhaust camshaft.
(e). Install the intake camshaft.
(f). Install the exhaust camshaft.
NOTICE:
• When installing the intake/exhaust camshaft,
they shall be put down gently in horizontal
direction.
• When installing the intake/exhaust camshaft,
you shall adjust to make the spur of each cam
do not face down.
(g). Install the intake/exhaust camshaft according to the mark requirements.

NOTICE:
• If there is a direction sign on the camshaft, it cannot be interchanged while installing.
• I2/I3/I4/I5are used for the intake camshaftandE2/E3/E4/E5are used for the exhaust
camshaft.
• While installing, the arrow direction of the bearing cap should be turned to the crankshaft
belt pulley of the engine.
(h). From the middle to two sides, gradually

tighten the bolts of the bearing cap
of exhaust camshaft according to the
sequence shown in the figure.
Torque : 10N•m
(i). From the middle to two sides, gradually

tighten the bolts of the bearing cap of
inhale camshaft according to the sequence
shown in the figure.
Torque : 10N•m
12B
(j). Install the OCV valve, install the fixed bolts

and fasten them.
Torque : 10N•m
NOTICE:
• Avoid knocking in the process of installation,
and check whether the strainer filter is clean
and intact without obvious granules, whether the
O-ring is in good condition, and whether the seal
ring is scratched, or else the installation cannot
be implemented.
• Before installation, lubricate the O-type ring
with oil, and then push the OCV valve into the
mounting holes of the cylinder head carefully
till the mounting surface is connected with the
cylinder head, and at last, tighten the bolt.
• Clean the OCV valve with clean oil rather than oil of powerful solvent (e.g. gasoline), nor
can it be blew by compressed air. If OCV valve is pasted with oils except for the engine
oil, it should be cleaned promptly.
11. Install the sparking plug

(a). Set ignition coil in the head of spark plug,
put the spark plug into mounting hole,
rotate the ignition coil, install the spark
plug.
(b). Pull out the ignition coil, tighten the spark

plug with spark plug socket.
Tightening torque of the spark
plug:25~30N•m
Spark plug model:TORCH K7RTPP
Correct electrode gap:0.80~0.90mm
NOTICE:
• Simple measuring method: Measure the gap
between two electrodes with feeler gauge.
• If the spark plug gap is not correct, carefully
bend the side electrode to adjust to the correct
electrode gap.
• Before installation, clean the spark plug with
wire brush, visual check whether the spark
plug electrode is burned, whether the screw
thread is damaged, and whether the insulator
is damaged. If there is a damage, the spark
plug shall be replaced. When replacing, special
tools shall be applied to install. Under normal
circumstances, the spark plug shall be replaced
when the automobile drives each 20000km.
12. Install the timing sprocket mechanism

(a). Turn crankshaft until No.1 cylinder piston
reaches upper dead center, adjust the
upper keyway of crankshaft to the position
of straight up.
(b). Rotate the intermediate shaft, adjust the
upper keyway of intermediate shaft to the
position of straight up.
12B
(c). Align the two coppery chain links of timing

chain1to the round hole on the edge of
crankshaft sprocket and intermediate shaft
sprocket1, respectively.
(d). Align to the position of intermediate shaft

and crankshaft keyway, meanwhile, install
the timing chain1,intermediate shaft
sprocket1and crankshaft sprocket.
(e). Install the intermediate shaft sprocket 2 to

the intermediate shaft.
NOTICE:
When installing the intermediate shaft sprocket
2, it shall be ensured that the round hole on the
edge of wheel aligns to the round hole of sprocket
wheel1.
(f). Install the fixed bolt of intermediate shaft

sprocket and fasten it according to
requirements.
Step 1: Fasten to65~75N•m
Step 2: Loosen60°
Step 3: Fasten to100N•m
(g). Install the tensioner 1, install the fixed bolts

and fasten them.
Torque : 30N•m
NOTICE:
When installing the tensioner1, ensure that the
tensioner1is in state of compression.
(h). Pull out the locking small-gauge wire of the
tensioner1.
(i). Install the No.2 fixed rail, assemble the

fixed bolts and fasten them.
Torque : 22N•m
12B
(j). Find out three coppery chain links on timing

chain2, adjust the chain,align the lowest
coppery chain link to the intermediate shaft
sprocket2, at this time,check the other two
coppery chain links, if the farthest coppery
chain link is at the right hand side, the
position alignment is correct, otherwise, it
shall be re-adjusted.
NOTICE:
The right two coppery chain links are at a distance
of27links, while the left two coppery chain links
are at a distance of15links.
(k). Put the timing chain2 to the intermediate shaft sprocket2, use the jackstay to tension
the timing chain2.
NOTICE:
Align the lowest coppery chain link to the round hole on the edge of intermediate shaft
sprocket2.
(l). Install the exhaust camshaft sprocket,

install the fixed bolts and fasten them.
Torque : 50N•m
NOTICE:
While tightening the fixed bolts of the camshaft
sprocket, stick the hexagon section of the exhaust
camshaft with a wrench.
(m). Take down the timing chain2from the

jackstay, and put it to the camshaft
sprocket.
NOTICE:
Align the coppery chain link at the right hand
side to the round hole on the edge of exhaust
camshaft sprocket.
(n). Align the coppery chain link at the left hand

side to the round hole on the edge of phase
regulator. Set the chain on the phase
regulator, install the phase regulator to the
intake camshaft, install the fixed bolts and
tighten them.
Torque : 60N•m
NOTICE:
• For the convenient installation of the phase regulator, rotate the intake camshaft
appropriately while installing.
• While tightening the fixed bolts of the phase regulator, stick the hexagon section of the
intake camshaft with a wrench.
• After the installation, check every timing mark again to make sure the alignment
installation is correct.
(o). Install the slide rail, install the slide rail pin
and fasten it.
Torque : 23~26N•m
12B
(p). Install the No.2 tensioner and fasten it.

Torque : 10N•m
(q). Install the No.2 fixed rail, assemble the

Torque : 22N•m
(r). Press the front oil seal to the sprocket

chamber cover by using the installation tool
of the crankshaft front oil seal.
NOTICE:
The lower end face of press-in front oil seal is
required to align at the inner shell of sprocket
chamber.
(s). Evenly apply the Loctite 5999 sealant to

the sprocket chamber cover.
Width : 2~3mm
Thickness : 1mm
(t). Align the dowel, install the sprocket

chamber cover, install the fixed bolt and
fasten it.
M6bolt Torque : 10N•m
M8bolt Torque : 22N•m
12B
(u). Evenly apply the Loctite 5999 sealant to

the front shroud of the cylinder head.
Width:2~3mm
Thickness:1mm
(v). Install the front shroud of the cylinder head,

install and fasten the fixed bolt.
Torque : 10N•m
13. Install camshaft hood

(a). Flatly install the sealing gasket of camshaft
hood to the groove of camshaft hood.
(b). Install the camshaft hood, fix it with the
fixed bolts and fasten the bolts.
Torque : 10N•m
NOTICE:
• When fastening the bolts of the camshaft hood,
the sequence should be from middle to both
sides alternately.
• After the bolts are fastened, the bearing surface
of the camshaft hood should contact with the
cylinder head.
14. Install the phase sensor of the intake

camshaft
(a). Press the phase sensor into the camshaft
hood, fix it with fixed bolts and fasten the
bolts.
Torque : 10N•m
15. Install the ignition coil

(a). Install the ignition coil, fix it with fixed bolts
and fasten the bolts.
Torque : 10N•m
16. Install the cylinder inlet pipe joints

(a). Install the thermostat dead plate and
thermostat mat, fix them with fixed bolts
12B
(b). Install the thermostat.

NOTICE:
Make the end with words of the thermostat toward
the inlet pipe joint, and adjust the oscillating valve
of the thermostat in the upper left.
(c). Install the inlet pipe joints, fix them with

Torque : 22N•m
17. Install the cylinder outlet pipe joints

(a). Install the outlet pipe, fix it with fixed bolts
Torque : 10N•m
(b). Install the water temperature sensor.
Torque : 20N•m
NOTICE:
Before installing the water temperature sensor,
apply sealant to the sensor thread.
18. Install knock sensor

(a). Install the knock sensor bolts, fix them with
Torque : 22N•m
NOTICE:
• When installing the knock sensor, adjust the
plug-in to be level toward the front, which
provides convenience to the follow-up wire
installation.
• In the process of installation, any kind of gaskets
is not allowed. And it must be the metal surface
of the sensor that clings closely to the cylinder
block.
19. Install the fuel injector assembly of the fuel

rail
(a). Aim the injection side of the fuel injector
respectively at the mounting hole of the
cylinder head fuel injector, press it into the
cylinder head, during which the strength of
hands should be equal.
(b). Install and fasten the fixed bolts of the fuel
rail injector assembly.
Torque : 22N•m
NOTICE:
• Before the installation, check whether the O-rings are sealed in good condition or are
scratched.
• After installation, confirm that the O-rings are completely into the mounting hole of the oil
injector, and the oil injector is not tilted.
• Do not tap it with a hammer or other tools when installing , and push it into the mounting
hole vertically.
20. Install the oil filter assembly

(a). Install the oil filter base spacer.
(b). Install the oil filter base, fix it with fixed
12B
bolts and fasten the bolts.
Torque : 23N•m
(c). Install the oil pressure sensor.
NOTICE:
Before installing the oil pressure sensor, apply a
suitable amount of moderate intensity sealant 243
in thread.
(d). Install the oil cooler, and assemble the

hollow bolt and fasten it, make the pipe
connecting mouth towards the rear of
engine.
Torque : 23N•m
(e). Tighten the oil filter by hand, and then use

the oil filter wrench to tighten the oil filter.
NOTICE:
• Oil filter is disposable item and shall not be
reused after removal.
• When installing the oil filter, in order to facilitate
installation, you can apply a small amount of
engine oil to the rubber seal ring of oil filter.
• When tightening the oil filter, after the filter
contacts the mating face of cooler, then screw in
3/4 circle again.
21. Install the warm wind pipe components

(a). Evenly apply Loctite 5999 sealant to the
flange of warm wind water return pipe.
Width: 2~3mm
Thickness: 1mm
(b). For positioning hole, install the flange
gasket.
(c). Install the fixed bolt of warm wind water
return pipe component flange, and fasten
it.
Torque : 22N•m
(d). Install the fixed bolt on the left side of

cylinder body and fasten it.
Torque : 22N•m
(e). Install the warm wind water return pipe and

the fixed bolt on the left side of cylinder
body, and fasten it.
Torque : 23N•m
12B
(f). Connect the warm wind water return hose

at the end of engine.
(g). Adjust the hose clamp position and fix the
hose.
(h). Connect the warm wind water return hose
at the end of engine.
(i). Adjust the hose clamp position and fix the
hose.
(j). Install the fixed bolt of warm wind water

inlet/return pipe at the end of engine.
Torque : 23N•m
(k). Connect the U hose on the right side of

engine.
(l). Adjust the hose clamp position and fix the
hose.
22. Install the intake manifold assembly

(a). Install the intake manifold gasket.
(b). Install the intake manifold sembly,assemble
a fixed nut and tighten it.
Torque : 25~31N•m
NOTICE:
Before install the intake tube, need to apply
adequate amount of Loctite 262 sealant on inlet
side double end studs.
(c). Install the intake manifold bracket,

assemble a fixed nut and tighten it.
Torque : 22N•m
(d). Electronic throttle component installation,

mount fixed bolts and tighten.
Torque : 10N•m
12B
(e). Connect the PCV valve hose.

(f). With forceps adjust clamp position make
the PCV valve tube fixed.
23. Install the exhaust system

(a). Install the exhaust manifold gaskets.
(b). Install the exhaust manifold, assemble a
fixed nut and tighten it.
Torque : 25~31N•m
NOTICE:
Before install the exhaust manifold, apply
adequate amount of Loctite 262 sealant to the
double end studs on the exhaust side.
(c). Install the turbocharger assembly and

gaskets, assemble a fixed nut and tighten
it.
(d). Connect the water inlet of turbocharger,

install the hollow bolt ① and fasten it.
Torque : 50N•m
(e). Connect the water return pipe of the
turbocharger, assemble hollow bolt ② and
tighten it.
Torque : 50N•m
(f). Install the thermal baffle of the supercharger,

assemble the fixed bolts and fasten them.
Torque : 22N•m
NOTICE:
In order to facilitate subsequent installation
of machine cold water pipe, do not install the
supercharger left heat insulation plate bolts first.
(g). Install the supercharger tail pipe gaskets.

(h). Install the supercharger tail pipe, mount
fixed nut and tighten it.
Torque : 25~31N•m
NOTICE:
Before installing the tail pipe, apply adequate
amount of Loctite 262 sealant to the double end
studs on the exhaust side.
12B
(i). Install the front oxygen sensor.
(j). Install the thermal baffle of the supercharger

tail pipe, assemble the fixed bolts and
fasten them.
Torque : 22N•m
(k). Install the intake manifold bracket,

assemble a fixed nut ① and tighten.
Torque : 22~28N•m
(l). Install the supercharger tail pipe holder,
install the fixed bolt ② and tighten it.
Torque : 22~28N•m
24. Install the oil level gauge tube assembly

(a). Insert the oil level gauge tube into the
mounting hole of oil level gauge tube on
the right side of cylinder block.
(b). Adjust the oil level gauge tube to the right
direction, install the oil level gauge tube,
assemble fixed bolts and tighten them.
Torque : 22N•m
(c). Insert the oil level gauge into the oil level
gauge tube.
25. Install the oil cooler inlet and return pipe

assembly
(a). Connect the cooler water inlet and return
pipe on the left side of the cylinder body.
(b). Adjust the clamp and fix it on the left side
of hose.
(c). Connect the cooler water inlet and return

pipe on the left side of the cylinder body.
(d). Adjust the clamp and fix the hose on the
left side.
12B
(e). Install the fixed bolt ① of oil cooler water

inlet and return pipe in the front-left of
cylinder block.
Torque : 22N•m
(f). Install the fixed bolts ② on the left side of
supercharger thermal baffle.
Torque : 22N•m
(g). Install the bolt of the water inlet/return pipe

of the oil cooler at the left-rear side of the
engine.
Torque : 22N•m
26. Install the turbocharger inlet and return

pipe assembly
(a) Install the oil return pipe flange gasket and
oil return pipe flange, assemble the fixed
bolts and tighten them.
Torque : 10N•m
NOTICE:
When installing the supercharger oil return pipe
flange gasket, it is not allowed to glue.
(b). Connect the turbocharger oil return hose.

(c). Adjust the clamp position, and fix the oil
return hose.
(d). Connect the turbocharger oil inlet pipe to

the main oil passage of engine.
Torque : 30N•m
(e). Connect the oil inlet of turbocharger to the

turbocharger.
Torque : 30N•m
12B
(f). Install the fixed bolt of turbocharger oil inlet

pipe, which is on the intake manifold, and
fasten the bolt.
Torque : 10N•m
(g). Install the fixed bolt of turbocharger oil inlet

pipe, which is at the end of engine, and
fasten the bolt.
Torque : 10N•m
(h). Install the pipe clamp of the supercharger

oil inlet pipe, assemble the fixed bolts and
fasten them.
Torque : 10N•m
(i). Fix the front oxygen sensor connector.
27. Install the crankshaft pulley

(a). Install the flywheel stop dog, fix the
flywheel.
(b). Install the crankshaft belt pulley, fix and

fasten the fixed bolts.
Torque : 180N•m
12B
28. Install the water pump

(a). Install the water pump, assemble fixed
bolts and tighten them.
Torque : 23N•m
NOTICE:
• After the installation, rotate the water pump,
water pump should be flexible without noise.
• The pump shell have spillway hole, don't put
spillway hole closed during installation.
29. Install the water pump pulley

(a). Install the water pump pulley, fix and fasten
the fixed bolts.
Torque : 10N•m
NOTICE:
When install the water pump pulley fixed bolt, use
waste belt winding on the water pump pulley, and
fastened with the clench hand.
30. Install the generator

(a). Install the generator support, assemble the
fixed bolts and tighten them.
(b). Install the generator support, fix and fasten

the fixed bolts.
Torque : 39N•m
(c). After installation of generators, from the

forward pass through bolts ② ,screw the
nut with the hand, the generator is fixed on
the pedestal.
NOTICE:
This fixed bolt does not need to be tightened
temporarily.
(d). I n s t a l l t h e f i x e d b o l t o f t e n s i o n i n g
block ① ,the generator is fixed on the
bracket.
NOTICE:
The fixed bolts ①、② do not need to be tightened
temporarily.
31. Install the drive belt

(a). The generators is put forward to the
cylinder block, belt is covered on the
corresponding pulley of the crankshaft,
water pump, and generator.
12B
(b). Adjust the drive belt and bolts, making the

drive belt arrive at specified tension.
(c). Tighten generator fixed bolt ① of tensioning

block.
Torque : 22N•m
(d). Tighten generator fixed bolt ② .
Torque : 50N•m
32. Remove the flywheel stop dog, review any

missing parts and wrong parts installed,
complete the assembly of engine
ENGINE MECHANICAL - DRIVING BELT 12B-83
DRIVING BELT
PARTS DRAWING
12B
1 Driving belt
12B-84 ENGINE MECHANICAL - DRIVING BELT
INSPECTION
1. Check drive belt

(a). Check whether the drive belt is aged, there
is crack or wear and replace if necessary.
Judgment standard:
On the every 100 mm effective length,
five or more deep and even crack of cotton
rope , can judge the belt failure, need to
change the belt.
(b). Use Belt tension meter ① to measure the

tensile force of transmission belt.
(c). If the drive belt tension is not in deviation
range, adjust transmission belt tension.
ADJUSTMENT
1. Adjust driving belt tension force

(a). Loosen generator fixed bolt ① .
(b). Loosen generator fixed bolt ② of tensioning
block.
(c). Adjust generator and bolts ③ ,check the
drive belt tension, until the drive belt of
generator tension force reach regulated
tension force.
12B
(d). Tighten generator fixed bolt ①、fixed bolt

tensioning block ② .
Torque (generator fixed bolt) :50N•m
Torque (fixed bolt of generator tensioning
block) :22N•m
12B-86 ENGINE MECHANICAL - DRIVING BELT
REPLACEMENT
1. Remove the drive belt

(a). Loosen generator fixed bolt ① .
(b). Loosen generator fixed bolt ② of tensioning
block.
(c). Loosen the adjusting bolt ③ ,remove the

drive belt.
2 Install the drive belt

(a). As shown in the figure, install the drive belt
to the correct position.
(b). Adjust driving belt tension force and fasten

bolt ③ .(Refer to"Chapter 12B Engine
Mechanical Systerm-Drive Elt,Replacement")
12B
12B-88 ENGINE MECHANICAL - TURBOCHARGER
TURBOCHARGER
INSPECTION
1. Check each part of the pressurization system

(a). Check whether the supercharger tail pipe
gasket is damaged, if damaged, need to
replace the gasket.
(b). Check whether the supercharger exhaust
manifold is damaged, if damaged, need to
replace the gasket.
(c). Check whether the supercharger blade

rotation is flexible, whether there is card
lag phenomenon or not, if has, replace the
supercharger assembly.
(d). Check whether the supercharger impeller

is worn or damaged, if it is worn or
damaged, to replace the supercharger
assembly.
ENGINE MECHANICAL - TURBOCHARGER 12B-89
NOTICE:
Supercharger impeller generally will not damage, but if the supercharger is in high-speed
operation, and foreign body get into the engine air intake or the exhaust pipe, it will cause
the turbine and compressor blade damaged, and it can smash turbine shell in serious
condition. When using supercharged engine in desert area and area with bad working
environment, small dust can get into supercharger by damaged pipeline gap of air filter or
air intake system, which will lead to the wear of supercharger impeller air inlet. Therefore,
frequently check and maintain the air intake system pipeline and air filter, and timely
change filter element to reduce the happening of this fault.
(e). Check whether there is cracking in

12B
turbocharger shell, such as the
replacement of supercharger assembly.
(f). As shown in the figure, measure the axial

clearance of impeller shaft with dial
indicator.
12B-90 ENGINE MECHANICAL - INTAKE AND EXHAUST MANIFOLD
INTAKE AND EXHAUST MANIFOLD

INSPECTION
1. Check the intake manifold

(a). Check whether the intake manifold has
cracks or other damage, if has, replace it.
2. Check the intake manifold

(a). Check whether the exhaust manifold has
cracks or other damage, if has, replace it.
ENGINE MECHANICAL - TIMING SPROCKET MECHANISM 12B-91
TIMING SPROCKET MECHANISM

PARTS DRAWING
12B
12B-92 ENGINE MECHANICAL - TIMING SPROCKET MECHANISM
Fixed bolts of intermediate shaft Fixed bolts on the sprocket wheel of

1 13
sprocket the exhaust camshaft
2 Intermediate shaft 2 14 Woodruff key
3 Intermediate shaft 1 15 Intermediate shaft
4 Slide rail pin 16 Thrust washer of intermediate shaft
Fixed bolts of intermediate shaft

5 Slide rail components 17
thrust washer
6 Tensioner component 2 18 Fixed bolts of set pattern component 1
7 Timing Chain 2 19 Set pattern component 1
8 Bolts of phase regulator 20 Timing Chain 1
9 Phase regulator 21 Tensioner component 1
10 Fixed bolts of set pattern component 2 22 Fixed bolts of tensioner component 1
11 Set pattern component 2 23 Crankshaft sprocket
12 Exhaust camshaft sprocket

INSPECTION
1. Check timing chain 1

(a). Visually inspect whether timing chain 1
has cracks and obvious wear or not, if has,
replace it.
12B
2. Check timing chain 2

(a). Visually inspect whether timing chain 2
has cracks and obvious wear or not, if has,
replace it.
3. Check all the chain wheels on the timing

mechanism
(a). Twine the chain on the chain wheel.
(b). Use vernier caliper to measure its diameter.
• If the measured diameter is less than the
specified value, replace the timing chain
and camshaft timing sprocket.
NOTICE:
The two measurement feet of vernier caliper must
cling to the chain pin roller in measurement.
4. Check tensioner 1
(a). Compress the tensioner, then loosen it,
check whether the tensioner 1 is capable
of expansion and contraction freely without
clamping stagnation.
(b). Lock the tensioner with the steel wire

inserting into the locking hole of tensioner,
check whether the tensioner can make
concertina movement.
• If the tensioner can do contractions,
change the tensioner.
5. Check tensioner 2
(a). Compress the tensioner, then loosen it,
check whether the tensioner 2 is capable
of expansion and contraction freely without
clamping stagnation.
6. Check the intermediate shaft clearance

(a). Meanwhile, install transmission shaft and
intermediate shaft of oil pump.
(b). Tighten the bolts of oil pump transmission
shaft.
NOTICE:
• When installing, the cylinder block shall be put
horizontally.
• Before installation, you can apply a small
amount of engine oil to the internal surface of
intermediate shaft bearing, intermediate shaft
12B
journal, O-ring of oil pump transmission shaft
and the tooth surface of oil pump drive gear, to
facilitate installation.
• If it is hard to install, you can slightly rotate the
intermediate shaft and oil pump transmission
shaft to make them fully engaged, then rotate
the intermediate shaft to confirm its rotating
flexibility.
(c). Install intermediate shaft thrust washer.

NOTICE:
When installing the thrust washer, make the thrust
washer surface with pit orient to the sprocket
wheel.
(d). Install the fixed bolt of thrust washer.
(e). I n s t a l l t h e d i a l i n d i c a t o r, s h a k e t h e
intermediate shaft in axial direction, check
the axial clearance of intermediate shaft.
Maximum clearance:0.05~0.20mm
NOTICE:
If maximum clearance is beyond the scope,
replace intermediate shaft thrust washer.
ENGINE MECHANICAL - CAMSHAFT 12B-97
CAMSHAFT
PARTS DRAWING
12B
1 Intake camshaft 2 Exhaust camshaft

12B-98 ENGINE MECHANICAL - CAMSHAFT
INSPECTION
1. Check the radial runout of the intake/

exhaust camshaft
(a). Put the camshaft on the v-shaped blocks,
measure the radial run-out with a dial
indicator in the center journal.
Maximum value:0.06mm
• If the radial runout is greater than the
maximum value, the camshaft should be
replaced.
2. Check the maximum height of the cam of

intake/exhaust camshaft
(a). Measure the maximum height of the cam
of intake/exhaust camshaft with screw
micrometer.
• Replace the camshaft if the measured
value exceeds the limit value.
3. Check the intake/exhaust camshaft journal

(a). Check whether there is wear or other
damage in camshaft journal or not.
• If there is, replace it; if necessary, check
the cylinder head.
(b). Measure the camshaft journal with a screw
micrometer.
Standard values:
Intake:23.939~23.960mm
Exhaust:23.939~23.960mm
Limit value:
• Replace the camshaft if the measured
value exceeds the limit value.
4. Check the axial clearance of the intake/

exhaust camshaft
(a). Remove all the valves.(Refer to"Chapter
12B Engine Mechanical System
Valve,Replacing")
(b). Install the the intake/exhaust camshafts on
the cylinder head and screw the bolt to the
torque required.
(c). Install the micrometer on the camshaft
end, fix the cylinder head and promote the
camshaft in the axial direction to measure
12B
the axial clearance of the camshaft.
Standard axial clearance:
Intake Camshaft:0.05~0.15mm
Exhaust Camshaft:0.05~0.15mm
Limit axial clearance:
Intake Camshaft:0.3mm
Intake Camshaft:0.3mm
• If the measured value is out of the standard clearance range, replace the bearing cap of
the camshaft, and replace the cylinder head if necessary.
REPLACEMENT
1. Remove camshafts
(a). Remove the fixed bolts of the all the
cylinder ignition coils to remove all the
ignition coils.
(b). Disconnect the PCV valve hose.
(c). Remove the fixed bolts of the camshaft

hood to remove the camshaft hood.
(d). Remove the fixed bolts from the front

shroud of the cylinder head to remove the
the front shroud of the cylinder head.
12B
(e). Remove the inspection hole cover of two

sprocket chambers.
(f). Make the align marks on the timing

sprocket and the phase regulator of the
exhaust camshaft respectively.
NOTICE:
Be sure to make the align marks readable.
(g). Make the align marks on the No.2 counter

shaft sprocket through the inspection hole.
NOTICE:
Be sure to make the align marks readable.
(h). Remove the fixed bolts of the No.2 set

pattern to remove the the No.2 set pattern.
(i). Remove the No.2 component of the

tensioner.
(j). Stick the hexagon section of the intake

camshaft with a wrench to remove the fixed
bolts from the phase regulator of the intake
camshaft.
NOTICE:
Rotate the crankshaft to avoid the camshaft tip
being vertical downwards after removing the
intake / exhaust camshafts.
12B
(k). Stick the hexagon section of the exhaust

camshaft with a wrench to remove the
fixed bolts from the timing sprocket of the
exhaust camshaft.
(l). Push the timing sprocket of the exhaust

camshaft slightly with a stick to remove the
timing sprocket.
NOTICE:
While removing, tighten the No.2 timing sprocket
manually to keep it in the state of tension to avoid
dislocation.
(m). Tighten the No.2 timing sprocket manually.

NOTICE:
Be sure the No.2 timing sprocket is in the state
of tension to avoid the dislocation of the timing
mark of the counter shaft sprocket and the No.2
chain.
(n). Push the phase regulator slightly with a
stick to remove the phase regulator.
(o). Stick on the fixed bolts of the No.1 set

pattern required with the fork end of the
special tools and straighten the left chain
to be supported and fixed on the top of
the special tools. If the distance is not long
enough, the length of the frock can be
adjusted slightly and appropriately.
(p). Remove the fixed bolts from the front gland

of the intake camshaft to remove the front
gland of the camshaft.
(q). Remove the fixed bolts from the intake

camshaft gland to remove the bearing cap
of the intake camshaft according to the
sequence shown in the fig.
(r). Remove the intake camshaft assembly.
12B
(s). Remove the fixed bolts from the front gland

of the exhaust camshaft to remove the
(t). Remove the fixed bolts from the exhaust

camshaft gland to remove the bearing
cap of the exhaust camshaft according to
the sequence shown in the fig.
(u). Remove the exhaust camshaft assembly.
2. Install camshaft
(a). Place the camshaft on the installation
position and tighten the fixed bolts of the
camshaft bearing cap as shown in the
figure.
Torque : 10N•m
NOTICE:
•If there is a direction sign on the bearing cap of
the camshaft, it cannot be interchanged while
installing.
•I2/I3/I4/I5 are used for the intake camshaftandE2/
E3/E4/E5 are used for the exhaust camshaft.
•While installing, the arrow direction of the
bearing cap should be turned to the crankshaft
belt pulley of the engine.
•Spread a small amount of engine oil to the
journal, the bearing hole and the protruding point
of the exhaust camshaft.
(b). Install the fixed bolts on the front gland of

the exhaust camshaft to tighten them to the
torque required.
Torque : 10N•m
(c). Place the intake camshaft on the

installation position and tighten the fixed
bolts of the camshaft as shown in the
figure.
Torque : 10N•m
• Spread a small amount of engine oil to
the journal, the bearing hole and the
protruding point of the intake camshaft.
12B
(d). Install the fixed bolts on the front gland of

the intake camshaft to tighten them to the
torque required.
Torque : 10N•m
(e). Stick the hexagon section of the exhaust

camshaft with a wrench and rotate
appropriately. Install the sprocket on the
camshaft, install the fixed bolts and tighten
them.
Torque : 50N•m
(f). Take the No.2 timing chain manually and

install it on the sprocket of the exhaust
camshaft according to the enfilade marks
made previously.
NOTICE:
• For the convenience of installation, rotate the
exhaust camshaft appropriately with a wrench
before installing.
• While installing, make sure that the marks in the
inspection hole are in the right position.
(g). Set the chain on the phase regulator, install

the phase regulator to the intake camshaft
and install the fixed bolts and tighten them.
Torque : 60N•m
NOTICE:
• For the convenient installation of the
phase regulator, rotate the intake camshaft
appropriately while installing.
• While tightening the fixed bolts of the phase
regulator, stick the hexagon section of the intake
camshaft with a wrench.
• After the installation, check every timing mark
again to make sure the alignment installation is
correct.
(h). Install the No.2 fixed rail, assemble the

(i). Install the No.2 tensioner.
12B
(j). Install the front shroud of the cylinder head,

assemble the fixed bolts and fasten them.
Torque : 10N•m
(k). Install the inspection hole cover of the
sprocket chamber.
(l). Install the camshaft hood, assemble the

Torque : 10N•m
(m). Connect the connection betweenPCVhose

and the camshaft hood.
(n). Install all the ignition coils, assemble the

Torque : 10N•m
ENGINE MECHANICAL - CYLINDER HEAD 12B-111
CYLINDER HEAD
PARTS DRAWING
12B
The fixed bolts of the front cover The front gland of the exhaust
1 7
plate of the cylinder head camshaft
The fixed bolts of the gland on the i

2 The front shroud of the cylinder head 8
ntake/exhaust camshaft
The gland of the intake/exhaust

3 The fixed bolts of the cylinder head 9
camshaft
4 The fixed bolts of the cylinder head 10 Cylinder Head
The fixed bolts of the sprocket

5 11 Cylinder head gasket
chamber cover
The front gland of the intake

6
camshaft
12B-112 ENGINE MECHANICAL - CYLINDER HEAD
INSPECTION
1. Check the cylinder head bolt

(a). Check whether the wire tooth of the
cylinder head bolt is damaged.
NOTICE:
If it is damaged, replace the cylinder head bolt.
(b). Measure the length of the cylinder head

bolt A.
NOTICE:
If the measured length exceeds the limit value of
the bolt length, replace the cylinder head bolt.
(c). Measure the outside diameter B at the
position as shown in the fig.
(d). Measure the smaller outside diameter C at
the position as shown in the figure.
Limit value:0.15mm
NOTICE:
If the difference value between BandC, exceeds
the limit value, replace the cylinder head bolt.
2. Check the cylinder head

(a). Check whether there are cracks on the
cylinder head.
NOTICE:
• If there are cracks, replace the cylinder head.
• The dye-penetrant method can be used to check
the cylinder head.
• The emphasis of the checkup is combustion
chamber, intake, exhaust, cylinder surface and
the top of the cylinder head.
ENGINE MECHANICAL - CYLINDER HEAD 12B-113
(b). Measure the installation surface of the

intake and exhaust manifold of the cylinder
head as well as the planeness of the
bottom plane of the cylinder head with the
precise straightedge and feeler gauge.
Max value:
The bottom plane of the cylinder
head:0.15mm
The installation surface of the intake /
exhaust manifold:0.1mm
NOTICE: 12B
• If the planeness measured exceeds the limit
value, replace or grind the cylinder head.
• While measuring the planeness, measure the
cylinder head along the diagonal direction and
measure the two diagonals of both directions for
every plane.
(c). Measure the height of the cylinder head.
Standard height:113mm
Maximum grinding amount:0.2mm
NOTICE:
• If the height of the cylinder head is not in
conformity with the standard, replace the
cylinder head.
• If the height of the cylinder head is in conformity
with the standard, grind or replace the cylinder
head.
(d). Measure the diameter both of the tappet

hole and the tappet to count the clearance
between them and decide whether
the clearance is in conformity with the
standard. If not, replace the tappet and the
cylinder head.
Standard diameter of the tappet
hole:31.00~31.02mm
Standard diameter of the
tappet:30.946~30.980mm
Standard clearance:0.020~0.056mm
12B-114 ENGINE MECHANICAL - VALVE
VALVE
PARTS DRAWING
1 Tappets 6 Valve spring lower seat
2 Valve lock clamp 7 Valve guide
3 Valve spring upper seat 8 Intake valve
4 Valve spring 9 Exhaust valve
5 Valve oil seal

ENGINE MECHANICAL - VALVE 12B-115
INSPECTION
1. Check the valve components

(a). Measure the thickness of the top center of
the valve tappet.
12B
(b). There is an identification label on each

valve tappet at the position shown in the
fig.
(c). If the measured value does not conform
to the standard value, replace the valve
tappet according to the identification labels
and the diagrams below.
For example:
If the identification label on the tappet is
"322", the corresponding thickness
should be 3.22mm.
• The size of the valve tappet is 50set, with the unit as mm，increasing by the degree
of 0.03mm in the range of 2.55mm-2.70mm, 2.82mm-3.12mmand 3.60-3.72mm and
increasing by the degree of 0.02mm in other ranges.
NO. Ply NO. Ply NO. Ply NO. Ply NO. Ply
1 2.55 11 2.80 21 3.09 31 3.30 41 3.50
2 2.58 12 2.82 22 3.12 32 3.32 42 3.52
3 2.61 13 2.85 23 3.14 33 3.34 43 3.54
4 2.64 14 2.88 24 3.16 34 3.36 44 3.56
5 2.67 15 2.91 25 3.18 35 3.38 45 3.58
6 2.70 16 2.94 26 3.20 36 3.40 46 3.60
7 2.72 17 2.97 27 3.22 37 3.42 47 3.63
8 2.74 18 3.00 28 3.24 38 3.44 48 3.66
9 2.76 19 3.03 29 3.26 39 3.46 49 3.69
10 2.78 20 3.06 30 3.28 40 3.48 50 3.72
(d). Check whether the valve lock clamp is

cracked or damaged.
NOTICE:
If it is damaged, replace the valve lock clamp.
(e). Measure the length of the valve spring in

the free state with the vernier caliper.
Standard values:43.1mm
Limit value:42.1mm
NOTICE:
If the length measured is lower than the limit
value, replace the valve spring.
12B
(f). Check the perpendicularity of each valve

spring.
Standard value:<2°
Limit value:4°
NOTICE:
If measured value exceeds the limit value, replace
the valve spring.
(g). Check whether the working surface and the

valve stem of each valve are worn or
deformed.
NOTICE:
If it is, maintain them, and replace the valve if
necessary.
(h). Measure the thickness of the valve edge

with the vernier caliper.
Standard value:
Intake valve：1.0~1.2mm
Exhaust valve：1.0~1.2mm
Limit value:
Intake：0.9 mm
Exhaust：0.9 mm
NOTICE:
If the value measured is less than the limit value,
replace the valve.
(i). Measure the length of the valve with the

vernier caliper, and replace the valve if it is
not in conformity with the regulation.
Standard value:
Intake：105.7 mm
Exhaust：104.9 mm
Limit value:
Intake：105.5 mm
Exhaust：104.7 mm
(j). Measure the diameter of valve stem with

the spiral micrometer.
Intake valve stem diameter (D)：
5.468~5.480mm
Exhaust valve stem diameter (D)：
5.458~5.470mm
(k). Measure the inner diameter of the valve guide with the inside caliper and count the
clearance between the valve guide and the valve stem.
Standard value:
Intake：0.020~0.050mm
Exhaust：0.030~0.060mm
Limit value:
Intake：0.10 mm
Exhaust： 0.12 mm
NOTICE:
If the clearance exceeds the limit value, replace the valve and the valve guide.
12B
(l). Check the contact width of the valve seat.
• Spread a layer of Prussian Blue or white
lead, and install the valve on the cylinder
head.
• Rotate the valve within the range of 90°
with the valve grinding tools for several
times to take out the valve.
Standard value:1.0~1.2mm
NOTICE:
The moulage on the valve matching surface must
be the toroidal one without disconnection and the
width of the toroidal moulage must be within the
range required. If the moulage on the valve seat
and the valve contact is uneven or the width of the
moulage is out of the range required, the valve
seat must be burnished, ground and polished
again.
(m). Install the valve and measure the distance

between the valve stem end and the spring
seat surface.
• If the value measured exceeds the
limit value, replace the cylinder head
assembly.
ADJUSTMENT
1. Check the clearance of the valve(without

removing the timing mechanism )
(a). Remove the camshaft hood.(Refer
To " C h a p t e r 1 2 B E n g i n e M e c h a n i c a l
Systerm- Camshaft,Replacing")
(b). Remove the spark plug with the spark plug
sleeve.
(c). Insert a long bamboo stick or something

similar through the spark plug of No.1
cylinder.
(d). Rotate the crankshaft and observe the
height of the bamboo stick. Stop rotating
when the bamboo stick reaches the highest
position.
(e). At this time, watch from the front to the

back and observe the protruding position
of the intake / exhaust camshaft of No.1
cylinder as shown in the fig. to identify the
piston is on the top dead center of the No.1
cylinder compression stroke.
NOTICE:
If the protruding position of the No.1 cylinder
camshaft is at the position shown in the fig., it
means that the piston is at the top dead center of
the No.1 cylinder compression stroke.
(f). Measure the clearance of the eight valves

including the No.1、2、5 and 7 with the
feeler gauge, and record the measuring
results.
(g). Rotate the crankshaft with 360 ° (the
piston is at the top dead center of the No.4
cylinder compression stroke at this time)
Measure the clearance of the other eight
valves with the feeler gauge, and record
the measuring results.
Clearance of the intake valve：
12B
0.22~0.28mm
Clearance of the exhaust valve：
0.27~0.33mm
NOTICE:
If the measured clearance of the valve is not in
conformity with the standard value, adjust the
valve clearance (replace the valve tappet).
2. Check the clearance of the valve(removing

the timing mechanism)
(a). Stick the hexagon section of the intake
camshaft with a wrench to rotate camshaft.
(b). When a certain protruding point of the
camshaft is at the position shown in the
fig., measure the valve clearance of the
two valves corresponding to the protruding
point of the camshaft with the feeler gauge
and record the measuring results.
(c). Measure the valve clearance of all the
other valves one by one with the same
method and record the results.
Clearance of the intake valve：
0.22~0.28mm
Clearance of the exhaust valve：
0.27~0.33mm
NOTICE:
If the measured clearance of the valve is not in
conformity with the standard value, adjust the
valve clearance (replace the valve tappet).
3. Adjust the valve clearance

(a). Remove camshafts. (Refer to Chapter 12B
Engine Mechanical System-Camshaft,
Replacing)
(b). Take out the valve tappet, which need to
be replaced, with the magnetic bar.
NOTICE:
Adjust the valve clearance, i.e. choose the valve
tappet of different thickness.
(c). Measure the thickness of the top center
of the valve tappet with the spiral
micrometer.
(d). Count the top thickness of the new tappet.

Computing method:
The top thickness of the new mechanical tappet = clearance value measured-
standard clearance value + the top thickness of the valve tappet need to be
replaced
Clearance of the intake valve：0.22~0.28mm
Clearance of the exhaust valve：0.27~0.33mm
(e). Replace the valve stem.
REPLACEMENT
1. Remove valve
(a). Take out the valve tappet with the magnetic
bar.
12B
(b). As shown in the fig., remove the valve lock

clamp with special tools.
(c). Take out the valve lock clamp ①、valve

spring upper seat ② and valve spring ③ .
(d). Remove the valve oil seal with the valve oil
seal remover.
NOTICE:
• Remove the valve oil seal, which can not be
used again.
• Avoid scratching the valve tappet hole of the
cylinder head while removing.
(e). Take out the spring lower seat ① of the

valve with the magnetic bar.
(f). Take out the valve ② .
(g). Heat up the cylinder head to80-100℃ with

the boiling water.
(h). Suspend the cylinder head on the board
and dash out the valve guide out of the
cylinder head.
NOTICE:
• The valve guide, which has been removed,
cannot be used again.
• Because of the interference fit of the valve guide
and the valve head, the size must be chosen
while installing the new valve guide.
2. Install the intake / exhaust valve and the

valve oil seal
(a). Install the valve guide.
• Refrigerate the valve guide in the liquid
nitrogen for 2~3 minutes.
• Dash the valve guide into the installation
position of the cylinder head with the
special tools.
• Check the mounting depth of the valve
guide. If it is not in conformity with the
standard valve, adjust the depth of the
12B
valve guide till it is installed to the depth
required.
(b). Install the valve ② .

(c). Install the spring lower seat ① of the valve.
NOTICE:
Spread the engine oil on the valve stem before
installing the valve.
(d). Install the valve oil seal with the valve oil
seal pliers.
(e). Install the valve spring ③ and the valve

spring upper seat ② .
(f). Place the valve lock clamp ① at the
installation position.
(g). Install the valve lock clamp with the tools of

installing valve lock clamps.
NOTICE:
Knock the top of the valve with the copper bar
after finishing installing the valve lock clamp to
check whether the valve lock clamp is installed
into the appropriate position and install it again if
the valve lock clamp is loosed or bounced.
(h). Install the valve tappet.

NOTICE:
lubricate the external surface of the valve tappet
and the internal surface of tappet hole with the
engine oil before installing the valve tappet.
ENGINE MECHANICAL - PISTON AND CONNECTING ROD 12B-127
PISTON AND CONNECTING ROD

PARTS DRAWING
12B
1 Top compression ring 7 Connecting rod sleeve
2 Second compression ring 8 Connecting rod
Bearing shell of the connecting rod

3 Oil ring 9
(upper shell)
Bearing shell of the connecting rod

4 Snap ring of the piston pin 10
(lower shell)
5 Pistons 11 Connecting rod cap
6 Piston Pin 12 Connecting rod cap bolts

12B-128 ENGINE MECHANICAL - PISTON AND CONNECTING ROD
INSPECTION
1. Check the components of the piston

connecting rod visually
(a). Check whether there are drawing stamp,
crack, rag, scratch and abrasion on the
connecting rod and the connecting rod cap.
NOTICE:
If there is obvious abrasion on any part of the
connecting rod or the connecting rod cap, both of
them must be replaced together.
(b). Check whether there are cracks, scars or

other damages on the bearing shell of the
connecting rod and the piston pin, and
replace them if there are.
(c). Check whether there are cracks or

abrasion on the piston skirt, pin hole, top
and piston ring groove, and replace them if
there are.
2. Check the axial clearance of the piston

connecting rod
(a). Install the piston and connecting rod.
(b). Moving the connecting rod to one side,
and measure the axial clearance of the
piston connecting rod on the side of larger
clearance with the feeler gauge.
Standard axial clearance：0.160~0.312mm
Max axial clearance：0.35mm
• Replace the connecting rod components
if the clearance measured is larger than
12B
the limit clearance.
3. Check the oil film clearance of the

connecting rod
(a). Clean the stem and the shell of the
connecting rod to wipe off the oil film from
the connecting rod journal surface and the
internal surface of the connecting rod shell.
(b). Cut plastic clearance gauge material with
the same width of the connecting rod
shell, and place them on the journal of the
connecting rod, making it parallel with the
journal.
(c). Install the connecting rod and the

connecting rod cap carefully and fasten the
fixed bolts of the connecting rod cap.
Torque : 49N•m
(d). Remove the fixed bolts of the connecting
rod cap and remove the bearing shell
assembly of the connecting rod cap.
(e). Measure the width of the plastic oil gauge
material which is compressed with the
plastic oil gauge (width of the widest part) .
• If the oil clearance is greater than the
maximum value, replace the upper and
lower bearing shell of the connecting rod
and polish or replace the crankshaft if
necessary.
4. Check the diameter of the piston

(a). Check and measure the diameter of the
piston as shown in the fig.
(b). Compare and check the diameter of the
piston according to the letter identification
on the top of the piston and the table
below.
Letters Standard piston diameter(mm)

A 85.95~85.96
B 85.96~85.97
C 85.97~95.98
• If the diameter of the piston does not conform to

the standard diameter, replace the piston.
5. Calculate the clearance between the piston and the cylinder
(a). Check the diameter of the cylinder bore.(Refer To"Chapter 12B Engine Mechanical
Systerm- Cylinder Block,Checking")
Computing method:
The clearance between the piston and the cylinder = the diameter of the cylinder
bore - the diameter of the piston
• If the clearance between the piston and the cylinder does not conform to the
standard clearance, replace the piston,and bore or replace the cylinder if
necessary.
6. Check the oil clearance of the piston pin

(a). Measure the diameter of the mounting hole
on the piston pin.
(b). Check the excircle diameter of the piston
pin.
(c). The diameter of the mounting hole on the
piston pin - the excircle diameter of the
piston pin = the oil clearance between the
piston and the piston pin.
NOTICE:
If the oil clearance is greater than the clearance
value, replace the piston pin, and replace the
piston if necessary.
(d). Check the internal diameter of the bush at

the small end of connection rod.
(e). The diameter of the bush at the small end
of connection rod - the excircle diameter of
the piston pin = the oil clearance between
the piston pin and the bush at the small
end of connection rod.
• If the oil clearance is greater than the
maximum value, replace the bush of the
connection rod or the piston pin.
12B
7. Check the clearance between the piston

ring and the piston ring groove
(a). Measure the clearance between the piston
ring and the wall of the piston ring with the
feeler gauge.
•If the clearance is larger than the
maximum value, replace the piston.
The the clearance of the piston ring groove:
The first circular groove:0.04~0.085mm
The second circular
groove:0.03~0.07mm
Oil ring:0.03~0.13mm
8. Check the end gap of the piston ring

(a). Embed the piston ring in the cylinder hole.
(b). As shown in the figure, push the piston ring
into the cylinder hole by using the piston.
(c). Measure the piston ring end gap by using a feeler.

Standard opening clearance:
The first ring:0.20~0.40mm
The second ring: 0.35~0.55mm
Oil ring:0.20~0.90mm
NOTICE:
• If the opening clearance is larger than the maximum opening clearance, the piston ring
should be replaced.
• If the opening clearance is still larger than the maximum opening clearance after a new
piston ring is used, the four cylinders should be resized or the cylinder block should be
replaced.
REPLACEMENT
1. Decompose the piston connecting rod

assembly
(a). Use the piston ring expander to remove the
first and second piston rings.
(b). Take out the combination oil ring of the
piston by hand.
NOTICE:
When removing the oil ring, the oil ring spacer
may not be bended too much to avoid deformation 12B
of oil ring.
(c). Remove the piston pin clamping spring by

using the circlip plier.
(d). Remove the piston pin and the connecting
rod.
(e). Rinse out the connecting rod sleeve by

using the brushing rod.
2. Assemble the piston connecting rod

assembly
(a). Aiming at the connecting rod small oil
hole, press the connecting rod sleeve into
the connecting rod small hole by using a
special tool.
NOTICE:
• After the installation of the bush is completed,
check to ensure that the bush is flush with the
connecting rod small end face.
• After the installation, the oil film clearance of the
piston should be checked.
(b). Apply a layer of clean oil to the piston pin

evenly.
(c). Aim the little head of the connecting rod at
the piston pin hole, and insert the piston
pin into the piston pin hole.
NOTICE:
When assembling the piston connecting rod, the
forward marks should be in the same direction,
instead of the opposite direction.
(d). Install the piston pin clamping spring.

(e). Install the piston ring.

NOTICE:
When installing the oil ring, the cushion spring
comes first, and then is the top and bottom rails.
(f). Use the piston ring expander to install the
first and second piston rings.
NOTICE:
• The first piston ring has an "ATG" mark, ensure
to install with the mark toward the piston top.
• The second piston ring has an "A" mark, ensure
to install with the mark toward the piston top.
12B
12B-136 ENGINE MECHANICAL - CRANKSHAFT AND FLYWHEEL
CRANKSHAFT AND FLYWHEEL

PARTS DRAWING
1 Locating pin 5 Locating pin
2 The fixed bolts of the flywheel 6 Crankshaft
3 Flywheel 7 Woodruff key
4 Pilot bearing
ENGINE MECHANICAL - CRANKSHAFT AND FLYWHEEL 12B-137
INSPECTION
1. Check the radial runout of the crankshaft

main journal
(a). Place the crankshaft on theV-shape block.
(b). Measure the radial runout of the crankshaft
main journal with a micrometer.
The maximum radial runout is:0.06mm
• If the radial runout is greater than the
maximum value, the crankshaft should
be replaced. 12B
2. Check the diameter of the crankshaft main

journal
(a). Measure the diameter vertically of each
main journal with the spiral micrometer.
Standard diameter:57.981~58.000mm
• If it does not conform to the standard
value, the oil film clearance should
be checked, and grind or replace the
crankshaft when necessary.
3. Check the ovality of the crankshaft main
journal
(a). The result of the substraction of the
measurement value in the two directions is
the ovality of the main journal.
• If the ovality is greater than the maximum
value, the crankshaft should be replaced.
4. Check the diameter of the crankshaft

connecting rod neck
(a). Measure the diameter of each connecting
rod neck with the spiral micrometer.
The diameter of the connecting rod neck
is:47.981~48.000mm
• If the value is beyond the standard value,
the oil film clearance should be checked,
grind or replace the crankshaft when
necessary.
5. Che ck the ova li ty of the cr anksh aft
connecting rod neck
(a). The result of the substraction of the
measurement value in the two directions is
the ovality of the connecting rod neck, and
if the ovality is greater than the maximum
value, the crankshaft should be replaced.
Maximum ovality: 0.02mm
6. Check the oil film clearance of the

crankshaft
(a). Clean the crankshaft journal and all the
crankshaft bearings, and remove the oil
film on the crankshaft journal surface and
inside the bearing surface.
(b). Install the crankshaft.
(c). Cut plastic clearance gauge materials with
the same width of the bearing, and place
them on each shaft journal respectively,
and ensure that they are parallel with the
journal.
NOTICE:
When placing the plastic gauge materials, do not
turn the crankshaft.
ENGINE MECHANICAL - CRANKSHAFT AND FLYWHEEL 12B-139
(d). Place the crankshaft bearing cover

carefully according to the sequence as
shown in the figure, and fasten the fixed
bolts of the main bearing cap successively.
Torque : 78N•m
NOTICE:
Fasten the fixed bolts of the main bearing cap two
times.
12B
(e). Remove the bolt carefully and take out the

main bearing cap.
(f). Measure the width of the plastic oil gauge
material which is compressed by using the
plastic oil gauge. (width of the widest part)
Standard value: 0.020~0.051mm
NOTICE:
If the oil clearance is greater than the maximum
value, replace the lower bearing shell of the
crankshaft and polish or replace the crankshaft if
necessary.
7. Check the axial clearance of the crankshaft

(a). Push the crankshaft to one end, install and
fix the dial indicator.
NOTICE:
When measuring the crankshaft axial clearance,
ensure that the crankshaft meets the requirements
and has been installed correctly, the oil film
clearance is within the specified scope.
(b). Push the crankshaft in the opposite direction, and record the dial indicator reading.
Limit value:0.35mm
NOTICE:
• If the value of the crankshaft axial clearance is beyond the limit value, the thrust washer
needs to be replaced.
• When replacing the thrust washer, make the direction of the oil tank opening toward the
crankshaft.
8. Check the diameter of the fixed bolts of the

main bearing cap of the crankshaft
(a). Measure the length of the fixed bolts of the
main bearing cap of the cylinder by using
the vernier caliper.
NOTICE:
If the length is less than the limit value, the fixed
bolts of the main bearing cap of the crankshaft
should be replaced.
ENGINE MECHANICAL - CYLINDER BLOCK 12B-141
CYLINDER BLOCK
PARTS DRAWING
12B
1 Bolts of the reverse oil seal 6 Lower bearing of the crankshaft
2 Reverse oil seal 7 Upper bearing of the crankshaft
Bottom thrust washer of the

3 Cylinder block 8
crankshaft
4 Main bearing cap bolt 9 Top thrust washer of the crankshaft
5 Main bearing cover

12B-142 ENGINE MECHANICAL - CYLINDER BLOCK
INSPECTION
1. Check the surface flatness of the cylinder

block
(a). Measure the flatness of the top of the
cylinder block with a tight ruler and feeler.
Limit value:0.04mm
NOTICE:
If the flatness deviation is greater than the limit
value, grind the cylinder block surface mildly by
using the grinding machine, otherwise the cylinder
block should be replaced.
(b). Calculate the cylindricity of the cylinder

bore by using the bore table.
Standard value:
The first group:86.00~86.01mm
The second group: 86.01~86.02mm
The third group: 86.02~86.03mm
Cylinder bore cylindricity0.007mm
NOTICE:
If it wears serious, bore the cylinder and replace
the piston and cylinder piston rings; bore or
replace cylinder when necessary.
ENGINE MECHANICAL - CRANKSHAFT OIL SEAL 12B-143
CRANKSHAFT OIL SEAL

REPLACEMENT
1. Remove the front oil seal from the

crankshaft
(a). Turn the vehicle shift handle to gear five.
(b). Remove the drive belt of the generator.
(Refer To"Chapter 12B Engine Mechanical
Systerm - Drive Belt,Replacement")
(c). Remove the fixed bolt of the crankshaft belt
12B
pulley, and remove the crankshaft belt
pulley.
(d). Extract the front crankshaft oil seal.

NOTICE:
• Oil seal shall not be used again after being
taken down, a new oil seal should be used for
installation.
• Do not scratch the oil seal installation hole of the
sprocket chamber cover when extracting the oil
seal.
2. Install the crankshaft front oil seal

(a). Install the oil seal on the sprocket chamber
cover by using the installation tool of the
crankshaft oil seal.
NOTICE:
• Before installing the front oil seal of the
crankshaft, a layer of oil should be applied to the
lip.
• When pressing the oil seal, the end surface of
the oil seal should be flush with the inner shell of
the sprocket chamber.
12B-144 ENGINE MECHANICAL - CRANKSHAFT OIL SEAL
(b). Install the crankshaft belt pulley, fix and

fasten the fixed bolts.
Torque : 180N•m
(c). Install the generator drive belt.(Refer
To " C h a p t e r 1 2 B E n g i n e M e c h a n i c a l
Systerm - Drive Belt,Replacement")
3. Remove the crankshaft rear oil seal

(a). Remove the transmission assembly.
(Refer To"Chapter 21 Transmission Case –
Transmission Assembly,Replacement")
(b). R e m o v e t h e c l u t c h a s s e m b l y.
(Refer To"Chapter 22 Clutch – Clutch
Assembly,Inspection And Maintenance)
(c). Install the flywheel stop dog, loosen the
fixed bolt of the flywheel.
(d). Remove the flywheel stop dog.
(e). Remove the flywheel.
(f). Remove the fixed bolts which supports the

rear cover plate.
(g). Remove the fixed bolts of the crankshaft

rear oil seal seat, take down the rear oil
sea assembly and the rear oil seal seat
gasket assembly of the crankshaft.
NOTICE:
The crankshaft rear oil seal seat gasket shall not
be used again after it is taken down.
(h). Use a special tool to remove the rear oil
seal.
NOTICE:
Oil seal shall not be used again after being
12B
taken down, a new oil seal should be used for
installation.
4. Install the crankshaft rear oil seal

(a). Install the rear oil seal of the crankshaft by
using the rear oil seal guide tools.
NOTICE:
A layer of engine oil should be applied to the
lip of the crankshaft rear oil seal to facilitate the
installation.
(b). Apply the sealant evenly and continuously

on the crankshaft rear oil seal seat.
12B-146 ENGINE MECHANICAL - CRANKSHAFT OIL SEAL
(c). Install the crankshaft rear oil seal seat

cushion aiming at the dowel pin.
(d). Install the the crankshaft rear oil seal seat
assembly, fix and fasten the bolts.
Torque : 22N•m
(e). Install the rear cover plate, fix and fasten

the bolts.
Torque : 22N•m
(f). Apply the Loctite 263 sealant to the
flywheel bolts evenly.
Requirement for the glue line: single
straight line
(g). Install the flywheel to the crankshaft, fix

and screw the bolts tight by hand.
(h). Install the flywheel stop dog, and fix the

flywheel.
(i). Tighten the flywheel bolts to the specified
torque three times in a diagonal cross
order.
Torque : 100±5 N•m
12B
(j). Remove the flywheel stop dog.

- MEMO -
FUEL
FUEL SYSTEM ..................................... 13-1
NOTICES .......................................... 13-1
SYMPTOMS ..................................... 13-2
PARTS DRAWING ............................ 13-3
FUEL TANK .......................................... 13-5
REPLACEMENT ............................... 13-5
FUEL LEVEL SENSOR ASSEMBLY .... 13-9
REPLACEMENT ............................... 13-9
FUEL FILTER ASSEMBLY ................. 13-10
REPLACEMENT ............................. 13-10 13
FUEL TANK CAP COVER .................. 13-15
REPLACEMENT ............................. 13-15
FUEL TANK CAP ................................ 13-17
CHECKING ..................................... 13-17
FUEL - FUEL SYSTEM 13-1
FUEL SYSTEM
NOTICES
1. Since fuel is hazardous and flammable, be sure to keep spark or flame source, such
as cigarrette,working lamp, arc unit and switch, away from the site before working
on the fuel system. It is also important to equip fire extinguisher and ventilation
system at the site, in order to avoid personal casualty.
2. Disconnect the negative battery cable before overhauling the fuel system.
3. When disassembling the fuel pipes, collect the discharged fuel with a proper
container.
4. Since there is pressurized fuel inside the fuel pump, high-pressure fuel pipes and
fuel rail, do not unscrew any fuel connector when the engine is running, in order to 13
prevent personal injury.
5. Keep the fuel away from any part or component made of rubber or leather.
6. Since the fuel injection unit is a precise component, keep the site clean when
operating the fuel system. Seal the disconnected fuel connector to prevent
impurities from entering.
7. Before disconnecting the fuel pipes, clean the dirt or impurities around the fuel
connector, or i may enter the connector and damage the fuel system.
8. The cleaner should not get in touch with the rubber or plastic parts in the fuel
system, or it may lead to fuel leakage.
9. Do not twist the fuel pipes by force.
10. Make sure there is no damage or dirt on the fuel connectors before connecting the
fuel pipes.
11. Wear safety goggles when working on or near fuel-related parts and components,
or the injected fuel may injure your eyes.
12. The removed fuel system parts and components shall be placed in a clean area.
13. Since zinc, manganese and other active metals may be easily dissolved by diesel,
it may result in injector coking under high temperature and thus block the nozzle.
Therefore, do not use any part containing zinc, manganese or other active metals in
the pipes of pressurized common-rail fuel system.
14. Keep the interior of the fuel system clean and free of rust, weld slag or other
impurities, or it may lead to fuel pipe blockage, automatic switch-off of the engine
or even damage the precise fuel common-rail parts and components in extreme
circumstance.
13-2 FUEL - FUEL SYSTEM

The table below can help you to rapidly find out the required malfunction information.
Malfunction
Possible Cause Reference
Symptoms
Fuel pump relay broken Replace fuel pump relay
No fuel or inferior fuel in fuel

Use quality fuel
tank
Air in fuel system Discharge air
Fuel pipe blocked or leaking Clean fuel system or replace defective parts
Engine unable Fuel screen blocked or broken Replace fuel screen

or hard to start High-pressure fuel pump
Overhaul or replace high-pressure fuel pump
blocked or broken
Glow plug broken Replace glow plug
Injector solenoid valve defective Overhaul or replace injector solenoid valve
Injector control or circuit

Troubleshoot with analyzer
defective
No fuel or inferior fuel in fuel

Use quality fuel
tank
Air in fuel system Discharge air
Fuel pipe blocked or leaking Clean fuel system or replace defective parts
Engine idle Injector blocked and doesn't
Overhaul or replace injector
rough work
Injector control or circuit

Troubleshoot with analyzer
defective
High-pressure fuel pump

Overhaul or replace high-pressure fuel pump
blocked or broken
Inferior fuel Use quality fuel
Low-pressure fuel pipe blocked

Engine loss of Clean fuel system or replace defective parts
or with insufficient pressure
power
Injector doesn't work Overhaul or replace injector
High-pressure fuel pump broken Overhaul or replace high-pressure fuel pump
Black fume from Poor performance of fuel injector Overhaul or replace injector
the engine Injector control defective Troubleshoot with analyzer
FUEL - FUEL SYSTEM 13-3
PARTS DRAWING
16
19
15
18
21
22
17
13
20 23
24
25
1 27 26
13 30
11
2 4
3 5 9 14 28
6 29
12
10
7
fuwx13A001
13-4 FUEL - FUEL SYSTEM
1 Oil pipe assembly 16 Hinge pin
Hexagon head bolt ,spring washer and

2 Oil-water separator assembly 17
flat washer subassembly
3 Type I all-metal hexagon nuts 18 Fuel tank rear drawstring assembly
4 Screw 19 Fuel tank front drawstring assembly
5 Fuel filter bracket 20 Fuel tank assembly
6 Spring type elastic hose clamps 21 Rubber hose 7
Type A worm transmission type hose

7 Rubber hose 22
hoop
8 Fuel tube clip 23 Rubber hose 6

9 Fuel steel pipe 24
hoop
10 Fuel steel pipe 25 Hexagonal flange nut
AType A worm transmission type

11 26 Refueling pipe assembly
hose hoop
12 Rubber hose 27 Oil filler port rubber seat circlip 2
13 Return pipe assembly 28 Oil filler port rubber seat circlip 1
14 Oil pipe assembly 29 Oil filler port rubber seat
15 Hinge pin 30 Fuel tank cover assembly

FUEL - FUEL TANK 13-5
FUEL TANK
REPLACEMENT
NOTICE:
• Ensure the working site is equipped with fire extinguishers before operaing the fuel
system.
• Do not use any spark or flame source during the operation of the fuel system.
• After the disconnection of fuel pipeline, timely wrap and seal the fuel pipeline ports to
prevent the ingress of impurities into the fuel pipeline ports.
1. Disconnect the negative cable of the battery (Refer to "Chapter 18 Starting &
2. Lift up the vehicle 13
3. Remove the fuel tank assembly

(a). Use a fuel recoverer to recover the fuel.
(b). Place a bracket beneath the fuel tank and
enable it to bear a light load.
fuwx13A002
(c). Loosen the fuel tank filler pipe and

breather pipe clamps and unplug the pipes.
fuwx13A003
13-6 FUEL - FUEL TANK
(d). Remove the fastening bolts for the front

and rear straps of the fuel tank and
slowly lower the bracket to lower the fuel
tank assembly, until the fuel level sensor
connector is visible.
fuwx13A004
(e). Disconnect the connector of fuel level

sensor.
fuwx13A005
(f). Press the lock pin of fuel pipe connector,

disconnect the fuel outlet pipe connector
and fuel return pipe connector, and take
out the fuel tank assembly.
NOTICE:
Add the assembly markings to the fuel pipes and
corresponding mounting holes.
fuwx13A006
FUEL - FUEL TANK 13-7
(g). Remove the fuel level sensor assembly. (Refer to "Chapter 13 Fuel - Fuel Level
Sensor Assembly,Replacement")
(h). Loosen the connecting clamps of fuel tank

filler pipe and breather pipe from the fuel
tank and unplug the fuel pipes.
13
fuwx13A007
4. Install the fuel tank assembly

(a). Install the fuel tank filler pipe and breather
pipe onto the fuel tank and tighten the
fastening clamps.
(b). Remove the fuel level sensor assembly.
(Refer to "Chapter 13 Fuel - Fuel Level
Sensor Assembly,Replacement")
(c). Place the fuel tank assembly on a bracket
and slowly elevate the fuel tank.
fuwx13A007
(d). Install the fuel tank outlet pipe and return

pipe to the fuel level sensor as per the
markings, until a clear “click” sound is
heard.
fuwx13A006
13-8 FUEL - FUEL TANK
(e). Connect the connector of fuel level sensor

assembly, until a clear “click” sound is
heard.
fuwx13A005
(f). Slowly elevate the fuel tank to the

installation position and install and tighten
the fastening bolts for front and rear straps
of the fuel tank.
Torque:41~51N•m
fuwx13A004
(g). Install the fuel tank filler pipe and breather

pipe and tighten the fastening clamps.
NOTICE:
Before the installation of breather pipe, check for
secure fixing, in order to prevent abnormal wear.
fuwx13A003
5. Take out the bracket, lower the vehicle, and add fuel
6. Connect the negative cable of the battery (Refer to "Chapter 18 Starting & Charging
- Battery, Replacement")
FUEL - FUEL LEVEL SENSOR ASSEMBLY 13-9
FUEL LEVEL SENSOR ASSEMBLY

REPLACEMENT
1. Remove the fuel tank assembly (Refer to "Chapter 13 Fuel - Fuel Tank,
Replacement")
2. Remove the fuel level sensor

(a). Turn and remove the seawl counterclockwise.
(b). Remove the fuel level sensor assembly.
13
fuwx13A008
3. Install the fuel level sensor

(a). Align the triangle mark on the fuel level
sensor assembly with that on the fuel tank
housing.
(b). Install the seal and tighten it clockwise.
fuwx13A019
4. Install the fuel tank assembly (Refer to "Chapter 13 Fuel - Fuel Tank, Replacement")
13-10 FUEL - FUEL FILTER ASSEMBLY
FUEL FILTER ASSEMBLY

REPLACEMENT
1. Disconnect the negative cable of the battery (Refer to "Chapter18 Starting &
2. Remove the Fuel filter assembly

(a). Disconnect the connector of fuel filter
heater.
fuwx13A009
(b). Disconnect the connector of fuel filter

water level sensor.
fuwx13A020
FUEL - FUEL FILTER ASSEMBLY 13-11
(c). Drain the fuel from fuel filter.

• Press the lock pin to unplug the fuel inlet
pipe of the fuel filter.
fuwx13A010 13
• Press the lock pin to unplug the fuel outlet

pipe of fuel filter and collect the drained
fuel with a specified container.
fuwx13A011
(d). Remove the nuts from the fastening bolts

of fuel filter assembly and take out the fuel
filter assembly.
fuwx13A012
3. Install the Fuel filter assembly

(a). Install and tighten the nuts on the fastening
bolts of fuel filter assembly.
Torque:12~14N•m
fuwx13A012
(b). Install the fuel filter outlet pipe to the fuel

filter, until a clear “click” sound is heard.
fuwx13A011
(c). Install the fuel filter inlet pipe to the fuel

filter, until a clear “click” sound is heard.
fuwx13A010
FUEL - FUEL FILTER ASSEMBLY 13-13
(d). Install the connector of fuel filter water

level sensor, until a clear “click”sound is
heard.
fuwx13A020 13
(e). Install the connector of fuel filter heater,

until a clear “click” sound is heard.
fuwx13A009
4. Bleed the air from the fuel filter

(a). Loosen the air bleeding screw.
fuwx13A013
(b). Press the cap to pump the fuel for

approximate 30 times, until the fuel filter is
full of fuel.
fuwx13A014
(c). Tighten the air bleeding screw.

Torque:1.5N•m
fuwx13A013
FUEL - FUEL TANK CAP COVER 13-15
FUEL TANK CAP COVER

REPLACEMENT
1. Remove the fuel tank cap gate

(a). Pull the fuel tank cap gate cable.
13
fuwx13A015
(b). Unscrew the retaining bolts of the cap

cover and remove the cover and the cap
from the tank.
fuwx13A016
13-16 FUEL - FUEL TANK CAP COVER
2. Install the fuel tank cap gate

(a). Install the fuel tank cap gate and install and
tighten the fastening bolts.
NOTICE:
If the fuel tank cap gate fails to close closely,
appropriately adjust the bayonet position of the
gate.
(b). Install the fuel tank cap onto the gate.
fuwx13A016
3. Close the fuel tank cap gate

FUEL - FUEL TANK CAP 13-17
FUEL TANK CAP

CHECKING
1. Turn off the ignition switch

2. Open the cap cover (Refer to "Chapter 13 Fuel - Fuel Tank Cap Cover, Replacement")
3. Unscrew the fuel tank cap counterclockwise
13
fuwx13A017
4. Check the fuel tank cap

(a). Check for damage or distortion on the tank
cap and base and replace them if needed.
(b). Check the seal inside the tank cap and
apply some lubricant if needed.
fuwx13A018
13-18 FUEL - FUEL TANK CAP
5. Tighten the fuel tank cap clockwise
fuwx13A017
6. Close the fuel tank cap cover

INTAKE AIR
INTAKE AIR SYSTEM .......................... 14-1
NOTICES .......................................... 14-1
SYMPTOMS ..................................... 14-2
PARTS DRAWING ............................ 14-3
AIR FILTER ASSEMBLY....................... 14-4
REPLACEMENT ............................... 14-4
INTER-COOLER ASSEMBLY .............. 14-7
REPLACEMENT ............................... 14-7
INTAKE LINE ...................................... 14-10
REPLACEMENT ............................. 14-10
14
INTAKE AIR - INTAKE AIR SYSTEM 14-1
INTAKE AIR SYSTEM

NOTICES
1. The filter is mainly functioned to prevent the ingress of dust and sand into the intake
system.
2. To avoid impuriy entry, the intake air must be filtered before entrying the engine.
If the intake pipe is broken or loosen, the unfiltered air will enter and can abrade
engine rapidly.
3. The intake line connection must be reliable enough to avoid leaks and looseness,
etc.
4. The connection between intake pipe and bracket must be firm and reliable, free of
visible crack and/or leakage on the connection to intake rubber pipe. The connection
between cushion and intake pipe bracket must be reliable. 14
5. When using compressed air, wear proper protective goggles and mask. Flying
fragment and dirt may lead to personal injury.
14-2 INTAKE AIR - INTAKE AIR SYSTEM

Malfunction
Symptoms
Broken or leaking intake line Check and replace intake line
Ventilation check valve in

Flunctuating Replace ventilation check valve in crankcase
crankcase is stuck
engine at idle
Overly fouling at inlet Clean inlet
Broken or leaking inter-cooler Replace inter-cooler
Difficult Air filter blocked Replace air filter element

ignition or slow
Intake duct blocked Check or replace intake line
acceleration
Abnormal fuel Air filter blocked Replace air filter element
consumption, Intake line blocked Check or replace intake line

black smoke Broken or leaking inter-cooler Replace inter-cooler
Noise in Foreign object in intake duct Check intake line

turbocharger Dirty or contaminated air filter Replace air filter element
INTAKE AIR - INTAKE AIR SYSTEM 14-3
PARTS DRAWING
3
4
7
1 5
6
10
9
10
8 14
10
5
12
11
fuwx14A001
1 Air filter intake plastic pipe 7 Air filter housing
2 Air filter assembly 8 Intercooler intake hose bracket
Cross recessed pan head tapping

3 9 Intercooler intake hose
screw and flat washer assembly

4 10 Type T spring strong clamp (D74)
hoop
Hexagon head bolt ,spring washer and
5 11 Intercooler assembly
flat washer subassembly

6 12 Engine intake hose
hoop
14-4 INTAKE AIR - AIR FILTER ASSEMBLY
AIR FILTER ASSEMBLY

REPLACEMENT
Charging - Battery,Replacement")
2. Remove the air filter assembly

(a). Pull out the lock pin along the direction
shown by arrow in the figure.
fuwx14A002
(b). Vertically press down the pin and unplug

the connector of intake flow sensor.
fuwx14A003
(c). Unscrew the clip screw and unplug the air

filter outlet hose.
fuwx14A004
(d). Remove the air filter assembly bolt.
fuwx14A005
INTAKE AIR - AIR FILTER ASSEMBLY 14-5
(e). Remove the air filter assembly bolt.

(f). Remove the air filter assembly.
fuwx14A006
14
3. Mount the air filter assembly
(a). Install the air filter assembly onto the
body and install and tighten the fastening
bolts.
Torque:21~25N•m
fuwx14A006
(b). Install and tighten the fastening bolt of the

air filter.
Torque:21~25N•m
fuwx14A005
14-6 INTAKE AIR - AIR FILTER ASSEMBLY
(c). Install the air outlet hose of air filter onto

the air filter and tighten the clamp screws.
fuwx14A004
(d). Install the air intake flow sensor connector,

till one clear “click” sound is heard.
fuwx14A003
(e). Push the lock pin in place along the

direction shown by arrow in the figure.
fuwx14A007
4. Connect the negative cable of the battery (Refer to "Chapter18 Starting & Charging
INTAKE AIR - INTER-COOLER ASSEMBLY 14-7
INTER-COOLER ASSEMBLY
REPLACEMENT
2. Remove the front bumper assembly (Refer to "Chapter 56 Interior & Exterior Trims -
Front Bumper Assembly, Replacement")
3. Remove the inter-cooler intake rubber pipe (Refer to "Chapter 14 Intake Air - Intake
Line,Replacement")
4. Remove the engine intake rubber pipe (Refer to "Chapter 14 Intake Air - Intake
Line,Replacement")
5. Install the inter-cooler assembly

14
(a). Unscrew the A/C pipe bolt and remove the
A/C pipe.
fuwx14A008
(b). Unscrew the inter-cooler bolt.
fuwx14A009
14-8 INTAKE AIR - INTER-COOLER ASSEMBLY
(c). Unscrew the inter-cooler bolt.Remove the

inter-cooler assembly.
fuwx14A010
6. Mount an inter-cooler assembly

(a). Install the inter-cooler assembly onto the
body and install and tighten the upper
fastening bolts.
Torque:21~25N•m
fuwx14A010
(b). Install and tighten the lower fastening bolts

of the inter-cooler.
Torque:21~25N•m
fuwx14A009
INTAKE AIR - INTER-COOLER ASSEMBLY 14-9
(c). Install and tighten the fastening bolts of

A/C pipeline bracket.
fuwx14A008
14
7. Mount the engine intake rubber pipe (Refer to "Chapter 14 Intake Air - Intake Line,
Replacement")
8. Mount the inter-cooler intake rubber pipe (Refer to "Chapter 14 Intake Air - Intake
Line,Replacement")
9. Mount the front bumper assembly (Refer to "Chapter56 Interior & Exterior Trims -
Front Bumper Assembly, Replacement")
14-10 INTAKE AIR - INTAKE LINE
INTAKE LINE
REPLACEMENT

2. Open the engine hood
3. Replace the air cleaner plastic intake pipe

(a). Remove the front-right wing.
(b). Unscrew the bolt and remove the air
cleaner plastic intake pipe.
fuwx14A011
(c). Mount a new plastic intake pipe for air

cleaner and tighten the bolt.
Torque:9~11N•m
(d). Mount the front-right wing.
fuwx14A011
4. Replace the air filter outlet hose

(a). Loosen the bolts of connecting clamps
between air outlet hose and air filter and
pull out the air outlet hose of air filter.
fuwx14A004
INTAKE AIR - INTAKE LINE 14-11
(b). Loosen the bolts of connecting clamps

between air outlet hose and turbocharger
and pull out the air outlet hose of air filter.
fuwx14A012
14
(c). Install the air outlet hose of air filter onto
the air filter and tighten the clamp bolts.
fuwx14A004
(d). Install the air outlet hose of air filter onto

the turbocharger and tighten the clamp
bolts.
fuwx14A012
5. Replace the inter-cooler intake rubber pipe

(a). Unscrew the rear-end clip screw of the
inter-cooler intake rubber pipe and remove
the pipe.
fuwx14A013
(b). Remove the bolt of the retaining bracket for

the inter-cooler intake rubber pipe.
fuwx14A014
(c). Unscrew the front-end clip screw of the

inter-cooler intake rubber pipe and remove
the pipe.
fuwx14A015
(d). Mount a new inter-cooler intake rubber

pipe and tighten the front-end clip screw.
fuwx14A015
14
(e). Tighten the rear clip screw of the inter-
cooler intake rubberpipe.
fuwx14A013
(f). Tighten the bolt of the retaining bracket for

the inter-cooler intake rubber pipe.
Torque:9~11N•m
fuwx14A014
6. Replace the engine intake rubber pipe

(a). Unscrew the rear-end clip screw of the
engine intake rubber pipe and remove the
pipe.
fuwx14A016
(b). Unscrew the front-end clip screw of the

engine intake rubber pipe and remove the
pipe.
fuwx14A017
(c). Mount a new engine intake rubber pipe and

tighten the front-end clip screw.
fuwx14A017
(d). Tighten the rear clip screw of the engine

intake rubber pipe.
fuwx14A016
14
7. Restore the engine hood
- MEMO -
EXHAUST
EXHAUST SYSTEM ............................. 15-1
NOTICES .......................................... 15-1
SYMPTOMS ..................................... 15-2
PARTS DRAWING ............................ 15-3
EXHAUST PIPE ................................... 15-4
REPLACEMENT ............................... 15-4
15
EXHAUST - EXHAUST SYSTEM 15-1
EXHAUST SYSTEM
NOTICES
1. Before the servicing,the mechanic shall wear necessary protective shoes, gloves
and goggles,to ensure personal safety.
2. Before lifting the vehicle, check whehter the lifing system is working properly,
whehter the vehicleis appropriately parked and whehter the connection points
between the lifting arm and the vehicleare optimally adjusted. Before lifting or
lowering the vehicle, ensure the space beneath the vehicleis clear.
3. Use genuine or authorized parts and components instead of unauthorized ones, or
it may affectthe normal operations of the vehicle.
4. Switch off the ignition before operating the exhaust system and cooling down, or it
may causeburn.
5. Replace the exhaust pipe washer after each disassembly to ensure its air-tightness.
6. When assembling or disassembling the rubber hanger of the exhaust pipe, apply 15
some engineoil at the connection to facilitate the work.
7. When assembling or disassembling the oxidation catalysts, doesn't wet or
contaminate the catalystinside the assembly, or it will no longer work.
15-2 EXHAUST - EXHAUST SYSTEM

Malfunction
Symptoms
Silencer assembly broken or
Replacement silencer assembly
leaking
Front exhaust pipe assembly

Replacement front exhaust pipe assembly
broken or leaking
Noisy exhaust
Rear exhaust pipe assembly
Replacement rear exhaust pipe assembly
broken or leaking
Exhaust manifold broken or

Replace exhaust manifold washer or assembly
leaking
Oxidation catalysts assembly

High exhaust Replacement oxidation catalysts assembly
blocked
temperature
Mixture not fully combusted Check for blockage in the intake air system
Inferior fuel blocks oxidation Clean fuel system and replace oxidation catalysts
Exhaust pipe catalysts assembly assembly
blocked Engine oil is burnt, which blocks
Overhaul cylinders and pistons
catalyst converter assembly
Exhaust pipe seal damaged Replacement seal
Overhaul exhaust pipe

Exhaust pipe Uneven connection of exhaust
connection and
leaking pipe
replace assembly if needed
Exhaust pipe broken Replacement exhaust pipe assembly

EXHAUST - EXHAUST SYSTEM 15-3
PARTS DRAWING
9
6
6 11
6
8
10
5 15
5 7
6
2
3 6
1 4
fuwx15A001
1 Spring washer 7 Sealing gasket
2 Flat washer 8 All-metal hexagon flange face nuts
3 Type I hexagon nuts 9 Muffler heat shield
4 Front exhaust pipe assembly 10 Front muffler and pipe assembly
5 Hexagon flange bolt 11 Rear exhaust pipe assembly
6 Rubber lug
15-4 EXHAUST -EXHAUST PIPE
EXHAUST PIPE
REPLACEMENT
NOTICE:
• When assembling or disassembling the rubber hanger, apply some engine oil on the
interface tofaciliate assembly or disassembly.
• Replace a new seal when installing the exhuast pipe and do not reuse the old seal, or it
may affectthe air-tightness.
• After long-term use, the seal may stick to the interface. Thus, before installing a new seal,
cleanthe interface with a scraper to avoid potential leakage.

2. Wait for it cooling down
4. Remove the rear exhaust pipe assembly

(a). Unscrew the connecting nuts between the
rear exhaustpipe assembly and the silencer
assembly, and removethe seal.
fuwx15A002
(b). Apply some engine oil on the rubber

hanger and remove the rubber hanger of
the rear exhaust pip eassembly and then
the assembly.
fuwx15A003
EXHAUST - EXHAUST PIPE 15-5
5. Remove the silencer assembly

(a). Unscrew the connecting nuts between the
silencer assembly and the front exhaust
pipe assembly, andremove the seal.
fuwx15A004

15
hanger and remove the front rubber hanger
of the silencer.
fuwx15A005
(c). Apply some engine oil on the rubber

hanger andremove the rear rubber hanger
of the silencer and thenthe silencer
assembly.
fuwx15A007
6. Remove the front exhaust pipe assembly

(a). Unscrew the connecting nuts between
the frontexhaust pipe assembly and the
silencer assembly,and remove the seal.
fuwx15A008

hanger and remove the rubber hanger of
the front exhaust pipe assembly and then
the assembly.
fuwx15A009
7. Remove the lower engine baffle (Refer to "Chapter 04 Vehicle Maintenance

-Replacement, Engine Oil And Oil Filter Replacement)
8. Remove the oxidation catalysts

(a). Remove the connecting bolts between the
oxidation catalysts and the bracket.
fuwx15A006
(b). Remove the connecting bolts between the

oxidation catalysts and the turbocharger
and then the oxidation catalysts assembly
and the seal.
fuwx15A010
9. Install the oxidation catalysts

15
(a). Install the washer and the catalyst
converter assembly and tighten the
connecting bolts.
Torque:22~27N•m
fuwx15A010
(b). Install and tighten the connecting bolts

between the oxidation catalysts and the
bracket.
Torque:45~55N•m
fuwx15A006
10. Install the front exhaust pipe assembly

(a). Install the rubber hanger of the front
exhaust pipe assembly.
fuwx15A009
(b). Clean the interface between the catalyst

converter and the front exhuast pipe
assembly and install a new seal.
(c). Connect the front exhaust pipe assembly
and the oxidation catalysts assembly and
tighten the connecting nuts.
Torque:45~55N•m
fuwx15A008
11. Install the silencer assembly

(a). Install the rear rubber hanger of the
silencer.
fuwx15A007
(b). Install the front rubber hanger of the

silencer.
fuwx15A005
(c). Clean the interface between the front

15
exhuast pipe assembly and the silencer,
and install a new seal.
(d). Connect the front exhaust pipe assembly
and the silencer assembly and tighten the
connecting nuts.
Torque:45~55N•m
fuwx15A004
12. Install the rear exhaust pipe assembly

(a). Install the rubber hanger of the rear
exhaust pipe assembly.
fuwx15A003
(b). Clean the interface between the silencer

and the rear exhaust pipe assembly, and
install a new seal.
(c). Connect the silencer assembly and the
rear exhaust pipe assembly and tighten the
connecting nuts.
Torque:45~55N•m
fuwx15A002
13. Remove the lower engine baffle (Refer to "Chapter 4 Vehicle Maintenance -
Replacement, Engine Oil And Oil Filter Replacement )
COOLING
COOLING SYSTEM ............................. 16-1
NOTICES .......................................... 16-1
SYMPTOMS ..................................... 16-2
ONBOARD CHECKING .................... 16-3
COOLANT ............................................ 16-5
REPLACEMENT ............................... 16-5
HEAT RADIATOR ................................. 16-8
REPLACEMENT ............................... 16-8
ELECTRONIC FAN ............................ 16-11
REPLACEMENT ............................. 16-11
16
COOLING - COOLING SYSTEM 16-1
COOLING SYSTEM
NOTICES
1. Do not open the coolant filler cap when the vehicle is hot. It can only be opened
when the engine cools down to the ambient temperature. Otherwise the hot coolant
or steam may lead to personal injury.
2. When disconnecting the cooling system or drain the coolant, collect it in a specified
container.If the coolant is unsuitable to recycle, dispose it as required.
3. Use FOTON approved coolant only. Do not mix the coolants of differnt types and/or
different models.
4. Do not use water as coolant, which may cause scale in the cooling system or even
damage the engine.
5. When disconnecting the pipes of the cooling system, do not let debris enter the
pipes, or it may damage the cooling system and/or the engine.
6. When disconnecting the fittings of the cooling system, seal the openings to prevent
dirt or impurities from entering. 16
7. Since coolant is poisonous, oral intake is strictly forbidden. If in touch with skin,
clean and rinse it immediately.
8. After topping up the coolant, ensure to drain air from the engine cooling system, or
the engine may become overheated.
9. Frequently clean the exterior of the heat radiator and prevent dust, leaves and other
impurities from affecting the radiation performance.
16-2 COOLING - COOLING SYSTEM

Malfunction
Symptoms
Lack of coolant Fill up coolant to normal level
Check leakage point and replace

Coolant leakage
damaged parts if necessary
Unnecessary air in cooling pipe Drain air in cooling system
Faulty thermostat Replace thermostat
Check and adjust injector advance angle if

Noisy engine
necessary
Overheated
Poor radiation due to impurities
water in engine Clean exterior impurities
on heat radiator exterior,
Poor radiation due to internal

Clean or replace heat radiator
blockage
Check electronic fan harness or replace electronic

Electronic fan not working
fan
Blockage in cooling system pipe Clean or replace pipe
Damaged coolant filler cap Replace coolant filler cap
Cold water in Electronic fan runs frequently Check electronic fan and harness
engine Thermostat is always open Check or replace thermostat
Heat radiator leakage Check or replace heat radiator
Aged and leaking cooling pipe Replace cooling pipe
Loose or leaking water pump

Replace water pump
bearing
Insufficient
Damaged coolant filler cap Replace coolant filler cap
engine coolant
Damaged engine cylinder
Replace cylinder gasket
gasket
Leakage in engine cylinder or

Replace plug
cylinder head plug
Strange noise in Faulty electronic fan Check or replace electronic fan

engine Faulty water pump Check or replace water pump
Open-circuit fuse Replace fuse
Faulty relay Replace relay

Electronic fan
Faulty coolant temperature
not working Replace coolant temperature sensor
sensor
Faulty engine control unit Check and replace engine control unit
COOLING - COOLING SYSTEM 16-3
ONBOARD CHECKING
1. If the coolant decreases quickly, check whether there is any leakage in the cooling
system
(a). Turn off the ignition switch.
(b). Open the engine hood.
(c). Unscrew the coolant filler cap.

NOTICE:
Do not open the coolant filler cap when the
vehicle is hot. It can only be opened when the
engine cools down to the ambient temperature.
Otherwise the hot coolant or steam
may lead to personal injury.
16
fuwx16A002
(d). Install a testing tool on the opening of the

coolant reservoir and pressurize the
cooling system at 1.4 bar.
(e). Observe the pressure measurement. If the
pressure remains stable over time, it
means the system is properlysealed. If
the pressure drops quickly, it means the
system is poorly sealed, with possible
leakage. It is necessary to carefully check
all parts of the cooling system.
fuwx16A003
2. Check the electronic fan

(a). Turn off the ignition switch.
(b). Open the engine hood.
16-4 COOLING - COOLING SYSTEM
(c). Disconnect the electronic fan connector.
fuwx16A004
(d). Test the electronic fan with battery, current

meter and wires.
"1" refers to the negative pole of the
battery. "2" refers to the positive pole of the
battery in the serial connected with a curren
connected with a t meter. "3" refers to the
negative pole of the main electronic fan. "4"
refers to the low-speed level of the master
electronic fan. "5" refers to the high-speed
level of the master electronic fan. "6" refers
to the negative pole of the supplementary
electronic fan. And "7" refers to the high-
fuwx16A005 speed level of the supplementary electronic
fan.
• Connect "1" to "3" and "2" to "4". Now the
master electronic fan runs in low speed
and the current meter shows ≤ 10A.
master electronic fan runs in high speed
and the current meter shows ≤ 17A.
supplementary electronic fan runs
in high speed and the current meter
shows ≤ 19A.
(e). Plug the electronic fan connector back to
its place.
(f). Restore the engine hood.
fuwx16A004
COOLING - COOLANT 16-5
COOLANT
REPLACEMENT

2. Wait until the engine cools down
3. Slowly open the coolant filler cap

DANGER:
Do not open the coolant filler cap before the
engine cools down to the ambient temperature.
Otherwise the hot coolant or steam may lead to
personal injury.
16
fuwx16A002
5. Remove the lower engine baffle

(a). Unscrew the retaining bolts of the small
baffles on both sides and remove the
baffles.
fuwx16A006
16-6 COOLING - COOLANT
(b). Unscrew the retaining bolts of the front

baffle and remove the baffle.
6. Slowly unscrew the coolant drainage plug

and drain the coolant
NOTICE:
Collect the coolant in a specified container. If not
recycled,it shall be disposed properly.
fuwx16A008
7. Once the coolant is drained up, tighten the plug
8. Remove the upper engine baffle

(a). Install the front baffle and tighten the
retaining nuts.
Torque:23±2N·m
COOLING - COOLANT 16-7
(b). Install the small baffles on both sides and

Torque:23±2N·m
fuwx16A006
10. Top up the engine coolant to the specified 16

level
Volume: 9L
fuwx16A009
11. Tighten the coolant filler cap

NOTICE:
Remember to turn the free point on the inlet cap
to that between the two free points on the inlet.
12. Start the engine and accelerate to 2,500
RPM, until the electronic fan runs quickly.
Check whehter the coolant in the coolant
reservoir reaches the specified level. If not,
continue to top it up to the said level
fuwx16A002
16-8 COOLING - HEAT RADIATOR
HEAT RADIATOR
REPLACEMENT

2. Remove the electronic fan assembly and the coolant reservoir assembly (Refer to
"Chapter 16 Cooling - Electronic Fan, Replacement")
3. Remove the heat radiator assembly

(a). Unscrew the clip screw of the engine water
outlet hose and pull out the hose.
fuwx16A010
(b). Unscrew the clip screws of the engine

water inlet hose and the heat radiator water
inlet hose and put out the hoses.
fuwx16A011
COOLING - HEAT RADIATOR 16-9
(c). Unscrew the retaining bolts and nuts and

remove the heat radiator assembly.
fuwx16A012
4. Install heat radiator assembly

(a). Replace it with a new heat radiator assembly
and tighten the retaining bolts and nuts.
Bolt Torque: 45~55N•m
Nut Torque: 45~55N•m 16
fuwx16A012
(b). Install the engine water inlet hose and the

heat radiator inlet hose, and tighten the clip
screws.
fuwx16A011
16-10 COOLING - HEAT RADIATOR
(c). Install the engine water outlet hose and

tighten the clip screw.
fuwx16A010
5. Install the electronic fan assembly and the coolant reservoir assembly (Refer to
"Chapter 16 Cooling - Electronic Fan, Replacement")
COOLING - ELECTRONIC FAN 16-11
ELECTRONIC FAN
REPLACEMENT

2. Disconnect the negative cable of the battery (Refer to "Chapter 18 Starting & Charging-
Battery, Replacement")
3. Drain the coolant (Refer to "Chapter 16 Cooling - Coolant, Replacement")
4. Remove the coolant reservoir assembly

(a). Loose the clip screws of the heat radiator
air outlet hose and the engine air outlet
hose, and pull out the hoses.
16
fuwx16A013
(b). Loose the clip screw of the heat radiator

water inlet hose and pull out the hose.
fuwx16A014
16-12 COOLING - ELECTRONIC FAN
(c). Unscrew the retaining bolts of the coolant

reservoir assembly and remove the assembly.
fuwx16A015
5. Remove the electronic fan assembly

(a). Disconnect the electronic fan connector.
fuwx16A004
(b). Remove the harness connector at the left.
fuwx16A016
(c). Remove the harness connector at the right.
fuwx16A017
(d). Unscrew the retaining bolts of the

electronic fan assembly and remove the
assembly. 16
6. Install the electronic fan assembly

(a). Install the electronic fan assembly and
Torque:21~25N•m
16-14 COOLING - ELECTRONIC FAN
(b). Reset the harness connector at the right.
fuwx16A017
(c). Reset the harness connector at the left.
fuwx16A016
(d). Insert the electronic fan connector back,

until you hear the click.
fuwx16A004
7. Install the coolant reservoir assembly

(a). Install the coolant reservoir assembly and
Torque: 23 N·m
fuwx16A015
(b). Install the heat radiator water inlet hose

and tighten the clip screw.
16
fuwx16A014
(c). Install the heat radiator and engine air

outlet hoses and tighten the clip screw.
8. Fill up the coolant (Refer to "Chapter 16
Cooling - Coolant, Replacement")
9. Connect the negative cable of the battery
(Refer to "Chapter 18 Starting & Charging-
Battery, Replacement")
fuwx16A013
- MEMO -
LUBRICATION
LUBRICATING SYSTEM ...................... 17-1
NOTIES............................................. 17-3
PARTS DRAWING ............................ 17-4
ENGINE OIL ......................................... 17-5
CHECKING ....................................... 17-5
REPLACEMENT ............................... 17-9
OIL FILTER ......................................... 17-11
REPLACEMENT ............................. 17-11
OIL SUMP........................................... 17-12
REPLACEMENT ............................. 17-12
OIL DIPSTICK ................................... 17-14
REPLACEMENT ............................. 17-14
OIL PUMP........................................... 17-16
CHECKING ..................................... 17-16
REPLACEMENT ............................. 17-18
17
LUBRICATION - LUBRICATING SYSTEM 17-1
LUBRICATING SYSTEM
SYSTEM DESCRIPTION
1. Function
The lubrication system is functioned to supply a sufficient amount of clean oil at
appropriate temperature continuously to the friction surfaces of all drive parts and
form an oil film on the friction surfaces to realize the liquid friction, reduce the friction
resistance, lower the power consumption, relieve the wear of parts, and promote the
working reliability and durability of the engine.
2. Composition
The lubrication system is mainly composed of engine oil filter, oil sump, engine oil
pump, engine oil strainer, engine oil pressure sensor, and engine oil dipstick.
17
17-2 LUBRICATION - LUBRICATING SYSTEM
3. OPERATING PRINCIPLE
fuwx17B001
LUBRICATION - LUBRICATING SYSTEM 17-3
NOTIES
1. Periodically check the engine oil and as appropriate add or replace the engine oil.
2. During the work of lubricating system, it must be performed after the engine is
cooled.
3. During the work, prevent the oil from spraying on the drive belt.
4. Uniformly collect the used engine oil and always maintain clean the maintenance
site.
5. Note the following points for use of sealing gum:
• Remove the residual sealing gum thoroughly from the mounting surfaces of oil
sump and air cylinder body (including the surface grooves where the sealing gum
is applied, fastening bolts and bolt mounting holes) with a scraper.
• While using the sealant, wipe clean the surface on which the sealant is to be
applied and remove the adhered water and other foreign materials.
• If any foreign substance on the sealing gum, remove it immediately.
17
17-4 LUBRICATION - LUBRICATING SYSTEM
PARTS DRAWING
10 11
4
6
3
2
fuwx17B032
1 Oil pump drive shaft 7 Oil cooler
2 Oil pump 8 Oil pressure sensor
3 Gasket 9 Oil filter base
4 Oil strainer 10 Oil dipstick
5 Oil sump 11 Oil dipstick tube
6 Oil filter
LUBRICATION - ENGINE OIL 17-5
ENGINE OIL
CHECKING
1. Check engine level

(a). Park the vehicle on a level ground, warm
up the engine, and then stop the engine
and wait for at least 5min.
(b). Check whether the engine oil level is
between the upper limit and lower limit of
the oil dipstick.
• Place a rag beneath the end of oil
dipstick and pull out the engine oil
dipstick.
• Wipe clean the oil dipstick and fully re-
insert the oil dipstick.
fuwx17B002 • Pull out the oil dipstick and check the oil
level.
17
2. Check the quality of engine oil
(a). Visual examination.
• Pull out the oil dipstick and observe
against the light whether the engine oil
is clear and transparent and whether the
texture of oil dipstick is clearly legible.
If the texture of oil dipstick is illegible
through the oil on the oil dipstick or there
are clear particle impurities in the engine
oil, it indicates that the engine oil is too
dirty and must be replaced immediately.
fuwx17B003
17-6 LUBRICATION - ENGINE OIL
(b). Odor examination.

• Pull out the oil dipstick and smell the
odor of engine oil. The engine oil shall
be slightly sweet-scented, without
peculiar odor. Any engine oil with high
smell irritation or peculiar odor is of
deteriorated or poor quality engine oil
and must be immediately replaced.
NOTICE:
• If a clear fuel odor (stinking odor) can be
smelled, it indicates that the engine oil is mixed
with fuel and it’s necessary to check for the
fuwx17B004 cause of fuel leakage.
• To smell the engine oil, do not put your nose too
close to the engine oil. Smell for a while and do
not smell the engine oil for a long time.
(c). Twisting examination.

• Get a few of engine oil and twist on
fingers. If a viscous feeling can be felt,
with threading symptom, during the
twisting, it indicates that the engine oil
is not deteriorated and can be used
further. Otherwise, the engine oil shall be
replaced.
NOTICE:
After the examination, immediately wipe away the
engine oil from your fingers.
fuwx17B005
(d). Pouring examination.

• Pour a few of engine oil from the oil sump
into one container and then pour the
engine oil slowly from the container and
observe the luster and viscosity of the
engine oil. If the engine oil can maintain
thin and uniform, it indicates that the
engine oil is free of impurity and can be
used further for a period. Otherwise, the
engine oil shall be replaced.
fuwx17B006
NOTICE:
Upon detection of clear stratification of engine oil
in the container, with presence of water on the
under layer, it indicates that the engine oil is mixed
with water and it’s necessary to check the cause
for water ingress of engine oil.
A：Water
B B：Engine oil
fuwx17B007
(e). Oil drop examination.

• Drip a drop of engine oil on a piece
of white paper. If the black spot in the
center of the oil drop is large and uniform
17
in dark brown, without particle, and the
surrounding yellow infiltration is really
small, it indicates that the engine oil
is deteriorated and shall be replaced.
If the black spot in the center of oil
drop is small and light in color and the
surrounding yellow infiltration trace is
large, it indicates that the engine oil can
fuwx17B008 be further used.
3. Check engine oil pressure

(a). Disconnect the connector of engine oil
pressure sensor.
(b). Clean the surfaces of engine oil pressure
sensor.
NOTICE:
• Use compressed air to clean the engine
oil pressure sensor and the engine body
connections, in order to prevent the ingress of
impurities (such as dust) into oil passage and
the accelerated contamination of the engine oil.
• W h i l e u s i n g t h e c o m p r e s s e d a i r, i t ’ s
fuwx17B009 recommended to wear goggles and protective
mask, in order to prevent the slashing fragments
from causing personal injuries.
(c).
Remove the engine oil pressure sensor
40 60 and install the engine oil pressure gauge.
20
(d). Start the engine to warm up and observe
80
the engine oil pressure gauge.

NOTICE:
• If the pressure reading is out of specified range,
check the engine oil pump.
• While installing the engine oil pressure sensor,
it’s necessary to apply sealant to the thread of
the sensors.
Model of sealant:
• After the installation of engine oil pressure
fuwx17B010 sensor, it’s prohibited to start the engine
immediately. Wait for the thread sealant to
solidify (approximate 10min) before starting the
engine.
(e). Stop the engine and wait for the engine to cool down before removing the engine oil
pressure gauge.
(f). Install the engine oil pressure sensor.
(g). Connect the connector of engine oil pressure sensor.
REPLACEMENT
NOTICE:
• During operation, perform after the engine is cooled.
• During operation, prepare a rag for cleaning the leaked or splashed engine oil.
• Don’t spray the engine oil on the drive belt.
• Remove the oil sprayed on the engine and vehicle thoroughly.
1. Drain the engine oil

(a). Place one recoverer beneath the drainage
plug of the oil sump.
(b). Remove the drain plug of oil sump, and
drain the engine oil into the recycling
container.
NOTICE:
While removing the drainage plug, keep your arm
paralleling with the ground, in order to prevent the
engine oil from flowing along your arm.
17
fuwx17B011
(c). Install the oil sump drain plug.

Torque:40N•m
fuwx17B012
2. Add engine oil

(a). Remove the engine oil filler cap.
(b). Add engine oil.
Engine oil capacity:6.2L
NOTICE:
• Choose qualified engine oil depending on
different environment temperatures.
• Use the oil dipstick to check for appropriate oil
filling amount.
(c). Install and tighten the engine oil filler cap.
LUBRICATION - OIL FILTER 17-11
OIL FILTER
REPLACEMENT
1. Remove the oil filter

(a). Drain the engine oil. (Refer to"Chapter 17 Lubrication - Engine Oil, Replacement")
(b). Loosen the engine oil filter with the engine

oil filter wrench.
17
fuwx17B014
2. Install the oil filter

(a). Remove the foreign materials adhered on
the surfaces of the engine oil cooler.
(b). Apply an appropriate amount of engine oil
onto the seal rings of the engine oil filter.
(c). Install the engine oil filter to the engine oil
cooler with the engine oil filter wrench.
fuwx17B015
(d). Add engine oil. (Refer to"Chapter 17 Lubrication - Engine Oil, Replacement")
(e). Start the engine and check the installation location of engine oil filter for presence of
oil leakage.
17-12 LUBRICATION - OIL SUMP
OIL SUMP
REPLACEMENT
1. Remove the oil sump

(a). Drain the engine oil. (Refer to"Chapter 17 Lubrication - Engine Oil, Replacement")
(b). Remove the fastening bolts of oil sump.
fuwx17B016
(c). As shown in the figure, insert the oil sump

remover into the mounting surface between
oil sump and cylinder block.
(d). Knock the oil sump remover along the
diagonal plane to move it horizontally.
(e). Use the oil sump remover to separate the
sealing surface between oil sump and
cylinder block and remove the oil sump.
NOTICE:
• While installing the oil sump remover, pay
attention to check the installation positions of the
studs.
fuwx17B017 • While installing the oil sump remover, slide along
the oil sump carefully without prying its surface,
in order to prevent damaging the mounting
surface of oil sump and causing oil leakage.
LUBRICATION - OIL SUMP 17-13
2. Install the oil sump

(a). As per the shape shown in the figure, apply
continuously and uniformly the sealant onto
the mounting surface of oil sump.
NOTICE:
Before applying the sealant, make sure to
thoroughly remove the old residual sealant from
the cylinder block and oil sump.
fuwx17B018
(b). Install the oil sump onto the cylinder block

and install and tighten the fastening bolts.
Torque:10N•m
17
fuwx17B016
(c). Add engine oil. (Refer to"Chapter 17 lubrication - engine oil, replacement")
17-14 LUBRICATION - OIL DIPSTICK
OIL DIPSTICK
REPLACEMENT
1. Remove the engine oil dipstick and engine

oil dipstick tube
(a). Pull out the engine oil dipstick ① .
(b). Remove the fastening bolts ② of engine oil
1
dipstick tube.
fuwx17B019
(c). Lightly shake the engine oil dipstick tube to

pull out the engine oil dipstick tube.
fuwx17B020
2. Install the engine oil dipstick and engine oil

dipstick tube
(a). Adjust the engine oil dipstick tube to an
appropriate direction and insert the engine
oil dipstick tube into the engine oil dipstick
tube mounting hole on the right side of the
cylinder block.
fuwx17B021
LUBRICATION - OIL DIPSTICK 17-15
(b). Install and tighten the fastening bolts ② of

engine oil dipstick tube.
Torque:10N•m
(c). Insert the engine oil dipstick ① into the
1
engine oil dipstick tube.
fuwx17B019
17
17-16 LUBRICATION - OIL PUMP
OIL PUMP
CHECKING
1. Check the engine oil pump and its

subassembly
Inspection method:
• Immerse the engine oil strainer into the
engine oil and then rotate the pump
shaft clockwise with the drive shaft or a
straight screwdriver. The engine oil shall
flow out from the oil outlet port of the
engine oil pump.
• Plug the oil outlet port of engine oil pump
with a thumb and rotate the pump shaft.
In such case, it should be difficult to
fuwx17B022 rotate the pump shaft.
2. Check the rotor gap of the engine oil pump

(a). Remove the fastening bolts of engine oil
pump cap and remove the oil pump cap.
fuwx17B023
(b). Use a feeler gauge to check the tip gap

between drive rotor and driven rotor of the
engine oil pump. If beyond the limit, replace
the engine oil pump.
Limit gap:0.2mm
fuwx17B024
LUBRICATION - OIL PUMP 17-17
(c). Use a feeler gauge to check the gap

between driven rotor and housing of the
engine oil pump. If beyond the limit, replace
the engine oil pump.
Limit gap:0.38mm
fuwx17B025
(d). Use a feeler gauge and high precision ruler

to measure the top gap between two rotors
and the housing of the engine oil pump.
If beyond the limit, replace the engine oil
17
pump.
Limit gap : 0.2mm
(e). Install the engine oil pump cap and install
and tighten the fastening bolts.
Torque : 10N•m
fuwx17B026
3. Check the drive shaft and intermediate

shaft of engine oil pump
(a). Check the gear engagement surface
between drive shaft and intermediate shaft
of engine oil pump. Upon detection of
cracking or wear, replace the drive shaft
and intermediate shaft of engine oil pump.
fuwx17B028
17-18 LUBRICATION - OIL PUMP
REPLACEMENT
1. Remove the oil sump (Refer to "Chapter17 Lubrication-Oil Sump, Replacement")
2. Remove the engine oil pump and engine

oil strainer
(a). Remove the fastening bolts of engine oil
strainer.
(b). Remove the flange connecting bolts of
strainer and remove the strainer.
fuwx17B029
(c). Remove the fastening bolts of engine oil

pump and lightly rotate to remove the
engine oil pump.
fuwx17B030
3. Remove the drive shaft and intermediate shaft of engine oil pump (Refer to
"Chapter12B Engine Mechanical System - Engine Assembly, Breakup")
4. Install the drive shaft and intermediate shaft of engine oil pump (Refer to
"Chapter12B Engine Mechanical System - Engine Assembly, Assembly")
LUBRICATION - OIL PUMP 17-19
5. Install the engine oil pump and engine oil

strainer
(a). Observe the rotor of engine oil pump
drive shaft through the mounting hole of
the engine oil pump, install the engine
oil pump, and align with the rotor slot of
engine oil pump and install.
fuwx17B031
(b). Lightly rotate the engine oil pump and

install and tighten the fastening bolts of
engine oil pump.
Torque:25N•m
17
fuwx17B030
(c). Install the engine oil strainer and install

and tighten the flange fastening bolts.
Torque:22N•m
(d). Install and tighten the fastening bolts of
engine oil strainer.
Torque:22N•m
fuwx17B029
6. Install the oil sump (Refer to "Chapter17 Lubrication-Oil Sump,Replacement")

- MEMO -
START AND CHARGING
START AND CHARGE SYSTEM.......... 18-1
NOTICES .......................................... 18-1
SYMPTOMS ..................................... 18-2
GENERATOR ....................................... 18-4
OVERHAUL ...................................... 18-4
STARTER ........................................... 18-11
PARTS DRAWING .......................... 18-11
REPLACEMENT ............................. 18-12
BATTERY ........................................... 18-21
PARTS DRAWING .......................... 18-21
USEING AND MAINTENANCE....... 18-22
BASIC INSPECTION ...................... 18-24
REPLACEMENT ............................. 18-26
18
START AND CHARGING - START AND CHARGE SYSTEM 18-1
START AND CHARGE SYSTEM

NOTICES
1. Battery may have escaping explosive gas. In order to avoid personal injury, keep
ventilated in engine compartment before maintaining battery.To avoid electric arc,
disconnect the negative cable of the battery first and connect the negative cable
last.
2. When using compressed air, wear proper goggles and mask. Flying fragment and
dirt may lead to personal injury.
3. Don't excessively tighten the electrical connectors, which may damage the starter.
4. Never make two cables of the battery in short circuit. Otherwise it will enable battery
to heat rapidly or explode.The escaping gas from battery is easily be ignited by the
spark, so do not use fire near battery.
5. When removing the battery, remove the negative wire before the positive one.
Then remove the battery retaining plate and remove the battery from the tray. For
installation, reserve the removal order.
6. Never operate the engine when battery connection is not reliable. Otherwise, it may
damage electrical system (electrical components).
7. As the generator is negative grounding, the polarity of the battery should conform 18
to that of the generator. Otherwise, battery will discharge through diode and burn
diode.
8. After the generator begins operating, do not try to use spark to check whether the
generator works. Use a bulb or multimeter to perform the test. Otherwise it will
damage the generator diode.
9. Check the generator silicon rectifier devices, multimeter and 220V check is strictly
forbidden to check generator insulation, otherwise it will make diode broken down
and damaged.
18-2 START AND CHARGING - START AND CHARGE SYSTEM

Malfunction
Symptoms
Starter switch control circuit
Check circuit to assure reliable connection
(Open)
Starter out-of- Brush and rectifier (Poor Chapter 18 Starting & Charging-generator,
operation connection) overhaul
Starter inside circuit (Open or Chapter 18 Starting & Charging-generator,

short) overhaul
Chapter 18 Starting & Charging - battery, use and

Battery (Low voltage)
maintenance
Starter wire (Poor connection) Check circuit to assure reliable connection
Starter Rectifier (Surface damage or Chapter 18 Starting & Charging-generator,

losspower, can stains) overhaul
not srart engine Brush (Wear) or Brush spring Chapter 18 Starting & Charging-generator,
(Loss elastic force) overhaul
Brush (Wear) or Brush spring Chapter 18 Starting & Charging-generator,

(Loss elastic force) overhaul
Bearing (Wear), commutator Chapter 18 Starting & Charging-generator,

(Wipe shell) overhaul
Engine has
started and Starter relay (Copper contacts Chapter 18 Starting & Charging-generator,
starter continues bond) overhaul
to rotate and Starter commutator (Bend or Chapter 18 Starting & Charging-generator,
produce harsh break) overhaul
noise
Starter gear tooth surface Chapter 18 Starting & Charging-generator,
contact (Roughening or stuck) overhaul
Generator connect wire Check circuit to assure reliable connection
Chapter 18 Starting & Charging-generator,

Rotor coil (Open)
overhaul

Generator out- Rectifier diode (Damaged)
overhaul
of-operation
Brush (Poor connection)
overhaul

Regulator (Damaged)
overhaul
START AND CHARGING - START AND CHARGE SYSTEM 18-3
Malfunction
Symptoms
Chapter 12A Engine Mechenical-engine accessory
Loose belt
belt, replacement
Insufficient Brush (Poor connection) or Chapter 18 Starting & Charging-generator,

charging of Collector ring (Oil stain) overhaul
generator Chapter 18 Starting & Charging-generator,
Regulator (Damaged)
battery overhaul
Chapter 18 Starting & Charging- battery, use and

Battery loses electrolyte
maintenance
18
18-4 START AND CHARGING - GENERATOR
GENERATOR
OVERHAUL
2. Cool the engine, make the belt temperature close to the normal temperature
3. Rotate the generator belt and check for crack
4. Remove the generator

(a). Unscrew the supporting bolts of the
generator.
(b). Remove the drive belt.
fuwx18A002
(c). Unscrew the nuts of the generator

terminals and remove the harness.
(d). Disconnect the connector of the generator.
fuwx18A003
(e). Unscrew the supporting bolts of the

generator and remove the generator.
fuwx18A002
START AND CHARGING - GENERATOR 18-5
5. Disassemble and overhaul the generator

(a). Using pneumatic tools, remove generator
belt pulley retaining bolt.
fuwx18A004
(b). Remove retaining bolts attaching generator

front cover and stator component.
18
fuwx18A005
(c). Insert screwdriver to the internal between front cover and stator and separate them.
NOTICE:
• If it is difficult to separate them, slap the front cover slightly with a rubber hammer and pry
it witha screwdriver.
• Do not insert screwdriver too deep to prevent stator component from being damaged.
(d). Using an electric iron (180 - 250W), and

remove stator.This operation should be
completed within 4 seconds to prevent
transmitting heat to diode.
fuwx18A006
(e). Remove the rectifier retaining bolts.
fuwx18A007
(f). Using an electric iron, remove rectifier from

regulator.
NOTICE:
• Ensure that heat is not transmitted from electric
iron to diode for long time.
• Do not let diode pin bear too much force.
fuwx18A008
(g). Remove and inspect rotor.

•Check whether the rotor coil is
conductive, and confirm that the collector
rings are conductive. Measure the
resistance of rotor. If the resistance is
less than the specified value, it means
the rotor is a short circuit. If it is not
fuwx18A009 conductive or it is a short circuit, replace
the rotor assembly.
Standard: 3~5Ω
• Check the rotor coil ground. Confirm that
it is insulative between collector ring and
core. If not insulative, replace the rotor
assembly.
fuwx18A010
• Using a vernier caliper, measure the slip 18

ring diameter.
Standard: 14.2~14.4 mm
Limit: 12.8 mm
fuwx18A011
(h). Remove and inspect stator.

• Check the stator for continuity. Confirm
whether the coil lead is conductive. If not
conductive, replace the stator assembly.
Standard: 5~6Ω
• Check the coil ground. Confirm that it is

conductive between coil and stator core.
If conductive, replace the stator
assembly.
fuwx18A013
(i). Inspect stator rectifier.

• Diode group (three diodes) check:
Using an ammeter,connect both ends
of each diode, check if three diodes
are conductive. If it is not conductive
in both directions, it means the diodes
are broken down, and it is required to
fuwx18A014 replace the rectifier assembly.
(j). Get rid of welding point of brush lead, then

take out the brush.
fuwx18A015
(k). If brush is so worn to reach wearing limit

line, replace brush.
6. Assemble the generator

(a). When installing a new brush, weld brush
lead in the condition that brush is pressing
into brush bracket as shown.
fuwx18A017
(b). Install the rectifier retaining bolts.

Torque : 6~8N•m
fuwx18A007
(c). Weld rectifiers and stator connection.

(d). Install rotor.
NOTICE:
While installing the rotor, take cautions to prevent
damaging the carbon brush. Install the rotor into
the stator coil after fixing the carbon brush with 18
steel wire or locating pin.
fuwx18A006
(e). Retaining bolts attaching generator front

cover to stator component.
fuwx18A005
(f). Using pneumatic tools, install generator

belt pulley retaining nut.
fuwx18A004
7. Install the generator

(a). Install supporting bolts of the generator.
fuwx18A002
(b). Connect the generator connector.

(c). Tighten the nuts of generator terminals.
Torque: 21~25 N•m
(d). Install the generator belt.
fuwx18A003
(e). Ti g h t e n s u p p o r t i n g b o l t s o f t h e A C
generator.
Torque: 20~24 N•m
fuwx18A002
START AND CHARGING - STARTER 18-11
STARTER
PARTS DRAWING
18
fuwx18A001
1 Starter Drive Lever 14 Locating Snap Ring
2 Washer 15 Spring
3 Rubber Washer 16 Retaining Bolt
4 Washer 17 Front Bracket
5 Solenoid Component 18 Washer
6 Return Spring 19 Spring
7 Solenoid Component 20 Starter Shell Bolt
8 Rubber Washer 21 Retaining Bolt
9 Steel Ball 22 Rear Bracket
10 Planetary Gear 23 Magnet Yoke Assembly (with Brush
11 Planetary Gear Bracket 24 Commutator
12 Front Bracket 25 Washer
13 Overdrive Clutch
18-12 START AND CHARGING - STARTER
REPLACEMENT
2. Raise and support vehicle
3. Remove the starter

(a). Remove 3 starter retaining bolts.
fuwx18A019
(b). Disconnect starter electrical wire

connecting nut.
(c). Disconnect starter control wire connector.
Remove starter.
fuwx18A020
4. Inspect the starter

(a). Pinion gap adjustment.
• Disconnect the field coil wire from the
M-terminal of the magnetic switch.
• Connect a 12V battery between the
S-terminal and M-terminal.
WARNING:
fuwx18A021 This test must be performed quickly (less than 10
seconds) to prevent the coil from burning.
• When the 12V battery is connected
between the S-terminal and M-terminal,
the pinion will move out.
• Check the pinion-to-stopper clearance
(pinion gap) with a feeler gauge.
Standard: 0.5~2.0mm
fuwx18A022
• If the pinion gap is out of specification,

adjust by adding or removing gasket(s)
between the magnetic switch and front
bracket.
fuwx18A023
(b). Magnetic switch pull-in test.

WARNING:
This test must be performed quickly (less than 10
fuwx18A021 seconds) to prevent the coil from burning.
• Switch on the ignition, the pinion will 18
eject. If it doesn't eject, replace the
magnetic switch.
(c). Magnetic switch return test.
WARNING:
• Manually pull out the pinion as far as the
pinion stopper position.
• If the pinion remains out, everything is
operating properly. If the pinion moves
in, the hold-in circuit is open. Replace
the magnetic switch.
(d). Magnetic switch return test.
M-terminal and body.
WARNING:
• Pull the pinion out and release. If the pinion quickly returns to its original position,
everything is operating properly. If it doesn't return to its original position, replace the
magnetic switch.
DANGER：
Be careful not to get your fingers caught when pulling out the pinion.
5. Disconnect the magnetic coil lead from

magnetic switch
fuwx18A026
6. Remove the magnetic switch retaining

bolts
fuwx18A027
7. Remove the starter shell retaining bolts
fuwx18A028
8. Disassemble starter as components figure

shown
WARNING:
When removing commutator, do not lose the steel
ball mounted in the bearing ends.
(a). Using a proper control sleeve, push
and press the locating snap ring to the
overdrive clutch side, and make it separate
from the clip spring.
fuwx18A029
(b). Remove the snap spring with snap ring

pliers, then remove the locating snap ring
and overdrive clutch.
18
fuwx18A030
9. Clean the starter parts

(a). Do not put the parts in the detergent for cleaning. If the magnet yoke, excitation
winding lead or rotor is immerged in detergent, their insulating ability is undermined.
(b). Clean starter parts with cloth.
(c). Drive parts cannot be immerged in detergent for cleaning. Before delivering out of
factory, the overdrive clutch is greased. If clean it by detergent, its grease might be
removed.
(d). Using a brush and dipping with detergent, clean drive parts then dry them with a
cloth.
10. Inspect the commutator

(a). Support the commutator with a pair of
V-shaped blocks and turn them to measure
the runout of the surface using a dial
gauge.
Standard: 0.05mm
Limit: 0.1mm
fuwx18A031
(b). Measure the diameter of the commutator.

Standard: 29.4mm
Limit: 28.4mm
fuwx18A032
(c). Measure the depth of the undercut

between segments.
Standard: 0.5mm
Limit: 0.2mm
fuwx18A033
11. Inspect the brush and brush bracket

(a). Check whether it is conductive between brush plate and brush bracket, if not
conductive, it is normal.
(b). Check the commutator contact surface of each brush for abnormal roughness. Also
check the height of the brush. Replace the brush holder if the height is lower than
the limit.
Limit: 7.0mm
(c). When the contact surface of the brush is rectified or the brush holder is replaced,
recondition the contact surface with sandpaper wrapping around the commutator.
12. Inspect the overdrive clutch

(a). Make sure that the pinion can not be
turned counterclockwise and can be turned
clockwise freely.
(b). Check the pinion for abnormal ware and
damage.
fuwx18A034
13. Inspect the rotor coil

(a). Set the rotor in a growler.
(b). While holding a thin strip of iron against the
rotor in parallel with its axis, turn the rotor
slowly. The rotor is normal if the iron strip
is not attracted to the rotor or it does not
vibrate.
fuwx18A035 WARNING
Clean the surface of the rotor thoroughly before
performing the test.
(c). Check the insulation between commutator

segments and rotor coils. The rotor coils
are properly insulated if no continuity is
present.
fuwx18A036
18
(d). Check continuity between a segment and
another. It is normal if there is continuity.
fuwx18A037
14. Inspect the magnetic switch

(a). Coil short circuit test.
• Check that there is continuity between
the M terminal and body A.
• If there is no continuity, replace the
magnetic switch.
fuwx18A038
(b). Contact fusion check.

• Check the continuity between the B
terminal and M terminal.
magnetic switch.
fuwx18A039
(c). Switch contact check.

• Push the indicated end of the magnetic
switch with a strong force to close the
internal contacts.Without releasing the
switch end, check the continuity between
the B terminal and M terminal.
fuwx18A040 magnetic switch.
15. Using a suitable puller, pull stop ring until it

gets over snap ring
fuwx18A041
16. Install the overdrive clutch and locating

snap ring
fuwx18A030
17. Assembly starter as components figure shown

18. Install the starter shell retaining bolts

Torque: 8~10N•m
fuwx18A028
19. Install the magnetic switch and tighten

retaining bolts
Torque: 8~10N•m
18
fuwx18A027
20. Connect the magnetic coil lead nut from

magnetic switch
Torque: 14~16N•m
fuwx18A026
21. Connect the starter electrical wire

connecting nut
Torque: 18~20N•m
22. Connect the starter control wire connector
fuwx18A020
23. Install the two retaining bolts of the starter

Torque: 68~72N•m
fuwx18A019

25. Connect the negative cable of the battery (Refer to "Chapter18 Starting & Charging
START AND CHARGING - BATTERY 18-21
BATTERY
PARTS DRAWING
4
18
4
fuwx18A001
1 Battery 4 Hexagonal flange nut
2 Hexagonal flange nut 5 Battery installation pallet assembly
3 Battery fixed platen

18-22 START AND CHARGING - BATTERY
USEING AND MAINTENANCE
1. Charging device
(a). Rectifier.
(b). Controllable silicone voltage regulation charger.
2. Charge notice
(a). Battery should be charged in a dry and ventilated room with indoor temperature at 5
to 40 degree Celsius.
(b). Battery can not be placed on another one. Neither should it be placed on the ground
directly. It should be put on the wooden support, and cannot be placed with alkaline
battery or other chemicals.
(c). Charging field should be far away from fire and heat.
(d). Liquid temperature should not exceed 45 degree Celsius. Otherwise cooling
measures should be taken (by reducing filling current or stopping charge or being
cooled down in water tank).
3. Charge connection
(a). The positive pole of charger is to be connected with the positive pole of battery,
while the negative pole of charger should be connected with the negative pole of
battery. Never connect them reversely.
(b). Charge of most batteries may be determined based on the size of moter power.
Connection for charge must be firm.
4. Charging modes
(a). Constant current charge, constant voltage charge and quick charge.
5. After charging, check whether the battery capacity is restored to standard with the
voltage mode or indicator display state
(a). Voltage method.
Voltage Determination Treatment

Above 12.5V Normal Go on using
11.5V~12.5V Undercharge Additional charge
To be further checked after
Below 11.5V Over-discharge or internal failure
charging
(b). Indicator display state.
Capacity Tester Display Determination Treatment

Blue Good Go on using
White Need charging Additional charge
Red Low liquid and replace it Check or replace after charging
6. Using and maintenance of battery in winter

(a). Keep the battery fully charged to avoid the electrolyte from being frozen arising from
drop in density, which may give rise to breakage of container, curve of pole plats, as
well as smash and dropout of active substances, and other failures.
(b). Because the battery capacity is reduced in winter, when starting the engine in cold
status, preheat the it. And each time starting the engine should not more than 15
seconds. Interval of two startings should be 2 to 3 minutes. If engine could not be
started in three times, troubleshoot it and then restart it.
18
BASIC INSPECTION
1. Appearance inspection
(a). Observe whether the battery appearance is in good condition. Check if fixed
terminal and wires are connected firmly.
(b). Observe whether the battery shell and the center partition cracks, and use a
wooded stick to beat shell and center partitions respectively. Breaking sound is not
heard. Especially the central baffle and shell side of shell wall at the junction of four,
prone to crack, should be carefully examined.
(c). Through mirrors, blue shows good battery state, red and white indicate lack of
electricity and no electricity. The following capacity, specific gravity and voltage
inspection should be done.
2. Capacity tes
(a). The excel tester is also known as the
discharging tongs. It consists of a DC
voltmeter and one load resistance.
(b). The tips of the two tongs shall be
pressed on the anode and the cathode
tightly and sustain for five seconds in
the measurement. Observe the terminal
voltage in the state of the big load
discharging and the discharging content
and the starting ability can be judged
correctly.
fuwx18A043 (c). For the excel tester of different brands,
the readings of the current and the voltage
shall be read according to the regulations
of the factory manual. Generally, the single
voltage of the battery in good state should
be above 1.5 and keep steady within five
seconds. If the voltage drops rapidly within
five seconds or the voltage of one single
cell is 0.1V lower than that of others, it
indicates there are troubles in the battery
and it should be repaired.
Below is the use of excel tester of discharge plan detection income cross-references.
Display Zone Determination Treatment

White zone Fully charged Go on using
Green zone Normal Go on using
Additional charge (refer to "Chapter18 Starting &
Yellow zone Undercharge
Charging -Battery, Use And Maintenance")
To be further checked after charging (refer to "Chapter
Red zone Over-discharge
18 Starting & Charging-Battery, Use And Maintenance")
3. Voltage test
The following table is derived using the digital multimeter test table.
Voltage Determination Treatment

Above 12.5V Normal Go on using
Additional charge (refer to "Chapter18 Starting &
11.5 - 12.5V Undercharge
Charging - Battery, Use And Maintenance")
To be further checked after charging (refer to
Over-discharge or
Below 11.5 V "Chapter 18 Starting & Charging - Battery, Use And
internal failure 18
Maintenance")
REPLACEMENT
1. Turn the ignition switch off
2. Unscrew the retaining bolts of the battery

cable and disconnect the positive and
negative cables of the battery
WARNING:
Take off the negative cable of the battery first.
fuwx18A044
3. Unscrew the bolts of the battery retaining

plate and remove the battery retaining
plate
fuwx18A045
4. Remove the battery

WARNING
Battery should be put up and placing the battery upside down is avoided.
5. Remove the battery tray assembly retaining

bolts.Remove the battery tray assembly
fuwx18A046
6. Install the battery tray assembly retaining

bolts
Torque: 21~25N•m
18
fuwx18A046
7. Install the battery.Install the battery

retaining plate and tighten the bolts
Torque: 9~11N•m
fuwx18A045
8. Connect the positive and negative cables

of the battery and tighten battery cable
retaining bolts
Torque: 9~11N•m
WARNING:
• If terminals has sediments, remove the impurities
then apply a thin layer of grease to terminal.
• Install positive battery cable first.
fuwx18A044
9. Install engine cover and intake air duct

(a). Install 4 engine cover retaining bolts.
(b). Install 2 intake air duct retaining bolts.
IGNITION
IGNITION SYSTEM .............................. 19-1
NOTICES .......................................... 19-2
PARTS DRAWING ............................ 19-3
CHECKING ....................................... 19-4
IGNITION COIL .................................... 19-5
CHECKING ....................................... 19-5
REPLACEMENT ............................... 19-6
SPARK PLUG ....................................... 19-8
CHECKING ....................................... 19-8
REPLACEMENT ............................... 19-9
19
IGNITION - IGNITION SYSTEM 19-1
IGNITION SYSTEM
SYSTEM DESCRIPTION
1. Function
The ignition system is functioned to convert the low voltage power supplied by the
onboard battery to high voltage power and, as per the requirement of powering
sequence and ignition timing of the engine, accurately and appropriately supply to
the spark plugs of all cylinders to generate electric spark at the gaps of spark plugs
and ignite the flammable air mixture within the cylinders.
2. Composition
The ignition system is mainly composed of ignition coils and spark plugs.
19
19-2 IGNITION - IGNITION SYSTEM
NOTICES
1. During the removal of spark plug, be sure to avoid the damages of spark plug
threads.
2. Don’t fall or knock the spark plug electrodes.
3. During the ground ignition test of spark plug, its duration shall not exceed 2s.
IGNITION - IGNITION SYSTEM 19-3
PARTS DRAWING
3 19
fuwx19B001
1 Inner hexagon bolt 3 Spark plug
2 Ignition coil
19-4 IGNITION - IGNITION SYSTEM
CHECKING
1. Check whether the operation of spark plug

is normal
(a). Disconnect the ignition coil connectors of
cylinders in turns.
NOTICE:
It’s recommended to disconnect the connector
of fuel injector.
To disconnect the connector of ignition coil,
pull backward the lock tab of the ignition coil
connector and then push down the lock tab while
pulling out the connector.
(b). Remove each cylinder ignition coil and
fuwx19B002 spark plug (Refer to"Chapter 19 Ignition-
Spark Plug, Replacement")
(c). Install spark plug on the ignition coil, and

connect the ignition coil connector.
fuwx19B016
(d). Ground the spark plug, and check whether

the sparks occur to the spark plug during
the start of engine.
NOTICE:
The starting time of engine shall not exceed 2s.
(e). Check the spark plugs of other cylinders
with the same method.
(f). Install each cylinder ignition coil and spark
plug (Refer to"Chapter 19 Ignition-Spark
Plug, Replacement")
(g). Connect the ignition coil connectors of
cylinders in turns.
fuwx19B003
IGNITION - IGNITION COIL 19-5
IGNITION COIL
CHECKING
1. Check the ignition coil

(a). Check the ignition coil insulation cap or
housing for presence of cracking and
damage. If yes, replace.
fuwx19B004
(b). Measure the resistance between 1# and 2#

pins of ignition coil with the resistance
Ω measurement range of a digital multimeter.
19
If the measured resistance is beyond the
OF
F
MΩ
Ω
standard, replace the ignition coil.

mV V
A
mA
MA COM
fuwx19B005
19-6 IGNITION - IGNITION COIL
REPLACEMENT

2. Disconnect the negative cable of the
battery
3. Remove the ignition coil
(a). Pull out the fastening clamp of ignition coil
connector.
fuwx19B006
(b). Press and hold the fastening clamp and

remove the connector of ignition coil.
fuwx19B007
(c). Remove the ignition coil fastening bolt, and

take out the ignition coil.
fuwx19B008
IGNITION - IGNITION COIL 19-7
4. Install the ignition coil

(a). Install the ignition coil ① to installation
position.
(b). Install and tighten the fastening bolts ② of
ignition coil.
1
Torque:10N•m
(c). Connect the connector ③ of ignition coil
and press in the fastening clamp.
3
2
fuwx19B009
19
19-8 IGNITION - SPARK PLUG
SPARK PLUG
CHECKING
1. Clean the spark plug

(a). Clean the spark plugs with a brush.
NOTICE:
Don’t apply any force between the electrodes,
otherwise it may damage the center electrode.
fuwx19B010
2. Check the spark plug

(a). Check the threads of spark plug for
damages. If they are damaged, replace the
spark plug.
(b). Check the surrounding area of spark plug
electrode for presence of serious carbon
deposit. If yes, replace the spark plug.
(c). Check the spark plug electrode for
presence of serious ablation. If yes, replace
the spark plug.
(d). Check the ceramic insulator of spark plug
for presence of damage and cracking. If
fuwx19B011 yes, replace the spark plug.
(e). Check the gap of spark plug electrode. If

beyond the standard value, repair or
replace.
Standard value: 0.80~0.90mm
fuwx19B012
IGNITION - SPARK PLUG 19-9
REPLACEMENT
1. Remove the spark plug

(a). Turn off the ignition switch, disconnect the negative cable of battery.
(b). Use compressed air to clean the surrounding area of the ignition coil.
(c). Remove the ignition coil.(Refer to "Chapter 19 Ignition - Spark Plug, Replacement")
(d). Loosen the spark plug with the spark plug

installation/removal socket.
fuwx19B013
19
(e). Attach the ignition coil removed onto the
head of spark plug and rotate to remove
the spark plug.
NOTICE:
• Do not knock the spark plug, especially the
electrodes.
• After the removal of spark plug, it’s
recommended to seal the mounting hole of
spark plug, in order to prevent the ingress of
foreign material into the cylinder.
• The removal method is same for the spark plugs
of all cylinders.
fuwx19B014
19-10 IGNITION - SPARK PLUG
2. Install the spark plug

(a). Attach the ignition coil onto the head of
spark plug and carefully screw in the spark
plug.
fuwx19B015
(b). Tighten the spark plug with the spark plug

installation/removal socket.
Torque:28N•m
fuwx19B013
(c). Install the ignition coil. (Refer to "Chapter 19 Ignition -Ignition Coil,Replacement")
(d). Connect the negative cable of the battery.
TRANSMISSION
TRANSMISSION SHIFTING SYSTEM........
.............................................................. 21-1
PARTS DRAWING ............................ 21-1
REPLACEMENT ............................... 21-2
TRANSMISSION ASSEMBLY .............. 21-4
NOTICES .......................................... 21-4
SYMPTOMS ..................................... 21-5
PARTS DRAWING(4WD).................. 21-7
REPLACEMENT (4WD).................... 21-9
DISASSEMBLE(4WD) .................... 21-13
FIRST SHAFT & REVERSE SHAFT
ASSEMBLY ........................................ 21-22
PARTS DRAWING .......................... 21-22
REPLACEMENT ............................. 21-23
SECOND SHAFT ASSEMBLY............ 21-24
PARTS DRAWING .......................... 21-24
DISASSEMBLE............................... 21-26
INTERMEDIATE SHAFT ASSEMBLY .........
............................................................ 21-38
PARTS DRAWING .......................... 21-38
DISASSEMBLE............................... 21-39 21
TRANSMISSION - TRANSMISSION SHIFTING SYSTEM 21-1
TRANSMISSION SHIFTING SYSTEM

PARTS DRAWING
21
1 Knob Assembly 5 Shift Knob
2 Shift Sleeve Assembly 6 Gasket
3 Dust Cover Assembly 7 Hexagonal Bolt
4 Screw
21-2 TRANSMISSION - TRANSMISSION SHIFTING SYSTEM
REPLACEMENT
1. Park the vehicle, switch off the engine and perform park brake
2. Remove the transmission shifting system

(a). Pry out the trim panel of the gearshift
sleeve.
(b). Remove the gearshift lever ball assembly
and gearshift sleeve.
(c). Remove the console (Refer to "Chapter 52 Instrument Panel and Auxiliary Instrument
Panel - Auxiliary Instrument Panel, Replacement")
(d). Unscrew the retaining screw and the dust cover.
(e). Unscrew the retaining bolts and remove

the shift knob.
NOTICE:
When removing the transmission shift knob, the
shift shall be placed at N.
TRANSMISSION - TRANSMISSION SHIFTING SYSTEM 21-3
3. Install the transmission shifting system

(a). Install the shift knob and tighten the
retaining nuts.
NOTICE:
When installing the transmission shift knob, the
shift shall be placed at N.
(b). Install the dust cover and tighten the

retaining screws.
(c). Install the console (Refer to "Chapter 52 Instrument Panel and Auxiliary Instrument 21
Panel - Auxiliary Instrument Panel, Replacement")
(d). Install the gearshift lever ball assembly and

gearshift sleeve.
4. Check whether the transmission shifting system shifts smoothly

21-4 TRANSMISSION - TRANSMISSION ASSEMBLY
TRANSMISSION ASSEMBLY
NOTICES
1. The drained manual transmission gear oil cannot be reused.

2. When checking or changing the manual transmission gear oil, please keep the
vehicle level.
3. While removing and installing the transmission, ensure that the inside is free of dust
and impurity.
4. Before removal/disassembly, please check and determine the correct installation
position. If installation marks should be made, please ensure the marks won’t
affect the function of other components.
5. As per the specification, tighten the middle bolts and nuts and then the outer
bolts and nuts in diagonal manner by multiple steps. If the tightening sequence is
specified, follow the tightening sequence.
6. Take cautions not to damage the sliding surfaces and fitting surfaces.
TRANSMISSION - TRANSMISSION ASSEMBLY 21-5

Malfunction
Symptoms
1. Lubricant (low viscosity) -
2. Lubricant (insufficient volume) -
Chapter 21 Transmission- transmission assembly,

3. Bearing (worn or broken)
replacement

4.Shift fork and synchronizer replacement
gear(improper engagement) Chapter 21 Transmission- second shaft assembly,
Abnormal or disassemble
overly noise Chapter 21 Transmission- transmission assembly,
replacement
5.Synchronizer (worn or broken)
Chapter 21 Transmission- second shaft assembly,
disassemble
6.Gear tooth (scratched or worn)
replacement
7.Transmission housing
-
(distorted) 21
1. Lubricant (overly viscosity) -
Chapter 22 Clutch - clutch pedal,adjustment

2.Clutch (incomplete separation)
Chapter 22 Clutch - clutch module, replacement

3. Bearing (worn or broken)
replacement

Transmission hard
replacement
to shift 4. Synchronizer (broken)
disassemble

5. Shift fork (distorted or broken)
replacement

6.Fork shaft (distorted or broken)
replacement

7. Lifting ball (overly worn)
replacement
Malfunction
Symptoms
1. Locking nut (loose)
replacement

2. Gear (large radial clearance)
replacement
3.Gear engagement end (overly Chapter 21 Transmission- transmission assembly,

worn) replacement
Transmission
skips or misses
replacement
gear 4. Synchronizer (broken)
disassemble

5. Bearing (radial runout)
replacement

6. Shift fork (distorted or broken)
replacement

Gear disorder 1. Interlock pin (worn)
replacement

1. Ventilation plug (blocked)
replacement
2. Lubricant (too much) -

3. Seal (defective or broken)
Transmission replacement
leakage 4.Fastener (loose) -
5.Transmission housing
-
(distorted)
6.Bolt sealant unevenly Chapter 21 Transmission- transmission assembly,

appliedor missed replacement
PARTS DRAWING(4WD)
21
1 Second Shaft Bearing 13 First Shaft Cylindrical Bearing
2 Second Shaft Oil Seal 14 First Shaft Module
Fastening Bolts For Front And Rear

3 15 First Shaft Bearing
Housings
4 Rear Housing Assembly 16 First Shaft Oil Seal
5 Gear Shift Shaft Oil Seal 17 First Shaft End Cover
6 Extension Housing 18 First Shaft End Cover Retaining Bolt
7 Reverse Lamp Switch Assembly 19 Clutch Housing
8 Reverse Idler Shaft Retaining Bolt 20 Clutch Housing Retaining Bolt
9 Shift Shaft Fork Module 21 Reverse Idler Shaft Bracket
10 Second Shaft Module 22 Intermediate Shaft Module
Intermediate Shaft Cylindrical

11 23 Front Housing Assembly
Bearing
12 Reverse Idler Module 24 Shift Shaft Fork Module Retaining

REPLACEMENT (4WD)
1. Park the vehicle on level ground, engage the park brake and shift in N position
3. Unscrew the drain plug at the bottom of the

transmission, drain the transmission oil
NOTICE:
• Before draining, ensure the ventilation plug is
clear.Unscrew the drain plug and drain the oil
when the engine is hot, in order to drain as
much gearbox oil as possible.
• When draining the gearbox oil, recycle it with a
special container and dispose it as required.
• After the lubricating oil of the transmission is fully
drained, install the oil drainage plug, in order to
prevent missing installation.
Torque:65~78N•m
4. Disconnect the connector of the reverse lamp

switch
21
5. Remove the transmission shifting system (refer to "Chapter21 Transmission - Transmission

Shifting System, Replacement")
6. Remove the clutch cylinder (Refer to "Chapter 22 Clutch - Clutch Cylinder, Overhaul")
7. Remove the transmission shaft (Refer to "Chapter 34 Axle & Transmission Shaft -
Transmission Shaft Assembly, Overhaul")
8. Remove the transfer case assembly (Refer to "Chapter 23 Transfer Case - Transfer Case ,
Replacement")
9. Remove the transmission assembly

(a). Unscrew the bolts connecting the gearbox
and the body bracket.
(b). Unscrew the retaining bolts.

(c). Remove the body bracket.
DANGER:
Before operation, support the transmission with a
jack and take necessary protective measures.
(d). Support the transmission with a support.

(e). Unscrew 8 retaining bolts, disconnect
the connection between the transmission
and the engine, and carefully lower the
transmission assembly.
10. Install the transmission assembly

(a). Operate the gearshift lever to shift a
forward gear, elevate the transmission
assembly with the support, and align the
1st shaft with the pressure plate center of
the clutch and fully insert.
DANGER:
• Support the transmission with a jack and take necessary protective measures.
• Keep the transmission as level as possible, in order to ease the installation.
• Apply a slight amount of lubricating grease on the 1st shaft spline to ease the installation.
(b). Tighten the retaining bolts of the transmission.
Torque:30~42N•m
(c). Install the body bracket.

(d). Tighten the retaining bolts of the body bracket.
Torque:21~25N•m
(e). Tighten the bolts connecting the gearbox

and the body bracket.
Torque:46~56N•m
21
11. Install the transfer case assembly (Refer to

"Chapter 23 Transfer Case - Transfer Case ,
Replacement")
NOTICE:
While installing the fastening bolts of transfer
case, connect the grounding wires of transfer
case and body.
12. Install the transmission shaft (Refer to "Chapter 34. Axle & Transmission Shaft -
Transmission Shaft Assembly, Overhaul")
13. Install the clutch cylinder (Refer to "Chapter 42 Clutch- Clutch Cylinder, Overhaul")
14. Install the transmission shifting system (Refer to "Chapter 21. Transmission -
Transmission Shifting System, Replacement")
15. Connect the reverse lamp switch connector
16. Top up the gearbox oil and tighten the filler

plug
Torque:65~78N•m
Transmission oil (model):GL-4 75W/90
NOTICE:
• Don't mix the gearbox oil of different brands.
• When checking the oil level, ensure the vehicle
is level and the oil level is no lower than 5mm
from the bottom of the filler plug.
18. Transmission grinding standards and tests
(a). It shall be performed at approx. 1500 RPM, with the oil temperature no lower than
15℃ and without load. It shall run no less than 15 minutes at the neutral gear and
20 minutes at any other gear.
(b). Check whether the shifting is smooth and the gears are completely engaged.
(c). When testing the transmission, there shall be no abnormal sound of friction or impact.
(d). The transmission shall have no leakage.
(e). After grinding, drain the gear oil used for grinding, thoroughly clean the interior of
the transmission and fill it with the gearbox oil as required.
DISASSEMBLE(4WD)
1. Remove the disengagement bearing

(a). Release the clip of the disengagement fork.
(b). Remove the disengagement bearing and

the disengagement fork.
21
(c). Disassemble the disengagement bearing,

retaining clip and disengagement fork.
2. Remove the clutch housing

(a). Unscrew the retaining bolts.
(b). Remove the clutch housing.
NOTICE:
If the fitting between the clutch housing and
transmission is especially secure, knock the
secure portions of the clutch housing with a
rubber hammer.
3. Remove the front bearing cap

(b). Remove the front bearing cap.
(c). Remove the front bearing oil seal.
4. Remove the front housing assembly

(a). Remove the front bearing snap ring.
(b). Unscrew the shift fork dowel bolt.

(c). Unscrew the front housing retaining bolts.

(d). Remove the front housing.
(e). Remove the first shaft bearing and the

snap ring.
5. Remove the extension housing 21
(a). Remove the gear shift retaining pin with a tool.

(c). Remove the extension housing.
6. Remove the rear housing

(a). Pray the second shaft oil seal.
(b). Remove the second shaft snap ring.
(c). Unscrew the retaining bolts.

(d). Remove the reverse idler shaft bracket.
(e). Remove the first shaft assembly.

NOTICE:
To lower the weight, knock the 2nd shaft output
end with a rubber hammer to withdraw the 2nd
shaft from the rear housing and take out the 1st
shaft assembly.
(f). Remove the intermeidate shaft assembly,

second shaft assembly, gear shift fork
assembly and reverse gear shaft.
(g). Unscrew the retaining bolts and remove

the retaining plate.
(h). Remove the second shaft bearing.

(i). Remove the rear housing assembly.
7. Install the rear housing 21
(a). Install the second shaft bearing.
(b). Install the retaining plate and tighten the

retaining nuts.
Torque:14~21N•m
(c). Install the first shaft assembly.
(d). Install the intermeidate shaft assembly,

second shaft assembly, gear shift fork
assembly and reverse gear shaft with a
tool.
NOTICE:
Firstly install the intermediate shaft assembly,
1st shaft assembly, 2nd shaft assembly, gearshift
fork assembly, and reverse gear shaft onto the
housing and then install the 1st shaft to complete
the overall installation.
(e). Install the reverse idler shaft bracket.

(f). Tighten the retaining bolts.
Torque:38~49N•m
(g). Install the second shaft snap ring.

(h). Install the second shaft oil seal.
8. Install the extension housing

NOTICE:
• Before installation, clean the impurities and dirt
on the housing interface.
• During installation, apply Loctite 518 sealant
evenly on the extension housing interface.
(a). Tighten the retaining bolts.
Torque:30~42N•m
NOTICE:
During installation, align the gearshift gear with
the gearshift fork and install.
(b). Install the gear shift retaining pin with a tool.
21
9. Install the front housing assembly

(a). Install the clip ring to the first shaft bearing.
(b). Install the first shaft bearing and the clip
ring assembly.
(c). Install the front housing.

NOTICE:
evenly on the housing interface.
(d). Tighten the front housing retaining bolts.
Torque:30~42N•m
(e). Tighten the shift fork dowel bolt.

Torque:38~49N•m
(f). Install the front bearing snap ring.
10. Install the front bearing cap

(a). Install the front shaft oil seal.
NOTICE:
Before the installation, pay attention to the
orientation of oil seal.
(b). Tighten the retaining bolts.

Torque:7~11N•m
NOTICE:
evenly on the front bearing cap interface.
11. Install the clutch housing

(a). Tighten the retaining bolts.
Torque:30~42N•m
12. Install the disengagement bearing

(a). Assemble the disengagement bearing,
NOTICE:
Check whether the disengagement bearing
rotates smoothly and replace it if needed.
(b). Install the disengagement bearing and the 21
disengagement fork.
NOTICE:
Apply some grease inside the disengagement
bearing during installation.
(c). Install the clip.

21-22 TRANSMISSION - FIRST SHAFT & REVERSE SHAFT ASSEMBLY
FIRST SHAFT & REVERSE SHAFT ASSEMBLY

PARTS DRAWING
1 Bearing Circlip 7 Thick Gasket
2 First Shaft Bearing Stop Ring 8 Reverse Idler
3 Ball Bearing 9 Reverse Idler Shaft
4 First Shaft Module 10 Reverse Idler - Needle Bearing
5 First Shaft Cylindrical Bearing 11 Ball
6 Reverse Idler Shaft Circlip

TRANSMISSION - FIRST SHAFT & REVERSE SHAFT ASSEMBLY 21-23
REPLACEMENT
Refer To "Chapter 21 Transmission - Transmission Assembly, Replacement"
21
21-24 TRANSMISSION - SECOND SHAFT ASSEMBLY
SECOND SHAFT ASSEMBLY

PARTS DRAWING
TRANSMISSION - SECOND SHAFT ASSEMBLY 21-25
1 Third/Fourth Gear Hub Circlip 14 First Gear Synchronizer Ring Set
Third/Fourth Gear Synchronizer

2 15 Spline Set
Assembly
3 Third Gear Synchronizer Ring 16 Second Shaft First Gear Assembly
4 Second Shaft Third Gear Assembly 17 First Gear Needle Bearing
5 Third Gear Needle Bearing 18 Second Shaft Fifth Gear Assembly
6 Second/Third Gear Washer 19 Fifth Gear Needle Bearing
7 Second/Third Gear Washer Ring 20 Fifth Gear Synchronizer Ring
Fifth/Reverse Gear Synchronizer

8 Second Shaft Second Gear Assembly 21
Assembly
9 Second Gear Needle Bearing 22 Reverse gear synchronizer ring
Second Shaft Reverse Gear

10 Second Gear Hub Circlip 23
Assembly
11 Second Gear Synchronizer Ring Set 24 Reverse Gear Needle Bearing
12 Spline Set 25 Second Shaft assembly
13 First/Second Synchronizer Assembly
21
DISASSEMBLE
1. Remove the fifth gear assembly

(a). Remove the fifth gear.
(b). Remove the fifth gear needle bearing.
2. Remove the fifth gear synchronizer assembly

(a). Remove the fifth gear synchronizer assembly.
(b). Disassemble the synchronizer gear sleeve,

gear hub and sliding block.
3. Remove the reverse gear assembly

(a). Remove the reverse gear.
(b). Remove the reverse gear needle bearing.
4. Remove the third/fourth gear synchronizer 21
assembly
(a). Remove the circlip with circlip pliers.
(b). Remove the third/fourth gear synchronizer

assembly from the second shaft.
(c). Disassemble the synchronizer gear sleeve,

(d). Remove the third gear synchronizer ring.
5. Remove the third gear module

(a). Remove the third gear.
(b). Remove the third gear needle bearing.

6. Remove the second gear module

(a). Remove the second/third gear washer and
washer ring module.
(b). Remove the second gear.
(c). Remove the second gear needle bearing. 21
7. Remove the first/second gear synchronizer

assembly
(a). Remove the second gear synchronizer ring
module and the second gear hub circlip.
(b). Remove the first/second gear synchronizer

module.
(c). Disassemble the synchronizer gear sleeve,

(d). Remove the first gear synchronizer inner

and outer rings.
(e). Remove the first gear synchronizer inner

ring module and the second gear hub
circlip.
8. Remove the first gear assembly

(a). Remove the first gear assembly.
(b). Remove the first gear needle bearing.
9. Check the second shaft 21
(a). Measure the second shaft round runout.

Standard:0~0.2mm
10. Check the radial clearance between the

synchronizer ring and the gear
(a). Check the radial clearances between
all gear synchronizer assemblies,
synchornizer rings and gears.
Limit:0.5mm
NOTICE:
• Check the radial clearances of all gear synchronizer
rings and gears in the same direction.
• If the clearance exceeds the limit, replace the
synchronizer ring and/or gear.
(b). Check for wear and damage on the

synchronizer rings.
(c). Press the synchronizer rings onto the
fourth gear and rotate them in one
direction, to check the locking performance
of the synchronizer rings. If the locking
is inefficient, apply some quality grinding
compound to the interface between the
synchronizer ring and the gear, and grind it
gently.
11. Install the first gear assembly

(a). Install the first gear needle bearing.
NOTICE:
• When installed in the gear, the needle bearing
shall be no higher than the gear end, or check
the installation position or replace the bearing.
• When installing the needle bearing, shake it and
check for missing needle. Replace it in case of
any damage.
• During installation, apply some lubricant to the
needle bearing, to avoid wear caused by dry
friction.
(b). Install the first gear assembly.
12. Install the first/second gear synchronizer

assembly
(a). Install the first gear synchronizer inner ring
NOTICE:
The synchronizer inner ring shall be installed in
the gear groove.
(b). Install the first gear synchronizer inner and

outer rings.
NOTICE:
During installation, apply some lubricant to the
synchronizer inner and outer rings, to avoid wear
caused by dry friction.
(c). Install the synchronizer gear sleeve, gear

hub and sliding block.
(d). Install the first/second gear synchronizer 21
module.
(e). Install the second gear synchronizer ring

13. Install the second gear module

(a). Install the second gear needle bearing.
NOTICE:
any damage.
friction.
(b). Install the second gear.
(c). Install the second/third gear washer and

washer ring module.
14. Install the third gear module

(a). Install the third gear needle bearing.
NOTICE:
• When installed in the gear, the needle bearing shall be no higher than the gear end, or
check the installation position or replace the bearing.
• When installing the needle bearing, shake it and check for missing needle. Replace it in
case of any damage.
• During installation, apply some lubricant to the needle bearing, to avoid wear caused by
dry friction.
(b). Install the third gear.
15. Install the third/fourth gear synchronizer

assembly
(a). Install the third gear synchronizer ring.
21
(b). Install the synchronizer gear sleeve, gear

(c). Install the third/fourth gear synchronizer

assembly from the second shaft.
(d). Install the circlip with circlip pliers.

NOTICE:
• Before installation, check for distortion of the
circlip and replace it if needed.
• Select the right circlip so that the radial
clearance of the synchronizer gear base meets
the standard.
16. Install the reverse gear assembly

(a). Install the reverse gear needle bearing.
NOTICE:
any damage.
friction.
(b). Install the reverse gear.
17. Install the fifth gear synchronizer assembly

(a). Install the synchronizer gear sleeve, gear
(b). Install the fifth gear synchronizer assembly.
18. Install the fifth gear assembly 21
(a). Install the fifth gear needle bearing.

NOTICE:
any damage.
friction.
(b). Install the fifth gear.
21-38 TRANSMISSION - INTERMEDIATE SHAFT ASSEMBLY
INTERMEDIATE SHAFT ASSEMBLY

PARTS DRAWING
1 Intermeidate Shaft Fourth Gear 4 Intermediate Shaft Third Gear
2 Intermeidate Shaft Fourth Gear Circlip 5 Intermediate Shaft Second
3 Intermeidate Shaft Third Gear Circlip 6 Intermediate Shaft Fifth Gear

TRANSMISSION - INTERMEDIATE SHAFT ASSEMBLY 21-39
DISASSEMBLE
NOTICE:
Since there is interference fit between the intermediate shaft fourth and fifth gears and the
intermediate shaft, during disassembly, remove the fourth gear first and then the fifth gear
with press.
1. Remove the intermediate shaft fourth gear

(a). Remove the intermeidate shaft fourth gear
with a tool.
2. Remove the intermediate shaft fifth gear

(a). Remove the intermeidate shaft fifth gear
with a tool.
21
3. Remove the intermediate shaft third gear

(a). Remove the retaining circlip.
(b). Remove the intermeidate shaft third gear
with a tool.
21-40 TRANSMISSION - INTERMEDIATE SHAFT ASSEMBLY
4. Remove the intermediate shaft
5. Assemble the intermediate shaft

NOTICE:
When assembling the intermediate shaft, lubricate
all parts to install with gear oil.
6. Install the intermediate shaft third gear

(a). Install the retaining circlip.
NOTICE;
Before installation, check for distortion of the
circlip and replace it if needed.
7. Install the intermediate shaft fourth gear

NOTICE:
Since there is interference fit between the
intermediate shaft fourth gear and the intermediate
shaft, heat the fourth gear before installation.
TRANSMISSION - INTERMEDIATE SHAFT ASSEMBLY 21-41
8. Install the intermediate shaft fifth gear

NOTICE:
Since there is interference fit between the
intermediate shaft fifth gear and the intermediate
shaft, heat the fifth gear before installation.
21
- MEMO -
CLUTCH
CLUTCH SYSTEM ............................... 22-1
NOTICE ............................................ 22-1
SYMPTOMS ..................................... 22-2
CLUTCH SYSTEM AIR DISCHARGE .. 22-4
DISCHARGE AIR .............................. 22-4
CLUTCH PEDAL .................................. 22-5
PARTS DRAWING ............................ 22-5
ADJUSTMENT .................................. 22-6
REPLACEMENT ............................... 22-7
CLUTCH MASTER CYLINDER .......... 22-10
PARTS DRAWING .......................... 22-10
REPLACEMENT ............................. 22-11
CLUTCH CYLINDER .......................... 22-16
PARTS DRAWING .......................... 22-16
REPLACEMENT ............................. 22-17
CLUTCH MODULE............................. 22-19
PARTS DRAWING .......................... 22-19
OVERHAUL .................................... 22-20
22
CLUTCH - CLUTCH SYSTEM 22-1
CLUTCH SYSTEM
NOTICE
1. The brake fluid drained can’t be reused.

2. Make sure to use the dedicated brake fluid and not to use other brake fluid,
otherwise it will lead to corrosion and reduce the service life of the clutch system.
3. Never splash the brake fluid onto the vehicle, or it will probably damage the paint.
The brake fluid splashed on the paint shall be flushed clean immediately with water.
4. Don’t wash the clutch pressure plate with gasoline.
5. As the release bearing is filled with grease, so please don’t wash it with oils or
liquid substances.
6. During the installation of clutch, apply the heat-resistant or pressure-resistant
grease, lubricate the splines of friction lining and transmission input shaft properly,
and ensure that the friction lining can move freely on the spline of transmission input
shaft. Its excessive lubrication will cause the slippage of friction lining.
7. When the friction lining is worn up to the specified wear limit, replace the friction
lining assembly in time to avoid the slippage of clutch and scratches of pressure
plate and flywheel surface.
8. During the repair of the clutch subassembly, it’s prohibited to conduct sanding
or clean with a dry brush and compressed air, in order to prevent generation of
powdered scrap.Clean with a cloth dipped with water or with a vacuum cleaner.
22
22-2 CLUTCH - CLUTCH SYSTEM

The table below can help you to rapidly find out the required malfunction information.
Malfunction
Symptoms
1.Clutch pedal free travel (too
Chapter22. Clutch - clutch pedal,adjustment
small)
2. Lining (excessive wear) Chapter 22. Clutch - clutch module,overhaul
Clutch slips 3. Flywheel (warping) -
4. Clutch cover (distorted) Chapter 22. Clutch - clutch module,overhaul
5.Clutch diaphragm spring

Chapter 22. Clutch - clutch module,overhaul
(defective)
1.Clutch pedal free travel (too

Chapter 22. Clutch - clutch pedal,adjustment
large)
2.Clutch diaphragm spring

(defective)
3. Clutch Master Cylinder

(leakage)
Chapter 22. Clutch - master cluth cylinder,

Incomplete 4.Clutch cylinder (leakage)
replacement
clutch
Chapter 22. Clutch - cluth cylinder booster,
disengagement 5. Clutch pipe (containing air)
replacement
6. Lining (abnormal wear) Chapter 22. Clutch - clutch module,overhaul
7. Clutch cover (distorted) Chapter 22. Clutch - clutch module,overhaul
8. Disengagement bearing
(exceesive wear)
9.Clutch disengagement fork
(abnormalwear)
1. Shock absorption spring

(broken)
2. Lining (excessive wear) Chapter 22. Clutch - clutch module,overhaul

Clutch noise
3. Disengagement bearing
(loose)
4. Clutch pedal (distorted) Chapter 22. Clutch - cluth pedal, replacement

CLUTCH - CLUTCH SYSTEM 22-3
Malfunction
Symptoms
1.Lining (distorted or abnormal
wear)
2. Flywheel (abnormal wear) -
3. Clutch cover (abnormal wear) Chapter 22. Clutch - clutch module,overhaul
4. Shock absorption spring

Clutch shaking
(broken or distorted due to Chapter 22. Clutch - clutch module,overhaul
fatigue)
5. Clutch diaphragm spring

(distorted)
6.Engine bracket (loose or

-
damaged rubber gasket)
22
22-4 CLUTCH - CLUTCH SYSTEM AIR DISCHARGE
CLUTCH SYSTEM AIR DISCHARGE

DISCHARGE AIR
1. Top up the brake fluid into the oil cup

NOTICE:
Don't spill the brake fluid on the paint or your skin.
If that's the case, clean it immediately.
2. Discharge the air in the clutch cylinder

(a). Connect the rubber hose to the clutch
cylinder discharge plug.
(b). Quickly press the clutch pedal for several
times, hold it in place and release the
clutch discharge plug.
(c). Tighten the discharge plug and release
the clutch pedal as soon as the brake fluid
stops.
(d). Repeat Steps (b) and (c) until the air in the
brake fluid is fully discharged.
3. Check the level in the oil cup

(a). Check the clutch fluid level and top it up if
needed.
CLUTCH - CLUTCH PEDAL 22-5
CLUTCH PEDAL
PARTS DRAWING
22
1 Bracket Retaining Bolt 5 Clutch Pedal Retaining Bolt
2 Fitting 6 Clutch Pedal Return Spring
3 Clutch Pedal Bracket 7 Clutch Pedal
4 Retaining Nut 8 Clutch Position Sensor

22-6 CLUTCH - CLUTCH PEDAL
ADJUSTMENT
1. Check the height of the clutch pedal

(a). Check the height H from the clutch pedal to
the floor.
Standard:155±10mm
(b). Unscrew the locking nut, rotate the stop
bolt until the pedal reaches the correct
position, and tighten the locking nut.
Torque: 9~11N•m
2. Check the clutch pedal free travel and the

push rod travel
(a). Press the pedal until you feel the
resistance. Check the free travel L of the
clutch pedal.
Standard:7.5±2.5mm
(b). Slowly press the pedal until the resistance
increases. Check the push rod travel L2.
3. Adjust the clutch pedal free travel and the push rod travel
(a). Release the locking nut, turn the push rod until the pedal free travel and the push
rod travel are correct, and tighten the locking nut.
(b). Check the pedal height after adjusting the pedal free travel.
REPLACEMENT
1. Remove the Clutch Master Cylinder push

rod pin
(a). Remove the Clutch Master Cylinder push
rod pin and the split pin.
2. Remove the clutch position sensor

(a). Disconnect the clutch position sensor
connector.
22
(b). Loosen the lock nuts and screw out the
clutch position sensor.
22-8 CLUTCH - CLUTCH PEDAL
3. Remove the clutch pedal assembly

(a). Unscrew 2 retaining nuts inside the driver's
cab.
(c). Remove the clutch pedal assembly.
4. Install the clutch pedal assembly

(a). Tighten 2 retaining nuts inside the driver's
cab.
Torque: 9~11N•m
Torque: 21~25N•m
5. Install the Clutch Master Cylinder push rod

pin
(a). Install the Clutch Master Cylinder push rod
pin and the split pin.
6. Install the Clutch Position Sensor

(a). Install the Clutch Position Sensor and
tighten the retaining nuts of the clutch
position sensor.
(b). Connect the connector of the clutch 22

position sensor. .
7. Check and adjust the height of the clutch pedal (Refer to "Chapter 22 Clutch -
Clutch Pedal,Adjustment")
8. Check and adjust the clutch pedal free travel and the push rod travel (Refer to
"Chapter 22 Clutch- Clutch Pedal, Adjustment")
22-10 CLUTCH - CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER

PARTS DRAWING
1 Circlip 7 Clutch Booster Assembly
Locking Nut Clutch Master Cylinder

2 Gasket 8
Push Rod
Clutch Master Cylinder Push Rod

3 Piston 9
Pin
4 Spring 10 Split Pin
5 Clutch Master Cylinder 11 Push Rod U-joint
6 Retaining Nut
CLUTCH - CLUTCH MASTER CYLINDER 22-11
REPLACEMENT
1. Drain the clutch fluid

NOTICE:
Don't spill the clutch fluid on the paint or your skin. If that's the case, clean it immediately.
2. Remove the Clutch Master Cylinder

(a). Unscrew the oil cup hose clip and remove
the hose.
(b). Unscrew the nuts and remove the Clutch

Master Cylinder oil pipe.
22
(c). Unscrew the retaining nuts of the Clutch

Master Cylinder inside the engine
compartment.
(d). Remove the Clutch Master Cylinder.
3. Remove the clutch booster assembly

(a). Unscrew the vacuum hose clip and remove
the hose.
(b). Remove the Clutch Master Cylinder push

rod pin and the split pin.
(c). Unscrew 2 retaining nuts inside the driver's

cab.
(d). Remove the clutch booster assembly.
4. Install the clutch booster assembly

(a). Install the clutch booster assembly.
(b). Tighten 2 retaining nuts inside the driver's

cab. 22
Torque: 21~25N•m
(c). Install the clutch master cylinder push rod

pin and the split pin.
(d). Install the vacuum hose and the vacuum

hose clip.
5. Install the clutch master cylinder

(a). Tighten the retaining nuts of the clutch
master cylinder inside the engine
compartment.
Torque:21~25N•m
(b). Install the clutch master cylinder oil pipe

and tighten the nuts.
Torque:29~35N•m
(c). Install the oil cup hose and tighten the oil
cup hose clip.
6. Discharge the air in the clutch pipe (Refer to "Chapter 22 Clutch - Clutch Fluid,
Discharge Air")
7. Check and adjust the height of the clutch pedal (Refer to "Chapter 22 Clutch -Clutch
Pedal, Adjustment")
8. Check the level in the oil cup (Refer to "Chapter 22 Clutch - Clutch Fluid, Discharge
Air")
22
22-16 CLUTCH - CLUTCH CYLINDER
CLUTCH CYLINDER
PARTS DRAWING
1 Clutch Cylinder Dust Cover 4 Spring
2 Clutch Cylinder Push Rod 5 Clutch Cylinder
3 Piston 6 Discharge Plug

CLUTCH - CLUTCH CYLINDER 22-17
REPLACEMENT
NOTICE:
Don't spill the clutch fluid on the paint or your skin. If that's the case, clean it immediately.
1. Remove the clutch cylinder

(a). Unscrew the plug and remove the clutch
cylinder oil pipe.
NOTICE:
After the disconnection of oil pipes, use plugs to
seal the clutch oil pipes.
(b). Remove 2 retaining bolts of the clutch

cylinder.
(c). Remove the clutch cylinder.
22
2. Install the master clutch cylinder

(a). Install the clutch cylinder and tighten 2
clutch cylinder retaining bolts.
Torque: 21~25N•m
22-18 CLUTCH - CLUTCH CYLINDER
(b). Install the clutch cylinder oil pipe and

tighten the clutch cylinder oil pipe plug.
Torque: 19~21N•m
NOTICE:
During installation, replace a new gasket.
3. Discharge the air in the clutch pipe (Refer to "Chapter 22 Clutch - Clutch Fluid,
Discharge Air")
4. Check the level in the oil cup (Refer to "Chapter 22 Clutch - Clutch Fluid, Discharge
Air")
CLUTCH - CLUTCH MODULE 22-19
CLUTCH MODULE
PARTS DRAWING
22
1 Clutch friction plate 5 Hexagon head bolt
2 Clutch platen with cover assembly 6 Release bearing
3 Flat washer 7 Fixed buckle
4 Spring washer 8 Release fork

22-20 CLUTCH - CLUTCH MODULE
OVERHAUL
1. Remove the transmission assembly (Refer to "Chapter 21 Transmission -

Transmission Assembly,Replacement")
2. Remove the clutch disengagement bearing

and disengagement fork
(a). Release the clip.
(b). Remove the disengagement bearing and

the disengagement fork.
(c). Disassemble the disengagement bearing,

3. Remove the clutch cover

(a). Align the mark on the clutch cover to that
on the flywheel and label them accordingly.
(b). Unscrew each bolt round by round, in a
diagonal manner, until the clutch diaphragm
spring is fully released. Unscrew all 6 bolts.
(c). Remove the clutch cover.

NOTICE:
Do not fall off the clutch friction plate. As the
clutch pressure plate is heavy, take cautions
during the handling of clutch pressure plate, in
order to prevent the falloff of parts from causing
damage or personal injury.
4. Remove the clutch lining

NOTICE: 22
When the lining is removed, keep it away from oil
and dirt.
5. Check the clutch lining assembly

(a). Measure the rivet head depth and lining
wear with vernier calipers. Replace the
lining if needed.
Limit: 2.0mm
(b). Fix the clutch friction plate and use a dial

gauge to inspect the swing deviation of
clutch frication plate.
Limit: ±0.3mm
(c). Check for loose lining rivet, deterioration
caused by lagging and in turn uneven
contact, lubricant or grease or other
defects. If yes, replace the clutch lining.
(d). Check for windage or damage in the shock
absorption spring. Replace the lining if
needed.
6. Check the clutch cover

(a). Check the wear thickness and width of the
diaphragm spring with vernier calipers.
Replace the clutch cover if needed.
(b). Check the height difference of the clutch
diaphragm spring.Replace the clutch cover
if needed.
Standard:0.1mm
(c). Check for wear, crack and blockage on the
surface of the clutch. Replace the clutch
cover if needed.
(d). Check for loose rivet on the splice plate
and replace a new part if needed.
7. Check the flywheel

(a). Check the swing of the flywheel with dial
indicator. Replace the flywheel if needed.
8. Install the clutch disengagement bearing

(a). Check for blockage, damage, noise or
abnormal rotation on the bearing. And
check for damage on its interface with the
clutch diaphragm spring.
NOTICE:
The bearing is permanently lubricated. No
cleaning orlubrication is needed.
WARNING:
• Before installation, check the inner and outer
diameter surface of the bearing and replace it if
any distortation or damage.
• If any wear on the interface between the
disengagement bearing and the disengagement
fork, check the fork and the bearing and replace
them if needed.
9. Check the clutch disengagement fork

(a). Check the position on the disengagement
fork as illustrated. Replace it if any wear or
distortion.
22
10. Install the clutch lining

(a). Install the clutch lining with a special tool.
NOTICE:
Pay attention to the direction of the clutch lining
during installation.
11. Install the clutch cover

(a). Align the mark on the clutch cover with that
on the flywheel.
(b). Install the clutch cover with a special tool.
(c). Tighten the bolts of the clutch cover diagonally.

Torque:41~51N•m
12. Check and adjust the clutch cover

(a). After installation, check the evenness
of the diaphragm and make necessary
adjustment to ensure its evenness.
13. Install the clutch disengagement bearing

and disengagement fork
(a). Apply some grease at the point indicated
by the arrow.
(b). Assemble the disengagement bearing,

(c). Install the disengagement bearing and the

disengagement fork.
(d). Install the locating snap rings.

22
14. Install the transmission assembly (Refer to "Chapter 21 Transmission - Transmission

Assembly,Replacement")
- MEMO -
TRANSFER CASE
TRANSFER CASE ............................... 23-1
PARTS DRAWING ............................ 23-1
SYMPTOMS ..................................... 23-3
REPLACEMENT ............................... 23-5
OVERHAUL ...................................... 23-8
TRANSFER CASE CONTROL UNIT.. 23-25
REPLACEMENT ............................. 23-25
23
TRANSFER CASE - TRANSFER CASE 23-1
TRANSFER CASE
PARTS DRAWING
23
23-2 TRANSFER CASE - TRANSFER CASE
1 Stud 30 Oil Seal
2 Front Oil Seal 31 Rear Flange
3 Front Bearing Circlip 32 Gasket
4 Circlip 33 Gear Shift Motor Assembly
5 Front Bearing 34 Nut
6 Thrust Washer 35 O-ring
7 Planetary Gear Assembly 36 Speed Sensor
8 Input Shaft Assembly 37 Gear Shift Fork Oil Seal
9 Clutch Coil Housing 38 Oil Plug
10 4WD Shifting Gear Sleeve Assembly 39 Needle Bearing
11 Driving Sprocket 40 Shift Fork Shaft
12 Oil Pump 41 Gear Shift Cam
13 Oil Pipe Circlip 42 Spring
14 Rear Output Shaft 43 Oil Filter Module
15 Spring Pin 44 Front Output Shaft Oil Seal
16 Reduction Gear Sleeve 45 Gasket
17 Ring Gear 46 Front Flange
18 Front Transfer Case Housing 47 Nut
19 Oil Pipe 48 Gasket
20 Reduction Shift Fork Assembly 49 O-ring
21 4WD Gear Shfit Fork 50 Bolt
22 Electromagnetic Clutch Coil Assembly 51 Front Output Shaft Bearing
23 Rear Bearing Circlip 52 Circlip
24 Rear Bearing 53 Front Output Shaft
25 Rear Transfer Case Housing 54 Driven Sprocket
26 Housing Retaining Bolt 55 Gasket
27 Nameplate 56 Front Output Shaft Circlip
28 Electromagnetic Clutch Retaining Nut 57 Chain
29 Odometer Gear 58 Odometer Sensor Assembly


In case of operational difficulty, it is recommended to stop the transfer case.In most
cases,to accurately detect the fault,it may be necessary to remove,disassemble or partially
disassemble the transfer case.
Malfunction
Symptoms
Chapter 23 Transfer Case - Transfer Case Control
1.Electronic component (broken)
Unit, Replacement
2.Speed sensor (broken) Chapter 23 Transfer Case - Transfer Case, Overhau
3.Electric motor (broken) Chapter 23 Transfer Case - Transfer Case, Overhau
4.Electric clutch (broken or

Chapter 23 Transfer Case - Transfer Case, Overhau
defective)
Electronic gear
shift defective 5.Internal connection harness
(broken or defective)
6.Gear shift cam, engagement

sleeve, locking sleeve, fork or Chapter 23 Transfer Case - Transfer Case, Overhau
shift shaft (broken or worn)
7.Shift fork, locking sleeve or

gear (glued)
No front wheel
driving under 1. ransmission chain (broken) Chapter 23 Transfer Case - Transfer Case, Overhau
4WD 23
Noise at high 1.Sprocket (broken or worn) Chapter 23 Transfer Case - Transfer Case, Overhau
and low gears 2.Chain (broken or worn) Chapter 23 Transfer Case - Transfer Case, Overhau
under 4WD 3.Tire (improper pressure) -
1. Transfer case housing Chapter 23 Transfer Case - Transfer Case,

(broken) Replacement
2.Transfer case assembly Chapter 23 Transfer Case - Transfer Case,

(leakage from other parts) Replacement
3. Ventilation pipe (blocked) -
Noise in transfer 4. Lubricant (more than required Chapter 23 Transfer Case - Transfer Case,
case or improper brand) Replacement
Chapter 23 Transfer Case - Transfer Case,

5. Sealing surface bolt (loose)
Replacement
6.Sealant (different brands or Use authorized sealant and tighten bolts as

unauthorized sealant) required
7.Oil seal (worn or broken) Chapter 23 Transfer Case - Transfer Case, Overhau
Malfunction
Symptoms
1. Lubricant (insufficient volume)
Replacement
Chapter 23 Transfer case - Transfer Case,

2. Lubricant (wrong lubricant)
Replacement

3. Connecting bolt (loose)
Noise in transfer Replacement
case Chapter 23 Transfer Case - Transfer Case,
4. Connector (loose)
Replacement

5. Transfer case bearing (noise)
Replacement
6. Gear (noise)
Replacement
REPLACEMENT
1. During disassembly, the gearbox shall be engaged in neutral position and the
transfer case in 2H position
3. Remove the front transmission shaft the rear transmission shaft (Refer To "Chapter
34 Axle & Transmission Shaft - Transmission Shaft, Replacement")
4. Drain the transfer case oil

(a). Unscrew the drain bolt and drain the
transfer case oil.
Torque:19~30N•m
NOTICE:
Install the transfer case oil drainage plug after the
drainage of transfer case lubricating oil.
5. Remove other accessories of the transfer

case
(a). Disconnect the odometer sensor connector.
23
(b). Disconnect the gear shift motor connector.

(c). Disconnect the transfer case harness.
6. Remove the transfer case assembly

(a). Unscrew the retaining nuts.
(b). Remove the transfer case assembly.
7. Install the transfer case assembly

(a). Tighten the retaining nuts.
Torque:41~51N•m
NOTICE:
While installing the fastening nuts of transfer case,
connect the transfer case grounding wire.
8. Install other accessories of the transfer

case
(a). Connect the transfer case harness.
(b). Connect the gear shift motor connector.
(c). Connect the connector of the odometer

sensor.
9. Fill up the transfer case oil

(a). Unscrew the drain bolt and fill up the
transfer case oil.
Required transfer case lubricant:
Dexron III, XT-2-QDX (Ford ESP-M2C138-
CJ) or equivalent.
Filling volume:1.2L
NOTICE:
• Don't mix the transfer case oil of different
brands.
• When checking the oil level, ensure the vehicle
is level and the oil level is no lower than 5mm
from the bottom of the filler plug.
(b). Install the transfer case oil filler plug.
23
Torque:19~30N•m
10. Install the front transmission shaft and the rear transmission shaft (Refer to"Chapter
34 Axle & Transmission Shaft - Transmission Shaft, Replacement")
OVERHAUL
1. Remove the odometer sensor

(b). Remove the odometer sensor pressure
plate and odometer sensor.
2. Remove the gear shift motor assembly

(b). Remove the gear shift motor assembly.
3. Remove the front flange

(a). Fix the flange with tool, unscrew the flange
fastening nuts, and take out the washers.
(b). Pull out the flange with a puller.
NOTICE:
The front driving shaft flange can be removed in
the same way as the rear driving shaft flange.
4. Remove the rear housing assembly

(a). Unscrew the transfer case retaining bolts.
(b). Remove the transfer case housing.
(c). Unscrew the fastening nuts of electromagnetic

clutch coil and disconnect the wire
connector of clutch coil.
(d). Remove the electromagnetic clutch.
NOTICE:
Generally it’s unnecessary to remove the
electromagnetic clutch coil. When it’s necessary
23
to remove, disconnect the wire connector of clutch
coil before removal.
(e). Remove the circlip and the rear bearing.

(f). Remove the odometer gears and spacers.

(g). Pry the output shaft oil seal.
5. Remove the transmission chain and the

gear shift system assembly
(a). Remove the spring.
(b). Remove the clutch coil housing.

(c). Remove the AWD gearshift fork and AWD

gearshift gear sleeve assembly.
(d). Disassemble the 4WD gear shift sleeve

assembly.
(e). Remove the washer.
23
(f). Remove the drive sprocket, driven

sprocket, and chain together.
(g). Remove the front output shaft.
(h). Remove the oil pump.

NOTICE:
Before the disassembly of oil pump, firstly remove
the magnet for absorption of impurities.
(i). Remove the rear output shaft.
(j). Remove the reduction gearshift gear sleeve,

reduction gearshift fork, reduction gearshift
fork shaft, and gearshift camshaft assembly
together.
6. Disassemble the front housing assembly

(a). Remove the planetary gear circlip.
(b). Remove the outer gear ring of planetary

gear.
(c). Pry open the snap rings of input shaft with

planetary gear.
23
(d). Remove the input shaft assembly with

planetary gear.
(e). Remove the oil seals of front housing.
7. Break up the input shaft assembly with

planetary gear
(a). Remove the snap rings of input shaft
bearings.
(b). Pull out the input shaft bearings.
(c). Remove the input shaft pressure plate.

(d). Remove the fastening snap rings of input

shaft pressure cap and remove the
pressure cap.
(e). Remove the input shaft assembly with

gear.
(f). Remove the snap rings of input shaft.
23
(g). Remove the input shaft.

8. Assemble the input shaft assembly with

planetary gear
(a). Install the center gear onto the input shaft.
(b). Install the snap rings of input shaft.
(c). Install the input shaft gear assembly with

gear onto the planetary gear.
(d). Install the input shaft pressure cap and

install the fastening snap rings.
(e). Install the input shaft pressure plate.
(f). Install the input shaft bearings.
(g). Install the input shaft snap rings.
23
9. Install the front housing assembly

(a). Install the the front housing oil seal.
(b). Install the input shaft assembly with

planetary gear.
(c). Pry open the input shaft with planetary

gear snap rings and install the input shaft
assembly with planetary gear in place.
(d). Install the outer gear ring of planetary gear.
(e). Install the snap ring for outer gear ring of

planetary gear.
10. Install the transmission chain and the gear

shift system assembly
(a). Install the front output shaft.
(b). Install the reduction gearshift gear sleeve,

reduction gearshift fork, reduction gearshift
fork shaft, and gearshift camshaft
assembly together.
(c). Install the rear output shaft.
23
(d). Install the oil pump and magnet.

NOTICE:
The oil pump and the output shaft are properly
installed, closely related and rotate smoothly.
(e). Assemble the sprocket and the chain

assembly.
(f). Install the drive sprocket, driven sprocket,

and chain assembly together.
(g). Install the washer.
(h). Assemble the 4WD gear shift sleeve

assembly.
(i). Install the 4WD gear shift sleeve assembly.
(j). Install the clutch coil housing.
(k). Install the spring.
23
11. Install the rear housing assembly

(a). Install the rear output shaft oil seal.
(b). Install the odometer gear and the washer.
(c). Install the rear bearing and the circlip
(d). Install the electromagnetic clutch coil.

(e). Tighten the fastening nuts of electromagnetic
clutch coil.
Torque:8~11N•m
NOTICE:
After the installation of clutch coil, connect the
wire connector of clutch coil.
(f). Apply the sealant and install the housing.

(g). Tighten the fastening bolts of the transfer
case housing.
Torque:27~40N•m
12. Install the front flange

(a). Install the gasket and flange.
(b). Fix the flange with a tool and tighten the
fastening nuts of the flange.
Torque(front):203~241N•m
Torque(rear):305~332N•m
NOTICE:
23
The front driving shaft flange can be installed in
the same way as the rear driving shaft flange.
13. Install the gear shift motor assembly

(a). Install the gear shift motor assembly.
Torque:8~11N•m
14. Install the odometer sensor

(a). Install the odometer sensor and odometer
sensor pressure plate.
Torque:3~6N•m
TRANSFER CASE - TRANSFER CASE CONTROL UNIT 23-25
TRANSFER CASE CONTROL UNIT

REPLACEMENT
1. Disconnect the negative cable of the battery

2. Remove the instrument panel (Refer to "Chapter 52 Instrument Panel And Auxiliary
Instrument Panel - Instrument Panel, Replacement")
3. Remove the transfer case control unit

(a). Disconnect the transfer case control unit
connector.
(b). Unscrew the retaining nuts and remove the
transfer case control unit.
4. Install the transfer case control unit

(a). Tighten the retaining nuts.
Torque:6~10N•m
(b). Connect the connector of the transfer case
control unit .
23
5. Install the instrument panel. (Refer to"Chapter 52 Instrument Panel And Auxiliary
Instrument Panel - Instrument Panel, Replacement")
- MEMO -
1
INDEX
(In Alphabetical Order)
CHECK HEADLAMP(INSPECTION) ............ 04-16

A CHECK PARKING BRAKE AND BRAKE
PEDAL(INSPECTION) ................................... 04-8
ABOUT USING DIAGNOSTIC DEVICE(HOW TO CHECK SAFETY BELT(INSPECTION) .......... 04-5
TROUBLESHOOT THE VEHICLE) .............. 01-19 CHECK SUSPENSION BALL JOINT AND DUST
ADJUSTMENT(CLUTCH PEDAL).................. 22-6 COVER(INSPECTION) ................................ 04-20
ADJUSTMENT(DRIVING BELT) ................12B-85 CHECK SUSPENSION MEMBER (INSPECTION)
ADJUSTMENT(VALVE) ............................12B-120 ...................................................................... 04-19
ANALYZING FAULT DESCRIBED BY CHECK THE ACCESSORY BELT (INSPECTION)
CUSTOMER(HOW TO TROUBLESHOOT THE ...................................................................... 04-13
VEHICLE) ..................................................... 01-21 CHECK THE BRAKING DISC, BRAKE DRUM
ASSEMBLING ENGINE ASSEMBLY(ENGINE AND BRAKE LINING (INSPECTION) .......... 04-23
ASSEMBLY) ...............................................12B-41 CHECK THE DRAIN HOLE OF FRONT
WINDSHIELD DRAIN TANK (INSPECTION) ........
B ...................................................................... 04-11
CHECK THE ENGINE OIL LEVEL(BJ486ZLEQ4)
(INSPECTION) ............................................. 04-30
BASIC INSPECTION(BATTERY) ................. 18-24
CHECK THE ENGINE OIL LEVEL(ISF2.8)
(INSPECTION) ............................................. 04-28
C CHECK THE HEAD OF STEERING ROD BALL
JOINT AND THE DUST COVER(INSPECTION) ...
CHANGE BRAKE FLUID (REPLACEMENT) ........ ...................................................................... 04-14
...................................................................... 04-62 CHECK THE OIL LEVEL OF THE BRAKE
CHANGE SPARK PLUG (REPLACEMENT) ......... FLUID RESERVOIR OF THE CHECK THE
...................................................................... 04-51 OIL LEVEL OF THE COOLING BRAKE FLUID
CHANGE THE AIR FILTER ELEMENT RESERVOIR(INSPECTION) ........................ 04-27
(REPLACEMENT) ........................................ 04-35 CHECK THE WINDSHIELD WIPER AND
CHECK ABRS(INSPECTION) ........................ 04-4 CLEANING DEVICE(INSPECTION) ............ 04-17
CHECK AND TIGHTEN THE BOLT ON THE CHECK THE WORKING CONDITION OF
CHASSIS ACCORDING TO THE ELECTRIC SYSTEM(INSPECTION).............. 04-2
CHECK BATTERY(INSPECTION) ................. 04-3 CHECK TIRE(INSPECTION) ....................... 04-25
CHECK BRAKE SYSTEM(INSPECTION)............. CHECKING(ENGINE OIL).............................. 17-5
...................................................................... 04-22 CHECKING(FUEL TANK CAP) .................... 13-17
CHECK DOOR CHECK, DOOR LOCK AND CHECKING(IGNITION COIL) ......................... 19-5
HINGE(INSPECTION) .................................... 04-9 CHECKING(IGNITION SYSTEM) .................. 19-4
CHECK ENGINE COMPONENTS (INSPECTION) CHECKING(OIL PUMP) ............................... 17-16
...................................................................... 04-12 CHECKING(SPARK PLUG) ........................... 19-8
CHECK EXHAUST SYSTEM(INSPECTION) ........ CLEAN THE ENGINE PARTS(ENGINE
...................................................................... 04-26 ASSEMBLY) ...............................................12B-40
2
D H
DETECTION PROCEDURE OF CIRCUITS(HOW HOW TO PERFORM TROUBLESHOOTING

TO TROUBLESHOOT THE VEHICLE) ........ 01-29 (HOW TO TROUBLESHOOT THE VEHICLE) ......
DETECTION(HOW TO TROUBLESHOOT THE ...................................................................... 01-20
VEHICLE) ..................................................... 01-22
DIAGNOSTIC TROUBLE CODES(DTC) I
LIST(HOW TO TROUBLESHOOT THE
VEHICLE) ..................................................... 01-27
INSPECTION(CAMSHAFT) .......................12B-98
DISASSEMBLE ENGINE ASSEMBLY(ENGINE
INSPECTION(CRANKSHAFT AND FLYWHEEL) .
ASSEMBLY) .................................................12B-7
..................................................................12B-137
DISASSEMBLE(4WD)(TRANSMISSION
INSPECTION(CYLINDER BLOCK) ..........12B-142
ASSEMBLY) ................................................. 21-13
INSPECTION(CYLINDER HEAD) ............12B-112
DISASSEMBLE(INTERMEDIATE SHAFT
INSPECTION(DRIVING BELT) ..................12B-84
ASSEMBLY) ................................................. 21-39
INSPECTION(INTAKE AND EXHAUST
DISASSEMBLE(SECOND SHAFT ASSEMBLY) ...
MANIFOLD) ................................................12B-90
...................................................................... 21-26
INSPECTION(PISTON AND CONNECTING
DISCHARGE AIR(CLUTCH SYSTEM AIR
ROD) ........................................................12B-128
DISCHARGE) ................................................. 22-4
INSPECTION(TIMING SPROCKET
DRIVE )(REPLACEMENT) ........................... 04-69
MECHANISM) ............................................12B-93
INSPECTION(TURBOCHARGER).............12B-88
E INSPECTION(VALVE) ..............................12B-115
INTRODUCTION TO SYSTEM
ENGINE CONTROL MODULE (ECM) ......... 11-12 FUNCTION(ENGINE CONTROL SYSTEM) .. 11-7
F M
MAINTENANCE DATA(AXLE AND

FAULT SYMPTOM CONFIRMATION AND DTC TRANSMISSION SHAFT) ............................ 03-25
(AND DATA FLOW)FUNCTION DESCRIPTION MAINTENANCE DATA(CLUTCH) ................ 03-19
OF SYSTEM COMPONENTS(ENGINE MAINTENANCE DATA(COOLING) .............. 03-11
CONTROL SYSTEM) ................................... 11-10 MAINTENANCE DATA(ENGINE CONTROL
SYSTEM)........................................................ 03-1
G MAINTENANCE DATA(ENGINE MECHANICAL
SYSTEM (BJ486ZLEQ4))............................... 03-3
MAINTENANCE DATA(FRONT SUSPENSION) ...
...................................................................... 03-21
GENERAL(HOW TO TROUBLESHOOT THE
MAINTENANCE DATA(FUEL) ........................ 03-8
VEHICLE) ..................................................... 01-18
MAINTENANCE DATA(HEATER & AIR
GENERAL(HOW TO USE THIS MANUAL) .... 01-1
CONDITIONING) .......................................... 03-34
MAINTENANCE DATA(IGN) ........................ 03-15
MAINTENANCE DATA(LUBRICATION) ....... 03-12
MAINTENANCE DATA(PARKING BRAKE) .. 03-31
3
MAINTENANCE DATA(POWER STEERING) ....... OVERHAUL(ENGINE ACCESSORY BELT)..........

...................................................................... 03-33 ....................................................................12A-17
MAINTENANCE DATA(SERVICE BRAKE) .. 03-29 OVERHAUL(FRONT OXYGEN SENSOR) .. 11-24
MAINTENANCE DATA(STARTING AND OVERHAUL(FUEL INJECTOR) ................... 11-40
CHARGING) ................................................. 03-13 OVERHAUL(GENERATOR) ........................... 18-4
MAINTENANCE DATA(STEERING GEAR) .......... OVERHAUL(IGNITION COIL) ...................... 11-38
...................................................................... 03-32 OVERHAUL(INTAKE PRESSURE/
MAINTENANCE DATA(SUPPLEMENTAL TEMPERATURE SENSOR) ......................... 11-19
SAFEGUARD SYSTEM) .............................. 03-36 OVERHAUL(KNOCK SENSOR) .................. 11-34
MAINTENANCE DATA(TIRE AND WHEEL) ......... OVERHAUL(OCV VALVE) ........................... 11-36
...................................................................... 03-24 OVERHAUL(PHASE SENSOR) ................... 11-30
MAINTENANCE DATA(TRANSMISSION) ............ OVERHAUL(REAR OXYGEN SENSOR) ..... 11-26
...................................................................... 03-16 OVERHAUL(SPEED SENSOR) ................... 11-28
OVERHAUL(TRANSFER CASE) ................... 23-8
N
P
NOTICE(CLUTCH SYSTEM) ......................... 22-1
NOTICES(COOLING SYSTEM) ..................... 16-1 PARTS DRAWING(4WD)(TRANSMISSION
NOTICES(ENGINE CONTROL SYSTEM) ..... 11-2 ASSEMBLY)(TRANSMISSION ASSEMBLY) ........
NOTICES(ENGINE MECHANICAL) .............12B-1 ........................................................................ 21-7
NOTICES(EXHAUST SYSTEM) .................... 15-1 PARTS DRAWING(BATTERY) ..................... 18-21
NOTICES(FUEL SYSTEM) ............................ 13-1 PARTS DRAWING(CAMSHAFT) ...............12B-97
NOTICES(IGNITION SYSTEM) ..................... 19-2 PARTS DRAWING(CLUTCH CYLINDER) ... 22-16
NOTICES(INTAKE AIR SYSTEM) .................. 14-1 PARTS DRAWING(CLUTCH MASTER
NOTICES(START AND CHARGE SYSTEM) ........ CYLINDER) .................................................. 22-10
........................................................................ 18-1 PARTS DRAWING(CLUTCH MODULE) ...... 22-19
NOTICES(TRANSMISSION ASSEMBLY) ...... 21-4 PARTS DRAWING(CLUTCH PEDAL) ............ 22-5
NOTICES(VEHICLE CARE) .......................... 04-1 PARTS DRAWING(CRANKSHAFT AND
NOTIES(LUBRICATING SYSTEM) ................ 17-3 FLYWHEEL) .............................................12B-136
PARTS DRAWING(CYLINDER BLOCK) ..12B-141
O PARTS DRAWING(CYLINDER HEAD) .... 12B-111
PARTS DRAWING(DRIVING BELT) ..........12B-83
PARTS DRAWING(EXHAUST SYSTEM) ...... 15-3
ONBOARD CHECKING(COOLING SYSTEM)......
PARTS DRAWING(FIRST SHAFT & REVERSE
........................................................................ 16-3
SHAFT ASSEMBLY) ..................................... 21-22
OPERATION PRECAUTIONS(GENERAL RULES
PARTS DRAWING(FUEL SYSTEM) .............. 13-3
OF MAINTENANCE OPERATION) ................ 01-7
PARTS DRAWING(IGNITION SYSTEM) ....... 19-3
OVERHAUL(AIR fLOW METER).................. 11-14
PARTS DRAWING(INTAKE AIR SYSTEM) .... 14-3
OVERHAUL(CANISTER PURGE CONTROL
PARTS DRAWING(INTERMEDIATE SHAFT
VALVE) ......................................................... 11-32
ASSEMBLY) ................................................. 21-38
OVERHAUL(CLUTCH MODULE) ................ 22-20
PARTS DRAWING(LUBRICATING SYSTEM) ......
OVERHAUL(COOLANT TEMPERATURE
........................................................................ 17-4
SENSOR) ..................................................... 11-22
PARTS DRAWING(PISTON AND CONNECTING
OVERHAUL(ELECTRONIC THROTTLE) .... 11-16
ROD) ........................................................12B-127
4
PARTS DRAWING(SECOND SHAFT PREPARATION(THE HORN AND THE

ASSEMBLY) ................................................. 21-24 CIGARETTE LIGHTER) ............................... 02-36
PARTS DRAWING(STARTER) ..................... 18-11 PREPARATION(TIRE AND WHEEL) ........... 02-21
PARTS DRAWING(TIMING SPROCKET PREPARATION(TRANSFER CASE) ............ 02-18
MECHANISM) ............................................12B-91 PREPARATION(TRANSMISSION) .............. 02-12
PARTS DRAWING(TRANSFER CASE) ......... 23-1 PREPARATION(VEHICLE CONTROL SYSTEM) .
PARTS DRAWING(TRANSMISSION SHIFTING ...................................................................... 02-35
SYSTEM)........................................................ 21-1 PREPARATION(WIPER AND WASHER) ..... 02-33
PARTS DRAWING(VALVE) ......................12B-114
POWER STEERING(INSPECTION) ............ 04-21 R
PREPARATION(AUDIO SYSTEM) ............... 02-34
PREPARATION(AXLE AND TRANSMISSION
REGULATED TORQUE(INSPECTION) ....... 04-15
SHAFT)......................................................... 02-22
REPLACE COOLANT(REPLACEMENT) ..... 04-58
PREPARATION(CLUTCH) ........................... 02-17
REPLACE FUEL FILTER ELEMENT(ISF2.8)
PREPARATION(COOLING) ........................... 02-9
(REPLACEMENT) ........................................ 04-53
PREPARATION(DOOR LOCKS) .................. 02-40
REPLACE MANUAL TRANSMISSION CASE
PREPARATION(DOOR OF THE VEHICLE/
LUBRICATING OIL (JC538)(REPLACEMENT) .....
ENGINE HOOD) ........................................... 02-41
...................................................................... 04-65
PREPARATION(ENGINE CONTROL SYSTEM) ...
REPLACE POWER TRANSFER
........................................................................ 02-1
OILREPLACEMENT(REPLACEMENT) ....... 04-71
PREPARATION(ENGINE MECHANICAL) ..... 02-2
REPLACE THE AIR FILTER ELEMENT
PREPARATION(EXHAUST) ........................... 02-8
(REPLACEMENT) ........................................ 04-32
PREPARATION(FRONT SUSPENSION) ..... 02-19
REPLACE THE ENGINE OIL AND OIL
PREPARATION(FUEL) ................................... 02-6
FILTER(BJ486ZLEQ4)(REPLACEMENT) .... 04-45
PREPARATION(GLASS AND REAR-VIEW
REPLACE THE ENGINE OIL AND OIL
MIRROR) ...................................................... 02-37
FILTER(ISF2.8)(REPLACEMENT) ............... 04-38
PREPARATION(HEATER & AIR
REPLACE THE FRONT MAIN REDUCER GEAR
CONDITIONING) .......................................... 02-30
OIL(FOUR-WHEEL REPLACE THE REAR MAIN
PREPARATION(ILLUMINATIONS)............... 02-32
REDUCER GEAR OIL(REPLACEMENT) .... 04-67
PREPARATION(INSTRUMENT DESK AND
REPLACEMENT (4WD)(TRANSMISSION
SECONDARY INSTRUMENT DESK) .......... 02-38
ASSEMBLY) ................................................... 21-9
PREPARATION(INTAKE) ............................... 02-7
REPLACEMENT(AIR FILTER ASSEMBLY) ... 14-4
PREPARATION(INTERIOR AND EXTERIOR
REPLACEMENT(BATTERY) ........................ 18-26
DECORATIONS) .......................................... 02-42
REPLACEMENT(CAMSHAFT) ................12B-100
PREPARATION(LUBRICATION) .................. 02-10
REPLACEMENT(CLUTCH CYLINDER) ...... 22-17
PREPARATION(PARKING BRAKE) ............. 02-27
REPLACEMENT(CLUTCH MASTER CYLINDER)
PREPARATION(POWER STEERING) ......... 02-29
...................................................................... 22-11
PREPARATION(REAR SUSPENSION) ....... 02-20
REPLACEMENT(CLUTCH PEDAL) ............... 22-7
PREPARATION(SEAT) ................................. 02-39
REPLACEMENT(COOLANT) ......................... 16-5
PREPARATION(SERVICE BRAKE) ............. 02-26
REPLACEMENT(CRANKSHAFT OIL SEAL) ........
PREPARATION(STARTING AND CHARGING) ....
..................................................................12B-143
...................................................................... 02-11
REPLACEMENT(DRIVING BELT) .............12B-86
PREPARATION(STEERING GEAR) ............ 02-28
REPLACEMENT(ELECTRONIC FAN) ......... 16-11
PREPARATION(SUPPLEMENTAL SAFEGUARD
REPLACEMENT(ENGINE ASSEMBLY) ......12A-1
SYSTEM)...................................................... 02-31
5
REPLACEMENT(ENGINE OIL)...................... 17-9 SYSTEM DESCRIPTION(LUBRICATING

REPLACEMENT(EXHAUST PIPE) ................ 15-4 SYSTEM)........................................................ 17-1
REPLACEMENT(FIRST SHAFT & REVERSE SYSTEM OVERVIEW(ENGINE CONTROL
SHAFT ASSEMBLY) ..................................... 21-23 SYSTEM)........................................................ 11-3
REPLACEMENT(FUEL FILTER ASSEMBLY) ........
...................................................................... 13-10 T
REPLACEMENT(FUEL LEVEL SENSOR
ASSEMBLY) ................................................... 13-9
TABLE OF MALFUNCTION SYMPTOMS (INTAKE
REPLACEMENT(FUEL TANK CAP COVER) .........
AIR SYSTEM)................................................. 14-2
...................................................................... 13-15
REPLACEMENT(FUEL TANK) ....................... 13-5
SYMPTOMS(CLUTCH SYSTEM) .................. 22-2
REPLACEMENT(HEAT RADIATOR).............. 16-8
REPLACEMENT(IGNITION COIL) ................. 19-6
SYMPTOMS(COOLING SYSTEM) ................ 16-2
REPLACEMENT(INTAKE LINE) .................. 14-10
TABLE OF MALFUNCTION SYMPTOMS(ENGINE
REPLACEMENT(INTER-COOLER ASSEMBLY) ...
MECHANICAL) .............................................12B-2
........................................................................ 14-7
REPLACEMENT(OIL DIPSTICK) ................. 17-14
SYMPTOMS(EXHAUST SYSTEM) ................ 15-2
REPLACEMENT(OIL FILTER) ..................... 17-11
TABLE OF MALFUNCTION SYMPTOMS(FUEL
REPLACEMENT(OIL PUMP) ....................... 17-18
SYSTEM)........................................................ 13-2
REPLACEMENT(OIL SUMP) ....................... 17-12
TABLE OF MALFUNCTION SYMPTOMS(START
REPLACEMENT(PISTON AND CONNECTING
AND CHARGE SYSTEM)............................... 18-2
ROD) ........................................................12B-133
REPLACEMENT(SPARK PLUG) ................... 19-9
SYMPTOMS(TRANSFER CASE) .................. 23-3
REPLACEMENT(STARTER) ........................ 18-12
REPLACEMENT(TRANSFER CASE CONTROL
SYMPTOMS(TRANSMISSION ASSEMBLY) .........
UNIT) ............................................................ 23-25
........................................................................ 21-5
REPLACEMENT(TRANSFER CASE) ............ 23-5
TORQUE REQUIREMENT(ENGINE
REPLACEMENT(TRANSMISSION SHIFTING
MECHANICAL SYSTEM (BJ486ZLEQ4)) ...... 03-5
SYSTEM)........................................................ 21-2
TORQUE REQUIREMENTS (LUBRICATION) .......
REPLACEMENT(VALVE) .........................12B-123
...................................................................... 03-12
TORQUE REQUIREMENTS (TRANSFER) ...........
S ...................................................................... 03-20
TORQUE REQUIREMENTS (TRANSMISSION) ...
SERIAL NO. (SN)(IDENTIFICATION ...................................................................... 03-18
INFORMATION) ............................................. 01-6 TORQUE REQUIREMENTS((POWER
SIMULATING DETECTION FOR STEERING)) ................................................. 03-33
SYMPTOM(HOW TO TROUBLESHOOT THE TORQUE REQUIREMENTS(AXLE AND
VEHICLE) ..................................................... 01-25 TRANSMISSION SHAFT) ............................ 03-26
SYMPTOM TABLE(HOW TO TROUBLESHOOT TORQUE REQUIREMENTS(CLUTCH) ....... 03-19
THE VEHICLE) ............................................. 01-28 TORQUE REQUIREMENTS(COOLING) ..... 03-11
SYSTEM DESCRIPTION(ENGINE CONTROL TORQUE REQUIREMENTS(DOOR LOCKS) ........
SYSTEM)........................................................ 11-1 ...................................................................... 03-43
SYSTEM DESCRIPTION(IGNITION SYSTEM) ..... TORQUE REQUIREMENTS(DOOR OF THE
........................................................................ 19-1 VEHICLE/ENGINE HOOD) .......................... 03-44
6
TORQUE REQUIREMENTS(ENGINE V
MECHANICAL SYSTEM(ISF2.8)) .................. 03-2
TORQUE REQUIREMENTS(EXHAUST) ..... 03-10
VEHICLE IDENTIFICATION NUMBER(VIN)
TORQUE REQUIREMENTS(FRONT
(IDENTIFICATION INFORMATION) ............... 01-5
SUSPENSION) ............................................. 03-21
VEHICLE JACKING AND SUPPORTING
TORQUE REQUIREMENTS(FUEL)............... 03-8
POSITION(GENERAL RULES OF
TORQUE REQUIREMENTS(GLASS AND REAR-
MAINTENANCE OPERATION) .................... 01-17
VIEW MIRROR)............................................ 03-40
TORQUE REQUIREMENTS(HEATER & AIR
CONDITIONING) .......................................... 03-34
TORQUE REQUIREMENTS(IGN) ............... 03-15
TORQUE REQUIREMENTS(ILLUMINATIONS) ....
...................................................................... 03-37
TORQUE REQUIREMENTS(INSTRUMENT
DESK AND SECONDARY INSTRUMENT DESK) .
...................................................................... 03-41
TORQUE REQUIREMENTS(INTAKE) ........... 03-9
TORQUE REQUIREMENTS(INTERIOR AND
EXTERIOR DECORATIONS) ....................... 03-45
TORQUE REQUIREMENTS(PARKING BRAKE) ...
...................................................................... 03-31
TORQUE REQUIREMENTS(REAR
SUSPENSION) ............................................. 03-23
TORQUE REQUIREMENTS(SEAT) ............. 03-42
TORQUE REQUIREMENTS(SERVICE BRAKE) ...
...................................................................... 03-29
TORQUE REQUIREMENTS(STARTING AND
CHARGING) ................................................. 03-13
TORQUE REQUIREMENTS(STEERING GEAR) ..
...................................................................... 03-32
TORQUE REQUIREMENTS(SUPPLEMENTAL
SAFEGUARD SYSTEM) .............................. 03-36
TORQUE REQUIREMENTS(TIRE AND WHEEL) .
...................................................................... 03-24
TORQUE REQUIREMENTS(VEHICLE CONTROL
SYSTEM)...................................................... 03-39
TORQUE REQUIREMENTS(WIPER AND
WASHER) ..................................................... 03-38
USEING AND MAINTENANCE (BATTERY) 18-22

U201 Service Manual Volume 1

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Edition:July 2014 VOLUME 1

Printing:August 2014 INTRODUCTION 01

HOW TO USE THIS MANUAL

6. "Danger", "Warning" and "Attention"

Bold expression indicates that it may cause personal injury

7. Units - International System of Units

China Beiqi Foton motor Co. Ltd. Manufacture

Gross mass Kg Number P

Engine Type Rated power Kw

SERIAL NO. (SN)

1. Serial No. of the rear driving axle

2. Serial No. of drive shaft

GENERAL RULES OF MAINTENANCE OPERATION

• Be sure to wear uniform clean work clothes.

• Before performing maintenance operations, get ready the

• When two people or above jointly operate, be sure to pay

• Before performing maintenance operations, always get

• Perform complete analysis and diagnosis for fault symptom,

• Put the removed parts according to sequence to avoid

(b). Jacking and supporting the vehicle.

Figure Symbol Part name Abbreviation

(h). Disassembly and assembly of vacuum

• When disconnecting the vacuum hose

(i). Use the torque wrench with a longer handle.

• Formula: T'=T×L2/(L1 ＋ L2)

(b). Clock spring.

(c). Horn button assembly (Conﬁgured with air

(b). Operate electrical components.

5. Remove and install the engine air intake system parts

6. Operation Of Hose Hoop

7. Three way catalyst

VEHICLE JACKING AND SUPPORTING POSITION

1. Pay attention to the vehicle condition when jacking

HOW TO TROUBLESHOOT THE VEHICLE

Air bag system Chapter 62 Diagnosis -Air bag system

Reversing radar system Chapter 62 Diagnosis – Reversing radar system

Chapter 62 Diagnosis – Power window control

Power Mirrors Chapter 62 Diagnosis – Power Mirrors

Chapter 62 Diagnosis – Power door lock control

Wiper and washer Chapter 62 Diagnosis – Wiper and washer

Rear window defrosting system – Rear window defrosting system

Horn Chapter 62 Diagnosis – Horn

Audio system Chapter 62 Diagnosis –Audio system

Lighting system Chapter 62 Diagnosis – Lighting system

Combination meter Chapter 62 Diagnosis – Combination meter

Integrated display Chapter 62 Diagnosis – Integrated display

Body controller Chapter 62 Diagnosis – Body controller

Chapter 62 Diagnosis – Tire pressure monitoring

Transfer case Chapter 62 Diagnosis – Transfer case

ABOUT USING DIAGNOSTIC DEVICE

1. Before using diagnostic device, be sure to read the instruction carefully

HOW TO PERFORM TROUBLESHOOTING

1. Fault vehicle entering factory

ANALYZING FAULT DESCRIBED BY CUSTOMER

What's the situation? Model No., system name

FAULT SYMPTOM CONFIRMATION AND DTC (AND DATA FLOW)

Heater and air

(e). Check DTC again.

SIMULATING DETECTION FOR SYMPTOM