Geely CK 2009, CK 2007, CK 2008, CK 2010 User Manual

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Table of Contents

Part I Engine ...........................................................................1

Chapter 1 Engine Assembly (MR479Q, MR479QA, MR481QA)...................1

Section 1 Routine Inspection.........................................................................................1

Section 2 Drive Belt Replacement ...............................................................................5

Section 3 Valve Clearance Adjustment ...........................................................................6

Chapter 2 Engine Components Replacement

(MR479Q, MR479QA, MR481QA) ................................................................10

Section 1 Engine Components ....................................................................................10

Section 2 Engine Components Replacement ............................................................13

Section 3 Timing Belt Replacement .........................................................................17

Section 4 Camshaft Replacement ............................................................................22

Section 5 Cylinder Head Gasket Replacement .........................................................28

Section 6 Oil Pump Oil Seal Replacement ................................................................33

Section 7 Engine Rear Oil Seal Replacement ............................................................34

Chapter 3 Lubrication System (MR479Q, MR479QA, MR481QA) ...............35

Section 1 Oil Pressure Gage Sensor Replacement ....................................................35

Section 2 Oil Pump Assembly Replacement ..............................................................36

Section 3 Oil Filter Replacement ................................................................................38

Section 4 Starter Replacement .................................................................................39

Section 5 Generator Replacement ............................................................................40

Chapter 4 Fuel System (MR7131A, MR7151A, MR7161A) ........................41

Section 1 Check Fuel System Pressure .....................................................................41

Section 2 Fuel Pump Inspection ...................................................................................42

Section 3 Fuel Injector Replacement .........................................................................43

Section 4 Fuel Pump Replacement ............................................................................45

Section 5 Fuel Emission Control System ....................................................................47

Section 6 Carbon Canister Replacement ....................................................................48

Chapter 5 Exhaust System (MR7131A, MR7151A, MR7161A) .................50

Chapter 6 Cooling System Inspection

(MR7131A, MR7151A, MR7161A) .................................................................52

Section 1 System Check

Section 2 Water Pump, Thermostat and Radiator Replacement.................................... 54

...............................................................................................52

Chapter 7 Clutch (MR7131A, MR7151A, MR7161A) ....................................56

Section 1 Clutch Replacement ...................................................................................57

Chapter 8 Maunal Transaxle Assembly

(MR7131A, MR7151A, MR7161A) ................................................................59

Section 1 Manual T ransaxle Replacement ..................................................................60

Section 2 Vehicle Speed Sensor Replacement

Section 3 Transmission Case Oil Seal ..........................................................................62

Section 4 Transaxle Case Oil Seal Replacement ........................................................63

..............................................................61

Chapter 9 General Engine Troubles and Their Troubleshooting ....................64

Section 1 Overview ........................................................................................................64

Section 2 General Engine Fault and T roubleshooting .......................................................64

Section 3 Engine Noise Diagnosis and T roubleshooting ................................................77

Chapter 10 Engine Management Unit..............................................................81

Section 1 System Description .........................................................................................81

Section 2 System Component and W orking Principle ......................................................82

Part II Chassis............................................................................85

Chapter 1 Transmission Control Device .........................................................85

Section 1 Transmission Control Device .........................................................................85

Section 2 Lever Type Transmission Control Device ......................................................85

Section 3 Cable T ype Transmissi on Control Module ......................................................87

Chapter 2 Accelerator Pedal............................................................................90

Section 1 Accelerator Pedal ..........................................................................................90

Chapter 3 Clutch Control System ....................................................................91

Section 1 Clutch Control System ....................................................................................91

Section 2 Clutch Cable Control Mechanism .....................................................................91

Section 3 Clutch hydraulic Control Device .......................................................................94

Chapter 4 Propeller Shaft ...............................................................................97

Section 1 Propeller Shaft .................................................................................................. 97

Chapter 5 Front Suspension System ............................................................... 103

Section 1 Front Suspension System ................................................................................ 103

Section 2 Front Suspension ............................................................................................105

Section 3 Front Wheel Alignment .......................................................................................106

Section 4 Front Strut Assembly ....................................................................................... 107

Section 5 Lower Swing Arm Assembly ............................................................................ 110

Section 6 Front Stabilizer Bar and Link Rod Assembly .....................................................113

Chapter 6 Rear Suspension System ................................................................116

Section 1 Rear Suspension System

Section 2 Rear Suspension ............................................................................................117

Section 3 Rear Wheel Alignment .................................................................................... 118

Section 4 Left & Right Rear Strut Assembly .....................................................................119

Section 5 Rear stabilizer bar assembly, strut rod components ..........................................121

Section 6 Left & Right Trailing Rod Assembly .............................................................. 123

Section 7 No. 1 Transverse Arm Assembly .....................................................................124

Section 8 No. 2 Transverse Arm Assembly .....................................................................125

..................................................................................116

Chapter 7 Wheel ................................................................................................126

Section 1 Tire Inspection ................................................................................................. 126

Section 2 Wheel Replacement ......................................................................................... 127

Chapter 8 Power Steering System .................................................................. 128

Section 1 Power Steering System .................................................................................... 128

Section 2 Steering Drive and Control Mechanism ......................................................... 130

Section 3 Steering Pipeline Component .......................................................................... 133

Section 4 Power Steering Gear Retaining Device

..........................................................136

Chapter 9 Brake System .................................................................................. 139

Section 1 Brake System................................................................................................... 139

Section 2 Brake Fluid ....................................................................................................... 140

Section 3 Brake Pedal...................................................................................................... 141

Section 4 Vacuum Booster with Brake Master Cylinder Assembly ....................................143

Section 5 Front Brake Assembly ..................................................................................... 144

Section 6 Rear Brake

Section 7 Brake Line ....................................................................................................... 151

.....................................................................................................147

Section 8 Parking Brake System ..................................................................................... 155

Part III Electrical Equipment

........................................................157

Chapter 1 Survey................................................................................................157

Chapter 2 Starting and Charging System .........................................................161

Section 1 Starting System (MR479Q MR479QA MR481QA) ..........................................161

Section 2 Charging System (MR479Q, MR479QA, MR481QA) .......................................164

Chapter 3 Combination Meter System ..............................................................171

Section 1 Circuit Diagram of Combination Meter and Location of Multi-pin Plug-in

Terminal ............................................................................................................................ 171

Section 2 Malfunction Symptom T able and Solution Pr ocedure ...........................................174

Section 3 Combination Meter .......................................................................................... 187

Chapter 4 Wiper and Washer System ...............................................................193

Section 1 Wiper and W asher System Inspection ............................................................ 193

Section 2 Replacement and Adjustment ............................................................................196

Chapter 5 Light System ......................................................................................198

Section 1 Survey of Light System......................................................................................198

Section 2 Light System Symptom Inspection .................................................................. 202

Section 3 Headlamp Replacement ....................................................................................211

Section 4 Front Fog Lamp Replacement ............................................................................215

Section 5 Rear Combination Lamp Replacement ..............................................................217

Section 6 High Mounted Stop Lamp Replacement ............................................................218

Section 7 Interior Dome Lamp Replacement .....................................................................219

Section 8 Rear Row Reading Lamp Replacement ...........................................................220

Section 9 License Plate Lamp Replacement ...................................................................220

Chapter 6 Audio System......................................................................................221

Section 1 Audio System Description .................................................................................221

Section 2 Audio System Connector Terminal Layout ...........................................................224

Section 3 Audio System Inspection ................................................................................. 225

Section 4 Audio and V ideo System Replacement ........................................................... 238

Chapter 7 SRS (Supplemental Restraint System).............................................242

Section 1 SRS-General Information .................................................................................242

Section 2 Troubleshooting ................................................................................................ 251

Section 3 Removal & Installation ................................................................................... 262

Chapter 8 MK-20 ABS System ........................................................................ 272

Section 1 ABS Diagnosis ................................................................................................. 272

Section 2 ABS System Check.......................................................................................... 276

Section 3 Removal and Installation .................................................................................292

Part IV Air Conditioner and Inside & Outside Trim ......................297

Chapter 1 A/C System ...................................................................................... 297

Section 1 The Structure & W orking Principle of Refrigeration System ...............................297

Section 2 Heating System ................................................................................................ 299

Section 3 A/C contr olling system .................................................................................... 302

Section 4 Service Caution & Notice ................................................................................ 304

Section 5 The Refrigeration System Operation Procedure ..............................................305

Section 6 Basic System.................................................................................................... 308

Section 7 A/C System Faults Check & Troubleshooting ................................................ 313

Chapter 2 Inside & outside Trim and Accessory................................................318

Section 1 Configuration Index ............................................................................................318

(I) Outside Trim And Front Accessory .................................................................................318

(II) Outside Trim and Rear Accessory .................................................................................319

(III) Front inside trim ..........................................................................................................320

(IV) Rear inside trim ............................................................................................................321

Section 2 Inside & Outside T rim and Accessories Removal and Installation .......................322

(I) Front Bumper ..................................................................................................................322

(II) Engine Hood .................................................................................................................324

(III) Outside Rear View Mirror

(IV) Rear trunk Lid ...............................................................................................................327

(V) Rear Bumper ...................................................................................................................329

(VI) Seat Removal, Installation and Adjustment ...................................................................331

(VII) Seat Belt .....................................................................................................................335

...............................................................................................326

(VIII) Instrument panel and auxiliary console .....................................................................338

(IX) A pillar inside trim and front door sill ............................................................................343

(X) B pillar inside trim ........................................................................................................344

(XI) Cpillar inside trim and rear door sill .............................................................................345

(XII) Roof inside trim

(XIII) Carpet and Heat Insulator.............................................................................................347

...........................................................................................................346

(XIV) Rear trunk Inside Trim ............................................................................348

(XV) Engine Hood Inside Trim ...........................................................................349

(XVI) Door ..............................................................................................................350

Part V Body............................................................................359

Chapter 1 General Information .....................................................................359

Section 1 Body Structure ..............................................................................................359

Chapter 2 Body Repair..................................................................................369

Section 1 Body Damage Forms and Requirements for Repair ....................................369

Section 2 T ypical Technology Of Body Panel Repair ..................................................372

Section 3 Repair after Body Damage ..........................................................................372

Section 4 Features and Composition of Automobile Body ............................................. 377

Section 5 Painting Technique after Body Repair............................................................383

Section 6 Service Data For Body ................................................................................385

Part I Engine

Chapter 1 Engine Assembly

(MR479Q, MR479QA, MR481QA)

Section 1 Routine Inspection

1. Check coolant

2. Check engine oil

3. Check battery

4. Check air cleaner element assembly

5. Check spark plug

6. Check drive belt

Water pump

generator

Power steering pump

crankshaft

Belt Looseness

Notice:

Check the belt deflection at the specified point See (Figure 1).

Measuring Point

Figure 1

Air condition

compressor

Fan Belt 7

Power steering Belt 5～66

A/C Belt 6. 5～78

Belt deflection See (Table 1)

Belt pressure : 98N

New Belt mm Old Belt mm

～

11.5

～

13.5

8 9

z Set tension to specified value when installing new belt. z Check the deflection to ensure it is below the specified value after the belt runs for over 5 minutes. z Reinstall the belt which has been running for over 5 minutes. The deflection of the old belt is regarded as

the standard for inspection.

z Check V-belt for tension and distortion after the engine cranks for 2

turns.

7. Check ignition timing See (Figure 2) a) Warm up the engine.

b) When using fault diagnosis tester

Connect fault diagnosis tester to fault diagnosis interface socket.

Ignition timing: MR479Q: 10 ± 2° BTDC (before top dead center) at idle MR479QA: 10 ± 2° BTDC at idle MR481QA: 10 ± 2° BTDC at idle

Figure 2

c) When fault diagnosis tester is not used

(1) Shorting fault diagnosis interface socket 13 (TC) terminal and 4(CG) terminal.

Notice:

z Ensure correct connection, otherwise the engine will be damaged. z Switch off all electrical appliance system. z Check when disconnecting cooling fan motor.

(2) Using timing light to check ignition timing.

Ignition timing: 10 ± 2° BTDC at idle Notice: (1) Transmission shift lever should be in neutral position when checking ignition timing. (2) Running engine at 1,000-1,300rpm for 5s and check at idle. (3) Remove the tester on fault diagnosis socket. (4) Ignition timing advance angle becomes larger when the engine roate speed is higher. (5) Remove timing light.

8. Check engine idle See (Figure 3) (a) Warm up the engine.

(b) Connect fault diagnosis tester to fault diagnosis interface socket. (c) Connect tachometer testing pen to fault diagnosis socket terminal

9 when not using fault tester.

(d) Check idle See (Table 2).

Table 2

MR479Q 800±50 (rpm) MR4 79QA 800±50 (rpm) MR 4 81QA 800±50 (rpm)

Notice:

z Check idle when cooling fan motor is disconnected.

Switch off all electrical accessories and A/C.

9. Check compression pressure See (Figure 4) (a) Engine switched off.

Techometer

Battery

Figure 3

(b) Detach high voltage cable. (c) Detach spark plug. (d) Check the compression pressure in the cylinder.

(1) Insert pressure gauge into the hole of the spark plug. (2) Throttle valve full open.

(3) Crank the engine, measure the compression pressure.

Figure 4

The Min. compression pressure: 980 kPa The tolerance range of the cylinders pressure: 100 kPa Notice:

Ensure sufficient battery power and the engine speed is no less than 250 RPM (revolutions per minute).

z Check the compression pressure of other cylinders in the same way. z Complete the measure as quick as possible.

(4) If the compression pressure in several cylinder is too low, fill some engine oil to the cylinder via the

hole of the spark plug. Check by repeating step 1-3.

Hint:

z If the compression pressure is improved after filling oil, the piston ring or the cylinder may be abrased

or damaged.

z If the pressure is still too low, the valve is stagnation or poor seal, or there is a leakage in gasket.

10. Check CO/HC (a) Start engine. (b) Running engine at 2500rpm for approximately 3 minutes. (c) Insert CO/HC meter testing probe into tailpipe at least 40cm during idling. (d) Check CO/HC concentration at idle and 2500rpm. Hint:

Complete measurement within 3 minutes.

z z Test the CO/HC emission concentration at idle and 2500 rpm on QC/T630-1999 standard.

(e) Take the following steps to diagnose the fault if the CO/HC concentration does not comply with standard .

(1) Check the oxygen sensor operation. (2) See (Table 3) for the possible cause and check and repair.

CO HC Problems Causes

1. F ault . I ncorrect ignition timing

Table 3

Normal

Low High

High High

Rough idleHigh

Rough idle

(Bla c k smoke

from exhaust

pipe)

. Fouled, s hor t ed or improperly cle ara nce of spar k plug

2. Incorrect valve clearance

3. Leaky inta ke & exhaus t valves

4. Leaky cylinders

1. Air leaks . PCV hoses, intake manifold . Throttle body . Brake booster circuit

2. L ean mixture gas caus ing misfire

1. Clogged air filter

2. C logged PCV valve

. Faulty ECU . Faulty fuel pre ssure regula t or . Faulty wa ter temperature sensor . Faulty air compressor . Faulty injectors . Faulty throttle position sensor

Section 2 Drive Belt Replacement

1. Disconnect all engine pipe hose and wire joint. Remove engine assembly from the engine compartment, jack up the body, take out the engine assembly slowly (See Provision 20, Section Two, Chapter Two for detailed information)

2. Remove generator V-belt See (Figure 5)

3. Remove No. 1 V-belt A/C compressor to crankshaft pulley

4. Remove water pump belt See (Figure 6)

5. Install water pump V-belt

6. Adjust V-belt of steering assisting pump (a) Adjust power steering belt tension, tighten bolt B.

(b) Tighten bolt A. Torque : 39N. m

7. Install V-belt A/C compressor No. 1 to crankshaft pulley

8. Adjust V-belt A/C compressor No. 1 to crankshaft pulley

(a) Adjust A/C belt tension by tightening bolt B. (b) Tighten nut A.

Torque : 39N. m

9. Install Generator V-belt See (Figure 7)

10. Adjust Generator V-belt. Tighten bolt A and then bolt B.

Figure 6Figure 5

Torque: Bolt A 18N. m Bolt B 58N. m

11. Check driving belt for distortion and tension

Figure 7

Section 3 Valve Clearance Adjustment

1. Remove right camshaft timing gear

2. Remove ignition coil and high voltage cable

3. Remove cylinder head cover sub-assembly See (Figure 8) (a) Disconnect generator wire joint.. (b) Disconnect generator circuit. (c) Disconnect oil pressure switch connector. (d) Disconnect A/C compressor switch connector. (e) Open the wire harness clip. (f) Remove wire harness from cylinder head cover. (g) Separate 2 ventilation hoses from cylinder head cover. (h) Remove 4 screw nuts, 4 oil seal gaskets, cylinder head and gasket.

4. Adjust piston of Cylinder 1 to the compression position (a) Turn crankshaft pulley, align notch to timing mark "0" on Cylinder 1. See (Figure 9).

Figure 8

(b) Align mark "K" on camshaft timing pulley to the timing mark on bearing cap. See (Figure 10) Crank 360°

if it is not aligned.

Figure 9

5. Check valve clearance (cool). See (Table 5)

Table

Figure 10

Intake Valve mm Exha ust Valve mm

MR479Q 0.20 ± 0.05 0.30 ± 0.05 MR479Q A 0. 20 ± 0.05 0.30 ± 0.05 MR481Q A 0.20 ± 0.05 0.30 ± 0.05

(a) Turn the crankshaft pulley for 360°. Align notch to timing mark "0" on timing belt cover No. 1. (b) Only check the valve as shown in the figure. Valve clearance measurement. See (Figure 11).

Figure 11

6. Adjust intake valve clearance (a) Detach intake camshaft

Notice: Because the camshaft end play is quite small, keep camshaft horizontal when removing it. If not, cylinder

head may be partially damaged by the thrust force£¬it may stuck or damage camshaft when turning crankshaft. Take the following steps to avoid the damage:

(1) Turn the pulley to access the hole on the camshaft drive gear where the counter gear is installed. See

(Figure 12).

Hint: The above condition allows the cylinders No. 1 and No. 3 of the intake camshaft to push up the valve tappet.

Figure 12

Figure 13

(2) Remove bolt and bearing cap No. 1. (3) Install camshaft counter gear to drive gear with service bolt. See (Figure 13).

(4) Uniformly loose and remove 8 bearing cap bolts in several passes as

shown in the figure. See (Figure 14).

(5) Remove 4 bearing caps and camshafts.

Figure 14

Notice: Due to the small end play on camshaft, the cylinder head may be damaged by the thrust force when removing

it, it may stuck or damage camshaft. Take the following steps to avoid damage: (1) Turn the crankshaft pulley to make exhaust camshaft dowel pin is a bit higher than the cylinder head. See

(Figure 15).

(2) Align the matchmark on each gear to engage intake camshaft gear and exhaust camshaft gear. See

(Figure 16).

(3) When the gears are engaged, install the intake camshaft bearing onto bearing journal.

Install Mark

March Mark

Timing Mark

Figure 15

Figure 16

Hint: The intake camshaft lobe of cylinder 1 and 3 can jack up their own valve tappet. (5) Install 4 bearing caps to the right position. (6) Apply a light layer of engine oil on the thread and under the head of bearing cap bolts. (7) Uniformly install and tighten 8 bearing cap bolts in several times, in the sequence shown in the figure.

Torque: 13N. m (8) Remove service screw. (9) Install the bearing cap No. 1. in the direction of the forward arrow mark. (10)Apply a light layer of engine oil on the thread and under the head of bearing cap bolts. (11)Alternatively tighten and install 2 bearing bolts.

Torque: 13N. m

Cam Lobe

Upward

7. Adjust exhaust valve clearance. See (Figure 17)

Remove adjust gasket.

Front

(1) Crank to keep the camshaft head upward.

Nick

(2) Face valve tappet nick to vehicle front. (3) Press valve tappet, put special tool between camshaft and valve tappet.

Figure 17

Hint:

z Lean the end with mark "9" into the position in (Figure 18).

Figure 18

(4) Alternatively press valve tappet with the special tool (A) (B). Check

valve clearance. See (Figure 19).

8. Install cylinder head sub-assembly (a) Remove all old gasket material. (b) Apply the seal glue to the cylinder head. (c) Connect wire harness and clip. (d) Install gasket under of cylinder head. (e) Install the cylinder head cover with 4 seal gaskets and 4 screw caps.

T orque: 7.8N. m (f) Install 2 ventilation hoses to cylinder head cover. (g) Connect generator wire joint. (h) Connect generator wires. (i) Connect oil pressure switch connector. (j) Install wire clip. (k) Connect A/C compressor switch connector.

9. Install electronic ignition coil and high voltage cable

10. Check engine oil for leakage

Figure 19

Chapter 2 Engine Components Replacement

(MR479Q, MR479QA, MR481QA)

Section 1 Engine Components

Component 1

Air Filter Assembly W/ Hose

Accelerator Control

Cable Assembly

Heater Inlet Hose

Heater Outlet Hose

Fuel Sub-Assembly

Efi Fuel Pipe Clamp

Radiator Assembly

MT: Clutch Release

Cylinder Assembly

Radiator Inlet Pipe

AT: Oil Cooler

Outlet

Pipe

Inlet

Pipe

Radiator Outlet Pipe

Starter Assembly

MT: Transmission Control Cable Assembly

AT: Transmission Control Cable Assembly

Battery

Front Exhaust

Pipe Assy.

Tail Pipe

Muffler

3-way catalytic converter

Figure 20

Component 2

Fan & Generator V-Belt

Vane-Type Pump V-Belt (V/ Power Steering)

V-Belt No.1

Right Engine Glove Compartment

Steering Column Hole Cover

Mounting Insulator

Door Assembly

Steering Column Assembly

Steering Column Hole Cover

One-off accessory

Front Shaft Hub Left Nut

Front exhauxt pipe assembly

Gasket

Figure 21

Left Engine Mounting Bracket

Left Front Speed Sensor

Gasket

Flywheel

Component 3

Clutch Disc

Clutch Release Fork

Clutch Cover

Clutch Release Bearing

Release Fork Support

Release Fork Boot

Figure 22

Section 2 Engine Components Replacement

1. Avoid gasoline ejection when work.

2. Drain the coolant to empty.

3. Remove air filter assembly with hose. See (Figure 23)

4. Remove battery

5. Remove fuel delivery pipe sub-assembly

6. Disconnect water hoses, disconnect heater outlet hose

from A/C hose.

7. Loose nut, remove accelerator control cable

8. Remove throttle body assembly

9. Remove power steering pump reservoir assembly

10. Remove front exhaust pipe assembly

11. Remove steering gear boot

12. Seperate steering column assembly. See (Figure 24)

13. Remove front wheel hub nut

Figure 23

14. Disconnect front wheel vehicle speed sensor (with ABS)

15. Detach steering tie rod ball stud pin assembly

16. Detach front lower swing arm sub-assembly

17. Detach front propeller assembly. See (Figure 25)

Detach front propeller from the shaft hub with plastic hammer.

18. Disconnect transmission shift cable or gear shift level assembly

19. Disconnect clutch cylinder assembly or disconnect clutch cable

20. Detach engine assembly and transaxle (a) Hoisting engine ; (b) Remove 3 bolts. Detach the right engine mounting bracket. See (Figure 26) ; (c) Remove 1 bolt. Detach the left engine mounting bracket; (d) Remove 1 bolt. Detach the rear engine mounting bracket; (e) Remove engine and transaxle and put them on the pallet; (f) Jack up the boday.

Figure 24

Figure 25 Figure 26

21. Remove radiator assembly

22. Remove engine V-belt

23. Remove No. 1 V- belt (A/C compressor to crankshaft pulley)

24. Remove generator assembly

25. Remove A/C compressor

26. Remove compressor installing No. 1 bracket. Remove 4 bolts and compressor installing No. 1 bracket.

27. Remove starter assembly

28. Remove power steering pump V- belt

29. Detach power steering pump assembly

30. Remove power steering pump, adjust the bracket

31. Detach manual transaxle assembly (Separate automatic transaxle assembly)

32. Detach clutch cover panel assembly.

33. Detach clutch pressure plate assembly.

34. Detach flywheel sub-assembly.

35. Remove engine rear end cover.

36. Remove injector assembly and remove intake manifold.

Remove 2 bolts and intake manifold support and remove 7 bolts, 2 nuts, intake manifold and gasket. See (Figure 27).

37. Remove knock sensor

38. Remove water temperature gauge sensor

39. Remove crankshaft position sensor

40. Remove engine oil pressure switch

41. Remove water inlet hose housing

42. Remove water outlet hose joint

43. Detach exhaust manifold. See (Figure 28)

44. Remove engion oil filter sub-assembly

45. Remove ignition coil and high voltage cable

46. Install engine sub-assembly

47. Install ignition coil and high voltage cable

48. Install engine oil filter sub-assembly

49. Install exhaust manifold

Figure 27

(a) Install new gasket and exhaust manifold stay with

5 nuts, Torque: 34N. m

(b) Install exhaust manifold stay with two bolts.

Torque: 59N. m

Torque: 17N. m

Figure 28

50. Install water outlet hose joint. See (Figure 29, 30)

Figure 29

Figure 30

51. Install water inlet hose housing. See (Figure 31, 32)

Figure 31 Figure 32

52. Install engine oil pressure switch

53. Install crankshaft position sensor T orque: 9, 3N. m

54. Install water temperature gauge and water temperature sensor T orque: 15N. m

55. Install knock sensor Torque: 44N. M

56. Install intake manifold. See (Figure 33)

Install the intake manifold with new gasket with 7 bolts and 2 nuts. Uniformly tighten bolts and nuts in several time.

57. Install injector assembly

58. Install rear end cover

59. Install flywheel sub-assembly. See (Figure 34)

(a) Install flywheel to crankshaft. (b)Install and uniformly tighten and connect bolt as shown in the

figure. Torque: 78N. m

60. Install clutch assembly

61. Install flywheel and ring gear. See (Figure 35)

(a)Install the oil thrower, it’s chamfer side on crankshaft in

the axie direction.

(b) Install flywheel and ring gear on crankshaft.

Figure 33

Figure 34

the figure.

Torque: 64N. m

62. Install manual transaxle assembly

63. Install starter assembly

64. Install power steering pump bracket

65. Install power steering pump adjusting bracket with 2 bolts.

66. Connect power steering pump assembly

67. Install engine assembly and transaxle

68. Connect left, right, front and rear lower suspension arm sub-assembly

69. Connect left and right tie rod ball stud pin assembly

70. Connect left, right and front vehicle speed sensor (with ABS)

71. Install left & right nuts on the front shaft hub

72. Install front exhaust pipe assembly

73. Connect steering shaft assembly and steering column hole cover. See (Figure 36)

74. Connect wire harness

75. Install belt adjusting bracket of A/C compressor

76. Connect A/C compressor

77. Install generator assembly

78. Install A/C compressor to crankshaft pulleyV-belt

79. Install generator belt

80. Install engine assembly with transaxle

81. Install radiator assembly

82. Install throttle body assembly

83. Install fuel delivery pipe sub-assembly

84. Install battery

85. Install air filter assembly with hose

86. Install front wheel

87. Fill engine oil

88. Fill coolant

89. Check engine oil for leakage

90. Check engine coolant for leakage

Figure 35

91. Check fuel for leakage

92. Check idle and ignition timing

93. Check CO/HC

94. Check and adjust front wheel alignment

95. Check ABS vehicle speed sensor signal

Figure 36

Right Engine Mounting

Section 3 Timing Belt Replacement

Air Filter Assembly W/ Hose

Ventilation Pipe

Seal

Cylinder Head

Vane-Type Pump V-Belt V/ Power Steering

Cylinder Head Gasket

High Pressure Cable

Gasket

V-Belt No.1

Timing Chain Or Timing Belt Cover Assembly No. 2

Crankshaft Or Pulley

Cover Sub-Assembly

Timing Chain Timing Belt

Crankshaft Pulley

Cover Sub-Assembly

Fan & Generator V-Belt

Timing Belt

Timing Belt Guide

Fan Pulley

Generator Assembly

Figure 37

1. Disconnect engine from all the wire harnesses and cables connected to body.

2. Remove air filter assembly with hose. See (Figure 38)

3. Disconnect oil pipe and water hoses

4. Loose positive and negative cables on battery

5. Detach propeller shaft

6. Loose engine left & right rear brackets after hoisting engine

7. Disconnect all the connectors of engine and the body

8. Remove engine per "Provision 20, Section 2, Chapter 2"

9. Remove A/C compressor to crankshaft pulley V-belt

10. Remove power steering pump V-belt

11. Remove water pump fan pulley

12. Remove high pressure cable.

13. Remove cylinder head cover sub-assembly

14. Remove generator assembly. See (Figure 39)

15. Put the piston in Cylinder 1 to TDC compression position (a)Turn crankshaft pulley to align its notch to the timing mark "0"

on the timing belt cover. See (Figure 40).

(b) Check if the "K" mark on camshaft timing pulley and the timing mark

on the bearing cap are aligned. Crank the crankshaft for 360 degrees if not. See (Figure 41).

16. Remove crankshaft pulley

17. Remove timing belt cover

18. Remove crankshaft gear or pulley cover sub-assembly

19. Remove timing belt cover sub-assembly

Figure 38

Figure 39

Figure 40

Figure 41

20. Remove timing belt guide wheel Hint: (a) Mark on pulley and belt (in engine turning direction) if re-using timing belt (See Figure 42). (b) Install bolt to the idler pulley. Move pulley to its far left and tighten it temperarily (See Figure 43).

21. Remove spark plug and gasket

Figure 42

22. Install spark plug and gasket

23. Put the piston in Cylinder 1 to TDC compression position. See (Figure 44)

(a) Turn camshaft hexagon part. Align the mark "K" on the camshaft

timing pulley to the mark on the bearing cap.

(b) Using the crankshaft pulley bolt, turn the crankshaft, align the mark

on crankshaft timing pulley to the oil pump.

24. Install timing belt. See (Figure 45) Notice: The engine must be cool. (a) Install timing belt. Check the tension force between crankshaft timing

pulley and camshaft timing pulley. Hint: Align the marks if re-using the timing belt when removing. The

engine's rotating direction should be the same with the arrow's when installing belt.

Figure 43

Figure 44

(b) Check valve timing. Loose idler bolt.

(1) Turn crankshaft from TDC to BDC slowly.

Notice: Crank always in clockwise.

Figure 45

(2) Align each pulley to timing mark as shown in the figure. If the timing mark is not aligned,

remove timing belt and reinstall it.

(3) Tighten idler bolt.

T orque: 37N. m

(4) Remove crankshaft pulley bolt.

Check the belt distorn as shown in the figure. Belt deflection: 20N: 5~6mm Re-adjust the idler if the deflection does not comply with the regulation.

25. Install timing belt guide wheel. See (Figure 46) Install guide, place the cup side outward.

26. Install timing belt cover sub-assembly

Torque: 9.3N. m

27. Install crankshaft gear or pulley cover sub-assembly Torque: 9.3N. m

28. Install timing belt cover Torque: 9.3N. m

29. Install crankshaft pulley. See (Figure 47)

(a) Align pulley lock key and pulley key groove. Install pulley .

Figure 46

(b) Install pulley bolt T orque: 127N. M

30. Install generator assembly

31. Install water pump pulley

32. Install power steering pump V-belt

33. Install A/C compressor fan to crankshaft pulleyV-belt

34. Install cylinder head cover sub-assembly.

(a) Wipe off all seal packing material. (b) Apply the seal glue on cylinder head cover as shown in Figure 48. (c) Install gasket onto cylinder head cover. (d) Install cylinder head cover with 4 seal gaskets and 4 nuts.

Torque: 7.8N. M (e) Install 2 ventilation hoses onto cylinder head cover. (f) Install engine wire harness onto cylinder head cover. (g) Connect generator wire joint. (h) Connect generator wire.

Figure 47

(i) Connect oil pressure switch connector. (j) Install wire clip. (k) Connect A/C compressor switch connector.

35. Hoist the engine back into the compartment

36. Install left & right rear engine mounting brackets

37. Install ignition coil and high pressure cable

38. Install air filter assembly with hose

Figure 48

39. Install oil pipe and water hose

40. Install left & right propeller shaft

41. Install left & right front wheel

42. Check engine oil for leakage

43. Install all connected wire harnesses and the cables on engine and vehicle body

Section 4 Camshaft Replacement

Air Filter Assembly W/ Hose

Vane-Type Pump V-Belt

V/ Power Steering

Fan & Generator V-Belt

V-Belt No.1

Cylinder Head

Crankshaft Bearing Cap

Crankshaft Timing Belt Washer

Crankshaft Counter Gear

Wave Gasket

Ventilation Pipe

Cylinder

Head Gasket

High Pressure Cable

Seal

Right Engine Mounting

Snap Ring

Camshaft Timing Pulley

Fan Pulley

Timing Belt Cover No. 2

Crankshaft Or Pulley Cover Sub-Assembly

Figure 49

Camshaft

Camshaft No. 2

Oil Seal

Generator Assembly

1. Disconnect all connected wire harnesses and the cable on the engine and the vehicle body

2. Remove air filter assembly with hose

3. Disconnect oil pipe and water hose

4. Loose positive and negative cables of the battery

5. Detach propeller shaft

6. Loose left & right rear engine mounting bracket after hoisting the engine.

7. Disconnect all other connectors between the engine and the vehicle body.

8. Remove engine per "Provison 20, Section 2, Chapter 2"

9. Remove A/C compressor to crankshaft pulleyV-belt

10. Remove power steering pump V- belt

11. Remove water pump fan pulley

12. Disconnect ignition coil and high voltage cables

13. Remove cylinder head cover sub-assembly

14. Remove generator assembly

15. Remove cylinder head cover sub-assembly (a) Disconnect generator wire joint. (b) Disconnect generator circuit (c) Disconnect A/C compressor switch connector. (e) Open wires clips. (f) Disconnect wire harness from the cylinder head cover. (g) Disconnect 2 ventilation PCV hoses from cylinder head cover. (h) Remove 4 screws, 4 seal gaskets, cylinder head and gasket.

16. Remove generator assembly. See (Figure 50)

17. Remove timing belt cover

18. Remove crankshaft gear or pulley cover sub-assembly

19. Put the piston on Cylinder 1 to TDC compression position. (a) Turn crankshaft pulley. Align its notch to the timing mark "O" on the

timing belt cover.

(b) Check if the mark "K" on camshaft timing pulley is aligned to the

timing mark on the bearing cap. Turn crankshaft 360° if not.

20. Remove ignition coil assembly

Figure 50

Figure 51

21. Remove timing belt. See (Figure 51) (a) Mark on the timing belt and the camshaft pulley. The mark on the

timing belt to the timing belt cover No. 1 should match.

(b) Remove rubber gasket from timing belt cover.

its far left and tighten it temporarily. (d) Remove the belt from the camshaft timing pulley. Notice:

z Hold the timing belt, the engagement of the crankshaft timing

pulley and timing belt will not move.

z Be careful not to drop anything into the timing belt cover. z Do not let the belt contact oils, water or dirt.

Figure 52

Figure 53

22. Remove the camshaft and the timing pulley. See (Figure 53) (a) Turn the camshaft hexagon head and loose pulley bolt. (b) Remove pulley bolt and timing pulley.

23. Remove camshaft. See (Figure 54) Because the camshaft end play is quite small, keep camshaft horizontal

when removing it.Take the following steps to avoid the damage: (a) Remove the camshaft

(1) Turn the camshaft to access the hole of the counter gear installed on camshaft drive gear.

Hint: The intake camshaft lobe of Cylinder 1 and 3 can push up their

own valve tappet. (2) Remove 2 bolts and bearing cap No. 1. (3) Install the counter gear on the intake camshaft with the service

bolt onto the drive gear.

(4) Uniformly loose and detach 8 bearing cap bolts in several times

in the sequence shown in Figure 55.

Figure 54

Figure 55

(5) Remove 4 bearing caps and camshaft. If the camshaft can not be kept horizontal, lift it vertically. Reinstall the

bearing cap with 2 bolts. Alternatively loose and detach the bearing cap bolts and lift the camshaft gear. See (Figure 56)

Figure 56

(b) Remove the counter gear of the camshaft.

(1) Clamp the camshaft's hexagon on the vise. (2) Turn the counter gear cloclwise, Remove the service bolt. (3) Remove the snap ring with a circlip pliers. See (Figure 57). (4) Remove waved gasket, camshaft counter gear and the camshaft gear spring. See (Figure 58)

24. Remove and install spark plug hole gasket. See Provision 15 and 16, Section 3 Timing Belt Replacement for detailed information. See (Figure 44, 45).

Rotate

Figure 57

Figure 58

25. Install camshaft (a) Install exhaust camshaft and turn camshaft counterclockwise to make the dowel pin cross the vertical

line a little. See (Figure 59).

(b) Apply grease to a new oil seal lip and install it into the oil seal. See (Figure 60).

Figure 59

Figure 60

Figrue 61

(1) Clamp the camshaft's hexagon head with a vise. (2) Install camshaft gear spring, camshaft counter gear and waved washer. (Figure 61). Hint: Align the pin on the gear to the spring end of the counter gear. (3) Install the snap ring with a circlip plier. (4) Turn the counter gear clockwise with the special tool. Align the

holes on the camshaft drive gear. Install the service bolt.

(d) Install intake camshaft.

(1) Make the exhaust camshaft dowel pin a bit higher than the top of the cylinder head. (2) Apply grease to camshaft's contact surface. (3) Install intake camshaft gear to exhaust camshaft gear ,

Align the matchmarks on each gear. See (Figure 62).

(4) Check the timing marks on the camshaft gear for

alignment.See (Figure 63).

Hint: Matchmark is on the top.

26. Adjust valve clearance

Install Mark

Timing Mark

27. Install camshaft timing pulley

Turn the camshaft's hexagon head. Tighten the timing pulley bolt. See (Figure 64). Torque: 59N. M

Install Mark

Timing Mark

Install Mark

Figure 62

Figure 63

5-6mm

Figure 65

Figure 64

Figure 66

28. Install the timing belt

(a) Align the marks on timing belt and the one on camshaft timing pulley. (b) Install timing belt. Check tension force between the crankshaft timing pulleys. See (Figure 65).

29. Check valve timing

(a) Loose idler bolt. (b) Turn crankshaft from TDC clockwise for 2 cycles. (c) Check and align each pully to the timing mark as shown in Figure 66. Remove timing belt and reinstall it

if not.

30. Install crankshaft gear or pulley cover sub-assembly

Torque: 9.3N. m

31. Install timing belt cover

Torque: 9.3N. m

32. Install generator assembly

33. Install right engine mounting bracket. See (Figure 67)

34. Install cylinder head cover sub-assembly

(a) Install 2 ventilation PCV hoses to the cylinder head cover. (b) Connect the generator wire. (c) Install the wire clip. (d) Connect A/C compressor switch connector.

35. Install water pump pulley

36. Install power steering pump V-belt

37. Install A/C compressor to crankshaft pulleyV-belt

38. Install generator V-belt

39. Install left & right rear mounting bracket of engine.

40. Install ignition coil and high voltage cable

41. Hoist the engine back into the compartment

42. Install propeller shaft

43. Install air filter assembly with hose

44. Install oil pipe and water hoses

45. Install left and right front tires.

Figure 67

46. Check engine oil for leakage

47. Install all the wire harnesses and the cables on the engine connected to car body

Section 5 Cylinder Head Gasket Replacement

Component 1

Vane Pump Assembly V/ Power Steering

Throttle Body Assembly

Dipstick

Fuel Delivery Pipe No.1

Inlet Pipe

Gasket

O-Ring

Timing Chain Or Timing Belt Cover No. 2

Crankshaft Or Pulley Cover Sub-Assembly

Fan Pulley

Gasket

Wire Harness

Figure 68

Component 2

High Pressure Cable

Camshaft Bearing Cap

Oil Seal

Camshaft Timing Pulley

Cylinder Head Sub-Assembly

Cylinder Head Gasket

Camshaft

Camshaft No.2

Ventilation Pipe

Seal

Cylinder Head Cover

Cylinder Head Cover Gasket

Exhaust Manifold Insulator No. 1

Figure 69

Gasket

Exhaust Manifold

Manifold Mounting

Air Filter Assembly W/ Hose

Right Scuttle Ventilation Grille

Component 3

Engine Hood

Right Wiper Arm

Left Wiper Arm

Right Engine Mounting Bracket

Left Scuttle Ventilation Grille

Vane-Type Pump

V-Belt V/ Power Steering

V-Belt No.1

Accelerator Cable Assembly

Generator Assembly

Heater Inlet Hose

Radiator Inlet Hose

Fan & Generator V-Belt

Wiper Arm Subassembly

EFI Fuel Hose Clamp

Fuel Pipe Sub-Assembly

Heater Outlet Hose A

Radiator Outlet Hose

Figure 70

Replacement

1. Disconnect all the wire harnesses and the cables on the engine connected to the car body.

2. Detach air filter assembly with hose

3. Disconnect oil pipe and water hose

4. Loose positive and negative cables of the battery.

5. Detach propeller shaft. Detach front exhaust pipe assembly

6. Loose engine left & right rear brackets after hoisting the engine.

7. Disconnect all the other connectors between the engine and the car body.

8. See "Provision 20, Section 2, Chapter 2". Lift the car body and take out the engine assembly.

9. Remove A/C compressor to the crankshaft pulleyV-belt.

10. Remove power steering pump V-belt.

11. Detach water pump fan pulley.

12. Disconnect ignition coil and high voltage cable.

13. Detach cylinder head cover sub-assembly.

14. Detach generator assembly.

15. Detach the camshaft.

16. Detach the throttle body assembly

17. Detach intake manifold stay No. 2.

18. Take out the dipstick

19. Detach No. 1 fuel delivery pipe

20. Detach the wire harness.

21. Detach the steering assisting pump assembly

22. Detach exhaust manifold. See (Figure 71)

23. Pry cylinder head from the dowel pin on the cylinder block. See (Figure 72)

24. Remove the cylinder head gasket.

25. Install cylinder head gasket

26. Install cylinder head sub-assembly

27. Install exhaust pipe assembly.

(a) Install the new gasket and exhaust manifold with 5

bolts. Torque: 34N. m

Figure 71

(b) Install exhaust manifold stay with 2 bolts. (c) Install upper heat shield with 4 bolts

T orque: 17N. m

Figure 72

28. Install power steering adjusting pole

29. Install power steering pump assembly

30. Install wire harness.

31. Install No. 1 fuel delivery pipe

32. Set the new gasket on cylinder head with flange upward. Install water inlet hose. See (Figure 73)

33. Install manifold stay No. 2

34. Connect front exhaust pipe assembly

35. Install throttle body assembly

36. Install camshaft

37. Install engine cylinder head cover

38. Hoist the engine back to the compartment.

39. Install engine right left and rear brackets

40. Install propeller shaft

Figure 73

41. Install ignition coil and high pressure cables. Install air filter assembly with hose

42. Install oil pipe and water hose

43. Install left & right front tire

44. Install all the wire harnesses and cables on the engine connected to car body

45. Check compression pressure

46. Check CO/HC. Check idle and ignition timing

Section 6 Oil Pump Oil Seal Replacement

1. Pry with 2 screwdrivers. Detach crankshaft timing pulley. See (Figure 74)

2. Remove oil pump oil seal. See (Figure 75)

(a) Using a knife, cut off oil seal lip. (b) Using a screwdriver, pry out the oil seal.

3. Install oil pump oil seal. See (Figure 76)

(a) Smear grease to a new oil seal lip. (b) on the oil seal with hammer until the edge of the oil pump

case is filled with the seal packing.

4. Install crankshaft timing pulley. See (Figure 77)

(a) Align pulley set key to the key groove. (b) Place the flange face inward. Install timing pulley.

5. Install timing belt

6. Check engine oil for leakage

Figure 74

Figure 75

Figure 76

Figure 77

Section 7 Engine Rear Oil Seal Replacement

1. Detach engine and manuel transaxle assembly on "Provision 20, Section 2, Chapter 2"

2. Detach clutch case assembly

3. Remove clutch plate assembly

4.Fix the front end of crankshaft. Detach flywheel. See (Figure 78)

5. Remove rear crankshaft end cover

6. Remove engine rear oil seal. See (Figure 75)

7. Install engine rear oil seal. See (Figure 76)

8. Install flywheel sub-assembly. See (Figure 79)

(a) Fix crankshaft. (b) Install flywheel to crankshaft. as the sequence shown in the figure, (c) Install and uniformly tighten and install bolt

T orque: 78N. m

9. Install clutch plate assembly

10. Install clutch case assembly

11. Install manual transaxle assembly

Figure 78

Figure 79

Chapter 3 Lubrication System

(MR479Q, MR479QA, MR481QA)

Section 1 Oil Pressure Gage Sensor Replacement

1. Check oil level

Warm up the engine. Check the dipstick to ensure oil level between "L" and "F" after engine stopped 5 minutes. Check for leakage if it is too low. Fill oil to "F.

2. Check oil for deterioration. Water entry, discolor and dilution. Replace oil if it is obviously deteriorated.

3. Detach oil pressure sensor assembly. See (Figure 80)

4. Install oil pressure gage sensor. See (Figure 81) Start engine to normal operation temperature.

5. Check for oil pressure

6. Smear adhesive on 2 or 3 threads of the oil pressure sensor. Install oil pressure sensor. See (Figure 82)

Figure 80

Figure 82

Figure 81

Section 2 Oil Pump Assembly Replacement

1. Remove timing belt

2. Remove timing belt idler sub-assembly

3. Detach crankshaft timing pulley. See (Figure 74)

4. Remove the dipstick guide

5. Detach oil sump sub-assembly. See (Figure 83)

6. Detach oil strainer sub-assembly. See (Figure 84)

7. Detach oil pump assembly. See (Figure 85)

8. Remove oil pump oil seal

9. Install oil pump oil seal

10. Install oil pump assembly

11. Install oil strainer sub-assembly

12. Install oil sump assembly. See (Figure 86)

Figure 84

Figure 83

Figure 86

Figure 85

13. Install the dipstick guide. See (Figure 87)

14. Install crankshaft timing pulley. See (Figure 77)

15. Install timing belt idler sub-assembly No.1

16. Install timing belt

17. Fill in engine oil

18. Check oil for leakage

Figure 87

Section 3 Oil Filter Replacement

1. Detach oil filter sub-assembly. See (Figure 88)

2. Install oil filter sub-assembly. See (Figure 89)

Figure 88 Figure 89

3. Install drain plug

Clean and use new washer to install drain plug. Torque: 54N. m

4. Oil fill

Capacity: Oil refill amount with the filter replaced: 3.0L Oil refill amount without the filter dry fill replaced: 2.80L Dry fill: 3.3L

5. Check oil for leakage

Section 4 Starter Replacement

1. Detach starter assembly. See (Figure 90)

2. Install starter assembly

Torque: Bolt 37N. m

Figure 90

Section 5 Generator Replacement

1. Detach V-belt of generator

2. Detach generator assembly

(a) Disconnect wire joint of generator. (b) Remove wire of generator. (c) Disconnect oil pressure switch interface. (d) Disconnect A/C compressor switch connector. (e) Open wire clips. (f) Detach 2 bolts and generator.

3. Install generator assembly

Torque: M12 bolt 18N. m M14 bolt 58N. m

4. Transmit belt tilt and tension state inspection

Chapter 4 Fuel System

(MR7131A, MR7151A, MR7161A)

Section 1 Check Fuel System Pressure

1. Remove the fuel tank from the vehicle

2. Check the fuel pump running

(a) Connect the positive and negative battery terminal to the concerned

fuel pump connector. See (Figure 91). Notice: Do not start engine The sound of fuel flowing can be heard if there is pressure. Check fusible link, fuse, EFI open circuit relay, fuel pump, ECU and

wire connector if there is no pressure.

(b) Turn the ignition switch to "OFF" position.

3. Check fuel pressure

(a) Check battery electrical pressure to be above 12V. (b) Detach negative terminal cable from the battery. (c) Install pressure gage from the fuel delivery pipe. See (Figure 92). (d) Connect battery negative terminal. (e) Measure fuel pressure

Fuel pressure: 304-343kPa Check fuel pipe & union, fuel pump, fuel filter if the pressure is too

low. (f) Start engine. Measure fuel pressure at idle. Fuel pressure: 304-343kPa (g) Check fuel pressure and retain the pressure for approximately 5min after the engine stopped.

Fuel pressure: 147kPa

Figure 91

Figure 92

Section 2 Fuel Pump Inspection

1. Fuel pump

at 20°. Replace fuel pump if the resistance is not as specified.

(a) Check fuel pump resistance, 0.2~3.0

See (Figure 93)

(b) Fuel pump running:

Check fuel pump by connecting with battery. Replace fuel pump or wire if the running is not as specified. See (Figure 94).

The test should be conducted within 10s to prevent coil from damage.

2. Fuel injector assembly

Injection V olume: 40~50cm

/s Error between each injector: less than 10 cm Replace injector if the injection volume is not as specified. (a) Check for leakage: Disconnect the cable from the battery. The fuel drop/min is no more than 1 drop.

Ohmmeter

Ω

Battery

Figure 93 Figure 94

Section 3 Fuel Injector Replacement

1. Check fuel for ejection.

2. Remove PCV ventilation hoses. See (Figure 95). Remove fuel pipe clamp.

3. Detach fuel hose sub-assembly

4. Detach fuel delivery pipe sub-assembly. See (Figure 96)

(a) Press the connector to lock the spring and pull the connector from the injector. (b) Remove 2 screws and detach fuel delivery pipe with injector.

5. Remove fuel injector assembly

6. Install injector assembly

(a) Smear a light layer of oil on two O-rings and install them to injector. See (Figure 97). (b) Install 4 injectors to feul delivery pipe by rotating them left and right. See (Figure 98). (c) Install retain frame to each injector.

New O-ring

Figure 95 Figure 96

Upward

Rotate

Ratain Frame

Push

Figure 97 Figure 98

7. Install fuel delivery pipe sub-assembly

(a) Install two washers in intake manifold. See (Figure 99). (b) Install 4 injectors and fuel delivery pipe assembly into intake manifold . (c) Temperarily install 2 bolts to attach the fuel delivery pipe to intake

manifold .

(d) Check injector for smooth rotation. See (Figure 100).

Hint: If injector doesn't rotate smoothly, replace O-ring with the injector connector upward.

(e) Tighten the 2 bolts and attach the fuel delivery pipe to intake manifold

See (Figure 101). Torque: 15N. m

Upward

Rotate

Washer

Figure 99

Figure 100 Figure 101

Section 4 Fuel Pump Replacement

Figure 102

1. Avoid fuel ejection

2. Disconnect fuel tank hose

3. Disconnect fuel tank return hose

4. Disconnect fuel tank gas exhaust hose

5. Detach fuel pump assembly with filter screen. See (Figure 103)

Using special tool, loose fuel tank cap. Be careful not to bend the fuel level sensor arm when pulling out fuel pump.

6. Install fuel pump assembly. See (Figure 104). Replace ring seal .

Align the tab on the fuel pump to the notch on the fuel tank port. Tighten the fuel tank cap with special tool.

Torque: 40N. m

7. Install fuel gas exhaust hose

(a) Install return hose; (b) Install fuel hose; (c) Check fuel for leakage.

Figure 104

Figure 103

New Washer

Section 5 Fuel Emission Control System

1. Check the operation when the fuel is cut off.

(a) Warm up the engine for at least 2500rpm. Using sound grade meter , check injector's noise when running.

See (Figure 105).

(b) The noise from the injector should stop immediately after loosing the throttle. Repeat for several times.

2. Check fuel vapor emission control system. See (Figure 106)

(a) Disconnect vacuum pipe after starting the engine. (b) Select "ACTIVE TEST" and "PURGE VSV (Vacuum Solenoid Valve)" from the display on the fault

diagnosis tester. Confirm vacuum at VSV port. (c) Connect the vacuum pipe after completing "ACTIVE TEST". (d) After conducting "ECM DATA MONITOR"on the fault diagnosis tester, select "PURGE VSV" to

check operation. (e) Start the vehicle after warming up the engine to confirm the VSV status is changed from disconnected to

connected. See (Figure 107).

3. Check the fill fuel port cap and gasket for distortion or damage. See (Figure 108)

Sound Grade Meter

Figure 105 Figure 106

Figure 107 Figure 108

Gasket

Section 6 Carbon Canister Replacement

1. Check and replace carbon canister

(a) Eye-inspect the carbon canister for crack or damage. See (Figure 109). (b) Check the carbon canister's operation.

1. Plug the exhaust hole. See (Figure 110).

2. Blow air in through (4.71kpa, 48kgf/cm hole is closed. Check and ensure air is blew out from the blow purge hole.

) fuel tank hole when the exhaust

Replace the carbon carnister if the operation is not as specified.

Figure 109

3. Blow air in through the fuel tank hole. Check and ensure air flows out from the other hole without resistance.

Replace the carbon carnister if the operation is not as specified.

out from the exhaust port. See (Figure 111).

Figure 110 Figure 111

2. Vacuum Solenoid Valve (VSV)

(a) Using ohmmeter, check VSV open circuit. The resistance is 27-33 ¸ when the temperature is 20°. See

Ω

(Figure 112).

Ohmmeter

Trigger

Ohmmeter

No trgger

Figure 112 Figure 11 3

(b) Using ohmmeter, check VSV grounding. Replace VSV if it is continuity. See (Figure 113).

(3) Check VSV operation from hole E to F and that the air flow should be difficult. See (Figure 114).

3. PCV sub-assembly

It should be easy for air to pass through the cylinder head.

Notice:

z Do not suck air through valve. z Never put any object into the valve. Replace PCV if the operation is

not as specified.

z Blow air in from the intake manifold side. Check that the air flow

should be difficult. Replace PCV if the operation is not as specified. See (Figure 115).

Near cylinder head

Cleaning pipe

Figure 115

Near the intake manifold

Air

Figure 114

Chapter 5 Exhaust System

(MR7131A, MR7151A, MR7161A)

Component1

Figure 116

1. Detach tail exhaust pipe assembly

Remove 2 bolts and the tail exhaust pipe assembly.

2. Remove intermediate exhaust pipe assembly

Replace exhaust system Detach 2 bolts and intermediate exhaust pipe assembly.

3. Detach front exhaust pipe assembly

Remove 2 bolts and front exhaust pipe assembly.

4. Install front exhaust pipe assembly

Using vernier calipers, measure the free length of the spring. Free length: 42mm Using the new gasket, install the front exhaust pipe to the exhaust manifold. Notice:

z Do not use removed gasket any more.

5. Install front exhaust pipe assembly.

Torque: 43N. m

6. Install intermediate exhaust pipe assembly

Using the new gasket, install the intermediate exhaust pipe to the front exhaust pipe. Torque: 44N. m

7. Install tail exhaust pipe assembly

Using the new gasket, install the tail exhaust pipe to the intermediate exhaust pipe. See T orque: 43N. m

(Figure 117).

Tail Pipe side

8. Check exhaust for leakage

Washer

Figure 117

Chapter 6 Cooling System Inspection

(MR7131A, MR7151A, MR7161A)

Section 1 System Check

1. Check the cooling system for leakage. See (Figure 118)

(a) Fill coolant into radiator. Install the tester onto the radiator cap port. (b) Start engine. (c) The water pump pressure is 118Kpa. Check the pressure and ensure the

pressure will not drop. If the pressure drops, check the port, radiator and water pump for leakage. If there is no leakage, check the heat exchanger, cylinder block and cylinder head.

2. Check the engine coolant level in the reservoir.

The coolant level should be between low and full marks.

3. Check coolant quality

Radiator Cap Tester

Figure 118

(a) Remove radiator cap.

To avoid being scalded, do not remove radiator cap while the engine and radiator are still hot, as fluid and steam can be sprayed under pressure.

(b) There should not be excessive deposits of rust or scale around the radiator,

and the coolant should be free from oil.

4. Thermostat

Hint: The thermostat temp indicates the valve opening temperature.

See (Figure 119). (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 -- 84°C (c) Check the valve lift. See (Figure 120, Figure 121). V alve lift: 8mm or mor at

95°C

(d) Check the thermostat is fully closed when the thermostat is at low temperature

( 77°C).

≤

5. Radiator cap valve

Figure 119

Figure 120

8.0mm or More

Standard opening pressure: 93-123kpa Minimum opening pressure: 78kpa If the opening pressure is less thanminimum, replace the radiator cap.

Figure 121

6. Fan

(1) Check the cooling fan operation with low temperature (Lower than

83°C) (a) Turn the ignition switch to “ON” position. (b) Check that the cooling fan stops. (c) Pull out the water temperature sensor connector. See (Figure

122)

(d) Connect the water temperature sensor to car body with the

wire and ground the wire. (e) Check the cooling fan operation. (f) Insert water temperature sensor connector.

(2) Check the cooling fan operation with high temperature (over 93°C)

See (Figure 123)

(a) Start engine and make the coolant temp. higher than 93°C.

Disconnest

Figure 122

> 93°C

(b) Check that the cooling fan turns.

Replace it with water temperature switch if it doesn't run)

(3) Check the cooling fan. See (Figure 124)

(a) Disconnect the cooling fan connector. (b) Connect the battery and ammeter to the connector. (c) Check that the cooling fan rotates smoothly and check

the reading on the ammeter.

Standard amperage: 5.7 - 7.7A (d) Reconnect the cooling fan connector.

Figure 123

Amperometer

Battery

Figure 124

Section 2 Water Pump, Thermostat and Radiator Replacement

Hoist the engine from the compartment. See "Provison 20, Section 2, Chapter 2".

1. Replace water pump. See (Figure 125)

(1) Drain the coolant. (2) Detach timing belt. (3) Detach power steering pump assembly. (4) Remove the oil dipstick guide. (5) Detach water pump assembly. (6) Install water pump assembly.

(7) The installation is in the reverse order of the removal.

2. Replace thermostat

(1) Remove thermostat (See Figure 126). (2) Install thermostat.

a. Install a new gasket to the thermostat. See (Figure 127).

Figure 125

b.Align the main valve of the thermostat to the top of the

stud. Insert the thermostat into the water inlet case.

Hint: The main valve is set at around 10°C as shown in the figure. See (Figure 128). (3) Install inlet connector.

Figure 127 Figure 128

3. Replace radiator (1) Open radiator cap. (2) Open the drain valve and drain the coolant.

Figure 126

(3) Detach radiator water inlet hose. (4) Detach radiator water outlet hose.

(5) Disconnect auto-transmission oil cooler input pipe (Auto-transmission). (6) Disconnect auto-transmission oil cooler output pipe (Auto-transmission). (7) Remove 4 bolts from the radiator mounting bracket. See (Figure 129). (8) Detach radiator assembly, Remove 3 bolts. Detach the fan and fan shroud. See (Figure 130).

Figure 127 Figure 128

(9) Install the cooling fan assembly

(a) Fix the reservoir assembly on the cooling fan bracket with the bolt. Torque: 16 N. m. (b) Install the fan and fan shroud with 3 bolts. Torque: 7.5N. m. (c) Install the cooling fan assembly to radiator assembly with 3 bolts. Torque: 16N. m. (d) Connect the overflow pipe on the reservoir assembly and radiator assembly. Fix it with the spring

band.

(f) The installation of the radiator assembly is in the reverse order of the removal.

Chapter 7 Clutch

(MR7131A, MR7151A, MR7161A)

Component 1 (Hydraulic Manipulation)

Figure 131

Section 1 Clutch Replacement

Hoist the engine from the compartment. See "Provison 20, Section 2, Chapter 2".

1. Remove manual transaxle assembly

2. Remove the clutch release fork. See (Figure 132)

3. Detach clutch release fork boot.

4. Detach clutch release bearing

5. Detach clutch release bearing fixed clamp

6. Remove clutch fork pivot pin

7. Align the clutch cover to the mark on the flywheel. Detach clutch cover. See (Figure 133)

8. Remove clutch plate

9. Check and remove clutch plate assembly. See (Figure 134)

10. Check clutch cover. See (Figure 135)

Depth wear: A: 0.6mm Width wear: B: 5mm

Figure 132 Figure 133

Figure 134 Figure 135

11. Using the dial gauge, check the flywheel runout. See (Figure 136).

The maximum runout: 0.3mm

12. Check clutch release bearing

The bearing is permanently lubricated. There is no need to lubricate or clean.

13. Check clutch plate

14. Install clutch cover. See (Figure 137)

Align the Clutch cover to the mark on the flywheel. Hint: (1) Uniformly tighten the bolt in the sequence shown.

Torque: 19 N. m

(2) Shake the clutch plate up and down, left and right to ensure

it is centered, then tighten the bolt.

15. Check and adjust the clutch cover. See (Figure 138)

Check the diaphragm tip flatness with the dial gauge with roller. Max. roughness: 0.5mm.

16. Install the release fork pivot pin

17. Install clutch release fork boot

18. Install clutch release bearing fixed clamp

19. Install clutch release fork

20. Install clutch release bearing

21. Install manual transaxle assembly

Figure 136

Figure 137

Figure 138

Chapter 8 Maunal Transaxle Assembly

(MR7131A, MR7151A, MR7161A)

Component 1

Figure 139

Section 1 Manual Transaxle Replacement

1. Open the engine hood

2. Remove the battery

3. Remove clutch cylinder sub-assembly. See (Figure 140)

4. Detach transmission shift cable assembly. See (Figure 141)

5. Remove the connector and turn on the back-up lamp switch connector.

6. Disconnect vehicle speed sensor

Disconnect vehicle speed sensor connector.

7. Detach the front exhaust pipe

8. Drain transmission oil

9. Detach left & right front wheel hub nut

10. Detach left & right front wheel speed sensor (ABS)

11. Detach front balance rod

12. Detach left & right tie-rod with ball stud pin

13. Detach front balance rod

14. Detach left & right lower swing arm

15. Detach left & right front propeller assembly

16. Hoist the engine from compartment. See "Provision 20, Section 2, Chapter 2"

17. Detach starter assembly

18. Detach engine mounting bracket

19. Detach manual transaxle assembly

20. Install engine mounting bracket

21. Install manual transaxle assembly

22. Connect engine vibration insulating cushions

23. Install starter assembly

24. Install left & right front propeller assembly

25. Connect left & right lower swing arm

26. Connect left & right tie-rod with ball stud pin

27. Connect front balance rod

Figure 140

Figure 141

28. Connect left & right front speed sensor (ABS)

29. Installleft & right front shaft nut

30. Install front exhaust pipe

31. Connect speedometer sensor connector.

32. Connect back-up lamp switch connector.

33. Connect transmission shift cable assembly. See (Figure 141)

34. Install clutch sub-pump assembly. See (Figure 140)

Section 2 Vehicle Speed Sensor Replacement

1. Disconnect vehicle speed sensor. See (Figure 142)

2. Remove bolt and vehicle speed sensor.

3. Install vehicle speed sensor. See (Figure 142)

4. Connect vehicle speed sensor connector. See (Figure 143)

Figure 142 Figure 143

Section 3 Transmission Case Oil Seal

1. Remove transmission case oil seal. See (Figure 144)

2. Install transmission case oil seal. See (Figure 145) Notice: Be careful not to damage oil seal lip.

Figure 144 Figure 145

Section 4 Transaxle Case Oil Seal Replacement

1. Using special tool, remove transaxle case oil seal. See (Figure 146)

2. Install transaxle case oil seal. See (Figure 147)

Figure 144 Figure 145

Chapter 9 General Engine Troubles and Their

Troubleshooting

Section 1 Overview

The wide application of the electronic technologies to the vehicles brings innovation on diagnosis of the vehicle, many varieties of diagnosis instruments that are very effective and efficient for the vehicle diagnosis are innovated. Once the fault occurs, the best choice is to go to service station for help. However, even the most advanced instrument has its limit. For some faults, manual diagnosis is far more convenient and easier than that of instrument. In case of the crack, distortion and leakage of the components, the manual diagnosis is even superior to the instrument diagnosis. The faults occurred shall be carefully analyzed and troubleshot in accordance with the repair manual for normal usage.

Section 2 General Engine Fault and Troubleshooting

I. Fuel pipeline and circuit fault causing the engine starting failure

engine starting failure normally include: starter does not run or starter runs but fails to crank the engine, or cranks the engine but cranks slowly; starter can crank but fail to start the engine. There are many causes that result in starting failure, such as failures in starting system, ignition system, fuel injection system and engine mechanical failure.

1. starter does not run or fails to crank the engine or cranks slowly

(1) Symptom: starter does not run or spongy rotation (2) Causes:

b. Low battery voltage, excessive battery discharge, damaged generator or failure in charging circuit; c. Battery terminal rust and backed out; d. Failure in starting circuit, ECU can not receive STA signal; e. Damaged starter.

2. engine can not start and crank

(1) Symptom

With the start switch on, starter can crank but fail to start the engine.

(2) Causes

a. Empty fuel tank; b. Electrical fuel pump inoperative; c. Injector inoperative; d. Low fuel pressure; e. Unreasonable starting operation; f. Damaged throttle position sensor or no signal is sent to ECU due to the open in throttle position

sensor circuit;

g. Ignition system failure; h. Low engine compression pressure.

(3) Diagnosis and Troubleshooting

a. First, check the fuel tank for fuel level, turn on the ignition switch, if fuel gauge pointer does not

move or fuel level warning lamp lights, then the fuel tank is empty, fuel shall be filled at this time.

b. Check that the electrical fuel pump for operation. Remove the fuel tank, you may use a wire to

connect the two jacks of the fuel pump for short, then turn on the ignition switch. The fuel pump operation sound shall be able to be heard from the fuel tank nozzle or fuel flow can be felt with hand

pinching the tube; or remove the return hose on the fuel pressure regulator, check that the fuel flows out; Direct judgment can be made if it is equipped with fuel pressure gage.

If electrical fuel pump is inoperative, check whether the main fuse, main relay, fuel pump relay,

fuel pump control circuit and ECU are OK. If all of them are OK, check fuel pump circuit for open, short or damaged check valve. Repair or replacement shall be made when problems are found.

c. If there is no injection sound in injector, check injector control circuit for fault. You may use a

testing lamp with big resistance to be connected to the injector wiring connector, turn on the ignition

switch. If the testing lamp lights up, it indicates that the injector has been damaged and shall be

replaced; if the testing lamp does not light up, check whether the main fuse, EFI relay, fuse, ignition switch and ECU terminal are OK, repair or replace them if they are not OK.

d. If there is low fuel pressure, the injection amount would be small and the engine won't start, you

should check the fuel filter for block and fuel pump safety valve for damage and check whether the fuel pressure regulator is within the normal range, otherwise those components shall be repaired or

replaced. e. Electric injection engine normally spot contact start the engine. f. Check for open in the throttle position sensor (TPS) circuit. g. Check whether there is Diagnostic Trouble Code (DTC), if there is, check it by the DTC; if there

is not, check the high voltage spark for intensity, if it is too weak, check spark plug, high voltage wire, high voltage coil, distributor cover for faults, if there are faults, repair or replace them.

h. Check the compression pressure in the cylinder, insert the compression pressure gauge into the

spark plug hole, completely open the throttle, measure the compression pressure while starting the engine. If the compression pressure is less than 980kPa when engine speed is more than 250r/min,

remove and inspect the engine and troubleshoot it.

3. The engine cranks but can not start

(1) Symptom

When starting the engine, starter can crank the engine but fail to start the engine.

(2) Causes:

a. Ignition advance angle is unfavorable; b. Ignition is out of sequence, there is misfire; c. High voltage spark is too weak; d. The fuel pressure is too low; e. fuel pressure regulator leakage;

f. The idle control valve is faulty; g. The water temperature sensor is damaged; h. The vacuum pressure sensor is damaged; i. The air filter is blocked; j. The injector leaks; k. The compression pressure in the cylinder is too low; l. The intake temperature sensor is damaged.

(3) Diagnosis and Troubleshooting

a. Check high pressure spark, check whether the high pressure spark on the ignition coil high pressure

bus and extension are OK, if the bus spark is week, replace the ignition coil, if the bus spark is OK while the extension spark is too week, replace the ignition coil also; In addition, excessive spark

plug clearance will influence the starting feature, the clearance of the spark plug shall be adjusted

to normal value (0.8±0.1mm);

b. If there is low fuel pressure, check whether the battery voltage is OK, otherwise it shall be

troubleshot or replaced; check fuel pump check valve for leakage, check fuel filter and fuel pipe for block, if there are leakage or block, replace or troubleshoot them;

c. If there is leakage for fuel pressure regulator, intake manifold is likely to be mixed with gasoline and

it is hard to start, troubleshoot or replace them;

d. Idle control valve can not be opened to maximum position due to mechanical wear, aging or control

circuit failure, the idle control valve shall be replaced and the control circuit failure shall be troubleshot;

e. If the water temperature sensor data is not accurate, it may cause small injection, check the water

temperature sensor based on the standard data and calibrate the data;

f. There is big time lag for intake pressure temperature sensor that makes it somewhat insensitive at

low speed and result in inaccurate injection, adjustment or replacement shall be made;

g. If the air cleaner filter is too dirty, the air flow resistance is excessively big, resulting in hard start,

as a result of it, the filter shall be replaced.

In a word, there are many factors causing the starting failure of the engine, analysis shall be made based on the severe conditions of the faults. Generally speaking, check the ignition system first, then check intake system, fuel system, control system, at last check the cylinder pressure, check the DTC before checking the trouble. The diagnosis and troubleshooting procedures for starting failure of the engine are shown in (Figure

148).

Engine can not start

Check the starting system Repair or replace the part if it is faulty

Check the high voltage spark

No high voltage spark or weak spark OK

Check the ignition system Is there any sign of cranking

No sign of cranking There is sign of cranking

Check the electric fuel pump for operation Check the air cleaner filter

Operative Inoperative OK Clogged

Check the injector Check the electric fuel Check the Replaced pump and its control circuit spark clearance

Operative Inoperative Measure the fuel pressure

Measure the fuel pressure Check the injector Measure the vapor pressure, water temperature and intake

Excessively low OK Check the control circuit air temperature sensor

Check the fuel Check thecylinder pressure Check the cylinder pressure

pressure regulator

Figure 148

II. Fuel pipeline and Circuit Fault for Hard Engine Starting

Hard engine starting indicates that starter can crank but fail to start the engine, or it may take multiple consecutive starting efforts or long time rotation to successfully start the engine. For hard start fault, make sure whether it occurs at cold or hot status or regardless of the cold or hot status.

1. Symptom When starting, engine cranks at normal speed, but it takes longer to start or fails to start although cranks.

2. Causes: a. Air cleaner is clogged; b. Intake temperature sensor fault; c. Water temperature sensor fault;

d. Fuel pressure system abnormal; e. Idle control valve fault; f. Vacuum pressure sensor fault; g. Ignition system fault; h. The compression pressure in the cylinder is a little lower; i. Injector leakage.

3. Diagnosis and Troubleshooting a. Perform self-diagnosis first, check whether there is any DTC, if there is, find the reason and cause by the

DTC;

b.If it is hard for cold start but easy for hot start, check water temperature sensor and intake temperature

sensor for fault;

c. If the engine can not be started quickly in hot condition, the relief of the fuel pressure will be fast, then

repair and replacement shall be made;

d. If the spark is too weak, check high pressure coil, spark plug clearance and spark plug for carbon deposit,

repair or replace them one by one after isolating the problem;

e. Intake and exhaust valve is not completely closed, piston ring failure is likely to cause low compression

pressure in the cylinder, you should carefully repair intake & exhaust valve and seat, or replace them; failed piston ring shall be replaced.

4. Diagnosis and Troubleshooting for hard starting and trouble shooting procedure. (Figure 149)

III. Fuel Pipeline and Circuit Faults for Poor Engine Operation

Poor engine operation includes: insufficient power, poor acceleration, poor deceleration, big fuel consumption, rough idle and Engine overheat.

1. Insufficient Power (1) Symptom:

Engine operation is normal without load but slow at load, insufficient power when uphill and not improved even if the accelerator pedal is completely depressed, speed can not be increased and unable to reach the maximum vehicle speed.

(2) Causes:

a. Air cleaner is clogged; b. Poor intake system seal; c. Intake pressure temperature sensor fault; d. Low fuel pressure; e. Broken pressure adjustor; f. Clogged injector or poor atomization; g. Throttle position sensor fault; h. High pressure spark is too weak; i. Improper valve clearance;

j. Poor intake and exhaust valve seal, failed piston ring, low compression pressure; h. Too many carbon deposit in spark plug and combustion chamber; k. Water temperature switch and thermostat fault; l. Aging of Oxygon sensor;

Engine is difficult to start

Check whether the air cleaner is clogged

Clogged

Troubleshooting

Check the idle control valve

Repair or replace

Excessivly low

Check the fuel pressure

Service the electric fuel pump, fuel filter and fuel pressure regulator OK

Check the vacuum pressure sensor NG Replace

Check the water temperature sensor and intake air temperature sensor

Check the start switch signal

Check the ignition timing

Check the cylinder pressure NG Disassemble the engine

Replace the ECU to retry

m. Incorrect ignition timing; n. Check valve fault.

Replace

Service the start signal wire

Misaligned

Adjust

Figure 149

(3) Diagnosis procedure for insufficient engine power (Figure 150)

Insufficient power

Insufficient

Unable to be fully open

Check whether throttle valve can be fully open

Clogged

Check whether the air cleaner is clogged

Clean or replace

Abnormal

Check the throttle valve position sensor for failure

Check the water temperature switch and thermostat

Replace

Check the vacuum pressure sensor for failure

Replace

Adjust

Repair or replace

Check the fuel pressure fuel filter and fuel pressure regulator OK

Check the oxygen sensor

Check the injector

Replace the spark plug, ignition coil and high voltage wire

Disassemble the engine

2. Poor deceleration (1) Symptom

Excessively low or high

Service the electric fuel pump,

Incorrect

Replace

Incorrect

Replace

Figure 150

Idling is normal, but the engine is frequently turned off upon sudden release of the accelerator pedal during driving.

(2) Causes and Troubleshooting:

a. Throttle position sensor is damaged and shall be replaced; b. Initial idling is not properly adjusted or automatic idle control is wrong, fuel cut RPM is too low,

ECU fault, repair or replace them.

3. Poor acceleration (1) Symptom

Engine speed can not be increased immediately after depressing the accelerator pedal, there is

time lag,and the acceleration reaction is delayed or there is slight fluctuation during the acceleration.

(2) Causes and Troubleshooting

a. There is fault in throttle position sensor, repair or replace it; b. Poor intake system seal, repair it; c. There is low fuel pressure, troubleshoot it; d. Poor injector operation, clean or replace it; e. Intake pressure temperature sensor fault, repair or replace it; f. Check valve is damaged and shall be replaced; g. Ignition advance angle is not correct and shall be adjusted; h. Fuel pressure regulator is damaged and shall be replaced; i. Air cleaner is clogged and shall be cleaned or replaced;

(3) Diagnosis procedure for poor acceleration (Figure 151)

Poor acceleration

Check the air tightness of the intake air system

Poor seal

Repair

Clogged

Check whether the air cleaner is clogged

Clean or replace

Abnormal

Check the throttle valve position sensor for failure

Repair or replace

Abnormal

Check the fuel pressure

Service the electric fuel pump, fuel filter and fuel pressure regulator OK

Check whether the injector inject properly at idle and maximum load

Replace

Yes

Check whether the check valve and EVAP are faulty

Repair or replace

Check whether the vacuum pressure sensor is OK

Adjust a ECU to retry

Figure 151

Replace

4. Big fuel consumption (1) Symptom:

Engine power is ok, but the fuel consumption is big, exhaust pipe discharges black smoke.

(2) Causes and Troubleshooting:

a. When idling, idle speed is high and shall be adjusted; b. Water temperature sensor fault, service or replace it; c. Water temperature switch and thermostat fault, repair or replace it; d. Oxygen sensor fault, repair or replace it; e. Fuel pressure is big and shall be adjusted; f. Injector fault (fuel leakage), repair or replace it; g. Throttle position sensor fault, repair or replace it; h. Fuel pressure regulator is damaged and shall be replaced; i. Intake pressure temperature sensor fault, repair or replace it.

5. Unstable idle, liable to be turned off (1) Symptom:

Engine starts normally, but the idle is unstable regardless of cold or hot status, idle speed is too low and the engine is liable to be turned off.

(2) Causes and Troubleshooting

a. Poor idle control valve operation, repair or replace it; b. Low idle speed and faulty or improperly adjusted idle control valve, troubleshoot it; c. Water temperature sensor fault, repair or replace it; d. Poor intake system seal, need to be repaired; e. High voltage spark is too weak, spark plug carbon deposit or electrode clearance is too small, need

to be repaired, cleared and adjusted; f. Pressure sensor fault, repair or replace it; g. The compression pressure in the cylinder is too low, need to be serviced; h. Fuel line pressure is too low, needed to be serviced; i. Air cleaner is clogged, clean or replace it; j. Poor injector atomization, fuel leakage, block or big injection variation, need to be repaired;

(3) Diagnosis procedure (Figure 152)

6. Unstable idle at cold status, liable to be turned off (1) Symptom

During the cold start, idle is unstable and engine is liable to be turned off, the normal idle is recovered after warming of the engine.

(2) Causes and Troubleshooting

a. Water temperature sensor fault, repair or replace it; b. idle control valve fault, repair or replace it.

7. Unstable idle or engine shut off at hot status (1) Symptom

Idle speed is normal during the cold start and becomes unstable at hot status, idle speed is too low or engine is shut off.

(2) Causes and Troubleshooting

a. Idle is adjusted too low, adjust it to normal condition; b. Water temperature sensor fault, repair or replace it; c. Poor injector operation or big injection variation, repair or replace it; d. Poor water temperature switch and thermostat operation, repair or replace it; e. Check valve is damaged and needs to be replaced.

Rough ildling, easy for engine shut off

Check whethe the air tightness of the intake system is good

Poor

Troubleshooting

Inoperative

Check idle control valve for operation

Disassemble or replace

Operative

Reset the initial idle speed

Poor

Check the spark plug

Adjust the clearance or replace

Check the fuel pressure

pressure regulator and fuel filter

Check the electric pump, fuel

Check the injector

Replace

Check the pressure sensor

Replace

Check the cylinder compression pressure NG Disassemble the engine

Check and adjust the valve clearance

Figure 152

8. Idle speed too high at hot status (1) Symptom

The engine runs at fast idle during cold start and remains fast idle at hot status, leading to excessively fast idle.

(2) Causes and Troubleshooting

a. The initial idle value is not properly adjusted, b. High system fuel pipeline pressure, need to be adjusted; c. Water temperature sensor fault, repair or replace it; d. Water temperature switch and thermostat fault, repair or replace it; e. Idle control valve fault, repair or replace it; f. Throttle is binding and not tightly closed, repair or replace it; g. Fuel evaporation control valve is always open, repair or replace it; h. Speed sensor fault, repair or replace it.

9. Idle fluctuation (1) Symptom

when idling, the engine speed fluctuates.

(2) Causes and Troubleshooting

a. Intake pressure temperature sensor fault, repair or replace it; b. Check valve is damaged and needs to be replaced; c. Water temperature sensor , water temperature switch and thermostat is poorly coordinated, repair,

adjust and troubleshoot them; d. Oxygen sensor fault, need to be replaced; e. Spark plug poor connection, repair or replace it; f. Idle control valve and its control circuit fault, repair or replace it; g. Idle switch is not closed, need to be repaired.

10. Engine overheat (Table 6) T able 6

Item Symptom Troubleshooting

Cause

Bad radiator cover

Repair or replace

Bad radiator hose Replace

Supplement welding, otherwise

Insufficient

coolant

Water

leaka ge

Bad radiator tube strap

replace it

Bad cylinder gasket Replace

Remedy with infiltration technology

Cracky cylinder block

or replace it

Poor water pump seal Replace the seal

Poor

cooling

Radiator is

faulty

Anti-freeze liquid not replaced

Bad thermostat

Water

leaka ge

Corrosion result in pin hole

Clogged cooling tube

Broken weld

Poor ventilation

Faulty water pump

Faulty fan voltage

Replace the anti-freeze liquid Replace the thermostat Supplement welding Fill the pinhole with clear coat, otherwise replace it Repair and dredge Improve the ventilation Repair or replace the water pump Troubleshooting, replace the motor if it is damaged

Poor Fan

Disabled radiator temperature control

switch

Water jacket is clogged because of too much scale

Replace Repair and dredge Repair or replace the oil pan if there

Insufficient engine oil (oil leakage or d elaye d filling)

is oil leakage, refill the oil if it is not supplemented in time

11. General engine fault symptom and faulty area (Table 7)

Table 7

Suspect Area

Control

system

Symptom

Intake abosolute pressure

sensor

Water temperature senso

Revolution speed sensor

Throttle valve position

sensor

Vehicle speed sensor

Difficult to start Poor idling Engine off

No fast ilde

Low idle speed

High idle speed

Difficult for hot start

Difficult for cold start

Unable to explode initially

Unable to explode completely

ccccccc cc

cccc cc c cc c

Idle hunting

Rough ildling

At urgent acceleration

When the accelerator pedal is releasec

ccc ccccc

Poor driving

During idling

Poor acceleration

Knock

Insufficient power

Hunting during driving

Fuel

system

Ignition

system

Intake

air

system

Fuel pump system

Fuel pressure regulator

Fuel filter and pipeline

Injector

Starter signal

Ignition coil

Spark plug

High pressure cable

Ignition timing

Igniter in the ECU

Throttle valve

Throttle valve bod

Air leakage in the intake

air syste

Air valve

cc c cc c ccccc c cccc cc c cccc ccccc c ccc cc

ccc cccc c cc c cc

cc c c c cc

c ccc

cccc c

cc c

cc ccccc c

ccccc

Power supply

system

ECU power supply circuit

Ignition swtich

Main relay

Fuel pump rela

c c c c

IV. Exhaust Pipe Discharges Gas with Abnormal Color (or odor)

When there is failure in engine combustion system, the exhaust pipe discharges gas with abnormal color.

1. The discharged gas is thickly black

This is caused by incomplete combustion. Since the mixed air is too thick, the combustion is not complete and part of the fuel is discharged without combustion, leading to decrease of engine power . At this moment, you should check fuel pressure regulator, throttle position sensor, injector and ECU system and correct the problems in time.

2. Exhaust is blue and stinks

This is caused by large amount of oil vapor mixed in the exhaust gas that enters in the cylinder and participates in combustion. One of the primary reasons is that the piston oil ring is dirty and damaged, and shall be replaced; another reason may be the failure of valve oil seal or excessive clearance between the valve stem and guide bush hole resulting in oil entering the combustion chamber for combustion, oil seal or valve guide bush shall be replaced to resume normal condition.

3. Exhaust is white

This is caused by water or fuel vapor mixed in the exhaust. The primary reason is that cylinder head gasket is damaged, resulting in slow infiltration of coolant into cylinder and the water vapor entry into the exhaust pipe after combustion, cylinder head gasket shall be replaced to resume the normal condition.

Section 3 Engine Noise Diagnosis and Troubleshooting

Abnormal sounds generated during engine operation (e.g. knocking sound, chuckle, hiss, rattle) are called noise.

Engine noise is primarily generated in valve train, connecting rod piston crankshaft components and other accessory system. The following description discusses the diagnosis and troubleshooting of the noise generated in valve train and crankshaft connecting rod mechanism.

I. Diagnosis and troubleshooting of the noise in valve train

valve train consists of intake & exhaust camshaft , valve, valve bushing, tappetand counter gear.

1. camshaft noise

(1) camshaft end play is excessively big (normal intake camshaft : 0.030~0.085mm, exhaust camshaft : 0.

035~0.090mm) , when it exceeds 0.11mm and noise is generated, replace it; (2) Camshaft bend is another cause for noise; it shall be aligned or scraped. ; (3) Camshaft journal is excessively worn, resulting in big radial clearance between camshaft and bearing and

noise, replace it;

2. Valve group knock noise

(1) Valve noise is caused by excessive valve clearance, the valve spring seat flange is damaged and shall be

replaced; (2) Valve spring knock noise is caused by broken valve spring. It shall be replaced;

(3) Valve free movement noise is caused by dropped valve keeper or broken valve head. It shall be replaced; (4) Noise between the intake & exhaust valve and valve bushing is caused by stagnation valve and bushing

that can not be closed, repair the bushing or replace it;

(5) V alve and valve seat can not be tightly closed and noise is generated, leading to abnormal engine operation.

Valve shall be grinded to fit, otherwise it shall be replaced.

3. Gear noise is mainly caused by excessive wear of the gear which results in excessive clearance,

generating the noise during the operation. The counter gear shall be replaced.

II. Crankshaft connecting rod noise diagnosis and troubleshooting

No.N

play

1. crankshaft connecting rod noise cause and troubleshooting

Connecting rod

bearing noise

Ma in be a ring

oise area

noise

Crankshaft

axia l runout

noise

oise cause Troubleshootin

Excessive connecting rod bearing radial

Connecting rod cover bolt loosene

Replace the bearing

Tighte

Connecting rod bearing insert dimension

not a s specified result in rotation or

Replace the insert

rupture

Connecting rod bearing insert burne

Poor lubrication for connecting rod

earin

Drill the lubricant hole to normal,

Replace the insert

improve the lubricant line

Excessive main bearing raidal play Replace the main bearing

Main bearing cover bolt loosened Tighten

Main bearing insert burned Replace the insert

Poor lubrica tion for main bearing

Main bearing insert dimension not as

specified result in rotation or rupture

Smoothen the lubricant line or

enla rge the oil hole

Replace the main bearing insert

Excessive crankshaft bearing raidal play Adjust (pad) to normal

Excessive wear of the cranshaft thrust

washer

Replace the thrust washer

2. Piston ring leakage, knock and noise causes and troubleshooting

Flywheel

impact noise

Flywheel set bolt loosened Tighten

Noise cause Elimination method

Piston ring broken Replace

Excessive piston ring backlash Replace

Piston ring contra aperture Correct (stagger)

Piston ring is locked Replace

Insufficient elasticity of the piston ring Replace

Poor seal between te piston and cylinder wall Replace

3. Piston knocking noise causes and troubleshooting

o. Ite

Ma in be a ring oil c hannel depth and width

Knock when

engine is cold

misaline d or insufficient oil pressure result

in poor lubrication of the cylinder wall

Excessively big clearance between the

Connecting rod journal is not parallel with

Connecting rod bushing axial declination Replace the bushin

Knock when engine is hot

Excessively small clearance between the

Excessively small backlash and end gap for

Poor lubrication for cylinder wall and piston

Knock no

Piston pin and connecting rod end are

matter the

engine is cold

Connecting rod bearing is assembled too

or hot

Troubleshooting

Repair or adjust the oil pressure to

spe cif ica tion

Replace the piston to resume the normal

iston and the cylinder wal

Connecting rod ben

the ma in journa

Correct or replace the connecting ro

Replace the connecting rod

clearance

Pistion counter ellipse Replace the piston

istion and cylinder wal

the piston ring.

Repair the cylinder or replace the piston

Repair or replace the piston ring

Dredge the oil line to improve the

lubric ant spla shing problem

installed too tightly

tightly

Piston skirt ovality is too bi

Adjust piston pin tension to normal level

Adjust the bearing tension to normal level

Replace the piston with normal ovalit

Chapter 10 Engine Management Unit

Section 1 System Description

Engine Control System generally consists of sensor, controller and actuator. Sensor: convert the physical parameter of the device into electric signal (digital or analog) to monitor the

operating condition of the device and send these signals to the controller. Controller: receive and process information sent from the sensor, and analyze the information to learn the

conditions of the device: use predefined control strategy and procedure, determine how to control the device under current conditions; convert the decision into one or more orders and send them to the actuator. The controller contains a microprocessor and stores pre-developed the programs or control software in the memory. The controller can be regarded as the brain of the control system.

Actuator: receive orders from the controller, covert the electric signal into the action of the actuating elements (either action of electric element or mechanical movement). The actions of these elements will change the operating conditions of the device and determine the operation and output of the device.

Large amount of information flows through the entire control system. Engine Control Unit learns the operation of the device from the information sent from the sensor, determines the approach and orders of the control with the input and information stored by itself and ends up in sending the information about the orders to the actuator.

I. Engine Fuel System Electronic Control System

Engine fuel system electronic control focuses on the quantified electronic control of the fuel, and actually is the electronic control over the excessive air coefficient  .

ECU controls the by controlling the fuel injection. When the engine is running, ECU receives the information about the air flow from the sensor and determines the fuel injection by calculations to make the excessive air coefficient of the mixed air reach the predefined value. The control order output by ECU is only a control signal to trigger the injector. ECU output the pulse width and timing in this signal.

The pulse width of injection signal determines the fuel amount of the injection. The pulse is the function of the following parameter. The input and output are modified into closed loop control.

ECU calculate the target - air fuel ratio. Air flow value. Other operating conditions of the engine, such as throttle position sensor, exhaust manifold oxygen sensor. low feature of the injector. Engine ignition system electronic control The control of Engine Control Unit over the ignition includes ignition advance angle control, knock control and

ignition power control (dewell angle control). The control over the ignition advance angle is the basic function of the ignition control. Ignition advance angle

= ignition advance angle basic value + correction. The control over the ignition advance angle also relates to the operating conditions of the engine. The factor

varying with the operating conditions can be reflected by the correction factor.

Starting condition ¡ª fixed ignition advance angle

advance angle basic value - determined by MAP

Ignition advance angle control

Running condition

stable idle correction

air fuel ratio feedback correction

instantaneous correction

advance angle correction

engine overheat correction

knock control

maximum advance/delayed angle control

Special control

other correction

The control over the ignition advance angle is generally open loop control. But this open loop control is different from the general open loop control, ECU test the knock signal with the knock sensor while controlling and outputting ignition advance angle orders in way of open loop. Once the knock occurs, it is converted into closed loop control, and its feedback signal is knock sensor signal. Therefore, basically, it is also a closed loop control.

Section 2 System Component and W orking Principle

ECU receives information from the sensors and sends control signals to actuators after processing and analyzing these information. It plays a role of nerve center in the electronic control system.

ECU hardware consists of input level, micro-computer and output level (see figure 153).

Figure 153

ECU microcomputer consists of microprocessor, memory, clock generator, timer, I/O interface and input level A/D converter that are integrated in a large scale integrated circuit chip, that is SCM (Single Chip Microcomputer).

1. Input level

The input signals from the sensor are pre-processed by the input level. The input signals are sent to protected circuit first, sometimes through the signal converter and amplifier, and then sent to microcomputer.

The sensor signal is separated into switch type and analog type. Ignition on/off signal, camshaft position signal, vehicle speed signal and A/C signal are switch type; Signals such as battery voltage, engine temperature, intake temperature, airflow, intake manifold absolute pressure, throttle opening, excessive air coefficient, knock, A/C refrigerant pressure are analog type. Analogy signal can only be processed by the digital microcomputer after being converted into digital signal by A/D converter. Hence, data collection shall be made first for analog signal, and the sampling shall be maintained also.

Speed and crankshaft position reference signal from the sensor is processed in a dedicated circuit to restrain the interference pulse.

2. Microcomputer

The microcomputer of the engine electronic control unit is integrated in a single chip microcomputer, consisting of the following:

(1) Microprocessor, microprocessor is also called as central processing unit (CPU), consisting of the following

three parts: Arithmetic logic unit. Register group. Controller.

(2) System assembly, The data transferred among the internal sections of the single chip microcomputer

(SCM) is performed on the internal bus, while that between the SCM and other components is performed on the external bus. The external bus is also called system bus. It is separated into data bus, address bus and control bus.

(3) Memory, the memory is designed to store the binary data. The primary components of the memory are:

Memory. Data register. Address register, address decoder.

a. Memory controller (4) A/D converter (5) I/O interface. (6) Clock generator. (7) Timer (8) CAPCOM unit. (9) Watchdog timer. (10) Interrupt system.

3. Output Level

ECU output level is designed to send control signal to the actuators of the electronic control system based on the orders of the microprocessor in the micro-controller. The microprocessor control the output level by controlling the occurrence position of the pulse, its length and duty ratio.

(1) Injection output level

The microprocessor controls the pulse length of the injection output level by making sure whether to trigger to circuit or not in the injection output level.

(2) Ignition input level

The ignition output level is designed to amplify the ignition signal from the microprocessor into the primary current of the ignition coil.

(3) Electric fuel pump output level

ECU microcontroller control the pump relay through electric fuel pump output level, and then control the on and off of the electric fuel pump based on the current operating conditions.

(4) Other output levels

Control the output levels of the idle control valve, carbon canister solenoid valve, malfunction indicator lamp. MR479Q, MR479QA, MR481QA engine idle control are closed loop control system, their injection and ignition control are also closed loop control system.

Part II Chassis

Chapter 1 Transmission Control Device

Section 1 Transmission Control Device

Description on Transmission Control Device

This model is equipped with lever and cable transmission control devices, respectively used for 1.3L and 1.5L engine, both of their gears are: 5 forward gears + 1 reverse gear.

PROBLEM SYMPTOMS T ABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.

Symptom

Transmission out of gear

Transmission shift difficult

Section 2 Lever Type T ransmission Control Device

Components

Suspected Area

1. Transmission control device selector (position changing) cable (improperly assembled)

2. Cable or related parts worn

3. Cable assembly (incorrect)

4. Transmis sion (faulty)

1. Transmission control device selector (position changing ) cable (improperly assembled)

2. Cable or related parts worn

3. Cable assembly (incorrect)

4. Transmission (faulty)

Control lever Assembly

Dust Proof Cover

Botton Panel

Assembly of body

Dust Proof Cover Retainer

Control Pull Rod Assembly

Bottom Panel Assembly of Body

Control Pull Rod Assembly

Transmission Assembly

Replacement

1. Remove shift lever assembly

(1) Pull upwards to separate the shift lever assembly leather boot from the auxiliary console (2) Loosen the shift lever set screw with inner hex wrench. Remove the shift lever assembly counterclockwise

2. Remove auxiliary console

3. Remove control lever dust cover

Remove the 4 nuts on the control lever dust cover and the body.

4. Remove dust cover retainer

5. Remove control pull rod assembly

(1) Remove the pull rod connecting bolt (Place 2) (2) Remove 2 hex flange bolts (Place 1) (3) Remove the 2 flange nuts attaching the control pull rod to the body in the trench

6. The installation is in the reverse order of the above operation.

Notice: (1) Pull rod (to transmission) attach bolt torque: 40~50N.m (2) The torque of the two nuts attaching the control mechanism to the body: 20~25N.m

(3) Dust cover retainer shall be assembled well, otherwise the dust seal effect will be af-

fected (4) Dust cover fixing nut torque: 20~25N.m (5) Make sure the shift number words on the top of shift lever ball face towards the driving

direction of the vehicle, properly tighten the set screw of the shift lever

(6) Check whether the shift control is flexible and reliable; the shift lever shall be vertical

when in neutral shift.

Section 3 Cable T ype T ransmission Control Module

Components

Shift Lever Assembly

Shift Control Device

Cowl Baffle

Cushion

E Shaped clip plate

Bottom Panel Assembly of Body

Cotter Pin

Big Washer

Cotter Pin

Big Washer

E Shaped clip plate

Transmission Assembly

E Shaped

Clip Plate Shift Control Cables

E Shaped Clip Plate

Ball Seat

Wave Washer

Replacement

1. Remove shift lever assembly

Bottom Bracket

Spindle II

Spindle I

Support Plate

Shift Lever Assembly

Conjuction Frame

Lever

Bush

Torsion Spring

Ball Pin Seat

Spring Bush

Bush

Ball Pin

(1) Pull upwards to separate shift lever assembly leather boot from the auxiliary console (2) Loosen shift lever set screw with inner hex wrench. Remove the shift lever assembly counterclockwise.

2. Remove the auxiliary console

3. Remove the 4 nuts connecting manual shift assembly and the floor

4. Remove the shift cushion

5. Remove transmission control device assembly

(1) Remove the set nut on the cable seal press plate (2) Remove the cotter pin and the flat washer connecting the cable and the rocker arm on the transmission (3) Remove the E-shaped clip plate on the cable bracket retaining the cable

6. Separate the manual shift assembly from the transmission control cable assembly

(1) Remove the E-shaped clip plate between the transmission control cable assembly and manual

shift assembly (2) Remove the cotter pin and flat washer between the selector cable and shift assembly (3) Remove the locking nut connecting the cable and the shift assembly

7. Installation is in the reverse order of the above operation

Notice:

(1) All the E-shaped clip plate and lock pins should be assembled correctly. Otherwise, the

shifting will be impacted.

(2) The shift device cushion should be correctly assembled. Otherwise, it will affect the seal

effect (3) Torque of the 4 nuts attaching the shift assembly to the floor: 20~25N.m (4) The set nut attaching the selector control cable to the shifter shall be adjusted properly

(if the set nut is improperly adjusted, the shift operation will be affected), when in neutral

shift, the shift lever shall be in correct position (you must check whether the shift control is flexible and reliable in the meantime), after the adjustment is completed, tighten the two nuts

(5) Make sure the shift number words on the top of shift lever ball face towards the driving

direction of the vehicle, properly tighten the set screw of the shift lever

Components

Accelerator

Pedal Assembly

Chapter 2 Accelerator Pedal

Section 1 Accelerator Pedal

Hole Plug

Cowl Baffle

Accelerator Cable

Adjusting Nut

Connect

The Engine

Replacement

1. Remove the accelerator cable

Loosen the set nut attaching the accelerator cable to the accelerator cable bracket on the engine, remove the accelerator cable from the throttle valve rocker arm

2. Remove accelerator pedal

(1) Remove two set nut between the accelerator pedal

and vehicle body

(2) Separate the accelerator cable

3. Detach the accelerator cable

4.Install the accelerator cable and accelerator pedal assembly in the reverse order of the above procedure.

Notice: (1) Accelerator pedal assembly fixing bolt torque: 20~25N.m (2) Properly adjust the position of the accelerator cable set screw to ensure the adequate

tension of the accelerator cable

(3) Check whether the accelerator control is flexible and reliable

Chapter 3 Clutch Control System

Section 1 Clutch Control System

Clutch operating system description

This model is equipped with hydraulic and cable clutch control system, respectively used for 1.3L engine

1.5L engine.

Symptom Suspect ed Are a

1. C lutc h pedal position (Too low)

C lutch slips

C lutch does not releas e 1 . Hy dr au lic pipe line (Air in line)

Clutch noisy

2. C ont r ol mechanism ( St agnat ion)

3. C lutc h pedal fr ee stroke (too large)

1. Control system (Incorrect assembly & adjustment)

2. C lutc h assembly (Faulty)

PROBLEM SYMPTOMS T ABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.

Section 2 Clutch Cable Control Mechanism

Components

Connect The

Clutch Fork

Adjusting Nut

Clutch Cable

Assmbly

Cowl Baffle

Clutch and Brake

Pedal Assembly

Clutch Pedal Bracket Assembly

Adjusting Bolt

Brake Pedal Assembly

Connect The

Bushing

Clutch Cable

Clutch Pedal Assembly

Bushing

Sleeve

Clutch Pedal Torsion Spring

Retainer

Pedal Mat

Adjustment

1. Check and adjust clutch pedal height

The clutch pedal height should be 180~186 mm. Adjust the pedal by adjusting bolts.

2. Check and adjust clutch pedal stroke and free stroke

(1) The clutch pedal stroke: 134~142mm (2) The clutch pedal free stroke: 10~30 mm

If the clutch pedal stroke and free stroke are not within specification, adjust it by adjusting the location of the adjusting nut on the clutch cable. Re-adjust the clutch pedal height if necessary.

3. Check that the clutch pedal operates in flexible and reliable way

Notice: (1) Make sure the clutch is fully applied and completely released when control the clutch

pedal.

(2) The clutch pedal must have certain free stroke. Otherwise, the full application of the

clutch may be impacted

(3) Tighten the lock nut after adjustment

Adjusting Nut

Adjusting Bolt

Nut

Stroke

Minimum Distance from the Cowl Panel

Free Stroke

Install Height

Replacement

1. Remove the clutch cable

(1) Loosen the clutch adjusting nut. Separate the clutch cable from the accelerator rocker arm (2) Remove the 2 set bolts from the clutch cable on the cowl panel (3) Separate the clutch cable from the clutch pedal

Adjusting Nut

2. Install the clutch cable assembly in the reverse order of the above procedure.

Notice: (1) The clutch cable assembly on the cowl panel set bolt torque : 20~25N.m (2) Check and adjust the pedal according to the above-mentioned requirement in

"Adjustment".

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