Page 1 Service Manual 1100GKE 4×4...
Page 2: Table Of Contents
FOREWORD This service manual is designed primarily for use by certified XINYANG Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.
Page 3: Service Information
1. SERVICE INFORMATION A few Words About Safety ……………1-1 Main Data Table………………………1-20 Fasteners…………………………………1-3 Tightening Torque………………………1-24 Basic tools………………………………1-5 Lubricating oil, and brake liquid………1-26 Description and vehicle identification…1-18 VIN Number Engine Number…………1-19 A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Page 4 1. SERVICE INFORMATION wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: ● Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. ●...
Page 5: Screw
1. SERVICE INFORMATION Cleaning Parts Cleaning parts is one of the more tedious and difficult service jobs performed in the home garage. Many types of chemical cleaners and solvents are available for shop use. Most are poisonous and extremely flammable. To prevent chemical exposure, vapor buildup, fire and serious injury, observe each product warning label and note the following: 1.
Page 6 1. SERVICE INFORMATION Self-Locking Fasteners Several types of bolts. Screws and nuts incorporate a system that creates interference between the two fasteners. Interference is achieved in various ways. The most common types are the nylon insert nut and a dry adhesive coating on the threads of a blot. Self-locking fasteners offer greater holding strength than standard fasteners, which improves their resistance to vibration.
Page 7 1. SERVICE INFORMATION application, install the sharp edge facing away from the part producing the thrust. E-clips are used when it is not practical to use a snap ring. Remove E-clips with a flat blade screwdriver by prying between the shaft and E-clip. To install an E-clip.
Page 8: Head Screws
1. SERVICE INFORMATION damaged screwdrivers. A worn tip may damage the fastener, making it difficult to remove. Phillips-head screws are often damaged by incorrectly fitting screwdrivers. Quality Phillips screwdrivers are manufactured with their crosshead tip machined to Phillips Screw Company specifications. Poor quality or damaged Phillips screwdrivers can back out (cam out) and round over the screw head.
Page 9 1. SERVICE INFORMATION box-end wrench is preferred in most instances, especially when braking loose and applying the final tightness to a fastener. The combination wrench has a box-end on one end and an open-end on one end and an open-end on the other.
Page 10 1. SERVICE INFORMATION Various handles are available for sockets. Use the speed handle for fast operation. Flexible ratchet heads in varying length allow the socket to be turned with varying force and at odd angles. Extension bars allow the socket setup to reach difficult areas.
Page 11 1. SERVICE INFORMATION A torque wrench is a precision tool that must be properly cared for to remain accurate. Store torque wrenches in cases or separate padded drawers within a toolbox. Follow the manufacturer’s instructions for their care and calibration. Torque Adapters Torque adapters or extensions extend or reduce the...
Page 12 1. SERVICE INFORMATION When using a beam-type wrench, tighten the fastener until the pointer aligns with 16.5 ft. –lb. In this example, although the torque wrench is pre set to 16.5 ft. –lb., the actual torque is 20 ft. –lb. Pliers Pliers come in a wide range of types and sizes.
Page 13 1. SERVICE INFORMATION Ignition Grounding Tool Some test procedures require turning the engine over without starting it. To prevent damage to the ignition system from excessive resistance or the possibility of fuel vapor being ignited by an open spark, remove the spark plug cap and ground it directly to a good engine ground with the tool shown in (Figure 18).
Page 14 1. SERVICE INFORMATION Calipers Calipers (Figure 20) are excellent tools for obtaining inside, outside and depth measurements. Although not as precise as a micrometer, they allow reasonable precision, typically to within 0.05 mm (0.001 in.). Most calipers have a range up to 150 mm (6 in.).
Page 15 1. SERVICE INFORMATION procedures in this manual call for an outside micrometer. Use the outside micrometer to measure the outside diameter of cylindrical forms and the thickness of materials. A micrometer’s size indicates the minimum and maximum size of a part that it can measure. The usual sizes (Figure 23) are 0-25mm (0-1 in.), 25-50 mm (1-2 in.), 50-75 mm (2-3 in.) and 75-100 mm (3-4 in.).
Page 16 1. SERVICE INFORMATION c. Follow the manufacturer’s instructions to adjust the micrometer. 2B. To check a micrometer larger than 1 in. or 25 mm use the standard gauge supplied by the manufacturer. A standard gauge is a steel block, disc or rod that is machined to an exact size. a.
Page 17 1. SERVICE INFORMATION steps while referring to Figure 25. 1. Read the upper half of the sleeve line and count the number of lines visible. Each upper line equals 1mm. 2. See if the half –millimeter line is visible on the lower sleeve line.
Page 18 1. SERVICE INFORMATION Telescoping and Small Bore Gauges Use telescoping gauges (Figure 28) and small bore gauges (Figure 29) to measure bores. Neither gauge has a scale for direct readings. Use an outside micrometer to determine the reading. To use a telescoping gauge, select the correct size gauge for the bore.
Page 19 1. SERVICE INFORMATION Compression Gauge A compression gauge (Figure 33) measures combustion chamber (cylinder) pressure, usually in PSI or kg/ cm2 . The gauge adapter is either inserted or screwed into the spark plug hole to obtain reading. Disable the engine so it does not start and hold the throttle in the wide-open position when performing a compression test An engine that does not have adequate compression cannot be properly...
Page 20 1. SERVICE INFORMATION Description and vehicle identification 1. Warning indicator light switch 2. Ignition Switch 3. Turning switch 4. Driver model turn switch 5. Light switch 6. Low beams/High beams turn 7. Horn switch 8. Meter 9. Cigarette lighter 10. Gear Selector 11.
Page 21 1. SERVICE INFORMATION Identification number records Record the vehicle identification number and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen. Vehicle Identification Number (1100GKE): LCXESAS3~ Engine Number: SQR472F NOTE: The vehicle identification number is used to identify your...
Page 22 1. SERVICE INFORMATION Main Data Table Item Parameter Model 1100GKE Length 2960mm Width 1600mm Height 1500mm Wheel base 2250mm Engine type SQR472F Displacement 1083ml Fuel type Unleaded gasoline 93octane or above Mass of whole equipments (Not include driver) 658 kg Number of Passengers Max.
Page 23 1. SERVICE INFORMATION Parameter Item Fuel type 93 unleaded gasoline high cleanliness Transmission V-belt with teeth on, auto stepless gear change, plus gear change cam with change gear transmission Gear change type gear lever with hand Clutch type wet, hoof centrifugal type Primary speed change ratio (stepless speed 0.84—3.28 change)
Page 24 1. SERVICE INFORMATION Recommended Oil (see original) ● Specially for 4-stroke motorcycle SAE-10W-40、20W-50 Substitutes must be used in the following range. ●API type: SE or SF grade ●SAE type: Choose from the left chart according to environmental temperature Cooling Device Item Standard Full Capacity...
Page 25 1. SERVICE INFORMATION Battery、Charging System Item Standard Permanent magnet AC type AC magneto Model 3- phase AC Motor Output Charging coil Resistance (20℃) 0.2-0.3Ω Rectifier Three-phase annular rectification, Silicon controlled parallel-connected regulated voltage Battery Capacity 12V36Ah Terminal point Fully charged 12.8V voltage Insufficient...
Page 26 1. SERVICE INFORMATION Screwing moment of important bolts FRONT, REAR SUSPENSION： THREAD TORQUE REMARK S.Q. ITEM QTY. DIAMETER （N·m） FRONT/REAR SHOCK M12×1.25×55 40~50 ABSORBER FRONT BRAKE DISK M8×20 30~40 REAR BRAKE DISK M8×20 30~40 RUBBER WASHER OF M10×1.25 40~50 ENGINE ENGINE SUPPORT A M10×25 40~50...
Page 27 1. SERVICE INFORMATION REAR CALIPER, M12×1.25×25 40~50 BRAKE(L/R) FRONT CALIPER, M12×1.25×25 40~50 BRAKE(L/R) GEARBOX: THREAD TORQUE REMARK S.Q. ITEM DESCRIPTION. DIAMETER （N·m） SMALL PAN ALL POSITION M6×20 10~20 HEAD SCREWS SMALL PAN ALL POSITION M8×30 24~28 HEAD SCREWS SPEED SENSOR M6×20 9~11 HEXAGON BOLT...
Page 28 1. SERVICE INFORMATION Specification Tightening moment 10N·m Other screws （ 8.8 25N·m grade） 50N·m 80N·m Specification and usage quantity for fuel Lubricating oil and brake liquid Category Specification Capacity Remark Fuel RQ-93or upper grade lead-free gasoline Lubricating oil（engine, SAE15W—40/SF or 3600ml(change oil) Gear box）...
Page 29 2. Vehicle body，Muffler Overhaul info……………………………2-1 Meter assy……………………………….2-7 Troubleshooting…………………………2-1 Front cover r assy…………………….….2-6 Steering wheel & platfond ……………..2-2 ..Bracket,shift gear…………………………2-8 Bracket,shoot light……………………...2-3 Front decorating plate…………………….2-9 Main protect pole assy………………….2-3 Rear board adorn …………………...……2-10 Fender……………………………….….2-4 Spare wheel frame ………………………..2-10 Seat and seat belt…………………...…..2-5 Fuel tank…………………………..……...2-11 Left/right side cover…………...…..
Page 30 2. Vehicle body，Muffler Steering wheel and cover of steering wheel Remove Remove six bolts Remove cover of steering wheel Remove steering wheel Installation Reverse the removal procedure for Installation. Installation Note Align the front wheel first, and then adjust steering wheel; Reverse the removal procedure for Installation Platfond...
Page 31 2. Vehicle body，Muffler SPOTLIGHT BRACKET (OPTIONAL) Remove Remove all the connectors of spotlight. Remove bolt. Remove another spotlight bracket. bolt of Remove the spotlight bracket. Installation Reverse the removal procedure for Installation. Main Protect Pole Assy Remove Remove four bolts 1. Remove oblique of ceiling joist underprop Remove four bolts 2 Remove the main protect pole assy of the another...
Page 32 2. Vehicle body，Muffler XY1100GK: 1. CEILING JOIST 2. SCREW (M6×20) 3. RUBBER WASHER (φ6×φ12×2) 4. BOLT, FLANGE(M6) 5. MAIN PROTECT POLE (TOP) 6. BOLT (M10×25) 7. OBLIQUE OF CEILING JOIST UNDERPROP 8. HANDLE, MAIN PROTECT POLE 9. BOLT, FLANGE (M6×16) 10.
Page 33 2. Vehicle body，Muffler Seat and seat belt Remove Remove two bolts 4 Remove driver seat. Remove the passenger seat in the above way. Remove three bolts 5 Remove driver seat belt. Remove the passenger seat belt in the above way. Installation Reverse the removal procedure for Installation.
Page 34 2. Vehicle body，Muffler Left/right side cover Remove Remove six bolts 1 Remove the left side cover. Remove four bolts 1 Remove the seat cover. Remove three bolts 1 Remove the cover,left side(rear). Remove two bolts 2 Remove the footrest board (L). Remove the other right cover in same method Installation...
Page 35 2. Vehicle body，Muffler Meter assy Remove Remove one bolt 1 Remove two bolts 2 Loosen the two clasp of deposit bag. Remove all the connector of meter. Remove meter cover assy. Remove three nuts (6), remove meter. Installation Reverse the removal procedure for Installation.
Page 36 2. Vehicle body，Muffler Bracket, shift gear Remove Remove eight bolts 1. Remove decorate cover. Remove hand brake cable.（→9-4） Remove one bolt (6) Remove two bolts 2 Remove two bolts 3 Remove bracket of shift gear Installation Reverse the removal procedure for Installation.
Page 37 2. Vehicle body，Muffler 8. HOLDER,SHIFT CHANGE LEVER 9. OLT,FLANGE(M10×1.25) 10. HANDBRAKE 11. BOLT,FLANGE(M8×16) 12. BOLT,FLANGE(M8) 13. GEAR SHTFT CABLE 14. FIXED PLATE 15. KNVCKLE REARTNG(M8) 16. SCREW(M8×40) 17. BOLT(M8) 18. BOLT,FLANGE(M10×1.25×130) 19. NUT(M6) 20. DECORATE COVER 21. SCREW(ST4.8×20) 22.WASHER(φ6×φ18×1.5) 23. HAND BRAKE CABLE(SHORT) 24. ARC,BLOCK 25.
Page 38 2. Vehicle body，Muffler Rear board adorn Remove Remove all the connector of license plate light. Remove five bolts. Remove rear board adorn Installation Reverse the removal procedure for Installation. Spare wheel frame Remove four bolts. Remove spare wheel frame. Installation Reverse the removal procedure for Installation.
Page 39 2. Vehicle body，Muffler Fuel tank Remove Remove the connector of fuel tank. Remove hoop Remove hose of fuel. Remove four bolts 1. Remove fuel tank. Remove bolt 2. Remove fixed pipe. Installation Reverse the removal procedure for Installation. 1.SCREW(M6×16) 2. RUBBER WASHER(φ6×φ12×2) 3. COVER,LEFT SIDE 4.
Page 40 2. Vehicle body，Muffler Muffler Caution: Perform disassembly only after the muffler is cooled down. Remove Remove two flange bolts (M10×1.25×35) tension spring of exhaust pipe Remove exhaust pipe Remove Remove muffler. Note: Replace seal ring when installing the muffler. Installation Reverse the removal procedure for installation 1.
Page 41: Checks & Adjustment
3. CHECKS & ADJUSTMENT Overhaul Info………………………………………………………………………………3-1 Regular maintenance Table………………………………………………………………3-2 Inspection & Maintenance…………………………………………………………………3-3 Shift Linkage Inspection / Adjustment……………………………………………………3-6 Steering Stem………………………………………………………………………………3-8 Wheels………………………………………………………………………………………3-10 Suspension System…………………………………………………………………………3-12 Gear Shifting, Fuel Device…………………………………………………………………3-13 Throttle Pedal check……………………………………………………………………… 3-14 … Cooling System………………………………………………………………………………3-15 Overhaul Info Operation Cautions Note ● DO NOT keep the engine running for long time in a poorly ventilated or enclosed place because of the harmful components like CO, etc, in the exhaust gas.
Page 42: Regular Maintenance Table
3. CHECKS & ADJUSTMENT Regular Maintenance Table The table below lists the recommended intervals for all the required periodic maintenance work necessary to keep the vehicle at its best performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and hours, whichever occurs first. Note: More frequent maintenance may be required on vehicles that are used in severe conditions.
Page 43: Inspection & Maintenance
3. CHECKS & ADJUSTMENT ： ○ Inspection & Maintenance Interval Check Item Interval Standard Part Item Daily 1/2 Year Annual Steering Steering Operation agility ○ ○ System wheel Steering Damage ○ ○ System Installation ○ ○ condition of steering system Sway of ball stud ○...
Page 44: Cooling System
3. CHECKS & ADJUSTMENT Check Item Intervals Standard Part Item Daily 1/2 year Annual Drive Train Final shaft Looseness of ○ ○ ○ (Drive joint parts shaft) Sway of ○ Spline Electrical Ignition Spark plug ○ ○ System Device Ignition ○...
Page 45 3. CHECKS & ADJUSTMENT Check Item Intervals Standard Part Item Daily 1/2 year Annual Lighting device Function ○ ○ ○ and turning indicators Alarm and lock Function ○ device Instruments Function ○ Exhaust pipe Looseness or damage caused ○ and muffler by improper installation Function of muffler ○...
Page 46: Shift Linkage Inspection / Adjustment
3. CHECKS & ADJUSTMENT Shift Linkage Inspection / Adjustment Linkage rod adjustment is necessary when symptoms include: • No All Wheel Drive light • Noise on deceleration • Inability to engage a gear • Excessive gear clash (noise) • Shift selectors moving out of desired range NOTE: Remove necessary components to gain access to shift linkage cable ends.
Page 47 3. CHECKS & ADJUSTMENT Air Filter Service It is recommended that the air filter be replaced annually. When riding in extremely dusty conditions replacement will be required more often. The filter should be inspected periodically before each ride, using the following procedure. The air box is located rearward of the engine.
Page 48: Steering Stem
3. CHECKS & ADJUSTMENT Steering Stem Park the vehicle on level place, hold steering wheel, and shake in the direction as illustrated on the right and see if there is any sway In case of any sway, check if it is the problem of the steering stem or other parts and then do the maintenance accordingly.
Page 49 3. CHECKS & ADJUSTMENT BRAKE SYSTEM Master Cylinder Fluid level Check the brake fluid level When the brake fluid level is near to the minimum( ) limit Minimum=1/4H line, check master cylinder, brake hoses and joints for leakage. Remove fluid reservoir cap. add DOT3 or DOT4 brake liquid till the maximum ) limit line.
Page 50: Wheels
3. CHECKS & ADJUSTMENT Wheels Lift front wheel on level place, and make sure there is no loading on the wheels. Shake the front wheel left and right to check whether the joint of front wheel is tightened and check whether it sways. Not tighten enough ? Tighten it sway: Replace the rocker arm Front Toe-in size...
Page 51 3. CHECKS & ADJUSTMENT Tire pressure Check the pressure of the tires with a pressure gauge. Note Check the tire pressure after tires are cooled. Driving under improper tire pressure will reduce the comfort of operation and riding, and may cause deflected wear of the tires.
Page 52: Suspension System
3. CHECKS & ADJUSTMENT Wheel Nut and Wheel Axle Check front and rear wheel axle nuts for looseness Loosened axle nuts Tighten Tightening Torque: Front wheel axle nut: 180-200N.m (18.3kgf.m-20.3kgf.m) Rear wheel axle nut: 180-200N.m (18.3kgf.m-20.3kgf.m) Sway of Wheel Bearing Lift the front wheel Make sure there is loading on the vehicle shake the wheel in axial direction for any sway In case...
Page 53 3. CHECKS & ADJUSTMENT Adjusting the Absorber Use special tools to adjust the length of absorber according to loading requirement Turn clockwise to adjust from high to low. Gear Shifting Shift the gear to check for flexibility and gear engagement Adjust the gearshift rod if necessary Release the lock nut to adjust the length of gearshift Rod.
Page 54: Throttle Pedal Check
3. CHECKS & ADJUSTMENT Throttle Pedal Check Check the free play of throttle pedal Free play: 1.5-3mm If out of range, then adjust Loosen locknut of throttle cable turn the regulator and adjust free play of throttle pedal After adjusting, tighten locknuts and install throttle cable sleeve.
Page 55 3. CHECKS & ADJUSTMENT Cooling System Note Check coolant level from reservoir tank. ● Do not check from radiator. If the radiator cap is opened while the engine is hot (over 100 ℃), the pressure of the cooling system will drop down and the coolant will get boiled rapidly.
Page 56 3. CHECKS & ADJUSTMENT When the coolant level is below the LOWER limit, remove reservoir tank cap and add coolant till upper limit. (Add coolant or diluted original liquid). Recommended coolant: XYPOWER coolant Standard density: 50% ( Freezing temperature of coolant varies according to the different mixture ratio.
Page 57: Cooling System
4. COOLING SYSTEM Overhauling Info…………………………4-1 Adding Coolant………………………4-5 Trouble Shooting…………………………4-2 Cooling System Chart…………………4-6 Check and Maintenance…………………4-3 Cooling System Assembly Disassembly Reservoir Tank……………………. ……4-5 /Installation……………………………4-7 Overhaul Information Note ● If the radiator cap is opened when the coolant temperature is above 100℃, the pressure of coolant will drop and get boiled rapidly.
Page 58 4. COOLING SYSTEM Trouble Shooting Sharp rise of water temperature ● Faulty radiator cap ● Air in cooling system ● Faulty water pump ● Faulty thermostat (thermostat is not open) ● Clogged radiator pipe or cooling pipes ● Damage or clogged radiator fin ●...
Page 59 4. COOLING SYSTEM Check and Maintenance Checking coolant density Note: Open the radiator cap after coolant is fully cooled. Remove radiator cap (counter clockwise). Check with a densimeter if the coolant density adapts to the local temperature. Check coolant for stains or impurities. Inspection of radiator cap Note Open the radiator cap after the coolant is fully cooled.
Page 60 4. COOLING SYSTEM Pressure testing of cooling system Install the radiator cap tester to the radiator cap; Apply the specified pressure (radiator cap opening pressure) for 6 seconds and make sure that there is drop in pressure. Note Do not apply pressure over the specified pressure [108~137kpa(1.1~1.4kgf/cm )], or the cooling system may be damaged.
Page 61 4. COOLING SYSTEM Reservoir Tank Remove: Remove 2 bolts Remove water hose of reservoir tank Remove reservoir tank; discharge coolant; Flush reservoir tank Install reservoir tank; Adding Coolant Add coolant through filling port. Start the engine and discharge air from cooling system Check from filling port that air is fully discharged from cooling system and install the radiator cap Remove reservoir tank cap and add coolant...
Page 62 4. COOLING SYSTEM Cooling System Chart...
Page 63 4. COOLING SYSTEM COOLING SYSTEM ASSEMBLY DISASSEMBLY/INSTALLATION 1. RADIATOR 2. BUMPERBLOCK,RADIATOR 3. NUT,FLANGE(M8) 4. BOLT,FLANGE(M8×16) 5. CLAMP（φ12） 6. WATER HOSE 7. AIR SWITCH,RADIATOR 8. CLAMP (φ32-φ44) 9. COCK WATER PIPE 10.INTAKE PIPE,ENGINE(FRONT) 11. INTAKE PIPE,ENGINE(AFTER) 12. CLAMP(φ25-φ38) 13. CLAMP (φ22-φ32) 14.
Page 64 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Inspection Information……………5-1 Removal and Installation of Front and Rear Engine Removal and Installation…5-2 axle……………………………………5-7 Removal and Installation of Gearshift…5-7 Inspection Information Note: When removal Engine, please use jack to support the bodywork. Don’t damnify the ●...
Page 65 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Disassembly Engine Remove spare wheel frame. (→2-2) Remove fuel tank. (→2-11) Remove seat. (→2-5) Remove plastic covers ( →chapter2) Remove hoop. Remove water inlet hose of engine Remove bolt 1 Remove gear shift rod. Remove hoop1.
Page 66 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Remove nut. Remove the throttle cable, Remove all the connector of engine. Remove the bolt. Remove the Protection cover of ECU. Remove all the connector of ECU.
Page 67 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Remove all the connector of engine. Remove hoop. Remove water circulatet hose of engine Remove tension spring of exhaust pipe. Remove muffler. Remove the connector of oxygen sensor. Remove two nuts. Remove exhaust pipe.
Page 68 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Remove hoop. Remove hose of air filter Remove hoop of air filter. Remove two bolts. Remove air filter. Remove hoop of air inlet duct for CVT. Remove bolt. Remove air inlet duct of CVT. Remove the CVT disassembly/installation.
Page 69 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT 14. BUSH,CVT DRIVEN WHEEL 15. SPRING WASHER(φ12) 16. CVT COVER(L) 17.PAN HEAD BOLT(M6×12) 18. WASHER(φ6×φ18×1.5) 19.BOLT,FLANGE(M6×25) 20. ADAPTER 21. BOLT,FLANGE(M6×14) 22.CVT COVER(R) 23. CVT HOSE, IMPORT WIND 24. CVT HOSE, IMPORT WIND COVER 25.
Page 70 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT 24. MIDDLE TRANSMISSION SHAFT (MIDDLE) 25. BRIDGE 26. WASHER(φ14×φ28×2) 27. SPRING WASHER(φ14) 28. NUT(M14×1.5) 29. FLANGE CONNECTING 30. BUSH 31. BUSH 32. BOLT,FLANGE(M10×1.25×110) 33. LOCKNUT,FLANGE(M10×1.25) 34. BACK TRANSMISSION SHAFT 35. REAR ENGINE SUPPORT 36.
Page 71 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Remove rear axle. Remove nut. Remove Cable of difference lock. Remove four bolts 1. Remove drive shaft (rear). Remove two bolts 2. Remove rear axle Installation Installation as contradictorily process of remove Bolt torque of rear axle (M8): 23-25N·m Bolt torque of rear axle (M10): 45-50N·m Bolt torque of rear drive shaft (M8):...
Page 72: Mechanical Part Of Sqr 472Engine
Chery QQ Service Manual Mechanical Part of SQR 472Engine CONTENTS Chapter 1 Reading Instruction ............................2 1) Reading method of Maintenance Instruction......................2 2) Meaning of Marks and Abbreviations ........................3 3) Special Maintenance Tool............................4 Chapter 2 Disassembly, Assembly and Maintenance....................6 1) Timing Belt................................6 1.
Page 73 Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 3 Table of Main Fit Clearance for SQR472 Engine ..................55 Chapter 4 Table of Measurement Parameters of SQR472 Engine ................59 Chapter 5 Table of Main Fitting Torque for SQR472 Engine ..................61 Chapter 6 Positions on SQR472 Engine to be Lubricated ..................62 Chapter 7 Positions on SQR472 Engine to be Spread with Sealant................65...
Page 74: Chapter 1 Reading Instruction
Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 1. Reading Instruction 1) Reading Method of Maintenance Instruction １.1 Auxiliary Materials If it is required in the operation instruction to prepare the auxiliary materials such as special tools, tools, measuring instruments and grease in advance, you should list all auxiliary materials required in a table before carrying out each operation.
Page 75: Meaning Of Marks And Abbreviations
Chery QQ Service Manual Mechanical Part of SQR 472Engine 1 .4 Definitions Refers to allowed value during inspection, maintenance and adjustment. Standard value Refers to the maximum or minimum value that should not be exceeded during Limit inspection, maintenance and adjustment Set the standard value for simple measurement to prevent from its measuring Reference difficulty and inconsistency to facts.
Page 76: Special Maintenance Tool
Chery QQ Service Manual Mechanical Part of SQR 472Engine 3) Special Maintenance Tools: Outside view Name or symbol Purpose Engine disassembly and inspection auxiliary Mount on the engine service device stand Disassembly and assembly Engine service stand of engine Disassembly of camshaft Clamp hole wrench for camshaft timing gears timing gears Assembly of camshaft Oil...
Page 77 Chery QQ Service Manual Mechanical Part of SQR 472Engine Outside view Name or symbol Purpose Disassembly and assembly Piston pin puller of piston pin Embeded combination oil seal and helical Installation of oil seal gear puller Disassembly and assembly Crankshaft pulley holding tool of crankshaft pulley Disassembly and assembly Wrench...
Page 78: Chapter 2 Disassembly, Assembly And Maintenance
Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 2. Disassembly, Assembly and Maintenance Disassemble or assemble the engine with roll over stand. Disassemble or assemble the engine parts on the roll over stand. 1) Timing Belt 1. Structure Diagram ①...
Page 79: Disassembly
Chery QQ Service Manual Mechanical Part of SQR 472Engine 2. Disassembly 2.1 Remove the water pump pulley as the view showing. It will be better of disassembling with special tool. Torque: 25±1.5 N.m 2.2 Disassembly of Timing Belt Cover Torque: 6±1N.m 2.3 Disassembly of torsional damper Use special tools to prevent the gear ring from rotating.
Page 80 Chery QQ Service Manual Mechanical Part of SQR 472Engine Disassembly of tension pulley 2.5.1 Compress the top dead center at the first cylinder Timing Mark Clockwise piston. After disassembly of timing cover, pull the bolt and clockwise rotate the timing gear with wrench.
Page 81 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.8 Inspect the timing belt carefully, and replace new components under any of the following circumstances or when the mileage is up to the conditions of replacement: 2.8.1 Chap of back-side rubber 2.8.2 Chap of dedendum, chap of separated cord fabric.
Page 82: Installation
Chery QQ Service Manual Mechanical Part of SQR 472Engine Check the timing belt back plate for any deformation. Standard size of crankshaft timing gear Width 28.6mm 3. Installation 3.1 Assembly of crankshaft timing pulley. Timing Mark 3.2 Installation of timing (at the top dead center of the first cylinder piston) 3.2.1 Put the camshaft timing gear on the front end of the exhaust camshaft, align the locating slot on the gear with...
Page 83 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.3.2 Rotate the crankshaft along the rotating direction of the engine for 2 rounds so that the timing mark on the timing gear of camshaft and crankshaft is matched respectively, and then tighten the crankshaft belt pulley bolts.
Page 84 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.5.2 With flywheel 3.5.2.1 Prevent the gear from rotating with special tool. 3.5.2.2 Then screw down the bolt of torsional damper. 3.6 Assembly of timing cover. Mount the sealing strips at the positions as indicated in the right figure.
Page 85: Camshaft
Chery QQ Service Manual Mechanical Part of SQR 472Engine 2) Camshaft 1. Structure Diagram (1) Cylinder head chamber cover assembly (2) Cylinder head cover gasket (3) Camshaft timing belt (4) Camshaft cover ※: Components which may (5) Blanking cover not be reused (6) Camshaft bearing cap Unit: N·m(kg·cm) (7) Exhaust camshaft assembly...
Page 86: Disassembly
Chery QQ Service Manual Mechanical Part of SQR 472Engine 2. Disassembly 2.1 ① Cylinder head chamber cover assembly; ② Disassembly sequence cylinder head chamber cover; 2.2 Remove the camshaft timing gear with special tool. Notice: ·The special tool should be made as indicated in the right figure.
Page 87 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.3.2 Position the main sub gear on intake camshaft with bolts, as can be seen from the right picture. Fixing Bolt Notice: In order to eliminate the radial force of the camshaft, the camshaft should be kept at the horizontal position in the course of disassembly so as to prevent the damage caused by the excessively high radial force.
Page 88: Installation
Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.7.1 Measure the camshaft with micrometer caliper. If it is below to the specified limit, replace with a new one. Camshaft journal Unit: mm Type Item ZL, RL GL, GS, ZS φ23.0 -0.02 -0.033...
Page 89 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.2 Under the circumstance that special tools are not available: 3.2.1 Screw the M6 bolts into the camshaft driven gear at the position indicated in the right figure. Insert a Bolt screwdriver into the gap between the M6 bolt and the camshaft journal and trun the driven gear rightwards so that the fitting mark of the 2 gears match with each other...
Page 90 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.6 Assembly of camshaft cove Spread sealant on the position (slot) of camshaft cover as Glue Spread Line can be seen from the right picture. 3.6.1 Assembly of Camshaft Cover Tighten the bolts in the order as indicated in the right figure and with the specified torque.
Page 91 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.9 Installation of cylinder head cover 3.9.1 The old cushion of the timing belt cover which contacts the cylinder head cover should be removed completely. 3.9.2 Put the new cushion into the gloove of the timing belt cover accurately.
Page 92 Chery QQ Service Manual Mechanical Part of SQR 472Engine clearance once again: Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 — — — — If the clearance exceeds the standard value, adjust it by replacing the adjustment gasket. Notice: The position at which the measurement result exceeds the standard value as well as the measurement result should be recorded.
Page 93: Cylinder Head
Chery QQ Service Manual Mechanical Part of SQR 472Engine micrometer caliper. 4.4.3.3 Select the gasket on the basis of the standard value of valve tappet ① Intake valve Select gasket thickness = Unload thickness + (Measured valve clearance -0.25mm) ② Exhaust valve Select gasket thickness = Unload thickness + (Measured valve clearance -0.25mm) [Reference]...
Page 94: Disassembly
Chery QQ Service Manual Mechanical Part of SQR 472Engine Spark plug 20±1Nm Cylinder Head Weather Strip I Cylinder cushion Adjustment gasket Valve tappet Valve spring retainer Valve spring seat Valve Spring 10 Intake valve 11 Exhaust valve ※ 12 Valve oil seal Components which may not be 13 Valve seat reused...
Page 95: Routine Inspection
Chery QQ Service Manual Mechanical Part of SQR 472Engine of the assembly of cylinder head, slowly tighten these bolts in the order as indicated in the right figure for several times untill ther are tightened properly. Notice: Remove the cylinder head bolts with a torque socket wrench in the contrary order.
Page 96 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.2.2 Measure the free state of the spring. Standard value: 37mm 3.3 Inspection of valve 3.3.1 Check if it is deformed or abrades. Inspection of valve Unit: mm Limit: Item Standard value 0.10 —...
Page 97 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.3.3 Replacement of valve guide. 3.3.3.1 Heat the cylinder head with hot water to 80-100 ℃. 3.3.3.2 Take out the valve guide from one side of combustion chamber with special tool, as can be seen from the right picture.
Page 98 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.3.4.2 Repair of valve seat insert Notice: The repair of valve seat is always conducted in the course of the inspection of valve’s fitting position. The surface repaired should be free from any breakage. Take it out slowly after the inspection.
Page 99 Chery QQ Service Manual Mechanical Part of SQR 472Engine 3.4.3 Installation 3.4.3.1 Assembly of valve spring washer and valve oil Auxilary Tool of Valve Spring Assembly seal 3.4.3.1.1 Clamp the special auxiliary tool on the top of Valve valve stem and spread oil around the auxiliary tool and the Valve Oil Seal inner of new valve oil seal.
Page 100 Chery QQ Service Manual Mechanical Part of SQR 472Engine assembly Spread 3.4.4.1 Spread a little oil on the flange side of bolt and Position threaded part 3.4.4.2 Tighten the cylinder bolts in the order indicated in the right figure for 3 times till the torque reaches the specified value.
Page 101: Water Pump
Chery QQ Service Manual Mechanical Part of SQR 472Engine 4) Water Pump 1. Structure Diagram Components which may not be reused ① O-ring (nonreusable) ② Water pump body ③ Dust seal 2. Disassembly 2.1.○ 1 Disassembly O-ring Notice: The O-ring is nonreusable. 2.2 Screw off 3 bolts and disassemble water pump body.
Page 102: Oil Pump
Chery QQ Service Manual Mechanical Part of SQR 472Engine 5) Oil Pump 1. Structure Diagram Components which may not be reused ① Torq ue for oil pan bolt: 8±2 N.m ② Oil collector ③ Oil collector spacer (nonreusable) ④ Oil pump ⑤...
Page 103: Cleanup
Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.2 Remove the engine oil drainer, engine oil collector gasket Notice: The oil collector gasket is nonreusable. 2.3 Remove the engine oil pump assembly and the engine oil pump gasket. 2.4 Remove the rear oil seal bracket. 3.
Page 104: Disassembly And Assembly Of Engine Oil Pump
Chery QQ Service Manual Mechanical Part of SQR 472Engine 4 Disassembly and Assembly of Engine Oil Pump 4.1 Structure Diagram ① Seal Ring ② Engine Oil Pump Cover Sheet ③ Engine Oil Pump Inner Rotor ④ Engine Oil Pump Outer Rotor ⑤...
Page 105: Routine Inspection
Chery QQ Service Manual Mechanical Part of SQR 472Engine 4.2.4 Remove the cotter pin Notice: The cotter pin is nonreusable. Notice: When removing the cotter pin, be careful not to let the spring or the spring seat spring out or fall off abruptly.
Page 106: Installation
Chery QQ Service Manual Mechanical Part of SQR 472Engine 4.3.1.3 Measure the clearance between the rotor and pump body. Standard value: 0.10-0.181mm Limit: 0.25 mm 4.3.2 Inspect the oil pressure relief valve 4.3.2.1 No abrasion or scrape shall be found on the oil pressure relief valve.
Page 107: Disassembly Of Oil Seal
Chery QQ Service Manual Mechanical Part of SQR 472Engine 4.4.3 When the outer gear or inner gear is put into the engine oil pump, its mark should be seen. Mark 4.4.4 The new weather strip should be fixed in the groove of oil pump cover.
Page 108: Disassembly
Chery QQ Service Manual Mechanical Part of SQR 472Engine 5.2 Disassembly 5.2.1 Remove the rear crankshaft oil seal with a screwdriver. Notice: The rear oil seal of the crankshaft is nonreusable. 5.3 Inspection Inspect the oil seal for damage and the abrasion at its lip. 5.4 Assembly of oil seal 5.4.1 Spread engine oil over the lip of the new oil seal.
Page 109 Chery QQ Service Manual Mechanical Part of SQR 472Engine engine oil drainer Torque: 6±1N.m Assembly of the oil pan 6.4.1 Clean up the joint surface between the oil pan with the cylinder. 6.4.2 Spread sealant, then assemble it. Grease: Loctite 5699 Notice: ·The sealing line should be unbroken with its diameter being ф3-4mm ·Assembly should take place fifteen minutes...
Page 110: Crank Connecting Rod Mechanism
Chery QQ Service Manual Mechanical Part of SQR 472Engine 6) Crank Connecting Rod Mechanism 1 Structure Diagram Components which may not be reused ① Connecting rod cover ② Connecting rod bushing ③ Piston connecting rod assembly ④ Main bearing cap ⑤...
Page 111 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2 Disassemble of Crank Connecting Rod Mechanism 2.1 Inspect the axial momentum of the connecting rod 2.1.1 Measure the axial clearance with a dial gauge or feeler gauge. Standard value: 0.15-0.25mm Limit: 1.2mm 2.2 Inspect the connecting rod bushing for its radial clearance.
Page 112 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.2.5 If it is beyond the limit, replace the bearing bushing. Notice: Replacing the bearing bushing with the product of the same manufacturer’s brand. The thickness of the connecting rod bushing which meets the requirements of Connecting Rod clearance = diameter of big end hold –...
Page 113 Chery QQ Service Manual Mechanical Part of SQR 472Engine Inspect the crankshaft for its radial clearance. 2.4.1 Remove the crankshaft bearing cap by softly tapping with a resin hammer. 2.4.2 Clean the inside and surface of the bearing bushing, the inside and surface of the bearing cap, the cylinder wall and journal.
Page 114 Chery QQ Service Manual Mechanical Part of SQR 472Engine 2.5 Disassembly and assembly of the piston and connecting rod assembly 2.5.1 Remove the first ring, second ring and the oil ring with a pair of piston ring moving pliers. Notice: Don’t get the piston and piston ring of each cylinder confused.
Page 115 Chery QQ Service Manual Mechanical Part of SQR 472Engine 4 Routine Inspection 4.1 Cylinder Body 4.1.1 Inspect the top surface of cylinder body for its flatness (1) Measure at the six points shown in the right figure with a ruler and a feeler gauge. Limit: 0.08mm 4.1.2 Use of bore gauge...
Page 116 Chery QQ Service Manual Mechanical Part of SQR 472Engine 4.2.4 Measure the diameter of the piston 4.2.4.1 Measure at about 11 mm to the bottom of the piston, along the direction vertical to the piston pin. φ Standard value: 4.2.5 Inspect the clearance between the piston ring and the ring gloove 4.2.5.1 Measure around the ring gloove with a piston...
Page 117 Chery QQ Service Manual Mechanical Part of SQR 472Engine 4.2.7 Inspect the clearance between the piston and cylinder wall Measurement position of piston 4.2.7.1 Measure the inner diameter of the cylinder and Outer Diameter the outer diameter of the piston at the positions as indicated in the right figure.
Page 118 Chery QQ Service Manual Mechanical Part of SQR 472Engine 5.1.1 Assemble the piston, connecting rod and the Mark Forward piston pin with special tool following the instructions below: 5.1.1.1 Spread engine oil over the pin hole of the connecting rod, assemble according to the group mark and direction mark of piston and connecting rod.
Page 119 Chery QQ Service Manual Mechanical Part of SQR 472Engine Resemble crankshaft main bearing cap, Thrust Plate crankshaft, crankshaft bearing bushing and the crankshaft axial thrust plate, pay attention to the following: 5.3.1 Assembling the bearing bushing, its raised thrust block should fit into the locating groove in the cylinder body.
Page 120 Chery QQ Service Manual Mechanical Part of SQR 472Engine 5.4 Assemble the piston and connecting rod assembly, connecting rod bearing bushing and the connecting rod bearing cap, pay attention to the following: 5.4.1 The opening of compression ring and the opening of oil ring should be in the specified direction.
Page 121: Chapter 3 Table Of Main Fit Clearance For Sqr472 Engine
Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 3. Table of Main Fit Clearance for SQR472 Engine SQR472 Clearance between Cylinder Hole and Piston Skirt (Piston to Cylinder Clearance) Name of Component Size and Tolerance Clearance or Value of Remark Interferenc 0.005...
Page 122 Chery QQ Service Manual Mechanical Part of SQR 472Engine Piston Pin φ18 Fit Clearance between Connecting Rod Body Hole and Bolt Bar Name of Component Size and Tolerance Clearance or Value of Remark Interferenc The hole should be processed along Connecting rod body hole φ8.08 H with the connecting rod body.
Page 123 Chery QQ Service Manual Mechanical Part of SQR 472Engine of φ28H Remarks: In the above tables, the capital letter and suffix following the sizes (For example, H ) mean the process precision, which are unconcerned with the maintenance and may be ignored in the course of maintenance. Chapter 4.
Page 124: Chapter 5 Table Of Main Fitting Torque For Sqr472 Engine
Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 5. Table of Main Fitting Torque for SQR472 EngineSQR472 Name Specification Quantity Fixing Torque (Nm) Remark Main bearing cap bolt M10X1.25 70±3.5 Connecting rod cover bolt M8X1 40±2 Oil pump bolt M8X1 20±1.5 Nut (oil collector –...
Page 125 Chery QQ Service Manual Mechanical Part of SQR 472Engine Spread glue Intake/exhaust stud 10±1 Intake pipe nut 25±1.5 Ignition coil bracket assembly bolt 20±1.5 Front lifting lug bolt 20±1.5 Exhaust pipe nut 25±1.5 Exhaust pipe thermal shroud bolt 6±1 Bolt on crankshaft pulley & torsional damper M12X1.25 100±5 assembly...
Page 126: Chapter 6 Positions On Sqr472 Engine To Be Lubricated
Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 6. Positions on SQR472 Engine to be Lubricated Type of lubricating oil: Engine lubricating oil Designation of lubricating oil: SAE10W/30-50(SF Class) Position to be lubricated Remark Joint surface of connectong rod bolt head Screw of connecting rod bolt Exicrcle of piston pin Inner wall of piston pin hole...
Page 127: Chapter 7 Positions On Sqr472 Engine To Be Spread With Sealant
Chery QQ Service Manual Mechanical Part of SQR 472Engine Chapter 7. Positions on SQR472 Engine to be Spread with Sealant SQR472 Position to be spread with Form and amount of Type of sealant Remark sealant sealant (reference) ф(3~4)mm Joingt surface of oil pan Loctite 5699 ф(3~4)mm Rear oil seal bracket...
Page 128: Fuel Injector System
7. FUEL INJECTOR SYSTEM Overhaul Info…………………………………………………………………7-2 Fuel Injector System Disassembly/ Installation………………………………7-3 High Pressure Fuel Line Disassembly/ Installation…………………………7-4 Throttle Body Disassembly/Installation………………………………………7-4 Fuel rail with injector assy Disassembly/Installation…………………………7-5 Fuel injector Removal/Assembly………………………………………………7-5...
Page 129: Overhaul Info
7. FUEL INJECTOR SYSTEM Overhaul Info CAUTION NOTE Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Special attention should also be paid to sparks. Gasoline may also be explosive when it is vaporized, so operation should be done in a well-ventilated place. Do not over twist or bend the cables.
Page 130: Fuel Injector System Disassembly/ Installation
7. FUEL INJECTOR SYSTEM Fuel Injector System Disassembly/ Installation 1. HID 9.49 . HID 7.89 3. FIXED PIPE 4. BOLT,FLANGE(M8×40) 5. FUEL TANK 6. BOLT, FLANGE (M8×20) 7. LOCKNUT,FLANGE(M8) 8. CAP, FUEL TANK 9. FUEL, PUMP 10. HOOP 11. “O”SEAL RING(φ6×φ100) 12.
Page 131: High Pressure Fuel Line Disassembly/ Installation
7. FUEL INJECTOR SYSTEM High Pressure Fuel Line Disassembly Loosen the special fuel line clamp on fuel injector cap. loosen the special fuel line clamp on fuel tank. Disassemble High pressure fuel line. NOTE: Use container to keep the remaining fuel from high pressure fuel line, when loosening the special fuel line clamp.
Page 132: Fuel Rail With Injector Assy Disassembly/Installation
7. FUEL INJECTOR SYSTEM Fuel rail with injector assy disassembly Disassemble the special high pressure fuel Remove the strap and fuel injector connector. Disassemble 2 bolts and remove fuel rail with injector assy. Fuel rail with injector assy installation Reverse the disassembly procedure for installation. Fuel injector removal to remove snap spring.
Page 133 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Overhaul Info……………………..…8-1 Brake System…………………………8-4 Troubleshooting………………….…8-2 Suspension……………………………8-7 Front Wheel………………………...8-3 Steering………………………………8-12 Overhaul Information Operating cautions Notes ● Securely support the vehicle when overhauling the front wheel and suspension system. ● Refer to chapter10 for overhaul and inspection of lighting, instruments and switches. ●...
Page 134 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Troubleshooting Heavy Steering Wheel Cannot Turn Freely ● Steering bearing is damaged or worn ● Faulty wheel bearing ● Inner & outer bearing races are damaged, ● Front wheel axle is bended worn or stepped ●...
Page 135 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Reverse the removal procedure for Front wheel installation. Removal Securely support the front wheels Remove: --Wheel cap --4 bolts from wheel hub --Front wheel Inspection Rim Damage, warpage or serious scrapes: →Replace Replace with a new one, if any. Slowly turn the wheel, measure the rim vibra-tion with a dial gauge.
Page 136 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Torque, Rim axle nut: 180-200N· m Brake System Front brake caliper Removal Remove: --Front wheel（→8-3） --2 bolts from arm --Front caliper Inspection Check brake caliper for cracks and tightening parts for oil leakage. Replace if any. Installation Reverse the removal procedure for installation.
Page 137 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Brake Disc Removal Remove: --Front wheel（→8-3） --Brake caliper（→8-4） --Front brake disc and wheel hub --4 bolts from brake disc --Brake disc Inspection： Brake disc thickness: <3mm →Replace Installation Install brake disc Tightening Torque Fixing bolt, brake disc：25-30N·m Brake Master Cylinder Disassembly Remove: -- Two Nuts 1...
Page 138 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Brake Pedal Removal Remove: --One bolt 1 and one nut 1 -- One bolt 2 and one nut 2 -- Torsion spring -- Brake Pedal Seperate Brake Pedal from vehicle Disassembly of front brake master cylinder （→...
Page 139 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Front Left Suspension NOTE: DO NOT Remove both left and right suspension at the same time to avoid fall down of the vehicle. Park the vehicle on a level ground and securely support front part of the vehicle.
Page 140 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING 1. FRONT SHOCK 2. BOLT,FLANGE(M12×1.25×55) 21. SCREW(M6×16) 22. RUBBER WASHER 3. NUT,FLANGE(M12×1.25) 4. FR.UPPER SWING (φ6×φ12×2) 23 . WIRE CLAMP 24. BUSH ,ARM ARM 5. OILINESS AXLETREE 6. BUSH,FR.UPPER 25. CENTER SPACE 26. FRONT SHOCK SWING ARM 7.
Page 141 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Pull up joint knuckle from the driveshaft, Installation remove front right suspension assy. Reverse the removal procedure for installation. Refer to front left shock absorber for removal, installation and inspection of front right shock absorber. Arm Assembly Attention: There are 8 suspension arms in the vehicle, they dismantle, inspection and assemble...
Page 142 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Constant Velocity Drive Shaft NOTE： The removal, inspection and installation of Left and Right Constant Velocity Drive Shafts of the Front/Rear Axles are the same. The following will give instruction only on the removal, inspection and inspection of Left Constant Velocity Drive Shaft of Front Axle.
Page 143 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Rear View Mirror Removal Remove left and right rear view mirrors. Note: Left rear view mirror is right-threaded. Turn counter clockwise for removal. Note: Right rear view mirror is left-threaded. Turn clockwise for removal. 8-11...
Page 144 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Steering Stem Removal Remove: --Steering wheel.（→ 2-2） --Two bolts 1. --Shaft assy, steering joint. --Four bolts 2. --Steering stem. 8-12...
Page 145 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Steering System 1. BOLT(M5×15) 2. COVER,HORN BUTTON 3. STEERING WHEEL 4. STEERING COLUMN 5. LOCKNUT,FLANGE(M8) 6. HOLDER,STEERING COLUMN 7. BOLT,FLANGE(M8×30) 8. COVER OF STEERING COLUMN 9. BOLT,(M8×25) 10. STEERING JOINT,STEERING 11. STEERING ASSY 12. HOOP,STEERING COLUMN(IRON) 3.
Page 146 9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Overhaul Info………………………………9-1 Rear brake………………………………9-4 Troubleshooting……………………………9-2 Rear suspension…………………………9-5 Rear wheel…………………………………9-3 Overhaul info: Note: ● Securely support the vehicle when overhauling the rim and suspension system. ● Use genuine parts of bolts and nuts for rear rim and suspension. ●...
Page 147: Troubleshooting
9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Troubleshooting Rear wheel wobbles ● Rim warpage ● Faulty tire. ● Tire pressure too low ● Improper wheel balance ● Improper tightening of wheel axle nut ● Loosened wheel nut Rear shock absorber is too soft ●...
Page 148 9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Rear wheel removal: Refer to front wheel remove.（→8-3） Inspection Rim: Damage, warpage, serious scrapes, etc. Replace if necessary. Slowly turn the wheel, measure the rim vibration with a dial gauge. Service limit：Axial: 2.0mm Radial: 2.0mm Installation: Refer to front wheel installation.（→8-3）...
Page 149 9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Rear Brake Rear Brake Caliper ● Remove: ● Rear right wheel（→9-3） ● 2 bolts from rear wheel flange. ● Brake caliper Inspection: Brake Caliper: Cracks, Oil leakage: → Replace Installation Reverse the removal procedure for installation.
Page 150: M12×1.25×25 4
9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Rear Suspension System Rear Right Suspension NOTE DO NOT remove both left and right suspension at the same time to avoid fall down of the vehicle. 1.BOLT,FLANGE(M12×1.25×55) 2.LOCKNUT,FLANGE(M12×1.25) 3.REAR SHOCK 4.BUFFERING COLLAR 5. BOLT(M12×90) 6. SPRING WASHER(φ12) 7. BOLT(M12) 8. DUST CAP 9.
Page 151 9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Right rear absorber Removal: Note: Securely support the vehicle when removing rear left and right absorbers. Maintenance of rear absorbers only does not require removal of rear suspension. Remove the following parts for rear right shock absorber： (11) Bolt (1) (12) Nut (2) (11) Bolt (1)
Page 152 10. CVT TRANSMISSION SYSTEM Catalog 1. Main technical parameter and specification………………………………………2 2. Tightening torque of product…………………………………………………………2 3. Usage and maintenance………………………………………………………………3 4. Countermark position …………………………………………………………………6 5. Appearance 、 installation dimension map……………………………………………7 10–1...
Page 153 10. CVT TRANSMISSION SYSTEM 1. CVT---main technical parameter and specification main technical parameters CVT type Rubber PulleyCVT Sheave angle driving plate(°) Sheave angle driven plate(°) Grooved surface angle (°) Adjustment scope on speed 3.28～0.84 Dimension(a×b×h) 473×245×221 约 11 Net weight kg 2.
Page 154 10. CVT TRANSMISSION SYSTEM 3. Usage and maintenance 3.1Install ：和和和和和和和和和，如如主主主和主主主主主主主主，会会会会 Pulley 3.1.1 响响响响响响响响和响响响响响。 When assemble CVT and gearbox, if the CVT driving plate is not accord with the center of driven plate will serious effect the operating life of belt and performance of vehicle. 因因因和和因响因因，必必响...
Page 155 10. CVT TRANSMISSION SYSTEM Adjust gasket （ Picture 3-1-1-2 ）皮皮皮皮： 3.1.2 皮皮皮皮皮皮皮，皮皮皮皮皮皮皮。皮皮皮皮皮皮皮皮皮皮，都都都都都都皮皮都都都。因此皮皮皮皮皮，必必必必皮皮皮必都必必必：其其必其必～。如如 3-1- ： 10 15mm ： Belt Assembly After the belt assembly is finished, the belt tension should be appropriate. Too loose or too tight will obvious effect the operating life of belt. So the verticality of loose edge should be checked after the belt assembly is finished, the drooping height is 10~~15mm, refer to picture 3-1-2 Check this position...
Page 156 10. CVT TRANSMISSION SYSTEM 3.2 使使和使使 Usage and maintenance 3.2.1 磨皮：响磨皮的主，对响响使使对对对会对会响，因因响磨皮的的会对，本使规规磨皮规规专，因磨皮规规在，发主使发和主发发皮发其发和响，油油主发发 1000km 皮过过响。 running-in: Running-in or not of CVT is very important, will affect the operating life of belt a lot. t. 1000 km is stipulated as running-in mileages, during in the running-in mileages, the rmp of engine should not more than 2/3 of max rmp, and throttle should not more than 60% of full opening.
Page 157 10. CVT TRANSMISSION SYSTEM 使使安安维 3.2.4 CVT Maintenance and Check List 请请其维任车使使安安： Please maintenance and check the CVT as below methord. 使使维维 maintenance Period （以以以维专以 As anyone is fisrtly expired ） Item 和专 /Time 月月 /Mont 规规（ km （...
Page 158 10. CVT TRANSMISSION SYSTEM Fan-shaped array 5. 系系系系、安和安安如 / Appearance 、 installation dimension map 10–7...
Page 159: Efi System Of Sqr 472Engine
11. EFI SYSTEM OF SQR 472ENGINE Foreword The 472 engine is a cylinder increase in R & D base 372 engine, to meet the more large capacity and power requirements. On the structure and technical characteristics of the engine, and it is the same as the 372 engine.
Page 160 11. EFI SYSTEM OF SQR 472ENGINE CONTENTS Chapter 1 Description the SIMK-31 engine management system..........1 Summary............................1 The basic components of electronic control system...............1 A、 The SIMK-31ECU module input and output electrical diagram............1 B、 1、The input and output SIMK-31ECU module................1 2、Engine management system diagram..................2 3、Wiring diagram of ECU......................3 4、ECU function module layout....................4 5、Pin output definition ECU......................5...
Page 161: Speed Sensor
11. EFI SYSTEM OF SQR 472ENGINE 2.10、Coolant temperature sensor circuit shorted to ground (fault code P0117) ........44 2.11、Coolant temperature sensor circuit for the power supply circuit (fault code P0118) ....44 2.12、Coolant temperature sensor circuit discontinuity (fault code P0119) ........45 2.13、Solar term door position sensor circuit shorted to ground (fault code P0122) ......45 2.14、Solar term door position sensor circuit for the power supply circuit (fault code P0123) ...46 2.15、Oxygen sensor circuit fault (fault code P0130) .................46 2.16、Oxygen sensor circuit output voltage is too low (fault code P0131) .........47...
Page 162 3.1、Start engine does not rotate or move slowly................66 3.2、When starting the engine can be dragged to but failed to start...........67 3.3、Difficulty in starting the car......................68 3.4、Difficult cold start.........................69 3.5、The normal speed, any time starting difficulty................70 3.6、Start normal, but any time idling instability.................71 3.7、Normal starting, warm process of unstable idle speed...............72 3.8、Normal starting, warm after the end of unstable idle speed............73 3.9、Normal starting, part load (such as: air conditioning) when idling instability or flameout....74...
Page 163: The Basic Components Of Electronic Control System
11. EFI SYSTEM OF SQR 472ENGINE Chapter 1 Describes the SIMK-31 engine management system 一、 Overview The engine management system mainly consists of sensors, microprocessors (ECU), executive device is composed of three parts, the inhalation of air traffic control, fuel injection and ignition advance angle of the engine work.
Page 164 11. EFI SYSTEM OF SQR 472ENGINE Speed signal Knock signal The above information into the ECU after the treatment the actuator control signal needed, these signals are driven by amplifying circuit at the output, and transmitted to the corresponding actuator control signal, which includes: Idle speed regulator opening Fuel injection timing and injection duration Ignition coil closed angle and ignition advance angle...
Page 165 11. EFI SYSTEM OF SQR 472ENGINE 3、The ECU control principle diagram 11-3...
Page 166: 4、Ecu Function Module Layout
11. EFI SYSTEM OF SQR 472ENGINE 4、 The ECU function module layout. 11-4...
Page 167: 5、Pin Output Definition Ecu
11. EFI SYSTEM OF SQR 472ENGINE 5、Pin output definition ECU Connection point / description Type Connection point / description Type The power of 1 Earth Oxygen sensors downstream signal Input The power of 2 Earth Upstream oxygen sensor signal Input Empty Battery power supply 1 Input...
Page 168 11. EFI SYSTEM OF SQR 472ENGINE The speed signal input Input Empty Empty Empty Empty 11-6...
Page 169: Chapter 2 The Working Principle Of Engine Management System Components
11. EFI SYSTEM OF SQR 472ENGINE Chapter 2 The working principle of engine management system components 1、Water temperature sensor 1) Diagram and pin 2) Installation position Installed in the cooling water flow rate is high, and can correctly reflect the engine cooling water temperature, such as the water outlet of the engine or the engine cooling system circuit.
Page 170 11. EFI SYSTEM OF SQR 472ENGINE 4) Technical parameters The water temperature sensor contains two thermistor, a dedicated water temperature signal input pin ECU, use A, C, a water temperature sensor and instrumentation for temperature signal input pin, used for B and shell as earth. Limit data measure A, C value...
Page 171: 2, The Crankshaft Position Sensor
11. EFI SYSTEM OF SQR 472ENGINE 2. The crankshaft position sensor 1) Diagram and pin 2) Installation position The back of the engine flywheel plane. 3) Working principle Holzer type crankshaft position sensor with the target wheel is matched, provide check point information of engine speed and the cylinder piston.
Page 172 11. EFI SYSTEM OF SQR 472ENGINE (2) Characteristic data measure value unit least maximum The phase accuracy +0.45 -0.45 。 The air gap The target wheel speed 8000 Supply voltage 5) Installation notes The sensor is only allowed in the soon to be installed prior to the car or to the test device to remove from packaging materials.
Page 173: 3, The Camshaft Position Sensor
11. EFI SYSTEM OF SQR 472ENGINE 3, The camshaft position sensor 1) Diagram and pin 2) Installation position Camshaft end cover. 3) Working principle The sensor makes use of the magnetic induction intensity changes by Holzer Holzer in the principle of voltage made into. 11-11...
Page 174 11. EFI SYSTEM OF SQR 472ENGINE 4) Technical parameters Limit data measure Value unit Least Typical The maximum The sensor Storage temperature +150 ℃ Don't run when the +120 ℃ withstand environment temperature temperature Long-term environmental +120 ℃ temperature during operation The whole 200hour ℃...
Page 175: 4, The Throttle Body
11. EFI SYSTEM OF SQR 472ENGINE 4. The throttle body Throttle valve control intake air into the engine cylinder, so as to control the engine speed and load. The festival Flow valve is composed of two channels, namely a main channel and side channel. Solar term door pedal through the throttle cable control main channel opening, gas flow throttling into a cylinder of the engine;...
Page 176 11. EFI SYSTEM OF SQR 472ENGINE the C terminal. So it is in fact a angular potentiometer, potentiometer output and solar term door position into a voltage signal proportional. 4) Technical parameters The relationship between data for throttle valve opening and voltage as shown in the following table Aperture(°) 85（Fully open）...
Page 177: 6, Idle Speed Control Motor
11. EFI SYSTEM OF SQR 472ENGINE 6. Idle speed control motor 1) Diagram and pin 2) installation position Solar term door body. 3) working principle Stepper motor is a miniature motor, it is encircled by a ring composed of a plurality of steel stator and a rotor, see fig..
Page 178 11. EFI SYSTEM OF SQR 472ENGINE 4) Technical parameters (1) Limit data measure value unit maximum Least typical Working temperature +125 ℃ Stepper motor plug contact the maximum 2.0x10° time number of transposon Characteristic data value unit maximum Least typical Resistance of 20 ℃...
Page 179: 7, Heated Oxygen Sensor
11. EFI SYSTEM OF SQR 472ENGINE 6) Fault phenomenon and judgment method Fault phenomenon: idle speed is too high; idling flameout; idle vibration. Repair the matters needing attention: 1, shall not be applied in any form of axial force to axial compression into or out of a;...
Page 180: Hexagon
11. EFI SYSTEM OF SQR 472ENGINE The oxygen sensor is the oxygen ion concentration sensing ceramic tube inside and outside the difference into voltage signal output implementation. When the sensing ceramic tube temperature reaches 350 ℃, which has the characteristics of solid electrolyte. Because of its special material, the oxygen ions can freely through the ceramic tube.
Page 181 11. EFI SYSTEM OF SQR 472ENGINE （2）Characteristic data measure 250 hours after the bench test Exhaust temperature characteristics of data set 350℃ 850℃ 350℃ 850℃ Mixed gas concentration sensor voltage (Mv) 750~920 710±70 840±80 710±70 Mixed gas concentration sensor voltage (Mv) 40~100 55±30 20±50...
Page 182: 8, The Intake Air Temperature And Absolute Pressure Sensor
11. EFI SYSTEM OF SQR 472ENGINE The exhaust pipe of the request: to make the exhaust gas oxygen sensor in front region of the tube rapid heating. If possible, the exhaust pipe should be designed to tilt, in order to avoid condensation water together in the front area of the sensor.
Page 183 11. EFI SYSTEM OF SQR 472ENGINE 3) Technical parameters (1) Limit data measure value unit Least typical maximum Tolerance power supply voltage for 1 hours 30 minutes of tolerance pressure Tolerance Storage Temperature +130 ℃ (2) Characteristic data measure value unit Least typical...
Page 184: 9, The Fuel Rail Assembly
11. EFI SYSTEM OF SQR 472ENGINE Pressure sensor: (Connect the connector) The digital multimeter to DC voltage, the black pen grounding, the red pen is respectively connected with the c#, the d# pin. The idle state, the reference voltage c# pin should be 5V, d# pin voltage is about 1.3V (about a specific numerical and models);...
Page 185: 10, The Fuel Injector
11. EFI SYSTEM OF SQR 472ENGINE 3) Technical parameters (1) Limit data measure maximum maximum least typical maximum Continuous work permit temperature +120 ℃ The maximum allowable temperature of fuel ℃ Maximum permissible pressure drift -30 ℃ (reversible) Maximum permissible pressure drift -85 ℃ (reversible) Maximum peak acceleration The maximum pressure fluctuation value of import license (2) Characteristic data...
Page 186 11. EFI SYSTEM OF SQR 472ENGINE 1 The fuel injectors for cylinders Power supply Main relay V_RLY Injection signal ECU X1-24 3 The fuel injectors for cylinders Power supply Main relay V_RLY Injection signal ECU X1-61 4 The fuel injectors for cylinders Power supply Main relay V_RLY...
Page 187 11. EFI SYSTEM OF SQR 472ENGINE In particular, gasoline storage for a long time will go bad. In particular, LPG and gasoline dual fuel engine in a taxi, long-term with LPG as fuel, gasoline is used for starting, gasoline consumption rarely.
Page 188: 11, Carbon Canister Solenoid Valve
11. EFI SYSTEM OF SQR 472ENGINE 11. Carbon canister solenoid valve 1) Diagram and pin Pin: the carbon canister control valve has two pins, one by the main relay output pin, another ECU. 2) Installation position The vacuum line on the carbon canister and intake manifold. 3) Working principle The carbon canister control valve consists of an electromagnetic coil, armature and valve etc..
Page 189 11. EFI SYSTEM OF SQR 472ENGINE 4) Technical parameters (1) Limit data measure value unit least typical maximum working voltage 1 minutes over voltage Minimum starting voltage The minimum voltage drop Permission temperature +120 ℃ Working temperature term license +130 ℃...
Page 190: 12, The Engine Control Unit (Ecu)
11. EFI SYSTEM OF SQR 472ENGINE General failure: due to foreign body into the valve, leading to corrosion or poor sealing etc.. Repair note: 1, must be installed with flow direction in accordance with the provisions; 2, when the body as black particles leads to a control valve failure, need to replace the control valve, please check the carbon canister status;...
Page 191 11. EFI SYSTEM OF SQR 472ENGINE 3) Technical parameters Limit data measure value unit least typical maximum Normal 16.0 The battery voltag operatio Limited 6.0to8.0 16.0 function 18.0 Battery over-voltage 16Vto24 Keep part of the function of the tolerance limits and engine can be started.
Page 192: 13, Electric Fuel Pump
11. EFI SYSTEM OF SQR 472ENGINE 13. Electric fuel pump 1) Installation position Through the flange bracket is fixed in the tank, Fuel pump relay Get an electric shock SW_A Battery anode V_BAT SW_B Fuse pump Coil Supply Main relay power supply V_RLY ECU X1-69 RLY_EFP...
Page 193 11. EFI SYSTEM OF SQR 472ENGINE motor, thereby adjusting flow. So can not be electric fuel pump for vehicle use another type to. 3) Technical parameters (1) Limit data measure value unit least typical maximum working voltage V（Direct Direct） system voltage Output voltage The environment temperature (suitable for ℃...
Page 194: 14, The Ignition Coil
11. EFI SYSTEM OF SQR 472ENGINE 5) Fault phenomenon and judgment method Fault phenomenon: running noise, poor acceleration, can not start (starting difficulty) etc.. General failure: due to the use of inferior fuel,: 1, glial accumulation formed on the insulating layer; 2.
Page 195: 15, Three Way Catalytic Converter
11. EFI SYSTEM OF SQR 472ENGINE 4) Installation notes Requirements for fixed bolt and nut firmly, to prevent loosening caused by vibration, ignition coil, mechanical damage. 5) Fault phenomenon and judgment method The high-pressure line on the engine pulled out, the spark plug on good, will spark plug metal shell on the engine body, by the spark plug spark ignition coil and the high-voltage wire to judge whether good.
Page 196: Chapter 3 Introduces The Function Of Fault Diagnosis System
11. EFI SYSTEM OF SQR 472ENGINE Chapter 3 Introduces the function of fault diagnosis system The electronic control unit continuously monitoring sensor, actuator, circuit, fault indicating lamp and battery voltage and so on, and the electronic control unit itself, and the actuator driving signal and the internal signal of the sensor output signal, (such as closed loop control, coolant temperature, the idle speed control and battery voltage control) for reliability detection.
Page 197: 3, Fault Code List
11. EFI SYSTEM OF SQR 472ENGINE 2. The target speed, engine load, ambient temperature, relative ignition dwell time, the evaporator temperature, gas flow rate, fuel consumption; 3. Solar term door position sensor signal voltage, coolant temperature sensor signal voltage, the intake air temperature sensor signal voltage, the intake pressure sensor signal voltage.
Page 198 11. EFI SYSTEM OF SQR 472ENGINE Oxygen sensor 2 circuit output voltage is too low P0137 P0138 Oxygen sensor 2 circuit output voltage is too high P0140 Oxygen sensor 2 is not activated P0230 Circuit pump failure P0261 One cylinder injector circuit shorted to ground P0262 One cylinder injector circuit shorted for the power supply circuit P0264...
Page 199 11. EFI SYSTEM OF SQR 472ENGINE 4. Clear fault codes The use of diagnostic instrument 1) Turn off the ignition switch. 2) By reading the fault code the same method, the diagnosis instrument to diagnose interface. 3) Connected to the ignition switch. 4) According to the diagnostic tester instructions clear fault code.
Page 200: Chapter 4 Troubleshooting Diagnostic Process
11. EFI SYSTEM OF SQR 472ENGINE Chapter 4 Troubleshooting diagnostic process 1. Fault diagnosis based on the fault code description 1. Has been recognized as a steady-state current failure to the following maintenance, otherwise it will lead to wrong diagnosis. 2.
Page 201: The Lower The Oxygen Sensor Heater Control Circuit Shorted To Ground (Fault Code P0037)
11. EFI SYSTEM OF SQR 472ENGINE 2.2. The upstream oxygen sensor heater control circuit for the power supply circuit (fault code P0032) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the ignition Next step switch is in the "ON" Dial the joint oxygen sensor wire harness, check Next step with a multimeter, the joint 1# (connected with the...
Page 202: P0038)
11. EFI SYSTEM OF SQR 472ENGINE 2.4. The lower oxygen sensor heater control circuit for the power supply circuit (fault code P0038) Serial Operation steps Test Next step number results Connect the diagnostic instrument, ignition switch is Next step in the "ON" Dial the joint oxygen sensor wire harness, check Next step with a multimeter, the joint 1# (and oxygen sensor...
Page 203: Manifold Pressure Sensor Circuit For The Power Supply Circuit (Fault Code P0108)
11. EFI SYSTEM OF SQR 472ENGINE 2.6. Manifold pressure sensor circuit for the power supply circuit (fault code P0108) Serial Operation steps Test Next step number results Connect the diagnostic instrument, ignition switch is Next step in the "ON" The observation data stream of "pressure". It is To step 5 about 101kPa (numerical and pressure).
Page 204 11. EFI SYSTEM OF SQR 472ENGINE 2.8. The intake air temperature sensor circuit for the power supply circuit (fault code P0113) order Operation steps Test Next step number results Connect the diagnostic instrument, ignition switch Next step is in the "ON" The observed data stream "air temperature".
Page 205 11. EFI SYSTEM OF SQR 472ENGINE 2.9. The coolant temperature sensor circuit output range / character error (error code P0116) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the ignition Next step switch is in the "ON". The observed data stream "coolant temperature", Next step whether...
Page 206: Coolant Temperature Sensor Circuit Shorted To Ground (Fault Code P0117)
11. EFI SYSTEM OF SQR 472ENGINE 2.10. The coolant temperature sensor circuit shorted to ground (fault code P0117) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the ignition Next step switch is in the "ON". The observed data stream "coolant temperature", and To step 6 whether the engine temperature quite (numerical and Next step...
Page 207: Coolant Temperature Sensor Circuit Discontinuity (Fault Code P0119)
11. EFI SYSTEM OF SQR 472ENGINE 2.12. The coolant temperature sensor circuit discontinuity (fault code P0119) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the ignition Next step switch is in the "ON" The observed data stream "coolant temperature", To step 6 and whether the engine temperature quite (specific Next step...
Page 208: Solar Term Door Position Sensor Circuit For The Power Supply Circuit (Fault Code P0123)
11. EFI SYSTEM OF SQR 472ENGINE 2.14. Solar term door position sensor circuit for the power supply circuit (fault code P0123) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the Next step ignition switch is in the "ON" The observation data stream of "solar term Next step door is opening", value is between 4 $~10%...
Page 209: Oxygen Sensor Circuit Output Voltage Is Too Low (Fault Code P0131)
11. EFI SYSTEM OF SQR 472ENGINE 2.16. Oxygen sensor circuit output voltage is too low (fault code P0131) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the Next step ignition switch is in the "ON” Start the engine, idle running to the Diagnostic procedures coolant temperature reach normal values, Next step...
Page 210: The Oxygen Sensor Is Not Active (Error Code: P0134)
11. EFI SYSTEM OF SQR 472ENGINE 2.18. The oxygen sensor is not active (error code: P0134) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the Next step ignition switch is in the "ON” Start the engine, idle running to the Diagnostic procedures coolant temperature reach normal values, Next step...
Page 211: Oxygen Sensor Circuit Output Voltage Is Too Low (Fault Code P0137)
11. EFI SYSTEM OF SQR 472ENGINE 2.20. Oxygen sensor circuit output voltage is too low (fault code P0137) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the Next step ignition switch is in the "ON” Start the engine, idle running to the Diagnostic procedures coolant temperature reach normal values, Next step...
Page 212: The Oxygen Sensor Is Not Active (Fault Code P0140)
11. EFI SYSTEM OF SQR 472ENGINE 2.22. The oxygen sensor is not active (fault code P0140) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the Next step ignition switch is in the "ON” Start the engine, idle running to the Diagnostic procedures coolant temperature reach normal values, Next step...
Page 213: A Cylinder Injector Circuit Shorted To Ground (Fault Code P0261)
11. EFI SYSTEM OF SQR 472ENGINE 2.24. A cylinder injector circuit shorted to ground (fault code P0261) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the Next step ignition switch is in the "ON" Dial the joint stiffness of injector on wire To step 4 harness, using a multimeter to check the Next step...
Page 214: A Cylinder Injector Circuit For The Power Supply Circuit (Fault Code P0262)
11. EFI SYSTEM OF SQR 472ENGINE 2.25. A cylinder injector circuit for the power supply circuit (fault code P0262) Serial Operation steps Test Next step number results Connect diagnosis instrument, Next step ignition switch is in the "ON" Dial the joint stiffness of injector on wire To step 4 harness, using a multimeter to check the Next step...
Page 215: Two Cylinder Injector Circuit For The Power Supply Circuit (Fault Code P0265)
11. EFI SYSTEM OF SQR 472ENGINE 2.27. Two cylinder injector circuit for the power supply circuit (fault code P0265) Serial Operation steps Test Next step number results Connect diagnosis instrument, Next step ignition switch is in the "ON" Dial the joint stiffness of injector on wire To step 4 harness, using a multimeter to check the Next step...
Page 216: Three Cylinder Injector Circuit For The Power Supply Circuit (Fault Code P0268)
11. EFI SYSTEM OF SQR 472ENGINE 2.29. Three cylinder injector circuit for the power supply circuit (fault code P0268) Serial Operation steps Test Next step number results Connect diagnosis instrument, Next step ignition switch is in the "ON" Dial the joint stiffness of injector on wire To step 4 harness, using a multimeter to check the Next step...
Page 217: Four Cylinder Injector Circuit Shorted To Ground (Fault Code P0270)
11. EFI SYSTEM OF SQR 472ENGINE 2.30. Four cylinder injector circuit shorted to ground (fault code P0270) Serial Operation steps Test Next step number results Connect diagnosis instrument, Next step ignition switch is in the "ON" Dial the joint stiffness of injector on wire To step 4 harness, using a multimeter to check the Next step...
Page 218: Knock Sensor Fault (Fault Code P0325)
11. EFI SYSTEM OF SQR 472ENGINE 2.32. The knock sensor fault (fault code P0325) Serial Operation steps Test Next step number results Connect the diagnosis instrument Next step Dial the joint of the knock sensor wire Repair or replace the wire harness harness, using a multimeter to check the Next step connection between 1# 2# and ECUX1_10...
Page 219: The Camshaft Position Sensor Fault (Fault Code P0340)
11. EFI SYSTEM OF SQR 472ENGINE 2.34. The camshaft position sensor fault (fault code P0340) Serial Operation steps Test Next step number results round which is diagnostic instrument, the Next step ignition switch is in the "ON" Dial the joint sensor wire harness, using a To step 4 multimeter to check voltage between the 3# Next step...
Page 220: Two Cylinder Ignition Coil Circuit Fault (Fault Code P0352)
11. EFI SYSTEM OF SQR 472ENGINE 2.36. Two cylinder ignition coil circuit fault (fault code P0352) Serial Operation steps Test Next step number results round which is diagnostic instrument, the Next step ignition switch is in the "ON" Dial the joint on wire harness for ignition To step 4 coil, using a multimeter to check voltage Next step...
Page 221: Four Cylinder Ignition Coil Circuit Fault (Fault Code P0354)
11. EFI SYSTEM OF SQR 472ENGINE 2.38. Four cylinder ignition coil circuit fault (fault code P0354) Serial Operation steps Test Next step number results round which is diagnostic instrument, the Next step ignition switch is in the "ON" Dial the joint on wire harness for ignition To step 4 coil, using a multimeter to check voltage Next step...
Page 222: Carbon Irrigation Control Valve (Short Circuit Fault Code P0445)
11. EFI SYSTEM OF SQR 472ENGINE 2.40. Carbon irrigation control valve (short circuit fault code P0445) Serial Operation steps Test Next step number results round which is diagnostic instrument, the Next step ignition switch is in the "ON" Dial the joint on wire harness for ignition To step 4 coil, using a multimeter to check voltage Next step...
Page 223: The System Voltage Fault (Fault Code P0560)
11. EFI SYSTEM OF SQR 472ENGINE 2.42. Idle speed step motor fault (fault code P0505) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the Next step ignition switch is in the "ON" Dial the idle adjuster connector, electrical Next step idling regulator of A and D and the B and The replacement of the stepper...
Page 224 11. EFI SYSTEM OF SQR 472ENGINE 2.44. Internal control (read-only memory) fault (fault code P0605) Serial Operation steps Test Next step number results Connect the diagnostic instrument, wait Next step for 30 seconds or more, to the ignition switch is in the "ON" Check whether the fault code To step 3 Switch off ignition, disconnect the...
Page 225: Short Circuit Of The Air Conditioning Evaporator Temperature Sensor Circuit (Fault Code P1536)
11. EFI SYSTEM OF SQR 472ENGINE 2.46. Air-conditioning evaporator temperature sensor for short circuit or open circuit (power line fault code P1535) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the Next step ignition switch is in the "ON" The observation data stream in the To step 4 "evaporator temperature", and whether the...
Page 226 11. EFI SYSTEM OF SQR 472ENGINE 2.48. Air-conditioning high-voltage switch or air conditioning clutch relay line fault (fault code P1545) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the Next step ignition switch is in the "ON" Dial the fan connectors relay on wire To step 4 harness, multimeter voltage check fan relay...
Page 227: Cooling Fan Relay Line Fault (Fault Code P1624)
11. EFI SYSTEM OF SQR 472ENGINE 2.49. Cooling fan relay line fault (fault code P1624) Serial Operation steps Test Next step number results Connect the diagnosis instrument, the Next step ignition switch is in the "ON" Dial the fan connectors relay on wire To step 4 harness, multimeter voltage check fan relay Next step...
Page 228 11. EFI SYSTEM OF SQR 472ENGINE 3. The fault diagnosis according to the fault phenomena In this note the fault appears after the preliminary examination Before starting the engine fault diagnosis according to the fault phenomena should be the first step, a preliminary inspection: (1) Confirm the engine fault indicator light work;...
Page 229 11. EFI SYSTEM OF SQR 472ENGINE Serial Operation steps Test Next step number results Using a multimeter to check the battery Next step voltage between two terminals, whether the Replace the battery voltage of more than 8~12V when the engine start.
Page 230 11. EFI SYSTEM OF SQR 472ENGINE The general procedure of diagnosis: Serial Operation steps Test Next step number results Connect the fuel pressure gauge (access Next step point for the fuel distribution pipe assembly Maintenance supply coefficient inlet pipe end), start the engine, check the fuel pressure in the idling condition is about 380kPa Connect...
Page 231 11. EFI SYSTEM OF SQR 472ENGINE The general procedure of diagnosis: Serial Operation steps Test Next step number results Connect the fuel pressure gauge (access Next step point for the fuel distribution pipe assembly Maintenance supply coefficient inlet pipe end), start the engine, check the fuel pressure in the idling condition is about 380kPa Appropriated...
Page 232 11. EFI SYSTEM OF SQR 472ENGINE 5. The ignition coil; 6. Solar term door body and idle bypass airway; 7. The engine mechanical part. The general procedure of diagnosis: Serial Operation steps Test Next step number results Connect the fuel pressure gauge (access Next step point for the fuel distribution pipe assembly Maintenance of oil supply system...
Page 233 11. EFI SYSTEM OF SQR 472ENGINE The general procedure of diagnosis: Serial Operation steps Test Next step number results Check the air filter is clogged, the intake Maintenance intake pipe is leaking system Next step Connect the fuel pressure gauge (access Next step point for the fuel distribution pipe assembly inlet pipe end), start the engine, check the...
Page 234 11. EFI SYSTEM OF SQR 472ENGINE 3. The spark plug; 4. Solar term door body and idle bypass airway; 5. The inlet; 6. Idle speed regulator; 7. The ignition timing; 8. The spark plug; 9. The engine mechanical part. The general procedure of diagnosis Serial Operation steps Test...
Page 235 11. EFI SYSTEM OF SQR 472ENGINE 4. Solar term door body and idle bypass airway; 5. The inlet; 6. Idle speed regulator; 7. The engine mechanical part. The general procedure of diagnosis: Serial Operation steps Test Next step number results Check the air filter is clogged, the intake Check the intake system pipe is leaking...
Page 236 11. EFI SYSTEM OF SQR 472ENGINE 3. The spark plug; 4. Solar term door body and idle bypass airway; 5. The inlet; 6. Idle speed regulator; 7. The engine mechanical part. The general procedure of diagnosis: Serial Operation steps Test Next step number results...
Page 237 11. EFI SYSTEM OF SQR 472ENGINE 2. Idle speed regulator; 3. The fuel injector. The general procedure of diagnosis: Serial Operation steps Test Next step number results Remove the idle adjuster, check the solar Cleaning of parts term door body, idle speed and idle bypass Next step airway carbon deposition Observation on the output power of the...
Page 238 11. EFI SYSTEM OF SQR 472ENGINE 1. Solar term door body and idle bypass airway; 2. The vacuum tube; 3. Idle speed regulator; 4. The coolant temperature sensor; 5. The ignition timing. The general procedure of diagnosis: Serial Operation steps Test Next step number...
Page 239 11. EFI SYSTEM OF SQR 472ENGINE 3.11. Accelerate the speed to go up not to go or stop General fault location: 1. The fuel moisture content; 2. The intake pressure sensor and solar term door position sensor; 3. The spark plug; 4.
Page 240 11. EFI SYSTEM OF SQR 472ENGINE 3.12. Accelerating the slow response General fault location: 1. The fuel moisture content; 2. The intake pressure sensor and solar term door position sensor; 3. The spark plug; 4. Solar term door body and idle bypass airway; 5.
Page 241 11. EFI SYSTEM OF SQR 472ENGINE 3.13. Accelerating weakness, poor performance General failure position: 1. Fuel moisture content; 2. The intake pressure sensor and solar term door position sensor; 3. Spark plug; 4. The ignition coil; 5. Solar term door body and idle bypass airway; 6.
Page 242: Lighting And Switches
12. LIGHTING AND SWITCHES Overhaul Information………………12-1 Brake Light Switch……………….12-9 Troubleshooting…………………….12-2 Horn………………………………12-9 Replacing bulbs…………………..…12-3 Remove lamp ………………………12-6 Ignition Switch……………………..12-7 Combined switch……………….…..12-8 Winch motor………………………..12-9 Overhaul Information Warning ● Headlight bulb will be very hot when it is turned on. Do not touch it after it is just turned off. Operation should be done when the bulb is cooled down.
Page 243: Troubleshooting
12. LIGHTING AND SWITCHES TROUBLESHOOTING Head Light Cannot Turn On ● Broken fuse ● Open circuit with main cable ● Burnt Bulb ● Faulty Switch 12-2...
Page 244 12. LIGHTING AND SWITCHES Replacing Bulb Headlight bulb Headlight bulb will be very hot when it is turned on. Do not touch it after it is just turned off. Operation should be done when the bulb is cooled down. Remove Remove headlight(→12-5）.
Page 245 12. LIGHTING AND SWITCHES Front turning light bulbs Remove Remove front cover.（→2-6） Remove front turning light. （→12-6） Remove bolt. Replace turning light bulb. Bulb Specification: R10W 12 V Reverse the removal procedure for installation. Brake light/Tail light bulbs Remove Remove Brake light/Tail light（→12-6） Remove two bolts 1.
Page 246 12. LIGHTING AND SWITCHES Rear turning light bulbs Remove Remove rear turning light（→12-7） Refer to front turning light bulbs for rear turning light bulbs （→12-4） Remove other rear turning light in the above way. Bulb Specification: R10W 12 V Reverse the removal procedure for installation. Spotlight bullbs Remove Remove Spotlight...
Page 247 12. LIGHTING AND SWITCHES Note: Be careful not to damage main cable when assembling. After replacing, adjust the headlight beam. Front turning light Remove Remove front cover.（→2-6） Remove the connector of front turning light. Remove nut. Remove front turning light Remove front turning light of the another side in the above way.
Page 248: Ignition Switch
12. LIGHTING AND SWITCHES Rear turning light Refer to front turning light for rear turning Light.（→12-6） Remove rear turning light of the another side in the above way. Reverse the removal procedure for installation. Spotlight Remove Remove spotlight bracket (→2-3) Remove nut.
Page 249 12. LIGHTING AND SWITCHES Combined Switch Remove Remove meter cover assy (→2-7) . Disconnect connector of warning switch. Check according to the following table if the connector terminals are in continuity. Reverse the removal procedure for installation. 2WD、4WD、4WD Diff-Lock Switch No continuity: Change the switch.
Page 250 12. LIGHTING AND SWITCHES Winch motor Brake light switch Disconnect brake light switch connector and check terminators for continuity. Hold the brake pedal——Brake lights are open. Release the brake pedal—Brake light is off. When hold the brake pedal, the brake light is off: Replace brake pump assembly.
Page 251 13. TROUBLESHOOTING （I）Engine malfunction…………………………………………………………………13-2 （II）Malfunction in transmission system ………………………………………………13-5 （IV）Malfunction in brake system ……………………………………………………13-6 （V）Malfunction in lamplight, circuit and meter system………………………………13-7 13‐1 ...
Page 252: I）Engine Malfunction
13. TROUBLESHOOTING （I）Engine malfunction Malfunction Malfunction Reason Solving method phenomenon system ① Cylinder wear out change 1. pressure in ② Piston wear out. change cylinder is too low. ③ Leakage on Washer of cylinder. change ④ Wearing on Pipe of air valve or seat of valve is not suitable.
Page 253 13. TROUBLESHOOTING ⑥ Ignition loop problem Change ⑦ Air filter is dirty. Clean or change ⑧ Block in fuel pipe cause fuel Clean supply problem ⑨ Fuel pipe problem Change ⑩ Under pressure in hight-pressure fuel pump Adjust or change ①...
Page 254 13. TROUBLESHOOTING ⑥ Leakage on Air inlet pipe Repair or change ① Block in water channel or radiator 4. Engine cooling Clear ② Air in Cooling system or coolant is system Release air, refill coolant not enough Change ③ Water pump problem Change ④...
Page 255: Malfunction In Transmission System
13. TROUBLESHOOTING ① Blocked in muzzle Starting problem Clean ② Blocked in muzzle channel Clean Throttle body ③Leakage on connecting part of Tighten, Adjust or change works not starting part Adjust properly ④ Starting pin not work properly ① Reducer valve blocked or loose Idle and low speed Clean or tighten ②...
Page 256 13. TROUBLESHOOTING （III）Malfunction in running system, suspension and steering organization ①Air pressure in left and right wheel is different Running Running Adjust air pressure in tyre ②Load of left and right wheel is different leaning system Adjust load ③Spring force of left and right absorbing spring Adjust or Change ④Front wheel location is wrong Check or adjust...
Page 257: Malfunction In Brake System
13. TROUBLESHOOTING （IV）Malfunction in brake system ①Brake pipeline leaks oil Brake is not Brake Repair ②Brake disk and brake hoof contacts badly or hard enough system Repair or clean the dust dirt on surface ③Brake drum and brake hoof wear badly Change ④Brake main pump is damaged or leaks oil Repair or change...
Page 258 13. TROUBLESHOOTING ②Individual steering bulb has burned does not Change ③Grounding is bad illuminate Repair ④Fuse burn out Change ⑤Switch damaged Change ①Starter has been damaged Starter does Repair or Change ②Starting relay has been damaged not rotate Change ③Grounding of starter is bad when starting Repair ④Ignition switch has been damaged...
Page 259 14. FUSES AND RELAYS 1. The fuses and relays are under the meter cover. 2. If a fuse is blown, turn off the main switch and the switch of the circuit in question. Then install a new fuse of the specified amperage. Turn on the main switch. If the fuse immediately blows again, consult your dealer.

Polar Fox 1100 GKE OutLaw Service Manual

Foreword

Gearbox

Checks & Adjustment

Mechanical Part of Sqr 472Engine

Chapter 1 Reading Instruction

Chapter 2 Disassembly, Assembly and Maintenance

Chapter 3 Table of Main Fit Clearance for SQR472 Engine

Chapter 5 Table of Main Fitting Torque for SQR472 Engine

Chapter 6 Positions on SQR472 Engine to be Lubricated

Chapter 7 Positions on SQR472 Engine to be Spread with Sealant

Fuel Injector System

11. Efi System of Sqr 472Engine

Chapter 4 Troubleshooting Diagnostic Process

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Summary of Contents for Polar Fox 1100 GKE OutLaw

Table of Contents