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Section I Summary
The model MP.Midi is a brand new sedan independently developed and designed by BEIJING FOTON
MOTOR CO.LTD, which is displayed in the world by its sculptural outlook, smooth and robust line and
active visual effect.
It uses the engine, model 4G13S-7L/4G18S-7L, which is characterized by strong power, stable operability,
smooth drivability, reliability, durability and easy maintainability
Product classification of the Foton, MP.Midi Maintenance Manuals:
By the classification of model uses: the model Foton MP.Midi is divided in to dual-purpose type and
passenger type
Passenger type
Duo-purpose type
4288/1725/1728
4338/1725/1768
Trunk(cargo space)capacity(m3)
6242800
8243000
Axle base(mm)
Front
Wheel
base(mm)
Rear
Front suspension(mm)
Rear suspension(mm)
Drive type
Dynamic displacement and gearbox
pattern
Number of seats
Type of front rear suspension bracket
Drive brake type
Steering system type
269
1420
1440
830
763
FF
2695
1420
1440
830
813
FF
1.3.L/1.6L,5MT
1.3.L/1.6L,5MT
6/7
McPherson/vertical arm torsion bar
Front disc/rear drum
Power steering by rack/pinion
7
McPherson/vertical arm torsion bar
Front disc/rear drum
Power steering by rack/pinion
Passenger type
1290
748/542
2
1440
830/610
5
1665
883/782
7
525
1815
873/942
Duo-purpose type
1320
722/598
2
1470
804/666
5
1695
857/838
7
650
1970
881/1089
Front axle
type
Introversion
of master pin
Backward
tilt of master
pin
Wheel
camber
Toe-in of
front wheel
Steering angle of
front wheel
Internal
External
corner
corner
BJ6438MC6VA-1
BJ6438MC6VA-2
BJ6438MC6VA-P1
BJ6438MC6VA-P2
Steering
booster
10830
23030
1530
13 mm
(1510)
37
31
BJ6438MC6VA-P1
BJ6438MC6VA-P2
Mechanical
steering
10830
130
1530
13 mm
(1510)
37
31
Type of product
BJ6438MC6VA-1
BJ6438MC6VA-2
BJ6438MC6VA-P1
BJ6438MC6VA-P2
4.052
4.333
4.052
4.333
-2010 or
-1-3mm
-12530
Passenger type
5.65
156/124
16
24
Duo-purpose type
5.65
154/121
16
22
Passenger type
(4G18S)
(4G13S)
57.5
48.4
103.9
83.7
161
154
40
30
15.5
19.3
Duo-purpose type
(4G18S)
(4G13S)
56.2
47.3
100.7
81.8
160
152
40
30
16.36
19.6
20.39
24.41
20.39
24.41
21
6.66
20
6.51
21
6.66
20
6.51
7.6
7.6
7.6
7.6
Chapter II Engine
The vehicles, Model-MP.Midi have been fitted, on demand, with the engine model
4G13S-7L/4G18S-7L produced by Harbin Andong Automobile Engine Manufacturing
Corp.Litd. The engine, Model-4G13S-7L/4G18S-7L is the ideal dynamic of the family
multi-purpose vehicles and sedans with displacements of 1.3l/1.6l. In comparison with
homologue type, the engine is characterized with the compact construction, large power per
liter, good fuel economy, high speed and less noise etc., By adopting the electronically
controlled fuel injection system, which reduces considerably the harmful constituents in
off-gases, the engine is worth of the Green Earth power fully meeting the III of new National
Emission Regulations III.
4G18S-7L
4G13S-7L
Type
L4/16VSOHCMPI
Displacement
1299cm3
1584cm3
Cylinder bore
71.0mm
76.0mm
Stroke
Compression ratio
9.5
Max.power
62.5Kw /6000r/min
74.2Kw /6000r/min
Max.Torque
108N.m / 4500r/min
134N.m / 4500r/min
272g/Kw.h
6000r/min
Idle
75050r/min
Steering
Ignition sequence
1-3-4-2
Oil pressure
150kpa(750r/min)\54050kpa(2000r/min)
Overall dimension
Overall lengthwidthheight=617.8mm613.3mm622.2mm
1152kg
1132kg
Net weight
Fuel
Use of oil
Emissions regulation to meet
Number of cylinders
Combustion chamber
Roof type
Roof type
Stroke mm
82
87.3
SOHC-4
SOHC-4
82
82
Cylinder height
201
201
131
131
Intake valve
Exhaust valve
National 3
National 3
Lubrication system
Cooling system
Centrifugal, impeller
Centrifugal, impeller
Number of valves
e.g:
4G13S Engine Model
Engine no. print area 7L 79A0001
79A0001production serial number
72007
9Septermber
A0001Production S/N
Identification sign of the engine model
startup after several attempts, please check the fuel system and electric system, or call on the
automobile manufacturer and our service station for maintenance.
5. Idle
After the engine started, you should keep it run at idle speed for several minutes for engine
preheating.
Attention: The idle emission level of our engine products prior to delivery is strictly limited
within the specified range by the national standard. The idle speeds of gasoline engine,
models 4G13S-7L/4G18S-7L are set at 75050r/min. The idle mechanism of the gasoline
engine delivered with the car has been properly adjusted, there is no need for user to change it.
In case of necessary adjustment, you should call on the special maintenance department for
assistance. When the emission is tested, the engine should be in warm state, i.e. the water
temperature over 80; the oil temperature over6 0 (Idle speed: 75050r/min). The idle
speed and emission level are changeable all time. During the usage, the engine should be
regularly inspected and adjusted at the testing point.
6. Drive
During the drive in the car, the coolant temperature should be kept at 8090. At the
moderate speed, be careful that the oil pressure be 54050kPa.
7. Stopping
When the engine is working, especially running at high speed under heavy duty, do not shut
down the engine, you should shut down the engine after it has run at the low speed for
5mins instead of doing it immediately.
8. Driving in rainy day or wading
When driving on the puddle in rainy day or wading, be sure that the air filter be well sealed,
otherwise it will cause the engine cylinder inflowed and the connecting rod etc. damaged.
Attention: The water can not be compressed liquid. After the cylinder inflowed, the
connecting rod will bear the pressure of several times under the inertia action of car and bend
or break up the connecting rod.
9. Preheating in winter
As the temperature in winter is lower, the viscosity of oil increases. For the time being, the
lubrication effect of engine is worser than in summer. Hence, the engine after started up can
not operate at high speed as well as under heavy duty, instead, you should preheat the engine
at idle speed for 10mins and start driving only after increasing the oil and coolant
temperatures and lubricating the engine sufficiently.
Attention: When the gasoline engine is driving without adequately lubricated in wintergine,
it will cause the parts such as camshaft excessively worn and even, locking.
10. Electric injection system
In case of the engine inspection, do not randomly modify the electrical devices or wiring,
otherwise it will cause the electric devices overloaded, short-circuited and sparking. When the
electric system is inpected, the neg. cable should be disconnected fron the battery terminal.
Prior to connect or disconnect the neg.cable, be sure to turn off the ignition switch and
lighting switch(If not, it will burn up the semiconductor elements).
II. Regular check and maintenance of engine
Table of the regular checkand maintenance of engine
Each item is expressed by the running distance and time (month), and whichever comes first
(distance or time) is taken as the check basis.
Maintenance job code: IInspection;
RReplacement; CCleaning;
10
11
12
13
14
15
16
17
18
I
I
I
I
R: per 70,000km
I
I
I
R
I
R
I
R
I
I
I
I
I
I
I
R
R
I
R
I
R
I
I
I
I
I
I
I: per 5,000KM
I: More frequently
R R R R R
R: More frequently
R: per 5000KM
R: per 3001KM
R: per 5002KM
R: per 3003KM
I
I
I
I
I
I
I
I
I
I
I
C C C C C C C C C C
C* C* C* C* C* C* C* C* C* C*
I
I
I
I
I
I
Note:
C* for the cleaning and maintenance of the injection nozzle, it is recommended to use the
special cleaning analyzer of injection nozzlecheck once per 3months or per 5000km. the
failures such as vapor lock on the nozzle and block etc. are not considered as the quality
problems of product, the maintenance of which is charged by the user.
The Use speficiation under the harsh conditions is only applicable to the vehicles used under
the harsh conditions.
The harsh conditions of use include the following subjects:
(1) Driving in the dusty areas, or the car often at exposure to the salty air or seawater.
Regulating bolt
Locking nut
Specifications
Check method
Check time
Driving belt deflection of A/C
generator
(under acting force of 100N)
On inspection
5.6~6.7(mm)
8.3~10.4(mm)
785~981(N)
392~588(N)
Attention: Do not open the coolant tank lid or radiator lid when the engine remains in
hot state. The cooling system in the hot state is under a certain pressure. If opening the
lid, the hot coolant will spray out and scald the people around.
Drains the engine coolant through thedrainage plug of cylinder.
1) Removes the drainage plug, then radiator lid, and drains out the coolant from the engine.
2) Removes the drainage plug of cylinder and drains the engine coolant.
3) Removes the reserve tank and drains out the engine coolant (alternative dependint the
availability of car)
4) After the engine coolant drained out, fills in the clean water through the radiator lid to clean
up the pipleline of engine coolant.
5) Applies the specified sealant on the drainage plug thread of cylinder and thghtens as per the
moment as specified.
6) Firmly tightens the drainage plug of radiator.
7) Fits the reserve tank (alternative dependint the availability of car).
8) Removes the bleed bolt and replaces the seal washer (alternative dependint the availability
of engine).
9) Fills the radiator with the engine coolant until it overflows from the bleed bolt. Then closes
the bleed bolt (alternative dependint the availability of engine)
10) Slowly poors the engine coolant through the filler of radiator into the radiator until it is
filled up, while filling the reserve tank with the engine coolant unti the level is up to the
FULL line (alternative dependint the availability of car).
11) Fits tightly the radiator lid.
12) Starts up the engine and lets it run unti the thermostat turns on(touches by hands the
radiator hose to verify if the hot water is flowing).
13) After the thermostat is turned on, keeps the engine run idle at the high speed for several
times, then shuts down the engine
14) After the engine cooled, fills the reserve tank with the engine coolant as long as the level
reaches the FULL line. If the level is still lower, please repeat the procedure from (13).
7. Checks if there are any blocks and damages on the air filter elements.
(1) Checks if there any blocks and damages on the filter elements
(2) Removes the dirt deposit on the filter elements as per the method as below.
Blows the compressed air from the internal side of filter elements.
O-ring
Or marketed tools
Gearbox: N-gear
Gearbox: N-gear
(2) Inserts a paper clip along the wiring side into the connector between the primary side of
ignition coil and the tachometer.
(3) Connects a tachometer for the primary voltage to the paper clip.
(4) Fits the timing lamp.
(5) Starts up the engine and let it run at idle speed.
(6) Checks if the engine idle is within the range of standard value.
13. Check of the air hose of crankcase
(1) In case of need, checks with reflector the full peripheryand length.
(2) Checks if all clippers are well tightened, whether there are any leakages on the joints.
(3) If there are any clear signs of deterioration or damage, the replacement should be made at
once.
14.
Notch
Identification sign
(1) Starts up the engine and preheats the engine until the coolant temperature is up to 80-90.
(2) In order to facilitate inspectio, removes all spark plugs from the cylinder head.
(3) Removes the cover of rocker chamber.
(4) Turns clockwise the crankshaft until the notch of pulley aligns with the markT on the
timing dashboard.
(5) Moves up and down the rocker arms of the 1st and 4th cylinders to be sure that the pistons
of both cylinders are located at the top dead center of compression stroke. If there are the
clearances between the rocker arms of both intake and exhaust valves, the pistons in the
cylinder correspongding to those rocker arms should be positioned in the top dead center of
the compression stroke
(6) When the pistion of the cylinder No.1 is sited at the top dead center of compression stroke,
The valve clearance can be checked and adjusted with the rocker arm indicated by the white
arrowand when the pistion of the cylinder No.4 is sited at the top dead center of compression
stroke, the valve clearance can be checked and adjusted with the rocker arm indicated by the
solid arrow;
(7) Check of valve clearance
If the valve clearance is non-conform to the specified requirements, you may unscrew the
locking nut of rocker arm, and turns the governing screw while measuring with a feeler gauge
the clearance and makes the adjustment.
Standard values:
Valve
Intake valve
Exhaust valve
Ambient temperature(C)
0~15
15~25
0.120.03mm
0.140.03mm
0.170.03mm
0.190.03mm
25~40
0.160.03mm
0.210.03mm
Note: The variation of the valve clearance against the external temperature: every 1 degree
rise in temperature , the valve clearance is added by 0.0018mm.
(8) Fixes the governing screw with the screwdriver to prevent it from turning, tightens the
locking nut up to the specified moment.
(9) Turn s the crankshaft by 360, and aligns the notches on the crankshaft pulley with the
markTon the timing dashboard.
(10) Repeats the procedures (7) and (8) and adjusts the clearances of other valves.
(11) Fits the cover of rocker chamber.
(12) Fits the spark plugs and tightens them as per the specified moment.
15. Checks if there are any leakage on the exhaust pipe joint.
(1) Be sure that the exhaust pipe cause no interferences on any parts of car.
(2) Checks if the exhaust pipe has been damaged due to the impact by the gravel etc.
(3) Starts up the engine, to check if there is any leakage on the exhaust pipe joint.
16 Cleaning of the throttle assembly
In case where the following cases occur in your car, you should clean the throttle assembly:
(1) After completed the travel of 10,000kms or 6 months, whichever comes the first.
(2) When the following problems occur to your car: insteady idle, throttle valve lock, high
idle and low idle.
The portion to be cleaned as below:
Drain hole
Leakage inspection of
water pump
NON
YES
YES
NON
YES
Engine heater
Idle turbine driver20min
Normal
NON
Pump replacement
Nm
15~20
27~34
15~20
15~20
27~33
27~33
15~20
3~4
Items
Nm
28~34
governing screw
8~10
Cylinder headbolt
Tightens up to 49Nm
Releases
202
90 to 94
90 to 94
42~54
19~27
34~44
6~8
22~25
Oil filter
12~16
12~15
Connecting rod
Connecting rod nut
16.72.090 to 94
127~137
Backboard bolt
8~12
8~12
10~12
34.32.030 to 34
40~50
575
7~11
20~25
34~54
19~28
176~186
Spark plug
20~29
34~54
Ignition coil
8~12
7.5~8.5
12~15
17~26
Timing belt
Fitting bolt, timing belt shell,
10~12
20~27
6~10
Items
Nm
30~42
17~25
4~6
8~10
15~22
10~13
15~25
10~12
17~26
20~40
19~28
10~15
12~15
Troubleshooting
Tightens or unscrews
Inspection and maintenance
Repair or replace
Adjustment
Repair
Replacement
Adjustment or replacement
Repair or replace
Repair or replace
Cleaning
Replacement
Adjustment, repair or replace
Tightening
Repair or replace
Troubleshooting
Adjustment
1. Checks the valves, spark plugs
and valve pads for any leakages
2. Cylinder grinding
Adjustment
Adjustment or reparation
Checks the intake system
Checks the air exhaust system and
cleans out the carbon deposit
Adjustment or replacement
Troubleshooting
Replacement
Repair or replace
Replacement
Adjustment
Adjustment
Engine overheated
Troubleshooting
Adjustment
Cleaning or adjustment
Tightening or cleaning
Adjustment
Adding orcleaning
Repair or Replace
Adding
Cleaning or replacement
Replacement
Repair or Replace
Cleaning or replacement
Rroubleshooting
Replacement
Replacement
Adjustment
Rroubleshooting
Replacement
Replacement
Checks the relevant parts and
exclude them therefrom.
Troubleshooting
Replacement
Replacement
Repair
Replacement
Maintenance or replacement
Cleaning or replacement
Replacement
8) In case of any technique problems difficult to resolve encountered during the overhaul, it is
recommended to consult with our Products Sale Department.
7.2 Materials necessary for the overhaul
The materials listed in the table below are indispensable for the overhaul of the engine.
Therefore, gets them prepared for readily accessible all times. In addition, the specified type
of washing liquid and lubricant should be applied as far as possible.
Table of the auxiliary materials for DA Engine:
S/N
Name
Inteded use
Oil
Silica gel
LT5699
Sealant
LT243
Sealant
LT648
Silica gel
LT5699
Gasoline
Sealant
LT271
AOS materials
and Model
Lubricant
Lubricant
Lubricant
Gear oil
Lubricant
Sealant TB1501
LT480
7
8
9
Anti-rust oil
Gear oil
Gear oil
10
Sealant TB1303
LT243
Differentialbolt
11
Sealant TB1216
LT5699
12
Gear oil
13
Sealant TB1216
LT5699
S/N
Assembly position
Shift fork
Release bearing
Input shaft oil seal
Gearbox assembly
Shifting block
Air respirator
Input shaft
Input shaft needle bearing
Input shaft needle bearing
Oil
Oil
Sealant TB1386D
Oil
Assembly position
Valve head
Camshaft, rocker arm, rocker arm shaft
Stud bolt
Camshaft oil seal
S/N
5
LT962T
Assembly position
Spark plug guide bush, cylinder
body/cylinder head
Bowled expansion plug, filler neck
Number
Name
Intended use
When unscrewing or
tightening the bolt(clamps
the sprocket wheel of
camshaft with the tool
MD998715)
MB990767
MD998718
MD998054
MD998304
MD998305
Tools
Number
Name
Intended use
MD998713
MD998719
or MD998754
Pins
When unscrewing or
tightening the bolt(clamps
the sprocket wheel of
camshaft with the tool
MD990767)
MD998727
MD998772
Valve spring
compressor
MD991671
MD998780
MB991659
Guide bushD
MD998735
Compressor of
valve spring
Compression of valve
spring
MD998781
Flywheel stopper
MB991653
Compression valve
spring
Standard value
Limit values
Camshaft
Air intake
37.298
36.8
Air exhaust
37.161
36.66
44.92544.94
0.1
119.9120.1
Intake valve
1.35
0.85
Exhaust valve
1.85
1.35
Air intake
Air exhaust
5.5
0.020~0.036
0.030~0.045
0.1
0.15
45~45.5
Intake valve
53.21
53.71
Exhaust valve
54.1
54.6
Intake valve
111.56
111.06
Exhaust valve
114.71
114.21
50.87
50.37
216/44.2
588/34.7
Less than 2
0.9~1.3
5.5
Extra.0.05
Extra.0.25
23
10.605~10.615
10.805~10.815
Extra.0.50
11.055~11.065
Extra.0.3
28.425~28.445
Extra.0.6
28.725~28.745
Extra.0.3
26.425~26.445
Extra.0.6
26.725~26.745
Extra.0.3
30.425~30.445
Extra.0.6
30.725~30.745
Extra.0.3
28.425~28.445
Extra.0.6
28.725~28.745
0.06~0.18
0.04~0.11
0.100.18
0.35
Camshaft height in mm
in mm
Air exhaust
4G18S-7L
Air intake
Air exhaust
Item
Standard value
Limit value
4G13S-7L
71
4G18S-7L
76
st
0.03~0.07
0.1
nd
0.02~0.06
0.1
st
0.20~0.35
0.8
nd
0.35~0.50
0.8
4G13S-7L
0.20~0.50
1.0
4G18S-7L
0.10~0.40
1.0
18.0
4900~14700
0.02~0.04
0.1
0.10~0.25
0.4
0.05~0.18
0.25
48.0
42.0
0.02~0.04
0.1
0.1
256
0.01
4G13S-7L
71.0
4G18S-7L
76.0
0.02~0.04
1 ring
2 ring
1 ring
2 ring
Oil ring
9. Crankshaftpulley
2. Dipstick duct
3. O-RING
4. Timing belt
5. Water pumppulley
7. A/C generator
B Installation of the crankshaft bolt. Uses the special tool shown in figure to lock up the
flywheel or drive plate on the relevant position, then tightens the crankshaft bolts
Removal procedure
1.Timing belt upper cover
A C
3. Timing belt
9.Engine bracket
4. Tensioner spring
Tensionner of
the timing belt
(2) Hooks the one extended end of tensioner spring on the clevis part of the timing belt
tensioner and fits the tensioner on the oil pump shell.
(3) Clamps the other extended end of tensioner spring and hooks it on the lug of oil pump
shell shown as in Figure
(4) Removes the timing belt tensioner as shown in figure and tightens the belt in time.
C Installation of the timing belt
(1) Aligs the timing mark on the timing gear of camshaft with that on the cylinder head.
(2) Aligs the timing mark on the timing gear of camshaft with that on the front shell.
(3) Keeps the tension side of timing belt tightened, and fits orderly, the timing belt into the
timing gear of crankshaft and tensioner pulley.
Timing gear of the
camshaft
Belt pulley of
tensionner
Timing gear of
the crankhaft
(4) Unscrews the fitting bolts of tensioner pulley by the turn of 1/41/2, enabling the tension
effect of tensioner springto act on the timing belt.
(5) Turns the crankshaft for two cycles in the normal direction of rotation (clockwise) to
check if the timing marks is properly aligned.
Attention: by this method, the tension effect acts evenly on the timing belt by the driving
moment of the crankshaft. The crankshaft has to be turn as per the above-said direction
instead of turning counterclockwise the crankshaft.
(6) Tightens the fixing bolts of tensioner pulley.
2.3 Fuel control system
Removal and installation procedures
1. Engine sub-assembly
3. Throttle spacer
4. Bolted spacer
5. Bolted spacer
6. Harness bracket
7. Flange bolt
Essentials for installation operation
A Installation of oil rail assembly
(1) Prior to the injector installation, a layer of the clean oil should be applied on the surface of
the O-rubber ring for easy installation.
(2) Be careful not to damage the O-ring when fitting the injector.
(3) Fixes up the 8 with the bolt 5 on the intake manifold 1.
2.4 Water pump and cooling water hose
Removal and installation procedures
1. Cooling waterhose
7. Thermostat shell
2. Cooling waterhose
8. Thermostat spacer
E 3. Water temperaturesensor
D 4. Water thermostat
B 10. O-RING
B 11. O-RING
A12. Water pump essentials for installation operation
If the water temperature sensor is intended to be reused, the specified coolant should be
applied on its threads.
Removal procedure
1. Engine sub-assembly
2. Intake manifold
8. Bolted spacer
9. Bolted spacer
4. Bolted spacer
5. Nut
6. Spring spacer
21. Nut
23. Nut
Removal procedure
1. Air hoses
2. Oilfiller cap
3. PCV VALVE
4. PCV spacer
D 7. Oil seal
8. Oil seal
C10. Rocker arm and rocker arm shaft assembly(air exhaust) 20. Camshaft
Essentials for installation operation
A Installation of governing screw.
Places the screw into the rocker arm for a while. Puts it inside and keeps the the
bottom of screw in line with falling edge of rocker arm or slightly protruding (less
than 1mm)).
B Installation of rocker arm shaft
(1) Places the large inclined plane toward the side of timing belt.
Note: there are 8 oil holes on the rocker arm shaft of air intake valve.
(2) Faces the oil holes side of rocker arm shaft on the cylinder head.
C Installation of rocker arm/rocker arm shaft assembly
When assembling the rocker arm and rocker arm shaft, attentions should be paid on
the identification sign. Then, fits this assembly on the cylinder head.
Side of the timing belt
Identification sign
Removal procedure
A D 1. Cylinder headbolt
2. Cylinder head asssembly
9. Intake valve
10. Exhaust valve
3.Cylinder pad
B C 4. Lock pin
5. Intake valve spring holder
B 6.Valve spring
C A 7.Valve duct
8.Valve housing washer
Essentials for removal operation:
A Removal of cylinder head bolts
Unscrews the cylinder head bolts with the special tool shown in Figure
Attention:
1. The valveoil seal can be reused.
2. The correct special tools has be used for installing the valveoil seal. Incorrect
installation may cause the oil leakage when passing through the valve guide bush.
B Installation of valve spring
When fitting up the valve spring, keeps the end to be painted position at the side of rocker
arm.
Printing side
(7) Marks the plaint signs on the cylinder head bolts and cylinder head(shown in figure )
Print mark
(8) Each bolt is screwed by a plus 90 as per the tightening order.
(9) Each bolt is tightened by 90 to check whether the paint mark on the bolt head is aligned
with that on the cylinder head.
Attention: If the tightening angle of bolts is less than 90, it is impossible for them to have
sufficient power to fasten theif the tightening angle of bolt is larger than 90, they should be
removed down and refixed.
(10) If the old cylinder head bolts have been replaced during the maintenance, the overhaul
should be carried out as per the sequence (2)~(9).
(11) If no used cylinder head bolts have been replaced, the overhaul should be effected
following the order of (2),(3),(6),(7),(8) and(9).
2.8 Oil pump and oil sump
Essentials for removal operation:
A Removal of oil sump
(1) Removes the fitting bolts of oil sump.
(2) As shown in figure drives the special tool between the oil sump and cylinder body.
(3) Taps the side of special tool and makes it move along the sealing side of oil sump
/cylinder body, than removes the oil sump.
Essentials for installation operation
A Installation of front oil seal shell (oilpump shell)
(1) Cleans out the sealant painted surface of cylinder body and front oil seal shell.
(2) Applies the 3mm field shaping curl spacer on the overall periphery of the oil sump fange.
(1) Places the special tools in front of the crankshaft, and applies engine oil on its pheripher.
(2) Applies the engine oil on the sealing lips, then pushes by hands the oil seal along the guide
bush until it touches the oil seal shell. Taps the oil seal with the special tool to make it in
position
Removal procedure
1. Connecting rod nut
8. Oil ring
B A 9. Piston pin
10. Pistons
st
C 6. 1 piston ring
In favor of the re-installation, marks the cylinder number on the large head side of connecting
rod.
Cylinder no.
Front sign
Front sign
Guide bush D
Base
Attention: After the piston pins removed, puts the pistons, piston pins and connecting
rod together. Do not put the pistons, piston pins and connecting rod of each cylinder
together.
Essentials for installation operation
A Installation of piston pins
(1) Measures the following lenghs (shown in figure )
A: Outer size between the pistons bosses
B: Inner size between the pistons bosses
C: Length of piston pin
D: Thickness of the small head of connecting rod
(2) Fills the measured values into the following formula:
L=
( A C ) ( B D)
2
Link rod
Piston pin
Piston
(3) Inserts the tappet (special tool) into the piston pin, then fits the guide bush A(special tool).
(4) When the pistons and connecting rod are installed, the signs in front of them should be
located in the same side.
(5) Applies the engine oil on the outer circle of piston pin.
(6) Started from the guide bush A, presses theguide bush A, piston pin and tappet into the side
of signs in front of the pistons.
(7) Screws the guide bush B into the guide bush A. the clearance between both guide bushes
is 3mm plus the value L approached from the calculation in Step 2.
Guide
bush B
Guide
bush A
(8) In case where the sign in front of the piston is down, fits the pistons and connecting rod on
the foot mounting of piston pin.
(9) Fits the piston pin by a press. If the load I overrated, replaces the piston pins, piston
assembly and connecting rod or both replaced.
Push rod
Piston pin
Front sign
Front
sign
Guide-bush A
Base
Guide-bush B
Spacing
ring
Attention:
1. The spacing ring and steel ring may be fitted in any of directions. There is no
difference between the upper and lower steel rings
2. Color codes used for the spacing ring and steel ring sizes are shown as follows:
Sizes
Colors
Standard
None
Extra, 0.50mm
Blue
Extra, 1.00mm
Yellow
(2) In order to fit up the steel ring, fits the one end of steel ring into the groove as shown in
figure, then press-fits the other parts into the places.
Attention: Do not fit the steel ring with the expander of piston ring, otherwise they are
likelyto be broken.
(1) After the steel ring fitted up, checks whether they are slidable in both directions.
C Installation of the 2nd and 1st piston rings
Fits the 1st and 2nd piston rings with the expander of pistion ring. Their dentification signs
should face upward (top of the piston).
Identification sign:
The 1st piston ring: 1T
The 2nd piston ring: 2T
Expander of
pistion ring
Attention:
The following signs of size are marked on the piston rings:
Sizes
Standard
Extra, 0.50mm
Extra,1.00mm
Size sign
None
50
100
ID sign of 1T
ID sign of 2T
Sign of size
1st ring
2nd ring
1st ring
Piston pin
Steel ring
(3) Ains the arrow sign in front of the top of piston at the side of timing belt, from the upper
side of cylinder, press-fits the pistons and connecting rod assembly into the cylinder.
(4) Presses tightly the piston ring with the suitable pressing tool of piston ring, then press-fits
the pistons and connecting rod together into the cylinder. Do not knock forcely the pistons,
otherwise, the piston ring will be broken and the connecting rod journal crackled.
White
None
Yellow
White
None
Yellow
White
None
Yellow
I.Yellow
II.None
III.White
Col.code position
3#
ID sign position
1#
Col.code position
1#
4#
3#
2#
2#
ID sign position
4#
2#
3#
4G13S-7L Crankshaft
ID color
1#
4#
2#
1#
4#
3#
4G18S-7L Crankshaft
Cylinder No.
Notch locking
(2) Checks whether the lateral clearance of the large head of connecting rod is conform to the
provisions.
Standard value: 0.100.25mm
Printing sign
Printing
sign
Nut
Bolt
(6) Starting from the paint mark on the nut, turns clockwise toward the angle 90~94, and
makes the paint mark on the bolt.
(7) Turns the nut until it is aligned with the paint mark on the bolt and that on the nut.
Attention:
1. If the turning angle of nut is less than 90, the fastening power of connecting rod cap will
be insufficient.
2. If the turning angle of nut is more than 94, they should be fully unscrewed, and renews the
tightening steps.
1.10 Crankshaft and cylinder body
7. Lower partition
6. Upper partition
14. Crankshaft
C 11. Bearing cap bolt C 12. Main bearing cap AA16. Oil pressure switch
17. Cylinder body
Essentials for removal operation:
A Removal of oil pressure switch
Pushing direction
Specified sealant
Attention:
1. When the sealant is applied, do not let the sealant beyond the end do thread.
2. Do not overtighten the oil pressure switch. Moment: 15~22Nm.
Crankshaft journal
White
Identification sign
47.995~48.000
47.988~47.995
47.982~47.988
Identification sign
Axile diameter 2
Axile diameter 3
Axile diameter4
Axile diameter 4
None
Diameter of journal
Yellow
Identification
sign
Axile diameter 1
Color
code
Axile diameter 2
Range
Bearing
4G18S-7L Crankshaft
4G13S-7L Crankshaft
The shaft diameter level is classified as 5, 4, 3, 2 and 1 counted from front to back.
(2) The identification sign representing the bearing aperture of cylinder is the position
engraved by the number 1 in front of the engine. The selection and installation of bering have
to be made on the basisi of these identification signs have to be.
(3) On the basis of the verification of identification signs according to the steps (1) and (2),
the bearings are to be selected from the above table.
The example is given as below:
1. If the measured result of a journal is 48.000mm, it corresponds the class 1 in the above
table.
2. If the identification sign of the bearing aperture of a cylinder is the number, the bearing
with the identification sign 2 should be choosen.
(4) Except the intermediate bearing, all bearings are grooved. The intermediate bearings are
fitted with spport lugs instead of the grooves. The upper parts of the intermediate bearings are
identical.
(5) All lower bearings are without grooves.
Groove
Grooveless
(2) After the bearing fitted up, the axial clearing of crankshaft is to be measured. If the
measured value exceeds the specified limit, the crankshaft bearing should be replaced.
Crack
Separated
Crack side
Abnormal wear
(Exposed core)
Attention: If the belt sides are as sharp as the knif cutting, it should be considered as
normal.
(7) Abnormal wear on the teeth
Initial phase:
(Canvas fibers loosened, rubber destructed, white faded, canvas texture unidenfied)
Final phase:
Toothless
Height limit of
camshaft, in mm
Air intake
36.8
Air exhaust
36.666
(3) Checks with the ruller or clearance gauge to see if there are any deformations on the
surface of cylinder head spacer. If the degree of deformation exceeds the specified limit value,
the surface of spacer has to be ground according to the specification.
Standard value of spacer surface deformation: less than 0.03mm
Height of cylinder head (new): 1200.1mm
Attention: The grinding margin allowable for the fitting surface of cylinder head and
cylinder body is not larger than 0.2mm.
2. Valve
(1) Checks the valve surface to see if it is in correct contact. If the contact is not uniform or
complet, the surface of valve seat should be refixed.
(2) If the edge thickness is less than the fixed value, the valve should be replaced.
Contact
(within the
surface center)
Edge thickness
Standard value:
Limit values:
(3) Total length of measured valve. If the measured result is less than fixed value, the valve
should bereplaced.
Standard value:
Limit values:
3. Valve spring
(1) Measurement of the free height of valve spring. If the measured result is less than fixed
value, the valve spring should be replaced
Standard value: 50.87
(2) Measurement of the vertical height of valve spring. If the measured result is less than
fixed value, the valve spring should be replaced
Standard value : 2
Limit values : 4
Verticality
Free height
4. Valve duct
Measurement of the clearance between the valve guide bush and valve rod. If the clearance
exceeds the limit value, one or two parts should be replaced.
Standard value :
Intake valve guide bush: 0.0200.036mm
Exhaust valveguide bush : 0.0300.045mmm
Limit values :
Intake valve guide bush : 0.10mm
Exhaust valveguide bush : 0.15mm
Valce duct
3. Valve seat
Fits up the valve, then measures the protrusion height between the end surface of valve rod
and surface of valve spring seat. If the measured result is less than fixed value, the valve seat
should be replaced.
Standard value:
Limit value:
Cut off
(2) Rebores the hole of valve seat on the cylinder boring head to match it with the
selected extra diameter of valve seat.
Aperture of intake valve seat (Extra. 0.3mm)
Intake valve 4G13S-7L : 28.425-28.445mm
Intake valve 4G18S-7L: 30.425-30.445mm
Aperture of intake valve (Extra. 0.6mm)
Intake valve 4G13S-7L : 28.725-28.745mm
Intake valve 4G18S-7L : 30.725-30.745mm
Aperture of exhaust valve seat (Extra. 0.3mm)
Exhaust valve 4G13S-7L: 26.425-26.445mm
Exhaust valve 4G18S-7L: 28.425-28.445mm
Aperture of exhaust valve seat (Extra. 0.6mm)
Exhaust valve 4G13S-7L: 26.425-26.445mm
Exhaust valve 4G18S-7L: 28.425-28.445mm
I/D of extra.aperture
(3) Prevents the cylinder head holes from being grazed by the valve seat cooled by liquid
nitrogen prior to assembly.
(4) Corrects the valve seat to match it with the specified width and angle(refer to the operating
essentials of valve seat)
Operating essentials for the valve duct replacement
(1) Pushes out the valve duct with a pressing machine from the side of cylinder body.
(2) Rebores the hole of valve duct on the cylinder boring head to match it with the extra-sized
valve duct .
Attention: Do not fit the valve guide bush of same size
Aperture of the valve duct:
Extra,0.05: 10.605-10.615mm
Extra,0.25: 10.805-10.815mm
Extra,0.50: 11.055-11.065mm
(3) Press-fits the valve duct until its flange height reaches the fixed value.
Standard value: 23.0mm
Extruding heigh
Attention:
1. The valve duct has to be fitted in from the upper side of cylinder head.
2. The duct length on the air intake side is different from that on the air exhaust side.
3. After the duct valve fitted in, inserts the new valve and checks if it slides smoothly.
8) Pump and oil sump
1. Pump
(1) Fits the rotor into the front cover.
(2) Checks the tooth top clearance with the thickness gauge
Limit values :
(2) Places the piston ring into the cylinder hole, pushes it down with the piston. The top of
piston has to be used to contact the piston ring, so as to form an anle 90 between the ring and
the cylinder. Then measures the open clearance with the clearance gauge. If the open
clearance is too large, the piston ring has to be replaced.
Standard value:
The 1st ring: 0.200.35mm
The 2nd ring: 0.350.50mm
Oil ring 4G13S-7L: 0.200.50mm
Oil ring 4G18S-7L: 0.100.40mm
Limit value: The 1st ring: 0.8mm
The 2nd ring: 0.8mm
Oil rings 4G13S-7L and 4G18S-7L: 1.0mm
Push in with the piston
Pistion ring
Opening clearance
(3) Cuts the length of plastic wire gauge into that matching with the width of bearing.
Then places it on the journal along the axial line of journal.
(4) Softly fits the bearing cap of crankshaft and tightens the bolt till the specified moment.
(5) Removes the bolt and softly detaches the cap form the crankshaft bearing.
(6) Measures the extruding part of the plastic wire gauge with the ruler printed on the plastic
wire gauge bag.
Standard value: 0.020.04mm
Limit values: 0.1mm
Attention: The connecting rod journal of crankshaft and main journal have
been subject to the rolling process, it is unnecessary to reduce the size by the
machine tool.
2. Cylinder body
(1) Vusually checks the crackles, rust and corrosion, and examins the cylinder body with the
defection tester. Repairs the defections as much as possible or replaces the cylinder body.
(2) No spacer debris and other dyed stuff are allowed on the top surface. Checks the
deformation on the top of cylinder with the ruler and clearance gauge.
Standard value: less than 0.03mm
Limit value: less than 0.1 mm
(3) Checks if there are signs of cylinder crackles or scors on the cylinder wall. If the defection
is distinct, all cylinders should be bored to the extra size or replaced.
(4) Measures the aperture of each cylinder and the cylindricity with the cylinder gauge. If any
of the cylinders is seriously worn, it should be bored to the extra size and the piston and
piston ring replaced accordingly. The measuring points are shown as below.
Standard value:
Cylinderaperture: 71.0mm(4G13S-7L)
76.0mm(4G18S-7L)
Cylindricity: less than 0.01mm
Piston O/D
Sealant
application
(4) Bores each cylinder to the calcultated boring size. Attention: In order to prevent the
heating deformation, please proceed with the cylinder boring as per the following order: 2nd
cylinder, 4th cylinder, 1st cylinder, and 3rd cylinder.
(5) Grinds the cylinder to the final process size(piston O/Dclearance between the piston and
cylinder )
(6) Checks the clearance between the piston and the cylinder.
Standard value: 0.020.04mm
failure parts of exhaust emission as well as the engine state of primary performance. It has the
function of identifying, saving and dislaying the failure information through the
self-diagnostic malfunction indication lamps (MIL).
To guarantee the durability of the emission control performance during the use of vehicle, In
China, it is clearly stated in the Contaminant Emission Limits of Light-Duty Vehicles and
Measure Method (Phases III and IV in China)that All vehicles have to be fitted with OBD
system, which is able to ensure the identification of worsen of failure parts during the whole
service life of vehicle.
When the vehicle fitted with the OBD system is maintained, the service men are able to
rapidly and accurately locate the failure parts through the diagnostic set, which largely
increases the maintenance quality and efficiency.
The model Foton MP. Midi is equipped with the Kingtec Failure Diagnostic Set.
The OBD technology is involved with many brandnew concepts. The following pages will be
contributed to the introduction of same basic knowledge relevant to the OBD technology, so
as to facilitate the understanding of the follow-up content.
I
Failures
Once the following cases are detected by the OBD system, they are considered as Failures.
The conversion efficiency of catalytic converter decreases, and the emissions exceed the
OBD value.
The engine catches fire, the contaminants of air exhaust will surpass the OBD value, or
cause the catalyst temperature too high or damaged.
The oxygen sensor damaged or aged to the extent that the contaminants of air exhaust
will be higher than OBD value.
The parsts connecting the ECU and relevant to the emission are ineffective, and possibly
cause the contaminants of air exhaust over the OBD value.
The power train parts connecting the computer, including the abnormal circuit
communication of any sensors able to achieve the monitoring functions nitoring
functions.
1. Troubleshooting
After detecting the failure, the OBD system will proceed the following steps according to the
failure conditions:
In the ECU(Addition, Update and deletion of the relevant failure information), these
information can be accessed by the standard diagnostic set through the standard
diagnosis interface.
A failure prior to be confirmed is known as the Random Failureand then the Identified
Failuresafter it has been confirmed. In general, there are two method of confirmation of
failure:
The time, where the detected failure continues to exit, is more than 2.5s.
For the more reliable diagnosis function, this process will be applied, e.g. speed sensor
diagnosis.
The restoration of failure is referred to the fact, where the OBD system detects no existence
of failure after the failure has been eliminated. The failure restoration is also a process of
confirmation. In terms of the random failure. After the failure detected by the OBD has been
restored, the record of failure will be immediately cleaned upIn terms of the confirmed
failure, Only no such failure has been detected by three consequent operating cycles that the
OBD system can confirm the restoration of the failure, then operates accordingly the failure
indicator and failure according to the failure resolution strategy .
Depending to whether the failure has been confirmed, restored and restored by confirmation
or not, the failures can be devided into the following status:
Fault condition
Whether found
by detection
Whether
restored
Whether
confirmed
Whether
restored
Whether the
restoration
confirmed
Random and
non-confirmed
Random and
confirmed
Confirmed and
not restored
Confirmed but
restoration not
confirmed
Confirmed
with
restoration
confirmed
MI CONTROL
Random and
non-confirmed
Random and
restored
Fault condition
MI CONTROL
Failure confirmed
but not restored
yet
Failure confirmed
prior to the
restoration
confirme
Failure confirmed
after the
restoration
confirmed
MI deactivated.
When the ignition switch is turned on and the engine has not started up or run, MI will
lighten.
If the confirmed failures relevant to the emission (except the catch-fire failures caused
by the catalyst damage) already exist in the system, the OBD system will light up the MI
lamp to remind the driver for check.
Once the engine caught on fire meets the level specifield by the manufacutrer, to the
extent that the catalytic converter risks to be burnt out, MI will immediately flash at the
frequency of 1Hz.
After engine started, MI will go out in 3s if no failures have been detected before.
If the fire rate of engine able to destroy the catalytic converter doent exist anymore or
the fire rate of engine is not to such an extent as to damage the catalytic converter after
the engine speed and load have been changed, MI should be switched to the original
state prior to the activation.
For all of other failures, during three consequent operating cycles, if the monitor system
of the activated MI detects no failures and other MI failures which can be individually
activated, MI will deactivate (go out).
The 1st character of the failure codes is a letter, refleting the system, which the failure belongs
to:
Pxxxx
Bxxxx
Body failure
Cxxxx
Chassis failure
Uxxxx
Netword failure
The failures relevant to the OBD system are mainly expressed with the code P.
The 2nd character of failure codes represents the failure code maker:
P0xxx
in conformity with to the SAE definitions and applicable to the diagnosis system
and freely select the failure code, they comprises specific text description of
failures(From the model year 2000: P0xxx and P2xxx)
P1xxx
The 3rd character of failure codes represents the type of failures, which are defined as follows:
Px7xx Gearbox
Px8xx Gearbox
Px9xx Gearbox
The 4th and 5th characters of failure codes represent the signs of failure part/system.
The failure code of random failure detected by continuous monitoring will be output in the
Mode 7 of scan tool throught the standard scan tool and diagnosis interface; the failure code
of the identified failure will be output through the Mode 3; the failure code corresponding to
the blocked frames (if any) will be output through the Mode 2.
II. Performance description of failure diagnostic set
The OBD system is able to provide many information relevant to the failure diagonse, which
are of reference value in terms of the maintenance of electric injection system. According to
the definitions of ISO/DIS15031-5, the information relevant to the OBD system may be
03 Reads out the failure code by the power system diagnosis relevant to the emission.
04 Cleans out and resets the diagnosis information relevant to the emission.
06 Reads out the OBD test result by the continuous monitoring system.
07 Reads out the OBD test result by the continuous monitoring system.
The output information under each mode is identical, which are described respectively in the
following text. It is worthy of noting that,
The different diagnostic sets vary in design and use, but the it is certain that the content to be
accessed be one of the above modes.
(1) Mode 1
The function of the Mode 1 is to allow the exteriour standard diagnosis set to get access to
some data values relevant to the current basic parameters of the emission according to the
requirements of regulations. These parameters include the information of some
system-simulated input/output, digital input/output and system states etc.
The International Standard ISP/DIS15031-5 has defined all parameters, which can be output
from the Mode 1. The definitions contain the Name, unit, format, text description of
parameters. The parameters between them are recognized by the parameter identifiers(PID).
In the output of the Mode 1, all parameters relevant to the emission of the OBD system,
including the PID, parameter values, unit and text description will be listed one by one.
According to the regulations, the output of the Mode 1 has to comprise at least the following
parameters (If the on-board ECU is fitted with, or determined via the on-board ECU):
PID 0A
Fuel pressure
PID 0B
PID 0C
Engine in rpm
PID 0D
Speed
PID 10Airflow
PID 1C
In addition, the output of the Mode 1 includes in general the information of the oxygen sensor
position (PID 13) and the voltage value of each oxygen sensor output (The oxygen sensors in
different types and positions correspond to different PID). The outcomes from the Mode 1 are
the current true values of the electric control system(In case of some failures, the system may
use the default or alternative value), these results provide important reference values to the
maintenance service.
It is particularly noteworthy that the PID 01 reflects the state of OBD system.
(2) Mode 2
According to the requirements of regulations, once the initial failure has been detected by the
ODB system on any of the parts or systems, the blocked data frame of the engine state has to
be stored into the ECU memory. The function of the Mode 2 is to output the information of
blocked frames of OBD system.
Each information of the blocked frames output by the Mode 2, same as the Mode 1, has to be
conform to the relevant definition of the International Standard ISO/DIS 15031-5. All states
of engine saved, include but not limited to the following parameters:
PID 03
PID 04
PID 05
Coolant temperature
PID 0A
PID 0B
PID 0C
Engine in rpm
PID 0D
Speed(if available)
PID 02
It is noteworthy that only one group of the blocked frame information can be saved in the
Mode 2. In case of multiple failures detected by the system, only the failure possessing the
higher priority of blocked frames will display in the output of Mode 2.
Higher priority
Lower priority
(3) Mode 3
The function of the Mode 3 is allow the access of the exterior testing devices to the failure
codes of dynamic system relevant to the emission. Different from the Mode 2, the Mode 3 can
output multiple failure codes.
If the same failure doent show up during more than 40 operating cycles of engine preheating,
it can be delected by the on-board diagnosis system, including the information of travel
distance since the failure dislay and blocked frames.
The alleged the cycle of engine preheating refers to the vehicle fully driven to get the
temperature of engine coolant at least 22 K higher than that at the time of starting, and
achieve up to min.343K (70deg).
(4) Mode 4
The objective of the Mode 4 is to enable the exterior testing devices for deactivating the MIL,
clearing out the diagnosis information relevant to the emission in ECu. Those information
include:
Codes ready for the failure diagnosis (accessible through the PID01 under the Mode 1)
Data on failure code and blocked frames corresponding to the blocked frames(accessible
through the Mode 2)
Drive mileage after the MIL has been activated(accessible through PID 21 of Mode 1)
(5) Mode 5
The objective of the Mode 5 is to access to the monitor result of each oxygen sensor. The
information output includes the constant values predefined and some outcomes of
measurements/calculations. In terms of the results of the measurement /calculation, their
corresponding max./min.values will be output at the same time, the format of which is listed
as follows:
TID
Test Value
Min Limit
Max Limit
The test ID signs reflect the different test projects of the oxygen sensorwhich are
defined as per the corresponding international standards.
ISO/DIS 15031-5 provides the definitions for all accessible information of oxygen sensor.
Each information has a corresponding test identifier (TID)
In terms of the two-point oxygen sensor system, the commonly used TIDs are listed as
follows:
TID 09 Switching time required for two times from dense to thin
In terms of the widthbanded oxygen sensor at the upstream of catalyst, the output of the
Model 5 include the following TIDs:
Based on the information from the Mode 5, it is convenient to know the main index of each
oxygen sensor and its corresponding boundary, which enables for judging whether therea are
failures in the oxygen sensor, types of failures and the level of failure.
(6) Mode 6
The objective of the Mode 6 is to access to the result of non-continuous monitoring by the
on-board diagnosis system on a component/system. the alleged non-continuous monitoring
refers commonly to the single diagnosis completed by a cycle of drive, e.g. The diagnosis
CID
Test Value
Min Limit
Max Limit
The test ID number is classified as per the diagnosed objectwhich is definedby the automobile manufacturer.
The information accessed from the Mode 6 is the last diagnosis result of the OBD system,
which will be saved until the next diagnosis has been finished and will be not disappeared by
turning off the switch key.
According to the test result provided by the Mode 6, it is judgeable wheterh there are any
failures in the index corresponding to the component as well as the failure level.
After the maintenance, the determination on whether the failure has been correctly eliminated
or not can be made according to the test result from the Mode 6.
(7) Mode 7
The mode 7 is able to output the test result by continuous diagnosis , e.g.
The Mode 7 only displays the random failure. The random failure has been detected, but it is
not yet finally confirmed. The random failure is unable to activate the MIL.
Once the failure confirned, the record of failure will display in the Mode 3 instead of in the
Mode 7. The recorded result from the Mode 7does not necessarily indicate that the
corresponding failure still existing in the system.
The service men can confirm whether the failure has been truly cleaned out by accessing the
output of the Mode 7 after eliminated the failure and completed a cycle of drive, instead of
driving several cycles unti the failure has been confirmed and the MIL activated.
(8) Mode 8
The regulations in China and Europe do not require the function activation of the Mode 8 by
the OBD system.
(9) Mode 9
The objective of the Mode 9 is to allow the exterior devices for getting access to the
designated information, e.g. the Vehicle Identification Number(VIN), Calibration
Identification Number(CID or CVN) EOBD, which only requires that the Mode 9 outputs the
Calibration Identification Number(CID).
III. Inspection procedure of failure
For the vehicles fitted with the OBD function, the inspection of failures respects in general the
following procedure:
1. Connects the diagnosis device to the diagnosis interface to get through the diagnosis
device.
Position of diagnosis seat
Device connection
Function interface
Interface of models
Interface of systems
4. Troubleshooting
5. Troubleshooting memoryDriving the car adequately, but in a way meeting the
conditions of failure diagnosisgets accesss to the failure information and confirms the
elimination of failure.
IV. Connection of diagnostic set
The system adopts the KLine Communication Protocol and applies the standard diagnosis
connector ISO 9141-2 as shown below in figure 2.5. This standard diagnosis connector is
perminently connected on the harness of engine. The standard diagnosis connectors used for
the Engine Management System (EMS) are the pins no. 4,7 and 16.
The pin number 4 of the standard diagnosis connector is connected to the grounding of the
vehiclethe pin number 7 to the pin no.71 of the ECU, i.e. the Kline of engine datathe pin
no.16 to the positive of the battery.
ISO9141-2
37.9
4150300
2.833 ( 51/18 )
31.51.0
O/D I/D( mm )
200130
Friction materials
B8805
Spline size
24/48-30 0 20NT
control mode
2.87
None
Self-aligning type
Clutch disc
2. Basic specifications
Items
Specifications
200130
3. Inspection specifications
Items
Specifications(limit value)
0.3
0.5
0.15
Specifications(N.m)
15 ( 1.5 )
18 ( 1.9 )
22 ( 2.3 )
11 ( 1.1 )
18 ( 1.9 )
35 ( 3.6 )
Removal procedures
1. Clutch cable bracket
6. Reset spring
2. Bolts
3. Dust cover
A A
9. Clutch disc
Checks the damping spring to see if there are any looseness and breakage. In such problems occurred,
the clutch driven disc should be replaced.
Fits up the clutch driven disc on the input shaft. Checks if the lubrication state and turning direction are
loosened. If they are sliding in poor state, then you should clean them up. Replacement after the assembly.
If obviously loosenedthe clutch driven disc or input shaft should be replaced or both replaced at the same
time.
1.3 Release thrust bearing of clutch
Attention: As the release thrust bearing is packed with the greasebe sure not to use the grease, Substances
to clean it
(1) Checks the bearing to see if there are burns, damages, abnormal noise and uneven revolution etc
(2) Checks the contact face between the release thrust bearing and diaphragm spring to see if there are any
wears. If any abnormal wears on the contact face, the replacement should be made.
(3) Checks the contact face between the release thrust bearing and release fork to see if there are any
abnormal wears on the contact face. If any abnormal wears on the contact face, the replacement should be
made.
1.4 Clutch release fork
(1) Checks he contact face between the release fork and release thrust bearing to see if there are any wears.
If such case, the replacement should be made.
Chapter IV Gearbox
Section I Summary
1. Baseline profile
Gearbox model
F5M41-7L
F5M41-71
Applicable engine
4G13
4G18
Mode
4.333 (78/18)
4.052 (77:19)
Wheelbase (mm)
78 126 204
Full length(mm)
390
390543365
st
3.583 ( 43:12 )
nd
1.947 ( 37:19 )
rd
1.343 ( 43:32 )
th
0.976 ( 41:42 )
1 gear
2 gear
Gear ratio
3 gear
4 gear
th
5 gear
0.767 ( 33/43 )
0.804 ( 37:46 )
Reverse gear
3.416 ( 41:42 )
No.4.2
1st gear
0.98
nd
0.98
rd
0.98
th
0.98
th
5 gear
0.98
Reverse gear
0.97
1st gear
71 bicone
2 gear
Transmission efficiency
3 gear
4 gear
nd
71 bicone
rd
71 bicone
th
71 monocone
th
5 gear
71 lever synchronizer
Reverse gear
Lever synchronizer
2 gear
Synchronous ring size (mm)
Synchronous ring mode
Speed sensor
Lubricant oil
3 gear
4 gear
Gearshift lever
ratio
Gear selecting
lever ratio
55/22.37
60/35
Gear ratio
31/36
mode
Electronic
SAE viscosity
classification
API
classification
Oil mass(L)
2.1
41
Materials and
models used by AOS
Lubricant oil
Lubricant oil
Lubricant oil
S/N
Assembly location
Shift fork
Clutch Bearing
Input shaft oil seal
Gear oil
Gearbox assembly
Lubricant oil
Sealant TB1501
LT480
Air respirator
Anti-rust oil
Input shaft
Gear oil
Gear oil
10
Sealant TB1303
LT243
Differential bolt
11
Sealant TB1216
LT5699
12
Gear oil
13
Sealant TB1216
LT5699
3. Special tools
Tools
Numbers
Names
Intended uses
MD998812
MD998813
Fitting tools100
MD998814
Fitting tool200
MD998817
Tools
Numbers
Names
Intended uses
MD998822
MB990926
MB990927
MD990934
MD990935
MD990938
Handle
MD998818
MD998819
MD998820
Tools
Numbers
Names
Intended uses
MB998325
Fitting tool of
differential oil seal
MB998346
Dismantle tool of
bearing outer ring
MB998801
Dismantle tool of
bearing
MD998826
MD998917
Dismantle tool of
bearing
4. Baseline profile
Model of gearbox
F5M41-7L
F5M41-71
Applicable engine
4G13
4G18
4.333 ( 78/18 )
4.052 ( 77/19 )
th
mode
3.583
3.583
nd
1.947
1.947
rd
3 gear
1.343
1.343
4th gear
0.976
0.976
5 gear
0.767
0.804
Reverse gear
3.416
2 gear
Gear ratio
th
3.416
31/36
5. Inspection specifications
Items
Front bearing clearance of Input shaft in mm
Limit value
0 0.12
0 0.09
0 0.09
Items
Limit value
0 0.12
0 0.09
0 0.09
0.05 0.17
0 0.150
0.5
rd
Identifier
Mitsubishi-Part No.
2.24
None
MD706537
BS15-1701037-1
2.31
Blue
MD706538
BS15-1701037-2
2.38
Brown
MD706539
BS15-1701037-3
7.
Thickness
Identifier
Mitsubishi-Part No.
2.31
Black
MD747149
BS15-1701038-11
2.35
None
MD746561
BS15-1701038-1
2.39
Blue
MD746562
BS15-1701038-2
2.43
Brown
MD746563
BS15-1701038-3
2.47
Green
MD746564
BS15-1701038-4
2.51
White
MD746565
BS15-1701038-5
2.55
Yellow
MD746566
BS15-1701038-6
2.59
Black
MD746567
BS15-1701038-7
2.63
Orange
MD746568
BS15-1701038-8
2.67
Blue
MD746569
BS15-1701038-9
2.71
Brown
MD746570
BS15-1701038-10
Nm( kgfm )
50 ( 5.1 )
44 ( 4.5 )
9.8 ( 1.0 )
18 ( 1.9 )
18 ( 1.9 )
3.9 ( 0.4 )
18 ( 1.8 )
18 ( 1.8 )
11 ( 1.2 )
132 ( 13.5 )
32 ( 3.3 )
18 ( 1.8 )
32 ( 3.3 )
Items
Nm( kgfm )
32 ( 3.3 )
48 ( 4.9 )
18 ( 1.8 )
69 ( 7.0 )
Break-down procedure:
1. Gearbox bracket
7. Gasket
2. Speedometer sensor
9. Gasket
11. Gasket
12. Bracket
17. Gasket
A I 18. Sealing Cap
B H 19. Gearbox shell
C G 20. Reverse gear
Break-down procedure:
D 28. Spring pin
DRemoval of the 34 shift fork shaft/34 shift rail/5reverse shift rail/elastic ring/reverse shift lug/5reverse shift fork shaft/steel ball/reverse interlock rail.
(1) Moves the reverse shift lug to the direction shown in the figure. while dismantling the sub-assembly of
5- reverse shift fork shaft and reverse gear arm snap ring, steel ball and reverse interlock rail.
(2) Moves the reverse shift lug to the direction shown in the figure. and removes it together with the fork.
(1) On the position of gearbox shell as shown in figure., places soldering tin(Length ca. 10mmdiameter, ca.
1.6mm)then fits up the differential.
(2) Fits up the clutch shell and tightens the bolts to the specified moment.
If the soldering tin is not pressed flatuses the thicker soldering tin to repeat the procedure of (1) and (2).
(3) Measures with a micrometer the thickness(T) of flattened soldering tin and selects the gasket according
to the formula shown as below.
To select the thickness of gasket: (T 0.05mm) to (T 0.17mm).
Operating essentials to the reassembly.
CFitting of the reverse interlock rail/steel ball/5-reverse shift rail/reverse shift lug/snap ring /5-reverse
shift fork /34 shift fork /34 shift rail.
(1) Fitting of the 3th 4th shift rail and fork.
(2) Fitting of reverse interlock rail, steel ball, 5threverse shift rail. 5-reverse shift fork, reverse shift lug,
snap ring and positions them as shown in figure.
(3) Moves the reverse shift lug to the direction shown in figure. while fitting the 5-reverse shift fork, shift
rail and reverse shift lug, snap ring, steel ball, reverse interlock rail.
(2) Orients the bolt hole on the reverse gear to the direction shown in figure.
(2) Tightens the shell connected bolts with the specified moment.
Attention: Be sure of pressing down to the position shown in figure.
Break-down procedure:
L1. Snap ring
A K2. ball bearing
3. Snap ring
Attention: presses in the gear hub to push the synchronous ring in instead of meshing in.
(2) Aligns the deep groove of the synchronizer hub with the bump of the gear sleeve and fits up.
Attention: Pushes the hub in to prevent the synchronous ring from meshing up
(1) Aligns the deep groove of the synchronizer hub with the bump of the gear sleeve and fits up.
Break-down procedure:
J 1. Snap ring
A I 2. Ball bearing
3. Snap ring
4. 5th gear, driven gear
th
(1) Fits up the synchronizer gear sleeve to make it in the direction shown in figure.
(2) Aligns the deep groove of the synchronizer hub with the bump of the gear sleeve and fits up.
Break-down procedure:
1. E clip
3. O-race
4. Sleeve
Break-down procedure:
A 1. Dust cover
2. Nuts
3. Spring gasket
4. Gasket
5. Gear selector sleeve
A 9. Dust cover
10. Gear selector shaft
Break-down procedure: :
A F 1. Lock pin
2. Interlock plate
3 Control arm
4 Pin
5 Return spring
6. Limiting plate
E 7. Spring pin
D 8. Spring pin
9. Limiting shoe
C 13. Aerator
14. Dust cover, control shaft
B 15. Oil seal
A 16. Needle bearing
17. Spring gasket
18. Limit show bracket
19. Control shaft shell
(2) Start fitting up and making the bump in the direction shown in figure.
Break-down procedure::
1. Cage retainer, clutch bearing
D 2. Oil seal
C 3. Oil seal
5. Oil guider
A 6. Sleeve
7. Clutch shell
Installation operating essentials only referred when replacing the clutch shell.
Essentials to the break-down procedures
8) Gearbox shell
Break-down and reassembly
Break-down procedure::
C 1. Oil seal
B 2. Needle bearing
3. Oil guider
4. Snap ring
A 5. Sleeve
6. Gearbox shell
Installation operating essentials only referred when replacing the gearbox shell.
9) Differential
Break-down and reassembly
Break-down procedure::
D 1. Gear, driven gear
A C 2. Ball bearing
B 3. Lock pin
A 4. Shaft, planet pinion
A 5. Planet pinion
Essentials to the break-down procedures
A 6. Gasket
A 7. Differential gear
A 8. Gasket
9. Differential case
(5) If the teeth clearance exceeds the standard valueyou should select the suitable gasket and measures the
teeth clearance.
Remark: Adjusts to make even the teeth clearances at both sides.
BFitting of the lock pin
Fits it up to make it in the direction shown in figure.
Conductivity
Non-conductive
Conductive
2) Input shaft
1. Input shaft
(1) There should be no damage on the outer circle of the needle bearing mounting as well as abnormal
wears and scalds.
(2) Checks the splines to see whether there are damages or wears,
2. Needle bearing
(1) Combines the input shaft, sleeve and the gears and let them run to verify if they run smoothly and with
any abnormal noise.
(2) Whether the cage retainer is deformed.
3. Synchronous ring
(1) The teeth face of the synchronous ring should have no damages and breakages
(2) On the conical inner surface, there should be no damages, wears or no breakage on the thread teeth.
(3) Pushes the synchronous ring toward the gear to check the clearance A. When the clearance A is
lower than the limit value, it should be replaced. Limit value: 0.5mm
3) Output shaft
1. Output shaft
Checks the damage and wear of the spline.
2. Needle bearing
(1) When combining the input shaft sleeve with the gears for running together, checks to see if they run
smoothly and with any of abnormal noise
(2) Whether the cage retainer is deformed.
3. Synchronous ring
(1) The teeth face of the synchronous ring should have no damages and breakages.
(2) On the conical inner surface, there should be no wears or no breakages on the thread teeth.
(3) Pushes the synchronous ring toward the gear to check the clearance A. When the clearance A is
lower than the limit value, it should be replaced. Limit value: 0.5mm.
4. Synchronizer sleeve and hub
(1) When combining the synchronizer sleeve with the synchronizer hub to let them skiddingthey should be
able to skid smoothly with no retardation.
(2) On the front/rear end of the inner surface of gear sleeve, there should be no damages.
Attention: In replacementthe synchronizer sleeve and synchronizer hub should be replace as one group.
5. Synchronizer spring
The spring elasticity should not decay and there are no deformation and breakages.
6. Speed gear at each gear
(1) Helical gear and the teeth face of outer gear should have no damages or wears.
(2) On the conical surface of outer gear, there should be no roughness, damages and wears.
(3) On the inside peripheral and front/rear surface of gear, there should be no damages and wears.
Description
Type of steering
Rack trip
148mm
4.64 circles
Description
Type of steering
Rack trip
143mm
(3.34 circles)
Vane typed
7.5mL/r
1.52.0MPa
Section II
Steering wheel
Meachnical steering
2. Operation principle of steering booster: Under the control of driver, the change of direction of the wheel
is actualized by the hydraulic pressure produced from the power steering pump driven by the engine.
Steering oil
reservoir
Steering
wheel
Steering oil
pump
Steering
device
of the
Heavy steering(mechanical
steering)
Heavy
booster)
steering(steering
Driving deflection
Solutions
front wheel
Replaces the
CS drive shaft, LH
CS drive shaft, RH
Figure 1.1
1) Applies the gear oil on the surfaces of drive shaft splines and gearbox shell.
2) Be sure that the opening of snap spring faces down prior to the assembly of drive shaft.
3) Inserts the sliding end 2 of CS axle shaft, LH into in the left end of differential, and fits the fixing end
1in the front wheel hub LHInserts the sliding end 2 of CS axle shaft, RH into in the right end of
differential, and fits the fixing end 1in the front wheel hub LH (See figure 1.1).
Attention: be sure to insert the ends 2 and 3 of differential on the position until a Click from the snap
spring is heard. There is a clearance in 3-5mm on the outermost face of gearbox in the sections 4 and 5 of
the universal joint at the sliding end (See figure 1.1)
4) Checks by hand the drive shaft after the assembly.
5) Fits up the axle nuts and locks the nut caps and lock pins (See figure 1.2)
6) Fits up the wheel assembly.
Lock pin
Figure 1.2
Sub-frame assembly
2. The rear suspension uses the trailing arm typed, torsion rod independent suspension, which is
characterized by less space occupation, compact structure and strong load capacity. It is fitted with the
torsion bar stabilizer assembly, which is able to control effectively body heeling and increase the safety.
The rear suspension assembly is shown in figure 2.
2. Failure symptom: Oil leakage on the front/rear shock absorbers accompanied with abnormal noise.
Causal analysis: Hydraulic oil leakage in the shock absorber due to the failure of shock absorber
gasket, abnormal noise caused by the absorbing performance degradation of the
shock absorber.
Solution:
Tests the front wheel positioning, adjusts the toe-in, supplements the tire pressure.
Replaces the lower ball joint when necessary.
Front wheels
Steering angle of
front wheels
Front axle
type
Introversion
of master pin
Backward
tilt of master
pin
Camber of
wheels
Toe-in of
front wheels
Internal
corner
Outer
corner
Steering
booster
10830
23030
1530
13 mm
(1510)
37
31
Mechanical
steering
10830
130
1530
13 mm
(1510)
37
31
BJ6438MC6VA-1
BJ6438MC6VA-2
BJ6438MC6VA-P1
BJ6438MC6VA-P2
BJ6438MC6VA-P1
BJ6438MC6VA-P2
2.
Rear wheels
Model of product
BJ6438MC6VA-1
4.052
BJ6438MC6VA-2
4.333
BJ6438MC6VA-P1
4.052
BJ6438MC6VA-P2
4.333
-12530
-2010 or
-1-3mm
Items
Data
Hydraulic operated with vacuum booster,
double-loop-wheel brake system and front disc and rear
drum brake.
Disc brake
Rear wheel
Drum brake
Brake disc(mm)
Standard thickness
22 01
Friction plate(mm)
Standard thickness
18 0.2
Standard value
228.6
Standard thickness
Cylinder diameter
23.81
Stroke
35.68
Brake
+02
22.22
brake liquid
10
11
166
12
50m
2) In reassembly, takes care of the cleanness of each brake connector. The oil pipe has to be securely
clamped with the clip and joints fastened. The oil pipe should be free of obstruction and the joints without
leakage.
2. Exhaust adjustment of the brake lines system
The brake system is fitted with the ABS, type MK60.
In terms of the air exhaust of line, please refer to the specifications of the ABS liquid filling and air exhaust
3. Inspection of the brake performance
The automotive brake performance may be inspected on the brake tester. Drives the car onto the test-bed
and tests respectively the weight of front axle and rear axle. Then drives the tested car on the brake tester
and keeps it in straight position. Operates as per the operating instructions of equipment. Only one
inspector is allowed in the car.
60%
15%
20%
Percentage(%) between the front axle brake power and the shaft load
Ratio between the R/L difference of the front axle and the greater (%)
Brake
performance
testing
Ratio between the R/L difference of the rear axle and the
Greater (%)
Ratio (%) between the max. value of the brake power difference and the rear axle load
when the rear axle brake power is 60% lower than the rear axle load.
7%
Ratio (%) between the sum of the parking brake power and the vehicle weight.
20%
60%
Percentage (%) between the total brake power and the vehicle mass.
Troubleshooting
Replacement
Reassembly
(2) Ineffective brake. The car is unable to stop immediately when the brake pedal is stepped down, even
with poor effect followed by several steps.
Causes
Troubleshooting
Excessive gap between the brake pedal and the free stroke
Excessive gap between the brake drum and friction plate clearance
(3) Brake deviation. When making the brake, the brake power at both side is unbalanced or asynchronous
which deviates the car during the brake process.
Causes
Troubleshooting
The clearance of the brake shoe plate on the right wheel is inconsistent
Joint of some brake hose jammed. Air leaked into the pipeline
Repair
Troubleshooting
Troubleshooting
Too narrow clearance between the brake drum and friction plate
The reset spring of brake shoe weakens or support pin of brake shoe and
eccentric resistances too large
Replace or repair
3. Abnormal brake noise. When making the brake, you often hear the squeak noise or discontinuous
friction.
Causes
Troubleshooting
4. Gradual depression of brake pedal. When braking during the drive, it suddenly happens to step down
brake pedal to the end or not rebound sufficiently by continuous steps on the brake pedal.
Causes
Troubleshooting
Oil leakage of the brake line or air leaked into the system
Reparation
5. Brake pedal gradually raised up. When braking in the drive, the brake pedal raises up gradually by
several continuous steps
Causes
Troubleshooting
Readjustment
6. Brake pedal too ponderous. It feels difficult with poor braking effect when stepping down the brake
pedal due to the vacuum booster failure.
Causes
Troubleshooting
Appendix: Test method to prove whether the brake drum is in normal heating process or not:
Drives the car on a plain road for 10km and uses the brake properly, then touches the brake drum. If the
temperature is tolerable, it is considered that the brake drum is in normal temperature.
Attention:
1. Under the above state, it is allowable that the temperature difference exists between the front/rear brake
drums or R/L brake drums.
2. In case where the temperature of brake drum is intolerable by hand touch when several emergency
brakes have been tried on the road test path, it is considered that the brake drum is in abnormal temperature.
Section I Battery
I. Introduction to the product structure of battery
z This is afully service-free lead-acid battery.
z The positive/negative grids of battery are made on the lead-calcium alloy. The grid applies the
intermediate plate lugs and radial-grided frame in lesser thickness.
z The battery uses the PE bag-partition.
z The polar group of battery is made in general, through the forge welding.
z The positive/negative plates of battery are made in the application of the active substances in most
rational formular and painted by machine, the substance of positive/negative nature are formulated
through calculation in best ratio.
z The plastic enclosure of battery adopted the seal structure.
z The plastic grooved bottom is designed in fixed structure.
z The plastic cover is in double layers, two covered rooms are designed in the structure of labyrinthed
acid reflux and air exhaust.
z In the host exhaust port are fitted the hydrophobic air filter plates, which, in case of no acid leakage do
not restrict the air overflow, but once the acid exhaust into the system, it will reflow into the battery.
z The air filter plates in the exhaust system also perform the effect of antiflame device, which is able to
prevent
z The battery explosion due to the exterior open fire or the entry of sparks into the battery.
z The battery applies the sulfuric acid of higher purity and strictly controls the quantity of electrolyte in
the battery.
z The battery is fitted with the charge indicator,
z Through the sight hole of indicator, you may keep track of three states such as the adequate charge,
shortage of charge and insufficient electrolyte.
The battery is located near the gearbox at the left side of the engine compartment. In application of the
following fixing method, it is press-fixd on the battery bracket by the battery platen.
Precautions to the installation: The battery grooves have to match up with the bumps on the battery bracket.
When fixing the platen, Places first the bump into the groove, then, tightens the nut.After the completion of
installation, the battery must be ensured with any shakes.
Charge
indicator
Color description:
Green
Good
Black
Charge required
Liquid insufficient and
necessary for replacement
None
The battery contains the highly corrosive dilute sulfuric acid. Wear the protective gloves and
safety goggle during operation. Care for protecting your eyes and face. Once exposed to the
skin, rinses it with plenty of water for several minutes, then calls on the doctor for medical
treatment.
The battery belongs to the dangerous parts. Reads carefully the operating instruction manual
prior to the operation!
The battery is able to produce flammable and explosive gases. The cigarettes, sparks or sparkle
are possilbe to cause the battery explosion, thus, use of open flame, coverless lamp and
smoking are strictly prohibited near the battery
The charge of battery can easily produce flammable and explosive gases, hence the charge
should be carried out in a well ventilated place.
Sing of recycle. The material of value of the battery may be reused. Therefore, it is prefereable
to give the used or damaged battery to the Dealership or service station of Foton Company
The battery also contains the toxic substances e.g. sulfuric acid and lead etc. The are the
special garbage harmful to the environment. Be sure not to handle it as household waste.
Operation notes and cautions:
z Chechs the voltage of battery measuring terminal prior to the loading. If the voltage at terminal is lower
than 12.5V, the charge is necessaire.
z Handls the battery with care during the loading. In the process of handling and use, the battery inclined
should be less than 30. Be careful of the polarity and positive anchoring when loading. Avoid the
mechanical shock during the use.
z De sure not to disconnect the battery when the ignition switch is turned on the engine runs, otherwise it
may damage the electric system or parts.
z When a metal part comes into contact with two polarities of battery electrical wiring, or the
positive of battery with the body, the short-circuit will come about and cause the fire and serious burns
z Prior to operating the electric system, you have to shut down the engine and all powered devices,
disconnect the negative cable of battery.
z When disconnecting the battery with the vehicle electric system, the negative cable has to be cut off,
then the positive. The reverse order is required when encasing.
z Do not keep the battery under direct sunshine for longtime, to avoid the damage of the battery shell by
strong ultraviolet ray.
z It is recommended to disconnect the battery when the car is going to leave unused more than 1 month.
z Provided the car is not used at low temperature for longtime, the proper measures for battery protection
should be taken to prevent the frozen damage.
z Be sure not to charge the frozen or defrost battery, otherwise it is likely to cause explosion. The frozen
battery has to be replaced. The empty battery is likely to freeze at about 0.
z In storage of battery, be sure that no large difference of temperature between the upper and lower parts,
otherwise the free discharge will come about.
Maintenance and testing
z The ambient temperature for battery storage is at 5-40, the heating or cooling measure should be
taken in excess of this rage.
z The environment of battery storage should be kept clean and dry, and the protective measures from
dust, rain and moisture should be available.
z If the storage of battery is longer than 90 days, it should be charged, the charge is to be made by the
ways as follows:
(1) The current at the rate capacity of 0.1 time for 20 hours (e.g. 6-QW-70: the charge current
=0.170=7A): After the battery voltage charged with the constant current reached to 14.40V,
continues to charge it for 1-2hours.
(2) Before the sale of car, the voltage should be measured. If the terminal voltage is lower than 12.50V,
the charge should be supplemented as per the above method.
z Visually checkes the outlook to observe if the battery shell shows any expansions or fractures. In case
of such expansion or fracture, be sure not to use again.
z Checks if there are any corrosions and contaminations on the connections of battery cable and the
cables. If contaminated, loosens them and wipes out.
z Checks through dropping the voltage of battery poles, and judges by the voltage dropout if there are
poor contacts at the joints. If the voltage dropout is higher than 0.1V, it indicates that extra-high
resitance exists at the pole connection, the joints need to be cleaned out.
z Leak detection of battery: connects the negative lead of voltmeter to the negative column of battery;
moves the positive lead to different position of battery shell. If no leakage of battery, there is no votage
display.
z This is the maintenance-free battery. With an interscope, the rough judgment can be made: when the
battery is of adequate charge (over 65%), it displays in green, when the charge is lower than 65%, it
displays in black. If colorless, it means the shortage of electrolyte. For the time being, the battery has to
be replaced.
z The voltage tesing by open circuit may substitutes the gravity testing: Bridges two test leads of
voltmeter over two pole columns of battery to measure the open-circuit voltage. The corresponding
relation between the test value of open-circuit voltage and the power state are shown as below:
Open-circuit voltage/V
12.6
12.4
12.2
12.0
11.9
Power state /%
100
75
50
25
Fully discharged
Battery charge:
Additional charge of battery
z Storage period: three months for the storage of battery with liquid. When using in excess of the time
limit, the charge should be supplemented by the ways as follows:
In terms of maintenance-free battery: the charge applies the method of constant voltage: constant
voltage at 16V; max. tolerance current: 0.25C20A, until the charge current approaches the zero, and
keep continuousely steady for 2-3hours without change.
Description: C20 refers to the nominal rate capacity of battery for 20hours, e.g. the nominal rate
capacity for 20hrs of the battery in 54Ah: 54Ah, max. tolerance charge of current: 0.2554=14A
z When charging the battery, the temperature should not be higher than 45, otherwise the measures
such as the water bath should be used to reduce the temperature to temporarily lower the charge current
or voltage.
z During the first 3 hours of the charge process, be sure to observe in time and adjust the charge current,
so as to prevent the burnout of charger due to the overcurrent or other accidents.
Difference of supplementary charges between the fully free-service battery and open battery
z Because of the structural difference of the maintenance-free battery from the open typed battery, the
former one requires no water supplementary supply during the usage, thus the different charge method
is applied for the routine maintenance and application.
z In the maintenance and charge of open typed battery, the actual interior of the battery can be visible
because of the openable stopper, which enables the density measurement of each cell. While testing the
battery, each cell can be individually checked by the methods of constant voltage limit and constant
current charge; the distilled water can be supplemented during the use and maintencance, while the
service-free battery is different instead.
z When charging the maintenance free battery, the constant voltage limit should be applied, the voltage
at each terminal of battery in average should not exceed 16V(12V battery, same as below). If the
voltage is over 16V, large amount of air will exhaust from the air outlet, and cause the loss of
electrolyte. During the use, the battery can not be added with water. The overdissipated air will
premature the failure of battery. Therefore, the charge voltage of the service-free battery has to be
strictly controlled during the use and maintenance.
z In normal cases, the service-free battery doesnt require the charge by constant current, for the
temperature of battery will increase at the later period of the constant-current charge, most electrolyte
water from electric power will cause the loss of electrolyte. The repetition of constant current charge
will loosen too much of electrolyte and affect the starting performance of battery as well as the
premature of service life.
Table of causes of battery common defects(failures) and solution of testing and determination
Defects
Analysis of cause
1. Overcharged
Battery bulging
2. Air outlet blocked
and deformation
3. Pole plate seriously bended
Battery leakage
Insufficient
charge
1. Mechanical shock
2. Batter explosion due to the
overcharge.
3. Fracture at the heat sealing
part
4. Terminal crept and seepted
with acid liquid
1. The set value of voltage
regulator is lower sited
2. Pole columns and wires
corroded
3. Failures of generator or lines.
Over charged
Short-circuit
False welding
Handle of defects
Responsi
bility
Renew supply
for customer
Company claims
Renew supply
for customer
Company claims
Check and
adjustement
Supplementary
charge
Renew supply
for customer
Check and
adjustement
Renew supply
for customer
Supplementary
charge
Check and
adjustement
Renew supply
for customer
Company claims
Company claims
1. Voltage abnormal and insteady
2. Terminal damaged by solution
3. Unable to charge and discharge
Bad use condition
Renew supply
for customer
Inverse charge by
customer or renew
Repeated charge
Renew supply
for customer
Renew supply
for customer
Indicator
replacement
Company claims
Cassette player
Vehicle
function
Failure
modes
Possible reason of
failures
Poor contact of fuse
tube
Poor contact of wire
with the host
Poor contact of the
ignition switch
Bad/few
broadcasting
stations
Antenna not
pulled out
Antenna feeder
broken/short-circuit
Poor contact of
antenna with the host
Audio-system failure
No memory
of timer
Division of
Responsibili
ties
Solution
Replug-in
Not
determined
Replug-in
Lock-pin
replaced
Audio
replacement and
retry
Pulls out the
antenna
Antenna
replacement
Replug-in
Spare part
supplier
Not
determined
Use
Spare part
supplier
Automobile
manufacturer
Audio
replacement and
retry
Not
determined
Reset
Use
Re-solding or
connecting
Speaker
replacement
Audio
replacement and
retry
Trial run after
adequately
charged
readjusts the
connection
position
Audio
replacement and
retry
Spare part
supplier
Not
determined
Use
Not
determined
III. Judgment of CD Player failures per se in the vehicle system and solutions
Functions S/N
Failure
modes
Definition of failure
modes
Possible reason of
failures
Main power
supply/fuse tube
burnt
Partial
function
Solution
Replaces the fuse
tube(due to the
conductor inserted
into the device)
Division of
Responsibilities
Not determined
Use
Functions S/N
Failure
modes
Screen has
no
display/show
insufficiency
Botton
function
lost/wrong
function
Definition of failure
modes
No display: when
You turn on the radio
set, the display lamp
lightens, but no digital
display; Insufficient
dislay: On the screen,
there are number of
missing strokes or
overstrokes.
All bottons ineffective:
whenn pressing any of
the bottons on the
dashboard, no one is
active;
A certain botton
ineffective: if some
botton can not performs
its function;
Wrong butoon function:
the function of button is
not consistent with the
actual performance;
Possible reason of
Solution
failures
Screen is damaged by
Displayer replacement
impact
Contact with the
Displayed IC pin is special service station
false welded
of R/C player
manufacturer
Contact with the
special service station
Others
of R/C player
manufacturer
Wrong operation
Mute speaker
in one side
A group of
front or rear
speakers
mute.
Not determined
Poor contact/false
welding of dashboard Replug-in/reweld
wiring
Mute speaker
Product
manufacturer
Buttons on dashboard
Readjusts the bottons
lock up
Other problems
Use
Use
Partial
function
Division of
Responsibilities
The balance(BAL) is
not set in the middle
When receiving the
Speaker wire fall
broadcasting or playing
off/speaker burnt
CD, no audio output
from the left or right
side.
Others
Product
manufacturer
Not determined
Use
Product
manufacturer
Spare part
supplier
Front/rear
Retunes to the middle
balance(FAD) is not
position
Whatever playing CD
tuned on the middle
or broadcasting, only
Speaker wire fall
one of front/rear group
Speaker replacement
off/speaker burnt
of speakers has audio
Contact with the
output, the other group
special service station
mute.
Other problems
of R/C player
manufacturer
Use
Spare part
supplier
Not determined
Functions S/N
9
Radio
Failure
modes
No
broadcasting
stations
received
FM or AM
receives not
stations
Radio or
FM/AM mute
Definition of failure
modes
When you press down
the search button or
tune the station
selection knob, the
wavebands of
frequency modulation
(FM)/ amplitude
modulation (AM) are
unable to receive any
stations
Possible reason of
failures
Radio antenna falls
off
Radio antenna is
short-circuited
Broadcast station
pause
Division of
Responsibilities
Automobile
Replug-in the antenna
manufacturer
Spare
part
Antenna replacement
supplier
Solution
Normal condition
Mis-judgment
Others
Automobile
manufacturer
Product
manufacturer
Use
Mis-judgment
Not determined
Product
manufacturer
Not determined
Functions S/N
Failure
modes
No disc
reading/poor
12
reading
performance
Definition of failure
modes
CD
14 No disc out
Disc
15
auto-In/Out
16
17
Lack of
anti-shocking
CD mute or
L/R mute
Possible reason of
Solution
failures
Heavy taps/scratches on
CD disc replacement
CD disc
Inconsistent CD format
CD disc replacement
(MP3/VCD etc)
Cleans out the laser
Laser head dirty (dusty)
head with swab.
Aged laser head
Laser head
(Tapping disc use for
replacement
longtime)
Contact with the
special service station
Others
of R/C player
manufacturer
Presses down the
CD disc already in the
Disc Out button to
core
reject the disc.
The press-dish sinks
Presses Disc Out
down in the playing
button and resets the
state
disc dish.
The core wiring loosens Replugs in the
off
pin-socket
Contact with the
special service station
Others
of R/C player
manufacturer
Multi-discs or disc in
Takes out the disc
wrong format inserted
Disc tray mouth
Replaces the core of
deformed by prying
CD player
Contact with the
The Disc Out button
special service station
ineffective (No EJECT
of R/C player
display)
manufacturer
Contact with the
special service station
Others
of R/C player
manufacturer
Contact with the
The core structure
special service station
dislocated
of R/C player
manufacturer
Contact with the
special service station
Others
of R/C player
manufacturer
Driving continuously on
Pauses the CD playing
the uneven road (45S)
CD track tapping
Replaces the CD disc
Contact with the
special service station
Others
of R/C player
manufacturer
Contact with the
The core wiring loosens special service station
off
of R/C player
manufacturer
Contact with the
special service station
Others
of R/C player
manufacturer
Division of
Responsibilities
Use
Not determined
Use
Product
manufacturer
Not determined
Use
Not determined
Use
Not determined
Product
manufacturer
Unot determined
V. Judgment of Cassette Players failures per se in the vehicle system and solutions
Functions
Vehicle
function
S/N
Failure
modes
No power
supply or
display
Bad/feu
stations
received
Definition of failure
modes
When turning on the
ignition switch by
inserting the key and
pressing down the
power supply switch,
neither the radio
reacts, nor the screen
lamp lightens and
displays
When you press down
the search button or
tune the station
selection knob, the
Possible reason of
failures
Poor contact of
fuse tube
Poor contact of car
connecting wire
with the host
Poor contact of
ignition switch
Damage inside
audio -system
Antenna not pulled
out
Antenna feeder
broken/short-circuit
Solution
Division of
Responsibilities
Replug-in
Not determined
Replug-in
Lock-pin replaced
Audio replacement
and retry
Pulls out again the
antenna
Antenna replacement
Spare part
supplier
Not determined
use
spare part
supplier
Functions
S/N
Failure
modes
Vehicle
function
Definition of failure
modes
wavebands of
frequency modulation
(FM)/amplitude
modulation (AM) are
unable to receive any
stations
Possible reason of
Solution
failures
Poor contact of
Replug-in
antenna with the
host
Audio-system
damaged
Whether the
balance R/L is not
set at the middle
point
Speaker connection
wire falloff/poor
contact
Speaker damaged
Unhealthy in
audio-system
Battery short of
charge
Lines of B+and
ACC power supply
in inverse position
Unhealthy in
audio-system
Division of
Responsibilities
automobile
manufacturer
Audio replacement
and retry
Not determined
Reset
Use
re-solding or
connecting
Spare part
supplier
Speaker replacement
Audio replacement
Not determined
and retry
Trial run after
Use
adequately charged
readjusts the
connection position
Not determined
Audio replacement
and retry
S/N
Failure
modes
Definition of failure
modes
Possible reason of
failures
Main power
supply/fuse tube
burnt
Unable to
turn on
Function
Solution
Division of
Responsibilities
Not determined
Reconnect
Readjusts the bottons Use
Others
Screen is damaged
by impact
Displayed IC pin is
false welded
Others
Functions
S/N
Failure
modes
Function
Definition of failure
modes
A certain button
ineffective: if some
button can not performs
its function;
Wrong button function:
the function of button is
not consistent with the
actual performance;
Possible reason of
failures
Buttons on
dashboard lock up
Poor contact/false
welding of
dashboard wiring
Replug-in/reweld
Control panel
wiring damped and
with leakance
Other problems
Playback
Solution
Product
manufacturer
Replug-in the
connecting wire
Not determined
Use
Amplifier IC
Rewelds the IC pins
burnt/false welded
One speaker
grounding/short-circ Speaker replacement
uit
Contact with the
special service station
Others
of R/C player
manufacturer
The balance(BAL)
Retunes to the middle
is not set in the
position
middle
When receiving the
broadcasting or playing Speaker wire fall
Mute
Speaker replacement
speaker
in CD, no audio output
off/speaker burnt
from the left or right
one side
Contact with the
side.
special service station
Others
of R/C player
manufacturer
Front/rear
Retunes to the middle
balance(FAD) is not
position
Whatever playing CD
tuned on the middle
A group of or broadcasting, only
Speaker wire fall
front or rear one of front/rear group
Speaker replacement
off/speaker burnt
speakers
of speakers has audio
Contact with the
mute.
output, the other group
special service station
mute.
Other problems
of R/C player
manufacturer
Silent
Available audio output Laser head
Laser head cleaning
dirty(dusty)
playback
in radio state; no
speaker in cassette
Switch of laser head
Adjusts the switch
playback.
damaged
Mute switch
Adjusts the switch
short-circuited
Tape in wrong drop Adjusts the tape room
position(deformatio or takes out the
n or foreign matters) foreign matter
Motor burnt
Motor replacement
Core belt falls off
Belt replacement
Mute
speaker
Division of
Responsibilities
Core
Product
manufacturer
spare part supplier
Not determined
Use
Spare part
supplier
Not determined
Use
Sare part supplier
Not determined
Use
Product
manufacturer
Product
manufacturer
Use
Product
manufacturer
Functions
S/N
Failure
modes
Definition of failure
modes
Playback
8
10
Playback
sounds
small/tonal
modulation
No tape -in
No tape-out
In playback state,
speaker output smaller
or tonal modulation
Audio
11
12
13
Playback
with
abnormal
sound
In playback state,
There are other sounds
combined except the
soft tape tracking noise.
Radio
available, but
no stations
received
14
Radio
Possible reason of
Solution
failures
falls off
line.
Contact with the
special service station
Others
of R/C player
manufacturer
Core magnetic head
Laser head cleaning
(dirty)
Core guide pulley
Guide pulley
dirty (dusty)
cleaning
Broken tape on the Takes out the broken
guide pulley
tape
Contact with the
special service station
Others
of R/C player
manufacturer
Tape deformed
Tape replacement
Tape room
Tape room
deformed
adjustment
Contact with the
special service station
Others
of R/C player
manufacturer
Tape
room
Tape deformed
adjustment
Tape label locking Takes out the tape
Foreign matters into Takes out foreign
the core.
matters
Tape eject button Adjusts the tape eject
deformed/locked
button
Contact with the
special service station
Others
of R/C player
manufacturer
Foreign matters
Takes out foreign
locked in the core
matters
Shift button
Regulates the shift
deformed/locked
button.
Contact with the
special service station
Others
of R/C player
manufacturer
The chassis pully of
Takes out the foreign
core is locked by
matters
foreign matters.
Tape too tight due
Tape replacement
to moisture.
Cleans out the pully
Pully in the core
dust or
dirty or with foreign
takes out foreign
matters
matters
Guide pulley of core Cleanss out the guide
dirty
pulley
Probleme of tape
Tape replacement
Radio antenna falls Replug-in the
off
antenna
Radio antenna is
Antenna replacement
short-circuited
Broadcast station
Normal condition
pause
Division of
Responsibilities
Not determined
Use
Not determined
Use
Not determined
Use
Not determined
Use
Not determined
Use
Automobile
manufacturer
spare part supplier
Mis-judgment
Functions
S/N
15
16
Radio
17
18
Failure
modes
FM or AM
unable to
receive
stations
Definition of failure
modes
(FM)/ amplitude
modulation (AM) are
unable to receive any
stations
Some of wavebands
normal, but another
waveband unable to
receive stations.
Possible reason of
failures
Solution
Division of
Responsibilities
Replug-in the
antenna
automobile
manufacturer
Section III
Combination instrument
The instrument includes the engine tachometer(max. speed 7500), speedometer (max. speed 200), water
thermometer, fuel gauge and L/R turn indicators, rear fog lamp, high-beam light as well as indicators such
as the oil charge pressure, safety belt, safety airbag, ABS, engine failures, water temperature alarm, brake
failure, handbrake, door opening indication, coolant level, oil level alarm, process water, backup, vacuum
alarm, failure lamp, SVS, rear defroster etc.
22 Indicators 4 reserved indicator:
S/N
Indicator
Legends
Description
L turn indicator
R turn indicator
Service lamp
3
4
5
High-beam
indicator
Rear fog lamp
indicator
Backup indicator
Water
temperature alarm
indicator
Brake
indicator
10
ABS indicator
Handbrake
indicator
Preheating
indicator
13
Charge indicator
14
Enginefailure
indicator
11
12
15
16
17
failure
S/N
18
19
20
21
22
Indicator
Safety airbag
indicator
Oil
pressure
indicator
Coolan
level
indicator
Vacuum
alarm
indicator
Process
water
indicator
Legends
Description
It lights up in case of the safety airbag failure or disconnection.
After the ignition, the indicator lightens for 3s. It lights up when
the oil pressures is too low.
It lights up when the coolanl level is too low.
It lights up when the vacuum degree is too low.
It lights up when the water-oil ratio is too high.
II Techique profil
a. When the strength of the front collision is less than that of a car impacting at the speed of (131)km/h, on
a rigid fixed wall perpendicular to the direction of vehicles, the airbag system will not activate.
b. When the strength of the front collision is stronger than that of a car impacting at the speed of
(231)km/h, on a rigid fixed wall perpendicular to the direction of vehicles, the airbag system shoud
activate reliably and in time.
c. When the strength of the front collision is stronger than that of a car impacting at the speed between
(131)km/h and (231)km/h, on a rigid fixed wall perpendicular to the direction of vehicles, the system
remains in a fuzzy control state and the airbag system may either activate or disactivate. Both cases are
normal.
d. In case of occurrence of the collisions as below, the safety airbag provides the driver and passenger in
front row with effective protection and confoms to the relevant regulations:
Equal to a collision by a car at the speed of 23Km/h on a rigid fixed wall perpendicular to the
direction of vehicles;
Equal to a collision by a car at the speed of 30Km/h on a rigid fixed wall at 30(or smaller than
30)perpendicular to the direction of vehicles;
Equal to a collision by a car at the speed of 30Km/h on a rigid fixed column wall of 250mm
perpendicular to the direction of vehicles;
Equal to a collision by a car at the speed of 56Km/h on a 40%bias wall perpendicular to the
direction of vehicles;
Spiral cable
Indicator light
(fitted on the combination
instrument)
Controller(ECU)
IV. Precautions
4.1 The assembly, disassembly and maintenance personnel have to receive the special training.
4.2 The safety airbag is relevant to the parameters of delivery car. Do not modify the Front bumper
configuration or add the bumper without permission.
4.3 When removing the steering wheel for maintenance, the wheel has to be in right position, as only such
enables the spiral cable assembly for locking at the proper position, otherwise it will damage the spiral
cable assembly.
4.4 Special danger! If fitted with the safety airbag assembly of passenger, allow the chidren neither for
sitting on the front row seat, nor for using the faceback child seat!
4.5 Prior to fit up the product on the car, it is forbidden for non-professional personnel to power up so as to
prevent the accidents.
4.6 During the drive, it is required to fasten the safety belt. The safety airbag should be used in combination
with the safety belt. In order to obtain the optima protection effect in case of the accident. Do not mistake
that the airbag may replace the airbag.
4.7 The ECUtechnique specification matches with the parameters of airbag components, they should be use
in match-up way. Do not substitute the airbag component or ECU by other types of ECU or airbag
components.
4.8 After turning on the power supply, both permanent lighting or non-lighting of safety airbag indicator
indicates a failure in the safety airbag system. Such a failure means that the ECU per se is damaged or not
powered on (or harness in open circuit)
4.9 The failure of power supply voltage can be repaired by the user, but others failures have to be
maintained at the special service station.
4.10 Disassembly and reparation at the unauthorized service station are strictly prohibited
4.11 In case of failure alarm, the reparation has to be made. If continue to use instead of repair, the damage
due to the collision will be born on own responsibility
4.12 When repairing the car (especially welding), you have to turn off the switch (1st gear), and disconnect
completely the positive of battery.
4.13 In case of the reparation of car, the special tools have to be used to remove the airbag assembly. After
the airbag explosion, the airbag components, spiral cable controller, main and short harnesses should be
completely replaced.
4.14 In case of failure of safety airbag assembly, it is unrepairable and has to be replaced.
4.15 When removing or handling the airbag components, the trim cover should be faced up. The airbag
components can not be piled up so as to prevent the airbag from unintentional explosion and the accident.
4.16 Airbag components should be kept under the ambient temperature lower than 93, relative humidity
75% and far awary from the interference by electric field.
4.17 Be sure not to test the ignition resistance of safety airbag with the analog multimeter, otherwise it will
cause the unintentional airbag explosion.
4.18 Special danger!
prohibited!
Disassembly of airbag components and its inside air generator are strictly
4.19 To prevent the damage, it is strictly prohibited for the controller to connect with the A/C or D/C higher
than 20V
4.20 StatementIn case of the following collisions occurred, the safety airbag system stays in the state
between folding and unfolding phases. We do not undertake any responsibility for the personnel injury and
property damage caused therefrom.
The car A is the mode fitted with our safety airbag system.
Side-collision
Tail -collision
12 V
In normal cases, the safety airbag system is powered on. The indicator lights up for 4s, then goes
out. It indicates that the system passes by the self-diagnosis.
Indicator lightens up
Indicator goes out
4S
When the battery voltage is lower than 9V, powers on , the indicator flashes 2 times, and keeps
lighting. This indicates that the battery needs the charge of replacement instead of repairing.
Indicator
lightens up
1.5 S
4S
Indicator
goes out
3S
1.2 S
Indicator
lightens up
State of failures
1
2
3
4
5
6
To take, for an example, the low resistance of the drivers side igniter and 3times of flashing,
the flash sequence of the indicator is given as below:
Indicator
lightens up
4S
Indicator
goes out
3S
1.2 S
1.5 S
Indicator
lightens up
In case where the above state occurs in the safety airbag system, you have to send it to the
special service station for reparation.
b. Failure in the controller
In case of failures in the controller, the indicator keeps flashing, while the ECU interior is locke
up and stops working.
Indicator
lightens up
4S
Indicator goes
out
3S
1.2 S
1.5 S
Indicator
flashes out
In case where the above state occurs in the safety airbag system, you should turn off the key
switch, then turn it on again to restart. If the information hint can not relieved, then you should
have the ECU replaced by the special service station.
3. In the outer bushing assembly of cigar-lighter, no other parts except the inner bushing assembly are
allowed to insert, such as the power supply socket. The cigar-lighter can not be use as the power supply
socket.
4. After powered on, the inner bushing assembly of cigar-lighter is very high in temperature. In usage, the
user must pay attention to the safety. Do not hand directly the metal surface, to prevent from scald.
5. After use, the inner bushing assembly of cigar-lighter should be inserted in time into the outer bushing
assembly instead of other place to prevent the objects from burn out
The
cigar-ligher
after pressed
down
The
cigar-lighter
boucns out
R/L doors
unlocking
Lifting
button of the
left
power
window
R/L
doors
locking
Child
lock
Lifting
button of the
right power
window
Lifting
button of the
right power
window
Relay
and
controller
inspection cap
Door
state
controller
Cnetro lock
controller
Bulb replacement
Long bodied car
Headlamp :
Low/high-beam lamp
Position lamp
Turn light
2
3
Attention
The replacement of halogen bulb should be made a few minutesafter the headlamp goes outotherwise
there is a serious risk of burns. Do not hand touch the bulband wrap it with lint free cloth.
Signed by:
Positioning lamp:
Do not pull out the connector. Tuns the lamp
holder by 1/4 circle, then takes it out from the
holder, then pulls out bulb for replacement.
Bulb type: W5W.
Front turn lamp:
Do not pull out the connector. Tuns the lamp
holder by 1/4 circle, Then refit it and checks to
see if it is well fitted in place.
2
Side-turn lamp:
Pushes forward or rearward the side-turn lamp,
pulls it out after releasing it. Turns by 1/4 cicle to
take out the lamp holder, then pulls out bulb for
replacement.
Note: Do not let the lamp and other connectors,
locked in the metal sheet hole, otherwise it is not
convenient for taking it out.
Bulb type: W5W
Dismantle:
Emoves the screw fixing the lamp;
Oves the lamp outward to take the
buckle locked on the metal plate
from the hole and remove the lamp
License lamp:
Takes out the license lamp from the
guard board of license lamp.
Replaces the failed bulb.
Bulb type: W5W
Bulb replacement
Short bodied car
Headlamp :
Low/high-beam lamp
Position lamp
Turn light
Note: In some of use condition, a
thin layer of water vapor will emerge
on the headlamp glass.
Attention
The replacement of halogen bulb should be made a few minutesafter the headlamp goes outotherwise
there is a serious risk of burns. Do not hand touch the bulband wrap it with lint free cloth.
Signed by:
II
I
Positioning lamp:
Do not pull out the connector. Tuns the lamp
holder by 1/4 circle, then takes it out from the
holder, then pulls out bulb for replacement.
Bulb type: W5W.
Front turn lamp:
Do not pull out the connector. Tuns the lamp
holder by 1/4 circle, Then refit it and checks to
see if it is well fitted in place.
Side-turn lamp:
Pushes forward or rearward the side-turn lamp,
pulls it out after releasing it. Turns by 1/4 cicle to
take out the lamp holder, then pulls out bulb for
replacement.
Note: Do not let the lamp and other connectors,
locked in the metal sheet hole, otherwise it is not
convenient for taking it out.
Bulb type: W5W
Dismantle:
Emoves the screw fixing the lamp;
Oves the lamp outward to take the
buckle locked on the metal plate
from the hole and remove the lamp
License lamp:
Takes out the license lamp from the
guard board of license lamp.
Replaces the failed bulb.
Bulb type: W5W
In case of failures, please contact with the special service station, be sure not to make any disassembly
and adjustmeng individually.
Piping
Bolts
Condenser
A/C switch.
Temperature
control
Coolant leakage
(incl. oil leakage)
Noise
(In startup state)
Belt
Routine
6 months or mileage
of 5, 000km
12months or initiao
mileage of 10, 000km
Compressor
Idle pulley
Check schedule
Check subject
Routine
6 months or mileage
of 5, 000km
Airblow motor
12months or initiao
mileage of 10, 000km
Expansion valve
Air leakage
Coolan media
leakage
(incl.oil leakage)
Routine
6 months or
mileage of 5,
000km
12months or initiao
mileage of 10, 000km
Failures infos
User infor-collection
Vehicle check
A/C switch ON
1. Evaporator
Cool air supply insufficient caused by the evaporator failure due to the center leakage of evaporator. Other
reasons include:
1) The evaporator core has been jammed by the filth or debris which needs to be eliminated.
2) The cracks or fractures on cases. Replaces or repairs the box cracks.
3) Leakage of seals or O-ring. Replaces them.
2. Compressor
The failed compressor will show one or several features as below:
1) The noise indicates the premature of failure.
2) Locking(cylinder sticking)commonly due to the leakage.
3) Leakage due to the failure of sealing, air cushion or O-ring.
4) The low pressure of the in/outlet port is commonly caused by the insufficient filling of refrigerant or the
throttle at the low pressure side.
5) High pressure at the inlet port and low pressure at the outlet port are normally due to the failure of the
compressor valve disc or sealing packing assembly.
Most noises during the operation are considered as normal. The abnormal chocks and noises are caused by
the premature of failure of leakage or part damage. When the refrigeration is required by the A/C system
control, the compressor fails to work. The determination should be done to verify if the voltage on the
clutch joint is normal. Checks if the compressor is jammed.
1) Shuts down the engine
2) Disconnects the power supply of compressor and clutch and adjusts the tension pulley to fall off the belt
3) Manually turns the drive disc
Attention: If the drive disc doesnt run or painfully, it means the compressor is blocked.
The low pressure at the outlet port is originated either from the bad sealing of the compressor, e.g. valve
disc or valve sealing pad group ineffective, or from the throttle at the low pressure side of compressor or
system. the insufficient filling of refrigerant may also result in the low pressure at the outlet. All possible
reasons should be determined through the failure diagnosis.
Checks if there is a leakage of the compressor.
3. Condenser
There are three possible failures of condenser as below:
1) Due to the rust, corrosion or leakage resulted from the impact of sharp object and stones.
2) Throttle due to the pipes bent by the impact of foreign matters. E.g. when the leakage of pipe is caused
by the stone beating in weak force and the pipe bent or broken when the force is sufficiently powerful.
Maintenance advice: the throttle of condenser will induce the overpressure at the compressor outlet. The
partial throttle will lead to the change of temperature and frost or frozen case at the throttle.
3) Air throttled due to the filth, debris or foreign matters through the condenser. When the airflow is
jammed or throttled, it will result in the overpressure at the outlet.
Attention: Although uneasy to detect, but in normal operation, the outlet pipe of condenser is slightly
cooler than the inlet pipe.
To determine the throttle by searching the frosted section.
4. Throttle pipe
The low pressure at the in/outlet port occurs normally due to the throttle failure, which leads to the
insufficient cool air supply in the evaporator.
The common factors of throttle pipe failures are the blockage. The others are the inefficiency of the liquid
reservoir , the filth , corroded grains in the refrigerant system or the inner strainer jammed due to the looser
dryer agent in the refrigerant. For whatever reasons, it is recommended to replace the throttle pipe at the
time of maintenance.
5. Thermal expansion valve (TXV)
The failure feature is same as that of the throttle. The failures of many thermal expansion valves are caused
by the ineffective dynamic elements, which are able in general to shut down the valves and keep the
refrigerant from entry into the evaporator. For whatever reasons of failures, it is suggested to replace it in
time at the time of the maintenance is except the jammed inner strainer.
The blockage of the inner strainer of thermal expansion valve occurs due to the failure the liquid storage
dryer, which loosens the filth and corrosive grain in the system or the refrigerant drying agent.
6. Refrigerant piping
The throttle of the refrigerant piping has one or several features as below:
1) The throttle of the inlet pipe causes the low pressure in the in/outlet ports, insufficient refrigeration or no
refrigeration available. The evaporator is short of refrigerant.
2) The outlet throttle leads to the opening of relief valve. When the pressure drops down to the design value,
the relief valve will sit down automatically.
3) The throttle feature of liquid pipe is same as that of the inlet throttle. The low pressure of in/outlet ports,
insufficient refrigeration or no refrigeration available.
The inlet pipe is normally the largest horse or pipe, while the liquid pipe the smallest horse or pipe
3.2.5 Causes of failures
1) Leakage: Insufficient volume of refrigerant.
2) High pressure: Refrigerant surplus, air entry into the system and oil surplus in the system etc.
3) Poor connection.
4) Throttle
5) Contamination
6) Humidity
7) Failure of parts
3.2.6 Functional testing
The functional testing is able to determine the operating state of the A/C control panel and air supply
system. The functional testing includes the subjects of the knob operating states of the fan, heater, A/C
control components. It also comprises the air supply state of the comparison status knob and switch when
they are in different places.
The fast testing on the system may determine whether the refrigerant volume of A/C system is suitable.
This testing can be effected only when the ambient temperature is higher than 21.
The fast testing is able to simplify the system diagnosis through the determination of the failure of
insufficient refrigerant, and also to eliminate the failure source of the insufficient refrigerant. The fast
testing is to be made as per the following procedures:
1) Starts up the engine and preheat it at idle speed.
2) Opens the engine hood and doors.
3) Selects the standard (NORM) state.
4) Adjusts the knob to the full position COLD.
5) Selects the max. fan speed (4th level)
6) Measures the inlet temperature of evaporator behind the throttle pipe.
7) Measures the temperature of the liquid storage level while the compressor is operating.
Maintenance advice: If the compressor recycles, waits until the clutch meshes up.
Both temperatures [(6) and7)] should be at same level. If different, checks the other failure
If the inlet temperature of evaporator is lower than the inlet level of the storage, or there is frost
accumulation on the inlet, it indicates the shortage of refrigerant.
8) If the volume of refrigerant is at shortage, adds 120ml of refrigerant and repeats the procedures of
(6)and(7).
9) Adds the 120ml of refrigerant until the temperatures on both levels are same.
Maintenance advice: Every time when adding the refrigerant, be sure to allow the time for the system to
be stabilized, e.g. about 5mins.
Warning: By using the method to add the refrigerant, you should know perfectly the system and besides,
the system has no leakage. To fill the leak system with the refrigerant may cause greater damage.
3.3 Maintenance of system parts
3.3.1 Preparations
Prior to any maintenances, some preparations have to be made. Whatever it is practical or not, the
following processes should be taken as the reference during the various maintenance.
1) The ignition switch on the position (OFF).
2) Puts the protective cover to protect the car surface.
3)
Pulls out the battery lead. Carries out the operation as per the relevant maintenance manual.
4) Drains out the refrigerant from the system. Uses the suitable recycle equipment and operates as per the
relevant maintenance manual.
5)
6) Takes out from the observation panel, the metal parts or others imperative to be detached, so as to get
access to the parts.
Be especially careful when pulling out the battery leads.
3.3.2 Maintenance of refrigerant horse and connectors
There are many types of other pars used to connect the refrigerant hoses and A/C system(this model
classified to the 2nd case).
1) SAE flaring typed connectors
2) Bump flange connectors commonly referred as to O-ring connectors
3) Spring-locking connectors
4) Insert typed connectors.
Checks to verify if there are the following modes of failures and repairs.
1) If the O-ring has any broken damages or serious aging deformation. If in such case, you should replace
then with the same type of O-ring.
2) If there are any signs of leakage at the pressed hoses and hard tubes. If in such case, you should replace
them with one ones.
3) If the threads of connector joints have any tripping disengagement. If in such case, you should replace
them with one ones.
4) If the hoses have any aging damage and leakage. If in such case, you should replace them with one ones.
5) When reconnecting the pipeline, applies the specified brand of refrigerant oil on the connector joints of
pipeline.
Uses the special tools: nut spanner;1/4in socket wrench; torque wrench; hacksaw and saw blade in 32tpi;
pliers; spring lock assembly tools ;single-blade scraper. Keeps them away from your body when they are
used.
3.3.3 Replacement of A/C system parts
The followings are the elementary procedure guide for the replacement of A/C system parts. For the more
detailed operation of replacement, the maintenance manuals relevant to the specific year, model and date of
manufacturing should be referred.
3.3.4 Removal and replacement of thermal expansion valve (TXV)
The maintenance of thermal expansion valve is not recommended.
This practice rules are divided into the maintenance standard TXV and H valve maintenance(H-LOCK)
Special tool: Horn-shaped wrench.
H-valve TXV
1) Carries out the items as per the section Preparation.
2) Takes out the conductor of the pressure stop switch or pressure differential switch.
3) Takes out the seal disc bolt between the inlet pipe and liquid pipe.
5) Covers the pipe opening to prevent the foreign matter from entry.
6) Takes out and rejects the seal padding between the coil and H-valve.
7) Removes two screws from the H-valve.
8) Removes the H-valve from the evaporator bracket.
9) Removes and rejects the seal padding between the H-valve and evaporator bracket.
10) Fits up the new H-valve with new seal padding.
11) Fits up two screws and tightens them to 20~26Nm
12) Replaces the seal padding between the coil and H-valve
13) Fits up the pipe to its original position and tightens the bolts to 20~26N-m.
14) Fits up the observing plate and detached parts.
15) Reconnects the battery as per the requirements of Maintenance Manual.
16) Checks the leakage and the vacuum pumping, and fills the system with refrigerant as per the Chapter19
of the Manual.
17) Makes the functional testing when necessary. Be careful not to scratch the fitting surface.
3.3.5 Removal and replacement of the compressor
1) Completes the Preparation.
2) Removes the in/outlet hoses or service valve of the compressor.
Attention: the in/outlet pipes of many systems use a common manifold to connect the compressor.
3) Removes the lead of the clutch.
4) Loosens and removes the belt.
5) Removes the fixing bolt from the compressor bracket or socket.
6) Removes the compressor from the car.
7) Positions the new or repaired compressor.
8) Fits up the bolts to the compressor bracket and socket.
9) Positions and fits up the belt.