Outline
Outline
How to use this manual ................................... GI-1
Subject scope ............................................. GI-1
Maintenance procedure ............................. GI-1
Symbols ..................................................... GI-3
Fault diagnostic procedure ........................ GI-3
Use of diagnostic steps..................................... GI-4
Use of basic inspection .............................. GI-4
Use of diagnostic diagram ......................... GI-5
Use of fault diagnostics ............................. GI-6
Order of versions ....................................... GI-7
Unit ................................................................... GI-8
Basic operation steps ....................................... GI-9
Protection of vehicle.................................. GI-9
Preparation of tools and measuring apparatus
................................................................... GI-9
Special tools .............................................. GI-9
Check of oil leakage .................................. GI-9
Disconnection of negative cable of battery GI-9
Removal of parts ..................................... GI-10
Decomposition ........................................ GI-10
Checks during the disassembly ............... GI-10
Placement of parts ................................... GI-10
Cleaning of parts ..................................... GI-10
Assembly ................................................. GI-10
Adjustment .............................................. GI-11
Rubber parts and pipe .............................. GI-11
Hose clamp .............................................. GI-11
Formula of torque .................................... GI-11
Pliers........................................................ GI-11
Installation of radio system .......................... GI-12
Electric system ............................................... GI-12
Electric parts............................................ GI-12
Harness .................................................... GI-12
Jumper of circuit fault diagnostic tool ..... GI-14
Lifting of vehicle ............................................. GI-15
The position to be jacked up by a jack .... GI-15
Position to be jacked up by the lifter ....... GI-16
Towing vehicle ............................................... GI-17
Trailer ...................................................... GI-17
Towing hook ............................................ GI-18
How to use this manual
GI-1
How to use this manual
Subject scope
Ÿ The present manual includes all procedures of maintenance operations，which can be divided into five
basic operations:
Ⅰ Removal/installation
Ⅱ Disassembly/assembly
Ⅲ Reset
Ⅳ Check
Ⅴ Adjustment
Ÿ Simple operations can be completed through the observation of vehicle outlook ， e.g. the
removal/installation of parts, jack, lifting of vehicle, cleaning of parts and visual observation etc.,
Maintenance procedure
Check and adjustment
Ÿ The check and adjustment shall be carried out in several steps with the key positions and procedures as
shown in the following Fig.:
Maintenance steps
1. Before most of maintenance work，the illustration should be observed. It can identify the parts and
explain how the parts are fixed together and the part appearance checked. Of course，the interpretation
will be given by the icons only when the system requires the demonstration of removal/installation
procedures,
2. The legend described the symbols of wearing parts, tightening torques, lubricants and grease and sealant.
The descriptions are also provided for special tools or equipment necessary for removal or installation.
3. The operation sequence and the main process of part operations have been numbered with the description
in the figure. This information is usually the focus of diagnostic procedures or core content, which shall
be noted at the time of spare parts maintenance.
Maintenance procedure
Tightening torque
How to use this manual
GI-2
Process
Maintenance item
S
pecial tools
necessary during the
maintenance
P
osition where the
lubricant shall be
applied
P
ortions to be
removed/installed
P
ortions to be checked
after installation
Maintenance steps
R
elevant references
necessary during the
installation
Install in the reversing
order of steps 1-3
Tightening torque
Wearing parts
M
agnification
description
Torque unit
R
efer to the
repair items
Refer to the repair items
How to use this manual
GI-3
Symbols
There are 8 symbols to represent the uses of
lubricant, grease and sealant and special tools. These
symbols stand for the application of the above-said
materials during the maintenance.
Symbols
Meaning Remark
Add the lubricant
Add new engine or
gear oil
Add the brake
liquid
Use only the brake
liquid
Add the
auto-transmission
liquid
Add new
auto-transmission
oil
Add the grease Appropriate grease
Add the sealant Appropriate sealant
Add the Vaseline
Appropriate
Vaseline
Part replacement
O-seal ring, spacer
etc.
Use of special
tools
Suitable special
tools or equipment
Hint signal:
You will read, in this manual, warning, caution,
attention, statement and upper/lower limits;
Warning:
The overlook of warning notice will result in
personnel injury.
Caution:
Be careful of vehicle damage caused by negligence.
Attention:
Pay attention to additional information necessary for
the completion of some procedures.
Statement:
Prompt the range allowed by the check or adjustment.
Upper/lower limits:
Prompt the upper/lower limits which cannot be
exceeded by check or adjustment.
Fault diagnostic procedure
Basic diagnostic flow:
On-board diagnostics
Ÿ The fault codes are the important clues of fault
repair. The fault diagnostics may be quickly
executed according to the listed fault codes.
When the fault codes are in display, the cause of
fault is identified. Afterward, the inspection is
carried out according to the indication of
diagnostic.
Engine adjustment (Part F)
Ÿ All adjustments must be carried out after the
engine started.
Basic inspection (Part K)
The basic check is intended to quickly exclude the
unrelated fault reasons to lessen the fault scope while
determining the failure part for the fault exclusion.
Diagnostic index
Ÿ The diagnostic index lists out the symptoms of
faults, according to which, the suitable or similar
system and methods are searched for inspection.
Fast diagnostic diagram (if related)
Ÿ The fast diagnostic diagram lists out the
diagnostic items and relevant inspection process.
Symptom diagnostics
According to the diagnostic steps of symptoms,
quickly determine the cause and location of failure.
On-board diagnostic
Engine diagnostic
Actual overhaul process
Basic check
Diagnostic index
Fast diagnostic diagram
Symptom diagnostic
System check
Only for Part F
Only for Part K
Only for Part F
Check of
diagnostic
If prompted
Use of diagnostic steps
GI-4
Use of diagnostic steps
Use of basic inspection
Ÿ Basic inspection to be carried out prior to the diagnostics。
Ÿ The diagnostic operation shall be implemented according to the order listed in the Table.
Ÿ Detailed operation of each basic inspection listed in the Table.
Ÿ Although the inspection and adjustment are carried out as per the operation steps listed in the Table，the
corresponding fault diagnostic items in the Table can be directly found and checked and repaired as per
the relative diagnostic procedures, if the fault reasons have been identified by the basic inspection.
Use of diagnostic index
Ÿ The fault diagnostics are listed in the diagnostic index to discover and solve the system faults.
Ÿ The fault diagnostics may be found in the details.
S
equence of
inspection
Contents of operation steps
P
recautions to be taken in the
result of inspection
Use of diagnostic steps
GI-5
Use of diagnostic diagram
Ÿ The diagram lists out the consequence relationship of symptoms with the faults.
Ÿ The diagram applies to quickly lessen the scope of diagnostic when multiple fault symptoms are in
display.
Ÿ According to the fault symptoms obtained based on the following Fast Diagnostic Diagram，check the
fault relevant causes.
Use of diagnostic steps
GI-6
Use of fault diagnostics
List out the process of fault diagnostics, check method and specific operations.
Fast Diagnostic Diagram
P
ortions where the
problems
are likely to occur
P
ortions where the
corresponding symptoms
are likely to display
Ch
oose the correct
symptom
Use of diagnostic steps
GI-7
Order of versions
The order of versions is shown as the following arrow.
Fault symptoms
P
ossible causes and
places where the faults
are likely to occur
Carry out the suitable
operation and give the
result of inspection
(Yes/no)
F
ault diagnostic
steps
D
escribe the inspection
method of the fast
judgment of partial
failure
H
ow to check the description
in the relevant material
R
eference part during the
detailed operation
Unit
Unit
Current A
Power W
Resistance Ω
Voltage V
Length
mm
in
Negative
pressure
kpa
mmHg
inHg
Positive
pressure
kpa
kgf/cm
2
psi
Speed rpm
Torque
N·m
kgf·m
kgf·cm
ft·lbf
in·lbf
Volume
L
US qt
Lmp qt
ml
cc
cu in
fl oz
Weight
g
oz
Conversion of international units (international
system of units)
The values in this manual apply the international
system of units. The conventional units indicated in
the text are worked out through the conversion of
international units.
Rounding
The value after conversion should be rounded as per
the same precision as the international system of
units.
E.g.: 17.2 in the international system of units become
37.84 after the conversion，thus 37.8 should be taken
as the value after the conversion.
Upper and lower limits
In case of the data displayed with the upper and lower
limits，if the value is the upper limit，the value after
the conversion should be “rounded off”，if the value
is the lower limit, the value shall be “rounded in”.
Therefore, the value of non international units may be
different from the actual value of the corresponding
international unit.
e.g.: in the following cases，the value of 2.7 kgf/cm
2
after the conversion are not the same
210-260 kpa｛2.1-2.7 kgf/cm
2
，30-38 psi｝
270-310 kpa｛2.7-3.2 kgf/cm
2
，39-345psi｝
The accurate value of 2.7 kgf/cm
2
after the
conversion will be 264kpa and 38.4psi，
For the upper row in the example，2.7 is the upper
limit，thus the result after the conversion will be
rounded in to 260 and 38；for the lower row，2.7 is
the lower limit，then the result after the conversion
will be rounded off to 270 and 39.
Basic operation steps
Basic operation steps
Protection of vehicle
Prior to the work, cover the fenders, seats and floor
etc.,
Preparation of tools and measuring
apparatus
When starting the work, the tools and measuring
apparatus necessary are ready for availability should
be determined.
Special tools
Use the special tools when necessary.
Check of oil leakage
Apply any of the following methods to identify the
type of leakage.
Use of UV light (full color light)
1. Drain all oil inside the engine or transmission.
Attention:
According to the Instruction Manual Fluorescent
Dyes，mix up a certain amount of dyes with the
engine or transmission oil.
2.
Refill the mixed engine or transmission oil into
the engine or transmission.
3. Run the engine idle for 30mins.
4. Use the fuel leaked from the illumination by UV
light (full-color light) and determine the type of
leakage.
5. If no leakage of fuel found，it is allowed to run
the engine for another 30min or recheck after the
drive.
6. Identify the position of oil leakage and repair as
needed.
Attention:
According to the Instruction Manual Fluorescent
Dyes, confirm whether it is necessary to replace the
oil after the fluorescent dyes added.
Non-use of UV light (full-color light)
1. Use a piece of color cotton fabric to absorb
some of leaked oil.
2. Use the dipstick to respectively to take out some
of engine or transmission oil specimen and
displace it on a cotton paper.
3. According to the appearance and smell，identify
the type of leaked oil.
4. Add the engine and transmission oil on the level
of standard scale.
5. Run the engine idle for 30mins.
6. Find out the position of oil leakage and repair as
necessary.
Disconnection of negative cable of battery
Prior to start all jobs，you should turn the key in the
LOCK position，and then disconnect the connection
of battery and wait for more than 1min to drain out
the residual power in the SAS unit.
When the parts such as the battery cable, clock, radio
and DTS etc., are disconnected, the saved
information will be deleted，thus the data of these
parts should be recorded before the disconnection.
Use of diagnostic steps
GI-10
Removal of parts
While the problems are being solved，the causes shall
be identified.
The work can be started only after identified which
parts or sub-assemblies have to be removed or
disassembled during the replacement or repair. After
the removal of parts, all holes shall be plugged to
prevent the ingress of external materials.
Decomposition
If the decomposition procedures are very
complicated，and many parts have to be decomposed，
the mark shall be made on each position of part under
the premise of no effect on the appearance parts，in
order to effectively and easily re-assemble.
Checks during the disassembly
In the disassembly, each part should be inspected for
faults, deformation, damage or other problems
Placement of parts
Ÿ All removed parts should be placed according to
the need of assembly.
Ÿ Separately place or mark the still usable parts
and replaced ones.
Cleaning of parts
All parts still usable shall be carefully and completely
cleaned with the suitable method.
Warning:
Use of compressed air for cleaning will result in
eyes injury by slashes such as dust. Blinders
should be worn when the compressed air is used
for cleaning.
Assembly
Ÿ The torque and some standard adjustment values
shall be strictly respected at the assembly time.
Ÿ The following parts have to be replaced once
disassembled.
1
Oil seal
2
Spacer
3
O-seal ring 4
Lock washer
5
Cotter pin 6
Nylon nut
Ÿ The gasket should be fitted up on the designated
position. The seals should be installed before the
sealant hardened. It will result in leakage once
installed after the sealant hardened.
Ÿ Oil shall be added on the movng position of
component.
Ÿ Prior to the assembly, the oil or grease of
defined type shall be added on the specified
position(e.g. seal).
Use of diagnostic steps
GI-11
Adjustment
In the adjustment, use an appropriate ruler or
measuring apparatus.
Rubber parts and pipe
Avoid gasoline or oil to drop onto the rubber parts or
pipe.
Hose clamp
In the reassembly，the pipe clamp should be placed
on the original assembly position of pipe， and
adjusted to the most suitable place by clamping with
the slip joint pliers.
Formula of torque
When using a torque wrench or equipment，the torque
stated in written has to be recalculated according to
the additional length of special tool of torque wrench
or apparatus. The recalculation uses the following
formulas, where a corresponding group shall be
selected for the calculation.
Pliers
In use of vices，a protection disc of pliers shall be
added to prevent damage on the part.
Unit of t
orque
Formula
A.
The length in front of the drive part of
torque wrench of special tool or apparatus
B. The length of the torque wrench
Installation of radio system
Installation of radio system
If a radio system is not properly installed or a radio
set of large power used，CIS or other systems will be
affected.
When a radio system is going to be installed on a
vehicle，the following precautions shall be taken:
1. The position, where the antenna is used, has to
be away as far as possible from the control
module.
2. In installation of the antenna holder，try to keep
it away as much as possible from the control
module harness and perpendicular to the
harness.
3. Do not install the radio system of large power
4. After the radio system installed，start the engine
and run it idle to confirm whether the engine is
under the effect of waveband.
Electric system
Electric parts
Battery cable
When the connection is disconnected or an electric
parts removed，the negative cable of battery shall be
firstly disconnected.
Harness
Remove the harness from the clamp in the engine
room and pry up the clamp snaps with a straight
screwdriver.
Plug
Plug of data connection wire
When connection a jumper with a data plug， a
detector shall be inserted into the measuring hole
Caution:
When inserting a jumper detector into the data
plug，the terminal will be likely damaged.
Use of diagnostic steps
GI-13
Disconnection of harness
plug
Ÿ To pull out two harness plugs，seize two plugs
instead of harness.
Ÿ As shown in the following figure, press or draw
the snaps to pull apart the connection.
Lock-up of plug
In connection of plug，the proper connection can be
determined once a sound “Click” is heard.
Check
1. Use a detection device to check the circuit
connection or to measure the voltage ，
the
detector lead shall be inserted from the harness
side
2. When checking the interface of waterproof
plug，the detector lead shall be inserted from the
port side instead of the harness side.
Attention:
To prevent damage on the terminal，a length of thin
wire shall be wrapped on the detector lead prior to
insert into the port
Terminal
Check
Slightly pull each wire and check whether it has been
securely connected.
Replacement
Use a suitable tool to remove the terminal as per the
following figure. In assembly, try to insert as much as
possible to assure that the plug port has been locked
up.
Insert a piece of metal plate from the side of plug
port，draw the harness terminal from the plug while
latching on.
Sensor, switch and relay
Cares should be taken when the sensor, switch and
replay fingered. Do not let it drop to the ground or hit
other objects.
Click
Use of diagnostic steps
GI-14
Harness
Codes of wire color
Double-color wire is represented by a double color
code
Ÿ The 1
st
letter stands for the back color of wire；
Ÿ The 2
nd
letter stands for the strip color.
Fuse
Replacement
1. In replacement of fuse, identify first the
specification of fuse. If the fuse just replaced is
burned out ， it is properly caused by the
short-circuits in the line and needs to be
checked.
2. Prior to replace the main fuse，confirm that the
negative cable of battery has been disconnected；
3. The fuse puller shall be used for the replacement
of fuse.
Jumper of circuit fault diagnostic tool
The jumper is designated to shorten the connection
with both ends of switch or ground for the inspection.
Attention:
Do not use the jumper to ground directly，because
this will result in damage or fire of electric
elements.
Voltmeter
A DC voltmeter can be used to measure the circuit
voltage，the voltmeter with a scale of 15V shall be
applied. Connect the points to be measured with the
positive (red lead) and the negative (black lead) to the
grounding.
Ohmmeter
The ohmmeter is an instrument designated to
measure the resistance between two points in the
circuit ， and used to check the connection or
short-circuit.
Attention :
It is not allowed to connect the ohmmeter with any
circuits where the voltage exists，otherwise it will
damage the ohmmeter.
Voltmeter
PS wire
Black lead
Red lead
Grounding
point
PS wire
Grounding
wire
Ohmmeter
红
黑
Code
Color
Color
Code
Black
Brown
Green
Gray
Blue
Light Blue
Orange
Pink
Red
Purple
White
Yellow
Light Green
Black
Red
Brown
Yellow
Lifting of vehicle
Lifting of vehicle
The position to be jacked up by a jack
Warning
It is dangerous to jack up a vehicle in an improper way，for the vehicle may slide down from the jack
and result in serious personnel injury or vehicle damage. The vehicle has to be jacked up at the defined
position.
Use of diagnostic steps
GI-16
Position to be jacked up by the lifter
Warning:
It is dangerous to lift the vehicle in an unstable way, as the vehicle may be running down from the lifter
and causing serious injury or damage to vehicles. Be sure that the vehicle is within the maximum load of
support equipment.
Front
Rear
Towing vehicle
Towing vehicle
Trailer
Ÿ Correctly lift and tow up the vehicle is necessary
for the vehicle protection;
Ÿ Conform to the local government and laws;
Ÿ Towed by the trailer with the rear wheels
grounded and handbrake released;
Ÿ The front wheels of towed vehicle shall leave
the ground. If the vehicle is seriously damaged
or not allowed by other cases，a tablet car shall
be applied
Attention:
Do not tow in reverse the drive wheels，otherwise, it
will damage the transmission.
Attention:
Do not use the equipment such as pulley for towing，
otherwise it will damage the vehicle.
Attention
:
Ÿ When towing with four wheels grounded，please
observe the following principles:
1. set the shift lever of transmission in the “N”
position;
2. turn the key in the “ACC” position;
3. Release the handbrake;
4. the speed is not allowed to exceed 56km/h，
and the distance of trailer more than 80km，
otherwise it will damage the transmission.
Ÿ Remember that the brake and power steering are
ineffective when the engine flames out.
Ÿ If the speed per hour has to exceed 56km/h
when towing，and the towing distance over
80km，the following methods may be chosen:
— Place the drive wheels on a tablet car;
— Keep the front wheels off the ground;
— Use the tablet car for transport
Use of diagnostic steps
GI-18
Towing hook
Attention:
Ÿ The towing hook shall be used only in case of
emergency(e.g. draw out a vehicle from a ditch
or snowdrift)
Ÿ In use of a tow hook，a rope or chain should be
used to face the towing hook. Side use is not
allowed.
Front end
Rear end
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
Ask a question and I''ll find the answer in the document
Finding information in a document is now easier with AI
Related papers
Other documents
-
Mazda 3 Workshop Manual
-
-
Chery A Series User manual
-
Suzuki GA413 User manual
-
Isuzu C22NE Workshop Manual
-
Great Wall Voleex C30 Workshop Manual
-
-
-
-
Mitsubishi 3000GT 1994 User manual
