Lifan 620 Maintenance Manual

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Troubleshooting

Summary of Contents for Lifan 620

Page 1 www.CarGeek.ir www.cargeek.ir...
Page 2 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, and distribute any part of the manual in any form or by any method.
Page 3: Table Of Contents
www.CarGeek.ir Content Foreword Content Part 1 Introduction 4-19 Part 2 System Repair 20-362 Chapter I Electronic Injection System 20-102 Section I Introduction 21-21 Section II Principle of controlling and actuating components 22-37 Section III Steps for Trouble Diagnosis with DTC 38-65 Section IV Steps for Trouble Diagnosis Based on Engine Symptom...
Page 4: Table Of Contents
www.CarGeek.ir Section III BCM Central Lock, Burglar Alarm System 216-229 Section IV Electric Side Mirror 230-233 Section V Illumination System 234-245 Section VI Wiper and Washer 246-253 Section VII Audio System 254-260 Section VIII Reverse Radar System 261-266 Section IX Power Supply and Other Electrical System 267-269 Chapter V...
Page 5: Introduction
www.CarGeek.ir Part1 Introduction www.cargeek.ir...
Page 6: Brake System
www.CarGeek.ir Chapter I Entire Vehicle Overview LF620 sedans are devised to give expression to the human orientation with features of portable operation, comfortable ride, spacious inner room, excellent dynamic quality and economical efficiency. The high tech and low price endow them with the stronger market competition. I.
Page 7: Instrument Cluster
www.CarGeek.ir 3. Ignition and electronic injection system ① Ignition switch: Only the mature products can be employed and the corresponding current is set to satisfy the functional requirement. ② The engine is the mature product of the TRITEC and the electronic injection system adopts the multi-point electronic injection system supplied and calibrated by the SUN &...
Page 8 www.CarGeek.ir electronic anti-theft. (9) A/C system: JSS-120 swinging-vane type compressor with delivery capacity 120ml/r and excellent refrigerating effect, consisted of the condenser, evaporator, thermostat, sensor, pressure switch and blower, etc. 7. Safe anti-theft device (1) Air bag: The electric double air bags are located on the steering wheel and the dash board of the co-driver room respectively.
Page 9 Chapter II Main Technical Parameters of Lifan Vehicles I. Basic performance parameters 1. Complete vehicle basic parameter (Table 1) 2. Complete vehicle performance index (Table 2) Table 1 Complete Vehicle Main Parameter Item LF7162 sedan 3 compartments, 4 doors, 5 seats and 2...
Page 10 www.CarGeek.ir Table 2 Complete Vehicle Performance Parameter Item LF7160 ≥180km/h (BMW 1.6) ≥170km/h Maximum vehicle speed Km/h (Domestic vehicle 1.6) Acceleration performance Performance ＜15.5 ( 0-100km ) parameter Fuel consumption of uniform L/90km 5.64 speed traveling Maximum climbing angle (﹪) ≥35 Number of passengers People...
Page 11 www.CarGeek.ir Table 4 Main Performance Parameter of LF481Q3 Engine Item Unit Model and parameter Four-stroke, water cooling, 4 cylinders in line, Model 16 valves, double overhead camshafts and multipoint electronic injection Cylinder bore Stroke Total delivery capacity Compression ratio 9.5:1 Lubricant capacity Fuel No.
Page 12 www.CarGeek.ir 2. Model and parameter of main assemblies of chassis (Table 5) Table 5 Model and Parameter of Main Assemblies Name Structure and parameter Exhaust system Three-way catalytic converter (one section) and muffler (two sections) Intake system Intake pipeline and air cleaner Including fuel pump, fuel cleaner, pressure regulator, accelerator pedal, Fuel supply system fuel tank...
Page 13 www.CarGeek.ir 3. Vehicle body structure model and parameter (Table 6) Table 6 Vehicle Body and Inner and Outer Trim Name Structure and parameter Integral body, 3 compartments, 4 doors, 2 covers and 5 Vehicle model seats Body-in-white All metal closed type structure Vehicle Framed, 4 doors open in regular direction, card lock, with Door assembly...
Page 14: Electrical System
www.CarGeek.ir 4. Structure and parameter of electrical system (Table 7) Table 7 Structure and Parameter of Electrical System Name Structure and parameter Wire Single wire, negative pole grounded, direct current 12V Generator Integral type, AC, built-in voltage regulator, specification 14V/80A Start Motor solenoid-operated (with generator), power 1.2kw...
Page 15 www.CarGeek.ir 5. Lubricant, fuel, steering fluid, brake fluid, coolant, refrigerant and capacity (1) Lubricant Table 8 Lubricant Lubricant Weight Bearing and button head pin Lithium base grease 7022 0.34kg (2) Fuel Table 9 Fuel No. and Fuel Tank Capacity Name Performance index Fuel No.
Page 16: Steering System
2. Airbag: Visually check if its surface is damaged. 3. Self-check: Read the fault information of all systems in memorizer with Lifan special diagnostic tools. II. Outer vehicle body 1.
Page 17 www.CarGeek.ir IV. Engine and vehicle body bottom 1. Vehicle body bottom: Check if the fuel pipe, brake oil pipe and bottom protection layer are damaged; check if the exhaust pipe leaks and if fastening is reliable. 2. Steering tie rod: Check the clearance; check if the connection is reliable and if dustproof cover is damaged.
Page 18 www.CarGeek.ir Brake on-off BTDS Before top dead center ABS control unit with electromagnetic coil Canister Purge exhaust valve CANP CMP Sensor Camshaft position sensor (crankshaft turning angle sensor) Carbon monoxide Circuit CPP Switch Clutch pedal position switch (clutch switch) Crankshaft position sensor Central processing unit Continuously variable transmission Child restraint system...
Page 19 www.CarGeek.ir Emergency locking retractor Electric power steering Electronic spark timing EVAP Evaporative system EVAP Canister Evaporative system canister Fuel pump Fuel pump control ECU Engine Grounding Hydrocarbon HO2S Heated oxygen sensor Hydraulic unit control with solenoid valve IAC Valve Idle air control valve IAT Sensor Intake air temperature sensor Ignition Control Module...
Page 20 www.CarGeek.ir Minimum Malfunction indicator light, engine check light Manual transmission Neutral Engine rotation speed, engine efficient power Nitrogen oxides On-board diagnostics Over-speed driving Overhead camshaft Parking Power control module Positive crankcase vent Power distribution control Pressure of intake manifold Park/neutral position Park/neutral Power steering pressure switch PSPS...
Page 21: System Repair
www.CarGeek.ir Part II System Repair www.cargeek.ir...
Page 22: Electronic Injection System
www.CarGeek.ir Chapter I 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.
Page 23: Principle Of Controlling And Actuating Components
www.CarGeek.ir Section II Principle of controlling and actuating components 1. Intake pressure/temperature sensor (Fig. 1-1) Fig. 1-1 (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.
Page 24 www.CarGeek.ir (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.
Page 25 www.CarGeek.ir (3) Connection of wiring diagram (Fig. 1-4) Fig. 1-4 (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: Fastening torque for installation screw is 1.5N·m～2.5N·m.
Page 26 www.CarGeek.ir (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).
Page 27 www.CarGeek.ir polars of the piezoelectric crystal, and the 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.
Page 28 www.CarGeek.ir (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.
Page 29 www.CarGeek.ir (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.
Page 30 www.CarGeek.ir Table 1-1 (Continued) Definition Definition Definition Number Number Number Idle speed phase A output J1-34 J1-35 Acceleration signal J1-36 Power steering signal negative Rear oxygen sensor signal J1-37 Not used J1-38 J1-39 A/C demand (+) high J1-40 Not used J1-41 Not used J1-42...
Page 31 www.CarGeek.ir (5) TRITEC 1. 6 engine controller pin (see Table 1-2) Table 1-2 Mark Name Resistance value Tolerance J1-01 V-IGK Ignition switch 11.9K ±0.1% J1-02 V-EL Main relay output 1.8K ±0.1% J1-03 Vehicle speed sensor ∞ Pressure/temperature sensor J1-04 TMAP-VCC 189.2K ±10K power supply...
Page 32 www.CarGeek.ir Table 1-2 continued J1-35 Acceleration signal 48.8K ±0.5K J1-36 PSTE Power assisted steering 7.1M ±0.2M Mark Name Resistance value Tolerance J1-37 J1-38 VLS-DN-A Rear oxygen signal 42.6K ±0.3K J1-39 ACIN A/C demand 9.9K ±0.2K J1-40 J1-41 Park/Neutral switch 13.3M ±0.5M J1-42 Manifold...
Page 33 www.CarGeek.ir (Fig. 1-11) 7. Electric fuel pump Fig. 1-11 (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.
Page 34 www.CarGeek.ir r (Fig. 1-13) 8. Electro-magnetic injecto Fig1-13 (1) Function: According to the orde 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.
Page 35 www.CarGeek.ir 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.
Page 36 www.CarGeek.ir (3) Connection of wiring diagram (Fig. 1-16) Fig. 1-16 (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.
Page 37 www.CarGeek.ir (4) Wiring diagram of the parts (Fig. 1-18) Fig. 1-18 (5) 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.
Page 38 www.CarGeek.ir 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.
Page 39: Steps For Trouble Diagnosis With Dtc
www.CarGeek.ir Section III Steps for Trouble Diagnosis with DTC LF Self-developed Engine (LF481Q3) (see Table 1-3) 1. A/C evaporator outlet temperature sensor Table 1-3 Diagnostic Trouble Code (DTC) Trouble Location or Type P1535 A/C evaporator temperature circuit high input---short or open to power supply P1536 A/C evaporator temperature circuit high input---short to ground P1545...
Page 40 www.CarGeek.ir 3. Shock sensor (see Table 1-5) Table 1-5 Diagnostic Trouble Code (DTC) Trouble Location or Type P0325 Shock sensor 1 circuit trouble Operation Test Results Actions Turn off the ignition switch, and stop the engine. Next step Disconnect the shock sensor from the harness. Next step Measure the resistance between pin (1) and pin (2) Renew sensor...
Page 41 www.CarGeek.ir 5. Oxygen sensor (see Table 1-7) Table 1-7 Diagnostic Trouble Code (DTC) Trouble Location or Type 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...
Page 42 www.CarGeek.ir 6. Intake manifold air temperarure sensor (see Table 1-8) Table 1-8 Diagnostic Trouble Code (DTC) Trouble Location or Type P0112 Intake air temperature circuit input low P0113 Intake air temperature circuit input high Operation Test Results Actions Ignition switch in position ON. Next step Disconnect the intake manifold absolute Next step...
Page 43 www.CarGeek.ir (see Table 1-10) 8. Fuel injector Table 1-10 Diagnostic Trouble Code (DTC) Trouble Location or Type P0261 Cyinder 1 fuel injector circuit low P0264 Cyinder 2 fuel injector circuit low P0267 Cyinder 3 fuel injector circuit low P0270 Cyinder 4 fuel injector circuit low P0262 Cyinder 1 fuel injector circuit high P0265...
Page 44 www.CarGeek.ir 9. Canister control valve driving stage (see Table 1-11) Table 1-11 Diagnostic Trouble Code (DTC) Trouble Location or Type Evaporative emission control system, canister control valve P0444 circuit open Evaporative emission control system, canister control valve P0445 circuit short Operation Test Results Actions...
Page 45 www.CarGeek.ir 10. Malfunction indicator light (MIL) driving stage (see Table 1-12) Table 1-12 Diagnostic Trouble Code (DTC) Trouble Location or Type P0650 MIL control circuit Operation Test Results Actions Ignition switch in position ON. Next step Open the instrument panel, remove the MIL bulb, Next step and measure the voltage of the jack.
Page 46 www.CarGeek.ir II. LF TRITEC Engine 1. DTC: P0112, Intake Air Temperature Sensor Temperature Too Low (see Table 1-14) Table 1-14 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to ON. Check the “intake air temperature” as per the data flow. Does it Go to step 5 match with the temperature within the intake pipe (related to the temperature of the engine at that moment)?
Page 47 www.CarGeek.ir 2. DTC: P0113, Intake Air Temperature Sensor Temperature Too High (see Table 1-15) Table 1-15 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn Next step the ignition switch to ON. Check the “intake air temperature” as per the data flow. Go to step 5 Does it match with the temperature within the intake pipe (related to the temperature of the engine at that moment)?
Page 48 www.CarGeek.ir 3. DTC: P0117, Engine Coolant Temperature Sensor Temperature Too Low (see Table 1-16) Table 1-16 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to ON. Check the “coolant temperature” as per the data flow. Does it Go to step 6 match with the temperature of the engine (related to the temperature of the engine at that moment)?
Page 49 www.CarGeek.ir 5. DTC: P0122, Throttle Position Sensor Circuit Voltage Too Low (see Table 1-18) Table 1-18 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to ON. Check the “throttle absolute openning” as per the data flow. Next step Does it within 4%-10% (related to vehicle model)? Go to step 5...
Page 50 www.CarGeek.ir 7. DTC: P0130, Upper Oxygen Sensor Signal Circuit Trouble (see Table 1-20) (Note: If the trouble of P0135 occurs simultaneously, please remove the trouble of P0135 at first, and then go to the following steps.) Table 1-20 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step...
Page 51 www.CarGeek.ir 9. DTC: P0134, Upper Oxygen Sensor Signal Circuit Trouble (see Table 1-22) (Note: If the trouble of P0135 occurs simultaneously, please remove the trouble of P0135 at first, and then go to the following steps.) Table 1-22 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step...
Page 52 www.CarGeek.ir 11. DTC: P0171, Air Fuel Ratio Closed Loop Control Self-adaptation Upper Limit Break (see Table (1-24) (Note: If the DTC related to intake air pressure sensor, canister control valve, oxygen sensor is produced, please remove these troubles at first, and then go to the following steps.) Table 1-24 Operation Test Results...
Page 53 www.CarGeek.ir 12. DTC: P0172, Air Fuel Ratio Closed Loop Control Self-adaptation Bottom Limit Break (see Table 1-25) (Note: If the DTC related to intake air pressure sensor, canister control valve, oxygen sensor is produced, please remove these troubles at first, and then go to the following steps.) Table 1-25 Operation Test Results...
Page 54 www.CarGeek.ir 13. DTC: P0204, 4-cylinder Feul Injector Circuit Trouble (see Table 1-26) Table 1-26 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to ON. Disconnect the 4-cylinder fuel injector from the harness. Go to step 4 Check the voltage between pin 1# of the injector and the negative pole of the power supply with a multimeter.
Page 55 www.CarGeek.ir 15. DTC: P0325, Shock Sensor Circuit Trouble (see Table 1-28) Table 1-28 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to OFF. Disconnect the shock sensor from the harness. Measure the Next step resistance between pin 1# and pin 2# with a multimeter.
Page 56 www.CarGeek.ir 17. DTC: P0336, Crankshaft Position Sensor Signal Abnormal (see Table 1-30) Table 1-30 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to OFF. Disconnect the rotation speed sensor from the harness. Next step Measure the resistance between pin 2# and pin 3# with a multimeter.
Page 57 www.CarGeek.ir 19. DTC: P0443, Canister Control Valve Driving Stage Control Circuit Trouble (see Table 1-32) Table 1-32 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to ON. Disconnect the canister control valve from the harness. Go to step 4 Measure the voltage between the pin 1# of the control valve and the power supply negative pole with a multimeter.
Page 58 www.CarGeek.ir 20. DTC: P0444, Canister Control Valve Driving Stage Control Circuit Voltage Too Low (see Table 1-33) Table 1-33 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to ON. Disconnect the canister control valve from the harness. Go to step 4 Measure the voltage between the pin 1# of the control valve and the power supply negative pole with a multimeter.
Page 59 www.CarGeek.ir 21. DTC: P0445, Canister Control Valve Driving Stage Control Circuit Voltage Too High (see Table 1-34) Table 1-34 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to ON. Disconnect the canister control valve from the harness. Go to step 4 Measure the voltage between the pin 1# of the control valve and the power supply negative pole with a multimeter.
Page 60: Abs System
www.CarGeek.ir 23. DTC: P0481, A/C Condenser Cooling Fan B Relay Control Circuit Trouble (see Table 1-36) Table 1-36 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to OFF. Disconnect A/C condenser cooling fan relay, and turn the Go to step 4 ignition switch to ON.
Page 61 www.CarGeek.ir 25. DTC: P0506, Idle Speed Too Low (see Table 1-38) Table 1-38 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to OFF. Next step Check the throttle adjusting bolt, accelerator cable, throttle for normal operation.
Page 62 www.CarGeek.ir 27. DTC: P0508, Idle Speed Regulator Control Circuit Voltage Too Low (see Table 1-40) Table 1-40 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to ON. Disconnect the idle speed regulator. Check the resistance Next step between pin A and pin D, as well as between pin B and pin C of the regulator.
Page 63 www.CarGeek.ir 30. DTC: P0560, System Voltage Signal Abnormal (see Table 1-43) Table 1-43 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to OFF. Next step Check the volatage with a multimeter. Is the voltage about 12V? Replace battery Repair or replace...
Page 64 www.CarGeek.ir 32. DTC: P0601, Electronic Control Unit Check Code Unprogrammed (see Table 1-45) Table 1-45 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to ON. Next step Clear the DTC, and check once again if the trouble is stable. Normal Replace ECU.
Page 65 www.CarGeek.ir 35. DTC: P0646, A/C Compressor Relay Control Circuit Voltage Too Low (see Table 1-48) Table 1-48 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to OFF. Disconnect the A/C compressor relay, and turn the ignition Go to step 4 switch to ON.
Page 66 www.CarGeek.ir 37. DTC: P1651, Malfunction Indicator Light Control Circuit Trouble (see Table 1-50) Table 1-50 Operation Test Results Actions Connect the diagnostic instrument and adapter, and turn the Next step ignition switch to ON. Next step Carry out action tests for the MIL of the engine with a diagnostic instrument.
Page 67: Steps For Trouble Diagnosis Based On Engine Symptom
www.CarGeek.ir 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.
Page 68 www.CarGeek.ir I. LF481Q3 engine 1. If the engine fails to run or runs slowly at start, carry out the trouble diagnosis and removal as per Table 1-51. Table 1-51 Operation Test Results Actions Measure the voltage between the two terminals of the Next step battery with a multimeter.
Page 69 www.CarGeek.ir 2. If the engine can not be successfully started, carry out the trouble diagnosis and removal as per Table 1-52. Table 1-52 Operation Test Results Actions Turn the ignition switch to ON. Check if there is Remove the trouble trouble information records with a diagnostic Next step instrument.
Page 70 www.CarGeek.ir Table 1-52 (Continued) Operation Test Results Actions Replace or repair fuel intake Check the fuel intake pipe for leakage or blockage. pipe Replace fuel pump Repair or replace fuel return pipe Check if the fuel return pipe is blocked or bent. Replace fuel pressure regulator Connect an adapter between the ECU and the...
Page 71 www.CarGeek.ir Table 1-53 (Continued) Operation Test Results Actions Replace fuel injector and fuel pipe Check the fuel injector and the fuel pipe for leakage. Next step Check the coolant Take out the water temperature sensor, and start the temperature and line engine.
Page 72 www.CarGeek.ir Table 1-54 (Continued 1) Operation Test Results Actions Connect the fuel pressure gauge valve. Short-circuit Next step the pin 30 and the pin 87 of the fuel bump relay, and run the fuel pump. Check if the fuel pressure is about 300kPa.
Page 73 www.CarGeek.ir Table 1-54 (Continued 2) Operation Test Results Actions Check if the compressed pressure of the engine Next step cylinder is normal. Remove the trouble Check if the intake air manifold absolute pressure and Repair or replace temperature sensor is blocked. Next step Check if the coolant temperature sensor for normal Replace ECU...
Page 74 www.CarGeek.ir Table 1-55 (Continued) Operation Test Results Actions Next step Clean the fuel injector and check the fuel injector for normal operation. Replace fuel injector Renew fuel Check if the fuel is wrong or contains water. Next step Check if the fuel pressure is lower than 250kPa. Close the fuel gauge valve.
Page 75 www.CarGeek.ir 6. Unstable idle speed at any time Table 1-56 Operation Test Results Actions Turn the ignition switch to ON. Check if there is trouble Remove the trouble information records with a diagnostic instrument. Next step Check if the idle speed actuator or the stepper motor Replace idle speed actuator idle speed actuator is locked.
Page 76 www.CarGeek.ir Table 1-56 (Continued) Operation Test Results Actions Replace fuel Check if the fuel is wrong or contains water. Next step Check if the fuel pressure is lower than 380kPa. Close the fuel gauge valve. Turn on the ignition switch Next step again and keep the fuel pump working for 3 seconds.
Page 77 www.CarGeek.ir 7. Unstable idle speed during warm-up Table 1-57 Operation Test Results Actions Remove the trouble Turn the ignition switch to ON. Check if there is trouble information records with a diagnostic instrument. Next step Next step Check the air filter for smoothness. Replace Run the engine at an idle speed.
Page 78 www.CarGeek.ir Table 1-58 (Continued) Operation Test Results Actions Next step Check if the intake air manifold pressure is between Remove leakage for the air 35kPa and 65kPa under idle speed. intake system Connect the fuel pressure gauge valve. Short-circuit the Next step pin 30 and the pin 87 of the fuel bump relay, and run the fuel pump.
Page 79 www.CarGeek.ir 9. Unstable idle speed or flameout under load (A/C etc) Table 1-59 Operation Test Results Actions Turn the ignition switch to ON. Check if there is trouble Remove the trouble information records with a diagnostic instrument. Next step Turn on the A/C switch. Connect an adapter between Next step the ECU and the harness.
Page 80 www.CarGeek.ir Table 1-60 (Continued) Operation Test Results Actions Run the engine at an idle speed. Check if the ignition Next step advance angle is normal after the coolant reaches Adjust ignition advance normal operation. angle Clean up Check if the sense hole of the intake air manifold pressure and temperature sensor is blocked.
Page 81 www.CarGeek.ir 11. Idle speed too high Table 1-61 Operation Test Results Actions Turn the ignition switch to ON. Check if there is Remove the trouble trouble information records with a diagnostic instrument. Next step Adjust or replace Check if the cable connected the the accelerator pedal is locked or tightened.
Page 82 www.CarGeek.ir 12. Ineffective acceleration or flameout Table 1-62 Operation Test Results Actions Turn the ignition switch to ON. Check if there is Remove the trouble trouble information records with a diagnostic Next step instrument. Next step Check the air filter for smoothness. Replace Next step Run the engine at an idle speed.
Page 83 www.CarGeek.ir Table 1-62 (Continued) Operation Test Results Actions Replace fuel pressure Turn on the fuel gauge valve, and block the fuel return regulator pipe. Check if the fuel pressure is quickly produced. Repair or replace fuel injector or fuel pipe Repair or replace fuel intake pipe Check the fuel intake pipe for leakage or blockage.
Page 84 www.CarGeek.ir Table 1-63 (Continued) Operation Test Results Actions Turn the ignition switch to ON. Connect an adapter Next step between the ECU and the harness. Check the voltage of the pin J1-24 (signal output end of the throttle position sensor), J1-05 (grounding end), J1-20 (as the Repair or replace harness power supply for 4.5-5V sensor).
Page 85 www.CarGeek.ir 14. Poor acceleration Table 1-64 Operation Test Results Actions Repair Check the clutch, tyre pressure, brake, tyre size and four-wheel alignment for normal operation. Next step Next step Check if the throttle can be fully opened. Replace or repair throttle Turn the ignition switch to ON.
Page 86 www.CarGeek.ir Table 1-64 (Continued) Operation Test Results Actions Next step Check if the fuel pressure is lower than 250kPa. Close the fuel gauge valve. Turn on the ignition switch Next step again and keep the fuel pump working for 3 seconds. Check if fuel pressure can be produced.
Page 87 www.CarGeek.ir 15. A/C system trouble Table 1-65 Operation Test Results Actions Check if the refrigerant of the A/C system is enough. Next step Check the A/C belt, clutch, pressure switch for normal operation. Remove the trouble Run the engine at an idle speed. Turn on the A/C switch. Remove the trouble Check if the A/C thermal resistance is under trouble with a diagnostic instrument.
Page 88 www.CarGeek.ir Table 1-66 (Continued) Operation Test Results Actions Remove the ignition metal wire from the spark plug. Install Next step the wire to a normal spark plug. Place the bottom end of Check ignition coil, giant the spark plug towards the gound, and then turn to the transistor, and their engine.
Page 89 www.CarGeek.ir II. TRITEC 1.6 engine 1. Fail to run or run slowly at start Common trouble location： 1. Battery; 2. Start motor; 3. Harness or ignition switch; 4. Mechanical paof the engine. Diagnosis Flow Table 1-67 Operation Test Results Actions Check the voltage between the two terminals of the Next step battery with a multimeter.
Page 90 www.CarGeek.ir 2. Start failure of the engine Common trouble location: 1. No fuel in the tank; 2. Fuel pump; 3. Rotation speed sensor; 4. Ignition coil; 5. Mechanical part of the engine Diagnosis Flow Table 1-68 Operation Test Results Actions Connect the fuel pressure gauge (the connection Next step point is the front end of the intake pipe of the fuel...
Page 91 www.CarGeek.ir 3. Difficult to start after warm-up Common trouble location: 1. Fuel with water; 2. Fuel pump; 3. Coolant temperature sensor; 4. Fuel pressure regulator vacuum pipe; 5. Ignition coil. Diagnosis Flow Table 1-69 Operation Test Results Actions Connect the fuel pressure gauge (the connection Next step point is the front end of the intake pipe of the fuel distribution pipe assembly), and start the engine.
Page 92 www.CarGeek.ir 4. Difficult cold start Common trouble location: 1. Fuel with water; 2. Fuel pump; 3. Coolant temperature sensor; 4. Fuel injector; 5. Ignition coil; 6. Throttle body and idle speed by-pass air way; 7. Mechanical part of the engine. Diagnosis Flow Table 1-70 Operation...
Page 93 www.CarGeek.ir 5. With normal rotation speed, difficult to start at any time Common trouble location: 1. Fuel with water; 2. Fuel pump; 3. Coolant temperature sensor; 4. Fuel injector; 5. Ignition coil; 6. Throttle body and idle speed by-pass air way; 7.
Page 94 www.CarGeek.ir Table 1-71 (Continued) Operation Test Results Actions Next step Check if the ignition sequence and timing of the Check and repair ignition engine can meet with the standards. timing Connect the electronic injection system adapter. Diagnosis help Turn on the ignition switch. Check the power supply of the pin 12#, 13#, 44#, 45#, 63#.
Page 95 www.CarGeek.ir Table 1-72 (Continued) Operation Test Results Actions Remove the mechanical Check the pressure for each cylinder of the engine. troubles for the engine Are they great different? Next step Next step Check if the ignition sequence and timing of the Check and repair ignition engine can meet with the standards.
Page 96 www.CarGeek.ir Table 1-73 (Continued) Operation Test Results Actions Remove the fuel injector. Check the fuel injector for Remove the trouble leakage, blockage or abnormal flow with a special fuel injector cleaner & analyzer. Next step Replace fuel Check the fuel for normal operation. Next step Remove the mechanical troubles for the engine...
Page 97 www.CarGeek.ir Table 1-74 (Continued) Operation Test Results Actions Replace sensor Disconnect the coolant temperature sensor, and start the engine. Check the engine under warm-up for unstable idle speed. Next step Remove the trouble Remove the fuel injector. Check the fuel injector for leakage, blockage or abnormal flow with a special fuel injector cleaner &...
Page 98 www.CarGeek.ir 9. With normal start, unstable idle speed or flameout under partial load (with A/C on, etc) Common trouble location: 1. A/C system; 2. Idle speed regulator; 3. Fuel injector Diagnosis Flow Table 1-75 Operation Test Results Actions Adjust Check if the accelerator cable is locked or over tightened.
Page 99 www.CarGeek.ir 10. With normal start, idle speed too fast Common trouble location: 1. Throttle body and idle speed by-pass air way; 2. Vacuum pipe; 3. Idle speed regulator; 4. Coolant temperature sensor; 5. Ignition timing Diagnosis Flow Table 1-76 Operation Test Results Actions Adjust...
Page 100 www.CarGeek.ir 11. Unfavorable rotation speed or flameout during acceleration Common trouble location: 1. Fuel with water; 2. Intake air pressure sensor and throttle position sensor; 3. Spark plug; 4. Throttle body and idle speed by-pass air way; 5. Intake air way; 6.
Page 101 www.CarGeek.ir Table 1-77 (Continued) Operation Test Results Actions Next step Check the exhaust pipe for smoothness. Repair or replace exhaust pipe Connect the electronic injection system adapter. Turn on Diagnosis help the ignition switch. Check the power supply of the pin 12#, 13#, 44#, 45#, 63#.
Page 102 www.CarGeek.ir Table 1-78 (Continued) Operation Test Results Actions Next step Check the spark plug for each cylinder. Check if its model and gap can meet with starndards. Adjust or replace Wash relevant parts Remove the idle speed regulator. Check the throttle body, idle speed regulator, and idle speed by-pass air way for carbon deposition.
Page 103: Security Items For System Maintenance
www.CarGeek.ir Section V Security Items for System Maintenance 1. Security items for the diagnosis and maintenance of the fuel injection electronic control system (1) Remove and install requirements for the controller Remove the controller before welding and paint baking; ① Turn the ignition switch to OFF when remove the controller to avoid damage;...
Page 104: Chassis System
www.CarGeek.ir Chapter II Chassis System Section I Suspension and Axle I. Overview 1. Front axle and front suspension, Fig. 2-1. Fig. 2-1 1. Hexagon flange nut (36 N·m) 2. Front shock damper upper pressure plate 3. Left front shock damper assembly 4.
Page 105 www.CarGeek.ir They can receive larger traction under the same conditions. As the main indicator for automobile performance, the dynamic power should be strengthened by all means thus to determine the drive axle. Generally, autos are driven by rear axles because 2/3 weight of the entire vehicle is burdened by the rear axle which thus can receive better traction.
Page 106 www.CarGeek.ir road surface better, reduces the vehicle vibration due to uneven road surface and enhances the comfort and driving stability. 2. Rear suspension. Refer to Fig. 2-2. Fig. 2-2 1. Left rear shock damper assembly 2. Hexagon flange nut (75N·m) 3.
Page 107 www.CarGeek.ir most prominent advantage lies in the large space between the left and right wheels together with no camber angle of the body, and a sunken rear wheel of the swing arm suspension to balance the vehicle body. 3. Specifications of wheel alignment parameters If the wheels enjoy good geometric alignment, the fuel economic efficiency and tire service life will be improved.
Page 108 www.CarGeek.ir The negative toe-in means that the wheel moves outward, as shown in Fig. 2-5. Fig. 2-5 The toe-in is designed to ensure a parallel roll of the wheels. The toe-in can also complement the little excursion of the wheel supporting system during driving forwards. Only with a proper toe-in can the wheels run in parallel on the road surface.
Page 109 www.CarGeek.ir II. Fault Elimination Table, Table 2-2. Table 2-2 Fault Possible Cause Action Check if the load is abnormal, if the ring Incorrect vehicle height (high or low front or rear) spring is sunken or is not standard spring. Worn or broken steering gear or connecting rod. Check the steering system.
Page 110 www.CarGeek.ir III. Maintenance i. Wheel alignment adjustment 1. Front wheel extroversion adjustment The front wheel extroversion is adjusted as shown in Fig. 2-7. Raise the vehicle, and dismantle the support from the vehicle. Fix the support on the bench clamp and gouge holes on the side panel. The extroversion can be adjusted by the bolt hole between the file support and steering knuckle.
Page 111 www.CarGeek.ir ii. Replacement of parts and components assembly 1. Replacement of front brake wheel hub assembly (1) Disassembly of front brake wheel hub assembly 1) Raise and properly support the vehicle and dismantle the wheel assembly. 2) As per Fig. 2-9, disconnect the wheel speed sensor connector, and remove the sensor from the bracket.
Page 112 www.CarGeek.ir (2) Installation of front brake wheel hub assembly To install, reverse the removal procedure. When installing front wheel speed sensor, please ensure that the connector clip is well matched. 2. Replacement of front stabilizer bar (1) Disassembly of front stabilizer bar. Disconnect the related connections. Lower the whole front sub-frame according to Fig.
Page 113 www.CarGeek.ir The steering knuckle is replaced together with the brake gear assembly according to related sections about brake gear. 4. Replacement of lower arm assembly (1) Disassembly of the lower arm assembly 1) Revolve the steering wheel to move the relevant front wheel to the minimum side position. 2) According to Fig.
Page 114 www.CarGeek.ir tightening torque reading at the fifth turn. Tightening torque: 0.05～1.98Nm. Fig. 2-16 (2) Installation 1) Temporarily screw down the front suspension lower arm assembly. Fasten the front suspension lower arm assembly by 2 bolts and nuts. No need to use torque tools, as shown in Fig. 2-17. Fig.
Page 115 www.CarGeek.ir 5. Replacement of shock damper (1) Disassembly of front shock damper assembly. 1) Dismantle the front wheel. 2) Disconnect the brake hose. Remove the bolt, brake hose and ABS vehicle speed sensor harness clip from the shock damper bracket (of vehicle with ABS) according to Fig. 2-19. Fig.
Page 116 www.CarGeek.ir (3) Disassembly of the rear shock damper assembly 1) Dismantle the rear wheel. 2) Dismantle the left and right rear shock damper assembly according to Fig. 2-22. Fig. 2-22 ① Raise the rear axle frame by a jack. ② Dismantle the thickened flange nut connecting the rear shock damper from the rear sub-frame assembly.
Page 117 www.CarGeek.ir Section II Steering System The steering system is a special mechanism to change or maintain the driving direction of a vehicle. It is used to change the direction at a proper time according to the requirement of the driver during driving, and cooperate with the driving system to keep the vehicle moving stably in case that the vehicle moves off the driving direction due to the accidental impact from the road surface.
Page 118: Fault Diagnosis
www.CarGeek.ir I. Fault Diagnosis of Steering System 1. Note for inspection (1) Take extra care while replacing the components. Incorrect operation may affect the performance of the steering system and lead to driving accident. (2) Notes for SRS system. This vehicle is equipped with SRS, like driver air bag and front passenger air bag.
Page 119 www.CarGeek.ir Table 2-3 (Continued 1) Fault Possible Cause Actions In case of a vehicle speed below 50 km/h (30mph), turn the transmission to NEUTRAL, and turn the ignition switch to position I (engine OFF-sliding). In case that the vehicle does not lean to one side when stopping, install a new steering gear.
Page 120 www.CarGeek.ir Table 2-3 (Continued 2) Fault Possible Cause Actions After steering, the steering Blocked or broken tie-rod. Install a new steering gear if necessary. wheel will not go back to the Broken or worn front Install new front suspension components if central position without the suspension components.
Page 121 www.CarGeek.ir Table 2-3 (Continued 3) Fault Possible Cause Actions Oil at a temperature below 54°C (130°F) flow into the bypass Swish noise Normal. valve of the housing of pump valve. With air in the oil and leakage in Purify the air in the system. the system.
Page 122 www.CarGeek.ir Table 2-3 (Continued 4) Fault Possible Cause Actions Steering knuckle (worn). Replace it if necessary. Suspension arm ball joint (worn). Replace it if necessary. Intermediate shaft, and slip Over large clearance Replace it if necessary. joint/yoke (worn). Front wheel bearing (worn). Replace it if necessary.
Page 123: Removal And Installation
www.CarGeek.ir 2. Steering wheel and column as shown in Fig. 2-25. Fig. 2-25 3. Removal and installation of steering wheel and column assembly Note: ① Follow the notes for the maintenance of steering pump. ② Disconnect the negative terminal of the battery. Make sure that the front wheels are in the straight ahead position.
Page 124 www.CarGeek.ir 3) Push out the horn button assembly from the steering wheel, as shown in Fig. 2-27. Fig. 2-27 4) Use a screwdriver to release the locked part of the air bag connector and then remove the air bag connector. Note: Do not drag the air bag harness when removing the horn button assembly;...
Page 125 www.CarGeek.ir 10) Locate the ignition switch at position ACC, and dismantle the coil spring assembly. Note: The combination switch is connected to the installation plate by a metal clip and 2 plastic clips. Firstly prize the metal clip from the installation hole by a screwdriver and then remove the 2 plastic clips. See structure drawing in Fig.
Page 126 www.CarGeek.ir Mark the matching place on the slip yoke and intermediate shaft. ① Loosen the bolt A and B, and then disconnect the intermediate shaft. ② 15) Remove the steering column assembly, as shown in Fig. 2-33. Fig. 2-33 Disconnect the connector and harness clip from the steering column assembly. ①...
Page 127 www.CarGeek.ir 19) Remove the ignition switch lock core assembly as shown in Fig. 2-36. Fig. 2-36 ① Turn the ignition switch to position ACC. Press down the lock by a screwdriver and pull out the lock core. ② 20) Dismantle the unlocked warning switch assembly. Disconnect the unlocked warning switch from the ignition switch ass embly.
Page 128 www.CarGeek.ir 14) Install the upper cap of the steering column. Install the upper & lower caps of the steering column with three bolts. 15) Align the clock spring. ① Make sure the ignition switch at position OFF. Make sure the negative terminal of the battery is disconnected. Note: Operate 90s later. ②...
Page 129 www.CarGeek.ir (4) Connect the return hose, and fix with clip. (5) Fill the reservoir with the specified oil, neither higher than the maximum level, nor lower than the minimum level. Oil: ESSOATF.D. Filling amount for reference: 0.825L. (6) With idle operation of the engine, repeatedly turn the steering wheel from lock to lock, to discharge the air for the steering system.
Page 130 www.CarGeek.ir (2) Discharge the air and turn the steering wheel for several times to raise the fluid temperature to 50-60 . ℃ (3) Start the engine and keep it rotating at a speed of 1000±100r/min. (4) Close the cut-off valve of the pressure gauge completely and check if the safety pressure of the oil pump is within the standard value.
Page 131 www.CarGeek.ir Discharge steering fluid. ① ② Dismantle the high pressure oil outlet pipe connected to the steering oil pump, screw off the hollow bolt, and remove the hose bracket connected to the engine. ③ Disconnect the steering gear from the steering lower shaft. ④...
Page 132 www.CarGeek.ir Section III Brake System The brake system is used to transform the force on the brake pedal from the driver to braking force of all wheels. Then the hydraulic system will distribute the braking force to each wheel. The vacuum brake booster is used to decrease the force from the pedal and increase the hydraulic pressure.
Page 133 www.CarGeek.ir Table 2-4 Fault Possible Cause Actions With air in system Discharge the air in system. Low-position or soft pedal Brake pad Check and install a new component if necessary. Brake booster Check the booster components. Brake pad Check and install a new component if necessary. Locked pedal when gently Brake disc Check and install a new component if necessary.
Page 134 www.CarGeek.ir Brake fluid: DOT4, filling amount: 0.72L. 2. Discharge the air in the brake master pump Note: Discharge the air in the brake master pump if it has been dismantled or the reservoir is empty. 1) Disconnect the oil pipeline connector from the brake master pump. 2) Slowly step down the pedal and maintain without movement, as shown in Fig.
Page 135 www.CarGeek.ir 2) Step down the pedal for times and then keep it stepped down, and then screw off the air discharging bolt. 3) Screw down the air discharging bolt immediately when the brake fluid flows out, and release the brake pedal. 4) Repeat step 2) and 3) until all air in brake fluid flow out.
Page 136 www.CarGeek.ir 1) Stop the engine, step down the pedal repeatedly until there is no vacuum in booster. 2) Step down the pedal until resistance is felt. Measure the distance shown in Fig. 2-44. Free play of pedal: 1-6mm. In case of clearance out of specifications, check the clearance of the brake lamp switch.
Page 137 www.CarGeek.ir 5. Removal and installation. See Fig. 2-46. Fig. 2-46 (1) Removal 1) Remove the components of instrument cluster. 2) Disconnect the U connector of the push rod of brake master pump. Dismantle the clip and push rod pin, and disconnect the brake master pump from the brake pedal. 3) Remove the brake pedal support.
Page 138 www.CarGeek.ir 5) Remove the brake lamp components. Release the brake lamp switch and locking nuts. ① Remove the brake lamp switch from the brake pedal support. ② 6）Remove the pad of brake pedal from the brake pedal. (2) Installation 1) Install the brake pedal pad on the pedal. 2) Install the brake lamp components on the brake pedal.
Page 139 www.CarGeek.ir braking distance is changed. ② Step down the pedal and start the engine. Note: The operation is normal if the pedal drops slightly. 2. Check the vacuum one-way valve. 1) Glide the clip and disconnect the vacuum pipe. 2) Remove the vacuum one-way valve. 3) Check if the way from the booster to engine is ventilated.
Page 140 www.CarGeek.ir brake master pump. 6) Remove the sliding pin of the slave cylinder of front disc brake. Remove the sliding pin from the support of the disc brake master pump. 7) Remove the dustproof cover of the front disc sliding pin. Remove the 2 dustproof cover from the support of the slave cylinder of front disc brake.
Page 141 www.CarGeek.ir 12) Remove the oil seal of piston. Take out the oil seal from the brake slave cylinder by a screwdriver. See Fig. 2-55. Fig. 2-55 (2) Inspection 1) Inspect eh brake slave cylinder and piston. Check if the piston is rusty or scratched. 2) Check the lining thickness of the brake pad.
Page 142 www.CarGeek.ir 2) Install the oil seal of piston. Smear the lithium base glycol grease on the new oil seal of the piston. ① Insert the new oil seal into the brake slave cylinder. ② 3) Install brake piston. Smear the lithium base glycol grease on the brake piston.
Page 143 www.CarGeek.ir Install the new washer and hose by joint bolt. Tightening torque: 30N·m. Note: Secure the hose ② tightly in the locking hole of the brake slave cylinder. 10) Discharge the air in the brake slave cylinder. 11) Discharge the air in the brake pipeline. 12) Check if there is brake fluid leakage.
Page 144 www.CarGeek.ir Dismantle the 2 bolts after securing the sliding pin of the slave cylinder of the rear disc brake. ② See Fig. 2-62. Fig. 2-62 4) Dismantle the rear brake pad suite. Dismantle the brake pad with 2 silencer pads. ①...
Page 145 www.CarGeek.ir 10) Dismantle the air discharging bolt of the rear disc brake gear. 11) Dismantle the piston of the rear brake slave cylinder. Place a cloth or equivalent betw een the slave cylinder and piston. ① ② Blow out the piston from the brake slave cylinder by compressed air. See Fig. 2 -65.
Page 146 www.CarGeek.ir Fig.2-68 In case that the swaying of brake disc reaches or exceeds the limit, check the axial clearance of ③ the bearing and the swaying of wheel hub. If both bearing and hub are normal, adjust the swaying of brake disc. (3) Installation 1) Temporarily screw down the air discharging bolt on the rear brake slave cylinder.
Page 147 www.CarGeek.ir Fig. 2-69 Install silencer pad on each brake pad. ② ③ The wear indicator is upwards. Install the inside brake pad, and then the outside. Note: The friction surface between the brake pad and the brake disc should be free of engine oil or grease.
Page 148 www.CarGeek.ir 2. Front and rear cables support 3. Parking brake cable 1. Fault elimination Table 2-5 Fault Possible Cause Action 1. Check the parking cable and Inactive parking 1. Parking brake cable adjustment brake 2. Parking brake control 2. Check the parking brake control Unreleased parking 1.
Page 149 www.CarGeek.ir Fig. 2-73 (1) Removal 1) Remove the trim strip of the instrument cluster and air conditioning control panel as shown in Fig. 2-74. Fig. 2-74 1. Trim strip of the instrument cluster 2. Air conditioning control panel 3. Bolt 4.
Page 150 www.CarGeek.ir Fig. 2-75 Dismantle the connector of the parking brake rod switch. ① Take off the parking brake rod after rem oving the 2 bolts. ② 8) Dismantle the parking brake switch components. Remove the bolts and parking brake switch components.
Page 151 www.CarGeek.ir 6) Remove the No. 1 adjustment nut lead. 7) Remove the accessories of the parking brake rod as shown in Fig. 2-76. Dismantle the connector of the parking brake rod switch. ① ② Take off the parking brake rod after removing the 2 bolts.
Page 152 www.CarGeek.ir brake cable to the soleplate by bolts. Tightening torque: 7.8N·m. 3) Smear the heat-resistant grease. 4) Install the brake shoe. 5) Install the pull-back spring of brake shoe. 6) Install the self-adjusting rod of LR brake. 7) Install the front brake shoe. 8) Inspect the installation of brake disc.
Page 153 www.CarGeek.ir Section IV Fuel System I. Removal and Installation 1. Operation before removal ① Suck the fuel Avoid fuel flowing to the floor ② ③ Remove the secondary muffler 2. Operation after installation Fill fuel ① nfirm if there is fuel leakage ②...
Page 154 www.CarGeek.ir (3) Cover the accessory and block the hole when the fuel system works to avoid dust and other dirties entering the fuel system from open pipeline or entries. (4) Take care to keep all components of fuel system clean. Note: (1) Reinstall the 4 M10 fixing bolts used for fuel tank, and tighten them by a tightening torque of 40N·m.
Page 155: Engine Cooling System
www.CarGeek.ir Section V Engine Cooling System Warning: Do not open the cover of radiator or loose the bolt for drainage when the engine runs or the radiator is too hot, to avoid serious hurt caused by the boiling coolant and steam. Besides, the engine and cooling system may also be damaged.
Page 156 www.CarGeek.ir (2) Check if the coolant is mixed with engine oil. 3. Replacement of coolant (1) Dismantle the bolt for drainage and radiator cover in order. Discharge the coolant in the radiator, warm air blower and engine; (2) Dismantle the drain valve of the cylinder body, and discharge the coolant in the water-cooled jacket;...
Page 157 www.CarGeek.ir 2) Smear the specified sealant evenly. Sealant and sealing is not need at some place. 3) Install the thermostat when the sealant is still damp (within 15 min). (3) Connection of radiator water outlet and inlet pipes 1) Insert the water outlet and inlet pipes into the connectors or projected part of the drain pipe connector.
Page 158: Intake And Exhaust System
www.CarGeek.ir Section VI Intake and Exhaust System I. Air Cleaner Assembly Removal and installation (Fig. 2-82 shows the air cleaner assembly of sedan with TRITEC1.6L engine). Note: The filter core is made from waste paper and resin. Notes for operation: Do not inflict severe collision and load after assembly and removal.
Page 159 www.CarGeek.ir II. Removal and Installation of Exhaust Pipe and Muffler 1. Removal and installation (Fig. 2-83 shows the exhaust system of the TRITEC1.6L engine) Fig. 2-83 1. Front floor lower heat-insulating pad of exhaust pipe 2. Dash panel lower heat-insulating pad of exhaust pipe 3.
Page 160: Function And Composition Of Abs
www.CarGeek.ir Chapter III ABS Section I Function and Composition of ABS I. Function of ABS ① To improve stability of the vehicle; ② To ensure steering performance of the vehicle; ③ To guarantee shortest braking distance. II. ABS Composition (in Fig. 3-1) The ABS of LF620 sedan is composed of electronic control unit, hydraulic control unit, sensor and motor.
Page 161: Principle Of Abs
www.CarGeek.ir Section II Principle of ABS I. Control Principle of ABS Fig. 3-2 shows the control principle of ABS. Fig. 3-2 II. Operating Mode of ABS 1. Operating condition of regular brake (Table 3-1 and Fig. 3-3). Table 3-1 Solenoid valve Electricity Solenoid valve condition Normally opened valve...
Page 162 www.CarGeek.ir 2. ABS operation (pressure decrease) condition (Table 3-2 and Fig. 3-4). Table 3-2 Solenoid valve Electricity Solenoid valve condition Normally opened valve Closed Normally closed valve Open Fig. 3-4 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.
Page 163 www.CarGeek.ir 4. ABS operation (pressure increase) condition (Table 3-4 and Fig. 3-6). Table 3-4 Solenoid valve Electricity Solenoid valve condition Normally opened valve Open Normally closed valve Closed Fig. 3-6 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.
Page 164: Removal And Installation Of Abs
www.CarGeek.ir Section III Removal and Installation of ABS I. Spare Parts Supply Condition 1. Difference between dry HECU and wet HECU (Fig. 3-8) Fig. 3-8 The biggest difference between dry HECU and wet HECU is the second circuit (between normally closed valve and master pump) of dry HECU does not exhaust.
Page 165 www.CarGeek.ir 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 20N·m with a special tool, torque wrench, as shown in Fig.
Page 166 www.CarGeek.ir 5. Replacement of HECU (1) Remove connecting piece of pin 25 and wire harness of HECU in engine compartment when engine stops, as shown in Fig. 3-11. Fig. 3-11 (2) Remove the 6 M10×1 nuts of brake pipe of HECU with wrench 10 in a counterclockwise (clockwise when installing) direction.
Page 167 www.CarGeek.ir (5) Remove the 6 bolts on wet HECU with 6mm hexagonal wrench in a counterclockwise direction, as in Fig. 3-13. Fig. 3-13 (6) Assemble the wet HECU and bracket with a 5mm tool (hexagonal wrench) by tightening the 3 inserted nuts M6 in clockwise direction, as shown in Fig.
Page 168: Fault Diagnosis And Troubleshooting
www.CarGeek.ir Section IV Fault Diagnosis and Troubleshooting I. Fault Detection Procedure (Fig. 3-15) Fig. 3-15 II. Notes on Fault Diagnosis (Table 3-5) 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 3-5 Phenomenon Description...
Page 169 www.CarGeek.ir 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.
Page 170 www.CarGeek.ir 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.
Page 171 www.CarGeek.ir 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.
Page 172 www.CarGeek.ir 4. DTC Table (1) DTC content is in Table 3-8. (2) See Table3-9, Table 3-10, Table 3-11, Table 3-12, Table 3-13, Table 3-14 and Table 3-15 for DTC Table. Table 3-8 Content Content C1 200 Left front sensor open/short circuit C1 206 Left rear sensor open/short circuit C1 201...
Page 173 www.CarGeek.ir Table 3-9 (continued) Elimination procedure www.cargeek.ir...
Page 174 www.CarGeek.ir Table 3-10 ① C1 202 C1 205 Note: Air gap is the gap between gear ring and sensor; ② C1 208 C1 211 If faults corresponding to more than 2 DTC can be confirmed, delete the DTC (that can be deleted), drive the Air gap error: no signal because of vehicle at a speed of over 40 km/h, confirm the fault air gap too large or sensor short...
Page 175 www.CarGeek.ir Table 3-11 ① Note: Foreign materials, like engine oil and scrap iron in C1 201 C1 204 gear may cause asymmetrical sensor signal; C1 207 C1 210 ② Air gap means the gap between gear ring and sensor; ③ If faults corresponding to more than 2 DTC can be confirmed, delete the DTC (that can be deleted), drive the Gear ring or sensor disturbance:...
Page 176 www.CarGeek.ir Table 3-12 Note: If faults corresponding to more than 2 DTC can be C1 101 C1 102 confirmed, delete the DTC (that can be deleted), drive the vehicle at a speed of over 40 km/h, confirm the fault Battery voltage abnormal: corresponding to this DTC again and refer to the recorded Cause Occurring when voltage too high or...
Page 177 www.CarGeek.ir Table 3-13 Note: If faults corresponding to more than 2 DTC can be C2402 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 Cause Motor fuse/motor fault DTC (and confirm the same fault code).
Page 178 www.CarGeek.ir Table 3-14 Note: If faults corresponding to more than 2 DTC can be C2112 confirmed, delete the DTC (that can be deleted), drive the vehicle at a speed of over 40 km/h, confirm the fault Valve fuse and relay faults: corresponding to this DTC again and refer to the recorded Cause a) Main replay or fuse disconnection...
Page 179 www.CarGeek.ir Table 3-15 Note: If faults corresponding to more than 2 DTC can be C1 604 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 ECU internal circuit and valve coil DTC (and confirm the same fault code).
Page 180 www.CarGeek.ir 5. No DTC Fault Table is in Table 3-16, Table 3-17, Table 3-18, Table 3-19 and Table 3-20. Table 3-16 Fault Start the engine, but ABS warning lamp can not be turned on ① ② Fuse is blew out Bulb of ABS warning lamp is broken Cause ③...
Page 181 www.CarGeek.ir Table 3-17 Fault Start the engine, but ABS warning lamp is always on ① Controller of ABS warning lam p is broken ② Cause Return circuit of warning lamp controller is open ③ ECU is broken Elimination procedure www.cargeek.ir...
Page 182 www.CarGeek.ir Table 3-18 Fault ABS works abnormally ① Sensor is damaged ② Sensor is not properly installed ③ Foreign material adheres to sensor ④ Wire harness of sensor is broken Cause ⑤ ⑥ Gear ring is broken Wheel axle is broken ⑦...
Page 183 www.CarGeek.ir Table 3-19 Fault Brake pedal play is too long ① Parking brake is not properly adjusted ② Brake fluid leaks ③ Friction plate of brake is severely worn ④ Cause Normally closed valve can not be closed tightly ⑤ Air is in the system Elimination procedure...
Page 184 www.CarGeek.ir Table 3-20 Fault No fault code output (unable to communicate with fault diagnostic instrument) ① ② Fuse is blew out Fault diagnostic instrument is broken Cause ③ Diagnosis wire is broken or connector is loose ④ ECU is broken Elimination procedure www.cargeek.ir...
Page 185 www.CarGeek.ir V. Exhaust and Filling 1. Regular operation procedures (Fig. 3-19). Fig. 3-19 Regular operation procedures of exhaust and filling: A. Move vacuum device and brake oil filling device; B. Start after connection of vacuum, brake oil filling devices and SDL; C.
Page 186 www.CarGeek.ir (4) HECU voltage of 10 ~ 12V is preferred during exhaust mode operation. As battery on vehicle is used when using diagnostic instruments, there should be no problem. (If exhaust mode operation is repeated with high voltage, ECU coil may be damaged.) 4.
Page 187 www.CarGeek.ir ⑤ (7) Rework of operation of item (exhaust) should be carried out for all wheels. (8) Measure the play of brake pedal; if not in compliance with specification, repeat the ⑥ ⑤ processes in item (exhaust mode) and item (exhaust).
Page 188 www.CarGeek.ir 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.
Page 189 www.CarGeek.ir 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.
Page 190 www.CarGeek.ir Appendix III: ABS Interior Hydraulic Pressure Flow Diagram Fig. 3-20 Appendix IV: MGH-25 ABS ECU Connecting Piece Pin Layout Fig. 3-21 www.cargeek.ir...
Page 191 www.CarGeek.ir Appendix V: Electric Circuit Diagram Fig. 3-22 www.cargeek.ir...
Page 192 www.CarGeek.ir Chapter IV Electrical System General Rules Trouble Shooting I. Appearance inspection before repair 1. Check for relevant fuses and relays. 2. Check for possible damage, charging state, surface cleanness and harness interface tightening of battery; Notes: (1) When the battery has a loose earth connection, do not attempt to start up the engine, or the connection will be seriously damaged.
Page 193 www.CarGeek.ir 6. As for the ones with protective plastic or rubber sleeve, install the sleeve while removing. (Fig. 4-3) Fig. 4-3 7. Before connecting interfaces, make sure the terminal (B) locates at its origin, free from bending or other distortion; regarding some multihole interfaces, make sure the socket is filled with grease (waterproof interface excluded).
Page 194 www.CarGeek.ir 6. After fixing the wire clip, make sure that it does not interfere with other movable components. 7. Keep the harness away from exhaust pipes and other heating components, edge components, and screws or bolt mounting positions. 8. Locate the gum cover right into the groove of corresponding mounting hole, and be aware not to distort the gum cover (B).
Page 195 www.CarGeek.ir contaminated, change it. Refer to Fig. 4-12. Fig. 4-12 IV. Troubleshooting and steps 1. Fault verification Switch on all components of faulty circuit to verify the fault, and pay attention to symptoms. Before locate the fault, do not start dismantling or testing. 2.
Page 196 www.CarGeek.ir Work out investigational procedures and scope of systems and components concerned with the help of DTC or trouble symptom table based on DTC data or symptoms. 5. Electrical check Locate and figure out further causes of trouble in this way. 6.
Page 197 www.CarGeek.ir Section I Instrument Cluster I. Overview Fig. 4-16 1. Engine tachometer 2. Engine OBD indication 3. Engine coolant overheated indication 4. Oil pressure insufficient indication 5. Charging warning 6. Subtotal odometer adjusting rod 7. Engine coolant temperature indication 8. Subtotal odometer 9.
Page 198 www.CarGeek.ir Behind the transparent plastic sheet are protective cover and panel of instrument cluster. The light screen is integrated into the protective cover, to keep the instrument face unaffected from ambient illumination and reflection, so as to ease the dazzle. The instrument cluster panel and dial enjoy multi-layer structures.
Page 199 www.CarGeek.ir The instrument cluster is lit to have necessary visibility by adjustable LED from the back. Each indicator of instrument cluster is lit by special LED. All LED are wholly welded to the circuit board at the back of the cluster housing. The instrument cluster is connected to the electrical system of the complete vehicle with connecting circuits, which are integrated into the vehicle harness and go along different paths, secured in varied ways.
Page 200 www.CarGeek.ir 2. For terminal description, refer to Table 4-2 Table 4-2 Testing Wire Terminal description Test condition Standard value terminal color Ignition switch ON, indicator lit → Less than A1—body SRS air bag fault signal unlit 1V→10～14V Parking brake indication 10～14V→less A3—body Braking indicator unlit →...
Page 201 www.CarGeek.ir Table 4-2 (Continued) Testing Wire Terminal description Test condition Standard value terminal color Engine rotation speed Pulse signal A22—body Engine runs signal generated A23—body Fuel indication signal Always Less than 1Ω Engine coolant Engine runs, coolant temperature Pulse signal A24—body temperature signal rises...
Page 202 www.CarGeek.ir Table 4-3 IV. Trouble Symptom Table 4-3 Symptom Cause Symptom Cause 1 Faulty fuse 1 Faulty speed sensor Instrument cluster 2 Faulty wiring and connector Speedometer 2 Faulty wiring and connector does not work 3 Faulty instrument cluster fault 3 Faulty instrument cluster 1 Faulty engine or ECM 1 Faulty fuel level sensor...
Page 203 www.CarGeek.ir If it is in a normal condition, go to step 2), if not, repair or change the fuse, wire and connector. 2) Check the ground end of speed sensor as shown in Fig. 4-20. Check the resistance between 2-T2 and the body, normally less than 1Ω. If it is in a normal condition, go to step 3), if not, repair or change the wire and connector.
Page 204 www.CarGeek.ir 3. Tachometer fault (1) Check steps 1) Check rotation speed signal output of engine ECM. Check the voltage between connector terminals A22 and A9 of instrument cluster when engine runs, normally, pulsed voltage peaking around 5V generated. If it is in a normal condition, replace the instrument cluster, if not, repair or change the wire, connector or electronic injection system.
Page 205 www.CarGeek.ir (2) Check the circuit as shown in Fig. 4-23. Fig. 4-23 5. Water thermometer fault (1) Check steps 1) Check the coolant temperature sensor. Disconnect the harness connector of engine coolant temperature sensor when the coolant temperature is at 90 , ℃...
Page 206 www.CarGeek.ir 6. Door lamp alarm buzzer does not work properly (1) Check steps 1) Check left front door lamp switch Open → close left front door, check the on off state between the instrument cluster A13 and the body, normally should be from on (and resistance less than 1Ω) → off (resistance more than 100 KΩ).
Page 207 www.CarGeek.ir 7. Driver’s seat belt reminder buzzer does not work properly, as shown in Table 4-4. Table 4-4 Symptom Cause 1 Faulty instrument cluster Driver’s seat belt reminder buzzer does 2 Faulty air bag ECU not work properly 3 Faulty wiring and connector 4 Faulty seat belt buckle switch VI.
Page 208 www.CarGeek.ir 3. Check the tachometer Start the engine at DC 13.5V±0.5V, ambient temperature 25 ±5 , ℃ externally connect with ℃ trouble diagnostic instrument to measure the rotation speed, the value measured should correspond to the instrument display within a permissible range, as shown in the table below. Tachometer permissible range (see Table 4-5) Table 4-5 Value measured (rpm)
Page 209 www.CarGeek.ir 10. Check the door lamp alarm buzzer Check the working condition: Ignition switch at ON (IG1) position, if one of the four doors is unclosed, it will buzz, till one condition is eliminated, buzz stops. 11. Check the brake warning lamp (1) Check the parking brake warning lamp: Disconnect the parking brake switch Connect the connector terminal at the side of parking brake switch wire and the body with harness connector, ignition switch ON-position, check the parking brake warning lamp, normally lit;...
Page 210 www.CarGeek.ir Section II Power Window I. Overview System operation: Operate the switch on door trim panel to make the window ascend or descend, as shown in Fig. 4-27 and Fig. 4-28. The driver can operate switches of all windows by operating the main switch on front door trim panel at driver’s side;...
Page 211 www.CarGeek.ir EX/LX/DX: Press the window glass controller for ≤300ms, corresponding window glass will descend, the window lifter will power off till touch the bottom. If the detection signal is lost when touch the bottom, then the window lifter will work for 8 seconds at one time and stop to protect the motor.
Page 212 www.CarGeek.ir (See Fig. 4-29) II. Placement Fig. 4-29 A: Balustrade panel switch of left front door B: Motor of left front door glass frame riser C: Bracket of left front door glass frame riser D: Balustrade panel switch of right front door E: Motor of right front door glass frame riser F: Bracket of right front door glass frame riser G: Balustrade panel switch of left rear door...
Page 213 www.CarGeek.ir 2. Definitions of balustrade panel switches of right front, left rear and right rear doors (See Fig. 4-32 and Fig. 4-33) Fig. 4-32 1. Glass up 5. Child lock (safety switch) 2. NC 6. Ground 3. NC 7. Glass down 4.
Page 214 www.CarGeek.ir 4. Switch of left front glass frame riser (Fig. 4-36 and Table 4-6) Fig. 4-36 Table 4-6 Testing Wire Terminal description Test condition Standard value terminal color Left rear door glass frame 4～5V →Less 1—body Ignition ON-position, rise-stop glass riser motor up than 1V Left rear door glass frame...
Page 215 www.CarGeek.ir 5. Power window circuit (Fig. 4-37) Fig. 4-37 6. Power window trouble symptom table (Table 4-7) Table 4-7 Symptom Cause 1. Faulty BCM controller All power windows do not work 2. Faulty glass frame riser power fuse 3. Faulty wiring 1.
Page 216 www.CarGeek.ir III. Component check 1. Check balustrade panel switch of left front door. For the check of left front door glass frame riser switch, refer to the table above. As for the rest doors: check the conductivity between terminals of glass frame riser switch connector.
Page 217: Bcm Central Lock, Burglar Alarm System
www.CarGeek.ir Section III BCM Central Lock, Burglar Alarm System I. Overview The central lock system is part of BCM (body control module), jointly used with burglar alarm system, mainly responsible for the control of four door-lock motors, remote keyless entry and inner lighting control, inactive car start after entering burglar alarm, car locating and so forth.
Page 218 www.CarGeek.ir Fig. 4-39 The control logic of central lock conforms to Q/LFQ J07.009-2008 Logic Technology Specifications on LF7162 Sedan Central Control Lock/Burglar Alarm System. Alarm setting condition: Ignition switch disconnected, ignition key pulled out, four doors and luggage boot well closed. Remote control condition: Remote control operation is useless when ignition key is in ignition lock.
Page 219 www.CarGeek.ir simultaneously, the steering light flashes for once and annunciator sounds for once. (4) Locking through inserting door lock key Insert door lock key into door lockhole, turn it counterclockwise, locking of four doors will act simultaneously. (5) Locking by door locking button Door locking button may display the status of door lock, i.e.
Page 220 www.CarGeek.ir As shown in Fig. 4-41. Fig. 4-41 Note 1: When the key is inserted into ignition lock, it’s useless to press the locking key unlocking key of remote controller. 3. Alarm setting Alarm setting condition: Ignition switch connected, ignition key pulled out, four doors and luggage boot closed.
Page 221 www.CarGeek.ir As shown in Fig. 4-42. Fig. 4-42 4. Disarming Under alarm setting condition is met, unauthorized entry or burglar behavior will be detected and the car immobilized, only upon correct disarming by authorized person, can the car recover. (1) Disarming operation through unlocking key of remote controller Press the unlocking key of remote controller, unlocking of four doors will act simultaneously, when the system is at alert state, the steering light flashes for twice, annunciator sounds for twice;...
Page 222 www.CarGeek.ir 2) If the locking key of remote controller is not pressed for alarm setting within ten seconds, the steering light flashes for three times and annunciator sounds for three times for locking indication with alarm setting implemented. (2) Logical flow of locking alarm setting indication As shown in Fig.
Page 223 www.CarGeek.ir 7. Open the luggage boot through electrical operation (EX) (1) Press the luggage boot key on remote controller when it is not alerted When it is not alerted, the luggage boot opening key on central console is available for luggage hood springing up, the luggage boot indicator on instrument cluster (No.
Page 224 www.CarGeek.ir Table 4-8 Testing Terminal Wire color Test condition Standard value terminal description Central lock Always Less than 1Ω (3-1)－body power Locking of left (3-2)－body Always Less than 1Ω front door lock Unlocking of left (3-3)－body Always Less than 1Ω front door lock (3-4)－body Grounding...
Page 225 www.CarGeek.ir Table 4-9 Testing Wire Terminal Standard Test condition terminal color description value When roof light is at “DOOR” position, the roof Extended light is lit upon unlocking by remote controller or illumination opening of any door. If no door is opened within (1-1)－body Less than 1 V control output of...
Page 226 www.CarGeek.ir Table 4-10 Testing terminal Wire color Terminal description Test condition Standard value Unlocking of central Active low Less than 1Ω (2-1)－body control switch Locking of central (2-2)－body Active low Less than 1Ω control switch Remote control (2-17)－body receiving antenna of Always Less than 1Ω...
Page 227 www.CarGeek.ir Table 4-11 Symptom Cause Symptom Cause 1 Faulty air conditioning controller Door lock control 1 Faulty power supply fuse Door lock locking/unlocking 2 Faulty body control module system does not 2 Faulty body control module fault (apply central control 3 Faulty wiring work 3 Faulty wiring...
Page 228 www.CarGeek.ir (1) Check the conductivity of locking/unlocking switch of left front door central lock actuator: When the locking/unlocking switch of left front door central lock actuator is at locking position, actuator terminals 2 and 4 should be conducted; when it is at middle position, actuator terminals 2 and 4 should be not conducted, terminals 2 and 3 not conducted either;...
Page 229 www.CarGeek.ir locking of all doors will not be implemented. 3) Security check When the key is inserted into the ignition lock cylinder and the lock ing or unlocking key on ① remote controller is pressed, no door lock will be locked or unlocked. ②...
Page 230 www.CarGeek.ir If it is the case, proceed to the next step; if not, insufficient battery capacity is indicated, change a battery with designated specification. (3) Back inner light check The back inner light at position ON, check if the light is lit. The back inner light at position DOOR, check if the light is lit.
Page 231: Electric Side Mirror
www.CarGeek.ir Section IV Electric Side Mirror I. Overview Fig. 4-53 Electric side mirror Sealed pad Electrical interface ① ② ③ By operating the electric switcher on the dashboard at the left side of the driver’s seat, the left and right electric side mirrors can be ordered for turning to left, right or up and down, with adjustable angle over 7 degrees.
Page 232 www.CarGeek.ir 2. Exploded view Fig. 4-55 Fig. 4-55 1: Electric side mirror 2: Side mirror cover 3: Bracket 4: Commutator 5: Mirror extension unit 6: Mirror 7: Base 8: Mounting bolt 9: Seating washer III. Terminal end voltage 1. For electric side mirror switch, refer to Fig. 4-56 and Fig. 4-57. Fig.
Page 233 www.CarGeek.ir Fig. 4-57 Ignition switch ACC, select left electric side mirror for left and right adjustment Left: 2-3 conducted, resistance less than 1Ω, 5-1 conducted, resistance less than 1Ω Right: 5-3 conducted, resistance less than 1Ω, 2-1 conducted, resistance less than 1Ω Ignition switch ACC, select left electric side mirror for up and down adjustment Up: 6-3 conducted, resistance less than 1Ω, 1-2 conducted, resistance less than 1Ω...
Page 234 www.CarGeek.ir V. Component check 1. Switch check, check items as mentioned before, if the conductivity is unqualified, change the side mirror switch. 2. Mirror check, check items as mentioned before, if corresponding requirement is not met, change the side mirror motor, wire connector of side mirror motor ③...
Page 235: Illumination System
www.CarGeek.ir Section V Illumination System I. Overview The illumination system is to offer lighting for night driving, consists of outer lights of headlight, backup light, license plate lamp, fog light etc, and inner ones of dashboard light, inner light, luggage boot lamp, door lamp, various backlights etc. Each light is installed at required position, equipped with control switch, wire, fuse protector and so forth, to make up the illumination system, which also enjoys signal indication, comes out with light signals to warn the driver of another car and the foot passenger, to ensure safe driving, including signals for steering, brake, danger...
Page 236 www.CarGeek.ir II. Placement 1. Headlight assembly (Fig. 4-60) Fig. 4-60 1.1 Front combination lamp interface (Fig. 4-61) Fig. 4-61 www.cargeek.ir...
Page 237 www.CarGeek.ir 1.2 Headlight checking circuit (Fig. 4-62) Fig. 4-62 www.cargeek.ir...
Page 238 www.CarGeek.ir 2. Rear combination lamp (Fig. 4-63, Fig. 4-64 and Fig. 4-65) Fig. 4-63 Fig. 4-64 Fig. 4-65 www.cargeek.ir...
Page 239 www.CarGeek.ir 3. Front fog light (Fig. 4-66 and Fig. 4-67) Fig. 4-66 Fig. 4-67 4. Side turn signal light (Fig. 4-68) Fig. 4-68 www.cargeek.ir...
Page 240 www.CarGeek.ir 5. High-mounted brake lamp (Fig. 4-69) Fig. 4-69 6. Rear roof light (Fig. 4-70 and Fig. 4-71) Fig. 4-70 Fig. 4-71 7. Luggage boot lamp (Fig. 4-72 and Fig. 4-73) Fig. 4-72 Fig. 4-73 III. Check and repair 1. Disassemble and assemble left and right of front combination lamp in the same steps, disassembling steps are contrary to assembling steps.
Page 241 www.CarGeek.ir (1) Remove radiator grille (2) Remove left front fender inner panel (3) Remove right front fender inner panel (4) Remove front bumper (5) Remove left headlight Remove the three screws to pull out the left front combination lamp assembly as per the direction shown in the Fig., disconnect the bracket at the side of the car, and disconnect each electrical connector lug of lamp socket, as shown in Fig.
Page 242 www.CarGeek.ir 2. Focusing adjustment of front combination lamp (1) Car preparation: Ensure the part around front combination lamp is not damaged or distorted, fuel tank filled. Make sure unladen mass of complete vehicle: Fill coolant to designated level; charge the tire to proper pressure, put spare wheel, jack, and tool kit to original position, and empty the luggage boot, a man of common weight (75kg) seated at driver’s seat.
Page 243 www.CarGeek.ir (3) Check: When checking one side of front combination lamp, cover the other side or disconnect the electrical connector plug to prevent the unchecked front combination lamp interfere the focusing check. Note: Do not cover the front combination lamp for more than 3 minutes, because the glass block of front combination is made of synthetic resin, which is vulnerable to overheating.
Page 244 www.CarGeek.ir 3. Check left combination switch (light control) as shown in Fig. 4-84 and Fig. 4-85. Fig. 4-84 Fig. 4-85 (1) Check the conductivity of control switch of front and rear fog lights When the light control switch is at OFF, terminals should be not conducted with each other, when the switch is at front fog light position, terminals 1 and 2, 4, 6 and 7 should be conducted, when the switch is at rear fog light position, terminals 1 and 2, 17 should be conducted.
Page 245 www.CarGeek.ir (4) Check the conductivity of front fog light switch: When the switch is at OFF, terminals 1 and 2, 4 should be not conducted, when the switch is at ON, terminals 1 and 2, 4 should be conducted. (5) Check the conductivity of control switch of front headlight before AUTO is lightened: When the switch is at AUTO, terminals 5 and 6, 7 should be conducted.
Page 246 www.CarGeek.ir voltage as well as conductivity between terminals of flash wire connector. If the check results can not meet the requirements in the table, check corresponding circuit. To find more, refer to Fig. 4-89 and Table 4-14. Fig. 4-89 Table 4-14 Standard Testing terminal Wire color...
Page 247 www.CarGeek.ir Section VI Wiper and Washer I. Overview The wiper system is composed of wiper blade arm, connecting rod mechanism, blade and wiper motor. It enjoys one-step wiping, intermittent wiping, slow-speed wiping and high-speed wiping. The washer system is composed of pump, detergent pot, filler and nozzle. Both the wiper and washer systems attempt to provide a convenient, safe and reliable means to ensure the view of the windshield.
Page 248 www.CarGeek.ir II. Layout Diagram of Wiper and Washer System 1. Layout diagram of wiper and washer system Fig. 4-91 and Fig. 4-92 Fig. 4-91 Fig. 4-92 1. Rocker arm cap pattern 2. Hexagon nut with taper spring gasket 3. Right rocker arm with blade 4.
Page 249 www.CarGeek.ir Fig. 4-95 Spraying position adjustment: a=485mm b=675mm c=450mm d=330mm e=530mm f=500mm g=210mm h=245mm Spraying position adjustment area: a 60×60 square area Use the special tool (a thin probe) for nozzle Adjustment scope: ±10° 4. Sketch map of wiper motor as shown in Fig. 4-96 Fig.
Page 250 www.CarGeek.ir Table 4-15 Testing Wire Standard Terminal description Test condition terminal color value Ignition switch ON; the right High-speed power output of wiper combination switch is at 1-body 10～14V motor high-speed wiping position, always Ignition switch ON; the right Low-speed power output of wiper combination switch is at 2-body 10～14V...
Page 251 www.CarGeek.ir Fig. 4-99 Table 4-17 Testing Terminal Wire color Test condition Standard value terminal description Ignition switch is at ON; right Power input of combination switch is at 1－body 10～14V washer motor washing position, always Washer motor 2－body Always ＜1Ω grounding 2.
Page 252 www.CarGeek.ir (as shown in Table 4-18) IV. Fault Table of Wiper and Washer System Table 4-18 Fault Cause Fault Cause 1 Fault in accessory relay 2 Fault in wiper fuse 1 Fault in wiper combination Inactive wiper and 3 Fault in wiper Inactive wiper at LO switch assembly washer...
Page 253 www.CarGeek.ir Check the conductivity between terminals of wiper connector of the wiper combination switch ① assembly. When the wiper is at MIST, the terminal 2 and terminal 11 should be conducted. When at OFF, terminal 2 and terminal 10 should be conducted; when at INT, terminal 2 and terminal 10 should be conducted as well as terminal 2 and terminal 11;...
Page 254 www.CarGeek.ir 4. Check the washer nozzle Blow air to the direction of washer spraying and confirm the airflow only pass in a single way, rather than in a reverse direction. See Fig. 4-103. Fig. 4-103 www.cargeek.ir...
Page 255 www.CarGeek.ir Section VII Audio System I. Overview This system combines digital video and various devices to decorate your car to be a tiny music theater and satisfy you with CD music, USB interface, AM/FM radio. It is composed of: (1) antenna amplifier, (2) AM/FM printed antenna, (3) CD assembly, (4) speaker and (5) USB interface.
Page 256 www.CarGeek.ir II. Definitions of Interfaces of Audio System Fig. 4-105 Table 4-19 Testing Wire Standard Terminal description Test condition terminal color value Steering wheel control (-) A1－body (reserved) Steering wheel control (+) A2－body (reserved) Power input while ignition switch at A4－body Ignition switch at ACC, always 10～14V...
Page 257 www.CarGeek.ir Radio assembly of audio system: Fig. 4-106 Fig. 4-106 (Definition of harness terminal of speaker) Refer to Fig. 4-107 and Table 4-20. Fig. 4-107 Table 4-20 Testing terminal Wire color Terminal description Test condition Standard value 1-body — Speaker drive input Audio system in process —...
Page 258 www.CarGeek.ir III. Fault Table of Audio System Table 4-21 Fault Cause Fault Cause 1. Fault in audio Press down power switch, 1. Fault in audio system power Audio system night system illumination audio system does not circuit illumination system can not circuit work 2.
Page 259 www.CarGeek.ir IV. Audio system component check Fig. 4-108 1. Press down power switch, can not start audio system: According to the circuit diagram Fig. 4-108, check the environment of CAB, for possible ① features causing electrical short-circuit, and keep CAB dry and ventilative; ② Test the voltage between audio system assembly connector terminal A7 and vehicle body, the voltage shall be 10-14V.
Page 260 www.CarGeek.ir (3) Check speaker Disconnect speaker connector, test the resistance between speaker terminals, the resistance shall be 2~9Ω. If it is normal, proceed to the next step; if not, replace speaker. (4) Check connector between audio system and speaker If it is normal, proceed to the next step; if not, repair or replace wiring and connector. (5) Check CD player assembly ①...
Page 261 www.CarGeek.ir (4) Check the installation of CD player assembly If it is normal, fault of CD disk exists; if not, proceed to the next step. (5) Check CD player assembly ① Check the voltage between audio system assembly connector terminal A7 and vehicle body, the voltage shall be 10~14V.
Page 262: Reverse Radar System
www.CarGeek.ir Section VIII Reverse Radar System I. Overview Vehicle reverse radar system is a kind of vehicle monitoring system imitating bat detection principles. By installing several ultrasonic radar probes, receive and send signals, and send feedback information to controller. According to signal reentrant time, controller can calculate the distance to the tested barrier, and trigger different sound and indicator warning according to different distances to remind driver for the distance between the barrier and vehicle, and increase backup convenience and safety.
Page 263 www.CarGeek.ir See Fig. 4-111 and Table 4-22. II. Reverse radar system terminal: Fig. 4-111 Table 4-22 Standard Testing terminal Wire color Terminal description Test condition value Turn ignition switch to ON, 10～14V BCM (1-8) - body Input reverse signal take reverse gear, always 10~14V Input reverse LIN signal to Pulse signal...
Page 264 www.CarGeek.ir Check circuit as shown in Fig. 4-112 Fig. 4-112 III. Reverse radar system notes The system is the driving auxiliary equipment; the use of rearview mirror is indispensable. Driver shall be at his/her own risk for accident caused by overspeed reverse and his/her negligence. 1.
Page 265 www.CarGeek.ir (6) Sensor is hit or knocked heavily (7) Vehicle is close to stairs too much, system can not correctly detect the distance between bottom stair and the vehicle rear, causing damage on rear mudguard (Fig. 4-113) Fig. 4-113 (8) As shown in Fig. 4-114, when driving approaching the wall, warning mistake is caused by inaccurate distance detecting Fig.
Page 266 www.CarGeek.ir 3. Fault table, Table 4-23 Table 4-23 Fault Cause Fault Cause Buzzer does not 1. Fault in buzzer drive Totally can not work (can not 1.Fault in power circuit work (can circuit self-check) 2.Fault in reverse radar self-check) 2. Fault in reverse radar 1.
Page 267 www.CarGeek.ir ① Disconnect instrument cluster connector. ② After starting engine, take reverse gear, check whether square signal output exists in BCM (1-19) with oscillograph. If it is normal, proceed to the next step; if not, check whether BCM controller and probe are damaged. 2) Check wire harness or connector ①...
Page 268: Power Supply And Other Electrical System
www.CarGeek.ir Section IX Power Supply and Other Electrical System I. Overview This section covers battery, power distribution network, rear defrost system, electric horn system and electronic clock. II. Battery Fig. 4-116 Note： ①: If an auxiliary battery and a jumper cable are required for engine starting, please apply the battery of 12V.
Page 269 www.CarGeek.ir IV. The rear defrosting system includes: rear window glass heating net, rear window defroster relay, rear window defroster switch: in combination with the emergency light switch, inner integration on the air conditioner controller (for electrical air conditioning) 1. Fault table, Table 4-24. Table 4-24 Fault Cause...
Page 270 www.CarGeek.ir 1. Check circuit as shown in Fig. 4-118 Fig. 118 2. Fault table, Table 4-25 Table 4-25 Fault Cause 1. Fuse blown 2. Deficiency of horn relay Deficiency of the two horns 3. Deficiency of horn switch 4. Deficiency of horn 5.
Page 271: Air Bag System
www.CarGeek.ir Chapter V Air Bag Section I Composition, Principle and Safety Rules for Maintenance I. Composition & layout of air bag system LF7162 adopts electronic double-air-bag system, with air bag in the central ornamental cap of steering wheel and in the dash board in front of the passenger respectively. 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...
Page 272 www.CarGeek.ir 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. 5-2. Fig.
Page 273 www.CarGeek.ir 4. Front passenger air bag module The front passenger air bag module, comprising of gas generator, bag and a series of auxiliary components, etc, is installed above the sundries box of dash board, as shown in Fig. 5-4. Fig. 5-4 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) after certain collision and then spark the gas generator and produce abundant air...
Page 274 www.CarGeek.ir 6. SRS warning lamp SRS warning lamp can be observed in the instrument cluster, as shown in Fig. 5-6. Fig. 5-6 When the self-diagnostic circuit of air bag ECU assembly detects fault, the SRS warning lamp shall be illuminated so as to inform the driver of the malfunction of air bag system. Under normal circumstances, the illumination of the warning lamp will last for 5s before run out when the ignition switch has been turned to the position ON.
Page 275 www.CarGeek.ir resistance. 3. Read out the flash DTC (Diagnostic Trouble Code) before removing the battery ground line when clear off air bag system fault. 4. Remove the negative ground line of the battery before carrying out specific maintenance. Then wait for over 3min and perform maintenance operation, or the air bag may be unexpectedly deployed.
Page 276: Diagnosis & Fault Clearing
(1) Connect to the fault diagnostic interface of the vehicle. (2) Read out the fault as per the indication shown in the diagnostic instrument, as shown in DTC Table 5-1 DTC Table 5-1 Bosch Lifan DTC Description DTC in EEPROM Electronic Control Unit (ECU) Internal Fault...
Page 277 DTC Table 5-1 (Continued) Bosch Lifan DTC Description DTC in EEPROM Driver Belt Pretensioner Short to Battery 8067 Passenger Belt Pretensioner Resistance High 8058 Passenger Belt Pretensioner Resistance Low 8057 Passenger Belt Pretensioner Short to GND or Cross Coupling...
Page 278 www.CarGeek.ir Table 5-2 (Continued) Possible Areas Fault Clearing Methods Faults 1. Preparation before checking; 2. Check the front passenger air bag circuit, if normal, go to 3; if not, repair or renew the Front passenger harness or interface between the air bag ECU and front air bag module passenger air bag module;...
Page 279 www.CarGeek.ir 1. Air bag circuit (as shown in Fig. 5-7 and Table 5-3) Fig. 5-7 Table 5-3 Names of Air Bag ECU Pins and Terminals Name K line, diagnostic interface 12 feet Safety belt reminder buzz output Collision output to BCM Driver safety belt switch Power line Driver’s safety belt reminder warning lamp...
Page 280 www.CarGeek.ir 2. 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 3min. (2) Remove the driver and front passenger air bag modules, keep the air bag module upwards when storing the module (See the removal methods in Section IV).
Page 281 www.CarGeek.ir (4) Connect the negative ground wire on the battery and wait for at least 3min. (5) Turn the ignition switch to the position of ACC or ON and wait for at least 20s. (6) Eliminate the flash DTC by the diagnostic instrument and read out the flash DTC. 7.
Page 282 www.CarGeek.ir 11. 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 shall be above 1MΩ. (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.
Page 283 www.CarGeek.ir 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.
Page 284: Diagnosis Of Vehicles After Collision
www.CarGeek.ir Section III Diagnosis of Vehicles after Collision Check and maintain the vehicles after collision even without the deployment of air bag. Refer to Section IV for related methods of removal and installation. I. Diagnosis, with the deployment of air bag 1.
Page 285 www.CarGeek.ir 5. Front passenger safety belt pre-tensioner. Check the front passenger safety belt pre-tensioner for depression, crack and distortion, the harness and interface for damage and the terminal for distortion. Check the pre-tensioner for normal installation. Renew if necessary. 6. Clock spring. Check the interface and harness of the clock spring for damage and the circuit performance of the clock spring as per 2.3.14.
Page 286 Do not knock the air bag module. If knocked, install a new one. Forbid exposing the module under the temperature over 90°C, and contact with lubricants, lubricant grease as well as water. Seal the old module removed in a sealing bag, and return it to Lifan Passenger Car Co., Ltd.
Page 287 Seal the old front passenger air bag module removed in a sealing bag, and return it to Chongqing Lifan Passenger Vehicle Co., Ltd.
Page 288 (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.
Page 289 If something abnormal appears in the process of deployment, contact the service center of Lifan Passenger Car Co., Ltd. When lacking in the conditions of scrapping, please deliver the module to related departments for disposal.
Page 290 www.CarGeek.ir Chapter VI A/C System Section I Introduction This series of sedan has a full air conditioning system with functions of refrigeration, heating and ventilation. The air conditioner can be used to reduce the temperature of the vehicle in summer, heating and defrost the windscreen in winter.
Page 291 www.CarGeek.ir Figure 6-2 II. Principle of heating system Water heating is applied for the heating system, with the coolant of engine as the heat source. Heating system mainly consists of heat exchanger, coolant pipeline, blower, air duct, air vent, and control mechanism, etc.
Page 292 www.CarGeek.ir When engine works, heated by the high temperature of the engine cylinder, the coolant is pumped into the heat exchanger through water pipe by the water pump of the cooling system. Air from blower can take the heat given off by the coolant into the vehicle or the windscreen to raise the temperature in the vehicle or defrost.
Page 293 www.CarGeek.ir Security protection control mainly guarantees the normal operation of the system. Monitoring the system pressure and temperature by the pressure switch installed on the high-pressure hard pipe can realize the security protection control. Functions of security protection control as follows: (1) Low pressure protection: for pressure below 0.196±0.02 MPa, pressure switch (between 1-A4 and 3-A4) switches off, the power of compressor clutch is cut off, and compressor stops working;...
Page 294 www.CarGeek.ir Section II System Layout Heating and air conditioning electronic control system layout 1 (Figure 6-5) Figure 6-5 Heating and air conditioning electronic control system layout 2 (Figure 6-6) Figure 6-6 Sunlight sensor Instrument cluster Air conditioning control module ① ②...
Page 295 www.CarGeek.ir Electrical air conditioning controller, as shown in Figure 6-7. Figure 6-7 1. “A/C” switch 2. Internal and external recycling modes option button 3. Cool/warm wind regulation knob 4. Air regulation knob 5. Air blowing mode option knob Heating and air conditioning electronic control system layout 2 (Figure 6-8) Figure 6-8 www.cargeek.ir...
Page 296 www.CarGeek.ir Exploded view of air conditioner parts as shown in Figure 6-9. Figure 6-9 www.cargeek.ir...
Page 297 www.CarGeek.ir Exploded view of air conditioner parts as shown in Figure 6-10. Figure 6-10 www.cargeek.ir...
Page 298: Component Maintenance
www.CarGeek.ir Section III Component Maintenance I. Performance parameter of LF7162 electrical air conditioning system Table 6-1 Compressor Model WXH-086 Type Parallel flow Condenser Specification L×W×D mm 590×370×16mm assembly Heat transfer capacity ≥4.5m/s frontal velocity Type Cascading style Specification Evaporator 38×250×258 D×H×W mm core Refrigerating...
Page 299 www.CarGeek.ir II. Inspection of air conditioner compressor belt New belt is that used on the engine for not more than 5 min. Used belt is that used on the engine for more than 5 min. Install the drive belt and check whether the belt is well contacted with the belt groove (Figure 6-11).
Page 300 www.CarGeek.ir 3. Take out filter element upwards, and check the ventilation property. Change the filter element for bad ventilation property, as shown in Figure 6-14. Figure 6-14 IV. Inspection for evaporator housing 1. Disassemble air duct (1) Disassemble upper air duct of the housing ①...
Page 301 www.CarGeek.ir Disconnect the upper air duct on the left floor. According to the position indicated by the arrowhead, move the upper air duct on the left floor sideways to loosen it, as shown in Figure 6-16. Figure 6-16 Disconnect the upper air duct on the right floor. According to the position indicated by the arrowhead, move the upper air duct on the right floor sideways to loosen it, as shown in Figure 6-17.
Page 302 www.CarGeek.ir Clamp the two ends of M16’s pipe with 24mm and 27mm open end wrenches; clamp the two ends of M8’s pipe with 17mm and 19mm open end wrenches; then disassemble nuts and disconnect air conditioner pipeline assembly. (3) Remove clamp from air conditioner pipeline assembly. Disassemble the hoop of heater inlet and outlet pipes from the heater unit (as shown in Figure 6-19).
Page 303 www.CarGeek.ir (11) Disassemble nuts in Figure 6-21. Figure 6-21 (12) Disassemble bolts and nuts in the following figure, then the air conditioner housing can be taken out. See Figure 6-22. Figure 6-22 (13) Disassemble evaporator unit assembly. 1) Disassemble the inlet and outlet cover board of evaporator 2) Take off 2 inlet and outlet pipes and their retaining clamps as well as expansion valves 3) Disassemble the right pipe plate of evaporator 4) Evaporator can be taken out...
Page 304 www.CarGeek.ir (14) Disassemble heater unit. 1) Disassemble the inlet and outlet cover board of heater and lower air outlet of the CAB, as shown in Figure 6-24. Figure 6-24 2) Disassemble 2 bolts of the retaining clamp of heater core inlet and outlet pipes, take off the retaining clamp.
Page 305 www.CarGeek.ir (18) Disassemble evaporator temperature sensor. 1) Take out the evaporator, as shown in Figure 6-26. 2) Disassemble the evaporator temperature sensor from the plunger piston of the evaporator right housing. Figure 6-26 3. Installation notes (1) Install the evaporator assembly 1) Coat the 2 new O-shape rings and the interface of expansion valve surface with sufficient compressor oil;...
Page 306 www.CarGeek.ir Connect battery positive to the connector clip of electromagnetic clutch directly, negative to the body of compressor. If the electromagnetic clutch is normal, you will hear a rattle. If the belt pulley does not touch the armature (no rattle), fault exists, Figure 6-27. Figure 6-27 2.
Page 307 www.CarGeek.ir When installing clutch coil to compressor housing, aim the compressor housing pin hole to the clutch coil lug boss. Assembly of snap ring; see Figure 6-31. Figure 6-31 Note: install snap ring with its conical surface towards outside. In the installation of self-locking nut, special tools are applied to fasten the electromagnetic clutch. Then screw the nut with the same method of disassembly.
Page 308 www.CarGeek.ir Put the metal part of engine overheating protection switch into engine oil, heat with gas stove until reaching standard temperature, check whether switch terminals are on, as shown in Figure 6-34. Figure 6-34 Compressor overheating protection switch On: Lower than 105℃ Off: Higher than 130 ℃...
Page 309 www.CarGeek.ir VII. Replacement of air conditioner amplifier assembly 1. Disassembly (1) Disassemble auxiliary dashboard assembly (2) Disassemble air conditioner amplifier assembly 1) Disconnect the connector 2) Remove air conditioner amplifier assembly 2. Installation To install, reverse the removal procedure. VIII. Removal and repair of refrigeration pipeline 1.
Page 310 www.CarGeek.ir (2) For installation, coat the O-ring seal with some compressor oil; (3) Before connection, coat some compressor oil on pipe joint; (4) After pipe installation, it is necessary to check the correctness of pipeline layout, whether the pipelines will collide with other parts. After completing the installation, check the existence of leak, vacuumize pipes, inject refrigerant and check the performance of air conditioning system.
Page 311 www.CarGeek.ir Section IV Fault Diagnosis I. Fault diagnosis of system i. Direct observation check 1. For checking faults like stop working or abnormal working of air conditioning system, some apparent symptoms will appear by applying direct observation check. Direct observation check (of looking, touching and listening) can diagnose faults accurately and easily, and quickly eliminate faults.
Page 312 www.CarGeek.ir conditioning system circuits should be loose or hot. If some connector is loose or the surface temperature of connector felt by touching is relatively high (hot), the inside of connector is in poor contact, which makes air conditioning system stop working or work in abnormal condition. 3.
Page 313 www.CarGeek.ir sometime accompanying abnormal knocking. Change the compressor. 5) Compressor drive belt is too loose—compressor rotation speed is too slow, outlet air is not cold, noise of belt skidding can be heard. Strain the drive belt or replace it. 6) Compressor clutch skidding—compressor can not work normally. Disassemble the clutch, repair or replace it;...
Page 314 www.CarGeek.ir 4) Dust deposit or deformation of heater fins, and poor ventilation—clean or replace the heater; 5) The hot-water pipe of heater is blocked by scale deposit—replace the heater; 6) Insufficient engine cooling water—check whether leakage exists in cooling system, repair it and replenish cooling water;...
Page 315 www.CarGeek.ir Table 6-2 (Continued) Phenomenon & state Cause analysis Measure 1. Inlet air cleaner is blocked. Replace with a new inlet air cleaner core. 2. Air duct is blocked. Clean air duct. Normal voltage 3. Evaporator surface dust Clean the evaporator surface. Insufficient Inspect the blower motor, or replace with a 4.
Page 316 www.CarGeek.ir iv. Refrigerant injection, as shown in Figure 6-38. Figure 6-38 1. Expel refrigerant from refrigerating system. ① Switch on air conditioner. ② When engine runs at 1000r/min, make air conditioner compressor work 5~6min, circulate refrigerant and collect residual oil of all parts to the compressor. ③...
Page 317 www.CarGeek.ir Figure 6-39 www.cargeek.ir...
Page 318 www.CarGeek.ir Figure 6-39 (Continued) www.cargeek.ir...
Page 319 www.CarGeek.ir Fig. 6-40 www.cargeek.ir...
Page 320 www.CarGeek.ir Fig. 6-41 www.cargeek.ir...
Page 321 www.CarGeek.ir Fig. 6-41 (Continued) www.cargeek.ir...
Page 322: Precautions Of Air Conditioning System
www.CarGeek.ir Section V Precautions of Air Conditioning System I. Apply pure R-134a refrigerant (1) Must apply authentic R-134a cooling medium with qualified standard of component, moisture content, foreign matters and foul gas. 13.6kg canned cooling medium is recommend for service station;...
Page 323 www.CarGeek.ir and replace all the lubricant; Note: Water, corrosive agents or combustible & explosive agents are forbidden to clean air conditioning system. Cleaning agents of R-141b and methane are recommended. 5. Lubricant should be injected from compressor exhaust vent before vacuumizing. III.
Page 324: Auxiliary Component System
www.CarGeek.ir Chapter VII Auxiliary Component System Section I Cable I. Inner control handle and cable assembly of engine hood During the installation, the inner control handle and cable assembly of the engine hood penetrate the part 1 first and then part 2, connect with the part 4 along part 3 and finally install the inner control handle and dash board.
Page 325 www.CarGeek.ir Section II Windshield I. Introduction The windshield is installed by the one-component Polyurethane sealant. As for its renewing, what is essential is to use the adhesive which can offer the surface cementing strength, and adopt the appropriate process. Note: ①...
Page 326 www.CarGeek.ir primer manufacturer. ② Don’t touch the bo dy and old adhesive surfaces to adhere and connect with the glass. (3) Install the new strip on the glass. For convenience, heat the strip at the temperature of 35 ℃ one and a half hours. (4) Clean the glass surface to adhere and connect to the body with the clean cloth.
Page 327 www.CarGeek.ir III. Rear windshield 1. Rear windshield removal: (1) Clear the inner and outer surfaces and surrounding parts of the glass. (2) Disconnect the interface connected to the rear windshield. Note: When disconnecting the interface, don’t pull the cable wire but loosen the lock card of the interface first, and then hold the interface and loosen the interface.
Page 328 www.CarGeek.ir ④ After coating, use the rubber adhesive disc to install and convey the glass. ⑤ Complete the step 6 and 7 within 10 minutes to guarantee the agglutinate strength. ⑥ The corre ct operation and drying time shall be practiced as per the Instruction Manual of the manufacturer.
Page 329 www.CarGeek.ir Section III Safety Belt Note: (1) The fasteners removed must be reinstalled in the original position. If any fasteners need renewing, the ones with the same part No. are required. However, if there is no such fastener with the same part No., the ones with the same dimension and intensity (or higher intensity) are acceptable.
Page 330 www.CarGeek.ir acceptable. (2) Make sure that screw the fixing bolt to the designated torque, refer to the Fig. above. (3) Tightening torque (a): 45N·m II. Rear seat safety belt: 1. Removal, as shown in Fig. 7-4. Fig. 7-4 a. Fastener torque 45N·m (1) Disconnect the cathode cable from the battery (2) Deactivate the air bag system.
Page 331: Front Side Door
www.CarGeek.ir Section IV Front Side Door I. Decomposition Diagram. See Fig. 7-5: Fig. 7-5 1. Right front safety belt retractor 2. Safety belt head guard cap 3. Hexangular flange bolt (a) 4. Hexangular flange bolt (b) 5. Hexangular flange bolt (c) 6.
Page 332 www.CarGeek.ir (1) Remove the front side door glass referring to the front side door glass removal process. (2) Disconnect the motor harness of the electric glass frame riser. (3) Remove the bolt of the glass frame riser, and take out the glass frame riser. 2.
Page 333: Rear Side Door
www.CarGeek.ir Section V Rear Side Door I. Decomposition Diagram. See Fig. 7-6: Fig .7-6 1. Right rear side window assembly 2. Right rear side door angle window assembly 3. Right rear side door angle window glass seal 4. Right rear side door window glass sealing strip 5.
Page 334 www.CarGeek.ir 2) Disconnect the motor harness of the electric glass frame riser. 3) Remove the bolt of the glass frame riser, and take out the glass frame riser. 2. Exam: 1) Check whether the components for movement and rotation of the glass frame riser need lubricating or not.
Page 335: Seat Assembly
www.CarGeek.ir Section VI Seat Assembly I. Structure of the driver seat assembly: The assembly structure as shown in Fig. 7-7. Fig. 7-7 Fix the bolt at the torque of 20.4N·m II. Components and maintenance of the driver seat: Note: The process of installation and that of removal are reverse. Therefore, only the extra steps for the installation will be referred.
Page 336 www.CarGeek.ir III. Structure of the front passenger seat assembly: 1. The assembly structure as shown in Fig. 7-8. Fig. 7-8 Note: The process of installation and that of removal are reverse. Therefore, only the extra steps of the installation will be referred. 1.
Page 337 www.CarGeek.ir IV. Components and maintenance of the rear seat assembly 1. The assembly structure as shown in Fig. 7-9. Fig. 7-9 2. Removal Note: The process of installation and that of removal are reverse. Therefore, only the extra steps of the installation will be referred.
Page 338 www.CarGeek.ir (3) Remove the left rear seat back assembly, as shown in Fig. 7-11. Fig. 7-11 ① Open the front part of the rear seat back cover. ② Incline the seat back assembly. ③ Remove the two bolts and the seat back. (4) Remove the right rear seat side back assembly, as shown in Fig.
Page 339 www.CarGeek.ir (6) Remove the rear seat right side back assembly, bolts and side seat back. ① Remove the bottom fixing bolts on the rear seat right side back. ② Pull out the right sid e back. (7) Remove the left hinge of the rear seat back, bolts and hinge. (8) Remove the right hinge of the rear seat back, bolts and hinge.
Page 340 www.CarGeek.ir V. Components and maintenance of the rear seat assembly 1. Structure of the components as shown in Fig. 7-16. Fig. 7-16 2. Removal (1) Remove the rear seat back pad assembly ① Lift the unlocking button to unlock the back pad and push over the back pad, as shown in Fig. 7-17.
Page 341 www.CarGeek.ir ① Remove the bolts ② Hold the side back assembly upwardly along the direction of the arrowhead so as to separate the armrest pothook with the body, as shown in Fig. 7-18. Fig. 7-18 Note: If the pothook is damaged during the removal, renew the side back assembly. (3) Remove the right side back assembly in accordance with the process of the left side back, mentioned above.
Page 342 www.CarGeek.ir installation. Torque: 9.8N·m (4) Install the rear seat back pad assembly, as shown in Fig. 7-20. Fig. 7-20 Use a side hinge flange bolt at the left side as well as the right side to install it. After installation, the rear back pad can be turned.
Page 343: Inside & Outside Decorations
www.CarGeek.ir Section VII Inside & Outside Decorations I. Roof 1. Roof (standard scheme) removal: As shown in Fig. 7-21, first remove the A, B, C pillars, dismantle the roof light, sun visor and the inner rearview mirror, remove 8 with the buckle clamp, and dismantle 6 with the sleeve, take out of 7 buttressing the roof and then the roof can be removed.
Page 344 www.CarGeek.ir Removal of the rack board: First, remove the C pillar and high-mounted brake lamp; second, turn over the rear seats and take out of the safety belt from 4 and remove 6, 7 and 5 successively. 1 and 2 are fixed on 6 through 3 and 4. (Note: The rear sun visor device is added at 4 in the luxury scheme so the buckle is installed on the lower place of the rear sun visor device.
Page 345 www.CarGeek.ir IV. Rear side door guard panel 1. Installation of rear side door ① Glue the door horn mouth cap to the lower side round mouth at the position as shown in the figure. ② Glue the rear side door sealing felt pad assembly on the door inner metal sheet and after confirming that its hole position directly faces with that of the metal sheet, press them tightly.
Page 346 www.CarGeek.ir V. Rear wall 1. Removal of rear wall, as shown in Fig. 7-25: Fig. 7-25 The luggage boot hood can be removed after dismantling the 11 fixing buckles. The luggage carpet is on the top of the inner luggage boot. Uncovering the carpet, the caudal cover board and spare tire cover board can be revealed, all of which are not fixed by the fasteners.
Page 347 www.CarGeek.ir Removal of rear wall air opening, as shown in Fig. 7-26. Fig. 7-26 The four buckle corners of the air opening will be unveiled after the other components of the rear wall are removed. Support the buckle corners with hands or tools to push them outward and the rear wall air opening will be dismantled.
Page 348 www.CarGeek.ir (2) Fix the buckle on the buckle installing bracket (Total: 2) of the A pillar upper guard panel. First put the front small buckle foot into the corresponding installing holes on the dash board, the two buckles into the buckle holes of the A pillar metal sheet so that the A pillar upper guard panel can be fixed.
Page 349 www.CarGeek.ir holes precisely, or the buckles will be bent. The door sill guard panel will match with the thread clip below. VII. Heat-insulating pad 1. Installation of heat-insulating pad of front wall (1) First install five buckles on the buckle installing holes of the heat-insulating pad of front wall, open the upper mouth of the pad and hang it on the beam under the windshield (see Fig.
Page 350 www.CarGeek.ir Fig. 7-32 VIII. Carpet Installation of the carpet, as shown in Fig. 7-33: Fig. 7-33 a. Clean the surface of the floor. b. Put the carpet in, stretch out the inner control handle first. Glue the front right fibula of the carpet first and the left one second.
Page 351 www.CarGeek.ir Fig. 7-35 1. Hexangular flange bolt 2. Screw 3. Hexangular flange bolt 4. Hexangular flange bolt 5. Hexangular flange nut 6. Screw 7. Plastic buckle 8. Snap spring nut 9. Hexangular flange nut www.cargeek.ir...
Page 352 www.CarGeek.ir X. Main instrument desk, as shown in Fig. 7-36 Fig. 7-36 1. Sunshine sensor cover stem 2. Optical sensor cover stem 3. Instrument panel upper guard panel 4. Front passenger air bag cover board 5. Instrument cluster face shield 6.
Page 353 www.CarGeek.ir Then insert lower part of sundries box as shown in Fig. 7-38. Fig. 7-38 2. Connect fascia console upper guard panel with vehicle body As shown in Fig. 7-39, seen from back side, there are 5 buckles attaching to vehicle body in front part of instrument panel.
Page 354 www.CarGeek.ir XI. Auxiliary fascia console (Fig. 7-42) Fig. 7-42 1. Buckle 2. Middle and lower face shield 3. Outer panel spring of front cup salver cover 4. Buffer pad of front cup salver cover 5. Outer panel of front cup salver cover 6.
Page 355 www.CarGeek.ir 1. Removal 1) Remove trim strip of instrument panel and A/C control panel. 2) Remove the two screws fastening instrument panel and auxiliary fascia console under the A/C control panel. 3) Remove and replace screw 3 (2 screws in left and right) 4) Remove floor type handbrake cover board.
Page 356 www.CarGeek.ir 3. Remove mudguard of left front wheel. (a) Remove 2 screws. (b) Remove mudguard of left front wheel. Notes: It is not necessary to completely remove the mudguard of left front wheel; the bumper can be removed in Step 4 if it is partly removed. 4.
Page 357 www.CarGeek.ir XIII. Rear bumper components (Fig. 7-44) Fig. 7-44 1. Remove rear wall pedal ① Remove 3 buckles. ② Disconnect the 8 jack catches and rear skirt plate with screwdriver. Notes: Wrap the screwdriver tip with adhesive tape before use. 2.
Page 358 www.CarGeek.ir ③ Remove the 2 bolts in the left side of rear bumper. ④ Remove the 2 bolts in the right side of rear bumper. ⑤ Remove the 2 BL1409 snap buttons in the bottom of rear bumper. ⑥ Put protecting tape under the side wall plate. ⑦...
Page 359: Vehicle Body Dimension
www.CarGeek.ir Chapter VIII Vehicle Body Dimension www.cargeek.ir...
Page 360 www.CarGeek.ir www.cargeek.ir...
Page 361 www.CarGeek.ir Dimension Dimension Measuring Measuring parameter Remark parameter Remark point point (mm) (mm) 1223.6 835.2 1146.4 685.2 1490.6 1365 1126.5 1136.6 834.7 1256.4 1024.9 1147.4 374.8 952.8 1066.6 1028 911.5 1524.9 1398 507.9 1097 β-β 848.8 1506.7 δ-δ 1437.9 1550.2 1130.4 P-β...
Page 362 www.CarGeek.ir www.cargeek.ir...
Page 363 www.CarGeek.ir Front and rear shock dampers and front and rear sub-frames mounting holes coordinate: Hole name X (mm) Y (mm) Z (mm) Sub-frame mounting hole 1 56.9 -455.6 113.0 Sub-frame mounting hole 2 56.9 455.6 113.0 Front shock damper mounting hole 1 -39.7 -568.3 621.4...
Page 364 www.CarGeek.ir www.cargeek.ir...

Lifan 620 Maintenance Manual

System Repair

Electronic Injection System

ABS System

Chassis System

Quick Links

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