Haima S5 1.5T Service Manual-1

Table of Contents
General Contents
Volume I
Chapter I Engine Body ····················································································· 1A-1

Chapter 2 Electronic Fuel Injection Control System ··················································· 1B-1
Chapter 3 Fuel System ······················································································ 1C-1
Chapter 4 Intake and Exhaust System ···································································· 1D-1
Chapter 5 Cooling System·················································································· 1E-1
Chapter 6 Engine Accessory-Belt ········································································· 1F-1
Chapter 7 Engine Suspension ·············································································· 1G-1
Chapter 8 MF515M Transmission ········································································ 1H-1
Chapter 9 Gearshift Mechanism ··········································································· 1J-1
Volume II
Chapter 10 Clutch System ··················································································· 2A-1
Chapter 11 List of tires and drive shafts ··································································· 2B-1
Chapter 12 Wheels and tires ················································································· 2C-1
Chapter 13 Suspension system ·············································································· 2D-1
Chapter 14 Steering system ·················································································· 2E-1
Chapter 15 Brake system····················································································· 2F-1
Volume III
Chapter 16 A/C System ······················································································ 3A-1
Chapter 17 Airbags and Restraint System ································································· 3B-1
Chapter 18 Body and Accessories ·········································································· 3C-1
Chapter 19 Electrical System················································································ 3D-1
Table of Contents
Chapter 1 Engine Body
Table of Contents
1.1 How to use this manual ················································································ 1A-0

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

1.7.5 Explanations on the timing chain dismantling ...............................................................1A-20
1.7.6 Explanations on the timing chain’s tensioner assembly mounting .................................1A-20
1.7.7 Explanations on the tensioner arm assembly mounting .................................................1A-21
1.7.8 Explanations on timing chain mounting.........................................................................1A-19
1.7.9 Explanations on the cylinder head hood mounting ........................................................1A-21
1.7.10 Explanations on the crankshaft pulley mounting .........................................................1A-22
1.7.11 Explanations on water pump pulley mounting .............................................................1A-22
1.8 Lubricating System ····················································································· 1A-22
1.8.1 Oil Sump Dismantling/Mounting ...................................................................................1A-22
1.8.2 Explanations on the oil sump dismantling......................................................................1A-22
1.8.3 Explanations on the oil sump mounting .........................................................................1A-22
1.8.4 Oil Pump and Timing Chain Case Assembly Dismantling/Mounting............................1A-23
1.8.5 Explanations on oil pump’s oil seal dismantling ............................................................1A-23
1.8.6 Explanations on oil pump’s oil seal mounting................................................................1A-23
1.8.7 Explanations on the oil filter mounting ..........................................................................1A-24
1.8.8 Explanations on oil pump disassembling/ mounting ......................................................1A-24
1.8.9 Inspection of Oil Pump...................................................................................................1A-24
1.9 Cooling System ························································································· 1A-25
1.9.1 Thermostat Dismantling/Mounting ................................................................................1A-25
1.9.2 Explanations on thermostat inspection and mounting ....................................................1A-25
1.9.3 Cooling water pipeline dismantling/mounting ...............................................................1A-26
1.9.4 Explanations on heater water pipe /O-ring mounting.....................................................1A-26
1.9.5 Water Pump Dismantling/Mounting...............................................................................1A-26
1.10 Cylinder Cover and Valve Mechanism ····························································· 1A-27
1.10.1 Cylinder Head Mechanism Dismantling/ Mounting.....................................................1A-28
1.10.2 Valve Mechanism Dismantling/ Mounting...................................................................1A-30
1.10.3 Cylinder Head Inspection /Repair ................................................................................1A-30
1.10.4 Inspection of Valve and Valve Guide ...........................................................................1A-32
1.10.5 Explanations on inspection of valve seat......................................................................1A-32
1.10.6 Explanations on inspection of valve spring..................................................................1A-33
1.10.7 Explanations on the inspection of camshaft .................................................................1A-33
1.10.8 Explanations on inspection of tappet hole and tappet ..................................................1A-35
1.11 Flywheel, clutch ······················································································· 1A-36
1.11.1 Flywheel and Clutch Dismantling/Mounting ...............................................................1A-35
1.11.2 Explanations on Clutch Pressure Plate/Friction Disc Dismantling...............................1A-37
1,11.3 Explanations on the clutch friction disc inspection /mounting.....................................1A-38
1.11.4 Explanations on the clutch pressure plate inspection/mounting ...................................1A-38
1.12 Cylinder body, Crank Connecting Rod Mechanism·············································· 1A-39
1.12.1 Cylinder Body, Crank Connecting Rod Mechanism Dismantling/Mounting...............1A-39
1.12.2 Cylinder Body Inspection /Repair ................................................................................1A-42
1.12.3 Connecting Rod Inspection ..........................................................................................1A-43
1.12.4 Inspection of Piston Connecting Rod Assembly ..........................................................1A-44
1.12.5 Crankshaft Inspection /Repair ......................................................................................1A-44
Table of Contents
Engine block 1A-0
tools tools or equipments

How to use this manual Prompt signals
In this manual there are such signals as
Subject Scope “Warning”, “Caution”, “Attention”,
“Explanation”, and “Limit”.
 This manual comprises procedures on engine
maintenance, and specific procedures fall into Warning
5 basic operation steps:
 Warning is used to prompt that personal
I: dismantling/mounting; II disassembling injury may be caused due to negligence.
/mounting; III: resetting; IV inspection; V
adjustment. Caution
 Simple operation may be completed by  Caution is used to prompt that engine damage
inspecting the engine appearance, such as may be caused due to negligence.
dismantling/mounting of periphery parts,
Notice
parts cleaning, and appearance inspection etc.
Overhaul Steps:  Notice is used to provide additional
information for completion of given
1. Prior to most overhaul work, illustrative procedures.
pictures shall be observed because they will
help distinguish parts & components, Explanation
illustrate the parts fastening way, and the way
of inspecting parts appearance. In addition,  Explanation is used to prompt the permissible
illustration explanations are attached to range for inspection or adjustment.
dismantling/mounting procedures in need of Limit
systematic demonstration.
Limit is used to prompt the upper and lower limit
2. On illustrations there are symbols of wearing for the inspection or adjustment.
parts, tightening torque, lubricating oil, and
sealant, and also corresponding explanations
and marks are made to special tools or
equipments for dismantling or mounting.
3. Corresponding numbers are marked on
pictures for the operation sequence and parts’
major operation process. In general,
information of this kind serves as key and
core content of the diagnosis procedure. Due
to this, please refer to these materials during
the overhauling process.
Symbol
Four kinds of symbols are used in this manual to
indicate application of lubricating oil, sealant, and
special tools etc., and they imply occasions where
foresaid materials shall be applied during the
maintenance period.
Symbol Connotation Remark
Inject
Inject new engine oil
lubricating oil
Inject appropriate
Inject sealant
sealant
wearing parts like
Replace parts
O-ring and gasket
Use special Appropriate special
Engine block 1A-1
1.1.1 Technical Parameters
Technical Parameters of Complete Equipment
Item Parameter Remark
Engine Model HMA GN15-TF
Code N01G N02G N16G N17G N18G

Cylinder quantity and
In-line 4-cylinder
arrangement
Combustion chamber Roof shape
Ignition sequence 1-3-4-2 By cylinder number
From back to front (flywheel
Rotation direction Counterclockwise
side taken as the back end)
dual overhead camshaft, timing chain
Valve timing mechanism
drive (silent chain), intake VVT
Valve quantity 16
Displacement (cc) 1497
Bore× stroke (mm) 74.8×85.2
Compression ratio 9.5
ON 4～44 BTDC
Valve Intake
OFF 48～8 ABDC
timing
ON 36 BBDC
(°) Exhaust
OFF 4 ATDC
Max. power(kW/rpm) 113/5500 Net power
Max. torque(N·m/rpm) 210/1800～4000
Air conditioning idle speed:800±50 Heat Engine
Idle speed (rpm)
Target idle speed:750±50 Heat Engine
Ignition advance angle(°) 0～10 Idle state
Starting mode Electrical starter
Cooling mode Water cooling forced circulation
Lubricating mode Pressure, Split, Complex
Dual Single-m Dual Single-ma
Flexible
Flywheel Type Mass ass Mass ss
flywheel
Flywheel flywheel Flywheel flywheel
Clutch Type No Dry No No Dry
According to the exhaust side
Overall dimension (mm) 554.2×621.7×619.3 15 degrees angle
measurement
Net weight (kg) No more than 115kg
Engine block 1A-2
Technical Parameters of Maintenance

Item Parameter
Cylinder head
Standard 112.9～113.1
Height (mm)
Max. grinding 0.2
Deformation at cylinder gasket’s abutment surface (mm) Max. 0.03
Max. 0.15
Deformation at manifold’s abutment surface (mm)
Max. grinding 0.20
Intake 0.18～0.26
valve clearance(engine in cold condition)(mm)
Exhaust 0.26～0.34
Valve and valve guide
Standard 1.35
Intake
Min. 0.85
Width of valve seal tape (mm)
Standard 1.85
Exhaust
Min. 1.35
Intake
Min. 89.31
Valve length (mm)
Exhaust
Min. 90.49
Intake
Min. 4.915
Valve stem diameter(mm)
Exhaust
Min. 4.905
valve guide’s inside diameter (mm) Standard 5.0～5.012
Intake 12.7～13.3
valve guide’s protrusion height (mm)
Exhaust 12.7～13.3
Valve seat
Width of valve seat’s contact surface (mm) 1.1～1.5
Intake 43.5～44
Angle of valve seat (°)
Exhaust 43.5～44
Intake 38.46
Valve seat sinking (valve protrusion height)(mm)
Exhaust 38.46
Valve spring
142.2～161.8{14.51～
Intake H1: 33.4mm
16.51kgf}
valve spring height H pressure (N{kgf})
293.4～324.4{29.94～
Exhaust H2: 24.9mm
33.10kgf}
Verticality(mm) 1.50mm
Valve oil seal
Engine block 1A-3
Intake 15.7～16.3
Depth L(mm)
Exhaust 15.7～16.3
Tappet
Tappet hole’s diameter(mm) Standard 31.000～31.025
Tappet diameter(mm) Standard 30.964～30.980
Clearance between tappet and tappet hole (mm)
Max. 0.180
Camshaft
Camshaft’s radial run-out(mm) Max. 0.03
Standard 44.5
Intake
Cam’s protrusion height Min. 43.4
(mm) Standard 43. 8
Exhaust
Min. 42.7
Standard 25.945～25.960
Journal diameter(mm)
Min. 25.915
Journal clearance(mm) Standard 0.040～0.076
End gap(mm)
Max. 0.21
Cylinder body
Height (division surface between upper surface and main Standard 205
cover)(mm) Max. grinding 0.20
Deformation of upper surface (mm) Standard 0.1
Cylinder bore’s inside diameter
[measure inside diameter at the place 37mm below the top surface] Standard 74.8～74.815
(mm)
Wearing limit (mm) 0.135
Piston diameter(mm)
[Measure the piston diameter at the place19.38mm below the Standard 74.76～74.78
lower rim of oil control ring slot along the vertical direction of the
piston pin hole’s axial line.]
Clearance between piston and cylinder bore (mm)
Max. 0.10
Piston ring
Top ring Standard 0.040～0.085
Second Ring Standard 0.030～0.070

Clearance between piston
ring and ring slot (mm) Oil Ring Standard 0.020～0.060
Top ring / Second Ring Max. 0.15
Oil Ring Max. 0.15

Engine block 1A-4
Top ring 0.20～0.35
Second Ring 0.40～0.60

Opening clearance [measure inside cylinder](mm)
Oil Ring 0.20～0.40
Max. 1.0
Piston pin
Piston pin’s diameter(mm) Standard 17.996～18.000
Piston pin hole’s inside diameter (mm) Standard 18.004～18.010
Clearance between connecting rod’s small end hole and piston

Standard 0.010～-0.027
pin (mm)
Clearance between piston pin hole and piston pin (mm) Standard 0.004～0.014
Connecting rod
Length [center to center](mm) Standard 133.32～133.40
Inside diameter of connecting rod’s small end (mm) Standard 18.010～18.023
Connecting rod’s end gap(mm)
Max. 0.40
Connecting rod bearing
Connecting rod bush size (mm) Standard 1.483～1.494
Standard 0.024～0.056mm
Connecting rod bearing clearance (mm)
Max. 0.10
Crankshaft
Crankshaft radial run-out(mm) 0.03
Main journal diameter(mm) Standard 45.982～46.000
Main journal clearance (mm)
Max. 0.1
Main bearing bush size (mm) Standard 1.988～2.003
Crank pin diameter(mm) Standard 43.979～44.000
Thrust bearing size (mm) Standard 3.205～3.255
Standard 0.09～0.273mm
Crankshaft end gap(mm)
Max. 0.30
Inspection to complete vehicle
Standard value 1200{12.2}[300]
Compression pressure Minimum limit 980{10.0}[300]
kPa{kgf/cm2}[rpm] Max. limit of

pressure difference 100{1.0}
between cylinders
Oil pressure (kPa{kfg/cm2}[rpm]) 375～450{4.1～6.0}[2500]
Oil adding volume L Oil replacement 4.6

Engine block 1A-5
Oil and oil filter

4.9
replacement
API engine oil grade higher

Oil grade
than SJ
Higher than –25 ℃ SAE 10W–30

Oil viscosity level
-30 ℃～37 ℃ SAE 5W–30
Starter
Voltage (V) 11
Zero-load test
Current (A) ＜95
Timing chain disassembling part
Automatic tensioner push rod’s extension strength (mm) 3
Crankshaft rotating speed sensor
Clearance between signal wheel and sensor (mm) 0.5～1.5
Thermostat
Opening temperature (℃) 80～84
Full-opening temperature (℃) 95
Full-opening stroke (mm) Min. 8.5
Clutch pressure plate
Diaphragn spring’s wearing depth (mm) Max. 0.6
Diaphragn spring’s radial circle run-out (mm) Max. 0.6
Pressure plate’s flatness (mm) 0.05

Clutch friction disc
Thickness of protrusion rivet (mm) Min. 0.3
End-on circle run-out(mm) Max. 0.7
Flywheel
End-on circle run-out(mm) Max. 0.10
Oil pump
Clearance between inner rotor’s prong Standard 0.06～0.18

and outer rotor (mm) Max. 0.22
Clearance between outer rotor and pump Standard 0.250～0.325

body (mm) Max. 0.35
Backlash (mm)
Max. 0.14
Compression spring’s length (mm)[pressure:97.7～107.4N{9.96～10.96kgf}] 34.50
Front-end oil seal’s driving distance (mm)[from oil pump body’s rim] 0～0.5
Rear oil seal

Engine block 1A-6
Rear oil seal’s driving distance (mm)[from crankshaft back cover’s rim] 0～0.5
Plastic fixing bolt’s length
Cylinder head bolt(mm) Standard 136.8～144.2
Main bearing cover bolt(mm)
Max. 75.3
Engine block 1A-7
Tightening torque
Torque value
Mounting place Remark
N•m kgf•m
Power generator
Bracket 45 4.6
Adjusting arm 45 4.6
Adjusting slider 21.6 2.2
Power generator pivot’s bolt and nut 55 5.6
Ignition, control system
Ignition coil 8.8 0.9 8～10
Spark plug 25 2.6 20～30
Fuel rail 21.6 2.2
Camshaft position sensor 8.8 0.9 8～10
Water temperature sensor 15 1.53 13～15
Knock sensor 21.6 2.2
Knock sensor bracket 16.8 1.7
Crankshaft position sensor 8.8 0.9 8～10
OCV valve 8.8 0.9 8～10
Intake and exhaust system
Throttle body 8.8 0.9
Intake manifold 21.6 2.2
Intake manifold bracket (manifold side) 21.6 2.2
Exhaust manifold 21.6 2.2
Exhaust manifold bracket (cylinder
21.6 2.2
body side)
Exhaust manifold bracket (manifold
45.1 4.6
side)
Exhaust manifold heat shield 8.8 0.9
Turbocharger 25 2.55 25～28
23.6 2.4
Turbocharger bracket
29 3.0
Turbocharger oil inlet pipe 25 2.55 25～28
Turbocharger oil return pipe 8.8 0.9 8～10
Turbocharger water inlet pipe 32 3.26 32～35
Turbocharger water return pipe 32 3.26 32～35
Turbocharger heat shield 8.8 0.9 8～10
Lubricating system
Oil switch 14.7 1.5
Engine block 1A-8
Oil filter 14.0 1.43

Oil filter adapter 21.6 2.2
Oil filter 8.8 0.9
Oil sump 8.8 0.9
Cylinder body, crank connecting rod mechanism
Torque value
Mounting place Remark
N•m kgf•m
50±2 16.7 First set the pretension torque and
Crankshaft pulley
60±2° then tighten the angle.
Flywheel
45±2° then tighten the angle.
Transmission baffle plate 8.8 0.9 6.9～9.8
Clutch 21.5 2.2 17.6～26.5
Crankshaft’s rear cover 8.8 0.9 8～11
then tighten the angle. Pay attention
Main bearing cover
Tightening 60°(0～ -4°) to the bolt’s length, which has limit
value (see corresponding part)
20±2N·m 2.0kgf·m First set the pretension torque for two
times, and then tighten the angle.
Connecting rod cover Pay attention to the bolt’s length,
90°(0～4°)
which has limit value (see
corresponding part)
Cylinder head, valve train and others
29 2.96 First set the pretension torque, and
tighten the angle two times. Pay
Cylinder head attention to the bolt’s length, which
Tighten 90°+ 90°(0～4°)
has limit value (see corresponding
part)
Camshaft’s front cover 20 2.04
Camshaft cover 11 1.12
Cylinder head hood 8.35 0.85
Oil pump and timing chain case 10 1.02 See corresponding part
assembly 39.5 4.03 See corresponding part
Timing chain guide rail 10 1.02
Tensioner arm 23.5 2.4
Timing chain tensioner 9.8 1.0
VVT fixing bolt 60 6.12
Front and rear hook 18.4 1.88
Cooling system
Engine block 1A-9
9.8 1.0 See corresponding part

Water pump
45 4.6 See corresponding part
Water pump pulley 9.35 0.95
Water inlet pipe seat 9.35 0.95
Heater water pipe assembly 9.35 0.95
Engine block 1A-10
1.1.2 Special tools
Oil pressure gauge Oil seal erector Valve spring ejector
Oil sump ejector Belt tensiometer Gear ring stop device
Valve oil seal ejector Oil filter sleeve Valve guide ejector / erector
Valve oil seal erector Flywheel brake Clutch guider

Engine block 1A-11
8. Measure all cylinders’ compression pressures

according to preceding method, and inspect if
1.2 Inspection and Maintenance of the pressure difference between cylinders is
Complete Vehicle lower than the limit value.
Limit value (maximum): 1300 (kPa)
1.2.1 Inspection of Compression Pressure Maximum
Warning pressure
Standard Minimum
 When the engine is running, the oil Item difference
value limit
temperature is extremely high. Therefore, between
keep cautious during dismantling and cylinders
mounting process since there is a danger of
burn. compression
1170 980 100
1. Set the vehicle into the normal pre-inspection pressure
{12.0} {10.0} {1.0
state: warm up the engine to a normal running kPa{kgf/cm
temperature; then stop the running and cool it [300] [300] kgf/cm2}
2}[rpm]
for 10 minutes.
2. Dismantle the fuel pump relay (see Note: If one cylinder or several cylinders
corresponding complete vehicle maintenance encounter excessively low pressure, or pressure
manual). difference between cylinders goes beyond the limit
value specified, some drops of engine oil shall be
3. Disconnect ignition coil’s wiring harness joint added for repeated operation. Repeat the
(see corresponding complete vehicle inspection following Step5-7.
maintenance manual).
■ If the compression pressure increases, the
4. Dismantle Cylinder 1’s ignition coil and spark fault cause should be attributed to piston, piston
plug(see Ignition, Control System part). ring, or cylinder inner surface’s wearing or
damage, and in turn an overhaul is needed.
■ If the adjacent cylinder encounters low
Injector pressure, the cylinder gasket may be damaged, or
the cylinder head likely suffers deformation, and in
turn an overhaul is needed.
■ If the compression pressure is still low, the
valve seat is burnt or in poor quality, and the
valve’s sealing face has poor contact. Thus, an
overhaul is needed.
9. Take off the gauge
Compression Gauge 10. Mount the spark plug tightening torque:20～

30N·m{2.1～3.1kgf·m }
11. Connect the ignition coil wiring.
1.2.2 Inspection of the Engine Oil
1. Park the automobile on the level ground.
2. Warm up the engine to a normal running
temperature and stop the running.
5. Mount the gauge into Cylinder 1’s spark plug 3. Wait for 5 minutes.
hole.
4. Pull out the dipstick and observe the oil level
6. Floor the accelerator pedal and start the and oil state, inspect if the oil level ranges
engine. between Scale F and Scale L.
7. Record the gauge’s maximum reading. 5. Add or replace oil according to needs.
Engine block 1A-12
6. Confirm the dipstick O-ring’s installation (see figure).

right figure).
7. Insert the dipstick again.
O-ring
Smearing
Sealant is needed when the bolt is reused.
1.2.3 Inspection of Oil Pressure
Warning 9. Mount the oil pressure switch. Tightening
torque:14.7N·m{1.5kgf·m}.
 Wasted and used oil is cancer-causing
substance, and so skin shall be cleaned with 10. Start the engine and inspect if the engine oil
soap and tap water immediately after the suffers leakage.
work. 1.2.4 Replacement of Engine Oil
1. Dismantle the oil pressure switch. 1. Dismantle the oil cover and oil drain plug.
2. Mount the special tools onto oil pressure 2. Pour the oil into appropriate vessel.
switch’s mounting hole.
3. Mount the new oil drain plug. Tightening
3. Warm up the engine to a normal running torque: 30～41N·m{3.1～4.2kgf·m}.
temperature.
4. Add engine oil of specified model and volume
4. Run the engine to a fixed rotating speed, and into the engine.
cast attention to the oil pressure gauge’s
5. Remount the oil cover.
reading.
6. Inspect the dipstick’s scale value.
5. Stop the running and cool the engine.
7. Start the engine and inspect if there is
6. Dismantle special tools.
leakage.
8. Inspect the engine oil level and add the oil if
necessary (see Inspection of Engine Oil).
Notice
 In some occasions, actual oil volume that is
added according to the oil scale may differ
Oil pressure gauge from the oil volume specified.
★ Note: if the pressure goes beyond the Item Oil capacity (L)
specified range, inspect the cause, and repair
the engine and replace the oil according to Oil replacement 4.6
needs.
Notice Oil and oil filter replacement 4.9
 Oil with different viscosities and temperatures  Engine Oil Grade: API Engine Oil Grade:
may vary in pressure above SJ
7. Oil pressure:375 ～ 450kPa{4.1 ～
6.0kgf/cm2}[2500rpm] Oil viscosity standard Oil viscosity level
8. Smear evenly the thread sealant (A6F011) Higher than–25℃ SAE10W–30

onto the oil pressure switch thread (see the –30℃～37℃ SAE5W–30
Engine block 1A-13
1.2.5 Replacement of Oil Filter 1.3 Application of Engine

1. Dismantle the oil filter with special tools. Maintenance Platform
2. Rub and clean the new oil filter with a clean
cloth. 1.3.1 Mount the Engine onto
3. Smear clean oil onto the new oil filter’s
Maintenance Platform
O-ring.
1. Lift the engine, and align the cylinder body’s
pin hole to the maintenance platform’s
mounting dowel pin to mount the engine(see
Smear clean oil onto the the figure).
new oil filter’s O-ring.
4. Mount the oil filter with special tools

Tightening torque:14.0～16.0N·m{1.42～
1.63kgf·m}.
2. Mount the work fixture according to the

figure and lock it.
Fixing bolt
5. Start the engine and inspect if there is leakage.

Inspect the oil level and check if oil adding is
needed (see Inspection of Engine Oil).
Others
Other inspection and maintenance like power
generator inspection and starter inspection etc can
be conducted on the complete vehicle. See this
manual and corresponding complete vehicle
maintenance manual for processing procedures.
3. Adjust the fixing bolt to appropriate place and

prevent the engine mounting from getting
loose.
4. Pour the engine oil into specified vessel.
Engine block 1A-14
5. Mount the new oil drain plug, and tighten the

oil drain plug. tightening torque: 30 ～
41N·m{3.1～4.2kgf·m} ②Power
1.3.2 Dismantle the Engine from Generator Belt
Maintenance Platform
Dismantle the engine from the maintenance ④Power
platform according to steps reverse to “Mount Generator
the Engine onto Maintenance Platform”.
Notice
 The engine maintenance platform’s
self-locking brake system may lose efficacy
in an unbalanced state, for instance, the
1 Generator adjusting arm
engine maintenance platform suffers
unbalance due to sudden and rapid action 2 Generator belt
resulting from the engine mounting onto and
dismantling from the platform, which will 3 Generator bolt
result in danger. Due to this, to ensure the
4 Generator
engine and the entire maintenance
platform’s balance during the operation 1.4.2 Explanations on Inspection of Power
process, the maintenance platform’s rotary Generator Belt
handle shall be held tightly in hands during
If necessary, inspect the power generator belt’s
the engine tilting process.
deflection and tension: see complete vehicle
maintenance manual’s corresponding part.
1.4 Power Generator and Starter 1.4.3 Explanations on adjustment to
tension of power generator and air
1.4.1 Power Generator’s conditioning drive belts
Dismantling/Mounting 1. Loosen the power generator’s bolt nut ①.
Warning 2. Loosen the power generator’s fixing nut ②.
 When dismantling /mounting the power Use the adjusting bolt ③, and adjust the belt
generator on the complete vehicle, the tension and belt difference to the specified value.
accumulator cable shall be dismantled firstly,
or the power generator’s Terminal B will 3. Tighten the power generator pivot bolt’s nut
contact the vehicle body, which will lead to ①: tightening torque:53～60N·m
sparks and further result in personal injury
4. Tighten the power generator’s fixing nut ②:
and electric element damage.
tightening torque:19～25N·m
1. Dismantle the power generator according to
the sequence illustrated in the figure.
③Adjust the bolt
2. Mount the power generator according to the
sequence reverse to the dismantling process. ②power generator’s
3. Inspect the belt’s deflection /tension (see fixing nut power
Inspection of the Power Generator Belt).
①generator’s bolt nut
Notice
 If mounting the new power generator belt or
running power generator belt for less than 5
minutes, adjustment shall be made according
Engine block 1A-15
to the new part’s standard value.

1 Binding post B cable
 If running power generator belt for more than
5 minutes, adjustment shall be made 2 Binding post S cable
according to old part’s standard value. 3 Starter
 If it fails to stay within the standard value,

readjustment shall be made from Step 1 on.
1.4.4 Explanations on inspection of power 1.4.6 Explanations on inspection of starter
generator Accompanying inspection:
1. Confirm if the accumulator has been charged.
1. Confirm if the accumulator is charged.
2. Confirm if the belt’s deflection /tension stays
2. Start the starter to Confirm if the starter runs
within the specified range (See power
stably and has no running noise.
generator part: Inspection of Power Generator
Belt). ★ Note: If there is abnormal situation, turn the
ignition switch to the “START” position, and
3. Turn the ignition switch to the “ON” position,
measure the voltage between Terminal S and
and the charge warning lamp will turn on.
Terminal B, and the standard voltage shall be
4. Confirm if the charge warning lamp is off greater than 8(V)
after the engine has been put into running.
—If the voltage stays beyond the specified range,
★ Note: If there is abnormal situation, see overhaul the wiring harness and ignition switch.
corresponding “Complete Vehicle Fault
—If the voltage stays within the specified range,
Diagnosis and Handling”.
dismantle the starter and inspect the solenoid
1.4.5 Starter Dismantling/Mounting switch and starter.
Warning Zero-load test
 When dismantling/mounting the starter on the 1. Confirm if the accumulator is charged.

complete vehicle, if the accumulator’s 2. Connect the starter, accumulator, voltmeter
positive cable fails to be loosened, the and ammeter (see right figure).
starter’s Terminal B will connect with or
contact the body, which will lead to sparks 3. Run the starter and Confirm if its running is
and further result in personal injury and stable.
electric element damage. Due to this,
accumulator’s positive cable shall be 4. During the starter running process, measure
dismantled firstly when the following the voltage and current.
operations are conducted:
Ignition switch
1. Dismantle the accumulator’s positive cable.

Accumulator
2. Dismantle the starter according to the

sequence illustrated in the figure.
3. Mount the starter according to the sequence Starter
reverse to the dismantling process.
Terminal S
Note: If there is abnormal situation, conduct

repair or replacement.
Standard voltage:11(V), standard current:＜95(A)
Engine block 1A-16
1.5 Ignition, Control System
Ignition Coil and PCV Valve

Dismantling/Mounting
Notice
 When dismantling the ignition coil and spark
plug, shield sleeve at the connecting rod can Air Ventilation Condition Table
be easily torn. Due to this, they should be
dismantled only when the replacement is Test Condition Test Result
necessary and tearing and damage shall be There is air outflow
avoided during the dismantling process. Blow to A
from Interface B
There is no air outflow from
1. Dismantle parts according to sequence Blow to B
Interface A
illustrated in the figure.
1.5.2 Control System Parts
1. Dismantle parts according to sequence
2. Mount parts according to sequence reverse to
the dismantling process.
1 Ignition coil
2 Spark plug
3 PCV valve
2. Mantle parts according to sequence reverse to

1.51 Spark Plug Dismantling/Mounting 1 Fuel distribution pipe assembly

Notice 2 Oil control valve
 Mount the spark plug cautiously because 3 Throttle body
strong impact will result in spark plug Crankshaft position sensor (see
damage.
4 Inspection of Crankshaft Position
PCV Valve Dismantling /Inspection Sensor)
1. Dismantle the PCV valve. 5 Knock sensor
2. Confirm if the air ventilation in PCV valve is 6 Oil pressure sensor

as the following table. If there is abnormal 7 Camshaft position sensor
situation, replacement shall be conducted.
8 Carbon tank solenoid valve assembly
Water temperature sensor (see
9
dismantling/mounting explanations)
Engine block 1A-17
Note: this part only lists different parts of

Clearance
the control system’s mounting conditions
on the engine. See the complete vehicle’s
corresponding part for relevant fault
diagnosis and inspection.
1.5.3 Crankshaft position sensor’s Crankshaft
dismantling/mounting explanations position sensor
1. When mounting the crankshaft position Crankshaft
sensor, smear “LOCTITE5971” onto the signal panel
cylinder body (shade line zone).
1.5.5 Explanations on water temperature
2. When smearing the sealant, keep clean the
unit surface’s bonding part. sensor dismantling/mounting
3. After smearing the sealant, mount the Use the sleeve to dismantle the water temperature
crankshaft position sensor within 3 minutes. sensor.
1.5.4 Explanations to inspection of

crankshaft position sensor
Clearance inspection
Attentions
Zone for smearing

the sealant
 Under-mentioned inspection shall be

conducted if necessary.
1. Confirm if the crankshaft rotating speed
sensor is correctly mounted.
2. Use the plug gauge to measure the clearance
between signal wheel protrusion platform and
crankshaft rotating speed sensor.
Notice
 If the clearance is incorrect, adjust the
crankshaft rotating speed sensor or inspect if
there is torsion and indentation in the signal
wheel’s protrusion part. (If have, replace the
crankshaft signal panel).
Standard clearance value:0.5～1.5mm
Engine block 1A-18
1.6 Intake and Exhaust System
1.6.1 Intake and Exhaust System Dismantling/Mounting

1. Dismantle parts according to sequence illustrated in the figure.
2. Mount the parts according to the sequence reverse to the dismantling process.
1 Throttle body 10 Turbocharger oil return pipe

Throttle body seal ring(see Mounting
2 11 Turbocharger
Instruction)
3 Intake manifold 12 Turbocharger gasket
Intake manifold seal ring(see
4 13 Heat shield bracket
Mounting Instruction)
5 Exhaust pipe gasket 14 Turbocharger bracket
6 Turbocharger heat shield 15 Exhaust manifold’s upper heat shield
7 Turbocharger oil inlet pipe 16 Exhaust manifold
8 Turbocharger water return pipe 17 Exhaust manifold’s sealing gasket
9 Turbocharger water inlet pipe
Engine block 1A-19
1.6.2 Explanations on intake manifold damage on seal ring. If there is, replacement
dismantling shall be made.
1. Dismantle parts according to the sequence 1.6.5 Explanations on the exhaust

illustrated in the figure. manifold dismantling
2. Mount parts according to the sequence 1. Dismantle parts according to the sequence
reverse to the dismantling process. illustrated in the figure.
2. Mount parts according to the sequence
1.6.3 Explanations on the intake manifold

seal ring mounting 1.6.6 Explanations on the turbocharger
During the mounting process, mount the seal ring mounting
into the intake manifold’s slot, and wedge the seal
Notice
ring’s anti-mistake mark into the intake manifold’s
locating slot.  Check turbocharger installed in the front
without foreign body, impeller rotation is
Caution
normal.
 Prior to the mounting, inspect if there is
 Installation turbocharger gaskets should be
damage on seal ring. If there is, replacement
checked, avoid installing dislocation.
shall be made.
 Turbocharger inlet and outlet water pipe
position do not reversed.
1.7 Timing System
1.7.1Timing system dismantling/mounting

1. Dismantle power generator belt (see power
1.6.4 Explanations on the throttle body generator part).
seal ring mounting 2. Dismantle ignition coil (see the ignition part).
During the mounting process, mount the seal ring 3. Dismantle cylinder head hood (see cylinder
into the intake manifold’s slot, and wedge the seal head hood part).
ring’s
Seal ring anti-mistake mark into the intake
manifold’s locating slot. 4. Dismantle oil sump.
Locating
5. Dismantle oil pump and timing chain case
assembly (see oil pump and timing chain case
Seal ring assembly part).
6. Dismantle parts according to the sequence
illustrated in the figure
7. Mount the parts according to the sequence
8. Adjust the power generator belt deflection
/tension (see power generator part).
Notice
 Prior to the mounting, inspect if there is
Engine block 1A-20
1.7.5 Explanations on the timing chain

dismantling
1. Mount the crankshaft pulley locking bolt.
1 Timing chain tensioner assembly 2. Rotate crankshaft along the clockwise
direction, and align the gas distribution
2 Tensioner arm assembly inspection mark.
3 Timing chain guide assembly
Notice
4 Timing chain
5 Camshaft sprocket  Keep the timing chain pulley’s key slot
upward.
6 Intake VVT assembly
 Align the gas distribution inspection mark at
1.7.2 Explanations on timing chain the timing chain pulley on the exhaust side of
tensioner assembly dismantling intake VVT.
1. Dismantle parts according to the sequence 3. Dismantle timing chain tensioner assembly
illustrated in the figure. (see Timing Chain Tensioner Assembly
Dismantling).
reverse to the dismantling process. 4. Dismantle the tensioner arm assembly.
Notice 5. Dismantle the timing chain’s guide rail
assembly.
 Loosen the timing chain tensioner assembly
bolt, and slowly take off the timing chain 6. Dismantle the timing chain.
tensioner assembly (prevent the plunger from
popping suddenly). 1.7.6 Explanations on the timing chain’s
tensioner assembly mounting
1.7.3 Explanations on crankshaft pulley
dismantling 1. Compress the pallet with bench clamp(see the
figure), and insert one hard steel wire into the
Use the special tools to secure the crankshaft for locking hole to lock the timing chain’s
dismantling. tensioner assembly.
2. Mount the timing chain’s tensioner assembly
Bolt unit onto the cylinder body, and tighten the bolt.
Fixture unit
Pallet compression
Locking hole direction
Pallet
Double-ended jointing fixture
1.7.4 Explanations on cylinder head hood

dismantling
Loosen the bolt according to the sequence
Engine block 1A-21
tensioner arm assembly and timing chain

1.7.7 Explanations on the tensioner arm guide rail assembly’s guiding slot.
assembly mounting 6. Confirm if all timing marks (4) and valve
After the mounting, tensioner arm assembly shall timing mechanism have been inspected Align
not be excessively tightened, and sway the the mark (1) accurately.
tensioner arm assembly to inspect if it can fall Notice
down freely.
1.7.8 Explanations on timing chain  Camshaft timing chain pulley and VVT
mounting assembly timing marks are “△”, gas
distribution inspection mark is “○”; and
1. Rotate the intake & exhaust camshaft to make crankshaft timing chain pulley timing mark is
two timing marks at the timing chain pulley semicircular groove
on exhaust side of the intake VVT face
toward specific angle.  In the event of failure in aligning, dismantle
the timing chain, and repeat the operation
2. Mount the timing chain’s guide rail assembly. from Step 1
3. Mount the timing chain. 7. Rotate the crankshaft for two circles along the
clockwise direction, and then rotate the
Notice crankshaft to make the intake VVT assembly
 Align the timing mark at the timing chain (timing chain pulley on the intake side) align
pulley on the exhaust side of the intake VVT with two gas distribution inspection marks at
the camshaft chain on the exhaust side.
Notice
 In the event of failure in aligning, repeat the
operation from Step 1
1.7.9 Explanations on the cylinder head

hood mounting
1. Confirm if the cylinder head hood groove is
free from oil, water, and other foreign
objects.
2. Confirm if the cylinder head hood’s sealing
gasket has been completely attached to the
cylinder head hood’s groove.
3. Smear the sealant onto the joint between
cylinder head and oil pump and timing chain
case assembly according to the illustration.
4. Mount the tensioner arm assembly (see
tensioner arm assembly mounting 4. Mount the cylinder head hood bolt according to
explanations). the sequence reverse to the dismantling process
of cylinder head hood (see the cylinder head
Notice
hood dismantling part), and tighten the cylinder
 Confirm if the timing chain is located in the head hood bolt by step.
timing chain guide rail assembly and
tensioner arm assembly’s slot. tightening torque:8～10N·m
5. Pull out the timing chain tensioner

assembly’s locking pin, when the push rod is
popped to push the tensioner arm assembly to
compress the timing chain.
Notice
 Confirm if the timing chain is located in the
Engine block 1A-22
1.8 Lubricating System

Sealant-smearing
zone
1.8.1 Oil Sump Dismantling/Mounting
1. Discharge the oil (see the complete vehicle’s
upper inspection part: Replacement of Engine
Oil).
Sealant-smearing
zone 3. Mount the parts according to the sequence
1.7.10 Explanations on the crankshaft reverse to the dismantling process.
pulley mounting
Use special tools to fasten the crankshaft for
mounting.
Bolt unit
Fixture unit
1 Oil drain plug

Double-ended jointing fixture 2 Combination washer
3 Bolt
4 Oil pan
Dowel hole 1.8.2 Explanations on the oil sump
dismantling
1. Dismantle the oil drain plug, and discharge
the oil in the oil sump.
2. Dismantle oil sump bolt step by step along the
clockwise direction.
3. Use the oil sump dismantling tool to dismantle
1.7.11 Explanations on water pump pulley the oil sump from the engine.
mounting
1.8.3 Explanations on the oil sump
Mount water pump pulley, and tighten the bolt. mounting
Notice
 If the bolt will be reused, eliminate the
sealant on original thread because bolt with
old sealant may lead to damage of the screw
hole.
 When mounting the reused oil sump, remove
the residual sealant at the oil sump and
corresponding mounting place.
1. Add continuous sealant on the internal side of
the oil sump bolt hole sealant, and overlap the
front ends, with sealant diameter ranging
between Φ2.0 and Φ3.0mm
Engine block 1A-23
2. Mount the soil sump according to the 1.8.5 Explanations on oil pump’s oil seal
sequence reverse to the dismantling process. dismantling
If necessary, use clean cloth to wrap the
Oil sump screwdriver, and dismantle the oil seal lightly.
Smear sealant prior Dismantled oil seal should be replaced, and further
to mounting application is prohibited.
1.8.6 Explanations on oil pump’s oil seal

mounting
1. Smear clean oil onto the oil seal’s peripheral
Cleft parts.
2. Mount the oil seal with hands.
3. Use the special tools to evenly compress the
oil seal.
Old sealant Compression depth:0～0.5mm
1.8.4 Oil Pump and Timing Chain Case Oil seal erector Compress
Assembly Dismantling/Mounting
1. Dismantle crankshaft pulley (see crankshaft oil pump
pulley part).
oil seal
2. Dismantle cylinder head hood (see oil pump
explanations on cylinder head hood
dismantling).
4. Continuously smear the sealant onto the oil
3. Dismantle oil sump (see oil sump, oil sump
pump and timing chain case assembly’s rims,
dismantling/mounting).
see the figure.
4. Dismantle water pump (see water pump Sealant diameter:Φ2±0.5mm
dismantling/mounting).
Notice
 If the bolt will be reused, eliminate the
sealant on original thread because bolt with
6. Mount the parts according to the sequence old sealant may lead to damage of the screw
reverse to the dismantling process. hole.
 When reusing the oil pump and timing chain
case assembly, remove the sealant on the
timing chain case and corresponding
mounting place.
1 Oil filter(see Mounting Instruction)

2 Dipstick guide
Oil pump and timing chain case assembly (see

3
Dismantling Explanations /see Mounting Explanations)
Engine block 1A-24
5. When mounting the oil pump and timing chain

case assembly, tighten bolts by steps according
to the sequence illustrated in the figure..
1.8.8 Explanations on oil pump

disassembling/ mounting
1. Dismantle oil pump and timing chain case
assembly (see oil pump and timing chain case
assembly dismantling/mounting).
2. Disassemble parts according to the sequence
reverse to the disassembling process.
Bolt Specifications and Mounting Torque
Bolt rod Mounting

No. Specification length torque
(mm) (N·m)
1a, 3a, 4a,
5a 25 8～12
M6
6a, 7a, 8a,
2b, 10b M6 30 8～12
12c M6 45 8～12 1 Bolt
2 Oil pump cover
13d, 14d M10 90 36.5～42.5 3 Screw plug
4 Pressure spring
1.8.7 Explanations on the oil filter 5 Control piston
mounting 6 Inner rotor (Smear oil before mounting)
7 Outer rotor (Smear oil before mounting)
Tighten bolts by steps according to the sequence
illustrated in the figure
1.8.9 Inspection of Oil Pump
Explanations on inspection of rotor clearance
1. Measure the following clearance, and replace
Engine block 1A-25
the rotor or pump body if necessary.

Standard gear tip clearance: 0.06～0.20mm
Maximum gear tip clearance: 0.22mm
Standard pump body clearance: 0.250～

0.325mm 1.9 Cooling System
Maximum pump body clearance: 0.35mm
1.9.1 Thermostat Dismantling/Mounting
Standard backlash: 0.03～0.09mm

Maximum backlash: 0.14mm
1 Thermostat cover
Thermostat
2
see explanations on thermostat mounting
1.9.2 Explanations on thermostat

inspection and mounting
1. Put the thermostat into a vessel with hot water,
in which a thermometer is inserted. Then heat
Explanations on inspection of pressure the thermostat to raise the temperature, and
inspect the thermostat. If it does not comply
spring
with regulations, replace the thermostat.
Exert pressure on the spring and inspect the spring
—Valve is closed at the room temperature.
height. If necessary, replace the pressure spring.
—Valve is opened after the temperature rise.
Pressure range:97.7～107.4N{9.96～10.96kgf}
Opening temperature (℃):80～84
Standard height: 34.50mm
Full-opening temperature (℃):95
Full-opening stroke (mm):≥8.5
2. Confirm if the thermostat’s movable pin is
upward, see the figure.
Engine block 1A-26
3. Align the cylinder body thermostat’s illustrated in the figure.

mounting place, and mount the thermostat
onto the cylinder body. 3. Mount the parts according to the sequence
Movable pin
Replace parts after

the dismantling
1.9.3 Cooling water pipeline

dismantling/mounting
1. Dismantle thermostat (see thermostat 1 Bolt (water pump pulley)
dismantling /mounting).
2 Water pump pulley
illustrated in the figure. 3 Bolt (water pump assembly)
3. Mount the parts according to the sequence 4 Bolt (water pump assembly)
5 Water pump assembly
Replace parts
after the
dismantling
3 bolt(heater water pipe assembly)

4 bolt(heater water pipe assembly)
5 heater water pipe assembly
1.9.4 Explanations on heater water pipe

/O-ring mounting
When replacing the O-ring, smear the water onto
the O-ring, in order to facilitate its mounting and
avoid damage.
Notice
 Do not smear engine oil or other greasy
substances onto the O-ring.
1.9.5 Water Pump Dismantling/Mounting
1. Dismantle power generator belt (see power
generator belt part).
Engine block 1A-27
1.10 Cylinder Cover and Valve Mechanism
Smear oil
before the
mounting
Smear oil
before the
mounting
Smear
Smear
oiloil
before
before
thethe
mounting
mounting
Smear sealant before mounting
the cylinder head hood Replace parts after the
dismantling
1 Intake VVT (see the dismantling /mounting explanations)

2 Camshaft sprocket (see the dismantling /mounting explanations)
3 Camshaft (see the dismantling /mounting explanations)
4 Tappet
5 Cylinder head (see the dismantling /mounting explanations)
6 Cylinder head gasket
Engine block 1A-28
3. Inspect the camshaft journal clearance (see

1.10.1 Cylinder Head Mechanism the camshaft inspection part).
Dismantling/ Mounting
4. Loosen the camshaft bearing seat bolts by
1. Dismantle the intake and exhaust manifold steps according to the sequence illustrated in
(see the intake/exhaust system part). the figure. First, loosen the front camshaft
bearing cover bolt, and then loosen other
2. Dismantle the timing chain(see the timing camshaft bearing cover bolts.
chain part).
Explanations on intake VVT dismantling

1. Lock the camshaft’s hexagon part with a
wrench (see the figure), so as to dismantle the
VVT and camshaft sprocket’s fixing bolts.
2. Dismantle the VVT’s fixing bolts. Explanations on cylinder head
dismantling
3. Shake the VVT slightly, and take off it from
camshaft with caution. Loosen the cylinder head bolt by step according to
the sequence illustrated in the figure.
Explanations on the cylinder head

mounting
1. Measure every cylinder head bolt’s outer
diameter differential (d1-d2). If the
differential exceeds 0.15mm, the cylinder
head bolt shall be replaced.
Note: d2 refers to the minimum outer diameter
VVT fixing bolt within the ※ mark’s range.
2. Tighten the cylinder head bolt to specified
torque by steps according to the sequence
Explanations on camshaft dismantling illustrated in the figure.
1. If necessary, inspect and adjust the valve Tightening torque: 29N·m{2.96kgf·m}

clearance (see the valve clearance inspection
part).
2. Inspect the camshaft end gap (see the
camshaft inspection part).
Engine block 1A-29
3. Mount the camshaft bearing cover onto

corresponding journal according to the
sequence.
4. Tighten the bolts according to the sequence
illustrated in the figure: first, tighten every
camshaft cover bolt, and then tighten the front
camshaft bearing cover bolt.
Explanations on the VVT mounting

1. Rotate the camshaft to make the dowel pin
3. Mark every bolt head.
keep upward.
4. According to the bolt-tightening sequence
2. Smear some oil onto the VVT assembly’s
(Step 2) illustrated in the figure, Each bolt
inserting part, align the VVT assembly
with a reference mark, rotated by 90 °, then
location hole to the camshaft dowel pin, and
rotated 90 °. (see the figure).
mount the VVT assembly slowly.
3. Lock the camshaft’s hexagon part with a
wrench (see the figure), so as to tighten
VVT’s fixing bolts.
VVT assembly location

hole (align camshaft
dowel pin)
Paint mark place Initial paint mark

after Step 4 VVT assembly
inserting part (smear
some oil around)
Explanations on the camshaft mounting
Notice
 Since the camshaft’s mounting clearance is
small, make sure that the camshaft journal is
closely attached to the bearing seat during the
mounting process, or the contact surface
between the shaft and bearing will incur
excessive pressure and in turn suffer damage.
To avoid foresaid situation, regulations below
shall be observed:
1. Smear some oil onto the camshaft journal and
bearing seat.
2. Mount the camshaft into camshaft bearing
seat, making camshaft journal closely
attached to the bearing seat.
Engine block 1A-30
1.10.2 Valve Mechanism Dismantling/

Mounting
1. Dismantle cylinder head(see the cylinder head
dismantling).
illustrated in the figure. .
Explanations on inspection of valve

clearance
1. Dismantle the cylinder head hood (see
cylinder head hood dismantling part).
2. Confirm if the engine has been cooled.
3. Measure valve clearance.
(1) Rotate the crankshaft along the clockwise
direction, making the piston located at the
stopping place on No.1 Cylinder, namely, gas
distribution mark shall be adjusted to the
position indicated in the right figure.
Valve Half (see dismantling/mounting

1 (2) Use plug gauge to measure valve clearances
explanations)
of all cylinders at Mark A indicated in the
2 Valve spring upper seat figure.
Valve spring (see the mounting
3
explanations)
4 Valve spring lower seat
5 Valve (see the mounting explanations)
6 Valve oil seal
Explanations on dismantling of valve

keeper
Use special tool valve spring pressure, remove the
★ Note:If the valve clearance exceeds the
valve keeper. standard value, replace the tappet(see the
valve clearance’s adjustment)valve
clearance’s standard value (when engine is in
cooling state):
Engine block 1A-31
Intake:0.18～0.26mm Notice:
Exhaust:0.26～0.34mm
 If the valve clearance will be adjusted when
(3) Rotate the crankshaft for 360 degrees along there is not timing chain, make the crankshaft
the clockwise direction, making the piston dowel pin towards side face, in order to
located at the stopping place on No.4 prevent the valve from colliding with the
Cylinder, namely, gas distribution mark shall piston top during the valve clearance
be adjusted to the position indicated in the adjustment process.
figure below.  Mark the tappet thickness inside the tapper
with 3 digits, see figure below:
Thickness mark
(4) Use plug gauge to measure valve clearances

of all cylinders at Mark B indicated in the
figure above.
★ Note:If the clearance exceeds standard value,
tappet shall be replaced(see the valve
clearance’s adjustment)
Valve clearance’s standard value (when the engine
is in cooling state):
ON:0.18～0.26mm
OFF:0.26～0.34mm
4. Mount cylinder head hood (see the timing
chain, cylinder head hood mounting part). 1.10.3 Cylinder Head Inspection /Repair
Explanations on the valve clearance’s
adjustment
To adjust the valve clearance, operation steps
below shall be observed:
1. Dismantle camshaft (see the camshaft
dismantling part).
2. Take out the tappet at the place where the
valve clearance shall be adjusted.
3. Select an apposite tappet. New tappet’s
thickness =old tappet’s thickness + measured
valve clearance － standard valve clearance.
(standard valve clearance: ON, 0.22mm; OFF,
0.30mm)
4. Mount the selected tappet into the tappet hole.
5. Confirm the valve clearance again (see valve
clearance, valve clearance inspection).
1. Inspect the cylinder head’s defect. If

Engine block 1A-32
necessary, replace the cylinder head. 7. If the distortion measured in Step 6 exceeds
the maximum value, grind the surface or
2. Inspect the following items, repair and replace the cylinder head.
replacement shall be conducted if necessary.
Maximum grinding volume: 0.20mm
(1). If there is indentation at the valve seat.
1.10.4 Inspection of Valve and Valve
(2). If the camshaft journal clearance and end gap
is excessive. Guide
3. Use the Straight Edge Ruler and plug gauge 1. Measure thickness of every valve’s head rim.
to inspect if the cylinder head is distorted If necessary, replace the valve.
along six directions, see the figure. Standard thickness: intake valve: 1.35mm; exhaust
Maximum distortion: 0.03mm valve: 1.85mm.
4. If the cylinder head’s distortion exceeds the Minimum thickness: intake valve: 0.85mm;
maximum value, inspect the cylinder head’s exhaust valve: 1.35mm.
height. If the height stays beyond the standard
value, replace the cylinder head.
Standard height:112.9-113.1mm
Brim thickness
2. Measure every valve’s length. If necessary,
replace the valve.
Standard length
5. If the cylinder head’s distortion exceeds the Intake valve:89.51～90.01mm
maximum value, and the height stays within
the standard value, grind the height or replace Exhaust valve:90.69～91.19mm
the cylinder head.
Minimum length
Maximum grinding volume:0.20mm
Intake valve: 89.31mm
6. Use the Straight Edge Ruler and plug gauge
to measure the cylinder head intake/ exhaust Exhaust valve: 90.49mm
manifold flange’s distortions along different
directions, see the figure.
Maximum distortion: 0.15mm
3. Measure every valve’s rod diameter

respectively at A, B, C point (see the figure)
Engine block 1A-33
along X and Y direction. If necessary, replace valve seat contact width. If necessary, use a 44
the valve.
° valve seat cutter reworked valve or valve
Standard diameter seat surface.
Intake valve: 4.965～4.980mm Standard width: 1.1 ~ 1.5mm
Exhaust valve: 4.955～4.970mm

Minimum diameter
Intake valve: 4.915mm
Exhaust valve: 4.905mm
4. Measure every valve guide’s inner diameter
respectively at A, B, and C point along X and
Y direction (see the figure). If necessary,
replace the valve guide.
Standard inner diameter
2. Check valve seat depression. Measure the
Standard:5.0～5.012mm valve stem projecting length (size L). If
necessary, replace the cylinder head.
Standard size L
Intake: 38.16 ~ 38.76mm
Exhaust: 38.16 ~ 38.76mm
5. When there is not valve spring’s lower seat,

measure every valve guide’s extrusion height
(Size A). If necessary, replace the valve
guide.
Standard height:12.7～13.3mm
Valve guide 1.10.6 Explanations on inspection of valve

spring
1. Use the special tools to exert pressure on the
valve spring, and inspect the spring height. If
necessary, replace the valve spring. Exert
pressure on the valve spring, and compress
the spring to a given height, when the
pressure value exceeds the specified range,
the valve spring shall be replaced.
When the height is 33.4mm, the pressure is 142.2～
Cylinder head 161.8N{14.51～16.51kgf};
When the height is 24.9mm, the pressure is
1.10.5 Explanations on inspection of valve 293.4～324.4N{29.94～33.10kgf}.
seat
2. Measure the valve spring verticality, and if
1. Surface painted with a method to measure the the verticality goes beyond the standard, the
Engine block 1A-34
valve spring shall be replaced.

Valve spring’s maximum verticality:1.50mm
3. Measure the journal diameter respectively at

A and B point along X and Y direction. If
necessary, replace the camshaft.
Standard diameter:25.945～25.96mm
Minimum diameter: 25.915mm
1.10.7 Explanations on the inspection of

camshaft
1. Place the camshaft’s No. 1 and No. 5 journals Point A
onto the V-shaped block to measure the
camshaft’s radial run-out. If necessary,
replace the camshaft. Point B
Radial run-out: 0.03mm
4. Dismantle the tappet, and measure camshaft

journal clearance according to steps below:
(1). Remove all oil on the journal and bearing
seat’s internal surface.
(2). Put the camshaft into the bearing seat.
(3). Make the plastic gauge match the bearing
width (see the figure), and then put it on the
top of journal along the axial direction.
(4). Mount the camshaft cover (see cylinder head
dismantling/mounting, camshaft mounting
attentions).
2. Measure heights of the two convex parts (see
the figure). If necessary, replace the camshaft. Axial direction
Standard height
Intake side: 44.5mm
Exhaust side: 43.8mm
Minimum height
Intake side: 44.2mm
Exhaust side: 43.5mm Plastic gauge
Notice
Engine block 1A-35
 When measuring the clearance, do not rotate 1.10.8 Explanations on inspection of

the camshaft tappet hole and tappet
(5). Dismantle camshaft cover (see cylinder head 1. Measure every tappet mounting hole’s inner
dismantling/mounting, camshaft dismantling diameter respectively at A and B Point (see
attentions). the figure) along X and Y direction.
(6). Use the scale on the plastic gauge bag to Standard inner diameter:31.000～31.025mm
measure the widest point on the plastic
gauge’s extruded part, and then calculate out
the journal clearance.
If necessary, replace the cylinder head and
camshaft cover.
Standard journal clearance:0.040～0.076mm
2. Measure every tappet’s diameter respectively

at the A and B point (see the figure) along X
and Y direction.
5. Mount the camshaft cover (see cylinder head
dismantling/mounting, camshaft mounting
attentions).
6. Mount the dial gauge, push camshaft forward
or backward at the end of camshaft (see the
figure), and measure the camshaft end gap. If
necessary, replace the cylinder head or
camshaft.
Caution
 Do not push the camshaft at the cam part, so
as to prevent the cam from being damaged.
Standard end gap:0.08～0.20mm
Maximum end gap:0.21mm 3. Calculate the clearance between tappet and
corresponding tappet hole. If necessary, replace
the tappet or cylinder head.
Standard clearance:0.020～0.061mm
Maximum clearance:0.180mm
Engine block 1A-36
1.11 Flywheel, clutch
1.11.1 Flywheel and Clutch Dismantling/Mounting

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

2 Clutch friction disc (see dismantling explanations/see mounting explanations)
3 flywheel (see dismantling explanations/see mounting explanations)
Crankshaft’s back cover (see the rear oil seal dismantling explanations /see rear oil seal
4
mounting explanations /see mounting explanations)
5 Transmission’s baffle plate
Engine block 1A-37
1.11.2 Explanations on Clutch Pressure

Disc/Friction Disc Dismantling Protective
cloth
1. Use the special tools to lock the flywheel, and
locate the clutch(see the figure).
2. Loosen the bolt in a disposable manner
according to the sequence of right-angled
intersection till the diaphragm spring’s
pressure is released.
Explanations on the crankshaft’s back
3. Dismantle the clutch pressure disc and cover mounting
friction disc.
1. Smear evenly sealant onto indentation of the
crankshaft’s back cover (see the figure).
Sealant diameter:Φ1.5～Φ2.5mm
Smear sealant
Clutch plate setting tool Gear ring fixture unit
Explanations on flywheel dismantling

1. Use the special tools (see the figure) to lock
the flywheel.
2. Follow the right-angled intersection sequence Explanations on the flywheel mounting
to evenly dismantle the mounting bolt (see the /inspection
figure), and dismantle the flywheel.
1. Mount the flywheel onto the crankshaft.
2. Clean the thread and hole before mounting the
bolt.
3. Smear evenly the sealant onto the thread.
Notice
Gear ring fixture unit
 There is no need to smear the sealant when
using new bolt
Explanations on Rear Oil Seal
1. Use the screwdriver, wrapped with protective
cloth, to dismantle the oil seal(see the figure)
Notice
 Normally, there is no need to dismantle the oil
seal, unless being replaced.
2. Add clean oil onto the oil seal opening.
3. Mount the oil seal with hands.
4. Tighten the flywheel bolt with hands.
4. Use the special tools and hammer to compress
the oil seal. 5. Mount special tools onto the flywheel (see the
figure).
Compression depth:0～0.5mm
6. Follow the sequence of right-angled
Engine block 1A-38
intersection to tighten the flywheel bolt little

by little.
Gear ring fixture

unit
Use the special tools to secure the clutch friction
disc’s position (see the figure).
7. Mount the dial gauge onto the cylinder body.
8. Rotate the flywheel and measure the Clutch disc
flywheel’s end-on circle run-out. If it exceeds locator
the standard, replace the flywheel.
Maximum end-on circle run-out:0.13mm
1.11.4 Explanations on the clutch pressure

disc inspection/mounting
1. Measure the diaphragm spring’s abrasion.
1.11.3 Explanations on the clutch friction If it exceeds standard, replace the clutch
disc inspection /mounting pressure disc
Use the vernier caliper to measure rivets on both Maximum height: 0.6mm
sides and the friction disc surface’s depth.
If it exceeds the standard, replace the clutch
friction disc
Minimum depth:0.3mm

to measure the pressure disc’s flatness.
If it exceeds standard, replace the clutch
assembly.
Use the dial gauge to measure the clutch friction
disc’s end-on circle run-out. Maximum clearance: 0.05mm
friction disc
Maximum end-on circle run-out:0.7mm
Engine block 1A-39
head part), oil sump, oil pump, and timing

chain case assembly (see lubricating system
part) and crankshaft’s back cover (see
flywheel, clutch part).
illustrated in the figure. .
Smear oil
before
mounting
3. Use the special tools to lock the flywheel, and
locate the clutch(see the figure).
Clutch disc setting tool Gear ring fixture unit
4. Follow the right-angled intersection sequence

to evenly tighten bolts.
5. Mount the dial gauge onto the cylinder body,
and rotate the flywheel to inspect the
diaphragm spring’s radial run-out.
pressure plate ⑩Smear oil
before
Maximum radial circle run-out:0.6mm mounting
②Smear oil
before mounting
connecting rod connecting rod

cover (see the
1 7
mounting
1.12 Cylinder body, Crank explanations)
Connecting Rod Mechanism connecting rod Main bearing cover
2 bearing 8 (see the mounting
explanations)
1.12.1 Cylinder Body, Crank Connecting piston ring(see the
Rod Mechanism Dismantling/Mounting 3 mounting 9 thrust bearing
1. Dismantle the cylinder head (see the cylinder explanations)
Engine block 1A-40
4 Piston pin retainer 10 Crankshaft bearing

5 Piston pin (see the Crankshaft
mounting 11
explanations)
6 piston 12 Cylinder body
Explanations on connecting rod cover 2. Tighten main bearing cover’s bolt to specified
dismantling torque by steps according to the sequence
illustrated in the figure, as well as mark every
Inspect the connecting rod end gap (see connecting bolt head. Tightening torque:33 ～
rod inspection part).
37N·m{3.357～3.784kgf·m}
Explanations on piston pin dismantling 3. according to the bolt-tightening sequence
1. The piston pin retainer with the tool removed. (Step 2) illustrated in the figure, rotate every
bolt for 60°～64° from the mark.
2.Hand push the piston pin, which was pushed out.
Explanations on main bearing cover

dismantling
1. Inspect the crankshaft end gap (see the
crankshaft inspection /repair part).
2. Loosen the main bearing cover’s bolt
according to steps illustrated in the figure.
Explanations on the piston pin mounting

1. Removing the piston, piston pin into the ring at
one end.
2. The clean oil applied to the piston pin.
3. Place the piston and connecting rod to press-fit
the stage, piston "→" on the mark side and
the link "HMA" or logo side, as shown.
Explanations on the crankshaft
dismantling 4. The piston pin into the piston, connecting rod
assembly, to be assembled in place, on the
Inspect the main journal clearance (see the other side of the piston pin into the piston
crankshaft inspection /repair part). rings.
Explanations on the piston ring mounting
Explanations on the main bearing cover
mounting 1. The following figure, the first spiral spring
loaded oil ring body support groove Connect
1. Measure every bolt’s length. If the length with the latch pin connector.
exceeds the standard value, replace the bolt.
2. The oil ring was placed in an oil ring groove.
Standard length: 74.15～74.85mm
3. The support spring connectors and oil ring body
Maximum length: 75.05mm openings staggered 180 °.
Engine block 1A-41
Explanations on the connecting rod cover

mounting
1. The bolt can be reused, but when the outer
diameter difference at the two points
illustrated below exceeds 0.1mm, the bolt
shall not be further used.
Piston ring dilator
4. Use the piston ring dilator to mount the No. 2

and No.1 piston ring.
diameter
diameter
Outer
5. Keep the marker side upward during the

Outer
mounting process.
6. Align all rings’ opening locations (see the 2. Tigthen the connecting rod bolt to specified
figure). torque by steps according to the sequence
Tightening torque:18.0 ～ 22.0N·m{1.84 ～
2.45kgf·m}
Row
Front
In
3. Mark every bolt head.

4. According to the bolt-tightening sequence
Explanations on piston connecting rod (Step 2) illustrated in the figure, rotate every
assembly mounting bolt for 90°～94° from its marker.
1. Pistons forward flag " " for the front of 1.12.2 Cylinder Body Inspection /Repair
the engine.
Engine block 1A-42
to measure the distortion on the cylinder Maximum grinding volume: 0.20mm

body’s upper surface along six directions
illustrated in the figure. 4. Use the inside dial indicator to measure the
cylinder’s inner diameter at the place 60mm
Cylinder body’s maximum distortion:0.1mm away from upper surface along the X and Y
direction (see the figure).
Cylinder body’s upper surface
2. If the distortion on the cylinder body’s upper

surface exceeds the maximum value, inspect
the cylinder body’s height. If the height stays 5. If the cylinder’s inner diameter goes beyond
beyond the standard value, replace the the abrasion limit, replace the cylinder body,
cylinder body. and install the corresponding piston, in order
to make it accord with the standard clearance
between piston and cylinder. Abrasion limit:
0.135mm
Size Diameter
1.12.3 Piston, Piston Ring, and Piston Pin

Inspection
1. Along the vertical direction of piston pin hole’s
axial line, measure the piston’s diameter at the
place that is 19.38mm below the lower rim of the
oil control ring groove
Cylinder body
Standard height:204.95～205.05mm
3. If the cylinder body’s distortion goes beyond
the maximum value and the height stays
within the standard value, grind the height or
replace the cylinder body.
Piston diameter (mm)

Size Diameter
Standard 74.7625～74.7775
Calculate the clearance between piston and

cylinder. If necessary, replace the piston.
Maximum clearance: 0.10mm
2. If replacing the piston, piston ring shall be
replaced as well.
Engine block 1A-43
3. Use the plug gauge to measure the clearance Maximum opening clearance:1.0mm
between piston ring and ring slot along the
entire perimeter (see the figure). If necessary, 6. Respectively at A, B, C, and D point along X
replace the piston and piston ring. and Y direction, measure every piston pin hole’s
diameter.
Standard clearance
Ring 1: 0.040～0.085mm
7. Respectively at A, B, C, and D point along X
Ring 2: 0.030～0.070mm
and Y direction, measure every piston pin’s
Oil ring: 0.020～0.060mm diameter
Maximum clearance Standard diameter:18.004～18.010mm
Ring 1, Ring2: 0.15mm

Oil ring: 0.15mm.
4. Put the piston ring into cylinder with hands,
and use the piston to push the piston ring to
the bottom of the cylinder bore stroke.
8. Calculate out the clearance between piston pin

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

5. Use the plug gauge to measure every piston
ring’s opening clearance. If necessary, replace 1. Use the plug gauge to measure the connecting
the piston ring. rod’s end gap. If necessary, replace the
connecting rod and connecting rod cover.
Standard opening clearance:
Ring 1: 0.20～0.35mm
Ring 2: 0.40～0.60mm
Oil Ring: 0.20～0.40mm

Engine block 1A-44
blue
φ43.979～φ43.986
1.489～1.494
yellow
φ43.986～φ43.993
1.486～1.491
red
43.993～φ44.000
1.483～1.488
3. As shown in X and Y direction of each of the

connecting rod small end diameter
Standard clearance:0.10～0.30mm measurement.
Maximum clearance:0.40mm
Standard diameter: 18.010～18.023mm
2. Measure the crank pin journal clearance
according to steps below.
(1). Remove all oil on the journal and bearing
seat’s internal surface.
width and then put it on the top of journal,
keeping parallel with the axial line.
(3). Mount the connecting rod cover (see piston
and connecting rod mounting part). 1.12.5 Inspection of Piston Connecting
(4). Dismantle the connecting rod cover’s bolt, Rod Assembly
and slowly take off the connecting rod cover.
Inspect the swaying torque (see the figure). If the
(5). Use the plastic gauge scale to measure the big head fails to drop down by virtue of its own
widest point on the plastic gauge’s extruded weight, replace the piston or piston pin.
part, and then calculate out the journal
clearance. If the clearance exceeds the
maximum value, replace the crankshaft and
corresponding connecting rod bearing to
ensure the standard clearance.
Drop down by virtue
of its own weight
1.12.6 Crankshaft Inspection /Repair

Maximum clearance:0.10mm 1. Mount the dial gauge, use the screwdriver to
Rod bearing matching table mm push the crankshaft frontward and backward,
and measure the crankshaft end gap (see the
figure). If the end gap surpasses the maximum
Crank pin diameter Rod bearing thickness value, replace the thrust bearing or crankshaft
to fit the standard end gap.
Engine block 1A-45
Standard end gap:0.09～0.273mm (1). Remove all oil on the crankshaft journal and
Maximum end gap:0.30mm bearing seat’s internal surface.
Thrust bearing’s size Thrust bearing’s thickness width and then put it on the top of journal,
keeping parallel with the axial line.
Standard 3.205～3.255 (3). Mount the main bearing cover (see the main
bearing cover mounting part).
(4). Dismantle the main bearing cover bolt, and
slowly take off the main bearing cover (see
main bearing cover mounting part).
(5). Use the plastic gauge scale to measure the
widest point on the plastic gauge’s extruded
part, and then calculate out the journal
clearance. If the clearance exceeds the
maximum value, replace the crankshaft and
corresponding bearing bush to ensure the
2. Measure the crankshaft’s radial run-out. If standard clearance.
necessary, replace the crankshaft.
Standard clearance: 0.018～0.036mm
Maximum radial circle run-out:0.03mm
Maximum clearance: 0.1mm
Crankshaft bearing matching table mm
Crankshaft Crankshaft main journal

diameter
bearing thickness 1:φ 2:φ 3:φ
45.994 45.988 45.982
～φ ～φ ～φ
46.000 45.994 45.988
3. Respectively at A and B point along X and Y
direction, measure the journal diameter. If Cylinder
necessary, replace the crankshaft. Cy 1:φ 1# 2# 3#
lin 50.000 1.988～ 1.991～ 1.994
de ～φ 1.991 1.994 ～
r 50.006 1.997
m
ai
n 2:φ 2# 3# 4#
be 50.006 1.991～ 1.994 1.997
ari ～φ 1.994 ～～
ng 50.012 1.997 2.000
ho
le
3:φ 3# 4# 5#
Main journal Diameter(mm) di
50.012 1.994～ 1.997 2.000
Standard 45.982～46.000 a
Crank pin Diameter(mm) ～φ 1.997 ～～
m
Standard 43.979～44.000 50.018 2.000 2.003
ete
4. Measure the main journal’s clearance r
according to method below.
Electronic Fuel Injection Control System 1B-1
Chapter 2 Electronic Fuel Injection Control System
1. Notices for Maintenance of Electronic Fuel Injection System······································1B-2

1.1 General Maintenance Notices······································································ 1B-2
1.2 Maintenance Attentions············································································· 1B-2
1.3 List of Maintenance Tools ···········································································1B-3

1.4 Manual annotation abbreviations in································································1B-5
2. Briefings of ME7 System ················································································1B-6
2.1 Basic Principle························································································· 1B-6
2.1.1 System Profile ME788-Motronic ·································································· 1B-6
2.1.2 Torque-based ME7 System·········································································· 1B-7
2.2 Control signal: ME7 system’s input /output signals·············································· 1B-9
2.3 Introduction of System Functions····································································1B-9

2.3.1 Start Control ······················································································ 1B-9
2.3.2 Warm-up and Three-way Catalyst Converter Heating Control ···························· 1B-10
2.3.3 Acceleration /Deceleration and Towing Astern Oil Cutoff Control······················· 1B-10
2.3.4 Idle Control ······················································································· 1B-10
2.3.5 Close-loop Control··············································································· 1B-11
2.3.6 Evaporation Emission Control ································································· 1B-11
2.3.7 Knock Control ····················································································· 1B-11
2.3.8 VVT Control······················································································ 1B-11
2.3.9Idle Start/Stop Control················································································ 1B-11
2.4 Introduction of System Troubleshooting Function ················································1B-11

2.4.1 Fault Information Record ······································································· 1B-11
2.4.2 Classification of Fault Types ··································································· 1B-12
2.4.3 Connection with Diagnostic Unit······························································ 1B-14
3.ME7’s Overhaul and Diagnosis Flow by Fault Code ················································ 1B-14
4.ME7’s Overhaul and Diagnosis Flow by Fault Phenomenon······································· 1B-21
5. Functional Requirements on ME7 System’s Diagnostic Unit ······································1B-334

5.1 Parts Mounting Torque Specification Table ························································1B-334
5.2 Electronic Fuel Injection System Maintenance Specification ···································1B-34
5.2.1 Family Vehicle ·················································································· 1B-35
5.2.2 Vehicle for Lease ··············································································· 1B-35
4. The electronic fuel injection system’s oil supply
pressure is relatively high (350kPa or so), and all
1. Notices for Maintenance of fuel pipelines adopt the fuel pipe resisting high
Electronic Fuel Injection System pressure. Even if the engine does not run, the oil
pipeline will keep a relatively high fuel pressure.
1.1 General Maintenance Notices Due to this, do not dismantle the oil pipe at
discretion during the maintenance process. In the
 Only the digital multimeter can be used to occasion where the fuel system shall be
inspect the electronic fuel injection maintained, pressure discharge treatment is needed
system. before the oil pipe is dismantled, with pressure
discharge method as follows: start the engine and
 Original parts and components shall be make it run at idle speed, connect it with the
used in maintenance work, or electronic diagnosis instrument, enter the “Actuator Test”,
fuel injection system’s normal running and turn off the fuel pump till the engine stops
cannot be ensured. automatically. Dismantling of oil pipe and
 Only the lead-free gasoline can be used replacement of fuel filter shall be completed by
during the maintenance process. maintenance professionals in the place with sound
ventilation condition.
 Observe standard maintenance and
diagnosis flow to conduct maintenance. 5. When dismantling the electric fuel pump from the
fuel tank, do not power on the oil pump, in order
 Disassembly and dismantling to to avoid electric sparks and fire disaster.
electronic fuel injection system’s
components shall be prohibited during the 6. Running experiment to fuel pump shall not be
maintenance process. conducted in a dry state or in water, or its service
life will be shortened. In addition, do not mistake
 Handle the electronic elements (like the fuel pump’s negative and positive electrodes.
electronic control unit and sensor etc)
with caution during the maintenance 7. When inspecting the ignition system, spark test
process, and do not let them drop on the shall not be conducted until it is necessary, and
floor. also the spark test time shall be as short as possible.
During the testing process do not turn on the
 Cultivate the consciousness of throttle or much unburned gasoline will flow into
environmental protection, and handle the exhaust pipe, which will in turn result in
efficiently wastes resulting from the damage to the three-way catalyst converter.
maintenance.
8. Since the idle adjustment is completed totally by
1.2 Maintenance Attentions the electronic fuel injection system, there is no
need to conduct manual adjustment. When leaving
1. Do not dismantle any of the electronic the factory, throttle’s accelerator stop bolt has been
fuel injection system’s components or adjusted by the manufacturer, and users’
connectors from its mounting place adjustment to its original location is prohibited.
without approval, in order to guard
against accidental damage and prevent 9. When connecting with the accumulator, do no
foreign objects like water and oil stain mistake the accumulator’s negative and positive
from entering the connector, which may electrodes, or the electronic elements will incur
affect the electronic fuel injection damage. In this system, minus earth is adopted.
system’s normal running.
10. During the engine running process, do not
2. When disconnecting and connecting the dismantle the accumulator cable.
connector, place the ignition switch to the
11. Before executing the electric welding in the vehicle,
“OFF” position, or the electric elements
dismantle the accumulator’s negative/positive
will incur damage.
cables and electronic control unit.
3. When conducting the fault heating
12. Do not test the parts’ electric signal input/output by
condition simulation or other
penetrating the cable sheath.
maintenance jobs that may lead to
temperature rise, make the temperature of
electronic control unit stay below 80℃.
1.3 List of Maintenance Tools
Tool name: Electronic fuel injection system diagnosis

instrument
Function:
Read/clear electronic fuel injection system’s faults,

read/clear electronic fuel injection system’s fault code,
observe the dataflow and parts action test etc.
(Picture here is only for your reference)
Tool name: Electronic fuel injection system commutator
Function:
Inspect the electric signal at the electronic control unit’s

every pin, and inspect the cable condition etc.
Tool name: Ignition Timing Lamp
Function:
Inspect the engine’s ignition timing etc.
Tool name: Digital Multimeter
Function:
Inspect the electronic fuel injection system’s

characteristic parameters like voltage, current, and
resistance etc.
Tool name: Vacuum Meter
Function:
Inspect the pressure in the intake manifold.
Tool name: Cylinder Pressure Gauge
Function:
Inspect every cylinder’s pressure.
Tool name: Fuel Pressure Gauge
Function:
Inspect the fuel system’s pressure, and judge the fuel

system’s fuel pump extrusion as well as the pressure
regulator’s working condition.
Tool name: Tail gas analyzer
Function:
Inspect the vehicle’s tail gas emission, which helps locate

the electronic fuel injection system’s faults.
Tool name: Fuel Injector Cleaning Analyzer
Function:
Make cleaning analysis on the fuel injector
1.4 Manual annotation abbreviations in
DG Speed sensor; DVE Electronic throttle body; FPM Accelerator pedal; DR Fuel pressure regulator
DS-S-TF Air intake pressure and temperature sensor
ECU Electronic control unit
EKP Fuel pump
EMS Engine management system
EV Injector
LSF Oxgen sensor(Heating type)
KS Knock sensor
KSZ Fuel distribution pipe assembly
KVS Fuel distribution pipe
PG Phase sensor
Ignition system with the distributor; RUV Ignition system without the distributor; TEE Fuel pump bracket
ROV
assembly
TEV Carbon canister control valve
TF-W Coolant temperature sensor
ZSK Ignition coil
VVT Variable valve timing system
DS-D2 Brake vacuum sensor
HFM Air Flow Meter
DV Turbocharger pressure relief valve
WGV Turbocharger exhaust valve

2. Briefings of ME7 System
2.1 Basic Principle

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

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

ME7 Engine Electronic Control System’s basic  Catalyst heating
components include:  Carbon canister control
Electronic control unit (ECU)  Idle control
Electronic accelerator pedal  Limp home
Air quality flowmeter (depending on project)
 Speed sensing by the incremental system
Fuel injector intake pressure /temperature
sensor(depending on project)  VVT control
Electronic fuel pump  Idle start/stop
Coolant temperature sensor 2) Additional functions

Fuel pressure regulator  Burglar alarm
Electronic throttle body  Connection between the torque and external
Oil pump bracket systems (like driving mechanism or vehicle
dynamic control)
Phase sensor
 Control over several engine parts and
Fuel distribution pipe components
Rotating speed sensor  Provision of interface on EOL-programming
Carbon canister control valve tools and maintenance tools
Knock sensor 3) Online OBD Diagnosis
Ignition coil  Complete a series of OBD functions
VVT controller  Management system used in diagnosis
Oxygen sensor
Brake vacuum sensor (idle start/stop) 2.1.2 Torque-based ME7 System
ME7-Motronicengine Management System is a In the ME7’s torque-based engine management
gasoline engine control system subject to system, all of the engine’s internal and external
electronic operation, and it provides lots of control demands shall be defined according to the engine’s
features relating to operators and torque or efficiency requirements (see Fig. 2.3).
vehicles/equipments. It is worth pointing out that Different engine demands will be converted into the
the system adopts open-loop and close-loop torque or efficiency’s control variables, and then
(feedback) control mode, which can provide these variables will be firstly processed in the central
different control signals for the engine’s running. torque demanding coordinator module. By
Major functions of the system include: sequencing these contradictory requirements by
priority, ME7 system will execute the most important
1) Basic management functions of the engine in requirement, and then it takes advantage of torque
physical model: conversion module to acquire needed engine control
 Torque-based system structure parameters like fuel injection time and ignition timing
etc. Meanwhile, execution to such control variable
 Cylinder load determined by the intake will not affect other variables, which is right the
pressure sensor/air flow rate sensor strong point of the torque-based control system.
 Gas mixture control function improved in Likewise, during the engine matching process, the
static and dynamic state. torque-based control system has independent
variables, and so only the engine data is required
 Close-loop control when matching the engine characteristic curve and
 Sequential fuel injection cylinder by cylinder map, and there is no interference with other
functions and variables. That in turn avoids
 Ignition timing, including knock control repetitive marking, simplifies the matching process,
cylinder by cylinder and reduces the matching cost.
 Emission control function
Fig. 2.3: Structure of ME7’s Torque-based System

start/stop)
In comparison with previous Collection M
engine electronic fuel injection management  Neutral position signal (dedicated to
system, ME7 system has the following start/stop)
characteristics:
 Clutch top switch signal (dedicated to
 All-new engine function structure with torque start/stop)
being the variable, which is easily compatible
with other systems and has strong scalability;  Clutch bottom switch signal (dedicated to
start/stop)
 All-new modularized software and hardware
structure that is highly transplantable;  Accumulator sensor signal (dedicated to
start/stop)
 Model-based engine characteristics maps
independent to one another, which helps  Engine compartment cover signal (dedicated
simplify the marking process; to start/stop)
 Sensor with phase, and sequential fuel  Door signal (dedicated to start/stop)
injection facilitates the improvement of After entering the ECU, above information will be
emission; processed to produce the needed actuator control
 System’s integration with anti-theft function; signals, which will be amplified in the output drive
circuit and transmitted to corresponding actuators.
 Coordinate different torque requirements in a These control signals include:
centralized manner to improve the driving
performance;  Opening of electronic throttle
 16-bit CPU, 40MHz clock frequency, and  Fuel injection timing and oil injection’s
768k cache; duration
 The system is scalable according to future  Fuel pump relay

demands like emission standard OBDII.  Opening of carbon canister control valve
2.2 Control signal: ME7 system’s input /output  Ignition coil’s angle of attachment and
signals ignition advance angle
In the ME7 system, ECU’s major sensor input  A/C compressor relay
signals include:
 Cooling fan relay
 Air flow signal
 Starter relay
 Intake pressure signal
 VVT angle
 Accelerator pedal signal
 Turbocharger pressure relief valve
 Intake temperature signal
 Turbocharger exhaust valve
 Throttle angle signal
 Coolant temperature signal 2.3 Introduction of System
 Engine rotating speed signal Functions
 Phase signal
2.3.1 Start Control
 Knock sensor signal
During the starting process, special calculation
 Oxygen sensor signal method will be adopted to control the charge, fuel
injection, and ignition timing. At the initial phase
 Vehicle speed signal
of this process, air in the intake manifold keeps
 A/C pressure signal still, and intake manifold’s internal pressure
reading is equal to the ambient atmosphere
 Brake signal pressure. When the throttle is closed, the idle speed
regulator is assigned a fixed parameter according
 Brake vacuum degree signal (dedicated to
to the starting temperature.
In the similar process, the given “Fuel Injection decreases, additional fuel included in the fuel film
Timing” is assigned the initial injection pulse. on the intake manifold wall will be released again.
Then, injection duration must decrease during the
Fuel injection volume varies according to the deceleration process.
engine temperature, in order to facilitate the
formation of oil film on the intake manifold and Towing astern or traction condition refers to the
cylinder’s walls. Therefore, when the engine situation in which the power at the flywheel from the
reaches a given rotating speed, thick gas mixture engine is negative. In this case, engine friction and
shall be added. pump gas loss can be used to make the vehicle
decelerate. When the engine stays in the towing
Once the engine starts running, the system will astern or traction condition, the oil injection will be
immediately reduce the starting excess fuel. When cut off to reduce the fuel consumption and waste gas
the starting process ends (600…700min-1), the emission. More importantly, the process will help
starting excess fuel is completely cancelled. protect the three-way catalyst converter.
During the engine starting process, the ignition Once the rotating speed declines to the given rotating
angle is being adjusted constantly, and it varies speed (above idle speed) for recovery of oil supply,
according to engine temperature, intake the oil injection system will resume the oil supply. As
temperature, and engine’s rotating speed. a matter of fact, among the ECU’s programs there is
Note: As for vehicles with start/stop function, a range for recovery of rotating speed, and it varies
vehicle starting can be determined according to the with change of parameters like engine temperature
vehicle gear and clutch information. If the and engine rotating speed’s dynamic change. Also, it
transmission is in gear and engages with the clutch, calculates the rotating speed to prevent it from
starter running shall be prohibited. declining to specified minimum threshold.
2.3.2 Warm-up and Three-way Catalyst Once the injection system resumes the oil supply,
the system will begin using the initial injection
Converter Heating Control pulse to supply the additional fuel, in addition to
When the engine has been started at low reconstructing the oil film on the intake manifold’s
temperature, cylinder charge, fuel injection, and wall. After recovery of the fuel injection,
electronic ignition will be adjusted to offset the torque-based control system will slow and stabilize
engine’s higher torque requirements. Such a the engine torque’s increase (smooth transition).
process will continue till appropriate temperature
threshold has been hit.
2.3.4 Idle Control
At the idle speed, engine will not offer torque to
Meanwhile, speedy heating to three-way catalyst
converter is most important, because speedy the flywheel. To make sure that the engine can run
transformation into three-way catalyst converter stably at a low idle speed, the close-loop idle
control system must maintain the balance between
running will help reduce emission of waste gas
the torque and the engine’s “Power Consumption”,
considerably. In such a working condition, ignition
advance angle should be postponed, in order to heat and it will generate a given power during the idling
the three-way catalyst converter by waste gas. process, in order to meet different load requirements,
which arise from engine crankshaft, gas distribution
2.3.3 Acceleration /Deceleration and mechanism, and auxiliary components (like friction
Towing Astern Oil Cutoff Control in the water pump).
Some of the fuel that has been injected into the intake ME788 System adopts the torque-based control
manifold will not duly flow into the cylinder to strategy, which, based on close-loop idle control,
partake into the subsequent combustion. On the determines the engine torque output that is required
contrary, it will produce a layer of oil film on the to maintain the idling speed in any working condition.
wall of the intake manifold. With improvement of the Such torque output increases with decline of the
load and extension of the fuel injection duration, fuel engine’s rotating speed, or vice versa. By requiring
deposited in the oil film will increase sharply. higher torque, the system makes response to the new
“Interference Factor”, such as the air conditioning
When the throttle opening increases, some compressor’s start/stop or automatic transmission
injected fuel will be absorbed by the oil film. Due shift. When the engine temperature is relatively low,
to this, supplementary fuel shall be injected to torque should be increased to offset more internal
prevent the gas mixture from getting thin during friction loss and/or maintain higher idling speed.
the acceleration process. Once the load coefficient All these torque output requirements are
transmitted to the torque coordinator, which will cycle. Once there is knock, ECU will trigger the
make processing calculation and obtain knock close-loop control. After the knock danger
corresponding charge concentration, components is eliminated, the affected cylinder’s ignition will
of gas mixture, and ignition timing. be gradually advanced to the preset ignition
advance angle again.
2.3 5 Close-loop Control
Knock control’s threshold is applicable to fuel of
Exhaust post-treatment in the three-way catalyst different working conditions and different
converter is an effective way to reduce density of grades.
harmful substances in the waste gas. Normally,
the three-way catalyst converter is able to reduce 2.3.8 VVT Control
HC, CO, and NOx by 98% ore more, and turn
them into H2O, CO2, and N2. However, By controlling the intake/exhaust camshaft phase,
above-mentioned high efficiency can be realized the system can efficiently reduce the engine’s
only when the engine’s excess air factor is equal emission at low speed and improve its torque at
to 1 or so. In fact, the close-loop control aims to high speed. According to the vehicle’s running
ensure that concentration of the gas mixture stays condition and the driver’s driving intention, the
within such a range. ECU can calculate out the intake/exhaust
camshaft’s target phase, as well as realize the
Close-loop control system takes effect only when the close-loop control to the camshaft phase according
oxygen sensor is installed. Oxygen sensor is used to to the phase information acquired from the phase
monitor the oxygen content in the waste gas on the sensor. Compared with the engine without VVT
three-way catalyst converter’s side: thin gas mixture system, the engine with VVT system can
(λ>1) produces sensor voltage of about 100mV, and efficiently reduce oil consumption and emission as
thick gas mixture (λ<1) produces sensor voltage of well as raise the maximum power.
about 900mV. When λ is 1, the sensor voltage will
incur a jumping. To the input signal, the close-loop 2.3.9 Idle Start/Stop Control
control will make response (λ>1: too thin gas
By analyzing the driver’s driving intention, the
mixture, λ<1: too thick gas mixture) to modify the
system will realize the automatic idle stop/start at a
control variable, and modifying factor therein will
proper time. By analyzing such information as
serve as the multiplier to modify the fuel injection clutch pedal, neutral gear, driving speed, brake
duration. vacuum degree, accumulator state, door, and engine
2.3.6 Evaporation Emission Control compartment cover etc., idle start/stop control will
determine if the automatic stop/start conditions have
Due to transmission of external radiation heat and oil been met. During the normal driving process, drivers
return radiation, fuel in the oil tank is heated to need to conduct any additional operation to realize
produce the fuel steam. Subject to the limitation of the automatic idle stop/start.
evaporation emission laws and regulations, steam
brimming with lots of HC shall not be discharged Since the idle start/stop control provides the complete
into the air directly. In the system, fuel steam will be vehicle with starter relay, there will be two additional
collected into the active carbon canister through the functions like automatic start after stalling and
duct. When condition permits, fuel steam will be starter’s failure in running when gearing chain
flushed and discharged into the engine to partake in engages (transmission is in gear and engages with
the combustion process. Meanwhile, the flow rate of clutch), which will do good to fresh drivers. In
the flushing air current is realized by ECU that addition, the idle start/stop control can help reduce
controls the carbon canister’s control valve. Only the complete vehicle’s oil consumption and gas
when the close-loop control system works in the emission.
close-loop condition can such a control run. 2.4 Introduction of System
2.3.7 Knock Control Troubleshooting Function
By virtue of the knock sensor that is mounted at 2.4.1 Fault Information Record
the appropriate place of the engine, the system
tests the characteristic vibration resulting from Electronic control unit constantly monitors the
the knock, and then converts the vibration into sensor, actuator, relevant circuits, fault indicators,
electronic signal, in order to transmit it in the and accumulator voltage etc., and even the
ECU for handling. By adoption of special electronic control unit itself, in addition to
processing algorithm, ECU tests if there is knock conducting the reliability test to the sensor output
phenomenon at every cylinder’s combustion signal, actuator drive signal, and internal signals
(like close-loop control, coolant temperature, displayed according to the fault occurrence
knock control, idling speed control, and sequence. According to the fault frequency, faults
accumulator voltage control etc). Once there is can be classified into “Steady-state Faults” and
fault at certain link or a given signal is unreliable, “Sporadic Faults” (like the faults resulting from
the electronic control unit will immediately set the short-lived open circuit or poor contact between
fault information record in RAM fault memory, connectors)
and save it in the form of fault code, which will be
Fig. 2.4 Electronic Fuel Injection System’s Troubleshooting Principle

2.4.2 Classification of Fault Types Class6, Class7, Class11, Class12, and Class13
belong to those fault types that have been defined
Diagnostic Fault Path and Fault Categories by the system in a uniform manner.
Diagnostic fault path (DFP) is, in fact, a Class2: fault is inputted into the fault memory upon
sub-function for fault diagnosis that is used to taking place; DFP fault types relating to misfire are
inspect functions of a given sensor, actuator, or usually defined as Class 2. As for the misfire fault
others in the EMS system. By respective resulting in damage of catalyst, the MIL lamp will
diagnostic path, the fault information will be flash in no time to prompt the driver. As for the
transmitted to the fault diagnosis management misfire fault resulting in deterioration of emission, if
module, which will take corresponding actions the misfire fault of corresponding extent has been
and determine if the fault lamp should be activated fully detected in three consecutive driving cycles, the
or the fault should be displayed on the diagnostic MIL lamp will be activated, and also the fault will be
unit. When a fault is detected at a given DFP, the displayed on the diagnostic unit. If the fault fails to
fault diagnosis management module will make be confirmed or eliminated in 40 driving cycles
definite the fault type. Usually, the fault types (namely, in a warm-up cycle, E_xxx＝1, but Z_xxx
include: ＝0), the fault information will be deleted from the
B_mxdfp Maximum fault, signal goes beyond the fault memory. if the fault disappears before the fault
upper limit of the normal range. confirmation and never occurs within 40 driving
cycles, the fault information will be deleted from the
B_mndfp Minimum Fault, the signal goes beyond fault memory; If the fault disappears after being
the lower limit of the normal range. confirmed, the fault information cannot be deleted
from the fault memory until it does not occur within
B_sidfp signal fault, without signal.
40 warm-up cycles, and the fault priority is defined
B_npdfp unreasonable signal, with signal, but as 20. After the fault confirmation, SVS lamp is off.
the signal is unreasonable. If the fault disappears after the fault confirmation and
never occurs within three driving cycles, it means
Definitions of Fault Types that the fault has been corrected.
In this project there are 10 fault types. Closed fault Class3: fault is inputted into the fault memory upon
path is defined as “Class0”, namely, the fault taking place. After the fault confirmation, the MIL
information will not enter the fault memory, and lamp is activated, and the fault confirmation needs
also the diagnostic unit will not read the fault. In three driving cycles, with fault being displayed on the
addition, faults of Class2, Class3, Class4, Class5, diagnostic unit. If the fault fails to be confirmed or
eliminated within 40 warm-up cycles(namely, in a ＝1, but Z_xxx＝0), the fault information will be
warm-up cycle, E_xxx＝1, but Z_xxx＝0), the fault deleted from the fault memory; If the fault disappears
information will be deleted from the fault memory; if after being confirmed, the fault information cannot be
the fault disappears before the fault confirmation and deleted from the fault memory until it does not occur
never occurs within 40 warm-up cycles, the fault within 40 warm-up cycles; and the fault priority is
information will be deleted from the fault memory; If defined as 50; after the fault confirmation, SVS lamp
the fault disappears after being confirmed, the fault is off; If the fault disappears after the fault
information cannot be deleted from the fault memory confirmation and never occurs within 1.2s, it means
until it does not occur within 40 warm-up cycles; and the fault has been corrected.
the fault priority is defined as 30; after the fault
confirmation, SVS lamp is off; If the fault disappears Class7:fault is inputted into the fault memory upon
after fault confirmation and never occurs within three taking place; after the fault confirmation, MIL
driving cycles, it means the fault has been corrected.. lamp is off; fault will be confirmed upon taking
place; the fault is not displayed on the diagnostic
Class4:fault is inputted into the fault memory upon unit;If the fault fails to be confirmed or eliminated
taking place. After 2.5s since the fault occurs, the within 40 warm-up cycles(namely, in a warm-up
MIL lamp will be activated, and also the fault is cycle, E_xxx ＝ 1, but Z_xxx ＝ 0), the fault
displayed on diagnostic unit; If the fault fails to be information will be deleted from the fault memory;
confirmed or eliminated within 40 warm-up If the fault disappears after the fault confirmation,
cycles(namely, in a warm-up cycle, E_xxx＝1, but the fault information cannot be deleted from the
Z_xxx＝0), the fault information will be deleted from fault memory until it does not occur within five
the fault memory; if the fault disappears before the warm-up cycles, and the fault priority is defined as
fault confirmation and never occurs within 40 50; after the fault confirmation, SVS lamp is off; If
warm-up cycles, the fault information will be deleted the fault disappears after the fault confirmation and
from the fault memory; If the fault disappears after never occurs within 120ms, it means the fault has
being confirmed, the fault information cannot be been corrected.
deleted from the fault memory until it does not occur
Class11:fault is inputted into the fault memory upon
within 40 warm-up cycles; and the fault priority is
taking place; after the fault confirmation, MIL lamp is
defined as 30; after the fault confirmation, SVS lamp
activated; fault confirmation needs 3 driving cycles;
is off; If the fault disappears after fault confirmation
the fault is displayed on diagnostic unit; If the fault
and never occurs within three driving cycles, it means
fails to be confirmed or eliminated within 40
the fault has been corrected..
warm-up cycles(namely, in a warm-up cycle, E_xxx
Class5:fault is inputted into the fault memory upon ＝1, but Z_xxx＝0), the fault information will be
taking place; after the fault confirmation, MIL lamp is deleted from the fault memory; if the fault disappears
off; fault confirmation needs 3 driving cycles; the before the fault confirmation and never occurs within
fault is displayed on diagnostic unit; If the fault fails 40 warm-up cycles, the fault information will be
to be confirmed or eliminated within 40 warm-up deleted from the fault memory; If the fault disappears
cycles(namely, in a warm-up cycle, E_xxx＝1, but after being confirmed, the fault information cannot be
Z_xxx＝0), the fault information will be deleted from deleted from the fault memory until it does not occur
the fault memory; if the fault disappears before the within 40 warm-up cycles; and the fault priority is
fault confirmation and never occurs within 40 defined as 20; after the fault confirmation, SVS lamp
warm-up cycles, the fault information will be deleted is off; If the fault disappears after the fault
from the fault memory; If the fault disappears after confirmation and never occurs within 4 driving cycles,
being confirmed, the fault information cannot be it means the fault has been corrected.
deleted from the fault memory until it does not occur Class12:fault is inputted into the fault memory
within 40 warm-up cycles; and the fault priority is upon taking place; after the fault confirmation,
defined as 40; after the fault confirmation, SVS lamp MIL lamp is off; fault is confirmed upon taking
is off; If the fault disappears after fault confirmation place, and it is not displayed on the diagnostic unit;
and never occurs within three driving cycles, it means If the fault fails to be confirmed or eliminated
the fault has been corrected.. within 40 warm-up cycles (namely, in a warm-up
Class6: fault is inputted into the fault memory upon cycle, E_xxx ＝ 1, but Z_xxx ＝ 0), the fault
taking place; after the fault confirmation, MIL lamp is information will be deleted from the fault memory;
off; fault will be confirmed upon taking place; the if the fault disappears before the fault confirmation
fault is not displayed on the diagnostic unit;If the fault and never occurs within 40 warm-up cycles, the
fails to be confirmed or eliminated within 40 fault information will be deleted from the fault
warm-up cycles(namely, in a warm-up cycle, E_xxx memory; If the fault disappears after being
confirmed, the fault information cannot be deleted pedal’s opening greater than 75%, and stepping
from the fault memory until it does not occur down the brake pedal), SVS will work in blink code
within 40 warm-up cycles; and the fault priority is mode. Since the ignition switch has been turned on
defined as 50; after fault confirmation, SVS lamp and the ECU embarks on initialization, SVS lamp
is activated; If the fault disappears after the fault will remain “ON” state for 4s. Then, after one
confirmation and never occurs within 120, it means second of interval, SVS will blink at the frequency
the fault has been corrected, and also the SVS is of 2HZ, in order to indicate “No Fault” till the blink
off. code request condition cannot be met.
Class13:fault is inputted into the fault memory upon 4) Blink code request, and there is fault in fault
taking place; after the fault confirmation, MIL lamp is memory
activated; fault confirmation needs 3 driving cycles;
the fault is displayed on diagnostic unit; If the fault If the ECU blink code request condition has been
fails to be confirmed or eliminated within 40 met (blink code request condition: ignition switch is
warm-up cycles(namely, in a warm-up cycle, E_xxx turned on under the precondition of no vehicle
＝1, but Z_xxx＝0), the fault information will be speed, no engine’s rotating speed, accelerator
pedal’s opening greater than 75%, and stepping
deleted from the fault memory; If the fault disappears
down the brake pedal), SVS will work in blink code
before the fault confirmation and never occurs within
mode.
40 warm-up cycles, the fault information will be
deleted from the fault memory; If the fault disappears Since the ignition switch has been turned on and the
after the fault confirmation, the fault information ECU embarks on initialization, SVS lamp will
cannot be deleted from the fault memory until it never remain “ON” state for 4s. Then, after one second of
occurs within 40 warm-up cycles; and the fault interval, SVS will indicate the fault code (P-code)
priority is defined as 30; after fault confirmation, SVS in the memory with a blink code. If all faults in the
lamp is activated; If the fault disappears after the fault memory have been indicated by SVS lamp in the
confirmation and never occurs within 4 driving cycles, form blink codes, and blink code request condition
it means the fault has been corrected, and also the is still met, the SVS lamp will go out till blink code
SVS lamp is off. request condition cannot be met.
SVS Lamp Control Strategy 2.4.3 Connection with Diagnostic Unit
In different working conditions, SVS lamps vary in This system adopts CAN communication protocol
working condition: and ISO 15031-3 standard diagnosis connector (see
1) No blink code request, and empty fault Fig.2.5). Such a standard diagnosis connector, in
memory the form of bus connector, is fixed at the position
between the cab’s steering shaft and the vehicle’s
When the ignition switch is turned on, ECU will medial axis. Pin 4, 6, 14, and 16 of the standard
start initialization in no time. Since the diagnosis connector are used in the engine’s
initialization, SVS lamp will be turned on for 4s. management system EMS. Of which, the standard
If the engine is started within 4s, SVS will diagnosis connector’s Pin 4 links with the earth
immediately go out if the engine’s rotating speed wire in vehicle, Pin 6 serves as the engine data
(B_nmot=true) has been located. cable CAN_H’s lead, Pin 14 serves as the engine
data cable CAN_L’s lead, and Pin 16 connects with
2) No blink code request, there is fault in the the accumulator’s positive electrode.
fault memory
Since the ignition switch has been turned on
and the ECU embarks on the initialization, SVS
lamp will remain “ON” state until the engine’s
rotating speed has been located. If the fault
manager requires that SVS lamp shall be turned
on in the fault mode, the SVS lamp will remain
Fig. 2.5: ISO15031-3 Standard Diagnosis
“ON” state in the subsequent driving cycle.
Connector
3) Blink code request and empty fault memory
Through “CAN” cable, ECU can communicate
If the ECU blink code request condition has been with the external diagnostic unit. See GEELY
met (blink code request condition: ignition switch is Instruction on Diagnostic Unit for detailed
turned on under the precondition of no vehicle operations of the diagnostic unit.
speed, no engine’s rotating speed, accelerator
3 ME7’s Overhaul and Diagnosis Flow by there is fault at a given circuit, it means that there
Fault Code likely exists open circuit or several types of faults in
the circuit.
Explanations:
Diagnosis help:
1. The overhaul cannot be executed only when
current fault has been confirmed as “Steady-state” 1. If the fault code cannot be cleared, the fault
fault, or the diagnosis error will take place. belongs to “Steady-state” fault. If the fault belongs
to sporadic fault, emphasis should be put on the
2. Multimeter required refers to the digital inspection to wiring connector’s looseness.
multimeter, and analogue multimeter shall not be
used to inspect the electronic fuel injection 2. No abnormal situation after preceding
system’s lines. inspection;
3. In the case of overhauling the vehicle with 3. During the overhaul process, do not overlook
anti-theft system, if the ECU will be replaced, other factors’ influence on the system, such as
programming to ECU shall be done after the automobile maintenance, cylinder pressure, and
replacement. mechanical ignition timing etc.
4. If the fault code indicates that a given circuit has 4. Replace ECU for further test.
too low voltage, it means that there likely exists short If the fault code can be cleared, the fault cause
circuit to the earth in the circuit. If the fault code should be attributed to ECU. However if the fault
indicates that a given circuit has too high voltage, it code cannot be cleared, remount original ECU and
means that there likely exists short circuit to the repeat the workflow for further overhaul work.
battery in the circuit. If the fault code indicates that
INDEX PCODES UAES Explanations CLASS MIL SVS

1 P000A Slow intake VVT response 5 × ×
2 P0010 VVT intake control valve circuit, open 3 √ ×
Intake VVT fails to stay at defaulted position when
3 P0012 5 × ×
starting
Improper relative position between crankshaft and
4 P0016 3 √ ×
camshaft
5 P0030 Upstream oxygen sensor heater control circuit, fault 3 √ ×
Upstream oxygen sensor heater control circuit, low
6 P0031 3 √ ×
voltage
Upstream oxygen sensor heater control circuit, high
7 P0032 3 √ ×
voltage
8 P0033 Discharge control valve control circuit. 3 √ ×
9 P0034 Discharge control valve control circuit voltage is too low. 3 √ ×
Discharge control valve control circuit voltage is too
10 P0035 3 √ ×
high.
11 P0036 Downstream oxygen sensor heater control circuit, fault 3 √ ×
Downstream oxygen sensor heater control circuit, low
12 P0037 3 √ ×
voltage,
Downstream oxygen sensor heater control circuit, high
13 P0038 3 √ ×
voltage
14 P0053 Upstream oxygen sensor heater resistance, improper 3 √ ×
15 P0054 Downstream oxygen sensor heater resistance, improper 3 √ ×
16 P006D Environmental pressure sensor signal circuit. 3 √ ×
17 P0101 Air flow meter sensor signal unreasonable. 3 √ ×
18 P0102 Air flow meter sensor signal voltage is too low. 3 √ ×
19 P0103 Air flow meter sensor signal voltage is too high. 3 √ ×
20 P0112 Intake temperature sensor signal circuit, low voltage 3 √ ×
21 P0113 Intake temperature sensor signal circuit, high voltage 3 √ ×
22 P0117 Engine coolant temperature sensor circuit, low voltage 3 √ ×
23 P0118 Engine coolant temperature sensor circuit, high voltage 3 √ ×
24 P0121 Electronic throttle position sensor1 signal, improper 3 √ ×
Electronic throttle position sensor1 signal circuit, low
25 P0122 3 √ ×
voltage
electronic throttle position sensor1 signal circuit, high
26 P0123 3 √ ×
voltage
27 P0130 Upstream oxygen sensor signal, improper 3 √ ×
28 P0131 Upstream oxygen sensor signal, low voltage 3 √ ×
29 P0132 Upstream oxygen sensor signal circuit, high voltage 3 √ ×
30 P0133 Upstream oxygen sensor, aging 3 √ ×
31 P0134 Upstream oxygen sensor circuit, signal circuit fault 3 √ ×
32 P0136 Downstream oxygen sensor signal, improper 3 √ ×
33 P0137 Downstream oxygen sensor signal, low voltage 3 √ ×
34 P0138 Downstream oxygen sensor signal circuit, high voltage 3 √ ×
35 P0140 Downstream oxygen sensor circuit, signal fault 3 √ ×
Offline detection A/F ratio close-loop control
36 P0170 7 × ×
self-learning, improper
37 P0171 7 × ×
self-learning, too lean
38 P0172 7 × ×
self-learning, too thick
39 P0201 Cylinder 1 fuel injector control circuit, open 3 √ ×
43 P0219 Engine rotating speed exceeds the upper limitation 6 × ×
44 P0221 Electronic throttle position sensor2 signal, improper 3 √ ×
Electronic throttle position sensor2 signal circuit, low
45 P0222 3 √ ×
voltage
Electronic throttle position sensor2 signal circuit, high
46 P0223 3 √ ×
voltage
47 P0234 Turbo boost control over. 3 √ ×
48 P0237 Turbocharger pressure sensor signal voltage is too low. 3 √ ×
49 P0238 Turbocharger pressure sensor signal voltage is too high. 3 √ ×
50 P0243 Exhaust gas control valve drive circuit. 3 √ ×
51 P0245 Exhaust gas control valve drive circuit voltage is too low. 3 √ ×
Exhaust gas control valve drive circuit voltage is too
52 P0246 3 √ ×
high.
Cylinder 1 fuel injector control circuit’s short circuit to
53 P0261 3 √ ×
ground
54 P0262 3 √ ×
the battery
55 P0264 3 √ ×
the ground
56 P0265 3 √ ×
the battery
57 P0267 3 √ ×
the ground
58 P0268 3 √ ×
the battery
59 P0270 3 √ ×
the ground
60 P0271 3 √ ×
the battery
61 P0299 Turbo boost control deficiencies. 3 √ ×
62 P0300 Multiple Cylinders Misfire Detected 2 √or Blink ×
63 P0301 Cylinder 1 Misfire Detected 2 √or Blink ×
67 P0321 Crankshaft TDC shortage signal, improper 3 √ ×
68 P0322 Rotating sensor signal, fault 3 √ ×
69 P0327 Knock sensor signal circuit, low voltage 3 √ ×
70 P0328 Knock sensor signal circuit high voltage 3 √ ×
71 P0340 Phase sensor mounting position, improper 3 √ ×
72 P0341 Phase sensor signal, improper 3 √ ×
73 P0342 Phase sensor signal circuit’s short circuit to the ground 3 √ ×
74 P0343 Phase sensor signal circuit’s short circuit to the battery 3 √ ×
Three-way catalyst oxygen storage capacity, aging
75 P0420 3 √ ×
(excessive emission)
76 P0444 Canister control valve control circuit, open 3 √ ×
77 P0458 Canister control valve control circuit, low voltage 3 √ ×
78 P0459 Canister control valve control circuit high voltage 3 √ ×
79 P0480 Cooling fan relay control circuit, open (low speed) 5 × ×
80 P0481 Cooling fan relay control circuit, open (high speed) 5 × ×
81 P0501 Vehicle speed sensor signal, fault 3 √ ×
Idling control rotating speed, lower than target idling
82 P0506 3 √ ×
speed
Idling control rotating speed, higher than target idling
83 P0507 3 √ ×
speed
84 P0560 System accumulator voltage signal, improper 5 × ×
85 P0562 System accumulator, low voltage 5 × ×
86 P0563 System accumulator, high voltage 5 × ×
Brake switch signal circuit, fault or out-of-step
87 P0571 5 × ×
correlation
88 P0602 Electronic control unit encoding, fault 3 √ ×
89 P0604 Electronic control unit RAM, fault 3 √ ×
90 P0605 Electronic control unit ROM, fault 3 √ ×
91 P0606 Electronic throttle safety monitoring function, fault 3 √ ×
92 P0627 Oil pump relay control circuit, open 3 √ ×
93 P0629 Oil pump relay control circuit, high voltage 3 √ ×
94 P0645 A/C compressor relay control circuit, open 5 × ×
95 P0647 A/C compressor relay control circuit, high voltage 5 × ×
96 P0688 Main relay’s output voltage, improper 5 × ×
Cooling fan relay control circuit, high voltage(low
97 P0692 5 × ×
speed)
Cooling fan relay control circuit, high voltage(high
98 P0694 5 × ×
speed)
99 P0704 Clutch pedal switch signal, improper 5 × ×
100 P1297 Throttle forward gas leak 3 √ ×
101 P1336 Electronic throttle safety monitoring torque, restriction 6 × ×
102 P1427 Brake vacuum booster pump control circuit high voltage 5 × ×
103 P1429 Brake vacuum booster pump control circuit voltage Open 5 × ×
104 P1479 Brake vacuum booster pump failure 5 × ×
105 P1523 Airbag ECM sends a signal to interrupt or incorrect. 5 × ×
Deflection between electronic throttle’s actual location
106 P1545 3 √ ×
and target location exceeds limit
107 P1558 Electronic throttle’s starting resistance, too high 3 √ ×
108 P1559 Electronic throttle’s self-learning process, fault 6 × ×
System voltage fails to meet electronic throttle’s
109 P1564 6 × ×
self-learning condition
Electronic throttle lower position limit initialization
110 P1565 3 √ ×
self-learning, fault
111 P1568 Electronic throttle return resistance, too high 3 √ ×
112 P1579 Electronic throttle self-learning condition, unsatisfied 6 × ×
113 P1604 Electronic throttle gain regulation self-learning, fault 6 × ×
114 P1615 ECM eeprom state error 35 × Blink
115 P1616 False alarms received certification reply. 35 × Blink
Did not receive anti-theft device authentication
116 P1617 35 × Blink
reply.(immo code resp)
117 P1618 Theft match Security Code (PIN code) entry errors 38 × Blink
118 P1619 ECM not be burglar match 38 × Blink
119 P1683 Airbag Communication Information unreasonable 5 × ×
Brake vacuum degree sensor voltage signal, higher than
120 P1912 5 × ×
upper limit
Brake vacuum degree sensor voltage signal, lower than
121 P1913 5 × ×
lower limit
122 P2088 VVT intake control valve’s short circuit to the ground 3 √ ×
VVT intake control valve circuit’s short circuit to the
123 P2089 3 √ ×
battery
124 P2106 Electronic throttle driving stage, fault 3 √ ×
Electronic throttle pedal position sensor1 signal, low
125 P2122 3 √ ×
voltage
Electronic throttle pedal position sensor1 signal, high
126 P2123 3 √ ×
voltage
Electronic throttle pedal position sensor2 signal, low
127 P2127 3 √ ×
voltage
Electronic throttle pedal position sensor2 signal, high
128 P2128 3 √ ×
voltage
129 P2138 Electronic throttle pedal position sensor signal, improper 3 √ ×
A/F ratio close-loop control self-learning value goes
130 P2177 11 √ ×
beyond upper limit (middle load zone)
131 P2178 11 √ ×
beyond lower limit (middle load zone)
132 P2187 3 √ ×
beyond upper limit (low load zone)
133 P2188 3 √ ×
beyond lower limit (low load zone)
136 P2261 Pressure relief valve mechanical failure 3 √ ×
1137 P2270 Downstream oxygen sensor, aging 3 √ ×
138 P2271 Downstream oxygen sensor, aging 3 √ ×
139 U0001 CAN communication’s relevant diagnosis 3 √ ×
4 ME7’s Overhaul and Diagnosis Flow by Fault Phenomenon

Preliminary inspection shall be conducted before troubleshooting by the engine’s fault phenomenon:
1. Confirm if the engine’s fault indicator runs normally;
2. Inspect the fault with fault diagnostic unit, and Confirm if there is no fault information record;
3. Confirm existence of the fault phenomenon complained by the car owner, and confirm conditions for
the fault occurrence. Then, inspect the appearance:
(1) Inspect if the fuel pipeline suffers leakage;
(2) Inspect if the vacuum pipeline incurs rupture and distortion, and if the connection is correct;
(3) Inspect if the intake pipeline suffers blockage, air leakage, compression to flat, or damage;
(4) Inspect if the ignition system’s HV cable suffers breakage and aging, and if the ignition sequence is
correct;
(5) Inspect if the wire grounding place is clean and secure;
(6) Inspect if the sensor and actuator connectors are loosed or poorly contacted.
Important Reminder: If foresaid phenomenon does exist, maintenance and repair work shall be done according
to the fault condition at first, or subsequent fault diagnosis and repair work will be affected.
Diagnosis Help:
1. Confirm the engine has not any fault record;
2. Confirm existence of the complained fault phenomenon;
3. No abnormal situation is found after preceding inspection steps have been done;
4. During the overhaul process, do not overlook other factors’ influence on the system, such as
automobile maintenance, cylinder pressure, and mechanical ignition timing and fuel etc.
5. Replace ECU for further test.
If the fault phenomenon can be cleared, the fault cause should be attributed to ECU. However if the fault
phenomenon still exists, remount original ECU and repeat the workflow for further overhaul work.
Analysis of Typical Faults
1. When starting, engine fails to run or runs slowly

2. When starting, engine can run in a dragging manner but fails to start successfully
3. Difficulty in heat starting
4. Difficulty in cold starting
5. Normal rotating speed and difficulty in starting at any time;
6. Normal starting but unstable idling speed at any time;
7. Normal starting but unstable idling speed during the warm-up process
8. Normal starting but unstable idling speed after the warm-up
9. Normal starting but unstable idling speed or stalling when there is partial load (like running of air
conditioning)
10. Normal starting but over high idling speed;
11. Rotating speed fails to increase or engine is stalled when being accelerated;
12. Slow response when being accelerated
13. Poor performance or lack of power when being accelerated
14. Idle start/stop function ineffective
1. When starting, engine fails to run or runs slowly

Ordinary faulted parts: 1. Accumulator; 2. Starting motor; 3. Wiring harness or ignition switch; 4 Engine’s
mechanical parts; 5 Neutral position switch;
Ordinary Troubleshooting Flow:
Test
No. Operation Steps Follow-up Steps
Results
If the engine does not run, floor the clutch pedal, and Repair neutral position
Yes
1 make another attempt to observe if the engine can be switch
started No Next step
Use the multimeter to inspect the voltage between the Yes Next step
accumulator’s two wiring terminals, and inspect if the
2
voltage ranges between 8V and 12V when the engine is No Replace accumulator
starting.
Maintain the ignition switch at the start position, and Yes Next step
use the multimeter to inspect if at the starting motor’s
3 Repair or replace wiring
positive wiring terminal there is a voltage of more than No
harness
8V.
Dismantle the starting motor, inspect the starting Repair or replace starting
Yes
motor’s working condition, and focus on inspecting if motor
4
it suffers open circuit or gets stuck due to poor
No Next step
lubrication.
If the fault only occurs in winter, inspect if the starting Make use of lubricating oil
Yes
motor suffers excessive resistance due to inappropriate of appropriate grade.
5
application of the engine lubricating oil and gearbox
No Next step
oil.
Inspect if the starting motor’s running failure or slow Overhaul the engine’s
Yes
6 running results from excessive mechanical resistance internal resistance
inside the engine. No Diagnosis Help
2. When starting, engine can run in a dragging manner but fails to start successfully
Ordinary faulted parts: 1. No oil in cylinder;2. Fuel pump;3 Rotating speed sensor;4. Ignition coil; 5.
Engine’s mechanical parts.
Test
Results
Connect with the fuel pressure gauge (front end of fuel distribution Yes Next step
1 pipe assembly’s inlet tube serves as the connection point), start the Overhaul the oil
No
engine, and inspect if the fuel pressure hovers around 350kPa. supply system
Yes Next step
Connect with the electronic fuel injection system’s diagnostic unit,
Overhaul the
2 and observe the “Engine Rotating Speed” data. After that, start the
No rotating speed
engine and observe if there is output of rotating signal.
sensor’s circuit
Pull out one cylinder’s spark plug wire, and connect with the spark Yes Next step
plug, during which make the spark plug’s electrode keep a distance
3 Overhaul the
of 5mm away from the engine body. Then start the engine, and No
ignition system
inspect if there is blue/white HV spark.
Rule out the
Inspect the engine cylinders’ pressure, and observe if the engine Yes engine’s
4
cylinders incur insufficient pressure. mechanical faults
No Next step
3. Difficulty in heat starting

Ordinary faulted parts: 1. Water in fuel;2. Fuel pump;3. Coolant temperature sensor;4. Fuel pressure
regulator vacuum tube;5. Ignition coil.
Test
Results
No
2 Overhaul the
ignition system
Pull out the coolant temperature sensor’s joint, and start the engine Overhaul the line
to observe if the engine can start successfully. (or connect in series Yes or replace the
3 with a 300ohm resistance to replace the coolant temperature sensor sensor
at the coolant temperature sensor’s joint to observe if the engine can
No Next step
start successfully )
4 Inspect if the fuel pressure regulator vacuum tube gets loosened or
Yes Overhaul or
replace
suffers air leakage
No Next step
Inspect the fuel condition, and observe if the fault occurs right after Yes Replace fuel
5
the oil is injected. No Next step
4. Difficulty in cold starting

Ordinary faulted parts: 1. Water in fuel;2. Fuel pump;3. Coolant temperature sensor;4. Fuel injector;5.
Ignition coil;6. Throttle body ;7. Engine’s mechanical parts.
Test
Results
No
2 Overhaul the
ignition system
Pull out the coolant temperature sensor’s joint, and start the engine Overhaul the line
to observe if the engine can start successfully. (or connect in series Yes or replace the
3 with a 2500ohm resistance to replace the coolant temperature sensor
sensor at the coolant temperature sensor’s joint to observe if the
No Next step
engine can start successfully
Clean throttle and
Step on the accelerator lightly and observe if the engine can be Yes
4 idling air path
easily started.
No Next step
Dismantle the fuel injector, and use the dedicated fuel injector Yes Fault replacement
5 cleaning analyzer to inspect if the fuel injector suffers leakage or
No Next step
blockage.
Inspect the fuel condition, and observe if the fault occurs right Yes Replace fuel
6 after the oil is injected. No Next step
Rule out the
7
cylinders incur insufficient pressure. mechanical fault
No Next step
Connect with the electronic fuel injection system adapter and turn Yes Diagnosis Help
on the ignition switch, inspect if the power supply at 12#, 13#, Overhaul
8
44#, 45#, and 63# pin is normal, and inspect the electrical ground No corresponding
at 3#, 51#, 53#, 61#, and 80# pin is normal. lines
5. Normal rotating speed and difficulty in starting at any time;

Ordinary faulted parts: 1. Water in fuel;2. Fuel pump;3. Coolant temperature sensor;4. Fuel injector;5.
Ignition coil;6. Electronic throttle body;7. Intake port;8. Ignition timing;9. Spark plug;10. Engine’s
mechanical parts.
Test
Results
Repair intake
Inspect if the air filter suffers blockage and if the intake port Yes
1 system
suffers air leakage.
No Next step
Connect with the fuel pressure gauge (front end of fuel Yes Next step
distribution pipe assembly’s inlet tube serves as the connection
2 Overhaul the oil
point), start the engine, and inspect if the fuel pressure hovers No
supply system
around 350kPa.
Pull out one cylinder’s spark plug wire, and connect with the Yes Next step
spark plug, during which make the spark plug’s electrode keep a
3 Overhaul the
distance of 5mm away from the engine body. Then start the No
ignition system
engine, and inspect if there is blue/white HV spark.
Yes Next step
Inspect every cylinder’s spark plug and observe if the model and
4 Adjustment or
clearance accord with specification. No
replacement
Overhaul the line
Pull out the coolant temperature sensor’s joint, and start the Yes or replace the
5
engine to observe if the engine can start successfully. sensor
No Next step
Clean throttle and
Step on the accelerator lightly and observe if the engine can be Yes
6 idling air path
easily started.
No Next step
No Next step
blockage.
Inspect the fuel condition, and observe if the fault occurs right Yes Fault replacement
8
after the oil is injected. No Next step
Rule out the
9
cylinders incur insufficient pressure. mechanical faults
No Next step
Yes Next step
Inspect if the engine’s ignition sequence and ignition timing
10 Overhaul ignition
accord with specification No
timing
11 Connect with the electronic fuel injection system’s adapter, and Yes Diagnosis Help
turn on the ignition switch, inspect if the power supply at 12#, Overhaul
13#, 44#, 45#, and 63# pin is normal, and inspect the electrical No corresponding
ground at 3#, 51#, 53#, 61#, and 80# pin is normal. lines
6. Normal starting but unstable idling speed at any time;

Ordinary faulted parts: 1. Water in fuel;2. Fuel injector;3. Spark plug;4. Throttle body and idling bypass air
path; 5. Intake port; 6. Electronic throttle body;7. Ignition timing;8. Spark plug;9. Engine’s mechanical
parts.
Test
Results
Overhaul the
1 intake system
No Next step
Yes Clean or replace
2 Inspect if the idling regulator gets stuck.
No Next step
Yes Next step
3 Adjustment or
replacement
Inspect if the throttle and idling bypass air path suffers carbon Yes Clean
4
deposition. No Next step
5 cleaning analyzer to inspect if the fuel injector suffers leakage,
No Next step
blockage, or excessive flow difference.
Inspect the fuel condition, and observe if the fault occurs right Yes Fault replacement
6
after the oil is injected. No Next step
Rule out the
Inspect all engine cylinders’ pressure, and observe if engine Yes engine’s
7
cylinders differ greatly in pressure. mechanical faults
No Next step
Yes Next step
Inspect if the engine’s ignition sequence and ignition timing Overhaul
8
accord with specification. No corresponding
lines
9
7. Normal starting but unstable idling speed during the warm-up process
Ordinary faulted parts: 1. Water in fuel;2. Coolant temperature sensor;3. Spark plug;4. throttle body’s
carbon deposition; 5. Intake port;6. Engine’s mechanical parts.
Test
Results
Overhaul the
1 intake system
No Next step
Yes Next step
2 Adjustment or
replacement
Clean relevant
Yes parts and
3 Inspect if the throttle body suffers carbon deposition.
components
No Next step
Overhaul the line
Pull out the coolant temperature sensor’s joint, start the engine,
Yes or replace the
4 and observe if the engine’s idling speed is unstable during the
sensor
warm-up process.
No Next step
No Next step
Step on the accelerator lightly and observe if the engine can be Yes Fault replacement
6
easily started. No Next step
Rule out the
7
No Next step
8
8. Normal starting but unstable idling speed after the warm-up

Ordinary faulted parts: 1. Water in fuel;2. Coolant temperature sensor;3. Spark plug;4、Electronic throttle
body;5. Intake port;6. Engine’s mechanical parts.
Test
Results
Overhaul the
1 intake system
No Next step
Yes Next step
2 Adjustment or
replacement
Clean relevant
Yes parts and
3 Inspect if the throttle body suffers carbon deposition.
components
No Next step
Overhaul the line
Pull out the coolant temperature sensor’s joint, start the engine,
Yes or replace the
4 and observe if the engine’s idling speed is unstable during the
sensor
warm-up process.
No Next step
No Next step
6
Rule out the
7
No Next step
8
9. Normal starting but unstable idling speed or stalling when there is partial load (like
running of air conditioning)
Ordinary faulted parts: 1. Air conditioning system;2. Idling speed regulator;3. Fuel injector.
Test
Results
Overhaul the
Inspect if the air filter suffers blockage and if the intake port suffers Yes
1 intake system
air leakage.
No Next step
Observe if the engine’s output power is increased when the air Yes To step 4
conditioning is turned on, namely, use the electronic fuel injection
2
system’s diagnostic unit to observe the ignition advance angle, fuel No Next step
injection pulse width and intake volume.
Connect with the electronic fuel injection system’s adapter, Yes Next step
disconnect the ECU 75# pin’s connecting line, and inspect if there
Overhaul A/C
is high-level signal at the wiring harness end after the air No
system
conditioning has been turned on.
Yes Next step
Inspect if the A/C system pressure, compressor’s magnetic clutch,
4 Overhaul A/C
and A/C pressure pump are normal. No
system
Dismantle the fuel injector, and use the dedicated fuel injector Fault
Yes
5 cleaning analyzer to inspect if the fuel injector suffers leakage, replacement
blockage, or excessive flow difference. No Next step
Connect with the electronic fuel injection system adapter and turn on Yes Diagnosis Help
the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, Overhaul
6
and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, No corresponding
61#, and 80# pin is normal. lines
10. Normal starting but over high idling speed;

Ordinary faulted parts: 1. Throttle body and idling bypass air path;2. Vacuum tube;3. Idling speed
regulator;4. Coolant temperature sensor;5. Ignition timing.
Test
Results
Yes Adjust
1 Inspect if the throttle cable gets stuck or over-tightened.
No Next step
Overhaul intake
Inspect if the intake system and connected vacuum tube suffer air Yes
2 system
leakage.
No Next step
Dismantle the idling speed regulator, and inspect if the throttle Overhaul the
Yes
3 body, idling speed regulator, and idling bypass air path suffer intake system
carbon deposition. No Next step
Overhaul the
Pull out the coolant temperature sensor’s joint, and start the engine, Yes line or replace
4
and observe if the engine has over high idling speed. the sensor
No Next step
Yes Next step
Overhaul
5 Inspect if the engine’s ignition timing accords with specification.
No corresponding
lines
Connect with the electronic fuel injection system adapter and turn on Yes Diagnosis Help
the ignition switch, inspect if the power supply at 12#, 13#, 44#, 45#, Overhaul
6
and 63# pin is normal, and inspect the electrical ground at 3#, 51#, 53#, No corresponding
61#, and 80# pin is normal. lines
11. Rotating speed fails to increase or engine is stalled when being accelerated;
Ordinary faulted parts: 1. Water in fuel;2. Intake pressure sensor and throttle position sensor;3. Spark
plug;4. Throttle body and idling bypass air path;5. Intake port;6. Idling speed regulator;7. Fuel injector;8.
Ignition timing;9. Exhaust pipe.
Test
Results
Overhaul intake
Yes
1 Inspect if the air filter suffers blockage. system
No Next step
2 Overhaul the oil
supply system
around 350kPa when being accelerated.
Yes Next step
3 Adjustment or
replacement
Yes
Yes Next step
Inspect if the intake pressure sensor, throttle position sensor, and Overhaul the line
5
the line are normal. No or replace the
sensor
6
cleaning analyzer to inspect if the fuel injector suffers leakage or No Next step
blockage.
7
Yes Next step
Inspect if the engine’s ignition sequence and ignition timing Overhaul
8
accord with specification. No corresponding
lines
Yes Next step
9 Inspect if the exhaust pipe can efficiently exhaust the air. Repair or replace
No
the exhaust pipe
10
12. Slow response when being accelerated

Ordinary faulted parts: 1. Water in fuel;2. Intake pressure sensor and throttle position sensor;3. Spark
plug;4. Throttle body and idling bypass air path;5. Intake port; 6. Idling speed regulator;7. Fuel injector;8.
Ignition timing;9. Exhaust pipe.
Test
Results
Overhaul intake
Yes
1 Inspect if the air filter suffers blockage. system
No Next step
2 Overhaul the oil
supply system
around 350kPa when being accelerated.
Yes Next step
3 Adjustment or
replacement
Yes
Yes Next step
Inspect if the intake pressure sensor, throttle position sensor, and Overhaul the line
5
the line are normal. No or replace the
sensor
No Next step
blockage.
7
Yes Next step
8 Overhaul the
accord with specification. No
ignition system
Yes Next step
No
the exhaust pipe
10
13. Poor performance or lack of power when being accelerated

Ordinary faulted parts: 1. Water in fuel;2. Intake pressure sensor;3. Spark plug;4. Ignition coil;5. Throttle
body ;6. Intake port;7. Fuel injector;8. Ignition timing;19. Exhaust pipe.
Test
Results
Inspect if there are faults like clutch slippage, low tire pressure, Yes Repair
1 incorrect size of brake dragging tire, and incorrect four-wheel
No Next step
positioning etc.
Overhaul the oil
Yes
2 Inspect if the air filter suffers blockage. supply system
No Next step
pipe assembly’s inlet tube serves as the connection point), start the
3 Overhaul the oil
engine, and inspect if the fuel pressure hovers around 350kPa No
supply system
when being accelerated.
Pull out one cylinder’s spark plug wire, and connect with Yes Next step
the spark plug, during which make the spark plug’s electrode keep
4 Overhaul the
a distance of 5mm away from the engine body. Then start the No
ignition system
engine, and inspect if the HV spark’s intensity is normal.
Yes Next step
5 Adjustment or
replacement
Overhaul the
Yes
6 Inspect if the throttle body and air path suffer carbon deposition. intake system
No Next step
Yes Next step
7 Inspect if the intake pressure sensor and throttle line are normal. Overhaul the line
No
or replace the
sensor
No Next step
blockage.
9
Yes Next step
10 Overhaul the
accord with specification. No
ignition system
Yes Next step
No
the exhaust pipe
14. Idle start/stop function ineffective

Ordinary faulted parts: 1. Engine compartment cover signal;2. Driver door signal;3. Clutch switch
signal;4.Neutral position signal;5. Accelerator pedal;6. Brake vacuum degree signal;7. Accumulator sensor.
Note: If the engine has been started, start/stop indicator blinks in yellow color and turns into yellow,
indicating the system has located relevant part faults, and the faults shall be diagnosed and repaired in the
repair factory.
1. Start/stop indicator is green, but the engine cannot stop automatically
Test
Results
System is right staying in the
If it is in green indicator blinking state or turns into Yes normal “Automatic Stop
1
yellow lamp now and then. Prohibited” condition.
No Next step
Inspect if the idling speed is a little bit high after the Yes Inspect the accelerator pedal
accelerator has been released, and the normal idling
2
speed should be 700 rpm(depending on specific No Next step
project).
After the engine stops, the gearbox stays in the Yes Next step
3 gear-engaging state, and then floor the clutch and turn
No Overhaul the clutch switch
the key to observe if the engine can be started.
2. After a period of driving (coolant temperature surpasses 75℃), start/stop indicator remains yellow,
and inspect if the accumulator temperature (ambient temperature) is excessively low (below 0℃, specific
temperature)
5 Functional Requirements on ME7 System’s Diagnostic Unit
Functions required:
I. Self-diagnosis
Mostly including: read fault code, and clear fault code;
II. System Parameter Display
Mostly including: including: water temperature, air intake temperature, throttle opening, engine rotating
speed, ignition angle, A/F ratio short-term modification, A/F ratio long-term plus and multiplication
modification, intake pressure, intake flow, oxygen sensor signal, system voltage, and torque demand value
etc;
III. System Modes
Mostly including: display of 10 modes like programming, cooling system, stable working condition,
dynamic working condition, emission control, oxygen sensor, idling speed, fault indicator, emergency
operation, and air conditioning etc.
IV. Actuator Test
Mostly including: six function tests on fault indicator, fuel pump, air conditioning relay, fan control,
ignition test, and single-cylinder oil interruption;
V. System Initialization Resetting (self-adaption stop resetting)
After being stalled, engine will send the initialization directive, and the system will stop resetting previous
self-adaption.
VI. Speedometer
Mostly including: display of vehicle driving mileage and driving time;
VII. Version Information
Mainly including: display of car frame number (optional), ECU hardware number, and ECU software
number
5.1 Parts Mounting Torque Specification Table
No. Part Name Mounting Torque (N·m)

Intake air pressure and
1 3.3
temperature sensor
2 Coolant temperature sensor 20 (Max)
3 Knock sensor 20±5
4 Oxygen sensor 50±10
5 Rotating speed sensor 8±2
6 Phase sensor 8±0.5
7 Magnetic fuel injector 6
5.2 Electronic Fuel Injection System Maintenance Specification
5.2.1 Family Vehicle

Note:
1. This maintenance specification is only tailored to family vehicles;
2. Maintenance interval depends on the speedometer reading or time interval, and the one that expires first
shall prevail.
3. Maintenance specification is based on the presumption that the automobile is used according to the
normal design, and so it shall be strictly observed.
Mileage x1000km 10 20 30 40 50 60 70 80
Items
Month 3 6 9 12 15 18 21 24
Ignition Coil I I I I
Ignition Cam I I I I
Ignition Cap I I I I
Ignition Wire I I I I
Spark Plug I I I R
Ignition Timing I I I I
Engine Idling Speed I I I I
Fuel Tank I C
Fuel Filter R R R R
Fuel Injector C* C* C* C*
Air Filter I R I R
EWD or Stepper Air Bypass C C C C
Throttle Body C C C C
Emission Check I I I I
Check by Diagnostic Tool I I I I

5.2.2 Vehicle for Lease
Explanation:
1. This maintenance specification is applicable to the vehicle for lease;
2. Maintenance interval depends on the speedometer reading or time interval, and the one that expires
first shall prevail.
3. Maintenance specification is based on the presumption that the automobile is used according to the
normal design, and so it shall be strictly observed.
Mileage x1000km 20 40 60 80 100 120 140 160

Items
Month 3 6 9 12 15 18 21 24
Ignition Coil I I I I I I I I
Ignition Cam I I I I I I I I
Ignition Cap I I I I I I I I
Ignition Wire I I I I I I I I
Spark Plug I R I R
Ignition Timing I I I I
Engine Idling Speed I I I I
Fuel Tank C C
Fuel Filter R R R R R R R R
Fuel Injector C* C* C* C* C* C* C* C*
Air Filter I R I R I R I R
EWD or Stepper Air Bypass I C I C I C I C
Throttle Body I C I C I C I C
Emission Check I I I I
Check by Diagnostic Tool I I I I
Note: R-Replace
C-Clean
I- Inspect (Replace the spare parts when find out failure in inspection.)
C- The maintenance of fuel injector had better clean by a special tool -- fuel injector cleaner
Fuel System 1C-1
Chapter 3 Fuel System

Table of Contents
1. Fuel System ································································································1C-2
1.1 Preparatory Work before Repair ··································································· 1C-2
1.1.1 Work Safety Steps ············································································ 1C-2
1.2 Inspection to Fuel Leakage········································································· 1C-2
1.2.1Fuel Hose Mounting··········································································· 1C-2
1.3 Cylinder Dismantling /Mounting ·································································· 1C-3
1.3.1Cylinder Air Tightness Test ·································································· 1C-4
1.3.2 Inspection of Check Valve ··································································· 1C-5
1.3.3 Inspection of Fuel Cylinder Pipeline Pressure ············································ 1C-5
1.3.4 Inspection of Fuel Pressure Maintenance·················································· 1C-6
1.4 Fuel Pump Assembly Dismantling /Mounting··················································· 1C-8
1.4.1 Fuel pump cover removal instructions ····················································· 1C-8
1.4.2 Fuel pump cover installation instructions ················································· 1C-8
1.4.3 Split fuel pump parts / assembly···························································· 1C-8
1.5 Spray Nozzle Dismantling /Mounting ···························································· 1C-11
1.5.1 Inspection of Spray Nozzle ·································································· 1C-11
2. Fuel Vaporation and Absorption System ·······························································1C-11

2.1 Inspection of Carbon Canister Assembly························································· 1C-11
2.1.1 Inspection of Carbon Canister’s Electromagnetic Valve ································ 1C-11
2.2 Inspection of Ventilation Condition ······························································· 1C-12
2.3 Inspection of Open/Short Circuit·································································· 1C-12
3. Dismantling the fuel pump assembly diagram ····················································1C-12

3.1 Demolition relief valve assembly ································································· 1C-12
3.2 Demolition Fuel quantity sensor ·································································· 1C-13
3.3 Demolition pump plug ·············································································· 1C-13
3.4 Demolition of the fuel hose fixed widget ······················································· 1C-13
3.5 Demolition fuel pump at the bottom case ························································ 1C-14
3.6 Demolition prefilter, pump core, fine filter ······················································ 1C-14
Fuel System 1C-2
Caution
1. Fuel System  Wrong connection with other wiring terminals
may lead to fault, and so caution is needed
1.1 Preparatory Work before Repair during the connection process.
Warning 1. Connect the DLC’s wiring terminal F/P with

the vehicle body (as the ground) with a
 Fuel vapor is dangerous and combustible, jumper wire.
which may lead to personnel injury and
property loss. Due to this, avoid spark or naked
flame at the place where there is fuel.
 Fuel overflow or leakage is dangerous, and the Jumper Wire
fuel is combustible, which may lead to
personnel injury and property loss. In addition,
the fuel has side effect on the skin and eye.
Due to this, work safety rules shall be observed
during the working process. 2. Turn the ignition switch to the “ON” position
to run the oil pump.
Notice:
3. Pressurize the oil circuit for at least five
 Even if the engine does not run, fuel in the fuel minutes according to preceding method, so as
system still stays within the high pressure to inspect if there is leakage.
state.
4. In the event that there is fuel leakage, inspect
1.1.1 Work Safety Steps if fuel hose and fuel pipe’s sealing faces
suffer damage. If necessary, replace them.
1. Dismantle the oil cylinder head, and release
the pressure from the oil cylinder. 5. After the overhaul and remounting, repeat
Step 1 to Step 3.
2. Pull out the fuel pump relay (located in the
electrical box at the centre of the engine 1.2.1 Fuel Hose Mounting
compartment).
1. Replace the damaged and distorted fuel hose,
3. Start the engine. fuel pipe, and pipe clamp.
4. Restart the engine several times after the 2. Fuel hose shall be mounted 25mm {0.98in}
engine stalls. above the fuel pipe, and if the fuel pipe has
5. Turn the ignition switch to the “OFF” position. limit device, mount the hose till it contacts the
limit device.
6. Reload the fuel pump relay.
1.2 Inspection Work after Maintenance

Warning
Fuel Pipe Fuel Hose
 Fuel overflow or leakage is dangerous, and
also the fuel is combustible, which may lead to Limit Device
personnel injury and property loss. Due to this,
follow the under-mentioned “Fuel Leakage
Inspection” to conduct inspection after
remounting the fuel hose.
Inspection to Fuel Leakage 3. Use the pipe clamp to clamp the hose within
Warning the mounting range (see the figure below),
and prevent the clamp from nipping previous
 Fuel overflow or leakage is dangerous, and nipping place.
also the fuel is combustible, which may lead to
fuel leakage shall be inspected frequently after
the engine stops.
Fuel System 1C-3
1. Inspect the fuel pipeline and supporting

pipeline joint’s sealing faces and avoid their
damage and distortion. If necessary, replace
them.
2. If the quick plug O-ring is damaged or
disengaged, mount the new fuel pipeline.
Avoid nipping previous nipping place
Warning on Plastic Fuel Pipe (fuel supply 3. Push the fuel pipeline quick plug into the
loading part till the pipe joint makes the
pipe assembly, fuel supply pipe, and fuel “click” sound.
return pipe assembly)
4. If the fuel pipeline quick plug is equipped
Dismantling with double-lock mechanism, mount the
 When dismantling the fuel pipe, pressure in the double locks till there is “click” sound.
fuel system will lead to ejection of fuel from 5. Pull the quick plug with hands to confirm if it
the fuel pipeline, and so oil cylinder head shall has been secured mounted.
be dismantled in advance according to
requirements while dismantling the fuel Explanations on fuel filter dismantling
pipeline, in order to release the pressure in the /mounting
oil cylinder and avoid personnel injury and
property loss. Warning :
Caution
The fuel filter is integrated in the fuel pump
 While dismantling the fuel pipeline, necessary assembly, disassembly, repair shop to replace
sheltering measures shall be adopted, in order
HAIMA.
to avoid the fuel’s ejection onto your body.
1. If the quick plug assembly is equipped with 1.3 Cylinder Dismantling /Mounting
double-lock mechanism, loosen the quick
plug assembly’s double locks along the Warning
direction illustrated in the figure.
 Unwashed cylinder is dangerous and may lead
to combustion or explosion, which will further
result in serious casualties. Due to this,
cylinder shall be cleaned with vapor before the
overhaul.
 Fuel overflow or leakage is dangerous, and the
do not damage the sealing face while
dismantling/ mounting the oil pump assembly.
2. Pinch locking devices on both sides of the quick
plug with fingers to remove the quick plug. Caution
3. Repeat Step 1 and Step 2, and dismantle the  Dismantling/mounting quick connector before
quick plug at the other end of the fuel pipeline cleaning will lead to damage of the fuel pipe
from the supporting pipeline. and quick connector. Due to this, cleaning is a
Explanations on Plastic Fuel Pipe (Fuel must before dismantling /mounting, in order to
Supply Pipe Assembly, Fuel Supply Pipe, make sure that no foreign objects enter the fuel
and Fuel Return Pipe) Mounting pipe and connector.
Notice 1. Park the vehicle stably on the lifting machine.
When mounting the new fuel supply pipe 2. Complete preparatory work before repair (see
assembly, assemble properly double locks on the Preparatory Work before Repair).
quick plug assembly. 3. Loosen the accumulator’s negative cable.
4. Dismantle the second-row seats (see Part S,
Fuel System 1C-4
Seat, Second-row Seats Dismantling

5 Fuel pump cover SA12-42-161
/Mounting).
6 Hose clamp S05B-42-239L1
5. Dismantle the cylinder repair cover plate.
6. Dismantle all fuel pipes that connect with the 7 Refueling hose SA12-42-231
oil pump. Fuel tank straps SA12-42-720
8
(R)
7. Drain fuel in the cylinder.
9 Refueling pipe SA12-42-211
8. Life the vehicle with lifting machine and
dismantle parts according to sequence 11 Dust cover SA12-42-240
10 Cap-filler FA1A-42-250
9. Mount parts according to the sequence reverse
to the dismantling process.
12 Bolt HQ99786-0816 20.0-
10. Complete inspection work after the repair (see 32.0
Inspection Work after Repair) Elastical clamp HQ99283-1900
13
14 Breather hose SA12-42-232
15 Canister bracket SA12-13-960
16 Canister SA12-13-96Z
17 Bolt HQ99786-0820
18 Elastical clamp HQ99283-1100
19 Snorkel SA12-13-963
20 Desorption SA12-20-374
canister hose
21 Pipe clip SA12-45-914
22 Fuel tank SA12-42-111
23 Fuel tank tie SA12-42-710

(left)
24 Fuel tank SA12-42-741

insulation panels
25 Screw HQ99845-0510
26 Hose SA12-20-377
27 Fuel supply pipe SA12-13-49X

assembly
No. Part name Part No. Torq R 28 Hose SA12-20-376

ue e Clip SA12-45-911
29
m
ar 30 Fuel hard tube SA12-45-110
k
31 Hard tube SA12-45-711
1 Bolt HQ90786-1030 36.3- evaporator
53.9
32 Elastical clamp HQ99283-1300
2 Fuelsupply pipe SA12-42-61X
3 Fuel pump SA12-42-166

gasket
4 Fuel pump SA12-13-35Z

Fuel System 1C-5
1.3.1 Cylinder Air Tightness Test

Notice
 Cylinder air tightness test is used to test the
welding quality between parts (like the upper oil
filling port, exhaust port, and gravity valve) and
the cylinder body.
1. Dismantle the cylinder mounting assembly
(see the Cylinder Dismantling/Mounting).
2. Block the special blanking plug (dedicated to
main fuel pipe) on the fuel pump assembly.
3. Use special blanking plug to block the gravity 1.3.2 Inspection of Check Valve
valve vapor hose’s joint on the cylinder body. 1. Check the direction of welding welding
4. Connect the special air pressure test tool with direction ICV logo on the body with the fuel
the cylinder’s oil filling port and exhaust port. tank logo are aligned, if not aligned, then
weld failed.
5. Put the cylinder horizontally into the special
water tank dedicated to cylinder test (the total 2. The role of the baffle is to prevent anti-jet fuel,
cylinder shall be immersed 100mm below the while the pressure drop is not too large, to
water surface). avoid early to jump the gun, and therefore
whether the rebound pressure baffle is
6. Charge compressed air into the cylinder’s oil designed to reflect the performance by
filling port, and pressurize the cylinder to refueling. ICV welded to the tank, can not
(30～50)kPa. Then, maintain the pressure for repair.
1min.
1.3.3 Inspection of Fuel Cylinder Pipeline
7. Inspect if there is air bubble between the parts Pressure
(like oil filling port, exhaust port, and gravity
valve) and the cylinder’s welding face. Warning
 If there is air bubble on the welding face,
replace the cylinder (see Cylinder
personnel injury and property loss. In addition,
Dismantling/Mounting)
the fuel has side effect on the skin and eye.
Caution
 Dismantling/mounting quick connector before
cleaning will lead to damage of the fuel pipe
and quick connector. Due to this, cleaning to
the quick connector’s contacting zone is a must
before dismantling /mounting, in order to make
sure that no foreign objects enter the fuel pipe
and connector.
Notice:
 The following tests can be conducted if
necessary
1. Complete preparatory work before repair (see
Preparatory Work before Repair)
2. Loosen the accumulator’s negative cable.
Caution
 To avoid the quick connector’s damage or oil
leakage, follow the “Explanations on plastic
Fuel System 1C-6
fuel pipe dismantling” to complete the  If the pressure is higher than the standard value,
under-mentioned work (see the Fuel System, inspect the fuel pump’s maximum pressure
Explanations on Plastic Fuel Pipe Dismantling)
 If the pressure is normal, inspect if the oil
3. Dismantle the main fuel hose (fuel supply return pipe and pressure regulator suffer
pipe assembly) from the main pipe (fuel rigid blockage.
pipe).
 If the pressure is lower than standard value,
4. Connect the special tool’s quick connector turn the switch handle and measure the oil
with the fuel distributor(fuel rail), and insert pressure’s variation (see the figure).
the fuel supply pipe assembly onto the special
tool’s interface. —If the oil pressure rises speedily, inspect the
pressure regulator.
—If the oil pressure rises slowly, inspect the oil
Switch handle pressure’s maximum value.
To main pipe  If the oil pump’s maximum pressure is normal,

inspect if the oil circuit between the oil pump
Fuel distributor
and pressure regulator suffers blockage.
Switch handle
To main pipe
Fuel distributor
5. Remount the accumulator’s negative cable.

Caution
 Wrong connection with other wiring terminals
during the connection process.
9. Dismantle the special tool unit.
6. Connect the DLC’s wiring terminal F/P with
the Vehicle body’s earthing point GND with a Caution
jumper wire.
fuel pipe dismantling” to complete the
Earthing under-mentioned work (see the Cylinder
jumper Dismantling/Mounting, Explanations on
Plastic Fuel Pipe Dismantling)
10. Connect the main fuel hose (fuel supply pipe
assembly) and the main pipe (fuel rigid pipe)
11. Complete the inspection work after repair (see
7. Turn the ignition switch to “ON” position to Inspection Work after Repair).
make fuel pump run, and measure the
pipeline’s maximum oil pressure. 1.3.4 Inspection of Fuel Pressure
Maintenance
Standard value
Warning
390～410kpa
 Fuel overflow or leakage is dangerous, and
8. Turn the ignition switch to the “OFF” the fuel is combustible, which may lead to
position and loosen the jumper wire. personnel injury. In addition, the fuel has side
effect on the skin and eye.
Fuel System 1C-7
Caution 7. Connect the DLC’s wiring terminal F/P with

the Vehicle body’s earthing point GND with a
jumper wire.
the quick connector’s contacting zone is a
must before dismantling /mounting, in order
Earthing
to make sure that no foreign objects enter the
jumper
fuel pipe and connector.
Notice:
necessary
1. Complete preparatory work before repair (see 8. Turn the ignition switch to the “ON” position
Preparatory Work before Repair) for about 10s, in order to make the fuel pump
2. Loosen the accumulator’s negative cable. run.
Caution 9. Turn the ignition switch to the “OFF”

position and loosen the jumper wire.
leakage, follow the “Explanations on plastic 10. Observe the oil pressure after 60 minutes.
fuel pipe dismantling” to complete the  If the oil pressure is lower than the standard
under-mentioned work (see the Fuel System, value, observe the oil pressure’s variation
Explanations on Plastic Fuel Pipe while rotating the switch handle
Dismantling)
—If the oil pressure maintains unchanged, replace
3. Dismantle the main fuel hose (fuel supply pipe
the pressure regulator (see Pressure Regulator
assembly) from the main pipe (fuel rigid pipe).
4. Connect the special tool’s quick connector
with the fuel distributor (fuel rail), and insert —If the oil pressure is changed, inspect if the oil
the main fuel hose (fuel supply pipe assembly) circuit and spray nozzle suffer oil leakage.
onto the special tool’s interface. Standard value:
5. Rotate the switch handle along the direction ≥250kpa(2.5kgf/cm2, 36psi)
Switch handle
To main pipe To main pipe Switch handle

Fuel distributor Fuel distributor
11. Loosen the special tool unit.

12. Connect the main fuel hose with main fuel
Caution
pipe.
13. Complete the inspection work after repair
(see Inspection Work after Repair).
Fuel System 1C-8
1.4 Fuel Pump Assembly Dismantling

/Mounting
Warning
Fuel is a combustible liquid is very strong, and if
the fuel spilled from the pressurized fuel system
will result in serious injury or death, while also
causing facilities were destroyed, oil can irritate 1.4.2 Fuel pump cover installation instructions
the skin and eyes, in order to avoid this case, be
1. Fuel tank and the fuel pump so that the
sure to perform "Fuel pipeline safety program,"
alignment marks in the alignment member, as
while referring to "maintenance precautions."
shown in Fig.
Fuel is a very strong combustible liquids, if spilled
or leaked from the fuel pressure in the fuel system,
it will cause serious injury or death, while also
causing facilities were destroyed, oil can irritate
the skin and eyes, in order to To avoid this
situation, the fuel pump components prior removal
/ installation, be sure to perform "After the
installation of the fuel pump assembly fuel leak
check."
1. Before performing any operations, comply
with "maintenance before precautions" to avoid
spilling fuel from the fuel system.
2. Disconnect the negative battery cable.
3. Remove the fuel tank.
4. In the order shown in the table to be demolished.
1 Quick release connectors 2. As shown in FIG. Fixed SST.
2 Fuel pump cover Using SST accordance with the provisions of the
tightening torque to tighten the fuel pump cover,
3 Fuel pump parts but can not move the alignment mark.
4 . If you can not achieve the required tightening
5. According to the order the demolition phase side torque, replace the fuel pump cover.
installation. 5 . If after replacing the fuel pump cover can not
6. Through the implementation of achieve the required tightening torque, replace the
"post-maintenance considerations" to check all tank.
relevant components. 1.4.3 Split fuel pump parts / assembly
1.4.1 Fuel pump cover removal instructions Explanation：
Notice: Can not be split fuel pump components.
In using the SST time, if there is a gap between the
Inspection of Fuel Pump Assembly
fuel pump cover and SST, then the fuel pump
cover may be damaged, the SST fixed so that the Simulation Test
SST tabs with no gap between the fuel pump side Inspect the fuel pump’s working condition (see
cover. Fault Diagnosis, Inspection of Engine Control
System’s Working Condition, Inspection of Fuel
Removing the fuel pump cover using the SST. Pump’s Working Condition).
Fuel System 1C-9
 If the condition is abnormal, conduct further Short Circuit

inspection to the fuel pump assembly.
 The circuit between the fuel pump assembly
Inspection of Conducting/Non-conducting connector B and fuel pump relay connector E,
State in which there is public connector and ground
short circuit (electrical ground)
Notice
2. Remount the fuel pump assembly connector.
 Inspection below can be conducted if
necessary 3. Remount the oil tank’s repair cover plate.
1. Loosen the accumulator’s negative cable. 4. Remount the second-row seats (see Seats,
Second-row Seats Dismantling /Mounting).
2. Remove the second-row seats (see Seats,
Second-row Seats Dismantling /Mounting). 5. Remount the accumulator’s negative cable.
3. Dismantle the oil tank’s repair cover plate. Inspection of Fuel Pump’s Maximum
Pressure
4. Loosen the fuel pump assembly’s connector.
Warning
5. Inspect the conducting/non-conducting state
between fuel pump or connector’s wiring  Fuel overflow or leakage is dangerous, and the
terminal B and wiring terminal D. If it is in fuel is combustible, which may lead to personnel
conducting state but the simulation test is injury and property loss. Due to this,
abnormal, inspect if the circuit suffers under-mentioned operations shall not be started
short/open circuit. If it is in non-conducting until the engine stops.
state, replace the fuel pump assembly.
Caution
the quick connector’s contacting zone is a must
before dismantling /mounting, in order to make
sure that no foreign objects enter the oil pipe
and connector.
Notice
Inspection of Open/Short Circuit
1. Inspect if there is open/short circuit on the necessary
following wiring harnesses. If there is, repair
or replace corresponding wiring harness: 1. Complete preparatory work before repair (see
Preparatory Work before Repair)
Open Circuit
 Earting circuit (between fuel pump assembly’s
connector D and the vehicle body GND) Caution
 Power circuit (between the fuel pump relay  To avoid the quick connector’s damage or oil
connector A and fuel pump assembly leakage, follow the “Explanations on plastic
connector B, and there is public connector) fuel pipe dismantling/ mounting” to complete
the under-mentioned work (see the Fuel
Fuel pump relay System, Explanations on Plastic Fuel Pipe
Dismantling)
3. Dismantle the main fuel hose (fuel supply
pipe assembly) from the main pipe
(vaporation rigid pipe).
4. Turn the switch handle to the position
illustrated in the figure to block the special
tool’s port.
Fuel System 1C-10
5. Push the special tool’s quick connector into  To avoid the quick connector’s damage or oil
the main pipe (fuel rigid pipe) till there is a leakage, follow the “Explanations on plastic
“click” sound. fuel pipe dismantling” to complete the
under-mentioned work (see the Fuel System,
6. Put the hose into a vessel in order to avoid the Explanations on Plastic Fuel Pipe Dismantling)
fuel overflow.
12. Remount the main fuel hose (fuel supply pipe
assembly).
13. Complete the inspection work after repair (see
Inspection Work after Repair)
Inspection of Fuel Pump Oil Pressure

Maintenance
Warning
7. Remount the accumulator’s negative cable. personnel injury and property loss. Due to this,
under-mentioned operations shall not be
Caution started until the engine stops.
 Wrong connection with other wiring terminals Caution
during the connection process.  Dismantling/mounting quick connector before
8. Connect the DLC’s wiring terminal F/P with and quick connector. Due to this, cleaning to
the vehicle body’s earthing point GND with a the quick connector’s contacting zone is a must
jumper wire. before dismantling /mounting, in order to make
sure that no foreign objects enter the oil pipe
and connector.
Jumper wire
Notice
necessary
1. Complete preparatory work before repair (see
Preparatory Work before Repair).
9. Turn the ignition switch to the “ON” position to
make the fuel pump run, and measure the fuel 2. Loosen the accumulator’s negative cable.
pump’s maximum output oil pressure.
Caution
Fuel pump’s maximum output oil pressure: 650～
900kpa
10. Turn the ignition switch to the “OFF” fuel pipe dismantling” to complete the
position and loosen the jumper wire. under-mentioned work (see the Fuel System,
Explanations on Plastic Fuel Pipe Dismantling)
If the maximum output oil pressure goes
beyond the specified range, inspect items below: 3. Dismantle the main fuel hose (fuel supply
pipe assembly) from the main pipe (fuel rigid
—Fuel pump relay (see Inspection of Fuel Pump pipe).
Relay)
4. Turn the switch handle along the direction
—If the fuel filter (LV, HV) suffers blockage. illustrated in the figure to block the special
—If the fuel pipeline suffers blockage or leakage. tool’s port.
11. Dismantle the special tool. 5. Push the special tool’s quick connector into
the main pipe (fuel rigid pipe) till there is a
Caution “click” sound.
Fuel System 1C-11
6. Put the hose into a vessel in order to avoid the 1.5 Spray Nozzle Dismantling /Mounting
fuel overflow.
(see the Control System)
Air hose Main fuel pipe
1.5.1 Inspection of Spray Nozzle
(see the Control System)
2 Fuel Vaporation and Absorption

System
Switch
handle
Location of Combustion Vaporation &
Absorption System’s Components (in Engine
Compartment)
Caution
8. Connect the DLC’s wiring terminal F/P with
the vehicle body’s earthing point GND with a
jumper wire.
2.1 Inspection of Carbon Canister

Earthing Assembly
jumper
1. Remove the carbon canister.
2. Block the interface on the carbon canister’s
ventilation side and the interface on the
9. Turn the ignition switch to the “ON” position carbon canister’s electromagnetic valve side.
to make fuel pump run for 10s or so. 3. Blow air into the carbon canister’s oil tank
10. Turn the ignition switch to the “OFF” interface, and Confirm if there is no air
position. After 5 minutes, inspect the fuel leakage (If there is air leakage, replace carbon
pump’s oil pressure maintenance. canister).
Fuel pump’s oil pressure maintenance: ＞ 2.1.1 Inspection of Carbon Canister’s

410kpa(4.1kgf/cm2, 59psi) Electromagnetic Valve
11. Loosen the jumper wire. Conduct simulation test
12. Remove the special tool. Inspect the carbon canister’s electromagnetic
valve (see Fault Diagnosis, Inspection of Engine
13. Connect the main fuel hose (fuel supply pipe Control System’s Working Condition, Inspection
assembly) with the main pipe(fuel rigid pipe). of Carbon Canister’s Electromagnetic Valve); if it
If the oil pressure maintenance fails to accord is abnormal, conduct further inspection to the
with standard, replace the fuel pump assembly carbon canister’s electromagnetic valve.
(see Fuel Pump Assembly
14. Confirm if around the quick plug’s bonding
zone there is not oil leakage.
15. Complete the inspection work after
repair(see Inspection Work after Repair)
Fuel System 1C-12
 Power circuit (the circuit between the carbon

canister’s electromagnetic valve connector
terminal 2 and main circuit breaker connector
terminal D, in which there is public connector)
Main relay
Connector on wiring harness’s side

(viewing from the electrode terminal side)
Short Circuit
 Electrical ground between carbon canister’s
2.2 Inspection of Ventilation Condition electromagnetic valve connector terminal 2 and
ECU connector terminal 46, in which there is
Notice public connector.
 The following tests can be conducted if 2. Remount the carbon canister’s
necessary electromagnetic valve.
1. Loosen the accumulator’s negative cable. 3. Remount the accumulator’s negative cable.
2. Dismantle the carbon canister’s
electromagnetic valve .
3. Inspect ventilation condition of the carbon 3 Dismantling the fuel pump
canister’s electromagnetic valve assembly diagram
(If normal, inspect if there is open /short circuit, 3.1 Demolition relief valve assembly
and if the vacuum hose is correctly arranged or
suffers distortion and air leakage. If abnormal,
replace the carbon canister’s electromagnetic
valve ).
2.3 Inspection of Open/Short Circuit With a screwdriver

inserted from here..
1. Inspect if there is open/short circuit on the
following wiring harnesses (If there is,
overhaul or replace corresponding wiring
harness).
Open Circuit
 Earthing circuit (the circuit between the carbon
canister’s electromagnetic valve connector 1
and ECU connector terminal 46, in which there
is public connector)
Fuel System 1C-13
Use a screwdriver or a
special tool to open
end of the buckle.
Demolition ends
snap. 3.3 Demolition pump plug
Inwards, and
then pull up.
Demolition pressure
relief valve.
3.2 Demolition Fuel quantity sensor

Remove the bracket
Inwards, and spring, pull out the
then pull up. fuel pump gland.
3.4 Demolition of the fuel hose fixed

widget
Fuel System 1C-14
Fuel pump prefilter.
Use a screwdriver to
open the plug-in.
Fuel pump core
Remove the pump

Fuel pump fine filter
core and fine filter.
3.5 Demolition fuel pump at the bottom After all the components apart..
case.
Bottom snaps open. Note:

1. the fuel filter assembly refers to the fine filter,
fine filter assembly UMC's part number F 01R
3.6 Demolition prefilter, pump core, fine 02S9B6. I only fuel pump assembly part number
filter. for SA12-13-35Z.
2. the use of fine filter fuel pump assembly time of
Bottom snaps open.
2 years or 20,000 kilometers.
Intake and Exhaust System 1D-1
Chapter 4 Intake and Exhaust System

Table of Contents
1. Intake system ······························································································1D-2

1.1 Intake System Dismantling/Mounting ·····························································1D-2
2. Exhaust System····························································································1D-3
2.1 Inspection of Exhaust System ·····································································1D-3
1. Intake system
1.1 Intake System Dismantling/Mounting

Warning
 When the engine and intake system stay at high
temperature, they can easily lead to personnel
injury. Before mounting or dismantling the intake
system, operation shall not be conducted until the
engine has stopped and cooled down.
 Fuel vapor is dangerous and combustible, which
may lead to serious injury and damage. Due to this,
avoid spark or naked flame at the place where there
is fuel.
 Fuel overflow or leakage is dangerous, which may
lead to personnel injury and property loss. In
addition, the fuel can irritate the skin and eye. Due
to this, Oil Circuit Safety Procedure shall be
always observed during the operation process.
1. Disconnect the accumulator’s negative cable.
illustrated in the table.
3. Mount parts according to the sequence reverse to
1 Intake duct 7 Intake hose bracket

2 Intake hose 8 Intercooler intake hose
3 Muffler tubes 9 Intercooler outlet hose
4 Air flow sensor 10 Intercooler assembly
5 O-ring 11 Turbocharger outlet rigid pipe
6 Air filter 12 Turbocharger outlet hose
2. Exhaust System
2.1 Inspection of Exhaust System
1. Start the engine, and inspect if the exhaust

pipeline suffers air leakage (If there is air
leakage, overhaul the exhaust pipeline, or
replace it if necessary).
Exhaust System Dismantling/Mounting
Warning
 When the engine and exhaust system have yet to
cool down, they may scald the skin. Due to this,
dismantling work shall not be started until the
engine has stopped and cooled down.
3. Mount parts according to sequence reverse to the
dismantling process.
1 Front oxygen sensor

2 Front three-way catalyst converter
3 Front hanging bracket
4 Rear three-way catalyst converter
5 Rear oxygen sensor
6 Front muffler assembly
Cooling System 1E-1
Chapter 5 Cooling System

Table of Contents
1. Cooling System ··························································································1E-2

1.1 Engine Coolant ·························································································1E-2
1.1.1 Inspection of Engine Coolant’s Liquid Level·············································· 1E-2
1.1.2 Replace Engine Coolant ······································································ 1E-2
1.2 Vice radiator cap ···················································································· 1E-3
1.2. 1 Inspection of vice radiator cap ···························································· 1E-3
1.3 Radiator ·······························································································1E-4

1.4 Vice water tank ······················································································ 1E-4
1.5 Thermostat ··························································································· 1E-4
1.5.1 Thermostat Dismantling/Mounting …………………………………………………. 1E-4

1.5.2 Instructions for installing the thermostat······················································1E-5
1.6 Water Pump ····························································································1E-5
1.6.1 Water Pump Dismantling/Mounting ·························································1E-5
1.6.2 Fan Motor························································································1E-5
1.7 Fan Relay································································································1E-6
1.7.1 Inspection of Fan Relay ··········································································1E-6
Cooling System 1E-2
no longer have to re-set in under the water in

the radiator outlet, and assembled in place and
1. Cooling System re-fix the elastic hose clamp in its original
location.
Warning on Cooling System Maintenance
When the engine is running or the engine and heat

sink are hot, do not dismantle the heat sink lid or
loosen the heat sink’s drain valve because hot
coolant and vapor may spout, which will result in
serious casualties and damage to the engine and
cooling system
Turn off the engine, and conduct further operation
after the engine cools down. Then, keep mindful
◆After the assembly ended, the reserve tank
when removing the heat sink’s filler lid, and wrap
the filler lid with thick cloth and slowly turn it to the filler injected into the designated coolant, when
first stop position along the anticlockwise direction. manually add, after the filling is completed, the
When the pressure declines, turn it along the reverse idling operation of the engine a few minutes,
direction;
after the coolant level in the tank drops to be
If there is not pressure, press the heat sink lid with deputy, no further exhaust gas cooling system,
cloth and dismantle it.
continue to inject cooling fluid, the sub-coolant
level in the tank to the vicinity of the following
1.1 Engine Coolant
MAX.
1.1.1 Inspection of Engine Coolant’s Warning

Liquid Level Alcohol or methanol antifreeze may damage
1. Confirm if the coolant’s liquid level in aluminum parts on the engine, and so alcohol or
subsidiary water tank ranges between MAX and methanol shall not be used in the cooling system,
MIN. and only the glycol-based coolant can be used.
If the engine coolant’s liquid level stays below Only the softening (demineralization) water can
MIN, open the subsidiary water tank’s lid and add be used to mix with the coolant, and water
the coolant near to the MAX mark. containing minerals will compromise the coolant’s
effect.
If there is no coolant in the subsidiary water tank,
wait till the engine cools down, and open the heat Engine coolant will result in damage to the
sink’s filler lid to add coolant from the heat sink lacquer surface, and so the engine coolant shall be
filler port till the coolant’s liquid level can be seen rinsed out in no time when it touches the lacquer
from the filler port. Then, mount the heat sink’s surface.
filler lid, and continue adding the coolant near to
◆ Refer to table below to select appropriate
the MAX mark.
volume percentage for mixture of water and
1.1.2 Replace Engine Coolant coolant. Add slowly the coolant into the
◆ Turn off the engine, and wait for the engine water tank till the coolant reaches the filler
port.
coolant completely cool down, removed fixed the
plumbing and radiator assembly of elastic tube Filling speed:1.0L(1.1USqt 、 0.9impqt)/min.
[Maximum Value]
outlet folder under the water from the radiator
assembly out of the outlet to unplug, let go of the Volume
Coolant Proportion at
engine and radiator the coolant assembly. When percentage
protective agent 20℃{68ºF}
unplug the pipes, be careful not to let the coolant Water Coolant
splash to humans. Higher than
65 35 1.054
◆ Wait outlet pipes and radiator coolant outflow -16℃{3ºF}
Cooling System 1E-3
Higher than 1.1.3 Inspection of Engine Coolant

55 45 1.066 Leakage
-26℃{-15ºF}
Higher than 1. Inspect the coolant’s liquid level.
45 55 1.078
-40℃{-40ºF} 2. Take off the heat sink lid.
3. Connect the heat sink lid tester and SST
special maintenance tool with the heat sink’s
filler port.
Notice
 If the pressure surpasses 123kPa {1.25kgf/cm2,
17.8psi}, hose joint and other parts will be
damaged, which will in turn lead to leakage.
4. Make the heat sink reach specified
pressure:
Pressure:123kPa{1.25kgf/cm2, 17.8psi}
◆ Start the engine and maintain the idling speed

till the cooling fan begins to work.
Notice 4. Inspect if the pressure can be maintained. If
cannot, inspect if the system suffers coolant
 If the coolant temperature is over high, stop the
leakage.
engine to prevent the coolant from being
overheated.
1.2 Vice radiator cap
◆ Conduct the following operations after the
engine temperature rises:
1.2.1 Inspection of vice radiator cap
Warning
(1) Make the engine run for one minute at the
rotating speed of 4000rpm;  When the engine is running or the engine and
heat sink are hot, do not dismantle the heat sink
(2) Make the engine run for one minute at the
lid because hot coolant and vapor may spout,
idling speed;
which will result in serious casualties and
(3) Repeat Step 1 and Step 2 for several times; damage to the engine and cooling system
(4) Turn on the front/rear heater unit (if has), and  Turn off the engine, and conduct further
confirm if there is hot air exhausted from the operation after the engine cools down. Then,
heater unit’s ventilation opening. wrap the vice radiator cap with thick cloth
carefully, and slowly turn it to the first stop
11. Stop the engine and wait till it cools down. position along the anticlockwise direction.
12. Confirm if there is coolant leakage. When the pressure declines, turn it along the
reverse direction;
13. Inspect the coolant’s liquid level. If the level
is relatively low, add the coolant into the  If there is not pressure, press the heat sink lid
subsidiary water tank till it reaches the MAX with cloth and dismantle it.
mark. 1. Use the SST special service tool to connect
the vice radiator cap with the tester.
2. Increase the pressure little by little.
Cooling System 1E-4
3. Inspect if the pressure stays within the 3 Fan wiring harness connector
specified range. If the pressure can keep for
10s, it indicates that the vice radiator cap is 4 Fan assembly
normal. 5 Vice-water tank hose I
Pressure range:94-122kPa{0.95-1.25kgf/cm2, 6 Vice-water tank hose II
13.5-17.7psi} 7 Radiator mounting bracket
1.4 Vice water tank

◆ Vice water tank removal / installation
1. Vice water tank drained coolant.
illustrated in the table;
3. Mount parts according to the sequence reverse
1.3 Radiator
Radiator Dismantling/Mounting
Fan Parts Dismantling/Mounting

1. Disconnect the accumulator’s negative cable;
2. Drain the engine coolant;
3. Dismantle the front grille and air intake duct.;
4. Remove the radiator and condenser mounting
bracket bolts bolts; remove the fan mounting
bolts;
5. Remove the engine Water pipe, remove the
expansion tank hose. (connect with the heat 1 Vice-water tank hose I
sink end);
2 Vice-water tank hose III
illustrated in the table; 3 Vice-water tank hose II
7. Mount parts according to the sequence 4 Vice-water tank bolt 1

5 Vice-water tank bolt 2
1.5 Thermostat
1.5.1 Thermostat Dismantling/Mounting
1. Drain the engine coolant.
1 Lower water pipe

2 Upper water pipe
Cooling System 1E-5
1.6 Water pump
1.6.1 Water Pump

See Engine Water Pump Dismantling/ Mounting

for the water pump dismantling/ mounting.
① Upper heat sink hose

1.6.2 Fan Motor
② Thermostat lid
③ O-ring ◆ Fan Motor Inspection
④ Thermostat Mounting Attentions 1. Confirm if the accumulator has been fully

charged.
1.5.2 Instructions for installing the thermostat
2. Connect the accumulator’s positive electrode
1. Mount the thermostat onto the thermostat and amperemeter with the fan motor plug.
housing, pay attention to the thermostat’s
direction, with clamping pin facing upward. 3. Confirm if the fan motor runs stably while
being driven by standard current. Replace fan
motor if it fails to meet technical
Clamping pin requirements.
①
Thermostat Inspection
1. Inspect thermostat according to items below.
—Valve temperature when being turned on or off. Standard Current:
—Valve’s critical temperature in full opening or ①Connected, High-speed Action 11-12.5A [12V]
full closing state. If technical requirements ①Disconnected, Low-speed Action 9-10.5A [12V]
cannot be met, replace the thermostat.
◆ Fan Motor Dismantling/Mounting
Condition Action Temperature℃
1. Dismantle the cooling fan.
Initial
81 2. Dismantle parts according to the sequence
Temperature rising opening
process Full
93 3. Mount parts according to the sequence reverse
opening
Start
90
Temperature closing
decline process Full
79
closing
Cooling System 1E-6
Compliance
Step Port
standard
Ohmmeter tests
Infinite
1 resistance at both ends of
resistance
Pin 30 and Pin 87
Hear the
Both ends of Pin 85 and
relay’s
2 Pin 86 directly link with
actuation
12V power supply
voice
Keep the relay’s
actuation state, and again
Resistance is
3 use the ohmmeter to test
zero
resistance at both ends of
1 Cooling fan heat shielding cover Pin 30 and Pin 87
2 Cooling fan blade High/low-speed relay pins have the

Remark
same definition
3 Fan motor assembly
1.7 Fan Relay Relay Diagram
1.7.1 Inspection of Fan Relay

1. Disconnect the accumulator’s negative cable
2. Dismantle the fan relay from the relay box.
Use the ohmmeter and 12V power supply to

inspect the fan relay’s quality. If the relay is unable
to run normally or meet technical requirements,
replace the fan relay. See table below for the relay
inspection:
Accessory-Belt 1F-1
Chapter 6 Engine Accessory-Belt

Table of Contents
1. Driving Belt ································································································1F-2
1.1 Inspection of Driving Belt ············································································1F-2
1.1.1 Inspection of Driving Belt’s Distortion ························································1F-2
1.1.2 Inspection of Driving Belt Tension·····························································1F-2
1.2 Adjusting the drive belt ···············································································1F-2
1.2.1 A/C Compressor Multi-wedge V Belt Adjustment ···········································1F-2
1.2.2 Power Steering Pump Belt Adjustment ························································1F-3
Accessory-Belt 1F-2
Use SST to inspect the tension of belt between two

driving wheels.
1. Driving Belt
 If the tension goes beyond the specified range,
1.1 Inspection of Driving Belt make adjustment (see Adjustment of Driving
Belt)
If necessary, inspect the driving belt’s distortion
and tension.
1.1.1 Inspection of Driving Belt’s Distortion
Notice:
 After 30 minutes since the automobile engine When measuring
stops, inspect the belt distortion with a belt
tensiometer, in order to confirm if the belt When mounting
tension stays within the standard value.
 If the belt tension goes beyond the specified
range, adjust the driving belt (see Adjustment
of Driving Belt) 1.2 Adjusting the drive belt
1.2.1 A/C Compressor Multi-wedge V Belt

Adjustment
1. Loosen appropriately the nut on the power

generator’s pivot bolt.
2. Loosen the power generator’s fixing bolt, and
then tighten it for about 5N.m, in order to
avoid the pulley’s deflection.
Adjust bolt
Fix power generator bolt
Power generator pivot nut
3. Use the adjusting bolt to adjust the belt

tension and belt deflection to the standard
value.
4. Tighten the power generator’s pivot nut.
Tightening torque: 43 ±4N·m
5. Tighten the power generator’s fixing bolt.
Tightening torque: 20±2N·m
1.1.2 Inspection of Driving Belt Tension
Notice
 The inspection shall be conducted after the
engine cools down
Accessory-Belt 1F-3
torque:40～48N.m
Notice
 If mounting new driving belt or running
driving belt for not greater than 5minutes,
adjustment shall be made according to the new
part’s standard value.
 If running the driving belt for more than 5
minutes, adjustment shall be made according
to the old part’s standard value.
1.2.2 Power Steering Pump Belt

Adjustment
1. First, loosen the tension pulley’s nut B, and

then tighten it for about 5N.m, in order to
avoid the pulley deflection.
Distortion (mm/98N)
Driving Belt New Old

900N-950N
A/C Compressor Belt (1.5T 500N-600N
600N-700N)
Power Steering Pump
Belt (With Tensioner 400N-500N 300N-350N
2. Adjust the stud bolt A to drive the tension pulley)
pulley’s location change in the tension pulley
Power Steering Pump
bracket’s slot, so as to adjust the belt tension.
Belt (Without Tensioner 300N-500N
3. After the tension meets requirements, tighten
pulley)
the tension pulley nut B, Tightening
Engine Suspension 1G-1
Chapter 7 Engine Suspension

Table of Contents
1.Engine Dismantling/Mounting ·········································································· 1G-2
1.1 Complete the dismantling work ····································································· 1G-2
1.1.1 Engine1# Suspension Bracket Dismantling/ Mounting ··································· 1G-3
1.1.2 Engine3# Suspension Bracket Dismantling/ Mounting ····································1G-4

1.1.3 Engine4# Suspension Bracket Dismantling/ Mounting ····································1G-4
1. Engine Dismantling/Mounting
Warning
 Fuel vapor is combustible, and keep away the spark and naked flame.
Fuel leakage and splash are dangerous, which will irritate the skin and eye. Due to this, follow the “Oil
Circuit Safety Inspection Procedure” (see Fuel System, Preparatory Work before Repair).
1.1 Complete the dismantling work
Respectively discharge A/C refrigerant, power steering liquid, gearbox oil, and engine coolant:
1. Disconnect the accumulator’s negative cable.
2. Dismantle the engine under the fender (see the engine under the fender removal / installation).
3. Dismantle the left/right driving axles (see Driving Axle Dismantling/Mounting).
4. Dismantle the engine trim cover (see engine trim cover removal / installation).
5. Dismantle the front suspension cross member assembly (see the front subframe of removal /
installation).
6. Dismantle heat sink(see Heat Sink, Heat Sink Dismantling/Mounting).
7. Dismantle three-way catalyst converter assembly (see Exhaust System, Exhaust System
Mounting/Dismantling).
8. Dismantle the accumulator and accumulator tray (see Engine Electrical System, Accumulator
Dismantling/Mounting).
9. Dismantle PM wiring harness and engine’s connector (see PM Wiring Harness
Dismantling/Mounting).
10. Dismantle the reverse switch joint and gear shift cable that are connected with the gearbox.
11. Dismantle the power steering pump hose on the engine, the intake hose connection.
12. Dismantle A/C compressor’s pipeline connection.
13. Dismantle the engine and engine suspension according to the sequence illustrated in the figure.
14. Mount parts according to the sequence reverse to the dismantling process.
15. Inject A/C refrigerant and discharge the power steering liquid, gearbox oil, and engine coolant.
16. Correct the driving belt’s tension (see Driving Belt, Driving Belt Dismantling/Mounting).
17. Star the engine and conduct the following inspection work:
(1) Inspect the belt pulley and driving belt’s deflection and interference.
(2) Inspect if there is engine oil, engine coolant, gearbox oil, and fuel leakage.
(3) Inspect the idling speed (see Engine Running, Idling Speed Inspection).
18. Confirm the road test.
19. Inspect the engine oil, engine coolant, gearbox oil and power steering liquid’s level again.
1 Engine1# suspension
1.1.1 Engine1# Suspension Bracket Dismantling/ Mounting

1. Dismantle the engine # 1 bracket bolts 1 and 2 (transmission side) ;
2. Remove the engine mounts bolt # 1 flat washer 5 ,3, 4 flat washers and bolts to remove the engine 1# 6;
3. Check rubber mounts broken, hardening or damage.
1.1.2 Engine3# Suspension Bracket Dismantling/ Mounting

1. Dismantle the engine mounts bolt 3 # 3 and nuts 1 and 2 (engine side);
2. Dismantle the engine mounts bolt 3 # 4, 5 and 6 (body side) ;
3. Whether to remove the engine mounts Check rubber damaged # 3 check 3 # suspended base oil leaks or
damage.
1.1.3 Engine4# Suspension Bracket Dismantling/Mounting

1. Dismantle 4 # 3 and 4-- suspension nut;
2. Dismantle 4 # suspension bolts 1 and 2 (body side);
3. Dismantle the four # mount bracket nut 6 and 7;
4. Dismantle the four # suspended inspection rubber is broken, hardening or damaged.
MF515L Transmission 1H-1
Chapter 8 6MT Transmission

Table of Contents
MF515L Transmission·······················································································1H-2
1. Overview ·································································································· 1H-2
2. Transmission Troubleshooting and Maintenance ···················································· 1H-3
2.1 Troubleshooting······················································································ 1H-3
2.2 On-spot Maintenance ··············································································· 1H-4
2.3 Transmission Assembly Dismantling ····························································· 1H-5
2.4 Transmission Components Dismantling, Overhaul, and Remounting ······················· 1H-7
6MT Transmission
1. Overview
The transmission, through 4 synchronizers and
three transmission shafts (input shaft, intermediate
shaft, and reverse gear shaft), can provide 6
forward gears and 1 reverse gear, of which all
forward gears belong to constant-mesh type, but
the reverse gear is a sliding idle gear.
1-2-gear synchronizer is mounted onto the
intermediate shaft, and coupled with the
intermediate shaft’s first gear and second gear.
3-4-gear synchronizer is mounted onto the input Fig. 1-2 Gear Mechanism
shaft, and coupled with the input shaft’s third gear
and fourth gear.
Five or six gear synchronizer assembly is mounted
on the input shaft, and with the input shaft 5th gear
and six-gear linked in. Reverse synchronizer
assembly is mounted in the reverse gear shaft
associated with the reverse gear.
Intermediate shaft drives the main reduction gear
and differential device, so as to rotate the front
driving axle that is connected with the front wheel.
As for the maintenance work, sealant or equivalent
products shall be smeared on gearbox housing
surface’s corresponding parts, and the gearbox
housing is made of aluminum. On the housing, the
fixing bolt shall be tightened to specific torque
with the torque wrench. Before remounting, all
parts shall be cleaned thoroughly with cleaning
agent or liquid and dry air, which is very Fig. 1-3 Internal gear shift mechanism
important.
Fig. 1-1 Transmission assembly Fig. 1-4 Gearshift Actuator

1.1 Shifting mechanism the adjusting mechanism is loosened.
Gear shift lever movement transmitted by the shift Solution: Place it to the “Neutral Gear”’ position
power to the shift shaft rotating arm, the pendulum again, and adjust the clearance.
is transmitted to the shift by shift shaft, then
h. Reason: the engine’s connection with the
through the shift rocker pin to transmit the power
transmission and complete vehicle is too loose,
to shift head, and finally delivered to the fork
or the clearance adjustment is inappropriate.
assembly. With a transmission gear interlock plate
to prevent double engagement. Solution: Adjust the clearance
When put up a gear shift interlock plate to lock the ◆ Transmission Emits High Noise or
other, it can not be linked to other gear shift Abnormal Sound Reasons and Solutions
operation between each gear interlock avoid while
hang two or more file archives. a. Reason:Transmission has insufficient oil or the
oil is not clean
2. Transmission Troubleshooting
Solution: Inject sufficient oil or replace the oil.
and Maintenance
b. Reason: Gear’s axial clearance is too large
2.1 Troubleshooting
Solution: Replace gear or gear check ring.
Transmission’s main faults and troubleshooting
methods: c. Reason: Gear suffers abrasion or gear teeth is
broken
◆ Out of Gear
Solution: If the gear backlash exceeds the specified
Reasons and Solutions: range, replace the gear. Standard backlash of the
five-gear transmission is 0.1mm, and the operating
a. Reason: shift rod suffers serious abrasion and
limit is 0.3mm.
distortion
d. Reason: synchronizer’s gear ring suffers
Solution: calibrate the shift rod manually. If the
abrasion or the gear is broken
shift rod bends or suffers serious abrasion, replace
it in time. Solution: Replace the gear ring.
b. Reason: shift rocker suffers serious abrasion e. Bearing suffers damage or abrasion
and distortion
Solution:Replace bearing.
Solution: replace the shift rocker in time.
f. Bearing press plate suffers damage or
c. Reason: Self-locking spring’s elasticity is abrasion.
weakened
Solution: Replace the gear check ring.
Solution: Replace the self-locking spring in time.
◆ Shifting Difficulty
d. Reason: Gear’s axial clearance is too large,
which should be mainly attributed to the gear Reasons and Solutions
check ring’s serious abrasion
a. Shift rod or shift fork incurs distortion or
Solution: Replace the gear check ring. uneven abrasion
e. Reason: shift fork’s abrasion and distortion Solution: Replace parts.
Solution: Calibrate the shift fork manually when it b. Self-locking steel ball and shift fork shaft’s
suffers distortion. Replace it when suffering groove suffer abrasion
serious abrasion.
Solution: Replace parts.
f. Reason: Synchronizer gear housing, gear
c. Synchronizer’s gear ring gets stuck on the
sleeve, or gear ring suffer abrasion
gear’s conic section
Solution: If there is out of gear, replace the
Solution: Replace the gear ring.
wear-out parts.
d. Synchronizer spring is damaged
g. Reason: After being adjusted, transmission
fails to reach the “Neutral Gear” position, or
Solution: Replace the synchronizer spring. oil (GL-4) grade:75W-90.

e. Gear sleeve and gear end suffer abrasion or Oil filling volume:1.8～2.0L
abrasion of gear ring’s key groove becomes
wider. Notice
Solution: Replace corresponding parts.  When the automobile is jacked for other
maintenance work besides the lubricating oil
◆ Oil Leakage replacement, inspection to leakage of
lubricating oil shall be conducted as well.
a. Oil leakage at the drain plug
2.2.2 Differential Right/Left Oil Seal
Solution: first, the plug’s tightening torque is less Replacement
than the specified value, and so inspect the tightening
torque. If the tightening torque does not comply with 1) Jack the automobile and drain the
requirements, tighten the plug. Second, there is transmission lubricating oil.
deflection in engagement or thread teeth damage,
replace corresponding parts. 2) Dismantle the driving shaft from the
differential.
b. Oil Leakage at Sealing Parts
3) Use the special tool and hammer to dismantle
Solution: Replace sealing parts while abiding by the oil seal and mount a new part. special
operation specifications. tools(A): oil seal erector1(right); oil seal
erector2(left)
c. Oil Leakage at the Bonding Surface
Differential limit end face seal in place.
Solution: Conduct inspection and make all
connection bolt’s tightening torques accord with 4) Smear lubricating grease on the oil seal’s rim,
specifications. in addition to inspecting the contacting part
between the driving shaft and oil seal, as well
d. Oil Leakage at the Input Shaft’s Seal Ring as ensure the smoothness.
Solution: first, inspect if the seal ring is damaged. “A”: Suzuki Lubricating Grease A.
If damaged, replace the sealing parts. Second,
inspect if the right tank body’s supporting port
suffers excessive abrasion. If it suffers, replace
right tank body.
2.2 On-spot Maintenance
2.2.1 Replace Oil
1) While replacing and inspecting the lubricating
oil, be sure to stop the engine and lift the
automobile steadily. Fig. 2-1 Differential oil seal replacement
2) Oil level and leakage cannot be inspected 5) Mount driving shaft into the differential.
until the automobile has been lifted. If there is
leakage, remedial actions shall be taken in Caution
time.
 When inserting the driving shaft’s bolt, do not
3) Drain original lubricating oil and inject new scratch the oil seal’s rim. Make sure the
and specified lubricating oil. driving shaft’s bolt has been inserted
sufficiently, and the elastic check ring is fixed
4) Drain plug and oil filler plug’s torque as original.
specifications are as follows, before installing
the application on a certain amount of drain 6) Inject transmission oil according to the
plug thread sealant. requirements, and make sure the oil has been
sealed tightly by the oil seal.
Sealant: Suzuki 1215
2.3 Transmission Assembly Dismantling
Tightening torque:12～18N·m
2.3.1 Dismantle Gearshift Actuator
Gear oil:GB13895-1992 heavy-load vehicle gear
Dismantle the locking bolt assembly and shift the

stop pin and the gearshift box’s assembling bolt,
in addition to taking off the gearshift box’s
components.
Fig. 3-2-b Dismantle assembling bolt

1 Assembling bolt M8×40(twelve)
2 Left bearing plate bolt M8×25(six)
3 Left case
Fig.3-1 Dismantle Gearshift Actuator

1 Gearshift box components
2 Gearshift box bolt M8×25(five)
Notice
 Make sure the gearshift box’s components are
Fig. 3-2-c Split the Box
dismantled when the transmission stays at the
“Neutral Gear” position 2.3.3 Dismantle the input shaft assembly, the
intermediate shaft assembly and into the gear
2.3.2 Dismantle the assembling bolt to split the
shift mechanism.
box
1) Use the soft hammer to knock input shaft
1) Dismantle the assembling bolt from internal
lightly;
and external sides of the transmission;
2) Take out the input shaft components,
2) Dismantle the Left bearing plate bolt from
intermediate shaft components, first /second gear
lateral side of transmission;
shift components, third/fourth gear shift
3) Use the soft hammer to knock the left box’s components, fifth/sixth gear shift components from
rim and dismantle the left box. the box once for all.
Special tool: Box splitter (A).
Fig. 3-2-a Dismantle assembling bolt Fig. 3-3-b Dismantle Gear Mechanism and Gear
1 Assembling bolt M8×40(five) Shift Mechanism
1 Input shaft components (B): Oil seal ejector

2 Intermediate shaft components 5) Use special tools to dismantle the
3 into the gear shift mechanism intermediate shaft’s ring bearing outer ring.
Special tools: (A): slide shaft;
3) The reverse shaft assembly, reverse fork
assembly and differential assembly box in the (B):Bearing ejector
right time overall removal;
6) Dismantle the differential’s right oil seal from
right box.
Fig. 3-4-b Dismantle the input shaft’s oil seal

Fig. 3-3-c Take off the gear mechanism and gear 1 Input shaft oil seal
shift mechanism Intermediate shaft’s right bearing
2
2.3.4 Dismantle left box’s other components outer ring
2.4 Transmission Components

Dismantling, Overhaul, and Remounting
2.4.1 Dismantle input shaft’s components
◆ Disassembly
1) Use the bearing puller and extrusion device to
dismantle the input shaft’s right bearing.
2) Use the puller and extrusion device to extrude
left bearing, fifth gear synchronizer unit, and
Fig. 3-4-a Take off other components fifth gear, fourth gear, third gear speed
1 Intermediate shaft oil tray synchronizer and together with the sleeve out
Intermediate shaft’s right bearing together.
2
outer ring Notice:
3 Magnet  To prevent the gear teeth from being damaged,
4 Close box pin（two） make the teeth lean against the smooth and
straight side of the bearing puller.
1.Input shaft
1) Take off other components 2.Right bearing
3.Bearing puller
2) Dismantle differential unit from the right box
3) Dismantle bolt,
4) Use special tools to dismantle the
input shaft’s oil seal
Special tools: (A): Slide shaft;
Fig.4-1-a Dismantle the input shaft’s right bearing 9 3th/4th gear synchronizer gear ring
10 3th/4th gear synchronizer components
11 Input shaft third gear assembly
12 Input shaft
13 Input shaft right bearing
14 Right gear input shaft bearing ring
1) Clean all parts thoroughly and inspect if there

is abnormal situation. Then mount the new
one according to demands.
 Notice
Before assembling, clean every component
and smear designated gear oil to slide the gear
and the bearing surface. During the
remounting process, use new gear ring on the
shaft, and application of used gear ring is
1 Input shaft 5 High-speed prohibited.
bearing left synchronous
2) If the synchronizer’s components will be
2 Five-speed 6 Third gear gear repaired, inspect the clearance “a” between
synchronous assembly the gear ring and the gear ring, and then
inspect every gear’s crowned teeth, ring, and
3 5th gear gear 7 Input shaft sleeve. After that, determine if the
assembly replacement shall be conducted.
4 4th gear gear 8 Bearing puller
Clearance a: Theoretical value: 1.0- 1.2mm
assembly
Ultimate value: 0.5mm
Fig.4-1-b Dismantle the input shaft’s left bearing,
each gear synchronizer unit 3) Ensure the lubrication, and blow air to every
oil port to make sure that there is not
◆ Assembly blockage.
Assemble Input Shaft Components
Fig.4-1-e
Fig.4-1-d Input Shaft Components 1 Gear wheel
1 Left input shaft bearing lock nut 2 Gear ring
2 Input shaft left bearing
3 Input shaft 6th gear assembly
4 5th/6th gear synchronizer gear ring
5 Shaft snap ring
6 5th/6th gear synchronizer components
Fig.4-1-f
4) Mount the high-speed synchronizer onto the After pressing and mounting the synchronizer
hub, insert three slide blocks, and then mount unit, inspect the third gear’s free rotation.
the spring according to the illustration.
Special tools(B):bearing erector1
Fig.4-1-i
1 Input shaft
2 Third gear
3 Gear ring
Fig.4-1-g 4 Synchronizer unit
1 High-speed synchronizer spring 7) Mount the four gear shaft sleeve and needle
2 Slide block bearing, smear lubricating grease on the
bearing, and then mount synchronizer gear
3 High-speed synchronizer gear hub
ring and fourth gear.
High-speed synchronizer gear
4 Notice
sleeve
5 3rd gear input shaft  Make sure the four gear shaft sleeve is
properly mounted.
5) Use special tool and hammer to mount the
right bearing.
Special tools(A):bearing erector
Fig.4-1-j
1 Shaft sleeve
2 Needle bearing
3 Gear ring
Fig.4-1-h 4 Fourth gear
5 Input shaft
1 Right bearing
2 Input shaft 9) Mount the fifth gear shaft sleeve and needle
bearing, smear lubricating grease on the
6) Mount the third gear needle bearing, smear bearing, and the mount the synchronizer gear
the lubricating grease, and mount the third ring and fifth gear synchronizer.
gear and synchronizer gear ring.
10) Press and mount the left bearing with special
7) Use special tool and hammer to drive in the tool and hammer.
high-speed synchronizer assembly.
special tools(C):bearing erector4
Note: when pressing and mounting the gear hub
2.4.2 Intermediate Shaft Components
and gear sleeve, make sure the synchronizer gear
ring’s teeth groove aligns with the synchronizer ◆ Disassembly
unit’s slide block.
1) Use the puller and holding-down device to
pull out the left conical bearing. Fig.4-2-c

1 Intermediate shaft 5 3rd gear
Caution
2 5th gear 6 2nd gear
Use the puller and holding-down device that can
support at least 5t load. 3 4th gear Low-speed
7
synchronizer unit
4 3rd/4th gear
8 1st gear
spacer bush
4) Dismantle the synchronizer unit.

5) Take out needle bearing from the shaft.
Fig.4-2-a
6) Use the puller to dismantle right conical
1 Holding-down device bearing.
2 Intermediate shaft’s left bearing
3 Puller
2) Use special tool to dismantle the fifth gear

snap ring
Special tools(A):snap ring plier
3） Take the pressure with a pull and pull out
together with all gear and low speed
synchronous assembly.
Fig.4-2-d
Notice 1 Metal rod
 To prevent the gear teeth from being damaged, Intermediate shaft’s right conical bearing
make the teeth lean against the smooth and 2
puller
straight side of the bearing puller.
◆ Assembly
Mount Intermediate Shaft Components
1) Clean all parts thoroughly, inspect if there is
abnormal situation, and mount new parts
according to demands.
Fig.4-2-b
1 Intermediate shaft 5th gear
2 Intermediate shaft 5th gear ring
Fig.4-2-e
1.Left intermediate shaft bearing lock nut 2.
Intermediate shaft’s left bearing assembly 3.
Intermediate shaft 6th gear 4. 5th/6th gear
spacer bush 5. Intermediate shaft 5th gear 6.
Intermediate shaft 4th gear 7. 3rd/4th gear spacer
bush 8. Intermediate shaft 3rd gear 9. Intermediate
shaft 2nd gear 10. 1st/2nd gear synchronizer gear
ring 11. Shaft snap ring 12. 1st/2nd gear
synchronizer 13. needle bearing 14. Intermediate

shaft first gear spacer bush 15. Intermediate shaft
first gear assembly 16. Intermediate shaft 17.
Intermediate shaft right bearing assembly 18.
Intermediate shaft right bearing ring
2) If the synchronizer’s components will be
repaired, inspect the clearance “a” between
the ring and the gear, and then inspect every
gear’s crowned teeth, ring, and gear ring.
After that, determine if the replacement shall
be conducted. Fig.4-2-h
Clearance “a”: standard value:1.0-1.2mm 1 Low-speed synchronizer snap ring
Ultimate value:0.5mm 2 Slide block
3 Low-speed synchronizer gear hub
4 Low-speed synchronizer gear sleeve
5) Use special tool and hammer to tighten the

right conical bearing.
Special tools(A):bearing erector3
Fig.4-2-f
1 Gear
2 Synchronizer ring
3) Ensure the lubrication, and blow air into

every oil port to inspect if there is blockage. 1. Right conical bearing
2. Intermediate shaft
Fig.4-2-i
1 Right conical bearing
2 Intemrmediate shaft
Fig.4-2-g 6) Mount the needle bearing, smear the

lubricating grease, and then mount the first
1 intermediate shaft gear and first gear synchronizer’s gear ring
2 Oil port components.
7) Use special tool and hydraulic pressure to
4) Mount the low-speed synchronizer onto the drive in the low-speed synchronizer unit.
gear sleeve, insert three slide blocks, and the
mount the spring according to the illustration. Notice
Notice:  Lean the shaft against special tool according
to the illustration, in order to prevent the
Not to slow-sync the tooth shell or each slide in a conical bearing retainer from being extruded.
predetermined direction , but slide blocks are
defined as an assembled unit.  When pressing and mounting the
synchronizer assembly, make sure the
Caution synchronizer slide block groove is aligned
 If the extrusion force exceeds 5t, release the with the slide block
extrusion immediately, and remount the  After pressing and mounting the
puller bracket. Then, continue the push and synchronizer assembly, inspect the first
compression. gear’s free rotation.
Special tools(A):bearing erector3;
(B):bearing erector2; Notice

(C):bearing erector5  It is recommended that bush and third gear
shall be firstly pressed and mounted before
the fourth gear pressing and mounting, which
can prevent the intermediate shaft from being
excessively extruded.
Special tools (A):bearing erector3
(D): bearing erector
Fig.4-2-j
1 Low-speed synchronizer unit
2 First-gear synchronizer gear ring components 1. Third/fourth gear spacer bushes
2. Third gear
3 Intermediate shaft first gear 3. Second gear
4 Intermediate shaft right bearing
A Key groove aligned with slide block Fig.4-2-l
8) Mount shaft sleeve and needle bearing, smear 1 Third/fourth gear spacer bushes
lubricating grease on the bearing, and then
mount second gear synchronizer ring and 2 Third gear
second gear. 3 Second gear
Caution 10) Press and mount the fourth gear and fifth
 Make sure the shaft sleeve is properly gear ditto.
mounted 11) Installation 5th gear collar with a special tool
(collar clamp).
12) Installation left intermediate shaft bearing
with special tools and hammers.
Notice
 To protect the conical bearing, make the shaft
lean against the special tool according to the
illustration.
Special tools (A):bearing erector3
Fig.4-2-k (E):bearing erector4

1 Intermediate shaft first gear
2 1st gear synchronizer gear ring
3 Low-speed synchronizer unit
4 2nd gear bushings
5 Needle bearing
2nd gear synchronizer gear ring
6
components
7 Intermediate shaft second gear
9) Use special tool and holding-down device to

press and mount the third gear and spacer Fig.4-2-m
bush.
1 Intermediate shaft left bearing

2 5th gear
3 4th gear
4 Third/fourth gear spacer bushes
5 Intermediate shaft right bearing
2.4.3 Reverse gear shaft assembly

(1) Installation
Fig.4-3-2
1 Shift fork
2 Synchronizer sleeve
Clearance “a”: standard value:1.0mm
2) Use special tools and a hammer to remove parts.
Special tool (A): the spring pin puller (5mm)
3) The shift shaft inserted into each shell and
Fig.4-3-1
check the smoothness of movement, if the
1 Reverse gear shaft left bearing 6207P53
movement is not flexible, be corrected on the
2 Reverse gear synchronizer snap ring
reamer or similar tool.
3 Reverse gear synchronizer components
4) Replace or correct as needed and installed shaft
4 Reverse gear synchronizer gear ring
parts to ensure the correct order of parts, as
5 Reverse gear gearwheel
shown in FIG.
6 Needle bearing
7 Reverse gear shaft sleeve
8 Reverse gear shaft
9 Reverse gear shaft right bearing 6306E
(2) 1 /2 gear shift assembly, 3rd/4th gear shift
st nd
components and 5th reverse gear components.

1) Using the gap between the plug, check the fork
and synchronizer sets, if it exceeds the limit
1.0mm, the need to replace such parts.
Note:
To achieve the right to judge whether the parts
need to be replaced, it is necessary to carefully
check the contact position of the fork and the
Fig.4-3-3
ring gear. st
1 1 /2nd gear shift fork assembly
2 3rd/4th gear shift fork assembly
3 5th/6th gear shift fork assembly
4 Reverse gear shift fork assembly
5 Ball gear lock assembly
2.4.4 Differential Unit

◆ Differential Unit Dismantling
1) Use special tool to dismantle the right
bearing.
Special tools(A)bearing puller;(B) bearing puller
accessories
Notice
 As for the bearing dismantling, if semilune
puller is used together with holding-down device,
the main reduction gear shall be dismantled in
advance.
Fig.4-4-2
2) Use the puller to dismantle the left bearing,
during which protect well the bearing. 1. Tapered Roller Bearings 2.Differential housing
3. Planet gear 4. Differential spacer 5.Planet
3) Use the soft bench clamp to clamp the gear shaft 6. A type shaft circlip 7. Main
differential housing, and dismantle eight reduction gear 8.Differential bolt 9. Induction
differential bolts. After that, take off the main ring gear 10.Differential half shaft 11.
reduction gear. Differential Adjusting washer
4) Use the snap ring plier to dismantle the 1) Mount the differential gear according to the
differential planet gear shaft check ring, and illustration and follow method below to
then dismantle components and parts. measure the differential’s pushing clearance.
Special tools(A): dial gauge;(B): magnet base
differential gear pushing clearance: 0.03-0.40mm
Left side: use the soft bench clamp to clamp the
differential assembly, and also insert the dial feeler
gauge’s measuring terminal onto the gear’s upper
surface. Use two screwdrivers to move the gear
upwards and downwards, in addition to reading the
gauge feeler gauge’s pointer travel.
Right side: use similar method and insert the dial
Fig.4-4-1 feeler gauge’s measuring terminal onto the gear’s
shoulder. Use the hand to move the gear upwards
◆ Differential Unit Adjustment and
and downwards and read the feeler gauge’s
Remounting reading.
Dismantling shall be determined according to the
fault denoted in preceding content. After the
dismantling, use naked eyes to inspect if the parts
have problems, and prepare spare parts for the
replacement and remount these parts, during
which make sure all parts are clean.
Fig.4-4-3
1 Screwdriver
2 Half axle gear
2) If the pushing clearance exceeds the specified

value, select appropriate thrust washer from the
following sizes for mounting, and inspect again
if specified gear clearance range has been met.
Thickness of thrust washers:0.9, 0.95, 1.0, 1.05,
1.15, and 1.2mm
3) Drive in the spring from right side till the pin 1 Intermediate shaft’s right bearing outer ring
keeps even with differential housing surface.
2 Input shaft oil seal
4) Use special tool and hydraulic pressure to press
and mount the left bearing. Special tool: 2) Use special tool and hammer to mount the
bearing erector 6 intermediate shaft’s right bearing outer ring
and intermediate shaft’s oil tray.
5) Follow the Step 4, to press and mount the right
bearing. Special tools (B): Mounting connection rod
6) Use soft bench clamp to clamp the differential (C): Bearing outer ring erector
assembly, mount main reduction gear, and then Special tools (D):Seal ring erector
use eight bolts to tighten the differential
assembly according to required torque. 3) Use special tool and hammer to mount the
differential’s right oil seal till it keeps even
Notice with the housing surface.
 Other bolts beyond requirements shall not be Notice
used.
 Make differential oil seal’s spring side face
Tightening torque inward
(a):80-100N·m Special tools (E): Oil seal erector1
Differential gear oil seal’s mounting depth:
“a”:1.0-1.5mm
2.4.5 Left Box Body
1. Main reducer gear bolt 1) With a special tool with a hammer on the
2. Final reduction gear differential left side oil package, until the
3. Torque wrench surface is flush with the housing.
4. Soft bench clamp
Notice
Fig.4-4-4
1 Differential bolt  Make the oil seal’s spring side face inward
2 Final reduction gear Special tools(A):Oil seal erector2: differential oil
3 Torque wrench seal’s mounting depth: “a”: 1.0-1.5mm
4 Soft bench clamp
2.4.4 Right box body

1) Mount the input shaft’s oil seal and keep the Oil seal
spring side upward. During the mounting
process, use special tool and hammer.
Special tool(A):bearing erector6
2) Intermediate shaft with a plastic hammer,
gently knock on the left side of the bearing
outer ring into the housing chamber.
Gearshift Mechanism 1J-1
Attached Table 1: Special Tools
Bearing outer ring Spring pin ejector Bearing puller

Snap ring plier Dial gauge Magnet base
erector (6.0mm) accessories
Bearing
Box splitter Bearing puller Oil seal erector1 Gear fixer Slide shaft
erector4
Oil seal Bearing

Bearing erector1 Bearing erector2 Bearing ejector Bush ejector
erector2 erector5
Spring pin
Bearing erector2 Oil seal ejector Bearing erector6 Bearing erector7
ejector(4.5mm)
Mounting connection
Bearing erector3 Seal ring erector
rod
Chapter 9 Gearshift Mechanism

Table of Contents
Gearshift Mechanism ························································································1J-2
Manual Gearshift Mechanism Dismantling/Mounting················································· 1J-2
CVT Automatic Gearshift Mechanism Dismantling/Mounting······································· 1J-2
1.2 CVT Automatic Gearshift Mechanism

1. Gearshift Mechanism Dismantling/Mounting
1. Firstly, dismantle the assistant instrument
1.1 Manual Gearshift Mechanism platform assembly;
Dismantling/Mounting 2. Then remove them as illustrated shift
1. Firstly, dismantle the assistant instrument mechanism, contrary installation and removal
platform assembly; order.
2. Then remove them as illustrated shift 3. After the mounting, confirm if the mechanism
mechanism, contrary installation and removal is fixed and can run stably.
order.
3. After the mounting, confirm if the mechanism
is fixed and can run stably.
1 Gearshift handle
2 Gear display cover
3 Flange bolt
4 Automatic gearshift lever assembly
1 Gearshift handle
5 Flat washer
2 Flange bolt
6 Cable assembly
3 Flat washer
7 Flange nut
4 Manual gearshift lever assembly
8 Cable bracket
5 Cable assembly 9 Spring clamp
6 Cable bracket 10 Shift cable mounting bracket
7 Flange nut 11 Flange bolt
Notice 12 Flange nut
1. Control the cable and connect it with Notice

the transmission correctly (no reverse mounting in
gear selection and shift) 1. Control the cable and connect it with
the transmission correctly.
2. During the dismantling process, keep
cautious and do not injure the cable buckle. After 2. During the dismantling process, keep
the assembly be sure to check whether the card slot cautious and do not injure the cable buckle. After
into place. the assembly be sure to check whether the card slot
into place.

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Table of Contents

Chapter I Engine Body ····················································································· 1A-1

Chapter 1 Engine Body

1.1 How to use this manual ················································································ 1A-0

1.7.4 Explanations on cylinder head hood dismantling...........................................................1A-20

tools tools or equipments

1.1.1 Technical Parameters

Technical Parameters of Complete Equipment

Item Parameter Remark

Engine Model HMA GN15-TF

Code N01G N02G N16G N17G N18G

Technical Parameters of Maintenance

Tappet diameter(mm) Standard 30.964～30.980

Camshaft’s radial run-out(mm) Max. 0.03

Journal clearance(mm) Standard 0.040～0.076

Deformation of upper surface (mm) Standard 0.1

Cylinder bore’s inside diameter

Wearing limit (mm) 0.135

Top ring Standard 0.040～0.085

Second Ring Standard 0.030～0.070

Top ring / Second Ring Max. 0.15

Oil Ring Max. 0.15

Top ring 0.20～0.35

Second Ring 0.40～0.60

Piston pin’s diameter(mm) Standard 17.996～18.000

Piston pin hole’s inside diameter (mm) Standard 18.004～18.010

Clearance between connecting rod’s small end hole and piston

Length [center to center](mm) Standard 133.32～133.40

Inside diameter of connecting rod’s small end (mm) Standard 18.010～18.023

Connecting rod bearing

Connecting rod bush size (mm) Standard 1.483～1.494

Crankshaft radial run-out(mm) 0.03

Main journal diameter(mm) Standard 45.982～46.000

Main bearing bush size (mm) Standard 1.988～2.003

Crank pin diameter(mm) Standard 43.979～44.000

Thrust bearing size (mm) Standard 3.205～3.255

Inspection to complete vehicle

Standard value 1200{12.2}[300]

Compression pressure Minimum limit 980{10.0}[300]

kPa{kgf/cm2}[rpm] Max. limit of

Oil pressure (kPa{kfg/cm2}[rpm]) 375～450{4.1～6.0}[2500]

Oil adding volume L Oil replacement 4.6

Oil and oil filter

API engine oil grade higher

Higher than –25 ℃ SAE 10W–30

Timing chain disassembling part

Automatic tensioner push rod’s extension strength (mm) 3

Crankshaft rotating speed sensor

Clearance between signal wheel and sensor (mm) 0.5～1.5

Opening temperature (℃) 80～84

Full-opening temperature (℃) 95

Full-opening stroke (mm) Min. 8.5

Clutch pressure plate

Diaphragn spring’s wearing depth (mm) Max. 0.6

Diaphragn spring’s radial circle run-out (mm) Max. 0.6

Pressure plate’s flatness (mm) 0.05

Clearance between inner rotor’s prong Standard 0.06～0.18

Clearance between outer rotor and pump Standard 0.250～0.325

Compression spring’s length (mm)[pressure:97.7～107.4N{9.96～10.96kgf}] 34.50

Rear oil seal

Plastic fixing bolt’s length

Cylinder head bolt(mm) Standard 136.8～144.2

Oil filter 14.0 1.43

9.8 1.0 See corresponding part