Shineray Auto Repair Manual

Contents

CHAPTER FINISHED VEHICLE APPLICATION AND MAINTENANCE ........................................................ 5

SECTION MAJOR TECHNICAL PARAMETER ................................................................................................................ 5

. Basic parameter ..................................................................................................................................................... 5

. Structure parameter ............................................................................................................................................... 7

. Other parameters (table 1-6) ................................................................................................................................. 7

SECTION APPLICATION OF FINISHED AUTO AND NOTICES ............................................................................................. 8

I. Elementary Knowledge for Application of New Auto ................................................................................................ 8

1. Inspection for New Auto ........................................................................................................................................... 8

II. Driving of Auto ...................................................................................................................................................... 10

III. Proper use of the fuel, lubricants and fluids ......................................................................................................... 13

IV. Use of the body facilities and accessories ............................................................................................................. 17

SECTION III FULL AUTO MAINTENANCE ........................................................................................................................... 18

I. Maintenance table ................................................................................................................................................... 18

II. Repair and maintenance ........................................................................................................................................ 23

CHAPTER II ENGINE MECHANICAL PART ............................................................................................................ 41

SECTION I OVERALL STRUCTURE OF ENGINE ................................................................................................................... 41

I. Composition of engine............................................................................................................................................. 42

II. Main features of the engine .................................................................................................................................... 43

I. Cleaning and protection .......................................................................................................................................... 43

II. Engine maintenance overview ............................................................................................................................... 44

III. Engine maintenance without disassembly ............................................................................................................ 46

Engine removal ...................................................................................................................................................... 46

SECTION CRANKSHAFT CONNECTING ROD .................................................................................................................. 47

I. Composition ............................................................................................................................................................ 48

II. Common faults diagnosis of crankshaft connecting rod ........................................................................................ 48

III. Maintenance of the crankshaft connection rod ..................................................................................................... 50

SECTION VALVE TRAIN ............................................................................................................................................... 61

. Composition of valve train ................................................................................................................................... 62

. Common fault diagnosis of cam valve train ......................................................................................................... 64

. Maintenance of cam valve train ........................................................................................................................... 65

SECTION LUBRICATING SYSTEM ................................................................................................................................. 71

. Composition of engines lubricating system ......................................................................................................... 72

. Common fault diagnosis of lubricating system ..................................................................................................... 73

. Maintenance of lubricating system ....................................................................................................................... 74

. Positive crankcase ventilation system (PCV system) ............................................................................................ 74

SECTION ENGINE COOLING SYSTEM ............................................................................................................................ 75

. Major component of cooling system ..................................................................................................................... 76

. Common fault of cooling system ........................................................................................................................... 77

. Repair and maintenance ....................................................................................................................................... 78

. In-car maintenance ............................................................................................................................................... 82

. Composition of starting system ............................................................................................................................. 86

. Common fault diagnosis of starting system .......................................................................................................... 87

. Repair and maintenance of starter ....................................................................................................................... 90

SECTION ENGINE ASSEMBLY ....................................................................................................................................... 95

. Assembly of internal parts of engines ................................................................................................................... 96

. Installation method of engines ............................................................................................................................ 106

. Check .................................................................................................................................................................. 107

. Engine vacuum test ............................................................................................................................................. 108

. Oil pressure check .............................................................................................................................................. 109

SECTION MAJOR TROUBLES AND TROUBLESHOOTING METHOD OF MECHANICAL ENGINE PARTS ............................... 111

CHAPTER DRIVE SYSTEM ................................................................................................................................... 125

SECTION FIVE SPEED TRANSMISSION ........................................................................................................................ 125

. Composition........................................................................................................................................................ 125

. Fault diagnosis ................................................................................................................................................... 125

.In-car maintenance .............................................................................................................................................. 129

. Transmission repair ............................................................................................................................................ 134

. Required servicing materials .............................................................................................................................. 152

. Special tools ....................................................................................................................................................... 154

SECTION CLUTCH ..................................................................................................................................................... 155

. Composition........................................................................................................................................................ 155

. Trouble diagnosis ............................................................................................................................................... 156

. In-car maintenance ............................................................................................................................................. 157

. Parts repair ........................................................................................................................................................ 158

. Servicing materials ............................................................................................................................................. 162

. Special tool ......................................................................................................................................................... 162

SECTION DRIVE SHAFT ............................................................................................................................................. 162

. Composition........................................................................................................................................................ 162



. Special tools ....................................................................................................................................................... 167

SECTION DIFFERENTIAL ............................................................................................................................................ 167

. Composition........................................................................................................................................................ 167

. Trouble diagnosis ............................................................................................................................................... 168


. Disassembly and repair ...................................................................................................................................... 170


. Special tools ....................................................................................................................................................... 179

DRIVE SYSTEM ....................................................................................................................................................... 180

SECTION FRONT SUSPENSION .................................................................................................................................... 180

. Composition........................................................................................................................................................ 180

. Check and Adjustment ........................................................................................................................................ 182


.Special tools ........................................................................................................................................................ 194

SECTION REAR SUSPENSION...................................................................................................................................... 195

. Composition........................................................................................................................................................ 195

. Disassembly and assembly ................................................................................................................................. 196


. Tightening torque of fastener ............................................................................................................................. 205

SECTION WHEEL AND TIRE ........................................................................................................................................ 206

. Composition........................................................................................................................................................ 206

. Trouble diagnosis .......................................................................................................................................... 208

. Maintenance and slight adjustment .................................................................................................................... 209


CHAPTER STEERING SYSTEM ........................................................................................................................... 213

SECTION TROUBLE DIAGNOSIS .................................................................................................................................. 213

. Diagnosis of common troubles ........................................................................................................................... 213

. Diagnosis of tire troubles ................................................................................................................................... 218

. Vibration fault diagnosis .................................................................................................................................... 220

SECTION FRONT WHEEL ALIGNMENT ......................................................................................................................... 221

. Composition........................................................................................................................................................ 221

. Technical requirement of tightening torque ........................................................................................................ 224

SECTION RACK AND PINION ...................................................................................................................................... 224

. Composition........................................................................................................................................................ 224

. Fault diagnosis ................................................................................................................................................... 225



. Special tools ....................................................................................................................................................... 234

SECTION 3 STEERING WHEEL AND STEERING COLUMN ................................................................................................... 234

. Composition........................................................................................................................................................ 234

. Fault diagnosis ................................................................................................................................................... 235



. Special tool ......................................................................................................................................................... 240

CHAPTER BRAKING SYSTEM .............................................................................................................................. 241

SECTION SYSTEM COMPOSITION AND OPERATING PRINCIPLE .................................................................................... 241

. Booster assembly ................................................................................................................................................ 241

. Master cylinder assembly ................................................................................................................................... 242

. Load sensing proportioning valve ...................................................................................................................... 243

. Front wheel disc brake ....................................................................................................................................... 244

. Rear drum brake assembly ................................................................................................................................. 245

. Parking braking system ...................................................................................................................................... 246

SECTION FAULT DIAGNOSIS ....................................................................................................................................... 247

. Check on brake fluid ........................................................................................................................................... 247

. Brake road test ................................................................................................................................................... 247

. Braking system fault diagnosis table .................................................................................................................. 247

SECTION CHECK AND ADJUSTMENT .......................................................................................................................... 252

SECTION IN-CAR MAINTENANCE ............................................................................................................................... 260

SECTION SERVICING MATERIALS, TIGHTENING TORQUE AND SPECIAL TOOLS ............................................................ 289


. Tightening torque ................................................................................................................................................ 289

. Special tools ....................................................................................................................................................... 290

CHAPTER CAR BODY MAINTENANCE ................................................................................................................. 291

SECTION STRUCTURE AND MAINTENANCE OF SY1020 FRONT DOOR ........................................................................ 291

. Structure of front door ........................................................................................................................................ 291

. Maintenance of front door .................................................................................................................................. 291

SECTION WINDSCREEN ............................................................................................................................................. 296

SECTION SEAT STRUCTURE AND ITS DISASSEMBLY AND ASSEMBLY ........................................................................... 301

SECTION DISASSEMBLY AND ASSEMBLY OF SEAT BELT .............................................................................................. 303

SECTION FRAME SIZE ................................................................................................................................................ 305

CHAPTER AIR CONDITIONING, HEATING, VENTILATION SYSTEM ....................................................... 306

SECTION HEATING AND VENTILATION EQUIPMENT .................................................................................................... 306

1. Composition ......................................................................................................................................................... 306

. Fault diagnosis ................................................................................................................................................... 308

. In-car service ...................................................................................................................................................... 308

SECTION AIR CONDITIONER ...................................................................................................................................... 313

. Composition........................................................................................................................................................ 313

. Assembly of air conditioner parts ....................................................................................................................... 315

. Fault diagnosis ................................................................................................................................................... 319


. Performance test ................................................................................................................................................. 331

CHAPTER ELECTRICAL SYSTEM ..................................................................................................................... 332

SECTION POWER SUPPLY SYSTEM ............................................................................................................................. 332

. General ............................................................................................................................................................... 332


SECTION CAR BODY ELECTRICAL SYSTEM ................................................................................................................ 351

. General ............................................................................................................................................................... 351

. Fault diagnosis ................................................................................................................................................... 359


. Circuit diagram .................................................................................................................................................. 383

Chapter Finished vehicle application and maintenance

Section Major technical parameter

. Basic parameter

1. Vehicle basic dimension and mass parameter (Table 1-1)

Table 1-1 Vehicle basic dimension (mm) and mass parameter (Kg)

Item Parameter

Model SY6370 SY6390 SY1020

Overall length 3730 3900 4590/4360

Overall width 1510 1510 1510

Overall height (no

load) 1823 1823 1823

Wheel base 2350 2430 2760

Front wheel tread 1300 1300 1300

Rear wheel tread 1310 1310 1310

Front suspension 690 510 690

Rear suspension 690 960 960

Front wheel toe-in 05 05 05

SY6370 SY6390 SY1020

Curb weight 985 1000 890

Fully loaded weight 1610 1650 1820

2. Vehicle service performance parameter (Table 1-2)

Table 1-2 Vehicle service performance parameter

Item Parameter

SY6370 SY6390 SY1020

Type of

engine XC4F18-T DL465Q5 XC4F18-T

XC4

F18-

T

DL465Q

5 XC4F18-T

Max. speed

(km/h) 105 105 105 105 105 105

Max.

gradability

()

30 30 30 30 30 30

0-90km/hs

sequential

shift

50 48 50 50 48

acceleration

time (s)

Integrated

cycling value

of fuel

consumption

L/100km

5.5 5.5 5.5 5.5 5.5

Braking

distance (m) 20 ( when the speed is 50 /h under full load)

noise emitted

by

accelerating

motor vehicle

(dB)

74

. Structure parameter

1. Major technical parameter of engine ( table 1-3

Table 1-3 Major parameter of engine

XC4F18-T DL465Q5

Type

four-stroke, water cooling, single

overhead camshaft, multi-point

electronic control fuel injection

four-stroke, water cooling, single

overhead camshaft, multi-point electronic

control fuel injection

Cylinder diameter (mm) 65.5 65.5

Piston travel (mm) 74 74

Displacement (mL) 997 998

compression ratio 9.31 9.51

Rated power /speed 45Kw/5200 r/min 45Kw/520050 r/min

Max. torque/speed 78Nm/2800~3200 r/min 85Nm/35004000 r/min

Mass (kg) 98 97

Fuel 93# superior nonleaded gasoline 93# or above nonleaded gasoline

Idle speedr/min 850 50 800 50

Max./Min speed (r/min) 5300/850 50 5600/800 50

2. Technical parameter of transmission (table 1-4)

Table 1-4 Technical parameter of transmission

XC4F18-T DL465Q5

transmission

ratio

Gear 1 3.652 3.652

Gear 2 1.948 1.947

Gear 3 1.424 1.423

Gear 4 1 1

Gear 5 0.795 0.795

Reverse 3.466 3.466

3. Wheel parameter (table 1-5)

Table 1-5 Wheel parameter

Item Parameter

Tire size 165/70R13165/70R14

Front wheel tire pressure (kPa) (half load and fully load ) 200/240

Rear wheel tire pressure (kPa) (half load and fully load ) 240/280

. Other parameters (table 1-6)

Type Item

Type

Item

Table 1-6 Volume data

Item Unit Jinbei Haixing

XC4F18-T DL465Q5

Engine cooling system L 5.5 5.5

Engine lubricating system L 3.5 3.5

Fuel tank L 40

Transmission lubricating oil L 1.2 1.2

Rear axle lubricating oil L 1.3

Brake fluid L 0.36

Section Application of Finished Auto and Notices

I. Elementary Knowledge for Application of New Auto

1. Inspection for New Auto

To ensure safe and reliable operation of auto, before putting into use, the new auto shall be conducted the following

inspections:

(1) Inspect from the outlook on whether the connection and tighten situation between key and crucial parts satisfy

requirements, particularly on steering and brake devices such as universal joint sheath, brake bottom plate, brake

piping, wheels, steering tension rod sheath, steering sheath and gearbox etc.

(2)Inspect whether the specification, type and quantity of all oils and liquids satisfy requirements, including

gasoline, oil and cooling fluid, electrolyte, window washer tank, brake fluid, gearbox oils and oils for brake and

steering etc., and inspect whether there occurs the situations such as oil spills and leaking in the auto.

3Inspect the working status of voltage of storage battery, electrical equipment, lamplight, horn, instrument and

indicator light, etc. Inspect the installation of fuse wire within driving cab.

4Inspect whether the type, specification and pattern of wheels satisfy requirements, whether the bolt tightening

moment of wheels(10010N.m)satisfies specified requirements and whether the inflation pressure of each wheel is

normal(including spare wheel) as well as the installations of valve core of wheels and wheel cowl.

(5) Inspect the connection and tightening status of all spare parts, especially the spare parts such as transmission,

steering, brake, suspension and wheel etc.

6Inspect whether the clutch and free pedal travel satisfy specified value and inspect braking system and free

pedal travel of braking, ensuring to remove the air within piping.

7Inspect external cleanness of auto, including painting, trimming and glass; Inspect internal cleanness of auto,

including saddle and internal trimming; Inspect status of windshield washing unit.

(8) Until normal work temperature after starting engine, heating of turbine, observe whether there exist

phenomena such as oil spills, gas spills, leaking and leakage of electricity.

9After putting into gear and starting to move, inspect the work situations of road tests for clutch, gearbox, hand

braking, foot braking and steering system.

1) Clutch: whether there occurs clickety-clacking and abnormal noise during operation.

2) Accelerator Pedal: shall be shown the phenomena with flexibility and no loose.

3) Gearbox: free shift, without the phenomena such as out of nimbleness, abnormal noise and out of gear.

4) Speedometer: During driving of auto, the pointer of speedometer shall be without sheering, when the auto speed

changes, the pointer runs stably.

5) Steering operational setting: whether the free play of steering wheel is normal, whether the control force is

appropriate and whether the automatic return ability could be realized after steering.

6) Foot braking: When braking at the auto speed of 40 km/h, the braking effect can be experienced, no derivation

during braking.

7) Hand braking: When lifting the handle of hand braking and when the auto is traveling at low speed 20 km/h, the

gearbox will be put into neutral, and the braking effect can be experienced.

8) Air conditioner: operate the buttons to inspect whether all the functions are normal.

9) Judge whether the noise of all parts is normal: during traveling of auto, especially at accelerating and

decelerating, please Notice whether there occurs obvious abnormal noise in all parts.

10) Inspect whether the technical materials of tool box and essential tool technology are comprehensive.

2. Running-in of New Auto

On account of processing and assembling errors, the frictional resistance of all the motional parts of new auto at

the time when it starts operation is much greater than that in normal situations. The running-in effect of initial

application period for auto produces enormous impact on service life, reliability of operation, economical

efficiency of the auto. Thereupon, the running-in regulations shall be strictly executed when the new auto is put

into use.

(1) Running-in regulations within 1000km that the auto travels:

1) Driving at full speed is absolutely prohibited.

2) In general, the driving speed is prohibited to excess 65km/h.

3) Driving at high speed within each bumping block shall be avoided.

(2) Running-in regulations between driving within 1000km to 15000km: could gradually accelerate to the highest

speed or at highest steering driving by permission of the engine.

(3) After running-in periods, please Notice:

1) When driving the auto with steering meter, the neighboring bumping block with high speed will be changed into

and the permitted highest steering speed of engine within short time is 5500r/min. The permitted highest speed of

each bumping block is: below 20km/h for the bumping block 1; 30km/h for bumping block 2; 50km/h for bumping

block 2; 70km/h for bumping block 4; above 80km/h for bumping block 5.

2) Avoid making the engine runs at unnecessary high speed, converting into the bumping blocking with high speed

as early as possible brings benefits to saving fuel oil and reducing operation noise.

3) The steering speed of engine during driving is prohibited to be too slow, only when the engine runs strenuously,

will the low bumping block be converted into.

4) The speed and revolving speed listed in the specification are only suitable for the engine with normal

temperature. When the engine is cold, no matter at neutral or at each bumping block, the engine is prohibited to

runs at the highest revolving speed.

5) The new wheels are without best adhesive force at initial application, thus, the new wheels also requires for

running-in. During driving with the first 100km, the speed shall be kept slow and the driving methods also shall be

cautious.

6) The new braking friction plate also requires for running-in. During driving within the first 200km, it still has no

ideal frictional force, during this stage, if the braking effect is a litter bit weak, the pressure of the pedal could be

increased appropriately. This situation also applies to changing braking friction plate each time later on.

II. Driving of Auto

Correct driving of auto not only could give full play to good technical performance of the auto, but above all could

ensure the safety of driving. Therefore, as a driver, the operation of auto maintenance must be conducted well

before utilization of vehicles. And during the process of driving, the vehicle shall be used correctly according to

different road situations.

1. Inspection and Preparation before Utilization of Auto

(1) Inspect fuel oil meter, to judge whether the fuel oil is needed to add.

(2) Inspect the oil level, to see whether the imprint of oil scale is within the mark of top and bottom limitation. Any

insufficiency, it shall be added promptly. When there occurs stoppage in lubrication system of the autos engine or

the mechanical oil alarm lamp is lit up during the operation of engine, the operation of engine shall be stopped

immediately and the reasons shall be analyzed to remove promptly.

(3) Inspect whether the height of coolant level satisfies requirements, any insufficiency, it shall be added promptly.

(4) Inspect whether the braking level satisfies requirements, any insufficiency, it shall be added promptly.

(5) Inspect whether the electrolyte level of storage battery satisfies requirements, any insufficiency, the distilled

water shall be supplemented.

(6) Inspect whether the air pressure of the wheels satisfies requirements and whether the spare wheels are

comprehensive.

(7) Inspect whether the lamplight, direction indicator light and braking indicator light function well.

(8) Inspect whether the front and rear windshield glass are clean, whether the degree of rearview mirrors in and out

of the auto is appropriate and whether the wiper functions well.

(9)Whether the seats and belts have been adjusted to the appropriate position;

(10)Inspect whether the operation of performance of wheel braking is reliable.

(11) Inspect whether the moving of each pedal is flexible, whether the free play is within specified scope, whether

the transposition is free and whether there exist jammed phenomena.

(12) Inspect whether the tool box is comprehensive and whether a proper amount of melt silk and bulb have been

prepared well.

(13) During long-distance driving, a proper amount of oils and coolant liquid are still needed to prepare.

Crucial Notices for safe driving:

(1) The safety belt shall be fastened well before utilization of vehicles each time and the headrest shall be adjusted

well according to figure.

(2) Be bound to Notice no object could exist to impede the operation of the pedal.

(3) No driving when tired. In general, a break shall be taken after driving for two hours.

(4) The reaction ability of the drivers will be influenced by alcohol, drugs and medicines. Therefore, driving is

prohibited after drinking wine or at absence of mind. The latest research achievements show: when the drivers use

mobile communication devices during driving, the descending degree of their reaction ability is even severer than

that after drinking wine. Thus, during the process of driving, the mobile communication devices shall be strictly

prohibited.

(5) In any case, the auto speed shall be suitable for the status of road and traffic. For example, it shall be

decelerated at the road with snow and ice, or at wet road or when it is trapped into traffic jam.

(6)For the sake of safety of drivers and others, please be sure to obey the traffic rules.

2. Starting engine

(1) Manual transmission auto

1) Before start the auto, move the gear selector to the neutral position, and pull the parking brake.

2) When start the auto with the manual transmission, step the clutch pedal to the end, and this needs drive the

engine only when engine is working,

3) Open the ignition switch, start the engine, but do not need to step the accelerator pedal.

Notice: Once start the engine, release the ignition switch immediately to prevent the starter from operating

passively.

4) After starting the engine, it not necessary to park the auto for preheating of the engine, and drive the auto after

starting.

Notice: Before the temperature of the engine reaches the normal temperature, do not make the engine

operate at high speed or step the accelerator pedal to the end.

(2) Notices when start the engine:

1) When start the engine in cold condition, because the engine used in this auto is equipped with the continuous

fuel injection device, it can provide the suitable the fuel mixed by the oil and gas in any condition. This starting

process is not affected by the external temperature, and do not step the accelerator pedal before start and when start

the auto. If the engine is not started immediately, you should turn off the ignition switch and repeat it after about

half a minute.

2) If the engine fails to be started, it is possible that the fuse of the electrical or the fuse of the engine control system

is fusing.

3. Notice in driving

In order to play the technical performances of the vehicle, reduce the fuel consumption, reduce the adverse impacts

for the environment by the exhaust gas and noise, you should pay attention to the following matters in driving:

(1) Avoid to step the accelerator pedal suddenly, and should step the accelerator by the gentle way, this shall not

only reduce the fuel consumption, but also reduce the abnormal wear between the pollution and automobile internal

motion.

(2) Exchange the shift according to the need to make the auto drive in the economy shift to avoid the engine to

operate at the high or low speed.

(3) Drive the auto as stable as possible, the operation should be predictable, and the unnecessary acceleration,

braking, starting and parking make the fuel consumption increase. Avoid the sharp turns and emergency braking.

(4) In the case of traffic jam, turn off the engine.

(5) Check the tire pressure regularly, and the lower pressure of the tire may increase the rolling resistance,

accelerate the tire wear and make the steel ring deformed.

(6) Clean out the unnecessary things in the trunk timely.

(7) Use the heating, air conditioner, rear window heating device, headlamp and other ancillary electrical

equipments only when necessary.

(8) After driving at high speed for a long time, do not turn off the engine immediately, and make the engine operate

at the idling speed for two minutes to make the temperature reduce gradually.

(9) Before drive the auto for long distance, should check and make the driving preparation according to the safety

driving precautions.

If you have known this long-distance driving, the oil changing or other maintenance items will be expired, and need

to implement these work in advance. Especially, the changing of the brake fluid has the significance for the safety

of the vehicle driving.

(10) When drive the automotive under full load, the external temperature is too high or too low, the sand is serious,

the fuel quality is poor and other conditions, should take some special technical measures, such as: use the

lubricants with the viscosity which meets the requirements of the external temperature (select the viscosity grade of

the lubricants according to the appropriate external temperature scope), install the air filter with the special

efficiency, and the maintenance cycle shall be changed correspondingly. If the engine load is large, the replacement

cycle of the lubricant should be shortened.

(11) Need to observe all instruments and indicators in driving. In order to facilitate the driver, in addition to the

common instruments, increase various indicator warning devices and engine failure diagnosis indicator. They can

reflect the working conditions of all systems accurately, if there is the hidden fault, it shall issue the warning and

request the driver to pay attention it immediately to avoid the traffic accidents caused by the serious mechanical

failure, and the warning device needed to be paid attention to include:

1) Alarm light of low oil level or pressure;

2) Alarm light of hand-brake system;

3) Alarm light of engine;

4Alarm light of no power of the engine;

(12) When drive the auto in the water, must reduce the speed and operate the auto carefully to prevent that the

water is sucked in the engine or wet the electrical equipment and cause the failures. After entering the water, restore

the brake performance immediately. When the surface water is more, do not pass through it forced.

(13) Do not attempt to change the vehicle as not to affect the normal technical condition of the vehicle and enjoy

the quality warranty.

(14) Maintain the repair the vehicles according to the regulations of the manufacturer strictly.

4. Proper use of the tractive device

There is a tractive hook at the end of the bumper, and it is used to be towed by other vehicles.

(1) When tow or be towed, the connect the towline and tow bar. It should be Noticed to avoid the forcible traction

or sudden tug, otherwise, it may damage the tow line and happen the danger.

(2) Comply with the traffic laws and regulations related to the traction, and the alarm lights of the towing and

towed vehicles must be flashing.

(3) The driver of the towed auto should pay attention to that the tow line must be kept taut state.

(4) The towed auto must be turned on the ignition switch to facilitate the steering gear to rotate freely, and the turn

signal, horn, windscreen wiper can work properly.

III. Proper use of the fuel, lubricants and fluids

1. Refueling properly

The quality of the fuel shall impact on the driving performance of the auto, performance of the engine and the

service life, and the fuel additives can improve the above performance, thus it is required to use the high-quality

fuel including the additives. If you can not buy the high-quality fuel including the additives, or if the engine occurs

the problems, such as difficult starting, unstable idle speed, descend power and other faults, you should add the

proper additives in refueling.

Pay attention to that the refueling mouth should be located in the small cover surface of the lower side panel

Behind the front door, the standard fuel tank capacity is 40L, after unscrewing the fuel tank cap, hang it on the

cover, and must use the refueling gun properly in refueling.

Description:

1) For safety reasons, do not carry the canned backup fuel to avoid to damage the oil reservoir in accident and the

overflowed gasoline may cause the fire.

2) When carry the fuel with the auto, please be sure to comply with the local traffic and safety regulations.

2. Proper use of engine lubricant

The auto has been added the high-quality engine lubricant before leaving the factory, in addition to the particularly

cold climate region, it can be as the full-year general-purpose lubricant. The high-quality lubricant is the

prerequisite which ensure the engine operation without faults and maintain the long life. Therefore, only use the

corresponding high-quality lubricant when add the lubricant or replace the lubricant.

(1) Check the lubricant level surface. When the engine is working, the consumption of the lubricant is very normal,

and the consumption of the lubricant can reach 0.138Ll000km. Therefore, must check the lubricant level surface

regularly, and it is better to check the auto in refueling every time.

When check the lubricant level, the auto should be maintained in a horizontal position. After stopping the engine

for a few minutes, so that the lubricant can be back to the lubricant tray. And then take out the dipstick wiping by

the clean cloth, and insert the dipstick into it to the place, and then take out the dipstick for reading, and the oil

level must be between the upper mark and the lower mark X.

The difference of the maximum oil level and the minimum oil level of the engine is about 1.OL.

(2) Make up the engine lubricant. Unscrew the refueling cover on the cylinder head , and use the dipstick to check

the oil height after adding the lubricant.

Notice: The oil level should not exceed the maximum mark, otherwise the lubricant may be sucked by the

crankcase breather. When make up the engine lubricant, do not allow the lubricant to drip on to the

high-temperature parts of the engine, otherwise, it may be burning.

After making up the lubricant, cover the fueling mouth. Insert the dipstick until it is locked, otherwise the

engine may flow out some lubricant in operating.

(3) Replace the engine lubricant. The load of the lubricant and the oxidation of the lubricant in working make the

nature of the engine lubricant change. Therefore, replacing time of the lubricant depends on the used load and the

used time. In the case of using SF Grade engine oil commonly, when the auto drives for 5000km, replace the engine

lubricant.

If the vehicle is driving in the special road sections or the region with the larger temperature range, you should

shorten the driving mileage of replacing the lubricant to ensure the reliable operation and safe driving.

Notice: The engine lubricant should not be added other things for mixture. The used lubricant must be

processed by the regulations strictly, and prohibit the children from contacting. In any case, do not allow the

lubricant flow into the drainage pipeline or the land.

3. Proper use of cooling liquid

The cooling system should be checked and maintained regularly.

The cooling system has been added the cooling liquid when the auto leaves the factory.

The cooling liquid is mixed by ethylene glycol and water at the rate of 5:5, the antifreezing capacity is -35, and it

has the excellent corrosion resistance performance. In addition, the additives can prevent the system to produce the

scale and improve the boiling point of the cooling liquid.

Based on the above excellent performance, the cooling system should use this kind of cooing liquid all year round,

and do not add the pure water at any time (especially in the summer or hot regions) so as not to reduce the

density of the cooling liquid. In order to ensure the normal function of the cooling liquid, the density of the cooling

liquid should not be less than 40% (volume ratio).

If need to improve the antifreezing capacity of the cooling liquid, you can increase the ratio of ethylene glycol, but

the density of the cooling liquid should not exceed 60% (volume ratio).

In the cold region (below -40), prepare the cold protection and replace -40ethylene glycol engine antifreezing

liquid.

(1) Check the height of the cooling liquid level: the cooling liquid reservoir is located in the front bulkhead. The

cooling liquid level must comply with the regulations to meet the work requirements of the cooling system.

Therefore, check the level height regularly.

In order to check the cooling liquid level correctly, turn off the engine before inspection, and check the engine after

stopping operation. The cooling liquid reservoir should be transparent plastic container with the maximum (max or

H) and minimum (min or L) mark, and you can check the level without opening the reservoir.

Notice: When the engine is in the cold state, the cooling liquid level must be between the maximum and minimum

mark, once reaching the hot state, the level may be higher than the maximum mark.

Notice: If the cooling liquid is lost abnormally, it indicates that the cooling system may have the leakage fault,

at this time, adding the cooling liquid can not resolve the problem completely. Therefore, do not delay and go

to the authorized service station to check the cooling system immediately.

(2) When add the cooling liquid, turn off the engine, use the both to cover the cooling tank lid after cooling, rotate

it by the clockwise, remove the tank lid after reducing the pressure, and add the cooling liquid.

Notice: When the engine is in the hot state, the cooling system is still in the high-temperature and

high-pressure state, at this time, do not open the tack lid to avoid burn!

In the emergency case, if you add the pure water, must add the cooling liquid additives according to the regulations

to make the density of the cooling liquid restore to the normal state.

If the cooling liquid is consumed substantially, must add the cooling liquid for the engine in the cold state to avoid

to damage the engine.

When add the cooling liquid, do not make the level exceed the maximum mark of the tank. Because once the

engine reaches the hot state, the excessed cooling liquid shall overflow the cooling system by the pressure limiting

valve of the tank. After adding the cooling liquid, must tighten the tank cap.

Notice: The cooling liquid and the cooling liquid additives are the toxic substances! Thus, the additives must

be stored in the original container to prevent the children from contacting it, if must let out the cooling liquid

in the system, collect it and store it in the safe area. The released cooling liquid should not be used again, and

process the disposal cooling liquid according to the regulations of the environment protection law strictly.

4. Proper use of brake fluid

(1) Check the brake liquid level. The brake liquid tank is located on the left side of the front bottom. The brake

liquid level should comply with the regulations to meet the work requirements of the brake system.

The level should be between the liquid tank maximum (max or H) and minimum (min or L) mark.

The brake system of this vehicle is equipped with the friction lining to adjust the gap. Therefore, in the using

process, the brake liquid level may be declined slightly, this situation is normal without worry, however, the level is

declined or declined below the lowest mark in the short period, it indicates that the brake system is leaked, at this

time, you should drive your auto to the authorized service station for maintenance of the brake system.

(2) Replace the brake liquid. The brake liquid has the hygroscopicity, and it can absorb the moisture in ambient

air in the using process. If the moisture content of the brake liquid is excessive, it may corrode the brake system,

and the boiling point of the brake liquid can be reduced significantly, and this shall affect the brake effect and

safety, based on the above reasons, replace the brake liquid once a year.

Notice: If the brake liquid is used for a long time or frequent braking, the brake system can produce the

steam bubbles, and this shall impact the brake effect and driving safety.

In order to ensure the brake effect and driving safety, please must use the original brake liquid equipped by

the company and used the unused brake fluid.

Notice: The brake liquid is the toxic liquid! Therefore, it must be stored in the original sealed container to

prevent the children from contacting it! The brake liquid can corrode the paint of the auto body!

The treatment of the waste brake liquid is a highly professional work, must use the special tool, therefore it

should be replaced by the authorized service station.

5. Proper use of the transmission gear oil

In order to ensure the normal work performance of the transmission, please pay attention to filling the gear oil

regulated by the manufacturer, if the quality of the gear oil is not proper, it can accelerate the abnormal wear of the

gears and impact the use performance of the vehicle.

(1) The specification model of the gear unused by the transmission is 85W-90 GL-5 GB13895-1999, in order to

maintain the transmission better, please replace the gear oil once a year or traveling 50000km.

Notice: After the vehicle is driving at high speed or full load for a long time, if the oil level can not meet the

requirements, fuel it or discharge the oil timely (the drain plug is located lower of the bottom of the transmission oil

tank ). The transmission oil should be red, if the oil is brown or black, it indicates that it contains the friction

materials and a large amount of impurities. If the oil fluid is pink or white, replace it. Under the normal

circumstances, replace the transmission gear oil once a year or driving 50000km. If the traveling road surface

condition is poor, you should shorten the driving mileage of replacing the transmission gear oil to ensure the

reliability and safety of driving.

IV. Use of the body facilities and accessories

1. Opening and closing of the door

(1) If you are outside of the car, pull the door handle outward when open the door. Lock or unlock the front two

doors by the key, when open the door, the safety lock button is popped up, when lock the door, it will be back to the

original position.

(2) In the car, all doors (the lock of the front left door must be in the engagement state) can be locked by pressing

the safety lock button rod. As long as press the safety lock rod, you can not open the door whether from outside or

inside of the car.

Notice: Do not press the safety lock button to lock the door when the car is driving. So that the door can be

opened from the outside of the car under the emergency circumstances.

2. Close the windows

(1) Window lifter. The windows in the car can be opened and closed by hand operating crank of the door. When

rotate the glass lifting device handle clockwise from the left side, the glass of the door shall be dropped. Rotate the

handle counterclockwise, the glass shall rise; in the right side, it is converse. Notice: some configured middle door

window lifter is the Grade 2 window lifter, when the glass of the middle door is dropped to half, need to rotate

1/41/2 cycles, and then continue to rotate the glass of all middle doors.

3. Adjustment of the rear view mirror

In order ensure the best visual effect at any time, you should adjust the rear view mirror in driving.

Adjust the rear view mirror outside of the car manually. The outside rear view mirror should be adjusted to the

position where you can see the upside of your car. This position can ensure the maximum field of vision.

4. Use and adjustment of the safety belt

A large number of facts prove that the safety belt may provide the very good protection in the accident. Thus, you

should wear the safety belt before drive the car.

Use of the safety belt rolling wheel safety belt.

1) Three-point inertia. In the normal driving state, the safety belt can be expanded freely according to the need of

the passengers, however, the speed of the auto or other factors (such fast pulling or emergency brake) are changed,

the safety lockup mechanism shall lock it and maintain a certain tightening force.

Notice: Correct use of the safety belt is very important for playing its role.

2) Fasten the safety belt to the pelvic. Pull one end of the lock tongue of the safety belt from the front of the pelvis

slowly by hand, insert the lock tongue and connect it to the other side of the lock until hear the sound of loc, and

then pull it outside to check whether it is locked really or not.

3) Fasten the safety belt to the shoulder. The safety belt should be across the middle of the shoulder and then be

across the chest to close to the body.

5. Adjustment of the seat

(1) Forward and backward adjustment of the front seats: in order to ensure the safety, adjust the driving set whether

auto is static. The forward and backward adjustment method of the front seat is to pull the rod in the font of the seat

to move the seat forward and backward.

(2) The adjustment of the seat backrest angle is to toggle the rod next to the backrest by leaning forward of the

body. The backrest should not be tilted to the back excessively in driving, otherwise, it may affect the effect of the

safety belt.

(3) Seat of the rear two rows. The backrest and the cushion of the rear seats of some models are separated, and it

has the tilt forward function to increase the volume of the trunk. The method of tilting the backrest: Move the

front seat to the appropriate position to prevent from collision with the rear seat. And then pull the plastic rod on

the top of the backrest of the rear seat to title the backrest forward.

Section III Full auto maintenance

I. Maintenance table

1. Maintenance table under the normal condition

Maintenance

interval:

Determine the

interval according to

the mileage reading

or month, and it

subject to the firs

arrival.

This table lists the maintenance requirements of the vehicles with the driving mileage of

80,000km, for the vehicle driving more than 80,000km, implement the same maintenance

by the same interval.

Km (1000) 10 20 30 40 50 60 70 80

Miles (1000) 6 12 18 24 30 36 42 48

Month 6 12 18 24 30 36 42 48

1. Engine

l-1Drive belt - - R - - R

1-2Camshaft timing belt Replace it every 100,00km.

l-3Valve clearance - J.T - J.T - J.T - J.T

l-4Engine oil (Grade SF engine oil) and

engine oil filter

After first maintenance, replace it every 5000 km or every six

months.

l-5Engine oil (Grade SJ engine oil) and

engine oil filter

After first maintenance, replace it every 10000 km or every six

months.

1-6Cooling system hoses and fittings

1-7Engine cooling liquid J J J R J J J R

l-8 Exhaust pipe and installation parts

(excluding the exhaust filter) I&(R)

2. exhaust gas control system

2-1Crankcase breather and connectors

2-2Crankcase ventilation capacity control

valve

2-3Fuel evaporative exhaust control system

3. Electrical system

3-1Harness and fittings

4. Ignition system

4-1Spark plug

If use the unleaded

gasoline. R R R R

If use the unleaded gasoline, please refer to the table of Driving Under the Harsh

Conditions.

4-3Ignition system line R

5. Fuel

5-1Mixture ratio of the engine speed (idling

speed) and idling speed ()

5-2Fuel tank head R

5-3Air filter element J J J R J J J R

5-4Oil filter Replace it every 10000 km.

5-5Fuel pipe and fittings/tank JT JT JT JT

Maintenance

interval:

Determine the

interval according to

the mileage reading

or month, and it

subject to the firs

arrival.

This table lists the maintenance requirements of the vehicles with the driving mileage of

80,000km, for the vehicle driving more than 80,000km, implement the same maintenance

by the same interval.

Km (1000) 10 20 30 40 50 60 70 80

Miles (1000) 6 12 18 24 30 36 42 48

Month 6 12 18 24 30 36 42 48

6. Brake

6-1

Brake disc and pad (front)

Brake drum and brake shoe

6-2Brake hoses and pipes

6-3Brake liquid R R

6-4 Brake pedal

6-5Bbrake lever and link

7Chassis and body

7-1Clutch

7-2Tire

7-3Wheel roulette

7-4Suspension devices

7-5Drive shaft

7-6Manual transmission oil R R

7-7Differential oil R R

7-8Steering system

7-9All latches, hinges and locks

7-10Transmission shift fork and shaft

Notice:

RReplacement, JInspection,TAdjustment

Check and repair, and replace it if necessary.

1-7Ris only suitable to the discharge device installation rubber parts.

Maintenance recommendations driving under the harsh conditions

If the auto is driving under the harsh conditions, it is recommended to perform the special maintenance

interval in the following table.

2. Code of harsh conditions

A-Repeated short trips

B-Driving on the uneven/or slimy road

C-Driving on the dusty road

D-Driving in the very cold weather conditions and /or on the salt road

E-Repeated short trip in the very cold weather conditions

F-Full load for long timer or driving on the mountain road

Code of harsh

conditions Maintenance

M

ain

ten

an

ce

op

era

tio

n

Maintenance interval

-BC--- Drive belt

Every 20,000km or 12 months

R Every 40,000km or 24 months

A-CDEF Engine oil and oil filter


AB-D-- Discharge pipes and

fittings


--C--- Air filter element *1

R Every 2,500km


ABC-E Spark plug


AB-D-- Drive shaft


-B--EF- Transmission (manual)

and differential oil


-B---- Chassis bolts and nuts

T Every 10,000km or 6 months

ABC---

Brake disc and pad

(front)

Brake drum and brake

shoe (rear)

Every lO,000km or 6 months

Notice:

RReplacement

Check and repair, and replace it if necessary.

TTighten it according to the regulated torque.

*1If the auto is driving on the dusty road, the inspection and replacement should be more frequent.

II. Repair and maintenance

1. Engine

Drive belt

Warning: Before check and adjust the tension of the belt, disconnect the negative post of the battery.

Water pump belt inspection

1) Check whether the belt has the cracks, incision, deformation, wear and cleanliness or not. If necessary, replace it.

2) Check the tension of the belt, press the middle of the belt by the force of about 10kg, it shall sink about 7

10mm.

The belt tension a: the subsidence value is 710mm.

Notice:

After replacing the belt, the tension shall be adjusted to: press the middle of the belt by the force of about

10kg, the subsidence value is 56mm.

Replacement of the water pump belt

1) Disconnect the negative pole of the battery.

2) If equipped with the air conditioning, remove the air conditioning compressor drive belt (refer to the air

conditioning compressor drive belt).

3) Replace the water pump belt by the new belt.

4) Adjust the belt tension according to the technical requirements.

5) Connect to the negative pole of the battery.

Check the air conditioning compressor drive belt (optional)

Check the wear, damage and tension of the belt. If necessary, replace

or adjust it in time.

Tension of the air conditioning compressor drive belt:

When press the middle of the belt by the force about 10kg, the

1. Drive belt

2. Crankshafte pulley

3. Air conditioning compressor

1. 10kg (22 Ibs)

2. Adjust the bolts

subsidence vaue is 811mm.

Replacement of the air conditioning compressor drive belt:

1) Disconnect the negative pole of the battery.

2) Release the belt tension, and replace the old belt by the new belt.

3) Adjust the belt tension according to the technical requirements.

4) Connect to the negative pole of the battery.

Notice:

When replace the new belt, the tension is adjusted to: Press the middle of the belt by the force of 10kg, and

the subsidence value is 89mm.

Camshaft timing belt inspection

1) Remove the hole plug from the belt

2) Use the light and special mirror to check the timing belt wear, cracks, damage, oil and other conditions. If

necessary, replace it.

3) Install the inspection hole plug.

Valve clearance inspection:

1) Remove the crankcase ventilating horse on the valve

mechanism cover.

1. Crankshaft belt wheel

2. Adjustment of bolts

3. Valve rod

4. Adjust the screw and lock the

nuts

Engine oil viscosity table

1. Crankshaft belt wheel

2. Adjustment of bolts

3. Valve rod

4. Adjust the screw and lock

the nuts

2) Remove the valve mechanism cover.

3) Check the clearance of the intake and exhaust valve, if necessary, adjust it.

4) Install the valve mechanism cover, and tighten the bolts according to the technical requirements.

5) Connect the crankcase ventilating horse.

Inspection and adjustment of valve clearance steps refer to Chapter II.

Technical

requiremen

ts of the

valve

clearance

(clearance

a)

Cold state the cooling

temperatureis 1525

Hot state the cooling liquid

temperature is 6068

XC4F18-T DL465Q5 XC4F18-T DL465Q5

Intake 0.15

0.19mm 0.150.19mm 0.230.28mm 0.230.28mm

Exhau

st

0.15

0.19mm 0.150.19mm 0.230.28mm 0.230.28mm

Engine oil and engine oil filter

Fill the engine oil:

If the temperature is more than 15 in summer, use SF15W-40, if the temperature is less than 15 in winter, use

SF10W-30, and in winter, the northeast, Inner Mongolia and Xinjiang shall use SF5W-30.

Notice: Replace the corresponding engine oil according to the different temperature.

Before discharge the engine oil, you should check whether the engine oil is leaked. If it is leaked, please replace

the damaged parts before perform the following work.

1) Remove the plug of discharging the oil to discharge the engine oil.

2) After discharging the engine oil, clean the plug of oil discharge. And then install the plug of oil discharge and

tighten it according to the following requirements.

Tightening torque: (a): 35 Nm

3) Use the engine filter spanner (special tool) to release the oil filter.

Special tool (A):09915-47340

4) Smear the engine oil on the O ring of the new engine oil filter.

5) Tighten the new engine oil filter on the filter base, until the filter O ring

contacts with the installation surface.

Caution:

1. Oil bottom shell

2. Plug of oil discharge

1. Oil filter

In order to tighten the engine oil filter appropriately, please pay attention to identifying the accurate position

of the filter o ring and the installation surface.

6) After contacting with the installation surface, use the engine oil filter spanner twist the filter 34 rings.

Special tool (A):09915-47340

Pressing torque(a35Nm

7) Fill the engine oil until it reaches the sign of full oil on the

dipstick, and the filling hole is located in the tope of the cylinder

head.

8) Before check the oil level, start the engine for 3 minutes no load.

After stopping, check the oil level after 5 minutes. If necessary, fill

the oil, until it reaches the sign of full oil on the dipstick.

Refer to Section 1 of this chapter Filling amount of engine oil

9) Check whether the engine filter and the plug of oil discharge are leaked.

Cooling system horses and fittings

Inspection

1) Visual inspection of the cooling system, check whether the horses of the

cooling system have the obvious leaks and cracks, check whether the horses are

damaged and check the tension of the pipe clamp.

2) Replace the horses with the leak, cracks and other damages. Replace all pipe

clamps without the appropriate tension.

3) Clean the front part of the radiator core.

4) The test pressure of the cooling system and the radiator cover is 108kPa. If

necessary, replace the radiator cover designed for the cooling system of this

vehicle.

5) Check the cooling liquid level and density. Refer to the inspection steps of Cooling Liquid Level in Section 6 of

Chapter II.

Engine cooling liquid

Warning:

When the engine and the radiator are still hot, do not remove the radiator cover to avoid the burn. If you

remove the radiator cover immediately, the steam and the hot water shall spray under the pressure.

Replacement

Model of filled cooling liquid: Fill No. -20 ethylene glycol engine

cooling liquid, in winter, in the regions of northeast, Inner Mongolia,

Xinjiang and the regions with the temperature less than -20, fill No.

1. Sign of low oil level

2. Sign of high oil level

1. Radiator

2. Radiator discharge plug

1. Full liquid level mark

2. Low liquid level mark

3. Tank cover

4. Matching mark

-4 ethylene glycol engine cooling liquid.

1) When the engine is cooling, remove the radiator cover.

2) Release the radiator discharge plug to discharge the cooling liquid.

3) Remove the liquid tank, and discharge the cooling liquid completely.

4) Tighten the discharge plug, and install the liquid tank.

5) Fill the quantitive cooling liquid for the radiator (refer to Section 6 of Chapter II), exhaust the air in the cooling

system, and then make the engine operate for 2-3 minutes at the idle speed, after stopping the operation, fill the

cooling liquid until the liquid level reaches the filling mouth of the radiator. Install and tighten the radiator cover.

6) Fill the cooling liquid to the liquid tank, until the liquid level reaches the sign of Full, and then cover the tank

head to make the matching signs on the tank and cover aligning.

Caution:

When replace the engine cooling liquid, and the temperature is less than -16 in winter, use the mixture

cooling liquid at the ratio of water of 50% and the ethylene glycol of 50%. When the temperature is more

than -16, use the cooling antifreezing liquid at the ratio of water of 70% and the ethylene glycol of 30%.

Even under the condition higher the freezing temperature, for the purpose of anticorrosion and lubrication,

use the mixed cooling antifreezing liquid at the ration of water of 70% and ethylene glycol of 30%.

Muffler and installation accessories

Warning:

When the discharging system is still hot, do not contact with it to avoid burn. Any maintenance work of the

discharging system shall be performed after cooling.

Inspection

When implement the regular maintenance or repairs according to the

following steps, you should check the discharging system.

Check whether the rubber installation parts are damaged and worn.

Check whether the discharging system is leaked, the connector is

loosened, has the impression and damages or not.

If the bots or the nuts are loosened, tighten them according to the

technical requirements. Refer to Chapter II.

Check whether there are the damaged, poor matching or misplaced components, or the slotting, hole, loosened

joints which may lead the discharged smoke to penetrate the vehicle or other damages.

Ensure the sufficient clearance between the discharge system components and bottom plate of the body to avoid

that the overheating may damage the floor carpet.

If all parts are damaged, please repair it immediately.

2. Exhaust pollution control system

Crankcase breather horses and fittings

Inspection

Check whether the crankcase breather has the leaks and cracks, if it is

damaged, you should repair or replace it, check and ensure that the horse

joints are fastened.

Crankcase ventilating volume control valve

1) Disconnect the crankcase ventilating volume control valve on the

valve mechanism cover, and then use the plug to plug the hole on the valve mechanism cover.

2) Operate the engine by the idling speed.

3) Put the hand on the end of the crankcase ventilating volume control valve, and check whether it is vacuum. If it

is not vacuum, check whether the valve is blocked or not. If necessary, replace it.

4) After checking the vacuum, stop to operate the engine, and remove the

crankcase ventilating volume control valve. Shake this valve, listen

whether there is the click sound, if there is the click sound, and replace this

valve.

5) After inspection, remove the plug. And install the crankcase ventilating

volume control valve.

Fuel evaporative pollution discharge control system

1) Check whether the horse is damaged, cracked or excessive bending by visual. Check whether all pipe clamps are

damaged and positioned properly or not.

2) In case of any damage, repair or replace it.

3) Check the evaporator, and refer to Section 6 of Chapter II. (Inspection

procedures of evaporator)

3. Electrical system

Harness and fittings

Inspection

Check al wires of the engine components are damaged or not visually.

Check the insulation (cracks) conditions, and all wire clips should be fastened.

Replace all damaged or poor harness.

4. Ignition system

Spark plug

Replacement

1. Crankcase ventilating volume

control valve

1. Pressure resistance 2. Cover

1) Remove the dust on the cylinder head around the spark plug.

2 ) Disconnect the high-pressure damping line on the spark plug. Pay attention to pulling the protective shield of

the high-pressure damping line.

3) Use the spark plug wrench to loosen the spark plug and remove the spark plug.

4) Re-install the new spark plug.

Notice:

Ensure to use the new spark plug with the regulated heating degree and si ze.

5) Tighten the spark plug by the regulated torque.

Tightening torque: 2528Nm465

6) Connect to the spark plug high-pressure damping line, do not push the high-voltage line in connecting, and you

can only push the protection cover.

Ignition system circuit (high resistance cable)

Inspection

Check whether the high resistance cable has the cracks or joints, the resistance data and the measurement procedure

should refer to Section 7 of Chapter III.

If it is damaged and the resistance value does not meet the requirements, replace it.

Notice:

Check and ensure that each high resistance cable terminal and joint have been fastened, and they have been

inserted in the corresponding components. Must replace all burned-out joints.

1) Disconnect the high resistance cable and ignition coil.

2) Connect to the new high resistance cable and clamp it by the clip firmly. Do

not push the high resistance cable joint in connecting, and you should push the

protective boot.

Ignition timing

Inspection

Inspection: Use the failure decoding to check it in the idling speed, and ensure

whether the setting of the ignition timing is appropriate. If it does not meet the

technical requirements, check the corresponding components or electrical control system.

5. Fuel

The fuel is 93 high-quality unleaded gasoline used by the auto.

Engine idling speed and idling speed mixture

Inspection

1. Air filter shell cover

2. Clamp

Check the idling speed by the engine speed or special instrument, and use the special instrument to check the ration

of the air and fuel.

Fuel tank cover

Inspection

Check the fuel pad by visual, if it is damaged, replace it timely.

Caution:

Replace the new fuel tank cover by the same specification,

otherwise, it shall cause poor work.

Replacement of the air filter element

Check and replace the air filter element regularly.

Notice: Replace it in the dusty conditions frequently.

Replace the air filter element according to the procedures of Section 5 of

Chapter III.

Inspection and cleaning

1) Check whether the air filter is too dirty, damaged or has the oil by visual, if there are the above situations, please

replace the air filter timely.

2) Use the compressed air to clean the element by the exhaust hole of the filter element.

Notice:

If the auto is driving on the dusty road, clean or replace it every 2,500km.

Fuel pump filter

1. Fuel filling port cover

2. Pad

1. Fuel pump 5. Drain valve

2. Fuel pump filter 6. Dual way check valve

3. Fuel filter 7. Fuel shut-off valve

4. Fuel ruler 8. Fuel pump assemblies

Fuel flow direction

Replacement warning:

Must replace the fuel filter in the ventilating area, and be away from the source of fire.

The fuel filter is located in the fuel tank, including the fuel pump

assemblies.

Clean or replace the fuel pump filter regularly.

Fuel pipe and fittings/tank

Inspection

Check whether the fuel tank, fuel pipe and joints have the leaks, horse cracks, damages or not, and ensure fasten all

pipe clamps.

If the fittings are leaked, repair them. If the horse is cracked, replace it.

6. Brake

Brake disc and pad (front)

Inspection

1) Remove the wheel and calipers, but do not remove the brake horse from the caliper.

2) Check whether the disc brake pad and the brake disc have the

excessive wear, damages, if necessary, replace it. Refer to Chapter VII.

The tightening torque of the caliper pin bolt should meet the technical

requirements.

Notice:

When step the brake pedal, if the front brake has the noise, check

whether the brake pad friction lining is worn seriously or not. If it is worn seriously, the right and left brake

pads should be replaced together.

Brake drum and brake shoe pad (rear)

Inspection

1) Remove the wheel and brake drum.

2) Check whether the brake drum and the brake friction lining are worn

and damaged or not. When remove the wheel and brake drum, check

whether the brake sub-pump is leaked or not. If necessary, replace it. Refer

to Chapter VII.

Brake horse and oil pipe

Inspection

When perform the inspection, the light intensity should be sufficient, if necessary, use the inspection mirror.

Check whether the brake horses and the oil pipe clamps are appropriate or not, whether have the leaks, cracks, jam,

wear, corrosion, bending, twisting and other damages. If necessary, replace it.

Check whether all pipe clamps are fastened, and the joints are leaked or

not.

Check the oil pipes and horses to avoid contacting with the sharp edges

and moving parts.

Caution:

After replacing any brake oil pipe and horse, must implement the

exhaust operation.

Brake liquid inspection

Check whether the brake master pump and liquid tank are leaked or not.

If it is leaked, repair it immediately.

Check the liquid level.

If the liquid level is below the minimum liquid level of the liquid tank, make up it by the regulated brake liquid.

Brake liquid:

The brake liquid brand No. is HZY3 GB12981-2003

Refer to Chapter VII Vehicle Maintenance.

Caution:

As the auto has been filled the brake liquid before leave the factory, if need to fill or make up it, you should

use the same brake liquid, otherwise it may cause the serious damages.

Do not use the expired and used brake liquid, or the brake which is not stored in the sealed container.

1. Fluid tank

2. Fluid tank cover

1. Fluid tank

2. Fluid tank

cover

Replacement

Replace the brake liquid according to the following requirements.

Drain the brake liquid in the brake system completely. Fill it by the above recommended brake liquid, and exhaust

the air.

The exhaust procedures refer to Chapter VII.

Brake pedal

Inspection

Check the travel of the brake pedal.

The inspection procedures refer to Chapter VII Inspection of Brake Pedal

Travel.

Brake handle and link

Inspection

Check whether the brake handle tooth tip is worn or damaged. If it is worn or damaged, replace the parking brake

handle.

Check whether the operation and travel of the parking brake handle are correct. If necessary, adjust it.

Inspection and adjustment procedures refer to Chapter 5 Inspection and Adjustment of Parking Brake.

aParking brake handle travel.

47 teeth (apply the pulling force of 25kg).

7. Chassis and body

Clutch inspection

Check the free travel of the clutch pedal. The inspection adjustment procedures refer to Section 2 of Chapter 6.

1. Clutch pedal

a free travel of the pedal is 1525mm

Tie

Inspection

Check whether the tire is worn or damaged excessively. If it is poor, replace it.

Check the pressure of each tire, if it does not comply with the technical

requirements, adjust the pressure value.

Notice:

Check the tire pressure after cooling.

Find out the regulated tire pressure from the tire pressure plate or manual

equipped with the vehicle.

Rotation of the tire: Rotate the tire after a certain period.

The detailed procedures refer to Section 3 of Chapter IV.

Wheel

Inspection of wheel rim

Check whether the wheel rim has the indentation, deformation and cracks. If the wheel rim is damaged seriously,

must replace it.

Inspection of wheel bearing

Check whether the bearing of the front wheel is worn and damaged, and has the noise or clicks. Refer to Section 1

of Chapter V Inspection of Front Suspension.

Check whether the bearing of the rear wheel is worn and damaged, and has the noise or clicks. Refer to Section 1 of

Chapter V Inspection of Rear Suspension.

Wheel nuts

Check whether the wheel nuts are fastened, if it is not fastened, fasten it by the regulations again.

1. Front tie

2. Rear tie

3. Reserved tire

1. Wear indication pattern

Suspension device

Inspection

Check whether the front/rear shock absorber has the oil leak, indentation or other damages on the bushing, and

check whether the end of the bas

Shineray Auto Repair Manual

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