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gio Vyper 4WD 1100cc 4 seater XY1100UEL, Service Manual

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gio Vyper 4WD 1100cc 4 seater XY1100UEL Service Manual Download Page 30

2. Vehicle body

，

Muffler 

2-3 

Windshield Assembly 

Remove 

Separate the connector of wiper motor. 
 
Remove four bolts 1. 
 
Remove windshield assembly. 
 

Installation

 

Reverse the removal procedure for   
Installation 

 

 

1. WIPER BLADE 

2. WIPER ARM 

3. BOLT(M6×20

）

 

4. WINDSHIELD SCALEBOARD 

5. BOLT(M6×16

）

 

6. FARDAGE WINDSHIELD 

7. CAP NUT (M6) 

8. HOOP (

Φ

45) 

9. WINDSHIELD IMMOBILITY   

PLANK

（

TOP

）

 

10. WINDSHIELD IMMOBILITY   

PLANK

（

BELOW

）

 

11. NUT

，

FLANGE(M6) 

12. WIPER 

13. DUST COVER, RUBBER 

14. NUT (M12) 

15. WASHER (

Φ

12) 

16. RUBBER WASHER 

17. WIPER ASSY 

 

Summary of Contents for Vyper 4WD 1100cc 4 seater XY1100UEL

Page 1: ...Service Manual 4 4 GIO MOTORS Vyper 4WD 1100cc Vyper 4WD 1100cc 4 seater ...

Page 2: ...l contains an introductory description of procedures for inspection maintenance overhaul disassembly assembly removal and installation of components and parts troubleshooting and service data together with illustrations of our vehicle Model XY1100UE and XY1100UEL CONTENTS Vehicle Service Information 1 Vehicle Body Muffler 2 Checks Adjustment 3 Cooling System 4 Removal and Installation of Engine 5 ...

Page 3: ...ng parts with the correct part number or an equivalent part We strongly recommend that you do not use replacement parts of inferior quality For Your Customer is Safety Proper service and maintenance are essential to the customer is safety and the reliability of the vehicle Any error or oversight while servicing a vehicle can result in faulty operation damage to the vehicle or injury to others For ...

Page 4: ...supported Use jack stands Make sure the engine is off before you begin any servicing procedures unless the instruction tells you to do otherwise This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you run the engine Burns from hot parts or coolant Let the engine and exhaust system cool before working in tho...

Page 5: ... case of fire Warning Labels Most manufacturers attach information and warning labels to the UTV These labels contain instructions that are important to personal safety when operating servicing transporting and storing the UTV Refer to the owner s manual for the description and location of labels Order replacement labels from the manufacturer if they are missing or damaged FASTENERS Proper fastene...

Page 6: ...from loosening In certain applications such as the rear axle on an UTV or motorcycle the fastener must be secured in this way For these applications A cotter pin and castellated slotted nut is used To use a cotter pin first make sure the diameter is correct for the hole in the fastener Aster correctly tightening the fastener and aligning the holes insert the cotter pin through the hole and bend th...

Page 7: ...ace is devoid of sharp edges and carefully polished They have an easy to clean finish and are comfortable to use Quality tools are a good investment Some of the procedures in this manual specify special tools In many cases the tools is illustrated in use Those with a large tool kit may be able to replacement However in some cases the specialized equipment or expertise may make it impractical for t...

Page 8: ...rs NOTE Another way to prevent cam out and to increase the grip of a Phillips screwdriver is to apply valve grinding compound or permute screw socket Gripper onto the screwdriver tip After loosening tightening the screw clean the screw recess to prevent engine oil contamination Wrenches Open end box end and combination wrenches figure 5 are available in a variety of types and sizes The number stam...

Page 9: ...ke certain the solid jaw is the one transmitting the force Socket Wrenches Ratchets and Handles Sockets that attach to a ratchet handle Figure 7 are available with 6 point or 12 point openings Figure8 and different drive sizes The drive size Indicates the size of the square hole that accepts the Ratchet handle The number stamped on the socket is the size of the work area and must the fastener head...

Page 10: ...r to Socket Wrenches Ratchets and handles in this section WARNING Do not use hand sockets with air or impact tools because they may shatter and cause injury Always wear eye protection when using impact or air tools Allen Wrenches Use Allen or setscrew wrenches Figure 11 on fasteners with hexagonal recesses in the fastener head These wrenches are available in L shaped bar Socket and T handle types ...

Page 11: ...e wrench to compensate for the change of lever length When using a torque adapter at a right angle to the drive head calibration is not required because the effective length has not changed To recalculate a torque reading when using a torque adapter use the following formula and refer to Figure 14 TW TA L L A TW is the torque setting or dial reading on the wrench TA is the torque specification and...

Page 12: ...e specialized pliers with tips that fit into the ends of snap rings to remove and install them Snap ring pliers Figure 17 are available with a fixed action either internal or external or convertible one tool works on both internal and external snap rings They may have fixed tips or interchangeable ones of various sizes and angles For general use select a convertible type pliers with interchangeabl...

Page 13: ...ools provide the best results if cared for properly Improper use can damage the tool and cause inaccurate results If any measurement is questionable verify the measurement using another tool A standard gauge is usually provided with micrometers to check accuracy and calibrate the tool if necessary Precision measurements can vary according to the experience of the person performing the procedure Ac...

Page 14: ... a slight drag Some calipers require calibration Always refer to the manufacturer s instructions when using a new or unfamiliar caliper To read a vernire Calipers refer to Figure 21 The fixed scale is marked in l mm increments Ten individual lines on the fixed scale equal 1 cm The movable scale is marked in 0 05 mm hundredth increments To obtain a reading establish the first number by the location...

Page 15: ...her The following sections describe how to adjust care for and read the measurements of various types of outside micrometers For accurate results properly maintain the measuring surfaces of the micrometer There cannot be any dirt or burrs between the tool and the measured object Never force the micrometer to close around an object Close the micrometer around the highest point so it can be removed ...

Page 16: ...hey do temperature changes and corrosion may damage the contact faces 3 Do not clean a micrometer with compressed air Dirt forced into the tool will cause wear 4 Lubricate micrometers with WD 40 to prevent corrosion Metric micrometer The standard metric micrometer Figure 24 is accurate to one one hundredth of a millimeter 0 01 mm The sleeve line is graduated in millimeter and half millimeter incre...

Page 17: ... in 0 025 in increments Every fourth sleeve mark is numbered 1 2 3 4 5 6 7 8 9 These numbers indicate 0 100 0 200 0 300 and so on The tapered end of the thimble has 25 lines marked around it Each mark equals 0 001 in One complete turn of the thimble will align its zero mark with the first mark on the sleeve or 0 025 in To read a standard inch micrometer perform the following steps and refer to Fig...

Page 18: ...e bore Do not over tighten the gauge because there is no built in release Excessive tightening can damage the bore surface and damage the tool Remove the gauge and measure the outside dimension Figure 30 Small bore gauges are typically used to measure valve guides Dial Indicator A dial indicator Figure 31 is a gauge with a dial face and needle used to measure variations in dimensions and movements...

Page 19: ... The ohmmeter function tests circuits for continuity or lack of continuity and measures the resistance of a circuit Some manufacturer s specifications for electrical components are based on results using a specific test meter Results may vary if using a meter not recommended by the manufacturer Such requirements are noted when applicable Ohmmeter analog calibration Each time an analog ohmmeter is ...

Page 20: ...r model turn switch 3 Turning switch 4 Light switch 5 Low beams High beams turn 6 Horn switch 7 Gear Selector 8 Ignition Switch 9 Meter 10 Warning indicator light switch 11 Wiper switch optional 12 Spot light optional 13 Cigarette lighter 14 winch switch optional 15 Auxiliary DC jack 12V 120W 10A ...

Page 21: ... in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen Vehicle Identification Number 1100UE LCXRSAS3 Vehicle Identification Number 1100UEL LCXLSAS3 Engine Number SQR472F NOTE The vehicle identification number is used to identify your machine 1 ...

Page 22: ... Lubrication Type Compound pressure splash lubrication Cool type Mandatory cycle of antifreeze coolant Maximal power 50Kw 6000 rpm EEC model less than 15kw Max torque 90N M 3500 4000 rpm EEC model 45N M 2240 rpm Lowest fuel consuming rate g Kw h 275g Kw h Idling speed r min 850 50 r min Starting Performance The engine should be started smoothly in 30S without any special measure when the air tempe...

Page 23: ...d cooling fluid circulating Cooling fluid type antifreeze with prevent rust Out dimension 555 8 x 455 9 x 699 Net weight 80kg Output type front and rear shaft output Engine Gearing Shaft running direction counter clockwise from back of engine Right 40 Steering device Steering angle Left 40 Front Hydraulic Disc Brake type Rear Hydraulic Disc Bumper Device Suspension Swing Arm Frame type Welded stee...

Page 24: ...f radiator cap 108kpa 1 1kgf cm2 Temperature valve open 72 2 ºC Temperature valve full open 88 ºC Thermostat Overall lift 3 5 4 5mm 95ºC Front Rear Wheel Item Standard Service Limit Vertical 1 0mm 2 0mm Play of wheel rim Horizontal 1 0mm 2 0mm Groove 3 0mm Front Wheel Tire Pressure 12PSI 83KPa 0 5PSI 3 5KPa Vertical 1 0mm 2 0mm Play of wheel rim Horizontal 1 0mm 2 0mm Groove 3 0mm Rear Wheel Tire ...

Page 25: ... 3Ω Rectifier Three phase annular rectification Silicon controlled parallel connected regulated voltage Capacity 12V36Ah Fully charged 12 8V Terminal point voltage Insufficient charge 11 8V Standard 0 9A 5 10H Battery Charging current time Quick 4A 1H Ignition system Item Standard Ignition ECU ignition Type K6RTG NGK Optional Spark Plug Spark plug gap 0 9 1 1mm 1 ...

Page 26: ... M10 1 25 90 8 40 50 10 JOINT ARM BALL M10 1 25 2 40 50 11 REAR LOWER UPPER ARM M10 1 25 90 8 40 50 12 FRONT REAR AXLE NUT M18 4 180 200 13 STEERING WHEEL M5 15 6 10 14 STEERING SHAFT M8 25 4 20 30 15 FRONT AXLE M10 1 25 145 1 40 50 16 FRONT AXLE M10 1 25 85 1 40 50 17 HOLDER FRONT AXLE FR RR M8 16 6 20 30 18 REAR AXLE M12 1 25 115 2 40 50 19 HOLDER REAR AXLE FR RR M8 16 6 20 30 20 FRONT DRIVE SHA...

Page 27: ...e liquid Category Specification Capacity Remark Fuel RQ 93or upper grade lead free gasoline 35L Lubricating oil engine Gear box SAE15W 40 SF or SC 3600ml change oil 3500ml change filter Front 500ml Gearbox Rear 1300ml Lubricating oil front main driver Change 0 25L Lubricating oil Rear main driver SAE80W 90 GL 4 Change 0 18L Brake liquid GB1083 JG3 0 5L Engine coolant Distilled water Glycol 1 1 Ext...

Page 28: ... attention should also be paid to sparks Gasoline may also be explosive when it is vaporized so operation should be done in a well ventilated place Remove and Install muffler after it is fully cold This chapter is on the disassembly and installation of rack visible parts exhaust pipe Muffler and fuel tank Hoses cables and wiring should be routed properly Replace the gasket with a new one after muf...

Page 29: ...val procedure for Installation Steering wheel Remove Remove six bolts 1 Remove steering wheel Installation Note Align the front wheel first and then adjust steering wheel Reverse the removal procedure for Installation Platfond Remove Remove four bolts 2 Remove platfond Installation Reverse the removal procedure for Installation 2 ...

Page 30: ...ation Reverse the removal procedure for Installation 1 WIPER BLADE 2 WIPER ARM 3 BOLT M6 20 4 WINDSHIELD SCALEBOARD 5 BOLT M6 16 6 FARDAGE WINDSHIELD 7 CAP NUT M6 8 HOOP Φ45 9 WINDSHIELD IMMOBILITY PLANK TOP 10 WINDSHIELD IMMOBILITY PLANK BELOW 11 NUT FLANGE M6 12 WIPER 13 DUST COVER RUBBER 14 NUT M12 15 WASHER Φ12 16 RUBBER WASHER 17 WIPER ASSY ...

Page 31: ...move bolt 2 Remove side door LR Remove the side door of the another side in the above way Installation Reverse the removal procedure for installation 15 TAPPING SCREW ST 4 2 20 16 SCREW M6 25 17 HANDLE HALF DOOR L 18 SCREW M5 20 19 INNER HALF DOOR L 20 INNER HALF DOOR R 21 WASHER Φ5 Φ10 1 22 BOLT FLANGE M6 23 BOLT FLANGE M6 16 24 BOLT FLANGE M5 25 CABLE HALF DOOR 26 HANDLE HALF DOOR R 27 OUTER HAL...

Page 32: ... the triangular cover of the another side in the above way Installation Reverse the removal procedure for installation Rear Left Board Remove Remove bolt 2 Remove bolt 3 Remove rear left board Remove the rear right board in the above way Installation Reverse the removal procedure for Installation ...

Page 33: ...elt of passenger in same method Installation Reverse the removal procedure for Installation Install rear seat belt of passenger in same method Main Protect Pole ASSY Remove Remove bolt 1 Remove bolt 2 Remove the main protect pole assy of the another side in the above way Remove main protect pole assy Installation Reverse the removal procedure for Installation 2 ...

Page 34: ...AR THWARTWISE PIPE 5 FRONT BENT PIPE 6 CAP NUT M8 7 BACKREST PIPE 8 HEADREST 9 SCREW M5 20 10 BACKREST 11 RUBBER STORE BOX 12 CAP NUT M6 13 CENTER SPACER HOOP 14 PLATFOND 15 BOLT FLANGE M6 55 16 WASHER Ф6 Ф12 2 17 BOLT M10 30 18 LOCK CATCH SAFETY BELT 19 SAFETY BELT ASSY 20 FRONT PROTECT POLE ASSY R ...

Page 35: ...PE 6 CAP NUT M8 7 BACKREST PIPE 8 HEADREST 9 SCREW M5 20 10 BACKREST 11 RUBBER STORE BOX 12 CAP NUT M6 13 CENTER SPACER HOOP 14 CEILING 15 BOLT FLANGE M6 55 16 WASHER φ6 φ12 2 17 BOLT M10 30 18 LOCK CATCH SAFETY BELT 19 SAFETY BELT ASSY 20 FRONT PROTECT POLE ASSY R 21 REAR PROTECT POLE ASSY L 22 REAE PROTECT POLE ASSY R 23 BACKREST 2 ...

Page 36: ...bumper Installation Reverse the removal procedure for Installation 1 COBBRA BUMPER 2 FRONT BUMPER 3 DECORATE COVER FRONT BUMPER 4 SCREW M6 20 5 BOLT FLANGE M6 20 6 BOLT FLANGE M8 16 7 CABLE FRONT COVER 8 LOCKNUT FLANGE M10 1 25 9 CABLE PULLEY 10 LOCKNUT FLANGE M8 11 WINCH HOLDER 12 WINCH 13 BOLT FLANGE M10 1 25 70 ...

Page 37: ... Remove the front right line cover R in same method Installation Reverse the removal procedure for Installation FRONT AIR GUIDE COVER ASSY Remove Separate the connector of headlight Remove the eight bolts 2 Remove the front air guide cover assy Installation Reverse the removal procedure for Installation 2 ...

Page 38: ...t air guide cover assy 2 10 Remove the steering wheel assy 2 2 Remove the gear change handle Remove the two bolts 1 Remove the nine bolts 2 Loosen all electronic component and plugs Remove the front cover assy Installation Reverse the removal procedure for Installation ...

Page 39: ...GUARDR L 12 ENGINE COVER BOARD 13 TAPPING SCREW ST4 2 20 14 ENGINE COVER BOARD DECORATE COVER 15 SCREW M6 20 16 RUBBER WASHER φ6 17 GEMEL 18 NUT CLIP M6 19 DECORATE COVER FRONT COVER 20 FRONT COVER 21 COVER LEFT LINE FR L 22 COVER RIGHT LINE FR R 23 SCALEBOARD METER PANEL 24 SEPTI BOARD STORE BOX 25 METER PANEL 26 AIRPROOF COVER GEARSHIFT 27 AIRPROOF COVER PARKING HANDLE 28 TEACUP COVER 29 COVER B...

Page 40: ...he pin of cargo box Use the same method to remove the R pin and cargo box pin on the other side of the cargo box Figure direction pulling tipping rocker of cargo box Remove R pin of gas spring Remove connection of gas spring and cargo Remove cargo box Installation Reverse the removal procedure for Installation ...

Page 41: ...HOOK SEAT 10 TORSION SPRING BIG 11 BOLT FLANGE M8 45 12 LOCKNUT FLANGE M8 13 HEAT INSULATION BOARD 14 RIVET 5 20 15 CARGO BOX FRAMRE 16 DECORATING COVER CARGO BOX 17 HALF DOOR FRAMRE 18 BOLT FLANGE M8 12 19 ROTATE PIN PIPE 20 BOARD CARGO BOX DOOR 21 REAR CORNER COVER CARGO BOX R 22 HANDLE CARGO BOX DOOR 23 LOCKNUT FLANGE M6 24 REAR HEIGHTEN WASHER R 25 TIE ROD HALF DOOR 26 LOCK GARGO BOX L 27 BOLT...

Page 42: ...L 38 REAR HEIGHTEN WASHER L 39 SCREW M6 30 40 RUBBER WASHER Φ6 41 STARBOARD COVER CARGO BOX 42 BUCKLE PLATE 43 BOLT FLANGE M8 20 44 CARGO BOX HANDLE RUBBER WASHER R 45 PROTECT COTE TUBE 46 FRONT HEIGHTEN WASHER L 47 SCREW M6 20 48 NUT CLIP M6 49 FRONT HEIGHTEN WASHER R 50 CARGO BOX HANDLE RUBBER WASHER L 51 PIN CARGO BOX 52 R PIN Ф4 53 R PIN Ф3 54 GAS SRPING CARGO BOX 55 CIRCLIP Ф8 56 LOCK GARGO B...

Page 43: ...xhaust pipe Remove catalytic converter assy Remove exhaust pipe and muffler Note Replace seal ring when installing the muffler Installation Reverse the removal procedure for installation MUFFLER ASSY 1 SEAL RING 2 BOLT FLANGE M10 30 3 LOCKNUT FLANGE M10 4 EXHAUST PIPE 5 RUBBER WASHER A 6 TENSION SPRING EXHAUST PIPE 7 CATALYTIC CONVERTER 8 RUBBER WASHER B 9 MUFFLER 2 ...

Page 44: ... still very hot when the engine is just stopped Careless contact may cause serious burn Be sure to wear fatigue dress with long sleeves and gloves if the work has to be done after the engine is just stopped Gasoline is highly flammable smoking is strictly forbidden in the work place Keep alert on the electrical sparks Besides vaporized gasoline is highly explosive so work should be done in a well ...

Page 45: ...d on vehicles that are used in severe conditions Km Initial 250km Every 500 km Every 1000 km Interval Item Hours Initial 20 hours Every 50 hours Every 100 hours Remarks Valve clearance I I IN 0 18 0 05 EX 0 25 0 05 Idle Speed I I 850 r min 50r min I I Spark plug R Every 6000km No carbon deposit Gap 0 9 1 1mm Air Filter I C R every 20000km Fuel Hose carburetor I Clutch I R every 4 year Drive Belt I...

Page 46: ...e disc Brake disc damage and wear Replace when the thickness of front brake disc is less than 3mm rear brake less than 3mm Tire pressure Front tire 83kPa 12 1PSI Rear tire 83kPa 12 1PSI Chap and damage No wear indication on the surface of tire the remained depth of groove should not be less than 3mm Groove depth and abnormal wear Loosened wheel nut and axle Sway of front wheel bearing Driving Syst...

Page 47: ... Looseness of joint parts Drive Train Final shaft Drive shaft Sway of Spline Spark plug Ignition Device Ignition timing Battery Terminal Joint Electrical System Wiring Looseness and damage of joints Fuel leakage Fuel device Throttle Coolant level Engine Cooling system Coolant leakage 3 ...

Page 48: ...tion Alarm and lock device Function Instruments Function Looseness or damage caused by improper installation Exhaust pipe and muffler Function of muffler Frame Looseness and or damage Others Lubrication grease of frame parts Abnormal parts which can be determined when driving Make sure if there is any abnormal with relative parts ...

Page 49: ...detents 4 With two wrenches loosen the outside jam nut counterclockwise Turn the outside jam nut 1 1 2 turns Perform this procedure on the shift lever end also 5 After turning the outside jam nut 1 1 2 turns Hold the outside jam nut with a wrench and tighten the inside jam nut clockwise until it is tight against the bracket 6 Repeat Step 4 and Step 5 until the proper adjustment is made for the tra...

Page 50: ...the main filter the filter should be replaced 3 Inspect main element and replace if necessary If the filter has been soaked with fuel or oil it must be replaced Installation 1 Reinstall the filter into the air box container Be sure the filter fits tightly in the air box NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 2 Check air box If oil o...

Page 51: ...rdingly In case of sway of the steering stem tighten the locknut or disassemble the steering stem for further check Park the vehicle on level place slowly turn the steering wheel left and right to see if it can turn freely In case there is any hindrance check if there is any interference If no check the steering tie rod end and check if the steering stem bearing is damaged Note Make sure the steer...

Page 52: ...lastic and rubber parts Keep the fluid away from these parts Slightly turn the steering wheel left and right till the master cylinder is in horizontal then remove the fluid reservoir cap Brake Disc Brake Pad Wear of brake pad Check the brake pad wears from the mark as indicated Replace the brake pad if the wear has reached position of wear limit trough Note The brake pad must be replaced with a wh...

Page 53: ...el is tightened and check whether it sways Not tighten enough Tighten it sway Replace the rocker arm Front Toe in size Park the vehicle on level place measure the front toe in Toe in B A 0 10mm Toe in out of the range Adjust the locknut of tie rod Note After the toe in has been adjusted slowly run the vehicle to check whether the direction of vehicle can be controlled by steering wheel 3 ...

Page 54: ...cause deflected wear of the tires Specified pressure tire Front wheel Rear wheel Pressure 96 5 3 5kPa 14 0 5PSI 96 5 3 5kPa 14 0 5PSI Tires sizes 27 9 14 27 11 14 OPTIONAL Front wheel Rear wheel Pressure 82 5 3 5kPa 12 0 5PSI 82 5 3 5kPa 12 0 5PSI Tires sizes 26 9 14 26 11 14 Tire Tread Check the tire tread Tread Height if 3mm then Replace with new tires Note When the tread height is less than 3mm...

Page 55: ...heel Bearing Lift the front wheel Make sure there is loading on the vehicle shake the wheel in axial direction for any sway In case of any sway disassemble the front wheel and check the bearing Suspension System Park the vehicle on lever place press the vehicle Several times up and down as illustrated on the right In case of any rocking or abnormal noise check whether there is any oil leakage from...

Page 56: ...ting Shift the gear to check for flexibility and gear engagement Adjust the gearshift rod if necessary Release the lock nut to adjust the length of gearshift rod Fuel Device Status of the fuel system Remove the seat Check the fuel hose for any aging or damage Aged or damaged fuel hose Replace Check if there is cracks or bending with the fuel hose Cracked or bended fuel hose Replace ...

Page 57: ...djust Loosen locknut of throttle cable turn the regulator and adjust free play of throttle pedal After adjusting tighten locknuts and install throttle cable sleeve Replace with a new throttle cable if the specified free play could not be acquired by adjusting the regulator or if there is still stickiness with the throttle 3 ...

Page 58: ...ts into eyes rinse with plenty of water and go to consult the doctor In case of swallowing the coolant induce vomit and consult the doctor Keep the coolant in a safe place and away from reach of children Coolant level Coolant might reduce due to natural evaporation Check the coolant level regularly Note Coolant can prevent rust and resist freeze Ordinary water may cause engine rust or cracks in wi...

Page 59: ... leakage In case of any leakage disassemble and do further check Refer to Chapter 4 Check the radiator hose for aging damages or cracks The rubber hose will naturally get aged after a period of service time The aged hose may get cracked when the cooling system is heated Nip the hose with fingers and check if there are any tiny cracks In case of any abnormal replace with a new hose Check the clamps...

Page 60: ...duce vomit immediately and see a physician Store the coolant properly and keep it away from reach of children Check radiator fins for mud block and or damage Correct the bent fins Clean off the mud With water and compressed air Replace with a new one if the damaged fin area reached 20 The overhauling of the water pump can be done without removing the engine Add coolant through reservoir tank Do no...

Page 61: ...ed radiator fin Coolant is not enough Faulty or malfunction of fan motor No rise or slow rise of water temperature Faulty thermostat thermostat is not closed Faulty circuit of water temperature display Coolant leakage Faulty water seal O rings are aged damaged or improperly sealed Washers are aged damaged or improperly sealed Improper installation of pipes or hoses Pipes and or hoses are aged dama...

Page 62: ... Check coolant for stains or impurities Inspection of radiator cap Note Open the radiator cap after the coolant is fully cooled Remove Remove bolt 1 and battery panel Remove radiator cap counter clockwise Note Apply coolant on the sealing surface of radiator cap before attaching the tester to the radiator cap Install the radiator cap tester to the radiator cap Apply the specified pressure radiator...

Page 63: ...t splashes in your eyes thoroughly wash your eyes with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomit immediately and see a physician Store the coolant properly and keep it away from reach of children Note Mix the coolant undiluted with soft water according to the temperature 5 lower t...

Page 64: ... cooling system and install the radiator cap Remove reservoir tank cap and add coolant till the full limit Note Check coolant level when the vehicle is on an even ground Air Discharge Discharge the air from cooling system according to the following steps 1 Start the engine and run it several minutes at idle speed 2 Quickly increase throttle 3 4 times to discharge air from cooling system 3 Add cool...

Page 65: ...4 COOLING SYSTEM 4 6 Cooling System Chart 4 ...

Page 66: ...RBLOCK RADIATOR 8 CLAMP 25 38 9 INLET PIPE ENGINE FRONT 10 TIE IN INTAKE PIPE 11 INLET PIPE ENGINE MIDDLE 12 INLET PIPE ENGINE REAR 13 T JOINT WATER PIPE 14 CLAMP 13 19 15 CYCLE PIPE REAR 16 OUTLET PIPE ENGINE FRONT 17 OUTLET PIPE ENGINE RAER 18 BOLT FLANGE M6 16 19 CYCLE PIPE FRONT 20 EXHAUST VALVE 21 CYCLE PIPE FRONT 22 BOLT M6 20 23 SPACER BUSH 24 WATER HOSE 2 φ6 φ10 200 ...

Page 67: ...Don t damnify the frame body of Engine bolt and cable etc Please blind up the frame when removal the engine Don t removal engine from the bodywork when operating as follows THROTTLE VALVE BODY AIR FILTER CVT SYSTEM CVT COVER FAN COVER ENGINE IGNITION COIL CAMSHAFT POSITION SENSOR CRANKCASE POSITION SENSOR Following operation require removal of engine from vehicle CRANKCASE Tightening torque RUBBER...

Page 68: ... Remove seat Remove plastic covers Remove air filter Remove exhaust pipe and muffler Remove hoop Remove water inlet hose of engine Remove bolt 1 Remove gear shift rod A Remove hoop Remove water outlet hose of engine Remove nut Remove the throttle cable Remove hoop Remove circulating water hose ...

Page 69: ...5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT 5 3 Remove all the connector of engine Remove the connector of ECU Remove tension spring of exhaust pipe Remove catalytic converter Remove muffler 5 ...

Page 70: ...STEM AND GEARSHIFT 5 4 Remove the connector of oxygen sensor Remove two nuts Remove exhaust pipe Remove hoop of air filter Remove two bolts Remove air filter Remove hoop of air inlet duct for CVT Remove bolt Remove air inlet duct of CVT ...

Page 71: ... DRIVER 43 CVT BELT 44 CVT IMPELLER 45 SPACER BUSH DRIVER 46 WASHER φ12 5 φ30 3 47 SPRING WASHER φ12 48 BOLT M12 175 49 SEAL CVT COVER LONG 50 SEAL CVT COVER SHORT 51 BOLT M6 12 52 CRANKSHAFT SENSOR 53 CVT COVER LEFT 54 JOINT AIR INLET DUCT 55 BOLT M6 15 56 WASHER φ6 φ12 1 6 57 CVT PIN 58 BOLT M6 25 59 CVT COVER RIGHT 60 CIRCLIP 80 100 61 RUBBER PIPE φ85 φ92 60 62 CVT HOSE IMPORT WIND 63 EXPANSION...

Page 72: ...ENGING 13 CLAMP φ10 14 FUEL HOSEΦ6 Φ10 5 400 15 GEAR BOX 16 COBBRA ENGINE HOSE 17 STOPPER ENGINE HOSE 18 CIRCLIP 16 25 19 BOLT M12 1 25 45 20 LOCKNUT FLANGE M10 1 25 21 BOLT FLANGE M12 1 25 35 22 ENGINE SUPPORT B 23 ENVELOP BOARD ENGINE 24 OUTLET WATER GAP ENGINE 25 BOLT M8 35 26 CVT SUPPORT COVER 27 SPRING WASHER φ12 28 BOLT FLANGE M12 1 75 30 29 FLANGE PLATE CVT SUPPORT 30 BOLT M10 20 31 NUT FLA...

Page 73: ... 8 Chapter 9 Remove front axle Remove bolt 1 Remove drive shaft front Remove bolt 2 Remove front axle Installation Installation as contradictorily process of remove Bolt torque of front axle M8 23 25N m Bolt torque of front axle M10 45 50N m Bolt torque of front drive shaft M8 23 25N m Remove rear axle Remove bolt 1 Remove drive shaft front Remove bolt 2 Remove front axle Installation Installation...

Page 74: ... 8 LOCKNUT FLANGE M10 1 25 9 HOLDER FRONT AXLE FR 10 HOLDER FRONT AXLE RR 11 AIR HOSE AXLE φ6 φ8 450 12 CLAMP φ10 13 REAR AXLE 14 SUPPORT PARKING CALIPER 15 BOLT M8 45 16 CIRCLIP φ32 17 BOLT FLANGE M12 1 25 115 18 SUPPORT REAR AXLE R 19 HOLDER REAR AXLE RR 20 LOCKNUT FLANGE M12 1 25 21 COUPLING FLANGE 22 WASHER φ14 φ28 2 23 NUT M14 1 25 24 PARKING DISC 25 PARKING CALIPER 26 SPRING WASHER φ8 27 BOL...

Page 75: ...2 2 Disassembly 23 3 Routine Inspection 23 4 Water Pump 29 1 Structure Diagram 29 2 Disassembly 29 3 Cleanup 29 4 Routine Inspection 29 5 Assembly 29 5 Oil Pump 29 1 Structure Diagram 30 2 Disassembly 30 3 Cleanup 30 4 Disassembly and Assembly of Engine Oil Pump 43 4 1 Structure Diagram 42 4 2 Disassembly 42 4 3 Routine Inspection 42 4 4 Installation 44 5 Disassembly of Oil Seal 45 5 1 Structure D...

Page 76: ...ain Fit Clearance for SQR472 Engine 55 Chapter 4 Table of Measurement Parameters of SQR472 Engine 59 Chapter 5 Table of Main Fitting Torque for SQR472 Engine 61 Chapter 6 Positions on SQR472 Engine to be Lubricated 62 Chapter 7 Positions on SQR472 Engine to be Spread with Sealant 65 ...

Page 77: ...omponents and installation status are set forth at the beginning of each chapter or section 2 The number in the figure refers to the disassembly sequence of each component The components which may not be reused and the tightening torque are indicated in the figure Seal Ring Engine Oil Pump Cover Sheet Engine Oil Pump Outer Rotor Engine Oil Pump Inner Rotor Cotter Pin Oil Drain Valve Spring Seat Oi...

Page 78: ...tion to the operation description It records the operation descriptions of cases about person accident 2 Meaning of Marks and Abbreviations Mark Original Words Intepretation RH Right Hand Right Hand LH Left Hand Left Hand FR Front Front RR Rear Rear IN Intake Intake EX Exhaust Exhaust SAE Society of Automotive Engineers Society of Automotive Engineers API American Petroleum Institute American Petr...

Page 79: ...sassembly and assembly of engine Clamp hole wrench for camshaft timing gears Disassembly of camshaft timing gears Spring bushing puller Assembly of camshaft Oil seal Valve keeper remove tool Auxiliary tools Assembly and disassembly of valve spring retainer lock Flywheel clamp Assembly and disassembly of crankshaft gear Valve guide punch pin Disassembly and assembly of Valve guide Axial Oil seal re...

Page 80: ...oil seal Crankshaft pulley holding tool Disassembly and assembly of crankshaft pulley Wrench Disassembly and assembly of crankshaft driven gear Replace valve clearance adjustment gasket Water pump pulley locking wrench Assembly of coolant pump Measuring tools Feeler gauge Micrometer caliper Ruler Dial gauge Cylinder gauge Caliber Pressure gauge Torque wrench torque wrench Tool Piston ring extracto...

Page 81: ...ble or assemble the engine with roll over stand Disassemble or assemble the engine parts on the roll over stand 1 Timing Belt 1 Structure Diagram Water pump pulley Timing shroud Timing belt Torsional damper Timing belt back plate Tension pulley Camshaft timing pulley Components which may not be reused Unit N m kg cm ...

Page 82: ...al tool Torque 25 1 5 N m 2 2 Disassembly of Timing Belt Cover Torque 6 1N m 2 3 Disassembly of torsional damper Use special tools to prevent the gear ring from rotating When disassembling the fixing bolts of the torsional damper make sure that the marks on the crankshaft timing pulley match with the timing marks on the engine oil pump 2 4 Remove the timing belt back plate ...

Page 83: ...cover 2 5 2 Screw off the bolt of tension pulley and remove the tension pulley 2 6 Disassembly of timing belt Notice Do not use sharp tools like screwdriver during disassembly of belt Notice Pay attention to the following items during using the timing belt l Do not bend the belt with small angle or the rigging in belt will break l Do not pollute grease and water because the using expectancy of bel...

Page 84: ...r pump leaks water out and requires continuing infusion If the belt is spotted with much oil stains and the rubber may be damaged due to expansion you should replace the belt Timing belt model and type Part number 372 1007081 Width of belt ２５ 3mm Tension Pulley of Timing BeltRotate the bolt of tension pulley bracket and hear if it is noisy check the contacting surface and look if it is damaged Mod...

Page 85: ...with bolts The tightening torque for the bolts is 100 5Nm Make sure that the clashing mark of crankshaft timing pulley aligns with the mark of oil pump 3 3 Install the tension pulley After adjust the tension of timing belt install the tension pulley bolt and tighten it with the torque specified Adjust the tension of the timing belt acording to the following instruction and install the tension pull...

Page 86: ...e deflection can not reach the standard it is necessary to adjust the fixing bolt of tension pulley mentioned above Tighten the fixing bolt of the tension pulley with the torque as specified The tightening torque is 25 3N m 3 4 Assembly of Timing Belt Back Plate Notice Install the timing belt back plate in the direction as indicated in the right figure 3 5 Install the torsional damper with special...

Page 87: ...ount the sealing strips at the positions as indicated in the right figure The sealing strips at the position 1 and 2 should be mounted before the assembly of the cylinder head assembly and the sealing strip at the position 3 should be mounted before tightening the water pump Install the timing cover screw in the bolts with hand and then tighten them Torque 6 1N m 3 7 Installation of water pump pul...

Page 88: ...y 2 Cylinder head cover gasket 3 Camshaft timing belt 4 Camshaft cover 5 Blanking cover 6 Camshaft bearing cap 7 Exhaust camshaft assembly 8 Intake camshaft assembly 9 Camshaft oil seal 10 Axial spring retainer ring 11 Saddle washer 12 Intake camshaft sub gear 13 Transmission ring Components which may not be reused Unit N m kg cm ...

Page 89: ...emove the camshaft timing gear with special tool Notice The special tool should be made as indicated in the right figure Use the special tool to prevent the camshaft from rotating 2 3 Remove the camshaft bearing cap 2 3 1 The marks on the camshaft gear should match with each other as indicated in the right figure Timing Mark Gear of Intake Camshaft Gear of Exhaust Camshaft ...

Page 90: ...operate as indicated in the right figure Clamp the camshaft and plug the pins of special tool into the hole on gear rotate the gear to keep the meshing of driven gear and driving gear and then remove the fixing bolt of driven gear Notice The surface of the camshaft may not be damaged 2 6 2 If not using the special tools operate as indicated in the right figure 1 Screw M6 bolts onto the sub gear of...

Page 91: ...ad 2 Confirm the mark forwards on the bearing cap as well as the axle number and then tighten the bolts 3 Measure the clearance of engaging tooth of the intake camshaft with dia indicator Notice Measure at 4 points on the circle of the piston Turn the intake camshaft with special tools Make sure that the marks on the driven gear and the driving gear of the camshaft match with each other Inspect th...

Page 92: ...h bolts M5 0 8 Notice Don t damage the journal adjust the operation 3 3 Assembly of camshaft Notice Pay attention to the axial clearance of the camshaft 3 3 1 Spread grease on the gear of camshaft and the axial of cylinder head 3 3 2 Remove the fixing bolts for camshaft driven gear after mounting the camshaft 3 3 3 Mount the camshaft align the timing mark as can be seen from the right picture 3 3 ...

Page 93: ...ated in the right figure After being pressed the blanking cover should be 1 1mm higher than the surface of thecylinder head 3 7 Spread the edge of the camshaft oil seal with oil and press it into the cylinder head with M10 bolt length 50 60mm and special tools Notice If the oil seal is reused spread it with oil before pressing it into the cylinder head After removing the bolt knock it with hand so...

Page 94: ... as indicated in the right figure and with the specified torque Torque 6 1N m 4 Inspection of valve 4 1 Standard valve clearance IN 0 18 0 05 Valve clearance EX 0 25 0 05 4 2 Make sure that the timing mark on the camshaft driving gear is aligned with that on the camshaft driven gear 4 3 Inspect the valve clearance as specified in the figure below with the feeler gauge Cylinder 1 Cylinder 2 Cylinde...

Page 95: ...m head of the cylinder which exceeds the standard value faces upwards and the opening of the valve tappet face inwards 4 4 2 Rotate the crankshaft and press down the valve tappet with the crown head of the cylinder cam 4 4 3 As indicated in the right figure put special tools on and around the valve tappet from the inside of the cylinder head and then rotate the crankshaft so that the crown head of...

Page 96: ...2 44 2 66 2 24 2 46 2 68 2 26 2 48 2 70 2 28 2 50 2 72 2 30 2 52 2 74 2 36 2 58 2 80 2 32 2 54 2 76 2 38 2 6 4 4 3 4 Adjust the valve clearance with selected adjustment gasket Notice Install the adjustment gasket with its identification mark facing downwards 4 4 3 5 Rotate the crankshaft so that the crown head of the cam faces downwards and presses down the the valve Pick up the special tool 4 4 3...

Page 97: ...nder cushion 5 Adjustment gasket 6 Valve tappet 7 Valve spring retainer 8 Valve spring seat 9 Valve Spring 10 Intake valve 11 Exhaust valve 12 Valve oil seal 13 Valve seat 14 Valve guide 2 Disassembly 2 1 Disassembly of spark plug 2 2 There are 8 boltes on the cylinder head In the course Components which may not be reused ...

Page 98: ... seat valve spring intake valve and exhaust Valve etc with special tools 2 6 Disassembly of valve oil seal and valve spring gasket 2 7 Cleanup 2 7 1 Clean the carbon dust on the valve 2 7 2 Clean the bottom surface of cylinder head and the surface of intake and exhaust manifold with scraper knife Notice The surface of the cylinder head may not be scratched in the course of cleanup Do not pollute t...

Page 99: ...meter of valve guide with dial gauge the outer diameter of valve stem with micrometer caliper 3 3 2 2 Figure out the difference of measured values and the clearance If the clearance is beyond the specified value replace valve or guide Notice As can be seen from the right picture at measuring point work out the clearance of last abrasion part Item Standard value Limit 0 10 Valve guide inside diamet...

Page 100: ...Mount the new valve guide with special tool at the place as can be seen from the right picture Notice strike the conduit slowly to the position in the cylinder head do not strike too far and be careful for size The height of the part of valve guide struck into the cylinder head Type Item EF GL ZL RL GS ZS Height mm IN 13 71 0 25 EX 12 11 0 25 3 3 3 4 Rub the inside diameter with reamer to reach th...

Page 101: ...sorted position with inner 70and outer 30 3 3 4 6 Prepare for polishing of valve seal 3 4 Assembly of cylinder head 3 4 1 Cylinder head Pay attention to the following for installing the other auxiliary part of cylinder head 3 4 2 Protective tube of spark plug 1 Press the protective tube of spark plug into the protective tube hole on the cylinder head with the special auxiliary tool Before pressing...

Page 102: ...y of intake valve and exhaust valve 3 4 3 2 1 Assembly of valve spring Notice The painting is used for recognizing the different suppliers so the same engine should use the valve spring with same painting 3 4 3 3 Assembly of valve keeper Warning Operate with goggle for protecting the eyes Be care for spring jumping out After assembly of valve spring and its seat press the valve spring with special...

Page 103: ... indicated in the right figure for 3 times till the torque reaches the specified value The tightening torque for each time is set forth as follows First time 30 2Nm second time 50 3Nm third time 70 3 5Nm Torque 70 3 5N m 3 4 4 3 Mount spark plug Torque 20 1Nm Notice Tools should be vertical to prevent the protective tube of spark plug from distorting or the oil will leak Oil Spread Position ...

Page 104: ...reusable 2 2 Screw off 3 bolts and disassemble water pump body 2 3 Disassembly of dust seal 3 Cleanup 3 1 Clean water pump joint surface 4 Routine Inspection 4 1 Check if it is deformed 4 2 Rotate it with hand and inspect whether the rotor rotates and is lubricated well 5 Assembly 5 1 Mount Dust seal 5 2 Mount Water Pump Body torque 25 1 5N m 5 3 Mount The New O ring Components which may not be re...

Page 105: ...il collector spacer nonreusable Oil pump Oil pump spacer nonreusable Rear oil seal bracket 2 Disassembly 2 1 Screw off the bolts and nuts and then remove the oil pan from the cylinder body with special tool The engine is placed on the disassemble shelf upside down Notice Don t make the oil pan flange deform Components which may not be reused ...

Page 106: ...tice The oil collector gasket is nonreusable 2 3 Remove the engine oil pump assembly and the engine oil pump gasket 2 4 Remove the rear oil seal bracket 3 Cleanup 3 1 Remove the old cushion from the oil pan oil pump and oil pan bracket with a scraper or shovel Notice Don t let the fragment of the cushion fall into the cylinder ...

Page 107: ...otter Pin Oil Drain Valve Spring base Oil Drain Valve Spring Slide Block Crankshaft Front Oil Seal Engine Oil Pump Housing 4 2 Disassembly 4 2 1 O ring Notice The O ring is nonreusable 4 2 2 Remove the oil pump cover Notice If the screws are tightened use a screw driver to remove them as indicated in the figure 4 2 3 Remove the inner rotor outer rotor of the engine oil pump Components which may no...

Page 108: ...p and oil pressure relief valve etc 4 2 6 Remove the front crankshaft oil seal Notice The oil seal removed may not be reused 4 3 Routine Inspection 4 3 1 Inspect the engine oil pump for clearance 4 3 1 1 According to the marks for inner gear and outer gear in the engine oil pump put the gears into the engine oil pump that is in the cylinder block 4 3 1 2 Measure the clearance between the inner and...

Page 109: ...the oil pressure relief valve 4 4 Installation 4 4 1 After the lip of the new oil seal for front crankshaft is spread with engine oil fix it with a special tool Notice Use new oil seal The oil seal should be left less than 0 5 mm at its outer edge after it is pressed down 4 4 2 Assembly of the oil pressure relief valve for engine oil pump and the cotter pin Notice The cotter pin is nonreusable Spe...

Page 110: ...6 4 4 3 When the outer gear or inner gear is put into the engine oil pump its mark should be seen 4 4 4 The new weather strip should be fixed in the groove of oil pump cover 5 Disassembly of Oil Seal 5 1 Structure Diagram Mark Components which may not be reused ...

Page 111: ... oil seal with special tool as indicated in the right figure 6 Assembly 6 1 Assembly of the oil seal seat Spread sealant over the oil seal seat as shown in the right figure Grease Loctite 5699 Notice Spread the liquid sealant on the position of the oil seal base which is to contact with the cylinder body and make sure the width of the sealant is 3 4mm Torque 25 1 5N m 6 2 Assembly of the new engin...

Page 112: ...l pan with the cylinder 6 4 2 Spread sealant then assemble it Grease Loctite 5699 Notice The sealing line should be unbroken with its diameter being ф3 4mm Assembly should take place fifteen minutes after glue spreading 6 4 3 Tighten the bolts in the middle first up to the specified torque then the bolts beside them as shown in the right figure Torque 6 1N m Front Rear ...

Page 113: ...1 Structure Diagram Connecting rod cover Connecting rod bushing Piston connecting rod assembly Main bearing cap Crankshaft Crankshaft bearing bushing Thrust plate Cylinder body First ring Second ring Steel tape combined oil ring Piston Connecting rod Piston pin Components which may not be reused ...

Page 114: ...ecting rod bushing for its radial clearance 2 2 1 Remove the bushing cap Notice The components of each cylinder shall be placed in order 2 2 2 Clean the bearing bushing and the axle 2 2 3 Conduct radial adjustment for the axial diameter of connecting rod with clearance gauge Tighten the bushing cap with specified torque Torque 40 2N m Notice The crankshaft may not rotate 2 2 4 Remove the bushing c...

Page 115: ...e connecting rod bearing bushing 2 2 7 Put vinyl resin protecting jacket on the threaded part of the connecting rod bolt so as to prevent the bolts from scraping the cylinder hole and the crannkshaft connecting rod journal and then disassemble the piston connecting rod by using the hammer handle striking it out 2 3 Inspect the axial clearance of crankshaft 2 3 1 Measure the axial clearance of the ...

Page 116: ...N m Notice After tightening the bolts the rotating torque of the crankshaft should be less than 1Nm The torque of crankshaft without piston connecting rod 2 4 4 Remove the bearing cap and measure the maximum width with a clearance gauge If the measurement result exceeds the limit replace the bearing bushing Standard value 0 025 0 069mm Limit 0 10mm 2 4 5 Remove the main bearing bushing cap of the ...

Page 117: ...e As indicated in the right figure disassemble the piston which is at the state mentioned above with special tools Remove the piston pin with special tool and then remove the piston and the connecting rod 3 Cleanup 3 1 Cylinder Body Warning In the course of cleanup protect your eyes with eyeglass 3 1 1 Clean up the cylinder body cylinder head oil pan oil pump and the oil seal with a flat blade 3 2...

Page 118: ...a b Cylindric degree A a or Reference Standard diameter of cylinder φ72 00 72 01mm 4 2 Piston 4 2 1 Inspect the piston pin hole for its clearance Measure the piston pin at several positions with a micrometer caliper shown in the figure make the maximum value as the diameter of pin 4 2 2 Measure the diameter of piston pin at several positions with an inner diameter dial gauge as shown in the figure...

Page 119: ... the ring gloove 4 2 5 1 Measure around the ring gloove with a piston ring and a feeler gauge Standard value mm Limit mm First ring 0 03 0 06 0 12 Second ring 0 03 0 06 0 11 4 2 6 Inspect the end clearance of piston ring 4 2 6 1 Put the piston ring 45mm below the top surface of the cylinder hole Press down the piston ring with the piston head and then measure the opening with a feeler gauge Standa...

Page 120: ... Crankshaft 4 3 1 Inspect the proper alignment of the main axle diameter 4 3 1 1 Measure the proper alignment with a dial gauge if the proper alignment is beyond the limit replace the crankshaft Limit 0 03mm Notice The bending value should be equal to one second the run out value of crankshaft rotating one circle 4 3 2 Inspect the crankshaft for the abrasion 4 3 2 1 Measure the connecting rod jour...

Page 121: ...achine Notice When pressing in the piston pin make sure the fitting direction is correct When the piston pin is pressed into the piston the small end of the connecting rod should be heated to 300 and the pin should be aligned properly 5 2 Install the first and second pistion ring and the oil ring according to the following instruction 5 2 1 Installation of piston ring Make the side with marks face...

Page 122: ...hat the side with oil gloove crankshaft shank face outwards Notice Spread the side of oil glove with oil 5 3 4 Fix the crankshaft bearing bushing lower piece in the bearing cap the bearing bushing should fit into the thrust groove 5 3 5 Spread engine oil over the friction surface of crankshaft bearing bushing lower piece assemble the bushing according to the mark forwards in the main bearing cap o...

Page 123: ...s should be spread with engine oil 5 4 4 Confirm the mark forwards of the piston and strike it into the cylinder body with the piston ring striking tool Notice The cylinder number of the piston and connecting rod assembly should be in accordance with the cylinder number 5 4 5 Assemble the connecting rod bearing cap and the connecting rod bushing pay attention to the following 5 4 5 1 Put the cover...

Page 124: ... Crankshaft Connecting Rod Bearing Name of Component Size and Tolerance Clearance or Value of Interferenc Remark Crankshaft connecting rod journal φ37h6 0 016 0 Bearing bushing 1 5 0 006 0 Bore of connecting rodbig end bearing φ40F6 041 0 025 0 Clearance 0 025 0 069 4 Clearance between Piston Pin and Piston Pin Hole Name of Component Size and Tolerance Clearance or Value of Interferenc Remark Pist...

Page 125: ... f6 005 0 014 0 Clearance 0 005 0 029 8 Radial Clearance of Camshaft Bearing Name of Component Size and Tolerance Clearance or Value of Interferenc Remark Cylinder Head φ26H7 021 0 0 1st bearing cap Camshaft φ26f6 020 0 033 0 Clearance 0 020 0 054 1st bearing cap Cylinder Head φ23H7 021 0 0 2nd 3rd 4th 5th bearing caps Intake Camshaft φ23f6 020 0 033 0 Clearance 0 020 0 054 2nd 3rd 4th 5th bearing...

Page 126: ...lt and spark plug on the cyllinder head tighten the camshaft bolt and then measure the torque of the camshaft rotating at uniform speed 32 Nm 3 Distance between the outer edge of steel ball and the front end of camshaft 5 65 0 5mm 4 Distance between the outer edge of steel ball and the rear end of camshaft 8 65 0 5mm 5 Axial clearance of intake camshaft 0 10 0 179 6 Axial clearance of exhaust cams...

Page 127: ...plug M12 1 45 3 9 Oil pan bolt M6 19 6 1 10 Bolt connecting exhaust camshaft with flange hexagonal M6 4 6 1 11 Exhaust camshaft locking nut M40X1 5 L 1 100 5 12 Cylinder head bolt M10X1 25 10 70 3 5 13 Camshaft bearing cap bolt M6 19 9 1 14 Cylinder head chamber cover bolt M6 8 4 5 0 5 15 Camshaft position sensor bolt M8 1 10 1 16 Bolt knock sensor M8 1 20 1 5 17 Camshaft timing gear bolt M12X1 25...

Page 128: ...25 1 100 5 32 Water pump pulley bolt M6 4 6 1 33 Water temperature sensor M12X1 5 1 15 1 5 34 Oil pressure switch 1 30 2 35 Spark plug M14X1 25 4 20 1 36 Fixing Bolt of spark plug cover board M6 8 2 5 0 5 37 Bolt intake pipe front bracket M8 1 20 1 5 38 Bolt intake pipe rear bracket M8 4 20 1 5 39 Bolt throttle cable M6 2 6 1 40 Bolt gas oil spearator bracket M6 2 6 1 41 Bolt throttle valve casing...

Page 129: ...g 6 Inner wall of cylinder hole 7 Crankshaft main neck 8 Connecting rod shaft neck 9 Upper lower main bearing bushing inside 10 Upper lower connecting rod bearing bushing inside 11 Crankshaft thrust plate the side of oil gloove 12 Front oil seal and crankshaft front oil seal journal 13 Rear oil seal and crankshaft rear oil seal journal 14 Valve seat hole 15 Valve tappet and valve pipe hole 16 Exci...

Page 130: ...octite 5699 ф 3 4 mm 5 Joint surface of camshaft cover Loctite 5699 ф 3 4 mm 6 Sealing surface of the bowl shaped plug of cylinder head Loctite 11747 Spread uniformly 7 Flywheel bolt Loctite 204 0 125 ml 6 Pre spread 3 8 Intake pipe stud Loctite 262 0 125 ml 7 The part screwed into the cylinder head 9 Exhaust pipe stud Loctite 262 0 125 ml 6 The part screwed into the cylinder head 10 Camshaft timi...

Page 131: ... 2 Fuel Injector System Disassembly Installation 7 3 High Pressure Fuel Line Disassembly Installation 7 4 Throttle Body Disassembly Installation 7 4 Fuel rail with injector assy Disassembly Installation 7 5 Fuel injector Removal Assembly 7 5 7 ...

Page 132: ...y dishcloth or tape for avoiding the entry of other objects into the engine from the air intake side of the engine When the vehicle will be stored for more than one month the gasoline in the high pressure fuel line and cap of the fuel injector must be discharged Otherwise the gasoline will age and form colloidal elements which may block the nozzle of fuel injector therefore the engine cannot start...

Page 133: ...300mm 8 BOLT FLANGE M8 16 9 FUEL FILTER ASSY 10 FUEL HOSE 400mm 11 PROTECTIVE SLEEVE FUEL TANK CAP 12 CAP FUEL TANK 13 SUPPORT FUEL TANK L 14 BOLT FLANGE M6 12 15 SUPPORT FUEL TANK R 16 CLAMP φ10 17 LOCKNUT FLANGE M6 18 INLET WINDPIPE FRONT 19 INLET WINDPIPE MIDDLE 20 RELAY CARBON CANISTER 21 INLET WINDPIPE RAER 22 CARBON CANISTER 23 DEAD PLATE CARBON CANISTER 24 RIVET 5 20 7 ...

Page 134: ...throttle valve opening sensor Remove the connector of idling solenoid valve sensor Loosen locknut remove adjust nut and remove the throttle cable from throttle rotory sleeve Loosen air filter clamp Remove intake tube of air filter Remove 2 clamps and remove circulating water hose Remove 4 bolts and remove throttle body Throttle Body Installation Reverse the disassembly procedure for installation N...

Page 135: ...l with injector assy Fuel rail with injector assy installation Reverse the disassembly procedure for installation Fuel injector removal Use Slotted screwdriver to remove snap spring Remove fuel injector from fuel rail with injector assy Fuel injector assembly install Install fuel injector into the fuel rail with injector assembly Press the snap spring into groove of fuel injector snap spring 7 ...

Page 136: ...n the wheel Avoid any damage to the wheel When removing tire use the special tire lever and rim protector Maintenance Standard Item Standard Service Limit Longitudinal 0 8mm 2 0mm Rim Vibration Lateral 0 8mm 2 0mm Remained groove 3 0mm 12 0 5PSI 82 5 3 5KPa Tire Tire pressure 12 0 5PSI 82 5 3 5KPa Front brake Free play brake lever 0mm Tightening Torque Nut Tie rod 20 30 N m Lock nut steering stem ...

Page 137: ...eformed frame Worn tiers Shaking of wheel bearing Vibration of Front Wheel Wheel rim distorted Faulty wheel bearing Faulty tire Improper balance of wheels Improper tightening of wheel axle Wheel Cannot Turn Freely Faulty wheel bearing Front wheel axle is bended Brake drag Faulty steering structure Front Suspension is Too Soft Weakened front shock absorbers Tire pressure is too low Front Suspension...

Page 138: ...wly turn the wheel measure the rim vibra tion with a dial gauge Service limit Axial 2 0mm Radial 2 0mm Assembly Press rim into wheel Install rim on the wheel hub Tightening Torque Bolt Wheel Hub 40 50 N m Front Wheel Hub Disassembly Remove Front wheel 8 3 Front brake caliper 8 4 Rim axle nut Brake disc and wheel hub 4 bolts from front brake disc Wheel hub Installation Reverse the removal procedure...

Page 139: ...aliper Removal Remove Front wheel 8 3 2 bolts from arm Front caliper Inspection Check brake caliper for cracks and tightening parts for oil leakage Replace if any Installation Reverse the removal procedure for installation Tightening Torque Fixing Bolt Brake Caliper 45 50N m 8 ...

Page 140: ...que Fixing bolt brake disc 40 50N m Brake Master Cylinder Disassembly Remove Blot 1 Cotter pin Pin shaft Do not remove brake master cylinder from vehicle unless when replacing master cylinder assembly Note Do not hang master cylinder on brake hose Do not put the master cylinder upside down to avoid possible entrance of air into brake system Keep the master cylinder in the installation position Pro...

Page 141: ...sassembly of front brake master cylinder 8 5 Installation Reverse the removal procedure for installation NOTE Do not put the master cylinder upside down to avoid possible entrance of air into brake system Keep the master cylinder in the installation position Refer to Chapter1 for proper routing of brake hose Check brake efficiency after installation 8 ...

Page 142: ...a level ground and securely support front part of the vehicle Removal Remove Front wheel 8 3 Front wheel hub 8 3 Front brake caliper 8 4 Bolt1 Nut1 Shock absorber Bolt2 Nut to Bolt2 for Front Left Arm Upper Bolt2 Nut to Bolt2 for Front Left Arm Lower Remove steering tie rod ball pin slot nut 3 Remove steering tie rod Pull up joint knuckle from the driveshaft remove front left suspension assy ...

Page 143: ...IGHT ARM UPPER Disassembly Disassembly Front Left Shock Absorber Disassembly ATTENTION You do not need to remove any other parts if you only replace the front suspension Park the vehicle on a level ground Remove front left shock absorber s bolt nut installed in arm Remove front left shock absorber Inspection Inspect the shock for oil leakage oil seal damage destroy replace if needed 21 BOLT FLANGE...

Page 144: ...own of the vehicle Park the vehicle on a level ground and securely support front part of the vehicle Removal Remove Front wheel 8 3 Front wheel hub 8 3 Front brake caliper 8 4 Bolt1 Nut1 Front Right Shock absorber Bolt Nut to Bolt for Front Right Arm Upper Bolt Nut to Bolt for Front Right Arm Lower Remove steering tie rod ball pin slot nut Remove steering tie rod Pull up joint knuckle from the dri...

Page 145: ...ive Shaft of Front Axle only does not require removal of Front Suspension Remove Front left wheel 8 3 Front left brake caliper 8 4 Front left wheel hub 8 3 Check dust boot Damaged dust boot Replace Shake constant velocity drive shaft check the agility of rzeppa universal joint free turning of bearing and any gap between rzeppa constant velocity joint and spline Stagnated turning noise gap with spl...

Page 146: ...8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING 8 11 Steering System Cover Steering Stem Removal Remove cover steering stem Chapter 2 Combination Switch Removal Remove combination switch 2 3 ...

Page 147: ...ON STEERING 8 12 Rear View Mirror Removal Remove left and right rear view mirrors Note Left rear view mirror is right threaded Turn counter clockwise for removal Note Right rear view mirror is left threaded Turn clockwise for removal 8 ...

Page 148: ...8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING 8 13 Steering Stem Removal Remove Steering wheel 2 2 cover steering stem 2 2 Combination switch 2 3 Bolt Shaft assy steering joint Steering stem ...

Page 149: ...8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING 8 14 Installation of Combination Switch Install combination switch 2 11 Insert main cable with connector of combination switch 8 ...

Page 150: ...NG STRENGTHENER 9 BOLT FLANGE M8 25 10 STEERING STRENGTHENER 11 FLANGE STEERING STRENGTHENER 12 BEARING 13 BOLT FLANGE M8 30 14 CIRCLIP ф30 15 OIL SEAL STEERING STRENGTHENER 16 STEERING SHAFT TOP 17 GASKET ф14 ф26 3 18 SPACER BUSH NYLON 19 LOCKING NUT M8 20 SPACER BUSH NYLON 21 BOLT STEERING COLUMN 22 LOCKING NUT M6 23 GAS SRPING STEERING COLUMN 24 BOLT M6 25 STEERING COLUMN 26 SPRING WASHER 27 CO...

Page 151: ...le damage to the wheels When removing tire from rim use special tire lever and rim protector to avoid damage to the rim Overhaul standard Item Standard Limit Longitudinal 2 0mm Rim vibration Horizontal 2 0mm Remained Tire Tread 3 0mm Tire pressure front 12 0 5PSI 82 5 3 5KPa Rear wheel Tire Tire pressure rear 12 0 5PSI 82 5 3 5KPa Rear brake Brake pedal Free Play 0mm Tightening torque Rear wheel a...

Page 152: ... balance Improper tightening of wheel axle nut Loosened wheel nut Rear shock absorber is too soft Weak spring Oil leakage from rear shock absorber Rear shock absorber is too hard Bent rear shock absorber Tire pressure is too high Poor brake efficiency Improper brake adjustment Stained brake pad or brake disk Worn or damaged brake pad ...

Page 153: ...Slowly turn the wheel measure the rim vibration with a dial gauge Service limit Axial 2 0mm Radial 2 0mm Installation Refer to front wheel installation 8 3 Wheel hub removal Remove rear wheel 9 3 Remove brake caliper Remove mounting bolt rim Remove wheel hub Installation Reverse the removal procedure for installation Tightening torque Rim Axle Nut 180 200N m 9 ...

Page 154: ...1 for brake hose routing Rear Brake Disc Remove Rear left wheel 9 3 Remove mounting bolt rim Remove wheel hub Rear brake caliper 9 4 Rear brake disc 8 3 Inspection Brake Disc Thickness 3mm Replace Installation Reverse the steps of removal for installation Note Refer to Chapter 1 for brake hose routing Parking caliper Remove rear wheel 9 3 Loosen the bolt 1 Remove the parking cable Remove bolt 2 Re...

Page 155: ...LIZER BOLT 9 BOLT FLANGE M10 1 25 50 10 LOCKNUT FLANGE M10 1 25 11 REAR SHOCK ABSORBER 12 BUSH ARM 13 CENTER SPACER 14 BOLT FLANGE M10 1 25 90 15 REAR UPPER ARM ASSY 16 BOLT FLANGE M10 1 25 110 17 BUSH RR KNUCKLE S 18 BUSH RR KNUCKLE L 19 REAR LEFT ARM LOWER 20 REAR RIGHT ARM LOWER 21 REAR STEERING KNUCKLE 22 BEARING 23 CIRCLIP φ75 24 BOLT FLANGE M10 25 25 REAR BRAKE DISC 26 REAR WHEEL HUB 27 NUT ...

Page 156: ...d right absorbers Maintenance of rear absorbers only does not require removal of rear suspension Remove the following parts for rear right shock absorber 11 Bolt 9 12 Nut 10 11 Bolt 9 12 Nut 10 Remove rear right shock absorber Installation Reverse the removal procedure for installation Rear Right Arm Refer to front right Arm in Chapter 8 for the removal inspection and installation of Rear Right Ar...

Page 157: ... Replaced Tightening Torque Table Item Qty Type Torque N m Remark Fornt axle bolt 6 M8 1 25 25 20 Screw 2 M4 22 10 Screw 2 M5 15 10 Screw 1 M6 16 12 Screw 3 M6 25 13 Screw 1 M12 10 15 Front screw 1 M12 1 5 70 Glue Bolt 6 M10 1 25 20 35 Front axle bolt 1 M18 1 25 8 20 Bolt 1 M10 1 25 12 25 Bearing Retainer 1 M65 2 0HL 60 Rear axle bolt 2 M10 20 30 Rear axle bolt 6 M8 40 25 Rear axle bolt 1 M8 20 25...

Page 158: ...re abnormal sound a Abnormal sounds during accelerating decelerating have little to do with engine working but possibly with gear worn b Constant abnormal sounds during accelerating or decelerating might be cause by gear clearance wrongly adjusted during assembling Note Wrong assembly or adjustment of the front or rear axle will aggravate gear worn and block c Slight sounds will be noticed during ...

Page 159: ... 1 12 FRONT AXLE RIGHT CASE 1 3 O RING ф16 5 ф2 5 1 13 BEARING 16007 1 4 BOLT M18 1 5 10 1 14 CIRCLIP 62 1 5 O RING ф15 5 ф1 5 1 15 O RING ф160 ф3 1 6 SPEED SENSOR 1 16 ALUNINUM PAD ф18 ф10 1 5 1 7 BOLT FLANGE M6 16 1 17 BOLT FLANGE M10 1 25 12 1 8 ALUNINUM PAD ф18 ф10 1 5 1 18 OIL SEAL 25 40 7 1 9 JOINT BREATHER PIPE M10 1 25 10 1 19 BOLT FLANGE M8 1 25 25 6 10 NEEDLE BEARING NA5903 1 10 ...

Page 160: ...NNTACT COMPONENTS 1 13 WASHER φ8 ф4 1 2 6 GASKET 1 14 SPRING PAD 2 7 SCREW 2 15 SCREW M4 22 2 8 CONTACT WIRE 1 16 DIFFERENTIAL CONTROLLER 1 3 FRONT AXLE HOUSING GROUP Ref No Description QTY Ref No Description QTY 1 DRIVEN BEVEL GEAR FRONT ASLE LEVOROTARY Z 33 1 6 BEARING RETAINER M65 2 0HL 1 2 BEARING 6008 P6 1 7 COUPLER 14T 1 3 ADJUST WASHER B φ 54 ф 66 0 2 1 8 WASHER φ12 ф30 4 1 4 DRIVE PINION G...

Page 161: ... WASHER 1 2 BOLT M8 40 4 10 BEARING 6010 1 3 SPRING WASHER φ8 5 2 5 4 11 ADJUST WASHER 1 4 DRIVE GEAR ASSEMBLY 1 12 DIFFERENTIAL GEAR ASSEMBLY 1 5 BEARING NA2512 1 13 DIFFERENTIAL GEAR CASE 1 6 OIL SEAL 35 55 8 1 14 SPRING WASHER φ8 5 2 5 8 7 FRONT DIFFERENTIAL GEAR CASE COVER 1 15 BOLT M8 40 8 8 DRAIN BOLT M10 20 1 16 10 ...

Page 162: ... 1 3 BUSH 1 11 GEAR SHAFT SET R 1 4 ADJUST WASHER 1 12 PLANET GEAR SHAFT 1 1 5 GEAR SHAFT SET R 1 13 PLANET GEAR SHAFT 2 1 6 RETAINER φ35 2 14 PLANET GEAR 4 7 LINK GEAR 1 15 SPHERE WASHER 4 8 SUPPORT DIFFERENTIAL GEAR L 1 16 RETAINER WASHER 6 6 REAR AXLE HOUSING GROUP Ref No Description QTY Ref No Description QTY 1 DRIVE GEAR 1 3 RETAINER φ35 1 2 BEARING 6307 1 4 RETAINER φ35 1 ...

Page 163: ...1 11 RETAINER φ10 1 2 OIL SEAL 10 22 7 1 12 SPRING 1 3 OIL SEAL 35 55 8 1 13 RETAINER φ10 1 4 WASHERΦ6 1 1 14 SPRING 1 5 BOLT M6 10 1 15 RETAINER GUIDE BAR 1 6 WASHER 1 16 BOLT M6 16 2 7 STOPPER 1 17 RETAINER SHIFT FORK 1 8 EXHAUST VALVE 1 18 INNER COVER 1 9 BEARING 61912 1 19 RETAINER 1 10 SHAFT φ5 20 1 20 O RING 160 2 65 1 10 ...

Page 164: ...cylndrical surface of front axle and oil seal lips Replace broken parts if necessary z Check drive pinion gear and differential gear inspect worn surface Replace broken if necessary z Check driven gears surface gear center differential bracket differential wearing situation on the differential gear assembly Replace parts if necessary z Check inside and outside spline washer wearing status in front...

Page 165: ... seal bearing and drive clutch assembly 24 Use screw thread fastening glue z Front differential gear case cover assembly Note Use engine oil for oil seal or bearing assembly z Differential gear assembly M10 1 25 20 Tightening torque35Nm Note Use engine for bearing and dif ferential gear Use proper washer to make gear working freely Adjust washer thickness 0 2 0 3 0 4 0 5 1 0 10 ...

Page 166: ...ance between drive pinion gear and differential gear Drive bevel gear clearance measurement Install sup port tools tightening bolts M10 1 25 put up dial indicator make sure 21 mm is between measuring point and support tools Turn support tools counter clock and read the data Standard 0 10 0 25 Adjust washer thickness 0 1 0 2 0 3 0 4 0 5 1 0 b Shift fork and drive clutch assembly should be against t...

Page 167: ... 10 11 c Use special equipment or vehicle control circuit into two stroke position M6 25 before gear motor assembly d Make sure b and c is assembled using illustrated positioning bolt before gear motor and front axle 10 ...

Page 168: ...turning stability rollway stell ball neddle bearing as well Replace bearing if necessary Special tools are required z Check rear axle if bearing clearance is normal turning status rollway stell ball neddle bearing as well Replace bearing if necessary Special tools are required z Check worn status of drive bevel gear and ring gear rear axle Replace if necessary z Check oil seal lips o ring shape Re...

Page 169: ...vice personnel to understand and familiar with Chery QQ SQR7110 models has the capability of rapid repair and maintenance specially written Chery QQ Technology Service Manual 472 engine mechanical part This manual details the disassembly inspection testing and diagnosis technology standard Chery QQ472 engine components or systems This manual is provided by Chery Engine Co Ltd The license without w...

Page 170: ... other is connected with ECU signal 33 Chapter 3 Introduces the function of fault diagnosis system 34 1 control the fault lamp 34 2 Connect the diagnosis instrument 34 3 Fault code list 35 4 Erase fault code 37 Chapter 4 Troubleshooting diagnostic process 38 1 Fault diagnosis according to the fault code description 38 2 System fault code diagnosis process 38 2 1 Upstream oxygen sensor heater contr...

Page 171: ...er injector circuit for the power supply circuit fault code P0268 54 2 30 Four cylinder injector circuit shorted to ground fault code P0270 55 2 31 Four cylinder injector circuit for the power supply circuit fault code P0271 55 2 32 Knock sensor fault fault code P0325 56 2 33 Crankshaft position sensor circuit fault fault code P0335 56 2 34 The camshaft position sensor fault fault code P0340 56 2 ...

Page 172: ...ormal but any time idling instability 71 3 7 Normal starting warm process of unstable idle speed 72 3 8 Normal starting warm after the end of unstable idle speed 73 3 9 Normal starting part load such as air conditioning when idling instability or flameout 74 3 10 Normal starting idle speed is too high 75 3 11 To accelerate the speed to go up not to go or stop 77 3 12 Acceleration response is slow ...

Page 173: ... control functions of the system for monitoring once detected faults and confirmation the memory fault code call limp home function when the detected fault is eliminate then normal recovery using 二 The basic components of electronic control system The electronic controller ECU Injector Crank position sensor Oil rail Camshaft position sensor Carbon canister control valve Intake manifold Oxygen sens...

Page 174: ...tor control signal which includes Idle speed regulator opening Fuel injection timing and injection duration Ignition coil closed angle and ignition advance angle The carbon canister control valve opening Oxygen sensor heater heating control Main relay Pump relay control The air conditioning compressor control relay Air conditioning cooling fan relay control Cooling fan relay Trouble light control ...

Page 175: ...11 EFI SYSTEM OF SQR 472ENGINE 11 3 3 The ECU control principle diagram ...

Page 176: ...11 EFI SYSTEM OF SQR 472ENGINE 11 4 4 The ECU function module layout ...

Page 177: ...t 18 Empty 59 Upstream oxygen sensor Earth 19 Stepper motor coil A Output 60 Inlet air pressure signal Input 20 Stepper motor coil A Output 61 2 cylinder injection signal Output 21 The main relay power Input 62 4 cylinder injection signal Output 22 After the ignition is switched power supply Input 63 Battery power supply 2 Input 23 The 3 cylinder output Output 64 Cooling fan relay high speed Outpu...

Page 178: ...11 EFI SYSTEM OF SQR 472ENGINE 11 6 39 The speed signal input Input 80 Empty 40 Empty 81 Empty 41 Empty ...

Page 179: ...rature sensor the resistance value varies with the temperature of the cooling water cooling water temperature is low the resistance of the thermistor is large The cooling water temperature is high the resistance of the thermistor is smaller Conversion of resistance into the change of voltage input to the ECU ECU according to the temperature of cooling water the basic injection time carries on the ...

Page 180: ...id sealant to ensure that the assembly and disassembly and good conductivity sensor In the installation process of tightening tighten six angle plane using spanner copper sleeve May not be a plastic parts are tightened so as not to damage the product Maximum tightening torque 20N m 6 the malfunction phenomenon and the judgment method General failure 1 The starting difficulty A simple method for te...

Page 181: ...n due to the lack of teeth and tooth alternation is produced by the variation of the magnetic field and the Schmidt trigger conversion by square wave signal 4 technical parameters 1 limit data be worth units measure Least Typical The maximum The launch area 40 150 Conductor area 40 150 Storage temperature 40 150 Don t run when the environment temperature 40 120 Long term environmental temperature ...

Page 182: ...ghtening torque of 8 2Nm Holzer type crankshaft position sensor and signal disc tooth tip of the air gap between nominal value is 1 0mm allow the range is 0 3 to 1 7mm 6 The malfunction phenomenon and the judgment method Fault phenomenon not starting General failure man made fault Note repair installation method of repair process by pressing instead of hammering A simple method to measure thenthef...

Page 183: ...1 3 The camshaft position sensor 1 Diagram and pin 2 Installation position Camshaft end cover 3 Working principle The sensor makes use of the magnetic induction intensity changes by Holzer Holzer in the principle of voltage made into 11 ...

Page 184: ...4000 rpm 5 Installation notes Installation method of sensor by indentation instead of hammering Recommended bolt fixed sensor M8 Tightening torque 10 14Nm The air gap between the camshaft position sensor and signal wheel allows the range is 0 3 to 2 0mm the Holzer elements working diagram two 6 fault phenomenon and judgment method Fault phenomenon emissions exceed the standard increased fuel consu...

Page 185: ...emolition to prevent the destruction of the initial setting 4 the vehicles running on certain mileage such as twenty thousand kilometers the large dust reduce it or solar term valve plate dust deposition is large the throttle valve of main channel and side channel cleaning cleaning agent is not conductive to the throttle body is cleaned dried check with a multimeter solar term door position sensor...

Page 186: ... kΩ Slider protecting resistor slider at zero pin B C 710 1380 Ω Operating temperature 40 130 The power supply voltage 5 V The right extreme position of the voltage ratio 0 04 0 093 The left extreme position of the voltage ratio 0 873 0 960 VP Vcc with the throttle angle increase rate 22 0 0009929 1 degree Weight 25 28 g 5 The malfunction phenomenon and the judgment method 1 The fault phenomenon c...

Page 187: ... designed into can not rotate so it can only move in the axial direction so it is also called linear axis End wire rod is a plug plug and therefore can be retracted or extended cross sectional area to increase or decrease the idle speed actuator bypass inlet passage until it blocked Whenever the current direction change of a coil rotor around a fixed point of view called step a number equal to 360...

Page 188: ...s opened at both ends of the pressure drop 60 kPa Gas pressure difference caused by the maximum axial force 6 28 N 5 Installation notes Idle with stepping motor actuator is installed on the solar term door body castings constitute a bypass channel at both ends of the solar term door Bolt installation using two M5 0 8 14 Bolt tightening torque of 4 0 4Nm The installation and use of the spring washe...

Page 189: ...t method is open the ignition switch but not immediately start the engine wait 20 seconds and then start the engine If at this time that the engine idling bad must repeat the above steps A simple method to measure unloading joints digital multimeter to Ohm two probes are respectively connected regulator AD BC pin 20 rated resistance was 53 5 3Ω 7 Heated oxygen sensor 1 Structure diagram and pin 2 ...

Page 190: ...utput voltage is low close to 100mV 200mV Signal voltage in the theory of equivalent air fuel ratio λ 1 occurred near mutation see below 4 Technical parameters Limit data value measure Least typical maximum unit Storage temperature 40 100 Ceramic pipe 350 900 Case six hexagon nuts 40 600 Cable metal buckles and connecting cable 40 210 Working temperature Connector plug 120 Ceramic tube short exhau...

Page 191: ...city of about 0 7M s 12 W The working voltage is 15V the heating current thermal equilibrium 350 the exhaust of greenhouse gas flow velocity of about 0 7m s 5 A Fuse filament heating circuit 8 A 4 The use of life Oxygen sensor life associated with gasoline lead content see the following table Gasoline lead content g L Life km 0 6 30000 0 4 50000 0 15 80000 0 005 gasoline 160000 4 Installation note...

Page 192: ...d be in the rapid fluctuation between 0 1 0 9V 8 The intake air temperature and absolute pressure sensor 1 Structure diagram and pin 2 Installation position The sensor consists of two sensors intake manifold absolute pressure sensor and the inlet temperature sensor assembly is installed in the The intake manifold 3 Working principle Intake manifold absolute pressure sensor element consists of a si...

Page 193: ...wn and so on can not ensure the formation of condensed water pressure sensitive element Drilling and fixed on the intake manifold must be carried out in accordance with the supply in order to ensure the long sealing and erosion resistance of medium Joint reliable electrical connection contact except mainly affected by components of joint but also with quality and size precision materials joints ma...

Page 194: ... 4V left and right specific numerical and vehicle and then drops to about 1 5V the specific numerical and vehicle 9 The fuel rail assembly The fuel rail assembly consists of the fuel distribution pipe rail composed of four injector and fixing clip 1 Installation notes Pay attention to dust dust shall not be allowed to enter the pipe or plug injector nozzle Fuel rail assembly shall not bump so as t...

Page 195: ... s Republic of China national standard GB 17930 1999 unleaded gasoline for vehicle and the national environmental protection standards GWKB 1 1999 standard harmful substance control gasoline regulations fuel 4 Fault phenomenon and judgment method Fault phenomenon low fuel pressure or high difficult to start General failure due to long term use 1 Lack of maintenance filter plug 2 Impurity particles...

Page 196: ...70 Permission temperature fuel injector in a car not working 30 130 Continuous 30 120 The working temperature of the fuel injector After the hot start about 5 minutes time 30 130 Continuous 40 110 The fuel injector inlet fuel temperature A short time about 3 minutes 30 130 Fuel flow relative to the deviation of 20 temperature can reach 4 40 130 The 35 to 40 temperature range of 0 ring leakage lice...

Page 197: ...quirements should be used for the axial and radial locating clamp and the positioning of injector and fuel injector seat positioning pins are respectively located at the card groove clip in the corresponding installation If fuel injector with two card slots care should be taken not to card error can refer to the original installation position Fuel injector installation manual no knocking injector ...

Page 198: ...electric pulse duty ratio on the other hand with the carbon canister control valve between the inlet pressure and the outlet pressure difference When no electric pulse the carbon canister control valve closed The carbon canister control valve section In the different pressure difference the carbon canister control valve in the 100 duty cycle i e all open under the conditions of the flow of each ar...

Page 199: ...y ratio 100 of traffic QA 2 7 3 0 3 3 m h The differential pressure 700mbar duty ratio 100 of traffic QB 3 5 3 8 4 1 m h 5 Installation notes The carbon canister control valve and the carbon canister intake manifold connected to see the installation diagram The carbon canister control valve installation diagram In order to transfer to avoid solid sound recommend the carbon canister control valve i...

Page 200: ...on canister control valve installed in the pipe hanging on A simple method to measure remove electric connector digital multimeter to Ohm two one two pin the carbon canister control valve respectively 20 rated resistance was 26 3 12 The engine control unit ECU 1 installation position The cockpit 2 principle of work Multi point sequential injection Ignition control Idle speed control Provide power ...

Page 201: ...e speed acceleration not starting idle speed is too high exhaust exceed the standard starting difficulty empty Adjustable injector control failure failure flameout Common fault 1 due to the external device electrical overload caused by ECU may lead to the failure of internal parts burned 2 because ECU water and cause the circuit board corrosion etc Note 1 Repair repair process do not disassemble t...

Page 202: ...nt and other components see below Pump and motor are coaxially arranged and closed in the same chassis Around the pump and motor shell are filled Full of gasoline the fuel cooling and lubrication The battery to the electric fuel pump relay power supply relay Only when in starting and running of the engine makes the electric fuel pump circuit When the engine is stopped by accident When running auto...

Page 203: ...ed on the eye size of not more than 60 or agreed with the customer common inlet strainer Please pay attention not to make the beam injection holes spewing oil into the oil inlet filter oil pump bracket and the oil tank wall Be careful when handling pump First of all we must protect the oil inlet filter is not affected by the load and impact Oil pump should be installed to carefully remove from pla...

Page 204: ...ntion to the fuel tank and pipeline cleaning and replacing fuel filter A simple method to measure Remove connector Digital multimeter to Ohm two probes are respectively connected fuel pump two pins measuring internal resistance not zero or infinity i e not short circuit open circuit state Connect the connector To start the engine into the tubing connected to the fuel gauge fuel pump observe whethe...

Page 205: ... surface temperature failure and alumina sintering Catalytic converter conversion efficiency and air fuel ratio in the ideal air fuel ratio 14 7 1 narrow area is 14 5 15 0 catalyst for CO HC and NOx conversion efficiency reached the highest at the same time When the air fuel ratio is too thick the pollutant conversion Efficiency were decreased CO and HC is more obvious while too thin when CO and H...

Page 206: ...ht starting find the speed signal out if the fault lamp fault class is defined as a light mode then meet the corresponding Confirmation conditions after the fault light To connect 2 diagnostic instrument This system uses the K line of communication protocol and uses the ISO 9141 2 standard diagnostic connector see below The criteria for the diagnosis of joint is fixedly connected on the engine wir...

Page 207: ...g fan relay vehicle speed signal the idle speed idle speed adjustment device system voltage ECU air conditioning compressor evaporator temperature sensor relay fault lamp 3 The fault code list number failure code 1 P0031 Oxygen sensor 1 heater control circuit shorted to ground 2 P0032 Oxygen sensor 1 heater control circuit shorted for the power supply circuit 3 P0037 Oxygen sensor 2 heater control...

Page 208: ...circuit failure 34 P0340 Camshaft position sensor fault 35 P0351 One cylinder ignition coil circuit fault 36 P0352 Two cylinder ignition coil circuit fault 37 P0353 Three cylinder ignition coil circuit fault 38 P0354 Four cylinder ignition coil circuit fault 39 P0444 The carbon canister control valve circuit open 40 P0445 The carbon canister control valve circuit shorted 41 P0501 Speed sensor is n...

Page 209: ...on switch 4 According to the diagnostic tester instructions clear fault code 5 To complete the fault code is cleared exit diagnosis procedure switch off the ignition and remove the diagnosis instrument from the diagnostic interface Do not use diagnosis instrument and computer 1 Turn off the ignition switch 2 Disconnect battery cathode line for more than 30 seconds then go on Note the fault does no...

Page 210: ...aintenance process don t ignore automobile maintenance cylinder pressure mechanical ignition timing and the influence on the system 4 Replacing ECU test If fault code can remove the fault location fault code in the ECU if still unable to clear is for the original ECU repeat the process again repair work 2 Fault code diagnosis flow 2 1 The upstream oxygen sensor heater control circuit shorted to gr...

Page 211: ... oxygen sensor is connected between pins relative color line to supply short circuit yes Diagnostic aid 2 3 The lower the oxygen sensor heater control circuit shorted to ground fault code P0037 order number Operation steps Test results Next step 1 Connect the diagnostic instrument ignition switch is in the ON Next step yes Next step 2 Dial the joint oxygen sensor wire harness check with a multimet...

Page 212: ...nsor connector relative to white 2 relative with the oxygen sensor cable whether to short circuit of power supply pin No Diagnostic aid 2 5 Manifold pressure sensor circuit shorted to ground fault code P0107 Serial number Operation steps Test results Next step 1 Connect the diagnostic instrument ignition switch is in the ON Next step Yes To step 5 2 The observed data stream pressure is about 101kP...

Page 213: ...to ground fault code P0112 Serial number Operation steps Inspec tion results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes To step 5 2 The observation data stream in the air temperature whether in the intake pipe of equivalent temperature numerical and when the engine temperature Note if the display value often is constant that there may be line short ...

Page 214: ...t pressure sensor on wire harness electrical multimeter check sensor 3 and 4 pins of value is commensurate with its temperature with specific reference to the evaluation of repair manual No Replace the sensor Yes To step 6 4 Dial the joint line beam The temperature sensor using a multimeter check resistance sensor a and b pins between whether the value is about 5V No Next step Yes Repair or replac...

Page 215: ...ss electrical multimeter check sensor a and c pins of value is commensurate with its temperature with specific reference to the relevant part of the repair manual No Repair or replace the wire harness Yes 4 Connector for coolant temperature sensor unplug the wire harness multimeter voltage check the joint a and c pins between whether the value is about 5V No Next step Yes Repair or replace the wir...

Page 216: ...sing a multimeter to check the joint line between the a c pin is broken No Next step Yes Repair or replace the wire harness 5 Check the ECU X1_31 X1_73 between pin are respectively connected with the sensor connector pin a c whether the circuit breaker No Next step Yes Diagnostic aid 6 Start the engine idle running To observe the diagnostic instrument coolant temperature value changes the display ...

Page 217: ...f the road Party member on the coolant temperature value changes the display values should be increased after the engine coolant temperature and elevated No Replace the sensor 2 13 Solar term door position sensor circuit shorted to ground fault code P0122 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes Next step...

Page 218: ... wire harness between ECU check X1_45 X1_38 X1_32 a b dB and sensor connector pin c whether the circuit breaker short circuit or short circuit of power supply No Next step Yes Replace the sensor 6 Using a multimeter to check voltage a and b pins of the joint between the value is about 5V No Diagnostic aid 2 15 The oxygen sensor circuit fault fault code P0130 Serial number Operation steps Test resu...

Page 219: ...st system blocking Fuel injector is leaking Fuel pressure is too large Valve clearance is too small No Diagnostic aid 2 17 Oxygen sensor circuit output voltage is too high fault code P0132 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes Diagnostic procedures 2 Start the engine idle running to the coolant tempera...

Page 220: ...aust system blocking Fuel injector is leaking Fuel pressure is too large Valve clearance is too small No Diagnostic aid 2 19 The oxygen sensor circuit fault fault code P0136 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes Diagnostic procedures 2 Start the engine idle running to the coolant temperature reach norm...

Page 221: ...st system blocking Fuel injector is leaking Fuel pressure is too large Valve clearance is too small No Diagnostic aid 2 21 Oxygen sensor circuit output voltage is too high fault code P0138 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes Diagnostic procedures 2 Start the engine idle running to the coolant tempera...

Page 222: ...r is leaking Fuel pressure is too large Valve clearance is too small No Diagnostic aid 2 23 Pump primary line fault fault code P0230 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the OFF Next step Yes To step 4 2 Pulling off the fuel pump relay the ignition switch to ON respectively check the pump relay power supply terminal 30 86...

Page 223: ...ess 3 Check in between a cylinder injector connector SM pin and the main relay line is open circuit or short circuit to ground No Next step Yes Next step 4 Using a multimeter to check a resistor between the fuel injectors for cylinders SM1 and SM2 pins at 20 in 14 5 0 5 ohm No Replace injector Yes Diagnostic aid 5 Whether the 3 7 Ω voltage with a multimeter to check a cylinder injector connector 2...

Page 224: ...linder injector connector 2 pin and the ECU line is broken or the power supply or short circuit to ground No Diagnostic aid 2 26 Two cylinder injector circuit shorted to ground fault code P0264 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes To step 4 2 Dial the joint stiffness of injector on wire harness using ...

Page 225: ...linder injector connector 2 pin and the ECU line is broken or the power supply or short circuit to ground Diagnostic aid 2 28 Three cylinder injector circuit shorted to ground fault code P0267 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes To step 4 2 Dial the joint stiffness of injector on wire harness using a...

Page 226: ...wire harness 3 Check in between a cylinder injector connector SM pin and the main relay line is open circuit or short circuit to ground No Next step Yes Next step 4 Using a multimeter to check a resistor between the fuel injectors for cylinders SM1 and SM2 pins at 20 in 14 5 0 5 ohm No Replace injector Yes Diagnostic aid 5 Whether the 3 7 Ω voltage with a multimeter to check a cylinder injector co...

Page 227: ...njector connector 2 pin and the ECU line is broken or the power supply or short circuit to ground Diagnostic aid 2 31 Four cylinder injector circuit for the power supply circuit fault code P0271 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes To step 4 2 Dial the joint stiffness of injector on wire harness using...

Page 228: ...er the fault has disappeared No Diagnostic aid 2 33 The crankshaft position sensor circuit fault fault code P0335 Serial number Operation steps Test results Next step 1 Ground which is diagnostic instrument the ignition switch is in the OFF Next step Yes Next step 2 Dial the joint curve position sensor wire harness electrical multimeter to check the sensor 2 and 3 pins between the value at 20 in 7...

Page 229: ...ext step Yes Diagnostic aid 6 Check the camshaft signal wheel is intact No Replace the signal disc 2 35 A cylinder ignition coil circuit fault fault code P0351 Serial number Operation steps Test results Next step 1 round which is diagnostic instrument the ignition switch is in the ON Next step Yes To step 4 2 Dial the joint on wire harness for ignition coil using a multimeter to check voltage betw...

Page 230: ...able to check the ignition coil 2 cylinder column and ignition anode stop should be 9 2K Ω 20 No Replace ignition coil 2 37 Three cylinder ignition coil circuit fault fault code P0353 Serial number Operation steps Test results Next step 1 round which is diagnostic instrument the ignition switch is in the ON Next step Yes To step 4 2 Dial the joint on wire harness for ignition coil using a multimet...

Page 231: ...between the table to check the ignition coil 4 cylinder column and ignition anode stop should be 9 2K Ω 20 No Replace ignition coil 2 39 Carbon irrigation control valve open circuit fault code P0444 Serial number Operation steps Test results Next step 1 round which is diagnostic instrument the ignition switch is in the ON Next step Yes To step 4 2 Dial the joint on wire harness for ignition coil u...

Page 232: ...a multimeter to check the carbon canister control valve street is about 3 7V voltage 2 pin and cathode will the house No Next step Yes Repair or replace the wire harness 6 Between the X1_26 pin to check the carbon canister control valve connector 2 pin and the ECU whether the circuit breaker No Diagnostic aid 2 41 The speed sensor is not working properly fault code P0501 Serial number Operation st...

Page 233: ...system voltage fault fault code P0560 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the OFF Next step Yes Next step 2 using a multimeter to check whether the battery voltage is about 12V No Replace the battery Yes Repair or replace the wire harness 3 The 87 pin check ECU X1_67 and the main relay the line between whether there is o...

Page 234: ...ther there is a fault code No 2 45 Fault display lamp control circuit fault fault code P0650 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON What s nex To step 4 2 Pulling off the fault lamp connector pin voltage check 1 and dia warm cathode will is about 12V Next step Repair or replace the wire harness 3 Check the main relay...

Page 235: ...ue changes the display values should be with the engine running down until the 5 degrees celsius Replace the sensor 2 47 Short circuit on the air conditioning evaporator temperature sensor circuit fault code P1536 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes To step 4 2 The observation data stream in the evap...

Page 236: ... between the 85 pin and the 87 pin of main relay circuit is open circuit or short circuit to ground check the fan relay between 86 positive power supply pin and whether the circuit breaker No To step 5 Yes Repair or replace the wire harness 4 Check the fan power supply circuit fuse is intact Check fan relay 87 increased with the fan power line is open circuit or short circuit to ground No Next ste...

Page 237: ...nector 85 between pin and ECU X_65 pin line is open circuit or short circuit to ground No Diagnostic aid 2 50 Air conditioning compressor fan relay or fan line fault fault code P1625 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes To step 4 2 Dial the fan connectors relay on wire harness multimeter voltage check...

Page 238: ...ion 1 Check whether the fuel pipeline leak 2 Check that the vacuum line whether there is fault kink the connection is correct 3 Check the intake pipeline is blocked leakage crushed or damaged 4 The high pressure line check ignition system is broken aging ignition sequence is correct 5 Check the wiring harness ground is clean firm 6 Check the sensor actuator connector is loose or poor contact Impor...

Page 239: ... motor disassembly inspection starting motor Focus on examination of whether there is open circuit or due to insufficient lubrication card dead No Next step Yes The lubricating oil for the appropriate label 4 If the failure is occurred in the winter then check for engine oil and gear selecting improper lead to start the motor power is too large No Next step Yes Maintenance of internal engine power...

Page 240: ...d sensor circuit Yes Next step 3 Appropriated the sub cylinder line a cylinder which is connected to spark plug spark plug electrode distance engine body around 5mm start the engine check whether there is a blue and white high pressure fire No Maintenance of the ignition system Yes Exclusion of unloading failure of engine 4 Check the engine cylinder pressure of each engine cylinder pressure observ...

Page 241: ...air or replace the sensor line 3 Pulling off the coolant temperature sensor connector start the engine when the engine is started successfully observed a 300 ohm resistor in series or in the coolant temperature sensor connector to replace coolant sensor observation of the engine is successful start No Next step Yes Repair or replace 4 Check the fuel pressure regulator vacuum tube whether there is ...

Page 242: ...in the coolant temperature sensor junction resistance to replace the coolant temperature sensor observation of the engine is successful No Next step Yes Cleaning solar term door and idle airway 4 Gently down on the accelerator observe whether easy to start No Next step Yes Failure to replace 5 Remove the injector injector clogging with special cleaning analyzer check whether the injector is there ...

Page 243: ...ormance to specification No Adjust or replace Yes Repair or replace the sensor line 5 Pulling off the coolant temperature sensor connector start the engine the engine is starting to observe No Next step Cleaning solar term door and idle airway 6 Check the fuel situation observe whether the fault now just gas caused by Next step Failure to replace 7 Gently down on the accelerator observe whether ea...

Page 244: ...osition No Next step Yes Failure to replace 5 Remove the injector injector with special cleaning analyzer to check whether the injector is there is a leak plugging or flow ultra difference phenomenon No Next step Yes Replace fuel 6 Check the fuel situation observe whether the failure phenomenon was caused due to gas No Next step Yes Remove engine mechanical fault 7 Check the engine cylinder pressu...

Page 245: ...ition No Next step Yes Failure to replace 5 Remove the injector injector with special cleaning analyzer to check whether the injector is there is a leak plugging or flow ultra difference phenomenon No Next step Yes Replace fuel 6 Check the fuel situation observe whether the failure phenomenon was caused due to gas No Next step Yes Remove engine mechanical fault 7 Check the engine cylinder pressure...

Page 246: ...step Yes Failure to replace 5 Remove the injector injector with special cleaning analyzer to check whether the injector is there is a leak plugging or flow ultra difference phenomenon No Next step Yes Replace fuel 6 Check the fuel situation observe whether the failure phenomenon was caused due to gas No Next step Yes Remove engine mechanical fault 7 Check the engine cylinder pressure of each engin...

Page 247: ...l signal No Next step Yes Next step 3 Disconnect the electrical control unit X1_68 pin connecting line check the open air conditioning wiring harness end is a high level signal No Maintenance of air conditioning system Yes Next step 4 Check system pressure air conditioning compressor electromagnetic clutch and the air conditioning compressor pump is normal No Maintenance of air conditioning system...

Page 248: ...ction whether there is leakage No Next step Yes Cleaning of parts 3 Remove the idle adjuster solar term door body check idle speed regulator and idle speed was the existence of the phenomenon of carbon deposition in the airway No Next step Yes Repair or replace the sensor line 4 Pulling off the coolant temperature sensor connector start the engine when the engine is idling too high observation No ...

Page 249: ...plug observe its model and gap meets the specifications No Adjust or replace Yes Cleaning of parts 4 Remove the idle adjuster check the solar term door body idle speed regulator and idling bypass airway carbon deposition No Next step Yes Next step 5 Check the intake pressure sensor solar term door position sensor and think you are normal No Repair or replace the sensor line Yes Failure to replace ...

Page 250: ...serve its model and gap meets the specification No Adjust or replace Yes Cleaning of parts 4 Remove the idle adjuster check the solar term door body idle speed regulator and idling bypass airway carbon deposition No Next step Yes Next step 5 Check the intake pressure sensor solar term door position sensor and think you are normal No Repair or replace the sensor line Yes Failure to replace 6 Remove...

Page 251: ... the spark plug the spark plug electrode distance engine body around 5mm start the engine check the high pressure fire intensity is normal No Maintenance of the ignition system Yes Next step 5 Check the cylinder spark plug observe its model and gap whether payment specification No Adjust or replace Yes Cleaning of parts 6 Remove the idle adjuster check the solar term door body idle speed regulator...

Page 252: ...eplace the bulb when it is turned on Keep ignition switch in the OFF position and replace after the bulb is cooled down Replace the bulb with hands in clean gloves to avoid oil stains on the glass surface Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of any oil stains on the glass surface If the Inspection has to be done with battery check if the battery is normal I...

Page 253: ...12 LIGHTING AND SWITCHES 12 2 TROUBLESHOOTING Head Light Cannot Turn On Broken fuse Open circuit with main cable Burnt Bulb Faulty Switch 12 ...

Page 254: ...he glass surface may cause break of bulb Clean the stained surface with alcohol or isoamyl acetate Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the terminal in the coupler Head lamp 12 V 55 W 2 Front position lamp 12 V 5 W Reverse the removal procedure for installation After replacing the bulb adjust headlight beam Inspection of Hea...

Page 255: ...r corner cover cargo box 2 13 Remove 3 nuts Remove taillight cover Replace brake light tail light bulb Bulb Specification Stop lamp 12 V 1 8 W 12 LED Rear position lamp 12 V 0 2 W 12 LED Reverse the removal procedure for installation Rear Turning Indicator Bulbs Remove taillight 12 4 Remove taillight cover Replace rear turning indicator bulbs Bulb Specification 12 V 2 W 15 LED Reverse the removal ...

Page 256: ...eadlight headlight connector Headlight Reverse the removal procedure for installation Note Be careful not to damage main cable when assembling After replacing adjust the headlight beam Note Main cables and wires should be routed properly Ignition Switch Inspection Remove front cover 2 11 Disconnect 4P connector of ignition switch ...

Page 257: ...y Remove Remove meter panel 2 11 Disconnect 4P connector of ignition switch Reverse the removal procedure for installation Combined Switch Remove front cover 2 11 Remove meter panel 2 11 Disconnect connector of combined switch Check according to the following table if the connector terminals are in continuity 12 ...

Page 258: ...12 LIGHTING AND SWITCHES 12 7 2WD 4WD 4WD Diff Lock Switch No continuity Change the switch ...

Page 259: ...r continuity Hold the brake pedal Brake lights are open Release the brake pedal Brake light is off When hold the brake pedal the brake light is off Replace brake pump assembly Horn Inspection Remove bolt Remove horn connector Connect with a fully charged 12V battery and check the horn sounds Faulty Horn Replace 12 ...

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