Manual Usuario, Servicio 320

Chongqing Lifan Industry(group) Imp.&Exp.co.,Ltd.
Add:NO.60 Zhangjiawan,Shangqiao,Shapingba District,Chongqing,China.

Webiste: www.lifan.com/car
E-mail: iecauto@lifan.com
August,2012 the first edition
Owner’s Manual LIFAN
Foreword
320 Owner’s Manual LIFAN
Content
320
Welcome to use LF320. To assist you for better use and maintenance of LF320, do please read this manual carefully.
Major technical specifications and vehicle identification of LF320 2
LF320 applies electronic fuel injection engine with complicated circuit structure of the entire vehicle. Please do not add or Chapter 1 Operation of instrument and controller 7
install electrical equipment that is not recommended by the original factory yourself. Otherwise, the fault generated will not 1-1 Appearance of instrument panel and controller 8
be covered by the warranty of the Company.
1-2 Key and door 12
In this manual, for places with note of “safety warning” or “vehicle damage”, operation shall be carried out following the 1-3 Seat, seat belt and rearview mirror 22
notice content carefully to avoid personal injury or vehicle damage. 1-4 Illumination, wiper and defroster 46
1-5 Instrument and maintenance indicator lamp 52
The note expression as follows: Safety mark
1-6 Ignition switch, manual transmission and parking brake 61
1-7 Audio system 64
Notice 1-8 Air conditioning system 69
Items must be followed for inspection convenience 1-9 Other equipments 75
Chapter 2 Drive guide for LF320 78
Chapter 3 Starting and driving 87
Warning
Chapter 4 Urgent trouble treatment 93
Avoid items endangering The safety mark in above picture means “can not
vehicle or personal safety do this” or “can not make this happen” Chapter 5 Anti-corrosive and vehicle exterior maintenance 106
Chapter 6 Maintenance instruction 112
The pictures in this manual are all illustrations, only for reference. For this manual is the general description of this vehicle Chapter 7 Self-maintenance 115
model which covers various schemes of the model, part of the description features might not be applicable for your specific 7-1 Engine Compartment appearonce 116
vehicle. For vehicle purchase, please consult the real product. 7-2 Engine and chassis 120
Lifan Indusry(Group) IMP.& EXP. CO.,LTD maintains the modification right of the technical features and content of this
manual without any restriction and giving prior notice. 7-3 Electrical Components 127
Thanks for choosing LF320. Any precious idea and suggestion are welcomed Chapter 8 Maintenance Specification 131
1
LIFAN INDUSTRY(GROUP) IMP, & EXP. CO., LTD. LIFAN INDUSTRY(GROUP) IMP, & EXP. CO., LTD.
320
Major technical specifications and vehicle identification of Lf320 Major technical specifications
Product model LF7132 LF7132A LF7132B

Major technical specifications…………………………………………………… 3
Length mm 3745
Vehicle identification of Lf320………………………………………………………5
Signs…………………………………………………………………………………6 Overall Width mm 1620
Height mm 1430
Wheel base mm 2340
Front mm 1385
Track
Rear mm 1365
Curb weight kg 900
Gross vehicle weight kg 1250
Tire specification 165/70R14
Approach angle ° 20
Departure angle ° 23
Front overhang mm 790
Rear overhang mm 615
Seats 5
2 3
Vehicle identification of Lf320

320
Vehicle identification number (VIN)
Product model LF7132 LF7132A LF7132B As shown in the figure, vehicle identification number
Maximum speed km/h 155 (VIN) locates in place 1 of the engine comparment
1 which is used for owner registration.
Engine model LF479Q3
Factory nameplate locates in place 2 of the
In-line4-cylinder, 16-valve, DOHC, multi-point 2 engine compartmentcompartment which
Model contains vehicle identification number too (VIN).
electronic injection
Displacement ml 1342
Maximum power kW 65
Maximum torque N•m 115
Idle speed r/min 800±50

As shown in the figure, the engine
identification number locates on the engine
Fuel consumption cylinder block.
of comprehensive L/100km 6.8
operation mode
Grade ability % ≥30
Emission
Euro Ⅲ Euro Ⅲ Euro Ⅳ
standard
4 5
Indicator and warning sign
Section 1-1
320
1 Operation of instrument and controller
2 3
Appearance of instrument panel …………………………………………………8

Manual air conditioning controller ………………………………………………9
Appearance of instrument cluster ……………………………………………10
4 5
1.Power steering fluid warning sign Tire pressure sign, locating in the middle of Fuel sign, locating in the inner side of the
2.washer fluidWindshiled washer fluid warning the two hinges of left front door. fuel tank cap.
sign
3. Oil filling and coolant warning sign
4. A/C refrigerant warning sign
5. Engine coolant warning sign
Indicator on instrument cluster
6 7
Appearance of instrument panel

Manual air conditioning controller

320
1. Side vent 1. Left combination switch (light)
2. Side defroster outlet 2. Right combination switch (wiper & washer)
1 2 3 2 1
3. Central vent 1 2 3 3. Emergency alarm lamp
4. Power window switch 4. Vehicle audio (CDMD-X)
5. Glove boxClove box 5. Air conditioning controller
6. Cup holderholder 6. Cigarette lighter
7. Parking brake lever 7. Rear fog light switch
8. Gear shift lever 8. Front fog light switch
9. Ashtray 9. Power rearview mirror control switch
10. Safety lock 10. Central control lock switch
11. Background light adjustment switch
11
4 4
10
9 8 7 6
10 4 9 8 7 6 5
8 9
Appearance of instrument cluster

Indicator on the instrument cluster

320
Brake fluid level warning indicator Air bag indicator
1 2 Seat belt indicator Headlamp highbeam indicator
Charging indicator Turn signal indicator (lightened separately)
svs
Oil pressure warning indicator Rear fog lamp indicator
OBD indicator(Check engine) Parking brake indicator
Low fuel level warning indicator Anti-theft indicator

3 4 5
1.Speedometer 2. Tachometer 3. Fuel gauge 4. Odometer 5. Clock display ABC indicator svs Engine electronic injection system fault indicator
Door open warning indicator Engine coolant temperature warning indicator
10 11
Section 1-2
320 Key
Remote controller (optional)

320
Remote controller is an electronic component;
Operation of instrument and controller please follow the following instruction to avoid
controller damage.
1 ● Do not put the remote controller at places
Key and door
2 with high temperature like instrument panel.
Key ………………………………………………………………………………13 ●Do not disassemble it.
Remote controller………………………………………………………………13 ● Avoid severe hit on other objects or
3
dropping on the ground.
Vehicle anti-theft system………………………………………………………14 ●Avoid placing it in water.
Door………………………………………………………………………………16 For failed door operation by remote controller or
Central control system…………………………………………………………17 failed operation in correct distance, or dim or unlit
indicator of remote controller:
Power window……………………………………………………………………18 ● Check the existence of radio station or radio
Each vehicle has 2 keys. 1. Lock switch
Trunk lid…………………………………………………………………………19 These keys can open all of the locks. 2. Unlock switch transmitting set of an airport which have interference
3. Indicator effect on the normal operation of the controller in the
Engine hood……………………………………………………………………19
neighborhood.
Fuel tank cover…………………………………………………………………21 For sufficient power supply of the remote controller, ● The battery power might be depleted. Check the
the control distance is no less than 20m. battery of remote controller. For battery replacement,
please refer the “Remote Controller Battery
Replacement” of this section.
For loss of remote controller, please contact with
LIFAN service station as soon as possible to avoid any
theft and accident.
12 13
Remote controller battery replacement

320
Locking operation Vehicle anti-theft system (optional)
For locking or unlocking all doors of the vehicle, please Door locking with remote controller can set the
Battery model: CR2016/3V Replace remote controller battery in the following procedures:
press the switch of remote controller slowly and accurately. anti-theft system of LF320.
Warning After battery replacement,
Locking: press the lock switch, and all doors of the Press the lock switch of controller can make the check whether remote
Great attention shall be paid to remote
vehicle are locked simultaneously. At the moment, vehicle enter anti-theft condition. controller can work normally.
turn signal lamp flashes twice. controller battery or component replaced
If it still can not work
Under anti-theft condition, press unlock switchlock to avoid being swallowed by children.
normally, please contact
Check whether the doors are locked. switch can disable anti-theft condition and enter with LIFAN service station.
normal condition. Anti-theft indicator flashes rapidly.
If any door is open, lock switch can not be applied Note
After opening the door or starting the ignition switch,
to lock the door.
anti-theft indicator goes off. If turn signal lamp
●Do not lose any component during 1. Open remote controller with flat- 3. Put new battery into remote
flashes once, locked doors are unlocked
Unlocking: press unlock switchlock switch, all the doors are remote controller battery replacement. tip screwdriver or similar tools. controller with positive side
unlocked simultaneously. At the moment, turn signal lamp simultaneously.
upwards. The controller cover
flashes once.
Unlocking operation Under anti-theft condition, press lock switch to lock ● Can only apply battery of the same must be closed tightly.
After using unlocking function of remote controller, the doors, turn signal lamp flashes twice. If door is model recommended by LIFAN service
not locked, turn signal lamp flashes 3 times. Note
doors can be opened in 30 seconds. If door is not station for the replacement.
opened within this period, all the doors will be ● Do not bend connector.
locked again automatically. Under anti-theft condition, if open the door or start
ignition switch, turn signal lamp keeps flashing. ●Do not leave waste remote controller ● Confirm remote controller is installed with correct
For press lock or unlock switchlock switch continuously, battery around. Please send waste battery positive and negative sides.
locking or unlocking can not be operated repeatedly. Within 30 seconds after disabling anti-theft to recycling collection site with approval. ● Do not replace battery with wet hand. Water can cause
Please loose the switch and press it again. condition, if the door is not opened and the ignition accident rust.
switch is not at ON, the control system will recover 2. Remove waste remote controller ● Do not touch or move any component of remote
After pressing lock or unlock switch, control module will anti-theft condition automatically. battery.
accept a feedback signal from the actuator. For wrong controller. Or correct operation will be interfered.
feedback signal (e.g.: actuator electric motor damage), Under anti-theft condition, anti-theft indicator is in ● Please pay attention not to bend electrode or leave dust
turn signal lamp flashes 5 times to remind the owner slow flashing, engine can not be started. or oil in remote controller box when putting in battery.
that the door is not locked (or not opened).
14 15
Door
320
Child-Protection Door Lock Central control system (optional)
Warning For speed over 20km/h, only hitting unlocking
order is valid, all other unlocking operations
Ensure all the doors are locked before are invalid. For speed less than 20km/h, other
driving, especially with child in your car. unlocking operations are allowed.
Correctly using seat belt and locking the
doors can protect you from serious injury For speed over 20km/h, if the vehicle is not
when crash occurs and prevent the doors locked, it will be locked automatically. And it
opening accidentally. will not be unlocked when speed is less than
20km/h. (This function is not available for
simple controller)
For traffic collision, the vehicle will be

unlocked automatically. When receiving the
Locking and unlocking with key Door lock button As shown in the figure, move the lock bar Driver side central control system
collision signal from the air bag, the
to “Lock” position.
controller will execute the unlocking function
Put the key into keyhole and turn it. Unlocking: pull the button up. Press the switch on control plate. Each press
3 times successively to ensure the unlocking
Locking: press the button down. When the children protective device is will change the central control system once,
state of the door lock. (This function is not
Locking: turn the key anticlockwise. locked, the rear door can not be opened with namely from unlocked state to locked state,
available for simple controller)
Unlocking: turn the key clockwise. For demand of door locking from the outside, inside door handle. This function is or from locked state to unlocked state.
remote key controller can be applied to lock recommended at any time with child in your
the doors. car.
16 17
Power window (optional)
320
Trunk lid Engine hood
Use of switch on driver’s door Note
Door window lock switch
Automatic: press for less than 300ms to enter ● Button pressing duration of less than
automatic descending operation, glass window 300ms: if the window controlled by the
stops automatically after reaching the due button is in lifting operation, the window
place. lifting operation will be stopped;
otherwise automatic work condition will
Manual: press for 300ms or more to enter be applied.
manual ascending or descending operation, ● Button pressing duration of 300ms or
press the button and hold it to operate, leave the more: if the window is in operation with the
button to stop operation. lifting direction different with the operation
direction controlled by the button, the
Time delay: window regulator system can work original operation will be stopped, then
manual lifting work condition will be Passenger’s window operation
Door window locking switch in 60s after turning off the ignition switch; if To open the trunk lid, pull up the trunk lid Open engine hood:
Switch on each door can operate the relevant press the remote controller lock switch within applied; for same direction, manual lifting open handle at the driver’s seat.
work condition will be applied directly. Any switch on passenger’s door or switch on
window the 60s, vehicle enters anti-theft condition, in 1. Pull up the open handle of engine hood,
driver’s door can control passenger’s window.
which condition window regulator system is To close the trunk lid, pull down and press the the engine hood will jump upwards slightly
Ignition key must be put at position “II”. prohibited from working. trunk lid. After closing it, try to pull it up to check
Open: press the switch.
whether it is closed tightly. Warning
Close: pull up the switch.
Operation of driver’s window Remote control: if press the remote controller
If the window lock switch of driver’s door side Warning Before driving, please confirm engine
lock switch and holding on, four glass windows
is pressed, operation of passenger’s side hood is closed and locked tightly.
Open: press the switch. will ascend to top, the frame riser stops when the Trunk lid must keep close in driving. Then
window is invalid. Otherwise, in driving, the possible sudden
Close: pull up the switch. switch is released or glass touches the top. luggage throwing out can be prevented, open of engine hood can cause accidents.
exhaust gas can be kept out of the vehicle.
18 19
320 Fuel tank cover
320
Warning
After putting engine hood brace rod into
the hole, please confirm the brace rod is
supporting the engine hood firmly to avoid
head or body injury caused by engine
hood falling.
Note
Before closing engine hood, please confirm

that engine hood brace rod is in original
2.Take the cover lock off from the engine 3.Put engine hood brace rod into the holder. Closing engine hood with loose 1.Pull up the open handle of fuel tank 2. Turn the fuel tank cover anticlockwise
hood and lift engine hood. engine hood reinforcement plate hole to brace rod can cause engine hood cover. slowly and take it out.
keep engine hood in open condition. deformation.
When refilling fuel, engine must be shut
Before closing engine hood, must check down.
whether tool or tatter, etc, are left in the
engine hood. Put brace rod to its original Warning
position. Then put engine hood down and
confirm it is locked in its position. No cigarette in fuel refilling to avoid burning
caused by generated spark or flame.
20 21
Section 1-3
320 Seat
Front seat
320
—Precautions for front seat Driver’s seat
Operation of instrument and controller In driving, passenger of the vehicle shall Warning
adjust the seat back to a comfortable position drivers’ seats, when they completely lean
and use seat belt correctly. SRS front seat air bag will be extended with forward, the distance of 250mm can be
Seat, seat belt and rearview mirror great power. Especially, severe injury and achieved by merely leaning the seat back
Warning death of front passenger can be caused by backward slightly. If it is difficult to see the
Seat… … … … … … … … … … … … … … … … … … … … … … … … … … … …23 road after leaning the back pad backward,
over short distance between front seat
Front seat… … … … … … … … … … … … … … … … … … … … … … … … …23 ● Do not drive before passengers use solid nonskid cushion to lift or apply
passenger and the air bag.
s i t t i n g c o r r e c t l y. P r o h i b i t a n y elevated seat if it is available by the vehicle.
Rear seat… … … … … … … … … … … … … … … … … … … … … … … … …25 passenger from sitting on folded seat
For the 50-75mm of initial charging is the
dangerous area of driver air bag, 250mm off
Headrest… … … … … … … … … … … … … … … … … … … … … … … … … …26 back or in luggage or on goods. For
from the driver air bag can guarantee a clear Shall adjust the seat following the above
emergency brake or collision,
Seat belt… … … … … … … … … … … … … … … … … … … … … … … … … …26 incorrect seated position or seat belt
safety range. The distance is the measured recommended measures. Besides control
distance from the center of steering wheel on the pedal and steering wheel, and
Air bag (SRS)… … … … … … … … … … … … … … … … … … … … … … … …31 application can cause severe personal
to breast bone. If the distance of current observation on instrument panel must be
Electric exterior rearview mirror… … … … … … … … … … … … … … … …44 injury.
seat is less than 250mm, seat position can maintained.
Interior rearview mirror… … … … … … … … … … … … … … … … … … … …45 ●In driving, any passenger is not allowed to be adjusted by the following measures:
stand up or move between seats. Otherwise, ● Remove seat backwards as much as
Vanity mirror… … … … … … … … … … … … … … … … … … … … … … … …45
severe injury can be caused on emergent possible and keep comfortable stepping on
accidents like emergency brake or collision. the pedal at the same time.
● Lean the seat back backward slightly.
Although vehicle design varies, for many
22 23
Front passenger seat
—Precautions of rear seat adjustment

Rear seat
320
Warning Warning Front seat adjustment 1. Seat position regulator handle Warning
Hold the middle of handle and pull
SRS front seat air bag will be extended ● Do not adjust seat when vehicle is still upward. Then make use of slight body When recover rear seat back to vertical
with great power. Especially, severe injury moving, which could cause accident move pressure to slide the seat to the needed position, to prevent personal injury in
and death of front passenger can be and make driver lose control of the vehicle. position; release the handle. accident or emergency brake, the
caused by over short distance between following protective measures must be
front seat passenger and the air bag. ● Attention shall be paid to ensure no 2. Seat back angle regulator handle followed:
Front passenger seat shall be removed by collision between seat and passenger or seat Lean forward, and pull the handle upward;
adjusting seat back; the longer distance and luggage. then lean backward to the needed angle; ●Push and pull the upper part of rear seat
release the handle.
between the seat and the air bag the back forward and backward to confirm the
better. ●After seat adjustment, loose the rod, try to rear seat back is locked tightly. Otherwise
slide the seat forward and backward to check the normal operation of seat belt will be
whether the seat is locked in due position. Pulling the buttons on the top of rear seat influenced.
back upward can unlock the seat back
●Do not put things under seat. Otherwise, and then it can be folded downwards. ● Confirm the ribbon of seat belt is not twisty
seat locking structure can be influenced or or jammed in the rear seat back. Put it in the
seat position regulator handle can be pushed right position for use preparation.
upwards accidentally which can cause
sudden seat move and make driver lose
control of the vehicle.
●For seat adjustment, do not put hand under 1 2

seat or near parts which are in operation.
Otherwise, hand or finger might be injured.
24 25
Headrest
320
Seat belt
For security and comfort, headrest must —Precautions for seat belt Warning
be adjusted before driving touch the safety part of shoulder. On front liquid or abrasive for cleaning, which are also
LIFAN reminds you that driver and
In driving, all passengers of the collision accident, the over lean of seat can not allowed to contact with seat belt directly.
Higher: pull headrest upward. passengers on the vehicle shall buckle seat
vehicle must sit on the seat with seat increase the danger of personal injury or death. Otherwise, seat belt can be greatly damaged.
Lower: press lock release button, press belts at any time to reduce injury or severe
headrest. belt correctly applied. Otherwise,
injury possibility in accidents.
severe body injury or death can be ●Note: do not damage belt or hardware of
The closer to the head position, the better
The seat belts of the vehicle are designed to fit caused much easier in emergency seat belt. Do not make them seized or
protective effect will the headrest have.
Therefore, it is not necessary to use cushion on adults, and a child can sit on a rear seat with brake or collision accident. jammed in the seat or door.
the seat back. protection of the seat belt. According to accident
statistics, a child sitting in rear seat with proper Use seat belt following instructions below: ● Check seat belt system regularly. Check
protection are much safer than whom sitting in for the existence of parts with incision,
Front front seat. ●In the same period, a seat belt can only be abrasion or loose. Do not disassemble or
Warning
applied by one person alone. It is not modify the system.
If a child has to sit in the front seat, seat belt
●Adjust, make the central part of headrest allowed to use one seat belt by 2 or more
must be applied correctly. For improper
close to the upper side of ears. people jointly, even for children. ● For severe collision accident, seat belt
application of seat belt in accident, the rapid
devices (including bolts) must be replaced.
● After adjustment, confirm it is locked extension of air bag can cause severe injury or
on the position. ●Avoid over lean of seat back. When driver and The entire device must be replaced even
death to the child.
front passenger sitting straight against the seat, though the damage is not obvious.
●Do not drive without headrest. No matter in front seat or rear seat, do not allow child to seat belt can provide maximum protection for
stand up or kneel on the seat. For emergency brake or front or rear collision accident. If lean on the ●Keep seat belt clean and dry. For cleaning
collision, the unprotected child can suffer severe injury or seat, seat belt part of waist can slide to breech necessity, apply neutral soap water or mild
even death. Besides, do not put child on your leg which and press pressure on abdomen, or neck will warm water. Do not use bleaching agent, fuel
Rear can not provide sufficient protection to the child.
26 27
320
—Buckle front and outside seat belts Content
For emergency brake or collision, retractor Warning Adjust position of waist and shoulder seat
will lock seat belt. It will also lock up for too belt parts
rapid forward lean. Seat belt can stretch out ● After putting in the belt head, please
Tighten loose part
for slow and stable move for free action. confirm the belt and lock catch are
Keep waist seat belt buckle at breech position as
locked firmly and seat belt ribbon is not
much as possible — do not keep it at waist part.
For failed seat belt pulling from the retractor, twisty. Too high
Then pull the shoulder part upward by the bar plate,
seat belt can be pulled out from the retractor adjust seat belt to a proper position.
smoothly by pulling it tightly first and then ● Do not put things like coin and clip into the
releasing it. lock catch to prevent blockage on the correct
buckle of belt head and lock catch. Keep it at breech position as well as you can
When the shoulder seat belt of rear

passengers is fully stretched, slight ●For abnormal seat belt function, inform
Adjust seat according to requirement and sit LIFAN service station immediately.
shrinkage can lock seat belt and it can not
straight on the seat with back against the seat. For Before seat belt repair, do not use the Tighten loose part Warning For seat belt release, press the open button
stretch any more. Release the seat belt again
need to buckle seat belt, pull it out from the seat, for its failed protection to on lock catch, ribbon will automatically
for full shrinkage, then it can be pulled out ● For collision or other accidents, waist
retractor and put the belt head into the lock catch. passenger can cause personal injury. retract into the retractor.
again. Too high seat belt at high position and loose seat
After putting belt head into the lock catch, you can belt can cause severe injury for slide of
Keep it at breech position as well as you can waist seat belt. Keep waist seat belt at For unsmooth automatic seat belt retraction, pull
hear a clatter.
breech position as much as possible. seat belt out to check for possible twist.
The ribbon length of seat belt can be adjusted
automatically according to the passenger
figure and seat position. ● Shoulder seat belt can not be
positioned under arms.
28 29
320
—Buckle rear middle seat belt tightly Air bag (SRS)
Warning — SRS for Driver and Front Passenger
Pull out
● For safety, please carefully read the
● After putting in belt head, please following information before use.
confirm that belt head and lock catch Information for use of SRS and air bag:
are locked firmly and seat belt is not ● Carefully read the Information Manual and
twisty. check your vehicle for the installation of air
Too high bags (driver side air bag and passenger side
●Do not put things like coin and clip into Adjust to suitable air bag).
the lock catch to prevent blockage on the position
● The front passenger SRS includes 2 air
correct buckle of belt head and lock catch.
Keep it at breech position as well as you can bags:
● For abnormal seat belt function, ●Driver side air bag
Pull out i n f o r m L I FA N s e r v i c e s t a t i o n Too high ●Passenger side air bag
Keep it at breech position as well as you can Adjust to suitable position
immediately. Before seat belt repair, do
not use the seat, for its failed protection
Sitting on rear seat, to tighten seat belt to passenger can cause personal injury. Retract the overlong seat belt ribbon, adjust the For seat belt release, press the open button The driver side air bag is installed at the
center of the steering wheel. The passenger
buckle, put belt head into lock catch. seat belt position. on lock catch.
side air bag is installed in the dash board
After putting belt head into the lock catch, you For seat belt ribbon retraction, pull the Warning under the cover marked with SRS/AIR BAG
can hear a clatter. unfixed end of the seat belt. above the glove box. While deploying at a
For collision or other accidents, waist high speed, the impact force of the air bag is
Please keep the waist seat belt at the breech seat belt at high position and loose seat very strong. The air bag can not well protect
For improper ribbon length of seat belt, make
position as much as possible — can not lock belt can cause severe injury for slide of the driver and the front passenger individually
belt head and seat belt at right angle, then pull
at the waist position; then adjust seat belt to waist seat belt. Keep waist seat belt at unless working together with the knee
the belt head to adjust ribbon length.
suitable position. breech position as much as possible. protection board within the dash board as
well as the seat belt.
30 31
320
●The main parts of the system include: ● Lower risk of personal injury in such Caution Caution Caution
●Steering wheel assembly accident as rollover or crash on the rear
● Steering wheel side air bag module without the deployment of air bag Seat belt must be used.Safety belt must The children should not be seated in Rearward-facing children restraint
component/passenger side air bag module ● Lower risk of personal injury in the frontal be used. the front, or serious personal injury will system: extremely dangerous!
component crash without the deployment of air bag occur.
●Passenger side module cover ●Lower risk of being thrown out ●The electronic air bag system is only a part
● Lower risk of lower body and leg injury in of the front passenger restraint system, which It is very dangerous to seat a child of 12 years Do not adopt the rearward-facing children
Spiral cable an accident can not provide protection individually unless old or below in the front, since the child may restraint system for the front passenger seat.
● Air bag module electronic control unit ● Restraint of driver for better control on working together with the seat seat belt. be seriously injured and even die under the Hit by the deployment of the air bag, the
(ECU) vehicle deployment of the air bag. If possible, please children restraint system will be moved
●Air bag harness ● The electronic air bag will not be deployed seat the child of 12 years old or below in the backward and seriously injure the children
● Rear cover plate of steering wheel, ECU Important safety tips in such accidents as crash on the rear, rear and adopt the special restraint system and even make them die. Never use the
bracket, connection screw, and other rollover, or the frontal crash without sufficient for children with suitable size. rearward-facing children restraint system for
accessories. force and so the upper body and lower body the front passenger seat with an air bag.
of the driver and passenger in the vehicle are Caution
● The air bag SRS is a supplementary only protected by the seat belt at this
restraint protection system designed for the moment. The air bag system will only be In front of the air bag: it is extremely
driver and front passenger under a particular deployed under a huge impact force and you dangerous to put your hand or foot too
situation. Without the seat belt, the air bag will be better protected only if you are in a close to the air bag.
will fail to give enough protection in an correct sitting posture.
accident. Therefore, the seat belt is also very
important for the safety of passengers.
Restraint of passenger body, keeping the
passenger away from the inflating air bag
32 33
320
While deploying at a very fast speed, the To protect the passengers in the vehicle, the Adjustment of vehicle suspension will component by the harness (the dismantling of incorrect deployment of the system. After the action of the system, the deployment
impact force of the front air bag is extremely electronic air bag system will be deployed in cause potential risk. If the vehicle height some interfaces requires special skills). In of the gas generator will generate a lot of heat
strong. If too close, serious personal injury a flash. Accordingly, the air bag system or suspension changed, the vehicle will addition, the gas generator in the system All the components of the air bag system are energy, so the components touching it will
may occur. Driver’s hand should always hold needs to be deployed by a huge opening fail to check the crash correctly and then includes some chemicals and the deployment exclusive for your vehicle model, thus they become hot and the hot air bag gas generator
on the rim of the steering wheel. The legs of force. The driver and passenger should sit as cause incorrect actuation of the air bag. of the generator is realized through the can not be moved and installed on other is dangerous. At the moment of the air bag
the front passenger should rest on the floor. backward as possible in a comfortable The accidental deployment of air bag may electrical signal; therefore, only the vehicle models. The installation of such deployment, the steering wheel and dash
Keep the front passenger seat as backward posture, leaving a space in front for the result in serious personal injury. personnel having received the training course components on other vehicle models may board will be very hot, so you may be burnt.
as possible and adjust the seat back for a deployment of the air bag. Do not put the of electronic air bag system can move some lead to injuries caused by the system After the deployment of the air bag, do not
normal sitting. Always wear your seat belt. child or any other thing between the front Do not place any sign or label on the component of the system appropriately inefficiency. touch the components within the air bag
passenger and the air bag. While deployed, steering wheel or on the front air bag, during the repairing, otherwise the non- deployment area. Maybe chemicals remained
Caution the air bag will greatly hit the driver or front which may influence the deployment of the professionals’ unnecessary maintenance and are contained as well. Therefore, after the
passenger if too close to the air bag or even air bag or even injure the passengers in movement may cause the unnecessary fault action of the system, please try to avoid
Do not put a child or any other thing injure the children more seriously if sit the vehicle while flying to the passengers of the system and even after-effect on the
Caution touching these places and wash the naked
between the front passenger and the air between the front passenger and the air bag. during the deployment of the air bag. future work. After the action of the system, avoid skin with the neutral soap.
bag. touching the middle of the air bag
Caution Do not try to maintain or remove any part Any component design in the system cannot bracket or the inside of the air bag.
of the electronic air bag system by be modified without the permission of the
Installation of front and rear devices yourself (only operated by the qualified qualified professionals, because the position
(e.g. front bumper): snowplow or technician). of any component and the linkage between
winch will cause potential risk, which components in the system are designed
may actuate the air bag collision professionally, and any modification may
sensor system. As a result, the air bag The sensor of air bag system is installed on cause the inefficiency of some components or
may be accidentally deployed, or fail to the chassis of the vehicle. Due to its even the whole system during the collision of
be deployed in an accident. performances, it is connected to every the vehicle, or even cause injuries due to the
34 35
320
Air bag indicator in the instrument Notes for air bag deployment
cluster This air bag system is designed not to be The speed of the air bag inflation and the gas dashes out from the center of the is not deprived of driving functions, the air bag system properly. If you do not install a
maintained. The air bag indicator in the dash deflation of the electronic air bag system is steering wheel and upper right of the dash driver can go on driving. The driver ’s air new air bag system (if the harness is not
board indicates the working condition of the so fast that you cannot know how the action board, the nylon material of the air bag may bag can be inserted into the protective cap damaged, keep the harness), you may
air bag system. That the warning lamp happens. The air bag is designed to deflate cause the bruise and/or erubescence of the at the center of the steering wheel for increase the injury risk during the next
illuminates or flashes for 6 to 8 seconds and quickly after the inflation to (A) absorb the driver and the front passenger. Such bruises driving convenience. The front passenger ’s collision.
then goes out means the normal condition of impulsive force of passengers’ head going are similar to that by ropes or carpets or air bag can be inserted into the cap at
this air bag system. ahead and (B) ensure passengers’ eyeshot floors, which are not caused by chemicals, upper right of the dash board. However, if
and guarantee the driver ’s driving so the symptoms will never last for a long the collision happens again, your safety
Please go to Lifan service station for capability after the collision. Do not touch time. If the blister appears on the skin, cannot be guaranteed.
maintenance if the following conditions the components in the system after the please go to hospital.
appear when starting up the vehicle: deployment to avoid burning. The Once the electronic air bag system acts, it
passengers will find the special gas and During the air bag deployment, all the cannot be used, so for your safety, the vehicle
● The warning lamp does not illuminate or smoke on their seats. That is normal and propellants will be used up, but some may should be maintained with the normal ways
flash for 6 to 8 seconds; the gas thus generated is harmless. These be left inside the air bag or at the edge of and the electronic air bag system as a whole
● The warning lamp always illuminates or particles will result in the irritant effect on the bag. Do not touch such exposed should be dismantled (if possible, keep the
flashes in driving. the skin, eyes, noses or throats. Please chemicals and do not cut the air bag having harness) and a brand new system should be
wash the skin or eyes with cold water and acted, but replace it with a new complete installed. Abnormal maintenance and no
turn to fresh air. If the effect cannot be one, which should be carried out by the m a i n t e n a n c e o f t h e v e h i c l e ’s b r o k e n
relieved, please go to hospital. If the qualified professionals dealing with air bag components will cause bad effect on the
particles drop on clothes, please clean the system technology. Wash your hands and whole air bag system. After the action of the
clothes according to the washing face with the neutral soap after the air bag air bag, please drive your car to Lifan service
indication. action. station and make the technicians change a
new electronic air bag system for you. The
At the moment of air bag deployment, when After the air bag deployment, if the vehicle technician will dispose and withdraw the used
36 37
320
Maintenance and service of air Air bag activation/deactivation
bag system Working principle of air bag Front air bag activation
Frequent maintenance is unnecessary if Caution The front air bag will expand for the following
there is no failure of air bag system (Self- collisions exceeding moderate degree:
checking will function when starting the Savagely driving on rough road on
system each time). The design can ensure purpose or cleaning up accumulated The front of the vehicle bumps against the
normal operation for 10 years from the day of snow with the vehicle with electronic hard wall at a speed over 22km\h (14mph).
installation. 10 years later, the professional air bag system may result in incorrect
technician of air bag system will renew it with deployment or malfunction of the
a new system. system.
Please send your vehicle to Lifan service The air bag system is exclusive for your
station in the following conditions: vehicle model, so any change of the original
● Air bag system indicator is continuously spare parts may result in adverse effect to
blinking. the air bag system.
●Air bag system indicator is always on.
When the air bag collision sensor detects a The vehicle bumps against curbstone, Hard landing or vehicle falling.
●Air bag system indicator can not illuminate
signal of collision exceeding medium power in pavement steps or hard objects.
when the ignition switch is on.
●Air bag is expanding. front or at side, it will send a current to the gas
generator.
When the air bag is full of gas, it will deflate
gas quickly.
The air bag can only be used for once. After
that, it doesn’t work and must be replaced. Front collision in an angle within 30.
Only the technician having received
professional training can renew the air bag
system.
38 39
320
The vehicle bumps against cement The vehicle bumps against the lower The vehicle bumps against the wall at The rear is bumped by another
pillar, tree or other long thin objects. part of the truck. its side part. vehicle.
The vehicle drives into a big hole or bumps Limit of front air bag activation The rear is bumped against by another The vehicle bumps against the wall at its side Front air bag deactivation The deployment of the front air bag may not
against the far side of the hole. vehicle or the vehicle bumps against the part, thus the resistance from the collision is The air bag will not deploy in the following occur when the vehicle turns over on one
lower part of the truck, but such collision is not strong enough to activate the air bag. cases. side.
Depending on the impact strength, the front
not strong enough to activate the air bag.
air bag may not expand in the following
The rear is bumped by another vehicle.
conditions:
The vehicle bumps against a tree or pole, but

the severe damage to the cover is not strong
enough to activate the air bag.
40 41
320
Maintenance
Regular maintenance is unnecessary for the Caution Dismantling of inside components:
The side is bumped by another vehicle.
air bag system, but please send your vehicle
to Lifan service station in case of the following Private maintenance of air bag safety Remove spare parts in the air bag and
conditions: system: components in the sensor. Front seat, front
● The air bag system indicator is dash board, components, steering wheel,
continuously blinking. It’s very dangerous to privately maintain or spare parts on the front and rear window
●The air bag system indicator is always on. modify the system. The occasional operation posts and the roof edge are very dangerous,
● The air bag system indicator can not or thorough damage of the air bag system because they contain the main parts of the air
illuminate when turning on the ignition
may cause much severe damage. Never bag. The occasional start-up of air bag may
switch.
●Air bag is expanding. m o d i f y t h e s y s t e m p r i v a t e l y. A s k t h e cause a series of adverse effects. Please ask
The air bag brake system indicator will technician having received professional the technician having received professional
illuminate in case of the following training to repair it. training for advice before moving these parts.
conditions:
●Children restrain system is not available Damaged air bag sensor: Handling of air bag:
The deployment of the front air bag may not occur when the side is bumped by another Real time monitoring on the front seat.
vehicle. ● There is a passenger or things on the It’s very dangerous to drive the vehicle with a It’s very dangerous to handle the air bag
The following components of the air bag front seat. damaged air bag sensor. The sensor can be inappropriately and if there is an active air
system are monitored by the diagnostic Children restrain system designed for air
damaged by minor collision that even can not bag in the vehicle. Please obey all the safety
bag brake system is installed on the front
system: activate the air bag. If collision persists, the measures so as to avoid any injury. Please
seat, but the air bag brake indicator can
not illuminate. air bag won’t expand for the damaged sensor. ask the technician having received
After the collision, please ask the technician professional training for how to handle the air
having received professional training to bag safely or scrap the useless vehicle with
check the air bag system. an air bag.
42 43
320
Other matters Electric exterior rearview mirror (optional) Electric exterior rearview mirror switch Interior rearview mirror
● If you want to transfer or demolish your Note Warning
vehicle, read the manual carefully and inform the
● Do not operate the switches or scrape Do not adjust the rearview mirror when
new owner or demolishing unit that your vehicle 1 the surface of rearview mirror if the mirror driving. Otherwise, this action may cause
has been equipped with air bag system, and
suggest them to read this manual carefully. is frosted. Adjust it after the deicing with driver to steer the vehicle by mistake, thus
L . R spray deicer or other methods. accident happens.
●Avoid contacting the air bag module assembly 1 2
directly (otherwise you may suffer scald or Vanity mirror
toxicosis) after the air bag system played its role. Warning
Adjust the interior rearview mirror to a proper
Removal work for air bag should be done by 2 ● Do not touch the rearview mirror when position so that you can see the rear part of
LIFAN service station. Once the air bag system vehicle in the mirror.
moving,avoiding injuries and rearview mirror
plays its role, replace a new one at once.
fault. Adjust the interior rearview mirror as per the
●Do not drive the vehicle when the rearview direction 2 shown in the figure above to
●Air bag system plays its role in case of a front Adjust the electric exterior rearview mirror 1.Selection switch, used to select the exterior
mirror is folding backward. Unfold and weaken the light from the Headlamp of
collision to certain extent. No problem may exist to the position that you can see the side of rearview mirror which needs adjusting. Press
correctly adjust the rearview mirror at driver vehicles behind it and prevent against dazzle
vehicle in the rearview mirror.
in the system itself even though it is not switch to “L” (left) or “R" (right). when driving at night.
and passenger side.
triggered. Damage of vehicle or abnormal repair
Warning Joystick at Position 1 in daytime: Rearview
can affect normal operation of air bag system. 2. Control switch is used to adjust exterior rearview
mirror boasts a good definition at this position.
Do not adjust the rearview mirror when driving. mirror. Press the switch as per the direction
required. Joystick at Position 2 at night: Bear in mind Fold down the sunshade and open the cover
This action may cause driver to steer the
that to decrease glare,the definition of rearview when using the mirror.
vehicle by mistake, thus accident happens.
mirror will be reduced.
The mirror can be adjusted when the key is at
“I” or “II”.
44 45
Section 1-4
320
Headlamp and turn signal lamp Turn signal lamp
Operation of instrument and controller
3 1
2
2
Illumination, wiper and defroster 1 2
Headlamp and turn signal lamp…………………………………………………47 OFF
Warning light………………………………………………………………………48 OF F
2 OF F
Front fog light……………………………………………………………………48

Rear fog light……………………………………………………………………49 1 1
Front dome light…………………………………………………………………49
Front windshield wiper and washer……………………………………………49 Headlamp High/low beam-Turn the left combination Press the left combination switch forward or backward
switch to the Headlamp position and push to Position 1 before sending the turn signal.
Rear windshield wiper and washer……………………………………………50 Turn on the following lights the switch handle forward (Position 3)
Defroster of rear windshield……………………………………………………51 when using high beam. And turn the Key should be located at “II”.
Position 1-Turn on the position light, license plate switch handle to Position 2 when using
lamp and taillight. low beam. The switch handle will be returned to its original
position automatically after the vehicle turns a corner.
Position 2 -Turn on the Headlamp and all the above
Front: the direction when driving forward
lights. Move the switch handle forward or backward to
Rear: the direction in reversing
pressure point (Position 2) and keep this action when
Warning Headlamp high beam indicator (blue) on
sending the lane change signal.
instrument cluster indicates high beam is on.
To avoid the battery discharging, do not
keep the lights on for a long time when the Overtaking signal (Position 1) - Uplift the switch
handle, and then the Headlamp beam twinkles.
engine is not in operation. When releasing the lever, the Headlamp high beam
46 glitters and then is turned off. 47
320
Emergency warning lamp Front fog light Rear fog light Front dome light Front windshield wiper and washer
Note
3
To avoid the battery discharging, do not keep
the lights on for a long time when the engine
2
is not in operation.
ON OFF
1
High-mounted brake lamp

(optional)
This lamp will light up with rear brake lamp when

Press this switch and all turn signal lamps stepping down the brake pedal, warning other To turn on front fog light, turn the knob on Turn the knob on the left combination switch Slide the switch as shown in the figure As shown in the figure, move the control
will twinkle if you want to turn on the drivers that the vehicle brakes, and avoiding the left combination switch to lamplet or to lamplet or Headlamp position. When front when turning on the Front dome light. lever to the set position needed when using
Emergency warning lamp. Repress it if accident. Headlamp position, press front fog light light is on, press rear fog light switch, rear the front windshield wiper.
you want to turn off the lamp. switch, the front fog light will light up. fog light will light up. The Front dome light switch has the following The key must be at position “II”.
locations:
Indicator of rear fog light on the instrument Lever position Mark Speed setting
The emergency light should be turned on to “ON”-Front dome light is on
cluster indicates the rear fog light is on.
caution other drivers if the vehicle stops at the Front dome light is on Intermittent
Position 1 INT
place where a traffic accident may occur.
“OFF” -Front dome light is off Position 2 LO Low speed
Try to stop the vehicle at the safety zone far
“O”-Front dome light is turned on when Position 3 HI High speed
away from the main lane.
opening any door. It will be turned off after all
doors are closed.
48 49
320
Rear windshield wiper and washer Rear defroster button
For the one-time wiping on the windshield, Push down the control lever when Defroster will be closed when pressing the switch
uplift and then release the control lever. spraying washer fluid. again.
After the washer fluid spraying, release the
Push up the control lever when spraying 2 control lever at once with the screenwiper to The rear defroster is equipped with the prolonging
washer fluid. wipe one time. function and will stop automatically 15 minutes after
its operation starts.
1
Release the control lever immediately after
spraying washer fluid. However, the wiper will
still work for several times. Note
In the chilly days, use defroster to warm the
windshield before cleaning, this can prevent Do not scratch or damage the heating coil
the washer fluid against freezing on the or connector when cleaning the inner side
windshield. Otherwise, clear vision will be of the rear window.
As shown in the figure, move the control lever Press this button when demisting or defrosting
affected. to the set position needed when using the rear the rear windshield.
windshield wiper.
Note The key must be at position “II”. The ignition switch must be at position “II”.
Do not use the wiper when the windshield
is dry. Otherwise, the shield will be Lever position Mark Speed setting Heating cord at the inner side of rear windshield
scratched. will quickly make the rear windshield surface
Position 1 OFF Close clear. The indicator will be on, indicating defroster
is in operation.
Position 2 ON Open
50 51
Section 1-5
320
Fuel gauge Tachometer Milometer and trip odometer
Instrument and Maintenance Indicator
Fuel gauge………………………………………………………………………53
Tachometer…………………………………………………………………… 53
Milometer and trip odometer…………………………………………………53
Dashboard lamp luminance adjustment…………………………………… 54 svs
Warning indicator………………………………………………………………55 svs
The gauge indicates the fuel volume in the Tachometer shows the rotation speed of engine
fuel tank when the ignition switch is at with 1/1000 of “ rpm” (round per minute). Its
“ON”. function is to select the right shift time to prevent
the engine from lugging down and overrunning.
Close to fill up --- pointer near “2/2”
3
Close to use up --- pointer near “0” The engine will be abraded excessively and waste
the fuel if driving the vehicle when the engine
overruns. 1
Caution to fill fuel-the yellow fuel warning lamp
illuminates. The cursor of fuel gauge will sway Note 2
when braking, accelerating or turning a corner,
which is caused by the sloshing fuel in the tank. Do not let the cursor turn into the red zone,
which may cause a serious damage to engine.
52 53
320
Dashboard lamp luminance adjustment Warning indicator
The display shows the following information.
If the indicator illuminates Please do as per the sign instruction
1. Clock shows the 24-hour time.
Check whether the brake fluid is insufficient; if it is sufficient, please
2. Odometer (ODO) displays the total traveled mileage (a)
stop at once and contact the with LIFAN service station.
L . R
and short-distance mileage of the vehicle.
3. Buttons for setting set the return-to-zero for the clock (b) Fasten seat belt.
and the trip odometer as well as the switch of the
odometer display.
(c) Stop and check.
When switching odometer display, press this button so
that the odometer display will be switched between the
Move this button to adjust the illuminance of (d) Stop and check.
total mileage and the short-distance mileage.
the dashboard lamp.
When adjusting the clock, switch the odometer display to
(e) Vehicle brought to the LIFAN service station for check and repair.
the total mileage display, press the button till the clock
twinkling and press the button to adjust the time.
Vehicle brought to the LIFAN service station for check and repair. If the warning
(f) lamp also illuminates, stop the car immediately and contact the LIFAN service
If you want to adjust the TRIP to zero, press the button till
station.
the instrument is set to zero after the display shows the
reading of TRIP.
(g) Close all doors.
54 55
320
( a ) Brake fluid low level indicator Warning (b) Seat belt indicator
If the indicator illuminates Please do as per the sign instruction This light will call drivers’ attention to fasten
When the ignition key is at position “II”, the Upon any of the following the seat belt.
brake fluid is not sufficient or EBD is with
circumstances, stop the car at a safe Once the ignition key is turned to “II” or “III”, if
malfunctions, this indicator illuminates.
(h) Vehicle brought to the LIFAN service station immediately for check and repair. place immediately and contact the the driver doesn’t buckle up, the indicator will
LIFAN service station. illuminate. Unless the driver buckles up, the
Warning indicator will continue to illuminate.
(i) Water temperature warning for engine coolant. Stop and check. ●This lamp illuminates when the engine is (c) Charging indicator
If the brake fluid level is low, it will be running. Under such circumstance, the The lamp is used to warn for the discharge
dangerous to drive normally and brake probably is in malfunction, which state of battery.
(j) continuously. may result in a longer braking distance.
Fuel warning. Fuel filling is required. If it illuminates in driving, it means that
Step on the brake pedal forcibly to make an something goes wrong in the charge system.
During the operation, the fact that the warning emergency brake. Turn off the electrical equipment like A/C,
(k) Vehicle brought to the LIFAN service station immediately for check and repair. indicator illuminates for a short while doesn’t fan, radio, etc. immediately, and vehicle
mean any problem. ● While the “ABS” warning lamp is brought to the nearest LIFAN service station
illuminating, the warning lamp of brake for check and repair.
system also illuminates.
(d) Oil pressure warning indicator
Under such circumstance, when a braking
The lamp is used to warn for over low oil
is made, the ABS doesn't serve, moreover,
pressure.
the car is extremely unstable as well.
If the lamp flickers or continues to illuminate

in driving, it is necessary to stop the car at a
safe place and stop the engine immediately.
56 57
320
Contact the LIFAN service station for help. (e) OBD indicator If any of the following circumstances occurs, it (g) Door open indicator times or continues lighting. Warning indicator for checking and maintenance
It illuminates when the electronic injection means the part monitored by the warning lamp is ● The lamp illuminates or flickers during driving.
When the engine idles, the lamp may flicker now system of engine is at fault. at fault. It is necessary to Vehicle brought to the The lamp keeps illuminating, till all doors close 1. Pull the parking brake.
and then or it illuminates for a short while after an LIFAN service station for check. completely. (I)Temperature warning indicator of engine The indicator for parking brake system should
emergency brake. During the gradual acceleration When it illuminates, it is necessary to contact ● When the ignition key is turned to “II” position, coolant illuminate.
of engine, if the lamp is out, it is normal. the LIFAN service station for check and the lamp does not illuminate or continues to (h) SRS indicator Used to warning for overheated engine coolant, if
repair as soon as possible. illuminate for about 3s. the lamp flickers or keeps illuminating during 2. Open any of the doors.
●The lamp illuminates in driving. When the ignition key is turned to “II” driving, it is necessary to stop the car at a safe The door open indicator will illuminate.
The oil level should be within the top and bottom
(f) ABS indicator position, SRS indicator will illuminate for place and stop the engine immediately.
limitation of oil dip rod.
When the ignition key is turned to “II” position, During the operation, the fact that the warning about 6 times, which indicates that the air 3. Close doors.
the “ABS” fault indicator will illuminate for lamp illuminates for a short while doesn't mean bag and front seat belt pretensioner work Check the quantity of engine coolant and refill; The door open indicator is out.
about 3s. After that, if the system goes wrong, any problem. normally. meanwhile, check the working state of electronic fan.
the lamp will continue to illuminate. 4. Turn the ignition key to “II”, but not start the
Warning The warning lamp system is used to monitor (j) Low fuel level indicator engine.
Note When the “ABS” fault indicator illuminates (the the air bag ECU, seat belt pretensioner Please fill fuel as soon as possible. All warning lamps except the door open
warning lamp of brake system is out), the ABS While the warning lamp of brake assembly, air charging device, warning lamp, indicator will illuminate. After about 3s, the
No driving when the warning lamp system doesn't work, but the brake system system is illuminating and the “ABS” connection and power supply. (k)Indicator for electronic injection fault of “ABS” fault indicator is out. And after
illuminates,even if just a short distance,or works normally. fault indicator illuminates as well, stop engine illuminating for 6 times, the SRS fault
else the engine will be damaged. the car at a safe place immediately and If any of the following circumstances occurs, It illuminates when the electronic injection system of indicator is out.
When the “ABS” fault indicator illuminates (the contact the LIFAN service station. it means the part monitored by the indicator is engine is at fault.
warning lamp of brake system is out), the wheel Under such circumstance, when a braking at fault or closed down. It is necessary to When any of the indicators for maintenance
may be blocked since the ABS system doesn't is made, the ABS doesn’t serve, moreover, contact the LIFAN service station for check. When it illuminates, it is necessary to contact doesn’t work as per the procedures above, it
work when an emergency brake is made or the LIFAN service station for check and is necessary to Vehicle brought to the LIFAN
the car is extremely unstable as well.
braking on slippery road. ● When the ignition key is turned to the position repair as soon as possible. service station for check.
of “II”, this light does not keep twinkling for six
58 59
Section 1-6
320
Ignition switch
speedometer may move, which doesn’t mean
Operation of instrument and controller something goes wrong.
1 3 5
5
3
PUSH Once the ignition key is turned to “I”, auxiliary equipments 1
R
Ignition switch, transmission and parking brake Ⅰ Ⅱ like radio are powered on, but the engine isn’t.
2
4
2 4 R
B
Ⅲ
Ignition switch……………………………………………………………………61
“B”-The engine is not connected to the power and the
Manual transmission……………………………………………………………62 steering wheel is locked. The key can only be inserted or
Parking brake……………………………………………………………………63 drawn out at this position.
It is necessary to insert the key completely to turn the key

Once the ignition key is turned to “III”, the engine is from “I” to “B”. The gear of manual transmission is shown at the
ready to be started. The key returns to “II” position shift button head, refer to the fig. above.
upon releasing automatically. When the engine starts, it seems that the key is blocked at The gear of manual transmission is shown at knob of the
For guidance of starting, refer to Section 3. “B” position. To release it, at first it is necessary to make gear shift lever.
sure that the key is inserted completely, then turn the key
When the ignition switch is turned to “III” position, the while joggling the steering wheel. Select proper gear position
pointer of tachometer, fuel gauge or thermometer for Select proper gear position according to the speed of
engine coolant returning to zero doesn’t mean car and the rotation speed of engine, which will save
Note
anything goes wrong with the car. fuel, protect the engine and lengthen its service life.
When the engine is not running, the key is It will result in engine lug down if shifting to higher gear
Once the ignition key is turned to “II”, the engine is ready to not allowed to be at “II” position, to avoid too quickly or to lower gear too slowly, possibly bring
start and all auxiliary equipments are powered on. that the battery discharges and igniter is about knock as well. Frequently operating the engine at
damaged. the maximum rotation speed at all gears will result in
When the ignition switch is turned to “II”, the pointer of over abrasion of engine and fuel waste.
60 61
Economical driving
320 Parking brake
320
Warning parking brake (position 3). Note
The fuel consumption has close relationship with ●Avoid the full throttle acceleration and try to drive
Don’t shift the gear to the position of reverse personal driving style; application of the following steadily. Unnecessary acceleration or brake will ● Before driving, it is necessary to confirm
For indicating that the parking brake is set, the
in driving so as to prevent the gear box from instructions will decrease the fuel consumption of increase the fuel consumption. if the parking brake is completely released
your car. 1 warning lamp of brake system on the instrument
damage. It is necessary to confirm the vehicle illuminates till the parking brake is released. and the indicator of the parking brake
comes to a full stop before practicing ●Stop the engine in the traffic jam. system goes out.
transmission reverse speed shift. ● It is suggested to choose the high gear low 2
Please do not step your foot on the clutch accelerator but not the low gear long distance ●Regularly check the tyre’s pressure. ●If the parking brake does not be completely
pedal; or the clutch will be worn out or driving in normal driving. Under the same speed, released in driving, the brake will be
damaged. the fuel consumption in gear 2 and gear 3 is two 3 overheated, which will result in poor braking
times and 1.5 times as the gear 4 respectively. or braking failure.
●Prevent the engine from high speed operation.

Warning
When stop the car, pull up the parking brake, to
When shifting during driving on slippery ●Don’t shift to low gear unless the engine cannot
avoid car slip.
road, be careful. A sudden gear shift will operate steadily.
result in slip or spin of the car.
Setting: pull the handle of parking brake. For better
●Avoid continuous driving at the highest speed. It
retentiveness, first keep stepping on the brake pedal
is suggested to drive at the speed of 60-80km/h.
till the parking brake is pulled up.
Note
Keep vehicle’s speed within the legal limits. Release: Pull up the parking brake handle
(position 1) gently, press the lock release
button (position 2) and then release the
62 63
Section 1-7
320
CDMD-X functions
Operation of instrument and controller 1. Power switch/Volume control knob
1 2 3 4 5 2. Dispaly screen
Audio system 3.Button for clock, band equalizer

4. Mode changebutton
Utilization of CDMD-X……………………………………………………………65
5. Band selection button
6. Manual scanning button
MODE BAND
7. System resetting button
DISP A.PS 8. Button for automatic scanning/storage
R ES E T MP3 DE CO DI NG 9. Pre-setting button 1, pause
1 2 IN T 3 RP T 4 R DM 5 D 6 D 10. Pre-setting button 2, skimming play
11. Pre-setting button 3, repeating play
12. Pre-setting button 4, random play
13. Pre-settingbutton 5, (Select upward the
7 10 12 14 document file when playing MP3)

14. Pre-setting button 6, (Select downward
6 9 11 13 15 8 the document file when playing MP3)
15. USB/SD card/audio-in cover
64 65
Instruction for plate function
320 Instruction for reception of a radio
320
Playing USB/SD card Browse play Hunting for designated position Radio station storage 3. In the state of receiving the FM, keeping knob clockwise or counterclockwise can adjust the
pressing down the key of “A.PS”, the radio will sound volume between 0 and 63.
1. Press the power switch on the plate and the When USB/SD card is playing, pressing “21NT” starts When USB/SD card is playing, keep pressing “ ” According to the order you select, 18 FM radio stations automatically scan and store 18 radio stations in 2. Bass pattern (BAS)
mainframe will be turned on. the browse with every song played 10 seconds of its or “ ” can speed or fast reverse. When locating the (six FM1, six FM2 and six FM3) and 12 AM radio this section of band wave with the strongest
beginning; pressing this key again will resume the position needed, press “ ” again and the music will stations (six AM1 and six AM2) can be stored at most. signal. After storing, the stations stored will be In the pattern of BAS, turning the volume control knob
2. Insert the U Disk/SD card into the USB/SD card normal mode and continue playing the current song. continue playing from the current position. browsed according to their order. Repeating the clockwise or counterclockwise can adjust the bass
interface, the display will show “READ” and start 1. In the state of receiving the radio, repeatedly operation mentioned above in the state of receiving volume between -14 and +14 at random.
searching, and then it will play automatically. Repeating play Choosing document file to be read press the key of “BAND” on the plate to choose the AM can store 12 radio stations in this section of
the wave band. The initial state of receiving the band wave with the strongest signal. 3. Treble pattern (TRE)
3. The following will be displayed during playing: When USB/SD card is playing, pressing the key of When playing USB/SD card, shortly pressing the radio is FM1. Every time you press the key, the In the pattern of TRE, turning the volume control knob
“3RPT” will repeat the current song and pressing pre-setting key 5 and 6 can carry out the document band wave will be changed as follows: Receiving the radio station stored clockwise or counterclockwise can adjust the treble
Track Time passed this key again will cancel this function. file selection directly, and the radio will play the FM 1 FM 2 FM 3 AM 1 AM 2 volume between -14 and +14 at random.
music in that document file from the first song on 1. Choose the band wave through the key of “BAND”
4. When USB/SD card is playing, pressing“ ” Random play according to the order. and press the number keys to confirm the station stored. 4. Balance pattern (BAL)
will pause and if pressing this key again, the play 2. In the state of receiving the radio, keeping In the pattern of BAL, turning the volume control knob
will be resumed. When USB/SD card is playing, pressing the key of pressing the key of “ ” or “ ” on the plate will 2. In the state of receiving a radio, shortly pressing the key clockwise or counterclockwise can adjust the volume of
“4RDM” will enter the mode of random play and automatically hunt for the next or the last clear radio of “A.PS” and the radio will skim the radio stations stored the left and right track between L15 and R15 at random.
5. When USB/SD card is playing, drawing out the U pressing this key again will cancel this function and station. Pressing on the “ ” or “ ” on the plate for a in this section of the band wave. Pressing the number
Disk/SD card will withdraw from playing and enter the mode of play according to the order. short time will manually hunt for the next or the last key marked the station can receive the radio station. 5. FAD pattern (FAD)
entering the radio. clear radio station. After receiving the signal, keep In the pattern of FAD, turning the volume control knob
Hunting for designated songs pressing down any number key for two seconds and Sound volume adjustment clockwise or counterclockwise can adjust the volume
this station will be stored on this number key. In case of the front and rear track between L15 and R15 at
When USB/SD card is playing, shortly pressing “ ” this number has been occupied by other station, the 1. Sound volume pattern (VOL) random.
and choose the next song while “ ”, the last song. formation station will be replaced. In the pattern of VOL, turning the volume control
66 67
Other functions
320
Section 1-8
Clock setting (DISP) Note Radio, USB/SB card, audio in switch
1. When active, repeatedly and shortly press the When the radio is in normal operation, if you
After the completion of clock adjustment, it
keep pressing the key of “MODE”, you can
key of “DISP” and the radio will display the clock is unnecessary to press any key and the
normal pattern will be resumed after 5 switch patterns of radio, USB/SD card and
display and sound pattern selection according to the
seconds and the clock setting will be the audio play. In case of USB/SD card not
following order: inserted, continuously press “ MODE” and A/C system
stored.
BAS (Bass) TRE (Treble) switch between radio reception and band
DISP (Clock)
only; in case of both USB and SD card
Manual A/C system
inserted, continuously press “MODE”, and
VOL
(Sound volume)
FAD
(Front and rear tra ck balance)
BAL
(Left and rig ht tra ck balance) the radio will switch according to this state:
Control plate………………………………………………………………………70
The normal pattern will be resumed if the Air vent mode setting……………………………………………………………72
key is not pressed for 5 seconds. Radio USB play SD card play Audio in Operating essentials……………………………………………………………72
Vent………………………………………………………………………………74
2. In the pattern of clock display, keeping
If only one device of the USB and SD card is
pressing the key of “DISP” can enter the
inserted, repeatedly press the key of “MODE”
pattern of clock adjustment. When the clock and the radio will switch patterns according to
is flashing, pressing the key of “ ” and “ ” orders as follows:
to adjust the clock; press the key of “DISP” Radio USB play/SD card play Audio in
again and when the minute clock is flashing,
press the keys of “ ” and “ ” to adjust the
minute. After the completion of setting,
press the key of “DISP” again to end the
clock adjustment.
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Manual A/C control plate
320
Recirculation control knob
1. “A/C” switch Fan speed knob Turn the knob to select blow direction
6 5 4 2. Recirculation control knob Turn the knob to adjust the blower speed;: 1. Panel: the air flow blows to the face of
clockwise for increase, counterclockwise for passengers through the central vent at dashboard
3. Defroster switch of rear decrease.
and the side vent.
windshield Temperature control knob
2. Panel/Floor: the air flow blows to both the face and
4. Temperature control knob Turn the knob to adjust the temperature: clockwise
feet of passengers through the central vent at
dashboard, side vent and down vent.
for increase, counterclockwise for decrease. Press keys to select air source
5. Fan speed knob
3. Floor: the air flow blows to the feet of passengers
6. Mode selector knob Mode selector knob through down vent. Press the button and the indicator will be
illuminated to recycle the air in the car. Press
4. Defroster/Floor: the air flow blows to the feet of it again, and the indicator willoff to take in the
passengers and the windshield through the down vent air outside of the car.
and defrost vent.
1 2 3 4 5 “A/C” Switch
Apply when the Recirculation control knob is at To start the A/C system, turn on the fan speed
outer circle position. knob, then press the “A/C” switch, indicator
1 2 3 illuminating. To shut down the A/C system,
5. Defrost and Demist: the air flow blows to the press the “A/C” switch again and reset the fan
windshield through the defrost vent. speed knob to zero.
Apply when the Recirculation control knob is at
outer circle position.
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Air vent mode setting
320
Operating essentials Heating Cooling Demist
In order to gain the perfect effect, please set In order to gain the perfect effect, please set Inside of windshield
● To quickly cool down the car which has parked under hot the controller at: the controller at: In order to gain the perfect effect, please set the
controller at:
sunshine, drive it for several minutes with window open. Air volume adjustment-air volume switch turned on Air volume adjustment-air volume switch turned on
● In wet weather, don’t let cold air blow to the windshield, since Air volume adjustment-air volume switch turned on
Temperature-toward warm zone (red zone) Temperature-towards cold zone (blue zone)
Temperature-towards warm zone (red zone) to raise
the temperature difference inside and outside of it will help mist Inlet-outer circle (air outside) Inlet-outer circle (air outside)
the temperature Towards cold zone (blue zone) to
growing. Air flow-down vent Air flow-top vents decrease the temperature
● The lower part of front seats should be kept as open space A/C-shut downt A/C-start up Inlet-outer circle (air outside)
Air flow- defrost, demist
to ensure full air circulation in the car.
● For a quick temperature increase, turn on the ● For a quick temperature decrease, turn the A/C-start up
● Make sure that the inlet grille in front of the windshield is not inner circle for several minutes. To avoid mist Recirculation control knob at inner circle for several
blocked by things like leaves or snow. Defrosting
growing on windows, after the temperature rises minutes.
● Close all windows when driving the car on the road with to certain degree, turn on the outer circle. Outside of windshield
Venting
much dust. If after doing this, the dust still goes into the car, it is In order to gain the perfect effect, please set the In order to gain the perfect effect, please set
● During defrost or demist of windshield, select controller at: the controller at:
recommended to temporarily set the Recirculation control defrost, demist and down vent for temperature
Air volume adjustment-air volume switch turned on
knob at inner circle and set the rotation speed selector of increase in the car.
Air volume adjustment-air volume switch turned on Temperature-towards warm zone (red zone)
blower at any position except “zero”.
Temperature-towards cold zone (blue zone) Inlet-outer circle (air outside)
● In cold weather, it is necessary to set a high rotation speed
Inlet-outer circle (air outside) Air flow-defrost, demist
of blower for one minute to clean the snow or moisture in the air
Air flow-top vents A/C-shut down
inlet passage, thus to reduce the mist growing on windows.
A/C-shut down
72 73
Vent
320
Section 1-9
Other equipments
Cigarette lighter and ashtray……………………………………………………76
Glove box…………………………………………………………………………76
Cup holder…………………………………………………………………………77
The passenger may adjust the mechanism

of the vent to change the air flow direction.
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320
Cigarette lighter and ashtray Glove box Cup holder
Cigarette lighter
Press lightly to use the cigarette lighter, which will
then spring out automatically to be at service.
If the engine is not running, the key should be at “I”
position.
It is strictly prohibited to press the cigarette lighter for
long.
When changing for another lighter, use the kind
designated by LIFAN.
Ashtray
Rear ashtray To use the ashtray, pull it out.

After enjoying a cigarette, it is necessary to crash out Turn the knob and open the glove box. It is used to firmly hold a cup or a beverage can.
the stub in the ashtray completely, for avoiding a fire.
Make sure that the stub is crashed out before Warning
pushing the tray back.
To decrease the accidents in driving or
possibility of injury caused by
Warning emergency brake, close the glove box
Completely close the ashtray after use, to reduce after utilization.
the possibility of personal injury due to accidents
or emergency brake during driving.
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Chapter 2
Run-in time No overloading: The first maintenance
LF320 enjoys an excellent performance. Make sure that the loading weight during the run- The first maintenance during run-in time
Lf320 Driving Guide However, this performance will reach the best in time will not reach the 80% of the maximum should be implemented after the first
state only after a proper run-in time and the first load; otherwise, damage will be caused to those mileage of3000km, to ensure a good using
Run-in time………………………………………………………………………79 maintenance. The effect for this run-in time components which have not been run in well. state of the vehicle. This maintenance is
mainly relies on the driving way within the first available at the LIFAN service station.
Fuel………………………………………………………………………………80 2000km.
No driving for a long distance:
Three-way catalytic converter…………………………………………………80 No high-speed driving: No driving for a long distance during run-in time; Note
otherwise, it will extend the continuous working
Engine exhaust warning……………………………………………………… 81 No driving at full speed within the initial mileage hour of the engine and cause damage to the The first maintenance should be
Oil consumption…………………………………………………………………82 of 2000km. engine parts.
carried out at the LIFAN service station
Brake system……………………………………………………………………83 Maximum driving speed for all gears during run- Avoid emergency brake: to ensure a good maintenance quality
in time: and the best performance of your
Brake pads over-wear alarm……………………………………………………85 Reduce the emergency brake times as possible
vehicle.
Gear Speed (km/h) as you can; otherwise the brake system will be
Notes of luggage loading………………………………………………………86 Gear 1 25 impacted, and the engine will suffer from a bigger
impact load from the chassis. Do not carry out
Suspension and chassis……………………………………………………… 86 Gear 2 40
emergency brake within the initial mileage of
Gear 3 60 300km except for necessary situations.
Gear 4 90
No trailering the vehicle within the first
Gear 5 100 2000km:
The maximum rotation speed allowed for An incorrect trailering may cause damage to the
the engine within the initial mileage of vehicle.
2000km is 4000r/min.
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320
Fuel Three-way catalytic converter Engine Exhaust Warning
The correct selection of fuel is the base for check, in case of a knock or regular knocking in Warning
Warning Warning
the full performance of the engine. a good road condition at a stable speed under
the condition of using the recommended fuel. Lots of incompletely burnt gas entering the three- pushing. ● Avoid inhaling the exhaust gas from the
way catalytic converter will cause the converter to ● Do not close the ignition switch during engine.
The damage to the engine due to the improper ●Always check the exhaust system and make
be over-heated and even a fire. Please abide by driving.
fuel will not be included in the guarantee scope the following precaution measures to prevent any sure there is no leakage or looseness in the
● Maintain a good operation state of the exhaust system. Immediately check the vehicle
of LF320. danger:
engine. The abnormal function in the electrical in case of a collision during driving or any
system, ignition system or fuel system of the abnormal exhaust sound.
Fuel type ●Only unleaded gasoline can be used. engine will cause an abnormally high ● Do not operate the engine in a garage or a
close place to avoid the danger due to an
●When the engine is working, don’t check the temperature in the three-way catalytic
unsmooth exhaust of the engine.
Warning engine by cutting off the cylinder supply and converter.
Unleaded gasoline In case of engine knock. ●Do not park the vehicle for a long time in case
The three-way catalytic converter is an emission misfiring. ● Immediately check the vehicle, in case of a of a running engine. If necessary, please park it
Forbid using the leaded gasoline. The
control device installed in the emission system ●Do not drive the vehicle with an extremely hard start or frequent running stop of the at an open place to let the fresh air flow into the
utilization of the leaded gasoline will lead
Please contact the LIFAN service station for with an aim to reduce the pollutants in the low oil level; the operation without sufficient oil engine. vehicle.
to inefficiency of the waste gas cleaning
exhaust. will lead to a misfire of the engine and increase ●Pleasecarryoutaregularcheckandmaintenance ● The luggage boot cover should be closed
device and the venting pollution control during driving. An open or unclosed luggage
device as well as increase the the over-load of the three-way catalytic forthevehicleaccordingtothemaintenancescheme
Warning boot will cause a flow of exhaust gas into the
maintenance cost. converter. of LIFAN so as to guarantee the normal operation of vehicle.
When the engine runs, the high- ● Do not run the engine at a high or low idle the three-way catalytic converter and the entire ● Please make sure that there is no snow,
temperature gas will be exhausted. speed for a long time. emissioncontroldevice. leaves or other barriers in the inlet grille, to
Therefore, any person and flammable guarantee a normal ventilation system of the
●Avoid running the engine at over-speed.
vehicle.
materials should be kept away from the ● No starting the vehicle by trailering or ●In case of an exhaust gas smell in the vehicle,
exhaust pipe. please immediately check the cause and correct
it.
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320 Brake System
320
Oil Consumption
Oil function The oil consumption will increase with a high- Warning It is a two-circuit brake system. In case that Note This system is used to prevent the wheel
The oil mainly works for lubricating and cooling the speed driving, frequent acceleration or one brake system loses effect, the other from being locked during braking on a wet
inside of the engine to keep a normal working state. deceleration. If a regular check at the oil level can not be one will still work. Meanwhile, it is harder ● In case of a misfire of the engine, do not and slippery road. It is helpful for ensuring
than usual to step down the brake pedal and
achieved, a severe trouble will be caused step on the brake pedal repeatedly, because the stability and steering function of the
the brake distance will also increase. vehicle under the above-stated situation.
Oil consumption More oil will be consumed due to the piston, piston to the engine due to a relatively low oil every stepping will consume parts of
The engine will consume some oil during a normal ring and cylinder wall of a new engine, all of which level. Note vacuum pressure. Effective ways for stepping on ABS brake pedal:
operation. In a normal case, the engine consumes have not been run in. ● The brake will still be effective even if the When the anti-lock system operates, you can feel
oil due to the following causes: Do not drive the vehicle for a long distance the impulsive motion of the brake pedal and also
vacuum power is entirely lost. However, the
Percentage of oil and fuel: ≤0.3% in case of only a brake circuit working. hear a noise. Under this situation, you can step
force to step on the brake pedal will be much
● Lubricating the piston, piston ring and cylinder: Please immediately repair the ineffective down the brake pedal with bigger force than usual,
When the piston moves down in the cylinder, it will bigger than usual and the brake distance will
Importance for checking the oil level brake system. and then the anti-lock brake system will work. In
leave a layer of oil film. When the vehicle decelerates, also increase.
Keeping the oil level at the best level is one of the case of an emergency brake, do not step on the
the high negative pressure will absorb such oil into key points for the normal maintenance for a brake repeatedly, because that will increase the
the combustion chamber. Like part of oil film left on Vacuum booster If the braking device is immersed in water brake distance.
vehicle, which will not weaken the function of the
the cylinder wall, this oil will be combusted by the oil. Therefore, it is very important to check the oil It is used to assist the braking by the inlet Seeper, heavy rain or cleaning, water film will be When the engine starts or after the vehicle starts, you
high-temperature combustion gas. level regularly. You are recommended to check the negative pressure of engine. In case the formed on the brake drum or brake disc will affect the may hear a click sound or motor noise from the
oil level every time you fill oil. engine stops during driving, a pedal force braking effect. Therefore, if the braking device is engine compartment for several seconds
● Lubricating the intake valve stem: The oil and the bigger than usual is required to stop the immersed in water, please take extra attention to continuously. That means the anti-lock brake
inlet air will be together absorbed into the vehicle. vehicles ahead or at the back, and drive it at low speed system is under self-checking.
combustion chamber and combust with the fuel. and meanwhile lightly step down the brake for times
The high-temperature waste gas will also combust to dry the brake pads until the brake effect resumes to When the anti-lock brake system works, the
the oil used for lubricating the exhaust valve stem. a normal state. following situation may occur. They do not
represent faults in the system.
Anti-lock brake system (with ABS
The consumption of oil is related with its
indicator-optional) ● Hearing the operation sound of the anti-
viscosity, quality and the vehicle use state. lock brake system and feeling the impulsive
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320
Brake Pads Over-wear Alarm
motion of the brake pedal together with the lock brake system will not work, but the Warning
control to the vehicle if the non-skid
vibration of the vehicle body and steering
performance of the tire exceeds the brake system will still work normally.
wheel. The motor noise from the engine In case of an illuminating warning
compartment will be heard even if the vehicle admissible ability or in case of a wheel spin.
lamp of brake system together with
has been parked. The anti-lock brake system is not used to When ABS indicator illuminates, the anti- illuminating ABS indicator, please
shorten the brake distance. Compared with lock brake system will not work. Therefore, park the vehicle at a safe place and
● The brake pedal may move forward a little at the
end of the operation of the anti-lock brake system. vehicles without anti-lock brake system, a the wheels may be locked in case of an contact LIFAN service station.
longer brake distance may be needed under svs emergency brake or braking on slippery
In this case, the anti-lock brake system
the following situations: roads. will not be effective and the vehicle will
● Driving on a bumpy road and road covered also become extremely unstable during
Note withsmallstonesorsnow. Any of the following cases indicates a faulty braking.
component monitored by the warning lamp system.
Do not overrate the anti-lock brake system: It ● Vehicleswithtirechains.
You must immediately contact the special service
is significant to abide by all notes and keep
● Driving on the steps at the junction of ABS indicator indicator station of LIFAN for check. A disc brake has an in-built over-wear alarm
proper vehicle speed and vehicle spacing, Drum parking brake
roads. which will produce warning sound when the
although this system is helpful for
Install tires with specified specifications on If the ignition key is turned to the position “II”, the light ● In case that the ignition key is turned to the position brake pads are overworn and need to be
controlling the vehicle; because, even if it The vehicle is equipped with a drum parking
performs, the effect for the stability of all wheels: The anti-lock brake system uses will illuminate. If the anti-lock brake system works replaced.
“ON”, the light will not illuminate or illuminate brake. This brake system should be checked
vehicle and the operation of steering wheel the speed sensor to measure the vehicle normally, it will go out after several seconds. Then, it continuously. In case of scream or friction noise during
and adjusted regularly.
is limited. speed to get the rotation speed of each will illuminate again in case of any trouble. driving, please immediately drive to the
wheel. Other undesignated tires can not closest special service station of LIFAN for
When driving in rainy days, the anti-lock ● It will illuminate during driving.
measure the correct rotation speed and will When ABS indicator illuminates, the anti- check or replacing the brake pads. No driving
brake system will be unable to maintain a extend the brake distance. A short illumination of the warning lamp indicates no
the vehicle continuously in case of alarm
trouble.
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Chapter 3
sound. Suspension and Chassis
Notes for Luggage Loading Warning
Starting and Driving
When loading luggage or goods, please abide by Do not refit the suspension or chassis Before starting the engine… … … … … … … … … … … … … … … … … …88
the following instructions: randomly, because that will change the
operation performance and then cause
Engine starting ways… … … … … … … … … … … … … … … … … … … …88
● Put the luggage or goods into the luggage boot
the vehicle to lose control. Safety-check before driving… … … … … … … … … … … … … … … … …89
as possible as you can and make sure that all
objects have been fixed tightly. Driving guidance under different situations… … … … … … … … … … …90
● Keep the balance of the vehicle and put the Driving tips in winter… … … … … … … … … … … … … … … … … … … …91
weight forward as possible as you can to achieve How to save fuel and extend the service life of the vehicle… … … …92
balance.
● Do not load unnecessary heavy objects to save

fuel.
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320
Before Starting the Engine Engine Starting Ways Safety-check before Driving
1. Check the situation around the vehicle (a) Before starting (b) Starting the engine You’d better carry out a safety-check before Headlamp, brake lamp, position lamp,
before entering the vehicle. driving the vehicle. A check for minutes will steering indicator lamp and other Battery and cable: Check if there is any
2. Adjust the position of the seat, the angle 1. Check the parking brake. Please make sure that all steps in “(a) be beneficial for your safe and enjoyable illumination all work. Check the aiming of corrosion, looseness or crack at the
the Headlamp. harness connector and check if the cable
of seat backrest, the height of headrest and 2. Turn off all lights and accessory electrical Before starting” have been processed, driving.
and connection is good.
the angle of the steering wheel. equipments. before starting the engine. The inner vehicle
3. Adjust the rearview mirrors inside and 3. Set the shift lever at neutral position.
Note Harness: Check if there is damage or
Spare tire, jack and wrench for wheel looseness to the harness.
outside the vehicle. 4. Release the anti-theft system. Normal starting
In case of a check in a closed garage, nuts: Check the pressure of the spare tires
4. Tighten the seat belt. Turn the key to “Ⅲ ” and start the engine. and make sure there is a jack and wrench Fuel pipe: Check if there is leakage and
make sure that the garage is well
Release the key after the engine starts. for wheel nuts. looseness at the pipeline joint.
If you have set the vehicle anti-theft system, ventilated. The waste gas exhausted
from the engine is harmful. Seat belt: Check if the buckle can be tightly Oil level: Park the vehicle on flat ground
you must cancel this system before starting In case of a misfire of the engine…
fixed and make sure there is no wear nor and check if the oil level is correct.
the engine; otherwise the engine can not be Carry out another starting according to the
scratch on the belt. After the engine starts
started. correct starting process. Check before Starting the Engine
Instrument and controller: Specially make Exhaust system: Check if there is gas
If the engine can not start… The outer vehicle sure that indicator, instrument illumination leakage. In case of a leakage, immediately
Refer to “If the vehicle can not start” in Tire: Check the tire pressure with a tire and defroster work normally. repair it
Chapter 4. pressure gauge and check carefully if there Brake: Make sure that there is enough free
is cut, damage or excessive wear. During driving
clearance for the pedal and ensure a normal
Wheel nuts: Make sure no looseness or braking. Instrument: Make sure that indicators and
loss of nuts. gauges of all kinds in the instrument cluster
The inside of the engine compartment work normally.
Spare fuse: Make sure there are fuses of all
Leakage: Check if there is leakage of oil or specifications for rating carrying capacity in
liquid under the vehicle after the vehicle Brake: Find a safe place and make sure
the fuse box. that the vehicle does not pull to one side
stops for a while. (It is normal in case of
drips from A/C in operation.) Coolant level: Make sure that the coolant when braking.
level is correc Pay attention to the initial stage and check
Illumination: Make sure that the
carefully if there is abnormal noise.
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Driving Guidance under Different Situations Driving tips in winter
1.Stopping the vehicle ●Drive slowly against the wind. It is convenient Note Make sure that the coolant has the right station for assistance. Avoid ice and snow accumulated under
for controlling vehicle. function of freeze protection. the mudguard
The vehicle should not be stopped at once Prevent the door lock from being frozen
when the engine is working, especially at a high ●Drive slowly on the ashlar at the side of street ● Before driving, make sure that the The ice and snow accumulated under the
parking brake has been fully released Only coolant designated by LIFAN can be
rotation speed with high load. It should be and keep the correct angle as possible as you used. Fill the coolant with proper type Spray the deicing agent or glycerin into the mudguard will cause difficulty in steering.
stopped after 3-5 minutes low-speed run. can. Avoid driving on high and sharp-edged and the parking brake indicator has door lockhole to avoid freezing. When driving in cold winter, please always
according to the ambient temperature into
objects or other road barriers; otherwise the tire gone out. check if there is ice and snow under the
the cooling system.
2. Rainy day or wading through water will be damaged abnormally. ●The engine should work at idle speed An improper coolant will damage the Use the washer fluid with antifreeze. mudguard.
for minutes for warm-up. cooling system.
Make sure that the air cleaner has been sealed ● Decelerate when driving on a bumpy road; This kind of product is available at LIFAN
well when running on the road with seeper in
● In case of a long-distance driving Yo u are recommended to take some
otherwise the tire or wheel will be seriously down on a steep hill, please decelerate Note service station. necessary instruments according to different
rainy days or wading through water in normal damaged. driving conditions, such as tire chain, window
the vehicle and shift to a low-speed Warning
times; otherwise, the water may enter the No use of clean water. scraper, a bag of sand or salt, signal flash
engine cylinder and cause damage to the ●If the vehicle is parked on the hillside, rotate gear. Remember that too many times of
the front wheels to make them contact the stepping on the brake will cause over- device, small shovel and connecting cables.
components such as engine connecting rod. Inspect the battery and cable Do not use the antifreeze or other
roadside and use the parking brake to make heating and result in abnormal working
substitute as washer fluid; otherwise the
3. Warming the engine in winter them not slip. If necessary, place a crosstie of the brake. A cold weather will decrease the charge
under the wheels. ● Be careful in case of accelerating, paint of the vehicle will be damaged.
In winter with relatively low temperature, the capacity of the battery. Therefore, the battery
shifting to a high-speed gear or low- should keep a sufficient charge capacity to be
viscosity of oil will increase and its lubrication ● The brake will become damp in case of
speed gear or braking on a slippery helpful for starting in winter. And the
effect is worse than that in summer. Therefore, cleaning or passing by water. Check if the brake
road surface. An abrupt acceleration or inspection of charge level can be carried out
the engine should not work under large load at is normal under a safe condition. If the brake is In winter the parking brake may be frosted.
abnormal due to the dampness, you can lightly braking may cause a skid or spin. at LIFAN service station.
high speed immediately after it is started. It Therefore do not use it in such a case.
should be warmed for minutes at idle speed to step on the brake pedal while driving carefully ● Do not continue to drive the vehicle
normally when the brake is damp. In Make sure that the oil viscosity is suitable
increase the temperature of the oil and coolant. under a condition of using the parking brake. If for driving in winter. When parking in winter, set the shift knob at
Only after the engine is fully lubricated, can you it still can not work normally, please stop the case of a damp brake, a relatively long the first gear or (reverse gear) and block the
drive the vehicle. In case of driving when the vehicle and contact LIFAN service station. brake distance is needed and the In winter, use of summer oil will cause rear wheels. Do not use the parking brake;
engine is not well lubricated, the components of vehicle may be pulled to one side when difficulty in starting the engine. In case of otherwise the parking brake device will be
the engine may suffer from over wear or even braking. Likewise, the parking brake uncertainty about the oil type, please turn to frosted by seeper or snow, and then cause a
be locked. also can not stop the vehicle urgently. the sales service store or LIFAN service hard release to the parking brake.
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How to save fuel and extend the service life of the vehicle Chapter 4
It is simple and easy to save fuel. It is also the engine: Select a proper gear according ●The chassis should be kept clean without
helpful for extending the service life of a to the road conditions. slurry: That will not only ease the load of
vehicle. The following are tips for saving
● Avoid continuous acceleration and
vehicle body but also prevent corrosion. Emergency Trouble Treatment
fuel and repair expense:
deceleration: A driving with frequent stops ●Adjust the vehicle and maintain it under the If the vehicle can not start…………………………………………………………94
● Maintain a correct tire pressure: An will increase the oil consumption. best working state: The performance of the
insufficient tire pressure will cause wear to engine will be affected and the oil If the engine misfires during driving…………………………………………… 97
the tire and waste fuel. Refer to Section 7-2 ● Avoid unnecessary parking or braking: consumption will also be increased by the
for instruction. Keep a stable vehicle speed. Coordinate unclean air cleaner, improper valve clearance, If the vehicle is over-heated………………………………………………………97
with the traffic light to achieve minimum unclean spark plug, oil and lubricant and If the tire leaks…………………………………………………………………… 98
● No unnecessary loads on the vehicle: parking times; or keep space to avoid unadjusted brake. A regular maintenance
Excessive weight will increase the load of the emergency brake when driving on the road should be carried out for a longer service life If the vehicle gets stuck…………………………………………………………103
engine and cause an increase of oil consumption. without traffic light, which will also reduce of all components and a reduction in operation
the wear of brake. expense. In case of frequent driving under If the vehicle needs trailering……………………………………………………103
●Avoid warm-up idling for a long time: Start extreme condition, a more frequent
driving the vehicle once the engine operates ●Avoid passing by area with busy traffic or maintenance should be implemented.
stably, but it must be stable. Be careful, it traffic congestion as possible as you can.
will take a longer time for the warm-up of the Warning
engine in winter. ● Keep proper vehicle speed on the
expressway: The higher the vehicle speed
●Slow and stable acceleration: Avoid rapid is, the more oil will be consumed. No stopping the engine when driving
starting. You should drive at a high-speed down the slope. Once the engine is
gear as quickly as possible. ● Maintain a correct alignment of the front stopped, the power steering and
wheels: Avoid colliding with the road edge
●Avoid engine idling for a long time: In case vacuum booster will not fully display
and drive slowly on bumpy road. An
of parking to wait for someone for a long time incorrect alignment of the front wheels will their performance. Likewise, emission
in a place with no busy traffic, you’d better result in a fast wear to the tires and also control device can work correctly only
stop the engine and restart it later. increase the load of the engine, namely when the engine is running.
●Avoid lug down or over-speed rotation of expand the oil consumption.
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If the vehicle can not start
(a) Simple inspection Note In that case, step down the accelerator (c) Jump-starting
pedal to the bottom and meanwhile turn the continuously on the way to hospital. Booster battery
Before these examinations, make sure if No starting the vehicle by trailering or key to “START”, and retain the accelerator The following instructions must be abode by ● The gas discharged by the battery will
you have started the engine according to pedal and the key and then release them 5 explode in case of flame or spark around.
the correct starting procedures described in
pushing. Otherwise, damage or to avoid serious personal injury as well as
During the jump-starting, you must use
a
seconds later; and then restart the engine damage to vehicle or electrical fittings due
“Engine Starting Ways” in Chapter 3, and collision may be caused to the vehicle standard jumper cable and must not smoke
when the accelerator pedal is under a free to battery explosion, sulphuric acid Discharged battery
check if the fuel is sufficient. At the same when the engine starts. Meanwhile, the state. or light a match.
corrosion and electrical combustion.
time, check whether another key can start three-way catalytic converter will be
the engine. If another key can start the over-heated to cause a fire. If the engine still can not start after 5- Note
engine, it is manifested that the key has second starting, release the key and restart
You are strongly recommended to seek help Positiv e terminal connector
b
from the service station of LIFAN, if you are not (“＋”)
been damaged, so please contact the the engine several minutes later. The discharged battery must be 12V. Do Positiv e terminal connector
special service station of LIFAN for check. If clear about the process. Jumper cable
not carry out the jump-starting before (“＋”)
all the keys cannot work, the engine must If the engine still can not start, an adjusting confirming the correct discharged
have faults; please contact the special If the engine rotates at a normal speed or repair is needed. You can contact LIFAN Warning battery. 2. If necessary, remove all orifice plugs of
service station of LIFAN. but can not start service station. discharged battery and booster battery. Cover
● The battery contains corrosive and toxic Jump-starting process the open battery orifice with a cloth. (This can
If the engine can not rotate or rotate too 1. Turn the ignition key to “I” or “B”, and then sulphuric fluid. Therefore, you must wear reduce explosive danger, personal injury and
restart the engine. Note burn)
slowly protective goggles during jump-starting. 1. In case that the discharged battery is
2. When the engine can not start, “engine Avoid sulphuric acid spattering on your installed in another vehicle, you must confirm
Each starting period should not exceed 3. In case that the engine of the vehicle with
1. Check if the battery connector is tightly flooding” may be caused due to restarting that the vehicles have no contact with each discharged battery does not rotate, start it and
3 to 5 seconds, otherwise the engine skin, clothes or the vehicle body.
screwed down and clean. repeatedly. other and turn down all unnecessary lights run for several minutes.
3. If the engine still can not start, a repair or ● In case of sulphuric fluid spattering on
2. If the battery connector works normally, and circuit will be over-heated. and accessory equipments. During jump-starting, lightly step on the
adjusting is needed. You may contact LIFAN your body or into eyes due to carelessness, accelerator pedal and operate the engine at a
please turn on the compartment light.
3. The battery has been used up if the light service station. immediately take off the clothes with For battery charging, corresponding battery rotation speed of 2,000 rpm (round/minute).
does not illuminate or illuminate dimly or the (b) Starting “flooded engine” sulphuric fluid and clean the affected part of battery with higher quality shall be
with clear water and then seek medical help. applied. Any other battery can cause 4. Connect the cable according to the process
vehicle can not start. in a, b and c.
If the light illuminates, but the engine can When the engine can not start, “engine If possible, use sponge or clean cloth with difficulty to jump-starting.
a. Connect the clip of the positive terminal (red)
not start, a repair or adjusting is needed. flooding” may be caused due to clean water to wash the affected part of the jumper cable to the equivalent connector
restarting repeatedly. For jump-starting is difficult, charge battery (+) of the booster battery.
Please contact LIFAN service station. for a few minutes.
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Jumper cable
the accelerator pedal and make the engine If the engine misfires during driving If the vehicle is over-heated Warning
d rotate at a speed of 2,000 rpm.
The engine may be over-heated in case of Your hands and clothes should keep a
If the Engine Misfires during Driving
6. Carefully dismantle the cable reverse to water temperature warning lamp lights up, certain distance with the fan and engine
1. Slowly decelerate the vehicle and belt in operation when the engine runs.
the installation procedure; firstly dismantle or loss of power, or a knocking sound or
carefully drive the vehicle off the road to a
the negative terminal cable and then the bang noise. Please take the following
safe place. treatment procedures… 4. Immediately stop the engine in case of a
positive terminal cable. 2. Open the emergency light. leakage of coolant. Contact the special service
c 3. Turn the ignition key to “I”, and restart 1. Drive the vehicle safely off the road, park it station of LIFAN for help.
Booster battery
7. Carefully take off the cloth on the battery the engine. 5. Check the coolant Coolant reservoir in case
and open the emergency light. Set the shift
which may be stuck to by electrolyte knob at neutral position and pull up the parking of no evident leakage. In case that the Coolant
Negative terminal connector Discharged battery
If the engine still can not start, refer to “ If brake. In case of using A/C, close it. reservoir is dry, fill it with coolant to the
(“-”)
In case that the battery discharges due to the Vehicle Can Not Start” of this section. 2. Stop the engine in case of coolant or steam standard scale during the engine runs.
unclear reasons (e.g. the light still ejecting from the radiator or Coolant reservoir. 6. Recheck the coolant level in the Coolant
b. Connect the clip of the other end of the Connection points of engine illuminates), you should contact LIFAN Note Open the engine hood after the steam fades reservoir when its temperature decreases to
positive terminal (red) of the jumper cable to Do not contact the jumper cable to any authorized service station for check. away. Keep engine working and close the normal. If necessary, refill the coolant to half of
the equivalent connector (+) of the movable components during starting the In case that the engine does not run, the ignition switch in case of no coolant or steam the tank. A serious loss of coolant indicates a
discharged battery. engine. power assisting device of the brake and ejection. leakage in the system. In that case, contact
If first starting fails steering gear will not fully work. LIFAN authorized service station for immediate
c. Connect the clip of the negative terminal Check if the clip of jumper cable is fixed Therefore, it is much difficult than usual Warning check.
(black) of the jumper cable to the equivalent 5. Start the engine in the normal way. firmly. Recharge the booster battery for a to carry out the steering and braking.
connector (-) of the discharged battery. Before starting the engine, lightly step on few minutes with the jumper cable To avoid personal injury, keep the engine Warning
d. Connect the clip of the other end of connection method. Then start engine in hood closed until there is no steam any
negative terminal (black) of the jumper normal way. more. The flowing of steam or coolant Do not dismantle the radiator cap when
cable to an unpainted metal fixed point in indicates a rather high pressure. the engine and radiator are in a high-
If the starting still fails, the battery is
the vehicle with a booster battery. temperature state.
indicated to be fully discharged. It shall be
checked by the special service station of 3. Check if there is an evident leakage in the
Connection points are shown as below: LIFAN. radiator, hose and underside of the vehicle.
However, it is normal in case of drips from A/C
in use.
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If the Tire Leaks Tools required and spare tires
1. Slowly decelerates the vehicle and drive Warning Note
it off the road to a safe place far away from
ground, pull up the parking brake tightly
traffic. Avoid parking the vehicle on the Never drive a vehicle with a flat tire, 1
central turnout track. Park the vehicle on a and turn the transmission to the neutral because even a short distance driving
solid and even ground. position. If necessary, set a baffle plate will result in a tire damaged too badly
2. Stop the engine and open the Emergency under the tire in the diagonal direction of to be repaired.
warning lamp. the replaced tire.
3. Pull up the parking brake and turn the ● Make sure that the jack has been set on
shift knob to the neutral position. 1 2
the correct jacking point. An incorrect
4. All persons on the vehicle must get off to
jacking position will cause damage to the
a safe place.
vehicle or make the vehicle drop from the
5. Please read the following instructions
carefully. jack and cause personal injury.
● Any person should not be under the
Warning vehicle supported only by a jack. 1.Take out the tools required and spare Turn the jack joint Screw off the bolts and remove the spare
Please follow the instructions below ●The vehicle can be supported by a jack tires tire, and then take off the spare tire from the
when raising the vehicle by a jack to only when replacing the tire. Removal: Turn the joint according to vehicle.
avoid severe personal injury: ● No jacking the vehicle in case of 1. Spare tires direction 1 until the jack becomes loose.
● Follow the instructions about jacking. anybody in the vehicle. If you have to repair the vehicle by yourself S t o r a g e : Tu r n t h e j o i n t a c c o r d i n g t o Put the spare tire with the outside up into
under an urgent state, you must be familiar direction 2 until the jack is fixed tightly to the storage compartment when storing the
● Do not make any part of your body
with the usage and storage place of the jack prevent the jack from being thrown forward spare tire. And then fix it, reverse to the
under the vehicle supported by a jack to ● Do not place any object on or under the
and various tools. in case of a collision or an emergent brake. above removal procedures to prevent the
avoid personal injury. jack when raising the vehicle.
tire from being thrown forward in case of an
● Do not start or run the engine when the ● Only raise the vehicle to a height at emergent brake or collision.
vehicle is supported by a jack. which the tire can be taken off and
● Park the vehicle on flat and firm replaced.
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320
Block the wheels Screw off the wheel nuts Jack alignment Lifting the vehicle Replace the wheel
2. Set a baffle plate under the tire in the 3.Screw off all wheel nuts of the flat tires. 4.Put the jack at the correct jacking point 5.Raise the vehicle by a jack to the proper height 6. Remove the wheel nuts and then Brush all the corrosives on the installation
diagonal direction of the replaced tire when according to this fig. at which the spare tire can be installed after replace the tire surface by a wire brush before installing the
using a jack, to avoid vehicle slide. When Screw off the wheel nuts before lifting the ensuring that there is no people in the vehicle. wheels. A bad contact between the metal
blocking the wheel, put the baffle plate in vehicle. Make sure that the jack is put on flat and Roll the spare tire to the installation faces of the installation surface during the
firm ground. Before lifting the vehicle, insert the jack knob into
front of the front wheel or behind the rear the jack (loose contact), and then turn it clockwise. position. Align the bolts to the wheel hole. installation will make the wheel nuts loose
Turn the wheel nuts counter-clockwise and
wheel. screw them off. To get a maximum torque, When the jack contacts the vehicle and starts Then raise the wheel until the bolt at the and cause the wheel to fall off during
put the wrench into the nut according to the rising, recheck if it is at the correct position. uppermost goes through the screw. Rotate driving.
fig. above and make the wrench knob at the tire and push it backwards until other
right. Hold the end of wrench knob and pull Warning bolts go through the screw.
it up. Be noted that the wrench should not
slip out from the nut. Do not remove the nut, Personnel should not be under the
only screw it off for one and a half turns. vehicle supported by a jack only.
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320
Reinstall the wheel nuts Lower the vehicle After replacing the wheel If the vehicle gets stuck If the vehicle needs trailering
order shown in the fig., and screw them Check the tire pressure after replacement Try to push the vehicle back and forth to
tighter each time. Repeat this process until release it from the trouble if the vehicle is
all nuts are screwed down tightly. Adjust the tire pressure to the value regulated stuck in snow, mud basin and sands. Trailering from the front
in Chapter 8. In case of an air pressure lower
than the regulated value, drive the vehicle
Warning Warning
1 slowly to the close service station for inflation
● When lowering the vehicle, please to make the air pressure reach the correct When driving a stuck vehicle, do not
make sure that all people have left to value. push the vehicle back and forth to let it
4 3 avoid any injury due to the vehicle Remember to install the valve cork, otherwise move if there is people or object near the
descending. the dust and moisture will enter the valve core vehicle, because the vehicle, when it is
2 ● Immediately use a torque wrench with and may cause a leakage. In case the valve being pushed, will suddenly move
120N•m torque to screw down the wheel cork is lost, immediately replace a new one. forwards or backwards after escaping
7. Reinstall all wheel nuts nuts after replacing the wheel. Otherwise, from the trap, which may cause an injury
Store all tools, jack and flat tires properly Trailering from the back
When reinstalling the wheel nuts (the the nuts will become loose and cause the to the people or damage to objects
wheel to fall off, and then cause a serious around.
wedge-shaped end facing inward), screw After wheel replacement, use the torque
8. Completely lower the vehicle and accident.
down the nuts to full, push the wheel inward wrench to screw down the wheel nuts to the
screw down the wheel nuts to fall off and bring severe accidents. In
to see if it can be further screwed down. torque value regulated in Chapter 8. The flat
case of oil or lubricant on the bolt or nut,
Warning Rotate the jack knob counter-clockwise to clean them out. tires should be repaired by the professional
lower the vehicle. personnel.
Do not apply oil or lubricant onto the bolt
or nut, because that may cause the nut to Only the wheel nut wrench can be used to Warning Use a platform truck
be screwed down over-tightly and even
screw down the nuts. No use of other tools
damage the bolt. The nut will become Before driving, make sure that all tools,
loose for that, which will cause the wheel or any other lever except your hands. Make
sure that the wrench has been tightly set jack and flat tires are fixed at the storage
to fall off and bring severe accidents. In place to reduce the possibility of
case of oil or lubricant on the bolt or nut, on the nuts.
personal injury in case of emergent brake
clean them out. or collision.
Screw down the nuts according to the
102 103
Urgent trailering
320
The application of proper trailering In case of a need for trailering, the LIFAN
equipments during trailering process will service station are recommended to handle Note Note
Warning
ensure no damage to the vehicle. that for you.
Special care should be taken when Only use the special towing cable or In case that the engine does not run, the
Wrong towing methods will cause damage In case that a trailer company can not be trailering a vehicle. Avoid abrupt starting chain and fasten them at the towing power assisting device of the brake and
to the vehicle. Mistakes may always occur found during an urgent trouble, you can or unstable driving operation, because pothook. steering gear will not work. Therefore, it
although most of towing personnel are fasten the towing cable or chain at the
these will cause huge pressure on the is much difficult than usual to carry out
familiar with the correct methods. urgent towing pothook and trailer the
urgent towing pothook and towing cable Before trailering, release the parking brake and the steering and braking.
Therefore, the following precautions must vehicle temporarily. Extra care must be paid
be abided by to protect the vehicle from during trailering. or chain. The pothook and towing cable turn the shift knob to the neutral position. And
damage. or chain may be broken and then cause the key should be at “I” (engine closed) or “II”
Note severe injury to people or damage to the (engine running).
Front
Precaution measures for trailering: vehicle.
● Only the specified towing pothook can
All trailering should use a safety chain
be used, otherwise the vehicle may be
system and abide by the laws of the damaged.
state/province or municipality and the local
● Do not trailer the vehicle backwards in
government. The wheels and axle case of four wheels on ground; otherwise
contacting the ground should be at a good the vehicle may be damaged.
state. In case of any damage, apply a
platform truck.
The driver must sit in the vehicle for driving
and operating the brake.
This trailering way can be used only on hard
ground at low speed for a short distance.
Meanwhile, the wheel, axles, transmission
system, steering wheel and brake must be
Back at a good state.
104 105
320 Anti-corrosive on Vehicle Body
320
Chapter 5 A correct maintenance of the vehicle can The above shows that it is very important to Check the paint and trims: In case of any
protect it from corrosion for long. keep the vehicle clean as much as possible, fragment or crack on the paint layer, please
especially the bottom of the vehicle body, and immediately go to the service station of LIFAN for
Most common causes for vehicle corrosion:
Anti-corrosive and Outer Maintenance of the Vehicle repair the damaged paint and protection layers repair to prevent corrosion. In case of fragment
as soon as possible. or crack falling off the metal surface, please go to
●The underside of vehicle is covered with salt
the service station of LIFAN for repair.
Anti-corrosive on vehicle body…………………………………………………107 and alkali, dust and moisture. Follow the rules below to prevent LF320
Vehicle cleaning and waxing……………………………………………………108 ● Protective paint cover scratched by a light from corrosion: Check the inner vehicle compartment: The
collision or stone and grit. moisture and dust covering the floor mat will
Inner cleaning……………………………………………………………………109 Always clean the vehicle: A regular cleaning cause corrosion. Please always check the place
It is essential to take an extra care in case of may keep the vehicle body clean. Please abide under the mat and make sure it is dry. Take an
living in a special region or operating the by the following rules to avoid corrosion. extra care during the transportation of chemicals,
vehicle under special environment. cleanser, fertilizer, salt and other materials which
● Clean the running part of the vehicle at least should be transported by proper containers. In
● The salt and alkali or dust with chemical once each month to avoid corrosion in case of case of any spill or leakage, please immediately
materials on the road will accelerate the driving on the road with salt and alkali in winter clean and keep it dry.
corrosion. Even in the coastal area or industrial or at coastal areas.
pollution region, there is still salinity in the air. Application of mudguard: The mudguard can
● High-pressure or steam is very effective for protect the vehicle in case of driving in salty and
●A high humidity will accelerate the corrosion, cleaning the chassis and wheel cover. It is hard alkali region or on gravel roads. It is better if the
especially in case of a temperature barely to see all the slurry and dirt in those two places. mudguard is bigger and closer to the ground.
above zero. Therefore, an extra attention must be paid. It
will cause more serious danger in case of only Park the vehicle in a fully-ventilated garage
● A certain part of the vehicle being wet or roughly moistening but not cleaning the slurry or a place with roof. Do not park it in a damp
damp for a long time will be corroded, although and chips. The drain holes of door lower brim, and airproof garage. The garage will become
other parts keep dry. doorsill plate and the vehicle frame must not be damp due to cleaning vehicle in it or the vehicle
obstructed by dust; otherwise the seeper in driving through a seeper or snow road, resulting
●A high room temperature will cause corrosion in corrosion. Although the garage is very dry,
those parts will cause corrosion;
to the vehicle components which can not get bad ventilation will also cause corrosion to a
dry fast due to the lack of correct ventilation. ●Completely clean the chassis after winter. damp vehicle.
106 107
Vehicle cleaning and waxing
320
Cleaning LF320 Note containing abrasive. Warning from the manufacturer carefully; the chrome you should turn the front wheel to make it
plating and paint surface both need contact with the edge of the road, so that the
Clean the car in normal way. Be careful not to hurt your hands when Asphaltum: Clean it by turpentine or the No using organism (petrol, kerosene, polishing and waxing too. vehicle can’t slip. Please use the parking
cleaning the underside of the floor or the cleanser labeled no harm to the paint. naphtha or strong dissolvent);
The following cases will cause the paint chassis. brake. If necessary, a sleeper should be
otherwise, poisoning or damage will be placed under the wheel.
layer to fall off or result in corrosion to the Note
vehicle body and components. Please caused.
1. Wash away the loose dirt by a water pipe,
immediately clean the vehicle and repair and wash away all the slurry on the vehicle Warning In case redoing the waxing and parking ● Cleaning the vehicle or driving through
that. bottom and depressed part of the wheel or the vehicle in a painting workroom at deep water may wet the brake. Check
Do not install the seriously damaged Waxing of LF320 high temperature, take off the plastic
the salt and alkali on the road. whether the brake is normal under a safe
●Driving in the coastal region plastic wheel trims; otherwise, the bumper; otherwise, it will be damaged
Polishing and waxing for the vehicle body is due to the high temperature. condition, if the wet brake causes braking
2. Clean the vehicle with neutral washer wheel trims will fly off the wheel and
recommended for maintaining a shining abnormally, you can use the parking brake,
● Driving on the road covered with fluid. The mixture of washer fluids should be cause an accident during driving.
antifreeze carried out according to the instructions of outlook of the vehicle. drive carefully and tread the brake lightly at
● Please drive slowly against the wind to the same time. If you can’t brake normally
the manufacturer. Dip a soft cloth with
● Stuck by coal tar, resin, ornithocopros washer fluid and wipe away the dirt by suds 3 . Wa s h a w a y t h e s u d s c o m p l e t e l y ; A waxing should be implemented for once control the vehicle easier. still, please stop the vehicle and contact the
and dead insects and clean water. Do not wipe it forcefully. otherwise, it will become speckles when it is each month or anytime when the vehicle
● Be slowly when you drive on the street service station of LIFAN for help.
dry. In case of cleaning in summer, clean surface can not be well water-resistant.
● Driving in a region with a great deal of Plastic wheel trims: The plastic wheel trims each part with clean water correctly. with stones, and if possible, keep the right
soot, coal ash, dust, scrap iron or chemical are easily damaged by organism. In case of 1. Before waxing, do wash the vehicle first angle to avoid driving on the road with
materials any organism spattering on the trim, do 4. Use a clean soft towel to dry the vehicle a n d d r y i t s b o d y, e v e n i f u s i n g t h e sharp-high objects or other obstructions; or
wipe it away by clean water and check if the body to avoid water marks. Do not wipe or compound of cleanser and car wax. the tyre will be damaged abnormally.
●Being evidently dirtied by dust and slurry trim is damaged. press the vehicle forcefully; otherwise the
paint surface will be damaged. 2. Use high-quality polish agent and car ● Please drive slowly when driving at the
Manual cleaning of LF320 Aluminum-quality wheel: Only use
neutral suds or neutral washer fluids. wax. In case that the car polishing has rough roads; or the tyre or wheel will be
Clean the vehicle after its body feels not hot seriously effloresced, use the cleaning damaged badly.
in a shady place. Plastic bumper: Take care of cleaning the polish agent separately from waxing. Follow
bumper. No wiping it with washer fluid the instructions and precaution measures ● If the vehicle is parked on the hillside,
108 109
Inner Cleaning
320
Note Seat belt A/C control plate, acoustics, dashboard, Leather trims inside the vehicle body Note
control plate and switch
Do not clean the inner floor by water or The seat belt can be cleaned by neutral The leather trims can be cleaned by neutral ● The nylon brush or synthetic fiber
make water flow into the floor when suds or lukewarm water. Clean them with a moist soft cloth. cleanser applied to woolen textiles. cloth will scratch the good texture on
cleaning the inner or outer vehicle. Water the leather surface
Use sponge or soft cloth for cleaning. Do Moisten a clean soft cloth in water or Wipe the dust by a soft cloth immersed with ● Dirty leather trim will produce
may enter the carpet (or mat) or the
check if the belt is excessively worn, lukewarm water, and then wipe away the solution with 5% neutral cleanser applied to mildew. Be extremely careful to avoid
acoustics components or other electrical
frazzled or has shear mark. dust lightly. woolen textiles. And then wipe away the oil stain and always keep the trim clean.
components on and below the carpet and ● A long-time exposure to the
residual cleanser completely by a clean
cause a malfunction, and even result in sunshine will result in surface
Note Note moist cloth.
corrosion on the vehicle. hardening or shrinkage of leather.
●The seat belt should not be cleaned by a ● No using organism (dissolvent, In case of any moistened part of the leather Therefore, park the vehicle at a shady
kerosene, alcohol, petrol etc.) or acid and or after cleaning, clean it with a clean cloth place, especially in summer
staining agent or bleaching agent which
Carpet alkali solution, which will result in fading, and lay it at a ventilated and shady place for ● Since the temperature of the inner
will weaken the strength of the belt.
drying. vehicle becomes high easily in hot
●No using the belt before it is dry. staining or peeling of the surface.
Clean the carpet with high-quality foam summer, you should avoid placing any
washer fluid. ● Confirm that the components do not Note object made of vinyl plastic, plastic or
Door and window have the above-stated materials in case material containing wax, because these
Use a dust collector to wipe away the dust of using cleanser or polish agent. ● In case that the dirt can not be wiped objects will stick to the leather under a
possibly. There is various foam washer The door and window can be cleaned by any ● Do not spatter the fluid into the inner away by the neutral cleanser, a cleanser high temperature.
fluids for use. Some is stored in an aerosol cleanser for home-use surface of the vehicle in case of using a not containing organic solvent can be ● A wrong cleaning of the leather trim
can; others are powder or fluids which new-type washer fluid, because it may applied. will result in color fading or stain.
produce foams when mixed with water. Note contain the above-stated components. ● No using organism such as naphtha,
Clean the carpet by a sponge or brush alcohol, petrol or acid and alkali solution In case of any question about cleaning,
Clean all the spattered fluid immediately
immersed with foams. Wipe it in a circle Take care not to scratch or damage the please contact with the special repair
in the above-stated way. for cleaning the leather, because these
way. heating wire or connectors when station or local sales service store of LIFAN.
materials will result in color fading.
cleaning the inside of rear window.
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320
Chapter 6 Maintenance Whether the Vehicle Needs to Be Repaired?
Maintenance Instructions It is important and necessary to carry out Where to get maintenance? Pay attention to the change in performance
a regular maintenance. and sound of the vehicle. Some important
Routine maintenance must be done in the cases as below:
Maintenance………………………………………………………………………113 LIFAN strongly advises you to carry out a repair station of LIFAN.
regular maintenance according to the ● The engine misfires, is unstable or
Whether the Vehicle Needs to Be Repaired…………………………………113 maintenance scheme, which will be helpful All the technicians in authorized repair sounds bang noise
for: station of LIFAN have received professional ● Power decreases evidently
trainings in LIFAN Automobile before ● Abnormal noise from engine
● Saving fuel practices. They know about the latest ● Oil and water leakage under the vehicle
● Extending the service life of the vehicle service information of technology (the drip from the A/C is normal)
● Enjoying the fun in driving magazine, maintenance guidance and the ● Change in exhaust sound (That may be
● Safe driving inner training scheme of agents. due to the leakage of dangerous CO. Drive
● Stable traveling with the window open and immediately
● Meeting the guarantee regulation A u t h o r i z e d r e p a i r s t a t i o n o f L I FA N check the exhaust system)
● Conform to the government regulations contributes a great deal of capital to provide ● Leakage of tire; excessive tire noise
special tools and maintenance equipments when turning; uneven tire wear
L I FA N c a r h a s b e e n d e s i g n e d f o r for all styles of LIFAN vehicles. That will be ● The vehicle pulls to one side during a
economical driving and maintenance. Many greatly helpful for accomplishing the straight-line running on flat ground.
maintenance items required before are not maintenance work and reducing the ● Abnormal noise relevant with the
needed now or not needed as much as expense. movement of suspension equipments
before. The maintenance must be carried ● Ineffective brake; stepping on the brake
out according to the maintenance scheme Authorized LIFAN service station provides pedal or clutch pedal feels like on a sponge;
to guarantee the vehicle operating at the reliable and economical maintenance the pedal nearly contacts the floor; the
best running efficiency. service for all vehicles according to the vehicle pulls to one side when braking
maintenance scheme.
112 113
320
● Continuously high temperature of engine
coolant
Chapter 7
Self-maintenance
In case of any case described above,
immediately contact the authorized repair
station of LIFAN. The vehicle maybe needs Engine Compartment Appearance……………………………………………116
adjusting or repair.
Notes for Maintenance DIY……………………………………………………117
Warning Alignment of Jack………………………………………………………………119
No continuing to drive an unchecked

vehicle; otherwise, that may cause
damage to the vehicle and injury to
persons.
114 115
320
Engine Compartment Appearance Notes for Maintenance DIY
1. Power steering fluid reservoir To carry out maintenance DIY, it is Warning ignition switch is turned on, if the
1 2 3 4 2. Oil filler cap necessary to do as per correct
temperature of engine coolant rises or
3. Brake fluid reservoir procedures in this section. ● When engine runs, hands, clothes
and tools should be far away from the the A/C is turned on, the electrical
4. Coolant reservoir
running fan and engine belt. (Better to cooling fan of engine will run
5. Fuse and relay box Be careful, incorrect or incomplete
6. Battery maintenance work will lead to operation take off things like ring, watch and automatically.
7. Oil dipstick trouble. tie.) ● When disposing the battery, be
8. Windshiled washer fluid reservoir ● When the car has exactly finished a especially careful, for the battery
This section is just for some maintenance driving, the temperature of engine contains corrosive electrolyte.
work which is easy to carry out for users. As c o m p a r t m e n t — e n g i n e , r a d i a t o r, ●When the car is only jacked by body
mentioned in Chapter 6, some items should exhaust pipe, power-assisted steering jack, people don’t come under the car,
be carried out by professional technicians fluid storage tank, spark plug etc. is do support the car with support frame
using special tools. or other strong strut.
very high. So be careful not to touch.
During maintenance work, be especially ●Whether working above or below the
The temperature of oil, coolant and
careful to avoid incidental injuries. The car, goggles are to be worn, for
spark plug is also very high.
following prevention measures should be avoiding falling or dropping articles
abided by especially. ● If the engine is too heated, then
don’t take off the radiator cap or loose and spattering fluid.
the drainage plug, for avoiding burns.
● Never leave behind such flammable
articles as paper, cloth in the engine
compartment.
● Before working around the grille
plate of cooling fan or radiator, it is
8 7 6 5 necessary to make sure that the
ignition switch is turned off. When the
116 117
320
Vehicle Lift
Note ● When closing the engine hood, Note
● Both battery and ignition coil bear check whether there is anything like Strictly prohibit from jacking the car at
high current or voltage. Be careful to tools, cloth etc left behind the engine
the place of engine, transmission, rear
prevent accidents resulting in short compartment.
axle or front axle, etc, or it will result in
circuit. serious damage.
● Prevent any miscellany from
dropping into the spark plug hole.
● Strictly prohibit from prying the
outer electrode beside the central
electrode of spark plug.
● Only use the spark plug of
designated model.
● No overfill the power-assisted
steering fluid, or the power-assisted
steering will be damaged.
●If the brake fluid is overflowing, it is
necessary to clean it with water, for
avoiding damaging components or
paint coat. Make sure that the liftadjustable arm locates under the correct position as shown in the
illustration;
● Strictly prohibit from driving when
the air cleaner is taken off, or it will Removable lift
result in excessive wear of engine. Thesupport position should be in accord with the position as shown in the illustration.
● Be careful not to scratch the To avoid damage of body, add rubber attachment, if necessary.
windshield by the wiper.
118 119
320
Daily Maintenance Chapter 7-2 Check the oil level
Note Check the engine coolant level
Low level High level
Noted that not drop any oil on the When the engine is under cooling state, check
Engine and Chassis the coolant level in the Coolant reservoir, if it is
components of the car.
between the marking lines of “FULL” and
Check the oil level………………………………………………………………121 If the oil level is below or just a little above “LOW”, it conforms to the requirements. If the
Check the engine coolant level………………………………………………121 the low level, it is necessary to fill the oil of oil level is on the low side, it is necessary to fill
the same type. coolant. (For the type of engine coolant, refer to
Check the radiator and condenser……………………………………………122 the “selection of coolant type” below.)
The coolant level in the Coolant reservoir will
Check the tire pressure…………………………………………………………122 To fill Correct Overfilled
Take off the oil filler cap, fill small quantities
change along with the temperature variation,
of oil every time and check the oil rule.
Check and replace the tire………………………………………………………122 however, if the level is at or below the “LOW”
line, it is necessary to fill coolant, to make the
Install tire chain…………………………………………………………………123 When the engine is under working When the oil level reaches the right range,
level reach the “FULL” line.
temperature, shut down the engine, put on the filler cap and screw it down.
After filling coolant, if the level of coolant
Tires replacement………………………………………………………………124 check the oil level with oil rule. declines within a short time, then some leakage
Note
Notes for aluminums alloy wheel………………………………………………126 exists in the system. It is necessary to check
1. To obtain correct reading, it is necessary the radiator, hose, radiator cap, drain plug and
to park the car at flat ground, shut down the ● Avoid overfilling, or the engine will be water pump.
engine and wait for several minutes, let the damaged. If no leakage is found, it is necessary to test the
oil gather at the bottom of engine. ● When the filling is finished, recheck the oil cap pressure and check whether there is any
2. Pull out the oil rule and clean its end. level on the oil rule. leakage at the LIFAN service station.
3. Insert the oil rule again, and try to stick it ●Insufficient oil will cause under-pressure of
to the bottom, or else the reading is engine oil, resulting in poor lubrication,
inaccurate. Warning
bringing about intensified wear and poor
4. Pull out the oil rule and check the oil
cooling of engine, causing frequent troubles To avoid burns, when the engine is at hot
level.
and affecting the service life of engine. condition, don’t take off the radiator cap.
120 121
320
Check the tire pressure Check the tire
Coolant selection Check the radiator and condenser Maintain a correct tire pressure. When checking the tire pressure, it is
Warning
necessary to abide by the following
Only use the coolant designated by LIFAN. When either radiator or condenser has For the recommended cold tire pressure Maintain a correct tire pressure, or instructions:
It is necessary to fill proper type of coolant already extremely dirty or their condition and tire size, refer to Chapter 8. else, the following circumstances or
into the cooling system as per the ambient can’t be made sure, it is necessary to even serious injuries will occur. ●Check the tire pressure only when the car
temperature. Vehicle brought to be checked and repaired It is necessary to check the tire pressure is cold. Only when the car has been parked
at service station of LIFAN. once every two weeks or at least every for at least 3h or drives less than 1.5km, can
Note Low tire pressure (insufficient charge)
month. Don’t forget to check the pressure of the reading of tire pressure be correct.
spare tire. ●Excessive wear
Don’t use clean water. ● Do use tire pressure gauge, since to
Note ●Supernormal wear
judge the tire pressure by experience may
To avoid burns, when the engine is under Incorrect tire pressure will lead to oil waste, ●Hard to control lead to error. Although the variation of tire
Use of improper coolant will damage the
hot condition, be careful not to touch the lowered driving comfort, shortened tire ● Leakage resulting from overheated pressure may be tiny, it will also reduce the
cooling system of engine.
radiator or condenser. service life and lowered driving safety. tire driving comfort and operating stability. Check the tire
For details, contact the service station of
LIFAN. ● Weakened sealing performance at ● After driving, don’t deflate the tire or
If the tire needs to be charged too the hoop of tire reduce the tire pressure randomly. The tire The wear indicating mark is used to help
Note
Warning frequently, it is necessary to demand pressure after driving is always high, which check the tire tread. If it is observed, it is
● Deformed wheel and/or tire
To avoid the damage of radiator and service station of LIFAN for checking. is normal. necessary to replace the tire.
condenser, don’t carry out operation by separation
It is necessary to obtain enough coolant ● Make sure the valve cork is installed.
for the cooling system to ensure the yourself. The tire of LF320 is embedded with wear
Without valve cork, dust or moisture will
normal operation of engine, or “boiling” High tire pressure (overcharge) indicating mark for indicating the time for tire
enter the valve core, and result in leakage.
of car will occur. When the engine is ●Hard to control If the valve cork is lost, it is necessary to replacement. When the wear depth of tire
working under overheated condition, the ● The central of tread pattern is over tread reaches 1.6mm or less, the wear
service life will be affected, so much as install a new one.
worn indicating mark may be seen. If there is wear
resulting in bad accidents like engine
●The hard part of road will more likely indicating mark between two or more adjacent
scraping.
cause tire damage. pattern grooves, it is necessary to replace the
tire. The thinner the tire tread is, the greater
122 123
320
Tires replacement
the risk or slipping and tire burst is. Replacement of tires No using any old tire on Lf320. abnormally worn due to the incorrect tire Warning
pressure, improper wheel alignment and
If damages like cut, rupture, crack which In case of replacing the tire, use a tire of the It is very dangerous to use tires without unbalanced wheel or frequent braking. ● When using tire chain, the driving
is so deep that cord fabric is exposed, same specification and model with the replaced clear identification. speed should not exceed 50km/h or the
and bulging occur to the tire, which one and whose carrying capacity is equal to or Install tire chain lower speed limit specified by the tire
indicates the inner damage of tire, it is larger than that of a common one. You are advised to replace the four tires chain manufacturer.
necessary to replace the tire. at the same time, or two front tires or two Selection of tire chain ● When using tire chain, be careful in
Use of a tire of any other model will cause a driving to note the ridge, hole and sharp
rear ones at least.
If tire leakage is frequently experienced or the serious impact to the vehicle driving and riding, Use the tire chain of correct size. turn of the road, which may result in the
calibration of the speedometer/odometer, jump of car.
size and location of cut and other damages Refer to “If the Tire Leaks” in Chapter 4 for The use rules of tire chain will change
are not proper for correct repair, then it is ground clearance and the space between the ● When using tire chain, avoid sudden
steps of tire replacement. according to different places or roads,
vehicle body and the tire or the tire chain. turn or wheel lock brake, which may
necessary to replace the tire. If you’re not therefore, make sure the local rules before bring about bad effect to the operation of
sure, contact service station of LIFAN. Keep the wheels balanced when installing the tire chain. the car.
If leakage occurs in driving, don’t drive any Warning replacing tires.
Installation of tire chain ● When the car is installed with tire
more, because just a little more driving will You are recommended to exchange the tires
Follow the instructions below; otherwise, a chain, the driver should be careful to
cause unrepairable damages. Unbalanced wheels will effect the vehicle after each mileage of 10,000km so as to decelerate before making a turn, for
serious injury or even death will be caused. maintain the same wear of the tires and Try to install the tire chain at the front tires
operation and the service life of the tires. as tight as possible. Don’t use tire chains at avoiding losing the control over the car,
If any tire serves more than 6 years, ● Radial tire, bias belted tire and The wheels may loose balance in case of a extend their service life. However, the or accident will occur.
proper time for that should be determined rear tires. After driving for 0.5-1.0km, tighten
although no obvious damage is seen, it is diagonal-ply tire can not be mixed in a normal use. Therefore, carry out a regular the tire chain again.
necessary to be checked by professional vehicle; otherwise a typical operation according to the habit of the driver and also
check-up to keep them balanced. the road conditions.
technicians. danger will be resulted in and then cause When installing the tire chain to the tire, be
the vehicle to lose control. The air valves must be replaced with new Refer to “If the Tire Leaks” in Chapter 4 for careful to abide by the guidance of the tire
Although the tire is unused or seldom used, chain manufacturer.
● Do not use any tire with a size not ones in case of a tire replacement. steps of tire replacement.
the aging will lead to quality decline. recommended by LIFAN; otherwise a
Check if there is uneven wear and damage on When the wheel house is used, it may be
These are suitable to spare tires as well. typical operation danger will be resulted in
the tires when exchanging them. The tire will be scratched by the tire chain, so it is necessary to
and then cause the vehicle to lose control. take off the wheel house before installing the
tire chain.
124 125
320
Replace wheel
Chapter 7-3
When to replace the wheel ground and the space between the tire or Notes for aluminum alloy wheel Daily Maintenance
tire chain and the vehicle body and chassis.
If there are damages like twist, crazing or Don’t use old wheels for replacement, because ● The car installed with aluminum wheels,
severe corrosion in the wheel, it is necessary these wheels may be treated or serve a long after the initial 2,000km, it is necessary to
Electrical components
to make a replacement. mileage, and may go wrong without any warning. check whether the nut is screwed.
Meanwhile, the twisted wheels having undergone Check the battery…………………………………………………………………128
If don’t replace the damaged wheel, then alignment always have structural damages, so ● In case of the exchange, repair or
the tire may separate from the wheel or it don’t use them either. Don’t use the inner tube replacement of tires, check whether the nut
Check and replace fuse …………………………………………………………129
will make the car lose control. specially designed for tires without inner tube is screwed after driving for 2,000km.
inside a flat tire.
Selection of wheel ● When using the tire chain, be careful not
to damage the aluminum alloy wheel.
Warning
In case of replacing the wheel, be sure to
use a wheel of the same specification Since wheels of different sizes will cause ● Only use the wheel nut and wrench
and model with the replaced one. typical operation danger which in turn specially designed for aluminum wheel.
makes the car lose control, therefore, do
The service station of LIFAN can carry out not use any wheel with a size not ●When using the tire chain to adjust the wheel
correct wheel replacement. recommended by the manufacturer. balance, only use balancer or tools equal to it
Otherwise, accident will occur. and plastic hammer or rubber hammer.
Wheels of different sizes or types will bring
about bad effect to the control, service life ● Like all vehicles, it is necessary to check
of wheel and bearing, cooling of brake, whether there is damage of aluminum wheels
calibration of the speedometer/odometer, timely. If damages are found, it is necessary
brake performance, Headlamp aiming, to replace it for a new one immediately.
height of bumper, car height above the
126 127
320 Check and replace fuse
320
Check the battery Check the external part of battery
Notes
If the Headlamp or other electrical Find out which fuse is in trouble. The circuit name for
Warning Note components don’t work, it is necessary each fuse is identified on the cover of the fuse box.
to check the fuse. If the fuse has been See Chapter 8 for the control function of each circuit.
Notes of battery: ● Before carrying out the maintenance, it
blown, replace it for a new one.
Overcharge of battery will produce is necessary to make sure that the engine Pull out type A fuse with a picker.
flammable and volatile oxygen and and all auxiliary equipment have been Shut down the ignition switch and
hydrogen. shut down. If it is impossible to confirm whether the fuse
corresponding components, and
● To check the battery, it is necessary to has been burned or not, replace the fuses
● When using tools around battery, vertically pull out the possible blown
possible in trouble
sparks are to be prevented. take off the ground cable connected to fuse for check.
Good Blow out
● Don’t light a cigarette or fire around the negative terminal (“一 ” marking) Install new fuse for the jacket if the old fuse has
battery. first and install it last. been burned.
● Don’t let children approach to ● Be careful, do not cause short circuit Type A
Install the fuse with the amperage specified on
battery. when using tools.
the cover of the fuse box.
● To clean the battery, be careful not to
Check whether there is any corrosion or let the washing liquid enter the battery If the specified fuse is not available, the fuse with
loose joint, crazing or loose hold-down case. relatively low amperage should be adopted.
of battery.
However, the fuse with lower amperage than the
a. If the battery joint has been corroded, it is specified amperage may be burned again, which
necessary to clean it with the mixture of is not an essential problem. Renew correct fuse
warm water and saleratus. Lubricate the as soon as possible, and place the temporary
Good Blow out
outside of joint with grease to prevent fuse back to the original jacket.
further corrosion.
b. If the connection of joints is loosened, Prepare a set of spare fuse in your car for
screw the nut. emergent application.
Type B
128 129
320
Chapter 8
The electrical system may have trouble if Maintenance specification
the renewed fuse is burned immediately.
Then, go to the repair station of LIFAN for
maintenance.
Maintenance specification………………………………………………………132
Warning
Using the fuse with overhigh amperage
or making any other subject as the fuse
is forbidden. Otherwise, serious damage
or fire may occur.
130 131
Maintenance Specification
320
Type and Amount for Fluid Filled
Oil level
S/N Item Amount Specification & Type API SG level or above
Amount 3.2L
Recommended viscosity
Brak fluid (without ABS) 0.5L
1 DOT4
Brak fluid (ABS) 0.6L
2 Coolant 7.0L Lucent -30℃
Expected temperature range before

3 Transmission oil 1.8L SAE85W/90 API GL -4 level
the next change of oil
Dimension of tire
ESSO ATF.D2 165/70R14
4 Steering fluid 1.0L
Pressure of the tire kPa
Front/rear 230/230
120N·m
5 Fuel 37L 93＃ or above Gasoline without lead Wheel nut torque N.m (kgf.m)
120N·m
6 A/C refrigerant 480g R134a
132
LIFAN INDUSTRY(GROUP) IMP, & EXP. CO., LTD.
Ver：LF-20121225
LIFAN320 Service manual
LIFAN320 Service Manual
Chongqing LIFAN Industry (Group) Imp. & Exp. Co., Ltd.

Ver：LF-20121225
Foreword
LF7132 Service Manual on common treatment of troubles is to help you correctly use and
maintain your beloved sedan.
This manual, with illustrative figures and easy-going words, thoroughly introduces the
structure features, use and maintenance of LF320 sedan, which will be a good guide for wide
users and maintenance technicians. Meanwhile, LF7132 Spare Parts List will also be referred
if necessary. For any questions and doubts, please do not hesitate to contact the service
stations of Chongqing Lifan Passenger Vehicle Co., Ltd.
The figures, notes, specifications etc. contained in this manual will take effect as of the date
of printing, which can be modified and terminated at any moment by Chongqing Lifan
Passenger Vehicle Co., Ltd. without any notice in advance.
Any comment on anything improper in the manual shall be preferred, and no responsibility on
anything improper shall be undertaken by Chongqing Lifan Passenger Vehicle Co., Ltd.
Without a permit from Chongqing Lifan Passenger Vehicle Co., Ltd., any unit or individual
shall not be allowed to duplicate, store, or distribute any part of the manual in any form or by
any method.
Great appreciation for your support!
Ver：LF-20121225
Contents
1
Part I Introduction
Chapter I Vehicle Overview 2
Chapter II Main Technical Parameters of LF320 Sedan 5
Chapter III LIFAN Vehicle Maintenance Rules 13
22
Part II Engine Maintenance
Chapter I Mechanical Part 23
Section I Check and Adjustment of Carbon Monoxide Concentration 23

Section II Compression Pressure Check 25
Section III Valve Clearance Check and Adjustment 27
Section IV Idle Speed Check and Adjustment 36
Section V Timing Belt Check and Adjustment 37
Section VI Cylinder Head 50
Section VII Cylinder Body 95
Chapter II Cooling System 128
Section I Coolant 128

Section II Water Pump 130
Section III Thermostat 138
Section IV Electrical Cooling Fan 141
Section V Cooling Fan Relay 144
Chapter III Lubrication System 145
Section I Engine Oil and Fuel Filter 145

Section II Engine Oil Pump 148
Chapter IV Exhaust Gas Emission Control 155
Section I Overview 155

Section II PCV System 156
Section III IEVAP Control System 158
Chapter V Electric Parts 160
Section I Electronic Fuel Injection (EFI) System 160

Section II Electronic Control System 161
Section III Ignition System 171
Section IV Start-up System 176
Section V Discharge System 182
Chapter VI Electronic Injection System 202
Section I Introduction 202

Section II Part Structure and Performance 204
Section III Steps for Trouble Diagnosis with DTC 219
Ver：LF-20121225
Section IV Steps for Trouble Diagnosis Based on Engine Symptom 226
Section V Security Items for System Maintenance 243
Chapter VII Three Way Catalytic Reaction System 244
246
Part III Chassis Maintenance
Chapter I Suspension 247
Section I Introduction 247
Chapter II Axle, Wheel and Tire 257
Section I Brief Introduction of Axle, Wheel and Tire 257
Section II Common Problems and Recovery of Axle, Wheel and Tire 262
Section II Axle Overhauling 265
Section IV Application and Maintenance of Wheel 271
Section V Inspection and Adjustment to Wheel Location 273
Chapter III Steering System 276
Section I Configuration and Technique Parameter of Steering System 276
Section II Overhauling and Problem Detection of Steering System 280
Chapter IV Brake System 288
Section I Brake System Composition 288
Section II Brake System Common Fault and Fault Elimination 294
Section III Brake System Check and Repair 297
Section IV Maintenance and Adjustment of Brake System 304
Chapter V ABS Anti-lock Brake System (Optional) 310

Section I Composition of ABS 310
Section II Principle of ABS 311
Section III Removal and Installation of ABS 313
Section IV Fault Diagnosis and Troubleshooting 316
339
Part IV Electrical System Maintenance
Chapter I Electrical System 340
Section Ⅰ System Principle 340
Section Ⅱ Battery 351
Section III BCM System 356
Chapter II Composition and Principle of Instrument Cluster 361

Ver：LF-20121225
Chapter III Air Bag 367
Section I Composition and Arrangement 367
Section II Working Principle 370
Section III Air Bag Repair Safety Rules 371
Section IV Diagnosis & Fault Elimination 373
Section V Removal and Installation 379
Chapter IV Vehicle Air Conditioning System 382
Section I Structure and Principle of Air Conditioning System 383
Section II Air Conditioner Control System 388
Section III Air Conditioner Fault Diagnosis 390
Section IV Air Conditioning System Diagnosis Repair and Maintenance 396
Chapter V Overall Lamps 399
Chapter VI Charge system 404
416
Part V Transmission Maintenance
430
Part VI Vehicle Body Service
Chapter I Vehicle Body 431
Section I Structure and Features of Vehicle Body 431
Section II Vehicle Body Repair Tools 434
Section III Vehicle Part Repair 437
Section IV Touch-up Paint 443
Section V Size of Vehicle Body 444
Chapter II Screen Wiper and Washer 448

Ver：LF-20121225
Part I Introduction
Chapter I Vehicle Overview
With the advantages of good power nature, commodious internal space and comfortable ride, LF320 sedans
reflect the people-oriented design tenet. Compared with domestic similar vehicles, LF320 sedans have the
advantages of complete vehicle technology and performance leader. It has strong market competitiveness
for its comfortable ride and favorable price.
I. Shape: a new fashion design, smooth appearance, and low air resistance coefficient.
Body: it has a bearing-type body which has passed the frontal crash test and the inspection by state test
institutions.
II. Inner and outer trims:

1. Dash board, inner and outer trims and lamps are made of new technology and new material.
2. Air conditioning system: it fully reflects the man-machine engineering, air evenly and quietly. The air
filter provides clean fresh air.
III. Power transmission system:

1. The power assembly adopts LF479Q3 engine. The layout of the power assembly adopts horizontal
front-wheel drive.
2. Hanging clutch pedal body, mechanical clutch control system and diaphragm-dry type clutch.
3. With a five-gear manual transmission, the vehicle has a reliable performance.
IV. Chassis
1. The front suspension adopts a Mcpherson independent suspension with a horizontal stabilizer bar, and
the rear suspension adopts a Mcpherson independent suspension with a horizontal stabilizer bar and a
single longitudinal arm.
2. The steering gear adopts hydraulic power gears and racks
3. The front brake is a ventilation disc brake, and the rear brake is a drum brake with proportional valve,
matching ABS and EBD. The brake pedal is of hanging type. The load distribution condition makes
reasonable distribution of front and rear brake force. The parking brake is a mechanical cable drum brake.
4. It adopts 165/70R14 meridian tires, and the wheel rim is 14×5J.
V. Electrical system
The electrical system is designed according to the highest configuration of Lifan, and includes all the
electrical optional parts to cater for the diversified needs of different users, and achieve the control function
of the whole electrical equipment.
Classification of automotive electrical system
1. electronic fan
The electronic fan adopts single-stage and single-fan style.
Ver：LF-20121225
2. Power supply start and charge system
The power supply start system mainly includes starter, battery, generator, voltage regulator and so on.
3. Ignition electronic injection system
The electronic injection system uses the multi-point electronic injection system of Sunshine-Tek Company,
and is demarcated by the company. This type has the following components:
Sensor: Intake pressure temperature sensor, throttle position sensor, speed sensor, knock sensor, oxygen
sensor, crankshaft position sensor and water temperature sensor;
Control module: ECU;
Actuator: electric fuel pump, fuel injector, ignition coil and CanCV Canister Control Valve;
Ignition coil: double coil, non-distributor;
Ignition switch: it adopts four-gear combination switch, cooperating with the vehicle door and luggage boot
cover lock.
4. Illumination signal system
Signal system sends the signal of warning and indication to the surrounding environment, mainly including
horns, steering light signal, emergency light switch, reversing and brake light switch, as well as front and
rear fog lights.
5. Instrument system
Instrument cluster includes: engine tachometer, speedometer, fuel gauge and indicator.
Indicators include battery charging indicator, oil pressure indicator, engine fault test indicator, hand brake
indicator, anti-theft indicator, brake shoe abrasion indicator, safety belt indicator, fuel warning indicator,
high bean indicator, steering (emergency) indicator, ABS indicator, door ajar indicator, rear fog light
indicator, and SVS indicator.
Sensors and switches: fuel capacity sensor, oil pressure sensor, speed sensor, hand brake sensor, brake shoe
sensor, safety belt switch, brake fluid level sensor.
6. Auxiliary electrical system
(1) Front and rear windshield wiper system: it is controlled by the combination switch handle, with the
front wiper motor and linkage arranged in the front board panel.
(2) CDMD-X and CD (optional) machine: it is equipped with two speakers and tweeters with regulatory
function. With 4 speakers (installed in the front doors and the retaining plate of column C), the CD is
installed on the instrument board; also it has the functions of radio, disc player and time display. Both
CDMD-X and CD machine have USB interface and accept external player devices.
(3) A cigarette lighter.
(4) Rear windshield defrosting: resistance wire heating style, controlled by switch.
(5) Electric window regulator (optional): four-door layout, and the master control beside the driver and
independent control of right door and window, also the operating switches installed on the handle of the
door.
(6) Central door locks (optional): four-door installed and unified switches, with the remote control function,
mature products to be chosen according to the body structure and shape. The control box is in the central
channel.
(7) Air conditioning system: Otter-86 compressor, with the greatest cooling capacity of 3956Kcal/h. It is
made up of condenser, evaporator, thermostat, sensor, pressure switch, blower and so on. It enjoys good
cooling effect.
7. Safety control system
(1) Air bag (optional);
Ver：LF-20121225
Double air bags are arranged on the steering wheel and the dashboard next to the co-driver.
(2) ABS system;
Anti-lock Brake System is called ABS for short. It is a safety device, with the function of preventing
wheels slipping when braking to improve the direction stability, steering control ability and shorten the
braking distance to make braking more safe and effective. And it greatly improves the safety and reliability
on different roads.
(3) Anti-theft system (optional):
The anti-theft system is made up of anti-theft ECU, anti-theft antenna (outside the ignition switch), and
anti-theft chip (installed on the handle of the ignition key). There is a communication wire between
anti-theft ECU and engine ECU. When the ignition key is installed, the antenna will pass the signal of the
ignition key to the anti-theft ECU. If the signal is right, the ignition system will work, or the engine should
not start.
8. Other electrical items
Other electrical items mainly include harness, the central control box, relay, safety gaskets, connectors,
switches, corresponding fixed parts and packs. The use meets the requirements of standard QC/T420-1999
with the function of blown fuse indicator.
Ver：LF-20121225
Ver：LF-20121225
Chapter II Main Technical Parameters
I. Basic parameters
Model LF7132
Two compartments, five seats, four
Basic model doors, one cover, and one rear luggage
boot door
Horizontal engine and front wheel
Drive model
drive
Length mm 3745
Appearance
Width mm 1620
size
High (non-loaded) mm 1430
Wheelbase (non-loaded) mm 2340
Wheelbase (full loaded) mm 2345
Front tread (non-loaded) mm 1385
Tread
Rear tread (non-loaded) mm 1365
Front suspension mm 790
Rear suspension mm 615
Approach angle （°） 20
Passability Departure angle （°） 23
parameters Minimum ground clearance mm 135
Minimum turning radius m ≤4.76
Luggage boot cubage L 300
Oil tank cubage L 37
Whole quality kg 900
Shaft load distribution (front/rear) kg 565/335
Fully loaded quality kg 1250
Quality
Shaft load distribution (front/rear) kg 710/540
parameters
Fully loaded shaft load ratio
% 52.6/47.4
(front/rear)
Centroid height (empty/full) mm 558.2/573.9
Maximum speed km/h 155
Acceleration performance (0-100
s 14.5
Performance km/h)
parameters Fuel consumption under constant
L/100km 4.8
velocity driving (90 km/h)
Maximum gradability （%） ≥30
Passengers Person 5
II. Structure forms and performance parameters of main assemblies

Ver：LF-20121225
1. Engine characteristic parameters

Model LF479Q3
Aligned 4 cylinders, 16 valves, water cooling,
From
double-roof camshaft
General
mL 1342
displacement
Cylinder diameter ×
Mm 78.7×69
stroke
Compression
9.3:1
ratio
Maximum
[kW/r/min] 65/6000
power
Maximum
[Nm/r/min] 110/3000～5000
torque
Minimum ratio
g/（kw•h） 270
fuel consumption
Fuel supply
Multi-point electronic fuel injection
mode
Ignition mode Double-coil non-distributor ignition
Length×width×
Mm 1010×605×640
height
2. Forms and parameters of engine accessories and chassis assemblies
Structure
parameter
Model LF7132
Assembly
Exhaust system One three-way catalytic converter and two mufflers
Intake system Intake manifold, air cleaner
Including fuel pump, fuel filter, pressure regulator and accelerator
Fuel supply system
pedal
Cooling system Pipe radiator, electronic fan
Clutch
Monolithic, dry-type, diaphragm spring
Maximum clutch pedal play 116 mm～130mm
Clutch pedal force Clutch pedal force should be less than 300N ruled by GB7258
Ver：LF-20121225
Form Manual 5-gear box , mechanic cable control

Transmission
1st gear 3.181
nd
2 .gear 1.842
rd
3 gear 1.25
th
Gear speed ratio 4 gear 0.864
th
5 gear 0.707
Reverse
3.142
gear
Main
Speed ratio 4.266
reducer
Drive
Form 3-pin sliding bush, ball-formed fixed end
shaft
Front suspension Mcpherson independent suspension with a horizontal stabilizer
Suspension
fork bar
fork
Mcpherson independent suspension with a horizontal stabilizer
Rear suspension fork
bar and a single longitudinal arm
3. Body structure form and parameters

Tire types Meridian wheel
wheels and tire steering
Tire spec 165/70R14

Wheel rim spec Steel wheel rim 5J×14
Tire pressure Front and rear: 220kPa
Steering gear model Gear-rack form, hydraulic power assisted steering
Steering equipment External diameter of the steering wheel is ∅380,
non-adjustable column angle
(non-loaded) (full loaded)
Front-wheel extroversion 0°20′±30′ 0°15′±30′
Wheel alignment
Toe-in front wheels 1±2mm 1±2mm

Kingpin inclination 12°00′±30′ 12°30′±30′
Kingpin caster 2°55′±30′ 3°35′±30′
Rear wheel camber －1º±30′ -1°30′±30′
Toe-in rear wheels 6±2mm 6±2mm
Structure model Double hydraulic pipelines with a vacuum booster, optional
Brake system
ABS
Driving brake Front wheels with disc brake, rear wheels with drum brake
Parking brake Mechanic cable, braking rear wheels
4. Electrical system structure and parameter

Ver：LF-20121225
Structure
parameter
LF7132
Model
Assembly
Bearing body, two compartments, five seats, four doors, one
Body model
cover, and one rear luggage boot door
All-metal closed structure, hidden A column, undercurrent
White body
launder
Overall frame, 4 doors opened in the same direction, buckle
Body
Door assembly
door locks, anti-collision door beam
Engine hood Open backwards, curved-arm hinge
Cubage about 300 liters, leaf-joined hinge with pneumatic
Luggage boot and hood
support
Front and rear bumpers Injection molded parts
Inner trim Intenerated structure
Intenerated structure, injection molded structure with exterior
Dash board
veins
A, B, C pillar and inner-door shield Injection molded structure with exterior veins
Front windshield: interlayer glass

Windshield
Rear windshield: toughened glass
Inner and outer trims
Outer rearview mirror: left and right are convexity reflector,

Rearview mirror manual/power adjustment
Inner rearview mirror: anti-dizzy mode
Front seat: independent seats, adjustable front-rear seats,
backrest angle and seat head, with seat belts
Seat
Rear seat: not adjustable, non-independent seats with belts,
folded
Structure model Vaporization compression cooling, water warm heating
With knob operation, it can control the airflow direction,

Operation and choose and adjust wind speed, temperature and air
cycle
Air conditioning system
Refrigerant Model R134a, injection added 480g
Compressor model Ortega -86
Maximum cooling capacity (Kcal/h) 3956
Fan flux (㎡/h) 380
Fan noise (dB) ≤78
Magnetic clutch 12V DC ≥48W

Ver：LF-20121225
5. Lubricants, fuel, steering fluid, brake fluid, cooling fluid, A/C refrigerant and capability
Structure
parameter
LF7132
Model
System
Circuit Mongline, negative pole earthing, direct current 12V
Power supply, start and
Integral type, alternating, built-in pressure regulator, spec

Generator
charge system
12V/80A
Starter Magnetic operation (in engine), power 1kW
Electronic fan Single speed single fan
Battery Lead-acid battery without maintenance, capability 45Ah
Headlight (55w, white, 2)

Front combination lamps Position lights (5W, white, 2)
Steering lights (21W, amber, 2, combination switch)
Side steering lights 5W, amber, 2
Front fog lights (55W, white, 2)
Lighting and signal system
Front-rear fog lights and reversing lights Rear fog light/reversing light (21W, red/white, I), switch
on the dashboard
Steering light (21W, amber, 2, combination switch)
Rear combination lamps Brake lamp (21W, red, 2, closing contact switch)
Rear position light (5w, white, 2)
Rear license plate lamp 5W, white, 2
High-mounted brake lamp LBD, red, 1
Interior group roof light 10W, white, 1
Rear luggage boot lamp 5W, white, door control model
Instrument cluster with electronic odometer, including

Instrument cluster
fuel gauge, speedometer, engine tachometer
Instrument system
Include battery charge indicator, oil pressure indicator,

fuel warning indicator, brake liquid level indicator,
engine fault test indicator, hand brake indicator,
Indicator anti-theft indicator, brake shoe abrasion indicator,
safety belt indicator, instrument lighting indicator, high
beam indicator, steering (emergency) indicator, ABS
indicator, and door ajar indicator.
Ver：LF-20121225
（Continued）
Structure
parameter
LF7132
Model
System
Auxiliary electric
Include CDMD-X (CD), cigarette lighter, and equipments

system
such like rear defrosting, wiper-washer, remote lock,

anti-theft, air bag and window regulator.
(1) Lubricant
Lubricant Trademark Capability and quality

10W/30 or above
15W/40SG (choosing
Engine Engine oil About 2.7L
trademark according
to different area)
SAE 85w -90
Transmission Hyperboloid gear oil 2.0L
（API GL-4）
Bearing and
button head Lithium base grease 7022 0.34kg
pin
(2) Fuel
Engine model
LF479Q3
Performance index
Fuel type 93# or higher number vehicle-used unleaded gasoline
Fuel tank capability s(L) 37
(3) Steering fluid, brake fluid, cooling fluid, and A/C refrigerant.
Name Trademark Capability and quality

Power steering fluid ESSO ATF.D2 1.0L
Brake fluid DOT 4 0.6/0.5（ABS/not ABS）
Coolant Lucent -30℃ 7L
A/C refrigerant R134a 0.48kg
Windshield cleaning
NFC-60 About 3.0L
solution
Ver：LF-20121225
Chapter III LIFAN Vehicle Maintenance

Rules
Notes for regular check and maintenance

If you have abundant basic knowledge of vehicle structure and equipments, you can do the regular check
and maintenance by yourself. If you do that by yourself, please read the following knowledge, instructions
and advices. If you can’t follow the instruction, your vehicle would be damaged or experience some other
dangers.
If you find problems of oil or fluid refilling, components repair and adjustment during checking, you must
refer to repair service center of LIFAN. There would be harm or fault without plentiful knowledge of
vehicle maintenance and technology.
1. Notice for checking preparation and place
● Do not check the vehicle in the place blocking people or traffic. Maybe accidents will arise without
ensuring surrounding safety.
● Do not check the vehicle at an acclivitous place, because it may bring harm for vehicle sliding, or can’t
measure the oil mass and fluid quantity exactly.
● Carry out the check until all wheels stop after parking brake. If you check when parking brake is
incomplete, or wheels do not stop running completely, it may bring accidents for tire slip.
● Jack would be used only when changing tire and installing tire chain, do not use it in checking and
maintenance.
2. Notice for engine compartment check
● Do not check the vehicle when the engine is working. When the engine is in action, you would be injured
if you touch the rotating part of strap or fan. Contact with the spark plug and high voltage wire may cause a
dangerous electric shock.
● Do not check the vehicle when ignition connected or on. In addition, even cooling fan stops, it still starts
again when the temperature of the cooling water is high, and thus causes harm.
● Do not touch high temperature part like exhaust pipe and radiator when the engine stops for a while, or
you may be burned.
● Do not place goods in engine compartment, especially paper, cloth or tinder. If you forget to take them
away, they would be on fire, and very dangerous.
● Do not remove the wiring to avoid fault.
3. Daily maintenance items table

Checking and
Items Order Measures Notice
maintenance content
Engine Whether fluid level is If brake fluid ★Do not drive the vehicle
Braking
compartment between the MAX and level is under when the brake fluid level is
fluid
MIN datum line of fluid or approaches under MIN or brake fluid
quantity
reservoir MIN level, do deceases distinctly.
Ver：LF-20121225
contact the ★Air entering brake system
special repair degrades the braking effect,
shop of and brake fluid leakage will
LIFAN as cause accident.
soon as ★Impurity interfused in brake
possible. fluid will affect the braking
effect and cause accidents.
★Do not suck out battery
electrolyte.
★There are deleterious caustic
vitriol in battery, so wrong
operation would lead to
accident.
In case battery electrolyte
sticks to your eye or skin, wash
the affected part with a great
deal of water immediately, and
If the fluid
receive treatment as soon as
level is under
possible.
the level line,
Battery When battery electrolyte
do refer to the
electrolyte level is low, do check all ★If you drink the battery
customers’
amount the six units. electrolyte by accident, drink a
manual or
great deal of water
contact the
immediately, and receive
special repair
treatment as soon as possible.
station.
★When you clean the battery,
do not rub with a dry cloth.
Because it may bring static and
lead to explosion.
★Do not use short-circuit
battery, or approach beacon.
Because it would fire the
combustible gas, and lead to
explosion.
(Continued 1)
Checking and
maintenance content
Check the oil before the If the oil level ★Do not inject oil higher than
engine starts or stops for line is lower the high level line, because it
Engine at least 5 minutes. or a little may bring bad effect to the
Engine oil
compartment higher than engine.
After pulling out the oil the low oil ★Do not put impurity into
dipstick, rub it clean and level, inject engine from the oil filler, or it
Ver：LF-20121225
put it to the end and then oil of the may bring bad effect to engine
pull it out. Check same model and damage the engine.
whether the high oil into the ★Do not let oil leak, because
level line and the low engine. it may cause the oil burning
level line is stained with when the temperature of the
oil. engine is high. Rub it
completely in case of leakage.
★Except changing coolant and
renewing coolant when the
engine is too hot; please do not
open the cap of the radiator.
★Don’t let coolant level line
higher than F (upper limit) of
expansion tank. It will bring
After the coolant is bad effect to the engine if the
cooled, check the coolant is not between F and L.
When coolant
coolant quantity of the If the fluid level is lower than
is lacking,
radiator and expansion L, please refill coolant after
renew it with
tank. checking whether the cooling
Coolant antifreeze
Check whether the system is leaking.
quantity G11 to the
coolant measure is ★Please do not refill water, or
upper limit of
between the F(upper the melting point of the coolant
expansion
limit) and L(lower limit) will rise, and the anti-rust
tank.
beside the expansion ability will fall. It will make
tank the coolant ice up and rust
easily.
★Do not make the coolant
leakage in the engine
compartment, or it will damage
the accessories and paint. Even
the hot engine compartment
would be on fire.
(Continued 2)
Checking and maintenance
content
★Do not use suds
If all the cleaners can’t
instead of cleaning
work, the cleaner tank may
Add cleaning solution, or the paint
be empty. Please check the
Engine Cleaning solution in case will be damaged.
cleaning solution level on
compartment solution of insufficient ★Don’t only add
the liquidometer. Fill
amount. water, or it will ice up
cleaning solution in case of
in winter; the cleaning
level lower than LOW.
solution can’t erupt.
Ver：LF-20121225
.
★Do not drive the

vehicle under very
low air pressure, or a
Check the tire when it is in
When the air bad contact between
low temperature. Check
pressure is tire and wheel hub
whether the air pressure is
Tire abnormal, will cause leakage. In
proper through observing
pressure please adjust to addition, if you run
the distortion condition of
standard air the steering wheel
the contact part between
pressure. abruptly, the tire may
tire and ground.
Around the be off from the rotary
vehicle table, leading to traffic
accident.
Check whether there are
distinct scar and crazing in If there is scar
tire side and the contact or crazing,
Tire crazing
tread with the ground; please contact
or damage
check whether the tire tread with repair
was embedded with nails, service center
stones or other impurity. of LIFAN.
(Continued 3)
Checking and maintenance
content
If the wearing
limit sign
emerges, please
change the tire.
Check whether the wearing If the tire is ★If the wearing limit
limit sign of the contact wearing sign emerges, please
Tire groove
condition between tire and extremely or change the tire. The
face is
Around the ground the wearing use of tire over
wearing
vehicle emerges; check whether condition is wearing limit sign may
deeply and
there is wearing part of the very different cause accidents such
abnormally.
contact part between tire from other tires, as skid.
and ground. you can
consider the air
pressure is too
low, or the tire
top is incorrect,
Ver：LF-20121225
so please
contact the
repair service
center of
LIFAN.
Please clean the
lamps when
they are
Damage to smudgy. Please
Check whether the
light contact the
lampshades are stained or
equipments repair service
broken. Check if all lamps
and signal center of
are installed stably by hand.
indicators LIFAN when
they are broken,
cracking or not
installed stably.
(Continued 4)
Checking and
maintenance content
If the times of
Pull up the parking brake ratting sound
Parking handle by hand; check are more than
Sitting on the
brake the times of ratting ruled times,
driver seat
operation sound from the ratchet please carry
wheel. out
adjustment.
Check whether there is
abnormal sound or the
When engine
engine working
starts up, such
condition is good when
condition will
Engine starting;
cause damage
working
to engine and
condition In addition, check
even hidden
and whether there is
troubles.
abnormal abnormal sound of
Please contact
sound engine working
the repair
condition, when at idle
service center
speed condition or the
of LIFAN.
rotation speed is added a
little.
Brake pedal Start the engine, and step ★Brake fluid leakage, and
stepping on the pedal to the interfused with air will cause
condition bottom to check whether worsening braking effect.
Ver：LF-20121225
the distance between the Please contact the repair
pedal and bottom is service center of LIFAN
small, and whether the instead of self-check in case of
feeling of stepping on the below conditions.
the pedal is normal.
★Check the condition of pedal
sinking when stepping on the
pedal continuously. It feels
softened when the pedal is
trampled to the end.
(Continued 5)
Checking and
maintenance content
Do change the
wiper rubber
Put the ignition switch to
and clean the
“on”. Start the cleaner,
windshield
and check after wetting
when the
Wiper the windshield.
wiping
condition Start the wiper; check if
condition is
the wiping condition is
not good.
normal at low speed,
Please contact
high speed, and
the repair
intermission.
service center
of LIFAN.
Headlight: Visually
check whether it can be
Sitting on the illuminated or the
driver seat luminance is insufficient
under the condition of
headlight on.
Please contact
Work Steering light: turn on
the repair
condition of the left and right steering When the bulbs are
service center
lighting light control lever, and open-circuited, the glittering
of LIFAN, if
system and check whether all the speed would be faster.
they are not
steering steering lights glitter.
on or
light Brake lamp: step on the
glittering.
brake pedal lightly and
repeatedly, and check
whether the brake light
is on.
Other lamps: check the
working condition of the
Ver：LF-20121225
taillight, hazard warning
light and reversing light.
(Continued 6)
Checking and
maintenance content
Pay attention to the traffic
Please contact the
condition around, please check
When driving normally, repair service
in a safe place, especially brake
Braking check whether the brake center of LIFAN,
In driving checking; please ensure
effect is effective, or there is if the braking
whether there are vehicles
one-side brake. effect is not good.
around.
If you continue
driving when the
low speed and
speedup condition
is not good, it will
During normal driving,
cause accidents
when stopping for the
Low like engine
traffic signal, please Pay attention to the traffic
speed and wearing, drive
check whether the condition around, and please
speedup uncontrolled, and
engine stops, and check check in a safe place.
condition worsening braking
whether you can speed
of engine effect. It is very
up placidly with
dangerous, so
stepping on the pedal.
please refer to
repair service
center of LIFAN
as soon as
possible.
Please refer to the
repair service
Check the
Ensure whether there are center of LIFAN
abnormal
problems in the as soon as
part last
abnormal parts last day. possible, if there
day.
is continuous
abnormality.
4. LIFAN maintenance scheme

Odometer Readings Or Months, Whichever Is First
Maintenance
NO. 13,000k 18,000k 23,000k 28,000k 33 ,000k 38 ,000k 43 ,000k 48,000 53,000k 58,000k
Item 3,000km 8,000km
m m m m m m m km m m
Ver：LF-20121225
15Month 21Month 27Month 33Month 39Month 45Month 51Month 57 63Month 69Month
3Months 9Months
s s s s s s s Months s s
Oil & Fluid

Replacement
Replacing the
1.1 engine oil & R R R R R R R R R R R R
the oil filter
Replacing the
1.2 R R R R R
fuel filter
Replacing the
1.3 power steering R R
fluid
Replacing the
1.4 It should be replaced every 40,000 km or 2 years
brake fluid
Replacing the
1.5 It should be replaced every 40,000 km or 2 years
coolant
Replacing the
transmission
1.6 R It should be replaced every 40,000 km or 2 years
oil (MT)& rear
axle gear oil
Fluid Level
Add As The Case May Be
Check
Inspecting the
fluid level &
add (including
brake fluid,
1.7 I I I I I I I I I I I I
coolant, glass
cleaning fluid
etc.) to the
proper level.
Inspecting &
Adjust As Necessary
Adjustment
Inspecting the
lighting system
of the whole
vehicle
Inspecting the
clutch pedal &
1.9 its position as I I I I I I I I I I I I
well as the
parking brake
Ver：LF-20121225
13,000k 18,000k 23,000k 28,000k 33 ,000k 38 ,000k 43 ,000k 48,000 53,000k 58,000k
Maintenance 3,000km 8,000km
NO. m m m m m m m km m m
Item
3Months 9Months
handle position
Inspecting the
ABS system
1.1 Inspecting the

I I I I I I I I I I I I
1 tire pressure
Rotate the tires

and check the
1.12 parameter of I I I I I
four wheel
alignment
Inspecting the
parking brake
1.13 mechanism I I I I I I I I I I I I
working
performance
Inspecting the
brake system
working
performance
Inspecting the
steering system
working
performance
Inspecting the
A/C & HVAC
working
condition
Cleaning throttle
1.17 & injection C C C C C
nozzle
Inspecting the
engine timing
1.18 I I I I I I
chain
(VVT-engine)
1.19 Inspecting the I I I I I I I I I I I I

Ver：LF-20121225
13,000k 18,000k 23,000k 28,000k 33 ,000k 38 ,000k 43 ,000k 48,000 53,000k 58,000k
Item
3Months 9Months
exhaust
emission
condition
Inspecting &
Replace As Necessary
Replacement
Inspecting the
glass cleaning
1.20 system & I I I I I I I I I I I I
windshield
wiper system
Inspecting or
replacing the
1.21 I It should be replaced every 40,000 km or 2 years
high-tension
cable
Replacing the
drive belt
1.22 (generator, It should be replaced every 80,000 km or 2 years
A/C
compressor)
Inspecting or I I I I I I
replacing the
1.23
engine timing It should be replaced every 60,000 km or 3 years
belt
Replacing the
three-way
1.24 It should be replaced every 80,000 km
catalytic
converter
Cleaning or
1.25 replacing the C C R C R C R C R C R C
air filter
Cleaning or
replacing the
interior
1.26 C C R C R C R C R C R C
ventilation
system air
filter
Ver：LF-20121225
13,000k 18,000k 23,000k 28,000k 33 ,000k 38 ,000k 43 ,000k 48,000 53,000k 58,000k
Item
3Months 9Months
Inspecting if
1.27 there is oil I I I I I I I I I I I I
leakage
Inspecting the
1.28 radio， CD or I I I I I I I I I I I I
DVD
Inspecting the
instrument
cluster &
speaker
Inspecting or
1.30 replacing the I I I R I I I R I I I R
spark plug
Inspecting the
1.31 suspension I I I I I I I I I I I I
system
Inspecting the
brake system
condition
(including pipe
line leakage,
mechanism
performance,
friction
condition of
brake pads or
brake shoes),
dust boot &n
rubber boot
condition
Inspecting the
dust boot & the
rubber boot
condition
(leakage &
damage) of the
Ver：LF-20121225
13,000k 18,000k 23,000k 28,000k 33 ,000k 38 ,000k 43 ,000k 48,000 53,000k 58,000k
Item
3Months 9Months
whole vehicle
Inspecting the
cooling system
1.34 & fuel system I I I I I I I I I I I I
(leakage &
damage)
Inspecting the
related control
units (ECU,
immobilizer
control unit,
A/C control
unit, TCU,
EPS,TCU,EPS,
ABS control
unit, etc.)
working
condition
Inspecting the
vehicle body
1.36 (dent, paint off, I I I I I I I I I I I I
discoloration,
etc. )
Inspecting the
lubrication of
the lock, hinge,
etc.
Road Test
1.3 Carrying out

T T T T T T T T T T T T
8 the road test
① Meaning of I, R, C in the table

I—check these items and accessories; correct, clean, adjust or replace them when necessary;
R—Replacement;
C=Cleaning;
Ver：LF-20121225
② Shorten the replacement cycle of engine oil and filter as necessary if driving in bad condition, for short
distance, at idle speed or in dust flying condition.
③ If you drive in dust flying condition, you must check the air cleaner component every 5,000 Km, and
clean or replace it if necessary;
④ If the vehicle is often drive in hills, hilly landform or used as a trailer, you should replace the brake or
clutch fluid every 20,000 km.
Part II
Engine Maintenance
Chapter I Mechanical Part
Section I Check and Adjustment of Carbon Monoxide Concentration
Tips: The check can only be used for emission regulation conformity at fixed idle speed.
1. Initial condition:
(a) Engine in normal work temperature.
(b) With air filter.
(c) Ready connection of all piles and houses of pipes and hoses.
(d) All auxiliary facilities in off condition.
(e) Correct connection of all vacuum line.
(f) Ready connection of wire connector of electronic fuel injection (EFI) system.
(g) Correct ignition time setting
(h) Transmission in natural position
(i) Air conditioner in off condition.
(j) Tachometer and carbon monoxide tester with manual alignment
2. Check and adjust carbon monoxide concentration of carbon monoxide of idle speed
Note: Carbon monoxide tester must be applied for idle speed gas mixture adjustment. Must not adjust idle
speed gas mixture without a carbon monoxide tester.
(a) Apply special service tool to connect the two terminals, TE1 and E1 of check connector. Refer to Fig.
2-1.
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Fig. 2-1
(b) Make engine speed to 2,500 rpm for about 3 minutes.
(c) Put tester probe into tailpipe for at least 40cm.
(d) 1 minute is needed for concentration stability before test, and test shall be finished within 3 minutes.
Refer to Fig. 2-2.
Fig. 2-2
Idle speed carbon monoxide concentration: 0.5%.
Failure searching
Table 2-1
Carbon
Phenomenon Cause
monoxide
1. Blockage of air filter
2. Failure of electronic fuel injection (EFI) system
Failure of fuel pressure regulator
Unstable idle speed
Failure of water temperature sensor
High (black smoke in
Failure of intake air temperature pressure sensor
exhaust)
Failure of electronic control unit (ECU)
Failure of fuel injection nozzle
Failure of throttle position sensor
Section II Compression Pressure Check

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Tips: For insufficient engine power, too much fuel consumption or bad fuel economical efficiency, cylinder
compression pressure shall be tested.
1. Preheat engine, then stop to preheat engine to normal work temperature
2. Disconnect joint of ignition coil
3. Dismantle high voltage wire from spark plug
Dismantle high voltage wire at rubber boot cap, do not pull wire. Refer to Fig. 2-3.
Fig. 2-3
Note: Pull or bent wire can damage the inner conductor.
4. Remove spark plug

Remove 4 spark plugs with spark plug socket and wrench.
5. Check cylinder compression pressure

(a) Put compression pressure gauge into spark plug opening. Refer to Fig. 2-4
Fig. 2-4
(b) Open throttle completely.
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(c) Test compression pressure when starting engine.
Tips: Must apply fully charged battery and make engine speed to over 250 rpm.
(d) Repeat from procedure (a) to (c) for every cylinder
Note: The test must be finished in time as short as possible.
Compression pressure: 1,100Kpa (11.0 kgf/cm2) or higher.
Minimum pressure: 981Kpa (10.0kgf/cm2).
Pressure difference between cylinders: 100Kpa (1.0kgf/cm2) or less.
(e) If one or more cylinders have relatively lower compression pressure, inject little engine to cylinder
through spark plug opening. Repeat from procedure (a) to (c) for cylinders with low compression pressure.
· If engine oil can improve compression pressure, it indicates wear or damage on piston ring and cylinder
wall.
· If compression pressure is still low, it could be the blockage or unsealed closeness of throttle, or gas
leakage at cylinder ring.
6. Reinstall spark plug

Install 4 spark plugs with spark plug socket and wrench
7. Reconnect high voltage wire to spark plug
8. Reconnect ignition coil joint
Section III Valve Clearance Check and Adjustment
Tips: Check and adjust valve clearance when engine is cold.
1. Dismantle high voltage wire from spark plug
2. Dismantle cylinder head

(a) Dismantle following wire and clip.
1) Engine connector
2) Engine wire
3) Oil pressure switch connector
4) Wire clip
(b) Dismantle wire harness from cylinder head. Refer to Fig. 2-5.
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Fig. 2-5
(c) Dismantle 2 positive crankcase ventilation (PCV) hoses from cylinder head.
(d) Dismantle 4 retaining nuts, gasket seal, cylinder head and washer.
3. Set No. 1 cylinder as the compression stroke top dead center (TDC)
(a) Turn crankshaft pulley, make the groove of crankshaft pulley aiming at the timing mark of No. 1 timing
belt housing.
(b) Check whether mark “K” of camshaft timing pulley is aiming at the timing mark of bearing cap. If not,
turn crankshaft a circle. Refer to Fig. 2-6.
Fig. 2-6
4. Check valve clearance

(a) Only check valves indicated in the figure. Refer to Fig. 2-7.
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Fig. 2-7
· Measure the clearance between valve tappet and camshaft by feeler gauge.
· Record valve clearance measuring structure with stipulation disconformity. All the data are used to
specify the filling piece needed in replacement.
Valve clearance (cold):
Intake air: 0.20-0.25mm
Exhaust: 0.25-0.30mm
(b) Turn crankshaft pulley a circle, make groove of crankshaft pulley aim at the timing mark of No. 1
timing belt housing.
(c) Only check valves indicated in the figure, measure valves (refer to method in procedure (a)). Refer to
Fig. 2-8.
Fig. 2-8
5. Intake air
Adjust valve clearance
A. Dismantle intake camshaft

Note: As the axial clearance of camshaft is very little, keep the horizontal status of camshaft when
dismantling it. If the horizontal status of camshaft can not be maintained, crack or damage might happen to
cylinder head part bearing axial thrust which can cause blockage or break of camshaft. To avoid these
situations, please take following procedures.
(a) Turn camshaft pulley, make pinion hole upwards (occlusion of pinion and drive gear and pinion). Refer
to Fig. 2-9.
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Fig. 2-9
Tips: Conditions above allow that No. 1 and No. 3 cylinder camshaft nose bits of intake camshaft to press
their valve tappets evenly.
(b) Dismantle 2 bolts and No. 1 bearing cap.
(c) Use 1 service bolt to fix intake camshaft pinions on drive and driven gears. Refer to Fig. 2-10.
Fig. 2-10
Recommended service bolt:

Thread diameter: 6mm
Thread pitch: 1.0mm
Bolt length: 16-20mm
Tips: When dismantling camshaft, make sure to eliminate twisting spring force of auxiliary gear through
above operations.
(d) Loose and dismantle 8 bearing cap bolts step by step according to order indicated in the figure. Refer to
Fig. 2-11.
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Fig. 2-11
(e) Dismantle 4 bearing cap and camshafts.

Tips: If camshaft is flat lifted, use 2 bolts to reinstall No. 3 bearing cap. Then lift crankshaft gear,
alternately loose and dismantle bearing cap bolts.
Note: Do not use tool or other object to lever or attach force to camshaft.
B. Take filling piece off

Use little screwdriver to adjustment filling piece.
C. Specify size of filling piece for replacement. Refer to Fig. 2-12.
Fig. 2-12
(a) Measure the thickness of filling piece taken off by micrometer screw gauge.
(b) Calculate thickness of new filling piece; make valve clearance within prescribed scope.
Cold clearance value: 0.20-0.25mm
(c) Choose new filling piece with possible thickness close to calculated valve.
Tips: There are filling pieces with 20 kinds of thickness. The size varies from 2.35mm to 3.30mm, with the
level difference of 0.05mm.
D. Install new filling piece.

Install new filling piece to valve tappet.
E. Install intake camshaft.

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Note: As the axial clearance of camshaft is very little, camshaft must be kept horizontal when being
installed. If the camshaft can not be kept horizontal, crack or damage might happen to cylinder head part
bearing axial thrust which can cause blockage or break of camshaft. To avoid these situations, install it with
following procedures.
(a) Turn crankshaft pulley, fix exhaust camshaft to make its alignment pin a little higher than the upper
surface of cylinder head.
(b) Coat lubricant grease on thrust part of camshaft.
(c) Aim at assembly mark of each gear to make occlusion of intake camshaft gear and exhaust camshaft
gear. Refer to Fig. 2-13.
Fig. 2-13
Note: As shown in Fig. 2-14, each gear has the timing mark (for TDC), do not use these marks.
Fig. 2-14
(d) Tighten intake camshaft to bearing pivot and make occlusion between gears.
Tips: Above angles allow No. 1 and No. 3 cylinder camshaft nose bits of intake camshaft to press their
valve tappets evenly.
(e) Install 4 bearing caps on their positions.
(f) Coat thin engine oil on F surface of bolt head and thread of bearing cap.
(g) Tighten 8 bearing cap bolts step by step with order indicated in Fig. 2-15.
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Torque: 11N·m
Fig. 2-15
(h) Dismantle service bolt.

(i) For No. 1 bearing cap installation, arrow mark toward forward.
Note: If the assembly of No. 1 bearing cap is not good, use screwdriver to lever and separate cylinder head
and camshaft gear, push camshaft gear backwards.
(j) Coat thin engine oil under bearing cap bolt head and on thread.
(k) Install 2 bearing cap bolts alternately step by step.
Torque: 11N·m
F. Recheck valve clearance
6. Exhaust:
Adjust valve clearance
A. Take filling piece off

(a) Turn crankshaft to make upwards the camshaft nose bits of camshaft on adjustment valve.
(b) Make valve tappet notch towards the front of vehicle. Refer to Fig. 2-16.
Fig. 2-16
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(c) Use special service tool (A) to press valve tappet down, and place special service tool (B) between
camshaft and valve tappet. Refer to Fig. 2-17. Dismantle special service tool (A).
Fig. 2-17
Tips:
· Apply service tool (B) in a little angle at the side with mark “9”. The position is shown in Fig. 2-18.
Fig. 2-18
· When special service tool (B) is inserted too deep, it may be blocked by filling piece. To avoid that, it
must be put in at the air intake side in a small angle.
· For the shape of camshaft, it is difficult to make special service tool (B) to reach the rear part of No. 3. It
is better to put filling piece in from the exhaust side.
(d) Use screwdriver and magnetic stick to dismantle filling piece. Refer to Fig. 2-19.
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Fig. 2-19
B. Confirm the size of replaced filling piece.

(a) Measure the thickness of taken off filling piece by using micrometer screw gauge.
(b) Calculate thickness of new filling piece; make valve clearance within prescribed value.
Cold exhaust valve clearance value: 0.25-0.30mm
(c) Choose new filling piece with thickness of most proximity to calculated valve. Fig. 2-20.
Fig. 2-20
Tips: There are filling pieces with 20 kinds of thickness. The size vary from 2.35mm to 3.30mm, with the
level difference of 0.05mm.
C. Install new filling piece.

(a) Install a new filling piece to valve tappet.
(b) Use special service tool (A), press down valve tappet, and then dismantle special service tool (B). Refer
to Fig. 2-17.
D. Recheck valve clearance.
7. Install cylinder head

(a) Remove all the old filling material.
(b) Coat cylinder head with sealing filler as shown in Fig. 2-21.
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Fig. 2-21
(c) Install gasket seal for cylinder cover.

(d) Use 4 gasket seals to successively tighten nuts to install cylinder head cover
Torque: 11N·m
(e) Connect 2 positive crankcase ventilation (PCV) hoses to cylinder head cover.
(f) Use 2 bolts to install engine wire harness and protective sleeve.
(g) Connect following wires and clips.
(1) Engine connector.
(2) Engine wire
(3) Oil pressure switch connector.
(4) 2 wire clips.
8. Connect high voltage wire to ignition plug again.
Section IV Idle Speed Check and Adjustment
1. Initial condition
(a) Engine in normal work temperature.
(b) With air filter.
(c) Ready connection of all piles and hoses of pipes and hoses.
(d) Correct connection of all vacuum line.
(e) Electronic fuel injection (Well connection of wire connector of electronic fuel injection (EFI) system).
(f) Turn off all working auxiliary facilities.
(g) Transmission in neutral position.
2. Connect tachometer
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3. Check idle speed
Idle speed (cooling fan off: 800±50rpm.If idle speed is not in conformity with prescribed value, check idle
speed control (ISC) system.
4. Remove tachometer
Section V Timing Belt Check and Adjustment
Breakdown drawing of timing belt part

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I. Remove
1. Remove AC-generator drive belt and water pump pulley

(a) Loosen 4 bolts of water pump pulley. Refer to Fig. 2-23.
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Fig. 2-23
(b) Loosen pivot bolt and adjust lock bolt.

(c) Loosen adjustment bolt and remove drive belt.
(d) Remove 4 bolts and water pump pulley. Refer to Fig. 2-24.
Fig. 2-24
3. Remove cylinder head cover

(a) Remove following wire and clop
1) AC-generator connector;
2) AC-generator wire;
3) Oil pressure switch connector;
4) Wire clip; refer to Fig. 2-25.
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Fig. 2-25
(b) Remove wire harness from cylinder head cover.

(c) Remove 2 PCV hoses from cylinder head cover.
(d) Remove 4 lock nuts, gasket seal, cylinder head cover and washer.
(a) Turn crankshaft pulley, make the groove of crankshaft pulley aim at the timing mark “O” of No. 1
timing belt housing. Refer to Fig. 2-26.
Fig. 2-26
(b) Check whether mark “K” of camshaft timing pulley is aiming at the timing mark of No. 2 bearing cap.
If not, turn crankshaft a circle (360°).
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Fig. 2-27
5. Remove crankshaft pulley

(a) Use special service tool to remove crankshaft pulley bolt. Refer to Fig. 2-28.
Fig. 2-28
(b) Use special service tool to remove belt pulley. Refer to Fig. 2-29.
Fig. 2-29
6. Remove timing belt housing

Remove 9 bolts and timing belt housing. Refer to Fig. 2-30.
Fig. 2-30
7. Remove timing belt guide wheel

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8. Remove timing belt

Tips: If timing belt will remain in working, mark a direction arrow on the belt; then marking matching
marks on belt pulley and belt as shown in the figure. Refer to Fig. 2-31.
Fig. 2-31
(a) Loosen install belts of belt tension wheel and push belt pulley towards left as much as possible; then fix
it temporarily.
(b) Remove belt.
9. Remove belt tension wheel and tension spring

Remove bolts, belt pulley and spring. Refer to Fig. 2-32.
Fig. 2-32
10. Remove crankshaft timing pulley

If belt pulley can not be taken off by hand, apply 2 screwdrivers. Refer to Fig. 2-33.
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Fig. 2-33
Note: Put a piece of cloth as shown in the figure to prevent part damage.
11. Remove crankshaft timing pulley stopper
12. Remove camshaft timing pulley

Use wrench to fix the hexagon part of the camshaft; remove bolt and timing belt pulley at the same time.
Refer to Fig. 2-34.
Fig. 2-34
Note: Do not damage cylinder head by wrench.
II. Check
1. Check timing belt

Note:
Do not bend, twist or turn over the timing belt.
Do not make timing belt contact with engine oil, water or steam.
Do not use the tension power of timing belt when removing or installing bolts of camshaft timing pulley.
For the flaw existence as shown in Fig. 2-35, check following items:
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Fig. 2-35
(a) Separate too early

Check if installation is correct. Check for the damage of timing cover bushing, and the correctness of
installation.
(b) If split or damage exists for belt dentations, check whether camshaft or pump is seized.
(c) If obvious abrasion or split exists on belt surface, check whether split exists on one side of the lock pin
of tension belt pulley.
(d) If abrasion or split only exists on one side, check the position of belt guide wheel and every belt pulley.
(e) If obvious abrasion exists for belt dentations, check for the damage of belt cover, correctness of washer
installation as well as the foreign material existence on belt pulley dentations. Replace timing belt when
necessary.
2. Check belt tension wheel

Check whether belt tension wheel can turn smoothly and flexibly. Refer to Fig. 2-36. Replace belt tension
wheel when necessary.
Fig. 2-36
3. Check tension spring

(a) Measure the free length of tension spring. Refer to Fig. 2-37.
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Fig. 2-37
Free length: 36.9mm
If free length is not in conformity with prescribed value, replace the tension spring.
(b) Measure the tension power of spring at prescribed installation length
Installation tension power: at length of 43.6mm, tension power is 34-38N.
If installation tension power is not in conformity with prescribed value, replace the tension spring
III. Installation
1. Install camshaft timing pulley

(a) Make camshaft alignment pin aim at alignment pin groove (with 2 alignment pin grooves) of the belt
pulley on the side with mark “K”, and slide to the timing belt pulley.
Fig. 2-38
Tips: There are two types of camshaft timing pulley, with 1 or 2 alignment pins respectively.
(b) Temporarily install bolts of timing belt pulley.
(c) Use wrench to fix the hexagon part of camshaft, and screw down bolts of timing belt pulley.
Torque: 59±2N·m
2. Install crankshaft timing pulley and stopper

(a) Install timing belt pulley stopper, alignment pin aiming at key groove, with conicity towards outside.
(b) Make belt positioning key aim at belt pulley key groove.
(c) Slide into timing belt pulley, with flange side towards inside. Refer to Fig. 2-39.
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Fig. 2-39
3. Temporarily install belt tension wheel and tension spring
(a) Use bolt install belt tension wheel, but not tighten it.
(b) Install tension spring.
(c) Push belt pulley to left as much as possible, then screw down bolts tightly. Refer to Fig. 2-40.
Fig. 2-40
(a) Turn the hexagon part of camshaft, and make mark “K” of camshaft timing pulley aim at the timing
mark of bearing cap. Refer to Fig. 2-41.
Fig. 2-41
(b) Turn crankshaft with crankshaft pulley bolt, and make the timing mark of crankshaft timing pulley aim
at oil pump body. Refer to Fig. 2-42.
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Fig. 2-42
5. Install timing belt
Note: Engine in cold condition.
Tips: If use removed timing belt, keep marks made in remove with correct alignment; when installing belt,
arrow shall aim at the running direction of engine. Refer to Fig. 2-43. For timing belt installation, check the
tension power between crankshaft timing pulley and camshaft timing pulley.
Fig. 2-43
6. Check valve timing
(a) Loosen belt tension wheel bolts.
(b) Turn crankshaft for 2 circles slowly, from TDC to TDC. Refer to Fig. 2-44.
Fig. 2-44
Tips: Must turn crankshaft in clockwise direction.
(c) Check whether every belt pulley is aiming at timing mark as shown in the figure. If not, remove timing
belt and install it again. Refer to Fig. 2-45.
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Fig. 2-45
(d) Screw down belt tension wheel bolt.
Torque: 33N·m
(e) Remove the temporarily installed crankshaft pulley bolt.
7. Reference:
Check timing belt flexivity.
Check whether a certain flexivity exists at the position shown in Fig. 2-46.
Fig. 2-46
Belt flexivity:
5-6mm at 20N
If flexivity is not in conformity with prescribed value, adjust belt tension wheel again. Refer to Fig. 2-47.
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Fig. 2-47
8. Install timing belt guide wheel
Install timing belt guide wheel and make outer ring towards outside. Refer to Fig. 2-48.
Fig. 2-48
9. Install timing belt housing

(a) Use 3 bolts to install No. 1 timing belt housing
Torque: 11N·m
(b) Use 6 bolts to install No.2 and No. 3 timing belt housing.
Torque: 11N·m
10. Install crankshaft pulley

(a) Make belt pulley positioning key aim at the key groove of belt pulley; smoothly push it into belt pulley.
(b) Apply special service tool to install belt pulley bolts. Refer to Fig. 2-49.
Torque: 120N·m
图2-49
Fig. 2-49
11. Install cylinder head cover

(a) Clear old filling material.
(b) Coat cylinder head with sealing filler as shown in Fig. 2-50.
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Fig. 2-50
(c) Install washer for cylinder head cover.

(d) Apply 4 gasket seals and lock nut to install cylinder head cover.
Torque: 11N·m
(e) Connect to 2 positive crankcase ventilation (PCV) hoses to cylinder head cover.
(f) Connect following wires and clips:
1) AC-generator connector
2) AC-generator wires
4) 2 wire clips
12. Install spark plug
13. Install water pump pulley and driving belt of AC-generator

(a) Use 4 bolts to install water pump pulley temporarily
(b) Use adjustment bolt and pivot bolt to install driving belt.
(c) Screw down 4 water pump pulley bolts tightly.
14. Adjust driving belt
Section VI Cylinder Head
The breakdown drawing of cylinder head parts are shown in Fig. 2-51.
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Fig. 2-51
I. Remove
1. Discharge engine coolant

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2. Remove the driving belt of AC-generator and water pump pulley
3. Remove engine wire harness. Refer to Fig. 2-52.
Fig. 2-52
(a) Remove following wire harness and clip:

1) AC-generator connector;
2) AC-generator wire:
3) Oil pressure switch connector;
4) Wire clip;
(b) Remove bolts and wire harness bracket.
(c) Remove engine wire harness from cylinder head.
4. Remove AC-generator
5. Remove exhaust manifold. Refer to Fig. 2-53.
Fig. 2-53
(a) Remove 4 bolts and upper heat shield.

(b) Remove 2 bolts and exhaust manifold support bar.
(c) Remove 5 bolts, exhaust manifold and washer.
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(d) Remove 2 bolts and take lower heat shield off from exhaust manifold.
6. Remove outlet pipe. Remove 2 bolts and outlet pipe as shown in Fig. 2-54.
Fig. 2-54
7. Remove ignition coil mounting
8. Remove right engine suspension bracket
9. Remove intake pipe and thermostat seat

(a) Remove water temperature sensor connector.
(b) Remove 2 coolant bypass hoses.
(c) Remove bolts, 2 nuts, intake pipe and thermostat seat
10. Remove throttle valve body
11. Remove intake manifold support bar

Remove 2 bolts and intake manifold support bar.
12. Remove coolant bypass hose
13. Remove engine wire harness

Remove 2 nuts, and remove engine wire harness.
14. Remove fuel distribution pipe and injection nozzle
15. Remove fuel intake hose from fuel distribution pipe
16. Remove intake manifold. Refer to Fig. 2-55.

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Fig. 2-55
Remove 7 bolts, 2 nuts, earth wire blade, intake manifold and washer.
17. Remove oil level indicator and guide pipe

(a) Remove fastening bolt
(b) Take out oil level indicator and guide pipe.
(c) Remove the O ring of oil level indicator guide pipe
18. Remove intake pipe of water pump. Refer to Fig. 2-56
Fig. 2-56
(a) Remove 2 nuts fixing intake pipe of water pump on cylinder head.
(b) Disconnect intake hose and water pump; remove intake pipe of water pump and the washer.
20. Remove cylinder head housing

Remove 4 fastening nut, bowl type washer, cylinder head cover and sealant pad.
21. Remove No. 3 and No. 2 timing belt housing

Remove 5 bolts and timing belt housing.
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(a) Turn crankshaft pulley, make the groove of crankshaft pulley aiming at the timing mark “O” of No. 1
timing belt housing.
(b) Check whether mark “K” of camshaft timing pulley is aiming at the timing mark of bearing cap. Refer
to Fig. 2-57.
Fig. 2-57
If not, turn crankshaft a circle (360°).
23. Remove timing belt from camshaft timing pulley

(a) Make matching marks on camshaft pulley and timing belt with matching mark of timing belt aiming at
the end of timing belt housing. Refer to Fig. 2-58.
Fig. 2-58
(b) Remove rubber seal ring from No.1 timing belt housing. Refer to Fig. 2-59.
Fig. 2-59
(c) Loosen fix bolts of belt tension wheel and push to left as much as possible, then fix it temporarily.
(d) Remove belt from camshaft timing belt.
Note:
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Support timing belt, make crankshaft timing pulley match with timing belt and do not move.
Be cautious and keep anything from falling into No. 1 timing belt housing.
Do not make belt contact with oil, water or dust.
24. Remove generator engine mounting

Remove 3 bolts and generator mounting. Refer to Fig. 2-60.
Fig. 2-60
25. Remove camshaft timing belt wheel
Use wrench to fix hexagon part of the camshaft and remove bolts and timing belt wheel. Refer to Fig. 2-61.
Fig. 2-61
Note: Be carefully and do not damage cylinder head with wrench.
26. Remove camshaft

Note: The axial clearance of camshaft is very small. When removing camshaft, it must be kept level. If not,
the cylinder head part with axial thrust might crack or be damaged and make camshaft be blocked or
broken.
To avoid this situation, please follow the steps.
A. Remove intake camshaft

(a) Turn camshaft, make the hole of auxiliary gear turn to the upper side (it makes auxiliary gear occlude
with drive gear). Refer to Fig. 2-62.
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Fig. 2-62
Tips: For above situations, No.1 and No.3 cylinder camshaft nose bits are allowed to press their valve
tappets evenly.(b) Remove 2 bolts and No.1 bearing cap. Refer to Fig. 2-63.
Fig. 2-63
(c) Use a service bolt to make the auxiliary gear of intake camshaft back against the drive gear. Refer to Fig.
2-64.
Fig. 2-64
Recommended service bolt:

Thread diameter: 6mm
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Thread pitch: 1.0mm
Bolt length: 16-20mm
Tips: When removing camshaft, make sure the spring twisting resistance of auxiliary gear is offset by
above operation.
(d) Following order indicated in Fig. 2-65, evenly loosen and remove 8 bearing cap bolts in several times.
Fig. 2-65
(e) Remove 4 bearing caps and intake camshaft. Refer to Fig. 2-66.
Fig. 2-66
Tips: If camshaft is not lifted levelly in straight direction, use 2 bolts to reinstall bearing cap. Then lift
camshaft gear and alternately loosen and remove bearing cap bolts.
Note: Do not use tool or other things to move or try to take camshaft off by great force.
B. Remove exhaust camshaft

(a) Place exhaust camshaft and make its alignment pin position at the 1 o’clock of anticlockwise camshaft
vertical axis. Refer to Fig. 2-67.
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Fig. 2-67
Tips: For above angle, No. 1 and No. 3 cylinder camshaft nose bits of intake camshaft to press their valve
tappets evenly.
(b) Remove 2 bolts, No.1 bearing cap and oil seal. Refer to Fig. 2-68.
Fig. 2-68
Note: If No.1 bearing cap can not be removed by hand, do not remove by force, but leave it there without
bolt.
(c) According to order indicated in Fig. 2-69, evenly loosen and remove 8 bearing cap bolts in several
times.
Fig. 2-69
(d) Remove 4 bearing caps and exhaust camshafts. Refer to Fig. 2-70.
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Fig. 2-70
Tips: If camshaft is not lifted at level and in straight direction, use 2 bolts to reinstall No. 3 bearing cap.
Then loosen and remove 2 bearing cap bolts when lifting camshaft gear.
Note: Do not use tool or other things to move or try to remove camshaft by force.
27. Remove intake air camshaft

(a) Hold the hexagon part of camshaft on the bench clamp.
Note: Do not damage camshaft.
(b) Use service tool turn auxiliary gear clockwise and remove service bolt. Refer to Fig. 2-71.
Fig. 2-71
(c) Take snap ring off by snap ring plier. Refer to Fig. 2-72.
Fig. 2-72
(d) Remove following parts:

1) Wave washer
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2) Camshaft auxiliary gear;
3) Camshaft backlash spring
28. Remove semicircular plug
29. Remove cylinder head

(a) Use special service tool to evenly loosen and remove 10 cylinder head bolts in several times with order
indicated in Fig. 2-73.
Fig. 2-73
Note: Incorrect order of bolt removing can cause twisting or fracture of cylinder head.
(b) Remove 10 plate washers.
(c) Lift cylinder head from the cylinder alignment pin; put cylinder head on the wood block of the
workbench.
Tips: If cylinder head is hard to lift, a screwdriver can be applied to prize between cylinder head and
cylinder lug boss.
Note: Please be careful. Do not damage the contact surface between cylinder head and cylinder body.
II. Remove
1. Remove valve tappet
Tips: Should place valve tappets in correct order.
2. Remove valve
(a) Use special service tool, compress valve spring and remove 2 alignment lock blades. Refer to Fig. 2-74.
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Fig. 2-74
(b) Remove following parts:

Spring seat, valve spring, valve.
(c) Use needle nose pliers to take out valve oil seal. Refer to Fig. 2-75.
Fig. 2-75
(d) Use compressed air and magnetic stick to blow removed spring seat. Refer to Fig. 2-76.
Fig. 2-76
Tips: Place valve, valve spring, spring seat and spring pedestal in correct order.
Ver：LF-20121225
III. Check
1. Clean piston top and cylinder body
(a) Turn crankshaft and make each piston rise to top dead center (TDC). Use bushing scraper to clear all
carbon deposit on piston top. Refer to Fig. 2-77.
Fig. 2-77
(b) Use bushing scraper to eliminate all bushing materials on cylinder surface.
(c) Use compressed air to blow carbon deposit and engine oil in bolt hole. Refer to Fig. 2-78.
Fig. 2-78
Caution: Please protect your eyes when using high pressure compressed air.
2. Clean cylinder head
A. Clear bushing material

Use bushing scraper to clear all bushing materials on contact surface of cylinder body. Refer to Fig. 2-79.
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Fig. 2-79
Note: Please be careful. Do not scratch contact surface of cylinder body.
B. Clean and wash combustion chamber

Use wire brush to clean all carbon deposit in combustion chamber. Refer to Fig. 2-80.
Fig. 2-80
Note: Please be careful. Do not scratch contact surface of cylinder body.
C. Clean valve guide bushing

Use valve guide bushing brush and solvent to clear clean and wash all guide bushings. Refer to Fig. 2-81.
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Fig. 2-81
D. Clean cylinder head

Use soft brush and solvent to clean and wash cylinder head thoroughly. Refer to Fig. 2-82.
Fig. 2-82
3. Check cylinder head

A. Check flatness
Use precise ruler and feeler gauge to measure whether twisting exists on the contact surface between
cylinder body and manifold. Refer to Fig. 2-83.
Fig. 2-83
Maximum twisting:
Cylinder body side: 0.05mm
Manifold side: 0.10mm
If twisting exceeds maximum twisting value, cylinder head should be replaced.
B. Check for crack existence

Use dye penetrant to check whether crack exists for combustion chamber, air inlet, air outlet and cylinder
body surface. Refer to Fig. 2-84.
Ver：LF-20121225
Fig. 2-84
If crack exists, cylinder head should be replaced.
4. Clean valve
(a) Use bushing scraper to clean carbon deposit on valve end.
(b) Use wire brush to clean valve thoroughly. Refer to Fig. 2-85.
Fig. 2-85
5. Check valve tappet and guide bushing

(a) Use caliber gauge to measure inside diameter of guide bushing. Refer to Fig. 2-86.
Fig. 2-86
Bushing inside diameter: 6.010-6.030mm
(b) Use micrometer screw gauge to measure diameter of valve tappet. Refer to Fig. 2-87.
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Fig. 2-87
Valve tappet diameter:

Intake: 5.970-5.985mm
(c) Measured value of guide bushing inside diameter minus measured value of valve tappet diameter
Standard oil clearance:
Intake: 0.025-0.060mm
Maximum oil clearance:
Intake: 0.08mm
Exhaust: 0.10mm
If clearance exceeds maximum value, valve and guide bushing should be replaced.
6. Check and grind valve. Refer to Fig. 2-88.
Fig. 2-88
(a) Grind valve until pockmarks and carbon deposit are all eliminated.
(b) Check whether valve grinding is with correct face angle.
Valve face angle: 44.5°.

(c) Check the edge thickness of valve head. Refer to Fig. 2-89.
Ver：LF-20121225
Fig. 2-89
Standard edge thickness: 0.8-1.2mm

Minimum edge thickness: 0.5mm
If edge thickness is less than minimum value, valve should be replaced.
(d) Check the overall length of valve. Refer to Fig. 2-90.
Fig. 2-90
Standard overall length:

Intake: 87.5mm
Exhaust: 87.8mm
Minimum overall length:
Intake: 86.35mm
Exhaust: 87.65mm
If overall length is less than minimum value, valve should be replaced.
(e) Check wearing condition and damage of valve tappet end surface.
For wearing valve tappet end, apply grinding wheel to grind the end or replace valve. Refer to Fig. 2-91.
Ver：LF-20121225
Fig. 2-91
Note: Do not grind to a valve less than minimum value.
7. Check and wash valve seat

(a) Use 45° carbonide ceramic cutting tool to polish valve seat again. Clear appropriate metal to clear valve
seat. Refer to Fig. 2-92.
Fig. 2-92
(b) Check valve seat position

Coat valve surface with a thin layer of Prussia blue (or white lead), slightly press valve to valve seat and do
not turn valve.
(c) Check following items of valve surface and valve seat:
If blue paint of valve surface is 360° around the valve center, the valve is coaxial. Otherwise, valve should
be replaced.
If blue paint of valve seat is 360° around valve center, guide pipe is coaxial with surface. Otherwise, valve
should be replaced.
Check whether the seat contact surface is at the center of valve surface; the width is: 1.0-1.4mm. Refer to
Fig. 2-93.
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Fig. 2-93
Otherwise, valve pedestal ring shall be modified with following method:

1) If pedestal is too high away from valve surface, modify pedestal ring with 30° and 45° cutting tools.
Refer to Fig. 2-94.
Fig. 2-94
2) If pedestal is too close to valve surface, modify pedestal with 60° and 45° cutting tools. Refer to Fig.
2-95.
Fig. 2-95
(d) Use grinding material to grind valve and valve pedestal by hand.
(e) After hand grinding, clear valve and valve pedestal.
8. Check valve spring

(a) Use iron bevel protractor to measure perpendicularity of valve spring. Refer to Fig. 2-96.
Ver：LF-20121225
Fig. 2-96
If the deviation is more than maximum value, valve spring should be replaced.
(b) Use vernier caliper to the free length of valve spring. Free length: 38.57mm. Refer to Fig. 2-98.
Fig. 2-97 Fig. 2-98

If free length is not in conformity with prescribed valve, valve spring should be replaced.
(c) Use spring tester to measure the stretching force of valve spring at prescribed installation length.
Installation stretching force (length of 31.7mm): 152-168N. Refer to Fig. 2-99.
Fig. 2-99
If installation stretching force is not in conformity with prescribed value, valve spring should be replaced.
9. Check camshaft and bearing
A. Check radial runout of camshaft

(a) Place camshaft on V-block.
(b) Use dial indicator gauge to measure circular runout at bearing journal. Refer to Fig. 2-100.
Ver：LF-20121225
Fig. 2-100
Maximum circular runout: 0.03mm

If circular runout exceeds the maximum value, camshaft should be replaced.
B Check camshaft nose bit

Use micrometer screw gauge to measure the height of camshaft nose bit. Refer to 2-101.
Fig. 2-101
Standard camshaft nose bit height:
Intake: 41.76±0.05mm
Exhaust: 42.01±0.05mm
If camshaft nose bit height is not in conformity with prescribed valve, camshaft should be replaced.
C Check camshaft bearing journal

Use micrometer screw gauge to measure the diameter of bearing journal. Refer to Fig. 2-102.
Ver：LF-20121225
Fig. 2-102
Bearing journal diameter:

No.1 exhaust: 24.949-24.965mm
Other: 22.949-22.965mm
If bearing journal is not in conformity with prescribed valve, oil clearance should be checked.
D. Check camshaft bearing

Check whether bearing is spalt or burned. If bearing is damaged, replace the entire set of bearing cap and
cylinder head. Refer to Fig. 2-103.
Fig. 2-103
E. Check camshaft backlash spring

Use vernier caliper measure the free distance between the two ends of spring. Refer to Fig. 2-104.
Fig. 2-104
Free distance: 17.0-17.6mm

If free distance is not in conformity with prescribed valve, replace backlash spring.
F. Check oil clearance of camshaft bearing journal

(a) Clean bearing cap and camshaft bearing journal
(b) Place camshaft on cylinder head.
(c) Place 1 plastic feeler gauge on each camshaft bearing journal. Refer to Fig. 2-105.
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Fig. 2-105
(d) Install bearing cap. Refer to Fig. 2-106
Fig. 2-106
Torque: 11N·m
Note: Do not turn camshaft.
(e) Remove bearing cap.

(f) Use plastic clearance gauge to measure clearance at the widest part. Refer to Fig. 2-107.
Ver：LF-20121225
Fig. 2-107
Standard oil clearance: 0.035-0.072mm

Maximum oil clearance: 0.10mm
If oil clearance exceeds maximum value, camshaft should be replaced. When necessary, the entire set of
bearing cap and cylinder head can be replaced.
(g) Completely remove all plastic feeler gauges.
G. Check camshaft axial clearance

(a) Install camshaft
(b) Use dial indicator gauge to measure axial clearance when moving camshaft forward and backward.
Refer to Fig. 2-108.
Fig. 2-108
Standard axial clearance:

Intake: 0.030-0.085mm
Maximum axial clearance: 0.11mm
If axial clearance exceeds maximum value, camshaft should be replaced. When necessary, bearing cap and
cylinder head can be replaced.
H. Check camshaft gear clearance

(a) Install camshaft, but not install exhaust camshaft auxiliary gear
(b) Use dial indicator gauge to measure gear clearance. Refer to Fig. 2-109.
Ver：LF-20121225
Fig. 2-109
Standard gear clearance: 0.020-0.200mm

Maximum gear clearance: 0.30mm
If gear clearance exceeds maximum value, camshaft should be replaced.
10. Check valve tappet and tappet pore diameter

(a) Use caliper gauge to measure cylinder head tappet pore diameter. Refer to Fig. 2-110.
Fig. 2-110
Tappet pore diameter: 31.000-31.025mm

(b) Use micrometer screw gauge to measure tappet diameter. Refer to Fig. 2-111.
Fig. 2-111
Tappet diameter: 30.966-30.976mm
(c) Measured tappet pore diameter minus measured tappet diameter

Standard oil clearance: 0.024-0.059mm
If oil clearance exceeds maximum value, tappet should be replaced .When necessary, cylinder head can be
replaced.
11. Check intake manifold and exhaust manifold

Use precise ruler and finger gauge to measure for the twisting of cylinder head contact surface. Refer to Fig.
2-112.
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Fig. 2-112
Maximum twisting
Intake manifold: 0.20mm
Exhaust manifold: 0.30mm
If twisting value exceeds maximum value, manifold should be replaced.
12. Check cylinder head bolt

Standard external diameter: 8.5mm
Minimum external diameter: 8.3mm
If external diameter is less than minimum value, bolt should be replaced. Refer to Fig. 2-113.
Fig. 2-113
IV. Replace
1. Replace valve guide bushing

(a) Gradually heat cylinder head to 80-100℃. Refer to Fig. 2-114.
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Fig. 2-114
(b) Use special service tool and hummer to knock out guide bushing slightly. Refer to Fig. 2-115.
Fig. 2-115
(c) Use caliper gauge to measure cylinder head bushing internal diameter. Refer to Fig. 2-116.
Fig. 2-116
Standard valve guide pore diameter (cold):
11.000-11.027mm
(d) Select new guide bushing (standard value or with enlarged size of 0.05)
If cylinder head bushing internal diameter exceeds 11.027mm, process bushing internal diameter to
following size:
11.050-11.077mm
If bushing internal diameter of cylinder head exceeds 11.077mm, cylinder head should be replaced.
Ver：LF-20121225
(e) Gradually heat cylinder head to 80-100℃.
(f) Use special service tool and hummer to knock new guide bushing until it stretches 12.7-13.1mm out of
cylinder head. Refer to Fig. 2-118.
Fib. 2-118
(g) Use sharp 6mm reamer to cut guide bushing to make the clearance between guiding bushing and valve
tappet meet the prescribed clearance value (please refer above step c). Refer to Fig. 2-119.
Fig. 2-119
2. Replace cylinder head oil seal
(a) Upwards bend little tongue piece of wind screen; the little tongue piece is to prevent oil seal sliding.
(b) Take oil seal by screwdriver. Refer to Fig. 2-120.

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Fig. 2-120
(c) Use special service tool and hummer to knock new oil seal as shown in Fig. 2-121.
Fig. 2-121
(d) Coat a thin layer of multipurpose grease on washer edge.

(e) Place tongue piece of wind screen to its original position.
V. Reassembly
Tips:
Clean and wash all parts thoroughly; all the parts are prepared for installation.
Before part installation, coat new engine oil on all sliding and turning surfaces.
Replace all washers and oil seals with new ones.
1. Install spark plug pipe

Tips: When using new cylinder head, spark plug pipe must be installed.
(a) The standard position of spark plug mark to the edge. Refer to Fig. 2-122.
Fig. 2-122
Standard stretching length: 46.8-47.6mm

(b) Coat adhesive in spark plug pore of cylinder head. Refer to Fig. 2-123.
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Fig. 2-123
(c) Use punch to press in new spark plug pipe until it stretches 46.8-47.6mm out of installation platform of
cylinder head camshaft bearing cap. Refer to Fig. 2-124.
Fig. 2-124
Note: Measure stretching length when pressing to avoid too much stretching length of new spark plug pipe.
2. Install valve
(a) Use special service tool to press in new valve oil seal. Refer to 2-125.
Fig. 2-125
Note: Intake valve oil seal is gray while exhaust valve oil seal is black. Refer to Fig. 2-126.
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Fig. 2-126
(b) Install following parts. Refer to Fig. 2-127.
Fig. 2-127
1) Valve
2) Spring pedestal
3) Valve spring
4) Spring seat
(c) Use special service tool to compress valve spring, place 2 lock blades around valve tappet. Refer to Fig.
2-128.
Fig. 2-128
(d) Use plastics-coated hummer to knock the valve rod top slightly to make sure the perfect matching.
Ver：LF-20121225
Fig. 2-129
3. Install valve tappet and filling piece

(a) Install valve tappet and filling piece.
(b) Check valve tappet by hand. Valve tappet shall be able to be moved freely.
VI. Installation

A. Place cylinder head on cylinder body
(a) Place new cylinder head bushing on cylinder body well.
Note: Pay attention to the installation direction. Place the surface with mark (character) upwards. Refer to
Fig. 2-130.
Fig. 2-130
(b) Place cylinder head on cylinder head bushing.
B. Install cylinder head bolt

Tips:
Bolts with crack or deformation shall not be applied.
(a) A thin layer of engine oil should be coated on thread and under the cylinder head bolt head.
(b) Use special service tool install and evenly screw down 10 cylinder head bolts in several times with the
order indicated in Fig. 2-131.
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Fig. 2-131
Torque: 90N·m. Refer to Fig. 2-132.
Fig. 2-132
If any bolt is not in conformity with torque specification, it should be replaced.

Tips: For cylinder head bolts with length of 90mm and 108mm, the 90mm bolt (B) should be installed to
the side of intake manifold while 108mm (A) bolt should be installed to the side of exhaust manifold.
2. Assemble intake camshaft

(a) Hold the hexagon part of camshaft on the bench clamp.
Note: Be careful and do not damage camshaft.
(b) Install following parts: Refer to Fig. 2-133.
Ver：LF-20121225
Fig. 2-133
1) Camshaft gear snap spring
2) Camshaft auxiliary gear
3) Wave washer
Note: Make pin on gear aim at the end of gear snap spring.
(c) Use snap ring plier to install snap ring. Refer to Fig. 2-134.
Fig. 2-134
(d) Use special service tool to turn camshaft auxiliary gear in clockwise direction, make camshaft drive
gear aim at the pore of auxiliary gear and install service bolts. Refer to Fig. 2-135.
Ver：LF-20121225
Fig. 2-135
3. Install intake and exhaust camshafts

Note: For the small axial clearance of camshaft, keep the horizontal status of camshaft when installing it. If
not, If the horizontal status of camshaft can not be maintained, crack or damage might happen to cylinder
head part bearing axial thrust which can cause blockage or break of camshaft. To avoid these situations,
please take following procedures.
A. Install exhaust camshaft

(a) Coat thrust part of camshaft with multipurpose grease.
(b) Place exhaust camshaft and make alignment pin at the position that is at a certain angle in anticlockwise
direction to vertical axis of camshaft. Refer to Fig. 2-136.
Fig. 2-136
Tips: Above angles make the nose bits of No. 1 and No. 3 cylinders of exhaust camshaft evenly press valve
tappet.
(c) Eliminate all old filling materials.
(d) As shown in Fig. 2-137, coat sealing filler on bearing cap.
Fig. 2-137
Ver：LF-20121225
Fig. 2-138
(e) Install 5 bearing caps at proper positions.

(f) A thin layer of engine oil should be coated on thread and under the bearing cap bolt head.
(g) Evenly screw down 10 bearing cap bolts in several times with the order shown in Fig. 2-139.
Fig. 2-139
Torque: 13N·m
(h) Coat multipurpose grease to new oil seal edge.
(i) Use special service tool to knock oil seal slightly. Refer to Fig. 2-140.
Fig. 2-140
Note:
Ver：LF-20121225
· Do not make mistake on edge direction when installing oil seal.
· Put oil seal to the deepest part of cylinder cap.
B. Install intake camshaft

(a) Place exhaust camshaft and make alignment pin a little higher than the cylinder head top. Refer to Fig.
2-141.
Fig. 2-141
(b) Coat lubricant grease on thrust part of camshaft.

(c) Match installation mark of each gear, to make intake camshaft gear occlude with exhaust camshaft gear.
Fig. 2-142
Note: As shown in the figure, each gear also has timing mark (for TDC). Do not use these marks.
(d) For mutual occlusion of gear, make intake camshaft locate on the bearing journal.
Note: Above angles allow No. 1 and No. 3 cylinder camshaft nose bits of intake camshaft to press their
valve tappets evenly
(e) Install 4 bearing caps at proper positions. Refer to Fig. 2-143.
Ver：LF-20121225
Fig. 2-143
(f) A thin layer of engine oil should be coated on thread and under the bearing cap bolt head.
(g) Evenly install and screw down 8 bearing cap bolts in several times with order indicated in Fig. 2-144.
Torque: 11N·m
Fig. 2-144
(h) Remove service bolts.

(i) With arrow mark toward forward, install No. 1 bearing cap. Refer to Fig. 2-145.
Fig. 2-145
Note: If No. 1 bearing cap can not match perfectly, use screwdriver to move and separate cylinder head and
camshaft gear; then push camshaft gear backwards.
(j) A thin layer of engine oil should be coated on thread and under the bearing cap bolt head.
(k) Install and alternately screw down 2 bolts in several steps. Torque: 11N·m
Ver：LF-20121225
(l) Turn exhaust camshaft in clockwise direction and make alignment pin face upwards. Refer to Fig.
2-146.
Fig. 2-146
(m) Check for the correct alignment of timing mark of camshaft gear.
Tips: Installation mark is at upper part. Refer to Fig. 2-147.
Fig. 2-147
4. Check and adjust valve clearance

Turn camshaft; make camshaft nose bit towards upwards; check and adjust valve clearance.
Valve clearance (cold): Intake: 0.20~0.25mm, exhaust: 0.30-0.35mm
5. Install camshaft timing pulley

(a) Make camshaft alignment pin aim at the alignment pin groove (with 2 alignment pin grooves) on the
side of belt pulley with mark “K”, slide it to timing belt pulley. Refer to Fig. 2-148.
Fig. 2-148
Ver：LF-20121225
(b) Temporarily install timing belt pulley bolt.
(c) Use wrench to fix the hexagon head part of camshaft and screw down timing belt pulley bolt.
Torque: 59N·m
6. Install AC-generator mounting

Use 3 bolts to install AC-generator mounting. Refer to Fig. 2-149.
Fig. 2-149
Torque: 23N·m

Tips:
Check whether matching mark of timing belt is aiming at the end of timing belt housing mark. If not, move
the occlusion part of timing belt pulley to meet correct alignment. Refer to Fig. 2-150.
Fig. 2-150
Aim at the match marks of timing belt and camshaft timing pulley.
(a) Clean oil or water of camshaft timing pulley and keep clean.
(b) Install timing belt, check the tension force between crankshaft timing pulley and camshaft timing
pulley.
8. Check valve timing

(a) Loosen belt tension wheel bolts. Refer to Fig. 2-151.
Ver：LF-20121225
Fig. 2-151
(b) Slowly turn crankshaft for 2 circles, from TDC to TDC.

Note: Do turn crankshaft clockwise.
(c) Check whether each belt pulley is aiming at timing mark as shown in the figure. If not, timing belt
should be removed and reinstalled. Refer to Fig. 2-152.
Fig. 2-152
(d) Screw down belt tension wheel bolt. Torque: 33N·m
(e) Install rubber seal ring for No. 1 timing belt housing.
9. Reference:
Check timing belt flexivity
Check belt fexivity of position shown in Fig. 2-153.
Fig. 2-153
Flexivity: 20N: 5-6mm. If flexivity is not in conformity with prescribed value, readjust belt tension wheel.
Ver：LF-20121225
10. Install No. 2 and No. 3 timing belt housing

Use 6 bolts to install No. 2 and No. 3 timing belt housing. Refer to Fig. 2-154 and Fig. 2-155.
Fig. 2-154 Fig. 2-155

Torque: 11N·m
11. Install semicircular plug

(a) Eliminate all old filling material.
(b) Coat sealing filler on semicircular plug. Refer to Fig. 2-156.
Fig. 2-156
(c) Install semicircular plug on cylinder head.

(a) Eliminate old filling material.
(b) Coat sealing filler on cylinder head as shown in Fig. 2-157.
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Fig. 2-157
(c) Install cylinder head gasket seal on cylinder head cover.
(d) Use 4 wave seal ring and lock nut to install cylinder head cover.
Torque: 11N·m
13. Install spark plug
14. Install water pump intake pipe

(a) Place a new washer on cylinder head, with projecting part toward upward. Refer to Fig. 2-158.
Fig. 2-158
(b) Connect water pump intake pipe to water pump.

(c) Use 2 nuts to install water pump intake pipe. Torque: 23N·m
15. Install oil level indicator and guide pipe

(a) Install new O ring to oil level indicator guide pipe.
(b) Coat soap water to O ring.
(c) Push in oil level indicator and guide pipe and fixed them with bolts. Refer to Fig. 2-159.
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Fig. 2-159
Torque: 11N·m
16. Install intake manifold

Use 7 bolts, 2 nuts to install new washer and intake manifold. Evenly screw down bolts and nuts in several
times.
Torque: 23N·m
17. Install fuel injection nozzle and fuel distribution pipe
18. Connect fuel hose to transmission pipe

Torque: 29N·m
19. Connect engine wire harness

Use 2 nuts to fix engine wire harness.
20. Install coolant bypass hose

Use 2 nuts to connect water bypass hose and fuel return hose to intake manifold. Refer to Fig. 2-160.
Fig. 2-160
Torque: 11N·m
21. Install intake manifold support bar

Ver：LF-20121225
Use 2 bolts to install intake manifold support bar
Torque:
Bolt with 12mm head: 23N·m
Bolt with 14mm head: 44N·m
22. Install throttle valve body
23. Install intake pipe and thermostat seat

(a) Use bolt and 2 nuts to install intake pipe, thermostat seat and gasket seal. Torque: 23N·m
(b) Connect 2 water bypass hoses.
24. Install right engine suspension bracket

Use bolt to install right engine suspension bracket. Torque: 48±1N·m
25. Install ignition coil mounting

Use bolt to install ignition coil mounting
26. Install outlet pipe

Use 2 bolts to install water outlet. Refer to Fig. 2-161.
Fig. 2-161
Torque: 23N·m
27. Install exhaust manifold

(a) Use 2 bolts to install lower heat shield to exhaust manifold.
Torque: 11N·m
(b) Use 5 bolts to install new washer and exhaust manifold. Evenly screw down nut in several times. Refer
to Fig. 2-162.
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Fig. 2-162
Torque: 33N·m
(c) Use 2 bolts to install manifold support bar and alternately tighten bolts.
Torque: 23N·m
(d) Use 4 bolts to install upper heat shield.
力矩：11N·m
Torque: 11N·m
28. Install AC-generator
29. Connect engine wire harness

(a) Use bolt to install engine wire harness bracket.
(b) Connect following wire and clip:
1) AC-generator connector
2) AC-generator wire
(c) Wire clip
30. Install water pump belt pulley and AC-generator drive belt
(a) Use 4 bolts to install water pump belt pulley temporarily.
(b) Use adjustment bolt and pivot bolt to install drive belt.
(c) Screw down 4 water pump belt pulley bolts tightly.
31. Adjust drive belt
32. Inject engine coolant
Section VII Cylinder Body
Breakdown drawing of cylinder body parts

Ver：LF-20121225
I. Disassembly
1. Remove flywheel
Remove 6 bolts and flywheel. Refer to Fig. 2-164.
Ver：LF-20121225
Fig. 2-164
2. Remove transmission bulkhead

Remove 2 bolts and end cap. Refer to Fig. 2-165.
Fig. 2-165
3. Install engine to engine support for disassembly.
4. Remove timing belt and belt pulley
5. Remove cylinder head
6. Remove adjustment block of engine

Remove 2 bolts and adjustment block of AC-generator. Refer to Fig. 2-166.
Fig. 2-166
7. Remove right engine installation support
Remove 3 bolts and right engine installation support
8. Remove water pump

Ver：LF-20121225
(a) Remove 3 bolts and water pump. Refer to Fig. 2-167.
Fig. 2-167
(b) Take off O ring.
9. Remove oil filter
10. Remove oil pressure switch
11. Remove knock sensor
12. Remove oil pan and oil pump
13. Remove rear oil seal pedestal ring

Remove 6 bolts, rear end cap and washer.
14. Check axial clearance of connecting rod

Move connecting rod forward and backward, and use dial indicator gauge to measure the axial clearance.
Fig. 2-168

0.15-0.25mm
Maximum axial clearance:
Ver：LF-20121225
0.30mm
If axial clearance exceeds maximum value, connecting rod component should be replaced. When necessary,
crankshaft can be replaced.
15. Remove connecting rod cap and check oil clearance

(a) Check connecting rod and the matching mark on the cap to guarantee the correctness of reinstallation.
Fig. 2-169
(b) Remove connecting rod cap nut
(c) Use plastics-coated hummer to knock connecting rod bolt and lift connecting rod cap. Refer to Fig.
2-170.
Fig. 2-170
Tips: Keep lower bearing shell embedded in connecting rod cap.
(d) Use short hose to cover connecting rod bolt to protect crankshaft from damage.
Fig. 2-171
(e) Clean crank pin and bearing shell
(f) Check crank pin and bearing shell for existence of pockmark and scratch. Refer to Fig. 2-172.
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Fig. 2-172
If damage exists for crank pin or bearing shell, bearing shell should be replaced. When necessary, crank pin
can be polished or replaced.
(g) Put a section of plastic oil clearance gauge through crank pin. Refer to Fig. 2-173.
Fig. 2-173
(h) Install connecting rod cap.

Screw down connecting rod cap bolts in several times. Refer to Fig. 2-174.
Fig. 2-174
Torque: 60N·m
Note: Do not turn crankshaft.
(i) Remove connecting rod cap.
Ver：LF-20121225
(j) Apply plastic oil clearance gauge at the widest part. Refer to Fig. 2-175.
Fig. 2-175

Standard type: 0.020-0.051mm
Enlarged size 0.25: 0.019-0.065mm
If oil clearance exceeds maximum value, bearing shell should be replaced. When necessary, crankshaft can
be polished or replaced.
Tips: If using standard bearing shell, bearing shell with the same number on connecting rod must be
applied for replacement. Standard bearing shell has 3 sizes with relevant number of “1”, “2” and “3”. Refer
to Fig. 2-176.
Fig. 2-176
Center wall thickness of standard size bearing shell:
Number “1”:
1.486-1.490mm
Number “2”:
1.490-1.494mm
Number “3”:
1.494-1.498mm
(k) Take out all plastic oil clearance gauges.
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16. Remove piston and connecting rod component

(a) Use cylinder port reamer to eliminate all carbon deposit on cylinder top. Refer to Fig. 2-177.
Fig. 2-177
(b) Use short hose to cover connecting rod bolt to protect crankshaft from damage.
(c) Push piston, connecting component and upper bearing shell through cylinder body top.
Tips:
· Place bearing shell, connecting rod and connecting rod cap together.
· Place piston and connecting rod components in correct order.
17. Check crankshaft axial clearance

Use dial indicator gauge to measure axial clearance when using screwdriver to move crankshaft forward
and backward. Refer to Fig. 2-178.
Fig. 2-178

0.020-0.220mm
Maximum axial clearance:
0.30mm
If axial clearance exceeds maximum value, the entire set of thrust washers should be replaced.
Thickness of thrust washer:
20440-2490mm
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18. Remove main bearing cap and check oil clearance
(a) Evenly loosen and remove main bearing cap bolts in several times with order as shown in Fig. 2-179.
Fig. 2-179
(b) Use removed main bearing cap bolt to move main bearing cap forward and backward, and remove main
bearing cap, lower main bearing shell and lower thrust washer (only for No. 3 main bearing cap). Refer to
Fig. 2-180.
Fig. 2-180
Tips:
Place lower mian bearing shell and main bearing cap together.
Place main bearing cap and lower thrust washer in correct order.
(c) Take out crankshaft upwards. Refer to Fig. 2-181.
Fig. 2-181
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Tips: Place upper main bearing shell, upper thrust washer and cylinder body together.
(d) Clean all main bearing journal and main bearing shell.
(e) Check all main bearing journal and main bearing shell for existence of pockmark and scratch. If any
damage exists for main bearing journal or main bearing shell, bearing shell should be replaced. When
necessary, crankshaft can be polished or replaced. Refer to Fig. 2-182.
Fig. 2-182
(f) Install crankshaft to cylinder body.

(g) Put a section of plastic oil clearance gauge through each bearing journal. Refer to Fig. 2-183.
Fig. 2-183
(h) Install main bearing cap. Refer to Fig. 2-184.
Fig. 2-184
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Torque: 78±2N·m
Note: Do not turn crankshaft.
(i) Remove main bearing cap.
(j) Measure plastic oil clearance gauge at the widest part. Refer to Fig. 2-185.
Fig. 2-185

Tips: For cylinder body part replacement, bearing shell standard clearance should be: 0.015-0.045mm.
If oil clearance exceeds maximum value, bearing shell should be replaced. When necessary, crankshaft can
be polished or replaced.
Tips: If using standard bearing shell, bearing shell with same number must be applied for replacement.
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Fig. 2-186
If bearing shell number can not be confirmed, add the numbers on cylinder body and crankshaft. The sum
number that is same to the number of bearing shell should be chosen. Then the correctness of bearing shell
selection can be guaranteed. Standard bearing shell has 5 sizes with relevant number of “1”, “2”, “3”, “4”
and “5”.
Number
Cylinder
1 2 3
body
Crankshaft 0 1 2 0 1 2 0 1 2
Matching
bearing 1 2 3 1 2 3 1 2 3
shell
e.g. No. 3 cylinder body’s number “2” + crankshaft number “1” = sum number “3” (Then apply No. 3
bearing shell)
Reference table of standard bearing shell
‐ Number mm
“1” 52.025‐52.031
Internal diameter of cylinder body main bearing journal “2” 52.032‐52.037
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“3” 52.038‐52.043
“0” 47.993‐48.000
Diameter o crankshaft bearing journal “1” 47.987‐47.994
“2” 47.982‐47.988
“1” 2.002‐2.005
“2” 2.006‐2.008
Center wall thickness of bearing shell of standard type “3” 2.009‐2.011
“4” 2.012‐2.014
“5” 2.015‐2.017
(k) Take out all plastic oil clearance gauges.
19. Remove crankshaft

(a) Take out crankshaft upwards. Refer to Fig. 2-187.
Fig. 2-187
(b) Remove main bearing shell and upper thrust washer from cylinder body.
Tips:
Place main bearing cap, main bearing shell and thrust washer in correct order.
II. Check
1. Clean cylinder body

(a) Eliminate bushing material
Use bushing scraper to eliminate all bushing material from cylinder top. Refer to Fig. 2-188.
Fig. 2-188
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(b) Clean cylinder body

Use soft brush and solvent to clean and wash cylinder body thoroughly.
2. Check the flatness of cylinder top surface

Use precise ruler and feeler gauge to measure whether twisting exists on the surface contacting with
cylinder head washer. Refer to Fig. 2-189.
Fig. 2-189
Maximum twisting: 0.05mm

Is twisting exceeds maximum value, cylinder body should be replaced.
3. Check for vertical scratch on cylinder

Apply visual check for existence of vertical scratch. If relatively deep scratch exists, 4 cylinders should be
rebored to standard size. When necessary, cylinder body should be replaced. Refer to Fig. 2-190.
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Fig. 2-190
4. Check cylinder internal diameter

Tips: Standard cylinder internal diameter has 3 sizes in all with relevant marks of “1”, “2” and “3”
respectively. The number is printed on the top of cylinder body. Refer to Fig. 2-191.
Fig. 2-191
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Use cylinder diameter gauge to measure the diameters of thrust direction and axis direction at 3 positions A,
B and C. Refer to Fig. 2-192.
Fig. 2-192
Standard diameter:
Standard type:
Number “1”
78.700-78.710mm
Number “2”
78.710-78.720mm
Number “3”
78.720-78.730mm
Maximum diameter:
Standard type: 78.93mm
Enlarged size 0.50: 79.43mm
If diameter exceeds maximum value, 4 cylinders should be rebored. When necessary, cylinder body should
be replaced.
5. Eliminate projecting part of cylinder port

If abrasion loss is less than 0.2mm, use cylinder port reamer to polish cylinder top. Refer to Fig. 2-193.
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Fig. 2-193
6. Check the coordination between connecting rod and piston pin
Try and see whether piston can move forward and backward on piston pin. Refer to Fig. 2-194. If any
movement is felt, the entire set of connecting rod and piston pin should be replaced.
Fig. 2-194
7. Remove piston ring

(a) Use piston ring expander to remove 2 compression rings. Refer to 2-195.
Fig. 2-195
(b) Remove 2 film loops and lined rings by hand.

Tips: Do place piston rings in correct order.
8. Remove connecting rod from piston

Use special service tool to press out piston pin from connecting rod. Take connecting rod off. Refer to Fig.
2-196.
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Fig. 2-196
Tips:
Connecting rod, pin and piston form a matched set.
Place piston, pin, ring, connecting rod and bearing in correct order.
9. Clean piston
(a) Use bushing scraper to eliminate carbon deposit on piston top. Refer to Fig. 2-197.
Fig. 2-197
(b) Use ring groove cleaning tool or broken ring to clean piston ring groove. Refer to Fig. 2-198.
Fig. 2-198
(c) Use solvent and brush to clean piston thoroughly. Refer to Fig. 2-199.
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Fig. 2-199
Note: Do not use wire brush.
1. Check piston and piston ring

A. Check piston oil clearance
Tips: Standard piston diameter has 3 sizes in all, with relevant mark of “I”, “II” and “III”. The mark is on
piston top. Refer to Fig. 2-200.
Fig. 2-200
(a) At 44.5mm to piston top, use micrometer screw gauge to measure the piston diameter at right angle to
piston pin centerline. Refer to Fig. 2-201.
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Fig. 2-201
Piston diameter
Standard type:
Number “1”: 78.655-78.665mm
Number “2”: 78.665-78.675mm
Number “3”: 78.675-78.685mm
Enlarged size 0.50 type:
79.175-79.185mm
(b) Measure internal diameter of cylinder hole at thrust direction (refer to page EM.60)
(c) Measured internal diameter of cylinder hole minus measured piston diameter.
0.035—0.055毫米
0.035-0.055mm
Maximum oil clearance:
0.075毫米
0.075mm
If oil clearance exceeds maximum value, all of 4 pistons should be replaced and be rebored. When
necessary, cylinder body can be replaced.
Tips (when applying new cylinder body): Apply piston with number mark equal to cylinder pore diameter
on cylinder body. Refer to Fig. 2-202.
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Fig. 2-202
B. Measure piston ring groove clearance

Use finger gauge to measure the clearance between new piston ring and ring groove wall.
Ring groove clearance:
The first ring groove:
0.040-0.080mm
The second ring groove:
0.030-0.070mm
If clearance exceeds maximum value, piston should be replaced. Refer to Fig. 2-203.
Fig. 2-203
C. Check piston ring gap clearance

(a) Put piston ring into cylinder pore.
(b) Use piston to push piston ring to the place a little over piston stroke end, with 97mm from cylinder top.
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Fig. 2-204
(c) Use finger gauge to measure gap clearance. Refer to Fig. 2-205.
Fig. 2-205
Standard gap clearance:

The first ring: 0.250-0.450mm
The second ring: 0.350-0.600mm
Film loop: 0.150-0.500mm
Maximum gap clearance:
The first ring: 1.05mm
The second ring: 1.20mm
Film loop: 1.10mm
If gap clearance exceeds maximum valve, piston ring should be replaced. If gap clearance still exceeds
maximum value after applying new piston ring, 4 cylinders should be rebored, or the cylinder bodies
should be replaced.
11. Check connecting rod

A. Check connecting rod straightness
Use connecting rod collimator and finger gauge to check the straightness of connecting rod. Refer to Fig.
2-206.
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Fig. 2-206
Check nonstraightness
Maximum nonstraightness: 0.05mm/100mm. If nonstraightness exceeds maximum value, connecting rod
components should be replaced.
Check torsion resistance as shown in Fig. 2-207.
Fig. 2-207
Maximum torsion resistance: 0.05mm/100mm. If torsion resistance exceeds maximum value, connecting
rod components should be replaced.
B. Check connecting rod bolts.

(a) Install lock nut of connecting rod bolt. Check whether lock can be rotated to thread end easily by hand.
Fig. 2-20
(b) If lock nut can not be rotated freely, use vernier caliper to measure the external diameter of connecting
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rod bolt. Refer to Fig. 2-209.
Fig. 2-209
Standard external diameter: 8.860-9.000mm

Minimum external diameter: 8.60mm
If external diameter is smaller than minimum value, the entire set of connecting bolts and nuts should be
replaced.
12. Bore
Tips:
Piston external diameter of 4 cylinders enlarged with matching size.
Use pistons enlarged with matching size to replace all piston rings.
A. Keep piston with enlarged size
Piston diameter with enlarged size:
Enlarged size 0.50:
79.115-79.145mm
B. Calculate bore amount

(a) At 44.5mm to cylinder head, use micrometer screw gauge to measure the piston diameter at right angle
to piston pin centerline. Refer to Fig. 2-210.
Fig. 2-210
(b) Calculate rebore amount of each cylinder with following formula: Rebore size=P+C-H
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P= Piston diameter
C= Piston oil clearance: 0.035-0.055mm
H= Honing amount: 0.02mm or less
C. Bore and hone cylinder to calculated size
Maximum honing amount: 0.02mm
Note: Over honing can damage the roundness of finished pieces.
13. Check radial runout of crankshaft

(a) Put crankshaft on V-block.
(b) Use dial indicator gauge to measure radial runout at bearing journal. Refer to Fig. 2-211.
Fig. 2-211
Maximum radial runout: 0.03mm

If radial runout exceeds maximum value: crankshaft should be replaced.
14. Check main bearing journal and connecting rod neck

(a) Use micrometer screw gauge to measure diameter of each main bearing journal and connecting rod neck.
Fig. 2-212
Main bearing journal diameter:

Connecting rod neck diameter:
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If diameter is not in conformity with prescribed value, oil clearance should be checked. When necessary,
grind or replace crankshaft.
(b) As shown in the figure, check the conicity and out-of-roundness of each main bearing journal and
connecting rod neck.
Maximum conicity and out-of-roundness: 0.02mm
If conicity and out-of-roundness are larger than maximum value, crankshaft should be replaced.
15. Grind and bone main bearing journal and/or connecting rod neck when necessary
Grind and bone main bearing journal and/or connecting rod neck to relatively smaller diameter of finished
piece size (refer to method in step 14). Install bearing shell with new size matching main bearing journal
and/or connecting rod neck.
III. Replacement
Tips: Oil seal replacement has 2 methods (A and B) as indicated in following statement:
1. Replace crankshaft front seal
A. If oil pump has been removed from cylinder body
(a) Use screwdriver to remove oil seal. Refer to Fig. 2-213.
Fig. 2-213
(b) Use special service tool and hummer to knock new oil seal slightly until its surface and oil pump
housing edge are at the same level. Refer to Fig. 2-214.
Fig. 2-214
(c) Coat oil seal edge with lubricant grease.
B. If oil pump is installed on cylinder body

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(a) Use knife to cut down oil seal edge.
(b) Use screwdriver to move oil seal out. Refer to Fig. 2-215.
Fig. 2-215
Note: Be careful, do not damage crankshaft. Use adhesive tape to cover the sharp end of screwdriver.
(c) Coat new oil seal edge with lubricant grease.
(d) Use special service tool and hummer to knock oil seal slightly until its surface and pump housing edge
are at the same level. Refer to Fig. 2-216.
Fig. 2-216
2. Replace crankshaft rear end cap
A. If crankshaft rear end cap has been removed from cylinder body
(a) Use screwdriver and hummer to knock out oil seal slightly. Refer to Fig. 2-217.
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Fig. 2-217
(b) Use special service tool and hummer to knock new oil seal slightly until its surface and rear oil seal
edge are at the same level. Refer to Fig. 2-218.
Fig. 2-218
(c) Coat oil seal edge with MP lubricant grease.
B. If crankshaft rear end cap has been installed on cylinder cap.
(a) Use knife to cut down oil seal edge.

(b) Use screwdriver move oil seal out. Refer to Fig. 2-219.
Fig. 2-219
Note: Be careful, do not damage crankshaft. Use adhesive tape to cover the sharp end of screwdriver.
(c) Coat new oil seal edge with lubricant grease.
(d) Use special service tool and hummer to knock new oil seal until its surface and crankshaft rear end cap
edge are at the same level. Refer to Fig. 2-220.
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Fig. 2-220
IV. Reassembly
Tips:
Clean all parts to be installed thoroughly.
Before part installation, coat new engine oil on all sliding and turning surfaces.
Replace all washers, O rings and oil seals with new ones.
1. Install piston and connecting rod

(a) Coat engine oil on piston pin and piston pin hole；
(b) Make piston at the same side with front mark of connecting rod, and use thumb to push it into piston pin.
Fig. 2-221
(c) Use special service tool to press in piston pin. Refer to Fig. 2-222.
图2-222
Fig. 2-222
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2. Install piston ring
(a) Install film loop and lined ring by hand.
(b) Use piston ring expander to install 2 compression rings, and make their code mark toward upwards.
Fig. 2-223
Code mark (only for 2 compression rings)
(c) Position of placing piston ring should make open end as shown in Fig. 2-224.
Fig. 2-224
Note: Ring openings should not on the same line.
3. Install bearing shell

(a) Make the projecting part of bearing shell aim at the groove of connecting rod or connecting rod cap.
Fig. 2-225
(b) Put bearing shell into connecting rod and connecting rod cap.
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4. Install main bearing shell

Tips: Upper main bearing shell has oil groove and oil hole, while lower main bearing shell does not have.
Fig. 2-226
(a) Make projection of main bearing shell aim at the groove of cylinder body; then push 5 upper main
bearing shells in. Refer to Fig. 2-227.
Fig. 2-227
(b) Make projection of main bearing shell aim at the groove of main bearing cap; then push 5 lower main
bearing shells in.
5. Install thrust washer

Install 2 upper thrust washers under the No. 3 bearing journal of cylinder body, with oil groove toward
outside. Refer to Fig. 2-228.
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Fig. 2-228
6. Put crankshaft on cylinder body, Fig. 2-229.
Fig. 2-229
7. Install main bearing cap and lower thrust washer

(a) Install 2 thrust washers on No. 3 main bearing cap, with oil groove toward outside. Refer to Fig. 2-230.
Fig. 2-230
(b) Install 5 main bearing caps to proper position. Refer to Fig. 2-231.
Fig. 2-231
Tips: Every bearing cap has number and front mark.
(c) A thin layer of engine oil should be coated on thread and under the main bearing cap bolt head.
(d) Install and evenly screw down 10 main bearing bolts in the order shown in Fig. 2-232.
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Fig. 2-232
Torque: 78±2N·m
(e) Check whether crankshaft can be turned easily.
8. Check crankshaft axial clearance
9. Install piston and connecting rod component

(a) Use short hose cover connecting bolt to protect crankshaft from damage. Refer to Fig. 2-233.
Fig. 2-233
(b) Use piston ring compressor to push piston and connecting rod group into relevant cylinders and make
front mark of piston toward forward. The piston and connecting rod group should have matching numbers
with cylinders. Refer to Fig. 2-234.
Fig. 2-234
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10. Install connecting rod cap

A. Connect connecting rod cap to connecting rod
(a) According to number, match connecting rod cap with relevant connecting rod.
(b) Install connecting rod cap with front mark in front. Refer to Fig. 2-235.
Fig. 2-235
B. Install connecting rod cap nut

Tips:
Connecting rod cap nut should be gradually screwed down in 2 steps.
If any crack or deformation exists for connecting cap bolts, replace them.
(a) A thin layer of engine oil should be coated under connecting rod cap nut.
(b) Install and alternately screw down lock nut in several times. Refer to Fig. 2-236. Torque: 60N·m
Fig. 2-236
If any lock nut can not meet the prescribed torque requirement, the entire set of connecting rod bolts and
lock nuts should be replaced.
(c) Use paint to mark on connecting rod bolts and lock nuts. Refer to Fig. 2-237 and Fig. 2-238.
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Fig. 2-237 Fig. 2-238
(d) Check whether crankshaft can rotate freely.
11. Check connecting rod axial clearance
12. Install rear oil seal pedestal ring

Use 6 bolts to install crankshaft rear end cap with oil seal pedestal ring. Refer to Fig. 2-239.
Fig. 2-239
Torque: 11N·m
13. Install oil pump and oil pan
14. Install knock sensor

Use special service tool to install knock sensor. Refer to Fig. 2-240.
Fig. 2-240
Torque: 23N·m
15. Install oil pressure switch
(a) Coat the second or third thread of oil pressure switch with adhesive.
(b) Use special service tool to install oil pressure switch.
16. Install Oil filter
17. Install water pump

(a) Put a new O ring on cylinder body.
(b) Use 3 bolts to install water pump. Refer to Fig. 2-241.
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Fig. 2-241
Torque: 23N·m
18. Install right engine installation support

Use 3 bolts to install right engine installation support
Torque: 59±2N·m
19. Install AC-generator regulating block

Use 2 bolts to install AC-generator regulating block. Refer to Fig. 2-242.
Fig. 2-242
Torque: 23N·m
21. Install timing belt and belt pulley
22. Remove engine from engine support
23. Install rear end cap

Use 2 bolts to install rear end cap.
Torque: 11N·m
24. Install fly wheel

(a) Install flywheel on crankshaft.
(b) Install and evenly screw down installation bolts in several times in order shown in Fig. 2-243.
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Fig. 2-243
Torque: 78±2.5N·m
Chapter II Cooling System
Section I Coolant
I. Check
1. Check the engine coolant level in the radiator water tank

When engine is at cold condition, the coolant level should be between “LOW” and “FULL” lines.
In case of a lower level, please check if there is a leakage and refill the coolant to “FULL” line.
2. Check the quality of the engine coolant

(a) Removal of radiator cover
Note: For protection from scald, please do not remove the radiator cover when the engine and radiator are
too hot, because the fluid and steam will eject under pressure.
(b) There should be not too much rust or water scale around the radiator cover or intake pipe, and no oil in
the coolant. In case of too dirty coolant, please replace the coolant.
(c) Reinstall the radiator cover.
II. Replacement
1. Discharging the engine coolant

(a) Removal of radiator cover
Note:
For protection from scald, please do not remove the radiator cover when the engine and radiator is too hot,
because that the fluid and steam will be ejected under pressure.
(b) Release the drain plug of the radiator (at the right side of water tank below the radiator) and engine
coolant drain plug (at the rear left of cylinder) on the coolant drain pipe, and then drain the coolant. See Fig.
2-244.
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Fig. 2-244
(c) Close the drain plug

Torque: (at one side of engine)
12.7N·m
2. Refilling engine coolant

(a) Refilling coolant into the cooling system slowly
· Using high quality glycol coolant and mix it according to the instructions of the manufacturer.
· Coolant with above 50% (less than 70%) glycol recommended.
Note:
· Ethanol coolant should not be used.
· The coolant should be mixed with soft water or distilled water.
Capacity: 5.3L
(b) Install the radiator cover.
(c) Start the engine and drain the air in the cooling system.
(d) Refill coolant into the coolant tank to “FULL”.
3. Check if there is leakage in the engine coolant
Section II Water Pump
I. Removal
1. Drain the engine coolant
2. Remove the driving belt of alternator and belt pulley of water pump
3. Remove the cylinder head cover

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4. Remove timing belt cover 3 and 4
Remove 6 bolts and timing belt cover 3 and 2. See Fig. 2-245.
Fig. 2-245
5. Dismantle the conductor bundle cover

6. Take out the oil level indicator and the pipe
(a) Remove the installation bolt.
(b) Pull out the oil level indicator and the pipe.
(c) Take out the O ring from the oil level indicator pipe.
7. Remove the water pump and its intake pipe
(a) Disconnect the water temperature sensor connector. See Fig. 2-246.
Fig. 2-246
(b) Remove the 2 nuts connecting water pump pipe to the cylinder head. See Fig. 2-247.
Fig. 2-247
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(c) Remove 3 bolts, water pump and water pump intake pipe.
(d) Take out the O ring from the cylinder body.
8. Disconnect the water pump and its intake pipe. See Fig. 2-248.
Fig. 2-248
II. Check
Check the water pump

(a) Visually check if there is coolant leakage at the air pore and water pore.
In case of leakage, please replace the water pump.
(b) Revolve the belt pulley, check the turning of the water pump bearing. It should be smooth and without
noise. Please replace the water pump as necessary.
III. Removal
1. Remove the suction cover of water pump

(a) Remove 4 bolts.
(b) Disconnect the suction cover of water pump by a screwdriver. See Fig. 2-249.
Fig. 2-249
2. Remove the belt pulley seat
Press down the shaft of the bearing by a special service tool and a punch, and then dismantle the belt pulley
seat. See Fig. 2-250.
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Fig. 2-250
3. Remove the water pump bearing

(a) Polish the water pump rotor by a grinding wheel as shown in Fig. 2-251.
Fig. 2-251
Note: Do not polish the shaft of the water pump bearing.

(b) Gradually warm the water pump to 85℃.
(c) Press down the shaft of the bearing by a special service tool and a punch, and take out the rotor and
bearing. See Fig. 2-252.
Fig. 2-252
(d) Take out the seal receptacle.
Note: Do not damage the water pump body.
4. Remove the seal part

Press down the seal parts by a special service tool and punch. See Fig. 2-253.
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Fig. 2-253
IV. Reinstallation
Note: During reassembly of water pump, new seal parts, rotors and bearing should be used.
1. Install water pump bearing
(a) Gradually warm the water pump to 85℃.
(b) Press down the bearing outer ring by a special service tool and punch to make the surface flush with
water pump body surface. See Fig. 2-254.
Fig. 2-254
2. Install seal parts

(a) Smear seal filling on the new seal part and pump body. See Fig. 2-255.
Fig. 2-255
(b) Press the seal part by a special service tool and punch. See Fig. 2-256.
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Fig. 2-256
3. Install belt pulley seat

Press down the belt pulley seat onto the shaft of the water pump bearing by a special service tool and punch,
and make it leave the pump body installation surface for 76.7mm. See Fig. 2-257.
Fig. 2-257
4. Install rotor
(a) Install new filling and seat into the rotor. See Fig. 2-258.
Fig. 2-258
(b) Smear little silicone fluid on the contact surface of the wheel seat and rotor. See Fig. 2-259.
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Fig. 2-259
(c) Press down the new rotor onto the shaft of water pump bearing by a punch and let it away from the
pump installation surface for 7.8 mm. See Fig. 2-260.
Fig. 2-260
5. Install suction cover of water pump

Install the suction cover of water pump by a new washer and 3 bolts. See Fig. 2-261.
Fig. 2-261
Torque: 11N·m
6. Check if the water pump can rotate smoothly. See Fig. 2-262.
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Fig. 2-262
V. Installation
1. Assemble the water pump and its intake pipe
2. Install the water pump and its intake pipe

(a) Put a new O ring onto the cylinder body.
(b) Put a new washer onto the cylinder head with the upper mark upwards. See Fig. 2-263.
Fig. 2-263
(c) Temporarily install the water pump and its intake pipe by 3 bolts and 2 nuts. See Fig. 2-264.
Fig, 2-264
(d) Screw down the bolts and nuts. See Fig. 2-265.
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Fig. 2-265
Torque: bolt: 23N·m
Nut: 23N·m
3. Install oil level indicator and the pipe

(a) Install a new O ring on the scaled rule pipe.
(b) Smear suds on the O ring.
(c) Push the oil level indicator together with the pipe and install them by bolts. See Fig. 2-266. torque:
11N·m
Fig. 2-266
4. Connect the conductor bundle cover
5. Install timing belt pulley cover 2 and 3

Install the timing belt pulley cover 2 and 3 by 6 bolts. See Fig. 2-267.
Fig. 2-267
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6. Install cylinder head cover
7. Install the belt pulley and alternator driving belt
8. Refill the engine coolant
9. Start the engine and check if there is leakage
Section III Thermostat
I. Removal
Note: The removal of thermostat will bring about adverse effects and lower the cooling efficiency. Even
though the engine is too hot, the thermostat should not be removed.
1. Drain the engine coolant
2. Dismantle the water temperature sensor connector
3. Remove the intake pipe and thermostat

(a) Remove the 2 bolts and intake pipe. See Fig. 2-268.
See Fig. 2-268
(b) Remove the thermostat.

(c) Take out the washer from the thermostat.
II. Check
Check the thermostat

Note: There is a mark of valve opening temperature on the thermostat. See Fig. 2-269.
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Fig. 2-269
(a) Immerge the thermostat into water. Warm the water slowly. See Fig. 2-270.
Fig. 2-270
(b) Check the valve opening temperature.

Valve opening temperature: 82±2℃
If the valve opening temperature does not reach the regulation, please replace the thermostat.
(c) Check the valve lift.
Valve lift:
When the valve opening temperature is at 95℃, the valve lift should be at least 8mm or more. See Fig.
2-271.
Fig. 2-271
If the valve lift does not reach the regulation, please replace the thermostat.
(d) When the thermostat is at a lower temperature (less than 40℃), please check if the valve is completely
closed.
If it is not closed, please replace the thermostat.
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III. Installation
1. Put the thermostat into the water inlet housing

(a) Install the new washer onto the thermostat. See Fig. 2-272.
Fig. 2-272
(b) Align the bypass valve of thermostat with the top of double-head bolt. Insert the thermostat into the
water inlet housing.
Tips: The bypass valve can be installed within 10 degrees at the two sides of the regulated position. See Fig.
2-273.
Fig. 2-273
2. Install water inlet

Install water inlet by 2 nuts
Torque: 11N·m
3. Connect the water temperature sensor connector
4. Refill engine coolant
5. Start the engine and check if there is coolant leakage

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Section IV Electrical Cooling Fan
I. Inspection on vehicle
1. Check the rotation of cooling fan at low temperature (lower than 83℃)
(a) Turn on the ignition switch (ON). See Fig. 2-274.
Fig. 2-274
(b) Check if the cooling fan stops rotation.

If it does not stop rotation, please check the cooling fan relay and water temperature switch.
Check if the connector between the relay and water temperature switch is disconnected or the wire is
disconnected.
2. Disconnect the water temperature switch connector

(a) Removal the water temperature switch connector.
(b) Use a wire to connect the water temperature switch connector and earth wire.
(c) Check if the cooling fan rotates.
If it does not rotate, please check the cooling fan relay, cooling fan, fuse, engine main relay, and also check
if there is short circuit between the cooling fan relay and water temperature switch.
3. Reconnect the water temperature switch connector.
4. Check the rotation of cooling fan at high temperature

(a) Start the engine to warm the coolant temperature to above 93℃. See Fig. 2-275.
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Fig. 2-275
(b) Check if the cooling fan rotates.
If it does not rotate, please replace the water temperature sensor.
5. Check the cooling fan

(a) Dismantle the cooling fan connector.
(b) Connect the battery, ammeter and cooling fan connector. See Fig. 2-276.
Fig. 2-276
(c) Check if the cooling fan rotates smoothly and check the reading of ammeter.
Standard current intensity: 5.7-7.7A
(d) Reconnect the cooling fan connector.
II. Removal
1. Remove the fan cover

Remove the nut and fan. See Fig. 2-277.
Fig. 2-277
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2. Removal fan motor
Disconnect the wire from the cooling cover and remove 3 bolts and fan motor. See Fig. 2-278.
Fig. 2-278
III. Reassembly
1. Install fan motor
(a) Install fan motor with 3 bolts. See Fig. 2-278. Torque: 26N·m.
(b) Connect the wire to fan cover. See Fig. 2-277.
2. Install fan
Install fan by nuts. Torque: 6.2N·m.
Section V Cooling Fan Relay
1. Check cooling fan relay

(a) Remove the relay box cover.
(b) Remove the cooling fan relay. See Fig. 2-279.
Fig. 2-279
(c) Check the conductivity of cooling fan relay:
1) Check it by an ohmmeter. Terminal 1 and 3 should be conducted. If not, please check the relay.
2) Check the conductivity of Terminal 2 and 4, which should not be conducted. If conducted, please replace
the replay. See Fig. 2-280.
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Fig. 2-280
(d) Check the working condition of cooling fan relay:
1) Connect the positive voltage of battery to Terminal 1 and 3.
2) Check the conductivity between Terminal 2 and 4 by an ohmmeter, which should be conducted. If not,
please replace the relay. See Fig. 2-281.
Fig. 2-281
(e) Reinstall cooling fan relay.
(f) Reinstall relay box cover.
Chapter III Lubrication System

Section I Engine Oil and Fuel Filter
I. Inspection
1. Check the engine oil quality
Check if the engine oil is deteriorated, with water, faded or diluted. If it evidently goes bad, please replace
engine oil. Recommended viscidity is shown in Fig. 2-282.
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Fig. 2-282
2. Check engine oil level
After the engine warms up and stops for 5 minutes, the engine oil level should be between oil dipstick L
and F. If too low, please check if there is leakage and refill the engine oil to mark F.
Note: Do not refill the engine oil above mark F.
3. Remove the oil pressure switch and install the oil pressure gauge
(a) Take off the oil pressure switch by a special service tool. See Fig. 2-283.
Fig. 2-283
(b) Install oil pressure gauge. See Fig. 2-284.
Fig. 2-284
4. Engine warm-up
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Warm up the engine to normal working temperature.
5. Check the oil pressure
Oil pressure: no less than 80 kilopascal at idle speed
300-480 kilopascal in case of 3,000rpm
6. Remove the oil pressure gauge and reinstall oil pressure switch
(a) Remove the oil pressure gauge
(b) Smear bond onto the 2 or 3 screw threads of the oil pressure switch. See Fig. 2-285.
Fig. 2-285
(c) Install the oil pressure switch by a special service tool.
Torque: 18N·m
7. Start engine and check if there is leakage
II. Replacement
Notes:
Long-time contact with the mineral oil will eliminate the natural fat of skin and cause dryness, stimulus and
dermatitis. Besides, the used engine oil contains harmful pollutants that may result in skin cancer.
Please be careful and reduce the time and frequency of contact with the used engine oil as possible as you
can. Please wear the blue protective suite and gloves. Completely clean your skin by soap and water or
hand cleaner without water to clean all used engine oil. Do not use petroleum, thinner or solvent.
For environmental protection, please dispose the used engine oil and fuel filter at specified place.
1. Drain the engine oil
(a) Dismantle the engine oil charger cap. See Fig. 2-286.
Fig. 2-286
(b) Dismantle the engine oil drain plug and drain the engine oil into a container.
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2. Replacement of engine oil filter
(a) Remove the engine oil filter by a special service tool.
(b) Check and clean the installation surface of the filter.
(c) Check if the part number of the new oil filter is the same with that of the original one.
(d) Smear clean engine oil on the washer of the new oil filter.
(e) Slightly screw the oil filter and screw it down when the washer contacts the pedestal.
(f) Screw it down again for 3/4 turn by a special service tool. See Fig. 2-287.
Fig. 2-287
3. Fill engine oil again

(a) Clean the engine oil drain plug, and then return it after washer replacement.
Torque: 44N·m
(b) Fill new engine oil.
Capacity
Drainage and reinstallation:
Replace the oil filter: 3.0 L
Not replace the oil filter: 2.8 L
Fill the dry oil tank: 3.5 L
(c) Install engine oil charger cap.
4. Start the engine and check if there is oil leakage
5. Recheck the engine oil level
Section II Engine Oil Pump
I. Removal
Tips: Remove the oil pan and oil rough filter first for cleaning when repairing the oil pump.
1. Drain the engine oil.
2. Dismantle the timing belt.
3. Dismantle tension wheel and tension spring.
4. Dismantle the crankshaft timing belt pulley.
5. Remove the oil dipstick and pipe.
(a) Remove the installation bolt. See Fig. 2-288.
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Fig. 2-288
(b) Take out the oil dipstick and pipe.

(c) Take off the O ring from the oil dipstick pipe.
6. Remove the oil pan
(a) Remove 19 bolts and 2 nuts. See Fig. 2-289.
Fig. 2-289
(b) Install a special knife blade for servicing between the cylinder body and oil pan. Cut the sealant and
remove the oil pan. See Fig. 2-290.
Fig. 2-290
Note:
Do not apply the special service tool to the side of oil pump body and rear receptacle.
Do not damage the oil pan flange.
7. Dismantle oil rough filter
Remove 2 bolts, 2 nuts, rough filter and washer. See Fig. 2-291.
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Fig. 2-291
8. Remove the oil pump
(a) Remove 7 bolts. See Fig. 2-292.
Fig. 2-292
(b) Slightly knock the oil pump body by a hammer with plastic surface, and remove the oil pump. See Fig.
2-293.
Fig. 2-293
(c) Remove the washer.
II. Removal
1. Remove the reducing valve
(a) Take out the snap ring by clip. See Fig. 2-294.
Fig. 2-294
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(b) Remove the limiter and driven rotor
2. Remove the drive and driven rotors
Remove 5 bolts, pump housing, O ringand drive and driven rotors
III. Inspection
1. Check the reducing valve
Smear the engine oil onto the reducing valve. Check if it can fall into the valve hole successfully by its
body weight. See Fig. 2-295.
Fig. 2-295
If not, please replace the reducing valve. Replace the oil pump components as necessary.
2. Check the drive and driven rotors
A. Check the clearance of rotor body.
Measure the clearance between the driven rotor and main body by a thickness meter. See Fig. 2-296.
Fig. 2-296
Standard main body clearance: 0.10-0.18mm
Max main body clearance: 0.20mm
In case of a clearance over the max value, please replace the whole set of rotor. Replace the oil pump
components as necessary.
B. Check the rotor tip clearance.
Measure the clearance between the tips of driven and drive rotors by a thickness meter. See Fig. 2-297.
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Fig. 2-297
Standard tip clearance: 0.060-0.180mm
Max tip clearance: 0.35mm
In case of tip clearance over the max value, replace the whole set of rotor.
C. Check the rotor side clearance.

Measure the clearance between rotor and precision straight edge by a thickness meter and precision straight
edge. See Fig. 2-298.
Fig. 2-298
Standard side clearance: 0.025-0.075mm
Max side clearance: 0.10mm
In case of a side clearance over the max value, replace the whole set of rotor. Replace the oil pump
components as necessary.
IV. Replacement
Replace the crankshaft front oil seal
V. Reinstallation
1. Install the driven and drive rotors
(a) Rotate the driven and drive rotors into the pump body to make the mark towards the pump body cap.
See Fig. 2-299.
Fig. 2-229
(b) Install the oil pump body cap by 5 bolts.
Torque: 11N·m
2. Install reducing valve

(a) Insert the reducing valve, spring and limiter into the oil pump body hole
(b) Install the snap spring by a clamp.
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VI. Installation
1. Install oil pump
(a) Put a new washer onto the specified end face of the cylinder body. See Fig. 2-300.
Fig. 2-300
(b) Make the key slot of oil pump driven rotor occlude with the crankshaft and roll in the oil pump.
(c) Install the oil pump by 7 bolts. See Fig. 2-301.
Fig. 2-301
Torque: 23N·m
Stay bolt: 35mm
Other bolts: 25mm
2. Install engine oil rough filter
Install the new washer and engine oil rough filter by 2 bolts and 2 nuts.
Torque: 11N·m
3. Install oil pan

(a) Clean all old fillings. Be careful and do not leave the oil on contact surface between the oil pan and
cylinder body.
Clean all the old fillings in the washer surface and seal groove by knife blade and washer cleaner.
Completely wash all parts and clean all loose materials.
Clean the two sides of seal surface by solvent without residual.
Note: Do not use solvent that may affect paint surface.
(b) Smear seal fillings on the oil pan as shown in Fig. 2-302.
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Fig. 2-302
Install a filler with a diameter of 3-5mm.
Assemble the parts within 5 minutes after smearing fillings, otherwise clean all fillings and re-smear oil.
Remove the filler from the pipe immediately and reinstall the cap.
(c) Install the oil drip pan by 19 bolts and 2 nuts.
Torque: 11N·m
4. Install oil dipstick and pipe
(a) Install the new O ring onto the pipe of oil dipstick.
(b) Smear soap water on the O ring.
(c) Push into the oil dipstick and the pipe together and install them by bolts. See Fig. 2-303.
Fig. 2-303
Torque: 11N.m
5. Install crankshaft timing gear
6. Install the tension wheel and tension spring temporarily
8. Fill engine oil
9. Start engine and check if there is oil leakage
10. Recheck the engine oil level
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Chapter IV Exhaust Gas Emission Control

Section I Overview
Purpose
The exhaust gas emission control system is to reduce the CO and hydrocarbon discharged by the engine so
as to prevent the leaked gas containing hydrocarbon to the air and the fuel steam containing hydrocarbon
emitted by the petroleum tank to the air.
System functions shown as below:
Table 2-3
System Abbreviation Purpose
(1) Positive crankcase PCV Reduce gas leakage (hydrocarbon)
ventilation EVAP Reduce the evaporation of hydrocarbon
(2) Evaporation circulation EFI Adjust the working of all parts of engine to
(3) Electronic fuel injection reduce exhaust gas
Schematic diagram:
Fig. 2-304
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Section II PCV System
Inspection
1. Remove PCV valve
(a) Remove PCV hose from PCV valve.
(b) Remove PCV valve.
2. Install clean hose on the PCV valve
3. Check the work of PCV valve
(a) Blow air into PCV valve from one side of cylinder cap and check if the air path is smooth. See Fig.
2-305.
Fig. 2-305
Note:
Do not blow air through the PCV valve.
Petroleum content in PCV valve is harmful.
(b) Blow air into the PCV valve from one side of the air intake and check if the air path is smooth. See Fig.
2-306.
Fig. 2-306
In case the working situation does not reach the regulations, please replace the PCV valve.
4. Remove the clean hose from PCV valve
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5. Reinstall PCV valve
6. Visually check the hose, connector and washer. Check if there is a crack, leakage or damage. See
Fig. 2-307.
Fig. 2-307
Section III IEVAP Control System
Inspection
1. Visually check the pipe and connector
Check if there is loose connector, sudden bent or damage.
2. Visually check the fuel tank
Check if there is distortion, crack or fuel leakage. See Fig. 2-308.
Fig. 2-308
3. Visually check the fuel tank cap

Check if the fuel tank cap and/or washer is distorted or damaged. Repair or replace the tank cap as
necessary.
4. Check the activated charcoal canister
A. Remove the activated charcoal canister.
B. Visually check the housing of activated charcoal canister. See Fig. 2-309.
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Fig. 2-309
C. Check if the filter is blocked and the non-return valve is locked.

(a) Blow the low-pressure compressed air into the fuel tank pipeline and check if the air flows out smoothly
from the pipeline. See Fig. 2-310.
Fig. 2-310
(b) Blow the air into the steam pipeline and check if the air flows out smoothly from the pipeline.
In case of any question, replace the activated charcoal canister.
D. Clean the filter inside the activated charcoal canister
Close other pipelines on the upper part of the activated charcoal canister. Blow air into the canister through
fuel tank pipeline to clean the filter. See Fig. 2-311.
Fig. 2-311
Tips: Do not try to clean the activated charcoal canister and do not let charcoal leak.
E. Install activated charcoal canister.
5. Check the EVAP vacuum valve
Chapter V Electric Parts

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Section I Electronic Fuel Injection (EFI) System
1. Note:
Disconnect the wire from the negative pole of the battery before repairing the fuel system.
Note: Each DTC stored in the computer will be deleted when the wire of the negative pole (-) of the battery
is disconnected. Therefore, please read the DTC before the wire of the negative pole (-) of the battery is
disconnected when necessary.
(a) Do not smoke or repair it in the vicinity of obvious flame;
(b) Do not let the rubber or leather part contact the gasoline;
(c) Repair one set of parts at one time to avoid confusing of parts with similar shapes;
(d) Keep the repair ground clean to avoid polluting the other parts;
(e) Do not mistakenly install or miss any clamp or spring.
2. Notes before repairing:
(a) The battery should supply power for timing light, revolution meter, etc.
(b) If the engine can not ignite, diagnose it with reference to the following notes:
1) Check if the wires on the terminals of the battery are connected correctly.
2) Remove the high voltage coil carefully as shown in Fig. 2-312.
Fig. 2-312
3) Check if the terminals of ignition coil are tightly connected to the wires of other ignition systems.
4) Prevent specially water seepage of electronic systems when cleaning the engine compartment.
(c) Notes to removal of oxygen sensor
1) Do not let the oxygen sensor drop or collide with other objects.
2) Do not let the oxygen sensor contact with water.
(d) Connect the wire harness to adapting piece plug.
1) Insert the wire harness terminal to socket connector, and lock it safely in the bayonet of socket
connector.
2) Pull out the wire harness to check if it is tightly locked.
3. Air inlet system
(a) If the engine oil level meter, engine oil filler cover, PCV (positive crankcase ventilation) and other parts
drop off, the engine may work abnormally.
(b) If the parts of air inlet system between throttle valve section and cylinder head drop off, loose or crack,
the air will be taken in, and the engine will work abnormally.
Section II Electronic Control System

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1. Notes before repairing:

(a) First disconnect power wire or battery negative pole (-) terminal when the ignition key is on off position
before removing ECM wire harness socket connector, wire connector, etc.
Note: Check the DTC before disconnecting the battery negative pole (-) terminal.
(b) Be careful when installing the battery. Do not mistakenly connect the two poles of the battery.
(c) Do not let the parts affect each other for avoiding vice effects when remove and install electronic parts.
Process all the electronic parts carefully, especially the ECM.
(d) Be especially careful during fault diagnosis, because there are lots of transistor circuit in ECM and even
slight contact may cause fault.
(e) Do not open the ECM outer cover.
(f) Be especially careful when checking during a raining day for water penetration to ECM. Meanwhile
when washing the engine compartment, water penetration to ECM and wire harness socket connector
should also be prevented.
(g) ECM part should be replaced in the form of an assembly.
(h) Be specially careful when inserting and unplugging wire harness terminal.
1) When loosening the lock catch, the force pulling the socket connector should affect on the socket
connector.
Fig. 2-313
2) As shown in Fig. 2-314, the socket connector should be totally inserted and locked up when installing.
Fig. 2-314
(i) When checking the connector with voltmeter/ohmmeter
1) Pull out the waterproof plug carefully if it is waterproof socket connector.
2) Insert the test probe from one side of the wire harness into the socket connector to check the conduction,
current and voltage.
3) Do not apply unnecessary strong force on the terminal head.
4) Install the waterproof plug onto the wire harness socket connector and fix it after finishing checking.
(j) Check and test the oil injection nozzle or wire connector with special tools.
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2. Check engine alarm light
(a) The engine alarm light should be on when the ignition switch is in the ON position and the engine is not
started.
(b) After the engine is started, the engine alarm light should be off. As shown in Fig. 2-315, if the alarm
light is not off, there should be fault in the engine electrical system.
Fig. 2-315
3. Check the DTC with hand-held diagnostic equipment (diagnostic equipment type: OBD II)
(a) Connect the hand-held diagnostic equipment to the diagnosis socket.
(b) Read the DTC displayed on the screen of diagnostic equipment. For more detailed information please
refer to the instruction manual of the hand-held diagnostic equipment.
4. Clear the DTC
(a) The DTC still remains in the ECM storage after fixing the fault area. To clear these codes, the ignition
switch should be in the OFF position, disconnect the electronic fuel injection fuse (15A), or disconnect the
negative pole of the battery at least for 10 seconds so as to clear the DTC by cutting off the system power.
The duration is determined by the environmental temperature (The temperature is lower, the duration for
cutting off power is longer.).
Note:
The DTC can also be cleared by disconnecting the negative pole (-). However, this will also clear the
information in other storage systems (like timing system).
If the DTC is not cleared, it will be stored in ECM and appear together with the new DTC as past DTC in
the future fault diagnosis.
First check if the DTC is recorded during necessary maintenance for terminals on engine assembly without
power supply.
(b) Check if the engine alarm light works normally through road testing after clearing the DTC. If the same
DTC appears, it means that the fault area is not completely repaired.
5. Monitor ECM data with hand-held tester

(a) Connect the hand-held tester to the diagnosis socket connector.
(b) Monitor the ECM data according to the hints on the tester screen.
The operation procedures are as follows:
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6. Diagnose fault with high resistance multimeter

Note:
The following fault diagnosis procedures are designed for checking each separate system. Therefore, the
practical diagnosis procedures may be different from the following ones. However, fault diagnosis should
refer to the diagnosis mode mentioned in this manual.
First simply check the connecting condition of fuse, intense current fuse and socket connector.
The following fault diagnosis procedures are based on the following assumption: The fault is caused by
short or open circuit in the computer.
If the fault still remains when the working voltage in the diagnosis equipment interface is normal, the fault
may be in ECM and replace the ECM with a new one
.
7. Diagnosis procedure for electronic fuel injection system
Preparation before diagnosis:
Measure the voltage of all equipments under the condition of well connection of all socket connectors.
Make sure the battery voltage is not less than 11V when the ignition switch is in ON position.
(a) Fault diagnosis for intake air temperature and pressure sensor
The schematic diagram is as following:
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Fig. 2-316
Diagnose with hand-held tester and read its value.
(1) Turn the ignition switch to ON position.
(2) Start the hand-held tester and operate according to the instructions. Read the values displayed on the
tester (Pressure and temperature are the same with atmospheric pressure and intake air temperature.) and
relevant fault (if there is). If normal, check if there is intermittent fault; if abnormal, proceed to the next
procedure.
(3) Check voltage of ECM Terminal J104.
a. Turn the ignition switch to ON position.
b. Measure the voltage between Terminal J104 and J121 of ECM connector. The normal value should be
between 4.5-5.5V.
If abnormal, check and replace ECM; if normal, proceed to the next procedure.
(4) Check voltage of Terminal J142 of ECM connector.
a. Turn the ignition switch to ON position.
b. Measure the voltage between Terminal J142 and J121 of ECM connector. The normal value should be
between 3.4-3.8V.
If abnormal, check and replace ECM; if normal, proceed to the next procedure.
(5) Check voltage of Terminal J127 of ECM connector.
Measure the voltage between Terminal J127 and J121 of ECM connector. The voltage should be 0.5-3.4V
when the intake air temperature is 20℃; and the voltage should be 0.2-1.0V when the intake air
temperature is 60℃. If normal, check and replace ECM; if abnormal, proceed to the next procedure.
(6) Check wire harness and connector (ECM-intake air temperature and pressure sensor):
a. Disconnect ECM connector and intake air temperature and pressure sensor connector.
b. Measure the electric resistances between ECM connector Terminal J104, J121, J142, J127 and sensor
connector Terminal B, D, A, C. The resistance value should not be more than 1Ω.
c. Measure the electric resistances between ECM connector Terminal JI04, J121, J127, J142 and vehicle
body earth wire. The resistance value should not be more than 1Ω.
If abnormal, repair or replace wire harness or connector; if normal replace intake air temperature and
pressure sensor.
8. Fault diagnosis for water temperature sensor
The schematic diagram is as following:
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Fig. 2-317
Diagnose fault with hand-held tester.
(a) Read the value of hand-held tester (engine coolant temperature).
1) Turn the ignition switch to ON position.
2) Start the hand-held tester, and operate according to the instructions. Read the value displayed on the
tester (engine coolant temperature) and relevant DTC (if there is). If normal, check if there is intermittent
fault; if abnormal, proceed to the next procedure.
(b) Check the connection condition of the wire harness.
2) Disconnect the water temperature sensor connector. Measure the voltage between Terminal 3 and 1 of
water temperature sensor connector. The value should be 4.5-5.5V. If normal, replace sensor; if abnormal,
proceed to the next procedure.
3) Turn the ignition switch to OFF position, and disconnect the water temperature sensor and ECM
connector. Measure the electric resistance between ECM connector Terminal J143 and sensor Terminal 3
and between Terminal J105 and sensor Terminal 1. The value should not be more than 1Ω. Measure the
electric resistance between sensor terminal and vehicle body earth wire. The value should not be more than
1Ω. If abnormal, replace the wire harness; if normal, replace the sensor.
If there is still fault or abnormal display value after replacing sensor, replace ECM.
9. Fault of throttle valve position sensor circuit

The diagnosis schematic diagram is as following:
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Fig. 2-318
Diagnose the fault with hand-held tester.
(a) Read the value of hand-held tester (throttle valve opening percentage).
2) Start hand-held tester, and there the value it displayed or the DTC (if there is). If there is not DTC, check
if there is intermittent fault; if there is fault or abnormal display value, proceed to the next procedure.
(b) Check throttle valve position sensor:
1) Disconnect connector of throttle valve position sensor.
2) Measure the voltage between Terminal A and B of throttle valve position sensor. The voltage should be
5±0.5V. If abnormal, Check ECM and wire harness; if normal, proceed to the next procedure.
3) Measure the electric resistance between the sensor Pin A, B and C. The resistance between Pin A and B
should be 12KW, and between Pin A and C 3-12KW. If the resistance is abnormal, replace the sensor
which can work with throttle valve body. If normal, proceed to the next procedure.
(c) Check wire harness and connector (ECM-throttle valve position sensor):
1) Disconnect ECM connector and sensor connector.
2) Measure the electric resistance between ECM connector Terminal J120 and sensor Terminal A, between
ECM connector Terminal J124 and sensor Terminal C, and between ECM connector Terminal J105 and
sensor Terminal B. The resistance value should not be more than 1Ω. If normal, proceed to the next
procedure; if abnormal, replace the sensor.
3) Measure the electric resistance between Terminal J120, J124, J105 of ECM connector and vehicle body
earth wire. The resistance value should not be more than 1MΩ. If abnormal, replace the wire harness; if
normal, replace sensor. If the problem still remains after replacing sensor, replace the ECM.
10. Oxygen sensor circuit fault diagnosis
(a) Method:
1) Check the voltage between Pin J162 and J106 of ECM connector.
2) Start the engine, and warm it to normal working temperature.
3) Maintain the engine rotation speed at 2,000rpm, and measure the temperature between the two pins.
Check if the voltage is around 0.45V. If it is, the oxygen sensor and loop is well, and then check if there is
intermittent fault. If it is not, proceed to the next procedure.
(b) Check if the voltage is maintained above 0.45V.
1) If it is, check if J162 and the power supply loop are short-circuited or if the air-fuel gas is too dense. If
the circuit is normal, check the intake air temperature and pressure sensor, engine water temperature sensor,
fuel pressure, injector and the loops. If the above are normal, check the ECM and its circuit.
2) If voltage is normal, proceed to the next procedure.
3) Maintain the engine rotation speed at 2,000rpm for 1min, and repeat rapid acceleration of the engine.
Then check the voltage.
a. If the voltage is 0.45 or even more than 1 time, the circuits of J162 and J106 are contacted poorly or the
air-fuel gas is too thick; if the circuit is normal, check intake air temperature and pressure, engine water
temperature sensor, fuel pressure, injector and loops. If the above are normal, check ECM and its circuit.
b. If the voltage is lower than 0.45V, the circuits of J162 and J106 are shortened or opened, or there is
function fault for the oxygen sensor. If the circuit and connection are normal, replace the oxygen sensor. If
it is still not normal after replacing the oxygen sensor, replace the ECM.
11. Knock sensor circuit fault
The diagnosis schematic diagram is as following:
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Fig. 2-319
Read the stable data with a hand-held tester. The stable data records the engine condition when a fault is
detected. It can be used to judge that if the sedan is running or stopped when a fault occurred, if the engine
is preheated, and if the air-fuel percentage is too high or too low, etc.
(a) Check wire harness and connector:
Check the connection condition of the wire harness between ECM and knock sensor. Disconnect ECM and
sensor connector, measure the electric resistance between ECM connector terminal and vehicle body earth
wire, which should be more than 1MΩ. If abnormal, replace the wire harness.
(b) Check knock sensor: If the oscillation frequency is not 8.1kHz under normal condition, the sensor is
abnormal, and the conduction condition between the terminal and vehicle body should be checked. If not
normal, replace knock sensor; if normal, proceed to the next procedure.
(c) Check wire harness and connector (ECM-knock sensor)
1) Disconnect ECM connector.
2) Disconnect knock sensor connector.
3) Measure the electric resistance between Terminal J169 of ECM connector and terminal of knock sensor
connector. The resistance value should be less than lMΩ.
4) Measure the electric resistance between Terminal J169 of ECM connector and vehicle body earth wire.
The value should not be less than 1MΩ. If electric resistance value is abnormal, repair or replace wire
harness or connector; if normal, proceed to the next procedure.
(d) Confirm that the circuit fault disappears after installing new knock sensor.
1) Replace with new knock sensor.
2) Conduct road testing after eliminating the fault.
3) Read the DTC. If there is no new DTC output, the knock sensor should be replaced; if there is new DTC
output, check and replace ECM.
12. The schematic diagram for diagnosing the fault of circuit of crankshaft position sensor
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Fig. 2-320
Read the stable data with the hand-held tester. The stable data records the engine condition when a fault is
detected. It can be used to judge that if the sedan is running or stopped when a fault occurred, if the engine
is preheated, and if the air-fuel percentage is too high or too low, etc. First check the fault with DTC. If
there is no fault detected, diagnose and eliminate the mechanical system faults.
(a) Check crankshaft position sensor (including electric resistance)
Measure the electric resistance between Terminal A and B of crankshaft position sensor connector. The
value should be 560Ω±10％ (25Ω)
(b) Check wire harness and connector (ECM-crankshaft position sensor):
1) Disconnect ECM connector.
2) Disconnect the connector of crankshaft position sensor.
3) Measure the electric resistance Terminal J112 of ECM connector and Terminal A of crankshaft position
sensor connector. The resistance value should not be more than 1Ω.
4) Measure the electric resistance between Terminal J128 of ECM connector and Terminal B of crankshaft
position sensor connector. The resistance value should not be more than 1Ω.
5) Measure the electric resistance between Terminal J112 and J128 of ECM connector. The value should
not be less than 1MΩ.
The value should not be less than 1MΩ.
The value should not be less than 1MΩ.
If the electric resistance is abnormal, repair or replace the wire harness or connector. If normal, proceed to
the next procedure.
(c) Check the installation condition of crankshaft position sensor. If abnormal, tighten the sensor; if normal,
proceed to the next procedure.
(d) Check the timing belt pulley (signal plate) of the crankshaft:
1) Remove the timing belt pulley of the crankshaft
2) Check signal plate tooth. If abnormal, repair or replace timing belt pulley of the crankshaft; if abnormal,
check and replace ECM.
13. The schematic diagram for diagnosing the fault of circuit of idle speed control system:
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Fig. 2-321
(a) Use hand-held tester

1) Start the engine to maintain the idle speed until the engine temperature is normal.
2) Connect the tester, and check if the engine rotation speed displayed on the tester is within the range of
800±50rpm. If the rotation speed is normal, the idle speed air control valve is normal. If not within the
range, proceed to the next procedure.
3) Check if the values of opening of throttle valve position sensor, water temperature sensor and system
voltage are normal. If the values above are abnormal, check the sensors above and their circuits. If the
values are normal, proceed to the next procedure.
(b) Turn the ignition switch to OFF position, disconnect the connector of ECM and sensor, and check the
connection condition of wire harness,
1) Measure the electric resistance between Terminal J133 of ECM connector and Terminal B of sensor. The
value should not be more than 1Ω.
2) Measure the electric resistance between Terminal J134 of ECM connector and Terminal A of sensor.
The value should not be more than 1Ω.
3) Measure the electric resistance between Terminal J153 of ECM connector and Terminal C of sensor. The
value should not be more than 1Ω.
4) Measure the electric resistance between Terminal J154 of ECM connector and Terminal D of sensor.
The value should not be more than 1Ω.
5) Measure the electric resistances between connector Terminal J133, J134, J153, J154 and vehicle body
earth wire. The value should not be less than 1MΩ.
If the resistance values above are abnormal, repair or replace wire harness or connector; if normal, proceed
to the next procedure.
(c) Replace idle speed air control valve and restart the engine. Check if the idle speed is normal. If
abnormal, replace the ECM.
14. Injector circuit fault diagnosis
(a) Check the working condition of injector
1) Check the working noise of each injector
Check with sound detector if the working noise of engine at constant rotation speed is normal when the
engine is running or starting.
2) If there is no sound detector, the working condition of the injector can be checked with your finger. If
there is no working noise or abnormal working noise, check the wire harness pin, injector or fuel injection
signal.
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(b) Check the electric resistance of the injector
1) Remove the injector connector.
2) As shown in Fig. 2-322, measure the electric resistance between the two pins of the injector with
ohmmeter.
Fig. 2-322
Electric resistance: 12-16Ω at 20℃ (68°F)
If the electric resistance is out of the range, replace the injector.
3) Reconnect the injector connector.
Section III Ignition System
Note:
1. Connect a revolution meter in ignition system, and connect the test wire of revolution meter to the
Terminal IG (-) of diagnosis connector.
2. As some revolution meter are not compatible with the ignition system, it is advised to confirm the
compatibility of the revolution meter and ignition system to be diagnosed.
3. Do not connect the earth terminal of revolution meter with the earth wire. Otherwise, the lighter and (or)
ignition coil may be damaged.
4. Do not disconnect with the battery when the engine is running.
5. The vehicle body earth wire should be connected correctly when checking the lighter.
Check on vehicle
1. Spark test
A. Check the generation of spark
(a) Disconnect high voltage damping wire from spark plug.
(b) Remove the spark plug.
(c) Install spark plug to each high voltage damping wire.
(d) Connect the spark plug to the earth.
(e) Check if there is spark when the engine is started.
Note: In order to prevent the gasoline spray out from the injector during test, the engine start duration should not
exceed 1-2 seconds. If there is no spark, proceed to the following test.
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2. Check high voltage damping wire

(a) Remove the high voltage damping wire from the spark plug.
(b) Disconnect the high voltage damping wire from rubber cap. Do not pull the damping wire.
Note:
Pulling or bending the damping wire would damage the inner conductor.
Do not wipe off all the oil on the grommet after removing the high voltage damping wire.
(c) Check the electric resistance of high voltage damping wire.
As shown in Fig. 2-323, measure the electric resistance of high voltage damping wire with ohmmeter.
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Fig. 2-323
Maximum electric resistance: 25KΩ for each damping wire
If the electric resistance of damping wire is over the maximum electric resistance, check the terminal. And
replace the high voltage damping wire.
(d) Reconnect the high voltage damping wire to the spark plug.
Make sure the high voltage damping wire and clip are correctly installed.
3. Check the spark plug
(a) Disconnect the high voltage damping wire from the spark plug.
(Refer to the first step of checking of high voltage damping wire.)
(b) Remove the spark plug
As shown in Fig. 2-324, remove the spark plug with 16mm spark plug special wrench.
Fig. 2-324
(c) Wash the spark plug
As shown in Fig. 2-325, wash the spark plug with spark plug cleaner or wire brush.
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Fig. 2-325
(d) Visually check the spark plug
Check the electrode abrasion, screw thread damage and insulator damage condition of spark plug.
If an abnormal condition is detected, replace the spark plug.
Recommended spark plug: CHAMPION
(e) Adjust electrode space
As shown in Fig. 2-326, bend the out electrode carefully to correct the electrode space.
Fig. 2-326
Correct electrode space: 0.8mm
(f) Install spark plug
Install spark plug with 16mm spark plug special wrench.
Torque: 18N·m
(g) Reconnect the high voltage damping wire to spark plug.
(Refer to the (c) 3 steps of checking the high voltage damping wire.)
4. Check the ignition coil

(a) Check the electric resistance of primary coil
Measure the electric resistance between Terminal A and C with ohmmeter.
Electric resistance of primary coil:
Cold condition: 0.36-0.55Ω
Hot condition: 0.45-0.65Ω
If the measured electric resistance is out of the range, replace the ignition coil.
(b) Check the electric resistance of secondary coil
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Measure the electric resistance between the positive pole (+) of ohmmeter and high voltage damping wire
terminal.
Electric resistance of secondary coil: cold condition: 9.0-15.4KΩ; hot condition: 11.4-18.1KΩ
If the measured electric resistance value is out of the range, replace the ignition coil.
5. Check the crankshaft position sensor
Note: The “cold condition” and “hot condition” mean the temperature of the sensor. “Cold condition” is
from -10℃ to 50℃, and “hot condition” is from 50℃ to 100℃.
(a) Remove the crankshaft position sensor (refer to the removal of crankshaft position sensor in the
crankshaft position sensor)
(b) Check the electric resistance of crankshaft position sensor
Measure the electric resistance of Terminal B and C with ohmmeter.
Electric resistance: cold condition: 1,630-2,740Ω; hot condition: 2,065-3,225Ω. If the electric resistance is
out of the range, replace the crankshaft position sensor.
(c) Reinstall the crankshaft position sensor
Installation of crankshaft position sensor (To install, reverse the removal procedure.)
Repair regulation Repair data
Table 2-5
Ignition order --- 1—3—2--4
High voltage damping
Electric resistance Maximum value 25KΩ for each damping wire
wire
Recommended spark plug ND K7RTC
Spark plug
Correct electrode space 0.8mm
Electric resistance of primary coil cold
condition 0.36-0.55Ω
Hot condition 0.45-0.65Ω
Ignition coil
Electric resistance of secondary coil cold 9.0-15.4KΩ
condition 11.4-18.1KΩ
Hot condition
Crankshaft position Electric resistance cold condition B-C 1,630-2,740Ω
sensor Hot condition B-C 20,65-3,225Ω
Section IV Start-up System
Check on vehicle
Note: Recheck the following items before operating the starter:
(1) Connection condition of connector
(2) Accessory installation, like anti-theft system
A. Removal and installation of starter
(a) Remove the magnetic switch
1) Remove the nut, cut the wire of magnetic switch terminal.
2) Loosen 2 nuts fasten on starter house by magnetic switch.
3) Pull on the magnetic switch, and loosen the plunger piston couple on drive rod at the same time. Then
loosen the magnetic switch.
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4) Remove plunger piston cover.
B. Remove magnetic pole frame and armature
1) Remove the connection wire between solenoid switch and motor; remove the nut; and cut the wire from
the terminal.
Torque: 5.9 N·m
2) Remove 2 through bolts. Torque: 5.9N·m; model: 1.2KW
3) Remove magnetic pole frame and armature from solenoid switch assembly.
4) Remove the O ring.
Assembly notes:
Use new O ring.
Match the scab of magnetic pole frame and notch of solenoid switch.
C. Remove starter house, clutch assembly and gear
1) Remove 2 screws. Torque:
Model 1.2KW: 5.9 N·m
2) Remove the following parts from solenoid switch assembly:
Starter house, reverse spring, bearing, idler wheel and clutch assembly.
3) Remove the steel ball: aspirate the ball with magnetic needle from clutch bearing hole.
D. Remove brush carrier
1) Remove the 2 screws and the cover in magnetic pole frame.
Torque:
2) Remove the O ring from the magnetic pole frame. Assembly note: use new O ring.
3) Press down the spring with screwdriver and remove brush from brush carrier. Disconnect 4 brushes and
remove the brush carrier.
E. Remove armature from magnetic pole frame
F. Armature coil
1) Check the conduction condition of commutator
As shown in Fig. 2-327, the 2 bars on commutator to be checked with ohmmeter should be conductive. If
one bar is not conductive, replace the armature winding.
2) Check earth connection condition of commutator
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Fig. 2-327
As shown in Fig. 2-328, check with ohmmeter. It should not be conductive between commutator and
armature coil core. If it is conductive, replace the armature winding.
Fig. 2-328
G. Commutator
(a) Check the surface burn and pollution condition of commutator
If the surface is polluted or burnt, process it with sand paper or on lathe.
(b) Check gear ring difference of commutator
1) Lay the commutator on V shape stow-wood.
2) Measure gear ring difference with dial indicator gauge.
Maximum gear ring difference: 0.05mm
If the gear ring difference exceeds the maximum value, correct it on lathe.
(c) Check commutator diameter
As shown in Fig. 2-329, measure the diameter of commutator with vernier caliper.
Fig. 2-329
Standard diameter:
Model 1.2KW: 30mm
Model 1.4KW: 30mm
Model 2.0KW: 35mm
Minimum diameter:
Model 1.2KW: 29mm
Model 1.4KW: 29mm
Model 2.0KW: 34mm
If the diameter is smaller than the minimum value, replace the armature.
(d) As shown in Fig. 2-330, check under cut depth.
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Fig. 2-330
Make sure that the under cut part is clean and without foreign material. And the fringe should be smooth.
Standard under cut depth:
Model 1.2KW: 0.6mm
Model 1.4KW: 0.6mm
Model 2.0KW: 0.7mm
Minimum under cut depth:
0.2mm
If the under cut depth is smaller than the minimum value, correct it with hacksaw blade.
H. Magnetic pole frame (magnet exciting coil)
(a) Check the open circuit condition of magnet exciting coil
As shown in Fig. 2-331, check with ohmmeter. It should be conductive between the wire and carbon brush
of magnet exciting coil. If not conductive, replace the magnetic pole frame.
Fig. 2-331
(b) Check the earth connection condition of magnet exciting coil
As shown in Fig. 2-332, check with ohmmeter. And it should not be conductive between the end of magnet
exciting coil and magnetic pole frame. If conductive, repair or replace the magnetic pole frame.
Fig. 2-332
Model 2.0kW
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Check electric resistance of commutating coil
Check the electric resistance with ohmmeter between Terminal A and Terminal B of commutator.
Standard electric resistance:
1.5-1.9Ω at 20℃
I. Brush
Check brush length
As shown in Fig. 2-333, measure the brush length with vernier caliper.
Fig. 2-333
Standard length:
Model 1.2kW: 15.5mm
Model 1.4kW: 15.5mm
Model 2.0kW: 15.0mm
Minimum length:
Model 1.2kW: 10.0mm
Model 1.4kW: 10.0mm
Model 2.0kW: 9.0mm
If the length is smaller than the minimum value, replace the brush carrier and magnetic pole frame.
J. Brush spring. As shown in Fig. 2-334
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Fig. 2-334
K. Brush carrier
检查电刷架绝缘情况
Check the insulation condition of brush
As shown in Fig. 2-335, check with ohmmeter. It should not be conductive between the positive pole (+)
and negative pole (-) of brush carrier. If conductive, repair or replace the brush carrier.
Fig. 2-335
L. Clutch and gear
(a) Check gear tooth
Check the abrasion or damage condition of gear tooth of small planet gear, idler wheel and clutch
assembly.
If there is damage, replace the gear or clutch assembly.
If there is damage, check the abrasion or damage condition of ring gear of fly wheel.
(b) Check small planet gear of clutch
As shown in Fig. 2-336, hold the starter clutch and rotate the small planet gear in clockwise direction. The
small gear should be able to rotate freely. And then try to turn the small planet gear in counter-clockwise
direction, which should not be able to rotate. If necessary, replace the clutch assembly.
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Fig. 2-336
Section V Discharge System
Precaution items------CH-2
Preparation--------------CH-2
Checking on vehicle---CH-3
AC-generator----------CH-7
Repair regulation------CH-1
Precaution items
1. Check if the battery wire is correctly connected to the terminals.
2. Disconnect the battery wire, and discharge the battery quickly.
3. Do not use high voltage insulation resistance detector when testing.
4. Do not disconnect the battery when the engine is rotating.
Special tools (special service tools)
Table 2-6
Jet pump camshaft taper bearing inner ring replacer Rotator rear bearing cap
Jet pump spline shaft puller Rectifier end bracket
AC-generator rear bearing puller
AC-generator bearing replacer Rotator rear bearing

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AC-generator belt device nut wrench suit
Replacer suit Rotator front bearing
Replacer 26
Replacer 50
Adapter
Equipment
Table 2-7
Ammeter (A)
Battery weight meter
Belt tension meter
Torque spanner
Vernier caliper Rotator (slip ring), brush
I. Check on vehicle
Check battery electrolyte position
Check the electrolysis amounts of all batteries.
1. Maintenance free battery
If lower than the lower level, replace the battery (or add distilled water if possible). Check the discharge
system. As shown in Fig. 2-337.
Fig. 2-337
2. Non-maintenance free battery
(a) Check electrolyte density
As shown in Fig. 2-338, check the electrolyte density of each battery. If lower than the lower level, add
distilled water.
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Fig. 2-338
Standard density: 20℃: 1.25-1.29
If the density is smaller than the standard density, discharge the battery.
(b) Check battery voltage
1) After the vehicle is driven, within 20 minutes after engine stop, the ignition switch in ON position and
electrical system (headlight, blower fan rotator, rear defroster, etc.) 60 seconds so as to remove the surface
charge.
2) Turn the ignition switch to OFF position and turn off the electrical system.
3) As shown in Fig. 2-339, measure the voltage between positive pole (+) and negative pole (-) of battery.
Fig. 2-339
Standard voltage:
20℃ (68°F): 12.5-12.9V
If the voltage is below the standard value, discharge the battery.
Note: As shown in Fig. 2-340, check indicator.
Fig. 2-340
(c) Check battery electrode, fusible wire or fuse.
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1) As shown in Fig. 2-341, check if the battery electrode is loose or corrupted.
Fig. 2-341
If the electrode is corrupted, clean the electrode.
2) Check the conduction conditions of fusible wire and fuse
3. Check drive belt
(a) As shown in Fig. 2-342, visually check if there is excessive wear, inhaul cable break and other problems
in the belt. And replace the drive belt if any problem is detected.
Fig. 2-342
Note: Crack is allowed in the surface of drive belt. If there is no gear rib, replace the drive belt.
(b) As shown in Fig. 2-343, press on the position shown in the figurewith the force of 98N to check the
deviation of drive belt.
Fig. 2-343
Drive belt deviation
New drive belt 7-9mm (0.28-0.35 inch)
Old drive belt 11.5-13.5mm (0.45-0.53 inch)
Adjust the drive belt deviation if necessary
Reference
Check the tension degree of drive belt with tension meter.
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Tension degree of drive belt:
New drive belt 685-785N
Old drive belt 295-440N
If the tension degree of drive belt is too poor, adjust it.
Note:
“New belt” means drive belt that not used for over 5 minutes in rotating engine.
“Old belt” means drive belt that used for 5 minutes or above in rotating engine.
As shown in Fig. 2-344, check if the drive belt matches the gear groove after installing the drive belt.
Fig. 2-344
Check with hand to confirm the belt does not roll out of the groove.
Run the engine for about 5min after installing a new belt, and recheck the tension degree of the belt.
(c) Visually check the AC-generator wire and listen for the noise.
1) Check if the wire is in good condition.
2) Check if there is abnormal noise in AC-generator when engine is running.
(d) Check discharge alarm light circuit
1) Ignition switch should be in ON position, and the discharge alarm light should be turned on.
2) Start engine, and the discharge alarm light should be turned off.
If the discharge alarm light does not work as described above, check and repair the DTC of circuit of
discharge alarm light.
(e) Check idle load charge circuit
Note: If use battery/AC-generator tester, connect the tester and indicator according to the manufacturer’s
instructions.
If there is no tester, connect the voltmeter and ammeter with charge circuit:
Disconnect the circuit from the Terminal B of AC-generator, and connect it to the contact clip of negative
pole (-) of ammeter
Connect the contact clip of positive pole (+) of ammeter to the Terminal B of AC-generator.
Connect the wire of positive pole (+) of voltmeter to Terminal B of AC-generator.
As shown in Fig. 2-345, connect the negative pole (-) of voltmeter to the ground.
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Fig. 2-345
(f) Check the charge circuit according to the following regulations:
Rotate the engine at 2,000rpm, and check and read the number on the ammeter and voltmeter.
Standard current: 10A or less
Standard voltage: 14.0-14.8V (25℃)
13.5-14.3V (115℃)
If the number displayed on voltmeter is larger than standard voltage, replace IC regulator.
As shown in Fig. 2-346, if the number displayed on voltmeter is smaller than standard voltage, check the IC
regulator and AC-generator in the following order: earth connection condition of Terminal F, and start
engine and check the number displayed on voltmeter of Terminal B.
Fig. 2-346
If the number displayed on voltmeter is larger than the standard voltage, replace the IC regulator.
If the number displayed on voltmeter is smaller than the standard voltage, check the AC-generator.
(g) Check loaded discharge circuit
1) When the engine is rotating at 2,000rpm, turn on the high beam and set the heater switch in HI position.
2) Check the number displayed on ammeter.
Standard current: 30A or larger
If the number displayed on ammeter is smaller than the standard current, replace the AC-generator.
Note: If the battery is completely discharged, sometimes the number displayed on ammeter will be smaller
than the standard current.
Removed and installed parts of AC-generator
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Fig. 2-347
II. AC-generator removal
1. Remove the rear end cap
(a)As shown in Fig. 2-348, remove nut and terminal insulated sleeve.
Fig. 2-348
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(b) M/T:
As shown in Fig. 2-349, remove 3 nuts and the end cap.
Fig. 2-349
2. Remove brush
(a) M/T:
1) As shown in Fig. 2-350, remove 2 screws and brush carrier.
Fig. 2-350
2) Remove brush carrier cover from brush carrier.
3. Remove IC regulator
As shown in Fig. 2-351, remove 3 screws and IC regulator.
Fig. 2-351
4. Remove rectifier bracket
(a) As shown in Fig. 2-352, remove 4 screws and rectifier bracket.
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Fig. 2-352
(b) Remove 4 rubber insulators.
5. Remove pulley
As shown in Fig. 2-353, hold the special tool (A) with torque wrench, and screw down the special tool (B)
in clockwise direction to appointed torque.
Fig. 2-353
Torque: 39N·m
Special tool (A) should be tightly fastened to rotator bearing.
(b) As shown in Fig. 2-354, put special tool (C) in punch pliers.
Fig. 2-354
(c) Install generator to special tool (C).
(d) As shown in Fig. 2-355, loosen the belt pulley nut, and turn special tool (A) in direction shown in the
figure.
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Fig. 2-355
Note: In order to prevent rotator bearing, do not loosen the pulley nut for over half-turn.
(e) Remove generator from special tool (C).
(f) As shown in Fig. 2-356, turn special tool (B) and remove special tool (A and B).
Fig. 2-356
(g) Remove belt pulley nut and belt pulley.
6. Remove rectifier end bracket
(a) As shown in Fig. 2-357, remove 4 nuts.
Fig. 2-357
(b) As shown in Fig. 2-358, remove rectifier end bracket with special tool.
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Fig. 2-358
7. Remove rotator from drive end bracket.
Check and repair the AC-generator
(a) Check and repair the rotator.
1) Check the conduction condition of rotator.
As shown in Fig. 2-359, check the conduction condition between slip rings with ohmmeter.
Fig. 2-359
Standard electric resistance (cold condition): M/T: 2.1-2.5Ω
As shown in Fig. 2-360, replace rotator.
Fig. 2-360
2) Check the earth connection condition of rotator.
As shown in Fig. 2-361, check with ohmmeter. And it should not be conductive between the slip ring and
rotator.
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Fig. 2-361
As shown in Fig. 2-362, if not conductive, replace rotator.
Fig. 2-362
3) Check slip ring
a. Check roughness or scratch on slip ring.
If it is too rough or there is scratch, replace rotator.
b. Measure diameter of slip ring with vernier caliper.
Standard diameter: 14.2-14.4mm
Minimum diameter: 12.8mm
As shown in Fig. 2-363, if the diameter measured is smaller than the minimum diameter, replace rotator.
Fig. 2-363
(b) Check and repair stator (drive end bracket)
1) Check if the circuit of stator is open.
Check with ohmmeter, and it should be conductive between coil and wire.
If not conductive, replace drive end bracket assembly.
2) Check earth connection condition of stator.
Check coil wire and drive end frame with ohmmeter, and it should not be conductive between them.
If conductive, replace drive end bracket assembly.
(c) Check and repair brush
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1) Check exposed length of brush.
Measure the exposed length of brush with vernier caliper.
Standard exposed length: 10.5mm
Minimum exposed length: 1.5mm
If exposed length is less than the minimum exposed length, replace brush (M/T).
M/T: If necessary, replace brush.
2) As shown in Fig. 2-364, cut and remove brush and spring.
Fig. 2-364
3)As shown in Fig. 2-365, insert a new brush wire harness in the brush hole, and then insert the spring and
brush.
Fig. 2-365
4) Weld the brush on brush carrier in accordance with regulated exposed length.
End. Exposed length: 10.5mm
5) Check the brush which should be able to move smoothly on brush carrier.
6) Cut spare wire harness. Coat insulated paint on welding area.
(d) Check and repair rectifier (rectifier bracket)
1) Check positive direction rectification of rectifier
As shown in Fig. 2-366, connect one probe of ohmmeter to positive pole (+), and the other to each rectifier
terminal.
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Fig. 2-366
Exchange the pole of tester probe and repeat Step (a).
Check the ohmmeter. One should be conductive and the other should not be conductive.
If the conduction condition is not the same as described above, replace rectifier.
2) Check negative pole of rectifier
As shown in Fig. 2-367, connect a probe of ohmmeter to each positive pole, and the other probe to the
terminal of rectifier.
Fig. 2-367
Exchange the pole of tester probe and repeat step (a).
One should be conductive and the other should not be conductive. If the conduction condition is not the
same as described above, replace rectifier.
(e) Check and repair bearing
1) Check front bearing
Check roughness degree or wear condition of bearing.
2) Replace front bearing if necessary
As shown in Fig. 2-368, remove 4 bolts, bearing bearer and bearing.
Fig. 2-368
As shown in Fig. 2-369, press out the bearing with special tool and holding-down device.
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Fig. 2-369
Press in a new bearing with special tool and holding-down device.
As shown in Fig. 2-370, install bearing bearer and 4 bolts.
Fig. 2-370
Torque: M/T: 2.6N·m

3) Install rear bearing
Check roughness degree and wear condition of bearing.
Replace rear bearing if necessary.
As shown in Fig. 2-371, remove bearing cap and bearing with special tool.
Fig. 2-371
Note: Do not damage the fan.
Place the bearing cap on rotator.
As shown in Fig. 2-372, press down a new bearing with special tool and holding-down device.
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Fig. 2-372
As shown in Fig. 2-373, push in bearing cap with special tool.
Fig. 2-373
(f) AC-generator assembly
1) Place drive end bracket to belt pulley.
2) As shown in Fig. 2-374, install the rotator to drive end bracket.
Fig. 2-374
3) Install rectifier end bracket.
As shown in Fig. 2-375, slowly press down the rectifier end bracket with a 29mm socket wrench and
holding-down device.
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Fig. 2-375
Install 4 nuts.
Torque: 4.5 N·m
4) Install belt pulley
Screw down the belt pulley nut with your hand, and install the belt pulley to stator bearing.
As shown in Fig. 2-376, hold special tool (A) with torque wrench, and tighten special tool (b) to appointed
torque in clockwise direction.
Fig. 2-376
Torque: 39N·m
Special tool (A) should be fastened on belt pulley bearing.
As shown in Fig. 2-377, put special tool (C) in punch pliers.
Fig. 2-377
As shown in Fig. 2-378, install AC-generator to special tool (C).
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Fig. 2-378
As shown in Fig. 2-379, turn special tool (A) in the direction shown in the figure so as to screw the belt
pulley nut.
Fig. 2-379
Torque: 110.5 N·m
Remove AC-generator from special tool (C).
Use special tool (B) and remove special tool (A and B).
5) Install rectifier bracket

As shown in Fig. 2-380, install 4 rubber insulators on wire.
Fig. 2-380
Note: Pay attention to the installation direction of rubber insulators.
Install rectifier bracket and 4 screws.
Torque: M/T: 2.0N·m
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6) As shown in Fig. 2-381, install IC regulator and brush carrier.
Fig. 2-381
M/T:
As shown in Fig. 2-382, install brush carrier cover to brush carrier.
Fig. 2-382
Note: Pay attention to the installation direction of brush carrier.
As shown in Fig. 2-383, put together the IC regulator and brush carrier on the same level.
Fig. 2-383
As shown in Fig. 2-384, install 5 screws, and the space between brush and socket connector should be
about 1mm (0.04in).
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Fig. 2-384
Torque: 2.0N·m
Install brush carrier cover
7) Install rear end cap
A. M/T:
Install end cap and 3 nuts.
Torque: 4.4N·m
B. Install terminal insulated sleeve and nut.
Torque: 4.1N·m
7. Check if the rotator rotates smoothly
Repair data
Table 2-6
Battery Proportion At 20℃ (68°F) 1.25-1.29
Skewness degree New 5-7mm
Old 7-8mm
Drive belt
Tension degree New 685-785N
Old 295-440N
Rated output M/T 12 V 7A
Electric resistance of rotator coil M/T 2.1-2.5Ω
Slip ring diameter STD 14.2-14.4mm
AC-generator
Minimum value 12.8mm
Brush exposed length STD 10.5mm
Minimum value 1.5mm
IC regulator Calibration voltage 13.2-14.8V
Torque range
Table 2-7
Parts to be tightened N·m
Bearing bearer×drive end bracket M/T 2.6
Rectifier end bracket×driven end bracket 4.5
AC-generator belt×rotator 110.5
Rectifier end bracket×brush carrier, IC regulator 2.0
Rectifier bracket×rectifier end bracket coil wire M/T 2.0
Rear end cap×rectifier bracket 4.4
Plate electrode terminal×rectifier bracket bolt 3.8
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Terminal insulator×rectifier bracket 4.1
Chapter VI Electronic Injection System
Section I Introduction
I. Fundamentals
The electronic injection system is a multi-point fuel injection system with electronic control unit (ECU).
With various sensors installed on different parts of the engine to measure each working parameter of the
engine, the ECU can precisely control the fuel injection volume by controlling the fuel injector according to
the pre-set control program in the computer, and achieve the most favorable air-fuel mixture for the engine
under any working condition. With the control program in the ECU and relevant actuator, such functions as
fuel increase at start, fuel increase at warm-up, fuel increase at acceleration, fuel increase at full load, fuel
decrease at deceleration, fuel cut at idle speed, and automatic idle speed control are available in this system,
which can achieve special air-fuel mixture for the engine under the special working condition. Therefore,
the engine enjoys good performances in fuel efficiency and exhaust emission, and the service performance
of the vehicle is improved at the same time. Besides, the trouble diagnostic modes in the ECU can make the
researching of troubles much easier.
II. Structure of electronic control system
The electronic control system is divided into the following three parts:
1. (1) Sensor---Convert various non-electrics physical quantities of the engine into electrics physical
quantities, and then send them to the ECU. The sensors on ECU of Lifan 320 (LF479Q3 engine, close
coupling catalytic converter, aluminous intake manifold) include:
① Intake pressure and temperature sensor
②Throttle position sensor
③Coolant temperature sensor
④ Heated oxygen sensor (front and rear oxygen sensor, only front oxygen senor available under National
III Emission Standard, front and rear oxygen sensor available under National III Emission Standard
(Simplified) + EOBD and in National IV Emission Standard)
⑤ Knock sensor
⑥ Crankshaft position sensor
Weak acceleration sensor (unavailable under National III Emission Standard (Simplified), available under
National III Emission Standard +EOBD and under National IV Emission Standard).
2. Electronic control unit (ECU) is the “brain” for the whole electronic control system, which analyses and
processes all the information from sensors, sends orders to actuator, and makes the engine work under the
best condition.
3. Actuator is to perform the orders from the ECU. The actuator is the “hand” and “leg” of the electronic
control system, which include: ① Fuel pump, ② Fuel injector, ③ Ignition coil, ④ Idle speed actuator with
stepper motor, ⑤ Canister control valve.
III. Four stroke engine multi-point electronic fuel injection
1. Simultaneous injection: Injectors in all cylinders inject fuel simultaneously, with 2 times of fuel
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injection at each circle in each cylinder.
2. Group injection: Even number cylinders ignite in succession, and two cylinders inject fuel
simultaneously. For example, Cylinder 1 and 3 in the 4 cylinders inject fuel simultaneously; and Cylinder 2
and 4 inject fuel after the crankshaft turn over 360°. Each cylinder injects one time in each circle.
3. Orderly injection: Injector in each cylinder injects fuel in fixed phase, and injects one time at each
circle in each cylinder.
As the gas mixtures in all the cylinders are different during simultaneous injection, it is the worst situation
for the engine to work. And the gas mixtures in all cylinders are the same during orderly injection, which is
the best situation for the engine to work. Group injection is between the former two.
IV. Basic functions of gasoline engine ECU
1. Electronic fuel quantitative control
As the most important function in gasoline engine ECU, it plays an key role in power, energy saving and
exhaust of the engine and mobility and comfort degree of the whole vehicle, which involves O2 closed-loop
control, start control, after-start control, engine warming control, idle speed control (idle speed rotation
control), full load control, acceleration and deceleration control, overspeed fuel cut control, towing astern
fuel cut control and evaporative emission control (canister control), etc.
2. Electronic control on electronic ignition timing and ignition close angle
As an important function next to fuel quantity in ECU, it also plays an important role in power, energy
saving and exhaust of the engine and mobility and comfort degree of the whole vehicle, including
electronic knock control.
V. Air-fuel ratio in gasoline engine
Air-fuel ratio is the quality proportion of air and fuel in air-fuel gas mixture (gas mixture).
Theoretical air-fuel ratio is the quality proportion of air and fuel in gas mixture when both air and fuel are
completely burnt out. As a constant, theoretical air-fuel ratio changes with different fuels, and the ratio for
gasoline and diesel oil is about 14.7:1.
The ratio between actual air-fuel ratio and theoretical air-fuel ratio is excess air coefficient (λ).
λ=1 means that the actual ratio equals theoretical ratio;
λ>1 means that the actual ratio is larger than the theoretical ratio, the gas mixture is dilute;
λ<1 means that the actual ratio is smaller than the theoretical ratio, the gas mixture is thick.
VI. Fundamentals of electronic control of gasoline engine ignition timing
1. Key aspect of electronic control of ignition timing
The key aspect of electronic control of ignition timing is to control the ignition advance angle. And the
ignition advance angle should be adjusted to achieve the largest power, torque and lowest fuel consumption
result under the condition of no knock and no excess of emission limitation.
2. Knock and knock control
Knock is the spontaneous combustion phenomenon of unburned gas mixture in the cylinder. Knock harms
the engine greatly, and severe knock will damage the engine. And because of this knock, the traditional
carburetter engine has to choose a small ignition advance angle at the cost of low torque and power and
high fuel consumption. While the engine with electronic fuel injection control can prevent knock through
adjusting the ignition advance angle to a smaller angle. As a result, a comparatively large ignition advance
angle in usual time can obviously improve the power and torque and decrease the fuel consumption.
The knock control function of fuel injection engine with electronic control is based on the knock signal
from the knock sensor. As the signals from knock sensor include other vibration signals caused by other
mechanical reasons, ECU has to process and analyze these signals and choose the right one. If necessary
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ECU will also adjust the ignition advance angle to a smaller angle to avoid knock, and resume to the
previous ignition angle gradually when there is no knock signal.
Section II Part Structure and Performance
I. Intake pressure and temperature sensor
Fig. 2-1 Intake air sensor element

1. Function: Measure the absolute pressure of the 0.1-0.2bar intake manifold and the temperature of the
intake air flow, and provide load information for the engine.
2. Structure and principle: The sensor consists of intake manifold absolute pressure sensor and intake air
temperature sensor, which is installed on the pressurizer tank.
3. Intake air pressure sensor: made by a silicon chip. There is a pressure diaphragm on the silicon chip
and are 4 piezoelectric resistances on the diaphragm. The 4 piezoelectric resistances build up a wheatstone
bridge. Besides the pressure diaphragm, there is also a signal process circuit on the chip. The silicon chip
and a metal housing build up a closed referential space, in which the absolute pressure of the air is
approximately zero. Then, a microelectronic mechanical system is established. There is a zero pressure on
the active side of the silicon chip and an absolute pressure of the intake manifold on the back side of the
chip. The thickness of the silicon chip is only several microns (μm), and the form of the chip will be
mechanically changed with the change of the absolute pressure of the intake manifold. Then, the 4
piezoelectric resistances and their resistance values will be also changed. After treated by the signal process
circuit on the chip, the pressure signal, which is linearly related to pressure, will be formed.
4. Intake air temperature: Made by a resistance with negative temperature coefficient (NTC). Similar to
water temperature sensor, the resistance value will decrease with the increase of the intake air temperature.
The change of the intake air temperature will be supervised and measured by a comparative electric circuit
within the ECU.
5. Connection circuit
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Fig. 2-2 Circuit diagram of intake air temperature and pressure sensor
6. Trouble diagnosis: The electronic devices of the intake air pressure sensor can diagnose such troubles
as open/short circuit and the damage of senor. When the ECU detects that the signal output by the sensor is
beyond its normal signal curve, the sensor will be in trouble. For example, when the intake air pressure is
higher or lower than its limit, the ECU will confirm that the sensor is in trouble (The pressure lower than
the limit at start will be excluded by the ECU.), then the engine MIL will be lighted and the operation under
trouble mode will be applied.
II. Throttle valve position sensor
1
2
Fig. 2-3 Throttle valve position sensor
1 - Voltage input 2 - Signal earth connection 3 - Signal output
1. Function: To provide throttle-alternator position information to the ECU. According to this information,
the ECU can obtain other information on engine load, working condition (start, idle speed, backing, partial
load, and full load), acceleration and deceleration. With the three-wire sensor, the ECU can detect the
opening of throttle through the change of pressure
2. Structure and principle: As an angle sensor with linear output, the sensor is made by two arc sliding
contact resistances and two sliding contact arms. The turning shaft of the sliding contact arm shares the
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same axis with the throttle shaft. Power supply voltage (US) of 5V is added to the both ends of the sliding
contact resistance. When the throttle turns, the arm turns and moves on the sliding contact resistance. Then,
the electric potential (UP) at the contact point will be led out as an output voltage. Actually, it is an angle
sensor and the real value adopted by the ECU is the value of Up/Us, and the value fluctuation of the sensor
caused by the fluctuation of the generator voltage will be avoided.
3. Connection circuit: As shown in the following circuit diagram of throttle valve position sensor.
Fig. 2-4 Circuit diagram of throttle valve position sensor
1 - Voltage input 2 - Signal earth connection 3 - Signal output
4. Trouble diagnosis: By monitoring the throttle-alternator position, when the signal higher or lower than
its limit, the ECU will confirm that the throttle position sensor is in trouble, then the engine operation under
trouble mode will be applied, and the engine MIL will be lighted (Knock on sensor and internal dirt will
contribute to engine troubles.)
5. Installation: Allowed fastening torque for fastening screw is 1.5N.m-2.5N.m. (Fastening torque for
installation screw is 1.5N.m～2.5N.m.)
III. Coolant temperature sensor
1. Function: To provide information on coolant temperature. To provide water temperature signal for the
ECU, and to control ignition timing and fuel injection pulse width at start, idle speed, and normal operation.
2. Structure and principle: Made by a thermistance with NTC. The resistance value will decrease with the
increase of the coolant temperature (not a linear relation). The thermistance with NTC is installed within a
copper sleeve. With a voltage division circuit, the resistance value of the thermistance is converted into a
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changing voltage and then provided to the ECU, and then the change of water temperature can be
monitored (internal structure of ECU).
4. Trouble diagnosis: When the coolant temperature is higher than its upper limit, or lower than its bottom
limit, the engine MIL will be lighted and the engine operation under trouble mode will be applied. Then,
the ECU will carry out the ignition and fuel injection control as per the water temperature set under the
engine water temperature trouble mode, and make the fan run at a high speed at the same time.
5. Limit data: 2.5±5%KΩ
6. Installation note: Tightening torque is 15±2N.m.
c b a
Fig. 2-5 Coolant temperature sensor
a - Water temperature signal pin of electronic injection system b - Meter water temperature pin c-
Signal earth connection
Fig. 2-6 Circuit diagram of coolant temperature sensor
a - Water temperature signal of electronic injection system b - Meter water temperature signal
IV. Knock sensor

1. Function: To provide engine knock information for the ECU for knock control.
2. Structure and principle: As a vibration acceleration sensor, installed on the cylinder block of the
engine. The sense element of the sensor is a piezoelectric element. The vibration of the cylinder block of
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the engine can be transferred to the piezoelectric crystal through the mass block within the sensor. Under
the mass block vibration pressure, voltage will be produced at the two polars of the piezoelectric crystal,
and the vibration signal will be changed into alternately changing voltage signal and be put out. Since the
frequency of the vibration signal caused by the engine knock is much higher than that of the vibration
signal caused by normal engine shock, the ECU can tell knock signal or non-knock signal after processing
the signal with wave filtering technology. When the load, rotation speed, and coolant temperature exceed
the threshold value and no trouble information record is available for the shock sensor, the signal of the
shock sensor will be used for shock closed loop control. When the shock closed loop control is activated,
the signal of the shock sensor will be sent to the ECU for amplification and wave filtering, and then
accumulated. If the accumulation exceeds the limit within a certain crank angle, the ECU will confirm that
shock occurs and decrease the ignition advance angle at this moment. If shock still occurs at the next cycle,
the ECU will further decrease the ignition advance angle. If no shock occurs at the following cycles, the
ECU will recover the original normal ignition advance angle.
Fig. 2-7 Knock sensor

J1-05
1 2 1 2
J1-69
Fig. 2-8 Circuit diagram of knock sensor
1 - Signal high 2 - Signal low
4. Trouble diagnosis: The ECU will monitor the sensors, actuators, power amplifying circuit and detecting
circuit. In case of any of the following situations, like shock sensor trouble, shock control data process
circuit trouble, unreliable cylinder judgment signal, incorrect shock sensor trouble mark level, and shock
closed loop control closed, the ignition advance angle stored in the ECU will be decreased for a safety
angle. When the trouble frequency is lower than the set value, the trouble mark level will be repositioned.
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5. Installation notes: Tightening torque is 20±5N·m. There is a hole in the middle of knock sensor, which
can be used to fasten it on the cylinder block with a M8 bolt. And use 25mm long bolt for cast-iron cylinder
block. Installation position should be easy for sensor to receive vibration signal from all cylinders, which
should be decided by modal analysis of cylinder block. Usually the knock sensor should be installed
between Cylinder 2 and 3 for an engine with 4 cylinders. Do not let engine oil, coolant, brake fluid, water
and other materials contact the sensor for a long time. Do not use any kind of washer when installing. The
metal surface of sensor must contact the cylinder block. Avoid resonance vibration of signal wire for
rupture prevention when installing the signal wire. And high voltage current between Pin 1 and 2 is not
allowed because this may damage piezoelectric element.
V. Oxygen sensor
1. Function: To provide the information that whether oxygen in the cylinder is too high after the fuel is
burned with the air in the cylinder. With this information, the ECU can carry out closed loop control for the
fuel ration. Therefore, the three main toxic elements (HC, CO, and NOX) of the engine exhaust can be best
converted and purified in the three-way catalytic converter.
2. Structure and principle: The sense element of the oxygen sensor is a ceramic pipe with holes and gaps.
The pipe is surrounded by engine exhaust and the air flows within the pipe. The ceramic pipe wall is a kind
of solid electrolyte with electric heating tube inside, which begins work when the ceramic pipe has been
heated to 300 0C (a feature of a solid electrolyte). With such a special material, the oxygen ions can freely
go through the ceramic pipe. Then, the concentration difference of the mixture will be converted into
potential difference, which will be put out in the form of electric signal. If the concentration of the mixture
is relatively high, the concentration difference of the oxygen ions inside and outside the ceramic pipe will
be relatively high, and the potential difference will be relatively high as well. At the same time, a lot of
oxygen ions will move to the outside from the inside, and the voltage output will be relatively high. If the
concentration of the mixture is relatively low, the concentration difference of the oxygen ions inside and
outside the ceramic pipe will be relatively low, and the potential difference will be relatively low as well.
At the same time, little oxygen ions will move to the outside from the inside, and the voltage output will be
relatively low. The working voltage of the oxygen sensor fluctuates from 0.1V to 0.9V, which will be
changed for 5-8 times within 10 seconds. In case of lower than the changing frequency, the oxygen sensor
shall be renewed, as it can not be repaired.
Fig. 2-9 Oxygen sensor

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Fig. 2-10 Circuit diagram of oxygen sensor
1 - Main relay output 2 - Oxygen sensor heating control 3 - Signal low 4 - Signal high
4. Trouble diagnosis: The ECU will monitor the sensors, actuators, power amplifying circuit and detecting
circuit. In case of any of the following situations, like unreliable battery voltage, unreliable air intake
manifold absolute pressure singal, unreliable engine coolant temperature signal, fuel injector driving stage
trouble, incorrect oxygen sensor trouble mark level, and fuel ration closed loop control closed, the fuel
ration will be confirmed according to the basic fuel injection time stored in the ECU.
5. Installation notes: The tightening torque of the oxygen sensor is 50～60N.m. Apply anti-rust oil to the
renewed oxygen sensor to prevent difficult removal due to rust. Oxygen sensor should be installed on
exhaust pipe where can represent the exhaust gas composition and meet the temperature limit, which means
that the position should be at the nearest position to the engine.
VI. Electronic control unit (ECU)
1. Function: The ECU is the key part of the electronic control system of the engine. The sensors provide
various signals to the ECU, and the ECU calculates the signals and sends orders to the actuators like fuel
injector, ignition coil etc to control the engine.
2. Structure: Made by a shielded housing and printed circuit board, many electronic control units
integrated on the board to control the electronic injection system.
3. Installation: Fixed under the instrument panel sundries box with bolt, the double interfaces ECU is
adopted.
4. Definition of LF479Q3 engine controller pin
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1 16
17 32 73
33 52
53 72
Fig. 2-11 ECU
Pin Pin Pin

Definition Definition Definition
Number Number Number
Main relay rear
J1-01 Ignition switch J1-02 J1-03 Vehicle speed
power supply
Oxygen sensor
J1-04 C, 5V, positive J1-05 D, 5V, negative J1-06
signal low
Medium-voltage
J1-07 Not used J1-08 Not used J1-09
switch
Crankshaft 58
J1-10 Not used J1-11 Serial data J1-12
teeth signal high
CAN line
J1-13 Not used J1-14 CAN line negative J1-15
positive
J1-16 Not used J1-17 Power supply 1 J1-18 Power supply 2
J1-19 Not used J1-20 D, 5V, positive J1-21 C, 5V, negative
J1-22 Trouble indicator J1-23 Not used J1-24 Throttle position
Intake air
J1-25 Not used J1-26 Not used J1-27
temperature
J1-28 Crankshaft 58 teeth signal low J1-29 Not used J1-30 Not used
Idle speed phase
J1-31 Engine trouble indicator J1-32 Ignition switch A J1-33
B output positive
Idle speed phase A output Power steering
J1-34 J1-35 Acceleration signal J1-36
negative signal
Rear oxygen sensor
J1-37 Not used J1-38 J1-39 A/C demand (+)
signal high
Pin Definition Pin Definition Pin Definition
Number Number Number
J1-40 Not used J1-41 Not used J1-42 Intake air
pressure
J1-43 Coolant temperature J1-44 Not used J1-45 Tachometer
J1-46 A/C compressor clutch relay J1-47 Fuel pump relay J1-48 Not used
control control
J1-49 Instrument power supply J1-50 High speed fan J1-51 Not used
relay control
J1-52 Ignition coil B J1-53 Idle speed phase A J1-54 Idle speed phase
output negative A output positive
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J1-55 Fuel injector of cylinder 1 J1-56 Fuel injector of J1-57 Not used
cylinder 3
J1-58 Not used J1-59 Not used J1-60 Not used
J1-61 Front oxygen sensor heating J1-62 Front oxygen J1-63 Canister solenoid
control sensor signal high valve control
J1-64 Rear oxygen sensor heating J1-65 Not used J1-66 Not used
control
J1-67 Low speed fan relay control J1-68 Not used J1-69 Knock signal
J1-70 Fuel injector of cylinder 2 J1-71 Fuel injector of J1-72 Headlight signal
cylinder 4
J1-73 System earth wire
VII. Electric fuel pump

1. Function: To deliver fuel in the oil tank to the engine with a certain oil pressure and volume, not greatly
affected by temperature and voltage.
2. Structure and principle: The fuel pump consists of DC motor, vane pump, and end cap (integrating
check valve, pressure release valve and anti-electromagnetic interference element), which shares the same
axle and housing with the motor. The bump and motor in the housing is surrounded by gasoline, which can
be used for cooling and lubricating material. The battery supplies power for the electric fuel pump through
a relay. The relay is connected with the fuel pump only when the engine starts and operates. When the
engine stops due to some troubles, the fuel pump will stop automatically. The maximum pressure at the
outlet of the fuel pump will be decided by the pressure release valve. As no-oil-return system is adopted,
the fuel pressure regulator is installed on the fuel pump assembly. The fuel pressure regulator can adjust the
pressure of the fuel pump to 380±10kPa to meet the demand of the system.
Fig. 2-12 Electric fuel pump

Fig. 2-13 ECU

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Note: The temperature of the fuel greatly affects the performance of the fuel pump. When operates under a
high temperature for a long time, the pressure of the fuel pump will decrease sharply. Therefore, if the
engine fails to start up after warm-up, please carefully check the fuel pump for working performance under
a high temperature.
VIII. Electro-magnetic injector
1. Function: According to the order from the ECU, the injector will carry out fuel injection and
atomization within a required time for the engine.
2. Structure and principle: The ECU will send electric pulse to the fuel injector coil to form magnetic
force. When the magnetic force is high enough to overcome the joint force of return spring pressure, pin
valve gravity, and friction, the pin valve begins to rise and the fuel injection starts. The maximum rise of
the pin valve will not exceed 0.1mm. When the fuel injection pulse stops, the pressure of the return spring
will close the pin valve.
Fig. 2-14 Injector

Fig. 2-15 Injector circuit diagram

Installation notes: The plugs for certain fuel injectors should be selected as per requirement. To facilitate
installation, it is recommended to apply clean silicon-free oil on the surface of the upper O ring connected
to the fuel distribution pipe. Take care not to pollute the internal of the injector and the injection hole by the
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oil. Install the injector vertically into the injector seat and fix the injector on the seat with a clip.
Note: For vehicles out of use for a long time, the adhesive gasoline within the injector can make the vehicle
fail to start.
4. Trouble diagnosis: The electronic injection system will carry out trouble diagnosis for the driving stage
of the fuel injector. When the driving stage of the injector is short or overloaded to the battery voltage, as
well as short and open to the ground, the trouble mark level will be positioned. At this moment, the closed
loop control and the self-learning pre-control of the oxygen sensor will be closed, while the self-learning
data last time will be effective. The trouble mark level will be repositioned after the trouble being removed.
IX. Idle speed actuator stepper motor
1. Function: A by-pass air intake passage will be provided by the idle speed actuator with stepper motor.
When the throttle is closed, air will enter into the engine through this by-pass passage. With a stepper
motor, the ECU can adjust the size of the passage, and then confirm the air volume into the engine. At the
same time, the ECU can also adjust the fuel injection volume on the basis of the air volume. With the
stepper motor, the ECU can change the working condition for the engine according to actual situations.
2. Structure and principle: As a mini-size motor, the stepper motor consists of several steel stators in a
circle and one rotator. Every stator is winded with a coil. The rotator is a permanent magnet, and at the
center of the magnet, there is a nut. All the coils of the stators are connected with the power supply
constantly. As long as the current direction of one of the coils changes, the rotator will turn for an angle.
When the current direction of the coil of each stator changes in a certain proper sequence, a rotary magnetic
field will be formed, and the rotator of the permanent magnet will rotate in a certain direction.
1
2
Fig. 2-16 Idle speed actuator stepper motor diagram
1 - To Pin ECU19 2 - To Pin ECU20 3 - To Pin ECU35 4 - To Pin ECU36
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Fig. 2-17 Circuit diagram of idle speed actuator stepper motor
1 - To Pin ECU19 2 - To Pin ECU20 3 - To Pin ECU35 4 - To Pin ECU36
4. Trouble diagnosis: The short and open circuit of the two coils of the idle speed stepper motor will be
monitored by the ECU. When such troubles occur, the engine MIL will be lighted and the engine will be
operated under trouble mode. If the engine fails to work normally after check the steps of the stepper motor
with a diagnostic instrument, the intake air pressure should be checked to ensure the normal operation of
the piston of the stepper motor.
X. Ignition coil
1. Function: To convert primary winding low voltage electricity into secondary winding high voltage
electricity, to produce spark to burn the mixture of fuel and air in the cylinder.
2. Grouped ignition: Based on the signal from the crankshaft/camshaft position sensor, the ECU controls
the low signal of ignition coil for the ignition of the engine according to crankshaft position sensor.
3. Structure and principle: Consists of primary winding, secondary winding, iron core, housing, etc.
When the battery is connected with the primary winding, the primary winding will be charged. When the
circuit of the primary winding is cut down by the ECU, the charge will stop. Meanwhile, the high voltage
electricity will be induced in the secondary winding.
Fig. 2-18 Ignition coil

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4. Trouble diagnosis: The ECU will not carry out trouble diagnosis for the ignition coil. Therefore, when
trouble occurs on the ignition coil, no diagnostic trouble code will be produced. Only the resistance of the
ignition coil can be checked for the normal operation of the coil. Under normal situation, the heat emitted
by the coil under operation will be high, and the over-high temperature of the coil will increase its
resistance value, which will cause such troubles as unstable running, automatic misfiring for the engine.
Fig. 2-19 Circuit diagram of ignition coil

Primary winding: 0.52±0.05- 221 - secondary winding: 9.84±0.9
XI. Canister control valve
1. Function: To control the air flow to clean the canister. The canister control valve is controlled by the
ECU based on the engine load, electric pulse duration and frequency (duty cycle). The over-accumulated
gasoline vapor in the activated canister will cause gasoline leakage and environmental pollution. Thus, the
canister solenoid valve is designed to be opened properly to introduce the over-accumulated gasoline vapor
into the intake pipe for combustion.
2. Structure and principle: Consists of solenoid coil, armature, valves, etc. A filter is considered for the
inlet hole. The air volume flows through the canister control valve is affected by the duty cycle of the
electric pulse output by the ECU, meanwhile, it is also affected by the pressure difference between the inlet
and outlet hole. When no electric pulse is produced, the canister control valve will be closed. According to
the signals from each sensor, the ECU can control the time for power connection of the canister solenoid
valve, and then control the volume of the cleaning air flow.
Fig. 2-20 Canister control valve

3. Trouble diagnosis: The ECU will carry out trouble diagnosis for the driving stage of the canister control
valve. When the driving stage of the canister control valve is short or overloaded to the battery voltage, as
well as short and open to the ground, the fuel ration closed loop control self-learning and the idle speed air
Ver：LF-20121225
ration self-learning will be closed, while the self-leaning data at that moment will be effective. When the
canister solenoid valve is under trouble, the engine is likely to experience unstable idle speed or over-high
idle speed.
Fig. 2-21 Circuit diagram of canister control valve
XII. Fuel distribution pipe

1. Function: To store and distribute fuel, and let redundant fuel return to fuel tank. The injector and fuel
pressure regulator are installed on it to provide a stable pressure environment for fuel injection system,
which can balance the fuel supply pressure and fuel supply amount and maintain the stable working
condition of engine.
2. Structure and principle: The fuel distribution pipe in this system consists of injector and fuel supply
pipe. As the system adopts no-return fuel control, there is no fuel pressure regulator in fuel supply pipe.
3. Installation requirements: Inlet and outlet fuel pipes are connected to rubber pipe and tightened by clip.
And the clip should match the rubber pipe to ensure that the inlet and outlet fuel pipe are tightly connected
with rubber pipe.
4. Trouble diagnosis: Usually there is a little chance for malfunction of fuel supply pipe. In most situations
the leakage in fuel system is caused by improper installation. Therefore, the old O ring for injector that has
been used can not be reused again when installing.
Section III Steps for Trouble Diagnosis with DTC
1. A/C evaporator outlet temperature sensor

Diagnostic Trouble Code (DTC) Trouble Location or Type
A/C evaporator temperature circuit high input---short or open to
P1535
power supply
P1536 A/C evaporator temperature circuit high input---short to ground
P1545 A/C high pressure switch or relay circuit trouble
Test
S/N Operation Actions
Results
1 Ignition switch in position ON. Next step
Disconnect the A/C evaporator outlet temperature sensor from Yes Next step
2 the harness. Measure the voltage between the two pins with a
No 4
multimeter. Is the voltage about 5V?
Check for open or short circuit between the two pins with a Yes Replace sensor
3
multimeter. No Replace ECU
Ver：LF-20121225
Connect an adapter between the ECU and the harness. Check Repair or replace
Yes
4 for open or short circuit between pin J1-09, J1-39 of the ECU harness
and the pin (1), (2) of the sensor with a multimeter. No Replace ECU
2. Throttle valve position sensor

P0122 Throttle/pedal position sensor/switch A circuit input low
P0123 Throttle/pedal position sensor/switch A circuit input high
Test
Results
Disconnect the throttle position sensor from the harness. Yes Next step
2 Measure the voltage between pin (1) and pin (2) with a
5
multimeter. Is the voltage about 5V? No
Measure the resistance between pin (1) and pin (2) with a Yes Next step
3
multimeter. Is the resistance between 1.6k and 2.4k? No Replace sensor
Slowly turn the throttle position sensor from one side to the Yes Replace sensor
other side. Check for open or short circuit or a jump
4
resistance between pin (1) (-) and pin (3) (+) with a No Replace ECU
multimeter.
Connect an adapter between the ECU and the harness.
Check for open or short circuit between pin J1-20, J1-05, Repair or replace
5 Yes
J1-24 of the ECU and the pin (1), (2), (3) of the sensor with harness
a multimeter.
3. Shock sensor
P0325 Shock sensor 1 circuit trouble
Test
Results
1 Turn off the ignition switch, and stop the engine. Next step
Disconnect the shock sensor from the harness. Measure the Yes Next step
resistance between pin (1) and pin (2) with a multimeter. Is
2
the resistance greater than 1MΩ? No Renew sensor
Gently knock around the shock sensor with a small hammer. Yes Next step
3 Check for AC signal output between pin (1) and pin (2)
No Replace sensor
with a multimeter.
4 Turn on the ignition switch, and do not start the engine. Next step
Connect an adapter between the ECU and the harness. Repair or replace
Yes
5 Check for open or short circuit between pin J1-05, J1-69 of harness
the ECU and the pin (1), (2) of the sensor with a multimeter. No Replace ECU
4. Intake manifold absolute pressure temperature sensor

Ver：LF-20121225
Intake manifold absolute pressure/atmospheric pressure circuit
P0107
input low
Intake manifold absolute pressure/atmospheric pressure circuit
P0108
input high
Test
Results
Disconnect the intake manifold absolute pressure/intake air Yes 4
temperature sensor from the harness. Measure the voltage
2
between pin (1) and pin (3) with a multimeter. Is the voltage No Next step
about 5V?
Yes
Check for open or short circuit between pin J1-21, J1-27, harness
3
J1-42 of the ECU and the pin (1), (3), (4) of the sensor with
No Next step
a multimeter.
In neutral position, start the engine, and keep idle speed.
Yes Replace ECU
Step on the accelerator. Through the adapter, measure the
5 voltage between pin (4) and pin (1) with a multimeter, Replace ECU
namely between pin J1-42 and pin J1-21 of the ECU. Does No Replace sensor
the voltage gradually increase to 4V?
5. Oxygen sensor
P0031 Heated oxygen sensor heater control circuit low (front)
P0032 Heated oxygen sensor heater control circuit high (front)
P0037 Heated oxygen sensor heater control circuit low (rear)
P0038 Heated oxygen sensor heater control circuit high (rear)
P0130 Oxygen sensor circuit trouble (front)
P0131 Oxygen sensor circuit voltage low (front)
P0132 Oxygen sensor circuit voltage high (front)
P0134 Unactivated oxygen sensor (front)
P0136 Oxygen sensor circuit trouble (rear)
P0137 Oxygen sensor circuit voltage low (rear)
P0138 Oxygen sensor circuit voltage high (rear)
P0140 Unactivated oxygen sensor (rear)
P1166 Oxygen sensor controller self-adaptive trouble diagnosis
Test
Results
2 Disconnect the oxygen sensor from the harness. Measure Yes Next step
Ver：LF-20121225
the voltage between pin (1) (+) and pin (2) (-) with a
No 4
Yes Replace ECU
Measure the resistance between pin (1) and pin (2) with a
3 Next step
multimeter. Is the resistance between 6k and 25k? No
Replace sensor
Check the fuse for the oxygen sensor heated circuit. Is the Yes Replace fuse
4
fuse OK? No Next step
Check for open or short circuit between pin (1) of the Repair or replace
Yes
oxygen sensor and the pin J1-02 of the main relay, as well harness
5
as between pin (2) of the oxygen sensor and the pin J1-61
No Next step
(front)/J1-64 (rear) of the ECU with a multimeter.
Connect the oxygen sensor, keep neutral position, start the
6 engine, and keep idle speed until the coolant reaches normal Next step
temperatue.
Disconnect the oxygen sensor from the harness. Measure Yes Next step
the voltage between pin (4) (+) and pin (3) (-) with a
7
multimeter. Is the voltage between 0V and 0.9V? No Replace sensor
Yes
Check for open or short circuit between pin J1-06, pin J1-62 harness
8
(front)/ J1-38 (rear) of the ECU and pin (3), pin (4) of the
No Replace ECU
sensor with a multimeter.
6. Intake manifold air temperature sensor

P0112 Intake air temperature circuit input low
P0113 Intake air temperature circuit input high
Test
Results
Disconnect the intake manifold absolute pressure/intake air Yes Next step
temperature sensor from the harness. Measure the voltage
2 As per S/N 4
between pin (1) and pin (2) with a multimeter. Is the voltage No
about 5V?
Measure the resistance between pin (1) and pin (2) with a Yes Replace ECU
3 multimeter. Does the resistance match with its temperature?
No Replace sensor
(refer to relevant part of the manual)
Yes
Check for open or short circuit between pin J1-21, J1-04, harness
4
J1-27 of the ECU and the pin (1), (3), (2) of the sensor with
No Replace ECU
a multimeter.
7. Coolant temperature sensor

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P0116 Engine coolant temperature circuit range/performance
P0117 Engine coolant temperature circuit input low
P0118 Engine coolant temperature circuit input high
P0119 Engine coolant temperature circuit breaks at interval
Test
Results
Disconnect the coolant temperature sensor from the Yes Next step
2 harness. Measure the voltage between pin (1) (+) and pin
No 4
(3) (-) with a multimeter. Is the voltage about 5V?
Yes Replace ECU
3
multimeter. Does the resistance match with its No Replace sensor
temperature? (refer to relevant part of the manual)
Yes
Check for open or short circuit between pin J1-05, J1-43 harness
4
of the ECU and the pin (1), (3) of the sensor with a
No Replace ECU
multimeter.
8. Fuel injector
P0261 Cylinder 1 fuel injector circuit low
P0262 Cylinder 1 fuel injector circuit high
Test
Results
1 Ignition switch in position ON, do not start the engine. Next step
Disconnect the electromagnetic fuel injector from the
2 harness. Connect the two pins of the multimeter with the Next step
pin (1) (+) and the engine respectively.
Yes Repeat 2
Ignition switch in position ON. Check if the voltage of 12V
3 Yes (all) As per S/N 6
can be read in the multimeter for about 1 second.
No Next step
Check for open or short circuit between pin J1-02 of the Repair or replace
Yes
4 main relay and pin (1) of solenoid fuel injector with a harness
multimeter. No Next step
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Repair or replace the fuel pump relay/main relay and Repair or replace
5 Yes
relevant circuit. harness
Connect an adapter between the ECU and the harness.
Check for open or short circuit between pin J1-55, pin
6 No Next step
J1-70, J1-56, J1-71 of the ECU and pin (2) of the solenoid
fuel injector with a multimeter.
Yes Repeat 7
Measure the resistance between pin (1) and pin (2) of the Yes (all) Next step
7 solenoid fuel injector with a multimeter. Is the resistance Replace
between 12Ω and 16Ω under the temperature of 200C? No electro-magnetic
fuel injector
Connect the solenoid fuel injector, keep neutral position, Yes Repeat 8
start the engine and keep idle speed. Disconnect the
8
electromagnetic fuel injector in sequence. Check the engine No Replace ECU
for vibration when each connector is removed.
9. Canister control valve driving stage

Evaporative emission control system, canister control valve
P0444
circuit open
Evaporative emission control system, canister control valve
P0445
circuit short
Test
Results
Start the engine, keep idle speed until the coolant reaches
1 Next step
normal temperature.
Disconnect the canister control valve from the harness. Yes Next step
2 Measure the voltage between the two pins with a
No 5 (check hot wire)
Connect the canister control valve, increase the engine Yes Next step
3 rotation speed to 1500r/m, touch the valve with your hand,
No 7 (check earth wire)
and check the valve for slight vibration and shock.
Yes Replace ECU
4 Check canister
multimeter. Is the resistance between 22 and 30? No
control valve
Check for open or short circuit between pin J1-02 of the Repair or replace
Yes
5 main relay and the pin (1) of the canister control valve with harness
a multimeter. No Next step
6 Repair or replace the main relay and its circuit.
Stop the engine. Check for open or short circuit between Repair or replace
Yes
7 pin J1-63 of the ECU and the pin (2) of the canister control harness
valve with a multimeter. No Replace ECU
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10. Malfunction indicator light (MIL) driving stage
P0650 MIL control circuit
Test
Results
Open the instrument panel, remove the MIL bulb, and Yes Next step
2
measure the voltage of the jack. Is the voltage about 12V? No 5 (check hot wire)
Check the MIL bulb for normal operation with a Yes Next step
3
multimeter. No Replace bulb
Yes
Check for open or short circuit between pin J1-63 of the harness
4
ECU and the input connector of the MIL bulb with a
No Replace ECU
multimeter.
Check the fuse for the heating circuit of the oxygen sensor. Yes Replace fuse
5
Is the fuse OK?
Repair or replace
Check for open or short circuit between pin 87 of the main Yes
6 harness
relay and pin (1) of the MIL jack with a multimeter.
No Next step
7 Repair or replace the main relay and its circuit.
11. Driving stage of stepper motor coil 1 and 2

Test
Results
Disconnect the stepper motor from the harness. Measure the Yes Next step
resistance between pin (1) and pin (2), as well as between pin
2 Replace idle speed
(3) and pin (4) of the stepper motor with a multimeter. Is the No
resistance between 40Ω and 80Ω? actuator
Measure the resistance between pin (1) and pin (2), as well as Yes Next step
3 between pin (3) and pin (4) of the stepper motor with a Replace idle speed
No
multimeter. Is the resistance infinite? actuator
Measure the resistance between pin (1) and pin (2), as well as Replace idle speed
Yes
between pin (3) and pin (4) of the stepper motor connected actuator
4
with the harness with a multimeter. Is the resistance about
No 下一步 Next step
12V?
Connect an adapter between the ECU and the harness. Check Repair or replace
Yes
for open or short circuit between pin J1-34, J1-33, J1-53, harness
5
J1-54 of the ECU and the pin (1), (2), (3), (4) of the stepper
No Replace ECU
motor with a multimeter.
Ver：LF-20121225
Section IV Steps for Trouble Diagnosis Based on Engine Symptom
Before the steps for trouble diagnosis based on engine symptom, carry out the following primary checks at
first:
1. Check the ECU and MIL for abnormal condition (for vehicles without MIL, skip this step);
2. To confirm no trouble information record found with a trouble diagnostic instrument or flasher;
3. Check the idle speed data after warm-up of the electronic control system with a trouble diagnostic
instrument for normal range;
4. Confirm the concern of the user and the actual location of the symptom.
Then, check the appearance:
1. Check the harness grounding for cleanness and tightness;
2. Check the vacuum pipe for break, twist and correct connection;
3. Check if the pipe is blocked; check if the inlet pipe is extruded or damaged;
4. Check the sealing between the throttle body and the intake manifold for damage;
5. Check the high voltage wire of the ignition system for break, aging and wrong connection;
6. Check the lead for correct connection and check the connector for looseness.
Key note: In case of the above-mentioned conditions, repair these troubles at first. Otherwise, the following
trouble diagnosis and maintenance will be affected.
Diagnosis help:
1. To confirm no trouble record found for the engine;
2. To confirm the concern of the user;
3. No abnormal condition is found after check following the above-mentioned steps;
4. During check and maintenance, do not ignore the impact on the system from the vehicle maintenance,
cylinder pressure, mechanical ignition timing, fuel condition, and so on.
5. Replace the ECU, and then carry out tests.
If the trouble is removed at this moment, the trouble is produced within the ECU. If the trouble can not be
removed at this moment, replace the original ECU, and repeat the steps.
1. Engine fails to run or runs slowly at start
Test
Operation Actions
S/N Results
Measure the voltage between the two terminals of the Yes Next step
1 battery with a multimeter. Is the voltage about Repair or replace
No
10-12.5V? battery
Turn the ignition switch to ON. Measure the voltage Yes Next step
2 between the ignition switch and the terminal of the Repair terminal or
No
battery positive pole. Is the voltage about 10-12.5V? replace lead
Turn the ignition switch to START. Measure the Yes Next step
voltage of the terminal of the ignition switch to connect
3 Repair or replace
with the positive pole of the start motor with a No
ignition switch
multimeter. Is the voltage greater than 8V?
Keep the ignition switch in START. Measure voltage of Yes Next step
4 the terminal of the positive pole of the start motor with Repair terminal or
No
a multimeter. Is the voltage greater than 8V? replace lead
Ver：LF-20121225
Repair or replace start
Check the start motor for open or short circuit with a Yes
5 motor
multimeter.
No Next step
Yes Remove the trouble
6 Check if the engine is locked for lack of lubrication.
No Next step
In winter, check if the start motor is affected by high Yes Replace the oil
7 resistance as improper engine lubricant and gear box Repair or replace timing
No
oil is applied. belt
2. Engine can not be successfully started

Test
Results
Turn the ignition switch to ON. Check if there is Yes Remove the trouble
1 trouble information records with a diagnostic
No Next step
instrument.
Take out the spark plug, and make the electrode of the Yes 8
spark plug 5-10mm from the engine block. Run the
2
engine with the start motor, and check if the blue white No Next step
high voltage fire is produced.
Yes Next step
Check if the resistance of the high pressure wire is
3 Repair or replace the
normal (about 16k/m, if too low, the wire is in trouble). No
high pressure wire
Yes Replace
4 Check each ignition coil for damage or crack.
No Next step
Yes Replace
5 Check the ignition coil for looseness or damage.
No Next step
Test
Results
Yes Next step
6 Check the ignition coil for normal operation.
No replace
Check if the interfaces of the high pressure coil are Yes Next step
7
well connected. No Connect
Turn the ignition switch to ON. Check if the fuel pump Yes Next step
8 relay and the fuel pump can keep running for 3 Check and repair fuel
No
seconds. pump circuit
Connect the fuel pressure gauge valve. Short-circuit the Yes Next step
pin J1-47 and the pin J1-73 of the fuel bump relay, and
9
run the fuel pump. Check if the fuel pressure is about No 13
300kPa.
Take out the fuel distribution pipe together with the Yes 12
10
fuel injector. Disconnect the fuel injector from the No Next step
Ver：LF-20121225
harness. Check the fuel injector for fuel injection with
the voltage of 12V directly from the battery.
Clean the fuel injector and check the fuel injector for Yes Next step
11
fuel injection. No Replace fuel injector
Yes Replace fuel
12 Check if the fuel is wrong or contains water.
No 18
Yes Next step
13 Check if the fuel pressure is lower than 300kPa.
No 17
Close the fuel gauge valve. Turn on the ignition switch Yes Next step
14 again and keep the fuel pump working for 3 seconds. No
16
Check if fuel pressure can be produced.
Yes Replace or repair fuel
16 Check the fuel intake pipe for leakage or blockage. intake pipe
No Replace fuel pump
Yes Repair or replace fuel
return pipe
17 Check if the fuel return pipe is blocked or bent.
No Replace fuel pressure
regulator
Connect an adapter between the ECU and the harness. Yes Next step
Check the pin J1-73 of the ECU for voltage. Check the
18 positive power supply line of the above-mentioned Repair or replace
No
ECU pin and the earth wire of the pin J1-01, J1-17, harness
J1-18 connected to the ECU for normal operation.
Check the parts and components of the intake system Yes Repair
19
for leakage. No Next step
Check if the intake manifold absolute pressure and Yes Repair or replace
20
temperature sensor is blocked. No Next step
Check if the coolant temperature sensor for normal Yes Next step
21
operation. No Repair or replace
Remove mechanical
Check if the gap between the piston and the cylinder is Yes
22 trouble
too wide. Check the cylinder for leakage.
No Replace ECU
3. Hard to start after warm-up

Test
Results
No Next step
instrument.
Connect the fuel pressure gauge valve (the connection Yes Next step
point is related to the vehicle model). Short-circuit the
2
pin J1-47 and the pin J1-73 of the fuel bump relay, and No 9
run the fuel pump. Check if the fuel pressure is about
Ver：LF-20121225
300kPa.
Disconnect the fuel pipe, and turn the ignition switch. Yes Next step
3 Check if the pressure of the fuel system still keeps Repair fuel system
No
between 150kPa and 200kPa after 1 hour. leakage
Connect the fuel pipe. Block the fuel return pipe, and Replace fuel pressure
Yes
turn off the fuel pressure gauge valve. Turn off the regulator (inbuilt)
4 ignition switch. Check if the pressure of the fuel
system still keeps between 150kPa and 200kPa after 1 No Next step
hour.
Replace fuel injector
Yes
5 Check the fuel injector and the fuel pipe for leakage. and fuel pipe
No Next step
Check the coolant
Take out the water temperature sensor, and start the Yes
6 temperature and line
engine. Is the engine OK?
No Next step
Yes
Check the pin J1-17, J1-18, J1-04 and J1-20 of the harness
7
ECU for voltage. Check if the earth wires of the pin
No Next step
J1-05, J1-21 and J1-73 are connected to the ECU.
Replace the fuel. Start the vehicle after warm-up. Is it Yes End
8
OK? No Replace ECU
Check if the fuel pipe is blocked or bent. Check the Yes Next step
9 fuel pump pressure regulation valve for normal Repair or replace
No
operation.
Yes Next step
Check the interfaces of the fuel pump at both ends for
10 Repair or replace fuel
battery voltage with a multimeter. No
pump relay and lead
Check if the resistance of the fuel pump is correct with Yes Next step
11
a multimeter. No Replace fuel pump
Yes Replace fuel pump
12 Check if the fuel pump is locked.
Replace ECU
4. With normal rotation speed, difficult to start

S/N Operation Test Results Actions
Turn the ignition switch to ON. Check if there Yes Remove the trouble
1 is trouble information records with a
No Next step
diagnostic instrument.
Yes Next step
2 Check the air filter for smoothness.
No Replace
After successful start, check if the intake air Yes Next step
3 manifold pressure is between 35kPa and 65kPa Remove leakage for the air
No
at idle speed. intake system
Ver：LF-20121225
Gently step on the throttle, and check if the Check and replace throttle and
4 Yes
vehicle can be started easily. idle speed passage
Connect the fuel pressure gauge valve. Yes Next step
Short-circuit the pin 30 and the pin 87 of the
5
fuel bump relay, and run the fuel pump. Check No 9
if the fuel pressure is about 380kPa.
Test
Results
Connect the battery and the fuel injector with a special Yes 8
6 connector. With the voltage supply of 12V, check the
No Next step
fuel injector for normal operation.
Wash the fuel injector and check the fuel injector again Yes Next step
7
for normal operation. No Replace fuel injector
Replace the fuel. Check if the fuel is wrong or contains Yes Replace fuel
8
water. No 14
Yes Next step
No 13
10 again and keep the fuel pump working for 3 seconds.
No 12
Replace fuel pressure
Yes
Turn on the fuel gauge valve, and block the fuel return regulator
11
pipe. Check if the fuel pressure is quickly produced. Repair or replace fuel
No
injector or fuel pipe
Repair or replace fuel
Yes
return pipe
Yes
return pipe
No
regulator
Before the engine coolant reaches 35°C, take out the Yes Next step
14 idle speed actuator connector, and check if the rotation Replace idle speed
No
speed of the engine is decreased. actuator
Turn the ignition switch to ON. Check the voltage of Yes Next step
the following pins of the ECU. Is the voltage of the pin
15 J1-12 (crankshaft position sensor) is about 12V? Is the Check harness and
empty pin and the pin J1-54 (idle speed stepper motor No
interface
A+) is 0V?
16 Check if the compressed pressure of the engine Yes Next step
Ver：LF-20121225
cylinder is normal. No Remove the trouble
Check if the intake air manifold absolute pressure and Yes Repair or replace
17
temperature sensor is blocked. No Next step
Check if the coolant temperature sensor for normal Yes Replace ECU
18
operation. No Repair or replace
5. Difficult cold start

Test
Results
Turn the ignition switch to ON. Check if there is trouble Yes Remove the trouble
1
information records with a diagnostic instrument. No Next step
Check the coolant for normal temperature with a Yes Next step
2
multimeter (resistance: between XX and XX) No Replace sensor
Turn on the ignition switch. Connect an adapter between Yes Next step
the ECU and the harness, and check the voltage of the
following pins of the ECU. Is the voltage of the pin J1-12
3 (crankshaft position sensor) is about 12V? Is the empty Check harness and
No
pin and the pin J1-54 (idle speed stepper motor A+) is interface
0V?
Check the air filter for smoothness.。 Yes Next step

4
Check the air filter for smoothness. No Replace
Yes Next step
After start, check if the pressure of the intake air
5 Remove leakage for the
manifold at idle speed is between 35kPa and 65kPa. No
air intake system
Check throttle and idle
Gently step on the throttle, and check if the vehicle can Yes
6 speed passage
be started easily.
No Next step
Before the engine coolant reaches 35°C, take out the idle Yes Next step
7 speed actuator connector, and check if the rotation speed Replace idle speed
No
of the engine is decreased. actuator
Connect the fuel pressure gauge valve (the connection Yes Next step
point is related to the vehicle model). Carry out direct
grounding for the pin 86 of the fuel pump relay. Turn on
8
the ignition switch and run the fuel pump relay and fuel No 12
pump. Check if the fuel pressure is between 370kPa and
390kPa.
9 connector. With the voltage supply of 12V, check the fuel
No Next step
injector for normal operation.
10
normal operation. No Replace fuel injector
Ver：LF-20121225
Yes Renew fuel
11 Check if the fuel is wrong or contains water.。
No 17
Yes Next step
No 16
No 15
Yes
14
pipe. Check if the fuel pressure is quickly produced.。 Repair or replace fuel
No
Yes
Yes
return pipe
No
regulator
Yes Next step
17 Check if the cylinder pressure of the engine is normal.
No Remove the trouble
Yes Repair
18 Check the air intake system of the engine for leakage.
No Next step
Check if the intake air manifold absolute pressure and Yes Repair or replace
19
temperature sensor is blocked. No Replace ECU
6. Unstable idle speed at any time

Test
Results
1
Replace idle speed
Check if the idle speed actuator or the stepper motor idle Yes
2 actuator
speed actuator is locked.
No Next step
Turn the ignition switch to ON. Connect an adapter Check harness and
Yes
between the ECU and the harness. Check the voltage of interface
the pin J1-27, J1-43 (signal output end of the intake air
3 temperature sensor and coolant temperature sensor),
J1-54, J1-33, J1-53, J1-34 (signal output end of the No Next step
stepper motor), J1-54, and J1-53 of the ECU. Is the
voltage normal?
Run the engine at an idle speed. Cut off each cylinder in Yes 8
4 sequence. Check if the rotation speed of the engine is
No Next step
decreased or fluctuated.
Ver：LF-20121225
Yes Next step
Check the fuel injector of each cylinder for normal
5 Check fuel injector and
operation. No
harness
Check the resistance of the high voltage wire for each Yes Next step
6
cylinder. Is the resistance OK? No Replace
Yes Replace
7 Check the ignition coil for damage or crack.
No Next step
Yes Next step
8 Check the spark plug for normal operation.
No Replace spark plug
pin J1-47 and the pin J1-73 of the fuel bump relay, and
9
run the fuel pump. Check if the fuel pressure is about No 13
300kPa.
No Next step
11
Yes Replace fuel
No 18
Yes Next step
No 17
否No 16
Yes
15
No
Yes
16 Check the fuel intake pipe for leakage or blockage. return pipe
Yes
return pipe
No
regulator
Check if the sense hole of the intake air manifold Yes Clean up
18
pressure and temperature sensor is blocked. No Next step
Run the engine at an idle speed. After the coolant Yes Next step
19 reaches the temperature activated by the closed loop Check oxygen sensor
No
control, check the oxygen sensor for normal operation. and harness
Yes Repair the leakage
20 Check the intake air system of the engine for leakage.
No Next step
Ver：LF-20121225
Yes Next step
21 Check if the cylinder pressure of the engine is normal.
7. Unstable idle speed during warm-up

Test
Results
1
Yes Next step
No Replace
Run the engine at an idle speed. Check if the intake air Yes Next step
3 manifold pressure is between 35kPa and 65kPa during Remove leakage for the
No
warm up. air intake system
Stop the engine, and turn on the ignition switch. Connect Yes Next step
an adapter between the ECU and the harness. Check the
4 pin J1-27 and J1-35 of the ECU (signal output end of the
No Check and repair
intake air temperature sensor and coolant temperature
sensor).
Take out he connector of the idle speed actuator after Yes Next step
5 warm-up. Check if the rotation speed of the engine is Replace idle speed
No
changed. actuator
Check the coolant temperature sensor for normal Yes Next step
6
operation. No Replace
8. Unstable idle speed after warm-up

Test
Results
1
Turn the ignition switch to ON. Connect an adapter
Yes Next step
between the ECU and the harness. Check the voltage of
the pin J1-42 (intake air manifold absolute pressure
sensor output), J1-27 (intake air temperature sensor
2
output), J1-43 (coolant temperature sensor output), J1-62, Repair or replace
J1-06, J1-38 (oxygen sensor output), J1-54, J1-33, J1-53, No
harness
J1-34 (output to idle speed actuator) of the ECU. Is the
voltage normal?
Yes Next step
No Replace
Yes Next step
Check if the intake air manifold pressure is between
4 Remove leakage for the
35kPa and 65kPa under idle speed. No
air intake system
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5 pin 30 and the pin 87 of the fuel bump relay, and run the
No 9
fuel pump. Check if the fuel pressure is about 300kPa.
No Next step
Clean the fuel injector and check the fuel injector for Yes Replace
7
Test
Results
Yes Replace fuel
No 14
Yes Next step
No 13
No 12
Yes
11
No
Yes
Yes
return pipe
No
regulator
Replace coolant
Take out the coolant temperature sensor, and check the Yes
15 temperature sensor
engine for normal operation.
No Next step
Yes Next step
16 Check the compressed pressure.
17
Yes Replace
No Next step
Yes Replace ECU
19 Check the spark plug for normal operation.。
9. Unstable idle speed or flameout under load (A/C etc)
S/N Operation Test Actions

Ver：LF-20121225
Results
No Next step
instrument.
Turn on the A/C switch. Connect an adapter between Yes Next step
2 the ECU and the harness. Check the pin J1-09 and Check and repair A/C
No
J1-39 (A/C switch) of the ECU for signal input. circuit
Check the A/C system pressure, electromagnetic Yes Next step
3 clutch of the compressor, A/C pump for normal
No Repair or replace
operation.
Turn the ignition switch to ON. Check the voltage of Yes Next step
4 the pin 33, 34, 53, 54 (output to idle speed actuator) Check the control
No
of the ECU. Is it OK? circuit
Repair or replace
Remove the stepper motor. Check if the stepper Yes
5 stepper motor
motor is locked or blocked.
No Next step
Start the engine, and run the A/C. Check if the idle Yes Replace ECU
speed actuator is under normal operation as per the
6 Replace idle speed
steps of the motor on the trouble diagnostic No
actuator
instrument.
10. Unstable periodicity (self-learning after power cutoff of the ECU)

S/N Operation Test Results Actions
No Next step
instrument.
Yes Next step
2 Check the air filter for smoothness.。
No Replace
Yes Next step
Run the engine at an idle speed. Check if the intake air
3 Check air intake and
pressure is between 35kPa and 65kPa. No
leakage
Run the engine at an idle speed. Cut off each cylinder Yes 7
4 in sequence. Check if the rotation speed of the engine
No Next step
is decreased or fluctuated.
between the ECU and the harness. Check the voltage Yes Next step
of the pin J1-42 (intake air manifold absolute pressure
sensor output), J1-27 (intake air temperature sensor
5
output), J1-43 (coolant temperature sensor output), Repair or replace
J1-62, J1-06, J1-38 (oxygen sensor output), J1-01 No
harness
(ignition switch), J1-54, J1-33, J1-53, J1-34 (output to
idle speed actuator). Is it OK?
6 Run the engine at an idle speed. Check if the ignition Yes Next step
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advance angle is normal after the coolant reaches Adjust ignition advance
No
normal operation. angle
Check if the sense hole of the intake air manifold Yes Clean up
7
pressure and temperature sensor is blocked. No Next step
Yes Replace fuel
No Next step
Yes Next step
Connect the battery and the fuel injector with a special
Check and repair fuel
No injector and relevant
harness
10
Yes Replace
No Next step
Yes Replace ECU
12 Check the spark plug for normal operation.。
11. Idle speed too high (self-learning after power cutoff of the ECU)
Test
Results
No Next step
instrument.
Check if the cable connected the accelerator pedal is Yes Adjust or replace
2
locked or tightened. No Next step
Check the canister control valve, fuel pressure Yes Adjust or replace
regulator, crankcase compulsory ventilation vacuum
3
pipe, and the vacuum booster tube of the brake system No Next step
for reliable installation or damage.
Run the engine at an idle speed, keep neutral position, Yes Next step
4 step on the brake pedal, and check if the idle speed is
No 6
too high.
Repair or replace
Clamp the vacuum booster tube. Check if the idle Yes
5 vacuum booster
speed becomes normal.
No Next step
Replace the PVC valve. Clamp the crankcase Yes Replace PVC valve
6 compulsory ventilation vacuum tube. Check if the idle
No Next step
Replace canister control
Clamp the canister control valve tube. Check if the idle Yes
7 valve
No Next step
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Yes Repair or replace
8 Check if the idle speed actuator is blocked or locked.
No Next step
Repair or replace. Check the other parts of the intake Yes Repair or replace
9
air pipe for leakage. No Next step
Yes Next step
10 Check the fuel injector seal ring for damage.
No Replace seal ring
Check the intake air manifold absolute pressure and Yes Replace ECU
11
intake air temperature sensor for damage. No Replace sensor
12. Ineffective acceleration or flameout

Test
Results
No Next step
instrument.
Yes Next step
No Replace
Yes Next step
Run the engine at an idle speed. Check if the rotation Next step
3
speed is normal. No Check and repair as per
idle speed trouble items
4
pressure is between 35kPa and 65kPa. No Check and repair
Run the engine at an idle speed. Check if the ignition Yes Next step
5 advance angle is normal after the coolant reaches Adjust ignition advance
No
normal operation. angle
Connect the fuel pressure gauge valve. Short-circuit Yes Next step
the pin J1-47 and the pin J1-73 of the fuel bump relay,
6
and run the fuel pump. Check if the fuel pressure is No 10
about 380kPa.
No Next step
Wash the fuel injector and check the fuel injector again Yes Next step
8
for normal operation. No Replace fuel injector
Yes Replace fuel
No 15
Yes Next step
No 14
No 13
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Turn on the fuel gauge valve, and block the fuel Yes
regulator
12 return pipe. Check if the fuel pressure is quickly
produced. No
Check the fuel intake pipe for leakage or Yes
13 intake pipe
blockage.
Yes
return pipe
No
regulator
Turn the ignition switch to ON. Connect an Yes Next step
adapter between the ECU and the harness. Check
the voltage of the pin J1-24 (signal output end of
15 Repair or replace
the throttle position sensor), J1-05 (grounding No
end), J1-20 (as the power supply for 4.5-5V harness
sensor). Is it OK?
Yes Replace ECU
Check the ignition coil, distributor, high voltage
16 Repair or replace
wire, and spark plug for normal operation. No
relevant parts
13. Slow acceleration

Test
Results
No Next step
instrument.
Yes Next step
No Replace
Yes Next step
Run the engine at an idle speed. Check if the rotation Check and repair as
3
speed is normal. No per idle speed trouble
items
Run the engine at an idle speed. Check if the intake Yes Next step
4
air pressure is between 35kPa and 65kPa. No Check and repair
Turn the ignition switch to ON. Connect an adapter Yes Next step
between the ECU and the harness. Check the voltage
5 of the pin J1-24 (signal output end of the throttle Repair or replace
No
position sensor), J1-05 (grounding end), J1-20 (as harness
the power supply for 4.5-5V sensor). Is it OK?
6 advance angle is normal after the coolant reaches Adjust ignition
No
normal operation. advance angle
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Connect the fuel pressure gauge valve. Short-circuit Yes Next step
the pin J1-47 and the pin J1-73 of the fuel bump
7
relay, and run the fuel pump. Check if the fuel No 11
pressure is between 250kPa and 300kPa.
Connect the battery and the fuel injector with a No 10
8 special connector. With the voltage supply of 12V,
No Next step
check the fuel injector for normal operation.
Wash the fuel injector and check the fuel injector Yes Next step
9
again for normal operation. No Replace fuel injector
Yes Replace fuel
No 16
Yes Next step
No 15
Close the fuel gauge valve. Turn on the ignition Yes Next step
12 switch again and keep the fuel pump working for 3
No 14
seconds. Check if fuel pressure can be produced.
Replace pressure
Yes
Open fuel gauge valve, and block the fuel return adjustor
13
pipe to check if fuel pressure can be produced. Repair or replace
No
injector or oil pipe
Yes
Yes
return pipe
Replace pressure
No
regulator
Yes Replace or clean up
16 Check if the exhaust system is blocked.
No Replace ECU
14. Poor acceleration
Test
Results
Check the clutch, tire pressure, brake, tire size and Yes Repair
1
four-wheel alignment for normal operation. No Next step
Yes Next step
2 Check if the throttle can be fully opened. Replace or repair
No
throttle
3
4 advance angle is normal after the coolant reaches normal Adjust ignition
No
operation. advance angle
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between the ECU and the harness. Check the voltage of Yes Next step
the pin J1-42 (intake air manifold absolute pressure sensor
output), J1-27 (intake air temperature sensor output), J1-43
5
(coolant temperature sensor output), J1-62, J1-06, J1-38
Repair or replace
(oxygen sensor output), J1-01 (ignition switch), J1-54, No
harness
J1-33, J1-53, J1-34 (output to idle speed actuator) of the
ECU. Is it OK?
6
pressure is between 35kPa and 65kPa. No Check and repair
7 pin J1-47 and the pin J1-73 of the fuel bump relay, and run
No 11
the fuel pump. Check if the fuel pressure is about 380kPa.
No Next step
Wash the fuel injector and check the fuel injector again for Yes Next step
9
Yes Replace fuel
No 16
Yes Next step
No 15
No 14
Replace pressure
Yes
13
No
Yes
Test
Results
Yes
return pipe
Replace pressure
No
regulator
Check the data of the intake air manifold absolute pressure Yes Next step
16
and intake air temperature sensor. Is it OK? No Replace sensor
Check the spark plug, high voltage wire, distributor, No Next step
17
ignition coil for normal operation. No Replace or adjust
18 Does it caused by A/C system? Yes Check A/C system
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No ECU Replace ECU
15. A/C system troubl

Test
Results
Check if the refrigerant of the A/C system is enough. Yes Next step
1 Check the A/C belt, clutch, pressure switch for normal
operation.
Run the engine at an idle speed. Turn on the A/C switch. Yes Remove the trouble
2 Check if the A/C thermal resistance is under trouble with
No Next step
a diagnostic instrument.
Turn on the A/C switch. Connect an adapter between the Yes Next step
3 ECU and the harness. Check the pin J1-09 and J1-39
No Check harness
(A/C switch) of the ECU for signal input.
Replace bulb or repair
If the vehicle adopts low-level control, turn off the A/C Yes
4 harness
and check if it still keeps operation.
No Next step
Check the pin J1-46 (grounding end connected to the

Yes Repair A/C relay and
5 vibration absorption coil of the A/C relay) of the ECU
harness
for low-level output.
No Replace ECU
16. Cylinder misfire

Test
Results
Yes Next step
Start the engine, and run the engine under idle speed.
1 Check and repair the
Check the sound for air leakage of the air intake pipe. No
leakage
Stop the engine and carry out visual inspection for the Yes Next step
2
exhaust pipe, three-way catalyzer and the muffler. No Repair or replace
Take out the connector of each ignition coil in Yes 5
3 sequence. Check if no decrease of the rotation speed of
No Next step
the engine is produced at any moment for the cylinder.
Yes Next step
Check if there is running sound for each fuel injector at
4 Check fuel injector and
idle speed. No
relevant circuits
Remove the ignition metal wire from the spark plug. Yes Next step
Install the wire to a normal spark plug. Place the bottom Check ignition coil, giant
5
end of the spark plug towards the ground, and then turn No transistor, and their
to the engine. Check if the spark is normal. circuits
No Next step
6 Remove the spark plug. Check the place for dirts. Repair or replace spark
Yes
plug (standard type)
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Yes Next step
Check the pressure of the compressor. Standard:
Check piston, piston ring,
7 1275kPa/300rpm; minimum: 981kPa/300rpm;
No air intake valve, valve seat
difference among cylinders: 98kPa/300rpm.
and cylinder head gasket
Test
Results
Install all the removed parts. Release the fuel pressure Yes Next step
8 to 0. Install fuel pressure gauge. Check if the pressure is Check as per fuel pressure
No
normal. test method
Check the ignition time (-5°-20°BTDC). The target idle Yes Next step
9
speed is M/T: 750±50rpm. No Basic check
Start the engine for warm-up. After the engine reaches
normal operation speed, measure the voltage between Yes Next step
the pin J1-62 (front oxygen sensor high signal) or J1-06
(front oxygen sensor low signal) of the ECU and the
10
ground. Under the rotation speed of 2000rpm, the
changes between 0V-0.3V and 0.6V-1.0V should be no Renew front oxygen
No
less than 5 times, at least one time higher than 0.6V, at sensor
least one time lower than 0.3V, an no higher than 1V.
Yes Replace ECU
Check the intake air sensor signal with a diagnostic Check the connector of the
11 instrument. (2.0-6.0gm/sec, at idle speed, air intake temperature
No
7.0-20.0gm/sec, at 2500rpm) sensor circuit for rust or
looseness.
17. Three way catalyzer diagnosis
Test
Actions
S/N Operation Results
Yes Next step
1 Visually check if the exhaust pipe and muffle is normal.
Start engine and run at idle speed; and listen if there is Yes Next step
2 sound of exhaust gas leak before heating three way
catalyzer.
Listen if there is leak from the exhaust pipe behind intake Yes Next step
3
air sensor. No Repair or replace
Check if ignition time is -5°-20°BTDC; and check if target Yes Next step
4
idle speed is M/T: 750±50rpm. No Basic check
Injector check: Stop engine and turn ignition switch to ON Yes Next step
position, and check if the voltage between Pin J1-55, J1-70,
5 Execute injector
J1-56 and J1-71 of ECU and earth output voltage is No
normal. diagnosis procedure
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Turn ignition switch to OFF position; remove ignition coil
Yes Next step
and connect with a normal spark plug; and face the end
6
with the ground and rotate the engine to check if the spark
No Check ignition coil
plug is normal.
Turn ignition switch to OFF position; remove injector, Replace three way
Yes
remove fuel injection pipe and all injection connectors, catalyzer
7 remove connector of fuel injection coil; turn ignition
Replace injector with
switch to ON position; and make sure there is no gasoline No
fuel leak
runs out of the injector.
Section V Security Items for System Maintenance
I. Security items for the diagnosis and maintenance of the fuel injection
electronic control system

1. Remove and install requirements for the controller
① Remove the controller before welding and paint baking;
② Turn the ignition switch to OFF when remove the controller to avoid damage;
③ When the engine is running or the electrical system is under operation, do not disconnect with the
battery;
④ Do not start the engine with high electricity from charger;
⑤ The ambient temperature of the controller shall not exceed 800℃.
2. Requirements on cleanness:
① Before operate the oil supply and injection system, please abide by the following demands:
② The parts and components removed should be covered and placed in a clean field, and do not use the
cloth scattering fibers.
3. Connect and disconnect the harness (including the harness of the trouble diagnostic instrument) only
after turn off the ignition switch. To ensure correct wire connection when measuring the voltage or
grounding of the electronic control system. To disconnect the power supply wire or the harness of the
controller connector from the battery can erase the relevant diagnosis and self-learning information.
4. Notes for fuel supply system maintenance
① When remove and install the fuel pump for a fuel tank fully or partially filled, please pay attention to:
② Before the maintenance, the device to absorb the gasoline leaked should be installed near the fuel tank
mouth.
③ To avoid direct contact with the gasoline;
④ Before loosening the connection parts, thoroughly clean these parts and the surrounding areas.
⑤ To avoid fuel injection at the loosened part, place a cloth around the connection part;
⑥ Carefully cover or close the opened parts and components if not repaired at once.
⑦ Take out the spare parts just before the installation. The spare parts without packaging shall not be used.
⑧ Take care not to damage the O ring when installing the fuel injector. To facilitate assembly, apply a little
lubricant to the O ring.
II. Security measures
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To avoid personal injury and damage the fuel injection and ignition device:
Do not connect or disconnect the ignition harness if the engine is under operation or at a rotation speed for
start-up; disconnect the harness connector from the hall sensor (distributor) if the engine is driven by the
starting motor yet not actually started (like compressed pressure check, etc.).
Chapter VII Three Way Catalytic Reaction

System
Structure: Three way catalytic converter is similar to a muffler. Its outside is surrounded by a tube made
from double layer stainless thin steel plate with heat insulating material --- asbestos fibrofelt in the middle
of two layers. And accelerant purificant is installed in the netty clapboard inside it.
Purificant: Purificant is composed of carrier and accelerant. Carrier is made of Al203, with ball, polygon
and netty clapboard shapes. It is also called a catalyst for its actual catalytic action. This catalyst consists of
precious metals like rhodium, palladium and platinum.
Working principle of three way catalytic converter: When engine gas goes through exhaust pipe, CO, HC
and NOx contact the accelerant in the three way catalytic converter, which increases the activity of the 3
gases and leads to redox reaction. CO is oxidized to colorless and innoxious CO2. HC compound is
oxidized to H2O and CO2. NOx is recovered to N2 and O2. As a result, most of the 3 noxious gases are
converted to innocuous gas, and the exhaust gas is purified.
In order to maximize the purification function of three way catalytic converter and prevent malfunction
caused by early damage, pay attention to the following aspects when using the vehicle.
I. Vehicle with three way catalytic converter can not use leaded gasoline, and be especially careful when
fueling in unfamiliar regions. As after the leaded gasoline is burnt, lead granule will cover the catalyzer
surface when go through the three way catalytic converter with exhaust gas, which will decrease the
catalyzer working surface and greatly decrease the reaction efficiency of the converter. And this is the
usually called “three way catalytic converter lead poisoning”. Experience shows that only one tank of
leaded gasoline can also lead to serious malfunction of three way catalytic converter. Therefore, the drivers
must pay attention to this.
II. Avoid unburned gas mixture to enter the converter. Three way catalytic converter starts to work at about
200℃, and the best working temperature is 400℃-800℃. And the precious metals as catalyzers will also
react chemically if the temperature is over 1000℃, which will decrease the effective ingredients in the
converter and weaken the catalysis.
Through burning inside the converter, HC and CO is converted to H2O and CO2, which decreases the
amount of HC and CO as hazardous substance.This reaction will generate heat. And if the proportion of the
two ingredients is proper and the engine is under normal working condition, the heat generated when
burning will maintain a best working temperature for the converter. However, if the engine is under
abnormal working condition, the proportion of the two ingredients will far exceeds the normal value, and
the heat generated from burning may probably make the temperature of converter exceeds its maximum
working temperature, which will damage the catalyzer and then the converter. As a result, pay attention to
the following situations when using the vehicle: (1) idle speed rotation too long; (2) ignition time delay too
much; (3) some cylinders misfire and not work; (4) fuel injection normal but difficult to start; (5) gas
Ver：LF-20121225
mixture too thick; (6) engine oil combustion in engine, etc.
III. Do not rub the ground when driving, because the catalyzer carrier inside the three way catalytic
converter is alveolate crockery which may easily break up and block the converter and exhaust system.
If the injector valve can not be closed well, fuel pressure regulator does not work (fuel pressure too high),
oxygen sensor does not work, air flow senor does not work, etc., they may be caused by too thick gas
mixture. If the gas mixture is too thick, black smoke may come out of the exhaust pipe, and oil
consumption may increase.
IV. Soot, tar and other materials in exhaust gas will block the active surface of catalyzer. Unburnt gas
mixture must to be avoided to enter the three way catalytic converter, because the gunge in unburnt gas
mixture will corrade the converter, and the large amount of hydrocarbon and CO will force too much
oxidation reaction in converter and generate too much heat to damage the converter.
V. Stop the vehicle to check when there is spontaneous combustion, severe surging, backfire, repeated
stallout or other abnormal phenomenon in the engine. Otherwise, the converter may be damaged
permanently.
VI. When the three way catalytic converter is stored, it can not be polluted by gasoline or lubricant.
Repair:
Check throttling of catalytic converter: Visually check the catalytic converter core with endoscope. And if
there is no endoscope, check if there is crack or dissolved matrix with flashlight.
Note:
(1) As the operation temperature of exhaust system is very high, do not work or maintain part around it
before it cool down. Be especially careful when operating around the catalytic converter, because the
temperature of converter will increase to the highest point in a short period after the engine is started.
(2) Original part (or equivalent part) should be used when replacing any part in exhaust system.
(3) Confirm the source of fault before replacing the catalytic converter, because most malfunctions of
converter are caused by gas, fuel or ignition problem.
(4) As the shapes of catalytic converter and exhaust assembly are similar, be careful when replacing a part.
For some regions (especially vehicles for regions with strict exhaust standards) and models, the converts
are quite different.
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Part III Chassis Maintenance
Chapter I Suspension
Section I Introduction
I. Main technical data of suspension and wheel

Technical data
Items
Standard value Regulated value
Kingpin caster angle 2°55′ 2°55′±1°
Kingpin inclination angle 12° 12°±30′
Front wheel Wheel camber angle 0°20′ 0°20′±1°
Toe‐in/mm 1.0 ‐1～3
Side‐slip amount/(mm/mm) ±3
Wheel camber angle ‐1° ‐1°±30′

Rear wheel Toe‐in/mm 5.0 4～8
Side‐slip/(mm/mm) ±5
Axial clearance of wheel hub
Not exceeding 0.2
Front and rear bearing
wheel Wheel rim radial, end face
Not exceeding 3.0
running out amount/mm
Front wheel Interior wheel turning angle 37°55′±2°
turning angle Exterior wheel turning angle 33°00′±2°
II. Introduction of suspension structure

The suspension fitting of sedan LF7132 is shown in Fig. 3-1. The McPherson independent suspension with
the stablizer bar (of traveller oscillating arm type) is applied in the front suspension, while the McPherson
independent suspension with vertical tension rod is adopted by the rear suspension, and the stablizer bar is
added to the rear suspension.
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Fig. 3-1 Suspension fitting of LF7132
1. Front suspension
The front suspension is structured by the front oscillating arm, coil spring, shock damper and stablizer bar
as shown in Fig. 3-2.
Fig. 3-2 Sturcture of front suspension

1. Coil spring 2. Shock damper 3. Steering knuckle
4. Front oscillating arm 5. Stablizer bar 6. Stablizer bar bracket
7. Steering track rod 8. Buffer stopper of coil spring 9. Rubber plinth
Fig. 3-3 Structure of front oscillating arm

1. Steering knuckle 2. Ball pin dustproof cover 3. Lateral osciallating arm
4. Rubber bushing 5,8. Flat gasket 6. Sping washer
7. Nut 9. Bolt 10. Installation bracket of front oscillating arm 11. Carrying shaft of front oscillating arm
The upper end of the telescopic shock damper 2 of the front suspension is mounted on the body through
rubber mount of the front suspension and its lower end is fixed on the steering knuckle which is connected
to the lateral oscillating arm by ball chain. For the suspension of this type, most of the side force
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undertaken by the wheel is shared by the front oscillating arm through steering knuckle, while the left force
by the shock damper. Because the two ends of the stablizer bar are connected with the front oscillating arm,
the stabilizer works as the vertical track bar meantime.
(1) Front oscillating bar. The structure of front oscillating bar is shown in Fig. 4-3. The lateral oscillating
arm 3 made through forging and presenting shape of “I” boasts high degree of stiffness and strength. The
inner end of the front oscillating arm 3 hinges with carrying shaft of front oscillating arm 11 on the front
oscillating arm bracket 10 through the rubber bushing 4. Two sides of the rubber bushing are equipped with
gaskets 5 and 8, the end of which is tightened by nut 7. The carrying shaft of front oscillating arm 11 is
jointed with braket 10 which is fixed on the bottom of the body through bolts.
The position and structure of the connecting hole of lateral oscillating arm and stablizer bar are shown in
Fig. 3-4 (a) and the structure of ball pin in Fig. 3-4 (b). The ball pin 1 is mounted on the integral type ball
cup 3 whose position is limited by cover stem 4 and the rim of the ball cup 3 is turned over so as to rivet
tight the cover stem and make it an indecomposable integral structure. To improve the reliability of the
joint between ball pin and steering knuckle, the connecting bolt locks the ball pin through the ring groove at
the end of the ball pin. The ball pin is lubricated by grease and is equipped with dustproof cap 2 on the
lateral oscillating arm so as to prevent the entrance of filth.
Fig. 3-4 Structure of ball pin

(a) Front oscillating arm and ball pin (b) Ball pin
1. Ball pin 2. Dustproof cap 3. Ball cup 4. Cover stem 5. Front oscillating arm 6. Lubricant grease
(2) Stablizer bar. In order to lessen the lateral inclination and lateral angle vibration of the body when
turning in high-speed driving, LIFAN sedans are added with stablizer bar in suspension.
The fitting of front suspension’s stablizer bar is shown in Fig. 3-5. The flat “U” shape stablizer bar made of
spring steel is installed in the front bottom of the car laterally. Two ends of the middle of bar 1 bear in two
rubber buffer covers 9 freely, while the buffer cover 9 is fixed on sway bar bracket 2 and 3 through the
sway bar retaining clip 10 and left beam 4 by bolt 12 and the stablizer bar bracket is connected to the body
through bolt. Ends of stablizer bar’s two sides’ vertical parts joint each other through rubber ring 8 and
corresponding holes on lateral oscillating arm 5, terminals of which are tightened by retaining ring 7 and
nut 6.
(3) Coil spring and shock damper. The structure of coil spring and shock damper is shown in Fig. 4-6. The
shock damper is the bi-directional hydraulic barrel type, the upper end of which is mounted on the body
through front suspension mount assembly 14 and connected with the body by bolts. The lower end of the
shock damper is jointed with lower mount of the shock damper 15 and connected with the steering knuckle
through the lower mount.
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Fig. 3-5 Structure of stablizer bar

1. Stablizer bar 2. Right installation mount panel 3. Left installation mount panel
4. Left trimming beam of front suspension 5. Front oscillating arm 6. Nut 7. Retaining ring
8. Rubber bushing 9. Buffer cover 10. Retaining clip 11. Spring washer 12. Bolt
Fig. 3-6 Coil spring and shock damper

1. Rubber mount cap 2. Rubber mount 3. Spring upper seat 4. Cylinder rod 5. Coil spring
6. Spring lower seat 7. Shock damper 8. Dustproof cap 9. Buffer stopper 10. Thrust bearing
11. Rubber mount lining 12. Dustproof cap 13. Nut 14. Front suspension mount
15. Lower mount of shock damper
The front suspension mount 14 is integrated by rubber mount 2, rubber mount cap 1 and rubber mount
lining 11. The rubber mount 2 with larger volume can effectively mitigate the impact so as to improve the
comfort. The rubber mount lining 11 is installed on the cylinder rod 4 with its terminal fixed by nut 13.
Equipped with bolt, the rubber mount cap 1 is connected with the body through the bolt and is fixed.
The coil spring 5 is equipped on the shock damper, the upper and lower ends of which are mounted on the
spring upper seat 3 and spring lower seat 6 respectively.
The spring upper seat is on the cylinder rod, while the lower seat is jointed with the shock damper. In order
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to ensure the convenience and agility of steering, the thrust bearing 10 lubricated with grease is installed
between front suspension mount 14 and spring upper seat 3. In order to prevent the entrance of dust from
upper part, the dustproof cap 12 is installed on the rubber mount lining.
When the coil spring is forced to be compressed and deformed, if the stae of deforming is excessive, the
cylinder rod will move downward longer than that of the shock damper cylinder so that the shock damper
will be damaged; therefore, the rubber buffer stopper 9 is installed on the bottom of spring upper seat to
lessen the impact and limit the position. Dustproof cap 9 and buffer stopper 9 are merged into a whole.
The axis line of McPherson suspension’s kingpin is the line between the centers of upper and lower hinges.
Because the lower mount of the shock damper sways with the lateral oscillating arm, the angle of the axis
line of its kingpin is changeable. Therefore, when this kind of suspension is deformed, the kingpin
orientation angle and the track will be altered to some extent. If the deployment of lever system is
appropriately designed, the orientation parameter of the wheel can be changed only a little. The outstanding
feature of this kind of suspension is that it can enlarge two front wheels’ inside flexible space so as to
facilitate the deployment of the engine and other parts; therefore, it is often applied to sedans.
2. Rear suspension
The rear suspension consists of lateral oscillating arm I of the rear suspension, lateral oscillating arm II of
the rear suspension, vertical tension rod, coil spring and shock damper with their structures shown as
follows:
(1) Lateral oscillating arm and vertical tension rod. The structure of the lateral oscillating arm and vertical
tension rod is shown as Fig. 3-8. The lateral oscillating arm of the rear suspension is made through the butt
weld to the armor plate with its cross section of box type. The outside of lateral oscillating arms I and II
hinges with bottom of the rear shaft head bracket 3 through bolt 8 and the rubber bush installed in
corresponding holes in the rear shaft head bracket. The inner end of the lateral oscillating arm, whose hole
is equipped with rubber bush, joints with the body through bolts.
Fig. 3-7 Structure of rear suspension

1. Coil spring 2. Shock damper 3. Vertical tension rod 4. Rear oscillating arm I
5. Rear oscillating bar II 6. Stablizer bar of rear suspension
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Figure 3-8 Lateral oscillating bar and vertical tension rod

1. Rear oscillating arm I 2. Rear oscillating arm II 3. Rear shaft head bracket 4. Vertical tension rod
5. Adjusting cam for toe-in 6. Toe-in adjusting plate 7,8. Bolt 9. Nut
The joint between inner end of oscillating arm II and the body is equipped with rear wheel toe-in adjusting
mechanism, which consists of adjusting cam for toe-in 5, toe-in adjusting plate 6 and bolt 7. Turning the
adjusting cam for toe-in can change the toe-in value of the rear wheel. The vertical tension rod 4 is made of
steel tube, which decreases the unsprung weight. The tension rod, whose front holes are installed with
rubber bushing and rear end is shaped to furcation, joints with the body through bolts, hinging with the rear
shaft head bracket through bolt 8 and the rubber bushing in corresponding holes of the rear shaft head
bracket 3.
Less longitudinal rigidity of rubber bushing at every joint between lateral oscillating arm of rear suspension
and the vertical tension bar may effectively ease the longitudinal impact from road surface; meanwhile,
larger lateral stiffness may change the wheel orientation angle less. There are grooves on the outer ring
surface of rubber bushes at two sides of the vertical tension bar, which can diminish the longitudinal
rigidity of the vertical tension bar so as to ease the vertical impact.
(2) Coil spring and shock damper. The structure of coil spring and shock damper of rear suspension is
shown as Fig. 3-9. The structure of shock damper of the rear suspension is the same as that of the front
suspension, with its supporting characters that the upper end of shock damper mounts on the body through
the rear suspension mount 1 and its lower end joints with the shock damper bracket and connects to the rear
shaft head bracket through a mount.
The structure of coil spring 5 is the same as that of the front suspension with its supporting feature of the
rubber pad 2 added between the coil spring and spring upper seat. The rear suspension mount 1, made of
rubber, is added back plate 10 during compression molding. Through this back plate, the rear suspension
mount connects with the upper end of cylinder rod of shock damper 9 with its end fixed by nut 11. The rear
suspension mount 1 is equipped between the body 12 and spring upper seat 3, connecting the spring upper
seat and the body with bolts.
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Fig. 3-9 Coil spring and shock damper

1. Rear suspension mount 2. Rubber pad 3. Spring upper seat 4. Buffer stopper
5. Coil spring 6. Shock damper 7. Sping lower seat 8. Dustproof cap
9. Cylinder rod 10. Back plate 11. Nut 12. Body 13. Shock damper mount
(3) Stablizer bar of rear suspension. LF7132 is equipped with the stablizer bar on its rear suspension with
its structure manifested in Fig. 3-10. The basic structure of the stablizer bar is the same as that of the front
suspension. Their key distinction lies in the connection of ends of the stablizer bar’s two sides and the
lateral oscillating arm. The stablizer bar 6, whose ends are shaped to be flat, is set on the stablizer bar
supporting rod 8, with its top and bottom installed with rubber pad 5 and gasket and nuts’ axial fastening.
Lower end of stablizer bar supporting rod 8 hinges with supporting rod mount 9 through bushes and bolts
with the supporting rod mount fixed by bolts on rear oscillating II 7.
Fig. 3-10 Stablizer bar of rear suspension

1. Coil spring 2. Shock damper 3. Body 4. Stablizer bar retaining clip
5. Rubber bushing 6. Stablizer bar 7. Rear oscillating arm II
8. Stablizer bar supporting rod 9. Supporting rod mount
III. Inspection for suspension

i. Front suspension inspection
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1. Inspection for front suspension mount, front coil spring, etc. (Figure 3-11)
Figure 3-11 Inspection to parts like front coil spring, etc.
(1) Check the failure of front suspension mount rubber.

(2) Check the overworn bearing.
(3) Check the deforming, failure of the coil spring upper seat as well as failure of the spring buffer stopper.
(4) Check the plastic deformation of the front coil spring.
(5) Check the oil leakage of shock damper.
If any of the faults above is detected, the parts involved shall be repaired or replaced.
2. Inspection to front oscillating arm
(1) As shown in Fig. 3-12, check whether the front oscillating arm has been damaged and cracked or not
and the failure of rubber bushing and lower button head pin.
Fig. 3-12 Inspection to front oscillating arm
(2) Replacement of button head pin dustproof cap. Dismantle the dustproof cap with a screwdriver, during
which, don’t damage the dustproof cap mount. Inject lubricant grease into the button head pin dustproof
cap then and finally press into the dustproof cap with special maintenance tool. Please don’t splash the
lubricant grease or oil on the dustproof cap mount.
(3) Replacement of front oscillating arm bush. Dismantle the lower lateral oscillating bush with special
tools and press into a new bush
3. Inspection to stablizer bar
As shown in Fig. 3-13, check the deformation or damage of the stablizer bar and its retaining clip as well as
deformation of the left and right brackets of the stablizer bar.
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Fig. 3-13 Inspection to lateral sway bar
ii. Inspection to rear suspension

1. The inspection to rear suspension mount, rear coil spring, etc. may refer to the examination process to
the front suspension, front coil spring, etc.
2. Inspection to oscillating arm of rear suspension

The inspection to oscillating arm of rear suspension is shown as Fig. 3-14. Carefully check the deformation,
damage, etc. of oscillating arms I and II; if there are any faults, repair or replace them.
Fig. 3-14 Inspection to rear oscillating arm
3. Inspection to vertical tension rod

Check whether the vertical tension rod has been deformed, damaged, etc. If there is any deformation,
damage, etc., please repair it or replace it.
iii. Inspection to shock damper

(1) When the shock damper cylinder rod is pulled or pushed at even speed by hands, the force needed
during the whole course shall not be changed. However, when the cylinder rod is pulled forcibly, the force
used will increase slightly within 30mm to the end, which is normal.
(2) Turn the front and rear bumper with force to make them move upwards and downwards so as to check
whether the shock damper works within the scope of extending and compressing. If the vehicle body
vibrates upwards and downwards for two to three times with no abnormal sounds, it can be concluded that
the shock damper works well.
(3) After driving for a distance, stop the vehicle and feel the shock damper with hands. The shock damper
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without temperature difference has faults.
(4) Within mileage of 5mm-10mm, when the cylinder rod is moved upwards and downwards rapidly, the
force needed should not be changed.
(5) In the course of above inspection, if there are any abnormal states or sounds, the shock damper shall be
changed.
Note: Move the cylinder rod for three to four times upwards and downwards before implementing above
inspections. The oil leakage or damage inspection shall be carried on the shock damper of LIFAN sedans
every 40,000km. If the shock damper leaks oil or is damaged, please replace it.
Chapter II Axle, Wheel and Tire
Section I Brief Introduction of Axle, Wheel and Tire
LF7132 adopts front axle (front shaft) drive, and its rear axle (rear shaft) is a lateral oscillating dead axle.
I. Brief introduction for front axle

(1) Steering knuckle and front wheel hub. The structure of steering knuckle and front wheel is shown as Fig.
3-15.
Fig. 3-15 Structures of steering knuckle and front wheel hub

1. Bolt of wheel hub 2. Taper spring gasket 3. Nut locking cover 4. Cotter pin
5. Half shaft 6. Nut 7. Wheel hub 8. Ball pin 9. Bearing 10. Front oscillating arm
11. Front drive shaft assembly 12. Steering knuckle 13. Shock damper 14. Lower mount of shock damper
15. Wheel hub assembly 16. Splash guard 17. Brake disc 18,19 Oil seal 20. Spring retaining ring
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The upper end of steering knuckle 12 is firmly linked with the lower mount of shock damper 14 through
bolts, with its lower part clamping button head pin 8 through bolts. The center hole in the steering knuckle
is fixed with two-row ball bearing 9 limited by the spring retaining ring 20. The wheel hub 7, whose end
part is fastened by taper spring gasket 2 and nut 6 with locking cover and cotter pin to prevent looseness, is
connected to the external spline on the stub shaft through the internal spline. What is featured is: that wheel
hub 7 whose neck is mounted on the inner race of the two-row ball bearing directly improves the stiffness
of the bearing. The bearing unifying seal rings 18 and 19 is the maintenance-free type. Therefore, the
bearing is endowed with outstanding tightness. Note: The larger opening of the taper spring gasket shall be
towards the wheel hub in installation.
(2) Front drive shaft assembly. The two ends of LIFAN sedans’ front drive shaft adopt constant velocity
joints whose functions are to directly deliver transmission’s torque to drive shaft and make the drive shaft
and wheel rotate at constant speed which will be convenient for working in large angles. The structure of
the front drive shaft is shown in Fig. 3-16, consisting of inner half shafts 23 and 25, stub shaft 24 and 26,
intermediate driving shaft 13 and 21, rzeppa universal joint 6 and tripod joints 17 and 22 (called trident
type as well). Installation: The inner half shafts 23 and 25 are connected to deferential half shaft gear, while
the stub shafts 24 and 26 to the wheel hub.
Figure 3-16 Drive shaft and relevant parts

1. Nut retaining ring 2. Half shaft retaining nut 3. Flat gasket 4. Cotter pin 5. Rzeppa of fixed end
6. Rzeppa universal joint 7. Steel wire retaining ring of fixed end 8. Nylon separating ring
9. Disc washer 10. Large clip of fixed end 11. Protective cover of fixed end
12. Small clip of fixed end 13. Intermediate shaft (Short shaft) 14. Small clip of extending end
15. Protective cover of slipping end 16. Large clip of slipping end 17. Tripod assembly (Left)
18. Spring retaining ring 19. Rzeppa of slipping end 20. Differential sping retaining ring
21. Intermediate shaft (Long shaft) 22. Tripod assembly (Right) 23. Half shaft (Right) 24. Stub shaft (Right)
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25. Inner half shaft (Left) 26. Stub shaft (Left)
The configuration of the tripod universal joint is shown as Figure 3-17. The universal joint bushing 5 is
framed with the internal half shaft with three axial raceways processed inside.
Figure 3-17 Tripod universal joint

1. Intermediate drive shaft 2. Clip 3. Snap ring 4. Clip
5. Universal joint bushing 6. Ball type roller 7. Gasket and snap ring
8. Needle roller bearing 9. Dustproof cover 10. Tripod assembly
The tripod assembly 10 is connected to intermediate drive shaft 1 through spline with its end limited by
snap ring 3. Three shaft journals, with three ball type rollers 6 limited by the gasket and snap ring through
needle roller bearing 8, are processed on the tripod assembly. With the cooperation of the three rollers and
the three axial raceways in the universal joint bushing, the tripod assembly can not only conduct axial
movement relatively to the universal joint bushing to modify the length of the drive shaft, but also turn a
angle relatively to the axes of the universal joint bushing so as to transmit the force when there is a certain
angle between the internal half shaft and the intermediate drive shaft. This tripod universal joint with
simple structure saves the part of expansion bend, so the resistance is small, and the impact from the
ground to the body can be eased.
The configuration of the rzeppa universal joint is shown as Figure 3-18. The universal joint mainly consists
of internal ball seat, ball type housing, retainer and steel drive ball, etc. The internal ball seat 7 limited by
snap ring 9, with 6 grooves on the surface as the external raceway, is connected to the intermediate drive
shaft 1 through the internal spline. Six steel drive balls 6 are installed in every groove respectively with the
retainer 4 keeping them within the half facet. During the transmission, the drive force is delivered by the
intermediate drive shaft 1, internal ball seat 7, steel drive ball 6 and ball type housing 8 in turn. Both the
rzeppa universal joint and the tripod universal joint adopt the lubricant grease. The rzeppa universal joint
can deliver the drive force under maximum corner of 42 degree between 2 shafts, and in working, whatever
the drive force transmission direction, the six steel balls will participate in the transmission; this universal
joint with strong carrying capability, compact structure and easy dismantling process is widely used in the
steering drive axle. The relationship of the steering knuckle, front wheel hub, front drive shaft and relevant
parts of LIFAN sedans is shown in Figure 3-19.
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Figure 3-18 Rzeppa universal joint
1. Intermediate drive shaft 2. Clip 3. Dustproof cap 4. Retainer 5. Clip
6. Steel drive ball 7. Internal ball seat 8. Ball type housing 9. Snap ring 10. Steel ball
Figure 3-19 Relationship of steering knuckle, front wheel hub, front drive shaft and relevant parts
1. Brake disc 2. Caliper assembly 3. Wheel hub 4. Splash guard 5. Steering knuckle
6. Bolt 7. Nut 8. Shock damper 9. Half shaft 10. Cotter pin 11. Steering track rod
12. Nut 13. Front oscillating arm 14. Bolt 15. Snap ring 16. Nut
II. Brief introduction on rear bearing

The rear bearing mainly consists of rear bearing head, rear bearing head bracket, and so on shown in Figure
3-20. For the processing convenience, the rear bearing head 14 and bearing head bracket 18 are
manufactured separately. The rear bearing head is connected to the corresponding holes on the bracket
through the shaft journal with coning, the end of which is fixed axially by the gasket and nut 15. The upper
end of the rear bearing head bracket 18 is linked firmly with the lower mount of the shock damper with
bolts; its lower end with the two lateral oscillating arms and vertical tension rod respectively as shown in
Figure 3-21. The wheel hub on the rear bearing is framed with the brake drum 1 and mounts on the shaft
journal of rear bearing head 14 through the two radial ball bearings 9 and 10, between the internal housing
washer of which, spacer bush 4 is installed, with ends fixed by gasket 5 and nut 6, and the nut locking cap 7
and cotter pin installed to prevent looseness. In order to prevent the entrance of dust and mud as well as
water into the bearing of rear bearing head, the dustproof cap 8 is installed on the rear bearing.
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Figure 3-20 Structure of rear bearing

1. Wheel hub (brake drum) 2. Wheel hub bolt 3. Wheel hub nut 4. Spacer bush
5, 16. Gasket 6, 15. Nut 7. Nut locking cap 8. Dustproof cap
9, 10. Radial ball bearing 11, 12. Wheel hub assembly 13. Brake backing plate
14. Rear bearing head 17. Inner shaft bush of rear bearing 18. Rear bearing head bracket
Figure 3-21 Relationship of relevant rear bearing parts

1. Brake drum 2. Rear bearing head and bracket 3. Vertical tension rod 4. Parking brake cable
5. Rear shock damper 6. Bolt 7. Nut 8. Bolt 9. Nut 10. Rear wheel toe-in adjusting cam
11. Rear wheel toe-in adjusting plate 12. Bolt 13. Rear lateral oscillating arm assembly II
14. Rear lateral oscillating arm assembly I
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Section II Common Problems and Recovery of Axle, Wheel and Tire
I. Problems and recovery of drive shaft imbalance

Due to the friction among parts of the universal joint in the drive shaft assembly during operation, and the
movement of ball stud in the pin boss towards the axial direction, when the drive shaft is turning, the
centrifugal force will be generated because of the quality eccentricity caused by imbalance and the
vibration will be further raised. When the rotation speed of the drive shaft reaches a certain value, powerful
vibration or danger will be spurred. When the quality eccentricity hits a high value, the abnormal knocking
will be heard with its body vibrating during the vehicle starting.
If the problems above appear, the following checks shall be carried out:
(1) Check the damage and defect of the drive shaft assembly as well as its parts.
(2) Check whether the universal joint can move freely towards every direction along the axle without
looseness.
(3) Check whether the spline is loose in the turning direction and can slide in the axial direction.
(4) Whether the universal joint is lack of lubricant grease.
(5) Whether the universal joint mark is installed correctly.
II. Common problems and recovery of tire

Incorrect maintenance and adjustment to the vehicle as well as inappropriate utilization of the tire will
cause the abrasion of the tire. The problems can be analyzed based on the worn characteristics of the tire.
1. Main causes of tire utensil type abrasion (Fig. 3-22)
Utensil type abrasion
Fig. 3-22 Tire utensil type abrasion
(1) Excessively small toe-in;

(2) Incorrect toe-in and imbalanced wheel;
(3) Imbalanced wheel and loose joints of every steering link, etc;
(4) Incorrect tire location parameters;
(5) Insufficient tire air pressure.
2. Main causes of tire thread eccentric wear (Fig. 3-23)
Fig. 3-23 Tire thread eccentric wear

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(1) Incorrect toe-in;
(2) Distorted frame, etc.
3. Main causes of tire outside wear (Fig. 3-24)
(1) Insufficient tire air pressure;
(2) Excessive extroversion of tire;
(3) Excessively small tire;
(4) Wheeling semi-diameter without conforming to regulation, etc.
4. The excessively large tire negative camber is the main cause of tire inside abrasion.
Tire outside abrasion Tire shoulders abrasion
Fig. 3-24 Tire outside abrasion Fig. 3-25 Tire shoulders abrasion
Tire center abrasion
Fig. 3-26 Tire center abrasion
5. The main cause of tire shoulders abrasion is the excessively low tire air pressure.
6. The main cause of tire center abrasion is the excessively high tire air pressure.
7. Main cause of tire jagged abrasion
Fig. 3-27 Tire transverse striation jagged abrasion

(1) Inappropriate wheel alignment parameter;
(2) Excessively large wheel hub bearing wear or clearance, looseness;
(3) Kingpin negative caster or right and left kingpin caster is unequal;
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(4) Imbalanced wheel;
(5) Incorrect wheel deflection angle.
8. Main cause of tire wave type abrasion
Fig. 3-28 Tire wave type abrasion

(1) Unbalanced wheel
(2) Incorrect wheel alignment parameter
(3) Excessively large wheel hub bearing wear, clearance or looseness;
9. The imbalanced wheel is mainly caused by the tire dent wear.
Fig. 3-29 Tire dent wear

10. The flow mark chip off-falling or bean curd pattern wear is mainly caused by usual driving on road
with edges and corners.
Section III Axle Check and Repair
I. Removal, mounting and inspection to front drive shaft

1. Front drive shaft assembly removal
(1) Removal:
① Lift the vehicle, remove the front wheel, and dismantle as well as trice the front brake caliper. (Fig.
3-30)
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Fig. 3-30 Dismantle the front wheel and front brake caliper
② Take out the cotter pin, nuts of front wheel hub, and the brake disc. (Fig. 3-31)
Fig. 3-31 Taking out the front wheel hub
③ Take apart the steering track rod and the front stabilizer, bulb cotter bolt of lower transverse arm of front
suspension and button head. (Fig. 3-32)
Fig. 3-32 Bulb cotter bolt of front transverse arm removal

④ Dismantle the connecting nut between the steering knuckle and shock damper, but keep the bolt on
temporarily. Hold the steering knuckle, pull out that bolt and draw out the steering knuckle from the drive
shaft at last. (Fig. 3-33)
Fig. 3-33 Drawing out the steering knuckle from the drive shaft
⑤ Dismantle the front wheel bearing. Remove the oil seal of wheel hub bearing with screwdriver first and
dismantle the inside (outside) of the bearing from the wheel hub with special tools.
⑥ Take out the snap ring with needle nose pliers, and remove the bearing from the steering knuckle with
special maintenance tools.
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(2) Decomposition:
① Unscrew the strap on the front drive shaft with a screwdriver to take apart the dustproof cover.
② Take apart the inside universal joint. As shown in Fig. 3-34, make assembly mark inside the universal
joint bushing and on the surface of the bearing with oil paint to prevent washing out.
Fig. 3-34 Making assembly mark inside the universal joint bushing
③ Remove the snap ring with snap spring pliers.
④ Dismantle the inside universal joint tripod assembly, make the assembly mark at the end of the tripod
assembly and the axle with drift pin, as shown in Fig. 3-35, and knock down the tripod assembly from the
axle with a copper rod, as shown in Fig. 3-36. Make sure to put the copper rod at the protruding part of
tripod assembly and not at the roller.
Fig. 3-35 Making the assembly mark at the Fig. 3-36 Pushing the tripod assembly
end of the tripod assembly and the axle
2. Assembly
The assembly order of the front drive shaft is reverse to that of removal, and pay attention to items below:
(1) When assemble the inside universal joint tripod assembly to the universal joint, please make the
edentulous end of the tripod assembly face the axle and aim at the assembly mark made during the removal.
(2) During the tripod assembly installation, make sure to put the copper rod at the protruding part of tripod
and not at the roller.
(3) When assemble the inside universal joint bushing, fill the universal joint bushing with lubricant grease
and aim at the assembly mark made during the removal.
3. Inspection
As shown in Fig. 3-37, check the crack and damage of the front steering knuckle, damage of the front
wheel hub, damage or the abrasion of the brake disc surface, deformation of the dustproof cap of the brake,
etc. If there are any problems, please repair or renew in time.
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Fig. 3-37 Inspection to parts of steering knuckle, wheel hub, etc.
As shown in Fig. 3-38, check the wearing parts of the front drive shaft. Check the damage or abrasion of
the inside universal joint bushing, damage or abrasion of the universal joint tripod assembly, crack of the
dustproof rubber cover, abrasion or damage of the outside universal joint assembly end, etc. If seriously
worn or damaged parts are detected, they shall be repaired or changed.
Fig. 3-38 Check wearing parts of the front drive shaft

II. Removal, assemble and inspection to the rear shaft
1. Removal
(1) Lift rear end of the vehicle, stabilize the vehicle and remove the rear wheel.
(2) Remove the dustproof cap of the rear wheel hub, cotter pin, castle nut and flat washer; dismantle the
brake drum with special tool. (Fig. 3-39)
Fig. 3-39 Dismantling the brake drum
(3) Remove the brake pipe from the slave cylinder with special tools, and dismantle the rear brake
assembly (Fig. 3-40).
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Fig. 3-40 Rear brake assembly removal
(4) Dismantle the rear shaft head sub-assembly. Remove the rear shaft head and connecting bolt and nut of
the vertical tension rod; remove the connecting bolt and nut of the rear shaft head and suspension
oscillating arm I; remove the connecting bolt and nut of the rear shift and suspension oscillating arm II;
remove the connecting bolt and nut of the rear shaft head and shock damper mount; dismantle the rear shaft
(Fig. 3-41).
Fig. 3-41 Remove rear shaft head

(5) Remove the rear wheel hub bearing. Dismantle the inside and outside bearing with steel rod as well as
the inside bearing spacer bush (Fig. 3-42).
Fig. 3-42 Rear wheel hub bearing removal

2. Assembly
The assembly order of the rear shaft is reverse to that of the removal, and pay attention to items below:
(1) When install the brake assembly, coat the brake backing plate and rear shaft head with sealant; when
coating, never block the 5mm-diameter hole.
(2) After the installation of the wheel, the sedan descends the wheel jack in the state of idle load; vibrate the
sedan upwards and downwards to make the parts of rear suspension into their position. When all weight of
the vehicle acts on the suspension, screw the every bolt and nut.
3. Inspection
The parts and contents to be inspected on the rear suspension are shown as figure (3-43). If any excessive
abrasion or damage is detected, maintenance or changing shall be carried out.
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Fig. 3-43 Inspection to parts of rear shaft
III. Maintenance to front and rear shafts

(1) The front drive shaft has passed the dynamic balancing test when released from the factory. Don’t break
up the front drive shaft unless it is necessary in utilization. If it has to be taken apart, the assembly mark
shall be made inside the universal joint bushing and on the surface of intermediate drive shaft (Fig. 3-34)
with oil paint and never punch it; meanwhile, when dismantle the inside universal joint tripod assembly,
make a assembly mark at the tripod and end of the intermediate drive shaft with drift pin (Fig. 3-35). When
take apart the outside rzeppa universal joint, make a assembly mark with oil paint as well.
(2) After every 40,000km, carefully inspect the noise of three ball and trunnion universal joint as well as
the rzeppa universal joint; if the noise can be detected during working, the causes must be found out and
the lubricant grease of the two universal joints must be changed.
(3) After every 20,000km, crack of the universal joint dustproof cover shall be checked; if any, change the
cover. Meanwhile, inspect the rupture or deformation of the dustproof cover strap; if any, change the strap.
(4) After every 20,000km, check whether the steering knuckle as well as the rear shaft head assembly and
their joints of parts connected are firmly fixed or not, and screw tightly the bolts or nuts according to the
newly-regulated tightening torque.
IV. Tightening torque for main parts of front and rear shafts
As for tightening torque for main parts of front and rear shafts, please refer to Table 3-1
Table 3-1 Tightening torque for main parts of front and rear shafts
Name of parts to tighten Tightening torque/N∙m Name of parts to tighten Tightening torque/N∙m
Conneting bolt of 88.2～127 Connecting bolt of rear 73.5～102.9
steering knuckle and shaft head bracket and
shock damper oscillating arm II
Fixing bolt of steering 78.4～102.9 Connecting bolt of rear 73.5～102.9
knuckle and lower shaft head bracket and
oscillating bulb vertical tension rod
Connecting bolt of rear 88.2～117.6 Tightening nut of front 180～230
shaft head bracket and and rear shaft wheel
shock damper lower hub
mount
Connecting bolt of rear 73.5～102.9
shaft head bracket and

oscillating arm I
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Section IV Application and Maintenance of Wheel
The model of tire of LF7132 sedan is 165/70R14, which belongs to tubeless transverse-cord tire.
I. Adjustment and maintenance of tire

(1) Inspection and tightening to the wheel fixing bolt. After every 20,000km, check the looseness of wheel
fixing bolt or nut firming the wheel hub assembly; if any, tighten the bolt or nut with tightening torque of
88.2N·m～117.6/N·m.
(2) Inspection to car wheel hub bearing. After every 40,000km, check the abnormal noise of front and rear
wheel hub bearings; if necessary, change the bearing lubricant grease; if any excessive abrasion and
looseness, change the bearing. The end clearance between the front and rear wheel bearing is regulated as
no more than 0.2mm.
(3) Inspection to wheel air pressure. The wheel air pressure will affect the car’s performance and longevity,
especially to the radial ply tire. Therefore, the wheel air pressure shall be checked usually and adjusted if
necessary, with barometer or estimation by eyes, as shown in Fig. 3-44.
Figure 3-44 Inspection to tire pressure

A. Normal tire pressure B. High tire pressure C. Insufficient tire pressure
Pay attention to following items when check tire air pressure:

① Check the tire air pressure in cold conditions;
② Usually check the spare wheel and its air pressure to make it available at any time;
③ Avoid insolating the tire for a long time;
④ Wipe off the dirt and stone nipped by the tire plies.
(4) Transposition of tire. After every 10,000km, the tire of the car shall be changed; otherwise, the uneven
abrasion will be caused due to long-term work.
(5) Avoid mixed application of the tire. The four tyres shall be produced by the same factory with the same
specification, and the tyres with different specifications are forbidden. Otherwise, the tire abrasion will be
intensified, fuel consumption increased and the car’s operation stability damaged.
(6) Depth of tire plies. After every 10,000km, the depth of tire plies shall be checked. If the safe driving
make can be seen due to the tire abrasion, try to renew the tire (when the depth of the tire plies is only
1.6mm); otherwise, skidding will be caused because of the shallow plies.
(7) Check the wheel tread. After every 10,000km, check the crack and damage of the tire. Don’t use the
tyres with large crack; otherwise, the tire will blow up, which is dangerous to high-speed driving cars.
(8) Breaking in of the new tire. The new tire shall not undertake the maximum traction load, because the
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new tire is prone to skid. At the first 160km, the tire shall be broken in with appropriate speed.
(9) The vehicle has passed the dynamic balancing test before released from the factory. If the vehicle is not
balanced, it has been added the wheel equalizer at the edge of the wheel hub. Therefore, the wheel
equalizer shall not be dismantled. If the equalizer falls and the original position is unknown, the dynamic
balancing test shall be carried out again.
II. Tire transposition

The loads of front and rear axles are different, and the loads of front and rear axles as well as the left and
right tyres will change during the upgrading, downgrading, swerving, braking and speeding; when driving
on the arch pattern road surface, the loads of the left and right tyres are different as well. Therefore, the
abrasion of each tire is not identical, so the tire shall be changed after a certain mileage to balance the
abrasion state of all tyres and prolong the longevity of the tyres.
Notes in tire transposition: the tire at the same axle shall be with the same type and plies; the face-lifting
tire shall no be applied in the steering wheel. After every 10,000km, transposition shall be carried out on
the tire of LIFAN sedan shown as Fig. 3-45:
Fig. 3-45 Tire transposition
Front left wheel-rear left wheel-front right wheel-rear right wheel-front left wheel
III. Tire application and maintenance

1. Tire air pressure
Both the excessively high or low air pressure will intensify the tire abrasion. The standard tire air pressure
of LIFAN sedan is 220kPa.
2. Measures to improve longevity of tire
The tire consumption will cover 10% to 20% of the transport cost; therefore, it is very important to apply
and maintain the tire correctly as well as prolong its longevity.
Pay attention to following items to improve the tire application longevity:
(1) Correctly choose the specification and plies of the tire, and carry out tire transposition regularly.
(2) Carefully realize the tire air pressure standard, which shall be neither excessively high nor low.
(3) Strictly control the tire load. The tire longevity will shorten 30% with operation at 20% overloading.
(4) Usually check the location parameter of each wheel and keep the steering, driving brake system
technique in good shape.
(5) The wheel shall be balanced with correct installation.
(6) Carefully drive to prevent accidental damage.
(7) Keep the tire well and avoid exposing to the sun and rain or petroleum products, etc.
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Section V Inspection and Adjustment to Wheel Alignment
I. Parameter of wheel alignment

1. Front wheel alignment
The front wheel alignment consists of wheel camber, kingpin inclination, kingpin caster and toe-in. LIFAN
sedan parameters of front wheel alignment are as follows:
Kingpin caster angle is 2°55’; kingpin inclination is 12°; camber angle is 0°20’; front wheel toe-in is 1mm.
Among the front wheel alignment, the kingpin caster, kingpin inclination and wheel camber are guaranteed
by the disposal of the suspension and only the toe-in can be adjusted.
2. Rear wheel alignment
Not only the front wheel of the LIFAN sedan is equipped with the orientation angle, but also its rear wheel.
The rear wheel orientation is the rear wheel toe-in and rear wheel camber angle with the orientation angle
that the wheel camber angle is -1°; the rear wheel toe-in is 4～8mm.
II. Inspection and adjustment of front wheel toe-in

(1) Park the vehicle on the level road and keep the height of the vehicle at the same level.
(2) Move the vehicle 5m forward on the level road and make the front wheel of the vehicle in the state of
beeline driving. Don’t move the vehicle backward during the measurement.
(3) Turn the hand of the toe-in measuring apparatus to the height of the center of the front wheel, as shown
in Fig. 3-46.
Fig. 3-46 Distance A between measuring marks
(4) Make a mark at the tire center of rear end of every front wheel and measure the distance A between
measuring marks (Fig. 3-46).
(5) Push the vehicle forward slowly until the wheel turns over 180° (Fig. 3-47).
Fig. 3-47 Wheel turning over 180°
(6) Measure the distance B between marks made in step (4), as shown in (Fig. 3-48). Calculate the front
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wheel toe-in value, namely A-B value. The front wheel toe-in value is regulated as -1mm～3mm.
Fig. 3-48 Distance B between measuring marks
(7) Adjust the front wheel toe-in (Fig. 3-49). Relax the locknut of steering lateral rod joint; adjust the toe-in
through turning the steering lateral rod joint. Note: Don’t turn the dustproof cover during adjustment; the
turning amount of the left and right lateral rod shall be identical before the toe-in adjustment; the length of
C shown in Fig. 4-49 must be the same; otherwise, the turning angle of left and right angle will be different.
Fig. 3-49 Steering lateral rod and joint

1- Lateral rod joint 2- Adjusting nut 3- Steering lateral rod
(8) Check whether the sideslip value accords with the regulated value of -3mm/m～3mm/m or not with
sideslip measuring apparatus.
III. Inspection and adjustment to rear wheel toe-in

(1) Check the rear wheel toe-in. The steps and method of checking the rear wheel toe-in is the same as
those of the front wheel toe-in, with regulated rear wheel toe-in value of 4mm～8m.
(2) Adjust the rear wheel toe-in:
① Unscrew the fixing bolt of toe-in adjusting cam on the rear suspension oscillating arm II (Fig. 3-50)
Fig. 3-50 Fixing bolt of adjusting cam
② Insert the hexagon wrench into the hexagon hole on the back of the adjusting cam (Fig. 3-51) and turn
the hexagon wrench. When the left and right adjusting cam is turning, the rear wheel toe-in value will
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change about 5mm, with identical angular turning of the left and right adjusting cams. When the adjusting
cam turns in clockwise direction, the rear wheel toe-in will increase; in counter-clockwise direction,
decrease.
Fig. 3-51 Adjusting rear wheel toe-in

③ After the completion of adjustment, screw the fixing bolt of the adjusting cam.
(3) Check whether the sideslip value accords with the regulated value of 1mm/m～7mm/m or not, with
sideslip measuring apparatus.
Chapter III Steering System

The steering system is applied to change or maintain vehicle’s travel direction, the function of which is: to
make the vehicle change its travel direction in time according to driver’s operation requirement in driving,
and maintain the vehicle’s stable driving together with the drive system when the vehicle accidentally
deviates outside the travel direction due to the occasional impact from the road. The steering system is one
of the important systems to guarantee the vehicle’s safe travel; therefore, the timely inspection and
maintenance to it will be effective to ensure the safe travel and decrease the traffic accident. LF320 sedan
adopts the pinion-and-rack steering system with hydraulic booster (the basic model without hydraulic
booster). The position of steering wheel can not be changed. The steering axle can carry out the protection
function of impact energy-absorbing. The steering wheel is equipped with the air bag (the basic model
without air bag).
Section I Configuration and Technique Parameter of Steering System
I. Technique parameter of steering system

The technique data of LIFAN sedan steering system are shown as Table 3-2
Table 3-2 Technique parameter of steering system

Minimum swerving semi-diameter (m) 4.76
Steering gear angle ratio 19.39
Circles of steering wheel 3.41
Force Fk (N) to steering wheel by steering resistance 118.5
Diameter of steering wheel (mm) 380
Type of steering gear Integral type of pinion-and-rack power
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steering gear
Type LF7132-3411000
Load applied to front axle (N) 7900
Output load (N) 5700
Maximum operation load (MPa) 7.9
Recommended oil pump flow (L/min) 5
Line angle gear ratio (mm/r) 42.83
Applied temperature scope (℃) -40～+120
Rack travel range (mm) 143±1
Total circles of input axle 3.34±0.1
II. Configuration of steering system

1. Steering system assembly
The steering system of LIFAN sedan mainly consists of steering wheel, steering gear, power steering pump,
oil tank, hydraulic power cylinder, steering control valve and steering gear machine. The configuration of
relevant parts in steering system is shown as figure (3-52).
Fig. 3-52 Steering system configuration

1. Steering wheel 2. Steering gear 3. Steering drive axle 4. Power steering pump
5. Oil tank 6. Hydraulic power cylinder 7. Steering control valve
This power steering system consists of manual steering system and hydraulic power steering booster. Its
hydraulic power cylinder is fixed on the housing of steering gear, and the piston control lever of the
hydraulic power cylinder hinges on the steering rack, by which, the steering power is output.
The LIFAN sedan power steering system adopts the rotary type steering control valve with compact
structure as the control device, vane type power steering pump as the power source, piston control lever of
the hydraulic power cylinder and rack as the power delivery mechanism. When the vehicle needs steering,
the engine drives the power steering pump through the transmission belt and generates the hydraulic power.
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The flow of the steering fluid and pressure is adjusted by the adjuster in the pump. The hydraulic pressure
is delivered to the rotary type steering control valve of the steering gear mechanism by the steering pump.
The steering control valve will adjust the hydraulic pressure according to the turning state of the steering
wheel and change the flowing direction of the steering fluid, guide the pressure oil fluid into the hydraulic
power cylinder, boost the piston control lever and rack to do beeline movement to help the swerving wheel
to turn and realize the power steering so as to deliver the filtrated steering fluid in the fluid reservoir
returing from the low pressure side of the power cylinder to the steering pump to circulate.
2. Power steering assembly

The power steering assembly mainly consists of the steering control valve, hydraulic power cylinder,
steering tie rod, and so on, as shown in (Fig. 3-53).
Fig. 3-53 Power steering assembly

1. Cotter pin 2. Hexagon thin slotted and castle nut 3. Steering ball joint assembly
4. Adjusting nut 5. Steering lateral rod 6. Hex bolt and spring washer
7. Bracket 8. Rubber cover 9. Steering control valve 10. Left steering oil pipe
11. Right steering oil pipe
3. Steering gear tube, steering axle and steering drive axle (Fig. 3-54)
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Fig. 3-54 Steering gear tube, steering axle and steering drive axle
1. Steering gear tube 2. Upper bracket 3. Lower bracket
4. Steering axle 5. Universal joint 6. Steering drive axle
7. Dustproof cover I 8. Dustproof setting bracket 9, 11, 13. Bolt
10. Dustproof cover II 12. Nut
The steering gear tube is fixed with bolts on the bottom of front dash panel and dash board in cab through
the lower flange and upper fixing panel.
The steering axle consists of axle and bushing connected by colophony pin. When the vehicle crash
happens, the excessively large impact can snip the colophony pin so that the steering axle and bushing can
move relatively so as to protect the driver from the stab of the steering axle. Considering the overall vehicle
disposal and safety as well as the malfunction of the steering gear due to the vehicle body transformation,
the steering drive axle is adopted between the steering axle and steering gear.
The round vehicle steering wheel is the two radial type wheel made of colophony materials
4. Steering drive assembly

The steering drive assembly consists of the lateral rod and corresponding joints as shown in Fig. 3-55.
Fig. 3-55 Steering lateral rod and joints

1. Lateral rod joint 2. Adjusting nut 3. Steering lateral rod
4. Ball joint 5. Ball joint seat 6. Dustproof cover
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Section II Check and Repair and Fault Diagnosis of Steering System
I. Inspection and adjustment of steering system

The power steering system is a complex hydraulic system; therefore, the regular inspection and adjustment
are important to ensure its safe and stable operation as well as prolong its longevity. The fact indicates that
most of the faults of the power steering system are caused by inspection and maintenance failure. Therefore,
in order to decrease the malfunction of the power steering system, the regular inspection and maintenance
to the power steering system are necessary.
1. Check oil of the oil reservoir
(1) Parking the vehicle on the level road surface.
(2) Turn the steering wheel several times during the vehicle’s idle speed to make the steering fluid
temperature up to about 80℃.
(3) Check whether the steering fluid has generated fluid or emulsification; if so, it indicates that the air has
come into the steering fluid, so the exhaust operation shall be carried out.
(4) Check the quality of the steering fluid. If the quality of steering fluid has changed or its duration of
service is mature, the fluid shall be changed.
(5) Check the oil height in the oil reservoir to make sure the oil height is between the upper and lower
limits of the oil reservoir. When the fluid does not change its quality and no air comes into the fluid but the
fluid surface is lower than the fluid lower limit, the leakage has possibly happened. The inspection and
maintenance to the leaking part shall be carried out and the oil recommended shall be used according to the
necessity and keep the oil level near the upper limit. The oil type applied by this steering system is ESSO
ATED.
2. Exhaust the air in the power steering hydraulic system
When the air intermingles the steering hydraulic system, the instable operation of the vehicle steering will
be caused due to the condensability of the air, which will affect the steering safety.
Main causes of the air leakage to the hydraulic system are: unfirm connection or damage of the oil pipe
joint; without implementing exhaust operation or thorough exhaust after the oil pipe breaking or
re-connecting the oil pipe; without carrying out thorough exhaust during the steering fluid exchange;
excessively low oil level in the oil reservoir, etc. In order to guarantee the power-saving steering and stable
safe operation, timely exhaust to the air in the steering hydraulic system shall be executed. Before the
exhaust to the power steering system, first check the oil level in the oil reservoir, and add the hydraulic oil
according to necessity. After the fluid level is appropriate, carry out the exhaust in accordance with the
following method:
(1) Lift the front part of the sedan with jack or lifting jack and fix it with bracket.
(2) Turn the steering wheel from the left utmost position to the right utmost position three to five times.
(3) Start the engine and make it operate at idle speed and repeat the process of turning steering wheel above
three to five times.
(4) Let the front part of the sedan down. Turn the steering wheel five to eight times with the engine at the
idle speed to raise the oil temperature and place the steering wheel at the central position and check the oil
level in the oil reservoir.
(5) Turn down the ignition switch to stop the engine. Three to five minutes after its stop, check the oil level
in the oil reservoir and compare the result with that of the step (4). If the comparing difference is zero or
less than 5.0mm and there is no air bubble or emulsification in the oil fluid, the air in the system has been
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completely exhausted. Otherwise, repeat the step (4) and (5) until the air is completely exhausted.
(6) Check the oil level, fill the oil reservoir with oil fluid to the regulated oil level according to necessity.
3. Replace power steering fluid
When the power steering device has problems and needs taking apart as well as inspecting, the power
steering fluid shall be replaced; if the oil fluid deterioration is detected, the oil shall be replaced in time as
well. The replacing steps are as follows:
(1) Lift the front part of the sedan with jack or lifting jack, and support the sedan firmly.
(2) Remove the oil return hose of the oil reservoir, and discharge the worn oil into a proper container from
the oil reservoir and oil return hose. Don’t splash the worn oil on the vehicle body or parts to avoil the
vehicle paint damage. If there is any splash, please wipe it immediately:
(3) Make the engine work at the idle speed. When discharge the oil, successively turn the steering wheel to
the left and right utmost position until the oil is completely discharged, and then stop the engine.
(4) Re-install the oil return hose to the oil reservoir.
(5) Fill the oil reservoir with specified hydraulic oil to the upper oil level limit; the capability of the system
is 1.0L; the capability of the oil reservoir is 0.3L.
(6) Start the engine and let it operate at the idle speed; turn the steering wheel from the left utmost position
to the right utmost position several times so as to exhaust the air in the steering hydraulic system.
(7) Re-check the oil level. Add the specified hydraulic oil if necessary to the upper limit of the oil reservoir.
4. Check and adjust tension of the power steering pump transmission belt
The driving force of the steering pump springs from the engine and is delived by the transmission belt. If
the transmission belt is too loose, it will be easy to skid, which will cause the decrease of the hydraulic
pump oil supply amount, and the low oil pressure in the steering system will cause the heavy steering; if the
transmission belt is too tight, the force imposed on the hydraulic pump axle and bearing will be increase
and the part abrasion will be intensified; the service longevity of the parts and transmission belt will be
shortened and the power consumption of the engine will be raised. Therefore, the tension of the power
steering pump transmission belt shall be adjusted. However, the adjustment is different for the new and old
transmission belt. For the new transmission belt, adjust it according to the new belt deflection standard;
after the engine works for 5min, adjust the deflection to the standard value for the old transmission belt.
(1) Inspection
1) Inspection method for transmission belt deflection. Impose the force of 100N to the middle of power
steering pump transmission belt. Measure the deflection of the transmission belt to check whether
deflection value accords with the standard or not; if not, adjust it.
Standard deflection of old transmission belt: 13mm～14mm;
Standard deflection of new transmission belt: 9mm～10mm.
2) Inspection method for transmission belt operation: Park the vehicle on the dry road surface; start the
engine to make the oil temperature up to normal value; turn the steering wheel right and left; when the
steering wheel turns to the utmost position, the output oil pressure of the power steering pump is at the
maximum; at this time, the load of the transmission belt is at the maximum as well; if the transmission belt
skids, it indicates that the tension of the transmission belt is insufficient or there are machinery damages in
the hydraulic pump.
(2) Adjustment
1) Loosen fixing bolt of the tension wheel.
2) Press the tension wheel tightly and make the transmission belt tighten; meanwhile, screw tightly the
fixing bolt.
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3) Start the engine; turn the steering wheel between the left and right utmost positins several times
successively and stop the engine.
4) Re-check the transmission belt deflection. If the tension of the transmission belt does not accord with the
standard, re-adjust it to conform to the requirement.
5. Inspect output pressure of the power steering pump
The purpose of checking the output pressure of the power steering pump is to inspect whether there are any
faults in power steering pump or steering gear mechanism. In order to measure the output pressure of the
power steering pump correctly, the oil level in the oil reservoir and the tension of the power steering pump
transmission pump shall accord with the standard.
Inspect the output pressure of the power steering pump with pressure gauge. Dismantle the pressure pipe
from the power steering pump when the engine stops; connect the measuring end of the pressure gauge to
the draining connector of the pump and the other end of the hand valve to the input end of the steering
control valve, by which, the pressure gauge and the hand valve will be in series connection to the pressure
pipe of the power steering pump and the steering control valve.
Inspection steps to output pressure of the power steering pump are as follows:
(1) Completely start the hand valve.
(2) Start the engine and make it work at the idle speed.
(3) Turn the steering wheel between the left and right utmost positions several times in succession to raise
the oil temperature up to 80℃ and guarantee the normal oil level.
(4) Measure the static oil pressure at the engine’s speed of 800r/min; if the power stering pump operates
well, the reading on the pressure gauge shall be 300kPa at least (minimum pressure when no steering).
(5) Gradually turn off the hand valve until the hand of the pressure gauge stands still and read the pressure
value. At this time, the output standard pressure of the power steering pump shall be 6.2－6.9MPa at least
(the maximum wheel steering resistance).
(6) Rapidly turn on the hand valve completely; note that the closing period of the hand valve shall not
exceed 5s every time, or the steering pump will be too hot to be damaged easily.
The oil pressure measured during the complete close of the hand valve can reflect the working state of the
power steering pump. If the power steering pump works well, the reading on the pressure gauge shall be
6.2MPa～6.9MPa at least. If the reading on the pressure gauge is too low, it indicates that the output
pressure of the steering pump is excessively low and the steering can not be completed well, which shows
that the power steering pump has problems and the power steering pump shall be repaired or replaced.
6. Check the steering operating force
When check the operating force at the beginning of the wheel turning, park the vehicle on the clean dry
level road surface, inflate the tire to normal air pressure, and make the oil level in the oil reservoir and the
tension of the steering pump transmission belt accord with the standard value with the inspection process as
follows:
(1) Start the engine; make it at the idle speed; and turn the steering wheel between the left and right utmost
positions several times in succession so as to raise the steering oil fluid temperature.
(2) Make the front wheel at the beeline driving position.
(3) Hang the spring dynamometer on the edge of steering wheel.
(4) Start the engine; make it at the idle speed; pull the spring dynamometer; once the steering tire begins to
turn, record the reading on the spring dynamometer.
(5) The reading of the spring dynamometer shall be less than 40N; if the reading is too high, it indicates
that the steering wheel operating force needed at the beginning of the wheel turning is too large, and the
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power steering does not work well so the power steering pump and steering gear shall be checked; if the
power steering pump is normal but the steering operating force is too large, the steering control valve,
power hydraulic cylinder and steering gear shall be checked.
7. Inspection to exterior oil leakage of power steerng hydraulic system
The exterior oil leakage of the power steering hydraulic system is mainly caused by the damage or failure
of the oil seal and ring seal, crack of the housing or the metal piece, oil pipe leakage or loose oil pipe
connector, etc. The parts involving leakage possibly include the oil pipe, power steering pump, steering
control valve, power hydraulic cylinder, oil reservoir, etc., which can be repaired through changing the oil
seal and damaged parts or screwing the connector.
Common leakage parts in the hydraulic power steering system include: the pump oil seal leakage, pump
housing and pump bonnet end leakage, oil seal leakage of the steering control valve housing top, power
hydraulic cylinder leakage, and leakage at every oil pipe connector of the power steering pump and steering
control valve as well as the power hydraulic cylinder. Therefore, the highlighted inspection to leakage shall
be carried out on parts above.
When inspect the leakage, start the engine first, and then turn the steering wheel to the right and left utmost
positions several times (staying at the utmost position for less than 5s) to make the steering pump output
the maximum pressure so as to make the whole power hydraulic pipe system generate the maximum
pressure; at that moment, check the leakage at such common leaking points as the joint of the steering
pump pipe, the power steering pump, the steering control valve, and the power hydraulic cylinder.
Specific inspection process is as follows:
(1) Lift the vehicle; support it safely and wipe the oil leaking parts.
(2) Check whether the oil in the oil reservoir is surplus; if so, discharge the surplus oil.
(3) Check and tighten the joint of the steering pump, steering control valve and oil pipe on the power
hydraulic cylinder.
(4) Start the engine; repeatedly turn the steering wheel to find out the leaking part. Once the leaking part is
detected, stop the engine; check and eliminate the faults.
8. Inspection and adjustment after the re-assembly of the power steering gear
After the re-assembly of the power steering gear, the inspection shall be carried out as well as the
adjustment if necessary so as to ensure the steering performance.
(1) Sealing performance inspection. The sealing performance inspection after the installtion of the power
steering gear assembly must be carried out on operating vehicle. Therefore, first start the engine and make
it work at the idle speed; turn the steering wheel between the left and right utmost positions several times to
raise the oil temperature of the power steering oil; and turn the steering wheel to the left and right utmost
positions for several seconds (less than 5s) to make the pressure pipe generate the maximum pressure.
Check the power pipe and every oil pipe joint, valve devices and power hydraulic cylinder handspike of the
power steering system. If the the leakage appears, the cause must be found out and eliminate the faults.
(2) Steering performance inspection. Start the engine. Make the engine work at the idle speed and turn the
steering wheel right and left. The steering gear assembly shall perform well in its working range with easy
operation, smooth turning of the steering wheel, low noise and no vibration. At this time, the power
steering pump is required to work normally.
(3) Check and adjust the toe-in of the front wheel to get it right;
(4) Check whether the steering wheel is in the center or not when the steering tire is at the beeline driving
position; if necessary, adjust it through turning the left and right lateral rod with equal extent.
II. Diagnosis to steering system faults
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The common faults of the hydraulic power steering system include the oil leakage of the hydraulic
transmission part, air in-leakage, failure of the power steering pump, steering control valve damage and the
machinery transmission mechanism damage, etc. with diversified expression, such as the heavy steering,
steering noise, steering difficulty and steering vibration, etc. When the power steering system has problems,
the fault diagnosis shall be executed immediate so as to eliminate the faults in time.
1. Fault diagnosis to steering wheel returing problems
(1) Faults. After the vehicle’s steering, the steering wheel can not return to the central driving position
(beeline driving position), and needs the driver’s operation to return.
(2) Causes
1) The air has leaked into the hydraulic circuit.
2) The circuit pipe has been deformed and blocked.
3) The steering control valve or power hydraulic cylinder has been blocked.
4) The steering control valve cannot locate the center.
5) Inappropriate adjustment to rack top or deformed rack.
6) Excessively tightened joint of the steering transmission mechanism.
(3) Fault diagnosis and elimination
1) Exhaust the air in the hydraulic system and fill enough steering oil fluid after the exhaust according to
the regulation.
2) Check whether the power hydraulic cylinder pipe and circuit pipe are deformed and blocked; if so,
replace them.
3) Check the turning of the rack and pinion mechanism at the returned position of the wheel and other
positions of the wheel; if the turning torque is too large, check the deflection of the rack and adjustment of
the rack; adjust the rack top tightening force or replace the rack and pinion mechanism if necessary.
4) Check whether the steering control valve is blocked and cannot return well; replace the steering control
valve if necessary.
5) Take apart and check the power hydraulic cylinder; replace the damaged parts.
6) Adjust the button head pin of every joint of the steering transmission mechanism to guarantee it work
well.
2. Fault diagnosis to heavy steering
(1) Fault: the steering wheel is difficult to steer in driving.
(2) Causes: Usually, the heavy steering is due to the inefficiency of the hydraulic steering power assited
system or insufficient power, damaged machinery transmission mechanism or inappropriate adjustment
with the main causes as follows:
1) The oil reservoir is lack of oil or the oil level is lower than the specific requirement.
2) The sealing performance of every oil pipe joint is inefficient and leakage happens.
3) The air leaks in the steering hydraulic circuit.
4) The oil pipe is deformed and the oil route is blocked.
5) The tension of power steering transmission belt is insufficient and the transmission belt skids.
6) Inside of the steering pump is worn and leaked heavily, which makes the steering pump output pressure
not reach the standard.
7) The interior pressure adjustor of the steering pump is inefficient, which causes the excessively low
output pressure.
8) Leakage of the steering control valve, and inside of the power hydraulic cylinder.
9) The steering gear mechanism is damaged or adjusted inappropriately.
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1) Check whether the tire air pressue is normal or not and inflate the tire according to the regulation.
2) Check whether every oil pipe joint of the steering hydraulic system leaks or not, and whether the oil pipe
is damaged, deformed or cracked. Once the fault of the oil pipe is detected, the pipe shall be changed; if the
leadkage is at the oil pipe joint, screw it and replace the oil pipe if necessay.
3) Check the oil quality and level in the oil reservoir. If the oil quality has been alterative, the oil shall be
replaced with the specified oil; if the oil level is lower than the regulated height, the causes shall be found
out; refill the reservoir with oil to the designated oil level.
4) Check whether the oil circuit is invaded by air. If air bubble is detected in the oil of the oil reservoir, it
indicates that the air has invaded into the oil circuit; in this condition, inspect the causes of the air
in-leakage, and check the oil pipe joint looseness, oil pipe crack, seal component damage, low oil level in
oil reservoir, etc. and eliminate the problems; then carry out exhaust operation to the oil pressure system
and finally fill the reservoir with steering oil fluid to the designated level.
5) Check whether the transmission belt of the steering pump skids or is damaged. If these problems are
detected, adjust the tension of the transmission belt according to the regulation or apply a new belt.
6) Check the performance of the power steering pump, pressure adjustor and the power hydraulic cylinder.
Before the inspection, connect the pressure gauge conforming to the specified oil pressure and the hand
valve to the position between the power steering pump pressure outlet and the steering control valve
pressure input oil pipe. During inspection, turn on the hand valve completely; turn the steering wheel to the
left or right utmost position; start the engine and make it work at the idle speed; measure the output oil
pressure of the steering pump. At this time, if the oil pressure cannot reach the regulated pressure:
6.2MPa～6.9MPa and the oil pressure cannot be raised when the hand valve is gradually closed, it indicates
that the steering pump or the pressure adjustor has problems; if the oil pressure cannot reach the regulated
value, but it can be raised when the hand valve is gradually closed and the oil pressure can reach the
regulated value, it indicates that the steering pump performs well and the problems should be in the steering
control valve or power hydraulic cylinder; if the pressure cannot reach the regulated value when the hand
valve is completely turned on, the problems should be in the steering transmission mechanism.
If the power steering pump, pressure adjustor and the power hydraulic cylinder have problems, they shall
be repaired or replaced; if the steering control valve has faults, it shall be changed.
7) Check the steering transmission mechanism: Turn the steering wheel to check whether the parts related
to the steering gear axle are sensitive or not; check whether the steering universal joint, and ball joint of
every transmission rod are excessively tightened; if the problems are detected, the parts shall be adjusted or
replaced; check the steering rack and pinion mechanism; adjust the tension force of the rack top to make
the side clearance bwteen the rack and pinion appropriate, guarantee the free movement of the rack and
replace the crooked rack.
3. Fault diagnosis to the steering wheel vibration during steering
(1) Faults. When the engine works, if the steering wheel is turned, the steering wheel will vibrate,
especially when the steering wheel is turned to the utmost position.
(2) Causes
1) The steering pump transmission belt skids.
2) Excessively low oil reservoir.
3) The air invades into the oil circuit of the steering hydraulic system.
4) Insufficient steering pump output pressure.
5) The piston of the pressure adjustor within the steering pump is sluggished.
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1) Check whether the steering pump transmission belt skids or the transmission belt is damaged or not.
Adjust the tension of the transmission belt if necessary or replace the inefficient transmission belt.
2) Check whether the oil level of the oil reservoir accords with the regulation or not; fill with reservoir with
oil if necessary.
3) Check all pipe joints of the steering hydraulic system; eliminate the fault of steering oil fluid leakage and
exhaust the air in the oil circuit.
4) Check the steering pump output pressure. Separate the steering pump if the pressure is insufficient:
check whether the steering pump is worn or the inside leakage is serious; the pressure limiting valve or the
pressure adjustor piston leaks seriously or is blocked; and the seal components of the steering pump are
damaged. Clear the faults and repair them; replace the steering pump if necessary.
4. Fault diagnosis to instable or deviated steering wheel during straight-line driving
(1) Faults. When the vehicle is driving on a straight line, it is difficult to drive right ahead and the vehicle
always deviates.
(2) Causes
1) The torsion bar of the steering control valve is damaged or too weak so that the steering gear
contradictory transmission resistance can not be overcome and the valve cover cannot return in time.
2) The valve core and the movement of the valve cover are retarded due to the oil dirt.
3) The valve core of the steering control valve deviates the center, or although it is in the central position,
but it does not conform to the gap of the groove shoulder of the valve cover.
4) The pressure adjusting piston of the steering pump adjustor is blocked, which makes the flow of the
pump oil too large and the gap between the left and right cavities in the dynamic cylinder too big.
5) The gap between the steering transmission mechanism joints is too large or the connecting parts are
loose or overworn.
1) First, check whether the connecting parts of the steering transmission mechanism are loose or not;
whether the gap between every parts are too large or not; whether the transmission is too loose or not; and
eliminate the faults of the steering transmission mechanism.
2) Check whether the oil fluid is dirty or not. The new vehicle or the vehicle through check and repair
which has not carefully implemented the oil replacement regulation in the break-in maintenance period
tends to contaminate the oil fluid.
3) Check the steering control valve. First, turn the steering wheel in the condition that the engine does not
be started and judge whether the steering control valve can move freely with hand; if any doubt, remove
and check it.
4) Finally, check whether the steering pump pressure adjustor performs normally; check whether the
pressure adjusting piston of the adjustor is retarded or not; check the steering pump output pressure to judge
the faults if necessary.
5. Fault diagnosis to steering noise
(1) Faults. Great noise can be heard during steering.
(2) Causes. When the vehicle is steering, noise can be heard in the steering system normally as well as at
the first 2min～3min in the steering pump in winter after the engine is started, but if the noise is too great
or it has affected the steering performance of the vehicle, the noise is regarded as the fault with its main
causes as follows:
1) The great steering noise is due to the loose steering transmission mechanism.
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2) The great steering noise may be due to the damaged or overworn power steering pump or the oil mixed
with air.
3) The great steering noise may be due to the loose power steering pump transmission belt or skidding
transmission belt.
4) The steering control valve does not perform well.
5) The loose oil pipe joint or cracked oil pipe.
6) The filter sieve of the oil filter is blocked, or there are excessive deposits in the hydraulic circuit.
1) If the clickety-clack can be heard during the steering, it is possibly due to the loose steering gear axle
joint, lateral rod or ball type joint. The parts above shall be checked; tighten or replace the damaged parts if
necessary; if the steering gear axle sways heavily, the steering gear assembly shall be changed; if the
steering gear installed is too loose, it shall be tightened; lubricate the lubricant parts at the connecting part.
In addition, the looseness of the steering pump belt pulley will cause the clickety-clack as well; therefore,
check whether the steering pump belt pulley is loose or not; tighten it or change it if necessary to eliminate
the noise.
2) If the clickety-clack can be heard during the steering and the noise is raised when the steering wheel is
turned from one utmost position to the other one, the fault may be caused by the skidding of the power
steering pump transmission belt. At this time, the tension of the transmission belt and its abrasion shall be
inspected; tighten or replace the transmission belt if necessary.
3) If the clickety-clack can be heard from the steering pump during the steering, it indicates that there are
air bubbles in the oil fluid so that when the oil flows, the air powered noise is generated. At this time, first
check the oil level; if the oil level is too low, fill the oil reservoir with oil to the correct position and check,
eliminate the leakage. Then check whether the hose is damaged or the clip is loose which causes the air into
the system; replace the damaged hose or clip if necessary. If the air in-leakage to the power steering system
has been confirmed, the air shall be exhausted from the power steering system so as to eliminate the noise.
If the hiss or screech is heard from the steering pump and there is no air leakage in the hydraulic system
and the tension of the transmission belt is normal, it indicates that the oil circuit is blocked or the steering
pump is overworn and damaged; therefore it shall be repaired or replaced.
4) If the hiss is heard from the steering gear when the steering wheel at the utmost position or the original
place is turned, the abnormal sound may be caused by the malfunction of the steering control valve;
therefore, replace the control valve and carry out the comparing inspection to eliminate the faults.
Chapter IV Brake System
Section I Brake System Composition
The brake system of LF 320 is composed of driving brake system and parking brake system. The driving
brake consists of brake pedal, brake master cylinder, vacuum booster, ABS mechanism, brake wheel
cylinder, brake and brake pipeline. See Figure 3-56. The parking brake system consists of control lever and
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parking brake cable, etc.
Fig. 3-56 Driving brake system
I. Driving break system

The driving break system is composed of brake pedal, vacuum booster, brake pump, brake, ABS system
(optional) and brake pipeline. It serves to decrease speed steadily during driving, and achieve steady brake
in emergency.
1. Brake
(1) The structure and the installation disposal of the front wheel brake are shown in Figure 3-57. The front
wheel brake is the floating pliers disc brake. Clearance self-adjusting device and brake pad wear limit
warning device are installed in the brake.
Fig. 3-57 Structure of front brake

1-Brake disc 2-Wheel hub 3-Wheel speed sensing fluted disc 4-Splash guard 5-Bearing
6-Dust shield 7-Steering knuckle 8-Wheel speed sensor 9-Bolt
10-Dust shield 11-Washer 12-Brake piston 13-Brake caliper
14-Brake pad steel back plate 15-Brake lining pad 16-Silent pad
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When braking, the brake fluid is pressed into the brake caliper oil tank. The piston is moved to the brake
disc under hydraulic pressure to make the brake pad pressed on the brake disc through the silent pad. At the
same time, the brake caliper is axially floating under the hydraulic pressure and press the outside brake pad
on the brake disc to actualize brake.
Brake pad wear limit warning device has been installed on brake pad of the disc brake for LIFAN sedan,
with structure shown in Fig. 3-58.
Fig. 3-58 Brake pad and warning pad

When the wear of the brake lining pad is less than 1.5mm, the warning spring piece will contact with the
brake disc and utter metallic sound, indicating the brake pad of this side is at wear limit and brake pad
should be replaced. A bleed screw is set on the body of the brake caliper; if air exists in the brake fluid
system, release the air through the bleed screw.
(2) The rear brake is the leading trailing shoe drum brake with clearance self-adjusting mechanism. The
structure is shown in Fig. 3-59, and the clearance self-adjusting mechanism of the rear brake is shown in
Fig. 3-60.
Fig. 3-59 Structure of rear brake

1-Grease cover 2-Hexagon slotted nut 3-Split pin 4-Thrust washer 5-Outer bearing 6-Brake drum
7-Inner bearing 8-Oil seal 9-Brake shoe pull-back spring 10-Parking brake push-plate 11-Parking brake crank
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12-Brake shoe 13-Brake push-plate spring 14-Brake shoe stretching spring 15-Brake shoe fixed pin
16-Brake shoe fixed spring 17-Hexagon head bolt and flat washer combination 18-Hexagon head bolt and flat washer
combination 19-Brake wheel cylinder 20-Bleed screw cap 21-Brake base plate
22-Hexagon flange bolt 23-Hexagon flange nut 24- Hexagon flange bolt
25- Hexagon head bolt, spring washer and flat washer combination
26-upper rocker components
Fig. 3-60 Clearance self-adjusting mechanism of rear brake

1-Parking brake rocker 2, 5, 9- split washers 3, 11-Brake shoes 4-Brake shoe pull-back spring
6-Parking brake push-plate 7-Self-adjusting lever 8-Self-adjusting locking claw 10-Torsion spring
12-Parking brake cable and sleeve
Step on the brake pad, and the brake shoe will splay with the influence of the brake wheel cylinder. The
push plate will be pulled to the side of the driven shoe by the spring. Adjusting rod will be pulled to the side
of drive shoe by pawl engagement power. When the clearance of the shoe is normal, the total left and right
movement will be not more than the clearance between the push plate and the adjusting rod. The
engagement location between adjusting rod and the pawl remains unchanged, and the shoe clearance
remains the same too.
When the shoe clearance is too big and the push plate is moved to the side of the driven shoe by the spring,
the clearance between the push plate and adjusting rod is disappeared, and the adjusting rod will be pulled
to the side of the driven shoe. The engagement between the adjusting rod and the pawl will be off and
engaged in a new place, because the drive shoe pulled the pawl; then the brake shoe will return to the
original normal place. At the same time the place of the new engagement will keep the same, which makes
the shoe clearance in normal condition.
2. Vacuum booster and master brake cylinder
(1) The installation and connection of vacuum booster is shown in Fig. 3-61, and the structure of the
vacuum booster is shown in Fig. 3-62.
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Fig. 3-61 Vacuum booster and master brake cylinder

1-Cotter pin 2-Adjusting fork 3-Pin shaft 4-Control valve push rod 5-Dust cover 6-Rear housing
7-Front housing 8-Vacuum tube 9-Brake fluid kettle 10-Master brake cylinder 11-Brake oil level sensor
Fig. 3-62 Vacuum booster

1- Adjusting fork 2-Lock nut 3- Control valve push rod 4- Dust cover 5- Vacuum tube 6- Brake fluid kettle
7-Master brake cylinder 8-Master brake cylinder push rod 9-Master brake cylinder installation pad
10-Film pull-back spring
When loosen the brake pedal, servo valve spring pulls the control valve rod to the right, which makes the
film away from the valve port. At the same time, the chamber spring pushes the chamber film and vacuum
servo valve to the right, and return to the original position.
(2) Master brake cylinder. LIFAN sedan adopts tandem master brake cylinder, whose structure is shown in
Fig. 3-62. And the installation is shown in Fig. 3-63.
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Fig.3-63 Installation of master brake cylinder

1-Brake oil can lock cover 2- Brake oil can filter screen
3- Brake oil can floater components 4-Double steel
5-Brake oil can body 6-Baffle plate
7-Hexagon flange nut 8-Brake master cylinder
9-Oil lever sensor bracket 10-Top rod
11-Seal pad 12-Vacuum booster assembly
The master brake cylinder is made up of cylinder body, piston, spring, spring seat, oil seal and filter, and
connected with power-assistant front end with two bolts. There is a brake store fluid can on the master
cylinder, and two working cavities are connected in the master cylinder. When stepping on the brake pedal,
the push rod will move to the left to make the seal ring plug up the front oil hole, which produces fluid
pressure in the front cavity; then it will push the piston to the left to plug up the rear oil hole, which
produces fluid pressure in the rear cavity, and connects to the front and rear brake trough brake pipe and
brake hose.
3. Brake pipeline and proportional valve

(1) Brake pipeline. The brake pipeline disposal of LIFAN sedan is shown in Fig. 3-64. The left front-wheel
brake is connected with the master cylinder with pipeline 2 separately; the rear-wheel brake is connected
with the master cylinder with pipeline 3 separately; a proportional valve is installed in the brake pipeline
between the rear wheel and right front wheel’
(2) Proportional valve. The center of gravity of LIFAN sedan is low, and the ratio of the gravity height and
wheel base is small. Therefore, a proportional valve is applied in the brake pipeline connecting rear wheel.
The structure of hydraulic proportional valve applied by LIFAN sedan is shown in Fig. 3-65. For position
of proportional valve in the entire pipeline, please refer to Fig. 3-64.
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Fig. 3-64 Brake pipeline

1-Proportional valve 2-Front brake pipeline 3-Rear brake pipeline 4-Parking brake cable
5, 6, 7-Brake pipeline clamp 8-Brake master cylinder 9-Vacuum booster assembly
Fig. 3-65 Proportional valve

1-Plunger piston 2-Dust plug 3-Oil seal 4-Spring seat 5-Spring 6-Oil seal seat
7-Valve seat 8-Valve body 9-Balance plate assembly 10-Washer 11-Hole steel wire shaft
Section II Brake System Common Fault and Fault Elimination
For brake system common fault and fault elimination of LIFAN sedan, please refer to Table 3-3.
Table 3-3 Brake system common fault and fault elimination
Fault
Possible cause Elimination method
phenomena
(1) The clearance self-adjusting mechanism
(1) Repair or replace the parts of the
of the brake is ineffective, and the clearance
self-adjusting mechanism
Ineffective is too big.
brake, and too (2) The brake shoe of rear brake is excessive
(2) Replace the pad of brake shoe.
big clearance of wore.
brake pedal (3) Adjust the free play of the pedal.
(3) The free play of the pedal is too big.
(4) Bend and distortion of brake shoe (4) Replace the brake shoe
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(5) Vent the air in this system

(5) Air exists in hydraulic system
(1) Look for the leaking position, and

(1) The hydraulic system is leaking repair or replace the parts.
Step on the
(2) Vent the air in this system
pedal with (2) There is air in hydraulic system
invariable
(3) Inject the specified brake fluid
power, with (3) Use the unspecified brake fluid
pedal touching
(4) The piston leather packing of master
floor (4) Replace the leather packing
brake cylinder is too wore or scraped.
(5) The body of master brake cylinder is too
(5) Replace the master brake cylinder
wore or eroded.
(1) The air pressure of left and right tires is (1) Adjust tire pressure
different.
(2) Replace hub bearing
(2) Hub bearing is wore or broken.
(3) The brake pad or shoe of one side is dirty. (3) Clean the brake pad or shoe
(4) Brake shoe of one side is bent or
(4) Replace the brake shoe
Braking distorted.
deviation (5) Brake bottom plate of one side is (5) Fasten or replace the brake bottom
distorted or loose. plate
(6) The fixed bolt of one-side brake caliper is
(6) Fasten the fixed bolt.
loose.
(7) The piston of one-side brake caliper is
(7) Repair or replace the brake caliper.
felted or locked.
(8) Installation of mounting bracket or the (8) Fasten the bolt or replace the parts
fixed bolt is loose of the mounting bracket
Table 3-3 (continued)

Fault
Possible cause Elimination method
phenomena
(1) The function of vacuum booster is loose (1) Fasten the connection or replace
or leaking the hose
(2) The brake pad or shoe falls short of the
(2) Replace the brake pad or shoe
regulation or bad quality
The brake pedal
(3) Bend and distortion of brake shoe (3) Replace the brake shoe
is too hard,
(4) Clean and lubricate the guide
possibly with (4) The brake caliper is felted or locked
piston
brake decline
(5) The brake shoe is locked on the brake (5) Clean and lubricate the supporting
disc boss or replace the bottom plate
(6) The piston of master brake cylinder is
(6) Repair or replace parts
felted or locked in the cylinder tube
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(7) The piston of wheel cylinder is felted or
(7) Repair or replace the parts
locked in the cylinder barrel
(8) Repair or replace the vacuum
(8) Vacuum booster is locked inside
booster
(9) Bypass hole beside the master brake
(9) Dredge the bypass hole
cylinder is jammed
(10) Oil pipe or joint of brake tube is jammed (10) Dredge or replace the parts
(11) The brake fluid is smirched by the (11) Replace the rubber parts and
ill-suited oil clean the hydraulic system
(12) The degree of the engine vacuum is low (12) Adjust or repair the engine
Appendix table 3-3

Fault Possible cause Elimination method
(1) Bend and distortion of brake shoe (1) Replace brake shoe
(2) Loose fixed bolt of brake caliper (2) Fasten the bolt
Dithering or tremor (3) Ineffective brake drum (3) Replace brake drum
when brake (4) Surface of brake disc jumps too big (4) Repair or replace brake disc
(5) Too serious wear and too small
(5) Replace brake disc
thickness of brake disc
(1) Brake pad without free play (1) Adjust the free play of brake pad
(2) Bracing wire of parking brake is
(2) Adjust or replace the bracing wire
improper adjusted or locked
(3) Brake shoe is improper or loose (3) Replace the brake shoe
(4) Loose fixed bolt of brake caliper (4) Fasten the bolt
(5) Brake shoe is locked in the brake (5) Clean the supporting boss and
bottom plate lubricate or replace the bottom plate
(6) Loose brake bottom plate (6) Fasten the fixed bolt
(7) Brake pad is locked in the pin shaft (7) Loosen and add lubricant grease
Brake grab (8) Repair or replace the vacuum
(8) Vacuum booster is locked inside
booster
(9) Pull-back spring of brake shoe is loose
(9) Replace the pull-back spring
or broken off for too soft
(10) Clearance self-adjusting mechanism (10) Adjust or replace the self-adjusting
of brake is ineffective mechanism
(11) Piston of master cylinder or wheel
(11) Repair or replace the parts
cylinder of brake caliper is felted or locked
(12) Bypass hole beside the master brake
(12) Dredge the bypass hole
cylinder is jammed
(1) Bend and distortion of brake shoe (1) Replace brake shoe
(2) There is rust on the surface of brake
(2) Wipe off the rust
Brake noise disc
(3) Brake pad is cracked or loose (3) Replace the brake pad or brake shoe
(4) Supporting boss of brake bottom plate (4) Lubricate the supporting boss
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is uneven or lack of lubricant grease
(5) Brake disc or brake drum is broken to
(5) Replace the brake disc or brake drum
groove or scraped
Brake pedal touches
floor in the first
brake, but become The guide sleeve of the brake caliper is Remove the dirt or replace the guide
normal when dirty or eroded sleeve
continue stepping
on
Section III Brake System Check and Repair
I. Master brake cylinder check and repair

1. Dismantle the master brake cylinder from the vehicle
(1) Dismantle the wire pin of the level warning switch, see Fig. 3-66.
Fig. 3-66 Dismantle warning switch pin

(2) Discharge the brake fluid.
(3) Dismantle 3 brake oil pipes. Don’t make brake fluid spatter to the paint surface of the vehicle body.
(4) Dismantle the 2 installation nuts of the master brake cylinder, and dismantle the master brake cylinder
and the installation washer from the vacuum booster.
2. Master brake cylinder disassembly
(1) Nip the flange of the master cylinder with bench clamp. Don’t nip the cylinder body, or the cylinder
would be distorted.
(2) Dismantle the reservoir tank, diaphragm, spacer bush, floater, clip and fluid reservoir. See Fig. 3-67.
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Fig. 3-67 Disassembly of master cylinder and brake oil can

1-Lock cover of brake oil can 2-Filter screen
3-Floater 4-Hoop 5-Oil can body
6-Baffle plate 7-Nuts 8-Sensor support 9-Top rod 10-Seal pad
(3) Pull the piston with cross-recessed screwdriver, and dismantle the limiter bolt and seal pad.
(4) Pull the piston with cross-recessed screwdriver, and dismantle the flexible retaining ring with caliper.
(5) Remove the first and secondary piston from the master cylinder.
3. Check the brake master cylinder
After disassembling the brake master cylinder, please pay attention to the parts and contents as shown in
Fig. 3-68.
Fig. 3-68 Check the parts of brake master cylinder
II. Check and maintenance of vacuum booster
1. Removal and disassembly of vacuum booster

As shown in Fig. 3-69, remove the master cylinder, vacuum hose, clutch cable and ignition coil, and
dismantle the vacuum booster from the vehicle body.
Disassemble the vacuum booster. Remove the master cylinder push rod and nut by the special tool shown
in Fig. 3-70. Remove the lower rear housing and rotate the screw of the special tool clockwise on the
special tool to separate the front and rear housings.
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Fig. 3-69 Remove the vacuum booster from the vehicle body Fig. 3-70 Disassemble the vacuum booster
2. Check the vacuum booster

Check the vacuum booster as shown in Fig. 3-71. Distorted or damaged parts should be replaced.
Fig. 3-71 Check the vacuum booster
3. Install the vacuum booster

(1) Before assembly. Smear grease special for leather bucket at the position specified in Fig. 3-72.
Fig. 3-72 Smear grease
(2) Install the diaphragm, push rod and air valve assembly onto the piston and lock them with a retaining
ring (Fig. 3-73).
Fig. 3-73 Assemble piston
(3) Install reaction plate, reaction rubber block and reaction ring and lock them with a tooth ring (Fig. 3-74)
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Fig. 3-74 Install reaction ring, etc.

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(4) Install rear housing air seal, pad, tooth ring and piston (Fig. 3-75).
Fig. 3-75 Install tooth ring
(5) Install the control valve on the valve seat. Then install them together on the rear housing and install the
control valve spring, valve spring and spring seat (Fig. 3-76).
Fig. 3-76 Assemble control valve
(6) Install the filter cartridge and washer and lock them with E retaining ring. Then install the dustproof cap
and assemble the front and rear housings of the booster. Screw down the nuts at left and right sides of the
special tool by even force. Please remind not to tighten the nuts too much and make sure that the diaphragm
is not pressed; counterclockwise rotate the screw of special tool to align the assembly marks on the front
and rear housings.
(7) Install the front housing air seal, output stem, nut and push rod fork.
(8) Adjust the clearance of booster output stem. Adjust the clearance of output stem by rotating nuts on the
top of the output stem to reach the regulated value.
III. Check and repair of front brake

1. Removal of front brake
Remove two fixing bolts of brake caliper (Fig. 3-77).
Fig. 3-77 Remove the bolts of brake caliper

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Remove the brake lining, sound-proof plate and two guide vanes (Fig. 3-78).
Fig. 3-78 Remove the lining, sound-proof plate and guide vane
2. Check the front brake
Check the brake lining. Check the thickness of brake lining by the access hole on the clamp (Fig. 3-79).
The regulated thickness of brake lining is 10mm and limit thickness is 1mm.
Fig. 3-79 Check the brake lining thickness

Check the thickness of brake disc. The regulated thickness is 11mm and limit thickness is 10mm.
3. Install the front brake

Install the new guide vane on the steering knuckle (Fig. 3-80). Install the new sound-proof plate on the new
brake lining and then install them on the brake caliper (Fig. 3-81).
Fig. 3-80 Install new guide vane
Fig. 3-81 Install new sound-proof plate

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IV. Check and maintain the rear brake
1. Remove the rear brake
(1) Remove the dustproof cap, cotter pin, slotted nut and washer on the brake. Then dismantle the rear
brake drug, rear brake shoe pull-back spring by special tools and dismantle the tension spring of supporting
plate by a straight screwdriver.
(2) Firstly remove the fixed pin of brake shoes and then brake drive shoe of the rear wheel as shown in Fig.
3-82.
Fig. 3-82 Remove the brake drive shoe of rear wheel
(3) As shown in Fig. 3-83, firstly remove the fixed pin and tension spring of brake shoe, and dismantle the
parking brake cable from the parking brake rocker arm and remove the brake driven shoe of rear wheel.
Fig. 3-83 Remove the brake driven shoe of rear wheel
(4) Remove the split retaining ring on the brake shoe, and also parts such as brake rocker arm, adjustment
plate and pawl.
(5) Remove oil pipe from the brake slave pump, then the fixed bolts of slave pump and also brake slave
pump of the rear wheel from the brake bottom plate.
2. Check the rear brake
Check the parts and contents of rear brake as shown in Fig. 3-84.
Fig. 3-84 Remove the brake drive shoe of rear wheel

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V. Check and repair of parking brake control lever and cable
1. Removal of parking brake control lever
Firstly dismantle the wire plug and adjustment nut of the parking brake indicator switch according to
Figure 3-85. Remove the 2 bolts and dismantle the parking brake control lever from vehicle.
Fig. 3-85 Remove the wire plug and adjustment nut
2. Install parking brake control lever

Install the parking brake control lever by 2 bolts. Torque: 9.8N·m-15N·m
Install the wire plug and adjustment nut of parking brake indicator switch. Rotate the adjustment nut and
adjust the working stroke of parking brake control lever to the regulated value. 5-9 teeth at 196N. Check if
the parking brake indicator works normally.
3. Removal and installation of parking brake cable
(1) Remove the shield;
(2) Remove the parking brake cable from the pulling rod;
(3) Raise the vehicle and remove the fixed clip of parking brake cable under the vehicle body (Fig. 3-86).
Fig. 3-86 Remove the cable fixed clip
(4) Remove the rear brake shoe;

(5) Remove the parking brake cable from the brake bottom plate.
Install the parking brake cable, reverse the removal procedure.
After installation, adjust the working stroke of parking brake control lever according to regulations.
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Section IV Maintenance and Adjustment of Brake System
I. Check and adjustment of brake pedal
1. Check and adjustment of brake pedal free play

(1) After stopping engine, step on the pedal again for times (at least 5 times) to reach zero degree of
vacuum in the vacuum booster.
(2) Lightly push the pedal by fingers to measure the free play of the pedal. It should be 3mm-7mm.
(3) If the free play does not reach the regulated value, adjustment is needed.
Note: After adjustment, please ensure that the pedal height is normal and the brake lamp switch works
normally.
2. Check and adjustment of brake pedal height

Check the brake pedal height after vehicle drives for each 10000km. measure the pedal height, namely the
distance between upper center of pedal and the front dash panel. The regulated value is 176mm-181mm. If
it does not reach the regulated value, please adjust it as below process:
(1) Disconnect the wire plug of brake lamp switch, loose the lock nut of brake lamp switch, and then screw
off the brake lamp until there is clearance between the pedal arm and switch.
(2) Loose the lock nut (Fig. 3-87), rotate the control valve lever of vacuum booster to adjust the pedal
height and then screw down the lock nut.
Fig. 3-87 Check and adjustment of the free play of brake pedal
(3) Screw in the brake lamp to make the thread end contact the buffer pad, and then lock it by lock nut 1 of
brake lamp switch.
(4) Connect the wire plug of brake lamp switch.
Note: After adjustment, please make sure that the free play is normal and the brake lamp works normally.
3. Check of the reserve travel of brake pedal

Check the reserve travel of brake pedal after vehicle drives for each 10000km. The regulated value should
be less than 102mm.
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Loose the parking brake control lever during check to make the engine run at idle speed. Step on the pedal
by 294N force to measure the distance between pedal back and the front dash panel of vehicle body (Fig.
3-88). This distance is the reserve travel of the brake pedal.
Fig. 3-88 Remove the driven shoe of rear brake
II. Check of vacuum booster

Check the functions and air tightness of the vacuum booster after the vehicle drives for each 10000km.
simple measures or vacuum booster tester can be used to check the functions of vacuum booster.
1. Check by simple measures
(1) Check of air tightness. Start the engine and stop it after it operates for 1-2 min. Step on the pedal by
regular force for many times (interval between two stepping is more than 5s). The pedal height should be
higher than the previous stepping (Fig. 3-89).
Fig. 3-89 Check of air tightness
(2) Check the load air tightness. Start the engine and then step on the pedal after it operates for 1-2 min.
Stop the engine while keeping the pedal force unchanged. The pedal height should no change within 30s
(Fig. 3-90).
Fig. 3-90 Check of load air tightness

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(3) Check of vacuum booster. Under the condition that the engine does not work, step on the pedal by the
same force for many times. After ensuring no change of pedal height, keep stepping on the pedal and then
start the engine. The pedal should move frontward slightly (Fig. 3-91).
Fig. 3-91 Check of vacuum booster
2. Check by vacuum booster tester

(1) Connect the tester and discharge the air in tester (Fig. 3-92).
Fig. 3-92 Check and adjustment of brake pedal free play
(2) Check the air tightness. Start the engine, and then stop it when the degree of vacuum is over 66.5 kPa,
and measure the degree of vacuum. It should not descend within 15s after stopping the engine.
(3) Check the load air tightness. Under condition that the engine works, step on the pedal by 196N force.
When degree of vacuum at 66.5 kPa, stop the engine and measure the degree of vacuum. It should not
descend for 3.325 kPa within 15s after stopping the engine.
(4) Check the working state under no power assisted. Make the degree of vacuum be zero when engine
does not work. Check the relation between the brake pedal force and the master cylinder output hydraulic
pressure. The regulated value as follows:
When pedal force is at 98N, the output hydraulic pressure is 637 kPa; when pedal force is at 294N, the
output hydraulic pressure is 3704.0kPa.
(5) Check the working state under power assisted. Make the engine operate. When the vacuum meter reads
4547.2 kPa, stop the engine and then step on the brake pedal and check the relation between brake pedal
force and pedal master cylinder output hydraulic pressure. The regulated value is as follows: when pedal
force is at 49N, the output hydraulic pressure is 1803 kPa; when pedal force is 98N, the output hydraulic
pressure is 4547.2 kPa; when pedal force is 147N, the output hydraulic pressure is 4588.0 kPa; when pedal
force is 196N, the output hydraulic pressure is 6262.2 kPa.
III. Inspection and replacement of brake fluid
1. Inspection of brake fluid liquid level
Ver：LF-20121225
It is recommended to check the liquid level of brake fluid in fluid reservoir after 10,000 km’s drive. The
proper fluid level should be between the upper limit marking (max) and lower limit marking (min) (Fig.
3-93).
Fig. 3-39 Inspection of brake fluid level
If brake fluid level is out of the range, some brake fluid (Fig. 3-94) need to be injected into the fluid
reservoir, till the fluid level up to the upper limit marking.
Fig. 3-94 Brake fluid injection

2. Replacement of brake fluid
It is recommended to replace the brake fluid after one year or 30,000 km’s drive. Pay attention to the
following matters when you make brake fluid injection or replacement:
(1) Make sure to use DOT-4 brake fluid.
(2) Please do not use the brake fluid which absorbs moisture in the air or becomes dirty. Otherwise, it will
result in braking efficiency decline, or premature wear of brake master cylinder or round cylinder.
(3) Brake fluid is poisonous, and it could destroy vehicle’s paintwork. So, clear it as soon as you find it
flows on the surface of your car.
(4) The mixed-use of brake fluid in different brands is not allowed; otherwise the brake fluid will be
invalid.
IV. Discharge air from the brake system

Brake will be weakened if air gets into the hydraulic-brake system. Discharge the air of the brake system in
the wheel cylinders so as to guarantee good braking effect. All tires should be deflated. The discharge
process includes the following:
(1) Check the fluid level, if it’s against the specification, fill the brake fluid.
(2) The sequence of discharge: right rear wheel---left rear wheel---right front wheel---left front wheels.
(3) Connect the air bleed screw of the wheel cylinder with a transparent plastic tube, and put the lower end
of the tube into the tank with brake fluid (Fig. 3-95). The lower end of the tube should not be out of the
fluid surface during the deflation process.
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Fig. 3-95 Air discharging of the brake system
(4) Make the maximum pedal travel heavily after trampling the brake pedal for several times, and keep
trampling.
(5) Loosen the air bleed screw by turning it for 1/3 to 1/2 turn each time, the brake fluid flows out of the
tube. And the air bleed screw must be then screwed up tightly before the fluid pressure inside the wheel
cylinder disappears.
(6) Repeat (4) and (5) for several times. Only when the brake fluid flows without bubbles from the tube,
can the operation be stopped.
(7) Fill brake fluid into the fluid reservoir.
(8) Trample the brake pedal and check each part of the brake tube. No fluid should leak.
V. Check and repair of main parts in brake system

1. Regular replacement of easily damaged parts
There are many rubber parts in the brake system. They are easily aged and will influence the normal
operation of system. Therefore, they should be replaced regularly or as necessary. The brake master
cylinder rubber part, brake cylinder rubber part, brake hose should be replaced every two years or as
necessary; the vacuum booster rubber part, vacuum booster hose should be replaced every four years or as
necessary.
2. Check of brake disc and brake lining
(1) Check the abrasion of brake lining. After the vehicle drives for every 2000km, please check the wear
and tear of the brake lining. Its limit wear thickness should be 1.0 mm.
(2) After the vehicle drivers for every 4000km, please check the wear and tear of brake disc. Its limit wear
thickness is 2.0 mm. In case of thickness below 9 mm, please replace the brake disc.
VI. Adjustment of the clearance between the push rod and 1st piston of the brake master
cylinder
Proper clearance between master cylinder and piston should be ensured when connecting the brake master
cylinder and vacuum booster servo chamber. The clearance should be adjusted as below:
(1) Firstly correctly place the special maintenance tool to make the stew stem contact the brake master
cylinder piston, as shown in Fig. 3-96. Mounting pad of brake master cylinder should be installed during
adjustment.
Fig. 3-96 Place the special service tool

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(2) As shown in Fig. 3-97, connect the vacuum pump on the connector of vacuum energy transmission line
of the servo gas front housing 1 and impose 66.5 kPa negative pressure.
Fig. 3-97 Adjust the brake master cylinder push rod
(3) Place the special maintenance tool as shown in Fig. 3-97. Adjust the length of brake master cylinder
push rod 2 to make the clearance between it and the screw stem on special tool be zero.
(4) As shown in Fig. 3-98, adjust the clearance between the push rod and piston by rotating the nut on the
end of the push rod.
Fig. 3-98 Adjust the length of master cylinder push rod
VII. Check and adjustment of parking brake

Pull the parking brake control lever of hand brake to the braking position and rotate the parking brake shoe
rocker of the rear brake by a series of cable and achiever braking through making the two brake shoes
tightly pressed on the brake drum.
The adjustment of parking brake is shown in Fig. 3-99. Rotate the adjustment nut. Adjust the operating
stroke, which should be at 5-9 teeth.
Fig. 3-99 Adjustment of parking brake

1-Control knob 2-Adjustment nut 3-Brake lamp switch 4-Cable bracket
After adjustment, under full load, when pulling the parking brake knob by a force less than 400N, the
parking gradient should be more than 20% as required.
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Chapter V ABS Anti-lock Brake System (Optional)
Section I Composition of ABS
The ABS of LF320 sedan is composed of electronic control unit, hydraulic control unit, sensor and motor.
I. Electronic control unit (ECU)

Electronic control unit is actually a microprocessor, which calculates the speed of the 4 wheels and speed
increase and decrease according to the signal from the sensor so as to determine the slide situation and
drive the solenoid valve and motor to increase, decrease and maintain the pressure and so on.
II. Hydraulic control unit (HCU)

Hydraulic control unit is composed of two hydraulic circuits and solenoid valve, which calculates and
determines slide situation to decide the ABS operation according to the signal from the sensor, and then
controls the program to start the solenoid valve and motor to increase, decrease and maintain the pressure
and so on.
Fig. 3-100 HECU system

1- Motor 2- HCU 3- ECU
III. Sensor
The sensor sends the signal from the gear rotation detection to ECU.
IV. Motor
The motor rotates according to the signal of ECU. And the bearing transfers the rotation into straight
reciprocating motion to cycle the brake fluid.
Section II Principle of ABS

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I. Control principle of ABS

Fig. 3-101 shows the control principle of ABS.
Fig. 3-101 ABS control principle

II. Operating mode of ABS
1. Operating condition of regular brake
If a vehicle is equipped with ABS and the brake pressure to wheel does not lock the wheel, the pressure of
assemble pump will be transmitted to wheel slave cylinder through normally opened valve to apply the
brake. If no further braking is needed, the driver can reduce the pressure to brake pedal, which allows the
brake fluid return to assemble pump for pressure decrease, as shown in Table 3-4.
2. ABS operation (pressure decrease) condition
If a vehicle is equipped with ABS and the braking pressure is too large, the friction coefficient will be
decreased and the wheel speed will be decreased much quickly than the vehicle body. Finally the wheel
will be locked, which makes ECU send HCU a signal of pressure decrease to wheel. In order to decrease
the pressure of wheel slave cylinder, the normally opened valve will close and the normally closed valve
will open. Then the brake oil from wheel slave cylinder will return to low pressure accumulator (LPA)
temporarily, and return to assemble pump with the oil pump started by the motor. High pressure
accumulator (HPA) between LPA and assemble pump will decrease the high pressure pulse produced by oil
pump with the help of metering jet fluid resistance.
3. ABS operation (maintaining) condition
Solenoid
Solenoid valve
Solenoid valve Electricity valve Solenoid valve Electricity
condition
condition
Normally Normally opened
Off On On Off
opened valve valve
Normally Normally closed
Off Off On On
closed valve valve
Table 3-4 ABS pressure decrease operation condition Table 3-5 ABS pressure decrease operation
condition
The pressure of wheel slave cylinder is maintained by the closed normally opened valve and normally
closed valve, when proper pressure is applied to the salve cylinder through increase or decrease of pressure,
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as shown in Table 3-6.
4. ABS operation (pressure increase) condition

When the pressure is decreased, if too much brake fluid is discharged or friction coefficient is increased,
the pressure to every wheel should be increased. ECU will send HCU a signal of pressure increase to wheel.
In order to increase the pressure of wheel slave cylinder, the normally opened valve will open and the
normally closed valve will close. In case of pressure decrease, the brake fluid in LPA will flow out under
the pressure increase condition with rotation of motor and then into wheel slave cylinders through the
assemble pump and the normally opened valve. HPA between LPA and assemble pump will decrease the
high pressure pulse produced by oil pump with the help of metering jet fluid resistance, as shown in Table
3-7.
Concerning operations described in item 2 ~ 4 above, ABS will work until the vehicle has been completely
stopped according to locking condition, so as to guarantee the safety and steering performance.
Solenoid Solenoid
Solenoid valve valve
valve Electricity condition Solenoid valve Electricity condition
Normally
opened Normally
valve On Off opened valve Off On
Normally Normally
closed valve Off Off closed valve Off Off
Table 3-6 ABS pressure decrease operation condition Table 3-7 ABS pressure decrease operation condition
III. EBD control mode

EBD is to guarantee the operation stability. Rear wheel will be stopped after front wheel. As front brake
does more work than rear brake, the rear wheel will stop first if it receives equal pressure. In order to
prevent it, the equipment, pressure reducing valve (P-Valve), to decrease the pressure of rear wheel is
needed. A special P-Valve is not necessary for the vehicle with ABS, as ABS can control the rear wheel
braking pressure with supplementary procedures and improve the operation stability.
Section III Removal and Installation of ABS
I. Spare parts supply condition

1. Difference between dry HECU and wet HECU
The biggest difference between dry HECU and wet HECU is the second circuit (between normally closed
valve and assemble pump) of dry HECU does not exhaust. As a result, only regular exhaust and filling will
be necessary for brake system after replacement in case of wet HECU; regular exhaust and filling and that
to the second circuit will be necessary for brake system after replacement in case of dry HECU. Besides,
there is a seal bolt for wet HECU and protection film for dry HECU. The product’s part number is marked
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on the product label on the motor; therefore, the dry HECU and wet HECU can be differentiated through
the part number, as shown in Fig. 3-102.
Fig. 3-102 HECU

a-Dry HECU b-Wet HECU
II. Notes on removal and installation

1. Notes on HECU installation
(1) Remove the protection film on HECU, and confirm pipelines of assemble pump and wheel slave
cylinder before operation (assemble pump: MCP and MCS; wheel slave cylinder: FR, FL, RR and RL).
(2) Make sure the brake pipe is tightened and torque is 12～16N·m with a special tool, torque wrench or
other equipments.
(3) No foreign material is allowed in HECU holes and brake pipes.
2. Notes on HECU bracket assembly
(1) As installation error may occur for the frictional resistance of buffer pad when tightening (3) bolts,
lubricant not affecting physical property of buffer pad is preferred.
(2) For easy operation, (3) bolts can be inserted into the buffer pad on bracket and then to HECU.
(3) Make sure the tightening torque of (3) bolts is 8～12N·m with a special tool, torque wrench, as shown
in Fig. 3-103.
Fig. 3-103 HECU bracket installation
3. Notes on HECU and bracket assembly installation

(1) Install brake pipe and bracket part to HECU and then install HECU to vehicle body with bolt special for
vehicle body fastness.
(2) Make sure the tightening torque of bolt special for vehicle body fastness is 8～12N·m with a special
tool or torque wrench.
(3) Make sure again the pipelines of assemble pump and wheel slave cylinder are installed correctly
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(assemble pump: MCP and MCS; wheel slave cylinder: FR, FL, RR and RL).
(4) Tighten the loose brake pipe with a specified torque (12～16N·m) by a special tool or torque wrench.
4. Other notes
(1) Use diagnostic instrument to find out fault reason before repair.
(2) Wrap off spare part only before installation.
(3) Use original part only.
(4) Pay attention to cleanliness. Only use cloth except tweed.
(5) Clean the surface with cleanser without mineral oil before removal.
(6) Do not use compressed air or move the vehicle when system is opened.
(7) Block the hydraulic pressure outlets with plugs as soon as possible after removal of ABS assembly.
(8) Remove other parts hindering operation.
(9) Use DOT#4 brake fluid.
(10) Soak the seal component with brake fluid, not with engine oil or brake unguent.
(11) Check for leakage of connectors of all hydraulic pipes.
5. Replacement of HECU
(1) Remove connecting piece of pin 25 and wire harness of HECU in engine compartment when engine
stops. See Fig. 3-104.
Fig. 3-104 Remove connecting piece of pin 25 and wire harness

(2) Remove the 6 M10×1 nuts of brake pipe of HECU with 11mm wrench in a counterclockwise
(clockwise when installing) direction. Tightening torque of brake pipe is 12～16N·m.
(3) Remove the 3 bolts on bracket with 12mm wrench in a counterclockwise (clockwise when installing)
direction. Tightening torque of bolts or nuts for bracket fastness is 8～12N·m.
(4) Remove the 3 M6 bolts in HECU with 5mm hexagonal wrench in a counterclockwise direction after
removal of products. (As shown in Fig. 3-105)
Fig. 3-105 Remove inserted bolts

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(5) Remove the 6 bolts on wet HECU with 6mm hexagonal wrench in a counterclockwise direction, as in
Figure 3-106.
Fig. 3-106 Remove protective bolts
(6) Assemble the wet HECU and bracket with a 5mm tool (hexagonal wrench) by tightening the 3 inserted
nuts M6 in clockwise direction with tightening torque of 8～10N·m.
(7) To install spare HECU, reverse the removal procedures of item (1) ~ (3) above.
Section IV Fault Diagnosis and Troubleshooting
I. Fault detection procedure (Table 3-8)
Table 3-8 Fault detection procedure

Valve condition
ECU ID confirmation Valve and port
confirmation
check
ECU fault code Pipe assembly condition
Regular check
confirmation confirmation
Warning lamp condition
Fault code confirmation
confirmation
Sensor air gap Check results
Fault code record
Wheel speed confirmation record
sensor check Sensor installation
confirmation
II. Notes on fault diagnosis (Table 3-9)
As ABS is controlled by the electronic hydraulic pressure, the phenomena in the following table are normal
under normal working condition of ABS, not faults.
Table 3-9 Notes on fault diagnosis

Phenomenon Description
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System
Sometimes there will be sound like collision from the engine compartment after engine
self-check
is started. It is normal because it is caused by the ABS self-check.
sound
1. Motor sound in ABS hydraulic unit
2. Sound with brake pedal vibration
ABS working
3. Suspension impact sound caused by braking or screak caused by friction between
sound
wheel and ground when ABS works
Note: Wheel may screak when ABS is working normally.
ABS works, but Sometimes the braking distance of the vehicle with ABS will be longer than that of the
the braking vehicle without ABS on snow or sandstone road. The driver should be more careful
distance is long. when driving on these roads.
III. Key Points on maintenance of dynamic faults

Instantaneous poor contact may occur in the electronic control system, electrical circuit and signal input
and output areas, which may cause occasional dynamic fault or DTC during ECU self-check. If fault cause
continues, the abnormal part can be detected with reference to DTC table. As sometimes fault cause
vanishes itself, it is difficult to figure out the real cause.
In such a situation, faults can be simulated to check if the fault occurs again.
1. When vibration may be the main reason:
(1) Shake the connector lightly in all directions;
(2) Shake the harness lightly in all directions;
(3) Shake the sensor lightly in all directions;
(4) Shake the other moving parts (like wheel bearing) lightly.
Note: If the harness is twisted off or fractured for tight pull, it must be replaced with new parts. Especially
when vehicle is moving, the sensor will move up and down, which may cause instantaneous open/short
circuit. As a result, sensor signal check must be carried out when vehicle is moving.
2. When overheating or supercooling may be the main reason:

Heat the possibly faulted part with a blower;
Check for cold welding phenomenon with a cold spray.
3. When overlarge contact resistance of power supply circuit may be the main reason:
Open all electrical switches, including the headlight and rear defrosting lamp.
If fault does not show again, it can only be diagnosed and repaired when it comes out next time. Generally
the occasional dynamic fault will only get worse, not better.
IV. ABS fault diagnosis and troubleshooting
1. Check ABS warning lamp

Check if ABS warning lamp is turned on in the following ways
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(1) Turn the vehicle key to connect the circuit, and then ABS warning lamp is turned on and then turned off
after 3 seconds.
(2) Fault exists if not the same with the situation in (1); check the DTC and refer to DTC Check Table.
(3) Refer to No DTC Fault Table if the warning lamp can not be turned on.
2. Regular fault table (Table 3-10)

Table 3-10 Regualr fault table
Warning lamp
Location Reason Structure
ABS EBD
Brake pipe
Wheel locked, braking deviation
installation error
Oil leakage of brake
Vehicle ABS and EBD abnormal start
gear Off Off
harness
Wire installation
Unable to brake
error
Exhaust fault ABS performance decreased
Motor Motor fault ABS unable to start On Off
ECU power cord
ABS and EBD unable to start
fault
Control valve power
ABS and EBD unable to start On On
cord fault
ECU
ECU poor grounding ABS and EBD unable to start
ECU fault ABS and EBD unable to start
Motor power cord
ABS unable to start On Off
fault
Sensor open/short One fault: ABS unable to start On Off
circuit Two faults: ABS/EBD unable to start On On
Wheel
Gear ring fault
speed
Sensor disturbance One fault: ABS wrong start On Off
sensor
fault
Air gap fault Two faults: ABS and EBD unable to start On On
3. DTC read and deletion without fault diagnostic instrument

(1) Purpose and condition of DTC read without diagnostic instrument
If no diagnostic instrument is available, ABS fault condition can be indicated and DTC can be read through
ABS warning lamp, so as to confirm and eliminate the fault.
The use conditions are:
1) Speed is less than 2 km/h;
2) Not connected to fault diagnostic instrument;
3) Wire L (pin 7 in the internal diagnosis interface) is always grounded during diagnosis.
Besides, restore ECU mode of ABS to normal mode (diagnosis mode before) after DTC read. Method: after
diagnosis, disconnect wire L from ground, turn the key to off-power condition, and connect again.
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(2) Method of DTC read without fault diagnostic instrument
Read in the following steps if meeting the conditions of DTC read without fault diagnostic instrument.
The procedures in Fig. 3-107 are:
1) Ground wire L and turn the vehicle key to connect the circuit;
2) ABS warning lamp is turned on and then turned off after 3 seconds, which indicates the start of
diagnosis;
3) ABS warning lamp is turned off for 3 seconds, which indicates the DTC display stage;
4) DTC read;
5) ABS warning lamp is turned off for 3 seconds, which indicates the next DTC display or circular display
stage;
6) New DTC display and read, or circular display of previous DTC.
The meanings of marks in Fig. 3-107 are listed in Table 3-11.
Fig. 3-107 DTC read method
Take the procedure illustrated in Figure 3-107 for example. In the display area of the first DTC, as warning
lamp blinks twice (each on and off is T3, 0.5 second) before T4 (1.5 seconds before warning lamp is turned
on), the first mark (ten’s place) of the 2 digital code is 2; as warning lamp blinks once after T4 (1.5 seconds
after warning lamp is turned off), the second mark of the 2 digital code (unit’s place) is 1; as then warning
lamp is turned off for 3 seconds (T2), the display of the first DTC is finished, and the DTC is 21. Detailed
description of the fault can be found in DTC Table. It is the same with DTC 22.
(3) Deletion of DTC without fault diagnostic instrument
After DTC read and fault elimination according to DTC Table, previous DTC should be deleted before next
DTC check. The terms of DTC deletion is the same with that of DTC read, as shown in Fig. 3-108.
Table 3-11 Meanings of symbols

Symbol Symbol description Duration
T1 Symbol of diagnosis start; warning lamp flickers 3.0s
T2 Interval of different DTC 3.0s
T3 Warning lamp flash interval in case of DTC 0.5s
Interval of different digital place of a DTC (the ten’s
T4 place is displayed before the interval and the unit’s 1.5s
place is after the interval)
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Fig. 3-108 DTC deletion
Procedures in the figure are:

1) Step on the brake pedal, ground wire L and then turn the vehicle key to connect the circuit;
2) ABS warning lamp is turned on, and then is turned off after 3 seconds;
3) Release the brake pedal within 1 second after ABS warning light is turned off;
4) Release the pedal for about 1 second, and then press it again for about 1 second. Repeat this procedure
for 5 times; warning lamp is not turned off during this process;
5) ABS warning lamp is turned on, and then turned off after 3 seconds; DTC is deleted in this process.
After DTC deletion, restore ECU mode of ABS to normal mode. Operation process is the same with that of
DTC diagnosis. If no DTC is in ECU of ABS, ground wire L and turn the key to connect the circuit; the
ABS warning lamp will flash in a way illustrated in Figure 3-109, and meanings of symbols are the same
with that above.
Fig. 3-109 Twinkling of ABS warning lamp after DTC deletion

4. DTC table
(1) DTC content is in Table 3-12.
Table 3-12 DTC content
DTC Content DTC Content
Left front sensor open/short
C1 200 C1 206 Left rear sensor open/short circuit
circuit
Left front sensor or gear ring Left rear sensor or gear ring
C1 201 C1 207
disturbance disturbance
C1 202 Left front sensor air gap error C1 208 Left rear sensor air gap error
C1 203 Right front sensor open/short C1 209 Right rear sensor open/short circuit
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circuit
Right front sensor or gear ring Right rear sensor or gear ring
C1 204 C1 210
disturbance disturbance
C1 205 Right front sensor air gap error C1 211 Right rear sensor air gap error
Too high battery voltage (17V
C1 101 C2 112 Fault in solenoid valve fuse or relay
above)
Too low battery voltage (9.4V
C1 102 C2 402 Fault in motor fuse or motor
below)
Fault in ECU internal circuit or
C1 604
solenoid valve coil
(2) DTC Table
Table 3-13 DTC table 1
C1 200 C1 203 Note: If faults corresponding to more than 2 DTC can be

DTC
C1 206 C1 209 confirmed, delete the DTC (that can be deleted), drive the vehicle
at a speed of over 40 km/h, confirm the fault corresponding to this
Sensor open/short circuit: fault due to
Cause
DTC again and refer to the recorded DTC (and confirm the same
sensor battery positive or negative
DTC).
pole short circuit or open circuit
Check the resistances in the two sides of pin A beside wire

harness corresponding to bad number after removing the
ECU connecting piece
Remove the connecting piece between

Elimination procedure
No
harness and sensor; confirm installation
Whether within 700~1500Ω
condition and pin location
Yes No Correct connecting

Check if each pin A beside piece pin and install
Whether condition is good
harness connects with earth wire connecting piece
(of vehicle body) Yes correctly
Check whether the two circuits between pin

A beside harness and sensor connecting piece
B are connected
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Confirm and repair broken part

Whether connected
of wire; replace the wire
Check the resistances at the two ends

of connecting piece beside sensor
Whether within 700~1500Ω

No
Replace sensor
Yes
Restart check from item ①
Whether not ② Remove connecting piece B and C

No
connected beside sensor; check whether each
connecting piece A beside harness is Check whether each
connected with ground wire connecting piece C is
Yes No connected with earth

wire
Check whether each Whether with electricity
connecting piece A is
connected with positive Yes Yes Whether with No
electricity
pole of battery Replace harness wire
③ Remove connecting
Replace sensor Restart check
piece B and C beside
Whether without electricity不 from item ②
sensor; check whether
Yes each connecting piece A

beside harness is
Replace HECE connected with battery
Check whether
不是 each
No connecting piece C
Whether with electricity is connected with
Yes
Yes No
Replace harness wire Whether with
electricity
Replace sensor
Restart check
from item ③
Sensor
Harness Harness
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Note: ① Air gap is the gap between gear ring and sensor; ② If
DTC
C1 202 C1 205 C1 208 C1 211

faults corresponding to more than 2 DTC can be confirmed,
delete the DTC (that can be deleted), drive the vehicle at a speed
Air gap error: no signal because of air
of over 40 km/h, confirm the fault corresponding to this DTC
gap too large or sensor short circuit
Cause
again and refer to the recorded DTC (and confirm the same
(resistance is 0), or gear ring is not
DTC).
properly installed.
Remove wheel corresponding to bad

number; check gear ring and sensor
Measure the air gap with a gap dip stick
Whether within 0.4 ~ 1.2mm No Adjust the air gap to specified range
Yes
①Check the resistance at two ends of

pin corresponding to bad number after
removing the connecting piece A beside
harness
Check whether connecting piece A beside
No harness is connected with the two ends of pin

Whether within 700~1500Ω corresponding to bad number after removing
Yes connecting piece B and C beside sensor
Measure the resistance of the two ends

Replace HECU
Whether with electricity No of pin corresponding to bad number at
the connecting piece C beside sensor
Yes
Repair and replace wire Whether below

Yes No
700Ω or above
1500Ω
Replace sensor Restart check

from item ①
※. Air gap adjustment method
Not to adjust the type of air gap, but to set automatically according to the tolerance of relevant part. As
a result, confirm the part with abnormal air gap and replace or adjust to specified air gap (by burnishing
the mounting surface contact area of sensor); thin washer should be placed on the mounting surface of
sensor to adjust to specified air gap.
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Note:
DTC
C1 201 C1 204 C1 207 C1 210 ① Foreign materials, like engine oil and scrap iron in gear
may cause asymmetrical sensor signal;
② Air gap means the gap between gear ring and sensor;
Gear ring or sensor disturbance: ③ If faults corresponding to more than 2 DTC can be confirmed,
Cause
delete the DTC (that can be deleted), drive the vehicle at a speed of
If nonstandard gear ring is installed over 40 km/h, confirm the fault corresponding to this DTC again and
refer to the recorded DTC (and confirm the same fault code).
Remove wheel corresponding to bad

number; check gear ring and sensor
Measure the air gap with gap dip stick
No
Whether within 0.4 ~ 1.2mm Adjust air gap to specified range
Yes
Check whether ring shape is damaged

or there is foreign material
No Replace gear ring

Whether normal
Yes
No
Whether there is foreign material Replace HECU
Yes
Eliminate foreign material

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DTC
C1 101 C1 102 Note: If faults corresponding to more than 2 DTC can

be confirmed, delete the DTC (that can be deleted),
drive the vehicle at a speed of over 40 km/h, confirm
Battery voltage abnormal: the fault corresponding to this DTC again and refer to
Cause
Occur when voltage too high or too low the recorded DTC (and confirm the same fault code).
Remove the connecting piece beside harness; measure

the voltage between pin 4 (+) and 8 (-) and the voltage
between pin 4 (+) and 24 (-) with the condition that the
circuits of the whole vehicle are connected
No ① Measure the voltage between

Whether within 9.4V ~ 17V
positive and negative poles of battery
Yes
Measure the resistance

Check installation condition of No
Whether below 9.4V between pin 4 (+) of
pin 4, 8 and 24 beside harness
connecting piece beside
and the replacement of pins Yes harness and battery (+) pole
Check and replace
battery
Whether condition is good Yes No
Whether below
Yes 1Ω
Replace HECU Confirm and check the grounding

condition of grounding connectors Check and replace
of pin 8 (-) and 24 (-) beside harness wire
No Adjust grounding
Whether condition is good
condition of
Yes grounding connectors
Check the voltage between pin 4 (+)

and pin 8 (-), as well as between pin 4
(+) and pin 24 (-) under the circuit
connection of the whole vehicle
No
Restart check
Whether above 17V
from item ①
Yes
Replace alternator

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DTC
C2 402 Note: If faults corresponding to more than 2 DTC can be

confirmed, delete the DTC (that can be deleted), drive the vehicle at
a speed of over 40 km/h, confirm the fault corresponding to this
DTC again and refer to the recorded DTC (and confirm the same
Cause
Motor fuse/motor fault

fault code).
① Check whether pin 25 beside harness

is connected with ground wire after
removing the connecting piece
No Check whether pin 25 beside harness is

Whether connected
connected with the terminals in the fuse box
Yes
Check and replace wire of No Check and replace wire of

Whether connected
pin 25 beside harness pin 25 beside harness
Yes
Check whether valve fuse (30A)

in the fuse box is broken
No
Whether fuse is normal Check and replace valve fuse
Yes
Confirm installation condition of pin 25 of connecting

piece beside harness and replacement of pins
Adjust pin of connecting

不是
Whether condition is good piece and install
Yes connecting piece

correctly
Drive HECU forcibly with
diagnostic instrument (valve
relay and motor are started)
No
Whether forcible driving is good Replace HECU
Yes

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DTC
C2 112 Note: If faults corresponding to more than 2 DTC can
Valve fuse and relay faults:
the fault corresponding to this DTC again and refer to
Cause
a) Main replay or fuse disconnection

the recorded DTC (and confirm the same fault code).
b) Main relay short circuit
① Check whether pin 25 beside harness is

connected with ground wire after removal of
connecting piece beside harness
No Check whether pin 25 beside harness is

Whether connected
connected with terminal in fuse box
Yes
Check and replace wire of No Check and replace wire of

Whether connected
pin 25 beside harness pin 25 beside harness
Yes
Check whether valve fuse

(30A) in fuse box is broken
No
Whether fuse is normal Check and replace valve
Yes fuse
Confirm the installation condition of pin 25 of connecting

piece beside harness and the replacement of pins
No Adjust pin of connecting piece

Whether condition is good and install connecting piece
Yes correctly
Drive HECU forcibly with a

diagnostic instrument (valve relay
and motor are started)
No
Whether forcible driving is good Replace HECU
Yes

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DTC
C1 604 Note: If faults corresponding to more than 2 DTC can
ECU internal circuit and valve coil the fault corresponding to this DTC again and refer to
Cause
faults the recorded DTC (and confirm the same fault code).
Remove connecting piece beside wire harness;

measure resistances between pin 8 (-), 24 (-) of
interface beside harness the earth wire
No Confirm and check grounding condition of

Whether below 1Ω
grounding connectors of pin 8 (-) and 24
Yes (-) of interface beside wire harness
Replace HECU
Whether condition is good No Replace wire

harness
Yes
Adjust the interface pin and

install it correctly
5. No DTC fault table

Table 3-20 No DTC fault table 1
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Fault Start the engine, but ABS warning lamp can not be turned on
① Fuse is blew out ② Bulb of ABS warning lamp is broken
Cause
③ Circuit is open ④ Warning lamp controller is broken
Check fuse of ABS warning

lamp in the fuse box
Whether fuse is normal No Replace fuse
Yes
Check fuse socket

of fuse box
No
Whether socket is normal Repair fuse socket
Yes
Remove connecting piece beside

harness; check ABS warning lamp
with the condition that the circuits
of the whole vehicle are connected
No Check whether Whether bulb YesReplace

Whether ABS
bulb of ABS is broken bulb
warning lamp
warning lamp is No
is turned on
broken
Yes Check whether circuit of

warning lamp in ABS
Check whether the circuit between
harness is open
pin 16 beside harness and warning
lamp drive components is shorted
No Replace
after removal of connecting piece Whether normal
harness
beside harness
Yes
Check circuit of warning lamp power and

Short circuit or not
connecting piece of grounding circuit
Yes
Check and replace wire Repair

Whether normal No
of pin 16 beside harness connecting
piece
Yes
Check and replace drive components of warning lamp

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Fault Start the engine, but ABS warning lamp is always on
① Controller of ABS warning lamp is broken ② Return circuit of warning lamp controller
Cause
is open ③ ECU is broken
Check whether pin 16 beside harness is connected with

drive components of warning lamp after removal of
connecting piece beside harness
No Check and replace wire of pin 16

Whether connected
beside harness
Yes
Whether fuse is normal
Connect pin 16 beside harness with earth

wire with the condition that the circuits of the
whole vehicle are connected
No
Check and replace drive
Whether warning lamp is turned off

components of warning lamp
Yes
Replace HECU

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Fault ABS works abnormally
① Sensor is damaged ② Sensor is not properly installed ③ Foreign material adheres to
Cause sensor ④ Wire harness of sensor is broken ⑤ Gear ring is broken ⑥ Wheel axle is broken
⑦ HCU of ABS is broken ⑧ ECU of ABS is broken
Whether sensor is installed correctly
No
Reinstall sensor correctly
Whether problem still No

exists Complete check
Yes
Replace sensor
No
Whether problem still exists Complete check
Yes
Check whether ECU socket of ABS No Replace HECU or

and connecting piece are normal connecting piece
Yes
Replace harness, connecting piece or

HECU
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Fault Brake pedal play is too long
① Parking brake is not properly adjusted ② Brake fluid leaks
Cause ③ Friction plate of brake is severely worn ④ Normally closed valve can not be closed tightly
⑤ Air is in the system
Check whether hydraulic connector leaks
Whether leak exists No Check wearing condition of brake disc
Yes
Screw down the pipe connect Whether normal No Replace brake

with torque of 120 ~ 160N•M disc
Yes
Check parking brake adjustment equipment
No Replace parking
Whether normal
brake adjustment
Yes equipment
Exhaust check
Whether normal No Re-exhaust
Yes
Replace HECU
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Fault No fault code output (unable to communicate with fault diagnostic instrument)
① Fault diagnostic instrument is broken ② Fuse is blew out
Cause
③ Diagnosis wire is broken or connector is loose ④ ECU is broken
Confirm the connecting condition between connecting

pieces of diagnostic instrument and relevant vehicle parts
Whether normal No Install connecting piece correctly
Yes
Check whether pin 7 beside harness is connected with

pin 7 of vehicle diagnosis connecting piece after
removing the connecting piece beside harness
Check and replace wire of pin

Whether connected No
7 beside harness
Yes
Check whether ECU fuse (10A) in fuse

box is blew out
No
Whether fuse is normal Check and replace ECU fuse
Yes
Connect the connecting piece beside harness correctly;

check whether communication is normal
No
Whether normal Check and replace diagnostic instrument
Yes
Take different measures according to different bad

numbers after confirmation of fault number
V. Exhaust and filling

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As the inside of spare HECU is wet, exhaust mode operation is not necessary; exhaust can be carried out to
all wheels directly
1. After stepping on brake pedal, open the bleed screw on the caliper or drum brake to exhaust the air
inside.
This operation should be carried out for all wheels before that the brake fluid exhausted through the bleed
screw contains no air and brake pedal is hard enough.
2. Operate the exhaust mode with the reassembled equipment or diagnostic instrument and step on brake
pedal, if there is no reaction force, repeat stepping on and releasing the pedal until exhaust mode is finished.
(Exhaust mode: repeat the process of start and stop of normally closed solenoid valve with interval of 2
seconds for 1 minute, and keep motor working. The repeat of stepping on and releasing of pedal should be
carried out on the normally closed solenoid valve while motor is operating.)
3. Item 1 (exhaust) should be carried out for all wheels.
Appendix I Fault Cases and Mistaken Repair Cases
HECU mistaken repair cases:

1. HECU replacement concerning ABS working sound
Case of HECU replacement for misjudging sounds of solenoid valve and motor as fault when ABS is
working
It is normal that there is noise during brake pressure decrease or increase when ABS is working. The
volume of noise varies according to different pressures to all wheels. It is not a fault, which should be
explained to clients.
When ECU diagnoses whether motor is working at the vehicle speed of 10 km/h for the first time after start,
a sensitive client may hear noise, which is also a normal ABS working condition.
2. HECU replacement concerning EBD working sound

Case of HECU replacement for misjudging “click” sound from rear wheel as fault when braking.
ABS can work as EBD. When rear wheel is blocked before front wheel, ABS will reduce the brake
pressure of rear wheel, which may cause noise. It is normal.
3. HECU replacement concerning braking deviation

Case of HECU replacement concerning the phenomenon that vehicle drifts to one side when braking
ABS is an auxiliary brake equipment to calculate the speeds of all wheels by ECU and maintain the best
brake force and operation stability. When a fault occurs to HECU, ECU will turn on the warning lamp after
diagnosis. As a result, if braking deviation occurs while ABS warning lamp is not turned on, other
hydraulic brake equipments should be checked.
Braking deviation may occur when ABS is working if brake hose is mistakenly assembled.
4. Case of replacement concerning that ABS works during low speed (below 40 km/h) brake
Case of HECU and sensor replacement concerning that ABS works during every low speed brake
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ABS may work during low speed braking according to road condition and brake pressure. If ABS works
every time, check whether the air gap of sensors of all wheels is too large, whether the ring gear is
disturbed and damaged.
Air gap adjustment method: After confirmation of part with abnormal air gap, replace or burnish the
mounting surface (contact area) of sensor and adjust to the specified air gap; when disturbance occurs, a
thin washer should be placed on the surface of sensor and then adjust to specified air gap.
Appendix II ABS Common Sense

1. If braking distance will be shorter after installing ABS?
According to experimental statistics, the braking distance will be shorter (about 5% ~ 20%) on most roads;
but it can be longer on some special roads (like snow, non-asphalt and uneven roads), but with stable
steering.
2. What are the main purposes of ABS?

The main purpose of ABS is to prevent block. The functions are as follows:
(1) To stabilize the vehicle when braking
(2) To control the direction of the vehicle during braking to avoid collision
(3) To maintain the best brake pressure regardless of the skill of driver
3. Why ABS warning lamp is turned on?

After the vehicle is started, warning lamp will be turned off if no fault is detected by the self-diagnosis of
ECU of ABS. If warning lamp is turned on or can not be turned off when vehicle is running, the ABS is
abnormal and ABS check in appointed service factory is necessary. When warning lamp is turned on and
ABS is abnormal, the brake system still has the basic braking ability, but the careful driving is still
required.
4. Will no accident happen if ABS is installed?

ABS is an equipment to improve driving safety, not to avoid accident caused by driving mistake or traffic
condition. As a result, do not depend too much on ABS. Please always drive safely.
5. Is it caused by ABS that the vehicle drifts to one side when running on a slippery road?
This is because the friction coefficients of the left and right wheels are different. ABS can stabilize the
vehicle in this situation, but the driver should also control the steering wheel to avoid accident.
6. The vehicle will drift before braking when turning on a slippery road. Does ABS work if to brake
now?
Definitely ABS will work effectively and may stabilize the vehicle according to the speed, but the position
of vehicle can only be adjusted slightly even ABS works because the outward force is too large for the
inertia. Usually there are two kinds of forces during turning: one is needed when running and braking; the
other is needed when turning and stabilizing. Actually running, braking and turning of the vehicle are
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coordinated by the two kinds of forces above; and they are in inverse proportion to each other. As a result,
the brake force will increase while the turning and stabilizing force will decrease if to brake when turning.
The two kinds of forces can be adjusted to the best on the vehicle with ABS; but they can not be adjusted
on the vehicle without ABS, which will weaken its steering performance and stability.
If the two kinds of forces are too small (For example, the vehicle will leave the running route as the speed
is too high when drifting), the force to adjust the vehicle is too small, the ABS effect is not obvious. In a
word, deceleration in advance and safe turning is the best solution.
Appendix III ABS Interior Hydraulic Pressure Flow Diagram
Fig. 3-110 ABS interior hydraulic flow diagram
Appendix IV Electric Circuit Diagram

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Fig. 3-112 Electric circuit diagram of ABS system

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Part IV Electrical System Maintenance

Chapter I Electrical System
Section Ⅰ System Principle
The electrical system of LIFAN sedan includes: power startup system, electronic injection system, ABS
system, electric rear view mirror system, wiper and washer system, audio system, illumination signal
system, instrument cluster system, A/C system, air bag system, keyless entry system, window regulator
system, and BCM system.
1. Power startup system (Fig. 4-1)
Fig. 4-1 Schematic diagram of power startup system
2. Schematic diagram of electric rear view mirror system (Fig. 4-2)

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Fig. 4-2 Schematic diagram of electric rear view mirror system
3. Schematic diagram of electronic injection system (Fig. 4-3)

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Fig. 4-3 Schematic diagram of electronic injection system

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4. Schematic diagram of ABS system (Fig. 4-4)
Fig. 4-4 Schematic diagram of ABS system
5. Schematic diagram of wiper and washer system (Fig. 4-5)

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Fig. 4-5 Schematic diagram of wiper and washer system
6. Schematic diagram of audio system (Fig. 4-6)
Fig. 4-6 Schematic diagram of audio system

7. Schematic diagram of illumination signal system (Fig. 4-7)
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Fig. 4-7 Schematic diagram of illumination signal system

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8. Schematic diagram of instrument cluster system (Fig. 4-8)
Fig. 4-8 Schematic diagram of instrument cluster system

9. Schematic diagram of A/C system (Fig. 4-9)
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Fig. 4-9 Schematic diagram of A/C system

10. Schematic diagram of BCM system (Fig. 4-10)
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Fig. 4-10 Schematic diagram of BCM system
Wire color code table (4-1)

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Table 4-1 Wire color code table
Colour Black White Red Green Yellow Brown Blue Grey Violet Orange
Code B W R G Y Br Bl Gr V O
Fuse specs table (4-2)

Table 4-2 Fuse specs table
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11
50A 100A 120A 10A 10A 15A 20A 25A 10A 15A 15A
F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22
30A 30A 10A 15A 15A 10A 15A 15A 10A 15A 20A
F23 F24 F25 F26 F27 F28 F29 F30 F31
15A 15A 15A 10A 30A 15A 15A 20A 10A
Section Ⅱ Battery
Ⅰ. Composition & Principle

1. Functions
Battery, connected with the engine in parallel, is one of the automobile power supplies. Its functions are:
(1) When the engine is started, provide starting current to engine, and power supply to ignition system.
(2) Assist the power supply to support current-using equipments individually or with the generator when
the generator does not work or is at low voltage.
(3) When electrical energy in the battery is insufficient, the generator can charge the battery, transform the
spare electrical energy into chemical energy and store them, so as to meet the next use.
(4) Guarantee voltage stabilization. The battery is equal to a large capacitance. It can absorb the transient
over voltage in the automotive electrical system so as to protect the electronic components. As there are
lots of electronic components in LF 320 sedan, it’s important to make sure the battery is in good connection,
so as to prevent the on-vehicle electronic equipments to be damaged by the instantaneous high pressure in
the electrical system.
2. Basic components
The lead-acid battery used by LIFAN sedans is mainly composed of positive/negative plates and sulfuric
acid electrolyte; refer to Fig. 4-11. The storage, discharge, and recharge of the battery are realized by the
electrochemical reaction bwtween active material and electrolyte on the polar plate. The active material
which is brown on the positive plate of the battery is PbO2, while the active material on the negative plate
is Pb. The electrolyte of the battery is made up from a mixture of pure sulphuric acid and distilled water
proportionally. Both positive plate and negative plates are connected in parallel with multichips in order to
enlarge the capacity of the battery. Positive plate group is interdigitated with negative plate group, and an
insulating barrier is installed between the two groups so as to avoid shortcircuits. A pair of positive and
negative plates groups forms a cell, and its normal voltage is 2V. Therefore, a battery rated 12V requires 6
cells to be connected in series. The structure of common battery refers to Fig. 4-12.
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Fig. 4-11 Component unit of lead-acid battery

1- Electrolyte 2- Container
3- Positive plate 4- Negative plate
Fig. 4-12 Structure of lead-acid battery

1- Negative pile 2- Liquid filler cap 3- Positive pile
4, 6- Insulating barrier 5- Negative plate 7- Positive plate
3. Basic principles of lead-acid battery

(1) Build up electromotive force (EMF) of the battery
Some active material on the polar plate will dissolve and ionize when the positive and negative plates are in
the electrolyte. After ionization, the PbO2 on the positive plate will leave Pb4+ on the positive plate which
can increase the electrical potential of the positive plate, while the pure lead on the negative plate will leave
the negative plate with electrons which can decrease the electrical potential of the negative plate. As a
result of the ionization, the electric potential difference which is called EMF is formed. It enables the
battery to transmit electricity to external circuit. The EMF of the battery is affected by Pb4+ and electron
density. The EMF of the positive and negative plates is about 2.1V when the battery is fully charged.
(2) Discharge of battery
When the positive and negative plates are connected with the external circuit, the electrons will flow from
the negative plate to the positive plate. When Pb4+ on the positive plate gains electrons, it will change into
Pb2+, and then dissolve in electrolyte. Meanwhile, PbO2 on the positive plate keeps ionizing so as to add
the lost Pb4+. Pb on the negative plate provides electrons by continuous ionization. During the discharge
process, Pb2+ and SO42- in the electrolyte combine and release PbSO4, and they will then attach to the
surface of the positive and negative plates. The active material PbO2 and Pb on the plates will gradually be
converted into PbSO4. H2SO4 in the electrolyte decreases while H2O increases, as a result of this, the
density of electrolyte falls.
(3) Charge of battery
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When the battery stops discharging, a little PbSO4 on both positive and negative plates will inoize.When
the battery is charging, the charging supply will form electric field force, which can absorb electrons on the
positive plate and transform them to the negative plate, and then charge current will come into being. Pb2+
on the positive plate loses electrons and changes into Pb4+. By combining with water in the electrolyte,
Pb4+ is reduced to PbO2 and attaches to the positive plate. Pb2+ is reduced to Pb and attaches to the
negative plate after it gains electrons. During the charge process, PbSO4 on the positive and negative plates
is gradually reduced to PbO2 and Pb, H2O in the electrolyte decreases while H2SO4 increases, as a result
of this, the density of electrolyte rises.
4. Battery type & capacity
The battery capacity of LIFAN sedan increases in order to meet the increasing power consumption of
automotive electrical and electronic equipments. The Battery type& capacity: 12V60Ah 640CCA.
II. Common Faults& Elimination

1. Polar plate vulcanization
Polar plate vulcanization is the most common fault of battery. Coarse crystal lead sulfate forms on the
plates is hard to be reduced when charging. When plates are vulcanized, battery interior resistance increases,
capacity and starting ability decrease. Charge and discharge performance: terminal voltage decreases
quickly when discharging. Terminal voltage and temperature increase quickly and “boils” too early when
charging. The density of electrolyte rises slowly and it couldn't reach the standard level.
(1) Fault causes
1) Low power battery. PbSO4 isn't reduced to active material in time, the PbSO4 in the electrolyte will be
crystallized because of being over-saturated. This recrystallization process is polar plate vulcanization.
2) Low electrolyte level. Polar plates are oxidized because of exposition. When the car bumps and shakes,
electrolyte recrystallizes with the already oxidized plates. And then polar plate vulcanization forms.
3) Deep discharge. It refers to that low current has been over discharged for a long time, active material
then changes into PbSO4, and charge the battery with car generator; PbSO4 can not be restored, and then
coarse crystal lead sulfate forms in the course of time.
Besides, polar plate vulcanization can also be caused by over high or impure density of the electrolyte,
rapid variations of external temperature, etc.
(2) Fault elimination measures
If it is serious, you could give up repair (maintain) that battery as the battery capacity is low and fails to
work normally. If not, do eliminate vulcanization with the following instructions:
1) Pour out the electrolyte, wash the battery twice by using distilled water, and finally infuse it with plenty
of distilled water.
2) Turn on the current, charge the battery with 1/30A of its rated capacity. When the density of electrolyte
increases to 1.15g/cm3, pour out the electrolyte, infuse it with fresh electrolyte before put it under
recharging, keep doing this until the density of electrolyte is stable.
3) Discharge the battery with 1/10A of its rated capacity. When the cell voltage decreases to 1.7V, stop
discharging, charge the battery with 1/10A of its rated capacity, and then keep discharging and charging
alternatively until the battery capacity reaches 80% of the rated capacity.
4) Adjust the density of electrolyte to required value.
2. Self-discharge
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Self-discharge refers to that battery loses energy without any connection of the external circuit. Normally,
self-discharge is inevitable; however, self-discharge fault forms if the self-discharge capacity is over 2%
per day and night. Self-discharge fault can cause shortage of the stored charge only hours or days after the
battery is out of use for days.
(1) Fault causes
1) Creepage will occur if the battery cap is covered with oil stains, dust and electrolyte.
2) Too much sediment in the bottom of battery case result in short circuit of positive and negative plates.
3) Insulating barrier fracture result in short circuit of positive and negative plates.
4) Impure electrolyte with too much metal impurities.
(2) Fault elimination measures
Elimination method should be selected according to the fault causes
1) Check the surface of battery, clean it if necessary.
2) Check whether electrolyte is brown when charging, if yes, the battery is self-charge because of too much
sediment in the bottom of battery case. Pour out the electrolyte, use distilled water to wash the inside of the
battery case, infuse it with fresh electrolyte, and finally fully charge the battery.
3) If self-discharge fault still exists since all check results are normal or all faults have been excluded, it
might be caused by impure electrolyte, elimination method: fully or over discharge the battery so as to
transfer all the impurities into electrolyte, then pour out the electrolyte, use distilled water to wash the
inside of the battery case, infuse it with fresh electrolyte, and finally fully charge the battery.
Note: The same phenomenon with self-discharge fault can be caused when the current-using equipments
are not turned on or when short circuit and creepage occure, therefore, external circuit should be checked
firstly before checking or eliminating self-discharge fault.
Quartz digital clock, electronic tuning radio (with radio memory), and computer memory of electronic
injection engine are in power-up status even if the ignition switch is turned off, so when the ignition switch
and all current-using equipments switches are turned off, it’s normal to find the output current is not 0 or
the circuitous resistance is not open. But the electric current should be less than 1A, and the electric
resistance should be less than 100Ω, otherwise, circuit or switch has short circuit or creepage fault.
3. Active material sheds in early period

Electrlyte will become brown and turbid when the battery is charging. If charging voltage increases too
rapidly, electrolyte will boil prematurely, and its density can’t reach the maximum of required value. If
discharging voltage decreases too rapidly, electrolyte is obviously not enough, which indicates active
material sheds a lot.
(1) Fault cause. During normal use period, only limited active material sheds from the plates. The cause of
active material sheds in early period could be the following:
1) Over current charge or over time charge can electrolyze lots of water and release gas. The gas press on
the holes of plates, this pressure leads active material to shed. Over current charge could also make the
electrolyte temperature become over high, plates will distort and cause active material to shed. Over time
charge could cause over oxidation of the fence, which makes active material shed from the fence.
2) Over current charge for a long time, especially in low temperature, can add its production PbSO4 with
dense-layer. PbO2 will enjoy a dendrite formation when charging, and dendrite is easy to fall.
3) Over time charge will produce too much PbSO4 on the plates, inflation of the plates press on the active
material and make them to shed.
4) False battery plates installation makes the battery be active in the car, and the plates bump and shake
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seriously. Active material sheds.
5) When the battery doesn’t charge in time after discharge in winter, the electrolyte will freeze because of
low density. Active material sheds.
(2) Fault elimination methods. When active material sheds little, pour out the electrolyte, use distilled water
to wash the battery, infuse it with fresh electrolyte, and then use it after charging. If active material sheds a
lot, replace the plates or battery with new ones.
III. Use and Maintenance of Battery

1. Daily inspection and maintenance
(1) Appearance check:
1) Check if the battery is stably installed and if the clamp and pile are well connected. Clear off oxide on
the clamp and pile, and coat them with vaseline or consistent grease to prevent oxidation.
2) Check if the battery cap is clean. Dust, oil stains and electrolyte should be removed in time.
3) Check if the breeder tube on the infusion manhole cover is unobstructed, if not, gases inside the battery
will gather together and then increase the pressure. The housing can be broken and even explosion may
occur.
(2) Check the electrolyte level The electrolyte level should be 10mm-15mm above the plates normally,
distilled water should be added when electrolyte level is abnormally low, electrolyte is not recommend, or
its density will be abnormally high. Natural evaporation and electrolyzation of water decrease the
electrolyte level. Electrolyte with the same density can only be infused when electrolyte is poured out,
leaked or insufficient.
(3) Discharge level Discharge level can be checked by testing the density of electrolyte or voltage drop of
cell (Fig. 4-13). Normally, density decreases every 0.01g/cm3, battery discharges 6%. If the battery
discharges exceed 25% in winter or 50% in summer, battery should be charged before use.
Note: Electrolyte density should not be tested right after heavy current discharge or distilled water infusion,
meanwhile, temperature of electrolyte also requires test, and convert the actual density value to density
value at 25℃. Conversion formula:
r25℃=rt+0.00075（T-25）
r25℃--Density of electrolyte when the temperature is at 25C°(g/cm3）;
rt－－Actual density value (g/cm3); T－－Actual temperature of electrolyte (℃)

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Fig. 4-13 Test the electrolyte density of the battery

1-Suction nozzle 2- Densimeter 3- Glass tube 4- Rubber ball
Section III BCM System
I. Overview
BCM controller is a body integrated controller. It controls various functions of the body by a modern
embedded microcomputer, such as central control of door lock; automatic control of power windows and
user-friendly intelligent control; anti-theft control, engine and alarm are unavailable without lawful
authority; remote control, the remote is easy to use for it sends and receives non-directionally with wireless
technique. When the remote controller is fully charged, the remote control distance is required ≥20m. BCM
main functions:
Standard: remote control for central lock, window regulator control, and anti-theft system.
Simple: central lock (no remote controller) and window regulator control.
(Note: burglar alarm is selective with an interface reserved. Alarm is assumed in the following
descriptions.)
II. Functional Definition& Operating Instructions

1. Start
Controller enters into standby state when it is power on. Central lock switch and remote controller are
available. Press the key lock switch, and the controller will enter the alert state; press keys on central lock
switch to enter locking and unlocking. Open the door or turn on the ignition switch, controller will be out of
anti-theft state. (Normal state)
2. Standby state
(1) Press the locking key, controller will enter anti-theft state when it gets the signal.
(2) Open the door or turn on ignition switch, controller will enter normal state. Central control lock switch
and window regulator are available.
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3. Anti-theft state
(1) Normal state is available when the unlock key is pressed to disarm alert state. The anti-theft indicator
will flash rapidly. Open the door or the ignition switch and the anti-theft indicator will go out. Small lamps
flash for once, the siren sounds for once. Door is unlocked at the same time when it is locked.
(2) Press lock keying to lock doors under anti-theft state, small lamps flash for twice and siren sounds for
twice.
(3) If anti-theft state is unreleased, open the door or turn on ignition switch, the alarm will sound (small
lamps flash at the same time). Press any key on the remote controller, alarm will rering 3 seconds later.
Only system intrusion stops 30 seconds later can the alarm stop, otherwise, the alarm will keep ringing.
(4) If the door is not opened or the ignition switch is not turned on within 30 seconds after the alert has
been disarmed, the control system will return to anti-theft state.
(5) Anti-theft indicator LED flashes slowly at anti-theft state.
4. Non anti-theft state

Central lock system:
(1) Unlock: Press unlocking key to open the central control lock. This can always be implemented no
matter under what state. Small lamps flash for once, the siren sounds for once.
(2) Lock: Press locking key to close central control lock. This can always be implemented no matter under
what state. Small lamps flash for twice, the siren sounds for twice, and controller enters anti-theft state. If
ignition switch is turned on, only lock operation is done, anti-theft state is unavailable.
(3) After unlock and lock operations, control module will then receive a feedback signal from the actuator.
If the feedback signal is wrong (such as actuator motor is damaged), the siren will sound for five times, and
small lamps flash for five times, so as to remind the driver that doors are unlocked (or not open).
(4) Press contact switch on the control panel (effective at low level), central control lock state alternates
every time the switch is pressed, which means the unlock state will turn into lock, or the lock state will turn
into unlock.
(5) When the vehicle speed exceeds 20km/h, only collision unlock order works. When the vehicle speed is
lower than 20km/h, other unlock operations work too.
(6) When the vehicle speed exceeds 20km/h, the vehicle will lock automatically if it is in unlock state.
When the vehicle speed is lower than 20km/h, the vehicle will not unlock. (no such function in simple
equipments)
(7) The vehicle will unlock automatically if it crashes. When the controller receives collision signal from
air bag, the controller will repeat unlock operation for three times continuously to ensure doors are
unlocked.
Window glass control:

(1) Automatic down: press the window glass switch for ＜ 300ms, corresponding window glass will
descend automatically. After reaching the right position, the window glass stops automatically.
(2) Manual up and down: press the window glass switch for≥ 300ms, corresponding window glass will
ascend or descend by keeping pressing, and then release the switch, ascending or descending stops.
(3) Press time ＜ 300ms: the window glass stops if it is working, if not, it will enter automatic work state.
(4) Press time ≥ 300ms: if the window glass is working against the supposed orientation that the key
controls, it will first stop, and then enters into manual work state.
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(5) Window regulator system can work within 60 seconds after ignition switch has been turned off, if
locking key or both locking and unlocking key are pressed within the 60 seconds, then the controller will
enter anti-theft state, meanwhile, window regulator system is unable to work.
(6) When keeping pressing the locking key on the remote controller, the four windows will automatically
ascend until closed one by one, when the remote controller is released or the top of the windows have been
reached, windows stops ascending.
III. Definition of BCM Interface Functions

BCM interface as shown in Fig. 4-14
Fig. 4-14 Schematic diagram of BCM interface
Function of BCM interface as shown in Table. 4-3
Table 4-3 Functions of BCM interface

25 cores
1 U1 Driver's door ascending output
2 Tout Engine power output
3 Tim Engine power input
4 Key Unlock and lock of the central lock
5 30 Power window, central lock working power supply
7 VPP Microcontroller working power supply
8 31 Earth wire
9 31 Earth wire
10 BB+ High level output when anti-theft alarm works
11 KOF Locking output of central lock
12 KON Unlocking output of central lock
13 DR Right steering light
14 D1 Driver's door descending output
15 U1 CO-driver’s door ascending output
16 U2 Co-driver’s door descending output
17 U4 Right rear door ascending output
18 U4 Right rear door descending output
20 15 Ignition switch signal input
21 31 Earth wire
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22 U3 Left rear door descending output
23 U3 Left rear door descending output
24 VS According to left and right steering lights selection
25 DL Left steering light
Table 4-3 (continued）

16 cores
1 u1 Driver’s door ascending control input
2 d Co-driver’s door descending control input
3 u2 Co-driver’s door ascending control input
4 d2 Right rear door descending control input
5 u4 Right rear door ascending control input
6 d3 Left rear door descending control input
7 u3 Left rear door ascending control input
8 SPD Speed input
9 d1 Driver’s door descending control input
10 STA Door open/close input
11 SRS Air bag input unlocking signal
12 NC Not connected
13 LED Indicating current module state
14 TK Check door state
15 NC Not connected
16 T Wireless input
V. Frequent Faults & Elimination Methods
Table 4-4 Frequent faults & elimination methods of BCM
Fault Cause Diagnosis & elimination

Press the remote for once, the indicator of the remote should flash
Dead remote battery for once; if not, the battery is dead or the remote is damaged,
Remote battery is advised to be replaced first.
control Damaged remote Replace the remote controller from LIFAN designated repair
failure controller station.
Damaged remote
Replace BCM assembly.
control receiver BCM
Check fuse related to the system is damaged or not; if yes, check
Locking Faulty power supply the wire short circuited or not, if yes, replace fuse with the same
system type after the wire fault is eliminated.
does not Check the circuit with multimeter; if there is a short circuit or
work Faulty circuit open circuit, repair or change the circuit according to the
damage degree.
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Connect the two pins of actuator with electricity +12V or -12V,
Damaged locking
the lock should response to it; if not, the executive body is
executive body
damaged and needs to be replaced.
If all the possible faults are eliminated, BCM must be damaged,
Damaged BCM
and replace BCM assembly.

Faulty power supply
if the circuit is short; if yes, replace fuse of the same type after
system
the circuit fault is eliminated.
Check if the pins are connected or disconnected when checking
Damaged switch of
the switch with multimeter; details of switch pins refer to
Window window glass
schematic diagram; replace the switch assembly if there is any
regulator regulator
fault.
system
Check if open or short circuits happen in the switch input circuit
does not
Faulty circuit and the window regulator output circuits with multimeter. Repair
work
or replace the circuit according to the damage degree.
Connect the two pins of window regulator actuator with
Damaged window
electricity +12V or -12V, the window regulator should respose to
regulator executive
it; if not, or the regulator is dumb, the window regulator is
body
damaged and executive body needs to be replaced.
If all the possible faults are eliminated, BCM must be damaged.
Damaged BCM
Replace BCM assembly.
Faulty power supply
if the circuit is short; if yes, replace the fuse with the same type
system
after the wire fault is eliminated.
Check if open or short circuits happen in the circuit related to the
Anti-theft Faulty circuit system with a multimeter. If yes, repair or replace the circuit
system according to the damage degree.
does not In anti-theft state, the anti-theft indicator of the instrument should
work Damaged anti-theft illuminate, while the vehicle is not in anti-theft state, it should go
indicator off. Connect the pin to the ground, the indicator should
immuninate; if not, check if the instrument is damaged.
If all the possible faults are eliminated, BCM must be damaged.
Damaged BCM
Replace BCM assembly
Chapter II Composition and Principle of

Instrument Cluster
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I. Composition and principle
1. Composition
LF7132 Sedan uses combined dash board. This instrument consists of dial instrument, various indicators
and liquid crystal display screen. The dial instrument includes speedometer, tachometer and fuel gauge.
Indicator symbol and colour as shown in Fig. 4-5
Table 4-5 Indicator symbol and colour
Indicators layout as shown in Fig. 4-15
Fig. 4-15 Indicators layout

Schematic diagram of instrument cluster as shown in Fig. 4-16:
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2. Operating principle
Each instrument cluster works individually although they are installed on one circuit board. Speed is
provided by speed sensor; rotation speed is provided after electronic injection ECU treatment, to enable the
speedometer and odometer to work. Other instruments wrning lamps and indicator circuits enable loops
with their own sensors, and show their own monitor objective parameters and states on the instruments or
warning lamps.
3. Model
(1) Speedometer with a stepper motor;
(2) Tachometer with a stepper motor;
(3) Fuel gauge with a stepper motor;
(4) Odometer with LCD;
(5) Instruments are connected with sockets.
(6) Speedometer
1) Odometer
Show mileage through speed sensor and instruments board circuit. Odometer consists of subtotal odometer
and accumulated odometer. As for short mileage count, subtotal odometer can be reset by pressing the reset
button.
2) Speedometer
Instrument gets the signal from speed sensor, the signal will then be sent to instrument cluster after treated
by ECU; then the instrument cluster will drive the stepper motor to make the pointer swing and indicate the
driving speed of he vechicle.
3) Tachometer
Engine rotation speed signal is generated by engine rotation speed sensor; the signal will then be sent to
instrument cluster after treated by ECU; then the instrument cluster will drive the stepper motor to make the
pointer swing and indicate the rotation speed of engine.
4) Fuel gauge
Fuel gauge is used to indicate the fuel in the tank. The lowest fuel level warning lamp will flash when the
fuel gauge indicates “0” level; there are about 8L fuel left, fuel is advised to be filled immediately in nearby
gasoline station. Fuel gauge gets fuel tank level signal through the fuel level sensor. The fuel level sensor is
asliding resistance potentiometer. Float rod changes with the fuel level, driving the the movement of
gleithretter and change the resistance of circuit in the fuel gauge. Test this resistance, and make the electric
motor to turn to the right position (Fig. 4-17).
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Fig. 4-17 Fuel level sensor
5) Oil pressure warning lamp is used to monitor engine oil pressure. When the oil pressure is lower than the
set one during the engine operation process, the warning lamp will then flash. Stop the vehicle and check
the oil level. If the oil level is normal while the warning lamp keeps flashing, check the engine lubrication
system. Oil pressure warning lamp is controlled by oil pressure sensor on the main oil passage of the engine
lubricating system. When the engine operates, normal oil pressure will disconnect the sensor contact, and
the warning lamp goes put. If the pressure is lower than the set one, the switch will close and the alarm
lamp will then be lit.
6) Brake fluid level warning lamp is used to warn the too low brake fluid level.
7) If engine fault warning lamp flashes or shines when the engine is under operation, engine injection or
ignition system has faults. Stop the vehicle and check it.
8) Charging indicator monitors charging system fault. If the indicator lights under normal engine operation,
charging system fault exists.
II. Instrument system check and repair

1. General method for check and repair of instrument cluster
(1) When instrument cluster fault exists, try to analyze fault cause according to fault and circuit principle,
then check and repair the fault by “outside to inside” steps. First check sensors, switches, fuse, circuits, and
interfaces, etc. except dash board, and eliminate the fault sources. If the instruments fail to work normally,
then check instruments, printing circuit board, and bulbs inside the dash board.
(2) If more than one indicator or warning lamp doesn’t shine, check relevant fuse and power supply wires;
if normal, check the ground connection of dashboard.
(3) If fuel gauge, oil pressure gauge, and other instruments don’t work at the same time, check related fuse
and power supply wires, and then check the earthing state of the dash board.
(4) Check instruments and sensors by replacing them with good ones. Replace them with normal sensors,
and check if the instruments can restore normally.
2. Fuel gauge check and repair

(1) Open circuit fault
If the fuel gauge pointer indicates E level always, an open circuit exists. Check and repair methods:
Ver：LF-20121225
1) Disassemble harness plug of fuel gauge when igniton swith is disconnected.
2) Connect the ignition switch, using the DC voltage of multimeter to test the 2 terminals of the plug. If
there is not DC 12 V, check the wire of fuel gauge. And dismantle and check the fuel gauge if the wire is
normal; Check the fuel level sensor if the voltage is normal.
(2) Short circuit
If the fuel gauge pointer indicates F level always no matter how much fuel is left inside the fuel tank, a
short circuit exists, check and repair method:
1) Disassemble harness plug of fuel gauge when ignition switch is disconnected.
2) Connect the ignition switch, and check if the fuel gauge pointer is towards to F.
If the pointer still indicates F level, check the wire of fuel gauge. And dismantle and check the fuel gauge.
If the wire is normal; dismantle and check or replace the fuel level sensor if the pointer indicates 0 level.
(3) Fuel level sensor check and repair method:
1) Before disassembling the fuel level sensor, test the resistance between sensor signal terminal and ground.
If the terminal is not connected to earth (resistance is ∞), the connection inside fuel level sensor is poor,
replace it. If the resistance is 0, a short circuit inside fuel level sensor exists, replace the sensor.
2) After disassembling the fuel level sensor, test the resistance of the sensor when the float rod is rotating.
The float is under E level 1/2 level and F level should be in accordance to that in Fig. 4-6. If the resistance
is not continuously changing (resistance ∞ appears) or abnormal when the float rod is rotating, replace the
fuel level sensor.
3. Oil pressure warning lamp check and repair
Table 4-6 Fuel level sensor resistance reference

Float rod F 1/2 E Alarm point
position
Resistance /Ω 3±1 32.5±5 110±6 95±5
(1) Warning lamp fault check and repair

If the warning lamp does not shine when the ignition switch is connected, an open circuit exists. Check and
repair methods:
1) Disassemble wiring harness plug of oil pressure switch when ignition switch is disconnected.
2) Ground the terminal on oil pressure switch plug directly, and then connect ignition switch, and check if
the warning lamp shines. If not, check wire of the warning lamp. If wire is normal, dismantle or repair the
warning lamp; if the warning lamp shines, check or replace the oil pressure switch.
(2) Oil pressure switch check and repair
Unplug the oil pressure switch; test the resistance between oil pressure switch terminal and ground. Normal
status: connected when engine is operating and disconnected when the engine is not operating. If the test
result is abnormal, replace the switch.
4. Brake fluid level switch check and repair
(1) Warning lamp fault check and repair
If the warning lamp does not shine when the fluid is under the minimum level, an open circuit exists. Check
and repair method:
1) Unplug the brake fluid level switch when the ignition switch is connected.
2) Short-circuit the two terminals of the switch plug, connect the ignition switch, and check if the warning
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lamp shines. If not, check wire of the warning lamp. If wire is normal, disassemble and check the dash
board, repair or replace the circuits or lamps of the brake fluid level warning lamp on the dash board. If the
lamp shines, check the brake fluid level switch.
(2) Brake fluid level switch check and repair
Unplug the brake fluid level switch; test the resistance between terminals of the plug. Normal status: switch
is connected when the float is pressed, while switch is disconnected when the float is not pressed (normal
brake fluid level). If the test result is abnormal, replace brake fluid level switch.
Chapter III Air Bag
Section I Composition and Arrangement
The whole air bag system is mainly composed of driver air bag module (DAB), front passenger air bag
module (PAB), air bag clock spring (SRS CS), air bag electronic control unit (SRS ECU), safety belt
pre-tensioners for driver side and front passenger side (deluxe scheme), air bag harness, warning label, and
so on.
1. Air bag ECU

The air bag ECU assembly is installed at the central axis of the vehicle, under the central control panel, as
shown in Fig. 4-18. The air bag ECU can keep in operation for over 100ms under the circumstances that the
battery voltage drops too low or the power supply disconnects because of collision.
2. Driver air bag module

The un-removable driver air bag module, containing gas generator, bag, ornamental cap and a series of
auxiliary components, is installed in the central ornamental cap of the steering wheel, as shown in Fig.
4-19.
3. Air bag clock spring
Fig. 4-18 Air bag ECU Fig. 4-19 Driver air bag module
1. Hexagon head bolt, spring washer, and flat washer assemblies
2. Air bag ECU
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Driver air bag module, whose communication with ECU is carried out through air bag clock spring, is
installed on the steering wheel and turns simultaneously with the steering wheel. The clock spring,
comprising swirly calbe, turnplate, housing, harness, auxiliary components, etc, is installed on the
combination switch, as shown in Fig. 4-20.
Fig. 4-20 Air bag clock spring
The working principle of air bag clock spring: the installation housing of the clock spring is fixed on the
steering column, the upper part of the clock spring turn plate is inserted into the steering wheel, and the
swirly cable is installed between the turnplate and installation housing. When the steering wheel turns left
or right, the clock spring turnplate will turns simultaneously with the steering wheel, turning the output end
of the cable and stretching or tightening the swirly cable. For this reason, the harness is prevented from
being wound upon the steering column. Beyond that, the continuity of the harness and the connection of the
electronic signal is assured. Thus, the harness of the clock spring is also the bridge for supplying electricity
from the vehicle body to the related functional components of steering wheel.
4. Front passenger air bag module (optional)

The front passenger air bag module, comprising gas generator, bag and a series of auxiliary components,
etc, is installed above the sundries box of dash board, as shown in Fig. 4-21.
The main function of front passenger air bag module: under normal usage, the front passenger air bag
module shall receive ignition signal from SRS ECU (Supplement Restraint System Electronic Control Unit)
and then spark the gas generator and produce abundant air rapidly for the deployment of air bag. With all of
these, the passenger can be protected.
Fig. 4-21 Front-passenger air bag module

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5. Air bag harness
Air bag harness is used to connect the air bag ECU, clock spring and dash board harness.
6. Air bag warning lamp
Air bag warning lamp is installed on the dash board as shown in Fig. 4-22.
SRS warning lamp will shine when the self-diagnosis circuit of air bag ECU assembly is faulty, so as to
inform the driver of the fault. Normally, the warning lamp shines for 5 seconds and then goes out
automatically when the ignition switch is turned to ON. When the circuit is under poor contact or the fault
exists from time to time, the warning lamp will keep shining after 8 historical records accumulation. Driver
is advised to go to the service station for a check in time when a SRS warning fault is found.
Fig. 4-22 Air bag warning lamp
Section II Working Principle
When frontal collision accident occurs, the collision sensor shall produce signal for the collision, and the
air bag ECU shall detect and analyze the collision signal to determine the necessity for ignition requirement.
If necessary, the ignition impulse shall be sent out immediately, the ignition pipe in each air bag module be
ignited, and then the gas generating material in each of the air bag module shall be ignited by the ignition
pipe. Therefore, abundant gas generated in extremely short time shall inflate the air bag suddenly, forcedly
open the ornamental cap, and the fully inflated air bag be formed. By this way, the impact upon the driver
and passenger arising from the collision accident shall be absorbed, and the injury of the driver and
passenger shall be avoided or lessened. Working principle of the air bag is shown in Fig. 4-23.
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Fig. 4-23 Operating principle of the air bag
Section III Air Bag Repair Safety Rules
If the air bag is not repaired according to the right operation instructions, it may be deployed by accident
and lead to serious accident! Besides, if the air bag is repaired in a wrong operation, it may not be deployed
when it is needed! Before repair, read the following instructions and follow the right operational procedure!
1. The check, installation and repair must be operated by professionals.
2. Use special voltmeter and ohmmeter (minimum 10/V) to test the voltage and the resistance instead of
detector lamp, general voltmeter and ohmmeter.
3. When eliminating the air bag system fault, fault codes must be read first before disassembling the earth
wire of the battery.
4. Before specific repair operation, disassemble the earth wire on the negative pole of the battery, and carry
out repair work after at least 3 minutes later. If not, the air bag may be deployed by accident. Besides,
cover the disassembled negative pole with insulating tape for insulation.
Notes: Operations must be performed more than 3 minutes after the power is shut. If not, serious accident
could happen.
5. After slight collision, the driver air bag module and air bag ECU assembly should be checked even
though the air bag is not deployed.
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6. If the repair work may cause the sensor to vibrate, disassemble the air bag ECU assembly before
repairing.
7. Do not use air bag system components from other vehicles. Replace the components with new ones.
8. Do not disassemble or repair the driver and front passenger air bag modules or the air bag ECU assembly
for reusage or other purpose.
9. If the driver and front passenger air bag modules and the air bag ECU assembly drop and vibrate, or
there are crack, indentation or other damages on the shells, support saddles, or interfaces, replace them
with new ones.
10. Do not place the driver and front passenger air bag modules and the air bag ECU assembly in hot air
or fire.
11. Disassemble and put away the air bag ECU, air bag module and clock spring if there are affections
caused by over heat (more than 93℃) during the operation.
12. Interfaces of air bag ECU assembly, between air bag ECU assembly and clock spring, between clock
spring and driver air bag module, between front passenger air bag module and air bag ECU are
equipped with protection mechanism to avoid the air bag to be deployed by accident. Follow the
instructions when operating the air bag system, otherwise the air bag may unfold by accident or
damages will be caused to components.
13. Follow the instructions on the components of the air bag system and the relevant positions inside the
vehicle while operating.
14. When the air bag system is under operation, put the air bag modules into the vehicle immediately when
they are taken out from the conveyer. If the operation is stopped, put the modules back to the conveyer;
do not place them into an overlooked place. Unfold the air bag and face it up when putting away the air
bag modules.
15. After operation, check the electricity and confirms there is no mistake first, and then connect the air bag
module with the circuit.
16. No one should be inside the vehicle when connecting the air bag system to the power supply. When the
air bag ECU is not fixed, do not connect it to the power supply.
17. Check if the SRS warning lamp is normal after operation.
18. For the service life of the air bag is limited (see the operating instructions), replace the air bag and
labels when the air bag reaches its service life time.
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Section IV Diagnosis & Fault Elimination
LF7132 air bag system can carry out self-diagnosis, and the basic diagnostic procedure is as follows:
I. Self-diagnosis of SRS warning lamp circuit

1. Turn the ignition switch to position ACC or ON, and check SRS warning lamp for illumination.
2. The system is ok if the warning lamp keeps light for about 5.5s and then dark and keeps unchanged.
3. The continuous illumination of the warning lamp indicates that single fault or multiple faults have been
detected, then read out DTC and clear off the faults as per part II in this section.
4. If SRS warning lamp illuminates sometimes after connected with the ignition switch for 5s, or SRS
warning lamp illuminates again even the ignition switch has been turned to position LOCK, check SRS
warning lamp circuit for short circuit as per Section 2.4.
II. Read out fault

Read out the fault by special hand-held diagnostic instrument
(1) Connect to the fault diagnostic interface of the vehicle.
(2) Read out the fault as per the indication shown in the diagnostic instrument.
III. Fault checking and repairing

Fault Checking & Repairing Methods Table 4-7
Table 4-7 Air bag fault checking and repairing
No. Fault Area Elimination
1. Preparation before checking.
2. Check the earth wire, if normal, go to the step 3; if loose or
Earth wire Earth wire
1 disconnected, repair it.
deficient harness
3. Check the harness, if normal, the parts with faults have been
recovered; if not, repair or renew the harness.
Voltage too
2 Battery 2. Check the battery voltage, if normal, the parts with faults
high
have been recovered; if too low, charge or renew the battery.
2. Check the driver air bag circuit; if normal, go to the step 3; if
not, go to 5.
3. Check the air bag ECU, if normal, go to 4; if not, renew the
Driver air bag air bag ECU.
module 4. Check the driver air bag module, if normal, the parts with
DAB
3 Clock spring faults have been recovered; if not, renew the driver air bag
inexistence
Harness module.
Air bag ECU 5. Check the clock spring, if normal, go to 6; if not, renew the
clock spring.
6. Check the harness between the air bag ECU and clock
spring, if normal, the parts with faults have been recovered; if
not, repair or renew the harness.
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Table 4-7 (continued)
No. Fault Area Elimination
2. Check the front passenger air bag circuit; if normal, go to 3;
if not, repair or renew the harness or interface between the air
Front passenger
bag ECU and front passenger air bag module.
PAB air bag module
4 3. Check the air bag ECU, if normal, go to 4; if not, renew the
inexistence Harness
air bag ECU.
Air bag ECU
4. Check the front passenger air bag module, if normal, the
parts with faults have been recovered; if not, renew the front
passenger air bag module.
2. Check driver safety belt pre-tensioner, if normal, go to 3; if
1. Driver safety not, repair or renew the harness or interface between air bag
belt ECU and driver safety belt pre-tensioner mould.
LPSB
5 pre-tensioner 3. Check air bag ECU, if normal, go to 4; if not, renew the air
inexistence
2. Harness bag ECU.
3. Air bag ECU 4. Check the driver safety belt pre-tensioner, if normal, the
parts with faults have been recovered; if not, renew the driver
safety belt pre-tensioner.
2. Check front passenger safety belt pre-tensioner circuit; if
1. Front normal, go to 3; if not, repair or renew the harness or interface
passenger safety between air bag ECU and front passenger safety belt
RPSB does belt pre-tensioner mould.
6
not exist pre-tensioner 3. Check the air bag ECU, if normal, go to 4; if not, renew air
2. Harness bag ECU.
3. Air bag ECU 4. Check front passenger safety belt pre-tensioner, if normal,
the parts with faults have been recovered; if not, renew the
front passenger safety belt pre-tensioner.
Simultaneo
us over 2 Related Diagnose and clear the fault one by one according to the flash
7
faults components DTC.
shown
1. Preparation before checking

Before maintenance, carefully read the section 1.3 about the safety rules for air bag maintenance. In
addition, following preparation work shall be carried out.
(1) Remove the negative ground wire from the battery and wait for at least 3 min.
(2) Remove the driver and front passenger air bag modules, keep the air bag module upwards when storing
the mould (See the removal methods in Section IV).
(3) Disconnect the interface of the driver and front passenger air bag modules, air bag ECU interface, as
shown in Fig. 4-24.
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2. Check for too low or too high voltage
Fig. 4-24 Interface
(1) Connect the negative ground wire on the battery, turn on the ignition switch at the position of ON.
(2) Measure the PW voltage at the end of the air bag harness.
(3) Normal voltage: 10-14V.
3. Check for harness and interface

(1) Exam the connection of the air bag harness. Check if the resistance is below 1Ω.
(2) Check whether the other harnesses and the corresponding terminals are connected.
(3) Check all the leads of the harness for damage.
(4) Check the interface of the harness for damage.
4. Check for air bag ECU

(1) Connect the air bag ECU with the air bag harness. See Fig. 5-8.
(2) Connect the negative ground wire to the battery, and wait for at least 3 min.
(3) Turn the ignition switch to the position of ACC or ON and wait for at least 20s.
(4) Eliminate the flash DTC by the diagnostic instrument and read out the flash DTC.
5. Check for the driver air bag module

(1) Turn the ignition switch to position LOCK.
(3) Connect the driver air bag module. See Fig. 4-25.
(4) Connect the negative ground wire on the battery and wait for at least 3 min.
Fig. 4-25 Install driver air bag module

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6. Check for driver air bag circuit

(1) Measure the resistance between the DA+ and DA- at one side of the clock spring. Normal resistance
shall be above 1MΩ.
(2) Measure the resistance between the DA+ at one side of the clock spring and DA+ at one side of the air
bag ECU. Normal resistance shall be within 1MΩ.
(3) Measure the resistance between DA- at one side of the clock spring and DA- at one side of the air bag
ECU. Normal resistance shall be within 1MΩ.
7. Check for front passenger air bag module

(3) Connect the interface of the front passenger air bag module.
8. Check for front passenger air bag circuit

(1) Measure the resistance between the PA+ and PA- at one side of the air bag ECU. Normal resistance
(2) Measure the resistance between the PA+ at one side of the air bag ECU and PA+ at one side of the front
passenger air bag module. Normal resistance shall be within 1MΩ.
(3) Measure the resistance between the PA- at one side of the air bag ECU and PA- at one side of the front
passenger air bag module. Normal resistance shall be within 1MΩ.
9. Check for driver safety belt pre-tensioner

(3) Connect the interface on the driver safety belt pre-tensioner. See Fig. 4-26.
Fig. 4-26 Connect driver’s safety belt pretensioner interface

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10. Check for driver safety belt pre-tensioner

(1) Measure the resistance between the RLP+ and RLP- at one side of the air bag ECU. Normal resistance
(2) Measure the resistance between the RLP+ at one side of the air bag ECU and RLP+ at one side of the
driver safety belt pre-tensioner. Normal resistance shall be within 1Ω.
(3) Measure the resistance between the RLP- at one side of the air bag ECU and RLP- at one side of the
driver safety belt pre-tensioner. Normal resistance shall be within 1Ω.
11. Check for front passenger safety belt pre-tensioner

(3) Connect the interface on the front passenger safety belt pre-tensioner. See Fig. 4-26.
12. Check for front passenger safety belt pre-tensioner circuit

(1) Measure the resistance between the RRP+ and RRP- at one side of the air bag ECU. Normal resistance
(2) Measure the resistance between the RRP+ at one side of the air bag ECU and RRP+ at one side of the
front passenger safety belt pre-tensioner. Normal resistance shall be within 1Ω.
(3) Measure the resistance between the RRP- at one side of the air bag ECU and RRP- at one side of the
front passenger safety belt pre-tensioner. Normal resistance shall be within 1Ω.
13. Check for clock spring

(1) Unplug the interface between the air bag ECU and the clock spring. See Fig. 4-25.
(2) Measure the resistance at one side of the air bag ECU. Normal resistance shall be above 1Ω.
(3) Measure the resistance between the A+ at one side of the clock spring and A+ at one side of the air bag
ECU. Normal resistance shall be within 1Ω.
(4) Measure the resistance between the A- at one side of the clock spring and A- at one side of the air bag
ECU. Normal resistance shall be within 1Ω.
IV. Check for SRS alarm light circuit fault

In the normal conditions, when the ignition switch turns from the position LOCK to ON, the SRS warning
lamp shall keep lighting for 5.5s, and then go out automatically; If there is any faults in the air bag system,
the SRS warning lamp will keep lighting and never go out. Read out the flash DTC according to the normal
process.
Provided that the lamp keeps lighting when the ignition switch is at the position of LOCK, or keeps dark
when the switch is at the position of ACC or ON, there must be malfunctions in the SRS warning lamp
circuit. With reference to the air bag system wiring diagram (see Fig. 4-23), check the circuit as per the
Ver：LF-20121225
following process.
1. Check for constant illumination when ignition switch at LOCK
(3) Unplug the air bag ECU interface.
(4) Connect the ground wire to the battery negative pole and wait for at least 3 min.
(5) Check whether the SRS warning lamp goes out or not. If it goes out, the air bag ECU shall be renewed;
if not, check the SRS warning lamp circuit.
2. Check for SRS warning lamp circuit

Before checking the SRS warning lamp circuit, exam the fuse of the engine ECU; if the fuse has been
burned out, it shall be renewed; if it works normally, go to the following checking process.
(1) Preparation before checking.

(3) Turn the ignition switch to position ON.
(4) Measure the voltage between the LA pin of the air bag ECU and the vehicle body.
(5) Normal voltage: 0-4V. If the voltage is abnormal, check the SRS warning lamp or repair the SRS
warning lamp circuit. If normal, go to the following process.
(7) Connect the air bag ECU interface. See Fig. 4-27.
Fig. 4-27 Connect air bag ECU interface

(9) Turn the ignition switch to position ON.
(10) Observe whether the SRS warning lamp is lighted or not; if lighted, the malfunctions have been
cleared; if not, check the LA terminal of the air bag ECU. If normal, the air bag ECU shall be renewed.
Section V Removal and Installation
Note: Make the following preparations before removal and installation:

1. Locate the ignition switch in position LOCK, and encrypt the air bag SRS ECU with diagnostic
instrument.
2. Locate the ignition switch in position LOCK.
3. Remove the negative ground wire from the battery and wait for at least 3 min.
I. Removal and installation of air bag ECU assembly

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Note: Forbid to open the housing of air bag ECU assembly unless absolutely necessary. The integrated
circuit may be damaged in case of contact with its terminal.
1. Tips for removal of air bag ECU assembly

(1) Unplug the interface. Note: Unplug the interface under the state of installation for ECU assembly.
(2) Remove the screws with wrench and take off the air bag ECU assembly.
2. Tips for installation of air bag ECU assembly

(1) Install the air bag ECU assembly with wrench at the correct direction. Note: Make sure the screwing
torque is 10 N·m.
(2) Connect interface.
3. Check after installation

After installation, shake the air bag ECU assembly to check the tightness.
II. Notes for removal, installation and maintenance of driver air bag module (DAB)
1. Removal process and notes
(1) Locate the ignition switch in position LOCK.
(2) Disconnect the battery negative cable for more than 3 min.
(3) Remove the two hexagon flange bolts at the left and right sides of steering wheel hub.
(4) Pull the driver air bag module from the steering wheel, and disconnect the interface of clock spring with
the terminal of gas generator
(5) Disconnect the interface of horn wire, and take out the air bag module. Removal is finished.
Note: Take care not to haul the air bag harness when removing the driver air bag module and keep the
ornamental cap upwards when storing the mould. Disassembling the driver air bag module is not allowed.
Do not knock the air bag module. If knocked, install a new one. Forbid exposing the mould under the
temperature over 90°C, and contact with lubricants, lubricant grease as well as water. Seal the old mould
removed in a sealing bag, and return it to Lifan Passenger Car Co., Ltd.
2. Installation and notes

(1) Install a new driver air bag module, and plug the interface between the clock spring and gas generator.
Note: Clip the yellow interface buckle into gas generator, and make sure it is well installed. Then plug the
horn wire interface.
(2) Place the whole mould in the steering wheel, adjust the position of the air bag module and ensure the
equality of the gap at the four corners. And then screw two hexagon bolts into the corresponding position
using hexagon socket wrench at the torque of 8N·m.
(3) Check the middle of steering wheel. After installation, gently revolve the steering wheel to left and right,
making sure that no noise or something abnormal exists.
3. Maintenance and notes

For the driver air bag module of the LF7162, there is no need for maintenance of any part except repairing
and changing the horn. If trouble occurs, install a new one.
Note: Make sure that new component is installed by the professionals at the designated service center.
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III. Notes for removal, installation and maintenance of front passenger air bag module
(PAB)
(2) Disconnect the negative cable of the battery for more than 3 min.
(3) Remove the trim strip of the sundries box door in the sundries box of dash board, unscrew the bolts
connecting front passenger air bag module with tubular beam by the wrench.
Note: When handling the air bag interface, take care not to damage the air bag harness.
(4) When dismantling the sundries box of dash board, gently uplift the dash board, and pick up the interface
in the air generator terminal of front passenger air bag with a mini-type straight screwdriver.
(5) Remove the front passenger air bag module. Dismantle the nuts fixing the front passenger air bag
module and dash board with a wrench, draw out the ropes tied on the front passenger air bag from the gap,
take out the front passenger air bag module from the top of the dash board. Seal the old front passenger air
bag module removed in a sealing bag, and return it to Chongqing Lifan Passenger Vehicle Co., Ltd.
Note: Forbid to disassemble the front passenger air bag module.
2. Installation steps and notes

(1) Install a new front passenger air bag module. Place the mould mount rightly into the corresponding
bolts on the dash board. And tighten the three flange locknuts with the wrench at the torque of 8N•m.
(2) After installing the dash board at the corresponding position in the car, plug the interface of air bag
harness into the corresponding air generator terminal of front passenger air bag module.
(3) Fix the dash board on the vehicle.
(4) At this moment, the installing hole at the bottom of the air bag module shall directly face the installing
hole at the tubular beam. Fix them with the bolt.
(5) Install sundries box
(6) After installation, watch the surface of dash board for its levelness. Check the clearance also. Reinstall
and adjust if unqualified.
Note: The installation and adjustment of the mould must be operated by professionals to avoid danger!
3. Notes for maintenance

For the driver air bag module of this model, there is no need of maintenance for front passenger air bag
module. Install a new one when trouble occurs.
Note: Make sure that new component is installed by the professionals at the designated service center.
IV. Notes for removal, installation and maintenance of clock spring
(1) Make sure that the road wheels are in the straight ahead position.
(3) Disconnect the negative cable of battery for more than 3 min.
(4) Dismantle the driver air bag module. Remove the M12 nuts fixing steering wheel with Φ19 socket, and
take down the steering wheel gently.
(5) Remove the screws on the cover of combination switch with cross screwdriver, and then take down the
cover of combination switch gently.
(6) Unplug the interface connected in the input jack of clock spring.
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(7) Remove the clock spring from the steering column, and pay attention to the two buckles fastening
the clock spring on the steering column. Seal the old clock spring removed in a sealing bag, and
return it to Chongqing Lifan Passenger Vehicle Co., Ltd.
2. The installation process and notes

Install a new air bag clock spring. Do not remove the lock piece before installing the steering wheel.
(1) Locate the clock spring to the steering column shaft.
(2) Press the clock spring downward with proper pressure, making the two plastic buckles and a metal
buckle engage in the corresponding mount of the steering column.
Note: Uneven force shall be avoided when engaging the two plastic buckles! If the buckles are broken, a
new clock spring is needed.
(3) Check whether the buckles of the clock spring are engaged in the corresponding position.
(4) Install the covers at the front and back of combination switch for the steering wheel, and tighten the 2
installation screws.
(5) Make sure that the road wheels are in the straight ahead position (refer to the installation instruction of
clock spring) and install the steering wheel. Then align the steering wheel with the mark on the main shaft
of steering column, and tighten the installation nuts of steering wheel. Adjust the direction if the steering
wheel is new, and then unplug the lock piece of clock spring.
Note: Callback for the lock piece of clock spring is needed!
(6) Connect the battery negative pole and turn the ignition switch to the position ON.
3. Notes for maintenance

For the air bag clock spring of LF7162, no maintenance and calibration is needed!
Chapter IV Vehicle Air Conditioning System

Air conditioner is to regulate air, making a control of temperature and humidity in closed space. Air
conditioner in modern vehicle is used to improve driving conditions and make passenger fell more
comfortable. As vehicle air conditioner is designed for its passengers, it focuses on comfort degree, which
is determined by the feeling and reaction of people in the vehicle on temperature, humidity, air velocity,
oxygen content, noxious gas content, noise, pressure, smell, dust, bacterium and so on. Current vehicle air
conditioner creates good condition and environment in it to improve driver’s work efficiency and driving
safety through adjusting the environment in the vehicle to a most suitable condition. In order to achieve all
the standards mentioned above, current vehicle should obtain all the functions and the necessary devices
shown in Fig. 4-8. All the devices can be used alone, as well as cooperate with others to complete the air
adjusting task.
LIFAN sedan air conditioning system provides an air condition system with all the functions including
refrigeration, heating and ventilation service. In summer, air conditioner works to cool down the
temperature in the vehicle; while in winter, heating device works to keep warm and defrost the glasses.
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Table 4-8 Functions of vehicle air conditioning system
Purpose Functions devices
Maintain favorable temperature Heating and cooling device
Maintaining favorable humidity Humidifying and dehumidifying
Maintain a comfortable
device
environment for passengers
Maintaining favorable air flow Air supply device
Maintaining clean air Ventilation device and air purifier
Remove the frost and mist from Defroster or demist equipment
Maintain a clear field of vision
front and rare window glasses
Section I Structure and Principle of Air Conditioning System
The principle of LIFAN sedan cooling system is shown as Fig. 4-28. Refrigerant fluid takes away the heat
in the vehicle from vaporizer. Then it is changed into low-pressure and low-temperature steam. At last it
was pumped in compressor. Compressor compresses the steam into high-temperature and high-pressure gas,
and then emits it into condenser. The gas cools down with the effect of the air in condenser and becomes
fluid after giving out heat. Water could be filtered when the fluid goes through reservoir. Before it goes into
vaporizer, both the pressure and temperature of refrigerant would decrease with choking effect of
expansion valve. The refrigerant fluid with low temperature and low pressure would change into gas again
by absorbing the heat in the vehicle. Then the gas would be absorbed in compressor. Air conditioning
system works in a cycle to cool down the temperature.
Fig. 4-28 Refrigeration mechanism
I. Cooling system
LIFAN sedan cooling system is mainly formed by compressor, Vaporizer, condenser, drying chamber,
expansion valve, air-blower, control structure and so on, as shown in Fig. 4-29. Vaporizer is the core of the
cooling system with the temperature lower than dew point of air. So the cooling system also can provide
dehumidifying service and pure air.
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Fig. 4-29 LIFAN sedan cooling system components

1-Condenser 2-Drying chamber 3-Safety vale 4-Air-blower 5-Vaporizer
6-Expansion valve 7-Conpressor
Main technical parameter of cooling system is shown in Fig. 4-9
Table 4-9 LF7132 Vehicle cooling system main technical parameters
Adjustment measures of temperature Temperature controller
Nominal cooling capacity 3,800W（3,267kcal/h）
Compressor WXH‐086 WXH‐086
86 86
Lubricant/mL PAG56 120ml
Magnetic clutch power consumption/W 44W
Air-blower Maximum quantity of wind（m/h） 380m3/h
Air regulation stick shift Gear III
Motor power consumption/W 230
Condenser Size (thickness×width×height)/mm 143×478×410
Heat exchange/W ≥10,200W（8,770kcal/h）
Air resistance/Pa ≤145pa
Fan motor current/A 5.6
Fan motor speed/(r/min) 2,700
Vaporizer Size (thick×width×height)/mm 351×280×366
Cooling capacity/W ≥3,800W（3267kcal/h）
Expansion valve External blance model
Drive belt 4PK815
Refrigerant fill amount/g 480g
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1. Compressor
(1) Compressor function
Compressor is the corn instrument of cooling system, which is to pump, compress refrigerant and recycle
the process.
○1 Suction function. Compressor reduces the pressure of refrigerant in evaporation hose through suction
(work with expansion valve choking effect), to achieve the conversation process from fluid to gas and take
away heat in the vehicle through absorption of heat.
○2 Compression function. Compressor compresses the low-pressure refrigerant gas to increase its pressure
and temperature. This could change the refrigerant from gas to fluid and take heat out of the vehicle
through condenser.
○3 Circulating pump function of compressor. The circulation of refrigerant could be achieved through
ceaselessly suction and compression, so compressor is regard as the power source of refrigerant circulation.
(2) The structure of compressor:
As shown in Fig. 4-30, LIFAN sedan air conditioner adopts scroll air conditioner compressor for vehicle.
Fig. 4-30 Structure of compressor

1-Compressor 2-Magnetic clutch
2. Condenser
(1) Condenser function
Condenser is to take out the heat of high-temperature and high pressure refrigerant gas from compressor so
as to transform refrigerant into fluid.
(2) The structure of condenser:
Condenser introduces the parallel flow structure. It is installed in the front of engine radiator. It works
forcibly throught radiator fan and the wind blew into the vehicle. Its structure is similar with engine
radiator. Cooling plates are added to condenser wall to increase radiating area. Refer to Fig. 4-31.
Fig. 4-31 Condenser
(3) The working process of condenser

Divide refrigeration process into three stages:
○1 High-temperature refrigerant gas transforms into saturated steam. Over-hot refrigerant steam would
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become saturated steam quickly by condenser pipe thermolysis.
② Saturated steam gas transforms into saturated fluid. During this process, the temperature will not change,
but large amount of heat would be emitted. Most heat generated in the circulation could be emitted in this
process.
③ Saturated fluid state refrigerant transform into saturated fluid. The temperature of saturate fluid state
refrigerant is higher than environment temperature, so the saturated fluid in condenser will be further
cooled.
3. Vaporizer
(1) The function of vaporizer:
Vaporizer could make the low pressure fluid state refrigerant change into steam by reducing pressure
process in expansion valve, and to cool down the temperature and achieve dehumidification effect in the
vehicle.
(2) The structure of vaporizer:
As shown in Fig. 4-32, vaporizer core of LIFAN sedan is installed inside the housing.
Fig. 4-32 Vaporizer

(3) The working process of vaporizer
After throttling and pressure reducing, refrigerant would change into saturate steam because of the low
pressure in vaporizer. During this process, both refrigerant pressure and evaporating temperature will not
change. The low temperature air around the vaporizer surface would be blowed into the vehicle to reduce
the temperature by air-blower.
4. Expansion valve
Expansion valve function:
Expansion valve could lower the pressure of high pressure refrigerant fluid by the choking effect. It can
automaticly adjust the refrigerant flow according to the temperature change of refrigerant flowed into
compressor. This could guarantee the refrigerant is gas before it flows into compressor.
5. Drying chamber
Drying chamber is used to absorb moisture, filter impurities and store refrigerant to make up the system
normal leakage.
Drying chamber is 1/3 of cooling system working medium volume. Silica gel desiccant is filled between
the two filters, and it could change color when it absorbs water.
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II. Heating system
LIFAN sedan heating system supplies heat by water. Housings of fan heater and vaporizer are connected
together. And it shares air-blower and air duct with cooling system. Its structure is shown in Fig. 4-33.
Fig. 4-33 Heating system

1-Blower 2-Evaporizer 3-Heater
Warm air-blower draws engine cooling water into radiator inside the heater. Then air-blower would blow
the heat into the vehicle or window glass to improve the temperature inside the vehicle and defrost. Heat
exchanger is the main component in heating system.
Heat exchanger is installed inside the heating system housing. High temperature cooling water flows into
heat exchanger from inlet, then flows out to pump connected with engine. The high heat cooling water
flows in circulation in heat exchanger. The heat emitted by it is sent into the vehicle or windowpane
through air duct with the effect of air-blower. The flow of heat exchanger cooling water is adjusted by
thermostat next to engine outlet, while the supply air temperature is controlled by fan speed controller and
output temperature adjustment switch.
Air duct of heating air unit contains four ventilation doors.

(1) One external loop recycling ventilation door is to control fresh air and circulation air, as well as the
temperature.
(2) One temperature adjustment ventilation door
(3) Two vehicle air distribution ventilation door.
As shown in Fig. 4-34, all four doors of air doors are charged by air conditioner control panel.
Fig.4-34 Air conditioner control panel
Section II Air Conditioner Control System

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I. Fundamental components of air conditioner control system
Air conditioner control system consists of power control circuit, compressor clutch control circuit, safety
control circuit, air conditioner control circuit layout and so on.
1. Thermostat (temperature switch)

Thermostat is a temperature control switch component of vehicle air conditioning system. It works by
detecting the temperature of vaporizer surface.
2. Pressure switch
Air conditioning system has a two-state pressure switch.
(1) When the refrigerant pressure is low (OFF). When the refrigerant pressure is lower than spring pressure,
the mental plate will bounce under the force of spring, and then disconnect the up and low contacts (OFF).
(2) Normal working (ON). When the refrigerant pressure is higher than spring pressure, mental plate would
move down to press the up contact, and then connect the tow contacts (ON).
(3) Refrigerant pressure too high (OFF). When the refrigerant pressure continues to increase and the up
contact is already in the limit position, the slipper block moves and then the metal plate moves, which will
disconnect the up and low contacts (OFF).
3. Magnetic clutch
Air conditioning system compressor works with engine main shaft through magnetic clutch. Magnetic
clutch determines the start and close of compressor. Therefore, magnetic clutch is the implementation
component in air conditioner automatic system, and is controlled by temperature switch, pressure switch,
speed relay, power switch and so on.
4. Air conditioner blower control device

Air conditioner blower is controlled by two parts. First, it is controlled by the A/C switch of air conditioner
blower relay, which is to synchronize the start of air conditioning system and the system work. Or, start air
conditioner blower first, and then turn on the A/C switch. Second, it is controlled by air flow switch of air
conditioner. The switch could make blower work in different rotation speed. Meanwhile, the heat air can be
used separately without using the cold air.
5. Control and adjustment device

Air conditioner computer or amplifier receives the signals of temperature, pressure, speed and so on, and
controls compressor, cooling fan, air-blower, and idle speed and so on.
6. Improve Magnetic clutch in idle speed condition

Turning on air conditioner at idle speed would result in engine flameout, because low engine rotation speed
and power output could not provide enough power to drive air conditioning system. What’s more, engine
can only generates a little power at idle speed, which could not meet the power demand of air conditioner
motor and compressor magnetic clutch. And this process would consume the power of battery, and cause
trouble for engine restart. As a result, an idle speed control solenoid valve installation on the position of
throttle body to open the throttle valve in the certain degree could increase the engine speed while the
compressor is working.
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7. Condensing fan relay
The relay is used to make condensing fan automaticly work when air conditioner switch is turned on.
Otherwise, the condensation temperature and pressure would be too high, and cooling system be destroyed.
Fan relay is controlled by cooling water temperature and A/C switch. Fan would work if one switch is
turned on.
II. Air conditioner control

1. Temperature control
The temperature control system consists of evaporator temperature sensor, air conditioner control box,
magnetic clutch and relevent circuits. Evaporator temperature sensor is a temperature characteristic
thermistor. When evaporator temperature changed, the resistance of sensor would also change to make air
conditioner control box receive the temperature corresponding to voltage signal. This signal would be
amplified with the effect of amplifier circuit in control box to control magnetic clutch relay. When
magnetic clutch relay turns on, compressor and magnetic clutch work together. Compressor works, air
conditioner works. When magnetic clutch relay turns off, compressor and magnetic clutch are disconnected,
compressor stops working, and air conditioner stops working.
2. Pressure control
Pressure control protects system working normally by pressure switch. Functions are shown below:
(1) Low pressure protection. When pressure <0.2MPa, disconnect the compressor.
(2) Over pressure protection. When pressure >3.14MPa, disconnect the compressor.
(3) Normal pressure. When pressure is 0.2MP-3.14MP, air conditioning system work normally.
(4) High pressure control. When pressure >0.17MPa, control fan rotating in high speed.
3. Engine cooling system (electric fan) control

Engine cooling system consists of water temperature sensor, water temperature control box, fan control
relay, electric fan switching relay and some related circuits. Control introductions are shown below:
(1) Water temperature at 93℃, radiator fan works.
(2) Water temperature at 96℃, condenser fan works.
(3) Water temperature at 110℃, disconnect the air conditioner and compressor circuit.
(4) When air conditioner switch is closed, condenser fan rotates in low speed.
(5) Cooling system pressure larger than 1.7MPa, electric fan rotates in high speed.
(6) If the water temperature signal is abnormal (water temperature sensor damaged), temperature control
box would think engine is in heavy load operation, and then make electric fan rotate in high speed.
Section III Air Conditioner Fault Diagnosis
I. Air conditioner fault diagnosis
1. Check by hand
You can check by your hands to touch the components and make diagnosis according to the temperature.
When you touch the high voltage loop (compressor outlet→condenser→reservoir→expansion valve inlet),
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the temperature should be a little hot. If one part is especially hot or temperature at inlet and outlet are
different, it indicates the part is blocked. When you touch low voltage loop (expansion valve
outlet→evaporator→compressor inlet), the temperature should be a little cold. If the compressor high and
low voltage sides have no temperature difference, this indicates no refrigerant in system.
2. Appearance inspection
Check whether oil stain exists in pipe joints, compressor oil seal, condenser and evaporator surface. The oil
stained indicates leakage existed in system.
3. Inspection from sight window

As shown in Table 4-10, check refrigerant from observation window installed on the high pressure pipe. In
normal condition, refrigerant should be clear without bubble, and the wind out of the air conditioner should
be cold. If everything is in normal condition, except the air outlet is hot, all the refrigerant is leaked. If
refrigerant is clear with bubbles, and the wind out of the air conditioner is not cold, it indicates refrigerant
is not enough.
Table 4-10 Observation window check
Refrigerant
volume Insufficient Appropriate Excessive
No refrigerant
Item refrigerant refrigerant refrigerant
High pressure side High pressure side
High and low High and low
temperature is temperature is little
pressure side pressure side High pressure
little higher than higher than low
pipeline temperature are side is over hot.
low pressure side pressure side
temperature the same
temperature temperature
Almost transparent.
Continuous Bubbles could be seen
bubbles are when engine speeds
No bubble.
generated. When up or down and air
Refrigerant is
Observe the refrigerant run Bubbles could be conditioning is
transparent and
condition inside out, bubbles seen every 1‐2 turn‐off. Then the
no bubble when
the window would disappear seconds bubbles would
air conditioner
but something gradually disappear.
is turned off.
like moist There is no distinction
bubbles flow. between the two
conditions.
High pressure Pressures in
Cooling system Pressures in both Pressures in both
side pressure is both sides are
pressure sides are low sides are normal
too low high
Put out
Check, repair,
Check and add excrescent
Solution vacuumize, add
refrigerant refrigerant from
refrigerant
low pressure
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repair valve.
4. Inspection by pressure gauge

Check when air inlet temperature is 30℃-35℃, engine rotate speed is 2,000r/min. Adjust to largest air
speed, and the normal condition is: pressure in high pressure side should up to 1.420MPa-1.470MPa; low
pressure side should be 0.147MPa-0.196MPa. If the pressure isn’t within the range, it indicates faults
existed in the system.
II. Air conditioner fault analysis

We often analyze pressure in cooling system for fault diagnosis. Besides, cooling effect and refrigerant
leakage are also the important check items: cooling system fault analysis table is shown in Table 4-11.
Table 4-11 Cooling system fault analysis table

Analysis Low High
pressur pressur Inspectio
e side e side n Suction pipe dehydrator Fluid pipe Output pipe Exhaust
pressur pressur window
Fault e e
R134a Very Very Comparative Comparative Comparative Comparative
Clear Warm
deficiency low low ly cold ly warm ly warm ly warm
R134a No Comparative
High High Cold Warm to hot Warm Warm to hot
excessive bubble ly cold
Compress Comparative
High Low Clear Cold Warm Warm Warm
or fault ly cold
Clear or
Comparative
Condenser bubbles
High High ly cold to Hot Hot Hot Warm
abnormal at some
warm
time
Cold,
Expansion
High or excessive Comparative
valve can’t High Clear Warm Warm Hot
normal sweating, ly cold
open
frost
Block
existed
The part
between Cold, Cold,
before the Comparative
condenser Low Low Clear Cold sweating or sweating or
block place ly cold
and frost frost
is hot
expansion
valve
Block High High, Clear Comparative Warm or hot Warm or hot Hot Warm
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existed normal ly cold to
between or low warm
compress
or and
condenser
Cold,
expansion
excessive
valve can’t Low Low Clear Warm Warm Hot Slightly cold
sweating in
closed
outlet, frost
Cold, little
Normal Normal Normal Clear Warm Warm Hot Cold
sweating
III. Air conditioning system common fault clearance

The cause and elimination of air conditioning system common fault are shown in Table 4-12.
Table 4-12 Air conditioning system fault elimination table

Phenomenon Reasons Solutions
Intermittent 1. System is blocked by ice; thermo‐bulb is 1. Check thermo‐bulb, change expansion
decrease of flexible or cankerous. valve, and change desiccant in system.
cooling 2. Relay, air‐blower engine fault. 2. Remove the faulty components, repair
system 3. Compressor clutch skids or change.
temperature 4. Line connection fault 3. Remove the clutch and readjust the
rooms.
4. Repair, if is possible.
1. Clutch noise 1. Remove and repair
2.Transmission strap noise 2. Tighten it or change another one.
3. Compressor noise 3. Check compressor tighten
4. Air‐blower noise components, repair or change
5. If refrigerant is filled too much, press the 4. Repair or replace a air‐blower
Loud noise in pipe, you can hear a tremulous noise, and a 5. Remove excessive refrigerant.
system hammering noise. 6. Check the leakage place, and inject the
6. Refrigerant is insufficient, evaporator inlet refrigerant.
has a noise. 7. Replace or add new oil
7. Oil is insufficient in compressor. 8. Improve its voltage
8. Clutch doesn’t have enough power. 9. Screw down installation bolts
9. Bolster bolts become flexible.
Compressor 1.System leakage 1. Check and repair
pressure 2. Expansion valve fault 2. Clear or change a new one
lower than 3. Insufficient refrigerant 3. Add refrigerant
normal level 4. Tank dehydrator block 4. Change
5. Compressor damage 5. Change
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Compressor 1. Air in the system 1. Vacuumize, and add refrigerant
pressure 2. Condenser block 2. Clear condenser
higher than 3. Condenser fan damage 3. Check fan
normal 4. Excessive refrigerant 4. Eliminate excessive refrigerant
level
1. Insufficient refrigerant 1. Inject refrigerant
suction
2. High pressure pipe block 2. Check tank, expansion valve
pressure too
3. Expansion valve damage 3. Change
low
4. Water in system 4. Change desiccation filter
1. Excessive refrigerant 1. Remove excessive refrigerant
Sunction 2. Evaporator inlet wind temperature is too 2. Reduce the wind volume
pressure is high
over high

1. Air‐blower connection fault 1. Reconnect
2. Insufficient voltage 2. Improve voltage
Air‐blower fault
3. Relay damage 3. Change
4. Engine damage 4. Change
1. Wire damage 1. Connect a new wire
2. Motor damage 2. Change
Condenser fan motor fault
3. Fan damage 3. Change
4. Fuse blow out 4. Check and change a new one
1. Insufficient refrigerant. 1. Inject refrigerant, until bubbles
Bubbles in sight window. High disappeared and pressure
pressure side pressure is so low. become normally
2. Expansion valve is block, then 2. Empty the system, clear it or
result in suction pressure lower, change
exhaust pressure higher. 3. Blow dusts out by compressor
Refrigeration effect is not so good 3. Evaporator blocked by dusts. 4. Clear out the dusts on the
4. Condenser patch is blocked by condenser
dusts. 5. Clear the air filter net
5. Air filter net is blocked. 6. Remove clutch, repair or
6. Compressor clutch skids. change
7. Air conditioner amplifier fault 7. Check air conditioner amplifier

Hose joint leakage 1. Hose leakage 1. Change
2. Joint becomes flexible 2. Change
3. O type ring damage 3. Change
1. Cooling water circulation pipe 1. Dredge pipe or change
Heated air not hot is blocked. condenser.
2. Cooling water circulation pipe 2. Refasten pipeline.
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is disconnected. 3. Check air‐blower speed
3. Air‐blower rotates in low regulation resistance.
speed. 4. Check air‐blower motor and its
4. Air‐blower is not work. circuits.
5. Mixed air door does not 5. Adjust mixed air door.
return.

1. Fuse is broken 1. Change a new one.
2. Wire or earth wire is 2. Check whether earth wires
disconnected become flexible or unglued;
3. Air‐blower engine is make sure all the wires are well
disconnected connected.
4. Clutch ring damage 3. Check whether air‐blower
5. Thermistor fault engine has current or not, then
6. Leakage exists in system decide if it needs to repair or
7. Tank desiccator is blocked change.
8. Expansion valve damage 4. Check whether clutch loop has
9. Compressor oil seal leakage current or not, then decide if it
10. Air conditioner amplifier needs to change.
compressor is not work 5. Check thermal resistor.
11. Transmission strap is flexible 6. Pump out the system, detect
No refrigeration or broken whether the system has leak
12. Pipe is blocked fault, then repair the leak point.
13. Air conditioner amplifier fault 7. Repair if it needs.
8. Check whether the
thermometer bulb is rusty, or
cling to the tail pipe of
evaporator.
9. Change compressor oil seal.
10. Remove compressor, then
repair or change.
11. Tighten or change
transmission strap.
12. Clear the pipe by compressor.
13. Check air conditioner
amplifier.
Section IV Air Conditioning System Diagnosis Repair and Maintenance
I. Use and maintenance of air conditioner

1. Air conditioner notes
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(1) When you use air conditioner，if the temperature is high in the vehicle, you should open the window.
And close the door when the hot air in the vehicle has been emitted;
(2) Close the doors and windows when using cooling function. This could reduce energy consumption to
achieve the needed temperature as soon as possible;
(3) In order to prevent air pollution inside the vehicle, you can open the window or vent to change air for a
while when you use a long time cool air;
(4) Choose a middle level engine speed when you make refrigeration during parking, which is good for
cooling and heat elimination;
(5) It is normal to find cooling water temperature a little high because of engine load increasing when
cooling system works;
(6) Make sure cooling system works once a week if it lay out for a long time, especially in winter. This
could protect compressor and seal with enough lubrication and make sure cooling system is always in an
optimal state;
(7) Make a regular inspection to engine, and make sure it works in order and prevent accumulator damage
because of over discharge.
2. Air conditioning system maintenance

(1) Routine maintenance
① Check compressor belt and its tension degree. Compressor belt abrasion, partial fracture or insufficient
tighten degree would affect the compressor normal work, or even result in cooling system stopping
working or refrigeration insufficiency. When belt is too loose or destroyed, remember to tighten or change a
new one.
② Check the connection between wire harness and linker. Short circuit, circuit break or poor contact of
wire harness and linker would affect the system normal work, even make the system stop working. Repair
or change once you find fault.
③ Check whether the pipe and joints have leak. Insufficient refrigerant is the main cause. Once you find
the leak point, fix it in time. Otherwise, it will affect system working.
④ Check whether the abnormal noise exists during system working. The abnormal noise is mostly from
compressor or clutch.
(2) Maintenance before using season:
① Check whether dust exists on the surface of condenser, evaporator. Clear it by water after removing the
dust, then blow it by compressed-air, if it is necessary.
② Check whether switches and electronic control system work normally. Repair or change once fault is
found.
③ Check whether the joints and fasteners are loose or broken. If it is necessary, change a new one or
tighten it.
④ Start work to check refrigerant, according to the steps below:
a. Inspection from sight window. Bubbles flow continuously, disappear or flow in state like moist, it
indicates refrigerant is seriously insufficient. If bubbles appear every 1-2 seconds, it indicates refrigerant is
insufficient. If bubbles appear when engine speed quickly changes, it indicates refrigerant is enough. No
bubble exists, it indicates refrigerant is excessive.
b. Check high and low pressure pipe side temperature. If there is no obvious difference between high, low
pressure pipe side temperatures, it indicates refrigerant is seriously insufficient. If high pressure side is
warm, low pressure side is cold, it indicates refrigerant is insufficient. If high pressure side is hot, low
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pressure side is cold, it indicates refrigerant is enough. If high pressure side is abnormally hot, it indicates
refrigerant is excessive.
c. Check high and low pressure side pressure. If the pressure of high pressure side is abnormally low, it
indicates that refrigerant is seriously insufficient. If both sides pressure are a little low, it indicates that
refrigerant is insufficient. If both sides pressure is normal, it indicates refrigerant is enough. If both sides
pressure is over high, it indicates refrigerant is excessive.
(3) Maintenance after using season:
① Check out leak by detector. If leak exists, try to find the cause and repair it, then inject refrigerant.
② Check compressor belt and Belt pulley bearing. Replace it if there is damage or abnormal sound.
③ Check cooling oil. Add some more, if it is necessary.
3. Refrigerant leak inspection

First visually check the refrigerant leak. And you can use detector if it is necessary.
1. Refrigerant leak inspection
(1) First check the compressor. Check the compressor and magnet clutch joint part and find the leak place
by touch or wipe with white gloves.
a. Check whether clutch and O seal ring are lost or have leakage problem.
b. Check whether compressor cylinder head has leakage, and compressor tank has damage.
c. Check whether oil filler plug on the compressor and O type seal ring on maintenance intake have
leakage.
d. Check all joints and detect whether it has leakage.
2. Refrigerant leak detector inspection
(1) When you use electric leak detector, make sure the detection probe approach the dubitable place as far
as you can. The distance should be in the range of 3mm. Make sure the probe removal speed is within
30Imm/s. Before using, make sure that the device could work; power and voltage are correct; and probe is
clear. Otherwise the detection could be invalid.
(2) Pay attention when you use the flame type leak detector. Poison gas would be generated from substance
burning when leakage is detected. So the detection process should be operated in ventilation condition.
II. Air conditioning system maintenance

In order to make sure air conditioning system is used under a good condition, proper inspection and
maintenance are necessary, as shown in Fig. 4-13. You should make sure position of heating control knob
is coherent with the actions of air doors on heater and air-blower, because the cooling system and heating
system use the same air flue. What’s more, no control valve exists in radiator of heater.
Table 4-13 Air conditioning system maintenance

Maintenance cycle
Maintenance
Content Use Nine
item Daily Weekly Monthly
season months
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Check refrigerant
Refrigerant
volume from sight ○ ○ ○
volume
window
1. Check whether hose
Refrigeration is broken
circulation 2. Check whether the
system joint part need tighten ○
Pipe
3. Check whether the ○
joint place is loose or
rub between bodywork
and chassis
Compressor Tighten the
installation components, if it is ○
situation necessary
Check the tension
Compressor
Compressor degree of compressor ○
belt
belt
Operate the air
Abnormal
conditioner, check the ○
noise
noise.
Clear heat sink and pipe
Condenser by compressed air or ○
water
Condenser
Check other
Condenser
instruments operation ○
fan engine
situation
Note: Refers to the item must be checked, adjusted and changed.
Chapter V Overall Lamps

The overall lamps of LF7132 include left and right group headlights, left and right rear group lights, front
fog light, rear fog light, luggage boot lamp, high-mounted brake lamp, as well as front group roof light. The
following are the maintenance disassembly sketch maps and principle figures of the overall lamps of
LF7132.
I. Overall lamps maintenance instruction
Table 4-14 Lamps maintenance

Fault
Fault Fault reason Solution
classification
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Expanding with
heat and
Headlight contracting with Change
assembly cold lead to
broken distortion
Mechanical
Change
damage
High beam broken Change
One high beam
Lamp holder ablation Check and repair the lamp holder
unlit
Connecting circuit broken Check and repair connecting circuit
Safety level of high beam Change safety level or check and repair
High beam broken connecting circuit
fault Two high beams High beam relay broken Change
unlit at the same Group switch broken Check and repair or change
time Two high beams broken Change
Connecting circuit open or
Check and repair connecting circuit
short
Low beam broken Change
One low beam
Lamp holder ablation Check and repair the lamp holder
unlit
Connecting circuit broken Check and repair connecting circuit
Low beam safety level Change safety level or check and repair
Low beam broken connecting circuit
fault Two low beams Low beam relay broken Change
unlit at the same Check and repair or change group
Group switch broken
time switch
Two low beams broken Change
Connecting circuit with
Check and repair connecting circuit
turnoff or short
Fault
Fault classification Fault reason Solutions
located
One or several steering
Change
lights broken
Steering signal indicator
Connecting circuit of
glittering fast Check and repair
steering light with turnoff
Steering light connecting circuit
or short
broken Safety level of steering
Change
light broken
All steering lights off Glitter relay broken Change
Check and repair
Connecting circuit broken
connecting circuit
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Front position lamp broken Change front position lamp

or connecting circuit or overhaul connecting
broken circuit
Front position
All steering lights off
lamp fault
Change safety level or
Safety level broken or
check and repair
connecting circuit broken
connecting circuit
Bulb broken or connecting Change bulbs or overhaul

circuit broken connecting circuit
Brake lamp Brake lamp switch broken Change
fault Check and repair
None of small lamps lit Connecting circuit broken
connecting circuit
All bulbs broken Change
Bulb broken Change
Check and repair
Reversing connecting circuit
Reversing light unlit
light fault Reversing light switch
Change
broken
Safety level broken Change
Fault
Fault classification Fault reason Solutions
located
Bulb broken Change
Left front fog light unlit Check and repair
connecting circuit
Bulb broken Change
Right front fog light unlit Check and repair
connecting circuit
Bulb broken Change
Check and repair
Rear fog light unlit Connecting circuit broken
connecting circuit
Fog light Fog light switch broken Change
assembly Bulb broken Change
Right rear fog light unlit Check and repair
connecting circuit
All bulbs broken Change
All front fog lights unlit Check and repair
connecting circuit
Safety level broken Change
Fog light relay broken Change
All fog lights unlit
Front fog light switch
Change
broken
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II. Disassembly sketch map
1. Install headlights into the proper position first when fixing the headlight assembly, and then fix the lights
with 3 sets of bolt group components.
2. Both high beam and low beam bulbs adopt model H1 (12V 55W). When installing, you must align the
heave part and the sunken part of bulbs, and then fix with spring steer wire.
3. The light beam of low beam and high beam can be adjusted by the two knobs on the group light
assembly.
4. Position indicator bulbs (12V 5W) adopt interface model, while steering lights bulbs is 12V 21W.
5. Rear group light assembly includes rear position light, steering light, and the combination of brake lamps.
Rear position light and brake lamp adopts combination bulbs of 12V 5W/21W. When install, you should
fix the lamps to the rear body with the cross recessed screw, gasket combinations and a buckle.
6. Reversing light, rear position light, steering light and brake lamp adopt bulbs of 12V, 21W.
7. Roof lamp is fixed in the middle of the cab with 2 taps, and the bulb is vasiform with 12V, 10W.
8. Front fog lights are fixed on the front bumper with 2 Q32006nuts separately, adopting H3 bulbs (12V,
55W).
9. Rear fog light and reversing light assembly is the combination of rear fog light and reversing light, with
bulbs of 12V, 21W. When installing, fix them to the rear bumper with 2 hexagon flange face nuts.
10. High-mounted brake lamp and spoiler assembly are fixed on the rear luggage boot cap with 4 hexagon
flange face nuts. High-mounted brake lamp adopts LED.
Fig. 4-35 Luggage boot light Fig. 4-36 License plate lamp assembly
1-Bulb 2-Lamp holder 1-Bulb 2-Lampshade
3-Cross recessed screw and gasket combination
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Fig. 4-37 Left front group lamps assembly Fig. 4-38 Left rear group lamps
1- Hexagon bolt, spring gasket and gasket combination 1-Cross recessed screw and gasket combination
2-Left front group lamps 3-Bulbs 4-Bulbs 5-Bulbs 2-Left and right group lamps 3-Bulbs
Fig. 4-39 Front roof light Fig. 4-40 Rear fog light and reversing light assembly
1-Bulbs 2-Front roof light 1-Lampshade 2- Hexagon flange face nuts 3-Bulbs
3-Hexagon flange face nuts
Fig. 4-41 Left front fog light Fig. 4-42 High-mounted brake lamp and spoiler assembly
1-Lampshad e 2-Bulbs 1- High-mounted brake 2- Spoiler
Chapter VI Charge System

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I. Generator structure and principle

Generator is the main power supply of a vehicle, and it generates electricity by pulley. When the generator
generates electricity normally, it not only supply the electro-equipments, but also the battery to ensure there
is enough electricity when starting the engine next time.
1. Generator composing
The generators of LIFAN sedans are adjuster inner installed silicon rectifier generators, mainly including
rotor (pole), stator (armature), rectifier, adjuster, brush and brush carrier. The generator composing is
shown in Fig. 4-43.
Fig. 4-43 Generator composing

1-Rotor 2- Stator 3-Silicon rectifier
4-Adjuster 5-Bearing and cap 6-Brush and brush carrier
(1) Rotor: Rotor is the pole of generator, with the effect that it can bring current through brush and slip
ring and create a revolving magnetic field. Rotor is made up of unguiform iron core and exciting winding
and the two slip rings on the axis of the rotor are connected with two ends of exciting winding.
(2) Stator: Stator is the armature of the generator, with the effect of producing faradism electromotive
force in the revolving magnetic field. The stator is also made of iron core and winding, with 3 windings
symmetrically installed, and connecting as a triangle.
(3) Silicon rectifier: The effect of silicon rectifier is to commute the three-phase alternating current made
by generator armature winding into direct current. The generator silicon rectifier of LIFAN sedans has 9
diodes, including 6 high-power diodes to form the three-phase bridge rectification circuit offering
rectification to generator, and 3 low-power diodes to form bridge rectification circuit offering magnetizing
current to exciting winding
(4) Adjuster: The effect of adjuster is to stabilize the pressure of the generator through adjusting
magnetizing current when the engine rev changed. The purpose is to ensure electro-equipments can work
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normally. The adjuster is made up of molectron and a high-power audion.
(5) Brush and brush carrier: The functions of brush and brush carrier are to bring direct current in to
rotational exciting winding. Depended on the spring of the brush fame, the brush is contacted with the slip
ring on the rotor well.
2. Generator working principle

The generator circuit principle of LIFAN sedans is shown in Fig. 4-44.
Fig. 4-44 Generator circuit principle

1-Battery 2-Ignition switches 3-Charge indicator
4- Generator assembly 5-Adjustor 6-Brush and slip ring (linked with exciting winding)
7-High-power adjustor switch audion
(1) Power generation principle: The exciting winding of the generator brings direct current through brush
and slip ring. When the generator is running, there will be a revolving magnetic field within the generator.
And the stator winding installed symmetrically incises the magnetic line of force to create an, which is
shown in Fig. 4-45 (a).
(2) Commutating principle of rectifier: The three-phase bridge rectification circuit made up of VD1,
VD3, VD5, VD2, VD4 and VD6 commutes the three-phase alternating electromotive force created by
armature winding to be direct current to export to electro-equipments and accumulator (Fig. 4-45b). While
the three-phase bridge rectification circuit made up of VD7, VD8, VD9, VD2, VD4 and VD6 is mainly
used to offer magnetizing current to the exciting winding of the generator.
(3) Magnetizing mode of the generator: Before the generator builds the pressure, the accumulator will
offer magnetizing current (separate excitation) to the exciting winding through ignition switches, brush, slip
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ring and adjuster (switch audion); when the generator achieves certain rotation speed, and the direct current
pressure accumulated by the generator is higher than the accumulator pressure, the three-phase bridge
rectification circuit made up of VD7, VD8, VD9, VD2, VD4 and VD6 offers magnetizing current
(self-excitation).
Fig. 4-45 Voltage fluctuation waveforms

a) Armature winding electromotive force
b) Voltage fluctuation waveforms after commuted
3. Adjuster working principle

(1) Effects of adjuster: The relation of the induction electromotive force created by the armature winding of
the generator, the rotation speed and the magnetic field strength is positive correlation, so the terminal
voltage after commuted, the rev and the magnetic field strength is positive correlation. When the generator
is running, the rotation speed is changed in a biggish extension, which makes the pressure change all the
time, and can’t fulfill the use requirements. The effects of the adjuster are to make the pressure stable
through adjusting the magnetic field strength, when the rev is changing.
(2) The stabilized voltage principle of the adjuster：The import of the adjuster brings to the pressure of the
generator, and the high-power audion of the adjuster is in series in the energizing loop of the generator (Fig.
4-44). Only if the audion is connected, the energizing loop would be connected. The adjusting process of
the adjuster as follows:
1) When the rotation speed is low and the pressure is lower than the designed pressure, the electron circuit
of the adjuster makes the high-power audion saturate and connect, and the exciting winding is connected to
offer magnetizing current by accumulator or the rectification circuit of the generator.
2) When the generator achieves certain rotation speed and the pressure of the generator achieves the
working pressure of the adjuster, the electron circuit makes the high-power audion stop and change
alternately all the time, and the pressure of the generator waves in a certain extension of up limited and
down limited (Fig. 4-46) to keep its average pressure in the design level.
3) when the rotation speed of the engine is up，the pressure of the engine is ascended fast and descended
slowly, which makes the connected time of the high-power audion of the adjuster reduced, and the stop
time is increased. It makes the average magnetizing current of the engine descended and the intensity of
magnetic field weaken, which makes the pressure of the engine keep stable. The rotation speed changing
condition of the pressure and magnetizing current with adjuster is shown in Fig. 4-47.
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Fig. 4-46 Engine pressure wave in a certain rotation speed with adjuster
U1-Up-limited voltage which makes the switch audion of the adjuster connected
U2-Down-limited voltage which makes the switch audion of the adjuster stopped
Fig. 4-47 Working characteristics of the engine with pressure adjuster

n1- Rotation speed when the adjuster starts adjusting
nmax- Rotation speed when the adjuster loses effect
4. Charge indicator working principle

When turn on the ignition switch but not start, the input end of the adjuster is the battery pressure, which is
lower than the adjusted pressure. Then the power transistor is connected to form a loop from the anode of
the battery to ignition switch, charge indicator, magnetic field winding, and large power transistor to the
ground circuit to light the charge indicator. When the engine is started and the pressure of the engine is
reached or upper than the pressure of battery, the two ends of the charge indicator are the terminal pressure
of the engine, which means the charge indicator has gone out for out of pressure, and indicates that the
generator is generating normally.
When the generator doesn’t work, the two ends of the charge indicator would be lighted which indicates
there is some fault in charge system.
5. Engine model and performance parameter of LIFAN sedans

The engine performance parameters are:
The standard pressure is 14V.
The regulation voltage is 13.5V-14.5V.
II. Frequent fault and troubleshooting

1. Charge indicator on all the time
When the engine is started, the charge indicator on the instrumentation panel is on all the time or the charge
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indicator is on when the engine is running normally, which both indicate that there is a no charge fault in
the engine.
(1) Fault reasons: The possible fault reasons are the following:
1) Generator fault, for example there is short or turnoff or ground circuit in armature winding or generator
magnetizing field.
2) Adjuster fault, the interior electron components of the adjuster broken make the high-power audion not
connected.
3) Driving belt of the generator is loose. The generator isn’t running or the rotation speed is too low for the
skid of the driving belt.
(2) Troubleshooting: Check whether the driving belt is slip, and if it is normal, please check the generator
and adjuster.
2. Charge indicator off

When you turn on the ignition switch and the generator is running normally, but the charge indicator is off
all the time which indicates the charge system is not charging well or there is a not-charging fault.
(1) Fault reasons: The possible fault reasons are the followings:
1) The brush and slip ring of the generator is not connected well.
2) The interior electron components of the adjuster broken make the high-power audion not be connected
or the circuit of high-power audion open.
3) Short circuit in commutation diode
4) The circuit of charge indicator is turning off, for example, there is connecting problems among the fuse,
charge indicator, magnetic field wiring terminal and the ignition switch.
(2) Troubleshooting: The troubleshooting of not-light charge indicator are as follows:
1) When the ignition switch is not on, check the voltage to earth of the magnetic field wiring terminal of the
generator. The normal voltage should be 0. If there is battery voltage, it means that there is short of
commutation diode, you should dismantle and check the generator; if the voltage is 0, take the next check.
2) Check the voltage to earth of the magnetic field wiring terminal of the generator after switching on the
ignition switch. The normal voltage should be the battery voltage. If the pressure was 0 still, check the
circuit of charge indicator; if the voltage is 0, take the next check.
3) Dismantle and check whether the connection of the brush and slip ring is good or whether the magnetic
field winding is turning off, if there is no problem, please repair or change the adjuster.
3. Normal charge indicator but not charging of generator or charge fault

The charge indicator is on when turn on the ignition switch and can be off after the generator is started and
when the generator is running, but there is a decrease of electricity in battery soon.
(1) Fault reasons: The possible fault reasons are the followings:
1) Bad power generation of generator
2) Too low regulation voltage of the adjuster or faulty interior circuit
3) Bad connection of charge circuit from the generator to battery
4) Serious sulfuration of battery plate
5) Local action fault of battery or creepage of electric appliances and circuit
(2) Troubleshooting: Troubleshoot in the following steps:
1) Check the voltage to earth of the armature terminal stud with volts DC gear of multimeter. The normal
voltage should be battery voltage. If the voltage is 0, it means that the circuit from the armature terminal
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stud to the battery is turning off, please check and repair; if the voltage is normal, do the next check. .
2) Start the generator to make the engine run at a medium speed. When the charge indicator is off, check
the earth pressure of the armature stud. If the pressure is battery voltage still, check and repair the generator
and adjuster; if the pressure increases, do the next check.
3) Check the output current and terminal voltage of the generator when the engine is running above
medium speed, which is shown in Fig. 4-48. If the voltage can be 13.8V-14.5V when the rotation speed of
the engine is raised and there is a biggish charge current indicated by the ampere meter, it means that the
generator and the adjuster are normal and the reason of a quick decrease of electricity in battery may be the
battery fault or creepage fault of electric appliances and circuit, please check them; if the voltage can
achieve 13.8V-14.5V quickly, but there is not charge current or little charge current, please check the
circuit from the armature terminal stud to the battery; if not, there may be a serious sulfuration of battery
plate.
Fig. 4-48 Check the fault of generator and charge circuit

1-Check the earth pressure of the armature terminal stud 2-Check the charge current of the engine
3-Ignition switches 4-Check the earth pressure of magnetic field stud
4. Too large charge current of the engine

The bulbs are easy to be burned, the temperature of the battery is too high and the electrolyte is used too
fast, which all mean the charge current of the engine is too large.
(1) Fault reason: too high regulation voltage of the adjuster or invalidation of the adjuster
(2) Troubleshooting: If you can ensure there are no other reasons that bulbs are easy to be burned, the
temperature of the battery is too high and the electrolyte is used too fast, you should dismantle the
generator and change the adjuster.
5. Unstable charge current

When the engine is running stably, the charge indicator is flashing or the intensity of illumination of the
headlights is changing at times when the lights are on in the night, which means the charge current of the
charge system is instable.
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(1) Fault reasons: The reasons for unstable charge current are:
1) Bad connection of brush and slip ring
2) Bad pressure adjuster of the engine
3) Bad connection for a loose connection of the external circuit or the interior circuit
(2) Troubleshooting: Fix a headlight bulb between the armature terminal stud and the ground circuit (Fig.
4-49) to make the generator running in a medium speed. If the bulb is flashing still, it means that there is
bad connections in the interior circuit of the generator, the brush and lip ring or the pressure adjuster, you
should dismantle and check the generator; if the brightness is stable, the fault may be a loose connection in
output circuit of the generator or rust in contact surface, please check and repair it.
Fig.4-49 Check the generating stability of the generator

1-Check bulbs 2-Charge indicator of the generator 3-Ignition switches
III. Check and repair the generator

1. Disassembly and decomposition of generator
(1) Disassembly of generator: After loosening the binding bolt on the front and rear brackets as well as the
tensioning brackets, you can disassemble the generator.
(2) Decomposition: The disassembly figure is Fig. 4-50, and the disassembly methods are as follows:
1) Disassemble the connecting bolt of the front and rear end closures, and dispart the front and rear end
closures and the pontes.
2) Tear down the end line joint of stator winding, and take out it from the rear end closure.
3) Tear down the binding nuts and bolts of the brush, and then take off the adjuster and the brush brackets
discreteness.
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Fig. 4-50 Generator and its parts related to installation

1-Generator 2-Driving belt of generator 3-Rear brackets of generator 4-Front bracket
5-Tensioning bracket 6-Tensioning bracket discreteness 7-bracket 8, 9-Jackets
10, 11, 12, 15-Screws 13, 14- Bolts 16, 17, 19-Washers
18-Wave spring washers 20, 21, 22-Nuts
2. Rotor overhauling
(1) Common rotor fault:
1) The surface of slip ring smudged and ablated makes bad connection between brush and slip ring, also
cutout or decrease of magnetizing current, which leads to no generation or bad generation.
2) Short, open or ground circuit of magnetic field winding make the rotor can’t produce electromagnetic
field or a decrease of magnetic field, which leads to no or bad power generation.
(2) Check and repair methods are as follows:

1) Check whether the surface of the rotor is clean or not, if there is oil stain, you can clean it with a piece of
cloth wetted with gas; if there is burn or nick, you can burnish with “00” emery cloth.
2) Check whether there is open and short circuit in the rotor winding. Check the resistance between the two
slip rings with the ohms range of multimeter, which is shown in Fig. 4-51. The normal resistance value
should be about 3Ω. Too little resistance means short circuit in rotor winding, and the resistance value is ∞
means turnoff of rotor winding.
Fig. 4-51 Short of rotor winding

3) Check whether there is earth wire in rotor winding and measure the resistance between the slip ring and
the rotor bearing, which is shown in Fig. 4-52. The normal resistance should be disconnected. If it is
connected, it means that there is a short circuit fault in the winding or slip ring.
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If there is fault in rotor winding, please change the rotor assembly.
Fig. 4-52 Ground circuit of rotor winding

3. Check and repair stator
(1) Common faults: short, open or ground circuit of armature winding leads to no or bad power generation.
(2) The check and repair methods are as follows:

1) Measure the resistance between the line ends of stator winding with the ohms range of multimeter to
check whether there is open circuit in stator winding (Fig. 4-53). The normal condition is closed circuit, or
it means there is turnoff in the winding, please change the stator.
Fig. 4-53 Check the turnoff of stator winding
2) Measure the resistance between the line end of the stator winding and the iron core with the ohms range
of multimeter to check whether there is ground circuit in stator winding (Fig. 4-54). The normal condition
should be unconnected. If the closed circuit or the resistance is less than 50MΩ, it means that there is a
ground circuit fault or bad insulation, and you should change the stator.
Fig. 4-54 Ground circuit overhauling of stator winding
4. Check and repair brush and brush carrier

(1) Common fault:
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1) Overweared brush makes bad connection between the brush and slip ring as the contact pressure
decreased, also cut or decrease of magnetizing current, which leads to no or bad power generation.
2) Invalidated spring in the brackets makes bad connection between the brush and slip ring as the contact
pressure decreased, also cut or decrease of magnetizing current, which leads to no or bad power generation.
3) Distortion of the bracket or dunghill in the bracket trough makes the brush blocked, and bad connection
with slip ring, which leads to no generation or bad generation.
(2) Check and repair methods are as follows:

1) Check the length of the brush. If the exposed part between the brush and bracket is less than 5mm, it
means that the brush has been overweared, and the brush should be changed.
2) Check whether the brush can slip freely in the brush bracket, or whether the brush has a certain spring
pressure. If there is bad condition, please change it.
5. Rectifier overhauling
(1) Common fault: short and turnoff of commutation diode leads to bad generation or no generation.
(2) Check and repair: measure the forward and reverse resistance of each commutation diode with the
resistance range of multimeter. The normal condition is that the difference is very big. If the forward and
reverse resistance of some commutation diode is ∞, it means that there is a turnoff in the diode; if the
forward and reverse resistance is 0, it means there is a short in the diode. You should change the rectifier in
both conditions.
6. Assembly and installation

The generator must be assembled and installed in the opposite order of decomposition and disassembly.
When install the bearing, you should smear the lube on it.
7. Performance check of generator and adjuster

(1) Output current check methods are as follows:
1) Check whether the battery is charging. If it is undercharging, you should makeup. This check must be
done under the condition of full charging.
2) If you turn on the ignition switch, charge indicator is on and start the engine, charge indicator is off, and
then you can take the next performance check of the generator. Or there is fault in the charge system, you
should solve it.
3) Connect a voltmeter, an ampere meter and a rheostat into the output circuit of the generator, which is
shown in Fig. 4-55.
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Fig. 4-55 Performance check of generator and adjuster

1-Voltmeter 2-Ignition switch 3- Rheostat
4- Ampere meter 5-Charge indicator
4) When the engine is in a normal work temperature, make the rotation speed of the engine stable in
2,000r/min, 3,000r/min, and 4,000r/min. Adjust the resistor in the stable-rotation speed condition to make
the terminal voltage is 13.5V, and then check the output current. The output current in stable-rotation speed
condition is shown in Table 4-15.
If it can’t achieve the value listed in the Table 4-15, please check and repair the generator.
Table 4-15 Output current when the terminal voltage is 13.5
Rotation speed (r/min) 2,000 3,000 4,000

Terminal voltage (V) 13.5 13.5 13.5
Level 8 49 62 68
Output current (A)
Level 9 62 76 83
(2) Performance check methods of adjuster are as follows:

1) Connect the voltmeter and rheostat according to Fig. 4-55.
2) Adjust the rheostat to 0 (R=∞), and cut off all the electro-equipments.
3) In the condition that the battery is full charged and the engine achieves its normal work temperature,
make the rotation speed of the engine stable in 5,000r/m, and then pay attention to the pressure indicated by
voltmeter.
If the pressure is more than 14.7V, it means that the adjuster is performed badly or damaged fully, please
change it.
8. Notes in generator check and repair
(1) When the engine is running, please don’t cut off the cable of the battery to avoid burning out the
commute diode and damaging other electron components caused by excessive pressure.
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(2) When the generator is running, please don’t check the generation of the generator by the way of
spurting fire, which may damage the commute diode.
(3) Please cut off the connection between the commute diode and armature winding first, if you check the
insulation performance of the armature winding with the alternating light of 220V and megohmmeter.
Otherwise it will damage the commute diode.
(4) Do not turn on the ignition switch for long time in the condition of the off engine, because the battery
will discharge the magnetic field winding continuously, which not only wastes the energy of the battery,
but also may damage the magnetic field winding.
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Part V Transmission Maintenance

I. LF479Q3-1700000A4 transmission assembly profile drawing:
II. Main technical parameters

Model and parameters LF479Q3-1700000A4
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Transmission ratio: Z2:Z1 main drive 63：16=3.938
I gear 35：11=3.181
II gear 35：19=1.842
III gear 35：28=1.250
IV gear 33：36=0.917
V gear 29：41=0.707
Reverse gear 44：14=3.142
Lubricant model SAE80W-90 gear oil
Lubricant capacity 2.1~2.25L
Maximum torque 110N∙m
Maximum rotation speed 6000 r/min
Rated power 63 KW
Central distance 63 mm
Gear number 20
Modulus 1
Input shaft spline Pressure angle 30°
Major diameter
φ 21(-0.01/-0.3)
Minor diameter φ18.2
External dimension (L×b×h) 432×353.5×354
Weight (including gear oil and bracket) 29.3Kg

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III. Operation principle illustration:
1. 5th gear synchronizer
2. 5th gear synchronizing ring
3. 5th gear drive gear
4. 4th gear drive gear
5. 4th gear synchronizing ring
6. 3rd & 4th gear synchronizer
7. 3rd gear synchronizing ring
8. 3rd gear drive gear
9. Input shaft
10. Clutch
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11. Crankshaft
12. Engine
13. Idler shaft
14. Idler
15. 1st driven gear
16. 1st gear synchronizing ring
17. Half shaft
18. Half shaft gear
19. Planet gear
20. Main reducer driven gear
21. 1st &2nd gear synchronizer
22. 2nd gear synchronizing ring
23. 2nd driven gear
24. 3rd driven gear
25. Output shaft
26. 4th driven gear
27. 5th driven gear
IV. Assembly relation illustration:

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1. Clutch housing
2. Input shaft
3. I gear
4. Reverse gear
5. II gear
6. III gear
7. IV gear
8. V gear
9. Rear cover
10. Transmission housing
11. Differential
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20121225
12. Output
O shaft
V. Transmis
T ssion structure anaalysis illusstration:
1. Transmissio
T on housing assembly
2. Transmission geear drive

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2. Deep groove ball bearing of
1. Elastic retaining ring for shaft 3. Bearing lock of input shaft
input shaft
5. Constant mesh gear of input shaft

4. Bolt 6. Input shaft reversed gear
I gear
7. Constant mesh gear of input shaft 9. Constant mesh gear of input shaft
8. Input shaft
II gear III gear
12. 3rd & 4th gear synchronizer

10. 3rd & 4th gear synchronizer hub 11. 3rd & 4th gear joint sleeve
spring ring
14. 3rd & 4th gear synchronizer 15. 3rd & 4th gear synchronizer lock
13. 3rd & 4th gear synchronizer hub
spring ring loop
16. Constant mesh gear of 17. Constant mesh gear bush 18. Deep groove ball bearing
input shaft IV gear of input shaft IV gear of input shaft
19. Constant mesh gear bush 20. Constant mesh gear of

21. 5th gear synchronizer lock loop
of input shaft V gear input shaft V gear
22. 5th gear synchronizer joint sleeve 23. Synchronizer spring ring 24. 5th gear synchronizer slides
25. 5th gear synchronizer hub 26. Synchronizer spring ring 27. Synchronizer thrust washer
28. Taper spring gasket 29. Lock nut of input shaft 30. Oil guide cover of input shaft
31. Output shaft cylindrical roller bearing 32. Bearing lock of output shaft 33. Bolt
34. Main drive gear of main reducer 35. Output shaft 36. Needle roller bearing
39. Constant mesh gear damping

37. needle roller bearing retaining ring 38. Elastic retaining ring for shaft
plates of output shaft Ⅰ gear
41. Constant mesh gear of 42. 1st & 2nd gear synchronizer
40. Taper spring gasket
output shaft I gear lock loop
44. 1st & 2nd gear synchronizer 45. 1st & 2nd gear
43. 1st & 2nd gear joint sleeve
spring ring synchronizer slides
47. 1st & 2nd gear synchronizer 48. Constant mesh gear bush
46. 1st & 2nd gear synchronizer hub
spring ring of output shaft II gear
50. Constant mesh gear bush

49. 1st & 2nd gear synchronizer lock loop 51. Taper spring gasket
of output shaft II gear
52. Constant mesh gear damping plates 54. Constant mesh gear of
53. Elastic retaining ring for shaft
of output shaft II gear output shaft III gear
55. Odometer transmission 56. Constant mesh gear bush 57. Deep groove ball bearing
drive gear of output shaft IV gear of output shaft
59. Constant mesh gear of

58. Elastic retaining ring for shaft 60. Taper spring gasket
output shaft V gear
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61. Lock nut 62. 5th speed shift fork 63. Elastic cylinder lock
65. Shift-selection axle,

64. 5th speed fork-axle 66. Reverse gear pull-back spring
reverse gear
67. Shift-selection axle
3. Shifting components
1. Shifting shaft
2. Shifting shaft protection sleeve
3. Shifting shaft oil seal
4. Shifting shaft arm swing
5. Washer
6. Lock nuts
7. Bolt
8. Torsion spring
9. Reverse gear restricted cam
10. Reverse gear restricted camshaft
11. Spring-type cylindrical pin
12. Reverse shifting arm shaft
13. Reverse shifting arm

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14. Reverse shifting arm
15. Wave washer
16. E-type retaining ring
17. Washer
18. Shifting swing link bracket assembly
19. Bolt
20. 1st/2nd speed shift fork
22. 1st/2nd speed shift fork-axle
23. Self-locking ball
24. Self-locking spring
25. 1st/2nd speed shift fork rocker die
26. 3rd/4th speed shift fork
27. Interlocked slides
28. 3rd/4th speed shift fork-axle
29. Reverse shifting rocker die
30. 5th/rev speed shift fork-axle
31. 5th/rev speed fork
32. Self-locking ball clamp
33. Bolt
34. Clutch housing
35. Pull-back spring
36. Shifting swing link
37. Pull-back spring
4. Differential assembly
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1. Half shaft gear washer
2. Half shaft gear
3. Planet gear
4. Planet gear
5. Half shaft gear
6. Half shaft gear washer
7. T-type Differential oil seal
8. Deep groove ball bearing
9. Bolt
10. Ring gear
12. Differential housing
13. Deep groove ball bearing
14. Elastic retaining ring
15. T-type differential oil seal

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VI. Approach and notes of disassembly and installation:

Disassembly:
1. Put the transmission on the table; unscrew drain screw plug and circumrotate the work bench to
dump all the fuel. Then take off the odometer from driven gear and reverse gear lamp switch.
2. Take off the reverse gear lamp switch attached on wire harness clip by hand. Open the rear cover by
using a special tool to unscrew rear cover bolt. At the same time, you should unscrew the Self-locking ball
clamp bolt and take out three self-locking ball springs and three balls.
3. Remove the nylon lubricant path, and then apply V gear. Put the thin copper stick between the 5th gear
drive and driven gear. Unscrew the 5th gear drive gear lock nuts by spanner.
4. Take out lock nut of input shaft, taper spring gasket, and then remove the spring pin of 5th speed
fork by a special tool.
5. Remove 5th gear synchronizer assembly, 5th gear synchronizer ring, 5th drive gear and 5th speed
fork.
6. Remove the bolt connected transmission and clutch by a special tool. Take out bracket-cable-support
and clip bracket of clutch.
7. Use snap ring pliers to unscrew the input shaft elastic retaining ring, and take out transmission
housing by using special tools to separate transmission housing and clutch housing.
8. Fix three shift lever by using special tools, then knock in the rocker dies, which could fix 1st/2nd
speed fork, 3rd/4th speed fork and 1st/2nd speed shift fork, and the spring pin of reverse speed fork.
9. Draw 1st/2nd, 3rd/4th and 5th gear reverse speed fork-axle, remove 3rd/4th, 1st/2nd speed shift
forks rocker dies and reverse speed shift rocker die. At the same time, draw the reverse idler shaft; remove
the reverse idler shaft as well as the pull-back spring on it.
10. Remove the retaining bolt of shifting swing link bracket assembly by special tools, then take out
the shifting swing link bracket assembly. Pull out the speed shift fork-axle lock and 1st/2nd speed shift
fork.
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11. Remove the input shaft bearing clamp by using special tools to unscrew the retaining bolt on it.
12. Take out input and output shaft assemblies by two hands. And remove the differential assembly.
Installation:
Differential installation is in reverse order of its disassembly. Please pay attention to following items:
1. Make sure all the components are clear before installation. Guarantee clean environment to
guarantee service life of transmission.
2. Be carefully for installation to avoid oil leakage caused by oil seal scratch. Special protection sleeve
can be applied.
3. Make sure the joint surfaces are clear before coating with sealant to avoid oil leakage.
4. All the bolts tightening torques should be operated according to the data showed in appendix.
5. Coating with lubricant grease at nozzle of oil seal when installing the input shaft oil seal and
differential oil seal. Then completely press the oil seal into the transmission housing by special tools.
Appendix I
Prescription of tightening torque:
Item Assembly torque (N∙M)
Shifting self-locking ball clamp M6×16 6.9--9.8
Lock nuts of shifting shaft and shifting swing link M10

19.6—29
×1.25
Lock bolts of shifting shaft and shifting swing link

39—49
M10×1.25
Shifting swing link bracket assembly M6×20 6.9—9.8
Release lever assembly M8×25 29.4—39.2

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Bolts of transmission housing and rear end cover M6×14 6.9—9.8
Input shaft assembly lock nuts M22×1.5 98.1—137.3
Output shaft assembly lock nuts M22×1.5 98.1—137.3
Output shaft bearing clamp-locking nuts M6×16 6.9—9.8
Input shaft bearing clamp-locking nuts M8×16 14.7—21.5
Bolts of clutch housing and transmission housing M8 ×40 14.7—21.5
Odometer clamp-locking bolts M6×16 6.9—9.8
Ventilation plug M10 9.8—12.7
Reverse gear switch assembly M16 29.4—49
Oil inlet plug M16×1.5 29.4—49
Oil outlet plug M16×1.5 29.4—49
Differential assembly M10 93.2—104.9
VII. Notes for operation:
1. For clutch shift up and down, press down clutch pedal completely when shifting. Immediately
operate shifting lever to shift gear after making transmission separate from engine torque.
2. Gear down for declivity and swerve. Clutch is not allowed.
3. Random gear selection should not be applied when shifting from low gear to high gear. Otherwise,
the service life of synchronizer can be influenced.
4. Starting engine with forcing synchronizer work is forbidden on the neutral flameout condition.
Otherwise the service life of synchronizer would be influenced.

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5. Flap (push and pull) is forbidden during gear shift. Consistently hold the shifting switch so as to
greatly reduce the sliding-time and abrasion of synchronizer.
6. Don’t put hands on the shifting switch when driving. Otherwise abrasion can be caused to shifting
speed fork too early.
7. For discovery of abnormal voice or obvious abnormal operations like heavy operation, stop vehicle
to check for fault immediately. Continue driving only after eliminating faults.
VIII. Frequent faults and elimination methods:

Elimination
Fault Possible cause
method
Input or output bearing damage Replace bearing
Gear tooth surface knock, burr, corrosive pitting or Repair or replace
poor contact gear

Over
noise or Improper gear axial position and clearance Check and adjust
abnormal
Add oil to the
noise Too low oil level, insufficient lubrication
prescribed position
Check and
Foreign material exists in assembly
remove
Over wear or damage of oil seal Replace
Replace seal pad,

Oil Uneven sealant coating or seal pad damage
coat sealant
leakage
Joint surface knock without timely restoration Check and restore
Differential bearing damage Replace
Shifting Improper clutch adjustment, and insufficient Adjust

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difficulty separation
Improper shifting transmission system adjustment or

Check and adjust
action barrier
Failure synchronizer ring Replace
The joint surfaces between synchronizer gear sheath Change the

Gear
and gear wear out broken parts
slide
Improper shifting transmission system adjustment Check and adjust
Full Shifting transmission system becomes flexible Repair
range
Transmission shifting rockers become flexible Repair
Foreign metal objects exist in lubricant Replace

Abnorma
l damage for Insufficient lubrication or unqualified lubricant Replace
bearing
Unqualified bearing Replace
Gear Shifting swing link bracket assembly abrasion Replace
down when
Gear abrasion Replace
reverse gear
IX. List of easily worn parts

S/N Item Qty
1 Release bearing assembly 1
2 III, IV, V synchronizer ring 3
3 S-type oil seal (AH1292G) 1
4 Radial ball bearing 2

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5 Needle bearing 1
6 Gear I synchronizer ring 1
7 Gear II synchronizer ring 1
8 Radial ball bearing 305 1
9 Single row radial short cylindrical roller bearing 1
10 V-type oil seal 1
11 T-type oil seal (BR1940FNOK) 1
12 Differential radial ball bearing 40×80×18 1
13 T-type oil seal 1
14 Differential radial ball bearing 40×68×15 1
15 T-type differential oil seal 1
16 O-ring seal 1
17 Loctite 5699 sealant
18 Loctite 510 sealant
X. Transportation and storage
1. Rust prevention measure should be applied for transmission to guarantee transmission in normal
transportation and storage avoid from rustiness.
2. Encasement and transport frame should be applied before transmission transportation to guarantee
no damage could be caused to transmission in normal transportation condition.
3. Transmission should be stored in dry warehouse with good ventilation.

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Part VI
Vehicle Body Service
Chapter I Vehicle Body

Section I Structure and Features of Vehicle Body
Integral body structure is adopted in LIFAN sedan. And the body of hatchback model LF7132 is steel with
5 doors. As a combination of practicality and elegance, the modern beauty originates from the elegant body
framework and streamline shape with decoration of large angle window. Impact effect is considered during
the front engine bay and hatchback door designs, and the strength and rigidity of the passenger
compartment can guarantee the safety of the passengers in the vehicle.
I. Body structure
The body of LIFAN sedan is composed of body framework, exterior assembly parts and interior assembly
parts. (This chapter is mainly to focus on the body framework.)
As the basic part of the vehicle, the body framework (body-in-white assembly) carries the whole weight of
the vehicle. The performance, quality and reliability of the vehicle are closely related to the body
framework, and its quality plays an important role in the modern manufacturing.
Fig. 6-1 Body framework

Fig. 6-1 is the illustration of vehicle body of LF7132, and the breakdown drawing is shown in Fig. 6-2.
Most parts of the body framework are welded except that some parts like front wing is connected with bolt.
II. Features of vehicle body

1. Beautiful shape with small coefficient of air resistance
The streamline design of the vehicle body of LF7132 contributes to the beautiful shape and small cd value
of coefficient of air resistance.
2. Reasonable design of the whole vehicle body with reliable safety

The body design of LF7132 sedan provides the best protection for the passengers and the vehicle under
emergent situations. During computer assisted design of the vehicle body, the passenger compartment is
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ultimately optimized in its rigidity, adding its strong vehicle body. The vehicle body bottom is reinforced
with 3 beams and 4 girders and connected to the metal plate of the whole compartment. Integral shock
resistance structure is used for the side wall of vehicle body, reinforcement bar is installed inside the door,
and the roof is also reinforced with steel bar. Besides, a safety area to absorb impact energy is also designed
the front metal plate of the vehicle. Both strong and soft parts are adopted in the vehicle body. As a result,
the LF7132 sedan can guarantee the integrality of the passenger compartment during any kind of hit or
overturn from any direction, which can effectively protect the driver and passenger in the vehicle. The
impact test of LF7132 can demonstrate its safety.
3. Good noncorrosibility of vehicle body with long service life

Thanks to the following corrosion prevention measures, its excellent noncorrosibility prolongs the service
life of the body vehicle.
Fig. 6-2 Breakdown drawing of main parts of body framework

1 - Engine hood assembly 2 - Front wall upper beam assembly 3 - Front metal sheet weld assembly
4 - Outer plate of front left fender 5 - Left side wall assembly 6 - Door assembly in front left side
7 - Door assembly in rear left side 8 - Front floor assembly 9 - Rear floor assembly
10 - Rear wall assembly 11 - Rear door assembly 12 - Door assembly in rear right side
13 - Door assembly in front right side 14 - Right side wall assembly 15 - Outer plate of front right fender
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16 - Top cover assembly
(1) Strict and advanced processing technology before painting is adopted. For example, 11 working
procedures of parkerizing are carried out before painting so that a thin zinc phosphate film is coated, which
is useful for the adherence of next dope and can protect the surface of the vehicle body.
(2) The vehicle body is immediately painted with priming after cathodic electrophoretic coating processing,
which can greatly improve its antisepsis ability.
(3) Anti-stone-bumping PVC is coated on the underbody and wheel shield to effectively prevent corrosion
in the surface of the vehicle body caused by sandrock damage and road surface scuffing.
(4) Sealant is coated in the weld seam of vehicle body metal sheets to improve its antisepsis ability.
4. Comparatively economical light vehicle body

Lightweight design is adopted for the vehicle body to reduce the deadweight of the vehicle. The main
measures are as following:
(1) Use light material as much as possible, such as plastics and other nonmetal materials.
(2) High strength steel plate is selected so that its steel plate is thinner than other vehicles and fewer
materials are used.
(3) Resistance welding is extensively used to reduce the weld material consumption.
5. Reliable seal
As the seal is crucial for dust prevention, water prevention, antisepsis, heat prevention, heat preservation,
noise reduction and other performances, the seal of vehicle body of LIFAN sedan is carefully considered.
Various effective seal measures are adopted to guarantee its sealing performance. The main measures are as
following:
(1) Electric seal gum is coated on the overlap edge when the metal parts are welded.
(2) All the overlap edges of vehicle body are coated with seal gum after the assembly welding is finished.
(3) Polystyrene foam is sprayed in the closed cavity of the body framework to seal, prevent dust, preserve
heat and insulate heat.
(4) Thick anti-stone-bumping dope with excellent sealing performance is sprayed on the underbody.
(5) Traditional sealing measures are adopted for the assembly parts on the vehicle body, such as rubber seal
ring, cover stem, rubber strip and dustproof cover.
6. Large vehicle body space utilization rate

As LIFAN sedan is hatchback with 5 doors, and the rear seat can be folded, its internal capacity is the
largest, or the space utilization rate is the largest if compared with the sedans with the same length. And
this can also be very useful for the passenger to place the luggage.
Section II Vehicle Body Repair Tools
I. Hand tool
1. The regular hand tools for vehicle body repair are shown in Fig. 6-3. Choose the appropriate type of
tool during repair according to the shape of curved surface and other conditions of the steel plate to be
repaired.
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Fig. 6-3 Hand tools
A) Standard special vehicle body tool suit B) Rivet holder C) Metal plate working hammer
1 - Hammer rivet holder 2 - Beat rivet holder 3 - Regular rivet holder
4 - Plane rivet holder 5 - Weld dregs shovel 6 - Vehicle body trimming knife
7 - Long hammer 8 - Flanging tool 9 - Rubber hammer
10 - Long crane beak bar 11 - Bulletheaded shaping hammer 12 - Flatheaded shaping hammer
13 - Body file 14 - Crane beak hammer 15 - Beat hammer
16 – Flat trimming knife 17 - Long arm rivet holder 18 - Plane rivet holder
19 – Regular rivet holder 20 - Long rivet holder 21 - Beating rivet holder
22 - Hammer rivet holder 23 - Long head hammer 24 - Rubber or wood hammer
25 - Metal plate hammer 26 - Crane beak hammer
2. Power tool
(1) Body and frame straightener As show in Fig. 6-4, the body and frame straightener is mainly composed
of plummer, stretcher, measurement system, clamping and positioning device and lifting device. Before
poling or stretching rectification to one or above places on the distorted vehicle body, this machine fastens
the vehicle body on the plummer, lift the vehicle to the appropriate position and then diagnose and examine
the vehicle (Fig. 6-5). The universal vehicle body and frame straightener can rectify the shapes of various
vehicles. Different from the traditional rectification method, its application can lower the labor intensity,
improve the vehicle body repair efficiency and guarantee the repair quality. As a result, this kind of
universal vehicle body and frame straightener is highly praised and widely accepted in the international
vehicle repair industry.
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Fig. 6-4 Universal vehicle body and frame straightener
Fig. 6-5 Vehicle body rectification
(2) Roll flattening machine As a popular flattening machine among the numerous leveling equipments, roll
flattening machine (Fig. 6-6) is used to flatten the surface of metal plate so as to improve its surface
precision. When working the metal plate is clamped between the two rollers which are to drive the metal
plate to repeat parallel movement continuously for flattening purpose. The repeated back and forth rolling
of the rollers is driven by the piston rod spline and gear system. In order to guarantee the flattening quality
of the metal plate surface, the surface of the roller should be highly precisely smooth.
Fig. 6-6 Roll flattening machine Fig. 6-7 Polishing method of polisher
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Apart from its stability and much higher efficiency, the roll flattening machine is also featured with more
reasonable machinery processing technic, higher precision, better quality, lower labor intensity and lower
noise than the manual beating with hammer. However, it still can not completely replace the manual
hammer beating.
(3) Disk polisher. There are electric and pneumatic disk polishers which are to polish the metal plate of the
vehicle body after repair with higher efficiency and easier operation than the manual polishing. The contact
angle between the polishing disk and polishing surface affects greatly the polishing quality of the metal
plate. As a result, 1/3 of the disk surface should contact with the polishing surface (Fig. 6-7) to get the best
polishing quality. If the contact angle is too large, only an extremely small part of the disk can rub with the
polishing surface, which will cause rough processed surface; and if the disk contacts with the surface
parallelly, scraggly processed surface will be produced as the movement will not be stable for too large
rotation resistance.
Section III Vehicle Part Repair
I. Front part of vehicle body

The metal plate breakdown drawing of the front part of vehicle body is shown in Fig. 6-8.
Fig. 6-8 Metal plate breakdown drawing of the front part of vehicle body
1 - Engine hood assembly 2 - Front anti-collision beam assembly 3 - Water tank upper beam assembly
4 - Front headlight right mounting beam 5 - Front headlight left mounting beam 6 - Water tank lower beam assembly
7 - Front anti-collision beam left mounting plate
8 - Left front girder baffle 9 - Left front wheel cover connection plate assembly 10 - Left bracket of mudguard
mounting support
11 - Front tow hook assembly 12 - Left front girder wheel cover assembly 13 - Outer panel
of left front fender 14 - Upper beam assembly of front baffle
15 - Front baffle assembly 16 - Outer panel of upper beam of front baffle 17 - Right bracket of mudguard mounting
support 18 - Right front wheel cover connection plate assembly
19 - Right front girder baffle 20 - Front anti-collision beam right mounting plate 21 - Right front girder wheel cover
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assembly 22 - Outer panel of right front fender
1. Replace the radiator frame

Tools needed during replacement: CO2 gas-shield welder, pneumatic spade, spot welder, angle grinder,
sander and vehicle body alignment support.
(1) Prepare. Disconnect the earth line of the battery. Remove the following parts: headlight, guard grille
and trim strip of radiator, engine, engine hood rod, engine support rod bracket, engine hood latch hook,
engine cable (remove from the original position), radiator, condenser, horn, front bumper, front fender and
wire harness (remove from the original position).
(2) Remove the radiator frame. Remove the sealant/loading agent in the joint of radiator frame and vehicle
body and drill the spot welding at the following joints: joint of middle support of radiator frame and lower
beam of radiator, joint of headlight bottom and front wheel cover of front girder and joint of radiator upper
plate and front wheel cover. And then remove the radiator frame.
(3) Process the cutting area. Remove the residual corner plate and burr with wire-cutter. Coat the
unreachable part with cold zinc paint after welding.
(4) Prepare new part. Paint the inner side of new part, polish the contact surface and coat the unreachable
part with cold zinc paint after welding.
(5) Weld the radiator frame. Fasten the radiator frame with pressure clamp. Spot-weld the following joints:
joint of headlight bottom, front girder of vehicle body and front wheel cover; joint of upper beam of
radiator frame and wheel cover, joint of middle support of radiator and lower beam of radiator frame.
(6) Complete. Clean all the welds with wire brush, paint the repaired part with priming and replace
sealant/loading agent, paint the radiator frame and coat it with antirust and finally install the removed parts
in correct order.
2. Replace the front wheel cover

Tools needed during replacement: spot welder, CO2 gas-shield welder, angle grinder, sander, pneumatic
spade and vehicle body saw.
(1) Prepare. Disconnect the earth line of the battery. Remove the following parts: front suspension fork
(including the engine), engine hook and hinge, front bumper, radiator, condenser, headlight, radiator shield,
engine hood cable, horn (remove when replacing the right front wheel cover), steering mast (remove when
replacing the left front wheel cover), battery (remove when replacing the right front wheel cover),
expansion water tank, window washing liquid reservoir, front fender, front door, instrument panel, window
glass, front seat, front door inner trimming part, floor sound absorbent pad, carpet, fuse element, relay
board, front wire harness, brake pipe and fuel pipe.
(2) Remove wheel cover. Remove the sealant/loading agent in the joint of the front wheel cover and vehicle
body and drill the spot welding at the following joints: joint of lower beam plywood of radiation frame and
lower beam of radiation frame, and then remove the plywood, the joint of lower beam of radiation frame
and front girder, joint of front wheel cover, radiator frame and lower beam of radiator frame, joint of front
wheel cover and radiator frame, joint of front wheel cover and battery bracket, (if replace right front wheel
cover), joint of front wheel cover and left shock damper (if replace left front wheel cover); joint of front
wheel cover, lower plate of front baffle and front clapboard, joint of front wheel cover, A-pillar (front pillar)
and inner and outer doorsills, joint of A-pillar, lower plate of front window frame and outside panel of top
frame, joint of front wheel cover and upper plate of front baffle, joint of front wheel cover, upper plate of
front baffle and inside panel of top frame and joint of front wheel cover, lower baffle plate of front baffle
Ver：LF-20121225
and inner doorsill. And then remove the wheel cover.
(3) Process the cutting area. Remove the residual corner plate and burr. Coat the unreachable part with cold
zinc paint after welding.
(4) Prepare new part. Remove the paint on the contact surfaces of new wheel cover and reinforcement plate,
and coat the unreachable part with cold zinc paint after welding.
(5) Weld the new wheel cover. Fasten the wheel cover with pressure clamp, and check the horizontal
position of one wheel cover to another wheel cover (align with special tool).
Weld in the following procedures: Spot-weld the joint of the wheel cover, A-pillar and upper baffle plate of
front baffle, and then weld the upper c position with gas-shield. Spot-weld the joint of wheel cover, inner
doorsill and lower baffle plate of front baffle; spot-weld the joint of the wheel cover, A-pillar and middle
girder, spot-weld the upper part of the joint of rubber wheel cover, lower plate of front window frame and
outside of top frame; stop-weld the joint of front wheel cover and upper baffle plate of front baffle; weld
the joint of front wheel cover, lower plate of front baffle, front clapboard and middle girder with gas-shield,
spot-weld the joint of front wheel cover, radiator frame and lower beam of radiator frame; spot-weld the
joint of rubber wheel cover and radiator frame; spot-weld the joint of radiator frame and front girder, fasten
the plywood of lower beam of radiator frame with pressure clamp and spot-weld it; spot-weld the joint of
front wheel cover and battery support (if replace right front wheel cover); weld the joint of front wheel
cover and left shock damper support with gas-shield; and fasten the reinforcement plate for front wheel
cover and spot-weld it.
(6) Complete. Clean the welding line and welding spot with steel wire cap. Paint the cleaned parted with
primer and replace the sealant/loading agent. Paint the front part of the vehicle and coat it with anti-rust
paint, and finally install the removed parts in correct order.
3. Replace the front part of vehicle

Tools needed during replacement: spot welder, CO2 gas-shield welder, angle grinder, sander, welding spot
remover, pneumatic spade and vehicle body alignment support.
(1) Prepare. Disconnect the earth line of the battery and remove the following parts: front suspension fork
(including the engine), exhaust pipe, steering column house, vacuum booster, front brake pipe, middle
brake pipe, fuel pipe, battery, wire harness, coolant pipe, radiator, condenser, expansion water bottle,
washing device of screen wiper, engine compartment cover, lower tapered end of engine compartment,
guard grille of radiator, headlight, engine hood, engine hood hinge, brace rod of engine compartment cover,
front fender, front vehicle door, instrument panel, window glass, air intake cover, front seat, floor sound
absorbent pad, front wire harness and central circuit board.
(2) Remove the front part of vehicle body. First remove the sealant/loading agent in the joint of the front
part of vehicle body and vehicle body, and then drill the welding spots of the following joints: joint of the
front part of vehicle body, middle girder and floor; joint of front part of vehicle body, A-pillar and doorsill,
joint of front part of vehicle body, outside panel of A-pillar top frame and lower plate of front window
frame, joint between upper plates of front baffle, joint of front part of vehicle body, beam of redirector
support, inner doorsill, lower plate of front baffle, floor and inside plate of top frame. Finally remove the
front part of vehicle body.
(3) Process the cutting area (joint). Remove the residual corner plate and burr with wire-cutter. Coat the
(4) Prepare new part (front part of vehicle body and reinforcement plate for wheel cover). Paint the surface
of front part of vehicle body facing the passenger seat, rubdown the joint and coat the unreachable part with
Ver：LF-20121225
cold zinc paint after welding.
(5) Weld the front part of vehicle body. Fasten the front part of vehicle body to the proper position on the
vehicle body with pressure clamp and align the parts next to vehicle body (align with special tool).
Weld the front part of vehicle body in the following order. Spot-weld the joint of front part of vehicle body,
A-pillar, outside plate of top frame and lower plate of front window frame (use CO2 gas-shield weld in the
joint of lower plate of front window frame and A-pillar); spot-weld the joint of front part of vehicle body,
A-pillar and middle girder; spot-weld the joint of front part of vehicle body, beam of redirector support,
A-pillar and inner doorsill; weld the joint of front part of vehicle body, lower plate of front baffle and
inside plate of top frame with gas-shield; weld the joint of upper plate support of front baffle and upper
plate of front baffle with gas-shield; spot-weld the joint of front part of vehicle body and floor and weld the
joint of front girder and middle girder with gas-shield. Fasten the reinforcement plate for wheel cover with
pressure clamp and spot-weld it.
(6) Complete. Clean the welding line and welding spot with steel wire cap. Paint the cleaned parted with
primer and replace the sealant/loading agent. Paint the front part of the vehicle and coat it with anti-rust
paint, and finally install the removed parts in correct order.
II. Middle part of vehicle body

The metal plate breakdown drawing of the middle part of vehicle body is shown in Fig. 6-9.
Fig. 6-9 Metal plate breakdown drawing of the middle part of vehicle body
1 - Roof panel assembly 2 - Rear beam assembly of roof panel 3 - Right clapboard assembly 4 - Upper curb girder
assembly of right B-pillar 5 - Inner plate assembly of right A-pillar
6 - Close board of right side wall 7 - Inner plate assembly of right B-pillar 8 - Right rear wheel cover assembly 9-
Left rear wheel cover assembly 10 - Inner plate assembly of left A-pillar
11 - Close board of left side wall 12 - Inner plate assembly of left B-pillar 13 - Left clapboard assembly 14 - Upper
curb girder assembly of left B-pillar 15 - Cover plate assembly of parking brake
Ver：LF-20121225
16 - Front floor weld assembly 17 - Right girder assembly of front floor 18 - Left girder assembly of front floor
1. Replace roof panel

(1) Prepare. Disconnect the earth line of battery and remove the following parts: front and rear seats, trim
strip of roof drip and roof light circuit (remove from original position).
(2) Remove the roof. Wipe off the paint on the joint of roof, upper plate of side wall, windshield frame and
rear window frame, front beam of roof panel and rear beam of roof panel; rub out, cut or open the welding
lines and welding spots in joint of roof and upper plate of side wall and the joint of roof and front window
glass frame, joint of roof, outside of top frame and inner glass frame. Then finally remove the roof.
(4) Prepare new part. Paint the inner side of roof. Wipe off the paint on the joint of roof and vehicle body.
Coat a thin film of welding paint on the unreachable part after welding.
(5) Weld the new roof. Fasten the roof to the proper position of the vehicle body with pressure clamp, and
weld the roof in the following order: spot-weld the joint of roof panel, front windshield frame and lateral
plate of top frame, and braze the two corners; spot-weld the joint of roof, rear windshield frame and outer
panel of top frame and front and rear beams of roof panel, and braze the two corners; and finally install the
filling plug with vehicle body repair machine.
(6) Complete. Strickle the welding line and clean the welding spot. Replace the sealant/loading agent in the
repaired part. Paint the roof with anti-rust paint, and finally install the removed parts in correct order.
2. Replace girder (left and right)

Tools needed during replacement: spot welder, CO2 gas-shield welder, angle grinder and sander.
(1) Prepare. Disconnect the earth line of battery, and then remove the following parts: front and rear wheels,
front fender, front and rear doors, accessories of front and rear doors, front and rear seats, pressure plate of
doorsill (girder), trim plate of middle pillar and carpet (remove from the original place).
(2) Remove out girder. Remove the sealant/loading agent in the working area, and then drill the spot
welding in the following joints and welds: joint of out doorsill, A-pillar and inner doorsill; joint of out
doorsill, B-pillar and doorsill (girder); joint of out doorsill, lower plate of side wall and inner doorsill.
Finally remove the girder.
(4) Prepare new part. Wipe off the paint on the joint of girder and vehicle body, and coat the unreachable
part with cold zinc paint after welding.
(5) Weld the new doorsill. Fasten the outer doorsill to the proper position on vehicle body with pressure
clamp. And weld the outer doorsill in the following order: spot-weld the joint of out doorsill, A-pillar and
inner doorsill; spot-weld the joint of out doorsill, outer plate of side wall and inner doorsill; and spot-weld
the joint of outer doorsill and B-pillar.
(6) Complete. Clean all the welds with wire brush, paint the repaired part with priming and replace
sealant/loading agent. Paint the doorsill beam with anti-rust paint, and finally install the removed parts.
III. Rear part of vehicle body

The metal plate breakdown drawing of rear part of vehicle body is shown in Fig. 6-10.
Ver：LF-20121225
Fig. 6-10 Metal plate breakdown drawing of rear part of vehicle body
1 - Weld assembly of rear floor 2 - Front beam assembly of rear floor 3 - Right rear girder assembly
4 - Left rear girder assembly 5 - Rear beam assembly of rear floor
6 - Inner plate assembly of apron board of rear wall 8 - Anti-collision beam of rear wall
9 - Inner plate assembly of rear door 10 - Outer plate assembly of rear door
Replace apron board of rear wall

Tools needed during replacement: CO2 gas-shield welder, angle grinder, sander, pneumatic spade and
vehicle body saw.
(1) Prepare. Disconnect the earth line of battery, and remove the rear bumper, tail lamp, sound absorbent
pad on lateral surface of luggage boot, sound absorbent pad on bottom of luggage boot, accessories of
luggage hood and wire harness of tail lamp.
(2) Remove the apron board of rear wall. Remove the sealant/loading agent in joint areas. And drill the
following welds: joint of apron board of rear wall, rear floor and rear inner girder; joint of apron board of
rear wall, and rear lower part of outer plate of side wall and joint of apron board of rear wall and fixing
plate of tail lamp; joint of apron board of rear wall and spare wheel groove. And finally remove the apron
board of rear wall.
(3) Process the cutting and welding area. Remove the residual corner plate and burr with wire-cutter to
prepare for welding. Coat the unreachable part with cold zinc paint after welding.
(4) Prepare new part. Paint the inner surface of the new part. Wipe off the paint on the joint of apron board
of rear wall and vehicle body, and coat the unreachable part with cold zinc paint after welding.
(5) Weld the new apron board of rear wall. Fasten the apron board of rear wall on the proper position with
pressure clamp. And weld the apron board of rear wall in the following order: spot-weld the joints between
the apron board of rear wall and rear floor, rear inner girder, outer plate of side wall, fixing plate of rear tail
lamp, spare wheel groove, etc.
(6) Complete. Clean the weld spots, and replace the sealant/loading agent in the repaired parts. Paint the
outer plate of rear wall with antirust and finally install the removed parts.
For information about the sizes of welding parts, please refer to Section V Vehicle Body Size.
Section IV Touch-up Paint

Ver：LF-20121225
The touch-up paint procedures for LIFAN sedans are mainly as follows:
(1) Remove the wax and oil
(2) Phosphatization
(3) Soak cleaning
(4) Wash to get rid of hydronium
(5) Paint primer
(6) Drying
(7) Coat some parts with lacquer putty
(8) Drying
(9) Polish the lacquer putty
(10) Clean
(11) First finish paint
(12) Leave it for volatilization
(13) Drying
(14) Second finish paint
(15) Leave it for volatilization
(16) Drying
Pay attention to the following points during touch-up paint

(1) After thoroughly wash the metal surface with the solution for removing wax and grease, dry it with
glutinous cloth (Glutinous cloth is made of hopsacking infused with special varnish.). The dust and particle
will be cleaned when wiping the surface.
(2) Use lacquer putty matched with the primer.
(3) Use No. 280-320 sand paper for polishing and No. 400-600 sand paper for levigation, and sander with
gasket is preferred. Manual polishing is also acceptable if sander is not available. As the appearance and
lifetime of paint is decided by the preparation before painting, lacquer putty is coated and the polishing
must be careful and thorough.
(4) When painting, mix the paint to appropriate viscosity (usually 15s-35s). And the pressure intensity of
the compressed air is usually 300kPa-600kPa, and the distance between nozzle and surface of vehicle body
20mm-300mm. The paint flow should be vertical to the surface of vehicle body and move at uniform speed
of 10m/min-12m/min. The brim of paint strip should overlap the1/3-1/2 of former one.
Section V Size of Vehicle Body
I. Hole position distance

The positions of datum holes during servicing of vehicle body are shown in Fig. 6-11, Fig. 6-12 and Fig.
6-13. And the size parameters are shown in Table 6-1.
Ver：LF-20121225
Fig. 6-11 Distance of hole positions on vehicle body A
Fig. 6-12 Distance of hole positions on vehicle body B

Ver：LF-20121225
Fig. 6-13 Distance of hole positions on vehicle body C
Table 6-1 Size parameters of hole positions on vehicle body

Measured Size parameter Measured Size parameter
No. Remark No. Remark
part (mm) part (mm)
1 A-a 320 12 I-K 1157.97
2 A-B 1125.1 13 I-L 1054.87
3 A-C 856 14 L-l 1405.9
4 B-b 1311.2 15 M-m 1061.45
5 B1-b1 1276.8 16 M-N 863
6 B2-b2 1241.8 17 P-p 996.15
7 C-c 1065.3 18 R-r 1408.9
8 C-b 1218.7 19 S-s 1071.2
9 C-F 390.1 20 T-t 1013.5
10 G-H 1233.55 21 G-g 996.2
11 I-i 1070.47
II. Usages of hole positions

The usages of hole positions are listed in Table 6-2
Ver：LF-20121225
Table 6-2 Usages of hole positions in vehicle body
No. Remark No. Remark
Mounting hole for rear bumper to install
A, a Mounting hole for engine radiator R, r
connecting support
B, b Mounting hole for fender S, s Mounting hole for rear tail lamp
B1,b1 Mounting hole for fender T, t Mounting hole for rear tail lamp
B2,b2 Mounting hole for fender U, u Mounting hole for engine radiator
Mounting hole for front shock damper Positioning hole for welding of front
C, c V, v
assembly floor
Positioning hole for welding of front
F Mounting hole for five-way valve W, w
floor
K Mounting hole for front door limiter X, x Mounting hole for rubber cover stem
Mounting hole for rear shock damper
L, l Mounting hole for fender itself Y. y
assembly
N Mounting hole for rear door limiter
III. Coordinates of hole positions

The coordinates of hole positions are shown in Fig. 6-14 and Table 6-3.
Fig. 6-14 Mounting hole for shock damper
Table 6-3 Coordinates of hole positions in vehicle body

Hole position name X(㎜） Y(㎜） Z(㎜)
Mounting hole for front
-751.302 532.672 563.502
shock damper 1
-639.603 530.664 555.551
shock damper 2
Ver：LF-20121225
-751.302 -532.672 563.502
shock damper 3
-639.603 -530.664 555.551
shock damper 4
Mounting hole for rear
1615.551 501.194 582.253
shock damper 1
1701.656 587.586 579.748
shock damper 2
1659.491 544.323 591.858
shock damper 3
1659.491 -544.323 591.858
shock damper 4
1615.551 -501.194 582.253
shock damper 5
1701.656 -587.586 579.748
shock damper 6
Chapter II Screen Wiper and Washer

The front windshield of the sedan is equipped with screen wiper and washer to maintain a clear visual for
the driver and guarantee the safety of the vehicle. They can wipe off the water drop and dew and wash the
dust on the windshield. The structure is as follows:
I. Structure of screen wiper and washer of front windshield

The screen wiper and washer of front windshield are composed of connecting rod mechanism, wiper arm,
blade, motor, washing bottle, water inlet pipe, cover, washer nozzle, washer hose, electric washing motor
assembly, etc. It can work intermittently, slowly, quickly and work simultaneously with the washer.
II. Fault diagnosis and repair of screen wiper and washer

The regular faults of screen wiper and washer are wiper blade no movement, wiper blade wrong stop
position, wiper blade shaking, washer no fluid spray, etc.
1. Wiper blade no movement

(1) The reasons for no response of wiper when the switch is on are:
1) Circuit fault, such as blowout, poor contact or open circuit;
2) Timing relay damaged;
3) Transmission mechanism damaged;
4) Motor damaged.
(2) Fault diagnosis and repair
1) Check the fuse and circuit, and repair and replace it if an open circuit is detected. Proceed to the next
step if there is no problem.
2) Check if the voltage to earth of power terminal is the same as the voltage of the battery. If there is no
voltage, recheck carefully the circuit before the switch; and if the voltage is normal, proceed to the next
Ver：LF-20121225
step.
3) Check the voltage to earth of switch output terminal when the switch is on. If there is no voltage, the
switch is broken and should be replaced; if the voltage is normal, the switch is normal and proceed to the
next step.
4) Touch the motor when the switch is on. If there is no response from the motor, the motor may be broken.
Repair or replace the motor. If there is slight vibration or buzz sound from the hot motor, the transmission
mechanism may be jammed or broken, and should be diagnosed and repaired.
2. Wiper blade wrong stop position

(1) The main reasons for this fault are:
1) Abrasion or deformation of part of transmission mechanism.
2) Bad motor stop device.
(2) Fault diagnosis and repair: Check transmission mechanism. If there is no problem, remove and check
the motor.
3. Wiper blade shaking

(1) The main reasons for wiper blade shaking are:
1) Wiper blade aging, bending or inappropriate angle to the glass.
2) Abnormal working condition of transmission mechanism.
3) Window glass to dirty.
(2) Diagnosis and repair: First check if there is dunghill on the window glass and wiper blade is normal. If
both of them are normal, diagnose and repair the transmission mechanism.
4. Washer no fluid spray

(1) The main reasons for this fault are:
1) No cleaning solution in washing bottle, fluid pipe broken or nozzle blocked.
2) Washer pump circuit is open.
3) Washer pump broken.
(2) Fault diagnosis and repair: First check if there is cleaning solution in washing bottle, if the hose is
broken and if the nozzle is blocked. If there is no problem for all of them, check if the washer pump circuit
is open. And if there is no problem for the circuit, diagnose and repair the washer pump.
Ver：LF-20121225
CIRCUIT DIAGRAM
OF LIFAN 320
1 2 3 4
RE R1
LH L1 L2 L3 L4 L5 L6
1 2 3 4
1 2 3 4
I1 I2 I3 I4 IB G11 I5 I6 I7 I8 I9 I10
I11 G21 IK IH1 IH2 I12 I13 I14
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I15 I16 I17 I18 I19
I20 I21 I22 I23 I24 I25 I26 I27 I28
1 2 3 4
1 2 3 4
UB UC EA1 EA2 E1 E2 EC G02 E4

73
E5 E6 E7 E9 E10 E11 E12 E13 E14
E15 E16 E17 E18 E19 E20 E21 E22
E23 E24 E25
1 2 3 4
1 2 3 4
DH1 DH2 D1 D2 D3 D4 D5
D6 DB D7 D8 D9 DH3
DH4 D10 D11 D12 D13 D14 DG D15
D16 D17
1 2 3 4
1 2 3 4
I29 I30 I31 I32 IA1 IA2 IF G22
I33 I34 I35 I36 IE IH3 IH4 ID1
ID2 I37 I38 I39 I40 G13 I41 I42 I43
S1 S2 S3 G24 SF
1 2 3 4
G01
UC
UB UC
UC
UB
UC
UB
UC
UC
UC
UB UC
UB
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UB
UB
I39
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IF
IA1
I30
I16
I16
IB
I32
I21 I27
I12
IA1
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ID2
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I28
I28
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I20
I30
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IH1
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ID2
I22
ID2
IE
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I40
I17
ID1
I13
I45
I44
I40
I05
I20
I17
I40
I5
I20
I16
IA1
I16
I16
I16
I21 I14
I04
I43
I43
I39
I39
I18
I17
I27
I14
I8
G01
I21
E21
I21 I21 I21 I21
E23 E23 E23
Bl
EA1
IA1
B B
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A
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8
A
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UC
EC
UB
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E12 E12 E11 E11 E10 E10 E9 E9 E7 E7
UC UC ID1
EC EC BD1
E1 E1 E1 E1 E1 E1 E1 E1 E1
I21
I21
B2
I8
E1 E1 E1 E1 E1 B2
EA1
IA1
I16 E17 E17 E17
I16
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UC
G01 G02 G02
EC
I21
I21
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UC UC E18 E18 E18 E18 E19 E19 E19 E19 E14 E14 E22 E22 E22 E22
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EA1 EA1 EA1

IA1 IA1 IA1
E6 E6 E6 E6 E20 E20 E21 E21 E21 E13 E13 E13 E4 E4 E4 E16 E16 E25
I18 I18 I18

G01 G02
I21
I21
E24
UC UC
EC EC UC UC
EC EC UB UB
IB IB
E1 E1 E1
I3 I1
t
I8
E1 E1 E1 E1
I17
EA1 EA1
IA1 IA1
E4 E4 E4 I35
I31
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G01 G11
I21
I17 I15 I18

I21
IF IF IF IF
SF SF SF SF
IA1
EA1
S1 S1 S1 S1
I17
I17
I8 EA1
IA1
S1 S1 S1 S1 S1
IK
ID1 FK
BD1
F2
S3 S3
S2 S2
B6 B9
F2
FK
B6 B9 IK
G01 G23 G24 G21

I21
I21
I22
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I22
I18
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I39 I39 I39 I39 I39 I39 I39 I39 BD1
UB UB
IB IB
I2 I23
BH
LH
I39 I39 I39 I39 I39 I39 I39 I39
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IK IK ID2 ID2
FK FK BD2 BD2
I6 I6 I38 F3 F3 B3 B6 L1 B9
I38 B3
LH
BH
G01 G11 G13 G23
I21
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8
Wiring terminal b
I21 h f g c d e
Gear
RE BD2 Up
R1
IE ID2 B11 Left Down
I17 I16 I16 I16 Left
1
A
5
A
6
A
1
9
Right
B11 Up
Rigtht Down
2
1
B
6
R1 Left
Right
6
3
RE
I17 I15
IE
BH I8 I12 I12 I12 I12 I12
I8
LH
IK ID1 IH2 IH3 IH3 IH3 IH2 IH2

FK BD1 DH2 DH3 DH3 DH3 DH2 DH2
I12
D3 D12 D12 D12 D3 D3

1
L4 F5 F4 B1 B4
3
G12 G12 G21

I21
I24 I24 I25

I21 I21 ID2 ID2
A
7
A
2
B
1
Assembly switch
BD2 BD2
INT Power Front reset Low speed High speed Front washer Rear washer Rear wiper Power Power
F OFF
F LOW
BH BH
F HIGH
LH LH
F INT
F Wash
I17 R ON
4
R Wash
A
8
A
9
A
1
0
A
6
A
1
A
4
A
5
B
2
I24 I24 I24 I24 I24 I24 I24 I25

1
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1
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L3 L3
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IK I10
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I9 I9
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UB
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I30 I30 I30 I30 E15 I22 I14 I14
I20 I20
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I8 I20 I20 I19 I19 I14 I14 I14 I14 I14
IA1
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ID1 ID1 ID1 ID1 ID1
I20 I20 I19 I19 BD1 BD1 BD1 BD1 BD1 I17 I17
BH
ID1
LH BH
L1
L1
BH
LH
I17
I17
BD1
LH
I17 I17 I17
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I44 I5 I45 I40 B9 B6 L5 I7 I37 I4 I43 B8 B7

LH
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IH1 IH1 IH1 DH4 IH4 FK FK BD2 BD2
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Manual Usuario, Servicio 320

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Manual Usuario, Servicio 320

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Chongqing Lifan Industry(group) Imp.&Exp.co.,Ltd.

Add:NO.60 Zhangjiawan,Shangqiao,Shapingba District,Chongqing,China.

Product model LF7132 LF7132A LF7132B

Wheel base mm 2340

Curb weight kg 900

Gross vehicle weight kg 1250

Tire specification 165/70R14

Front overhang mm 790

Rear overhang mm 615

Vehicle identification of Lf320

Maximum torque N•m 115

Idle speed r/min 800±50

Grade ability % ≥30

Appearance of instrument panel …………………………………………………8

Indicator on instrument cluster

Appearance of instrument panel

Manual air conditioning controller

Appearance of instrument cluster

Indicator on the instrument cluster

1 2 Seat belt indicator Headlamp highbeam indicator

Charging indicator Turn signal indicator (lightened separately)

Oil pressure warning indicator Rear fog lamp indicator

OBD indicator(Check engine) Parking brake indicator

Low fuel level warning indicator Anti-theft indicator

Door open warning indicator Engine coolant temperature warning indicator

Remote controller (optional)

Remote controller battery replacement

For traffic collision, the vehicle will be

Before closing engine hood, please confirm

—Precautions of rear seat adjustment

●For seat adjustment, do not put hand under 1 2

When the shoulder seat belt of rear

The vehicle bumps against a tree or pole, but

Front fog light……………………………………………………………………48

High-mounted brake lamp

This lamp will light up with rear brake lamp when

Instrument and Maintenance Indicator

Warning indicator………………………………………………………………55 svs

If the lamp flickers or continues to illuminate

It is necessary to insert the key completely to turn the key

●Prevent the engine from high speed operation.

Audio system 3.Button for clock, band equalizer

7 10 12 14 document file when playing MP3)

The passenger may adjust the mechanism

Rear ashtray To use the ashtray, pull it out.

● Do not load unnecessary heavy objects to save

No continuing to drive an unchecked

2 Coolant 7.0L Lucent -30℃

Expected temperature range before

6 A/C refrigerant 480g R134a

LIFAN320 Service Manual

Chongqing LIFAN Industry (Group) Imp. & Exp. Co., Ltd.

Chapter II Main Technical Parameters of LF320 Sedan 5

Chapter III LIFAN Vehicle Maintenance Rules 13

Section I Check and Adjustment of Carbon Monoxide Concentration 23

Section I Coolant 128

Section I Engine Oil and Fuel Filter 145

Section I Overview 155

Section I Electronic Fuel Injection (EFI) System 160

Chapter VI Electronic Injection System 202

Section I Introduction 202

Chapter VII Three Way Catalytic Reaction System 244