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 MF515L 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

Overview ...........................................................................................................................................1A-0
Subject Scope ............................................................................................................................1A-0
Overhaul Steps: .........................................................................................................................1A-0
Symbol ......................................................................................................................................1A-0
Prompt signals ...........................................................................................................................1A-0
Technical Parameters.........................................................................................................................1A-1
Technical Parameters of Complete Equipment .........................................................................1A-1
Technical Parameters of Maintenance.......................................................................................1A-2
Tightening torque ......................................................................................................................1A-7
Special tools ......................................................................................................................................1A-9
Inspection and Maintenance of Complete Vehicle ..........................................................................1A-10
Inspection of Compression Pressure .......................................................................................1A-10
Inspection of the Engine Oil....................................................................................................1A-10
Inspection of Oil Pressure ....................................................................................................... 1A-11
Replacement of Engine Oil ..................................................................................................... 1A-11
Replacement of Oil Filter ........................................................................................................ 1A-11
Others ......................................................................................................................................1A-12
Application of Engine Maintenance Platform.................................................................................1A-12
Mount the Engine onto Maintenance Platform........................................................................1A-12
Dismantle the Engine from Maintenance Platform .................................................................1A-12
Power Generator and Starter ...........................................................................................................1A-13
Power Generator’s Dismantling/Mounting .............................................................................1A-13
Explanations on Inspection of Power Generator Belt .............................................................1A-13
Explanations on adjustment to tension of power generator and air conditioning drive belts ..1A-13
Explanations on inspection of power generator ......................................................................1A-13
Starter Dismantling/Mounting.................................................................................................1A-13
Explanations on inspection of starter ......................................................................................1A-14
Ignition, Control System .................................................................................................................1A-14
Ignition Coil and PCV Valve Dismantling/Mounting .............................................................1A-14
Spark Plug Dismantling/Mounting..........................................................................................1A-14
PCV Valve Dismantling /Inspection........................................................................................1A-14
Control System Parts Dismantling/Mounting .........................................................................1A-15
Crankshaft position sensor’s dismantling/mounting explanations ..........................................1A-15
Explanations to inspection of crankshaft position sensor........................................................1A-15
Explanations on water temperature sensor dismantling/mounting..........................................1A-16
Intake and Exhaust System..............................................................................................................1A-17
Intake and Exhaust System Dismantling/Mounting ................................................................1A-17
 Table of Contents

Explanations on intake manifold dismantling .........................................................................1A-18

Explanations on the intake manifold seal ring mounting ........................................................1A-18
Explanations on the throttle body seal ring mounting.............................................................1A-18
Explanations on the exhaust manifold dismantling.................................................................1A-18
Timing System ................................................................................................................................1A-18
Timing system dismantling/mounting .....................................................................................1A-18
Explanations on timing chain tensioner assembly dismantling...............................................1A-18
Explanations on crankshaft pulley dismantling.......................................................................1A-19
Explanations on cylinder head hood dismantling....................................................................1A-19
Explanations on the timing chain dismantling ........................................................................1A-19
Explanations on the timing chain’s tensioner assembly mounting ..........................................1A-19
Explanations on the tensioner arm assembly mounting ..........................................................1A-19
Explanations on timing chain mounting..................................................................................1A-20
Explanations on the cylinder head hood mounting .................................................................1A-20
Explanations on the crankshaft pulley mounting ....................................................................1A-20
Explanations on water pump pulley mounting ........................................................................1A-21
Lubricating System .........................................................................................................................1A-21
Oil Sump Dismantling/Mounting ............................................................................................1A-21
Explanations on the oil sump dismantling...............................................................................1A-21
Explanations on the oil sump mounting ..................................................................................1A-21
Oil Pump and Timing Chain Case Assembly Dismantling/Mounting.....................................1A-21
Explanations on oil pump’s oil seal dismantling .....................................................................1A-22
Explanations on oil pump’s oil seal mounting ........................................................................1A-22
Explanations on the oil filter mounting ...................................................................................1A-22
Explanations on oil pump disassembling/ mounting...............................................................1A-23
Inspection of Oil Pump............................................................................................................1A-23
Explanations on inspection of pressure spring ........................................................................1A-23
Cooling System ...............................................................................................................................1A-24
Thermostat Dismantling/Mounting .........................................................................................1A-24
Explanations on thermostat inspection and mounting.............................................................1A-24
Cooling water pipeline dismantling/mounting ........................................................................1A-24
Explanations on heater water pipe /O-ring mounting..............................................................1A-24
Water Pump Dismantling/Mounting........................................................................................1A-24
Cylinder Cover and Valve Mechanism............................................................................................1A-25
Cylinder Head Mechanism Dismantling/ Mounting ...............................................................1A-26
Explanations on intake VVT dismantling ...............................................................................1A-26
Explanations on camshaft dismantling....................................................................................1A-26
Explanations on cylinder head dismantling.............................................................................1A-26
Explanations on the cylinder head mounting ..........................................................................1A-26
Explanations on the camshaft mounting..................................................................................1A-27
Explanations on the VVT mounting........................................................................................1A-27
Valve Mechanism Dismantling/ Mounting..............................................................................1A-28
Explanations on inspection of valve clearance........................................................................1A-28
Explanations on the valve clearance’s adjustment ..................................................................1A-29
 Table of Contents

Cylinder Head Inspection /Repair ...........................................................................................1A-29

Inspection of Valve and Valve Guide ......................................................................................1A-30
Explanations on inspection of valve spring.............................................................................1A-31
Explanations on the inspection of camshaft ............................................................................1A-31
Explanations on inspection of tappet hole and tappet .............................................................1A-33
Flywheel, clutch ..............................................................................................................................1A-34
Flywheel and Clutch Dismantling/Mounting ..........................................................................1A-34
Explanations on Clutch Pressure Plate/Friction Disc Dismantling .........................................1A-35
Explanations on flywheel dismantling ....................................................................................1A-35
Explanations on Rear Oil Seal Dismantling/Mounting ...........................................................1A-35
Explanations on the crankshaft’s back cover mounting ..........................................................1A-35
Explanations on the flywheel mounting /inspection................................................................1A-35
Explanations on the clutch friction disc inspection /mounting................................................1A-36
Explanations on the clutch pressure plate inspection/mounting..............................................1A-36
Cylinder body, Crank Connecting Rod Mechanism........................................................................1A-37
Cylinder Body, Crank Connecting Rod Mechanism Dismantling/Mounting..........................1A-37
Explanations on connecting rod cover dismantling.................................................................1A-37
Explanations on piston pin dismantling ..................................................................................1A-37
Explanations on main bearing cover dismantling....................................................................1A-38
Explanations on the crankshaft dismantling............................................................................1A-38
Explanations on the main bearing cover mounting .................................................................1A-38
Explanations on the piston pin mounting ................................................................................1A-39
Explanations on the piston ring mounting...............................................................................1A-40
Explanations on piston connecting rod assembly mounting....................................................1A-40
Explanations on the connecting rod cover mounting ..............................................................1A-40
Cylinder Body Inspection /Repair ...........................................................................................1A-41
Piston, Piston Ring, and Piston Pin Inspection........................................................................1A-41
Connecting Rod Inspection .....................................................................................................1A-42
Inspection of Piston Connecting Rod Assembly .....................................................................1A-43
Crankshaft Inspection /Repair .................................................................................................1A-43
 Engine block 1A-0

tools tools or equipments

Overview 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

Technical Parameters

Technical Parameters of Complete Equipment

Item Parameter Remark

Model GN15-VF
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 side
Rotation direction Counterclockwise
taken as the back end)
dual overhead camshaft, timing chain
Valve timing mechanism
drive (silent chain), intake VVT
Valve quantity 16

Displacement (cc) 1497

Bore× stroke (mm) 74.8×85.2

Compression ratio 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 Net power

Max. torque(N·m/rpm) 140/4000

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

Net weight (kg) 94.8

 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
Standard 89.31～89.91
Intake
Min. 89.11
Valve length (mm)
Standard 90.63～91.23
Exhaust
Min. 90.43
Standard 4.965～4.980
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
 Engine block 1A-3

Intake 15.7～16.3
Depth L(mm)
Exhaust 15.7～16.3
Tappet
Tappet hole’s diameter(mm) Standard 31.000～31.025

Tappet diameter(mm) Standard 30.964～30.980

Standard 0.020～0.061
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

Standard 0.08～0.20
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

 Engine block 1A-4

Top ring 0.15～0.30

Opening clearance [measure inside Second Ring 0.20～0.40

cylinder](mm)
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

Standard 0.005～0.013
pin (mm)

Connecting rod

Length [center to center](mm) Standard 135.3～135.4

Inside diameter of connecting rod’s small end

Standard 17.974～17.985
(mm)

Standard 0.100～0.350
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

Standard 0.014～0.034
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

Standard 0.030～0.090
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

Standard 74.15～74.85
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

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

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

Compression Gauge 9. Take off the 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 }
Inspection of the Engine Oil
1. Park the automobile on the level ground.
5. Mount the gauge into Cylinder 1’s spark plug 2. Warm up the engine to a normal running
hole. temperature and stop the running.
6. Floor the accelerator pedal and start the 3. Wait for 5 minutes.
engine.
4. Pull out the dipstick and observe the oil level
7. Record the gauge’s maximum reading. and oil state, inspect if the oil level ranges
8. Measure all cylinders’ compression pressures between Scale F and Scale L.
according to preceding method, and inspect if 5. Add or replace oil according to needs.
the pressure difference between cylinders is
lower than the limit value. 6. Confirm the dipstick O-ring’s installation (see
right figure).
Limit value (maximum): 980 (kPa)
Maximum 7. Insert the dipstick again.
Standard Minimum
Item pressure
value limit
difference
 Engine block 1A-11

O-ring

Smearing
Inspection of Oil Pressure Sealant is needed when the bolt is reused.

Warning
8. Mount the oil pressure switch. Tightening
 Wasted and used oil is cancer-causing torque:14.7N·m{1.5kgf·m}.
substance, and so skin shall be cleaned with
soap and tap water immediately after the 9. Start the engine and inspect if the engine oil
work. suffers leakage.
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
switch’s mounting hole. 2. Pour the oil into appropriate vessel.

3. Warm up the engine to a normal running 3. Mount the new oil drain plug. Tightening
temperature. torque: 30～41N·m{3.1～4.2kgf·m}.

4. Run the engine to a fixed rotating speed, and 4. Add engine oil of specified model and volume
cast attention to the oil pressure gauge’s into the engine.
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
Oil replacement
the engine and replace the oil according to
needs. Oil and oil filter replacement 3.8

Notice  Engine Oil Grade: API Engine Oil Grade:

above SL
 Oil with different viscosities and temperatures
may vary in pressure
Oil viscosity standard Oil viscosity level
Oil pressure:400 ～ 588kPa{4.1 ～
Higher than–25℃ SAE10W–30
6.0kgf/cm2}[2500rpm]
–30℃～37℃ –30
7. Smear evenly the thread sealant (A6F011)
Replacement of Oil Filter
onto the oil pressure switch thread (see the
figure). 1. Dismantle the oil filter with special tools.
2. Rub and clean the new oil filter with a clean
cloth.
 Engine block 1A-12

3. Smear clean oil onto the new oil filter’s

O-ring.

Smear clean oil onto the

new oil filter’s O-ring.

2. Mount the work fixture according to the

figure and lock it.

4. Mount the oil filter with special tools Fixing bolt

Tightening torque:13.0～15.0N·m{1.32～
1.52kgf·m}.

3. Adjust the fixing bolt to appropriate place and

prevent the engine mounting from getting
loose.
4. Pour the engine oil into specified vessel.
5. Start the engine and inspect if there is leakage.
Inspect the oil level and check if oil adding is 5. Mount the new oil drain plug, and tighten the
needed (see Inspection of Engine Oil). oil drain plug. tightening torque: 30 ～
Others 41N·m{3.1～4.2kgf·m}
Dismantle the Engine from Maintenance
Other inspection and maintenance like power
Platform
generator inspection and starter inspection etc can
be conducted on the complete vehicle. See this Dismantle the engine from the maintenance
manual and corresponding complete vehicle platform according to steps reverse to “Mount
maintenance manual for processing procedures. the Engine onto Maintenance Platform”.
Notice
Application of Engine Maintenance
 The engine maintenance platform’s
Platform self-locking brake system may lose efficacy
in an unbalanced state, for instance, the
Mount the Engine onto Maintenance engine maintenance platform suffers
Platform unbalance due to sudden and rapid action
resulting from the engine mounting onto and
1. Lift the engine, and align the cylinder body’s dismantling from the platform, which will
pin hole to the maintenance platform’s result in danger. Due to this, to ensure the
mounting dowel pin to mount the engine(see engine and the entire maintenance
the figure). platform’s balance during the operation
process, the maintenance platform’s rotary
handle shall be held tightly in hands during
the engine tilting process.
 Engine block 1A-13

Power Generator and Starter ③Adjust the bolt

Power Generator’s ②power generator’s

Dismantling/Mounting fixing nut power
Warning

 When dismantling /mounting the power ①generator’s bolt nut

generator on the complete vehicle, the
accumulator cable shall be dismantled firstly,
or the power generator’s Terminal B will Notice
contact the vehicle body, which will lead to
sparks and further result in personal injury  If mounting the new power generator belt or
and electric element damage. running power generator belt for less than 5
minutes, adjustment shall be made according
1. Dismantle the power generator according to to the new part’s standard value.
the sequence illustrated in the figure.
 If running power generator belt for more than
2. Mount the power generator according to the 5 minutes, adjustment shall be made
sequence reverse to the dismantling process. according to old part’s standard value.
3. Inspect the belt’s deflection /tension (see  If it fails to stay within the standard value,
Inspection of the Power Generator Belt). readjustment shall be made from Step 1 on.
Explanations on inspection of power
②Power generator
Generator Belt 1. Confirm if the accumulator has been charged.
2. Confirm if the belt’s deflection /tension stays
within the specified range (See power
④Power
generator part: Inspection of Power Generator
Generator
Belt).
3. Turn the ignition switch to the “ON” position,
and the charge warning lamp will turn on.
4. Confirm if the charge warning lamp is off
after the engine has been put into running.
Explanations on Inspection of Power
Generator Belt ★ Note: If there is abnormal situation, see
corresponding “Complete Vehicle Fault
If necessary, inspect the power generator belt’s Diagnosis and Handling”.
deflection and tension: see complete vehicle
maintenance manual’s corresponding part. Starter Dismantling/Mounting
Explanations on adjustment to tension of Warning
power generator and air conditioning
drive belts  When dismantling/mounting the starter on the
complete vehicle, if the accumulator’s
1. Loosen the power generator’s bolt nut ①. positive cable fails to be loosened, the
starter’s Terminal B will connect with or
2. Loosen the power generator’s fixing nut ②. contact the body, which will lead to sparks
Use the adjusting bolt ③, and adjust the belt and further result in personal injury and
tension and belt difference to the specified value. electric element damage. Due to this,
accumulator’s positive cable shall be
3. Tighten the power generator pivot bolt’s nut dismantled firstly when the following
①: tightening torque:43～60N·m operations are conducted:
4. Tighten the power generator’s fixing nut ②: 1. Dismantle the accumulator’s positive cable.
tightening torque:37.3～52N·m
2. Dismantle the starter according to the
 Engine block 1A-14

sequence illustrated in the figure. repair or replacement.

3. Mount the starter according to the sequence Standard voltage:11(V), standard current:＜95(A)
reverse to the dismantling process.
Ignition, Control System

Ignition Coil and PCV Valve

Dismantling/Mounting
Notice
 When dismantling the ignition coil and spark
plug, shield sleeve at the connecting rod can
be easily torn. Due to this, they should be
dismantled only when the replacement is
necessary and tearing and damage shall be
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.
2. Start the starter to Confirm if the starter runs
stably and has no running noise.
★ Note: If there is abnormal situation, turn the
ignition switch to the “STAR” position, and
measure the voltage between Terminal S and
Terminal B, and the standard voltage shall be
greater than 8(V)
—If the voltage stays beyond the specified range,
overhaul the wiring harness and ignition switch.
—If the voltage stays within the specified range,
dismantle the starter and inspect the solenoid
switch and starter. 2. Mantle parts according to sequence reverse to
the dismantling process.
Zero-load test
Spark Plug Dismantling/Mounting
1. Confirm if the accumulator is charged.
Notice
2. Connect the starter, accumulator, voltmeter
and ammeter (see right figure).  Mount the spark plug cautiously because
strong impact will result in spark plug
3. Run the starter and Confirm if its running is damage.
stable.
PCV Valve Dismantling /Inspection
4. During the starter running process, measure
the voltage and current. 1. Dismantle the PCV valve.
2. Confirm if the air ventilation in PCV valve is
Ignition switch

as the following table. If there is abnormal

situation, replacement shall be conducted.
Accumulator

Starter

Terminal S

Note: If there is abnormal situation, conduct

 Engine block 1A-15

Air Ventilation Condition Table cylinder body (shade line zone).

Test Condition Test Result

2. When smearing the sealant, keep clean the
unit surface’s bonding part.
There is air outflow
Blow to A
from Interface B 3. After smearing the sealant, mount the
There is no air outflow from crankshaft position sensor within 3 minutes.
Blow to B
Interface A
Explanations to inspection of crankshaft
Control System Parts position sensor
Dismantling/Mounting
Clearance inspection
1. Dismantle parts according to sequence
illustrated in the figure. Attentions
2. Mount parts according to sequence reverse to
the dismantling process.

⑥ Not greater
than 15{1.53}

Zone for smearing

the sealant

 Under-mentioned inspection shall be

conducted if necessary.
1. Confirm if the crankshaft rotating speed
Not greater
than 29.4{3}
sensor is correctly mounted.

Note: this part only lists different parts of the 2. Use the plug gauge to measure the clearance
control system’s mounting conditions on the engine. between signal wheel protrusion platform and
See the complete vehicle’s corresponding part for crankshaft rotating speed sensor.
relevant fault diagnosis and inspection. Notice
1 Oil rail  If the clearance is incorrect, adjust the
Crankshaft position sensor (see crankshaft rotating speed sensor or inspect if
there is torsion and indentation in the signal
2 Inspection of Crankshaft Position wheel’s protrusion part. (If have, replace the
Sensor) crankshaft signal panel).
3 Camshaft position sensor Standard clearance value:0.5～1.5mm
4 Pressure temperature sensor
5 Throttle body
Water temperature sensor (see
6
dismantling/mounting explanations)
7 Oil control valve
8 Oil pressure sensor
9 Knock sensor

Crankshaft position sensor’s

dismantling/mounting explanations
1. When mounting the crankshaft position
sensor, smear “LOCTITE5971” onto the
 Engine block 1A-16

Use the sleeve to dismantle the water temperature

Clearance sensor.

Crankshaft
position sensor
Crankshaft
signal panel

Explanations on water temperature

sensor dismantling/mounting
 Engine block 1A-17

Intake and Exhaust System

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

Explanations on intake manifold  Prior to the mounting, inspect if there is

dismantling damage on seal ring. If there is, replacement
shall be made.
1. Dismantle parts according to the sequence
illustrated in the figure. Explanations on the exhaust manifold
dismantling
2. Mount parts according to the sequence
reverse to the dismantling process. 1. Dismantle parts according to the sequence
Explanations on the intake manifold seal illustrated in the figure.
ring mounting 2. Mount parts according to the sequence
During the mounting process, mount the seal ring reverse to the dismantling process.
into the intake manifold’s slot, and wedge the seal
ring’s anti-mistake mark into the intake manifold’s
locating slot.
Caution
 Prior to the mounting, inspect if there is
damage on seal ring. If there is, replacement
shall be made.
Timing System

Timing system dismantling/mounting

1. Dismantle power generator belt (see power
generator part).
2. Dismantle ignition coil (see the ignition part).

Locating slot 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
Seal ring
assembly part).
6. Dismantle parts according to the sequence
Explanations on the throttle body seal illustrated in the figure
ring mounting 7. Mount the parts according to the sequence
During the mounting process, mount the seal ring reverse to the dismantling process.
into the intake manifold’s slot, and wedge the seal 8. Adjust the power generator belt deflection
ring’s anti-mistake mark into the intake /tension (see power generator part).
manifold’s locating slot.
Explanations on timing chain tensioner
Locating assembly dismantling
Seal ring 1. Dismantle parts according to the sequence
illustrated in the figure.
2. Mount the parts according to the sequence
reverse to the dismantling process.
Notice
 Loosen the timing chain tensioner assembly
bolt, and slowly take off the timing chain
Notice tensioner assembly (prevent the plunger from
popping suddenly).
 Engine block 1A-19

Explanations on crankshaft pulley the timing chain pulley on the exhaust side of
dismantling intake VVT.
3. Dismantle timing chain tensioner assembly
(see Timing Chain Tensioner Assembly
Dismantling).
4. Dismantle the tensioner arm assembly.
5. Dismantle the timing chain’s guide rail
assembly.
6. Dismantle the timing chain.

Explanations on the timing chain’s

tensioner assembly mounting
1. Compress the pallet with bench clamp(see the
figure), and insert one hard steel wire into the
locking hole to lock the timing chain’s
Use the special tools to secure the crankshaft for tensioner assembly.
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

Explanations on cylinder head hood

dismantling
Loosen the bolt according to the sequence
illustrated in the figure.

Explanations on the timing chain

dismantling
1. Mount the crankshaft pulley locking bolt.
2. Rotate crankshaft along the clockwise
direction, and align the gas distribution
inspection mark.
Notice
Explanations on the tensioner arm
 Keep the timing chain pulley’s key slot
upward. assembly mounting

 Align the gas distribution inspection mark at After the mounting, tensioner arm assembly shall
 Engine block 1A-20

not be excessively tightened, and sway the Notice

tensioner arm assembly to inspect if it can fall
down freely.  In the event of failure in aligning, repeat the
operation from Step 1
Explanations on timing chain mounting
1. Rotate the intake & exhaust camshaft to make Explanations on the cylinder head hood
two timing marks at the timing chain pulley mounting
on exhaust side of the intake VVT face 1. Confirm if the cylinder head hood groove is
toward specific angle.
free from oil, water, and other foreign
2. Mount the timing chain’s guide rail assembly. objects.

3. Mount the timing chain. 2. Confirm if the cylinder head hood’s sealing
gasket has been completely attached to the
Notice cylinder head hood’s groove.
 Align the timing mark at the timing chain 3. Smear the sealant onto the joint between
pulley on the exhaust side of the intake VVT cylinder head and oil pump and timing chain
case assembly according to the illustration.
4. Mount the tensioner arm assembly (see
tensioner arm assembly mounting 4. Mount the cylinder head hood bolt according to
explanations). the sequence reverse to the dismantling process
of cylinder head hood (see the cylinder head
Notice
hood dismantling part), and tighten the cylinder
 Confirm if the timing chain is located in the head hood bolt by step.
timing chain guide rail assembly and
tensioner arm assembly’s slot. Sealant-smearing
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
tensioner arm assembly and timing chain zone
guide rail assembly’s guiding slot.
6. Confirm if all timing marks (4) and valve Explanations on the crankshaft pulley
timing mechanism have been inspected Align mounting
the mark (1) accurately.
Use special tools to fasten the crankshaft for
Notice mounting.
 Camshaft timing chain pulley and VVT
assembly timing marks are “△”, gas
Bolt unit
distribution inspection mark is “○”; and
crankshaft timing chain pulley timing mark is
semicircular groove Fixture unit
 In the event of failure in aligning, dismantle
the timing chain, and repeat the operation
from Step 1
Double-ended jointing fixture
7. Rotate the crankshaft for two circles along the
clockwise direction, and then rotate the
crankshaft to make the intake VVT assembly
(timing chain pulley on the intake side) align
with two gas distribution inspection marks at
the camshaft chain on the exhaust side.
 Engine block 1A-21

the oil sump from the engine.

Explanations on the oil sump mounting

Dowel hole
Notice
 If the bolt will be reused, eliminate the
sealant on original thread because bolt with
old sealant may lead to damage of the screw
hole.
 When mounting the reused oil sump, remove
the residual sealant at the oil sump and
corresponding mounting place.
Explanations on water pump pulley
mounting 1. Add continuous sealant on the internal side of
the oil sump bolt hole sealant, and overlap the
Mount water pump pulley, and tighten the bolt. front ends, with sealant diameter ranging
between Φ2.0 and Φ3.0mm
2. Mount the soil sump according to the
sequence reverse to the dismantling process.

Oil sump

Smear sealant prior

to mounting

Lubricating System

Oil Sump Dismantling/Mounting Cleft

1. Discharge the oil (see the complete vehicle’s
upper inspection part: Replacement of Engine
Oil).
2. Dismantle parts according to the sequence
illustrated in the figure. Old sealant

3. Mount the parts according to the sequence

Oil Pump and Timing Chain Case
reverse to the dismantling process.
Assembly Dismantling/Mounting
1. Dismantle crankshaft pulley (see crankshaft
pulley part).
2. Dismantle cylinder head hood (see
explanations on cylinder head hood
dismantling).
3. Dismantle oil sump (see oil sump, oil sump
dismantling/mounting).
4. Dismantle water pump (see water pump
Explanations on the oil sump dismantling dismantling/mounting).
1. Dismantle the oil drain plug, and discharge 5. Dismantle parts according to the sequence
the oil in the oil sump. illustrated in the figure.
2. Dismantle oil sump bolt step by step along the 6. Mount the parts according to the sequence
clockwise direction. reverse to the dismantling process.
3. Use the oil sump dismantling tool to dismantle
 Engine block 1A-22

 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)

Explanations on oil pump’s oil seal

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

1. Smear clean oil onto the oil seal’s peripheral Bolt rod Mounting
parts. No. Specification length torque
2. Mount the oil seal with hands. (mm) (N·m)

3. Use the special tools to evenly compress the 1a, 3a, 4a,
oil seal. 5a 25 8～12
M6
6a, 7a, 8a,
Compression depth:0～0.5mm
2b, 10b M6 30 8～12
Oil seal erector Compress 12c M6 45 8～12
13d, 14d M10 90 36.5～42.5
oil pump

oil seal Explanations on the oil filter mounting

oil pump
Tighten bolts by steps according to the sequence
illustrated in the figure
4. Continuously smear the sealant onto the oil
pump and timing chain case assembly’s rims,
see the figure.
Sealant diameter:Φ2±0.5mm
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.
 Engine block 1A-23

Inspection of Oil Pump

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
Explanations on oil pump disassembling/ Standard backlash: 0.03～0.09mm
mounting
Maximum backlash: 0.14mm
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
illustrated in the figure.
3. Mount parts according to the sequence
reverse to the disassembling process.
Explanations on inspection of pressure
spring
Exert pressure on the spring and inspect the spring
height. If necessary, replace the pressure spring.
Pressure range:97.7～107.4N{9.96～10.96kgf}
Standard height: 33.50mm

1 Bolt
2 Oil pump cover
3 Screw plug
4 Pressure spring
5 Control piston
6 Inner rotor (Smear oil before mounting)
7 Outer rotor (Smear oil before mounting)
 Engine block 1A-24

Cooling System Cooling water pipeline

dismantling/mounting
Thermostat Dismantling/Mounting 1. Dismantle thermostat (see thermostat
dismantling /mounting).
1. Dismantle parts according to sequence
illustrated in the figure. 2. Dismantle parts according to sequence
illustrated in the figure.
2. Mount the parts according to the sequence
reverse to the dismantling process. 3. Mount the parts according to the sequence
reverse to the dismantling process.

Replace parts
after the
dismantling
1 Thermostat cover
Thermostat
2
see explanations on thermostat mounting
3 bolt(heater water pipe assembly)
Explanations on thermostat inspection 4 bolt(heater water pipe assembly)
and mounting 5 heater water pipe assembly
1. Put the thermostat into a vessel with hot water, Explanations on heater water pipe
in which a thermometer is inserted. Then heat /O-ring mounting
the thermostat to raise the temperature, and
inspect the thermostat. If it does not comply When replacing the O-ring, smear the water onto
with regulations, replace the thermostat. the O-ring, in order to facilitate its mounting and
avoid damage.
—Valve is closed at the room temperature.
Notice
—Valve is opened after the temperature rise.
 Do not smear engine oil or other greasy
Opening temperature (℃):80～84 substances onto the O-ring.
Full-opening temperature (℃):95 Water Pump Dismantling/Mounting
Full-opening stroke (mm):≥8.5 1. Dismantle power generator belt (see power
generator belt part).
2. Confirm if the thermostat’s movable pin is
upward, see the figure. 2. Dismantle parts according to sequence
illustrated in the figure.
3. Align the cylinder body thermostat’s
mounting place, and mount the thermostat 3. Mount the parts according to the sequence
onto the cylinder body. reverse to the dismantling process.

Movable pin

Replace parts after

the dismantling
 Engine block 1A-25

Cylinder Cover and Valve Mechanism

Smear oil
before the
mounting

Smear oil
before the
mounting

Smear
Smearoiloil
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-26

3. Inspect the camshaft journal clearance (see

Cylinder Head Mechanism Dismantling/ the camshaft inspection part).
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).
3. Dismantle parts according to sequence
illustrated in the figure.
4. Mount the parts according to the sequence
reverse to the dismantling process.

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.
VVT fixing bolt Note: d2 refers to the minimum outer diameter
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-27

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-28

Valve Mechanism Dismantling/ Mounting direction, making the piston located at the
stopping place on No.1 Cylinder, namely, gas
1. Dismantle cylinder head(see the cylinder head distribution mark shall be adjusted to the
dismantling). position indicated in the right figure.
2. Dismantle parts according to sequence (2) Use plug gauge to measure valve clearances
illustrated in the figure. . of all cylinders at Mark A indicated in the
figure.
3. Mount the parts according to the sequence
reverse to the dismantling process.

★ Note:If the valve clearance exceeds the

standard value, replace the tappet(see the
valve clearance’s adjustment)valve
clearance’s standard value (when engine is in
cooling state):
Intake:0.18～0.26mm
Exhaust:0.26～0.34mm
(3) Rotate the crankshaft for 360 degrees along
the clockwise direction, making the piston
located at the stopping place on No.4
Cylinder, namely, gas distribution mark shall
be adjusted to the position indicated in the
figure below.

Valve Half (see dismantling/mounting

1
explanations)
2 Valve spring upper seat
Valve spring (see the mounting
3 (4) Use plug gauge to measure valve clearances
explanations)
of all cylinders at Mark B indicated in the
4 Valve spring lower seat figure above.
5 Valve (see the mounting explanations) ★ Note:If the clearance exceeds standard value,
6 Valve oil seal tappet shall be replaced(see the valve
clearance’s adjustment)
Explanations on inspection of valve
Valve clearance’s standard value (when the engine
clearance
is in cooling state):
1. Dismantle the cylinder head hood (see
cylinder head hood dismantling part). ON:0.18～0.26mm

2. Confirm if the engine has been cooled. OFF:0.26～0.34mm

3. Measure valve clearance. 4. Mount cylinder head hood (see the timing
chain, cylinder head hood mounting part).
(1) Rotate the crankshaft along the clockwise
 Engine block 1A-29

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. Cylinder Head Inspection /Repair
3. Select an apposite tappet. New tappet’s 1. Inspect the cylinder head’s defect. If
thickness =old tappet’s thickness + measured necessary, replace the cylinder head.
valve clearance － standard valve clearance.
(standard valve clearance: ON, 0.22mm; OFF, 2. Inspect the following items, repair and
0.30mm) replacement shall be conducted if necessary.

4. Mount the selected tappet into the tappet hole. (1). If there is indentation at the valve seat.

5. Confirm the valve clearance again (see valve (2). If the camshaft journal clearance and end gap
clearance, valve clearance inspection). is excessive.

Valve spring ejector

3. Use the Straight Edge Ruler and plug gauge
to inspect if the cylinder head is distorted
along six directions, see the figure.
Maximum distortion: 0.06mm

Pivot

Notice:
 If the valve clearance will be adjusted when
there is not timing chain, make the crankshaft
dowel pin towards side face, in order to
prevent the valve from colliding with the
piston top during the valve clearance
adjustment process.
 Mark the tappet thickness inside the tapper
with 3 digits, see figure below:

Thickness mark

4. If the cylinder head’s distortion exceeds the

maximum value, inspect the cylinder head’s
height. If the height stays beyond the standard
value, replace the cylinder head.
Standard height:112.9-113.1mm
 Engine block 1A-30

Brim thickness
5. If the cylinder head’s distortion exceeds the
maximum value, and the height stays within 2. Measure every valve’s length. If necessary,
the standard value, grind the height or replace replace the valve.
the cylinder head.
Standard length
Maximum grinding volume:0.20mm
Intake valve:89.31～89.91mm
6. Use the Straight Edge Ruler and plug gauge
to measure the cylinder head intake/ exhaust Exhaust valve:90.63～91.23mm
manifold flange’s distortions along different
directions, see the figure. Minimum length
Maximum distortion: 0.05mm Intake valve: 89.11mm
Exhaust valve: 90.43mm

7. If the distortion measured in Step 6 exceeds

the maximum value, grind the surface or
replace the cylinder head. 3. Measure every valve’s rod diameter
respectively at A, B, C point (see the figure)
Maximum grinding volume: 0.20mm
along X and Y direction. If necessary, replace
Inspection of Valve and Valve Guide the valve.

1. Measure thickness of every valve’s head rim. Standard diameter

If necessary, replace the valve.
Intake valve: 4.965～4.980mm
Standard thickness: intake valve: 1.35mm; exhaust
valve: 1.85mm. Exhaust valve: 4.955～4.970mm

Minimum thickness: intake valve: 0.85mm; Minimum diameter

exhaust valve: 1.35mm. 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
 Engine block 1A-31

Y direction (see the figure). If necessary, valve spring shall be replaced.

replace the valve guide.
Valve spring’s maximum verticality:1.50mm
Standard inner diameter
Standard:5.0～5.012mm

5. When there is not valve spring’s lower seat,

measure every valve guide’s extrusion height
(Size A). If necessary, replace the valve
Explanations on the inspection of
guide. camshaft

Standard height:12.7～13.3mm 1. Place the camshaft’s No. 1 and No. 5 journals

onto the V-shaped block to measure the
Valve guide camshaft’s radial run-out. If necessary,
replace the camshaft.
Radial run-out: 0.03mm

Cylinder head

Explanations on inspection of valve

spring
1. Use the special tools to exert pressure on the
valve spring, and inspect the spring height. If 2. Measure heights of the two convex parts (see
necessary, replace the valve spring. Exert the figure). If necessary, replace the camshaft.
pressure on the valve spring, and compress Standard height
the spring to a given height, when the
pressure value exceeds the specified range, Intake side: 44.71mm
the valve spring shall be replaced.
Exhaust side: 44.28mm
When the height is 33.4mm, the pressure is 142.2～
Minimum height
161.8N{14.51～16.51kgf};
Intake side: 44.51mm
When the height is 24.9mm, the pressure is
293.4～324.4N{29.94～33.10kgf}. Exhaust side: 44.08mm
2. Measure the valve spring verticality, and if
the verticality goes beyond the standard, the
 Engine block 1A-32

 When measuring the clearance, do not rotate

the camshaft
(5). Dismantle camshaft cover (see cylinder head
dismantling/mounting, camshaft dismantling
attentions).
(6). Use the scale on the plastic gauge bag to
measure the widest point on the plastic
gauge’s extruded part, and then calculate out
the journal clearance.
3. Measure the journal diameter respectively at If necessary, replace the cylinder head and
A and B point along X and Y direction. If camshaft cover.
necessary, replace the camshaft.
Standard journal clearance:0.040～0.076mm
Standard diameter:25.940～25.965mm
Minimum diameter: 25.910mm

Point A

Point B
5. Mount the camshaft cover (see cylinder head
dismantling/mounting, camshaft mounting
attentions).
4. Dismantle the tappet, and measure camshaft
journal clearance according to steps below: 6. Mount the dial gauge, push camshaft forward
or backward at the end of camshaft (see the
(1). Remove all oil on the journal and bearing
figure), and measure the camshaft end gap. If
seat’s internal surface.
necessary, replace the cylinder head or
(2). Put the camshaft into the bearing seat. camshaft.

(3). Make the plastic gauge match the bearing Caution

width (see the figure), and then put it on the
 Do not push the camshaft at the cam part, so
top of journal along the axial direction.
as to prevent the cam from being damaged.
(4). Mount the camshaft cover (see cylinder head
Standard end gap:0.08～0.20mm
dismantling/mounting, camshaft mounting
attentions). Maximum end gap:0.21mm
Axial direction

Plastic gauge

Notice
 Engine block 1A-33

Explanations on inspection of tappet hole 2. Measure every tappet’s diameter respectively

and tappet at the A and B point (see the figure) along X
and Y direction.
1. Measure every tappet mounting hole’s inner
diameter respectively at A and B Point (see Standard diameter:30.964～30.980mm
the figure) along X and Y direction.
Standard inner diameter:31.000～31.025mm

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-34

Flywheel, clutch

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-35

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 4. Tighten the flywheel bolt with hands.
Dismantling/Mounting
5. Mount special tools onto the flywheel (see the
1. Use the screwdriver, wrapped with protective figure).
cloth, to dismantle the oil seal(see the figure)
6. Follow the sequence of right-angled
Notice intersection to tighten the flywheel bolt little
 Normally, there is no need to dismantle the oil by little.
seal, unless being replaced.
2. Add clean oil onto the oil seal opening.
3. Mount the oil seal with hands.
4. Use the special tools and hammer to compress
the oil seal.
Gear ring fixture
unit
Compression depth:0～0.5mm
 Engine block 1A-36

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

Explanations on the clutch pressure plate

inspection/mounting
1. Measure the diaphragm spring’s abrasion.
Explanations on the clutch friction disc If it exceeds standard, replace the clutch
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

2. Use the Straight Edge Ruler and plug gauge

to measure the pressure plate’s flatness.
If it exceeds standard, replace the clutch
Use the dial gauge to measure the clutch friction assembly.
disc’s end-on circle run-out.
Maximum clearance: 0.05mm
If it exceeds standard, replace the clutch
friction disc
Maximum end-on circle run-out:0.7mm

3. Use the special tools to lock the flywheel, and

locate the clutch(see the figure).
Use the special tools to secure the clutch friction
disc’s position (see the figure).
 Engine block 1A-37

Smear oil
before
mounting

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
diaphragm spring’s radial run-out.
If it exceeds standard, replace the clutch ⑨Smear oil
pressure plate before
mounting
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
Cylinder body, Crank Connecting explanations)
Rod Mechanism Piston pin (see the
4 mounting 10 Crankshaft
explanations)
Cylinder Body, Crank Connecting Rod 5 piston 11 Cylinder body
Mechanism Dismantling/Mounting 6 connecting rod
1. Dismantle the cylinder head (see the cylinder
head part), oil sump, oil pump, and timing Explanations on connecting rod cover
chain case assembly (see lubricating system dismantling
part) and crankshaft’s back cover (see
flywheel, clutch part). Inspect the connecting rod end gap (see connecting
rod inspection part).
2. Dismantle parts according to sequence
illustrated in the figure. . Explanations on piston pin dismantling
3. Mount parts according to the sequence 1. Mount No. 1 and No. 2 special tools and
reverse to the dismantling process. insert the No. 2 special tool into piston pin
and tighten it (see the figure)
 Engine block 1A-38

Explanations on the crankshaft

No. 2 tool dismantling
Piston F’s mark side
Inspect the main journal clearance (see the
crankshaft inspection /repair part).

Explanations on the main bearing cover

mounting
Piston pin No. 1 tool 1. Measure every bolt’s length. If the length
exceeds the standard value, replace the bolt.
Standard length: 74.15～74.85mm
2. Mount the special tools and piston connecting
rod assembly, which have been assembled in Maximum length: 75.05mm
Step 2, onto the special tools (see the figure).

Piston F’s mark side

Extrusion direction

2. Tighten main bearing cover’s bolt to specified

Catch bolt
torque by steps according to the sequence
illustrated in the figure, as well as mark every
bolt head. Tightening torque:33 ～
Piston pin assembly tool
35N·m{3.357～3.784kgf·m}
3. according to the bolt-tightening sequence
3. Use the press machine to extrude the piston
(Step 2) illustrated in the figure, rotate every
pin.
bolt for 60°～64° from the mark.
Explanations on main bearing cover
dismantling
1. Inspect the crankshaft end gap (see the
crankshaft inspection /repair part).
2. Loosen the main bearing cover’s bolt
according to steps illustrated in the figure.
 Engine block 1A-39

Explanations on the piston pin mounting

1. Use the special tools for mounting. Piston F’s mark side
2. Measure the following sizes (see the figure): Connecting rod“HM15” mark side

(1)A: exterior size of piston’s pin seat convex

plate
(2)B: piston cavity’s spread width
(3)C: piston pin length 6. Place the piston and connecting rod onto the
(4)D: connecting rod’s small head width compression platform, and keep upward the
piston “F” mark side and connecting
(5) Put measured values into the formula rod“HM15A” or “474Q-C” mark side (see the
below: figure).

BCAD No. 1 tool

h= 2 Connecting rod
Piston “F” mark side

No. 2 tool

7. Insert the piston pin and the special tool that

has been assembled in Step 2 into the piston
Piston pin 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
special tool (guide) contact the special
Connecting rod tool(catch bolt).

3. Insert the No. 2 special tool into the piston pin 9. When pressing the piston pin, inspect the
and tighten it onto the No. 1 special tool. compression pressure. If the pressure is
lower than the index, replace the piston
4. Measure length of No. 2 special tool’s pin or connecting rod.
guiding part (L2), and adjust it to compress
the special tool (catch bolt), so as to make the Pressure:5～11kN(510～1122kgf)
L’s size equal to L2＋h.

Catch bolt

Piston pin
assembly tool
Piston pin
assembly tool

5. Smear the clean engine oil onto the piston pin.

10. Inspect the piston pin’s compression depth, if
it goes beyond the standard value, repeat the
operation from step 1.
Piston pin’s compression depth:0.350～1.375mm
 Engine block 1A-40

Possible locations of all

piston rings’ abutment joints
Piston pin’s No. 1
depth in the gas ring
convex plate Upper
scraper
Thrusting
direction

Lower No. 2 gas

scraper ring

Piston pin direction

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

Explanations on the connecting rod cover

mounting
1. The bolt can be reused, but when the outer
diameter difference at the two points
 Do not use the piston ring dilator to mount the illustrated below exceeds 0.1mm, the bolt
oil scraper, or rupture may be caused. shall not be further used.

Piston ring dilator

diameter

diameter
Outer

Outer

2. Use the piston ring dilator to mount the No. 2 2. Tigthen the connecting rod bolt to specified
and No.1 piston ring. Keep the marker side torque by steps according to the sequence
upward during the mounting process. illustrated in the figure.
3. Align all rings’ opening locations (see the
Tightening torque:13.0 ～ 17.0N·m{1.32 ～
figure).
1.74kgf·m}
 Engine block 1A-41

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.

Cylinder Body Inspection /Repair

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

Cylinder body’s upper surface

2. If the distortion on the cylinder body’s upper

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

Piston, Piston Ring, and Piston Pin

Inspection
Along the vertical direction of piston pin hole’s
axial line, measure the piston’s diameter at the
place that is 19.38mm below the lower rim of the
oil control ring groove
Cylinder body
 Engine block 1A-42

Ring 1:0.15～0.30mm

Ring 2:0.20～0.40mm

Oil Ring:0.10～0.40mm
Maximum opening clearance:1.0mm

Piston diameter (mm)

Size Diameter
Standard 74.78～74.79

Calculate the clearance between piston and

cylinder. If necessary, replace the piston.
Standard clearance:0.010～0.035mm
Maximum clearance: 0.10mm
1. If replacing the piston, piston ring shall be
replaced as well.
2. Use the plug gauge to measure the clearance
between piston ring and ring slot along the
entire perimeter (see the figure). If necessary,
replace the piston and piston ring.

Respectively at A, B, C, and D point along X and

Y direction, measure every piston pin hole’s
diameter.
Standard clearance
Standard diameter:18.010～18.014mm
Ring 1:0.030～0.070mm
Respectively at A, B, C, and D point along X and
Ring 2:0.020～0.060mm Y direction, measure every piston pin’s diameter

Oil ring:0.040～0.12mm Standard diameter:18.001～18.005mm; Calculate

out the clearance between piston pin and piston pin
Maximum clearance hole. If necessary, replace the piston or piston pin.
Ring 1, Ring2:0.15mm Standard clearance:0.005～0.013mm
Oil ring:0.15mm.
5. Measure the connecting rod’s small head
3. Put the piston ring into cylinder with hands, diameter (see connecting rod inspection), and
and use the piston to push the piston ring to calculate the clearance between connecting
the bottom of the cylinder bore stroke. rod’s small head and piston pin. If necessary,
replace the connecting rod or piston pin.
4. Use the plug gauge to measure every piston Standard clearance:-0.031～-0.016mm.
ring’s opening clearance. If necessary, replace
the piston ring. Connecting Rod Inspection
Standard opening clearance: 1. Use the plug gauge to measure the connecting
 Engine block 1A-43

rod’s end gap. If necessary, replace the Standard 1.485～1.496

connecting rod and connecting rod cover.

Inspection of Piston Connecting Rod

Assembly
Inspect the swaying torque (see the figure). If the
big head fails to drop down by virtue of its own
weight, replace the piston or piston pin.

Standard clearance:0.100～0.350mm
Maximum clearance:0.40mm
2. Measure the crank pin journal clearance
according to steps below.
(1). Remove all oil on the journal and bearing Drop down by virtue
seat’s internal surface. of its own weight
(2). Make the plastic gauge match the bearing
width and then put it on the top of journal,
keeping parallel with the axial line.
(3). Mount the connecting rod cover (see piston
and connecting rod mounting part).
(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 Crankshaft Inspection /Repair
widest point on the plastic gauge’s extruded
1. Mount the dial gauge, use the screwdriver to
part, and then calculate out the journal
push the crankshaft frontward and backward,
clearance. If the clearance exceeds the
and measure the crankshaft end gap (see the
maximum value, replace the crankshaft and
figure). If the end gap surpasses the maximum
corresponding connecting rod bearing to
value, replace the thrust bearing or crankshaft
ensure the standard clearance.
to fit the standard end gap.
Standard clearance:0.014～0.058mm
Standard end gap:0.09～0.273mm
Maximum end gap:0.30mm

Thrust bearing’s sizeThrust bearing’s thickness

Standard 3.205～3.255

Maximum clearance:0.10mm

Size of connecting Thickness of connecting

rod bearing rod bearing
 Engine block 1A-44

Main journal Diameter(mm)

Standard 46.004～46.029
Crank pin Diameter(mm)
Standard 39.980～40.000
4. Measure the main journal’s clearance
according to method below.
(1). Remove all oil on the crankshaft journal and
bearing seat’s internal surface.
2. Measure the crankshaft’s radial run-out. If (2). Make the plastic gauge match the bearing
necessary, replace the crankshaft. width and then put it on the top of journal,
Maximum radial circle run-out:0.03mm 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
3. Respectively at A and B point along X and Y clearance. If the clearance exceeds the
direction, measure the journal diameter. If maximum value, replace the crankshaft and
necessary, replace the crankshaft. corresponding bearing bush to ensure the
standard clearance.
Standard clearance: 0.014～0.034mm
Maximum clearance: 0.1mm

Bearing bush size Bearing bush thickness

Standard 1.971～1.996
 Electronic Fuel Injection Control System 1B-1

Chapter 2 Electronic Fuel Injection Control System

Notices for Maintenance of Electronic Fuel Injection System···············································1B-3

General Maintenance Notices ············································································ 1B-3
Maintenance Attentions ··················································································· 1B-3

List of Maintenance Tools ························································································1B-4

Briefings of ME788 System ······················································································1B-7
Basic Principle······························································································ 1B-7
Torque-based ME788 System ············································································ 1B-9
Control signal: ME788 system’s input /output signals················································ 1B-10

Introduction of System Functions················································································1B-10

Start Control ································································································ 1B-10
Warm-up and Three-way Catalyst Converter Heating Control ······································ 1B-11
Acceleration /Deceleration and Towing Astern Oil Cutoff Control ································· 1B-11
Idle Control ································································································· 1B-11
Evaporation Emission Control ··········································································· 1B-12
Knock Control······························································································· 1B-12
Close-loop Control ······························································································ 1B-36
VVT Control ································································································ 1B-12
Idle Start/Stop Control····················································································· 1B-12

Introduction of System Troubleshooting Function ····························································1B-13

Classification of Fault Types ············································································· 1B-13
SVS Lamp Control Strategy ·············································································· 1B-15
Connection with Diagnostic Unit ········································································ 1B-15
ME788’s Overhaul and Diagnosis Flow by Fault Code ·············································· 1B-15
ME788’s Overhaul and Diagnosis Flow by Fault Phenomenon ····································· 1B-22

Analysis of Typical Faults ························································································1B-23

1. When starting, engine fails to run or runs slowly··················································· 1B-24
2. When starting, engine can run in a dragging manner but fails to start successfully ··········· 1B-25
3. Difficulty in heat starting··············································································· 1B-26
4. Difficulty in cold starting ·············································································· 1B-27
5. Normal rotating speed and difficulty in starting at any time; ····································· 1B-28
6. Normal starting but unstable idling speed at any time; ············································ 1B-29
7. Normal starting but unstable idling speed during the warm-up process························· 1B-30
8. Normal starting but unstable idling speed after the warm-up ····································· 1B-31
9. Normal starting but unstable idling speed or stalling when there
is partial load (like running of air conditioning)··················································· 1B-32
10. Normal starting but over high idling speed; ······················································· 1B-32
11. Rotating speed fails to increase or engine is stalled when being accelerated;················· 1B-34
12. Slow response when being accelerated ····························································· 1B-35
13. Poor performance or lack of power when being accelerated ···································· 1B-36
14. Idle start/stop function ineffective··································································· 1B-37
 Electronic Fuel Injection Control System 1B-2
Functional Requirements on ME788 System’s Diagnostic Unit·············································1B-38
Parts Mounting Torque Specification Table ····································································1B-38
Electronic Fuel Injection System Maintenance Specification ···············································1B-39
Family Vehicle······························································································ 1B-39
Vehicle for Lease ··························································································· 1B-40
 Electronic Fuel Injection Control System 1B-3
4. The electronic fuel injection system’s oil supply
pressure is relatively high (350kPa or so), and all
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.
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
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℃.
 Electronic Fuel Injection Control System 1B-4

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.
 Electronic Fuel Injection Control System 1B-5

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.
 Electronic Fuel Injection Control System 1B-6

Tool name: Fuel Injector Cleaning Analyzer

Function:

Make cleaning analysis on the fuel injector

 Electronic Fuel Injection Control System 1B-7

Briefings of ME788 System

Basic Principle
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 ME788 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 ME788 Engine Electronic
components of the system or their control Control System
functions. Once the fault has been detected and

Fig. 2.2: Structure of ME78 Engine Electronic Control System

 Electronic Fuel Injection Control System 1B-8
ME788 Engine Electronic Control System’s 1) Basic management functions of the engine in
physical model:
basic components include:
 Torque-based system structure
Electronic control unit (ECU)
Electronic accelerator pedal  Cylinder load determined by the intake
pressure sensor/air flow rate sensor
Air quality flowmeter (depending on project)
 Gas mixture control function improved in
Fuel injector intake pressure /temperature static and dynamic state.
sensor(depending on project)
 Close-loop control
Electronic fuel pump
Coolant temperature sensor  Sequential fuel injection cylinder by cylinder

Fuel pressure regulator  Ignition timing, including knock control

cylinder by cylinder
Electronic throttle body
 Emission control function
Oil pump bracket
 Catalyst heating
Phase sensor
Fuel distribution pipe  Carbon canister control

Rotating speed sensor  Idle control

Carbon canister control valve  Limp home

Knock sensor  Speed sensing by the incremental system
Ignition coil  VVT control
VVT controller  Idle start/stop
Oxygen sensor 2) Additional functions
Brake vacuum sensor (idle start/stop)
 Burglar alarm
ME788-Motronicengine Management System is a
 Connection between the torque and external
gasoline engine control system subject to
systems (like driving mechanism or vehicle
electronic operation, and it provides lots of control
dynamic control)
features relating to operators and
vehicles/equipments. It is worth pointing out that  Control over several engine parts and
the system adopts open-loop and close-loop components
(feedback) control mode, which can provide
different control signals for the engine’s running.  Provision of interface on EOL-programming
Major functions of the system include: tools and maintenance tools
3) Online OBD Diagnosis
 Complete a series of OBD functions
 Management system used in diagnosis
 Electronic Fuel Injection Control System 1B-9
control parameters like fuel injection time and
ignition timing etc. Meanwhile, execution to such
Torque-based ME788 System control variable will not affect other variables, which
is right the strong point of the torque-based control
In the ME788’s torque-based engine management
system, all of the engine’s internal and external system.
demands shall be defined according to the engine’s Likewise, during the engine matching process, the
torque or efficiency requirements (see Fig. 2.3). torque-based control system has independent
Different engine demands will be converted into the variables, and so only the engine data is required
torque or efficiency’s control variables, and then when matching the engine characteristic curve and
these variables will be firstly processed in the central map, and there is no interference with other
torque demanding coordinator module. By functions and variables. That in turn avoids
sequencing these contradictory requirements by repetitive marking, simplifies the matching process,
priority, ME788 system will execute the most and reduces the matching cost.
important requirement, and then it takes advantage of
torque conversion module to acquire needed engine

Fig. 2.3: Structure of ME788’s Torque-based System

 Electronic Fuel Injection Control System 1B-10
 Neutral position signal (dedicated to
In comparison with previous Collection M start/stop)
engine electronic fuel injection management
system, ME788 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
Control signal: ME788 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 Introduction of System Functions
 Throttle angle signal
Start Control
 Coolant temperature signal
During the starting process, special calculation
 Engine rotating speed signal method will be adopted to control the charge, fuel
 Phase signal injection, and ignition timing. At the initial phase
of this process, air in the intake manifold keeps
 Knock sensor signal still, and intake manifold’s internal pressure
reading is equal to the ambient atmosphere
 Oxygen sensor signal
pressure. When the throttle is closed, the idle speed
 Vehicle speed signal regulator is assigned a fixed parameter according
to the starting temperature.
 A/C pressure signal
In the similar process, the given “Fuel Injection
 Brake signal Timing” is assigned the initial injection pulse.
 Brake vacuum degree signal (dedicated to Fuel injection volume varies according to the
start/stop) engine temperature, in order to facilitate the
formation of oil film on the intake manifold and
 Electronic Fuel Injection Control System 1B-11
cylinder’s walls. Therefore, when the engine situation in which the power at the flywheel from the
reaches a given rotating speed, thick gas mixture engine is negative. In this case, engine friction and
shall be added. pump gas loss can be used to make the vehicle
decelerate. When the engine stays in the towing
Once the engine starts running, the system will astern or traction condition, the oil injection will be
immediately reduce the starting excess fuel. When cut off to reduce the fuel consumption and waste gas
the starting process ends (600…700min-1), the emission. More importantly, the process will help
starting excess fuel is completely cancelled. protect the three-way catalyst converter.
During the engine starting process, the ignition Once the rotating speed declines to the given rotating
angle is being adjusted constantly, and it varies speed (above idle speed) for recovery of oil supply,
according to engine temperature, intake the oil injection system will resume the oil supply. As
temperature, and engine’s rotating speed. a matter of fact, among the ECU’s programs there is
Note: As for vehicles with start/stop function, a range for recovery of rotating speed, and it varies
vehicle starting can be determined according to the with change of parameters like engine temperature
vehicle gear and clutch information. If the and engine rotating speed’s dynamic change. Also, it
transmission is in gear and engages with the clutch, calculates the rotating speed to prevent it from
starter running shall be prohibited. declining to specified minimum threshold.

Warm-up and Three-way Catalyst Once the injection system resumes the oil supply,
the system will begin using the initial injection
Converter Heating Control pulse to supply the additional fuel, in addition to
When the engine has been started at low reconstructing the oil film on the intake manifold’s
temperature, cylinder charge, fuel injection, and wall. After recovery of the fuel injection,
electronic ignition will be adjusted to offset the torque-based control system will slow and stabilize
engine’s higher torque requirements. Such a the engine torque’s increase (smooth transition).
process will continue till appropriate temperature
threshold has been hit.
Idle Control
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
transformation into three-way catalyst converter stably at a low idle speed, the close-loop idle
running will help reduce emission of waste gas control system must maintain the balance between
the torque and the engine’s “Power Consumption”,
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
the three-way catalyst converter by waste gas. process, in order to meet different load requirements,
which arise from engine crankshaft, gas distribution
Acceleration /Deceleration and Towing mechanism, and auxiliary components (like friction
Astern Oil Cutoff Control in the water pump).

Some of the fuel that has been injected into the intake ME788 System adopts the torque-based control
manifold will not duly flow into the cylinder to strategy, which, based on close-loop idle control,
partake into the subsequent combustion. On the determines the engine torque output that is required
contrary, it will produce a layer of oil film on the to maintain the idling speed in any working condition.
wall of the intake manifold. With improvement of the Such torque output increases with decline of the
load and extension of the fuel injection duration, fuel engine’s rotating speed, or vice versa. By requiring
deposited in the oil film will increase sharply. higher torque, the system makes response to the new
“Interference Factor”, such as the air conditioning
When the throttle opening increases, some compressor’s start/stop or automatic transmission
injected fuel will be absorbed by the oil film. Due shift. When the engine temperature is relatively low,
to this, supplementary fuel shall be injected to torque should be increased to offset more internal
prevent the gas mixture from getting thin during friction loss and/or maintain higher idling speed.
the acceleration process. Once the load coefficient All these torque output requirements are
decreases, additional fuel included in the fuel film transmitted to the torque coordinator, which will
on the intake manifold wall will be released again. make processing calculation and obtain
Then, injection duration must decrease during the corresponding charge concentration, components
deceleration process. of gas mixture, and ignition timing.
Towing astern or traction condition refers to the
 Electronic Fuel Injection Control System 1B-12
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 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 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
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.
Fault Information Record
Knock Control
Electronic control unit constantly monitors the
By virtue of the knock sensor that is mounted at sensor, actuator, relevant circuits, fault indicators,
the appropriate place of the engine, the system and accumulator voltage etc., and even the
tests the characteristic vibration resulting from electronic control unit itself, in addition to
the knock, and then converts the vibration into conducting the reliability test to the sensor output
electronic signal, in order to transmit it in the signal, actuator drive signal, and internal signals
ECU for handling. By adoption of special (like close-loop control, coolant temperature,
processing algorithm, ECU tests if there is knock knock control, idling speed control, and
phenomenon at every cylinder’s combustion accumulator voltage control etc). Once there is
cycle. Once there is knock, ECU will trigger the fault at certain link or a given signal is unreliable,
knock close-loop control. After the knock danger the electronic control unit will immediately set the
is eliminated, the affected cylinder’s ignition will fault information record in RAM fault memory,
be gradually advanced to the preset ignition and save it in the form of fault code, which will be
 Electronic Fuel Injection Control System 1B-13
displayed according to the fault occurrence “Sporadic Faults” (like the faults resulting from
sequence. According to the fault frequency, faults short-lived open circuit or poor contact between
can be classified into “Steady-state Faults” and connectors)

Introduction of System Troubleshooting Function

Fig. 2.4 Electronic Fuel Injection System’s Troubleshooting Principle

Classification of Fault Types taking place; DFP fault types relating to misfire are
usually defined as Class 2. As for the misfire fault
Diagnostic Fault Path and Fault Categories resulting in damage of catalyst, the MIL lamp will
Diagnostic fault path (DFP) is, in fact, a flash in no time to prompt the driver. As for the
sub-function for fault diagnosis that is used to misfire fault resulting in deterioration of emission, if
the misfire fault of corresponding extent has been
inspect functions of a given sensor, actuator, or
fully detected in three consecutive driving cycles, the
others in the EMS system. By respective
diagnostic path, the fault information will be MIL lamp will be activated, and also the fault will be
transmitted to the fault diagnosis management displayed on the diagnostic unit. If the fault fails to
be confirmed or eliminated in 40 driving cycles
module, which will take corresponding actions
and determine if the fault lamp should be activated (namely, in a warm-up cycle, E_xxx＝1, but Z_xxx
or the fault should be displayed on the diagnostic ＝0), the fault information will be deleted from the
unit. When a fault is detected at a given DFP, the fault memory. if the fault disappears before the fault
fault diagnosis management module will make confirmation and never occurs within 40 driving
definite the fault type. Usually, the fault types cycles, the fault information will be deleted from the
include: fault memory; If the fault disappears after being
confirmed, the fault information cannot be deleted
B_mxdfp Maximum fault, signal goes beyond the from the fault memory until it does not occur within
upper 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_mndfp Minimum Fault, the signal goes beyond
If the fault disappears after the fault confirmation and
the lower limit of the normal range.
never occurs within three driving cycles, it means
B_sidfp signal fault, without signal. that the fault has been corrected.

B_npdfp unreasonable signal, with signal, but Class3: fault is inputted into the fault memory upon
the signal is unreasonable. taking place. After the fault confirmation, the MIL
lamp is activated, and the fault confirmation needs
Definitions of Fault Types three driving cycles, with fault being displayed on the
In this project there are 10 fault types. Closed fault diagnostic unit. If the fault fails to be confirmed or
path is defined as “Class0”, namely, the fault eliminated within 40 warm-up cycles(namely, in a
information will not enter the fault memory, and warm-up cycle, E_xxx＝1, but Z_xxx＝0), the fault
also the diagnostic unit will not read the fault. In information will be deleted from the fault memory; if
addition, faults of Class2, Class3, Class4, Class5, the fault disappears before the fault confirmation and
Class6, Class7, Class11, Class12, and Class13 never occurs within 40 warm-up cycles, the fault
belong to those fault types that have been defined information will be deleted from the fault memory; If
by the system in a uniform manner. the fault disappears after being confirmed, the fault
information cannot be deleted from the fault memory
Class2: fault is inputted into the fault memory upon until it does not occur within 40 warm-up cycles; and
 Electronic Fuel Injection Control System 1B-14
the fault priority is defined as 30; after the fault Class7:fault is inputted into the fault memory upon
confirmation, SVS lamp is off; If the fault disappears taking place; after the fault confirmation, MIL
after fault confirmation and never occurs within three lamp is off; fault will be confirmed upon taking
driving cycles, it means the fault has been corrected.. place; the fault is not displayed on the diagnostic
unit;If the fault fails to be confirmed or eliminated
Class4:fault is inputted into the fault memory upon within 40 warm-up cycles(namely, in a warm-up
taking place. After 2.5s since the fault occurs, the cycle, E_xxx ＝ 1, but Z_xxx ＝ 0), the fault
MIL lamp will be activated, and also the fault is
information will be deleted from the fault memory;
displayed on diagnostic unit; If the fault fails to be
If the fault disappears after the fault confirmation,
confirmed or eliminated within 40 warm-up
the fault information cannot be deleted from the
cycles(namely, in a warm-up cycle, E_xxx＝1, but fault memory until it does not occur within five
Z_xxx＝0), the fault information will be deleted from warm-up cycles, and the fault priority is defined as
the fault memory; if the fault disappears before the 50; after the fault confirmation, SVS lamp is off; If
fault confirmation and never occurs within 40 the fault disappears after the fault confirmation and
warm-up cycles, the fault information will be deleted never occurs within 120ms, it means the fault has
from the fault memory; If the fault disappears after been corrected.
being confirmed, the fault information cannot be
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
＝1, but Z_xxx＝0), the fault information will be
Class5:fault is inputted into the fault memory upon deleted from the fault memory; if the fault disappears
taking place; after the fault confirmation, MIL lamp is before the fault confirmation and never occurs within
off; fault confirmation needs 3 driving cycles; the 40 warm-up cycles, the fault information will be
fault is displayed on diagnostic unit; If the fault fails deleted from the fault memory; If the fault disappears
to be confirmed or eliminated within 40 warm-up after being confirmed, the fault information cannot be
cycles(namely, in a warm-up cycle, E_xxx＝1, but deleted from the fault memory until it does not occur
Z_xxx＝0), the fault information will be deleted from within 40 warm-up cycles; and the fault priority is
the fault memory; if the fault disappears before the defined as 20; after the fault confirmation, SVS lamp
fault confirmation and never occurs within 40 is off; If the fault disappears after the fault
warm-up cycles, the fault information will be deleted confirmation and never occurs within 4 driving cycles,
from the fault memory; If the fault disappears after it means the fault has been corrected.
being confirmed, the fault information cannot be
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
cycle, E_xxx ＝ 1, but Z_xxx ＝ 0), the fault
Class6: fault is inputted into the fault memory upon information will be deleted from the fault memory;
taking place; after the fault confirmation, MIL lamp is if the fault disappears before the fault confirmation
off; fault will be confirmed upon taking place; the and never occurs within 40 warm-up cycles, the
fault is not displayed on the diagnostic unit;If the fault fault information will be deleted from the fault
fails to be confirmed or eliminated within 40 memory; If the fault disappears after being
warm-up cycles(namely, in a warm-up cycle, E_xxx confirmed, the fault information cannot be deleted
＝1, but Z_xxx＝0), the fault information will be from the fault memory until it does not occur
deleted from the fault memory; If the fault disappears within 40 warm-up cycles; and the fault priority is
after being confirmed, the fault information cannot be defined as 50; after fault confirmation, SVS lamp
deleted from the fault memory until it does not occur is activated; If the fault disappears after the fault
within 40 warm-up cycles; and the fault priority is confirmation and never occurs within 120, it means
defined as 50; after the fault confirmation, SVS lamp the fault has been corrected, and also the SVS is
is off; If the fault disappears after the fault off.
confirmation and never occurs within 1.2s, it means
the fault has been corrected. Class13:fault is inputted into the fault memory upon
 Electronic Fuel Injection Control System 1B-15
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 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 ME788’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
will remain “ON” state for 4s. Then, after one 1. The overhaul cannot be executed only when
second of interval, SVS will blink at the frequency current fault has been confirmed as “Steady-state”
of 2HZ, in order to indicate “No Fault” till the blink fault, or the diagnosis error will take place.
code request condition cannot be met.
2. Multimeter required refers to the digital
4) Blink code request, and there is fault in fault
 Electronic Fuel Injection Control System 1B-16
multimeter, and analogue multimeter shall not be 1. If the fault code cannot be cleared, the fault
used to inspect the electronic fuel injection belongs to “Steady-state” fault. If the fault belongs
system’s lines. to sporadic fault, emphasis should be put on the
inspection to wiring connector’s looseness.
3. In the case of overhauling the vehicle with
anti-theft system, if the ECU will be replaced, 2. No abnormal situation after preceding
programming to ECU shall be done after the inspection;
replacement.
3. During the overhaul process, do not overlook
4. If the fault code indicates that a given circuit has other factors’ influence on the system, such as
too low voltage, it means that there likely exists short automobile maintenance, cylinder pressure, and
circuit to the earth in the circuit. If the fault code mechanical ignition timing etc.
indicates that a given circuit has too high voltage, it
means that there likely exists short circuit to the 4. Replace ECU for further test.
battery in the circuit. If the fault code indicates that If the fault code can be cleared, the fault cause
there is fault at a given circuit, it means that there should be attributed to ECU. However if the fault
likely exists open circuit or several types of faults in code cannot be cleared, remount original ECU and
the circuit. repeat the workflow for further overhaul work.
Diagnosis help:

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 √ ×
 Electronic Fuel Injection Control System 1B-17
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
Offline detection A/F ratio close-loop control
38 P0171 7 × ×
self-learning, too lean
Offline detection A/F ratio close-loop control
39 P0172 7 × ×
self-learning, too thick
40 P0201 Cylinder 1 fuel injector control circuit, open 3 √ ×
41 P0202 Cylinder 2 fuel injector control circuit, open 3 √ ×
42 P0203 Cylinder 3 fuel injector control circuit, open 3 √ ×
43 P0204 Cylinder 4 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 Cylinder 1 fuel injector control circuit’s short circuit to 3 √ ×
 Electronic Fuel Injection Control System 1B-18
the battery
Cylinder 2 fuel injector control circuit’s short circuit to
50 P0264 3 √ ×
the ground
Cylinder 2 fuel injector control circuit’s short circuit to
51 P0265 3 √ ×
the battery
Cylinder 3 fuel injector control circuit’s short circuit to
52 P0267 3 √ ×
the ground
Cylinder 3 fuel injector control circuit’s short circuit to
53 P0268 3 √ ×
the battery
Cylinder 4 fuel injector control circuit’s short circuit to
54 P0270 3 √ ×
the ground
Cylinder 4 fuel injector control circuit’s short circuit to
55 P0271 3 √ ×
the battery
56 P0300 Multiple Cylinders Misfire Detected 2 √or Blink ×
57 P0301 Cylinder 1 Misfire Detected 2 √or Blink ×
58 P0302 Cylinder 2 Misfire Detected 2 √or Blink ×
59 P0303 Cylinder 3 Misfire Detected 2 √or Blink ×
60 P0304 Cylinder 4 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
81 P0507 Idling control rotating speed, higher than target idling 3 √ ×
 Electronic Fuel Injection Control System 1B-19
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
112 P1511 EBS LIN communicating load rate, too high, beyond 5 × ×
 Electronic Fuel Injection Control System 1B-20
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
141 P2091 VVT exhaust control valve circuit’s short circuit to the 3 √ ×
 Electronic Fuel Injection Control System 1B-21
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)
150 P2195 Upstream oxygen sensor, aging 3 √ ×
151 P2196 Upstream oxygen sensor, aging 3 √ ×
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
 Electronic Fuel Injection Control System 1B-22

ME788’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.

ME788 Pin Distribution

1 Ignition 4 2 Ignition 2 3 Ignition 4 Ignition 3 5 Ignition 1
Brake Vacuum Degree
81 CAN Low 62 CAN High 43 24
Signal
Intake Temperature Start/Stop Main
80 Power Ground 61 Power Ground 42 23
Signal Switch
79 Phase Sensor1 60 A/C MV Switch 41 Neutral Position Switch 22 Clutch Bottom Switch
Accelerator Pedal
78 Sensor Ground 4 59 Vehicle Speed Signal 40 21 Brake Lamp
Signal
Cooling Water
77 Electronic Load 2 58 Brake Switch 39 20 Knock Signal B
Temperature Signal
Drive Chain Mode
76 Electronic Load 1 57 38 Throttle Signal 19 Knock Signal A
Switch
75 A/C Switch 56 Starter Feedback 37 Intake Pressure Signal 18 Upstream Oxygen
 Electronic Fuel Injection Control System 1B-23
Sensor Signal
Downstream Oxygen
74 Clutch Switch 55 36 Sensor Ground 2 17 Sensor Ground 1
Sensor Signal
Accelerator Pedal
73 Anti-theft Switch 54 Throttle Signal 35 Sensor Ground 3 16
Signal
72 Phase Sensor2 53 Electronic Ground 34 Rotating Speed B 15 Rotating Speed A
71 K-wire Communication 52 Starter 33 5V Power Supply 1 14 Main Relay Control
70 Oil Pump Relay 51 Electronic Ground 32 5V Power Supply 2 13 Ignition Switch
Constant Power
69 A/C Compressor Relay 50 Fan 1 31 12
Supply
Idle Start/Stop Output to Anti-theft
68 Fan 2 49 30 LIN Wire 11
Warning Lamp Control
Intake Variable Valve Exhaust Variable Valve
67 Throttle Actuator 48 29 10
Timing Timing
Downstream Oxygen
66 Throttle Actuator 47 Fuel Injector 3 28 9
Sensor Heating
Carbon Canister
65 Throttle Actuator 46 27 Fuel Injector 1 8
Control Valve
Nterrupted Power Upstream Oxygen
64 Throttle Actuator 45 26 7 Fuel Injector 2
Supply Sensor Heating
Interrupted Power Nterrupted Power Idle Start/Stop Mode
63 44 25 6 Fuel Injector 4
Supply Supply Indicator
=Idled or optional configuration

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
 Electronic Fuel Injection Control System 1B-24
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
 Electronic Fuel Injection Control System 1B-25

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.
Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
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
 Electronic Fuel Injection Control System 1B-26

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.
Ordinary Troubleshooting Flow:
Test
No. Operation Steps Follow-up Steps
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
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
2 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.
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 )
Overhaul or
Inspect if the fuel pressure regulator vacuum tube gets loosened or Yes
4 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
 Electronic Fuel Injection Control System 1B-27

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.
Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
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
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
2 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.
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
Inspect the engine cylinders’ pressure, and observe if the engine Yes engine’s
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
 Electronic Fuel Injection Control System 1B-28

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.

Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
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
Dismantle the fuel injector, and use the dedicated fuel injector Yes Fault replacement
7 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 Fault replacement
8
after the oil is injected. No Next step
Rule out the
Inspect the engine cylinders’ pressure, and observe if the engine Yes engine’s
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
 Electronic Fuel Injection Control System 1B-29
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.
Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
Results
Overhaul the
Inspect if the air filter suffers blockage and if the intake port Yes
1 intake system
suffers air leakage.
No Next step
Yes Clean or replace
2 Inspect if the idling regulator gets stuck.
No Next step
Yes Next step
Inspect every cylinder’s spark plug and observe if the model and
3 Adjustment or
clearance accord with specification. No
replacement
Inspect if the throttle and idling bypass air path suffers carbon Yes Clean
4
deposition. 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,
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
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
9
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
 Electronic Fuel Injection Control System 1B-30

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.
Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
Results
Overhaul the
Inspect if the air filter suffers blockage and if the intake port Yes
1 intake system
suffers air leakage.
No Next step
Yes Next step
Inspect every cylinder’s spark plug and observe if the model and
2 Adjustment or
clearance accord with specification. No
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
Dismantle the fuel injector, and use the dedicated fuel injector Yes Fault replacement
5 cleaning analyzer to inspect if the fuel injector suffers leakage,
No Next step
blockage, or excessive flow difference.
Step on the accelerator lightly and observe if the engine can be Yes Fault replacement
6
easily started. 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
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
 Electronic Fuel Injection Control System 1B-31

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.
Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
Results
Overhaul the
Inspect if the air filter suffers blockage and if the intake port Yes
1 intake system
suffers air leakage.
No Next step
Yes Next step
Inspect every cylinder’s spark plug and observe if the model and
2 Adjustment or
clearance accord with specification. No
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
Dismantle the fuel injector, and use the dedicated fuel injector Yes Fault replacement
5 cleaning analyzer to inspect if the fuel injector suffers leakage,
No Next step
blockage, or excessive flow difference.
Step on the accelerator lightly and observe if the engine can be Yes Fault replacement
6
easily started. 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
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
 Electronic Fuel Injection Control System 1B-32

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.
Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
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.
Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
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
 Electronic Fuel Injection Control System 1B-33
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
 Electronic Fuel Injection Control System 1B-34

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.
Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
Results
Overhaul intake
Yes
1 Inspect if the air filter suffers blockage. system
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 when being accelerated.
Yes Next step
Inspect every cylinder’s spark plug and observe if the model and
3 Adjustment or
clearance accord with specification. No
replacement
Dismantle the idling speed regulator, and inspect if the throttle Overhaul the
Yes
4 body, idling speed regulator, and idling bypass air path suffer intake system
carbon deposition. No Next step
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
Dismantle the fuel injector, and use the dedicated fuel injector Yes Fault replacement
6 cleaning analyzer to inspect if the fuel injector suffers leakage or
No Next step
blockage.
Step on the accelerator lightly and observe if the engine can be Yes Fault replacement
7
easily started. No Next step
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
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
10
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
 Electronic Fuel Injection Control System 1B-35

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.
Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
Results
Overhaul intake
Yes
1 Inspect if the air filter suffers blockage. system
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 when being accelerated.
Yes Next step
Inspect every cylinder’s spark plug and observe if the model and
3 Adjustment or
clearance accord with specification. No
replacement
Dismantle the idling speed regulator, and inspect if the throttle Overhaul the
Yes
4 body, idling speed regulator, and idling bypass air path suffer intake system
carbon deposition. No Next step
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
Dismantle the fuel injector, and use the dedicated fuel injector Yes Fault replacement
6 cleaning analyzer to inspect if the fuel injector suffers leakage or
No Next step
blockage.
Step on the accelerator lightly and observe if the engine can be Yes Fault replacement
7
easily started. No Next step
Yes Next step
Inspect if the engine’s ignition sequence and ignition timing
8 Overhaul the
accord with specification. No
ignition system
Yes Next step
9 Inspect if the exhaust pipe can efficiently exhaust the air. Repair or replace
No
the exhaust pipe
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
10
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
 Electronic Fuel Injection Control System 1B-36

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.
Ordinary Troubleshooting Flow:

Test
No. Operation Steps Follow-up Steps
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
Connect with the fuel pressure gauge (front end of fuel distribution Yes 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
Inspect every cylinder’s spark plug and observe if the model and
5 Adjustment or
clearance accord with specification. No
replacement
Overhaul the
Yes
6 Inspect if the throttle body and air path suffer carbon deposition. intake system
No Next step
Yes Next step
Overhaul the line
7 Inspect if the intake pressure sensor and throttle line are normal.
No or replace the
sensor
Dismantle the fuel injector, and use the dedicated fuel injector Yes Fault replacement
8 cleaning analyzer to inspect if the fuel injector suffers leakage or
No Next step
blockage.
Step on the accelerator lightly and observe if the engine can be Yes Fault replacement
9
easily started. No Next step
Yes Next step
Inspect if the engine’s ignition sequence and ignition timing
10 Overhaul the
accord with specification. No
ignition system
Yes Next step
11 Inspect if the exhaust pipe can efficiently exhaust the air. Repair or replace
No
the exhaust pipe
 Electronic Fuel Injection Control System 1B-37

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.
Ordinary Troubleshooting Flow:
1. Start/stop indicator is green, but the engine cannot stop automatically

Test
No. Operation Steps Follow-up Steps
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)
 Electronic Fuel Injection Control System 1B-38

Functional Requirements on ME788 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

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
 Electronic Fuel Injection Control System 1B-39

Electronic Fuel Injection System Maintenance Specification

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

 Electronic Fuel Injection Control System 1B-40

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
Fuel System ·········································································································1C-2
Preparatory Work before Repair ···········································································1C-2
Inspection Work after Maintenance········································································1C-2
Inspection to Fuel Leakage ·················································································1C-2
Fuel Hose Mounting ·························································································1C-2
Warning on Plastic Fuel Pipe (fuel supply pipe assembly, fuel supply pipe,
and fuel return pipe assembly) ·············································································1C-3
Explanations on Plastic Fuel Pipe (Fuel Supply Pipe Assembly,
Fuel Supply Pipe, and Fuel Return Pipe) Mounting·····················································1C-3
Explanations on fuel filter dismantling /mounting ······················································1C-3
Cylinder Dismantling /Mounting ··········································································1C-4
Cylinder Air Tightness Test ·················································································1C-5
Inspection of Check Valve ··················································································1C-5
Inspection of Fuel Cylinder Pipeline Pressure ···························································1C-5
Inspection of Fuel Pressure Maintenance·································································1C-7
Fuel Pump Assembly Dismantling /Mounting ···························································1C-8
Inspection of Fuel Pump Assembly········································································1C-8
Inspection of Conducting/Non-conducting State ························································1C-36
Inspection of Open/Short Circuit ··········································································1C-8
Inspection of Fuel Pump’s Maximum Pressure ··························································1C-8
Inspection of Fuel Pump Oil Pressure Maintenance ····················································1C-9
Spray Nozzle Dismantling /Mounting·····································································1C-10
Inspection of Spray Nozzle ·················································································1C-10
Fuel Vaporation and Absorption System ········································································1C-10
Inspection of Carbon Canister Assembly ·································································1C-11
Inspection of Carbon Canister’s Electromagnetic Valve················································1C-11
Inspection of Ventilation Condition ·······································································1C-11
Inspection of Open/Short Circuit ··········································································1C-11
 Fuel System 1C-2

Caution
Fuel System  Wrong connection with other wiring terminals
may lead to fault, and so caution is needed
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
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 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.

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
personnel injury and property loss. Due to this,
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.
Avoid nipping previous nipping place 2. If the quick plug O-ring is damaged or
Warning on Plastic Fuel Pipe (fuel supply disengaged, mount the new fuel pipeline.
pipe assembly, fuel supply pipe, and fuel 3. Push the fuel pipeline quick plug into the
return pipe assembly) loading part till the pipe joint makes the
“click” sound.
Dismantling
4. If the fuel pipeline quick plug is equipped
 When dismantling the fuel pipe, pressure in the with double-lock mechanism, mount the
fuel system will lead to ejection of fuel from double locks till there is “click” sound.
the fuel pipeline, and so oil cylinder head shall
be dismantled in advance according to 5. Pull the quick plug with hands to confirm if it
requirements while dismantling the fuel has been secured mounted.
pipeline, in order to release the pressure in the
oil cylinder and avoid personnel injury and Explanations on fuel filter dismantling
property loss. /mounting
Caution Warning

 While dismantling the fuel pipeline, necessary  When dismantling the fuel pipe, pressure in the
sheltering measures shall be adopted, in order fuel system will lead to ejection of fuel from the
to avoid the fuel’s ejection onto your body. fuel pipeline, and so cylinder head shall be
dismantled in advance according to requirements
1. If the quick plug assembly is equipped with while dismantling the fuel pipeline, in order to
double-lock mechanism, loosen the quick release the pressure in the cylinder and avoid
plug assembly’s double locks along the personnel injury and property loss.
direction illustrated in the figure.
Caution
Double Locks Locking Device (two sides)
 While dismantling the fuel pipeline, necessary
sheltering measures shall be adopted, in order
to avoid the fuel’s ejection onto your body.
1. Complete the preparatory work before the
repair (See Preparatory Work before Repair).
2. Dismantle fuel filter from the longitudinal
beam on the left side of the bottom plate.

2. Pinch locking devices on both sides of the quick Fuel filter

Fuel supply pipe Fuel return pipe
plug with fingers to remove the quick plug.
assembly
3. Repeat Step 1 and Step 2, and dismantle the
quick plug at the other end of the fuel pipeline
from the supporting pipeline.
Explanations on Plastic Fuel Pipe (Fuel
Supply Pipe Assembly, Fuel Supply Pipe,
and Fuel Return Pipe) Mounting
Bolt
Notice
When mounting the new fuel supply pipe
assembly, assemble properly double locks on the Loosen the cylinder fuel supply pipe and fuel
quick plug assembly. return pipe assembly along the direction illustrated
in the figure.
 Fuel System 1C-4

Caution 8. Life the vehicle with lifting machine and

dismantle parts according to sequence
 To avoid the quick connector’s damage or oil illustrated in the figure.
leakage, follow the “Explanations on plastic
fuel pipe dismantling” to complete the 9. Mount parts according to the sequence reverse
under-mentioned work (see the Fuel System, to the dismantling process.
Explanations on Plastic Fuel Pipe Dismantling)
10. Complete inspection work after the repair (see
Dismantle fuel filter bracket’s mounting bolt, and Inspection Work after Repair)
remove the fuel filter.
Mount parts according to the sequence reverse to
the dismantling process.
Caution
 To avoid the quick connector’s damage or oil
leakage, follow the “Explanations on plastic
fuel pipe mounting” to complete the
under-mentioned work (see the Fuel System,
Explanations on Plastic Fuel Pipe Mounting)

Cylinder Dismantling /Mounting

Warning
 Unwashed cylinder is dangerous and may lead
Tightening
to combustion or explosion, which will further
No. Part Name Torque
result in serious casualties. Due to this,
cylinder shall be cleaned with vapor before the (N·m)
overhaul.
1 Oil filling pipe cover
 Fuel overflow or leakage is dangerous, and the
fuel is combustible, which may lead to 2 Assembling bolt 3.9～5.9
personnel injury and property loss. Due to this,
do not damage the sealing face while 3 Dustproof cover
dismantling/ mounting the oil pump assembly.
4 Elastic pipe clamp
Caution
5 Ventilation hose
 Dismantling/mounting quick connector before
cleaning will lead to damage of the fuel pipe 6 Elastic pipe clamp
and quick connector. Due to this, cleaning is a
7 Oil filling hose
must before dismantling /mounting, in order to
make sure that no foreign objects enter the fuel 8 Anti-looseness bolt 8.8～12.7
pipe and connector.
9 Oil filling pipe assembly
1. Park the vehicle stably on the lifting machine.
10 Flange nut 43.1～60.8
2. Complete preparatory work before repair (see
Preparatory Work before Repair). 11 Fuel tank mounting unit
3. Loosen the accumulator’s negative cable. 12 Fuel tank mounting
4. Dismantle the second-row seats (see Part S,
13 Electric pump gland 75～85
Seat, Second-row Seats Dismantling
/Mounting). 14 Fuel pump assembly
5. Dismantle the cylinder repair cover plate. 15 Electric pump gasket
6. Dismantle all fuel pipes that connect with the
16 Fuel tank assembly
oil pump.
7. Drain fuel in the cylinder.
 Fuel System 1C-5

Cylinder Air Tightness Test 3. If they are not aligned, dismantle the check
valve, and remount it after the aligning.
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).
Bulge
2. Block the special blanking plug (dedicated to
main fuel pipe) on the fuel pump assembly.
4. Confirm if picking up the check valve again,
3. Use special blanking plug to block the gravity the check valve should be closed.
valve vapor hose’s joint on the cylinder body.
5. If it is open, replace the check valve (see
4. Connect the special air pressure test tool with Cylinder Dismantling/Mounting).
the cylinder’s oil filling port and exhaust port.
6. Confirm if the check valve can be opened in
5. Put the cylinder horizontally into the special dead weight.
water tank dedicated to cylinder test (the total
cylinder shall be immersed 100mm below the
water surface).
6. Charge compressed air into the cylinder’s oil
filling port, and pressurize the cylinder to
(30～50)kPa. Then, maintain the pressure for
1min.
7. Inspect if there is air bubble between the parts
(like oil filling port, exhaust port, and gravity
valve) and the cylinder’s welding face.
 If there is air bubble on the welding face,
replace the cylinder (see Cylinder 7. If it cannot be opened, replace the check valve
Dismantling/Mounting) (see Cylinder Dismantling/Mounting).
Inspection of Fuel Cylinder Pipeline Pressure
Warning
 Fuel overflow or leakage is dangerous, and the
fuel is combustible, which may lead to
personnel injury and property loss. In addition,
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
Inspection of Check Valve sure that no foreign objects enter the fuel pipe
and connector.
1. Dismantle the oil filling pipe assembly (see
Cylinder Dismantling/Mounting). Notice:
2. Confirm if the check valve’s bulge is aligned  The following tests can be conducted if
with the oil filling pipe’s slot. necessary
 Fuel System 1C-6

1. Complete preparatory work before repair (see pipeline’s maximum oil pressure.
Preparatory Work before Repair)
Standard value
2. Loosen the accumulator’s negative cable.
390～410kpa
Caution
8. Turn the ignition switch to the “OFF”
 To avoid the quick connector’s damage or oil position and loosen the jumper wire.
leakage, follow the “Explanations on plastic
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 —If the oil pressure rises speedily, inspect the
tool’s interface. 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
may lead to fault, and so caution is needed
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.
 To avoid the quick connector’s damage or oil
leakage, follow the “Explanations on plastic
fuel pipe dismantling” to complete the
under-mentioned work (see the Cylinder
Earthing Dismantling/Mounting, Explanations on
jumper
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
 Fuel System 1C-7

Inspection of Fuel Pressure Maintenance 6. Remount the accumulator’s negative cable.

Warning Caution
 Fuel overflow or leakage is dangerous, and  Wrong connection with other wiring terminals
the fuel is combustible, which may lead to may lead to fault, and so caution is needed
personnel injury. In addition, the fuel has side during the connection process.
effect on the skin and eye.
7. Connect the DLC’s wiring terminal F/P with
Caution the Vehicle body’s earthing point GND with a
 Dismantling/mounting quick connector before jumper wire.
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 Earthing
to make sure that no foreign objects enter the jumper
fuel pipe and connector.
Notice:
 The following tests can be conducted if
necessary
8. Turn the ignition switch to the “ON” position
1. Complete preparatory work before repair (see for about 10s, in order to make the fuel pump
Preparatory Work before Repair) run.
2. Loosen the accumulator’s negative cable. 9. Turn the ignition switch to the “OFF”
Caution position and loosen the jumper wire.

 To avoid the quick connector’s damage or oil 10. Observe the oil pressure after 60 minutes.
leakage, follow the “Explanations on plastic
 If the oil pressure is lower than the standard
fuel pipe dismantling” to complete the
value, observe the oil pressure’s variation
under-mentioned work (see the Fuel System,
while rotating the switch handle
Explanations on Plastic Fuel Pipe
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). Dismantling/Mounting)

4. Connect the special tool’s quick connector —If the oil pressure is changed, inspect if the oil
with the fuel distributor (fuel rail), and insert circuit and spray nozzle suffer oil leakage.
the main fuel hose (fuel supply pipe assembly) Standard value:
onto the special tool’s interface.
≥250kpa(2.5kgf/cm2, 36psi)
5. Rotate the switch handle along the direction
illustrated in the figure.

Switch handle
To main pipe Switch handle
To main pipe Fuel distributor
Fuel distributor
 Fuel System 1C-8

1. Loosen the special tool unit. Inspection of Open/Short Circuit

12. Connect the main fuel hose with main fuel 1. Inspect if there is open/short circuit on the
pipe. following wiring harnesses. If there is, repair
or replace corresponding wiring harness:
13. Complete the inspection work after repair
(see Inspection Work after Repair). Open Circuit
Fuel Pump Assembly Dismantling  Earting circuit (between fuel pump assembly’s
/Mounting connector D and the vehicle body GND)

Dismantle /Mount Fuel Pump Assembly (see  Power circuit (between the fuel pump relay
Cylinder Dismantling/Mounting) connector A and fuel pump assembly
connector B, and there is public connector)
Warning
Fuel pump relay
 Fuel pump assembly cannot be disassembled

Inspection of Fuel Pump Assembly

Simulation Test
Inspect the fuel pump’s working condition (see
Fault Diagnosis, Inspection of Engine Control
System’s Working Condition, Inspection of Fuel
Pump’s Working Condition).
 If the condition is abnormal, conduct further
inspection to the fuel pump assembly.
Short Circuit
Inspection of Conducting/Non-conducting  The circuit between the fuel pump assembly
State connector B and fuel pump relay connector E,
in which there is public connector and ground
Notice
short circuit (electrical ground)
 Inspection below can be conducted if
2. Remount the fuel pump assembly connector.
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,
2. Remove the second-row seats (see Seats,
Second-row Seats Dismantling /Mounting).
Second-row Seats Dismantling /Mounting).
5. Remount the accumulator’s negative cable.
3. Dismantle the oil tank’s repair cover plate.
4. Loosen the fuel pump assembly’s connector. Inspection of Fuel Pump’s Maximum
Pressure
5. Inspect the conducting/non-conducting state
between fuel pump or connector’s wiring Warning
terminal B and wiring terminal D. If it is in
 Fuel overflow or leakage is dangerous, and the
conducting state but the simulation test is
fuel is combustible, which may lead to personnel
abnormal, inspect if the circuit suffers
injury and property loss. Due to this,
short/open circuit. If it is in non-conducting
under-mentioned operations shall not be started
state, replace the fuel pump assembly.
until the engine stops.
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 oil pipe
 Fuel System 1C-9

and connector.
Notice Jumper wire
 The following tests can be conducted if
necessary
1. Complete preparatory work before repair (see
Preparatory Work before Repair)
9. Turn the ignition switch to the “ON” position to
2. Loosen the accumulator’s negative cable. make the fuel pump run, and measure the fuel
Caution pump’s maximum output oil pressure.

 To avoid the quick connector’s damage or oil Fuel pump’s maximum output oil pressure: 650～
leakage, follow the “Explanations on plastic 900kpa
fuel pipe dismantling/ mounting” to complete 10. Turn the ignition switch to the “OFF”
the under-mentioned work (see the Fuel position and loosen the jumper wire.
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 pump relay (see Inspection of Fuel Pump
(vaporation rigid pipe). Relay)
4. Turn the switch handle to the position —If the fuel filter (LV, HV) suffers blockage.
illustrated in the figure to block the special
tool’s port. —If the fuel pipeline suffers blockage or leakage.

5. Push the special tool’s quick connector into 11. Dismantle the special tool.
the main pipe (fuel rigid pipe) till there is a Caution
“click” sound.
 To avoid the quick connector’s damage or oil
6. Put the hose into a vessel in order to avoid the leakage, follow the “Explanations on plastic
fuel overflow. fuel pipe dismantling” to complete the
under-mentioned work (see the Fuel System,
Explanations on Plastic Fuel Pipe Dismantling)
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.
 Fuel overflow or leakage is dangerous, and the
Caution fuel is combustible, which may lead to
personnel injury and property loss. Due to this,
 Wrong connection with other wiring terminals under-mentioned operations shall not be
may lead to fault, and so caution is needed started until the engine stops.
during the connection process.
Caution
8. Connect the DLC’s wiring terminal F/P with
the vehicle body’s earthing point GND with a  Dismantling/mounting quick connector before
jumper wire. 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 oil pipe
 Fuel System 1C-10

and connector.
Notice
Earthing
 The following tests can be conducted if jumper
necessary
1. Complete preparatory work before repair (see
Preparatory Work before Repair).
9. Turn the ignition switch to the “ON” position
2. Loosen the accumulator’s negative cable. to make fuel pump run for 10s or so.

Caution 10. Turn the ignition switch to the “OFF”

position. After 5 minutes, inspect the fuel
 To avoid the quick connector’s damage or oil pump’s oil pressure maintenance.
leakage, follow the “Explanations on plastic
fuel pipe dismantling” to complete the Fuel pump’s oil pressure maintenance: ＞
under-mentioned work (see the Fuel System, 410kpa(4.1kgf/cm2, 59psi)
Explanations on Plastic Fuel Pipe Dismantling)
11. Loosen the jumper wire.
3. Dismantle the main fuel hose (fuel supply
pipe assembly) from the main pipe (fuel rigid 12. Remove the special tool.
pipe). 13. Connect the main fuel hose (fuel supply pipe
4. Turn the switch handle along the direction assembly) with the main pipe(fuel rigid pipe).
illustrated in the figure to block the special If the oil pressure maintenance fails to accord
tool’s port. with standard, replace the fuel pump assembly
5. Push the special tool’s quick connector into (see Fuel Pump Assembly
the main pipe (fuel rigid pipe) till there is a Dismantling/Mounting)
“click” sound. 14. Confirm if around the quick plug’s bonding
6. Put the hose into a vessel in order to avoid the zone there is not oil leakage.
fuel overflow. 15. Complete the inspection work after
Air hose repair(see Inspection Work after Repair)
Main fuel pipe
Spray Nozzle Dismantling /Mounting
(see the Control System)

Inspection of Spray Nozzle

(see the Control System)
Switch
handle
Fuel Vaporation and Absorption
System
7. Remount the accumulator’s negative cable.
Location of Combustion Vaporation &
Caution Absorption System’s Components (in Engine
Compartment)
 Wrong connection with other wiring terminals
may lead to fault, and so caution is needed
during the connection process.
8. Connect the DLC’s wiring terminal F/P with
the vehicle body’s earthing point GND with a
jumper wire.
 Fuel System 1C-11

Inspection of Carbon Canister Assembly

1. Remove the carbon canister.
2. Block the interface on the carbon canister’s
ventilation side and the interface on the
carbon canister’s electromagnetic valve side.
3. Blow air into the carbon canister’s oil tank
interface, and Confirm if there is no air
leakage (If there is air leakage, replace carbon
Inspection of Open/Short Circuit
canister).
1. Inspect if there is open/short circuit on the
Inspection of Carbon Canister’s following wiring harnesses (If there is,
Electromagnetic Valve overhaul or replace corresponding wiring
harness).
Conduct simulation test
Open Circuit
Inspect the carbon canister’s electromagnetic
valve (see Fault Diagnosis, Inspection of Engine  Earthing circuit (the circuit between the carbon
Control System’s Working Condition, Inspection canister’s electromagnetic valve connector 1
of Carbon Canister’s Electromagnetic Valve); if it and ECU connector terminal 46, in which there
is abnormal, conduct further inspection to the is public connector)
carbon canister’s electromagnetic valve.
 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)

Connect with air hose

Main relay
Connect with cylinder

Connect with vacuum

tube, to carbon canister’s
electromagnetic valve
Connector on wiring harness’s side
(viewing from the electrode terminal side)
Inspection of Ventilation Condition
Notice
Short Circuit
 The following tests can be conducted if
 Electrical ground between carbon canister’s
necessary
electromagnetic valve connector terminal 2 and
1. Loosen the accumulator’s negative cable. ECU connector terminal 46, in which there is
public connector.
2. Dismantle the carbon canister’s
electromagnetic valve . 2. Remount the carbon canister’s
electromagnetic valve.
3. Inspect ventilation condition of the carbon
canister’s electromagnetic valve 3. Remount the accumulator’s negative cable.

(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 ).
 Intake and Exhaust System 1D-1

Chapter 4 Intake and Exhaust System

Table of Contents

Intake system ·······································································································1D-2

Exhaust System·····································································································1D-2
Accelerating System ·······························································································1D-3
 Intake and Exhaust System 1D-2

Intake system

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.
2. Dismantle parts according to the sequence
illustrated in the table.
3. Mount parts according to the sequence reverse to
the dismantling process.

1 Intake duct
2 Intake hose
3 Air filter

Exhaust System

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.
1. Loosen the accumulator’s negative cable.
2. Dismantle parts according to the sequence
illustrated in the figure.
3. Mount parts according to sequence reverse to the
 Intake and Exhaust System 1D-3

dismantling process.

1 Front muffler assembly

2 Rear muffler assembly
3 Rear oxygen sensor
4 Three-way catalyst converter

Accelerating System

Accelerating System Dismantling/Mounting

1. Dismantle parts according to the sequence
illustrated in the table;
2. Mount parts according to the sequence reverse to
the dismantling process.

1 Accelerator pedal’s wiring harness

2 Nut
3 Accelerator pedal

Notice
 Connect the wiring harness with the accelerator
pedal with caution, and insert the joint uprightly.
 Cooling System 1E-1

Chapter 5 Cooling System

Table of Contents

Warning on Cooling System Maintenance······································································1E-2

Engine Coolant ·····································································································1E-2
Inspection of Engine Coolant’s Liquid Level ····························································1E-2
Replace Engine Coolant·····················································································1E-2
Inspection of Engine Coolant Leakage····································································1E-3
Inspection of Heat Sink Lid ··················································································1E-3
Heat Sink Dismantling/Mounting················································································1E-4
Fan Parts Dismantling/Mounting ··········································································1E-4
Thermostat ····································································································1E-4
Water Pump Dismantling/Mounting·············································································1E-5
Fan Motor ···········································································································1E-5
Fan Relay············································································································1E-5
 Cooling System 1E-2

5. Mount the water tank’s drain plug and

subsidiary water tank.
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 Drain valve
Turn off the engine, and conduct further operation
after the engine cools down. Then, keep mindful
when removing the heat sink’s filler lid, and wrap
the filler lid with thick cloth and slowly turn it to the Warning
first stop position along the anticlockwise direction.
Alcohol or methanol antifreeze may damage
When the pressure declines, turn it along the reverse
aluminum parts on the engine, and so alcohol or
direction;
methanol shall not be used in the cooling system,
If there is not pressure, press the heat sink lid with and only the glycol-based coolant can be used.
cloth and dismantle it.
Only the softening (demineralization) water can
be used to mix with the coolant, and water
Engine Coolant containing minerals will compromise the coolant’s
effect.
Inspection of Engine Coolant’s Liquid Engine coolant will result in damage to the
Level lacquer surface, and so the engine coolant shall be
rinsed out in no time when it touches the lacquer
1. Confirm if the coolant’s liquid level in surface.
subsidiary water tank ranges between FULL and
LOW. 6. Refer to table below to select appropriate
volume percentage for mixture of water and
If the engine coolant’s liquid level stays below coolant. Add slowly the coolant into the
LOW, open the subsidiary water tank’s lid and add water tank till the coolant reaches the filler
the coolant near to the FULL mark. port.
If there is no coolant in the subsidiary water tank, Filling speed:1.0L(1.1USqt 、 0.9impqt)/min.
wait till the engine cools down, and open the heat
[Maximum Value]
sink’s filler lid to add coolant from the heat sink
filler port till the coolant’s liquid level can be seen Volume
from the filler port. Then, mount the heat sink’s Coolant Proportion at
filler lid, and continue adding the coolant near to percentage
protective agent 20℃{68ºF}
the FULL mark. Water Coolant

Replace Engine Coolant Higher than

65 35 1.054
-16℃{3ºF}
1. Dismantle the subsidiary water tank, drain the
Higher than
coolant in the subsidiary water tank, and clean 55 45 1.066
the subsidiary water tank. -26℃{-15ºF}
Higher than
2. Take off the heat sink’s filler lid, and loosen 45 55 1.078
the water tank’s drain valve to drain the -40℃{-40ºF}
coolant into a vessel.
3. Wash the heat sink with water till all colored
marks have been removed.
4. Dry completely the heat sink and subsidiary
water tank in the air.
 Cooling System 1E-3

Inspection of Engine Coolant Leakage

1. Inspect the coolant’s liquid level.
2. Take off the heat sink lid.
3. Connect the heat sink lid tester and SST
special maintenance tool with the heat sink’s
filler port.
Notice
 If the pressure surpasses 123kPa {1.25kgf/cm2,
17.8psi}, hose joint and other parts will be
damaged, which will in turn lead to leakage.
4. Make the heat sink reach specified
pressure:
Pressure:123kPa{1.25kgf/cm2, 17.8psi}

7. Open the heat sink’s filler lid, and add the

coolant from the filler port till the coolant’s
liquid level can be seen from the filler port.
8. Tighten the heat sink lid, and add the coolant
near to the FULL mark from subsidiary water
tank.
9. Start the engine and maintain the idling speed
4. Inspect if the pressure can be maintained. If
till the cooling fan begins to work.
cannot, inspect if the system suffers coolant
Notice leakage.

 If the coolant temperature is over high, stop the Inspection of Heat Sink Lid
engine to prevent the coolant from being
overheated. Warning

10. Conduct the following operations after the  When the engine is running or the engine and
engine temperature rises: heat sink are hot, do not dismantle the heat sink
lid because hot coolant and vapor may spout,
(1) Make the engine run for one minute at the which will result in serious casualties and
rotating speed of 4000rpm; damage to the engine and cooling system
(2) Make the engine run for one minute at the  Turn off the engine, and conduct further
idling speed; operation after the engine cools down. Then,
wrap the heat sink lid with thick cloth carefully,
(3) Repeat Step 1 and Step 2 for several times; and slowly turn it to the first stop position
(4) Turn on the front/rear heater unit (if has), and along the anticlockwise direction. When the
confirm if there is hot air exhausted from the pressure declines, turn it along the reverse
heater unit’s ventilation opening. direction;

11. Stop the engine and wait till it cools down.  If there is not pressure, press the heat sink lid
with cloth and dismantle it.
12. Confirm if there is coolant leakage.
1. Use the SST special service tool to connect
13. Inspect the coolant’s liquid level. If the level the heat sink lid with the tester.
is relatively low, add the coolant into the
subsidiary water tank till it reaches the F 2. Increase the pressure little by little.
mark. 3. Inspect if the pressure stays within the
specified range. If the pressure can keep for
10s, it indicates that the heat sink lid is
 Cooling System 1E-4

normal. 6 Heat sink assembly

Pressure range:94-122kPa{0.95-1.25kgf/cm2,
13.5-17.7psi}
Thermostat
Thermostat Dismantling/Mounting
1. Drain the engine coolant.
2. Dismantle parts according to the sequence
illustrated in the table.
3. Mount parts according to the sequence
reverse to the dismantling process.

Heat Sink Dismantling/Mounting

Fan Parts Dismantling/Mounting

1. Disconnect the accumulator’s negative cable;
2. Drain the engine coolant;
3. Dismantle the front grille;
4. Dismantle the heat sink bracket bolt and ① Upper heat sink hose
condenser fixing bolt;
② Thermostat lid
4. Dismantle the subsidiary water tank’s hose
③ O-ring
(connect with the heat sink end);
④ Thermostat Mounting Attentions
5. Dismantle parts according to the sequence
illustrated in the table; Instructions for installing the thermostat
6. Mount parts according to the sequence 1. Mount the thermostat onto the thermostat
reverse to the dismantling process. housing, pay attention to the thermostat’s
direction, with clamping pin facing upward.
(8.8-12.7)N*m
Clamping pin

Thermostat Inspection
1. Inspect thermostat according to items below.
—Valve temperature when being turned on or off.
(4.5-6.0)N*m —Valve’s critical temperature in full opening or
full closing state. If technical requirements
1 Upper water pipe cannot be met, replace the thermostat.
2 Lower water pipe
Condition Action Temperature℃
3 Fan wiring harness connector
4 Subsidiary water tank assembly Temperature rising Initial
81
5 Fan assembly process opening
 Cooling System 1E-5

Full
93
opening
Start
90
Temperature closing
decline process Full
79
closing

Water Pump Dismantling/Mounting

See Engine Water Pump Dismantling/ Mounting

for the water pump dismantling/ mounting.
1 Cooling fan blade
2 Fan motor assembly
Fan Motor

Fan Motor Inspection Fan Relay

1. Confirm if the accumulator has been fully
charged. Inspection of Fan Relay

2. Connect the accumulator’s positive electrode 1. Disconnect the accumulator’s negative cable
and amperemeter with the fan motor plug. 2. Dismantle the fan relay from the relay box.
3. Confirm if the fan motor runs stably while
High-speed relay socket
being driven by standard current. Replace fan Low-speed
motor if it fails to meet technical relay socket
requirements.

Connect with the power supply end

Standard Current:
Connect with the ECU control end
①Connected, High-speed Action 11-12.5A [12V]
①Disconnected, Low-speed Action 9-10.5A [12V]
Fan Motor Dismantling/Mounting
1. Dismantle the cooling fan.
2. Dismantle parts according to the sequence
illustrated in the table.
Use the ohmmeter and 12V power supply to
3. Mount parts according to the sequence reverse inspect the fan relay’s quality. If the relay is unable
to the dismantling process. to run normally or meet technical requirements,
replace the fan relay. See table below for the relay
inspection:
Compliance
Step Port
standard
1 Ohmmeter tests Infinite
 Cooling System 1E-6

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

Relay Diagram
 Accessory-Belt 1F-1

Chapter 6 Engine Accessory-Belt

Table of Contents
Driving Belt ·········································································································1P-2
A/C Compressor Multi-wedge V Belt Adjustment ····························································1P-2
Power Steering Pump Belt Adjustment ·········································································1P-3
 Accessory-Belt 1F-2

Driving Belt

If necessary, inspect the driving belt’s distortion

and tension. When measuring

Inspection of Driving Belt’s Distortion

When mounting
Notice:
 After 30 minutes since the automobile engine
stops, inspect the belt distortion with a belt
tensiometer, in order to confirm if the belt A/C Compressor Multi-wedge V Belt
tension stays within the standard value. 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: 39.5±4N·m
5. Tighten the power generator’s fixing bolt.
Tightening torque: 20±2N·m

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

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.

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 Distortion (mm/98N)
the tension pulley nut B, Tightening
torque:40～48N.m
Driving Belt New Old
Notice
A/C Compressor Belt 600N-700N500N-600N
 If mounting new driving belt or running
Power Steering Pump Belt400N-500N300N-350N
driving belt for not greater than 5minutes,
adjustment shall be made according to the new
part’s standard value.
 If running the driving belt for more than 5
minutes, adjustment shall be made according
to the old part’s standard value.
 Engine Suspension 1G-1

Chapter 7 Engine Suspension

Table of Contents

Engine Suspension ·································································································1G-2

Engine Dismantling/Mounting ·································································1G-2
Engine Suspension Dismantling/Mounting···················································1G-2
Engine Suspension Diagram····································································1G-4
 Engine Suspension 1G-2

according to the sequence illustrated in the

figure.
Engine Suspension
14. Mount parts according to the sequence
Engine Dismantling/Mounting reverse to the dismantling process.

Warning 15. Inject A/C refrigerant and discharge the

power steering liquid, gearbox oil, and engine
 Fuel vapor is combustible, and keep away the coolant.
spark and naked flame.
16. Correct the driving belt’s tension (see Driving
 Fuel leakage and splash are dangerous, which Belt, Driving Belt Dismantling/Mounting).
will irritate the skin and eye. Due to this,
follow the “Oil Circuit Safety Inspection 17. Star the engine and conduct the following
Procedure” (see Fuel System, Preparatory inspection work:
Work before Repair). (1) Inspect the belt pulley and driving belt’s
Complete the dismantling work deflection and interference.

 Respectively discharge A/C refrigerant, (2) Inspect if there is engine oil, engine
power steering liquid, gearbox oil, and engine coolant, gearbox oil, and fuel leakage.
coolant: (3) Inspect the idling speed (see Engine
1. Disconnect the accumulator’s negative cable. Running, Idling Speed Inspection).

2. Dismantle the left/right driving axles (see 18. Confirm the road test.
Driving Axle Dismantling/Mounting). 19. Inspect the engine oil, engine coolant,
3. Dismantle the air filter (see Intake System gearbox oil and power steering liquid’s level
Dismantling/Mounting). again.
Engine Suspension Dismantling/Mounting
4. Dismantle heat sink(see Heat Sink, Heat Sink
Dismantling/Mounting). Engine1# Suspension Bracket Dismantling/
Mounting
5. Dismantle the throttle cable(see Throttle
Cable Inspection /Adjustment). Dismantle engine1# suspension bolt ①— take off
engine1# suspension to inspect if the rubber is
6. Dismantle the fuel hose (see Fuel System, broken, hardened, or damaged --Dismantle
Preparatory Work before Repair)(see Fuel engine1# Bracket Bolt ② (Engine End).
System, Inspection Work after Repair).
Mount parts according to the sequence reverse to
7. Dismantle three-way catalyst converter the dismantling process.
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
Engine3# Suspension Bracket Dismantling/
gearbox.
Mounting
11. Dismantle power steering pump’s oil pipe
Dismantle 3# suspension bracket bolt and nut ③
connection.
(engine end)--Dismantle engine3# suspension bolt
12. Dismantle A/C compressor’s pipeline ② (body end)—take off engine3# suspension to
connection. inspect if the resonance block rubber is damaged,
and inspect if 3# suspension seat suffers oil
13. Dismantle the engine and engine suspension leakage or damage.
 Engine Suspension 1G-3

Mount parts according to the sequence reverse to

the dismantling process.
 Engine Suspension 1G-4

Engine4# Suspension Bracket

Dismantling/Mounting
Dismantle 4# suspension bracket bolt ①
(transmission end)--Dismantle 4# suspension nut ③
—take off 4# suspension to inspect if the rubber is
broken, hardened, or damaged --Dismantle engine4#
suspension bolt ② (body end). Mount parts
according to the sequence reverse to the dismantling
process.

Engine Suspension Diagram

1 Engine1# suspension
2 Engine3# suspension
3 Engine4# suspension

1
 MF515L Transmission 1H-1

Chapter 8 MF515L Transmission

Table of Contents

MF515L Transmission·····························································································1G-2
Overview ······································································································1G-2
Transmission Troubleshooting and Maintenance ························································1G-3
Troubleshooting ······························································································1G-3
Transmission Emits High Noise or Abnormal Sound Reasons and Solutions ·······················1G-3
Transmission Assembly Dismantling······································································1G-5
Transmission Components Dismantling, Overhaul, and Remounting ································1G-7
Differential Unit Dismantling and Mounting·····························································1G-12
Left/right box body ··························································································1G-14
Attached Table 1: Special Tools············································································1G-15
Attached Table 2: Reference List of MF515L
Transmission Bolt Tightening Torques····································································1G-16
 MF515L Transmission 1H-2

MF515L Transmission

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. 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. Gearshift Actuator

Transmission assembly

Gear Mechanism
 MF515L Transmission 1H-3

Transmission Troubleshooting and which should be mainly attributed to the gear

Maintenance check ring’s serious abrasion

The gearshift control lever’s motion is transmitted Solution: Replace the gear check ring.
to transmission shaft and shift shaft through the e. Reason: shift fork’s abrasion and distortion
transmission control shaft, and then transmitted to
the transmission and gear shift lever, shaft, and Solution: Calibrate the shift fork manually when it
fork or arm through the transmission cross arm and suffers distortion. Replace it when suffering
yoke. In addition, transmission interlocking plate is serious abrasion.
prepared to avoid the gear’s double engagement. In
the mechanism there are five-gear and reverse-gear f. Reason: Synchronizer gear housing, gear
cams, cam guide spring, and fifth gear-reverse gear sleeve, or gear ring suffer abrasion
interlocking guide pin, in order to avoid the gear’s Solution: If there is out of gear, replace the
direct shifting from fifth gear to reverse gear. wear-out parts.
1) When the transmission shifts to the fifth gear, g. Reason: After being adjusted, transmission
the fifth gear-reverse gear shift cam will fails to reach the “Neutral Gear” position, or
rotate with the shift shaft along the clockwise the adjusting mechanism is loosened.
direction, and cam return spring will jack the
cam to shift to the reverse gear. Solution: Place it to the “Neutral Gear”’ position
again, and adjust the clearance.
2) Shift from the fifth gear to the neutral gear is
permitted, but further shift to the reverse gear h. Reason: the engine’s connection with the
is prohibited. transmission and complete vehicle is too loose,
or the clearance adjustment is inappropriate.
3) Shift position is located at the neutral gear
position of the fifth gear-reverse gear (see Fig. Solution: Adjust the clearance
1-4). When the shift shaft moves upwards to
facilitate the gear shift lever’s shift from fifth Transmission Emits High Noise or Abnormal
gear to the reverse gear, shift cam will stop Sound Reasons and Solutions
due to blockage by the guide rod. a. Reason:Transmission has insufficient oil or the
4) At this time, the system can shift to the oil is not clean
reverse gear when there is not interference by Solution: Inject sufficient oil or replace the oil.
shift cam.
b. Reason: Gear’s axial clearance is too large
Troubleshooting
Solution: Replace gear or gear check ring.
Transmission’s main faults and troubleshooting
methods: c. Reason: Gear suffers abrasion or gear teeth is
broken
Out of Gear
Solution: If the gear backlash exceeds the specified
Reasons and Solutions: range, replace the gear. Standard backlash of the
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 e. Bearing suffers damage or abrasion
and distortion
Solution:Replace bearing.
Solution: replace the shift rocker in time.
f. Bearing press plate suffers damage or
c. Reason: Self-locking spring’s elasticity is abrasion.
weakened
Solution: Replace the gear check ring.
Solution: Replace the self-locking spring in time.
Shifting Difficulty
d. Reason: Gear’s axial clearance is too large,
 MF515L Transmission 1H-4

Reasons and Solutions until the automobile has been lifted. If there is
leakage, remedial actions shall be taken in
a. Shift rod or shift fork incurs distortion or time.
uneven abrasion
3) Drain original lubricating oil and inject new
Solution: Replace parts. and specified lubricating oil.
b. Self-locking steel ball and shift fork shaft’s 4) Drain plug and oil filler plug’s torque
groove suffer abrasion 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.
Differential Right/Left Oil Seal Replacement
Oil Leakage
1) Jack the automobile and drain the
a. Oil leakage at the drain plug transmission lubricating oil.
Solution: first, the plug’s tightening torque is less 2) Dismantle the driving shaft from the
than the specified value, and so inspect the tightening differential.
torque. If the tightening torque does not comply with
requirements, tighten the plug. Second, there is 3) Use the special tool and hammer to dismantle
deflection in engagement or thread teeth damage, the oil seal and mount a new part. special
replace corresponding parts. tools(A): oil seal erector1(right); oil seal
erector2(left)
b. Oil Leakage at Sealing Parts
Oil seal’s mounting degree “a” on the differential
Solution: Replace sealing parts while abiding by side: 1.0-1.5mm
operation specifications.
4) Smear lubricating grease on the oil seal’s rim,
c. Oil Leakage at the Bonding Surface in addition to inspecting the contacting part
Solution: Conduct inspection and make all between the driving shaft and oil seal, as well
connection bolt’s tightening torques accord with as ensure the smoothness.
specifications. “A”: Suzuki Lubricating Grease A.
d. Oil Leakage at the Input Shaft’s Seal Ring
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.
On-spot Maintenance
Replace Oil
1) While replacing and inspecting the lubricating
oil, be sure to stop the engine and lift the
automobile steadily.
2) Oil level and leakage cannot be inspected
 MF515L Transmission 1H-5

Differential oil seal replacement 2) Dismantle the reverse gear shaft bolt from
lateral side of transmission;
5) Mount driving shaft into the differential.
3) Use the soft hammer to knock the left box’s
Caution rim and dismantle the left box.
 When inserting the driving shaft’s bolt, do not Special tool: Box splitter (A).
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.

Transmission Assembly Dismantling

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

1 Locking bolt assembly

2 Assembling bolt M8×20(four)
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
1. Dismantle the assembling bolt to split the box
1) Dismantle the assembling bolt from internal
and external sides of the transmission;
Split the Box
 MF515L Transmission 1H-6

Dismantle Reverse Gearshift Mechanism and 2 Intermediate shaft components

Reverse Gear
3 Input shaft components
1) Take off input shaft’s oil tray and shim, and 4 Reverse gear shaft
the intermediate shaft’s left bearing adjusting
5 Reverse gear assembly
shim;
2) Dismantle the reverse shift fork bolt, and take 5) Use the soft hammer to knock input shaft
off reverse shift fork assembly; lightly;
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.

Dismantle the reverse gear shift mechanism and Take off the gear mechanism and gear shift
reverse gear mechanism
1 Internal gear shift mechanism 1 Internal gear shift mechanism
2 Input shaft’s oil tray 2 Input shaft oil tray
3 Input shaft’s shim 3 Input shaft shim
Intermediate shaft’s left bearing adjusting
4 Intermediate shaft’s left bearing
shim 4
5 5. reverse shift fork bolt adjusting shim

6 6. reverse shift fork assembly 5 Reverse gear shaft bolt

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

Take off other components

1 Right box
2 Magnet
Intermediate shaft’s right bearing
3
outer ring
Dismantle Gear Mechanism and Gear Shift
Mechanism 4 Intermediate shaft oil tray
1 Differential unit
 MF515L Transmission 1H-7

1) Take off other components  To prevent the gear teeth from being damaged,
make the teeth lean against the smooth and
2) Dismantle differential unit from the right box straight side of the bearing puller.
3) Dismantle bolt, Caution
4) Use special tools to dismantle the  Be sure to use the puller’s flat surface, in
input shaft’s oil seal order to avoid the damage to third gear
Special tools: (A): Slide shaft; 6) Take out the third gear needle bearing from
(B): Oil seal ejector the shaft.
1.Input shaft
5) Use special tools to dismantle the
2.Right bearing
intermediate shaft’s ring bearing outer ring.
3.Bearing puller
Special tools: (A): slide shaft;
(B):Bearing ejector
6) Dismantle the differential’s right oil seal from
right box.

Dismantle the input shaft’s right bearing

1 Input shaft
2 Right bearing
3 Bearing puller

Dismantle the input shaft’s oil seal

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

Transmission Components Dismantling, Dismantle the input shaft’s left bearing, fifth gear,
Overhaul, and Remounting and fifth-gear synchronizer unit
Dismantle input shaft’s components
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. Dismantle the fifth gear shaft sleeve, four gear
shaft sleeve, four gear synchronizer gear ring,
4) Take off the fifth gear shaft sleeve, fourth fourth gear assembly, fourth gear needle bearing,
gear shaft sleeve, fourth gear synchronizer 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 Assemble Input Shaft Components
synchronizer unit.
Notice:
 MF515L Transmission 1H-8

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.

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 1 Gear wheel
7 High-speed synchronizer gear hub 2 Gear ring
8 High-speed synchronizer slide block
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
4) Mount the high-speed synchronizer onto the
15 Input shaft fifth gear needle bearing hub, insert three slide blocks, and then mount
16 Input shaft fifth gear assembly the spring according to the illustration.
17 Fifth gear synchronizer gear ring
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 1 High-speed synchronizer spring
shaft, and application of used gear ring is 2 Slide block
prohibited.
3 High-speed synchronizer gear hub
 MF515L Transmission 1H-9

High-speed synchronizer gear Notice

4
sleeve  Make sure the four gear shaft sleeve is
properly mounted.
5) Use special tool and hammer to mount the
right bearing.
Special tools(A):bearing erector

1 Shaft sleeve
2 Needle bearing
3 Gear ring
4 Fourth gear

1 Right bearing 9) Mount the fifth gear shaft sleeve and needle
bearing, smear lubricating grease on the
2 Input shaft
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 10) Press and mount the left bearing with special
gear and synchronizer gear ring. tool and hammer.
7) Use special tool and hammer to drive in the special tools(C):bearing erector4
high-speed synchronizer assembly.
Dismantle Intermediate Shaft Components
Note: when pressing and mounting the gear hub
and gear sleeve, make sure the synchronizer gear 1) Use the puller and holding-down device to
ring’s teeth groove aligns with the synchronizer pull out the left conical bearing.
unit’s slide block.
Caution
After pressing and mounting the synchronizer
unit, inspect the third gear’s free rotation. Use the puller and holding-down device that can
support at least 5t load.
Special tools(B):bearing erector1

1 Holding-down device
2 Intermediate shaft’s left bearing
1 Input shaft 3 Puller
2 Third gear 2) Use special tool to dismantle the fifth gear
3 Gear ring snap ring
4 Synchronizer unit Special tools(A):snap ring plier

7) Mount the four gear shaft sleeve and needle 3) Use puller and holding-down device to pull
bearing, smear lubricating grease on the out the fifth gear and fourth gear together.
bearing, and then mount synchronizer gear
Notice
ring and fourth gear.
 To prevent the gear teeth from being damaged,
 MF515L Transmission 1H-10

make the teeth lean against the smooth and shaft.

straight side of the bearing puller.
7) Use the puller to dismantle right conical
4) Use the puller to operate the second gear and bearing.
make use of the holding-down device to pull
out the third gear and the second gear
together. After that, pull out the needle
bearing and third/ fourth gear spacer bushes.
Caution
 If the extrusion force exceeds 5t, release the
extrusion immediately, and remount the
puller bracket. Then, continue the push and
compression.
1 Metal rod
Intermediate shaft’s right conical bearing
2
puller

Mount Intermediate Shaft Components

1) Clean all parts thoroughly, inspect if there is
abnormal situation, and mount new parts
according to demands.

1 Intermediate shaft
2 Third/fourth gear spacer bushes
3 Third gear
4 Second gear 1. Intermediate shaft’s left bearing assembly 2.
Intermediate shaft snap ring 3. Intermediate shaft
3) Take out the second gear synchronizer gear fifth gear 4. Intermediate shaft fourth gear 5.
ring. Third/fourth gear spacer bush 6. Intermediate shaft
third gear 7. Intermediate shaft second gear
4) Use the puller to operate the first gear, and
assembly 8. Second gear needle bearing 9.
make use of the holding-down device to pull
Second gear shaft sleeve 10. low-speed
out the low-speed synchronizer unit, and first
gear and second gear shaft sleeves. synchronizer gear ring components 11. low-speed
synchronizer unit 12.intermediate shaft second
Puller (with plane gear needle bearing 13. intermediate shaft first
facing upward) 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
the ring and the gear, and then inspect every
gear’s crowned teeth, ring, and gear ring.
After that, determine if the replacement shall
be conducted.
1 Low-speed synchronizer unit Clearance “a”: standard value:1.45-2.35mm
2 First gear Ultimate value:0.5mm
3 Puller(with plane facing upward)

5) Dismantle the synchronizer unit.

6) Take out first gear needle bearing from the
 MF515L Transmission 1H-11

1. Right conical bearing

2. Intermediate shaft

1 Right conical bearing

1 Right conical bearing
2 Intermediate shaft
2 Synchronizer gear ring
3) Ensure the lubrication, and blow air into
every oil port to inspect if there is blockage. 6) Mount the needle bearing, smear the
lubricating grease, and then mount the first
gear and first gear synchronizer’s gear ring
components.
7) Use special tool and hydraulic pressure to
drive in the low-speed synchronizer unit.
Notice
1 intermediate shaft  Lean the shaft against special tool according
2 Oil port to the illustration, in order to prevent the
conical bearing retainer from being extruded.
4) Mount the low-speed synchronizer onto the
gear sleeve, insert three slide blocks, and the  When pressing and mounting the
mount the spring according to the illustration. synchronizer assembly, make sure the
synchronizer slide block groove is aligned
Notice: Direction will not be specified to slide with the slide block
blocks, but slide blocks are defined as an
assembled unit.  After pressing and mounting the
synchronizer assembly, inspect the first
gear’s free rotation.
Special tools(A):bearing erector3;
(B):bearing erector2;
(C):bearing erector5

1 Low-speed synchronizer snap ring

2 Slide block
3 Low-speed synchronizer gear hub
4 Low-speed synchronizer gear sleeve

5) Use special tool and hammer to tighten the 1 Low-speed synchronizer unit
right conical bearing. 2 First-gear synchronizer gear ring components
Special tools(A):bearing erector3 3 Intermediate shaft first gear
4 Intermediate shaft right bearing
A Key groove aligned with slide block
 MF515L Transmission 1H-12

8) Mount second gear shaft sleeve and needle 11) Mount the intermediate shaft snap ring with
bearing, smear lubricating grease on the special tool and the left conical bearing with
bearing, and then mount second gear hammer.
synchronizer ring and second gear.
Notice
Caution
 To protect the conical bearing, make the shaft
 Make sure the shaft sleeve is properly lean against the special tool according to the
mounted illustration.
Special tools (A):bearing erector3
(E):bearing erector4

1 Intermediate shaft first gear

2 Low-speed synchronizer unit
1. Left conical bearing
3 Shaft sleeve 2. Fourth/fifth gear
3. Right conical bearing
4 Needle bearing
Second gear synchronizer gear ring 1 Left conical bearing
5
components
2 Fourth/fifth gear
6 Intermediate shaft second gear
3 Right conical bearing
9) Use special tool and holding-down device to
Differential Unit Dismantling and
press and mount the third gear and spacer
bush. Mounting

Notice Differential Unit Dismantling

 It is recommended that bush and third gear 1) Use special tool to dismantle the right
shall be firstly pressed and mounted before bearing.
the fourth gear pressing and mounting, which Special tools(A)bearing puller;(B) bearing puller
can prevent the intermediate shaft from being accessories
excessively extruded.
Notice
Special tools (A):bearing erector3
 As for the bearing dismantling, if semilune
(D): bearing erector puller is used together with holding-down device,
the main reduction gear shall be dismantled in
advance.
2) Use the puller to dismantle the left bearing,
during which protect well the bearing.

1. Third/fourth gear spacer bushes 3) Use the soft bench clamp to clamp the
2. Third gear differential housing, and dismantle eight
3. Second gear differential bolts. After that, take off the main
reduction gear.

1 Third/fourth gear spacer bushes 4) Use the snap ring plier to dismantle the
differential planet gear shaft check ring, and
2 Third gear then dismantle components and parts.
3 Second gear

10) Press and mount the fourth gear and fifth

gear ditto.
 MF515L Transmission 1H-13

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
3. Planet gear 4. Differential spacer 5.Planet
bearing (see the figure) and follow the Step 4)
gear shaft 6.Planet gear shaft
to press and mount the right bearing.
7. Main reduction gear 8.Differential bolt
6) Use soft bench clamp to clamp the differential
9.Differential right bearing 10.Differential half
assembly, mount main reduction gear, and then
shaft
use eight bolts to tighten the differential
1) Mount the differential gear according to the assembly according to required torque.
illustration and follow method below to
Notice
measure the differential’s pushing clearance.
 Other bolts beyond requirements shall not be
Special tools(A): dial gauge;(B): magnet base
used.
differential gear pushing clearance: 0.03-0.40mm
Tightening torque
Left side: use the soft bench clamp to clamp the
differential assembly, and also insert the dial feeler (a):80-100N·m
gauge’s measuring terminal onto the gear’s upper
surface. Use two screwdrivers to move the gear
upwards and downwards, in addition to reading the
gauge feeler gauge’s pointer travel.
Right side: use similar method and insert the dial
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
 MF515L Transmission 1H-14

Differential gear oil seal’s mounting depth:

“a”:1.0-1.5mm
Left Box Body
1) Use strap hammer and special tool to mount
1. Main reducer gear bolt the oil seal on the left side of differential till
2. Final reduction gear the height difference with the housing surface
3. Torque wrench ranges between 1.0mm and 1.5mm.
4. Soft bench clamp
Notice
1 Differential bolt  Make the oil seal’s spring side face inward
2 Final reduction gear
Special tools(A):Oil seal erector2: differential oil
3 Torque wrench seal’s mounting depth: “a”: 1.0-1.5mm
4 Soft bench clamp

Left/right box body

Right box body
1) Mount the input shaft’s oil seal and keep the
spring side upward. During the mounting
Oil seal
process, use special tool and hammer.
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.
Special tools (B): Mounting connection rod
(C): Bearing outer ring erector
Special tools (D):Seal ring erector
3) Use special tool and hammer to mount the
differential’s right oil seal till it keeps even
with the housing surface.
Notice
 Make differential oil seal’s spring side face
inward
Special tools (E): Oil seal erector1
 MF515L Transmission 1H-15

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
 MF515L Transmission 1H-16

Attached Table 2: Reference List of MF515L 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
Automatic Gearshift Mechanism Dismantling/Mounting ··············································1J-2
 Gearshift Mechanism 1J-2

elements;
Gearshift Mechanism 2. Follow the illustration to dismantle parts, and
the mounting sequence is reverse to the
Manual Gearshift Mechanism dismantling sequence.
Dismantling/Mounting 3. After the mounting, confirm if the mechanism
is fixed and can run stably.
1. Firstly, dismantle the assistant instrument
platform assembly, and then dismantle the
wiring harness buckle that is fixed at the gear
shift mechanism;
2. Follow the illustration to dismantle the gear
shift mechanism, and the mounting sequence
is reverse to the dismantling sequence.
3. After the mounting, confirm if the mechanism
is fixed and can run stably.

1 Gearshift handle
2 Automatic gearshift lever assembly
3 Cable assembly
4 Flange nut
5 Locking bolt
6 Locking bolt
7 Flange nut
8 Gearshift cable bracket
1 Gearshift handle
Notice
2 Flange nut
3 Locking bolt 1. On the gear display cover assembly there
are four clamp pins that are respectively engaged
4 Flange nut with four clamp slots on the gearshift lever base
5 Cable assembly assembly, and they help fasten the parts. During
6 Manual gearshift lever assembly the dismantling process, force shall be added
slowly to take off the gear display cover along
Notice “right front-right rear-left rear -left front”
sequence.
1. Control the cable and connect it with
the transmission correctly (no reverse mounting in 2. When dismantling the gearshift cable
gear selection and shift) assembly, the gear shift lever shall be placed on P
position, during which tightening gearshift rocker and
2. Control the cable fixing bracket and gearshift cable’s nuts at the transmission’s upper
avoid reverse mounting gearshift rocker shall be loosened.
3. During the dismantling process, keep 3. When mounting the gearshift cable,
cautious and do not injure the cable buckle. After make sure the gearshift mechanism assembly’s
the assembling, inspection shall be conducted. gearshift lever is placed at the P position, and
gearshift rocker on the transmission is also placed
Automatic Gearshift Mechanism at the P position, only after that can the nuts at
gearshift rocker be tightened. After the tightening,
Dismantling/Mounting make sure the all gear indicators have normal
display.
1. Firstly, dismantle the assistant instrument
platform assembly, and then disconnect the
wiring harness connectors that are connected
with gear shift mechanism’s electrical