Haima S5 Service Manual-1

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

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

1.1.1Technical Parameters ················································································· 1A-1
1.1.2 Special tools··························································································· 1A-9
1.2 Inspection and Maintenance of Complete Vehicle ················································· 1A-10
1.2.1 Inspection of Compression Pressure ..............................................................................1A-10
1.2.2 Inspection of the Engine Oil...........................................................................................1A-10
1.2.3 Inspection of Oil Pressure .............................................................................................. 1A-11
1.2.4 Replacement of Engine Oil ............................................................................................ 1A-11
1.2.5 Replacement of Oil Filter ...............................................................................................1A-12
1.3 Application of Engine Maintenance Platform ······················································ 1A-12
1.3.1 Mount the Engine onto Maintenance Platform...............................................................1A-12
1.3.2 Dismantle the Engine from Maintenance Platform ........................................................1A-13
1.4 Power Generator and Starter ·········································································· 1A-13
1.4.1 Power Generator’s Dismantling/Mounting ....................................................................1A-13
1.4.2 Explanations on Inspection of Power Generator Belt.....................................................1A-13
1.4.3 Explanations on adjustment to tension of power generator and air conditioning drive belts
.................................................................................................................................................1A-13
1.4.4 Explanations on inspection of power generator .............................................................1A-13
1.4.5 Starter Dismantling/Mounting........................................................................................1A-14
1.4.6 Explanations on inspection of starter .............................................................................1A-14
1.5 Ignition, Control System··············································································· 1A-14
1.5.1 Spark Plug Dismantling/Mounting.................................................................................1A-15
1.5.2 Control System Parts Dismantling/Mounting.................................................................1A-15
1.5.3 Crankshaft position sensor’s dismantling/mounting explanations .................................1A-15
1.5.4 Explanations to inspection of crankshaft position sensor...............................................1A-15
1.5.5 Explanations on water temperature sensor dismantling/mounting .................................1A-16
1.6 Intake and Exhaust System············································································ 1A-17
1.6.1 Intake and Exhaust System Dismantling/Mounting .......................................................1A-17
1.6.2Explanations on intake manifold dismantling .................................................................1A-18
1.6.3 Explanations on the intake manifold seal ring mounting ...............................................1A-18
1.6.4 Explanations on the throttle body seal ring mounting ....................................................1A-18
1.6.5 Explanations on the exhaust manifold dismantling ........................................................1A-18
1.7 Timing System ·························································································· 1A-18
1.7.1 Timing system dismantling/mounting ............................................................................1A-18
1.7.2 Explanations on timing chain tensioner assembly dismantling ....................................1A-199
1.7.3 Explanations on crankshaft pulley dismantling..............................................................1A-19
1.7.4 Explanations on cylinder head hood dismantling...........................................................1A-19
Table of Contents
1.7.5 Explanations on the timing chain dismantling ...............................................................1A-19

1.7.6 Explanations on the timing chain’s tensioner assembly mounting .................................1A-19
1.7.7 Explanations on the tensioner arm assembly mounting .................................................1A-19
1.7.8 Explanations on timing chain mounting.........................................................................1A-19
1.7.9 Explanations on the cylinder head hood mounting ........................................................1A-20
1.7.10 Explanations on the crankshaft pulley mounting .........................................................1A-20
1.7.11 Explanations on water pump pulley mounting .............................................................1A-21
1.8 Lubricating System ····················································································· 1A-21
1.8.1 Oil Sump Dismantling/Mounting ...................................................................................1A-21
1.8.2 Explanations on the oil sump dismantling......................................................................1A-21
1.8.3 Explanations on the oil sump mounting .........................................................................1A-21
1.8.4 Oil Pump and Timing Chain Case Assembly Dismantling/Mounting............................1A-22
1.8.5 Explanations on oil pump’s oil seal dismantling ............................................................1A-22
1.8.6 Explanations on oil pump’s oil seal mounting................................................................1A-22
1.8.7 Explanations on the oil filter mounting ..........................................................................1A-23
1.8.8 Explanations on oil pump disassembling/ mounting ......................................................1A-23
1.8.9 Inspection of Oil Pump...................................................................................................1A-23
1.9 Cooling System ························································································· 1A-24
1.9.1 Thermostat Dismantling/Mounting ................................................................................1A-24
1.9.2 Explanations on thermostat inspection and mounting ....................................................1A-24
1.9.3 Cooling water pipeline dismantling/mounting ...............................................................1A-24
1.9.4 Explanations on heater water pipe /O-ring mounting.....................................................1A-25
1.9.5 Water Pump Dismantling/Mounting...............................................................................1A-25
1.10 Cylinder Cover and Valve Mechanism ····························································· 1A-26
1.10.1 Cylinder Head Mechanism Dismantling/ Mounting.....................................................1A-27
1.10.2 Valve Mechanism Dismantling/ Mounting...................................................................1A-29
1.10.3 Cylinder Head Inspection /Repair ................................................................................1A-30
1.10.4 Inspection of Valve and Valve Guide ...........................................................................1A-31
1.10.5 Explanations on inspection of valve seat......................................................................1A-31
1.10.6 Explanations on inspection of valve spring..................................................................1A-32
1.10.7 Explanations on the inspection of camshaft .................................................................1A-33
1.10.8 Explanations on inspection of tappet hole and tappet ..................................................1A-34
1.11 Flywheel, clutch ······················································································· 1A-35
1.11.1 Flywheel and Clutch Dismantling/Mounting ...............................................................1A-35
1.11.2 Explanations on Clutch Pressure Plate/Friction Disc Dismantling...............................1A-36
1,11.3 Explanations on the clutch friction disc inspection /mounting.....................................1A-37
1.11.4 Explanations on the clutch pressure plate inspection/mounting ...................................1A-37
1.12 Cylinder body, Crank Connecting Rod Mechanism·············································· 1A-38
1.12.1 Cylinder Body, Crank Connecting Rod Mechanism Dismantling/Mounting...............1A-38
1.12.2 Cylinder Body Inspection /Repair ................................................................................1A-42
1.12.3 Connecting Rod Inspection ..........................................................................................1A-44
1.12.4 Inspection of Piston Connecting Rod Assembly ..........................................................1A-44
1.12.5 Crankshaft Inspection /Repair ......................................................................................1A-45
Engine block 1A-0
tools tools or equipments

How to use this manual Prompt signals
In this manual there are such signals as
Subject Scope “Warning”, “Caution”, “Attention”,
“Explanation”, and “Limit”.
 This manual comprises procedures on engine
maintenance, and specific procedures fall into Warning
5 basic operation steps:
 Warning is used to prompt that personal
I: dismantling/mounting; II disassembling injury may be caused due to negligence.
/mounting; III: resetting; IV inspection; V
adjustment. Caution
 Simple operation may be completed by  Caution is used to prompt that engine damage
inspecting the engine appearance, such as may be caused due to negligence.
dismantling/mounting of periphery parts,
Notice
parts cleaning, and appearance inspection etc.
Overhaul Steps:  Notice is used to provide additional
information for completion of given
1. Prior to most overhaul work, illustrative procedures.
pictures shall be observed because they will
help distinguish parts & components, Explanation
illustrate the parts fastening way, and the way
of inspecting parts appearance. In addition,  Explanation is used to prompt the permissible
illustration explanations are attached to range for inspection or adjustment.
dismantling/mounting procedures in need of Limit
systematic demonstration.
Limit is used to prompt the upper and lower limit
2. On illustrations there are symbols of wearing for the inspection or adjustment.
parts, tightening torque, lubricating oil, and
sealant, and also corresponding explanations
and marks are made to special tools or
equipments for dismantling or mounting.
3. Corresponding numbers are marked on
pictures for the operation sequence and parts’
major operation process. In general,
information of this kind serves as key and
core content of the diagnosis procedure. Due
to this, please refer to these materials during
the overhauling process.
Symbol
Four kinds of symbols are used in this manual to
indicate application of lubricating oil, sealant, and
special tools etc., and they imply occasions where
foresaid materials shall be applied during the
maintenance period.
Symbol Connotation Remark
Inject
Inject new engine oil
lubricating oil
Inject appropriate
Inject sealant
sealant
wearing parts like
Replace parts
O-ring and gasket
Use special Appropriate special
Engine block 1A-1
1.1.1 Technical Parameters
Technical Parameters of Complete Equipment
Item Parameter Remark
Model GN15-VF GN16-VF GN16-VF1

Cylinder quantity and
In-line 4-cylinder
arrangement
Combustion chamber Roof shape
Ignition sequence 1-3-4-2 By cylinder number

From back to front (flywheel
Rotation direction Counterclockwise
side taken as the back end)
dual overhead camshaft, timing chain
Valve timing mechanism
drive (silent chain), intake VVT
Valve quantity 16
Displacement (cc) 1497 1591
Bore× stroke (mm) 74.8×85.2 74.8x90.5
Compression ratio 10 10
ON -14～26(BTDC)
Intake
Valve OFF 66～26(ABDC)
timing
(°) ON 39(BBDC)
Exhaust
OFF 5(ATDC)
Max. power(kW/rpm) 77/6000 81.5/6000 85/6000 Net power
Max. torque(N·m/rpm) 140/4000 149/4000 153/4000 Net torgue
Air conditioning idle speed:800±50

Idle speed (rpm)
Target idle speed:750±50
Ignition advance angle(°) 3～10 Idle state
Starting mode Electrical starting
Cooling mode Water cooling forced circulation
Lubricating mode Pressure, Split, Complex
Overall dimension (mm) 573.2×615.0×606.3 573.32x724.2x6063
Net weight (kg) 94.8 96.5

Engine block 1A-2
Technical Parameters of Maintenance

Item Parameter
Cylinder head
Standard 112.9～113.1
Height (mm)
Max. grinding 0.2
Deformation at cylinder gasket’s abutment
Max. 0.03
surface (mm)
Deformation at manifold’s abutment Max. 0.15
surface (mm) Max. grinding 0.20
valve clearance(engine in cold Intake 0.18～0.26
condition)(mm) Exhaust 0.26～0.34
Valve and valve guide
Standard 1.35
Intake
Width of valve seal tape Min. 0.85
(mm) Standard 1.85
Exhaust
Min. 1.35
Intake
Min. 89.11
Valve length (mm)
Exhaust
Min. 90.43
Intake
Valve stem Min. 4.915
diameter(mm) Standard 4.955～4.970
Exhaust
Min. 4.905
valve guide’s inside diameter (mm) Standard 5.0～5.012
Intake 12.7～13.3
valve guide’s protrusion height (mm)
Exhaust 12.7～13.3
Valve seat
Width of valve seat’s contact surface (mm) 1.1～1.5
Intake 43.5～44
Angle of valve seat (°)
Exhaust 43.5～44
Valve seat sinking (valve protrusion Intake 30.4
height)(mm) Exhaust 34.6
Valve spring
valve spring height H Intake H1: 33.4mm 142.2～161.8{14.51～16.51kgf}
pressure (N{kgf}) Exhaust H2: 24.9mm 293.4～324.4{29.94～33.10kgf}
Verticality(mm) 1.50mm
Valve oil seal
Depth L(mm) Intake 15.7～16.3
Engine block 1A-3
Exhaust 15.7～16.3
Tappet
Tappet hole’s diameter(mm) Standard 31.000～31.025
Tappet diameter(mm) Standard 30.964～30.980
Clearance between tappet and tappet hole (mm)
Max. 0.180
Camshaft
Camshaft’s radial run-out(mm) Max. 0.03
Standard 44.71
Intake
Cam’s protrusion height Min. 44.51
(mm) Standard 44.28
Exhaust
Min. 43.58
Standard 25.945～25.960
Journal diameter(mm)
Min. 25.915
Journal clearance(mm) Standard 0.040～0.076
End gap(mm)
Max. 0.21
Cylinder body
Height (division surface between upper surface Standard 205

and main cover)(mm) Max. grinding 0.20
Deformation of upper surface (mm) Standard 0.1
Cylinder bore’s inside diameter
[measure inside diameter at the place 37mm Standard 74.8～74.815

below the top surface] (mm)
Wearing limit (mm) 0.135
Piston diameter(mm)
[Measure the piston diameter at the

place19.38mm below the lower rim of oil Standard 74.78～74.79
control ring slot along the vertical direction of
the piston pin hole’s axial line.]
Clearance between piston and cylinder bore Standard 0.010～0.035

(mm)
Max. 0.10
Piston ring
Top ring Standard 0.030～0.070
Second Ring Standard 0.020～0.060
Clearance between piston Oil Ring Standard 0.040～0.120

ring and ring slot (mm)
Top ring / Second
Max. 0.15
Ring
Oil Ring Max. 0.15
Opening clearance [measure inside Top ring 0.15～0.30

Engine block 1A-4
cylinder](mm)
Second Ring 0.20～0.40
Oil Ring 0.10～0.40
Max. 1.0
Piston pin
Piston pin’s diameter(mm) Standard 18.001～18.005
Piston pin hole’s inside diameter (mm) Standard 18.010～18.014
Clearance between connecting rod’s small end

Standard -0.031～-0.016
hole and piston pin (mm)
Clearance between piston pin hole and piston

pin (mm)
Connecting rod
Length [center to center](mm)
Standard 135.3～135.4(132.9～133.0)
（GN16-VF）
Inside diameter of connecting rod’s small end

Standard 17.974～17.985
(mm)
Connecting rod’s end gap(mm)
Max. 0.40
Connecting rod bearing
Connecting rod bush size (mm) Standard 1.485～1.496
Standard 0.014～0.058mm
Connecting rod bearing clearance (mm)
Max. 0.10
Crankshaft
Crankshaft radial run-out(mm) 0.03
Main journal diameter(mm) Standard 46.004～46.029
Main journal clearance (mm)
Max. 0.1
Main bearing bush size (mm) Standard 1.971～1.996
Crank pin diameter(mm) Standard 39.980～40.000
Thrust bearing size (mm) Standard 3.205～3.255
Standard 0.09～0.273mm
Crankshaft end gap(mm)
Max. 0.30
Inspection to complete vehicle
Standard value 1170{12.0}[300]
Compression pressure Minimum limit 980{10.0}[300]
kPa{kgf/cm2}[rpm] Max. limit of

pressure difference 100{1.0}
between cylinders
Oil pressure (kPa{kfg/cm2}[rpm]) 400～588{4.1～6.0}[2500]
Oil adding volume L Oil replacement 3.6

Engine block 1A-5
Oil and oil filter

3.8
replacement
Oil grade API engine oil grade higher than SL
Higher than –25 ℃ SAE 10W–30

Oil viscosity level
-30 ℃～37 ℃ SAE 5W–30
Starter
Voltage (V) 11
Zero-load test
Current (A) ＜95
Timing chain disassembling part

Automatic tensioner push rod’s extension strength (mm) 3
Crankshaft rotating speed sensor
Clearance between signal wheel and sensor (mm) 0.5～1.5
Thermostat
Opening temperature (℃) 80～84
Full-opening temperature (℃) 95
Full-opening stroke (mm) Min. 8.5
Clutch pressure plate

Diaphragn spring’s wearing depth (mm) Max. 0.6
Diaphragn spring’s radial circle run-out (mm) Max. 0.6
Pressure plate’s flatness (mm) 0.05

Clutch friction disc
Thickness of protrusion rivet (mm) Min. 0.3
End-on circle run-out(mm) Max. 0.7
Flywheel
End-on circle run-out(mm) Max. 0.13
Oil pump
Clearance between inner rotor’s prong Standard 0.06～0.20

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

body (mm) Max. 0.35
Backlash (mm)
Max. 0.14
Compression spring’s length (mm)[pressure:97.7 ～

33.50
107.4N{9.96～10.96kgf}]
Front-end oil seal’s driving distance (mm)[from oil pump

0～0.5
body’s rim]
Engine block 1A-6
Rear oil seal

Rear oil seal’s driving distance (mm)[from crankshaft back
0～0.5
cover’s rim]
Plastic fixing bolt’s length
Cylinder head bolt(mm) Standard 136.8～144.2
Main bearing cover bolt(mm)
Max. 75.3
Engine block 1A-7
Tightening torque
Torque value
Mounting place Remark
N•m kgf•m
Power generator
Bracket 45.1 4.6
Adjusting arm 45.1 4.6
Adjusting slider 21.6 2.2
Power generator pivot’s bolt and nut 45.1 4.6
Ignition, control system
Ignition coil 8.8 0.9
Spark plug 25 2.6
Fuel rail 21.6 2.2
Camshaft position sensor 8.8 0.9
Water temperature sensor 15 1.53
Knock sensor 21.6 2.2
Knock sensor bracket 16.8 1.7
Crankshaft position sensor 8.8 0.9
OCV valve 8.8 0.9
Intake and exhaust system
Throttle body 8.8 0.9
Intake manifold 21.6 2.2
Intake manifold bracket (manifold side) 21.6 2.2
Exhaust manifold 21.6 2.2
Exhaust manifold bracket (cylinder
21.6 2.2
body side)
Exhaust manifold bracket (manifold
45.1 4.6
side)
Exhaust manifold heat shield 8.8 0.9
Lubricating system
Oil switch 14.7 1.5
Oil filter 14.0 1.43
Oil filter adapter 21.6 2.2
Oil filter 8.8 0.9
Oil sump 8.8 0.9
Cylinder body, crank connecting rod mechanism
50±2 16.7 First set the pretension torque and
Crankshaft pulley
60±2° then tighten the angle.
Flywheel 100 10.3
Engine block 1A-8
Transmission baffle plate 8.8 0.9 6.9～9.8

Clutch pressure plate 18.6 1.9 18.6～25.5
Crankshaft’s rear cover 8.8 0.9
35±2.5 3.5 First set the pretension torque and
then tighten the angle. Pay attention
Main bearing cover
Tightening 60°(0～ -4°) to the bolt’s length, which has limit
value (see corresponding part)
1.32～ First set the pretension torque for two
15±2N·m
1.74kgf·m times, and then tighten the angle.
Connecting rod cover Pay attention to the bolt’s length,
90°～94° which has limit value (see
corresponding part)
Cylinder head, valve train and others
24.5 2.5 First set the pretension torque, and
tighten the angle two times. Pay
Cylinder head attention to the bolt’s length, which
Tighten 90°+ 90°(0～4°)
has limit value (see corresponding
part)
Camshaft’s front cover 20 2.04
Camshaft cover 11 1.12
Cylinder head hood 8.35 0.85
Oil pump and timing chain case 10 1.02 See corresponding part
assembly 39.5 4.03 See corresponding part
Timing chain guide rail 10 1.02
Tensioner arm 23.5 2.4
Timing chain tensioner 9.8 1.0
VVT fixing bolt 60 6.12
Front and rear hook 18.4 1.88
Cooling system
9.8 1.0 See corresponding part
Water pump
45.1 4.6 See corresponding part
Water pump pulley 9.35 0.95
Water inlet pipe seat 9.35 0.95
Heater water pipe assembly 9.35 0.95
Engine block 1A-9
1.1.2 Special tools
Oil pressure gauge Oil seal erector Valve spring ejector
Piston pin assembling tool set Belt tensiometer Gear ring stop device
Valve oil seal ejector Oil filter sleeve Valve guide ejector / erector
Valve oil seal erector Flywheel brake Clutch guider
Oil sump ejector

Engine block 1A-10
8. Measure all cylinders’ compression pressures

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

11. Mount the fuel pump relay
12. Mount the spark plug tightening torque:20～
30N·m{2.1～3.1kgf·m }
13. Connect the ignition coil wiring.
1.2.2 Inspection of the Engine Oil
1. Park the automobile on the level ground.
5. Mount the gauge into Cylinder 1’s spark plug
hole. 2. Warm up the engine to a normal running
temperature and stop the running.
6. Floor the accelerator pedal and start the
engine. 3. Wait for 5 minutes.
7. Record the gauge’s maximum reading. 4. Pull out the dipstick and observe the oil level
Engine block 1A-11
and oil state, inspect if the oil level ranges 7. Oil pressure:400 ～ 588kPa{4.1 ～
between Scale F and Scale L. 6.0kgf/cm2}[2500rpm]
5. Add or replace oil according to needs. 8. Smear evenly the thread sealant (A6F011)
onto the oil pressure switch thread (see the
6. Confirm the dipstick O-ring’s installation (see
figure).
right figure).
7. Insert the dipstick again.
O-ring
Smearing
Sealant is needed when the bolt is reused.
1.2.3 Inspection of Oil Pressure
Warning 9. Mount the oil pressure switch. Tightening
torque:14.7N·m{1.5kgf·m}.
 Wasted and used oil is cancer-causing
substance, and so skin shall be cleaned with 10. Start the engine and inspect if the engine oil
soap and tap water immediately after the suffers leakage.
work. 1.2.4 Replacement of Engine Oil
1. Dismantle the oil pressure switch. 1. Dismantle the oil cover and oil drain plug.
2. Mount the special tools onto oil pressure 2. Pour the oil into appropriate vessel.
switch’s mounting hole.
3. Mount the new oil drain plug. Tightening
3. Warm up the engine to a normal running torque: 30～41N·m{3.1～4.2kgf·m}.
temperature.
4. Add engine oil of specified model and volume
4. Run the engine to a fixed rotating speed, and into the engine.
cast attention to the oil pressure gauge’s
reading. 5. Remount the oil cover.
5. Stop the running and cool the engine. 6. Inspect the dipstick’s scale value.
6. Dismantle special tools. 7. Start the engine and inspect if there is
leakage.
8. Inspect the engine oil level and add the oil if
necessary (see Inspection of Engine Oil).
Notice
 In some occasions, actual oil volume that is
Oil pressure gauge added according to the oil scale may differ
from the oil volume specified.
★ Note: if the pressure goes beyond the Item Oil capacity (L)
specified range, inspect the cause, and repair
the engine and replace the oil according to
Oil replacement 3.6
needs.
Notice Oil and oil filter replacement 3.8
 Oil with different viscosities and temperatures
may vary in pressure  Engine Oil Grade: API Engine Oil Grade:
above SL
Engine block 1A-12
Oil viscosity standard Oil viscosity level 1.3 Application of Engine

Maintenance Platform
Higher than–25℃ SAE10W–30
–30℃～37℃ SAE5W–30
1.3.1 Mount the Engine onto
1.2.5 Replacement of Oil Filter
Maintenance Platform
1. Dismantle the oil filter with special tools.
2. Rub and clean the new oil filter with a clean 1. Lift the engine, and align the cylinder body’s
cloth. pin hole to the maintenance platform’s
mounting dowel pin to mount the engine(see
3. Smear clean oil onto the new oil filter’s the figure).
O-ring.
Smear clean oil onto the

new oil filter’s O-ring.
4. Mount the oil filter with special tools 2. Mount the work fixture according to the
Tightening torque:13.0～15.0N·m{1.32～ figure and lock it.
1.52kgf·m}.
Fixing bolt
5. Start the engine and inspect if there is leakage.

Inspect the oil level and check if oil adding is
needed (see Inspection of Engine Oil).
Others
Other inspection and maintenance like power
generator inspection and starter inspection etc can 3. Adjust the fixing bolt to appropriate place and
be conducted on the complete vehicle. See this prevent the engine mounting from getting
manual and corresponding complete vehicle loose.
maintenance manual for processing procedures.
4. Pour the engine oil into specified vessel.
5. Mount the new oil drain plug, and tighten the
oil drain plug. tightening torque: 30 ～
41N·m{3.1～4.2kgf·m}
Engine block 1A-13
1.3.2 Dismantle the Engine from

Maintenance Platform 1 Generator adjusting arm
Dismantle the engine from the maintenance
2 Generator belt
platform according to steps reverse to “Mount
the Engine onto Maintenance Platform”. 3 Generator bolt
Notice 4 Generator
 The engine maintenance platform’s 1.4.2 Explanations on Inspection of Power
self-locking brake system may lose efficacy Generator Belt
in an unbalanced state, for instance, the
If necessary, inspect the power generator belt’s
engine maintenance platform suffers
deflection and tension: see complete vehicle
unbalance due to sudden and rapid action
maintenance manual’s corresponding part.
resulting from the engine mounting onto and
dismantling from the platform, which will 1.4.3 Explanations on adjustment to
result in danger. Due to this, to ensure the tension of power generator and air
engine and the entire maintenance conditioning drive belts
platform’s balance during the operation
process, the maintenance platform’s rotary 1. Loosen the power generator’s bolt nut ①.
handle shall be held tightly in hands during 2. Loosen the power generator’s fixing nut ②.
the engine tilting process.
Use the adjusting bolt ③, and adjust the belt
tension and belt difference to the specified value.
1.4 Power Generator and Starter
3. Tighten the power generator pivot bolt’s nut
①: tightening torque:43～60N·m
1.4.1 Power Generator’s
Dismantling/Mounting 4. Tighten the power generator’s fixing nut ②:
tightening torque:37.3～52N·m
Warning
 When dismantling /mounting the power

generator on the complete vehicle, the ③Adjust the bolt
accumulator cable shall be dismantled firstly,
or the power generator’s Terminal B will ②power generator’s
contact the vehicle body, which will lead to fixing nut power
sparks and further result in personal injury
and electric element damage.
①generator’s bolt nut
1. Dismantle the power generator according to
the sequence illustrated in the figure.
2. Mount the power generator according to the
Notice
sequence reverse to the dismantling process.
 If mounting the new power generator belt or
3. Inspect the belt’s deflection /tension (see
running power generator belt for less than 5
Inspection of the Power Generator Belt).
minutes, adjustment shall be made according
to the new part’s standard value.
②Power  If running power generator belt for more than
Generator Belt 5 minutes, adjustment shall be made
according to old part’s standard value.
 If it fails to stay within the standard value,
④Power readjustment shall be made from Step 1 on.
Generator 1.4.4 Explanations on inspection of power
generator
1. Confirm if the accumulator has been charged.
Engine block 1A-14
2. Confirm if the belt’s deflection /tension stays 2. Start the starter to Confirm if the starter runs
within the specified range (See power stably and has no running noise.
generator part: Inspection of Power Generator
Belt). ★ Note: If there is abnormal situation, turn the
ignition switch to the “START” position, and
3. Turn the ignition switch to the “ON” position, measure the voltage between Terminal S and
and the charge warning lamp will turn on. Terminal B, and the standard voltage shall be
greater than 8(V)
4. Confirm if the charge warning lamp is off
after the engine has been put into running. —If the voltage stays beyond the specified range,
overhaul the wiring harness and ignition switch.
★ Note: If there is abnormal situation, see
corresponding “Complete Vehicle Fault —If the voltage stays within the specified range,
Diagnosis and Handling”. dismantle the starter and inspect the solenoid
switch and starter.
1.4.5 Starter Dismantling/Mounting
Zero-load test
Warning
1. Confirm if the accumulator is charged.
 When dismantling/mounting the starter on the
complete vehicle, if the accumulator’s 2. Connect the starter, accumulator, voltmeter
positive cable fails to be loosened, the and ammeter (see right figure).
starter’s Terminal B will connect with or
3. Run the starter and Confirm if its running is
contact the body, which will lead to sparks
stable.
and further result in personal injury and
electric element damage. Due to this, 4. During the starter running process, measure
accumulator’s positive cable shall be the voltage and current.
dismantled firstly when the following
operations are conducted:
Ignition switch
1. Dismantle the accumulator’s positive cable.
Accumulator
2. Dismantle the starter according to the
sequence illustrated in the figure.
3. Mount the starter according to the sequence Starter
reverse to the dismantling process.
Terminal S
Note: If there is abnormal situation, conduct

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

Dismantling/Mounting
1 Binding posts B cable Notice
2 Binding posts S cable  When dismantling the ignition coil and spark
plug, shield sleeve at the connecting rod can
3 Starter be easily torn. Due to this, they should be
dismantled only when the replacement is
necessary and tearing and damage shall be
1.4.6 Explanations on inspection of starter avoided during the dismantling process.
Accompanying inspection: 1. Dismantle parts according to sequence

illustrated in the figure.
1. Confirm if the accumulator is charged.
Engine block 1A-15
the dismantling process.
⑥ Not greater
than 15{1.53}
1 Ignition coil Not greater

than 29.4{3}
2 Spark plug
3 PCV valve 1 Oil rail
2. Mantle parts according to sequence reverse to Crankshaft position sensor (see
the dismantling process. 2 Inspection of Crankshaft Position
Sensor)
1.51 Spark Plug Dismantling/Mounting
3 Camshaft position sensor
Notice
4 Pressure temperature sensor
 Mount the spark plug cautiously because
5 Throttle body
strong impact will result in spark plug
damage. Water temperature sensor (see
6
dismantling/mounting explanations)
PCV Valve Dismantling /Inspection
7 Oil control valve
1. Dismantle the PCV valve.
8 Oil pressure sensor
2. Confirm if the air ventilation in PCV valve is
9 Knock sensor
as the following table. If there is abnormal
situation, replacement shall be conducted.
Note: this part only lists different parts of
the control system’s mounting conditions
on the engine. See the complete vehicle’s
corresponding part for relevant fault
diagnosis and inspection.
1.5.3 Crankshaft position sensor’s
dismantling/mounting explanations
Air Ventilation Condition Table 1. When mounting the crankshaft position
sensor, smear “LOCTITE5971” onto the
Test Condition Test Result cylinder body (shade line zone).
There is air outflow 2. When smearing the sealant, keep clean the
Blow to A
from Interface B
There is no air outflow from
unit surface’s bonding part.
Blow to B
Interface A 3. After smearing the sealant, mount the
1.5.2 Control System Parts crankshaft position sensor within 3 minutes.
Dismantling/Mounting 1.5.4 Explanations to inspection of
1. Dismantle parts according to sequence crankshaft position sensor
illustrated in the figure. Clearance inspection
2. Mount parts according to sequence reverse to Attentions
Engine block 1A-16
Zone for smearing

the sealant
 Under-mentioned inspection shall be

conducted if necessary.
1. Confirm if the crankshaft rotating speed
sensor is correctly mounted.
2. Use the plug gauge to measure the clearance
between signal wheel protrusion platform and
crankshaft rotating speed sensor.
Notice
 If the clearance is incorrect, adjust the
crankshaft rotating speed sensor or inspect if
there is torsion and indentation in the signal
wheel’s protrusion part. (If have, replace the
crankshaft signal panel).
Standard clearance value:0.5～1.5mm
Clearance
Crankshaft
position sensor
Crankshaft
signal panel
1.5.5 Explanations on water temperature

sensor dismantling/mounting
Use the sleeve to dismantle the water temperature
sensor.
Engine block 1A-17
1.6 Intake and Exhaust System
1.6.1 Intake and Exhaust System Dismantling/Mounting

1. Dismantle parts according to sequence illustrated in the figure.
2. Mount the parts according to the sequence reverse to the dismantling process.
Throttle body seal ring(see Mounting

1 Exhaust manifold’s upper heat shield 5
Instruction)
2 Exhaust manifold 6 Intake manifold
Intake manifold seal ring(see Mounting
3 Exhaust manifold’s sealing gasket 7
Instruction)
4 Throttle body
Engine block 1A-18
1.6.2 Explanations on intake manifold damage on seal ring. If there is, replacement
dismantling shall be made.
1. Dismantle parts according to the sequence 1.6.5 Explanations on the exhaust

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

seal ring mounting
During the mounting process, mount the seal ring 1.7 Timing System
into the intake manifold’s slot, and wedge the seal
ring’s anti-mistake mark into the intake manifold’s
locating slot. 1.7.1Timing system dismantling/mounting
Caution 1. Dismantle power generator belt (see power
generator part).
 Prior to the mounting, inspect if there is
damage on seal ring. If there is, replacement 2. Dismantle ignition coil (see the ignition part).
shall be made.
3. Dismantle cylinder head hood (see cylinder
head hood part).
4. Dismantle oil sump.
5. Dismantle oil pump and timing chain case
assembly (see oil pump and timing chain case
assembly part).
6. Dismantle parts according to the sequence
Locating slot illustrated in the figure
1.6.4 Explanations on the throttle body
seal ring mounting 7. Mount the parts according to the sequence
During the mounting process, mount the seal ring
into the intake manifold’s slot, and wedge the seal 8. Adjust the power generator belt deflection
ring’s
Seal ring anti-mistake mark into the intake /tension (see power generator part).
manifold’s locating slot.
Locating
Seal ring
Notice
 Prior to the mounting, inspect if there is
Engine block 1A-19
direction, and align the gas distribution

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

dismantling
Loosen the bolt according to the sequence
1.7.7 Explanations on the tensioner arm

assembly mounting
After the mounting, tensioner arm assembly shall
not be excessively tightened, and sway the
tensioner arm assembly to inspect if it can fall
down freely.
1.7.5 Explanations on the timing chain 1.7.8 Explanations on timing chain
dismantling mounting
1. Mount the crankshaft pulley locking bolt. 1. Rotate the intake & exhaust camshaft to make
two timing marks at the timing chain pulley
2. Rotate crankshaft along the clockwise on exhaust side of the intake VVT face
Engine block 1A-20
toward specific angle. the timing chain, and repeat the operation
from Step 1
2. Mount the timing chain’s guide rail assembly.
7. Rotate the crankshaft for two circles along the
3. Mount the timing chain. clockwise direction, and then rotate the
Notice crankshaft to make the intake VVT assembly
(timing chain pulley on the intake side) align
 Align the timing mark at the timing chain with two gas distribution inspection marks at
pulley on the exhaust side of the intake VVT the camshaft chain on the exhaust side.
Notice
 In the event of failure in aligning, repeat the
operation from Step 1
1.7.9 Explanations on the cylinder head

hood mounting
1. Confirm if the cylinder head hood groove is
free from oil, water, and other foreign
objects.
2. Confirm if the cylinder head hood’s sealing
gasket has been completely attached to the
cylinder head hood’s groove.
3. Smear the sealant onto the joint between
cylinder head and oil pump and timing chain
case assembly according to the illustration.
4. Mount the tensioner arm assembly (see
4. Mount the cylinder head hood bolt according to
tensioner arm assembly mounting
the sequence reverse to the dismantling process
explanations).
of cylinder head hood (see the cylinder head
Notice hood dismantling part), and tighten the cylinder
head hood bolt by step.
 Confirm if the timing chain is located in the
timing chain guide rail assembly and Sealant-smearing
tensioner arm assembly’s slot. zone
5. Pull out the timing chain tensioner
assembly’s locking pin, when the push rod is
popped to push the tensioner arm assembly to
compress the timing chain.
Notice
 Confirm if the timing chain is located in the Sealant-smearing
zone
tensioner arm assembly and timing chain
guide rail assembly’s guiding slot.
1.7.10 Explanations on the crankshaft
6. Confirm if all timing marks (4) and valve pulley mounting
timing mechanism have been inspected Align
the mark (1) accurately. Use special tools to fasten the crankshaft for
mounting.
Notice
 Camshaft timing chain pulley and VVT
assembly timing marks are “△”, gas
distribution inspection mark is “○”; and
crankshaft timing chain pulley timing mark is
semicircular groove
 In the event of failure in aligning, dismantle
Engine block 1A-21
Bolt unit
Fixture unit
Double-ended jointing fixture
1 Oil drain plug

Dowel hole
2 Combination washer
3 Bolt
4 Oil pan
1.8.2 Explanations on the oil sump
dismantling
1. Dismantle the oil drain plug, and discharge
the oil in the oil sump.
1.7.11 Explanations on water pump pulley 2. Dismantle oil sump bolt step by step along the
mounting clockwise direction.
Mount water pump pulley, and tighten the bolt. 3. Use the oil sump dismantling tool to dismantle
the oil sump from the engine.
1.8.3 Explanations on the oil sump

mounting
Notice
 If the bolt will be reused, eliminate the
sealant on original thread because bolt with
old sealant may lead to damage of the screw
hole.
1.8 Lubricating System
 When mounting the reused oil sump, remove
the residual sealant at the oil sump and
1.8.1 Oil Sump Dismantling/Mounting corresponding mounting place.
1. Discharge the oil (see the complete vehicle’s 1. Add continuous sealant on the internal side of
upper inspection part: Replacement of Engine the oil sump bolt hole sealant, and overlap the
Oil). front ends, with sealant diameter ranging
between Φ2.0 and Φ3.0mm
illustrated in the figure. 2. Mount the soil sump according to the
sequence reverse to the dismantling process.
Oil sump
Smear sealant prior
to mounting
Engine block 1A-22
1.8.6 Explanations on oil pump’s oil seal

Cleft
mounting
1. Smear clean oil onto the oil seal’s peripheral
parts.
2. Mount the oil seal with hands.
Old sealant 3. Use the special tools to evenly compress the
1.8.4 Oil Pump and Timing Chain Case oil seal.
Assembly Dismantling/Mounting Compression depth:0～0.5mm
1. Dismantle crankshaft pulley (see crankshaft
pulley part). Oil seal erector Compress
2. Dismantle cylinder head hood (see
explanations on cylinder head hood oil pump
dismantling).
oil seal
oil pump
3. Dismantle oil sump (see oil sump, oil sump
dismantling/mounting).
4. Dismantle water pump (see water pump 4. Continuously smear the sealant onto the oil
dismantling/mounting). pump and timing chain case assembly’s rims,
5. Dismantle parts according to the sequence see the figure.
illustrated in the figure. Sealant diameter:Φ2±0.5mm
6. Mount the parts according to the sequence Notice

reverse to the dismantling process.  If the bolt will be reused, eliminate the
sealant on original thread because bolt with
old sealant may lead to damage of the screw
hole.
 When reusing the oil pump and timing chain
case assembly, remove the sealant on the
timing chain case and corresponding
mounting place.
1 Oil filter(see Mounting Instruction)

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

3
Dismantling Explanations /see Mounting Explanations)
1.8.5 Explanations on oil pump’s oil seal

dismantling
If necessary, use clean cloth to wrap the
screwdriver, and dismantle the oil seal lightly.
Dismantled oil seal should be replaced, and further
application is prohibited.
5. When mounting the oil pump and timing
chain case assembly, tighten bolts by steps
according to the sequence illustrated in the
Engine block 1A-23
figure..
Bolt Specifications and Mounting Torque
Bolt rod Mounting

No. Specification length torque
(mm) (N·m)
1a, 3a, 4a,
5a 25 8～12
M6
6a, 7a, 8a,
2b, 10b M6 30 8～12 1 Bolt
2 Oil pump cover
12c M6 45 8～12 3 Screw plug
13d, 14d M10 90 36.5～42.5 4 Pressure spring
5 Control piston
6 Inner rotor (Smear oil before mounting)
1.8.7 Explanations on the oil filter
7 Outer rotor (Smear oil before mounting)
mounting
Tighten bolts by steps according to the sequence
1.8.9 Inspection of Oil Pump
illustrated in the figure
Explanations on inspection of rotor clearance
1. Measure the following clearance, and replace
the rotor or pump body if necessary.
Standard gear tip clearance: 0.06～0.20mm
Maximum gear tip clearance: 0.22mm
Standard pump body clearance: 0.250～0.325

Maximum pump body clearance: 0.35mm
1.8.8 Explanations on oil pump

disassembling/ mounting
1. Dismantle oil pump and timing chain case
assembly (see oil pump and timing chain case
assembly dismantling/mounting).
2. Disassemble parts according to the sequence
Standard backlash: 0.03～0.09mm
reverse to the disassembling process.
Maximum backlash: 0.14mm
Engine block 1A-24
1.9.2 Explanations on thermostat

inspection and mounting
1. Put the thermostat into a vessel with hot water,
in which a thermometer is inserted. Then heat
the thermostat to raise the temperature, and
inspect the thermostat. If it does not comply
with regulations, replace the thermostat.
—Valve is closed at the room temperature.
Explanations on inspection of pressure —Valve is opened after the temperature rise.

spring Opening temperature (℃):80～84
Exert pressure on the spring and inspect the spring Full-opening temperature (℃):95
height. If necessary, replace the pressure spring.
Full-opening stroke (mm):≥8.5
Pressure range:97.7～107.4N{9.96～10.96kgf}
2. Confirm if the thermostat’s movable pin is
Standard height: 33.50mm upward, see the figure.
3. Align the cylinder body thermostat’s
mounting place, and mount the thermostat
onto the cylinder body.
Movable pin
1.9.3 Cooling water pipeline

1.9 Cooling System dismantling/mounting
1. Dismantle thermostat (see thermostat
1.9.1 Thermostat Dismantling/Mounting dismantling /mounting).
1. Dismantle parts according to sequence 2. Dismantle parts according to sequence
illustrated in the figure. illustrated in the figure.
2. Mount the parts according to the sequence 3. Mount the parts according to the sequence
reverse to the dismantling process. reverse to the dismantling process.
Replace parts
after the
dismantling
1 Thermostat cover
Thermostat
2
see explanations on thermostat mounting
Engine block 1A-25
3 bolt(heater water pipe assembly)

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

/O-ring mounting
When replacing the O-ring, smear the water onto
the O-ring, in order to facilitate its mounting and
avoid damage.
Notice
 Do not smear engine oil or other greasy
substances onto the O-ring.
1.9.5 Water Pump Dismantling/Mounting
1. Dismantle power generator belt (see power
generator belt part).
2. Dismantle parts according to sequence
Replace parts after

the dismantling
1 Bolt (water pump pulley)

2 Water pump pulley
3 Bolt (water pump assembly)
4 Bolt (water pump assembly)
5 Water pump assembly
Engine block 1A-26
1.10 Cylinder Cover and Valve Mechanism
Smear oil
before the
mounting
Smear oil
before the
mounting
Smear
Smear
oiloil
before
before
thethe
mounting
mounting
Smear sealant before mounting
the cylinder head hood Replace parts after the
dismantling
1 Intake VVT (see the dismantling /mounting explanations)

2 Camshaft sprocket (see the dismantling /mounting explanations)
3 Camshaft (see the dismantling /mounting explanations)
4 Tappet
5 Cylinder head (see the dismantling /mounting explanations)
6 Cylinder head gasket
Engine block 1A-27
3. Inspect the camshaft journal clearance (see

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

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

mounting
1. Measure every cylinder head bolt’s outer
diameter differential (d1-d2). If the
differential exceeds 0.15mm, the cylinder
head bolt shall be replaced.
Note: d2 refers to the minimum outer diameter
VVT fixing bolt within the ※ mark’s range.
2. Tighten the cylinder head bolt to specified
torque by steps according to the sequence
Explanations on camshaft dismantling illustrated in the figure.
1. If necessary, inspect and adjust the valve Tightening torque:17.2 ～ 22.0N·m{1.75 ～

clearance (see the valve clearance inspection 2.25kgf·m}
part).
2. Inspect the camshaft end gap (see the
camshaft inspection part).
Engine block 1A-28
attached to the bearing seat.

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

3. Mark every bolt head.
1. Rotate the camshaft to make the dowel pin
4. According to the bolt-tightening sequence
keep upward.
(Step 2) illustrated in the figure, rotate every
bolt for 180°～184° from its marker (see the 2. Smear some oil onto the VVT assembly’s
figure). inserting part, align the VVT assembly
location hole to the camshaft dowel pin, and
mount the VVT assembly slowly.
3. Lock the camshaft’s hexagon part with a
wrench (see the figure), so as to tighten
VVT’s fixing bolts.
VVT assembly location

hole (align camshaft
Paint mark place dowel pin)
Initial paint mark
after Step 4
VVT assembly
inserting part (smear
Explanations on the camshaft mounting some oil around)
Notice
 Since the camshaft’s mounting clearance is
small, make sure that the camshaft journal is
closely attached to the bearing seat during the
mounting process, or the contact surface
between the shaft and bearing will incur
excessive pressure and in turn suffer damage.
To avoid foresaid situation, regulations below
shall be observed:
1. Smear some oil onto the camshaft journal and
bearing seat.
2. Mount the camshaft into camshaft bearing
seat, making camshaft journal closely
Engine block 1A-29
1.10.2 Valve Mechanism Dismantling/

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

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

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

keeper
Use special tool valve spring pressure, remove the
★ Note:If the valve clearance exceeds the
valve keeper. standard value, replace the tappet(see the
valve clearance’s adjustment)valve
clearance’s standard value (when engine is in
cooling state):
Engine block 1A-30
Intake:0.18～0.26mm Notice:
Exhaust:0.26～0.34mm
 If the valve clearance will be adjusted when
(3) Rotate the crankshaft for 360 degrees along there is not timing chain, make the crankshaft
the clockwise direction, making the piston dowel pin towards side face, in order to
located at the stopping place on No.4 prevent the valve from colliding with the
Cylinder, namely, gas distribution mark shall piston top during the valve clearance
be adjusted to the position indicated in the adjustment process.
figure below.  Mark the tappet thickness inside the tapper
with 3 digits, see figure below:
Thickness mark
(4) Use plug gauge to measure valve clearances

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

Engine block 1A-31
necessary, replace the cylinder head. 7. If the distortion measured in Step 6 exceeds
the maximum value, grind the surface or
2. Inspect the following items, repair and replace the cylinder head.
replacement shall be conducted if necessary.
Maximum grinding volume: 0.20mm
(1). If there is indentation at the valve seat.
1.10.4 Inspection of Valve and Valve
(2). If the camshaft journal clearance and end gap
is excessive. Guide
3. Use the Straight Edge Ruler and plug gauge 1. Measure thickness of every valve’s head rim.
to inspect if the cylinder head is distorted If necessary, replace the valve.
along six directions, see the figure. Standard thickness: intake valve: 1.35mm; exhaust
Maximum distortion: 0.06mm valve: 1.85mm.
4. If the cylinder head’s distortion exceeds the Minimum thickness: intake valve: 0.85mm;
maximum value, inspect the cylinder head’s exhaust valve: 1.35mm.
height. If the height stays beyond the standard
value, replace the cylinder head.
Standard height:112.9-113.1mm
Brim thickness
2. Measure every valve’s length. If necessary,
replace the valve.
Standard length
5. If the cylinder head’s distortion exceeds the Intake valve:89.31～89.91mm
maximum value, and the height stays within
the standard value, grind the height or replace Exhaust valve:90.63～91.23mm
the cylinder head.
Minimum length
Maximum grinding volume:0.20mm
Intake valve: 89.11mm
6. Use the Straight Edge Ruler and plug gauge
to measure the cylinder head intake/ exhaust Exhaust valve: 90.43mm
manifold flange’s distortions along different
directions, see the figure.
Maximum distortion: 0.05mm
3. Measure every valve’s rod diameter

respectively at A, B, C point (see the figure)
Engine block 1A-32
along X and Y direction. If necessary, replace valve seat contact width. If necessary, use a 44
the valve.
° valve seat cutter reworked valve or valve
Standard diameter seat surface.
Intake valve: 4.965～4.980mm Standard width: 1.1 ~ 1.5mm
Exhaust valve: 4.955～4.970mm

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

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

spring
1. Use the special tools to exert pressure on the
valve spring, and inspect the spring height. If
necessary, replace the valve spring. Exert
pressure on the valve spring, and compress
the spring to a given height, when the
pressure value exceeds the specified range,
the valve spring shall be replaced.
When the height is 33.4mm, the pressure is 142.2～
Cylinder head 161.8N{14.51～16.51kgf};
When the height is 24.9mm, the pressure is
1.10.5 Explanations on inspection of valve 293.4～324.4N{29.94～33.10kgf}.
seat
2. Measure the valve spring verticality, and if
1. Surface painted with a method to measure the the verticality goes beyond the standard, the
Engine block 1A-33
valve spring shall be replaced.

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

A and B point along X and Y direction. If
necessary, replace the camshaft.
Standard diameter:25.940～25.965mm
Minimum diameter: 25.910mm
1.10.7 Explanations on the inspection of

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

journal clearance according to steps below:
(1). Remove all oil on the journal and bearing
seat’s internal surface.
(2). Put the camshaft into the bearing seat.
(3). Make the plastic gauge match the bearing
width (see the figure), and then put it on the
top of journal along the axial direction.
(4). Mount the camshaft cover (see cylinder head
dismantling/mounting, camshaft mounting
attentions).
2. Measure heights of the two convex parts (see
the figure). If necessary, replace the camshaft. Axial direction
Standard height
Intake side: 44.71mm
Exhaust side: 44.28mm
Minimum height
Intake side: 44.51mm
Exhaust side: 44.08mm Plastic gauge
Notice
Engine block 1A-34
 When measuring the clearance, do not rotate 1.10.8 Explanations on inspection of

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

at the A and B point (see the figure) along X
and Y direction.
5. Mount the camshaft cover (see cylinder head
dismantling/mounting, camshaft mounting
attentions).
6. Mount the dial gauge, push camshaft forward
or backward at the end of camshaft (see the
figure), and measure the camshaft end gap. If
necessary, replace the cylinder head or
camshaft.
Caution
 Do not push the camshaft at the cam part, so
as to prevent the cam from being damaged.
Standard end gap:0.08～0.20mm
Maximum end gap:0.21mm 3. Calculate the clearance between tappet and
corresponding tappet hole. If necessary, replace
the tappet or cylinder head.
Standard clearance:0.020～0.061mm
Maximum clearance:0.180mm
Engine block 1A-35
1.11 Flywheel, clutch
1.11.1 Flywheel and Clutch Dismantling/Mounting

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

2 Clutch friction disc (see dismantling explanations/see mounting explanations)
3 flywheel (see dismantling explanations/see mounting explanations)
Crankshaft’s back cover (see the rear oil seal dismantling explanations /see rear oil seal
4
mounting explanations /see mounting explanations)
5 Transmission’s baffle plate
Engine block 1A-36
1.11.2 Explanations on Clutch Pressure

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

1. Use the special tools (see the figure) to lock
the flywheel.
2. Follow the right-angled intersection sequence Explanations on the flywheel mounting
to evenly dismantle the mounting bolt (see the /inspection
figure), and dismantle the flywheel.
1. Mount the flywheel onto the crankshaft.
2. Clean the thread and hole before mounting the
bolt.
3. Smear evenly the sealant onto the thread.
Notice
Gear ring fixture unit
 There is no need to smear the sealant when
using new bolt
Explanations on Rear Oil Seal
1. Use the screwdriver, wrapped with protective
cloth, to dismantle the oil seal(see the figure)
Notice
 Normally, there is no need to dismantle the oil
seal, unless being replaced.
2. Add clean oil onto the oil seal opening.
3. Mount the oil seal with hands.
4. Tighten the flywheel bolt with hands.
4. Use the special tools and hammer to compress
the oil seal. 5. Mount special tools onto the flywheel (see the
figure).
Compression depth:0～0.5mm
6. Follow the sequence of right-angled
Engine block 1A-37
intersection to tighten the flywheel bolt little

by little.
Gear ring fixture

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

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

to measure the pressure plate’s flatness.
If it exceeds standard, replace the clutch
assembly.
Use the dial gauge to measure the clutch friction
disc’s end-on circle run-out. Maximum clearance: 0.05mm
friction disc
Maximum end-on circle run-out:0.7mm
Engine block 1A-38
head part), oil sump, oil pump, and timing

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

to evenly tighten bolts.
5. Mount the dial gauge onto the cylinder body,
and rotate the flywheel to inspect the ⑨Smear oil
diaphragm spring’s radial run-out. before
mounting
pressure plate
Maximum radial circle run-out:0.6mm
②Smear oil
before mounting
connecting rod Main bearing cover

cover (see the (see the mounting
1 7
mounting explanations)
explanations)
connecting rod
2 8 thrust bearing
bearing
piston ring(see the
3 mounting 9 Crankshaft bearing
explanations)
Piston pin (see the
4 mounting 10 Crankshaft
1.12 Cylinder body, Crank explanations)
Connecting Rod Mechanism 5 piston 11 Cylinder body
6 connecting rod
1.12.1 Cylinder Body, Crank Connecting
Rod Mechanism Dismantling/Mounting
1. Dismantle the cylinder head (see the cylinder
Engine block 1A-39
Explanations on connecting rod cover Explanations on main bearing cover

dismantling dismantling
Inspect the connecting rod end gap (see connecting 1. Inspect the crankshaft end gap (see the
rod inspection part). crankshaft inspection /repair part).
Explanations on piston pin dismantling 2. Loosen the main bearing cover’s bolt
according to steps illustrated in the figure.
1. Mount No. 1 and No. 2 special tools and
insert the No. 2 special tool into piston pin
and tighten it (see the figure)
Explanations on the crankshaft

dismantling
Inspect the main journal clearance (see the
crankshaft inspection /repair part).
No. 2 tool
Piston F’s mark side
Explanations on the main bearing cover
mounting
1. Measure every bolt’s length. If the length
exceeds the standard value, replace the bolt.
Piston pin No. 1 tool Standard length: 74.15～74.85mm
Maximum length: 75.05mm
2. Mount the special tools and piston connecting

rod assembly, which have been assembled in
Step 2, onto the special tools (see the figure).

Extrusion direction
2. Tighten main bearing cover’s bolt to specified
illustrated in the figure, as well as mark every
Catch bolt bolt head. Tightening torque:33 ～
35N·m{3.357～3.784kgf·m}
3. according to the bolt-tightening sequence
Piston pin assembly tool (Step 2) illustrated in the figure, rotate every
bolt for 60°～64° from the mark.
3. Use the press machine to extrude the piston
pin.
Engine block 1A-40
Catch bolt
Piston pin
assembly tool
Piston pin
assembly tool
5. Smear the clean engine oil onto the piston pin.

Connecting rod“HM15” mark side
Explanations on the piston pin mounting
1. Use the special tools for mounting.
2. Measure the following sizes (see the figure):
(1)A: exterior size of piston’s pin seat convex 6. Place the piston and connecting rod onto the
plate compression platform, and keep upward the
(2)B: piston cavity’s spread width piston “F” mark side and connecting
rod“HM15A” or “474Q-C” mark side (see the
(3)C: piston pin length figure).
(4)D: connecting rod’s small head width No. 1 tool
(5) Put measured values into the formula Connecting rod
below:
“F” mark side
BCAD
h= 2
Piston
No. 2 tool
7. Insert the piston pin and the special tool that

has been assembled in Step 2 into the piston
and connecting rod (see the figure).
8. Use the press machine to press the piston pin
into the piston and connecting rod till No. 2
Piston pin special tool (guide) contact the special
tool(catch bolt).
9. When pressing the piston pin, inspect the
compression pressure. If the pressure is
Connecting rod lower than the index, replace the piston
pin or connecting rod.
3. Insert the No. 2 special tool into the piston pin Pressure:5～11kN(510～1122kgf)
and tighten it onto the No. 1 special tool.
4. Measure length of No. 2 special tool’s
guiding part (L2), and adjust it to compress
the special tool (catch bolt), so as to make the
L’s size equal to L2＋h.
Engine block 1A-41
Piston ring dilator
10. Inspect the piston pin’s compression depth, if

it goes beyond the standard value, repeat the 2. Use the piston ring dilator to mount the No. 2
operation from step 1. and No.1 piston ring. Keep the marker side
upward during the mounting process.
Piston pin’s compression depth:0.350～1.375mm
3. Align all rings’ opening locations (see the
figure).
Piston pin’s
depth in the
convex plate Possible locations of all
piston rings’ abutment joints
No. 1
gas ring Upper
scraper
Thrusting
direction
Lower No. 2 gas

Explanations on the piston ring mounting scraper ring
1. Mount the corrugated ring into the piston ring Piston pin direction
slot, and then mount one end of the oil scraper
into the slot with hands. After that, compress
other parts (see the figure). After the Explanations on piston connecting rod
mounting, inspect if all pieces can move assembly mounting
smoothly along two directions.
1. Keep the piston “F” marker side face towards
Caution the engine’s frontal part;
2. When mounting the connecting rod cover,
align the connecting rod cover’s location
marker.
Explanations on the connecting rod cover

 Do not use the piston ring dilator to mount the mounting
oil scraper, or rupture may be caused.
1. The bolt can be reused, but when the outer
diameter difference at the two points
illustrated below exceeds 0.1mm, the bolt
Engine block 1A-42
shall not be further used. surface exceeds the maximum value, inspect
the cylinder body’s height. If the height stays
beyond the standard value, replace the
cylinder body.
diameter
diameter
Outer
Outer
2. Tigthen the connecting rod bolt to specified

Tightening torque:13.0 ～ 17.0N·m{1.32 ～ Cylinder body
1.74kgf·m}
Standard height:204.95～205.05mm
Row
3. If the cylinder body’s distortion goes beyond
the maximum value and the height stays
within the standard value, grind the height or
replace the cylinder body.
Front
In
3. Mark every bolt head.

4. According to the bolt-tightening sequence
(Step 2) illustrated in the figure, rotate every
bolt for 90°～94° from its marker.
1.12.2 Cylinder Body Inspection /Repair

to measure the distortion on the cylinder Maximum grinding volume: 0.20mm
body’s upper surface along six directions
illustrated in the figure. 4. Use the inside dial indicator to measure the
cylinder’s inner diameter at the place 60mm
Cylinder body’s maximum distortion:0.1mm away from upper surface along the X and Y
direction (see the figure).
Cylinder body’s upper surface
2. If the distortion on the cylinder body’s upper

Engine block 1A-43
5. If the cylinder’s inner diameter goes beyond Ring 2: 0.020～0.060mm

the abrasion limit, replace the cylinder body,
and install the corresponding piston, in order Oil ring: 0.040～0.12mm
to make it accord with the standard clearance
Maximum clearance
between piston and cylinder. Abrasion limit:
0.135mm Ring 1, Ring2: 0.15mm
Size Diameter Oil ring: 0.15mm.
Standard 74.8～74.815 4. Put the piston ring into cylinder with hands,
and use the piston to push the piston ring to
1.12.3 Piston, Piston Ring, and Piston Pin the bottom of the cylinder bore stroke.
Inspection
1. Along the vertical direction of piston pin hole’s
axial line, measure the piston’s diameter at the
place that is 19.38mm below the lower rim of the
oil control ring groove
Piston diameter (mm)

Size Diameter
5. Use the plug gauge to measure every piston
Calculate the clearance between piston and ring’s opening clearance. If necessary, replace
cylinder. If necessary, replace the piston. the piston ring.
Standard clearance:0.010～0.035mm Standard opening clearance:
Maximum clearance: 0.10mm Ring 1: 0.15～0.30mm
2. If replacing the piston, piston ring shall be Ring 2: 0.20～0.40mm

replaced as well.
Oil Ring: 0.10～0.40mm
3. Use the plug gauge to measure the clearance
between piston ring and ring slot along the Maximum opening clearance:1.0mm
entire perimeter (see the figure). If necessary, 6. Respectively at A, B, C, and D point along X
replace the piston and piston ring. and Y direction, measure every piston pin hole’s
diameter.
Standard clearance
Ring 1: 0.030～0.070mm
Engine block 1A-44
7. Respectively at A, B, C, and D point along X width and then put it on the top of journal,
and Y direction, measure every piston pin’s keeping parallel with the axial line.
diameter
(3). Mount the connecting rod cover (see piston
and connecting rod mounting part).
(4). Dismantle the connecting rod cover’s bolt,
and slowly take off the connecting rod cover.
(5). Use the plastic gauge scale to measure the
widest point on the plastic gauge’s extruded
part, and then calculate out the journal
clearance. If the clearance exceeds the
maximum value, replace the crankshaft and
corresponding connecting rod bearing to
ensure the standard clearance.
8. Standard diameter:18.001 ～ 18.005mm;
Calculate out the clearance between piston pin and
piston pin hole. If necessary, replace the piston or
piston pin.
9. Measure the connecting rod’s small head
diameter (see connecting rod inspection), and
calculate the clearance between connecting
rod’s small head and piston pin. If necessary,
replace the connecting rod or piston pin.
Standard clearance:-0.031～-0.016mm. Maximum clearance:0.10mm
1.12.4 Connecting Rod Inspection Size of connecting Thickness of connecting

1. Use the plug gauge to measure the connecting rod bearing rod bearing
rod’s end gap. If necessary, replace the Standard 1.485～1.496
connecting rod and connecting rod cover.
3. As shown in X and Y direction of each of the
connecting rod small end diameter
measurement.
Standard diameter: 17.974～17.985mm
Maximum clearance:0.40mm
2. Measure the crank pin journal clearance 1.12.5 Inspection of Piston Connecting
according to steps below.
Rod Assembly
(1). Remove all oil on the journal and bearing
Inspect the swaying torque (see the figure). If the
seat’s internal surface.
big head fails to drop down by virtue of its own
(2). Make the plastic gauge match the bearing weight, replace the piston or piston pin.
Engine block 1A-45
3. Respectively at A and B point along X and Y

direction, measure the journal diameter. If
necessary, replace the crankshaft.
Drop down by virtue

of its own weight
1.12.6 Crankshaft Inspection /Repair

Main journal Diameter(mm)
1. Mount the dial gauge, use the screwdriver to Standard 46.004～46.029
push the crankshaft frontward and backward,
Crank pin Diameter(mm)
and measure the crankshaft end gap (see the
Standard 39.980～40.000
figure). If the end gap surpasses the maximum
value, replace the thrust bearing or crankshaft 4. Measure the main journal’s clearance
to fit the standard end gap. according to method below.
Standard end gap:0.09～0.273mm (1). Remove all oil on the crankshaft journal and
Maximum end gap:0.30mm bearing seat’s internal surface.
(2). Make the plastic gauge match the bearing
Thrust bearing’s size Thrust bearing’s thickness width and then put it on the top of journal,
keeping parallel with the axial line.
(3). Mount the main bearing cover (see the main
bearing cover mounting part).
(4). Dismantle the main bearing cover bolt, and
slowly take off the main bearing cover (see
main bearing cover mounting part).
(5). Use the plastic gauge scale to measure the
widest point on the plastic gauge’s extruded
part, and then calculate out the journal
clearance. If the clearance exceeds the
maximum value, replace the crankshaft and
corresponding bearing bush to ensure the
2. Measure the crankshaft’s radial run-out. If standard clearance.
necessary, replace the crankshaft.
Standard clearance: 0.014～0.034mm
Maximum radial circle run-out:0.03mm
Maximum clearance: 0.1mm
Bearing bush size Bearing bush thickness

Electronic Fuel Injection Control System 1B-1
Chapter 2 Electronic Fuel Injection Control System
1. Notices for Maintenance of Electronic Fuel Injection System······································1B-2

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

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

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

2.4.1 Fault Information Record ······································································· 1B-11
2.4.2 Classification of Fault Types ··································································· 1B-12
2.4.3 Connection with Diagnostic Unit······························································ 1B-14
3.ME7’s Overhaul and Diagnosis Flow by Fault Code ················································ 1B-14
4.ME7’s Overhaul and Diagnosis Flow by Fault Phenomenon······································· 1B-21
5. Functional Requirements on ME7 System’s Diagnostic Unit ······································1B-344

5.1 Parts Mounting Torque Specification Table ························································1B-344
5.2 Electronic Fuel Injection System Maintenance Specification ···································1B-35
5.2.1 Family Vehicle ·················································································· 1B-35
5.2.2 Vehicle for Lease ··············································································· 1B-36
4. The electronic fuel injection system’s oil supply
pressure is relatively high (350kPa or so), and all
1. Notices for Maintenance of fuel pipelines adopt the fuel pipe resisting high
Electronic Fuel Injection System pressure. Even if the engine does not run, the oil
pipeline will keep a relatively high fuel pressure.
1.1 General Maintenance Notices Due to this, do not dismantle the oil pipe at
discretion during the maintenance process. In the
 Only the digital multimeter can be used to occasion where the fuel system shall be
inspect the electronic fuel injection maintained, pressure discharge treatment is needed
system. before the oil pipe is dismantled, with pressure
discharge method as follows: start the engine and
 Original parts and components shall be make it run at idle speed, connect it with the
used in maintenance work, or electronic diagnosis instrument, enter the “Actuator Test”,
fuel injection system’s normal running and turn off the fuel pump till the engine stops
cannot be ensured. automatically. Dismantling of oil pipe and
 Only the lead-free gasoline can be used replacement of fuel filter shall be completed by
during the maintenance process. maintenance professionals in the place with sound
ventilation condition.
 Observe standard maintenance and
diagnosis flow to conduct maintenance. 5. When dismantling the electric fuel pump from the
fuel tank, do not power on the oil pump, in order
 Disassembly and dismantling to to avoid electric sparks and fire disaster.
electronic fuel injection system’s
components shall be prohibited during the 6. Running experiment to fuel pump shall not be
maintenance process. conducted in a dry state or in water, or its service
life will be shortened. In addition, do not mistake
 Handle the electronic elements (like the fuel pump’s negative and positive electrodes.
electronic control unit and sensor etc)
with caution during the maintenance 7. When inspecting the ignition system, spark test
process, and do not let them drop on the shall not be conducted until it is necessary, and
floor. also the spark test time shall be as short as possible.
During the testing process do not turn on the
 Cultivate the consciousness of throttle or much unburned gasoline will flow into
environmental protection, and handle the exhaust pipe, which will in turn result in
efficiently wastes resulting from the damage to the three-way catalyst converter.
maintenance.
8. Since the idle adjustment is completed totally by
1.2 Maintenance Attentions the electronic fuel injection system, there is no
need to conduct manual adjustment. When leaving
1. Do not dismantle any of the electronic the factory, throttle’s accelerator stop bolt has been
fuel injection system’s components or adjusted by the manufacturer, and users’
connectors from its mounting place adjustment to its original location is prohibited.
without approval, in order to guard
against accidental damage and prevent 9. When connecting with the accumulator, do no
foreign objects like water and oil stain mistake the accumulator’s negative and positive
from entering the connector, which may electrodes, or the electronic elements will incur
affect the electronic fuel injection damage. In this system, minus earth is adopted.
system’s normal running.
10. During the engine running process, do not
2. When disconnecting and connecting the dismantle the accumulator cable.
connector, place the ignition switch to the
11. Before executing the electric welding in the vehicle,
“OFF” position, or the electric elements
dismantle the accumulator’s negative/positive
will incur damage.
cables and electronic control unit.
3. When conducting the fault heating
12. Do not test the parts’ electric signal input/output by
condition simulation or other
penetrating the cable sheath.
maintenance jobs that may lead to
temperature rise, make the temperature of
electronic control unit stay below 80℃.
1.3 List of Maintenance Tools
Tool name: Electronic fuel injection system diagnosis

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

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

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

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

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

the electronic fuel injection system’s faults.
Tool name: Fuel Injector Cleaning Analyzer
Function:
Make cleaning analysis on the fuel injector
1.4 Manual annotation abbreviations in
DG Speed sensor; DVE Electronic throttle body; FPM Accelerator pedal; DR Fuel pressure regulator
DS-S-TF Air intake pressure and temperature sensor
ECU Electronic control unit
EKP Fuel pump
EMS Engine management system
EV Injector
LSF Oxgen sensor(Heating type)
KS Knock sensor
KSZ Fuel distribution pipe assembly
KVS Fuel distribution pipe
PG Phase sensor
Ignition system with the distributor; RUV Ignition system without the distributor; TEE Fuel pump bracket
ROV
assembly
TEV Carbon canister control valve
TF-W Coolant temperature sensor
ZSK Ignition coil
VVT Variable valve timing system
DS-D2 Brake vacuum sensor
EBS Battery sensor
2. Briefings of ME7 System
2.1 Basic Principle

2.1.1 System Profile ME788-Motronic
Engine management system usually consists of sensor, microprocessor (ECU), and actuator, which is used
to control the air absorption, oil injection volume, and ignition advance angle during the engine running
process. See Fig. 2.1 for its basic structure.
Diagnosis Diagnosis
Sensor EUC Actuator
Engine
Fig. 2.1 Components of Engine Electric Control System

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

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

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

 Neutral position signal (dedicated to
In comparison with previous Collection M start/stop)
engine electronic fuel injection management
system, ME7 system has the following  Clutch top switch signal (dedicated to
characteristics: start/stop)
 All-new engine function structure with torque  Clutch bottom switch signal (dedicated to
being the variable, which is easily compatible start/stop)
with other systems and has strong scalability;
 Accumulator sensor signal (dedicated to
 All-new modularized software and hardware start/stop)
structure that is highly transplantable;
 Engine compartment cover signal (dedicated
 Model-based engine characteristics maps to start/stop)
independent to one another, which helps
simplify the marking process;  Door signal (dedicated to start/stop)
 Sensor with phase, and sequential fuel After entering the ECU, above information will be
injection facilitates the improvement of processed to produce the needed actuator control
emission; signals, which will be amplified in the output drive
circuit and transmitted to corresponding actuators.
 System’s integration with anti-theft function; These control signals include:
 Coordinate different torque requirements in a  Opening of electronic throttle
centralized manner to improve the driving
performance;  Fuel injection timing and oil injection’s
duration
 16-bit CPU, 40MHz clock frequency, and
768k cache;  Oil pump relay
 The system is scalable according to future  Opening of carbon canister control valve
demands like emission standard OBDII.  Ignition coil’s angle of attachment and
2.2 Control signal: ME7 system’s input /output ignition advance angle
signals  A/C compressor relay
In the ME788 system, ECU’s major sensor input  Cooling fan relay
signals include:
 Starter relay
 Intake pressure signal
 VVT angle
 Accelerator pedal signal
 Intake temperature signal 2.3 Introduction of System
 Throttle angle signal Functions
 Coolant temperature signal
2.3.1 Start Control
 Engine rotating speed signal
During the starting process, special calculation
 Phase signal method will be adopted to control the charge, fuel
injection, and ignition timing. At the initial phase
 Knock sensor signal
of this process, air in the intake manifold keeps
 Oxygen sensor signal still, and intake manifold’s internal pressure
reading is equal to the ambient atmosphere
 Vehicle speed signal pressure. When the throttle is closed, the idle speed
regulator is assigned a fixed parameter according
 A/C pressure signal
to the starting temperature.
 Brake signal
In the similar process, the given “Fuel Injection
 Brake vacuum degree signal (dedicated to Timing” is assigned the initial injection pulse.
start/stop)
Fuel injection volume varies according to the
engine temperature, in order to facilitate the Towing astern or traction condition refers to the
formation of oil film on the intake manifold and situation in which the power at the flywheel from the
cylinder’s walls. Therefore, when the engine engine is negative. In this case, engine friction and
reaches a given rotating speed, thick gas mixture pump gas loss can be used to make the vehicle
shall be added. decelerate. When the engine stays in the towing
astern or traction condition, the oil injection will be
Once the engine starts running, the system will cut off to reduce the fuel consumption and waste gas
immediately reduce the starting excess fuel. When emission. More importantly, the process will help
the starting process ends (600…700min-1), the protect the three-way catalyst converter.
starting excess fuel is completely cancelled.
Once the rotating speed declines to the given rotating
During the engine starting process, the ignition speed (above idle speed) for recovery of oil supply,
angle is being adjusted constantly, and it varies the oil injection system will resume the oil supply. As
according to engine temperature, intake a matter of fact, among the ECU’s programs there is
temperature, and engine’s rotating speed. a range for recovery of rotating speed, and it varies
Note: As for vehicles with start/stop function, with change of parameters like engine temperature
vehicle starting can be determined according to the and engine rotating speed’s dynamic change. Also, it
vehicle gear and clutch information. If the calculates the rotating speed to prevent it from
transmission is in gear and engages with the clutch, declining to specified minimum threshold.
starter running shall be prohibited. Once the injection system resumes the oil supply,
2.3.2 Warm-up and Three-way Catalyst the system will begin using the initial injection
pulse to supply the additional fuel, in addition to
Converter Heating Control reconstructing the oil film on the intake manifold’s
When the engine has been started at low wall. After recovery of the fuel injection,
temperature, cylinder charge, fuel injection, and torque-based control system will slow and stabilize
electronic ignition will be adjusted to offset the the engine torque’s increase (smooth transition).
engine’s higher torque requirements. Such a
process will continue till appropriate temperature
2.3.4 Idle Control
threshold has been hit. At the idle speed, engine will not offer torque to
Meanwhile, speedy heating to three-way catalyst the flywheel. To make sure that the engine can run
converter is most important, because speedy stably at a low idle speed, the close-loop idle
control system must maintain the balance between
transformation into three-way catalyst converter
the torque and the engine’s “Power Consumption”,
running will help reduce emission of waste gas
considerably. In such a working condition, ignition and it will generate a given power during the idling
advance angle should be postponed, in order to heat process, in order to meet different load requirements,
which arise from engine crankshaft, gas distribution
the three-way catalyst converter by waste gas.
mechanism, and auxiliary components (like friction
2.3.3 Acceleration /Deceleration and in the water pump).
Towing Astern Oil Cutoff Control ME788 System adopts the torque-based control
Some of the fuel that has been injected into the intake strategy, which, based on close-loop idle control,
manifold will not duly flow into the cylinder to determines the engine torque output that is required
partake into the subsequent combustion. On the to maintain the idling speed in any working condition.
contrary, it will produce a layer of oil film on the Such torque output increases with decline of the
wall of the intake manifold. With improvement of the engine’s rotating speed, or vice versa. By requiring
load and extension of the fuel injection duration, fuel higher torque, the system makes response to the new
deposited in the oil film will increase sharply. “Interference Factor”, such as the air conditioning
compressor’s start/stop or automatic transmission
When the throttle opening increases, some shift. When the engine temperature is relatively low,
injected fuel will be absorbed by the oil film. Due torque should be increased to offset more internal
to this, supplementary fuel shall be injected to friction loss and/or maintain higher idling speed.
prevent the gas mixture from getting thin during All these torque output requirements are
the acceleration process. Once the load coefficient transmitted to the torque coordinator, which will
decreases, additional fuel included in the fuel film make processing calculation and obtain
on the intake manifold wall will be released again. corresponding charge concentration, components
Then, injection duration must decrease during the of gas mixture, and ignition timing.
deceleration process.
2.3 5 Close-loop Control advance angle again.
Exhaust post-treatment in the three-way catalyst Knock control’s threshold is applicable to fuel of
converter is an effective way to reduce density of different working conditions and different
harmful substances in the waste gas. Normally, grades.
the three-way catalyst converter is able to reduce
HC, CO, and NOx by 98% ore more, and turn 2.3.8 VVT Control
them into H2O, CO2, and N2. However, By controlling the intake/exhaust camshaft phase,
above-mentioned high efficiency can be realized the system can efficiently reduce the engine’s
only when the engine’s excess air factor is equal emission at low speed and improve its torque at
to 1 or so. In fact, the close-loop control aims to high speed. According to the vehicle’s running
ensure that concentration of the gas mixture stays condition and the driver’s driving intention, the
within such a range. ECU can calculate out the intake/exhaust
Close-loop control system takes effect only when the camshaft’s target phase, as well as realize the
oxygen sensor is installed. Oxygen sensor is used to close-loop control to the camshaft phase according
monitor the oxygen content in the waste gas on the to the phase information acquired from the phase
three-way catalyst converter’s side: thin gas mixture sensor. Compared with the engine without VVT
(λ>1) produces sensor voltage of about 100mV, and system, the engine with VVT system can
thick gas mixture (λ<1) produces sensor voltage of efficiently reduce oil consumption and emission as
about 900mV. When λ is 1, the sensor voltage will well as raise the maximum power.
incur a jumping. To the input signal, the close-loop 2.3.9 Idle Start/Stop Control
control will make response (λ>1: too thin gas
mixture, λ<1: too thick gas mixture) to modify the By analyzing the driver’s driving intention, the
control variable, and modifying factor therein will system will realize the automatic idle stop/start at a
serve as the multiplier to modify the fuel injection proper time. By analyzing such information as
duration. clutch pedal, neutral gear, driving speed, brake
vacuum degree, accumulator state, door, and engine
2.3.6 Evaporation Emission Control compartment cover etc., idle start/stop control will
Due to transmission of external radiation heat and oil determine if the automatic stop/start conditions have
return radiation, fuel in the oil tank is heated to been met. During the normal driving process, drivers
produce the fuel steam. Subject to the limitation of need to conduct any additional operation to realize
evaporation emission laws and regulations, steam the automatic idle stop/start.
brimming with lots of HC shall not be discharged Since the idle start/stop control provides the complete
into the air directly. In the system, fuel steam will be vehicle with starter relay, there will be two additional
collected into the active carbon canister through the functions like automatic start after stalling and
duct. When condition permits, fuel steam will be starter’s failure in running when gearing chain
flushed and discharged into the engine to partake in engages (transmission is in gear and engages with
the combustion process. Meanwhile, the flow rate of clutch), which will do good to fresh drivers. In
the flushing air current is realized by ECU that addition, the idle start/stop control can help reduce
controls the carbon canister’s control valve. Only the complete vehicle’s oil consumption and gas
when the close-loop control system works in the emission.
close-loop condition can such a control run.
2.4 Introduction of System
2.3.7 Knock Control Troubleshooting Function
By virtue of the knock sensor that is mounted at
the appropriate place of the engine, the system
2.4.1 Fault Information Record
tests the characteristic vibration resulting from Electronic control unit constantly monitors the
the knock, and then converts the vibration into sensor, actuator, relevant circuits, fault indicators,
electronic signal, in order to transmit it in the and accumulator voltage etc., and even the
ECU for handling. By adoption of special electronic control unit itself, in addition to
processing algorithm, ECU tests if there is knock conducting the reliability test to the sensor output
phenomenon at every cylinder’s combustion signal, actuator drive signal, and internal signals
cycle. Once there is knock, ECU will trigger the (like close-loop control, coolant temperature,
knock close-loop control. After the knock danger knock control, idling speed control, and
is eliminated, the affected cylinder’s ignition will accumulator voltage control etc). Once there is
be gradually advanced to the preset ignition fault at certain link or a given signal is unreliable,
the electronic control unit will immediately set the can be classified into “Steady-state Faults” and
fault information record in RAM fault memory, “Sporadic Faults” (like the faults resulting from
and save it in the form of fault code, which will be short-lived open circuit or poor contact between
displayed according to the fault occurrence connectors)
sequence. According to the fault frequency, faults
Fig. 2.4 Electronic Fuel Injection System’s Troubleshooting Principle

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

1 P000A Slow intake VVT response 5 × ×
2 P000B Slow exhaust VVT response 5 × ×
3 P0010 VVT intake control valve circuit, open 3 √ ×
Intake VVT fails to stay at defaulted position when
4 P0012 5 × ×
starting
5 P0013 VVT exhaust control valve circuit, open 3 √ ×
Exhaust VVT fails to stay at defaulted position when
6 P0015 5 × ×
starting
Improper relative position between crankshaft and
7 P0016 3 √ ×
camshaft
Improper relative position between crankshaft and
8 P0017 3 √ ×
camshaft
9 P0030 Upstream oxygen sensor heater control circuit, fault 3 √ ×
Upstream oxygen sensor heater control circuit, low
10 P0031 3 √ ×
voltage
Upstream oxygen sensor heater control circuit, high
11 P0032 3 √ ×
voltage
12 P0036 Downstream oxygen sensor heater control circuit, fault 3 √ ×
Downstream oxygen sensor heater control circuit, low
13 P0037 3 √ ×
voltage,
Downstream oxygen sensor heater control circuit, low
14 P0038 3 √ ×
voltage
15 P0053 Upstream oxygen sensor heater resistance, improper 3 √ ×
16 P0054 Downstream oxygen sensor heater resistance, improper 3 √ ×
17 P0105 Intake pressure sensor signal, no fluctuation (freezing) 3 √ ×
Intake pressure sensor/barometric pressure sensor,
18 P0106 3 √ ×
improper
19 P0107 Intake pressure sensor’s short circuit to the ground 3 √ ×
20 P0108 Intake pressure sensor’s short-circuit to the battery 3 √ ×
21 P0112 Intake temperature sensor signal circuit, low voltage 3 √ ×
22 P0113 Intake temperature sensor signal circuit, high voltage 3 √ ×
23 P0117 Engine coolant temperature sensor circuit, low voltage 3 √ ×
24 P0118 Engine coolant temperature sensor circuit, high voltage 3 √ ×
25 P0121 Electronic throttle position sensor1 signal, improper 3 √ ×
Electronic throttle position sensor1 signal circuit, low
26 P0122 3 √ ×
voltage
electronic throttle position sensor1 signal circuit, high
27 P0123 3 √ ×
voltage
28 P0130 Upstream oxygen sensor signal, improper 3 √ ×
29 P0131 Upstream oxygen sensor signal, low voltage 3 √ ×
30 P0132 Upstream oxygen sensor signal circuit, high voltage 3 √ ×
31 P0133 Upstream oxygen sensor, aging 3 √ ×
32 P0134 Upstream oxygen sensor circuit, signal circuit fault 3 √ ×
33 P0136 Downstream oxygen sensor signal, improper 3 √ ×
34 P0137 Downstream oxygen sensor signal, low voltage 3 √ ×
35 P0138 Downstream oxygen sensor signal circuit, high voltage 3 √ ×
36 P0140 Downstream oxygen sensor circuit, signal fault 3 √ ×
Offline detection A/F ratio close-loop control
37 P0170 7 × ×
self-learning, improper
38 P0171 7 × ×
self-learning, too lean
39 P0172 7 × ×
self-learning, too thick
40 P0201 Cylinder 1 fuel injector control circuit, open 3 √ ×
44 P0219 Engine rotating speed exceeds the upper limitation 6 × ×
45 P0221 Electronic throttle position sensor2 signal, improper 3 √ ×
Electronic throttle position sensor2 signal circuit, low
46 P0222 3 √ ×
voltage
Electronic throttle position sensor2 signal circuit, high
47 P0223 3 √ ×
voltage
Cylinder 1 fuel injector control circuit’s short circuit to
48 P0261 3 √ ×
ground
49 P0262 3 √ ×
the battery
50 P0264 3 √ ×
the ground
51 P0265 3 √ ×
the battery
52 P0267 3 √ ×
the ground
53 P0268 3 √ ×
the battery
54 P0270 3 √ ×
the ground
55 P0271 3 √ ×
the battery
56 P0300 Multiple Cylinders Misfire Detected 2 √or Blink ×
57 P0301 Cylinder 1 Misfire Detected 2 √or Blink ×
61 P0321 Crankshaft TDC shortage signal, improper 3 √ ×
62 P0322 Rotating sensor signal, fault 3 √ ×
63 P0327 Knock sensor signal circuit, low voltage 3 √ ×
64 P0328 Knock sensor signal circuit high voltage 3 √ ×
65 P0340 Phase sensor mounting position, improper 3 √ ×
66 P0341 Phase sensor signal, improper 3 √ ×
67 P0342 Phase sensor signal circuit’s short circuit to the ground 3 √ ×
68 P0343 Phase sensor signal circuit’s short circuit to the battery 3 √ ×
69 P0365 Phase sensor mounting position, improper 3 √ ×
70 P0366 Phase sensor signal, improper 3 √ ×
71 P0367 Phase sensor signal circuit’s short circuit to the ground 3 √ ×
72 P0368 Phase sensor signal circuit’s short circuit to the battery 3 √ ×
Three-way catalyst oxygen storage capacity, aging
73 P0420 3 √ ×
(excessive emission)
74 P0444 Canister control valve control circuit, open 3 √ ×
75 P0458 Canister control valve control circuit, low voltage 3 √ ×
76 P0459 Canister control valve control circuit high voltage 3 √ ×
77 P0480 Cooling fan relay control circuit, open (low speed) 5 × ×
78 P0481 Cooling fan relay control circuit, open (high speed) 5 × ×
79 P0501 Vehicle speed sensor signal, fault 3 √ ×
Idling control rotating speed, lower than target idling
80 P0506 3 √ ×
speed
Idling control rotating speed, higher than target idling
81 P0507 3 √ ×
speed
82 P0560 System accumulator voltage signal, improper 5 × ×
83 P0562 System accumulator, low voltage 5 × ×
84 P0563 System accumulator, high voltage 5 × ×
Brake switch signal circuit, fault or out-of-step
85 P0571 5 × ×
correlation
86 P0602 Electronic control unit encoding, fault 3 √ ×
87 P0604 Electronic control unit RAM, fault 3 √ ×
88 P0605 Electronic control unit ROM, fault 3 √ ×
89 P0606 Electronic throttle safety monitoring function, fault 3 √ ×
Starter relay R1 ECU driving stage’s open circuit to relay
90 P0615 5 × ×
circuit
Starter relay R1 ECU driving stage’s short circuit to the
91 P0616 5 × ×
ground
Starter relay R1 ECU driving stage’s short circuit to the
92 P0617 5 × ×
battery
93 P0627 Oil pump relay control circuit, open 3 √ ×
94 P0628 Oil pump relay control circuit, low voltage 3 √ ×
95 P0629 Oil pump relay control circuit, high voltage 3 √ ×
96 P0645 A/C compressor relay control circuit, open 5 × ×
97 P0646 A/C compressor relay control circuit, low voltage 5 × ×
98 P0647 A/C compressor relay control circuit, high voltage 5 × ×
99 P0688 Main relay’s output voltage, improper 5 × ×
100 P0691 Cooling fan relay control circuit, low voltage(low speed) 5 × ×
Cooling fan relay control circuit, high voltage(low
101 P0692 5 × ×
speed)
Cooling fan relay control circuit, low voltage(high
102 P0693 5 × ×
speed)
Cooling fan relay control circuit, high voltage(high
103 P0694 5 × ×
speed)
104 P0704 Clutch pedal switch signal, improper 5 × ×
Neutral position switch, ineffective, neutral signal
105 P081D 5 × ×
maintains high level or low level
106 P083F Clutch low-position switch fails to disengage 5 × ×
107 P1336 Electronic throttle safety monitoring torque, restriction 6 × ×
108 P1500 LIN bus check and checksum error 5 × ×
109 P1501 LIN bus frame error 5 × ×
110 P1502 LIN bus response overtime, possibly disconnection 5 × ×
LIN bus read back, error, possibly LIN line’s short circuit
111 P1503 5 × ×
to the ground
EBS LIN communicating load rate, too high, beyond
112 P1511 5 × ×
hardware fault
EBS value indicates EBS circuit is open or other EBS
113 P1512 5 × ×
hardware with fault
Battery changed and long time no tester confirmation (no
114 P1513 5 × ×
function temporarily)
115 P1530 Door switch short circuit to ground 5 × ×
116 P1531 Door switch short circuit to the battery 5 × ×
Deflection between electronic throttle’s actual location
117 P1545 3 √ ×
and target location exceeds limit
118 P1558 Electronic throttle’s starting resistance, too high 3 √ ×
119 P1559 Electronic throttle’s self-learning process, fault 6 × ×
System voltage fails to meet electronic throttle’s
120 P1564 6 × ×
self-learning condition
Electronic throttle lower position limit initialization
121 P1565 3 √ ×
self-learning, fault
122 P1568 Electronic throttle return resistance, too high 3 √ ×
123 P1579 Electronic throttle self-learning condition, unsatisfied 6 × ×
124 P1604 Electronic throttle gain regulation self-learning, fault 6 × ×
125 P1610 SecretKey and SecurityCode not programmed 39 × ×
126 P1611 SecurityCode reception, error 39 × ×
127 P1612 Challenge request, failure 36 × ×
128 P1613 IMMOCode request, failure 36 × ×
129 P1614 Transponder check, error 36 × ×
Anti-theft certification communication, error, or burglar
130 P1626 6 × ×
alarm, no response
131 P1660 S/S state indicator’s ECU driving stage, fault 5 × ×
132 P1661 S/S fault indicator’s ECU driving stage, fault 5 5 × ×
133 P1701 Power train state signal wire, open 5 5 × ×
Clutch low-position switch error, or neutral switch error,
134 P1702 5 × ×
or power train signal wire error
Brake vacuum degree sensor voltage signal, higher than
135 P1912 5 × ×
upper limit
Brake vacuum degree sensor voltage signal, lower than
136 P1913 5 × ×
lower limit
137 P1914 Brake vacuum chamber pressure, beyond the limit value 5 × ×
138 P2088 VVT intake control valve’s short circuit to the ground 3 √ ×
VVT intake control valve circuit’s short circuit to the
139 P2089 3 √ ×
battery
VVT exhaust control valve circuit’s short circuit to the
140 P2090 3 √ ×
ground
VVT exhaust control valve circuit’s short circuit to the
141 P2091 3 √ ×
battery
142 P2106 Electronic throttle driving stage, fault 3 √ ×
Electronic throttle pedal position sensor1 signal, low
143 P2122 3 √ ×
voltage
Electronic throttle pedal position sensor1 signal, high
144 P2123 3 √ ×
voltage
Electronic throttle pedal position sensor2 signal, low
145 P2127 3 √ ×
voltage
Electronic throttle pedal position sensor2 signal, high
146 P2128 3 √ ×
voltage
147 P2138 Electronic throttle pedal position sensor signal, improper 3 √ ×
A/F ratio close-loop control self-learning value goes
148 P2177 11 √ ×
beyond upper limit (middle load zone)
A/F ratio close-loop control self-learning value goes
149 P2178 11 √ ×
beyond lower limit (middle load zone)
152 P2270 Downstream oxygen sensor, aging 3 √ ×
153 P2271 Downstream oxygen sensor, aging 3 √ ×
154 P254F Front hatch cover’s short circuit to the ground 5 × ×
155 P3046 Starter relay R1(Crank relay) fails to engage 5 × ×
Power train state relayR2(PT State Relay) fails to
156 P3050 5 × ×
disengage
157 P3052 Starter relay R1(Crank relay) fails to disengage 5 × ×
starter relay R1(Crankrelay) or power train state
158 P3053 relayR2(PT 5 × ×
StateRelay) fails to engage 5
Engine blocked or starter is not engaged with flywheel
159 P3054 5 × ×
5
Key start switch feedback voltage signal wire (KL50r)’s
160 P3055 5 × ×
short circuit to the ground
Key start switch feedback voltage signal wire (KL50r)’s
161 P3056 5 × ×
short circuit to the battery
162 P3088 Starter damaged or starter wire disconnected 5 × ×
163 U0001 CAN communication’s relevant diagnosis 3 √ ×
... ... ... ... √=on √=on
×=off ×=off
4 ME7’s Overhaul and Diagnosis Flow by Fault Phenomenon

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

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

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

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

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

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

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

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

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

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

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

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

1 Coolant temperature sensor 39.2 (Max)
2 Knock sensor 20±5
3 Oxygen sensor 50±10
4 Rotating speed sensor 10±2
5 Phase sensor 10±2
6 Magnetic fuel injector 6
7 Electronic accelerator pedal 6±0.5
8 Electronic throttle 10 (Max)
9 Brake vacuum degree sensor 10±2
5.2 Electronic Fuel Injection System Maintenance Specification
5.2.1 Family Vehicle

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

5.2.2 Vehicle for Lease

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

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

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

2.1 Inspection of Carbon Canister Assembly························································· 1C-11
2.1.1 Inspection of Carbon Canister’s Electromagnetic Valve ································ 1C-11
2.2 Inspection of Ventilation Condition ······························································· 1C-12
2.3 Inspection of Open/Short Circuit ·································································· 1C-12
Fuel System 1C-2
Caution
1. Fuel System  Wrong connection with other wiring terminals
may lead to fault, and so caution is needed
1.1 Preparatory Work before Repair during the connection process.
Warning 1. Connect the DLC’s wiring terminal F/P with

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

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

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

5 Elastic pipe HQ99286-3900
/Mounting). clamp
5. Dismantle the cylinder repair cover plate. Refueling hose SA12-42-231
6
6. Dismantle all fuel pipes that connect with the Fuel tank straps SA12-42-720
7
oil pump. (R)
7. Drain fuel in the cylinder. 8 Refueling pipe SA12-42-211
8. Life the vehicle with lifting machine and 9 Dust cover SA12-42-240
dismantle parts according to sequence
illustrated in the figure. 10 Cap-filler FA1A-42-250
9. Mount parts according to the sequence reverse

11 Elastical clamp HQ99283-1900
to the dismantling process.
12 Breather hose SA12-42-232
10. Complete inspection work after the repair (see
Inspection Work after Repair) Canister bracket SA12-13-960
13
14 Canister SA12-13-96Z
15 Bolt HQ99786-0820
16 Snorkel SA12-13-963
17 Desorption SA12-20-374
canister hose
18 Pipe clip SA12-45-914
19 Fuel tank SA12-42-111
20 Fuel tank tie SA12-42-710

(left)
21 Bolt HQ90786-1030 36.3-

53.9
22 Fuel tank SA12-42-741

insulation panels
24 Bolt HQ99786-0816 20.0-

32.0
25 Hose SA12-20-377
26 Fuel supply pipe SA12-13-49X

assembly
27 Hose SA12-20-376
28 Clip SA12-45-911
No. Part name Part No. Torq Re 29 Fuel hard tube SA12-45-110
ue mar
k 30 Hard tube SA12-45-711
evaporator
1 Fuelsupply pipe SA12-42-61X
2 Fuel pump SA12-42-166
gasket 32 Screw HQ99845-0510
3 Fuel pump SA12-13-35Z
4 Fuel pump cover SA12-42-161

Fuel System 1C-5
1.3.1 Cylinder Air Tightness Test

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

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

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

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

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

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

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

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

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

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

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

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

410kpa(4.1kgf/cm2, 59psi) Electromagnetic Valve
11. Loosen the jumper wire. Conduct simulation test
12. Remove the special tool. Inspect the carbon canister’s electromagnetic
valve (see Fault Diagnosis, Inspection of Engine
13. Connect the main fuel hose (fuel supply pipe Control System’s Working Condition, Inspection
assembly) with the main pipe(fuel rigid pipe). of Carbon Canister’s Electromagnetic Valve); if it
If the oil pressure maintenance fails to accord is abnormal, conduct further inspection to the
with standard, replace the fuel pump assembly carbon canister’s electromagnetic valve.
(see Fuel Pump Assembly
14. Confirm if around the quick plug’s bonding
zone there is not oil leakage.
15. Complete the inspection work after
repair(see Inspection Work after Repair)
Fuel System 1C-12
is public connector)
 Power circuit (the circuit between the carbon
canister’s electromagnetic valve connector
terminal 2 and main circuit breaker connector
terminal D, in which there is public connector)
Main relay
Connector on wiring harness’s side

(viewing from the electrode terminal side)
2.2 Inspection of Ventilation Condition Short Circuit

Notice  Electrical ground between carbon canister’s
 The following tests can be conducted if electromagnetic valve connector terminal 2 and
necessary ECU connector terminal 46, in which there is
public connector.
2. Remount the carbon canister’s
2. Dismantle the carbon canister’s electromagnetic valve.
electromagnetic valve .
3. Inspect ventilation condition of the carbon
canister’s electromagnetic valve
(If normal, inspect if there is open /short circuit,
and if the vacuum hose is correctly arranged or
suffers distortion and air leakage. If abnormal,
replace the carbon canister’s electromagnetic
valve ).
2.3 Inspection of Open/Short Circuit

1. Inspect if there is open/short circuit on the
following wiring harnesses (If there is,
overhaul or replace corresponding wiring
harness).
Open Circuit
 Earthing circuit (the circuit between the carbon
canister’s electromagnetic valve connector 1
and ECU connector terminal 46, in which there
Intake and Exhaust System 1D-1
Chapter 4 Intake and Exhaust System

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

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

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

the dismantling process.
2. Exhaust System
2.1 Inspection of Exhaust System
1. Start the engine, and inspect if the exhaust

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

2 Three-way catalyst converter
3 Front muffler assembly
Cooling System 1E-1
Chapter 5 Cooling System

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

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

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

1.5.2 Instructions for installing the thermostat······················································1E-5
1.6 Water Pump ····························································································1E-5
1.6.1 Water Pump Dismantling/Mounting ·························································1E-5
1.6.2 Fan Motor························································································1E-5
1.7 Fan Relay································································································1E-6
1.7.1 Inspection of Fan Relay ··········································································1E-6
Cooling System 1E-2
the radiator outlet, and assembled in place and

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

sink are hot, do not dismantle the heat sink lid or
loosen the heat sink’s drain valve because hot
coolant and vapor may spout, which will result in
serious casualties and damage to the engine and
cooling system
Turn off the engine, and conduct further operation
after the engine cools down. Then, keep mindful Warning
when removing the heat sink’s filler lid, and wrap
the filler lid with thick cloth and slowly turn it to the Alcohol or methanol antifreeze may damage
first stop position along the anticlockwise direction. aluminum parts on the engine, and so alcohol or
When the pressure declines, turn it along the reverse methanol shall not be used in the cooling system,
direction; and only the glycol-based coolant can be used.
If there is not pressure, press the heat sink lid with Only the softening (demineralization) water can
cloth and dismantle it. be used to mix with the coolant, and water
containing minerals will compromise the coolant’s
effect.
1.1 Engine Coolant
Engine coolant will result in damage to the
lacquer surface, and so the engine coolant shall be
1.1.1 Inspection of Engine Coolant’s rinsed out in no time when it touches the lacquer
Liquid Level surface.
1. Confirm if the coolant’s liquid level in ◆ Refer to table below to select appropriate
subsidiary water tank ranges between MAX and volume percentage for mixture of water and
MIN. coolant. Add slowly the coolant into the
water tank till the coolant reaches the filler
If the engine coolant’s liquid level stays below
port.
MIN, open the subsidiary water tank’s lid and add
the coolant near to the MAX mark. Filling speed:1.0L(1.1USqt 、 0.9impqt)/min.
If there is no coolant in the subsidiary water tank, [Maximum Value]
wait till the engine cools down, and open the heat
Volume
sink’s filler lid to add coolant from the heat sink Coolant Proportion at
filler port till the coolant’s liquid level can be seen percentage
protective agent 20℃{68ºF}
from the filler port. Then, mount the heat sink’s Water Coolant
filler lid, and continue adding the coolant near to
Higher than
the MAX mark. 65 35 1.054
-16℃{3ºF}
1.1.2 Replace Engine Coolant Higher than
◆ Turn off the engine, and so the engine coolant 55 45 1.066
-26℃{-15ºF}
completely cooled, removed fixed the plumbing and
Higher than
radiator assembly of elastic tube outlet folder under 45 55 1.078
-40℃{-40ºF}
the water from the radiator assembly out of the outlet
to unplug, let go of the engine and radiator the
coolant assembly. When unplug the pipes, be careful
not to let the coolant splash to humans.
◆ Wait outlet pipes and radiator coolant outflow

no longer have to re-set in under the water in
Cooling System 1E-3
filler port.
Notice
 If the pressure surpasses 123kPa {1.25kgf/cm2,
17.8psi}, hose joint and other parts will be
damaged, which will in turn lead to leakage.
4. Make the heat sink reach specified
pressure:
Pressure:123kPa{1.25kgf/cm2, 17.8psi}
◆ Start the engine and maintain the idling speed

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

◆ Vice water tank removal / installation
1. Vice water tank drained coolant.
illustrated in the table;
to the dismantling process.
1.3 Radiator
Radiator Dismantling/Mounting
Fan Parts Dismantling/Mounting

1. Disconnect the accumulator’s negative cable;
2. Drain the engine coolant;
3. Dismantle the front grille and air intake duct.;
4. Remove the radiator and condenser mounting
bracket bolts bolts; remove the fan mounting
bolts;
5. Remove the engine Water pipe, remove the
expansion tank hose. (connect with the heat 1 Vice-water tank hose I
sink end);
2 Vice-water tank hose III
illustrated in the table; 3 Vice-water tank hose II
reverse to the dismantling process. 4 Vice-water tank bolt 1
5 Vice-water tank bolt 2
1.5 Thermostat
1.5.1 Thermostat Dismantling/Mounting
1. Drain the engine coolant.
1 Lower water pipe

2 Upper water pipe
3 Fan wiring harness connector
4 Fan assembly
5 Vice-water tank hose I
6 Vice-water tank hose II
7 Radiator mounting bracket
① Upper heat sink hose
Cooling System 1E-5
② Thermostat lid charged.

③ O-ring 2. Connect the accumulator’s positive electrode
and amperemeter with the fan motor plug.
④ Thermostat Mounting Attentions
3. Confirm if the fan motor runs stably while
1.5.2 Instructions for installing the thermostat being driven by standard current. Replace fan
1. Mount the thermostat onto the thermostat motor if it fails to meet technical
housing, pay attention to the thermostat’s requirements.
direction, with clamping pin facing upward.
Clamping pin
Standard Current:
Thermostat Inspection
①Connected, High-speed Action 11-12.5A [12V]
1. Inspect thermostat according to items below.
①Disconnected, Low-speed Action 9-10.5A [12V]
—Valve temperature when being turned on or off.
◆ Fan Motor Dismantling/Mounting
—Valve’s critical temperature in full opening or
full closing state. If technical requirements 1. Dismantle the cooling fan.
cannot be met, replace the thermostat. 2. Dismantle parts according to the sequence
Condition Action Temperature℃
Initial to the dismantling process.
81
Temperature rising opening
process Full
93
opening
Start
90
Temperature closing
decline process Full
79
closing
1.6 Water pump
1.6.1 Water Pump

See Engine Water Pump Dismantling/ Mounting

for the water pump dismantling/ mounting.
1 Cooling fan heat shielding cover
2 Cooling fan blade
1.6.2 Fan Motor
3 Fan motor assembly
◆ Fan Motor Inspection
1. Confirm if the accumulator has been fully
Cooling System 1E-6
1.7 Fan Relay Relay Diagram
1.7.1 Inspection of Fan Relay

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

inspect the fan relay’s quality. If the relay is unable
to run normally or meet technical requirements,
replace the fan relay. See table below for the relay
inspection:
Compliance
Step Port
standard
Ohmmeter tests
Infinite
1 resistance at both ends of
resistance
Pin 30 and Pin 87
Hear the
Both ends of Pin 85 and
relay’s
2 Pin 86 directly link with
actuation
12V power supply
voice
Keep the relay’s
actuation state, and again
Resistance is
3 use the ohmmeter to test
zero
resistance at both ends of
Pin 30 and Pin 87
High/low-speed relay pins have the
Remark
same definition
Accessory-Belt 1F-1
Chapter 6 Engine Accessory-Belt

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

When measuring
If necessary, inspect the driving belt’s distortion
and tension.
When mounting
1.1.1 Inspection of Driving Belt’s Distortion
Notice:
 After 30 minutes since the automobile engine 1.2 Adjusting the drive belt
stops, inspect the belt distortion with a belt
tensiometer, in order to confirm if the belt
tension stays within the standard value. 1.2.1 A/C Compressor Multi-wedge V Belt
Adjustment
 If the belt tension goes beyond the specified
range, adjust the driving belt (see Adjustment
1. Loosen appropriately the nut on the power
of Driving Belt)
generator’s pivot bolt.
2. Loosen the power generator’s fixing bolt, and
then tighten it for about 5N.m, in order to
avoid the pulley’s deflection.
Adjust bolt
Fix power generator bolt
Power generator pivot nut
3. Use the adjusting bolt to adjust the belt

tension and belt deflection to the standard
value.
4. Tighten the power generator’s pivot nut.
Tightening torque: 43 ±4N·m
5. Tighten the power generator’s fixing bolt.
Tightening torque: 20±2N·m
1.1.2 Inspection of Driving Belt Tension
Notice
 The inspection shall be conducted after the
engine cools down
Use SST to inspect the tension of belt between two
driving wheels.
 If the tension goes beyond the specified range,
make adjustment (see Adjustment of Driving
Belt)
Accessory-Belt 1F-3
to the old part’s standard value.
1.2.2 Power Steering Pump Belt

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

then tighten it for about 5N.m, in order to
avoid the pulley deflection.
Distortion (mm/98N)
Driving Belt New Old
A/C Compressor Belt 600N-700N500N-600N

Power Steering Pump Belt
400N-500N300N-350N
(With Tensioner pulley)
Power Steering Pump Belt
300N-500N
(Without Tensioner pulley)
2. Adjust the stud bolt A to drive the tension
pulley’s location change in the tension pulley
bracket’s slot, so as to adjust the belt tension.
3. After the tension meets requirements, tighten
the tension pulley nut B, Tightening
torque:40～48N.m
Notice
 If mounting new driving belt or running
driving belt for not greater than 5minutes,
adjustment shall be made according to the new
part’s standard value.
 If running the driving belt for more than 5
minutes, adjustment shall be made according
Engine Suspension 1G-1
Chapter 7 Engine Suspension

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

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

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

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

1. Dismantle 4 # 3 and 4-- suspension nut;
2. Dismantle 4 # suspension bolts 1 and 2 (body side);
3. Dismantle the four # mount bracket nut 6 and 7;
4. Dismantle the four # suspended inspection rubber is broken, hardening or damaged.
Resonance block and insulation panels disassembly

1. Dismantle the heat shield bolts 1 and 2, remove the insulation panels;
2. Dismantle the resonator block bolt 3;
3. Dismantle the resonator block check rubber is broken, hardening or damaged.
MF515L Transmission 1H-1
Chapter 8 MF515M Transmission

Table of Contents
MF515L Transmission·······················································································1H-2
1. Overview ·································································································· 1H-2
1.1 Shifting mechanism ················································································· 1H-3
2. Transmission Troubleshooting and Maintenance ···················································· 1H-3
2.1 Troubleshooting······················································································ 1H-3
2.2 On-spot Maintenance ··············································································· 1H-4
2.2.1 Replace Oil ······················································································ 1H-4
2.2.2 Differential Right/Left Oil Seal Replacement ·············································· 1H-4
2.3 Transmission Assembly Dismantling ····························································· 1H-5
2.3.1 Dismantle Gearshift Actuator································································· 1H-5
2.3.2 Dismantle the assembling bolt to split the box ············································· 1H-5
2.3.3 Dismantle Reverse Gearshift Mechanism and Reverse Gear ···························· 1H-5
2.3.4 Dismantle left box’s other components ····················································· 1H-6
2.4 Transmission Components Dismantling, Overhaul, and Remounting ······················· 1H-7
2.4.1 Dismantle input shaft’s components························································· 1H-7
2.4.2 Intermediate Shaft Components ······························································ 1H-9
2.4.3 Differential Unit ················································································ 1H-12
2.4.4 Right box body·················································································· 1H-14
2.4.5 Left box body ··················································································· 1H-14
MF515M Transmission
1. Overview
The transmission, through three synchronizers and
three transmission shafts (input shaft, intermediate
shaft, and reverse gear shaft), can provide five
forward gears and one reverse gear, of which all
forward gears belong to constant-mesh type, but
the reverse gear is a sliding idle gear.
Low-speed synchronizer is mounted onto the
intermediate shaft, and coupled with the
intermediate shaft’s first gear and second gear. Fig. 1-3 Internal gear shift mechanism
High-speed synchronizer is mounted onto the input
shaft, and coupled with the input shaft’s third gear
and fourth gear.
On the input shaft the fifth-gear synchronizer is
engaged with the fifth gear on the input shaft.
Intermediate shaft drives the main reduction gear
and differential device, so as to rotate the front
driving axle that is connected with the front wheel.
As for the maintenance work, sealant or equivalent
products shall be smeared on gearbox housing
surface’s corresponding parts, and the gearbox
housing is made of aluminum. On the housing, the
fixing bolt shall be tightened to specific torque
with the torque wrench. Before remounting, all
parts shall be cleaned thoroughly with cleaning
agent or liquid and dry air, which is very
important. Fig. 1-4 Gearshift Actuator
Fig. 1-1 Transmission assembly

Fig. 1-2 Gear Mechanism
1.1 Shifting mechanism Solution: Replace the self-locking spring in time.
The gearshift control lever’s motion is transmitted d. Reason: Gear’s axial clearance is too large,
to transmission shaft and shift shaft through the which should be mainly attributed to the gear
transmission control shaft, and then transmitted to check ring’s serious abrasion
the transmission and gear shift lever, shaft, and
Solution: Replace the gear check ring.
fork or arm through the transmission cross arm and
yoke. In addition, transmission interlocking plate is e. Reason: shift fork’s abrasion and distortion
prepared to avoid the gear’s double engagement. In
the mechanism there are five-gear and reverse-gear Solution: Calibrate the shift fork manually when it
cams, cam guide spring, and fifth gear-reverse gear suffers distortion. Replace it when suffering
interlocking guide pin, in order to avoid the gear’s serious abrasion.
direct shifting from fifth gear to reverse gear.
f. Reason: Synchronizer gear housing, gear
1) When the transmission shifts to the fifth gear, sleeve, or gear ring suffer abrasion
the fifth gear-reverse gear shift cam will
Solution: If there is out of gear, replace the
rotate with the shift shaft along the clockwise
wear-out parts.
direction, and cam return spring will jack the
cam to shift to the reverse gear. g. Reason: After being adjusted, transmission
fails to reach the “Neutral Gear” position, or
2) Shift from the fifth gear to the neutral gear is
the adjusting mechanism is loosened.
permitted, but further shift to the reverse gear
is prohibited. Solution: Place it to the “Neutral Gear”’ position
again, and adjust the clearance.
3) Shift position is located at the neutral gear
position of the fifth gear-reverse gear (see Fig. h. Reason: the engine’s connection with the
1-4). When the shift shaft moves upwards to transmission and complete vehicle is too loose,
facilitate the gear shift lever’s shift from fifth or the clearance adjustment is inappropriate.
gear to the reverse gear, shift cam will stop
due to blockage by the guide rod. Solution: Adjust the clearance
4) At this time, the system can shift to the ◆ Transmission Emits High Noise or
reverse gear when there is not interference by Abnormal Sound Reasons and Solutions
shift cam.
a. Reason:Transmission has insufficient oil or the
2. Transmission Troubleshooting oil is not clean
and Maintenance Solution: Inject sufficient oil or replace the oil.
2.1 Troubleshooting b. Reason: Gear’s axial clearance is too large
Transmission’s main faults and troubleshooting Solution: Replace gear or gear check ring.
methods:
c. Reason: Gear suffers abrasion or gear teeth is
◆ Out of Gear broken
Reasons and Solutions: Solution: If the gear backlash exceeds the specified
range, replace the gear. Standard backlash of the
a. Reason: shift rod suffers serious abrasion and five-gear transmission is 0.1mm, and the operating
distortion limit is 0.3mm.
Solution: calibrate the shift rod manually. If the d. Reason: synchronizer’s gear ring suffers
shift rod bends or suffers serious abrasion, replace abrasion or the gear is broken
it in time.
Solution: Replace the gear ring.
b. Reason: shift rocker suffers serious abrasion
and distortion e. Bearing suffers damage or abrasion
Solution: replace the shift rocker in time. Solution:Replace bearing.
c. Reason: Self-locking spring’s elasticity is f. Bearing press plate suffers damage or

weakened abrasion.
Solution: Replace the gear check ring. oil, be sure to stop the engine and lift the
automobile steadily.
◆ Shifting Difficulty
2) Oil level and leakage cannot be inspected
Reasons and Solutions until the automobile has been lifted. If there is
a. Shift rod or shift fork incurs distortion or leakage, remedial actions shall be taken in
uneven abrasion time.
Solution: Replace parts. 3) Drain original lubricating oil and inject new
and specified lubricating oil.
b. Self-locking steel ball and shift fork shaft’s
groove suffer abrasion 4) Drain plug and oil filler plug’s torque
specifications are as follows, and the drain
Solution: Replace parts. plug itself has sealant.
c. Synchronizer’s gear ring gets stuck on the Tightening torque:12～18N·m
gear’s conic section
Gear oil:GB13895-1992 heavy-load vehicle gear
Solution: Replace the gear ring. oil (GL-4) grade:75W.
d. Synchronizer spring is damaged Oil filling volume:1.8～2.0L
Solution: Replace the synchronizer spring. Notice
e. Gear sleeve and gear end suffer abrasion or  When the automobile is jacked for other
abrasion of gear ring’s key groove becomes maintenance work besides the lubricating oil
wider. replacement, inspection to leakage of
lubricating oil shall be conducted as well.
Solution: Replace corresponding parts.
2.2.2 Differential Right/Left Oil Seal
◆ Oil Leakage
Replacement
a. Oil leakage at the drain plug 1) Jack the automobile and drain the
Solution: first, the plug’s tightening torque is less transmission lubricating oil.
than the specified value, and so inspect the tightening 2) Dismantle the driving shaft from the
torque. If the tightening torque does not comply with differential.
requirements, tighten the plug. Second, there is
deflection in engagement or thread teeth damage, 3) Use the special tool and hammer to dismantle
replace corresponding parts. the oil seal and mount a new part. special
tools(A): oil seal erector1(right); oil seal
b. Oil Leakage at Sealing Parts erector2(left)
Solution: Replace sealing parts while abiding by Oil seal’s mounting degree “a” on the differential
operation specifications. side: 1.0-1.5mm
c. Oil Leakage at the Bonding Surface 4) Smear lubricating grease on the oil seal’s rim,
Solution: Conduct inspection and make all in addition to inspecting the contacting part
connection bolt’s tightening torques accord with between the driving shaft and oil seal, as well
specifications. as ensure the smoothness.
d. Oil Leakage at the Input Shaft’s Seal Ring “A”: Suzuki Lubricating Grease A.
Solution: first, inspect if the seal ring is damaged.

If damaged, replace the sealing parts. Second,
inspect if the right tank body’s supporting port
suffers excessive abrasion. If it suffers, replace
right tank body.
2.2 On-spot Maintenance
2.2.1 Replace Oil
1) While replacing and inspecting the lubricating Fig. 2-1 Differential oil seal replacement
5) Mount driving shaft into the differential. rim and dismantle the left box.
Caution Special tool: Box splitter (A).
 When inserting the driving shaft’s bolt, do not
scratch the oil seal’s rim. Make sure the
driving shaft’s bolt has been inserted
sufficiently, and the elastic check ring is fixed
as original.
6) Inject transmission oil according to the
requirements, and make sure the oil has been
sealed tightly by the oil seal.
2.3 Transmission Assembly Dismantling

2.3.1 Dismantle Gearshift Actuator
Dismantle the locking bolt assembly and the
gearshift box’s assembling bolt, in addition to Fig. 3-2-a Dismantle assembling bolt
taking off the gearshift box’s components. 1 Assembling boltM8×40(nine)
2 Assembling boltM8×40(five)
Fig.3-1 Dismantle Gearshift Actuator

1 Locking bolt assembly
2 Assembling bolt M8×20(four)
Fig. 3-2-b Dismantle assembling bolt
3 Gearshift box components 1 Assembling boltM8×40(fourteen)
4 Gearshift stop pin 2 Left box
Notice 3 reverse gear shaft bolt(one)
 Make sure the gearshift box’s components are

dismantled when the transmission stays at the
“Neutral Gear” position
2.3.2 Dismantle the assembling bolt to split the
box
1) Dismantle the assembling bolt from internal Fig. 3-2-c Split the Box
and external sides of the transmission;
2.3.3 Dismantle Reverse Gearshift Mechanism
2) Dismantle the reverse gear shaft bolt from and Reverse Gear
lateral side of transmission;
1) Take off input shaft’s oil tray and shim, and
3) Use the soft hammer to knock the left box’s the intermediate shaft’s left bearing adjusting
shim; 5) Use the soft hammer to knock input shaft

lightly;
2) Dismantle the reverse shift fork bolt, and take
off reverse shift fork assembly; 6) Take out the input shaft components,
intermediate shaft components, first /second
gear shift components, third/fourth gear shift
components, fifth/reverse gear shift
components from the box once for all.
Fig. 3-3-c Take off the gear mechanism and gear

shift mechanism
Fig. 3-3-a Dismantle the reverse gear shift
mechanism and reverse gear 1 Internal gear shift mechanism
1 Internal gear shift mechanism 2 Input shaft oil tray
2 Input shaft’s oil tray 3 Input shaft shim
3 Input shaft’s shim Intermediate shaft’s left bearing
Intermediate shaft’s left bearing adjusting 4
4 adjusting shim
shim
5 Reverse shift fork bolt 5 Reverse gear shaft bolt
6 Reverse shift fork assembly 6 Reverse gear shift fork assembly

7 Reverse gear fork spacer block
3) Take off reverse idler gear shaft and reverse
idler gear assembly. 2.3.4 Dismantle left box’s other components
4) Dismantle gear mechanism and gear shift
mechanism
Fig. 3-4-a Take off other components

1 Right box
2 Magnet
Intermediate shaft’s right bearing
3
outer ring
4 Intermediate shaft oil tray
Fig. 3-3-b Dismantle Gear Mechanism and Gear
Shift Mechanism
1 Differential unit
1) Take off other components
2 Intermediate shaft components
3 Input shaft components 2) Dismantle differential unit from the right box
4 Reverse gear shaft 3) Dismantle bolt,
5 Reverse gear assembly 4) Use special tools to dismantle the
input shaft’s oil seal Caution

Special tools: (A): Slide shaft;  Be sure to use the puller’s flat surface, in
order to avoid the damage to third gear
(B): Oil seal ejector
6) Take out the third gear needle bearing from
5) Use special tools to dismantle the the shaft.
intermediate shaft’s ring bearing outer ring.
1.Input shaft
Special tools: (A): slide shaft; 2.Right bearing
(B):Bearing ejector 3.Bearing puller
6) Dismantle the differential’s right oil seal from

right box.
Fig.4-1-a Dismantle the input shaft’s right bearing
1 Input shaft
2 Right bearing
3 Bearing puller
Fig. 3-4-b Dismantle the input shaft’s oil seal

1 Input shaft oil seal
Intermediate shaft’s right bearing
2
outer ring
2.4 Transmission Components

Dismantling, Overhaul, and Remounting
2.4.1 Dismantle input shaft’s components Fig.4-1-b Dismantle the input shaft’s left bearing,
fifth gear, and fifth-gear synchronizer unit
◆ Disassembly
1) Use the bearing puller and extrusion device to
dismantle the input shaft’s right bearing.
2) Use the puller and extrusion device to extrude
left bearing, fifth gear synchronizer unit, and
fifth gear once for all.
3) Take off the fifth gear needle bearing. Fig.4-1-c Dismantle the fifth gear shaft sleeve,
four gear shaft sleeve, four gear synchronizer gear
4) Take off the fifth gear shaft sleeve, fourth
ring, fourth gear assembly, fourth gear needle
gear shaft sleeve, fourth gear synchronizer
bearing, third gear ring, third gear assembly, and
gear ring, fourth gear assembly, fourth gear
high-speed synchronizer unit
needle bearing, third gear synchronizer gear
ring, third gear assembly, and high-speed ◆ Assembly
synchronizer unit.
Assemble Input Shaft Components
Notice:
 To prevent the gear teeth from being damaged,
make the teeth lean against the smooth and
straight side of the bearing puller.
2) If the synchronizer’s components will be

repaired, inspect the clearance “a” between
the gear ring and the gear ring, and then
inspect every gear’s crowned teeth, ring, and
sleeve. After that, determine if the
replacement shall be conducted.
Clearance a: Theoretical value: 0.95- 1.45mm
Ultimate value: 0.5mm
3) Ensure the lubrication, and blow air to every
oil port to make sure that there is not
blockage.
Fig.4-1-d Input Shaft Components

1 Input shaft right bearing
2 Input shaft
3 Input shaft third gear needle bearing
4 Input shaft third gear assembly
5 Third gear synchronizer gear ring
6 Synchronizer spring Fig.4-1-e
7 High-speed synchronizer gear hub 1 Gear wheel
8 High-speed synchronizer slide block 2 Gear ring
9 High-speed synchronizer gear sleeve
10 Input shaft fourth gear shaft sleeve
11 Input shaft fourth gear needle bearing
12 Four gear synchronizer gear ring
13 Input shaft fourth gear assembly
14 Input shaft fifth gear shaft sleeve
Fig.4-1-f
15 Input shaft fifth gear needle bearing
4) Mount the high-speed synchronizer onto the
16 Input shaft fifth gear assembly
hub, insert three slide blocks, and then mount
17 Fifth gear synchronizer gear ring the spring according to the illustration.
18 Fifth gear synchronizer gear hub
19 Fifth gear synchronizer slide block
20 Fifth gear synchronizer gear sleeve
21 Input shaft left bearing
1) Clean all parts thoroughly and inspect if there

is abnormal situation. Then mount the new
one according to demands.
 Notice
Before assembling, clean every component
and smear designated gear oil to slide the gear
and the bearing surface. During the
remounting process, use new gear ring on the
shaft, and application of used gear ring is
prohibited. Fig.4-1-g
1 High-speed synchronizer spring 7) Mount the four gear shaft sleeve and needle
bearing, smear lubricating grease on the
2 Slide block bearing, and then mount synchronizer gear
3 High-speed synchronizer gear hub ring and fourth gear.
High-speed synchronizer gear Notice
4
sleeve
 Make sure the four gear shaft sleeve is
5 3rd gear input shaft properly mounted.
5) Use special tool and hammer to mount the
right bearing.
Special tools(A):bearing erector
Fig.4-1-j
1 Shaft sleeve
2 Needle bearing
3 Gear ring
4 Fourth gear
Fig.4-1-h 5 Input shaft
1 Right bearing 9) Mount the fifth gear shaft sleeve and needle
2 Input shaft bearing, smear lubricating grease on the
bearing, and the mount the synchronizer gear
6) Mount the third gear needle bearing, smear ring and fifth gear synchronizer.
the lubricating grease, and mount the third
gear and synchronizer gear ring. 10) Press and mount the left bearing with special
tool and hammer.
7) Use special tool and hammer to drive in the
high-speed synchronizer assembly. special tools(C):bearing erector4
Note: when pressing and mounting the gear hub 2.4.2 Intermediate Shaft Components
and gear sleeve, make sure the synchronizer gear
ring’s teeth groove aligns with the synchronizer ◆ Disassembly
unit’s slide block. 1) Use the puller and holding-down device to
After pressing and mounting the synchronizer pull out the left conical bearing.
unit, inspect the third gear’s free rotation. Caution
Special tools(B):bearing erector1 Use the puller and holding-down device that can
support at least 5t load.
Fig.4-2-a
Fig.4-1-i
1 Holding-down device
1 Input shaft
2 Intermediate shaft’s left bearing
2 Third gear
3 Puller
3 Gear ring
4 Synchronizer unit 2) Use special tool to dismantle the fifth gear
snap ring Puller (with plane
Special tools(A):snap ring plier facing upward)
4) Use puller and holding-down device to pull

out the fifth gear and fourth gear together.
Notice
 To prevent the gear teeth from being damaged,
make the teeth lean against the smooth and
straight side of the bearing puller. Fig.4-2-c
4) Use the puller to operate the second gear and 1 Low-speed synchronizer unit
make use of the holding-down device to pull 2 First gear
out the third gear and the second gear together.
3 Puller(with plane facing upward)
After that, pull out the needle bearing and
third/ fourth gear spacer bushes. 5) Dismantle the synchronizer unit.
Caution 6) Take out first gear needle bearing from the
 If the extrusion force exceeds 5t, release the shaft.
extrusion immediately, and remount the 7) Use the puller to dismantle right conical
puller bracket. Then, continue the push and bearing.
compression.
Fig.4-2-d
1 Metal rod
Fig.4-2-b Intermediate shaft’s right conical bearing
2
1 Intermediate shaft puller
2 Third/fourth gear spacer bushes
◆ Assembly
3 Third gear
4 Second gear Mount Intermediate Shaft Components
5 Puller 1) Clean all parts thoroughly, inspect if there is
abnormal situation, and mount new parts
3) Take out the second gear synchronizer gear according to demands.
ring.
4) Use the puller to operate the first gear, and
make use of the holding-down device to pull
out the low-speed synchronizer unit, and first
gear and second gear shaft sleeves.
Fig.4-2-e
1. Intermediate shaft’s left bearing assembly 2.
Intermediate shaft snap ring 3. Intermediate shaft
fifth gear 4. Intermediate shaft fourth gear 5.
Third/fourth gear spacer bush 6. Intermediate shaft

third gear 7. Intermediate shaft second gear
assembly 8. Second gear needle bearing 9.
Second gear shaft sleeve 10. low-speed
synchronizer gear ring components 11. low-speed
synchronizer unit 12.intermediate shaft second
gear needle bearing 13. intermediate shaft first
gear assembly 14. intermediate shaft right bearing
assembly 15. intermediate shaft
2) If the synchronizer’s components will be
repaired, inspect the clearance “a” between Fig.4-2-h
the ring and the gear, and then inspect every
gear’s crowned teeth, ring, and gear ring. 1 Low-speed synchronizer snap ring
After that, determine if the replacement shall 2 Slide block
be conducted.
3 Low-speed synchronizer gear hub
Clearance “a”: standard value:1.45-2.35mm 4 Low-speed synchronizer gear sleeve
Ultimate value:0.5mm
5) Use special tool and hammer to tighten the
right conical bearing.
Special tools(A):bearing erector3
Fig.4-2-f
1 Gear 1. Right conical bearing

2. Intermediate shaft
2 Synchronizer ring
Fig.4-2-i
3) Ensure the lubrication, and blow air into 1 Right conical bearing
every oil port to inspect if there is blockage.
2 Intemrmediate shaft
6) Mount the needle bearing, smear the

lubricating grease, and then mount the first
gear and first gear synchronizer’s gear ring
components.
Fig.4-2-g
7) Use special tool and hydraulic pressure to
1 intermediate shaft drive in the low-speed synchronizer unit.
2 Oil port Notice
4) Mount the low-speed synchronizer onto the  Lean the shaft against special tool according
gear sleeve, insert three slide blocks, and the to the illustration, in order to prevent the
mount the spring according to the illustration. conical bearing retainer from being extruded.
Notice: Direction will not be specified to slide  When pressing and mounting the
blocks, but slide blocks are defined as an synchronizer assembly, make sure the
assembled unit. synchronizer slide block groove is aligned
with the slide block
 After pressing and mounting the
synchronizer assembly, inspect the first
gear’s free rotation.
Special tools(A):bearing erector3;
(B):bearing erector2; the fourth gear pressing and mounting, which

can prevent the intermediate shaft from being
(C):bearing erector5 excessively extruded.
Special tools (A):bearing erector3
(D): bearing erector
1. Third/fourth gear spacer bushes

2. Third gear
Fig.4-2-j 3. Second gear
1 Low-speed synchronizer unit
2 First-gear synchronizer gear ring components Fig.4-2-l
3 Intermediate shaft first gear
1 Third/fourth gear spacer bushes
4 Intermediate shaft right bearing
2 Third gear
A Key groove aligned with slide block
3 Second gear
8) Mount second gear shaft sleeve and needle
bearing, smear lubricating grease on the 10) Press and mount the fourth gear and fifth
bearing, and then mount second gear gear ditto.
synchronizer ring and second gear. 11) Mount the intermediate shaft snap ring with
Caution special tool and the left conical bearing with
hammer.
 Make sure the shaft sleeve is properly
mounted Notice
 To protect the conical bearing, make the shaft
lean against the special tool according to the
illustration.
Special tools (A):bearing erector3
(E):bearing erector4
Fig.4-2-k
1 Intermediate shaft first gear

2 Low-speed synchronizer unit
3 Shaft sleeve
4 Needle bearing 1. Left conical bearing
2. Fourth/fifth gear
Second gear synchronizer gear ring
5 3. Right conical bearing
components
6 Intermediate shaft second gear 1 Left conical bearing
2 Fourth/fifth gear
9) Use special tool and holding-down device to
press and mount the third gear and spacer 3 Right conical bearing
bush.
2.4.3 Differential Unit
Notice
◆ Differential Unit Dismantling
 It is recommended that bush and third gear
shall be firstly pressed and mounted before 1) Use special tool to dismantle the right
bearing. 3. Planet gear 4. Differential spacer 5.Planet

gear shaft 6.Planet gear shaft
Special tools(A)bearing puller;(B) bearing puller
accessories 7. Main reduction gear 8.Differential bolt
9.Differential right bearing 10.Differential half
Notice shaft
 As for the bearing dismantling, if semilune 1) Mount the differential gear according to the
puller is used together with holding-down device, illustration and follow method below to
the main reduction gear shall be dismantled in measure the differential’s pushing clearance.
advance.
Special tools(A): dial gauge;(B): magnet base
2) Use the puller to dismantle the left bearing, differential gear pushing clearance: 0.03-0.40mm
during which protect well the bearing.
Left side: use the soft bench clamp to clamp the
3) Use the soft bench clamp to clamp the differential assembly, and also insert the dial feeler
differential housing, and dismantle eight gauge’s measuring terminal onto the gear’s upper
differential bolts. After that, take off the main surface. Use two screwdrivers to move the gear
reduction gear. upwards and downwards, in addition to reading the
4) Use the snap ring plier to dismantle the gauge feeler gauge’s pointer travel.
differential planet gear shaft check ring, and Right side: use similar method and insert the dial
then dismantle components and parts. feeler gauge’s measuring terminal onto the gear’s
shoulder. Use the hand to move the gear upwards
and downwards and read the feeler gauge’s
reading.
◆ Differential Unit Adjustment and

Remounting
Dismantling shall be determined according to the
fault denoted in preceding content. After the
dismantling, use naked eyes to inspect if the parts
have problems, and prepare spare parts for the
replacement and remount these parts, during
which make sure all parts are clean.
1 Screwdriver
2 Half axle gear
2) If the pushing clearance exceeds the specified

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

1) Mount the input shaft’s oil seal and keep the
spring side upward. During the mounting
process, use special tool and hammer. Oil seal
Special tool(A):bearing erector6
2) Use special tool and hammer to drive the

intermediate shaft’s left bearing outer ring
and intermediate shaft’s shim into left box
body’s left bearing hole.
1 Intermediate shaft’s right bearing outer ring
2 Input shaft oil seal
2) Use special tool and hammer to mount the

intermediate shaft’s right bearing outer ring
and intermediate shaft’s oil tray.
Attached Table 1: Special Tools
Bearing outer ring Spring pin ejector Bearing puller

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

Bearing erector1 Bearing erector2 Bearing ejector Bush ejector
erector2 erector5
Spring pin
Bearing erector2 Oil seal ejector Bearing erector6 Bearing erector7
ejector(4.5mm)
Mounting connection
Bearing erector3 Seal ring erector
rod
Attached Table 2: Reference List of MF515M01 Transmission Bolt Tightening Torques

No. Name Qty Tightening torque(N·m) Remark
1 Shift locking bolt assembly 1 20～25
2 Shift stop pin 1 10～15
3 Reverse shift fork bolt 2 15～20
4 Neutral signal sensor bolt 1 7～10
5 reverse gear shaft bolt 1 18～28
6 Release bearing mounting bolt 2 7～10
7 Assembling bolt 14 18～28
8 Reversing lamp switch assembly 1 15～20
9 Oil inlet plug 1 12～18
10 Observation plug screw 1 12～18
11 Drain plug 1 12～18
12 Gearbox bolt 4 10～15
13 Lifting lug bolt 1 10～15
14 Cable bracket bolt 2 19～25
15 Oil delivery groove bolt 1 7～10
16 Suspension connection bolt 1 65～75
17 Double-head bolt 2 65～75
18 Differential bolt 8 80～100
19 Spring seat bolt 2 7～10
Gearshift Mechanism 1J-1
Chapter 9 Gearshift Mechanism

Table of Contents
Gearshift Mechanism ························································································1J-2
Manual Gearshift Mechanism Dismantling/Mounting················································· 1J-2
Gearshift Mechanism 1J-2
1. Gearshift Mechanism
1.1 Manual Gearshift Mechanism

1. Firstly, dismantle the assistant instrument
platform assembly;
2. Then remove them as illustrated shift
mechanism, contrary installation and removal
order.
3. After the mounting, confirm if the mechanism
is fixed and can run stably.
1 Manual gearshift lever assembly

2 Gearshift handle
3 Flange bolt
4 Flat washer
5 Cable assembly
6 Flange nut
Notice
1. Control the cable and connect it with
the transmission correctly (no reverse mounting in
gear selection and shift)
2. During the dismantling process, keep
cautious and do not injure the cable buckle. After
the assembly be sure to check whether the card slot
into place.

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Table of Contents

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

Chapter 1 Engine Body

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

1.7.5 Explanations on the timing chain dismantling ...............................................................1A-19

tools tools or equipments

1.1.1 Technical Parameters

Technical Parameters of Complete Equipment

Item Parameter Remark

Model GN15-VF GN16-VF GN16-VF1

Ignition sequence 1-3-4-2 By cylinder number

Displacement (cc) 1497 1591

Bore× stroke (mm) 74.8×85.2 74.8x90.5

Max. power(kW/rpm) 77/6000 81.5/6000 85/6000 Net power

Max. torque(N·m/rpm) 140/4000 149/4000 153/4000 Net torgue

Air conditioning idle speed:800±50

Ignition advance angle(°) 3～10 Idle state

Starting mode Electrical starting

Cooling mode Water cooling forced circulation

Lubricating mode Pressure, Split, Complex

Overall dimension (mm) 573.2×615.0×606.3 573.32x724.2x6063

Net weight (kg) 94.8 96.5

Technical Parameters of Maintenance

Tappet diameter(mm) Standard 30.964～30.980

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

Journal clearance(mm) Standard 0.040～0.076

Height (division surface between upper surface Standard 205

Deformation of upper surface (mm) Standard 0.1

Cylinder bore’s inside diameter

[measure inside diameter at the place 37mm Standard 74.8～74.815

Wearing limit (mm) 0.135

[Measure the piston diameter at the

Clearance between piston and cylinder bore Standard 0.010～0.035

Top ring Standard 0.030～0.070

Second Ring Standard 0.020～0.060

Clearance between piston Oil Ring Standard 0.040～0.120

Oil Ring Max. 0.15

Opening clearance [measure inside Top ring 0.15～0.30

Oil Ring 0.10～0.40

Piston pin’s diameter(mm) Standard 18.001～18.005

Piston pin hole’s inside diameter (mm) Standard 18.010～18.014

Clearance between connecting rod’s small end

Clearance between piston pin hole and piston

Inside diameter of connecting rod’s small end

Connecting rod bearing

Connecting rod bush size (mm) Standard 1.485～1.496

Crankshaft radial run-out(mm) 0.03

Main journal diameter(mm) Standard 46.004～46.029

Main bearing bush size (mm) Standard 1.971～1.996

Crank pin diameter(mm) Standard 39.980～40.000

Thrust bearing size (mm) Standard 3.205～3.255

Inspection to complete vehicle

Standard value 1170{12.0}[300]

Compression pressure Minimum limit 980{10.0}[300]

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

Oil pressure (kPa{kfg/cm2}[rpm]) 400～588{4.1～6.0}[2500]

Oil adding volume L Oil replacement 3.6

Oil and oil filter

Oil grade API engine oil grade higher than SL

Higher than –25 ℃ SAE 10W–30

Timing chain disassembling part

Crankshaft rotating speed sensor

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

Opening temperature (℃) 80～84