Tiger Truck Extended Cab 2019 Service Manual Download Page 72 | Manualshive

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Malfunction Analyse & Elimination

70

Abnormal Noise with
Front Wheel

Abrasion of unworkable or loose of the turning
sidelong coupling bar end, global joint(left/right
front suspension arm), inner side global joint of the
coupling bar or tramsmission shaft joint.
Damage of Strut or fixing piece
Abrasion of suspension arm bush
Stabilizer bar becoming flexible
Nut of wheel becoming flexible
Bolt or nut of the suspension shelf becoming
flexible
Damage of the wheel bearing or other problems
Damage of the spring of the suspension shelf
Poor Lubrication or Abrasion of Strut Bearing
Abrasion of the joint of stabilizer bar

Repair or Replace
Replace
Screw Down Bolt, Replace Bush
Screw Down Wheel Nut
Screw Down the Bolt or Nut
Replace Wheel Bearing
Replace Spring
Infuse Lubricant or Replace Strut
Bearing
Replace

Sway while Turning or
Turning with Poor
Stability

Tyres not matching
Damage or Sagging of Spring
Improper Adjustment of Rack & Pinion
Improper Front Wheel Alignment
stabilize connecting rod loose

Replace Tyre or Charge the Tyre to
Proper Pressure
Replace suspension arm or the end
of turning sidelong coupling bar.
Replace Strut or Repair
Replace Spring
Check & Adjust Torque of Rack &
Pinion
Check & Adjust Front Wheel
Alignment
Replace stabilize connecting rod

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Summary of Contents for Extended Cab 2019

Page 1: ...2019 Extended Cab Truck Service Manual ...

Page 2: ...Vehicle Devices Operation Error Bookmark not defined 0 4 Usage of the Vehicle 29 5 Vehicle Operation Manual 35 6 Checkout Maintenance Service Error Bookmark not defined 7 Malfunction Analyse Elimination 57 8 Disposition of Emergency Error Bookmark not defined 9 Maintenance of the Vehicle Error Bookmark not defined ...

Page 3: ...Vehicle Identification 1 1 Vehicle Identification ...

Page 4: ...de of the frame beam which is under the seat that beside the driver s and above the Meter Board and on the nameplate 2 VIN There are two VINs one is on the aluminum plate which is on the right front side of the meter the other is on the body which is under the front row right side seat 3 Serial Number of the Engine The serial number of the Engine should be marked on the convexity of the rear lower...

Page 5: ...Main Technical Parameter of the Complete Vehicle 3 2 Main Technical Parameter of the Complete Vehicle ...

Page 6: ... Engines of EQ1021GF24Q7 BG13 20 EQ474i AF10 06 EQ465i 21 BG10 01 DK12 01 Max Speed km h 135 110 120 130 Gradibility 33 1 25 4 24 6 27 9 42 3 Brake Distance at 50km h full loading m 20 Any part of the vehicle shall not exceed the width of the trial driveway that is 2 5 M MinmumTurning Diameter m 10 3 3 Fuel Ecomomy Items Unit Optional Engines of EQ1021GF24Q7 BG13 20 AF10 06 BG10 01 DK12 01 ...

Page 7: ... 4 9 5 2 5 1 5 1 Note The real fuel consumption will be higher than this numerical value for different use conditions 4 Main Dimensions Items Unit Vlalue Total Length mm 4280 20 Total Width mm 1560 10 Total Height Unladen mm 1880 15 W O Guardrail 1850 15 Wheel Space mm 2760 15 Front Track mm 1310 Rear Track mm 1310 ...

Page 8: ...tional Engines of EQ1021GF24Q7 BG13 20 EQ474i AF10 06 EQ465i 21 BG10 01 DK12 01 Kerb Weight kg 940 930 930 940 Gross Weight kg 1665 1655 1655 1665 Passenger Rating Loading Capacity Pax kg 2 Include drive 595 6 Toe in Parameter Item Unit Optional Engines for EQ1021GF24Q7 BG13 20 EQ474i AF10 06 EQ465i 21 BG10 01 DK12 01 Toe in mm 0 108 0 5 ...

Page 9: ...i EQ465i 21 Optional Tire for EQ1021GF24Q7 165 70R14 165R13LT 155R13LT Front Tire Unladen kPa 180 200 200 Fully Loaded kPa 220 240 240 Rear Tire Unladen kPa 200 220 220 Fully Loaded kPa 250 300 375 8 Capacity Data Items Unit Optional Engines of EQ1021GF24Q7 BG13 20 EQ474i AF10 06 EQ465i 21 BG10 01 DK12 01 Cooling System of Engine L 5 5 4 5 4 5 5 5 ...

Page 10: ...5 3 2 3 2 3 Fuel Tank L 40 Lubricating Oil of Gear Box L 1 3 1 5 1 3 1 3 1 3 0 15 Rear axle lubricating oil L 1 2 Brake Fluid L 0 6 9 Cooling System Data Item Unit Optional Engines of EQ1021GF24Q7 BG13 20 EQ474i AF10 06 EQ465i 211 BG10 01 DK12 01 Capacity of Refrigerating W 7200 5350 7200 ...

Page 11: ...sumption Power of the Compressor W Nc2000r min 3430 2610 3430 Control Parameters Automatic Increase of Idle Speed r min 1100 50 A C Water Tempreture Protection 110 Engine Water Tempreture Protection 90 High Pressure Protection MPa 3 2 Low Pressure Protection MPa 0 2 Overheating Protection 150 5 ...

Page 12: ...Vehicle Devices Operation 10 3 Vehicle Devices Operation ...

Page 13: ...own the locked button After that one cannot open the door either inside or outside the vehicle When open pull the locked button out The front door can be opened or locked by keys While open the locked button out while locking the locked button press down Note Press down the locked button while the vehicle running the door should be locked safely to prevent the door opening accidently 2 Keys This v...

Page 14: ...me up or come down 4 Rocking window outfit by electric When by electric there is a button on the inner side of the door Button One Electrical Riser Button on the driver s side to control the door window of the copilot Button Two Riser Button for door window on the side of the driver Button Three Electrical Riser Button on side of Copilot Pull the button up the door window will be closed press the ...

Page 15: ...st adjusting handlebar beside the seat the backrest will turing automatically then loose the handlebar the backrest will be fixed in the position And the backrest can be folded forward Note Do not adjust the driver s seat while driving otherwise the seat may move forward or backword abruptly which may cause driver lose its control 6 Safety Belt The safety belt of the front row seat is automatic co...

Page 16: ...to the structure human body skeleton See the picture Please note that the waise band part shall not be across the abdomen The adjustment of the safety belt is not only reliable and comfortable but also can help to make safer Flexible safety belt will influence its protection function Safety belt should be prevented from polishing compound grease spot chemical article especially storage battery sou...

Page 17: ...igh low beam converting switch 4 Head lamp control switch 5 Rear Foglam 6 Rear Foglam 7 Cigarette Lighter 8 Auxiliary Frame Air Bag 9 Side Intake 10 Centre Intake 11 A C Switch 12 Switch Assy Defroster 13 Rear fog Switch 14 Fog Switch 15 Emergency Switch 16 Tool Box 17 Control Board for Heating 18 Ignition Switch ...

Page 18: ...ally Do not keep the ignition key in ON position for a long time unless the engine is running or else the battery will discharge Note The working time for starter shall not exceed 5 seconds If the engine cannot be started please wait at least five to ten seconds and try again If the engine fail to start after several times please check the fuel power supply system or pay a visit to the Maintanence...

Page 19: ...leanser Control Pole The control lever is on the right of the steering wheel and the control lever has four gears INT Wiper is the intermission gear which is suitable for fogy and rainy day LO The wiper will run at stable and low speed HIGH Wiper will run at a stable high speed OFF Wiper will stop running Pull back the control lever it can jet cleaning liquid Note When the cleanser stop spraying s...

Page 20: ... turning lights glitter simultaneously Press the other end will turn off the lights This switch is only used for emergency situation and running in abnormal situation 13 Foglight Switch Front Foglight Turn the headlight switch to the second gear and press the foglight switch the foglight will be turned on and so will the indicator light press again the foglight is turned off so is the indicator li...

Page 21: ...evices Operation 19 14 Heating System The heating system to provide heating defrosting and ventilation funvtion Windshield defrosting air door The central vent hole The side defrost vent hole The broad vent hole ...

Page 22: ...ost exhaust port Defrost Cycle Control Button of Inside Outside Control the circulation of the air of inside outside Tempreture control button Control the tempreture of cold warm air blue is cold air and red is warm air Draft Control Button Control the rotate speed of fan that is adjust the draft Optional Button for Ventilate Position Note The time for blowing should not be too long while the air ...

Page 23: ...unt for the first time Note Pay attention to the running mileage and maintain the vehicle according to this instruction manual Water Thermometer While driving the water tempreture should be kept in the normal scope that is between C H When the pointer moves to H direction and exceeds the scope it means the engine too hot you should stop the vehicle Fuel Gauge While the pointer at the F position it...

Page 24: ... pressure indicator light When putting ignition switch through this indicator lamp lights immediately after the engine is started it will go out immediately Otherwise it shows the oil level of the bottom shell of the engine passes low or the lubricating system breaks down please make the engine go out and carry on the oil level check and annotate immediately If fail to fix a breakdown yet please g...

Page 25: ...evel of the container of brake liquid is lower than the fixed liquid level the light will be on And it will be out after adding brake liquid according to the regulation Note It shows the brake system breaks down when the ignition switch is on the position of ON or START but the indicator light is not on or it is not out after the engine starts or the indicator puts through abnormally while driving...

Page 26: ...r Lighter Press the cigarette lighter button wait several seconds and the resistance wire will turn red and hot and it can be taken out to use after it automatically rebounds to its original position 18 Cigarette Ash Box The ash box can be used after being pulled out while clearing up the cigarette ash push it downwards then totally pull out from the socket outwards Push the ash box along the guid...

Page 27: ...nterior placement a little thing 21 Interior Light Inner Rear View Mirror The indoor light button consists of three pieces of shelf location OFF is closed DOOR means switch at the door when the button is in this shelf the light is not on while closing the door and the light is on while opening the door As any door is closed uncompletely this light will not go out ON means being turned on while at ...

Page 28: ...rear view mirror is protruding surface Note While judging by the vehicle or other objects through the protruding lens please pay attention that the articles will be much smaller and farther than seeing through the flat mirror 23 Sunshading Board The sunshading board can rotate up and down by winding its pivot While adjusting place hands close to both ends of the mount ing pad and rotate There is a...

Page 29: ...p the brake rod the vehicle will stop when release the stopping brake pull the brake rod a little up and push the button on the top of the brake rod with thumb and then put back the brake rod in the normal position 27 Pedal Clutch Pedal Clutch pedal can break transmission of engine and wheel Step down the footboard the engine power disconnects loose footboard power Note Parking brake rod should be...

Page 30: ...not change the gearlever from 5th gear into reverse gear Please first push the gearlever to neutral and then change into reverse gear 1st gear first pull towards to left and then push forward 2nd gear first pull towards to left and then pull backward 3rd gear push forwards in the central position 4th gear push backwards in the central position 5th gear pull towards right first and then push backwa...

Page 31: ...Usage of the Vehicle 29 4 Usage of the Vehicle ...

Page 32: ...eating the engine 2 Start of the Engine Before Start of Engine Make sure the parking brake has been unlocked Make sure the joy stick of the derailler is in the position of neutral Note Before starting the engine hold the hand brake to unlock and the gearlever should be in the position of neutral 3 Safety Driving Start the Engine While turning the ignition switch to START you can start the engine T...

Page 33: ...dal gradually When driving the vehicle don t regard the footboard as a stop for a rest or don t half step on clutch while parking at the slope which may damage the clutch While driving the vehicle drivers should frequently observe the instrument and indicator lamp and do not step on the gas before the engine do not reach normal working temperature 80 degrees Centigrade 90 degrees Centigrade otherw...

Page 34: ... and fro while applying the brake When the vacuum booster system lose efficiency the energy stored will gradually subside effort in brake pedal with applying the brake each time Note Without the vacuum booster system it will need bigger footforce while applying the brake and perhaps the braking distance will be longer 5 Economy Driving Environmental Adaptability Economy Driving The following items...

Page 35: ...use the vehicle sideslip Avoid the operation of the steering wheelby turning fast or at large angle Decrease to the safe speed and slowly change direction If the friction is increased by equipping with tyre chain please pay attention to following points Assemble the vehicle according to the Instruction Manual of the manufacturer The speed should be limited below 50KM H while driving with tyre chai...

Page 36: ...Usage of the Vehicle 34 of abrupt slope long slope which will cause the brake to lose its braking ability for being overheated ...

Page 37: ...Vehicle Operation Manual 35 5 Vehicle Operation Manual ...

Page 38: ... addition check whether the belt is damaged and method of adjusting and changing of the belt are as follows 1 Unclamp the three setscrews of the generator 2 While wanting to stretch the strap unscrew and draw outwards the generator fix the generator when the strength of the belt reaches above mentioned criterion 3 While changing the strap unscrew and make the generator slip and move inwards Tighte...

Page 39: ...wise the clean the engine installation surface with a clean cloth Spread some engine oil around the rubber washer of the engine oil strain and twist to new oil strain with hand i until the oil strains rubbers reach to the installing surface And then twist the strain engine oil to 3 4 of the circles by strain spanners 5 Engine Strap Note In order to make oil filter fasten properlr the more importan...

Page 40: ...tematic electricjet serial petrol machine use and maintain the manual 9 Gasoline Filter Oil Sulpply Tube Oil Return Tube There is 0 3MPa in the oil supply system While changing gasoline filter and oil supply tube and oil return tube and tie in you should adopt the right fittings from Dongfeng Sokon You had better go to Dongfeng Sokon Auto maintainance station otherwise may leave your car in hidden...

Page 41: ...f screw is incorrect in size is not to be used If the whorl is stretched out or indentation while covering it will gather the charcoal powder in the exposed whorl part In this way when dismantle the spark plug or change with the correct spark plugging will cause the damage of the whorl Note While fitting the spark plug please exert to screw it to prevent damage to the whorl then screw it tightly b...

Page 42: ...or can reduce the harmful gas effectively It is quite easy for three way convertor to be overheated while the gasolines engine working and which may cause the damage of the three way convertor In order to protect three way convertor while the driver is in the course of operating please refer to instruction maintainance manual of gasoline engine of DELPHI system or unite electricity systematic elec...

Page 43: ...and mechanical technology The work of ABS system is automatic no matter when as long as the apperceive wheel is locked up namely begin to work automatically Step on the brake pedal directly while applying the brake don t step on the brake pedal repeatedly Note When the ABS loses its function the function of the braking system will be the same as that of the common braking system And please use the...

Page 44: ... wainscot and the rubber washer on the pedal are not included When step the brake pedal down the distance A between the pedal and the front wall shall not less than 95mm And it should be checked and maintained if the following things happan while stepping on the brake pedal by 294N 30kg The braking force is insufficient The braking is not stable The stroke for the pedals is too big Brake blocked B...

Page 45: ...re scutcheon on the driver s side door When the air pressure is too low it will cause the tire worn and torn too much and difficult to drive and heavy fuel consumption while the air pressure is too high the vehicle shakes badlly and cause the stability bad and the middle of the tire will be badly worn and torn The air pressure of the tire should be checked by the pressure gage Note While pumping t...

Page 46: ...ohibited Replacement of the Tyre Take off the jack tool and spare tire from the vehicle Loosen the tire but do not remove the nut Put the jack in a proper position and raise it up Discharge the wheel Fix the wheel and change the nut Lower the jack fix the nut by spanner The spare tire is put under the floor of box of the vehicle screw the fixed screw on the vehicle counter clockwise and put down t...

Page 47: ...cause the damage of the electric system even the fire Fuse of Branch Circuit The fuse box lies in the left of the pedal bracket When take down the fuse first remove the cover of the fuse box and draw out the fuse In order to differentiate the capacity amp position of the fuse please refer to the indication diagram on the cover of the fuse box Note Users should use the right capacity fuse while cha...

Page 48: ...h soft cloth If the bulb is frequently burnt it shows that there are some problems with the circuit Please go the Dongfeng SOKON Auto Maintainance Station for help 23 Replacement of the Bulb Open the front storehouse cover Remove two screws and draw out the headlight forwad Pull out the flashboard Remove the pressurized rubber Push forward the spring making it release from the hook then change the...

Page 49: ...e from the hook then change the headlight bulb 23 Replacement of the Bulb Remove two screws and draw out the headlight forwad Pull out the flashboard Remove the pressurized rubber Push forward the spring making it release from the hook then change the headlight bulb Contrarotate the tailstock of the turning lights and then removes the bulbs for replacement 24 ECU ECU is the key component of electr...

Page 50: ...turn to the storehouse and make sure they have been fixed up firmly While using the jack the vehicle shall be put in the horizontal and hard ground If you stop the vehicle on the road please turn on the emergency light Lock up the parking brake and put gearshift rod in the reverse gear and fix the the tire on the cross of the rising angle by chock Put the jack under the jacking position and uprigh...

Page 51: ...Vehicle Operation Manual 49 Triangle Warning Plate ...

Page 52: ...Checkout Maintenance Service 50 6 Checkout Maintenance Service ...

Page 53: ...nning kilometers and months will be the standard maintenance time The check adjustment lubricant and other maintenance service should be strictly subject to the stipulated time in the form Make form recommend several project of checking emphatically through is it pinpoint the problems to check take the pertinence measure in time With go kilometer count or moon count as standard confirm maintain ti...

Page 54: ...Checkout Maintenance Service 52 G means change R means needing to be lubriacant X means screwing to the regulated torque J means checking T means adjustment ...

Page 55: ...elt Strain Abrasion etc G G G G 2 Camshaft Synchronization Tooth Belt Strain abrasion damage J T G J T G J T G J T G 3 Valve Gap J T J T J T J T 4 Engine Bolt all cylinder cover fixing piece X X X X 5 Machine Oil Cleaner G G G G G G G G 6 Machine Oil Replace for every 5000km 7 Engine Coolant Infuse at any time 8 Soft Tube and Tie in of Colling System Soft Tube and Tie in of Colling System leaking ...

Page 56: ... replace for every 40000km Gravel Road Clean while driving 25000km replace for every 40000km 14 Fuel Box fuel pipe and tie in J T G J T G J T G 15 Fuel Cleaner G G G G G G G G Exhaust Control of Crankcase 16 Exhaust Soft Pipe Tie in J T G J T G J T G J T G 17 Fuel Steam Storing Device J T G J T G J T G J T G 18 PCV Valve J T G J T G J T G J T G Electric Equipment 19 Electric Wiring Connect Lamps J...

Page 57: ...T G J T G J T G J T G J T G J T G 26 Brake Soft Pipe Pipeline Leakage damage J T G J T G J T G J T G J T G J T G J T G J T G 27 Tire Abnormal Abrasion Abnormal Air Pressure J T G J T G J T G J T G J T G J T G J T G J T G 28 Wheel Boss Nut J T G J T G J T G J T G J T G J T G J T G J T G 29 Bolt Nut Elasticity X X X X 30 Steering Wheel Gap Elascticity J T G J T G J T G J T G J T G J T G J T G J T G ...

Page 58: ...Checkout Maintenance Service 56 35 Evaporator J T J T 36 Desiccator G G 37 Refrigerate Pipeline X X X X ...

Page 59: ...Malfunction Analyse Elimination 57 7 Malfunction Analyse Elimination ...

Page 60: ... 2 1 Lack of Gasoline 2 2 Gasoline Cleaner Blocked 2 3 Fuel Pipeline Defiled or Blocked 2 4 Electric gasoline pump doesn t work 2 5 Impurity Fuel eg Including water Infuse Gasoline Clean or Replace Clean Repair or Replace Rectify 3 Lack of Crock Pressure 3 1 Spark Plug not Screw Down or Damage of Gasket 3 2 Incorrect Valve Gap 3 3 Leakage of Cylinder Cover Gasket 3 4 Piston piston ring or abrasion...

Page 61: ...st or Replace Repair or Replace Clean Clean or Replace Repair or Replace Clean or Huff Replace Replace 3 Insufficient Crock Pressure As Above Mentioned 4 Others 4 1 Brake Problems 4 2 Clutch Skidding 4 3 Connect Flex or Vacuum Soft Pipe Break Off Repair or Replace Adjust or Replace Reliable Connect Unstable Idle Speed of Engine 1 Trouble with Fuel System 1 1 Block of the Air Cleaner 1 2 Leakage of...

Page 62: ...ve Guide Pipe 1 3 Failure or Damage of Valve Spring 1 4 Distort or Curve of Valve Adjust Replace Replace Replace 2 Abrasion of Piston piston ring and Valve Repair or Replace 3 Rod Noise 3 1 Rod Bearing Abrasion 3 2 Winch Pin Abrasion Replace Repair or Replace 4 Crank Shaft Noise 4 1 Bearing Abrasion 4 2 Crank Shaft Neck Abrasion 4 3 Bearing cover bolt flex 4 4 Gas of crank shaft thrust piece too b...

Page 63: ...t Gas freezing adding coolant Adjust Replace Replace Repair or Replace Clean or Repair Choosing the right kind Replace or Clean Add Repair or Replace Repair or Replace Repair or Replace Replace Consumption of Engine Oil 1 Leakage of Engine Oil 1 1 Flexible Discharging Oil Bolt 1 2 Bolt of the Oil Case Flexible 1 3 Seal Glue of Oil Case deterporate or Break 1 4 Leaking of Oil Seal 1 5 Damage of the...

Page 64: ...ce Replace Screw Down or Replace High Consumption of Gasoline 1 Malfunction Of Fuel System 1 1 Fuel Tank Carburetor or Leakage pipeline 1 2 Block of Air Cleaner 2 Malfunction of Ignition System 2 1 High Voltage Damping Wire Flexible or Creepage 2 2 Malfunction of Spark Plug Improper Gap Burnt accumulated carbon Repair or Replace Repair or Replace Connect or Replace Adjust or Replace 3 Insufficient...

Page 65: ... the Free Stroke Replace Clutch Flake Replace Clutch Flake Clutch Compressive Board or Flywheel Replace Clutch Cover Replace Cable Hard Seperation of Clutch Improper Free Stroke of Clutch Diaphragm Spring Weak or Abrasion of Reed Input Spline Rust Damage or Abrasion of Transmission Input Shaft Spline Serious Sway of Clutch Flake Clutch Flake Abrased or with Oily Soil Adjust Free Stroke Replace Clu...

Page 66: ... Bearing Guard Ring Replace Clutch Flake Replace Clutch Flake Replace Clutch Flake Replace Clutch Cover or Flywheel Screw Down Again or Replace fixing Washer Clutch Sounding Abrasion or Damage of Separate Bearing Abrasion of Front Input Shaft Bearing Loose of Clutch Flake Hub Crakes in Clutch Flake Compressive Plate or the Diaphragm Spring Loose Replace Separate Bearing Replace Input Shaft Bearing...

Page 67: ...ormation of Gearshift Axle or Gearshift Fork Replace Replace Gearshift Troubled Incorrect Clutch Pedal Stroke Deformation or Break of the Cluch Friction Disc Damage of Clutch Compressive Plate Abrasion of Synchronizer Alligatoring Ring Deformation of Gearshift Axle Adjust Replace Replace Clutch Cover Replace Replace Gear Replace Noise Insufficiency Lubricant or the Improper Type Complement or Repl...

Page 68: ... or Infuse Adjust Adjust or Replace Replace or Screw Down Again Replace Bearing Noise Gear Oil going bad or including water Insufficient Gear Oil or Incorrect Kind Damage of Taper Driving Gear Bearing noise sending off while Gliding Noise while rotating Damage of axle bearing of differential gear or the back axle bearing Replace Oil Re infuse Replace Oil Re infuse Replace Replac Oil Leakage Chock ...

Page 69: ...uspension Abnormal Abrasion or over Abrasion of Tire Sagging or Damage of Spring Imbalance of Tire Maladjustment of Front Wheel Alignment Trouble with Strut Shock Absorber Bad Road Condition Overloading Tyre not Transposition Abrasion or Sagging of Wheel Bearing Sway of Wheel or Tyre Insufficient of Air Pressure of Tyre Replace Spring Adjust to make it Balance or Replace Tyre Check Adjust Front Wh...

Page 70: ...ace the end of turning sidelong coulping bar Front suspension arm Repair or replace wheel and or tire Replace the tire Replace tire or wheel Check Adjust the front wheel alinment Screw down or replace the driving rod Screw down the turning gear bolt Turning Problems Improper Charge Pressure of Tyre Sluggish of Steering Global Scolex or L R Global Scolex of Suspension Arm Maladjustment of Front Whe...

Page 71: ...delong coupling bar end Jamming of Global Joint Jamming of Steering Column Poor Lubricant of Rack Pinion Maladjustment of Front Wheel Alignment Improper Adjustment of Rack Pinion Improper Charge Pressure of Tyre Replace the turning sidelong coupling bar end Replace Front Suspension Arm Repair or Replace Check Repair or Lubricate the Rack Pinion Check Adjust Front Wheel Alignment Check Adjust Torqu...

Page 72: ... Poor Lubrication or Abrasion of Strut Bearing Abrasion of the joint of stabilizer bar Repair or Replace Replace Screw Down Bolt Replace Bush Screw Down Wheel Nut Screw Down the Bolt or Nut Replace Wheel Bearing Replace Spring Infuse Lubricant or Replace Strut Bearing Replace Sway while Turning or Turning with Poor Stability Tyres not matching Damage or Sagging of Spring Improper Adjustment of Rac...

Page 73: ...trut Suspension arm being pressed to the bottom The vehicle decline or shake while turning Overloading Shock Absorber or Strut with Troubles Spring with Troubles or Sagging Loose of Stabilizer Bar Damage or Sagging of Spring Overloading Check the Carrying Loading Replace Shock Absorber or Strut Replace Spring Screw Down Stabilizer or Nut or Replace Bush or Joint Replace Strut or Fixing Accessories...

Page 74: ...Repair the Trachea Replace the Core Replace the Soft Tube 7 Malfunction of Cooling System Problems Reason Solution Air Conditioning not send off Abnormal Work of Air Conditioner Air Conditioner not Work 1 Without Refrigerant 2 Blowout 3 Trouble with Air Conditioner Fan Switch 4 Low Idle Speed 5 Trouble with Air Conditioner Thermister 6 Trouble with Air Conditioner Water Tempreture Sensor 7 Trouble...

Page 75: ...r Fan Relay 3 Trouble with Line Earthing 4 Trouble with A C Condensor Fan Electric Manchine Replace Fuse Check if it Short Circuit Check Condensor Fan Replay Repair as Requirement Check the Fan Electric Machine of Condensor Electric Machine of Fan not Work 1 Trouble with Resistor of Fan Electric Machine 2 Trouble with A C Fan Switch 3 Trouble with Line Earthing 4 Trouble with Fan Electric Machine ...

Page 76: ...ectric Machine Excessive Compressor Oil in A C Check Compressor Replace Desiccator Pump Out Infuse Refrigerant Repair if Necessary Check the Evaporator Check the heating system Check Fan Electric Machine Pump Out Compressor Oil in A C Replace Compressor Cooling Intermittence Trouble with Line Trouble with Expansion Valve Too Much Humidity in A C Trouble with accelerate cut off switch Trouble with ...

Page 77: ...vaporate Frozen Check the accelerate cut off switch Check the Complement of Refrigerant Check the Evaporator Check the Thermister of A C Insufficient Wind Power of Air Conditioning Evaporator Blocked or Frozen Cooling Sysem or the Windpipe Leaking Trouble with Fan Electric Machine Trouble with Line Earthing Check Evaporator Check the Thermister of A C Check Fan Electric Machine Repair if Necessary...

Page 78: ...ner of Brake Pad Damage of Wheel Cylinder Trouble with Brake Caliper Improper adjustment of the length transducer spring if there is There is air in the system The transducer spring of LSPV is damaged The ringer of LSPV is damaged if there is a ringer Make sure the Leaking Part and Repair Clean or Replace Repair or Replace Repair to make it Connect Correctly Replace Replace Repair or Replace Repai...

Page 79: ...ction liner Replace Friction liner Earlier Seizure of rear brake only for vehicle with LSPV Improper adjustment of length of LSPV transducer spring Trouble with LSPV Check or adjust Replace Brake seizure only for vehicle with ABS Troublw with ABS ABS ANTI BRAKE SYSTYEM Refer to ABS Stroke For Pedals too long Trouble with part of Brake System Insufficient brake liquid in liquid container of brake m...

Page 80: ...tire internerate oil pipe damaged replace by the soft pipe double level brake steel pipe Check and adjust according to the techncal requirement Replace Repair or replace Repair if necessary Replace the seal of piston See ABS Pedals jump step on the pedal brake it jumps Wheel and axle damaged or loose Deformation of knuckle or rear wheel and axle Radial jump of brake disc too big The parallelism fa...

Page 81: ...ake check and turn off the braking warning light and infuse brake fluid Check the leaking position repair and infuse brake fluid Please see ABS Check the leaking position repair and infuse brake fluid Infuse brake fluid Braking warning light is not on while stop braking Trouble with the circuit of braking warning light Replace the bulb or repair the line ABS warning light will be on while starting...

Page 82: ...C Generator Trouble with the Line Adjust or Replace Driving Belt Check the Charging System Repair the Line 10 Malfunction of Lamps Indicator Lights Malfunction of Headlight Problems Reasons Solutions Headlights Not On Bulb Damaged Trouble with the Headlight Switch Blowout of the Headlight L R Troublw with Wire or Earthing Check the Bulb Check the Headlight Switch Check Fuse Replace if Necessary If...

Page 83: ...Relay Check the Switch Repair the Line Only One Headlight not On Bulb Damaged Trouble with Wire or Earthing Check the Bulb Repair the Line Malfunction of daytime running lamps Problems Reason Solution Daytime running lamps not On Bulb Damaged Blowout of the daytime running lamps Trouble with the control Work improper Trouble with Wire or Earthing Bulb Damaged Check Fuse Replace if Necessary If Rep...

Page 84: ...of Backup Light Horn Backup Signal Damaged Open Circuit Big Resistance Exsisting between the Battery Switch Trouble with Turning Signal Warning Relay Trouble with Combination Switch and or Warning Switch Check the Bulb Check the Bul Check the Relay Repair the Line Repair the Line Check the fuse and replace if Necessary Check the Bulb Wire Check the Relay Flicker Frequency too Low Voltage of Electr...

Page 85: ... with Wire or Earthing Check the Bulb Repair the Line Malfunction of Backup Light Problems Reasons Solutions Backup Light Not On Bulb Damaged Blowout of the Backup Light Fuse Trouble with Backup Light Switch Trouble with Wire or Earthing Check the Bulb Check Fuse Replace if Necessary If Replace Check if it Short Circuit Check the Switch Repair the Line BackUP Light not being Turned off Trouble wit...

Page 86: ...cuit Check the Switch Repair the Wire Brake Light not being Turned Off Trouble with the Brake Light Switch Check Adjust or Replace the Switch Problems Reason Solution Rear Foglight not On Damage of the Bulb Blowout of the Rear Foglight Trouble with the Switch of the Rear Foglight Trouble with the Switch of Headlight Trouble with the Wire or Earthing Check the Bulb Check Fuse Replace if Necessary I...

Page 87: ... it Short Circuit Check the Fuel Meter Measurement Module Check the Fuel Meter Repair the Line Check the Sensor ECT ECT Transducer Problems Reasons Solutions Thermometer of Engine Coolant Not Work Blowout of the Fuse of Meter Board Trouble with the Engine Coolant Thermometer Trouble with the Engine Cooling Tempreture Transducer Trouble with the Wire or Earthing Check Fuse Replace if Necessary If R...

Page 88: ...e Switch Repair the Line Malfunction of Brake Parking Brake Warning Signal Light Problems Reasons Solutions Brake Warning Signal Light ot On while the Brake Fluid below the Fluid Level Bulb not Work Blowout of the Meter Board Trouble with the Meter Line Trouble with the Brake Level Switch Trouble with the Wire or Earthing Check the Bulb Check Fuse Replace if Necessary If Replace Check if it Short ...

Page 89: ...rt Circuit Check Meter Line Check the Parking Brake Switch Repair Line Warning Signal Light of Seat Belt Problems Reasons Solutions Warning Signal Light not on Bulb not Work Trouble with the Switch of Seat Belt Blowout of the Meter Board Trouble with the Line or Earthing Check the Bulb Check the Switch of Seat Belt Check Fuse Replace if Necessary If Replace Check if it Short Circuit Repair the Lin...

Page 90: ...lfunction of Wiper or not Return to its Original Position Blowout of Wiper Washing Apparatus Trouble with Wiper Electric Machine Trouble with Wiper Switch Trouble with Line or Earthing Check Fuse Replace if Necessary If Replace Check if it Short Circuit Check Wiper Switch Check Wiper Switch Repair Line Malfunction of Washing Apparatus Washing Pipe or Nozzle Blocked Trouble with Washing Apparatus E...

Page 91: ...Disposition of Emergency 89 8 Disposition of Emergency ...

Page 92: ... can produce explosive gas and the causticity acid in which and the big output electric current may cause to be burnt In order to reduce personnel s injury you should follow following information when work near storage battery Make you eyes protected and do not bend over the battery Do not expose the battery to direct fire or make it under the spark Keep your eyes skin away from the storage batter...

Page 93: ...g the vehicle in a safe place and make the engine running for several minutes at idle speed till the value of the water thermometer go down to the safe range If the tempreture of the water still does not go down please check the following items A Check and verify whether the water pump belt and belt pulley damage and skid and the working condition of the fan when the engine operates If there is an...

Page 94: ...steps while traction Don t adopt the way in which the rear wheel land while drawing otherwise may cause the damage of the gear box While the vehicle is dragged away the front wheels land and the rear wheel lifted Put the ignition switch on ACC position to unlock the steering wheel the front wheel faces just in the front The steering wheel is locked up firmly by special lock framework If you use th...

Page 95: ...Maintenance of the Vehicle 93 9 Maintenance of the Vehicle ...

Page 96: ...th can be cleaned up by water neutral soap from ethylene plastic Make the dirt soft with brush and then washes the floor cushion completely by water and dry by airing in the shady and cool place Note Do not use varnish thinner petrol such volatility solvent or such materials as bleaching agent house using strong syringe while scrubing inside and outside of the car The above mentioned material may ...

Page 97: ...surface to see if there are damages needing to be repaired a Clear up all damaged part and dry b Mix the paint round and repaired the damaged place gently with the small brush c Dry it up after painting Note After washing please check whether there are water entering the brake or not If yes please stepped on the brake repeatedly and slowly to dehumidify it during driving a vehicle at a low speed N...

Page 98: ...lease keep the vehicle clean C When loading and unload some goods like corrosivity material articles such as chemical article fertilizer cleaning the article alkali sour salt etc which should be packed in the special container to transport if there are leaking or overflowing please clean up immediately D Don t park your automobile in the car moistly poor ventilation place and don t wash the automo...

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